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Komatsu ASX-HP, BSX-HP High Performance, Electric Stand-up, Counterbalanced Forklift Truck Service Manual SM400

$30.00

Type Of Manual: Service Manual
Manual ID: SM400
Format: PDF
Size: 7.1MB
Number of Pages: 225

Category: Komatsu Service Manual PDF

Model List:
- ASX-HP High Performance Electric Stand-up Counterbalanced Forklift Truck
- BSX-HP High Performance Electric Stand-up Counterbalanced Forklift Truck

1. SM40000
1.1. SERVICE MANUAL
1.1.1. INTRODUCTION
1.1.2. SERIAL NUMBER LOCATION
1.1.3. CONTENTS
1.1.4. FORKLIFT TRUCKSCOVERED IN THIS PUBLICATION
2. SM40001
2.1. SAFETY SECTION
2.1.1. SAFETY MANAGEMENT
2.1.2. SAFE TRAVEL
2.1.3. LOADING OPERATIONS
2.1.4. STOPPING AND PARKING
2.1.5. INSPECTION AND MAINTENANCE
2.1.6. STRUCTURE AND STABILITY OF THE LIFT TRUCK
2.1.7. SAFETY LABELS
2.1.8. OPTIONAL EQUIPMENT
2.2. GENERAL INFORMATION
2.2.1. INTRODUCTION TO THE EQUIPMENT
2.2.2. ABOUT THIS MANUAL
2.2.3. SERVICE PRECAUTIONS
2.2.4. ELECTRONIC ASSEMBLY PRECAUTIONS
3. SM40002
3.1. GENERAL MAINTENANCE PROCEDURES
3.1.1. GENERAL MAINTENANCE PROCEDURES
3.1.1.1. MOVING A DISABLED LIFT TRUCK
3.1.1.2. TOWING A DISABLED LIFT TRUCK
3.1.1.3. LIFTING A DISABLED LIFT TRUCK
3.1.1.4. PUTTING THE LIFT TRUCK ON BLOCKS
3.1.1.5. CLEANING INSTRUCTIONS
3.1.2. DRIVE WHEEL ASSEMBLY
3.1.3. CHANGING DRIVE TIRES
3.1.4. DRIVE WHEEL SEAL
3.1.5. DRIVE WHEEL SPINDLE
3.1.6. ENCODER ASSEMBLY
3.1.7. ENCODER BELT ADJUSTMENT
3.1.8. DRIVE SHAFT INSERT
3.1.9. DRIVE UNIT REBUILD
3.1.9.1. DISASSEMBLY
3.1.9.2. ASSEMBLY
3.1.10. CARRIER REBUILD
3.1.11. OVERHEAD GUARD REAR POST
3.1.12. BATTERY GATES
3.1.13. BATTERY ROLLERS
3.1.14. FRONT COVER
3.1.15. TOP COVER
3.1.16. CONTROL COVER
3.1.17. OPERATOR COMPARTMENT PADS
3.1.18. FLOOR MAT / BRAKE PEDAL PAD
3.1.19. DISC BRAKE UNIT
3.1.20. MASTER CYLINDER
3.1.21. BRAKE PEDAL
3.1.22. BLEEDING THE BRAKE SYSTEM
3.1.23. BRAKE ADJUSTMENTS
4. SM40006
4.1. STEERING
4.1.1. STEERING SYSTEM ELECTRIC STEER
4.1.2. TILLER / ENCODER ASSEMBLY
4.1.3. GEARMOTOR
4.1.4. SPUR GEAR FORK
4.1.5. STEER WHEEL ASSEMBLY
4.1.6. CHANGING STEER TIRES
4.1.7. STEER POSITION POTENTIOMETER
5. SM40007
5.1. OPERATOR CONTROLS
5.1.1. OPERATOR CONTROLS DIAGRAM
5.1.2. CONTROL HANDLE ASSEMBLY
5.1.3. CONTROL HANDLEPOTENTIOMETER
5.1.4. BATTERY DISCONNECT LEVER
5.1.5. HORN BUTTON SPRING
5.1.6. LIFT AND TRAVEL SPRINGS
6. SM40008
6.1. LIFT AND AUXILIARY HYDRAULICS
6.1.1. THEORY OF OPERATION
6.1.2. LIFT PUMP MOTOR ASSEMBLY
6.1.3. LIFT PUMP
6.1.4. LIFT PUMP MOTOR BRUSHES
6.1.5. SOLENOID VALVE CARTRIDGES
6.1.6. MANUAL LOWERING VALVE, RELIEF VALVE, CHECK VALVE,FLOW REGULATORS
6.1.7. HYDRAULIC OIL FILTER
6.1.8. HYDRAULIC OIL
6.1.9. TILT CYLINDERS
6.1.10. TILT ANGLE ADJUSTMENT
6.1.11. RELIEF PRESSURE ADJUSTMENT
6.1.12. HYDRAULIC MANIFOLD DIAGRAM
6.1.13. HYDRAULIC MANIFOLD ASSEMBLY (S/N K957001 K02499U)
6.1.14. HYDRAULIC MANIFOLD ASSEMBLY (S/N K02500U)
7. SM40009
7.1. ELEVATING
7.1.1. EQUIPMENT DESCRIPTIONS
7.1.2. MAST
7.1.3. MAST ADJUSTMENT
7.1.4. CARRIAGE
7.1.5. INNER CHAINS
7.1.6. OUTER LIFT CHAINS (TRIPLEX)
7.1.7. CHAIN ADJUSTMENT
