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

Download Complete Service Repair Manual for Hyster B457 (K10L) Forklift

This Factory Service Repair Manual offers all the service and repair information about Hyster B457 (K10L) 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
200 WIRING DIAGRAMS MOD K10L FP
201 WIRING DIAGRAMS MOD K10L FF/WP
202 WIRING DIAGRAMS MOD K10L SL
203 DESCRIPTION OF SENSOR AND PUSH BUTTON FUNCTIONS
300 ELECTRIC COMPONENTS MOD

K10L FP
301 ELECTRIC COMPONENTS MOD K10L FF/WP
302 ELECTRIC COMPONENTS MOD K10L SL
400 TABLE OF THE FUNCTION INPUTS
500 TABLES OF MODULE 2 CONTROL COMBI PARAMETERS
501 TABLES OF MODULE 1 CONTROL SICOS PARAMETERS
5

02 TABLES OF MODULE 6 CONTROL EPS-AC PARAMETERS
600 MODULE CALIBRATION ACCESS PROCEDURE
601 MODULE SEARCH PROCEDURE
602 BATTERY VOLTAGE SETTING ON CONTROL COMBI
603 TRACTION START SEQUENCE
6

04 SPEED REDUCTIONS
700 MODULE REPLACEMENT PROCEDURE
701 MODULE 2 CONTROL COMBI REPLACEMENT
702 MODULE 6 CONTROL EPS-AC REPLACEMENT
703 MODULE 1 CONTROL SICOS REPLACEMENT
705 MAIN CONTACTOR REPLACEMENT
7

06 COOLING FAN REPLACEMENT
707 STEER STEPPER MOTOR REPLACEMENT
708 LIFTING AND BRAKING JOYSTICK REPLACEMENT
709 GEAR CONTROL POTENTIOMETER CARD REPLACEMENT
710 INSTRUMENT PANEL PUSH BUTTON REPLACEMENT
7

11 EMERGENCY PUSH BUTTON AND KEY-OPERATED SWITCH REPLACEMENT
714 OPERATOR PRESENCE SENSOR AND WARNING HORN REPLACEMENT
715 LIFTING CHAIN SENSOR REPLACEMENT
716 WHEEL CENTERING SENSOR REPLACEMENT
717 CABIN SIDE GUARD SENSOR REPLACEMENT
8

00 ENCODER HEIGHT PRESELECTOR
801 ENCODER REPLACEMENT
802 ENCODER RESETTING TO ZERO SENSOR REPLACEMENT
900 SICOS DISPLAY
901 CONTROL COMPONENT GENERAL DESCRIPTION
10 00 HEIGHT PRESELECTOR
1100 DIAGNOSTICS
11

01 MODULE 2 CONTROL COMBI
1102 MODULE 1 CONTROL DISPLAY SICOS
1103 MODULE 6 CONTROL EPS-AC
TRUTH TABLE
TRUTH TABLE
ELECTRIC COMPONENTS MOD K10L FF K10L WP
ELECTRIC COMPONENTS MOD

K10L FP
ELECTRIC COMPONENTS MOD K10L SL
FUNCTIONAL WIRING DIAGRAM POWER AND AUXILIARIES MOD K10L FF K10L WP
FUNCTIONAL WIRING DIAGRAM CONTROL COMBI EPS-AC MOD K10L FF K10L WP
FUNCTIONAL WIRING DIAGRAM CONTROL SICOS (DISPLAY) MOD

K10L FF K10L WP
MOTOR COMPARTMENT SHEATH DIAGRAM MOD K10L FF K10L WP
INSTRUMENT PANEL SHEATH DIAGRAM MOD K10L FF K10L WP
FUNCTIONAL WIRING DIAGRAM POWER AND AUXILIARIES MOD K10L FP
FUNCTIONAL WIRING DIAGRAM CONTROL COMBI EPS-AC MOD

K10L FP
FUNCTIONAL WIRING DIAGRAM CONTROL SICOS (DISPLAY) MOD K10L FP
MOTOR COMPARTMENT SHEATH DIAGRAM MOD K10L FP
INSTRUMENT PANEL SHEATH DIAGRAM MOD K10L FP
FUNCTIONAL WIRING DIAGRAM POWER AND AUXILIARIES MOD

K10L SL
FUNCTIONAL WIRING DIAGRAM CONTROL COMBI EPS-AC MOD K10L SL
FUNCTIONAL WIRING DIAGRAM CONTROL SICOS (DISPLAY) MOD K10L SL
MOTOR COMPARTMENT SHEATH DIAGRAM MOD K10L SL
INSTRUMENT PANEL SHEATH DIAGRAM MOD

K10L 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
100 HYDRAULIC SYMBOL LEGEND
1

01 CORRECT ASSEMBLY METHOD FOR FEMALE PIPE FITTINGS
200 FUNCTIONAL HYDRAULIC DIAGRAM MOD K10L FP-FF WP
202 FUNCTIONAL HYDRAULIC DIAGRAM MOD K10L SL
300 HYDRAULIC POWER PACK COMPONENTS MOD K10L FP
3

02 HYDRAULIC POWER PACK COMPONENTS MOD K10L FF-FP
304 HYDRAULIC POWER PACK COMPONENTS MOD K10L SL
400 HYDRAULIC SYSTEM COMPONENTS MOD K10L FP
401 HYDRAULIC SYSTEM COMPONENTS MOD K10L FF-WP
4

