Komatsu FD70-10 FD80-10 DX50 Forklift Truck Service Manual SM230 BED10E1-01 – PDF DOWNLOAD

Description

Komatsu FD70-10 FD80-10 DX50 Forklift Truck Service Manual SM230 BED10E1-01 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu FD70-10 FD80-10 DX50 Forklift Truck Service Manual SM230 BED10E1-01 – PDF DOWNLOAD

S/N 55001~

How to read the shop manual:

• Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU FORKLIFT distributors.
• Materials and specifications are subject to change without notice.
• Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
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.

TABLE OF CONTENTS:

Komatsu FD70-10 FD80-10 DX50 Forklift Truck Service Manual SM230 BED10E1-01 – PDF DOWNLOAD

00 Index and foreword
100 Index
Composition of shop manual 2
Table of contents 4
200 Foreword and general information
Safety notice 2
How to read the shop manual 13
Explanation of terms for maintenance standard 15
Handling of electric equipment and hydraulic component 17
Handling of connectors newly used for engines 26
How to read electric wire code 29
Precautions when carrying out operation 32
Standard tightening torque table 35
Conversion table 39
01 Outline
100 Specifications
Specification dimension drawing 2
Weight table 4
Lubricant list 5
10 Structure, function and maintenance standard
100 Engine and cooling system
Cooling system 2
Hydraulic oil cooling system piping diagram 4
Brake cooling system hydraulic piping diagram 5
Torque converter oil filter 6
200 Power train
Power train 2
Power train system diagram 3
Torque converter 4
Transmission 12
Transmission control valve 25
Relief valve 29
Drive shaft 31
Front axle 32
Differential 34
Final drive 37
300 Steering system
Steering piping diagram (orbit roll valve – power steering cylinder) 2
Orbit roll valve 3
Power steering cylinder 5
400 Brake system
Brake control 2
Brake piping diagram (brake – service brake) 3
Service brake 4
Accumulator charge valve 7
Brake valve 12
Accumulator (for brake) 17
Parking brake 18
500 Undercarriage and frame
Rear axle 2
Hydraulic tank piping diagram 4
00-100 4 DX50 Series
00 INDEX AND FOREWORD
Frame 5
600 Hydraulic system
Control valve piping diagram (control valve – pump) 2
Work equipment piping diagram (control valve – tilt cylinder/lift cylinder) 3
Attachment piping diagram 4
Work equipment control lever linkage 5
Work equipment pump 6
Control valve 14
OLMS 26
Brake and steering pump 28
700 Work equipment
Tilt cylinder 2
Lift cylinder 3
Mast and fork 4
801 Electric devices (Part 1)
Accelerator pedal sensor 2
ISO controller (Operator Presence Sensing (OPS) system) 3
EPACS controller 10
Instrument panel 12
Engine starting circuit 14
Engine stopping circuit 15
Electrical system wiring diagram 16
802 Electric devices (Part 2)
Sensors 2
Switches 5
Lamps 12
Buzzer 16
Flasher 20
F/R solenoid valve and F2/R2 solenoid valve 21
Relay box 22
Resistor 28
Diode 29
Fuse 32
Battery 34
20 Standard value table
100 Standard value table
Standard value table 2
30 Testing and adjusting
100 Testing and adjusting
Check of troubleshooting software functions and failure codes 3
Hydraulic piping pressure release procedure 9
Replacement of engine oil and engine oil filter 10
Replacement of fuel filter 11
Cleaning of radiator 14
Check of air cleaner and replacement of cleaner element 15
Oil level check and oil replacement of differential case 16
Oil replacement and strainer cleaning of TORQFLOW transmission 17
Testing power train oil pressure 18
Check of hydraulic tank 26
Measurement of wear amount of service brake disc 28
Check of parking brake 29
Air bleeding procedure 31
Adjustment of brake pedal 33
DX50 Series 00-100 5
00 INDEX AND FOREWORD
Adjustment of inching pedal 34
Initialization of orbit-roll valve 35
Measurement of cylinder hydraulic drift and hydraulic forward drift 36
Adjustment of mast 37
Adjustment of fork carriage 39
Check of drive shaft for looseness, play and damage 40
Installation of wheel (Applicable model: FD80-10) 41
Check of diode 42
40 Troubleshooting
100 General information on troubleshooting
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Testing before troubleshooting 4
