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Hyster A257 A262 (B80ZAC) Service Manual – PDF DOWNLOAD
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Hyster A257 A262 (B80ZAC) Service Manual – PDF DOWNLOAD
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Description
Hyster A257 A262 (B80ZAC) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A257 A262 (B80ZAC) Service Manual – PDF DOWNLOAD
HOW TO FIND THE DESIRED PART NUMBER
WHEN THE PART NUMBER AND THE NEXT
HIGHER ASSEMBLY IS NOT KNOWN:
1 ·. Determine the function and application of the part
required. Turn to the Sections Page. Choose the
general area of reference most likely to include the
part.
2. Turn to the section you chose. Use the Section
Table of Contents to determine the assembly
which would normally contain the part required.
Then locate the part on the assembly breakdown
page.
WHEN THE PART NUMBER IS NOT KNOWN
AND THE NEXT HIGHER ASSEMBLY IS
KNOWN:
3. Determine tl”le c1~semblyJher-eq1..1ired part is used
on. Turn to the Table of Contents (Page i).
4. Locate the assembly the required part is used on
and turn to the page indicated for that assembly.
Then locate the part on the assembly breakdown
page.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 8-1) to find the
part number. Turn to the page listed and locate the
part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers,
descriptions, quantities required, keys and
footnotes to help in selecting. correct parts.
6. Parts Supersessiori Information. Part numbers that
have this history will be displayed in the parts list
in the order that they were superseded (from oldest
to newest). The superseded part numbers will be
shown with a line through them.
TABLE OF CONTENTS:
Hyster A257 A262 (B80ZAC) Service Manual – PDF DOWNLOAD
Hyster-B60ZAC-and-B80ZAC-Pallet-Jack-Parts-Manual................................................ 1 Hyster-B80ZAC-AC-Motor-Controller1640805-2200SRM1286-(04-2011)-US-EN.............................189 toc..........................................................................................189 AC Motor Controller......................................................................189 Safety Precautions Maintenance and Repair................................................190 General..................................................................................193 Discharging the Capacitors...........................................................193 Description..............................................................................194 Electrical System....................................................................194 AC Traction Motor................................................................195 Controller.......................................................................195 Service PC Connection............................................................195 Parameters...............................................................................195 General..............................................................................195 Parameter Description....................................................................197 Parameters...........................................................................197 Extended Shift...................................................................197 Walk Speed (Both Directions).....................................................197 Hi Speed (FWD)...................................................................197 Hi Speed (REV)...................................................................197 Minimum Acceleration.............................................................197 Maximum Acceleration.............................................................197 Plugging.........................................................................197 ADS-Neutral......................................................................197 ADS-Throttle.....................................................................197 Pick Acceleration................................................................197 Pick Deceleration................................................................198 Battery Full Voltage.............................................................198 Lift Interrupt...................................................................198 Troubleshooting..........................................................................198 General..............................................................................198 Non-Status Code Errors...............................................................199 Powered Black Screen.............................................................199 Tiller Oscillation and Bias (EPAS Option)........................................200 Status Codes.........................................................................200 Electrical Checks........................................................................293 General Electrical System Checks.....................................................293 Static Checks on Power and Ground Connections........................................293 Static Checks on CAN Connections.....................................................294 Tiller Harness Shorts and Continuity Checks..........................................295 Control Card Functional Test.............................................................296 Dash Display.............................................................................299 General..............................................................................299 Startup..............................................................................299 Status LED...........................................................................299 Performance Mode Indicator...........................................................299 Hourmeter............................................................................300 Battery Charge Indicator.............................................................300 Fault Log............................................................................300 Connector Pin-Outs.......................................................................301 System Logic Diagram.....................................................................302 tables.......................................................................................189 Table 1. Parameter Default Values........................................................196 Table 2. Fault Codes.....................................................................201 Hyster-B80ZAC-AC-Motor-Repair-1640802-0620SRM1283-(04-2011)-US-EN................................305 toc..........................................................................................305 AC Motor Repair..........................................................................305 Safety Precautions Maintenance and Repair................................................306 General..................................................................................309 Accessing the Drive Unit Compartment.................................................309 B60-80Z AC and B60-80Z HD........................................................309 C60-80Z AC and T5-7Z AC..........................................................310 Special Precautions......................................................................311 Discharging the