Komatsu FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06282-00 – PDF DOWNLOAD

Description

Komatsu FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06282-00 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06282-00 – PDF DOWNLOAD

Applicable model Serial number
FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 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 FH40-1 FH45-1 FH50-1 Forklift Truck Shop Manual SEN06282-00 – PDF DOWNLOAD

00 Index and foreword
Table of contents 00-2
Table of contents 00-2
Foreword and general information 00-9
Safety notice 00-9
How to read the shop manual 00-20
Explanation of terms for maintenance standard 00-22
Handling of electric equipment and hydraulic component 00-24
Handling of connectors newly used for engines 00-33
How to read electric wire code 00-36
Precautions when carrying out operation 00-39
Standard tightening torque table 00-42
Conversion table 00-46
01 General Information
Specifications 01-3
Specification dimensions drawing 01-3
Weight table 01-5
Lubricant list 01-6
List of specified fuel and lubricant 01-7
10 Structure, function and maintenance standard
Engine and cooling system 10-4
Engine mount and transfer mount 10-4
Cooling system 10-6
Power train 10-8
Power train 10-8
Power train system diagram 10-9
PTO 10-10
HST piping diagram 10-13
HST pump 10-14
HST motor 10-26
Axle 10-36
Differential 10-37
Steering system 10-43
Steering piping diagram (control valve – power steering cylinder) 10-43
Orbitrol valve 10-44
Power steering cylinder 10-46
Brake system 10-47
Brake control 10-47
Brake piping diagram (control valve – accumulator) 10-48
Service brake 10-50
Accumulator charge valve 10-52
Brake valve 10-58
Slack adjuster 10-61
Accumulator (for brake) 10-65
Parking brake 10-66
Undercarriage and frame 10-67
Rear axle 10-67
Hydraulic tank piping diagram 10-68
Frame 10-69
Hydraulic system 10-70
Control valve piping diagram (tank – control valve) 10-70
Work equipment piping diagram (control valve – tilt cylinder/lift cylinder) 10-71
FH40-1, FH45-1, FH50-1 00-3
Table of contents
Table of contents
Attachment piping diagram 10-72
Work equipment control lever linkage 10-73
Work equipment and steering pump 10-74
Control valve 10-82
CLSS 10-88
Each function and operation of each valve 10-90
Work equipment 10-105
Tilt cylinder 10-105
Lift cylinder 10-106
Mast 10-107
Finger board 10-114
Fork 10-115
Electrical system 10-116
Electrical control system 10-116
HST controller 10-138
Engine controller 10-140
Accelerator pedal sensor 10-142
EPACS controller 10-144
Instrument panel 10-146
Pilot box 10-148
DC/DC converter 10-149
KOMTRAX system 10-150
Sensor 10-153
Combination switch 10-163
Seat switch 10-164
Service switch/Preheater lamp 10-165
Flasher unit 10-166
Relay box 10-167
Relay 10-168
20 Standard value table
Standard value table 20-3
Standard value table 20-3
30 Testing and adjusting
Testing and adjusting 30-3
Check of failure code of engine controller 30-3
Displaying, setting, checking by using HST controller 30-6
Travel speed control function for general operator
(description in Operation and Maintenance Manual of the lift truck) 30-8
Setting controlled travel speed 30-9
Maximum travel speed control function 30-11
Banning function of changing controlled travel speed 30-14
Electrical-system abnormality record display function (only for HST controller system) 30-16
Mechanical-system abnormality record display function 30-22
Adjusting function 30-23
Memory clear function 30-30
Automatic engine stop set interval changing function 30-33
Releasing pressure from hydraulic piping 30-35
Replacement of engine oil and engine oil filter 30-36
Replacement of fuel filter 30-38
Fuel pre-filter water drain 30-40
Fuel filter air bleeding 30-41
Cleaning of water separator strainer 30-42
Radiator cleaning 30-43
Air cleaner inspection and element replacement 30-44
Testing and adjusting engine speed 30-45
Testing and adjusting HST oil pressure 30-47
00-4 FH40-1, FH45-1, FH50-1
Table of contents
Table of contents
Testing work equipment and steering pump oil pressure 30-50
Oil level check and changing oil in differential case 30-51
Changing PTO oil and cleaning strainer 30-52
Inspection of hydraulic tank 30-53
Measuring brake performance 30-55
Measurement of wear of service brake disc 30-56
Checking parking brake 30-57
Bleeding air 30-58
Adjusting brake pedal 30-59
Testing and adjusting brake pedal angle sensor linkage 30-60
Initial setting of Orbitrol valve 30-62
Measurement of hydraulic drift and forward tilt down by hydraulic drift of cylinder 30-63
Adjustment of mast 30-64
