Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Shop Manual PDF

Description

Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Shop Manual SEN06571-10 – PDF DOWNLOAD

FILE DETAILS:

Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Shop Manual SEN06571-10 – PDF DOWNLOAD 

Language : English
Pages : 1262
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Shop Manual SEN06571-10 – PDF DOWNLOAD 

SERIAL NUMBERS 140001 and up

Cover 1
00 Index and foreword 3
Table of contents 4
Foreword, safety, basic information 14
How to read the shop manual 14
Safety notice for operation 16
Precautions to prevent fire 25
Action if fire occurs 27
Precautions for handling hydraulic equipment 28
Precautions for disconnection and connection of pipings 30
Precautions for handling electrical equipment 37
Precautions for handling fuel system equipment 39
Precautions for handling intake system equipment 40
Precautions for replacing HST controller and monitor panel 41
Practical use of KOMTRAX 42
Disconnect and connect push-pull type coupler 43
Precautions for disconnection and connection of connectors 47
Method for disconnecting and connecting deutsch connector 52
Method for disconnecting and connecting slide lock type connector 53
Method for disconnecting and connecting connector with lock to pull 55
Method for disconnecting and connecting connector with lock to push 56
Method for disconnecting and connecting connector with housing to rotate 58
How to read electrical wire code 59
Explanation of terms for maintenance standard 63
Abbreviation list 65
Standard tightening torque table 70
Conversion table 77
01 Specification 83
Contents 84
Specifications 85
Specification Drawing 85
Weight Table 87
Lubricant List 88
10 Structure and function 91
Contents 92
Engine and cooling system 94
Variable flow turbocharger 94
Piping drawing of EGR system 98
Circuit diagram of EGR system 100
EGR valve 101
EGR cooler 103
Layout drawing of KCCV 105
KCCV ventilator 107
CDR valve 109
KDOC muffler 112
Cooling system 114
Power train 116
Power train 116
Power train system diagram 117
PTO 118
HST piping diagram 120
HST pump 121
HST motor 133
Axle 144
Differential 145
Steering system 148
Steering piping diagram (control valve – power steering cylinder) 148
Orbitrol valve 149
Brake system 151
Brake control 151
Brake piping diagram 152
Service brake 153
Accumulator charge valve 155
Brake valve 160
Slack adjuster 162
Accumulator (for brake) 164
Parking brake 165
Undercarriage and frame 166
Rear axle 166
Frame 167
Hydraulic system 168
Control valve piping diagram (tank to control valve) 168
Hydraulic tank piping diagram 169
Work equipment piping diagram (control valve to tilt cylinder/lift cylinder) 170
Attachment piping diagram 171
Work equipment control lever linkage 172
Work equipment and steering pump 173
Control valve 181
CLSS 188
Each function and operation of each valve 190
Work equipment 205
Mast 205
Finger board 212
Fork 213
Electrical system 214
Electrical control system 214
HST controller 243
System component parts 245
Accelerator pedal sensor 250
EPACS controller 251
Monitor system 255
KOMTRAX system 256
Sensor 259
Combination switch 269
Seat switch, seat belt switch (Except European specification (including Turkey)) 270
Flasher 272
Relay box 273
20 Standard value table 277
Contents 278
Standard value table 279
Standard value table for engine 279
Standard value table for machine 287
30 Testing and adjusting 299
Contents 300
Precautions before work 301
Related information on testing and adjusting 303
Tools for testing and adjusting 303
Engine and cooling system 305
Testing engine speed 305
Testing exhaust gas color 307
Testing and adjusting valve clearance 309
Testing compression pressure 311
Testing blowby pressure 314
Testing engine oil pressure 315
Visual check inside of EGR valve 316
Clean inside of EGR valve 317
Testing fuel pressure 319
Testing fuel return and leakage volume 320
Bleeding air from fuel system 323
