Hyster C457 Operating instructions

Hyster C457 (K1.0L AC) Forklift

Revision: 0 (04/2010)
Technical information for
Hyster customer care centres
This manual is addressed to the skilled technicians of Hyster
service network
C457..... K1.0L
Part n°: 4006755

2
SERVICE
PREFACE
IMPORTANT
This manual contains detailed information about the routine and preventive maintenance, troubleshooting,
disassembly/assembly of components, adjustment procedures for the following Hyster models:
K1.0L FP, K1.0L 12, K1.0L SL, K1.0L WP
These procedures require specic technical knwoledge and they must be carried out only by qualied and
trained staff. Please read this manual carefully in order to prevent damage or accidents to people; it must
be kept in good conditions so that it is always readable and complete in all its parts.
This manual is an integral part of the use and maintenance manual and it does not replace it.
Product support group

3
SERVICE PREFACE
HOW TO USE THE MANUAL
ENCLOSED MANUALS
Motors (Part no.1641577)
Industrial battery (2240 SRM 1)
SECTIONS
This manual is divided in the following sections:
Section 1: Presentation
Section 2: Installation and settings
Section 3: Diagnostic
Section 4: Electric system
Secttion 5: Hydraulic system
Sezione 6: Frame mechanics
Sezione 7: Mast mechanics
Sezione 8: Cabin mechanics
Sezione 9: Reduction unit
Sezione 10: Breaking system
Sezione 11: Ordinary maintenance
Always refer to the index with the numbered black bands in order to go to the desired section.
SYMBOLS
It indicates the presence of a danger that can cause accidents to people or damage to the truck.
It indicates a danger due to high temperatures.
It indicates notes or important information to be taken into consideration.
It indicates that, in the electronic version of the manual, by clicking on this symbol it is possible
to display a lmed sequence.
ASSEMBLY PROCEDURE
For the assembly carry out the disassembly procedure in the reverse order complying with the informa-
tion and the notes concerning the correct operation of the truck.

4
GENERAL SAFETY STANDARDS
PERSONAL SAFETY
Always use the personal protective equipment when it is required.•
Pay attention to the squashing risks due to moving parts, oscillations, not correctly fastened materials• when lifting operations are carried out or when the loads are moved.
Do not wear rings, watches, jewels, unbuttoned or hanging clothes such as scarves, unbuttoned jackets• or smocks with open zips that can get entangled in the moving parts.
Never carry out cleaning, lubrication or maintenance operations when the battery is connected.•
IIf you use compressed air to clean the parts, wear glasses with lateral guards. The air pressure must• not be higher than 1 bar.
SAFETY IN THE WORKPLACE
Make sure that all working tools are perfectly efcient and ready to use. Keep the working surfaces • clean and free from the deposits that settle on the truck parts and cause damage.
Keep sparks, free ames and cigarettes at a distance from fuels or ammable materials such as the • gas of the batteries.
Make sure that the working area is well ventilated, illuminated, dry and clean. Remove any water pud-• dles or oil spots.
Make sure that the lifting equipment, devices or machines can bear the load.•
ver use petrol, gas oil or other ammable liquids as detergents: use commercial non-toxic and non-•
ammable solvents.
In case the interventions are carried out of the workshop, lay the truck at and block it. If it is necessary •
to carry out the work on slopes, block the truck and bring it in a at area as soon as possible within a
certain safety limit.
Disconnect the batteries and label all controls in order to indicate that an intervention is in progress.• Block the truck and any equipment to be lifted.
Do not carry out any intervention on the truck when the operators are controlling it, except that they are•
qualied operators and help to carry out the intervention.
During towing operations use only the prescribed attachment points and make sure that the pins and/or• bolts are tightly secured. Lift and move all heavy components by means of a lifting device of proper
carrying capacity. Use the proper eyebolts. Make sure that nobody stays near the load to be lifted.
Do not twist chains or metal ropes.•
Do not use damaged or bent chains or ropes: do not use them during lifting or towing operations. While• handling them always wear safety gloves.
Do not accumulate cloths soaked with grease or oil: they represent a risk of re. Always put them in a • closed metal container.
The oil must be collected and not be let off in the drain pipes; the industrial oils must be disposed of by• specialized companies under the protection of the law in force in every Country.
When welding operations are carried out, it is necessary to use proper accident-prevention protections:• protective glasses, helmet, overalls, shoes. The protective glasses must be worn also by the people
who do not carry out the works if they stay near a welding area.
SERVICE
PREFACE

