Komatsu Forklift Truck FH40-1 FH45-1 FH50-1 138001 & Up Shop Manual SEN06282-00
Komatsu Forklift Truck FH40-1 FH45-1 FH50-1 138001 & Up Shop Manual SEN06282-00
Komatsu Forklift Truck FH40-1 FH45-1 FH50-1 138001 & Up Shop Manual SEN06282-00
Table of contents
Table of contents
00 Index and foreword
Table of contents .................................................................................................................................... 00-2
Table of contents ................................................................................................................................ 00-2
Foreword and general information ......................................................................................................... 00-9
Safety notice ...................................................................................................................................... 00-9
How to read the shop manual .......................................................................................................... 00-20
Explanation of terms for maintenance standard .............................................................................. 00-22
Handling of electric equipment and hydraulic component ............................................................... 00-24
Handling of connectors newly used for engines .............................................................................. 00-33
How to read electric wire code......................................................................................................... 00-36
Precautions when carrying out operation......................................................................................... 00-39
Standard tightening torque table ...................................................................................................... 00-42
Conversion table .............................................................................................................................. 00-46
01 General Information
Specifications ......................................................................................................................................... 01-3
Specification dimensions drawing ...................................................................................................... 01-3
Weight table ....................................................................................................................................... 01-5
Lubricant list....................................................................................................................................... 01-6
List of specified fuel and lubricant...................................................................................................... 01-7
40 Troubleshooting
Information related to troubleshooting ................................................................................................... 40-5
Points to remember when troubleshooting ........................................................................................ 40-5
How to proceed in troubleshooting .................................................................................................... 40-6
Checks before troubleshooting .......................................................................................................... 40-7
Classification and procedures of troubleshooting .............................................................................. 40-8
Phenomena seemed to be failures and troubleshooting Nos. ........................................................... 40-9
Information described in troubleshooting table ................................................................................ 40-12
Locations of fuses ............................................................................................................................ 40-17
Connector pin connection by pin No. ............................................................................................... 40-20
T-branch box and T-branch adapter table ........................................................................................ 40-60
Troubleshooting by failure code (HST controller system) .................................................................... 40-63
Failure code list................................................................................................................................ 40-63
Failure code [--/AB00MA] Alternator: Malfunction............................................................................ 40-66
Failure code [--/B@CRNS] HST Oil: Overheating ........................................................................... 40-67
Failure code [--/2G40ZG] Brake accumulator: Dropped hydraulic pressure .................................... 40-68
Failure code [--/6091NX] Hst oil filter: Clogging............................................................................... 40-69
Failure code [12/DDK6KA] FNR lever: Open circuit ........................................................................ 40-70
Failure code [12/DDK6KY] FNR lever: Hot short circuit................................................................... 40-74
Failure code [14/DLT4KZ] Travel speed sensor A:
Open circuit, ground fault, or hot short circuit .............................................................................. 40-76
Failure code [14/DLT6KZ] Travel speed sensor B:
Open circuit, ground fault, or hot short circuit .............................................................................. 40-78
Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B:
Open circuit, ground fault, or hot short circuit .............................................................................. 40-80
Failure code [14/DLT4MA] Travel speed sensors A and B: Malfunction .......................................... 40-82
Failure code [14/DLT4LC] Travel speed sensors A and B: Mismatch of rotation speed signals...... 40-83
Failure code [15/7REXKA] Seat switch: Open circuit ...................................................................... 40-84
Failure code [15/7REXKB] Seat switch: Ground fault...................................................................... 40-86
Failure code [18/D5ZTKZ] Pump EPC valve ground return signal:
Open circuit or hot short circuit .................................................................................................... 40-88
Failure code [22/DHHBKX] HST pump A-port pressure sensor: Open circuit or ground fault ......... 40-90
Failure code [22/DHHBKY] HST pump A-port pressure sensor: Hot short circuit ........................... 40-92
Failure code [23/DHHCKX] HST pump B-port pressure sensor: Open circuit or ground fault ......... 40-94
Failure code [23/DHHCKY] HST pump B-port pressure sensor: Hot short circuit ........................... 40-96
Failure code [25/DK70KZ] Brake pedal angle sensor: Open circuit or ground fault ........................ 40-98
Failure code [25/DK70KY] Brake pedal angle sensor: Hot short circuit......................................... 40-100
Failure code [26/DGS1KA] HST oil temperature sensor: Open circuit .......................................... 40-102
Failure code [26/DGS1KB] HST oil temperature sensor: Ground fault .......................................... 40-104
Failure code [27/AB00KZ] Alternator R signal circuit: Open circuit or ground fault ....................... 40-106
Failure code [27/AB00KY] Alternator R signal circuit: Hot short circuit.......................................... 40-108
Failure code [28/DHPCKZ] Lift cylinder pressure sensor: Open circuit or ground fault ................. 40-110
Failure code [28/DHPCKY] Lift cylinder pressure sensor: Hot short circuit ................................... 40-112
Failure code [29/DH2FKZ] Brake charge pressure sensor: Open circuit or ground fault .............. 40-114
Failure code [29/DH2FKY] Brake charge pressure sensor: Hot short circuit................................. 40-116
Failure code [32/DXATKA] HST pump forward travel EPC solenoid valve: Open circuit............... 40-118
Failure code [32/DXATKB] HST pump forward travel EPC solenoid valve: Ground fault .............. 40-120
Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve: Hot short circuit......... 40-122
Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid valve: Open circuit .............. 40-124
Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid valve: Ground fault ............. 40-126
Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid valve: Hot short circuit ........ 40-128
Failure code [34/DXAVKA] HST motor EPC solenoid valve: Open circuit ..................................... 40-130
Failure code [34/DXAVKB] HST motor EPC solenoid valve: Ground fault .................................... 40-132
Failure code [34/DXAVKY] HST motor EPC solenoid valve: Hot short circuit ............................... 40-134
Failure code [35/D110KZ] HST controller power relay: Open circuit or hot short circuit................ 40-136
Failure code [35/D110KB] HST controller power relay: Ground fault............................................. 40-138
Failure code [37/DW9NKA] Work equipment lock solenoid valve: Open circuit ............................ 40-140
Failure code [37/DW9NKB] Work equipment lock solenoid valve: Ground fault............................ 40-142
Failure code [37/DW9NKY] Work equipment lock solenoid valve: Hot short circuit ...................... 40-144
Failure code [38/DW9MKA] Lift lock solenoid valve: Open circuit ................................................. 40-145
Failure code [38/DW9MKB] Lift lock solenoid valve: Ground fault................................................. 40-146
Failure code [38/DW9MKY] Lift lock solenoid valve: Hot short circuit ........................................... 40-148
Failure code [39/D140KB] Starter relay: Ground fault ................................................................... 40-150
Failure code [39/D140KY] Starter relay: Hot short circuit .............................................................. 40-152
Failure code [47/D161KA] Backup buzzer and backup lamp relay: Open circuit .......................... 40-154
Failure code [47/D161KB] Backup buzzer and backup lamp relay: Ground fault .......................... 40-156
Failure code [47/D161KY] Backup buzzer and backup lamp relay: Hot short circuit..................... 40-158
Failure code [48/DV00KB] Warning buzzer: Ground fault ............................................................. 40-160
Failure code [48/DV00KY] Warning buzzer: Hot short circuit ........................................................ 40-161
Failure code [49/D19UKA] Pump EPC valve ground cutout relay: Open circuit ............................ 40-162
Failure code [49/D19UKB] Pump EPC valve ground cutout replay: Ground fault ......................... 40-164
Failure code [49/D19UKY] Pump EPC valve ground cutout relay: Hot short circuit ...................... 40-166
Failure code [52/DAJ0KK] HST controller: Drop of power voltage ................................................ 40-168
Failure code [53/DAJ2KK] HST controller: Drop of load power supply voltage ............................. 40-170
Failure code [54/7REHKA] Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit ............ 40-172
Failure code [55/DAJ5KX] HST controller sensor 5 V-power supply:
Ground fault or hot short circuit ................................................................................................. 40-174
Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL): Open circuit ...................... 40-176
Failure code [62/DB2RKR] CAN communication (between HST controller and
engine controller): Communication failure (Component system failure) .................................... 40-178
Failure code [63/DAJ000] HST Controller: Memory error .............................................................. 40-180
Failure code [63/DAJ0KT] HST Controller: Memory error ............................................................. 40-181
Troubleshooting by failure code (EPACS controller system) ............................................................. 40-182
Display of EPACS controller failure code....................................................................................... 40-182
Failure code [LED: OFF] EPACS controller abnormality................................................................ 40-183
Failure code [LED: 1 flashing] Initialization is not completed......................................................... 40-184
Failure code [LED: 2 flashings] Controller is being initialized ........................................................ 40-185
Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality .................................... 40-186
Failure code [LED: 4 flashings] Tire angle sensor abnormality...................................................... 40-188
Troubleshooting for electrical system (E-mode) ................................................................................ 40-190
Information described in troubleshooting table .............................................................................. 40-190
E-1 Engine does not start .............................................................................................................. 40-191
E-2 Engine preheater does not operate......................................................................................... 40-196
E-3 Parking brake reminder alarm does not sound or does not stop sounding ............................. 40-198
E-4 EPACS is abnormal................................................................................................................. 40-201
E-5 Headlamp, clearance lamp, tail lamp and license plate lamp do not light up or go off............ 40-204
E-6 Turn signal lamps do not light up or go off .............................................................................. 40-210
E-7 Brake lamps do not light up or go off....................................................................................... 40-214
E-8 Backup lamps do not light up or go off .................................................................................... 40-216
E-9 Backup buzzer does not sound or does not stop sounding..................................................... 40-218
E-10 Horn does not sound or does not stop sounding................................................................... 40-220
E-11 Fuel level is not displayed normally ....................................................................................... 40-222
E-12 Engine coolant temperature level is not displayed normally ................................................. 40-224
E-13 All of indicator and warning lamps of instrument panel do not light up
when starting switch is turned to the ON position. ..................................................................... 40-226
E-14 When starting switch is turned to the ON position,
all of indicator and warning lamps of pilot box do not light up.................................................... 40-233
E-15 When starting switch is turned to the ON position,
engine preheater lamp does not light up.................................................................................... 40-238
E-16 When starting switch is turned to the ON position, alarm buzzer does not sound ................ 40-240
E-17 Backup lamp of instrument panel does not light up............................................................... 40-242
E-18 Charge warning lamp lights up while engine is running ........................................................ 40-244
E-19 HST oil temperature warning lamp lights up while engine is running .................................... 40-246
E-20 HST oil filter clogging warning lamp lights up while engine is running .................................. 40-247
E-21 Engine oil pressure warning lamp lights up while engine is running ..................................... 40-248
E-22 Sedimenter (water separator) warning lamp lights up while engine is running ..................... 40-248
E-23 Abnormality warning lamp lights up while engine is running ................................................. 40-250
E-24 Engine abnormality warning lamp lights up while engine is running ..................................... 40-252
E-25 Travel speed restriction cannot be released or enabled........................................................ 40-254
E-26 Impossible to select HST controller failure display mode, HST controller
adjustment mode, speed limit setting mode, or engine stop time auto-change mode ............... 40-256
E-27 KOMTRAX system does not operate normally...................................................................... 40-259
Troubleshooting for hydraulic and mechanical system (H-mode) ...................................................... 40-261
How to use troubleshooting table................................................................................................... 40-261
Hydraulic and mechanical system diagram ................................................................................... 40-264
Table of failure modes and causes ................................................................................................ 40-266
H-1 Lift truck cannot travel ............................................................................................................. 40-270
H-2 Slow travel speed.................................................................................................................... 40-271
H-3 Insufficient towing force........................................................................................................... 40-272
H-4 Engine stops during traveling, or engine speed drops excessively......................................... 40-273
H-5 HST (hydraulic) oil temperature is too high............................................................................. 40-274
H-6 Impossible steering ................................................................................................................. 40-275
H-7 Response is low during turning ............................................................................................... 40-276
H-8 Steering is heavy..................................................................................................................... 40-277
H-9 Unstable during turning ........................................................................................................... 40-278
H-10 When steering wheel is released it does not return to neutral or it rotates by itself .............. 40-279
H-11 Steering wheel is turned in reverse or it kicks (while work equipment is operated) .............. 40-279
H-12 Large shock is made when steering wheel is returned ......................................................... 40-280
H-13 EPACS does not work ........................................................................................................... 40-281
H-14 Steering wheel vibrates ......................................................................................................... 40-282
H-15 Steering system makes abnormal sound .............................................................................. 40-282
H-16 Oil leaks from steering circuit ................................................................................................ 40-282
H-17 Service brake does not work or its performance is low ......................................................... 40-283
H-18 Service brake is not reset or it drags..................................................................................... 40-284
H-19 Parking brake does not work or its performance is low......................................................... 40-285
H-20 Parking brake is not reset or it drags .................................................................................... 40-286
H-21 Abnormal noise around the work equipment or steering pump............................................. 40-287
H-22 Engine speed drops excessively or stops during work equipment operation
or wheel steering........................................................................................................................ 40-288
H-23 Fine control performance of entire work equipment is low or response is low ...................... 40-289
H-24 Work equipment cannot be locked (and the equipment operates when operator leaves) .... 40-290
H-25 Control valve lever does not move smoothly and it is heavy ................................................ 40-291
H-26 Lift cylinder and fork do not lift............................................................................................... 40-292
H-27 Lifting speed or power of lift cylinder and fork is insufficient ................................................. 40-293
H-28 Forklift speed lowers at specific height ................................................................................. 40-294
H-29 Lift cylinder natural drift is large............................................................................................. 40-295
H-30 Lift cylinders do not come down ............................................................................................ 40-296
H-31 Fork lowering speed is low or high or fine control performance is low or response is low.... 40-297
H-32 Mast does not tilt forward or backward ................................................................................. 40-298
H-33 Forward/backward tilting speed or force of mast is insufficient............................................. 40-299
H-34 Tilting speed lowers halfway ................................................................................................. 40-300
H-35 Tilt cylinder natural forward drift is large ............................................................................... 40-301
H-36 Mast is unstable during travel with load ................................................................................ 40-302
H-37 Work equipment is heavy when work equipment and
steering are operated simultaneously........................................................................................ 40-303
H-38 Steering is heavy when work equipment and steering are operated simultaneously............ 40-304
90 Circuit diagrams
Hydraulic circuit diagram........................................................................................................................ 90-3
Hydraulic circuit diagram.................................................................................................................... 90-3
Electrical circuit diagram ........................................................................................................................ 90-5
Electric circuit diagram (1/4) .............................................................................................................. 90-5
Electric circuit diagram (2/4) .............................................................................................................. 90-7
Electric circuit diagram (3/4) .............................................................................................................. 90-9
Electric circuit diagram (4/4) ............................................................................................................ 90-11
Connector list and layout ................................................................................................................. 90-13
Index
Index ........................................................................................................................................................... 1
1. General precautions
k Mistakes in operation are extremely thoroughly check the tools, lift truck, ser-
dangerous. Read the Operation and vice car, etc.
Maintenance Manual carefully before 7) If welding repairs are needed, always
operating the lift truck. In addition, read have a trained and experienced welder
this manual carefully before starting carry out the work. When carrying out
work. welding work, always wear w elding
1) Before carrying out any greasing or gloves, apron, shielding goggles, cap and
repairs, read all the safety labels stuck to other clothes suited for welding work.
the lift truck. For the locations of the safety 8) Before starting work, warm up your body
labels and detailed explanation of precau- thoroughly to start work under good condi-
tions, see the Operation and Maintenance tion.
Manual. 9) Avoid working continuously for long hours
2) Decide a place in the repair workshop to and take rests at proper intervals to keep
keep tools and removed parts. Always the good condition. Take rests in a fixed
keep the tools and parts in their correct safe place.
places. Always keep the work area clean
and make sure that there is no dirt, water, Safety points
or oil on the floor. Smoke only in the areas
1 Good arrangement
provided for smoking. Never smoke while
working. 2 Correct work clothes
3) When carrying out any operation, always 3 Following work standard
wear safety shoes and helmet. Do not 4 Making and checking signs
wear loose work clothes, or clothes with
Prohibition of operation and handling by
buttons missing. 5 unlicensed workers
q Always wear safety glasses when hit-
ting parts with a hammer. 6 Safety check before starting work
q Always wear safety glasses when 7 Wearing protective goggles
grinding parts with a grinder, etc. (for cleaning or grinding work)
8 Wearing
4) When carrying out any operation with 2 or shielding goggles and protectors
more workers, always agree on the oper- (for welding work)
ating procedure before starting. Always 9 Good physical condition and preparation
inform your fellow workers before starting Precautions against work which you are
any step of the operation. Before starting 10 not used to or you are used to too much
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition. Learn the
correct way to use them, and use the
proper ones of them. Before starting work,
3. Precautions during work 10) Be sure to assemble all parts again in their
1) Before disconnecting or removing compo- original places. Replace any damaged
nents of the oil, water, or air circuits, first parts and parts which must not be reused
release the pressure completely from the with new parts. When installing hoses and
circuit. When removing the oil filler cap, a wires, be sure that they will not be dam-
drain plug, or an oil pressure pickup plug, aged by contact with other parts when the
loosen it slowly to prevent the oil from lift truck is operated.
spurting out. 11) When installing high pressure hoses,
2) The coolant and oil in the circuits are hot make sure that they are not twisted. Dam-
when the engine is stopped, so be careful aged tubes are dangerous, so be
not to get scalded. Wait for the oil and extremely careful when installing tubes for
coolant to cool before carrying out any high pressure circuits. In addition, check
work on the oil or water circuits. t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
3) Before starting work, stop the engine. installed.
When working on or around a rotating 12) When assembling or installing parts,
part, in particular, stop the engine. When always tighten them to the specified
checking the machine without stopping torques. When installing protective parts
the engine (measuring oil pressure, such as guards, or parts which vibrate vio-
revolving speed, temperature, etc.), take lently or rotate at high speed, be particu-
extreme care not to get rolled or caught in larly careful to check that they are
rotating parts or moving parts. installed correctly.
4) Before starting work, remove the leads 13) When aligning 2 holes, never insert your
from the battery. Always remove the lead fingers or hand. Be careful not to get your
from the negative (–) terminal first. fingers caught in a hole.
5) When raising a heavy component (heavier 14) When measuring hydraulic pressure,
than 25 kg), use a hoist or crane. Before check that the measuring tools are cor-
starting work, check that the slings (wire rectly assembled.
ropes, chains, and hooks) are free from 15) If the engine is operated for a long time in
damage. Always use slings which have a place which is not ventilated well, you
ample capacity and install them to proper may suffer from gas poisoning. Accord-
places. Operate the hoist or crane slowly ingly, open the windows and doors to ven-
to prevent the component from hitting any tilate well.
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
8) When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electri-
cal parts, in particular.
k
Use right tools for inspection and maintenance
Precautions for inspection and mainte-
work. Use of a broken tool or use a tool for a
nance work (preparation)
purpose other than its true purpose is very
1) Perform inspection and maintenance on a
dangerous.
flat, dry, and dustless place.
2) When working in a warehouse, ventilate
well.
3) Keep the inside of the maintenance shop
arranged well and work safely.
4) Prepare a fire extinguisher against a fire
and learn how to use it.
5) Before starting inspection work, lower the
fork to the ground.
6) Before starting inspection work, turn the
starting switch OFF and pull out the key.
7) Turn the starting switch OFF and keep the
key pulled out unless necessary.
8) Pull the parking brake lever and put
chocks in front and rear of the front and
rear tyres.
k Beware of rotating cooling fan and belt k Tyre inspection and inflation proce-
1) Keep hand off the rotating fan or fan belt. dures
2) When inspecting the rotating parts, stop 1) If the tyre inflation pressure is low, the lift
the engine. truck stability is lowered. Do not inflate the
3) Do not bring a thing near the rotating parts tyre immediately, however. The inflation
which can be caught easily. pressure may have decreased because of
a damage of the rim. If the tyre is inflated
to high pressure while the rim is damaged
or cracked, the tyre will burst and cause
an injury or a death.
2) When checking the tyre inflation pressure,
place your body in front of the tread face
of the tyre. Do not work from the side of
the tyre.
3) Stop jacking up when the tyres are floated 4) When slinging the lift truck, use wires hav-
above the ground a little and put blocks ing sufficient strength and no damage.
under both sides of the frame to prevent
the lift truck from falling.
4) Lock the tyres with chocks.
8) When installing wire ropes to an angular 6. Precautions for using overhead hoist crane
load, apply pads to protect the wire ropes. k When raising a heavy part (heavier
If the load is slippery, apply proper mate- than 25 kg), use a hoist, etc. In Disas-
rial to prevent the wire rope from slipping. sembly and assembly, the weight of a
9) Use the specified eyebolts and fix wire part heavier than 25 kg is indicated
ropes, chains, etc. to them with shackles, after the mark of 4.
etc. 1) Before starting work, inspect the wire
10) Apply wire ropes to the middle portion of ropes, brake, clutch, controller, rails, over
the hook. wind stop device, electric shock preven-
q Slinging near the tip of the hook may tion earth leakage breaker, crane collision
cause the rope to slip off the hook prevention device, and power application
during hoisting. The hook has the warning lamp, and check safety.
maximum strength at the middle por- 2) Observe the signs for sling work.
tion. 3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
11) Do not use twisted or kinked wire ropes.
and passage.
12) When lifting up a load, observe the follow-
11) After operating the hoist, do not swing the
ing.
control switch.
q Wind in the crane slowly until wire
12) Remember the position of the main switch
ropes are stretched. When settling
so that you can turn off the power immedi-
the wire ropes with the hand, do not
ately in an emergency.
grasp them but press them from
13) If the hoist stops because of a power fail-
above. If you grasp them, your fingers
ure, turn the power switch OFF. When
may be caught.
turning on a switch which was turned OFF
q After the wire ropes are stretched,
by the electric shock prevention earth
stop the crane and check the condi-
leakage breaker, check that the devices
tion of the slung load, wire ropes, and
related to that switch are not in operation
pads.
state.
q If the load is unstable or the wire rope
14) If you find an obstacle around the hoist,
or chains are twisted, lower the load
stop the operation.
and lift it up again.
15) After finishing the work, stop the hoist at
q Do not lift up the load slantingly.
the specified position and raise the hook
13) When lifting down a load, observe the fol-
to at least 2 m above the floor. Do not
lowing.
leave the sling installed to the hook.
q When lifting down a load, stop it tem-
porarily at 30 cm above the floor, and
then lower it slowly.
q Check that the load is stable, and
then remove the sling.
q Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU FORKLIFT distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the lift truck.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. For troubleshooting "S mode" related to the engine, see Engine.
2. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
1
Special precautions are necessary for lift truck security during
Security
assembly work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5 Oil, coolant Places where oil, etc. must be added, and capacity.
6 Drain Places where oil, etc. must be drained, and quantity to be drained.
3. Unit
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. microcom-
puter and electronic control circuits. These
control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
Disconnect connector (3) according to the fol- 3) While pressing lock (D), pull out connector
lowing procedure. (4) in the direction of the arrow.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 95E-5 engine
4) While pressing lock (E), pull out connector
(5) in the direction of the arrow.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
Example: 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nom-
inal No. of 0.85.
Indicates color of wire by color code.
Color codes are shown in Table 3.
1. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov- AV Standard – – – – – – – 4.6
er D CAVS Standard – 1.6 – 1.8 – 2.1 – – – – –
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
(Table 1)
Using
Type Symbol Material temperature Example of use
range (°C)
Annealed copper for electric
Low-voltage wire Conductor Wiring conducting large current
AV appliance
for automobile (Nominal No. 5 and above)
Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric
Conductor
low-voltage wire appliance General wiring
AVS –30 to +60
for automobile, (Nominal No. 0.5 – 3)
Insulator Soft polyvinyl chloride
type 1
Thin-cover Annealed copper for electric
Conductor
low-voltage wire appliance General wiring
CAVS
for automobile, (Nominal No. 0.5 – 1.25)
type 2 Insulator Soft polyvinyl chloride
Annealed copper for electric
Heat-resistant Conductor General wiring in extremely
appliance
low-voltage wire AEX –50 to +110 cold district, wiring at
for automobile Heat-resistant crosslinked
Insulator high-temperature place
polyethylene
(Table 3)
Color code Color of wire Color code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: "GW" means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
When carrying out removal, installation, disassembly or assembly of units, be sure to follow the general pre-
cautions given below.
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions (mm)
Nominal No. Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 22.5 22.5 34
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
a When using the lift truck for the first time after repair or long storage, follow the same procedure.
Thread diameter
Width across flats Tightening torque
of bolt
mm mm Nm kgfm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
Thread diameter
Width across flats Tightening torque
of bolt
mm mm Nm kgfm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
Thread diameter
Width across flats Tightening torque
of bolt
mm mm Nm kgfm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
Thread diameter
Width across flats Tightening torque Nm {kgfm}
Nominal No. of bolt
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03, 04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
Thread diameter
Width across flats Tightening torque Nm {kgfm}
Nominal No. of bolt
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 107 engine series (mounted on EX50 Series) (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 107 engine series to
the torque below.
a For tightening torques for 95 engine series, see "Standard tightening torque table".
Tightening torque
Thread size
Bolts and nuts
mm Nm kgfm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 – –
8. Table of tightening torques for 107 engine series (mounted on EX50 Series) (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 107 engine series to the
torque below.
a For tightening torques for 95 engine series, see "Standard tightening torque table".
9. Table of tightening torques for 107 engine series (mounted on EX50 Series) (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 107 engine series
to the torque below.
a For tightening torques for 95 engine series, see "Standard tightening torque table".
Tightening torque
Material Cast iron or steel Aluminium
Thread size (inch) Nm kgfm Nm kgfm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.20 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.20
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
Conversion table
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
01 General Information
Table of Contents
01 General Information
Specifications ......................................................................................................................................... 01-3
Specification dimensions drawing ...................................................................................................... 01-3
Weight table ....................................................................................................................................... 01-5
Lubricant list....................................................................................................................................... 01-6
List of specified fuel and lubricant...................................................................................................... 01-7
Specifications
Specification dimensions drawing
Weight table
Unit: kg (dry weight)
Model
FH40-1 FH45-1 FH50-1 Remarks
Equipment
Engine assembly 300 300 300
PTO 118 118 118
HST pump 67 67 67
HST motor 80 80 80
Front 327 327 327 Including differential gear and brake disc
Axle
Rear 162 162 162 PS with cylinder and hub
Front 90 90 90 Single tire+rim
Wheel
Rear 35 35 35 Tire+rim
Overhead guard 115 115 115 Guard+stay+dashboard+ cover
Counterweight 2,384 2,786 3,115
Lift cylinder assembly (1 piece) 40 45 45 Lift height 3m
Tilt cylinder assembly (1 piece) 20 20 20
Power steering cylinder assembly 19 19 19
Hydraulic pump 18 18 18 Work equipment and steering pump
Control valve 12 12 12 2CV
Steering valve 8 8 8
FV, lift height 3m, excluding finger board and
Mast assembly 690 905 905
guard
Finger board assembly 190 210 290
Guard 35 35 45
FH40-1: L = 1,070
Fork assembly (1 piece) 100 100 115 FH45-1: L = 1,070
FH50-1: L = 1,220
Lubricant list
CHART OF OIL AND GREASING FOR MAINTENANCE
Important
Be sure to use the Komatsu genuine oil and
grease.
To lubricate the rear axle, steer the tire as shown in
the figure on the right .
EO10W30-DH
Engine oil
Engine oil pan
(for diesel engine)
EO15W40-DH
G2-LI
Capacity(l) Engine
oil pan Differential
PTO Hydraulic tank Fuel tank Cooling system
case
Model SAA4D95LE-5-C
83
(replacement)
4.0 to 5.0 ton 11 5.5 11 105 9
110
(disassembly)
Important
• Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted
on this lift truck uses an electronically controlled high-pressure fuel injection device. This device requires
high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durabil-
ity of the device may drop remarkably.
• Be sure to use the Komatsu genuine oil and grease.
