Komatsu FG10, FG15, FG18, FG15H, FG18H Shop Manual

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SHOP MANUAL AX50/BX50 Series

BEB16E1-02

FG10/15/18 FG15H/18H FD10/15/18 FG20/25/30 FG20H/25H FG20N/25N/30N FG35A

-16

-20

-16

Printed in Japan

01-05(YC)01001

FD20/25/30 FD20H/25H/30H FD20N/25N/30N FD35A

-16

FG10/15/18

-20

FG15H/18H FD10/15/18 FG20/25/30 FG20H/25H/ FG20N/25N/30N FG35A

-16

FD20/25/30

-20

-16

FD20H/25H/30H FD20N/25N/30N FD35A

-16

PRECAUTIONS WHEN PERFORMING THE SERVICE WORK

Always pay attention to “Safety” before starting any work — this is important.

Never attempt any work where danger to yourself or to other persons.

Whenever work requiring safety precautions are described in this manual, a flag mark

inserted, always make double sure that safety measures are taken.

Other unmarked work, should always be performed after studying and using your

common sense to prevent accidents.

DESCRIPTION OF THE SYMBOLS

The symbols described below are used in this manual for convenience and better understanding.

Symbol Item Description

Safety Special safety precautions are needed to perform the work.

Note Special technical precautions are needed to perform the work

Tightening torque Fastening parts that require specified tightening force when assembling.

