Komatsu CX50 Series Forklift Truck Shop Manual – PDF DOWNLOAD

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Komatsu CX50 Series Forklift Truck Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu CX50 Series Forklift Truck Shop Manual – PDF DOWNLOAD

Language : English
Pages : 896
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu CX50 Series Forklift Truck Shop Manual – PDF DOWNLOAD

Cover......................................................................................................................................  1
	00 Index and foreword..................................................................................................................  3
		100 Index..........................................................................................................................  3
			Composition of shop manual.....................................................................................................  4
			Table of contents..............................................................................................................  6
		200 Foreword and general information............................................................................................... 15
			Safety notice.................................................................................................................. 16
			How to read the shop manual.................................................................................................... 27
			Explanation of terms for maintenance standard.................................................................................. 29
			Handling of electric equipment and hydraulic component......................................................................... 31
			Handling of connectors newly used for engines.................................................................................. 40
			How to read electric wire code................................................................................................. 43
			Precautions when carrying out operation........................................................................................ 46
			Standard tightening torque table............................................................................................... 49
			Conversion table............................................................................................................... 53
	01 Outline............................................................................................................................. 59
		100 Specifications................................................................................................................. 59
			Specification dimension drawing................................................................................................ 60
			Weight table................................................................................................................... 75
			Lubricant list................................................................................................................. 76
	10 Structure, function and maintenance standard........................................................................................ 85
		100 Engine and cooling system...................................................................................................... 85
			Cooling system (Lift truck with SAA4D95LE-5-A/S4D95LE-3 engine)................................................................ 86
			Cooling system (Lift truck with EBT-TB45-1A/2A/3A engine)...................................................................... 88
			Cooling system (Lift truck with EBT-GK45-1B/2B/3B engine)...................................................................... 90
			Brake cooling system hydraulic piping diagram.................................................................................. 92
		200 Power train.................................................................................................................... 95
			Power train.................................................................................................................... 96
			Power train system diagram..................................................................................................... 97
			Torque converter............................................................................................................... 99
			Transmission...................................................................................................................107
			Transmission control valve.....................................................................................................121
			Relief valve...................................................................................................................125
			Drive shaft....................................................................................................................126
			Front axle.....................................................................................................................128
			Differential...................................................................................................................129
			Final drive....................................................................................................................134
		300 Steering system................................................................................................................139
			Steering piping diagram (control valve – power steering cylinder)..............................................................140
			Orbit-roll valve...............................................................................................................141
			Power steering cylinder........................................................................................................143
		400 Brake system...................................................................................................................145
			Brake control..................................................................................................................146
			Brake piping diagram (control valve – accumulator).............................................................................147
			Service brake..................................................................................................................148
			Accumulator charge valve.......................................................................................................150
			Brake valve....................................................................................................................156
			Slack adjuster.................................................................................................................160
			Accumulator (for brake)........................................................................................................164
			Parking brake..................................................................................................................165
		500 Undercarriage and frame........................................................................................................167
			Rear axle......................................................................................................................168
			Hydraulic tank piping diagram..................................................................................................169
			Frame..........................................................................................................................170
		600 Hydraulic system...............................................................................................................173
			Control valve piping diagram (tank – control valve)............................................................................174
			Work equipment piping diagram (control valve – tilt cylinder/lift cylinder)....................................................175
			Attachment piping diagram......................................................................................................176
			Work equipment and steering pump...............................................................................................178
			Control valve..................................................................................................................186
			CLSS...........................................................................................................................192
			Each function and operation of each valve......................................................................................194
		700 Work equipment.................................................................................................................211
			Tilt cylinder..................................................................................................................212
			Lift cylinder..................................................................................................................213
