Komatsu BX50 Forklift Trucks SM160, BEB16E1-06 (Preview)
SM160 BX50 SHOP SEPT 2006
CONTENTS
INTRODUCTION
FED. EPA STATEMENT – K21/K25 ENGINES
FED. EPA STATEMENT – 4D94LE ENGINES
FORKLIFT MODEL TABLE
CH. 00 – SAFETY
SAFETY MANAGEMENT
SAFE TRAVEL
LOADING OPERATIONS
STOPPING & PARKING
INSPECTION & MAINTENANCE
CH. 10 – GENERAL DATA & SPECIFICATIONS
SPEC. TABLES – PNEUMATIC TRUCKS
SPEC. TABLES – CUSHION TRUCKS
PERIODIC REPLACEMENT – CONSUMABLE PARTS
TORQUE TABLE – BOLTS
TORQUE TABLE – PIPE JOINTS
CH. 20 – TESTING & ADJUSTING
SERVICE DATA TABLE – GASOLINE PNEUMATIC
SERVICE DATA TABLE – GASOLINE CUSHION
SERVICE DATA – DIESEL PNEUMATIC
GASOLINE ENGINES
CHANGE ENGINE OIL & FILTER
CHANGE FUEL FILTER
INSPECT SPARK PLUGS
DIESEL ENGINE
CHANGE ENGINE OIL & FILTER
DRAIN FUEL FILTER
REPLACE FUEL FILTER
AIR CLEANER SERVICING
IGNITION TIMING
FUEL INJECTION TIMING
COMPRESSION – MEASURING
VALVE CLEARANCE – ADJUSTING
CYL. HEAD BOLTS – TORQUE
TORQFLOW TRANSMISSION CASE
OIL LEVEL, STRAINER, LINE FILTER
DIFFERENTIAL CASE
OIL LEVEL, CHANGING OIL
HYDRAULIC TANK
HYDRAULIC DRIFT – LIFT & TILT CYL.
INCHING & BRAKE PEDALS – ADJUSTMENT
ACCELERATOR PEDAL – K21/K25 GASOLINE
ACCELERATOR PEDAL – 4D94LE DIESEL
PARKING BRAKE LEVER – ADJUST
WHEEL BRAKE – ADJUST
BLEEDING AIR
FUEL & LUBE OIL CHART – GASOLINE
FUEL & LUBE OIL CHART – DIESEL
CH. 30 – REMOVAL & INSTALLATION
EXPLODED VIEW – BX50
WEIGHT TABLES – COMPONENTS
MAST REMOVAL
LIFT CYLINDER
ENGINE
TORQUE CONV., TRANS., DRIVE AXLE
POWER TRAIN – ALIGNMENT
STEERING AXLE & POWER STEERING
WHEEL BRAKES
CH. 40 – DISASSEMBLY & ASSEMBLY
TORQUE CONVERTER
DISASSEMBLY
EXPLODED VIEW
INSPECTION CHART
MAINTENANCE STANDARD
HYDRAULIC PORT POSITION
HYDRAULIC CIRCUIT DIAGRAM
TROUBLESHOOTING CHART
TORQFLOW TRANSMISSION
DISASSEMBLY
CLUTCH PACKS
ASSEMBLY
ASSEMBLY DRAWING
DIFFERENTIAL
EXPLODED VIEW
ADJ. PINION SHAFT ASSY
ADJUST DIFFERENTIAL GEARS
ASSEMBLY DRAWING
WHEEL BRAKES
ADJUSTMENT
BRAKE MASTER CYLINDER
COMBINATION SWITCH
SOLENOID VALVE
STEERING VALVE
STEERING AXLE
POWER STEERING CYLINDER
LIFT CYLINDER
TILT CYLINDER
CONTROL VALVE
FORK CARRIAGE
FLOW DIVIDER
RESERVOIR ASSEMBLY
HYDRAULIC PUMP
PROPELLER SHAFT
CH. 50 – MAINTENANCE STANDARD
TORQUE CONVERTER
TORQFLOW TRANSMISSION
TRANS. CONTROL VALVE
DIFFERENTIAL
WHEEL BRAKES
BRAKE MASTER CYLINDER
BRAKE BOOSTER
STEERING AXLE
POWER STEERING VALVE
LIFT CYLINDER
MAST, FORK CARRIAGE, FORKS
HYDRAULIC PUMP
PROPELLER SHAFT
CH. 60 – STRUCTURE & FUNCTION
TORQUE CONV., GEAR PUMP, CONTROL VALVE
HYD. PRESSURE CIRCUIT DWG.
