Komatsu EX50 Series Forklift Truck Service Manual SM228

Description

• Model List:
  • EX50 Series Forklift Truck

• 1. CONTENTS
• 2. GENERAL INFORMATION SPECIFICATIONS
• 2.1. SPECIFICATIONS
• 2.2. PERIODIC REPLACEMENT OF CONSUMABLE PARTS
• 2.3. STANDARD TIGHTENING TORQUE
• 2.3.1. Bolts
• 2.3.2. Elbows, Nipples And Unions
• 2.4. HOW TO USE LOCTITE
• 3. TESTING ADJUSTING
• 3.1. SERVICE DATA
• 3.2. DEPRESSURIZE HYDRAULIC SYSTEM
• 3.3. REPLACE ENGINE OIL/ENGINE OIL FILTER
• 3.3.1. CHANGE ENGINE OIL
• 3.3.2. REPLACE ENGINE OIL FILTER
• 3.4. REPLACE FUEL FILTERS
• 3.4.1. REPLACE FUEL PREFILTER CARTRIDGE
• 3.4.2. BLEED AIR FROM FUEL PREFILTER
• 3.4.3. REPLACE FUEL MAIN FILTER CARTRIDGE
• 3.4.4. BLEED AIR FROM FUEL MAIN FILTER
• 3.5. CLEAN INSIDE THE COOLING SYSTEM
• 3.6. AIR CLEANER
• 3.6.1. CLEAN FILTER ELEMENT
• 3.6.2. REPLACE FILTER ELEMENT
• 3.7. ADJUST VALVE CLEARANCE
• 3.8. CHECK COMPRESSION PRESSURE
• 3.9. TIGHTEN CYLINDER HEAD MOUNTING BOLTS
• 3.10. DIFFERENTIAL CASE
• 3.10.1. CHECK OIL LEVEL
• 3.10.2. REPLACE OIL
• 3.11. TORQFLOW TRANSMISSION CASE
• 3.11.1. CHECK OIL LEVEL
• 3.11.2. REPLACE OIL AND CLEAN STRAINER
• 3.12. SERVICE HYDRAULIC TANK
• 3.13. REPLACE BRAKE COOLING OIL (WET DISC BRAKE)
• 3.14. MEASURE HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS
• 3.15. ADJUST BRAKE/INCHING PEDAL (HYDRAULIC DRUM BRAKE)
• 3.15.1. ADJUST BRAKE PEDAL
• 3.15.2. ADJUST INCHING PEDAL
• 3.16. ADJUST BRAKE/INCHING PEDAL (WET DISC BRAKE)
• 3.16.1. ADJUST BRAKE PEDAL
• 3.16.2. INCHING PEDAL
• 3.17. ACCUMULATOR FOR BRAKE
• 3.17.1. CHARGE ACCUMULATOR WITH NITROGEN GAS (HYDRAULIC DRUM BRAKE)
• 3.17.2. CHARGING ASSEMBLY
• 3.17.3. JOINT ASSEMBLY
• 3.17.4. CHARGE ACCUMULATOR WITH NITROGEN GAS (WET DISC BRAKE)
• 3.17.5. MEASURE ACCUMULATOR CHARGE VALVE PRESSURE (WET DISC BRAKE)
• 3.17.6. ADJUST ACCUMULATOR CHARGE VALVE PRESSURE (WET DISC BRAKE)
• 3.18. ADJUST ACCELERATOR PEDAL OPERATION
• 3.19. ADJUST PARKING BRAKE
• 3.19.1. ADJUST LEVER OPERATING EFFORT
• 3.19.2. ADJUST PARKING BRAKE SHOE CLEARANCE
• 3.20. BLEEDING AIR
• 3.20.1. BRAKE PIPING (HYDRAULIC DRUM BRAKE)
• 3.20.2. LIFT CYLINDER
• 3.20.3. BRAKE (WET DISC BRAKE)
• 3.21. CHECK WEAR OF BRAKE DISC (WET DISC BRAKE)
• 3.22. ADJUST STEERING AXLE
• 3.22.1. alignment
• 3.22.2. TURNING ANGLE
• 3.23. INSPECT THE AIR CONDITIONER (OPTION)
• 3.24. INSPECT BATTERY
• 3.25. OIL AND GREASING CHART
• 3.26. LUBRICANT LIST
• 4. INSPECTION
• 4.1. GENERAL LOCATIONS
• 4.2. WEIGHT TABLE
• 4.3. INSPECTION CHECKLIST BY COMPONENT
• 4.4. REMOVAL AND INSTALLATION OF COMPONENTS
