Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SM166 SEN06640-04 – PDF DOWNLOAD

Description

Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SM166 SEN06640-04 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SM166 SEN06640-04 – PDF DOWNLOAD

SERIAL NUMBER:

FH60-51001 and up
FH70-51001 and up
FH80-51001 and up

FOREWORD, SAFETY AND GENERAL INFORMATION :
HOW TO READ THE SHOP MANUAL :

• Some attachments and optional parts in this shop manual may not be delivered to certain areas. When they
  are requested, consult with Komatsu.
• Materials and specifications are subject to change without notice.
• Shop manuals are divided into “Chassis volume” and “Engine volume”. For the engine unit, see the engine
  volume of the engine model mounted on the machine.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
  the illustrations of this shop manual.

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.

TABLE OF CONTENTS:

Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Shop Manual SM166 SEN06640-04 – PDF DOWNLOAD

00 INDEX AND FOREWORD
INDEX 00 2
LIST OF ABBREVIATIONS 00 14
FOREWORD, SAFETY AND GENERAL INFORMATION 00 19
HOW TO READ THE SHOP MANUAL 00 19
PRECAUTIONS RELATED TO WORK SAFETY 00 21
FIRE PREVENTION 00 30
IF A FIRE BREAKS OUT 00 32
INSTRUCTIONS FOR WASTE DISPOSAL 00 33
INSTRUCTIONS FOR HANDLING HYDRAULIC COMPONENTS 00 34
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING PIPING 00 36
INSTRUCTIONS FOR HANDLING ELECTRIC COMPONENTS 00 44
INSTRUCTIONS FOR HANDLING FUEL SYSTEM COMPONENTS 00 46
INSTRUCTIONS FOR HANDLING INTAKE SYSTEM COMPONENTS 00 47
USE OF KOMTRAX 00 48
DISCONNECTING AND CONNECTING PUSH PULL TYPE COUPLER 00 49
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING CONNECTORS 00 53
HOW TO DISCONNECT AND CONNECT DT CONNECTORS 00 58
HOW TO DISCONNECT AND CONNECT SLIDE LOCK TYPE CONNECTORS 00 59
HOW TO DISCONNECT AND CONNECT CONNECTORS THAT REQUIRE PULLING LOCK 00 61
HOW TO DISCONNECT AND CONNECT CONNECTORS THAT REQUIRE PRESSING LOCK 00 62
HOW TO DISCONNECT AND CONNECT CONNECTORS THAT REQUIRE TURNING HOUSING 00 64
HOW TO READ ELECTRIC WIRE CODE 00 65
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 71
STANDARD TIGHTENING TORQUE TABLE 00 73
UNIT CONVERSION TABLE 00 80
01 SPECIFICATION
LIST OF ABBREVIATIONS 01 3
SPECIFICATIONS 01 8
SPECIFICATION DRAWING 01 8
SPECIFICATIONS 01 14
WEIGHT TABLE 01 26
FUEL, COOLANT, AND LUBRICANT 01 29
10 STRUCTURE AND FUNCTION
LIST OF ABBREVIATIONS 10 5
STARTING SYSTEM 10 10
STARTING SYSTEM COMPONENT LAYOUT DRAWING 10 10
PREHEATING SYSTEM 10 11
ENGINE SYSTEM 10 14
ENGINE SYSTEM COMPONENT LAYOUT DRAWING 10 14
ENGINE CONTROL SYSTEM 10 15
AUTOMATIC ENGINE STOP SYSTEM 10 17
ENGINE SYSTEM COMPONENTS 10 20
COOLING SYSTEM 10 37
COOLING SYSTEM COMPONENT LAYOUT DRAWING 10 37
CONTROL SYSTEM 10 39
CONTROL SYSTEM COMPONENT LAYOUT DRAWING 10 39
MONITOR PANEL SYSTEM 10 40
KOMTRAX SYSTEM 10 41
SEAT BELT INTERLOCK SYSTEM 10 42
CONTROL SYSTEM COMPONENTS 10 44
00 INDEX AND FOREWORD INDEX
FH60,70,80 2 00 3
HYDRAULIC SYSTEM 10 67
HYDRAULIC SYSTEM COMPONENT LAYOUT DRAWING 10 67
CLSS 10 68
HYDRAULIC SYSTEM COMPONENTS 10 70
POWER TRAIN SYSTEM 10 100
POWER TRAIN SYSTEM COMPONENT LAYOUT DRAWING 10 100
TRAVEL SPEED LIMIT SYSTEM 10 102
DIRECTIONAL LEVER NEUTRAL ALARM SYSTEM 10 103
TRAVEL INTERLOCK SYSTEM 10 104
POWER TRAIN SYSTEM COMPONENTS 10 106
WORK EQUIPMENT SYSTEM 10 136
WORK EQUIPMENT SYSTEM COMPONENT LAYOUT DRAWING 10 136
STRUCTURE OF VALVE CONTROL 10 137
LIFT INTERLOCK SYSTEM 10 138
