Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SEN06640-08 PDF

Description

Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SEN06640-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SEN06640-08 – PDF DOWNLOAD 

Language : English
Pages : 1532
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SEN06640-08 – PDF DOWNLOAD 

SERIAL NUMBERS
FH60-51001 and up
FH70-51001 and up
FH80-51001 and up

Cover 1
00 Index and foreword 3
Index 4
List of abbreviations 16
Foreword, safety and general information 21
How to read the shop manual 21
Precautions related to work safety 23
Fire prevention 32
If a fire breaks out 34
Instructions for waste disposal 35
Instructions for handling hydraulic components 36
Instructions for disconnecting and connecting piping 38
Instructions for handling electric components 46
Instructions for handling fuel system components 48
Instructions for handling intake system components 49
Use of KOMTRAX 50
Disconnecting and connecting push-pull type coupler 51
How to disconnect and connect Type 1 push-pull coupler 51
How to disconnect and connect Type 2 push-pull coupler 53
How to disconnect and connect Type 3 push-pull coupler 54
Instructions for disconnecting and connecting connectors 55
How to disconnect and connect DT connectors 60
How to disconnect and connect slide lock type connectors 61
How to disconnect and connect connectors that require pulling lock 63
How to disconnect and connect connectors that require pressing lock 64
How to disconnect and connect connectors that require turning housing 66
How to read electric wire code 67
Explanation of terms for maintenance standard 73
Standard tightening torque table 75
Unit conversion table 82
01 Specification 87
Contents 88
List of abbreviations 89
Specifications 94
Specification drawing 94
Specification drawing: FH60-2 94
Specification drawing: FH70-2 96
Specification drawing: FH80-2 98
Specifications 100
Specifications: FH60-2 100
Specifications: FH70-2 104
Specifications: FH80-2 108
Weight table 112
Weight table: FH60-2 112
Weight table: FH70-2 113
Weight table: FH80-2 114
Fuel, coolant, and lubricant 115
Contents 120
List of abbreviations 123
Starting system 128
Starting system component layout drawing 128
Preheating system 129
Automatic warm-up system diagram 129
Function of automatic warm-up system 130
Automatic preheating system diagram 131
Function of automatic preheating system 131
Engine system 132
Engine system component layout drawing 132
Engine control system 133
Engine control system diagram 133
Function of engine control system 133
Operation of engine control system 134
Automatic engine stop system 135
Automatic engine stop system diagram 135
Operation of automatic engine stop system 136
Engine system components 138
Variable flow turbocharger 138
EGR system 142
EGR valve 145
EGR cooler 147
KCCV system 149
KCCV ventilator 151
KDOC muffler 153
Cooling system 155
Cooling system component layout drawing 155
Specification of cooling system 156
Control system 157
Control system component layout drawing 157
Monitor panel system 158
Monitor panel system drawing 158
KOMTRAX system 159
KOMTRAX system diagram 159
Function of KOMTRAX system 159
Seat belt interlock system 160
Seat belt interlock system diagram 160
Function of seat belt interlock system 161
Operation of seat belt interlock system 161
Control system components 162
Monitor panel 162
KOMTRAX terminal 172
HST controller 174
Engine controller 178
Accelerator pedal 183
Hydraulic system 185
Hydraulic system component layout drawing 185
CLSS 186
Structure of CLSS 186
Function of CLSS 187
Hydraulic system components 188
Hydraulic tank 188
Steering and work equipment pump 189
Control valve 200
Power train system 218
Power train system component layout drawing 218
Operation of power train system 219
Travel speed limit system 220
Travel speed limit system diagram 220
Function of travel speed limit system 220
Directional lever neutral alarm system 221
Directional lever neutral alarm system diagram 221
Function of directional lever neutral alarm system 221
Travel interlock system 222
Travel interlock system diagram 222
