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

Description

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

FILE DETAILS:

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

Language : English
Pages : 781
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

SEN06282-00 2
00 Index and foreword 2
Table of contents 3
Table of contents 3
Foreword and general information 10
Safety notice 10
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
How to read electric wire code 37
Precautions when carrying out operation 40
Standard tightening torque table 43
Conversion table 47
01 General Information 52
Table of Contents 53
Specifications 54
Specification dimensions drawing 54
Weight table 56
Lubricant list 57
List of specified fuel and lubricant 58
10 Structure,function and maintenance standard 60
Table of Contents 61
Engine and cooling system 63
Engine mount and transfer mount 63
Cooling system 65
Power train 67
Power train 67
Power train system diagram 68
PTO 69
HST piping diagram 72
HST pump 73
HST motor 85
Axle 95
Differential 96
Steering system 102
Steering piping diagram (control valve-power steering cylinder) 102
Orbitrol valve 103
Power steering cylinder 105
Brake system 106
Brake control 106
Brake piping diagram (control valve-accumulator) 107
Service brake 109
Accumulator charge valve 111
Brake valve 117
Slack adjuster 120
Accumulator (for brake) 124
Parking brake 125
Undercarriage and frame 126
Rear axle 126
Hydraulic tank piping diagram 127
Frame 128
Hydraulic system 129
Control valve piping diagram (tank-control valve) 129
Work equipment piping diagram (control valve-tilt cylinder/lift cylinder) 130
Attachment piping diagram 131
Work equipment control lever linkage 132
Work equipment and steering pump 133
Control valve 141
CLSS 147
Each function and operation of each valve 149
Work equipment 164
Tilt cylinder 164
Lift cylinder 165
Mast 166
Finger board 173
Fork 174
Electrical system 175
Electrical control system 175
HST controller 197
Engine controller 199
Accelerator pedal sensor 201
EPACS controller 203
Instrument panel 205
Pilot box 207
DC/DC converter 208
KOMTRAX system 209
Sensor 212
Combination switch 222
Seat switch 223
Service switch/Preheater lamp 224
Flasher unit 225
Relay box 226
Relay 227
20 Standard value table 230
Table of Contents 231
Standard value table 232
Standard value table 232
30 Testing and adjusting 234
Table of Contents 235
Testing and adjusting 236
Check of failure code of engine controller 236
Displaying,setting,checking by using HST controller 239
Travel speed control function for general operator (description in Operation and Maintenance Manual of the lift truck) 241
Setting controlled travel speed 242
Maximum travel speed control function 244
Banning function of changing controlled travel speed 247
Electrical-system abnormality record display function (only for HST controller system) 249
Mechanical-system abnormality record display function 255
Adjusting function 256
Memory clear function 263
Automatic engine stop set interval changing function 266
Releasing pressure from hydraulic piping 268
Replacement of engine oil and engine oil filter 269
Replacement of fuel filter 271
Fuel pre-filter water drain 273
Fuel filter air bleeding 274
Cleaning of water separator strainer 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 310
Table of Contents 311
Information related to troubleshooting 314
Points to remember when troubleshooting 314
How to proceed in troubleshooting 315
Checks before troubleshooting 316
Classification and procedures of troubleshooting 317
Phenomena seemed to be failures and troubleshooting Nos 318
Information described in troubleshooting table 321
Locations of fuses 326
Connection table for connector pin numbers 329
T-branch box and T-branch adapter table 369
Troubleshooting by failure code (HST controller system) 372
Failure code list 372
Failure code [–/AB00MA] Alternator: Malfunction 375
Failure code [–/B@CRNS] HST Oil: Overheating 376
Failure code [–/2G40ZG] Brake accumulator: Dropped hydraulic pressure 377
Failure code [–/6091NX] Hst oil filter: Clogging 378
