MidWestTechService, Parts and Operator's Manuals, in stock and ready to ship!
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3+

Hyster A257 (B60ZHD, B80ZHD) Electric Pallet Jack Service Manual

547 pages · Publication A257

$69.63
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Models
A257 (B60ZHD, B80ZHD)
Manual type
Service Manual
Pages
547
Publication
A257
Condition
Brand new
Hyster A257 (B60ZHD, B80ZHD) Electric Pallet Jack Service Manual, publication A257

What's inside

From the manual's own table of contents: 108 sections, 360 entries. See sample pages (PDF, 193 KB)

Troubleshooting and Adjustments Using the AC Controls Program (E
Safety Precautions Maintenance and Repair
General6 topics
  • Computer Requirements
  • Software, Install
  • Language Selection
  • Demo Mode
  • Connect PC to Lift Truck
  • Starting AC Controls Program
Lift Truck Control Setup6 topics
  • Change Lift Truck Serial Number or Hourmeter
  • Setting Factory Default Values or Changing Lift Truck Parameters
  • Create New Custom Lift Truck Configuration
  • Lift Truck Configuration Properties
  • Import New Lift Truck Configuration From Disk
  • Delete Custom Lift Truck Configuration or Password File
Dash Display3 topics
  • Custom Display Languages
  • Download Display Language
  • Clear Operator Log
Password Functions7 topics
  • Enable/Disable Password and Lift Truck Inspection Functions
    • Truck Inspection Checklist
    • Password
  • Password Properties
  • Create New Password File
  • Download Passwords
  • Upload Passwords
Reports Menu7 topics
  • Devices Report
  • Custom Report
  • Password Report
  • Operator Report
  • Current Settings Report
  • Status Code Report
  • Status Codes Log
Troubleshooting1 topic
  • Diagnostics
Help Menu3 topics
  • General
  • Technical Support
  • About Electric Truck AC Controls Program
Brakes1 topic
  • Accessing the Drive Unit Compartment
Description
Special Precautions
Brake Check4 topics
  • Brake Release
  • Brake Apply
  • Air Gap
  • Hold On Grade Test
Brake Assembly Repair6 topics
  • Remove
    • Repair
    • Install
    • Remove
    • Repair
    • Install
Table 1. Stator Resistance
Table 2. Adjustment Specifications
AC Motor Controller5 topics
  • Discharging the Capacitors
  • Electrical System
    • AC Traction Motor
    • Controller
    • Service PC Connection
Parameters
Parameter Description18 topics
  • Parameters
    • Extended Shift
    • Walk Speed (Both Directions)
    • Hi Speed (FWD)
    • Hi Speed (REV)
    • Minimum Acceleration
    • Maximum Acceleration
    • Plugging
    • ADS-Neutral
    • ADS-Throttle
    • Pick Acceleration
    • Pick Deceleration
    • Battery Full Voltage
    • Lift Interrupt
  • Non-Status Code Errors
    • Powered Black Screen
    • Tiller Oscillation and Bias (EPAS Option)
  • Status Codes
Electrical Checks4 topics
  • General Electrical System Checks
  • Static Checks on Power and Ground Connections
  • Static Checks on CAN Connections
  • Tiller Harness Shorts and Continuity Checks
Control Card Functional Test6 topics
  • Startup
  • Status LED
  • Performance Mode Indicator
  • Hourmeter
  • Battery Charge Indicator
  • Fault Log
Connector Pin-Outs
System Logic Diagram
Table 1. Parameter Default Values
Show all 108 sections
Table 2. Fault Codes
Diagrams
User Interface3 topics
  • Description
  • Dash Display Menu Access (Standard Handle)
  • Dash Display Menu Access (Metal Handle Option)
Menu Navigation2 topics
