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KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06649-11 – PDF DOWNLOAD
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KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06649-11 – PDF DOWNLOAD
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Description
KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06649-11 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06649-11 – PDF DOWNLOAD
Language : English
Pages : 2302
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06649-11 – PDF DOWNLOAD
Cover.................................................................................................................................................. 1 00 Index and foreword.............................................................................................................................. 3 Index.......................................................................................................................................... 4 List of abbreviations.......................................................................................................................... 19 Foreword, safety and general information....................................................................................................... 24 How to read the shop manual................................................................................................................ 24 Precautions related to work safety......................................................................................................... 26 Fire prevention............................................................................................................................ 35 If a fire breaks out....................................................................................................................... 37 Instructions for waste disposal............................................................................................................ 38 Actions taken to meet exhaust gas regulations.............................................................................................. 39 Handling instructions of DEF............................................................................................................... 40 Regarding storage of DEF................................................................................................................... 41 Regarding handling of DEF in cold weather.................................................................................................. 41 Instructions for handling hydraulic components............................................................................................. 42 Instructions for disconnecting and connecting piping....................................................................................... 44 Instructions for handling electric components.............................................................................................. 52 Instructions for handling fuel system components........................................................................................... 54 Instructions for handling intake system components......................................................................................... 55 Precautions for replacing HST controller and monitor panel................................................................................. 56 Use of KOMTRAX............................................................................................................................. 57 Disconnecting and connecting push-pull type coupler........................................................................................ 58 Instructions for disconnecting and connecting connectors................................................................................... 62 How to disconnect and connect DT connectors................................................................................................ 67 How to disconnect and connect slide lock type connectors................................................................................... 68 How to disconnect and connect connectors that require pulling lock......................................................................... 70 How to disconnect and connect connectors that require pressing lock........................................................................ 71 How to disconnect and connect connectors that require turning housing...................................................................... 73 How to read electric wire code............................................................................................................. 74 Explanation of terms for maintenance standard.............................................................................................. 80 Standard tightening torque table........................................................................................................... 82 Unit conversion table...................................................................................................................... 89 01 Specification................................................................................................................................... 95 Contents....................................................................................................................................... 96 List of abbreviations.......................................................................................................................... 97 Specifications................................................................................................................................. 102 Specification drawing...................................................................................................................... 102 Specifications............................................................................................................................. 110 Weight table............................................................................................................................... 126 Fuel, coolant, and lubricant............................................................................................................... 130 10 Structure and function.......................................................................................................................... 135 Contents....................................................................................................................................... 136 List of abbreviations.......................................................................................................................... 139 Urea SCR system................................................................................................................................ 144 Urea SCR system component layout drawing................................................................................................... 144 Urea SCR system diagram.................................................................................................................... 147 Function of urea SCR system................................................................................................................ 148 Urea SCR system components................................................................................................................. 166 Starting system................................................................................................................................ 175 Starting system component layout drawing................................................................................................... 175 System operating lamp system............................................................................................................... 176 Preheating system.......................................................................................................................... 177 Engine system.................................................................................................................................. 179 Engine system component layout drawing..................................................................................................... 179 Engine control system...................................................................................................................... 180 Automatic engine stop system............................................................................................................... 182 Automatic engine power control system...................................................................................................... 185 Engine system components................................................................................................................... 188 Cooling system................................................................................................................................. 203 Cooling system component layout drawing.................................................................................................... 203 Control system................................................................................................................................. 205 Control system component layout drawing.................................................................................................... 205 Monitor panel system....................................................................................................................... 207 Rearview monitor system.................................................................................................................... 208 KOMTRAX system............................................................................................................................. 209 Seat belt interlock system................................................................................................................. 210 Control system components.................................................................................................................. 212 Hydraulic system............................................................................................................................... 243 Hydraulic system component layout drawing.................................................................................................. 243 CLSS....................................................................................................................................... 244 Hydraulic system components................................................................................................................ 246 Power train system............................................................................................................................. 276 Power train system component layout drawing................................................................................................ 276 Travel speed limit system.................................................................................................................. 278 Directional lever neutral alarm system..................................................................................................... 279 Travel interlock system.................................................................................................................... 280 Power train system components.............................................................................................................. 282 Work equipment system.......................................................................................................................... 313 Work equipment system component layout drawing............................................................................................. 313 Structure of valve control................................................................................................................. 314 Lift interlock system...................................................................................................................... 315 Work equipment system components........................................................................................................... 317 Steering system................................................................................................................................ 323 Steering system component layout drawing................................................................................................... 323 Electronic proportional active control steering (EPACS) system............................................................................. 324 Steering column............................................................................................................................ 326 Steering system component.................................................................................................................. 327 Brake system................................................................................................................................... 333 Brake system component layout drawing...................................................................................................... 333 Parking brake reminder system.............................................................................................................. 334 Parking brake dragging prevention system................................................................................................... 336 Brake system components.................................................................................................................... 338 Undercarriage and frame........................................................................................................................ 348 Structure of frame......................................................................................................................... 348 Tire....................................................................................................................................... 349 Work equipment................................................................................................................................. 350 Structure of work equipment................................................................................................................ 350 Cab and its attachments........................................................................................................................ 351 Cab........................................................................................................................................ 351 20 Standard value table............................................................................................................................ 353 Contents....................................................................................................................................... 354 List of abbreviations.......................................................................................................................... 355 Standard value table for engine................................................................................................................ 360 Standard value table for engine FH100-1.................................................................................................... 