Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06487-04 PDF

Description

Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06487-04 – PDF DOWNLOAD

FILE DETAILS:

Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06487-04 – PDF DOWNLOAD 

Language : English
Pages : 790
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06487-04 – PDF DOWNLOAD 

SERIAL NUMBERS 138001 and up

How to read the shop manual
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.

TABLE OF CONTENTS:

Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06487-04 – PDF DOWNLOAD 

SERIAL NUMBERS 138001 and up

Cover 1
00 Index and foreword 3
Table of contents 4
Table of contents 4
Foreword and general information 11
Safety notice 11
How to read the shop manual 22
Explanation of terms for maintenance standard 24
Handling of electric equipment and hydraulic component 26
Handling of connectors newly used for engines 35
How to read electric wire code 38
Precautions when carrying out operation 41
Standard tightening torque table 44
Conversion table 48
01 General Information 53
Table of Contents 54
Specifications 55
Specification dimensions drawing 55
Weight table 57
Lubricant list 58
List of specified fuel and lubricant 59
10 Structure, function and maintenance standard 61
Table of Contents 62
Engine and cooling system 64
Engine mount and transfer mount 64
Cooling system 66
Power train 68
Power train 68
Power train system diagram 69
PTO 70
HST piping diagram 73
HST pump 74
HST motor 86
Axle 96
Differential 97
Steering system 103
Steering piping diagram (control valve – power steering cylinder) 103
Orbitrol valve 104
Power steering cylinder 106
Brake system 107
Brake control 107
Brake piping diagram (control valve – accumulator) 108
Service brake 110
Accumulator charge valve 112
Brake valve 118
Slack adjuster 121
Accumulator (for brake) 125
Parking brake 126
Undercarriage and frame 127
Rear axle 127
Hydraulic tank piping diagram 128
Frame 129
Hydraulic system 130
Control valve piping diagram (tank – control valve) 130
Work equipment piping diagram (control valve – tilt cylinder/lift cylinder) 131
Attachment piping diagram 132
Work equipment control lever linkage 133
Work equipment and steering pump 134
Control valve 142
CLSS 148
Each function and operation of each valve 150
Work equipment 165
Tilt cylinder 165
Lift cylinder 166
Mast 167
Finger board 174
Fork 175
Electrical system 176
Electrical control system 176
HST controller 198
Engine controller 200
Accelerator pedal sensor 202
EPACS controller 204
Instrument panel 206
Pilot box 208
DC/DC converter 209
KOMTRAX system 210
Sensor 213
Combination switch 223
Seat switch 224
Service switch/Preheater lamp 225
Flasher unit 226
Relay box 227
Relay 228
20 Standard value table 231
Table of Contents 232
Standard value table 233
Standard value table 233
30 Testing and adjusting 235
Table of Contents 236
Testing and adjusting 237
Check of failure code of engine controller 237
Displaying, setting, checking by using HST controller 240
Travel speed control function for general operator (description in Operation and Maintenance Manual of the lift truck) 242
Setting controlled travel speed 243
Maximum travel speed control function 245
Banning function of changing controlled travel speed 248
Electrical-system abnormality record display function (only for HST controller system) 250
Mechanical-system abnormality record display function 256
Adjusting function 257
Memory clear function 264
Automatic engine stop set interval changing function 267
Releasing pressure from hydraulic piping 269
Replacement of engine oil and engine oil filter 270
Replacement of fuel filter 272
Fuel pre-filter water drain 274
Fuel filter air bleeding 275
Radiator cleaning 276
Air cleaner inspection and element replacement 277
Testing and adjusting engine speed 278
Testing and adjusting HST oil pressure 280
Testing work equipment and steering pump oil pressure 283
Oil level check and changing oil in differential case 284
Changing PTO oil and cleaning strainer 285
Inspection of hydraulic tank 286
Measuring brake performance 288
Measurement of wear of service brake disc 289
Checking parking brake 290
Bleeding air 291
Adjusting brake pedal 292
Testing and adjusting brake pedal angle sensor linkage 293
Initial setting of Orbitrol valve 295
Measurement of hydraulic drift and forward tilt down by hydraulic drift of cylinder 296
