Komatsu CX50 Forklift Truck SM203 Service Manual PDF

Description

Komatsu CX50 Forklift Truck SM203 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu CX50 Forklift Truck SM203 Service Manual – PDF DOWNLOAD 

Language : English
Pages : 680
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu CX50 Forklift Truck SM203 Service Manual – PDF DOWNLOAD 

Dual Fuel/LPG
S/N 133001 – 134755 (EPA Tier 2) FG40ZTU-10
S/N 134756~ (EPA/CARB 2010) FG40TU/45TU/50ATU-10
Diesel
S/N 133001~ (EPA Tier 3)
FD40ZTU-10
FD40TU/45TU/50ATU-10

General precautions:
1. Before carrying out any greasing or repairs, read all the safety labels stuck to the lift truck. For the locations of
the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor.
Smoke only in the areas provided for smoking. Never smoke while working.
3. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
a. Always wear safety glasses when hitting parts with a hammer.
b. Always wear safety glasses when grinding parts with a grinder, etc.
4. When carrying out any operation with 2 or more workers, always agree on the operating procedure before
starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang
UNDER REPAIR warning signs in the operator’s compartment.
5. Only qualified workers must carry out work and operation which require license or qualification.
6. Keep all tools in good condition. Learn the correct way to use them, and use the proper ones of them. Before
starting work, thoroughly check the tools, lift truck, service car, etc.
7. If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for
welding work.
8. Before starting work, warm up your body thoroughly to start work under good condition.
9. Avoid working continuously for long hours and take rests at proper intervals to keep the good condition. Take
rests in a fixed safe place.
 Safety Points
1. Good arrangement
2. Correct work clothes
3. Following of work standard
4. Making and checking of signs
5. Prohibition of operation and handling by unlicensed workers
6. Safety check before starting work
7. Wearing protective goggles (for cleaning or grinding work)
8. Wearing shielding goggles and protectors (for welding work)
9. Good physical condition and preparation
10. Precautions against work which you are not used to or you are used to too much

TABLE OF CONTENTS:

