Komatsu Forklift Truck FH100-1 FH120-1 FH135-1 FH160-1 service & repair manual

Description Komatsu Forklift Truck FH100-1 FH120-1 FH135-1 FH160-1 service & repair manual

Komatsu Forklift Truck FH100-1, FH120-1, FH135-1, FH160-1 pdf workshop service repair manual

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

Serial number 7001 and up

SERVICE MANUAL CONTENT:
INDEX AND FOREWORD
FOREWORD, SAFETY AND GENERAL INFORMATION
HOW TO READ THE SHOP MANUAL
PRECAUTIONS RELATED TO WORK SAFETY
FIRE PREVENTION
IF A FIRE BREAKS OUT
INSTRUCTIONS FOR WASTE DISPOSAL
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
HANDLING INSTRUCTIONS OF DEF
REGARDING STORAGE OF DEF
REGARDING HANDLING OF DEF IN COLD WEATHER
INSTRUCTIONS FOR HANDLING HYDRAULIC COMPONENTS
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING PIPING
INSTRUCTIONS FOR HANDLING ELECTRIC COMPONENTS
INSTRUCTIONS FOR HANDLING FUEL SYSTEM COMPONENTS
INSTRUCTIONS FOR HANDLING INTAKE SYSTEM COMPONENTS
PRECAUTIONS FOR REPLACING HST CONTROLLER AND MONITOR PANEL
USE OF KOMTRAX
DISCONNECTING AND CONNECTING PUSH-PULL TYPE COUPLER
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING CONNECTORS
HOW TO DISCONNECT AND CONNECT DT CONNECTORS
HOW TO DISCONNECT AND CONNECT SLIDE LOCK TYPE CONNECTORS
HOW TO DISCONNECT AND CONNECT CONNECTORS THAT REQUIRE PULLING LOCK
HOW TO DISCONNECT AND CONNECT CONNECTORS THAT REQUIRE PRESSING LOCK
HOW TO DISCONNECT AND CONNECT CONNECTORS THAT REQUIRE TURNING HOUSING
HOW TO READ ELECTRIC WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
UNIT CONVERSION TABLE

SPECIFICATION
SPECIFICATION DRAWING
WEIGHT TABLE
FUEL, COOLANT, AND LUBRICANT

STRUCTURE AND FUNCTION
UREA SCR SYSTEM
UREA SCR SYSTEM COMPONENT LAYOUT DRAWING
UREA SCR SYSTEM DIAGRAM
FUNCTION OF UREA SCR SYSTEM
UREA SCR SYSTEM COMPONENTS
STARTING SYSTEM
STARTING SYSTEM COMPONENT LAYOUT DRAWING
SYSTEM OPERATING LAMP SYSTEM
PREHEATING SYSTEM
ENGINE SYSTEM
ENGINE SYSTEM COMPONENT LAYOUT DRAWING
ENGINE CONTROL SYSTEM
AUTOMATIC ENGINE STOP SYSTEM
AUTOMATIC ENGINE POWER CONTROL SYSTEM
ENGINE SYSTEM COMPONENTS
COOLING SYSTEM
COOLING SYSTEM COMPONENT LAYOUT DRAWING
CONTROL SYSTEM
CONTROL SYSTEM COMPONENT LAYOUT DRAWING
MONITOR PANEL SYSTEM
REARVIEW MONITOR SYSTEM
KOMTRAX SYSTEM
SEAT BELT INTERLOCK SYSTEM
CONTROL SYSTEM COMPONENTS
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM COMPONENT LAYOUT DRAWING
CLSS
HYDRAULIC SYSTEM COMPONENTS
POWER TRAIN SYSTEM
POWER TRAIN SYSTEM COMPONENT LAYOUT DRAWING
TRAVEL SPEED LIMIT SYSTEM
DIRECTIONAL LEVER NEUTRAL ALARM SYSTEM
TRAVEL INTERLOCK SYSTEM
POWER TRAIN SYSTEM COMPONENTS
WORK EQUIPMENT SYSTEM
WORK EQUIPMENT SYSTEM COMPONENT LAYOUT DRAWING
STRUCTURE OF VALVE CONTROL
LIFT INTERLOCK SYSTEM
WORK EQUIPMENT SYSTEM COMPONENTS
STEERING SYSTEM
STEERING SYSTEM COMPONENT LAYOUT DRAWING
ELECTRONIC PROPORTIONAL ACTIVE CONTROL STEERING (EPACS) SYSTEM
STEERING COLUMN
STEERING SYSTEM COMPONENT
BRAKE SYSTEM
BRAKE SYSTEM COMPONENT LAYOUT DRAWING
PARKING BRAKE REMINDER SYSTEM
PARKING BRAKE DRAGGING PREVENTION SYSTEM
BRAKE SYSTEM COMPONENTS
UNDERCARRIAGE AND FRAME
STRUCTURE OF FRAME
TIRE
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
CAB AND ITS ATTACHMENTS
CAB

