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 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 |
