Komatsu CX20 FD40/45(Z)T(2)-8, FD50AT2-8 Diesel; FG35/45BCS/ST-8, FG40/45(Z)T(2)-8, FG50AT2-8 LPG Forklift Truck Service Manual (SM202)

Illustrated factory Service Manual for Komatsu CX20 Series Diesel Forklift Trucks Models FD40T-8, FD40T2-8, FD40ZT-8, FD40ZT2-8, FD45T-8, FD45T2-8, FD50AT2-8, CX20 LPG Forklift Trucks Models FG35BCS-8, FG35ST-8, FG40T-8, FG40T2-8, FG40ZT-8, FG40ZT2-8, FG45BCS-8, FG45ST-8, FG45T-8, FG45T2-8 and FG50AT2-8.

This manual will assist you in diagnosing, analyses, testing, and repair for your diesel forklift truck or lpg forklift truck.
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Covered Models (CX20 Series):
   FD40T-8 Diesel Forklift Truck (SN: 130001-)
   FD40T2-8 Diesel Forklift Truck (SN: 130001-)
   FD40ZT-8 Diesel Forklift Truck (SN: 130001-)
   FD40ZT2-8 Diesel Forklift Truck (SN: 130001-)
   FD45T-8 Diesel Forklift Truck (SN: 130001-)
   FD45T2-8 Diesel Forklift Truck (SN: 130001-)
   FD50AT2-8 Diesel Forklift Truck (SN: 130001-)
   FG35BCS-8 LPG Forklift Truck (SN: 130001-)
   FG35ST-8 LPG Forklift Truck (SN: 130001-)
   FG40T-8 LPG Forklift Truck (SN: 130001-)
   FG40T2-8 LPG Forklift Truck (SN: 130001-)
   FG40ZT-8 LPG Forklift Truck (SN: 130001-)
   FG40ZT2-8 LPG Forklift Truck (SN: 130001-)
   FG45BCS-8 LPG Forklift Truck (SN: 130001-)
   FG45ST-8 LPG Forklift Truck (SN: 130001-)
   FG45T-8 LPG Forklift Truck (SN: 130001-)
   FG45T2-8 LPG Forklift Truck (SN: 130001-)
   FG50AT2-8 LPG Forklift Truck (SN: 130001-)

Format: PDF, 540 pages
Language: English
Table of Contents:
   INTRODUCTION
   ENGINE SERIAL NUMBER LOCATION
   FORKLIFT TRUCKS COVERED IN THIS PUBLICATION
   FEDERAL EPA EMISSION CONTROL STATEMENTS
      LABELS REQUIRED AND LABEL LOCATIONS
      WARRANTY
      LABELS REQUIRED AND LABEL LOCATIONS
      WARRANTY
      SAFETY MANAGEMENT
      SAFE TRAVEL
      LOADING OPERATIONS
      SAFETY IN PERIODIC MAINTENANCE
      TOWING
      STRUCTURE AND STABILITY OF THE LIFT TRUCK
      SAFETY LABELS
      OPTIONAL EQUIPMENT
   GENERAL INFORMATION & SPECIFICATIONS
      SPECIFICATIONS - MAST DATA & FEATURES - INDOOR (CUSHION) TRUCK
      SPECIFICATIONS - MAST DATA & FEATURES - OUTDOOR (PNEUMATIC) TRUCKS
      TRUCK DATA - CUSHION TIRE LIFT TRUCKS (INDOOR)
      TRUCK DATA - PNEUMATIC TIRE LIFT TRUCKS
      PERIODIC REPLACEMENT OF CONSUMABLE PARTS
      STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
      STANDARD TIGHTENING TORQUE FOR BOLTS
   SERVICE DATA
      SERVICE DATA - GASOLINE ENGINE TRUCKS
      SERVICE DATA - DIESEL ENGINE TRUCKS
   TESTING, ADJUSTING AND MEASURING
      CHECK ENGINE OIL (TB45E)
      ADJUST ENGINE OIL LEVEL
      ADJUST IGNITION TIMING (TB45E)
      ADJUST SPARK PLUG GAP (TB45E)
      ADJUST VALVE CLEARANCE (TB45E)
      ADJUST VALVE CLEARANCE (S6D102E)
      ADJUST ENGINE DRIVE BELTS (TB45E)
      MEASURE ENGINE CYLINDER COMPRESSION (TB45E)