02 HYDRAULIC SYSTEM COMPONENTS MOD K10L SL
403 LIFTING CYLINDER COMPONENTS MOD ALL MODELS
404 LIFTING CYLINDER BRAKING OPERATION MOD ALL MODELS
500 VALVE ADJUSTMENT REPLACEMENT MOD K10L FP-FF-WP
5

04 VALVE ADJUSTMENT REPLACEMENT MOD K10L SL
600 FORK LIFTING CYLINDER REMOVAL MOD K10L FP
601 CABIN LIFTING CYLINDER REMOVAL MOD K10L FF-WP
602 FORK LIFTING CYLINDER REMOVAL MOD K10L SL
603 CABIN LIFTING CYLINDER REMOVAL MOD

K10L SL
700 CYLINDER GASKET REPLACEMENT MOD ALL MODELS
701 HYDRAULIC BRAKE VALVE REPLACEMENT MOD ALL MODELS
800 FORK CYLINDER HYDRAULIC PIPE REMOVAL MOD K10L FP
801 CABIN CYLINDER HYDRAULIC PIPE REMOVAL MOD

K10L FF-WP
802 FORK CYLINDER HYDRAULIC PIPE REMOVAL MOD K10L SL
804 CABIN CYLINDER HYDRAULIC PIPE REMOVAL MOD K10L SL

MECHANICAL Section
100 GUIDE TABLES FOR THE CHOICE OF LIFTING STRAPS AND ROPES
1

01 SCREW DRIVING TORQUE TABLE
200 TRACTION WHEEL REMOVAL MOD ALL MODELS
201 LOAD WHEEL REMOVAL MOD K10L FP
202 LOAD WHEEL REMOVAL MOD K10L FF-SLWP
203 TRACTION MOTOR REMOVAL MOD ALL MODELS
2

04 TRACTION MOTOR COMPONENTS MOD ALL MODELS
205 TRACTION MOTOR BEARING REPLACEMENT MOD ALL MODELS
206 TRACTION MOTOR BRUSH REPLACEMENT MOD ALL MODELS
207 TRACTION AND STEERING MOTOR SCREW DRIVING TORQUE TABLE MOD

ALL MODELS
300 MOTOR PUMP UNIT REMOVAL MOD K10L FP
301 PUMP CASING REPLACEMENT MOD K10L FP
302 PUMP MOTOR REPLACEMENT MOD K10L FP
303 PUMP MOTOR BRUSH REPLACEMENT MOD K10L FP
304 MOTOR PUMP UNIT SCREW DRIVING TORQUE MOD

K10L FP
305 MOTOR PUMP UNIT REMOVAL MOD K10L FF-WP
306 PUMP CASING REPLACEMENT MOD K10L FF-WP
307 PUMP MOTOR REMOVAL MOD K10L FF-WP
308 MOTOR PUMP UNIT REMOVAL MOD K10L SL
309 PUMP CASING REPLACEMENT MOD

K10L SL
310 PUMP MOTOR REMOVAL MOD K10L SL
311 PUMP MOTOR BRUSH REPLACEMENT MOD K10L FF-SL WP
312 MOTOR PUMP UNIT SCREW DRIVING TORQUE MOD K10L FF-WP-SL
400 LIFTING CHAINS MOD ALL MODELS
4

01 FORK LIFTING CHAIN REMOVAL MOD K10L FP
402 PLATFORM LIFTING CHAIN REMOVAL MOD K10L FF H 1200MM
403 FORK LIFTING CHAIN REMOVAL MOD K10L SL
404 PLATFORM LIFTING CHAIN REMOVAL MOD K10L SL-WP H 1700MM
5

00 PLATFORM SIDE GUARD COMPONENTS MOD K10L SL-WP
502 REMOVAL OF THE GUARD KIT FROM THE TRUCK MOD K10L SL-WP
503 SIDE GUARD GAS RETURN SPRING REPLACEMENT MOD K10L SL-WP
504 UPPER GUARD REMOVAL MOD

K10L SL-WP
505 INTERMEDIATE GUARD REMOVAL MOD K10L SL-WP
506 LOWER GUARD REMOVAL MOD K10L SL-WP
507 GUARD CONTROL BAR REMOVAL MOD K10L SL-WP
600 MOVABLE FORK UNIT COMPONENTS MOD K10L FP-SL
6

01 FIXED FORK UNIT COMPONENTS MOD K10L FP-SL
602 FIXED OR MOVABLE FORK PLATE BEARING REPLACEMENT MOD K10L FP
604 MOVABLE OR FIXED FORK PLATE BEARING REPLACEMENT MOD K10L SL
700 STEERING WHEEL PIN BEARING REPLACEMENT

Section: REDUCTION UNIT
1

00 REDUCTION UNIT COMPONENTS
101 REDUCTION UNIT COMPONENT TABLE
200 REDUCTION UNIT DISASSEMBLY
201 TRACTION MOTOR SHAFT OIL SEAL REPLACEMENT

Section: BRAKING SYSTEM
100 ELECTROMAGNETIC BRAKE COMPONENTS
2

00 BRAKING SYSTEM
300 ELECTRIC BRAKE COIL AND BRAKE LINING REPLACEMENT
304 ADJUSTMENT AND STARTING

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

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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