Function of travel interlock system 223
Power train system components 224
HST pump 224
HST charge and brake double type pump 236
HST motor 237
Front axle 248
Differential 250
Final drive 252
Combination switch 253
Work equipment system 254
Work equipment system component layout drawing 254
Structure of valve control 255
Lift interlock system 256
Lift interlock system diagram 256
Operation of lift interlock system 257
Work equipment system components 258
Work equipment lock solenoid valve 258
Pilot circuit accumulator 260
Work equipment PPC valve 261
Steering system 264
Steering system component layout drawing 264
Steering column 265
Structure of steering column 265
Steering system componentS 266
Priority valve 266
Orbitrol valve 270
Rear axle 272
Brake system 274
Brake system component layout drawing 274
Parking brake reminder system 275
Parking brake reminder system diagram 275
Operation of parking brake reminder system 275
Parking brake dragging prevention system 277
Parking brake dragging prevention system diagram 277
Operation of parking brake dragging prevention system 278
Brake system components 279
Brake circuit accumulator charge valve 279
Brake circuit accumulator 284
Brake valve 285
Slack adjuster 287
Front brake 289
Structure of front brake 289
Parking brake 291
Brake cooling pump 292
Structure of brake cooling pump 292
Specification of brake cooling pump 292
Function of brake cooling pump 292
Undercarriage and frame 293
Structure of frame 293
Tire 294
Structure of bias tire 294
Work equipment 295
Structure of work equipment 295
10 Structure and function 119
Contents 120
List of abbreviations 123
Starting system 128
Starting system component layout drawing 128
Preheating system 129
Automatic warm-up system diagram 129
Function of automatic warm-up system 130
Automatic preheating system diagram 131
Function of automatic preheating system 131
Engine system 132
Engine system component layout drawing 132
Engine control system 133
Engine control system diagram 133
Function of engine control system 133
Operation of engine control system 134
Automatic engine stop system 135
Automatic engine stop system diagram 135
Operation of automatic engine stop system 136
Engine system components 138
Variable flow turbocharger 138
EGR system 142
EGR valve 145
EGR cooler 147
KCCV system 149
KCCV ventilator 151
KDOC muffler 153
Cooling system 155
Cooling system component layout drawing 155
Specification of cooling system 156
Control system 157
Control system component layout drawing 157
Monitor panel system 158
Monitor panel system drawing 158
KOMTRAX system 159
KOMTRAX system diagram 159
Function of KOMTRAX system 159
Seat belt interlock system 160
Seat belt interlock system diagram 160
Function of seat belt interlock system 161
Operation of seat belt interlock system 161
Control system components 162
Monitor panel 162
KOMTRAX terminal 172
HST controller 174
Engine controller 178
Accelerator pedal 183
Hydraulic system 185
Hydraulic system component layout drawing 185
CLSS 186
Structure of CLSS 186
Function of CLSS 187
Hydraulic system components 188
Hydraulic tank 188
Steering and work equipment pump 189
Control valve 200
Power train system 218
Power train system component layout drawing 218
Operation of power train system 219
Travel speed limit system 220
Travel speed limit system diagram 220
Function of travel speed limit system 220
Directional lever neutral alarm system 221
Directional lever neutral alarm system diagram 221
Function of directional lever neutral alarm system 221
Travel interlock system 222
Travel interlock system diagram 222
Function of travel interlock system 223
Power train system components 224
HST pump 224
HST charge and brake double type pump 236
HST motor 237
Front axle 248
Differential 250
Final drive 252
Combination switch 253
Work equipment system 254
Work equipment system component layout drawing 254
Structure of valve control 255
Lift interlock system 256
Lift interlock system diagram 256
Operation of lift interlock system 257
Work equipment system components 258
Work equipment lock solenoid valve 258
Pilot circuit accumulator 260