      MEASURE HYDRAULIC DRIFT ON LIFT & TILT CYLINDERS
      ADJUST TYPICAL MAST
      ADJUST PARKING BRAKE LEVER
      ADJUST ACCELERATOR PEDAL (TB45E Engine)
      TESTING, ADJUSTING AND MEASURINGTHROTTLE POSITION SENSOR SYSTEM
      ACCELERATOR PEDAL POSITION SENSOR - TB45 Engine
      ADJUST ACCELERATOR PEDAL (S6D102E Engine)
      MEASURE BRAKE STOPPING DISTANCE (BRAKING EFFECT)
      ADJUST INCHING / BRAKE PEDAL (TORQFLOW TRUCKS)
      ADJUST STOP LAMP SWITCH
      ADJUST WHEEL BRAKE
      CHECK OPERATION OF THE AUTOMATIC ADJUSTMENT DEVICE
      CHECK TORQFLOW CLUTCH ACTUATION PRESSURE - PNEUMATIC TIRE
      CHECK TORQUE CONVERTER STALL SPEED
      CHECK TORQFLOW CLUTCH ACTUATION PRESSURE - CUSHION TIRE
      CHECK TORQUE CONVERTER STALL SPEED
      ADJUST INCHING VALVE / SPOOL
      TEST SPECIFIC GRAVITY OF BATTERY ELECTROLYTE
      CHECK TIRES AND ADJUSTING PNEUMATIC TIRE PRESSURE
      MEASURE MINIMUM LEFT AND RIGHT TURNING RADIUS
      ADJUST TURNING RADIUS
      ADJUST REAR AXLE - THRUST CLEARANCE
   INSPECTION
      INSPECT ENGINE STARTING OPERATION
      INSPECT ENGINE RUNNING CONDITION
      INSPECT AIR CLEANER ASSEMBLY
      INSPECT THE FILTER ELEMENT
      INSPECT / RE-TORQUE CYLINDER HEAD MOUNTING BOLTS (TB45E)
      INSPECT / RE-TORQUE CYLINDER HEAD BOLTS (S6D102E)
      INSPECT ENGINE MOUNTS
      INSPECT THE ENGINE LUBRICATING SYSTEM
      INSPECT ENGINE FUEL SYSTEM
      INSPECT DIESEL FUEL INJECTION NOZZLES
      INSPECT LPG VAPORIZER FOR TAR BUILDUP (TB45E)
      INSPECT BLOW-BY GAS RECIRCULATION SYSTEM (TB45E)
      INSPECT COOLING SYSTEM AND RADIATOR
      INSPECT COOLANT SUB-TANK LEVEL
      INSPECT FAN ASSEMBLY
      INSPECT CHARGING SYSTEM WIRING
      INSPECT FRONT AXLE AND RE-TORQUE MOUNTING BOLTS
      INSPECT REAR AXLE AND RE-TORQUE MOUNTING BOLTS
      INSPECT WHEELS
      INSPECT RIM SIDE RING
      INSPECT WHEEL BEARINGS
      INSPECT STEERING AXLE
      INSPECT STEERING WHEEL
      INSPECT LIGHTING / TURN SIGNAL SWITCH - W/O DIMMER SWITCH
      INSPECT LIGHTING / TURN SIGNAL SWITCH - WITH DIMMER SWITCH
      INSPECT LIGHTING / TURN SIGNAL SWITCH
      INSPECT F/R SWITCH
      INSPECT POWER STEERING SYSTEM
      INSPECT BRAKE SYSTEM RODS, CABLES AND LINKS
      INSPECT BRAKE PIPING AND CONNECTIONS
      INSPECT BRAKE MASTER AND WHEEL CYLINDERS
      INSPECT BRAKE SHOES AND ASSOCIATED PARTS
      INSPECT BRAKE DRUMS
      INSPECT BRAKE BACKING PLATES
      INSPECT LOAD FORKS
      INSPECT MAST
      INSPECT FORK CARRIAGE
      INSPECT LIFT CHAINS
      INSPECT CHAIN WHEELS
      INSPECT ATTACHMENTS
      INSPECT HYDRAULIC TANK
      INSPECT CHASSIS AND ATTACHMENT PIPING
      INSPECT HYDRAULIC PUMP
      INSPECT LIFT CYLINDER
      INSPECT TILT CYLINDERS
      INSPECT ATTACHMENT CYLINDERS (IF EQUIPPED)
      INSPECT LIFT TRUCK CHASSIS AND FRAME
      INSPECT CAB (IF EQUIPPED)