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Before using the batteries, make sure that the cables are connected to the terminals as described: (+)• with (+) and (-) with (-).
Do not short-circuit the terminals.•
The gas emanated during a recharge is higly ammable. During the recharge of the battery leave the •
battery compartment uncovered in order to use a more efcient ventilation and remove the plugs.
Do not check the condition of the battery charge by means of “jumpers” obtained by placing metal• objects on the terminals.
Before any intervention check if there are no short-circuit elements.•
Disconnect the batteries before acting on the electric system.•
For the battery chargers and similar equipment, use only auxiliary electric power supply sources in• order to avoid any electric shocks.
A uid passing through a very small hole can be almost invisible but strong enough to penetrate into •
the skin; in these cases check the uid by means of a card or a piece of wood.
To chek the pressure of the plant use the proper devices.•
BANDS, ROPES AND HANGING ROPES: SUGGESTIONS FOR THE USE•
Register all used hanging ropes, whose features and data are shown on the identication plate.•
Do not use bands, ropes or hanging ropes, whose identication plate has been lost.•
Always use bands, ropes or hanging ropes of proper dimensions.As far as the hanging ropes are con-• cerned, take into consideration the lifting angle and the unbalance of the load.
The hooks of the hanging ropes must have a proper size according to the hook of the bridge crane and• they must move freely.
Position the load in the hook mouth.•
Do not place the load on the point of the hook.•
During lifting, do not carry out sudden operations that could tear the ropes and the bands.•
Do not carry out lifting operations with twisted ropes and bands.•
Knots are forbidden.Always protect the ropes and the bands when they are near sharp edges.•
During the movements without load in order to avoid unintentional collisions or hooking, fasten the• hooks to the proper seats and lock them.
Use of hanging ropes with unbalanced load
If unbalanced loads must be lifted it is advisable to reduce the carrying capacity of the hanging ropes:
Slings with 2 arms, consider them as the slings with 1 arm.•
Slings with 3 and 4 arms, consider them as the slings with 2 arms.•
Suggestions for maintenance
Check the bands, the ropes and the hanging ropes according to the law in force in order to determine their
working conditions. Carry out the replacement in the following cases:
When the components are deformed, cut or when there are cracks, hollows, notches or abrasions on• them.
When the wear of the components is higher than 10% of the initial dimensions.•
When the sling is overloaded.•
SERVICE PREFACE

6
Rope capacity table
Band capacity table
Colour (mm)
Working
capacity (kg)
nero 35 500 1000 700 400
viola 50 1000 2000 1400 800
nero 50 1500 3000 2100 1200
verde 60 2000 4000 2800 1600
giallo 75 3000 6000 4200 2400
grigio 120 4000 8000 5600 3200
rosso 150 5000 10000 7000 4000
marrone 180 6000 12000 8400 4800
blu 240 8000 16000 11200 6400
arancio 300 10000 20000 14000 8000
Coefcient 1 2 1,4 0,8
Colour
Working
capacity (kg)
viola 1000 2000 1400 800
verde 2000 4000 2800 1600
giallo 3000 6000 4200 2400
grigio 4000 8000 5600 3200
rosso 5000 10000 7000 4000
marrone 6000 12000 8400 4800
blu 8000 16000 11200 6400
arancio 10000 20000 14000 8000
arancio 12000 24000 16800 9600
arancio 15000 30000 21000 12000
arancio 20000 40000 28000 16000
arancio 25000 50000 35000 20000
arancio 30000 60000 42000 24000
1 2 1,4 0,8
Coefcient
Width
SERVICE
PREFACE

7
Colour
Working
capacity (kg)
viola 1000 1400 2100 2100
verde 2000 2800 4200 4200
giallo 3000 3800 6300 6300
grigio 4000 5600 8400 8400
rosso 5000 6600 9800 10500
Coefcient 1 1,4 2,1 2,1
Hanging rope capacity table
Working capacity: the working capacity is calculated with an angle in the centre of 90°.
SERVICE PREFACE