Weight Weight of parts or systems

Coat Places to be coated with adhesives, etc. when assembling

00-2 AX50/BX50 Series

SECTION INDEX

00. FOREWORD

10. GENERAL AND SPECIFICATIONS

20. INSOECTION AND ADJUSTMENT

30. REMOVAL AND INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

80. CRITERIA FOR PERIODICAL INSPECTION AND JUDGMENT

90. CONVERSION TABLE

AX50/BX50 Series 00-3

10. GENERAL AND SPECIFICATIONS

SPECIFICATIONS .....................................................10-2

PERIODIC REPLACEMENT OF

CONSUMABLE PARTS ..........................................10-12

SAFETY ITEMS FOR MAINTENANCE ...................10-13

STANDARD TIGHTENING TORQUE

FOR BOLTS.............................................................10-21

STANDARD TIGHTENING TORQUE

FOR PIPE JOINTS .................................................10-22

AX50/BX50 Series 10-1

SPECIFICATIONS

GENERAL AND SPECIFICATIONS

SPECIFICATIONS

AX50 (1.0 - 1.8ton) Series

1.2 Model Manufacturer's Designation FG10T-20 FG10C-20 FD10T-20 FD10C-20

1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 1000 1000

1.6 Load Center Rated Load Center mm 500 500

1.6.1 Alternative Capacity Capacity@600mm Load Center kg 910 910

Characteristics

1.8 Load Distance Front Axle Center to Fork Face mm L2 400 400

1.9 Wheelbase mm L3 1400 1400

2.1 Service Weight kg 2080 2095 2180 2195

2.2

2.2.1 Rear kg 355 360 420 430

Weight

Tyres

Dimensions

Performance

I.C Engine

Others

Axle Loading

2.3

2.3.1 Rear kg 1015 1020 1085 1090

3.1 Tyre Type Pneumatic Pneumatic

3.2 Tyre Size Front 6.50-10-10PR(I) 6.50-10-10PR(I)

3.3 Rear 5.00- 8- 8PR(I) 5.00-8-8PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2

3.6 Tread, Front mm b4 890 890

3.7 Tread, Rear mm b3 895 895

4.1 Tilting Angle Forward/Backward

4.2 Mast Height, Lowered 2-stage Mast mm h2 1995 1995

4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 135 135

4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000

4.5 Mast Height, Extended 2-stage Std. Mast mm h3 3955 3955

4.7 Height, Overhead Guard mm h4 2030 2030

4.19 Length, with Std. Forks mm L1 2965 2965

4.20 Length, to Fork Face mm 2195 2195

4.21 Width, at Tyre Single mm b1 1070 1070

4.22 Forks Thickness x Width x Length mm 31x100x770 31x100x770

4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2 Class 2

4.24 Width, Fork Carriage mm 970 970

4.31 Ground Clearance

4.32 at Center of Wheelbase mm 130 130

4.33 Right Angle Stacking Aisle

4.34 with L1200 x W800 pallet mm 3515 3515

4.35 Turning Radius mm Wa 1915 1915

5.1 Travel Speed (FWD)

5.2 Lifting Speed

5.3 Lowering Speed

5.6 Max. Drawbar Pull Loaded KN 10 11 13 14

5.8 Max. Gradeability Loaded % 34 38 49 41

5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic

5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical

5.12 Steering Type FHPS FHPS

6.4 Battery Voltage/ Capacity at 5-hour rating V/ah

7.1 Maker Model NISSAN K15 Komatsu 4D92E

7.2 Rated Output, SAE gross KW 27@2500 35@2450

7.3 Rated RPM min-1 2500 2450

7.3.1 Max. Torque, SAE gross

7.4 No. of Cylinder/Displacement

7.6 Fuel Tank Capacity Ltr 40 40

8.2 Relief Pressure for Attachment bar 172 172

8.7 Transmission

Loaded

Unloaded

Under Mast mm 120 120

with L1000 x W1200 pallet mm 3315 3315

L o ad e d , 1 s t / 2n d km / h 1 9 . 0 9 .0 / 1 9 . 0 19 . 0 8 . 5 / 19 . 0 Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.5 8.5/19.5 Loaded mm/s 580 620 Unloaded mm/s 640 670 Loaded mm/s 500 500 Unloaded mm/s 550 550

Front kg 2725 2735 2760 2765

Front kg 1065 1075 1095 1105

*/2 2*/2

degree

Nm@min-1

cm3

6/10 6/10

12/33 12/64

113@1600 142@1800

4-1486 4-2659

TORQFLOW

Manual

TORQFLOW

Manual

10-2 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

SPECIFICATIONS

FG15T-20 FG15C-20 FD15T-20 FD15C-20

Gasoline Diesel Gasoline Gasoline Diesel Gasoline

Sitting Sitting Sitting Sitting Sitting Sitting

1500 1500 1500 1750 1750 1750

500 500 500 500 500 500

1360 1360 1360 1590 1590 1590

405 405 405 405 405 405

1400 1400 1400 1400 1400 1400 2450 2465 2550 2565 2450 2465 2645 2660 2745 2760 2645 2660 3500 3510 3530 3540 3500 3510 3870 3880 3900 3910 3870 3880

450 455 520 525 450 455 525 530 595 600 525 530 1005 1015 1035 1045 1005 1015 960 970 990 1000 960 970 1445 1450 1515 1520 1445 1450 1685 1690 1755 1760 1685 1690

Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic

6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I)

5.00- 8- 8PR(I) 5.00-8-8PR(I) 5.00- 8- 8PR(I) 5.00- 8- 8PR(I) 5.00-8-8PR(I) 5.00- 8- 8PR(I) 2

*/2 2*/2 2*/2 2*/2 2*/2 2* /2

890 890 890 890 890 890 895 895 895 895 895 895

6/10 6/10 6/10 6/10 6/10 6/10

1995 1995 1995 1995 1995 1995

140 140 140 140 140 140 3000 3000 3000 3000 3000 3000 3955 3955 3955 3955 3955 3955 2030 2030 2030 2030 2030 2030 3160 3160 3160 3200 3200 3200 2240 2240 2240 2280 2280 2280 1070 1070 1070 1070 1070 1070