Table of Contents
10 Structure, function and maintenance standard
Engine and cooling system .................................................................................................................... 10-4
Engine mount and transfer mount...................................................................................................... 10-4
Cooling system .................................................................................................................................. 10-6
Power train ............................................................................................................................................. 10-8
Power train......................................................................................................................................... 10-8
Power train system diagram .............................................................................................................. 10-9
PTO.................................................................................................................................................. 10-10
HST piping diagram ......................................................................................................................... 10-13
HST pump........................................................................................................................................ 10-14
HST motor........................................................................................................................................ 10-26
Axle .................................................................................................................................................. 10-36
Differential ........................................................................................................................................ 10-37
Steering system ................................................................................................................................... 10-43
Steering piping diagram (control valve – power steering cylinder)................................................... 10-43
Orbitrol valve.................................................................................................................................... 10-44
Power steering cylinder.................................................................................................................... 10-46
Brake system ....................................................................................................................................... 10-47
Brake control.................................................................................................................................... 10-47
Brake piping diagram (control valve – accumulator)........................................................................ 10-48
Service brake ................................................................................................................................... 10-50
Accumulator charge valve................................................................................................................ 10-52
Brake valve ...................................................................................................................................... 10-58
Slack adjuster .................................................................................................................................. 10-61
Accumulator (for brake) ................................................................................................................... 10-65
Parking brake................................................................................................................................... 10-66
Undercarriage and frame ..................................................................................................................... 10-67
Rear axle.......................................................................................................................................... 10-67
Hydraulic tank piping diagram.......................................................................................................... 10-68
Frame............................................................................................................................................... 10-69
Hydraulic system.................................................................................................................................. 10-70
Control valve piping diagram (tank – control valve) ......................................................................... 10-70
Work equipment piping diagram (control valve – tilt cylinder/lift cylinder)........................................ 10-71
Attachment piping diagram .............................................................................................................. 10-72
Work equipment control lever linkage .............................................................................................. 10-73
Work equipment and steering pump ................................................................................................ 10-74
Control valve .................................................................................................................................... 10-82
CLSS................................................................................................................................................ 10-88
Each function and operation of each valve ...................................................................................... 10-90
Work equipment ................................................................................................................................. 10-105
Tilt cylinder ..................................................................................................................................... 10-105
Lift cylinder ..................................................................................................................................... 10-106
Mast ............................................................................................................................................... 10-107
Finger board................................................................................................................................... 10-114
Fork................................................................................................................................................ 10-115
Electrical system ................................................................................................................................ 10-116
Electrical control system ................................................................................................................ 10-116
HST controller ................................................................................................................................ 10-138
Engine controller ............................................................................................................................ 10-140
Accelerator pedal sensor ............................................................................................................... 10-142
EPACS controller ........................................................................................................................... 10-144
Instrument panel ............................................................................................................................ 10-146
Pilot box ......................................................................................................................................... 10-148
DC/DC converter............................................................................................................................ 10-149
KOMTRAX system......................................................................................................................... 10-150
Sensor............................................................................................................................................ 10-153
Cooling system
1. Fan 4. Radiator
2. Oil cooler 5. Aftercooler
3. Radiator cap 6. Coolant reservoir tank
Specifications
Aftercooler
Radiator Hydraulic oil cooler
Cooling air side Intake air side
CF59-3 CF40-1
Core type Wave fin Offset fin
(Rectangular wave fin) (Wave fin)
Power train
Power train
1. Engine
2. PTO
3. HST pump
4. HST motor
5. Parking brake
6. Front axle
7. High-pressure hose
PTO
Specifications
• PTO lubricating oil quantity: 5.5 l
• PTO reduction ratio:
C/A=50/57=0.877
D/A=49/57=0.860
B/A=71/57=1.246
Unit: mm
HST pump
Model: HPV75
a HST: Abbreviation for Hydrostatic Transmission
1. Shaft
2. Cradle bearing
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Drive piston
Function Structure
• This pump converts the engine speed and • Cylinder block (7) is supported on shaft (1) by
torque transmitted to its shaft into hydraulic spline (9).
pressure and discharges pressurized oil • Shaft (1) is supported by each bearing (10) and
according to the load. (11) at the front and rear.
• It is possible to change the discharge by chang- • The tip of piston (6) is shaped as a concave
ing the swash plate angle. sphere and crimped on shoe (5) to get together.
• Piston (6) and shoe (5) form a spherical bear-
ing.
• Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular pattern.
• Rocker cam (4) rocks on cylindrical surface (B)
with cradle bearing (2) fixed on case (3).
• Piston (6) moves relatively in the axial direction
in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve
plate (8) while sealing the pressurized oil.
• This surface is designed so that the oil pressure
balance is maintained at a suitable level.
• The pressurized oil is sucked in and discharged
from each cylinder chamber in cylinder block
(7) through valve plate (8).
Operation of pump • When center line (X) of rocker cam (4) matches
• Cylinder block (7) rotates together with shaft (1) the axis of cylinder block (7) (the swash plate
and shoe (5) slides on plane (A). angle is zero), the difference between volumes
• Rocker cam (4) moves along cylindrical surface (E) and (F) inside cylinder block (7) is zero.
(B). As a result, angle (a) between center line • Pressurized oil is not sucked or discharged,
(X) of rocker cam (4) and the axis of cylinder namely pumping action is not performed. (Actu-
block (7) changes. ally, however, the swash plate angle does not
• Angle (a) is called the swash plate angle. become 0 deg.)
Control of discharge
• When swash plate angle (a) is increased, the
difference between volumes (E) and (F) is
increased, then discharge (Q) is increased.
• Swash plate angle (a) is changed by drive pis-
ton (9).
• Drive piston (9) reciprocates linearly according
to the output pressure from EPC valve.
• This linear reciprocating motion is transmitted
to rocker cam (4) through slider (12).
• Being supported by cradle bearing (2) on the
cylindrical surface, rocker cam (4) slides on the
cylindrical surface.
• The maximum swash plate angle (a) of this
pump is 17.6 degrees.
When the directional lever is in NEUTRAL When the directional lever is operated
• Pressurized oil from EPC valve does not enter. • When the directional lever is operated, an elec-
• Because drive piston (1) does not operate, tric signal is sent from the controller to EPC
rocker cam (2) is in NEUTRAL as shown in the valve.
figure. • Pressurized oil from EPC valve enters port
(CSA).
• Drive piston (1) moves to the left to the position
where the force of spring (S2) balances with the
force of pressurized oil.
Function Function
• This valve limits the maximum pressure in HST • It secures the amount of oil flow in HST closed
circuit to protect the circuit. circuit. It prevents charge flow from flowing into
pump high-pressure side (discharge side).
Operation
• Port (a) is connected to the pump circuit Operation
selected by shuttle valve (4). [ Pressure (A) > When HST pump discharge is 0
Pressure (B) ] • HST closed circuit is sealed and the charge
• Port (c) is connected to the charge circuit. pressurized oil does not flow into HST circuit.
• The pressurized oil sent to port (a) fills chamber • Therefore, all the charge pressurized oil from
(b) through orifice (g). charge pump (1) is drained into the case
• Poppet (3C) is in firm contact with valve seat through charge safety valve (2).
(3D).
• When abnormal pressure is generated in the
circuit, if the pressurized oil in chamber (b)
increases to the pressure set by spring (3E),
poppet (3C) is pushed to the right to relieve the
pressurized oil in chamber (b) into chamber (c).
• If the oil pressure in chamber (b) decreases,
differential pressure is generated between
before and after orifice (g).
• Poppet (3A) is pushed to the right by the pres-
surized oil in port (a) to release the pressurized
oil in port (a) into port (c).
• This prevents the oil pressure in main circuit
from exceeding the maximum set pressure.
When HST pump discharges oil from PA port Valve on suction side of piston pump
HST motor
Model: KMV160
a HST: Abbreviation for Hydrostatic Transmission
1. Drive shaft
2. Clinoaxis variable displacement type piston
motor
3. EPC valve
4. Flushing valve
Specifications
Model KMV160
Clinoaxis variable
Type displacement type
piston motor
Theoretical displacement
71 to 160
(cm3/rev)
Charge relief valve set pressure 2.06 to 2.16
(MPa {kg/cm2}) {21 to 22}
Function
• The motor capacity is maximum when servo
piston (2) is in the lowest position.
• The motor capacity is minimum when it is in the
highest position.
• The motor capacity is decided according to the
Structure command current to EPC valve when the servo
• Pistons (13) (7 pieces) are installed on the disc piston is between the above two positions.
portion of drive shaft (1) as spherical joints.
• Piston (13) is at an angle to drive shaft (1) and Operation
enclosed in cylinder block (12). • The servo mechanism portion has chambers
• The inclination of cylinder block (12) and pis- (A), (B), and (C).
tons (13) varies depending on the capacity con- • The self pressures in chambers (A) and (C) act
trol input current of EPC valve. on their respective pressure receiving areas,
• The relationship between the current and the and servo piston (2) operates according to the
capacity is shown in the figure. balance of the forces acting on the chambers.
• When the output pressure from EPC valve is 0
MPa {0 kg/cm2}, main piston (2) is in the lowest
position. (Max. side)
• The capacity control pressure is supplied from
EPC valve to chamber (B) according to the
command current to EPC valve.
• Servo spool (3) leads the self pressure into
chamber (C) up to the set motor capacity,
according to the balance of the force generated
by the capacity control pressure in chamber (B)
and the force of servo spring (1).
Flushing valve
1. Valve 4. Poppet
2. Spring 5. Spring
3. Valve seat 6. Adjustment screw
Function
• The charge relief valve is installed inside the
flushing valve. It prevents the pressure on the
main low pressure side of HST motor selected
by the low-pressure shuttle valve (charge pres-
sure) from increasing above the specified level
and relieves the oil of the specified flow rate
into the case to prevent from overheating.
• The charge relief valve also discharges the dirt-
iest oil in the main circuit to the outside to keep
it clean.
Operation
• Port (A) is connected to the low pressure side
(charge circuit) selected by the low-pressure • When abnormal pressure is generated in the
shuttle valve. circuit, if the oil pressure in ports A and cham-
• Port (B) is connected to the tank drain circuit ber C increases to the pressure set by spring
through the case. (5), poppet (4) is pushed to the left to relieve
• Pressurized oil also fills chamber (C) through the oil in chamber C into port B and the oil pres-
orifice (g) of valve (1). Poppet (4) is in firm con- sure in chamber C decreases.
tact with valve seat (3).
Axle
Differential
21 0 to +0.07
Housing hole diameter 192 +0.06 to +0.10
22
25 Tolerance
Backlash
26 0.15 to 0.23mm
+0.000 0.035 0 to
Ball bearing Outer race 90 ―
-0.015 0.000 +0.005
36 clearance (differ-
ential side) +0.011 +0.000 -0.023 to
Inner race 50 ―
-0.005 -0.012 +0.005
+0.000 +0.030 0 to
Ball bearing Outer race 75 ―
-0.013 0.000 +0.043
37 clearance (axial
end side) +0.008 +0.000 -0.020 to
Inner race 45 ―
-0.008 -0.012 +0.008
+0.000 +0.030 0 to
Ball bearing Outer race 80 ―
-0.013 0.000 -0043
38 clearance (differ-
ential side) +0.011 +0.000 -0.023 to
Inner race 40 ―
-0.005 -0.012 +0.005
Steering system
Steering piping diagram (control valve – power steering cylinder)
1. Orbitrol valve
2. Hose (steering T line)
3. Power steering cylinder
4. Hose (for power steering)
5. Hose (steering P line)
6. Hose (steering LS line)
Orbitrol valve
Unit: mm
Symbol Item Criteria Remedy
Brake system
Brake control
1. Brake pedal
2. Brake pedal angle sensor linkage
3. Brake pedal angle sensor
4. Brake valve
1. Brake valve
2. Hose (for charging accumulator)
3. Hose (for charging brake)
4. Brake pump
5. Oil pressure sensor (for accumulator oil pres-
sure warning)
6. Accumulator
7. Accumulator charge valve
8. Slack adjuster
Service brake
Unit: mm
1. Valve body
2. Main relief valve
3. Unload spool
4. Safety valve
2. When pressure reaches cut pressure • Interconnected unload spool (3) generates
• The hydraulic oil sent from the pump accu- a differential pressure from spool pressure
mulates in the accumulator. When the pres- chamber (D) because spring chamber (C)
sure in the accumu lator reaches the pressure drops, and moves to the right to
specified pressure (cut-out), the accumula- flow the hydraulic oil from the pump to the
tor pressure opens main relief valve (1) and tank. The unload dondition continues until
interconnects with T port (relief chamber the accumulator pressure drops to the
pressure reduced). specified pressure (cut-in).
• As a result, a differential pressure is gener-
ated between pilot spool chamber (A) and
relief chamber (B), and pilot spool (2) that is
in contact opens main relief valve (1) fur-
ther.
Operating
Start of cut-in condition
operation
Brake valve
Unit: mm
Load at Load at
Outside Free Installed Free
installed installed
diameter length length length
3 Control spring length length
22N 19.8N
1 28.8 (59.5) 49.7 53.6
{2.2kgf} {2.0kgf}
13.6N 12.2N
6 Spool return spring 9.0 40 30 36
{1.4kgf} {1.3kgf}
Standard dimension
Standard Allowable
Flange Piston clearance clearance
Clearance between flange Base diameter
7 diameter diameter
and piston
+0.043 -0.016 0.016 to
18.0 0.150
+0.043 -0.043 0.086
Operation
Not in operation When operated (Piston is moved halfway)
• The hydraulic oil is led from the pump through • If piston (2) is pushed in, spool (7) moves
accumulator to IN port (P) but the oil passage is through control springs (4) and (5) and OUT
stopped by spool (7). port (A) is disconnected from drain port (T).
• The hydraulic oil in the brake chamber flows
from OUT port (A) through the valve, spool
notch (B) and drain port (T) to the tank to
relieve the brake pressure into the atmosphere.
Slack adjuster
A. Inlet port
B. Outlet port
Unit: mm
Standard dimension
Standard Allowable
Cylinder Piston clearance clearance
Cylinder body and piston Base diameter
1 diameter diameter
clearance
+0.052 -0.020 0.020 to
30.0 0.205
+0.052 -0.053 0.105
43.5N 39.2N
7.2 (17.7) 14.0 15.9
{4.4 kgf} {4.0 kgf}
26.9N 24.2N
3 Slack adjuster spring 18.6 (76.2) 37.6 68.6
{2.7 kgf} {2.5 kgf}
• The 4-ɸ4 main oil passages are shut off by • If the brake is released and the check valve
cushion valve mechanism spool (2) at 3 mm closes, slack adjuster mechanism piston (1) is
before the stroke end of slack adjuster mecha- returned by the force of return spring (8) in the
nism piston (1), and then the oil is sent through axle and the remaining pressure on the OUT
only ɸ0.7 orifice (5) to OUT port (B) to operate port (B) side, while compressing spring (8), thus
the brake. (Cushion mechanism) oil necessary for brake operation (substitution
oil quantity) is stored in cushion valve mecha-
nism cylinder (3). (Slack adjuster mechanism)
1. Cylinder Function
2. Free piston • This accumulator is installed between the accu-
mulator charge valve and brake valve. The
space between cylinder (1) and free piston (2)
is charged with nitrogen gas.
• The brake hydraulic oil pressure is accumu-
lated by utilizing compressibility of nitrogen gas
and used as a pressure source for braking
force for the lift truck.
• Because the unit of supply is the assembly, it is
not disassembled.
Specifications
Gas used Nitrogen gas
Charge quantity cc 500
Charge pressure 3.43±0.1 {35±
MPa {kgf/cm2}
(at 20°C) 1.0}
Parking brake
Unit: mm
4 3
6
A A
5 1
A-A
9JL02241
Unit: mm
Rear axle, hub, knuckle and Crack, damage and peeling Replace
-
bearing Seizure, abnormal rotation, abnormal noise
1. Cap/Gauge
2. Breather
3. Tank cover
4. Filter element
5. Valve
6. Spring
Frame
1. Frame
2. Counterweight
3. Hydraulic tank
4. Fuel tank
5. Counterweight mounting bolt
6. Rear axle mounting bolt
7. Front axle support mounting bolt
8. Front axle mounting bolt
Hydraulic system
Control valve piping diagram (tank – control valve)
1. Control valve
2. Hose (LS line)
3. Hose (pump main)
4. Suction strainer (for work equipment)
5. Work equipment pump
6. Hose (for bleeding air)
7. Hose (PP line)
8. Orbitrol valve
9. Pipe (return from control valve)
10. Hydraulic tank cover
11. Hose (return from Orbitrol valve)
X 128-186 Nm
{13-19 kgfm}
9JM07459
1. Control valve
1. Lift lever
2. Tilt lever
3. 3-valve lever
4. 4-valve lever
5. 5-valve lever
6. Work equipment control linkage
7. Control valve
1. Pump body
2. Gear pump
3. LS valve
Sectional view
1. Shaft
2. Case
3. Servo piston
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Shoe retainer
11. Oil seal
12. Bearing
13. Retainer
Function Structure
• This pump receives the rotation and torque • Cylinder block (7) is supported on shaft (1)
from the engine with its shaft (1) and converts through spline (S), and shaft (1) is supported on
them into hydraulic pressure and discharges front and rear bearings (12).
pressurized oil according to the load. • The tip end of piston (6) has a spherical hollow
• It is possible to change the discharge by chang- a n d i s c ri m p e d o n s h o e ( 5 ) t o g e t t h e m
ing the swash plate angle. together. Piston (6) and shoe (5) form a spheri-
cal bearing.
• Rocker cam (3) is supported on case (2) and
retainer (13), and has plane (A). Shoe (5) is
kept pressed against this plane and slid circu-
larly. Shoe (5) leads high-pressure oil to form a
static pressure bearing and slides on it.
• Piston (6) in each cylinder chamber of cylinder
block (7) moves relatively in the axial direction.
• Cylinder block (7) rotates relatively against
valve plate (8), sealing the pressurized oil. The
hydraulic pressure balance on the valve plate is
maintained properly.
• The pressurized oil in each cylinder chamber of
cylinder block (7) can be sucked and dis-
charged through valve plate (8).
• If center line (X) of rocker cam (4) matches the Control of discharge
axial direction of cylinder block (7) (the swash • If swash plate angle (a) increases, the differ-
plate angle is 0), there is nodifference between ence between volumes (E) and (F) increases,
volumes (E) and (F) in cylinder block (7) and and consequently discharge (Q) increases.
the oil is not sucked nor discharged. Swash plate angle (a) is changed with servo
piston (3).
• Servo piston (3) reciprocates straight according
to the signal pressure of the LS valve. This
straight motion is transmitted to rocker cam (4).
Then, rocker cam (4) supported on case (2)
with retainer (13) slides in rotational directions.
LS valve
Unload valve
Function
• The unload valve is built in the LS valve and
relieves the pressurized oil in the main pump
discharge pressure circuit to the tank circuit
when the LS differential pressure (∆PLS)
exceeds the unload set differential pressure.
• The unload set differential pressure is set
higher than the LS set differential pressure con-
trolled by the LS valve.
• The unload valve does not operate while the LS
valve is controlling the pump delivery according
to the demand of the actuator.
• When the actuator is stopped suddenly by the
operation of the control valve spool and the
pump circuit pressure increases, the unload
valve relieves the pressurized oil in the pump
circuit to the tank circuit to prevent abnormally
high pressure generation.
Control valve
Outline A1: To lift cylinder
The control valves of the following types are avail- A2: To tilt cylinder
able. A3: To attachment actuator
• 2-spool valve for FH40 B2: To tilt cylinder
• 3-spool valve for FH40 B3: To attachment actuator
• 4-spool valve for FH40 C1: From lift truck wiring
• 4-spool valve (3, 4 port) for FH40 C2: From lift truck wiring
• 5-spool valve for FH40 LS: To work equipment and steering pump
• 5-spool valve (4, 5 port) for FH40 P: From work equipment and steering pump
• 2-spool valve for FH45/50 PP: To work equipment and steering pump
• 3-spool valve for FH45/50 STLS: From Orbitrol valve
• 4-spool valve for FH45/50 STP: To Orbitrol valve
• 4-spool valve (3, 4 port) for FH45/50 T: To tank
• 5-spool valve for FH45/50 TS: To tank
• 5-spool valve (4, 5 port) for FH45/50
1. Valve block
Outside view of each control valve 2. Service valve
• A general view and sectional view of the 3- 3. Cover
spool valve for FH40 are shown below.
• If the service valve under the cover of the 3-
spool valve is removed, the appearance of
the remaining portion is the same as the 2-
spool valve.
• All the service valves have the same gen-
eral view.
3-spool valve
General view
1. Spool (lift)
2. Spool (tilt)
3. Spool (attachment)
4. Down control valve
5. Emergency lowering valve
6. LS shuttle valve (lift/tilt)
7. LS shuttle valve (attachment)
8. LS shuttle valve (steering)
9. Load check valve (lift)
10. Load check valve (tilt)
11. Load check valve (attachment)
Unit: mm
8.83 N 7.06 N
15 Load check valve spring 29.44 x 6 25.5 ―
{0.9 kgf} {0.72 kgf}
9.81 N 7.85 N
16 Load check valve spring 43.92 x 6 34 ―
{1 kgf} {0.8 kgf}
15.2 N 12.2 N
17 Lift lock valve spring 48.75 x 6.4 40 ―
{1.55 kgf} {1.24 kgf}
(2/2)
Valve block
1. ON-OFF solenoid (lift lock)
2. ON-OFF solenoid (work equipment lock)
3. Lift lock valve
4. Spool (lift)
5. Priority valve
6. Down control valve
7. Spool (tilt)
8. LS shuttle valve (lift/tilt)
9. Load check valve (tilt)
10. Tilt lock valve
Service valve
11. Spool (attachment)
12. Suction safety valve (attachment)
13. LS shuttle valve (attachment)
14. Load check valve (attachment)
15. Suction safety valve (attachment)
Cover
16. LS shuttle valve (steering)
17. LS relief valve
Unit: mm
14.8 N 11.9 N
19 Tilt lock valve spring 26.98 x 7 16 ―
{1.51 kgf} {1.21 kgf}
CLSS
Outline of CLSS
Features Configuration
The CLSS is the abbreviation for Closed center • CLSS consists of variable capacity piston
Load Sensing System, which has the following fea- pump, control valves, and respective actuators.
tures. • The hydraulic pump is composed of the pump
• Fine controllability not influenced by load unit and LS valve.
• Energy saving by variable discharge pump con-
trol
Basic principle
• If the LS differential pressure (∆PLS) lowers
Pump swash plate angle control below the LS valve set pressure (the actuator
• The pump swash plate angle (pump delivery) is load pressure is high), the pump swash plate
so controlled that the LS differential pressure angle is increased.
(∆PLS) will be constant. The LS differential • If the LS differential pressure rises above the
pressure is the differential pressure between set pressure (the actuator load pressure is low),
the pump discharge pressure(PP) and LS pres- the pump swash plate angle is decreased.
sure (PLS)(actuator load pressure) at the con-
trol valve outlet. LS differential pressure (∆PLS) and pump
• [LS differential pressure(∆PLS) = Pump dis- swash plate angle
charge pressure(PP) – LS pressure(PLS)]
1. LS relief valve
Set pressure: 17.15 MPa {175 kgf/cm2}
2. Safety valve with suction
Set pressure: 17.64 MPa {180 kgf/cm2}
Set pressure: 15.19 MPa {155 kgf/cm2}
3. Priority valve
4. Down control valve
5. Lift lock valve
6. Tilt lock valve
7. Load check valve
8. LS shuttle valve
9. ON-OFF solenoid (lift lock)
10. ON-OFF solenoid (work equipment lock)
Supply of LS pressure
Function
• LS pressure is the actuator load pressure • The highest LS pressure of supplied LS
on the outlet side of the control valve. pressures (PLS) is selected by the LS shut-
• The downstream pressure of control notch tle valve and supplied to the pump LS
(4) of spool (1) is supplied as LS pressure valve.
(PLS) to LS shuttle valve (3).
a The figure shows the state when the fork is tilted forward.
Operation
• If spool (1) is operated, pump pressure (PP) • Since the opening area of spool notch (5) is
flows through load check valve (2), control wide and less pressure loss is made, LS pres-
notch spool notches (4) and (5) to actuator cir- sure approximates the actuator load pressure.
cuit (B).
• The pressure decreased by control notch spool
notch (4) is supplied as LS pressure (PLS)
through passage (6) to LS shuttle valve (3).
LS relief valve
Function
• The LS relief valve sets the maximum LS pres- • The maximum pump pressure is set by control-
sure. ling the pump LS valve with that differential
• When the LS relief valve is relieved, differential pressure and making the pump swash plate
pressure is generated between pump pressure angle minimum (C 0 swash plate).
(PP) and LS pressure (PLS) by control valve
orifice (1).
Operation
• If the work equipment control lever is operated • Since there is orifice (1) on the upstream side of
to move the work equipment cylinder to the the LS relief valve, pump pressure (PP)
stroke end, pump pressure (PP) increases. increases further and generates differential
• Since no pressurized oil flows to the actuator pressure between pump pressure (PP) and LS
circuit, LS pressure (PLS) is the same as pump pressure (PLS).
pressure (PP). • If the differential pressure acts on the pump LS
• LS pressure (PLS) which is the same as valve and increases to a certain pressure,
increased pump pressure (PP) acts on LS relief pump pressure (PP) is balanced when the
valve poppet (2). If it reaches the set load of swash plate angle is minimum (C 0 swash
spring (3), LS pressure (PLS) is relieved into plate).
tank circuit (T).
Priority valve
Function
The priority valve distributes the pump delivery to
the steering circuit first.
Operation
When work equipment is operated singly
Function
• The down control valve controls the cylinder cir-
cuit return flow according to the load pressure
when the fork is lowered.
Operation
When lift spool (1) is operated for lowering
Function
• This function prevents the pump delivery from
flowing to the work equipment circuit (W) when
work equipment lock solenoid valve (6) is
turned OFF.
Operation
When work equipment lock solenoid valve (6) is ON
• If the signal to work equipment lock solenoid • When the work equipment control lever is oper-
valve (6) is turned ON, pump pressure (PP) ated, pump circuit (PP) is connected to work
through clearance (3) of valve chest (2) is equipment circuit (W) through spool notch (4),
applied to the right end of spool (1) and steering thus oil from pump flows to the work equipment
LS pressure (STLS) is applied to the left end cylinder.
[spring (5) chamber].
• Since the steering is not operated, steering LS
pressure (STLS) is approximately0 MPa {0 kg/
cm2}.
• Spool (1) is moved to the left by a full stroke by
pump pressure (PP) applied to its right end.
Function
• This function prevents lift cylinder (2) from oper-
ating when lift lock solenoid valve (6) is de-
energized.
Operation
When lift spool (1) is operated for lowering and lift lock solenoid valve (6) is energized
• If lift spool (1) is operated while solenoid valve • If the differential pressure reaches the set load
(6) is energized, the cylinder pressure is of spring (5), check valve (4) opens and lift cyl-
drained into the tank through check valve orifice inder (2) operates.
(3), solenoid valve (6) and lift spool notch (7).
• Differential pressure is generated between front
and rear of check valve (4) by the above flow.
When lift spool (1) is operated for lowering and lift lock solenoid valve (6) is de-energized
Function
• This function prevents the tilt cylinder from
operating when the work equipment lock sole-
noid valve is de-energized.
Operation
When tilt spool is operated for tilting forward and work equipment lock solenoid valve is energized
When tilt spool is operated for tilting forward and work equipment lock solenoid valve is de-
energized
Operation
• While lift lock valve solenoid valve (7) is de- • If emergency lowering valve (2) is opened
energized, check valve (5) does not open even slowly under this condition, the pressurized oil
if lift spool (1) is lowered, thus lift cylinder (3) in the spring chamber of check valve (5) is
does not operate. [See Lift lock function (lift lock drained into the tank and differential pressure is
valve)] generated between front and rear of check
valve orifice (4).
• If the differential pressure reaches the set load
of spring (6), check valve (5) opens and lift cyl-
inder (3) lowers.
Work equipment
Tilt cylinder
Unit: mm
Bushing inside
Clearance between rod Pin diameter
3 diameter 0.04 to 0.14 2.5
head pin and head pin hole
35 35
Lift cylinder
1. Drain pipe
Unit: mm
Mast
A-A
A A
B-B
147-196 Nm
{15.0-20.0 kgfm}
C-C
B B
2
C C
147-196 Nm
{15.0-20.0 kgfm}
343-427 Nm
{35.0-43.5 kgfm}
9JM07758
1. Inner mast
2. Outer mast
A3
A5
A4
V
A1
A2,B
B
9JM07761
1. Front cylinder
2. Rear cylinder
3. Block
Operation
When the lift is raised
• Because of the difference in operating pressure
due to the size difference between front cylin-
der (1) and rear cylinder (2), oil discharged from
the control valve goes through block (3), and
goes through the rear cylinder hollow rod on the
route of (A1) to (A5), and extends front cylinder
(1) first.
• When front cylinder (1) reaches the stroke end,
the oil goes through the routs of (B), and
extends rear cylinder (2).
Triple mast
A6 A3
A3
A5
A4 A4
B3
A2
B3 A2
2
A1
A1 3
V
B1
B4
4 B5,
B5,T
B4 B2
B2
9JM07762
Operation
When the lift is raised
• Oil discharged from the control valve goes
through block (3). Because of the difference in
operating pressure due to the size difference
between front cylinder (1) and rear cylinder (2),
it goes through the rout of (A1) to (A5) to extend
the front cylinder first.
• When front cylinder (1) reaches the stroke end,
the oil goes through the rout of (B1) to (B2), and
extends rear cylinder (2). Oil in the upper part of
rear cylinder (2) goes through the rout of (B3) to
(B5), and is discharged from return hose (4) to
the tank.
Finger board
B B
A A
C C
D D
27.4-34.3 Nm
{2.8-3.5 kgfm}
1. Finger board
Fork
Unit: mm
Right
B1 0.5 to 1.0 Max. 2.5 Adjust shim
Clearance between outer and left
B
mast and finger cover Back
B2 0.4 to 1.6 Min. 2.0
and forth
C Bushing oil groove in the mast support part Oil groove exists. Whether oil groove exits
Replace
4.0t lift truck 55 Min. 50
Electrical system
Electrical control system
General system diagra
Function
• It detects the oil pressure between control valve
(8) and lift cylinder (10) with lift cylinder pres-
sure sensor (1), and switches the two prepared
maximum output torques of the engine based
on the detected pressure.
