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KOMATSU DX50 Series FORKLIFT TRUCK SHOP MANUAL BED10E1-07 – PDF DOWNLOAD
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Description
KOMATSU DX50 Series FORKLIFT TRUCK SHOP MANUAL BED10E1-07 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU DX50 Series FORKLIFT TRUCK SHOP MANUAL BED10E1-07 – PDF DOWNLOAD
Language : English
Pages : 670
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU DX50 Series FORKLIFT TRUCK SHOP MANUAL BED10E1-07 – PDF DOWNLOAD
COVER................................................................................................................................................................................... 1 00 Index and foreword................................................................................................................................................................... 3 100 Index........................................................................................................................................................................... 3 Table of contents............................................................................................................................................................... 4 200 Foreword and general information................................................................................................................................................ 11 Safety notice................................................................................................................................................................... 12 How to read the shop manual..................................................................................................................................................... 23 Explanation of terms for maintenance standard................................................................................................................................... 25 Handling of electric equipment and hydraulic component.......................................................................................................................... 27 Handling of connectors newly used for engines................................................................................................................................... 36 How to read electric wire code.................................................................................................................................................. 39 Precautions when carrying out operation......................................................................................................................................... 42 Standard tightening torque table................................................................................................................................................ 45 Conversion table................................................................................................................................................................ 49 01 Outline.............................................................................................................................................................................. 55 100 Specifications.................................................................................................................................................................. 55 Specification dimension drawing................................................................................................................................................. 56 Weight table.................................................................................................................................................................... 58 Lubricant list.................................................................................................................................................................. 59 10 Structure, function and maintenance standard......................................................................................................................................... 61 100 Engine and cooling system....................................................................................................................................................... 61 Cooling system.................................................................................................................................................................. 62 Hydraulic oil cooling system piping diagram..................................................................................................................................... 64 Brake cooling system hydraulic piping diagram................................................................................................................................... 65 Torque converter oil filter..................................................................................................................................................... 66 200 Power train..................................................................................................................................................................... 67 Power train..................................................................................................................................................................... 68 Power train system diagram...................................................................................................................................................... 69 Torque converter................................................................................................................................................................ 70 Transmission.................................................................................................................................................................... 78 Transmission control valve...................................................................................................................................................... 91 Relief valve.................................................................................................................................................................... 95 Drive shaft..................................................................................................................................................................... 97 Front axle...................................................................................................................................................................... 98 Differential....................................................................................................................................................................100 Final drive.....................................................................................................................................................................103 300 Steering system.................................................................................................................................................................109 Steering piping diagram (orbit roll valve • power steering cylinder)............................................................................................................110 Orbit roll valve................................................................................................................................................................111 Power steering cylinder.........................................................................................................................................................113 400 Brake system....................................................................................................................................................................115 Brake control...................................................................................................................................................................116 Brake piping diagram (brake • service brake)....................................................................................................................................117 Service brake...................................................................................................................................................................118 Accumulator charge valve........................................................................................................................................................121 Brake valve.....................................................................................................................................................................126 Accumulator (for brake).........................................................................................................................................................131 Parking brake...................................................................................................................................................................132 500 Undercarriage and frame.........................................................................................................................................................135 Rear axle.......................................................................................................................................................................136 Hydraulic tank piping diagram...................................................................................................................................................138 Frame...........................................................................................................................................................................139 600 Hydraulic system................................................................................................................................................................141 Control valve piping diagram (control valve • pump).............................................................................................................................142 Work equipment piping diagram (control valve • tilt cylinder/lift cylinder).....................................................................................................143 Attachment piping diagram.......................................................................................................................................................144 