WORK EQUIPMENT SYSTEM COMPONENTS 10 140
STEERING SYSTEM 10 146
STEERING SYSTEM COMPONENT LAYOUT DRAWING 10 146
STEERING COLUMN 10 147
STEERING SYSTEM COMPONENT LAYOUT DRAWING 10 148
BRAKE SYSTEM 10 156
BRAKE SYSTEM COMPONENT LAYOUT DRAWING 10 156
PARKING BRAKE REMINDER SYSTEM 10 157
PARKING BRAKE DRAGGING PREVENTION SYSTEM 10 159
BRAKE SYSTEM COMPONENTS 10 161
FRONT BRAKE 10 171
BRAKE COOLING PUMP 10 174
UNDERCARRIAGE AND FRAME 10 175
STRUCTURE OF FRAME 10 175
TIRE 10 176
WORK EQUIPMENT 10 177
STRUCTURE OF WORK EQUIPMENT 10 177
20 STANDARD VALUE TABLE
LIST OF ABBREVIATIONS 20 3
STANDARD VALUE TABLE FOR ENGINE 20 8
STANDARD VALUE TABLE FOR ENGINE: FH60 2 20 8
STANDARD VALUE TABLE FOR ENGINE: FH70 2 20 10
STANDARD VALUE TABLE FOR ENGINE: FH80 2 20 12
STANDARD VALUE TABLE FOR MACHINE 20 14
STANDARD VALUE TABLE FOR MACHINE: FH60 2 20 14
STANDARD VALUE TABLE FOR MACHINE: FH70 2 20 18
STANDARD VALUE TABLE FOR MACHINE: FH80 2 20 22
30 TESTING AND ADJUSTING
LIST OF ABBREVIATIONS 30 4
RELATED INFORMATION ON TESTING AND ADJUSTING 30 9
TOOLS FOR TESTING AND ADJUSTING 30 9
ENGINE AND COOLING SYSTEM 30 14
TESTING ENGINE SPEED 30 14
TESTING EXHAUST GAS COLOR 30 15
TESTING AND ADJUSTING VALVE CLEARANCE 30 17
TESTING COMPRESSION PRESSURE 30 19
TESTING BLOWBY PRESSURE 30 22
TESTING ENGINE OIL PRESSURE 30 23
00 4 FH60,70,80 2
INDEX 00 INDEX AND FOREWORD
TESTING FUEL PRESSURE 30 25
TESTING FUEL RETURN VOLUME AND LEAKAGE VOLUME 30 27
BLEEDING FUEL SYSTEM OF AIR 30 31
TESTING LEAKAGES FROM FUEL SYSTEM 30 33
HANDLING OF CYLINDER CUTOUT MODE OPERATION 30 35
HANDLING OF NO INJECTION CRANKING OPERATION 30 36
CHANGING ENGINE OIL 30 37
REPLACING ENGINE OIL FILTER 30 38
REPLACING KCCV FILTER ELEMENT 30 39
REPLACEMENT OF FUEL FILTER 30 41
DRAINING FUEL PREFILTER OF WATER 30 44
BLEEDING FUEL FILTER OF AIR 30 45
BLEEDING COOLING CIRCUIT OF AIR 30 46
RADIATOR CLEANING 30 47
TESTING AIR CLEANER AND CLEANING AND REPLACING ELEMENT 30 48
WRITING COMPENSATION VALUES AT REPLACEMENT OF INJECTOR AND ENGINE CONTROLLER
30 53
TESTING ALTERNATOR BELT 30 59
TESTING AUTO TENSIONER 30 60
POWER TRAIN 30 61
TESTING HST OIL PRESSURE 30 61
TESTING OIL IN FLYWHEEL HOUSING 30 65
TESTING OIL LEVEL AND CHANGING AXLE OIL IN DIFFERENTIAL CASE 30 66
REPLACING FRONT AXLE LUBRICATION FILTER 30 68
STEERING SYSTEM 30 69
TESTING STEERING WHEEL 30 69
BLEEDING STEERING CYLINDER CIRCUIT OF AIR 30 70
TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE 30 71
BRAKE SYSTEM 30 73
BLEEDING BRAKE CIRCUIT OF AIR 30 73
TESTING BRAKE OIL PRESSURE 30 74
TESTING ACCUMULATOR CHARGE PRESSURE 30 76
TESTING BRAKING PERFORMANCE OF BRAKE 30 77
TESTING WEAR OF SERVICE BRAKE DISC 30 78
TESTING AND ADJUSTING PARKING BRAKE 30 79
TESTING AND ADJUSTING BRAKE PEDAL 30 81
TESTING AND ADJUSTING BRAKE PEDAL ANGLE SENSOR LINKAGE 30 83
HYDRAULIC SYSTEM 30 85
RELEASING REMAINING PRESSURE FROM HYDRAULIC PIPING 30 85
CHANGING HYDRAULIC OIL 30 86
REPLACING HYDRAULIC OIL LINE FILTER 30 87
CLEANING HYDRAULIC TANK STRAINER 30 88
TESTING HYDRAULIC TANK BREATHER 30 90
WORK EQUIPMENT 30 91
BLEED AIR FROM LIFT CYLINDER 30 91
TESTING HYDRAULIC DRIFT AND HYDRAULIC DRIFT FORWARD TILTING OF THE HYDRAULIC CYLINDER
30 92
ADJUSTMENT OF MAST 30 94
ADJUSTMENT OF FINGER BAR 30 97
CAB AND ITS ATTACHMENTS 30 98
TESTING LIFT LEVER AND TILT LEVER 30 98
ELECTRICAL SYSTEM 30 99
SETTING AND OPERATION OF MONITOR PANEL 30 99
KOMTRAX TERMINAL START UP PROCEDURE 30 154
00 INDEX AND FOREWORD INDEX
FH60,70,80 2 00 5
