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The speed/direction control is for selecting forward
or reverse movement and the travel speed of the lift
truck.  The  control  is  spring  loaded  and  should  re-
turn to the off position when the control is released.
The control can be operated by either hand. The op-
erator controls the speed and direction of travel by
rotating the control in the desired direction. Maxi-
mum  rotation  of  the  control  causes  maximum
travel speed. To stop or change direction, the opera-
tor rotates the control in the opposite direction. The
lift truck will come to a stop. If the speed/direction
control is not released when the lift truck stops, it
will  accelerate  in  the  opposite  direction.  Changing
direction  with  the  speed/direction  control  is  called
plugging. Arrows on the control indicate the direc-
tion of travel.

  WARNING 

The traction reverse button causes rapid accelera-
tion  and  should  not  be  used  for  changing  direc-
tion.

Check the operation of the traction reverse button.
The traction reverse button is on the end of the con-
trol  handle.  When  the  button  is  pushed,  the  lift
truck  will  move  away  from  the  operator  (forks
first).  When  the  button  is  no  longer  pushed,  the
traction motor will be turned off. The traction mo-
tor  will  not  move  the  lift  truck  in  the  direction  of
the control handle until the control is reset. To re-
set, move the speed/direction control to the neutral
position.

Gauges, Horn, Fuses

Check  that  all  the  instruments  and  controls  oper-
ate  as  described  in  the  Operating  Manual.  The
Operating  Manual  is  located  in  the  container  on
the MDU cover. This is a permanent reference and
must be available for use at all times.

Check the operation of the gauges and horn.

If  the  truck  is  equipped  with  a  multifunction  dis-
play indicator (MDI), the battery indicator has a 4
LED  display.  As  the  battery's  state  of  charge  de-
creases,  successive  LEDs  turn  off.  When  the  bat-
tery  reaches  70%  discharge,  the  horn  will  sound
twice  when  the  lift  button  is  selected.  At  80%  dis-
charge,  the  bottom  LED  will  flash  indicating
empty. The battery must be charged. Continued op-
eration with the LED flashing can damage the bat-
tery, motors, or the contactors. This unit also indi-
cates  lift  interrupt.  Lift  interrupt  prevents  the  lift
pump from operating when the battery is 80% dis-
charged. The system will automatically reset when
a charged battery is connected.

The  hourmeter  on  the  combination  battery  indica-
tor/hourmeter will continually display the total op-
eration hours.

NOTE:  

Periodic maintenance recommendations are

based on either the operating hours, as recorded by
the  hourmeter,  or  the  time  passed,  as  recorded  by
the calendar, whichever comes first.

There are two control fuses located in a fuse block
mounted  to  the  control  panel  and  a  power  fuse
mounted to standoffs on the control panel. The con-
trol panel is located in the MDU compartment. Re-
move  the  MDU  compartment  cover  to  check  the
fuses.  Check  that  the  fuses  are  the  correct  amper-
age and are not blown. Some types of fuses must be
checked  with  an  ohmmeter.  Replace  a  bad  fuse
with a fuse of the correct rating. NEVER use a fuse
with a higher rating.

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 1379

18

Summary of Contents for B495

Page 1: ...Hyster B495 W25ZA2 W30ZA2 Forklift Service Repair Manual...

Page 2: ...PERIODIC MAINTENANCE W25 30ZA2 B495 PART NO 1692609 8000 SRM 1379...

Page 3: ...dic Maintenance 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 ma...

Page 4: ...System 16 How to Make Checks With Key Switch ON 17 Check for Leaks in Lift System 17 Control Buttons 17 Direction Speed Control and Switches 17 Gauges Horn Fuses 18 Maintenance Procedures Every 350 Ho...

Page 5: ...l Battery Charging 30 Battery Pack Charging 31 How to Change the Battery 31 Standard Battery Spacer Adjustment 31 Changing the Battery With an Overhead Crane 32 Remove 32 Install 33 This section is fo...

Page 6: ...ore information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions pl...

Page 7: ...repairs Your Hyster lift truck dealer has the trained personnel and equipment to do a complete program of inspection lubrication and maintenance This complete program will help your lift truck operat...

Page 8: ...Until repairs are complete keep a tag on the control handle stating DO NOT OPERATE Remove the key In order to move a disabled lift truck the electric brake must be released A jumper is provided in the...

Page 9: ...otal weight equal to or greater than the weight of the disabled lift truck 13 Make sure the Brake Override Circuit is disconnected from the Brake Harness prior to operating the lift truck HOW TO PUT T...

Page 10: ...umper on both sides or hook lift strap under drive frame cowl See Figure 2 3 Install additional blocks under the frame near the drive tire See Figure 3 A TOP VIEW B LEFT VIEW 1 DRIVE END 2 FORK END 3...

Page 11: ...ocks must prevent the lift truck from falling and causing personal injury or prop erty damage The capacitor in the transistor controller can hold an electrical charge after the battery is disconnec te...

Page 12: ...Figure 4 Discharging the Capacitor Legend for Figure 4 1 NEGATIVE CONNECTION 2 POSITIVE CONNECTION 3 200 OHM 2 WATT RESISTOR 4 INSULATED JUMPER WIRES Special Precautions 8000 SRM 1379 6...

Page 13: ...onnector Be careful of the forks When the mast is raised the forks can be at a height to cause an injury DO NOT climb on the mast or lift truck at any time Use a ladder or personnel lift to work on th...

Page 14: ...Operator Guard Not Shown Maintenance Schedule The Maintenance Schedule has time intervals for inspection lubrication and maintenance for your lift truck The service intervals are given in both operat...

Page 15: ...Figure 6 Maintenance Points 8000 SRM 1379 Maintenance Schedule 9...

Page 16: ...xamine for Rust Damage or Corrosion Check Torque Tighten if Required 115 N m 85 lbf ft 5 Load Wheels X Check Condition Load Wheels must roll smoothly and not be excessively loose L 1 Fitting Each Mult...

Page 17: ...n Minimum Springs X Check for Heat Damage Discoloration Replace as Required Commutator X Clean Vacuum or Low Pressure Air Gauges Horn and Fuses X Check Condition Replace as Required 11 Control Handle...

Page 18: ...s area Remove the key from the key switch Disconnect the battery connector before remov ing the MDU cover Personal injury or equipment and tool damage can occur if the battery is not disconnected The...

Page 19: ...sodium bicarbonate baking soda Acid in the eyes must be immediately flushed with water continuously for fifteen minutes then seek medical attention Batteries generate explosive fumes Keep the vents in...

Page 20: ...as shown in Figure 13 Tighten the bolts to the value shown in the When the bolts stay tight after 8 hours the interval for checking the torque can be extended to 350 hours Inspect the drive tire and...

Page 21: ...er hoses and fittings for hydraulic leaks Check the hose cover for cracks or exposed reinforcement Check for broken or defective clamping devices Repair or replace any damaged components as necessary...

Page 22: ...t the lift chains for cracks or broken links and pins 9 Inspect the chain anchors and pins for cracks and damage 10 Make sure the lift chains are adjusted so they have equal tension If the chains need...

Page 23: ...s Never check for leaks by putting hands on hy draulic lines or components under pressure Hy draulic oil under pressure can be injected into the skin Never allow any part of your body under the forks...

Page 24: ...nual The Operating Manual is located in the container on the MDU cover This is a permanent reference and must be available for use at all times Check the operation of the gauges and horn If the truck...

Page 25: ...maintenance The battery must fit the battery compartment so the battery restraint panels will operate correctly Use spacers to prevent the battery from moving more that 13 0 mm 0 5 in in any directio...

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