Capacitors...........................................................311 Description..............................................................................312 AC Motor Repair..........................................................................312 Remove...............................................................................312 Disassemble..........................................................................312 Inspect..............................................................................314 Assemble.............................................................................314 Install..............................................................................314 Troubleshooting..........................................................................315 Hyster-B80ZAC-Diagrams-1640808-8000SRM1288-(04-2011)-US-EN.......................................319 toc..........................................................................................319 Diagrams.................................................................................319 Safety Precautions Maintenance and Repair................................................320 Hyster-B80ZAC-Frame-4025071-0100SRM1448-(04-2011)-US-EN..........................................333 toc..........................................................................................333 Frame....................................................................................333 Safety Precautions Maintenance and Repair................................................334 General..................................................................................337 Frame Separation and Assembly............................................................338 Disassemble..........................................................................338 Assemble.............................................................................338 Painting Instructions....................................................................339 Label Replacement........................................................................339 Hyster-B80ZAC-Lifting-Mechanism-4025073-4000SRM1452-(07-2011)-US-EN..............................343 toc..........................................................................................343 Lifting Mechanism........................................................................343 Safety Precautions Maintenance and Repair................................................344 General..................................................................................347 Description of Operation.................................................................347 Load Wheel...............................................................................347 Remove...............................................................................347 Install..............................................................................348 Casters..................................................................................349 Caster Adjustment Check..............................................................349 Caster Adjust Heavy-Duty.............................................................349 Caster Replacement...................................................................350 Disassemble..........................................................................350 Heavy-Duty.......................................................................350 Assemble.............................................................................351 Heavy-Duty.......................................................................351 Rear Link and Load Wheel.................................................................351 Remove...............................................................................351 Install..............................................................................353 Pull Rod.................................................................................355 Remove...............................................................................355 End Replacement......................................................................355 Install..............................................................................355 Fork Height Adjustment...............................................................356 Rocker Arm...............................................................................358 Remove...............................................................................358 Install..............................................................................359 Upper Link...............................................................................359 Remove...............................................................................359 Install..............................................................................360 Troubleshooting..........................................................................361 Hyster-B80ZAC-Parts-Manual-4025069-[A257-A262]-H-PM-US-EN-(03-2012)..............................365 FRAME/DRIVE UNIT.............................................................................377 COVERS...................................................................................380 DECAL AND PLATE LOCATION.................................................................382 DRIVE UNIT ASSEMBLY A257.................................................................384 DRIVE UNIT ASSEMBLY A262.................................................................386 POWER STEER MOTOR AND GEARS OPTION A257..................................................388 POWER STEER MOTOR AND GEARS OPTION A262..................................................390 MASTER DRIVE UNIT A257 - MANUAL STEERING ................................................392 MASTER DRIVE UNIT A257 - POWER ASSIST STEERING ..........................................396 MASTER DRIVE UNIT A262 - MANUAL STEERING ................................................400 MASTER DRIVE UNIT A262 - POWER ASSIST STEERING ..........................................404 TRACTION MOTOR A257......................................................................408 TRACTION MOTOR A262......................................................................410 SHIELD...................................................................................412 BATTERY RETENTION........................................................................414 BATTERY RETENTION GALVANIZED.............................................................415 BATTERY DISCONNECT.......................................................................416 ELECTRICAL SYSTEM............................................................................419 ELECTRICAL ASSEMBLY......................................................................422 CONTROLLER ENCLOSURE.....................................................................424 EE CONTACTOR ASSEMBLY A257...............................................................426 WIRE HARNESS THERMOSTAT..................................................................428 WIRE HARNESS MAIN........................................................................430 WIRE HARNESS HANDRAIL....................................................................433 WIRE HARNESS STANDARD SWIVEL TILLER......................................................434 WIRE HARNESS QUICK