Hyster B457 (K1.0L) Forklift Service Repair Manual

Download Full Service Workshop Repair Manual for Hyster B457 (K1.0L) Forklift.

This Workshop Service Manual offers all the service and repair information about Hyster B457 (K1.0L) Forklift. The information on this manual covered everything you need to know when you want to repair or service Hyster B457 (K1.0L) Forklift.

Models Covered:

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Manual Contents:

Section: ELECTRIC SYSTEM
– GENERAL SAFETY RULES
1.00 TRUCK DESCRIPTION
2.00 WIRING DIAGRAMS – MOD. K1.0L FP
2.01 WIRING DIAGRAMS – MOD. K1.0L FF/WP
2.02 WIRING DIAGRAMS – MOD. K1.0L SL
2.03 DESCRIPTION OF SENSOR AND PUSH BUTTON FUNCTIONS
3.00 ELECTRIC COMPONENTS – MOD. K1.0L FP
3.01 ELECTRIC COMPONENTS – MOD. K1.0L FF/WP
3.02 ELECTRIC COMPONENTS – MOD. K1.0L SL
4.00 TABLE OF THE FUNCTION INPUTS
5.00 TABLES OF MODULE 2 CONTROL “COMBI” PARAMETERS
5.01 TABLES OF MODULE 1 CONTROL “SICOS” PARAMETERS
5.02 TABLES OF MODULE 6 CONTROL “EPS-AC” PARAMETERS
6.00 MODULE CALIBRATION ACCESS PROCEDURE
6.01 MODULE SEARCH PROCEDURE
6.02 BATTERY VOLTAGE SETTING ON CONTROL COMBI
6.03 TRACTION START SEQUENCE
6.04 SPEED REDUCTIONS
7.00 MODULE REPLACEMENT PROCEDURE
7.01 MODULE 2 CONTROL COMBI REPLACEMENT
7.02 MODULE 6 CONTROL EPS-AC REPLACEMENT
7.03 MODULE 1 CONTROL SICOS REPLACEMENT
7.05 MAIN CONTACTOR REPLACEMENT
7.06 COOLING FAN REPLACEMENT
7.07 STEER STEPPER MOTOR REPLACEMENT
7.08 LIFTING AND BRAKING JOYSTICK REPLACEMENT
7.09 GEAR CONTROL POTENTIOMETER CARD REPLACEMENT
7.10 INSTRUMENT PANEL PUSH BUTTON REPLACEMENT
7.11 EMERGENCY PUSH BUTTON AND KEY-OPERATED SWITCH REPLACEMENT
7.14 OPERATOR PRESENCE SENSOR AND WARNING HORN REPLACEMENT
7.15 LIFTING CHAIN SENSOR REPLACEMENT
7.16 WHEEL CENTERING SENSOR REPLACEMENT
7.17 CABIN SIDE GUARD SENSOR REPLACEMENT
8.00 ENCODER, HEIGHT PRESELECTOR
8.01 ENCODER REPLACEMENT
8.02 ENCODER RESETTING TO ZERO SENSOR REPLACEMENT
9.00 SICOS DISPLAY
9.01 CONTROL COMPONENT GENERAL DESCRIPTION
10. 00 HEIGHT PRESELECTOR
11.00 DIAGNOSTICS
11.01 MODULE 2 CONTROL COMBI
11.02 MODULE 1 CONTROL DISPLAY SICOS
11.03 MODULE 6 CONTROL EPS-AC
– TRUTH TABLE
– TRUTH TABLE
– ELECTRIC COMPONENTS MOD. K1.0L FF – K1.0L WP
– ELECTRIC COMPONENTS MOD. K1.0L FP
– ELECTRIC COMPONENTS MOD. K1.0L SL
– FUNCTIONAL WIRING DIAGRAM POWER AND AUXILIARIES MOD. K1.0L FF – K1.0L WP
