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KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06839-07 – PDF DOWNLOAD
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KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06839-07 – PDF DOWNLOAD
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Description
KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06839-07 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06839-07 – PDF DOWNLOAD
Language : English
Pages : 2290
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 SEN06839-07 – 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............................................................................................. 27 Fire prevention................................................................................................................ 36 If a fire breaks out........................................................................................................... 38 Actions taken to meet exhaust GAS regulations.................................................................................. 39 Instructions for waste disposal................................................................................................ 40 Handling instructions of DEF................................................................................................... 41 Regarding storage of DEF....................................................................................................... 42 Regarding handling of DEF in cold weather...................................................................................... 42 Instructions for handling hydraulic components................................................................................. 43 Instructions for disconnecting and connecting piping........................................................................... 45 Instructions for handling electric components.................................................................................. 53 Instructions for handling fuel system components............................................................................... 55 Instructions for handling intake system components............................................................................. 56 Precautions for replacing HST controller and monitor panel..................................................................... 57 Use of KOMTRAX................................................................................................................. 58 Disconnecting and connecting push-pull type coupler............................................................................ 59 Instructions for disconnecting and connecting connectors....................................................................... 63 How to disconnect and connect DT connectors.................................................................................... 68 How to disconnect and connect slide lock type connectors....................................................................... 69 How to disconnect and connect connectors that require pulling lock............................................................. 71 How to disconnect and connect connectors that require pressing lock............................................................ 72 How to disconnect and connect connectors that require turning housing.......................................................... 74 How to read electric wire code................................................................................................. 75 Explanation of terms for maintenance standard.................................................................................. 81 Standard tightening torque table............................................................................................... 83 Unit conversion table.......................................................................................................... 90 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..................................................................................................... 158 Starting system.................................................................................................................... 167 Starting system component layout drawing....................................................................................... 167 System operating lamp system................................................................................................... 168 Preheating system.............................................................................................................. 169 Engine system...................................................................................................................... 171 Engine system component layout drawing......................................................................................... 171 Engine control system.......................................................................................................... 172 Automatic engine stop system................................................................................................... 174 Automatic engine power control system.......................................................................................... 177 Engine system components....................................................................................................... 180 Cooling system..................................................................................................................... 195 Cooling system component layout drawing........................................................................................ 195 Control system..................................................................................................................... 197 Control system component layout drawing........................................................................................ 197 Monitor panel system........................................................................................................... 199 Rearview monitor system........................................................................................................ 200 KOMTRAX system................................................................................................................. 201 Seat belt interlock system..................................................................................................... 202 Control system components...................................................................................................... 204 Hydraulic system................................................................................................................... 235 Hydraulic system component layout drawing...................................................................................... 235 CLSS........................................................................................................................... 236 Hydraulic system components.................................................................................................... 238 Power train system................................................................................................................. 268 Power train system component layout drawing.................................................................................... 268 Travel speed limit system...................................................................................................... 270 Directional lever neutral alarm system......................................................................................... 271 Travel interlock system........................................................................................................ 272 Power train system components.................................................................................................. 274 Work equipment system.............................................................................................................. 305 Work equipment system component layout drawing................................................................................. 305 Structure of valve control..................................................................................................... 306 Lift interlock system.......................................................................................................... 307 Work equipment system components............................................................................................... 309 Steering system.................................................................................................................... 315 Steering system component layout drawing....................................................................................... 315 Electronic proportional active control steering (EPACS) system................................................................. 316 Steering column................................................................................................................ 318 Steering system component...................................................................................................... 319 Brake system....................................................................................................................... 325 Brake system component layout drawing.......................................................................................... 325 Parking brake reminder system.................................................................................................. 326 Parking brake dragging prevention system....................................................................................... 328 Brake system components........................................................................................................ 330 Undercarriage and frame............................................................................................................ 340 Structure of frame............................................................................................................. 340 Tire........................................................................................................................... 341 Work equipment..................................................................................................................... 342 Structure of work equipment.................................................................................................... 342 Cab and its attachments............................................................................................................ 343 Cab............................................................................................................................ 343 20 Standard value table................................................................................................................ 345 Contents........................................................................................................................... 346 List of abbreviations.............................................................................................................. 347 Standard value table for engine.................................................................................................... 352 Standard value table for engine FH100-1........................................................................................ 352 Standard value table for engine FH120-1........................................................................................ 355 Standard value table for engine FH135-1........................................................................................ 358 Standard value table for engine: FH160-1....................................................................................... 361 Standard value table for machine................................................................................................... 364 Standard value table for machine: FH100-1...................................................................................... 364 Standard value table for machine: FH120-1...................................................................................... 371 Standard value table for machine: FH135-1...................................................................................... 378 Standard value table for machine: FH160-1...................................................................................... 385 30 Testing and adjusting............................................................................................................... 393 Contents........................................................................................................................... 394 Precautions Before Work............................................................................................................ 398 List of abbreviations.............................................................................................................. 399 Related information on testing and adjusting....................................................................................... 