			Mast...........................................................................................................................214
			Fork carriage..................................................................................................................221
			Fork...........................................................................................................................222
		801 Electric devices (Part 1)......................................................................................................225
			Accelerator pedal sensor.......................................................................................................226
			ISO controller (Operator Presence Sensing (OPS) system)........................................................................228
			AS controller (Forklift truck with seat belt interlock)........................................................................239
			EPACS controller...............................................................................................................242
			Instrument panel...............................................................................................................244
			Engine starting circuit........................................................................................................246
			Engine stopping circuit........................................................................................................248
			Electrical system wiring diagram...............................................................................................249
		802 Electric devices (Part 2)......................................................................................................253
			Sensors........................................................................................................................254
			Switches.......................................................................................................................260
			Lamps..........................................................................................................................269
			Horn and buzzer................................................................................................................272
			Flasher........................................................................................................................275
			F/R solenoid valve and F2 solenoid valve.......................................................................................276
			Relay box......................................................................................................................277
			Resistor.......................................................................................................................286
			Resistor.......................................................................................................................287
			Diode..........................................................................................................................288
			Diode (Forklift truck with seat belt interlock)................................................................................289
			Fuse...........................................................................................................................314
			Battery........................................................................................................................317
	20 Standard value table................................................................................................................321
		100 Standard value table...........................................................................................................321
			Standard value table...........................................................................................................322
	30 Testing and adjusting...............................................................................................................351
		100 Testing and adjusting..........................................................................................................351
			Check of troubleshooting software functions and failure codes..................................................................353
			Hydraulic piping pressure release procedure....................................................................................356
			Replacement of engine oil and engine oil filter................................................................................357
			Replacement of fuel filter.....................................................................................................359
			Cleaning of radiator...........................................................................................................362
			Check of air cleaner and replacement of cleaner element........................................................................363
			Oil level check and oil replacement of differential case.......................................................................364
			Oil replacement and strainer cleaning of TORQFLOW transmission.................................................................365
			Testing power train oil pressure...............................................................................................366
			Check of hydraulic tank........................................................................................................370
			Measurement of wear amount of service brake disc...............................................................................372
			Check of parking brake.........................................................................................................373
			Air bleeding procedure.........................................................................................................374
			Adjustment of brake pedal......................................................................................................376
			Adjustment of inching pedal....................................................................................................377
			Initialization of orbit-roll valve.............................................................................................378
			Measurement of cylinder hydraulic drift and hydraulic forward drift............................................................379
			Adjustment of mast.............................................................................................................380
			Adjustment of fork carriage....................................................................................................383
			Check of drive shaft for looseness, play and damage............................................................................385
			Check of diode.................................................................................................................386
	40 Troubleshooting.....................................................................................................................389
		100 General information on troubleshooting.........................................................................................389
			Points to remember when troubleshooting........................................................................................390
			Sequence of events in troubleshooting..........................................................................................391
			Testing before troubleshooting.................................................................................................392
			Classification and procedures of troubleshooting...............................................................................393
			Phenomena looking like troubles and troubleshooting No.........................................................................394
			Information contained in troubleshooting table.................................................................................404
			Locations of fuses.............................................................................................................406
		201 Troubleshooting by failure code (ISO controller system (*)) (Part 1)...........................................................431
			Failure code display by ISO controller.........................................................................................432
			Failure code [[!]: 1 flashing, [N]: Flashing, [L]: Flashing]...................................................................436
			Failure code [[!]: 2 flashings, [N]: Flashing, [L]: OFF].......................................................................440
			Failure code [[!]: 3 flashings, [N]: OFF, [L]: OFF]............................................................................442
			Failure code [[!]: 4 flashings, [N]: OFF, [L]: Flashing].......................................................................446
			Failure code [[!]: 4 flashings, [N]: Flashing, [L]: Flashing]..................................................................448
			Failure code [[!]: 5 flashings, [N]: OFF, [L]: Flashing].......................................................................450
