Factory Shop Manual For Komatsu Forklift Truck. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 540
Number: SM202
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Komatsu Forklift Truck
CX Series
FG35-8
FG45ST-8
FG35-8
FG45BCS-8
FG40ZT-8
FG40ZT2-8
FG40-8
FG45T-8
FG45T2-8
FG50AT2-8
FD40ZT-8
FD40ZT2-8
FD40-8
FD45T-8
FD45T2-8
FD50AT2-8
SN130001A-134999A (EPA Tier 1)
SN135001A And Up (EPA Tier 2)
Contents
INTRODUCTION
ENGINE SERIAL NUMBER LOCATION
FORKLIFT TRUCKS COVERED IN THIS PUBLICATION
-FEDERAL EPA EMISSION CONTROL STATEMENTS
Labels Required And Label Locations
Warranty
Safety Management
Safe Travel
Loading Operations
Safety In Periodic Maintenance
Towing
Structure And Stability Of The Lift Truck
Safety Labels
Optional Equipment
-GENERAL INFORMATION & SPECIFICATIONS
Specifications – Mast Data & Features – Indoor (Cushion) Truck
Specifications – Mast Data & Features – Outdoor (Pneumatic) Trucks
Truck Data – Cushion Tire Lift Trucks (Indoor)
Truck Data – Pneumatic Tire Lift Trucks
Periodic Replacement Of Consumable Parts
Standard Tightening Torque For Pipe Joints
Standard Tightening Torque For Bolts
-SERVICE DATA
Service Data – Gasoline Engine Trucks
Service Data – Diesel Engine Trucks
-TESTING, ADJUSTING AND MEASURING
Check Engine Oil (TB45E)
Adjust Engine Oil Level
Adjust Ignition Timing (TB45E)
Adjust Spark Plug Gap (TB45E)
Adjust Valve Clearance (TB45E)
Adjust Valve Clearance (S6D102E)
Adjust Engine Drive Belts (TB45Ej
Measure Engine Cylinder Compression (TB45E)
Measure Hydraulic Drift On Lift & Tilt Cylinders
Adjust Typical Mast
Adjust Parking Brake Lever
Adjust Accelerator Pedal (TB45E Engine)
Testing, Adjusting And Measuring Throttle Position Sensor System
Accelerator Pedal Position Sensor – Tb45 Engine
Adjust Accelerator Pedal (S6D102E Engine)
Measure Brake Stopping Distance (Braking Effect)
Adjust Inching / Brake Pedal (Torqflow Trucks)
Adjust Stop Lamp Switch
Adjust Wheel Brake
Check Operation Of The Automatic Adjustment Device
Check Torqflow Clutch Actuation Pressure – Pneumatic Tire
Check Torque Converter Stall Speed
Check Torqflow Clutch Actuation Pressure – Cushion Tire
Check Torque Converter Stall Speed
Adjust Inching Valve / Spool
Test Specific Gravity Of Battery Electrolyte
Check Tires And Adjusting Pneumatic Tire Pressure
Measure Minimum Left And Right Turning Radius
Adjust Turning Radius
Adjust Rear Axle – Thrust Clearance
-INSPECTION
Inspect LPG Vaporizer For Tar Buildup (TB45E)
Inspect Blow-By Gas Recirculation System (TB45E)
Inspect Cooling System And Radiator
Inspect Coolant Sub-Tank Level
Inspect Fan Assembly
Inspect Charging System Wiring
Inspect Front Axle And Re-Torque Mounting Bolts
Inspect Rear Axle And Re-Torque Mounting Bolts
Inspect Wheels
Inspect Rim Side Ring
Inspect Wheel Bearings
Inspect Steering Axle
Inspect Steering Wheel
Inspect Lighting/Turn Signal Switch – W/O Dimmer Switch
Inspect Lighting/Turn Signal Switch – With Dimmer Switch
Inspect Lighting/Turn Signal Switch
Inspect F/R Switch
Inspect Power Steering System
Inspect Brake System Rods, Cables And Links