• 4.5. REMOVAL AND INSTALLATION FLOW CHART
• 4.6. MAST
• 4.6.1. Mast Removal Typical
• 4.6.2. Mast Installation Typical
• 4.6.3. BLEED AIR FROM LIFT CYLINDER
• 4.7. POWER TRAIN
• 4.7.1. REAR AXLE SUPPORT BUSHING
• 4.7.2. CENTER DRIVE SHAFT
• 4.7.3. CENTER ENGINE MOUNTS
• 4.7.4. WHEEL INSTALLATION
• 4.7.5. TIRE CLAMP TIGHTENING INSTRUCTION
• 4.7.6. Adjust runout
• 4.8. BRAKE SYSTEM (HYDRAULIC DRUM BRAKE)
• 4.8.1. METHOD OF BLEEDING AIR
• 4.8.2. Method of removing high pressure oil
• 4.9. WORK EQUIPMENT CONTROL LEVER
• 5. DISASSEMBLY AND ASSEMBLY
• 5.1. TORQUE CONVERTER
• 5.2. TORQFLOW TRANSMISSION
• 5.2.1. CONTROL VALVE (SOLENOID VALVE)
• 5.2.2. DISASSEMABLY
• 5.2.3. DISASSEMBLY OF CLUTCH PACK ASSEMBLY
• 5.2.4. PRECAUTIONS WHEN ASSEMBLING
• 5.2.5. CONNECTORS FOR SOLENOID VALVES
• 5.2.6. ASSEMBLY OF F/R (INPUT SHAFT) SHAFT SUB ASSEMBLY
• 5.2.7. ASSEMBLY OF 1ST/2ND SHAFT ASSEMBLY
• 5.2.8. ASSEMBLY OF 3RD (OUTPUT SHAFT) SHAFT SUB ASSEMBLY
• 5.2.9. Clutch shaft sub assembly
• 5.3. HYDRAULIC PUMPs
• 5.3.1. WORK EQUIPMENT pump and power steering pump
• 5.3.2. Torque converter charge pump
• 5.3.3. HYDRAULIC PUMPS
• 5.4. DRIVE AXLE
• 5.4.1. FRONT HUB
• 5.4.2. FRONT AXLE
• 5.4.3. DIFFERENTIAL
• 5.4.4. ADJUST PINION SHAFT SHIM
• 5.4.5. DIFFERENTIAL SUPPORT BEARING
• 5.5. STEERING AXLE
• 5.6. PARKING BRAKE
• 5.7. WHEEL BRAKE
• 5.8. BRAKE / INCHING PEDAL
• 5.9. BRAKE VALVE
• 5.9.1. DISASSEMBLY
• 5.9.2. ASSEMBLY
• 5.10. POWER STEERING VALVE
• 5.11. POWER STEERING VALVE
• 5.12. LIFT CYLINDER
• 5.13. TILT CYLINDER
• 5.13.1. INSPECTION
• 5.13.2. DISASSEMBLE LIFT AND TILT CYLINDERS
• 5.13.3. ASSEMBLE LIFT AND TILT CYLINDERS
• 5.14. POWER STEERING CYLINDER
• 5.15. CONTROL VALVE
• 5.16. MAST
• 5.16.1. SHIM ADJUSTMENT
• 5.16.2. CHAIN ADJUSTMENT
• 5.17. TABLE OF SPECIAL TOOLS
• 5.18. TABLE OF SPECIAL TOOLS FOR POWER STEERING CYLINDER
• 6. MAINTENANCE STANDARD
• 6.1. ENGINE AND ELECTRICAL PARTS
• 6.2. ACCELERATOR PEDAL
• 6.3. SPEEDOMETER SENSOR (OPTION)
• 6.4. LOCATION OF SWITCHES AND SENSORS
• 6.5. TORQUE CONVERTER
• 6.6. TORQFLOW TRANSMISSION
• 6.7. TRANSMISSION CONTROL VALVE
• 6.8. DRIVE SHAFT
• 6.9. DIFFERENTIAL
• 6.10. FINAL DRIVE
• 6.10.1. HYDRAULIC DRUM BRAKE
• 6.10.2. WET DISC BRAKE
• 6.11. REAR AXLE
• 6.12. STEERING
• 6.13. FRAME
• 6.14. BRAKE PEDAL
• 6.14.1. HYDRAULIC DRUM BRAKE
• 6.14.2. WET DISC BRAKE
• 6.15. BRAKE VALVE
• 6.15.1. HYDRAULIC DRUM BRAKE
• 6.15.2. WET DISC BRAKE
• 6.16. FRONT BRAKE
• 6.16.1. HYDRAULIC DRUM BRAKE
• 6.16.2. WET DISC BRAKE
• 6.17. PARKING BRAKE
• 6.18. CONTROL VALVE
• 6.19. PRIORITY VALVE
• 6.20. LIFT CYLINDER
