Komatsu CX50 Forklift Trucks Service Manual SM203 – PDF DOWNLOAD 

Description

Komatsu CX50 Forklift Trucks Service Manual SM203 – PDF DOWNLOAD

FILE DETAILS:

Komatsu CX50 Forklift Trucks Service Manual SM203 – PDF DOWNLOAD 

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

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu CX50 Forklift Trucks Service Manual SM203 – PDF DOWNLOAD 

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

TABLE OF CONTENTS:

Komatsu CX50 Forklift Trucks Service Manual SM203 – 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 13/12/24