8
DRIVING TORQUE OF SCREWS, NUTS AND CONNECTORS
Beforethedisassemblyofthevariousparts
and of the bolts and screws, read carefully
the instructions below.
To tighten the screws use the product LOCTITE 270 in
order to ensure the safety of the threaded couplings.
If it is not possible to loosen the screws because this
product is used, do not add extensions to the tools, but
heat the area (maximum 50°C) in oder to eliminate the
effect of LOCTITE 270.
In the above-mentioned cases use a small quantity of
LOCTITE 270 in the assembly phase (30% of the con-
nection surface).
The driving torque with which the threaded couplings
are tightened is very important to ensure the safety of
the truck connection.
Theboltsandnutsandthecorrespondingdrivingtorques
are shown in the tables on this page.
Nominal
diameter DRIVING TORQUE Nm
Class 8 Class 10
M 3 4 5.2
M 4 7 9.15
M 5 12.14 14.8
M 6 17.2 20.9
M 8 31.8 38.1
M 10 50.5 60.3
M 12 74.2 88.5
M 14 101.2 120.8
M 16 138,2 164.9
M 18 176.6 203.5
M 20 225.4 259.7
M 22 278.8 321.2
M 24 324.8 374.2
M 27 422.3 486.5
M 30 516.1 594.7
Preloading
N
DRIVING TORQUE Nm
Class 5.8 Class 8.8 Class 10.9
M 4 0.7 7 3 2400 1.92 1.44 3.07 2.3 4.17 3.13
M 5 0.8 8 4 3880 3.88 2.91 6.2 4.65 8.43 6.33
M 6 1 10 5 5490 6.58 4.94 10.5 7.9 14.3 10.8
M 8 1.25 13 6 9990 16 12 25.6 19.2 34.8 26.1
M 8 1 13 6 10700 17.1 12.8 27.4 20.5 37.3 27.9
M 10 1.5 16 8 15825 31.7 23.8 51 38 69 52
M 10 1.25 16 8 16700 33.4 25.1 53 40.1 73 55
M 12 1.75 18 10 23025 55 41.4 88 66 120 90
M 12 1.25 18 10 25150 60 45.3 96 72 130 98
M 14 2 21 12 31400 88 66 140 105 190 145
M 14 1.5 21 12 34125 96 72 155 115 210 155
M 16 2 24 14 42850 135 105 220 165 300 225
M 16 1.5 24 14 45600 145 110 235 175 320 240
M 20 2.5 30 17 66875 270 200 430 320 580 435
M 20 1.5 30 17 74250 295 225 475 355 650 485
= with lubricant
SERVICE
PREFACE

9
CORRECT METHOD TO APPLY THE FEMALE CONNECTORS
To ensure an optimum connection between the female connectors and the adapters mentioned in this ma-
nual, it is necessary to carry out the following procedure, which is different from the one for the assembly
of the rigid pipes.
Female connectors without gasket (metal/metal connection)
Screw the nut manually and then tigthen 1/4 turn by means of a spanner.
Female connectors with O-RING
Screw the nut manually and then tighten 1/4 turn by means of a spanner.
In any case make sure that the pipe is correctly aligned before tightening the nut to the adapter.
DRIVING TORQUE
The values shown in the tables refer to to galvanized steel connectors. Different values
correspond to connectors of different materials.
ROTARY METRIC FEMALE CONNECTOR jic
37°
Thread
UNF Dimension
Driving torque Nm
Nominal torque min / max
7/16-20 -4 15 9 - 21
1/2-20 -5 20 13 - 27
9/16-18 -6 30 18 - 42
3/4-16 -8 50 30 - 70
7/8-14 -10 69 44 - 94
1.1/16-12 -12 98 63 - 133
1.3/16-12 -14 118 73 - 163
1.5/16-12 -16 140 90 - 190
1.5/8-12 -20 210 135 - 285
1.7/8-12 -24 290 200 - 380
2.1/2-12 -32 450 300 - 600
ROTARY FEMALE CONNECTOR
BSP
Thread
UNF
Driving torque Nm
Nominal torque max
G1/4 20 15 - 25
G3/8 34 27 - 41
G1/2 60 42 - 76
G5/8 69 44 - 94
G3/4 115 95 - 135
G1 140 115 - 165
G1.1/4 210 140 - 280
G1.1/2 290 215 - 365
G2 400 300 - 500
ROTARY METRIC FEMALE CONNECTOR
Thread
UNF
External
diameter
of the pipe
Driving torque Nm
Nominal torque min / max
M 12x1.5 6 20 15 -25
M 14x1.5 8 38 30 - 45
M 16x1.5 845 38 - 52
10
M 18x1.5 10 51 43 - 85
12
M 20x1.5 12 58 50 - 65
M 22x1.5 14 74 60 - 88
15
M 24x1.5 16 74 60 - 88
M 26x1.5 18 105 85 - 125
M 30x2 20 135 115 - 155
22
M 36x2 25 166 140 - 192
28
M 42x2 30 240 210 - 270
M 45x2 35 290 255 - 325
M 52x2 38 330 280 - 380
42
ROTARY FEMALE CONNECTOR ORFS
Thread
UNF Dimension
Driving torque Nm
Nominal torque max.
9/16-18 -4 14 16
11/16-16 -6 24 27
13/16-16 -8 43 47
1-14 -10 60 68
1.3/16-12 -12 90 95
1.3/16-12 -14 90 95
1.7/16-12 -16 125 135
1.11/16-12 -20 170 190
2-12 -24 200 225
2-1/2-20 -32 460 490
SERVICE PREFACE

