Komatsu Forklift Truck FH40-1 FH45-1 FH50-1 138001 & Up Shop Manual SEN06282-00

SEN06282-00
FORKLIFT TRUCK FH40 -1

FH45 -1
FH50 -1
SERIAL NUMBERS 138001 and up
FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1
Applicable model Serial number

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
00 Index and foreword
FH40-1, FH45-1, FH50-1 00-1

Table of contents
Table of contents
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
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
00-2 FH40-1, FH45-1, FH50-1

Table of contents
Table of contents
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
Combination switch........................................................................................................................ 10-163
Seat switch .................................................................................................................................... 10-164
Service switch/Preheater lamp ...................................................................................................... 10-165
Flasher unit .................................................................................................................................... 10-166
Relay box ....................................................................................................................................... 10-167
Relay.............................................................................................................................................. 10-168
20 Standard value table

Standard value table .............................................................................................................................. 20-3
Standard value table .......................................................................................................................... 20-3
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
FH40-1, FH45-1, FH50-1 00-3

Table of contents
Table of contents
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
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:
Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B:
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
00-4 FH40-1, FH45-1, FH50-1

Table of contents
Table of contents
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
FH40-1, FH45-1, FH50-1 00-5

Table of contents
Table of contents
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
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
00-6 FH40-1, FH45-1, FH50-1

Table of contents
Table of contents
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
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
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
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
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
FH40-1, FH45-1, FH50-1 00-7

Table of contents
Table of contents
80 Yearly inspection criteria

Yearly inspection criteria ........................................................................................................................ 80-3
Yearly inspection criteria .................................................................................................................... 80-3
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 (4/4) ............................................................................................................ 90-11
Connector list and layout ................................................................................................................. 90-13
Index
Index ........................................................................................................................................................... 1
00-8 FH40-1, FH45-1, FH50-1

Foreword and general information
Safety notice

Safety notice (Rev. 2008/07)
Important safety notice
Proper service and repair are extremely important for safe lift truck operation. The service and repair
techniques recommended by KOMATSU UTILITY and described in this manual are both effective and
safe. Some of these techniques require the use of tools specially designed by KOMATSU UTILITY for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
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,
FH40-1, FH45-1, FH50-1 00-9

Safety notice
2. Preparation for work

1) Before adding oil or making any repairs,
park the lift truck on hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
lift truck from moving.
2) Before starting work, lower the work
equipment (mast) to the ground. If this is
not possible, insert the lock pin or use
blocks to prevent the work equipment from
falling and hang warning signs on them.
3) When disassembling or assembling, sup-
port the lift truck with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the lift
truck. Always use the handrails and steps
when getting on or off the lift truck. N ever
jump on or off the lift truck.
00-10 FH40-1, FH45-1, FH50-1

Safety notice
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.
FH40-1, FH45-1, FH50-1 00-11

Safety notice
4. Safety items on maintenance (for safe work) k Periodic inspection of safety-critical

k
parts
Inspection and maintenance shall be
1) Replace the safety-critical parts periodi-
carried out by persons having mainte-
cally, even if they are normal.
nance skill and experience.
They are deteriorated as the time passes
1) Inspection and repair work of the lift trucks
on and can cause a fire and a trouble in
shall be carried out by persons having suf-
the work equipment system.
ficient knowledge and experience in main-
2) Replace safety-critical parts even before
tenance and repair work.
their periodic replacement periods, if they
2) When inspecting or servicing a new model
are abnormal.
or a new component, fully understand its
k Use of right tools and equipment
structure, performance and mechanism.
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 Precautions for inspection and mainte-

nance work (safety)
1) If oil or grease is sticking, wipe it off. If oil
leaks, wipe it off immediately. Dirtiness
hides faults such as a crack. Keep clean.
2) No fire. Cloths impregnated with fuel or oil
can catch fire.
3) Wear adequate working clothes.
4) Use safety goods and protective items
(helm et, sa fety shoe s, goggle s and
gloves) suitable for work.
5) When working on the lift truck, take care
not to fall.
6) Do not put your foot under the fork.
7) When opening and closing the floor plate
or engine hood, take care not to have your
hand caught.
8) When inspecting with the fork raised, pat a
stand under the inner mast so that the fork
and mast will not fall.
9) When working with other personnel,
appoint a leader and follow his/her instruc-
tions.
00-12 FH40-1, FH45-1, FH50-1

Safety notice
k Be careful of boiling coolant

1) The engine coolant is high in temperature
and pressure just after the lift truck is
used. Do not remove the radiator cap
under this condition. Hot coolant will spout
and can scald you.
2) When removing the radiator cap, loosen it
slowly to release the internal pressure.
3) When checking the coolant level, stop the
engine and wait for it and radiator to cool.
If a reservoir tank is installed, check it.
4) If a reservoir tank is installed, add coolant
in it.
k Prohibition of welding fuel tank

Never weld the fuel tank since it may explode. 5) When inspecting the accumulator piping,
release the pressure inside it in advance.
k Take care of high-pressure and high- 6) If you are injured with high-pressure oil,
temperature oil see a doctor immediately.
1) The oil is high in temperature just after the 7) When removing the mast or lift cylinder,
lift truck is used. Do not drain the oil or be sure to release the pressure from the
replace the oil filter under this condition. hydraulic piping.
Hot oil will spout and can scald you. q Stop the lift truck and lower the fork to
2) Wait until the oil temperature decreases the ground.
and then carry out inspection or mainte- q Stop the engine.
nance according to the procedure q Turn the starting switch to the ACC
described in this manual. position.
3) There is residual pressure in the hydraulic q Sit on the operator seat and tilt the lift
circuit. Do not start inspection or mainte- lever and tilt lever forward and in
nan ce be fore the re sidua l p ressu re reverse 4 – 5 times each to release
decreases to zero. the pressure in the hydraulic piping.
4) High-pressure oil leaking through a small k The pressure is not released unless
hole is dangerous to the skin or eye. Do you operate the levers while sitting on
not check the hydraulic system for oil leak- the seat.
age with naked eye but put on safety
glasses and thick gloves and put a piece
of thick paper or plywood to the inspection
point.
FH40-1, FH45-1, FH50-1 00-13

Safety notice
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.
k Danger of being caught and falling

1) Never put your hand, foot or body in the
mast. You may be caught and injured in
the moving parts.
3) When inflating the tyre, you have to have

taken the special education.
4) The air pressure for the lift truck tyre is as
several times high as that for car tyre, thus
there is possibility of danger in inflating.
5) When pumping air into the tyre, dirt may
be blown with compressed air and may
enter your eye. Put of safety glasses.
2) Do not use the mast as a ladder.

You may slip off the mast and fall.
00-14 FH40-1, FH45-1, FH50-1

Safety notice
k Handling of tyres k Slinging lift truck (for checking or

Have the tyre disassembled and assembled by replacing tyre)
a specialist. Since the tyre inflation pressure is 1) Never sling the the lift truck by the over-
very high, the tyres must be handled carefully. head guard. When slinging the lift truck
1) When removing the tyre, release all air frequently, use special slings.
from it. When removing the tyre, loosen 2) The lift truck shall be slung by a person
hub nut (1). who has finished the sling skill course.
2) Never touch rim nut (2). Doing so is dan- 3) Install wires to the specified slinging
gerous. points.
3) After replacing the tyre, travel the lift truck 4) When slinging the lift truck, use wires hav-
on trial and then check the mounting nuts ing sufficient strength and no damage.
for looseness. If the tightening torque has 5) Lock the tyres with chocks.
decreased, tighten to the specified torque. 6) Put blocks under both sides of the slung
4) Tightening torque: See "Standard value lift truck to prevent fall.
table".
k Slinging lift truck (for loading on trailer

k Jack-up work (for checking or replac- etc.)
ing tyre) 1) Never sling the the lift truck by the over-
1) Do not go under the fork during jack-up head guard. When slinging the lift truck
work. frequently, use special slings.
2) Check the following items before starting 2) The lift truck shall be slung by a person
jack-up work. who has finished the sling skill course.
q No person is on the lift truck. 3) Install wires to the specified slinging
q No load is on the lift truck. points.
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.
FH40-1, FH45-1, FH50-1 00-15

Safety notice
k Handling of batteries 9) Do not short the battery terminals by a

1) Battery electrolyte contains dilute sulph- metallic thing.
uric acid, which attacks clothes and skins. 10) If the terminals are loosened, sparks are
If it sticks to the clothes or skins, take off made because of a defective contact and
the clothes immediately and wash the they can cause explosion. Tighten the ter-
skins which the electrolyte stuck with tap minals securely.
water and then consult a doctor. 11) When removing the battery, check its pos-
2) If battery electrolyte gets into your eyes, itive and negative terminals and take care
flush them immediately with fresh tap not to reconnect the cables with reverse
water for 10 – 15 minutes continually and polarities.
then consult a doctor. 12) Tighten the battery caps securely.
3) If you have drunk battery electrolyte by 13) When cleaning, keep the battery caps
accident, either drink a large quantity of tightened.
water or milk mixed with beaten egg white
or salad oil, and then consult a doctor at k Do not put a metallic piece on the bat-
once. tery.
Do not put a metallic piece on the battery,
since it can cause a fire from a short circuit.
k Precautions for charging

Nitrogen gas is produced while the battery is
being charge and the battery heats itself
because of the chemical reaction. To prevent
gas explosion, observe the following.
1) Charge the battery in a place ventilated
well.
2) No fire.
3) Start to charge the battery when its elec-
trolyte temperature is 35°C or below. (If
the electrolyte temperature increases
4) When handling the battery, always wear above 50°C, wait until it decreases to
safety glasses. below 35°C and then start charging
5) The battery generates hydrogen gas, again.)
which is highly explosive. Do not bring fire 4) When charging the battery with a charging
of a lighter or a cigarette or make a spark device, keep the battery caps removed.
near the battery.
k Starting engine with booster cables
1) When starting the engine with booster
cables, put on safety glasses.
2) When starting the engine with the battery
of another vehicle, do not bring the lift
truck body in contact with that vehicle.
3) Stop the engine before connecting the
cables.
4) Take extreme care that that the cables will
not be caught in the cooling fan or the fan
belt.
5) Do not make a mistake in connection of
the booster cable. Never bring the positive
and negative terminals in contact with
each other.
6) When inspecting or handling the battery,
k Prohibition of engine push-start
turn the starting switch OFF.
7) When removing the battery, be sure to dis-
Do not start the engine by pushing the lift truck.
connect the cable from the negative termi-
The lift truck starts suddenly and you may
nal first.
make a mistake in operation.
8) When installing the battery, be sure to
connect the cable to the positive terminal
first.
00-16 FH40-1, FH45-1, FH50-1

Safety notice
k Handling of antifreeze k Slinging with 1 rope may cause

1) Antifreeze contains flammable material. turning of the load during hoisting,
When handling it, do not bring fire near it. untwisting of the rope, or slipping
2) Since antifreeze is toxic, do not drink it. If of the rope from its original wind-
you have swallowed by mistake, drink ing position on the load, which can
much water and vomit and then consult a result in a dangerous accident.
doctor immediately. 7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
k Wastes ing a wide hanging angle from the hook.
When disposing of oil, fuel, coolant, solvent, fil- When hoisting a load with 2 or more
ter, battery, Freon (air conditioner refrigerant), ropes, the force subjected to each rope
etc., observe the applicable regulations and will increase with the hanging angle. The
rules. table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended. This
weight is reduced to 9.8 kN {1,000 kg}
when the 2 ropes make a hanging angle of
120°. If the 2 ropes sling a 19.6 kN {2,000
kg} load at a lifting angle of 150°, each of
them is subjected to a force as large as
39.2 kN {4,000 kg}.
5. Precautions for sling work and making signs

1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
FH40-1, FH45-1, FH50-1 00-17

Safety notice
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.
00-18 FH40-1, FH45-1, FH50-1

Safety notice
7. Selecting wire ropes 2) Connection

1) Select adequate ropes depending on the
1] When installing the air conditioner cir-
weight of parts to be hoisted, referring to
cuit hoses and tubes, take care that
the table below.
dirt, dust, water, etc. will not enter
them.
Wire ropes
(Standard "Z" twist ropes without galvanizing) 2] When connecting the air conditioner
(JIS G3525, No. 6, Type 6X37-A) hoses and tubes, check that O-rings
Nominal (1) are fitted to their joints.
Allowable load 3] Check that each O-ring is not dam-
diameter of rope
mm kN ton aged or deteriorated.
4] When connecting the refrigerant pip-
10 8.8 0.9
ing, apply compressor oil for refrigerant
12 12.7 1.3 (R134a) (DENSO: ND-OIL8, VALEO
14 17.3 1.7 THERMAL SYSTEMS: ZXL100PG
16 22.6 2.3 (equivalent to PAG46)) to its O-rings.
18 28.6 2.9
20 35.3 3.6 a Example of O-ring (Fitted to every joint of
hoses and tubes))
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
a The allowable load is one-sixth of the

breaking strength of the rope used (Safety
coefficient: 6).
8. Precautions for disconnecting and connect-

ing hoses and tubes in air conditioner circuit
1) Disconnection
k The air conditioner mounted on this a For tightening torque, see the precautions for
lift truck uses refrigerant (R134a), installation in each section of "Disassembly
which must not be discharged into and assembly"
the atmosphere as it is, although it
has less ozone layer breaking fac-
tors for preservation of the environ-
ment. When disconnecting the air
conditioner gas circuit, be sure to
collect the refrigerant to reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
When collecting or filling the it, be
sure to put on protective goggles,
gloves and protective clothes.
In addition, you must be qualified
for handling the refrigerant.
FH40-1, FH45-1, FH50-1 00-19

How to read the shop manual
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.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the lift truck.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
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.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
80. Yearly inspection criteria

This section explains the items, contents and criteria of the specific self-imposed inspection.
90. Diagrams and drawings (Chassis)

This section gives hydraulic circuit diagrams and electrical circuit diagrams.
00-20 FH40-1, FH45-1, FH50-1

2. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
1
Special precautions are necessary for lift truck security during
Security
assembly work.
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving

a Caution
standards are necessary when performing 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.
2 Coat Places to be coated with adhesives, etc. during 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 { }.
FH40-1, FH45-1, FH50-1 00-21

Explanation of terms for maintenance standard

The chapter of maintenance standard explains the criteria for replacing or reusing each product or part in the
disassembly maintenance. The criteria are described by the following terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the "standard size" and the range of differ-
ence from the standard size is called the
"tolerance".
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
00-22 FH40-1, FH45-1, FH50-1

2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the "standard clear- between them is increased to a certain
ance", which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the "clearance limit".
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
"standard value", which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value "interference limit".
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the "interference".
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the "standard interference".
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the "repair
limit".
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the "allowable
value" or "allowable dimension".
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
FH40-1, FH45-1, FH50-1 00-23

Handling of electric equipment and hydraulic component

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and
"Handling hydraulic equipment" (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
00-24 FH40-1, FH45-1, FH50-1

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.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet.
Accordingly, take care not to splash water
over the connector.
The connector is designed to prevent
water from entering, but at the same time,
if water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
FH40-1, FH45-1, FH50-1 00-25

3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip
have stoppers, which are
engaged with each other when
the connector is installed.
q When removing a connector from

a clip, pull the connector in a par-
allel direction to the clip for
removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
a Removal of resin clip

Lift up the stopper of range clip,
and then pull out the range clip.
00-26 FH40-1, FH45-1, FH50-1

3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
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.
FH40-1, FH45-1, FH50-1 00-27

3) Heavy duty wire connector (DT 8-pole, 12-

pole)
Disconnection (Left of figure) q Disconnection q Connection (Example of

While pressing both sides of locks (a) incomplete setting of (a))
and (b), pull out female connector (2).
Connection (Right of figure)

1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector

(2): Female connector
(a), (b): Locks
00-28 FH40-1, FH45-1, FH50-1

4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-

nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
FH40-1, FH45-1, FH50-1 00-29

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.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
00-30 FH40-1, FH45-1, FH50-1

Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
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.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
FH40-1, FH45-1, FH50-1 00-31

5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
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.
00-32 FH40-1, FH45-1, FH50-1

Handling of connectors newly used for engines

a Mainly, following engines are object for follow-
ing connectors.
q 95E-5
q 107E-1
1. Slide lock type 2. Pull lock type

(FRAMATOME-3, FRAMATOME-2) (PACKARD-2)
q 95E-5 engine, 107E-1 engine q 95E-5 engine, 107E-1 engine
q Various pressure sensors and NE q Various temperature sensors
speed sensor Example)
Example) Intake air temperature sensor in
Oil pressure switch intake manifold: TIM
Ne speed sensor of flywheel housing Fuel temperature sensor: TFUEL
: NE Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
Disconnect connector (1) according to the fol- etc.
lowing procedure.
1) Slide lock L1 to the right. Disconnect the connector by pulling lock
2) While pressing lock L2, pull out connector (B) (on the wiring harness side) of connec-
(1) toward you. tor (2) outward.
a Even if lock L2 is pressed, connector
(1) cannot be pulled out toward you, if
part A does not float. In this case,
float part A with a small screwdriver
while pressing lock L2, and then pull
out connector (1) toward you.
FH40-1, FH45-1, FH50-1 00-33

3. Push lock type q 107E-1 engine

Example) Example)
Fuel pressure sensor in common rail Intake air pressure/temperature sensor in
(BOSCH-03) intake manifold (SUMITOMO-04)
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, 107E-1 engine
q 95E-5 engine
4) While pressing lock (E), pull out connector
(5) in the direction of the arrow.
a If the lock is on the underside, use flat- Example)

head screwdriver [1] since you cannot Fuel pressure in common rail: PFUEL etc.
insert your fingers. (AMP-3)
2) While pressing up lock (C) of the connec-

tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
00-34 FH40-1, FH45-1, FH50-1

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.
FH40-1, FH45-1, FH50-1 00-35

How to read electric wire code

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
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.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
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
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov- AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D CAVS Standard – – – – – – – – –
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
"f" of nominal No. denotes "flexible".
00-36 FH40-1, FH45-1, FH50-1

2. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(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
3. Color codes table
(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.
FH40-1, FH45-1, FH50-1 00-37

4. Types of circuits and color codes
(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 – – – – – – –
00-38 FH40-1, FH45-1, FH50-1

Precautions when carrying out operation
When carrying out removal, installation, disassembly or assembly of units, be sure to follow the general pre-
cautions given below.
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal No. Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes

Nominal No. Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
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
FH40-1, FH45-1, FH50-1 00-39

2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
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.
3. Precautions when completing operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the hydraulic equipment has been removed, always bleed the air from the system after reas-
sembling the parts, referring to Testing and adjusting.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see "Disassembly and assembly".
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
00-40 FH40-1, FH45-1, FH50-1

4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly
and assembly".
FH40-1, FH45-1, FH50-1 00-41

Standard tightening torque table

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table corresponds to the bolts in Fig. A.
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
a The following table corresponds to the bolts in Fig. B.
Thread diameter
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.)
00-42 FH40-1, FH45-1, FH50-1

2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter
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
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
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}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
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}
FH40-1, FH45-1, FH50-1 00-43

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.
Tightening torque Nm {kgfm} Taper seal Face seal

Width
Nominal Nominal No. -
across Thread
No. of Thread size Number of
flats Range Target diameter (mm)
hose (mm) threads, type of
(mm) (Reference)
thread
34 – 54 { 3.5 – 5.5} 44 { 4.5} – 9/16-18UNF 14.3
02 19
34 – 63 { 3.5 – 6.5} 44 { 4.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joint

a Tighten the face joint seals (sleeve nut type) of steel pipes for plated low-pressure piping in engines
etc. to the torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Suitable Tightening torque Nm {kgfm} Face seal

Width
pipe
across Nominal No. - Thread diameter
outside
flats Range Target Number of threads, (mm)
diameter
(mm) type of thread (Reference)
(mm)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
00-44 FH40-1, FH45-1, FH50-1

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.
Thread size Tightening torque

mm Nm kgfm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
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.
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
FH40-1, FH45-1, FH50-1 00-45

Conversion table
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
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line
down from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
00-46 FH40-1, FH45-1, FH50-1

Conversion table
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
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
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
FH40-1, FH45-1, FH50-1 00-47

Conversion table
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
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
00-48 FH40-1, FH45-1, FH50-1

Conversion table
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
FH40-1, FH45-1, FH50-1 00-49

Conversion table
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
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-50 FH40-1, FH45-1, FH50-1

FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
FH40-1, FH45-1, FH50-1 01-1

Table of Contents
Table of Contents
Specifications ......................................................................................................................................... 01-3
Specification dimensions drawing ...................................................................................................... 01-3
Weight table ....................................................................................................................................... 01-5
Lubricant list....................................................................................................................................... 01-6
List of specified fuel and lubricant...................................................................................................... 01-7
01-2 FH40-1, FH45-1, FH50-1

Specifications
Specification dimensions drawing
Specifications
FH40-1, FH45-1, FH50-1 01-3

Specifications
Item Unit FH40-1 FH45-1 FH50-1

Maximum load kg 4,000 4,500 5,000
Load center mm 600 600 600
Performance
Max. lifting height A mm 3,000 3,000 3,000

Free lift B mm 150 145 140
Fork lifting speed (loaded) mm/s 485 420 420
Max. travel speed (unloaded) km/h 23.5 23.5 23.5
Gradability (loaded) (Max.) % 33 29 28
Overall length C mm 4,220 4,270 4,405
Overall width D mm 1,520 1,520 1,520
Dimension and weight
Mast E mm 2,105 2,205 2,205

Overall height Head
F mm 2,240 2,240 2,240
guard
Fork length x width x thickness
mm 1,070x150x55 1,070x150x55 1,220x150x55
JxKxL
Fork opening width
G mm 300/1,190 300/1,190 300/1,270
(Minimum/Maximum)
Unladen mass kg 6,290 6,920 7,380
Model – SAA4D95LE-5-C SAA4D95LE-5-C SAA4D95LE-5-C
Engine
Total piston displacement cc 3,260 3,260 3,260

Rated Gross kW{HP}/ 53{71}/2,150 53{72}/2,150 53{71}/2,150
horsepower Net rpm 50.8{68.1}/2,150 50.8{68.1}/2,150 50.8{68.1}/2,150
Front wheel – 300-15-18PR( ) 300-15-18PR( ) 300-15-18PR( )
Tire
Rear wheel – 7.00-12-12PR( ) 7.00-12-14PR( ) 7.00-12-14PR( )
01-4 FH40-1, FH45-1, FH50-1

Specifications
Weight table
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
FH40-1, FH45-1, FH50-1 01-5

Specifications
Lubricant list
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 .
01-6 FH40-1, FH45-1, FH50-1

Specifications
List of specified fuel and lubricant
Ambient Temperature (°C) Recommended

Lubrication point Type of oil
Komatsu Fluids
-20 -10 0 10 20 30 40 °C
EO10W30-DH
Engine oil
Engine oil pan
(for diesel engine)
EO15W40-DH
PTO Power line oil TO10
Differential case Axle oil AXO80
Hydraulic tank Engine oil

EO10W30-DH
(including HST) (for diesel engine)
ASTM Grade No. 1-D S15
Fuel tank Diesel fuel ASTM Grade No. 2-D S500
G2-LI
Greasing point Lithium grease AF-NAC
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.
FH40-1, FH45-1, FH50-1 01-7

Specifications
01-8 FH40-1, FH45-1, FH50-1

FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
10 Structure, function and

maintenance standard
FH40-1, FH45-1, FH50-1 10-1

Table of Contents
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
Rear axle.......................................................................................................................................... 10-67
Hydraulic tank piping diagram.......................................................................................................... 10-68
Frame............................................................................................................................................... 10-69
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 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
10-2 FH40-1, FH45-1, FH50-1

Table of Contents
Combination switch........................................................................................................................ 10-163

Seat switch .................................................................................................................................... 10-164
Service switch/Preheater lamp ...................................................................................................... 10-165
Flasher unit .................................................................................................................................... 10-166
Relay box ....................................................................................................................................... 10-167
Relay.............................................................................................................................................. 10-168
FH40-1, FH45-1, FH50-1 10-3

Engine and cooling system
Engine mount and transfer mount

10-4 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 10-5

Cooling system
Cooling system
10-6 FH40-1, FH45-1, FH50-1

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)
Fin pitch (mm) 5.0/2 4.5/2 4.5/2 2.75/2
Total heat dissipation area (m2) 14.16 6.79 9.19
Pressure 88±14.7 {0.9±

valve 0.15} ― ― ―
Cracking pressure
(kPa {kgf/cm2}) Vacuum
4.9 {0.05} ― ― ―
valve
FH40-1, FH45-1, FH50-1 10-7

Power train
Power train
Power train
Power train
1. Engine
2. PTO
3. HST pump
4. HST motor
5. Parking brake
6. Front axle
7. High-pressure hose
10-8 FH40-1, FH45-1, FH50-1

Power train
Power train system diagram
Power train system diagram
1. Engine 15. Front tire

2. Damper
3. PTO
4. Work equipment pump
5. Brake pump
6. HST pump
7. HST charge pump
8. HST high pressure piping
9. HST motor
10. Parking brake
11. Differential
12. Front axle
13. Wet-type multiple disc brake
14. Final drive
FH40-1, FH45-1, FH50-1 10-9

Power train
PTO
PTO
1. PTO case a. Flywheel mounting surface

2. HST pump b. HST pump mounting surface
3. Work equipment pump c. Work equipment pump mounting surface
4. PTO lubrication pump
5. Oil level gauge
6. Breather
7. Strainer
10-10 FH40-1, FH45-1, FH50-1

Power train
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
A: Drive gear (ENG)

B: Idler gear
C: HST pump gear
D: Work equipment & PTO lubrication pump gear
FH40-1, FH45-1, FH50-1 10-11

Power train
PTO
Unit: mm
No. Item Criteria Remedy
Backlash between drive gear Standard clearance Allowable clearance

8
and idler gear 0.88 to 0.254 0.508
Backlash between idler gear Replace
9 0.88 to 0.254 0.508
and HST pump gear
Backlash between idler gear
10 0.44 to 0.180 0.360
and work equipment pump gear
Measure the clearance between the shafts (3EC-12-61130) and
(3EC-12-61110), and select a shim for the measured clearance:
A - (0 to 0.05)mm.
11 Clearance adjustment Adjust
Standard Tolerance Standard Allowable

dimension Shaft Hole clearance clearance
+0.000 +0.035 0 to
Clearance of Outer race 100 ―
-0.015 -0.000 +0.050
12 input axis bear-
ing (engine side) Inner race +0.030 -0.000 -0.045 to
55 ―
+0.011 -0.015 -0.0 11
+0.000 +0.022 -0.013 to
-0.015 -0.013 0.037
13 input shaft bear-
ing (axle side) +0.030 +0.000 -0.045 to
Inner race 55 ―
+0.011 -0.015 -0.0 11
+0.000 -0.014 -0.033 to
-0.015 -0.033 0.001
14 idler shaft bear-
ing +0.011 -0.000 -0.023 to
Inner race 40 ―
+0.005 -0.012 -0.0 05
Clearance of +0.000 +0.022 -0.013 to Replace
Outer race 110 ―
HST pump shaft -0.015 -0.013 0.037
15
bearing (engine +0.030 +0.000 -0.045 to
side) Inner race 60 ―
+0.011 -0.015 -0.0 11
Clearance of +0.000 +0.035 0 to
Outer race 110 ―
HST pump shaft -0.015 -0.000 +0.050
16
bearing (axle +0.030 -0.000 -0.045 to
side) Inner race 60 ―
+0.011 -0.015 -0.0 11
Clearance of +0.000 +0.022 -0.013 to
Outer race 85 ―
work equipment -0.015 -0.013 0.037
17
pump shaft bear- +0.011 +0.000 -0.023 to
ing (engine side) Inner race 45
+0.005 -0.012 -0.0 05 ―
Clearance of +0.000 +0.035 0 to

Outer race 85 ―
work equipment -0.015 -0.000 +0.050
18
pump shaft bear- +0.011 +0.000 -0.023 to
ing (axle side) Inner race 45 ―
+0.005 -0.012 -0.0 05
10-12 FH40-1, FH45-1, FH50-1

Power train
HST piping diagram
HST piping diagram
1. HST pump 9. PTO

2. HST motor 10. Tow receiving plug
3. HST high pressure piping (forward side)
4. HST high pressure piping (reverse side)
5. HST A port (forward side) pressure sensor
6. HST B port (reverse side) pressure sensor
7. HST oil filter
8. Strainer
FH40-1, FH45-1, FH50-1 10-13

Power train
HST pump
HST pump
Model: HPV75
a HST: Abbreviation for Hydrostatic Transmission
10-14 FH40-1, FH45-1, FH50-1

Power train
HST pump
CPA: Charge pressure input port Outline

CSA: Servo pressure pickup port • The pump assembly consists of the variable
CSB: Servo pressure pickup port displacement swash plate type piston pump
ESA: Pilot current and charge pump.
ESB: Pilot current
P2: Charge pump discharge port Specifications
PA: To HST motor port (MB)
PB: To HST motor port (MA) Model HPV75
PR1: Tow receiving plug Variable displacement
S2: Charge pump suction port Type swash plate type
T1: Case drain port Piston pump
T2: Case drain port Theoretical discharge
0 to 73.2
T3: Refilling port (cm3/rev)
High pressure relief valve set 36.3 to 38.3
1. Piston pump pressure (MPa {kg/cm2}) {370 to 391}
2. Drive piston
3. HST charge pump
4. Charge safety valve
5. EPC valve (B side)
6. EPC valve (A side)
7. Suction valve
8. Shuttle valve
9. Safety valve
FH40-1, FH45-1, FH50-1 10-15

Power train
HST pump
1. Shaft
2. Cradle bearing
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Drive piston
10-16 FH40-1, FH45-1, FH50-1

Power train
HST pump
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).
FH40-1, FH45-1, FH50-1 10-17

Power train
HST pump
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.)
• While swash plate angle (a) is made between

center line (X) of rocker cam (4) and the axis of
cylinder block (7), plane (A) works as a cam for
shoe (5).
• Piston (6) slides inside cylinder block (7) and a
difference is made between volumes (E) and
(F) in cylinder block (7).
• Oil in amount of (F) minus (E) is sucked in and
discharged from each piston (6).
• Oil is discharged while cylinder block (7) rotates
and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber
(F) increases.
10-18 FH40-1, FH45-1, FH50-1

Power train
HST pump
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.
FH40-1, FH45-1, FH50-1 10-19

Power train
HST pump
Operation of drive piston
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.
10-20 FH40-1, FH45-1, FH50-1

Power train
HST pump
Safety valve, shuttle valve, suction valve
1. Charge pump 4. Shuttle valve

2. Charge safety valve 4A. Valve
3. Safety valve 4B. Spring
3A. Poppet 4C. Plug
3B. Spring 5. Suction valve
3C. Poppet (The structure is the same as that of the shuttle
3D. Valve seat valve.)
3E. Spring
3F. Adjustment screw
FH40-1, FH45-1, FH50-1 10-21

Power train
HST pump
Safety valve, shuttle valve Suction valve
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.
10-22 FH40-1, FH45-1, FH50-1

Power train
HST pump
When HST pump discharges oil from PA port Valve on suction side of piston pump
Valve on discharge side of piston pump Operation

• When pressurized oil is discharged from PA • On the other hand, PB port becomes the suc-
port side of HST pump (4), PA port becomes tion side and its pressure is low. Suction valve
the high-pressure side. (5) is pushed to the right because of the area
• The pressurized oil in PA port flows into port D difference (A1<A2) by the charge pressurized
through passage (b) of the body. oil, and the seat portion of suction valve (5)
• At this time, suction valve (5) is pushed to the opens.
left because of the area difference (A1>A2). • As a result, the charge pressurized oil in port B
• As a result, the pressurized oil from charge flows into port PB through this clearance and
pump (1) does not flow in. charges HST circuit.
FH40-1, FH45-1, FH50-1 10-23

Power train
HST pump
HST charge pump
1. Drive shaft Specifications

2. Drive gear Model SAR (1) 18
3. Idler gear
Gear pump
Type
(inscribed type)
Outline
Theoretical discharge
• It is installed to HST pump. It works together 18
(cm3/rev)
with HST pump to supply pilot pressure to HST
motor EPC valve as well as to charge HST cir-
Function
cuit.
• It is connected to the drive shaft of HST pump.
• Discharge pressure is determined by HST
It's rotation produces the pumping action.
charge safety valve.
• HST charge pump sucks in oil from the hydrau-
lic tank.
10-24 FH40-1, FH45-1, FH50-1

Power train
HST pump
Charge safety valve

Operation
• Chamber A is connected to the charge circuit,
and chamber C is connected to the tank drain
circuit. Pressurized oil fills chamber B through
orifice a of main valve (2F).
• When abnormal pressure is generated, if the
differential pressure due to the area difference
between diameters D and d (x/4 (D2-d2) x Pres-
sure in chamber A) increases to the pressure
set by main valve spring (2D), main valve (2F)
opens and the pressurized oil in chamber A is
relieved to chamber C to prevent the pressure
in chamber A from rising.
1. HST charge pump

2. Charge safety valve
2A. Adjustment screw
2B. Lock nut
2C. Sleeve
2D. Main valve spring
2E. Pilot piston
2F. Main valve
3. Suction valve
FH40-1, FH45-1, FH50-1 10-25

Power train
HST motor
HST motor
Model: KMV160
a HST: Abbreviation for Hydrostatic Transmission
10-26 FH40-1, FH45-1, FH50-1

Power train
HST motor
Rotation direction (facing drive shaft)

Inflow from MA: Clockwise rotation
Inflow from MB: Counterclockwise rotation
MA: High pressure port during forward travel

MB: High pressure port during reverse travel
PEPC: EPC valve source pressure input port
CH: Pressure sensor port (high pressure)
T1: Drain
T2: Drain
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}
FH40-1, FH45-1, FH50-1 10-27

Power train
HST motor
1. Drive shaft 10. Pin

2. Motor case 11. Valve plate
3. Charge relief valve 12. Cylinder block
4. End cover 13. Piston
5. Sleeve 14. Check valve (for high-pressure selection)
6. Seat 15. Low-pressure shuttle valve
7. Servo spring
8. Servo piston
9. Servo spool
10-28 FH40-1, FH45-1, FH50-1

Power train
HST motor
Operation of piston motor Operation

• The oil pumped from HST pump enters through
Principle HST motor inlet port.
• Supposed that the axis of the disc is supported • Oil pressure is generated at the back of piston
and the disc can rotate freely. Force (F) acts on (13), and drive shaft (1) rotates with inclination
this disc at an angle. (Q) of piston (13) and cylinder block (12).
• Force (F) is divided into force (F1) that is per-
pendicular to the disc and force (F2) that is in
the circumferential direction of the disc.
• (F1) pushes the disc in the axial direction, and
(F2) rotates the disc clockwise.
• When force (F'), not force (F), is applied to the
disc, the force (F') is also divided into (F'1) and
(F'2), and the disc is rotated counterclockwise
by force (F'2).
Capacity change of continuous variable type

motor
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).
FH40-1, FH45-1, FH50-1 10-29

Power train
HST motor
When motor capacity is maximum
10-30 FH40-1, FH45-1, FH50-1

Power train
HST motor
When motor capacity is minimum
FH40-1, FH45-1, FH50-1 10-31

Power train
HST motor
Flushing valve
1. Low-pressure shuttle valve

2. Charge relief valve
10-32 FH40-1, FH45-1, FH50-1

Power train
HST motor
Low-pressure shuttle valve
Function • When oil pressure MA < MB, spool (3) moves

• The main pressure MA or MB of HST motor up and MA is selected as the lower pressure
whichever is lower is selected and fed to and sent to the charge relief valve (1).
charge relief valve (1). • When oil pressure MA > MB, spool (3) moves
down and MB is selected as the lower pressure
Operation and sent to the charge relief valve (1).
• Oil pressure MA is led to the upper end surface
of low pressure shuttle valve (2), and oil pres-
sure MB is led to the lower end surface of low
pressure shuttle valve (2).
• When a differential pressure between oil pres-
sures MA and MB is small and low pressure
shuttle valve (2) is in the neutral position, the
passage to charge relief valve (1) is blocked.
FH40-1, FH45-1, FH50-1 10-33

Power train
HST motor
Charge relief 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).
10-34 FH40-1, FH45-1, FH50-1

Power train
HST motor
• If the oil pressure in port C decreases, differen-

tial pressure is generated by orifice (g) of valve
(1) between ports A and C.
• Valve (1) is pushed to the left by the pressur-
ized oil in port A and the oil in port A is relieved
into port B.
• Accordingly, the pressure in the charge circuit
does not increase more.
FH40-1, FH45-1, FH50-1 10-35

Power train
Axle
Axle
1. Reduction gear 7. Parking brake

2. Differential 8. Brake oil filler/Brake disc wear check port (2
3. Final drive places)
4. Axle shaft 9. Oil level gauge/Brake disc wear check gauge
5. Axle housing 10. Differential oil filler
6. Wet-type multiple disk brake 11. Bleeder
(FH40: 3 discs • FH45/50: 4 discs) 12. Drain plug
10-36 FH40-1, FH45-1, FH50-1

Power train
Differential
Differential
a 1 Applying LT-2 1. Pinion gear

a 2 Loctite 572 2. Bevel gear
3. Side gear
4. Shaft
FH40-1, FH45-1, FH50-1 10-37

Power train
Differential
10-38 FH40-1, FH45-1, FH50-1

Power train
Differential
(1) Part dimensions (bearing excluded)

Unit: mm
Standard Standard Allowable

Tolerance
Gear thickness dimension clearance value
6
4 ±0.1 3.7
Gear hole diameter 51 -0.10 to -0.15 50.7
7 Gear outside diameter 50.8 ±0.05 50.6
8 Washer thickness 2.25 ±0.1 1.65
9 Spacer thickness 5 ±0.2 4.7
10 Disc thickness 4.4 ±0.15 3.6
11 Plate thickness 3.7 ±0.1 3.5
12 Spider outside diameter 22 -0.020 to -0.041 Allowable

-0.10 to 0.161 clearance
13 Gear hole diameter 22 +0.08 to +0.12 MAX. 0.25
Replace
16 Drum inner diameter 180 0 to +0.1 181
17 Brake lining diameter 179.3 ±0.2 178
18 Gear hole diameter 30 +0.009 to +0.025
19 Shaft outside diameter 22 -0.07 to -0.020
20 Gear outside diameter +0.03 to +0.06
21 0 to +0.07
Housing hole diameter 192 +0.06 to +0.10
22
23 Drum outside diameter -0.016 to 0

50 -0.059 to -0.018
24 Retainer hole diameter -0.059 to -0.034
(2) Rotation starting torque and backlash

Unit: mm
25 Tolerance
Backlash
26 0.15 to 0.23mm
27 Differential input bearing rota-

5.8 to 1.1Nm {0.59 to 1.13kgm}
28 tion starting torque
0.5to 1.9Nm {0.05to 1.19kgm} Adjust

Differential side bearing rota- Measure it at the pinion gear. "Measured value-Differential
29
tion starting torque input bearing starting torque" must be 0.5 to 1.9Nm {0.05 to
1.19kgm}.
30 Wheel bearing rotation starting

0.8 to 4.6Nm {0.08 to 0.47kgfm}
31 torque
FH40-1, FH45-1, FH50-1 10-39

Power train
Differential
(3) Bearing dimensions

Unit: mm
Standard Tolerance Standard Allowable

dimension Shaft Hole clearance value
+0.000 +0.016 -0.006 to

Clearance of dif- Outer race 95
-0.018 -0.006 0.034 ―
32 ferential side
bearing +0.051 -0.000 -0.066 to
Inner race 60 ―
+0.032 -0.015 -0.0 32
+0.000 -0.010 -0.045 to

Pinion bearing Outer race 90 ―
-0.018 -0.045 0.008
33 clearance (axial
end side) +0.018 -0.000 -0.030 to
Inner race 40 ―
+0.002 -0.012 -0002
+0.000 -0.010 -0.045 to

Pinion bearing Outer race 100 ―
-0.018 -0.045 0.008
34 clearance (differ-
ential side) +0.033 -0.000 -0.045 to
Inner race 45 ―
+0.017 -0.012 -0.0 17
+0.000 -0.012 -0.052 to

Wheel bearing Outer race 125 ―
-0.02 -0.052 0.008
30 clearance (tire
side) +0.039 -0.000 -0.054 to
Inner race 70 ―
+0.017 -0.015 -0.0 20
+0.000 -0.010 -0.045 to Replace

Wheel bearing Outer race 100 ―
-0.018 -0.045 0.008
ential side) +0.021 -0.000 -0.036 to
Inner race 60 ―
+0.002 -0.015 -0.0 02
+0.016 +0.000 -0.032 to

Ball bearing Outer race 100 ―
-0.006 -0.015 -0006
35 clearance (axial
end side) +0.011 +0.000 -0.023 to
Inner race 45 ―
-0.005 -0.012 +0.005
+0.000 0.035 0 to
-0.015 0.000 +0.005
ential side) +0.011 +0.000 -0.023 to
Inner race 50 ―
-0.005 -0.012 +0.005
+0.000 +0.030 0 to
-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
-0.013 0.000 -0043
ential side) +0.011 +0.000 -0.023 to
Inner race 40 ―
-0.005 -0.012 +0.005
10-40 FH40-1, FH45-1, FH50-1

Power train
Differential
Outline When lift truck is turning

• The power from the engine is transmitted to the • When the lift truck is turning, the right and left
front axle through the PTO, HST pump, and wheels rotate at different speed. Accordingly,
HST motor. pinions (4) and side gears (3) in the differential
• In the axle, the power transmitting is changed in rotate and transmit the power of carrier (6) to
direction by 90 degrees and reduced in speed right and left sun gear shafts (2), depending on
by pinion gear (1) and bevel gear (5) and then the difference in rotation speed between the
transmitted through pinion gears (4) to sun gear right and left wheels.
shafts (2).
• The power of the sun gear is further reduced in
transmitting speed by the planetary gear type
final drives, and then transmitted to the axle
shaft and wheels.
When lift truck is traveling straight

• While the lift truck is traveling straight, the right
and left wheels rotate at the same speed.
Accordingly, the pinion gears (4) in the differen-
tial assembly do not rotate and the power of
carrier (6) is transmitted through pinion gears
(4) and side gears (3) to right and left sun gear
shafts (2) evenly.
FH40-1, FH45-1, FH50-1 10-41

Power train
Differential
Axle power transmission route
Power transmission route

Torque from HST motor (1)/parking brake (2)
↓
Transfer gear (3)
↓
Pinion gear (4)
↓
Differential gear (5)
↓
Final gear (6)
↓
Axle shaft (7)
↓
To tire
10-42 FH40-1, FH45-1, FH50-1

Steering system
Steering piping diagram (control valve – power steering cylinder)
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)
FH40-1, FH45-1, FH50-1 10-43

Steering system
Orbitrol valve
Orbitrol valve
1. EPACS (Electronic Proportional Active Control 14. Check valve assembly

Steering System) valve 15. Tube assembly
2. Retainer screw assembly 16. Coil with connector
3. Spacer 17. Electronic Proportional Active Control Steering
4. Gerotor System (EPACS) controller
5. Screw
6. End cap L: L port
7. Screwdriver P: P port
R: R port
8. Spool
T: T port
9. Sleeve
LS: LS port
10. Housing
11. Pin
12. Centering spring
13. Relief valve cartridge
10-44 FH40-1, FH45-1, FH50-1

Steering system
Orbitrol valve
Outline Hydraulic circuit diagram

• The Electronic Proportional Active Control
Steering System (EPACS) electronically cor-
rects the deviation between the steering wheel
position and tire position caused by leakage
inside the Orbitrol valve that is inevitable to the
full hydraulic power steering system.
• The oil discharged from the pump flows through

the EPACS valve port P into the Orbitrol and
the oil of an amount in proportion to the steering
wheel rotation number is discharged through
the cylinder port (port R) into the cylinder to
steer the wheels.
1. Steering wheel • The oil from the cylinder flows through the cylin-
2. Electronic Proportional Active Control Steering der port (port L) into the Orbitrol and returns to
System (EPACS) controller (containing steering the tank through port T.
wheel angle sensor) • The knob displacement correction (EPACS)
3. Orbitrol controller reads the steering wheel angle and
wheel angle from the steering wheel angle sen-
4. EPACS (Electronic Proportional Active Control
sor and wheel angle sensor respectively. If
Steering System) valve
there is deviation between them, the EPACS
operates the EPACS valve solenoid to supply a
6. Wheel angle sensor correction oil flow to the cylinder to correct the
deviation.
• As explained above, the leakage inside the
Orbitrol is compensated by the correction oil
flow to correct the deviation of the steering
wheel position from the Wheel angle.
FH40-1, FH45-1, FH50-1 10-45

Steering system
Power steering cylinder
Power steering cylinder
Unit: mm
Symbol Item Criteria Remedy
Standard dimension Tolerance Repair limit
Clearance between cylinder Piston outside

A Cylinder bore
and piston diameter 0.3 to 0.448 0.65
+0.074 -0
80 +0 79.7 -0.074
Bushing inside Rod outside Replace

Clearance between piston diameter diameter 0.032 to
B 0.492
rod and bushing +0.164 -0.025
0.228
50 +0.007 50 -0.064
C Piston rod Flaw felt with nail, dent, streak, dint
D Cylinder Flaw felt with nail, dent, streak, dint
10-46 FH40-1, FH45-1, FH50-1

Brake system
Brake control
Brake system
Brake control
1. Brake pedal
2. Brake pedal angle sensor linkage
3. Brake pedal angle sensor
4. Brake valve
FH40-1, FH45-1, FH50-1 10-47

Brake system
Brake piping diagram (control valve – accumulator)
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
10-48 FH40-1, FH45-1, FH50-1

Brake system
FH40-1, FH45-1, FH50-1 10-49

Brake system
Service brake
Service brake
1. Differential housing Function

2. Bearing carrier • The service brake is a wet-type multiple disc
3. Piston brake consisting of piston (3), plate (5), disc (9),
outer plate (8) and spring (4).
4. Spring
• The brake cylinder consists of differential hous-
5. Plate
ing (1) and bearing carrier (2) and has piston
6. Sun gear shaft (3) in it.
7. Axle housing • Plate (5) and outer plate (8) are fixed to the
8. Outer plate groove of differential housing (1) by lugs.
9. Disc • Disc (9) and plate (5) are installed between pis-
ton (3) and outer plate (8). When brake oil pres-
sure acts on piston (5), plate (8) and disc (9)
come into pressed contact to brake sun gear
shaft (6).
10-50 FH40-1, FH45-1, FH50-1

Brake system
Service brake
Unit: mm
Standard dimension Repair limit
Load at installed Load at installed

4 Spring load Installed length
length length
5.1 904N {92 kg} 768 N {78 kg}
Standard dimension Tolerance Repair limit Replace

5 Thickness of plate
3.7 ±0.1 3.5
Thickness of brake disc 4.4 ±0.15 3.6
9 Lining groove depth 0.6 (Min.) ― 0.4
Lining thickness 1.0 0.8 (Min.) ―
Operation When released

During operation • If the hydraulic pressure is relieved, piston (1) is
• If the brake pedal is depressed, hydraulic pres- returned to the original position by the reaction
sure (P) flows from the hydraulic tank through force of spring (6) and clearance is made
the pump, accumulator charge valve and slack between plate (2) and outer plate (3) and then
adjuster and pushes piston (1) in the brake cyl- disc (4) is set free.
inder to slide.
FH40-1, FH45-1, FH50-1 10-51

Brake system
Accumulator charge valve
ACC: To brake valve/accumulator Function

P: From brake valve • The accumulator charge valve works to main-
T: To hydraulic tank tains the oil pressure from the pump at the
specified pressure and keep the pressure in the
accumulator.
• When the oil pressure rises above the specified
pressure, the oil from the pump is led to the
drain circuit to reduce the load on the pump.
10-52 FH40-1, FH45-1, FH50-1

Brake system
1. Valve body
2. Main relief valve
3. Unload spool
4. Safety valve
FH40-1, FH45-1, FH50-1 10-53

Brake system
Operation 1. When oil is supplied to accumulator (cut-in)

• The hydraulic oil sent from the pump
pushes up check valve (4) and flows into
the accumulator. (Fig.1/Fig.2) Because the
accumulator and pilot spool chamber (A) is
interconnected, the accumulator pressure
acts on pilot spool (2).
• Because the hydraulic oil from the pump
flows into relief chamber (B) at the same
pressure as the accumulator pressure
through the orifice, pilot spool chamber (A)
and relief chamber (B) have the same pres-
sure, so pilot spool (2) does not move. Main
relief valve (1) is pressed by control spring
(5), so it does not move until the specified
pressure is achieved as pilot spool (2). (Fig.
2)
• Both ends of unload spool (3) have the
same pressure, and it is pushed to the left
side by the load of spool return spring (6),
disconnecting the interconnection between
the pump and drain.
10-54 FH40-1, FH45-1, FH50-1

Brake system
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.
FH40-1, FH45-1, FH50-1 10-55

Brake system
3. Cut-in operation 4. Safety valve

• As the pressure of interconnected pilot • When the pressure supplied from the pump
spool chamber (A) drops as the accumula- exceeds the pressure set by the safety
tor pressure drops, the load of pressure valve due to a functional defect of a compo-
control spring (5) overcomes the pushing nent, the hydraulic oil from the pump
power of pilot spool (2) and pushes back pushes down safety valve (7) to flow oil into
pilot spool (2) to the left and closes main the tank circuit to regulate the maximum
relief valve (1). At this time, the accumulator pressure of the brake circuit and protect the
pressure is the cut-in pressure, and it circuit.
becomes the charge condition of 1.
Not in operation
During cut-out
Operating
Start of cut-in condition
operation
10-56 FH40-1, FH45-1, FH50-1

Brake system
FH40-1, FH45-1, FH50-1 10-57

Brake system
Brake valve
Brake valve
1. Push rod Function

2. Piston • The brake valve controls the hydraulic pressure
3. Rod supplied from the brake pump and supplies it to
the wet brake chamber according to the pedal
4. Control spring (1)
depressing force (pedal travel).
5. Control spring (2)
• To avoid constant high-load pump operation,
6. Pedal return spring accumulator charge valve and accumulator are
7. Spool installed so that the brake can be operated by
8. Spool return spring the specified numbers even while the engine
(pump) is stopped.
10-58 FH40-1, FH45-1, FH50-1

Brake system
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}
2 18.6 32.3 32.3 0 29.1 ―

98.1N 88.0N
4 Pedal return spring 39.0 (71.7) 58.6 64.5 Replace
{10.0kgf} {9.0kgf}
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
FH40-1, FH45-1, FH50-1 10-59

Brake system
Brake valve
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.
• If spool (7) moves further, IN port (P) is con-

nected to OUT port (B) and the pressurized oil
flows from the accumulator through the valve to
the brake chamber.
• Since the pressure in the brake chamber (out-
put pressure) is also led to reaction force cham-
ber (C), it returns spool (7) toward control
springs (4) and (5). As a result, spool (7) dis-
connects IN and OUT ports in a position where
the spring load is balanced, and oil pressure is
kept.
• From the above operation, output pressure in
proportion to the pedal depressing force (con-
trol spring + pedal return spring) is obtained.
10-60 FH40-1, FH45-1, FH50-1

Brake system
Slack adjuster
Slack adjuster
1. Cushion valve mechanism spool Function

2. Cushion valve mechanism cylinder • The slack adjuster is installed to the brake oil
3. 2-ɸ0.7 orifice line between the brake valve and brake piston.
It evens the brake operation time lag and sup-
4. Slack adjuster mechanism piston
presses "jolty braking" and "backlash sound".
5. Check valve
6. 4-ɸ4 main oil passage
7. Axle
A. Inlet port
B. Outlet port
FH40-1, FH45-1, FH50-1 10-61

Brake system
Slack adjuster
Specifications Cushion mechanism

Unit: MPa {kgf/cm2} • If the brake pedal is depressed sharply, the
generated peak pressure causes "jolty brak-
Piston drive pressure 0.01 to 0.02 {0.1 to 0.2} ing", "backlash sound", etc. Generally, the peak
Check valve cracking pres- 0.88±0.098 {0.09± pressure is restricted by installing an orifice or
sure 0.01} damping part (ACC etc.) in the hydraulic piping
Check valve checking pres- 0.57±0.098 {0.06± after the brake valve so that hydraulic oil will be
sure 0.01} supplied to the brake chamber gently. If this
method is applied, the response is lowered
more or less, however.
Accordingly, the throttling rate is decided with
the balance between the response required by
the lift truck and the peak pressure restriction
effect. However, it is difficult to attain both peak
pressure restriction and high response for
medium and small-sized lift trucks, since high
brake response is required.
To solve this problem, the response reduction is
minimized and the peak pressure (backlash
sound) is restricted by starting oil flow control
just before the brake discs contact each other
while maintaining the slack adjuster mecha-
nism.
10-62 FH40-1, FH45-1, FH50-1

Brake system
Slack adjuster
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

Replace
Load at Load at
Outside Free Installed Free
installed installed
2 Check valve spring diameter length length length
length length
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}
FH40-1, FH45-1, FH50-1 10-63

Brake system
Slack adjuster
Operation • If the pressure in cushion valve mechanism cyl-

• The hydraulic oil sent from the brake valve inder (3) increases to the cracking pressure of
pushes slack adjuster mechanism piston (1) check valve (7), the pressure in the line
toward OUT port (B), and the cushion valve between the IN and OUT ports becomes con-
mechanism spool (2) moves inside the cushion stant. At this time, if the oil quantity is insuffi-
valve mechanism cylinder (3), following the cient for brake operation because of wear of the
slack adjuster mechanism piston (1). This discs, the hydraulic oil is supplied from check
hydraulic oil is sent through 4-ɸ4 main oil pas- valve oil passage (6) to the OUT port (B) side.
sages (4) to OUT port (B). (Slack adjuster mechanism)
• 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)
10-64 FH40-1, FH45-1, FH50-1

Brake system
Accumulator (for brake)
Accumulator (for brake)
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}
FH40-1, FH45-1, FH50-1 10-65

Brake system
Parking brake
Parking brake
1. Shoe and lining Structure

2. Drum • The parking brake is internal expanding type
3. Lever and consists of back plate (5), lever (3), cam-
shaft (4), shoe and lining (1) and other parts.
4. Camshaft
5. Back plate
Function
• If lever (3) is pulled, camshaft (4) rotates to
press shoe and lining (1) against drum (2), thus
the brake is applied.
Unit: mm

1 Lining thickness
4.9 ― 3.5 Replace
2 Wear/Damage of drum 180 0 to +0.1 181
10-66 FH40-1, FH45-1, FH50-1

Undercarriage and frame
Rear axle

Rear axle
4 3
6
A A
5 1
A-A
9JL02241
1. Tire angle sensor

2. Knuckle
Unit: mm

4 King pin diameter Replace
40 39.8
Knuckle top and bottom

5 ― 0.2 Adjust shim
play
6 Center pin diameter 65 64.5
Rear axle, hub, knuckle and Crack, damage and peeling Replace
-
bearing Seizure, abnormal rotation, abnormal noise
FH40-1, FH45-1, FH50-1 10-67

Hydraulic tank piping diagram
Hydraulic tank piping diagram
1. Cap/Gauge
2. Breather
3. Tank cover
4. Filter element
5. Valve
6. Spring
10-68 FH40-1, FH45-1, FH50-1

Frame
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
FH40-1, FH45-1, FH50-1 10-69

Hydraulic system
Control valve piping diagram (tank – control valve)
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)
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)
10-70 FH40-1, FH45-1, FH50-1

Hydraulic system
Work equipment piping diagram (control valve – tilt cylinder/lift cylinder)
Work equipment piping diagram (control valve – tilt cylinder/lift cylinder)
1. Hose (for lift)

2. Control valve
3. Hose (for tilt)
4. Pipe (for tilt)
FH40-1, FH45-1, FH50-1 10-71

Hydraulic system
Attachment piping diagram
Attachment piping diagram
X 128-186 Nm
{13-19 kgfm}
9JM07459
1. Control valve
10-72 FH40-1, FH45-1, FH50-1

Hydraulic system
Work equipment control lever linkage
Work equipment control lever linkage
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
FH40-1, FH45-1, FH50-1 10-73

Hydraulic system
Work equipment and steering pump

Model: LPV45
General view
10-74 FH40-1, FH45-1, FH50-1

Hydraulic system
P1: Pump discharge port

P1C: Pump pressure pickup plug
P2: Gear pump discharge port
PD1: Drain plug
PD2: Drain plug
PEN: Control pressure pickup plug
PLS: LS pressure input port
PP: Pump pressure input port
PS: Pump suction port
1. Pump body
2. Gear pump
3. LS valve
FH40-1, FH45-1, FH50-1 10-75