404 Tools for testing and adjusting................................................................................................ 404 Engine and cooling system.......................................................................................................... 412 Testing engine speed........................................................................................................... 412 Testing boost pressure......................................................................................................... 413 Testing exhaust gas color...................................................................................................... 415 Testing and adjusting valve clearance.......................................................................................... 417 Testing compression pressure................................................................................................... 419 Testing blowby pressure........................................................................................................ 424 Testing engine oil pressure.................................................................................................... 426 Visual check inside of EGR valve............................................................................................... 428 Clean inside of EGR valve...................................................................................................... 430 Testing fuel pressure.......................................................................................................... 433 Testing fuel discharge, return rate, and leakage volume........................................................................ 438 Bleeding air from fuel system.................................................................................................. 444 Checking fuel system for fuel leakage.......................................................................................... 446 Handling cylinder cutout mode operation........................................................................................ 448 Handling no-injection cranking................................................................................................. 449 Changing engine oil............................................................................................................ 450 Replacing engine oil filter.................................................................................................... 451 Replacing KCCV filter element.................................................................................................. 452 Replacing fuel filter.......................................................................................................... 454 Draining fuel prefilter........................................................................................................ 457 Bleeding air from coolant circuit.............................................................................................. 458 Cleaning radiator.............................................................................................................. 460 Checking air cleaner and cleaning or replacing element......................................................................... 462 Checking and adjusting tension of air conditioner compressor belt.............................................................. 466 Cleaning and replacing air conditioner filter.................................................................................. 468 Checking and cleaning air conditioner condenser fin............................................................................ 471 Checking refrigerant (gas) level............................................................................................... 472 Checking alternator belt....................................................................................................... 473 Checking auto-tensioner........................................................................................................ 474 Testing SCR-related functions.................................................................................................. 476 FLUSHING DEF TANK.............................................................................................................. 501 CLEAN DEF PUMP................................................................................................................. 505 REPLACING DEF TANK REFILL PORT FILTER.......................................................................................... 511 REPLACING DEF FILTER........................................................................................................... 514 REPLACING DEF TANK BREATHER.................................................................................................... 517 Power train........................................................................................................................ 519 Testing and adjusting HST oil pressure......................................................................................... 519 Replacing HST oil filter....................................................................................................... 534 Checking oil sump in flywheel housing.......................................................................................... 535 Checking oil level and changing oil in differential case....................................................................... 536 Steering system.................................................................................................................... 538 Testing steering wheel......................................................................................................... 538 Testing steering wheel angle sensor............................................................................................ 540 Testing and adjusting tire angle sensor........................................................................................ 541 Bleeding air from steering cylinder circuit.................................................................................... 543 Testing and adjusting steering circuit pressure................................................................................ 544 Brake system....................................................................................................................... 546 Bleeding air from brake circuit................................................................................................ 546 Testing brake oil pressure..................................................................................................... 548 Testing accumulator charge pressure............................................................................................ 550 Testing braking performance.................................................................................................... 551 Testing wear of service brake disc............................................................................................. 553 Testing and adjusting parking brake............................................................................................ 554 Testing brake pedal............................................................................................................ 558 Testing brake pedal angle sensor............................................................................................... 559 Hydraulic system................................................................................................................... 560 Releasing remaining pressure from hydraulic circuit............................................................................ 560 Testing and adjusting work equipment pressure.................................................................................. 562 Testing and adjusting work equipment PPC pressure.............................................................................. 569 Changing hydraulic oil......................................................................................................... 572 Replacing hydraulic oil line filter............................................................................................ 573 Cleaning hydraulic tank strainer............................................................................................... 574 Checking hydraulic tank breather............................................................................................... 576 Work equipment..................................................................................................................... 577 Bleeding air from lift cylinder................................................................................................ 577 Testing hydraulic drift and hydraulic drift forward tilt of cylinders.......................................................... 578 Adjusting mast................................................................................................................. 580 Adjusting finger bar........................................................................................................... 583 ADJUSTING TILT CYLINDER........................................................................................................ 586 Cab and its attachments............................................................................................................ 587 Testing directional lever...................................................................................................... 587 Testing lift lever and tilt lever.............................................................................................. 588 Testing accelerator pedal...................................................................................................... 589 Electrical system.................................................................................................................. 591 Setting and operation of monitor panel......................................................................................... 591 KOMTRAX terminal start-up procedure............................................................................................ 655 Stop using of KOMTRAX terminal (Machine with KOMTRAX terminal)................................................................. 659 Adjusting installed angle of rearview camera................................................................................... 661 Handling of engine controller power supply circuit............................................................................. 663 Guideline for testing diode.................................................................................................... 664 40 Troubleshooting..................................................................................................................... 665 Contents........................................................................................................................... 666 Precautions Before Work............................................................................................................ 675 List of abbreviations.............................................................................................................. 676 Information related to troubleshooting............................................................................................. 681 Points to remember when performing troubleshooting............................................................................. 681 Points to remember when performing troubleshooting of urea SCR system.......................................................... 682 How to proceed in troubleshooting.............................................................................................. 694 Check before troubleshooting................................................................................................... 696 Guideline for check before starting troubleshooting............................................................................ 697 Check according to check guideline............................................................................................. 698 Procedure for troubleshooting.................................................................................................. 722 Symptoms of failure and troubleshooting numbers................................................................................ 726 Information described in troubleshooting table................................................................................. 729 Connector list and layout...................................................................................................... 731 Connection table for connector pin No.......................................................................................... 742 T-box and T-adapter list....................................................................................................... 781 List and locations of installed fuses.......................................................................................... 785 About Circuit Breakers......................................................................................................... 