Adjustment of fork carriage 30-67
Lamp display of KOMTRAX terminal 30-69
KOMTRAX terminal start-up procedure 30-72
40 Troubleshooting
Information related to troubleshooting 40-5
Points to remember when troubleshooting 40-5
How to proceed in troubleshooting 40-6
Checks before troubleshooting 40-7
Classification and procedures of troubleshooting 40-8
Phenomena seemed to be failures and troubleshooting Nos 40-9
Information described in troubleshooting table 40-12
Locations of fuses 40-17
Connector pin connection by pin No 40-20
T-branch box and T-branch adapter table 40-60
Troubleshooting by failure code (HST controller system) 40-63
Failure code list 40-63
Failure code [–/AB00MA] Alternator: Malfunction 40-66
Failure code [–/B@CRNS] HST Oil: Overheating 40-67
Failure code [–/2G40ZG] Brake accumulator: Dropped hydraulic pressure 40-68
Failure code [–/6091NX] Hst oil filter: Clogging 40-69
Failure code [12/DDK6KA] FNR lever: Open circuit 40-70
Failure code [12/DDK6KY] FNR lever: Hot short circuit 40-74
Failure code [14/DLT4KZ] Travel speed sensor A:
Open circuit, ground fault, or hot short circuit 40-76
Failure code [14/DLT6KZ] Travel speed sensor B:
Open circuit, ground fault, or hot short circuit 40-78
Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B:
Open circuit, ground fault, or hot short circuit 40-80
Failure code [14/DLT4MA] Travel speed sensors A and B: Malfunction 40-82
Failure code [14/DLT4LC] Travel speed sensors A and B: Mismatch of rotation speed signals 40-83
Failure code [15/7REXKA] Seat switch: Open circuit 40-84
Failure code [15/7REXKB] Seat switch: Ground fault 40-86
Failure code [18/D5ZTKZ] Pump EPC valve ground return signal:
Open circuit or hot short circuit 40-88
Failure code [22/DHHBKX] HST pump A-port pressure sensor: Open circuit or ground fault 40-90
Failure code [22/DHHBKY] HST pump A-port pressure sensor: Hot short circuit 40-92
Failure code [23/DHHCKX] HST pump B-port pressure sensor: Open circuit or ground fault 40-94
Failure code [23/DHHCKY] HST pump B-port pressure sensor: Hot short circuit 40-96
Failure code [25/DK70KZ] Brake pedal angle sensor: Open circuit or ground fault 40-98
Failure code [25/DK70KY] Brake pedal angle sensor: Hot short circuit 40-100
Failure code [26/DGS1KA] HST oil temperature sensor: Open circuit 40-102
Failure code [26/DGS1KB] HST oil temperature sensor: Ground fault 40-104
Failure code [27/AB00KZ] Alternator R signal circuit: Open circuit or ground fault 40-106
Failure code [27/AB00KY] Alternator R signal circuit: Hot short circuit 40-108
FH40-1, FH45-1, FH50-1 00-5
Table of contents
Table of contents
Failure code [28/DHPCKZ] Lift cylinder pressure sensor: Open circuit or ground fault 40-110
Failure code [28/DHPCKY] Lift cylinder pressure sensor: Hot short circuit 40-112
Failure code [29/DH2FKZ] Brake charge pressure sensor: Open circuit or ground fault 40-114
Failure code [29/DH2FKY] Brake charge pressure sensor: Hot short circuit 40-116
Failure code [32/DXATKA] HST pump forward travel EPC solenoid valve: Open circuit 40-118
Failure code [32/DXATKB] HST pump forward travel EPC solenoid valve: Ground fault 40-120
Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve: Hot short circuit 40-122
Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid valve: Open circuit 40-124
Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid valve: Ground fault 40-126
Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid valve: Hot short circuit 40-128
Failure code [34/DXAVKA] HST motor EPC solenoid valve: Open circuit 40-130
Failure code [34/DXAVKB] HST motor EPC solenoid valve: Ground fault 40-132
Failure code [34/DXAVKY] HST motor EPC solenoid valve: Hot short circuit 40-134
Failure code [35/D110KZ] HST controller power relay: Open circuit or hot short circuit 40-136
Failure code [35/D110KB] HST controller power relay: Ground fault 40-138
Failure code [37/DW9NKA] Work equipment lock solenoid valve: Open circuit 40-140
Failure code [37/DW9NKB] Work equipment lock solenoid valve: Ground fault 40-142
Failure code [37/DW9NKY] Work equipment lock solenoid valve: Hot short circuit 40-144
Failure code [38/DW9MKA] Lift lock solenoid valve: Open circuit 40-145
Failure code [38/DW9MKB] Lift lock solenoid valve: Ground fault 40-146
Failure code [38/DW9MKY] Lift lock solenoid valve: Hot short circuit 40-148
Failure code [39/D140KB] Starter relay: Ground fault 40-150
Failure code [39/D140KY] Starter relay: Hot short circuit 40-152
Failure code [47/D161KA] Backup buzzer and backup lamp relay: Open circuit 40-154
Failure code [47/D161KB] Backup buzzer and backup lamp relay: Ground fault 40-156
