Hyster A459 (K1.0M) Forklift Service Repair Manual

Download Full Service Workshop Repair Manual for Hyster A459 (K1.0M) Forklift.

This Workshop Service Manual offers all the service and repair information about Hyster A459 (K1.0M) Forklift. The information on this manual covered everything you need to know when you want to repair or service Hyster A459 (K1.0M) Forklift.

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Manual Contents:

INDEX

Section: ELECTRICAL SYSTEM
– ELECTRIC SYSTEM DIAGRAM (1/3) MOD. K1.0L
– ELECTRIC SYSTEM DIAGRAM (2/3) MOD. K1.0L
– ELECTRIC SYSTEM DIAGRAM (3/3) MOD. K1.0L
– ELECTRIC SYSTEM DIAGRAM (1/5) MOD. K1.0H
– ELECTRIC SYSTEM DIAGRAM (2/5) MOD. K1.0H
– ELECTRIC SYSTEM DIAGRAM (3/5) MOD. K1.0H
– ELECTRIC SYSTEM DIAGRAM (4/5) MOD. K1.0H
– ELECTRIC SYSTEM DIAGRAM (5/5) MOD. K1.0H
– ELECTRIC SYSTEM DIAGRAM (1/5) MOD. K1.0M
– ELECTRIC SYSTEM DIAGRAM (2/5) MOD. K1.0M
– ELECTRIC SYSTEM DIAGRAM (3/5) MOD. K1.0M
– ELECTRIC SYSTEM DIAGRAM (4/5) MOD. K1.0M
– ELECTRIC SYSTEM DIAGRAM (5/5) MOD. K1.0M

1.0 MOTOR COMPARTMENT COMPONENTS K1.0L
1.1 MOTOR COMPARTMENT COMPONENTS K0.6M-K1.0M
1.2 MOTOR COMPARTMENT COMPONENTS K1.0H
1.3 COMPONENTS ON THE MACHINE K1.0L-12
1.4 COMPONENTS ON THE MACHINE K1.0L-20
1.5 COMPONENTS ON THE MACHINE K1.0L-12/20
1.6 POSITION OF COMPONENTS ON THE MACHINE
1.7 POSITION OF THE ELECTRIC STEERING K0.6M-K1.0M
1.8 POSITION OF THE ELECTRIC STEERING K1.0H
1.9 CONSOLE COMPONENTS
1.10 DRIVE SYSTEM COMPONENTS K1.0L
1.11 DRIVE AND LIFTING SYSTEM COMPONENTS K0.6M-K1.0M
1.12 DRIVE AND LIFTING SYSTEM COMPONENTS K1.0H
2.0 ELECTRONIC DRIVE MOTOR CONTROL
2.1 DEFINITION OF THE DIRECTION OF TRAVEL OF THE MACHINE
2.2 GENERAL CHARACTERISTICS OF THE CHOPPER H2B
2.3 FUNCTIONAL CHARACTERISTICS OF THE CHOPPER
2.4 SELF-DIAGNOSIS FOR CHOPPER H2-400A
2.5 MECHANICAL DRAWING OF CHOPPER H2B
2.6 CONNECTORS
2.7 DESCRIPTION OF CONNECTOR “B” INPUTS
2.8 DESCRIPTION OF CONNECTOR “E” INPUTS
2.9 CHOPPER CONNECTIONS DIAGRAM
3.0 PROGRAMMING CONSOLE
3.1 INTRODUCTION
3.2 USE OF THE PROGRAMMING CONSOLE
3.3 CONSOLE FUNCTIONS CHART
3.4 PROGRAMMING THE CHOPPER
3.5 CONFIGURATION MENU/SET MODEL
3.6 CONFIGURATION MENU/SET OPTIONS
3.7 MAIN MENU/ADJUSTMENT
3.8 MAIN MENU/PARAMETER CHANGE
3.9 MAIN MENU/TESTER
3.10 MAIN MENU/SAVE PARAMETER
3.11 MAIN MENU/RESTORE PARAMETER
3.12 MAIN MENU/ALARM
3.13 MAIN MENU/PROGRAM VACC
3.14 H2 SYSTEM CONFIGURATION TABLES
3.15 TABLE SHOWING EQUIVALENCE BETWEEN PARAMETER VALUES AND PROGRAMMING LEVELS
3.16 CALIBRATION PROCEDURE FOR INITIALISTAION OF A NEW CHOPPER
3.17 TROUBLESHOOTING
3.18 DECODING OF ALARMS DISPLAYED ON CONSOLE

