Komatsu FD40Z-5, FG40Z-5, FG40Z-6, FD40-5, FD45-5, FG40-5, FG45-5, FG40-6, FG45-6, FG35S-5, FG45S-5, FG35S-6, FG45S Shop Manual

Description

• Model List:
  • FD40Z-5 Forklift Truck
  • FG40Z-5 Forklift Truck
  • FG40Z-6 Forklift Truck
  • FD40-5 Forklift Truck
  • FD45-5 Forklift Truck
  • FG40-5 Forklift Truck
  • FG45-5 Forklift Truck
  • FG40-6 Forklift Truck
  • FG45-6 Forklift Truck
  • FG35S-5 Forklift Truck
  • FG45S-5 Forklift Truck
  • FG35S-6 Forklift Truck
  • FG45S-6 Forklift Truck

• 1. BCFORE
• 1.1. FORWORD
• 1.2. DISASSEMBLY AND ASSEMBLY DIAGRAM
• 1.3. DESCRIPTION OF THE SYMBOLS
• 2. BCGEN
• 2.1. GENERAL
• 3. AADIS
• 3.1. DISASSEMBLY AND ASSEMBLY
• 4. AAGEN
• 4.1. GENERAL VIEW
• 4.2. SPECIFICATIONS
• 4.3. ENGINE PERFORMANCE CURVE
• 4.4. WEIGHT TABLE
• 5. AAINSPM
• 5.1. INSPECTION AND MAINTENANCE
• 6. AAINSPS
• 6.1. TURBOCHARGER (S6D95L)
• 6.2. CYLINDER HEAD
• 6.3. VALVE AND VALVE GUIDE
• 6.4. ROCKER ARM SHAFT, PUSH ROD AND TAPPET
• 6.5. CYLINDER BLOCK
• 6.6. CRANKSHAFT
• 6.7. PISTON, PISTON RING AND PISTON PIN
• 6.8. CONNECTING ROD
• 6.9. TIMING GEAR
• 6.10. CAMSHAFT
• 6.11. FLYWHEEL AND FLYWHEEL HOUSING
• 6.12. OIL PUMP
• 6.13. REGULATOR VALVE
• 6.14. WATER PUMP AND THERMOSTAT
• 7. AAREP
• 7.1. CYLINDER HEAD SECTION
• 7.2. CYLINDER BLOCK SECTION
• 8. AASTRUC
• 8.1. GENERAL STRUCTURE
• 8.2. INTAKE AND EXHAUST SYSTEM
• 8.3. ENGINE BODY
• 8.4. LUBRICATION SYSTEM
• 8.5. FUEL SYSTEM
• 8.6. COOLING SYSTEM
• 8.7. ELECTRICAL SYSTEM
• 9. AATEST
• 9.1. TESTING AND ADJUSTING DATA
• 9.2. FUEL INJECTION PUMP CALIBRATION DATA
• 9.3. STANDARD VOLUME OF FUEL INJECTION
• 9.4. ADJUSTMENT OF GOVERNOR
• 9.5. PERFORMANCE TEST
• 10. AATROUB
• 10.1. METHOD OF USING TROUBLESHOOTING CHART
• 10.2. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 10.3. STARTING PERFORMANCE IS POOR
• 10.4. ENGINE DOES NOT START
• 10.5. ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOWUP IS POOR)
• 10.6. ENGINE STOPS DURING OPERATIONS
• 10.7. ENGINE DOES NOT ROTATE SMOOTHLY
• 10.8. ENGINE LACKS OUTPUT (NO POWER)
• 10.9. EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
• 10.10. OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
• 10.11. OIL BECOMES CONTAMINATED QUICKLY
• 10.12. FUEL CONSUMPTION IS EXCESSIVE
• 10.13. OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
• 10.14. OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
• 10.15. OIL LEVEL RISES
• 10.16. WATER TEMPERATURE BECOMES TOO HIGHT (OVERHEATING)
• 10.17. ABNORMAL NOISE IS MADE
• 10.18. VIBRATION IS EXCESSIVE
• 11. AXGEN
• 11.1. General view
• 11.2. Specifications
• 11.3. General assembly drawing
• 11.4. Engine performance curve
• 12. AXMAINT
• 12.1. MAINTENANCE STANDARD
• 12.2. Cylinder and cylinder head
• 12.3. Piston, Piston ring, piston pin and connecting rod
• 12.4. CRANKSHAFT
• 12.5. Camshaft, valve, tappet and timing
• 12.6. Manifold
• 12.7. Lubrication system
• 12.8. Cooling system
• 12.9. Fuel system
• 12.10. Ignition system
• 13. AXSERV
• 13.1. Idling check and adjustment
• 13.2. Clylinder head assembly
• 13.3. Manifold assembly
• 13.4. Carburetor assembly
• 13.5. Governor
• 13.6. Engine electricals
• 13.7. Radiator
• 13.8. Fan, fan pulley
• 13.9. Fuel system
• 14. AXSTRUC
• 14.1. STRUCTURE AND FUNCTION
• 15. AYCOOL
• 15.1. COOLING SYSTEM
• 15.2. COOLING CIRCUIT
• 15.3. WATER PUMP
• 15.4. THERMOSTAT
• 15.5. WATER INLET
• 15.6. SERVICE DATA AND SPECIFICATIONS
• 16. AYELEC
• 16.1. ELECTRICAL SYSTEM
• 16.2. STARTING MOTOR
• 16.3. ALTERNATOR
• 16.4. SERVICE DATA AND SPECIFICATIONS
• 17. AYENG
• 17.1. ENGINE MECHANICAL
• 18. AYENGMA
• 18.1. ENGINE MAINTENANCE/ENGINE TUNEUP
• 18.2. ENGINE MAINTENANCE
• 18.3. TROUBLE DIAGNOSES AND CORRECTIONS
• 18.4. ENGINE TUNEUP
• 18.5. SERVICE DATA AND SPECIFICATIONS
• 19. AYFUEL
• 19.1. FUEL SYSTEM
• 19.2. FUEL PUMP
• 19.3. CARBURETOR
• 19.4. MECHANICAL GOVERNOR
• 19.5. SERVICE DATA AND SPECIFICATIONS
• 20. AYLUB
• 20.1. LUBRICATION SYSTEM
• 20.2. LUBRICATION CIRCUIT
• 20.3. OIL PUMP
• 20.4. SERVICE DATA SPECIFICATIONS
• 21. AYSAFE
• 22. AYSPEC
• 22.1. SPECIAL SERVICE TOOLS
• 23. BCCONV
• 23.1. CONVERSION TABLE
• 24. BCDIS
• 24.1. DISASSEMBLY AND ASSEMBLY OF COMPONENTS
• 25. BCREMOV
• 25.1. REMOVAL AND INSTALLATION OF UNIT
• 25.2. STRUCTURE
• 25.3. FLOW CHART
• 25.4. REMOVAL AND INSTALLATION OF UNIT
• 26. BCTEST
• 26.1. TESTING AND ADJUSTING
• 26.2. MAINTENANCE AND INSPECTION PROCEDURE
• 26.3. ADJUSTMENT OF PARKING BRAKE LEVER
• 27. BCTROUB
• 27.1. TROUBLESHOOTING