35x100x920 35x100x920 35x100x920 35x100x920 35x100x920 35x100x920

Class 2 Class 2 Class 2 Class 2 Class 2 Class 2

970 970 970 970 970 970

120 120 120 120 120 120

130 130 130 130 130 130 3360 3360 3360 3395 3395 3395 3560 3560 3560 3595 3595 3595 1955 1955 1955 1990 1990 1990

18.5 8.5/18.5 18.5 8.5/19.0 18.5 8.5/18.5 18.5 8.5/18.5 18.5 8.5/18.5 18.5 8.5/18.5

19.0 9.0/19.0 19.0 8.5/19.5 19.0 9.0/19.0 19.0 9.0/19.0 19.0 8.5/19.0 19.0 9.0/19.0 570 620 590 570 620 590 640 670 640 640 670 640 500 500 500 500 500 500 550 550 550 550 550 550

10 11 13 14 15 14 10 11 13 14 15 14 26 27 33 31 37 35 25 24 29 28 33 32 Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic

Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical

FHPS FHPS FHPS FHPS FHPS FHPS

12/33 12/64 12/33 12/33 12/64 12/33

NISSAN K15 Komatsu 4D92E NISSAN K21 NISSAN K15 Komatsu 4D92E NISSAN K21

27@2500 35@2450 35@2450 27@2500 35@2450 35@2450

2500 2450 2450 2500 2450 2450

113@1600 142@1800 152@1600 113@1600 142@1800 152@1600

4-1486 4-2659 4-2065 4-1486 4-2659 4-2065

40 40 40 40 40 40

172 172 172 172 172 172

TORQFLOW

Manual

TORQFLOW

Manual

FG15HT-20

TORQFLOW

FG15HC-20

Manual

FG18T-20 FG18C-20 FD18T-20 FD18C-20

TORQFLOW

Manual

TORQFLOW

Manual

FG18HT-20

TORQFLOW

FG18HC-20

Manual

AX50/BX50 Series 10-3

SPECIFICATIONS

GENERAL AND SPECIFICATIONS

BX50 (2.0 - 2.5ton) Series

1.2 Model Manufacturer's Designation FG20T-16 FG20C-16 FD20T-16 FD20C-16

1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 2000 2000

1.6 Load Center Rated Load Center mm 500 500

1.6.1 Alternative Capacity Capacity@600mm Load Center kg 1810 1810

Characteristics

1.8 Load Distance Front Axle Center to Fork Face mm L2 460 460

1.9 Wheelbase mm L3 1650 1650

2.1 Service Weight kg 3220 3230 3310 3330

2.2

2.2.1 Rear kg 550 550 610 610

Weight

Tyres

Dimensions

Performance

I.C Engine

Others

Axle Loading

2.3

2.3.1 Rear kg 1740 1750 1800 1810

3.1 Tyre Type Pneumatic Pneumatic

3.2 Tyre Size Front 7.00-12-12PR(I) 7.00-12-12PR(I)

3.3 Rear 6.00-09-10PR(I) 6.00-09-10PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2

3.6 Tread, Front mm b4 965 965

3.7 Tread, Rear mm b3 960 960

4.1 Tilting Angle Forward/Backward

4.2 Mast Height, Lowered 2-stage Mast mm h2 1995 1995

4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 150 150

4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000

4.5 Mast Height, Extended 2-stage Std. Mast mm h3 4050 4050

4.7 Height, Overhead Guard mm h4 2070 2070

4.19 Length, with Std. Forks mm L1 3450 3450

4.20 Length, to Fork Face mm 2530 2530

4.21 Width, at Tyre Single mm b1 1150 1150

4.22 Forks Thickness x Width x Length mm 36x122x920 36x122x920

4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2 Class 2

4.24 Width, Fork Carriage mm 1020 1020

4.31 Ground Clearance

4.32 at Center of Wheelbase mm 160 160