Hydraulic system
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
10-76 FH40-1, FH45-1, FH50-1

Hydraulic system
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).
FH40-1, FH45-1, FH50-1 10-77

Hydraulic system
Operation • If angle (a) is made between center line (X) of

rocker cam (4) and the axis of cylinder block
Operation of pump (7), plane (A) works as a cam for shoe (5).
• Cylinder block (7) rotates together with shaft (1) • Piston (6) reciprocates inside cylinder block (7)
and shoe (5) slides on plane (A). At this time, and a difference is made between volumes (E)
rocker cam (4) slants around retainer (13), and and (F) in cylinder block (7) and oil is sucked in
consequently angle (a) between center line (X) and discharged by (F) - (E).
of rocker cam (4) and the axis of cylinder block • If cylinder block (7) rotates and the volume of
(7) changes. Angle (a) is called the swash plate chamber (E) is decreased, the oil is discharged
angle. during this stroke. On the other hand, the vol-
ume of chamber (F) is increased and the oil is
sucked in during this stroke. [In the figure,
chamber (F) is at the end of the suction stroke
and chamber (E) is at the end of the discharge
stroke.]
10-78 FH40-1, FH45-1, FH50-1

Hydraulic system
• 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.
• The pump discharge is in proportion to swash

plate angle (a).
FH40-1, FH45-1, FH50-1 10-79

Hydraulic system
LS valve
P1: Pump discharge pressure port Function

PD: Drain port • The LS valve controls the pump discharge
PEN: Control piston pressure port according to the travel of the control lever, or
PLS: LS pressure input port the flow demanded by the actuator.
PP: Pump discharge pressure input port • The LS valve detects the demand flow for the
actuator from differential pressure (∆PLS)
1. Spool between control valve inlet pressure (P1) and
2. Sleeve control valve outlet pressure (PLS), and con-
3. Retainer trols main pump delivery (Q). [(P1) is called the
LS pump pressure, (PLS) the LS pressure, and
4. Spring
(∆PLS) the LS differential pressure.]
5. Screw
• In other words, the pressure loss caused by
6. Nut flow of oil through the opening of the control
valve spool [= LS differential pressure(∆PLS)]
is detected, and then pump delivery (Q) is sup-
plied according to the demand flow for the actu-
ator by controlling it so that the pressure loss
will be constant.
• Main pump discharge pressure (PP), LS pump
pressure (P1) and LS pressure (PLS) are led to
the LS valve. The relationship between LS dif-
ferential pressure (∆PLS) and main pump deliv-
ery (Q) changes as shown below.
10-80 FH40-1, FH45-1, FH50-1

Hydraulic system
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.
FH40-1, FH45-1, FH50-1 10-81

Hydraulic system
Control valve
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.
Since the service valves are single add-on type,

they can be added and removed one by one at any
time.
10-82 FH40-1, FH45-1, FH50-1

Hydraulic system
Control valve
3-spool valve
General view
FH40-1, FH45-1, FH50-1 10-83

Hydraulic system
Control valve
Sectional view (1/2)
10-84 FH40-1, FH45-1, FH50-1

Hydraulic system
Control valve
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
Free length Load at Load at

Installed
x Outside installed Free length installed
12 Spool return spring length
diameter length length
45.58 x 152N 12.2 N

26.5 ―
23.1 {15.50 kgf} {12.4 kgf}
Down control valve spring (for 110.38 x 24.0 N 19.2 N

13 27.3 ―
FH45/50) 27.9 {2.45kgf} {1.96 kgf} Replace spring
if damaged or
Down control valve spring (for 24.81 x 21.5 N 17.2 N deformed
14 22.5 ―
FH45/50) 11.4 {2.19kgf} {1.75 kgf}
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}
FH40-1, FH45-1, FH50-1 10-85

Hydraulic system
Control valve
(2/2)
10-86 FH40-1, FH45-1, FH50-1

Hydraulic system
Control valve
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
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
Free length Load at Load at

Installed
x Outside installed Free length installed
18 Priority valve spring length Replace spring
diameter length length
if damaged or
41.19 x 120N 96.3 N deformed
34.0 ―
13.5 {12.28 kgf} {9.82 kgf}
14.8 N 11.9 N
19 Tilt lock valve spring 26.98 x 7 16 ―
{1.51 kgf} {1.21 kgf}
FH40-1, FH45-1, FH50-1 10-87

Hydraulic system
CLSS
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
10-88 FH40-1, FH45-1, FH50-1

Hydraulic system
CLSS
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)]
a For details of operation, see "work equipment

and steering pump".
FH40-1, FH45-1, FH50-1 10-89

Hydraulic system
Each function and operation of each valve

Hydraulic circuit diagram and names of valves
a The hydraulic circuit diagram shows the 3-spool valve.
10-90 FH40-1, FH45-1, FH50-1

Hydraulic system
1. LS relief valve
Set pressure: 17.15 MPa {175 kgf/cm2}
2. Safety valve with suction
3. Priority 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)
FH40-1, FH45-1, FH50-1 10-91

Hydraulic system
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).
10-92 FH40-1, FH45-1, FH50-1

Hydraulic system
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).
FH40-1, FH45-1, FH50-1 10-93

Hydraulic system
Priority valve
Function
The priority valve distributes the pump delivery to
the steering circuit first.
Operation
When work equipment is operated singly
• Pump pressure (PP) is applied to the right end

of spool (1) and steering LS pressure (STLS) is
applied to the left end [spring (5) chamber].
• Since the steering is not operated, steering LS
pressure (STLS) is approximately 0 MPa {0 kg/
cm2}.
• Spool (1) is moved to the left by a full stroke by
pump pressure (PP) applied to its right end.
• If the work equipment control lever is operated,
pump circuit (PP) is connected to work equip-
ment circuit (W) by spool notch (4) and pump
pressure (PP) flows to the work equipment cyl-
inder.
10-94 FH40-1, FH45-1, FH50-1

Hydraulic system
When steering is operated singly

• When the steering is operated, steering LS
pressure (STLS) is the steering cylinder load
pressure.
• Spool (1) is balanced at an opening area nec-
essary for supplying steering demand flow by
spool notch (4) according to the differential
pressure applied to both ends of spool (1) and
the set load of spring (5).
• If the steering wheel is kept operated oil from
the pump continues to flow to the Orabitrol
becausepump circuit (PP) is connected to
steering circuit (S) by spool notch (4)..
FH40-1, FH45-1, FH50-1 10-95

Hydraulic system
When steering and work equipment are operated simultaneously

• Since the steering is operated, steering LS
pressure (STLS) is the steering cylinder load
pressure.
• Spool (1) is balanced at an opening area nec-
essary for supplying steering demand flow and
work equipment demand flow according to the
differential pressure applied to both ends of
spool (1) and the set load of spring (5).
• If the steering wheel and work equipment are
operated simultaneously, pump circuit (PP) and
steering circuit (S) are connected by spool
notch (4) and oil from the pump flows to the
Orbitrol valve and also flows to the work equip-
ment cylinder since pump circuit (PP) and work
equipment circuit (W) are connected as well.
10-96 FH40-1, FH45-1, FH50-1

Hydraulic system
Down control valve
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
• If lift spool (1) is operated, down control spool

(5) is moved by springs (6) and (7) in the same
direction as that of lift spool (1).
• The stroke of down control spool (5) is con-
trolled by the differential pressure between the
front and rear of orifice (8) and the balance of
springs (6) and (7).
• Return flow (Q) from lift cylinder (3) is the total
of flow (QL) through lift spool notch (2) and flow
(QD) through down control spool notch (4).
FH40-1, FH45-1, FH50-1 10-97

Hydraulic system
Work equipment lock function (priority valve)
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.
10-98 FH40-1, FH45-1, FH50-1

Hydraulic system
When work equipment lock solenoid valve (6) is OFF
• If the signal to work equipment lock solenoid

valve (6) is turned OFF, pump pressure (PP),
as in valve chest (2) at the right end, is applied
to the left end [spring (5) chamber] of spool (1).
• Spool (1) is moved to the right by a full stroke
by spring (5).
• Since spool notch (4) is closed, oil from the
pump does not flow to work equipment circuit
(W) even if the work equipment control lever is
operated.
FH40-1, FH45-1, FH50-1 10-99

Hydraulic system
Lift lock function (lift lock valve)
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.
10-100 FH40-1, FH45-1, FH50-1

Hydraulic system
When lift spool (1) is operated for lowering and lift lock solenoid valve (6) is de-energized
• If lift lock solenoid valve (6) is de-energized, the

check valve spring chamber is filled with the
cylinder pressure and check valve (4) is seated.
• Since check valve (4) does not open even if lift
spool (1) is operated, lift cylinder (7) does not
operate.
FH40-1, FH45-1, FH50-1 10-101

Hydraulic system
Tilt lock function (tilt lock valve)
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
• If tilt spool (1) is operated for tilting forward,

pump pressure (PP) acts on tilt spool notch (6)
through load check valve (2), tilt spool notch (8)
and tilt cylinder (3).
• Since pump pressure (PP) is applied to the left
end of tilt lock valve (5) through tilt spool hole
(7), tilt lock valve (5) pushes spring (4) and
moves to the right.
• When the work equipment control lever is oper-
ated, pump circuit (PP) is connected to work
equipment circuit (W) through spool notch (4),
thus oil from pump flows to the work equipment
cylinder.
10-102 FH40-1, FH45-1, FH50-1

Hydraulic system
When tilt spool is operated for tilting forward and work equipment lock solenoid valve is de-
energized
• If the work equipment lock solenoid valve is de-

energized, pump pressure (PP) is stopped by
the priority valve and is not applied to the left
end of tilt lock valve (5).
• Since tilt lock valve (5) is pressed by spring (4),
tilt spool notch (6) is not connected to the tank,
thus tilt cylinder (3) does not operate even if tilt
spool (1) is operated for tilting forward.
FH40-1, FH45-1, FH50-1 10-103

Hydraulic system
Emergency lowering valve

Function
• When lift lock valve solenoid valve (7) breaks
down or the electric circuit has a trouble, lift cyl-
inder (3) can be lowered manually by using the
emergency lowering valve.
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.
10-104 FH40-1, FH45-1, FH50-1

Work equipment
Tilt cylinder
Work equipment
Tilt cylinder
Unit: mm

Clearance between piston
Bushing inside Piston outside
1 rod and cylinder head 0.032 to
diameter diameter 0.545
bushing 0.239
40 40
Clearance between cylin- Bushing inside

Pin diameter Replace
2 der mounting pin and bush- diameter 0.1 to 0.35 0.6
ing (bottom side) 40 40
Bushing inside
Clearance between rod Pin diameter
3 diameter 0.04 to 0.14 2.5
head pin and head pin hole
35 35
FH40-1, FH45-1, FH50-1 10-105

Work equipment
Lift cylinder
Lift cylinder
1. Drain pipe
Unit: mm
Clearance between cylin- Standard dimension Repair limit Replace

A
der rod and bushing 0.072 to 0.288 0.5 bushing
Clearance between piston Replace

B 0.05 to 0.30 0.5
ring and tube piston ring
10-106 FH40-1, FH45-1, FH50-1

Work equipment
Mast
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
FH40-1, FH45-1, FH50-1 10-107

Work equipment
Mast
Full free mast
1. Front cylinder Outline

2. Rear cylinder • Finger board (4) is raised by front cylinder (1)
3. Chain installed to inner mast (5). Finger board (4) has
the chain structure so it is raised twice the cylin-
4. Finger board
der stroke.
5. Inner mast
• When front cylinder (1) reaches the stroke end,
6. Outer mast inner mast (5) is raised by rear cylinder (2)
installed to outer mast (6). Inner mast (5) is
raised by the same amount as the cylinder
stroke.
10-108 FH40-1, FH45-1, FH50-1

Work equipment
Mast
A3
A5
A4
V
A1
A2,B
B
9JM07761
1. Front cylinder
2. Rear cylinder
3. Block
V: From control valve
FH40-1, FH45-1, FH50-1 10-109

Work equipment
Mast
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.
the oil goes through the routs of (B), and
extends rear cylinder (2).
When the lift is lowered

• When the lift is lowered, the oil flow and order
are reversed.
10-110 FH40-1, FH45-1, FH50-1

Work equipment
Mast
Triple mast
1. Front cylinder Outline

2. Rear cylinder • Finger board (4) is raised by front cylinder (1)
3. Chain installed to inner mast (5). Finger board (4) has
the chain structure so it is raised twice the cylin-
4. Finger board
der stroke.
5. Inner mast
6. Middle mast middle mast (6) and inner mast (5) are raised
7. Outer mast by rear cylinder (2) installed to outer mast (7).
Middle mast (6) is raised by the same distance
as the cylinder stroke, and inner mast (5) is
raised twice the cylinder stroke because of the
chain structure.
FH40-1, FH45-1, FH50-1 10-111

Work equipment
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
1. Front cylinder V: From control valve

2. Rear cylinder T: To tank
3. Block
4. Return hose
10-112 FH40-1, FH45-1, FH50-1

Work equipment
Mast
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.
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.
When the lift is lowered

• When the lift is lowered, the oil flow and order
are reversed.
FH40-1, FH45-1, FH50-1 10-113

Work equipment
Finger board
Finger board
B B
A A
C C
D D
27.4-34.3 Nm
{2.8-3.5 kgfm}
A-A B-B D-D

C-C
9JM07759
1. Finger board
10-114 FH40-1, FH45-1, FH50-1

Work equipment
Fork
Fork
Unit: mm
Right Adjust shim

Clearance between outer A1 0.5 to 1.0 Max. 2.5
A and left
mast and inner mast
Back
A2 0.4 to1.6 Min. 2.0 Replace
and forth
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
D Fork thickness (root) 4.5t lift truck 55 Min. 50
5.0t lift truck 55 Min. 50
FH40-1, FH45-1, FH50-1 10-115

Electrical system
Electrical control system
Electrical system
General system diagra
10-116 FH40-1, FH45-1, FH50-1

Electrical system
FH40-1, FH45-1, FH50-1 10-117

Electrical system
Engine control function
1. Battery Neutral start function

2. Slow-blow fuse • HST controller manages the engine so that the
3. Fuse box engine starts only when the directional lever is
in the N (neutral) position and the brake pedal
4. Starting switch
is depressed more than half.
5. Starting motor relay
* The condition of depressing the brake pedal at
6. Alternator the time of starting the engine exists to fill the
7. Starting motor slack adjuster circuit (from slack adjuster to
8. Directional lever brake piston chamber) with pressure. This is
9. Brake pedal (angle sensor) because the brake may be delayed when the
10. HST controller brake is applied with the circuit not pressurized.
11. PWM relay (engine controller power supply
relay) Function to prevent restarting of the engine
12. Engine controller during engine operation
• HST controller manages the engine so that the
13. Fuel supply pump
starting motor does not operate to protect it
14. Various sensors
when an engine starting operation is performed
15. KOMTRAX terminal by mistake during the engine is running.
16. Accelerator pedal
17. Alarm buzzer KOMTRAX engine cut function
• Engine start can be prohibited by HST control-
ler by sending an engine cut command from the
outside to the KOMTRAX terminal.
10-118 FH40-1, FH45-1, FH50-1

Electrical system
Engine start Engine speed control

• When starting switch (4) is turned to the ON • Engine controller (12) receives an operation
position, engine controller (12) sends a com- signal of accelerator pedal (16) and sends a
mand current to fuel supply pump (13). Accord- command current to fuel supply pump (13),
ingly, a fail-safe mechanism is provided, that is, adjusts the fuel injection rate, and controls
the engine stops when the electrical system engine speed.
has trouble.
• When starting switch (4) is turned to the START Engine stop
position with directional lever (8) in the N (neu- • When starting switch (4) is turned to the "OFF"
tral) position and brake pedal (9) depressed position, the current from the ACC terminal of
more than half, a start current flows through starting switch (4) to engine controller (12) is
starting motor (7) to start the engine. cut off, and consequently the command current
• If directional lever (8) is not in the N (neutral) to supply pump (13) is cut off. Fuel supply
position, or if brake pedal (9) is not depressed pump (13) stops supplying fuel and the engine
more than half, HST controller (10) blocks the speed decreases to stop.
current to starting motor relay (5), so the start
current to starting motor (7) is also blocked and
the engine does not start.
• If directional lever (8) is not in the N (neutral)
position, when starting switch (4) is turned to
the ON position, HST controller (10) sends a
signal to warning buzzer (17) to sound buzzer.
(Intermittent)
• When starting switch (4) is turned to the START
position with directional lever (8) in the N (neu-
tral) position and brake pedal (9) depressed
more than half while the engine is operating,
the current to starting motor relay (5) is blocked
because HST controller (10) detects L terminal
voltage of 20V or more at alternator (6) that
makes it determine the engine is operating.
Start current doesn't flow to starting motor (7),
which prevents the starting motor pinion from
engaging during operation.
• When KOMTRAX terminal (15) receives an
engine cut command from the external opera-
tion, HST controller (10) receives a signal, and
HST controller (10) blocks the current to start-
ing motor relay (5) to block the start current to
starting motor (7), so the engine cannot be
started.
FH40-1, FH45-1, FH50-1 10-119

Electrical system
Automatic engine output adjustment function
1. Lift cylinder pressure sensor Input/output signal

2. HST controller a. CAN signal
3. Engine controller b. Lift cylinder pressure signal
4. Fuel supply pump c. Accelerator signal
5. Various sensors
8. Control valve
9. Lift lever
10. Lift cylinder
10-120 FH40-1, FH45-1, FH50-1

Electrical system
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.
It selects the higher torque (T1) when the lift

cylinder pressure is high (high load weight) or
the lower torque (T2) when the lift cylinder pres-
sure is low (low load weight).
By switching the maximum output torque of the

engine under the conditions above, fuel con-
sumption can be reduced when the accelerator
pedal is depressed fully with no or light load,
and load can be lifted at the maximum lifting
speed when the load is heavy, and the maxi-
mum travel performance can be achieved with-
out poor acceleration.
Load weight and lift cylinder pressure

Lift cylinder
Model *Load weight
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]
* Indicates load weight with the standard

work equipment (mast, board, guard, and
fork).
FH40-1, FH45-1, FH50-1 10-121

Electrical system
Automatic warm-up function
1. Battery Input/output signal

2. Slow-blow fuse a. CAN signal
3. Starting switch b. Directional lever signal
4. Fuse box c. Accelerator signal
5. Directional lever
6. HST controller
7. Engine controller
9. Fuel supply pump
10. Various sensors
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.
10-122 FH40-1, FH45-1, FH50-1

Electrical system
Automatic preheating function
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
FH40-1, FH45-1, FH50-1 10-123

Electrical system
Automatic engine stop function

2. Slow-blow fuse a. Parking lever switch (brake release position)
3. Starting switch signal
4. Fuse box b. Directional lever signal
5. Parking lever switch c. Seat switch signal
6. Directional lever d. HST oil temperature signal
7. Seat switch e. Alarm buzzer output signal
8. HST oil temperature sensor f. CAN signal
9. HST controller g. Accelerator pedal signal
10. Alarm buzzer h. Engine sensor signals
11. Engine sensors i. Injector control output signal
14. Injector
10-124 FH40-1, FH45-1, FH50-1

Electrical system
Function • This function maintains the lift interlock even

• When HST controller detects an elapse of the when the operator is on the seat during the
set time (factory setting is 120 seconds) under engine stop. To cancel the lift interlock, restart
the conditions below, it outputs no injection the engine after sitting on the seat, or turn the
command of the injector to the engine controller starting switch to the OFF position and then to
via CAN signal, and the engine stops because the ON position.
the injector stops fuel injection. • This function prevents the engine from being
• Countdown buzzers sound from 5 seconds left running when the operator gets off as well
before the set time elapses. as reduces fuel consumption.
• This function sounds the alarm buzzer intermit- • The method to restart the engine is the same as
tently to encourage the operator to turn the starting the engine.
starting switch to the OFF position when the
engine is not running. (To prevent a dead bat-
tery)
Operating condition
(Operates when all the conditions below Operation
are satisfied and the set time elapses)
• Not on the seat
• The parking lever is at the lock position.
• FNR lever is at the N position.
• The fuel dial throttle is 5% or less. Setting time is over
• The coolant temperature is 50°C or (It is activated 5 seconds
before setting time is over.)
more.
• The coolant temperature is 95°C or
[1] The engine stops.
less.
[2] Buzzer sounds (intermittent).
• HST oil temperature is 95°C or less. [3] The lift interlock maintenance
• The battery voltage is 26V or more. control operates.
It is activated 5 seconds
• The engine speed is 700rpm or more.
before setting time is over.
• CAN communication with the engine
Engine stopped
controller is normal. The countdown buzzer
• No failure occurred in HST controller sounds.
system.
• No failure occurred in the engine con-
troller system.
(1) Conditions for releasing the engine stop state Release

• Engine restart
(Depress the brake pedal with the directional lever at
→ • Start engine.
the N position, and turn the starting switch to the START
position.)
(2) Conditions for releasing buzzer

Release
(When any of the following conditions is satisfied)
• Engine restart
→ • Buzzer sound stops.
• Turn the starting switch to the OFF position.
(3) Conditions for releasing the lift interlock holding con-

trol Release
(When any of the following conditions is satisfied)
• The operator sits down and restarts the engine.
• The operator sits down and turns the starting switch to
→ • Lift interlock released
the OFF position and turns the starting switch to the ON
position.
FH40-1, FH45-1, FH50-1 10-125

Electrical system
Buzzer sound pattern for engine stop countdowan
Buzzer sound pattern after the engine stops
* After that, the cycle is repeated.
Automatic engine stop set time change function

• The time before automatic engine stop oper- a When a user asks for setting of the 60 seconds
ates can be set in the following 6 stages with automatid engine stop, explain the user that
the service mode. 60 sec/120 sec/180 sec/240 there is a risk of shorter life of the battery and
sec/300 sec/OFF starting motor due to the increased number of
• The factory setting is 120 sec. starting.
• This function is protected by special operation a For the method to change the automatic engine
as a service function. stop set time, refer to "Displaying, setting,
checking by using HST Controller" in "Testing
and adjusting."
10-126 FH40-1, FH45-1, FH50-1

Electrical system
Travel speed limit function
1. HST controller Travel speed limit function for general operator

2. Engine controller • When the travel speed limit change switch is
3. Travel speed limit change switch turned to the ON position, the travel speed sig-
nal is monitored to control the upper limit value
4. Travel speed limit indicator lamp
of engine speed automatically to limit the travel
speed below the set speed even when the
6. Travel speed sensor accelerator pedal is depressed fully.
7. Fuel supply pump • Because the travel speed signal is monitored to
8. Various sensors control the upper limit of engine speed by feed-
9. HST pump back, the travel speed drops when the brake is
10. HST motor depressed and the upper limit of engine speed
11. Drive axle assembly increases to maintain the target travel speed
when inching operation is performed. There-
Input/output signal fore, operation can be done without dropping
a. Travel speed limit change switch signal lifting speed as if travel speed is not limited.
• The specified travel speed can be maintained
b. Travel speed limit indicator lamp output signal
when it is loaded or traveling uphills because
c. CAN signal
the travel speed signal is monitored to control
d. Accelerator signal the upper limit of engine speed by feedback.
e. Travel speed signal
• The following 4 sttages of travel speed can be
set. (Approximately 5km/h, approximately 8km/
h, approximately 15km/h, no limit)
a For the method to set the limit travel speed,
refer to "Displaying, setting, checking by using
HST Controller" in "Testing and adjusting."
FH40-1, FH45-1, FH50-1 10-127

Electrical system
Functions for administrators

• The following 2 functions that are protected by
special operation are provided as functions for
administrators.
1). Maximum travel speed limit function
This function limits the maximum speed of
the lift truck.
The travel speed is limited even when the
travel speed limit change switch is in the
OFF position.
If the limit travel speed of the travel speed

limit function for general operators is set to
8km/h and the maximum travel speed of the
maximum travel speed limit function is set
to 15km/h, the lift truck can travel at 15km/h
when the travel speed limit change switch is
in the OFF position, or at 8km/h when the
travel speed limit change switch is in the
ON position.
2). Limited travel speed change prohibition

function
This function prohibits a change of limited
travel speed of the travel speed limit func-
tion for general operators.
a For the method to set the functions for adminis-

trators, refer to "Displaying, setting, checking by
using HST Controller" in "Testing and adjust-
ing."
10-128 FH40-1, FH45-1, FH50-1

Electrical system
Reminder function for leaviing seat without returning directional lever to N position

2. Slow-blow fuse a. Seat switch signal
4. Fuse box c. Alarm buzzer output signal
5. Directional lever
6. Seat switch
7. HST controller
8. Alarm buzzer
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
FH40-1, FH45-1, FH50-1 10-129

Electrical system
Travel interlock function

4. Fuse box c. Travel interlock warning lamp (and neutral indi-
5. Directional lever cator lamp) output signal
6. Seat switch d. HST pump forward side EPC solenoid output
7. HST controller signal
8. Travel interlock warning lamp (and neutral indi- e. HST pump reverse side EPC solenoid output
cator lamp) signal
9. HST pump forward side EPC solenoid f. CAN signal
10. HST pump reverse side EPC solenoid g. Accelerator signal
11. HST pump h. Alarm buzzer output signal
12. HST motor
13. Drive axle assembly
17. Various sensors
18. Alarm buzzer
10-130 FH40-1, FH45-1, FH50-1

Electrical system
Function
• When the operator leaves the seat with the
directional lever in F or R position, the seat
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)
FH40-1, FH45-1, FH50-1 10-131

Electrical system
Lift interlock function

4. Fuse box c. Lift interlock warning lamp output signal
5. Directional lever d. Work equipment lock solenoid output signal
6. Seat switch e. Lift lock solenoid output signal
7. HST controller f. CAN signal
8. Lift interlock warning lamp g. Accelerator signal
9. Work equipment pump h. Alarm buzzer output signal
10. Priority valve
11. Work equipment lock solenoid
12. Lift lever
13. Lift valve
14. Lift lock solenoid
15. Tilt lever
16. Tilt valve
17. Lift cylinder
18. Tilt cylinder
22. Various sensors
23. Alarm buzzer
10-132 FH40-1, FH45-1, FH50-1

Electrical system
Function
• When the operator leaves the seat, the seat
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
• 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
• On the seat • Output to the work equipment lock solenoid
→
• The starting switch is in the ON position. • Output to the lift lock solenoid
FH40-1, FH45-1, FH50-1 10-133

Electrical system
When automatic engine stop operates

• When the automatic engine stop operates, lift
interlock is maintained when the operator sits
on the seat to prevent wrong operation. To can-
cel the loading interlock, restart the engine after
sitting on the seat, or turn the starting switch to
the OFF position and then to the ON position.
Operating condition
Operation
• Automatic engine stop operates. • Lift interlock maintenaning control operates.
• Alarm buzzer sounds.
(Output to the work equipment lock solenoid is
→
stopped)
(Output to the lift lock solenoid is stopped)
(The lift interlock warning lamp blinks)
↓
Release condition
Release
(releases when any of the conditions below is satisfied)
• The operator sits down and starts the engine. • Alarm buzzer sound stops.
• The operator sits down and turns the starting switch to • Output to the work equipment lock solenoid
→
the OFF position and turns the starting switch to the ON • Output to the lift lock solenoid
position. • The lift interlock warning lamp goes out.
10-134 FH40-1, FH45-1, FH50-1

Electrical system
Parking reminder function
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
FH40-1, FH45-1, FH50-1 10-135

Electrical system
When the engine is running (alternator L terminal voltage is high and starting switch is at ACC)
Operating condition
Operation
• 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
• 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
• The parking brake reminder lamp blinks.
• The parking lever is in the free position. →
• Alarm buzzer sounds (intermittent).
↓
Release condition
Release
• The parking brake reminder lamp goes out.
• The parking lever is in the lock position. →
• Alarm buzzer sound stops.
10-136 FH40-1, FH45-1, FH50-1

Electrical system
Parking drag prevention function

2. Slow-blow fuse a. Parking lever switch (brake release position)
3. Starting switch signal
4. Fuse box b. Directional lever signal
5. Parking lever switch c. Brake pedal angle signal
6. Directional lever d. CAN signal
7. HST controller e. Alarm buzzer output signal
8. Brake pedal (angle sensor) f. Abnormality warning lamp output signal
9. Engine controller g. Accelerator pedal signal
11. Alarm buzzer
12. Abnormality warning lamp
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
• 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.
FH40-1, FH45-1, FH50-1 10-137

Electrical system
HST controller
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
10-138 FH40-1, FH45-1, FH50-1

Electrical system
HST controller
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 –
FH40-1, FH45-1, FH50-1 10-139

Electrical system
Engine controller
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 –
10-140 FH40-1, FH45-1, FH50-1

Electrical system
Engine controller
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 –
FH40-1, FH45-1, FH50-1 10-141

Electrical system
Accelerator pedal sensor
1. Pedal Output characteristics

2. Connector
3. Sensor
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.
Idle validation signal

• The sensor detects the operating condition of
the accelerator pedal. It outputs the signal input
to pin No. 5 from pin No. 4 when the accelerator
pedal is released, and outputs the signal input
to pin No. 6 from pin No. 4 when the accelerator
pedal is depressed.
10-142 FH40-1, FH45-1, FH50-1

Electrical system
FH40-1, FH45-1, FH50-1 10-143

Electrical system
EPACS controller
EPACS controller
1. Orbitrol valve 5. Connector for solenoid valve connection

2. Solenoid valve block 6. Plug terminal for initial setting
3. EPACS controller 7. LED for condition display
4. Connector for wheel angle sensor connection
1. Wire and connector list
No. Wire color Pin No. Function Connector type
― 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)
10-144 FH40-1, FH45-1, FH50-1

Electrical system
EPACS controller
2. Outline of failure indication

Condition of LED
No. Problem Detail of failure Repair method Remarks
on controller
1) Check and repair controller
1 Knob deviates. Goes out. Controller malfunctions. power supply circuit.
2) Replace controller.
1) Check that controller plug is
open. (It is normally open:
2 ↑ Repeats 1 flash Initialization is not completed.
taken off)
2) Perform initial setting.
1) Perform initial setting from
first
2) Check and correct wheel
angle sensor installation
Under initial setting
3 ↑ Repeats 2 flashes 3) Check and correct loose
(May be normal) (*1)
rotor installed on the Orbit-
rol
Supply anti-rotation (tighten
and lock screws)
Steering wheel angle sensor mal-
4 ↑ Repeats 3 flashes. Replace controller.
functions.
Wheel angle sensor malfunctions.
• Disconnection or short circuit of 1) Check and repair wheel
signal line with-GND angle sensor (including
5 ↑ Repeats 4 flashes
installation).
• Wheel angle sensor installation 2) Check and repair wheel
is incorrect (direction). angle sensor circuit.
1) Check and repair Wheel
(1) Short circuit of wheel angle angle sensor (including
sensor power supply with sig- installation).
nal line 2) Check and repair wheel
angle sensor circuit.
1) Check if solenoid valve is
turned ON/OFF during
(2) Correction solenoid valve fail-
steering operation.
ure
2) Check and repair solenoid
valve wiring harness.
6 ↑ ON (*2)
1) Check and repair loose
rotor.
(3) Idle rotation of Orbitrol rotor
Supply anti-rotation (tighten
and lock screws).
(4) Controller solenoid valve drive 1) Perform (2).
circuit failure 2) Replace controller.
1) Check if initial setting can
(5) Short circuit in steering wheel be performed.
angle sensor 2) Perform (1).
*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)".
FH40-1, FH45-1, FH50-1 10-145

Electrical system
Instrument panel
Instrument panel
1. Main body Function

2. Combination switch • It is installed near the steering handle and dis-
3. Service meter plays fuel level, coolant temperature, warning
lamp, and operation hours.
4. Fuel gauge
5. Coolant temperature gauge
6. Indicator lamp
10-146 FH40-1, FH45-1, FH50-1

Electrical system
Instrument panel
Circuit diagram
Pole destination
FH40-1, FH45-1, FH50-1 10-147

Electrical system
Pilot box
Pilot box
1. HST oil temperature warning lamp Function

2. Parking brake indicator lamp • This pilot box is installed to the dashboard. Its
3. Parking brake reminder lamp operation is controlled by HST controller.
• The lamps light up and blink to warn of an error
4. HST oil filter clogging warning lamp
of the function or display the condition.
5. Travel speed limit indicator lamp
• The lamps light up and blink to display the pat-
6. Sedimenter (water separator warning lamp) tern of limit speed setting condition. The lamps
also display the condition in which the limit
speed is being set.
• The lamps light up and blink to display the pat-
tern of HST pump adjustment and brake pedal
angle sensor adjustment conditions.
• HST oil filter clogging warning lamp (4) displays
the history of the electric system failure codes.
• HST oil temperature warning lamp (1), HST oil
filter clogging warning lamp (4), and sedimenter
(water separator) warning lamp (6) display the
history of the mechanical system failure codes
of the functions.
10-148 FH40-1, FH45-1, FH50-1

Electrical system
DC/DC converter
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
FH40-1, FH45-1, FH50-1 10-149

Electrical system
KOMTRAX system
KOMTRAX system
• The KOMTRAX terminal transmits various

information of the lift truck by use of the radio
communication. KOMTRAX operator can refer
this information and provide various services to
the customers.
a To provide the services, you need to estab-
lish radio station for the KOMTRAX system
separately.
Information transmitted by the KOMTRAX terminal

includes
• Service meter reading
• Position information
• Fuel level
and others.
10-150 FH40-1, FH45-1, FH50-1

Electrical system
KOMTRAX system
KOMTRAX terminal
Model: TC530
1. GPS antenna connection port Outline

2. Lift truck wiring harness connection port • The KOMTRAX terminal can obtain various
3. Communication antenna connection port information of the lift truck through the network
signals and input signals in the lift truck and
transmit information through the wireless com-
munication antenna. It has a CPU (central pro-
cessing unit) installed inside and has the
wireless communication function and GPS
(global positioning system) function.
• The KOMTRAX terminal cannot be used in a
country other than specified in the communica-
tion contract.
• The display section has LED lamps and 7-seg-
ment lamp indicator used for testing and trou-
bleshooting.
FH40-1, FH45-1, FH50-1 10-151

Electrical system
KOMTRAX system
TYPE4 terminal connector signal table

AMP 173866-1 (8+12 potes)
Input or output Input or output

Part-PIN No. Signal Part-PIN No. Signal
signal signal
A-1 NC – B-1 Power supply GND –
A-2 NC – B-2 Power supply GND –
A-3 NC – B-3 ACC signal Input
A-4 NC – B-4 For R terminal input Input
A-5 NC – B-5 NC –
A-6 NC – Continuous power supply
B-6 Input
For network type selec- (12V)
A-7 Input
tion Continuous power supply
B-7 Input
For network type selec- (12V)
A-8 Input
tion Engine restart prohibition
B-8 Output
A-9 NC – output
A-10 CAN (+) Input/Output For radio station estab-
B-9 Input
lishment connector
A-11 CAN (-) Input/Output
B-10 NC –
A-12 NC –
B-11 For C terminal input Input
A-13 NC –
B-12 NC –
A-14 NC –
A-15 NC –
A-16 NC –
A-17 NC –
A-18 NC –
10-152 FH40-1, FH45-1, FH50-1

Electrical system
Sensor
Sensor
Fuel level sensor
1. Connector Maintenance standard

2. Float 1. The resistance value is continuously variable.
3. Arm 2. The specified resistance value must be
obtained at the following float position.
Function Fuel level Resistance Fuel in tank
• It is installed on the top face of the fuel tank.
+2
Float (2) moves up and down according to the Full (F) 0 -0 Ω 84l
fuel level.
1/2 (1/2) 50±3Ω 57l
• The movement of float(2)activates the variable
resistor through arm (3). The fuel level is dis- Empty (E) 150±10Ω 14l
played on the instrument panel with the change
of resistance corresponding to the operation
angle of arm (3).
FH40-1, FH45-1, FH50-1 10-153

Electrical system
Sensor
Wheel angle 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.
10-154 FH40-1, FH45-1, FH50-1

Electrical system
Sensor
Travel speed sensor
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
FH40-1, FH45-1, FH50-1 10-155

Electrical system
Sensor
HST oil temperature sensor
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.
10-156 FH40-1, FH45-1, FH50-1

Electrical system
Sensor
HST circuit oil pressure sensor
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.
FH40-1, FH45-1, FH50-1 10-157

Electrical system
Sensor
Brake pedal angle sensor
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.
10-158 FH40-1, FH45-1, FH50-1

Electrical system
Sensor
Brake charge pressure sensor
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.
FH40-1, FH45-1, FH50-1 10-159

Electrical system
Sensor
HST oil filter clogging sensor
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.
10-160 FH40-1, FH45-1, FH50-1

Electrical system
Sensor
Coolant temperature sensor
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.
FH40-1, FH45-1, FH50-1 10-161

Electrical system
Sensor
WIF (water-in-fuel) sensor
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.
10-162 FH40-1, FH45-1, FH50-1

Electrical system
Combination switch
Combination switch
1. Main body Function

2. Directional lever switch • It is built in between the steering wheel and
3. Light and turn signal lamp lever switch instru panel and turns the directional lever
switches, turns the light on and off, turns the
4. Horn switch
turn signal lamp lever switch, and turns the
5. Connector
horn switch ON and OFF.
FH40-1, FH45-1, FH50-1 10-163

Electrical system
Seat 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
10-164 FH40-1, FH45-1, FH50-1

Electrical system
Service switch/Preheater lamp
Service switch/Preheater lamp
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.
FH40-1, FH45-1, FH50-1 10-165

Electrical system
Flasher unit
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.
10-166 FH40-1, FH45-1, FH50-1

Electrical system
Relay box
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.
FH40-1, FH45-1, FH50-1 10-167

Electrical system
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.
10-168 FH40-1, FH45-1, FH50-1

Electrical system
Relay
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
FH40-1, FH45-1, FH50-1 10-169

Electrical system
Relay
10-170 FH40-1, FH45-1, FH50-1

FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
FH40-1, FH45-1, FH50-1 20-1

Table of Contents
Table of Contents
Standard value table .............................................................................................................................. 20-3
Standard value table .......................................................................................................................... 20-3
20-2 FH40-1, FH45-1, FH50-1

Standard value table

EquipmentWork Item Unit FH40-1 FH45-1 FH50-1
Engine model ― SAA4D95LE-5-C
Idling speed rpm 800±25
Basic engine Max. speed rpm 2,200±25
HST stall speed rpm 1,650 ± 50
MPa {kg/cm2}
Compression Min. 29 {Min. 30}/150 to250
/rpm
Engine oil capacity l 11
Lubricating oil Coolant quantity l 9

cooling
system Fan belt tension
Engine
(58.8 N {approximately mm 7 to 10
6kgf} finger pressure)
Injection timing deg-BTDC Electronic control system
Injection order ― 1-2-4-3

Fuel system
Injection pressure MPa {kg/cm2} 25.4 to 108 {250 to 1,100}
Fuel tank capacity l 105
Intake mm 0.35 (Cold)

Intake, exhaust Valve clear-
system ance
Exhaust mm 0.50 (Cold)
Battery electrolyte specific

Electric system ― 1.28 (20°C)
gravity
PTO Oil quantity l 5.5
High pressure relief pres-

Power train
MPa {kg/cm2} 36.3 to 38.3 {370 to 391}

sure
HST
HST charge circuit pres-
MPa {kg/cm2} 2.9±0.5 {30±5}
sure
Differential Oil quantity l 11
Front wheel kPa {kg/cm2} 800 {8.0} (single tire)

Traveling equipment
Inflation
Tire
pressure
Rear wheel kPa {kg/cm2} 850 {8.5} 1,000 {10.0}
Front wheel Nm {kgm} 294 to 490 {30 to 50}

Tightening
Hub nut
torque
Rear wheel Nm {kgm} 294 to 490 {30 to 50}
FH40-1, FH45-1, FH50-1 20-3

EquipmentWork Item Unit FH40-1 FH45-1 FH50-1
Steering wheel Play mm 10 to 30
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
With no load m Max. 5

Service Distance to
Brake stop
With load m Max. 2.5
Parking brake lever operat-

N {kg} 59 to 69 {6 to 7}
Parking ing effort
Brake Back plate mounting bolt
Nm {kgm} 59 to 74 {6 to 7.5}
tightening torque
Fork thickness (at base) mm Min. 50
Fork Height difference mm Max. 15
Tip opening mm Max. 35

Loading equipment
Chain Length of 17 links mm Max. 440
Hydraulic drift mm/15min Max. 50

Cylinder
Hydraulic drift tilting
mm/15min Max. 45
amount
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}
20-4 FH40-1, FH45-1, FH50-1

FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
FH40-1, FH45-1, FH50-1 30-1

Table of Contents
Table of Contents
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
30-2 FH40-1, FH45-1, FH50-1

Testing and adjusting
Check of failure code of engine controller

The electronically controlled engine controller of this lift truck issues the failure code if a failure occurs.
To check the failure code, there are two methods as follows.
(1) Check of the failure code by using a troubleshooting tool (PC)
(2) Check of the failure code by using KOMTRAX server screen
• The following functions are available in the troubleshooting tool.
1) Display of failure code
2) Deletion of failure code
3) Display of repair procedure
a Prepare the tools needed for the troubleshooting.

Symbol Part Name (Part No.) Remarks
Troubleshooting software • Diesel-engine/Gasoline-
CD-ROM engine model
(3EB-97-50030) common parts
• Windows 2000, Win-

dows XP
Windows Vista-compati-
A ble
Troubleshooting PC
software (KOMATSU FORKLIFT
(CD-ROM) distributor needs to prepare.)
Intermediate cable Only for diesel-engine lift

(3EA-55-38880) truck
Communication cable CANBUS made by Kvaser

C (3BA-97-71220) (Common parts to FB-12/
FBR-14)
FH40-1, FH45-1, FH50-1 30-3

Displaying the failure code by using a troubleshooting tool (PC)

a Description on how to use the software is
Install troubleshooting software (A) from CD-ROM included in CD-ROM.
to PC.
1. Turn the starting switch to the OFF position.
2. Open the cover at the left end on the top of the

dashboard upward.
3. Disconnect connector cap (1A) where connec-

tor (1) of the wiring harness is connected. Con-
nect communication cable (C) and intermediate
cable (B) of the troubleshooting software to
connector (1) in this order.
4. Connect intermediate cable (B) to PC.
5. Start up the installed software and check the

failure code.
30-4 FH40-1, FH45-1, FH50-1

Example of display of failure code
FH40-1, FH45-1, FH50-1 30-5

Displaying, setting, checking by using HST controller

1. Adjustment of brake pedal and HST pump
a When the electrical or hydraulic component shown in the following table is adjusted or replaced, adjust
the system as follows.
k Be sure to adjust the system, otherwise the lift truck may move unexpectedly.
System
Component Reference
Adjustment item
page
HST controller Adjustment of brake pedal angle sensor 30-25

HST pump adjustment (1) 30-25
HST pump adjustment (2) 30-26
HST pump HST pump adjustment (1) 30-25

HST pump EPC HST pump adjustment (2) 30-26
HST motor HST pump adjustment (1) 30-25
Brake pedal Adjustment of brake pedal angle sensor 30-25

Brake pedal angle sensor
a When the controller is replaced with a new one, the abnormality warning lamp lights up continuously until
the specified adjustment process is completed.
30-6 FH40-1, FH45-1, FH50-1

2. Ordinary and special functions of HST controller

HST controller is equipped with ordinary and special functions.
1) Ordinary function: Operator mode
This function becomes available when an operator performs the special operation. (For the operating
method, see Operation and Maintenance Manual or Shop Manual.)
2) Special function: Service mode
This function becomes available when a technician performs the special operation. (For the operat-
ing method, see Shop Manual.)
Reference Reference
No. Operator mode No. Service mode
page page
Travel speed control function for general Maximum travel speed control function (for
1. 30-8 2. 30-11
operator administrator)
Banning function of changing controlled
3. 30-14
travel speed (for administrator)
Electrical-system abnormality record dis-
4. play function 30-16
(Only for HST controller system)
Mechanical-system abnormality record dis-
5. 30-22
play function
Adjusting function
6. (HST pump and brake pedal angle sensor 30-23
adjustment function)
7. Memory clear function 30-30
Automatic engine stop set interval changing
8. 30-33
function
State transition diagram
Service mode 7 5 Mechanical-system

Memory clear mode abnormality record
display mode
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
FH40-1, FH45-1, FH50-1 30-7

Travel speed control function for general operator (description in Operation and Maintenance Manual of the lift truck)
Travel speed control function for

general operator
(description in Operation and
Maintenance Manual of the lift
truck)
When the travel speed control function is enabled
(ON), the travel speed is limited to the set value.
The controlled speed is set in 4 stages depending
on the operating condition.
(Approximately 5 km/h, Approximately 8 km/h,
Approximately 15 km/h, No control)
a Controlled travel speed is initially set to approx-

imately 15 km/h.
a The travel speed control selector switch allows
to switch between enabled (ON) and release
(OFF) even during the travel operation.
Travel speed control selector switch (2)

This switch allows for general operator to switch
between enabled (ON) and release (OFF) of the
travel speed control function .
When this switch is in the enabled position (ON),
travel speed control indicator lamp (1) lights up.
Enabled (ON): Operate the switch upward.

Release (OFF) Operate the switch downward.
k If the travel speed control selector switch is

switched unexpectedly, collision or load
collapsing may occur due to acceleration
or deceleration.
k Before operating the switch, be sure to
c he c k the s af e ty of the co ndit ions o f
surroundings and load.
30-8 FH40-1, FH45-1, FH50-1

Setting controlled travel speed
Setting controlled travel speed • Alarm buzzer (0.2 second) sounds.

• Parking brake indicator lamp (6) lights up
1) Set the lift truck in the following conditions. and then 6 indicator lamps (5) blinks.
• Turn the key of the starting switch to the This notifies of entry of the travel setting mode.
"OFF" position. Release service switch (3) and brake pedal (4).
• Place the parking lever in the LOCK posi-
tion.
• Place the directional lever in N (NEUTRAL)
position.
• Turn the travel speed control selector
switch to Release position (OFF).
a If 6 indicator lamps do not blink, repeat the

procedure from the first.
3) When pressing service switch (3),

• alarm buzzer (0.2 second) sounds,
• and indicator lamp (5) lights up.
2) Turn the key of the starting switch to the "ON" By the lighting pattern of indicator lamp (5), the
position (do not start the engine), co ntrol travel spe ed cu rren tly set can be
within 12 seconds, checked.
• while pressing service switch (3), Example: When the current set speed is 15 km/h
• fully depress brake pedal (4).
Keep this condition for 5 seconds or more.
If this operation is performed correctly, the
travel speed control indicator lamp blinks at
every second.
FH40-1, FH45-1, FH50-1 30-9

Setting controlled travel 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
6) When pressing down service switch (3) for 3

seconds or longer after setting the lighting pat-
a If the change of the controlled travel speed tern of the travel speed to be set,
is banned by the administrator, the control • alarm buzzer (0.4 second) sounds,
travel speed settings cannot be changed or • the indicator lamp changes from blinking to
selected (the indicator lamp does not blink). lighting up
to notify of the completion of the setting.
5) The pattern of the indicator lamp switches Example: Setting to 8 km/h
every time switching travel speed control selec-
tor switch (2) to OFF → ON → OFF. The control
travel speed to be set can be selected.
a When pressing service switch (3) again

after the setting is completed, the control
travel speed setting can be changed or
selected again.
7) Turn the starting switch key to the OFF position

to exit the setting.
a When turning the starting switch key to the
OFF position, starting the engine, or placing
the parking brake lever to FREE position
during the setting, the setting exits and the
control travel speed is not changed.
30-10 FH40-1, FH45-1, FH50-1

Maximum travel speed control function
Maximum travel speed control Maximum travel speed control setting

1) Set the lift truck in the following conditions.
function • Turn the key of the starting switch to the
"OFF" position.
The maximum travel speed of the lift truck can be
• Place the parking lever to the LOCK
controlled.
Even when travel speed control selector switch (2) position.
is in Release position (OFF), the travel speed is • Place the directional lever to N (NEU-
limited to the set value. TRAL) position.
This setting is protected by the special operation to • Turn the travel speed control selector
prevent general operators from using this setting. switch to Release position (OFF).
The controlled speed is set in 4 stages depending 2) Turn the key of the starting switch to the
on the operating condition. "ON" position. (Do not start the engine.)
(Approximately 5 km/h, Approximately 8 km/h, Within 12 seconds,
Approximately 15 km/h, No control) • while pressing service switch (3),
a The maximum travel speed control function is • fully depress brake pedal (4).
initially set to No control (Max. speed). Keep this condition for 5 seconds or more.
If this operation is performed correctly, the
travel speed control indicator lamp blinks
every second.
• Alarm buzzer (0.2 second) sounds,

• The parking brake indicator lamp lights
up and then 6 indicator lamps (5) blinks.
This notifies of entry of the travel setting
mode. Release service switch (3) and brake
pedal (4).
FH40-1, FH45-1, FH50-1 30-11

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).
• Alarm buzzer (0.2 second) sounds,

• and neutral indicator lamp (6) blinks
to notify that the maximum travel control
can be set.
5) When pressing service switch (3),

• and the indicator lamp lights up.
Then, the maximum travel speed settings
can be changed or selected.
Example: When currently set speed is 15 km/h
a Only the operation described in 3)is dif-

ferent from the operating method in
"Travel speed control value for general
operator".
30-12 FH40-1, FH45-1, FH50-1

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.
8) Turn the starting switch key to the OFF

position to exit the setting.
a When turning the starting switch key to
the OFF position, starting the engine, or
placing the parking brake lever to FREE
position during the setting, the setting
exits and the maximum travel speed is
not changed.
7) When pressing down service switch (3) for

3 seconds or longer after setting the lighting
pattern of the travel speed to be set,
• the indicator lamp changes from blink-
ing to lighting up
to notify of the completion of the setting.
Example: Setting to 12km/h
FH40-1, FH45-1, FH50-1 30-13

Banning function of changing controlled travel speed
Banning function of changing • Alarm buzzer (0.2 second) sounds.

• The parking brake indicator lamp lights
controlled travel speed up and then 6 indicator lamps (5) blinks
to notify of entry of the travel speed set-
When setting this function to "Enabled", changing
ting mode.
the travel speed control function for general opera-
tor is banned. Release service switch (3) and brake pedal
This setting is protected by the special operation to (4).
prevent general operators from using this setting.
a The banning function of changing controlled
travel speed is initially set to "Release".
Banning setting of changing controlled

travel speed
• Turn the key of the starting switch to the
"OFF" position.
position.
• Place the directional lever to the N
(NEUTRAL) position.
• Turn the travel speed control selector a If 6 indicator lamps do not blink, repeat
switch to Release position (OFF). the procedure from the first.
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.
30-14 FH40-1, FH45-1, FH50-1

Banning function of changing controlled travel speed
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.
• Alarm buzzer (0.4 second) sounds

to notify that the banning setting of chang-
in g c o n t r o ll e d t r a v e l s p e e d is s e t t o Example: When the control travel speed is set to
"Enabled" or "Release". 1 5 k m/h a nd the ba nn in g se ttin g o f
ch an ging co ntrolle d tra vel sp ee d is
• When the previous setting is "Release", "Release", the lighting condition changes
the setting changes to "Enabled". from lighting up to blinking by pressing
When the previous setting is "Enabled", the service switch.
the lighting condition of the monitor
does not change from lighting up to
blinking (the control travel speed can be
changed) even by pressing service
switch (3).
When setting to "Enabled", press ser-
vice switch (3) to check that lighting
condition does not change from lighting
up to blinking.
• When the previous setting is "Enabled",

the setting changes to "Release". By
pressing service switch (3), the lighting
condition of the monitor changes from
a The operation described in steps 1 to 3
lighting up to blinking (the control travel
in "Banning setting of changing con-
speed can be changed).
trolled travel speed" is the same as the
Whe n setting fro m "En abled" to
operating method in "Travel speed con-
"Release", press service switch (3) to
trol value for general operator".
check that lighting condition changes
from lighting up to blinking.
5) Turn the starting switch key to the "OFF"
position to exit the setting.
FH40-1, FH45-1, FH50-1 30-15

Electrical-system abnormality record display function (only for HST controller system)
Electrical-system abnormality record display function

(only for HST controller system)
a HST controller records the failures previously- 1. How to switch to electrical-system abnor-
occurred in the electrical system with 2-digit mality record display mode
failure code. The following operations allows 1) Check that the starting switch key is in the
the shift to failure code history display mode to ON position.
display the failure code by the blinking pattern 2) For service switch (3),
of HST oil filter clogging warning lamp (1) [1] Press down it for 2 seconds or more
depending on the type of failure code. and then release it.
a The 20 failure records can be displayed in [2] Press down it for 2 seconds or more
descending (new) order of SMR at the time of and then release it again.
the failure. Buzzer sounds for 0.2 seconds. The
a For the code of the currently-occurring failure, lig h t in g o f H S T o il f i lt e r c l o g g in g
travel speed control indicator lamp (2) blinks. warning lamp (1) changes to blinking in
the pattern specified to the type of
failure code.
a This function is available during the engine

operation or stop.
a If the process fails, restart from "[1] in step
2)" to enable the function.
a When entering this mode, the alarm buzzer
stops.
30-16 FH40-1, FH45-1, FH50-1

2. How to read failure code display

a By the blinking pattern of HST oil filter clog-
ging warning lamp (1), the 2-digit failure
code is displayed.
• The number of longer lighting indicates the
2nd digit (ten's place) of the failure code.
• The number of shorter lighting indicates the
1st digit (1's place) of the failure code.
Example of display: Lift truck failure code "23" (Failure of HST pump B port pressure sensor)
a For details of the displayed failure code, Example)

see "Failure codes list".
3. How to display old failure codes

a The 20 failure records can be recorded in
descending (new) order of SMR at the time
of the failure.
a In case of the multiple previously-occurring
failures, display them according to the fol-
lowing procedure.
1) Press service switch (3) shortly during the
failure display mode. Buzzer sounds for 0.1
second, and then the old failure codes are
displayed.
a When pressing the service switch while
the oldest failure is displayed, buzzer
sounds consecutively 3 times (for 0.1
seconds X 3) once, and the display
returns to the latest failure code.
FH40-1, FH45-1, FH50-1 30-17

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".
4. How to exit electrical-system failure code

history display mode
a By either of the following 3 types of opera-
tion, the failure display mode exits.
"OFF" position.
• Depress the accelerator pedal.
• For service switch (3),
[1] Press down it for 2 seconds or more
and then release it.
and then release it again.
* Same as the procedures to switch
from the normal condition to the fail-
ure display mode.
30-18 FH40-1, FH45-1, FH50-1

Failure codes list

a Failure code:
The code is sorted in a numerical and alphabetical order.
a Lift truck failure code:
A failure code displayed for the lift truck.
(To switch to the failure code display mode, see Testing and adjusting, "HST controller special function".
a KOMTRAX failure code
A failure code displayed on the server screen of KOMTRAX when a failure occurs
a History category:
Indicates that the related failure code is stored to either of electrical or mechanical system.
a Applicable component:
Indicates the controller system of the occurred failure.
HST: Controller system
ENG: Engine controller system
a Action code:
Classified into 4 categories depending on the details of the failures. However, they are not displayed.
Action Influence Abnormality Individual warning lamp
Buzzer Alarm type Operator's action
code degree warning lamp (To be displayed if it exists.)
Inspection and mainte-
L01 Low ● ● - Failure
nance after work
"Operate at low speed
of engine and lift truck."
L02 Middle ● Damage caution "Stop the work and
● ● (Intermittent)
operate at medium
speed with no load."
Stop the work and
move the lift truck to a
L03 High ● Failure safe place to perfprm
● ● (Intermittent)
inspection and mainte-
nance.
Immediately stop the lift
● truck to perform the
L04 High ● ● Failure
(Continuous) inspection and mainte-
nance.
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
FH40-1, FH45-1, FH50-1 30-19

Failure code
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
32 DXATKB Ground fault HST L04
valve system
DXATKY Hot short circuit HST L04
valve system
Reverse travel HST pump EPC solenoid Electrical
DXAUKA Open circuit HST L04
valve system
33 DXAUKB Ground fault HST L04
valve system
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
30-20 FH40-1, FH45-1, FH50-1

Failure code
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
47 D161KB Ground fault HST L01
relay system
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
system
FH40-1, FH45-1, FH50-1 30-21

Mechanical-system abnormality record display function
Mechanical-system abnormality 2. Mechanical system failure item to be dis-

played
record display function
1) HST oil filter clogging
• HST controller records the failures previously-
occurred in the mechanical system. By the fol- 2) HST oil temperature overheat
lowing operations, if a mechanical-system fail-
ure occurs previously once at least, the related 3) Sedimenter
warning lamp lights up. (Fluid in the fuel pre-filter)
4) Abnormality in alternator charging
1. How to switch to mechanical-system abnor- system
mality record display mode
5) Lowered engine oil pressure
During the electrical-system abnormality record
display mode, for the travel speed control 6) Brake accumulator
selector switch (2), Low oil pressure (occurred during the
[1] Switch from OFF to ON position and hold it engine operation)
for 5 seconds or more.
[2] Return from ON to OFF position. * Only for an abnormality due to low oil pres-
sure in the brake accumulator (while the
a When performing the same operation as engine is running), the abnormality warning
described above, lamp lights up because the meter panel is
From "Mechanical-system abnormality record not equipped with an individual warning
display mode", lamp.
↓ a The mechanical-system abnormality record
Return to "Electrical-system abnormality cannot be deleted.
record display mode".
3. How to exit mechanical-system abnormality
record display mode
• By either of the following 3 types of opera-
tion, the failure display mode exits.
1) Turn the key of the starting switch to the
"OFF" position.
2) Depress the accelerator pedal.
3) For service switch (3),
and then release it.
and then release it again.
* Same as the procedures to switch from
th e n orma l co nditio n to the failu re
display mode.
30-22 FH40-1, FH45-1, FH50-1

Adjusting function
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.
1. How to switch the adjustment mode (waiting

for selection)
"OFF" position.
position.
• Place the directional lever to N (NEU-
TRAL) position.
State transition
Normal mode
* Adjust each item from adjustment 1

mode (waiting for selection). Adjustment mode
(waiting for selection)
2 3 4
Adjustment of brake HST pump adjustment HST pump adjustment
pedal angle sensor (1) (2)
FH40-1, FH45-1, FH50-1 30-23

Adjusting function
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.
a When switching to the adjustment mode

(awaiting selection), HST oil filter clogging
warning lamp (1) and travel speed control
indicator lamp (2) blink alternately.
If it does not change to the adjustment
mode, restart from item 1).
30-24 FH40-1, FH45-1, FH50-1

Adjusting function
2. Adjustment of brake pedal angle sensor Perform the following operation.