10
INSTRUCTIONS FOR THE MAINTENANCE OF THE HYDRAULIC SYSTEM
Before proceeding with the maintenance of the hydraulic system, it is necessary to remove any
possible residual pressures inside it.
To lower the forks to the ground. Open valve “A” by using the supplied hexagonal wrench in order to di-
scharge the residual pressure in the cabin lifting circuit . At the end of the maintenance operations, close
the valves.
A
SERVICE
PREFACE

11
INSTRUCTIONS FOR THE INSTALLATION OF HOSES AND CONNECTORS
Visual check of hoses and connectors: if one of the following conditions occurs, the hose must be im-
mediately disconnected and replaced:
• movement of the connector on the hose;
• there are damage, cuts or abrasions on the surface;
• hardening or stiffness of the hose, burned parts or cracks due to heat;
• cracks, damage or corroded parts on the connector;
• leakages from the hose or connector;
• the hose has permanent folds, squashed or twisted parts;
• presence of bubbles, softening and wear of the external surface.
Pre-installation inspection: before installing a hose it is necessary to check the conditions of the pipes.
First of all check if the type, the size, the reference code and the length are correct and then make sure that
there are no impurities, obstructions, bubbles, external layer peeling-off or other visible defects.
Installation:
Do not twist the hose, otherwise it could break due to pressure.
Consider a proper radius of curvature in order to avoid the bending or breaking. If the radius of curvature
is lower than the minimum radius of curvature allowed, the life of the hose is considerably reduced.
The pressure can change the length of the hose, up to + 2%. Therefore it is advisable to consider a length
which is higher than the required one in order to compensate for such changes.
SPECIAL TOOLS
Drive motor support code 1586992
Pump motor support code 1586747
SERVICE PREFACE

12
SERVICE
PREFACE

13
1
2
3
4
6
8
7
5
9
10
11
1
2
3
4
6
8
7
5
9
10
11
SECTION INDEX
Installation and settings
Diagnostic
Electric system
Frame mechanics
Cabin mechanics
Mast mechanics
Hydraulic system
Reduction unit
Braking system
Routine maintenance
Presentation
SERVICE PREFACE