PICK..................................................................435 WIRE HARNESS TILLER......................................................................436 WIRE HARNESS SWIVEL TILLER - COAST CONTROL, FREEZER .....................................437 CONTROL MODULE TILLER INTERFACE..........................................................439 STEER HANDLE/BRAKE SYSTEM....................................................................441 TILLER WELDMENT ARM ASSEMBLY MANUAL OR POWER ASSIST STEERING - WITH COMPOSITE HEAD ......444 TILLER HANDLE ARM ASSEMBLY COMPOSITE - POWER ASSIST STEERING ............................446 TILLER HEAD ASSEMBLY COMPOSITE...........................................................448 TILLER WELDMENT ARM ASSEMBLY MANUAL OR POWER ASSIST STEERING - METAL HANDLE AND HEAD ....450 TILLER HEAD ASSEMBLY RUGGEDIZED METAL....................................................452 TILLER SWIVEL ASSEMBLY MANUAL STEERING...................................................456 TILLER SWIVEL ASSEMBLY POWER ASSIST STEERING.............................................458 AUXILIARY CONTROL BOX....................................................................462 BRAKE ASSEMBLY A262......................................................................464 BRAKE ASSEMBLY A257......................................................................465 LIFT LINKAGE AND FORKS.......................................................................467 LIFT LINKAGE.............................................................................470 CASTER SPRING LOADED.....................................................................474 CASTER ASSEMBLY HEAVY DUTY...............................................................476 SINGLE LOAD WHEEL TWO BEARING............................................................478 SINGLE LOAD WHEEL FOUR BEARING...........................................................479 SINGLE LOAD WHEEL TWO BEARING SEALED.....................................................480 SINGLE LOAD WHEEL FOUR BEARING SEALED....................................................481 DUAL LOAD WHEEL STANDARD.................................................................482 DUAL LOAD WHEEL SEALED BEARINGS..........................................................483 HYDRAULIC SYSTEM.............................................................................485 HYDRAULIC ASSEMBLY.......................................................................488 HYDRAULIC POWER UNIT.....................................................................490 LIFT CYLINDER ASSEMBLY...................................................................492 OPTIONS......................................................................................493 RF TERMINAL..............................................................................496 STROBE LIGHT POLE MOUNTED................................................................498 BACK-UP ALARM............................................................................500 CONVENIENCE TRAY.........................................................................502 COAST CONTROL MANUAL STEERING............................................................504 COAST CONTROL POWER ASSIST STEERING......................................................506 ADVANCED COAST CONTROL...................................................................508 ADVANCED COAST CONTROL VALVE ASSEMBLY....................................................510 BATTERY ROLLER ASSEMBLY..................................................................512 LOAD BACKREST............................................................................514 LOAD BACKREST BOLT-ON....................................................................516 FORK WELDMENTS AND PULL ROD OPTIONS A257.................................................518 FORK WELDMENTS AND PULL ROD OPTIONS A262.................................................522 NUMERICAL INDEX..............................................................................525 Hyster-B80ZAC-Report-an-Error....................................................................537 Hyster-B80ZAC-User-Interface-1654668-2200SRM1323-(04-2011)-US-EN.................................538 toc..........................................................................................538 User Interface...........................................................................538 Safety Precautions Maintenance and Repair................................................539 General..................................................................................542 Description..........................................................................542 Dash Display Menu Access (Standard Handle)...........................................542 Dash Display Menu Access (Metal Handle Option).......................................543 Menu Navigation..........................................................................544 Standard Handle......................................................................544 Metal Handle Option..................................................................546 Dash Display Versions....................................................................547 Supervisor Menu..........................................................................548 View Versions........................................................................549 Hourmeters...........................................................................549 Diagnostics..........................................................................549 Fault Log........................................................................550 Controller Inputs................................................................551 Control Handle Inputs............................................................551 Run Diagnostics..................................................................552 Traction Motor...............................................................553 Pump Motor and Valve.........................................................553 Control Handle...............................................................553 Temperatures.................................................................554 Power Steering...............................................................554 Service Reminder.....................................................................554 Change Supervisor Password...........................................................555 Operator Modes.......................................................................556 Exit to Run Mode.....................................................................556 tables.......................................................................................538 Table 1. Corresponding Buttons...........................................................546 Table 2. Supervisor Menu.................................................................548 Table 3. Diagnostics Menu................................................................550 Table 4. Controller Inputs...............................................................551 Table 5. Control Handle Inputs...........................................................551 Table 6. Run Diagnostics Menu............................................................552
HYSTER A257 A262 (B80ZAC) SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V
