Komatsu FG40ZT-8 User Manual

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.
WARNING
SERVICE MANUAL
CX Forklift Truck
Federal Environmental Protection Agency (EPA) Emission-Control Compliant
S/N 130001A~
CX20
ISSUED: APRIL 2008
SM202
Gasoline & LP FG35/45ST-8
FG40/45T(2)-8
FG35/45BCS-8
FG50AT2-8
FG40ZT(2)-8
Diesel FD40/45T(2)-8
FD50AT2-8
FD40ZT(2)-8
Komatsu Forklift USA, Inc.

Komatsu FG40ZT-8 Specifications

General

Model	FG40ZT-8
Category	Forklifts
Load Capacity	4000 kg
Power Source	Diesel
Lift Height	3000 mm
Tire Type	Pneumatic
Engine Power	55 kW
Transmission	Automatic
Overall Height	2200 mm
Load Center	500 mm

Summary

1. SAFETY

1.1. SAFETY MANAGEMENT

Guidelines for safe operation, inspection, and maintenance of the lift truck.

1.2. SAFE TRAVEL

Procedures and warnings for safe operation of the lift truck during travel.

1.3. LOADING OPERATIONS

Safety precautions for loading and unloading operations with the lift truck.

1.4. SAFETY IN PERIODIC MAINTENANCE

Safety precautions and procedures for performing periodic maintenance on the lift truck.

1.5. TOWING

3. SERVICE DATA

4. TESTING, ADJUSTING AND MEASURING

4.1. CHECK ENGINE OIL (TB45E)

4.2 ADJUST ENGINE OIL LEVEL

4.3 ADJUST IGNITION TIMING (TB45E)

4.4 ADJUST SPARK PLUG GAP (TB45E)

5. INSPECTION

6. MAINTENANCE OPERATIONS

6.4. CHANGE OIL AND FILTER IN GASOLINE ENGINES

7. REMOVAL, DISASSEMBLY, ASSEMBLY, INSTALLATION

7.1. MAST

7.2. ENGINE

7.3. TRANSMISSION AND DRIVE AXLE

7.4. TORQUE CONVERTER/TRANSMISSION CONTROL VALVE - PNEUMATIC TRUCKS

8. TROUBLESHOOTING

8.1. ENGINE TROUBLESHOOTING CHART

Chart for troubleshooting engine-related issues on the lift truck.

8.2. TORQFLOW TROUBLESHOOTING CHART

Chart for troubleshooting Torqflow transmission issues.

8.3. TORQUE CONVERTER TROUBLESHOOTING CHART - CUSHION TRUCKS

Chart for troubleshooting torque converter issues on cushion trucks.

8.4. TORQUE CONVERTER TROUBLESHOOTING CHART - PNEUMATIC TRUCKS

Chart for troubleshooting torque converter issues on pneumatic trucks.

FEDERAL EPA EMISSION CONTROL STATEMENT

2. WARRANTY

YOUR WARRANTY RIGHTS AND OBLIGATIONS

Explanation of warranty rights and obligations for diesel engines.

MANUFACTURER'S WARRANTY COVERAGE

Details on the warranty coverage period for emission-related parts.

FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD DIESEL ENGINES (S6D102E ENGINES)

1. LABELS REQUIRED AND LABEL LOCATIONS

Details on required emission control labels and their locations on S6D102E diesel engines.

CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEMS WARRANTY