Hyster A460 (K1.0H) Forklift Service Repair Manual

Download Complete Service Repair Manual for Hyster A460 (K10H) Forklift

This Factory Service Repair Manual offers all the service and repair information about Hyster A460 (K10H) Forklift The information on this manual covered everything you need to know when you want to repair or service Hyster A460 (K1

0H) Forklift

Models Covered:

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Manual Contents:

INDEX

Section: ELECTRICAL SYSTEM
ELECTRIC SYSTEM DIAGRAM (1/3) MOD

K10L
ELECTRIC SYSTEM DIAGRAM (2/3) MOD K10L
ELECTRIC SYSTEM DIAGRAM (3/3) MOD K10L
ELECTRIC SYSTEM DIAGRAM (1/5) MOD K10H
ELECTRIC SYSTEM DIAGRAM (2/5) MOD K10H
ELECTRIC SYSTEM DIAGRAM (3/5) MOD

K10H
ELECTRIC SYSTEM DIAGRAM (4/5) MOD K10H
ELECTRIC SYSTEM DIAGRAM (5/5) MOD K10H
ELECTRIC SYSTEM DIAGRAM (1/5) MOD K10M
ELECTRIC SYSTEM DIAGRAM (2/5) MOD K10M
ELECTRIC SYSTEM DIAGRAM (3/5) MOD

K10M
ELECTRIC SYSTEM DIAGRAM (4/5) MOD K10M
ELECTRIC SYSTEM DIAGRAM (5/5) MOD K10M

10 MOTOR COMPARTMENT COMPONENTS K10L
11 MOTOR COMPARTMENT COMPONENTS K06M-K10M
12 MOTOR COMPARTMENT COMPONENTS K1

0H
13 COMPONENTS ON THE MACHINE K10L-12
14 COMPONENTS ON THE MACHINE K10L-20
15 COMPONENTS ON THE MACHINE K10L-12/20
16 POSITION OF COMPONENTS ON THE MACHINE
17 POSITION OF THE ELECTRIC STEERING K06M-K1

0M
18 POSITION OF THE ELECTRIC STEERING K10H
19 CONSOLE COMPONENTS
110 DRIVE SYSTEM COMPONENTS K10L
111 DRIVE AND LIFTING SYSTEM COMPONENTS K06M-K10M
112 DRIVE AND LIFTING SYSTEM COMPONENTS K10H
20 ELECTRONIC DRIVE MOTOR CONTROL
2

1 DEFINITION OF THE DIRECTION OF TRAVEL OF THE MACHINE
22 GENERAL CHARACTERISTICS OF THE CHOPPER H2B
23 FUNCTIONAL CHARACTERISTICS OF THE CHOPPER
24 SELF-DIAGNOSIS FOR CHOPPER H2-400A
25 MECHANICAL DRAWING OF CHOPPER H2B
2

6 CONNECTORS
27 DESCRIPTION OF CONNECTOR B INPUTS
28 DESCRIPTION OF CONNECTOR E INPUTS
29 CHOPPER CONNECTIONS DIAGRAM
30 PROGRAMMING CONSOLE
31 INTRODUCTION
32 USE OF THE PROGRAMMING CONSOLE
3

3 CONSOLE FUNCTIONS CHART
34 PROGRAMMING THE CHOPPER
35 CONFIGURATION MENU/SET MODEL
36 CONFIGURATION MENU/SET OPTIONS
37 MAIN MENU/ADJUSTMENT
38 MAIN MENU/PARAMETER CHANGE
39 MAIN MENU/TESTER
3

10 MAIN MENU/SAVE PARAMETER
311 MAIN MENU/RESTORE PARAMETER
312 MAIN MENU/ALARM
313 MAIN MENU/PROGRAM VACC
314 H2 SYSTEM CONFIGURATION TABLES
315 TABLE SHOWING EQUIVALENCE BETWEEN PARAMETER VALUES AND PROGRAMMING LEVELS
3

16 CALIBRATION PROCEDURE FOR INITIALISTAION OF A NEW CHOPPER
317 TROUBLESHOOTING
318 DECODING OF ALARMS DISPLAYED ON CONSOLE

