Komatsu CX20 Series Service Manual
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Komatsu CX20 Series Service Manual

Forklift truck federal environmental protection agency (epa) emission-control compliant s/n 130001a~
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SERVICE MANUAL
CX Forklift Truck
Federal Environmental Protection Agency (EPA) Emission-Control Compliant
S/N 130001A~
CX20
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory-installed guards and shields are properly
secured in place.
ISSUED: APRIL 2008
Gasoline & LP FG35/45ST-8
Diesel
WARNING
FG40/45T(2)-8
FG35/45BCS-8
FG50AT2-8
FG40ZT(2)-8
FD40/45T(2)-8
FD50AT2-8
FD40ZT(2)-8
Komatsu Forklift USA, Inc.
SM202

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Summary of Contents for Komatsu CX20 Series

  • Page 1 CX20 Diesel FD40/45T(2)-8 FD50AT2-8 FD40ZT(2)-8 WARNING Read and observe all warnings on this unit before operating it. DO NOT operate this equipment unless all factory-installed guards and shields are properly secured in place. ISSUED: APRIL 2008 Komatsu Forklift USA, Inc.
  • Page 2 Neither Komatsu Forklift USA, Inc., nor its parent company nor any of its subsidiaries will be held responsible for damages due to misuse or inappropriate use of its products.
  • Page 3 INTRODUCTION This Service Manual has been developed as an information resource to help the reader learn about, understand, repair and maintain the CX20 Series forklift trucks, and the var- ious equipment, systems, inspections, sensors, diagnostic procedures and diagnostic equipment utilized to maintain, adjust and troubleshoot these systems. Although refer-...
  • Page 4 ENGINE SERIAL NUMBER LOCATION The TB45E series engine serial number is stamped on a flat machined, painted pad on the right side of the engine block just behind the dis- tributor. The right side is determined by the opera- tor’s right side when seated on the lift truck. The serial number faces upwards for ease of iden- tification.
  • Page 5 CONTENTS Page No. INTRODUCTION ..............3 ENGINE SERIAL NUMBER LOCATION .
  • Page 6 4.10 ADJUST - TYPICAL MAST ..........4-11 4.10.1 OUTER MAIN ROLLER .
  • Page 7 5.15 INSPECT FAN ASSEMBLY ..........5-8 5.16 INSPECT CHARGING SYSTEM WIRING .
  • Page 8 MAINTENANCE OPERATIONS LUBRICANT LIST - GASOLINE ENGINE LIFT TRUCKS ......6-2 LUBRICANT LIST - DIESEL ENGINE LIFT TRUCKS ......6-3 OIL AND GREASING CHART .
  • Page 9 POSITION OF TORQUE CONVERTER HOUSING HYDRAULIC PORTS ..7-28 TORQUE CONVERTER - TORQUE SPECIFICATIONS ....7-29 TORQUE CONVERTER PARTS BREAKDOWN ..... . . 7-30 TORQUE CONVERTER - PART STANDARD .
  • Page 10 BRAKE MASTER CYLINDER/BRAKE BOOSTER DIAGRAM ... . 7-106 7.8.1 BRAKE MASTER CYLINDER - DISASSEMBLY ......7-107 7.8.2 DISASSEMBLE BRAKE BOOSTER UNIT .
  • Page 11 7.13.8 ASSEMBLE HYDRAULIC PUMP - FRONT PUMP SECTION - GASOLINE (CUSHION) ............. . 7-152 7.13.9 INSPECTION AND REPAIR - HYDRAULIC PUMP - GASOLINE (CUSHION) .
  • Page 12 80D/100D/110D - MS 2-STAGE MAST 80D/100D/110D - MT 3-STAGE MAST CONVERSION TABLES 11.1 MILLIMETERS TO INCHES..........11-53 11.2 INCHES TO MILLIMETERS.
  • Page 13 FORKLIFT TRUCKS COVERED IN THIS PUBLICATION FORKLIFT TRUCKS COVERED IN THIS PUBLICATION S/N 130001A~ KOMATSU MODEL DESCRIPTION ENGINE DESIGNATION Gasoline and LPG Trucks FG35ST-8 8,000 lb. capacity, cushion tire truck, 1-speed transmission TB45 FG35BCS-8 8,000 lb. capacity, cushion tire truck, Box Car Special (BCS), 1-spd. trans.