Records the angles on the releasing and [1] Set to the adjustment mode (waiting for
depressing sides of the brake pedal to HST selection).
controller to correct the installation error. [2] Start the engine.
1) During the adjustment mode (waiting for [3] Place the parking brake lever to the release
selection), position.
[1] Release the brake pedal and hold it. [4] Place the directional lever to F (FOR-
[2] Switch the travel speed control selector WARD) position. (Adjustment of the pump
switch to OFF → ON → OFF. on the forward side)
• The alarm buzzer starts to sound [5] Fully depress the accelerator pedal.
intermittently. • The buzzer sounds intermittently and
• HST oil filter clogging warning lamp the lift truck starts to move in the for-
(1) itself blinks. ward direction slowly.
[3] Securely depress the brake pedal to the (If the re's an y dan ger, rele ase the
travel end. accelerator pedal or depress the brake
[4] Turn the travel speed control selector pedal. In this case, the adjustment pro-
switch to OFF → ON → OFF. cess is canceled. Restart from [4].)
• When the adjustment is completed, [6] When the adjustment is completed, the
the buzzer sounds for 1 second. buzzer sounds for 1 second.
• Entering the adjustment mode a If the lift truck moves 1m or longer and
(awaiting selection), HST oil filter the adjustment cannot be completed,
clog g ing w ar n in g lam p (1 ) a n d inspect the travel speed sensor.
travel speed control indicator lamp [7] Release the accelerator pedal.
(2) blink alternately. [8] Place the directional lever to N (NEUTRAL)
If the buzzer to notify of the adjustment position.
comple tion d oes no t sou nd, th e [9] Place the directional lever to R (REVERSE)
operation fails. Restart from [1]. position. (Adjustment of the pump on the
* Available during the engine opera- reverse side)
tion. [10] Fully depress the accelerator pedal.
• The buzzer sounds intermittently and
3. HST pump adjustment (1) th e lift tr uc k star ts t o mo ve in th e
Adjust the the variation at the beginning of the reverse direction slowly.
lift truck running due to the manufacturing varia- (If the re's an y dan ger, rele ase the
tion of individual HST pump. accelerator pedal or depress the brake
k Check that the lift truck is under the fol- pedal. In this case, the adjustment pro-
lowing conditions. cess is canceled. Restart from [4].)
• Hydraulic oil temperature must be [11] When the adjustment is completed, the
within the range between 30 and 50°C. buzzer sounds for 1 second.
• There must be no obstacles within 5m a If the lift truck moves 1m or longer and
or more before and after the lift truck. the adjustment cannot be completed,
* When adjusting the pump, do not inspect the travel speed sensor.
allow anyone to enter the surrounding [12] Release the accelerator pedal.
area of the lift truck because it moves [13] Place the directional lever to N (NEU-
a p p r o xi ma t e ly 0 . 3 m in f o rw a rd o r TRAL) position.
rev ers e d irec tio n ( wh en the tra ve l [14] Place the parking brake lever to the LOCK
speed sensor and pump is normal). position.
• The lift truck must be parked on the • Entering the adjustment mode (awaiting
paved roads. (Parking on the slope is selection), HST oil filter clogging warn-
prohibited.) ing lamp (1) and travel speed control
• The wheels to steer must be straight indicator lamp (2) blink alternately.
against the body.
• The work equipment must not touch the How to exit the adjustment mode
ground. Turn the key of the starting switch to the "OFF"
position.
FH40-1, FH45-1, FH50-1 30-25

Adjusting function
4. HST pump adjustment (2)

Adjust the variation at the engine torque match-
ings during acceleration and loading of the lift
truck due to the manufacturing variation of indi-
vidual HST pump.
Check before adjustment work

Note the compensation value stamped on HST
pump in advance.
Mark position
The compensation value is selected from the following symbols.

F E D C B A 0 1 2 3 4 5 6
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.
30-26 FH40-1, FH45-1, FH50-1

Adjusting function
Correlation between the compensation value and lighting pattern
[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)
FH40-1, FH45-1, FH50-1 30-27

Adjusting function
[8] 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
service switch during the lighting pattern
that indicates the current compensation
value, the adjustment mode (waiting for
selection) is set again.
Example: When "Compensation value C" is cur-
rently set
[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.
30-28 FH40-1, FH45-1, FH50-1

Adjusting function
[10] During the lighting pattern of the compen-

sation value marked on HST pump, press
down the service switch for 3 seconds or
longer and release it.
• The alarm buzzer to notify of the adjust-
ment completion of the reverse side
HST pump sounds (0.4 second).
• The adjustment mode (waiting for
selection) is set.
* At this time, if the service switch is
release d b efore 3 se cond s, th e
compensation value is not recorded.
* When HST controller is replaced with a
new one, be sure to press down the
service switch for 3 seconds or longer
a n d t h e n r e le a s e it t o r e c o r d t h e
compensation value even in case that
the va lue of the pump is "0". If the
adjustmen t mod e exits with out
recording, HST controller does not
accept it as the adjustment completion
and the abnormality warning lamp lights
up.
How to exit the adjustment mode

Turn the key of the starting switch to the "OFF"
position.
FH40-1, FH45-1, FH50-1 30-29

Memory clear function

Data item that can be deleted
Item number Adjustment item Outline
2. SRAM load frequency The lift truck's load frequency data accumulated in HST controller
Electrical-system abnormality
3. Electrical-system failure code history of HST controller system
record
4. E2P load frequency Load frequency data to be sent to KOMTRAX
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.)
1. How to switch to memory clear mode (wait-

ing for selection)
"OFF" position.
position.
• Place the directional lever to N (NEU-
TRAL) position.
30-30 FH40-1, FH45-1, FH50-1

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.
a When switching to the memory clear

mode (waiting for selection), HST oil fil-
ter clogging warning lamp (1) blinks.
If it does not change to the memory
clear mode, restart from item 1).
FH40-1, FH45-1, FH50-1 30-31

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.
30-32 FH40-1, FH45-1, FH50-1

Automatic engine stop set interval changing function
Automatic engine stop set • Alarm buzzer (0.2 second) sounds.

• The parking brake indicator lamp lights up
interval changing function and then upper and lower 3 indicator lamps
of 6 indicator lamps (3) blink alternately to
• The set interval until the automatic engine stop
notify of entering the change mode of the
operates can be selected from the following 6
stages. automatic engine stop set interval.
• 60 seconds/120 seconds/180 seconds/240
seconds/300 seconds/OFF
• Factory default is "120 seconds".
• This setting is protected by the special opera-
tion as the function for services.
a When setting to "60 seconds" upon request
from users, explain them about possible
decrease in the battery or starting motor life
due to increase in the number of starting.
Setting method
1. Set the lift truck in the following conditions.
"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).
FH40-1, FH45-1, FH50-1 30-33

Automatic engine stop set interval changing function
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.
Example: When setting is made

to 300 seconds
5. The pattern of the indicator lamp switches

every time switching travel speed control selec-
tor switch (3) to OFF → ON → OFF. The set
interval can be selected. a When pressing service switch (1) again
after the setting is completed, the set
interval can be changed or selected
again.
7. Turn the starting switch key to the "OFF" posi-

tion to exit the setting.
a When turning the starting switch key to the
"OFF" position, starting the engine, or plac-
ing the parking brake lever to FREE posi-
tion during the setting, the setting exits and
the set interval is not changed.
30-34 FH40-1, FH45-1, FH50-1

Releasing pressure from hydraulic piping
Releasing pressure from

hydraulic piping
k When releasing the pressure from the
hydraulic piping, be sure to sit on the
opera tor's sea t and opera te the lev er.
Otherwise, the shut off valve closes and the
pressure cannot be released.
1. Stop the lift truck and lower the fork to the

ground.
2. Stop the engine.
3. Turn the starting switch to the ON position (2).
4. Sit on the operator seat and operate the lift and

tilt levers backward and forward 5 to 6 times
each to release the pressure in the hydraulic
circuit.
5. Releasing remaining pressure in brake

accumulator circuit
a When disconnecting each piping between
the accumulator charge valve and brake
accumulator and between accumulator and
brake valve, release pressure from the cir-
cuit according to the following procedure.
1) Stop the engine.
2) Depress the brake pedal at least 50 times
to release the pressure from the brake
accumulator circuit.
FH40-1, FH45-1, FH50-1 30-35

Replacement of engine oil and engine oil filter
Replacement of engine oil and

engine oil filter
k Before the engine maintenance, stop and
sufficiently cool down the engine.
Engine oil
1. Remove drain plug (1) to drain the oil.
2. After draining the oil, tighten drain plug (1).

3 Drain plug (1):
44.1 to 58.8 Nm {4.5 to 6.0 kgm}
3. Fill the specified amount of the engine oil from

oil filler port (2)
4. Check the oil level by using oil level gauge (3).

Refill capacity: 11 l
30-36 FH40-1, FH45-1, FH50-1

Replacement of engine oil and engine oil filter
Engine oil filter

1. By using the filter wrench, remove cartridge (4).
2. Clean the filter holder, apply the engine oil to

the seal and thread portions of the new car-
tridge (4), and then install the cartridge to the fil-
ter holder.
a After installation of cartridge (4), start the
engine and check whether or not the oil
leaks from the filter mounting face.
FH40-1, FH45-1, FH50-1 30-37

Replacement of fuel filter
Replacement of fuel filter 5. Clean the filter holder.

a When filling the filter cartridge with fuel, per-
The fuel filter of this lift truck is equipped with the form the filling operation with cap (A) fitted.
pre-filter and main filter cartridges. a Cap (A) acts to prevent the entry of dirt or
dust into the filter cartridge.
k After the engine stops, all parts are still
v e r y h ot , s o do n ot r e pl a c e t he f i lt e r
immediately. Sufficiently cool down the
parts before replacement.
k When replacing the filter, wait for at least 30
seconds after stopping the engine to let the
internal pressure go down before replacing
the filter.
k Do not bring any open flame close.
a A special filter with high-efficiency filtering prop-

erties is adopted for Komatsu genuine fuel filter
cartridges. Be sure to use Komatsu genuine
parts when replacing.
a The common rail fuel injection system adopted 6. Fill the filter cartridge with clean fuel through
for this lift truck is configured with components the 8 small holes (B) in the new filter cartridge.
of higher accuracy compared with conventional
injection pumps and nozzles. If any cartridge 7. Apply oil to the packing surface of the filter car-
other than a Komatsu genuine fuel filter cartridge.
tridge is used, foreign material may enter and it
may cause problems in the injection system. Do 8. Remove filter cartridge cap (A) and install it to
not use substitute parts. the filter holder.
a For inspection and maintenance of the fuel sys-
tem, more care should be taken for the mixing 9. When installing the cartridge, tighten it until the
of foreign matters than before. Attached dirt, if packing surface contacts the sealing surface of
any, must be fully washed off using engine oil. the filter holder, then tighten it by 3/4 of a turn.
a If the filter cartridge is tightened too much,
Replacement of fuel pre-filter cartridge the packing will be damaged and this leads
to leakage of fuel. If the filter cartridge is too
Prepare a filter wrench. loose, fuel will also leak from gaps of the
packing. Therefore, be sure to observe the
1. Open the engine hood. fastening angle.
a When using a filter wrench, be careful not
2. Remove PTO breather bypass hose (1). to dent or damage the filter.
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).
12. Install breather bypass hose (1).
13. Start the engine, check that there is no leakage

of fuel from the filter seal portion, and then run
for approximately 10 minutes at low idling.
30-38 FH40-1, FH45-1, FH50-1

Replacement of fuel filter
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.
3. Clean the filter holder.

a Do not fill the new filter cartridge with fuel.
a Cap (A) acts to prevent the entry of dirt or
dust into the filter cartridge.
4. Apply oil to the packing surface of the filter car-

tridge.
5. Remove filter cartridge cap (A) and install it to

the filter holder.
6. When installing the cartridge, tighten it until the

packing surface contacts the sealing surface of
the filter holder, then tighten it 3/4 of a turn.
a If the filter cartridge is tightened too much,
the packing will be damaged and this leads
to leakage of fuel. If the filter cartridge is too
loose, fuel will also leak from gaps of the
packing. Therefore, be sure to observe the
fastening angle.
a When using a filter wrench, be careful not
to dent or damage the filter.
FH40-1, FH45-1, FH50-1 30-39

Fuel pre-filter water drain
Fuel pre-filter water drain

1. Place a container under drain hose (2) of fuel
pre-filter (1).
2. Loosen drain plug (3) to drain the sediment and

water accumulated at the bottom of the pre-fil-
ter.
3. When fuel starts flowing out through drain hose

(2), tighten drain plug (3) securely.
a Completely wipe off any spilled fuel.
30-40 FH40-1, FH45-1, FH50-1

Fuel filter air bleeding
Fuel filter air bleeding

1. Loosen air bleeding plug (2) of the bracket of
fuel pre-filter (1).
2. Loosen and pull out knob (3) of the priming

pump. Operate it backward and forward.
3. Check that fuel flows out of air bleeding plug (2)

and then tighten plug (2).
3 Air bleeding plug (2):
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
4. Loosen air bleeding plug (5) of fuel main filter

(4).
5. Loosen and pull out knob (3) of the priming

pump. Operate it backward and forward.
6. Check that fuel flows out of air bleeding plug (5)

and then tighten plug (5).
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
FH40-1, FH45-1, FH50-1 30-41

Cleaning of water separator strainer
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.
a If replacing damaged strainer, be sure to use a

Komatsu genuine part.
a If any water separator other than a Komatsu
genuine part is used, foreign material may
enter, and it may cause problems in the injec-
tion system.
Do not use substitute parts.
a For inspection and maintenance of the fuel sys-
tem, more care should be taken for the mixing
of foreign matters than before. Attached dirt, if
any, must be fully washed off using engine oil.
1. Remove side cover on the left side of the

machine.
2. Pull drain hose (2) of water separator (1) out.

Provide a container to catch drained oil.
3. Loosen pressure relief plug (3) on the top of

water separator (1) and drain valve (4) on the
bottom of it, and drain the fuel to the container.
Tighten pressure relief plug (3) and drain valve
(4) after fuel is completely drained.
3 Pressure relief plug (3):
2 to 4 Nm {0.2 to 0.4 kgm}
3 Drain valve (4):
1 to Nm 2 {0.1 to 0.4 kgm}
a Completely wipe off any spilled fuel.
4. Loosen ring nut (5), and take cup (6) out.
5. Take strainer (7) from separator base.
6. Clean inside the strainer (7) and cup (6).
7. Check strainer (7), and replace it if any damage

is found.
8. Clean separator base, install the strainer (7)

which is cleaned to the separator base.
30-42 FH40-1, FH45-1, FH50-1

Radiator 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).
3. Close drain valve (2) at the bottom of the radia-

tor and fill it with radiator detergent liquid and
clean water (city water) from the water filler
port. Run the engine at low idle for approxi-
mately 15 minutes.
4. Stop the engine and open drain valve (2) at the

bottom of the radiator to drain radiator deter-
gent liquid and clean water (city water).
5. Run the engine at low idle until clean water is

drained from drain valve (2) at the bottom of the
radiator while supplying radiator detergent liq-
uid and clean water (city water) from the water
filler port. (5 ti 10 minutes)
6. Stop the engine and drain clean water (city

water).
FH40-1, FH45-1, FH50-1 30-43

Air cleaner inspection and element replacement
Air cleaner inspection and Replacement of element

element replacement 1. Remove latches (3) (3 places) of cover (2) and
remove cover (2).
k Do not clean and replace the air cleaner
during the engine running.
k When using the compressed air to clean
the element, wear protective eyeglasses to
protect yourself from dirt that will fly out.
a If any grease or carbon sticks to the element,

use the special cleaner for the element to clean
it according to the procedure described in the
Operation and Maintenance Manual of the
cleaner.
a If the working environment or condition is poor,
clean or replace the air cleaner element earlier.
Check of air cleaner 2. Remove the outer element (4).
1. Check the display of dust indicator (1).
3. Clean inside of body (6).
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.
6. If the lip portion of evacuator valve (7) is

cracked, replace it.
7. Fit new outer element (4) to body (6) and install

cover (2).
30-44 FH40-1, FH45-1, FH50-1

Testing and adjusting engine speed
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.
FH40-1, FH45-1, FH50-1 30-45

Testing and adjusting engine speed
a Hook the wire rope to the part directed

by an arrow in the following figure.
[4] On the prepared lift truck to be towed,

start the e ngine, ap ply the parking
brake, and fu lly depress the brake
pedal.
(An operator must be seated also on
the operator's seat of the towed lift
truck.)
[5] On the lift truck to be measured, place
the directional lever in F (FORWARD)
position, slowly and fully depress the
accelerator pedal, and stall the engine.
k Move the lift truck slowly and be care-
ful not to apply any sudden load to the
wire rope.
k Do not allow anyone to enter the sur-
rounding area of the lift truck during
the measurement.
a Measure the engine speed during the

HST stall 2 or 3 times.
a Do not keep stalling for more than 20
seconds. Take care that HST oil tem-
perature does not exceed 105°C.
30-46 FH40-1, FH45-1, FH50-1

Testing and adjusting HST oil pressure
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.
FH40-1, FH45-1, FH50-1 30-47

Measurement of HST charge circuit oil pressure Adjusting

1. After removing hose (2) connected to the block Adjustment of high pressure oil relief valve
on the top of HST and installing adapter J2, (pump side)
install hydraulic tester J1. a If the high pressure relief oil pressure is not nor-
mal, ad just hig h pre ssu re relief valve (3)
according to the following procedure.
1. Loosen lock nut (4) of high pressure relief valve
(3) and turn adjustment screw (5) to adjust.
a When the adjustment screw is:
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure
is decreased.
a Quantity of pressure adjustment per turn of
adjustment screw
20.5 MPa {209 kg/cm2}
2. After finishing the adjustment, tighten lock nut

(4).
3 Locknut: 339 to 49 Nm {4 to 5 kgm}
2. Start the engine.
3. Measure the oil pressures when the engine

speed is the rated speed and when the direc-
tional lever is in N (NEUTRAL) position, and the
pressure during forward or reverse travel.
a When the lift truck stops, only the charge
safety valve on the pump side operates.
When the lift truck travels, the charge relief
valve on the motor side also operates.
a After the adjustment completed, check that

high pressure relief oil pressure is normal.
30-48 FH40-1, FH45-1, FH50-1

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)
a After finishing the adjustment, check that

HST charge circuit pressure is normal
according to the above testing procedure. 4. After finishing the adjustment, check that HST
charge circuit pressure is normal according to
the above testing procedure.
FH40-1, FH45-1, FH50-1 30-49

Testing work equipment and steering pump oil pressure
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
a HST oil temperature at measurement:

45 to 55°C
a Check that no leakage of hydraulic oil occurs at
each of the joints.
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
3. Start the engine and tilt the mast backward, and

measure the oil pressure when it is relieved.
4. After finishing the test, remove the testing tools

and restore the lift truck.
30-50 FH40-1, FH45-1, FH50-1

Oil level check and changing oil in differential case
Oil level check and changing oil in Changing Oil

differential case 1. Place a container under drain plug (2) to catch
the oil.
k Since oil is heated high immediately after
the operation, wait until it is cooled before 2. Remove drain plug (2) to drain the oil into the
starting your work. container.
k Stop the lift truck on a level ground, and
chock the wheels. If the lift truck suddenly 3. Tighten drain plug (2).
moves off, serious personal injuries may 3 Drain plug (2):
occur. 128 to 186 Nm {13 to 19 kgm}
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.
3. Wipe off the gauge portion of oil level gauge (1)

by using cloth and insert it to the oil filler port
again.
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.
6. After adding, check the oil level.
FH40-1, FH45-1, FH50-1 30-51

Changing PTO oil and cleaning strainer
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
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.
2. Remove drain plug (3) to drain the oil to the

container.
3. Tighten drain plug (3).

3 Drain plug (3):
59 to 78 Nm {6 to 8 kgm}
4. Remove mounting bolt (5) of strainer cover (4)

and remove strainer (6).
5. Clean strainer (6) by using cleansing oil.
6. Blow compressed air from inside of cleaned

strainer (6) to remove the cleansing oil and suf-
ficiently dry the strainer.
7. Install strainer (6).
8. Install the strainer cover.

3 Strainer cover mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
30-52 FH40-1, FH45-1, FH50-1

Inspection of hydraulic tank
Inspection of hydraulic tank 4. After disconnecting the hoses, remove cover

(2) and line filter (3).
Change oil in hydraulic tank
Replacement of hydraulic oil line filter
Cleaning hydraulic tank strainer
Cleaning inside of hydraulic tank
Cleaning hydraulic tank breather

the operation, wait until it is cooled before
starting your work.
1. Stop the engine.
2. Place a container under drain plug (1) of the

hydraulic tank to catch the oil.
3. Remove drain plug (1) to drain the oil to the

container.
* The silicon-based liquid gasket is applied to

the frame side surface of packing (9) to pre-
vent from removal.
When removing cover (2) and packing (9),
remove the applied gasket.
5. Remove strainer (4).
6. Clean strainer (4) by using cleansing oil.
7. Blow compressed air from inside of cleaned

strainer (4) to remove the cleansing oil and suf-
ficiently dry the strainer.
8. Clean inside of hydraulic tank.
FH40-1, FH45-1, FH50-1 30-53

Inspection of hydraulic tank
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).
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.
22. Run the engine at high idle and then, perform

the operation of Step 21.
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
16. Remove HST pump upper surface plug (10) to

refill with the oil: 1 l
30-54 FH40-1, FH45-1, FH50-1

Measuring brake performance
Measuring brake performance
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.
2. When the travel speed reaches the speed of

the measuring condition, depress the brake
pedal with the specified depressing force.
a Before performing this test, fix the runway
and the point for applying the brakes, then
apply the brakes when the lift truck reaches
that point.
3. Measure the distance between the point where

the brake is applied and the point where the lift
truck stops.
a Repeat this measurement three times and
take the average.
FH40-1, FH45-1, FH50-1 30-55

Measurement of wear of service brake disc
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):
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.
1. Stop the engine.
2. Remove right and left caps of brake disc wear

check port (1), horn (3), and return piping block
(4)
3. Remove brake disc wear check gauge (2).

a Brake disc wear check gauge (2) is also
used as the oil level gauge.
4. Depress the brake pedal to the travel end and

hold it.
5. Insert brake disc wear check gauge (2) to brake

disc wear check port (1), and rotate it.
a If brake disc wear check gauge (2) rotate 1
tu rn , the d is c ex cee d s we a r limit a nd
replace the disc with a new one.
30-56 FH40-1, FH45-1, FH50-1

Checking parking brake
Checking parking brake Checking wear of brake lining and

brake drum
Checking shoe clearance
k Stop the lift truck on a level ground, and chock the wheels. If the lift truck suddenly
chock the wheels. If the lift truck suddenly moves off, serious personal injuries may
moves off, serious personal injuries may occur.
occur.
1. Stop the engine.
1. Stop the engine.
2. Release the parking brake.
2. Release the parking brake.
3. Remove parking brake cable (3).
3. Pull the parking brake lever by the power of 30
to 50 N {3 to 5 kgf}. 4. Pull the cable mounting position of the parking
brake lever by the power of 30 to 50 N {3 to 5
4. Measure travel (a) at the cable mounting posi- kgf}.
tion when operating the parking brake lever.
• When tfavel (a) is 2.5 mm or more, the 5. Measure travel (b) at the cable mounting posi-
brake is normal. tion of the parking brake when operating the
cable mounting position of the parking brake.
• When travel (b) is 36 mm or less, the brake
is normal.
6. If travel (b) is more than 36 mm, replace the

shoe of the parking brake or replace the brake
drum.
7. After checking or replacing, check the operating

effort of the parking brake lever.
• Parking brake lever operating effort:
59 to 69 N {6.0 to 7.0 kgf}
5. If travel (a) is less than 2.5 mm, adjust the

travel to 2.5 mm or more by using cable adjust-
ment screw (1) of the parking brake.
FH40-1, FH45-1, FH50-1 30-57

Bleeding air
Bleeding air 7. Check the hydraulic oil level by using level

gauge (4) of the hydraulic tank and add the
Brake piping hydraulic oil to the drained level.

occur.
k Perform the work with two workers. One
worker depresses the brake pedal and the
other bleeds air from the air bleeding plug.
a Bleed air right and left separately.
1. Remove cap (1) of the bleeder on the top of the

front axle.
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.
occur.
1. Start and run the engine at low idle.
2. Raise or lower the mast and stop it at 100 mm

before the highest or lowest position.
3. Repeat the operations in 2. 4 or 5 times.
4. Raise or lower the mast to the highest or lowest

position.
3. Depress the brake pedal while the engine is 5. Repeat the operations in 4. 4 or 5 times.
running at low idle.
4. Slowly loosen air bleeding plug (2) and fully

depress the brake pedal when no more bubbles
come out from the hose. Tighten air bleeding
plug (2) while the oil is flowing.
5. Bleed air from the other side of the brake

according to the same procedure.
6. After air bleeding is completed, tighten the air

bleeding plug and install the cap.
30-58 FH40-1, FH45-1, FH50-1

Adjusting brake pedal
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.
3. After adjusting brake pedal (1), adjust clear-

ance (d) of thread part of stop lamp switch (7).
• Clearance (d): 0 to 0.4 mm
a When height (a) of the brake pedal is

adjusted, be sure to adjust the brake pedal
angle sensor. For details, see Testing and 4. After adjusting the brake pedal, install the
adjusting "Displaying, setting, checking by cover.
using HST controller".
FH40-1, FH45-1, FH50-1 30-59

Testing and adjusting brake pedal angle sensor linkage
Testing and adjusting brake pedal Adjusting

1. When the brake pedal has the correct angle,
angle sensor linkage adjust the length of rod (2) to standard dimen-
sion (L).
Testing
a Standard dimension (L): 122.5 mm
1. Remove the floor mat, cover, and floor plate.
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.
4. Check the voltage of the brake pedal angle

sensor.
k To prepare for the voltage measurement,
turn the starting switch to the "OFF"
position.
[1] Connect T-adapter between connectors
P14 (male) and (female) on the side of the
brake pedal angle sensor.
a Part No. of T-adapter: 799-601-9030
[2] Turn the starting switch to the "ON" position
and measure the voltage between (A) and
(B) of connector P14.
a Connect positive (+) side of the tester
lead to (A) side of connector P14.
a Connect negative (-) side of the tester
lead to (B) side of connector P14.
30-60 FH40-1, FH45-1, FH50-1

Testing and adjusting brake pedal angle sensor linkage
Related circuit diagram
Condition Model Voltage

Do not depress the
FH40/45/50-1 3.3±0.1V
pedal.
Fully depress the
FH40/45/50-1 1.7±0.2V
pedal.
a If the voltage is out of the range of the

standard value, readjust it.
If the voltage is out of the range of the
standard value even by adjusting it
again, replace the angle sensor.
5. After finishing the work, restore the lift truck.

a When the brake pedal angle sensor linkage
is adjusted, be sure to adjust the brake
pedal angle sensor. For details, see Testing
and adjusting "Displaying, setting, checking
by using HST controller".
See page 30-6 in Testing and adjusting.
FH40-1, FH45-1, FH50-1 30-61

Initial setting of Orbitrol valve
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.
9. Check that state display LED (2) lights up.

a If state display LED (2) does not lights up
but continuously blinks twice, restart the
work from step 1.
2. While the starting switch is in the "OFF" posi-

tion, connect initialization plug terminal (1).
3. Turn the starting switch to the "ON (ACC)" posi-

tion and check that state display LED (2) blinks.
4. Check that state display LED (2) blinks once.

a If state display LED (2) is OFF for a long
period of time or blinks 3 or 4 times, the
steering wheel angle sensor is abnormal. At
this time, check the steering wheel angle
sensor for open circuit or short circuit and
repair it.
5. Start the engine and operate the steering wheel

to check that the tires and steering wheel are in
the straight forward direction.
a If the tires and steering wheel are not in the
straight forward direction, restart from step
1.
30-62 FH40-1, FH45-1, FH50-1

Measurement of hydraulic drift and forward tilt down by hydraulic drift of cylinder
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.
3. Stop the lift truck 500 mm before the pallet.
4. Raise load height (H) to 1,500 mm and set mast

(1) vertically.
9. After leaving it for 15 minutes, read mark (B) of

piston rod (5) and obtain the forward tilt down
by hydraulic drift during the last 15 minutes.
• Forward tilt down by hydraulic drift for 15
minutes: 45 mm or less
FH40-1, FH45-1, FH50-1 30-63

Adjustment of mast
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.
3. Check the runout of the mast in right and left

directions.
4. In case of runout of the mast in right and left

directions, add shim (3) between lift cylinder (1)
and mast stay (2) on the runout side.
• Shim thickness (t) = 1.0 mm
30-64 FH40-1, FH45-1, FH50-1

Adjustment of mast
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
FH40-1, FH45-1, FH50-1 30-65

Adjustment of mast
Adjustment by shim for the strip

portion
1. Insert shim (6) so that clearance (b) between
the strip and rail is fixed all over the inner rail
when pushing the rail to the main roller.
• Clearance (b): 0.1 to 0.4 mm
• Standard clearance (b): 0.3 mm
30-66 FH40-1, FH45-1, FH50-1

Adjustment of fork carriage
Adjustment of fork carriage Selection of main roller on lower side

and adjustment by shim
1. Select roller (2) so that clearance (a) between
the rail of inner mast (1) and main roller (2) on
the lower side is within the following range.
• Clearance (a): 0.4 to 1.6 mm
a Only 1 type of roller is set for FH40/45/
50-1.
2. Raise the fork carriage to the highest position.
3. Insert shims (3) of the same thickness on the

r ig ht a n d le ft sid es s o th at clea ran ce (c)
between the rail and roller (2) is within the fol-
lowing range.
• Clearance (c): 0.5 to 1.0 mm
Selection of main roller on upper side

and intermediate main roller
1. Select roller (4) so that clearance (b) between
the rail of inner mast (1) and main roller (4) on
the upper side or intermediate main roller is
within the following range.
• Clearance (b): 0.4 to 1.6 mm
a Only 1 type of roller is set for FH40/45/
50-1.
• Standard shim thickness: 1 mm
FH40-1, FH45-1, FH50-1 30-67

Adjustment of fork carriage
Shim adjustment for the side roller Adjustment of chain

1. Raise the fork carriage to the highest position. 1. Check the mounting condition of the lift chain to
the outer mast to adjust the tension of right and
2. Adjust clearance (d) between the rail of inner left chains to be the same.
mast (1) and upper side roller (5) so that it is
within the range from 0.01 to 0.3 mm by using 2. Lower the mast to the lowest position.
shim (6).
• Clearance (d): 0 to 0.5 mm 3. Adjust the chain by using the lock nut of the
chain stopper so that protrusion (e) of the lower
end of the inner mast and main roller (2) on the
lower side are set to the following value.
• Protrusion (e): 39.5 mm
3. For the lower side roller, insert the shim 0.3 mm

thinner than that for the upper side roller.
4. Tilt the fork carriage to check contact surface

(A) of upper side roller (5) and lower side roller
(2) all over the inner mast rail.
30-68 FH40-1, FH45-1, FH50-1

Lamp display of KOMTRAX terminal
LED for CPU 7 segment dot for CPU

1. LED-1 [Green] (R signal, ACC signal) 5. 7 segment [Red] (Radio station establishment
2. LED-2 [Red] (Starting output condition) and operation condition)
3. LED-3 [Yellow] (S-NET, C signal condition) 6. Dot [Red] (GPS positioning, and connection
4. LED-4 [Green] (Fuel sensor, CAN condition) and disconnection condition of inspection con-
nector)
FH40-1, FH45-1, FH50-1 30-69

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.
Installation position and connector layout

1) Remove left step plate (1). 3) When removing cover (2), you can see antenna
(5) is installed to the head guard stay via the
bracket.
2) Remove cover (3) of KOMTRAX terminal.
4) Connector layouts of KOMTRAX terminal (4)

and of HST controller (6)
30-70 FH40-1, FH45-1, FH50-1

1. Details of the display of 7 segment dot for CPU

a Inspect LED display when the starting switch is at the "ON" or "START" position or when the engine is
starting.
LED
No. Name, function Display (*1) Contents
(color)
Lighting up Starting switch ACC signal: ON, Alternator R signal: ON
Quick
LED-1 Starting switch ACC signal, Starting switch ACC signal: OFF, Alternator R signal: ON
1 blinking
(green) Alternator R signal
Slow blinking Starting switch ACC signal: ON, Alternator R signal: OFF
Lighting off Starting switch ACC signal: OFF, Alternator R signal: OFF
LED-2 Starting and outputting Lighting up Engine control signal: ON
2
(red) condition Lighting off Engine control signal: OFF
Quick
Starting switch C signal: ON
LED-3 S-NET connection, Starting blinking
3
(yellow) switch C signal condition Lighting up Starting switch C signal: OFF, S-NET: Connected
Lighting off Starting switch C signal: OFF, S-NET: Disconnected
Lighting up Fuel sensor: Disconnected, CAN: Connected
Quick
LED-4 Fuel sensor and CAN con- Fuel sensor: Connected, CAN: Connected
4 blinking
(green) nection condition
Slow blinking Fuel sensor: Connected, CAN: Disconnected
Lighting off Fuel sensor: Disconnected, CAN: Disconnected
LED-5 Downloading and writing Lighting up Downloading and writing mode: ON
5
(red) condition Lighting off Downloading and writing mode: OFF (normal mode)
Before radio station establishment
Always displays [-] if radio station establishment is not com-
Radio station condition [-]
pleted.
Under radio station establishment
Progress of radio station * For details of display during radio station establishment,
*
establishment see "KOMTRAX terminal start-up procedure".
After radio station establishment completed
7 [C] When the server initial setting communication is not com-
6 segment Initial setting communi- Lighting up pleted, [C] display and lighting up indicates inside of the com-
(red) cation is not completed. Quick munication range, while quick blinking indicates outside of the
blinking communication range.
Operation condition
The number indicates the number of message(s) not yet sent
[0 to 9]
Number of message(s) (9 in case of 9 mails or more not yet sent), and lighting up indi-
Lighting up
not yet sent, inside/out- cates inside of the communication range.
side of the communica- [0 to 9] The number indicates the number of message(s) not yet sent
tion range Quick (9 in case of 9 mails or more not yet sent), and quick lighting
lighting up up indicates inside of the communication range.
Lighting up GPS position can be measured. Refer to *2.
GPS positioning, connec-
Dot Lighting off GPS position cannot be measured. Refer to *2.
7 tion and disconnection of
(red) Quick When connecting or disconnecting the connector for radio sta-
inspection connector
blinking tion establishment, blinks 2 or 3 times.
*1: Type of blinking and blinking time

Quick blinking: Blinking in approximately 1-second cycle: "ON for 0.5 second → OFF for 0.5 second"
repeated
Slow blinking: Blinking in approximately 4-second cycle: "ON for 2 seconds → OFF for 2 seconds"
repeated
*2: It may take 1 minute or longer from turning the starting switch to the "ON" position to completion of posi-
tion measurement even in the communication range (outdoors usually). The measurement is not avail-
able in the place where signal is extremely weak or outside of the communication range.
FH40-1, FH45-1, FH50-1 30-71

KOMTRAX terminal start-up procedure
KOMTRAX terminal start-up 3) Visually check that the connector of

KOMTRAX terminal is connected.
procedure • 1-pin connector for radio station
W h e n K O M T R A X t e rm i na l i s i n s ta l l e d a t establishment (1):
shipment: CN-CK06 (female)
a When KOMTRAX terminal is installed at ship- • 2-pin connector for inspection (2):
ment (as standard equipment), do as follows. CN-CK07 (male)
1. Notification of model, type code, and serial

number
Submit "Memorandum on use of KOMTRAX"
and "Request for registration of KOMTRAX lift
truck" to KOMTRAX key person.
2. Lift truck registration

KOMTRAX key person registers the lift truck
and customers by using KOMTRAX client PC.
a For the procedure, see Chapter 2 "Cus-
tomer management" and Chapter 6 "Lift
truck management" in "KOMTRAX key per-
son operation manual". 4) Turn the starting switch to the "ON"
a The work completes with the above. position and leave as it is for 5 seconds.
• Check that 7 segment display lamp
When replacing KOMTRAX terminal due to is "-".
failure, etc. after shipment.
a When replacing KOMTRAX terminal after ship-
ment, do as follows.
1. Lift truck side inspection for radio station

establishment
a Complete the operations in steps 5) to 7)
within 60 seconds.
1) To receive the satellite signal, move the
lift truck to the place sufficiently away
from buildings or the place with good
visibility of the upper portion of the lift
truck.
a The operation cannot be correctly
completed indoors. Be sure to per-
form this work outdoors.
2) Turn the starting switch key to the
"OFF" position, and check that 5 sec-
onds have passed. Proceed with the
next step.
30-72 FH40-1, FH45-1, FH50-1

5) Disconnect 1-pin connector (1) with 2-

pin connector connected, and leave as
it is for 5 seconds.
a When KOMTRAX terminal detects

connection or disconnection of the
connector, the dot of 7- segment
display lamp blinks 2 or 3 times.
6) Connect 1-pin connector (1) again, and

leave as it is for 5 seconds.
a If operations in steps 4) to 6) take
longer than 60 seconds, restart
from step 2).
7) Check that 7- segment display lamp of
KOMTRAX terminal displays correctly.
a For the correct display, 7- segment
display lamp (a) is displayed for 30
seconds after step 6) is completed.
("d", "0", and "-" repeated)
• The second "0" display may be
different from the beginning.
• The third "-" display changes to
the other display when 30 sec-
onds pass after the operation in
step 7).
a Check "Normal" display, and then
proceed with the next step.
a In case of "Abnormal" display (dis-
plays "-" consecutively), restart
from step 2).
FH40-1, FH45-1, FH50-1 30-73

8) Check that 7- segment display lamp of

KOMTRAX terminal changes and dis-
plays correctly.
a Check "Normal" display, and then
proceed with the next step. (It takes
90 seconds to 5 minutes until cor-
rect display is made.)
a If [Defective detection of GPS posi-
tion data] ([B] in the next section) is
displayed, check the GPS antenna
and cable (3) for external failure. If
any, repair it and restart from step
1).
a If [Defective reception] ([C] in the
next section) is displayed, check the
communication antenna and cable
(4) and antenna (5) for external fail-
ure. If any, repair it and restart from
step 1).
a If [Defective detection of GPS posi-
tion data and defective reception]
([B] and [C] in the next section) is
displayed, check the GPS antenna,
G PS cab le (3) , co mmu nica tion
antenna, communication cable (4)
and antenna box (5) for external
failure. If any, repair it and restart
from step 1).
a If [Defective network] ([D] in the
next section) is displayed, check the
[LED-4] display. For details, see
"Lamp display of KOMTRAX termi-
nal". (If CAN is not recognized,
check CAN harness of KOMTRAX
terminal. If any failure exists, repair
it and restart from step 1).
30-74 FH40-1, FH45-1, FH50-1

[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).
FH40-1, FH45-1, FH50-1 30-75

2. Application for use 2) KOMTRAX key person replaces the lift

a Be sure to apply for use after the radio sta- truck terminal by using the client PC.
tion establishment is completed on the lift a For the procedure, see "6-6 Replac-
truck side. ing terminal" in Chapter 6 "Lift truck
1) Notify KOMTRAX key person of the fol- management" of "KOMTRAX key
lowin g informatio n on the lift tru ck person manual". The initial SMR
whose radio station establishment has remains 0.
been completed. a The work iscompleted.
1] Information on the lift truck whose
radio station establishment has
been completed (model, type code,
and serial number)
2] Type code and serial number of
KOMTRAX terminal
3] The service meter reading at the
installation of KOMTRAX terminal
a KOMTRAX key person must con-

tact a technician in worksite first
thing in the morning to obtain infor-
mation on the hour meter of the lift
truck's meter panel and check that
the service meter matches SMR
displayed on KOMTRAX screen.
If it does not match, correct the dif-
f e r e n c e . Fo r d e ta il s , s e e " 6 - 4
Changing lift truck information" in
Chapter 6 "Lift truck management"
of "KOMTRAX key person manual".
30-76 FH40-1, FH45-1, FH50-1

FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
40 Troubleshooting
FH40-1, FH45-1, FH50-1 40-1

Table of Contents
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/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
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
40-2 FH40-1, FH45-1, FH50-1

Table of Contents
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
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
all of indicator and warning lamps of pilot box do not light up ................................................... 40-233
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
FH40-1, FH45-1, FH50-1 40-3

Table of Contents
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
40-4 FH40-1, FH45-1, FH50-1

Information related to troubleshooting
Points to remember when troubleshooting

Points to remember when troubleshooting
k Stop the lift truck on a level place and make sure than the lock pin, chocks, parking brake, etc.
are applied normally.
k When performing the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k When the radiator cap is removed while the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the cable from the negative (-) terminal of the
battery first.
k When removing the plug or cap from a location which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to pre-
vent reoccurrence of the failure. When performing troubleshooting, important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to give the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts may be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the lift truck before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the lift truck condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Had the same kind of failure occurred before?
3. Checks before troubleshooting
1) Is there abnormal symptoms in lift truck?
2) Check the check-before-starting items.
3) Check the other check items.
4) Other maintenance items can be checked externally, so check any item that is considered to be nec-
essary.
4. Checking failure
Check the extent of the failure yourself, and judge whether it is a real failure or a problem of the
method of operation, etc.
a When operating the lift truck to reenact the failure symptoms, do not perform any investigation or
measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of
failure, then use the troubleshooting flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will
occur again. To prevent this, always investigate the cause why the problem occurred. Then,
remove the root cause.
FH40-1, FH45-1, FH50-1 40-5

How to proceed in troubleshooting
How to proceed in troubleshooting
40-6 FH40-1, FH45-1, FH50-1

Checks before troubleshooting
Item Criterion Remedy
1. Check of level and type of fuel – Add oil
2. Check of fuel for foreign matter – Clean and drain
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
5. Check of air cleaner for clogging – Clean or replace
6. Check of level and type of hydraulic oil Between H and L Add oil
Within range on oil

7. Check of level and type of PTO oil Add oil
gauge
Within range on oil
8. Check of level and type of differential case oil Add oil
gauge
9. Check of fuel filter for clogging – Replace
10. Check of engine oil filter for clogging – Replace
11. Check of hydraulic oil filter for clogging – Replace
12. Check of HST oil filter for clogging – Replace
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
corrosion
15. Check of starting motor terminals and wiring for loose connection
and corrosion
16. Check of operations of instruments – Repair or replace
17. Check for unusual noise and smell – Repair

Hydraulic and work
equipment
18. Check for oil leakage – Repair
19. Bleeding air – Bleed air
20. Check of brake performance – Repair or adjust
21. Check of battery voltage (with engine stopped) 20 to 30 V Charge or replace
Upper level and Add electrolyte or

Electricity and electrical parts
22. Check of electrolyte level

Low level replace battery
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
FH40-1, FH45-1, FH50-1 40-7

Classification and procedures of troubleshooting
Classification and procedures of troubleshooting

Classification of troubleshooting
Mode Description
Failure code Troubleshooting by failure code (display with code)
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon which seems to be a failure occurs in the lift truck, select a proper troubleshooting No.
according to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure when "Abnormality warning lamp" or "Engine abnormality warning lamp" lights up on
the instrument panel:
When the "Abnormality warning lamp" or "Engine abnormality warning lamp" lights up on the instrument
panel, check the failure code.
Perform troubleshooting for the corresponding [Failure code] according to the displayed failure code.
a Check the failure code of both the HST controller and engine controller.
a For failure code checkup method of HST controller, refer to Testing and adjusting, "Display, setting,
and checkup methods in HST controller".
a For checkup method of failure code of engine controller, refer to Testing and adjusting, "Failure code
checkup method of engine controller".
2. Procedure when the failure code history is recorded in the controller:

If the "Abnormality warning lamp" and "Engine abnormality warning lamp" do not light up on the instru-
ment panel, check the failure code history.
Perform the troubleshooting for the [Failure code] displayed.
a Check the failure code histories for both the HST controller and engine controller.
a For failure code checkup method of HST controller, refer to Testing and adjusting, "Display, setting,
and checkup methods in HST controller".
a For checkup method of failure code history of engine controller, refer to Testing and adjusting, "Fail-
ure code checkup method of engine controller".
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
40-8 FH40-1, FH45-1, FH50-1

Phenomena seemed to be failures and troubleshooting Nos.

Applicable model: lift truck mounting SAA4D95LE-5-C engine
Troubleshooting
No. Phenomena seemed to be failure
Code display E-mode H-mode S-mode
Phenomena related to failure code
A failure code of HST controller system is displayed.
1 (The failure code is displayed by the failure code display function of q
HST controller.)
*A failure code of engine controller system is displayed.
2 (Display the failure code by connecting the PC and using the engine q
controller troubleshooting software.)
A failure code is displayed on the EPACS controller.
3 (It is displayed when the LED of EPACS controller is flashing or q
turned off.)
Phenomena related to engine
4 Poor engine starting (It always takes a time to start the engine.) *S-1
5 The engine does not crank. E-1 *S-2a)
The engine cranks but no gas is
6 *S-2b)
exhausted.
Engine does not start.
The gas is exhausted but the
7 engine does not start. *S-2c)
(The fuel is injected normally.)
8 Poor engine blowup (The engine has the poor response.) *S-3
9 The engine stalls when running. *S-4
10 Unstable engine running (engine hunting) *S-5
11 Insufficient output (No power) *S-6
12 Dark exhaust gas (incomplete combustion) *S-7
13 Large engine oil consumption (or blue exhaust gas) *S-8
14 Engine oil is contaminated quickly. *S-9
15 Large fuel consumption *S-10
16 Oil is mixed in coolant (or coolant blows out or reduces). *S-11
17 Hydraulic pressure of engine drops. *S-12
18 Engine oil increases (due to water or fuel mixture). *S-13
19 Coolant temperature is too high (overheating). *S-14
20 Unusual noise *S-15
21 Excessive vibration *S-16
22 Engine preheater does not operate normally. E-2
Phenomena related to power train
23 Lift truck cannot travel. H-1
24 Slow travel speed H-2
25 Insufficient towing force H-3
26 Engine stops during traveling, or engine speed drops excessively. H-4
27 HST (hydraulic) oil temperature is too high. H-5
Phenomena related to brake
Parking brake reminder alarm does not sound or does not stop
28 E-3
sounding.
29 Service brake does not work or its performance is low. H-17
30 Service brake is not released or it drags. H-18
31 Parking brake does not work or its performance is low. H-19
32 Parking brake is not released or it drags. H-20
*For the failure code and S-mode of engine controller system, refer to the "Engine Shop Manual;
"FH40/45/50-1 95E-5 Series".
FH40-1, FH45-1, FH50-1 40-9

Troubleshooting
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.
40-10 FH40-1, FH45-1, FH50-1

Troubleshooting
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
FH40-1, FH45-1, FH50-1 40-11

Information described in troubleshooting table

(Engine controller system)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action code Failure code
Troubleshoo
*2 Failure Failure symptom that appears on lift truck
*1 ting tool
KOMTRAX *3
Detail of failure Condition in which the controller detects the failure
Action of
Action taken to protect the system and equipment when the controller detects a failure
controller
Problem on lift
Problem that appears as failure on lift truck due to the action taken by controller (shown above)
truck
Related
Information on the occurred failure or troubleshooting
information
Cause Procedure, measuring location, criteria and remarks

<Description>
• Standard value in normal condition required to judge
assumed causes
1 • Remarks required to judge whether the cause is correct
<Phenomenon of defective wiring harness>

• Disconnection in wiring harness
The connector connection is defective or the wiring har-
ness is disconnected.
• Ground fault
A wiring harness not connected to the ground (earth) circuit
2 comes into contact with the ground (earth) circuit.
• Hot short circuit
A wiring harness not connected to power source (24V) cir-
cuit comes into connect with power (24V) circuit.
Possible cause of failure • Short circuit
Probable causes (The cause numbers are A wiring harness of an independent circuit abnormally
and criteria shown sequentially but they comes into contact with one of other circuits.
do not show the priority <Notes on troubleshooting>
3 sequence.) (1) Connector No. display method and T-adapter handling
For troubleshooting, connect the T-adapter as shown below
unless otherwise specified.
• If (male) or (female) is not displayed on the connector
No., disconnect the connector and insert the T-adapter
into both the male and female sides.
• If (male) or (female) is displayed on the connector No.,
disconnect the connector and insert the T-adapter into
either the male or female side.
(2) Pin number description sequence and tester lead handling
4
For troubleshooting, connect the positive (+) and negative (-)
leads as shown below unless otherwise specified.
• Connect positive (+) lead to a pin or wiring harness indi-
cated in the front.
• Connect negative (-) to a pin or wiring harness indicated
in the rear.
*1: An action code is described but not displayed.
*2: A failure code displayed on the troubleshooting tool
For checkup method of failure code, refer to Testing and adjusting, "Failure code checkup method of
engine controller".
*3: A failure code displayed on the KOMTRAX server screen
a For the failure code of engine controller system, refer to the separate Engine Shop Manual;
"FH40/45/50-1 95E-5 Series".
40-12 FH40-1, FH45-1, FH50-1

(HST controller system)

Troubleshoo
*2 Failure Failure symptom that appears on lift lift truck
*1 ting tool
KOMTRAX *3
Detail of failure State where the controller detects the trouble
Action of
Action taken to protect the system and equipment when the controller detects a trouble
controller
Problem on lift Problem that appears as abnormality on lift lift truck due to the action taken by controller (shown
truck above)
Related
Information on occurred failure or troubleshooting
information

<Description>
assumed causes
1 • Remarks required to judge whether the cause is correct

• Ground fault
2 comes into contact with the ground (earth) circuit.
Probable causes (The cause numbers are A wiring harness of an independent circuit abnormally
and criteria shown sequentially but they comes into contact with one of other circuits.
do not show the priority
3 sequence.) <Notes on troubleshooting>
(1) Connector No. display method and T-adapter handling
4
cated in the front.
in the rear.
*1: An action code is described but not displayed.
*2: A failure code that the HST controller failure display function shows by flashing the pilot box lamp
For failure code checkup method of HST controller, refer to Testing and adjusting, "Display, setting, and
checkup methods in HST controller".
*3: A failure code displayed on the KOMTRAX server screen
FH40-1, FH45-1, FH50-1 40-13

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.
* By using failure code display

function of HST controller system,
check the failure code and check
* Failure occurs in if that failure code occurs or not.
HST controller
NO
system.
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.
40-14 FH40-1, FH45-1, FH50-1

(EPACS controller system)

Failure code
Failure Failure symptom that appears on lift truck
Monitor display
Detail of failure Condition where the controller detects the failure
Action of
Action taken to protect the system and equipment when the controller detects a failure
controller
Problem on lift
Problem that appears as failure on lift truck due to the action taken by controller (shown above)
truck
Related
Information on occurred failure or troubleshooting
information

<Description>
assumed causes
1 • Remarks required to judge whether the cause is good

• Ground fault
A wiring harness not connected to the ground (earth) cir-
2 cuit comes into contact with the ground (earth) circuit.
Probable A wiring harness of an independent circuit abnormally
(The cause numbers are
causes and comes into contact with one of other circuits.
shown sequentially but they
criteria
do not show the priority
3 sequence.) <Notes on troubleshooting>
(1) Connector No. display method and T-adapter handling
4
cated in the front.
in the rear.
FH40-1, FH45-1, FH50-1 40-15

This is the excerpted circuit diagram related to

the failure.
• Symbols of devices and connector names
(numbers of pins) are shown.
40-16 FH40-1, FH45-1, FH50-1

Locations of fuses
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
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
Continuous power supply 5B and 5)
(batteries) 6
5B and 6)
7
7C and 7)
8 HST controller (Main and load power supplies)
KOMTRAX controller (Main power supply)
9D and 8)
9
(between terminals 5A DC/DC converter
9D and 9)
10 Parking brake lever switch
HST controller (Key signals)
9D and 10)
11 Meter • Backup lamp
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)
FH40-1, FH45-1, FH50-1 40-17

Locations of fuses
Type of power supply Capacity of

Fuse name Destination of power
(Source) fuse
Switching power supply 17
(BR terminal of starting (between terminals 10A HST controller (Auxiliary load power supply)
switch) 17G and 17)
--- 18 --- None
--- 19 --- None
Constant power supply 20

(between terminals 30A Engine controller (Main power supply)
(batteries)
20H and 20)
Location of fuses and fuse Nos.

• All fuses are installed in fuse box (1) on the battery side.
40-18 FH40-1, FH45-1, FH50-1

Locations of fuses
Slow blow fuse

Type of power supply
Fuse No. Capacity of fuse Destination of power
(Source)
Heater relay
Continuous power supply SB-B1 120A
Heater
(batteries)
SB-B2 40A Starting switch terminal B
Location of slow blow fuses and fuse Nos.