Testing leakage from fuel system 325
Replacing engine oil and engine oil filter 327
Replacing KCCV filter element 328
Replacing fuel filter 330
Draining water from fuel pre-filter 333
Bleeding air from fuel filter 334
Radiator cleaning 335
Testing air cleaner and replacing filter element 336
Handling cylinder cutout mode operation 339
Handling no-injection cranking operation 340
Writing compensation values at replacement of fuel injector and engine controller 341
Testing alternator belt 346
Testing auto-tensioner 347
Power train 348
Testing HST oil pressure 348
Checking oil level and changing oil in differential case 350
Changing PTO oil and cleaning strainer 351
Steering system 352
Initial setting of Orbitrol valve 352
Brake system 354
Bleeding air from brake circuit 354
Testing brake oil pressure 355
Checking accumulator charge pressure 356
Testing braking performance 357
Testing wear of service brake disc 358
Checking parking brake 359
Testing and adjusting brake pedal 361
Testing and adjusting brake pedal angle sensor linkage 363
Hydraulic system 365
Releasing remaining pressure in hydraulic piping 365
Inspection of hydraulic tank 366
Work equipment 369
Bleeding air from lift cylinder 369
Testing hydraulic drift and hydraulic drift tilting amount 370
Adjusting mast 371
Adjusting fork carriage 374
Handling engine controller voltage circuit 377
Testing procedure for diode 378
Electrical system 379
Special functions of monitor panel 379
KOMTRAX terminal start-up procedure 426
40 Troubleshooting 431
Contents 432
Precautions before work 438
Information related to troubleshooting 440
Points to remember when troubleshooting 440
How to proceed in troubleshooting 441
Checks before troubleshooting 443
Classification and procedures of troubleshooting 444
Symptoms of failure and troubleshooting numbers 445
Information in troubleshooting table 448
Locations of fuses 450
Connector list and layout 455
Connection table for connector pin No 462
T-box and T-adapter list 502
Troubleshooting by failure code 506
Failure codes table 506
Failure code [2G40ZG] Low) Accumulator Oil Pressure 514
Failure code [6091NX] HST Oil Filter: Clogging 515
Failure code [7REAKA] DISC OR SHORT_G) ACC input 1 516
Failure code [7REHKA] ACC input 2 518
Failure code [AB00KY] SHORT) Alternator 520
Failure code [AB00MA] Low) Battery Charge Voltage 522
Failure code [B@BAZG] Eng Oil press Low 524
Failure code [B@BCNS] Eng Water Overheat 525
Failure code [B@CRNS] Overheating HST Oil 526
Failure code [CA115] Eng Ne & Bkup Speed Sens Err 527
Failure code [CA122] Chg Air Press Sens High Err 528
Failure code [CA123] Chg Air Press Sens Low Error 530
Failure code [CA131] Throttle Sensor High Error 532
Failure code [CA132] Throttle Sensor Low Error 534
Failure code [CA144] Coolant Temp Sens High Error 536
Failure code [CA145] Coolant Temp Sens Low Error 538
Failure code [CA153] Chg Air Temp Sens High Error 540
Failure code [CA154] Chg Air Temp Sens Low Error 542
Failure code [CA187] Sens 2 Supply Volt Low Err 544
Failure code [CA221] Ambient Press Sens High Err 546
Failure code [CA222] Ambient Press Sens Low Error 548
Failure code [CA227] Sens 2 Supply Volt High Err 550
Failure code [CA234] Eng Overspeed 551
Failure code [CA238] Ne Speed Sens Sup V Low Err 552
Failure code [CA239] Ne Speed Sens Sup V High Err 553
Failure code [CA271] IMV/PCV1 Short Error 554
Failure code [CA272] IMV/PCV 1 Open Error 555
Failure code [CA322] Inj #1 (L#1) Open/Short Error 556
Failure code [CA324] Inj #3 (L#3) Open/Short Error 558
Failure code [CA331] Inj #2 (L#2) Open/Short Error 560
Failure code [CA332] Inj #4 (L#4) Open/Short Error 562
Failure code [CA343] ECM Critical Internal Failure 564
Failure code [CA351] Injector Drive Circuit Error 565
Failure code [CA352] Sens 1 Supply Volt Low Err 566
Failure code [CA356] MAF Sensor High Error 568
Failure code [CA357] MAF Sensor Low Error 570
Failure code [CA386] Sens 1 Supply Volt High Err 572