Work equipment control lever linkage............................................................................................................................................145 Work equipment pump.............................................................................................................................................................146 Control valve...................................................................................................................................................................154 OLMS............................................................................................................................................................................166 Brake and steering pump.........................................................................................................................................................168 700 Work equipment..................................................................................................................................................................169 Tilt cylinder...................................................................................................................................................................170 Lift cylinder...................................................................................................................................................................171 Mast and fork...................................................................................................................................................................172 801 Electric devices (Part 1).......................................................................................................................................................175 Accelerator pedal sensor........................................................................................................................................................176 ISO controller (Operator Presence Sensing (OPS) system).........................................................................................................................177 EPACS controller................................................................................................................................................................187 Instrument panel................................................................................................................................................................189 Engine starting circuit.........................................................................................................................................................191 Engine stopping circuit.........................................................................................................................................................192 Electrical system wiring diagram................................................................................................................................................194 802 Electric devices (Part 2).......................................................................................................................................................197 Sensors.........................................................................................................................................................................198 Switches........................................................................................................................................................................201 Lamps...........................................................................................................................................................................209 Buzzer..........................................................................................................................................................................213 Flasher.........................................................................................................................................................................217 F/R solenoid valve and F2/R2 solenoid valve.....................................................................................................................................218 Relay box.......................................................................................................................................................................219 Resistor........................................................................................................................................................................225 Diode...........................................................................................................................................................................227 Fuse............................................................................................................................................................................231 Battery.........................................................................................................................................................................234 20 Standard value table.................................................................................................................................................................237 100 Standard value table............................................................................................................................................................237 Standard value table............................................................................................................................................................238 30 Testing and adjusting................................................................................................................................................................241 100 Testing and adjusting...........................................................................................................................................................241 Check of troubleshooting software functions and failure codes...................................................................................................................243 Hydraulic piping pressure releaseprocedure......................................................................................................................................249 Replacement of engine oil andengine oil filter..................................................................................................................................250 Replacement of fuel filter......................................................................................................................................................251 Cleaning of radiator............................................................................................................................................................254 Check of air cleaner andreplacement of cleaner element..........................................................................................................................255 Oil level check and oilreplacement of differential case.........................................................................................................................256 Oil replacement and strainercleaning of TORQFLOW................................................................................................................................257 Testing power train oil pressure................................................................................................................................................258 Check of hydraulic tank.........................................................................................................................................................266 Measurement of wear amount ofservice brake disc.................................................................................................................................268 Check of parking brake..........................................................................................................................................................269 Air bleeding procedure..........................................................................................................................................................271 Adjustment of brake pedal.......................................................................................................................................................273 Adjustment of inching pedal.....................................................................................................................................................274 Initialization of orbit-roll valve..............................................................................................................................................275 Measurement of cylinderhydraulic drift and hydraulicforward drift...............................................................................................................276 Adjustment of mast..............................................................................................................................................................277 Adjustment of fork carriage.....................................................................................................................................................279 Check of drive shaft forlooseness, play and damage..............................................................................................................................280 Installation of wheel (Applicablemodel: FD80-10)................................................................................................................................281 Check of diode..................................................................................................................................................................282 40 Troubleshooting......................................................................................................................................................................283 100 General information on troubleshooting..........................................................................................................................................283 Points to remember when