3200[kg] 112[kg/cm2]
FH40-1
3550[kg] 123[kg/cm2]
3720[kg] 112[kg/cm2]
FH45-1
4120[kg] 123[kg/cm2]
3600[kg] 112[kg/cm2]
FH50-1
4000[kg] 123[kg/cm2]
Function
• If the coolant temperature is low after the
engine starts, it automatically increases the low
idle speed of the engine for warm-up.
Operating condition 1 (It operates when all the conditions
Operation
below are satisfied)
• The engine starts at a coolant temperature of 50°C or
lower. →
• The directional lever is in the N position.
Operating condition 2 (It operates when all the conditions
Low idle speed: 1,000rpm
below are satisfied)
• The coolant temperature changes from 50°C or more
to 45°C or lower during engine start. →
• The directional lever is in the N position.
↓
Release condition (It releases when any of the conditions
Release
below is satisfied)
• The directional lever is in F or R position.
→ Low idle speed: 800rpm
• The coolant temperature is 50°C or higher.
1. Battery Function
2. Slow-blow fuse (120 A) • To improve engine startability in a cold district,
3. Slow-blow fuse (40 A) intake air is automatically preheated by the rib-
bon heater when the starting switch is turned to
4. Starting switch
the ON position.
5. Fuse box
• The preheating time varies depending on the
6. Engine controller intake air temperature. The preheater lamp
7. Intake manifold temperature sensor lights up during preheating.
8. Ribbon heater relay • When the starting switch is turned to the
9. Ribbon heater START position during preheating, preheating
10. Preheater lamp stops.
• Intake temperature and preheating time set-
Input/output signal tings are shown in the figure below.
a. Starting switch ACC signal
b. Ribbon heater relay drive signal
c. Preheater lamp lighting up signal
Reminder function for leaviing seat without returning directional lever to N position
Function
• When the operator leaves the seat with the
directional lever in F or R position, the seat
switch installed to the seat operates. When
HST controller detects the absent condition for
0.5 sec, alarm buzzer sounds for 1 second to
warn the operator to return the directional lever
to the N position when leaving the seat.
Operating condition
(Operates when all the conditions below are satisfied and Operation
0.5 sec elapses)
• The directional lever is in F or R position.
→ • Alarm buzzer sounds (for 1 sec).
• Not on the seat
Function
• When the operator leaves the seat with the
directional lever in F or R position, the seat
switch installed to the seat operates. When
HST controller detects the absent condition for
3 sec, it stops output to HST pump EPC sole-
noid to make the lift truck unable to travel
(travel interlock operation).
• During interlock operation, the travel interlock
warning lamp blinks.
• To restart travel operation (release travel inter-
lock), the operator must sit on the seat properly
and turn the directional lever to the N position.
(To prevent wrong operation of the lift truck)
• When the lift interlock is in operation, alarm
buzzer sounds when the operator sits on the
seat with the directional lever in the F or R
position.
Operating condition
Operation
(operates when all the conditions below are satisfied)
• Output to EPC solenoids before and after HST
pump is stopped.
• The directional lever is in the F or R position.
→ • The travel interlock warning lamp blinks.
• 3 seconds elapses after the operator leaves the seat
(The alarm buzzer sounds when the operator
sits on the seat while it is operating.)
↓
Release condition
Release
(releases when all the conditions below are satisfied)
• Output to EPC solenoids before and after HST
• The directional lever is in the N position. pump is allowed.
→
• On the seat • The travel interlock warning lamp lights up.
(Alarm buzzer is stopped if installed)
Function
• When the operator leaves the seat, the seat
switch installed to the seat operates. When
HST controller detects the absent condition for
3 sec, it stops output to the work equipment
lock solenoid and lift lock solenoid to make lift-
ing operation impossible (lift interlock opera-
tion).
• During interlock operation, the lift interlock
warning lamp blinks.
• Lift operation can be restarted (lift interlock
release) when the operator sits on the seat
properly.
• Also, when the starting switch is in the OFF
position, output to the work equipment lock
solenoid and lift lock solenoid is stopped to
make lifting operation impossible. (Key OFF lift
lock function)
• Even when the engine is not running, lift lower-
ing operation can be done if the starting switch
is in the ON position and the operator sits on
the seat.
Operating condition 1
Operation
(operates when the conditions below are satisfied)
• Output to the work equipment lock solenoid is
• 3 seconds elapses after the operator leaves the seat stopped.
→
• The starting switch is in the ON position. • Output to the lift lock solenoid is stopped.
• The lift interlock warning lamp blinks.
↓
Release condition
Release
(releases when the conditions below are satisfied)
• On the seat • Output to the work equipment lock solenoid
→
• The starting switch is in the ON position. • Output to the lift lock solenoid
Operating condition 2
Operation
(operates when the conditions below are satisfied)
• Output to the work equipment lock solenoid is
• The starting switch is in the OFF position. → stopped.
• Output to the lift lock solenoid is stopped.
↓
Release condition
Release
(releases when the conditions below are satisfied)
• On the seat • Output to the work equipment lock solenoid
→
• The starting switch is in the ON position. • Output to the lift lock solenoid
1. Battery Function
2. Slow-blow fuse • When the operator leaves the seat without pull-
3. Starting switch ing the parking brake lever, the parking
reminder lamp blinks and alarm buzzer sounds
4. Fuse box
to remind the operator of applying the brake.
5. Seat switch
(Intermittent)
6. Parking lever switch • When the engine is running, the parking
7. HST controller reminder lamp blinks and alarm buzzer sounds
8. Alternator when 3 seconds elapse after the operator
9. Alarm buzzer leaves the seat.
10. Parking brake reminder lamp • When the engine is not running, the parking
reminder lamp blinks and alarm buzzer sounds
Input/output signal immediately when the parking lever is turned to
a. Seat switch signal the release position even when the operator is
b. Key ACC signal on the seat.
c. Parking lever switch (brake release position)
signal
d. Alternator L terminal voltage signal
e. Alarm buzzer output signal
f. Parking brake reminder lamp output signal
When the engine is running (alternator L terminal voltage is high and starting switch is at ACC)
Operating condition
Operation
(operates when the conditions below are satisfied)
• The parking brake lever is at the free position. • The parking brake reminder lamp blinks.
→
• 3 seconds elapses after the operator leaves the seat • Alarm buzzer sounds (intermittent).
↓
Release condition
Release
(releases when any of the conditions below is satisfied)
• The parking lever is in the lock position. • The parking brake reminder lamp blinks.
→
• On the seat • Alarm buzzer sounds (intermittent).
When the engine is not running (alternator L terminal voltage is low and starting switch is in the OFF
position)
Operating condition
Operation
(operates when the conditions below are satisfied)
• The parking brake reminder lamp blinks.
• The parking lever is in the free position. →
• Alarm buzzer sounds (intermittent).
↓
Release condition
Release
(releases when the conditions below are satisfied)
• The parking brake reminder lamp goes out.
• The parking lever is in the lock position. →
• Alarm buzzer sound stops.
Function
• When the lift truck travels with the parking
brake lever applied by the operator, the abnor-
mality warning lamp blinks and alarm buzzer
sounds to warn the operator of parking brake
drag travel. (Intermittent)
Operating condition
Operation
(operates when all the conditions below are satisfied)
• The parking brake lever is in the lock position.
• The directional lever is in F or R position. • The abnormality warning lamp blinks.
→
• The accelerator pedal is depressed by 40% or more. • Alarm buzzer sounds (intermittent).
• The brake pedal is not depressed.
↓
Release condition
Release
(releases when any of the conditions below is satisfied)
• The parking lever is in the free position.
• The directional lever is in the N position. • The abnormality warning lamp goes out.
→
• The accelerator pedal is depressed by 40% or less. • Alarm buzzer sound stops.
• The brake pedal is depressed.
HST controller
Input/output signal
Connector type
DEUTSCH-64 pins
Input/
Connector No.
Output
DEUTSCH-24P[CN-C01]
Signal
1 HST port pressure B Input
2 NC –
3 Brake pressure Input
4 NC –
5 Starting motor cut signal Input
6 NC –
7 HST port pressure A Input
8 NC –
9 Fuel level sensor Input
10 NC –
11 NC –
12 NC –
13 Lift pressure Input
14 HST oil temperature Input
15 Alternator R signal Input
16 NC –
17 NC –
18 NC –
19 Brake pedal potentiometer Input
20 NC –
21 NC –
22 NC –
23 NC –
24 HST filter clogging SW Input
Connector type
DEUTSCH-64 pins
Input/ Input/
Connector No. Connector No.
Output Output
DEUTSCH-40P(1)[CN-C02] DEUTSCH-40P(2)[CN-C03]
Signal Signal
1 NC – 1 NC –
2 NC – 2 NC –
3 NC – 3 NC ––
4 NC – 4 Battery relay Output
5 NC – 5 Fuel sedimenter lamp Output
6 Key ACC Input 6 Forward travel pump EPC Output
7 NC – 7 Pump EPC cut-off relay Output
8 Charge lamp Output 8 Engine oil pressure lamp relay Output
9 Error lamp Output 9 Service SW Input
10 NC – 10 EPC GND return Input
11 NC – 11 NC –
12 NC – 12 NC –
13 NC – 13 NC –
14 NC – 14 NC –
15 FNR lever N1 Input 15 Reverse travel buzzer and lamp relay Output
16 Parking lever SW Input 16 Reverse travel pump EPC Output
17 NC – 17 Parking lamp Output
18 Neutral lamp Output 18 Alarm buzzer Output
19 Mast lamp Output 19 NC –
20 NC – 20 Seat SW2 Input
21 NC – 21 NC –
Input/
22 CANO L 22 NC –
Output
23 NC – 23 NC –
24 NC – 24 NC –
25 FNR lever R1 Input 25 Unload ON/OFF SOL Output
26 NC – 26 Motor EPC Output
27 Travel speed sensor A Input 27 Starting motor relay Output
28 NC – 28 HST filter clogging lamp Output
29 NC – 29 Travel speed limit SW Input
30 NC – 30 SeatSW1 Input
31 NC – 31 NC –
Input/
32 CANO H 32 NC –
Output
33 NC – 33 NC –
34 NC – 34 NC –
35 FNR lever F1 Input 35 Mast ON/OFF SOL Output
36 NC – 36 Parking brake reminder lamp Output
37 Travel speed sensor B Input 37 HST oil temperature lamp Output
38 NC – 38 Travel speed limit lamp Output
39 NC – 39 NC –
40 NC – 40 NC –
Engine controller
Input/output signal
• The symbols in the signal category column of
the input/output signal table are as follows.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DTP-4P [CN-CE03]
Pin No. Signal name Signal category
1 GND C
2 NC –
3 Continuous power supply (+24V) A
4 NC –
DRC-60P(1) [CN-CE01]
Pin No. Signal name Signal category Pin No. Signal name Signal category
1 NC – 31 NC –
2 NC – 32 Engine oil pressure switch B
3 NC – 33 NC –
4 NC – 34 WIF B
5 NC – 35 NC –
6 NC – 36 Sensor power supply (5V) A
7 NC – 37 Cam speed sensor B
8 NC – 38 NC –
9 NC – 39 NC –
10 Fuel supply pump regulator (+) B 40 NC –
11 Boost temperature sensor B 41 NC –
12 NC – 42 Crankshaft speed sensor B
13 NC – 43 NC –
14 Fuel supply pump regulator (-) C 44 Crankshaft speed sensor GND C
15 NC – 45 Injector #2 (+) D
16 NC – 46 NC –
17 NC – 47 Coolant temperature sensor GND C
18 NC – 48 Sensor GND C
19 Boost pressure sensor B 49 Coolant temperature sensor D
20 Ambient pressure sensor B 50 NC –
21 NC – 51 Injector #4 (-) C
22 NC – 52 NC –
23 NC – 53 Injector #1 (-) C
24 NC – 54 NC –
25 NC – 55 Injector #3 (+) D
26 Crankshaft speed sensor (5V) A 56 Injector #4 (+) D
27 NC – 57 Injector #1 (+) D
28 NC – 58 Injector #2 (-) C
29 Common rail pressure sensor B 59 Injector #3 (-) C
30 NC – 60 NC –
DRC-60P(2) [CN-CE02]
Pin No. Signal name Signal category Pin No. Signal name Signal category
1 CAN (+) E 31 NC –
2 NC – 32 PWM relay GND C
3 NC – 33 NC –
4 NC – 34 NC –
5 NC – 35 Accelerator pedal signal B
6 NC – 36 NC –
7 NC – 37 NC –
8 NC – 38 NC –
9 NC – 39 NC –
10 NC – 40 NC –
11 NC – 41 Idle validation GND C
12 NC – 42 NC –
13 NC – 43 Abnormality warning lamp D
14 NC – 44 NC –
15 Idle validation signal 2 B 45 Starting switch ACC signal B
16 NC – 46 NC –
17 NC – 47 Engine abnormality warning lamp D
18 NC – 48 NC –
19 NC – 49 NC –
20 NC – 50 NC –
21 CAN (-) – 51 NC –
22 NC – 52 NC –
23 NC – 53 Preheater lamp D
24 Idle validation signal 1 B 54 Preheater D
25 NC – 55 PWM relay D
26 NC – 56 NC –
27 Accelerator pedal sensor (5V) A 57 NC –
28 Accelerator pedal sensor (-) C 58 NC –
29 NC – 59 NC –
30 NC – 60 NC –
Function
• It is installed to the top of the floor panel and
outputs accelerator signals and idle validation
signals according to the depressing angle of the
accelerator pedal.
Accelerator signal
• The sensor detects displacement of the accel-
erator pedal and outputs the variable voltage
through pin No. 2.
EPACS controller
― 1 ―
― 2 ―
Black 3 Power input (GND)
Red 4 Power input (Rated voltage) Connector manufactured by SUMITOMO
4 5 WIRING SYSTEMS, LTD.
― ―
(Model: 6195-0054)
Purple 6 Wheel angle sensor GND
Yellow 7 Wheel angle sensor input
Power output for wheel angle sen-
Pink 8
sor
Brown 1 Solenoid valve drive output (-) Connector manufactured by SUMITOMO
5 WIRING SYSTEMS, LTD.
Light green 2 Solenoid valve drive output (+) (Model: 6195-0003)
White Plug Initial setting input (+) Plug terminal (male)
6
Red Plug Initial setting input (GND) Plug terminal (female)
*1. When the controller is detecting failure (abnormality). For troubleshooting, see "Troubleshooting by fail-
ure code (EPACS controller system)".
*2. When the controller is not detecting failure (abnormality). For troubleshooting, see "Troubleshooting of
electrical system (E-mode)".
Instrument panel
Circuit diagram
Pole destination
Pilot box
DC/DC converter
1. Connector
Function
• It converts power supply voltage of 24VDC to
13.7VDC, and supplies power to the instrument
panel and feed pump of rated voltage of
12VDC.
Specifications
• Rated input voltage: 24VDC
• Rated output voltage: 13.7VDC
• Input voltage range: 18 to 32VDC
• Output voltage range: 13.7±0.5VDC
• Rated output current:14.7A
• Maximum current consumption: 10.8A
• Operating temperature range:-40 to 85°C
KOMTRAX system
KOMTRAX terminal
Model: TC530
Sensor
Fuel level sensor
1. Shaft
2. Housing
3. Connector
Function
• The wheel angle sensor is installed to the axle
portion on the right side of the lift truck at the
steering axle. As a result, it detects the angle of
the axle and outputs voltage signals based on
the resistance value of the variable resistor.
This is the turning angle of the steering wheel.
Specifications
• Resistance value: 2kΩ ± 20%
Maintenance standard
• The resistance value varies continuously.
1. Hall IC Function
2. Circuit board • This sensor is installed to the case of the front
3. Ring axle. It generates two types of pulse voltage
with different phases based on the rotating
4. Housing
direction and rotating speed of the gear.
5. Heat shrink tube
6. Protective tube
7. Lead wire
8. Connector
1. Thermistor
2. Plug
3. Connector
Function
• This sensor is installed to the drain pipe of the
motor. It senses temperature changes in the
change of resistance in the built-in thermistor
and generates a signal according to the mea-
sured temperature.
1. Sensor
2. Connector
Function
• This sensor is installed to HST pump. It senses
the right and left HST circuit pressures in the
change of voltage by using the built-in semi-
conductors and generates a signals according
to the measured pressures.
Operation
• The relationship between pressure (P) on the
sensor and output voltage (E) is shown on the
right.
1. Potentiometer
2. Connector
Function
• The angle sensor is connected to the brake
pedal. Its shaft rotates corresponding to the
operating angle of the pedal.
• The movement of the shaft activates the inter-
nal variable resistor. Signal voltage is gener-
ated when the resistor changes the voltage of
the 5V power supply corresponding to the
operating angle.
1. Sensor
2. Connector
Function
• This sensor is installed to the brake valve pipe.
It senses the circuit pressure supplied to the
brake valve in voltage changes by using the
built-in semiconductor and generates signals
corresponding to the measured pressure.
Operation
• The relationship between pressure (P) on the
sensor and output voltage (E) is shown on the
right.
1. Terminal
2. Plug
Function
• This sensor is installed to HST oil filter. It
senses oil pressures before and after the filter
and the switch is turned "ON"when the speci-
fied pressure is exceeded.
1. Body
2. Terminal
Function
• It is installed to the water outlet connector of the
radiator near the fan of the diesel engine. It is of
the thermistor type and outputs resistance val-
ues corrresponding to the engine coolant tem-
perature.
Function
• This sensor is installed to the cup of fuel prefil-
ter. This sensor outputs a signal when detecting
water which exists in the fuel beyond the speci-
fied level.
Combination switch
Seat switch
1. Switch
2. Wire
3. Connector
Function
• It is installed to the lower part of the operator's
seat. It detects the presence of an operator.
The switch is connected to HST controller to
activate the travel interlock and lift interlock
functions.
Maintenance standard
• A. When it is free : 22.7mm
• B. When the switch is ON : 18.7mm
Service switch
Function
This switch is installed to the dashboard.
• It is used to change the limit speed in the travel
speed limit function, to display failure codes,
and to adjust HST controller.
Preheater lamp
Function
This switch is installed to the dashboard.
• It lights up when the automatic preheating is
operating.
It lights up for 1.5 seconds for a lamp check
when the starting switch is turned to the ON
position as well.
Flasher unit
1. Case
2. Bracket
3. Terminal
4. Plate
Specifications
• Number of flashes
From 22V to 30V: 60 cycles/min to 120 cycles/
min
When the lamp is broken: 120 cycles/min to
250 cycles/min
Function
• The flasher unit is installed inside the left side
cover of the lift truck body. It controls blinking of
the turn signal lamps. If any of the right and left
turn signal lamps is broken, the current value
through the flasher unit changes, shortening
the blinking cycle.
Relay box
1. LAMP DIMMER
2. HST CONT POWER
3. OIL PRESS LAMP
4. POSITION
5. LAMP MAIN
6. METER POWER
7. BACK LAMP
8. HORN
9. PUMP EPC CUT
10. Vacant
Function
• It is installed to the left side in the engine room.
It has a control relay.
Relay
LAMP DIMMER
HST CONT POWER
OIL PRESS LAMP
POSITION
LAMP MAIN
METER POWER
BACK LAMP
HORN
PUMP EPC CUT
Specifications
• Coil voltage: 24V
• Contact configuration: 1C
• Contact rating: N.O.15A
N.C.8A
Function
• It is used for LAMP DIMMER, HST CONT
POWER, OIL PRESS LAMP, POSITION, LAMP
MAIN, METER POWER, BACK LAMP, HORN,
and PUMP EPC CUT in the relay box.
STARTER relay
PWM relay
Specifications
• Contact configuration: 1C
• Rating control capacity (resistance load):
N.O: 20A 24VDC
N.C: 10A 24VDC
• Coil rated voltage: 24V
• Rated excitation current: 75mA
• Coil resistance: 320Ω
• Rated power consumption: 1.8W
Table of Contents
20 Standard value table
Standard value table .............................................................................................................................. 20-3
Standard value table .......................................................................................................................... 20-3
MPa {kg/cm2}
Compression Min. 29 {Min. 30}/150 to250
/rpm
(58.8 N {approximately mm 7 to 10
6kgf} finger pressure)
Inflation
Tire
pressure
Rear wheel kPa {kg/cm2} 850 {8.5} 1,000 {10.0}
Rear
Min. turning radius mm 2,770 2,820 2,850
axle
Steering and brake systems
Play mm 0 to 4
Brake
pedal Height of pedal when
mm 82 to 86
depressed
Work equip- Pump pressure MPa {kg/cm2} 20.1 to 20.6 {205 to 210}
ment/
Steering pump LS pressure MPa {kg/cm2} 17.2 to 17.7 {175to180}
Table of Contents
30 Testing and adjusting
Testing and adjusting ............................................................................................................................. 30-3
Check of failure code of engine controller.......................................................................................... 30-3
Displaying, setting, checking by using HST controller ....................................................................... 30-6
Travel speed control function for general operator
(description in Operation and Maintenance Manual of the lift truck) .............................................. 30-8
Setting controlled travel speed........................................................................................................... 30-9
Maximum travel speed control function ........................................................................................... 30-11
Banning function of changing controlled travel speed ..................................................................... 30-14
Electrical-system abnormality record display function (only for HST controller system).................. 30-16
Mechanical-system abnormality record display function.................................................................. 30-22
Adjusting function............................................................................................................................. 30-23
Memory clear function...................................................................................................................... 30-30
Automatic engine stop set interval changing function ...................................................................... 30-33
Releasing pressure from hydraulic piping ........................................................................................ 30-35
Replacement of engine oil and engine oil filter ................................................................................ 30-36
Replacement of fuel filter ................................................................................................................. 30-38
Fuel pre-filter water drain ................................................................................................................. 30-40
Fuel filter air bleeding....................................................................................................................... 30-41
Cleaning of water separator strainer ................................................................................................ 30-42
Radiator cleaning ............................................................................................................................. 30-43
Air cleaner inspection and element replacement ............................................................................. 30-44
Testing and adjusting engine speed................................................................................................. 30-45
Testing and adjusting HST oil pressure ........................................................................................... 30-47
Testing work equipment and steering pump oil pressure ................................................................. 30-50
Oil level check and changing oil in differential case......................................................................... 30-51
Changing PTO oil and cleaning strainer .......................................................................................... 30-52
Inspection of hydraulic tank ............................................................................................................. 30-53
Measuring brake performance ......................................................................................................... 30-55
Measurement of wear of service brake disc .................................................................................... 30-56
Checking parking brake ................................................................................................................... 30-57
Bleeding air ...................................................................................................................................... 30-58
Adjusting brake pedal ...................................................................................................................... 30-59
Testing and adjusting brake pedal angle sensor linkage ................................................................. 30-60
Initial setting of Orbitrol valve........................................................................................................... 30-62
Measurement of hydraulic drift and forward tilt down by hydraulic drift of cylinder .......................... 30-63
Adjustment of mast .......................................................................................................................... 30-64
Adjustment of fork carriage .............................................................................................................. 30-67
Lamp display of KOMTRAX terminal ............................................................................................... 30-69
KOMTRAX terminal start-up procedure ........................................................................................... 30-72
Troubleshooting PC
software (KOMATSU FORKLIFT
(CD-ROM) distributor needs to prepare.)
System
Component Reference
Adjustment item
page
a When the controller is replaced with a new one, the abnormality warning lamp lights up continuously until
the specified adjustment process is completed.
6 4 Electrical-system
Adjustment mode abnormality record
display mode
8 Automatic engine
stop set interval
changing function
Normal
Operator mode
Travel speed
setting mode
1 3 Setting of prohibition 2
Vehicle speed limit Max vehicle
setting for general for change of limited speed limit setting
operator vehicle speed
(for administrator)
(for administrator)
Prohibit to change of
limited vehicle speed
4) When pressing service switch (3) again, a When the administrator sets the maximum
• alarm buzzer (0.2 second) sounds, travel speed control, the lighting pattern of
• and indicator lamp (5) blinks. the control travel speed is prioritized and
Then, the control travel speed settings can be set as the upper limit.
changed or selected.
Example: When current set speed is 15 km/h
a If 6 indicator lamps do not blink, repeat 4) When pressing service switch (3),
the procedure from the first. • alarm buzzer (0.2 second) sounds,
a The operation described in steps 1 and • and the indicator lamp lights up.
2 in "Maximum travel speed control set- By the lighting pattern of indicator lamp the
ting" is control travel speed currently set can be
the same as the operating method in checked.
"Travel speed control value for general Example: When currently set speed is 15 km/h
operator".
3) Fully depress brake pedal (4) and hold it.
• Slowly switch travel speed control
selector switch (2) to OFF → ON →
OFF → ON → OFF, and then
• release brake pedal (4).
6) The pattern of the indicator lamp switches a When setting the slower travel speed
every time switching travel speed control than that of the set speed by the travel
selector switch (2) to OFF → ON → OFF. speed control function for general oper-
The maximum travel speed to be set can be ator, the maximum travel speed control
selected. setting is enabled.
a When pressing service switch (3) again
after the setting is completed, the maxi-
m u m t r a v e l s p e e d s e t ti n g c a n b e
changed or selected again.
2) Turn the key of the starting switch to the 3) When pressing service switch (3),
"ON" position (do not start the engine), • alarm buzzer (0.2 second) sounds,
within 12 seconds, • and the indicator lamp lights up.
• while pressing service switch (3), By the lighting pattern of the indicator lamp,
• fully depress brake pedal (4). the currently-set control travel speed can
Keep this keep for 5 seconds or more. be checked.
If this operation is performed correctly, the Example: When Currently set speed is 15km/h
travel speed control indicator lamp blinks
every second.
4) Fully depress brake pedal (4) and hold it. Example: When the control travel speed is set to
• Set directional lever (7) slowly to N → F 1 5 k m/h a nd the ba nn in g se ttin g o f
→ N → R → N → F → N → R → N, ch an ging co ntrolle d tra vel sp ee d is
• and release brake pedal (4). "Enabled", the lighting condition does not
change even by pressing the service
switch.
Example of display: Lift truck failure code "23" (Failure of HST pump B port pressure sensor)
a When the same failure occurred previously, the failure codes of them are integrated into 1 item
and rearranged to the related place in the order of the occurrence.
Example) Abnormality record display if the failure occurred in order of the failure code 12 → 15 → 12 → 12
→ 12 → 23.
a To delete the electrical-system abnormality record, see pages 30 to 32 in "Testing and adjusting".