Work equipment PPC valve 261
Steering system 264
Steering system component layout drawing 264
Steering column 265
Structure of steering column 265
Steering system component layout drawing 266
Priority valve 266
Orbitrol valve 270
Rear axle 272
Brake system 274
Brake system component layout drawing 274
Parking brake reminder system 275
Parking brake reminder system diagram 275
Operation of parking brake reminder system 275
Parking brake dragging prevention system 277
Parking brake dragging prevention system diagram 277
Operation of parking brake dragging prevention system 278
Brake system components 279
Brake circuit accumulator charge valve 279
Brake circuit accumulator 284
Brake valve 285
Slack adjuster 287
Front brake 289
Structure of front brake 289
Parking brake 291
Brake cooling pump 292
Structure of brake cooling pump 292
Specification of brake cooling pump 292
Function of brake cooling pump 292
Undercarriage and frame 293
Structure of frame 293
Tire 294
Structure of bias tire 294
Work equipment 295
Structure of work equipment 295
20 Standard value table 297
Contents 298
List of abbreviations 299
Standard value table for engine 304
Standard value table for engine: FH60-2 304
Standard value table for engine: FH70-2 306
Standard value table for engine: FH80-2 308
Standard value table for machine 310
Standard value table for machine: FH60-2 310
Standard value table for machine: FH70-2 314
Standard value table for machine: FH80-2 318
30 Testing and adjusting 323
Contents 324
List of abbreviations 326
Related information on testing and adjusting 331
Tools for testing and adjusting 331
Engine and cooling system 336
Testing engine speed 336
Testing exhaust gas color 337
Testing and adjusting valve clearance 339
Testing compression pressure 341
Testing blowby pressure 344
Testing engine oil pressure 345
Visual check inside of egr valve 347
PROCEDURES FOR VISUAL CHECK INSIDE OF EGR VALVE 347
Clean inside of egr valve 349
PROCEDURES FOR CLEAN INSIDE OF EGR VALVE 349
Testing fuel pressure 352
Testing fuel return volume and leakage volume 354
Bleeding fuel system of air 358
Testing leakages from fuel system 360
Handling of cylinder cutout mode operation 362
Handling of no-injection cranking operation 363
Changing engine oil 364
Replacing engine oil filter 365
Replacing KCCV filter element 366
Replacement of fuel filter 368
Draining fuel prefilter of water 371
Bleeding fuel filter of air 372
Bleeding cooling circuit of air 373
Radiator cleaning 374
Testing air cleaner and cleaning and replacing element 375
Writing compensation values at replacement of injector and engine controller 380
Testing alternator belt 386
Testing auto-tensioner 387
Power train 388
Testing HST oil pressure 388
Testing oil in flywheel housing 392
Testing oil level and changing axle oil in differential case 393
Replacing front axle lubrication filter 395
Steering system 396
Testing steering wheel 396
Bleeding steering cylinder circuit of air 397
Testing and adjusting steering circuit oil pressure 398
Brake system 400
Bleeding brake circuit of air 400
Testing brake oil pressure 401
Testing accumulator charge pressure 403
Testing braking performance of brake 404
Testing wear of service brake disc 405
Testing and adjusting parking brake 406
Testing and adjusting brake pedal 408
Testing and adjusting brake pedal angle sensor linkage 410
Hydraulic system 412
Releasing remaining pressure from hydraulic piping 412
Changing hydraulic oil 413
Replacing hydraulic oil line filter 414
Cleaning hydraulic tank strainer 415
Testing hydraulic tank breather 417
Work equipment 418
Bleed air from lift cylinder 418
Testing hydraulic drift and hydraulic drift forward tilting of the hydraulic cylinder 419
Adjustment of mast 421
Adjustment of finger bar 424
Cab and its attachments 425
Testing lift lever and tilt lever 425
Electrical system 426
Setting and operation of monitor panel 426
KOMTRAX terminal start-up procedure 481
Handling of engine controller voltage circuit 486
Procedure for checking diode 487
40 Troubleshooting 489
Contents 490
List of abbreviations 497
Information related to troubleshooting 502