troubleshooting.........................................................................................................................................284 Sequence of events in troubleshooting...........................................................................................................................................285 Testing before troubleshooting..................................................................................................................................................286 Classification and procedures of troubleshooting................................................................................................................................287 Phenomena looking like troubles and troubleshooting No..........................................................................................................................288 Information contained in troubleshooting table..................................................................................................................................292 Locations of fuses..............................................................................................................................................................294 201 Troubleshooting by failure code (ISO controller system (*)) (Part 1) ...........................................................................................................303 Failure code display by ISO controller..........................................................................................................................................304 Failure code [[!]: 1 flashing, [N]: Flashing, [L]: Flashing]....................................................................................................................308 Failure code [[!]: 2 flashings, [N]: Flashing, [L]: OFF]........................................................................................................................312 Failure code [[!]: 3 flashings, [N]: OFF, [L]: OFF] Parking brake reminder buzzer output abnormality or N (neutral) lamp and lift interlock warning lamp output abnormality ....314 Failure code [[!]: 4 flashings, [N]: OFF, [L]: Flashing] Lift interlock relay output abnormality (1)...........................................................................318 Failure code [[!]: 5 flashings, [N]: OFF, [L]: Flashing] Travel interlock relay output abnormality (1) .........................................................................324 Failure code [[!]: 5 flashings, [N]: Flashing, [L]: Flashing] Travel interlock relay output abnormality (2) ....................................................................328 Failure code [[!]: 6 flashings, [N]: Flashing, [L]: Flashing] Main relay output abnormality ....................................................................................332 Failure code [[!]: 7 flashings, [N]: Flashing, [L]: Flashing] Controller abnormality............................................................................................334 202 Troubleshooting by failure code (ISO controller system (*)) (Part 2)............................................................................................................337 Failure code display by ISO controller..........................................................................................................................................338 Failure code [[!]: 1 flashing, [N]: Flashing, [L]: Flashing] Seat switch trouble ...............................................................................................342 Failure code [[!]: 2 flashings, [N]: Flashing, [L]: OFF] F/R lever trouble .....................................................................................................344 Failure code [[!]: 3 flashings, [N]: OFF, [L]: OFF] Parking brake reminder buzzer output abnormality or N (neutral) lamp and lift interlock warning lamp output abnormality ....346 Failure code [[!]: 4 flashings, [N]: OFF, [L]: Flashing] Lift interlock relay output abnormality (1) ...........................................................................350 Failure code [[!]: 4 flashings, [N]: Flashing, [L]: Flashing] Lift interlock relay output abnormality (2) ......................................................................352 Failure code [[!]: 5 flashings, [N]: OFF, [L]: Flashing] Travel interlock relay output abnormality (1) .........................................................................355 Failure code [[!]: 5 flashings, [N]: Flashing, [L]: Flashing] Travel interlock relay output abnormality (2) ....................................................................358 Failure code [[!]: 6 flashings, [N]: Flashing, [L]: Flashing] Main relay output abnormality ....................................................................................362 Failure code [[!]: 7 flashings, [N]: Flashing, [L]: Flashing] Controller abnormality ...........................................................................................364 203 Troubleshooting by failure code (EPACS controller system) (Part 1)..............................................................................................................367 Display of EPACS controller failure code........................................................................................................................................368 Failure code [LED: OFF] EPACS controller abnormality............................................................................................................................369 Failure code [LED: 1 flashing] Initialization is not completed..................................................................................................................370 Failure code [LED: 2 flashings] Controller is being initialized.................................................................................................................371 Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality.........................................................................................................372 Failure code [LED: 4 flashings] Tyre angle sensor abnormality...................................................................................................................374 204 Troubleshooting by failure code (EPACS controller system) (Part 2)..............................................................................................................377 Display of EPACS controller failure code........................................................................................................................................378 Failure code [LED: OFF] EPACS controller abnormality............................................................................................................................379 Failure code [LED: 1 flashing] Initialization is not completed..................................................................................................................380 Failure code [LED: 2 flashings] Controller is being initialized.................................................................................................................381 Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality.........................................................................................................382 Failure code [LED: 4 flashings] Tyre angle sensor abnormality...................................................................................................................384 301 Troubleshooting of electrical system(E-mode) (Part 1)...........................................................................................................................387 E-1 Engine does not start.......................................................................................................................................................388 E-2 Engine does not stop........................................................................................................................................................392 E-3 Lift truck cannot travel....................................................................................................................................................394 E-4 Parking brake reminder alarm does not sound or does not stopsounding........................................................................................................402 E-5 Travel direction is not changed normally....................................................................................................................................404 E-6 Lift truck cannot move work equipment.......................................................................................................................................410 E-7 Work equipment cannot be locked.............................................................................................................................................414 E-8 EPACS is abnormal...........................................................................................................................................................418 E-9 Headlamp, clearance lamp, tail lamp and license plate lamp do notlight or go off............................................................................................420 E-10 Turn signal lamps do not light or go off...................................................................................................................................424 E-11 Brake lamps do not light or go off.........................................................................................................................................426 E-12 Backup lamps do not light or go off........................................................................................................................................428 E-13 Backup buzzer does not sound or does not stop sounding.....................................................................................................................431 E-14 Horn does not sound or does not stop sounding..............................................................................................................................434 E-15 Fuel level is not displayed normally.......................................................................................................................................436 302 Troubleshooting of electrical system (E-mode) (Part 2)..........................................................................................................................439 