Failure code [12/DDK6KA] FNR lever: Open circuit 379
Failure code [12/DDK6KY] FNR lever: Hot short circuit 383
Failure code [14/DLT4KZ] Travel speed sensor A:Open circuit,ground fault,or hot short circuit 385
Failure code [14/DLT6KZ] Travel speed sensor B:Open circuit, ground fault, or hot short circuit 387
Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B:Open circuit,ground fault, or hot short circuit 389
Failure code [14/DLT4MA] Travel speed sensors A and B: Malfunction 391
Failure code [14/DLT4LC] Travel speed sensors A and B: Mismatch of rotation speed signals 392
Failure code [15/7REXKA] Seat switch: Open circuit 393
Failure code [15/7REXKB] Seat switch: Ground fault 395
Failure code [18/D5ZTKZ] Pump EPC valve ground return signal:Open circuit or hot short circuit 397
Failure code [22/DHHBKX] HST pump A-port pressure sensor: Open circuit or ground fault 399
Failure code [22/DHHBKY] HST pump A-port pressure sensor: Hot short circuit 401
Failure code [23/DHHCKX] HST pump B-port pressure sensor: Open circuit or ground fault 403
Failure code [23/DHHCKY] HST pump B-port pressure sensor: Hot short circuit 405
Failure code [25/DK70KZ] Brake pedal angle sensor: Open circuit or ground fault 407
Failure code [25/DK70KY] Brake pedal angle sensor: Hot short circuit 409
Failure code [26/DGS1KA] HST oil temperature sensor: Open circuit 411
Failure code [26/DGS1KB] HST oil temperature sensor: Ground fault 413
Failure code [27/AB00KZ] Alternator R signal circuit: Open circuit or ground fault 415
Failure code [27/AB00KY] Alternator R signal circuit: Hot short circuit 417
Failure code [28/DHPCKZ] Lift cylinder pressure sensor: Open circuit or ground fault 419
Failure code [28/DHPCKY] Lift cylinder pressure sensor: Hot short circuit 421
Failure code [29/DH2FKZ] Brake charge pressure sensor: Open circuit or ground fault 423
Failure code [29/DH2FKY] Brake charge pressure sensor: Hot short circuit 425
Failure code [32/DXATKA] HST pump forward travel EPC solenoid valve: Open circuit 427
Failure code [32/DXATKB] HST pump forward travel EPC solenoid valve: Ground fault 429
Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve: Hot short circuit 431
Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid valve: Open circuit 433
Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid valve: Ground fault 435
Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid valve: Hot short circuit 437
Failure code [34/DXAVKA] HST motor EPC solenoid valve: Open circuit 439
Failure code [34/DXAVKB] HST motor EPC solenoid valve: Ground fault 441
Failure code [34/DXAVKY] HST motor EPC solenoid valve: Hot short circuit 443
Failure code [35/D110KZ] HST controller power relay: Open circuit or hot short circuit 445
Failure code [35/D110KB] HST controller power relay: Ground fault 447
Failure code [37/DW9NKA] Work equipment lock solenoid valve: Open circuit 449
Failure code [37/DW9NKB] Work equipment lock solenoid valve: Ground fault 451
Failure code [37/DW9NKY] Work equipment lock solenoid valve: Hot short circuit 453
Failure code [38/DW9MKA] Lift lock solenoid valve: Open circuit 454
Failure code [38/DW9MKB] Lift lock solenoid valve: Ground fault 455
Failure code [38/DW9MKY] Lift lock solenoid valve: Hot short circuit 457
Failure code [39/D140KB] Starter relay: Ground fault 459
Failure code [39/D140KY] Starter relay: Hot short circuit 461
Failure code [47/D161KA] Backup buzzer and backup lamp relay: Open circuit 463
Failure code [47/D161KB] Backup buzzer and backup lamp relay: Ground fault 465
Failure code [47/D161KY] Backup buzzer and backup lamp relay: Hot short circuit 467
Failure code [48/DV00KB] Warning buzzer: Ground fault 469
Failure code [48/DV00KY] Warning buzzer: Hot short circuit 470
Failure code [49/D19UKA] Pump EPC valve ground cutout relay: Open circuit 471
Failure code [49/D19UKB] Pump EPC valve ground cutout replay: Ground fault 473
Failure code [49/D19UKY] Pump EPC valve ground cutout relay: Hot short circuit 475
Failure code [52/DAJ0KK] HST controller: Drop of power voltage 477
Failure code [53/DAJ2KK] HST controller: Drop of load power supply voltage 479
