SERVICE MANUAL FH40-1 FH45-1 FH50-1
Contents
1. moving parts Never put your hand foot or body in the mast You may be caught and injured in the 78205123 HJZ05120 2 Do not use the mast as a ladder You may slip off the mast and fall HJZ05121 00 8 When inflating the tire you have to have taken the special education The air pressure for the lift truck tire is as sev eral times high as that for car tire thus there is possibility of danger in inflating When pumping air into the tire dirt may be blown with compressed air and may enter your eye Put of safety glasses FH40 1 FH45 1 FH50 1 A Handling of tires Have the tire disassembled and assembled by a specialist Since the tire inflation pressure is very high the tires must be handled carefully 1 When removing the tire release all air from it When removing the tire loosen hub nut 1 2 Never touch rim nut 2 Doing so is danger ous 3 After replacing the tire travel the lift truck on trial and then check the mounting nuts for looseness If the tightening torque has decreased tighten to the specified torque 4 Tightening torque See Standard value table 9JL01315 A Jack up work for checking or replacing tire Do not go under the fork during jack up work Check the following items before starting jack up work e Noperson is on the lift truck e Noloadis on the lift truck Na2. 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 Yearly inspection criteria This section explains the items contents and criteria of the specific self imposed inspection Diagrams and drawings Chassis This section gives hydraulic circuit diagrams and electrical circuit diagrams FH40 1 FH45 1 FH50 1 How to read the shop manual 2 Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically Symbol Remarks B Security Special precautions are necessary for lift truck security during assembly work A Safety Special safety precautions are necessary when performing work Special technical precautions or other precautions for preserving Caution standards are necessary when performing work Weight of parts of component or parts Caution necessary when p Weight Mad parts otc EC selecting hoisting wire or when working posture is important etc Tightening Places that require special attention for tightening torque during oI torque assembly rs Coat Places to be coated with adhesives etc during assembly Oil coolant Places where oil etc must be added an
3. Precautions when carrying out installation work Tighten all bolts and nuts sleeve nuts to the specified KES torque Install the hoses without twisting or interference and fix them with intermediate clamps if there are any Replace all gaskets O rings cotter pins and lock plates with new parts Bend the cotter pins and lock plates securely When coating with adhesive clean the part and remove all oil and grease then coat the threaded portion with 2 3 drops of adhesive 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 Clean all parts and correct any damage dents burrs or rust Coat rotating parts and sliding parts with engine oil When press fitting parts coat the surface with anti friction compound LM P After fitting snap rings check that the snap ring is fitted securely in the ring groove When connecting wiring connectors clean the connector to remove all oil dirt or water then connect securely When using eyebolts check that there is no deformation or deterioration screw them in fully and align the direction of the hook When tightening split flanges tighten uniformly in turn to prevent excessive tightening on one side When operating the hydraulic cylinders for the first time after reassembling cylinders pumps and other hydrau lic equipment removed for repair always bleed the air as follow
4. ing procedure Disconnect the connector by pulling lock B 1 Slide lock L1 to the right on the wiring harness side of connector 2 2 While pressing lock L2 pull out connector 1 outward toward you Even if lock L2 is pressed connector 1 B 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 2 toward you j BJH12922 BJH12921 FH40 1 FH45 1 FH50 1 00 27 Handling of connectors newly used for engines 3 Push lock type Example Fuel pressure sensor in common rail BOSCH 03 Disconnect connector 3 according to the follow ing procedure 1 While pressing lock C pull out connector 3 in the direction of the arrow 95E 5 engine 107E 1 engine C BJH12924 If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers While pressing up lock C of the connector with flat head screwdriver 1 pull out con nector 3 in the direction of the arrow BJH12923 00 28 e 107E 1 engine Example Intake air pressure temperature sensor in intake manifold SUMITOMO 04 3 While pressing lock D pull out connector 4 in the direction of the arrow 4 D BJH12926 e 95E 5 engine 4 While pressing lock E pull out connector 5 in the direction of the arrow
5. 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 S AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 5 AV Standard 4 6 8 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 area mm 7 95 13 36 20 61 35 19 42 73 54 29 63 84 84 96 109 1 d approx 3 7 4 8 6 0 8 0 8 6 9 8 10 4 12 0 13 6 A AVS Standard 5 AV Standard 5 5 7 0 8 2 10 8 11 4 13 0 13 6 16 0 17 6 CAVS Standard hd AEX Standard 5 3 7 0 8 2 10 8 11 4 13 0 13 6 16 0 17 6 P of nominal No denotes flexible ri a UD 7 i 9J3502064 00 30 FH40 1 FH45 1 FH50 1 How to read electric wire code 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 pa Low voltage wire AV Conductor appliance Wiring conducting large current for automobile Nominal No 5 and above Insulator Soft polyvinyl chloride Thin cover Annealed copper for electric Conductor T low
6. e Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting The hook has the maximum strength at the middle portion Precautions for using overhead hoist crane When raising a heavy part heavier than 25 kg use a hoist etc In Disassembly and assembly the weight of a part heavier we 25 kg is indicated after the mark of Before starting work inspect the wire ropes brake clutch controller rails over wind stop device electric shock prevention earth leak age breaker crane collision prevention device and power application warning lamp and check safety 2 Observe the signs for sling work 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 SAD00479 lift it up 9 Consider the travel route in advance and lift up a load to a safe height Place the control switch on a position where it will not be an obstacle to work and passage 11 After operating the hoist do not swing the control switch 12 Remember the position of the main switch so that you can turn off the power imme
