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KOMATSU BX50 Series FORKLIFT TRUCK SHOP MANUAL BEB17E1-07 – PDF DOWNLOAD
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Description
KOMATSU BX50 Series FORKLIFT TRUCK SHOP MANUAL BEB17E1-07 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU BX50 Series FORKLIFT TRUCK SHOP MANUAL BEB17E1-07 – PDF DOWNLOAD
Language : English
Pages : 586
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU BX50 Series FORKLIFT TRUCK SHOP MANUAL BEB17E1-07 – PDF DOWNLOAD
COVER.............................................................................................................................. 1 00 Index and foreword.............................................................................................................. 3 100 Index...................................................................................................................... 3 Composition of shop manual................................................................................................. 4 Table of contents.......................................................................................................... 6 200 Foreword and general information........................................................................................... 13 Safety notice.............................................................................................................. 14 How to read the shop manual................................................................................................ 25 Explanation of terms for maintenance standard.............................................................................. 27 Handling of electric equipment and hydraulic component..................................................................... 29 Handling of connectors newly used for engines.............................................................................. 38 How to read electric wire code............................................................................................. 41 Precautions when carrying out operation.................................................................................... 44 Standard tightening torque table........................................................................................... 47 Conversion table........................................................................................................... 54 01 Outline......................................................................................................................... 61 100 Specifications............................................................................................................. 61 Specifications............................................................................................................. 62 Outside view............................................................................................................... 66 Weight table............................................................................................................... 67 Lubricant list............................................................................................................. 68 10 Structure, function and maintenance standard.................................................................................... 73 100 Engine and cooling system.................................................................................................. 73 Cooling system............................................................................................................. 74 200 Power train................................................................................................................ 77 Power train................................................................................................................ 78 Power train system diagram................................................................................................. 79 Torque converter, Gear pump and Control valve.............................................................................. 81 TORQFLOW transmission...................................................................................................... 92 Transmission control valve Assembly........................................................................................ 94 Clutch..................................................................................................................... 97 Clutch transmission........................................................................................................ 99 Clutch master cylinder.....................................................................................................101 Clutch release cylinder....................................................................................................102 Differential...............................................................................................................103 300 Steering system............................................................................................................107 Hydraulic steering system..................................................................................................108 Steering valve.............................................................................................................109 Power steering cylinder....................................................................................................111 400 Brake system...............................................................................................................113 Wheel brake................................................................................................................114 Brake master cylinder......................................................................................................115 Brake booster (FD35A)......................................................................................................116 500 Undercarriage and frame....................................................................................................119 Rear axle..................................................................................................................120 Frame......................................................................................................................121 600 Hydraulic system...........................................................................................................123 Control valve piping diagram (pump – control valve – tank).................................................................124 Work equipment piping diagram (control valve – tilt cylinder/lift cylinder)................................................125 Brake booster piping diagram...............................................................................................126 Work equipment and steering pump...........................................................................................127 Work equipment control valve...............................................................................................128 Flow divider...............................................................................................................133 700 Work equipment.............................................................................................................135 Tilt cylinder..............................................................................................................136 Lift cylinder..............................................................................................................139 Component parts............................................................................................................139 Mast, Fork carriage and Fork...............................................................................................140 801 Electric devices (Part 1)..................................................................................................147 ISO controller (Operator Presence Sensing (OPS) system)....................................................................148 AS controller (Forklift truck with seat belt interlock)....................................................................154 Troubleshooting............................................................................................................156 EPACS controller...........................................................................................................157 Instrument panel...........................................................................................................159 802 Electric devices (Part 2)..................................................................................................161 20 Standard value table............................................................................................................191 100 Standard value table.......................................................................................................191 Standard value table.......................................................................................................192 30 Testing and adjusting...........................................................................................................195 100 Testing and adjusting......................................................................................................195 Checking the engine speed..................................................................................................197 Hydraulic piping pressure release procedure................................................................................198 Replacement of engine oil and engine oil filter............................................................................199 Replacement of fuel filter.................................................................................................200 Cleaning of radiator.......................................................................................................201 Check of air cleaner and replacement of cleaner element (2 ton)............................................................202 Tightening torque of cylinder head mounting bolts..........................................................................203 Adjustment of valve clearance..............................................................................................204 Testing of compression.....................................................................................................205 