E-1 Engine does not start.......................................................................................................................................................440 E-2 Engine does not stop........................................................................................................................................................444 E-3 Lift truck cannot travel....................................................................................................................................................446 E-4 Parking brake reminder alarm does not sound or does not stop sounding.......................................................................................................450 E-5 Travel direction is not changed normally....................................................................................................................................452 E-6 Lift truck cannot move work equipment.......................................................................................................................................456 E-7 Work equipment cannot be locked.............................................................................................................................................458 E-8 EPACS is abnormal...........................................................................................................................................................460 E-9 Headlamp, clearance lamp, tail lamp and license plate lamp do not light or go off...........................................................................................462 E-10 Turn signal lamps do not light or go off...................................................................................................................................466 E-11 Brake lamps do not light or go off.........................................................................................................................................468 E-12 Backup lamps do not light or go off........................................................................................................................................470 E-13 Backup buzzer does not sound or does not stop sounding.....................................................................................................................473 E-14 Horn does not sound or does not stop sounding..............................................................................................................................476 E-15 Fuel level is not displayed normally.......................................................................................................................................478 400 Troubleshooting of hydraulic and mechanical system (H-mode).....................................................................................................................481 Method of using troubleshooting table...........................................................................................................................................484 Table of failure modes and causes...............................................................................................................................................486 H-1 Lift truck does not start...................................................................................................................................................492 H-2 Travel speed is low, rush force is low, gradeability is low and/or gear is not shifted......................................................................................493 H-3 Large shocks are made when lift truck starts and gear is shifted............................................................................................................494 H-4 Long time lag is made when lift truck starts and gear is shifted............................................................................................................495 H-5 Torque converter oil temperature is high....................................................................................................................................496 H-6 Lift truck does not turn....................................................................................................................................................497 H-7 Response is low during turning..............................................................................................................................................498 H-8 Steering is heavy...........................................................................................................................................................499 H-9 Lift truck is unstable or large shock is made when it turns.................................................................................................................500 H-10 Right and left turning radii are different.................................................................................................................................501 H-11 When steering wheel is released it does not return to neutral or it rotates by itself......................................................................................501 H-12 Steering wheel is turned in reverse or it kicks............................................................................................................................501 H-13 EPACS does not work........................................................................................................................................................502 H-14 Steering wheel vibrates....................................................................................................................................................503 H-15 Steering system makes abnormal sound.......................................................................................................................................503 H-16 Oil leaks from steering circuit............................................................................................................................................503 H-17 Service brake does not work or its performance is low......................................................................................................................504 H-18 Service brake is not reset or it drags.....................................................................................................................................505 H-19 Parking brake does not work or its performance is low......................................................................................................................506 H-20 Parking brake is not reset or it drags....................................................................................................................................507 H-21 Lift cylinder and fork do not lift.........................................................................................................................................508 H-22 Lifting speed or force of lift cylinder and fork is insufficient...........................................................................................................509 H-23 Fork lifting speed lowers at specific height...............................................................................................................................510 H-24 Lift cylinder cannot lift load.............................................................................................................................................510 H-25 Lift cylinder natural drift is large.......................................................................................................................................510 H-26 Fork lowering speed is too high............................................................................................................................................511 H-27 Mast does not tilt forward or backward.....................................................................................................................................512 H-28 Forward/backward tilting speed or force of mast is insufficient............................................................................................................513 H-29 Tilting speed lowers halfway...............................................................................................................................................514 H-30 Tilt cylinder cannot lift load.............................................................................................................................................514 H-31 Tilt cylinder natural forward drift is large...............................................................................................................................514 H-32 Mast is unstable during travel with load...................................................................................................................................514 H-33 Lift and tilt levers do not move smoothly and they are heavy...............................................................................................................515 H-34 Engine speed lowers remarkably or engine stalls when work equipment is operated............................................................................................516 H-35 Large shocks are made when work equipment is started and stopped...........................................................................................................516 H-36 Another part of work equipment moves when work equipment is relieved singly................................................................................................516 H-37 Work equipment speed or force is low.......................................................................................................................................517 H-38 When work equipment and steering are operated, engine speed lowers remarkably or engine stalls.............................................................................517 H-39 Work equipment and steering system do not move.............................................................................................................................518 H-40 Abnormal sound is heard from around work equipment and steering pump.......................................................................................................518 H-41 Work equipment fine control performance is low or response is low..........................................................................................................519 