Komatsu published shop manual SM043 ZC(KFM)-BE2 for its 40 and 45 series forklifts, and this 234-page shop manual PDF reproduces it across eight variants, from the FD40Z-5 and FG40Z-5 through the FG35S/45S-6. Power train work takes up the largest share of the book: clutch, torque converter, transmission and drive axle, while hydraulic schematics trace oil from the pump and flow divider through the steering valve, brake valve, and lift and tilt cylinders. Troubleshooting tables for the Torqflow system, brakes and hydraulics sit next to testing and adjusting procedures for your work equipment, steering and drive systems. Hold hydraulic circuit filtration to 20 μ and torque the drive axle cap bolts to 137 to 196 Nm. Pulling a power train out of a lift truck is slow, heavy work. Bookmarks and a searchable text layer get you to the right page quickly, and the serial number section confirms your variant so the part you order fits the first time.
What's Inside This Komatsu FD40Z-5 to FG45S-6 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 11-22 | General Locations, Machine Serial Number, Weight of Main Components, Standard Tightening Torque, Precautions for Maintenance |
| Removal and Installation of Unit | 23-58 | Structure, Flow Chart, Mast, Power Train, Engine, Muffler, Wheel Brake, Steering Axle |
| Power Train | 59-128 | Clutch, Transmission, Torque Converter, Drive Axle, Differential, Front/Rear Wheels |
| Steering System | 129-148 | Steering Valve, Hydraulic Circuit, Flow Divider, Power Steering Cylinder, Steering Axle |
| Brake System | 149-169 | Hydraulic Circuit, Brake Valve, Clutch System, Wheel Brake, Air Bleeding, Parking Brake |
| Hydraulic System | 170-186 | Hydraulic Circuit, Control Valve, Hydraulic Pump, Lift Cylinder, Tilt Cylinder |
| Mast | 187-194 | Mast Introduction, Mast Rail Lubrication, Roller Adjustment, Fork Carriage |
| Troubleshooting | 195-206 | Engine, Electrical System, Clutch and Clutch Transmission, Torqflow System, Brake System, Hydraulic System |
| Testing and Adjusting | 207-224 | Engine, Drive System, Travel System, Steering System, Brake System, Work Equipment System |
| Conversion Table | 225-234 | Length Conversion, Volume Conversion, Weight Conversion, Pressure Conversion, Torque Conversion, Temperature Conversion |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Standard tightening torque for bolts (Torque wrenches) | 6mm: 1.2-1.5 kgm, 8mm: 2.8-3.5 kgm, 10mm: 6-7.5 kgm, 12mm: 10-12.5 kgm, 14mm: 16-20.0 kgm, 16mm: 25-31.5 kgm, 18mm: 35-43.5 kgm, 20mm: 50-62.0 kgm, 22mm: 67.5-84.5 kgm, 24mm: 84-105 kgm, 27mm: 120-150 kgm, 30mm: 155-195 kgm, 33mm: 200-250 kgm, 36mm: 250-310 kgm, 39mm: 295-370 kgm | p. 16 |
| Drive axle cap bolt torque | 137 - 196 Nm | p. 57 |
| Hydraulic circuit filtration | 20 μ | p. 171 |
| Distance to insert radiator hose | 40 mm (1.6 in) | p. 41 |
| Standard Tightening Torque (M6 bolt, S43C) | 1.2 kgm (12 Nm) | p. 16 |
| Standard Tightening Torque (M39 bolt, S43C) | 300 kgm (2942 Nm) | p. 16 |
| Brake System Oil Pressure | 62 kg/cm² (61 bar, 882 psi) | p. 130 |
| 6D95L, P40 and TB42 | ||
| Distance to insert air cleaner hose | 25 mm (0.98 in) | p. 43 |
| P40 | ||
| Engine oil capacity (P40) | 5.5 L | p. 40 |
| TB42 | ||
| Engine oil capacity (TB42) | 8.5 L | p. 212 |
| 6D95L | ||
| Engine Oil Capacity (6D95L) | 11 L (2.9 gal US) | p. 212 |
| Compact wheel base chassis | ||
| Lift Cylinder Bore (Compact wheel base chassis) | 31.75 mm (1.25 in) | p. 164 |
Komatsu FD40Z-5 to FG45S-6 Series Common Problems This Manual Covers
Komatsu FD40/45 FG40/45 oil pressure caution lamp stays lit after the engine starts and runs
Check the oil level in the oil pan first and add oil if it is low, following the engine chart on page 196. If the level is good, replace the oil filter element, since a clogged element will keep the lamp lit. Then inspect every oil pipe joint for looseness, wear or weeping oil and repair it.