Inspect Brake Piping And Connections
Inspect Brake Master And Wheel Cylinders
Inspect Brake Shoes And Associated Parts
Inspect Brake Drums
Inspect Brake Backing Plates
Inspect Load Forks
Inspect Mast
Inspect Fork Carriage
Inspect Lift Chains
Inspect Chain Wheels
Inspect Attachments
Inspect Hydraulic Tank
Inspect Chassis And Attachment Piping
Inspect Hydraulic Pump
Inspect Lift Cylinder
Inspect Tilt Cylinders
Inspect Attachment Cylinders (If Equipped)
Inspect Lift Truck Chassis And Frame
Inspect Cab (If Equipped)
Inspect Operator’S Seat
Inspect Equipment Used For Accessing The Lift Truck
Inspect Display Panel
Inspect Overhead Guard
Inspect Lights, Gauges And Warning Devices
Inspect Rear View’ Mirror And Reflectors
-MAINTENANCE OPERATIONS
Lubricant List – Gasoline Engine Lift Trucks
Lubricant List – Diesel Engine Lift Trucks
Oil And Greasing Chart
Change Oil And Filter In Gasoline Engines
Change Oil And Filter In Diesel Engines
Change Gear Oil In Differential Case
Change Transmission Fluid In Torqflow Transmission Case
Change Oil In Hydraulic Tank
Replace Fuel Filter – Gasoline Engines
Replace Fuel Filter – Diesel Engines
Replace Air Cleaner Element
Clean Radiator
Clean Radiator Fins
Bleed Air From Brake System
-REMOVAL, DISASSEMBLY, ASSEMBLY, INSTALLATION
Unit Installation Positions Diagram
Overall Disassembly / Assembly Flow Chart
Weight Table – Component Assemblies And Parts
Mast
Engine
Transmission And Drive Axle
Torque Converter / Transmission Control Valve – Pneumatic Trucks
Torqflow Transmission W/ Torque Converter – Cushion Trucks
Drive Axle
Differential
Brake Booster And Master Cylinder
Wheel Brake
Steering Axle
Hydraulic Pump – Gasoline Engines
Hydraulic Pump – Diesel Engines
Test Hydraulic Pump
Hydraulic Control Valve
Tilt Cylinder
Sideshifter
Combination Switch
-TROUBLESHOOTING
Engine
Torqflow
Torqflow Converter – Cushion Trucks
Torqflow Converter – Pneumatic Trucks
Control Valve – Cushion Trucks
Control Valve – Pneumatic Trucks
Electrical System
Steering System
Power Steering Valve
Brake System
Hydraulic System
Hydraulic Pump
-80D/100D/110D – MS 2-STAGE MAST
Introduction
Installation Instructions
Periodic Maintenance
Troubleshooting
Service
-80D/100D/110D – MT 3-STAGE MAST
Introduction
Installation Instructions
Periodic Maintenance
Troubleshooting
Service
-CONVERSION TABLES
Millimeters To Inches
Inches To Millimeters
Cubic Meters To Cubic Yards
Cubic Yards To Cubic Meters
Liter To U.S. Gallon
U.S. Gallon To Liter
Kilogram To Pound
Pound To Kilogram
Kilograms Per Square Centimeter To Pounds Per Square Inch
Kilogram To Foot Pounds Of Force
Temperature – Fahrenheit To Centigrade Conversion
-SERVICE DIAGRAMS
Wiring Diagrams
Electrical Assembly Drawings
Transmission Drawings
Drive Axle Drawings
Steering Axle Drawings
Frame Drawings
Piping Diagrams
Control Valve Diagram
-E-SERIES SIDESHIFTER
Introduction
Periodic Maintenance
Troubleshooting
Service
Specifications
-D-SERIES SIDESHIFTER
Introduction
Installation
Periodic Maintenance
Troubleshooting
Service
Specifications
What you get
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