Komatsu CX20 Forklift Service Manual (EN)

SM202 SERVICE MANUAL CX Forklift Truck Federal Environmental Protection Agency (EPA) Emission-Control Compliant S/N 130001A~ Gasoline & LP FG35/45ST-8 FG40/45T(2)-8 FG35/45BCS-8 FG50AT2-8 FG40ZT(2)-8 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.

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The information and specifications contained herein were accurate at the time of publication, but may change without notice as required for product improvements. 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. Requests for information, comments and other inquiries should be sent to: Komatsu Forklift USA, Inc. 14481 Lochridge Blvd., Bldg. #2 Covington, Georgia 30014-4908 Voice phone: (770) 385-4815 Fax phone: (770) 385-4838 © Copyright 2008, Komatsu Forklift USA, Inc. All rights reserved.

No part of this document may be photocopied or reproduced in any way without prior written consent of Komatsu Forklift USA, Inc.

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INTRODUCTION

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- ence is made to maintenance procedures necessary to perform servicing of this vehicle, you should refer to the applicable Operation and Maintenance Manual for these lift trucks for more complete maintenance information.

Komatsu is involved in a concentrated and highly technical program of designing and developing cleaner burning, more efficient and more powerful engines for use in the industrial truck market. As a result, new computerized sensors, systems and diagnostic monitors have been created to make the job of maintaining and repairing these systems simple and easy. Read this manual carefully, refer to it often and learn the repair, testing and adjustment procedures to the best of your ability. Please note that some illustrations are generic and may not look exactly like your unit in every detail. Ensure that, when you are working on or around industrial trucks, Safety is priority Number One .

Read, understand and obey all WARNINGS and CAUTIONS . Follow the instructions and procedures presented in this manual when working on these lift trucks and their systems. Damage to the equipment, and possible injury to yourself or others, may result if these procedures are not adhered to carefully. Keep this manual nearby and accessible for use when necessary. If this book becomes dirty, worn or illegible, contact Komatsu for a replacement. The procedures outlined in this manual will be updated periodically. Be sure that you have the latest revision in order to learn the newest information available. Revision dates will be clearly displayed on the lower left hand corner of the cover page.

This will aid in maintaining your equipment in excellent condition and in ensuring that these lift trucks will operate safely at maximum efficiency. 3

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ENGINE SERIAL NUMBER LOCATION

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. The S6D102E series engine serial number is stamped on the left side of the engine to the left of the oil filter. NOTICE For EPA TB45E(D)(G)(L) engine-related troubleshooting, refer to the following manual: • TM100 - “EPA Engine Training Manual” NOTICE For EPA S6D102E engine-related troubleshooting, refer to the following manual: • SM140 - “S6D102E Service Manual” 4

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