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8. 

Fasten the chain to the lift truck. Make sure
the tow chain has the capacity to tow the
weight. Carefully fasten the tow chain
completely around the motor and battery
compartments on top of the forks. The chain
must not cause damage to either lift truck.

9. 

Steer the lift truck with the control handle
while it is being towed. Use one hand and walk
to one side of the truck. DO NOT get between
the towing vehicle and the lift truck.

10. 

Connect the battery connectors to disengage
the brake.

11. 

Tow the lift truck slowly.

12. 

If another lift truck that has the drive wheels
near the forks is used to tow the disabled lift
truck, that lift truck must have weight added to
the forks. The total weight of the lift truck and
load must be equal to or greater than the
weight of the disabled lift truck. Install a load

of approximately half the maximum capacity on
the forks of the lift truck that is used for
towing. This load will increase the traction of
the lift truck. Keep the load on the forks
lowered as much as possible.

If the lift truck used for towing has a master drive
unit (MDU) or drive unit similar to this lift truck,
DO NOT add weight to the forks. Additional
weight on the forks may DECREASE the traction of
the drive wheel(s). Make sure that the lift truck has
a total 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 THE LIFT TRUCK ON

BLOCKS

  WARNING 

DO NOT put the lift truck on blocks if the surface
is  not  solid,  even,  and  level.  Make  sure  that  any
blocks  used  to  support  the  lift  truck  are  solid,
one-piece  units.  Put  a  block  in  front  and  back  of
the  tires  touching  the  ground  to  prevent
movement of the lift truck.

DO  NOT  raise  the  lift  truck  by  attaching  an
overhead  lifting  device  to  areas  that  can  be
damaged. Some of these points are not designed
to support the weight of the lift truck. The lift truck
can  be  damaged  or  it  can  fall,  causing  serious
injury.  Attach  the  chain  or  sling  to  a  support
structure of the lift truck frame.

DO NOT make repairs or adjustments unless
specifically authorized to do so. Repairs and

adjustments must be performed by trained service
technicians.

How to Raise the Drive/Steer Tire

1. 

Put blocks on both the front and back sides of
the load wheels to prevent movement of the lift
truck. Refer to Figure 3.

Use a special low-clearance hydraulic jack,
crane, or another lift truck to raise the drive tire.
Make sure that the jack, crane, or other lift truck
has the correct capacity rating. The capacity
must equal at least two-thirds (2/3) the weight of
the lift truck, including the battery. See the
nameplate for the lift truck weight.

8000 SRM 1379

General

3

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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