Replacement of clutch disc.................................................................................................206 Oil replacement and strainer cleaning of TORQFLOW transmission.............................................................208 Oil level check and oil replacement of differential case...................................................................209 Testing power train oil pressure...........................................................................................210 Initial setting of power steering valve....................................................................................215 Checking the steering oil pressure.........................................................................................217 Testing and adjusting the work equipment oil pressure......................................................................218 Check of hydraulic tank....................................................................................................220 Adjustment of clutch and brake pedal (Clutch model)........................................................................221 Adjustment of inching and brake pedal (TORQFLOW model).....................................................................222 Adjustment of accelerator pedal............................................................................................223 Adjusting the parking brake lever..........................................................................................224 Adjustment of cables of the forward and backward control lever and the high and low speed lever (Clutch model).............225 Wheel brake................................................................................................................227 Bleeding air...............................................................................................................228 Measurement of cylinder hydraulic drift and hydraulic forward drift........................................................231 Adjustment of mast.........................................................................................................232 Checking the lift chain....................................................................................................239 Check of drive shaft for looseness, play and damage........................................................................240 Check of diode.............................................................................................................241 40 Troubleshooting.................................................................................................................243 100 General information on troubleshooting.....................................................................................243 Points to remember when troubleshooting....................................................................................244 Sequence of events in troubleshooting......................................................................................245 Testing before troubleshooting.............................................................................................246 Classification and procedures of troubleshooting...........................................................................247 Phenomena looking like troubles and troubleshooting No.....................................................................248 Information contained in troubleshooting table.............................................................................250 Locations of fuses.........................................................................................................252 Locations of fuses.........................................................................................................255 201 Troubleshooting by failure code (ISO controller system (*))................................................................259 Failure code display by ISO controller.....................................................................................260 Failure code [[!]: 1 flashing, [N]: Flashing, [L]: Flashing]...............................................................264 Seat switch trouble........................................................................................................264 Failure code [[!]: 2 flashings, [N]: Flashing, [L]: OFF]...................................................................268 F/R lever trouble..........................................................................................................268 Failure code [[!]: 3 flashings, [N]: OFF, [L]: OFF]........................................................................270 Parking brake reminder buzzer output abnormality or N (neutral) lamp and lift interlock warning lamp output abnormality....270 Failure code [[!]: 4 flashings, [N]: OFF, [L]: Flashing]...................................................................274 Lift interlock relay output abnormality (1)................................................................................274 Failure code [[!]: 4 flashings, [N]: Flashing, [L]: Flashing]..............................................................276 Lift interlock relay output abnormality (2)................................................................................276 Failure code [[!]: 5 flashings, [N]: OFF, [L]: Flashing]...................................................................278 Travel interlock relay output abnormality (1)..............................................................................278 Failure code [[!]: 5 flashings, [N]: Flashing, [L]: Flashing]..............................................................280 Travel interlock relay output abnormality (2)..............................................................................280 Failure code [[!]: 6 flashings, [N]: Flashing, [L]: Flashing]..............................................................282 Main relay output abnormality..............................................................................................282 Failure code [[!]: 7 flashings, [N]: Flashing, [L]: Flashing]..............................................................284 Controller abnormality.....................................................................................................284 202 Troubleshooting by failure code (EPACS controller system)..................................................................287 Display of EPACS controller failure code...................................................................................288 Failure code [LED: OFF] EPACS controller abnormality.......................................................................290 Failure code [LED: 1 flashing] Initialization is not completed.............................................................292 Failure code [LED: 2 flashings] Controller is being initialized............................................................293 Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality....................................................294 Failure code [LED: 4 flashings] Tyre angle sensor abnormality..............................................................296 300 Troubleshooting of electrical system (E-mode)..............................................................................299 E-1 Engine does not start..................................................................................................300 E-2 Engine does not stop...................................................................................................304 E-3 Lift truck cannot travel...............................................................................................306 E-4 Parking brake reminder alarm does not sound or does not stop sounding..................................................312 E-5 Travel direction is not changed normally...............................................................................316 E-6 Lift truck cannot move work equipment..................................................................................320 E-7 Work equipment cannot be locked........................................................................................324 E-8 EPACS is abnormal......................................................................................................328 E-9 Headlamp, clearance lamp, tail lamp and license plate lamp do not light or go off......................................330 E-10 Turn signal lamps do not light or go off..............................................................................332 E-11 Brake lamps do not light or go off....................................................................................334 E-12 Backup lamps do not light or go off...................................................................................336 E-13 Backup buzzer does not sound or does not stop sounding................................................................339 E-14 Horn does not sound or does not stop sounding.........................................................................342 E-15 Fuel level is not displayed normally..................................................................................344 400 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................347 Method of using troubleshooting table......................................................................................350 Table of failure modes and causes..........................................................................................352 H-1 Lift truck does not start..............................................................................................358 H-2 Travel speed is low, rush force is low, gradeability is low and/or gear is not shifted.................................359 H-3 Large shocks are made when lift truck starts and gear is shifted.......................................................360 H-4 Long time lag is made when lift truck starts and gear is shifted.......................................................361 H-5 Torque converter oil temperature is high...............................................................................362 H-6 Lift truck does not turn...............................................................................................363 H-7 Response is low during turning.........................................................................................364 H-8 Steering is heavy......................................................................................................365 H-9 Lift truck is