			Failure code [[!]: 5 flashings, [N]: Flashing, [L]: Flashing]..................................................................452
			Failure code [[!]: 6 flashings, [N]: Flashing, [L]: Flashing]..................................................................454
			Failure code [[!]: 7 flashings, [N]: Flashing, [L]: Flashing]..................................................................456
		202 Troubleshooting by failure code (ISO controller system (*)) (Part 2)...........................................................461
			Failure code display by ISO controller.........................................................................................462
			Failure code [[!]: 1 flashing, [N]: Flashing, [L]: Flashing]...................................................................466
			Failure code [[!]: 2 flashings, [N]: Flashing, [L]: OFF].......................................................................470
			Failure code [[!]: 3 flashings, [N]: OFF, [L]: OFF]............................................................................472
			Failure code [[!]: 4 flashings, [N]: OFF, [L]: Flashing].......................................................................476
			Failure code [[!]: 4 flashings, [N]: Flashing, [L]: Flashing]..................................................................478
			Failure code [[!]: 5 flashings, [N]: OFF, [L]: Flashing].......................................................................480
			Failure code [[!]: 5 flashings, [N]: Flashing, [L]: Flashing]..................................................................482
			Failure code [[!]: 6 flashings, [N]: Flashing, [L]: Flashing]..................................................................484
			Failure code [[!]: 7 flashings, [N]: Flashing, [L]: Flashing]..................................................................486
		203 Troubleshooting by failure code (EPACS controller system) (Part 3).............................................................489
			Display of EPACS controller failure code.......................................................................................490
			Failure code [LED: OFF] EPACS controller abnormality...........................................................................491
			Failure code [LED: 1 flashing] Initialization is not completed.................................................................492
			Failure code [LED: 2 flashings] Controller is being initialized................................................................493
			Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality........................................................494
			Failure code [LED: 4 flashings] Tyre angle sensor abnormality..................................................................496
		301 Troubleshooting of electrical system (E-mode) (Part 1).........................................................................499
			E-1 Engine does not start......................................................................................................502
			E-2 Engine does not stop.......................................................................................................506
			E-3 Lift truck cannot travel...................................................................................................508
			E-3 Lift truck cannot travel (Forklift truck with seat belt interlock).........................................................514
			E-4 Parking brake reminder alarm does not sound or does not stop sounding......................................................518
			E-5 Travel direction is not changed normally...................................................................................520
			E-6 Lift truck cannot move work equipment......................................................................................524
			E-6 Lift truck cannot move work equipment (Forklift truck with seat belt interlock)............................................528
			E-7 Work equipment cannot be locked............................................................................................530
			E-8 EPACS is abnormal..........................................................................................................534
			E-9 Headlamp, clearance lamp, tail lamp and license plate lamp do not light or go off..........................................536
			E-10 Turn signal lamps do not light or go off..................................................................................538
			E-11 Brake lamps do not light or go off........................................................................................540
			E-12 Backup lamps do not light or go off.......................................................................................542
			E-13 Backup buzzer does not sound or does not stop sounding....................................................................544
			E-14 Horn does not sound or does not stop sounding.............................................................................546
			E-15 Fuel level is not displayed normally......................................................................................548
		302 Troubleshooting of electrical system (E-mode) (Part 2).........................................................................551
			E-1 Engine does not start......................................................................................................554
			E-2 Engine does not stop.......................................................................................................564
			E-3 Lift truck cannot travel...................................................................................................566
			E-3 Lift truck cannot travel (Forklift truck with seat belt interlock).........................................................566
			E-4 Parking brake reminder alarm does not sound or does not stop sounding......................................................566
			E-5 Travel direction is not changed normally...................................................................................566
			E-6 Lift truck cannot move work equipment......................................................................................566
			E-6 Lift truck nannot move work equipment (Forklift truck with seat belt interlock)............................................566
			E-7 Work equipment cannot be locked............................................................................................566
			E-8 EPACS is abnormal..........................................................................................................566
			E-9 Headlamp, clearance lamp, tail lamp and license plate lamp do not light or go off..........................................567
			E-10 Turn signal lamps do not light or go off..................................................................................567
			E-11 Brake lamps do not light or go off........................................................................................567
			E-12 Backup lamps do not light or go off.......................................................................................567
			E-13 Backup buzzer does not sound or does not stop sounding....................................................................567
			E-14 Horn does not sound or does not stop sounding.............................................................................567
			E-15 Fuel (Gasoline) level is not displayed normally...........................................................................567
		303 Troubleshooting of electrical system (E-mode) (Part 3).........................................................................569
			E-1 Engine does not start......................................................................................................570
			E-2 Engine does not stop.......................................................................................................576
			E-3 Engine preheater does not operate normally.................................................................................578
			E-4 Lift truck cannot travel...................................................................................................580
			E-5 Parking brake reminder alarm does not sound or does not stop sounding......................................................588
			E-6 Travel direction is not changed normally...................................................................................590
			E-7 Lift truck cannot move work equipment......................................................................................596
			E-8 Work equipment cannot be locked............................................................................................604
			E-9 EPACS is abnormal..........................................................................................................610
			E-10 Headlamp, clearance lamp and tail lamp do not light or go off.............................................................612