– FUNCTIONAL WIRING DIAGRAM CONTROL COMBI – EPS-AC MOD. K1.0L FF – K1.0L WP
– FUNCTIONAL WIRING DIAGRAM CONTROL SICOS (DISPLAY) MOD. K1.0L FF – K1.0L WP
– MOTOR COMPARTMENT SHEATH DIAGRAM MOD. K1.0L FF – K1.0L WP
– INSTRUMENT PANEL SHEATH DIAGRAM MOD. K1.0L FF – K1.0L WP
– FUNCTIONAL WIRING DIAGRAM POWER AND AUXILIARIES MOD. K1.0L FP
– FUNCTIONAL WIRING DIAGRAM CONTROL COMBI – EPS-AC MOD. K1.0L FP
– FUNCTIONAL WIRING DIAGRAM CONTROL SICOS (DISPLAY) MOD. K1.0L FP
– MOTOR COMPARTMENT SHEATH DIAGRAM MOD. K1.0L FP
– INSTRUMENT PANEL SHEATH DIAGRAM MOD. K1.0L FP
– FUNCTIONAL WIRING DIAGRAM POWER AND AUXILIARIES MOD. K1.0L SL
– FUNCTIONAL WIRING DIAGRAM CONTROL COMBI – EPS-AC MOD. K1.0L SL
– FUNCTIONAL WIRING DIAGRAM CONTROL SICOS (DISPLAY) MOD. K1.0L SL
– MOTOR COMPARTMENT SHEATH DIAGRAM MOD. K1.0L SL
– INSTRUMENT PANEL SHEATH DIAGRAM MOD. K1.0L SL
Section: ADDITIONAL FUNCTIONS
– SHHET OPTION 1 = FAN KIT FOR THE CABIN
– SHEET OPTION 2 = KIT FOR READING DESK
– SHEET OPTION 3 = SAFETY TRACER KIT
Section: HYDRAULIC SYSTEM
1.00 HYDRAULIC SYMBOL LEGEND
1.01 CORRECT ASSEMBLY METHOD FOR FEMALE PIPE FITTINGS
2.00 FUNCTIONAL HYDRAULIC DIAGRAM – MOD. K1.0L FP-FF WP
2.02 FUNCTIONAL HYDRAULIC DIAGRAM – MOD. K1.0L SL
3.00 HYDRAULIC POWER PACK COMPONENTS – MOD. K1.0L FP
3.02 HYDRAULIC POWER PACK COMPONENTS – MOD. K1.0L FF-FP
3.04 HYDRAULIC POWER PACK COMPONENTS – MOD. K1.0L SL
4.00 HYDRAULIC SYSTEM COMPONENTS – MOD. K1.0L FP
4.01 HYDRAULIC SYSTEM COMPONENTS – MOD. K1.0L FF-WP
4.02 HYDRAULIC SYSTEM COMPONENTS – MOD. K1.0L SL
4.03 LIFTING CYLINDER COMPONENTS – MOD. ALL MODELS
4.04 LIFTING CYLINDER BRAKING OPERATION – MOD. ALL MODELS
5.00 VALVE ADJUSTMENT, REPLACEMENT – MOD. K1.0L FP-FF-WP
5.04 VALVE ADJUSTMENT, REPLACEMENT – MOD. K1.0L SL
6.00 FORK LIFTING CYLINDER REMOVAL – MOD. K1.0L FP
6.01 CABIN LIFTING CYLINDER REMOVAL – MOD. K1.0L FF-WP
6.02 FORK LIFTING CYLINDER REMOVAL – MOD. K1.0L SL
6.03 CABIN LIFTING CYLINDER REMOVAL – MOD. K1.0L SL
7.00 CYLINDER GASKET REPLACEMENT – MOD. ALL MODELS
7.01 HYDRAULIC BRAKE VALVE REPLACEMENT – MOD. ALL MODELS
8.00 FORK CYLINDER HYDRAULIC PIPE REMOVAL – MOD. K1.0L FP
8.01 CABIN CYLINDER HYDRAULIC PIPE REMOVAL – MOD. K1.0L FF-WP
8.02 FORK CYLINDER HYDRAULIC PIPE REMOVAL – MOD. K1.0L SL
8.04 CABIN CYLINDER HYDRAULIC PIPE REMOVAL – MOD. K1.0L SL