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE FH100-1
STANDARD VALUE TABLE FOR ENGINE FH120-1
STANDARD VALUE TABLE FOR ENGINE FH135-1
STANDARD VALUE TABLE FOR ENGINE: FH160-1
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: FH100-1
STANDARD VALUE TABLE FOR MACHINE: FH120-1
STANDARD VALUE TABLE FOR MACHINE: FH135-1
STANDARD VALUE TABLE FOR MACHINE: FH160-1

TESTING AND ADJUSTING
PRECAUTIONS BEFORE WORK
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TESTING ENGINE SPEED
TESTING BOOST PRESSURE
TESTING EXHAUST GAS COLOR
TESTING AND ADJUSTING VALVE CLEARANCE
TESTING COMPRESSION PRESSURE
TESTING BLOWBY PRESSURE
TESTING ENGINE OIL PRESSURE
VISUAL CHECK INSIDE OF EGR VALVE
CLEAN INSIDE OF EGR VALVE
TESTING FUEL PRESSURE
TESTING FUEL DISCHARGE, RETURN RATE, AND LEAKAGE VOLUME
BLEEDING AIR FROM FUEL SYSTEM
CHECKING FUEL SYSTEM FOR FUEL LEAKAGE
HANDLING CYLINDER CUTOUT MODE OPERATION
HANDLING NO-INJECTION CRANKING
CHANGING ENGINE OIL
REPLACING ENGINE OIL FILTER
REPLACING KCCV FILTER ELEMENT
REPLACING FUEL FILTER
DRAINING FUEL PREFILTER
BLEEDING AIR FROM COOLANT CIRCUIT
CLEANING RADIATOR
CHECKING AIR CLEANER AND CLEANING OR REPLACING ELEMENT
CHECKING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT
CLEANING AND REPLACING AIR CONDITIONER FILTER
CHECKING AND CLEANING AIR CONDITIONER CONDENSER FIN
CHECKING REFRIGERANT (GAS) LEVEL
CHECKING ALTERNATOR BELT
CHECKING AUTO-TENSIONER
TESTING SCR-RELATED FUNCTIONS
FLUSHING DEF TANK
CLEAN DEF PUMP
REPLACING DEF TANK REFILL PORT FILTER
REPLACING DEF FILTER
REPLACING DEF TANK BREATHER
POWER TRAIN
TESTING AND ADJUSTING HST OIL PRESSURE
REPLACING HST OIL FILTER
CHECKING OIL SUMP IN FLYWHEEL HOUSING
CHECKING OIL LEVEL AND CHANGING OIL IN DIFFERENTIAL CASE
STEERING SYSTEM
TESTING STEERING WHEEL
TESTING STEERING WHEEL ANGLE SENSOR
TESTING AND ADJUSTING TIRE ANGLE SENSOR
BLEEDING AIR FROM STEERING CYLINDER CIRCUIT
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
BRAKE SYSTEM
BLEEDING AIR FROM BRAKE CIRCUIT
TESTING BRAKE OIL PRESSURE
TESTING ACCUMULATOR CHARGE PRESSURE
TESTING BRAKING PERFORMANCE
TESTING WEAR OF SERVICE BRAKE DISC
TESTING AND ADJUSTING PARKING BRAKE
TESTING BRAKE PEDAL
TESTING BRAKE PEDAL ANGLE SENSOR
HYDRAULIC SYSTEM
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
TESTING AND ADJUSTING WORK EQUIPMENT PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT PPC PRESSURE
CHANGING HYDRAULIC OIL
REPLACING HYDRAULIC OIL LINE FILTER
CLEANING HYDRAULIC TANK STRAINER
CHECKING HYDRAULIC TANK BREATHER
WORK EQUIPMENT
BLEEDING AIR FROM LIFT CYLINDER
TESTING HYDRAULIC DRIFT AND HYDRAULIC DRIFT FORWARD TILT OF CYLINDERS
ADJUSTING MAST
ADJUSTING FINGER BAR
ADJUSTING TILT CYLINDER
CAB AND ITS ATTACHMENTS
TESTING DIRECTIONAL LEVER
TESTING LIFT LEVER AND TILT LEVER
TESTING ACCELERATOR PEDAL
ELECTRICAL SYSTEM
SETTING AND OPERATION OF MONITOR PANEL
KOMTRAX TERMINAL START-UP PROCEDURE
ADJUSTING INSTALLED ANGLE OF REARVIEW CAMERA
HANDLING OF ENGINE CONTROLLER POWER SUPPLY CIRCUIT
GUIDELINE FOR TESTING DIODE

