Service manual Komatsu BX50 Series Forklift Trucks | SM160, BEB16E1-06

Komatsu BX50 Series Forklift Trucks SM160, BEB16E1-06 (Preview)

SM160_JUN2014_01.pdf
CONTENTS
LIST OF FIGURES
FOREWORD
SM160_JUN2014_02.pdf
1. SAFETY
1.1 BASIC PRECAUTIONS
1.2 FIRE PREVENTION
1.3 SAFETY CHECKS BEFORE STARTING OPERATION
1.4 SAFE TRAVEL
1.5 STOPPING, PARKING AND TOWING
1.6 LOADING OPERATIONS
1.7 SAFETY IN INSPECTION AND MAINTENANCE
1.8 TOWING
1.9 STRUCTURE AND STABILITY OF THE LIFT TRUCK
1.10 SAFETY LABELS
1.11 OPTIONAL EQUIPMENT
SM160_JUN2014_03.pdf
2. SPECIFICATIONS AND GENERAL INFORMATION
2.1 GENERAL ASSEMBLY DIAGRAM
2.2 LUBRICANT LIST
2.2.1 GASOLINE/LPG MODELS
2.2.2 DIESEL MODELS
2.3 PERIODIC REPLACEMENT OF CONSUMABLE PARTS
2.4 SPECIFICATIONS
2.4.1 2-TON PNEUMATIC (OUTDOOR)
2.4.2 2.5-TON PNEUMATIC (OUTDOOR)
2.4.3 2.8-TON PNEUMATIC (OUTDOOR)
2.4.4 3.0-TON PNEUMATIC (OUTDOOR)
2.4.5 3.2-TON PNEUMATIC (OUTDOOR)
2.4.6 3.5-TON PNEUMATIC (OUTDOOR)
2.4.7 2.0 / 2.5-TON CUSHION (INDOOR))
2.4.8 2.8 / 3.0 / 3.2-TON CUSHION (INDOOR)
2.5 WEIGHT TABLE
2.5.1 PNEUMATIC MODELS
2.5.2 CUSHION MODELS
2.6 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
2.7 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
2.7.1 Elbows, nipples and unions
2.7.2 High-pressure rubber hoses, pipes and sleeve nuts
SM160_JUN2014_04.pdf
3. OPERATOR COMPARTMENT
3.1 STRUCTURE AND FUNCTION
3.1.1 VEHICLE CONTROLLER
3.1.2 Komatsu Operator Presence System (KOPS)
3.1.3 CONTROLLER TROUBLESHOOTING
3.1.4 ISO Controller TROUBLESHOOTING CHART
3.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS
3.2.1 Traveling Brake
3.2.2 Parking Brakes
3.2.3 Rod link, cable
3.2.4 Chassis frame, chassis
3.2.5 Cab
3.2.6 Seat
3.2.7 Devices for getting on/off truck, anti-slip
3.2.8 Display panel
3.2.9 Overhead Guard
3.2.10 Backrest
3.2.11 Lights, gauges, Warning devices
3.2.12 Rear view mirror, reflector
3.2.13 Lubrication
3.2.14 Function of each system
3.3 TESTING AND ADJUSTING
3.3.1 ADJUST INCHING AND BRAKE PEDAL (TORQFLOW MODEL)
3.3.2 ADJUST STOP LAMP SWITCH
3.3.3 ADJUST ACCELERATOR PEDAL
3.3.4 ADJUST PARKING BRAKE LEVER
3.3.5 Combination Switch
3.4 REMOVAL AND INSTALLATION – PARKING BRAKE CABLE
3.4.1 Removal
3.4.2 Installation
3.5 DISASSEMBLY AND ASSEMBLY
3.6 MAINTENANCE STANDARD
SM160_JUN2014_05.pdf
4. ENGINE
4.1 STRUCTURE AND FUNCTION
4.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS
4.2.1 Engine Start, Noise
4.2.2 Engine Revolution, Exhaust Emission Color
4.2.3 Idling Speed
4.2.4 Air Cleaner
4.2.5 Cylinder Head
4.2.6 Valve Clearance
4.2.7 Compression
4.2.8 Fuel Injection Starting Pressure (Diesel ModelS)
4.2.9 Fuel Injection State (Diesel ModelS)
4.2.10 Turbocharger
4.2.11 Engine Mount
4.2.12 Lubrication System
4.2.13 Fuel System
4.2.14 High-Pressure Gas Fuel System