Failure code [CA428] Water in Fuel Sensor High Error 573
Failure code [CA429] Water in Fuel Sensor Low Error 574
Failure code [CA431] Idle Validation Sw Error 575
Failure code [CA432] Idle Validation Process Err 578
Failure code [CA435] Eng Oil Press SW Error 581
Failure code [CA441] Battery Voltage Low Error 582
Failure code [CA442] Battery Voltage High Error 584
Failure code [CA449] Rail Press Very High Error 585
Failure code [CA451] Rail Press Sensor High Error 586
Failure code [CA452] Rail Press Sensor Low Error 588
Failure code [CA466] KVGT Motor D Position Error 590
Failure code [CA515] Rail Press Sens Sup V Hi Err 592
Failure code [CA516] Rail Press Sens Sup V Lo Err 594
Failure code [CA553] Rail Press High Error 596
Failure code [CA555] Crankcase Press High Error 1 597
Failure code [CA556] Crankcase Press High Error 2 598
Failure code [CA559] Rail Press Low Error 599
Failure code [CA689] Eng Ne Speed Sensor Error 602
Failure code [CA691] Intake Air Temp Sens Hi Err 604
Failure code [CA692] Intake Air Temp Sens Low Err 606
Failure code [CA697] ECM Int Temp Sens High Error 608
Failure code [CA698] ECM Int Temp Sens Low Error 609
Failure code [CA731] Bkup Speed Sens Phase Error 610
Failure code [CA778] Eng Bkup Speed Sensor Error 612
Failure code [CA1117] Persistent Data Lost Error 614
Failure code [CA1695] Sens 5 Supply Volt High Err 615
Failure code [CA1696] Sens 5 Supply Volt Low Error 616
Failure code [CA1843] Crankcase Press Sens Hi Err 618
Failure code [CA1844] Crankcase Press Sens Low Err 620
Failure code [CA1896] EGR Valve Stuck Error 622
Failure code [CA1942] Crankcase Press Sens Err 627
Failure code [CA1961] EGR_Motor D IC Temp Err (H) 628
Failure code [CA2185] Throt Sens Sup Volt High Err 629
Failure code [CA2186] Throt Sens Sup Volt Low Err 630
Failure code [CA2249] Rail Press Very Low Error 632
Failure code [CA2272] EGR Valve Pos Sens Low Error 633
Failure code [CA2311] IMV Solenoid Error 636
Failure code [CA2349] EGR Valve Solenoid Open Err 638
Failure code [CA2353] EGR Valve Solenoid Short Err 640
Failure code [CA2357] EGR Valve Servo Error 642
Failure code [CA2555] Grid Htr Relay Error (Open) 644
Failure code [CA2556] Grid Htr Relay Error (Short) 646
Failure code [CA2765] Inj Trim Data error 648
Failure code [CA3419] MAF Sens Sup Volt High Error 650
Failure code [CA3421] MAF Sens Sup Volt Low Error 652
Failure code [CA3724] Motor Driver Power Low Error 654
Failure code [CA3918] KVGT Stuck Error 656
Failure code [CA3919] Driver IC Over Temp Err, KVGT 657
Failure code [CA3921] KVGT Servo Error 2 658
Failure code [CA3922] KVGT Motor Driver Open Err 660
Failure code [CA3923] KVGT Motor Driver Short Err 662
Failure code [D110KA] DISC OR SHORT) H/Con Relay 664
Failure code [D110KB] SHORT_G) Hst Con Relay 666
Failure code [D140KB] SHORT_G) Starter Relay 668
Failure code [D140KY] SHORT) Starter Relay 670
Failure code [D160KA] DISC) Back Lamp Relay 672
Failure code [D160KB] SHORT_G) Back Lamp Relay 674
Failure code [D160KY] SHORT) Back Lamp Relay 676
Failure code [D161KB] SHORT_G) Back Alarm Relay 678
Failure code [D161KY] SHORT) Back Alarm Relay 679
Failure code [D190KB] SHORT_G) ACC Power Relay 680
Failure code [D190KY] SHORT) ACC Power Relay 681
Failure code [D19SKB] SHORT_G) Forward Alarm Relay 682
Failure code [D19SKY] SHORT) Forward Alarm Relay 683
Failure code [D19TKB] SHORT_G)OverspeedAlarmRelay 684
Failure code [D19TKY] SHORT) Overspeed Alarm Relay 685
Failure code [D19UKA] DISC) Pump EPC Cut Relay 686
Failure code [D19UKB] SHORT_G) Pump EPC Cut Relay 689
Failure code [D19UKY] SHORT) Pump EPC Cut Relay 692
Failure code [D5ZTKA] DISC OR SHORT) EPC Earth RET 695
Failure code [D5ZKKA] DISC OR SHORT) Start Cut SIG 698
Failure code [D5ZKKB] SHORT_G) Start Cut SIG (North America spec ) 700
Failure code [D5ZKKB] SHORT_G) Start Cut SIG (Except North America spec ) 701
Failure code [D811MC] ABNL) KOMTRAX 702
Failure code [D862KA] DISC) GPS Antenna 703
Failure code [D8ALKA] DISC) SYS-OPE Lamp (KMTX) 704