4.33 Right Angle Stacking Aisle

4.34 with L1200 x W800 pallet mm 3850 3850

4.35 Turning Radius mm Wa 2190 2190

5.1 Travel Speed (FWD)

5.2 Lifting Speed

5.3 Lowering Speed

5.6 Max. Drawbar Pull Loaded KN 14 14 18 17

5.8 Max. Gradeability Loaded % 28 27 36 34

5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic

5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical

5.12 Steering Type FHPS FHPS

6.4 Battery Voltage/ Capacity at 5-hour rating V/ah

7.1 Maker Model NISSAN K21 Komatsu 4D94LE

7.2 Rated Output, SAE gross KW 35@2450 46@2450

7.3 Rated RPM min-1 2450 2450

7.3.1 Max. Torque, SAE gross

7.4 No. of Cylinder/Displacement

7.6 Fuel Tank Capacity Ltr 58 58

8.2 Relief Pressure for Attachment bar 181 181

8.7 Transmission

Loaded

Unloaded

Under Mast mm 115 115

with L1000 x W1200 pallet mm 3650 3650

L o ad e d , 1 s t / 2n d km / h 1 8 . 5 8 .5 / 1 8 . 5 18 . 5 8 . 5 / 18 . 5 Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0 Loaded mm/s 545 630 Unloaded mm/s 600 685 Loaded mm/s 450 450 Unloaded mm/s 500 500

Front kg 4670 4680 4700 4720

Front kg 1480 1480 1510 1520

*/2 2*/2

degree

Nm@min-1

cm3

6/12 6/12

12/33 12/64

152@1600 186@1800

4-2065 4-3052

TORQFLOW

Manual

TORQFLOW

Manual

10-4 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

SPECIFICATIONS

FG20HT-16 FD20HT-16 FD20HC-16

Gasoline Diesel Gasoline Diesel Gasoline Diesel

Sitting Sitting Sitting Sitting Sitting Sitting

2000 2000 2500 2500 2500 2500

500 500 500 500 500 500

1810 1810 2270 2270 2270 2270

460 460 465 465 465 465 1650 1650 1650 1650 1650 1650 3220 3310 3330 3590 3600 3680 3700 3590 3680 3700 4670 4700 4720 5420 5430 5460 5470 5420 5460 5470

550 610 610 670 670 720 730 670 720 730 1480 1510 1520 1430 1430 1460 1470 1430 1460 1470 1740 1800 1810 2160 2170 2220 2230 2160 2220 2230

Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic

7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I)

6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I) 2*/2 2

965 965 965 965 965 965 960 960 960 960 960 960

6/12 6/12 6/12 6/12 6/12 6/12

1995 1995 1995 1995 1995 1995

150 150 155 155 155 155 3000 3000 3000 3000 3000 3000 4050 4050 4050 4050 4050 4050 2070 2070 2070 2070 2070 2070 3450 3450 3655 3655 3655 3655 2530 2530 2585 2585 2585 2585 1150 1150 1150 1150 1150 1150

36x122x920 36x122x920 40x122x1070 40x122x1070 40x122x1070 40x122x1070

Class 2 Class 2 Class 2 Class 2 Class 2 Class 2

1020 1020 1020 1020 1020 1020

115 115 115 115 115 115

160 160 160 160 160 160 3650 3650 3775 3775 3775 3775 3850 3850 3905 3905 3905 3905 2190 2190 2240 2240 2240 2240

19.0 18.5 8.0/18.5 18.5 8.5/18.5 18.5 8.5/18.5 19.0 18.5 8.0/18.5

19.5 19.0 8.5/19.0 19.0 9.0/19.0 19.0 8.5/19.0 19.5 19.0 8.5/19.0 620 660 545 630 620 660 670 710 600 685 670 710 450 450 450 450 450 450 500 500 500 500 500 500

