CAPACITIES AND

SPECIFICATIONS

A1.00-1.50XL (A20-30XL) [C203]

PART NO. 1482635

8000 SRM 804

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE:

The following symbols and words indicate safety information in this

manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Capacities and Specifications

Table of Contents

TABLE OF CONTENTS

Wheels and Tires................................................................................................................................................

1

Hydraulic System...............................................................................................................................................

1

Motors (24 Volt)..................................................................................................................................................

1

Mast Creep Speeds.............................................................................................................................................

1

Mast Speeds .......................................................................................................................................................

2

Battery Size Specifications ................................................................................................................................

3

Torque Specifications .........................................................................................................................................

3

Frame .............................................................................................................................................................

3

Master Drive Unit (MDU) (ZF Gotha)..........................................................................................................

3

Master Drive Unit (MDU) (Kordel) ..............................................................................................................

3

Steering System.............................................................................................................................................

3

Brake System.................................................................................................................................................

4

Hydraulic System ..........................................................................................................................................

4

Mast................................................................................................................................................................

4

Wheels ............................................................................................................................................................

4

Sevcon SC2126 Motor Controller Adjustments................................................................................................

4

This section is for the following models:

A1.00-1.50XL (A20-30XL) [C203]

©2002 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

8000 SRM 804

Mast Creep Speeds

Wheels and Tires

Model

Type

Size

Pressure

A1.00-1.50XL (A20-30XL)

Pneumatic Shaped Solid Tire

18 × 7-8

Not Applicable

Hydraulic System

Item

Specification

Hydraulic Tank Capacity (To FULL Mark)

8.3 liter (8.8 qt)

Hydraulic System Capacity

14.5 liter (15.3 qt)

Relief Valves Pressures*

Hydraulic System

17.2 MPa (2495 psi)

Secondary System

15.5 MPa (2248 psi)

Steering System

110 to 11.5 MPa (1595 to 1668 psi)

*Hydraulic Oil Temperature 50 C (122 F)

Motors (24 Volt)

Traction

Hydraulic

Rotation (From End of Shaft)

Two-Direction

Right

Winding

Series

Series

Number of Brushes

4

4

Mast Creep Speeds

Lift/Tilt

Creep Speeds

Lift at Carriage

* 100 mm (3.9 in.) in 10 minutes

Tilt at Carriage

*1.6 degrees in 10 minutes

*Hydraulic Oil Temperature 30 C (86 F).

Start measurement with mast at vertical position and the load raised to 2.5 m (8.2 ft).

Use maximum lift height if the maximum is less than 2.5 m (8.2 ft).

1

Mast Speeds

8000 SRM 804

Mast Speeds

Lifting*

Lowering*

No Load

Rated Load

No Load

Rated Load

Model

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

Two Stage Mast

A1.00XL (A20XL)

0.43

85

0.28

55

0.51

100

0.55

108

A1.25XL (A25XL)

0.43

85

0.26

51

0.51

100

0.55

108

A1.50XL (A30XL)

0.43

85

0.24

48

0.51

100

0.55

108

* Hydraulic Oil Temperature 30 C (86 F)

Lifting*

Lowering*

No Load

Rated Load

No Load

Rated Load

Model

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

Free-Lift Mast

A1.00XL (A20XL)

0.35

69

0.24

48

0.31

61

0.51

100

A1.25XL (A25XL)

0.35

69

0.23

45

0.31

61

0.51

100

A1.50XL (A30XL)

0.35

69

0.22

43

0.31

61

0.51

100

* Hydraulic Oil Temperature 30 C (86 F)

Lifting*

Lowering*

No Load

Rated Load

No Load

Rated Load

Model

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

Three-Stage Mast

A1.00XL (A20XL)

0.37

74

0.25

49

0.46

91

0.49

96

A1.25XL (A25XL)

0.37

74

0.23

45

0.46

91

0.49

96

A1.50XL (A30XL)

0.37

74

0.21

41

0.46

91

0.49

96

* Hydraulic Oil Temperature 30 C (86 F)

2

8000 SRM 804

Torque Specifications

Battery Size Specifications

Battery Size

Minimum/Maximum

Maximum

Minimum/Maximum

Model

Length

Width

Height

Weight

A1.00XL (A20XL)

486/497 mm

(18.9/19.5 in.)

825/830 mm

(32.5/32.6 in.)