Failure code [D8ALKB] SHORT) SYS-OPE Lamp (KMTX) 705
Failure code [D8AQKR] ABNL) CAN COMM (KMTX) 706
Failure code [D8AQK4] ABNL) CAN COMM 2 (KMTX) (North America spec ) 708
Failure code [D8AQK4] ABNL) CAN COMM 2 (KMTX) (Except North America spec ) 710
Failure code [DAF0KT] ABNL) EEPROM (MON) 712
Failure code [DAF0MB] ABNL) Monitor ROM 712
Failure code [DAF0MC] ABNL) Monitor 713
Failure code [DAF3KK] LOW) Power Moni 714
Failure code [DAFGMC] ABNL) GPS Module 716
Failure code [DAFLKA] DISC) Operating Lamp Line 716
Failure code [DAFLKB] SHORT) Operating Lamp Line 717
Failure code [DAFQKR] ABNL) CAN COMM (MON) 717
Failure code [DAJ000] ABNL) HST Con Memory 718
Failure code [DAJ0KK] LOW) HST/C Power Supply Volt 720
Failure code [DAJ0KT] ABNL) HST Con Memory 722
Failure code [DAJ0MC] RESET) Controller (HST) 723
Failure code [DAJ2KK] ABNL) HST/C Output Power 724
Failure code [DAJ5KX] SHORT_G OR SHORT) H/C Power 1 726
Failure code [DAJ9KQ] ABNL) Model Selection Line 728
Failure code [DAJJKB] SHORT_G) H/C Operating States 729
Failure code [DAJLKA] DISC) Operating Lamp Line 730
Failure code [DAJLKA] SYS_BUSY (System operating lamp) Open circuit, ground fault (Machines with system operating lamp) 731
Failure code [DAJLKY] SYS_BUSY (System operating lamp) Hot short (Machines with system operating lamp) 734
Failure code [DAJLKY] SHORT) Operating Lamp Line 737
Failure code [DAJRMA] ABNL) Model Selection Line 738
Failure code [DAJQKR] ABNL) CAN COMM (HST/C) 739
Failure code [DB2QKR] ABNL) CAN COMM (ENG/C) 742
Failure code [DB2RKR] ABNL) CAN COMMR (H/C~ENG/C) 745
Failure code [DDDTKA] DISC) Seat SW1 (North America spec ) 748
Failure code [DDDTKA] DISC) Seat SW1 (Except North America spec ) 750
Failure code [DDDTKB] SHORT_G) Seat SW1 (North America spec ) 752
Failure code [DDDTKB] SHORT_G) Seat SW1 (Except North America spec ) 754
Failure code [DDDUKA] DISC) Seat SW2 (North America spec ) 756
Failure code [DDDUKA] DISC) Seat SW2 (Except North America spec ) 758
Failure code [DDDUKB] SHORT_G) Seat SW2 (North America spec ) 760
Failure code [DDDUKB] SHORT_G) Seat SW2 (Except North America spec ) 762
Failure code [DDDVKA] ABNL) Seat SW (North America spec ) 764
Failure code [DDDVKA] ABNL) Seat SW (Except North America spec ) 766
Failure code [DDDVKM] OPE-ERROR) Seat SW (North America spec ) 768
Failure code [DDDVKM] OPE-ERROR) Seat SW (Except North America spec ) 770
Failure code [DDK6KA] DISC) Direction Lever 772
Failure code [DDK6KY] SHORT) Direction Lever 774
Failure code [DGS1KA] DISC) HST Temperature 776
Failure code [DGS1KB] SHORT_G) HST Temperature 778
Failure code [DH2FKA] DISC OR SHORT_G) Brake P SNSR 780
Failure code [DH2FKY] SHORT) Brake Press Sensor 783
Failure code [DHHBKA] DISC OR SHORT_G) HST PA SNSR 786
Failure code [DHHBKY] SHORT) HST PA Press Sensor 788
Failure code [DHHCKA] DISC OR SHORT_G) HST PB SNSR 790
Failure code [DHHCKY] SHORT) HST PB Press Sensor 792
Failure code [DHPCKA] DISC OR SHORT_G) Lift P SNSR 794
Failure code [DHPCKY] SHORT) Lift Press Sensor 796
Failure code [DJF1KA] DISC OR SHORT) Fuel Sensor 798
Failure code [DJF1L8] MISMATCH) Fuel Sensor (North America spec ) 800
Failure code [DJF1L8] MISMATCH) Fuel Sensor (Except North America spec ) 802
Failure code [DK70KA] DISC OR SHORT_G) Brake Pedal 804
Failure code [DK70KY] SHORT) Brake Pedal 806
Failure code [DLT4KA] DISC OR SHORT) Vehicle Speed A 808
Failure code [DLT4KA+DLT6KA] DISC OR SHORT)Vehicle Speed A+DISC OR SHORT) Vehicle Speed B 811
Failure code [DLT4LC] ABNL) Vehicle Speed Signal 814
Failure code [DLT4MA] ABNL) Vehicle Speed Sensor 815
Failure code [DLT6KA] DISC OR SHORT) Vehicle Speed B 816
Failure code [DV00KB] SHORT_G) Alarm Buzzer 818
Failure code [DV00KY] SHORT) Alarm Buzzer 820
Failure code [DV01KB] SHORT_G) Back Buzzer 822
Failure code [DV01KY] SHORT) Back Buzzer 823
Failure code [DW9MKA] DISC) LIFT LOCK SOL 824
Failure code [DW9MKB] SHORT_G) LIFT LOCK SOL 826
Failure code [DW9MKY] SHORT) LIFT LOCK SOL 828