Adjustment of mast 297
Adjustment of fork carriage 300
Lamp display of KOMTRAX terminal 302
KOMTRAX terminal start-up procedure 305
40 Troubleshooting 311
Table of Contents 312
Information related to troubleshooting 315
Points to remember when troubleshooting 315
How to proceed in troubleshooting 316
Checks before troubleshooting 317
Classification and procedures of troubleshooting 318
Phenomena seemed to be failures and troubleshooting Nos 319
Information described in troubleshooting table 322
Locations of fuses 327
Connection table for connector pin numbers 330
T-branch box and T-branch adapter table 370
Troubleshooting by failure code (HST controller system) 373
Failure code list 373
Failure code [–/AB00MA] Alternator: Malfunction 376
Failure code [–/B@CRNS] HST Oil: Overheating 377
Failure code [–/2G40ZG] Brake accumulator: Dropped hydraulic pressure 378
Failure code [–/6091NX] Hst oil filter: Clogging 379
Failure code [12/DDK6KA] FNR lever: Open circuit 380
Failure code [12/DDK6KY] FNR lever: Hot short circuit 384
Failure code [14/DLT4KZ] Travel speed sensor A: Open circuit, ground fault, or hot short circuit 386
Failure code [14/DLT6KZ] Travel speed sensor B: Open circuit, ground fault, or hot short circuit 388
Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B: Open circuit, ground fault, or hot short circuit 390
Failure code [14/DLT4MA] Travel speed sensors A and B: Malfunction 392
Failure code [14/DLT4LC] Travel speed sensors A and B: Mismatch of rotation speed signals 393
Failure code [15/7REXKA] Seat switch: Open circuit 394
Failure code [15/7REXKB] Seat switch: Ground fault 396
Failure code [18/D5ZTKZ] Pump EPC valve ground return signal: Open circuit or hot short circuit 398
Failure code [22/DHHBKX] HST pump A-port pressure sensor: Open circuit or ground fault 400
Failure code [22/DHHBKY] HST pump A-port pressure sensor: Hot short circuit 402
Failure code [23/DHHCKX] HST pump B-port pressure sensor: Open circuit or ground fault 404
Failure code [23/DHHCKY] HST pump B-port pressure sensor: Hot short circuit 406
Failure code [25/DK70KZ] Brake pedal angle sensor: Open circuit or ground fault 408
Failure code [25/DK70KY] Brake pedal angle sensor: Hot short circuit 410
Failure code [26/DGS1KA] HST oil temperature sensor: Open circuit 412
Failure code [26/DGS1KB] HST oil temperature sensor: Ground fault 414
Failure code [27/AB00KZ] Alternator R signal circuit: Open circuit or ground fault 416
Failure code [27/AB00KY] Alternator R signal circuit: Hot short circuit 418
Failure code [28/DHPCKZ] Lift cylinder pressure sensor: Open circuit or ground fault 420
Failure code [28/DHPCKY] Lift cylinder pressure sensor: Hot short circuit 422
Failure code [29/DH2FKZ] Brake charge pressure sensor: Open circuit or ground fault 424
Failure code [29/DH2FKY] Brake charge pressure sensor: Hot short circuit 426
Failure code [32/DXATKA] HST pump forward travel EPC solenoid valve: Open circuit 428
Failure code [32/DXATKB] HST pump forward travel EPC solenoid valve: Ground fault 430
Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve: Hot short circuit 432
Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid valve: Open circuit 434
Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid valve: Ground fault 436
Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid valve: Hot short circuit 438
Failure code [34/DXAVKA] HST motor EPC solenoid valve: Open circuit 440
Failure code [34/DXAVKB] HST motor EPC solenoid valve: Ground fault 442
Failure code [34/DXAVKY] HST motor EPC solenoid valve: Hot short circuit 444
Failure code [35/D110KZ] HST controller power relay: Open circuit or hot short circuit 446
Failure code [35/D110KB] HST controller power relay: Ground fault 448
Failure code [37/DW9NKA] Work equipment lock solenoid valve: Open circuit 450
Failure code [37/DW9NKB] Work equipment lock solenoid valve: Ground fault 452
Failure code [37/DW9NKY] Work equipment lock solenoid valve: Hot short circuit 454
Failure code [38/DW9MKA] Lift lock solenoid valve: Open circuit 455
Failure code [38/DW9MKB] Lift lock solenoid valve: Ground fault 456
Failure code [38/DW9MKY] Lift lock solenoid valve: Hot short circuit 458
Failure code [39/D140KB] Starter relay: Ground fault 460
Failure code [39/D140KY] Starter relay: Hot short circuit 462
Failure code [47/D161KA] Backup buzzer and backup lamp relay: Open circuit 464