794 Precautions when replacing KDOC................................................................................................ 795 Failure codes table............................................................................................................ 796 Troubleshooting by failure code.................................................................................................... 810 Failure code [2G40ZG].......................................................................................................... 810 Failure code [6091NX].......................................................................................................... 812 Failure code [7REAKA].......................................................................................................... 814 Failure code [7REHKA].......................................................................................................... 816 Failure code [A1U0N3].......................................................................................................... 818 Failure code [A1U0N4].......................................................................................................... 819 Failure code [AA10NX].......................................................................................................... 820 Failure code [AB00KY].......................................................................................................... 821 Failure code [AB00MA].......................................................................................................... 822 Failure code [AQ10MB].......................................................................................................... 824 Failure code [AQ10N3].......................................................................................................... 825 Failure code [AS00R2].......................................................................................................... 826 Failure code [AS00R3].......................................................................................................... 827 Failure code [AS00R4].......................................................................................................... 828 Failure code [AS00R5].......................................................................................................... 829 Failure code [AS00R6].......................................................................................................... 830 Failure code [AS00ZK].......................................................................................................... 831 Failure code [AS10KM].......................................................................................................... 832 Failure code [AS10NR].......................................................................................................... 833 Failure code [AS10NT].......................................................................................................... 834 Failure code [B@BAZG].......................................................................................................... 835 Failure code [B@BCNS].......................................................................................................... 836 FAILURE CODE [B@BCZK] (Serial No.: 7001 to 7137)............................................................................... 837 FAILURE CODE [B@BCZK] (Serial No.: 7138 and up)................................................................................ 838 Failure code [B@CRNS].......................................................................................................... 839 Failure code [CA115]........................................................................................................... 840 Failure code [CA122]........................................................................................................... 841 Failure code [CA123]........................................................................................................... 843 Failure code [CA131]........................................................................................................... 845 Failure code [CA132]........................................................................................................... 847 Failure code [CA144]........................................................................................................... 849 Failure code [CA145]........................................................................................................... 851 Failure code [CA153]........................................................................................................... 853 Failure code [CA154]........................................................................................................... 855 Failure code [CA187]........................................................................................................... 857 Failure code [CA221]........................................................................................................... 859 Failure code [CA222]........................................................................................................... 861 Failure code [CA227]........................................................................................................... 863 Failure code [CA234]........................................................................................................... 865 Failure code [CA238]........................................................................................................... 866 Failure code [CA239]........................................................................................................... 867 Failure code [CA249]........................................................................................................... 868 Failure code [CA256]........................................................................................................... 870 Failure code [CA271]........................................................................................................... 872 Failure code [CA272]........................................................................................................... 874 Failure code [CA295]........................................................................................................... 875 Failure code [CA322]........................................................................................................... 876 Failure code [CA324]........................................................................................................... 878 Failure code [CA331]........................................................................................................... 880 Failure code [CA332]........................................................................................................... 882 Failure code [CA343]........................................................................................................... 884 Failure code [CA351]........................................................................................................... 885 Failure code [CA352]........................................................................................................... 886 Failure code [CA356]........................................................................................................... 888 Failure code [CA357]........................................................................................................... 890 Failure code [CA386]........................................................................................................... 892 Failure code [CA428]........................................................................................................... 893 Failure code [CA429]........................................................................................................... 895 Failure code [CA431]........................................................................................................... 897 Failure code [CA432]........................................................................................................... 900 Failure code [CA435]........................................................................................................... 903 Failure code [CA441]........................................................................................................... 904 Failure code [CA442]........................................................................................................... 906 Failure code [CA451]........................................................................................................... 907 Failure code [CA452]........................................................................................................... 909 Failure code [CA488]........................................................................................................... 911 Failure code [CA515]........................................................................................................... 912 Failure code [CA516]........................................................................................................... 914 Failure code [CA553]........................................................................................................... 916 Failure code [CA555]........................................................................................................... 917 Failure code [CA556]........................................................................................................... 918 Failure code [CA559]........................................................................................................... 919 Failure code [CA595]........................................................................................................... 921 Failure code [CA687]........................................................................................................... 923 Failure code [CA689]........................................................................................................... 925 Failure code [CA691]........................................................................................................... 927 Failure code [CA692]........................................................................................................... 929 Failure code [CA697]........................................................................................................... 931 Failure code [CA698]........................................................................................................... 932 Failure code [CA731]........................................................................................................... 933 Failure code [CA778]........................................................................................................... 935 Failure code [CA1117].......................................................................................................... 940 Failure code [CA1664].......................................................................................................... 942 Failure code [CA1669].......................................................................................................... 944 Failure code [CA1673].......................................................................................................... 945 Failure code [CA1677].......................................................................................................... 946 Failure code [CA1678].......................................................................................................... 947 Failure code [CA1682].......................................................................................................... 948 Failure code [CA1683].......................................................................................................... 952 Failure code [CA1684].......................................................................................................... 954 Failure code [CA1686].......................................................................................................... 956 Failure code [CA1691].......................................................................................................... 957 Failure code [CA1694].......................................................................................................... 959 Failure code [CA1695].......................................................................................................... 961 Failure code [CA1696].......................................................................................................... 962 Failure code [CA1712].......................................................................................................... 964 Failure code [CA1713].......................................................................................................... 966 Failure code [CA1714].......................................................................................................... 