Komatsu FD100-8 FD115-8 FD135-8 FD150-8 FD160E-8 EX50 Forklift Truck Service Manual SM228 BEE08E1-01 – PDF DOWNLOAD

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Komatsu FD100-8 FD115-8 FD135-8 FD150-8 FD160E-8 EX50 Forklift Truck Service Manual SM228 BEE08E1-01 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu FD100-8 FD115-8 FD135-8 FD150-8 FD160E-8 EX50 Forklift Truck Service Manual SM228 BEE08E1-01 – PDF DOWNLOAD

INTRODUCTION:

• This Service Manual has been developed as an information resource to help the reader learn about, understand,
  repair and maintain the EX50 Series forklift trucks, and the various equipment, systems, inspections, sensors,
  diagnostic procedures and diagnostic equipment utilized to maintain, adjust and troubleshoot these systems.
• Although reference is made to maintenance procedures necessary to perform servicing of this vehicle, you should
  refer to the applicable Operation and Maintenance Manual for these lift trucks for more complete maintenance
  information.
• Komatsu is involved in a concentrated and highly technical program of designing and developing cleaner burning,
  more efficient and more powerful engines for use in the industrial truck market. As a result, new computerized
  sensors, systems and diagnostic monitors have been created to make the job of maintaining and repairing these
  systems simple and easy.
• Read this manual carefully, refer to it often and learn the repair, testing and adjustment procedures to the best of
  your ability. Please note that some illustrations are generic and may not look exactly like your unit in every detail.
  Ensure that, when you are working on or around industrial trucks, Safety is priority Number One. Read,
  understand and obey all WARNINGS and CAUTIONS.
• Follow the instructions and procedures presented in this manual when working on these lift trucks and their
  systems. Damage to the equipment, and possible injury to yourself or others, may result if these procedures are
  not adhered to carefully.
• Keep this manual nearby and accessible for use when necessary. If this book becomes dirty, worn or illegible,
  contact Komatsu for a replacement. The procedures outlined in this manual will be updated periodically. Be sure
  that you have the latest revision in order to learn the newest information available. Revision dates will be clearly
  displayed on the lower left hand corner of the cover page.
• This will aid in maintaining your equipment in excellent condition and in ensuring that these lift trucks will operate
  safely at maximum efficiency.

TABLE OF CONTENTS:

Komatsu FD100-8 FD115-8 FD135-8 FD150-8 FD160E-8 EX50 Forklift Truck Service Manual SM228 BEE08E1-01 – PDF DOWNLOAD