Failure code
Applicable Action History
Lift Failed part Failure
KOMTRAX component code category
truck
Electrical
- AB00MA Alternator Malfunction (low voltage) HST L03
system
Mechanical
- B@CRNS HST oil Overheating HST L02
system
Mechanical
- 2G40ZG Brake accumulator assembly Low oil pressure HST L03
system
Mechanical
- 6091NX HST oil filter Clogged HST L01
system
Electrical
DDK6KA Directional (FNR) lever Open circuit HST L03
system
12
Electrical
DDK6KY Directional (FNR) lever Hot short circuit HST L03
system
Open circuit, ground fault, or hot Electrical
DLT4KZ Travel speed sensor A HST L03
short circuit system
Open circuit, ground fault, or hot Electrical
DLT6KZ Travel speed sensor B HST L03
short circuit system
DLT4KZ+ Open circuit, ground fault, or hot Electrical
14 Travel speed sensors A and B HST L03
DLT6KZ short circuit system
Electrical
DLT4MA Travel speed sensors A and B Malfunction HST L03
system
Electrical
DLT4LC Travel speed sensors A and B Speed signal does not match. HST L01
system
Failure code
Applicable Action History
Lift Failed part Failure
KOMTRAX component code category
truck
Electrical
7REXKA Seat switch Open circuit HST L04
system
15
Electrical
7REXKA Seat switch Ground fault HST L04
system
Electrical
18 D5ZTKZ Pump EPC valve ground return signal Open circuit or hot short circuit HST L03
system
Electrical
DHHBKX HST pump A port pressure sensor Open circuit or ground fault HST L01
system
22
Electrical
DHHBKY HST pump A port pressure sensor Hot short circuit HST L01
system
Electrical
DHHCKX HST pump B port pressure sensor Open circuit or ground fault HST L01
system
23
Electrical
DHHCKY HST pump B port pressure sensor Hot short circuit HST L01
system
Electrical
DK70KZ Brake pedal angle sensor Open circuit or ground fault HST L03
system
25
Electrical
DK70KY Brake pedal angle sensor Hot short circuit HST L03
system
Electrical
DGS1KA HST oil temperature sensor Open circuit HST L01
system
26
Electrical
DGS1KB HST oil temperature sensor Ground fault HST L01
system
Electrical
AB00KZ Alternator Open circuit or ground fault HST L03
system
27
Electrical
AB00KY Alternator Hot short circuit HST L03
system
Electrical
DHPCKZ Lift cylinder oil pressure sensor Open circuit or ground fault HST L01
system
28
Electrical
DHPCKY Lift cylinder oil pressure sensor Hot short circuit HST L01
system
Electrical
DH2FKZ Brake charge pressure sensor Open circuit or ground fault HST L03
system
29
Electrical
DH2FKY Brake charge pressure sensor Hot short circuit HST L03
system
Forward travel HST pump EPC solenoid Electrical
DXATKA Open circuit HST L04
valve system
Forward travel HST pump EPC solenoid Electrical
32 DXATKB Ground fault HST L04
valve system
Forward travel HST pump EPC solenoid Electrical
DXATKY Hot short circuit HST L04
valve system
Reverse travel HST pump EPC solenoid Electrical
DXAUKA Open circuit HST L04
valve system
Reverse travel HST pump EPC solenoid Electrical
33 DXAUKB Ground fault HST L04
valve system
Reverse travel HST pump EPC solenoid Electrical
DXAUKY Hot short circuit HST L04
valve system
Electrical
DXAVKA HST motor EPC solenoid valve Open circuit HST L03
system
Electrical
34 DXAVKB HST motor EPC solenoid valve Ground fault HST L03
system
Electrical
DXAVKY HST motor EPC solenoid valve Hot short circuit HST L03
system
Electrical
D110KB HST controller power relay Ground fault HST L01
system
35
Electrical
D110KZ HST controller power relay Open circuit or hot short circuit HST L01
system
Electrical
DW9NKA Work equipment lock solenoid valve Open circuit HST L03
system
Electrical
37 DW9NKB Work equipment lock solenoid valve Ground fault HST L03
system
Electrical
DW9NKY Work equipment lock solenoid valve Hot short circuit HST L03
system
Failure code
Applicable Action History
Lift Failed part Failure
KOMTRAX component code category
truck
Electrical
DW9MKA Lift lock solenoid valve Open circuit HST L03
system
Electrical
38 DW9MKB Lift lock solenoid valve Ground fault HST L03
system
Electrical
DW9MKY Lift lock solenoid valve Hot short circuit HST L03
system
Electrical
D140KB Starter relay Ground fault HST L03
system
39
Electrical
D140KY Starter relay Hot short circuit HST L03
system
Backup alarm buzzer and backup lamp Electrical
D161KA Open circuit HST L01
relay system
Backup alarm buzzer and backup lamp Electrical
47 D161KB Ground fault HST L01
relay system
Backup alarm buzzer and backup lamp Electrical
D161KY Hot short circuit HST L01
relay system
Electrical
DV00KB Alarm buzzer Ground fault HST L01
system
48
Electrical
DV00KY Alarm buzzer Hot short circuit HST L01
system
Electrical
D19UKA Pump EPC valve ground cut relay Open circuit HST L03
system
Electrical
49 D19UKB Pump EPC valve ground cut relay Ground fault HST L03
system
Electrical
D19UKY Pump EPC valve ground cut relay Hot short circuit HST L04
system
Electrical
52 DAJ0KK HST controller Low voltage HST L03
system
Low voltage, open circuit, or Electrical
53 DAJ2KK HST controller load power supply line HST L03
ground fault system
Accessory input circuit 2 Electrical
54 7REHKA Open circuit HST L01
(KEY_ACC_SIGNAL) system
Electrical
55 DAJ5KX HST controller power output 1 Open circuit or hot short circuit HST L03
system
Electrical
56 7REAKA Accessory input circuit 1 (KEY_SIG) Open circuit or ground fault HST L03
system
CAN communication
Electrical
62 DB2RKR (between HST controller and engine con- Defective communication HST L04
system
troller)
Electrical
DAJ000 HST controller Memory malfunction HST L01
system
63
Electrical
DAJ000 HST controller Memory malfunction HST L01
system
Adjusting function
HST controller is equipped with the functions to compensate installation errors or manufacturing variations of
individual parts when repairing or replacing the brake pedal mechanism or when overhauling or replacing
HST pump.
a Adjusting function
Item number Adjustment item Outline
Adjustment of brake pedal angle Records the angle between the releasing and depressing sides of the
2
sensor brake pedal to HST controller to correct the installation errors.
Adjust the the variation at the beginning of the lift truck running due to
3 HST pump adjustment (1)
the manufacturing variation of individual HST pump.
Adjust the variation at the engine torque matching during acceleration
4 HST pump adjustment (2) of the loaded lift truck due to the manufacturing variation of individual
HST pump.
a When the controller is replaced with a new one, the abnormality warning lamp lights up continuously until
all the specified adjustment processes described in steps 2 to 4 are completed.
State transition
Normal mode
2 3 4
Adjustment of brake HST pump adjustment HST pump adjustment
pedal angle sensor (1) (2)
2) Turn the key of the starting switch to the "ON" position (do not start the engine),
Perform the following operations within 12 seconds.
[1] Fully depress brake pedal (4) and hold it.
[2] Press the service switch and hold it (until step [5]).
[3] Release the brake pedal.
[4] Switch the travel speed control selector switch to OFF → ON → OFF → ON → OFF.
[5] Fully depress brake pedal (4) and hold it.
[6] Release the service switch.
Mark position
Perform the following operation for the Example: When "Compensation value C" is cur-
adjustment. rently set
[1] Set to the adjustment mode (waiting for
selection).
[2] Check that the parking lever is in the LOCK
position or place it to the LOCK position.
[3] Place the directional lever to F (REVERSE)
position. (Adjustment of the pump on the
forward side)
[4] Press and release the service switch.
From the condition where HST oil filter clog-
ging warning lamp (1) and travel speed
control indicator lamp (2) blink alternately,
the lighting pattern is changed to the pat-
tern that indicates the current compensa-
tion value.
* By shortly pressing and releasing the
s e r vic e s w itc h d u rin g t h e li g h tin g
p a tt e r n th a t in d ic a t e s th e c u r r e n t
compensation value, the adjustment
mod e (wa itin g for selectio n) is set
again.
[5] By using the directional (FNR) lever, the lighting pattern is changed to the pattern of the compensa-
tion value marked on the forward side of HST pump.
[6] During the lighting pattern of the compensa- * When HST controller is replaced with a
tion value marked on HST pump, press new one, be sure to press down the
down the service switch for 3 seconds or service switch for 3 seconds or longer
longer and release it. and then release it to record the
• The alarm buzzer to notify of the adjust- compensation value even in case that
ment completion of the forward side the value of the pump is "0". If the
HST pump sounds (0.4 second). ad ju stme nt mo de e xits withou t
• The adjustment mode (waiting for recording, HST controller does not
selection) is set. accept it as the adjustment completion
* At this time, if the service switch is and the abnormality warning lamp lights
release d b efore 3 se cond s, th e up.
compensation value is not recorded. [7] Place the directional lever to R (REVERSE)
position (adjustment of the pump on the
reverse side)
[9] By using the directional (FNR) lever, change the lighting pattern to the pattern of the adjusted value
for reverse travel stamp on the HST pump.
a Do not delete data of "2: SRAM load frequency" and "4: E2P load frequency". (It is described consciously
to prevent the data from being deleted incorrectly.)
2) Turn the key of the starting switch to the "ON" position (do not start the engine),
Perform the following operations within 12 seconds.
[1] Fully depress brake pedal and hold it.
[2] Press the service switch and hold it (until step [6]).
[3] Release the brake pedal.
[4] Set the directional lever to N → F → N → R → N → F → N → R → N.
[5] Fully depress brake pedal and hold it.
[6] Release the service switch.
2. How to delete SRAM load frequency data 4. How to delete E2P load frequency data
1) During memory clear mode (waiting for 1) During memory clear mode (waiting for
selection), selection),
[1] Turn the travel speed control selector [1] Turn the travel speed control selector
switch to OFF → ON → OFF slowly. switch to OFF → ON → OFF → ON →
• The buzzer starts to sound for 0.2 OFF → ON → OFF slowly.
second in 1.5 second cycle. • The buzzer starts to sound consec-
• HST oil filter clogging warning lamp utively 3 times (0.2 second X 3) in
(1) blinks according to the cycle 1.5 second cycle.
when the buzzer sounds. • HST oil filter clogging warning lamp
[2] Slowly move the directional lever as N (1) blinks according to the cycle
→ F → N positions. when the buzzer sounds.
• The buzzer sounds for 1 second [2] Slowly move the directional lever to N
and the deletion of SRAM load fre- → F → N positions.
quency data is completed. • The buzzer sounds for 1 second
and the deletion of E2P load fre-
3. How to delete electrical-system abnormality quency data is completed.
record data
1) During memory clear mode (waiting for How to exit memory clear mode
selection), Turn the key of the starting switch to the "OFF"
[1] Turn the travel speed control selector position.
switch to OFF → ON → OFF → ON →
OFF slowly.
• The buzzer starts to sound consec-
utively twice (0.2 second X 2) in 1.5
second cycle.
• HST oil filter clogging warning lamp
(1) blinks according to the cycle
when the buzzer sounds.
a Also after the completion of dele-
tion, the above operation continues.
[2] Slowly move the directional lever to N
→ F → N positions.
• The buzzer sounds for 1 second
and the deletion of electrical-system
abnormality record data is com-
pleted.
Setting method
1. Set the lift truck in the following conditions.
• Turn the key of the starting switch to the
"OFF" position. REMARK
• Place the parking lever to the LOCK posi- a If upper and lower 3 indicator lamps of 6 indica-
tion. tor lamps (3) do not blink alternately, repeat the
• Place the directional lever to N (NEUTRAL) procedure from the first.
position.
• Turn the travel speed control selector 3. When pressing service switch (1),
switch to Release position (OFF). • alarm buzzer (0.2 second) sounds,
• and the indicator lamp lights up. By the
2. Turn the key of the starting switch to the "OFF" lighting pattern of the indicator lamp, the
position. currently-set interval can be checked.
(Do not start the engine.)
Within 12 seconds, Example: When current setting
• while pressing service switch (1), is 120 seconds
• leave the operator's seat→sit on the oper-
ator's seat→leave the operator's seat → sit
on the operator's seat,
• and release service switch (1).
4. When pressing service switch (1), 6. When pressing down service switch (1) for 3
• alarm buzzer (0.2 second) sounds, seconds or longer after setting the lighting pat-
• and the indicator lamp blinks. The set inter- tern of the interval to be set,
val can be changed or selected. • alarm buzzer (0.4 second) sounds,
• and the indicator lamp changes from blink-
Example: When current setting ing to lighting up to notify of completion of
is 120 seconds the setting.
Engine oil
1. Remove drain plug (1) to drain the oil.
3. Remove the sensor connector and drain hose 10. When the fuel main filter cartridge is replaced
connected to the bottom of filter cartridge (2). (every 1,000 hours), bleed air after replacing
the cartridge. (See "Bleeding air from fuel filter")
4. By using the filter wrench, turn filter cartridge
(2) to remove it. 11. Connect the sensor connector and drain hose
connected to the bottom of filter cartridge (2).
Replacement of fuel main filter 7. After completing the replacement of the fuel
cartridge main filter cartridge, bleed air. (See "Bleeding
air from fuel filter")
Prepare a filter wrench.
8. After bleeding air, start the engine and check
1. Open the engine hood. that there is no leakage of oil from the filter seal
portin. If there is any leakage of oil, check the
2. By using the filter wrench, turn main filter car- tightening condition of the filter cartridge. If
tridge (2) to remove it. there is still oil leakage, repeat Steps 1 to 2 to
remove the filter cartridge, and if any damage
or pinched foreign material on the packing sur-
face is found, replace it with a new cartridge
and repeat Steps 3 to 7 to install it.
Cleaning of water separator 9. Apply grease to separator base where ring nut
(5) and cup (6) are to be installed to.
strainer
10. Fill the cup with the clean fuel, install it to the
General specification of this machine is equipped
with water separator. separator base, and tighten ring nut (5).
3 Ring nut (5):
k After the engine stops, all parts are still 37 to 43 Nm {3.8 to 4.4 kgm}
v er y ho t , so d o n o t r ep l ac e t he fil te r Observe specified torque otherwise fuel leak-
immediately. Sufficiently cool down the age may occur from the loose part.
parts before replacement.
k When testing water separator strainer, wait 11. Perform air bleeding after installing the cup (5).
for inner pressure to drop down. When (See "Bleeding air from fuel filter")
more than 30 seconds passed after engine
stopped, drain fuel inside the separator, REMARK
and take the strainer out. Be careful not to lose O-ring, float, and spring as
k Do not bring any open flame close. they are to be installed after cleaning.
Radiator cleaning 7. Close drain valve (2) at the bottom of the radia-
tor and fill the radiator with supercoolant and
k The coolant is hot after the engine running. clean water (city water) from the water filler port
D raining the coolant immedia tely m ay of the radiator.
cause burn injury. Sufficiently cool down Coolant capacity: 9 l
the engine before draining.
k Entering under the lift truck for cleaning 8. Close radiator cap (1).
w hile the engine is r unning is ver y a Select the concentration of the supercool-
dangerous since the lift truck may start ant based on the lowest ambient tempera-
suddenly. Never enter under the lift truck ture in the operating environment.
when the engine is running. The concentration of the supercoolant based
k Do not remove the radiator cap when the on the lowest ambient temperature
radiator coolant is hot. Boiling coolant may Lowest ambient -10
spurt out. After the coolant temperature is -15 -20 -25 -30 -35 -40
temperature (°C) Min.
c ooled dow n, rotate the cap slowly to Coolant concen-
release the pressure, and then remove it. 30 36 41 46 50 54 58
tration (%)
k If bleeding air insufficiently when replacing
the coolant or radiator, the engine may a When not using the supercoolant, fill the
overheat. Therefore, bleed air completely. radiator with rustproof liquid to prevent the
engine corrosion.
1. Open radiator cap (1). a Clean the radiator on a level ground.
a Be sure to use Komatsu genuine detergent
2. Open drain valve (2) at the bottom of the radia- liquid, rustproof liquid, and supercoolant
tor to drain the coolant. (AF-NAC).
2. If the red piston is projected into the transparent 4. Remove the inner element, and then quickly
portion of dust indicator (1), clean or replace install the new inner element.
the air cleaner element.
• Condition for projection of dust indicator red 5. Clean inside of cover (2). When the dirt dis-
zone charged from evacuator valve (7) is accumu-
7.47±0.57 kPa {762±58 mmH2O} lated in the engine hood, clean it off.
Testing and adjusting engine 1) Testing engine speed (low idle and high idle
speeds)
speed a When the engine coolant temperature is
l o w e r th a n 5 0 ° C , t h e l o w id l e s p e e d
1. Turn the key to the OFF position and connect
becomes 1000rpm by the automatic warm-
the engine controller troubleshooting tool to the
lift truck. up function. (When the coolant temperature
a For the connection method of the tool, see is 50°C or higher, the speed is 800±25rpm.)
Testing and adjusting "Check of failure code a The following 2 methods are available to
of engine controller". operate the engine at the high idle speed.
Method 1). Fully depress the accelerator
2. Start the engine. pedal with the directional lever
in N (NEUTRAL) position to lift
3. Start the software (KOMATSU ENGINE SER- the fork.
VICE TOOL)and click the tabs in the following Method 2). Fully depress the brake and
order to check the engine speed. accelerator pedals when the
directional lever is in F (FOR-
WARD) position.
2) Testing HST stall speed
[1] Prepare a lift truck whose weight is the
same as that of the lift truck on which
the HST stall speed is to be measured.
(The prepared lift truck is used as a
towed lift truck to stall the lift truck to
measure HST stall speed.)
[2] Load materials as heavy as possible to
both the lift truck for the measurement
and another one.
(To prevent the tires from slip when
towing)
[3] Connect the prepared lift truck and the
one for the measurement by using a
wire rope.
k Select a wire rope that has ample
strength for the rim pull of the lift
truck. (The maximum rim pull of the
lift truck: 3600 kgf±10%)
k Never use a wire rope which has cut
strands (A), reduced diameter (B), or
kinks (C). There is a danger that the
rope may break during the towing
operation.
Testing and adjusting HST oil Measurement of oil pressure during reverse
travel
pressure 1. Remove side plug (1) of the block at the bottom
of HST motor and install hydraulic tester J1.
Testing tools
a Use the same pressure pickup plug as the
Symbol Part No. Part Name one used for "Measurement of oil pressure
799-101-5002
Analog hydraulic during forward travel".
tester
1
J Digital hydraulic 2. Start the engine, depress the brake pedal and
790-261-1204
tester then, release the parking brake.
2 799-401-3100 Adapter (1/16 and 27NPTF)
3. After placing the directional lever in R
a HST oil temperature at measurement: (REVERSE) position and slowly releasing the
45 to 55°C brake pedal, measure the pressure during
a Check for any leakage of hydraulic oil from travel at the full throttle engine speed.
each of the joints.
Measurement of oil pressure of high pressure
TESTING relief
Measurement of oil pressure during forward 1. Remove left side plug (1) of the block at the
travel bottom of HST motor and install hydraulic tester
1. Remove rear plug (1) on the left side of the J1.
block at the bottom of HST motor and install a Use the same pressure pickup plug as the
hydraulic tester J1. one used for "Measurement of oil pressure
during forward travel".
2. Start the engine, depress the brake pedal and
then, release the parking brake. 2. Measure the pressure during HST stall at for-
ward travel. For details, see "Testing and
3. After placing the directional lever in F (FOR- adjusting engine speed".
WARD) position and slowly releasing the brake
pedal, measure the pressure during travel at
the full throttle engine speed.
Adjustment of HST charge circuit pressure Adjustment of HST charge circuit pressure
(pump side) (motor side)
a If HST charge circuit pressure (only in HST a If HST charge circuit pressure (only in traveling)
neutral) is not correct, adjust charge safety is not correct, adjust charge relief valve (9) of
valve (6) of HST pump according to the follow- HST pump according to the following proce-
ing procedure. dure.
2. Loosen lock nut (7) of charge safety valve (6) 1. While fixing adjustment screw (10), loosen lock
and turn adjustment screw (8) to adjust. nut (11).
a When the adjustment screw is: 2. Turn adjustment screw (10) to adjust the pres-
• turned clockwise, the pressure is sure.
increased. a When the adjustment screw is:
• turned counterclockwise, the pressure • turned clockwise, the pressure is
is decreased. increased.
a Quantity of pressure adjustment per turn of • turned counterclockwise, the pressure
adjustment screw is decreased.
0.29 MPa {3.0 kg/cm2} a Quantity of pressure adjustment per turn of
adjustment screw
3. After finishing the adjustment, tighten lock nut 1.02 MPa {10.4 kg/cm2}
(7).
3 Locknut: 58.8 to 78.5 Nm (6 to 8 kgm) 3. After finishing the adjustment, tighten lock nut
(11).
3 Locknut: 58.8 to 78.5 Nm (6 to 8 kgm)
Testing work equipment and 2. Install nipple [1], hose [2], and oil pressure
gauge [3] of hydraulic tester K1.
steering pump oil pressure a Nipple: R1/8
Testing tools a Use oil pressure gauge [3] of 60 MPa {600
kg/cm2}.
Symbol Part No. Part Name
1 799-101-5002 Hydraulic tester
K
2 790-261-1204 Digital hydraulic tester
TESTING
1. Remove the oil pressure measuring plug from
measuring ports (1) and (2) in the lower part of
the floor panel.
• Port (1): Pump discharge pressure
• Port (2): LS pressure
Oil Level Check 4. Refill the case with oil from oil filler port (3) to
the specified level.
1. Stop the engine.
• Refill capacity: 11 l
2. Pull out oil level gauge (1).
5. After refilling, check the oil level.
4. Pull out oil level gauge (1) to check the oil level.
a When inserting oil level gauge (1), measure
while putting (Q surface) of the gauge por-
tion to (P) surface of the oil filler port.
5. If the oil level is low, add the gear oil from the oil
filler port.
Changing PTO oil and cleaning 9. Refill the PTO with oil from the oil filler port to
the specified level.
strainer • Refill capacity: 5.5 l
k Since oil is heated high immediately after
10. Check the oil level by using oil level gauge (1).
the operation, wait until it is cooled before
starting your work.
11. If the oil level is low, refill from oil level gauge
1. Place a container under drain plug (3) of PTO (1) portion.
to catch the oil.
9. Install drain plug (1). 17. Install HST pump upper surface plug (10).
3 Drain plug (1): 3 HST pump upper surface plug (10):
59 to 78 Nm {6 to 8 kgm} 44.1 to 53.9 Nm {4.5 to 5.5 kgm}
10. Install strainer (4). 18. Install air bleeding plug (5).
3 Air bleeding plug (5):
11. Replace line filter (3) and packing (9) with new 34 to 54 Nm {3.5 to 5.5 kgm}
ones and install cover (2).
* Apply the silicon-based liquid gasket to the 19. Check the vent hole of breather (7). Replace it if
frame side surface of packing (9) to fix the it is stained too much.
packing. (ThreeBond 1206C is recom-
mended.) 20. Start the engine, run engine at low idle for
approximately 5 minutes.
12. Remove air bleeding plug (5) of the work equip-
ment pump. 21. Operate the hydraulic cylinder (lifting, tilting and
steering) 5 or 6 times when running the engine
at low idle.
a Stop the piston rod approximately 50 mm
before the stroke end and take care not to
relieve.
23. Run the engine at low idle and operate the pis-
ton rods of the hydraulic cylinders to the end of
its stroke to relieve.
a Be sure to use Komatsu genuine oil and.
Engine oil (EO10W30-DH)
13. Remove cap (6) with the oil level gauge from
the hydraulic oil filler port.
14. Refill the tank with the oil from the hydraulic oil
filler port.
• Refill capacity (oil level inside the tank):
83 l
15. Check the oil level by using oil level gauge (6).
a Measuring condition
• Road surface: Flat, level, dry paved surface
• Speed:
• With no load
Speed when applying brake: 20 km/h
• With load
Speed when applying brake: 10 km/h
• Tire inflation pressure: Specified pressure
• Specified depressing effort: 392 N {40 kg}
Measuring method
1. Start the engine, and drive the lift truck.
Measurement of wear of service 6. After checking, return the caps of of brake disc
wear check port (1) and brake disc wear check
brake disc gauge (2).
3 Brake disc wear check gauge (2):
k Stop the lift truck on a level ground, and
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
chock the wheels. If the lift truck suddenly
moves off, serious personal injuries may
occur.
k Perform the operation with two workers.
One worker depresses the brake pedal and
the other determines the disc wear.
2. Install one end of vinyl hose (3) to brake air Lift cylinder
k
bleeding plug (2) and set the other end in a
Stop the lift truck on a level ground, and
container.
chock the wheels. If the lift truck suddenly
moves off, serious personal injuries may
occur.
3. Depress the brake pedal while the engine is 5. Repeat the operations in 4. 4 or 5 times.
running at low idle.
Adjusting brake pedal 2. Adjust clearance (c) between rod (4) of brake
valve (3) and piston (5) with nut (6) so that play
1. Adjust height (a) of brake pedal (1) by using (b) of the brake pedal is 0 to 4 mm.
stopper bolt (2). • Play (b): 0 to 4 mm
• Height (a): 62±2 mm a Loosen nut (6) and rotate rod (4) to adjust
a Remove the cover of the brake pedal and the clearance.
then measure the height.
2. Stop the engine and disconnect the rod at the 2. Loosen lock nut (3) and rotate rod (2) to adjust
bottom of the brake pedal and spring. Check the length of the rod.
whether the ball joint and linkage lever are stiff
or not. 3. After the adjustment, tighten lock nut (3) to the
specified torque.
3 Locknut:
3. Disconnect the ball joints on the both ends of
rod (2). Check whether the ball joint and brake 14.7 to 19.6 Nm {1.5 to 2.0 kgm}
pedal angle sensor are stiff or not.
Initial setting of Orbitrol valve 6. While the starting switch is in the ON (ACC)
position, disconnect the initialization plug termi-
a Initial setting is the work to store the standard nal (1).
conditions (center, right and left end positions)
to EPACS controller. 7. Check that state display LED (2) blinks twice.
1. After starting the engine and turning the tires 8. Operate the steering wheel to the right end and
straight-forward, stop the engine and turning then left end, and return it to the center.
the steering wheel knob straight-forward. a Prevent the steering wheel from slipping at
the end position.
Measurement of hydraulic drift 5. After 3 minutes, put mark (A) to piston rod (3) of
lift cylinder (2) and read the mark by using a
and forward tilt down by hydraulic scale.
drift of cylinder
k Do not allow anyone to enter under the load
during the measurement. If the fork lowers,
serious personal injury may occur.
k Use steps with ample height , strength, and
stability. Do not put your hands or legs on
t h e s ta y o f t h e m a s t o r d a s h b o a r d .
O therwise, your hands or le gs may be
pinched or falling off may occur.
k The measurement must be performed on a
level and flat road surface. Otherwise, the
lift truck may tip over.
k The measurement must be performed in
front of the pallet that can endure it if the lift 6. After leaving it for 15 minutes, read mark (A) of
truck tilt forward. piston rod (3) and obtain the hydraulic drift dur-
a Before the measurement, check that the ing the last 15 minutes.
hydraulic oil is not stained, different oil is not • Hydraulic drift for 15 minutes:
entered, and the oil level is normal. 50 mm or less
1. Repeat the lift and tilt operations to warm up the 7. Raise load position in height (H) to 1,500 mm
hydraulic oil temperature to approximately and set mast (1) vertically.
50°C.
8. After 3 minutes, put mark (B) to piston rod (5) of
2. Load the rated load and hook a wire to the fork tilt cylinder (4) and read the mark by using a
carriage to fix the load. scale.
Adjustment of mast 1. Stop the lift truck on a level and flat road sur-
face.
Adjustment of runout of mast
2. Raise the mast to the highest position.
Selection of outer roller and adjustment Selection of inner roller and adjustment
by shim by shim
1. Select roller (4) so that there is no difference 1. Select roller (6) so that clearance (a) between
between the right and left strip dimensions (V) the outer mast rail and roller (6) is within the fol-
of the inner and outer masts. lowing range.
• Clearance (a): 0.4 to 1.6 mm
2. Raise the mast to the highest position. a Only 1 type of roller is set for FH40/45/
50-1.
3. Insert shims (5) of the same thickness on the
rig h t a n d le ft s id e s so t ha t cle a ra n ce ( f) 2. Raise the mast to the highest position.
between the corner of the inner mast rail and
the corner of roller (4) is within the following 3. Insert shims (7) of the same thickness to the
range. r ig ht a n d le ft sid es s o th at clea ran ce (c)
• Clearance (f): 0.5 to 1.0 mm between the corner of the inner mast rail and
the corner of roller (6) is within the following
range.
• Clearance (c): 0.5 to 1.0 mm
In KOMTRAX system, information and details of process in the system is displayed on LED display unit on
the upper side of KOMTRAX terminal. If the system is wondered to be defective, perform the following
inspections.
• Antenna inspection
• Terminal LED unit inspection
To use KOMTRAX system, application for use and radio station establishment on the lift truck body side
must be completed.
Antenna inspection
a Before check of the LED display, check that there are no abnormalities around the communication
antenna and GPS antenna.
• The communication antenna must not be removed or damaged.
• There must be no open circuit of communication antenna cable or the connection to KOMTRAX terminal
must be normal.
• The GPS antenna must not be removed or damaged.
• There must be no open circuit of GPS antenna cable or the connection to KOMTRAX terminal must be
normal.
[A]: Normal completion (It takes 90 seconds at least a For display other than the above, con-
until this display appears.) tact customer support department.
[B]: Defective detection of GPS position data a In total, it takes 90 seconds to 5 min-
Check the GPS antenna and cable for external utes at most until [Normal completion] is
failure. displayed after the operation in step 7).
(It takes 90 seconds to 5 minutes.) 9) Turn the starting switch to the OFF
[C]: Defective reception position
Check the communication antenna and cable 10) Check that 7- segment display lamp
for external failure. displays correctly after 10 seconds.
(It takes 30 seconds to 1 minutes.) a When [Normal] is displayed, the
[D]: Abnormalities in network and wiring harness radio station establishment has
"Selection and entry of network type and net- been completed.
work obtaining data do not match each other." a If [Abnormal] is displayed, the radio
"Check whether the connection with the lift station establishment is not com-
truck is correct." pleted correctly. Restart from step
1).