680 mm (26.7 in.)

450/730 kg (992/1610 lb)

A1.25XL (A25XL)

486/497 mm

(18.9/19.5 in.)

825/830 mm

(32.5/32.6 in.)

680 mm (26.7 in.)

450/730 kg (992/1610 lb)

A1.50XL (A30XL)

486/497 mm

(18.9/19.5 in.)

825/830 mm

(32.5/32.6 in.)

680 mm (26.7 in.)

620/800 kg (1367/1764 lb)

NOTE:

Minimum gap is 4 mm (0.18 in.) and maximum gap is 18 mm (0.71 in.) for the size of the battery

compartment. The battery specification tables show the maximum size tolerances that will permit the bat-
tery to still fit into the battery compartment. The clearance between the battery lifting eyes and the hood
determine the minimum battery height.

WARNING

The battery must fit the battery compartment so that the battery restraint system will operate
correctly.

Torque Specifications

FRAME

Counterweight Capscrews

320 N•m (236 lbf ft)

Overhead Guard Capscrews

66 N•m (50 lbf ft)

MASTER DRIVE UNIT (MDU) (ZF GOTHA)

Hex Head Bolts Securing MDU to Lift
Truck Frame (6)

80 N•m (59 lbf ft)

Socket Head Capscrews Securing Traction
Motor to MDU (6)

23 N•m (17 lbf ft)

Wheel Lug Nuts (5)

140 N•m (103 lbf ft)

Oil Inlet Screw (1)

22 N•m (16 lbf ft)

Oil Outlet Screw (1)

22 N•m (16 lbf ft)

MASTER DRIVE UNIT (MDU) (KORDEL)

Nut On Helical Gear (1)

280 N•m (207 lbf ft)

Screws Holding Flange Shaft in Position (5)

130 N•m (96 lbf ft)

Oil Inlet Screw (1)

22 N•m (16 lbf ft)

Oil Outlet Screw (1)

22 N•m (16 lbf ft)

STEERING SYSTEM

Hydraulic Steering Motor

Capscrews for Flange Cover (6) 5 to
8 N•m (45 to 70 lbf in)
Capscrews for End Cover (7) 30 to 36 N•m
(22 to 25 lbf ft)
Drain Plug 25 to 30 N•m (18 to 22 lbf ft)
Gear Nut 100 N•m (74 lbf ft)

Hose Fittings to Steering Pump

9/16 UNF Fitting 25 N•m (18 lbf ft)
11/16 UNF Fitting 30 N•m (22 lbf ft)

3

Sevcon SC2126 Motor Controller Adjustments

8000 SRM 804

Steering Wheel Retaining Nut

40 to 54 N•m (30 to 40 lbf ft)

BRAKE SYSTEM

Vent Screw on Wheel Cylinder (1)

22 +13/ 0 N•m (16 +9.6 lbf ft)

Capscrews on Strap Plate Between
Brake Shoes (2)

10 ±2 N•m (88 ±17 lbf in)

Nut on Spindle of Load Wheel

68 N•m (50 lbf ft) Initial
3 N•m (2 lbf ft) Final

HYDRAULIC SYSTEM

Relief Valves (Main and Secondary)

20 to 24 N•m (15 to 18 lbf ft)

MAST

Capscrews for Mast Mounts, Cowl

51 N•m (38 lbf ft)

Capscrew and Nut for Rod End of Tilt Cylinder

90 N•m (66 lbf ft)

Capscrews for Sideshift Cylinder Mount

18 N•m (13 lbf ft)

Capscrews for Load Backrest

53 N•m (39 lbf ft)

Capscrews for Upper to Lower Apron
Weldments

435 N•m (320 lbf ft)

Sideshift Cylinder Glands

25 to 30 N•m (18 to 22 lbf ft)

WHEELS

Load and Steer Wheel (5 Per Wheel)

140 N•m (103 lbf ft)

Sevcon SC2126 Motor Controller Adjustments

The adjustments on the motor controller are set by
the manufacturer and must not be changed unless
the necessary equipment and trained personnel are
available. The parts of the controller and traction

circuit can be damaged by a wrong adjustment. See
Sevcon Motor Controller 2200 SRM 806 for addi-
tional information.

4

TECHNICAL PUBLICATIONS

8000 SRM 804

4/00 Printed in United Kingdom