PRESSURE PORT LOCATION
BRAKE BOOSTER
FLOW DIVIDER
TILT CYLINDER
VEHICLE CONTROLLER
SYSTEM OVERVIEW
TROUBLESHOOTING
HYDRAULIC CIRCUIT DRAWING
P-PORT OIL PRESSURE MEASURING PORT
CH. 80 – PERIODIC INSPECTION
INSPECTION CHARTS
CH. 90 – CONVERSION TABLES
SM300 – K21/K25 ENGINE SHOP MANUAL
INTRODUCTION
CONTENTS
OVERVIEW OF IMPROVEMENTS
ABBREVIATIONS – COMMON
LIFT TRUCK MODEL TABLE
CH. 1 – GENERAL INFORMATION
DESCRIPTION
DEFINITION OF TERMS
DEFINITION OF UNITS
DESCRIPTION
PRECAUTIONS FOR SAFETY & QUALITY
SAFE OPERATION
CORRECT OPERATION
RADIO EQUIP. INSTALLATION
PRECAUTIONS
DRAINING ENGINE COOLANT
DISCONNECTING FUEL PIPING
REMOVING & DISASSEMBLING
INSP., CORRECTION, REPLACEMENT
ASSEMBLY & INSTALLATION
ANGLE TIGHTENING
POWER TOOLS
USE OF LIQUID GASKET
TIGHTENING TORQUE
TORQUE TABLE – BOLTS
TORQUE TABLE – ENGINE
SPECIAL TOOLS
ENGINE DRAWING
MAIN SPECIFICATION TABLES
STANDARD & REPAIR LIMIT
ENGINE SERIAL NUMBER LOCATION
TROUBLESHOOTING
ENGINE ADJUSTMENT
ENGINE LPG FUEL SYSTEM
CH. 2 – ENGINE MECHANICAL
PRECAUTIONS
DRAINING ENGINE COOLANT
DISCONNECTING FUEL PIPING
REMOVING & DISASSEMBLING
INSP., CORRECTION & REPLACEMENT
ASSEMBLY & INSTALLATION
ANGLE TIGHTENING
POWER TOOLS
USE OF LIQUID GASKET
ENGINE DRAWING
MAIN SPECIFICATIONS
ADJUSTMENT VALUES
TORQUE TABLES
TROUBLESHOOTING
SPECIAL SERVICE TOOLS
REMOVAL & INSTALLATION – ENGINE
REMOVAL
INSTALLATION
INSPECTION
ENGINE SERVICE
DISASSEMBLY
INSPECTION & CORRECTION
ASSEMBLY
CH. 3 – ENGINE FUEL SYSTEM
EMISSION CONTROL SYSTEM
UNIT LAYOUT
SERVICE DATA & SPECS.