360 Standard value table for engine FH120-1.................................................................................................... 363 Standard value table for engine FH135-1.................................................................................................... 366 Standard value table for engine: FH160-1................................................................................................... 369 Standard value table for machine............................................................................................................... 372 Standard value table for machine: FH100-1.................................................................................................. 372 Standard value table for machine: FH120-1.................................................................................................. 379 Standard value table for machine: FH135-1.................................................................................................. 386 Standard value table for machine: FH160-1.................................................................................................. 393 30 Testing and adjusting........................................................................................................................... 401 Contents....................................................................................................................................... 402 Precautions Before Work........................................................................................................................ 406 List of abbreviations.......................................................................................................................... 407 Related information on testing and adjusting................................................................................................... 412 Tools for testing and adjusting............................................................................................................ 412 Engine and cooling system...................................................................................................................... 420 Testing engine speed....................................................................................................................... 420 Testing boost pressure..................................................................................................................... 421 Testing exhaust gas color.................................................................................................................. 423 Testing and adjusting valve clearance...................................................................................................... 425 Testing compression pressure............................................................................................................... 427 Testing blowby pressure.................................................................................................................... 432 Testing engine oil pressure................................................................................................................ 434 Visual check inside of EGR valve........................................................................................................... 436 Clean inside of EGR valve.................................................................................................................. 438 Testing fuel pressure...................................................................................................................... 441 Testing fuel discharge, return rate, and leakage volume.................................................................................... 446 Bleeding air from fuel system.............................................................................................................. 452 Checking fuel system for fuel leakage...................................................................................................... 454 Handling cylinder cutout mode operation.................................................................................................... 456 Handling no-injection cranking............................................................................................................. 457 Changing engine oil........................................................................................................................ 458 Replacing engine oil filter................................................................................................................ 459 Replacing KCCV filter element.............................................................................................................. 460 Replacing fuel filter...................................................................................................................... 462 Draining fuel prefilter.................................................................................................................... 465 Bleeding air from coolant circuit.......................................................................................................... 466 Cleaning radiator.......................................................................................................................... 468 Checking air cleaner and cleaning or replacing element..................................................................................... 470 Checking and adjusting tension of air conditioner compressor belt.......................................................................... 474 Cleaning and replacing air conditioner filter.............................................................................................. 476 Checking and cleaning air conditioner condenser fin........................................................................................ 479 Checking refrigerant (gas) level........................................................................................................... 480 Checking alternator belt................................................................................................................... 481 Checking auto-tensioner.................................................................................................................... 482 Testing SCR-related functions.............................................................................................................. 484 Flushing DEF tank.......................................................................................................................... 509 CLEAN DEF PUMP............................................................................................................................. 513 Replacing DEF tank refill port filter...................................................................................................... 519 Replacing DEF filter....................................................................................................................... 522 Replacing DEF tank breather................................................................................................................ 525 Power train.................................................................................................................................... 527 Testing and adjusting HST oil pressure..................................................................................................... 527 Replacing HST oil filter................................................................................................................... 542 Checking oil sump in flywheel housing...................................................................................................... 543 Checking oil level and changing oil in differential case................................................................................... 544 Steering system................................................................................................................................ 546 Testing steering wheel..................................................................................................................... 546 Testing steering wheel angle sensor........................................................................................................ 548 Testing and adjusting tire angle sensor.................................................................................................... 549 Bleeding air from steering cylinder circuit................................................................................................ 551 Testing and adjusting steering circuit pressure............................................................................................ 552 Brake system................................................................................................................................... 554 Bleeding air from brake circuit............................................................................................................ 554 Testing brake oil pressure................................................................................................................. 556 Testing accumulator charge pressure........................................................................................................ 558 Testing braking performance................................................................................................................ 559 Testing wear of service brake disc......................................................................................................... 561 Testing and adjusting parking brake........................................................................................................ 562 Testing brake pedal........................................................................................................................ 566 Testing brake pedal angle sensor........................................................................................................... 567 Hydraulic system............................................................................................................................... 568 Releasing remaining pressure from hydraulic circuit........................................................................................ 568 Testing and adjusting work equipment pressure.............................................................................................. 570 Testing and adjusting work equipment PPC pressure.......................................................................................... 577 Changing hydraulic oil..................................................................................................................... 580 Replacing hydraulic oil line filter........................................................................................................ 581 Cleaning hydraulic tank strainer........................................................................................................... 582 Checking hydraulic tank breather........................................................................................................... 584 Work equipment................................................................................................................................. 585 Bleeding air from lift cylinder............................................................................................................ 585 Testing hydraulic drift and hydraulic drift forward tilt of cylinders...................................................................... 586 Adjusting mast............................................................................................................................. 588 Adjusting finger bar....................................................................................................................... 591 Adjusting tilt cylinder.................................................................................................................... 594 Cab and its attachments........................................................................................................................ 595 Testing directional lever.................................................................................................................. 595 Testing lift lever and tilt lever.......................................................................................................... 596 Testing accelerator pedal.................................................................................................................. 597 Electrical system.............................................................................................................................. 599 Setting and operation of monitor panel..................................................................................................... 599 KOMTRAX terminal start-up procedure........................................................................................................ 663 Adjusting installed angle of rearview camera............................................................................................... 668 Handling of engine controller power supply circuit......................................................................................... 670 Guideline for testing diode................................................................................................................ 671 40 Troubleshooting................................................................................................................................. 673 Contents....................................................................................................................................... 674 Precautions Before Work........................................................................................................................ 683 List of abbreviations.......................................................................................................................... 684 Information related to troubleshooting......................................................................................................... 689 Points to remember when performing troubleshooting......................................................................................... 689 Points to remember when performing troubleshooting of urea SCR system...................................................................... 690 How to proceed in troubleshooting.......................................................................................................... 702 Check before troubleshooting............................................................................................................... 704 Guideline for check before starting troubleshooting........................................................................................ 705 Check according to check guideline......................................................................................................... 706 Procedure for troubleshooting.............................................................................................................. 730 Symptoms of failure and troubleshooting numbers............................................................................................ 