7.1.8. CENTER LIFT CYLINDER
7.1.9. OUTER LIFT CYLINDERS (TRIPLEX)
7.1.10. CENTER CYLINDER SHEAVES
7.1.11. MIDDLE RAIL SHEAVES
7.1.12. MAIN HYDRAULIC DISTRIBUTOR BLOCK
7.1.13. CENTER CYLINDER DISTRIBUTOR BLOCK
7.1.14. AUXILIARY INTERNAL REEVING (OPTION)
7.1.15. STANDARD HOSE ASSEMBLY
7.1.16. BLEEDING AIR FROM THE LIFT CYLINDERS
7.1.17. TILT ANGLE ADJUSTMENT
8. SM40010
8.1. ELECTRICAL
8.1.1. CAPACITOR DISCHARGE
8.1.2. SYSTEM CONTROLLER / OPERATORDISPLAY BOX
8.1.3. OPERATOR DISPLAY BOARD
8.1.4. TRACTION AMPLIFIER
8.1.5. LIFT AMPLIFIER
8.1.6. MAIN POWER CONTACTOR
8.1.7. CONTACTOR TIPS
8.1.8. FUSES
8.1.9. HORN
8.1.10. AMPLIFIER DIODES
8.1.11. ELECTRICAL SCHEMATIC FOLDOUT
9. SM40011
9.1. PERIODIC MAINTENANCE
9.1.1. PERIODIC MAINTENANCE INSPECTION POINTS DIAGRAM
9.1.2. SCHEDULED MAINTENANCE TABLE
9.1.3. HOUR DAILY INSPECTION
9.1.3.1. SRO CIRCUIT
9.1.3.2. GENERAL FUNCTIONS
9.1.3.3. BATTERY
9.1.3.4. CHARGING THE BATTERY
9.1.3.5. CHANGING THE BATTERY
9.1.3.6. BATTERY CONNECTOR
9.1.3.7. BATTERY GATES
9.1.3.8. BRAKES
9.1.3.9. BRAKE PEDAL / BRAKE LINKAGE
9.1.3.10. BRAKE SWITCH
9.1.3.11. CARRIAGE / LOAD BACKREST / FORKS
9.1.3.12. CONTROL HANDLE
9.1.3.13. DECALS
9.1.3.14. GEARBOX
9.1.3.15. HYDRAULIC SYSTEM
9.1.4. HOUR / 5DAY INSPECTION
9.1.4.1. BATTERY
9.1.4.2. SIDESHIFT CARRIAGE
9.1.4.3. HYDRAULIC SYSTEM
9.1.4.4. LIFT CHAINS
9.1.5. HOUR / 60DAY INSPECTION
9.1.5.1. BATTERY
9.1.5.2. BRAKES
9.1.5.3. CONTACTOR TIPS
9.1.5.4. GEARBOX
9.1.5.5. HYDRAULIC SYSTEM
9.1.5.6. LIFT CHAINS
9.1.5.7. MOTOR BRUSHES
9.1.6. HOUR / 360 DAY INSPECTION
9.1.6.1. BRAKES
9.1.6.2. GEARBOX
9.1.6.3. HYDRAULIC SYSTEM
9.1.6.4. TIRES / WHEELS
10. SM40012
10.1. PROGRAMMING AND DIAGNOSTICS
10.1.1. INTRODUCTION
10.1.2. PREOPERATION INFORMATION
10.1.3. PERFORMANCE AND DIAGNOSTICS MENU
10.1.4. STARTUP SEQUENCE
10.1.5. PASSWORD ENTRY
10.1.6. PROGRAMMING AND DIAGNOSTICS MENU DIAGRAN
10.1.7. CALIBRATION MENU (CALIBRAT)
10.1.8. USER PROFILES
10.1.9. PROGRAM MENU DIAGRAM
10.1.10. DIAGNOSTIC MENU (DIAGNSTC)
10.1.11. DIAGNOSTICS INPUT TESTS TABLE
10.1.12. DIAGNOSTICS OUTPUT TESTS TABLE
10.1.13. ERROR HISTORY
10.1.14. OPERATIONAL FEEDBACK DEVICES
10.1.15. OPERATIONAL MODES
10.1.16. ERROR CODE (SYSTEM FAULT CODES) TABLES
11. SM40013
11.1. TROUBLESHOOTING
11.1.1. TROUBLESHOOTING MECHANICAL
11.1.1.1. DRIVE
11.1.1.2. BRAKES
11.1.1.3. STEERING ELECTRIC
11.1.1.4. OPERATOR CONTROLS
11.1.1.5. LIFT AND AUXILIARY
11.1.1.6. ELEVATING
11.1.2. ELECTRONIC FAULT ISOLATION PROCEDURE SOFTWARE VERSION 3.20
11.1.2.1. ERRORS FAULT CONDITION CODES
11.1.3. ELECTRONIC FAULT ISOLATION PROCEDURE SOFTWARE VERSION 3.20
11.1.3.1. WARNINGS
12. SM40014
12.1. INDUSTRIAL BATTERY
12.1.1. INDUSTRIAL BATTERY
12.1.2. SAFETY
12.1.3. CHANGING THE BATTERY
12.1.4. CHARGING THE BATTERY
12.1.5. CLEANING THE BATTERY
12.1.6. MEASURING SPECIFIC GRAVITY
12.1.7. VOLTAGE CHECK
12.1.8. ELECTROLYTE LEVEL
12.1.9. BATTERY HISTORY RECORD
13. SM40015
13.1. TORQUE SPECIFICATIONS
13.1.1. SAE BOLTS 1/4 TO 1 1/2
13.1.2. METRIC BOLTS M3 TO M12
13.1.3. CAP / MACHINE SCREWS

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