• Slow blow fuses are installed in slow blow fuse boxes (1) and (2) on the side of batteries in engine com-
partment.
FH40-1, FH45-1, FH50-1 40-19

Connection table for connector pin numbers

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-20 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-21

40-22 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-23

40-24 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-25

40-26 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-27

40-28 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-29

40-30 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-31

40-32 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-33

40-34 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-35

40-36 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-37

40-38 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-39

40-40 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-41

40-42 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-43

40-44 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-45

40-46 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-47

40-48 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-49

40-50 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-51

40-52 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-53

40-54 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-55

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.
40-56 FH40-1, FH45-1, FH50-1

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.
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
FH40-1, FH45-1, FH50-1 40-57

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
40-58 FH40-1, FH45-1, FH50-1

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
FH40-1, FH45-1, FH50-1 40-59

T-branch box and T-branch adapter table

(Rev. 2009. 03)
a The separate T-branch box and T-branch adapters are listed in the vertical column, and the part number
of harness checker assemblies are listed in the horizontal line.
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
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 MS plate (14-pin) q
799-601-3410 BENDIX (MS) adapter 24 MS-24P q
799-601-3470 Case q
799-601-2710 MIC adapter 5 MIC-5P q q q
799-601-2720 MIC adapter 13 MIC-13P q q q
799-601-2730 MIC adapter 17 MIC-17P q q q q q q
799-601-2740 MIC adapter 21 MIC-21P q q q q q q
799-601-2950 MIC adapter 9 MIC-9P q q q q
799-601-2750 ECONO adapter 2 EANO 2P q q
799-601-2810 DLI adapter 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 EANO 12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC60 and ECONO) 60 q
799-601-4360 Case q
799-601-7010 X adapter (T-adapter) 1 q q
799-601-7020 X adapter 2 X2P q q q q
799-601-7030 X adapter 3 X3P q q q q
799-601-7040 X adapter 4 X4P q q q q
799-601-7050 SWP adapter 6 SW6P q q q
799-601-7060 SWP adapter 8 SW8P q q q
799-601-7310 SWP adapter 12 SW12P q
799-601-7070 SWP adapter 14 SW14P q q
799-601-7320 SWP adapter 16 SW16P q
799-601-7080 M adapter (T-adapter) 1 – q q
799-601-7090 M adapter 2 M2P q q q q
799-601-7110 M adapter 3 M3P q q q q
799-601-7120 M adapter 4 M4P q q q q
799-601-7130 M adapter 6 M6P q q q q
799-601-7340 M adapter 8 M8P q
40-60 FH40-1, FH45-1, FH50-1

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
799-601-7140 S adapter 8 S8P q q q q

799-601-7150 S adapter (white) 10 S10P q q q q
799-601-7160 S adapter (blue) 12 S12P q q q
799-601-7170 S adapter (blue) 16 S16P q q q q
799-601-7330 S adapter (white) 16 S16PW q
799-601-7350 S adapter (white) 12 S12PW q
799-601-7180 AMP040 adapter 8 A8P q
799-601-7190 AMP040 adapter 12 A12P q q
799-601-7210 AMP040 adapter 16 A16P q q q q
799-601-7220 AMP040 adapter 20 A20P q q q q
799-601-7230 X short connector 2 – q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 070 adapter 10 07-10 q
799-601-7520 070 adapter 12 07-12 q
799-601-7530 070 adapter 14 07-14 q
799-601-7540 070 adapter 18 07-18 q
799-601-7550 070 adapter 20 07-20 q
799-601-7360 Relay adapter 5 REL-5P q
799-601-7370 Relay adapter 6 REL-6P q
799-601-7380 JFC adapter 2 – q
799-601-9010 DTM adapter 2 DTM2 q q
799-601-9020 DT adapter 2 DT2 q q q q
799-601-9030 DT adapter 3 DT3 q q
799-601-9040 DT adapter 4 DT4 q q q q
799-601-9050 DT adapter 6 DT6 q q
799-601-9060 DT adapter (gray) 8 DT8GR q q
799-601-9070 DT adapter (black) 8 DT8B q q
799-601-9080 DT adapter (green) 8 DT8G q q
799-601-9090 DT adapter (brown) 8 DT8BR q q
799-601-9110 DT adapter (gray) 12 DT12GR q q
799-601-9120 DT adapter (black) 12 DT12B q q
799-601-9130 DT adapter (green) 12 DT12G q q
799-601-9140 DT adapter (brown) 12 DT12BR q q
799-601-9210 HD30-18 adapter 8 D18-8 q q
799-601-9220 HD30-18 adapter 14 D18-14 q q
799-601-9230 HD30-18 adapter 20 D18-20 q q
799-601-9240 HD30-18 adapter 21 D18-21 q q
799-601-9250 HD30-24 adapter 9 D24-9 q q
799-601-9260 HD30-24 adapter 16 D24-16 q q
799-601-9270 HD30-24 adapter 21 D24-21 q q
799-601-9280 HD30-24 adapter 23 D24-23 q q
799-601-9290 HD30-24 adapter 31 D24-31 q q
799-601-9310 HD30 plate (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 DRC adapter 40 DRC-40 q
799-601-9360 DRC adapter 24 DRC-24 q
799-601-9410* Engine (CRI-T2) socket 2 G q
Engine (CRI-T2) adapter
799-601-9420 Engine (CRI-T3) adapter PFUEL 3 A3 q q
Hydraulic sensor
FH40-1, FH45-1, FH50-1 40-61

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
Engine (CRI-T2) socket

799-601-9430* 2 P q q
Engine (CRI-T3) socket PCV
799-601-9440* Engine (CRI-T2) socket 3 1,2,3 q
795-799-5520* Engine (HPI-T2) socket 2 S q
Engine (HPI-T2) socket
795-799-5530* Engine (CRI-T3) socket 2 C q q
Temperature sensor
Engine (HPI-T2) socket
795-799-5540* 2 A q q
Engine (CRI-T3) socket TIM
795-799-5460 Engine (HPI-T2) cable 3 – q
799-601-4110 Engine (140-T3) adapter PIM 4 ITT3N q q
799-601-4130 Engine (CRI-T3) adapter NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atmosphere pressure
799-601-4150 Engine (CRI-T3) adapter POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Engine (CRI-T3) adapter PEVA 3 4180 q q
799-601-4190* 3 1, 2, 3L q q
Common rail pressure
799-601-4230* 4 1, 2, 3, 4C q q
Manifold pressure/temperature
799-601-4240* Engine (CRI-T3) socket PAMB 3 1, 2, 3A q q
799-601-4250* Engine (CRI-T3) socket PIM 3 1, 2, 3B q q
799-601-4330* Engine (CRI-T3) socket G 3 1, 2, 3, G q q
799-601-4340* 2 2, PA q q
Pump actuator
Engine (CRI-T3) (95) socket
799-601-4380* 4 1, 2, 3, 4T q
Manifold pressure/temperature
799-601-4260 Controller (ENG) adapter 4 DTP4 q q
799-601-4211 Controller (ENG) adapter 50 DRC50 q
799-601-4220 Controller (ENG) adapter 60 DRC60 q
799-601-4390* Controller (95ENG) socket 60 – q
12
799-601-4280* Controller (Pump) box – q
1
799-601-9720 Controller (HST) adapter 16 HST16A q
799-601-9710 Controller (HST) adapter 16 HST16B q
799-601-9730 Controller (HST) adapter 26 HST26A q
Multi-adapter for DT2 to 4 and 2,
799-601-9890 3, – q
DTM2 pins 4
*: Indicates a socket, not a T-adapter.
40-62 FH40-1, FH45-1, FH50-1

Troubleshooting by failure code (HST controller system)
Failure code list

Failure code list
a Failure code:
The failure codes are listed in a numerical and alphabetical order.
a Lift truck failure code:
A failure code displayed for the lift truck
(To switch to the failure code display mode, see the "Testing and Adjusting; HST Controller Special Func-
tions".)
a KOMTRAX failure code:
A failure code displayed on the server screen of KOMTRAX when a failure occurs
a History category:
Indicates that the related failure code is stored to either of electrical or mechanical system.
a Applicable component:
Indicates the controller system of the occurred failure.
HST: Controller system;
ENG: Engine controller system
a Action code:
Classified into 4 categories depending on the details of the failures. However, they are not displayed.
Individual warning
Abnormality
Action code Severity lamp Buzzer Alarm type Operator's action
warning lamp
(displayed if any)
Inspection and mainte-
L01 Low q q – Failure
nance after work.
"Operate at low speed of
engine and lift truck."
q
L02 Middle q q Damage caution Stop the work and operate
(Intermittent)
at medium speed with no
load."
Stop the work and move
q the lift truck to a safe place
L03 High q q Failure
(Intermittent) to perform inspection and
maintenance.
Immediately stop the lift
q
L04 High q q Failure truck to perform the inspec-
(Continuous)
tion and maintenance.
Failure code Control History

Failure location Failure Action code
Lift truck KOMTRAX device class
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 Electrical
DLT4KZ Travel speed sensor A HST L03
hot short circuit system
Open circuit, ground fault, or Electrical
14 DLT6KZ Travel speed sensor B HST L03
hot short circuit system
DLT4KZ+ Open circuit, ground fault, or Electrical
Travel speed sensors A and B HST L03
DLT6KZ hot short circuit system
FH40-1, FH45-1, FH50-1 40-63

Failure code list

Electrical
DLT4MA Travel speed sensors A and B Malfunction HST L03
system
14
Electrical
DLT4LC Travel speed sensors A and B Speed signal does not match HST L01
system
Electrical
7REXKA Seat switch Open circuit HST L04
system
15
Electrical
7REXKB Seat switch Ground fault HST L04
system
Pump EPC valve ground return Open circuit or hot short cir- Electrical
18 D5ZTKZ HST L03
signal cuit 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 Cut-off 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 Electrical
DXATKA Open circuit HST L04
solenoid valve system
32 DXATKB Ground fault HST L04
DXATKY Hot short circuit HST L04
Reverse travel HST pump EPC Electrical
DXAUKA Open circuit HST L04
33 DXAUKB Ground fault HST L04
DXAUKY Hot short circuit HST L04
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
Open circuit or hot short cir- Electrical
D110KZ HST controller power relay HST L01
cuit system
40-64 FH40-1, FH45-1, FH50-1

Failure code list

Work equipment lock solenoid Electrical
DW9NKA Open circuit HST L03
valve system
37 DW9NKB Ground fault HST L03
valve system
DW9NKY Hot short circuit HST L03
valve system
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 and backup lamp Electrical
D161KA Open circuit HST L01
relay system
47 D161KB Ground fault HST L01
relay system
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 Dropped voltage HST L03
system
HST controller load power supply Dropped voltage, open cir- Electrical
53 DAJ2KK HST L03
line cuit, or ground fault system
54 7REHKA Open circuit HST L01
(KEY_ACC_SIGNAL) system
Ground fault or hot short cir- Electrical
55 DAJ5KX HST controller power output 1 HST L03
cuit system
56 7REAKA Open circuit or ground fault HST L03
(KEY_SIG) system
CAN communication
Electrical
62 DB2RKR (between HST controller and Defective communication HST L04
system
engine controller)
Electrical
system
63
Electrical
DAJ0KT HST controller Memory malfunction HST L01
system
FH40-1, FH45-1, FH50-1 40-65

Failure code [--/AB00MA] Alternator: Malfunction
Failure code [--/AB00MA] Alternator: Malfunction

Alternator: Malfunction
Lift truck - Failure
L03 (Electrical system)
KOMTRAX AB00MA
• Battery charging system failed while engine was running. (The voltage of alternator R signal
Detail of failure
dropped below 7.8 V.)
• Turns on the battery charging alarm lamp.
Action of • Turns on the abnormality warning lamp.
controller • Sounds the warning buzzer (intermittently).
• When failure causes are removed, the system recovers automatically.
Problem on lift
• If the lift truck is continued to operate, the batteries may be discharged.
truck
Related
• Method of reproducing failure code: Start the engine.
information

A problem causing a poor battery charging has occurred currently
Insufficient battery charge
Probable 1 or in the past. Check the cause and damage, and repair the lift
(when system is normal)
causes and truck.
criteria Open circuit or ground fault
Check the display of failure code [Lift truck: 27/KOMTRAX:
2 in wiring harness
AB00KZ]. If displayed, troubleshoot it first.
(Alternator R signal circuit)
40-66 FH40-1, FH45-1, FH50-1

Failure code [--/B@CRNS] HST Oil: Overheating
Failure code [--/B@CRNS] HST Oil: Overheating

HST oil: Overheating
L02 (Mechanical system)
KOMTRAX B@CRNS
Detail of failure • The HST oil is overheated while engine is running (the HST oil temperature is above 105°C.
• Turns on the HST oil temperature alarm lamp.
Problem on lift • If the lift truck is continued to operate, the HST hydraulic system or work equipment hydraulic sys-
truck tem may be damaged.
Related
• Method of reproducing failure code: Start the engine. (HST oil temperature is above 105°C)
information

HST oil overheat A failure causing an HST overheating has occurred currently or in
1
Probable (when system is normal) the past. Check the cause and damage, and repair the lift truck.
causes and Ground fault in wiring har-
criteria ness Check the display of failure code [Lift truck: 26/KOMTRAX:
2
(HST oil temperature sensor DGS1KB]. If displayed, troubleshoot it first.
signal circuit)
FH40-1, FH45-1, FH50-1 40-67

Failure code [--/2G40ZG] Brake accumulator: Dropped hydraulic pressure
Failure code [--/2G40ZG] Brake accumulator:

Dropped hydraulic pressure
Brake accumulator: Dropped hydraulic pressure
KOMTRAX 2G40ZG
Detail of failure • Hydraulic pressure of brake accumulator dropped while engine is rotating.
• Turns on the abnormality warning lamp.
Action of
• Sounds the warning buzzer (intermittently).
controller
Problem on lift
• If the lift truck is continued to operate, the braking system may be damaged.
truck
Related
information

Dropped brake accumulator A failure causing the dropped hydraulic pressure of brake accumu-
1 oil pressure lator has occurred currently or in the past. Check the cause and
Probable
(when system is normal) damage, and repair the lift truck.
causes and
criteria Open circuit or ground fault
in wiring harness Check the display of failure code [Lift truck: 29/KOMTRAX:
2
(Brake charge pressure sen- DH2FKZ]. If displayed, troubleshoot it first.
sor signal circuit)
40-68 FH40-1, FH45-1, FH50-1

Failure code [--/6091NX] Hst oil filter: Clogging
Failure code [--/6091NX] Hst oil filter: Clogging

HST oil filter: Clogging
KOMTRAX 6091NX
Detail of failure • When HST oil temperature is above 30°C the HST oil filter clogging switch has been activated.
• Turns on the HST oil filter clogging warning lamp.
Action of
controller
Problem on lift
• If the lift truck is continued to operate, the hydraulic system devices may be damaged.
truck
Related • Method of reproducing failure code: Start the engine, and wait until HST oil temperature increases
information above 30°C

A problem causing the clogged HST oil filter has occurred currently
Clogged HST oil filter (when
1 or in the past. Check the cause and damage, and repair the lift
system is normal)
truck.
a Be ready with starting switch in OFF position, then perform trou-
bleshooting without turning starting switch to the ON position.
Differential pressure
Defective HST oil filter clog- P16 between inlet and Resistance
Probable 2 ging switch outlet of HST filter
causes and (internal short circuit) Max. 245 kPa
Between wiring har- Min. 1 Mz
criteria (Max. 2.5 kg/cm2)
ness connection ter-
minal and ground Min. 245 kPa
Max. 1z
(Min. 2.5 kg/cm2)
a Be ready with starting switch in the OFF position, then perform
Ground fault in wiring har- troubleshooting without turning starting switch to the ON position.
3 ness
(contact with ground circuit) Between ground and wiring harness C01
Resistance Min. 1 Mz
(female) (24) - P16 (terminal)
If no failure is found by check on causes 1 to 3, HST controller may
4 Defective HST controller
be defective.
FH40-1, FH45-1, FH50-1 40-69

Failure code [12/DDK6KA] FNR lever: Open circuit

Directional selector (FNR) lever: Open circuit
Lift truck 12 Failure
L03 (HST controller system)
KOMTRAX DDK6KA
• Because the directional selector (FNR) lever switch signal circuit is opened or grounded, none of
Detail of failure
directional selector (FNR) lever signals can be entered.
• Stops an output to both HST pump forward EPC solenoid valve and HST pump reverse EPC sole-
noid valve.
controller • Sounds the warning buzzer.
• After the failure is recovered, the lift truck returns to normal only when you shift the directional selec-
tor (FNR) lever to Neutral (N) position.
• If this failure occurs during traveling, the lift truck stops.
Problem on lift
• Once stopped, the lift truck cannot restart.
truck
• If the N signal circuit fails, the operator cannot start the engine (due to the Neutral Start function).
Related • Method of reproducing failure code: Turn the starting switch to the ON position, and hold the direc-
information tional selector (FNR) lever (in each position more than 10 seconds).

Blown fuse No. 12 in fuse If fuse is broken, circuit probably has ground fault (See cause 4).
1
box (F01) (If fuse is blown, the circuit may be grounded or others.)
troubleshooting without turning starting switch to the ON position.
Directional selector
S04 (male) Resistance
lever position
Defective directional selec- N Max. 1z
2 tor (FNR) lever (internal open Between (9) and (10) Other than N Min. 1 Mz
circuit or short circuit)
R Max. 1z
Between (6) and (5)
Other than R Min. 1 Mz
Probable F Max. 1z
causes and Between (6) and (8)
Other than F Min. 1 Mz
criteria
Between wiring harnesses from fuse No. 12
Resistance Max. 1z
of fuse box (F01) to S04 (female) (9)
Open circuit in wiring har- Between wiring harnesses from S04
Resistance Max. 1z
ness (female) (10) to C02 (female) (15)
3
(wire breakage or defective Between wiring harnesses from fuse No. 12
contact of connector) Resistance Max. 1z
of fuse box (F01) to S04 (female) (6)
Between wiring harnesses from S04
Resistance Max. 1z
(female) (5) to C02 (female) (25)
Between wiring harnesses from S04
Resistance Max. 1z
(female) (8) to C02 (female) (35)
40-70 FH40-1, FH45-1, FH50-1


Between ground and wiring harnesses from
fuse No. 12 of fuse box (F01) to S04 Resistance Min. 1 Mz
Ground fault in wiring har- (female) (9), and to S04 (female) (6)
4 ness Between ground and wiring harness from
(contact with ground circuit) S04 (female) (10) to C02 (female) (15)
Between ground and wiring harness from
S04 (female) (5) to C02 (female) (25)
Probable
causes and Resistance Min. 1 Mz
criteria
a Be ready with starting switch in the OFF position, and then turn
starting switch to the ON position to perform troubleshooting.
C02 FNR lever position Voltage
Between C02 (15) N 20 to 30 V
5 Defective HST controller and ground Other than N Max. 1 V
Between C02 (25) R 20 to 30 V
and ground Other than R Max. 1 V
Between C02 (35) F 20 to 30 V
and ground Other than F Max. 1 V
FH40-1, FH45-1, FH50-1 40-71

40-72 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-73

Failure code [12/DDK6KY] FNR lever: Hot short circuit

Directional selector (FNR) lever: Hot short circuit
KOMTRAX DDK6KY
• Because the directional selector (FNR) lever switch signal circuit is hot shorted, multiple directional
Detail of failure
selector (FNR) lever signals are entered.
• Stops an output to both HST pump forward EPC solenoid valve and HST pump reverse EPC sole-
noid valve.
• After the failure is recovered, the lift truck returns to normal only when you shift the directional selec-
tor (FNR) lever to Neutral (N) position.
• If this failure occurs during traveling, the lift truck stops.
Problem on lift • Once stopped, the lift truck cannot restart.
truck • If the forward or reverse signal circuit fails, the operator cannot start the engine (due to the Neutral
Start function).
Related • Method of reproducing failure code: Turn starting switch to the ON position, and shift the directional
information selector (FNR) lever.

S04 (male) Resistance
lever position
Defective directional selec- N Max. 1z
1 tor (FNR) lever switch (inter- Between (9) and (10) Other than N Min. 1 Mz
nal short circuit)
R Max. 1z
Between (6) and (5)
Other than R Min. 1 Mz
F Max. 1z
Between (6) and (8)
Other than F Min. 1 Mz
Probable Hot short of wiring harness S04 (female) (10) to C02 (female) (15) Voltage Max. 1 V
causes and 2 (incorrect contact to 24V cir-
criteria cuit) Between ground and wiring harness from
Voltage Max. 1 V
Voltage Max. 1 V
C02 Voltage
lever position
Between C02 (15)
N 20 to 30 V
and ground
Between C02 (25) Other than N Max. 1 V
and ground R 20 to 30 V
Other than R Max. 1 V
Between C02 (35)
F 20 to 30 V
and ground
Other than F Max. 1 V
40-74 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-75

Failure code [14/DLT4KZ] Travel speed sensor A: Open circuit, ground fault, or hot short circuit

Open circuit, ground fault, or hot short circuit
Action code Failure code Travel speed sensor A: Open circuit, ground fault, or hot short cir-
Lift truck 14 Failure cuit
KOMTRAX DLT4KZ
• When traveling at approx. 5 Km/h or faster, the input signal of travel speed sensor A was lost. (It is
Detail of failure
detected during traveling only).
• Knows the traveling speed by reading the input signal of travel speed sensor B.
• Sets the deviation to 0 and the accumulated deviation to 0 for the traveling speed feedback control
of the speed limiter function.
Action of
controller
• Sounds the warning buzzer.
• 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 engine upper speed is limited to a certain level while lift truck speed is limited. (The limited level
truck depends on the preset limit speed.)
• If failure code [KOMTRAX: DLT6KZ] (Travel speed sensor B: Open circuit, ground fault, or hot short
circuit) has also occurred, first troubleshoot for failure code [KOMTRAX: DLT4KZ & DLT6KZ] (Travel
Related speed sensors A and B: Open circuit, ground fault, or hot short circuit).
information • Method of reproducing failure code: Travel the lift truck at approx. 8 km/h or above.
(If you have already turned the key to the OFF position and try to reproduce the error, KOMTRAX
failure code: DLT4LC is displayed.)

Defective sensor power sup- Check the display of failure code [Lift truck: 55/KOMTRAX:
1
ply (5 V) system DAJ5KX]. If displayed, troubleshoot it first.
P05 Condition Voltage
During traveling
Between (1) and (2) 4.5 to 5.5 V
Defective travel speed sen- or stopped
2 sor During traveling Switching between below
(internal defect) Between (2) and (4) at constant 1 V and above 4 V
speed (Periodical switching)
If the voltage is abnormal, check causes 3 to 6 (for a damage of
wiring harness and controller) and make the final judgment after
checking that no failure is found.
Probable
causes and
criteria
Open circuit in wiring har- Wiring harness between P05 (female) (4)
Resistance Max. 1z
ness and C02 (female) (27)
3
(wire breakage or defective Wiring harness between P05 (female) (1)
and C01 (female) (22)
Wiring harness between P05 (female) (2)
Resistance Max. 1z
4 ness
(contact with ground circuit) Between ground and wiring harness from
P05 (female) (4) to C02 (female) (27)
Hot short circuit in wiring har- a Be ready with starting switch in the OFF position, and then turn
ness starting switch to the ON position to perform troubleshooting.
5
(contact with 24 V or 5 V cir- Between ground and wiring harness from
cuit) Voltage Max. 1 V
40-76 FH40-1, FH45-1, FH50-1

Failure code [14/DLT4KZ] Travel speed sensor A: Open circuit, ground fault, or hot short circuit

Probable C01, C02 Condition Voltage
causes and Between C01 (22) During traveling
criteria 6 Defective HST controller 4.5 to 5.5 V
and C02 (39) or stopped
During traveling Switching between below
Between C02 (27)
at constant 1 V and above 4 V
and C02 (39)
FH40-1, FH45-1, FH50-1 40-77

Failure code [14/DLT6KZ] Travel speed sensor B: Open circuit, ground fault, or hot short circuit

Action code Failure code Travel speed sensor B: Open circuit, ground fault, or hot short cir-
KOMTRAX DLT6KZ
• When traveling at approx. 5 Km/h or faster, the input signal of travel speed sensor B was lost. (It is
Detail of failure
detected during traveling only).
• Knows the traveling speed by reading the input signal of travel speed sensor A.
Action of
controller
Problem on lift • The engine upper speed is limited to a certain level while lift truck speed is limited. (The limited level
truck depends on the preset limit speed.)
• If failure code [KOMTRAX: DLT4KZ] (Travel speed sensor A: Open circuit, ground fault, or hot short
circuit) has also occurred, first troubleshoot for failure code [KOMTRAX: DLT4KZ & DLT6KZ] (Travel
Related speed sensors A and B: Open circuit, ground fault, or hot short circuit).
information • Method of reproducing failure code: Travel the lift truck at approx. 8 km/h or above
failure code: DLT4LC is displayed.)

1
During travel-
Defective travel speed sen- ing or stopped
2 sor During travel- Switching between below 1
(internal defect) Between (2) and (3) ing at constant V and above 4 V
Probable
causes and
criteria
Resistance Max. 1z
3
(wire breakage or defective Wiring harness between C01 (female) (22)
and P05 (female) (1)
Resistance Max. 1z
4 ness
5
40-78 FH40-1, FH45-1, FH50-1

Failure code [14/DLT6KZ] Travel speed sensor B: Open circuit, ground fault, or hot short circuit

Probable C01, C02 Condition Voltage
causes and Between C01 (22) During travel-
criteria 6 Defective HST controller 4.5 to 5.5 V
and C02 (39) ing or stopped
During travel- Switching between below 1
Between C02 (37)
ing at constant V and above 4 V
and C02 (39)
FH40-1, FH45-1, FH50-1 40-79

Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B: Open circuit, ground fault, or hot short circuit

Travel speed sensors A and B: Open circuit, ground fault, or hot
Lift truck 14
Failure short circuit
L03 DLT4KZ & (HST controller system)
KOMTRAX
DLT6KZ
• When traveling at approx. 5 km/h or faster, the input signals of travel speed sensors A and B are
Detail of failure
lost.
• Stops the forward/reverse switching time-lag control which operates according to the speed.
Action of
controller
• The forward movement time lags when the directional selector lever is shifted.
Problem on lift
truck • Engine upper speed is limited to a certain level while lift truck speed is limited. (The limit speed
depends on the preset speed.)
• Method of reproducing failure code: Travel the lift truck at approx. 8 km/h or above.
Related
information
failure code: DLT4MA is displayed.)

1
During travel-
ing or stopped
Defective travel speed sen- During travel- Switching between below 1
Between (2) and (4) ing at constant V and above 4 V
2 sor
(internal defect)
Between (2) and (3) ing at constant V and above 4 V
Probable wiring harness and controller) and make the final judgment after
causes and checking that no failure is found.
criteria a Be ready with starting switch in the OFF position, then perform
Resistance Max. 1z
Open circuit in wiring har- and C02 (female) (27)
ness Wiring harness between P05 (female) (3)
3 Resistance Max. 1z
(wire breakage or defective and C02 (female) (37)
contact of connector) Wiring harness between P05 (female) (1)
Resistance Max. 1z
Resistance Max. 1z
Ground fault in wiring har-
4 ness Resistance Min. 1 Mz
(contact with ground circuit)
40-80 FH40-1, FH45-1, FH50-1

Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B: Open circuit, ground fault, or hot short circuit

Hot short circuit in wiring har- starting switch to the ON position to perform troubleshooting.
ness Between ground and wiring harness from
5 Voltage Max. 1 V
(contact with 24 V or 5 V cir- P05 (female) (4) to C02 (female) (27)
cuit) Between ground and wiring harness from
Voltage Max. 1 V
Probable
causes and
criteria C01, C02 Condition Voltage
Between C01 (22) During travel-
4.5 to 5.5 V
and C02 (39) ing or stopped
6 Defective HST controller During travel- Switching between below 1
Between C02 (27)
and C02 (39)
Between C02 (37)
and C02 (39)
FH40-1, FH45-1, FH50-1 40-81

Failure code [14/DLT4MA] Travel speed sensors A and B: Malfunction
Failure code [14/DLT4MA] Travel speed sensors A and B: Malfunction

Travel speed sensors A and B: Malfunction
KOMTRAX DLT4MA
Detail of failure • Although lift truck is traveling, the input signal of travel speed sensors A and B is lost.
Action of
controller
• The forward movement time lags when the directional selector lever is shifted.
Problem on lift
Related
information

Defective travel speed sen-
1 Troubleshoot for KOMTRAX failure code [DLT4KZ & DLT6KZ].
sor system
If cause 1 is not found, the power train may be defective. Trouble-
shoot for "Lift truck cannot travel (H-1)", "Slow travel speed (H-2)"
and "Insufficient towing force (H-4)" in H-mode.
Probable Example: If the nut of towing plug of HST pump is loose, the HST
causes and pump discharge pressure is not transmitted to HST motor and the
criteria lift truck cannot travel.
2 Defective power train
If operator makes the followings during this time, the controller
cannot detect signals entered in travel speed sensors A and B
although they are normal. The controller determines the sensors
are in failure and gives alarm.
(1) Shift the directional selector (FNR) lever to F or R position.
(2) Release the parking brake lever.
(3) Depress the accelerator pedal.
40-82 FH40-1, FH45-1, FH50-1

Failure code [14/DLT4LC] Travel speed sensors A and B: Mismatch of rotation speed signals
Failure code [14/DLT4LC] Travel speed sensors A and B:

Mismatch of rotation speed signals
Travel speed sensors A and B: Mismatch of rotation speed signals
KOMTRAX DLT4LC
• When traveling at approx. 8 km/h or faster, the (traveling speed) input signals of travel speed sen-
Detail of failure sors A and B do not match.
(More than 0.3 km/h of speed difference between sensors A and B exists.)
• Sets the deviation to 0 and the accumulated deviation to 0 for the traveling speed feedback calcula-
Action of tion of the speed limiter function.
controller • Turns on the abnormality warning lamp.
• The start-up time lag when the directional select lever is shifted.
Problem on lift
Related
information

Incorrect installation of travel Make sure that travel speed sensors are installed correctly to the
Probable 1
speed sensors accelerator pedal.
causes and
criteria If cause 1 is not found, the travel speed sensor system may be
Defective travel speed sen-
2 defective. Troubleshoot for KOMTRAX failure code [DLT4KZ &
sor system
DLT6KZ].
FH40-1, FH45-1, FH50-1 40-83

Failure code [15/7REXKA] Seat switch: Open circuit

Seat switch: Open circuit
KOMTRAX 7REXKA
Detail of failure • 2 seat switch circuits are both turned OFF (or ON) simultaneously.
• Determines that the operator has left, and activates both loading interlock and traveling interlock.
Action of
controller
• Sounds the warning buzzer (continuously).
• The operator cannot start the work and cannot travel the lift truck (due to the loading interlock func-
Problem on lift tion).
truck • Shifts the lever to the N position and stops the lift truck if the problem occurs during traveling (by the
traveling interlock function).
Related • Method of reproducing failure code: Turn starting switch to the ON position, be seated or leave the
information operator's seat, and hold this condition more than 20 seconds.

P03 (male) Operator's seat Resistance
Defective seat switch
1 (internal open circuit or short Left Max. 1z
Between (3) and (1)
circuit) Seated Min. 1 Mz
Left Min. 1 Mz
Between (3) and (2)
Seated Max. 1z
Be ready with starting switch in the OFF position, then perform
Probable Open circuit in wiring har- troubleshooting without turning starting switch to the ON position.
causes and ness Wiring harness between P03 (female) (1)
criteria 2 Resistance Max. 1z
contact of connector) Wiring harness between P03 (female) (2)
Resistance Max. 1z
C03 Operator's seat Voltage
3 Defective HST controller Between C03 (20) Left Max. 1 V
and C01 (4) Seated 5 to 11 V
Between C03 (30) Left 5 to 11 V
and C01 (4) Seated Max. 1 V
40-84 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-85

Failure code [15/7REXKB] Seat switch: Ground fault

Seat switch: Ground fault
KOMTRAX 7REXKB
Detail of failure • 2 seat switch circuits are both turned ON (or closed) simultaneously.
• Determines that the operator has left, and activates both loading interlock and traveling interlock.
Action of
controller
• The operator cannot start the work and cannot travel the lift truck (due to the loading interlock func-
Problem on lift tion).
truck • Shifts the lever to the N position and stops the lift truck if the problem occurs during traveling (by the
traveling interlock function).
Related • Method of reproducing failure code: Turn starting switch to the ON position, be seated or leave the
information operator's seat, and hold this condition more than 20 seconds.

P03 (male) Operator's seat Resistance
Defective seat switch Left Max. 1z
1
(internal short circuit) Between (3) and (1)
Seated Min. 1 Mz
Left Min. 1 Mz
Between (3) and (2)
Seated Max. 1z
Probable troubleshooting without turning starting switch to the ON position.
causes and Ground fault of wiring har-
criteria 2 ness Resistance Min. 1 Mz
(Contact with ground circuit)
C03 Operator's seat Voltage
3 Defective HST controller Between C03 (20) Left Max. 1 V
and C01 (04) Seated 5 to 11 V
Between C03 (30) Left 5 to 11 V
and C01 (04) Seated Max. 1 V
40-86 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-87

Failure code [18/D5ZTKZ] Pump EPC valve ground return signal: Open circuit or hot short circuit

Open circuit or hot short circuit
Action code Failure code Pump EPC valve ground return signal: Open circuit or hot short cir-
KOMTRAX D5ZTKZ
• When pump EPC valve ground cutout relay output was OFF (normally closed), the signal of pump
EPC valve ground return signal circuit was not detected.
Detail of failure
(During normal, the signal of pump EPC valve ground return signal circuit is detected when the
pump EPC valve ground cutout relay output is OFF (normally closed).
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
Problem on lift
• It depends on the failure location on the related circuit.
truck
Related
• Method of reproducing failure code: Turn the starting switch to the ON position.
information

Open circuit of HST pump
DXATKA]
forward EPC solenoid valve,
1 or
or open circuit of HST pump
[Lift truck: 33/KOMTRAX: DXAUKA]. If displayed, troubleshoot it
reverse EPC solenoid valve
first.
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)
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-
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.
40-88 FH40-1, FH45-1, FH50-1

Failure code [18/D5ZTKZ] Pump EPC valve ground return signal: Open circuit or hot short circuit
FH40-1, FH45-1, FH50-1 40-89

Failure code [22/DHHBKX] HST pump A-port pressure sensor: Open circuit or ground fault
Failure code [22/DHHBKX] HST pump A-port pressure sensor:

Open circuit or ground fault
HST pump A-port pressure sensor: Open circuit or ground fault
KOMTRAX DHHBKX
Detail of failure • The input voltage of HST pump A-port pressure sensor dropped below 0.3 V.
Action of • Secures the motor capacity to the largest side.
Problem on lift
• The lift truck can travel at low speed only.
truck
• During inspection, carefully check to see that 5 V circuit (3) and ground circuit (1) are connected
Related
correctly. If connected incorrectly, pressure sensors may be damaged.
information
• Method of reproducing failure code: Turn the starting switch to the ON position or start the engine.

1
Between (3) and (1) Always 4.5 to 5.5 V
Defective HST pump A-port
2 pressure sensor (internal fail- Park the lift truck on a
ure) Between (2) and (1) level and apply the 0.4 to 0.6 V
parking brake.
Probable Open circuit in wiring har- Wiring harness between C01 (female) (7)
Resistance Max. 1z
causes and ness and P10 (female) (2)
criteria 3
Wiring harness between C01 (female) (22)
Resistance Max. 1z
4 ness
C01 (female) (7) to P10 (female) (2)
C01 Condition Voltage
5 Defective HST controller Between (22) and

Always 4.5 to 5.5 V
(21)
Park the lift truck on a
Between (7) and (21) level and apply the 0.4 to 0.6 V
parking brake.
40-90 FH40-1, FH45-1, FH50-1

Failure code [22/DHHBKX] HST pump A-port pressure sensor: Open circuit or ground fault
FH40-1, FH45-1, FH50-1 40-91

Failure code [22/DHHBKY] HST pump A-port pressure sensor: Hot short circuit
Failure code [22/DHHBKY] HST pump A-port pressure sensor:

Hot short circuit
HST pump A-port pressure sensor: Hot short circuit
KOMTRAX DHHBKY
Detail of failure • The input voltage of HST pump A-port pressure sensor exceeded 4.7 V.
Problem on lift
truck
Related
information

1
Defective HST pump A-port
parking brake.
criteria
3

Always 4.5 to 5.5 V
(21)
parking brake.
40-92 FH40-1, FH45-1, FH50-1

Failure code [22/DHHBKY] HST pump A-port pressure sensor: Hot short circuit
FH40-1, FH45-1, FH50-1 40-93

Failure code [23/DHHCKX] HST pump B-port pressure sensor: Open circuit or ground fault
Failure code [23/DHHCKX] HST pump B-port pressure sensor:

HST pump B-port pressure sensor: Open circuit or ground fault
KOMTRAX DHHCKX
Detail of failure • The input voltage of HST pump B-port pressure sensor dropped below 0.3 V.
Problem on lift
truck
Related
information

1
Defective HST pump B-port
parking brake.
Open circuit in wiring har- Wiring harness between C01 (female) (1)
Probable Resistance Max. 1z
ness and P11 (female) (2)
causes and 3
Resistance Max. 1z
Ground fault in wiring har- troubleshooting without turning starting switch to the ON posi-
4 ness tion.

Always 4.5 to 5.5 V
(21)
parking brake.
40-94 FH40-1, FH45-1, FH50-1

Failure code [23/DHHCKX] HST pump B-port pressure sensor: Open circuit or ground fault
FH40-1, FH45-1, FH50-1 40-95

Failure code [23/DHHCKY] HST pump B-port pressure sensor: Hot short circuit
Failure code [23/DHHCKY] HST pump B-port pressure sensor:

Hot short circuit
HST pump B-port pressure sensor: Hot short circuit
KOMTRAX DHHCKY
Detail of failure • The input voltage of HST pump B-port pressure sensor exceeded 4.7 V.
Problem on lift
truck
Related
information

1
Defective HST pump B-port
parking brake.
If the voltage is abnormal, check causes 3 and 4 (for a damage of
criteria
3

Always 4.5 to 5.5 V
(21)
parking brake.
40-96 FH40-1, FH45-1, FH50-1

Failure code [23/DHHCKY] HST pump B-port pressure sensor: Hot short circuit
FH40-1, FH45-1, FH50-1 40-97

Failure code [25/DK70KZ] Brake pedal angle sensor: Open circuit or ground fault
Failure code [25/DK70KZ] Brake pedal angle sensor:

Brake pedal angle sensor: Open circuit or ground fault
KOMTRAX DK70KZ
Detail of failure • The input voltage of brake pedal angle sensor dropped below 0.3 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
controller
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 press the brake
information pedal.

1
troubleshooting without turning starting switch to the ON posi-
tion.
P14 (male) Resistance
Between (C) and (B) 1.6 to 2.4 kz
Defective brake pedal angle
2 1.5 to 0.5 kz
sensor (internal failure)
Between (A) and (B) (Between release position and
stroke end position)
0.5 to 1.5 kz
Between (C) and (A) (Between release position and
causes and ness Wiring harness between C01 (female) (22)
criteria (wire breakage or defective and P14 (female) (C)
contact of connector) Wiring harness between C01 (female) (19)
Resistance Max. 1z
and P14 (female) (A)
4 ness
C01 (female) (19) to P14 (female) (A)
P14 Brake pedal Voltage
Defective adjustment of Released 3 to 3.65 V
5 brake pedal angle sensor Between (A) and (B) Depressed
linkage 1.35 to 2 V
(Stroke end)
If voltage is not within above range, follow procedure in Testing and
adjusting, "Testing and adjusting brake pedal angle sensor link-
age".
40-98 FH40-1, FH45-1, FH50-1

Failure code [25/DK70KZ] Brake pedal angle sensor: Open circuit or ground fault

Probable
C01 Voltage
causes and
criteria 6 Defective HST controller Between (22) and
Power supply 4.5 to 5.5 V
(21)
Between (19) and
Signal 0.3 to 4.7 V
(21)
FH40-1, FH45-1, FH50-1 40-99

Failure code [25/DK70KY] Brake pedal angle sensor: Hot short circuit
Brake pedal angle sensor: Hot short circuit
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
controller
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.

1
P14 (male) Resistance
Between (C) and (B) 1.6 to 2.4 kz
Defective brake pedal angle 1.5 to 0.5 kz
2
sensor (internal failure) Between (A) and (B) (Between release position and
0.5 to 1.5 kz
Between (C) and (A) (Between release position and
Probable 3
causes and cuit) Voltage Max. 1 V
C01 (female) (19) to P14 (female) (A)
criteria
P14 Brake pedal Voltage
Defective adjustment of
Released 3 to 3.6 V
4 brake pedal angle sensor
linkage Between (A) and (B) Depressed
1.3 to 2 V
(Stroke end)
adjusting, "Testing and adjusting brake pedal angle sensor linkage".
C01 Voltage
Power supply 4.5 to 5.5 V
(21)
Between (19) and
Signal 0.3 to 4.7 V
(21)
40-100 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-101

Failure code [26/DGS1KA] HST oil temperature sensor: Open circuit

HST oil temperature sensor: Open circuit
KOMTRAX DGS1KA
• The HST oil temperature sensor signal does not change and stays in low temperature even when
Detail of failure
engine coolant temperature increases.
Action of
• Acceleration or deceleration speed drops (due to the activated low temperature control).
Problem on lift • The towing force is lost (due to the activated low temperature control).
truck • When the brake pedal is deeply depressed, the lift truck is braked larger than usual (due to the acti-
vated low temperature control).
Related • Method of reproducing failure code: Warm up the engine enough (until engine coolant exceeds
information 76°C, and run engine for 10 minutes.

P12 (male) Temperature Resistance
10°C Approx. 90 Kz
Defective HST oil tempera-
1 ture sensor 30°C Approx. 35 Kz
Between (1) and (2)
(internal defect) 80°C Approx. 6.5 Kz
100°C Approx. 3.5 Kz
Between ground and -
Min. 1 Mz
each of (1) and (2) -
causes and Open circuit in wiring
criteria harness Wiring harness between C01 (female) (14)
(wire breakage or defective and P12 (female) (1)
Resistance Max. 1z
Hot short circuit in wiring starting switch to the ON position to perform troubleshooting.
3 harness (contact with 24 V
circuit) Between ground and wiring harness from
Voltage Max. 1 V
4 Defective HST controller C01 Temperature Voltage
Between (14) and
10 to 100°C 4.6 to 2.0 V
(21)
40-102 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-103

Failure code [26/DGS1KB] HST oil temperature sensor: Ground fault

HST oil temperature sensor: Ground fault
KOMTRAX DGS1KB
Detail of failure • The input voltage of HST oil temperature sensor dropped below 0.3 V.
• Considers the HST oil temperature as 130 °C
• An engine hunting may occur when the oil temperature is low (because the low-temperature control
is not activated).
Problem on lift
• The HST oil temperature warning lamp lights up (because the HST oil temperature overheat control
truck
is activated).
• The engine output drops (because the HST oil temperature overheat control is activated).
Related
information

P12 (male) Temperature Resistance
10°C Approx. 90 Kz
Defective HST oil tempera-
1 ture sensor 30°C Approx. 35 Kz
Between (1) and (2)
(internal defect) 80°C Approx. 6.5 Kz
100°C Approx. 3.5 Kz
Probable Between ground and -
causes and Min. 1 Mz
each of (1) and (2) -
criteria
2 ness
3 Defective HST controller C01 Temperature Voltage
Between (14) and
10 to 100°C 2.0 to 4.6 V
(21)
40-104 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-105

Failure code [27/AB00KZ] Alternator R signal circuit: Open circuit or ground fault
Failure code [27/AB00KZ] Alternator R signal circuit:

Alternator R signal circuit: Open circuit or ground fault
KOMTRAX AB00KZ
Detail of failure • The alternator R signal voltage dropped below a half of battery voltage while engine was rotating.
Problem on lift
• If the lift truck is continued to operate, the batteries may be discharged.
truck
Related
information

a Be ready with starting switch in the OFF position, then run
engine to perform troubleshooting.
Poor charging of alternator
1 E04 Engine speed Voltage
(when system is normal)
Between (1) and Medium speed or
27.5 to 29.5 V
ground above
Open circuit in wiring har- a Be ready with starting switch in the OFF position, then perform
ness troubleshooting without turning starting switch to the ON position.
2
Probable (wire breakage or defective Wiring harness between P04 (female) (1)
causes and and C01 (female) (15)
3 ness
(contact with ground circuit) Between ground and wiring harness E04
(female) (1) - C01 (female) (15)
4 Defective HST controller C01 Engine speed Voltage
Between (15) and Medium speed or
27.5 to 29.5 V
ground above
40-106 FH40-1, FH45-1, FH50-1

Failure code [27/AB00KZ] Alternator R signal circuit: Open circuit or ground fault
FH40-1, FH45-1, FH50-1 40-107

Failure code [27/AB00KY] Alternator R signal circuit: Hot short circuit

Alternator R signal circuit: Hot short circuit
KOMTRAX AB00KY
Detail of failure • The alternator R signal voltage increased above a half of battery voltage while engine was stopped.
Action of
controller
• The engine cannot start.
Problem on lift
• Although the starting switch is turned to the OFF position, the neutral (N) lamp continues to light.
truck
• The batteries are discharged.
Related
information

Probable Voltage 1Max. 1 V
E04 (female) (1) to C01 (female) (15)
causes and
criteria a Be ready with starting switch in the OFF position, then run
2 Defective HST controller C01 Engine Voltage
Between (15) and
STOPPING Max. 3 V
ground
40-108 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-109

Failure code [28/DHPCKZ] Lift cylinder pressure sensor: Open circuit or ground fault
Failure code [28/DHPCKZ] Lift cylinder pressure sensor:

Lift cylinder pressure sensor: Open circuit or ground fault
KOMTRAX DHPCKZ
Detail of failure • The input voltage of lift cylinder pressure sensor dropped below 0.3 V.
Action of
Problem on lift • The engine power is insufficient when loaded (because the automatic engine output control function
truck is not activated).
Related
information

1
When lift cylinder
Defective lift cylinder pres- pressure is released
2
sure sensor (internal failure) Between (2) and (1) * See Testing and 0.4 to 0.6 V
adjusting, "Releas-
ing pressure from
hydraulic piping".
Probable Open circuit in wiring har- Wiring harness between C01 (female) (13)
Resistance Max. 1z
causes and ness and P13 (female) (2)
criteria 3
Resistance Max. 1z
4 ness
Between (22) and
Always 4.5 to 5.5 V
(21)
5 Defective HST controller When lift cylinder
pressure is released
Between (13) and * See Testing and
0.4 to 0.6 V
(21) adjusting, "Releas-
ing pressure from
hydraulic piping".
40-110 FH40-1, FH45-1, FH50-1

Failure code [28/DHPCKZ] Lift cylinder pressure sensor: Open circuit or ground fault
FH40-1, FH45-1, FH50-1 40-111

Failure code [28/DHPCKY] Lift cylinder pressure sensor: Hot short circuit
Failure code [28/DHPCKY] Lift cylinder pressure sensor:

Hot short circuit
Lift cylinder pressure sensor: Hot short circuit
KOMTRAX DHPCKY
Detail of failure • The input voltage of lift cylinder pressure sensor exceeded 4.7 V.
Action of
Problem on lift
• The fuel consumption drops (because the automatic engine output control function is not activated.)
truck
Related
information

1
ply system DAJ5KX]. If displayed, troubleshoot it first.
When lift cylinder
Defective lift cylinder pres- pressure is released
2 * See Testing and
sure sensor (internal failure) Between (2) and (1) 0.4 to 0.6 V
adjusting, "Releas-
ing pressure from
hydraulic piping".
If the voltage is abnormal, check causes 3 and 4 (for a damage of
criteria
3
Between (22) and
Always 4.5 to 5.5 V
(21)
When lift cylinder
pressure is released
Between (13) and * See Testing and
0.4 to 0.6 V
(21) adjusting, "Releas-
ing pressure from
hydraulic piping".
40-112 FH40-1, FH45-1, FH50-1

Failure code [28/DHPCKY] Lift cylinder pressure sensor: Hot short circuit
FH40-1, FH45-1, FH50-1 40-113

Failure code [29/DH2FKZ] Brake charge pressure sensor: Open circuit or ground fault
Failure code [29/DH2FKZ] Brake charge pressure sensor:

Brake charge pressure sensor: Open circuit or ground fault
KOMTRAX DH2FKZ
Detail of failure • The input voltage of brake charge pressure sensor dropped below 0.3 V.
Action of
controller • Considers the brake charge pressure of 0 (zero) MPa.
Problem on lift
• None
truck
Related
information

1
When brake accumu-
lator pressure is
released
Defective brake charge pres- * Stop the engine,
2
sure sensor (internal failure) Between (2) and (1) and release the 0.3 to 0.6 V
accumulator pres-
sure by depressing
Probable the brake pedal
causes and approx. 50 times.
criteria If the voltage is abnormal, check causes 3 to 5 (for a damage of
Resistance Max. 1z
ness and P06 (female) (2)
3
Resistance Max. 1z
4 ness
40-114 FH40-1, FH45-1, FH50-1

Failure code [29/DH2FKZ] Brake charge pressure sensor: Open circuit or ground fault

Between (22) and
Always 4.5 to 5.5 V
(21)
Probable
causes and When brake accumu-
criteria 5 Defective HST controller lator pressure is
released
* Stop the engine,
Between (3) and (21) and release the 0.3 to 0.6 V
accumulator pres-
sure by depressing
the brake pedal
approx. 50 times.
FH40-1, FH45-1, FH50-1 40-115

Failure code [29/DH2FKY] Brake charge pressure sensor: Hot short circuit
Failure code [29/DH2FKY] Brake charge pressure sensor:

Hot short circuit
Brake charge pressure sensor: Hot short circuit
KOMTRAX DH2FKY
Detail of failure • The input voltage of brake charge pressure sensor exceeded 4.7 V.
• Turns on the abnormality warning lamp, and sounds the warning buzzer.
Action of • Considers the brake charge pressure 0 (zero) MPa.
Problem on lift
• None
truck
Related
information

1
When brake accumu-
lator pressure is
released
Defective brake charge pres- * Stop the engine,
2
sure sensor (internal failure) Between (2) and (1) and release the 0.3 to 0.6 V
accumulator pres-
sure by depressing
the brake pedal
approx. 50 times.
Probable
causes and Hot short circuit in wiring har- a Be ready with starting switch in the OFF position, and then turn
criteria 3
Voltage 1Max. 1 V
cuit) C01 (female) (3) to P06 (female) (2)
Between (22) and
Always 4.5 to 5.5 V
(21)
When brake accumu-
4 Defective HST controller lator pressure is
released
* Stop the engine,
Between (3) and (21) and release the 0.3 to 0.6 V
accumulator pres-
sure by depressing
the brake pedal
approx. 50 times.
The brake charge pressure may have exceeded 20 MPa {204.1
5 Defective hydraulic system kg/cm2} . Check the brake charge pressure and the brake pres-
sure.
40-116 FH40-1, FH45-1, FH50-1

Failure code [29/DH2FKY] Brake charge pressure sensor: Hot short circuit
FH40-1, FH45-1, FH50-1 40-117

Failure code [32/DXATKA] HST pump forward travel EPC solenoid valve: Open circuit
Failure code [32/DXATKA] HST pump forward travel EPC solenoid

valve: Open circuit
HST pump forward travel EPC solenoid valve: Open circuit
KOMTRAX DXATKA
Detail of failure • No current flowed through HST pump forward travel EPC solenoid valve circuit during output.
• Stops the output to HST pump forward travel EPC solenoid valve.
Action of
controller • Sounds the warning buzzer (continuously).
Problem on lift • If this problem occurs during traveling, the lift truck is stopped.
truck • Once stopped, the lift truck cannot travel forward.
information (FNR) lever to Forward (F) position.

Defective HST pump forward troubleshooting without turning starting switch to the ON position.
1 travel EPC solenoid valve
V01 (male) Resistance
(internal failure)
Between (1) and (2) 5 to 15 z
Defective pump EPC valve troubleshooting without turning starting switch to the ON position.
2 ground cutout relay
R17 (male) Resistance
Probable (internal failure)
causes and Between (30) and (87A) Max. 1z
Resistance Max. 1z
ness and V01 (female) (1)
3
(wire breakage or defective Wiring harness between V01 (female) (2)
Wiring harness between R17 (female) (87A)
Resistance Max. 1z
40-118 FH40-1, FH45-1, FH50-1

Failure code [32/DXATKA] HST pump forward travel EPC solenoid valve: Open circuit
FH40-1, FH45-1, FH50-1 40-119

Failure code [32/DXATKB] HST pump forward travel EPC solenoid valve: Ground fault
Failure code [32/DXATKB] HST pump forward travel EPC solenoid

valve: Ground fault
HST pump forward travel EPC solenoid valve: Ground fault
KOMTRAX DXATKB
Detail of failure • Abnormal current flowed through HST pump forward travel EPC solenoid valve circuit during output.
Action of
Problem on lift • If this problem occurs during traveling, the lift truck is stopped.
truck • Once stopped, the lift truck cannot move forward (but can move backward).
information (FNR) lever to Forward (F) position.

Defective HST pump forward
1 travel EPC solenoid valve V01 (male) Resistance
(internal short circuit) Between (1) and (2) 5 to 15 z
Probable
causes and Between (1) and ground Min. 1 Mz
2 ness
C03 (female) (6) to V01 (female) (1)
If causes 1 and 2 are not found, the HST controller may be defec-
tive.
40-120 FH40-1, FH45-1, FH50-1

Failure code [32/DXATKB] HST pump forward travel EPC solenoid valve: Ground fault
FH40-1, FH45-1, FH50-1 40-121

Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve: Hot short circuit
Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve:
Hot short circuit
HST pump forward travel EPC solenoid valve: Hot short circuit
KOMTRAX DXATKY
• Abnormal voltage was detected when there was no output to HST pump forward travel EPC sole-
Detail of failure
noid valve circuit.
• Outputs to the pump EPC ground cutout relay, and stops the current flow through pump EPC sole-
noid valve circuit.
Action of
controller
Problem on lift
• Lift truck cannot travel.
truck
Related
information

Probable a Be ready with starting switch in the OFF position, and then turn
causes and Hot short circuit in wiring har- starting switch to the ON position to perform troubleshooting.
criteria 1 ness (contact with 24 V cir-
Voltage Max. 1 V
40-122 FH40-1, FH45-1, FH50-1

Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve: Hot short circuit
FH40-1, FH45-1, FH50-1 40-123

Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid valve: Open circuit
Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid

valve: Open circuit
HST pump reverse travel EPC solenoid valve: Open circuit
lift truck 33 Failure
KOMTRAX DXAUKA
Detail of failure • No current flowed through HST pump reverse travel EPC solenoid valve circuit during output.
• Stops the output to HST pump reverse travel EPC solenoid valve.
Action of
Problem on lift • If this problem occurs during reverse traveling, the lift truck stops.
truck • Once stopped, the lift truck cannot move backward.
information (FNR) lever to Reverse (R) position.

Defective HST pump reverse troubleshooting without turning starting switch to the ON position.
1 travel EPC solenoid valve
(internal failure)
Probable (internal defect)
causes and Between (30) and (87A) Max. 1z
Resistance Max. 1z
ness and V02 (female) (1)
3
(wire breakage or defective Wiring harness between V02 (female) (2)
Wiring harness between R17 (female) (87A)
Resistance Max. 1z
40-124 FH40-1, FH45-1, FH50-1

Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid valve: Open circuit
FH40-1, FH45-1, FH50-1 40-125

Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid valve: Ground fault
Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid

valve: Ground fault
HST pump reverse travel EPC solenoid valve: Ground fault
KOMTRAX DXAUKB
Detail of failure • Abnormal current flowed through HST pump reverse travel EPC solenoid valve circuit during output.
Action of
Problem on lift • If this problem occurs during reverse travel, the lift truck stops.
truck • Once stopped, the lift truck cannot move backward (but can move forward).