  • Page 14 FEDERAL EPA EMISSION CONTROL STATEMENT FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (TB45E ENGINES) This section presents information concerning the correct labeling, warranty, parts and maintenance of TB45E engines in order to comply with the EPA off-road, large-spark-ignition (LSI) engine regulations. 1.
  • Page 15 All off-road large spark-ignition (LSI) engines must be designed, built and equipped to meet the Federal EPA’s stringent anti-smog standards. Komatsu Forklift USA, Inc. (“”) must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, damage, neglect or improper maintenance of your engine.
  • Page 16 For the first 2,500 operating hours, or for a period of thirty-six months from the date of the first use by the original purchaser from an Authorized Komatsu Forklift Dealer, whichever occurs first, KFI warrants the following emission- related parts: •...
  • Page 17 FEDERAL EPA EMISSION CONTROL STATEMENT FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD DIESEL ENGINES (S6D102E ENGINES) Exhaust emissions produced by diesel engines are regulated by the United States Environmental Protection Agency (EPA). This section presents information concerning the correct labeling, warranty, parts and maintenance of S6D102E diesel engines in order to comply with current EPA regulations.
  • Page 18 YOUR WARRANTY RIGHTS AND OBLIGATIONS The Federal EPA and Komatsu Forklift USA, Inc. (hereinafter referred to as “KFI”) are pleased to explain the emis- sion control system warranty on your 2004 or later Diesel heavy duty off-road engine. All new, heavy-duty off-road engines must be designed, built and equipped to meet the EPA’s stringent anti-smog standards.
  • Page 19 You are responsible for initiating the warranty process. It is suggested that you present your heavy duty off-road engine to an authorized Komatsu dealer as soon as you become aware that problem exists. The warranty repair should be completed by the dealer as expeditiously as possible.
  • Page 20 CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEMS WARRANTY Komatsu Forklift aims to ensure that the Emission Control Systems Warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Sys- tems Warranty, call or write to your Komatsu Forklift Dealer.
  • Page 21 1. SAFETY...
  • Page 22 Read this manual and safety labels again from time to time. If the Operation and Maintenance Manual or safety labels have been lost or have become dirty and cannot be read, obtain replacements from your Komatsu Forklift dealer and attach the safety labels in the specified positions. MAKE SAFETY PLANS BEFOREHAND •...
  • Page 23 Always be careful to prevent damage or injury from falling objects. • Do not use a Komatsu lift truck when it is equipped with a non-genuine overhead guard or load backrest. Note: Komatsu lift trucks are usually equipped with the optimum overhead guard and load backrest when they are shipped out of Komatsu Forklift plants.
  • Page 24 1.1. SAFETY MANAGEMENT PRECAUTIONS WHEN REFUELING LPG TRUCKS • Only trained and authorized personnel may fill or change LPG tanks. • When checking or filling tank, do not smoke, stop the engine and fill only at designated safe areas, preferably outdoors.
  • Page 25 1.1. SAFETY MANAGEMENT FIRE, FIRST AID AND GENERAL SAFETY • When you feel something unusual occurring with the lift truck, promptly stop working, move the lift truck to a safe place for parking, stop the engine for safety. Then report to the supervisor.
  • Page 26 1.2. SAFE TRAVEL 1.2. SAFE TRAVEL JUMPING ON AND OFF THE LIFT TRUCK IS STRICTLY PROHIBITED • When getting in or out of the lift truck, be sure to first stop the truck and use the handrails (assist grip) as well as the step to hold yourself securely.
  • Page 27 1.2. SAFE TRAVEL DON'T ALLOW A PASSENGER ON THE TRUCK • Never allow any other person to ride with you on the lift truck. • Do not use anyone for a makeshift human counterweight. BE SURE TO WEAR THE SAFETY SEAT BELT •...
  • Page 28 1.2. SAFE TRAVEL PERFORM A SAFETY CHECK BEFORE STARTING THE LIFT TRUCK • Before starting the lift truck, check that the surrounding area is safe. • Before moving the lift truck, raise the forks [approximately 15 to 20 cm (6 - 8 in) from the ground surface], and tilt the mast back.