HANDLING OF ENGINE CONTROLLER VOLTAGE CIRCUIT 30 159
PROCEDURE FOR CHECKING DIODE 30 160
40 TROUBLESHOOTING
LIST OF ABBREVIATIONS 40 9
INFORMATION RELATED TO TROUBLESHOOTING 40 14
POINTS TO REMEMBER WHEN TROUBLESHOOTING 40 14
HOW TO PROCEED WITH TROUBLESHOOTING 40 16
CHECK BEFORE TROUBLESHOOTING 40 18
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 40 20
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40 21
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 24
LOCATIONS OF FUSES (EXCEPT NORTH AMERICA SPEC.) 40 26
LOCATIONS OF FUSES (NORTH AMERICA SPEC.) 40 29
CONNECTOR LIST AND LAYOUT 40 33
CONNECTION TABLE FOR CONNECTOR PIN NO. 40 44
T BOX AND T ADAPTER LIST 40 83
FAILURE CODES TABLE 40 87
TROUBLESHOOTING BY FAILURE CODE 40 96
FAILURE CODE [2G40ZG] 40 96
FAILURE CODE [6091NX] 40 97
FAILURE CODE [7REAKA] 40 98
FAILURE CODE [7REHKA] 40 100
FAILURE CODE [AB00KY] 40 102
FAILURE CODE [AB00MA] 40 104
FAILURE CODE [B@BAZG] 40 106
FAILURE CODE [B@BCNS] 40 107
FAILURE CODE [B@CRNS] 40 108
FAILURE CODE [CA115] 40 109
FAILURE CODE [CA122] 40 110
FAILURE CODE [CA123] 40 112
FAILURE CODE [CA131] 40 114
FAILURE CODE [CA132] 40 116
FAILURE CODE [CA144] 40 119
FAILURE CODE [CA145] 40 121
FAILURE CODE [CA153] 40 123
FAILURE CODE [CA154] 40 125
FAILURE CODE [CA187] 40 127
FAILURE CODE [CA221] 40 129
FAILURE CODE [CA222] 40 131
FAILURE CODE [CA227] 40 133
FAILURE CODE [CA234] 40 134
FAILURE CODE [CA238] 40 135
FAILURE CODE [CA239] 40 136
FAILURE CODE [CA271] 40 137
FAILURE CODE [CA272] 40 138
FAILURE CODE [CA322] 40 139
FAILURE CODE [CA324] 40 141
FAILURE CODE [CA331] 40 143
FAILURE CODE [CA332] 40 145
FAILURE CODE [CA343] 40 147
FAILURE CODE [CA351] 40 148
FAILURE CODE [CA352] 40 149
FAILURE CODE [CA356] 40 151
00 6 FH60,70,80 2
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [CA357] 40 153
FAILURE CODE [CA386] 40 155
FAILURE CODE [CA428] 40 156
FAILURE CODE [CA429] 40 157
FAILURE CODE [CA431] 40 158
FAILURE CODE [CA432] 40 161
FAILURE CODE [CA435] 40 165
FAILURE CODE [CA441] 40 167
FAILURE CODE [CA442] 40 169
FAILURE CODE [CA449] 40 170
FAILURE CODE [CA451] 40 171
FAILURE CODE [CA452] 40 173
FAILURE CODE [CA466] 40 175
FAILURE CODE [CA515] 40 177
FAILURE CODE [CA516] 40 179
FAILURE CODE [CA553] 40 181
FAILURE CODE [CA555] 40 182
FAILURE CODE [CA556] 40 183
FAILURE CODE [CA559] 40 184
FAILURE CODE [CA689] 40 187
FAILURE CODE [CA691] 40 189
FAILURE CODE [CA692] 40 191
FAILURE CODE [CA697] 40 193
FAILURE CODE [CA698] 40 194
FAILURE CODE [CA731] 40 195
FAILURE CODE [CA778] 40 197
FAILURE CODE [CA1117] 40 199
FAILURE CODE [CA1695] 40 200
FAILURE CODE [CA1696] 40 201
FAILURE CODE [CA1843] 40 202
FAILURE CODE [CA1844] 40 204
FAILURE CODE [CA1896] 40 206
FAILURE CODE [CA1942] 40 207
FAILURE CODE [CA1961] 40 208
FAILURE CODE [CA2185] 40 209
FAILURE CODE [CA2186] 40 210
FAILURE CODE [CA2249] 40 212
FAILURE CODE [CA2272] 40 213
FAILURE CODE [CA2311] 40 215
FAILURE CODE [CA2349] 40 216
FAILURE CODE [CA2353] 40 218
FAILURE CODE [CA2357] 40 220
FAILURE CODE [CA2555] 40 221
FAILURE CODE [CA2556] 40 223
FAILURE CODE [CA2765] 40 225
FAILURE CODE [CA3419] 40 226
FAILURE CODE [CA3421] 40 228
FAILURE CODE [CA3724] 40 230
FAILURE CODE [CA3918] 40 232
FAILURE CODE [CA3919] 40 233
FAILURE CODE [CA3921] 40 234
FAILURE CODE [CA3922] 40 235
FAILURE CODE [CA3923] 40 237
FAILURE CODE [D110KA] 40 239
00 INDEX AND FOREWORD INDEX
FH60,70,80 2 00 7
FAILURE CODE [D110KB] 40 241
FAILURE CODE [D140KB] 40 243
FAILURE CODE [D140KY] 40 245
FAILURE CODE [D160KA] 40 248
FAILURE CODE [D160KB] 40 250