      INSPECT OPERATOR’S SEAT
      INSPECT EQUIPMENT USED FOR ACCESSING THE LIFT TRUCK
      INSPECT DISPLAY PANEL
      INSPECT OVERHEAD GUARD
      INSPECT LIGHTS, GAUGES AND WARNING DEVICES
      INSPECT REAR VIEW MIRROR AND REFLECTORS
   MAINTENANCE OPERATIONS
      LUBRICANT LIST - GASOLINE ENGINE LIFT TRUCKS
      LUBRICANT LIST - DIESEL ENGINE LIFT TRUCKS
      OIL AND GREASING CHART
      CHANGE OIL AND FILTER IN GASOLINE ENGINES
      CHANGE OIL AND FILTER IN DIESEL ENGINES
      CHANGE GEAR OIL IN DIFFERENTIAL CASE
      CHANGE TRANSMISSION FLUID IN TORQFLOW TRANSMISSION CASE
      CHANGE OIL IN HYDRAULIC TANK
      REPLACE FUEL FILTER - GASOLINE ENGINES
      REPLACE FUEL FILTER - DIESEL ENGINES
      REPLACE AIR CLEANER ELEMENT
      CLEAN RADIATOR
      CLEAN RADIATOR FINS
      BLEED AIR FROM BRAKE SYSTEM
   REMOVAL, DISASSEMBLY, ASSEMBLY, INSTALLATION
      UNIT INSTALLATION POSITIONS DIAGRAM
      OVERALL DISASSEMBLY / ASSEMBLY FLOW CHART
      WEIGHT TABLE - COMPONENT ASSEMBLIES AND PARTS
      MAST
      ENGINE
      TRANSMISSION AND DRIVE AXLE
      TORQUE CONVERTER / TRANSMISSION CONTROL VALVE - PNEUMATIC TRUCKS
      TORQFLOW TRANSMISSION W/ TORQUE CONVERTER - CUSHION TRUCKS
      DRIVE AXLE
      DIFFERENTIAL
      BRAKE BOOSTER AND MASTER CYLINDER
      WHEEL BRAKE
      STEERING AXLE
      HYDRAULIC PUMP - GASOLINE ENGINES
      HYDRAULIC PUMP - DIESEL ENGINES
      TEST HYDRAULIC PUMP
      HYDRAULIC CONTROL VALVE
      TILT CYLINDER
      SIDESHIFTER
      COMBINATION SWITCH
   TROUBLESHOOTING
      ENGINE
      TORQFLOW
      TORQFLOW CONVERTER - CUSHION TRUCKS
      TORQFLOW CONVERTER - PNEUMATIC TRUCKS
      CONTROL VALVE - CUSHION TRUCKS
      CONTROL VALVE - PNEUMATIC TRUCKS
      ELECTRICAL SYSTEM
      STEERING SYSTEM
      POWER STEERING VALVE
      BRAKE SYSTEM
      HYDRAULIC SYSTEM
      HYDRAULIC PUMP
   D/100D/110D - MS 2-STAGE MAST
      INTRODUCTION
      INSTALLATION INSTRUCTIONS
      PERIODIC MAINTENANCE
      TROUBLESHOOTING
      SERVICE
   D/100D/110D - MT 3-STAGE MAST
      INTRODUCTION
      INSTALLATION INSTRUCTIONS
      PERIODIC MAINTENANCE
      TROUBLESHOOTING
      SERVICE
   CONVERSION TABLES
      MILLIMETERS TO INCHES
      INCHES TO MILLIMETERS
      CUBIC METERS TO CUBIC YARDS
      CUBIC YARDS TO CUBIC METERS
      LITER TO U.S. GALLON
      U.S. GALLON TO LITER
      KILOGRAM TO POUND
      POUND TO KILOGRAM
      KILOGRAMS PER SQUARE CENTIMETER TO POUNDS PER SQUARE INCH
      KILOGRAM TO FOOT POUNDS OF FORCE
      TEMPERATURE - FAHRENHEIT TO CENTIGRADE CONVERSION
   A. SERVICE DIAGRAMS
      Wiring Diagrams
      Electrical Assembly Drawings
      Transmission Drawings
      Drive Axle Drawings
      Steering Axle Drawings
      Frame Drawings
      Piping Diagrams
      Control Valve Diagram
   B. E-SERIES SIDESHIFTER
   C. D-SERIES SIDESHIFTER