TROUBLESHOOTING
PRECAUTIONS BEFORE WORK
INFORMATION RELATED TO TROUBLESHOOTING
POINTS TO REMEMBER WHEN PERFORMING TROUBLESHOOTING
POINTS TO REMEMBER WHEN PERFORMING TROUBLESHOOTING OF UREA SCR SYSTEM
HOW TO PROCEED IN TROUBLESHOOTING
CHECK BEFORE TROUBLESHOOTING
GUIDELINE FOR CHECK BEFORE STARTING TROUBLESHOOTING
CHECK ACCORDING TO CHECK GUIDELINE
PROCEDURE FOR TROUBLESHOOTING
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
CONNECTOR LIST AND LAYOUT
CONNECTION TABLE FOR CONNECTOR PIN NO
T-BOX AND T-ADAPTER LIST
LIST AND LOCATIONS OF INSTALLED FUSES
PRECAUTIONS WHEN REPLACING KDOC
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE)
TROUBLESHOOTING FOR BASIC ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
PRECAUTIONS BEFORE WORK
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
ENGINE AND COOLING SYSTEM
REMOVAL AND INSTALLATION OF SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF INJECTOR ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL AND INSTALLATION OF EGR VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF EGR COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR BELT
REMOVAL AND INSTALLATION OF ALTERNATOR BELT
REMOVAL AND INSTALLATION OF AUTO-TENSIONER
REMOVAL AND INSTALLATION OF COOLING ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE AND HST PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE FRONT OIL SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR OIL SEAL
REMOVAL AND INSTALLATION OF KDOC ASSEMBLY
REMOVAL AND INSTALLATION OF BELLOWS PIPING ASSEMBLY
REMOVAL AND INSTALLATION OF KDOC AND SCR ASSEMBLY
REMOVAL AND INSTALLATION OF DEF TANK ASSEMBLY
REMOVAL AND INSTALLATION OF DEF TANK SENSOR FLANGE ASSEMBLY
REMOVAL AND INSTALLATION OF DEF TANK SENSOR
REMOVAL AND INSTALLATION OF DEF TANK STRAINER
REMOVAL AND INSTALLATION OF SCR ASSEMBLY
REMOVAL AND INSTALLATION OF KCCV ASSEMBLY
REMOVAL AND INSTALLATION OF DEF MIXING PIPING
REMOVAL AND INSTALLATION OF DEF INJECTOR
REMOVAL AND INSTALLATION OF DEF PUMP
REMOVAL AND INSTALLATION OF DEF HOSE
REMOVAL AND INSTALLATION OF AIR CLEANER ASSEMBLY
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
REMOVAL AND INSTALLATION OF FRONT AXLE AND HST MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF REAR AXLE ASSEMBLY
REMOVAL AND INSTALLATION OF BRAKE ASSEMBLY
REMOVAL AND INSTALLATION OF DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BRAKE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY
UNDERCARRIAGE AND FRAME
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY
REMOVAL AND INSTALLATION OF HEAD GUARD ASSEMBLY
HYDRAULIC SYSTEM
REMOVAL AND INSTALLATION OF HST PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF HST MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF O-RINGS OF ORBITROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF HST CHARGE CIRCUIT ACCUMULATOR
REMOVAL AND INSTALLATION OF PILOT CIRCUIT ACCUMULATOR
REMOVAL AND INSTALLATION OF BRAKE CIRCUIT ACCUMULATOR
REMOVAL AND INSTALLATION OF BRAKE CIRCUIT STRAINER
REMOVAL AND INSTALLATION OF FRONT AXLE LUBRICATING OIL STRAINER
REMOVAL AND INSTALLATION OF LIFT CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
CAB
REMOVAL AND INSTALLATION OF OPERATORS CAB ASSEMBLY
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
REMOVAL AND INSTALLATION OF OPERATORS SEAT (SUSPENSION SEAT)
REMOVAL AND INSTALLATION OF OPERATORS SEAT (DELUXE SUSPENSION SEAT)
REMOVAL AND INSTALLATION OF SEAT BELT
WORK EQUIPMENT
REMOVAL AND INSTALLATION OF MAST ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF MAST ASSEMBLY
ELECTRICAL SYSTEM
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY
REMOVAL AND INSTALLATION OF MASS AIR FLOW AND TEMPERATURE SENSOR
REMOVAL AND INSTALLATION OF SCR TEMPERATURE SENSOR
REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL ASSEMBLY
REMOVAL AND INSTALLATION OF KCCV CRANKCASE PRESSURE SENSOR