19 22 21 14 14 18 17 19 22 21 38 45 44 23 22 31 29 32 37 37

Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic

Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical

FHPS FHPS FHPS FHPS FHPS FHPS

12/33 12/64 12/33 12/64 12/33 12/64

NISSAN K25 Komatsu 4D98E NISSAN K21 Komatsu 4D94LE NISSAN K25 Komatsu 4D98E

43@2400 53@2400 35@2450 46@2450 43@2400 53@2400

2400 2400 2450 2450 2400 2400

186@1600 216@1700 152@1600 186@1800 186@1600 216@1700

4-2488 4-3318 4-2065 4-3052 4-2488 4-3318

58 58 58 58 58 58

181 181 181 181 181 181

TORQFLOW

*/2 2*/2 2*/2 2*/2 2*/2

Manual

FG25T-16 FG25C-16 FD25T-16 FD25C-16

TORQFLOW

Manual

TORQFLOW

Manual TORQFLOW

FG25HT-16 FD25HT-16 FD25HC-16

TORQFLOW

Manual

AX50/BX50 Series 10-5

SPECIFICATIONS

GENERAL AND SPECIFICATIONS

BX50 (3.0 - 3.5ton) Series

1.2 Model Manufacturer's Designation FG30T-16 FG30C-16 FD30T-16 FD30C-16

1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 3000 3000

1.6 Load Center Rated Load Center mm 500 500

1.6.1 Alternative Capacity Capacity@600mm Load Center kg 2720 2720

Characteristics

1.8 Load Distance Front Axle Center to Fork Face mm L2 490 490

1.9 Wheelbase mm L3 1700 1700

2.1 Service Weight kg 4210 4230 4310 4320

2.2

2.2.1 Rear kg 820 830 880 880

Weight

Tyres

Dimensions

Performance

I.C Engine

Others

Axle Loading

2.3

2.3.1 Rear kg 2610 2620 2670 2670

3.1 Tyre Type Pneumatic Pneumatic

3.2 Tyre Size Front 28x9-15-12PR(I) 28x9-15-12PR(I)

3.3 Rear 6.50-10-10PR(I) 6.50-10-10PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2

3.6 Tread, Front mm b4 1005 1005

3.7 Tread, Rear mm b3 965 965

4.1 Tilting Angle Forward/Backward

4.2 Mast Height, Lowered 2-stage Mast mm h2 2070 2070

4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 160 160

4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000

4.5 Mast Height, Extended 2-stage Std. Mast mm h3 4275 4275

4.7 Height, Overhead Guard mm h4 2090 2090

4.19 Length, with Std. Forks mm L1 3775 3775

4.20 Length, to Fork Face mm 2705 2705

4.21 Width, at Tyre Single mm b1 1235 1235

4.22 Forks Thickness x Width x Length mm 44x122x1070 44x122x1070

4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 3 Class 3

4.24 Width, Fork Carriage mm 1060 1060

4.31 Ground Clearance

4.32 at Center of Wheelbase mm 185 185

4.33 Right Angle Stacking Aisle

4.34 with L1200 x W800 pallet mm 4060 4060

4.35 Turning Radius mm Wa 2370 2370

5.1 Travel Speed (FWD)

5.2 Lifting Speed

5.3 Lowering Speed

5.6 Max. Drawbar Pull Loaded KN 18 18 18 17

5.8 Max. Gradeability Loaded % 26 25 25 23

5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic

5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical

5.12 Steering Type FHPS FHPS

6.4 Battery Voltage/ Capacity at 5-hour rating V/ah

7.1 Maker Model NISSAN K25 Komatsu 4D94LE

7.2 Rated Output, SAE gross KW 43@2400 46@2450

7.3 Rated RPM min-1 2400 2450

7.3.1 Max. Torque, SAE gross

7.4 No. of Cylinder/Displacement

7.6 Fuel Tank Capacity Ltr 58 58

8.2 Relief Pressure for Attachment bar 181 181

8.7 Transmission

Loaded

Unloaded

Under Mast mm 135 135

with L1000 x W1200 pallet mm 3930 3930

L o ad e d , 1 s t / 2n d km / h 1 8 . 5 8 .5 / 1 8 . 5 19 . 0 8 . 5 / 18 . 5 Unloaded, 1st/2nd km/h 19.5 9.0/19.5 19.5 9.0/19.0 Loaded mm/s 450 520 Unloaded mm/s 500 555 Loaded mm/s 400 420 Unloaded mm/s 500 500