• 6.21. TILT CYLINDER
• 6.22. POWER STEERING CYLINDER
• 6.23. WORK EQUIPMENT
• 7. STRUCTURE AND FUNCTION
• 7.1. POWER TRAIN DIAGRAM
• 7.1.1. HYDRAULIC DRUM BRAKE
• 7.1.2. WET DISC BRAKE
• 7.2. TORQUE CONVERTER
• 7.3. TORQFLOW TRANSMISSION 1/3
• 7.4. TORQFLOW TRANSMISSION 2/3
• 7.5. TORQFLOW TRANSMISSION 3/3
• 7.5.1. HYDRAULIC CIRCUIT (OUTLINE)
• 7.5.2. CLUTCH OPERATION DURING MANUAL SHIFT TRANSMISSION
• 7.6. INCHING VALVE
• 7.7. AUTOMATIC TRANSMISSION (OPTION)
• 7.7.1. BASIC SYSTEM CONFIGURATION
• 7.7.2. AUTO/MANUAL TRANSMISSION SELECTOR SWITCH
• 7.7.3. TROUBLESHOOTING TABLE
• 7.7.4. ABNORMALITIES NOT DETECTABLE BY THE TROUBLESHOOTING FUNCTION
• 7.8. DRIVE AXLE HYDRAULIC DRUM BRAKE
• 7.9. STEERING AXLE
• 7.10. STEERING SYSTEM
• 7.11. HYDRAULIC CIRCUIT DIAGRAMS OF STEERING SYSTEM AND CYLINDER
• 7.12. HYDRAULIC DRUM BRAKE
• 7.12.1. Wheel Brake
• 7.12.2. Brake Valve
• 7.12.3. HYDRAULIC DRUM BRAKE CIRCUIT DIAGRAM
• 7.13. WET DISC BRAKE
• 7.13.1. BRAKE VALVE
• 7.13.2. ACCUMULATOR CHARGE VALVE
• 7.13.3. BRAKE
• 7.13.4. WET DISC BRAKE HYDRAULIC CIRCUIT DIAGRAM
• 7.14. HYDRAULIC PUMPS
• 7.14.1. Hydraulic drum brake type
• 7.14.2. Wet disc brake type
• 7.15. TORQUE CONVERTER CHARGING PUMP
• 7.16. LIFT CYLINDER
• 7.17. TILT CYLINDER
• 7.18. METER PANEL
• 7.19. HYDRAULIC CIRCUIT DIAGRAMS
• 7.19.1. HYDRAULIC DRUM BRAKE
• 7.19.2. WET DISC BRAKE
• 7.20. ELECTRICAL CIRCUIT DIAGRAMS
• 7.20.1. HYDRAULIC DRUM BRAKE, MANUAL TRANS., NO KOPS
• 7.20.2. HYDRAULIC DRUM BRAKE, TORQFLOW TRANS., NO KOPS
• 7.20.3. HYDRAULIC DRUM BRAKE, MANUAL TRANS., WITH KOPS
• 7.20.4. HYDRAULIC DRUM BRAKE, MANUAL TRANS., WITH KOPS SEAT SWITCH CHANGE
• 7.20.5. HYDRAULIC DRUM BRAKE, TORQFLOW TRANS., WITH KOPS
• 7.20.6. HYDRAULIC DRUM BRAKE, TORQFLOW TRANS., WITH KOPS SEAT SWITCH CHANGE
• 7.20.7. WET DISC BRAKE, MANUAL TRANS., NO KOPS
• 7.20.8. WET DISC BRAKE, TORQFLOW TRANS., NO KOPS
• 7.20.9. WET DISC BRAKE, MANUAL TRANS., WITH KOPS
• 7.20.10. WET DISC BRAKE, MANUAL TRANS., WITH KOPS SEAT SWITCH CHANGE
• 7.20.11. WET DISC BRAKE, TORQFLOW TRANS., WITH KOPS
• 7.20.12. WET DISC BRAKE, TORQFLOW TRANS., WITH KOPS SEAT SWITCH CHANGE
• 8. TROUBLESHOOTING
• 8.1. TROUBLESHOOTING TOOL AND FAILURE CODEs
• 8.1.1. FUNCTIONS OF TROUBLESHOOTING TOOL
• 8.1.2. USING THE TROUBLESHOOTING TOOL
• 8.2. INDICATING FAILURE CODE WITH METER PANEL
• 8.2.1. Indication in normal state
• 8.2.2. Indication when trouble occurs
• 8.3. TABLE OF TROUBLESHOOTING TOOL FAILURE CODES
• 8.4. TORQUE CONVERTER TROUBLESHOOTING TABLE
• 8.5. CONTROL VALVE TROUBLESHOOTING TABLE
• 9. CONVERSION TABLES