7. see Standard tightening torque table FH40 1 FH45 1 FH50 1 Tightening torque Material Cast iron or steel Aluminium Thread size inch Nm kgfm Nm kgfm 1 16 1542 1 53 0 20 5 1 0 51 0 10 1 8 20 2 2 04 0 20 15 1 53 0 20 1 4 25 3 2 55 0 20 20 2 04 0 20 3 8 35 4 3 57 0 41 25 2 55 0 20 1 2 55 6 5 61 0 61 35 3 57 0 41 3 4 75 8 7 65 0 82 45 4 59 0 51 00 39 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 horizontal 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 millime ters 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
8. water heat or vibration Furthermore during inspection and repair operations they are fre quently 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 Main failures occurring in wiring harness 1 Defective contact of connectors defective contact between male and female Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector or because one or both of the connectors is deformed or the position is not correctly aligned or because there is corrosion or oxi dation of the contact surfaces The corroded or oxidized contact surfaces may become shiny again and contact may become nor mal by connecting and disconnecting the connector about 10 times 2 Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or sol dered portion but if there is excessive force brought to bear on the wiring the plating at the joint will peel and cause improper con nection or breakage 00 18 9J802113 Improper insertion 9JS03902 Crimped portion 9JS03903 FH40 1 FH45 1 FH50 1 Handling of electric equipment and hydraulic component 3 Disconnections in wiring If the wiring is held and the connectors are pulled apart or components
9. HJZ05125 3 Stop jacking up when the tires are floated above the ground a little and put blocks under both sides of the frame to prevent the lift truck from falling 4 Lock the tires with chocks FH40 1 FH45 1 FH50 1 Safety notice A Slinging lift truck for checking or replac ing tire Never sling the lift truck by the overhead guard When slinging the lift truck frequently use special slings The lift truck shall be slung by a person who has finished the sling skill course N 3 Install wires to the specified slinging points 4 When slinging the lift truck use wires having sufficient strength and no damage 5 Lock the tires with chocks 6 Put blocks under both sides of the slung lift truck to prevent fall a HJZ05126 A Slinging lift truck for loading on trailer etc 1 Never sling the lift truck by the overhead guard When slinging the lift truck frequently use special slings 2 The lift truck shall be slung by a person who has finished the sling skill course 3 Install wires to the specified slinging points how ZZ ZS d Sinat HJZ05127 4 When slinging the lift truck use wires having sufficient strength and no damage 00 9 Safety notice A Handling of batteries 1 Battery electrolyte contains dilute sulfuric acid which attacks clothes and skins If it sticks to the clothes or skins take off the clothes immediately and wash the
10. Tightening torque 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 The following table corresponds to the bolts in Fig B Bolt Thread diameter Width across flats Tightening torque 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 Fig A Fig B SA KS PON CY KLE A 7 N N B3P19393 9J302112 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 36 FH40 1 FH45 1 FH50 1 Standard tightening torque table 2 Table of tightening torques for split flange bolts Unless there are special instructions tighten split flange bolts to the torque below Ju Ces Width across flats Tightening torque 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 rin
11. 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 00 40 FH40 1 FH45 1 FH50 1 Conversion table Millimeters to inches 1 mm 0 03937 in Kilogram to pound 1 kg 2 2046 Ib Liters to U S Gallons 1 2 0 2642 U S Gal FH40 1 FH45 1 FH50 1 00 41 Conversion table Liters to U K Gallons 1 2 0 21997 U K Gal kgm to ft Ib 1 kgm 7 233 ft lb 00 42 FH40 1 FH45 1 FH50 1 Conversion table kg cm to Ib in 1 kg cm 14 2233 Ib in FH40 1 FH45 1 FH50 1 00 43 Conversion table Temperature Fahrenheit Centigrade conversion A simple way to convert a Fahrenheit temperature reading into a Centigrade 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 Fahrenheit tem peratures and read the corresponding Centigrade temperature in the column at the left When convert from Centigrade to Fahrenheit degrees consider the c
12. different toler ances of the hole and shaft The tightness of fitis decided by the tolerance e Indication of size of rotating shaft and hole and relationship drawing of them Example Tolerance Standard size Shaft Hals 0 030 0 046 9n 0 076 0 Standard size 60 cr Tolerance of hole i Upper 0 046 _ 1 Standard clearance Max 0 122 S Standard clearance Min 0 030 1 1 olerance of shaft Lower 0 olerance of shaft Upper 0 030 9J303901 00 16 FH40 1 FH45 1 FH50 1 2 Standard clearance and standard value e The clearance made when new parts are assembled is called the standard clearance which is indicated by the range from the mini mum clearance to the maximum clearance e When some parts are repaired the clearance is generally adjusted to the standard clear ance e A value of performance and function of new products or equivalent is called the standard value which is indicated by a range or a tar get value e When some parts are repaired the value of performance function is set to the standard value 3 Standard interference e When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft the difference between those diameters is called the interference e The range A B from the diffe
13. start fires 9 As a general rule do not use gasoline to wash parts Do not use it to clean electrical parts in particular 10 Be sure to assemble all parts again in their original places Replace any damaged parts and parts which must not be reused with new parts When installing hoses and wires be sure that they will not be damaged by contact FH40 1 FH45 1 FH50 1 00 5 Safety notice 4 Safety items on maintenance for safe work A Inspection and maintenance shall be car 1 00 6 ried out by persons having maintenance skill and experience Inspection and repair work of the lift trucks shall be carried out by persons having suffi cient knowledge and experience in mainte nance and repair work When inspecting or servicing a new model or a new component fully understand its struc ture performance and mechanism Precautions for inspection and mainte nance work preparation Perform inspection and maintenance on a flat dry and dustless place When working in a warehouse ventilate well Keep the inside of the maintenance shop arranged well and work safely Prepare a fire extinguisher against a fire and learn how to use it Before starting inspection work lower the fork to the ground Before starting inspection work turn the start ing switch OFF and pull out the key Turn the starting switch OFF and keep the key pulled out unless necessary Pull the parking brake lever and put chocks in front and r