H-42 Work equipment is not locked (It operates while operator is not in operator seat) or only work equipment does not move.....................................................519 H-43 Work equipment (lift-up) does not move, moves but slow or moves but force is low...........................................................................................520 H-44 Lift cylinder drift is large (while operator is not in operator seat)......................................................................................................521 H-45 Lift cylinder drift is large (while operator is in operator seat)..........................................................................................................521 H-46 Work equipment (lift-down) lowering speed is low or high or fine control performance is low or response is low.............................................................522 H-47 Fork does not lower........................................................................................................................................................523 H-48 Mast does not tilt/tilts but slow/tilts but force is low...................................................................................................................524 H-49 Tilt cylinder natural forward drift is large...............................................................................................................................524 H-50 Attachment does not move/moves but low/moves but force is low..............................................................................................................525 H-51 Attachment cylinder natural drift is large.................................................................................................................................525 H-52 Steering is heavy..........................................................................................................................................................526 H-53 Large shock is made when steering wheel is returned........................................................................................................................526 H-54 Work equipment is heavy when work equipment and steering are operated simultaneously.......................................................................................527 H-55 Steering is heavy when work equipment and steering are operated simultaneously.............................................................................................527 50 Disassembly and assembly.............................................................................................................................................................529 100 General information on disassemblyand assembly..................................................................................................................................529 Method of using this manual ....................................................................................................................................................530 Special tool list...............................................................................................................................................................531 How to use LOCTITE..............................................................................................................................................................536 200 Engine and cooling system.......................................................................................................................................................537 Removal and installation of powertrain..........................................................................................................................................538 300 Power train.....................................................................................................................................................................541 Removal and installation of frontaxle...........................................................................................................................................542 Disassembly and assembly of torque converter....................................................................................................................................544 Disassembly and assembly of torqflow transmission...............................................................................................................................551 Disassembly and assembly of drive shaft.........................................................................................................................................572 Disassembly and assembly of differential........................................................................................................................................573 Disassembly and assembly axle housing assembly..................................................................................................................................577 Disassembly and assembly of parking brake.......................................................................................................................................591 Removal and installation of rearaxle and power steering.........................................................................................................................592 Disassembly and assembly of rear axle...........................................................................................................................................595 Disassembly and assembly of brake pedal.........................................................................................................................................596 Disassembly and assembly of brake valve.........................................................................................................................................597 400 Hydraulic equipment.............................................................................................................................................................601 Disassembly and assembly of orbit roll valve....................................................................................................................................602 Brake and steering pump.........................................................................................................................................................609 Disassembly and assembly of control valve assembly..............................................................................................................................611 Removal and installation of lift cylinder.......................................................................................................................................614 Disassembly and assembly of lift cylinder.......................................................................................................................................615 Disassembly and assembly of tilt cylinder.......................................................................................................................................616 500 Work equipment..................................................................................................................................................................623 Removal and installation of mast................................................................................................................................................624 Disassembly and assembly of mast................................................................................................................................................625 600 Electric devices................................................................................................................................................................627 Disassembly and assembly of combination switch..................................................................................................................................628 80 Yearly inspection criteria...........................................................................................................................................................631 100 Yearly inspection criteria......................................................................................................................................................631 Yearly inspection criteria......................................................................................................................................................632 90 Diagrams and drawings................................................................................................................................................................655 100 Hydrauric circuit diagrams......................................................................................................................................................655 Hydrauric circuit diagrams......................................................................................................................................................657 200 Electrical diagrams and drawings................................................................................................................................................659 Electrical diagrams and drawings (For general)..................................................................................................................................661 Electrical diagrams and drawings (For USA)......................................................................................................................................665 Electrical diagrams and drawings (Forklift truck with seat belt interlock)......................................................................................................667
DESCRIPTION:
KOMATSU DX50 Series FORKLIFT TRUCK SHOP MANUAL BED10E1-07 – PDF DOWNLOAD
How to read the shop manual 1
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the lift truck.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. For troubleshooting “S mode” related to the engine, see Engine.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
80. Yearly inspection criteria
This section explains the items, contents and criteria of the specific self-imposed inspection.
90. Diagrams and drawings (Chassis)
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
S.S 13/12/24