FAILURE CODE [D160KY] 40 252
FAILURE CODE [D161KB] 40 254
FAILURE CODE [D161KY] 40 255
FAILURE CODE [D190KB] 40 256
FAILURE CODE [D190KY] 40 257
FAILURE CODE [D19SKB] 40 258
FAILURE CODE [D19SKY] 40 259
FAILURE CODE [D19TKB] 40 260
FAILURE CODE [D19TKY] 40 261
FAILURE CODE [D19UKA] 40 262
FAILURE CODE [D19UKB] 40 264
FAILURE CODE [D19UKY] 40 266
FAILURE CODE [D5XWKA] (EXCEPT NORTH AMERICA SPEC.) 40 268
FAILURE CODE [D5XWKA] (NORTH AMERICA SPEC.) 40 271
FAILURE CODE [D5XWKB] (EXCEPT NORTH AMERICA SPEC.) 40 274
FAILURE CODE [D5XWKB] (NORTH AMERICA SPEC.) 40 276
FAILURE CODE [D5XXKA] 40 278
FAILURE CODE [D5XXKB] 40 279
FAILURE CODE [D5XYL4] 40 280
FAILURE CODE [D5ZKKA] 40 281
FAILURE CODE [D5ZKKB] 40 283
FAILURE CODE [D5ZTKA] 40 284
FAILURE CODE [D811MC] 40 286
FAILURE CODE [D862KA] 40 287
FAILURE CODE [D8ALKA] 40 288
FAILURE CODE [D8ALKB] 40 289
FAILURE CODE [D8AQK4] 40 290
FAILURE CODE [D8AQKR] 40 295
FAILURE CODE [DAF0KT] 40 300
FAILURE CODE [DAF0MB] 40 301
FAILURE CODE [DAF0MC] 40 302
FAILURE CODE [DAF3KK] 40 303
FAILURE CODE [DAFGMC] 40 305
FAILURE CODE [DAFLKA] 40 306
FAILURE CODE [DAFLKB] 40 307
FAILURE CODE [DAFQKR] 40 308
FAILURE CODE [DAJ000] 40 314
FAILURE CODE [DAJ0KK] 40 315
FAILURE CODE [DAJ0KT] 40 317
FAILURE CODE [DAJ0MC] 40 318
FAILURE CODE [DAJ2KK] 40 319
FAILURE CODE [DAJ5KX] (EXCEPT NORTH AMERICA SPEC.) 40 321
FAILURE CODE [DAJ5KX] (NORTH AMERICA SPEC.) 40 323
FAILURE CODE [DAJ9KQ] 40 326
FAILURE CODE [DAJJKB] 40 327
FAILURE CODE [DAJLKA] 40 328
FAILURE CODE [DAJLKY] 40 329
FAILURE CODE [DAJQKR] 40 330
FAILURE CODE [DAJRMA] 40 336
00 8 FH60,70,80 2
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [DB2QKR] 40 337
FAILURE CODE [DB2RKR] 40 343
FAILURE CODE [DDDTKA] (EXCEPT NORTH AMERICA SPEC.) 40 348
FAILURE CODE [DDDTKA] (NORTH AMERICA SPEC.) 40 350
FAILURE CODE [DDDTKB] (EXCEPT NORTH AMERICA SPEC.) 40 352
FAILURE CODE [DDDTKB] (NORTH AMERICA SPEC.) 40 354
FAILURE CODE [DDDUKA] (EXCEPT NORTH AMERICA SPEC.) 40 356
FAILURE CODE [DDDUKA] (NORTH AMERICA SPEC.) 40 358
FAILURE CODE [DDDUKB] (EXCEPT NORTH AMERICA SPEC.) 40 360
FAILURE CODE [DDDUKB] (NORTH AMERICA SPEC.) 40 362
FAILURE CODE [DDDVKA] (EXCEPT NORTH AMERICA SPEC.) 40 364
FAILURE CODE [DDDVKA] (NORTH AMERICA SPEC.) 40 366
FAILURE CODE [DDDVKM] (EXCEPT NORTH AMERICA SPEC.) 40 369
FAILURE CODE [DDDVKM] (NORTH AMERICA SPEC.) 40 371
FAILURE CODE [DDK6KA] 40 374
FAILURE CODE [DDK6KY] 40 377
FAILURE CODE [DGS1KA] (EXCEPT NORTH AMERICA SPEC.) 40 379
FAILURE CODE [DGS1KA] (NORTH AMERICA SPEC.) 40 381
FAILURE CODE [DGS1KB] (EXCEPT NORTH AMERICA SPEC.) 40 383
FAILURE CODE [DGS1KB] (NORTH AMERICA SPEC.) 40 385
FAILURE CODE [DH2FKA] (EXCEPT NORTH AMERICA SPEC.) 40 387
FAILURE CODE [DH2FKA] (NORTH AMERICA SPEC.) 40 389
FAILURE CODE [DH2FKY] 40 391
FAILURE CODE [DHHBKA] (EXCEPT NORTH AMERICA SPEC.) 40 393
FAILURE CODE [DHHBKA] (NORTH AMERICA SPEC.) 40 395
FAILURE CODE [DHHBKY] 40 397
FAILURE CODE [DHHCKA] (EXCEPT NORTH AMERICA SPEC.) 40 400
FAILURE CODE [DHHCKA] (NORTH AMERICA SPEC.) 40 402
FAILURE CODE [DHHCKY] 40 404
FAILURE CODE [DHPCKA] (EXCEPT NORTH AMERICA SPEC.) 40 407
FAILURE CODE [DHPCKA] (NORTH AMERICA SPEC.) 40 409
FAILURE CODE [DHPCKY] 40 411
FAILURE CODE [DJF1KA] (EXCEPT NORTH AMERICA SPEC.) 40 413
FAILURE CODE [DJF1KA] (NORTH AMERICA SPEC.) 40 415
FAILURE CODE [DJF1L8] (EXCEPT NORTH AMERICA SPEC.) 40 417
FAILURE CODE [DJF1L8] (NORTH AMERICA SPEC.) 40 418
FAILURE CODE [DK30KA] 40 420
FAILURE CODE [DK30KY] 40 422
FAILURE CODE [DK5YKA] (EXCEPT NORTH AMERICA SPEC.) 40 424
