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

Description

• 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