LPG FUEL SYSTEM – TROUBLESHOOTING
DISASSEMBLY & ASSEMBLY
LPG INJECTOR DRIVE UNIT CONNECTOR
ELECT. CONTROL THROTTLE ASSY
GASOLINE FUEL INJECTOR
LPG & DUAL-FUEL SYSTEM
LPG SYSTEM DIAGRAM
INJECTOR HOLDER
LPG FUEL INJECTOR
LPG ASSIST FUEL INJECTOR
VAPORIZER
CH. 4 – ENGINE LUBRICATION & COOLING SYSTEM
LUBRICATION SYSTEM
SCHEMATIC
COOLING SYSTEM
CH. 5 – ENGINE SYSTEMS & DIAGNOSTICS
ENGINE & MAIN BODY
VALVES
LUBRICATION SYSTEM
INTAKE & EXHAUST
ENGINE CONTROL SYSTEM (ECS)
ECS DIAGRAM – GASOLINE
ECS DIAGRAM – LPG
ECS DIAGRAM – DUAL-FUEL
ECS COMPONENTS
ECM CIRCUIT DIAGRAM – GASOLINE
ECM CIRCUIT DIAGRAM – LPG
ECM CIRCUIT DIAGRAM – DUAL-FUEL
ECM TERMINAL LAYOUT
CRANKSHAFT POSITION SENSOR (POS)
ELECT. THROTTLE CONTROL ACTUATOR (ETCA)
FUEL INJECTION CONTROL
SOFIS SYSTEM – GASOLINE
SOFIS SYSTEM – LPG
IGNITION TIMING CONTROL
IDLE SPEED CONTROL
FUEL PUMP CONTROL – GASOLINE
HEATED OXYGEN SENSOR HEATER CONTROL
FAIL-SAFE FUNCTION
DIAGNOSTIC SYSTEM
SELF-DIAGNOSIS & MALFUNCTION CHART
SERVICE SUPPORT TOOL (SST)
LPG SYSTEM COMPONENTS
PCV GAS RECIRCULATION DEVICE
COOLANT SYSTEM
FUEL SYSTEM
APP. 1 – FUEL INJECTION PULSE WIDTH
APP. 2 – SST EXERCISE PROGRAM
APP. 3 – ERROR CODE LISTINGS
APP. 4 – SERVICE SUPPORT TOOL (SST)
CH. 6 – ENGINE CONTROLS
PRECAUTIONS
PREPARATION
DESCRIPTION
TROUBLESHOOTING
SYMPTOM CHART
COMPONENT PARTS
ECCS COMPONENTS
ECM CIRCUIT – DIAGRAM
ECM CIRCUIT – LPG
ECM CIRCUIT – DUAL-FUEL
CONTROL UNIT TERMINAL LAYOUT
ECCS INPUT/OUTPUT SIGNAL
DIAGNOSIS WITH SERVICE TOOL
DIAGNOSIS W/O SERVICE TOOL
DISPLAY ITEM LIST
FAIL-SAFE FUNCTION
POWER SUPPLY & GROUND SYSTEM
CRANKSHAFT POSITION SENSOR (POS)
CAMSHAFT POSITION SENSOR (PHASE)
MASS AIRFLOW SENSOR
COOLANT TEMP SENSOR
HEATED OXYGEN SENSOR
THROTTLE POSITION SENSOR
ACCEL. PEDAL POSITION SENSOR
INTAKE AIR TEMP SENSOR
PNP SWITCH SYSTEM
STOP LAMP SWITCH
ELECTRIC LOAD SWITCH
VEHICLE SPEED SENSOR
IGNITION SYSTEM
FUEL INJECTOR SYSTEM
FUEL PUMP SYSTEM
ENGINE WARNING LIGHT
THROTTLE CONTROL MOTOR
LPG INJECTOR
LPG ASSIST INJECTOR
LPG FUEL PRESSURE SENSOR
HEATED OXYGEN SENSOR HEATER
BLOWBY GAS RECIRCULATION
FUEL CUT FUNCTION
ECCS COMPONENTS – REMOVE/INSTALL
SERVICE DATA
CH. 7 – ENGINE TUNE-UP
SPECIFICATIONS
TIGHTENING TORQUE
TROUBLESHOOTING
INSPECTION & ADJUSTMENT
CH. 8 – ENGINE ELECTRICAL SYSTEM
ADJUSTMENT VALUES
TROUBLESHOOTING
STARTER MOTOR
ALTERNATOR
CH. 9 – ENGINE MAINTENANCE
SPECIFICATIONS
TIGHTENING TORQUE
MAINT. SCHEDULE
SM197 – 4D94LE ENGINE SHOP MANUAL
CONTENTS
SAFETY
CH. 0 – GENERAL DESCRIPTION
CH. 1 – ADJUSTMENT OF ENGINE
VALVE CLEARANCE
FAN BELT
IGNITION TIMING (EXPORT ONLY)
NO-LOAD ROTATING SPEED
CH. 2 – TROUBLESHOOTING
TROUBLESHOOTING TABLES
ENGINE COMPRESSION
CH. 3 – ENGINE BODY
INTRODUCTION
CYLINDER HEAD
GEAR TRAIN & CAMSHAFT
CYLINDER BLOCK
CH. 4 – LUBRICATION SYSTEM
CH. 5 – COOLING SYSTEM
CH. 6 – FUEL INJECTION / SPEED CONTROLLER
CH. 7 – STARTING SYSTEM
CH. 8 – CHARGING SYSTEM – ALTERNATOR W/ BUILT-IN FAN
CH. 9 – SPECIAL PURPOSE SERVICE TOOLS
CH. 10 – MAINTENANCE STANDARD
SM160_E-MD-MASTSERV.pdf
Cover
Contents
Special Definitions