14. sure to use lifting equipment of ample strength e When using forcing screws to remove any components tighten the forcing screws uniformly in turn e Before removing any unit clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal 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 04 07379 00400 Sleeve head tube end 07378 10400 Split flange 07371 30400 05 07379 00500 07378 10500 07371 30500 3 Ifthe part is not under hydraulic pressure the following corks can be used Nominal No Part Number Pimeneione Wim D d L 06 07049 00608 6 5 8 08 07049 00811 8 6 5 11 10 07049 01012 10 8 5 12 pese 12 07049 01215 12 10 15 14 07049 01418 14 11 5 18 m Tarer 7d 16 07049 01620 16 13 5 20 S p c 18 07049 01822 18 15 22 20 07049 02025 20 17 25 22 07049 02228 22 18 5 28 L 24 07049 02430 24 20 30 p 27 07049 02734 22 5 22 5 34 DENS FH40 1 FH45 1 FH50 1 00 33 Precautions when carrying out operation 2
15. untwisting of the rope or slipping of the rope from its original winding position on the load which can result in a dangerous accident Limit the hanging angle to 60 as a rule Do not sling a heavy load with ropes forming a wide hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allowable 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 verti cally 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 Load capacity kN kg 196 kg 2000 18 6 e 900 87 19 6 1700 13 7 2000 1400 98 e 9 8 4 9 1000 30 60 90 120 150 Hanging angle deg 9J503892 00 11 Safety notice When installing wire ropes to an angular load apply pads to protect the wire ropes If the load is slippery apply proper material to pre vent the wire rope from slipping Use the specified eyebolts and fix wire ropes chains etc to them with shackles etc 10 Apply wire ropes to the middle portion of the hook
16. used for the sling work and put them in the specified place 10 13 14 S wa 00 12 FH40 1 FH45 1 FH50 1 7 Selecting wire ropes 1 Select adequate ropes depending on the Safety notice 2 Connection weight of parts to be hoisted referring to the 1 When installing the air conditioner circuit table below hoses and tubes take care that dirt dust water etc will not enter them 2 When connecting the air conditioner Wire ropes Standard Z twist ropes without galvanizing hoses and tubes check that O rings 1 JIS G3525 No 6 Type 6X37 A are fitted to their joints Nominal 3 Check that each O ring is not damaged diameter of rope Allowable load or deteriorated mim kN ion 4 When connecting the refrigerant piping 10 38 09 apply compressor oil for refrigerant i R134a DENSO ND OIL8 VALEO 12 Lcd 1 3 THERMAL SYSTEMS ZXL100PG 14 17 3 1 7 equivalent to PAG46 to its O rings 16 22 6 2 3 18 28 6 29 Example of O ring Fitted to every joint of hoses 20 35 3 3 6 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 The allowable load is one sixth of the break l ing strength of the rope used Safety coeffi cient 6 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1 Disconnection A The air conditioner mounted on this lift truck uses refrigeran
17. 2 Since antifreeze is toxic do not drink it If you have swallowed by mistake drink much water and vomit and then consult a doctor immediately A Wastes When disposing of oil fuel coolant solvent filter battery Freon air conditioner refrigerant etc observe the applicable regulations and rules 9JL01084 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 con dition easily The sign maker must always stand in front of the load and guide the opera tor safely e Do not stand under the load e Donotstep 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 notsling 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 sym metrically FH40 1 FH45 1 FH50 1 7 Safety notice A Slinging with 1 rope may cause turn ing of the load during hoisting
18. 50 1 3 Action to take after removing connectors After removing any connector cover it with a vinyl bag to prevent any dust dirt oil or water from getting in the connector portion f the machine is left disassembled for a long time it is particularly easy for improper contact to occur so always cover the connector 2 Connecting connectors 1 2 3 Check the connector visually Check that there is no oil dirt or water stuck to the connector pins mating por tion Check that there is no deformation defective contact corrosion or damage to the connector pins Check that there is no damage or break age to the outside of the connector 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 care ful not to make it too hot as this will cause short circuits If there is any damage or breakage replace the connector Fix the connector securely Align the position of the connector cor rectly and then insert it securely For connectors with the lock stopper push in the connector until the stopper clicks into position Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots correct any protrusion of the boot In addition if the wiring harness is misaligned or the clamp is out of position adjust
19. 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 38 FH40 1 FH45 1 FH50 1 Standard tightening torque table 7 Table of tightening torques for 107 engine series mounted on EX50 Series Bolts and nuts Unless there are special instructions tighten the metric bolts and nuts of the 107 engine series to the torque below For tightening torques for 95 engine series see Standard tightening torque table Tightening torque intend Bolts and nuts mm Nm kgfm 6 10 2 1 02 0 20 8 2444 2 45 0 41 10 43 6 4 38 0 61 12 77412 7 85 1 22 14 8 Table of tightening torques for 107 engine series mounted on EX50 Series Eye joints Unless there are special instructions tighten the metric eye joints of the 107 engine series to the torque below For tightening torques for 95 engine series see Standard tightening torque table Thread size Tightening torque mm Nm kgfm 6 8 2 0 81 0 20 8 102 1 02 0 20 10 1242 1 22 0 20 12 24 t4 2 45 0 41 14 3645 3 67 0 51 9 Table of tightening torques for 107 engine series mounted on EX50 Series Taper screws Unless there are special instructions tighten the taper screws unit inch of the 107 engine series to the torque below For tightening torques for 95 engine series