14
SERVICE
PREFACE

1
PRESENTATION
SERVICE
PRESENTATION
TRUCK PRESENTATION ...........................................................................................................................................2
TECHNICAL FEATURES MOD. K1.0L 17 SL - K1.0L 1860 SL...................................................................................5
TECHNICAL FEATURES MOD. K1.0L 17 WP............................................................................................................7
TECHNICAL FEATURES MOD. K1.0L 12...................................................................................................................9
TECHNICAL FEATURES MOD. K1.0L 12 SL ......................................................................................................... 11
TECHNICAL FEATURES OF THE TRUCK MOD. K1.0L FP.....................................................................................13
TECHNICAL FEATURES MOD. K1.0L 32-36-40-44-48 SL .....................................................................................15
TECHNICAL FEATURES MOD. K1.0L 32-36-40-44-48 WP ...................................................................................17
TRUCK AND LOAD IDENTIFICATION DATA MOD. K10L SL - 12 .........................................................................20
TRUCK IDENTIFICATION DATA PLATE...................................................................................................................20
RESIDUAL LOAD PLATE .........................................................................................................................................20
TRUCK AND LOAD IDENTIFICATION DATA MOD. K10L FP.................................................................................21
TRUCK IDENTIFICATION DATA PLATE...................................................................................................................21
RESIDUAL LOAD PLATE .........................................................................................................................................21
DATA LOCATION.......................................................................................................................................................22

2
PRESENTATION SERVICE
TRUCK PRESENTATION
The range of lift trucks for medium/high level load collection consists of two models, with a nominal load
capacity of 1000 kg:
• K1.0L FP
• K10L12
• K10LSL
• K10LWP
Electrical system
On trucks in the K10L series, the motors benet from the use of three-phase AC alternating current tech-
nology: traction motor, steering motor and pump motor.
The high battery efciency is guaranteed by the regenerative nature of the braking system, energy retrieval
during the cab lowering stage with the load on the forks.
The electronic controls
Hydraulic system
On trucks in the K10L series, the 3 kW pump motor provides high level performance thanks to the ON/
OFF and proportional solenoid valves for the fork/cab lifting/lowering operations with uid actuator move-
ments.
Guidance system
For aisle guidance, the trucks can be equipped with contrast rollers and photocells that detect the side
guide rails.
The traction wheel performs self-centring once the photocells detect entry into an aisle.
Mast
The masts have one or two stages.
The rigidity and stability characteristics of the masts allow the forks to reach heights of 3200 mm.
The lifting cylinders are of the single acting hollow rod type, the single-acting solid plunger rod type or the
single-acting hollow plunger rod type.

3
PRESENTATION
PRESENTATION OF THE VARIOUS MODELS
Machine composed of the xed platform and movable forks that vary from
a height of from 800mm to 1500mm according to need.
Machine suited for Picking on the ground as the platform is very low ma-
king it easy for the operator to get on and off. In addition it has controls
that allow the operator to make small traction movements forwards (BA-
CKING) and raise the forks to the desired height while on the ground.
The platform ooring has been designed so that when pressure is applied
at any point the “PERSON PRESENT” sensor is activated
Inadditionithasnameplatesidentifyingtheserialnumberandtheresidual
loads and they are located over the operator's backrest.
Machinecomposedoftheliftingplatformwithforkssecuredtotheplatform
structure with lifting h2 from 1000mm to 1200mm without tting protective
panels. It is equipped with an Encoder, an instrument that measures the
lifting height of the platform.
The platform ooring has been designed so that when pressure is applied
at any point the “PERSON PRESENT” sensor is activated
Inadditionithasnameplatesidentifyingtheserialnumberandtheresidual
loads and they are located over the dashboard.
SERVICE
1.02 MOD. K1.0L FP
1.03 MOD. K1.0L 12
.

4
PRESENTATION
Machine composed of the lifting platform with central cylinder up to a
height h2 of 1700mm and with two side cylinders from h2 1700mm to
h2 3200m.
The forks can be raised independently from the cab with its own cylinder
and they can be xed or movable. The cab is complete with side protection
panels. It is equipped with an Encoder, an instrument that measures the
lifting height of the platform. It can be equipped to work in an aisle with
wire control and with the deceleration system and end-of aisle stop.
The platform ooring has been designed so that when pressure is applied
at any point the “PERSON PRESENT” sensor is activated
Machine composed of the lifting platform with forks secured to the pla-
tform structure with lifting greater than 1200mm, with transiting pallets
and protective guard all around the perimeter of the pallet, the protection
is completed with the gates at the sides of the cab. It is equipped with an
Encoder, an instrument that measures the lifting height of the platform.
It can be equipped to work in an aisle with wire control and with the de-
celeration system and end-of aisle stop.
The platform ooring has been designed so that when pressure is applied
at any point the “PERSON PRESENT” sensor is activated
SERVICE
1.04 MOD. K1.0L SL
1.05 MOD. K1.0LWP