Komatsu CX50, FG40Z-10, FG35, FG40, FG45, FG50A-10, FD40Z-10, FD35, FG40, FG45, FG50A-10 and 13 more Forklift Service Manual
755 pages · Publication BEC10E1-01 · CX50, FG40Z-10, FG35, FG40, FG45, FG50A-10, FD40Z-10, FD35, FG40, FG45, FG50A-10, FD40ZY-10, FD35Y, FG40Y, FG45Y, FG50AY-10, FG40ZU-10, FG40U, FG45U, FG50AU-10, FD40ZU-10, FD40U, FG45U, FG50AU-10
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- Models
- CX50, FG40Z-10, FG35, FG40, FG45, FG50A-10, FD40Z-10, FD35, FG40, FG45, FG50A-10, FD40ZY-10, FD35Y, FG40Y, FG45Y, FG50AY-10, FG40ZU-10, FG40U, FG45U, FG50AU-10, FD40ZU-10, FD40U, FG45U, FG50AU-10
- Serial coverage
- M250, M251, M252, M253-133001 and up
- Manual type
- Service Manual
- Pages
- 755
- Publication
- BEC10E1-01
- Condition
- Brand new
What's inside
From the manual's own table of contents: 116 sections, 230 entries. See sample pages (PDF, 957 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Standard tightening torque table
Conversion table
Specification dimension drawing
Weight table
Lubricant list
Cooling system (Lift truck with SAA4D95LE-5-A/S4D95LE-3 engine)
Cooling system (Lift truck with EBT-TB45-1A/2A/3A engine)
Brake cooling system hydraulic piping diagram
Power train
Power train system diagram
Torque converter
Transmission
Transmission control valve
Relief valve
Drive shaft
Front axle
Show all 116 sections
Differential
Final drive
Steering piping diagram (control valve – power steering cylinder)
Orbit-roll valve
Power steering cylinder
Brake control
Brake piping diagram (control valve – accumulator)
Service brake
Accumulator charge valve
Brake valve
Slack adjuster
Accumulator (for brake)
Parking brake
Rear axle
Hydraulic tank piping diagram46 topics
- Control valve piping diagram (tank – control valve)
- Work equipment piping diagram (control valve – tilt cylinder/lift cylinder)
- Attachment piping diagram
- Work equipment and steering pump
- Control valve
- CLSS
- Each function and operation of each valve
- Tilt cylinder
- Lift cylinder
- Mast
- Fork carriage
- Fork
- Accelerator pedal sensor
- ISO controller (Operator Presence Sensing (OPS) system)
- EPACS controller
- Instrument panel
- Engine starting circuit
- Engine stopping circuit
- Electrical system wiring diagram
- Sensors
- Switches
- Lamps
- Horn and buzzer
- Flasher
- F/R solenoid valve and F2 solenoid valve
- Relay box
- Resistor
- Diode
- Fuse
- Battery
- Standard value table
- Check of troubleshooting software functions and failure codes
- Hydraulic piping pressure release procedure
- Replacement of engine oil and engine oil filter
- Replacement of fuel filter
- Cleaning of radiator
- Check of air cleaner and replacement of cleaner element
- Oil level check and oil replacement of differential case
- Oil replacement and strainer cleaning of TORQFLOW transmission
- Testing power train oil pressure
- Check of hydraulic tank
- Measurement of wear amount of service brake disc
- Check of parking brake
- Air bleeding procedure
- Adjustment of brake pedal
- Adjustment of inching pedal
Initialization of orbit-roll valve
Measurement of cylinder hydraulic drift and hydraulic forward drift
Adjustment of mast
Adjustment of fork carriage
Check of drive shaft for looseness, play and damage
Check of diode
Points to remember when troubleshooting
Sequence of events in troubleshooting
Testing before troubleshooting
Classification and procedures of troubleshooting
Phenomena looking like troubles and troubleshooting No
Information contained in troubleshooting table
Locations of fuses
Failure code display by ISO controller
Failure code [[!]: 1 flashing, [N]: Flashing, [L]: Flashing] Seat switch trouble
Failure code [[!]: 2 flashings, [N]: Flashing, [L]: OFF] F/R lever trouble5 topics
- abnormality or N (neutral) lamp and lift interlock warning lamp output abnormality
- Lift interlock relay output abnormality (1)
- Lift interlock relay output abnormality (2)
- Travel interlock relay output abnormality (1)
- Travel interlock relay output abnormality (2)
Failure code [[!]: 6 flashings, [N]: Flashing, [L]: Flashing] Main relay output abnormality
Failure code [[!]: 7 flashings, [N]: Flashing, [L]: Flashing] Controller abnormality
Display of EPACS controller failure code
Failure code [LED: OFF] EPACS controller abnormality
Failure code [LED: 1 flashing] Initialization is not completed
Failure code [LED: 2 flashings] Controller is being initialized
Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality
Failure code [LED: 4 flashings] Tyre angle sensor abnormality18 topics
- Engine does not start
- Engine does not stop
- Lift truck cannot travel
- Parking brake reminder alarm does not sound or does not stop sounding
- Travel direction is not changed normally
- Lift truck cannot move work equipment
- Work equipment cannot be locked
- EPACS is abnormal
- Headlamp, clearance lamp, tail lamp and license plate lamp do not light or go off
- Turn signal lamps do not light or go off
- Brake lamps do not light or go off
- Backup lamps do not light or go off
- Backup buzzer does not sound or does not stop sounding
- Horn does not sound or does not stop sounding