40 Troubleshooting
Table of Contents
40 Troubleshooting
Information related to troubleshooting ................................................................................................... 40-5
Points to remember when troubleshooting ........................................................................................ 40-5
How to proceed in troubleshooting .................................................................................................... 40-6
Checks before troubleshooting .......................................................................................................... 40-7
Classification and procedures of troubleshooting .............................................................................. 40-8
Phenomena seemed to be failures and troubleshooting Nos. ........................................................... 40-9
Information described in troubleshooting table ................................................................................ 40-12
Locations of fuses ............................................................................................................................ 40-17
Connection table for connector pin numbers ................................................................................... 40-20
T-branch box and T-branch adapter table ........................................................................................ 40-60
Troubleshooting by failure code (HST controller system) .................................................................... 40-63
Failure code list................................................................................................................................ 40-63
Failure code [--/AB00MA] Alternator: Malfunction............................................................................ 40-66
Failure code [--/B@CRNS] HST Oil: Overheating ........................................................................... 40-67
Failure code [--/2G40ZG] Brake accumulator: Dropped hydraulic pressure.................................... 40-68
Failure code [--/6091NX] Hst oil filter: Clogging............................................................................... 40-69
Failure code [12/DDK6KA] FNR lever: Open circuit ........................................................................ 40-70
Failure code [12/DDK6KY] FNR lever: Hot short circuit................................................................... 40-74
Failure code [14/DLT4KZ] Travel speed sensor A:
Open circuit, ground fault, or hot short circuit .............................................................................. 40-76
Failure code [14/DLT6KZ] Travel speed sensor B:
Open circuit, ground fault, or hot short circuit .............................................................................. 40-78
Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B:
Open circuit, ground fault, or hot short circuit .............................................................................. 40-80
Failure code [14/DLT4MA] Travel speed sensors A and B: Malfunction.......................................... 40-82
Failure code [14/DLT4LC] Travel speed sensors A and B: Mismatch of rotation speed signals...... 40-83
Failure code [15/7REXKA] Seat switch: Open circuit ...................................................................... 40-84
Failure code [15/7REXKB] Seat switch: Ground fault...................................................................... 40-86
Failure code [18/D5ZTKZ] Pump EPC valve ground return signal:
Open circuit or hot short circuit .................................................................................................... 40-88
Failure code [22/DHHBKX] HST pump A-port pressure sensor: Open circuit or ground fault ......... 40-90
Failure code [22/DHHBKY] HST pump A-port pressure sensor: Hot short circuit ........................... 40-92
Failure code [23/DHHCKX] HST pump B-port pressure sensor: Open circuit or ground fault......... 40-94
Failure code [23/DHHCKY] HST pump B-port pressure sensor: Hot short circuit ........................... 40-96
Failure code [25/DK70KZ] Brake pedal angle sensor: Open circuit or ground fault ........................ 40-98
Failure code [25/DK70KY] Brake pedal angle sensor: Hot short circuit......................................... 40-100
Failure code [26/DGS1KA] HST oil temperature sensor: Open circuit .......................................... 40-102
Failure code [26/DGS1KB] HST oil temperature sensor: Ground fault.......................................... 40-104
Failure code [27/AB00KZ] Alternator R signal circuit: Open circuit or ground fault ....................... 40-106
Failure code [27/AB00KY] Alternator R signal circuit: Hot short circuit.......................................... 40-108
Failure code [28/DHPCKZ] Lift cylinder pressure sensor: Open circuit or ground fault ................. 40-110
Failure code [28/DHPCKY] Lift cylinder pressure sensor: Hot short circuit ................................... 40-112
Failure code [29/DH2FKZ] Brake charge pressure sensor: Open circuit or ground fault............... 40-114
Failure code [29/DH2FKY] Brake charge pressure sensor: Hot short circuit................................. 40-116
Failure code [32/DXATKA] HST pump forward travel EPC solenoid valve: Open circuit............... 40-118
Failure code [32/DXATKB] HST pump forward travel EPC solenoid valve: Ground fault .............. 40-120
Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve: Hot short circuit ......... 40-122
Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid valve: Open circuit .............. 40-124
Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid valve: Ground fault ............. 40-126
Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid valve: Hot short circuit ........ 40-128
Failure code [34/DXAVKA] HST motor EPC solenoid valve: Open circuit ..................................... 40-130
Failure code [34/DXAVKB] HST motor EPC solenoid valve: Ground fault..................................... 40-132
Failure code [34/DXAVKY] HST motor EPC solenoid valve: Hot short circuit ............................... 40-134
Failure code [35/D110KZ] HST controller power relay: Open circuit or hot short circuit ................ 40-136
Failure code [35/D110KB] HST controller power relay: Ground fault............................................. 40-138
Failure code [37/DW9NKA] Work equipment lock solenoid valve: Open circuit ............................ 40-140
Failure code [37/DW9NKB] Work equipment lock solenoid valve: Ground fault............................ 40-142
Failure code [37/DW9NKY] Work equipment lock solenoid valve: Hot short circuit ...................... 40-144
Failure code [38/DW9MKA] Lift lock solenoid valve: Open circuit ................................................. 40-145
Failure code [38/DW9MKB] Lift lock solenoid valve: Ground fault................................................. 40-146
Failure code [38/DW9MKY] Lift lock solenoid valve: Hot short circuit ........................................... 40-148
Failure code [39/D140KB] Starter relay: Ground fault ................................................................... 40-150
Failure code [39/D140KY] Starter relay: Hot short circuit .............................................................. 40-152
Failure code [47/D161KA] Backup buzzer and backup lamp relay: Open circuit .......................... 40-154
Failure code [47/D161KB] Backup buzzer and backup lamp relay: Ground fault.......................... 40-156
Failure code [47/D161KY] Backup buzzer and backup lamp relay: Hot short circuit..................... 40-158
Failure code [48/DV00KB] Warning buzzer: Ground fault ............................................................. 40-160
Failure code [48/DV00KY] Warning buzzer: Hot short circuit ........................................................ 40-161
Failure code [49/D19UKA] Pump EPC valve ground cutout relay: Open circuit ............................ 40-162
Failure code [49/D19UKB] Pump EPC valve ground cutout replay: Ground fault ......................... 40-164
Failure code [49/D19UKY] Pump EPC valve ground cutout relay: Hot short circuit ...................... 40-166
Failure code [52/DAJ0KK] HST controller: Drop of power voltage ................................................ 40-168
Failure code [53/DAJ2KK] HST controller: Drop of load power supply voltage ............................. 40-170
Failure code [54/7REHKA] Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit ............ 40-172
Failure code [55/DAJ5KX] HST controller sensor 5 V-power supply:
Ground fault or hot short circuit ................................................................................................. 40-174
Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL): Open circuit ...................... 40-176
Failure code [62/DB2RKR] CAN communication (between HST controller and
engine controller): Communication failure (Component system failure) .................................... 40-178
Failure code [63/DAJ000] HST Controller: Memory error .............................................................. 40-180
Failure code [63/DAJ0KT] HST Controller: Memory error ............................................................. 40-181
Troubleshooting by failure code (EPACS controller system) ............................................................. 40-182
Display of EPACS controller failure code....................................................................................... 40-182
Failure code [LED: OFF] EPACS controller abnormality................................................................ 40-183
Failure code [LED: 1 flashing] Initialization is not completed......................................................... 40-184
Failure code [LED: 2 flashings] Controller is being initialized ........................................................ 40-185
Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality .................................... 40-186
Failure code [LED: 4 flashings] Tire angle sensor abnormality...................................................... 40-188
Troubleshooting for electrical system (E-mode) ................................................................................ 40-190
Information described in troubleshooting table .............................................................................. 40-190
E-1 Engine does not start .............................................................................................................. 40-191
E-2 Engine preheater does not operate......................................................................................... 40-196
E-3 Parking brake reminder alarm does not sound or does not stop sounding ............................. 40-198
E-4 EPACS is abnormal................................................................................................................. 40-201
E-5 Headlamp, clearance lamp, tail lamp and license plate lamp do not light up or go off............ 40-204
E-6 Turn signal lamps do not light up or go off .............................................................................. 40-210
E-7 Brake lamps do not light up or go off....................................................................................... 40-214
E-8 Backup lamps do not light up or go off .................................................................................... 40-216
E-9 Backup buzzer does not sound or does not stop sounding .................................................... 40-218
E-10 Horn does not sound or does not stop sounding .................................................................. 40-220
E-11 Fuel level is not displayed normally....................................................................................... 40-222
E-12 Engine coolant temperature level is not displayed normally ................................................. 40-224
E-13 All of indicator and warning lamps of instrument panel do not light up
when starting switch is turned to the ON position...................................................................... 40-226
E-14 When starting switch is turned to the ON position,
all of indicator and warning lamps of pilot box do not light up ................................................... 40-233
E-15 When starting switch is turned to the ON position,
engine preheater lamp does not light up ................................................................................... 40-238
E-16 When starting switch is turned to the ON position, alarm buzzer does not sound ................ 40-240
E-17 Backup lamp of instrument panel does not light up............................................................... 40-242
E-18 Charge warning lamp lights up while engine is running ........................................................ 40-244
E-19 HST oil temperature warning lamp lights up while engine is running.................................... 40-246
E-20 HST oil filter clogging warning lamp lights up while engine is running .................................. 40-247
E-21 Engine oil pressure warning lamp lights up while engine is running ..................................... 40-248
E-22 Sedimenter (water separator) warning lamp lights up while engine is running ..................... 40-248
E-23 Abnormality warning lamp lights up while engine is running ................................................. 40-250
E-24 Engine abnormality warning lamp lights up while engine is running ..................................... 40-252
E-25 Travel speed restriction cannot be released or enabled........................................................ 40-254
E-26 Impossible to select HST controller failure display mode, HST controller
adjustment mode, speed limit setting mode, or engine stop time auto-change mode ............... 40-256
E-27 KOMTRAX system does not operate normally...................................................................... 40-259
Troubleshooting for hydraulic and mechanical system (H-mode) ...................................................... 40-261
How to use troubleshooting table................................................................................................... 40-261
Hydraulic and mechanical system diagram ................................................................................... 40-264
Table of failure modes and causes ................................................................................................ 40-266
H-1 Lift truck cannot travel ............................................................................................................. 40-270
H-2 Slow travel speed.................................................................................................................... 40-271
H-3 Insufficient towing force........................................................................................................... 40-272
H-4 Engine stops during traveling, or engine speed drops excessively......................................... 40-273
H-5 HST (hydraulic) oil temperature is too high............................................................................. 40-274
H-6 Impossible steering ................................................................................................................. 40-275
H-7 Response is low during turning ............................................................................................... 40-276
H-8 Steering is heavy..................................................................................................................... 40-277
H-9 Unstable during turning ........................................................................................................... 40-278
H-10 When steering wheel is released it does not return to neutral or it rotates by itself .............. 40-279
H-11 Steering wheel is turned in reverse or it kicks (while work equipment is operated) .............. 40-279
H-12 Large shock is made when steering wheel is returned ......................................................... 40-280
H-13 EPACS does not work ........................................................................................................... 40-281
H-14 Steering wheel vibrates ......................................................................................................... 40-282
H-15 Steering system makes abnormal sound .............................................................................. 40-282
H-16 Oil leaks from steering circuit ................................................................................................ 40-282
H-17 Service brake does not work or its performance is low ......................................................... 40-283
H-18 Service brake is not reset or it drags..................................................................................... 40-284
H-19 Parking brake does not work or its performance is low......................................................... 40-285
H-20 Parking brake is not reset or it drags .................................................................................... 40-286
H-21 Abnormal noise around the work equipment or steering pump............................................. 40-287
H-22 Engine speed drops excessively or stops during work equipment operation
or wheel steering........................................................................................................................ 40-288
H-23 Fine control performance of entire work equipment is low or response is low ...................... 40-289
H-24 Work equipment cannot be locked (and the equipment operates when operator leaves) .... 40-290
H-25 Control valve lever does not move smoothly and it is heavy ................................................ 40-291
H-26 Lift cylinder and fork do not lift............................................................................................... 40-292
H-27 Lifting speed or power of lift cylinder and fork is insufficient ................................................. 40-293
H-28 Forklift speed lowers at specific height ................................................................................. 40-294
H-29 Lift cylinder natural drift is large............................................................................................. 40-295
H-30 Lift cylinders do not come down ............................................................................................ 40-296
H-31 Fork lowering speed is low or high or fine control performance is low or response is low.... 40-297
H-32 Mast does not tilt forward or backward ................................................................................. 40-298
H-33 Forward/backward tilting speed or force of mast is insufficient ............................................. 40-299
H-34 Tilting speed lowers halfway ................................................................................................. 40-300
H-35 Tilt cylinder natural forward drift is large................................................................................ 40-301
H-36 Mast is unstable during travel with load ................................................................................ 40-302
H-37 Work equipment is heavy when work equipment and
steering are operated simultaneously ........................................................................................ 40-303
H-38 Steering is heavy when work equipment and steering are operated simultaneously ............ 40-304
3. Check of level and type of engine oil Between H and L Add oil
Between FULL
4. Check of coolant level Add coolant
and LOW
Fuel, lubricant and coolant
6. Check of level and type of hydraulic oil Between H and L Add oil
13. Check of battery terminals and wiring for loose connection and
– Retighten or replace
corrosion
Electrical parts
14. Check of alternator terminals and wiring for loose connection and
– Retighten or replace
corrosion
15. Check of starting motor terminals and wiring for loose connection
– Retighten or replace
and corrosion
23. Check of wires for discoloration, burn, and removal of cover – Replace
24. Check for loose wire clamp and drooping wire – Repair
25. Check of wires for wetness (Check connectors and terminals for Unplug connectors,
–
wet, in particular) and dry wires
26. Check of slow blow fuse and fuse for disconnection and corrosion – Replace
27.5 to 29.5 V after
27. Check of alternator voltage (while engine speed is at middle or
operation for sev- Repair or replace
higher)
eral minutes
3. Procedure when the failure code history is not recorded in the controller:
If the failure code history is not recorded in the controller, a failure that the lift truck cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon seems to be failure again and select the same phenomenon from
the table of "Phenomena seem to be failures and troubleshooting Nos." (see the next page), and then
perform troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode" or "S-mode".
* Location of "Abnormality warning lamp" and "Engine abnormality warning lamp" on the instru-
ment panel
1. Lift interlock warning lamp
2. Engine abnormality warning lamp
3. Abnormality warning lamp
Troubleshooting
No. Phenomena seemed to be failure
Code display E-mode H-mode S-mode
Phenomena related to steering
33 EPACS is abnormal. E-4
34 Lift truck can not be steered. H-6
35 Response is slow during turning. H-7
36 Steering operation is heavy. H-8
37 Unstable during turning H-9
When steering wheel is released it does not return to neutral or it
38 H-10
rotates by itself.
39 Steering wheel is turned in reverse or it kicks. H-11
40 Large shock occurs when steering wheel changes turning direction. H-12
41 EPACS controller does not work. H-13
42 Steering wheel vibrates. H-14
43 Steering system makes unusual sound. H-15
44 Oil leaks from steering circuit. H-16
Phenomena related to work equipment
45 Unusual noise around the work equipment pump H-21
Engine speed drops excessively or stops during work equipment
46 H-22
operation or steering wheel operation.
47 Fine control or response of work equipment is poor. H-23
Work equipment cannot be locked (the equipment operates when
48 H-24
operator leaves).
Lift and tilt levers do not move smoothly and they are heavy in oper-
49 H-25
ation.
50 Lift cylinder and fork do not lift. H-26
51 Lifting speed or power of lift cylinder and fork is insufficient. H-27
52 Forklift speed lowers at specific height. H-28
53 Lift cylinder hydraulic drift is large. H-29
54 Lift cylinders do not come down. H-30
Fork lowering speed is low or high, or fine control performance is
55 H-31
poor or response is low.
56 Mast does not tilt forward nor backward. H-32
57 Forward/backward tilting speed or power of mast is insufficient. H-33
58 Tilting speed lowers halfway. H-34
59 Tilt cylinder forward hydraulic drift is large. H-35
60 The mast is unstable during traveling with load. H-36
Work equipment is slow in operation when work equipment and
61 H-37
steering are operated simultaneously.
Steering is heavy in operation when work equipment and steering
62 H-38
are operated simultaneously.
Appendix
Headlamp, clearance lamp, tail lamp and license plate lamp do not
63 E-5
light up nor go off.
64 Turn signal lamps do not light up nor go off. E-6
65 The brake lamp does not light or go off. E-7
66 Back lamps do not light up nor go off. E-8
67 Backup buzzer does not sound or does not stop sounding. E-9
68 Horn does not sound or does not stop sounding. E-10
69 Fuel level is not displayed normally. E-11
70 Engine coolant temperature level is not displayed normally. E-12
All of indicator and warning lamps of instrument panel do not light up
71 E-13
when starting switch is turned to the ON position.
Troubleshooting
No. Phenomena seemed to be failure
Code display E-mode H-mode S-mode
When starting switch is turned to the ON position, all of pilot box indi-
72 E-14
cators and warning lamps do not light up.
When starting switch is turned to the ON position, preheater lamp
73 E-15
does not light up.
When starting switch is turned to the ON position, alarm buzzer does
74 E-16
not sound.
75 Backlight of instrument panel does not light up. E-17
76 Charge warning lamp lights up while engine is running. E-18
77 HST oil temperature warning lamp lights up while engine is running. E-19
78 HST oil filter clogging warning lamp lights up while engine is running. E-20
79 Engine oil pressure warning lamp lights up while engine is running. E-21
Sedimenter (water separator) warning lamp lights up while engine is
80 E-22
running.
81 Abnormality warning lamp lights up while engine is running. E-23
82 Engine abnormality warning lamp lights up while engine is running. E-24
83 Impossible to enable or cancel speed limiter. E-25
Impossible to select HST controller failure display mode, HST con-
84 troller adjustment mode speed limiter setting mode, or engine Auto E-26
Stop time change mode.
85 KOMTRAX system does not operate normally. E-27
1. Troubleshooting procedure when the warning lamp lights up on the instrument panel
Warning lamp
lights up.
Individual
warning lamp is lit. NO
Engine
abnormality NO
YES warning lamp is lit.
YES
Abnormality
warning lamp is lit.
YES
Investigate the cause for There is a failure in engine There is a failure in HST There is a failure in engine
each individual item of which controller system. Check the controller system. Check the controller system. Check the
warning lamp is lit, and failure code by using trouble- failure code and perform the failure code by using trouble-
restore it. shooting tool for engine troubleshooting. shooting tool for engine
controller, and perform the controller, and perform the
troubleshooting. troubleshooting.
Locations of fuses
Applicable model: Lift truck with SAA4D95LE-5-C engine
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a continuous power supply is a device which supplies power while the starting switch is in the OFF and
ON positions).
a When performing troubleshooting related to the electrical system, you should check the fuse box to see
if the power is supplied normally.
Fuse box
Type of power supply Capacity of
Fuse name Destination of power
(Source) fuse
1 HORN SWITCH
(between terminals 10A
Horn relay
2A and 1)
2 Clearance lamp
(between terminals 10A
Stop lamp
2A and 2)
3
(between terminals 15A Head lamp
2A and 3)
4
(between terminals --- To be used when optional equipment are mounted
5B and 4)
5
(between terminals --- To be used when optional equipment are mounted
Continuous power supply 5B and 5)
(batteries) 6
(between terminals --- To be used when optional equipment are mounted
5B and 6)
7
(between terminals --- To be used when optional equipment are mounted
7C and 7)
8 HST controller (Main and load power supplies)
(between terminals 10A
KOMTRAX controller (Main power supply)
9D and 8)
9
(between terminals 5A DC/DC converter
9D and 9)
10 Parking brake lever switch
(between terminals 5A
HST controller (Key signals)
9D and 10)
11 Meter • Backup lamp
(between terminals 10A
Directional lamp • Backup buzzer
12E and 11)
12
(between terminals 10A FNR lever
12E and 12)
13 PWM relay (Engine controller power supply relay)
(between terminals 5A Engine controller (Key signals)
Switching power supply 12E and 13) Engine PW return
(ACC terminal of starting
switch) 14
(between terminals 5A For optional parts
15F and 14)
15 Alternator (LG terminal), EPACS controller (main power
(between terminals 5A supply), KOMTRAX controller (ACC, R terminal and C
15F and 15) terminal)
16
(between terminals 5A HST controller (Key and ACC signals)
15F and 16)
Connector
Y 090 Y 090 Y RH Y 090
name
Manufacturer's
7123-1460 7283-7028-40 7283-8850-30 7283-1081-40
part No.
Komatsu part
– Sub-part 165 Sub-part 183 Sub-part 141
No.
Male/female Female Female Female Female
Connector
C-VC2 Y NS S NS Y NS
name
Manufacturer's
– 7223-6715-80 1300-7327 7223-6717
part No.
Komatsu part
22J-06-25150 Sub-part 120 Sub-part 121 Sub-part 125
No.
Male/female Female Female Female Female
Connector
S RS S DL Y 090 S DL
name
Manufacturer's
6185-0865 6195-0051 7283-8220 6195-0009
part No.
Komatsu part
Sub-part 109 Sub-part 112 Sub-part 145 Sub-part 54
No.
Male/female Female Female Female Female
Connector
Y mini ISO Y SSD SWP Y RV
name
Manufacturer's
7223-6055-30 7283-8730-30 7123-7414-40 7122-6535-80
part No.
Komatsu part
Sub-part 152 Sub-part 174 Sub-part 155 Sub-part 50
No.
Male/female Female Female Female Male
Connector
Y RH S TS
name
Manufacturer's
7283-8856 6189-0443
part No.
Komatsu part
Sub-part 85 Sub-part 127
No.
Male/female Female Female
Connector
S ISO micro relay box
name
Manufacturer's
–
part No.
Komatsu part
421-06-36130
No.
Male/female Female
Connector
Y Fuse box T S/B box
name
Manufacturer's
7154-5334 3536-0000
part No.
Komatsu part
Sub-part 138 421-06-22880
No.
Male/female
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
No. of pins
Part No. Part name ID marking
T-adapter kit
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
No. of pins
Part No. Part name ID marking
T-adapter kit
Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
No. of pins
Part No. Part name ID marking
Probable Open circuit in wiring har- a Be ready with starting switch in the OFF position, then perform
causes and ness troubleshooting without turning starting switch to the ON position.
2
criteria (wire breakage or defective Wiring harness between C03 (female) (10)
contact of connector) Resistance Max. 1z
and R17 (female) (30)
a Turn starting switch to OFF for preparation. Turn to ON and
Hot short circuit in wiring har- when 5 seconds pass, measure the voltage for troubleshooting.
3 ness (contact with 24 V cir-
cuit) Between ground and wiring harness from
Voltage Max. 1 V
C03 (10) to C03 (3)
4 Defective HST controller If causes 1 to 3 are not found, the HST controller may be defective.
Failure code [25/DK70KY] Brake pedal angle sensor: Hot short circuit
Action code Failure code
Brake pedal angle sensor: Hot short circuit
Lift truck 25 Failure
L03 (HST controller system)
KOMTRAX DK70KY
Detail of failure • The input voltage of brake pedal angle sensor exceeded 4.7 V.
• Gradually increases the sensitivity of brake pedal stroke and fix it to 25 % if the problem occurs
when the brake pedal stroke is below 25 %.
• Holds the sensitivity of stroke if the problem occurs when the brake pedal stroke is above 25 %.
Action of
• Turns on the abnormality warning lamp.
controller
• Sounds the warning buzzer (intermittently).
• After the failure has recovered, the lift truck returns to normal only when you turn the starting switch
to the OFF position.
Problem on lift • The lift truck can travel at low speed only.
truck • The HST brake does not work when the brake pedal stroke is small.
Related • Method of reproducing failure code: Turn the starting switch to the ON position and depress the
information brake pedal.
Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve:
Hot short circuit
Action code Failure code
HST pump forward travel EPC solenoid valve: Hot short circuit
Lift truck 32 Failure
L04 (HST controller system)
KOMTRAX DXATKY
• Abnormal voltage was detected when there was no output to HST pump forward travel EPC sole-
Detail of failure
noid valve circuit.
• Stops the output to HST pump forward travel EPC solenoid valve.
• Outputs to the pump EPC ground cutout relay, and stops the current flow through pump EPC sole-
noid valve circuit.
Action of
• Turns on the abnormality warning lamp.
controller
• Sounds the warning buzzer (continuously).
• After the failure has recovered, the lift truck returns to normal only when you turn the starting switch
to the OFF position.
Problem on lift
• Lift truck cannot travel.
truck
Related
• Method of reproducing failure code: Turn the starting switch to the ON position.
information
Failure code [34/DXAVKA] HST motor EPC solenoid valve: Open circuit
Action code Failure code
HST motor EPC solenoid valve: Open circuit
Lift truck 34 Failure
L03 (HST controller system)
KOMTRAX DXAVKA
Detail of failure • No current flowed through HST motor EPC solenoid valve circuit during output.
• Stops the output to HST motor EPC solenoid valve.
• Turns on the abnormality warning lamp.
Action of
controller • Sounds the warning buzzer (intermittently).
• After the failure has recovered, the lift truck returns to normal only when you turn the starting switch
to the OFF position.
Problem on lift • If this problem occurs during traveling, the lift truck is decelerated.
truck • The lift truck can travel at low speed only.
Related
• Method of reproducing failure code: Travel the lift truck at approx. 5 km/h or above.
information
Failure code [34/DXAVKB] HST motor EPC solenoid valve: Ground fault
Action code Failure code
HST motor EPC solenoid valve: Ground fault
Lift truck 34 Failure
L03 (HST controller system)
KOMTRAX DXAVKB
Detail of failure • Abnormal current flowed through HST motor EPC solenoid valve circuit during output.
• Stops the output to HST motor EPC solenoid valve.
• Turns on the abnormality warning lamp.
Action of
controller • Sounds the warning buzzer (intermittently).
• After the failure has recovered, the lift truck returns to normal only when you turn the starting switch
to the OFF position.
Problem on lift • If this problem occurs during traveling, the lift truck is decelerated.
truck • The lift truck can travel at low speed only.
Related
• Method of reproducing failure code: Travel the lift truck at approx. 5 km/h or above.
information
Failure code [38/DW9MKY] Lift lock solenoid valve: Hot short circuit
Action code Failure code
Work equipment lock solenoid valve: Hot short circuit
Lift truck 37 Failure
L03 (HST controller system)
KOMTRAX DW9NKY
• Abnormal voltage was detected in the work equipment lock solenoid valve circuit although no output
Detail of failure
was supplied.
• Turns on the abnormality warning lamp.
Action of • Sounds the warning buzzer (intermittently).
controller • After the failure has recovered, the lift truck returns to normal only when you turn the starting switch
to the OFF position.
Problem on lift • The forklift moves down (and the forklift can move down only) with the lowering operation even if the
truck operator leaves (or the work equipment is interlocked).
Related • Method of reproducing failure code: Turn the starting switch to the ON position and leave the opera-
information tor's seat.
1. LED
• Automatic preheating operating temperature and preheating time setting are as follows.
Related
information
E-3 Parking brake reminder alarm does not sound or does not stop
sounding
Detail of failure (1) When operator leaves seat without applying parking brake, alarm buzzer does not sound.
• If any failure code is displayed, perform troubleshooting for it first.
• In normal condition, parking brake reminder alarm sounds under the following conditions.
Related a. When parking brake is released with starting switch in the OFF position
information b. When parking brake is released with starting switch in the ON position and engine stopping
c. When parking brake is released with operator not seated (for 3 seconds) while engine is run-
ning
Detail of failure (2) While parking brake is applied, alarm buzzer does not stop sounding.
• If any failure code is displayed, perform troubleshooting for it first.
• Check following before troubleshooting.
Related a. Check that the buzzer sound is not an alarm for braking charge pressure (increase braking
information charge pressure by starting engine).
b. Check that the sound is not backup buzzer sound (place "directional lever in N (neutral) posi-
tion).
E-5 Headlamp, clearance lamp, tail lamp and license plate lamp do not
light up or go off
Detail of failure (1) Head lamps do not light up or go off.
Related
• Before troubleshooting, check head lamps for burned-out bulb.
information
Detail of failure (2) Clearance lamps or tail lamps do not light up or go off.
Related
• Before troubleshooting, check clearance lamps or tail lamps for burned-out bulb.
information
E-9 Backup buzzer does not sound or does not stop sounding
Detail of failure • Backup buzzer does not sound or does not stop sounding
Related
• If any failure code is displayed, perform troubleshooting for it first.
information
E-13 All of indicator and warning lamps of instrument panel do not light
up when starting switch is turned to the ON position.
(1) When starting switch is turned to the ON position, all of indicator and warning lamps of instrument
Detail of failure
panel do not light up.
• When engine does not start up, perform troubleshooting of E-1 "Engine does not start" first.
• If any failure code is displayed, perform troubleshooting for it first.
• Check following before troubleshooting.
a. Directional lever is in N (neutral) position.
(When it is not in N (neutral) position, neutral indicator lamp does not light up when starting
switch is turned to the ON position.)
b. Parking brake lever is in Lock position.
(If parking brake lever is not in Lock position, all lamps do not light up when starting switch is
turned to the ON position.)
• Layout of indicator and warning lamps on instrument panel is shown in figure below.
Related
information
(2) When starting switch is turned to the ON position, abnormality warning lamp of instrument panel
Detail of failure
does not light up.
Related
• Abnormality warning lamp lights up by controls of engine controller and HST controller.
information
(3) When starting switch is turned to the ON position, engine abnormality warning lamp of instrument
Detail of failure
panel does not light up.
Related
• Engine abnormality warning lamp lights up by control of engine controller.
information
(4) When starting switch is turned to the ON position, loading interlock warning lamp of instrument
Detail of failure
panel does not light up.
Related
• Loading interlock warning lamp lights up by control of HST controller.
information
(5) When starting switch is turned to the ON position, charge warning lamp of instrument panel does
Detail of failure
not light up.
Related
• Charge warning lamp lights up by control of HST controller.
information
(6) When starting switch is turned to the ON position, engine oil pressure warning lamp of instrument
Detail of failure
panel does not light up.
Related
• Engine oil pressure warning lamp lights up by control of HST controller.
information
(7) When starting switch is turned to the ON position, travel interlock warning lamp (also working as
Detail of failure
neutral indicator lamp) of instrument panel does not light up.
Related
information
(2) When starting switch is turned to the ON position, parking brake reminder warning lamp of pilot
Detail of failure
box does not light up.