Defective HST pump reverse
1 travel EPC solenoid valve V02 (male) Resistance
(internal short circuit) Between (1) and (2) 5 to 15 z
Probable
2 ness
tive.
40-126 FH40-1, FH45-1, FH50-1

Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid valve: Ground fault
FH40-1, FH45-1, FH50-1 40-127

Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid valve: Hot short circuit
Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid

valve: Hot short circuit
HST pump reverse travel EPC solenoid valve: Hot short circuit
KOMTRAX DXAUKY
• Abnormal voltage was detected when there was no output to HST pump reverse travel EPC sole-
Detail of failure
noid valve circuit.
• Outputs to the pump EPC ground cutout relay, and stops the current flow through pump EPC sole-
noid valve circuit.
Action of
controller
• Sounds the warning buzzer.
Problem on lift
truck
Related
information

Voltage Max. 1 V
40-128 FH40-1, FH45-1, FH50-1

Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid valve: Hot short circuit
FH40-1, FH45-1, FH50-1 40-129

Failure code [34/DXAVKA] HST motor EPC solenoid valve: Open circuit
HST motor EPC solenoid valve: Open circuit
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.
Action of
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
information

Defective HST motor EPC troubleshooting without turning starting switch to the ON position.
1 solenoid valve (internal open
circuit)
Probable a Be ready with starting switch in the OFF position, then perform
causes and troubleshooting without turning starting switch to the ON position.
Open circuit in wiring har-
criteria
ness Wiring harness between C03 (female) (26)
(wire breakage or defective and V03 (female) (1)
Resistance Max. 1z
and V03 (female) (2)
3 Defective HST controller 3
tive.
40-130 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-131

Failure code [34/DXAVKB] HST motor EPC solenoid valve: Ground fault
HST motor EPC solenoid valve: Ground fault
KOMTRAX DXAVKB
Detail of failure • Abnormal current flowed through HST motor EPC solenoid valve circuit during output.
Action of
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
information

Defective HST motor EPC
1 solenoid valve (internal open V03 (male) Resistance
circuit) Between (1) and (2) 5 to 15 z
Probable
2 ness
tive.
40-132 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-133

Failure code [34/DXAVKY] HST motor EPC solenoid valve: Hot short circuit
Failure code [34/DXAVKY] HST motor EPC solenoid valve:

Hot short circuit
HST motor EPC solenoid valve: Hot short circuit
KOMTRAX DXAVKY
• Abnormal voltage was detected in HST motor EPC solenoid valve circuit although no output was
Detail of failure
supplied.
Action of
• If this problem occurs during traveling, the lift truck is accelerated.
Problem on lift • The braking force is reduced when the accelerator pedal is released or when the brake pedal is
truck depressed.
• The towing force is reduced.
Related
information

Voltage Max. 1 V
40-134 FH40-1, FH45-1, FH50-1

Failure code [34/DXAVKY] HST motor EPC solenoid valve: Hot short circuit
FH40-1, FH45-1, FH50-1 40-135

Failure code [35/D110KZ] HST controller power relay: Open circuit or hot short circuit
Failure code [35/D110KZ] HST controller power relay:

Open circuit or hot short circuit
HST controller power relay: Open circuit or hot short circuit
KOMTRAX D110KZ
• When HST controller was started, 3.7 V or higher voltage was detected by the current detector cir-
Detail of failure
cuit although there was no output to HST controller power relay.
Action of
• If the circuit is open, the parking brake reminder alarm function does not work when starting switch
Problem on lift
is in the OFF position.
truck
• If hot short circuit occurs, the batteries may easily be discharged.
Related
information

Defective HST controller troubleshooting without turning starting switch to the ON position.
1 power relay (internal open
circuit)
Between (86) and (85) 200 to 400 z
Probable
causes and 2
Hot short circuit in wiring har- starting switch to ON position to perform troubleshooting.
Voltage Max. 1 V
C03 (female) (4) to R10 (female) (86)
40-136 FH40-1, FH45-1, FH50-1

Failure code [35/D110KZ] HST controller power relay: Open circuit or hot short circuit
FH40-1, FH45-1, FH50-1 40-137

Failure code [35/D110KB] HST controller power relay: Ground fault

HST controller power relay: Ground fault
KOMTRAX D110KB
Detail of failure • Abnormal current flowed through HST controller power relay circuit during output.
Action of
Problem on lift • The parking brake reminder alarm function does not work when starting switch is turned to the OFF
truck position.
Related
information

Defective HST controller troubleshooting without turning starting switch to the ON position.
1 power relay (internal short
circuit)
Probable Between (86) and (85) 200 to 400 z
causes and a Be ready with starting switch in the OFF position, then perform
criteria Ground fault in wiring har- troubleshooting without turning starting switch to the ON position.
2 ness
tive.
40-138 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-139

Failure code [37/DW9NKA] Work equipment lock solenoid valve: Open circuit
Failure code [37/DW9NKA] Work equipment lock solenoid valve:

Open circuit
Work equipment lock solenoid valve: Open circuit
KOMTRAX DW9NKA
Detail of failure • No current flowed through work equipment lock solenoid valve circuit during output.
Problem on lift
• The work equipment does not operate (only the forklift can move down).
truck
Related
• Method of reproducing failure code: Turn the starting switch to the ON position and be seated.
information

Defective work equipment troubleshooting without turning starting switch to the ON position.
1 lock solenoid valve (internal
open circuit)
criteria
Resistance Max. 1z
tive.
40-140 FH40-1, FH45-1, FH50-1

Failure code [37/DW9NKA] Work equipment lock solenoid valve: Open circuit
FH40-1, FH45-1, FH50-1 40-141

Failure code [37/DW9NKB] Work equipment lock solenoid valve: Ground fault
Failure code [37/DW9NKB] Work equipment lock solenoid valve:

Ground fault
Work equipment lock solenoid valve: Ground fault
KOMTRAX DW9NKB
Detail of failure • Abnormal current flowed through work equipment lock solenoid valve circuit during output.
• Turns OFF the output to work equipment lock solenoid valve circuit.
Action of
Problem on lift
• The work equipment does not operate (only the forklift can move down).
truck
Related
information

Defective work equipment
1 lock solenoid valve (internal V10 (male) Resistance
short circuit) Between (2) and (1) 32 to 40 z
Between (2) and ground Min. 1 Mz
Probable Ground fault in wiring har-
causes and 2 ness Resistance Min. 1 Mz
criteria (contact with ground circuit)
C03 (female) (25) to D01 (female) (2)
Defective diode D01 (male) Digital tester Continuity
3
(internal short circuit)
Between (2) and (6) Diode mode No continuity
Between (6) and (2) Diode mode Continuity
40-142 FH40-1, FH45-1, FH50-1

Failure code [37/DW9NKB] Work equipment lock solenoid valve: Ground fault
FH40-1, FH45-1, FH50-1 40-143

Failure code [37/DW9NKY] Work equipment lock solenoid valve: Hot short circuit
Failure code [37/DW9NKY] Work equipment lock solenoid valve:

Hot short circuit
Work equipment lock solenoid valve: Hot short circuit
KOMTRAX DW9NKY
• Abnormal voltage was detected in the work equipment lock solenoid valve circuit although no output
Detail of failure
was supplied.
Problem on lift • The work equipment operates (except for lowering of forklift) when the operator leaves (and work
truck 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.

Probable starting switch to the ON position to perform troubleshooting.
causes and Hot short circuit in wiring har-
criteria 1 ness (contact with 24 V cir- Voltage Max. 1 V
cuit)
Voltage Max. 1 V
40-144 FH40-1, FH45-1, FH50-1

Failure code [38/DW9MKA] Lift lock solenoid valve: Open circuit
Failure code [38/DW9MKA] Lift lock solenoid valve: Open circuit

Lift lock solenoid valve: Open circuit
KOMTRAX DW9MKA
Detail of failure • No current flowed through lift lock solenoid valve circuit during output.
Problem on lift
• The forklift does not move down.
truck
Related
information

Defective work equipment troubleshooting without turning starting switch to the ON position.
1 lock solenoid valve (internal
open circuit)
Probable
criteria Open circuit in wiring har- troubleshooting without turning starting switch to the ON position.
Resistance Max. 1z
3 Defective HST controller If causes 1 and 2 are not found, the HST controller may be defective.
FH40-1, FH45-1, FH50-1 40-145

Failure code [38/DW9MKB] Lift lock solenoid valve: Ground fault

Work equipment lock solenoid valve: Ground fault
KOMTRAX DW9MKB
Detail of failure • Abnormal current flowed through work equipment lock solenoid valve circuit during output.
• Turns OFF the output to lift lock solenoid valve circuit.
Action of
Problem on lift
• The forklift does not move down.
truck
Related
information

Defective lift lock solenoid V11 (male) Resistance
1
valve (internal short circuit)
Between (2) and ground Min. 1 Mz
Probable Ground fault in wiring har-
causes and 2 ness Resistance Min. 1 Mz
criteria (contact with ground circuit)
Defective diode D01 (male) Digital tester Continuity
3
40-146 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-147

Failure code [38/DW9MKY] Lift lock solenoid valve: Hot short circuit
Work equipment lock solenoid valve: Hot short circuit
KOMTRAX DW9NKY
• Abnormal voltage was detected in the work equipment lock solenoid valve circuit although no output
Detail of failure
was supplied.
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.

criteria 1 ness (contact with 24 V cir- Voltage Max. 1 V
cuit)
Voltage Max. 1 V
40-148 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-149

Failure code [39/D140KB] Starter relay: Ground fault

Starter relay: Ground fault
KOMTRAX D140KB
Detail of failure • Abnormal current flowed through starter relay circuit during output.
Problem on lift
• The engine does not start.
truck
Related • Method of reproducing failure code: Turn starting switch to the ON position, depress the brake
information pedal, and shift the directional (FNR) lever to Neutral (N).

Starting motor relay is defec- troubleshooting without turning starting switch to the ON position.
1 tive
2 ness
tive.
40-150 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-151

Failure code [39/D140KY] Starter relay: Hot short circuit

Starter relay: Hot short circuit
KOMTRAX D140KY
Detail of failure • Abnormal voltage was detected in the starter relay circuit although no output was supplied.
Problem on lift • The engine can be started even if the brake pedal is not depressed or the directional (FNR) lever is
truck in F or R position.
Related
information

Voltage Max. 1 V
40-152 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-153

Failure code [47/D161KA] Backup buzzer and backup lamp relay: Open circuit
Failure code [47/D161KA] Backup buzzer and backup lamp relay:

Open circuit
Backup buzzer and backup lamp relay: Open circuit
KOMTRAX D161KA
Detail of failure • No current flowed through backup buzzer and backup lamp relay circuit during output.
Action of
Problem on lift • The backup buzzer does not sound.
truck • The backup lamp does not light up.

Defective backup buzzer and troubleshooting without turning starting switch to the ON position.
1 backup lamp relay (internal
open circuit)
Between (86) and (85) 220 to 420 z
criteria
(wire breakage or defective and R15 (female) (86)
contact of connector) Wiring harness between R15 (female) (85)
Resistance Max. 1z
tive.
40-154 FH40-1, FH45-1, FH50-1

Failure code [47/D161KA] Backup buzzer and backup lamp relay: Open circuit
FH40-1, FH45-1, FH50-1 40-155

Failure code [47/D161KB] Backup buzzer and backup lamp relay: Ground fault
Failure code [47/D161KB] Backup buzzer and backup lamp relay:

Ground fault
Backup buzzer and backup lamp relay: Ground fault
KOMTRAX D161KB
Detail of failure • Abnormal current flowed through backup buzzer and backup lamp relay circuit during output.
• Turns OFF the output to backup buzzer and backup lamp relay circuit.
Problem on lift • The backup buzzer does not sound.
truck • The backup lamp does not light up.

Defective backup buzzer and troubleshooting without turning starting switch to the ON position.
1 backup lamp relay (internal
short circuit)
Between (86) and (85) 220 to 420 z
causes and
criteria Ground fault in wiring har-
C03 (female) (15) to R15 (female) (86), and Resistance Min. 1 Mz
2 ness
to A50 (female) (4)
Between ground and wiring harness (from
A50 (male) (4) to each connector and pin) if Resistance Min. 1 Mz
optional CN-A50 wiring harness is installed
tive.
40-156 FH40-1, FH45-1, FH50-1

Failure code [47/D161KB] Backup buzzer and backup lamp relay: Ground fault
FH40-1, FH45-1, FH50-1 40-157

Failure code [47/D161KY] Backup buzzer and backup lamp relay: Hot short circuit
Failure code [47/D161KY] Backup buzzer and backup lamp relay:

Hot short circuit
Backup buzzer and backup lamp relay: Hot short circuit
KOMTRAX D161KY
• Abnormal voltage was detected in the backup buzzer and backup lamp relay circuit although no out-
Detail of failure
put was supplied.
Action of
• The backup buzzer continues to sound even when the directional (FNR) lever is in any position
Problem on lift other than Reverse (R).
truck • The backup lamp continues to light up even when the directional (FNR) lever is in any position other
than Reverse (R).
Related
information

Probable Between ground and wiring harnesses from
C03 (female) (15) to R15 (female) (86) and Voltage Max. 1 V
A50 (female) (4)
cuit)
Between ground and wiring harness (from
A50 (male) (4) to each connector and pin) if Voltage Max. 1 V
optional CN-A50 wiring harness is installed
40-158 FH40-1, FH45-1, FH50-1

Failure code [47/D161KY] Backup buzzer and backup lamp relay: Hot short circuit
FH40-1, FH45-1, FH50-1 40-159

Failure code [48/DV00KB] Warning buzzer: Ground fault
Failure code [48/DV00KB] Warning buzzer: Ground fault

Warning buzzer: Ground fault
KOMTRAX DV00KB
Detail of failure • Abnormal current flowed through warning buzzer circuit during output.
• Turns OFF the output to the warning buzzer circuit.
Problem on lift
• The warning buzzer does not sound.
truck
Related
information

Defective alarm buzzer troubleshooting without turning starting switch to the ON position.
1
(internal short circuit) Between M03 (male)
24 V applied Buzzer sounds
Probable (1) and (2)
2 ness
C03 (female) (18) to M03 (female) (1)
tive.
40-160 FH40-1, FH45-1, FH50-1

Failure code [48/DV00KY] Warning buzzer: Hot short circuit
Failure code [48/DV00KY] Warning buzzer: Hot short circuit

Warning buzzer: Hot short circuit
KOMTRAX DV00KY
Detail of failure • Abnormal voltage was detected although no output was supplied to warning buzzer circuit.
Action of
Problem on lift
• The warning buzzer continues to sound.
truck
Related
information

Voltage Max. 1 V
FH40-1, FH45-1, FH50-1 40-161

Failure code [49/D19UKA] Pump EPC valve ground cutout relay: Open circuit
Failure code [49/D19UKA] Pump EPC valve ground cutout relay:

Open circuit
Pump EPC valve ground cutout relay: Open circuit
KOMTRAX D19UKA
• When the output of pump EPC valve ground cutout relay was turned ON (opened), the signal of
pump EPC valve ground return signal circuit was detected.
Detail of failure
(If normal, the signal of pump EPC valve ground return signal circuit is not detected when the output
of pump EPC valve ground cutout relay is turned ON (opened).
• None
Problem on lift (If a hot short circuit occurs concurrently in the pump EPC solenoid valve, the current passing
truck through pump EPC solenoid valve circuit cannot be turned OFF even when the current is output to
the pump EPC ground cutout relay.)
Related
information

Between (86) and (85) 200 to 400z
Defective pump EPC valve Between (30) and (87A) Max. 1z
1 ground cutout relay Between (30) and (87) Min. 1 Mz
(internal failure)
troubleshooting with starting switch turned to the ON position.
Replace the pump EPC valve ground cutout relay (R17) with a nor-
Probable mal one. If it operates normally, the HST controller power relay is
causes and defective.
Open circuit in wiring har- troubleshooting without turning starting switch to the ON position.
(wire breakage or defective and R17 (female) (86)
Resistance Max. 1z
3 ness Between ground and wiring harnesses from
(contact with ground circuit) C03 (female) (10) to each of V01 (female) Resistance Min. 1 Mz
(2), V02 (female) (2), and P17 (female) (30)
40-162 FH40-1, FH45-1, FH50-1

Failure code [49/D19UKA] Pump EPC valve ground cutout relay: Open circuit
FH40-1, FH45-1, FH50-1 40-163

Failure code [49/D19UKB] Pump EPC valve ground cutout replay: Ground fault
Failure code [49/D19UKB] Pump EPC valve ground cutout replay:

Ground fault
Pump EPC valve ground cutout relay: Ground fault
KOMTRAX D19UKB
Detail of failure • Abnormal current flowed through pump EPC valve ground cutout relay during output.
• Turns OFF the output of pump EPC valve ground cutout relay circuit.
Action of
• None
Problem on lift (If a hot short circuit occurs concurrently in the pump EPC solenoid valve, the current passing
truck through pump EPC solenoid valve circuit cannot be turned OFF even when the current is output to
the pump EPC ground cutout relay.)
Related
information

2 ness
iContact with ground circuit) Between ground and wiring harness from
tive.
40-164 FH40-1, FH45-1, FH50-1

Failure code [49/D19UKB] Pump EPC valve ground cutout replay: Ground fault
FH40-1, FH45-1, FH50-1 40-165

Failure code [49/D19UKY] Pump EPC valve ground cutout relay: Hot short circuit
Failure code [49/D19UKY] Pump EPC valve ground cutout relay:

Hot short circuit
Pump EPC valve ground cutout relay: Hot short circuit
KOMTRAX D19UKY
• Abnormal voltage was detected although the output of pump EPC valve ground cutout relay was
Detail of failure
turned OFF.
Action of • Sounds the warning buzzer (continuously).
Problem on lift
truck
Related
information

causes and Hot short circuit in wiring har- troubleshooting with starting switch turned to the ON position.
Voltage Max. 1 V
40-166 FH40-1, FH45-1, FH50-1

Failure code [49/D19UKY] Pump EPC valve ground cutout relay: Hot short circuit
FH40-1, FH45-1, FH50-1 40-167

Failure code [52/DAJ0KK] HST controller: Drop of power voltage

HST controller: Drop of power voltage
KOMTRAX DAJ0KK
Detail of failure • The power voltage of HST controller dropped below 18 V.
Action of
controller • Limits the HST pump absorption torque to 30%.
• After the failure has recovered, the lift truck returns to normal only when you shift the directional
(FNR) lever to Neutral (N) position.
Problem on lift • The monitor panel display may fail.
truck • The relays and solenoid valves may fail to operate, and the system may malfunction
(including traveling and work equipment operations).
Related
information

1 Drop of battery voltage Battery voltage 20 to 30 V
Blown fuse No. 8 in fuse box
2 If fuse is broken, circuit probably has ground fault (See cause 4).
(F01)
Wiring harness between F03 and F01-9D Resistance Max. 1z
Wiring harness between F01-8 and C03
ness Resistance Max. 1z
3 (female) (1)
(wire breakage or defective
Probable Resistance Max. 1z
and T02 (ground)
causes and
criteria Wiring harness between C03 (female) (31)
Resistance Max. 1z
and T02 (ground)
4 ness
F01-8 to C03 (female) (1)
5 Defective HST controller C03 Voltage
Between (1) and (21)
20 to 30 V
40-168 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-169

Failure code [53/DAJ2KK] HST controller: Drop of load power supply voltage
Failure code [53/DAJ2KK] HST controller: Drop of load power supply

voltage
HST controller: Drop of load power supply voltage
KOMTRAX DAJ2KK
• The power voltage (VB) of HST controller is above 20 V, but the load power supply voltage (VIS) of
Detail of failure
HST controller is below 18 V.
Action of
controller
• Forcibly turns to Neutral (N) and stops the engine.
Problem on lift • The monitor panel display may fail.
truck • The relays and solenoid valves may fail to operate, and the system may malfunction
(including traveling and work equipment operations).
Related
information

D110KB]. If displayed, troubleshoot it first.
Between (86) and (85) 200 to 400 z
Defective HST controller
1 Between (30) and (87A) Max. 1z
power relay (internal failure)
Between (30) and (87) Min. 1 Mz
a Be ready with starting switch in the OFF position, then trouble-
shoot with starting switch at START position.
Replace the HST controller power relay (R10) with other normal
Probable relay. If system operates normally, the HST controller power relay
causes and is defective.
2
(wire breakage or defective Wiring harness between R10 (female) (30)
3 ness
R10 (female) (30) to C03 (female) (2)
4 Defective HST controller C03 Voltage
20 to 30 V
40-170 FH40-1, FH45-1, FH50-1

Failure code [53/DAJ2KK] HST controller: Drop of load power supply voltage
FH40-1, FH45-1, FH50-1 40-171

Failure code [54/7REHKA] Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit
Failure code [54/7REHKA] Accessory input circuit 2

(KEY_ACC_SIGNAL): Open circuit
Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit
KOMTRAX 7REHKA
Detail of failure • An open circuit was detected on the accessory input circuit 2 (KEY_ACC_SIGNAL).
Action of
controller
• When the starting switch is turned to the OFF position first, and then to the ON position, the parking
Problem on lift
remainder warning lamp flashes and the warning buzzer sounds.
truck
• The engine cannot be started.
Related • Method of reproducing failure code: Impossible (This failure cannot be reproduced even if the start-
information ing switch is turned to the OFF position and then turned to the ON position again.)

Blown fuse No. 16 in fuse
box (F01)
2
(wire breakage or defective Wiring harness between fuse box (F01)-16
causes and
criteria Ground fault in wiring har- Between ground and wiring harnesses from
3 ness fuse box (F01)-16 to each of C02 (female) Resistance Min. 1 Mz
(contact with ground circuit) (6), and D20 (female) (6)
D20 (female) (2) to C03 (female) (14)
C02 Voltage
Between C02 (6) and ground 20 to 30 V
40-172 FH40-1, FH45-1, FH50-1

Failure code [54/7REHKA] Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit
FH40-1, FH45-1, FH50-1 40-173

Failure code [55/DAJ5KX] HST controller sensor 5 V-power supply: Ground fault or hot short circuit

Ground fault or hot short circuit
Action code Failure code HST controller sensor 5 V-power supply: Ground fault or hot short
Lift truck 55 Failure circuit
KOMTRAX DAJ5KX
• The voltage of HST controller sensor 5 V-power supply circuit dropped below 4.7 V or exceeded 5.3
Detail of failure V.
• Abnormal current flowed through HST controller sensor 5 V-power supply circuit.
Action of
controller
• Stops the output of 5 V-power supply circuit.
truck • The system may malfunction.
• If this failure occurs, other failure codes are also output to indicate the failures of pressure sensor
Related
and potentiometer which are powered by the supply.
information

a Turn starting switch to the OFF position to disconnect connec-
Travel speed sensor tors, and turn it to the ON position for troubleshooting.
Travel speed sensor CN-P05
Brake charge pressure sensor Disconnect the Brake charge pressure sensor CN-P06
HST pump A-port pressure devices listed on the
right one by one. If HST pump A-port pressure sensor CN-P10
1 sensor
the failure code dis-
HST pump B-port pressure
appears, the device HST pump B-port pressure sensor CN-P11
sensor
that you have just
HST oil temperature sensor disconnected has an HST oil temperature sensor CN-P12
Lift cyl bottom pressure sensor internal failure. Lift cyl bottom pressure sensor CN-P13
Brake pedal angle sensor Brake pedal angle sensor CN-P14
Ground fault in wiring har- Between ground and wiring harness of C01
Probable
2 ness (female) (22) and each of P05 (female) (1),
causes and
(contact with ground circuit) P06 (female) (3), P10 (female) (3), P11 Resistance Min. 1 Mz
criteria
(female) (3), P11 (female) (3), P12 (female)
(1), P13 (female) (3), and P14 (female) (C)
C01 (female) (22) to each of P05 (female)
Hot short circuit in wiring har-
(1), P06 (female) (3), P10 (female) (3), P11 Voltage Max. 1 V
(female) (3), P12 (female) (1), P13 (female)
cuit)
(3), and P14 (female) (C)
If a wiring harness has a hot short circuit, the controller and each
sensor may also fail. Check them after the repairs of the wiring har-
nesses.
C01 Voltage
Between (21) and (22) 4.7 to 5.3 V
40-174 FH40-1, FH45-1, FH50-1

Failure code [55/DAJ5KX] HST controller sensor 5 V-power supply: Ground fault or hot short circuit
FH40-1, FH45-1, FH50-1 40-175

Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL): Open circuit
Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL):

Open circuit
Accessory input circuit 1 (KEY_SIGNAL): Open circuit
KOMTRAX 7REAKA
Detail of failure • An open circuit was detected on the accessory input circuit 1 (KEY_SIGNAL).
Problem on lift • The parking brake reminder warning function may fail.
truck • The engine may not start.
• Method of reproducing failure code: Turn the starting switch to the ON position and operate the
Related
parking brake lever (between Free and Lock positions).
information
(The failure code may not be reproduced in some position where the harness is open.)

Blown fuse No. 10 or No. 16
of fuse box (F01)
D20 (male) Digital tester Continuity
Defective diode array D20 Between (6) and (2) Diode mode Continuity
2
(internal open circuit)
Defective parking brake lever
3 P01 (male) Parking brake lever Resistance
switch (internal open circuit)
Lock position Min. 1 Mz
Between (1) and (2)
Free position Max. 1z
Wiring harness between fuse box (F01)-16
Resistance Max. 1z
and D20 (female) (6)
Probable
Open circuit in wiring har- Wiring harness between D20 (female) (2)
causes and Resistance Max. 1z
criteria 4
(wire breakage or defective Wiring harness between fuse box (F01)-10
Resistance Max. 1z
Wiring harness between D20 (female) (1)
Resistance Max. 1z
fuse box (F01)-16 to each of C02 (female) Resistance Min. 1 Mz
(6) and D20 (female) (6)
Ground fault in wiring har- Resistance Min. 1 Mz
5 ness
(contact with ground circuit) Resistance Min. 1 Mz
fuse box (F01)-10 to P01 (female) (1)
P01 (female) (2) to each of D20 (female) (5) Resistance Min. 1 Mz
40-176 FH40-1, FH45-1, FH50-1

Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL): Open circuit

Probable
Parking brake lever Voltage
causes and
criteria 6 Defective HST controller Between D20 (6) and Can be in Free or
20 to 30 V
C03 (14) Lock position.
Between D20 (5) and
Free position 20 to 30 V
C03 (24)
FH40-1, FH45-1, FH50-1 40-177

Failure code [62/DB2RKR] CAN communication (between HST controller and engine controller): Communication failure
(Component system failure)
Failure code [62/DB2RKR] CAN communication (between HST

controller and engine controller): Communication failure
Action code Failure code CAN communication (between HST controller and engine control-
Lift truck 62 Failure ler): Communication failure (Component system failure)
KOMTRAX DB2RKR
Detail of failure • The HST controller cannot identify the engine controller on the CAN communication circuit.
Action of
controller • Shifts to N position and stops the engine.
• After the failure has recovered, the lift truck returns to normal only when you shift the directional
(FNR) lever to Neutral (N) position.
Problem on lift • Lift truck cannot travel.
truck • The system may malfunction.
Related
information

Short circuit in wiring har- troubleshooting without turning starting switch to the ON position.
1
ness N02 Resistance
(wire breakage or defective and CE02 (female) (1)
Resistance Max. 1z
and CE02 (female) (21)
Probable
causes and C02 (female) (32) to each of CE02 (female)
criteria
(1), N01 (female) (3), N02 (female) (1), N03 Resistance Min. 1 Mz
(female) (A), N04 (female) (A), and CK01
3 ness
(female) (10)
Between ground and wiring harness of C02
(female) (22) and each of CE02 (female)
(21), N01 (female) (10), N02 (female) (2), Resistance Min. 1 Mz
N03 (female) (B), N04 (female) (B), and
CK01 (female) (11)
Hot short circuit in wiring har- Between ground and wiring harnesses from
4 ness (contact with 24 V cir- C02 (female) (32) to each of CE02 (female)
cuit) (1), N01 (female) (3), N02 (female) (1), N03 Voltage Max. 1 V
(female) (A), N04 (female) (A), and CK01
(female) (10)
40-178 FH40-1, FH45-1, FH50-1

Failure code [62/DB2RKR] CAN communication (between HST controller and engine controller): Communication failure

Hot short circuit in wiring har- C02 (female) (22) to each of CE02 (female)
4 ness (contact with 24 V cir- (21), N01 (female) (10), N02 (female) (2), Voltage Max. 1 V
cuit) N03 (female) (B), N04 (female) (B), and
CK01 (female) (11)
criteria N03 (male) Resistance
Defective CAN terminating
5
resistor Between (A) and (B) 100 to 140 z
N04 (male) Resistance
Between (A) and (B) 100 to 140 z
If causes 1 to 5 are not found, the engine controller or HST control-
ler may be defective.
FH40-1, FH45-1, FH50-1 40-179

Failure code [63/DAJ000] HST Controller: Memory error
Failure code [63/DAJ000] HST Controller: Memory error

HST controller: Memory error
KOMTRAX DAJ000
Detail of failure • The ROM (non-volatile memory) data of HST controller is abnormal.
• Uses the main area data or backup area data whichever correct.
Problem on lift
• No affection (The lift truck operates normally.)
truck
Related
information

Since failure is inside the system, troubleshooting cannot be per-
Probable formed. (Complete the initial adjustment again. If the trouble does
causes and not recur and no failure is observed, you can continue to use this
criteria controller.)
Open circuit or ground fault The power voltage (VB) of HST controller may have dropped dur-
2
in wiring harness ing data writing in memory. Troubleshoot for [52/DAJ0KK] failure.
40-180 FH40-1, FH45-1, FH50-1

Failure code [63/DAJ0KT] HST Controller: Memory error
Failure code [63/DAJ0KT] HST Controller: Memory error

HST controller: Memory error
KOMTRAX DAJ0KT
• The ROM (non-volatile memory) data of HST controller is abnormal.
Detail of failure
(Both main area memory and backup area memory are abnormal.)
• Restricts some functions (according to the internal failure location).
• Clears the entire memory data, and uses the default values.
Action of
controller • Both the travel speed limit function for operator and the highest travel speed limit function for admin-
istrator are activated, and the travel speed is limited to 5 km/h in both modes.
• The system may malfunction.
Problem on lift • Because the initial adjustment values are cleared, the HST brake feeling and the slow speed travel
truck performance may drop.
• The travel speed is limited to 5 km/h.
Related
information

Since trouble is inside the system, troubleshooting cannot be per-
Probable formed. (Complete the initial adjustment again. If the trouble does
causes and not recur and no failure is observed, you can continue to use this
criteria controller.)
Open circuit or ground fault The power voltage (VB) of HST controller may drop during data
2
in wiring harness writing in memory. Troubleshoot for [52/DAJ0KK] failure.
FH40-1, FH45-1, FH50-1 40-181

Troubleshooting by failure code (EPACS controller system)
Display of EPACS controller failure code

Display of EPACS controller failure code
1. Outline
• The EPACS controller LED lights up during normal operation.
• The LED is located near the wiring harness base of the EPACS controller and its color is red.
• If the EPACS controller detects a failure, it indicates the failure information by the LED going out or flash-
ing.
• Even while the LED is lighting, the EPACS may not work and the steering wheel knob may deviate (The
details of this phenomena are described in "E-mode".)
1. LED
2. Outline of description of problem

Condition of LED on
No. Trouble controller Detail of failure Repair method Remarks
1) Check and repair controller power
1 Knob deviates Goes out Controller malfunctions. supply circuit.
1) Check that controller plug is open
2 I Repeats 1 flashing Initialization is not completed. (It is normally open: disconnected).
2) Initialize.
1) Perform initialization from first.
2) Check and correct tire angle sen-
Controller is being initialized sor installation.
3 I Repeats 2 flashings (May be normal) 3) Check orbit roll rotor for loose (*1)
installation and fix it (tighten set
screw and lock).
Steering wheel angle sensor malfunc-
4 I Repeats 3 flashings Replace controller.
tions
Tire angle sensor malfunctions
• Breakage or short circuit of signal 1) Check and repair tire angle sensor
5 I Repeats 4 flashings line to GND (including installation).
• Tire angle sensor wrong installation 2) Check and repair tire angle sensor
(direction) circuit.
1) Check and repair tire angle sensor
(1) Short circuit of tire angle sensor (including installation).
power supply to signal line 2) Check and repair tire angle sensor
circuit.
1) Check if solenoid valve is turned
ON/OFF during steering operation.
(2) Correction solenoid valve failure 2) Check
and repair solenoid valve
wiring harness.
6 I Lights up 1) Check rotor for loose installation
(*2)
(3) Idle rotation of orbit roll rotor and fix it (tighten set screw and
lock).
(4) Failure of controller solenoid 1) Perform (2).
valve drive circuit 2) Replace controller.
1) Check if system can be initialized.
(5) Short circuit in steering wheel
2) Perform (1)
angle sensor 3) Replace controller.
*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)".
40-182 FH40-1, FH45-1, FH50-1

Failure code [LED: OFF] EPACS controller abnormality
Failure code [LED: OFF] EPACS controller abnormality

Failure code EPACS controller abnormality
Failure
LED: OFF (EPACS controller system)
• Controller power supply voltage lowered to below rating.

Detail of failure
• CPU in controller unit does not function normally.
Action of
• None in particular
controller
Problem on lift
• Knob position is not corrected and knob deviates.
truck
Related
• LED goes OFF for a short time during initialization of controller.
information

Defective fuse No. 15 in fuse
box (F01)
Open circuit in wiring tion.
harness a Disconnect connectors at both ends of circuit and measure
2
(wire breakage or defective resistance between terminals.
contact of connector)
Check continuity between related circuit
Resistance Max. 1z
Probable terminals shown in figure for disconnection.
criteria troubleshooting without turning starting switch to the ON posi-
tion.
Ground fault in wiring a Disconnect connectors at both ends of circuit and measure
3 harness resistance between each terminal and ground.
Measure resistance between related power
supply system circuit, signal system circuit Resistance Min. 1 Mz
and ground shown in figure for ground fault.
If above causes are not the cause for the trouble, EPACS controller
Defective EPACS controller
4 may be defective. (Since trouble is in system, troubleshooting
(internal defect)
cannot be performed.)
FH40-1, FH45-1, FH50-1 40-183

Failure code [LED: 1 flashing] Initialization is not completed
Failure code [LED: 1 flashing] Initialization is not completed

Failure code Initialization is not completed.
Failure
LED: 1 flashing (EPACS controller system)
Detail of failure • Initialization is not completed (If completed afterward, it is not a failure).
Action of
• Flashes LED 1 time for alarm (Repeats flashing until cause of problem is removed).
controller
Problem on lift
• Steering wheel knob deviation is not corrected normally.
truck
Related
• If initialization plug is connected, initialization is not performed yet.
information

Initialization is not com- Referring to Testing and adjusting, "Initialization of orbit roll", per-
Probable 1
pleted. form initialization.
causes and
criteria If above cause is not the cause for the trouble, EPACS controller
2 may be defective. (Since trouble is in system, troubleshooting can-
(internal defect)
not be performed.)
40-184 FH40-1, FH45-1, FH50-1

Failure code [LED: 2 flashings] Controller is being initialized
Failure code [LED: 2 flashings] Controller is being initialized

Failure code Controller is being initialized
Failure
LED: 2 flashings (EPACS controller system)
Detail of failure • Initialization mode is selected (If completed afterward, it has no problem).
Action of
• Flashes LED 2 times for alarm (Repeats flashing until cause of trouble is removed).
controller
Problem on lift
• Steering wheel knob deviation is not corrected normally.
truck
Related
information

Initialization is not com- Referring to Testing and adjusting, "Initialization of orbit roll", per-
1
pleted. form initialization.
Defective installation of tire Check tire angle sensor installation condition and correct if neces-
Probable 2
angle sensor sary.
causes and
criteria Check orbit roll rotor for loose installation, then retighten and lock
3 Loose orbit roll rotor
mounting bolts if necessary.
If above causes are not the cause for the trouble, EPACS controller
(internal defect)
not be performed.)
FH40-1, FH45-1, FH50-1 40-185

Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality

Failure code Steering wheel angle sensor abnormality
Failure
Detail of failure • Steering wheel angle sensor became abnormal (disconnection in coil etc.)
Action of
• Flashes LED 3 times for alarm (Repeats flashing until cause of trouble is removed).
controller
Problem on lift
• Operation amount of steering wheel cannot be sensed and knob deviates.
truck
Related
• Steering wheel angle sensor is built in orbit roll and cannot be repaired or replaced singly.
information

Defective steering wheel
Steering wheel angle sensor may be defective (Since trouble is in
Probable 1 angle sensor
system, troubleshooting cannot be performed.)
causes and (internal defect)
criteria If above causes are not the cause for the trouble, EPACS controller
(internal defect)
not be performed.)
40-186 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-187

Failure code [LED: 4 flashings] Tire angle sensor abnormality

Failure code Tire angle sensor abnormality
Failure
Detail of failure • Tire angle sensor or related circuit had abnormality.
Action of
• Flashes LED 4 times for alarm (Repeats flashing until cause of failure is removed).
controller
Problem on lift
• Rear wheel angle cannot be sensed and steering wheel knob deviates.
truck
Related
information

Defective installation of tire Check tire angle sensor installation condition and correct if neces-
1
angle sensor sary.
tion.
Defective tire angle sensor A08 (male) Resistance
2
(internal defect) (Between (A) - (C) 2 kz ± 20%
Resistance changes linearly
(Between (B) and (C) according to rotation amount of
shaft.
Open circuit in wiring har- tion.
ness a Disconnect connectors at both ends of circuit and measure
3
(wire breakage or defective resistance between terminals.
Probable Check continuity between related circuit ter-
Resistance Max. 1z
causes and minals shown in figure for disconnection.
tion.
Ground fault in wiring har- a Disconnect connectors at both ends of circuit and measure
4 ness resistance between each terminal and ground.
Measure resistance between related power
supply system circuit, signal system circuit Resistance Min. 1 Mz
and ground shown in figure for ground fault.
tion.
Short circuit in wiring har- a Disconnect connectors at both ends of circuit and measure
5 ness resistance between each terminal and terminal of another cir-
(Contact with another circuit) cuit.
Measure resistance between related circuits
shown in figure for short circuit.
Defective EPACS controller If above causes are not the cause for the trouble, EPACS controller
6
(internal defect) may be defective.
40-188 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-189

Troubleshooting for electrical system (E-mode)

a The following information is summarized in the troubleshooting table and related circuit diagram. Before
performing troubleshooting, understand those information fully.
Failure Failure symptom that appears on lift truck
Related
Information of occurred failure or troubleshooting
information

<Description>
assumed causes
• Remarks required to judge whether the cause is correct
1
The connector connection is defective or the wiring harness
is disconnected.
• Ground fault
comes into contact with the ground (earth) circuit.
2 • Hot short circuit
A harness not connected to power source (12 V) circuit
comes into contact with power (24 V) circuit.
Probable Cause by which a failure is • Short circuit
assumed to be detected A wiring harness of an independent circuit abnormally
causes and comes into contact with one of other circuits.
(The cause number indicates
criteria
a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Connector No. display method and T-adapter handling
For troubleshooting, connect the T-adapter as shown
3
below unless otherwise specified.
• If (male) or (female) is not displayed on the connector No.,
either the male and female sides.
For troubleshooting, connect the positive (+) and negative
4 (-) leads as shown below unless otherwise specified.
cated in the front.
in the rear.
This is the excerpted circuit diagram related to failure.

• Connector No.: (model version code - number of pins)
(color)
• "Connector No. & pin number" display from the
branched portion or merging portion:
• Branch destination or merging source in the same wir-
ing harness part
• Arrow ( ): Approximate installation portion on the lift
truck
40-190 FH40-1, FH45-1, FH50-1

E-1 Engine does not start

The starting motor does not rotate even if you turn the starting switch to START.
Detail of failure
(Failure in starting motor system or starting signal system of starting switch)
• If any failure code is displayed, perform troubleshooting for it first.
• Check following before troubleshooting.
a. Directional lever is in N (neutral) position.
Related b. Brake pedal is depressed all the way.
information c. Function of KOMTRAX to prohibit engine starting is not applied.
d. Battery cable is not disconnected from battery.
e. Fuse or slow blow fuse is not broken.
(If broken, check related wiring harness for ground fault.)

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 24 V
Defective fuse
• Slow blow fuse No. B2
• Fuse box (F01) No. 8
• Perform the following testing and adjusting since defective
adjustment of brake pedal angle sensor is suspected.
(Because HST controller detects condition of depressed brake
Defective adjustment of pedal to judge engine starting).
3
brake pedal angle sensor (1) Follow procedure in Testing and adjusting, "Testing and
adjusting brake pedal angle sensor linkage".
(2) Follow procedure in Testing and adjusting, "Special function
of HST controller" for adjusting brake pedal angle sensor.
Probable a Be ready with starting switch in the OFF position, then turn start-
causes and ing switch to START position and perform troubleshooting.
criteria Starting motor terminal Voltage
Between B and
Power supply 20 to 30 V
4 Defective starting motor ground
Between C and
Starting input 20 to 30 V
ground
If power supply and starting input are normal and starting motor
does not rotate, starting motor is defective.
tion.
Between (86) and (85) 280 to 360 z
Defective starting motor relay
(internal defect)
a Be ready with starting switch in the OFF position, then turn start-
ing switch to START position and perform troubleshooting.
If starting motor relay (R01) is replaced with normal relay and
starting motor rotates normally, starting motor relay is defective.
FH40-1, FH45-1, FH50-1 40-191


tion.
Between (86) and (85) 280 to 360 z
Defective PWM relay
(internal defect)
If normal condition is recovered after PWM relay (R05) is replaced
with normal relay, PWM relay is defective.
tion.
Between (86) and (85) 280 to 360 z
Defective HST controller Between (30) and (87A) Max. 1z
7
power relay (internal defect) Between (30) and (87) Min. 1 Mz
Replace the HST controller power relay (R10) with other normal
relay. If system operates normally, the HST controller power relay
is defective.
tion.
Defective diode D20 (internal D20 (male) Digital tester Continuity
Probable defect) Between (8) and (4) Diode mode Continuity
causes and 8 (PWM relay circuit system,
criteria Between (4) and (8) Diode mode No continuity
HST controller KEY_SIG
circuit system) Between (7) and (3) Diode mode Continuity
Starting switch Resistance
Between S01 (male) OFF Min. 1 Mz
Defective starting switch (1) and (2)
9 START Max. 1z
(internal defect)
Between S01 (male) OFF Min. 1 Mz
(1) and (4) ON Max. 1z
tion.
Wiring harness between battery (+) terminal
Resistance Max. 1z
and starting motor B terminal
Wiring harness between F04 and starting
Resistance Max. 1z
switch B terminal
Wiring harness between starting switch C
Open circuit in wiring Resistance Max. 1z
terminal and R01 (female) (30)
harness
10 Wiring harness between R01(female) (87)
(wire breakage or defective Resistance Max. 1z
and A06 (female) (1)
Wiring harness between A06 (male) (1) and
Resistance Max. 1z
starting motor C terminal
Resistance Max. 1z
Between R01(female) (85) - T03 wiring
Resistance Max. 1z
harnesses
Wiring harness between F03 and fuse box
Resistance Max. 1z
F01-(9D)
40-192 FH40-1, FH45-1, FH50-1


Wiring harness between fuse box F01 -(8)
Resistance Max. 1z
Resistance Max. 1z
and T03
Resistance Max. 1z
and T03
Wiring harness between fuse box F01-(8)
Resistance Max. 1z
Wiring harness between R10 (female) (30)
Resistance Max. 1z
Wiring harness between ACC terminal of
Resistance Max. 1z
starting switch and fuse box F01-(12E)
Wiring harness between fuse box F01-(16) Resistance Max. 1z
and C02 (female) (6) Resistance Max. 1z
Resistance Max. 1z
Open circuit in wiring and C03 (female) (14)
harness Wiring harness between F03 and fuse box
(wire breakage or defective F01-(20H)
contact of connector) Wiring harness between fuse box F01-(20)
Resistance Max. 1z
Wiring harness between R05(female) (87) Resistance Max. 1z
and CE03 (female) (3) Resistance Max. 1z
Resistance Max. 1z
Probable Wiring harness between D20 (female) (4)
criteria Wiring harness between CE02 (female) (55)
Resistance Max. 1z
Resistance Max. 1z
Resistance Max. 1z
Resistance Max. 1z
tion.
Between wiring harness from F04 to S01
(female) (1) and ground
Between wiring harness from S01 (male) (1)
Check to starting switch B terminal and ground
Ground fault in points Between wiring harness from starting switch
wiring harness when slow C terminal to S01 (male) (3) and ground
11
(contact with blow fuse Between wiring harness from S01 (female)
ground circuit) No. B2 is (3) to R01 (female) (30) and ground Resistance Min. 1 Mz
damaged Between wiring harness from R01 (female)
(87) to A06 (female) (1) and ground
Between wiring harness from A06 (male) (1)
to starting motor C terminal and ground
Between wiring harness from ACC terminal
of F starting switch to fuse box F01-(12E) Resistance Min. 1 Mz
and ground
FH40-1, FH45-1, FH50-1 40-193


Check Between ground and wiring harness from
points fuse box F01-(8) to each of R10 (female)
when fuse (87), C03 (female) (1), CK03 (female) (6)
box (F01) and (7)
No. 8 is Between wiring harness from R10 (female)
damaged Resistance Min. 1 Mz
(87) to C03 (female) (1) and ground
Between fuse box F01-(12) and each of S04
Check (female) (9) and S04 (female) (6)
points Between ground and wiring harness from
when fuse S04 (female) (10) to C02 (female) (15)
box (F01) Between ground and wiring harness from
No. 12 is Resistance Min. 1 Mz
damaged Between wiring harness from S04 (female)
Check Between wiring harness from fuse box F01-
Ground fault in points Resistance Min. 1 Mz
(20) to R05 (female) (30) and ground
Probable wiring harness when fuse
11
causes and (contact with box (F01)
criteria ground circuit) No. 20 is Between wiring harness from R05 (female)
damaged (87) to CE03 (female) (3) and ground
Check Between ground and wiring harness from

points fuse box F01-(13) to each of D20 (female) Resistance Min. 1 Mz
when fuse (8) and CE02 (female) (45)
box (F01) Between ground and wiring harness from
No. 13 is D20 (female) (4) to each of R05 (female) Resistance Min. 1 Mz
damaged (86) and D20 (female) (3)
Check
points
when
starting
Between wiring harness from C01(female)
motor cut Resistance Min. 1 Mz
functions
(5) to CK03 (female) (8) and ground
due to
ground
fault
Defective HST controller or If causes 1 to 12 are not the cause for the failure, HST controller or
12
defective engine controller engine controller may be defective.
40-194 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-195

E-2 Engine preheater does not operate

• Intake air heater mounting portion is not heated even if starting switch is turned to the ON position
Detail of failure
(in low temperature season).
• Temperature of engine air intake manifold is detected when starting switch is turned to the ON posi-
tion and automatic preheating starts. Preheater lamp is lit during preheating.
• Automatic preheating operating temperature and preheating time setting are as follows.
Related
information

Defective slow blow fuse No.
B1
Open circuit in wiring Wiring harness between CE02 (female) (54)
harness Resistance Max. 1z
2 and E07
(wire breakage or defective
contact of connector) Wiring harness between slow blow fuse F05
Resistance Max. 1z
and E05
Wiring harness between E06 and E08 Resistance Max. 1z
Between wiring harness from F05 to E05
Ground fault in wiring Resistance 1Max. Mz
and ground
Probable 3 harness
(contact with ground circuit) Between wiring harness from E06 to E08
causes and Resistance 1Max. Mz
and ground
criteria
Between wiring harness from CE02 (female)
Resistance 1Max. Mz
(54) to E07 and ground
a Turn starting switch to th OFF position and remove wiring har-
ness of relay.
a Check relay unit (with relay installed to lift truck).
Defective heater relay Heater relay
4
(internal open circuit) Apply 24 V to E07
Max. 1z
Between E05 and (Relay: ON)
E06 Other than above
Min. 1 Mz
(Relay: OFF)
Defective intake air heater troubleshooting without turning starting switch to the ON position.
5
(internal open circuit)
Between E08 and ground Resistance 0.15 to 0.25 z
If causes 1 to 5 are not the cause for the trouble, engine controller
6 Defective engine controller
may be defective.
40-196 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-197

E-3 Parking brake reminder alarm does not sound or does not stop sounding
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.
• 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

box (F01)
Defective parking brake lever P01 (male) Parking brake lever Resistance
2
switch (internal defect)
(Between (1) and (2)
3
(internal defect) Between M03 (male)
(1) and (2)
Resistance Max. 1z
Resistance Max. 1z
Open circuit in wiring har- and C02 (female) (16)
Probable 4 Resistance Max. 1z
(wire breakage or defective and D20 (female) (5)
causes and
contact of connector) Wiring harness between D20 (female) (1)
criteria Resistance Max. 1z
Resistance Max. 1z
and M03 (female) (1)
Wiring harness between M03 (female) (2)
Resistance Max. 1z
Between wiring harness from fuse box F01-
Ground fault in wiring har- (10) to P01 (female) (1) and ground
5 ness Between ground and wiring harness from
(contact with ground circuit) P01 (female) (2) to each of C02 (female) Resistance Min. 1 Mz
Defective diode D20 troubleshooting without turning starting switch to the ON position.
6
(internal defect) D20 (male) Digital tester Continuity
If causes 1 to 6 are not the cause for the trouble, HST controller
may be defective.
40-198 FH40-1, FH45-1, FH50-1

Detail of failure (2) While parking brake is applied, alarm buzzer does not stop sounding.
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).

Defective parking brake lever P01 (male) Parking brake lever Resistance
1
switch (internal defect)
(Between (1) and (2)
Probable causes a Be ready with starting switch in the OFF position, and then turn
and criteria starting switch to the ON position to perform troubleshooting.
2 ness (contact with 24 V cir- Voltage Max. 1 V
cuit)
Between wiring harness from P01 (female)
Voltage Max. 1 V
If causes 1 and 2 are not the cause for the trouble, HST controller
may be defective.
FH40-1, FH45-1, FH50-1 40-199

40-200 FH40-1, FH45-1, FH50-1

E-4 EPACS is abnormal

Detail of failure • Knob position is not corrected normally and knob deviates.
• Perform following troubleshooting when EPACS controller LED lights up (controller does not detect
Related trouble) and knob deviates.
information (If EPACS controller LED goes off or flashing, see "Troubleshooting by failure code (EPACS control-
ler system)".)

box (F01)
Defective installation of tire Check tire angle sensor installing condition and correct if
2
angle sensor necessary.
A08 (male) Resistance
Defective tire angle sensor
3 (Between (A) and (C) 2 kz ± 20%
(internal defect)
Resistance changes linearly
(Between (B) and (C) according to rotation amount of
shaft.
a Start engine, steer lift truck, and perform troubleshooting.
Defective EPACS solenoid
4 When steering, check response of solenoid valve to see if it is
valve (internal defect)
turned ON or OFF.
Probable
causes and Loose or idle rotation of orbit Check rotor for loose installation and retighten mounting screw if
5
criteria roll rotor loose.
Defective steering wheel
6 angle sensor Perform initialization again to see if system can be initialized.
(internal defect)
Resistance Max. 1z
and CS01 (female) (4)
Open circuit in wiring har- Wiring harness between CS01 (female) (3)
Resistance Max. 1z
ness and T01
7
(wire breakage or defective Wiring harness between CS01 (female) (6)
and A08 (female) (A)
Wiring harness between CS01 (female) (7)
Resistance Max. 1z
and A08 (female) (B)
Wiring harness between CS01 (female) (8)
Resistance Max. 1z
and A08 (female) (C)
FH40-1, FH45-1, FH50-1 40-201


fuse box F01-(15) to each of E04 (female)
(2), CK03 (female) (3), (4), and (11), and Resistance Min. 1 Mz
wiring harness from fuse box F01-(15) to
CS01 (female) (4)
D20 (female) (4) to each of R05 (female) Resistance Min. 1 Mz
Between wiring harness from CK07 (male)
Ground fault in wiring har- Between wiring harness from CK07 (male)
Probable causes 8 ness Resistance Min. 1 Mz
and criteria (contact with ground circuit)
Between wiring harness from CS01 (female)
(6) to A03 (female) (A) and ground
Between wiring harness from A03 (male) (A)
to A08 (female) (A) and ground
(7) to A03 (female) (B) and ground
Between wiring harness from A03 (male) (B)
to A08 (female) (B) and ground
(8) to A03 (female) (C) and ground
Between wiring harness from A03 (male) (C)
to A08 (female) (C) and ground
Defective EPACS controller If causes 1 to 8 are not the cause for the trouble, EPACS controller
9
40-202 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-203

E-5 Headlamp, clearance lamp, tail lamp and license plate lamp do not light up or go off
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

box (F01)
Switch operation Resistance
Between S06 (male) (7) and S05 OFF (Upper, middle,
Min. 1 Mz
(male) (2) lower)
Between S06 (male) (7) and S05 1st position (Upper,
Min. 1 Mz
(male) (2) middle, lower)
Between S06 (male) (7) and S05 2nd position (Middle
Max. 1z
(male) (2) part)
Between S06 (male) (7) and S05 2nd position (Upper
Min. 1 Mz
(male) (2) and lower parts)
Defective combination switch
2 Between S06 (male) (7) and S06 OFF (Middle and
(internal defect) Min. 1 Mz
(male) (6) lower parts)
Between S06 (male) (7) and S06
OFF (Upper part) Max. 1z
(male) (6)
Between S06 (male) (7) and S06 1st position (Middle
Min. 1 Mz
Between S06 (male) (7) and S06 1st position (Upper
Max. 1z
(male) (6) part)
Probable Between S06 (male) (7) and S06 2nd position (Middle
Min. 1 Mz
causes and (male) (6) part)
criteria Between S06 (male) (7) and S06 2nd position (Upper
Max. 1z
Defective dimmer relay troubleshooting without turning starting switch to the ON position.
For head lamp low beam R09 (male) Resistance
(internal defect) Between (86) and (85) 280 to 360 z
Between (30) and (87A) Max. 1z
3 * Head lamps are switched to
high and low beam only Between (30) and (87) Min. 1 Mz
when optional 2-stage a Be ready with starting switch in the OFF position, and then turn
switching head lamps are starting switch to the ON position to perform troubleshooting.
mounted. If dimmer relay (R09) is replaced with normal relay and normal
condition is recovered, dimmer relay is defective.
Defective main lamp relay troubleshooting without turning starting switch to the ON position.
For head lamp high beam R13 (male) Resistance
(internal defect) Between (86) and (85) 280 to 360 z
Between (30) and (87A) Max. 1z
4 * Head lamps are switched to
high and low beam only Between (30) and (87) Min. 1 Mz
when optional 2-stage a Be ready with starting switch in the OFF position, and then turn
switching head lamps are starting switch to ON position to perform troubleshooting.
mounted. If lamp main relay (R13) is replaced with normal relay and normal
condition is recovered, lamp main relay is defective.
40-204 FH40-1, FH45-1, FH50-1


Resistance Max. 1z
Resistance Max. 1z
and A09R (female) (1)
Wiring harness between A09R (female) (2)
Resistance Max. 1z
and T01
Resistance Max. 1z
and A09L (female) (1)
Wiring harness between A09L (female) (2)
Resistance Max. 1z
Open circuit in wiring har- and T01
ness Wiring harness between fuse box F01-(3)
(wire breakage or defective and S06 (female) (7)
contact of connector) Wiring harness between S05 (female) (2)
Resistance Max. 1z
Resistance Max. 1z
and T03
Resistance Max. 1z
Resistance Max. 1z
Probable
criteria
Wiring harness between S06 (female) (6)
Resistance Max. 1z
tion.
fuse box F01-(3) to each of S06 (female) Resistance Min. 1 Mz
(7), R09 (female) (30), R12 (female) (30)
R09 (female) (87) to each of A01R (female) Resistance Min. 1 Mz
(4) and A01L (female) (4)
Ground fault in wiring har- A01R (male) (4) to each of A01R (male) (5) Resistance Min. 1 Mz
6 ness and A09R (female) (1)
A01L (male) (4) to each of A01L (male) (5) Resistance Min. 1 Mz
R13 (female) (87) to each of A01R (female) Resistance Min. 1 Mz
S05 (female) (2) to R09 (female) (86)
Between wiring harness from S06 (female)
FH40-1, FH45-1, FH50-1 40-205


R09 (female) (87) to each of A01R (female) Voltage Max. 1 V
R13 (female) (87) to each of A01R (female) Voltage Max. 1 V
Probable (5) and A01L (female) (5)
A01R (male) (4) to each of A01R (male) (5) Voltage Max. 1 V
cuit)
A01L (male) (4) to each of A01L (male) (5) Voltage Max. 1 V
Voltage Max. 1 V
S05 (female) (2) to R09 (female) (86)
Voltage Max. 1 V
40-206 FH40-1, FH45-1, FH50-1

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

box (F01)
tion.
Switch operation Resistance
Defective combination switch Between S05 (male) (4) and S05
2 OFF Min. 1 Mz
(internal defect) (male) (1)
1st position Max. 1z
(male) (1)
2nd position Max. 1z
(male) (1)
tion.
Between (86) and (85) 280 to 360 z
Defective position relay
(internal defect)
a Be ready with starting switch in the OFF position, then trouble-
shoot with starting switch at the START position.
If position relay (R12) is replaced with normal relay and normal
condition is recovered, position relay is defective.
Probable
criteria troubleshooting without turning starting switch to the ON position.
Resistance Max. 1z
Resistance Max. 1z
and A10R (female) (A)
Wiring harness between A10R (female) (B)
Resistance Max. 1z
and T01
Resistance Max. 1z
and A10L (female) (A)
Wiring harness between A10L (female) (B)
Resistance Max. 1z
Open circuit in wiring har- and T01
ness Wiring harness between R12 (female) (87)
(wire breakage or defective and L03R (female) (1)
contact of connector) Wiring harness between L03R (female) (6)
Resistance Max. 1z
and T03
Resistance Max. 1z
and L03L (female) (1)
Wiring harness between L03L (female) (6)
Resistance Max. 1z
and T03
Wiring harness between fuse box (F01) No.
Resistance Max. 1z
2 (outlet) and S05 (female) (4)
Resistance Max. 1z
Resistance Max. 1z
and T03
FH40-1, FH45-1, FH50-1 40-207


fuse box F01-(2) to each of S05 (female) (4) Resistance Min. 1 Mz
R12 (female) (87) to each of A01R (female)
(3), A01L (female) (3), L03R (female) (1),
5 ness
(contact with ground circuit) Between wiring harness from A01R (male)
(3) to A10R (female) (A) and ground
Between wiring harness from A01L (male)
(3) to A10L (female) (A) and ground
Probable Between ground and wiring harness of P02
causes and (female) (2) and each of L03R (female) (2) Resistance Min. 1 Mz
criteria and L03L (female) (2)
Between ground and wiring harness S05
(female) (1) - R12 (female) (86)
Voltage Max. 1 V
Hot short circuit in wiring har- and L03L (female) (1)
Between wiring harness from A01R (male)
Voltage Max. 1 V
Voltage Max. 1 V
(1) to R12 (male) (86) and ground
40-208 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-209