Failure code [47/D161KB] Backup buzzer and backup lamp relay: Ground fault 466
Failure code [47/D161KY] Backup buzzer and backup lamp relay: Hot short circuit 468
Failure code [48/DV00KB] Warning buzzer: Ground fault 470
Failure code [48/DV00KY] Warning buzzer: Hot short circuit 471
Failure code [49/D19UKA] Pump EPC valve ground cutout relay: Open circuit 472
Failure code [49/D19UKB] Pump EPC valve ground cutout replay: Ground fault 474
Failure code [49/D19UKY] Pump EPC valve ground cutout relay: Hot short circuit 476
Failure code [52/DAJ0KK] HST controller: Drop of power voltage 478
Failure code [53/DAJ2KK] HST controller: Drop of load power supply voltage 480
Failure code [54/7REHKA] Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit 482
Failure code [55/DAJ5KX] HST controller sensor 5 V-power supply: Ground fault or hot short circuit 484
Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL): Open circuit 486
Failure code [62/DB2RKR] CAN communication (between HST controller and engine controller): Communication failure (Component system failure) 488
Failure code [63/DAJ000] HST Controller: Memory error 490
Failure code [63/DAJ0KT] HST Controller: Memory error 491
Troubleshooting by failure code (EPACS controller system) 492
Display of EPACS controller failure code 492
Failure code [LED: OFF] EPACS controller abnormality 493
Failure code [LED: 1 flashing] Initialization is not completed 494
Failure code [LED: 2 flashings] Controller is being initialized 495
Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality 496
Failure code [LED: 4 flashings] Tire angle sensor abnormality 498
Troubleshooting for electrical system (E-mode) 500
Information described in troubleshooting table 500
E-1 Engine does not start 501
E-2 Engine preheater does not operate 506
E-3 Parking brake reminder alarm does not sound or does not stop sounding 508
E-4 EPACS is abnormal 511
E-5 Headlamp, clearance lamp, tail lamp and license plate lamp do not light up or go off 514
E-6 Turn signal lamps do not light up or go off 520
E-7 Brake lamps do not light up or go off 524
E-8 Backup lamps do not light up or go off 526
E-9 Backup buzzer does not sound or does not stop sounding 528
E-10 Horn does not sound or does not stop sounding 530
E-11 Fuel level is not displayed normally 532
E-12 Engine coolant temperature level is not displayed normally 534
E-13 All of indicator and warning lamps of instrument panel do not light up when starting switch is turned to the ON position 536
E-14 When starting switch is turned to the ON position, all of indicator and warning lamps of pilot box do not light up 543
E-15 When starting switch is turned to the ON position, preheater lamp does not light up 548
E-16 When starting switch is turned to the ON position, alarm buzzer does not sound 550
E-17 Backup lamp of instrument panel does not light up 552
E-18 Charge warning lamp lights up while engine is running 554
E-19 HST oil temperature warning lamp lights up while engine is running 556
E-20 HST oil filter clogging warning lamp lights up while engine is running 557
E-21 Engine oil pressure warning lamp lights up while engine is running 558
E-22 Sedimenter (water separator) warning lamp lights up while engine is running 558
E-23 Abnormality warning lamp lights up while engine is running 560
E-24 Engine abnormality warning lamp lights up while engine is running 562
E-25 Travel speed restriction cannot be released or enabled 564
E-26 Impossible to select HST controller failure display mode, HST controller adjustment mode, speed limit setting mode, or engine stop time auto-change mode 566
E-27 KOMTRAX system does not operate normally 569
Troubleshooting for hydraulic and mechanical system (H-mode) 571
How to use troubleshooting table 571
Hydraulic and mechanical system diagram 574
Table of failure modes and causes 576
H-1 Lift truck cannot travel 580
H-2 Slow travel speed 581
H-3 Insufficient towing force 582
H-4 Engine stops during traveling, or engine speed drops excessively 583
H-5 HST (hydraulic) oil temperature is too high 584
H-6 Impossible steering 585
H-7 Response is low during turning 586
H-8 Steering is heavy 587
H-9 Unstable during turning 588
H-10 When steering wheel is released it does not return to neutral or it rotates by itself 589
H-11 Steering wheel is turned in reverse or it kicks (while work equipment is operated) 589