Points to remember when troubleshooting 502
How to proceed with troubleshooting 504
Check before troubleshooting 506
Classification and procedures of troubleshooting 508
Symptoms of failure and troubleshooting numbers 509
Information described in troubleshooting table 512
Locations of fuses (Except North America spec ) 514
Locations of fuses (North America spec ) 517
Connector list and layout 521
Connection table for connector pin No 532
T-box and T-adapter list 571
Failure codes table 575
Troubleshooting by failure code 584
Failure code [2G40ZG] 584
Failure code [6091NX] 585
Failure code [7REAKA] 586
Failure code [7REHKA] 588
Failure code [AB00KY] 590
Failure code [AB00MA] 592
Failure code [B@BAZG] 594
Failure code [B@BCNS] 595
Failure code [B@CRNS] 596
Failure code [CA115] 597
Failure code [CA122] 598
Failure code [CA123] 600
Failure code [CA131] 602
Failure code [CA132] 604
Failure code [CA144] 607
Failure code [CA145] 609
Failure code [CA153] 611
Failure code [CA154] 613
Failure code [CA187] 615
Failure code [CA221] 617
Failure code [CA222] 619
Failure code [CA227] 621
Failure code [CA234] 622
Failure code [CA238] 623
Failure code [CA239] 624
Failure code [CA271] 625
Failure code [CA272] 626
Failure code [CA322] 627
Failure code [CA324] 629
Failure code [CA331] 631
Failure code [CA332] 633
Failure code [CA343] 635
Failure code [CA351] 636
Failure code [CA352] 637
Failure code [CA356] 639
Failure code [CA357] 641
Failure code [CA386] 643
Failure code [CA428] 644
Failure code [CA429] 645
Failure code [CA431] 646
Failure code [CA432] 649
Failure code [CA435] 653
Failure code [CA441] 655
Failure code [CA442] 657
Failure code [CA449] 658
Failure code [CA451] 659
Failure code [CA452] 661
Failure code [CA466] 663
Failure code [CA515] 665
Failure code [CA516] 667
Failure code [CA553] 669
Failure code [CA555] 670
Failure code [CA556] 671
Failure code [CA559] 672
Failure code [CA689] 675
Failure code [CA691] 677
Failure code [CA692] 679
Failure code [CA697] 681
Failure code [CA698] 682
Failure code [CA731] 683
Failure code [CA778] 685
Failure code [CA1117] 687
Failure code [CA1695] 688
Failure code [CA1696] 689
Failure code [CA1843] 690
Failure code [CA1844] 692
Failure code [CA1896] 694
Failure code [CA1942] 698
Failure code [CA1961] 699
Failure code [CA2185] 700
Failure code [CA2186] 701
Failure code [CA2249] 703
Failure code [CA2272] 704
Failure code [CA2311] 706
Failure code [CA2349] 707
Failure code [CA2353] 709
Failure code [CA2357] 711
Failure code [CA2555] 712
Failure code [CA2556] 714
Failure code [CA2765] 716
Failure code [CA3419] 717
Failure code [CA3421] 719
Failure code [CA3724] 721
Failure code [CA3918] 723
Failure code [CA3919] 724
Failure code [CA3921] 725
Failure code [CA3922] 726
Failure code [CA3923] 728
Failure code [D110KA] 730
Failure code [D110KB] 732
Failure code [D140KB] 734
Failure code [D140KY] 736
Failure code [D160KA] 739
Failure code [D160KB] 741
Failure code [D160KY] 743
Failure code [D161KB] 745
Failure code [D161KY] 746
Failure code [D190KB] 747
Failure code [D190KY] 748
Failure code [D19SKB] 749
Failure code [D19SKY] 750
Failure code [D19TKB] 751
Failure code [D19TKY] 752
Failure code [D19UKA] 753
Failure code [D19UKB] 755
Failure code [D19UKY] 757
Failure code [D5XWKA] (Except North America spec ) 759
Failure code [D5XWKA] (North America spec ) 762
Failure code [D5XWKB] (Except North America spec ) 765
Failure code [D5XWKB] (North America spec ) 767
Failure code [D5XXKA] 769
Failure code [D5XXKB] 770
Failure code [D5XYL4] 771
Failure code [D5ZKKA] 772
Failure code [D5ZKKB] 774
Failure code [D5ZTKA] 775
Failure code [D811MC] 777
Failure code [D862KA] 778
Failure code [D8ALKA] 779
Failure code [D8ALKB] 780
Failure code [D8AQK4] 781
Failure code [D8AQKR] 786
Failure code [DAF0KT] 791
Failure code [DAF0MB] 792
Failure code [DAF0MC] 793
Failure code [DAF3KK] 794
Failure code [DAFGMC] 796
Failure code [DAFLKA] 797
Failure code [DAFLKB] 798
Failure code [DAFQKR] 799
Failure code [DAJ000] 805
Failure code [DAJ0KK] 806
Failure code [DAJ0KT] 808
Failure code [DAJ0MC] 809
Failure code [DAJ2KK] 810
Failure code [DAJ5KX] (Except North America spec ) 812