Section: ELECTRIC STEERING
10 ELECTRIC STEERING BOARD EPS-DC
11 CONTROL UNIT
1

2 LOGIC BOARD
13 CONNECTION DIAGRAM
20 PROGRAMMING CONSOLE
21 INTRODUCTION
22 USE OF THE PROGRAMMING CONSOLE
23 DESCRIPTION OF THE CONSOLE MENU
24 STEERING WITH TACHOMETRIC GENERATOR
25 DESCRIPTION OF ALARMS
2

6 LIST OF THE MAIN MENU PARAMETERS
27 MAIN MENU: ALARMS FUNCTION
28 CONFIGURATION MENU/SET OPTIONS

Section: SAFETY CIRCUITS
10 STANDARD SAFETY FUNCTIONS
20 OPTIONAL SAFETY FUNCTIONS
3

0 CONTROL OF SAFETY FUNCTIONS
31 DESCRIPTION OF SAFETY CONTROL SYSTEM
32 GENERAL DESCRIPTION OF THE PLC
40 ELECTRICAL ADJUSTMENT OF PROPORTIONAL SOLENOID VALVES FOR CAB LOWERING AND MAST LOWERING
50 PROGRAMMING
5

1 PLC INPUTS AND OUTPUTS TABLE
60 REMOVAL OF THE PLC
70 FUNCTION AND REPLACEMENT OF THE BACKUP BATTERIES
80 PROBLEMS RELATED TO THE PLC PS3 POWER SUPPLY
81 REPLACING THE FUSES OF THE PLC PS3
82 FUSE REPLACEMENT PROCEDURE
Section: REMOVAL OF ELECTRICAL COMPONENTS
1

0 REMOVAL OF THE HOOD
20 REMOVAL OF THE CONTROL PANEL
30 REPLACEMENT OF THE HORN AND DEADMAN MICROSWITCH
40 REPLACEMENT OF BRUSHES AND DRIVE MOTOR
50 REPLACEMENT OF PUMP MOTOR BRUSHES

Section: HYDRAULIC SYSTEM
1

0 HYDRAULIC DIAGRAM WITHOUT FORK RAISING CIRCUIT K10L-12
11 HYDRAULIC DIAGRAM WITH FORK RAISING CIRCUIT K10L-20
12 HYDRAULIC DIAGRAM WITH FORK RAISING CIRCUIT K06M-K10M-K10H
20 DIAGRAM SHOWING HYDRAULIC SYSTEM COMPONENTS K1

0M
21 DIAGRAM SHOWING HYDRAULIC SYSTEM COMPONENTS K10H DUPLEX
22 DIAGRAM SHOWING HYDRAULIC SYSTEM COMPONENTS K10H TRIPLEX
30 SOLENOID VALVES BLOCK
40 DIAGRAM OF CAB RAISING CYLINDER K10L
41 DIAGRAM OF FORK RAISING CYLINDER K1

0L
42 CAB RAISING CYLINDER MOD K10L
43 DIAGRAM OF CAB RAISING CYLINDER K06M-K10M
44 DIAGRAM OF CAB RAISING CYLINDER K06M-K10M
45 DIAGRAM OF CAB RAISING CYLINDER K10H DUPLEX
46 DIAGRAM OF CAB RAISING CYLINDER K1

0H TRIPLEX
47 DIAGRAM OF FORK RAISING CYLINDER K10H DUPLEX-TRIPLEX
50 REMOVAL OF CAB RAISING CYLINDER MODK10L
60 REPLACEMENT OF THE HYDRAULIC UNIT
70 REMOVAL OF FORK CYLINDER REPLACEMENT OF SEALS MODK1

0L
80 REPLACEMENT OF FORK CYLINDER SEALS
81 REMOVAL OF CYLINDER
90 REPLACEMENT OF CAB CYLINDER SEALS
Section: MECHANICS
10 COMPONENTS OF THE K10L STEERING SYSTEM
20 OPENING THE HOODS
30 REPLACEMENT OF THE DRIVE WHEEL K1