Section: ELECTRIC STEERING
1.0 ELECTRIC STEERING BOARD EPS-DC
1.1 CONTROL UNIT
1.2 LOGIC BOARD
1.3 CONNECTION DIAGRAM
2.0 PROGRAMMING CONSOLE
2.1 INTRODUCTION
2.2 USE OF THE PROGRAMMING CONSOLE
2.3 DESCRIPTION OF THE CONSOLE MENU
2.4 STEERING WITH TACHOMETRIC GENERATOR
2.5 DESCRIPTION OF ALARMS
2.6 LIST OF THE MAIN MENU PARAMETERS
2.7 MAIN MENU: “ALARMS” FUNCTION
2.8 CONFIGURATION MENU/SET OPTIONS

Section: SAFETY CIRCUITS
1.0 STANDARD SAFETY FUNCTIONS
2.0 OPTIONAL SAFETY FUNCTIONS
3.0 CONTROL OF SAFETY FUNCTIONS
3.1 DESCRIPTION OF SAFETY CONTROL SYSTEM
3.2 GENERAL DESCRIPTION OF THE PLC
4.0 ELECTRICAL ADJUSTMENT OF PROPORTIONAL SOLENOID VALVES FOR CAB LOWERING AND MAST LOWERING
5.0 PROGRAMMING
5.1 PLC INPUTS AND OUTPUTS TABLE
6.0 REMOVAL OF THE PLC
7.0 FUNCTION AND REPLACEMENT OF THE BACKUP BATTERIES
8.0 PROBLEMS RELATED TO THE PLC PS3 POWER SUPPLY
8.1 REPLACING THE FUSES OF THE PLC PS3
8.2 FUSE REPLACEMENT PROCEDURE
Section: REMOVAL OF ELECTRICAL COMPONENTS
1.0 REMOVAL OF THE HOOD
2.0 REMOVAL OF THE CONTROL PANEL
3.0 REPLACEMENT OF THE HORN AND DEADMAN MICROSWITCH
4.0 REPLACEMENT OF BRUSHES AND DRIVE MOTOR
5.0 REPLACEMENT OF PUMP MOTOR BRUSHES