H-12 Large shock is made when steering wheel is returned 590
H-13 EPACS does not work 591
H-14 Steering wheel vibrates 592
H-15 Steering system makes abnormal sound 592
H-16 Oil leaks from steering circuit 592
H-17 Service brake does not work or its performance is low 593
H-18 Service brake is not reset or it drags 594
H-19 Parking brake does not work or its performance is low 595
H-20 Parking brake is not reset or it drags 596
H-21 Abnormal noise around the work equipment or steering pump 597
H-22 Engine speed drops excessively or stops during work equipment operation or wheel steering 598
H-23 Fine control performance of entire work equipment is low or response is low 599
H-24 Work equipment cannot be locked (and the equipment operates when operator leaves) 600
H-25 Control valve lever does not move smoothly and it is heavy 601
H-26 Lift cylinder and fork do not lift 602
H-27 Lifting speed or power of lift cylinder and fork is insufficient 603
H-28 Forklift speed lowers at specific height 604
H-29 Lift cylinder natural drift is large 605
H-30 Lift cylinders do not come down 606
H-31 Fork lowering speed is low or high or fine control performance is low or response is low 607
H-32 Mast does not tilt forward or backward 608
H-33 Forward/backward tilting speed or force of mast is insufficient 609
H-34 Tilting speed lowers halfway 610
H-35 Tilt cylinder natural forward drift is large 611
H-36 Mast is unstable during travel with load 612
H-37 Work equipment is heavy when work equipment and steering are operated simultaneously 613
H-38 Steering is heavy when work equipment and steering are operated simultaneously 614
50 Disassembly and assembly 615
Table of Contents 616
Related information on disassembly and assembly 617
How to read this manual 617
Coating materials list 618
Special tools list 621
Sketches of special tools 623
How to use Loctite 625
Engine and cooling system 626
Removal and installation of fuel supply pump assembly 626
Removal and installation of fuel injector assembly 630
Removal and installation of cylinder head assembly 634
Removal and installation of of radiator assembly 645
Removal and installation of aftercooler assembly 647
Removal and installation of oil cooler assembly 650
Removal and installation of engine and pump assembly 651
Removal and installation of starting motor assembly 659
Power train 662
Removal and installation of front axle and HST motor assembly 662
Disassembly and assembly of front axle assembly 665
Removal and installation of PTO assembly 666
Disassembly and assembly of PTO assembly 667
Disassembly and assembly of differential assembly 670
Disassembly and assembly of axle housing assembly 683
Disassembly and assembly of parking brake assembly 690
Disassembly and assembly of rear axle assembly 691
Disassembly and assembly of power steering cylinder assembly 694
Disassembly and assembly of brake pedal assembly 696
Undercarriage and frame 697
Removal and installation of counterweight assembly 697
Removal and installation of head guard assembly 699
Removal and installation of hood assembly 703
Hydraulic system 705
Removal and installation of HST pump assembly 705
Removal and installation of HST motor assembly 709
Removal and installation of work equipment and steering pump assembly 710
Removal and installation of control valve assembly 712
Disassembly and assembly of control valve assembly 714
Disassembly and assembly of orbitrol valve assembly 720
Removal and installation of lift cylinder assembly 727
Disasse mbly and assembly of lift cylinder assembly 730
Disassembly and assembly of tilt cylinder assembly 731
Work equipment 736
Removal and installation of mast assembly 736
Disassembly and assembly of mast assembly 738
Electrical system 742
Removal and installation of engine controller assembly 742
Removal and installation of HST controller assembly 744
Removal and installation of KOMTRAX terminal assembly 745
Disassembly and assembly of combination switch assembly 746
80 Yearly inspection criteria 747
Table of Contents 748
Yearly inspection criteria 749
Yearly inspection criteria 749
90 Circuit diagrams 769
Table of Contents 770
Hydraulic circuit diagram 771
Electric circuit diagram (1/4) 773
Electric circuit diagram (2/4) 775
Electric circuit diagram (3/4) 777
Electric circuit diagram (4/4) 779
Connector list and layout 781
Index 783

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24