Hyster B495, Service & Repair Manual

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...