Failure code [DW9NKA] DISC) WORK EQUIP LOCK SOL 830
Failure code [DW9NKB] SHORT_G) WORK EQUIP LOCK SOL 832
Failure code [DW9NKY] SHORT) WORK EQUIP LOCK SOL 834
Failure code [DXATKA] DISC) HST Forward EPC SOL (North America spec ) 836
Failure code [DXATKA] DISC) HST Forward EPC SOL (Except North America spec ) 838
Failure code [DXATKB] SHORT_G) HST Forward EPC SOL 840
Failure code [DXATKY] SHORT) HST Forward EPC SOL 843
Failure code [DXAUKA] DISC) HST Back EPC SOL (North America spec ) 846
Failure code [DXAUKA] DISC) HST Back EPC SOL (Except North America spec ) 848
Failure code [DXAUKB] SHORT_G) HST Back EPC SOL 850
Failure code [DXAUKY] SHORT) HST Back EPC SOL 853
Failure code [DXAVKA] DISC) HST Motor EPC SOL (North America spec ) 856
Failure code [DXAVKA] DISC) HST Motor EPC SOL (Except North America spec ) 858
Failure code [DXAVKB] SHORT_G) HST Motor EPC SOL 860
Failure code [DXAVKY] SHORT) HST Motor EPC SOL 862
Failure code [F7FQKR] ABNL) CAN COMM (IDKey) 864
Troubleshooting by failure code (EPACS controller system) 866
Display of EPACS controller failure code 866
Failure code [LED: OFF] EPACS Controller Abnormality 868
Failure code [LED: 1 flashing] Initialization Not Completed 869
Failure code [LED: 2 flashings] Under Initialization 870
Failure code [LED: 3 flashings] Steering Wheel Angle Sensor Abnormality 871
Failure code [LED: 4 flashings] Tire Angle Sensor Abnormality 872
Troubleshooting for electrical system (E-mode) 875
Information described in troubleshooting table 875
E-1 Engine does not start 876
E-2 Engine preheater does not operate 883
E-3 Parking brake reminder alarm does not sound or does not stop sounding 885
E-4 EPACS is abnormal 888
E-5 Headlamp, clearance lamp, tail lamp, and license plate lamp do not light up nor go out (North America spec ) 890
E-5 Headlamp, clearance lamp, tail lamp, and license plate lamp do not light up nor go out (Except North America spec ) 896
E-6 Turn signal lamps do not light up nor go out 902
E-7 Brake lamps do not light up nor go out 906
E-8 Backup lamps do not light up nor go out 909
E-9 Backup buzzer does not sound or does not stop sounding 912
E-10 Horn does not sound or does not stop sounding 914
E-11 Fuel level is not displayed normally (North America spec ) 916
E-11 Fuel level is not displayed normally (Except North America spec ) 917
E-12 KOMTRAX system does not operate normally 918
E-13 When starting switch is turned to ON position, alarm buzzer does not sound 919
E-14 When starting switch is turned to ON position, monitor panel is not displayed 920
E-15 HST oil filter clogging warning lamp lights up while engine is running 922
Troubleshooting for hydraulic and mechanical system (H-mode) 923
How to use troubleshooting table 923
Hydraulic and mechanical system diagram 926
Failure mode and cause table 928
H-1 Lift truck cannot travel 932
H-2 Slow travel speed 933
H-3 Insufficient rim pull 934
H-4 Engine stops during traveling, or engine speed drops excessively 935
H-5 HST (hydraulic) oil temperature is too high 936
H-6 Lift truck does not turn 937
H-7 Turning response is poor 938
H-8 Steering wheel is heavy to turn 939
H-9 Lift truck is unstable during turning 940
H-10 When steering wheel is released, it does not return to NEUTRAL or it rotates by itself 941
H-11 Steering wheel is turned in reverse or it kicks (in combined operation with work equipment) 941
H-12 Large shock is made when steering wheel is returned 942
H-13 EPACS does not work 943
H-14 Steering wheel vibrates 944
H-15 Steering system makes abnormal sound 944
H-16 Oil leaks from steering circuit 944
H-17 Service brake does not work or its performance is low 945
H-18 Service brake is not released or it drags 946
H-19 Parking brake does not work or its performance is low 947
H-20 Parking brake is not released or it drags 948
H-21 Unusual noise is heard around the work equipment and steering pump 949
H-22 Engine speed drops excessively or stops when work equipment and steering pump is operated 950