			E-11 Turn signal lamps do not light or go off..................................................................................614
			E-12 Brake lamps do not light or go off........................................................................................614
			E-13 Backup lamps do not light or go off.......................................................................................614
			E-14 Backup buzzer does not sound or does not stop sounding....................................................................614
			E-15 Horn does not sound or does not stop sounding.............................................................................614
			E-16 Fuel level is not displayed normally......................................................................................614
		304 Troubleshooting of electrical system (E-mode) (Part 4).........................................................................617
			E-1 Engine does not start......................................................................................................618
			E-2 Engine does not stop.......................................................................................................622
			E-3 Lift truck cannot travel...................................................................................................624
			E-4 Parking brake reminder alarm does not sound or does not stop sounding......................................................627
			E-5 Travel direction is not changed normally...................................................................................630
			E-6 Lift truck cannot move work equipment......................................................................................634
			E-7 Work equipment cannot be locked............................................................................................636
			E-8 Headlamp, clearance lamp and tail lamp do not light or go off..............................................................638
			E-9 Turn signal lamps do not light or go off...................................................................................640
			E-10 Brake lamps do not light or go off........................................................................................642
			E-11 Backup lamps do not light or go off.......................................................................................644
			E-12 Backup buzzer does not sound or does not stop sounding (Option)...........................................................646
			E-13 Horn does not sound or does not stop sounding.............................................................................648
			E-14 Fuel level is not displayed normally......................................................................................650
		305 Troubleshooting of electrical system (E-mode) (Part 5).........................................................................653
			E-1 Engine does not start......................................................................................................654
			E-2 Engine does not stop.......................................................................................................662
			E-3 Lift truck cannot travel...................................................................................................664
			E-4 Parking brake reminder alarm does not sound or does not stop sounding......................................................664
			E-5 Travel direction is not changed normally...................................................................................664
			E-6 Lift truck cannot move work equipment......................................................................................664
			E-7 Work equipment cannot be locked............................................................................................664
			E-8 Headlamp, clearance lamp and, tail lamp do not light or go off.............................................................664
			E-9 Turn signal lamps do not light or go off...................................................................................664
			E-10 Brake lamps do not light or go off........................................................................................665
			E-11 Backup lamps do not light or go off.......................................................................................665
			E-12 Backup buzzer does not sound or does not stop sounding (Option)...........................................................665
			E-13 Horn does not sound or does not stop sounding.............................................................................665
			E-14 Fuel (Gasoline) level is not displayed normally...........................................................................665
		400 Troubleshooting of hydraulic and mechanical system (H-mode)....................................................................667
			Method of using troubleshooting table..........................................................................................670
			Table of failure modes and causes..............................................................................................672
			H-1 Lift truck does not start..................................................................................................678
			H-2 Travel speed is low, rush force is low, gradeability is low and/or gear is not shifted.....................................679
			H-3 Large shocks are made when lift truck starts and gear is shifted...........................................................680
			H-4 Long time lag is made when lift truck starts and gear is shifted...........................................................681
			H-5 Torque converter oil temperature is high...................................................................................682
			H-6 Lift truck does not turn...................................................................................................683
			H-7 Response is low during turning.............................................................................................684
			H-8 Steering is heavy..........................................................................................................685
			H-9 Lift truck is unstable or large shock is made when it turns................................................................686
			H-10 Right and left turning radii are different................................................................................687
			H-11 When steering wheel is released it does not return to neutral or it rotates by itself.....................................687
			H-12 Steering wheel is turned in reverse or it kicks...........................................................................687
			H-13 EPACS does not work.......................................................................................................688
			H-14 Steering wheel vibrates...................................................................................................689
			H-15 Steering system makes abnormal sound......................................................................................689
			H-16 Oil leaks from steering circuit...........................................................................................689
			H-17 Service brake does not work or its performance is low.....................................................................690
			H-18 Service brake is not reset or it drags....................................................................................691
			H-19 Parking brake does not work or its performance is low.....................................................................692
			H-20 Parking brake is not reset or it drags....................................................................................693
			H-21 Lift cylinder and fork do not lift........................................................................................694
			H-22 Lifting speed or force of lift cylinder and fork is insufficient..........................................................695
			H-23 Fork lifting speed lowers at specific height..............................................................................696
			H-24 Lift cylinder cannot lift load............................................................................................696
			H-25 Lift cylinder natural drift is large......................................................................................696
			H-26 Fork lowering speed is too high...........................................................................................697
			H-27 Mast does not tilt forward or backward....................................................................................698
			H-28 Forward/backward tilting speed or force of mast is insufficient...........................................................699
			H-29 Tilting speed lowers halfway..............................................................................................700
			H-30 Tilt cylinder cannot lift load............................................................................................700