733 Information described in troubleshooting table............................................................................................. 736 Connector list and layout.................................................................................................................. 739 Connection table for connector pin No...................................................................................................... 750 T-box and T-adapter list................................................................................................................... 789 List and locations of installed fuses...................................................................................................... 793 Precautions when replacing KDOC............................................................................................................ 797 Failure codes table........................................................................................................................ 798 Troubleshooting by failure code................................................................................................................ 812 Failure code [2G40ZG]...................................................................................................................... 812 Failure code [6091NX]...................................................................................................................... 814 Failure code [7REAKA]...................................................................................................................... 816 Failure code [7REHKA]...................................................................................................................... 818 Failure code [A1U0N3]...................................................................................................................... 820 Failure code [A1U0N4]...................................................................................................................... 821 Failure code [AA10NX]...................................................................................................................... 822 Failure code [AB00KY]...................................................................................................................... 823 Failure code [AB00MA]...................................................................................................................... 824 Failure code [AQ10MB]...................................................................................................................... 826 Failure code [AQ10N3]...................................................................................................................... 827 Failure code [AS00R2]...................................................................................................................... 828 Failure code [AS00R3]...................................................................................................................... 829 Failure code [AS00R4]...................................................................................................................... 830 Failure code [AS00R5]...................................................................................................................... 831 Failure code [AS00R6]...................................................................................................................... 832 Failure code [AS00ZK]...................................................................................................................... 833 Failure code [AS10KM]...................................................................................................................... 834 Failure code [AS10NR]...................................................................................................................... 835 Failure code [AS10NT]...................................................................................................................... 836 Failure code [B@BAZG]...................................................................................................................... 837 Failure code [B@BCNS]...................................................................................................................... 838 Failure code [B@BCZK] (Serial No.: 7001 to 7137)........................................................................................... 839 Failure code [B@BCZK] (Serial No.: 7138 and up)............................................................................................ 840 Failure code [B@CRNS]...................................................................................................................... 841 Failure code [CA115]....................................................................................................................... 842 Failure code [CA122]....................................................................................................................... 843 Failure code [CA123]....................................................................................................................... 845 Failure code [CA131]....................................................................................................................... 847 Failure code [CA132]....................................................................................................................... 849 Failure code [CA144]....................................................................................................................... 851 Failure code [CA145]....................................................................................................................... 853 Failure code [CA153]....................................................................................................................... 855 Failure code [CA154]....................................................................................................................... 857 Failure code [CA187]....................................................................................................................... 859 Failure code [CA221]....................................................................................................................... 861 Failure code [CA222]....................................................................................................................... 863 Failure code [CA227]....................................................................................................................... 865 Failure code [CA234]....................................................................................................................... 867 Failure code [CA238]....................................................................................................................... 868 Failure code [CA239]....................................................................................................................... 869 Failure code [CA249]....................................................................................................................... 870 Failure code [CA256]....................................................................................................................... 872 Failure code [CA271]....................................................................................................................... 874 Failure code [CA272]....................................................................................................................... 876 Failure code [CA295]....................................................................................................................... 877 Failure code [CA322]....................................................................................................................... 878 Failure code [CA324]....................................................................................................................... 880 Failure code [CA331]....................................................................................................................... 882 Failure code [CA332]....................................................................................................................... 884 Failure code [CA343]....................................................................................................................... 886 Failure code [CA351]....................................................................................................................... 887 Failure code [CA352]....................................................................................................................... 888 Failure code [CA356]....................................................................................................................... 890 Failure code [CA357]....................................................................................................................... 892 Failure code [CA386]....................................................................................................................... 894 Failure code [CA428]....................................................................................................................... 895 Failure code [CA429]....................................................................................................................... 897 Failure code [CA431]....................................................................................................................... 899 Failure code [CA432]....................................................................................................................... 902 Failure code [CA435]....................................................................................................................... 905 Failure code [CA441]....................................................................................................................... 906 Failure code [CA442]....................................................................................................................... 908 Failure code [CA451]....................................................................................................................... 909 Failure code [CA452]....................................................................................................................... 911 Failure code [CA488]....................................................................................................................... 913 Failure code [CA515]....................................................................................................................... 914 Failure code [CA516]....................................................................................................................... 916 Failure code [CA553]....................................................................................................................... 918 Failure code [CA555]....................................................................................................................... 919 Failure code [CA556]....................................................................................................................... 920 Failure code [CA559]....................................................................................................................... 921 Failure code [CA595]....................................................................................................................... 923 Failure code [CA687]....................................................................................................................... 925 Failure code [CA689]....................................................................................................................... 927 Failure code [CA691]....................................................................................................................... 929 Failure code [CA692]....................................................................................................................... 931 Failure code [CA697]....................................................................................................................... 933 Failure code [CA698]....................................................................................................................... 934 Failure code [CA731]....................................................................................................................... 935 Failure code [CA778]....................................................................................................................... 937 Failure code [CA1117]...................................................................................................................... 942 Failure code [CA1664]...................................................................................................................... 944 Failure code [CA1669]...................................................................................................................... 946 Failure code [CA1673]...................................................................................................................... 947 Failure code [CA1677]...................................................................................................................... 948 Failure code [CA1678]...................................................................................................................... 949 Failure code [CA1682]...................................................................................................................... 950 Failure code [CA1683]...................................................................................................................... 954 Failure code [CA1684]...................................................................................................................... 956 Failure code [CA1686]...................................................................................................................... 958 Failure code [CA1691]...................................................................................................................... 959 Failure code [CA1694]...................................................................................................................... 961 Failure code [CA1695]...................................................................................................................... 963 Failure code [CA1696]...................................................................................................................... 964 Failure code [CA1712]...................................................................................................................... 966 Failure code [CA1713]...................................................................................................................... 968 Failure code [CA1714]...................................................................................................................... 970 Failure code [CA1715]...................................................................................................................... 971 Failure code [CA1776]...................................................................................................................... 972 Failure code [CA1777]...................................................................................................................... 