Komatsu CX50 Forklift Truck SM203 Service Manual – PDF DOWNLOAD 

1 Foreword and general information 9
1 1 Safety notice 11
1 2 How to read the shop manual 22
1 3 Explanation of terms for maintenance standard 24
1 4 Handling of electric equipment and hydraulic components 26
1 5 Handling of new types of connectors used on engines 34
1 6 How to read electric wire code 37
1 7 Precautions when carrying out operation 40
1 8 Standard tightening torque tables 43
1 9 Conversion tables 47
2 Specifications 53
2 1 Dimensional diagram 55
2 2 Diesel engine lift truck with SAA4D95LE-5-A engine (UL spec) 56
2 3 Gasoline engine lift truck with EBT-TB45-2A/3A (UL spec) 57
2 4 Weight table 58
2 5 Lubricants 59
3 Structure, function and maintenance standard 63
Engine and cooling system 63
3 1 Cooling system – diesel engine 64
3 2 Cooling system – gasoline engine 66
3 3 Brake cooling system hydraulic piping diagram 68
Power train 69
3 4 Power train overview 71
3 5 Power train system diagram 72
3 6 Torque converter 74
3 7 Hydraulic port locations – torque converter 76
3 8 Transmission 81
3 9 Forward (F) clutch 86
3 10 Reverse (R) clutch 88
3 11 Forward 2nd (F2) clutch 90
3 12 Power transmission route 93
3 13 Transmission control valve 95
3 14 Hydraulic port locations – transmission 97
3 15 Hydraulic system diagram 98
3 16 Relief valve 99
3 17 Drive shaft 100
3 18 Front axle 101
3 19 Differential 102
3 20 Final drive 106
Steering system 109
3 21 Steering piping diagram 111
3 22 Orbital valve 112
3 23 Power steering cylinder 113
Brake system 115
3 24 Brake control 117
3 25 Brake piping diagram 118
3 26 Service brake 119
3 27 Accumulator charge valve 121
3 28 Brake valve 126
3 29 Slack adjuster 129
3 30 Accumulator (for brake) 132
3 31 Parking brake 133
Undercarriage and frame 135
3 32 Rear axle 137
3 33 Hydraulic tank piping diagram 138
3 34 Frame 139
Hydraulic system 141
3 35 Control valve piping diagram 143
3 36 Work equipment piping diagram 144
3 37 Attachment piping diagram 145
3 38 Hydraulic pump 146
3 39 LS valve 151
3 40 Unload valve 152
3 41 Control valve 153
3 42 3-spool valve 154
3 43 Closed center Load Sensing System (CLSS) 159
3 44 Function and operation of each valve 161
Work equipment 175
3 45 Tilt cylinder 177
3 46 Lift cylinder – Japan manufacture 178
3 47 Mast – Japan manufacture 179
3 48 Fork carriage – Japan manufacture 186
3 49 Fork – Japan manufacture 187
Electric devices Part 1 189
3 50 Accelerator pedal sensor 191
3 51 ISO controller – Operator Presence Sensing (OPS) system 193
3 52 Instrument panel 200
3 53 Engine starting circuit 202
3 54 Engine stopping circuit 204
3 55 Electrical system wiring diagram 205
Electric devices Part 2 207
3 56 Sensors 209
3 57 Switches 211
3 58 Lamps 217
3 59 Horn and buzzer 219
3 60 Flasher 222
3 61 F/R solenoid valve and F2 solenoid valve 223
3 62 Relay box 224
3 63 Resistor 230
3 64 Diode 231
3 65 Fuse 242
3 66 Battery 244
4 Standard value table 247
4 1 Lift truck with SAA4D95LE-5-A engine (UL spec) 249
4 2 Lift truck with EBT-TB45-2A/3A engine (UL spec) 251
5 Testing and adjusting 253
5 1 Check of troubleshooting software functions and failure codes 255
5 2 Hydraulic piping pressure release procedure 258
5 3 Replacement of engine oil and engine oil filter 259
5 4 Replacement of fuel filter 260
5 5 Cleaning of radiator 263
5 6 Check of air cleaner and replacement of cleaner element 264
5 7 Oil level check and oil replacement of differential case 265
5 8 Oil replacement and strainer cleaning of Torqflow transmission 266
5 9 Testing power train oil pressure 267
5 10 Check of hydraulic tank 270
5 11 Measurement of wear amount of service brake disc 272
5 12 Check of parking brake 273
5 13 Air bleeding procedure 274
5 14 Adjustment of brake pedal 275
5 15 Adjustment of inching pedal 276
5 16 Measurement of cylinder hydraulic drift and hydraulic forward drift 277
5 17 Adjustment of mast – Japan manufacture 278
5 18 Adjustment of fork carriage – Japan manufacture 281
5 19 Check of drive shaft for looseness, play and damage 283
5 20 Check of diode 284
6 Troubleshooting 285
General information on troubleshooting 285
6 1 Points to remember when troubleshooting 287
6 2 Sequence of events in troubleshooting 288
6 3 Testing before troubleshooting 289
6 4 Classification and procedures of troubleshooting 290
