Hyster B495 Service & Repair Manual
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Hyster B495 Service & Repair Manual

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Hyster B495 (W25ZA2 W30ZA2) Forklift Service
Repair Manual

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Summary of Contents for Hyster B495

  • Page 1 Hyster B495 (W25ZA2 W30ZA2) Forklift Service Repair Manual...
  • Page 2 PERIODIC MAINTENANCE W25-30ZA [B495] PART NO. 1692609 8000 SRM 1379...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed 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.

  • Page 4: Table Of Contents

    Welding Repairs ..............................27 General Repairs ..............................28 Load Wheels (W25-30ZA2)..........................28 Remove ................................28 Install ................................28 Lift Cylinder Leak Test ............................ 29 Battery Maintenance ............................29 How to Charge the Battery ..........................29 Normal Charge ............................. 30 ©2014 HYSTER COMPANY...
  • Page 5 Industrial 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 for the following models: (W25-30ZA2) [B495]...
  • Page 6 Thanks very much for your reading, Want to get more 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 please write to me: admin@servicemanualperfect.com...

  • Page 7: General

    Hyster lift truck dealer to help users who do their own 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 operate...

  • Page 8: How To Tow A Lift Truck

    General 8000 SRM 1379 How to Tow a Lift Truck 5. Locate Brake Harness and Brake Override Circuit Connector (three, 4-pin connectors in the wiring harness near the brake). See WARNING Figure 1. Prior to releasing the electric brake, make sure 6.

  • Page 9: How To Put The Lift Truck On Blocks

    8000 SRM 1379 General HOW TO PUT THE LIFT TRUCK ON 8. Fasten the chain to the lift truck. Make sure BLOCKS the tow chain has the capacity to tow the weight. Carefully fasten the tow chain completely around the motor and battery WARNING compartments on top of the forks.
  • Page 10 General 8000 SRM 1379 3. Install additional blocks under the frame near WARNING the drive tire. See Figure 3. DO NOT lift both ends at once. 2. To raise drive end of the lift truck, hook a lift strap under bumper on both sides or hook lift strap under drive frame cowl.

  • Page 11: How To Raise The Load Wheels

    8000 SRM 1379 Special Precautions How to Raise the Load Wheels has a capacity of at least two-thirds (2/3) the total weight of the lift truck including the battery. See the nameplate for the lift truck WARNING weight. Never raise the base arms any higher than necessary to change the load wheels.
  • Page 12 Special Precautions 8000 SRM 1379 Legend for Figure 4 1. NEGATIVE CONNECTION 2. POSITIVE CONNECTION 3. 200-OHM, 2-WATT RESISTOR 4. INSULATED JUMPER WIRES Figure 4. Discharging the Capacitor...

  • Page 13: Safety Procedures When Working Near Mast

    8000 SRM 1379 Safety Procedures When Working Near Mast Safety Procedures When Working Near Mast The following procedures must be used when in- DO NOT use blocks to support the mast weld- specting or working near the mast. Additional pre- ments nor to restrain their movement.

  • Page 14: Maintenance Schedule

    Maintenance Schedule 8000 SRM 1379 a. Raise mast to align bottom or middle cross- member of inner weldment with the top of outer weldment. See Figure 5. b. Install a safety chain (3/8-in. minimum) with a hook. Put hook on back side of mast. Make sure hook is completely engaged with a link in the chain.
  • Page 15 8000 SRM 1379 Maintenance Schedule Figure 6. Maintenance Points...
  • Page 16 Maintenance Schedule 8000 SRM 1379 Table 1. Maintenance Schedule Item 350 hr 8 hr 2000 hr Procedure or or 2 Specification Quantity or 1 day or 1 year Description month Safety Labels and Replace if Necessary See Parts Manual Operating Manual Battery Check Water Level Review Battery...
  • Page 17 8000 SRM 1379 Maintenance Schedule Table 1. Maintenance Schedule (Continued) Item 350 hr 8 hr 2000 hr Procedure or or 2 Specification Quantity or 1 day or 1 year Description month SAE 20 or 30 Motor Clean and Lubricate Check Condition and Check With Fork Forks Operation...

  • Page 18: Maintenance Procedures Every 8 Hours Or Daily

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1379 Table 1. Maintenance Schedule (Continued) Item 350 hr 8 hr 2000 hr Procedure or or 2 Specification Quantity or 1 day or 1 year Description month Torque to Base Arm Capscrews Tighten if Required 300 N•m (221 lbf ft) Multipurpose...

  • Page 19: How To Make Checks With Key Switch Off

    8000 SRM 1379 Maintenance Procedures Every 8 Hours or Daily HOW TO MAKE CHECKS WITH KEY The acid in the electrolyte can cause injury. If the SWITCH OFF electrolyte is spilled, use water to flush the area. Make the acid neutral with a solution of sodium Safety Labels bicarbonate (baking soda).

  • Page 20: Brake

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1379 Make sure the battery is the correct weight and in the . When the bolts stay tight after 8 hours, the size. Prevent side-to-side movement of the battery interval for checking the torque can be extended by adjusting the brackets on either side of the bat- to 350 hours.
  • Page 21 8000 SRM 1379 Maintenance Procedures Every 8 Hours or Daily 1. FORK 3. LOAD BACKREST 2. CARRIAGE 4. LOCK PIN Figure 9. Fork Assembly 1. Inspect the welds on the mast and carriage for 3. Inspect the channel for excessive wear in the cracks.

  • Page 22: Control Handle

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1379 Fork Tip Alignment Length of Forks 3% Dimension 0914 mm (36 in.) 27.00 mm (1.10 in.) 1067 mm (42 in.) 32.00 mm (1.26 in.) 1220 mm (48 in.) 37.00 mm (1.46 in.) 1371 mm (54 in.) 40.00 mm (1.57 in.) 1524 mm (60 in.)

  • Page 23: How To Make Checks With Key Switch On

    8000 SRM 1379 Maintenance Procedures Every 8 Hours or Daily Completely lower forks to relieve hydraulic pres- Never check for leaks by putting hands on hy- sure before disassembling any part of the lift draulic lines or components under pressure. Hy- pump or disconnecting any hydraulic hoses.

  • Page 24: Gauges, Horn, Fuses

    Maintenance Procedures Every 8 Hours or Daily 8000 SRM 1379 The speed/direction control is for selecting forward Check the operation of the gauges and horn. or reverse movement and the travel speed of the lift truck. The control is spring loaded and should re- If the truck is equipped with a multifunction dis- turn to the off position when the control is released.

  • Page 25: Maintenance Procedures Every 350 Hours Or Every 2 Months

    8000 SRM 1379 Maintenance Procedures Every 350 Hours or Every 2 Months Maintenance Procedures Every 350 Hours or Every 2 Months NOTE: Perform these procedures in addition to the Batteries generate explosive fumes. keep the 8-hour checks. vents in the caps clean. Keep sparks or open flames away from the battery area.

This manual is also suitable for:

W25za2W30za2

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