Failure code [DAJ5KX] (North America spec ) 814
Failure code [DAJ9KQ] 817
Failure code [DAJJKB] 818
Failure code [DAJLKA] 819
Failure code [DAJLKY] 820
Failure code [DAJQKR] 821
Failure code [DAJRMA] 827
Failure code [DB2QKR] 828
Failure code [DB2RKR] 834
Failure code [DDDTKA] (Except North America spec ) 839
Failure code [DDDTKA] (North America spec ) 841
Failure code [DDDTKB] (Except North America spec ) 843
Failure code [DDDTKB] (North America spec ) 845
Failure code [DDDUKA] (Except North America spec ) 847
Failure code [DDDUKA] (North America spec ) 849
Failure code [DDDUKB] (Except North America spec ) 851
Failure code [DDDUKB] (North America spec ) 853
Failure code [DDDVKA] (Except North America spec ) 855
Failure code [DDDVKA] (North America spec ) 857
Failure code [DDDVKM] (Except North America spec ) 860
Failure code [DDDVKM] (North America spec ) 862
Failure code [DDK6KA] 865
Failure code [DDK6KY] 868
Failure code [DGS1KA] (Except North America spec ) 870
Failure code [DGS1KA] (North America spec ) 872
Failure code [DGS1KB] (Except North America spec ) 874
Failure code [DGS1KB] (North America spec ) 876
Failure code [DH2FKA] (Except North America spec ) 878
Failure code [DH2FKA] (North America spec ) 880
Failure code [DH2FKY] 882
Failure code [DHHBKA] (Except North America spec ) 884
Failure code [DHHBKA] (North America spec ) 886
Failure code [DHHBKY] 888
Failure code [DHHCKA] (Except North America spec ) 891
Failure code [DHHCKA] (North America spec ) 893
Failure code [DHHCKY] 895
Failure code [DHPCKA] (Except North America spec ) 898
Failure code [DHPCKA] (North America spec ) 900
Failure code [DHPCKY] 902
Failure code [DJF1KA] (Except North America spec ) 904
Failure code [DJF1KA] (North America spec ) 906
Failure code [DJF1L8] (Except North America spec ) 908
Failure code [DJF1L8] (North America spec ) 909
Failure code [DK30KA] 911
Failure code [DK30KY] 913
Failure code [DK5YKA] (Except North America spec ) 915
Failure code [DK5YKA] (North America spec ) 917
Failure code [DK5YKY] 919
Failure code [DK5YMA] 921
Failure code [DK70KA] (Except North America spec ) 923
Failure code [DK70KA] (North America spec ) 925
Failure code [DK70KY] 927
Failure code [DLT4KA] (Except North America spec ) 929
Failure code [DLT4KA] (North America spec ) 931
Failure code [DLT4KA+DLT6KA] (Except North America spec ) 933
Failure code [DLT4KA+DLT6KA] (North America spec ) 935
Failure code [DLT4LC] 937
Failure code [DLT4MA] 938
Failure code [DLT6KA] (Except North America spec ) 939
Failure code [DLT6KA] (North America spec ) 941
Failure code [DV00KB] 943
Failure code [DV00KY] 945
Failure code [DV01KB] 946
Failure code [DV01KY] 948
Failure code [DW4CKA] 950
Failure code [DW4CKB] 953
Failure code [DW4CKY] 956
Failure code [DWP0KA] (Except North America spec ) 958
Failure code [DWP0KA] (North America spec ) 960
Failure code [DWP0KB] 962
Failure code [DWP0KY] 965
Failure code [DXA1KA] (Except North America spec ) 967
Failure code [DXA1KA] (North America spec ) 969
Failure code [DXA1KB] 971
Failure code [DXATKA] (Except North America spec ) 974
Failure code [DXATKA] (North America spec ) 976
Failure code [DXATKB] 978
Failure code [DXATKY] 981
Failure code [DXAUKA] (Except North America spec ) 984
Failure code [DXAUKA] (North America spec ) 986
Failure code [DXAUKB] 988
Failure code [DXAUKY] 991
Failure code [DXAVKA] (Except North America spec ) 994
Failure code [DXAVKA] (North America spec ) 996
Failure code [DXAVKB] 998
Failure code [DXAVKY] 1000
Failure code [F7FQKR] 1002
Troubleshooting for electrical system (E-mode) 1007
Information described in troubleshooting table 1007
E-1 Engine does not start 1008
E-2 Engine preheater does not operate 1022
E-3 Parking brake reminder buzzer does not sound 1025
E-4 Parking brake reminder buzzer does not stop sounding 1028
E-5 EPACS is abnormal 1030
E-6 Headlamp does not light up or does not go out 1036
E-7 Clearance lamp and tail lamp do not light up or do not go out (Except North America spec ) 1041
E-8 Clearance lamp and tail lamp do not light up or do not go out (North America spec ) 1044
E-9 Turn signal lamps do not light up or do not go out (Except North America spec ) 1047
