Komatsu Duel Fuel/LPG FG40ZTU-10 FG40TU/45TU/50ATU-10 Diesel FD40ZTU-10 FD40TU/45TU/50ATU-10 CX50 Forklift Trucks Service Manual SM203 BEC10E1-02 – PDF DOWNLOAD

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Komatsu Duel Fuel/LPG FG40ZTU-10 FG40TU/45TU/50ATU-10 Diesel FD40ZTU-10 FD40TU/45TU/50ATU-10 CX50 Forklift Trucks Service Manual SM203 BEC10E1-02 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu Duel Fuel/LPG FG40ZTU-10 FG40TU/45TU/50ATU-10 Diesel FD40ZTU-10 FD40TU/45TU/50ATU-10 CX50 Forklift Trucks Service Manual SM203 BEC10E1-02 – PDF DOWNLOAD

CX50 Forklift Trucks
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

General precautions:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully
before operating the lift truck. In addition, read this manual carefully before starting work.
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.

TABLE OF CONTENTS:

Komatsu Duel Fuel/LPG FG40ZTU-10 FG40TU/45TU/50ATU-10 Diesel FD40ZTU-10 FD40TU/45TU/50ATU-10 CX50 Forklift Trucks Service Manual SM203 BEC10E1-02 – PDF DOWNLOAD
SM203_JULY2011_01_1_FOREWORD[1] 1
Safety 2
How to read the shop manual 13
Explanation of terms for maintenance standard 15
Handling of electric equipment and hydraulic components 17
Handling of new types of connectors used on engines 25
How to read electric wire code 28
Precautions when carrying out operation 31
Standard tightening torque tables 34
Conversion tables 38
SM203_JULY2011_02_2_SPECIFICATIONS[1] 44
Dimensional diagram 44
Diesel engine lift truck 45
Gasoline engine lift truck 46
Weight table 47
Lubricants 48
SM203_JULY2011_03_3_STRUCTURE[1] 52
3 Structure, function and maintenance standard 52
Engine and cooling system 52
Power train 57
Steering system 96
Brake system 100
Undercarriage and frame 118
Hydraulic system 122
Work equipment 155
Electric devices Part 1 167
Electric devices Part 2 184
SM203_JULY2011_04_4_STANDARD[1] 223
Lift truck with SAA4D95LE-5-A engine 223
Lift truck with EBT-TB45-2A/3A engine 225
SM203_JULY2011_05_5_TESTING[1] 227
Check of troubleshooting software functions and failure codes 227
Hydraulic piping pressure release procedure 230
Replacement of engine oil and eng ine oil filter 231
Replacement of fuel filter 232
Cleaning of radiator 235
Check of air cleaner and replacement of cleaner element 236
Oil level check and oil replacement of differential case 237
Oil replacement and strainer cleaning of TORQFLOW transmission 238
Testing power train oil pressure 239
Check of hydraulic tank 242
Measurement of wear amount of service brake disc 244
Check of parking brake 245
Air bleeding procedure 246
Adjustment of brake pedal 247
Adjustment of inching pedal 248
Measurement of cylinder hydraulic drift and hydraulic forward drift 249
Adjustment of mast 250
Adjustment of fork carriage 253
Check of drive shaft for looseness, play and damage 255
Check of diode 256
SM203_JULY2011_06_6_TROUBLESHOOTING[1] 257
6 Troubleshooting 0
General information on troubleshooting 257
Failure codes: ISO controller (UL spec) 274
Electrical system (E-mode) SAA4D95LE-5-A engine (UL spec) 297
Electrical system (E-mode) EBT-TB45-2A/3A engine (UL spec) 329
Hydraulic and mechanical system (H-mode) 340
SM203_JULY2011_07_7_DISASSEMBLY[1] 394
7 Disassembly and assembly 0
General information 0
Engine and cooling system 400
Power train components 407
Hydraulic equipment 469
Work equipment 491
Electric devices 497
SM203_JULY2011_08_8_YEARLY[1] 499
Prime mover 499
Power train 503
Traveling equipment 506
Steering system 507
Brake system 509
Loading equipment 510
Hydraulic equipment 512
Lift truck body, safety devices, etc 514
Comprehensive test 514
SM203_JULY2011_09_9_DIAGRAMS_11X17[1] 515
9 Diagrams and drawings 0
Hydraulic circuit 515
Electrical circuit – UL spec 516
EPA TIER 2 DUAL FUEL 516
EPA/CARB2010 DUAL FUEL 517
EPA TIER 2 LPG 518
EPA/CARB 2010 LPG 519
TIER 3 DIESEL 520

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PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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