20. Example Fuel pressure in common rail PFUEL etc AMP 3 FH40 1 FH45 1 FH50 1 Handling of connectors newly used for engines Example Injection pressure control valve of fuel supply pump PCV SUMITOMO 2 BJH12928 Example Speed sensor of fuel supply pump G SUMITOMO 3 Pull the connector straight up E BJH12929 FH40 1 FH45 1 FH50 1 00 29 How to read electric wire code How to read electric wire code In the electric circuit diagram the material thickness and color of each electric wire are indicated by symbols The electric wire code is helpful in understanding the electric circuit diagram Example 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 0 85 L Indicates blue heat resistant low voltage wire for automobile having nom inal No of 0 85 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 area mm 0 51 0 56 0 76 0 88 1 27 1 29 1 96 2 09 3 08 3 30 5 23 d approx
21. SM161 SEN06203 00 SERVICE MANUAL FH Series Forklift Truck Serial No 138001 FH40 1 FH45 1 FH50 1 FH A WARNING Read and observe all warnings on this unit before operating it DO NOT operate this equipment unless all factory installed guards and shields are properly sic KOMATSU REVISED SEPTEMBER 2013 Safety notice Important safety notice Proper service and repair are extremely important for safe lift truck operation The service and repair tech niques 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 spe cific purpose To prevent injury to workers the symbol amp is used to mark safety precautions in this manual The cau tions accompanying these symbols should always be followed carefully If any dangerous situation arises or may possibly arise first consider safety and take the necessary actions to deal with the situation 1 General precautions A Mistakes in operation are extremely dan gerous Read the Operation and Mainte nance Manual carefully before operating the lift truck In addition read this manual carefully before starting work Before carrying out any greasing or repairs read all the safety labels stuck to the lift truck For the locations of the safety labels and detailed explanation of precautions see the Operation and Maintenance Manual Deci
22. a hole ature etc take extreme care not to get 14 When measuring hydraulic pressure check rolled or caught in rotating parts or moving that the measuring tools are correctly assem parts bled 4 Before starting work remove the leads from 15 If the engine is operated for a long time in a the battery Always remove the lead from the place which is not ventilated well you may negative terminal first suffer from gas poisoning Accordingly open 5 When raising a heavy component heavier the windows and doors to ventilate well than 25 kg use a hoist or crane Before starting work check that the slings wire ropes chains and hooks are free from dam age Always use slings which have ample capacity and install them to proper places Operate the hoist or crane slowly to prevent the component from hitting any other part Do not work with any part still raised by the hoist or crane 6 When removing a cover which is under inter nal 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 wiring 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
23. are lifted with a crane with the wiring still connected ora heavy object hits the wiring the crimping of the connector may separate or the soldering may be damaged or the wiring may be bro ken 9JS02116 4 High pressure water entering connector The connector is designed to make it difficult for water to enter drip proof structure but if xS 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 con 9J902117 nector the pins will be short circuited 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 surface 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 compressed air and spray it with a contact restorer When wiping the mating portion of the connector be careful not to use exces sive force or deform the pins If there
24. d capacity i 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 convention ally used Gravitational System of units is indicated in parentheses FH40 1 FH45 1 FH50 1 00 15 Explanation of terms for maintenance standard Explanation of terms for maintenance standard The chapter of maintenance standard explains the criteria for replacing or reusing each product or part in the disas sembly maintenance The criteria are described by the following terms 1 Standard size and tolerance e To be accurate the finishing size of parts is a little different from one to another e To specify a finishing size of a part a tempo rary standard size is set and an allowable dif ference from that size is indicated e The above size set temporarily is called the standard size and the range of difference from the standard size is called the toler ance e 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 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 e Usually the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and
25. d the sec ond 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 31 How to read electric wire code 4 Types of circuits and color codes Table 4 Type of wire REX Charge Ground Start Light Instrument Gr Signal Br Type of cir cuit Others 00 32 FH40 1 FH45 1 FH50 1 Precautions when carrying out operation Precautions when carrying out operation When carrying out removal installation disassembly or assembly of units be sure to follow the general precau tions given below 1 Precautions when carrying out removal work e f the coolant contains antifreeze dispose of it correctly e After disconnecting hoses or tubes cover them or fit plugs to prevent dirt or dust from entering e When draining oil prepare a container of adequate size to catch the oil e Confirm the match marks showing the installation position and make match marks in the necessary places before removal to prevent any mistake when assembling e To prevent any excessive force from being applied to the wiring always hold the connectors when disconnect ing the connectors e Fit wires and hoses with tags to show their installation position to prevent any mistake when installing e Check the number and thickness of the shims and keep in a safe place e When raising components be