E-10 Turn signal lamps do not light up or do not go out (North America spec ) 1049
E-11 Brake lamps do not light up or do not go out (Except North America spec ) 1051
E-12 Brake lamps do not light up or do not go out (North America spec ) 1053
E-13 Backup lamps do not light or go off (Except North America spec ) 1055
E-14 Backup lamps do not light or go off (North America spec ) 1057
E-15 Backup buzzer does not sound or does not stop sounding (Except North America spec ) 1059
E-16 Backup buzzer does not sound or does not stop sounding (North America spec ) 1061
E-17 Horn does not sound or does not stop sounding 1063
E-18 Fuel level is not displayed correctly (Except North America spec ) 1066
E-19 Fuel level is not displayed correctly (North America spec ) 1068
E-20 KOMTRAX system does not operate normally 1070
E-21 When starting switch is turned to ON position, alarm buzzer does not sound 1072
E-22 When starting switch is turned to ON position, monitor panel is not displayed 1074
E-23 HST oil filter clogging caution lamp lights up while engine is running 1078
Troubleshooting for hydraulic and mechanical system (H-mode) 1080
Hydraulic and mechanical system diagram 1080
Failure mode and cause table 1082
H-1 Forklift truck cannot travel forward or backward 1086
H-2 Forklift truck cannot travel forward (but travels backward normally) 1087
H-3 Forklift truck cannot travel backward (but travels forward normally) 1088
H-4 Forklift truck travels slowly both forward and backward 1089
H-5 Forklift truck travels slowly forward (but travels backward normally) 1091
H-6 Forklift truck travels slowly backward (but travels forward normally) 1092
H-7 Insufficient traction force during forward and backward travel 1093
H-8 Insufficient traction force during forward travel (but normal during backward travel) 1095
H-9 Insufficient traction force during backward travel (but normal during forward travel) 1096
H-10 Engine stops during travel, or engine speed drops excessively 1097
H-11 Forklift truck starts suddenly during a slow start 1098
H-12 Forklift truck does not turn 1099
H-13 Steering wheel is heavy to turn 1100
H-14 Steering wheel is unstable 1101
H-15 Forklift truck naturally turns to one side during travel 1103
H-16 The knob shifts 1104
H-17 Service brake does not work or its performance is low 1106
H-18 Service brake is not released or it drags 1108
H-19 Parking brake does not work or its performance is low 1109
H-20 Parking brake is not released or it drags 1110
H-21 Engine speed drops excessively or the engine stops when the work equipment or steering wheel is operated 1111
H-22 Work equipment cannot be locked (Work equipment operates when the operator leaves the operator’s seat) 1112
H-23 Work equipment control levers are heavy and do not operate smoothly 1113
H-24 Lift cylinder and fork are not raised 1114
H-25 Fork lifting speed is low 1116
H-26 Fork lifting speed lowers at specific height 1118
H-27 Hydraulic drift of lift cylinder is large 1119
H-28 Lift cylinder and fork are not lowered 1120
H-29 Fork lowering speed is low or high, or fine control performance is low, or response is low 1121
H-30 Mast does not tilt forward or backward 1122
H-31 Mast moves slowly when tilting forward and backward 1124
H-32 Tilting speed reduces halfway 1126
H-33 Hydraulic drift of tilt cylinder (forward tilting) is large 1127
Troubleshooting for basic engine (S-mode) 1128
Information described in troubleshooting table (S-mode) 1128
S-1 Engine does not crank when starting switch is turned to “START” position 1129
S-2 Engine cranks but no exhaust smoke comes out 1130
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1131
S-4 Engine startability is poor 1132
S-5 Engine does not pick up smoothly 1134
S-6 Engine stops during operation 1136
S-7 Engine runs rough or is unstable 1137
S-8 Engine lacks power 1138
S-9 Exhaust gas color is black 1140
S-10 Engine oil consumption is excessive 1142
S-11 Oil becomes contaminated quickly 1143
S-12 Fuel consumption is excessive 1144
S-13 Oil is in coolant (or coolant spurts back or coolant level goes down) 1145