968 Failure code [CA1715].......................................................................................................... 969 Failure code [CA1776].......................................................................................................... 970 Failure code [CA1777].......................................................................................................... 973 Failure code [CA1843].......................................................................................................... 976 Failure code [CA1844].......................................................................................................... 978 Failure code [CA1885].......................................................................................................... 980 Failure code [CA1887].......................................................................................................... 982 Failure code [CA1896].......................................................................................................... 984 Failure code [CA1898].......................................................................................................... 988 Failure code [CA1938].......................................................................................................... 990 Failure code [CA1942].......................................................................................................... 992 Failure code [CA1961].......................................................................................................... 993 Failure code [CA1962].......................................................................................................... 994 Failure code [CA2185].......................................................................................................... 995 Failure code [CA2186].......................................................................................................... 997 Failure code [CA2198].......................................................................................................... 999 Failure code [CA2272]..........................................................................................................1000 Failure code [CA2288]..........................................................................................................1002 Failure code [CA2311]..........................................................................................................1003 Failure code [CA2349]..........................................................................................................1004 Failure code [CA2353]..........................................................................................................1006 Failure code [CA2357]..........................................................................................................1008 Failure code [CA2373]..........................................................................................................1009 Failure code [CA2374]..........................................................................................................1011 Failure code [CA2375]..........................................................................................................1013 Failure code [CA2376]..........................................................................................................1015 Failure code [CA2387]..........................................................................................................1017 Failure code [CA2554]..........................................................................................................1018 Failure code [CA2555]..........................................................................................................1020 Failure code [CA2556]..........................................................................................................1022 Failure code [CA2634]..........................................................................................................1024 Failure code [CA2635]..........................................................................................................1026 Failure code [CA2636]..........................................................................................................1027 Failure code [CA2637]..........................................................................................................1029 Failure code [CA2771]..........................................................................................................1030 Failure code [CA2961]..........................................................................................................1034 Failure code [CA2973]..........................................................................................................1035 Failure code [CA2976]..........................................................................................................1036 Failure code [CA3142]..........................................................................................................1038 Failure code [CA3143]..........................................................................................................1039 Failure code [CA3144]..........................................................................................................1040 Failure code [CA3146]..........................................................................................................1042 Failure code [CA3147]..........................................................................................................1043 Failure code [CA3148]..........................................................................................................1044 Failure code [CA3151]..........................................................................................................1046 Failure code [CA3165]..........................................................................................................1053 Failure code [CA3228]..........................................................................................................1055 Failure code [CA3229]..........................................................................................................1057 Failure code [CA3231]..........................................................................................................1059 Failure code [CA3232]..........................................................................................................1061 Failure code [CA3235]..........................................................................................................1065 Failure code [CA3239]..........................................................................................................1067 Failure code [CA3241]..........................................................................................................1070 Failure code [CA3242]..........................................................................................................1073 Failure code [CA3251]..........................................................................................................1075 Failure code [CA3313]..........................................................................................................1077 Failure code [CA3314]..........................................................................................................1078 Failure code [CA3315]..........................................................................................................1079 Failure code [CA3419]..........................................................................................................1081 Failure code [CA3421]..........................................................................................................1083 Failure code [CA3497]..........................................................................................................1085 Failure code [CA3498]..........................................................................................................1086 Failure code [CA3545]..........................................................................................................1087 Failure code [CA3547]..........................................................................................................1089 Failure code [CA3558]..........................................................................................................1090 Failure code [CA3559]..........................................................................................................1092 Failure code [CA3562]..........................................................................................................1094 Failure code [CA3563]..........................................................................................................1096 Failure code [CA3567]..........................................................................................................1099 Failure code [CA3568]..........................................................................................................1101 Failure code [CA3571]..........................................................................................................1106 Failure code [CA3572]..........................................................................................................1108 Failure code [CA3574]..........................................................................................................1110 Failure code [CA3575]..........................................................................................................1112 Failure code [CA3577]..........................................................................................................1113 Failure code [CA3578]..........................................................................................................1115 Failure code [CA3582]..........................................................................................................1117 Failure code [CA3583]..........................................................................................................1124 Failure code [CA3596]..........................................................................................................1126 Failure code [CA3649]..........................................................................................................1129 Failure code [CA3681]..........................................................................................................1131 Failure code [CA3682]..........................................................................................................1136 Failure code [CA3713]..........................................................................................................1141 Failure code [CA3717]..........................................................................................................1144 Failure code [CA3718]..........................................................................................................1145 Failure code [CA3724]..........................................................................................................1146 Failure code [CA3725]..........................................................................................................1147 Failure code [CA3741]..........................................................................................................1149 Failure code [CA3748]..........................................................................................................1150 Failure code [CA3755]..........................................................................................................1152 Failure code [CA3866]..........................................................................................................1154 Failure code [CA3868]..........................................................................................................1157 Failure code [CA4151]..........................................................................................................1160 Failure code [CA4152]..........................................................................................................1164 Failure code [CA4155]..........................................................................................................1168 Failure code [CA4156]..........................................................................................................1170 Failure code [CA4157]..........................................................................................................1172 Failure code [CA4159]..........................................................................................................1174 Failure code [CA4164]..........................................................................................................1175 Failure code [CA4165]..........................................................................................................1177 Failure code [CA4166]..........................................................................................................1179 Failure code [CA4168]..........................................................................................................1180 Failure code [CA4169]..........................................................................................................1183 Failure code [CA4171]..........................................................................................................1185 Failure code [CA4249]..........................................................................................................1187 Failure code [CA4251]..........................................................................................................1189 Failure code [CA4261]..........................................................................................................1191 Failure code [CA4277]..........................................................................................................1194 Failure code [CA4459]..........................................................................................................1196 Failure code [CA4461]..........................................................................................................1198 Failure code [CA4533]..........................................................................................................1201 Failure code [CA4534]..........................................................................................................1202 Failure code [CA4731]..........................................................................................................1203 Failure code [CA4732]..........................................................................................................1204 Failure code [CA4739]..........................................................................................................1205 Failure code [CA4768]..........................................................................................................1206 Failure code [CA4769]..........................................................................................................1208 Failure code [CA4842]..........................................................................................................1210 Failure code [CA4952]..........................................................................................................1213 Failure code [CA5115]..........................................................................................................1215 Failure code [CA5179]..........................................................................................................1218 Failure code [CA5181]..........................................................................................................1220 Failure code [CA5387]..........................................................................................................1222 Failure code [CA5388]..........................................................................................................1224 Failure code [CA5389]..........................................................................................................1226 Failure code [CA5392]..........................................................................................................1228 Failure code [CA5393]..........................................................................................................1230 Failure code [CA5394]..........................................................................................................1232 Failure code [CA5395]..........................................................................................................1234 Failure code [CA5396]..........................................................................................................1237 Failure code [CA5631]..........................................................................................................1238 Failure code [CA5632]..........................................................................................................1239 Failure code [CA5938]..........................................................................................................1240 Failure code [D110KA]..........................................................................................................1241 Failure code [D110KB]..........................................................................................................1243 Failure code [D140KB]..........................................................................................................1245 Failure code [D140KY]..........................................................................................................1247 Failure code [D160KA]..........................................................................................................1249 Failure code [D160KB]..........................................................................................................1251 Failure code [D160KY]..........................................................................................................1253 Failure code [D161KB]..........................................................................................................1255 Failure code [D161KY]..........................................................................................................1257 Failure code [D190KB]..........................................................................................................1259 Failure code [D190KY]..........................................................................................................1261 Failure code [D19HKA]..........................................................................................................1263 Failure code [D19HKB]..........................................................................................................1265 Failure code [D19HKY]..........................................................................................................1267 Failure code [D19SKB]..........................................................................................................1268 Failure code [D19SKY]..........................................................................................................1269 Failure code [D19TKB]..........................................................................................................1270 Failure code [D19TKY]..........................................................................................................1271 Failure code [D19UKA]..........................................................................................................1272 Failure code [D19UKB]..........................................................................................................1274 Failure code [D19UKY]..........................................................................................................1276 Failure code [D5XWKA]..........................................................................................................1278 Failure code [D5XWKB]..........................................................................................................1282 Failure code [D5XXKA]..........................................................................................................1284 Failure code [D5XXKB]..........................................................................................................1286 Failure code [D5ZKKA]..........................................................................................................1288 Failure code [D5ZKKB]..........................................................................................................1289 Failure code [D5ZTKA]..........................................................................................................1290 Failure code [D811MC]..........................................................................................................1292 Failure code [D862KA]..........................................................................................................1293 Failure code [D8ALKA]..........................................................................................................1294 Failure code [D8ALKB]..........................................................................................................1296 Failure code [D8AQK4]..........................................................................................................1298 Failure code [D8AQKR]..........................................................................................................1303 Failure code [DAF0KT]..........................................................................................................1308 Failure code [DAF0MB]..........................................................................................................1309 Failure code [DAF0MC]..........................................................................................................1310 Failure code [DAF3KK]..........................................................................................................1311 Failure code [DAFGMC]..........................................................................................................1313 Failure code [DAFLKA]..........................................................................................................1314 Failure code [DAFLKB]..........................................................................................................1316 Failure code [DAFQKR]..........................................................................................................1318 Failure code [DAJ000]..........................................................................................................1324 Failure code [DAJ0KK]..........................................................................................................1325 Failure code [DAJ0KT]..........................................................................................................1327 Failure code [DAJ0MC]..........................................................................................................1328 Failure code [DAJ2KK]..........................................................................................................1329 Failure code [DAJ5KX]..........................................................................................................1331 Failure code [DAJ9KQ]..........................................................................................................1334 Failure code [DAJJKB]..........................................................................................................1335 Failure code [DAJLKA]..........................................................................................................1336 Failure code [DAJLKY]..........................................................................................................1338 Failure code [DAJQKR]..........................................................................................................1340 Failure code [DB2QKR]..........................................................................................................1346 Failure code [DB2RKR]..........................................................................................................1353 Failure code [DDDTKA]..........................................................................................................1359 Failure code [DDDTKA]..........................................................................................................1361 Failure code [DDDTKB]..........................................................................................................1363 Failure code [DDDTKB]..........................................................................................................1365 Failure code [DDDUKA]..........................................................................................................1367 Failure code [DDDUKA]..........................................................................................................1369 Failure code [DDDUKB]..........................................................................................................1371 Failure code [DDDUKB]..........................................................................................................1373 Failure code [DDDVKA]..........................................................................................................1375 Failure code [DDDVKA]..........................................................................................................1377 Failure code [DDDVKM]..........................................................................................................1379 Failure code [DDDVKM]..........................................................................................................1381 Failure code [DDK6KA]..........................................................................................................1383 Failure code [DDK6KY]..........................................................................................................1385 Failure code [DGS1KA]..........................................................................................................1387 Failure code [DGS1KB]..........................................................................................................1389 Failure code [DH2FKA]..........................................................................................................1391 Failure code [DH2FKY]..........................................................................................................1394 Failure code [DHA4KA]..........................................................................................................1396 Failure code [DHHBKA]..........................................................................................................1397 Failure code [DHHBKY]..........................................................................................................1400 Failure code [DHHCKA]..........................................................................................................1402 Failure code [DHHCKY]..........................................................................................................1405 Failure code [DHPCKA]..........................................................................................................1407 Failure code [DHPCKY]..........................................................................................................1410 Failure code [DJF1KA]..........................................................................................................1412 Failure code [DJF1L8]..........................................................................................................1414 Failure code [DK30KA]..........................................................................................................1415 Failure code [DK30KY]..........................................................................................................1417 Failure code [DK5YKA]..........................................................................................................1419 Failure code [DK5YKY]..........................................................................................................1422 Failure code [DK5YMA]..........................................................................................................1424 Failure code [DK70KA]..........................................................................................................1426 Failure code [DK70KY]..........................................................................................................1429 Failure code [DLT4KA]..........................................................................................................1431 Failure code [DLT4KA+DLT6KA]...................................................................................................1433 Failure code [DLT4LC]..........................................................................................................1436 Failure code [DLT4MA]..........................................................................................................1439 Failure code [DLT6KA]..........................................................................................................1442 Failure code [DV00KB]..........................................................................................................1444 Failure code [DV00KY]..........................................................................................................1445 Failure code [DV01KB]..........................................................................................................1446 Failure code [DV01KY]..........................................................................................................1447 Failure code [DW4CKA]..........................................................................................................1448 Failure code [DW4CKB]..........................................................................................................1450 Failure code [DW4CKY]..........................................................................................................1452 Failure code [DWK0KA]..........................................................................................................1453 Failure code [DWK0KB]..........................................................................................................1455 Failure code [DWK0KY]..........................................................................................................1457 Failure code [DWP0KA]..........................................................................................................1458 Failure code [DWP0KB]..........................................................................................................1460 Failure code [DWP0KY]..........................................................................................................1462 Failure code [DXA1KA]..........................................................................................................1463 Failure code [DXA1KB]..........................................................................................................1465 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]..........................................................................................................1482 Failure code [M400N1]..........................................................................................................1483 Troubleshooting of electrical system (E-mode)......................................................................................1484 Information described in troubleshooting table.................................................................................1484 E-1 Engine does not start......................................................................................................1485 E-2 Engine preheater does not operate..........................................................................................1496 E-3 Parking brake reminder buzzer does not sound...............................................................................1498 E-4 Parking brake reminder buzzer does not stop sounding.......................................................................1501 E-5 Headlamp does not light up or does not go out..............................................................................1503 E-6 Clearance lamp and tail lamp do not light up or do not go out..............................................................1507 E-7 Turn signal lamps do not light up or do not go out.........................................................................1510 E-8 Brake lamps do not light up or do not go out...............................................................................1512 E-9 Backup lamps do not light or go off........................................................................................1514 E-10 Backup buzzer does not sound or does not stop sounding....................................................................1516 E-11 Horn does not sound or does not stop sounding.............................................................................1518 E-12 Fuel level is not displayed correctly.....................................................................................1520 E-13 KOMTRAX system does not operate normally..................................................................................1522 E-14 When starting switch is turned to ON position, alarm buzzer does not sound................................................1524 E-15 When starting switch is turned to ON position, monitor panel is not displayed.............................................1526 E-16 Seatbelt caution lamp does not go out or light up.........................................................................1529 E-17 Seatbelt caution lamp does not go out or light up. (For seat belt interlock system).......................................1531 E-18 Front wiper does not operate (Cab specification)..........................................................................1533 E-19 Rear wiper does not operate...............................................................................................1540 E-20 Roof wiper does not operate...............................................................................................1543 Troubleshooting for hydraulic and mechanical systems (H-mode)......................................................................1548 Failure mode and cause table...................................................................................................1548 H-1 Forklift truck cannot travel forward and in reverse........................................................................1552 H-2 Forklift truck cannot travel forward (can travel in reverse)...............................................................1553 H-3 Forklift truck cannot travel in reverse (can travel forward)...............................................................1554 H-4 Forklift truck travels slowly both forward and in reverse..................................................................1555 H-5 Lift ruck travels slowly forward (travels normally in reverse).............................................................1558 H-6 Lift ruck travels slowly in reverse (travels forward normally).............................................................1559 H-7 Forklift truck lacks rim pull when traveling both forward and in reverse...................................................1560 H-8 Forklift truck lacks rim pull when traveling forward (normal when traveling in reverse)....................................1562 H-9 Forklift truck lacks rim pull when traveling in reverse (normal when traveling forward)....................................1563 H-10 Engine stops while traveling, or engine speed decreases excessively.......................................................1564 H-11 Forklift truck moves off as it runs out in slow- speed start..............................................................1565 H-12 Forklift truck does not turn..............................................................................................1566 H-13 Steering wheel is heavy to turn...........................................................................................1567 H-14 Forklift truck is unstable during turning.................................................................................1568 H-15 Forklift truck turns to one side naturally while traveling................................................................1570 H-16 Tire angle does not follow steering wheel angle...........................................................................1571 H-17 Service brake does not work or its performance is low.....................................................................1574 H-18 Service brake is not released or it drags.................................................................................1576 H-19 Parking brake does not work or its performance is low.....................................................................1577 H-20 Parking brake is not released or it drags.................................................................................1578 H-21 Engine speed decreases excessively or engine stops when combined operation of work equipment and steering is executed.....1579 H-22 Work equipment lock does not work (work equipment operates when operator leaves operator's seat)..........................1580 H-23 Work equipment control lever does not move smoothly and it is heavy to operate............................................1581 H-24 Fork does not rise........................................................................................................1582 H-25 Fork rises slowly.........................................................................................................1584 H-26 Fork lifting speed is reduced at specific height..........................................................................1586 H-27 Hydraulic drift of lift cylinder is large.................................................................................1587 H-28 Fork does not lower.......................................................................................................1588 H-29 Fork lowering speed is low or high or fine control performance is low or response is low..................................1589 H-30 Mast does not tilt forward or backward....................................................................................1590 H-31 Mast moves slowly in both forward and backward tilt operations............................................................1592 H-32 Tilting speed is reduced halfway..........................................................................................1594 H-33 Hydraulic drift of tilt cylinder (forward tilting) is large...............................................................1595 Troubleshooting for basic engine (S-mode)..........................................................................................1596 Information described in troubleshooting table (S-mode)........................................................................1596 S-1 Engine does not crank when starting switch is turned to "START" position...................................................1597 S-2 Engine cranks but no exhaust smoke comes out...............................................................................1598 S-3 Fuel is being injected but engine does not start. (Misfiring: engine cranks but does not start.)