CONTENTS 3
INTRODUCTION 11
PRECAUTIONS WHEN PERFORMING SERVICE WORK 11
DESCRIPTION OF SYMBOLS 12
ENGINE MOUNTED IN THIS TRUCK 12
SAFETY 13
1 GENERAL INFORMATION & SPECIFICATIONS
1 1 SPECIFICATIONS 1-3
1 2 PERIODIC REPLACEMENT OF CONSUMABLE PARTS 1-9
1 3 STANDARD TIGHTENING TORQUE 1-10
1 3 1 BOLTS 1-10
1 3 2 ELBOWS, NIPPLES AND UNIONS 1-11
1 4 HOW TO USE LOCTITE 1-12
2 TESTING & ADJUSTING
2 1 SERVICE DATA 2-3
2 2 DEPRESSURIZE HYDRAULIC SYSTEM 2-5
2 3 REPLACE ENGINE OIL/ENGINE OIL FILTER 2-6
2 3 1 CHANGE ENGINE OIL 2-6
2 3 2 REPLACE ENGINE OIL FILTER 2-6
2 4 REPLACE FUEL FILTERS 2-7
2 4 1 REPLACE FUEL PRE-FILTER CARTRIDGE 2-7
2 4 2 BLEED AIR FROM FUEL PRE-FILTER 2-8
2 4 3 REPLACE FUEL MAIN FILTER CARTRIDGE 2-8
2 4 4 BLEED AIR FROM FUEL MAIN FILTER 2-8
2 5 CLEAN INSIDE THE COOLING SYSTEM 2-9
2 6 AIR CLEANER 2-10
2 6 1 CLEAN FILTER ELEMENT 2-10
2 6 2 REPLACE FILTER ELEMENT 2-10
2 7 ADJUST VALVE CLEARANCE 2-10
2 8 CHECK COMPRESSION PRESSURE 2-10
2 9 TIGHTEN CYLINDER HEAD MOUNTING BOLTS 2-10
2 10 DIFFERENTIAL CASE 2-11
2 10 1 CHECK OIL LEVEL 2-11
2 10 2 REPLACE OIL 2-11
2 11 TORQFLOW TRANSMISSION CASE 2-12
2 11 1 CHECK OIL LEVEL 2-12
2 11 2 REPLACE OIL AND CLEAN STRAINER 2-12
2 12 SERVICE HYDRAULIC TANK 2-13
2 13 REPLACE BRAKE COOLING OIL (WET DISC BRAKE) 2-14
2 14 MEASURE HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS 2-15
2 15 ADJUST BRAKE/INCHING PEDAL (HYDRAULIC DRUM BRAKE) 2-16
2 15 1 ADJUST BRAKE PEDAL 2-16
2 15 2 ADJUST INCHING PEDAL 2-17
2 16 ADJUST BRAKE/INCHING PEDAL (WET DISC BRAKE) 2-18
2 16 1 ADJUST BRAKE PEDAL 2-18
2 16 2 INCHING PEDAL 2-18
2 17 ACCUMULATOR FOR BRAKE 2-19
2 17 1 CHARGE ACCUMULATOR WITH NITROGEN GAS (HYDRAULIC DRUM BRAKE) 2-19
2 17 2 CHARGING ASSEMBLY 2-21
2 17 3 JOINT ASSEMBLY 2-22
2 17 4 CHARGE ACCUMULATOR WITH NITROGEN GAS (WET DISC BRAKE) 2-22
2 17 5 MEASURE ACCUMULATOR CHARGE VALVE PRESSURE (WET DISC BRAKE) 2-23
2 17 6 ADJUST ACCUMULATOR CHARGE VALVE PRESSURE (WET DISC BRAKE) 2-23
2 18 ADJUST ACCELERATOR PEDAL OPERATION 2-23
2 19 ADJUST PARKING BRAKE 2-24
2 19 1 ADJUST LEVER OPERATING EFFORT 2-24
2 19 2 ADJUST PARKING BRAKE SHOE CLEARANCE 2-24
2 20 BLEEDING AIR 2-25
2 20 1 BRAKE PIPING (HYDRAULIC DRUM BRAKE) 2-25
2 20 2 LIFT CYLINDER 2-25
2 20 3 BRAKE (WET DISC BRAKE) 2-25
2 21 CHECK WEAR OF BRAKE DISC (WET DISC BRAKE) 2-26
2 22 ADJUST STEERING AXLE 2-27
2 22 1 ALIGNMENT 2-27
2 22 2 TURNING ANGLE 2-27
2 23 INSPECT THE AIR CONDITIONER (OPTION) 2-28
2 24 INSPECT BATTERY 2-29
CONTENTS
5
2 25 OIL AND GREASING CHART 2-30
2 26 LUBRICANT LIST 2-31
3 INSPECTION
3 1 GENERAL LOCATIONS 3-3
3 2 WEIGHT TABLE 3-4
3 3 INSPECTION CHECKLIST BY COMPONENT 3-5
3 4 REMOVAL AND INSTALLATION OF COMPONENTS 3-22
3 5 REMOVAL AND INSTALLATION FLOW CHART 3-24
3 6 MAST 3-25