26. d with a rag there is danger of dirt entering or of the sur rounding 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 dis pose 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 cleaning 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 9JS02134 00 25 Handling of electric equipment and hydraulic component 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 men
27. de a place in the repair workshop to keep tools and removed parts Always keep the tools and parts in their correct places Always keep the work area clean and make sure that there is no dirt water or oil on the floor Smoke only in the areas provided for smok ing Never smoke while working When carrying out any operation always wear safety shoes and helmet Do not wear loose work clothes or clothes with buttons missing e Always wear safety glasses when hitting parts with a hammer e Always wear safety glasses when grind ing parts with a grinder etc When carrying out any operation with 2 or more workers always agree on the operating procedure before starting Always inform your fellow workers before starting any step of the operation Before starting work hang UNDER REPAIR warning signs in the opera tor s compartment Only qualified workers must carry out work and operation which require license or qualifi cation Keep all tools in good condition Learn the correct way to use them and use the proper ones of them Before starting work thor oughly check the tools lift truck service car etc If welding repairs are needed always have a trained and experienced welder carry out the work When carrying out welding work FH40 1 FH45 1 FH50 1 8 9 Safety notice Rev 2008 07 always wear welding gloves apron shielding goggles cap and other clothes suited for welding work Before starting work warm up you
28. diately in an emergency If the hoist stops because of a power failure turn the power switch OFF When turning on a switch which was turned OFF by the elec tric shock prevention earth leakage breaker check that the devices related to that switch are not in operation state If you find an obstacle around the hoist stop the operation After finishing the work stop the hoist at the specified position and raise the hook to at least 2 m above the floor Do not leave the sling installed to the hook 100 88 79 71 41 11 Do not use twisted or kinked wire ropes 12 When lifting up a load observe the following e Wind in the crane slowly until wire ropes are stretched When settling the wire ropes with the hand do not grasp them but press them from above If you grasp them your fingers may be caught e After the wire ropes are stretched stop the crane and check the condition of the slung load wire ropes and pads e If the load is unstable or the wire rope or chains are twisted lower the load and lift it up again e Donot lift up the load slantingly 13 When lifting down a load observe the follow ing u 45 e When lifting down a load stop it tempo rarily at 30 cm above the floor and then lower it slowly e Check that the load is stable and then remove the sling e Remove kinks and dirt from the wire ropes and chains
29. ear of the front and rear tires Precautions for inspection and mainte nance work safety 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 No fire Cloths impregnated with fuel or oil can catch fire Wear adequate working clothes Use safety goods and protective items hel met safety shoes goggles and gloves suit able for work When working on the lift truck take care not to fall Do not put your foot under the fork When opening and closing the floor plate or engine hood take care not to have your hand caught When inspecting with the fork raised pat a stand under the inner mast so that the fork and mast will not fall When working with other personnel appoint a leader and follow his her instructions A Periodic inspection of safety critical parts 1 Replace the safety critical parts periodically even if they are normal They are deteriorated as the time passes on and can cause a fire and a trouble in the work equipment system 2 Replace safety critical parts even before their periodic replacement periods if they are abnormal A Use of right tools and equipment Use right tools for inspection and maintenance work Use of a broken tool or use a tool for a pur pose other than its true purpose is very danger ous x ff HJZO5116 FH40 1 FH45 1 FH50 1 A Be careful of boiling coolant 1 The engine coo
30. enter column to be a table of Centigrade val ues and read the corresponding Fahrenheit temperature on the right 1 C 33 8 F FH40 1 FH45 1 FH50 1
31. ference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit The interference limit shows the repair limit of the part of smaller tolerance If the interference between the parts exceeds the interference limit they must be replaced or repaired 00 17 Handling of electric equipment and hydraulic component 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 amp 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 equip ment 1 Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component connectors used for connecting and disconnecting one wire from another wire and protectors or tubes used for protecting the wiring Compared with other electrical components fitted in boxes or cases wiring harnesses are more likely to be affected by the direct effects of rain
32. g boss piping joints Unless there are special instructions tighten O ring boss piping joints to the torque below Nominal No iis p Width across flats Tightening torque Nm kgfm 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 Unless there are special instructions tighten O ring boss plugs to the torque below Noua ko xs um Width across flats Tightening torque Nm kgfm mm mm Range Target 08 8 14 5 88 8 82 0 6 0 9 7 35 0 75 10 10 17 9 8 12 74 1 0 1 3 11 27 1 15 12 12 19 14 7 19 6 1 5 2 0 17 64 1 8 14 14 22 19 6 24 5 2 0 2 5 22 54 2 3 16 16 24 24 5 34 3 2 5 3 5 29 4 3 0 18 18 27 34 3 44 1 3 5 4 5 39 2 4 0 20 20 30 44 1 53 9 4 5 5 5 49 0 5 0 24 24 32 58 8 78 4 6 0 8 0 68 6 7 0 30 30 32 93 1 122 5 9 5 12 5 107 8 11 0 33 33 107 8 147 0 11 0 15 0 127 4 13 0 36 36 36 127 4 176 4 13 0 18 0 151 9 15 5 42 42 181 3 240 1 18 5 24 5 210 7 21 5 52 52 274 4 367 5 28 0 37 5 323 4 33 0 5 Table of tightening torques for hoses taper seal type and face seal type Unless there are special instructions tighten the hoses taper seal type and face seal
