Komatsu BBX50 Series Service Manual Download

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SERVICE MANUAL

ISSUED DECEMBER 2005

Read and observe all warnings on this unit
before operating it.

DO NOT

operate this equipment unless all

factory installed guards and shields are
properly secured in place.

WARNING

BBX50 SERIES ELECTRIC FORKLIFT TRUCKS - S/N 090001A~

FB20/25/30/32SH-6
FB20/25/30/32SHE-6
FB20/25SHG-6
FB20/25SHGE-6

SM150

BBX50

Komatsu Forflift USA, Inc.

Summary of Contents for BBX50 Series

Page 1: ...re operating it DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place WARNING BBX50 SERIES ELECTRIC FORKLIFT TRUCKS S N 090001A FB20 25 30 32SH 6...

Page 2: ...10 12 Periodic Replacement of Consumable Parts 10 14 Standard Tightening Torque for Bolts 10 15 Standard Tightening Torque for Pipe Joints 10 16 How to Use Loctite 10 17 Conversion Tables 10 18 CHAPTE...

Page 3: ...30 12 Hydraulic Pump Pump Motor 30 13 Removal 30 13 Installation 30 13 Controller 30 14 Removal 30 14 Installation 30 14 CHAPTER 40 DISASSEMBLY AND ASSEMBLY 40 1 Transfer 40 2 Disassembly and Assembly...

Page 4: ...60 5 Overview of FET Power Module 60 6 Control Functions of Controller 60 7 Travel Interlock Power Shutdown 60 8 Load Handling Interlock 60 9 Lift Interrupt 60 10 Travel Speed Limit 60 10 High Mast Ti...

Page 5: ...25 Removing Power Supply PCB 70 25 Connector Location and Pin Number of CPU PCBS 70 26 Connector Location and Pin Number of Power Supply PCB 70 28 Checking FET Power Module 70 29 Checking Main Fuse 7...

Page 6: ...ushion Tire High Option Extended Frame EE Rated FB25SH 6 5 000 lb Capacity Cushion Tire High Option FB25SHE 6 5 000 lb Capacity Cushion Tire High Option EE Rated FB25SHG 6 5 000 lb Capacity Cushion Ti...

Page 7: ...re that you carry out ample practice so that you become accustomed to each part of the equipment Even when you have become accustomed to handling the lift truck always drive carefully and do not try t...

Page 8: ...d contact in case of an emergency Provide a first aid kit at the storage point Do not use the lift truck if it is leaking fuel Inform the person on charge of the nature of the abnormality and repair t...

Page 9: ...thrown up by the tires When changing from a single tire to a double tire arrangement on your forklift truck always extend the tire fenders to cover the additional tires If the fenders are not extende...

Page 10: ...or the attachment Never exceed the permissible load REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT Avoid operating or leaving the lift truck outside in wet and rainy weather or snow and icy conditions Wh...

Page 11: ...belt immediately WEARING SEAT BELT NEVER JUMP OFF the lift truck even if it seems that it will tip Always do as follows 1 Hold the steering wheel securely 2 Stay in the operator s seat 3 Brace your l...

Page 12: ...s dangerous to change the direction of travel suddenly or when the lift truck is moving If the lever is moved without disengaging the clutch the lift truck will move suddenly and may cause injury PREC...

Page 13: ...lift truck may start to move down the slope depending on the amount the pedals are depressed Always leave ample room in front of and behind the lift truck when starting on slopes Be careful that the...

Page 14: ...ove the truck until the operation is completed If there is some system to secure the truck to the dock always use this system Secure the gangplanks so that they do not slip and fall LOADING HIGHWAY TR...

Page 15: ...t the area behind the lift truck is safe Always keep the surface of the mirror clean If the mirror is broken replace it with a new one for lift trucks equipped with rear view mirror Check that the lam...

Page 16: ...avel Interlock is activated about 3 seconds later shutting off the power of the lift truck The lift truck no longer moves even if you operate the accelerator pedal or forward reverse lever At the same...

Page 17: ...urrounding area When crossing roads or turning corners stop and confirm safety before continuing Always pay careful attention to the movements of people in the surrounding area and take steps to preve...

Page 18: ...ful that the front or rear wheels do not come off the ground When turning on soft road shoulders there is danger that the rear wheels may come off the road shoulder and cause the lift truck to tip PRE...

Page 19: ...ADING Never allow anyone to go under the load engaging means or load when it is raised The area under the forks is a danger area If the forks come down the person under the forks may be crushed or ser...

Page 20: ...f center There is danger that unbalanced loads may cause the lift truck to tip Place the load so that it contacts the load backrest Do not handle unstable loads If there is danger that the load may fa...

Page 21: ...hat the lift truck may tip Do not travel with the mast tilted forward Do not load and unload on slopes DO NOT TILT MAST FORWARD WHEN LOADED If the mast rail or forks catch in a load or on a shelf slac...

Page 22: ...ING DRAWBAR PIN Do not let anyone place a load on the forks Do not let anyone remove a load directly from the forks Standing on the forks is dangerous because the forks are slippery and the load may m...

Page 23: ...ft truck may tip ADJUST CHAIN Do not allow the tips of the forks to get close to people The tips of the forks are pointed so there is a risk that they may cause injury Do not hook the tips of the fork...

Page 24: ...t the load move HANDLING LONG OR WIDE LOADS Be careful not to let the mast overhead guard or load contact electrical wiring pipes sprinklers or roof beams If the truck hits such objects there is a ris...

Page 25: ...IONS WHEN STOPPING OR PARKING then put blocks under the tires to prevent the lift truck from moving Do not park near any holes for construction or elevator shafts PARKING If the lift truck has suffere...

Page 26: ...rator s compartment or near the control panel where it is easy to see Set the FORWARD REVERSE lever and work equipment lever to the neutral position Pull the parking brake lever and put blocks in fron...

Page 27: ...irst When carrying out the job with another worker decide who is the leader and carry out the job in accordance with instructions from that person After repairing make sure that the trouble has been c...

Page 28: ...n the tires have been replaced carry out a test drive and check again for any loose mounting bolts If the tightening torque is low tighten to the specified torque HANDLING TIRES Do not go under the fo...

Page 29: ...ally drink electrolyte drink a large quantity of water or milk mixed with beaten egg white or vegetable oil Call a doctor or poison control center immediately When working with batteries ALWAYS wear s...

Page 30: ...onfirm that the caps are closed A dirty top will badly affect battery life If the battery charger is used for a long time with remarkably deviated tap voltage at the power supply the charger could bur...

Page 31: ...lifting operations with a lift truck equipped with an optional steel cab Fit wire ropes to the specified lifting points When lifting the lift truck check that the wire ropes have ample strength and ar...

Page 32: ...The loads carried by forklift trucks come in various shapes and weights from boxes to planks and long objects To judge the stability of the lift truck it is important to distinguish the position of t...

Page 33: ...e lift truck is governed by the following factors Size weight shape of load Lifting height Tilting angle of mast Acceleration deceleration turning radius Condition of road surface angle of road Type o...

Page 34: ...the maximum load Before loading the forks check that the load and load center are within the permitted range on the load capacity chart If the shape of the load is complex set so that the heaviest par...

Page 35: ...does not operate steering control of the lift truck can be slow This can make the control of the lift truck difficult If there is no power there is no power steering DO NOT tow the lift truck if ther...

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