3 6 1 MAST REMOVAL – TYPICAL 3-25
3 6 2 MAST INSTALLATION – TYPICAL 3-26
3 6 3 BLEED AIR FROM LIFT CYLINDER 3-26
3 7 POWER TRAIN 3-27
3 7 1 REAR AXLE SUPPORT BUSHING 3-27
3 7 2 CENTER DRIVE SHAFT 3-27
3 7 3 CENTER ENGINE MOUNTS 3-27
3 7 4 WHEEL INSTALLATION 3-27
3 7 5 TIRE CLAMP TIGHTENING INSTRUCTION 3-28
3 7 6 ADJUST RUNOUT 3-29
3 8 BRAKE SYSTEM (HYDRAULIC DRUM BRAKE) 3-30
3 8 1 METHOD OF BLEEDING AIR 3-30
3 8 2 METHOD OF REMOVING HIGH PRESSURE OIL 3-30
3 9 WORK EQUIPMENT CONTROL LEVER 3-31
4 DISASSEMBLY AND ASSEMBLY
4 1 TORQUE CONVERTER 4-3
4 2 TORQFLOW TRANSMISSION 4-9
4 2 1 CONTROL VALVE (SOLENOID VALVE) 4-11
4 2 2 DISASSEMABLY 4-14
4 2 3 DISASSEMBLY OF CLUTCH PACK ASSEMBLY 4-18
4 2 4 PRECAUTIONS WHEN ASSEMBLING 4-21
4 2 5 CONNECTORS FOR SOLENOID VALVES 4-22
4 2 6 ASSEMBLY OF F/R (INPUT SHAFT) SHAFT SUB ASSEMBLY 4-23
4 2 7 ASSEMBLY OF 1ST/2ND SHAFT ASSEMBLY 4-25
4 2 8 ASSEMBLY OF 3RD (OUTPUT SHAFT) SHAFT SUB ASSEMBLY 4-27
4 2 9 CLUTCH SHAFT SUB ASSEMBLY 4-29
CONTENTS
6
4 3 HYDRAULIC PUMPS 4-31
4 3 1 WORK EQUIPMENT PUMP AND POWER STEERING PUMP 4-31
4 3 2 TORQUE CONVERTER CHARGE PUMP 4-31
4 3 3 HYDRAULIC PUMPS 4-32
4 4 DRIVE AXLE 4-33
4 4 1 FRONT HUB 4-35
4 4 2 FRONT AXLE 4-37
4 4 3 DIFFERENTIAL 4-39
4 4 4 ADJUST PINION SHAFT SHIM 4-40
4 4 5 DIFFERENTIAL SUPPORT BEARING 4-41
4 5 STEERING AXLE 4-45
4 6 PARKING BRAKE 4-46
4 7 WHEEL BRAKE 4-47
4 8 BRAKE / INCHING PEDAL 4-50
4 9 BRAKE VALVE 4-52
4 9 1 DISASSEMBLY 4-53
4 9 2 ASSEMBLY 4-54
4 10 POWER STEERING VALVE 4-58
4 11 POWER STEERING VALVE 4-67
4 12 LIFT CYLINDER 4-76
4 13 TILT CYLINDER 4-78
4 13 1 INSPECTION 4-79
4 13 2 DISASSEMBLE LIFT AND TILT CYLINDERS 4-80
4 13 3 ASSEMBLE LIFT AND TILT CYLINDERS 4-81
4 14 POWER STEERING CYLINDER 4-86
4 15 CONTROL VALVE 4-88
4 16 MAST 4-91
4 16 1 SHIM ADJUSTMENT 4-92
4 16 2 CHAIN ADJUSTMENT 4-94
4 17 TABLE OF SPECIAL TOOLS 4-95
4 18 TABLE OF SPECIAL TOOLS FOR POWER STEERING CYLINDER 4-97
5 MAINTENANCE STANDARD
5 1 ENGINE AND ELECTRICAL PARTS 5-3
5 2 ACCELERATOR PEDAL 5-3
5 3 SPEEDOMETER SENSOR (OPTION) 5-4
CONTENTS
7
5 4 LOCATION OF SWITCHES AND SENSORS 5-5
5 5 TORQUE CONVERTER 5-8
5 6 TORQFLOW TRANSMISSION 5-9
5 7 TRANSMISSION CONTROL VALVE 5-10
5 8 DRIVE SHAFT 5-11
5 9 DIFFERENTIAL 5-12
5 10 FINAL DRIVE 5-14
5 10 1 HYDRAULIC DRUM BRAKE 5-14
5 10 2 WET DISC BRAKE 5-15
5 11 REAR AXLE 5-16
5 12 STEERING 5-17
5 13 FRAME 5-18
5 14 BRAKE PEDAL 5-19
5 14 1 HYDRAULIC DRUM BRAKE 5-19
5 14 2 WET DISC BRAKE 5-20
5 15 BRAKE VALVE 5-21
5 15 1 HYDRAULIC DRUM BRAKE 5-21
5 15 2 WET DISC BRAKE 5-22
5 16 FRONT BRAKE 5-23
5 16 1 HYDRAULIC DRUM BRAKE 5-23
5 16 2 WET DISC BRAKE 5-25
5 17 PARKING BRAKE 5-26
5 18 CONTROL VALVE 5-27
5 19 PRIORITY VALVE 5-29
5 20 LIFT CYLINDER 5-30
5 21 TILT CYLINDER 5-31
5 22 POWER STEERING CYLINDER 5-32