975 Failure code [CA1843]...................................................................................................................... 978 Failure code [CA1844]...................................................................................................................... 980 Failure code [CA1885]...................................................................................................................... 982 Failure code [CA1887]...................................................................................................................... 984 Failure code [CA1896]...................................................................................................................... 986 Failure code [CA1898]...................................................................................................................... 990 Failure code [CA1938]...................................................................................................................... 992 Failure code [CA1942]...................................................................................................................... 994 Failure code [CA1961]...................................................................................................................... 995 Failure code [CA1962]...................................................................................................................... 996 Failure code [CA2185]...................................................................................................................... 997 Failure code [CA2186]...................................................................................................................... 999 Failure code [CA2198]......................................................................................................................1001 Failure code [CA2272]......................................................................................................................1002 Failure code [CA2288]......................................................................................................................1004 Failure code [CA2311]......................................................................................................................1005 Failure code [CA2349]......................................................................................................................1006 Failure code [CA2353]......................................................................................................................1008 Failure code [CA2357]......................................................................................................................1010 Failure code [CA2373]......................................................................................................................1011 Failure code [CA2374]......................................................................................................................1013 Failure code [CA2375]......................................................................................................................1015 Failure code [CA2376]......................................................................................................................1017 Failure code [CA2387]......................................................................................................................1019 Failure code [CA2554]......................................................................................................................1020 Failure code [CA2555]......................................................................................................................1022 Failure code [CA2556]......................................................................................................................1024 Failure code [CA2634]......................................................................................................................1026 Failure code [CA2635]......................................................................................................................1028 Failure code [CA2636]......................................................................................................................1029 Failure code [CA2637]......................................................................................................................1031 Failure code [CA2771]......................................................................................................................1032 Failure code [CA2961]......................................................................................................................1036 Failure code [CA2973]......................................................................................................................1037 Failure code [CA2976]......................................................................................................................1038 Failure code [CA3142]......................................................................................................................1040 Failure code [CA3143]......................................................................................................................1041 Failure code [CA3144]......................................................................................................................1042 Failure code [CA3146]......................................................................................................................1044 Failure code [CA3147]......................................................................................................................1045 Failure code [CA3148]......................................................................................................................1046 Failure code [CA3151]......................................................................................................................1048 Failure code [CA3165]......................................................................................................................1055 Failure code [CA3228]......................................................................................................................1057 Failure code [CA3229]......................................................................................................................1059 Failure code [CA3231]......................................................................................................................1061 Failure code [CA3232]......................................................................................................................1063 Failure code [CA3235]......................................................................................................................1066 Failure code [CA3239]......................................................................................................................1068 Failure code [CA3241]......................................................................................................................1071 Failure code [CA3242]......................................................................................................................1074 Failure code [CA3251]......................................................................................................................1076 Failure code [CA3313]......................................................................................................................1078 Failure code [CA3314]......................................................................................................................1079 Failure code [CA3315]......................................................................................................................1080 Failure code [CA3419]......................................................................................................................1082 Failure code [CA3421]......................................................................................................................1084 Failure code [CA3497]......................................................................................................................1086 Failure code [CA3498]......................................................................................................................1087 Failure code [CA3545]......................................................................................................................1088 Failure code [CA3547]......................................................................................................................1090 Failure code [CA3558]......................................................................................................................1091 Failure code [CA3559]......................................................................................................................1093 Failure code [CA3562]......................................................................................................................1095 Failure code [CA3563]......................................................................................................................1097 Failure code [CA3567]......................................................................................................................1100 Failure code [CA3568]......................................................................................................................1102 Failure code [CA3571]......................................................................................................................1107 Failure code [CA3572]......................................................................................................................1109 Failure code [CA3574]......................................................................................................................1111 Failure code [CA3575]......................................................................................................................1113 Failure code [CA3577]......................................................................................................................1114 Failure code [CA3578]......................................................................................................................1116 Failure code [CA3582]......................................................................................................................1118 Failure code [CA3583]......................................................................................................................1124 Failure code [CA3596]......................................................................................................................1126 Failure code [CA3649]......................................................................................................................1129 Failure code [CA3681]......................................................................................................................1131 Failure code [CA3682]......................................................................................................................1135 Failure code [CA3713]......................................................................................................................1139 Failure code [CA3717]......................................................................................................................1142 Failure code [CA3718]......................................................................................................................1143 Failure code [CA3724]......................................................................................................................1144 Failure code [CA3725]......................................................................................................................1145 Failure code [CA3741]......................................................................................................................1147 Failure code [CA3748]......................................................................................................................1148 Failure code [CA3755]......................................................................................................................1150 Failure code [CA3866]......................................................................................................................1152 Failure code [CA3868]......................................................................................................................1155 Failure code [CA4152]......................................................................................................................1158 Failure code [CA4155]......................................................................................................................1161 Failure code [CA4156]......................................................................................................................1163 Failure code [CA4157]......................................................................................................................1165 Failure code [CA4159]......................................................................................................................1167 Failure code [CA4164]......................................................................................................................1168 Failure code [CA4165]......................................................................................................................1170 Failure code [CA4166]......................................................................................................................1172 Failure code [CA4168]......................................................................................................................1173 Failure code [CA4169]......................................................................................................................1176 Failure code [CA4171]......................................................................................................................1178 Failure code [CA4249]......................................................................................................................1180 Failure code [CA4251]......................................................................................................................1182 Failure code [CA4261]......................................................................................................................1184 Failure code [CA4277]......................................................................................................................1187 Failure code [CA4459]......................................................................................................................1189 Failure code [CA4461]......................................................................................................................1191 Failure code [CA4533]......................................................................................................................1194 Failure code [CA4534]......................................................................................................................1195 