4.2.15 Blow-by Gas Return System
4.2.16 RADIATOR Coolant
4.2.17 Fan, Fan Belt
4.2.18 Distributor (Gasoline Export ModelS)
4.2.19 Spark Plug, Ignition Timing (Gasoline ModelS)
4.2.20 Battery Charging System, Wiring
4.3 TESTING AND ADJUSTING
4.3.1 GASOLINE ENGINE
4.3.2 DIESEL ENGINE
4.3.3 AIR CLEANER
4.3.4 ADJUST IGNITION TIMING
4.3.5 ADJUST FUEL INJECTION TIMING (DIESEL MODELS)
4.3.6 ADJUST NO-LOAD ROTATING SPEED (DIESEL MODELS)
4.3.7 MEASURE COMPRESSION PRESSURE
4.3.8 TORQUE CYLINDER HEAD MOUNTING BOLTS
4.3.9 ADJUST VALVE CLEARANCE
4.4 Removal and Installation
4.4.1 REMOVAL
4.4.2 INSTALLATION
4.5 Disassembly and Assembly
4.6 Maintenance Standard
SM160_JUN2014_06.pdf
5. TORQUE CONVERTER
5.1 Structure and function
5.1.1 Torque Converter
5.1.2 Gear pump
5.1.3 TORQUE CONVERTER ASSEMBLY
5.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS
5.2.1 CHECK OIL LEVEL
5.2.2 REPLACE OIL, INSPECT AND CLEAN STRAINER
5.2.3 REPLACE LINE FILTER
5.3 TESTING AND ADJUSTING
5.4 REMOVAL AND INSTALLATION
5.5 DISASSEMBLY AND ASSEMBLY
5.5.1 Disassembly
5.5.2 Assembly
5.5.3 CHECK FOR CORRECT OIL LEVEL PRESSURE
5.5.4 Tightening Torque for Bolts and Plugs
5.6 Maintenance Standard
SM160_JUN2014_07.pdf
6. TORQFLOW TRANSMISSION
6.1 Structure and function
6.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS
6.3 TESTING AND ADJUSTING
6.3.1 CHECK OIL LEVEL
6.3.2 REPLACE OIL, INSPECT AND CLEAN STRAINER
6.3.3 REPLACE LINE FILTER
6.4 Removal and Installation
6.4.1 Removal
6.4.2 Installation
6.5 Disassembly and Assembly
6.5.1 DISASSEMBLY
6.5.2 ASSEMBLY
6.5.3 SOLENOID VALVE DISASSEMBLY AND ASSEMBLY
6.6 Maintenance Standard
6.6.1 TRANSMISSION
6.6.2 TRANSMISSION CONTROL VALVE
SM160_JUN2014_08.pdf
7. DRIVE AXLE
7.1 Structure and function
7.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS
7.2.1 Differential
7.2.2 Front Axle
7.2.3 Tires
7.2.4 Wheel
7.2.5 Brake piping
7.2.6 Oil Brake
7.2.7 Brake Booster
7.2.8 Brake Shoe Lining
7.2.9 Brake Drum
7.2.10 Back Plate
7.2.11 Parking Brake Drum, Lining
7.3 TESTING AND ADJUSTING
7.3.1 INSPECT OIL LEVEL
7.3.2 REPLACE OIL
7.3.3 GREASE CROSS BEARING OF PROPELLER SHAFT
7.3.4 Adjust Pinion Shaft Assembly With Shim(S)
7.3.5 Adjust Pinion Gear Clearance
7.3.6 Inspect Pinion Bearing Clearance
7.3.7 Adjust Differential
7.4 Removal and Installation
7.4.1 REMOVAL
7.4.2 INSTALLATION
7.5 Disassembly and Assembly
7.6 Maintenance Standard
SM160_JUN2014_09.pdf
8. STEERING SYSTEM
8.1 Structure and function
8.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS
8.2.1 Rear Axle
8.2.2 Steering Wheel
8.2.3 Steering Valve
8.2.4 Knuckle
8.2.5 Steering wheel
8.2.6 Power steering
8.2.7 Right and left turning radius
8.2.8 Directional Control Valve (1)
8.2.9 Directional Control Valve (2)