5 23 WORK EQUIPMENT 5-33
6 STRUCTURE AND FUNCTION
6 1 POWER TRAIN DIAGRAM 6-3
6 1 1 HYDRAULIC DRUM BRAKE 6-3
6 1 2 WET DISC BRAKE 6-4
6 2 TORQUE CONVERTER 6-5
6 3 TORQFLOW TRANSMISSION – 1/3 6-6
6 4 TORQFLOW TRANSMISSION – 2/3 6-7
6 5 TORQFLOW TRANSMISSION – 3/3 6-8
6 5 1 HYDRAULIC CIRCUIT (OUTLINE) 6-9
6 5 2 CLUTCH OPERATION DURING MANUAL SHIFT TRANSMISSION 6-9
6 6 INCHING VALVE 6-11
6 7 AUTOMATIC TRANSMISSION (OPTION) 6-12
6 7 1 BASIC SYSTEM CONFIGURATION 6-12
6 7 2 AUTO/MANUAL TRANSMISSION SELECTOR SWITCH 6-13
6 7 3 TROUBLESHOOTING TABLE 6-14
6 7 4 ABNORMALITIES NOT DETECTABLE BY THE TROUBLESHOOTING FUNCTION 6-16
6 8 DRIVE AXLE – HYDRAULIC DRUM BRAKE 6-17
6 9 STEERING AXLE 6-18
6 10 STEERING SYSTEM 6-19
6 11 HYDRAULIC CIRCUIT DIAGRAMS OF STEERING SYSTEM AND CYLINDER 6-22
6 12 HYDRAULIC DRUM BRAKE 6-24
6 12 1 WHEEL BRAKE 6-24
6 12 2 BRAKE VALVE 6-24
6 12 3 HYDRAULIC DRUM BRAKE CIRCUIT DIAGRAM 6-28
6 13 WET DISC BRAKE 6-29
6 13 1 BRAKE VALVE 6-29
6 13 2 ACCUMULATOR CHARGE VALVE 6-31
6 13 3 BRAKE 6-35
6 13 4 WET DISC BRAKE HYDRAULIC CIRCUIT DIAGRAM 6-37
6 14 HYDRAULIC PUMPS 6-38
6 14 1 HYDRAULIC DRUM BRAKE TYPE 6-38
6 14 2 WET DISC BRAKE TYPE 6-38
6 15 TORQUE CONVERTER CHARGING PUMP 6-38
6 16 LIFT CYLINDER 6-39
6 17 TILT CYLINDER 6-39
6 18 METER PANEL 6-40
6 19 HYDRAULIC CIRCUIT DIAGRAMS 6-43
6 19 1 HYDRAULIC DRUM BRAKE 6-43
6 19 2 WET DISC BRAKE 6-45
6 20 ELECTRICAL CIRCUIT DIAGRAMS 6-47
6 20 1 HYDRAULIC DRUM BRAKE, MANUAL TRANS , NO KOPS 6-47
6 20 2 HYDRAULIC DRUM BRAKE, TORQFLOW TRANS , NO KOPS 6-49
6 20 3 HYDRAULIC DRUM BRAKE, MANUAL TRANS , WITH KOPS 6-51
6 20 4 HYDRAULIC DRUM BRAKE, MANUAL TRANS , WITH KOPS – SEAT SWITCH CHANGE 6-53
6 20 5 HYDRAULIC DRUM BRAKE, TORQFLOW TRANS , WITH KOPS 6-55
6 20 6 HYDRAULIC DRUM BRAKE, TORQFLOW TRANS , WITH KOPS – SEAT SWITCH CHANGE 6-57
6 20 7 WET DISC BRAKE, MANUAL TRANS , NO KOPS 6-59
6 20 8 WET DISC BRAKE, TORQFLOW TRANS , NO KOPS 6-61
6 20 9 WET DISC BRAKE, MANUAL TRANS , WITH KOPS 6-63
6 20 10 WET DISC BRAKE, MANUAL TRANS , WITH KOPS – SEAT SWITCH CHANGE 6-65
6 20 11 WET DISC BRAKE, TORQFLOW TRANS , WITH KOPS 6-67
6 20 12 WET DISC BRAKE, TORQFLOW TRANS , WITH KOPS – SEAT SWITCH CHANGE 6-69
7 TROUBLESHOOTING
7 1 TROUBLESHOOTING TOOL AND FAILURE CODES 7-3
7 1 1 FUNCTIONS OF TROUBLESHOOTING TOOL 7-3
7 1 2 USING THE TROUBLESHOOTING TOOL 7-4
7 2 INDICATING FAILURE CODE WITH METER PANEL 7-6
7 2 1 INDICATION IN NORMAL STATE 7-7
7 2 2 INDICATION WHEN TROUBLE OCCURS 7-7
7 3 TABLE OF TROUBLESHOOTING TOOL FAILURE CODES 7-9
7 4 TORQUE CONVERTER TROUBLESHOOTING TABLE 7-11
7 5 CONTROL VALVE TROUBLESHOOTING TABLE 7-14
8 CONVERSION TABLES

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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