Classification and procedures of troubleshooting 5
Phenomena looking like troubles and troubleshooting No 6
Information contained in troubleshooting table 10
Locations of fuses 12
202 Troubleshooting by failure code (ISO controller system (*)) (Part 2)
Failure code display by ISO controller 2
Failure code [[I]: 1 flashing, [N]: Flashing, [L]: Flashing] Seat switch trouble 6
Failure code [[I]: 2 flashings, [N]: Flashing, [L]: OFF] F/R lever trouble 8
Failure code [[I]: 3 flashings, [N]: OFF, [L]: OFF] Parking brake reminder buzzer output
abnormality or N (neutral) lamp and lift interlock warning lamp output abnormality 10
Failure code [[I]: 4 flashings, [N]: OFF, [L]: Flashing] Lift interlock relay
output abnormality (1) 14
Failure code [[I]: 4 flashings, [N]: Flashing, [L]: Flashing] Lift interlock relay
output abnormality (2) 16
Failure code [[I]: 5 flashings, [N]: OFF, [L]: Flashing] Travel interlock relay
output abnormality (1) 19
Failure code [[I]: 5 flashings, [N]: Flashing, [L]: Flashing] Travel interlock relay
output abnormality (2) 22
Failure code [[I]: 6 flashings, [N]: Flashing, [L]: Flashing] Main relay output abnormality 26
Failure code [[I]: 7 flashings, [N]: Flashing, [L]: Flashing] Controller abnormality 28
00-100 6 DX50 Series
204 Troubleshooting by failure code (EPACS controller system) (Part 2)
Display of EPACS controller failure code 2
Failure code [LED: OFF] EPACS controller abnormality 3
Failure code [LED: 1 flashing] Initialization is not completed 4
Failure code [LED: 2 flashings] Controller is being initialized 5
Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality 6
Failure code [LED: 4 flashings] Tire angle sensor abnormality 8
301 Troubleshooting of electrical system (E-mode) (Part 1)
E-1 Engine does not start 2
E-2 Engine does not stop 6
E-3 Lift truck cannot travel 8
E-4 Parking brake reminder alarm does not sound or does not stop sounding 12
E-5 Travel direction is not changed normally 14
E-6 Lift truck cannot move work equipment 18
E-7 Work equipment cannot be locked 20
E-8 EPACS is abnormal 22
E-9 Headlamp, clearance lamp, tail lamp and license plate lamp do not light or go off 24
E-10 Turn signal lamps do not light or go off 28
E-11 Brake lamps do not light or go off 30
E-12 Backup lamps do not light or go off 32
E-13 Backup buzzer does not sound or does not stop sounding 35
00 INDEX AND FOREWORD
E-14 Horn does not sound or does not stop sounding 38
E-15 Fuel level is not displayed normally 40
302 Troubleshooting of electrical system (E-mode) (Part 2)
E-1 Engine does not start 2
E-2 Engine does not stop 6
E-3 Lift truck cannot travel 8
E-4 Parking brake reminder alarm does not sound or does not stop sounding 12
E-5 Travel direction is not changed normally 14
E-6 Lift truck cannot move work equipment 18
E-7 Work equipment cannot be locked 20
E-8 EPACS is abnormal 22
E-9 Headlamp, clearance lamp, tail lamp and license plate lamp do not light or go off 24
E-10 Turn signal lamps do not light or go off 28
E-11 Brake lamps do not light or go off 30
E-12 Backup lamps do not light or go off 32
E-13 Backup buzzer does not sound or does not stop sounding 35
E-14 Horn does not sound or does not stop sounding 38
E-15 Fuel level is not displayed normally 40
400 Troubleshooting of hydraulic and mechanical system (H-mode)
Method of using troubleshooting table 4
Table of failure modes and causes 6
H-1 Lift truck does not start 12
H-2 Travel speed is low, rush force is low, gradeability is low and/or gear is not shifted 13
H-3 Large shocks are made when lift truck starts and gear is shifted 14
H-4 Long time lag is made when lift truck starts and gear is shifted 15
H-5 Torque converter oil temperature is high 16
H-6 Lift truck does not turn 17
H-7 Response is low during turning 18
H-8 Steering is heavy 19
H-9 Lift truck is unstable or large shock is made when it turns 20
H-10 Right and left turning radii are different 21
H-11 When steering wheel is released it does not return to neutral or it rotates by itself 21
H-12 Steering wheel is turned in reverse or it kicks 21
H-13 EPACS does not work 22
H-14 Steering wheel vibrates 23
DX50 Series 00-100 7