0L
31 REPLACEMENT OF THE DRIVE WHEEL K06M-K10M-K10H
40 REMOVAL OF THE LOAD WHEELS K10L
41 REMOVL OF THE LOAD WHEELS K06M-K10M-K10H
50 REMOVAL OF THE LATERAL GUARD RAILS
60 REMOVAL OF THE DRIVE MOTOR K1

0L
61 REMOVAL OF THE DRIVE MOTOR K06M-K10M
62 REMOVAL OF THE DRIVE MOTOR K10H
70 REMOVAL OF THE PUMP MOTOR K10L
80 REMOVAL OF THE ELECTRIC PUMP K06M-K10M
81 REMOVAL OF THE ELECTRIC PUMP K10H
90 REMOVAL OF THE FORK CARRIAGE PLATE
10

0 REMOVAL OF THE STEERING CHAIN/STEERING MOTOR K10L
101 REMOVAL OF THE STEERING CHAIN K06M-K10M
102 REMOVAL OF THE STEERING CHAIN K10H
110 REMOVAL OF THE CHAIN PULLEY
120 REMOVAL OF THE CAB/MASTS REPLACEMENT OF MOE BEARINGS
Section: REDUCTION GEAR
1

0 REDUCTION GEAR COMPONENTS K10L-K06M-K10M
20 REMOVAL OF THE REDUCTION GEAR K10L
21 REMOVAL OF THE REDUCTION GEAR K06M-K10M
30 REDUCTION GEAR COMPONENTS K10H
40 REMOVAL OF THE REDUCTION GEAR K10H
50 GENERAL
5

1 REDUCTION GEAR COMPONENTS
52 SERVICING PRODUCTS
53 STANDARD INSTRUMENTS AND TOOLS
54 MEASURING INSTRUMENTS
60 REMOVAL
61 INTRODUCTION
62 REMOVAL AND DISASSEMBLY OF THE UPPER PART OF THE REDUCTION GEAR CASING
6

3 REMOVAL OF THE REDUCTION GEAR COVER
64 REMOVAL OF THE CROWN WHEEL AND WHEEL AXLE
65 REMOVAL OF THE INNER RACE OF THE TAPER ROLLER BEARING FROM THE WHEEL AXLE AND THE CROWN WHEEL
66 REMOVAL OF THE PINION SHAFT
6

7 REMOVAL OF THE OUTER RACE OF THE TAPER ROLLER BEARING OF THE REDUCTION GEAR CASING
68 REMOVAL OF THE THREAD GUARD
70 ASSEMBLY
71 INTRODUCTION
72 PINION SHAFT ASSEMBLY MEASUREMENTS
73 PRE-ASSEMBLY OF THE REDUCTION GEAR CASING
7

4 PRE-ASSEMBLY OF THE PINION SHAFT
75 ASSEMBLY OF THE INNER RACE OF THE CROWN WHEEL BEARING
76 PRE-ASSEMBLY OF THE PINION SHAFT
77 INSTALLING THE PINION SHAFT IN THE REDUCTION GEAR CASING
78 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
710 MEASUREMENT AND ADJUSTMENT OF THE CROWN WHEEL RUN-OUT
711 CHECKING THE PROFILE OF THE GEAR TEETH
712 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
714 INSTALLING THE RADIAL SHAFT SEAL IN THE REDUCTION GEAR CASING
715 FITTING THE CASING COVER
716 UPPER PART OF THE REDUCTION GEAR
80 ADJUSTMENT DATA
8

1 TIGHTENING TORQUES
90 TROUBLESHOOTING
100 STORAGE
101 DISPOSAL
Section: BRAKING SYSTEM
10 COMPONENTS OF THE ELECTROMAGNETIC BRAKE
20 BRAKING SYSTEM
21 SERVICE BRAKE
22 EMERGENCY AND PARKING BRAKE
3

0 REMOVAL OF THE ELECTRIC BRAKE
31 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 can be used by anyone from a first time owner/amateur to a professional technician

Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawingsKeep this manual handy and use it often Performing routine preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs

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