Front kg 6390 6400 6430 6440

Front kg 1600 1610 1640 1650

*/2 2*/2

degree

Nm@min-1

cm3

6/12 6/12

12/33 12/64

186@1600 186@1800

4-2488 4-3052

TORQFLOW

Manual

TORQFLOW

Manual

10-6 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

SPECIFICATIONS

FD30HT-16 FD30HC-16

4310 4320 4910 5010 6430 6440 7440 7480

1640 1650 1820 1860 2670 2670 3090 3150

TORQFLOW Manual TORQFLOW TORQFLOW

Diesel Gasoline Diesel Sitting Sitting Sitting

3000 3500 3500

500 500 500

2720 3180 3180

490 505 505

1700 1700 1700

880 880 970 1030

Pneumatic Pneumatic Pneumatic

28x9-15-12PR(I) 250-15-16PR(I) 250-15-16PR(I)

6.50x10-10PR(I) 6.50x10-12PR(I) 6.50x10-12PR(I) 2

*/2 2*/2 2*/2

1005 1060 1060

965 965 965

6/12 6/12 6/12

2070 2100 2100

160 145 145 3000 3000 3000 4275 4280 4280 2090 2105 2105 3775 3865 3865 2705 2795 2795 1235 1290 1290

44x122x1070 50x150x1070 50x150x1070

Class 3 Class 3 Class 3

1060 1060 1060

135 135 135

185 185 185 3930 4055 4055 4060 4185 4185

18.5 8.0/18.5 18.0 18.0

19.0 8.5/19.0 19.0 19.0

2370 2480 2480

550 410 450

595 450 490

420 400 420

500 400 400

21 21 16 20 30 30 20 26

Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic

Hand/Mechanical Hand/Mechanical Hand/Mechanical

FHPS FHPS FHPS

12/64 12/33 12/64

Komatsu 4D98E NISSAN K25 Komatsu 4D98E

53@2400 43@2400 53@2400

2400 2400 2400

216@1700 186@1600 216@1700

4-3318 4-2488 4-3318

58 58 58

181 181 181

FG35A-16 FD35A-16

AX50/BX50 Series 10-7

SPECIFICATIONS

GENERAL AND SPECIFICATIONS

109 Series

1.2 Model Manufacturer's Designation FG20NT-16 FD20NT-16

1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 2000 2000

1.6 Load Center Rated Load Center mm 500 500

1.6.1 Alternative Capacity Capacity@600mm Load Center kg 1810 1810

Characteristics

1.8 Load Distance Front Axle Center to Fork Face mm L2 430 430

1.9 Wheelbase mm L3 1400 1400

2.1 Service Weight kg 3230 3330

2.2

2.2.1 Rear kg 630 700

Weight

Tyres

Dimensions

Performance

I.C Engine

Others

Axle Loading

2.3

2.3.1 Rear kg 1980 2050

3.1 Tyre Type Pneumatic Pneumatic

3.2 Tyre Size Front 22 1/4x7 1/2-15/5.50 22 1/4x7 1/2-15/5.50

3.3 Rear 17 3/4x6 1/2 -10/5.00 17 3/4x6 1/2 -10/5.00

3.5 Number of Wheel Front/Rear (x=driven) 2

3.6 Tread, Front mm b4 900 900

3.7 Tread, Rear mm b3 885 885

4.1 Tilting Angle Forward/Backward

4.2 Mast Height, Lowered 2-stage Mast mm h2 1995 1995

4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 150 150

4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000

4.5 Mast Height, Extended 2-stage Std. Mast mm h3 4050 4050

4.7 Height, Overhead Guard mm h4 2025 2025

4.19 Length, with Std. Forks mm L1 3260 3260

4.20 Length, to Fork Face mm 2340 2340