Failure code [CA4731]......................................................................................................................1196 Failure code [CA4732]......................................................................................................................1197 Failure code [CA4739]......................................................................................................................1198 Failure code [CA4768]......................................................................................................................1199 Failure code [CA4769]......................................................................................................................1201 Failure code [CA4842]......................................................................................................................1203 Failure code [CA4952]......................................................................................................................1206 Failure code [CA5115]......................................................................................................................1208 Failure code [CA5179]......................................................................................................................1211 Failure code [CA5181]......................................................................................................................1213 Failure code [CA5387]......................................................................................................................1215 Failure code [CA5388]......................................................................................................................1217 Failure code [CA5389]......................................................................................................................1219 Failure code [CA5391]......................................................................................................................1221 Failure code [CA5392]......................................................................................................................1225 Failure code [CA5393]......................................................................................................................1227 Failure code [CA5394]......................................................................................................................1229 Failure code [CA5395]......................................................................................................................1231 Failure code [CA5396]......................................................................................................................1233 Failure code [CA5631]......................................................................................................................1234 Failure code [CA5632]......................................................................................................................1235 Failure code [CA5938]......................................................................................................................1236 Failure code [D110KA]......................................................................................................................1237 Failure code [D110KB]......................................................................................................................1239 Failure code [D140KB]......................................................................................................................1241 Failure code [D140KY]......................................................................................................................1243 Failure code [D160KA]......................................................................................................................1245 Failure code [D160KB]......................................................................................................................1247 Failure code [D160KY]......................................................................................................................1249 Failure code [D161KB]......................................................................................................................1251 Failure code [D161KY]......................................................................................................................1253 Failure code [D190KB]......................................................................................................................1255 Failure code [D190KY]......................................................................................................................1257 Failure code [D19HKA]......................................................................................................................1259 Failure code [D19HKB]......................................................................................................................1261 Failure code [D19HKY]......................................................................................................................1263 Failure code [D19SKB]......................................................................................................................1264 Failure code [D19SKY]......................................................................................................................1265 Failure code [D19TKB]......................................................................................................................1266 Failure code [D19TKY]......................................................................................................................1267 Failure code [D19UKA]......................................................................................................................1268 Failure code [D19UKB]......................................................................................................................1270 Failure code [D19UKY]......................................................................................................................1272 Failure code [D5XWKA]......................................................................................................................1274 Failure code [D5XWKB]......................................................................................................................1278 Failure code [D5XXKA]......................................................................................................................1280 Failure code [D5XXKB]......................................................................................................................1282 Failure code [D5ZKKA]......................................................................................................................1284 Failure code [D5ZKKB]......................................................................................................................1285 Failure code [D5ZTKA]......................................................................................................................1286 Failure code [D811MC]......................................................................................................................1288 Failure code [D862KA]......................................................................................................................1289 Failure code [D8ALKA]......................................................................................................................1290 Failure code [D8ALKB]......................................................................................................................1292 Failure code [D8AQK4]......................................................................................................................1294 Failure code [D8AQKR]......................................................................................................................1299 Failure code [DAF0KT]......................................................................................................................1304 Failure code [DAF0MB]......................................................................................................................1305 Failure code [DAF0MC]......................................................................................................................1306 Failure code [DAF3KK]......................................................................................................................1307 Failure code [DAFGMC]......................................................................................................................1309 Failure code [DAFLKA]......................................................................................................................1310 Failure code [DAFLKB]......................................................................................................................1312 Failure code [DAFQKR]......................................................................................................................1314 Failure code [DAJ000]......................................................................................................................1320 Failure code [DAJ0KK]......................................................................................................................1321 Failure code [DAJ0KT]......................................................................................................................1323 Failure code [DAJ0MC]......................................................................................................................1324 Failure code [DAJ2KK]......................................................................................................................1325 Failure code [DAJ5KX]......................................................................................................................1327 Failure code [DAJ9KQ]......................................................................................................................1330 Failure code [DAJJKB]......................................................................................................................1331 Failure code [DAJLKA]......................................................................................................................1332 Failure code [DAJLKY]......................................................................................................................1334 Failure code [DAJQKR]......................................................................................................................1336 Failure code [DB2QKR]......................................................................................................................1342 Failure code [DB2RKR]......................................................................................................................1349 Failure code [DDDTKA]......................................................................................................................1355 Failure code [DDDTKA]......................................................................................................................1357 Failure code [DDDTKA]......................................................................................................................1359 Failure code [DDDTKB]......................................................................................................................1361 Failure code [DDDTKB]......................................................................................................................1363 Failure code [DDDTKB]......................................................................................................................1365 Failure code [DDDUKA]......................................................................................................................1367 Failure code [DDDUKA]......................................................................................................................1369 Failure code [DDDUKA]......................................................................................................................1371 Failure code [DDDUKB]......................................................................................................................1373 Failure code [DDDUKB]......................................................................................................................1375 Failure code [DDDUKB]......................................................................................................................1377 Failure code [DDDVKA]......................................................................................................................1379 Failure code [DDDVKA]......................................................................................................................1381 Failure code [DDDVKA]......................................................................................................................1383 Failure code [DDDVKM]......................................................................................................................1385 Failure code [DDDVKM]......................................................................................................................1387 Failure code [DDDVKM]......................................................................................................................1389 Failure code [DDK6KA]......................................................................................................................1391 Failure code [DDK6KY]......................................................................................................................1393 Failure code [DGS1KA]......................................................................................................................1395 Failure code [DGS1KB]......................................................................................................................1397 Failure code [DH2FKA]......................................................................................................................1399 Failure code [DH2FKY]......................................................................................................................1402 Failure code [DHA4KA]......................................................................................................................1404 Failure code [DHHBKA]......................................................................................................................1405 Failure code [DHHBKY]......................................................................................................................1407 Failure code [DHHCKA]......................................................................................................................1409 Failure code [DHHCKY]......................................................................................................................1411 Failure code [DHPCKA]......................................................................................................................1413 Failure code [DHPCKY]......................................................................................................................1416 Failure code [DJF1KA]......................................................................................................................1418 Failure code [DJF1L8]......................................................................................................................1420 Failure code [DK30KA]......................................................................................................................1421 Failure code [DK30KY]......................................................................................................................1423 Failure code [DK5YKA]......................................................................................................................1425 Failure code [DK5YKY]......................................................................................................................1427 Failure code [DK5YMA]......................................................................................................................1429 Failure code [DK70KA]......................................................................................................................1431 Failure code [DK70KY]......................................................................................................................1433 Failure code [DLT4KA]......................................................................................................................1435 Failure code [DLT4KA+DLT6KA]...............................................................................................................1437 Failure code [DLT4LC]......................................................................................................................1440 Failure code [DLT4MA]......................................................................................................................1442 Failure code [DLT6KA]......................................................................................................................1445 Failure code [DV00KB]......................................................................................................................1447 Failure code [DV00KY]......................................................................................................................1448 Failure code [DV01KB]......................................................................................................................1449 Failure code [DV01KY]......................................................................................................................1450 Failure code [DW4CKA]......................................................................................................................1451 Failure code [DW4CKB]......................................................................................................................1452 Failure code [DW4CKY]......................................................................................................................1454 Failure code [DWK0KA]......................................................................................................................1455 Failure code [DWK0KB]......................................................................................................................1456 Failure code [DWK0KY]......................................................................................................................1458 Failure code [DWP0KA]......................................................................................................................1459 Failure code [DWP0KB]......................................................................................................................1461 Failure code [DWP0KY]......................................................................................................................1463 Failure code [DXA1KA]......................................................................................................................1464 Failure code [DXA1KB]......................................................................................................................1466 Failure code [DXATKA]......................................................................................................................1467 Failure code [DXATKB]......................................................................................................................1469 Failure code [DXATKY]......................................................................................................................1471 Failure code [DXAUKA]......................................................................................................................1473 Failure code [DXAUKB]......................................................................................................................1475 Failure code [DXAUKY]......................................................................................................................1477 Failure code [DXAVKA]......................................................................................................................1479 Failure code [DXAVKB]......................................................................................................................1480 Failure code [DXAVKY]......................................................................................................................1481 Failure code [M400N1]......................................................................................................................1482 Troubleshooting of electrical system (E-mode)..................................................................................................1483 Information described in troubleshooting table.............................................................................................1483 E-1 Engine does not start..................................................................................................................1484 E-2 Engine preheater does not operate......................................................................................................1495 E-3 Parking brake reminder buzzer does not sound...........................................................................................1497 E-4 Parking brake reminder buzzer does not stop sounding...................................................................................1500 E-5 Headlamp does not light up or does not go out..........................................................................................1502 E-6 Clearance lamp and tail lamp do not light up or do not go out..........................................................................1506 E-7 Turn signal lamps do not light up or do not go out.....................................................................................1509 E-8 Brake lamps do not light up or do not go out...........................................................................................1511 E-9 Backup lamps do not light or go off....................................................................................................1513 E-10 Backup buzzer does not sound or does not stop sounding................................................................................1515 E-11 Horn does not sound or does not stop sounding.........................................................................................1517 E-12 Fuel level is not displayed correctly.................................................................................................1519 E-13 KOMTRAX system does not operate normally..............................................................................................1521 E-14 When starting switch is turned to ON position, alarm buzzer does not sound............................................................1523 E-15 When starting switch is turned to ON position, monitor panel is not displayed.........................................................1525 E-16 Seatbelt caution lamp does not go out or light up.....................................................................................1528 E-17 Seatbelt caution lamp does not go out or light up. (For forklift truck with deluxe suspension seat)...................................1529 E-18 Seatbelt caution lamp does not go out or light up. (For forklift truck with deluxe suspension seat and seat belt interlock system)....1530 Troubleshooting for hydraulic and mechanical systems (H-mode)..................................................................................1532 Failure mode and cause table...............................................................................................................1532 H-1 Forklift truck cannot travel forward and in reverse....................................................................................1536 H-2 Forklift truck cannot travel forward (can travel in reverse)...........................................................................1537 H-3 Forklift truck cannot travel in reverse (can travel forward)...........................................................................1538 H-4 Forklift truck travels slowly both forward and in reverse..............................................................................1539 H-5 Lift ruck travels slowly forward (travels normally in reverse).........................................................................1542 H-6 Lift ruck travels slowly in reverse (travels forward normally).........................................................................1543 H-7 Forklift truck lacks rim pull when traveling both forward and in reverse...............................................................1544 H-8 Forklift truck lacks rim pull when traveling forward (normal when traveling in reverse)................................................1546 H-9 Forklift truck lacks rim pull when traveling in reverse (normal when traveling forward)................................................1547 H-10 Engine stops while traveling, or engine speed decreases excessively...................................................................1548 H-11 Forklift truck moves off as it runs out in slow- speed start..........................................................................1549 H-12 Forklift truck does not turn..........................................................................................................1550 H-13 Steering wheel is heavy to turn.......................................................................................................1551 H-14 Forklift truck is unstable during turning.............................................................................................1552 H-15 Forklift truck turns to one side naturally while traveling............................................................................1554 H-16 Tire angle does not follow steering wheel angle.......................................................................................1555 H-17 Service brake does not work or its performance is low.................................................................................1558 H-18 Service brake is not released or it drags.............................................................................................1560 H-19 Parking brake does not work or its performance is low.................................................................................1561 H-20 Parking brake is not released or it drags.............................................................................................1562 H-21 Engine speed decreases excessively or engine stops when combined operation of work equipment and steering is executed.................1563 H-22 Work equipment lock does not work (work equipment operates when operator leaves operator's seat)......................................1564 H-23 Work equipment control lever does not move smoothly and it is heavy to operate........................................................1565 H-24 Fork does not rise....................................................................................................................1566 H-25 Fork rises slowly.....................................................................................................................1568 H-26 Fork lifting speed is reduced at specific height......................................................................................1570 H-27 Hydraulic drift of lift cylinder is large.............................................................................................1571 H-28 Fork does not lower...................................................................................................................1572 H-29 Fork lowering speed is low or high or fine control performance is low or response is low..............................................1573 H-30 Mast does not tilt forward or backward................................................................................................1574 H-31 Mast moves slowly in both forward and backward tilt operations........................................................................1576 H-32 Tilting speed is reduced halfway......................................................................................................1578 H-33 Hydraulic drift of tilt cylinder (forward tilting) is large...........................................................................1579 Troubleshooting for basic engine (S-mode)......................................................................................................1580 Information described in troubleshooting table (S-mode)....................................................................................1580 S-1 Engine does not crank when starting switch is turned to "START" position...............................................................1581 S-2 Engine cranks but no exhaust smoke comes out...........................................................................................1582 S-3 Fuel is being injected but engine does not start. (Misfiring: engine cranks but does not start.).......................................1583 S-4 Engine startability is poor............................................................................................................1584 S-5 Engine does not pick up smoothly.......................................................................................................1586 S-6 Engine stops during operation..........................................................................................................1588 S-7 Engine runs rough or is unstable.......................................................................................................1589 S-8 Engine lacks power.....................................................................................................................1590 S-9 Exhaust gas color is black.............................................................................................................1592 S-10 Engine oil consumption is excessive...................................................................................................1594 S-11 Oil becomes contaminated quickly......................................................................................................1595 S-12 Fuel consumption is excessive.........................................................................................................1596 S-13 Oil is in coolant (or coolant spurts back or coolant