  • Standard Handle
  • Metal Handle Option
Dash Display Versions
Supervisor Menu10 topics
  • View Versions
  • Hourmeters
    • Fault Log
    • Controller Inputs
    • Control Handle Inputs
    • Run Diagnostics
  • Service Reminder
  • Change Supervisor Password
  • Operator Modes
  • Exit to Run Mode
Table 1. Corresponding Buttons
Table 2. Supervisor Menu
Table 3. Diagnostics Menu
Table 4. Controller Inputs
Table 5. Control Handle Inputs
Table 6. Run Diagnostics Menu
Technician Menu31 topics
  • Fault Log
    • Controller Inputs
    • Control Handle Inputs
    • Run Diagnostics
  • Set Performance
    • Extended Shift
    • Walk Speed
    • High Speed (FWD)
    • High Speed (REV)
    • Minimum Acceleration
    • Maximum Acceleration
    • Plugging
    • ADS-Neutral
    • ADS-Throttle
    • Pick Acceleration
    • Pick Deceleration
    • Battery Full
    • Lift Interrupt
    • Min Steer Assist FWD (Power Steering Assist Only)
    • Min Steer Assist REV (Power Steering Assist Only)
    • Max Steer Assist (Power Steering Assist Only)
    • Defaults
    • Save and Exit
    • Exit Without Saving
  • Set General Items
    • A/V Alarm (Audible/Visual)
  • Clear Fault Log
  • Calibrations
    • Throttle
    • Steer Handle (Power Steering Assist Only)
  • Change Service Technician Password
Table 2. Technician Menu
Table 7. Performance Parameters
Table 8. Set Performance Menu
Table 9. Set General Items Menu
Table 10. Calibrations Menu
Periodic Maintenance5 topics
  • How to Move a Disabled Truck
    • How to Tow the Lift Truck
  • How to Put a Lift Truck on Blocks
    • How to Raise Drive/Steer Tire
    • How to Raise Load Wheels
Welding Repairs
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily6 topics
  • Checks With Key Switch Turned OFF
    • Battery
    • Hydraulic Leaks
    • Drive Tire, Load Wheels, Casters, and Frame
  • Checks With Key Switch Turned ON
    • Operation
Maintenance Procedures Every 250 Hours or Every 6 Weeks1 topic
  • Caster Lubrication
Maintenance Procedures Every 500 Hours or Every 3 Months13 topics
  • Hydraulic System
    • Hydraulic Oil
    • Hydraulic Reservoir Breather
  • Steering System
    • Power Assist Steering
  • Lift Linkage and Load Wheels
  • Casters
    • Caster Adjustment Check
    • Caster Adjust Heavy-Duty
  • Master Drive Unit
    • Change Gear Oil
    • Check Oil Level
  • Drive Tire Check
Maintenance Procedures Every 2000 Hours or Yearly7 topics
  • Lubrication
    • Repack Load Wheel Bearings
    • Repack Steer Bearings (Manual Steer Only)
    • Oil Change
  • Brake
  • Electrical
    • Oil Change
Battery Maintenance4 topics
  • How to Charge the Battery
    • Equalizing Charge
    • Normal Charge
  • How to Change the Battery
Transporting2 topics
  • Loading
  • Unloading
Preparation for Storage2 topics
  • Short-Term Storage (1 to 6 months)
  • Long-Term Storage (6 months or longer)
Preparation for Use2 topics
  • Preparation After Shipment
  • Preparation After Storage
Table 1. Maintenance Schedule
Table 2. Specific Gravity Corrections
Frame
Frame Separation and Assembly2 topics
  • Disassemble
  • Assemble
Painting Instructions
Label Replacement
Steering Mechanism1 topic
  • Electromagnetic Shield
Calibration1 topic
  • Power Assist Steering
Control Handle4 topics
  • Control Handle Head
  • Control Handle
    • Standard Steering
    • Power Assist Steering
Gas Spring3 topics
  • Discharging the Gas Spring
  • Remove
  • Install
