Komatsu BX50 Series Forklift Truck Shop Manual BEB17E1-06 – PDF DOWNLOAD

Description

Komatsu BX50 Series Forklift Truck Shop Manual BEB17E1-06 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu BX50 Series Forklift Truck Shop Manual BEB17E1-06 – PDF DOWNLOAD

FD20/25-17 300001 and up
FD30-17 300001 and up
FD20H/25H-17 300001 and up
FD30H/35A-17 300001 and up

How to read the shop manual :
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the lift truck.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. For troubleshooting “S mode” related to the engine, see Engine.

TABLE OF CONTENTS:

Komatsu BX50 Series Forklift Truck Shop Manual BEB17E1-06 – PDF DOWNLOAD

00 Index and foreword
100 Index BEB17E1-06AA
Composition of shop manual 2
Table of contents 4
00 Index and foreword
200 Foreword and general information BEB17E1-01AB
Safety notice 2
How to read the shop manual 13
Explanation of terms for maintenance standard 15
Handling of electric equipment and hydraulic component 17
Handling of connectors newly used for engines 26
How to read electric wire code 29
Precautions when carrying out operation 32
Standard tightening torque table 35
Conversion table 42
01 Outline
100 Specifications BEB17E1-01BA
Specifications 2
Outside view 6
Weight table 7
Lubricant list 8
10 Structure, function and maintenance standard
100 Engine and cooling system BEB17E1-01CA
Cooling system 2
200 Power train BEB17E1-02CB
Power train 2
Power train system diagram 3
Torque converter, Gear pump and Control valve 5
TORQFLOW transmission 16
Transmission control valve Assembly 18
Clutch 21
Clutch transmission 23
Clutch master cylinder 25
Clutch release cylinder 26
Differential 27
300 Steering system BEB17E1-01CC
Hydraulic steering system 2
Steering valve 3
Power steering cylinder 5
400 Brake system BEB17E1-02CD
Wheel brake 2
Brake master cylinder 3
Brake booster (FD35A) 4
500 Undercarriage and frame BEB17E1-01CE
Rear axle 2
Frame 3
600 Hydraulic system BEB17E1-01CF
Control valve piping diagram (pump – control valve – tank) 2
Work equipment piping diagram (control valve – tilt cylinder/lift cylinder) 3
Brake booster piping diagram 4
Work equipment and steering pump 5
Work equipment control valve 6
BEB17E1-06AA
BX50 Series 00-100 5
100 Index
Table of contents
Flow divider 11
700 Work equipment BEB17E1-01CG
Tilt cylinder 2
Lift cylinder 5
Component parts 5
Mast, Fork carriage and Fork 6
801 Electric devices (Part 1) BEB17E1-03CH
ISO controller (Operator Presence Sensing (OPS) system) 2
EPACS controller 11
Instrument panel 13
802 Electric devices (Part 2) BEB17E1-03CI
Sensors 2
Switches 5
Lamps 11
Horn and buzzer 14
Flasher 17
F/R solenoid valve 18
Relay box 19
Diode 23
Fuse load list 25
20 Standard value table
100 Standard value table BEB10E1-01DA
Standard value table 2
30 Testing and adjusting
100 Testing and adjusting BEB17E1-02EA
Checking the engine speed 3
Hydraulic piping pressure release procedure 4
Replacement of engine oil and engine oil filter 5
Replacement of fuel filter 6
Cleaning of radiator 7
Check of air cleaner and replacement of cleaner element (2 ton) 8
Tightening torque of cylinder head mounting bolts 9
Adjustment of valve clearance 10
Testing of compression 11
Replacement of clutch disc 12
Oil replacement and strainer cleaning of TORQFLOW transmission 14
Oil level check and oil replacement of differential case 15
Testing power train oil pressure 16
Initial setting of power steering valve 21
Checking the steering oil pressure 23
Testing and adjusting the work equipment oil pressure 24
Check of hydraulic tank 26
Adjustment of clutch and brake pedal (Clutch model) 27