Failure code [47/D161KY] Backup buzzer and backup lamp relay: Hot short circuit 40-158
Failure code [48/DV00KB] Warning buzzer: Ground fault 40-160
Failure code [48/DV00KY] Warning buzzer: Hot short circuit 40-161
Failure code [49/D19UKA] Pump EPC valve ground cutout relay: Open circuit 40-162
Failure code [49/D19UKB] Pump EPC valve ground cutout replay: Ground fault 40-164
Failure code [49/D19UKY] Pump EPC valve ground cutout relay: Hot short circuit 40-166
Failure code [52/DAJ0KK] HST controller: Drop of power voltage 40-168
Failure code [53/DAJ2KK] HST controller: Drop of load power supply voltage 40-170
Failure code [54/7REHKA] Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit 40-172
Failure code [55/DAJ5KX] HST controller sensor 5 V-power supply:
Ground fault or hot short circuit 40-174
Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL): Open circuit 40-176
Failure code [62/DB2RKR] CAN communication (between HST controller and
engine controller): Communication failure (Component system failure) 40-178
Failure code [63/DAJ000] HST Controller: Memory error 40-180
Failure code [63/DAJ0KT] HST Controller: Memory error 40-181
Troubleshooting by failure code (EPACS controller system) 40-182
Display of EPACS controller failure code 40-182
Failure code [LED: OFF] EPACS controller abnormality 40-183
Failure code [LED: 1 flashing] Initialization is not completed 40-184
Failure code [LED: 2 flashings] Controller is being initialized 40-185
Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality 40-186
Failure code [LED: 4 flashings] Tire angle sensor abnormality 40-188
Troubleshooting for electrical system (E-mode) 40-190
Information described in troubleshooting table 40-190
E-1 Engine does not start 40-191
E-2 Engine preheater does not operate 40-196
E-3 Parking brake reminder alarm does not sound or does not stop sounding 40-198
E-4 EPACS is abnormal 40-201
E-5 Headlamp, clearance lamp, tail lamp and license plate lamp do not light up or go off 40-204
E-6 Turn signal lamps do not light up or go off 40-210
E-7 Brake lamps do not light up or go off 40-214
E-8 Backup lamps do not light up or go off 40-216
00-6 FH40-1, FH45-1, FH50-1
Table of contents
Table of contents
E-9 Backup buzzer does not sound or does not stop sounding 40-218
E-10 Horn does not sound or does not stop sounding 40-220
E-11 Fuel level is not displayed normally 40-222
E-12 Engine coolant temperature level is not displayed normally 40-224
E-13 All of indicator and warning lamps of instrument panel do not light up
when starting switch is turned to the ON position 40-226
E-14 When starting switch is turned to the ON position,
all of indicator and warning lamps of pilot box do not light up 40-233
E-15 When starting switch is turned to the ON position,
engine preheater lamp does not light up 40-238
E-16 When starting switch is turned to the ON position, alarm buzzer does not sound 40-240
E-17 Backup lamp of instrument panel does not light up 40-242
E-18 Charge warning lamp lights up while engine is running 40-244
E-19 HST oil temperature warning lamp lights up while engine is running 40-246
E-20 HST oil filter clogging warning lamp lights up while engine is running 40-247
E-21 Engine oil pressure warning lamp lights up while engine is running 40-248
E-22 Sedimenter (water separator) warning lamp lights up while engine is running 40-248
E-23 Abnormality warning lamp lights up while engine is running 40-250
E-24 Engine abnormality warning lamp lights up while engine is running 40-252
E-25 Travel speed restriction cannot be released or enabled 40-254
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 40-256
E-27 KOMTRAX system does not operate normally 40-259
Troubleshooting for hydraulic and mechanical system (H-mode) 40-261
How to use troubleshooting table 40-261
Hydraulic and mechanical system diagram 40-264
Table of failure modes and causes 40-266
H-1 Lift truck cannot travel 40-270
H-2 Slow travel speed 40-271
H-3 Insufficient towing force 40-272
H-4 Engine stops during traveling, or engine speed drops excessively 40-273
H-5 HST (hydraulic) oil temperature is too high 40-274
H-6 Impossible steering 40-275
H-7 Response is low during turning 40-276
H-8 Steering is heavy 40-277
H-9 Unstable during turning 40-278
H-10 When steering wheel is released it does not return to neutral or it rotates by itself 40-279
H-11 Steering wheel is turned in reverse or it kicks (while work equipment is operated) 40-279
H-12 Large shock is made when steering wheel is returned 40-280
H-13 EPACS does not work 40-281