6 5 Phenomena indicating trouble and troubleshooting codes 291
6 6 Information contained in troubleshooting table 297
6 7 Locations of fuses 299
Failure codes: ISO controller (UL spec) 305
6 8 Failure code display by ISO controller 307
6 9 Failure code [[!]: 1 flashing, [N]: Flashing, [L]: Flashing] 310
6 10 Failure code [!]: 2 flashings, [N]: Flashing, [L]: OFF 312
6 11 Failure code [!]: 3 flashings, [N]: OFF, [L]: OFF 314
6 12 Failure code [[!]: 4 flashings, [N]: OFF, [L]: Flashing] 318
6 13 Failure code [[!]: 4 flashings, [N]: Flashing, [L]: Flashing] 320
6 14 Failure code [[!]: 5 flashings, [N]: OFF, [L]: Flashing] 322
6 15 Failure code [[!]: 5 flashings, [N]: Flashing, [L]: Flashing] 324
6 16 Failure code [[!]: 6 flashings, [N]: Flashing, [L]: Flashing] 326
6 17 Failure code [[!]: 7 flashings, [N]: Flashing, [L]: Flashing] 328
Electrical system (E-mode) SAA4D95LE-5-A engine (UL spec) 329
6 18 E-1 Engine does not start 331
6 19 E-2 Engine does not stop 334
6 20 E-3 Lift truck cannot travel 336
6 21 E-4 Parking brake reminder alarm does not sound or does not stop sounding 339
6 22 E-5 Travel direction is not changed normally 341
6 23 E-6 Lift truck cannot move work equipment 344
6 24 E-7 Work equipment cannot be locked 346
6 25 E-8 Headlamp, clearance lamp and tail lamp do not light or go off 348
6 26 E-9 Turn signal lamps do not light or go off 350
6 27 E-10 Brake lamps do not light or go off 352
6 28 E-11 Backup lamps do not light or go off 354
6 29 E-12 Backup buzzer (optional) does not sound or does not stop sounding 356
6 30 E-13 Horn does not sound or does not stop sounding 358
6 31 E-14 Fuel level is not displayed normally 360
Electrical system (E-mode) EBT-TB45-2A/3A engine (UL spec) 363
6 32 E-1 Engine does not start 365
6 33 E-2 Engine does not stop 372
6 34 E-3 Lift truck cannot travel 374
6 35 E-4 Parking brake reminder alarm does not sound or does not stop sounding 374
6 36 E-5 Travel direction is not changed normally 374
6 37 E-6 Lift truck cannot move work equipment 374
6 38 E-7 Work equipment cannot be locked 374
6 39 E-8 Headlamp, clearance lamp and, tail lamp do not light or go off 374
6 40 E-9 Turn signal lamps do not light or go off 374
6 41 E-10 Brake lamps do not light or go off 374
6 42 E-11 Backup lamps do not light or go off 374
6 43 E-12 Backup buzzer (optional) does not sound or does not stop sounding 374
6 44 E-13 Horn does not sound or does not stop sounding 374
6 45 E-14 Fuel (Gasoline) level is not displayed normally 374
Hydraulic and mechanical system (H-mode) 375
6 46 Method of using troubleshooting table 377
6 47 Table of failure modes and causes 380
7 Disassembly and assembly 429
General information 429
7 1 Using this chapter 431
7 2 Special tool list 432
7 3 How to use LOCTITE 436
Engine and cooling system 437
7 4 Power train removal 439
7 5 Power train installation 443
Power train components 445
7 6 Front axle removal 447
7 7 Front axle installation 451
7 8 Power train centering 454
7 9 Transmission disassembly 458
7 10 Transmission assembly 462
7 11 Torque converter disassembly 465
7 12 Torque converter component parts 468
7 13 Torque converter assembly 470
7 14 Drive shaft 471
7 15 Differential disassembly 472
7 16 Differential assembly 476
7 17 Axle housing disassembly 485
7 18 Axle housing assembly 489
7 19 Parking brake 496
7 20 Rear axle disassembly 497
7 21 Rear axle assembly 498
7 22 Power steering cylinder disassembly 501
7 23 Power steering cylinder assembly 503
7 24 Brake pedal 504
7 25 Brake valve disassembly 505
7 26 Brake valve assembly 507
Hydraulic equipment 509
7 27 Steering valve 511
7 28 Control valve 515
7 29 Lift cylinder – Japan manufacture 521
7 30 Tilt cylinder 525
Work equipment 531
7 31 Mast removal – Japan manufacture 533
7 32 Mast installation – Japan manufacture 533
Electric devices 539
7 33 Combination switch component parts 541
8 U S manufactured masts 543
80D/100D/110D-MS 2-Stage Masts 543
Introduction 544
Installation Instructions 545
Periodic Maintenance 550
Troubleshooting 551
Service 552
80D/100D/110D-MT 3-Stage Masts 571
Introduction 572
Installation Instructions 573
Periodic Maintenance 588
Troubleshooting 589
Service 590
D-Series Sideshifter 617
E-Series Sideshifter 633
9 Yearly inspection criteria 647
10 Diagrams and drawings 665
Hydraulic circuit 0
Electrical circuit – UL spec 0

S.V 11/12/24