- Fuel level is not displayed normally
- Fuel (Gasoline) level is not displayed normally
- Engine preheater does not operate normally
- Headlamp, clearance lamp and tail lamp do not light or go off
Turn signal lamps do not light or go off
Brake lamps do not light or go off
Backup lamps do not light or go off
Backup buzzer does not sound or does not stop sounding (Option)
Horn does not sound or does not stop sounding
Fuel level is not displayed normally
Engine does not stop
Lift truck cannot travel
Parking brake reminder alarm does not sound or does not stop sounding
Travel direction is not changed normally
Lift truck cannot move work equipment
Work equipment cannot be locked
Headlamp, clearance lamp and, tail lamp do not light or go off
Fuel (Gasoline) level is not displayed normally
Method of using troubleshooting table
Table of failure modes and causes
Lift truck does not start
Travel speed is low, rush force is low, gradeability is low and/or gear is not shifted
Large shocks are made when lift truck starts and gear is shifted
Long time lag is made when lift truck starts and gear is shifted
Torque converter oil temperature is high
Lift truck does not turn
Response is low during turning
Steering is heavy
Lift truck is unstable or large shock is made when it turns
Right and left turning radii are different
When steering wheel is released it does not return to neutral or it rotates by itself
Steering wheel is turned in reverse or it kicks
EPACS does not work
Steering wheel vibrates
Steering system makes abnormal sound
Oil leaks from steering circuit
Service brake does not work or its performance is low
Service brake is not reset or it drags
Parking brake does not work or its performance is low
Parking brake is not reset or it drags
Lift cylinder and fork do not lift
Lifting speed or force of lift cylinder and fork is insufficient
Fork lifting speed lowers at specific height
Lift cylinder cannot lift load
Lift cylinder natural drift is large
Fork lowering speed is too high
Mast does not tilt forward or backward
Forward/backward tilting speed or force of mast is insufficient
Tilting speed lowers halfway
Tilt cylinder cannot lift load
Tilt cylinder natural forward drift is large
Mast is unstable during travel with load45 topics
- Lift and tilt levers do not move smoothly and they are heavy
- Engine speed lowers remarkably or engine stalls when work equipment is operated
- Large shocks are made when work equipment is started and stopped
- Another part of work equipment moves when work equipment is relieved singly
- Work equipment speed or force is low
- or engine stalls
- Work equipment and steering system do not move
- Abnormal sound is heard from around work equipment and steering pump
- Work equipment fine control performance is low or response is low
- or only work equipment does not move
- Work equipment (lift-up) does not move, moves but slow or moves but force is low
- Lift cylinder drift is large (while operator is not in operator seat)
- Lift cylinder drift is large (while operator is in operator seat)
- low or response is low
- Fork does not lower
- Mast does not tilt/tilts but slow/tilts but force is low
- Tilt cylinder natural forward drift is large
- Attachment does not move/moves but low/moves but force is low
- Attachment cylinder natural drift is large
- Steering is heavy
- Large shock is made when steering wheel is returned
- operated simultaneously
- Steering is heavy when work equipment and steering are operated simultaneously
- Method of using this manual
- Special tool list
- How to use LOCTITE
- Removal and installation of power train
- Removal and installation of front axle
- Centering of power train
- Disassembly and assembly of transmission
- Disassembly and assembly of torque converter
- Disassembly and assembly of drive shaft
- Disassembly and assembly of differential
- Disassembly and assembly of axle housing assembly
- Disassembly and assembly of parking brake
- Disassembly and assembly of rear axle
- Disassembly and assembly of power steering cylinder
- Disassembly and assembly of brake pedal
- Disassembly and assembly of brake valve
- Disassembly and assembly of steering valve
- Disassembly and assembly of control valve assembly
- Removal and installation of lift cylinder
- Disassembly and assembly of lift cylinder
- Disassembly and assembly of tilt cylinder
- Removal and installation of mast
Disassembly and assembly of mast
Combination switch
Yearly inspection criteria
Hydrauric circuit diagrams
Electrical diagrams and drawings
Inside this manual
Real pages from this service manual (755 pages). Open the sample pages (PDF, 956 KB)
- Specifications, page 66: BEC10E1-01BA
- Troubleshooting, page 418: BEC10E1-01FD
- Diagram, page 539: BEC10E1-01FH
- Foldout diagram, page 751: Electrical diagrams and drawings
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 755 pages
Quantity one is the manual described above.
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Ships in 1 business day.
60-day returns
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).