Hyster B257, Service & Repair Manual

Page 1: ...Hyster B257 B60ZHD B80ZHD Forklift...

Page 2: ...STEERING MECHANISM B60ZAC C230 B60ZHD B262 B80ZHD B257 PART NO 4096087 1600 SRM 1637...

Page 3: ...iodic 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...

Page 4: ...inion Repair 12 Upper Pinion 12 Lower Pinion 13 Install 14 Steer Motor Assembly 14 Repair 14 Steer Motor Replace 14 Steer Motor Gear Replace 14 Gearbox Complete Assembly Replace 15 Steer Support Assem...

Page 5: ...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 6: ...This section is for the following models B60ZAC C230 B60ZHD B262 B80ZHD B257 Table of Contents Steering Mechanism ii...

Page 7: ...tment is concealed behind a molded cover which fits securely around the steer support assembly and into the frame The floor mat fits snugly in the operator platform after the drive unit cover has been...

Page 8: ...ting or disconnecting a handset or PC CAUTION To avoid controller damage always disconnect the battery Discharge the capacitor and never put power to the controller with any power wire dis connected N...

Page 9: ...to be performed Power assist steering calibration should be performed if ei ther the torque sensor or power assist steering unit is serv iced or replaced or anytime the drive tire is replaced 1 Posit...

Page 10: ...handle head refer to the section Electrical System 2200SRM1640 CONTROL HANDLE The following procedures describe the removal and disas sembly of parts of the control handle and dash assembly for repai...

Page 11: ...ecover shims for later installation Remove the control handle arm from the swivel 9 Carefully pull the wiring harnesses through the center of the support 10 Remove bushings from the control handle arm...

Page 12: ...d full down positions Turn the control handle fully to the left and right to check for restrictions 9 With the control handle in the upright position pull the harness and check for binding Position th...

Page 13: ...ecial Precautions in this section CAUTION DO NOT cut the wiring harnesses when removing the wire ties NOTE It is not necessary to remove the main wiring har ness unless harness is damaged and is being...

Page 14: ...sition control handle to swivel Install pivot pin into control arm and swivel 3 Install cotter pin into pivot pin Install grease fitting if removed 4 Reconnect control handle wiring as removed Refer t...

Page 15: ...lease with enough force to cause personal injury or property damage Review the following procedures before removing the gas spring DISCHARGING THE GAS SPRING WARNING Goggles and a face shield must be...

Page 16: ...punch and hammer Re move the gas spring See Figure 8 INSTALL 1 Install ball stud and nut into control arm if removed Tighten to 27 N m 20 lbf ft 2 Lubricate both connection points with multipurpose l...

Page 17: ...ws and remove the dash assembly Secure dash out of the way or tag identify and discon nect all wiring from the BDI display and key switch if necessary to remove the dash Refer to Electrical Sys tem 22...

Page 18: ...SE Figure 10 Gear Cover 2 Lift the upper pinion assembly from the support base Remove bearing from shaft Drive pin from gear and remove gear from shaft as necessary See Figure 11 3 Install gear to sha...

Page 19: ...aft and bearing from mounting bracket Remove bearing from shaft See Figure 13 1 LOWER PINION MOUNTING BRACKET 2 WASHER 3 LOCKWASHER 4 CAPSCREW 5 RETAINING WASHER 6 GEAR 7 BEARING 8 WOODRUFF KEY 9 PINI...

Page 20: ...y sec tions the electric motor the gearbox and the steer motor gear Repair procedures vary greatly depending on what components are being serviced If only the electric motor or the steer motor gear is...

Page 21: ...ring systems from operating properly 1 Mark the articulating shaft lower pinion gear and the steer gear so it can be reassembled in the exact same place Refer to Articulating Shaft and Pinions Power A...

Page 22: ...Install the Woodruff key into the groove in the motor shaft and install the steer gear onto the shaft and key 9 Install cover and floor mat as removed See General General Connect the battery and turn...

Page 23: ...washers and nuts securing stand off to steer plate b Lower stand off and bearing assembly from the support c Remove the lower bearing from stand off using a standard bearing puller then remove spacer...

Page 24: ...ect wiring to the BDI display and key switch if removed Align the slots in the dash with the retaining screws and position the dash to the steering support and frame Tighten the two screws to secure t...

Page 25: ...position and discon nect battery Remove the drive unit compartment cov ers 2 Discharge the capacitor See Special Precautions in this section 3 Remove the two capscrews securing the cover to the steer...

Page 26: ...ort base See Figure 19 Lower the support base from the center support 4 Remove the snap ring and bearing from the support base using an appropriate sized driver 5 Remove the pin from the bottom of the...