  • Page 29 1.2. SAFE TRAVEL DRIVING ON A ROAD SHOULDER IS STRICTLY PROHIBITED • There is a danger that soft road shoulders may collapse, so do not go near them. • Always maintain a safe distance from the edge of road shoulders and platforms. WHEN DRIVING INTO A RAILWAY CAR, TRUCK OR CONTAINER, EXERCISE EXTRA CARE •...
  • Page 30 1.2. SAFE TRAVEL BE AWARE OF THE LIFT TRUCK'S MAXIMUM HEIGHT AND WIDTH • Ensure that there is ample height and width for the lift truck to pass. • Do not extend your hands or legs outside the operator's compartment or the area covered by the overhead guard (safe area).
  • Page 31 1.2. SAFE TRAVEL WHEN MAKING A TURN, BE CAREFUL OF THE SWINGING COUNTERWEIGHT • Remember that a fork lift truck steers with the rear wheels, not the front wheels. It will not drive like an automobile. • When turning while traveling forward, the counterweight will swing far out.
  • Page 32 • When installing optional warning devices, call your Komatsu Forklift dealer for details. REQUIRED BRAKING DISTANCE DIFFERS DEPENDING ON THE ROAD CONDITIONS •...
  • Page 33 1.2. SAFE TRAVEL FOLLOW THESE STEPS FOR PARKING Stop the lift truck on level ground. Apply the parking brake securely to make sure that the lift truck cannot move. Set the directional lever and speed lever to neutral. Tilt the mast forward and lower the fork to the floor. Turn the starting switch to the OFF position.
  • Page 34 1.3. LOADING OPERATIONS 1.3. LOADING OPERATIONS PRECAUTIONS FOR LOADING AND UNLOADING • If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like standing up or leaning forward or sideways, Travel Interlock begins to alarm in approximately three seconds and cuts off the transmission of engine power.
  • Page 35 1.3. LOADING OPERATIONS BE CAREFUL NOT TO GET CAUGHT IN THE MAST STRUCTURE Never put your hands or feet into the mast structure. There is danger that you will get caught in moving parts and be seriously injured. DON'T CLIMB ON THE MAST OR LOAD BACKREST If you climb on the mast or load backrest, there is a danger that you could get caught up in the moving parts or fall off.
  • Page 36 1.3. LOADING OPERATIONS WATCH OUT OVERHEAD • As the fork goes up, the mast height increases. Be mindful of this fact during the operation. • Take care so that the mast or the overhead guard will not hit electric wiring, piping, sprinklers, beams in the ceiling, and so on.
  • Page 37 1.3. LOADING OPERATIONS BE CAREFUL OF THE FORK TIPS • Do not allow the tips of the forks to get close to people. The tips of the forks are pointed, so there is a risk that they may cause injury. •...
  • Page 38 1.3. LOADING OPERATIONS DON'T USE THE LIFT TRUCK IMPROPERLY • Do not use the lift truck for any other purpose than was originally intended (the loading work using the fork or attachments). • Do not use the forks to open or close the doors of railroad cars or warehouses.
  • Page 39 1.4. SAFETY IN PERIODIC MAINTENANCE 1.4. SAFETY IN PERIODIC MAINTENANCE PERIODIC MAINTENANCE WORK MUST BE CARRIED OUT BY QUALIFIED PERSONNEL Only persons authorized by the owner or operator of the equipment and having proper certification (local or national) may carry out inspection, maintenance and repairs of the lift truck. If inspection, maintenance, or repair work is carried out incorrectly, it may create a hazardous condition.
  • Page 40 1.4. SAFETY IN PERIODIC MAINTENANCE PERIODIC INSPECTION OF CRITICAL REPLACEMENT PARTS Replace critical safety parts with a new one periodically even if no defect is found. Parts tend to deteriorate as time goes by, and can cause fire or failure in the work equipment system. However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately.
  • Page 41 1.4. SAFETY IN PERIODIC MAINTENANCE BE CAREFUL OF HIGH PRESSURE AND HIGH TEMPERATURE HYDRAULIC OIL • Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the filter when the oil is hot as hot oil may spurt out and cause burns. •...