level goes down).................................................................1597 S-14 Oil pressure drops....................................................................................................................1598 S-15 Fuel mixes into engine oil............................................................................................................1599 S-16 Water mixes into engine oil (milky)...................................................................................................1600 S-17 Coolant temperature rises too high (overheating)......................................................................................1601 S-18 Unusual noise is heard................................................................................................................1602 S-19 Vibration is excessive................................................................................................................1603 S-20 Air cannot be bled from fuel circuit..................................................................................................1604 S-21 Active regeneration is executed excessively...........................................................................................1605 S-22 Active regeneration takes long........................................................................................................1606 S-23 White smoke is emitted during active regeneration.....................................................................................1607 S-24 DEF consumption is excessive..........................................................................................................1608 S-25 Abnormal smell (irritating smell) is noticed..........................................................................................1609 S-26 Foreign materials get into DEF (DEF level increases)..................................................................................1610 50 Disassembly and assembly........................................................................................................................1611 Contents.......................................................................................................................................1612 Precautions Before Work........................................................................................................................1617 List of abbreviations..........................................................................................................................1618 General information on disassembly and assembly................................................................................................1623 How to read this manual....................................................................................................................1623 Coating materials list.....................................................................................................................1624 Special tools list.........................................................................................................................1627 Engine and cooling system......................................................................................................................1635 Removal and installation of supply pump assembly...........................................................................................1635 Removal and installation of injector assembly..............................................................................................1641 Removal and installation of cylinder head assembly.........................................................................................1649 Removal and installation of EGR valve assembly.............................................................................................1672 Removal and installation of EGR cooler assembly............................................................................................1676 Removal and installation of starting motor assembly........................................................................................1688 Removal and installation of air conditioner compressor belt................................................................................1690 Removal and installation of alternator belt................................................................................................1692 Removal and installation of auto-tensioner.................................................................................................1694 Removal and installation of cooling assembly...............................................................................................1695 Removal and installation of radiator assembly..............................................................................................1705 Removal and installation of hydraulic oil cooler assembly..................................................................................1710 Removal and installation of aftercooler assembly...........................................................................................1714 Removal and installation of engine and HST pump assembly...................................................................................1718 Removal and installation of engine front oil seal..........................................................................................1733 Removal and installation of engine rear oil seal...........................................................................................1736 Removal and installation of KDOC assembly..................................................................................................1740 Removal and installation of bellows piping assembly........................................................................................1746 Removal and installation of KDOC and SCR assembly..........................................................................................1751 Removal and installation of DEF tank assembly..............................................................................................1783 Removal and installation of DEF tank sensor flange assembly................................................................................1791 Removal and installation of DEF tank sensor................................................................................................1800 Removal and installation of DEF tank strainer..............................................................................................1808 Removal and installation of SCR assembly...................................................................................................1809 Removal and installation of KCCV assembly..................................................................................................1817 Removal and installation of DEF mixing piping..............................................................................................1820 Removal and installation of DEF injector...................................................................................................1833 Removal and installation of DEF pump.......................................................................................................1842 Removal and installation of DEF hose.......................................................................................................1847 Removal and installation of air cleaner assembly...........................................................................................1866 Removal and installation of air conditioner compressor assembly............................................................................1877 Removal and installation of air conditioner condenser assembly.............................................................................1881 Power train....................................................................................................................................1885 Removal and installation of front axle and HST motor assembly..............................................................................1885 Removal and installation of rear axle assembly.............................................................................................1893 Disassembly and assembly of rear axle assembly.............................................................................................1897 Removal and installation of brake assembly.................................................................................................1907 Removal and installation of differential assembly..........................................................................................1909 Disassembly and assembly of differential assembly..........................................................................................1913 Disassembly and assembly of final drive assembly...........................................................................................1924 Disassembly and assembly of brake assembly.................................................................................................1931 Disassembly and assembly of parking brake assembly.........................................................................................1942 Undercarriage and frame........................................................................................................................1949 Removal and installation of counterweight assembly.........................................................................................1949 Removal and installation of head guard assembly............................................................................................1954 Hydraulic system...............................................................................................................................1964 Removal and installation of HST pump assembly..............................................................................................1964 Removal and installation of HST motor assembly.............................................................................................1981 Removal and installation of control valve assembly.........................................................................................1985 Removal and installation of O-rings of Orbitrol valve assembly.............................................................................1993 Removal and installation of HST charge circuit accumulator.................................................................................2000 Removal and installation of pilot circuit accumulator......................................................................................2003 Removal and installation of brake circuit accumulator......................................................................................2006 Removal and installation of brake circuit strainer.........................................................................................2008 Removal and installation of front axle lubricating oil strainer............................................................................2011 Removal and installation of lift cylinder assembly.........................................................................................2013 Disassembly and assembly of hydraulic cylinder assembly....................................................................................2017 Cab............................................................................................................................................2027 Removal and installation of operator's cab assembly........................................................................................2027 Removal and installation of air conditioner unit assembly..................................................................................2042 Removal and installation of operator’s seat (suspension seat)..............................................................................2051 Removal and installation of operator’s seat (deluxe suspension seat).......................................................................2053 Removal and installation of seat belt......................................................................................................2059 Work equipment.................................................................................................................................2060 Removal and installation of mast assembly..................................................................................................2060 Disassembly and assembly of mast assembly..................................................................................................2064 Electrical system..............................................................................................................................2071 Removal and installation of engine controller assembly.....................................................................................2071 Removal and installation of HST controller assembly........................................................................................2075 Removal and installation of monitor panel assembly.........................................................................................2076 Removal and installation of mass air flow and temperature sensor...........................................................................2079 Removal and installation of SCR temperature sensor.........................................................................................2083 Removal and installation of KOMTRAX terminal assembly......................................................................................2086 Removal and installation of KCCV crankcase pressure sensor.................................................................................2088 60 Maintenance standard............................................................................................................................2091 Contents.......................................................................................................................................2092 List of abbreviations..........................................................................................................................2093 Engine and cooling system......................................................................................................................2098 Maintenance standard of engine mount.......................................................................................................2098 Maintenance standard of cooling system.....................................................................................................2099 Power train....................................................................................................................................2100 Maintenance standard of HST pump...........................................................................................................2100 Maintenance standard of HST charge and brake double type pump..............................................................................2102 Maintenance standard of HST motor..........................................................................................................2104 Maintenance standard of front axle.........................................................................................................2106 Maintenance standard of