H-14 Steering wheel vibrates 40-282
H-15 Steering system makes abnormal sound 40-282
H-16 Oil leaks from steering circuit 40-282
H-17 Service brake does not work or its performance is low 40-283
H-18 Service brake is not reset or it drags 40-284
H-19 Parking brake does not work or its performance is low 40-285
H-20 Parking brake is not reset or it drags 40-286
H-21 Abnormal noise around the work equipment or steering pump 40-287
H-22 Engine speed drops excessively or stops during work equipment operation
or wheel steering 40-288
H-23 Fine control performance of entire work equipment is low or response is low 40-289
H-24 Work equipment cannot be locked (and the equipment operates when operator leaves) 40-290
H-25 Control valve lever does not move smoothly and it is heavy 40-291
H-26 Lift cylinder and fork do not lift 40-292
H-27 Lifting speed or power of lift cylinder and fork is insufficient 40-293
H-28 Forklift speed lowers at specific height 40-294
H-29 Lift cylinder natural drift is large 40-295
H-30 Lift cylinders do not come down 40-296
FH40-1, FH45-1, FH50-1 00-7
Table of contents
Table of contents
H-31 Fork lowering speed is low or high or fine control performance is low or response is low 40-297
H-32 Mast does not tilt forward or backward 40-298
H-33 Forward/backward tilting speed or force of mast is insufficient 40-299
H-34 Tilting speed lowers halfway 40-300
H-35 Tilt cylinder natural forward drift is large 40-301
H-36 Mast is unstable during travel with load 40-302
H-37 Work equipment is heavy when work equipment and
steering are operated simultaneously 40-303
H-38 Steering is heavy when work equipment and steering are operated simultaneously 40-304
50 Disassembly and assembly
Related information on disassembly and assembly 50-3
How to read this manual 50-3
Coating materials list 50-4
Special tools list 50-7
How to use Loctite 50-9
Engine and cooling system 50-10
Removal and installation of fuel supply pump assembly 50-10
Removal and installation of fuel injector assembly 50-14
Removal and installation of cylinder head assembly 50-18
Removal and installation of of radiator assembly 50-29
Removal and installation of aftercooler assembly 50-31
Removal and installation of oil cooler assembly 50-34
Removal and installation of engine and pump assembly 50-35
Removal and installation of starting motor assembly 50-43
Power train 50-46
Removal and installation of front axle and HST motor assembly 50-46
Disassembly and assembly of front axle assembly 50-49
Removal and installation of PTO assembly 50-50
Disassembly and assembly of PTO assembly 50-51
Disassembly and assembly of differential assembly 50-54
Disassembly and assembly of axle housing assembly 50-67
Disassembly and assembly of parking brake assembly 50-74
Disassembly and assembly of rear axle assembly 50-75
Disassembly and assembly of power steering cylinder assembly 50-78
Disassembly and assembly of brake pedal assembly 50-80
Undercarriage and frame 50-81
Removal and installation of counterweight assembly 50-81
Removal and installation of head guard assembly 50-83
Removal and installation of hood assembly 50-87
Hydraulic system 50-89
Removal and installation of HST pump assembly 50-89
Removal and installation of HST motor assembly 50-93
Removal and installation of work equipment and steering pump assembly 50-94
Removal and installation of control valve assembly 50-96
Disassembly and assembly of control valve assembly 50-98
Disassembly and assembly of orbitrol valve assembly 50-104
Removal and installation of lift cylinder assembly 50-111
Disasse mbly and assembly of lift cylinder assembly 50-114
Disassembly and assembly of tilt cylinder assembly 50-115
Work equipment 50-120
Removal and installation of mast assembly 50-120
Disassembly and assembly of mast assembly 50-122
Electrical system 50-126
Removal and installation of engine controller assembly 50-126
Removal and installation of HST controller assembly 50-128
Removal and installation of KOMTRAX terminal assembly 50-129
Disassembly and assembly of combination switch assembly 50-130
00-8 FH40-1, FH45-1, FH50-1
Table of contents
Table of contents
80 Yearly inspection criteria
Yearly inspection criteria 80-3
Yearly inspection criteria 80-3
90 Circuit diagrams
Hydraulic circuit diagram 90-3
Hydraulic circuit diagram 90-3
Electrical circuit diagram 90-5
Electric circuit diagram (1/4) 90-5
Electric circuit diagram (2/4) 90-7
Electric circuit diagram (3/4) 90-9
Electric circuit diagram (4/4) 90-11
Connector list and layout 90-13
Index
Index 1

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