FAILURE CODE [DK5YKA] (NORTH AMERICA SPEC.) 40 426
FAILURE CODE [DK5YKY] 40 428
FAILURE CODE [DK5YMA] 40 430
FAILURE CODE [DK70KA] (EXCEPT NORTH AMERICA SPEC.) 40 432
FAILURE CODE [DK70KA] (NORTH AMERICA SPEC.) 40 434
FAILURE CODE [DK70KY] 40 436
FAILURE CODE [DLT4KA] (EXCEPT NORTH AMERICA SPEC.) 40 438
FAILURE CODE [DLT4KA] (NORTH AMERICA SPEC.) 40 440
FAILURE CODE [DLT4KA+DLT6KA] (EXCEPT NORTH AMERICA SPEC.) 40 442
FAILURE CODE [DLT4KA+DLT6KA] (NORTH AMERICA SPEC.) 40 444
FAILURE CODE [DLT4LC] 40 446
FAILURE CODE [DLT4MA] 40 447
FAILURE CODE [DLT6KA] (EXCEPT NORTH AMERICA SPEC.) 40 448
FAILURE CODE [DLT6KA] (NORTH AMERICA SPEC.) 40 450
FAILURE CODE [DV00KB] 40 452
00 INDEX AND FOREWORD INDEX
FH60,70,80 2 00 9
FAILURE CODE [DV00KY] 40 454
FAILURE CODE [DV01KB] 40 455
FAILURE CODE [DV01KY] 40 457
FAILURE CODE [DW4CKA] 40 459
FAILURE CODE [DW4CKB] 40 462
FAILURE CODE [DW4CKY] 40 465
FAILURE CODE [DWP0KA] (EXCEPT NORTH AMERICA SPEC.) 40 467
FAILURE CODE [DWP0KA] (NORTH AMERICA SPEC.) 40 469
FAILURE CODE [DWP0KB] 40 471
FAILURE CODE [DWP0KY] 40 474
FAILURE CODE [DXA1KA] (EXCEPT NORTH AMERICA SPEC.) 40 476
FAILURE CODE [DXA1KA] (NORTH AMERICA SPEC.) 40 478
FAILURE CODE [DXA1KB] 40 480
FAILURE CODE [DXATKA] (EXCEPT NORTH AMERICA SPEC.) 40 483
FAILURE CODE [DXATKA] (NORTH AMERICA SPEC.) 40 485
FAILURE CODE [DXATKB] 40 487
FAILURE CODE [DXATKY] 40 490
FAILURE CODE [DXAUKA] (EXCEPT NORTH AMERICA SPEC.) 40 493
FAILURE CODE [DXAUKA] (NORTH AMERICA SPEC.) 40 495
FAILURE CODE [DXAUKB] 40 497
FAILURE CODE [DXAUKY] 40 500
FAILURE CODE [DXAVKA] (EXCEPT NORTH AMERICA SPEC.) 40 503
FAILURE CODE [DXAVKA] (NORTH AMERICA SPEC.) 40 505
FAILURE CODE [DXAVKB] 40 507
FAILURE CODE [DXAVKY] 40 509
FAILURE CODE [F7FQKR] 40 511
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E MODE) 40 516
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 516
E 1 ENGINE DOES NOT START. 40 517
E 2 ENGINE PREHEATER DOES NOT OPERATE. 40 531
E 3 PARKING BRAKE REMINDER BUZZER DOES NOT SOUND. 40 534
E 4 PARKING BRAKE REMINDER BUZZER DOES NOT STOP SOUNDING. 40 537
E 5 EPACS IS ABNORMAL. 40 539
E 6 HEADLAMP DOES NOT LIGHT UP OR DOES NOT GO OUT. 40 545
E 7 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR DO NOT GO OUT. (EXCEPT NORTH
AMERICA SPEC.) 40 550
E 8 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR DO NOT GO OUT. (NORTH AMERICA
SPEC.) 40 553
E 9 TURN SIGNAL LAMPS DO NOT LIGHT UP OR DO NOT GO OUT. (EXCEPT NORTH AMERICA
SPEC.) 40 556
E 10 TURN SIGNAL LAMPS DO NOT LIGHT UP OR DO NOT GO OUT. (NORTH AMERICA SPEC.) 40 558
E 11 BRAKE LAMPS DO NOT LIGHT UP OR DO NOT GO OUT. (EXCEPT NORTH AMERICA SPEC.) 40 560
E 12 BRAKE LAMPS DO NOT LIGHT UP OR DO NOT GO OUT. (NORTH AMERICA SPEC.) 40 562
E 13 BACKUP LAMPS DO NOT LIGHT OR GO OFF (EXCEPT NORTH AMERICA SPEC.) 40 564
E 14 BACKUP LAMPS DO NOT LIGHT OR GO OFF (NORTH AMERICA SPEC.) 40 566
E 15 BACKUP BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING. (EXCEPT NORTH
AMERICA SPEC.) 40 568
E 16 BACKUP BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING. (NORTH AMERICA
SPEC.) 40 570
E 17 HORN DOES NOT SOUND OR DOES NOT STOP SOUNDING. 40 572
E 18 FUEL LEVEL IS NOT DISPLAYED CORRECTLY. (EXCEPT NORTH AMERICA SPEC.) 40 575
E 19 FUEL LEVEL IS NOT DISPLAYED CORRECTLY. (NORTH AMERICA SPEC.) 40 577
E 20 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY. 40 579
00 10 FH60,70,80 2
INDEX 00 INDEX AND FOREWORD
E 21 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALARM BUZZER DOES NOT SOUND.