  • Page 42 1.4. SAFETY IN PERIODIC MAINTENANCE AVOID THE DANGER OF GETTING CAUGHT UP OR FALLING OFF • Never put your hands or feet into the mast structure. There is danger that you will get caught in moving parts and be seriously injured. •...
  • Page 43 1.4. SAFETY IN PERIODIC MAINTENANCE JACKING-UP THE LIFT TRUCK FOR INSPECTION AND REPLACEMENT OF TIRES • Do not go under the forklift truck when it is jacked up. • Check the following before jacking up the lift truck. • Check that there is no one on the lift truck. Check that there is no load on the forks.
  • Page 44 1.4. SAFETY IN PERIODIC MAINTENANCE SAFE HANDLING OF BATTERIES • Battery electrolyte contains sulfuric acid, and can quickly burn the skin and eat holes in clothing. If you spill battery electrolyte on yourself, immediately shed the clothes, flush the part with a large quantity of tap water and then consult a doctor.
  • Page 45 Never lift the truck by the overhead guard. If the truck has to be lifted frequently, it is necessary to install special lifting equipment, so please contact your Komatsu Forklift dealer. • Fit wire ropes to the specified lifting points.
  • Page 46 1.6. STRUCTURE AND STABILITY OF THE LIFT TRUCK 1.6. To operate the lift truck safely, it is important to understand the structure and stability of the lift truck. STRUCTURE AND STABILITY OF THE LIFT TRUCK This section will educate the operator in methods to prevent tipping-over the lift truck. STRUCTURE OF LIFT TRUCK Forklift trucks basically consist of a lifting mechanism (fork and mast) and a main body (vehicle).
  • Page 47 Even when the load center is shorter than 500 mm, the actual capacity is 2,500 kg (2). It is required to replace the present nameplate with a new one when the present nameplate is broken or has become difficult to read. In that case, call your Komatsu Forklift dealer asking for a new replacement nameplate. 1-27...
  • Page 48 1.6. STRUCTURE AND STABILITY OF THE LIFT TRUCK SPEED AND ACCELERATION If a stationary object is not subjected to external force, it will remain stationary. In the same way, if a moving object is not subjected to external force, it will continue to move at the same speed. This is called inertia. Because of inertia, a force is applied towards the rear when the lift truck starts to move, and is applied towards the front when the lift truck stops.
  • Page 49 1.7. SAFETY LABELS 1.7. Keep safety and other labels clean. If a label comes off, stick it on again or replace with a new one. SAFETY LABELS Overhead guard On dash to right On engine inside right Overhead guard of steering column inside left Right side Inside rear...
  • Page 50 1.7. SAFETY LABELS 1. Jump start prohibited. Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuit- ing the engine starting circuit. Such an act may cause serious bodily injury or fire. 2.
  • Page 51 1.7. SAFETY LABELS 4. Seating capacity – One No passengers allowed. 5. Prohibit the operator from standing on the forks. Never enter the area under the forks. WARNING 3EB-96-A5920 6. Use caution to avoid getting hand caught in fan (not shown). 7.
  • Page 52 1.7. SAFETY LABELS 8. Caution before operating machine. 9. Warning for operation. WARNING SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS! B e f o r e O p e r a t i n g •...
  • Page 53 1.7. SAFETY LABELS 10. Warning for use of split rim (pneumatic tires only). 11. Replace overhead guard if damaged. REPLACE IF DAMAGED! WARNING This overhead guard offers reasonable protection to operator from falling objects but cannot protect against every possible impact. Impact test rating: 16000 foot pounds.
  • Page 54 1.7. SAFETY LABELS 14. Slide seat forward prior to opening bonnet. 15. Fuel type. EPA REGULATION GASOLINE FUEL USE LOW SULFUR 37 B - 1QA - 3 010 37B -1 QB - 3010 FUEL OR ULTRA LOW SULFUR FUEL ONLY 3EB-96-A7910 SAFETY LABEL ORDERING INFORMATION Use the chart below to order the safety labels described above.
  • Page 55 Various safety devices a re available as options. If operating conditions demand it, please install these devices. The OPTIONAL EQUIPMENT devices listed below are only examples. Various other devices are also available. For details, please contact your Komatsu Forklift dealer. 1.8.1 REAR LAMP Install this when carrying out operations at night which require the rear area to be lighted.

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