8.3 TESTING AND ADJUSTING
8.4 Removal and Installation
8.4.1 Steering Valve
8.4.2 Power Steering Cylinder
8.4.3 Steering Axle
8.5 Disassembly and Assembly
8.5.1 Steering Valve DISASSEMBLY
8.5.2 Dismantle Pressure Relief Valve (OSPC)
8.5.3 Dismantle Pressure Relief Valve Cartridge (OSPC) (If equipped)
8.5.4 Assemble pressure Relief Valve (OSPC) (If equipped)
8.5.5 Assemble shock Valves (If equipped)
8.5.6 POWER STEERING CYLINDER ASSEMBLY
8.5.7 STEERING AXLE
8.6 Maintenance Standard – STEERING AXLE
SM160_JUN2014_10.pdf
9. WHEEL BRAKE
9.1 STRUCTURE AND FUNCTION
9.1.1 WHEEL BRAKE
9.1.3 BRAKE MASTER CYLINDER
9.2.1 Traveling Brake
9.2.2 Parking Brakes
9.2.3 Rod link, cable
9.2.4 Brake piping
9.2.5 Parking Brake Drum, Lining
9.2.6 Oil Brake
9.2.7 Brake Booster
9.2.8 Brake Shoe Lining
9.2.9 Brake Drum
9.2.10 Back Plate
9.3 TESTING AND ADJUSTING
9.3.1 INSPECT BRAKE ASSEMBLY
9.3.2 ADJUST BRAKE SHOE CLEARANCE
9.3.3 BLEED AIR FROM BRAKE PIPING
9.4 Removal and Installation
9.4.1 REMOVAL
9.4.2 INSTALLATION
9.5 Disassembly and Assembly
9.5.1 WHEEL BRAKE
9.5.2 BRAKE MASTER CYLINDER
9.6 Maintenance Standard – MASTER CYLINDER
SM160_JUN2014_11.pdf
10. HYDRAULIC SYSTEM
10.1 Structure and function
10.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS
10.2.1 Hydraulic Tank
10.2.2 Piping
10.2.3 Piping of Work Equipment
10.2.4 Hydraulic drift of lift cylinder and tilt cylinder
10.2.5 Directional Control Valve (1)
10.2.6 Directional Control Valve (2)
10.2.7 Solenoid Valve, Steering Pressure Port
10.2.8 Hydraulic Pump
10.2.9 Flow Divider (For P/S)
10.2.10 Oil Motor
10.2.11 Lift Cylinder
10.2.12 Tilt Cylinder
10.2.13 Reach Cylinder
10.2.14 Work Equipment Cylinder
10.3 TESTING AND ADJUSTING
10.3.1 SERVICE HYDRAULIC TANK
10.3.2 TROUBLESHOOTING
10.4 Removal and Installation
10.4.1 Remove Hydraulic Pump
10.4.2 Install Hydraulic Pump
10.5 Disassembly and Assembly
10.5.1 FLOW DIVIDER
10.5.2 HYDRAULIC PUMP
10.6 HYDRAULIC PUMP Maintenance Standard
SM160_JUN2014_12.pdf
11. WORK EQUIPMENT
11.1 Structure and function
11.1.1 TILT CYLINDER
11.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS
11.2.1 Fork (1)
11.2.2 Fork (2)
11.2.3 Mast (1)
11.2.4 Mast (2)
11.2.5 Fork Carriage
11.2.6 Lift Chain
11.2.7 Chain Wheel
11.2.8 Work Equipment System (1)
11.2.9 Work Equipment System (2)
11.2.10 Lift Cylinder
11.2.11 Tilt Cylinder
11.2.12 Reach Cylinder
11.2.13 Work Equipment Cylinder
11.2.14 Hydraulic drift of lift cylinder and tilt cylinder
11.3 Removal and Installation
11.3.1 MAST
11.3.2 LIFT CYLINDER
11.4 Disassembly and Assembly
11.4.1 LIFT CYLINDER
11.4.2 TILT CYLINDER
11.4.3 CONTROL VALVE
11.4.4 Cylinder Seal Service Kits
11.4.5 sideshifter
11.5 Maintenance Standard
11.5.1 CYLINDERS
11.5.2 LIFT CYLINDER
SM160_JUN2014_13.pdf
12.