S-14 Oil pressure drops 1146
S-15 Fuel mixes into engine oil 1147
S-16 Water mixes into engine oil (milky) 1148
S-17 Coolant temperature rises too high (overheating) 1149
S-18 Unusual noise is heard 1150
S-19 Vibration is excessive 1151
S-20 Air cannot be bled from fuel circuit 1152
50 Disassembly and assembly 1153
Contents 1154
List of abbreviations 1157
General information on disassembly and assembly 1162
How to read this manual 1162
Coating materials list 1163
Special tools list 1166
Sketches of special tools 1170
Engine and cooling system 1172
Removal and installation of supply pump assembly 1172
Removal and installation of injector assembly 1180
Removal and installation of cylinder head assembly 1189
Removal and installation of EGR valve assembly 1199
Removal and installation of EGR cooler assembly 1201
Removal and installation of starting motor assembly 1207
Removal and installation of alternator belt 1210
Removal and installation of auto-tensioner 1212
Removal and installation of radiator assembly 1213
Removal and installation of hydraulic oil cooler assembly 1216
Removal and installation of aftercooler assembly 1218
Removal and installation of engine and HST pump assembly 1226
Removal and installation of KDOC muffler assembly 1238
Removal and installation of KCCV assembly 1244
Removal and installation of air cleaner assembly 1247
Power train 1250
Removal and installation of front axle and HST motor assembly 1250
Disassembly and assembly of rear axle assembly 1254
Disassembly and assembly of differential assembly 1262
Disassembly and assembly of axle housing assembly 1277
Disassembly and assembly of parking brake assembly 1286
Disassembly and assembly of steering cylinder assembly 1293
Undercarriage and frame 1295
Removal and installation of counterweight assembly 1295
Removal and installation of head guard assembly 1299
Hydraulic system 1312
Removal and installation of HST pump assembly 1312
Removal and installation of HST motor assembly 1320
Removal and installation of steering and work equipment pump assembly 1322
Removal and installation of brake circuit strainer 1323
Disassembly and assembly of work equipment PPC valve assembly 1329
Removal and installation of control valve assembly 1331
Removal and installation of O-rings of Orbitrol valve assembly 1337
Removal and installation of lift cylinder assembly 1344
Disassembly and assembly of hydraulic cylinder assembly 1347
Operator’s cab 1354
Removal and installation of engine hood assembly 1354
Removal and installation of operator’s seat assembly 1360
Removal and installation of seat belt 1362
Work equipment 1364
Removal and installation of mast assembly 1364
Disassembly and assembly of mast assembly 1369
Electrical system 1375
Removal and installation of engine controller assembly 1375
Removal and installation of HST controller assembly 1377
Removal and installation of KOMTRAX terminal assembly 1381
Removal and installation of KCCV crankcase pressure sensor 1383
60 Maintenance standard 1385
Contents 1386
List of abbreviations 1387
Engine and cooling system 1392
Maintenance standard of engine mount 1392
Maintenance standard of cooling system 1393
Power train 1394
Maintenance standard of HST pump 1394
Maintenance standard of HST motor 1396
Maintenance standard of front axle 1398
Maintenance standard of differential 1399
Maintenance standard of final drive 1402
Steering system 1403
Maintenance standard of orbitrol valve 1403
Maintenance standard of steering column 1404
Maintenance standard of steering cylinder 1405
Brake system 1406
Maintenance standard of front brake 1406
Maintenance standard of slack adjuster 1407
Maintenance standard of parking brake 1408
Undercarriage and frame 1409
Maintenance standard of rear axle 1409
Maintenance standard of frame 1411
Hydraulic system 1412
Maintenance standard of hydraulic tank 1412
Maintenance standard of steering and work equipment pump 1413
Maintenance standard of servo valve for steering and work equipment pump 1416
Maintenance standard of control valve 1417
Maintenance standard of priority valve 1425
Maintenance standard of work equipment PPC valve 1426