MECHANICAL Section
1.00 GUIDE TABLES FOR THE CHOICE OF LIFTING STRAPS AND ROPES
1.01 SCREW DRIVING TORQUE TABLE
2.00 TRACTION WHEEL REMOVAL – MOD. ALL MODELS
2.01 LOAD WHEEL REMOVAL – MOD. K1.0L FP
2.02 LOAD WHEEL REMOVAL – MOD. K1.0L FF-SL.WP
2.03 TRACTION MOTOR REMOVAL – MOD. ALL MODELS
2.04 TRACTION MOTOR COMPONENTS – MOD. ALL MODELS
2.05 TRACTION MOTOR BEARING REPLACEMENT – MOD. ALL MODELS
2.06 TRACTION MOTOR BRUSH REPLACEMENT – MOD. ALL MODELS
2.07 TRACTION AND STEERING MOTOR SCREW DRIVING TORQUE TABLE – MOD. ALL MODELS
3.00 MOTOR PUMP UNIT REMOVAL – MOD. K1.0L FP
3.01 PUMP CASING REPLACEMENT – MOD. K1.0L FP
3.02 PUMP MOTOR REPLACEMENT – MOD. K1.0L FP
3.03 PUMP MOTOR BRUSH REPLACEMENT – MOD. K1.0L FP
3.04 MOTOR PUMP UNIT SCREW DRIVING TORQUE – MOD. K1.0L FP
3.05 MOTOR PUMP UNIT REMOVAL – MOD. K1.0L FF-WP
3.06 PUMP CASING REPLACEMENT – MOD. K1.0L FF-WP
3.07 PUMP MOTOR REMOVAL – MOD. K1.0L FF-WP
3.08 MOTOR PUMP UNIT REMOVAL – MOD. K1.0L SL
3.09 PUMP CASING REPLACEMENT – MOD. K1.0L SL
3.10 PUMP MOTOR REMOVAL – MOD. K1.0L SL
3.11 PUMP MOTOR BRUSH REPLACEMENT – MOD. K1.0L FF-SL WP
3.12 MOTOR PUMP UNIT SCREW DRIVING TORQUE – MOD. K1.0L FF-WP-SL
4.00 LIFTING CHAINS – MOD. ALL MODELS
4.01 FORK LIFTING CHAIN REMOVAL – MOD. K1.0L FP
4.02 PLATFORM LIFTING CHAIN REMOVAL – MOD. K1.0L FF H 1200MM
4.03 FORK LIFTING CHAIN REMOVAL – MOD. K1.0L SL
4.04 PLATFORM LIFTING CHAIN REMOVAL – MOD. K1.0L SL-WP H 1700MM
5.00 PLATFORM SIDE GUARD COMPONENTS – MOD. K1.0L SL-WP
5.02 REMOVAL OF THE GUARD KIT FROM THE TRUCK – MOD. K1.0L SL-WP
5.03 SIDE GUARD GAS RETURN SPRING REPLACEMENT – MOD. K1.0L SL-WP
5.04 UPPER GUARD REMOVAL – MOD. K1.0L SL-WP
5.05 INTERMEDIATE GUARD REMOVAL – MOD. K1.0L SL-WP
5.06 LOWER GUARD REMOVAL – MOD. K1.0L SL-WP
5.07 GUARD CONTROL BAR REMOVAL – MOD. K1.0L SL-WP
6.00 MOVABLE FORK UNIT COMPONENTS – MOD. K1.0L FP-SL
6.01 FIXED FORK UNIT COMPONENTS – MOD. K1.0L FP-SL
6.02 FIXED OR MOVABLE FORK PLATE BEARING REPLACEMENT – MOD. K1.0L FP
6.04 MOVABLE OR FIXED FORK PLATE BEARING REPLACEMENT – MOD. K1.0L SL
7.00 STEERING WHEEL PIN BEARING REPLACEMENT

Section: REDUCTION UNIT
1.00 REDUCTION UNIT COMPONENTS
1.01 REDUCTION UNIT COMPONENT TABLE
2.00 REDUCTION UNIT DISASSEMBLY
2.01 TRACTION MOTOR SHAFT OIL SEAL REPLACEMENT

Section: BRAKING SYSTEM
1.00 ELECTROMAGNETIC BRAKE COMPONENTS
2.00 BRAKING SYSTEM
3.00 ELECTRIC BRAKE COIL AND BRAKE LINING REPLACEMENT
3.04 ADJUSTMENT AND STARTING

USED INSTRUMENT CODES
P/N 2792832 CONSOLE (Electric section)
P/N 1527988 ADAPTER (Electric section)

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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