Hyster B257 Service & Repair Manual
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Hyster B257 Service & Repair Manual

Hyster B257 Service & Repair Manual

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Hyster B257 (B60ZHD, B80ZHD) Forklift

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  • Page 1 Hyster B257 (B60ZHD, B80ZHD) Forklift...
  • Page 2 STEERING MECHANISM B60Z [C230]; B60Z [B262]; B80Z [B257] PART NO. 4096087 1600 SRM 1637...
  • Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifi- cations 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

    Support Base ................................20 Steer Swivel ................................. 21 Assemble ...................................21 Steer Swivel ................................. 21 Support Base ................................22 Install (Complete Unit) ..............................24 Advance Coast Control................................24 Disassemble ................................... 24 Assemble ....................................27 Coast Control Adjustment Procedure ............................ 27 Troubleshooting ..................................28 ©2013 HYSTER COMPANY...
  • Page 5 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 6 Table of Contents Steering Mechanism This section is for the following models: (B60ZAC) [C230]; (B60ZHD) [B262]; (B80ZHD) [B257]...

  • Page 7: General

    1600 SRM 1637 General General The control handle assembly is designed to perform several With both hands, pull up and away from the truck until the functions. The standard control handle includes the speed/ bottom of the cover kicks out from the retaining clips. direction control and buttons for the horn, traction Repeat this for the other side of the cover.

  • Page 8: Special Precautions

    Special Precautions 1600 SRM 1637 Legend for Figure 2 1. DRIVE UNIT COMPARTMENT COVER 2. RETAINER TABS 3. GRIP SLOT 4. FRAME Figure 2. Drive Unit Compartment Cover Special Precautions Never short any controller terminal or motor ter- WARNING minal to battery. Make sure to use proper proce- The capacitor in the transistor controller can hold dures when servicing the controller.

  • Page 9: Electromagnetic Shield

    1600 SRM 1637 Calibration ELECTROMAGNETIC SHIELD WARNING Never operate Power Assist models with the Elec- tromagnetic Shield removed. A metallic shield is installed between the MDU and brake assembly and the steering assembly on power assist steer- ing units. This shield deflects the electromagnetic field gen- erated by the MDU and brake assembly which can interfere with the operation of the torque sensor.

  • Page 10: Control Handle

    Control Handle 1600 SRM 1637 NOTE: Communication error codes may appear during this process. This is a normal part of the calibration proc- ess. 6. The lift truck will start up in calibration mode and the tiller handle will begin to move on its own power dur- ing the calibration cycle.

  • Page 11: Remove

    1600 SRM 1637 Control Handle Remove 10. Remove bushings from the control handle arm if nec- essary. 1. Turn the key switch to the OFF position and discon- 11. If necessary, remove the control handle head. See the nect the battery. Remove the drive unit compartment cover.
  • Page 12 Control Handle 1600 SRM 1637 CAUTION CAUTION Make sure that the wiring is properly routed to Make sure the wiring harness is not wrapped prevent steering problems and chafing of the har- around the gas spring. Check the wiring harness ness.

  • Page 13: Power Assist Steering

    1600 SRM 1637 Control Handle 10. Remove excess slack by bundling control handle, NOTE: Be certain to tag, identify, and note the routing of brake, and brake switch wiring harnesses and secure the wires before disconnecting any wire. The wiring must using wire ties.

  • Page 14: Install

    Control Handle 1600 SRM 1637 9. Remove cotter pin from end of pivot pin. Remove 1. Install bushings into control arm. grease fitting if necessary. See Figure 7. 2. Position control handle to swivel. Install pivot pin into 10. Using a brass drift and hammer, remove pivot pin from control arm and swivel.

  • Page 15: Gas Spring

    1600 SRM 1637 Gas Spring 6. Calibrate the tiller angle potentiometer. Refer to the 8. Install drive unit compartment covers. See Accessing sections User Interface 2200SRM1323 or User Inter- the Drive Unit Compartment in this section. face 2200SRM1324 for calibration procedures. 9.

  • Page 16: Remove

    Gas Spring 1600 SRM 1637 REMOVE the gas spring to the ball stud inside the control handle arm. Install the retention clip to the gas spring ball To remove the gas spring from the control handle: socket as removed. 1. Remove the stop bolt from the control handle arm. CAUTION 2.

  • Page 17: Articulating Shaft And Pinions (Epas)

    2. Discharge the capacitor. See Special Precautions in this section. 3. Gently pry the Hyster cover from the center of the steer support cover. Remove the two screws and wash- ers securing the cover to the steer support and lift the cover off.

  • Page 18: Pinion Repair

    Articulating Shaft and Pinions (EPAS) 1600 SRM 1637 PINION REPAIR 3. Install gear to shaft as removed. Align hole in gear with hole in shaft and install retaining pin. Install bear- ing onto shaft. CAUTION Steering functions will not operate properly if pin- CAUTION ions are not aligned properly with steer swivel (control handle) and drive tire.

  • Page 19: Lower Pinion

    1600 SRM 1637 Articulating Shaft and Pinions (EPAS) Lower Pinion After removing the articulating shaft, the lower pinion can be removed from the mounting plate for repair. See Fig- ure 12. 1. LOWER PINION MOUNTING BRACKET 2. WASHER 3. LOCKWASHER 4.

  • Page 20: Install

    Steer Motor Assembly 1600 SRM 1637 INSTALL 4. Lower the steer support (control arm end) while guid- ing the articulated shaft onto the pinion shaft. CAUTION 5. Install the remaining two lower capscrews, washers, and nuts securing the steer support to the frame. Ensure that the drive tire and notch of the lower Tighten all four capscrews to 41 to 47 N•m (30 to pinion shaft are aligned in the steer swivel (con-...

  • Page 21: Gearbox/Complete Assembly, Replace

    1600 SRM 1637 Steer Motor Assembly 1. Remove the capscrew and washers from the bottom of the steer motor gear. 2. Slide the gear from the motor shaft and recover the Woodruff key. NOTE: Make sure the groove in the gear is aligned with the Woodruff key when installing.

  • Page 22: Steer Support Assembly

    Steer Support Assembly 1600 SRM 1637 14. STEER MOTOR 15. LOCK WASHER Figure 15. Steer Motor Assembly 5. If replacing the gearbox, remove the two screws and washer securing the electric motor to the gearbox. Re- move the gearbox from the motor and install the new gearbox.

  • Page 23: Disassemble

    Tighten the lifting device to support the weight proper size bearing driver, if removed. of the steering support. See Figure 17. 2. Pack bearings with Hyster synthetic grease, P/N 8. Remove the four capscrews, washers, and nuts secur- 2074114, using a standard bearing packing device.

  • Page 24: Install (Complete Unit)

    Steer Support Assembly 1600 SRM 1637 Install (Complete Unit) 6. Install the drive unit compartment covers as removed. Connect the battery and turn the key switch to the ON 1. Using the overhead lifting device, carefully position position. Test for proper operation. the steer support to the frame.

  • Page 25: Power Assist Steering (Option)

    1600 SRM 1637 Steer Support Assembly for access to other parts of the lift truck such as when re- moving the traction motor. Some items may be serviced without removing the steer support assembly. Remove only the components necessary to safely complete the required service.

  • Page 26: Disassemble

    Steer Support Assembly 1600 SRM 1637 Disassemble Support Base The support base may be disassembled to access the steer swivel bearings, the steering gear, or the torque sensor. 1. Remove the steer support assembly as a unit if neces- sary to access the support base. See Remove (Com- plete Unit) in this section.

This manual is also suitable for:

B60zhdB80zhd

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