40 581
E 22 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL IS NOT DISPLAYED.
40 583
E 23 HST OIL FILTER CLOGGING CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING. 40 587
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 40 588
HYDRAULIC AND MECHANICAL SYSTEM DIAGRAM 40 588
FAILURE MODE AND CAUSE TABLE 40 590
H 1 FORKLIFT TRUCK CANNOT TRAVEL FORWARD OR BACKWARD 40 594
H 2 FORKLIFT TRUCK CANNOT TRAVEL FORWARD (BUT TRAVELS BACKWARD NORMALLY) 40 595
H 3 FORKLIFT TRUCK CANNOT TRAVEL BACKWARD (BUT TRAVELS FORWARD NORMALLY). 40 596
H 4 FORKLIFT TRUCK TRAVELS SLOWLY BOTH FORWARD AND BACKWARD. 40 597
H 5 FORKLIFT TRUCK TRAVELS SLOWLY FORWARD (BUT TRAVELS BACKWARD NORMALLY). 40 599
H 6 FORKLIFT TRUCK TRAVELS SLOWLY BACKWARD (BUT TRAVELS FORWARD NORMALLY). 40 600
H 7 INSUFFICIENT TRACTION FORCE DURING FORWARD AND BACKWARD TRAVEL 40 601
H 8 INSUFFICIENT TRACTION FORCE DURING FORWARD TRAVEL (BUT NORMAL DURING BACKWARD
TRAVEL) 40 603
H 9 INSUFFICIENT TRACTION FORCE DURING BACKWARD TRAVEL (BUT NORMAL DURING FORWARD
TRAVEL) 40 604
H 10 ENGINE STOPS DURING TRAVEL, OR ENGINE SPEED DROPS EXCESSIVELY 40 605
H 11 FORKLIFT TRUCK STARTS SUDDENLY DURING A SLOW START. 40 606
H 12 FORKLIFT TRUCK DOES NOT TURN 40 607
H 13 STEERING WHEEL IS HEAVY TO TURN. 40 608
H 14 STEERING WHEEL IS UNSTABLE 40 609
H 15 FORKLIFT TRUCK NATURALLY TURNS TO ONE SIDE DURING TRAVEL. 40 611
H 16 THE KNOB SHIFTS 40 612
H 17 SERVICE BRAKE DOES NOT WORK OR ITS PERFORMANCE IS LOW 40 614
H 18 SERVICE BRAKE IS NOT RELEASED OR IT DRAGS 40 616
H 19 PARKING BRAKE DOES NOT WORK OR ITS PERFORMANCE IS LOW 40 617
H 20 PARKING BRAKE IS NOT RELEASED OR IT DRAGS 40 618
H 21 ENGINE SPEED DROPS EXCESSIVELY OR THE ENGINE STOPS WHEN THE WORK EQUIPMENT
OR STEERING WHEEL IS OPERATED 40 619
H 22 WORK EQUIPMENT CANNOT BE LOCKED (WORK EQUIPMENT OPERATES WHEN THE OPERATOR
LEAVES THE OPERATOR’S SEAT). 40 620
H 23 WORK EQUIPMENT CONTROL LEVERS ARE HEAVY AND DO NOT OPERATE SMOOTHLY. 40 621
H 24 LIFT CYLINDER AND FORK ARE NOT RAISED. 40 622
H 25 FORK LIFTING SPEED IS LOW 40 624
H 26 FORK LIFTING SPEED LOWERS AT SPECIFIC HEIGHT 40 626
H 27 HYDRAULIC DRIFT OF LIFT CYLINDER IS LARGE 40 627
H 28 LIFT CYLINDER AND FORK ARE NOT LOWERED. 40 628
H 29 FORK LOWERING SPEED IS LOW OR HIGH, OR FINE CONTROL PERFORMANCE IS LOW, OR
RESPONSE IS LOW 40 629
H 30 MAST DOES NOT TILT FORWARD OR BACKWARD 40 630
H 31 MAST MOVES SLOWLY WHEN TILTING FORWARD AND BACKWARD 40 632
H 32 TILTING SPEED REDUCES HALFWAY 40 634
H 33 HYDRAULIC DRIFT OF TILT CYLINDER (FORWARD TILTING) IS LARGE 40 635
TROUBLESHOOTING FOR BASIC ENGINE (S MODE) 40 636
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (S MODE) 40 636
S 1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO “START” POSITION 40 637
S 2 ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT 40 638
S 3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT
DOES NOT START) 40 639
S 4 ENGINE STARTABILITY IS POOR 40 640
S 5 ENGINE DOES NOT PICK UP SMOOTHLY 40 642
00 INDEX AND FOREWORD INDEX
FH60,70,80 2 00 11
S 6 ENGINE STOPS DURING OPERATION 40 644
S 7 ENGINE RUNS ROUGH OR IS UNSTABLE 40 645
S 8 ENGINE LACKS POWER 40 646
S 9 EXHAUST GAS COLOR IS BLACK. 40 648
S 10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40 650