33. he 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 If any part is loosened or damaged retighten or repair it Fuel system Check the piping for damage the mounting bolts and nuts for looseness and the joints for fuel leak age If any part is loosened or damaged retighten or repair it 00 34 FH40 1 FH45 1 FH50 1 Precautions when carrying out operation 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 loose ness 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 35 Standard tightening torque table Standard tightening torque table 1 Table of tightening torques for bolts and nuts Unless there are special instructions tighten metric nuts and bolts to the torque below The following table corresponds to the bolts in Fig A Bolt Thread diameter Width across flats
34. is oil or water in the compressed air the contacts will become even dirtier so remove the oil and water from the compressed air completely before clean ing with compressed air 9J302118 FH40 1 FH45 1 FH50 1 00 19 Handling of electric equipment and hydraulic component 3 Removing installing and drying connectors and wiring harnesses 1 Disconnecting connectors 1 Hold the connectors when disconnect ing Press lightly When disconnecting the connectors when removino f hold the connectors For connectors held Lock stopper U 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 connectors apart Never pull with one hand 9JS03904 2 When removing from clips e Both of the connector and clip have Both stoppers stoppers which are engaged with each other when the connector is installed 9JS03905 e When removing a connector from a clip pull the connector in a parallel direction to the clip for removing stoppers f the connector is twisted up and E down or to the left or right the hous ing may break nl 9J302120 Removal of resin clip Lift up the stopper of range clip and then pull out the range clip Stopper Resin clip 7BPZ17333 00 20 FH40 1 FH45 1 FH
35. it to its correct position Ifthe connector cannot be corrected easily remove the clamp and adjust the position e lf 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 Handling of electric equipment and hydraulic component 9J302122 Clicks into position 9J303906 9J802124 9J302125 00 21 Handling of electric equipment and hydraulic component 3 00 22 Heavy duty wire connector DT 8 pole 12 pole Disconnection Left of figure While pressing both sides of locks a and b pull out female connector 2 Connection Right of figure 1 Push in female connector 2 horizontally 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 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 e Disconnection e Connection Example of incomplete setting of a FI a ta j 1 fi E EL BJH12932 3 FH40 1 FH45 1 FH50 1 4 Drying wiring harness If there is any oil or dirt on the wiring harness wipe it off with a dry cloth Avoid washi
36. ivided into the following sections 00 01 10 20 30 40 50 80 90 00 14 Foreword This section explains the shop manuals list safety and basic information Specification This section explains the specifications of the lift truck 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 disassembly and service 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 adjust ing and to judge parts in troubleshooting 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 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
37. lant 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 9JL01183 A Prohibition of welding fuel tank Never weld the fuel tank since it may explode A Take care of high pressure and high tem perature oil 1 The oilis high in temperature just after the lift truck is used Do not drain the oil or replace the oil filter under this condition Hot oil will spout and can scald you 2 Wait until the oil temperature decreases and then carry out inspection or maintenance according to the procedure described in this manual 3 There is residual pressure in the hydraulic cir cuit Do not start inspection or maintenance before the residual pressure decreases to Zero 4 High pressure oil leaking through a small hole is dangerous to the skin or eye Do not check the hydraulic system for oil leakage 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 Safety notice EF HJZ05118 HJZ05119 When inspecting the accu
38. lic piece on the battery since it can cause a fire from a short circuit A 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 explo sion observe the following 1 Charge the battery in a place ventilated well 2 No fire 3 Startto charge the battery when its electrolyte temperature is 35 C or below If the electro lyte temperature increases above 50 C wait until it decreases to below 35 C and then start charging again 4 When charging the battery with a charging device keep the battery caps removed A 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 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 A Prohibition of engine push start Do not start the engine by pushing the lift truck The lift truck starts suddenly and you may make a mistake in operation FH40 1 FH45 1 FH50 1 A Handling of antifreeze 1 Antifreeze contains flammable material When handling it do not bring fire near it
39. mulator piping release the pressure inside it in advance If you are injured with high pressure oil see a doctor immediately When removing the mast or lift cylinder be sure to release the pressure from the hydrau lic piping e Stop the lift truck and lower the fork to the ground e Stop the engine e Turn the starting switch to the ACC posi tion e Sit on the operator seat and tilt the lift lever and tilt lever forward and in reverse 4 5 times each to release the pressure in the hydraulic piping The pressure is not released unless you operate the levers while sitting on the seat 00 7 Safety notice A Beware of rotating cooling fan and belt 1 Keep hand off the rotating fan or fan belt 2 When inspecting the rotating parts stop the engine 3 Do not bring a thing near the rotating parts which can be caught easily A Tire inspection and inflation procedures 1 If the tire inflation pressure is low the lift truck stability is lowered Do not inflate the tire immediately however The inflation pressure may have decreased because of a damage of the rim If the tire is inflated to high pres sure while the rim is damaged or cracked the tire will burst and cause an injury or a death When checking the tire inflation pressure place your body in front of the tread face of the tire Do not work from the side of the tire 9JL01082 amp Danger of being caught and falling