			H-31 Tilt cylinder natural forward drift is large..............................................................................700
			H-32 Mast is unstable during travel with load..................................................................................700
			H-33 Lift and tilt levers do not move smoothly and they are heavy..............................................................701
			H-34 Engine speed lowers remarkably or engine stalls when work equipment is operated...........................................702
			H-35 Large shocks are made when work equipment is started and stopped..........................................................702
			H-36 Another part of work equipment moves when work equipment is relieved singly...............................................702
			H-37 Work equipment speed or force is low......................................................................................703
			H-38 When work equipment and steering are operated, engine speed lowers remarkably or engine stalls............................703
			H-39 Work equipment and steering system do not move............................................................................704
			H-40 Abnormal sound is heard from around work equipment and steering pump......................................................704
			H-41 Work equipment fine control performance is low or response is low.........................................................705
			H-42 Work equipment is not locked (It operates while operator is not in operator seat) or only work equipment does not move....705
			H-43 Work equipment (lift-up) does not move, moves but slow or moves but force is low..........................................706
			H-44 Lift cylinder drift is large (while operator is not in operator seat).....................................................707
			H-45 Lift cylinder drift is large (while operator is in operator seat).........................................................707
			H-46 Work equipment (lift-down) lowering speed is low or high or fine control performance is low or response is low............708
			H-47 Fork does not lower.......................................................................................................709
			H-48 Mast does not tilt/tilts but slow/tilts but force is low..................................................................710
			H-49 Tilt cylinder natural forward drift is large..............................................................................710
			H-50 Attachment does not move/moves but low/moves but force is low.............................................................711
			H-51 Attachment cylinder natural drift is large................................................................................711
			H-52 Steering is heavy.........................................................................................................712
			H-53 Large shock is made when steering wheel is returned.......................................................................712
			H-54 Work equipment is heavy when work equipment and steering are operated simultaneously......................................713
			H-55 Steering is heavy when work equipment and steering are operated simultaneously............................................713
	50 Disassembly and assembly............................................................................................................715
		100 General information on disassembly and assembly................................................................................715
			Method of using this manual....................................................................................................716
			Special tool list..............................................................................................................717
			Sketches of special tools......................................................................................................721
			How to use LOCTITE.............................................................................................................722
		200 Engine and cooling system......................................................................................................725
			Removal and installation of power train........................................................................................726
		300 Power train....................................................................................................................733
			Removal and installation of front axle.........................................................................................734
			Centering of power train.......................................................................................................739
			Disassembly and assembly of transmission.......................................................................................742
			Disassembly and assembly of torque converter...................................................................................748
			Disassembly and assembly of drive shaft........................................................................................753
			Disassembly and assembly of differential.......................................................................................754
			Disassembly and assembly of axle housing assembly..............................................................................766
			Disassembly and assembly of parking brake......................................................................................775
			Disassembly and assembly of rear axle..........................................................................................776
			Disassembly and assembly of power steering cylinder............................................................................779
			Disassembly and assembly of brake pedal........................................................................................782
			Disassembly and assembly of brake valve........................................................................................783
		400 Hydraulic equipment............................................................................................................787
			Disassembly and assembly of steering valve.....................................................................................788
			Disassembly and assembly of control valve assembly.............................................................................795
			Removal and installation of lift cylinder......................................................................................801
			Disassembly and assembly of lift cylinder......................................................................................803
			Disassembly and assembly of tilt cylinder......................................................................................805
		500 Work equipment.................................................................................................................811
			Removal and installation of mast...............................................................................................812
			Disassembly and assembly of mast...............................................................................................813
			Removal and installation of chain(double mast).................................................................................817
			Removal and installation of chain(triple mast).................................................................................819
		600 Electric devices...............................................................................................................823
			Combination switch.............................................................................................................824
	80 Yearly inspection criteria..........................................................................................................827
		100 Yearly inspection criteria.....................................................................................................827
			Yearly inspection criteria.....................................................................................................828
	90 Diagrams and drawings...............................................................................................................853
		100 Hydrauric circuit diagrams.....................................................................................................853
			Hydrauric circuit diagrams.....................................................................................................855
		200 Electrical diagrams and drawings...............................................................................................861
			Electrical diagrams and drawings...............................................................................................863

DESCRIPTION:

Komatsu CX50 Series Forklift Truck Shop Manual – PDF DOWNLOAD

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.

S.S 19/12/24