Articulating Shaft and Pinions (Power Assist Models)3 topics
  • Pinion Repair
    • Upper Pinion
    • Lower Pinion
Steer Motor Assembly4 topics
  • Repair
    • Steer Motor, Replace
    • Steer Motor Gear, Replace
    • Gearbox/Complete Assembly, Replace
Steer Support Assembly10 topics
  • Standard Steering
    • Remove (Complete Unit)
    • Disassemble
    • Assemble
    • Install (Complete Unit)
  • Power Assist Steering (Option)
    • Remove (Complete Unit)
    • Disassemble
    • Assemble
    • Install (Complete Unit)
Electronic Coast Control (Option)1 topic
  • Checks
Lifting Mechanism
Description of Operation
Load Wheel
Casters4 topics
  • Caster Adjustment Check
  • Caster Adjust Heavy-Duty
  • Caster Replacement
    • Heavy-Duty
Rear Link and Load Wheel
Pull Rod2 topics
  • End Replacement
  • Fork Height Adjustment
Rocker Arm
Upper Link
Entry Rollers1 topic
  • Replacement
Capacities and Specifications
Hydraulic System
Hydraulic Oils
Gear Oils
Grease
Truck Weight
Tire Sizes
Torque Specifications4 topics
  • Caster Assembly
  • Drive Wheel Assembly
  • Lift Mechanism
  • Hydraulics
Battery Specifications
Table 1. B60Z HD
Table 2. B80Z HD6 topics
  • Lifting a Load
  • Lowering a Load
  • Hydraulic Lines
  • Hydraulic Oil
  • Clean
  • Sound Level
Hydraulic Reservoir
Drive Unit Compartment Covers
Lift Pump and Motor8 topics
  • Lift Pump and Motor Assembly
    • Remove Reservoir
    • Remove Pump Motor
    • Disassemble Pump
    • Assemble Pump
    • Install Pump Motor
    • Install Reservoir to Pump
    • Lift Pump and Motor Assembly
Valve Repair9 topics
  • Lowering Valve
    • Remove
    • Install
  • Relief Valve
    • Remove
    • Install
  • Check Valve
    • Remove
    • Install
Lift Cylinder
Relief Valve Pressure Check4 topics
  • Relief Valve Adjust
  • Lift Assemblies
  • Lift Cylinders
  • Lift Pump and Motor Assembly
Electrical System
Electrical System Checks2 topics
  • Safety Precautions
  • Power Assist Steering Sensor
Repairs4 topics
  • Controller, Replace
    • Remove
    • Install
  • Contactor Coil, Check
Fuses
Horn1 topic
  • Replace
Brake Switch Operation
Brake and Interlock Switches
Height Limit
Control Handle (Standard)
Control Handle (HD Option)12 topics
  • Remove Top Cover
    • Remove Function Switches
    • Remove Throttle Sensor Assembly
    • Remove Handle Shaft Assembly
    • Remove Side Glide Switches
    • Remove the Coast Control Switches
    • Install the Coast Control Switches
    • Install Side Glide Switches
    • Install Handle Shaft Assembly
    • Install Throttle Sensor Assembly
    • Install Function Switches
    • Install Top Cover
Control Module1 topic
  • Check
Proximity Switch (Power Assist Steering)
Remote Control Box Switches
Table 1. Voltage Checks
Table 2. Input Connector Voltages

Inside this manual

Real pages from this service manual (547 pages). Open the sample pages (PDF, 193 KB)

Sample pages from the Hyster A257 (B60ZHD, B80ZHD) Electric Pallet Jack Service Manual: Specifications, Diagram, Troubleshooting
  • Specifications, page 208: Troubleshooting
  • Diagram, page 304: Diagrams
  • Troubleshooting, page 512: Troubleshooting

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 547 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Hyster A262 (B60ZHD, B80ZHD)Service Manual · A262 · $69.97Hyster B257 (B60ZHD, B80ZHD)Service Manual · B257 · $69.77Hyster B262 (B60ZHD, B80ZHD)Service Manual · B262 · $69.83

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).