MAINTENANCE STANDARD
LIST OF ABBREVIATIONS
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF COOLING SYSTEM
POWER TRAIN
MAINTENANCE STANDARD OF HST PUMP
MAINTENANCE STANDARD OF HST CHARGE AND BRAKE DOUBLE TYPE PUMP
MAINTENANCE STANDARD OF HST MOTOR
MAINTENANCE STANDARD OF FRONT AXLE
MAINTENANCE STANDARD OF DIFFERENTIAL
MAINTENANCE STANDARD OF FINAL DRIVE
STEERING SYSTEM
MAINTENANCE STANDARD OF ORBITROL VALVE
MAINTENANCE STANDARD OF STEERING COLUMN
MAINTENANCE STANDARD OF STEERING CYLINDER
BRAKE SYSTEM
MAINTENANCE STANDARD OF FRONT BRAKE
MAINTENANCE STANDARD OF PARKING BRAKE
MAINTENANCE STANDARD OF BRAKE COOLING PUMP
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF REAR AXLE
MAINTENANCE STANDARD OF FRAME
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF PRIORITY VALVE
MAINTENANCE STANDARD OF WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT
MAINTENANCE STANDARD OF TILT CYLINDER
MAINTENANCE STANDARD OF LIFT CYLINDER
MAINTENANCE STANDARD OF MAST AND FORK

OTHERS
PRECAUTIONS BEFORE WORK
LIST OF ABBREVIATIONS
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENTS
AIR CONDITIONER SPECIFICATIONS
CONFIGURATION AND FUNCTIONS OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
AIR CONDITIONER SYSTEM COMPONENTS
AIR CONDITIONER UNIT
COMPRESSOR
CONDENSER
RECEIVER DRIER
AIR CONDITIONER CONTROL PANEL
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
A-1 TROUBLESHOOTING THE POWER CIRCUIT (AIR CONDITIONER DOES NOT OPERATE)
A-2 TROUBLESHOOTING THE COMPRESSOR AND REFRIGERANT SYSTEM (DOES NOT COOL)
A-3 TROUBLESHOOTING THE COMPRESSOR AND REFRIGERANT SYSTEM (MECHANICAL SYSTEM)
A-4 TROUBLESHOOTING THE HOT WATER CIRCUIT SYSTEM
A-5 ABNORMAL NOISE FROM AIR CONDITIONER-RELATED PARTS
A-6 WATER LEAKAGE FROM AIR CONDITIONER-RELATED PARTS
PRECAUTIONS FOR CONNECTING OR DISCONNECTING AIR CONDITIONER PIPING
HANDING THE COMPRESSOR OIL
YEARLY INSPECTION CRITERIA

DIAGRAMS AND DRAWINGS
LIST OF ABBREVIATIONS
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS FOR HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS FOR ELECTRICAL CIRCUIT DIAGRAM

Engine SAA4D107E-3 workshop service repair manual