Related
• Parking brake reminder warning lamp lights up by control of HST controller.
information
(3) When starting switch is turned to the ON position, HST oil temperature warning lamp of pilot box
Detail of failure
does not light up.
Related
• HST oil temperature warning lamp lights up by control of HST controller.
information
(4) When starting switch is turned to the ON position, HST oil filter clogging warning lamp of pilot box
Detail of failure
does not light up.
Related
• HST oil filter clogging warning lamp lights up by control of HST controller.
information
(5) When starting switch is turned to the ON position, parking brake indicator lamp of pilot box does
Detail of failure
not light up.
Related
• Parking brake indicator lamp lights up by control of HST controller.
information
(6) When starting switch is turned to the ON position, travel speed restriction indicator lamp of pilot
Detail of failure
box does not light up.
Related
• Travel speed restriction indicator lamp lights up by control of HST controller.
information
(7) When starting switch is turned to the ON position, sedimenter (water separator) warning lamp of
Detail of failure
pilot box does not light up.
Related
• Sedimenter warning lamp lights up by control of HST controller.
information
Detail of failure • When starting switch is turned to the ON position, the preheater lamp does not light up.
• If all of indicator and warning lamps of instrument panel do not light up when starting switch is ON,
Related
perform troubleshooting of E-13 "(1) When starting switch is turned to the ON position, all of indica-
information
tor and warning lamps of instrument panel do not light up" first.
E-20 HST oil filter clogging warning lamp lights up while engine is
running
Detail of failure • HST oil filter clogging warning lamp lights up while engine is running.
Related • When HST oil filter clogging is detected with HST oil temperature of 30°C or above, HST oil filter
information clogging warning lamp lights up.
E-21 Engine oil pressure warning lamp lights up while engine is running
Detail of failure • Engine oil pressure warning lamp lights up while engine is running.
• When engine oil pressure reduction is detected while engine is running,
(1) Engine oil pressure warning lamp lights up.
(2) Engine abnormality warning lamp lights up.
(3) Abnormality warning lamp lights up.
Related
(4) Alarm buzzer sounds intermittently.
information
(5) Engine speed is limited to medium speed.
(6) Engine output torque is limited.
• Engine oil pressure switch signal is sent from engine controller to HST controller, and HST control-
ler controls warning lamp and alarm buzzer based on received signal.
Detail of failure (2) Impossible to select HST controller adjustment mode or speed limit setting mode.
• For operation of HST controller adjustment mode and travel speed restriction setting mode, see
Related
Testing and adjusting, "Display, setting, and check methods in HST controller".
information
• If any failure code is displayed, perform troubleshooting for it first.
Detail of failure (3) Impossible to select engine stop time auto-change mode
• For operation of engine stop time auto-change mode, see Testing and adjusting, "Display, setting,
Related
and check methods in HST controller".
information
• If any failure code is displayed, perform troubleshooting for it first.
Display
3. Operate the lift truck and perform troubleshoot- 6. Repeat the operation in Step 3., 4., 5. until the
ing for the items not checked in Step 1., and if cause is narrowed down to 1 item (1 common
any problem occurs, put a check in the corre- item).
sponding line. (In troubleshooting item 5 in the a If cause items are 2 or more, continue until
figure below, the problem was re-produced.) number of items becomes minimum.
a The system diagram illustrates the simplified entire hydraulic circuit diagram as reference material for
troubleshooting of the hydraulic and mechanical systems.
Q
Q
Q
Q
Foreign matter caught in orbit-roll
Orbit roll
Q
Q
Damaged orbit-roll oil seal
Q
Q
Q
Q
Q
Defective tire angle sensor
Q
Q
Q
Q
Q
Q
Q
Q
Defective steering wheel or steering shaft operation
Q
Q
Defective brake charge valve operation
Q
Q
Q
Defective brake valve
Q
Q
Defective slack adjuster
Q
Defective brake piston seal in axle
Q
Malfunction of brake piston in axle
Q
Q
Defective brake portion in axle
Q
Q
Brake disc trouble in axle
Q
disc in axle
Q
Air in brake circuit
Q
Q
Defective parking brake actuating mechanism
Q
Q
Worn or problematic parking brake lining
Q
Q
Defective parking brake linkage
Defective pump
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Troubleshooting code
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-38
H-37
H-36
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
Troubleshooting for hydraulic and mechanical system (H-mode)
Table of failure modes and causes
40-267
Troubleshooting for hydraulic and mechanical system (H-mode)
Table of failure modes and causes
ing angle
Failure mode
Lift truck does not travel.
Slow travel speed
Insufficient towing force
Engine stops during traveling, or engine speed drops excessively.
HST (hydraulic) oil temperature is too high. Q Q
Impossible steering Q
Response is low during turning. Q
Steering operation is heavy. Q
Unstable during turning
When steering wheel is released, it does not return to neutral or it
rotates by itself.
Steering wheel is turned in reverse or it kicks (while work equip-
Q
ment is operated).
Large shock is made when steering wheel is returned. Q
EPACS does not work.
Steering wheel vibrates.
Steering system makes abnormal sound.
Oil leaks from steering circuit.
Service brake does not work or its performance is low.
Service brake is not released or it drags.
Parking brake does not work or its performance is low.
Parking brake is not released or it drags.
Unusual noise around work equipment or steering pump Q
Engine speed drops excessively or stops during work equipment
operation or steering.
Fine control or response of work equipment is low.
Work equipment cannot be locked (and the equipment operates
Q Q
when operator leaves).
Control valve lever does not move smoothly and it is heavy.
Lift cylinder and fork are not raised. Q Q Q Q Q
Q
Q
Q
Q
Q
Q
Defective LS shuttle valve
Q
Clogged LS circuit orifice
Q
Q
Q
Steering circuit orifice clogging
Q
Q
Defective clearance between valve body and spool
Q
Insufficient roundness of valve body and spool
Q
Foreign matter caught in valve spool
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Damaged lift cylinder piston seal
Q
Deformed lift cylinder
Q
Q
Q
Q
Damaged tilt cylinder piston seal
Q
Deformed tilt cylinder
Q
Defective adjustment of clearance between roller and rail
Q
Defective roller shim adjustment
Q
Q
Q
Improper hydraulic oil
Troubleshooting code
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-38
H-37
H-36
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
Troubleshooting for hydraulic and mechanical system (H-mode)
Table of failure modes and causes
40-269
Troubleshooting for hydraulic and mechanical system (H-mode)
H-1 Lift truck cannot travel
Defective motor
Defective PTO
Action to take E
E E E E E E E E E
No. X
Diagnosis X X X X X X X X X
A
1 Lift truck can travel neither forward nor backward. Q Q Q Q Q Q Q Q Q Q
Defective motor
Action to take E
E E E E E
No. X
X X X X X
Diagnosis A
1 Lift truck travels slow both forward and backward. Q Q Q Q Q Q
HST HST
Appendix
pump motor
a b c d
Defective motor
Action to take E
E E E
No. X
Diagnosis X X X
A
1 Insufficient towing force of both forward and backward travel Q Q Q Q
2 Insufficient towing force of both forward and backward travel, but maximum speed available. Q Q
Defective motor
Action to take E E
No.
Diagnosis X X
2 Main body moves with forward or backward lever placed at F or R position or engine in Lo mode. Q
Defective pump
Action to take E E
E E E E E E E
No. C X A
Diagnosis X X X X X X X X
C
Travel speed, towing force, and gradability are
1 Q Q Q Q Q
low.
Work equipment travel speed and work equipment
2 Q Q Q Q Q Q
capacity are low.
Engine low idle and high idle speeds are abnor-
3 Q Q Q Q Q Q Q Q Q Q
mal.
4 HST stall speed is abnormal. Q Q Q Q
Relief valve
Action to take E E
No. X X X
Diagnosis X X
1 Impossible steering neither right nor left Q Q Q Q Q
a Since the steering circuit and work equipment circuit are related closely with each other, check the oper-
ating condition of the work equipment, too, if abnormality is felt in the steering.
Steering System)
Defective pump
E Defective valve E E
Action to take
No. E E E
Diagnosis X X X
1 Response is low in both right and left steering directions Q Q Q Q Q Q
a Since the steering circuit and work equipment circuit are related closely with each other, check the oper-
ating condition of the work equipment, too, if abnormality is felt in the steering.
Relief valve
Action to take E E E
No. E E E
Diagnosis X X X
1 Steering wheel is heavy in both right and left directions Q Q Q Q Q Q
a Since the steering circuit and work equipment circuit are related closely with each other, check the oper-
ating condition of the work equipment, too, if abnormality is felt in the steering.
Cause
• Misalignment between orbit-roll and column
o Check installation state and correct misalignment.
• Foreign matter caught in orbit-roll hydraulic circuit
o Clean or replace.
• Damaged of orbit-roll oil seal
o Replace
Cause
• Foreign matter caught in check valve in orbit-roll
o Clean or replace.
• Malfunction of priority valve in control valve
o Clean or replace.
Action to take E E C
No. X
Diagnosis X X E
1 Large shocks are made when steering wheel is returned while operator is leaving seat. Q Q Q
Large shocks are made when steering wheel is returned while lift is being raised with no
2 Q Q Q
load.
3 Response of working equipment is low. Q
Cause
• Air in hydraulic circuit
o Bleed air
• Internal defect of orbit roll (wear etc.)
o Replace, clean or adjust
• Defect in following parts of EPACS valve
a. Defective solenoid
o Replace
b. Disconnection in electrical system
o Repair or replace
c. Improper voltage
o Check power supply and replace if necessary
o Repair power supply circuit
d. Foreign matter between housing spools
o Clean or replace
e. Clogged orifice
o Clean or replace
• Defective EPACS controller
o Since LED goes off or flashes, see "Troubleshooting by failure code (EPACS controller sys-
tem)".
• Defective installation of tire angle sensor
o Reinstall correctly and eliminate play
Cause
• Air in hydraulic circuit
o Bleed air
• Hydraulic pressure pulsation is large.
o Replace orbit roll and control valve.
• Defective installation of orbit roll
o Adjust
• Malfunction of steering linkage
o Grease
Cause
• Air in hydraulic circuit
o Bleed air
• Defective installation of orbit roll
o Adjust
• Malfunction of steering linkage
o Grease
Cause
• Contamination or improper viscosity of hydraulic oil
o Replace hydraulic oil and filter
• Too high back pressure
o Adjust back pressure
• Misalignment with orbit roll column
o Check installed condition and correct misalignment
• Wear, damage or defective installation of part
o Repair, replace or adjust
• Damaged O-ring seal
o Replace
Clogged orifice
Action to take E E E E E E E E E E E
No. E
Diagnosis X X X X X X X X X X X
1 When brake pedal is depressed, its response is low Q Q Q Q Q
2 Parking brake lever operating effort and stroke are normal, but brake performance is low. Q Q
2 When parking brake lever is pulled, parking brake does not work sufficiently. Q Q
a b c d
Check of abnormality
• Check that LS differential pressure is normal when work equip-
ment is operated.
a b c
H-25 Control valve lever does not move smoothly and it is heavy
a b c d
Action to take C E E E E E E E E E
No. X X
Diagnosis E X X X X X X X X X
Action to take C E E E E E E E
No. X X A A
Diagnosis E X X X X X X X
2 Tilting force and speed are abnormal and forklift speed is low Q Q Q Q Q Q
3 Tilting force and speed are normal and forklift speed is low Q Q Q Q Q Q Q
Cause
• Inflation or internal damage of lift cylinder tube
a For other troubles during lifting operation, see "H-27 Lifting speed or power of lift cylinder and fork is
insufficient".
Check of abnormality
• Check the lift cylinder natural drift with the criterion to see if it is actually
large.
2 Lowering speed remains large when key is set to ON and operator is seated or not seated. Q Q
a b c
a b c d
3 Though power is applied to lift lock solenoid during lowering operation, it lowers or stops lowering. Q Q
Action to take C E E E E E E E E E
No. X X
E X X X X X X X X X
Diagnosis
1 Work equipment or steering pump makes abnormal sound. Q Q
Mast can be tilted when not loaded but cannot be tilted when
2 Q Q Q
loaded
3 Mast cannot be tilted and fork cannot be lifted Q Q Q Q Q Q Q Q
Action to take C E E E E E E E
No. X X
E X X X X X X X
Diagnosis
1 Work equipment or steering pump makes abnormal sound. Q Q
2 Lifting force and speed are abnormal, and mast tilting speed is low. Q Q Q Q Q Q
3 Lifting force and speed are normal and mast tilting speed is low. Q Q Q Q Q
Cause
• Inflation or internal damage of tilt cylinder tube
a For other troubles during tilting operation, see "H-33 Forward/backward tilting speed or force of mast is
insufficient".
Check of abnormality
• Check the tilt cylinder natural drift with the criterion to see if it is actually
large.
Cause
Tilt cylinder natural drift may cause tilt cylinder bottom pressure to be negative pressure.
o See "H-35 Tilt cylinder natural forward drift is large"
H-37 Work equipment is heavy when work equipment and steering are
operated simultaneously
a b
H-38 Steering is heavy when work equipment and steering are operated
simultaneously
a b c
Action to take E E C
Diagnosis X X E
When work equipment and steering are operated simultaneously, LS differential pressure is
1 Q
abnormal.
2 Steering is heavy when steering is operated singly. Q Q Q
Table of Contents
50 Disassembly and assembly
Related information on disassembly and assembly ............................................................................... 50-3
How to read this manual .................................................................................................................... 50-3
Coating materials list.......................................................................................................................... 50-4
Special tools list ................................................................................................................................. 50-7
How to use Loctite ............................................................................................................................. 50-9
Engine and cooling system .................................................................................................................. 50-10
Removal and installation of fuel supply pump assembly ................................................................. 50-10
Removal and installation of fuel injector assembly .......................................................................... 50-14
Removal and installation of cylinder head assembly ....................................................................... 50-18
Removal and installation of of radiator assembly ............................................................................ 50-29
Removal and installation of aftercooler assembly............................................................................ 50-31
Removal and installation of oil cooler assembly .............................................................................. 50-34
Removal and installation of engine and pump assembly ................................................................. 50-35
Removal and installation of starting motor assembly....................................................................... 50-43
Power train ........................................................................................................................................... 50-46
Removal and installation of front axle and HST motor assembly .................................................... 50-46
Disassembly and assembly of front axle assembly ......................................................................... 50-49
Removal and installation of PTO assembly ..................................................................................... 50-50
Disassembly and assembly of PTO assembly ................................................................................. 50-51
Disassembly and assembly of differential assembly........................................................................ 50-54
Disassembly and assembly of axle housing assembly .................................................................... 50-67
Disassembly and assembly of parking brake assembly .................................................................. 50-74
Disassembly and assembly of rear axle assembly .......................................................................... 50-75
Disassembly and assembly of power steering cylinder assembly ................................................... 50-78
Disassembly and assembly of brake pedal assembly ..................................................................... 50-80
Undercarriage and frame ..................................................................................................................... 50-81
Removal and installation of counterweight assembly ...................................................................... 50-81
Removal and installation of head guard assembly .......................................................................... 50-83
Removal and installation of hood assembly..................................................................................... 50-87
Hydraulic system.................................................................................................................................. 50-89
Removal and installation of HST pump assembly ........................................................................... 50-89
Removal and installation of HST motor assembly ........................................................................... 50-93
Removal and installation of work equipment and steering pump assembly .................................... 50-94
Removal and installation of control valve assembly ........................................................................ 50-96
Disassembly and assembly of control valve assembly .................................................................... 50-98
Disassembly and assembly of orbitrol valve assembly .................................................................. 50-104
Removal and installation of lift cylinder assembly...........................................................................50-111
Disasse mbly and assembly of lift cylinder assembly .................................................................... 50-114
Disassembly and assembly of tilt cylinder assembly ..................................................................... 50-115
Work equipment ................................................................................................................................. 50-120
Removal and installation of mast assembly ................................................................................... 50-120
Disassembly and assembly of mast assembly .............................................................................. 50-122
Electrical system ................................................................................................................................ 50-126
Removal and installation of engine controller assembly ................................................................ 50-126
Removal and installation of HST controller assembly.................................................................... 50-128
Removal and installation of KOMTRAX terminal assembly ........................................................... 50-129
Disassembly and assembly of combination switch assembly ........................................................ 50-130
5
shown with the mark [*1] which correspondsto : Amount of oil or coolant to be refilled
the mark in “Removal” section.
• Common tools that are necessary for installa-
tionare described as [1], [2]••• etc. and their
partnumbers, part names and quantities are not
described.
• Marks shown in the "Installation" section stand-
for the following.
k : Precautions related to work safety
a: Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
MH 705
• Instantaneous adhesive
ThreeBond Polyethylene • Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Use mainly to bond metals, rubbers, plastics,
and woods.
• Instantaneous adhesive
• Quick-curing type (max. strength is obtained
Aron-alpha Polyethylene
790-129-9130 2g after 30 minutes)
201 container
• Use mainly to bond rubbers, plastics, and met-
als.
• General-purpose instantaneous adhesive with
excellent resistance to heat and impact
Loctite 499 428-99-80070 20 g Tube
• Use on the bushing mounting faces of axle
supports.
• Features: Resistance to heat and chemicals
Polyethylene
Loctite 648-50 79A-129-9110 50 cc
container • Use for fitting portions used at high tempera-
tures.
• Use to seal various thread portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container • Use to seal taper plugs, elbows, and nipples
for hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Liquid gasket
tant sealant.
LG-6 790-129-9160 200 g Tube
• Use to seal thread portions and flange surface.
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake manifold,
old, oil pan, thermostat housing, etc.
LG-8 • Features: Silicon-based, heat-resistant, vibra-
ThreeBond 419-15-18131 100 g Tube tion-resistant, impact-resistant sealant
1207B • Use to seal transfer case, etc.
Classifi-
Komatsu code Part No. Quantity Container Main features and applications
cation
• Use for rough surfaces such as the circle gear
LG-9
upper face seal which is not clamped by bolts,
ThreeBond 790-129-9310 200 g Tube
gaps in the weld , etc.
1206D
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the radiator
Liquid gasket
• Spray type
• Thin molybdenum disulfide films are made on
metal surfaces to prevent the metals from gall-
LM-S 09995-00250 190 g Can
ing.
• Use for the drive shaft splines, needle bear-
ings, pins and bolts of various links, etc.
prevention compound
LC-G
― ― Can • Use for the mounting bolts in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the tur-
bocharger, etc.
SYG2-400LI-A
G2-LI
SYG2-16LI
G0-LI (*) • Lithium grease with extreme pressure lubrica-
SYGA-16CNLI Various Various
*: For cold dis- tion performance, general purpose type
SYG0-400LI-A (*)
trict
SYG0-16CNLI (*)
• Use for parts under heavy load.
Caution:
Molybdenum
SYG2-400M 400 g x 10 Bellows-type • Do not use this grease for rolling bearings
disulfide
SYG2-400M-A 400 g x 20 container like swing circle bearings, etc. and splines.
grease
SYGA-16CNM 16 kg • Use this grease for work equipment pins
LM-G (G2-M) Can
only when installing them, but do not use it
afterward.
Grease
Hyper White
• This grease has higher seizure resistance,
Grease SYG2-400T
heat resistance and water resistance than
G2-T SYG2-16CNT 400 g Bellows-type
molybdenum disulfide grease.
G0-T (*) SYG0-400T (*) 16 kg Can
*: For cold dis- SYG0-16CNT (*) • Not conspicuous on machine since color is
trict white.
Bio grease
G2-B
SYG2-400B
G2-BT (*) • Since this grease is biodegradable in short
SYGA-16CNB 400 g Bellows-type
*: For use at period, it has less impact on microorganisms,
SYG2-400BT (*) 16 kg Can
high tempera- animals, and plants.
SYGA-16CNBT (*)
ture and under
high load
Classifi-
Komatsu code Part No. Quantity Container Main features and applications
cation
• Feature: Silicone grease with wide usable tem-
G2-S perature range, with better stability to thermal-
ThreeBond ― 200 g Tube oxidation and performance to prevent deterio-
1855 ration of rubber and plastic parts
Grease
22M-54-27230 20 ml
Primer 435-95 container (Effective period: 4 months after the pro-
duction)
• Use as primer for black ceramic-coated
glass surface and for hard polycarbonate-
Sunstar Glass
22M-54-27240 150 ml Steel can coated surface.
Primer 435-41
(Effective period: 4 months after the pro-
duction)
• Use as primer for sash (with aluminum sur-
Sunstar Sash
Glass face treatment)
Primer GP- 22M-54-27250 20 ml
container (Effective period: 4 months after the pro-
For adhering cab glass
402
duction)
• Use "S" in high temperature season (from
April to October on the Northern Hemi-
Sunstar Pen-
sphere) and "W" in low temperature sea-
guin Seal 580 Polyethylene
417-926-3910 320 ml son (from October to April on the Northern
Super "S" or container
Hemisphere) as adhesive for glass.
"W"
(Effective period: 4 months after the pro-
Adhesive
duction)
Sika Japan, • Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: 6 months after the pro-
container
256HV duction)
Sunstar Pen- Ecocart • Use as adhesive for glass.
guin Super 22M-54-27210 320 ml (special (Effective period: 6 months after the pro-
560 container) duction)
Sunstar Pen- • Use to seal joints of glass parts.
Polyethylene
guin Seal 417-926-3920 320 ml (Effective period: 4 months after the pro-
container
No.2505 duction)
Caulking material
Leaving Assembly
Applying Reassembling
LOCTITE 1) If Loctite is broken once around the thread por-
tions, it is changed to white powder and depos-
ited there. However, you can apply Loctite
1. Degrease and cleaning directly on those portions.
1) Use highly-volatile solvent for cleaning such 2) If Loctite is used at axle mating portions or
as trichloroethylene (trichlene), acetone, flange faces, the deposited materials must be
ether, or alkali solution. removed depending on the surface dimensions.
2) It is important to degrease as completely as In this case, you can remove them easily by
possible. using an iron brush.
3) Using gasoline, diesel fuel, kerosine, etc. is 3) If reassembling is required for the plane sur-
not recommendable due to lack of volatility. faces, be sure to remove Loctite completely
Sufficiently dry parts in case of using. and use sandpaper to scratch the surface.
4) When the mating surface is made of heat-
hardening plastic, use Locquic primer for
process after degreasing.
2. Natural drying
1) Wait until detergent liquid is dried.
2) When Locquic primer is used for the pro-
cess, do not wipe it off. Leave it for 5 to 10
minutes for natural drying. (If LOCTITE is
used before completely drying, its effect is
reduced.)
3. Applying Loctite
Apply Loctite sufficient to fill the clearance
between the screw or fit and the mating face to
one face or the both faces as follows.
• Apply directly from container nozzle.
• Dipping (Use container in case of the
screws.)
• Tumbling
• Brushing (Use container in case of the fits.)
• Sponge
• Automatic application machine
Do not allow metallic foreign materials to enter
or return the liquid received to the container.
4. Assembly
After applying Loctite, tighten and fit the parts
as usual.
[When using adhesive for assembling structure
or instantaneous adhesive, apply a pressure to
the mating surface lightly (approximately 49
kPa {0.5 kgf/cm2}).]
Removal
1. Remove right side cover (1) (3 bolts). [*1]
7. Remove joint bolts (10) and (11), and remove 9. Disconnect wiring harness clamp (15) and con-
fuel tube (12). [*4] nector (16).
a Joint bolt (11) fixes fuel tube (12) at the bot-
tom of supply pump (13).
a The following figure shows the positions a The following figure shows the position
of supply pump mounting bolts (17a) of mounting nut (24a) of supply pump
and pump holder mounting bolt (19a). (13).
Installation
Perform installation in the reverse order to removal.
[*1]
To install the right side cover, securely insert inlet
pipe (a) of the air cleaner into sponge (b).
[*4]
[*2] 3 Joint bolt (10):
k Face slits of fuel spray prevention caps 24.5 to 34.3 Nm {2.5 to 3.51 kgm}
outward and downward. 3 Joint bolt (11):
k The fuel spray prevention caps are installed 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
for fire prevention and expected to prevent
fuel from flying directly to highly heated [*5]
portions of the engine if fuel leaks. a To install mounting bolt (19), use M6 bolt with
LT-2A.
[*3] a When reusing bolt (19), apply the adhesive to
k Do not bend high-pressure pipe when the threaded portion.
using it. 2 Supply pump mounting bolt:
Removal
1. Remove right side cover (1) (3 bolts). [*1]
8. Remove the high-pressure piping according to 9. Remove the injector assembly according to the
the following procedure. following procedure.
a Following removal procedure is that for 1) Remove bolt (17), and remove holder (18).
removal of the injector assembly of No. 1 [*6]
cylinder as an example. 2) Pull out and remove injector assembly (19).
1) Remove high-pressure pipie clamp [*7]
(10).
2) Remove fuel spray prevention caps (11)
from the injector side and common rail
side. [*3]
Installation [*5]
Perform installation in the reverse order to removal. k Do not bend high-pressure pipe when
using it.
[*1] k Be sure to use the Komatsu genuine high-
To install the right side cover, securely insert inlet pressure pipe clamps and observe the
pipe (a) of the air cleaner into sponge (b). specified tightening torque.
k After installing the high-pressure pipe, be
sure to install the fuel spray prevention
caps to the sleeve nuts.
a Before installing the high-pressure pipe,
check it for the following. If the high-pres-
sure fuel pipe has any defect, replace it with
a new one since fuel may leak.
• The taper seal part of the connection
([a] part: 2 mm area from the tip) is free
from longitudinal slits [b] or pits [c].
• The portion [d] (end of taper seal por-
tion: 2 mm area from the tip) is free
from level differences (fatigue) that can
catch your fingernail.
[*2]
a Insert the hose to the position marked before
disassembling.
3 Aftercooler pipe (5) mounting clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
• Install the hose and clamp in the following
dimensions.
(Unit: mm)
L1 L2
Connection of tube and
50 15
hose
[*3]
k Face slits of fuel spray prevention caps
outward and downward.
k The fuel spray prevention caps are installed
for fire prevention and expected to prevent
fuel from flying directly to highly heated
portions of the engine if fuel leaks.
[*4]
To install spill hose (14) to the injector, insert it until
it "clicks" and then install pin (13).
[*6] [*7]
Installation procedure of injector
a Even if reusing injector assembly (19), replace
dust seal (20), O-ring (21), and gasket (22) with
new ones.
a Do not install O-ring (21) to groove (a).
Removal
1. Remove hood (1).
• For details, see "Removal and installation of
hood assembly".
7. Remove fan (8) (4 bolts). 12. Disconnect intake air heater terminal (15) and
connector (16).
8. Remove alternator belt (9).
a Loosen bolt (10) and relieve the tension of 13. Remove clamps (17) (2 places).
alternator belt (9) and remove it. [*3]
18. Remove clamps (24) (4 places). 23. Remove battery bracket (29) (4 bolts).
19. Remove clamps (25) (2 places). 24. Remove clamps (30) (2 places).
20. Remove bracket (26) (3 bolts). 25. Remove engine controller (31) (4 bolts) and
keep it and wiring harness together away from
the engine.
26. Remove clamp (32). 29. Remove bolts (38) (2 pieces) and remove
bracket (37).
27. Remove bolts (33) (5 pieces) and remove a The mounting bolts of exhaust manifold
bracket (34). (35) cannot be removed. Therefore, remove
bracket (37) in advance.
40. Remove brackets (52) (2 bolts) and bracket 43. Loosen sleeve nuts (56) (8 places) and remove
(53). high-pressure pipes (4 pieces). [*7]
a High-pressure pipe clamps No.1 and 2 can-
not be removed. Therefore, remove bracket
(52) in advance.
45. Remove bolts (60) (8 pieces) and remove air 48. Remove the injector assembly according to the
intake manifold (61). [*8] following procedure.
1) Remove bolts (67) (4 pieces), and remove
holders (68) (4 pieces).
2) Pull out and remove injector assembly (69)
(4 pieces). [*10]
[*1]
a Install the hose until its end comes to the mark
put on before disassembling.
3 Aftercooler pipe (6) mounting clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
• Install the hose and clamp in the following
dimensions.
(Unit: mm)
L1 L2
Connectionof pipe and hose 50 15
[*2]
a Install radiator hose (7) onto the pipe until its
52. Sling and remove cylinder head assembly (77). end comes to the mark put on before disassem-
[*13] bling.
4 Cylinder head assembly (77): 30 kg • Install the hose and clamp in the following
dimensions.
(Unit: mm)
L1 L2
Connection of engine hose
50 10
(inlet side)
Connection of engine hose
45 10
(outlet side)
[*3] [*6]
• Alternator belt tension: 7 to 10 mm k Face slits of fuel spray prevention caps
outward and downward.
[*4] k The fuel spray prevention caps are installed
a Replace gasket between engine and exhaust for fire prevention and is expected to
manifold, and between exhaust manifold and prevent fuel from flying directly to highly
connector with new ones. heated portions of the engine if fuel leaks.