E-6 Turn signal lamps do not light up or go off

Detail of failure • Turn signal lamps do not light up or go off.
Related
• Before troubleshooting, check turn signal lamps for burned-out bulb.
information

box (F01)
S06 (male) Switch operation Resistance
Between (5) and (4) Neutral Min. 1 Mz
Defective combination switch Between (5) and (4) L Max. 1z
2
(internal defect)
Between (5) and (4) R Min. 1 Mz
Between (5) and (8) Neutral Min. 1 Mz
Between (5) and (8) L Min. 1 Mz
Between (5) and (8) R Max. 1z
Defective flasher unit R02 Switch operation Voltage

3
(internal defect) Between (3) and (1) Neutral, L, R 20 to 30 V
Repetition of 20 – 30
Probable Between (4) and (1) L, R
V 0V
causes and
Be ready with starting switch in the OFF position, then perform
criteria
Resistance Max. 1z
Resistance Max. 1z
and S06 (female) (5)
Resistance Max. 1z
Open circuit in wiring har- Wiring harness between A12 (male) (5) and
Resistance Max. 1z
ness L03L(female)(3)
4
(wire breakage or defective Wiring harness between L03L (female) (6)
and T03
Resistance Max. 1z
Wiring harness between A12 (male) (3) and
Resistance Max. 1z
L03R(female)(3)
Wiring harness between L03R (female) (6)
Resistance Max. 1z
and T03
Resistance Max. 1z
and T03
40-210 FH40-1, FH45-1, FH50-1


fuse box F01-(11) to each of R02 (female)
(3), CM04 (female) (1), R15 (female) (30), Resistance Min. 1 Mz
A50 (female) (1), A50 (female) (2), A50
(female) (3), and N01 (female) (2)
Between wiring harness from R02 (female)
Ground fault in wiring har- (4) to S06 (female) (5) and ground
(contact with ground circuit) S06 (female) (4) to each of A12 (female) (5) Resistance Min. 1 Mz
to L03L (female) (3) and ground
Probable
causes and Resistance Min. 1 Mz
(2) to A10R (female) (C) and ground
criteria
R15 (female) (87) to each of L03R (female) Resistance Min. 1 Mz
(4), L03L (female) (4), and M02 (female) (1)
S06 (female) (4) to each of A12 (female) (5) Voltage Max. 1 V
6 ness (contact with 24 V cir- Voltage Max. 1 V
to A10L (female) (C) and ground
cuit)
S06 (female) (8) to each of A01R (female) Voltage Max. 1 V
(2) and L03R (female) (3)
Voltage Max. 1 V
FH40-1, FH45-1, FH50-1 40-211

40-212 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-213

E-7 Brake lamps do not light up or go off

Detail of failure • Brake lamps do not light up or go off.
Related
• Before troubleshooting, check brake lamps for burned-out bulb.
information

box (F01)
Defective stop lamp switch P02 (male) Brake pedal Resistance
2
(internal defect)
Between (1) and (2) Depressed Max. 1z
Between (1) and (2) Released Min. 1 Mz
Resistance Max. 1z
Resistance Max. 1z
ness and L03R (female) (2)
3
(wire breakage or defective Wiring harness between P02 (female) (2)
Resistance Max. 1z
and T03
Resistance Max. 1z
and T03
Probable
fuse box F01-(2) to each of S05 (female) (4) Resistance Min. 1 Mz
Ground fault in wiring har- and L03L (female) (1)
5 ness
(contact with ground circuit) Resistance Min. 1 Mz
P02 (female) (2) to each of L03R (female) Resistance Min. 1 Mz
(2) and L03L (female) (2)
(1) to R12 (male) (86) and ground
6 ness (contact with 24 V cir- Between ground and wiring harnesses from
cuit) P02 (female) (2) to each of L03R (female) Voltage Max. 1 V
(2) and L03L (female) (2)
40-214 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-215

E-8 Backup lamps do not light up or go off

Detail of failure • Backup lamps do not light up or go off.
Related • Before troubleshooting, check backup lamps for burned-out bulb.
information • If any failure code is displayed, perform troubleshooting for it first.

box (F01)
Between (85) and (86) 280 to 360 z
Defective backup buzzer and
2 backup lamp relay (internal Between (30) and (87) Min. 1 Mz
open circuit) a Be ready with starting switch in the OFF position, and then turn
If backup buzzer and backup lamp relay (R15) is replaced with nor-
mal relay and normal condition is recovered, backup buzzer and
backup lamp relay are defective.
Resistance Max. 1z
Open circuit in wiring har- Wiring harness between R15 (female) (87)
Resistance Max. 1z
ness and L03R (female) (4)
3
Resistance Max. 1z
and T03
Resistance Max. 1z
Probable and T03
(4) to S06 (female) (5) and ground
Ground fault in wiring har- S06 (female) (4) to each of A01L (female) Resistance Min. 1 Mz
4 ness (2) and L03L (female) (3)
(2) to A10L (female) (C) and ground
S06 (female) (8) to each of A01R (female) Resistance Min. 1 Mz
cuit) R15 (female) (87) to each of L03R (female) Voltage Max. 1 V
40-216 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-217

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
information

box (F01)
(Between (85) and (86) 280 to 360 z
Defective backup buzzer and
2 backup lamp relay (internal (Between (30) and (87) Min. 1 Mz
defect) a Be ready with starting switch in the OFF position, and then turn
If backup buzzer and backup lamp relay (R15) is replaced with nor-
mal relay and normal condition is recovered, backup buzzer and
backup lamp relay is defective.
Defective backup buzzer troubleshooting without turning starting switch to the ON position.
3
(1) and (2)
Open circuit in wiring har- Wiring harness between fuse box F01-(11)
Resistance Max. 1z
ness and R15 (female) (30)
4
Resistance Max. 1z
and T03
Probable
criteria
(3), CM04 (female) (1), R15 (female) (30),
(female) (3), N01 (female) (2), and R14
(female) (86)
Ground fault in wiring har- Between ground and wiring harnesses from
5 ness S06 (female) (4) to each of A01L (female) Resistance Min. 1 Mz
(contact with ground circuit) (2) and L03L (female) (3)
(2) to A10L (female) (C) and ground
S06 (female) (8) to each of A01R (female) Resistance Min. 1 Mz
cuit) R15 (female) (87) to each of L03R (female) Voltage Max. 1 V
40-218 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-219

E-10 Horn does not sound or does not stop sounding

Detail of failure • Horn does not sound or does not stop sounding.
Related
information

box (F01)
R03(male) Resistance
(Between (85) and (86) 280 to 360 z
Defective horn relay
2 (Between (30) and (87) Min. 1 Mz
(internal defect)
If horn relay (R03) is replaced with normal relay and normal condi-
tion is recovered, horn relay is defective.
Defective horn switch S03 (male) Switch operation Resistance
3
(internal defect)
Pressed Max. 1z
Between (2) and (1)
Released Min. 1 Mz
Defective horn troubleshooting without turning starting switch to the ON position.
4
24 V applied Horn sounds
(1) and (2)
Probable Wiring harness between fuse box F01-(1)
criteria
Resistance Max. 1z
Open circuit in wiring har- and M01 (female) (1)
ness Wiring harness between M01 (female) (2)
(wire breakage or defective and T03
Resistance Max. 1z
Resistance Max. 1z
and S03 (female) (2)
Resistance Max. 1z
and T03
fuse box F01-(1) to R03 (female) (30)
6 ness Resistance Min. 1 Mz
(87) to M01 (female) (1) and ground
cuit) Between wiring harness from R03 (female)
Voltage Max. 1 V
(87) to M01 (female) (1) and ground
40-220 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-221

E-11 Fuel level is not displayed normally

Detail of failure • Fuel level is not displayed normally.
• Perform following troubleshooting when there is remarkable difference between actual fuel level
and displayed fuel level.
Related • If all of indicator and warning lamps of instrument panel do not light up when starting switch is
information turned to the ON position, instrument panel power supply may be defective. Perform troubleshoot-
ing of E-13 "(1) All of indicator and warning lamps of instrument panel do not light up when starting
switch is turned to the ON position" first.

Defective fuel level sensor P07 (male) Fuel level Resistance
1
(internal defect)
Full 0 to 2 z
Between (3) and (2)
Empty 140 to 160 z
Defective DC/DC converter starting switch to the ON position to perform troubleshooting.
2
(internal defect) M04 Voltage
Between (4) and (3) 13.2 to 14.2V
Wiring harness between CM01 (female) (7)
Resistance Max. 1z
Open circuit in wiring har- and P07 (female) (3)
Probable contact of connector) Wiring harness between CM01 (female) (9)
Resistance Max. 1z
causes and and T01
criteria
Resistance Max. 1z
Ground fault in wiring har- Between ground and wiring harnesses from
4 ness CM01 (female) (7) to each of P07 (female) Resistance Min. 1 Mz
(contact with ground circuit) (3) and C03 (female) (9)
CM02 (female) (3) to R14 (female) (87)
Hot short circuit in wiring har- Between ground and wiring harnesses of
5 ness (contact with 24 V cir- CM01 (female) (7) to each of P07 (female) Voltage Max. 1 V
cuit) (3) and C03 (female) (9)
Voltage Max. 1 V
CM02 (female) (3) to R14 (female) (87)
Defective instrument panel If causes 1 to 5 are not the cause for the trouble, fuel gauge of
6
(internal defect) instrument panel may be defective.
40-222 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-223

E-12 Engine coolant temperature level is not displayed normally

Detail of failure • Engine coolant temperature level is not displayed normally.
• When engine coolant temperature indicator does not move or it remains at high temperature side
even if warming up operation is performed, perform the following troubleshooting.
Related • If all of indicator and warning lamps of instrument panel do not light up when starting switch is
information turned to the ON position, instrument panel power supply may be defective. Perform troubleshoot-
ing of E-13 "(1) All of indicator and warning lamps of instrument panel do not light up when starting
switch is turned to the ON position" first.

Defective engine coolant troubleshooting without turning starting switch to the ON position.
1 sensor E10 (male) Coolant temperature Resistance
(internal defect) Between (1) and
50 to 120°C 10 to 100 z
ground
2
Between (4) and (3) 13.2 to 14.2V
Probable
causes and ness Wiring harness between CM02 (female) (1)
criteria (wire breakage or defective and E10 (female) (1)
contact of connector) Wiring harness between CM01 (female) (9)
Resistance Max. 1z
and T01
4 ness
(contact with ground circuit) Between wiring harness from CM02
(female) (1) to E10 (female) (1) and ground
cuit) Between wiring harness from CM02
Voltage Max. 1 V
(female) (1) to E10 (female) (1) and ground
Defective instrument panel If causes 1 to 5 are not the cause for the trouble, coolant gauge of
6
(internal defect) instrument panel may be defective.
40-224 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-225

E-13 All of indicator and warning lamps of instrument panel do not light up when starting switch is turned to the ON position.
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.
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

Defective fuses No. 9 and
No. 11 in fuse box (F01)
Between (86) and (85) 280 to 360 z
Defective instrument power Between (30) and (87A) Max. 1z
Probable causes 2 supply relay Between (30) and (87) Min. 1 Mz
and criteria (internal defect)
If instrument panel power supply relay (R14) is replaced with nor-
mal relay and normal condition is recovered, instrument power sup-
ply relay is defective.
3
Between (4) and (3) 13.2 to 14.2V
40-226 FH40-1, FH45-1, FH50-1


Wiring harness between ACC terminal of
Resistance Max. 1z
starting switch and fuse box F01-(12E)
Resistance Max. 1z
Resistance Max. 1z
and T03
Wiring harness between F03 and fuse box
Resistance Max. 1z
F01-(9D)
Open circuit in wiring harness
4 (wire breakage or defective Resistance Max. 1z
Resistance Max. 1z
Resistance Max. 1z
and CM02 (female) (3)
Resistance Max. 1z
and T01
Resistance Max. 1z
and T03
Resistance Max. 1z
and T03
Probable causes Between ground and wiring harnesses from
and criteria fuse box F01-(11) to each of R02 (female)
Check (4) to S06 (female) (5) and ground
points Between ground and wiring harnesses from
when fuse S06 (female) (4) to each of A12 (female) (5) Resistance Min. 1 Mz
box (F01) and L03L (female) (3)
No. 11 is Between wiring harness from A12 (male) (5)
Ground fault in damaged to L03L (female) (3) and ground Resistance Min. 1 Mz
wiring harness
5 Between ground and wiring harnesses from
(contact with
S06 (female) (8) to each of A12 (female) (3) Resistance Min. 1 Mz
ground circuit)
and L03R (female) (3)
Check Resistance Min. 1 Mz
fuse box F01-(9) to M04 (female) (1)
points
when fuse
M04 (female) (3) to each of R11 (male) (30) Resistance Min. 1 Mz
box (F01)
No. 9 is
damaged Between wiring harness from R11 (female)
(87) to CM01 (female) (5) and ground
Defective instrument panel If causes 1 to 5 are not the cause for the trouble, instrument panel
6
FH40-1, FH45-1, FH50-1 40-227

40-228 FH40-1, FH45-1, FH50-1

(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

Burned-out bulb of When only abnormality warning lamp does not light up, check it for
1
abnormality warning lamp burned-out bulb or defective contact.
criteria
ness Wiring harness between CM02 (female) (5)
Resistance Max. 1z
(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

Burned-out bulb of engine When only engine abnormality warning lamp does not light up,
1
Probable abnormality warning lamp check it for burned-out bulb or defective contact.
ness
2
(wire breakage or defective Wiring harness between CM02 (female) (6)
(4) When starting switch is turned to the ON position, loading interlock warning lamp of instrument
Detail of failure
Related
• Loading interlock warning lamp lights up by control of HST controller.
information

Burned-out bulb of lift inter- When only loading interlock warning lamp does not light up, check
1
Probable lock warning lamp it for burned-out bulb or defective contact.
ness
2
and CO02 (female) (19)
FH40-1, FH45-1, FH50-1 40-229

(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

Burned-out bulb of charge When only charge warning lamp does not light up, check it for
1
Probable warning lamp burned-out bulb or defective contact.
ness
2
(wire breakage or defective Wiring harness between CM02 (female)
(12) and C02 (female) (8)
(6) When starting switch is turned to the ON position, engine oil pressure warning lamp of instrument
Detail of failure
Related
• Engine oil pressure warning lamp lights up by control of HST controller.
information

Burned-out bulb of engine oil When only engine oil pressure warning lamp does not light up,
1
pressure warning lamp check it for burned-out bulb or defective contact.
(Between (86) and (85) 280 to 360 z
Defective engine oil pressure
2 drop warning lamp (Between (30) and (87) Min. 1 Mz
relay (internal open circuit) a Be ready with starting switch in the OFF position, and then turn
Probable
If engine oil pressure drop warning lamp relay (R16) is replaced
causes and
with normal relay and normal condition is recovered, engine oil
criteria
pressure drop warning lamp relay is defective.
Resistance Max. 1z
ness Wiring harness between R16 (female) (87)
Resistance Max. 1z
Resistance Max. 1z
40-230 FH40-1, FH45-1, FH50-1

(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.
• Check that directional lever is in N (neutral) position before performing troubleshooting.

(When it is not in N (neutral) position, neutral indicator lamp does not light up when starting switch is
Related
turned to the ON position.)
information
• Travel interlock warning lamp (also working as neutral indicator lamp) lights up by control of HST
controller.

Burned-out bulb of travel
interlock warning lamp When only engine abnormality warning lamp does not light up,
1
Probable (also working as neutral indi- check it for burned-out bulb or defective contact.
causes and cator lamp)
2
FH40-1, FH45-1, FH50-1 40-231

40-232 FH40-1, FH45-1, FH50-1

E-14 When starting switch is turned to the ON position, all of indicator and warning lamps of pilot box do not light up
E-14 When starting switch is turned to the ON position, all of indicator

and warning lamps of pilot box do not light up
(1) When starting switch is turned to the ON position, all of indicator and warning lamps of pilot panel
Detail of failure
do not light up.
• Check that parking brake lever is in Lock position before performing troubleshooting.
(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 of pilot box is shown in figure below.
Related
information

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.
criteria 1
contact of connector) Resistance Min. 1 z
and each of CM03 (female) (1) and (7)
(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

Burned-out bulb of parking When only parking brake reminder warning lamp does not light up,
1
brake reminder warning lamp check it for burned-out bulb or defective contact.
causes and
criteria Wiring harness between CM03 (female) (1)
Resistance Max. 1z
3 ness Between wiring harness from CM03
(contact with ground circuit) (female) (2) to C03 (female) (36) and Resistance Max. 1z
ground
FH40-1, FH45-1, FH50-1 40-233

(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

Burned-out bulb of HST oil When only HST oil temperature warning lamp does not light up,
1
temperature warning lamp check it for burned-out bulb or defective contact.
causes and
Resistance Max. 1z
ground
(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

Burned-out bulb of HST oil When only HST oil filter clogging warning lamp does not light up,
1
filter clogging warning lamp check it for burned-out bulb or defective contact.
causes and
Resistance Max. 1z
ground
40-234 FH40-1, FH45-1, FH50-1

(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

Burned-out bulb of parking When only parking brake indicator warning lamp does not light up,
1
brake indicator lamp check it for burned-out bulb or defective contact.
causes and
Resistance Max. 1z
ground
(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

Burned-out bulb of travel
When only travel speed restriction indicator lamp does not light up,
1 speed restriction indicator
check it for burned-out bulb or defective contact.
lamp
Probable ness Wiring harness between CM03 (female) (6)
causes and (wire breakage or defective and C03 (female) (38)
criteria contact of connector)
Resistance Max. 1z
ground
FH40-1, FH45-1, FH50-1 40-235

(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

Burned-out bulb of sedi- When only sedimenter (water separator) does not light up, check it
1
menter warning lamp for burned-out bulb or defective contact.
Probable ness Wiring harness between CM03 (female) (8)
causes and (wire breakage or defective and C03 (female) (5)
criteria contact of connector)
Resistance Max. 1z
3 ness
(contact with ground circuit) Between wiring harness from CM03
Resistance Max. 1z
(female) (8) to C03 (female) (5) and ground
40-236 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-237

E-15 When starting switch is turned to the ON position, preheater lamp does not light up
E-15 When starting switch is turned to the ON position, preheater lamp

does not light up
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.

causes and ness Wiring harness between fuse box No. 11
criteria 1 Resistance Max. 1z
(wire breakage or defective (outlet) and CM04 (female) (1)
Resistance Max. 1z
40-238 FH40-1, FH45-1, FH50-1

E-15 When starting switch is turned to the ON position, preheater lamp does not light up
FH40-1, FH45-1, FH50-1 40-239

E-16 When starting switch is turned to the ON position, alarm buzzer does not sound
E-16 When starting switch is turned to the ON position, alarm buzzer

does not sound
Detail of failure • When starting switch is turned to the ON position, alarm buzzer does not sound.
• If normal, engine buzzer sounds for 1 second when starting switch is turned to the ON position.
Related • If any failure code is displayed, perform troubleshooting for it first.
information • Check that parking brake lever is in Lock position before performing troubleshooting.
(If parking brake lever is not in Lock position, "parking brake reminder alarm" (intermittent sound)
sounds when starting switch is turned to the ON position.)

1
(1) and (2)
causes and Open circuit in wiring har- troubleshooting without turning starting switch to the ON position.
criteria ness Between wiring harness C03 (female) (18)
(wire breakage or defective and M03 (female) (1)
contact of connector) Between wiring harness C03 (female) (3)
Resistance Max. 1z
may be defective.
40-240 FH40-1, FH45-1, FH50-1

E-16 When starting switch is turned to the ON position, alarm buzzer does not sound
FH40-1, FH45-1, FH50-1 40-241

E-17 Backup lamp of instrument panel does not light up

Detail of failure Backlight of instrument panel does not light up.
• When clearance lamps and tail lamps do not light up, perform troubleshooting of E-5 "(2) Clearance
lamps or tail lamps do not light up or go off" first.
Related
information • If all of indicator and warning lamps of instrument panel do not light up when starting switch is
turned to the ON position, perform troubleshooting of E-13 "(1) When starting switch is turned to the
ON position, all of indicator and warning lamps of instrument panel do not light up" first.

Burned-out bulb of backup
1 Check backup lamp for burned-out bulb or defective contact.
lamp
starting switch to ON position to perform troubleshooting.
Operation of
Defective DC converter M04 Voltage
2 combination switch
(internal defect)
OFF Max. 1 V
Between (5) and (3) 1st position 13.2 - 14.2V
Probable
causes and 2nd position 13.2 - 14.2V
Open circuit in wiring har- Wiring harness between R12 (female) (86)
Resistance Max. 1z
ness and M04 (female) (2)
3
(wire breakage or defective Wiring harness between M04 (female) (5)
and CM01 (female) (5)
Resistance Max. 1z
and T01
Defective instrument panel If causes 1 to 3 are not the cause for the trouble, instrument panel
4
40-242 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-243

E-18 Charge warning lamp lights up while engine is running

Detail of failure • Charge warning lamp lights up while engine is running.
• When abnormality (alternator R signal voltage is 7.8 V or below) is detected in battery charge sys-
tem while engine is running,
Related
(1) Charge warning lamp lights up.
information
(2) Abnormality warning lamp lights up.
(3) Alarm buzzer sounds intermittently.

Defective alternator power engine to perform troubleshooting.
Probable 1 generation E04 Engine speed Voltage
causes and (when system is normal) Between (1) and Medium speed or
criteria 27.5 to 29.5 V
ground above
Open circuit or ground fault Check whether HST controller system failure code [Lift truck: 27/
2 in wiring harness KOMTRAX:AB00KZ] is displayed or not. If it is displayed, perform
(alternator R signal circuit) troubleshooting for it first.
40-244 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-245

E-19 HST oil temperature warning lamp lights up while engine is running
E-19 HST oil temperature warning lamp lights up while engine is

running
Detail of failure • HST oil temperature warning lamp lights up while engine is running.
• When oil temperature at HST motor outlet reaches 105°C or above while engine is running,
Related (1) HST oil temperature warning lamp lights up.
information (2) Abnormality warning lamp lights up.

HST oil overheat HST oil overheat is suspected. Perform troubleshooting for H
1
Probable (when system is normal) mode "H-5: HST (hydraulic) oil temperature is too high".
causes and Ground fault in wiring
criteria Check whether HST controller system failure code [Lift truck: 26/
harness
2 KOMTRAX:DGS1KB] is displayed or not. If it is displayed, perform
(HST oil temperature sensor
troubleshooting for it first.
signal circuit)
40-246 FH40-1, FH45-1, FH50-1

E-20 HST oil filter clogging warning lamp lights up while engine is running
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.

Clogged HST oil filter (when
1 Clogging of HST oil filter is suspected. Check HST oil filter.
system is normal)
Differential pressure
Defective HST oil filter P16 between inlet and Resistance
2 clogging switch (internal outlet of HST filter
Probable short circuit) Max. 245 kPa
causes and Between wiring Min. 1 Mz
{Max. 2.5 kg/cm2}
criteria harness connection
terminal and ground Min. 245 kPa
Max. 1z
{Min. 2.5 kg/cm2}
Ground fault in wiring troubleshooting without turning starting switch to the ON position.
3 harness
C01 (female) (24) to P16 (terminal)
If causes 1 to 3 are not the cause for the trouble, HST controller
may be defective.
FH40-1, FH45-1, FH50-1 40-247

Troubleshooting
E-21 Engine oil pressure warning lamp lights up while engine is running
E-22 Sedimenter (water separator) 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
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.

Engine oil pressure drop Engine oil pressure drop is suspected. Perform troubleshooting of
Probable 1
(when system is normal) S mode "S-12: Oil pressure drops".
causes and
criteria Check whether engine controller failure code [Service tool: 435/
Defective engine oil pressure
2 KOMTRAX:CA435] is displayed or not. If it is displayed, perform
switch system
troubleshooting for it first.
E-22 Sedimenter (water separator) warning lamp lights up while engine

is running
Detail of failure • Sedimenter (water separator) warning lamp lights up while engine is running.
• While engine is running, sedimenter (water separator) warning lamp lights up when it is detected
Related that fuel prefilter is filled with water.
information • Water detection signal of fuel prefilter is sent from engine controller to HST controller, and HST con-
troller controls warning lamp based on received signal.

Fuel prefilter filled with water It is suspected fuel prefilter is filled with water. Drain water from fuel
1
(when system is normal) prefilter.
Probable
causes and Check whether engine controller failure code
criteria (1) [Service tool: 428/KOMTRAX: CA428] or
Defective water-in-fuel
2 (2) [Service tool: 429/KOMTRAX: CA429
detection sensor system
is displayed or not. If it is displayed, perform troubleshooting for it
first.
40-248 FH40-1, FH45-1, FH50-1

Troubleshooting
E-22 Sedimenter (water separator) warning lamp lights up while engine is running
FH40-1, FH45-1, FH50-1 40-249

E-23 Abnormality warning lamp lights up while engine is running

Detail of failure • Abnormality warning lamp lights up while engine is running.
• Abnormality warning lamp is controlled by HST controller and engine controller.
• When failure occurs in electrical system in HST controller or engine controller system, abnormality
waning lamp lights up.
• When brake accumulator oil pressure is reduced while engine is running, HST controller;
a. Lights up abnormality warning lamp.
b. Generates warning buzzer (intermittent)
• When following initial adjustments are not performed, HST controller lights up abnormality warning
Related lamp.
information (1) Brake pedal angle sensor adjustment
(2) HST pump adjustment (1)
(3) HST pump adjustment (2)
• If any of following individual warning lamps lights up, perform troubleshooting for corresponding
warning lamp first.
(1) Charge warning lamp (Perform troubleshooting of E-18.)
(2) HST oil temperature warning lamp (Perform troubleshooting of E-19.)
(3) Engine oil pressure warning lamp (Perform troubleshooting of E-21.)

When initial adjustments of HST controller are not performed,
abnormality warning lamp lights up.
Initial adjustments of HST When HST controller is replaced with new one, perform initial
1
controller are not performed. adjustments of HST controller.
* See Testing and adjusting, "Display, setting, and checkup
methods in HST controller".
Check failure code of HST controller. If it is occurring, perform trou-
Failure occurs in electrical bleshooting for that failure code.
2 system of HST controller * For failure code checkup method of HST controller, see Test-
system. ing and adjusting, "Display, setting, and checkup methods in
Probable HST controller".
causes and Check failure code of engine controller. If it is occurring, perform
criteria Failure occurs in electrical troubleshooting for that failure code.
3 system of engine controller * For checkup method of failure code of engine controller, see
system. Testing and adjusting, "Failure code checkup methods of
engine controller".
(contact with ground circuit) CM02 (female) (5) to each of C02 (female) Resistance Min. 1 Mz
(9) and CE02 (female) (43)
If causes 1 to 4 are not the cause for the trouble, drop of brake
Brake accumulator oil pres-
5 accumulator oil pressure may be detected. Check the cause and
sure drops.
scope of damage to recover the normal condition.
40-250 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-251

E-24 Engine abnormality warning lamp lights up while engine is running

Detail of failure • Engine abnormality warning lamp lights up while engine is running.
• Engine abnormality warning lamp lights up by control of engine controller.
• When failure occurs in electrical system in engine controller, engine abnormality warning lamp lights
Related up.
information • If any of following individual warning lamps lights up, perform troubleshooting for corresponding
warning lamp first.
(1) Engine oil pressure warning lamp (Perform troubleshooting of E-21.)

Check failure code of engine controller. If it is occurring, perform
Failure occurs in electrical troubleshooting for that failure code.
1 system of engine controller * For check method of failure code of engine controller, see
Probable system. Testing and adjusting, "Failure code check method of engine
causes and controller".
(contact with ground circuit) (female) (6) to CE02 (female) (47) and Resistance Min. 1 Mz
ground
40-252 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-253

E-25 Travel speed restriction cannot be released or enabled

Detail of failure (1) Travel speed restriction cannot be released.
• Before performing troubleshooting, check maximum travel speed restriction function is not set
(maximum travel speed restriction function enables travel speed restriction whether travel speed
restriction selector switch is set to ON or OFF).
• Travel speed restriction function for general operators is enabled when travel speed restriction
Related selector switch is set to the ON position.
information When travel speed restriction selector switch is set to the ON position, travel speed restriction indi-
cator lamp lights up.
* Even if travel speed restriction function is enabled, travel speed restriction indicator lamp lights up
only when travel speed restriction selector switch is set to the ON position (travel speed restriction
indicator lamp lights up when travel speed restriction function for general operators is enabled).

Defective travel speed Travel speed
1 restriction selector switch S07 (male) restriction selector Resistance
(internal defect) switch
ON Min. 1 Mz
Probable Between (2) and (3)
OFF Max. 1z
causes and
(wire breakage or defective and S07 (female) (2)
contact of connector) Wiring harness between S07 (female) (3)
Resistance Max. 1z
may be defective.
Detail of failure (2) Travel speed restriction cannot be enabled.

Related
information

Defective travel speed Travel speed
1 restriction selector switch S07 (male) restriction selector Resistance
(internal defect) switch
Probable ON Min. 1 Mz
causes and Between (2) and (3)
criteria OFF Max. 1z
2 ness
(contact with ground circuit) Between wiring harness from C03 (female)
may be defective.
40-254 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-255

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
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
Detail of failure (1) Impossible to select HST controller failure display mode or Auto engine stop time change mode
Related • For failure code check method of HST controller, see Testing and adjusting, "Display, setting, and
information check methods in HST controller".

Defective service switch CM04 (male) Service switch Resistance
1
(internal defect)
OFF Min. 1 Mz
Between (3) and (6)
ON Max. 1z
If travel speed restriction indicator lamp lights up even when travel
Defective travel speed speed restriction selector switch is set to the OFF position, travel
2
restriction selector switch speed restriction selector switch may be defective. Perform trou-
Probable
bleshooting of E-25 (1).
causes and
contact of connector) Wiring harness between CE04 (female) (6)
Resistance Max. 1z
4 ness
(9) to CE04 (female) (3) and ground
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

1
(internal defect)
OFF Min. 1 Mz
Between (3) and (6)
ON Max. 1z
Probable If travel speed restriction indicator lamp lights up even when travel
causes and Defective travel speed speed restriction selector switch is set to OFF position, travel
2
criteria restriction selector switch speed restriction selector switch may be defective. Perform trou-
contact of connector) Wiring harness between CE04 (female) (6)
Resistance Max. 1z
40-256 FH40-1, FH45-1, FH50-1


4 ness
(9) to CE04 (female) (3) and ground
causes and
criteria P14 Brake pedal Voltage
Defective adjustment of Released 3 to 3.65 V
5 brake pedal angle sensor Between (A) and (B) Depressed (Stroke
linkage 1.35 to 2 V
end)
adjusting, "Testing and adjusting brake pedal angle sensor link-
age".
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

1
(internal defect)
OFF Min. 1 Mz
Between (3) and (6)
ON Max. 1z
If travel speed restriction indicator lamp lights up even when travel
Defective travel speed speed restriction selector switch is set to the OFF position, travel
2
restriction selector switch speed restriction selector switch may be defective. Perform trou-
Probable
causes and
(wire breakage or defective and CM04 (female) (3)
Resistance Max. 1z
4 ness
(9) to CM04 (female) (3) and ground
FH40-1, FH45-1, FH50-1 40-257

40-258 FH40-1, FH45-1, FH50-1

E-27 KOMTRAX system does not operate normally

Detail of failure • KOMTRAX system does not operate normally.
• If it is requested to check system for failure from KOMTRAX system management, perform the fol-
lowing troubleshootings.
• Even if failure is detected in KOMTRAX system, nature of problem does not especially occur on lift
truck body.
Related • For details of display, see Testing and adjusting, "Lamp indication of KOMTRAX".
information • There are following flashing types, each of which shows corresponding flashing interval.
Short-time interval flashing: Flashes at approx. 1-second cycle (lights-on and -off process is
repeated at 0.5-second interval).
Long-time interval flashing: Flashes at approx. 4-second cycle (lights-on and -off process is
repeated at 2-second interval).

a Turn starting switch to the ON position and perform trouble-
shooting.
CK03 Signal Voltage
1 Defective power supply
Between each of (6)
Continuous power
and (7) and each of 20 to 30V
supply
(1) and (2)
a Turn starting switch to the ON position, start engine, and perform
troubleshooting.
Display position of KOMTRAX
Normal condition
terminal
LED-1 (Green) Lights up
Defective starting switch ACC a Be ready with starting switch in the OFF position, then start
2
signal and alternator R signal engine and perform troubleshooting.
CK03 Signal Voltage
Between (3) and each
Starting switch ACC 20 to 30V
of (1) and (2)
Between (4) and each
Alternator R 20 to 30V
of (1) and (2)
a Turn starting switch to engine start position, and perform trouble-
Probable causes shooting.
and criteria Display position of KOMTRAX
Normal condition
Defective starting switch C terminal
3
signal LED-3 (Yellow) Short-time interval flashing
CK03 Signal Voltage
(Between (11) and
Starting switch C 20 to 30V
each of (1) and (2)
shooting.
Normal condition
terminal
Defective CAN communica- LED-4 (Green) Lights up
4
tion signal a Be ready with starting switch in the OFF position, then turn start-
ing switch to the OFF position and perform troubleshooting.
CK01 Signal Voltage
(Between (10) and
CAN 40 to 80z
(11)
shooting.
Defective communication
5 Display position of KOMTRAX
environment Normal condition
terminal
7 segment (Red) [0-9] indicators light up.
FH40-1, FH45-1, FH50-1 40-259


Turn starting switch to the ON position and perform troubleshooting.
Normal condition
Probable causes terminal
and criteria 6 Defective GPS positioning Dot (Red) Lights up
* Even in outside place where electric wave transmission is
available, it may take 1 minute or longer after turning starting
switch to the ON position until positioning is completed.
Display
LED display position

1. LED-1 [Green]: R signal and ACC signal condi-
tion
2. LED-2[Red]: Engine start output condition
3. LED-3 [Yellow]: S-NET and C signal condition
4. LED-4 [Green]: Fuel sensor and CAN connec-

tion condition
7-segment, dot display

5. segment [Red]: Inspection for radio station
establishment and operation
condition
6. Dot [Red]: GPS positioning condition

Inspection connector plug-
ging-in and unplugging condi-
tion
40-260 FH40-1, FH45-1, FH50-1

Troubleshooting for hydraulic and mechanical system (H-mode)
How to use troubleshooting table

This troubleshooting chart indicates the location where the problem occurring on the lift truck and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to perform accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. How to read matrix

• The questions to ask the operator are given 1. Operate the lift truck and perform troubleshoot-
under the problem. If the answer to the ques- ing introduced in the Diagnosis column. If any
tion matches the description given, the cause problems occur as the result of the trouble-
given after the arrow is the probable cause. shooting, put a check in the corresponding box.
Keeping the description of the questions in a Perform the troubleshooting for easier
mind, read the matrix and proceed with Step 2 items first. It is not necessary to follow the
and Step 3 to pinpoint the correct cause. number order.
(Example)
Example: Lift truck does not turn Remedy
No. Diagnosis
Ask the operator and check the following points.
• Did the problem suddenly start? 1 Lift truck turns neither right nor left
→ Broken device related to steering 2 Lift truck turns only right or left
• Was the steering wheel operation heavy
before? Steering wheel operation is heavy in both right and
3
→ Worn part or defective seal in device related left directions
to steering Steering wheel is too heavy to turn in either right or
4
left direction
Step 2. Checks before troubleshooting
5 Work equipment operates.
• Before measuring the oil pressure or starting
the troubleshooting, perform the checks before
starting, check for oil leakage, or for loose bolts.
2. Find the matching cause in the cause column.
This will prevent wasting time when trouble-
The Q marks on the same line for the trouble-
shooting. The items given under Checks before
shooting item are the causes. (In Diagnosis
troubleshooting are checks that must be per-
item 2 in the diagram below, the cause is c or
formed with special care taking the condition of
e.)
the lift truck into consideration before starting
[Where there is 1 Q mark]
the actual troubleshooting.
Perform troubleshooting for the other items
marked with Q in the same column for the
Example: Check before starting troubleshoot-
cause to check if the problem occurs, then
ing
make repairs.
• Is oil level and type of oil in hydraulic tank cor-
[Where there are 2 Q marks]
rect?
Go to Step 3 to narrow down the cause.
• Is there any oil leakage from steering valve or
demand valve?
• Is steering linkage adjusted properly?
FH40-1, FH45-1, FH50-1 40-261

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.
4. Find the corresponding cause in the cause col- 7. Remedy

umn. After narrowing down the common causes, take
If a problem is found, the Q marks on the same the action given in the remedy line.
line for the troubleshooting item are the causes. [Symbols in remedy column and their mean-
(In Diagnosis item 5 in the figure below, the ings]
cause is b or e.)
X: Replace, E: Repair, A: Adjust, C: Clean
5. Narrow down the causes

Of the causes found in Step 2. and Step 4.,
there is a common cause (Q marks on the line
for each troubleshooting item and in the com-
mon Cause column for both) is a cause com-
mon to the problem items found in the
troubleshooting in Step 1. and Step 3.
a The items that are not common (items that
do not have Q marks in the same cause col-
umn) are probably not the cause, so they
can be eliminated. (The causes for trouble-
shooting item 2 in the figure below are c or
e, and the causes in troubleshooting item 5
are b or e, so Cause e is a common cause.)
40-262 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-263

Hydraulic and mechanical system diagram
a The system diagram illustrates the simplified entire hydraulic circuit diagram as reference material for
troubleshooting of the hydraulic and mechanical systems.
40-264 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 40-265

Table of failure modes and causes

Part that can cause failure HST pump Orbit roll
Defective EPACS (Electronic Proportional Active Con-

Defective brake pedal angle sensor linkage
Defective pump (on charge pump side)
Defective pump (on piston pump side)
Defective brake pedal angle sensor

Defective high pressure relief valve
Defective charge safety valve

trol Steering System) valve
Defective HST motor
Defective relief valve

Defective front axle
Defective orbit roll

Defective damper
Failure mode Defective PTO

Lift truck does not travel. Q Q Q Q Q Q Q Q Q Q
Slow travel speed Q Q Q Q Q Q
Insufficient towing force Q Q Q Q
Engine stops during traveling, or engine speed drops excessively. Q Q
HST (hydraulic) oil temperature is too high. Q Q Q Q Q
Impossible steering Q Q Q
Response is low during turning. Q Q
Steering operation is heavy. Q Q
Unstable during turning Q Q
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-
ment is operated).
Large shock is made when steering wheel is returned. Q
EPACS does not work. Q Q Q
Steering wheel vibrates. Q
Steering system makes abnormal sound. Q
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 Q
Q Q
operation or steering.
Fine control or response of work equipment is low.
Work equipment cannot be locked (and the equipment operates
when operator leaves).
Control valve lever does not move smoothly and it is heavy.
Lift cylinder and fork are not raised. Q
Lifting speed or power of lift cylinder and fork is insufficient.
Forklift speed lowers at specific height.

Lift cylinder hydraulic drift is large.
Lift cylinders do not come down.
Forklift lowering speed is low or high or fine control performance is
low or response is low.
Mast does not tilt forward or backward. Q
Forward/backward tilting speed or force of mast is insufficient.
Tilting speed lowers halfway.

Tilt cylinder forward-bent hydraulic drift is large.
The mast is unstable during traveling with load.
Work equipment operation is slow when work equipment and steer-
ing are operated simultaneously.
Steering operation is heavy when work equipment and steering are
operated simultaneously.
40-266 FH40-1, FH45-1, FH50-1

Misalignment of orbit-roll
Q
Q
Q
Q
Foreign matter caught in orbit-roll
Orbit roll
Q
Q
Damaged orbit-roll oil seal
Q
Q
Q
Q
Q
Internal defect of steering cylinder (Damaged piston seal)
Q
Q
Q
Q
Q
Q
Q
Q
Defective steering wheel or steering shaft operation
FH40-1, FH45-1, FH50-1

Q
Defective brake pump
Q
Q
Defective brake charge valve operation
Defective accumulator piston seal or insufficient gas pressure
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
Contact of metallic part caused by complete wear of brake
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
Defective LS valve operation
Q
Q
Defective unload valve

steering pump
Q
Q
Q
Q
Q
Q
Q
Q
Q
Clogging or sucked air on pump suction side

Work equipment and
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
40-267
Part that can cause failure Work equipment valve
Defective lift spool and work equipment valve mount-

Defective lift lock solenoid valve operation
Defective work equipment lock solenoid
Defective tilt load check valve operation

Defective lift load check valve operation
Defective down control valve operation
Insufficient oil-tightness of tilt spool

Defective oil-tightness of lift spool
Defective tilt lock valve operation

Suction strainer clogging
Defective LS relief valve
Defective lift lock valve

Defective priority valve
Defective valve spool
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
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
Lifting speed or power of lift cylinder and fork is insufficient. Q Q Q Q
Forklift speed lowers at specific height. Q Q

Lift cylinder hydraulic drift is large. Q Q Q
Lift cylinders do not come down. Q Q Q
Forklift lowering speed is low or high or fine control performance is
Q Q Q
low or response is low.
Mast does not tilt forward or backward. Q Q Q Q Q
Forward/backward tilting speed or force of mast is insufficient. Q Q Q Q
Tilting speed lowers halfway. Q Q Q

Tilt cylinder forward-bent hydraulic drift is large. Q Q
The mast is unstable during traveling with load. Q
Work equipment operation is slow when work equipment and steer-
Q
ing are operated simultaneously.
Steering operation is heavy when work equipment and steering are
Q
operated simultaneously.
40-268 FH40-1, FH45-1, FH50-1

Insufficient tilt lever stroke
Q
Q
Q
Q
Q
Q
Defective LS shuttle valve
Q
Clogged LS circuit orifice
Q
Q
Q
Steering circuit orifice clogging
Bend of valve spool
Q
Q
Defective clearance between valve body and spool
FH40-1, FH45-1, FH50-1

Work equipment valve
Q
Insufficient roundness of valve body and spool
Q
Foreign matter caught in valve spool
Internal fracture of valve body (lift spool portion)
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
Clogged hydraulic oil cooler
Malfunction of cold relief valve

Q
Q
Defective fan belt adjustment
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
40-269
H-1 Lift truck cannot travel
H-1 Lift truck cannot travel
Ask the operator about the following: Cause

• Did the problem suddenly start?
o Damaged HST pump or motor related device HST
• Did not lift truck travel before? HST pump Appendix
motor
o Worn part, defective seal, or contaminant
in HST pump or motor related device a b c d e f g h i j

• Check that level, temperature, and type of oil
in the hydraulic tank are proper.
• Check that oil is not leaking from hydraulic
hose, pump, or motor.
• Check that brake pedal angle sensor linkage
is adjusted properly.
• Check that the service brake and parking

brake are not locked.
• Check that towed valve of HST pump is not
Defective pump (at charge pump side)

Defective pump (at piston pump side)
open.

Defective front axle

Defective damper
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
2 Lift truck cannot travel forward (Can travel backward normally). Q
3 Lift truck cannot travel backward (Can travel forward normally). Q

Lift truck can travel neither forward nor backward, and motor
4 Q
rotation sound is heard.
40-270 FH40-1, FH45-1, FH50-1

H-2 Slow travel speed
H-2 Slow travel speed

o Damaged HST pump or motor related device HST
• Was travel speed slow before? HST pump Appendix
motor
o Worn part, defective seal, or contaminant in HST pump or motor
related device a b c d e f

• Check that level, temperature, and type of oil in the hydraulic tank
are proper.
• Check that oil is not leaking from hydraulic hose, pump, or motor.
• Check that brake pedal angle sensor linkage is adjusted properly.
• Check the service brake and parking brake for dragging.
• Check that towed valve of HST pump is not open.
• Check that air pressure and treads of tires are proper.


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
2 Slow forward travel speed (Normal backward travel speed). Q
3 Slow backward travel speed (Normal forward travel speed). Q
FH40-1, FH45-1, FH50-1 40-271

H-3 Insufficient towing force
H-3 Insufficient towing force
a When travel speed is low, perform troubleshooting H-2 first. Cause
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
40-272 FH40-1, FH45-1, FH50-1

H-4 Engine stops during traveling, or engine speed drops excessively
H-4 Engine stops during traveling, or engine speed drops excessively

• Did the problems occur before?
o Contamination in HST pump or motor related device HST HST
pump motor
• Check that level, temperature, and type of oil in the hydraulic tank are a b
proper.
• Check that oil is not leaking from hydraulic hose, pump, or motor.
Defective pump (at piston pump side of body)
Defective motor
Action to take E E
No.
Diagnosis X X
1 Engine stops during traveling, or engine speed drops excessively. Q Q
2 Main body moves with forward or backward lever placed at F or R position or engine in Lo mode. Q
FH40-1, FH45-1, FH50-1 40-273

H-5 HST (hydraulic) oil temperature is too high
H-5 HST (hydraulic) oil temperature is too high

• Did the HST oil temperature sud-
denly become high? HST
Work Work Brake
o Damaged HST pump or motor HST pump equipment and equipment charge Appendix
motor
steering pump valve valve
related device
• Has there been symptom of exces- a b c d e f g h i j k l m n
sive high HST oil temperature?
o Internal wear of HST pump,
motor, or work equipment pump
re lated, or dec line of c o ol er
capacity

• Check that the level and type of the
oil in the hydraulic tank are proper.
• Check the service brake and park-
ing brake for dragging.
Defective brake charge valve operation

• Check that towed valve of HST

pump is not open.
Malfunction of cold relief valve

• Check that work equipment oper-
Defective fan belt adjustment

Clogged hydraulic oil cooler

ates normally.
Defective LS relief valve

Defective unload valve
Defective valve spool

Defective motor
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
5 Engine coolant temperature is also high. Q Q
6 Engine coolant temperature is normal. Q
40-274 FH40-1, FH45-1, FH50-1

H-6 Impossible steering
H-6 Impossible steering

o Damaged device related to steering Work equipment
Work equipment
• Was the steering wheel heavy before? and steering Appendix
valve
pump
o Worn part or defective seal in device related to
steering a b c d

• Check that level, temperature, and type of oil in the
hydraulic tank are proper.

Damaged PTO or pump
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
2 Work equipment operates abnormally in the state of item 1. Q
3 Work equipment operates normally in the state of item 1. Q
4 Steering is possible only right or left. Q Q
5 Steering wheel is too heavy to turn. Q Q Q
6 Steering circuit oil pressure does not increase at all. 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.
FH40-1, FH45-1, FH50-1 40-275

H-7 Response is low during turning
H-7 Response is low during turning

• Did response to steering operation become
low suddenly? Work Work
o Broken device related to steering equipment and equipment Appendix
steering pump valve
• Did the trouble increase gradually?
o Worn part or defective seal in device a b c d e
related to steering

• Check that the level and type of the oil in the

EPACS (Electronic Proportional Active Control

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
2 Response is low in either right or left steering direction Q Q Q
3 Steering circuit oil pressure does not increase at all. Q Q
4 Steering wheel continues to turn even at steering end. Q Q
40-276 FH40-1, FH45-1, FH50-1

H-8 Steering is heavy
H-8 Steering is heavy
Check of abnormality Cause

Measure the steering wheel operating effort and
time required to rotate the steering wheel and Work equipment
Work equipment
check them with the criteria. and steering Appendix
valve
pump
Ask the operator about the following:
• Did the problem suddenly start? a b c d e
o Damaged device related to steering
• Has there been symptom of heavy steering effort?
o Worn part or defective seal in device related to
steering


• Check that level, temperature, and type of oil in
Defective steering wheel or steering shaft operation

the hydraulic tank are proper.
• Check that the tire inflation pressure is normal.

Defective pump
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
2 Steering wheel is heavy in both right and left directions Q Q Q

Steering wheel is still heavy after steering shaft and orbit roll is dis-
3 Q
connected
4 Oil pressures on both right and left sides are low or zero Q Q Q Q Q
5 Oil pressures on either right or left side is low or zero Q
FH40-1, FH45-1, FH50-1 40-277

H-9 Unstable during turning
H-9 Unstable during turning

• Operate lift truck in safe place, and check in what condition and how
steering wheel is unstable.
a When there is problem other than unstable steering wheel such as heavy Orbit roll Appendix
steering wheel operation. o See H-6, H-7, and H-8.
• Is abnormal sound heard from a device related to the steering? a b c

• Check that level, temperature, and type of oil in the hydraulic tank are
proper.

• Check that the steering wheel play is normal.
EPACS (Electronic Proportional Active Control

Steering System)
No. Action to take E Defective valve E
E E
Diagnosis X X
1 Main body is unstable while traveling on bumpy road. Q Q Q Q
2 Main body is unstable when steering wheel is turned suddenly when it lifts load or travels. Q Q
3 Main body is unstable when speed is increased during traveling straight. Q Q Q Q
If connector of orbit roll EPACS is removed in state of No. 1 or 3, main body becomes stable or
4 Q Q
unstableness lessens.
40-278 FH40-1, FH45-1, FH50-1

Troubleshooting
H-10, H-11
H-10 When steering wheel is released it does not return to neutral or it

rotates by itself
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
H-11 Steering wheel is turned in reverse or it kicks (while work

equipment is operated)
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.
FH40-1, FH45-1, FH50-1 40-279

H-12 Large shock is made when steering wheel is returned
H-12 Large shock is made when steering wheel is returned

a When there is problem other than shock of steering wheel such as
heavy steering wheel operation. o See H-6, H-7, and H-8. Work equipment
Work equip- Orbit
• Is abnormal sound heard from a device related to the steering? and steering
ment valve roll
pump
Checks before troubleshooting a b c d

proper.
• Check that the steering wheel play is normal.
Clogged steering circuit orifice


Defective pump
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
40-280 FH40-1, FH45-1, FH50-1

H-13 EPACS does not work
H-13 EPACS does not work
Check the following points.

• Check to see if orbit roll LED is OFF or flashing
o If the LED is OFF or flashing, see "Troubleshooting by failure code (EPACS controller sys-
tem)".
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
FH40-1, FH45-1, FH50-1 40-281

Troubleshooting
H-14, H-15, H-16
H-14 Steering wheel vibrates

• Location and condition of vibration occurrence
Cause
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
H-15 Steering system makes abnormal sound

• Location and condition of abnormal sound occurrence
Cause
o Bleed air
• Defective installation of orbit roll
o Adjust
• Malfunction of steering linkage
o Grease
H-16 Oil leaks from steering circuit
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
40-282 FH40-1, FH45-1, FH50-1

H-17 Service brake does not work or its performance is low
H-17 Service brake does not work or its performance is low

• Did the brake stop working suddenly?
o Broken brake device Brake Charge Accumu- Brake Slack
• Did the brake performance lower grad- Service brake Appendix
pump valve lator Valve adjuster
ually?
o Deteriorated seals, worn linings and a b c d e f g h i j k l
discs
Contact of metallic part caused by complete wear of brake disc in axle

• Check that the hydraulic oil level is
Defective accumulator piston seal or insufficient gas pressure

proper.
• Check that the brake pedal has proper
play.
• Check the brake tube and connectors
for oil leakage and deformation.
• Check the tire inflation pressure and
Oil leakage from check valve or piston seal

tire tread.
Worn or abnormal brake disc in axle

Defective brake piston seal in axle
Check of abnormality Defective charge valve operation
Defective brake portion in axle

• Referring to Testing and adjusting,
"Measurement of brake performance",
check the actual brake performance to
Defective brake valve

see if it is actually low or felt low by the
Air in brake circuit

operator.
Defective pump
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 Brake pedal is heavy to depress Q

Abnormal depressing force is required to obtain
3 Q Q Q Q Q Q Q
specified braking force
When brake operates, axle brake makes abnormal
4 Q Q
sound
Lift truck does not travel normally (Traction force is
5 Q
insufficient)
When front wheels are raised and brake is applied
6 while lift truck is in forward travel mode, specific Q Q Q Q Q Q Q Q
wheels rotates fast.
Air is bled from brake circuit by air bleeding opera-
7 Q
tion and then brake is normal
8 Brake oil leakage inside axle is abnormal Q
9 Much metallic dust is contained in axle oil Q

Depressing effort and stroke of brake pedal are nor-
10 Q Q Q Q Q Q
mal but brake performance is low
11 Brake works less times after engine is stopped Q Q Q Q Q Q Q
12 Accumulator is not charged and buzzer sounds Q Q Q
13 Brake works with time lag Q Q
FH40-1, FH45-1, FH50-1 40-283

H-18 Service brake is not reset or it drags
H-18 Service brake is not reset or it drags

• Check that the front axle oil is not overheating.
• Check that the lift truck coasts smoothly on a flat ground. Brake Slack Service
Valve adjuster brake
• Check that the brake pedal has returned perfectly. a b c d
• Check that the parking brake is reset perfectly.
Internal defect of brake valve (Stuck piston)

Brake disc trouble in axle
Malfunction of piston
Action to take E E E E
No.
Diagnosis X X X X
1 Brake keeps working after brake pedal is released Q Q Q Q
When brake pedal is released, if oil is drained through air bleeder, circuit pressure lowers and
2 Q
brake is reset
When front wheels are raised and put lift truck in forward (backward) travel mode, specific wheels
3 Q Q Q
rotates fast.
40-284 FH40-1, FH45-1, FH50-1

H-19 Parking brake does not work or its performance is low
H-19 Parking brake does not work or its performance is low

• Did the brake stop working suddenly?
o Damaged related device
Was abnormal sound heard at that time? From what part was it heard? Parking Brake
• Did the brake performance lower gradually?
o Worn related device a b c

• Check that parking brake lever is pulled to appropriate level
• Check that air pressure and treads of tires are proper.
Worn or problematic parking brake lining

Action to take E
E E
No. A
Diagnosis X X
C
1 Parking brake lever is heavy when it is pulled. Q
2 Parking brake lever operating effort and stroke are normal, but brake performance is low. Q Q
FH40-1, FH45-1, FH50-1 40-285

H-20 Parking brake is not reset or it drags
H-20 Parking brake is not reset or it drags

• Abnormal heat of brake
• Check that the lift truck coasts smoothly on a flat ground.
Parking Brake
• Check that parking brake lever has returned perfectly. a b c
Problematic parking brake lining

Action to take E
E E
No. A
Diagnosis X X
C
1 When parking brake lever is returned, parking brake is not reset. Q Q Q
2 When parking brake lever is pulled, parking brake does not work sufficiently. Q Q
3 When parking brake lever is returned, cable does not return. Q Q
40-286 FH40-1, FH45-1, FH50-1

H-21 Abnormal noise around the work equipment or steering pump
H-21 Abnormal noise around the work equipment or steering pump
Checks before troubleshooting Cause

• Is hydraulic tank oil level normal?
Tank - work
equipment and
steering pump
a b c d
Defective PTO and damper

Suction strainer clogging
Improper hydraulic oil
Defective pump
Action to take E C E
No. X
Diagnosis X X X
1 If pump load is changed, noise level changes. Q Q
2 There are bubbles in hydraulic tank. Q Q
3 Air bubbles do not disappear even if engine is stopped in state of item 2. Q
4 Suction strainer is clogged with metallic matter. Q
FH40-1, FH45-1, FH50-1 40-287

H-22 Engine speed drops excessively or stops during work equipment operation or wheel steering
H-22 Engine speed drops excessively or stops during work equipment

operation or wheel steering

• Check that work equipment and steering relief pressure
Work
are within respective reference values. HST equipment
Appendix
pump and steer-
ing pump
a b c d
Defective HST pump (at piston pump side)
Defective engine unit or PTO

Defective pump
Action to take E E E E
No.
X X X X
Diagnosis
Difficult engine start or abnormal sound and rotation of engine even in travel mode or neutral of
1 Q Q Q Q
work equipment
2 Main body moves with forward or backward lever placed at F or R position or engine in Lo mode. Q
Late start-up of engine or abnormal noise around pump when work equipment or steering wheel
Q Q
is operated
40-288 FH40-1, FH45-1, FH50-1

H-23 Fine control performance of entire work equipment is low or response is low
H-23 Fine control performance of entire work equipment is low or

response is low

Work
o Seizure and damage of each device equipment
Work
Was abnormal sound heard at that time? (From what part equipment
and steer-
valve
was it heard?) ing pump
• Has there been symptom such as slow response? a b c d
o Worn part or fatigued spring

• Check that level, temperature, and type of oil in the hydraulic
tank are proper.
• Check that control spool stroke is proper.
Check of abnormality
• Check that LS differential pressure is normal when work equip-
ment is operated.
Defective LS shuttle valve
Clogged LS circuit orifice

Defective LS valve
Action to take Defective pump
E E E C
No.
Diagnosis
X X X E
1 Low steering response and fine control performance Q Q Q
2 Abnormal LS differential pressure when work equipment is operated Q Q
3 Low response, but normal fine control performance Q Q Q
4 Low fine control performance, but normal response Q Q Q
FH40-1, FH45-1, FH50-1 40-289

H-24 Work equipment cannot be locked (and the equipment operates when operator leaves)
H-24 Work equipment cannot be locked (and the equipment operates

when operator leaves)

• Check that operator seat switch is normal.
• Check that work equipment lock solenoid operates. Work equipment
(Check that "click" is heard when it is operated with engine OFF and key ON. valve
a b c
Defective work equipment lock solenoid
Steering circuit orifice clogging

No.
Action to take Malfunction of priority spool
E
X
C
Diagnosis X E
1 Steering wheel operation is also defective (heavy, cannot be turned). Q Q
When lift lock solenoid (when operation is normal) and work equipment lock solenoid valves are replaced,
2 Q
operation becomes normal.
40-290 FH40-1, FH45-1, FH50-1

H-25 Control valve lever does not move smoothly and it is heavy
H-25 Control valve lever does not move smoothly and it is heavy

• Check the lever operating effort with the criterion to see if it is actually large.
Work equipment valve
a b c d
Defective clearance between valve body and spool
Insufficient roundness of valve body and spool
Foreign matter caught in valve spool

Bend of valve spool
No. X
Diagnosis X X E
1 Lever becomes heavy when load is applied and oil pressure is high Q Q
2 Lever becomes heavy as oil pressure changes Q Q
3 Lever is generally heavy, regardless of oil pressure and oil temperature Q Q
FH40-1, FH45-1, FH50-1 40-291

H-26 Lift cylinder and fork do not lift
H-26 Lift cylinder and fork do not lift

o Seizure and damage of each device Tank - work
Was abnormal sound heard at that time? equipment and Work equipment valve Cylinder
steering pump
(From what part was it heard?)
• Has there been symptom such as lowering of a b c d e f g h i j k l
speed?