Adjustment of inching and brake pedal (TORQFLOW model) 28
Adjustment of accelerator pedal 29
Adjusting the parking brake lever 30
Adjustment of cables of the forward and backward control lever and the high and low speed lever
(Clutch model) 31
Wheel brake 33
Bleeding air 34
Measurement of cylinder hydraulic drift and hydraulic forward drift 37
Adjustment of mast 38
Checking the lift chain 45
Check of drive shaft for looseness, play and damage 46
Check of diode 47
BEB17E1-06AA
00-100 6 BX50 Series
100 Index
Table of contents
40 Troubleshooting
100 General information on troubleshooting BEB17E1-02FA
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Classification and procedures of troubleshooting 5
Phenomena looking like troubles and troubleshooting No 6
Information contained in troubleshooting table 8
Locations of fuses 10
201 Troubleshooting by failure code (ISO controller system (*)) BEB17E1-02FB
Failure code display by ISO controller 2
Failure code [[!]: 1 flashing, [N]: Flashing, [L]: Flashing]
Seat switch trouble 6
Failure code [[!]: 2 flashings, [N]: Flashing, [L]: OFF]
F/R lever trouble 10
Failure code [[!]: 3 flashings, [N]: OFF, [L]: OFF]
Parking brake reminder buzzer output abnormality or N (neutral) lamp and lift interlock warning lamp
output abnormality 12
Failure code [[!]: 4 flashings, [N]: OFF, [L]: Flashing]
Lift interlock relay output abnormality (1) 16
Failure code [[!]: 4 flashings, [N]: Flashing, [L]: Flashing]
Lift interlock relay output abnormality (2) 18
Failure code [[!]: 5 flashings, [N]: OFF, [L]: Flashing]
Travel interlock relay output abnormality (1) 20
Failure code [[!]: 5 flashings, [N]: Flashing, [L]: Flashing]
Travel interlock relay output abnormality (2) 22
Failure code [[!]: 6 flashings, [N]: Flashing, [L]: Flashing]
Main relay output abnormality 24
Failure code [[!]: 7 flashings, [N]: Flashing, [L]: Flashing]
Controller abnormality 26
202 Troubleshooting by failure code (EPACS controller system) BEB17E1-01FC
Display of EPACS controller failure code 2
Failure code [LED: OFF] EPACS controller abnormality 4
Failure code [LED: 1 flashing] Initialization is not completed 6
Failure code [LED: 2 flashings] Controller is being initialized 7
Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality 8
Failure code [LED: 4 flashings] Tyre angle sensor abnormality 10
300 Troubleshooting of electrical system (E-mode) BEB17E1-02FD
E-1 Engine does not start 2
E-2 Engine does not stop 6
E-3 Lift truck cannot travel 8
E-4 Parking brake reminder alarm does not sound or does not stop sounding 14
E-5 Travel direction is not changed normally 18
E-6 Lift truck cannot move work equipment 22
E-7 Work equipment cannot be locked 26
E-8 EPACS is abnormal 30
E-9 Headlamp, clearance lamp, tail lamp and license plate lamp do not light or go off 32
E-10 Turn signal lamps do not light or go off 34
E-11 Brake lamps do not light or go off 36
E-12 Backup lamps do not light or go off 38
E-13 Backup buzzer does not sound or does not stop sounding 41
E-14 Horn does not sound or does not stop sounding 44
E-15 Fuel level is not displayed normally 46
400 Troubleshooting of hydraulic and mechanical system (H-mode) BEB17E1-01FF
Method of using troubleshooting table 4
Table of failure modes and causes 6
H-1 Lift truck does not start 12
H-2 Travel speed is low, rush force is low, gradeability is low and/or gear is not shifted 13
BEB17E1-06AA
BX50 Series 00-100 7
100 Index
Table of contents
H-3 Large shocks are made when lift truck starts and gear is shifted 14
H-4 Long time lag is made when lift truck starts and gear is shifted 15
H-5 Torque converter oil temperature is high 16