differential.......................................................................................................2107 Maintenance standard of final drive........................................................................................................2110 Steering system................................................................................................................................2112 Maintenance standard of orbitrol valve.....................................................................................................2112 Maintenance standard of steering column....................................................................................................2113 Maintenance standard of steering cylinder..................................................................................................2114 Brake system...................................................................................................................................2115 Maintenance standard of front brake........................................................................................................2115 Maintenance standard of Parking brake......................................................................................................2117 Maintenance standard of brake cooling pump.................................................................................................2118 Undercarriage and frame........................................................................................................................2120 Maintenance standard of rear axle..........................................................................................................2120 Maintenance standard of frame..............................................................................................................2122 Hydraulic system...............................................................................................................................2123 Maintenance standard of hydraulic tank.....................................................................................................2123 Maintenance standard of steering and work equipment pump...................................................................................2124 Maintenance standard of control valve......................................................................................................2128 Maintenance standard of priority valve.....................................................................................................2136 Maintenance standard of work equipment PPC valve...........................................................................................2137 Work equipment.................................................................................................................................2139 Maintenance standard of tilt cylinder......................................................................................................2139 Maintenance standard of lift cylinder......................................................................................................2140 Maintenance standard of mast and fork......................................................................................................2142 80 Others..........................................................................................................................................2145 Contents.......................................................................................................................................2146 Precautions Before Work........................................................................................................................2147 List of abbreviations..........................................................................................................................2148 Air conditioner system.........................................................................................................................2153 Precautions for refrigerant................................................................................................................2153 Air conditioner components.................................................................................................................2154 Air conditioner specifications.............................................................................................................2155 Configuration and functions of refrigeration cycle.........................................................................................2156 Outline of refrigeration cycle.............................................................................................................2157 Air conditioner system components..............................................................................................................2159 Air conditioner unit.......................................................................................................................2159 Compressor.................................................................................................................................2160 Condenser..................................................................................................................................2161 Receiver drier.............................................................................................................................2162 Air conditioner control panel..............................................................................................................2163 Information described in troubleshooting table.............................................................................................2165 A-1 Troubleshooting the power circuit (Air conditioner does not operate)...................................................................2166 A-2 Troubleshooting the compressor and refrigerant system (Does not cool)..................................................................2170 A-3 Troubleshooting the compressor and refrigerant system (Mechanical system)..............................................................2174 A-4 Troubleshooting the hot water circuit system...........................................................................................2175 A-5 Abnormal noise from air conditioner-related parts......................................................................................2176 A-6 Water leakage from air conditioner-related parts.......................................................................................2177 Precautions for connecting or disconnecting air conditioner piping.........................................................................2178 Handing the compressor oil.................................................................................................................2180 Yearly inspection criteria.....................................................................................................................2181 Yearly inspection criteria: FH100, 120, 135, 160-1.........................................................................................2181 90 Diagrams and drawings...........................................................................................................................2205 Contents.......................................................................................................................................2206 List of abbreviations..........................................................................................................................2207 Hydraulic circuit diagram......................................................................................................................2212 Symbols for hydraulic circuit diagram......................................................................................................2212 Hydraulic circuit diagram..................................................................................................................2217 Electrical circuit diagram.....................................................................................................................2219 Symbols for electrical circuit diagram.....................................................................................................2219 Electrical circuit diagram (head guard specification) (1/16)...............................................................................2223 Electrical circuit diagram (head guard specification) (2/16)...............................................................................2225 Electrical circuit diagram (head guard specification) (3/16)...............................................................................2227 Electrical circuit diagram (head guard specification) (4/16)...............................................................................2229 Electrical circuit diagram (head guard specification) (5/16)...............................................................................2231 Electrical circuit diagram (head guard specification) (6/16)...............................................................................2233 Electrical circuit diagram (head guard specification) (7/16)...............................................................................2235 Electrical circuit diagram (head guard specification) (8/16)...............................................................................2237 Electrical circuit diagram (head guard specification) (9/16)...............................................................................2239 Electrical circuit diagram (head guard specification) (10/16)..............................................................................2241 Electrical circuit diagram (head guard specification) (11/16)..............................................................................2243 Electrical circuit diagram (head guard specification) (12/16)..............................................................................2245 Electrical circuit diagram (head guard specification) (13/16)..............................................................................2247 Electrical circuit diagram (head guard specification) (14/16)..............................................................................2249 Electrical circuit diagram (head guard specification) (15/16)..............................................................................2251 Electrical circuit diagram (head guard specification) (16/16)..............................................................................2253 Electrical circuit diagram (cab specification) (1/18)......................................................................................2255 Electrical circuit diagram (cab specification) (2/18)......................................................................................2257 Electrical circuit diagram (cab specification) (3/18)......................................................................................2259 Electrical circuit diagram (cab specification) (4/18)......................................................................................2261 Electrical circuit diagram (cab specification) (5/18)......................................................................................2263 Electrical circuit diagram (cab specification) (6/18)......................................................................................2265 Electrical circuit diagram (cab specification) (7/18)......................................................................................2267 Electrical circuit diagram (cab specification) (8/18)......................................................................................2269 Electrical circuit diagram (cab specification) (9/18)......................................................................................2271 Electrical circuit diagram (cab specification) (10/18).....................................................................................2273 Electrical circuit diagram (cab specification) (11/18).....................................................................................2275 Electrical circuit diagram (cab specification) (12/18).....................................................................................2277 Electrical circuit diagram (cab specification) (13/18).....................................................................................2279 Electrical circuit diagram (cab specification) (14/18).....................................................................................2281 Electrical circuit diagram (cab specification) (15/18).....................................................................................2283 Electrical circuit diagram (cab specification) (16/18).....................................................................................2285 Electrical circuit diagram (cab specification) (17/18).....................................................................................2287 Electrical circuit diagram (cab specification) (18/18).....................................................................................2289 INDEX..............................................................................................................................................2291
DESCRIPTION:
KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06649-11 – PDF DOWNLOAD
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 contain the table of contents, safety, and basic information.
01 Specification
This section explains the specifications of the machine.
10 Structure and function
This section explains the structure and function of each device by system. The “Structure and function” section serves not only to give an understanding of the structure of each device, but also serves as reference material for troubleshooting.
20 Standard value table
This section explains the standard values for new machine and judgment criteria for testing and adjusting, and also troubleshooting. This standard value table is used to check the standard values in testing and adjusting and also to judge parts in troubleshooting.
30 Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and also methods required for adjusting each part. The standard values and judgment criteria for testing and adjusting are explained in Testing and adjusting.
40 Troubleshooting
This section explains how to find failed parts and how to repair them. The troubleshooting is explained by failure mode.
50 Disassembly and assembly
This section explains the special tools and procedures required for the removing, installing, disassembling, and assembling each component, as well as any precautions needed to be taken. In addition, tightening torques and quantity and weights of coating material, oil, grease, and coolant necessary for the work are also explained.
60 Maintenance standard
This section explains maintenance standard values for each device. The maintenance standard sub-section explains judgment criteria and remedies for disassembly and service.
80 Others
This section explains the following items.
A. Structure, function, testing, adjusting, and troubleshooting of devices and equipment that cannot be clearly classified into the chassis or engine volume
B. This section explains the inspection items, contents and criteria of the specific self-imposed inspection.
90 Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams
S.S 30/12/24