Work equipment 1428
Maintenance standard of tilt cylinder 1428
Maintenance standard of lift cylinder 1429
Maintenance standard of mast and fork 1430
80 Others 1433
Contents 1434
List of abbreviations 1435
Yearly inspection criteria 1440
Yearly inspection criteria: FH60, 70, 80-2 1440
90 Diagrams and drawings 1463
Contents 1464
List of abbreviations 1465
Hydraulic circuit diagram 1470
Symbols for hydraulic circuit diagram 1470
Hydraulic circuit diagram 1475
Electrical circuit diagram 1477
Symbols for electrical circuit diagram 1477
Electrical circuit diagram (1/11) (Except North America spec ) 1481
Electrical circuit diagram (2/11) (Except North America spec ) 1483
Electrical circuit diagram (3/11) (Except North America spec ) 1485
Electrical circuit diagram (4/11) (Except North America spec ) 1487
Electrical circuit diagram (5/11) (Except North America spec ) 1489
Electrical circuit diagram (6/11) (Except North America spec ) 1491
Electrical circuit diagram (7/11) (Except North America spec ) 1493
Electrical circuit diagram (8/11) (Except North America spec ) 1495
Electrical circuit diagram (9/11) (Except North America spec ) 1497
Electrical circuit diagram (10/11) (Except North America spec ) 1499
Electrical circuit diagram (11/11) (Except North America spec ) 1501
Electrical circuit diagram (1/10) (North America spec ) 1503
Electrical circuit diagram (2/10) (North America spec ) 1505
Electrical circuit diagram (3/10) (North America spec ) 1507
Electrical circuit diagram (4/10) (North America spec ) 1509
Electrical circuit diagram (5/10) (North America spec ) 1511
Electrical circuit diagram (6/10) (North America spec ) 1513
Electrical circuit diagram (7/10) (North America spec ) 1515
Electrical circuit diagram (8/10) (North America spec ) 1517
Electrical circuit diagram (9/10) (North America spec ) 1519
Electrical circuit diagram (10/10) (North America spec ) 1521
Index 1523

DESCRIPTION:

Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SEN06640-08 – PDF DOWNLOAD 

SERIAL NUMBERS
FH60-51001 and up
FH70-51001 and up
FH80-51001 and up

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 contain the table of contents, safety, and basic information.
01 Specification
This section explains the specifications of the machine.
10 Structure and function
This section explains the structure and function of each device by system. The “Structure and function” section
serves not only to give an understanding of the structure of each device, but also serves as reference material for
troubleshooting.
20 Standard value table
This section explains the standard values for new machine and judgment criteria for testing and adjusting, and
also troubleshooting. This standard value table is used to check the standard values in testing and adjusting and
also to judge parts in troubleshooting.
30 Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and also methods
required for adjusting each part. The standard values and judgment criteria for testing and adjusting are explained
in Testing and adjusting.
40 Troubleshooting
This section explains how to find failed parts and how to repair them. The troubleshooting is explained by failure
mode.
50 Disassembly and assembly
This section explains the special tools and procedures required for the removing, installing, disassembling, and
assembling each component, as well as any precautions needed to be taken. In addition, tightening torques and
quantity and weights of coating material, oil, grease, and coolant necessary for the work are also explained.
60 Maintenance standard
This section explains maintenance standard values for each device. The maintenance standard sub-section explains
judgment criteria and remedies for disassembly and service.
80 Others
This section explains the following items.
q Structure, function, testing, adjusting, and troubleshooting of devices and equipment that cannot be clearly
classified into the chassis or engine volume
q This section explains the inspection items, contents and criteria of the specific self-imposed inspection.
90 Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL:

S.V 28/12/24