Failure code [54/7REHKA] Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit 481
Failure code [55/DAJ5KX] HST controller sensor 5 V-power supply: Ground fault or hot short circuit 483
Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL): Open circuit 485
Failure code [62/DB2RKR] CAN communication (between HST controller and engine controller): Communication failure (Component system failure) 487
Failure code [63/DAJ000] HST Controller: Memory error 489
Failure code [63/DAJ0KT] HST Controller: Memory error 490
Troubleshooting by failure code (EPACS controller system) 491
Display of EPACS controller failure code 491
Failure code [LED: OFF] EPACS controller abnormality 492
Failure code [LED: 1 flashing] Initialization is not completed 493
Failure code [LED: 2 flashings] Controller is being initialized 494
Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality 495
Failure code [LED: 4 flashings] Tire angle sensor abnormality 497
Troubleshooting for electrical system (E-mode) 499
Information described in troubleshooting table 499
E-1 Engine does not start 500
E-2 Engine preheater does not operate 505
E-3 Parking brake reminder alarm does not sound or does not stop sounding 507
E-4 EPACS is abnormal 510
E-5 Headlamp,clearance lamp,tail lamp and license plate lamp do not light up or go off 513
E-6 Turn signal lamps do not light up or go off 519
E-7 Brake lamps do not light up or go off 523
E-8 Backup lamps do not light up or go off 525
E-9 Backup buzzer does not sound or does not stop sounding 527
E-10 Horn does not sound or does not stop sounding 529
E-11 Fuel level is not displayed normally 531
E-12 Engine coolant temperature level is not displayed normally 533
E-13 All of indicator and warning lamps of instrument panel do not light up when starting switch is turned to the ON position 535
E-14 When starting switch is turned to the ON position,all of indicator and warning lamps of pilot box do not light up 542
E-15 When starting switch is turned to the ON position,engine preheater lamp does not light up 547
E-16 When starting switch is turned to the ON position, alarm buzzer does not sound 549
E-17 Backup lamp of instrument panel does not light up 551
E-18 Charge warning lamp lights up while engine is running 553
E-19 HST oil temperature warning lamp lights up while engine is running 555
E-20 HST oil filter clogging warning lamp lights up while engine is running 556
E-21 Engine oil pressure warning lamp lights up while engine is running 557
E-22 Sedimenter (water separator) warning lamp lights up while engine is running 557
E-23 Abnormality warning lamp lights up while engine is running 559
E-24 Engine abnormality warning lamp lights up while engine is running 561
E-25 Travel speed restriction cannot be released or enabled 563
E-26 Impossible to select HST controller failure display mode, HST controlleradjustment mode, speed limit setting mode,or engine stop time auto-change mode 565
E-27 KOMTRAX system does not operate normally 568
Troubleshooting for hydraulic and mechanical system (H-mode) 570
How to use troubleshooting table 570
Hydraulic and mechanical system diagram 573
Table of failure modes and causes 575
H-1 Lift truck cannot travel 579
H-2 Slow travel speed 580
H-3 Insufficient towing force 581
H-4 Engine stops during traveling, or engine speed drops excessively 582
H-5 HST (hydraulic) oil temperature is too high 583
H-6 Impossible steering 584
H-7 Response is low during turning 585
H-8 Steering is heavy 586
H-9 Unstable during turning 587
H-10 When steering wheel is released it does not return to neutral or it rotates by itself 588
H-11 Steering wheel is turned in reverse or it kicks (while work equipment is operated) 588
H-12 Large shock is made when steering wheel is returned 589
H-13 EPACS does not work 590
H-14 Steering wheel vibrates 591
H-15 Steering system makes abnormal sound 591
H-16 Oil leaks from steering circuit 591
H-17 Service brake does not work or its performance is low 592
H-18 Service brake is not reset or it drags 593
H-19 Parking brake does not work or its performance is low 594
H-20 Parking brake is not reset or it drags 595