H-15 Steering system makes abnormal sound 23
H-16 Oil leaks from steering circuit 23
H-17 Service brake does not work or its performance is low 24
H-18 Service brake is not reset or it drags 25
H-19 Parking brake does not work or its performance is low 26
H-20 Parking brake is not reset or it drags 27
H-21 Lift cylinder and fork do not lift 28
H-22 Lifting speed or force of lift cylinder and fork is insufficient 29
H-23 Fork lifting speed lowers at specific height 30
H-24 Lift cylinder cannot lift load 30
H-25 Lift cylinder natural drift is large 30
H-26 Fork lowering speed is too high 31
H-27 Mast does not tilt forward or backward 32
H-28 Forward/backward tilting speed or force of mast is insufficient 33
H-29 Tilting speed lowers halfway 34
H-30 Tilt cylinder cannot lift load 34
H-31 Tilt cylinder natural forward drift is large 34
H-32 Mast is unstable during travel with load 34
H-33 Lift and tilt levers do not move smoothly and they are heavy 35
H-34 Engine speed lowers remarkably or engine stalls when work equipment is operated 36
H-35 Large shocks are made when work equipment is started and stopped 36
00 INDEX AND FOREWORD
H-36 Another part of work equipment moves when work equipment is relieved singly 36
H-37 Work equipment speed or force is low 37
H-38 When work equipment and steering are operated, engine speed lowers
remarkably or engine stalls 37
H-39 Work equipment and steering system do not move 38
H-40 Abnormal sound is heard from around work equipment and steering pump 38
H-41 Work equipment fine control performance is low or response is low 39
H-42 Work equipment is not locked (It operates while operator is not in operator seat)
or only work equipment does not move 39
H-43 Work equipment (lift-up) does not move, moves but slow or moves but force is low 40
H-44 Lift cylinder drift is large (while operator is not in operator seat) 41
H-45 Lift cylinder drift is large (while operator is in operator seat) 41
H-46 Work equipment (lift-down) lowering speed is low or high or fine control
performance is low or response is low 42
H-47 Fork does not lower 43
H-48 Mast does not tilt/tilts but slow/tilts but force is low 44
H-49 Tilt cylinder natural forward drift is large 44
H-50 Attachment does not move/moves but low/moves but force is low 45
H-51 Attachment cylinder natural drift is large 45
H-52 Steering is heavy 46
H-53 Large shock is made when steering wheel is returned 46
H-54 Work equipment is heavy when work equipment and steering are
operated simultaneously 47
H-55 Steering is heavy when work equipment and steering are operated simultaneously 47
50 Disassembly and assembly
100 General information on disassembly and assembly
Method of using this manual 2
Special tool list 3
How to use LOCTITE 8
200 Engine and cooling system
Removal and installation of power train 2
300 Power train
Removal and installation of front axle 2
Disassembly and assembly of torque converter 4
Disassembly and assembly of torqflow transmission 11
00-100 S DX50 Series
Disassembly and assembly of drive shaft 32
Disassembly and assembly of differential 33
Disassembly and assembly axle housing assembly 37
Disassembly and assembly of parking brake 51
Removal and installation of rear axle and power steering 52
Disassembly and assembly of rear axle 55
Disassembly and assembly of brake pedal 56
Disassembly and assembly of brake valve 57
400 Hydraulic equipment
Disassembly and assembly of orbit roll valve 2
Brake and steering pump 9
Disassembly and assembly of control valve assembly 11
Removal and installation of lift cylinder 14
Disassembly and assembly of lift cylinder 15
Disassembly and assembly of tilt cylinder 16
500 Work equipment
Removal and installation of mast 2
Disassembly and assembly of mast 3
600 Electric devices
Disassembly and assembly of combination switch 2
00 INDEX AND FOREWORD
80 Yearly inspection criteria
100 Yearly inspection criteria
Yearly inspection criteria 2
90 Diagrams and drawings
100 Hydraulic circuit diagrams
Hydraulic circuit diagrams 3
200 Electrical diagrams and drawings
Electrical diagrams and drawings 3

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