Komatsu Forklift Truck FH60-2 FH70-2 FH80-2 service & repair manual

Description Komatsu Forklift Truck FH60-2 FH70-2 FH80-2 service & repair manual

Komatsu Forklift Truck FH60-2, FH70-2, FH80-2 pdf workshop service repair manual

Serial number 51001 and up

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

SERVICE MANUAL CONTENT:
INDEX AND FOREWORD
LIST OF ABBREVIATIONS
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
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
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
STARTING SYSTEM
STARTING SYSTEM COMPONENT LAYOUT DRAWING
PREHEATING SYSTEM
ENGINE SYSTEM
ENGINE SYSTEM COMPONENT LAYOUT DRAWING
ENGINE CONTROL SYSTEM
AUTOMATIC ENGINE STOP SYSTEM
ENGINE SYSTEM COMPONENTS
COOLING SYSTEM
COOLING SYSTEM COMPONENT LAYOUT DRAWING
CONTROL SYSTEM
CONTROL SYSTEM COMPONENT LAYOUT DRAWING
MONITOR PANEL 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
STEERING COLUMN
STEERING SYSTEM COMPONENTS
BRAKE SYSTEM
BRAKE SYSTEM COMPONENT LAYOUT DRAWING
PARKING BRAKE REMINDER SYSTEM
PARKING BRAKE DRAGGING PREVENTION SYSTEM
BRAKE SYSTEM COMPONENTS
FRONT BRAKE
BRAKE COOLING PUMP
UNDERCARRIAGE AND FRAME
STRUCTURE OF FRAME
TIRE
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: FH60-2
STANDARD VALUE TABLE FOR ENGINE: FH70-2
STANDARD VALUE TABLE FOR ENGINE: FH80-2
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: FH60-2
STANDARD VALUE TABLE FOR MACHINE: FH70-2
STANDARD VALUE TABLE FOR MACHINE: FH80-2

TESTING AND ADJUSTING
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 VOLUME AND LEAKAGE VOLUME
BLEEDING FUEL SYSTEM OF AIR
TESTING LEAKAGES FROM FUEL SYSTEM
HANDLING OF CYLINDER CUTOUT MODE OPERATION
HANDLING OF NO-INJECTION CRANKING OPERATION
CHANGING ENGINE OIL
REPLACING ENGINE OIL FILTER
REPLACING KCCV FILTER ELEMENT
REPLACEMENT OF FUEL FILTER
DRAINING FUEL PREFILTER OF WATER
BLEEDING FUEL FILTER OF AIR
BLEEDING COOLING CIRCUIT OF AIR
RADIATOR CLEANING
TESTING AIR CLEANER AND CLEANING AND REPLACING ELEMENT
WRITING COMPENSATION VALUES AT REPLACEMENT OF INJECTOR AND ENGINE CONTROLLER
TESTING ALTERNATOR BELT
TESTING AUTO-TENSIONER
POWER TRAIN
TESTING HST OIL PRESSURE
TESTING OIL IN FLYWHEEL HOUSING
TESTING OIL LEVEL AND CHANGING AXLE OIL IN DIFFERENTIAL CASE
REPLACING FRONT AXLE LUBRICATION FILTER
STEERING SYSTEM
TESTING STEERING WHEEL
BLEEDING STEERING CYLINDER CIRCUIT OF AIR
TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE
BRAKE SYSTEM
BLEEDING BRAKE CIRCUIT OF AIR
TESTING BRAKE OIL PRESSURE
TESTING ACCUMULATOR CHARGE PRESSURE
TESTING BRAKING PERFORMANCE OF BRAKE
TESTING WEAR OF SERVICE BRAKE DISC
TESTING AND ADJUSTING PARKING BRAKE
TESTING AND ADJUSTING BRAKE PEDAL
TESTING AND ADJUSTING BRAKE PEDAL ANGLE SENSOR LINKAGE
HYDRAULIC SYSTEM
RELEASING REMAINING PRESSURE FROM HYDRAULIC PIPING
CHANGING HYDRAULIC OIL
REPLACING HYDRAULIC OIL LINE FILTER
CLEANING HYDRAULIC TANK STRAINER
TESTING HYDRAULIC TANK BREATHER
WORK EQUIPMENT
BLEED AIR FROM LIFT CYLINDER
TESTING HYDRAULIC DRIFT AND HYDRAULIC DRIFT FORWARD TILTING OF THE HYDRAULIC CYLINDER
ADJUSTMENT OF MAST
ADJUSTMENT OF FINGER BAR
CAB AND ITS ATTACHMENTS
TESTING LIFT LEVER AND TILT LEVER
ELECTRICAL SYSTEM
SETTING AND OPERATION OF MONITOR PANEL
KOMTRAX TERMINAL START-UP PROCEDURE
HANDLING OF ENGINE CONTROLLER VOLTAGE CIRCUIT
PROCEDURE FOR CHECKING DIODE

TROUBLESHOOTING
INFORMATION RELATED TO TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
HOW TO PROCEED WITH TROUBLESHOOTING
CHECK BEFORE TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
LOCATIONS OF FUSES
CONNECTOR LIST AND LAYOUT
CONNECTION TABLE FOR CONNECTOR PIN NO
T-BOX AND T-ADAPTER LIST
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
TROUBLESHOOTING FOR BASIC ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
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 EGR VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF EGR COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF ALTERNATOR BELT
REMOVAL AND INSTALLATION OF AUTO-TENSIONER
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 KDOC MUFFLER ASSEMBLY
REMOVAL AND INSTALLATION OF KCCV ASSEMBLY
REMOVAL AND INSTALLATION OF AIR CLEANER ASSEMBLY
POWER TRAIN
REMOVAL AND INSTALLATION OF FRONT AXLE AND HST MOTOR ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF REAR AXLE 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 STEERING CYLINDER 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 STEERING AND WORK EQUIPMENT PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF BRAKE CIRCUIT STRAINER
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF O-RINGS OF ORBITROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF LIFT CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
OPERATORS CAB
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
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
ELECTRICAL SYSTEM
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL ASSEMBLY
REMOVAL AND INSTALLATION OF KCCV CRANKCASE PRESSURE SENSOR

MAINTENANCE STANDARD
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 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 SLACK ADJUSTER
MAINTENANCE STANDARD OF PARKING BRAKE
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
YEARLY INSPECTION CRITERIA

DIAGRAMS AND DRAWINGS
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS FOR HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS FOR ELECTRICAL CIRCUIT DIAGRAM

Engine SAA4D95LE-6 workshop service repair manual