H-21 Abnormal noise around the work equipment or steering pump 596
H-22 Engine speed drops excessively or stops during work equipment operation or wheel steering 597
H-23 Fine control performance of entire work equipment is low or response is low 598
H-24 Work equipment cannot be locked (and the equipment operates when operator leaves) 599
H-25 Control valve lever does not move smoothly and it is heavy 600
H-26 Lift cylinder and fork do not lift 601
H-27 Lifting speed or power of lift cylinder and fork is insufficient 602
H-28 Forklift speed lowers at specific height 603
H-29 Lift cylinder natural drift is large 604
H-30 Lift cylinders do not come down 605
H-31 Fork lowering speed is low or high or fine control performance is low or response is low 606
H-32 Mast does not tilt forward or backward 607
H-33 Forward/backward tilting speed or force of mast is insufficient 608
H-34 Tilting speed lowers halfway 609
H-35 Tilt cylinder natural forward drift is large 610
H-36 Mast is unstable during travel with load 611
H-37 Work equipment is heavy when work equipment and steering are operated simultaneously 612
H-38 Steering is heavy when work equipment and steering are operated simultaneously 613
50 Disassembly and assembly 614
Table of Contents 615
Related information on disassembly and assembly 616
How to read this manual 616
Coating materials list 617
Special tools list 620
How to use Loctite 622
Engine and cooling system 623
Removal and installation of fuel supply pump assembly 623
Removal and installation of fuel injector assembly 627
Removal and installation of cylinder head assembly 631
Removal and installation of of radiator assembly 642
Removal and installation of aftercooler assembly 644
Removal and installation of oil cooler assembly 647
Removal and installation of engine and pump assembly 648
Removal and installation of starting motor assembly 656
Power train 659
Removal and installation of front axle and HST motor assembly 659
Disassembly and assembly of front axle assembly 662
Removal and installation of PTO assembly 663
Disassembly and assembly of PTO assembly 664
Disassembly and assembly of differential assembly 667
Disassembly and assembly of axle housing assembly 680
Disassembly and assembly of parking brake assembly 687
Disassembly and assembly of rear axle assembly 688
Disassembly and assembly of power steering cylinder assembly 691
Disassembly and assembly of brake pedal assembly 693
Undercarriage and frame 694
Removal and installation of counterweight assembly 694
Removal and installation of head guard assembly 696
Removal and installation of hood assembly 700
Hydraulic system 702
Removal and installation of HST pump assembly 702
Removal and installation of HST motor assembly 706
Removal and installation of work equipment and steering pump assembly 707
Removal and installation of control valve assembly 709
Disassembly and assembly of control valve assembly 711
Disassembly and assembly of orbitrol valve assembly 717
Removal and installation of lift cylinder assembly 724
Disasse mbly and assembly of lift cylinder assembly 727
Disassembly and assembly of tilt cylinder assembly 728
Work equipment 733
Removal and installation of mast assembly 733
Disassembly and assembly of mast assembly 735
Electrical system 739
Removal and installation of engine controller assembly 739
Removal and installation of HST controller assembly 741
Removal and installation of KOMTRAX terminal assembly 742
Disassembly and assembly of combination switch assembly 743
80 Yearly inspection criteria 744
Table of Contents 745
Yearly inspection criteria 746
Yearly inspection criteria 746
90 Circuit diagrams 766
Table of Contents 767
Hydraulic circuit diagram 768
Hydraulic circuit diagram 768
Electrical circuit diagram 769
Electric circuit diagram (1/4) 769
Electric circuit diagram (2/4) 770
Electric circuit diagram (3/4) 771
Electric circuit diagram (4/4) 772
Connector list and layout 773
Index 774
BACK COVER 781

DESCRIPTION:

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

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.

S.V 26/12/24