...........................1599 S-4 Engine startability is poor................................................................................................1600 S-5 Engine does not pick up smoothly...........................................................................................1602 S-6 Engine stops during operation..............................................................................................1604 S-7 Engine runs rough or is unstable...........................................................................................1605 S-8 Engine lacks power.........................................................................................................1606 S-9 Exhaust gas color is black.................................................................................................1608 S-10 Engine oil consumption is excessive.......................................................................................1610 S-11 Oil becomes contaminated quickly..........................................................................................1611 S-12 Fuel consumption is excessive.............................................................................................1612 S-13 Oil is in coolant (or coolant spurts back or coolant level goes down).....................................................1613 S-14 Oil pressure drops........................................................................................................1614 S-15 Fuel mixes into engine oil................................................................................................1615 S-16 Water mixes into engine oil (milky).......................................................................................1616 S-17 Coolant temperature rises too high (overheating)..........................................................................1617 S-18 Unusual noise is heard....................................................................................................1618 S-19 Vibration is excessive....................................................................................................1619 S-20 Air cannot be bled from fuel circuit......................................................................................1620 S-21 Active regeneration is executed excessively...............................................................................1621 S-22 Active regeneration takes long............................................................................................1622 S-23 White smoke is emitted during active regeneration.........................................................................1623 S-24 DEF CONSUMPTION IS EXCESSIVE..............................................................................................1624 S-25 Abnormal smell (irritating smell) is noticed..............................................................................1625 S-26 FOREIGN MATERIALS GET INTO DEF (DEF LEVEL INCREASES)......................................................................1626 50 Disassembly and assembly............................................................................................................1627 Contents...........................................................................................................................1628 Precautions Before Work............................................................................................................1633 List of abbreviations..............................................................................................................1634 General information on disassembly and assembly....................................................................................1639 How to read this manual........................................................................................................1639 Coating materials list.........................................................................................................1640 Special tools list.............................................................................................................1643 Engine and cooling system..........................................................................................................1651 Removal and installation of supply pump assembly...............................................................................1651 Removal and installation of injector assembly..................................................................................1657 Removal and installation of cylinder head assembly.............................................................................1665 Removal and installation of EGR valve assembly.................................................................................1688 Removal and installation of EGR cooler assembly................................................................................1692 Removal and installation of starting motor assembly............................................................................1705 Removal and installation of air conditioner compressor belt....................................................................1707 Removal and installation of alternator belt....................................................................................1709 Removal and installation of auto-tensioner.....................................................................................1711 Removal and installation of cooling assembly...................................................................................1712 Removal and installation of radiator assembly..................................................................................1722 Removal and installation of hydraulic oil cooler assembly......................................................................1726 Removal and installation of aftercooler assembly...............................................................................1730 Removal and installation of engine and HST pump assembly.......................................................................1734 Removal and installation of engine front oil seal..............................................................................1749 Removal and installation of engine rear oil seal...............................................................................1752 Removal and installation of KDOC assembly......................................................................................1756 Removal and installation of bellows piping assembly............................................................................1762 Removal and installation of KDOC and SCR assembly..............................................................................1767 REMOVAL AND INSTALLATION OF DEF TANK ASSEMBLY..................................................................................1799 REMOVAL AND INSTALLATION OF DEF TANK SENSOR FLANGE ASSEMBLY....................................................................1807 REMOVAL AND INSTALLATION OF DEF TANK SENSOR....................................................................................1816 REMOVAL AND INSTALLATION OF DEF TANK STRAINER..................................................................................1824 Removal and installation of SCR assembly.......................................................................................1825 Removal and installation of KCCV assembly......................................................................................1833 REMOVAL AND INSTALLATION OF DEF MIXING PIPING..................................................................................1836 REMOVAL AND INSTALLATION OF DEF INJECTOR.......................................................................................1849 REMOVAL AND INSTALLATION OF DEF PUMP...........................................................................................1858 REMOVAL AND INSTALLATION OF DEF HOSE...........................................................................................1863 Removal and installation of air cleaner assembly...............................................................................1882 Removal and installation of air conditioner compressor assembly................................................................1894 Removal and installation of air conditioner condenser assembly.................................................................1898 Power train........................................................................................................................1902 Removal and installation of front axle and HST motor assembly..................................................................1902 Removal and installation of rear axle assembly.................................................................................1910 Disassembly and assembly of rear axle assembly.................................................................................1914 Removal and installation of brake assembly.....................................................................................1924 Removal and installation of differential assembly..............................................................................1926 Disassembly and assembly of differential assembly..............................................................................1930 Disassembly and assembly of final drive assembly...............................................................................1941 Disassembly and assembly of brake assembly.....................................................................................1948 Disassembly and assembly of parking brake assembly.............................................................................1959 Undercarriage and frame............................................................................................................1966 Removal and installation of counterweight assembly.............................................................................1966 Removal and installation of head guard assembly................................................................................1972 Hydraulic system...................................................................................................................1982 Removal and installation of HST pump assembly..................................................................................1982 Removal and installation of HST motor assembly.................................................................................1999 Removal and installation of control valve assembly.............................................................................2003 Removal and installation of O-rings of Orbitrol valve assembly.................................................................2011 Removal and installation of HST charge circuit accumulator.....................................................................2018 Removal and installation of pilot circuit accumulator..........................................................................2021 Removal and installation of brake circuit accumulator..........................................................................2024 Removal and installation of brake circuit strainer.............................................................................2026 Removal and installation of front axle lubricating oil strainer................................................................2029 Removal and installation of lift cylinder assembly.............................................................................2031 Disassembly and assembly of hydraulic cylinder assembly........................................................................2035 Cab................................................................................................................................2045 Removal and installation of operator's cab assembly............................................................................2045 Removal and installation of air conditioner unit assembly......................................................................2060 Removal and installation of operator’s seat (suspension seat)..................................................................2069 Removal and installation of operator’s seat (deluxe suspension seat)...........................................................2071 Removal and installation of seat belt..........................................................................................2077 Work equipment.....................................................................................................................2078 Removal and installation of mast assembly......................................................................................2078 Disassembly and assembly of mast assembly......................................................................................2084 