S 11 OIL BECOMES CONTAMINATED QUICKLY 40 651
S 12 FUEL CONSUMPTION IS EXCESSIVE 40 652
S 13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 40 653
S 14 OIL PRESSURE DROPS 40 654
S 15 FUEL MIXES INTO ENGINE OIL 40 655
S 16 WATER MIXES INTO ENGINE OIL (MILKY) 40 656
S 17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40 657
S 18 UNUSUAL NOISE IS HEARD 40 658
S 19 VIBRATION IS EXCESSIVE 40 659
S 20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40 660
50 DISASSEMBLY AND ASSEMBLY
LIST OF ABBREVIATIONS 50 5
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY 50 10
HOW TO READ THIS MANUAL 50 10
COATING MATERIALS LIST 50 11
SPECIAL TOOLS LIST 50 14
SKETCHES OF SPECIAL TOOLS 50 18
ENGINE AND COOLING SYSTEM 50 20
REMOVAL AND INSTALLATION OF SUPPLY PUMP ASSEMBLY 50 20
REMOVAL AND INSTALLATION OF INJECTOR ASSEMBLY 50 28
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 50 37
REMOVAL AND INSTALLATION OF EGR VALVE ASSEMBLY 50 47
REMOVAL AND INSTALLATION OF EGR COOLER ASSEMBLY 50 49
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY 50 55
REMOVAL AND INSTALLATION OF ALTERNATOR BELT 50 58
REMOVAL AND INSTALLATION OF AUTO TENSIONER 50 60
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 50 61
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 50 64
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY 50 66
REMOVAL AND INSTALLATION OF ENGINE AND HST PUMP ASSEMBLY 50 74
REMOVAL AND INSTALLATION OF KDOC MUFFLER ASSEMBLY 50 86
REMOVAL AND INSTALLATION OF KCCV ASSEMBLY 50 92
REMOVAL AND INSTALLATION OF AIR CLEANER ASSEMBLY 50 95
POWER TRAIN 50 98
REMOVAL AND INSTALLATION OF FRONT AXLE AND HST MOTOR ASSEMBLY 50 98
DISASSEMBLY AND ASSEMBLY OF REAR AXLE ASSEMBLY 50 102
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY 50 110
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY 50 124
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY 50 133
DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY 50 140
UNDERCARRIAGE AND FRAME 50 142
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY 50 142
REMOVAL AND INSTALLATION OF HEAD GUARD ASSEMBLY 50 146
HYDRAULIC SYSTEM 50 159
REMOVAL AND INSTALLATION OF HST PUMP ASSEMBLY 50 159
REMOVAL AND INSTALLATION OF HST MOTOR ASSEMBLY 50 167
REMOVAL AND INSTALLATION OF STEERING AND WORK EQUIPMENT PUMP ASSEMBLY 50 169
REMOVAL AND INSTALLATION OF BRAKE CIRCUIT STRAINER 50 170
00 12 FH60,70,80 2
INDEX 00 INDEX AND FOREWORD
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 50 176
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY 50 178
REMOVAL AND INSTALLATION OF O RINGS OF ORBITROL VALVE ASSEMBLY 50 184
REMOVAL AND INSTALLATION OF LIFT CYLINDER ASSEMBLY 50 191
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 50 194
OPERATOR’S CAB 50 201
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY 50 201
REMOVAL AND INSTALLATION OF OPERATOR’S SEAT ASSEMBLY 50 207
REMOVAL AND INSTALLATION OF SEAT BELT 50 209
WORK EQUIPMENT 50 211
REMOVAL AND INSTALLATION OF MAST ASSEMBLY 50 211
DISASSEMBLY AND ASSEMBLY OF MAST ASSEMBLY 50 216
ELECTRICAL SYSTEM 50 222
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY 50 222
REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY 50 224
REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL ASSEMBLY 50 228
REMOVAL AND INSTALLATION OF KCCV CRANKCASE PRESSURE SENSOR 50 230
60 MAINTENANCE STANDARD
LIST OF ABBREVIATIONS 60 3
ENGINE AND COOLING SYSTEM 60 8
MAINTENANCE STANDARD OF ENGINE MOUNT 60 8
MAINTENANCE STANDARD OF COOLING SYSTEM 60 9
POWER TRAIN 60 10
MAINTENANCE STANDARD OF HST PUMP 60 10
MAINTENANCE STANDARD OF HST MOTOR 60 12
MAINTENANCE STANDARD OF FRONT AXLE 60 14
MAINTENANCE STANDARD OF DIFFERENTIAL 60 15
MAINTENANCE STANDARD OF FINAL DRIVE 60 18
STEERING SYSTEM 60 19
MAINTENANCE STANDARD OF ORBITROL VALVE 60 19
MAINTENANCE STANDARD OF STEERING COLUMN 60 20
MAINTENANCE STANDARD OF STEERING CYLINDER 60 21
BRAKE SYSTEM 60 22
MAINTENANCE STANDARD OF FRONT BRAKE 60 22
MAINTENANCE STANDARD OF SLACK ADJUSTER 60 23
MAINTENANCE STANDARD OF PARKING BRAKE 60 24
UNDERCARRIAGE AND FRAME 60 25
MAINTENANCE STANDARD OF REAR AXLE 60 25
MAINTENANCE STANDARD OF FRAME 60 27
HYDRAULIC SYSTEM 60 28
MAINTENANCE STANDARD OF HYDRAULIC TANK 60 28
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP 60 29
MAINTENANCE STANDARD OF CONTROL VALVE 60 33
MAINTENANCE STANDARD OF PRIORITY VALVE 60 41
MAINTENANCE STANDARD OF WORK EQUIPMENT PPC VALVE 60 42
WORK EQUIPMENT 60 44
MAINTENANCE STANDARD OF TILT CYLINDER 60 44
MAINTENANCE STANDARD OF LIFT CYLINDER 60 45
MAINTENANCE STANDARD OF MAST AND FORK 60 46
80 OTHERS
LIST OF ABBREVIATIONS 80 3
YEARLY INSPECTION CRITERIA 80 8
00 INDEX AND FOREWORD INDEX
FH60,70,80 2 00 13
YEARLY INSPECTION CRITERIA: FH60, 70, 80 2 80 8
90 DIAGRAMS AND DRAWINGS
LIST OF ABBREVIATIONS 90 3
HYDRAULIC CIRCUIT DIAGRAM 90 8
SYMBOLS FOR HYDRAULIC CIRCUIT DIAGRAM 90 8
HYDRAULIC CIRCUIT DIAGRAM 90 13
ELECTRICAL CIRCUIT DIAGRAM 90 15
SYMBOLS FOR ELECTRICAL CIRCUIT DIAGRAM 90 15
ELECTRICAL CIRCUIT DIAGRAM (1/11) (EXCEPT NORTH AMERICA SPEC.) 90 19
ELECTRICAL CIRCUIT DIAGRAM (2/11) (EXCEPT NORTH AMERICA SPEC.) 90 21
ELECTRICAL CIRCUIT DIAGRAM (3/11) (EXCEPT NORTH AMERICA SPEC.) 90 23
ELECTRICAL CIRCUIT DIAGRAM (4/11) (EXCEPT NORTH AMERICA SPEC.) 90 25
ELECTRICAL CIRCUIT DIAGRAM (5/11) (EXCEPT NORTH AMERICA SPEC.) 90 27
ELECTRICAL CIRCUIT DIAGRAM (6/11) (EXCEPT NORTH AMERICA SPEC.) 90 29
ELECTRICAL CIRCUIT DIAGRAM (7/11) (EXCEPT NORTH AMERICA SPEC.) 90 31
ELECTRICAL CIRCUIT DIAGRAM (8/11) (EXCEPT NORTH AMERICA SPEC.) 90 33
ELECTRICAL CIRCUIT DIAGRAM (9/11) (EXCEPT NORTH AMERICA SPEC.) 90 35
ELECTRICAL CIRCUIT DIAGRAM (10/11) (EXCEPT NORTH AMERICA SPEC.) 90 37
ELECTRICAL CIRCUIT DIAGRAM (11/11) (EXCEPT NORTH AMERICA SPEC.) 90 39
ELECTRICAL CIRCUIT DIAGRAM (1/10) (NORTH AMERICA SPEC.) 90 41
ELECTRICAL CIRCUIT DIAGRAM (2/10) (NORTH AMERICA SPEC.) 90 43
ELECTRICAL CIRCUIT DIAGRAM (3/10) (NORTH AMERICA SPEC.) 90 45
ELECTRICAL CIRCUIT DIAGRAM (4/10) (NORTH AMERICA SPEC.) 90 47
ELECTRICAL CIRCUIT DIAGRAM (5/10) (NORTH AMERICA SPEC.) 90 49
ELECTRICAL CIRCUIT DIAGRAM (6/10) (NORTH AMERICA SPEC.) 90 51
ELECTRICAL CIRCUIT DIAGRAM (7/10) (NORTH AMERICA SPEC.) 90 53
ELECTRICAL CIRCUIT DIAGRAM (8/10) (NORTH AMERICA SPEC.) 90 55
ELECTRICAL CIRCUIT DIAGRAM (9/10) (NORTH AMERICA SPEC.) 90 57
ELECTRICAL CIRCUIT DIAGRAM (10/10) (NORTH AMERICA SPEC.) 90 59
INDEX 1

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