40. ng 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 follows 1 Disconnect the connector and wipe off the water with a dry cloth f 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 compressed 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 Hot air from the dryer can be used but regulate the time that the hot air is used in order not to make the con nector or related parts too hot as this will cause deformation or dam age to the connector 3 Carry out a continuity test on the connec tor After drying leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water After completely drying the connec tor blow it with contact restorer and reassemble FH40 1 FH45 1 FH50 1 Handling of electric equipment and hydraulic component ARS 9JS02118 Ui A T adapter 9JS03907 00 23 Handling of electric equipment and hydraulic component 4 Handling controller 1 The controller contains a microcomputer and electronic control circuits microcomputer and elect
41. no change in the reading of the tes ter If there is any change there is probably defective contact in that circuit 9JS02130 9J302131 FH40 1 FH45 1 FH50 1 Points to remember when handling hydraulic equipment Handling of electric equipment and hydraulic component With the increase in pressure and precision of hydraulic equipment the most common cause of failure is dirt for eign 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 dan ger of dust entering the equipment It is also diffi cult 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 dust proof workshop and the performance 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 enter ing If the opening is left open or is blocke
42. p on or off the lift truck FH40 1 FH45 1 FH50 1 Precautions during work Before disconnecting or removing compo nents of the oil water or air circuits first release the pressure completely from the cir cuit When removing the oil filler cap a drain plug or an oil pressure pickup plug loosen it slowly to prevent the oil from spurting out The coolant and oil in the circuits are hot when the engine is stopped so be careful not to get scalded Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits Before starting work stop the engine When working on or around a rotating part in partic ular stop the engine When checking the machine without stopping the engine mea suring oil pressure revolving speed temper Safety notice with other parts when the lift truck is oper ated When installing high pressure hoses make sure that they are not twisted Damaged tubes are dangerous so be extremely careful when installing tubes for high pressure cir cuits In addition check that connecting parts are correctly installed When assembling or installing parts always tighten them to the specified torques When installing protective parts such as guards or parts which vibrate violently or rotate at high speed be particularly careful to check that they are installed correctly When aligning 2 holes never insert your fin gers or hand Be careful not to get your fin gers caught in
43. r body thor oughly to start work under good condition Avoid working continuously for long hours and take rests at proper intervals to keep the good condition Take rests in a fixed safe place Safety points 1 Good arrangement Correct work clothes Following work standard Making and checking signs Prohibition of operation and handling by unlicensed workers Safety check before starting work N ODO Oi A OJN Wearing protective goggles for cleaning or grinding work co Wearing shielding goggles and protectors for welding work Good physical condition and preparation Precautions against work which you are not used to or you are used to too much 00 3 Safety notice 2 Preparation for work 1 00 4 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 Before starting work lower the work equip ment mast to the ground If this is not possi ble insert the lock pin or use blocks to prevent the work equipment from falling and hang warning signs on them When disassembling or assembling support the lift truck with blocks jacks or stands before starting work 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 jum
44. rence A between the minimum size of the shaft and the maximum size of the hole to the differ ence B between the maximum size of the shaft and the minimum size of the hole is the standard interference e After repairing or replacing some parts mea sure the size of their hole and shaft and check that the interference is in the standard range 4 Repair limit and allowable value or allowable dimension e 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 e lf apart is worn to the repair limit must be replaced or repaired e The performance and function of a product 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 e If a product is worn to the allowable value it must be checked or repaired Since the per missible value is estimated from various tests or experiences in most cases however it must be judged after considering the operat ing condition and customer s requirement FH40 1 FH45 1 FH50 1 Explanation of terms for maintenance standard 5 Clearance limit Parts can be used until the clearance between them is increased to a certain limit The limit at which those parts cannot be used is called the clearance limit If the clearance between the parts exceeds the clearance limit they must be replaced or repaired 6 Inter
45. ronic control circuits These control all of the electronic circuits on the machine so be extremely careful when handling the control ler Do not place objects on top of the controller Cover the control connectors with tape or a vinyl bag Never touch the connector contacts with your hand During rainy weather do not leave the con troller in a place where it is exposed to rain 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 Precautions when carrying out arc welding When carrying out arc welding on the body disconnect all wiring harness connectors con nected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting elec tric circuits 1 2 00 24 Always turn the power OFF before discon necting or connecting connectors Before carrying out troubleshooting check that all the related connectors are properly inserted Disconnect and connect the related con nectors several times to check Always connect any disconnected connectors before going on to the next step If the power is turned ON with the con nectors still disconnected unnecessary abnormality displays will be generated When carrying out troubleshooting of circuits measuring the voltage resistance continu ity or current move the related wiring and connectors several times and check that there is
