Komatsu Forklift Truck FH35-2 FH40-2 FH45-2 FH50-2 service & repair manual

Description Komatsu Forklift Truck FH35-2 FH40-2 FH45-2 FH50-2 service & repair manual

Komatsu Forklift Truck FH35-2, FH40-2, FH45-2, FH50-2 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 140001 and up

SERVICE MANUAL CONTENT:
Index and foreword
Foreword, safety, basic information
How to read the shop manual
Safety notice for operation
Precautions to prevent fire
Action if fire occurs
Precautions for handling hydraulic equipment
Precautions for disconnection and connection of pipings
Precautions for handling electrical equipment
Precautions for handling fuel system equipment
Precautions for handling intake system equipment
Precautions for replacing HST controller and monitor panel
Practical use of KOMTRAX
Disconnect and connect push-pull type coupler
Precautions for disconnection and connection of connectors
Method for disconnecting and connecting deutsch connector
Method for disconnecting and connecting slide lock type connector
Method for disconnecting and connecting connector with lock to pull
Method for disconnecting and connecting connector with lock to push
Method for disconnecting and connecting connector with housing to rotate
How to read electrical wire code
Explanation of terms for maintenance standard
Abbreviation list
Standard tightening torque table
Conversion table

Specification
Specification Drawing
Weight Table
Lubricant List

Structure and function
Engine and cooling system
Variable flow turbocharger
Piping drawing of EGR system
Circuit diagram of EGR system
EGR valve
EGR cooler
Layout drawing of KCCV
KCCV ventilator
CDR valve
KDOC muffler
Cooling system
Power train
Power train system diagram
PTO
HST piping diagram
HST pump
HST motor
Axle
Differential
Steering system
Steering piping diagram (control valve - power steering cylinder)
Orbitrol valve
Brake system
Brake control
Brake piping diagram
Service brake
Accumulator charge valve
Brake valve
Slack adjuster
Accumulator (for brake)
Parking brake
Undercarriage and frame
Rear axle
Frame
Hydraulic system
Control valve piping diagram (tank to control valve)
Hydraulic tank piping diagram
Work equipment piping diagram (control valve to tilt cylinder/lift cylinder)
Attachment piping diagram
Work equipment control lever linkage
Work equipment and steering pump
Control valve
CLSS
Each function and operation of each valve
Work equipment
Mast
Finger board
Fork
Electrical system
Electrical control system
HST controller
System component parts
Accelerator pedal sensor
EPACS controller
Monitor system
KOMTRAX system
Sensor
Combination switch
Seat switch, seat belt switch
Flasher
Relay box

Standard value table
Standard value table for engine
Standard value table for machine

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 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 return and leakage volume
Bleeding air from fuel system
Testing leakage from fuel system
Replacing engine oil and engine oil filter
Replacing KCCV filter element
Replacing fuel filter
Draining water from fuel pre-filter
Bleeding air from fuel filter
Radiator cleaning
Testing air cleaner and replacing filter element
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Writing compensation values at replacement of fuel injector and engine controller
Testing alternator belt
Testing auto-tensioner
Power train
Testing HST oil pressure
Checking oil level and changing oil in differential case
Changing PTO oil and cleaning strainer
Steering system
Initial setting of Orbitrol valve
Brake system
Bleeding air from brake circuit
Testing brake oil pressure
Checking accumulator charge pressure
Testing braking performance
Testing wear of service brake disc
Checking parking brake
Testing and adjusting brake pedal
Testing and adjusting brake pedal angle sensor linkage
Hydraulic system
Releasing remaining pressure in hydraulic piping
Inspection of hydraulic tank
Work equipment
Bleeding air from lift cylinder
Testing hydraulic drift and hydraulic drift tilting amount
Adjusting mast
Adjusting fork carriage
Handling engine controller voltage circuit
Testing procedure for diode
Electrical system
Special functions of monitor panel
KOMTRAX terminal start-up procedure

Troubleshooting
Precautions before work
Information related to troubleshooting
Points to remember when troubleshooting
How to proceed in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Symptoms of failure and troubleshooting numbers
Information in troubleshooting table
Locations of fuses
Connector list and layout
Connection table for connector pin No
T-box and T-adapter list
Troubleshooting by failure code
Troubleshooting by failure code (EPACS controller system)
Troubleshooting for electrical system (E-mode)
Troubleshooting for hydraulic and mechanical system (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
Sketches of special tools
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 radiator assembly
Removal and installation of alternator belt
Removal and installation of auto-tensioner
Removal and installation of aftercooler assembly
Removal and installation of oil cooler assembly
Removal and installation of engine and pump assembly
Removal and installation of EGR valve assembly
Removal and installation of EGR cooler assembly
Removal and installation of KCCV crankcase pressure sensor assembly
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Removal and installation of KDOC muffler assembly
Removal and installation of starting motor assembly
Power train
Removal and installation of front axle and HST motor assembly
Disassembly and assembly of front axle assembly
Removal and installation of PTO assembly
Disassembly and assembly of PTO assembly
Disassembly and assembly of differential assembly
Disassembly and assembly of axle housing assembly
Disassembly and assembly of parking brake assembly
Disassembly and assembly of rear axle assembly
Disassembly and assembly of power steering cylinder assembly
Disassembly and assembly of brake pedal assembly
Undercarriage and frame
Removal and installation of counterweight assembly
Removal and installation of head guard assembly
Removal and installation of hood assembly
Hydraulic system
Removal and installation of HST pump assembly
Removal and installation of HST motor assembly
Removal and installation of work equipment and steering pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of Orbitrol valve assembly
Removal and installation of lift cylinder assembly
Disassembly and assembly of lift cylinder assembly
Disassembly and assembly of tilt cylinder assembly
Cab and its attachments
Removal and installation of operators seat assembly
Removal and installation of seat belt
Work equipment
Removal and installation of mast assembly
Disassembly and assembly of mast assembly
Removal and installation of chain (double mast)
Removal and installation of chain (triple mast)
Electrical system
Removal and installation of engine controller assembly
Removal and installation of HST controller assembly
Removal and installation of KOMTRAX terminal assembly
Disassembly and assembly of conditioner switch assembly

Maintenance standard
Engine and cooling system
Engine mount, PTO mount
Cooling system
Power train
PTO
HST pump
HST motor
Differential
Steering system
Orbitrol valve
Power steering cylinder
Brake system
Brake pipings diagram
Service brake
Slack adjuster
Parking brake
Undercarriage and frame
Rear axle
Frame
Hydraulic system
Work equipment and steering pump
Control valve
Work equipment
Tilt cylinder
Lift cylinder
Mast
Fork

Yearly inspection criteria
Precautions before work

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electrical circuit diagrams
Electric circuit diagram

Engine SAA4D95LE-6-C workshop service repair manual