Manual Section: Engine Troubleshooting p. 196Radiator pressure valve spouts steam and water temp gauge reads in the right black range
Check the coolant level and look for water leaks, then adjust a loose fan belt, per the engine chart on page 196. Clean clogged or damaged radiator fins, retighten the radiator filler cap or replace its packing, and replace a faulty thermostat. If dust and scale have built up, change the water and clean the cooling system interior.
Manual Section: Engine Troubleshooting p. 196Starting motor cranks slowly or comes to a stop before the engine starts
Check battery voltage and recharge the battery first, because the electrical chart on page 197 traces slow cranking and early stalls of the starting motor to insufficient battery voltage. Next, check the starter circuit for faulty wiring, loose terminals and disconnected wires and repair them. If the battery is up and the wiring is sound, replace the starting motor.
Manual Section: Electrical System Troubleshooting p. 197TORQFLOW torque converter and transmission show low output power and low oil pressure
Check the transmission oil level and add oil; capacity is 14.5 L (3.8 gal US) per page 94. Check inlet joints and pipes for sucked air, replace a clogged oil filter, check oil pressure following page 200 (a worn pump or fatigued regulator valve spring drops it), and adjust the inching rod.
Manual Section: TORQFLOW System Troubleshooting p. 200Service brake pedal travels too far and braking force feels insufficient when stopping
Adjust the brake first, then check the hydraulic lines for oil leaks and lack of oil and repair or top up, following the brake chart on page 205. If the line is sucking air, bleed the air from the system. Clean linings soiled with water or oil, and replace worn linings or repair or replace a malfunctioning wheel cylinder.
Manual Section: Brake System Troubleshooting p. 205Brakes drag and trail after release, or the parking brake fails to return
Check brake pedal play first and adjust it if there is none, following the brake chart on page 204. Repair or adjust a parking brake that fails to return, then confirm operating force is 20 to 30 kg (196 to 294 N) per page 169. Clean a clogged brake valve return port and replace fatigued return springs.
Manual Section: Brake System Troubleshooting p. 204Frequently Asked Questions
What causes a Komatsu FG40Z-5 forklift not to start?
If the engine fails to start, check for lack of fuel, air mixed in the fuel system, or a defective fuel injection pump or nozzle. Also, ensure the starting motor is not rotating slowly, which may indicate an electrical system issue, and check that the valve clearance is properly adjusted. p. 196
How do you troubleshoot hydraulic lift problems on a Komatsu FD40-5?
If the fork lowering speed is too large, check for a defective seal inside the control valve, oil leaks from joints or hoses, a defective cylinder seal, or a defective down control valve. If the fork lifting is slow, check for lack of hydraulic oil, air in the system, or excessive restriction on the pump suction side. p. 206
What is the standard torque for 6D95L engine mounting bracket bolts on a Komatsu FD40Z-5 to FG45S-6 Series?
The standard tightening torque for the engine mounting bracket bolts on a 6D95L engine is 6.5 to 7.5 kgm (64 to 74 Nm or 47 to 54 ft.lb). p. 39
How do I adjust the valve clearance on the 6D95L engine in the Komatsu FD40Z-5 to FG45S-6 Series forklift?
The valve clearance for a 6D95L engine should be adjusted when the engine is cold. The specified clearance is 0.35 mm for intake and 0.50 mm for exhaust (0.014/0.020 in). p. 209
What is the TORQFLOW transmission oil capacity for the FD40Z/FD45 on the Komatsu FD40Z-5 to FG45S-6 Series forklift?
The oil capacity for the T1 TORQFLOW transmission on an FD40Z/FD45 model is 14.5 liters (3.8 gal US). p. 94
Will this Komatsu FD40Z-5 Shop Manual download right away?
You get a 234-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Can I print pages of this Komatsu FD40Z-5 manual for my own shop?
Yes. Print individual pages or full chapters for your own shop use, on letter or A4 paper.
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