H-6 Lift truck does not turn 17
H-7 Response is low during turning 18
H-8 Steering is heavy 19
H-9 Lift truck is unstable or large shock is made when it turns 20
H-10 Right and left turning radii are different 21
H-11 When steering wheel is released it does not return to neutral or it rotates by itself 21
H-12 Steering wheel is turned in reverse or it kicks 21
H-13 EPACS does not work 22
H-14 Steering wheel vibrates 23
H-15 Steering system makes abnormal sound 23
H-16 Oil leaks from steering circuit 23
H-17 Service brake does not work or its performance is low 24
H-18 Service brake is not reset or it drags 25
H-19 Parking brake does not work or its performance is low 26
H-20 Parking brake is not reset or it drags 27
H-21 Lift cylinder and fork do not lift 28
H-22 Lifting speed or force of lift cylinder and fork is insufficient 29
H-23 Fork lifting speed lowers at specific height 30
H-24 Lift cylinder cannot lift load 30
H-25 Lift cylinder natural drift is large 30
H-26 Fork lowering speed is too high 31
H-27 Mast does not tilt forward or backward 32
H-28 Forward/backward tilting speed or force of mast is insufficient 33
H-29 Tilting speed lowers halfway 34
H-30 Tilt cylinder cannot tilt back of mast with load 34
H-31 Tilt cylinder natural forward drift is large 34
H-32 Mast is unstable during travel with load 34
H-33 Lift and tilt levers do not move smoothly and they are heavy 35
H-34 Engine speed lowers remarkably or engine stalls when work equipment is operated 36
H-35 Large shocks are made when work equipment is started and stopped 36
H-36 Abnormal noises comes out from around the work equipment pump or steering pump 37
50 Disassembly and assembly
100 General information on disassembly and assembly BEB17E1-01GA
Method of using this manual 2
Special tool list 3
Overall disassembly and assembly 5
How to use LOCTITE 7
200 Engine and cooling system
Removal and installation of power train
300 Power train
Removal and installation of drive axle and transfer
Alignment of power line (1)
Alignment of power line (2) 10
Disassembly and assembly of clutch 12
Disassembly and assembly of clutch master cylinder 14
Disassembly and assembly of clutch booster 18
Maintenance standard 23
Disassembly and assembly of clutch transmission 28
Disassembly and assembly of torque converter 36
Disassembly and assembly of TORQFLOW transmission 48
Universal joint 57
Disassembly and assembly of differential 58
Removal and installation of wheel brake 69
BEB17E1-06AA
00-100 8 BX50 Series
100 Index
Table of contents
Disassembly and assembly of brake booster 74
400 Hydraulic equipment BEB17E1-01GD
Steering axle and power steering 2
Flow divider 3
Disassembly and assembly of reservoir assembly 7
Disassembly and assembly of hydraulic pump 8
Disassembly and assembly of solenoid valve 17
Disassembly and assembly of steering valve 21
Disassembly and assembly of steering axle 28
Disassembly and assembly of power steering cylinder 33
Disassemly and assemly of lift cylinder 36
Tilt cylinder 42
Disassembly and assembly of control valve 43
500 Work equipment BEB17E1-01GE
Disassembly and assembly of mast 2
Remove and installation of lift cylinder 3
Removal and installation of chain 4
600 Electric devices BEB17E1-01GF
Combination switch 2
80 Yearly inspection criteria
100 Yearly inspection criteria BEB17E1-02HA
Yearly inspection criteria 2
90 Diagrams and drawings
100 Diagrams and drawings BEB17E1-03JA
Power train hydraulic circuit diagram 2
Work equipment hydraulic circuit diagram 3
Electrical circuit diagram 5

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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