3 Mounting bolt (40) of exhaust manifold
(35): [*7]
34.3 to 53.9 Nm {3.5 to 5.5 kgm} k Do not bend high-pressure pipe when
3 Connector mounting nut (39): using it.
27 to 34 Nm {2.8 to 3.5 kgm} k Be sure to use the Komatsu genuine high-
pressure pipe clamps and observe the
[*5] specified tightening torque.
a Replace O-ring (78) and gasket (79) with new k After installing the high-pressure piping, be
ones. sure to install the fuel spray prevention
a Securely install O-ring (78) to the O-ring groove caps to the sleeve nuts.
of water pump (44). a Before installing the high-pressure pipe, check
a Securely install gasket (79) to the mating sur- it for the following. If the high-pressure fuel pipe
faces of cylinder head (77) and water pump has any defect, replace it with a new one since
(44). fuel may leak.
• The taper seal part ([a] : 2mm area from the tip)
of the contacting part is free from longitudinal
streaks [b] or pits [c].
• The portion [d] (end of taper seal portion: 2mm
area from the tip) is free from level differences
(fatigue) that can catch your fingernail.
[*8] [*10]
When installing the air intake manifold, apply liquid Installation procedure of injector
gasket to the mounting surface of the air intake a Even if reusing injector assembly (69), replace
manifold according to the following procedure. dust seal (80), O-ring (81), and gasket (82) with
a Before applying liquid gasket, clean the mount- new ones.
ing face of cylinder head side and intake mani- a Do not install O-ring (81) to groove (a).
fold side thoroughly
a Evenly apply liquid gasket to the portions (f)
around the air inlets with approximately 1 mm
width without break.
2 Air intake manifold mounting face:
Liquid gasket (LG-7)
[*13]
a Replace the cylinder head gasket with a new
one.
• Tightening procedure of cylinder head mount-
ing bolt
Apply molybdenum disulfide lubricant to the
threads of cylinder head mounting bolts and Refilling of coolant
tighten them according to the procedure shown After starting the engine and circulate the coolant,
in the figure. recheck the coolant level and add it if it is lowered.
5 Coolant
(For details, see "List of specified fuel and
lubricant".): Replenishment only
Removal
1. Remove aftercooler (1).
• For details, see "Removal and installation of
aftercooler assembly".
4. Disconnect hose (4).
[*1]
a Install radiator hose (3) onto the pipe until its
end comes to the mark put on before disas-
sembling.
• Install the hose and clamp in the following
dimensions.
(Unit: mm)
L1 L2
Connection of engine hose
54 6.5
(inlet side)
Connection of engine hose
55.5 10
(outlet side)
[*2]
Put together brackets (6) and guides (9) on both
sides of the radiator and then install the brackets.
Refilling of coolant
After starting the engine and circulate the coolant,
recheck the coolant level and add it if it is lowered.
5 Coolant
(For details, see "List of specified fuel and
lubricant".): Replenishment only
Removal
1. Remove sub hood (1) (3 bolts).
Installation
Perform installation in the reverse order to removal.
[*1]
To install the right side cover, securely insert inlet
pipe (a) of the air cleaner into sponge (b).
[*2]
a Install aftercooler hose (10) onto the pipe until
its end comes to the mark put on before disas-
sembling.
3 Aftercooler pipe (10) mounting clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
• Install the hose and clamp in the following
dimensions.
(Unit: mm)
L1 L2
Connectionof after-
38 10
cooler hose (inlet side)
(Install the
Connection of after-
hose until it 10
cooler hose (outlet side)
strikes.)
[*3]
3 Bolt (11): 5 to 1 Nm {0.5 to 0.1 kgm}
Removal and installation of oil 4. Remove bolt (5) (4 pieces) and pull out oil
cooler assembly (6) upward and remove it.
cooler assembly
k Lower the forks to the ground, stop the
engine, apply the parking brake, and chock
the wheels.
k Loosen the cap of the hydraulic tank and
release the pressure in the hydraulic tank.
Removal
1. Remove sub hood (1) (3 bolts).
Installation
Perform installation in the reverse order to removal.
6. Remove plate (5) (4 bolts). 9. Disconnect radiator hoses (11) (2 pieces). [*2]
a Disconnect connectors (6) (2 places) of a Put a mark at the hoose tip portion on the
accelerator pedal sensor behind plate (5), pipe before disassembling to easily find the
and remove clamps (7) (2 pieces). hose installation position (length of inser-
tion).
14. Remove clamps (18) (4 places). 19. Remove bracket (23) (4 bolts).
15. Remove clamps (19) (2 places). 20. Remove exhaust pipe (24) (2 bolts and 1
clamp).
16. Remove bracket (20) (3 bolts). a If exhaust pipe (24) cannot be removed
even by removing the bolts, loosen the
mounting bolts of the muffler to secure the
room for pulling out.
21. Remove clamp (25) and disconnect aftercooler 25. Disconnect coolant temperature sensor termi-
pipe (26). nal (31).
23. Remove clamp (29) and keep the wiring har- 28. Disconnect intake air heater terminal (34) and
ness away from the engine. connector (35).
30. Disconnect B terminal (37) of the starting motor 33. Disconnect pressure sensor connectors (43) (2
and ground cable (38). places) and pump EPC connectors (44) (2
a Do not remove C terminal (39) due to diffi- places).
culty in disconnection. Disconnect it in the
connector portion as described later. 34. Remove clamp (45).
38. Disconnect HST pump return hose (51) on the 44. Disconnect HST high-pressure pipes (60) (2
hydraulic tank side. places).
39. Remove HST pump suction hose (52) on the 45. Disconnect HST charge pipes (61) (2 places).
hydraulic tank side.
46. Disconnect HST motor drain pipe (62).
40. Disconnect hose (53) on charge valve (54)
side.
41. Disconnect tilt cylinder pipes (55) (2 pieces) on 48. Remove bolts (64) (2 pieces), right and left
the control valve side. resin rivets (65) (4 pieces), and shroud (66).
[*3]
42. Remove clamp (56).
49. Remove fan (67) (4 bolts). 51. Sling the engine and pump assembly.
Installation [*3]
Perform installation in the reverse order to removal. 3 Bolt (64): 5 ± 1 Nm {0.5 ± 0.1 kgm}
[*1] [*4]
a Install the hose onto the pipe until its end 3 Nuts (71) and (72):
comes to the marke put on before disassem- 98 to 123 Nm {10 to 12.5 kgm}
bling.
3 Aftercooler pipe (10) mounting clamp: Refilling of oil (hydraulic tank)
8.8 ± 0.5 Nm {90 ± 5 kgcm} Refill the hydraulic tank with oil to the specified
• Install the hose and clamp in the following level through the oil filler port. Run the engine to cir-
dimensions. culate the oil through the system. Then check the
(Unit: mm) oil level again.
L1 L2 5 Hydraulic oil:
Connection of tube and hose 50 10 (For details, see "List of specified fuel and
lubricant".): 110 l
Refilling of coolant
After starting the engine and circulate the coolant,
recheck the coolant level and add the coolant if it is
lowered.
5 Coolant:
(For details, see "List of specified fuel and
lubricant".): 9 l
[*2]
a Install radiator hose (11) onto the pipe until its
end comes to the mark before disassembling.
• Install the hose and clamp in the following
dimensions.
(Unit: mm)
L1 L2
Connection and engine hose
50 10
(inlet side)
Connecton and engine hose
45 10
(outlet side)
Removal and installation of start- 4. Disconnect connector (5) and remove wiring
harness (6) from the clamp.
ing motor assembly
k Lower the forks to the ground, stop the
engine, apply the parking brake, and chock
the wheels.
k Disconnect the cable from the negative(-)
terminal of the battery.
Removal
1. Remove right side cover (1) (3 bolts). [*1]
6. Remove bolts (8) (2 pieces) and remove start- 7. Remove the C terminal according to the follow-
ing motor assembly (9). ing procedure.
a Do not remove C terminal (10) because of 1) Open cap (11).
difficulty in disconnecting. Remove the
whole wiring harness together with starter
assembly (9).
Installation
Perform installation in the reverse order to removal.
[*1]
To install the right side cover, securely insert inlet
pipe (a) of the air cleaner into sponge (b).
[*2]
3 B terminal (7) mounting nut:
17.7 to 24.5 Nm {1.8 to 2.5 kgcm}
[*3]
3 C terminal mounting screw (12):
2.6 to 4.6 Nm {0.27 to 0.47 kgcm}
Power train
Removal and installation of front
axle and HST motor assembly
k Lower the forks to the ground, stop the
engine, apply the parking brake, and chock
the wheels.
k Before disconcerting the hydraulic piping,
release the pressure remaining inside the
c i r c u i t . F o r d e ta i l s o f r e l e a s i n g t h e
remaining pressure from the hydraulic
p i p i n g , s e e Te s t i n g a n d a d j u s t i n g ,
"Bleeding air".
k Disconnect the cable from the negative(-)
terminal of the battery. 5. Disconnect HST charge circuit hose (2).
k To lift the lift truck by using blocks, etc.
considering the work to be done from the
bottom of the frame, use the solid blocks
that can support the weight.
a After disconnecting the pipe, plug it immedi-
ately to prevent oil from spilling and dust from
entering.
a Never drain the coolant or oil to the ground.
Removal
1. Considering the work to be done from the bot-
tom of the frame, use block [1] to lift the fork lift
truck approximately 30 cm.
6. Disconnect HST motor drain hose (3) on the
HST pump side.
8. Disconnect brake hose (5). [*1] 10. Disconnect speed sensor connector (8).
15. Remove bolts (13) (4 pieces) and slowly lower 16. Pull out and remove front axle and HST motor
front axle and HST motor assembly. [*2] assembly (12).
a Do not remove support mounting bolt (14). a The block portion of HST motor drain tube
(4) is likely to be caught by peripheral pip-
ing, etc. Take extreme care when pulling it
out.
4 Front axle and HST motor assembly
(12): 450 kg
Installation
Perform installation in the reverse order to removal.
[*1]
3 Tightening torque for brake hose (5) :
32.4 ± 3 Nm {3.3 ± 0.3 kgm}
[*2]
3 Bolt (13):
1,520 to 1,910 Nm {155 to 195 kgm}
* Applying LT-2
Removal and installation of PTO 4. Remove bolts (6) (2 pieces) to remove work
equipment and steering pump (3).
assembly
a After disconnecting the pipe, plug it immedi-
ately to prevent oil from spilling and dust from
entering.
Removal
1. Remove the engine and pump assembly.
• For details, see "Removal and installation of
engine and pump assembly".
Installation
Perform installation in the reverse order to removal.
[*1]
3 Bolt (7): 59 to 74 Nm {6.0 to 7.5 kgm}
3. Remove flange (9). 11. Use the bearing puller, etc. to remove the bear-
ing assembled on the gear.
4. Remove cover (10) and strainer (11).
Assembly
Basically, perform assembling work in the reverse
order to disassembling work.
1. Replace the O-ring, seal washer, gasket, and
strainer with new ones and tighten the bolts to
the specified torques. Apply grease (G2-LI) to
the O-ring. Apply lubricant (LM-S) to the
splines.
3. Adjustment of shim
Right after the installation of gear (25) and
bearing (26) assembly, and shaft (24)and O-
ring (27) assembly to the case, use the feeler
gauge to measure the clearance between case
(28) and the shaft flange at 2 places in the diag-
onal ( dimension A) while holding down shaft
(24) and O-ring (27) assembly. Select the shim
so that the clearance is the measured dimen-
sion A - (0 to 0.05) mm and put the shim in the
clearance and install shaft (24) by using the
bolts.
*1: FH40-1
*2: FH45-1, FH50-1
5. Differential assembly
1) Remove differential assembly (28) from dif-
ferential housing (19).
6. Parking brake
1) Remove bolt (12), and remove parking
brake (13).
7. Pinion shaft
1) Remove spacer (40), shim (41), transfer
gear (42) and bearing (43) from pinion shaft
(39).
3) Dimensional difference c
Measure the dimension c. Display the
dimensional difference in the unit of 1/100
for the basic dimension 27.44 mm.
a Considering the accuracy of the dimen-
sion of the bearing, when calculating,
you can recognize that the dimensions 2. Friction gear
are constant values. In this case, use 1) Install washer (52), gear (53), springs (50),
the following values. Reassemble the (51) and spacer (48) to gear (54).
parts if the tooth contact cannot be 2) By using a press, hold down spacer (48) of
accepted. shaft end bearing (46) with a force of 1,000
c = 10 mm to 1,200 N {101.97 to 122.37 kg} and install
snap ring (49).
3) Install bearings (46) and (47).
4) Install the friction gear assembly to differen-
tial housing (27).
5. Parking brake
1) Install parking brake (16) and tighten bolt
(15).
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
2 Mounting bolt: Liquid adhesive LT-2
2) Install O-ring (11b) to brake drum (11).
3) Press-fit retainer (11a) straight until it hit the
shoulder surface of the brake drum by
using the press.
a You can also warm retainer (11a) to 70
to 100°C and install it by press-fitting. 4) After installing drum (11), install O-ring
Press-fitting jig: 972-EC-57-000 (11b) and holder (10a) and tighten bolt (10).
a Put in the sleeve until it hits.
a Clean the press-fitting portion but do
not use oil, etc.
a Keep the sleeve direction as shown in
the figure.
a Take care so that S surface is not dam-
aged.
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
2 Mounting bolt: Adhesive (LT-2)
6. Differential case assembly 4) Install case (29) and tighten bolt (30).
1) Install pinions (36) and spherical bushings a Set the hook of thrust washer (34) to
(38) to spider shaft (37). the groove of case (29).
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
2 Mounting bolt: Loctite #271
5) Install bevel gear (31) and tighten bolt (32).
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
2 Mounting bolt: Adhesive (LT-2)
7. Adjustment of differential and bearing 8) Adjust the tightening torque of screw (62)
1) Sling the differential case assembly and set so that the starting torque of the bevel pin-
it in differential housing (19). ion is larger than torque T measured in 5) in
2) Install O-ring (63) and seal (60) from the 4 by 0.49 to 1.86 Nm {0.05 to 0.19 kgm}.
both sides of differential housing (19) to a Bevel pinion starting torque =
carrier (26) and tighten bolt (65). T + 0.49 to 1.86 Nm {0.05 to 0.19 kgm}
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm} 8. Backlash adjustment of bevel gear
3) Install outer race (61) of the bearing and 1) Measure the bevel gear backlash after the
screw (62) temporarily. adjustment of the differential gear bearing.
4) Tighten screw (62) on the back surface side
Backlash between bevel
of the bevel gear lightly so that the backlash 0.15 to 0.23 mm
gear and pinion gear
is equal to 0.
5) Tighten screw (62) on the tooth surface side 2) When the backlash is out of the range,
of the bevel gear. readjust it.
6) Loosen screw (62) on the back surface side a When loosening the onescrew, tighten
of the bevel gear so that the backlash is the other by the same number of notch.
0.15 to 0.23.
*1: FH40-1
*2: FH45-1, FH50-1
3) Install shaft (3). 3) Install shrouds (69) and (69a) to front cover
(2) and tighten bolts (70).
3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
2 Mounting bolt: Loctite #572
8. Axle housing
Remove bearing outer races (12) and (13), and
remove oil seals (14) and (15) from axle hous-
ing (9).
2) Set up axle shaft (10) on block [6] and fix it 3) Measure dimension a of the planetary gear.
securely. Apply the bearing grease.
2 Bearing: Grease (G2-LI)
3) Sling axle housing (9) vertically and install it
to axle shaft (10) by using its own weight.
4) By using tool [5], press-fit bearing (22) with
a press.
a Rotate the housing so that the bearing
operates smoothly.
a Apply engine oil (EO10) to the bearing.
5) Perform the following calculation to obtain 6) Install shim (6) according to the following
dimension c and determine the shim thick- figure and tighten bolt (4).
ness. 3 Mounting bolt:
c=a-b 245 to 309 Nm {25 to 31.5 kgm}
2 Mounting bolt: Liquid adhesive LT-2
Bearing starting torque:
0.78 to 4.61 Nm {0.08 to 0.47 kgm}
a Sufficiently rotate the housing both
clockwise and counterclockwise to fit
the bearing.
3) After making sure that bearing operates 3) Install dowel pin (26) to differential housing
smoothly, check the starting torque of the (25).
bearing by using drilled hole H of axle hous- 4) Sling axle housing assembly (3) horizon-
ing (9). tally and align the gear with dowel pin (26)
• Starting torque: to install gently.
0.78 to 4.61 Nm {0.08 to 0.47 kgm} a When installing, be careful not to drop
a If the starting torque is out of the range plate (27) and spring (28) of the brake.
of the standard value, select the shim a Note that the right and left axle housing
again. assemblies (3) are different each other
and the assembly has vertical direction.
7. Axle housing assembly
1) Install plate (27) to the axle housing assem-
bly.
a Align the plate hole with pin (24) pro-
truding from the housing for installation.
8. Refilling of oil
Tighten the drain plug and refill it with oil to the
specified level through the oil filler port.
5 Axle oil: 11 l
Assembly drawing
1. Installation of ball socket
To install the ball socket to the bell crank, the grease and paint must not be applied to the taper portions.
2. Refilling of oil
For the grease nipple and grease for the hub,
use lithium grease (G2-LI).
2. King pin
1) Keep 7 mm of distance from the end face of
boss (4) to the end face of needle bearing 4. Adjustment of hub starting torque
(3). 1) Tighten the lock nut until it is difficult to
2) Align the end face of needle bearing (5) rotate the hub by one hand, and then rotate
with the end face of boss (6). the hub reversely 1/4 turn from that posi-
3) Adjust the play above or under knuckle (7) tion. Set the spring scale to the hub bolt,
to the minimum by using shim (8). and apply pre-load to the taper roller bear-
Standard clearance a:0 to 1 mm ing while adjusting nut (12) so that the start-
ing torque is within the following range.
Starting force 39.2 to 78.5 N {4.0 to 8.0 kgf}
431 to 862 Ncm
Starting torque
{44 to 88 kgfcm}
1. Cylinder tube
2. Piston rod
3. Piston
4. Rod guide
5. Tie rod
6. Dust seal
7. Rod packing
8. Back-up ring
9. O-ring
10. Piston packing
11. Roll bushing
12. Small flange nut
Assembly
2. Loosen nuts (12) (4 pieces) and remove tie rod 1. Observe the following when assembling, and
(5). perform the assembly in the reverse order to
the disassembly.
PRECAUTIONS
a Apply the grease or hydraulic oil to the O-ring,
dust seal, and lip surface of the packing when
assembling.
a Degrease threaded parts (4) and (11) before
applying the bond.
a Warm the packing of the piston with hot water
(80°C or lower) and then install it.
Removal
1. Remove sub hood (1) (3 bolts).
[*1]
To install the right side cover, securely insert inlet
pipe (a) of the air cleaner in sponge (b).
[*2]
3 Bolt (5): 686 to 98 Nm {70 to 10 kgm}
When installing counterweight (6), be careful not to
put protruding portion b of counterweight (6) on
protruding portion a of the frame.
Removal
1. Remove hood (1).
• For details, see "Removal and installation of
hood assembly".
2. Remove right and left side covers (2) (3 bolts). 5. Remove dashboard (7) (bolt) on the left side.
[*1]
12. Disconnect connector (20). 17. Remove relay (26) and buzzer (27).
14. Pull out coolant drain hose (22) from the front
panel.
22. Remove front head guard stay mounting bolts 25. The front head guard stay is put on front panel
(33) (4 each on the right and left sides). (36). Therefore, remove head guard assembly
(32) while moving the stay backward.
a Be careful not to hit bracket (37) on the right
fender when moving the stay backward.
Removal and installation of hood 2) Remove bolts (4) (4 pieces) and remove
seat assembly (2).
assembly
4 Seat assembly (2): 20 kg
k Lower the forks to the ground, stop the
engine, apply the parking brake, and chock
the wheels.
k Disconnect the cable from the negative(-)
terminal of the battery.
Removal
1. Remove sub hood (1) (3 bolts).
Hydraulic system
Removal and installation of HST 3. Remove plate (3) (4 bolts).
a Be sure to disconnect connectors (4) (2
pump assembly places) of the accelerator pedal sensor on
k Lower the forks to the ground, stop the the back of plate (3) and to remove clamps
engine, apply the parking brake, and chock (5) (2 places).
the wheels.
k Disconnect the cable from the negative(-)
terminal of the battery.
a After disconnecting the pipe, plug it immedi-
ately to prevent oil from spilling and dust from
entering.
a Never drain the coolant or oil to the ground.
Removal
1. Remove hood (1).
• For details, see "Removal and installation of
hood assembly".
5. Disconnect pressure sensor connectors (8) (2 12. Disconnect hose (19) of steering brake return
places) and pump EPC connectors (9) (2 circuit on the hydraulic tank side and remove
places). clamps (20) (3 places).
a Keep hose (19) away from the HST pump.
6. Remove clamp (10).
13. Remove control valve return pipe (21) between
the control valve and hydraulic tank.
16. Disconnect HST high-pressure pipes (27) (2 24. Remove bracket (37) (2 bolts).
places).
25. Remove U-bolt (38).
17. Disconnect HST motor drain pipes (28).
Removal
1. Remove front axle and HST motor assembly
and fix it to block [1].
• For details, see "Removal and installation of
front axle and HST motor assembly".
Installation
Perform installation in the reverse order to removal.
Removal
1. Considering the work from the bottom of the
frame, use block [1] to lift the fork lift truck
approximately 30 cm.
Installation
Perform installation in the reverse order to removal.
Removal
1. Remove floor plate (1). 6. Remove plate (8) (4 bolts).
a Be sure to disconnect connectors (9) (2
2. Remove right and left side covers (2) (3 bolts). places) of the accelerator pedal sensor on
[*1] the back of plate (8) and to remove clamps
(10) (2 places).
3. Remove right and left steps (3) (4 bolts).
7. Disconnect connectors (11) (2 places). 10. Remove bolts (19) (3 pieces) to remove control
valve (12).
8. Disconnect all pipes (13) connected to control
valve (12).
Installation
Perform installation in the reverse order to removal.
9. Remove cotter pin (14) and then pin (15). Dis-
connect control lever (16) from spool (17) of
control valve (12).
k When disconnecting the lever from
spool (17), never loosen lock nut (18). If
loosening it incorrectly, it is difficult to
adjust the fork lowering speed, and it is
necessary to disassemble and adjust
control valve (12). (See "Precautions for
maintenance of control valve" in "Disas-
sembly and assembly of control valve
assembly".)
Disassembly
1. Remove cross-recessed flat-head screws (17)
(2 pieces) and EPACS controller (16).
Assembly
a Replace all of O-rings and oil seals with new ones.
Disassembly
a Do not press storongly the external wall by using a vise, etc.
1. Face the end cap side upward and fix the hous-
ing.
Assembly
a Replace all of O-rings and oil seals with new
ones.
a The size of O-ring (29) is different from that of
O-ring (28).
Removal and installation of lift 3. Remove cotter pin (2), pull out pin (3), and dis-
connect chain (4).
cylinder assembly k Chain (4) may come suddenly off chain
k Lower the forks to the ground, stop the roller by its own weight. Extreme care
engine, apply the parking brake, and chock should be taken when removing the
the wheels. chain.
k Before disconcerting hydraulic piping,
release the pressure remaining inside the
c i r c u i t . F o r d e ta i l s o f r e l e a s i n g t h e
remaining pressure from the hydraulic
piping, see Testing and adjusting "Bleeding
air".
a After disconnecting the pipe, plug it immedi-
ately to prevent oil from spilling and dust from
entering.
a Never drain the coolant or oil to the ground.
Removal
1. Remove the forks.
4 Fork (1 unit): 120 kg
6. Sling inner mast (6). 9. To prevent the inner mast from dropping by
mistake, fix inner mast (6) and outer mast (9) by
using belt [1] with sufficient strength.
a * When tightening the head, apply ThreeBond #1901 to the thread portion.
1. Cylinder 8. Bushing
2. Piston rod 9. Back-up ring
3. Ring 10. U-ring
4. O-ring 11. Wiper
5. Spacer 12. Packing
6. Head 13. Retainer
7. O-ring 14. Stopper
a * When tightening the head, apply ThreeBond #1344 to the thread portion.
Disassembly of lift and tilt cylinder a Use the holding tool as shown in the figure
to support the piston rod and cylinder head
1. Removal of cylinder head assembly assembly. Use the torque multiplier wrench
Remove the cylinder head assembly by using a and socket to loosen the piston nut.
wrench. a For details of the torque of the torque multi-
plier wrench and width across flats of the
socket, see "Standard tightening torque
table" in Index and foreword.
Work equipment
Removal and installation of mast 3. Sling mast (2).
a Be sure to use hole (3) for slinging at the
assembly top of the outer mast to sling mast (2).
k Lower the forks to the ground, stop the
engine, apply the parking brake, and chock
the wheels.
k Before disconcerting hydraulic piping,
release the pressure remaining inside the
c i r c u i t . F o r d e ta i l s o f r e l e a s i n g t h e
remaining pressure from the hydraulic
piping, see Testing and adjusting "Bleeding
air".
k To lift the lift truck by using blocks, etc.
considering the work from the bottom of
the frame, use the solid blocks that can
support the weight.
a After disconnecting the pipe, plug it immedi-
ately to prevent oil from spilling and dust from
entering.
a Never drain the coolant or oil to the ground.
Removal
1. Remove the forks.
4 Fork (1 unit): 120 kg
5. Remove right and left lock plate (6) (2 bolts) 8. Slowly move mast assembly (9) forward by
and pull out tilt pin (7). using a crane and remove it.
4 Mast assembly (9): 750 kg
Insecure since
Safety is secured
the mast is not
since the mast is
stably engaged.
stably placed on
the front axle.
Finger board
For 4.0 ton
Electrical system
Removal and installation of 4. Remove bolts (6) (4 pieces) and remove engine
controller assembly (7). [*2]
engine controller assembly a Bolt (6) (1 piece) fixing the lower left part
k Lower the forks to the ground, stop the cannot be removed since it hits the intake
engine, apply the parking brake, and chock piping. However, engine controller assem-
the wheels. bly (7) can be removed if the bolts are loos-
k Disconnect the cable from the negative(-) ened.
terminal of the battery.
Removal
1. Remove floor plate (1).
Installation
Perform installation in the reverse order to removal.
a Remove foreign objects (dust or water) from the
connector of engine controller assembly (7),
and then install the assembly.
[*1]
3 Hexagonal socket head bolt:
2.83 ± 0.28 Nm {0.29 ± 0.03 kgm}
[*2]
3 Bolt (6):
30.5 ± 3.5 Nm {3.15 ± 0.35 kgm}
a Securely insert connector (3) while paying
attention to the feeeling of the locking.
a Check that clearance (a) after insertion of con-
nector (3) is max. 2 mm.
Removal
1. Remove floor plate (1).
[*1]
3 Hexagonal socket head bolt:
2.83 ± 0.28 Nm {0.29 ± 0.03 kgm}
Removal
1. Remove floor plate (1).
Installation
Perform installation in the reverse order to removal.
a Remove foreign objects (dust or water) from the
connector of KOMTRAX terminal assembly,
and then install the assembly.
Table of Contents
80 Yearly inspection criteria
Yearly inspection criteria ........................................................................................................................ 80-3
Yearly inspection criteria .................................................................................................................... 80-3
3. Idling speed • Inspect the following regarding the idling speed of the engine.
a Perform the inspection after warm-up operation of the engine is finished.
a Before depressing the accelerator pedal, place the directional lever in the
neutral position, and pull the parking lever.
1. Is the low idling speed within the specified values?
Unit: rpm
Engine Rotating speed
SAA4D95LE-5 800±25
2. Is the high idling speed (maximum speed) within the specified values?
Unit: rpm
Engine Rotating speed
SAA4D95LE-5 2,200±25
4. Air cleaner • Inspect the following regarding the air cleaner and elements.
a Inspect the air cleaner and elements after stopping the engine.
1. Is there any crack or deformation on the air cleaner body or cover?
2. Is there any looseness in the mounting part of the air cleaner?
3. Is there any looseness in the connecting pipe of the air cleaner?
4. Is there any stain or damage in the element?
a For cleaning and replacement when there is stain or damage in the element,
refer to the corresponding item in "Testing and adjusting."
Equip-
Inspection Item Detail of inspection
ment
5. Cylinder head • Inspect the following regarding the cylinder head.
manifold 1. Is there any looseness of the cylinder head mounting bolt?
2. Is there any water leakage or gas leakage from the cylinder head?
a For the tightening torque for the cylinder head mounting bolt, refer to the shop
manual of the engine.
a For the method to adjust the valve clearance, refer to the shop manual of the
engine.
7. Compression • Inspect the following regarding the compression pressure of the engine.
pressure 1. Is the compression pressure within the limit values?
Unit: MPa {kgf/cm2}/rpm
Engine Standard value Limit value
Engine
3. Is there any gas leakage from the turbocharger or intake/exhaust pipe con-
nection?
Equip-
Inspection Item Detail of inspection
ment
11. Engine mount • Inspect the following regarding the engine mount.
1. Is there any crack or deformation in the bracket?
12. Lubrication sys- • Inspect the following regarding the engine lubrication system.
tem 1. Is there sufficient oil?
(Engine oil, Check it with an oil level gauge. If there is not enough oil, refill it with oil.
Engine oil Filter) Specified oil level in engine oil pan Unit: l
Engine Oil level
SAA4D95LE-5 11
13. Fuel system • Inspect the following regarding the fuel system.
1. Is there any fuel leakage from the fuel tank, fuel pump, hose, or pipe?
3. Is there any water or sediment accumulated in the fuel pre-filter? Drain the
fuel pre-filter.
a For the draining method, refer to the corresponding item in "Testing and
adjusting."
