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©2014 HYSTER COMPANY

TABLE OF CONTENTS

General .....................................................................................................................................................................1

How to Move a Disabled Lift Truck ................................................................................................................... 1

How to Tow a Lift Truck ................................................................................................................................ 2

How to Put The Lift Truck on Blocks ................................................................................................................ 3

How to Raise the Drive/Steer Tire .................................................................................................................3
How to Raise the Load Wheels ...................................................................................................................... 5

Special Precautions ................................................................................................................................................. 5

Discharging the Capacitor ..................................................................................................................................5

Safety Procedures When Working Near Mast .......................................................................................................7
Maintenance Schedule ............................................................................................................................................ 8
Maintenance Procedures Every 8 Hours or Daily ............................................................................................... 12

Checks Before Operation ..................................................................................................................................12
How to Make Checks With Key Switch OFF ...................................................................................................13

Safety Labels .................................................................................................................................................13
Battery ...........................................................................................................................................................13
Brake ............................................................................................................................................................. 14
Tires and Wheels .......................................................................................................................................... 14
Mast, Forks, and Lift Chains .......................................................................................................................14
Control Handle ..............................................................................................................................................16
Hydraulic 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 Hours or Every 2 Months ..........................................................................19

Fittings Lubrication ..........................................................................................................................................19
Other Lubrication ............................................................................................................................................. 19
Base Arm Capscrews ........................................................................................................................................ 19
Battery ...............................................................................................................................................................19
Brake ................................................................................................................................................................. 20
Lift Chain Adjustments .................................................................................................................................... 20
Drive Wheel .......................................................................................................................................................22
Hydraulic System ..............................................................................................................................................22
Master Drive Unit .............................................................................................................................................22
Traction and Pump Motor Brushes ..................................................................................................................23
Contactor ........................................................................................................................................................... 25

Maintenance Procedures Every 2000 Hours or Yearly ....................................................................................... 26

Load Wheels ...................................................................................................................................................... 26
Hydraulic Oil Change ....................................................................................................................................... 26
How to Change Drive Unit Oil ......................................................................................................................... 27

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

Table of Contents

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Содержание B495

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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