Introduction
Truck System
Requirements
Mounting Bracket
Installation
Mast Installation
Chain Inspection and Tension
Upright Rail Lubrication
Cylinder Bleeding
Mast Skewing
Single Function Internal Reeving
Double Function Internal Reeving
Periodic Maintenance
Daily Inspection
100 Hour Inspection
500 Hour Inspection
Section 4 Troubleshooting
Mast Removal
Main Lift Cylinder Description
21
Free Lift Cylinder Description
Cylinder Operation
Main Lift Cylinder Removal
Free Lift Cylinder Removal
Main Lift Cylinder Service
Free Lift Cylinder Service
Cylinder Bleeding
Valve Cartridge Service
Piston Removal
Carriage
Carriage Removal-Mast on Truck
Carriage Removal-Mast on Floor
Carriage Inspection
Upright Description
Upright Disassembly
Upright Inspection
Upright Reassembly
Mast Skewing
Chains
Inspection and Tension
Measuring Chain Stretch
Free Lift Chain Adjustment
Free Lift Chain Service
SM160_E-MS-MASTSERV.pdf
Contents
Introduction
Special Definitions
Truck System Requirements
Mounting Bracket Installation
Mast Installation
Chain Inspection and Tension
Internal Reeving Installation
Periodic Maintenance
Daily Inspection
100 Hour Inspection
500 Hour Inspection
Mast Removal
Main Lift Cylinder Description
Cylinder Operation
Main Lift Cylinder Removal
Main Lift Cylinder Service
Cylinder Bleeding
Valve Cartridge Service
Piston Removal
Carriage Description
Carriage Removal-Mast on Truck
Carriage Removal – Mast on Floor
Carriage Inspection
Upright Description
Upright Operation
Upright Disassembly
Upright Inspection
Uprights Reassembly
Mast Skewing
Chain Inspection and Tension
Measuring Chain Stretch
Main Lift Chain Adjustment
Main Lift Chain Service
SM160_E-MT-MASTSERV.pdf
Contents
Cover
Special Definitions
Introduction
Truck System
Requirements
Mounting Bracket
Installation
Mast Installation
Chain Inspection and Tension
Free lift Cylinder Supply
Upright Rail Lubrication
Cylinder Bleeding
Mast Skewing
Single Function Internal Reeving
Double Function Internal Reeving
Periodic Maintenance
Daily Inspection
100 Hour Inspection
500 Hour Inspection
Section 4 Troubleshooting
Mast Removal
Main Lift Cylinder Description
Free Lift Cylinder Description
Cylinder Operation
Main Lift Cylinder Removal-
Free Lift Cylinder Removal-
Main Lift Cylinder Service
Free Lift Cylinder Service
Cylinder Bleeding
Valve Cartridge Service
Piston Removal
Carriage
Carriage Removal-Mast on Truck
Carriage Removal-
Mast on Floor
Carriage Inspection
Upright Description
Upright Operation
Upright Disassembly
Upright Inspection
Upright Reassembly
Mast Skewing
Chains
Inspection and Tension
Measuring Chain Stretch
Main Lift Chain Adjustment
Free Lift Chain Adjustment
Free Lift Chain Service
Main Lift Chain Service
SM160_D-MQ-MASTSERV (QUAD MAST)
CONTENTS
INTRODUCTION
INSTALLATION
PERIODIC MAINTENANCE
DAILY INSPECTION
100-HOUR INSPECTION
500-HOUR INSPECTION
TROUBLESHOOTING
SERVICE
MAST REMOVAL
CYLINDERS
VALVE
CARRIAGE
MAST UPRIGHTS
MAST SKEWING ADJUSTMENT
CHAINS
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