MASTS
E-MS SERIES Limited Free Lift 2-Stage Mast
E-MD SERIES Full Free Lift 2-Stage MAST
E-MT SERIES Full Free Lift 3-Stage MAST
35D/45D/55D MQ QUAD MASTS
SM160_JUN2014_14.pdf
ELECTRICAL DIAGRAMS
BX50 TIER 2 DIESEL (4D94LE ENGINE) S/N 200001A – 215882A
BX50 INTERIM TIER 4 DIESEL (4D98E ENGINE) S/N 215883A – 219999A / 750875~ / A223001~
BX50 TIER 1 GASOLINE (K21/K25 ENGINE) S/N 200001A – 205849A
BX50 TIER 2 GASOLINE (K21/K25 ENGINE) S/N 210001A – 219999A / 750875 – 751863 / A224001~
BX50 TIER 1 LPG (K21/K25 ENGINE) S/N 200001A – 205849A
BX50 TIER 2 LPG (K21/K25 ENGINE) S/N 210001A – 219999A / 750875 – 751863 / A224001~
BX50 CARB 2010 LPG (K21/K25 ENGINE) S/N 751863~ / A224001~
BX50 CARB 2010 LPG (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM
BX50 TIER 1 LPS (K21/K25 ENGINE) S/N 200001A – 205849A
BX50 TIER 2 LPS (K21/K25 ENGINE) S/N 210001A – 219999A / 750875 – 751863 / A224001~
BX50 TIER 1 DUAL FUEL (K21/K25 ENGINE) S/N 200001A – 205849A
BX50 TIER 2 DUAL FUEL (K21/K25 ENGINE) S/N 210001A – 219999A / 750875 – 751863 / A224001~
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) S/N 751863~ / A224001~
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM
SM160_JUN2014_15.pdf
ELECTRICAL DIAGRAMS – 24X36

BX50 TIER 2 DIESEL (4D94LE ENGINE)
BX50 INTERIM TIER 4 DIESEL (4D98E ENGINE)
BX50 TIER 1 GASOLINE (K21/K25 ENGINE)
BX50 TIER 2 GASOLINE (K21/K25 ENGINE)
BX50 TIER 1 LPG (K21/K25 ENGINE)
BX50 TIER 2 LPG (K21/K25 ENGINE)
BX50 CARB 2010 LPG (K21/K25 ENGINE)
BX50 CARB 2010 LPG – NEW KOPS (K21/K25 ENGINE)
BX50 TIER 1 LPS (K21/K25 ENGINE)
BX50 TIER 2 LPS (K21/K25 ENGINE)
BX50 TIER 1 DUAL FUEL (K21/K25 ENGINE)
BX50 TIER 2 DUAL FUEL (K21/K25 ENGINE)
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE)
BX50 CARB 2010 DUAL FUEL – NEW KOPS (K21/K25 ENGINE)