Section: HYDRAULIC SYSTEM
1.0 HYDRAULIC DIAGRAM WITHOUT FORK RAISING CIRCUIT K1.0L-12
1.1 HYDRAULIC DIAGRAM WITH FORK RAISING CIRCUIT K1.0L-20
1.2 HYDRAULIC DIAGRAM WITH FORK RAISING CIRCUIT K0.6M-K1.0M-K1.0H
2.0 DIAGRAM SHOWING HYDRAULIC SYSTEM COMPONENTS K1.0M
2.1 DIAGRAM SHOWING HYDRAULIC SYSTEM COMPONENTS K1.0H DUPLEX
2.2 DIAGRAM SHOWING HYDRAULIC SYSTEM COMPONENTS K1.0H TRIPLEX
3.0 SOLENOID VALVES BLOCK
4.0 DIAGRAM OF CAB RAISING CYLINDER K1.0L
4.1 DIAGRAM OF FORK RAISING CYLINDER K1.0L
4.2 CAB RAISING CYLINDER MOD. K1.0L
4.3 DIAGRAM OF CAB RAISING CYLINDER K0.6M-K1.0M
4.4 DIAGRAM OF CAB RAISING CYLINDER K0.6M-K1.0M
4.5 DIAGRAM OF CAB RAISING CYLINDER K1.0H DUPLEX
4.6 DIAGRAM OF CAB RAISING CYLINDER K1.0H TRIPLEX
4.7 DIAGRAM OF FORK RAISING CYLINDER K1.0H DUPLEX-TRIPLEX
5.0 REMOVAL OF CAB RAISING CYLINDER MOD.K1.0L
6.0 REPLACEMENT OF THE HYDRAULIC UNIT
7.0 REMOVAL OF FORK CYLINDER – REPLACEMENT OF SEALS MOD.K1.0L
8.0 REPLACEMENT OF FORK CYLINDER SEALS
8.1 REMOVAL OF CYLINDER
9.0 REPLACEMENT OF CAB CYLINDER SEALS
Section: MECHANICS
1.0 COMPONENTS OF THE K1.0L STEERING SYSTEM
2.0 OPENING THE HOODS
3.0 REPLACEMENT OF THE DRIVE WHEEL K1.0L
3.1 REPLACEMENT OF THE DRIVE WHEEL K0.6M-K1.0M-K1.0H
4.0 REMOVAL OF THE LOAD WHEELS K1.0L
4.1 REMOVL OF THE LOAD WHEELS K0.6M-K1.0M-K1.0H
5.0 REMOVAL OF THE LATERAL GUARD RAILS
6.0 REMOVAL OF THE DRIVE MOTOR K1.0L
6.1 REMOVAL OF THE DRIVE MOTOR K0.6M-K1.0M
6.2 REMOVAL OF THE DRIVE MOTOR K1.0H
7.0 REMOVAL OF THE PUMP MOTOR K1.0L
8.0 REMOVAL OF THE ELECTRIC PUMP K0.6M-K1.0M
8.1 REMOVAL OF THE ELECTRIC PUMP K1.0H
9.0 REMOVAL OF THE FORK CARRIAGE PLATE
10.0 REMOVAL OF THE STEERING CHAIN/STEERING MOTOR K1.0L
10.1 REMOVAL OF THE STEERING CHAIN K0.6M-K1.0M
10.2 REMOVAL OF THE STEERING CHAIN K1.0H
11.0 REMOVAL OF THE CHAIN PULLEY
12.0 REMOVAL OF THE CAB/MASTS, REPLACEMENT OF MOE BEARINGS
Section: REDUCTION GEAR
1.0 REDUCTION GEAR COMPONENTS K1.0L-K0.6M-K1.0M
2.0 REMOVAL OF THE REDUCTION GEAR K1.0L
2.1 REMOVAL OF THE REDUCTION GEAR K0.6M-K1.0M
3.0 REDUCTION GEAR COMPONENTS K1.0H
4.0 REMOVAL OF THE REDUCTION GEAR K1.0H
5.0 GENERAL
5.1 REDUCTION GEAR COMPONENTS
5.2 SERVICING PRODUCTS
5.3 STANDARD INSTRUMENTS AND TOOLS
5.4 MEASURING INSTRUMENTS
6.0 REMOVAL
6.1 INTRODUCTION
6.2 REMOVAL AND DISASSEMBLY OF THE UPPER PART OF THE REDUCTION GEAR CASING
6.3 REMOVAL OF THE REDUCTION GEAR COVER
6.4 REMOVAL OF THE CROWN WHEEL AND WHEEL AXLE
6.5 REMOVAL OF THE INNER RACE OF THE TAPER ROLLER BEARING FROM THE WHEEL AXLE AND THE CROWN WHEEL
6.6 REMOVAL OF THE PINION SHAFT
6.7 REMOVAL OF THE OUTER RACE OF THE TAPER ROLLER BEARING OF THE REDUCTION GEAR CASING
6.8 REMOVAL OF THE THREAD GUARD
7.0 ASSEMBLY
7.1 INTRODUCTION
7.2 PINION SHAFT ASSEMBLY MEASUREMENTS
7.3 PRE-ASSEMBLY OF THE REDUCTION GEAR CASING
7.4 PRE-ASSEMBLY OF THE PINION SHAFT
7.5 ASSEMBLY OF THE INNER RACE OF THE CROWN WHEEL BEARING
7.6 PRE-ASSEMBLY OF THE PINION SHAFT
7.7 INSTALLING THE PINION SHAFT IN THE REDUCTION GEAR CASING
7.8 MEASURING THE PINION SHAFT BEARING CLEARANCE AND ADJUSTMENT OF THE PRELOADING
7.9 INSTALLING THE WHEEL AXLE AND THE CROWN WHEEL IN THE REDUCTION GEAR CASING
7.10 MEASUREMENT AND ADJUSTMENT OF THE CROWN WHEEL RUN-OUT
7.11 CHECKING THE PROFILE OF THE GEAR TEETH
7.12 MEASURING THE CLEARANCE OF THE WHEEL AXLE BEARINGS AND ADJUSTMENT OF THE PRELOADING ON THE BEARINGS
7.13 ASSEMBLY OF THE THREAD GUARD ON THE REDUCTION GEAR CASING
7.14 INSTALLING THE RADIAL SHAFT SEAL IN THE REDUCTION GEAR CASING
7.15 FITTING THE CASING COVER
7.16 UPPER PART OF THE REDUCTION GEAR
8.0 ADJUSTMENT DATA
8.1 TIGHTENING TORQUES
9.0 TROUBLESHOOTING
10.0 STORAGE
10.1 DISPOSAL
Section: BRAKING SYSTEM
1.0 COMPONENTS OF THE ELECTROMAGNETIC BRAKE
2.0 BRAKING SYSTEM
2.1 SERVICE BRAKE
2.2 EMERGENCY AND PARKING BRAKE
3.0 REMOVAL OF THE ELECTRIC BRAKE
3.1 ADJUSTMENT AND PUTTING INTO SERVICE

REDUCTION GEAR
SERIES HFK 100 – 200 400 – 600
SERIES GR 92 – 96 – 97

DC-EPS POWER STEERING AND WIRE GUIDANCE

This manual is appropriate for people with a range of degrees of knowledge, from novices and inexperienced owners to seasoned technicians. This manual’s step-by-step instructions are given in an easy-to-understand way with the help of images and drawings, making them understandable even to people with little prior experience. It is best to have this manual nearby and to refer to it frequently. You may successfully avoid early failures and needless repairs by regularly performing routine and preventive maintenance as directed, eventually saving significant time and money.

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Language: English