Electrical system..................................................................................................................2091 Removal and installation of engine controller assembly.........................................................................2091 Removal and installation of HST controller assembly............................................................................2095 Removal and installation of monitor panel assembly.............................................................................2096 Removal and installation of mass air flow and temperature sensor...............................................................2099 Removal and installation of SCR temperature sensor.............................................................................2103 Removal and installation of KOMTRAX terminal assembly..........................................................................2106 Removal and installation of KCCV crankcase pressure sensor.....................................................................2108 60 Maintenance standard................................................................................................................2111 Contents...........................................................................................................................2112 List of abbreviations..............................................................................................................2113 Engine and cooling system..........................................................................................................2118 Maintenance standard of engine mount...........................................................................................2118 Maintenance standard of cooling system.........................................................................................2119 Power train........................................................................................................................2120 Maintenance standard of HST pump...............................................................................................2120 Maintenance standard of HST charge and brake double type pump..................................................................2122 Maintenance standard of HST motor..............................................................................................2124 Maintenance standard of front axle.............................................................................................2126 Maintenance standard of differential...........................................................................................2127 Maintenance standard of final drive............................................................................................2130 Steering system....................................................................................................................2132 Maintenance standard of orbitrol valve.........................................................................................2132 Maintenance standard of steering column........................................................................................2133 Maintenance standard of steering cylinder......................................................................................2134 Brake system.......................................................................................................................2135 Maintenance standard of front brake............................................................................................2135 Maintenance standard of Parking brake..........................................................................................2137 Maintenance standard of brake cooling pump.....................................................................................2138 Undercarriage and frame............................................................................................................2140 Maintenance standard of rear axle..............................................................................................2140 Maintenance standard of frame..................................................................................................2142 Hydraulic system...................................................................................................................2143 Maintenance standard of hydraulic tank.........................................................................................2143 Maintenance standard of steering and work equipment pump.......................................................................2144 Maintenance standard of control valve..........................................................................................2148 Maintenance standard of priority valve.........................................................................................2156 Maintenance standard of work equipment PPC valve...............................................................................2157 Work equipment.....................................................................................................................2159 Maintenance standard of tilt cylinder..........................................................................................2159 Maintenance standard of lift cylinder..........................................................................................2160 Maintenance standard of mast and fork..........................................................................................2162 80 Others..............................................................................................................................2165 Contents...........................................................................................................................2166 Precautions Before Work............................................................................................................2167 List of abbreviations..............................................................................................................2168 Air conditioner system.............................................................................................................2173 Precautions for refrigerant....................................................................................................2173 Air conditioner components.....................................................................................................2174 Air conditioner specifications.................................................................................................2175 Configuration and functions of refrigeration cycle.............................................................................2176 Outline of refrigeration cycle.................................................................................................2177 Air conditioner system components..................................................................................................2179 Air conditioner unit...........................................................................................................2179 Compressor.....................................................................................................................2180 Condenser......................................................................................................................2181 Receiver drier.................................................................................................................2182 Air conditioner control panel..................................................................................................2183 Information described in troubleshooting table.................................................................................2185 A-1 Troubleshooting the power circuit (Air conditioner does not operate).......................................................2186 A-2 Troubleshooting the compressor and refrigerant system (Does not cool)......................................................2190 A-3 Troubleshooting the compressor and refrigerant system (Mechanical system)..................................................2194 A-4 Troubleshooting the hot water circuit system...............................................................................2195 A-5 Abnormal noise from air conditioner-related parts..........................................................................2196 A-6 Water leakage from air conditioner-related parts...........................................................................2197 Precautions for connecting or disconnecting air conditioner piping.............................................................2198 Handing the compressor oil.....................................................................................................2200 Yearly inspection criteria.........................................................................................................2201 Yearly inspection criteria: FH100, 120, 135, 160-1.............................................................................2201 90 Diagrams and drawings...............................................................................................................2225 Contents...........................................................................................................................2226 List of abbreviations..............................................................................................................2227 Hydraulic circuit diagram..........................................................................................................2232 Symbols for hydraulic circuit diagram..........................................................................................2232 Hydraulic circuit diagram......................................................................................................2237 Electrical circuit diagram.........................................................................................................2239 Symbols for electrical circuit diagram.........................................................................................2239 Electrical circuit diagram (1/18)..............................................................................................2243 Electrical circuit diagram (2/18)..............................................................................................2245 Electrical circuit diagram (3/18)..............................................................................................2247 Electrical circuit diagram (4/18)..............................................................................................2249 Electrical circuit diagram (5/18)..............................................................................................2251 Electrical circuit diagram (6/18)..............................................................................................2253 Electrical circuit diagram (7/18)..............................................................................................2255 Electrical circuit diagram (8/18)..............................................................................................2257 Electrical circuit diagram (9/18)..............................................................................................2259 Electrical circuit diagram (10/18).............................................................................................2261 Electrical circuit diagram (11/18).............................................................................................2263 Electrical circuit diagram (12/18).............................................................................................2265 Electrical circuit diagram (13/18).............................................................................................2267 Electrical circuit diagram (14/18).............................................................................................2269 Electrical circuit diagram (15/18).............................................................................................2271 Electrical circuit diagram (16/18).............................................................................................2273 Electrical circuit diagram (17/18).............................................................................................2275 Electrical circuit diagram (18/18).............................................................................................2277 Index..................................................................................................................................2279
DESCRIPTION:
KOMATSU FH100-1 FH120-1 FH135-1 FH160-1 FORKLIFT TRUCK SHOP MANUAL SEN06839-07 – PDF DOWNLOAD
HOW TO READ THE SHOP MANUAL
- Some attachments and optional parts in this shop manual may not be delivered to certain areas. When they are requested, consult with Komatsu.
- Materials and specifications are subject to change without notice.
- Shop manuals are divided into “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.
- Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
- All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
S.S 31/12/24