• Check that level, temperature, and type of oil in
the hydraulic tank are proper.
Defective work equipment lock solenoid valve operation

• Check that the lift control spool stroke is proper.
• Check that the engine speed is proper.
Internal fracture of valve body (Lift spool portion)

Defective LS shuttle valve operation

Defective LS relief valve operation
Defective priority valve operation

Defective LS valve
Defective pump
Defective PTO
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
1 Work equipment or steering pump makes abnormal sound. Q Q

Fork can be lifted when not loaded and cannot be lifted when
2 Q Q Q
loaded
3 Mast cannot be tilted and fork cannot be lifted Q Q Q Q Q Q Q Q
4 Mast can be tilted but fork cannot be lifted Q Q Q Q Q
5 Lift cylinder natural drift is large Q Q
40-292 FH40-1, FH45-1, FH50-1

H-27 Lifting speed or power of lift cylinder and fork is insufficient
H-27 Lifting speed or power of lift cylinder and fork is insufficient

Lifting force trouble and lifting speed trouble
are closely related to each other and these Tank - work
troubles are detected as insufficient lifting equipment and Work equipment valve Cylinder Mast
steering pump
speed at first.
Measure the lifting speed of the loaded fork a b c d e f g h i j k l
and check it with the criterion.

Defective adjustment of clearance between roller and rail

• Check that the control lever stroke is proper.
• Check that the mast rollers are free from
Internal fracture of valve body (Lift spool portion)

crack etc.

Defective roller shim adjustment

Defective LS valve
Defective pump
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
4 If oil temperature increases in 2, forklift speed lowers further Q
6 Relief pressure of relief valve of work equipment valve is low Q
7 No-load forklift speed is low Q Q Q
FH40-1, FH45-1, FH50-1 40-293

H-28 Forklift speed lowers at specific height
H-28 Forklift speed lowers at specific height

• External deformation of lift cylinder
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".
40-294 FH40-1, FH45-1, FH50-1

H-29 Lift cylinder natural drift is large
H-29 Lift cylinder natural drift is large

• Did the natural drift increase suddenly?
o Dirt in valve or broken part Work equipment
• Did the natural drift increase gradually? Cylinder
valve
o Worn part
a b c d
• Is the lift spool in neutral?
• Check the lift cylinder natural drift with the criterion to see if it is actually
large.
Defective oil-tightness of lift spool

Malfunction of lift lock solenoid
Action to take E E E
No. X
Diagnosis X X X
1 Large natural drift only when key is set to ON position and operator is seated Q
2 Lowering speed remains large when key is set to ON and operator is seated or not seated. Q Q
3 Lowering speed is large whether key is set to ON or OFF position. Q Q Q
FH40-1, FH45-1, FH50-1 40-295

H-30 Lift cylinders do not come down
H-30 Lift cylinders do not come down

• Check that operator seat switch is working.
• Check that the mast rollers are free from crack, etc. Work equipment
valve
a b c
Defective lift spool and work equipment valve mounting angle

Action to take E E
No. A
Diagnosis X X
1 Though power is applied to lift lock solenoid during lowering operation, it lowers or stops lowering. Q Q
2 Lift lever operating force is abnormal or discontinuous. Q
3 Lift cylinder lifting speed is low or lifting force is insufficient. Q
40-296 FH40-1, FH45-1, FH50-1

H-31 Fork lowering speed is low or high or fine control performance is low or response is low
H-31 Fork lowering speed is low or high or fine control performance is

low or response is low

• Check that the control lever stroke is proper.
• Check that the mast rollers are free from crack etc. Work equipment
• Check for oil leakage and deformation and damage of hoses and pipes. Cylinder
valve
a b c d
Defective lift spool and work equipment valve mounting angle

Action to take E E
No. A X
Diagnosis X X
1 The heavier the load is, faster lowering speed becomes. Q Q
2 Natural drift is large and lowering speed is fast. Q Q
3 Though power is applied to lift lock solenoid during lowering operation, it lowers or stops lowering. Q Q
4 Lift lever operating force is abnormal or discontinuous. Q
FH40-1, FH45-1, FH50-1 40-297

H-32 Mast does not tilt forward or backward
H-32 Mast does not tilt forward or backward

o Seizure and damage of each device Tank - work
Was abnormal sound heard at that time? equipment and Work equipment valve Cylinder
steering pump
(From what part was it heard?)
• Has there been symptom such as lowering of a b c d e f g h i j k l
speed?

Defective work equipment lock solenoid valve operation

• Check that the tilt control spool stroke is
proper.
Internal fracture of valve body (Tilt spool portion)



Defective LS valve
Defective pump
Defective PTO
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
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
4 Mast can be lifted but fork cannot be tilted. Q Q Q Q Q
5 Tilt cylinder natural forward drift is large Q Q
40-298 FH40-1, FH45-1, FH50-1

H-33 Forward/backward tilting speed or force of mast is insufficient
H-33 Forward/backward tilting speed or force of mast is insufficient

• Operate the lift truck actually to see if the tilt-back
force is insufficient. Tank - work
• Measure the tilting speed and check it with the crite- equipment and Work equipment valve Cylinder
steering pump
rion.
a b c d e f g h i j
• Check that level, temperature, and type of oil in the
• Check that the tilt control lever stroke is proper.
• Check that the mast bushing is not seized (Check for
abnormal sound).
Internal fracture of valve body (Tilt spool portion)



Defective LS valve
Defective pump
Action to take C E E E E E E E
No. X X
E X X X X X X X
Diagnosis
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
4 If oil temperature increases in 2, forklift speed lowers further Q
6 Relief pressure of relief valve of work equipment valve is low Q
7 No-load fork tilting speed is low. Q
FH40-1, FH45-1, FH50-1 40-299

H-34 Tilting speed lowers halfway
H-34 Tilting speed lowers halfway

• External deformation of tilt cylinder
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".
40-300 FH40-1, FH45-1, FH50-1

H-35 Tilt cylinder natural forward drift is large
H-35 Tilt cylinder natural forward drift is large

• Did natural forward drift increase suddenly?
o Dirt in valve or broken part Work
• Did natural forward drift increase gradually? Cylinder
equipment valve
o Worn part
a b c
• Is the tilt spool in neutral?
• Check the tilt cylinder natural drift with the criterion to see if it is actually
large.
Defective tilt lock valve operation (oil-tightness)

Defective oil-tightness of tilt spool

Action to take E E
No. X
Diagnosis X X
1 Work equipment or steering pump makes abnormal sound. Q
2 Tilt lever operating force is abnormal or discontinuous. Q

Natural forward drift is large when lift is raised after tilt head piping is blinded after loading and
3 Q
depressurizing.
FH40-1, FH45-1, FH50-1 40-301

H-36 Mast is unstable during travel with load
H-36 Mast is unstable during travel with load

• Check the pins and bushings of the mast (Check for abnormal sound).
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"
40-302 FH40-1, FH45-1, FH50-1

H-37 Work equipment is heavy when work equipment and steering are operated simultaneously
H-37 Work equipment is heavy when work equipment and steering are
operated simultaneously

proper. Work equipment
Work equipment
• Check that the control lever stroke is proper. and steering
valve
pump
a b

Defective pump
Action to take E E
Diagnosis X X
When work equipment and steering are operated simultaneously, LS differential pressure is
1 Q
abnormal.
2 Work equipment operation speed is low when it is operated singly. Q Q
FH40-1, FH45-1, FH50-1 40-303

H-38 Steering is heavy when work equipment and steering are operated simultaneously
H-38 Steering is heavy when work equipment and steering are operated
simultaneously

proper. Work equipment
Work equipment
• Check that the tire inflation pressure is normal. and steering
valve
pump
a b c
Clogged steering circuit orifice

Defective pump
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
40-304 FH40-1, FH45-1, FH50-1

FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
FH40-1, FH45-1, FH50-1 50-1

Table of Contents
Table of Contents
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
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
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
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
50-2 FH40-1, FH45-1, FH50-1

Related information on disassembly and assembly
How to read this manual

How to read this manual
Removal Disassembly
• In “Removal” section, the work procedures, pre- • The section of "Disassembly" provides precau-
cautionsand know-how to do the work, and tions and information related to the work to be
theamount of oil and coolant to be drained are performed, and amount of oil or coolant to be
described. drained.
• Common tools that are necessary for remova- • Marks used in the section of "Disassembly" are
lare described as [1], [2]••• etc. and their part- explained below.
numbers, part names and quantities are not k : Precautions related to work safety.
described. a: Precautions and information related to the work
• Various symbols used in “Removal” section are- to be performed
6
explained and listed below. : Amount of oil or coolant to be drained
k : Precautions related to work safety
4 : Weight of part or component
a: Know-how or precautions for work
[1]: This mark shows that know-how orprecautions
Assembly
for parts installation work aregiven in “Installa-
• The section of "Assembly" provides precautions
tion” section.
and information related to the work to be per-
6 : This mark shows the amount of oil formed, and amount of oil or coolant to be
orcoolant to be drained. refilled.
4 : This mark shows the weight of part or com- • Marks used in the section of "Assembly" are
ponent explained below.
Installation a: Precautions and information related to the work
• Unless otherwise instructed, installation is to be to be performed
done in the reverse order to removal. 2 : Type of coating materials
• Know-how and precautions for installationis 3 : Tightening torque
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.
a: Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
FH40-1, FH45-1, FH50-1 50-3

Coating materials list

(Rev. 2012.03)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Classifi-
Komatsu code Part No. Quantity Container Main features and applications
cation
• Use to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Use for plastic (except polyethylene, polypro-
20 g
Polyethylene pylene, tetrafluoroethylene, and vinyl chloride),
LT-1B 790-129-9050 (contained
container rubber, metal, and non-metal parts which
2 pieces)
require immediate and strong adhesion.
Polyethylene • Features: Resistance to heat and chemicals
LT-2 790-129-9180 50 g
container • Use to fix and seal bolts and plugs.
Adhesive:
790-129-9060
1 kg • Use to bond and seal metal, glass and plas-
LT-3 (Set of adhesive Can
Hardener: tics.
and hardener)
500 g
Polyethylene
LT-4 790-129-9040 250 g • Use to seal plugs for blank holes.
container
Holtz
790-126-9120 75 g Tube • Heat-resistant seal used to repair engines
Adhesive
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.
50-4 FH40-1, FH45-1, FH50-1

Classifi-
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
ThreeBond 790-129-9320 200 g Tube hoses are put on.

1206E • Can be coated with paint.
• Feature: Can be used together with solid gas-
LG-11
kets.
ThreeBond 790-129-9330 200 g Tube
1121 • Use for covers of the transmission case and
steering case etc.
ThreeBond
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211
• Use to prevent galling and seizure of pressfit
portions, shrinkfit portions, and threaded por-
Molybdenum disulfide
LM-P 09940-00040 200 g Tube

tions.
• Use to lubricate linkages, bearings, etc.
lubricant
• 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
• Feature: Seizure and galling prevention com-

pound with metallic super-fine-grain, etc.
Seizure
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
FH40-1, FH45-1, FH50-1 50-5

Classifi-
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
• Use for oil seals for the transmission, etc.

• Feature: Urea (organic system) grease with
G2-U-SENS heat resistance and long life. Enclosed type.
427-12-11871 2 kg Can
Grease • Use for rubber, bearing and oil seal in damper.
• Caution: Do not mix it with lithium grease.
Glass • Use to accelerate hardening of instantaneous
Loctite 712 428-99-80080 100 ml
container adhesive.
Sunstar paint • Use as primer for cab side.
Glass
surface primer 20 ml (Effective period: 4 months after the pro-
container
580 Super duction)
417-926-3910
Sunstar Glass • Use as primer for cab glass surface.
Glass
Primer 580 20 ml (Effective period: 4 months after the pro-
container
Super duction)
• Use as primer for painted cab sheet metal
Sunstar Paint Glass surface.
Primer
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"
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
• Use to seal front window.

Sekisui Sili- Polyethylene
20Y-54-55130 333 ml (Effective period: 6 months after the pro-
cone Sealant container
duction)
• Use to seal glass-to-glass joint. Translu-
GE TOSHIBA
cent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
TOSSEAL381
duction)
50-6 FH40-1, FH45-1, FH50-1

Special tools list
Special tools list
Name Part number of tool Diagram
Jig for removal and installation of rear

3BA-97-13310
wheel and rim bolt
Differential adjuster screw tightening jig 3EC-97-99150
Axle housing oil seal driving jig 3EC-97-99170
Axle housing oil seal driving jig 3EC-97-99180
FH40-1, FH45-1, FH50-1 50-7

Special tools list
Name Part number of tool Diagram
Oil seal driving jig 972-EC-579-000
Oil seal driving jig 972-EC-579-100
50-8 FH40-1, FH45-1, FH50-1

How to use Loctite
How to use Loctite Removing parts

When using Loctite for the screws or axle mating
Order of use of Loctite portions, the parts can generally be removed by
using the general tools such as the wrenches or
Male side pulley puller. If Loctite is strongly effective and the
parts may be damaged, use a soldering iron or gas
Degreasing Air drying torch to heat the fixed portion (200 to 250 °C) for
Female easy removal. Generally, it is difficult to dissolve the
side fixed portion by using chemicals, etc.
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}).]
FH40-1, FH45-1, FH50-1 50-9

Removal and installation of fuel supply pump assembly

Removal and installation of fuel 3. Loosen hose clamp (3) to remove air cleaner
assembly (4) (2 bolts).
supply pump assembly a Put a mark at the portion before disassem-
k Lower the forks to the ground, stop the bling to easily find the hose installation
engine, apply the parking brake, and chock position.
the wheels.
k Disconnect the cable from the negative(-)
terminal of the battery.
Removal
1. Remove right side cover (1) (3 bolts). [*1]
4. Disconnect connectors (5) and wiring harness

clamps (6) (3 places).
5. Remove fuel spray prevention caps (7) (2

places). [*2]
2. Remove step (2) (4 bolts).
6. Loosen sleeve nuts (8) (2 places) and remove

high-pressure pipe (9). [*3]
50-10 FH40-1, FH45-1, FH50-1

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).
10. Removing supply pump and pump holder

assembly
1) Remove mounting bolts (17) (4 pieces) of
the supply pump from the gear case.
8. Disconnect fuel hose (14) from supply pump

(13).
2) Completely loosen mounting bolt (19) from
pump holder (18). [*5]
a At this point, do not remove mounting
bolt (19) from supply pump (13) and
pump holder (18).
3) Remove supply pump and pump holder
assembly as a unit.
FH40-1, FH45-1, FH50-1 50-11

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).
11. Remove supply pump (13) from pump holder

(18) according to the following procedure.
1) Loosen nut (22) and by using gear puller
[1] remove supply pump gear (23). [*6]
a Sufficiently loosen nut (22) but keep it
installed to the shaft until supply pump
gear (23) is pulled out.
2) Remove nuts (24) (3 pieces) and remove

supply pump (13) from pump holder (18).
[*7]
50-12 FH40-1, FH45-1, FH50-1

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).
3 Sleeve nut on common rail side:

25.5 to 29.4 Nm {2.6 to 3.0 kgm}
3 Sleeve nut on supply pump side:
18 to 23 Nm {1.9 to 2.3 kgm}
[*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:
k Be sure to use the Komatsu genuine high- Adhesive (LT-2)

pressure pipe clamps and observe the
specified tightening torque. [*6]
k After installing the high-pressure fuel 3 Pump gear mounting nut (22):
pipes, be sure to install the fuel spray 65 to 75 Nm {6.6 to 7.6 kgm}
prevention caps to the sleeve nuts.
a Before installing the high-pressure pipe, [*7]
check it for the following. If the high-pres- a Install bolt (19) before installing supply pump
sure fuel pipe has any defect, replace it with (13) to pump holder (18).
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]
which can be found visually.
• 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.
FH40-1, FH45-1, FH50-1 50-13

Removal and installation of fuel injector assembly
Removal and installation of fuel 4. Remove aftercooler piping (5). [*2]

a Put a mark at the portion before disassem-
injector assembly bling to easily find the hose installation
k Lower the forks to the ground, stop the position (length of insertion).
engine, apply the parking brake, and chock
the wheels.
Removal
5. Disconnect intake air heater terminal (6) and

connector (7).
6. Remove clamps (8) (2 places).
7. Remove bracket (9) (2 bolts).

a High-pressure piping clamps No.1 and 2
cannot be removed. Therefore, remove
bracket (9) in advance.
3. Loosen hose clamp (3) and remove air cleaner
bling to easily find the hose installation
position.
50-14 FH40-1, FH45-1, FH50-1

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]
3) Disconnect connector (12) of the

injector wiring harness.
4) Remove pin (13) and spill hose (14).
[*4]
5) Loosen sleeve nuts (15) on the injector
side and common rail side and remove
high-pressure pipe (16). [*5]
FH40-1, FH45-1, FH50-1 50-15

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 Clamp mounting bolt (10):

5.9 to 7.8 Nm {0.6 to 0.8 kgm}
3 Sleeve nut (15):
25.5 to 29.4 Nm {2.6 to 3.0 kgm}
[*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).
50-16 FH40-1, FH45-1, FH50-1

[*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).
1) Install dust seal (20) to injector

assembly (19).
2) Install gasket (22) to injector assembly
(19).
3) Insert injector assembly (19) into
cylinder head.
a Be careful not to drop gasket (22)
when inserting injector assembly
(19).
4) Install holder (18) to injector assembly
(19).
5) Fasten holder (18) with injector
mounting bolt (17).
a Before tightening mounting bolt
(17), check that holder (18) is
securely installed to groove (e) of
injector assembly (19).
a When installing dust seal (20), be
careful not to make clearance
between the seal and cylinder head.
FH40-1, FH45-1, FH50-1 50-17

Removal and installation of cylinder head assembly
Removal and installation of 4. Drain the coolant.

a Install hose [1] to drain valve (5) and open
cylinder head assembly the radiator cap to drain the coolant.
kLower the forks to the ground, stop the 6 Coolant: 9 l
the wheels.
a Never drain the coolant or oil to the ground.
Removal
1. Remove hood (1).
• For details, see "Removal and installation of
hood assembly".
2. Remove head guard (2).

head guard assembly". 5. Remove aftercooler pipe (6). [*1]
position (length of insertion).
6. Disconnect radiator hoses (7) (2 pieces). [*2]


50-18 FH40-1, FH45-1, FH50-1

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]
14. Disconnect wiring harness (18) from positive

(+) terminal (19) of the battery and remove bat-
teries (20) (2 units).
9. Disconnect coolant temperature sensor termi-

nal (11).
15. Pull out and remove relay box (21).
16. Remove fuse box (22) (2 bolts).
11. Remove bolt (13) and move alternator (14) to
the opposite side to the engine. 17. Remove slow blow fuse box (23).
FH40-1, FH45-1, FH50-1 50-19

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.

a Keep bracket (28) and relay together away
from battery bracket (29).
50-20 FH40-1, FH45-1, FH50-1

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.
30. Remove nuts (39) (4 pieces) and bolts (40) (8

pieces) to remove exhaust manifold (35). [*4]
28. Remove brackets (36) (2 pieces) (4 bolts)

under exhaust manifold (35).
FH40-1, FH45-1, FH50-1 50-21

31. Disconnect coolant temperature sensor termi-

nal (41).
32. Remove clamp (42).
33. Remove bolts (43) (4 pieces) and remove water

pump (44). [*5]
37. Remove joint bolts (48) (4 places).
38. Remove bolts (49) (2 places) and remove fuel

main filter (50).
39. Remove bracket (51) (1 bolt).

a Keep bracket (51) and wiring harness
34. Disconnect injector connectors (45) (4 places). together away from the engine.
36. Disconnect connector (47).
50-22 FH40-1, FH45-1, FH50-1

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.
41. Remove fuel spray prevention caps (54) (8

pieces). [*6]
42. Remove clamps (55) (2 places). [*7]
44. Remove pins (58) (4 places) and remove spill

hose (59).
FH40-1, FH45-1, FH50-1 50-23

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]
46. Remove bolt (62) and clamp (63), and remove

tube (64).
49. Remove the rocker arm assembly according to

the following procedure.
1) Loosen lock nut (70) and fully loosen
adjustment screw (71). [*11]
a Loosen air intake adjustment screws
and exhaust adjustment screws for all
the cylinders.
2) Remove bolts (72) (3 pieces) and bolts (73)
(5 pieces), and remove rocker arm assem-
bly (74). [*12]
a The shape of bolt (72) is different from
that of (73). Check the installation posi-
47. Remove 3 bolts (65) to remove cylinder head tions.
cover (66). [*9]
50-24 FH40-1, FH45-1, FH50-1

50. Remove push rods (75) (8 pieces). Installation

[*1]
a Install the hose until its end comes to the mark
put on before disassembling.
8.8 ± 0.5 Nm {90 ± 5 kgcm}
dimensions.
(Unit: mm)
L1 L2
Connectionof pipe and hose 50 15
51. Remove 17 bolts (76).
[*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)
45 10
(outlet side)
FH40-1, FH45-1, FH50-1 50-25

[*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.
• Tighten water pump mounting bolt (13) together

with alternator (14) mounting bracket (83).
3 Clamp mounting bolt (55):

5.9 to 7.8 Nm {0.6 to 0.8 kgm}
3 Sleeve nut (56):
25.5 to 29.4 Nm {2.6 to 3.0 kgm}
50-26 FH40-1, FH45-1, FH50-1

[*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)
1) Install dust seal (80) to injector assembly

(69).
2) Install gasket (82) to injector assembly (69).
3) Insert injector assembly (69) into cylinder
head.
a Be careful not to drop gasket (82) when
a Mounting bolts (60) have different stem inserting injector assembly (69).
lengths. Install each bolt of which the length 4) Install holder (68) to injector assembly (69).
matches the length as checked at removal. 5) Fasten holder (68) with injector mounting
bolt (67).
[*9] a Before tightening mounting bolt (67),
a Replace the O-ring of the cylinder head cover check that holder (68) is installed to
with a new one. groove (e) of injector assembly (69).
3 Cylinder head cover mounting bolt: a When installing dust seal (80), be care-
7.84 to 9.8 Nm {0.8 to 1.0 kgm} ful not to make clearance between the
seal and cylinder head.
FH40-1, FH45-1, FH50-1 50-27

[*11] [*12] 3 Cylinder head mounting bolt:

a Before installing rocker arm assembly (74), 1st time:
loosen lock nut (70) and sufficiently loosen 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
adjustment screw (71) . 2nd time:
a When installing rocker arm assembly (74), 107.8 ± 4.9 Nm {11.0 ± 0.5 kgm}
make sure that the ball part of the adjustment 3rd time:Put marks on the bolt head
screw is fitted in the socket of the push rod, and and cylinder head, then turn
then tighten the mounting bolts alternately. bolt 90 degrees (+30 degrees/
a Check the installation positions of rocker arm 0 degrees) to tighten.
mounting bolts (72) and (73), and then install a After tightening, put a punch mark (n) on each
them. bolt head to indicate the number of tightening.
3 Rocker arm mounting bolts (72) and (73): a The bolt which has 5 punch marks must be
19.6 to 29.4 Nm {2.0 to 3.0 kgm} replaced with a new one. Do not reuse it.
• For the method to adjust the valve clearance, (In the figure)
refer to the shop manual of the engine. F indicates the front of the engine.
R indicates the rear of the engine.
(b) indicates the bolts tightened by torque plus
angle method.
(In the figure)

p1 indicates the mark on the cylinder head.
p2 indicates the mark on the bolt head.
[*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
50-28 FH40-1, FH45-1, FH50-1

Removal and installation of of radiator assembly
Removal and installation of of 3. Remove radiator hose (3). [*1]

radiator assembly bling to easily find the hose installation
k Lower the forks to the ground, stop the position (length of insertion).
the wheels.
k If you drain the coolant when it is still hot,
you may be scalded. Wait until the coolant
temperature drops before starting the work.
Removal
1. Remove aftercooler (1).
aftercooler assembly".
4. Disconnect hose (4).
5. Remove bolts (5) (2 pieces) and remove middle

cover (6). [*2]
a Move middle cover (6) to the engine side.
2. Drain the coolant.

the radiator cap to drain the coolant.
6 Coolant: 9 l
6. Disconnect drain hose (7).
FH40-1, FH45-1, FH50-1 50-29

Removal and installation of of radiator assembly
7. Remove bolts (8) (2 pieces) and pull out the Installation

radiator assembly upward to remove it. Perform installation in the reverse order to removal.
[*1]
end comes to the mark put on before disas-
sembling.
dimensions.
(Unit: mm)
L1 L2
54 6.5
(inlet side)
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
50-30 FH40-1, FH45-1, FH50-1

Removal and installation of aftercooler assembly
Removal and installation of 3. Disconnect connector (3).

aftercooler assembly
4. Remove clamps (5) (6 places) from sub hood
k Lower the forks to the ground, stop the stay (4).
the wheels.
Removal
1. Remove sub hood (1) (3 bolts).
5. Remove buzzer (6) and relay (7).
2. Remove right and left side covers (2) (3 bolts).

[*1]
7. Remove connector (9).
FH40-1, FH45-1, FH50-1 50-31

8. Remove sub hood stay (4) (4 bolts).

9. Remove aftercooler hose (10). [*2]
a Put a mark at the hose tip portion on the 12. Remove bolts (15) (4 pieces) and remove after-
pipe before disassembling to easily find the cooler (16).
hose installation position (length of inser-
tion).
10. Remove bolts (11) (2 pieces), right and left

resin rivets (12) (4 pieces), and shroud (13).
[*3]
a Move shroud (13) to the engine side.
50-32 FH40-1, FH45-1, FH50-1

Installation
[*1]
[*2]
a Install aftercooler hose (10) onto the pipe until
its end comes to the mark put on before disas-
sembling.
8.8 ± 0.5 Nm {90 ± 5 kgcm}
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}
FH40-1, FH45-1, FH50-1 50-33

Removal and installation of oil cooler assembly
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
the wheels.
k Loosen the cap of the hydraulic tank and
release the pressure in the hydraulic tank.
Removal
Installation
Refilling of oil (hydraulic tank)

Refill the hydraulic tank with oil to the specified
level through the oil filler port. Run the engine to cir-
culate the oil through the system. Then check the
oil level again.
5 Hydraulic oil:
2. Remove clamp (2) (1 bolt). (For details, see "List of specified fuel and
3. Remove right and left bolts (3) (2 bolts each)

and remove tube (4).
50-34 FH40-1, FH45-1, FH50-1

Removal and installation of engine and pump assembly
Removal and installation of 4. Drain the coolant.

engine and pump assembly the radiator cap, then drain the coolant.
k Lower the forks to the ground, stop the 6 Coolant: 9 l
the wheels.
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. 5. Drain the hydraulic oil.
a Remove drain plug (4), open the cap and
drain the oil.
Removal
6 Hydraulic oil: 110 l
1. Considering the work to be done from the bot-
tom of the frame, use block [1] to lift the lift truck
by approximately 30 cm.
2. Remove hood (1).

hood assembly".

head guard assembly".
FH40-1, FH45-1, FH50-1 50-35

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).
10. Disconnect wiring harness (12) and the cable

from positive (+) terminal (13) of the battery and
remove batteries (14) (2 units).
7. Loosen hose clamp (8) to remove air cleaner

a Put a mark at the hose tip portion on the
pipe before disassembling to easily find the
hose installation position (length of inser- 11. Pull out and remove relay box (15).
tion).
12. Remove fuse box (16) (2 bolts).
13. Remove slow blow fuse box (17).
8. Remove aftercooler pipe (10). [*1]

hose installation position (length of inser-
tion).
50-36 FH40-1, FH45-1, FH50-1

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.

a Keep bracket (22) and relay together away
from battery bracket (23).
FH40-1, FH45-1, FH50-1 50-37

21. Remove clamp (25) and disconnect aftercooler 25. Disconnect coolant temperature sensor termi-
pipe (26). nal (31).
27. Disconnect alternator terminal (33) (2 places)

and move it to the opposite side to the engine.
22. Disconnect connectors (27) and (28) of the

engine controller.
a The hexagonal socket head bolt (4 mm) is
used to install connector (28).
23. Remove clamp (29) and keep the wiring har- 28. Disconnect intake air heater terminal (34) and
ness away from the engine. connector (35).

a Keep the wiring harness away from the
engine.
24. Disconnect fuel pipes (30) (2 places).
50-38 FH40-1, FH45-1, FH50-1

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).
35. On the hydraulic tank side, disconnect hose

(46) of steering brake return circuit and remove
clamps (47) (3 places).
a Keep hose (46) away from the engine.
36. Remove control valve return pipe (48) between

the control valve and hydraulic tank.
37. Disconnect lift cylinder return pipe (49) on the

hydraulic tank side and remove clamps (50) (2
places).
32. Remove clamps (41) (3 places) and bands (42)

(3 places) and keep the wiring harness away
from the engine.
FH40-1, FH45-1, FH50-1 50-39

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.
47. Disconnect suction pipe (63) for work equip-

ment and steering pump.
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]
43. Disconnect hoses (pump main) (57), (PP line)

(58), and (LS line) (59).
50-40 FH40-1, FH45-1, FH50-1

49. Remove fan (67) (4 bolts). 51. Sling the engine and pump assembly.
52. Remove right and left engine mounting nuts

(71) and right and left PTO mounting nuts (72).
[*4]
53. Sling and remove engine and pump assembly

(73).
4 Engine and pump assembly (73): 600 kg
50. Remove bolt (68) to move air cleaner pipe (69)

forward, and install eyebolt (M20 x 2.5) to hole
(70) for lifting.
FH40-1, FH45-1, FH50-1 50-41

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:
lubricant".): 9 l
[*2]
end comes to the mark before disassembling.
dimensions.
(Unit: mm)
L1 L2
Connection and engine hose
50 10
(inlet side)
Connecton and engine hose
45 10
(outlet side)
50-42 FH40-1, FH45-1, FH50-1

Removal and installation of starting motor assembly
Removal and installation of start- 4. Disconnect connector (5) and remove wiring
harness (6) from the clamp.
ing motor assembly
the wheels.
Removal
5. Disconnect B terminal (7). [*2]

a Put on a mark at the portion before disas-
sembling to easily find the hose installation
position.
FH40-1, FH45-1, FH50-1 50-43

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).
2) Remove screw (12). [*3]
3) Pull out and remove wiring harness (13)

from C terminal (10).
50-44 FH40-1, FH45-1, FH50-1

Installation
[*1]
[*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}
FH40-1, FH45-1, FH50-1 50-45

Power train
Removal and installation of front axle and HST motor assembly
Power train
Removal and installation of front
axle and HST motor assembly
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".
terminal of the battery. 5. Disconnect HST charge circuit hose (2).
considering the work to be done from the
bottom of the frame, use the solid blocks
that can support the weight.
entering.
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.
7. Disconnect HST motor drain tube (4) on the

HST motor side.
2. Remove the forks.

4 Fork (1 piece): 120 kg
3. Remove mast assembly.

• For details of removing mast assembly, see
"Removal and installation of mast assem-
bly".
4. Disconnect HST high-pressure hoses (1) (2

places) on the HST motor side.
50-46 FH40-1, FH45-1, FH50-1

Power train
8. Disconnect brake hose (5). [*1] 10. Disconnect speed sensor connector (8).
9. Remove parking brake cable (6) and clamp (7).
12. Disconnect EPC valve connector (10).
14. Set jack [2] under the differential case to sup-

port front axle assembly.
FH40-1, FH45-1, FH50-1 50-47

Power train
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
[*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}

oil level again.
5 Hydraulic oil:
50-48 FH40-1, FH45-1, FH50-1

Power train
Disassembly and assembly of front axle assembly
Disassembly and assembly of front axle assembly

a This section indicates tightening torque only.
* Applying LT-2
FH40-1, FH45-1, FH50-1 50-49

Power train
Removal and installation of PTO assembly
Removal and installation of PTO 4. Remove bolts (6) (2 pieces) to remove work
equipment and steering pump (3).
assembly
entering.
Removal
1. Remove the engine and pump assembly.
engine and pump assembly".
2. Disconnect each of hoses (2) connected to

HST pump (1) and each of hoses (4) connected
to work equipment and steering pump (3).
5. Remove bolts (7) (8 pieces) to remove PTO (8).
[*1]
4 PTO (8): 120 kg
3. Remove bolts (5) (4 pieces) to remove HST

pump (1).
Installation
[*1]
3 Bolt (7): 59 to 74 Nm {6.0 to 7.5 kgm}
50-50 FH40-1, FH45-1, FH50-1

Power train
Disassembly and assembly of PTO assembly
FH40-1, FH45-1, FH50-1 50-51

Power train
Disassembly 6. Remove cover (14) by using the forcing tap and

1. Remove drain plug (1) and drain oil from the remove gear (15).
PTO assembly.
7. Remove covers (16) and (17) by using the forc-
2. Remove tubes (2), (3), hose (4), bracket (5), ing tap and remove gear (18).
tube (6), elbow (7), and breather (8).
8. Remove cover (19) by using the forcing tap.
Remove the cover while holding the gear end to
prevent gear (20) and bearing (21) from being
removed with the cover.
9. Remove bolt (23) that fixes shroud (22) and

remove shroud (22), and the gear assembly
from the case.
10. Remove shroud (22) by using the forcing tap

and pull out gear (25) from the hole from which
gear (20) has been removed.
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).
5. Remove lubrication pump (12).
50-52 FH40-1, FH45-1, FH50-1

Power train
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.
2. When installing shaft (24) and O-ring assembly

(27) to gear (25) and bearing assembly (26) in
the case, warm gear (25) and bearing assembly
(26) to 120 to 140 ºC, and cool shaft (24) and
O-ring assembly (27) to -30°C, then install
them. When installing shaft (24) and O-ring
assembly (27), apply G2-Li to O-ring fitting face
of case (28).
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.
FH40-1, FH45-1, FH50-1 50-53

Power train
Disassembly and assembly of differential assembly
*1: FH40-1
*2: FH45-1, FH50-1
50-54 FH40-1, FH45-1, FH50-1

Power train
Disassembly 3. Transfer case

1. Axle housing assembly 1) Loosen bolt (8) of the brake drum cover and
1) Remove the right and left axle housing remove brake drum cover (9).
assemblies. For details, see "Disassembly
and assembly of axle housing assembly".
4 Axle housing assembly: 314 kg
2) Place differential assembly (1) on blocks [1]
for stability.
3) Remove the rear differential cover (2).
a Use the forcing bolts.
2) Fix the spline of the HST motor installation

shaft. Loosen brake drum mounting bolt
(10) and remove brake drum (11).
3) Loosen brake mounting bolt (12) and
remove brake (13).
4) Loosen mounting bolt (14) of the cover and
remove cover (15).
2. Brake
shaft and remove pinion shaft end bolt (16).
1) Remove shaft (3).
6) Pull out the pinion shaft by using the press,
2) Remove outer plate (4).
etc.
a The outer plate is on the axle housing
a The pinion shaft may drop and the tooth
side.
may be damaged. Therefore, put the
3) Remove disc (7), spring (6), and plate (5).
cushioning material such as cloth under
a Put marks on the parts to avoid confu-
the pinion shaft.
sion between the right and left side
7) Remove bolt (17) of the cage to which the
parts.
HST motor is installed, and remove cage
(18).
8) Loosen bolts (20) and (21) used for install-
ing the transfer case to housing (19).
Remove transfer case (22) by using the
forcing screw.
9) Remove transfer gears (23) and (24).
FH40-1, FH45-1, FH50-1 50-55

Power train
4. Bearing carrier 5) Remove pinion gear (36), spider shaft (37),

Remove bolt (25) and screw in the forcing and spherical bushing (38) in a unit.
screw while lifting the differential assembly and
remove bearing carrier (26).
a Put marks on the bearing carriers on the
right and left sides to prevent confusion.
5. Differential assembly
1) Remove differential assembly (28) from dif-
ferential housing (19).
6) Remove spherical bushing (38) and pinion

gear (36) from removed spider shaft (37).
2) Remove bolt (32) and remove bevel gear

(31) from differential assembly (28).
3) Remove bolt (30) and remove small case
(29) from differential assembly (28).
6. Parking brake
1) Remove bolt (12), and remove parking
brake (13).
4) Remove thrust washer (34) from large case

(33), and remove side gear (35).
50-56 FH40-1, FH45-1, FH50-1

Power train
2) Make a groove on the surface of retainer 8. Friction gear

(11a) by using the sander, etc. to catch the 1) Remove bearings (46) and (47) by using
hook of the puller. Pull out the O-ring by the bearing puller.
using the puller and remove it. 2) Push spacer (48) at shaft end bearing (46)
side with the force of 1,000 to 1,200 N
{101.97 to 122.37 kg} by using press
machine, and remove snap ring (49).
3) Remove spacer (48), springs (50), 51),
washer (53), and gear (53) from gear (54).
k To remove the snap ring, securely fix
the gear to prevent it from tilting.
When removing the snap ring, the
spacer may jump out by the spring
force. Slowly reduce the press power
after removing the snap ring.
7. Pinion shaft
1) Remove spacer (40), shim (41), transfer
gear (42) and bearing (43) from pinion shaft
(39).
2) Remove bearing (43) and shim (41).
FH40-1, FH45-1, FH50-1 50-57

Power train
Assembly 4) Calculating shim thickness S1

1. Adjusting shim of pinion shaft Substitute the dimensional difference a, b,
1) Dimensional difference a and c obtained as above to the following
Read the display a on the pinion shaft end. formula and calculate shim thickness S1.
2) Dimensional difference b a+b+c
Read the stamp b on the case. S1 = 0.65 +
100
5) Insert shim (41) and press-fit bearing (43).

a Check that there is no clearance
between the mating faces of respective
parts.
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).
50-58 FH40-1, FH45-1, FH50-1

Power train
3. Installation of pinion shaft 4. Adjustment of pinion bearing pre-load

1) Install the outer race of bearing (43) to dif- 1) Measurement of level difference d
ferential housing (19). 1] Press the pinion shaft from the bottom
2) Set differential housing (19) in the direction to fix it.
shown in the following figure. 2] Rotate the bearing 10 turns each
3) Insert the pinion shaft assembly from the clockwise and counterclockwise to fit it.
center of the housing. 3] Measure the level difference d.
a After inserting, support the pinion by a There must be no clearance in por-
using jack [2], etc. to prevent it from tion (c).
dropping.
a Apply oil to the large flange portion of
the inner race of bearing (43 ).
2) Calculating shim thickness S2

1] Based on dimension d measured
above, calculate shim thickness S2.
4) Install oil seal (55) to transfer case (22) by
using the jig. S2 = 2.26 - d
a Jig: 972-EC-579-100 2] Select the shim so that the measured
a Facethe oil seal as shown in the figure. level difference is equal to S2.
5) Install spacer (41), transfer gear (42), and 3) Assembly
spacer (42). Install shim (S2) selected above and the
6) Press-fit the ball bearings to the both sides inner race of bearing (57), and then set
of gear (23) with shaft, and then install dif- holder (58) and tighten the bolt.
ferential housing (19).
7) Set gasket (56) and install transfer case
(22).
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
a Apply oil to bearings (43) and (57).

a There must not be clearance in portion
(c).
a To prevent rotation, install parking drum
(11) temporarily and use the bolt holes.
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
2 Mounting bolt:
Liquid adhesive LT-2
FH40-1, FH45-1, FH50-1 50-59

Power train
4) Tightening the bolt to the specified torque,

and then rotate the bearing 20 turns each
clockwise and counterclockwise to fit it.
5) If starting torque T of the bearing is not
equal to the following torque value, disas-
semble and readjust the shim thickness.
Starting torque
5.78 to 11.08 Nm {0.59 to 1.13 kgm}
a If starting torque T is larger than 11.08

Nm {1.13 kgm}, increase the shim thick-
ness.
a if starting torque T is smaller than 5.78
Nm {0.59 kgm}, decrease the shim
thickness.
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)
50-60 FH40-1, FH45-1, FH50-1

Power train
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)
2) After installing thrust washer (34) and side

gear (35), install the shaft assemblies
described above in a unit.
a Set the hook of thrust washer (34) to
the case groove and install it.
3) Install side gear (35) and thrust washer

(34).
FH40-1, FH45-1, FH50-1 50-61

Power train
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.
9. Measuring backlash of bevel gear

a Use special tool A to tighten adjuster screw
(62).
Special tool A 3EC-97-99150
1) Check again that the starting torque of the

differential side bearing is within the range
after the adjustment completed.
2) Install lock plate (64) to prevent the screw
7) Tighten screw (62) on the tooth surface side from loosening after the adjustment com-
(A) of the bevel gear. pleted. (Both side)
a Rotate the bearing approximately 10 a To install the lock plate, remove carrier
turns each clockwise and counterclock- mounting bolt (2).
wise to fit it. a Select and remove the bolt which
matches the groove position of the
screw.
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
50-62 FH40-1, FH45-1, FH50-1

Power train
10. Inspection of tooth contact Runout of bevel gear: Max. 0.1 mm

1) Apply red lead lightly to the tooth surface of
the bevel gear.
2) Rotate the bevel gear to the forward travel
side and reverse travel side a few turns.
3) Check the pattern remaining on the tooth
surface to determine the tooth contact con-
dition.
4) When the tooth contact is not correct,
adjust the shim thickness.
11. Correction of tooth contact

• Increase the shim thickness of the pinion
shaft and increase the protrusion of the pin-
ion. (In direction A)
Next, move the bevel gear away from the
pinion (in the direction B) and adjust the
backlash.
• Correct tooth contact condition (no load)

The pattern must be located at the center of
the tooth contact and the contact is even in
the direction of the tooth height.
a In case of strong contact (1) at the tooth

end, increase the shim thickness.
a In case of strong contact (2) at the tooth
end, decrease the shim thickness.
a The tooth contact must be adjusted cor-
rectly both for forward travel and reverse
travel. • Decrease the shim thickness of the pinion
shaft and decrease the protrusion of the
pinion. (In direction A)
Next, move the bevel gear closer to the pin-
ion (in direction B) and adjust the backlash.
FH40-1, FH45-1, FH50-1 50-63

Power train
• Decrease the shim thickness of the pinion 12. Assembly of brake

shaft and decrease the protrusion of the 1) Install seal (67) to piston (67) and install
pinion. (In direction A) them from the both sides of differential
Next, move the bevel gear closer to the pin- housing (19).
ion (in direction B) and adjust the backlash. a Apply engine oil to the seal portion
because the piston seal is hard.
a The piston can be easily installed by
using jig [3].
• Increase the shim thickness for the pinion

shaft and increase the protrusion of the pin-
ion. (In direction A)
Next, move the bevel gear away from the 2) Install disc (7), spring (6), plate (5) and
pinion (in direction B) and adjust the back- outer plate (4).
lash. a Note that there are several number of
sheets.
a Match the mark when reassembling.
*1: FH40-1
*2: FH45-1, FH50-1
50-64 FH40-1, FH45-1, FH50-1

Power train
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
13. Installation of axle housing assembly

a As for the assembly and disassembly of the
axle housing assembly, see Disassembly
and assembly "Disassembly and assembly
of axle housing assembly". 4) Install front cover (2) to differential housing
(1) and tighten bolt (71).
14. Installation of differential front cover 3 Mounting bolt:
1) Degrease and clean the surface to be 59 to 74 Nm {6 to 7.5 kgfm}

coated with liquid gasket, and let them dry
naturally.
2) Apply liquid gasket with 2 to 3 mm wide
without break as shown in the following fig-
ure.
2 Mounting bolt:
ThreeBond (TB1207B)
15. Removal of pinion shaft cover

1) Degrease and clean the surface to be
coated with liquid gasket, and let them dry
naturally.
2) Apply liquid gasket with 2 to 3 mm wide
without break as shown in the following fig-
ure.
2 Mounting bolt:
ThreeBond (TB1207B)
FH40-1, FH45-1, FH50-1 50-65

Power train
3) Install transfer gears (23) and (24).

4) Install transfer case (22) to housing (19) by
using bolts (20) and (21).
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
5) Install bolt (17) of the cage to which the
HST motor is installed.
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
6) Install pinion shaft, fix the spline of the HST
motor installation shaft, and fasten it with
pinion shaft end bolt (16).
3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
7) Install cover (15) with bolt (14).
3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
8) Install brake (13) with bolt (12).
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
shaft. Install the brake drum with brake
drum mounting bolt (10).
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
10) Install cover (11) to the brake drum.
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
50-66 FH40-1, FH45-1, FH50-1

Power train
Disassembly and assembly of axle housing assembly
Disassembly and assembly of

axle housing assembly
Disassembly
1. Draining oil
Remove plug (1) and drain oil.
6 Axle oil: 11 l
4. Planetary carrier assembly

1) Remove axle shaft mounting bolt (4), and
sling and remove planetary carrier assem-
bly (5).
a When removing mounting bolt (4),
cover thread part with cloth to protect
and stop rotation of axle shaft.
2) Remove shim (6).
2. Front axle assembly: a Note the thickness of shims for assem-
Remove front axle assembly from the lift truck. bly purpose.
• As for removaland and installation of the
front axle, see "Front axle and HST motor
assembly"
3. Axle housing assembly

Remove bolt (2), separate axle housing assem-
bly (3) from the axle assembly and set it straight
up.
a When removing both right and left axle
housing assemblies, put a match mark on
each housing and the differential case to
prevent confusion. (On both right and left
sides)
a If removing one-side axle housing assem-
5. Ring gear
bly, the balance of axle becomes ill and the
By using puller [1], pull up ring gear (7) evenly
axle tilts to the opposite side. Prevent it
to remove it from housing assembly (8).
from tilting.
a Install spacer [2] to the bolt tip of puller and
a The liquid gasket is applied to the housings.
adjust its height.
Use the forcing tap for disassembling.
a Be careful not to allow the hook of puller to
disengage from the ring gear.
FH40-1, FH45-1, FH50-1 50-67

Power train
6. Axle shaft 7. Wheel bearing

1) Sling axle housing (9). a Do not heat or flame-cut the bearing to
2) Hit the flange end face of axle shaft (10) by remove it.
using a copper hammer and pull the shaft 1) Install bearing race puller [3] to the bottom
out. Or pull out axle shaft by using a press. of bearing (11) and fix it securely.
2) Tighten the bolts and remove bearing (11).
8. Axle housing
Remove bearing outer races (12) and (13), and
remove oil seals (14) and (15) from axle hous-
ing (9).
50-68 FH40-1, FH45-1, FH50-1

Power train
9. Planetary carrier Assembly

1) Drive in spring pin (17) of planetary carrier 1. Axle housing
(16) into shaft (16) so that the pin does not 1) Press-fit bearing outer races (12) and (13)
protrude from shaft (18). to axle housing (9).
a Take care not to drive in the spring pin 2) By using the jig, install oil seals (14) and
excessively. (15) to axle housing (9).
Jig: 3EC-97-99170
Jig: 3EC-97-99180
2 Oil seal lip surface: Grease (G2-LI)
2 Outer periphery of outer ring of oil
seal: Loctite (#572)
2) Pull out shaft (18) by using a press.

3) Pull out spring pin (17) from removed shaft
(18).
2. Axle housing and shaft

1) By using tool [4], press-fit bearing (11) to
axle shaft (10).
4) Remove pinion gear (19), bearings (20) and

spacers (21) from planetary gear (16).
FH40-1, FH45-1, FH50-1 50-69

Power train
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.
4) Apply pre-load within the range from 2,940

to 5,880 N {300 to 600 kgm} to the bearing
and measure dimension b from the bearing
to end tip of the shaft.
3. Pre-load adjustment of wheel bearing

1) After making sure that the bearing operates
smoothly, measure the starting torque of
the bearing by using drilled hole H of the
axle housing.
2) When the starting torque of the bearing is
0.78 Nm {0.08 kgm} or more, the adjust-
ment cannot be performed. Reduce the
pre-load of the bearing according to the fol-
lowing procedure.
1] Just like when you disassemble the
axle housing, sling axle shaft and
housing assembly (3) approximately 20
to 30 mm with2-point sling method.
2] While rotating axle shaft (10), hit its
flange several times by using a copper
hammer in the arrow direction, then pull
out axle shaft (10) from axle housing
(9).
3] Perform Step 1) to adjust the starting
torque to 0.78 Nm {0.08 kgm}.
50-70 FH40-1, FH45-1, FH50-1

Power train
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.
a If the starting torque of the bearing is

less than the standard value, decrease
the shim thickness and readjust the
bearing so that the starting torque
reaches the standard value.
a If the starting torque exceeds the stan-
dard value, adjust it according to follow-
ing steps 1) to 3).
1] Just like when you install axle housing,
sling axle shaft and housing assembly (3)
approximately 20 to 30 mm with 2-point
sling method.
2] While rotating axle shaft (10), hit its flange
several times by using a copper hammer in
the arrow direction, then pull out axle shaft
(10) from axle housing (9).
3] Perform Step 1) to adjust the starting torque
to be in the standard range.
FH40-1, FH45-1, FH50-1 50-71

Power train
4. Planetary carrier 5. Ring gear

1) Install holder A into planetary carrier (16) Press-fit ring gear (7) to axle housing (9) and
beforehand. insert pin (24).
2) While lifting holder A, install bearing (20) to a Align pin holes of the axle housing and ring
gear (19) and spacer (21) to the combina- gear when press-fitting the ring gear.
tion carrier. a Press-fit the ring gear keeping it horizontal
so that it does not tilt.
a Note that pin (24) protrudes from the hous-
ing mounting surface.
3) Press-fit shaft (18) while aligning spring pin

holes (23) with the shaft.
2 Shaft: Oil (axle oil)
6. Planetary carrier assembly:
1) Install shim (6) selected for pre-load adjust-
ment of the wheel bearing to the end face of
the axle shaft.
2) Install planetary carrier assembly (5), and
then tighten mounting bolts (4).
a Be sure to degrease and clean axle
shaft bolt mounting holes and mounting
bolts.
k Take care that your fingers do not
get caught between the housing and
gear, etc. when the planetary gear
assembly is installed.
2 Mounting bolt:
a Align shaft (18) and hole of planetary
Liquid adhesive (LT-2)
carrier (16), drive in spring pin (17) so
3 Mounting bolt:
that the spring pin is flush with carrier
245 to 309 Nm {25 to 31.5 kgm}
(16) (portion J).
a Before installation, clean the shaft end
face and the spline of planetary carrier.
50-72 FH40-1, FH45-1, FH50-1

Power train
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.
2) Apply liquid gasket to the mounting surface

of axle housing assembly (3) and of differ-
ential housing (25). (Apply to the differential
housing side.)
1] Degrease and clean the surface to be
coated with liquid gasket, and let them
air dry.
2] Apply liquid gasket with 2 to 3 mm wide
without break as shown in the following 5) Install and tighten mounting bolts (6) diago-
figure. nally.
2 Housing mating surface: 3 Housing mounting bolt:
ThreeBond (TB1207B) 157 to 196 Nm {16 to 20 kgm}
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
FH40-1, FH45-1, FH50-1 50-73

Power train
Disassembly and assembly of parking brake assembly
Disassembly and assembly of parking brake assembly
50-74 FH40-1, FH45-1, FH50-1

Power train
Disassembly and assembly of rear axle assembly

Disassembly dtawing
FH40-1, FH45-1, FH50-1 50-75

Power train
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.
1. Wheel angle sensor
2. Refilling of oil
For the grease nipple and grease for the hub,
use lithium grease (G2-LI).
50-76 FH40-1, FH45-1, FH50-1

Power train
Details of rear axles 3. Hub

1. Bell crank 1) Sufficiently fill the grease (G2-LI) into hub
1) Lock nut (1) bearings (9) and (10) up to 1/2 to 2/3 of the
2) Grease nipple (2) hub space (hatched area). (On both sides)]
2) When installing the hub, apply the grease
(G2-LI) to seal (11) and lip.
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}
2) After the adjustment completed, insert the

cotter pin (lock) in the holes at the place
where the nut and shaft holes align and
bend it securely.
FH40-1, FH45-1, FH50-1 50-77

Power train
Disassembly and assembly of power steering cylinder assembly
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
50-78 FH40-1, FH45-1, FH50-1

Power train
Disassembly 4. Pull out piston rod (2) straight.

1. Clamp the outside diameter of cylinder tube (1).
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.
3. Slowly pull out right and left rod guides (4).

a Be careful not to damage the packing when
removing.
FH40-1, FH45-1, FH50-1 50-79

Power train
Disassembly and assembly of brake pedal assembly
Disassembly and assembly of brake pedal assembly
Adjustment procedure for stop lamp switch

After adjusting the brake pedal, adjust clearance A
(Detail is P in the above illustration.) to 0 to 0.4 mm.
50-80 FH40-1, FH45-1, FH50-1

Removal and installation of counterweight assembly

Removal and installation of 4. Remove cap (4).
counterweight assembly
the wheels.
Removal
5. Pass wire [1] and sling it.
2. Remove right and left side covers (2) (3 bolts).

[*1]
6. Remove bolt (5). [*2]
3. Disconnect right and left connectors (3) and

remove them from the clamps.
FH40-1, FH45-1, FH50-1 50-81

Removal and installation of counterweight assembly
7. Sling and remove counterweight (6). Installation

4 Counterweight (6): 3,150 kg Perform installation in the reverse order to removal.
[*1]
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.
50-82 FH40-1, FH45-1, FH50-1

Removal and installation of head guard assembly
Removal and installation of head

guard assembly
the wheels.
Removal
1. Remove hood (1).
hood assembly".
2. Remove right and left side covers (2) (3 bolts). 5. Remove dashboard (7) (bolt) on the left side.
[*1]
3. Remove right and left steps (3) (4 bolts).
4. Remove right and left covers (4) (3 bolts).

a Right cover (4) and dashboard (5) on the
right side are fastened together. Remove
screws (6) (5 pieces) as well.
FH40-1, FH45-1, FH50-1 50-83

8. Remove bracket (10).

a When slinging the head guard assembly,
the assembly hits those parts. Therefore,
remove them.

a Remove the bracket together with the
antenna box (12).
10. Remove cover (13) (1 bolt and 4 screws).