46. s 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 cylin der 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke When using the lift truck for the first time after repair or long storage follow the same procedure Precautions when completing operation 1 Refilling with coolant oil and grease e f 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 e f the hydraulic equipment has been removed and installed again add engine oil to the specified level Run the engine to circulate the oil through the system Then check the oil level again e f the hydraulic equipment has been removed always bleed the air from the system after reassem bling the parts referring to Testing and adjusting e Addthe specified amount of grease molybdenum disulfide 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 e 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 t
47. skins which the electrolyte stuck with tap water and then consult a doctor 2 If battery electrolyte gets into your eyes flush them immediately with fresh tap water for 10 15 minutes continually and then consult a doctor 3 If you have drunk battery electrolyte by acci dent either drink a large quantity of water or milk mixed with beaten egg white or salad oil and then consult a doctor at once HJZ05128 4 When handling the battery always wear safety glasses 5 The battery generates hydrogen gas which is highly explosive Do not bring fire of a lighter or a cigarette or make a spark near the bat tery HJZ05129 6 When inspecting or handling the battery turn the starting switch OFF 7 When removing the battery be sure to dis connect the cable from the negative terminal first 00 10 8 When installing the battery be sure to con nect the cable to the positive terminal first 9 Do not short the battery terminals by a metal lic thing 10 If the terminals are loosened sparks are made because of a defective contact and they can cause explosion Tighten the termi nals securely 11 When removing the battery check its positive and negative terminals and take care not to reconnect the cables with reverse polarities 12 Tighten the battery caps securely 13 When cleaning keep the battery caps tight ened A Do not put a metallic piece on the battery Do not put a metal
48. t R134a which must not be discharged into the atmo sphere as it is although it has less ozone layer breaking factors for pres ervation of the environment When dis connecting the air conditioner gas circuit be sure to collect the refriger ant to reuse it Ask professional traders for collecting and filling operation of refrigerant R134a Never release the refrigerant R134a to the atmosphere 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 BJH12937 For tightening torque see the precautions for installation in each section of Disassembly and assembly 00 13 How to read the shop manua How to read the shop manual 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 Materials and specifications are subject to change without notice Shop manuals are divided into the Chassis volume and Engine volume For the engine unit refer to engine shop manual SM204 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 d
49. t 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 flushing oil and secondary flushing is carried out with the specified hydraulic oil 9JS03908 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 con taminants in the hydraulic oil circuit The oil clean ing equipment is used to remove the ultra fine about 3 y particles that the filter built in the hydraulic equipment cannot remove so it is an extremely effective device 9JS02136 00 26 FH40 1 FH45 1 FH50 1 Handling of connectors newly used for engines Handling of connectors newly used for engines Mainly following engines are object for following connectors e 95E 5 e 107E 1 1 Slide lock type 2 Pull lock type FRAMATOME 3 FRAMATOME 2 PACKARD 2 e 95E 5 engine 107E 1 engine e 95E 5 engine 107E 1 engine e Various pressure sensors and NE speed e Various temperature sensors sensor Example Example Intake air temperature sensor in intake Oil pressure switch manifold TIM Ne speed sensor of flywheel housing Fuel temperature sensor TFUEL NE Oil temperature sensor TOIL Coolant temperature sensor TWTR etc Disconnect connector 1 according to the follow
50. type to the torque below FH40 1 FH45 1 FH50 1 Standard tightening torque table Apply the following torque when the threads are coated wet with engine oil em Width Tightening torque Nm kgfm Taper seal Face seal omina Nominal No No of pius R Target Thread size N rdber of di ara hose mm ange arge mm threads type of ee thread 02 19 34 54 3 5 5 5 44 4 5 9 16 18UNF 14 3 34 63 3 5 6 5 44 4 5 14 03 22 54 93 5 5 9 5 74 7 5 11 16 16UN 17 5 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 Tighten the face joint seals sleeve nut type of steel pipes for plated low pressure piping in engines etc to the torque below Apply the following torque when the threads are coated wet with engine oil Suitable Width Tightening torque Nm kgfm Face seal Pu across Nominal No Thread diameter diameter flats Range Target Number of threads mm mm mm type of thread Reference 8 19 14 16 1 4 1 6 15 1 5 9 16 18UN 14 3 10 22 24 27 2 4 2
51. voltage wire AVS appliance General wiring for automobile 30 to 60 Nominal No 0 5 3 t Insulator Soft polyvinyl chloride ype 1 Thin cover Annealed copper for electric Conductor T low voltage wire CAVS appliance General wiring for automobile Nominal No 0 5 1 25 t Insulator Soft polyvinyl chloride ype 2 A led for electri Heat resistant low Conductor oe NE quw General wiring in extremely voltage wire for AEX WeGpidnin linked pol 50 to 110 cold district wiring at automobile Insulator Palo relat Shere Ney high temperature place ethylene 3 Color codes table Table 3 Color code Color of wire Color code Color of wire B Black LgW Light green amp White Br Brown LgY Light green amp Yellow BrB Brown amp Black LR Blue amp Red BrR Brown amp Red LW Blue amp White BrwW Brown amp White LY Blue amp Yellow BrY Brown amp Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red amp Black GB Green amp Black RG Red amp Green GL Green amp Blue RL Red amp Blue Gr Gray RW Red amp White GR Green amp Red RY Red amp Yellow GW Green amp White Sb Sky Blue GY Green amp Yellow Y Yellow L Blue YB Yellow amp Black LB Blue amp Black YG Yellow amp Green Lg Light green YL Yellow amp Blue LgB Light green amp Black YR Yellow amp Red LgR Light green amp Red YW Yellow amp White Remarks In a color code consisting of 2 colors the first color is the color of the background an
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