H-23 Fine control or response of all work equipment is poor 951
H-24 Work equipment cannot be locked (the work equipment operates when operator leaves) 952
H-25 Control valve lever does not move smoothly and it is heavy 953
H-26 Lift cylinder and fork are not raised 954
H-27 Lifting speed or power of lift cylinder and fork is insufficient 955
H-28 Fork lifting speed lowers at specific height 956
H-29 Hydraulic drift of lift cylinder is large 957
H-30 Lift cylinders do not come down 958
H-31 Fork lowering speed is low or high or fine control performance is low or response is low 959
H-32 Mast does not tilt forward or backward 960
H-33 Forward/backward tilting speed or force of mast is insufficient 961
H-34 Tilting speed lowers halfway 962
H-35 Hydraulic drift of tilt cylinder (forward tilting) is large 963
H-36 Mast is unstable during travel with load 964
H-37 Work equipment operation is slow when work equipment and steering are operated simultaneously 965
H-38 Steering operation is heavy when work equipment and steering are operated simultaneously 966
Troubleshooting for basic engine (S-mode) 967
Information described in troubleshooting table (S-mode) 967
S-1 Engine does not crank when starting switch is turned to “START” position 968
S-2 Engine cranks but no exhaust smoke comes out 969
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 970
S-4 Engine startability is poor 971
S-5 Engine does not pick up smoothly 973
S-6 Engine stops during operation 975
S-7 Engine runs rough or is unstable 976
S-8 Engine lacks power 977
S-9 Exhaust gas color is black 979
S-10 Engine oil consumption is excessive 981
S-11 Oil becomes contaminated quickly 982
S-12 Fuel consumption is excessive 983
S-13 Oil is in coolant (or coolant spurts back or coolant level goes down) 984
S-14 Oil pressure drops 985
S-15 Fuel mixes into engine oil 986
S-16 Water mixes into engine oil (milky) 987
S-17 Coolant temperature rises too high (overheating) 988
S-18 Unusual noise is heard 989
S-19 Vibration is excessive 990
S-20 Air cannot be bled from fuel circuit 991
50 Disassembly and assembly 993
Contents 994
Precautions before work 996
General information on disassembly and assembly 998
How to read this manual 998
Coating materials list 1000
Special tools list 1004
Sketches of special tools 1006
Engine and cooling system 1008
Removal and installation of supply pump assembly 1008
Removal and installation of injector assembly 1012
Removal and installation of cylinder head assembly 1016
Removal and installation of radiator assembly 1025
Removal and installation of alternator belt 1027
Removal and installation of auto- tensioner 1028
Removal and installation of aftercooler assembly 1029
Removal and installation of oil cooler assembly 1031
Removal and installation of engine and pump assembly 1032
Removal and installation of EGR valve assembly 1038
Removal and installation of EGR cooler assembly 1039
Removal and installation of KCCV crankcase pressure sensor assembly 1042
Removal and installation of KCCV assembly 1043
Removal and installation of air cleaner assembly 1044
Removal and installation of KDOC muffler assembly 1046
Removal and installation of starting motor assembly 1048
Power train 1050
Removal and installation of front axle and HST motor assembly 1050
Disassembly and assembly of front axle assembly 1054
Removal and installation of PTO assembly 1055
Disassembly and assembly of PTO assembly 1056
Disassembly and assembly of differential assembly 1059
Disassembly and assembly of axle housing assembly 1072
Disassembly and assembly of parking brake assembly 1079
Disassembly and assembly of rear axle assembly 1080
Disassembly and assembly of power steering cylinder assembly 1083
Disassembly and assembly of brake pedal assembly 1085
Undercarriage and frame 1086
Removal and installation of counterweight assembly FH35, FH40 1086
Removal and installation of counterweight assembly FH45, FH50 1088