unstable or large shock is made when it turns............................................................366 H-10 Right and left turning radii are different............................................................................367 H-11 When steering wheel is released it does not return to neutral or it rotates by itself.................................367 H-12 Steering wheel is turned in reverse or it kicks.......................................................................367 H-13 EPACS does not work...................................................................................................368 H-14 Steering wheel vibrates...............................................................................................369 H-15 Steering system makes abnormal sound..................................................................................369 H-16 Oil leaks from steering circuit.......................................................................................369 H-17 Service brake does not work or its performance is low.................................................................370 H-18 Service brake is not reset or it drags................................................................................371 H-19 Parking brake does not work or its performance is low.................................................................372 H-20 Parking brake is not reset or it drags................................................................................373 H-21 Lift cylinder and fork do not lift....................................................................................374 H-22 Lifting speed or force of lift cylinder and fork is insufficient......................................................375 H-23 Fork lifting speed lowers at specific height..........................................................................376 H-24 Lift cylinder cannot lift load........................................................................................376 H-25 Lift cylinder natural drift is large..................................................................................376 H-26 Fork lowering speed is too high.......................................................................................377 H-27 Mast does not tilt forward or backward................................................................................378 H-28 Forward/backward tilting speed or force of mast is insufficient.......................................................379 H-29 Tilting speed lowers halfway..........................................................................................380 H-30 Tilt cylinder cannot tilt back of mast with load......................................................................380 H-31 Tilt cylinder natural forward drift is large..........................................................................380 H-32 Mast is unstable during travel with load..............................................................................380 H-33 Lift and tilt levers do not move smoothly and they are heavy..........................................................381 H-34 Engine speed lowers remarkably or engine stalls when work equipment is operated.......................................382 H-35 Large shocks are made when work equipment is started and stopped......................................................382 H-36 Abnormal noises comes out from around the work equipment pump or steering pump........................................383 50 Disassembly and assembly........................................................................................................385 100 General information on disassembly and assembly............................................................................385 Method of using this manual................................................................................................386 Special tool list..........................................................................................................387 Overall disassembly and assembly...........................................................................................389 How to use LOCTITE.........................................................................................................391 200 Engine and cooling system..................................................................................................393 Removal and installation of power train....................................................................................394 300 Power train................................................................................................................401 Removal and installation of drive axle and transfer........................................................................402 Alignment of power line (1)................................................................................................408 Alignment of power line (2)................................................................................................410 Disassembly and assembly of clutch.........................................................................................412 Disassembly and assembly of clutch master cylinder.........................................................................414 Disassembly and assembly of clutch booster.................................................................................418 Maintenance standard.......................................................................................................423 Disassembly and assembly of clutch transmission............................................................................428 Disassembly and assembly of torque converter...............................................................................436 Disassembly and assembly of TORQFLOW transmission..........................................................................448 Universal joint............................................................................................................457 Disassembly and assembly of differential...................................................................................458 Removal and installation of wheel brake....................................................................................469 Disassembly and assembly of brake booster..................................................................................474 400 Hydraulic equipment........................................................................................................487 Steering axle and power steering...........................................................................................488 Flow divider...............................................................................................................489 Disassembly and assembly of reservoir assembly.............................................................................493 Disassembly and assembly of hydraulic pump.................................................................................494 Disassembly and assembly of solenoid valve.................................................................................503 Disassembly and assembly of steering valve.................................................................................507 Disassembly and assembly of steering axle..................................................................................514 Disassembly and assembly of power steering cylinder........................................................................519 Disassemly and assemly of lift cylinder....................................................................................522 Tilt cylinder..............................................................................................................528 Disassembly and assembly of control valve..................................................................................529 Disassembly and assembly of mast...........................................................................................542 Remove and installation of lift cylinder...................................................................................543 Removal and installation of chain..........................................................................................544 500 Work equipment.............................................................................................................541 Disassembly and assembly ofmast............................................................................................542 Remove and installation of liftcylinder....................................................................................543 Removal and installation of chain1.........................................................................................544 600 Electric devices...........................................................................................................547 Combination switch.........................................................................................................548 80 Yearly inspection criteria......................................................................................................551 100 Yearly inspection criteria.................................................................................................551 Yearly inspection criteria.................................................................................................552 90 Diagrams and drawings...........................................................................................................575 100 Diagrams and drawings......................................................................................................575 Power train hydraulic circuit diagram......................................................................................576 Work equipment hydraulic circuit diagram...................................................................................577 Electrical circuit diagrams................................................................................................579
DESCRIPTION:
KOMATSU BX50 Series FORKLIFT TRUCK SHOP MANUAL BEB17E1-07 – PDF DOWNLOAD
How to read the shop manual 1
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.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
80. Yearly inspection criteria
This section explains the items, contents and criteria of the specific self-imposed inspection.
90. Diagrams and drawings (Chassis)
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
S.S 13/12/24