4) Remove bolts (19) (2 pieces) and remove
dashboard assembly (5).
11. Remove the dashboard assembly on the right

side according to the following procedure.
1) Disconnect connector (14) of the service
switch, connector (15) of the travel speed
control select switch, and connector (16) of
the pilot box.
2) Disconnect connector (17) of the starting
switch.
3) Remove clamp (18).
50-84 FH40-1, FH45-1, FH50-1

12. Disconnect connector (20). 17. Remove relay (26) and buzzer (27).
13. Remove clamp (21). 18. Remove clamp (28).
14. Pull out coolant drain hose (22) from the front
panel.
19. Remove clamps (29) (2 pieces), and remove

breather assembly (30).
20. Remove DC/DC converter (31) (2 screws).
15. Remove clamp (23), and remove breather

assembly (24). 21. Sling head guard assembly (32).
FH40-1, FH45-1, FH50-1 50-85

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.
23. Remove rear head guard stay mounting bolts

(34) (2 each on the right and left sides).
24. Remove reservoir tank (35) for the coolant from

the bracket and move it. Installation
a Move the tank to prevent it from being hit Perform installation in the reverse order to removal.
when lifting the head guard assembly.
50-86 FH40-1, FH45-1, FH50-1

Removal and installation of hood assembly
Removal and installation of hood 2) Remove bolts (4) (4 pieces) and remove
seat assembly (2).
assembly
4 Seat assembly (2): 20 kg
the wheels.
Removal
3. Remove clamps (6) (6 places) from sub hood

stay (5).
2. Remove seat assembly (2) according to the fol-

lowing procedure.
5. Remove connector (8).
6. Remove sub hood stay (5) (4 bolts).
1) Disconnect connector [3].
FH40-1, FH45-1, FH50-1 50-87

Removal and installation of hood assembly
7. Remove pins (9) (2 places) and remove Installation

damper (10). Perform installation in the reverse order to removal.
8. Remove bolts (11) (4 pieces) and remove hood

assembly (12).
4 Hood assembly (12): 25 kg
50-88 FH40-1, FH45-1, FH50-1

Hydraulic system
Removal and installation of HST pump assembly
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.
entering.
Removal
1. Remove hood (1).
hood assembly".


hose installation position.
FH40-1, FH45-1, FH50-1 50-89

Hydraulic system
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.
13. Remove control valve return pipe (21) between
the control valve and hydraulic tank.
14. Disconnect lift cylinder return pipe (22) on the

hydraulic tank side and remove clamps (23) (2
places).
7. Disconnect tilt cylinder pipes (11) (2 pieces) on

the control valve side.
9. Disconnect hoses (pump main) (13), (PP line)

(14), and (LS line) (15). 15. Remove bolt (24), clamps (25) (2 places), and
then bracket (26).
11. Remove clamps (17) (3 places) and bands (18)

(2 places), and keep the wiring harness away
from the HST pump.
50-90 FH40-1, FH45-1, FH50-1

Hydraulic system
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).
18. Disconnect HST charge pipes (29) (2 places).
26. Remove bracket (39) and release hoses (40) (2

pieces).
19. Remove clamp (30) and move air bleeder hose

(31) to the engine side.
20. Remove bolts (32) (4 pieces).
21. Disconnect HST pump return hose (33).
27. Sling HST pump assembly (41).
22. Remove suction pipe of HST charge pump (34)
23. Disconnect hose (35) on the charge valve side

and disconnect clamps (36) (2 places).
FH40-1, FH45-1, FH50-1 50-91

Hydraulic system
28. Remove HST pump mounting bolts (42) (4 Installation

pieces). Perform installation in the reverse order to removal.

Replenish oil to the specified level through the oil
filler port. Run the engine to circulate the oil through
the system. Then check the oil level again.
5 Hydraulic oil:
29. Sling and remove HST pump assembly (41).

4 HST pump assembly (41): 90 kg
50-92 FH40-1, FH45-1, FH50-1

Hydraulic system
Removal and installation of HST motor assembly
Removal and installation of HST 3. Remove bracket (3) (6 bolts).

motor assembly
4. Remove plate (4) (4 bolts).
entering.
Removal
1. Remove front axle and HST motor assembly
and fix it to block [1].
front axle and HST motor assembly".
5. Sling HST motor assembly (5) and remove

bolts (6) (4 pieces).
2. Remove drain bolt (2) and drain the axle oil

from the differential case.
6 Axle oil: 11 l
6. Pull out and remove HST motor assembly (12).

4 HST motor assembly (12): 90 kg
Installation
Refilling of oil (differential case)

5 Axle oil:
lubricant".): 11 l
FH40-1, FH45-1, FH50-1 50-93

Hydraulic system
Removal and installation of work equipment and steering pump assembly
Removal and installation of work

equipment and steering pump
assembly
the wheels.
k To support the lift truck by using blocks,
etc. considering the work from the bottom 4. Drain the hydraulic oil.
of the frame, use the solid blocks that can a Remove drain plug (3) and open the cap to
support the weight. drain the oil.
a After disconnecting the pipe, plug it immedi- 6 Hydraulic oil: 110 l
entering.
Removal
1. Considering the work from the bottom of the
frame, use block [1] to lift the fork lift truck
approximately 30 cm.
5. Disconnect suction pipe (4).
6. Disconnect hoses (PP line) (5) and (LS line)

(6).
2. Remove hood (1).

hood assembly".

50-94 FH40-1, FH45-1, FH50-1

Hydraulic system
Removal and installation of work equipment and steering pump assembly
7. Disconnect pipe (7) to the charge valve.
8. Disconnect delivery pipe (8) to the control

valve.
9. Disconnect air bleeding hose (9).
12. Sling and lower work equipment and steering

pump assembly (12) for removal it.
4 Work equipment and steering pump
assembly (12): 25 kg
10. Install eyebolt [2] (M10 X 1.5) and sling.
11. Remove 2 bolts (11).
Installation

oil level again.
5 Hydraulic oil:
lubricant".): 110 l
FH40-1, FH45-1, FH50-1 50-95

Hydraulic system
Removal and installation of control valve assembly
Removal and installation of 5. Remove cover (7) (1 bolt and 4 screws).

control valve assembly
the wheels.
entering.
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).
4. Remove right and left covers (4) (3 bolts).

a Right cover (4) and dashboard (5) on the
right side are fastened together. Remove
screws (6) (5 pieces) as well.
50-96 FH40-1, FH45-1, FH50-1

Hydraulic system
Removal and installation of control valve assembly
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
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".)
FH40-1, FH45-1, FH50-1 50-97

Hydraulic system
Disassembly and assembly of control valve assembly
Disassembly and assembly of

control valve assembly
This section explains only the precautions for
assembling the control valve assembly.
a Be sure to work inside a building where there is
no dust or dirt.
a Clean the parts with a clean solvent, and dry
them by air blow.
a Replace the parts which have burr or sharp
edge.
a Apply engine oil to the sliding surfaces and
assemble them.
a Be careful of the direction of the spool when
installing it.
a Apply a drop (approximately 0.02 g) of Loctite
(No. 638) to the plugs of the spools, and then
tighten them.
a Apply Seal End 242 or equivalent, to the mating
faces.
a For the details and tightening torque of each
portion, see Structure, function and mainte-
nance standard - Hydraulic system - Control
valve.
a Tighten the mounting bolts of the control valve
top cover in the order of (1), (2), and (3) in 3
times.
1st tightening torque:
9.8 to 14.7 Nm {1 to 1.5 kgm}
2nd tightening torque:
19.2 to 24.5 Nm {2 to 2.5 kgm}
3rd tightening torque:
29.4 to 34.3 Nm {3 to 3.5 kgm}
a Do not bend the wiring harness with R35 mm or
less, and do not pull it with a force of 4.9 N {0.5
kg} or more.
50-98 FH40-1, FH45-1, FH50-1

Hydraulic system
FH40-1, FH45-1, FH50-1 50-99

Hydraulic system
50-100 FH40-1, FH45-1, FH50-1

Hydraulic system
FH40-1, FH45-1, FH50-1 50-101

Hydraulic system
Precautions for maintenance of control PRECAUTIONS

valve a When assembling lift spool (2) and yoke (4)
If loosening lock nut (3) of lift spool (2) by mistake of control valve (1), do not loosen lock nut
at the maintenance of control valve (1), the fork (3). If loosening the lock nut, it is difficult to
may lower suddenly during lowering operation after adjust the lowering speed.
raising it even by operating lift lever (8) slowly. (As a As lift spool (2) has a directional character
sudden drop)) and is assembled so that the direction can
be checked with the direction of yoke (4). If
the lock nut is loosened, the direction can-
1. Precautions for replacement of control valve (1)
not be checked. Disassembly and adjust-
When performing the following works, observe
ment are required.
the precautions.
a Adjust lift spool (2) by loosening nut (right
• Replacing control valve (1)
screw) (7) and nut (left screw) (5) and rotat-
• Replacing lift lever (8) of control valve (1)
ing yoke (4) while rotating nut (6).
and adjusting the knob height
a Adjust the direction of lift spool (2) in control
• When removing or installing lift lever (8) for
valve (1) within the range of ±9°against the
replacement of other parts
longitudinal direction of the lift truck as
shown in section A-A and assemble it.
a Check the direction of lift spool (2) so that
yoke (4) is visible (inverted U-shaped) when
sitting on the seat.
a After the assembly completed, operate the
lift truck according to the testing method in
section 2 and check that it operates cor-
rectly.
50-102 FH40-1, FH45-1, FH50-1

Hydraulic system
2. Testing method after maintenance completed Description on the lift lever

k Park the lift truck in a safe place before
starting the operation.
Step 1: Start the engine and gently operate lift
lever (8) with no load.
(Shift lift lever (8): from N to D.)
↓
Step 2: Gently operate lift lever (8) and see
whether or not the forks lower slowly
when the lever moves by approximately
45 mm.
(Near point (A))
If the fork does not lower, go to step 3.
↓ → If the fork lowers slowly, it is normal.
Step 3: If the fork does not lower, operate the
Lever travel for lowering the forks (Unit: mm)
lever more slowly.
a The value varies a little.
↓ → The forks suddenly lowes on the way
of operation of the lever.
(Near point (B)) "As sudden drop"
Step 4: If the forks "lower as sudden drop"
repetitively when repeating steps 1 to 3
3 to 5 times, lock nut (3) of lift spool (2)
may be loosened by mistake during the
maintenance.
FH40-1, FH45-1, FH50-1 50-103

Hydraulic system
Disassembly and assembly of orbitrol valve assembly
1. Screw 17. Race bearing 33. Tube assembly

2. Spring spring 18. Thrust needle 34. Nut
3. End cap 19. O-ring 35. Coil with connector
4. Gerotor 20. Oil seal 36. O-ring
5. Spacer 21. Dust seal 37. O-ring
6. Spacer plate 22. Retaining ring 38. Hexagonal socket head bolt
7. Drive 23. Seal grounding bushing 39. Spring
8. Housing 24. O-ring 40. Core
9. Sleeve 25. O-ring 41. Hexagonal socket head plug
10. Spool 26. Ball 42. Orifice plug
11. Pin 27. Face seal (or plug) 43. O-ring
12. Centering spring 28. O-ring 44. Relief valve
13. EPACS controller 29. Name plate 45. (Check valve assembly)
14. Cross-recessed flat-head screw 30. Rivet 46. O-ring
15. Rotor 31. Valve block
16. Hexagonal socket head lock 32. Spool
screw
50-104 FH40-1, FH45-1, FH50-1

Hydraulic system
Replacement of EPACS valve seal Assembly

Before removing the piping, clean the external area a Replace all O-rings with new ones.
(around the port or peripheral joints) and replace
the seal in a clean place according to the following 1. Insert O-ring (43) into tube assembly (33).
procedure.
2. Insert O-ring (37) (1 piece) and O-rings (36) (4
pieces) into valve block (31).
3. Install tube assembly (33).

3 34 to 40 Nm {3.5 to 4.1 kgm}
4. Install coil with connector (35) and fasten it with

nut (34).
3 Nut: 5 to 8 Nm {0.51 to 0.81 kgm}
5. Install valve block (31) to housing (8) with hex-

agonal socket head bolts (38) (2 pieces).
3 Hexagonal socket head bolts:
Disassembly 34 to 44 Nm {3.5 to 4.5 kgm}
a Do not press the external wall by using a vise, a When installing, be careful not to allow the
etc. O-ring to be caught.
1. Remove nut (34) and coil with connector (35).
2. Remove tube assembly (33).

a Spring (39) and core (40) may unfasten. Be
careful not to lose them.
3. Remove hexagonal socket head bolts (38) (2

pieces) and remove valve block (31) from hous-
ing (8).
4. Remove O-ring (43) from tube assembly (33).
5. Remove O-ring (37) (1 piece) and O-rings (36)

(4 pieces) from valve block (31).
FH40-1, FH45-1, FH50-1 50-105

Hydraulic system
Replacement of seal on shaft side of

steering valve
Before removing the piping, clean the external area
(around the port or peripheral joints) do the work in
a clean place according to the following procedure.
Disassembly
1. Remove cross-recessed flat-head screws (17)
(2 pieces) and EPACS controller (16).
2. Remove dust seal (25) from EPACS controller

(16).
3. Remove hexagonal socket head lock screw

(19) and remove rotor (18) from spool (12).
a Hexagonal socket head lock screw (19)
may not be removed since Loctite is applied
to it. In this case, replace the steering body.
a Be careful not to lose removed hexagonal
socket head lock screw (19).
4. Remove retaining ring (26) from housing (10).

a Always wear protective eyeglasses since
retaining ring (26) may jump out of housing
(10).
5. Remove seal gland bushing (27) and then oil

seal (24).
6. Remove O-ring (23).
50-106 FH40-1, FH45-1, FH50-1

Hydraulic system
Assembly
a Replace all of O-rings and oil seals with new ones.
1. Insert O-ring (23).
2. Install oil seal (24).

a Be careful of the direction of oil seal (24).
Take care not to twist or deform it.
3. Install seal gland bushing (27) to housing (10).

Install retaining ring (26)
a Expand the retaining ring by using a flat-
head screwdriver so that the periphery of
retaining ring can enter securely in the
housing groove.
a Always wear protective eyeglasses since
retaining ring (26) may jump out of housing
(10).
4. Align the hole of the screw of rotor (18) with the

hole of spool (12).
5. Apply Loctite to hexagonal socket head lock

screw (19) and install rotor (18) to spool (12).
6. Install EPACS controller (16) to housing (10) by

using cross-recessed flat-headscrews (17) (2
pieces).
FH40-1, FH45-1, FH50-1 50-107

Hydraulic system
Replacement of seals on gerotor side of steering valve

Before removing the piping, clean the external area (around the port or peripheral joints) and do the work in
a clean place according to the following procedure.
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.
2. Remove screws (1) (7 pieces).
3. Remove end cap (3) and O-ring (28).
4. Remove spacer (5) from the spline portion in

the star of gerotor (4).
a Spacer (5) may not be installed or 2 spac-
ers may be used depending on the specifi-
cation.
5. Remove gerotor (4) and O-ring (28).

a Take care not to drop the star from the ring
of gerotor periphery.
6. Remove O-ring (32) of the gerotor star.

a Do not use O-ring (32) for the standard
specification equipment since it is designed
for the minimum slip specification.
7. Remove drive (8).
8. Remove spacer plate (7).
9. Remove O-ring (29) of the housing (10).

a The size of O-ring (29) is different from that
of O-ring (28).
50-108 FH40-1, FH45-1, FH50-1

Hydraulic system
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).

a Do not use O-ring (32) for the standard
specification equipment since it is designed
for the minimum slip specification equip-
ment.
3. Install O-ring (29) to housing (10).
4. Place spacer plate (7) on housing (10), and

align it with bolt hole position.
a Note that the bolt hole and the oil hole have
different pitch circle diameters.
5. Insert drive (8) and mate it with the drive yoke

and pin (13).
a To perform positioning exactly, use a felt
pen to draw a parallel line to pin (13) on the
end face of drive (8).
(This work is important to adjust the valve
timing correctly. Do it carefully.) 7. Take care not to disengage the drive and gero-
tor star, and rotate the gerotor ring to align with
6. Facde the O-ring of gerotor (4) to the spacer the bolt hole.
plate (7), and install the root side of the tooth a Incorrect combination may cause defective
profile of the gerotor star along with the line operation and lead to a serious accident.
drawn by a felt pen. At this time, check that the Be sure to securely work for positioning.
lines drawn by a felt pen on pin (13) and drive
(8) are parallel to the root of the gerotor star. 8. Install spacer (5) to the spline portion of the
gerotor star.
a Spacer (5) may not be installed or 2 spac-
ers may be used depending on the specifi-
cation.
9. Place end cap (3) on gerotor (4), and align their

bolt holes with each other.
FH40-1, FH45-1, FH50-1 50-109

Hydraulic system
10. Apply the hydraulic oil to the thread portions of

screws (1) (7 pieces) and install end cap (3).
At first, evenly tighten the screws to the torque
of 14.7 Nm {1.5 kgfm}. Then, tighten them to
the following tightening torque.
a Tighten in the order shown in the figure
below.
Tightening torque
Specifications Displacement
Nm {kgfm}
Max. 51 cm3/rev 28 {2.9}
Standard specifi-
60 to 277 cm3/rev 23 {2.3}
cation
Min. 369 cm3/rev 28 {2.9}
Lower than
Lower slip speci- 28 {2.9}
51 cm3/rev
fication
Min. 51 cm3/rev 21 {2.1}
11. Install the steering wheel to spool (12).

a Check that spool (12) rotates.
50-110 FH40-1, FH45-1, FH50-1

Hydraulic system
Removal and installation of lift cylinder assembly
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,
piping, see Testing and adjusting "Bleeding
air".
entering.
Removal
4 Fork (1 unit): 120 kg
2. Sling finger board (1) by approximately 300 mm

by using a crane, and loosen the chain tension.
4. Start the engine and raise the inner mast until

the roller of finger board (1) is pulled out.
5. Move the lift truck backward and remove finger

board (1).
4 Finger board (1): 370 kg
FH40-1, FH45-1, FH50-1 50-111

Hydraulic system
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.
10. Disconnect pipe (10).
7. Loosen right and left stopper bolts (7).
8. Operate the lift lever after slinging inner mast

(6) and lower cylinder head (8).
11. Disconnect hose (11) and remove band (12).
50-112 FH40-1, FH45-1, FH50-1

Hydraulic system
13. Push up the bottom of lift cylinder (14) by using Installation

a bar [2] and remove lift cylinder (14). Perform installation in the reverse order to removal.
4 Lift cylinder (14) (1 piece): 50 kg
Synchronous adjustment of mast
1. Lift the mast to the maximum lifting height.
2. Check the right and left play of the mast.
3. Adjust the play of the mast by using a shim so

that right and left cylinders are synchronized at
the maximum lifting height.
Put a shim onto the left side
Moving to the left
cylinder.
Put a shim onto the right side
Moving to the right
cylinder.
FH40-1, FH45-1, FH50-1 50-113

Hydraulic system
Disasse mbly and assembly of lift cylinder assembly
Disasse mbly and assembly of lift cylinder assembly
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
50-114 FH40-1, FH45-1, FH50-1

Hydraulic system
Disassembly and assembly of tilt cylinder assembly
a * When tightening the head, apply ThreeBond #1344 to the thread portion.
1. Cylinder sub assembly 12. O-ring

2. Rod 13. Back-up ring
3. Piston 14. O-ring
4. Nut 15. Head
5. Head 16. Bushing
6. Bushing 17. Dust seal
7. Packing 18. Bolt
8. Back-up ring 19. Nut
9. Packing 20. Washer
10. Back-up ring 21. Grease fitting
11. Dust seal 22. Bushing
FH40-1, FH45-1, FH50-1 50-115

Hydraulic system
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.
2. Removal of piston rod assembly

Pull out the piston rod and cylinder head
assembly from the cylinder.
a When slinging by using a wire, use cloth to 3. Disassembly of piston rod assembly
prevent the rod from being damaged. 1) Remove the piston rod head.
a When pulling out the assembly, prepare a (Tilt cylinder only)
container since the hydraulic oil in the cylin- 2) Remove the cylinder head from the piston
der spills out. rod assembly.
a If the assembly cannot be removed a Be careful not to damage the cylinder
smoothly, pull it out while rotating the piston head seal by thread portion of the pis-
rod. ton rod.
a When pulling out the assembly, be careful
not to damage the piston seal by thread
portion of the cylinder.
50-116 FH40-1, FH45-1, FH50-1

Hydraulic system
3) Remove the wear ring.

4) Remove the piston ring.
a Do not remove the ring, etc. unless it is
damaged. When the ring is removed,
replace it with a new one.
4. Disassembly of cylinder head assembly

a Do not remove the assembly unless the
seals are damaged. When disassembling
the assembly, replace the seals with new
ones.
1) Remove the snap ring (tilt cylinder only)
and remove the dust seal.
2) Remove the U-packing by using a screw-

driver.
a Be careful not to damage the portions
other than the U-packing.
FH40-1, FH45-1, FH50-1 50-117

Hydraulic system
Assembly of lift and tilt cylinder
1. Assembly of cylinder head assembly

1) To prevent the seal from being damaged, if
there is a burr or sharp edge in portion P
shown in the following figure, remove it by
using an oilstone as shown in portion Z.
2) Apply grease or hydraulic oil to the cylinder

head inner diameter part, packing, and
groove A for the O-ring installation.
5) By using the press-fitting tool, press-fit and

install the dust seal.
3) Crush the U-packing and push it in until it

enters groove B.
a Using a jig to push in: Use a copper,
aluminum, or plastic jig without a bur or
sharp edge on the contact face.
a Install the U-packing by hands as much
as possible instead of using the jig.
4) Check the inner periphery lip or contact with
the groove for unusual condition while
pushing the inner periphery of the U-pack-
ing toward the outer periphery by hands.
6) Install the O-ring.
50-118 FH40-1, FH45-1, FH50-1

Hydraulic system
2. Assembly of piston assembly 4) Install the wear ring.

1) To prevent the seal from being damaged, if
there is a burr or sharp edge in portion P
shown in the following figure, remove it by
using an oilstone shown in portion Z.
2) Apply grease or hydraulic oil to A portion on
the tapered surface of the piston.
3. Assembly of piston rod assembly

Insert the piston rod assembly into the cylinder.
a Be careful not to damage the seals by
thread portion of the cylinder.
4. Assembly of cylinder head assembly

Use a wrench to tighten and install the cylinder
3) Put one side of the piston ring in the groove head assembly to the cylinder.
and then expand the other side along the
tapered surface to put it in.
FH40-1, FH45-1, FH50-1 50-119

Work equipment
Removal and installation of mast assembly
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).
the wheels.
k Before disconcerting hydraulic piping,
piping, see Testing and adjusting "Bleeding
air".
considering the work from the bottom of
the frame, use the solid blocks that can
support the weight.
entering.
Removal
4 Fork (1 unit): 120 kg
2. Remove finger board (1).

• For details of removal of finger board (1),
see "Removal and installation of lift cylinder
assembly".
4. Disconnect hose (4) (3 places) and remove
clamp (5).
50-120 FH40-1, FH45-1, FH50-1

Work equipment
Removal and installation of mast assembly
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
6. Tilt the mast backward rather than in the per-

pendicular. Installation
k Removal of the cap bolts for mounting
the front axle may cause the mast to
suddenly remove and fall down. [*1]
3 Cap bolt for mounting front axle (8):
343 to 427 Nm {35 to 43.5 kgm}
Tilt back of mast Tilt forward of mast
Insecure since
Safety is secured
the mast is not
since the mast is
stably engaged.
stably placed on
the front axle.
7. Remove cap bolts (8) for mounting the right and

left front axles. [*1]
FH40-1, FH45-1, FH50-1 50-121

Work equipment
Disassembly and assembly of mast assembly
50-122 FH40-1, FH45-1, FH50-1

Work equipment
Finger board
For 4.0 ton
FH40-1, FH45-1, FH50-1 50-123

Work equipment
For 4.5 ton
50-124 FH40-1, FH45-1, FH50-1

Work equipment
For 5.0 ton
FH40-1, FH45-1, FH50-1 50-125

Electrical system
Removal and installation of engine controller assembly
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.
Removal
1. Remove floor plate (1).
3. Disconnect connectors (3) to (5). [*1]

a The hexagonal socket head bolt is used to
install connectors (4) and (5).
50-126 FH40-1, FH45-1, FH50-1

Electrical system
Removal and installation of engine controller assembly
Installation
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.
FH40-1, FH45-1, FH50-1 50-127

Electrical system
Removal and installation of HST controller assembly
Removal and installation of HST 6. Disconnect connectors (6) (3 places). [*1]

a The hexagonal socket head bolt is used to
controller assembly install connector (6).
the wheels.
Removal
2. Remove left side cover (2) (3 bolts).
3. Remove left step (3) (4 bolts).
7. Remove bolts (7) (4 pieces) and remove HST

controller assembly (8).

Installation
connector of HST controller assembly (8), and
then install the assembly.
[*1]
3 Hexagonal socket head bolt:
2.83 ± 0.28 Nm {0.29 ± 0.03 kgm}
50-128 FH40-1, FH45-1, FH50-1

Electrical system
Removal and installation of KOMTRAX terminal assembly
Removal and installation of 5. Remove cover (5) (1 bolts).

KOMTRAX terminal assembly
a Remove the KOMTRAX terminal assembly in
the following cases.
• Failure of KOMTRAX terminal assembly
• Export of the lift truck equipped with KOM-
TRAX terminal assembly
• Reselling the lift truck equipped with KOM-
TRAX terminal assembly domestically
(when removal is required)
a To use the lift truck without KOMTRAX terminal
assembly, connect and fix the assembly by
using the following parts.
• Plate (3EC-57-62610, 1 piece) 6. Disconnect connectors (6) (2 places) and
• Connector (22F-06-32410, 1 piece) antenna cables (7) (2 places).
• Connector (22F-06-32420, 1 piece)
the wheels.
Removal
2. Remove left side cover (2) (3 bolts).
3. Remove left step (3) (4 bolts).

7. Remove bolts (8) (4 pieces), and remove KOM-
TRAX terminal assembly (9).
4. Remove cover (4) (2 bolts).
Installation
connector of KOMTRAX terminal assembly,
and then install the assembly.
FH40-1, FH45-1, FH50-1 50-129

Electrical system
Disassembly and assembly of combination switch assembly
Disassembly and assembly of combination switch assembly

Component parts
1. Directional lever switch

2. Screw
3. Cover
4. Body
5. Cover
6. Screw
7. Light and turn signal lamp lever switch
50-130 FH40-1, FH45-1, FH50-1

FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
FH40-1, FH45-1, FH50-1 80-1

Table of Contents
Table of Contents
Yearly inspection criteria ........................................................................................................................ 80-3
Yearly inspection criteria .................................................................................................................... 80-3
80-2 FH40-1, FH45-1, FH50-1

Yearly inspection criteria

Equip-
Inspection Item Detail of inspection
ment
1. Engine startabil- • Inspect the following regarding the startability of the engine.
ity and unusual a Place the directional lever in the neutral position, pull the parking lever, and
noise start the engine.
1. Does the engine start smoothly?
2. Is there any unusual noise?
3. Does the electrical intake airheater operate?
4. Does the accelerator pedal operate smoothly?
2. Rotation condi- • Inspect the following regarding the rotation condition and exhaust of the engine.
tion and exhaust a Before depressing the accelerator pedal, place the directional lever in the
condition neutral position, and pull the parking lever.
1. Is there any stumble?
2. Is there any unusual noise?
3. Is there any abnormal combustion in the engine?
4. Is there any irregular engine vibration?
5. Does engine rotation starts up smoothly?
6. Is there any gas leakage from the exhaust connecting pipe or muffler?
7. Is the exhaust gas color normal?
When engine runs idle Clear
When pedal is depressed Light black
Engine
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."
FH40-1, FH45-1, FH50-1 80-3

Equip-
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.
• Inspect the following regarding the exhaust/intake manifold.

1. Is there any looseness of the exhaust/intake manifold mounting bolt?
2. Is there any gas leakage from the exhaust/intake manifold?

a For the tightening torque for the exhaust/intake manifold mounting bolt, refer
to the shop manual of the engine.
6. Valve clearance • Inspect the following regarding the valve clearance.

1. Is the valve clearance as specified?
Unit: mm (cold)
Engine Intake valve Exhaust valve
SAA4D95LE-5 0.35 0.5
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
SAA4D95LE-5 2.9 {30}/ 150 to 250 2.0 {20}/ 150 to 250
a Difference between cylinders:0.98 {1.0}/200

a For the method to measure the compression pressure, refer to the shop man-
ual of the engine.
8. Fuel injection - Not applicable to this lift truck model -

pressure
(Diesel engine lift
truck)
9. Fuel injection - Not applicable to this lift truck model -

condition
(Diesel engine lift
truck)
10. Turbocharger • Inspect the following regarding the turbocharger.

(Diesel engine lift a Also inspect the operation of the waste gate valve.
truck)
1. Is there any abnormal vibration from low idle to high idle?
2. Is there any abnormal sound from low idle to high idle?
3. Is there any gas leakage from the turbocharger or intake/exhaust pipe con-
nection?
80-4 FH40-1, FH45-1, FH50-1

Equip-
ment
11. Engine mount • Inspect the following regarding the engine mount.
1. Is there any crack or deformation in the bracket?
2. Is there any loose or missing mounting bolt or nut?

If there is a loose bolt or nut, tighten it to the specified torque.
3. Is there any damage or deterioration in the rubber vibration isolator?
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
2. Is there any significant stain?

Check the color of the oil accumulated on the oil level gauge.
a Engine oil must be replaced periodically. Check the replacement condition,
and replace the oil if necessary. (Refer to the lubricant list.)
3. Is there any oil leakage?
4. Is there any stain or clogging of the engine oil filter element?

a Stain or clogging cannot be found by visual check. The engine oil filter is of a
cartridge type. Replace it periodically.
Engine
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?
2. Is there any damage or deterioration of the fuel hose?
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?
2. Is there any crack or damage of the pipe or joint part?
3. Is there any looseness or damage of the gas cylinder mounting hardware?
15. Blowby gas • Inspect the following regarding the blowby gas return system.
return system 1. Is the operation of the PCV valve normal?
2. Is there any clogging or damage of the piping?
FH40-1, FH45-1, FH50-1 80-5

Equip-
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.
2. Is the coolant stained?
3. Is there any water leakage from the radiator main body, engine main body,
water pump, or hose?
4. Is there any clogging of the radiator fin?
5. Is there any damage, crack, or deterioration of the hose?
6. Does the radiator cap function properly?

k Do not remove the radiator cap immediately after the engine stops.
Boiling water may spurt out, causing burns.
k Do not open the radiator cap suddenly even when the temperature of the
coolant is low. Turn the radiator cap slowly to release pressure before
Engine
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.
2) Inspection of the vacuum valve

Pull the valve and check if it closes.
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.
80-6 FH40-1, FH45-1, FH50-1

Equip-
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.
2. Is there any wear or damage of the fan belt?

Also check the inside of the belt.
a Also check the bottom of the pulley of each part of the drive. If the bottom of
the pulley is shiny, the belt is worn. This will make the fan belt slippery, so
replace it.
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
18. Distributor - Not applicable to this lift truck model -
19. Spark plug and - Not applicable to this lift truck model -
ignition timing
(Gasoline engine
lift truck)
FH40-1, FH45-1, FH50-1 80-7

Equip-
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.
1. Is the electrolyte specific gravity of the battery proper?

Electrolyte specific gravity Charge condition Necessity of charging
1.280 Full charge
No
1.240 1/4 discharge
1.210 1/5 discharge
Charging required
1.130 Full discharge
Charge it when necessary.

a When charging is required, check the alternator because of the possibility of
defective charging.
Engine
2. Is the amount of electrolyte proper?

a When the amount of electrolyte is
not sufficient, replenish purified
water.
3. Is there any looseness or corrosion

of the battery terminal?
4. Is there any looseness of the wiring

connection?
5. Is there any damage of the wiring?
21. Clutch - Not applicable to this lift truck model -
22. Transmission - Not applicable to this lift truck model -

Power train
23. Torque converter - Not applicable to this lift truck model -
80-8 FH40-1, FH45-1, FH50-1

Equip-
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."
4. Is the oil stained?

a It is important to replace oil in the PTO periodically.
a For the method to replace PTO oil, refer to the corresponding item in "Testing
and adjusting."
Power train
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}
6. Is the HST charge circuit pressure within the standard value?

• For the method to measure the HST circuit pressure, refer to the correspond-
ing item in "Testing and adjusting."
Charge circuit pressure standard value 2.9 ± 0.5 (30 ± 5)
7. Is the HST stall speed proper?

• For the method to measure the HST stall speed, refer to "Testing and adjust-
ing engine speed."
Unit: rpm
HST stall speed standard value 1650 ± 50
FH40-1, FH45-1, FH50-1 80-9

Equip-
ment
26. Drive shaft - Not applicable to this lift truck model -
27. Differential • Inspect the following regarding the differential.

(Front axle) 1. Is there any unusual noise from the differential?
Drive the front wheel while it is in the air to check for unusual noise.
2. Is the oil level in the differential case proper?
For the method to check the oil level, refer to the corresponding item in "Testing
and adjusting."
3. Is the oil stained?
a It is important to replace axle oil of Oil level gauge
Power train
the differential periodically. Oil filler

a For the method to replace axle oil port
of the differential, refer to the cor-
responding item in "Testing and
adjusting."
4. Is there any oil leakage from the dif-

ferential case?
If oil leak forms oil drops, replace the Drain bolt
packing of the case.
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.

Traveling equipment
If there is a loose bolt, tighten it to the

specified torque.
Tightening torque for frame mounting
bolt (1)
Unit: Nm {kgfm}
3 1,520 to 1,910 {155 to 195}
80-10 FH40-1, FH45-1, FH50-1

Equip-
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.
2. Is there any play in the center pin?

If the play is big, replace the bushing of the pin.
3. Is the thrust clearance of the center

pin proper?
If the thrust clearance (a) of the center
pin exceeds the specified value,
adjust it with shims.
Unit: mm
Standard
Max. 0.5
clearance (a)
If the allowable clearance is exceeded,

adjust it to the standard clearance with
shims.
4. Is there any loose support mounting bolt?

Tightening torque for support mounting bolt (2)
Unit: Nm {kgfm}
3 490 to 608 {50 to 62}
Traveling equipment
31. Tire • Inspect the following regarding the tires.

1. Is the tire inflation pressure proper?
Unit:kPa {kgf/cm2}
Front wheel 300-15-18PR 800 {8.0}
FH40-1 Single
Rear wheel 7.00-12-12PR 850 {8.5}
Front wheel 300-15-18PR 800 {8.0}
FH45/50-1 Single
Rear wheel 7.00-12-14PR 1,000 {10.0}
FH40/45/50-1 Double Front wheel 300-15-18PR 775 {7.75}
2. Is there any crack in the tread or side wall portion?

If the crack is serious, replace the tire.
3. Does the wear of the tread exceed the limit?

For a pneumatic tire, replace the tire when the slip sign (wear limit mark) appears.
4. Is there any abnormal wear?

Replace tires with uneven wear or stepped-type wear.
5. Is there any pinched metal piece?

Remove pinched metal pieces.
FH40-1, FH45-1, FH50-1 80-11

Equip-
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}
2. Is there any deformation or crack in the side ring?

3. Is the tightening torque of the rim alignment bolt proper? (Rear wheel)
Unit: Nm {kgm}
3 FH40/45/50-1 196 to 294 {20 to 30}
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?
2. Is the weight (steering effort) proper?

If the steering effort is big, check the steering valve and hydraulic system.
3. Is the steering wheel play proper?

Unit: mm
Play (L)
10 to 30
(Engine low idle)
If the play is big, adjust it with the

steering valve.
4. Is there any looseness or play when

it is moved up and down, right and
Steering equipment
left and backward and forward?

Check for a loose mounting bolt, and
retighten it.
34. Steering valve • Inspect the following regarding the steering valve.
(Orbitrol valve) 1. Is there any oil leakage from the steering valve?
2. Is there any loose or missing mounting bolt?
35. Rod and arm, etc. - Not applicable to this lift truck model -
36. Knuckle • Inspect the following regarding the knuckle.

1. Is there any play or unusual noise in the wheel bearing?
Lift the rear wheels and inspect the following.
1) Move the tire up and down by hand to check for any play.
2) Rotate the tire by hand to check for any unusual noise.
2. Is there any play, crack, or damage in the kingpin or mounting portion?
3. Is there any damage on the knuckle?

80-12 FH40-1, FH45-1, FH50-1

Equip-
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.
Minimum turning radius standard value Unit: mm

FH40-1 2,770 (± 5%)
FH45-1 2,820 (± 5%)
FH50-1 2,850 (± 5%)
Right and left difference Max. ± 100
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?
2. Is the steered wheel (wheel) in contact with other part?
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.
2. Is there any damage or deterioration of the hose?

4. Does it interfere with the lift truck?
40. Steering chain, - Not applicable to this lift truck model -

etc.
FH40-1, FH45-1, FH50-1 80-13

Equip-
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
2. Is the brake pedal play within the specified value?

Unit: mm
Play (S1) 0 to 4.0

Travel on a dry flat paved surface, stop suddenly, and inspect the following.
Brake system
1) Is the steering wheel pulled?

2) Are both brakes responding?
3) Is there any unusual noise?
4) Is the distance to stop proper?
With no load Max. 5 m (at 20 km/h)
With load Max. 2.5 m (at 10 km/h)
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}
2. Is the braking force of the parking

brake proper?
On the following slopes, check if the
lift truck can hold the stop condition.
With no load Slope with a gradient of 20 degrees

With load Slope with a gradient of 15 degrees
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?
80-14 FH40-1, FH45-1, FH50-1

Equip-
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?
45. Oil brake - Not applicable to this lift truck model -
46. Air brake - Not applicable to this lift truck model -
47. Brake booster - Not applicable to this lift truck model -
48. Brake shoe, - Not applicable to this lift truck model -

lining
49. Brake drum - Not applicable to this lift truck model -
50. Back plate - 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
(1), check if the brake disk wear check

gauge (2) rotates one revolution.
(Righe and left)
Brake disc wear Does not rotate

check gauge (2) one revolution
a For the method to measure the

wear of the brake disc, refer to the
corresponding item in "Testing and
adjusting."
52. Brake pad - Not applicable to this lift truck model -
53. Parking brake • Inspect the following regarding the parking brake drum.
drum 1. Is there any loose or missing drum mounting bolt?
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
3. Is there any corrosion in the anchor pin?
FH40-1, FH45-1, FH50-1 80-15

Equip-
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
56. Fork (2) • Inspect the following regarding the fork.

1. Is there any crack or wear of the fork upper hook part or lower hook part?
2. Is there any crack or wear of the fork root part?

Check if the fork root thickness (C) is within the specified value.
Unit: mm
Loading equipment
FH40/45/50-1 Min. 50
a Check the fork root part and hook part where stress is focused by the pene-
trant check.
57. Mast (1) • Inspect the following regarding the mast.

1. Is there any deformation, crack, or damage of the mast?
Check the following visually or by the penetrant check.
• Mast stay
• Tilt cylinder bracket
• Roller shaft weld portion
2. Is there any wear or play in the mast roller, or any crack of the roller shaft?
58. Mast (2) • Inspect the following regarding the mast.

1. Is there any play in the mast support part?
Check for an oil groove left in the bushing of the mast support part.
2. Is there any loose mast cap mounting bolt?

Tightening torque Unit: Nm {kgm}
3 FH40/45/50-1 343 to 427 {35 to 43.5}
80-16 FH40-1, FH45-1, FH50-1

Equip-
ment
59. Fork carriage • Inspect the following regarding the fork carriage.
1 Is there any deformation, crack, or damage of the fork carriage?
2. Is there any wear or play of the roller?
3. Is there any crack in the roller shaft part?
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.
2. Is the chain elongation within the

specified value?
Measure the length (L) of 17 links and
check that it meets the specification.
Length (L) of 17 links Unit: mm

FH40/45/50-1 Max. 440
Loading equipment
3. Is there any abnormality in the

threaded part of the anchor bolt?
Check for any abnormality visually.
61. Chain wheel • Inspect the following regarding the chain wheel.
1. Is there any deformation, damage, or play in the chain wheel?

• Check the contact face with the chain visually.
• Rotate the chain wheel by hand to check for any play in the bearing.
62. Attachment (1) • Inspect the following regarding the attachment.

1. Is the mounting condition with the main body normal?
2. Is there any loose bolt or nut in the parts?

63. Attachment (2) • Inspect the following regarding the attachment.

1. Is there any crack, deformation, damage, or wear in the parts?
2. Is there any abnormality or unusual noise in the operation of the parts?
FH40-1, FH45-1, FH50-1 80-17

Equip-
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?
4. Is the line filter

replaced?
5. Is the breather stained

too much?
Check the breather for Strainer
Hydraulic system
stain, and replace it if

it is stained too much.
a For the method to inspect the hydraulic tank and filter, refer to the correspond-
ing item in "Testing and adjusting."
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.
2. Is there any oil leakage?

• Tighten the joint parts of the piping to the specified torque.
• If oil leakage remains after tightening it to the specified torque, replace the
part.
3. Is there any loose of mounting bolt or nut?

66. Attachment • Inspect the following regarding the attachment piping.

piping 1. Is there any crack, damage, deterioration, or distortion of the piping?
Replace parts with a crack, damage, deterioration, or distortion.
2. Is there any oil leakage from the piping joint?

• Tighten the joint of the piping to the specified torque.
• If oil leakage rermains after tightening it to the specified torque, replace the
part.

80-18 FH40-1, FH45-1, FH50-1

Equip-
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?
4. Is there any abnormal wear in the spline part?

67-2. Flow divider - Not applicable to this lift truck model -
68. Oil motor - Not applicable to this lift truck model -
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
leakage from the seal part, etc.
2. Is there any dent, crack, bent, or scratch in the lift cylinder or rod?

70. Tilt cylinder • Inspect the following regarding the tilt cylinder.
1. Is the operation condition of the tilt cylinder smooth without oil leakage?
• Check if the tilt cylinder operates smoothly.
• Extend and contract the tilt cylinder rod several times, and check for any oil
leakage from the seal part, etc.
2. Is there any dent, crack, bent, or scratch in the tilt cylinder or rod?

71. Reach cylinder - Not applicable to this lift truck model -
72. Attachment • Inspect the following regarding the attachment cylinder.

Cylinder 1. Is the operation condition of the attachment cylinder smooth without oil
leakage?
• Check if the attachment cylinder operates smoothly.
• Extend and contract the attachment cylinder rod several times, and check for
any oil leakage from the seal part, etc.
2. Is there any dent, crack, bent, or scratch in the attachment cylinder or rod?

FH40-1, FH45-1, FH50-1 80-19

Equip-
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.
Hydraulic drift Max. 50mm/15min

Hydraulic drift tilting amount Max. 45mm/15min
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))
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?
2. Is there any abnormal heating?
3. Is there any oil leakage from the solenoid valve or piping joint?
80-20 FH40-1, FH45-1, FH50-1

Equip-
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.

78. Cab • Inspect the following regarding the cab.

1. Is there any crack or deformation on the cab?
2. Is there any corrosion or leaking of rain?
3. Is there any lock defect, rattle, or damage of the door close/open condition?
79. Seat • Inspect the following regarding the seat.

1. Does the seat adjustment and locking device operate normally?

Main body • Safety device, etc.
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.
1. Is there any damage in the display board?
2. Is the mounting condition of the display board good?
82. Head guard • Inspect the following regarding the head guard.
1. Is there any looseness in the mounting part of the head guard?
2. Is there any crack, damage, or deformation of the head guard?
83. Backrest • Inspect the following regarding the backrest.

1. Is there any loose backrest mounting bolt?
2. Is there any crack, damage, or deformation in the backrest?
FH40-1, FH45-1, FH50-1 80-21

Equip-
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.
2. Is there any damage or water intrusion in the mounting conditions of the

lighting system, instruments, and alarms?
Check for any damage of the lens of the lighting system, and check for any dam-
age or water intrusion in the mounting conditions of the lighting system, instru-
Main body • Safety device, etc.
ments, and alarms.
3. Do the instruments operate normally?

Check the operation of the instruments when the engine is running and when the
lift truck is traveling.
85. Mirror, reflector • Inspect the following regarding the mirror and reflector.
1. Is there any stain or damage on the mirror and reflector?
2. Is the image normal?
86. Lubrication • Inspect the following regarding the lubrication.

1. Is the lubricating condition proper?
2. Does the auto lubrication operate normally?

- Not applicable to this lift truck model -
87. Function of each • Conduct a comprehensive test to inspect the following.

Comprehensive test
device 1. Is the function normal in the travel/work test?

Conduct a travel/work test to check if each of the devices operates normally and
check for any abnormal vibration, unusual noise, or abnormal heating.
80-22 FH40-1, FH45-1, FH50-1

FORKLIFT TRUCK
FH40-1
FH45-1
FH50-1

FH40-1 138001 and up
FH45-1 138001 and up
FH50-1 138001 and up
90 Circuit diagrams
FH40-1, FH45-1, FH50-1 90-1

Table of Contents
Table of Contents
90 Circuit diagrams
Hydraulic circuit diagram........................................................................................................................ 90-3
Hydraulic circuit diagram.................................................................................................................... 90-3
Electrical circuit diagram ........................................................................................................................ 90-5
Electric circuit diagram (4/4) ............................................................................................................ 90-11
Connector list and layout ................................................................................................................. 90-13
90-2 FH40-1, FH45-1, FH50-1

Hydraulic circuit diagram Hydraulic circuit diagram
FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1 90-3

Electric circuit diagram (1/4) Electrical circuit diagram
FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1 90-5

FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1 90-7

FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1 90-9

FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1
FH40-1, FH45-1, FH50-1 90-11

Connector list and layout
Connector list and layout FH40-1, FH45-1, FH50-1 FH40-1, FH45-1, FH50-1
Connector Number of Connector Number of

Connector No. type pins Equipment name Address Connector No. type pins Equipment name Address
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
FH40-1, FH45-1, FH50-1 90-13

Index
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
FH40-1, FH45-1, FH50-1 1

Index
E-12 Engine coolant temperature [F]

level is not displayed normally 40-224
E-13 All of indicator and warning lamps Failure code [--/2G40ZG]
of instrument panel do not light up Brake accumulator:
when starting switch Dropped hydraulic pressure 40-68
is turned to the ON position. 40-226 Failure code [--/6091NX]
E-14 When starting switch is turned Hst oil filter: Clogging 40-69
to the ON position, all of indicator Failure code [--/AB00MA]
and warning lamps of pilot box Alternator: Malfunction 40-66
do not light up 40-233 Failure code [--/B@CRNS]
E-15 When starting switch is turned to HST Oil: Overheating 40-67
the ON position, preheater lamp Failure code [12/DDK6KA]
does not light up 40-238 FNR lever: Open circuit 40-70
E-16 When starting switch is turned to Failure code [12/DDK6KY]
the ON position, alarm buzzer FNR lever: Hot short circuit 40-74
does not sound 40-240 Failure code [14/DLT4KZ]
E-17 Backup lamp of instrument panel Travel speed sensor A:
does not light up 40-242 Open circuit, ground fault,
E-18 Charge warning lamp lights up or hot short circuit 40-76
while engine is running 40-244 Failure code [14/DLT4KZ+DLT6KZ]
E-19 HST oil temperature warning lamp Travel speed sensors A and B:
lights up while engine is running 40-246 Open circuit, ground fault, or hot
E-20 HST oil filter clogging warning short circuit 40-80
lamp lights up while engine is running 40-247 Failure code [14/DLT4LC]
E-21 Engine oil pressure warning Travel speed sensors A and B:
lamp lights up while engine is running 40-248 Mismatch of rotation speed signals 40-83
E-22 Sedimenter (water separator) Failure code [14/DLT4MA]
warning lamp lights up while engine Travel speed sensors A and B:
is running 40-248 Malfunction 40-82
E-23 Abnormality warning lamp lights up Failure code [14/DLT6KZ]
while engine is running 40-250 Travel speed sensor B:
E-24 Engine abnormality warning lamp Open circuit, ground fault,
lights up while engine is running 40-252 or hot short circuit 40-78
E-25 Travel speed restriction cannot be Failure code [15/7REXKA]
released or enabled 40-254 Seat switch: Open circuit 40-84
E-26 Impossible to select HST controller Failure code [15/7REXKB]
failure display mode, HST controller Seat switch: Ground fault 40-86
adjustment mode, speed limit setting Failure code [18/D5ZTKZ]
mode, or engine stop time auto-change Pump EPC valve ground
mode 40-256 return signal: Open circuit
E-27 KOMTRAX system does not or hot short circuit 40-88
operate normally 40-259 Failure code [22/DHHBKX]
Each function and operation of each valve 10-90 HST pump A-port pressure sensor:
Electric circuit diagram (1/4) 90-5 Open circuit or ground fault 40-90
Electric circuit diagram (2/4) 90-7 Failure code [22/DHHBKY]
Electric circuit diagram (3/4) 90-9 HST pump A-port pressure sensor:
Electric circuit diagram (4/4) 90-11 Hot short circuit 40-92
Electrical control system 10-116 Failure code [23/DHHCKX]
Electrical-system abnormality record HST pump B-port pressure sensor:
display function Open circuit or ground fault 40-94
(only for HST controller system) 30-16 Failure code [23/DHHCKY]
Engine controller 10-140 HST pump B-port pressure sensor:
Engine mount and transfer mount 10-4 Hot short circuit 40-96
EPACS controller 10-144 Failure code [25/DK70KY]
Brake pedal angle sensor:
Hot short circuit 40-100
2 FH40-1, FH45-1, FH50-1

Index
Failure code [25/DK70KZ] Failure code [35/D110KZ]

Brake pedal angle sensor: HST controller power relay:
Open circuit or ground fault 40-98 Open circuit or hot short circuit 40-136
Failure code [26/DGS1KA] Failure code [37/DW9NKA]
HST oil temperature sensor: Work equipment lock solenoid valve:
Open circuit 40-102 Open circuit 40-140
Failure code [26/DGS1KB] Failure code [37/DW9NKB]
HST oil temperature sensor: Work equipment lock solenoid valve:
Ground fault 40-104 Ground fault 40-142
Failure code [27/AB00KY] Failure code [37/DW9NKY]
Alternator R signal circuit: Work equipment lock solenoid valve:
Hot short circuit 40-108 Hot short circuit 40-144
Failure code [27/AB00KZ] Failure code [38/DW9MKA]
Alternator R signal circuit: Lift lock solenoid valve: Open circuit 40-145
Open circuit or ground fault 40-106 Failure code [38/DW9MKB]
Failure code [28/DHPCKY] Lift lock solenoid valve: Ground fault 40-146
Lift cylinder pressure sensor: Failure code [38/DW9MKY]
Hot short circuit 40-112 Lift lock solenoid valve:
Failure code [28/DHPCKZ] Hot short circuit 40-148
Lift cylinder pressure sensor: Failure code [39/D140KB]
Open circuit or ground fault 40-110 Starter relay: Ground fault 40-150
Failure code [29/DH2FKY] Failure code [39/D140KY]
Brake charge pressure sensor: Starter relay: Hot short circuit 40-152
Hot short circuit 40-116 Failure code [47/D161KA]
Failure code [29/DH2FKZ] Backup buzzer and backup lamp relay:
Brake charge pressure sensor: Open circuit 40-154
Open circuit or ground fault 40-114 Failure code [47/D161KB]
Failure code [32/DXATKA] Backup buzzer and backup lamp relay:
HST pump forward travel EPC Ground fault 40-156
solenoid valve: Open circuit 40-118 Failure code [47/D161KY]
Failure code [32/DXATKB] Backup buzzer and backup lamp relay:
HST pump forward travel EPC Hot short circuit 40-158
solenoid valve: Ground fault 40-120 Failure code [48/DV00KB]
Failure code [32/DXATKY] Warning buzzer: Ground fault 40-160
HST pump forward travel EPC Failure code [48/DV00KY]
solenoid valve: Hot short circuit 40-122 Warning buzzer: Hot short circuit 40-161
Failure code [33/DXAUKA] Failure code [49/D19UKA]
HST pump reverse travel EPC Pump EPC valve ground cutout relay:
solenoid valve: Open circuit 40-124 Open circuit 40-162
Failure code [33/DXAUKB] Failure code [49/D19UKB]
HST pump reverse travel EPC Pump EPC valve ground cutout replay:
solenoid valve: Ground fault 40-126 Ground fault 40-164
Failure code [33/DXAUKY] Failure code [49/D19UKY]
HST pump reverse travel EPC Pump EPC valve ground cutout relay:
solenoid valve: Hot short circuit 40-128 Hot short circuit 40-166
Failure code [34/DXAVKA] Failure code [52/DAJ0KK]
HST motor EPC solenoid valve: HST controller: Drop of power voltage 40-168
Open circuit 40-130 Failure code [53/DAJ2KK]
Failure code [34/DXAVKB] HST controller:
HST motor EPC solenoid valve: Drop of load power supply voltage 40-170
Ground fault 40-132 Failure code [54/7REHKA]
Failure code [34/DXAVKY] Accessory input circuit 2
HST motor EPC solenoid valve: (KEY_ACC_SIGNAL): Open circuit 40-172
Hot short circuit 40-134 Failure code [55/DAJ5KX]
Failure code [35/D110KB] HST controller sensor 5 V-power supply:
HST controller power relay: Ground fault or hot short circuit 40-174
Ground fault 40-138
FH40-1, FH45-1, FH50-1 3

Index
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
4 FH40-1, FH45-1, FH50-1

Index
Hydraulic tank piping diagram 10-68 Power steering cylinder 10-46

Power train 10-8
Power train system diagram 10-9
[I] PTO 10-10
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
FH40-1, FH45-1, FH50-1 5

Index
Removal and installation of work

equipment and steering pump
assembly 50-94
Replacement of engine oil and engine
oil filter 30-36
Replacement of fuel filter 30-38
[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
6 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 FORKLIFT TRUCK
Form No. SEN06282-00
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 12-12 (02)
FH40-1, FH45-1, FH50-1

Komatsu Forklift Truck FH40-1 FH45-1 FH50-1 138001 & Up Shop Manual SEN06282-00

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Komatsu Forklift Truck FH40-1 FH45-1 FH50-1 138001 & Up Shop Manual SEN06282-00

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SEN06282-00

FORKLIFT TRUCK FH40 -1

Applicable model Serial number

00 Index and foreword

FH40-1, FH45-1, FH50-1 00-1

10 Structure, function and maintenance standard

00-2 FH40-1, FH45-1, FH50-1

Attachment piping diagram .............................................................................................................. 10-72

20 Standard value table

30 Testing and adjusting

FH40-1, FH45-1, FH50-1 00-3

Testing work equipment and steering pump oil pressure................................................................. 30-50

00-4 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 00-5

00-6 FH40-1, FH45-1, FH50-1

50 Disassembly and assembly

FH40-1, FH45-1, FH50-1 00-7

80 Yearly inspection criteria

00-8 FH40-1, FH45-1, FH50-1

Foreword and general information

FH40-1, FH45-1, FH50-1 00-9

2. Preparation for work

00-10 FH40-1, FH45-1, FH50-1

FH40-1, FH45-1, FH50-1 00-11

4. Safety items on maintenance (for safe work) k Periodic inspection of safety-critical

k Precautions for inspection and mainte-

00-12 FH40-1, FH45-1, FH50-1

k Be careful of boiling coolant

k Prohibition of welding fuel tank

FH40-1, FH45-1, FH50-1 00-13

k Danger of being caught and falling

3) When inflating the tyre, you have to have

2) Do not use the mast as a ladder.

00-14 FH40-1, FH45-1, FH50-1

k Handling of tyres k Slinging lift truck (for checking or

k Slinging lift truck (for loading on trailer

FH40-1, FH45-1, FH50-1 00-15

k Handling of batteries 9) Do not short the battery terminals by a

k Precautions for charging

00-16 FH40-1, FH45-1, FH50-1

k Handling of antifreeze k Slinging with 1 rope may cause

5. Precautions for sling work and making signs

FH40-1, FH45-1, FH50-1 00-17

00-18 FH40-1, FH45-1, FH50-1

7. Selecting wire ropes 2) Connection

a The allowable load is one-sixth of the

8. Precautions for disconnecting and connect-

FH40-1, FH45-1, FH50-1 00-19

How to read the shop manual

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

80. Yearly inspection criteria

90. Diagrams and drawings (Chassis)

00-20 FH40-1, FH45-1, FH50-1

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.