Removal and installation of head guard assembly 1090
Removal and installation of hood assembly 1097
Hydraulic system 1100
Removal and installation of HST pump assembly 1100
Removal and installation of HST motor assembly 1103
Removal and installation of work equipment and steering pump assembly 1104
Removal and installation of control valve assembly 1106
Disassembly and assembly of Orbitrol valve assembly 1108
Removal and installation of lift cylinder assembly 1114
Disassembly and assembly of lift cylinder assembly 1117
Disassembly and assembly of tilt cylinder assembly 1118
Cab and its attachments 1123
Removal and installation of operator’s seat assembly (except Turkey specification) 1123
Removal and installation of operator’s seat assembly (Turkey specification) 1124
Removal and installation of seat belt(except Turkey specification) 1125
Removal and installation of seat belt (Turkey specification) 1126
Work equipment 1127
Removal and installation of mast assembly 1127
Disassembly and assembly of mast assembly 1129
Removal and installation of chain(double mast) 1133
Removal and installation of chain(triple mast) 1135
Electrical system 1139
Removal and installation of engine controller assembly 1139
Removal and installation of HST controller assembly 1140
Removal and installation of KOMTRAX terminal assembly 1141
Disassembly and assembly of conditioner switch assembly 1143
60 Maintenance standard 1145
Contents 1146
Engine and cooling system 1147
Engine mount, PTO mount 1147
Cooling system 1148
Power train 1149
PTO 1149
HST pump 1151
HST motor 1153
Differential 1155
Steering system 1159
Orbitrol valve 1159
Power steering cylinder 1160
Brake system 1161
Brake pipings diagram 1161
Service brake 1162
Slack adjuster 1163
Parking brake 1164
Undercarriage and frame 1165
Rear axle 1165
Frame 1166
Hydraulic system 1167
Work equipment and steering pump 1167
Control valve 1168
Work equipment 1173
Tilt cylinder 1173
Lift cylinder 1174
Mast 1175
Fork 1176
80 Yearly inspection criteria 1177
Contents 1178
Precautions before work 1179
Yearly inspection criteria 1181
Yearly inspection criteria 1181
90 Diagrams and drawings 1201
Contents 1202
Hydraulic diagrams and drawings 1203
Symbols used in hydraulic circuit diagrams 1203
Hydraulic circuit diagram 1205
Electrical diagrams and drawings 1207
Symbols used in electrical circuit diagrams 1207
Electric circuit diagram 1211
Index 1253

DESCRIPTION:

Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Shop Manual SEN06571-10 – PDF DOWNLOAD 

SERIAL NUMBERS 140001 and up

Foreword, safety, basic information
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided
into the following chapters for the ease of use.
00 Index and foreword
This section describes the index, foreword, safety, and basic information.
01 Specifications
This section describes the specifications of the machine.
10 Structure and function
This section describes the structure and operation of each component with respect to each system.
“Structure and function” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 Standard value table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and
judge troubles in troubleshooting.
30 Testing and adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the
adjusting method of each part. The standard values and repair limit for “Testing and adjusting” are described
in “Standard value table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal,
installation, disassembly, and assembly of the components and parts. In addition, tightening torques,
quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance standard
This section describes the maintenance standard value of each component. The maintenance standard
shows the criteria and remedies for disassembly and assembly.
80 Yearly inspection criteria
This section describes the items, contents and criteria of the specific self-imposed inspection.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL:

S.V 22/12/24