4. Is there any stain or clogging of the fuel main filter element or fuel pre-filter
element?
a Stain or clogging cannot be found by visual check. The fuel filter is of a car-
tridge type. Replace it periodically.
a For the method to replace the filter element, refer to the corresponding item in
"Testing and adjusting."
14. High-pressure • Inspect the following regarding the high-pressure fuel gas system.
fuel gas system 1. Is there any gas leakage from the pipe or joint part?
15. Blowby gas • Inspect the following regarding the blowby gas return system.
return system 1. Is the operation of the PCV valve normal?
Equip-
Inspection Item Detail of inspection
ment
16. Coolant and radi- • Inspect the following regarding the
ator coolant and radiator.
1. Is there a sufficient amount of cool-
ant?
Check the amount of coolant with the
reservoir tank.
a The shape and location of the res-
ervoir tank varies depending on
the lift truck.
3. Is there any water leakage from the radiator main body, engine main body,
water pump, or hose?
removing it.
1) Inspection of the pressure regulat-
ing valve
Press down the spring of the cap
with a finger to check if there is
appropriate compression.
7. Is there any damage on the valve seat face of the radiator cap?
a If there is damage on the valve seat face of the radiator cap, replace the radi-
ator cap assembly.
Equip-
Inspection Item Detail of inspection
ment
17. Fan and fan belt • Inspect the following regarding the fan and fan belt.
1. Is the fan belt deflection as speci-
fied?
Press the center of the fan pulley and
alternator belt with a finger to measure
the deflection.
Unit: mm
Engine Deflection
7 to 10
SAA4D95LE-5 (Finger pressure:
58.5N{6kgf})
a For the method to adjust the fan belt deflection, refer to the shop manual of
the engine.
3. Is there any crack, damage, or deformation of the fan or fan cover (shroud)?
4. Is there any looseness of the mounting bolt of the fan or fan cover
(shroud)?
If there is a loose bolt, tighten it to the specified torque.
Engine
19. Spark plug and - Not applicable to this lift truck model -
ignition timing
(Gasoline engine
lift truck)
Equip-
Inspection Item Detail of inspection
ment
20. Charger system • Inspect the following regarding the charging equipment and wiring.
and wiring k The battery electrolyte is highly acidic. It will cause an injury when it
touches a hand, or it may cause blindness when it enters an eye. Make
sure to wear rubber gloves and goggles.
Equip-
Inspection Item Detail of inspection
ment
24. PTO • Inspect the following
regarding the PTO.
1. Is there any unusual
noise from the PTO
when the lift truck is
operating?
2. Is there any oil leak-
age from the PTO
case?
3. Is the oil level in the
PTO proper?
Stop the lift truck on a
level ground, inspect
it with an oil level
gauge (1), and supply
oil if the oil level is
low.
Unit: l
PTO oil level 5.5
a For the method to check the PTO oil level, refer to the corresponding item in
"Testing and adjusting."
25. HST pump and • Inspect the following regarding the HST pump and motor.
motor 1. Is there any oil leakage from the pipe, hose and joint, or seal part of the HST
pump or HST motor?
2. Is there any abnormal vibration from the HST pump or HST motor when the
lift truck is operating?
3. Is there any unusual noise from the HST pump or HST motor when the lift
truck is operating?
4. Is there any loose mounting bolt?
5. Is the high pressure relief pressure within the standard value?
• For the method to measure the high pressure relief pressure, refer to the cor-
responding item in "Testing and adjusting."
Unit: MPa {kgfm/cm2}
Relief pressure standard value 36.3 to 38.3 {370 to 391}
Equip-
Inspection Item Detail of inspection
ment
26. Drive shaft - Not applicable to this lift truck model -
28. Final drive a The final drive is built into the front axle. Refer to 27. Differential.
29. Front axle • Inspect the following regarding the front axle.
1. Is there any deformation, crack, or damage?
Check visually or by the penetrant check. Especially, check around the mounting
bolt and weld portion of the main frame.
a If any crack is suspected, check for a crack by the penetrant check.
Equip-
Inspection Item Detail of inspection
ment
30. Rear axle • Inspect the following regarding the rear axle.
1. Is there any deformation, crack, or damage?
Check visually or by the penetrant check.
a If any crack is suspected, check for a crack by the penetrant check.
Equip-
Inspection Item Detail of inspection
ment
32. Wheel • Inspect the following regarding the wheels.
1. Is the tightening torque of the hub nuts proper?
Unit: Nm {kgm}
Front wheel 294 to 490 {30 to 50}
3
Traveling equipment
FH40/45/50-1
Rear wheel 294 to 490 {30 to 50}
33. Steering wheel • Inspect the following regarding the steering wheel.
1. Is there any abnormal swing, pull, or return of the steering wheel when trav-
eling?
34. Steering valve • Inspect the following regarding the steering valve.
(Orbitrol valve) 1. Is there any oil leakage from the steering valve?
35. Rod and arm, etc. - Not applicable to this lift truck model -
Equip-
Inspection Item Detail of inspection
ment
37. Radius of right • Inspect the following regarding the turningradius of the lift truck.
and left turn 1. Is the minimum turningradius within the specified value?
• Measure the right and left minimum turning radius with the forward travelingof
the lift truck.
• Be the travel speed at the minimum speed, and the steering wheel at the max-
imum position in measuring.
• When the lift truck is turning, install a rod with chalk at the outermost position
of the weight to draw a circle on the ground.
a The outermost position during a turning varies depending on the turning direc-
tion.
a Change the position of the rod with chalk according to the turning direction.
a If it is not within the specified value of the minimum turning radius, check the
steering valve and steering cylinder.
Steering equipment
38. Steered wheel • Inspect the following regarding the steered wheel (wheel).
(wheel) 1. Is there any loose or missing stopper bolt?
If there is a loose bolt, tighten it to the specified torque.
39. Power steering • Inspect the following regarding the power steering system (power steering cylin-
system der).
(power steering 1. Is there any oil leakage from the power steering cylinder or hose?
cylinder) Operate the lift truck to operate the hydraulic pump to check it.
Equip-
Inspection Item Detail of inspection
ment
41. Service brake • Inspect the following regarding the service brake.
1. Is the brake pedal height within the specified value?
Unit: mm
Right side brake pedal height (H1) 62 ± 2
Right side brake pedal full travel (S2) 82 ± 2
42. Parking brake • Inspect the following regarding the parking brake.
1. Is the operating effort of the parking brake lever proper?
Unit: N {kgf}
Parking brake 59 to 69
lever operating effort {6 to 7}
43. Rod, link, cables • Inspect the following regarding the rod, link, and cables.
1. Is there any damage, looseness, or play in the rod, link, or cables?
2. Is there any looseness or play in the connenting part when the brake is
operated repetitively?
3. Is the cotter pin damaged?
Equip-
Inspection Item Detail of inspection
ment
44. Brake piping • Inspect the following visually regarding the pipe, hose, and joint of the brake.
1. Is there any damage in the brake piping?
2. Is there any oil leakage when brake is applied?
3. Is there any contact or possible contact in the brake piping?
4. Is there any deterioration of the brake piping hose?
5. Is there any loose mounting bolt in the brake piping?
If there is a loose bolt, tighten it to the specified torque.
45. Oil brake - Not applicable to this lift truck model -
51. Brake disc • Inspect the following regarding the brake disc.
1. Measure the wear?
Using the brake disc wear check port
Brake system
53. Parking brake • Inspect the following regarding the parking brake drum.
drum 1. Is there any loose or missing drum mounting bolt?
If there is a loose bolt, tighten it to the specified torque.
2. Is there any crack, damage, or wear of the drum?
Measure the following dimension and check if it is an allowable value.
Unit: mm
Drum inner diameter Max. 181
54. Parking brake • Inspect the following regarding the parking brake shoe and lining.
shoe, lining 1. Is there any abnormal operation condition, rust, or wear?
2. Is there any peeling, damage, or wear of the lining?
Unit: mm
Lining thickness Min. 3.5
Equip-
Inspection Item Detail of inspection
ment
55. Fork (1) • Inspect the following regarding the fork.
1. Is there any deformation, crack, or wear in the fork lock pin part?
2. Are the opening and height difference at the fork tips as specified without
any bend?
Unit: mm
Opening value (A) Max. 35
Height difference (B) Max. 15
FH40/45/50-1 Min. 50
a Check the fork root part and hook part where stress is focused by the pene-
trant check.
2. Is there any wear or play in the mast roller, or any crack of the roller shaft?
Equip-
Inspection Item Detail of inspection
ment
59. Fork carriage • Inspect the following regarding the fork carriage.
1 Is there any deformation, crack, or damage of the fork carriage?
60. Lift chain • Inspect the following regarding the lift chain.
1. Is the tension of the right and left chains proper?
Erect vertically the mast and lift up the fork by approximately 10cm from the
ground. Then, check that the right and left tension is proper by pushing the lift
chains in the middle by finger.
61. Chain wheel • Inspect the following regarding the chain wheel.
Equip-
Inspection Item Detail of inspection
ment
64. Hydraulic tank, • Inspect the following
filter regarding the hydraulic
tank and filter.
1. Is there any oil leak-
age from the hydrau-
lic tank?
Line filter
2. Is the oil level proper?
• Check the oil level
with the oil level Breather
gauge, and supply Oil level gauge
oil if the oil level is
low.
• Check for stain of
the oil, and replace
the oil if it is stained
too much.
3. Is the strainer
cleaned?
65. Main body piping • Inspect the following regarding the main body piping.
1. Is there any crack, damage, deterioration, or distortion in the piping?
Replace parts with a crack, damage, deterioration, or distortion.
Equip-
Inspection Item Detail of inspection
ment
67-1.Hydraulic pump • Inspect the following regarding the hydraulic pump.
1. Is there any oil leakage from the pipe, hose, joint, or seal part of the hydrau-
lic pump?
2. Is there any abnormal vibration when the lift truck is operating with or with-
out load?
3. Is there any unusual noise when the lift truck is operating with or without
load?
69. Lift cylinder • Inspect the following regarding the lift cylinder.
1. Is the operation condition of the lift cylinder smooth without oil leakage?
• Check if the lift cylinder operates smoothly.
• Extend and contract the lift cylinder rod several times, and check for any oil
Hydraulic system
2. Is there any dent, crack, bent, or scratch in the lift cylinder or rod?
2. Is there any dent, crack, bent, or scratch in the tilt cylinder or rod?
2. Is there any dent, crack, bent, or scratch in the attachment cylinder or rod?
Equip-
Inspection Item Detail of inspection
ment
73. Hydraulic drift, • Inspect the hydraulic drift and hydraulic drift tilting amount of the hydraulic cylin-
Hydraulic drift der.
tilting amount 1. Are the hydraulic drift and hydraulic drift tilting amount of the hydraulic cyl-
inder within the specified value?
• If it is not within the specified value, replace the packing of the control valve
and hydraulic cylinder.
a For the method to measure the hydraulic drift and hydraulic drift tilting amount of
the hydraulic cylinder, refer to the corresponding item in "Testing and adjusting."
74. Control valve (1) • Inspect the following regarding the control valve.
1. Is the operation condition of the control valve smooth without oil leakage?
• Operate the lever to check if the control valve operates smoothly.
• Check for any oil leakage from the control valve.
75. Control valve (2) • Inspect the following regarding the control valve.
1. Is the relief pressure within the standard value?
Hydraulic system
1) Install an oil pressure gauge to the relief pressure measurement port (1).
2) Tilt the mast backward, and measure the oil pressure when oil is relieved.
(Control valve relief pressure measurement port (R1/8))
Unit: MPa {kgfm/cm2}
Relief pressure standard value 20.6 {210}
76. Solenoid valve • Inspect the following regarding the solenoid valve.
1. Does it operate normally without any unusual noise when operated?
3. Is there any oil leakage from the solenoid valve or piping joint?
Equip-
Inspection Item Detail of inspection
ment
77. Frame and • Inspect the following regarding the frame and chassis.
chassis 1. Is there any crack or deformation of the frame or chassis?
• Check for any crack or deformation of the chassis frame, cross member,
fender, or side guard.
3. Is there any lock defect, rattle, or damage of the door close/open condition?
80. Lifting equip- • Inspect the following regarding the lifting equipment and anti-slipping.
ment, anti-slip- 1. Is there any crack, damage, or deformation of the lifting equipment and anti-
ping slipping?
81. Display board • Inspect the following regarding the display board.
a Check the items on the display board, caution/instruction nameplate as speci-
fied in the structure standard.
82. Head guard • Inspect the following regarding the head guard.
1. Is there any looseness in the mounting part of the head guard?
Equip-
Inspection Item Detail of inspection
ment
84. Lighting system, • Inspect the following regarding the lighting system, instruments, and alarms.
instruments, 1. Do the lighting system, instruments, and alarms operate normally?
Alarm Operate each of the switches to check the operation.
85. Mirror, reflector • Inspect the following regarding the mirror and reflector.
1. Is there any stain or damage on the mirror and reflector?
90 Circuit diagrams
Table of Contents
90 Circuit diagrams
Hydraulic circuit diagram........................................................................................................................ 90-3
Hydraulic circuit diagram.................................................................................................................... 90-3
Electrical circuit diagram ........................................................................................................................ 90-5
Electric circuit diagram (1/4) .............................................................................................................. 90-5
Electric circuit diagram (2/4) .............................................................................................................. 90-7
Electric circuit diagram (3/4) .............................................................................................................. 90-9
Electric circuit diagram (4/4) ............................................................................................................ 90-11
Connector list and layout ................................................................................................................. 90-13
A01L Y RH 6 Lamp (left) B-9 R17 micro ISO 5 Relay box (HST pump EPC cut) N-3
A01R Y RH 6 Lamp (right) C-6 S01 DTP 4 Starting switch N-8
A03 DT 3 Intermediate connector J-7 S03 S RS 2 Combination switch L-9
A04 X 4 Intermediate connector L-5 S04 Y NS 10 Combination switch L-9
A06 X 1 Intermediate connector O-6 S05 S NS 4 Combination switch M-9
A07 DT 3 Intermediate connector H-9 S06 Y NS 8 Combination switch M-9
A08 DT 3 Tire angle sensor J-6 S07 YAZAKI 10 Travel speed control switch N-8
A09L DT 2 Head lamp (Left) G-9 T01 Terminal 1 Ground C-5
A09R DT 2 Head lamp (Right) E-9 T02 Terminal 1 Ground J-8
A10L DT 3 Front combination lamp (Left) G-9 T03 Terminal 1 Ground J-4
A10R DT 3 Front combination lamp (Right) E-9 T04 Terminal 1 Body ground B-6
A12 DT 12 Intermediate connector J-4 TWTR PACKARD 2 Engine coolant temperature sensor P-4
A50 SWP 12 Optional M-5 V01 DT 2 HST pump EPC valve (Forward) M-5
A51 DT 3 Optional J-5 V02 DT 2 HST pump EPC valve (Reverse) N-5
A52 DT 4 Optional J-5 V03 DT 2 HST motor EPC valve L-5
C01 DRC 24 HST controller A-1 V10 S RS 2 Work equipment lock solenoid C-5
C02 DRC 40 HST controller A-4 V11 S RS 2 Lift lock solenoid C-4
C03 DRC 40 HST controller A-4 WIF DT 2 Intermediate connector G-9, T-2
CAM - 3 Camshaft speed sensor P-3
CE01 DRC 60 Engine controller O-8
CE02 DRC 60 Engine controller O-5
CE03 DTP 4 Engine controller P-5
CK01 AMP 18 KOMTRAX terminal C-1
CK03 AMP 12 KOMTRAX terminal C-4
CK06 SWP 1 Intermediate connector B-1
CK07 SWP 2 Intermediate connector B-1
CM01 Y SMC 10 Meter panel L-9
CM02 Y SMC 12 Instrument panel M-9
CM03 SWP 8 Pilot box M-9
CM04 Y 090 6 Service switch / Preheater lamp N-8
CN1 DT 2 Injector #1 Q-5
CN2 DT 2 Injector #2 S-5
CN3 DT 2 Injector #3 S-5
CN4 DT 2 Injector #4 T-5
CS01 S DL 8 Orbitrol K-9
D01 SWP 8 Diode array C-7
D20 SWP 8 Diode array J-4
E01 Terminal 1 Starter (B terminal) T-1
E02 Terminal 1 Starter (C terminal) T-1
E03 Terminal 1 Alternator S-7
E04 S TS 3 Alternator S-8
E05 Terminal 1 Intake air heater switch B-4
E06 Terminal 1 Intake air heater switch C-4
E07 Terminal 1 Intake air heater switch C-6
E08 Terminal 1 Intake air heater F-9
E09 DT 2 Intermediate connector J-7
E10 Terminal 1 Coolant temperature sensor R-9
F01 - 40 Fuse box I-1
F02A Terminal 1 Slow blow fuse K-3
F02B Terminal 1 Slow blow fuse K-3
F03A Terminal 1 Slow blow fuse K-3
F03B Terminal 1 Slow blow fuse K-3
F04 Terminal 1 Slow blow fuse J-3
F05 Terminal 1 Slow blow fuse K-2
J01 Y 090 8 Junction connector C-9
J02 Y 090 8 Junction connector C-1
J03 Y 090 8 Junction connector B-4
L03L DT 6 Rear lamp (L) J-6
L03R DT 6 Rear lamp (R) I-9
M01 Y 090 2 Horn E-2
M02 Y 090 2 Backup alarm buzzer B-6
M03 Y 090 2 Buzzer C-6
M04 DT 6 DC/DC converter J-5
M05 X 2 Feed pump K-5
N01 DT 12 Service connector C-9
N02 SWP 4 Engine controller data output B-9
N03 DT 3 CAN terminating resistor B-4
N04 DT 3 CAN terminating resistor B-4
NE - 3 NE sensor (crankshaft speed sensor) P-1
P01 DT 2 Parking brake lever switch B-7
P02 M 2 Stop lamp switch N-8
P03 AMP 3 Seat switch H-9
P05 DT 4 Speed sensor F-2
P06 AMP 3 Brake pressure sensor C-3
P07 Y SSD 3 Fuel level sensor I-3
P08 DT 2 Accelerator pedal K-9
P09 DT 6 Accelerator pedal K-9
P10 AMP 3 Pump A port pressure sensor (forward) N-5
P11 AMP 3 Pump B port pressure sensor (reverse) M-5
P12 DT 2 HST temperature sensor G-2
P13 AMP 3 Lift pressure sensor C-4
P14 DT 3 Brake potentiometer C-3
P15 DT 2 WIF (Water-in-fuel) sensor K-5
P16 Terminal 1 HST filter clogging sensor K-8
PAMB AMP 3 Ambient pressure sensor T-3
PFUEL BOSCH 3 Common rail pressure sensor T-4
POIL FRAMATOME 2 Engine oil pressure switch P-2
PREG BOSCH 2 Supply pump regulator S-1
PTIM BOSCH 4 Boost pressure and boost temperature sensor T-5
R01 Y mini ISO 5 Starter relay I-3
R02 CN (B) 4 Flasher unit H-3
R03 micro ISO 5 Relay box (horn) M-3
R05 Y mini ISO 5 PWM relay I-3
R09 micro ISO 5 Relay box (dimmer lamp) L-1
R10 micro ISO 5 Relay box (HST control power supply) M-1
R12 micro ISO 5 Relay box (position) N-1
R13 micro ISO 5 Relay box (lamp main) N-1
R14 micro ISO 5 Relay box (meter power supply) L-3
R15 micro ISO 5 Relay box (backup lamp) M-3
R16 micro ISO 5 Relay box (HST oil pressure lamp) M-1
Index
[A] Disassembly and assembly
of axle housing assembly 50-67
Accelerator pedal sensor 10-142 Disassembly and assembly
Accumulator (for brake) 10-65 of brake pedal assembly 50-80
Accumulator charge valve 10-52 Disassembly and assembly
Adjusting brake pedal 30-59 of combination switch assembly 50-130
Adjusting function 30-23 Disassembly and assembly
Adjustment of fork carriage 30-67 of control valve assembly 50-98
Adjustment of mast 30-64 Disassembly and assembly
Air cleaner inspection and element of differential assembly 50-54
replacement 30-44 Disassembly and assembly
Attachment piping diagram 10-72 of front axle assembly 50-49
Automatic engine stop set interval Disassembly and assembly
changing function 30-33 of mast assembly 50-122
Axle 10-36 Disassembly and assembly
of orbitrol valve assembly 50-104
Disassembly and assembly
[B] of parking brake assembly 50-74
Disassembly and assembly
Banning function of changing of power steering cylinder assembly 50-78
controlled travel speed 30-14 Disassembly and assembly
Bleeding air 30-58 of PTO assembly 50-51
Brake control 10-47 Disassembly and assembly
Brake piping diagram of rear axle assembly 50-75
(control valve – accumulator) 10-48 Disassembly and assembly
Brake valve 10-58 of tilt cylinder assembly 50-115
Display of EPACS controller
failure code 40-182
[C] Displaying, setting, checking
by using HST controller 30-6
Changing PTO oil and cleaning strainer 30-52
Check of failure code of engine controller 30-3
Checking parking brake 30-57 [E]
Checks before troubleshooting 40-7
Classification and procedures of E-1 Engine does not start 40-191
troubleshooting 40-8 E-2 Engine preheater does not
Cleaning of water separator strainer 30-42 operate 40-196
CLSS 10-88 E-3 Parking brake reminder alarm
Coating materials list 50-4 does not sound or does not stop
Combination switch 10-163 sounding 40-198
Connection table for connector E-4 EPACS is abnormal 40-201
pin numbers 40-20 E-5 Headlamp, clearance lamp,
Connector list and layout 90-13 tail lamp and license plate lamp
Control valve 10-82 do not light up or go off 40-204
Control valve piping diagram E-6 Turn signal lamps do not light up
(tank – control valve) 10-70 or go off 40-210
Cooling system 10-6 E-7 Brake lamps do not light up or
go off 40-214
E-8 Backup lamps do not light up or
[D] go off 40-216
E-9 Backup buzzer does not sound
DC/DC converter 10-149 or does not stop sounding 40-218
Differential 10-37 E-10 Horn does not sound or
Disassembly and assembly does not stop sounding 40-220
of lift cylinder assembly 50-114 E-11 Fuel level is not displayed
normally 40-222
Failure code [56/7REAKA] H-16 Oil leaks from steering circuit 40-282
Accessory input circuit 1 H-17 Service brake does not work
(KEY_SIGNAL): Open circuit 40-176 or its performance is low 40-283
Failure code [62/DB2RKR] H-18 Service brake is not reset
CAN communication or it drags 40-284
(between HST controller and H-19 Parking brake does not work
engine controller): or its performance is low 40-285
Communication failure H-20 Parking brake is not reset
(Component system failure) 40-178 or it drags 40-286
Failure code [63/DAJ000] H-21 Abnormal noise around
HST Controller: Memory error 40-180 the work equipment or steering pump 40-287
Failure code [63/DAJ0KT] H-22 Engine speed drops excessively or
HST Controller: Memory error 40-181 stops during work equipment operation
Failure code [LED: 1 flashing] or wheel steering 40-288
Initialization is not completed 40-184 H-23 Fine control performance of
Failure code [LED: 2 flashings] entire work equipment is low or
Controller is being initialized 40-185 response is low 40-289
Failure code [LED: 3 flashings] H-24 Work equipment cannot be locked
Steering wheel angle sensor (and the equipment operates when
abnormality 40-186 operator leaves) 40-290
Failure code [LED: 4 flashings] H-25 Control valve lever does not move
Tire angle sensor abnormality 40-188 smoothly and it is heavy 40-291
Failure code [LED: OFF] H-26 Lift cylinder and fork do not lift 40-292
EPACS controller abnormality 40-183 H-27 Lifting speed or power of
Failure code list 40-63 lift cylinder and fork is insufficient 40-293
Finger board 10-114 H-28 Forklift speed lowers at specific
Flasher unit 10-166 height 40-294
Fork 10-115 H-29 Lift cylinder natural drift is large 40-295
Frame 10-69 H-30 Lift cylinders do not come down 40-296
Fuel filter air bleeding 30-41 H-31 Fork lowering speed is low or
Fuel pre-filter water drain 30-40 high or fine control performance is
low or response is low 40-297
H-32 Mast does not tilt forward or
[H] backward 40-298
H-33 Forward/backward tilting speed
H-1 Lift truck cannot travel 40-270 or force of mast is insufficient 40-299
H-2 Slow travel speed 40-271 H-34 Tilting speed lowers halfway 40-300
H-3 Insufficient towing force 40-272 H-35 Tilt cylinder natural forward drift
H-4 Engine stops during traveling, is large 40-301
or engine speed drops excessively 40-273 H-36 Mast is unstable during travel
H-5 HST (hydraulic) oil temperature with load 40-302
is too high 40-274 H-37 Work equipment is heavy
H-6 Impossible steering 40-275 when work equipment and
H-7 Response is low during turning 40-276 steering are operated simultaneously 40-303
H-8 Steering is heavy 40-277 H-38 Steering is heavy when work
H-9 Unstable during turning 40-278 equipment and steering are
H-10 When steering wheel is released operated simultaneously 40-304
it does not return to neutral or it How to proceed in troubleshooting 40-6
rotates by itself 40-279 How to read this manual 50-3
H-11 Steering wheel is turned How to use Loctite 50-9
in reverse or it kicks How to use troubleshooting table 40-261
(while work equipment is operated) 40-279 HST controller 10-138
H-12 Large shock is made HST motor 10-26
when steering wheel is returned 40-280 HST piping diagram 10-13
H-13 EPACS does not work 40-281 HST pump 10-14
H-14 Steering wheel vibrates 40-282 Hydraulic and mechanical system
H-15 Steering system makes diagram 40-264
abnormal sound 40-282 Hydraulic circuit diagram 90-3
Information described in
troubleshooting table 40-12 [R]
Information described in
troubleshooting table 40-190 Radiator cleaning 30-43
Initial setting of Orbitrol valve 30-62 Rear axle 10-67
Inspection of hydraulic tank 30-53 Relay 10-168
Instrument panel 10-146 Relay box 10-167
Releasing pressure from hydraulic
piping 30-35
[K] Removal and installation of aftercooler
assembly 50-31
KOMTRAX system 10-150 Removal and installation of control valve
KOMTRAX terminal start-up procedure 30-72 assembly 50-96
Removal and installation of counterweight
assembly 50-81
[L] Removal and installation of cylinder head
assembly 50-18
Lamp display of KOMTRAX terminal 30-69 Removal and installation of engine and
Lift cylinder 10-106 pump assembly 50-35
List of specified fuel and lubricant 01-7 Removal and installation of engine
Locations of fuses 40-17 controller assembly 50-126
Lubricant list 01-6 Removal and installation of front axle and
HST motor assembly 50-46
Removal and installation of fuel injector
[M] assembly 50-14
Removal and installation of fuel supply
Mast 10-107 pump assembly 50-10
Maximum travel speed control function 30-11 Removal and installation of head guard
Measurement of hydraulic drift and assembly 50-83
forward tilt down by hydraulic drift Removal and installation of hood
of cylinder 30-63 assembly 50-87
Measurement of wear of service brake Removal and installation of HST controller
disc 30-56 assembly 50-128
Measuring brake performance 30-55 Removal and installation of HST motor
Mechanical-system abnormality record assembly 50-93
display function 30-22 Removal and installation of HST pump
Memory clear function 30-30 assembly 50-89
Removal and installation of KOMTRAX
terminal assembly 50-129
[O] Removal and installation of lift cylinder
assembly 50-111
Oil level check and changing oil in Removal and installation of mast
differential case 30-51 assembly 50-120
Orbitrol valve 10-44 Removal and installation of of radiator
assembly 50-29
Removal and installation of oil cooler
[P] assembly 50-34
Removal and installation of PTO
Parking brake 10-66 assembly 50-50
Phenomena seemed to be failures Removal and installation of starting
and troubleshooting Nos. 40-9 motor assembly 50-43
Pilot box 10-148
Points to remember when troubleshooting 40-5
[S]
Seat switch 10-164
Sensor 10-153
Service brake 10-50
Service switch/Preheater lamp 10-165
Setting controlled travel speed 30-9
Slack adjuster 10-61
Special tools list 50-7
Specification dimensions drawing 01-3
Standard value table 20-3
Steering piping diagram
(control valve – power steering cylinder) 10-43
[T]
Table of failure modes and causes 40-266
T-branch box and T-branch adapter table 40-60
Testing and adjusting brake pedal
angle sensor linkage 30-60
Testing and adjusting engine speed 30-45
Testing and adjusting HST oil pressure 30-47
Testing work equipment and steering
pump oil pressure 30-50
Tilt cylinder 10-105
Travel speed control function for general
operator (description in Operation
and Maintenance Manual of the
lift truck) 30-8
[W]
Weight table 01-5
Work equipment and steering pump 10-74
Work equipment control lever linkage 10-73
Work equipment piping diagram
(control valve – tilt cylinder/lift cylinder) 10-71
[Y]
Yearly inspection criteria 80-3
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All Rights Reserved
Printed in Japan 12-12 (02)