4.21 Width, at Tyre Single mm b1 1090 1090

4.22 Forks Thickness x Width x Length mm 36x122x920 36x122x920

4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2 Class 2

4.24 Width, Fork Carriage mm 960 960

4.31 Ground Clearance

4.32 at Center of Wheelbase mm 115 115

4.33 Right Angle Stacking Aisle

4.34 with L1200 x W800 pallet mm 3610 3610

4.35 Turning Radius mm Wa 1980 1980

5.1 Travel Speed (FWD)

5.2 Lifting Speed

5.3 Lowering Speed

5.6 Max. Drawbar Pull Loaded KN 14 17

5.8 Max. Gradeability Loaded % 27 34

5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic

5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical

5.12 Steering Type FHPS FHPS

6.4 Battery Voltage/ Capacity at 5-hour rating V/ah

7.1 Maker Model NISSAN K21 Komatsu 4D94LE

7.2 Rated Output, SAE gross KW 35@2450 46@2450

7.3 Rated RPM min-1 2450 2450

7.3.1 Max. Torque, SAE gross

7.4 No. of Cylinder/Displacement

7.6 Fuel Tank Capacity Ltr 40 40

8.2 Relief Pressure for Attachment bar 181 181

8.7 Transmission TORQFLOW TORQFLOW

Loaded

Unloaded

Under Mast mm 105 105

with L1000 x W1200 pallet mm 3410 3410

L o ad e d , 1 s t / 2n d km / h 1 7 . 0 1 7 . 0 Unloaded, 1st/2nd km/h 16.5 16.5 Loaded mm/s 545 630 Unloaded mm/s 600 685 Loaded mm/s 450 450 Unloaded mm/s 500 500

Front kg 4600 4630

Front kg 1250 1280

*/2 2*/2

degree

Nm@min-1

cm3

6/10 6/10

12/33 12/64

152@1600 186@1800

4-2065 4-3052

10-8 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

FG25NT-16 FD25NT-16 FG30NT-16 FD30NT-16

Gasoline Diesel Gasoline Diesel

Sitting Sitting Sitting Sitting

2500 2500 3000 3000

500 500 500 500

2270 2270 2720 2720

435 435 440 440 1400 1400 1450 1450 3630 3730 4070 4170 5350 5380 6250 6240

780 850 820 930 1140 1170 1260 1250 2490 2560 2810 2920

Pneumatic Pneumatic Pneumatic Pneumatic

22 1/4x7 1/2-15/5.50 22 1/4x7 1/2-15/5.50 22 1/4x7 1/2-15/5.50 22 1/4x7 1/2-15/5.50

17 3/4x6 1/2 -10/5.00 17 3/4x6 1/2 -10/5.00 17 3/4x6 1/2 -10/5.00 17 3/4x6 1/2 -10/5.00

2*/2 2*/2 2*/2 2*/2

900 900 900 900

885 885 885 885

6/10 6/10 6/10 6/10

1995 1995 2070 2070

155 155 160 160 3000 3000 3000 3000 4050 4050 4275 4275 2025 2025 2025 2025 3475 3475 3535 3535 2405 2405 2465 2465 1090 1090 1090 1090

40x122x1070 40x122x1070 44x122x1070 44x122x1070

Class 2 Class 2 Class 3 Class 3

960 960 940 940

105 105 105 105

115 115 115 115 3555 3555 3620 3620 3685 3685 3750 3750 2050 2050 2110 2110

16.5 16.5 16.0 16.0

16.5 16.5 16.0 16.0 545 630 515 520 600 685 550 555 450 450 420 420 500 500 500 500

14 17 16 16 23 29 24 24

Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic

Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical

FHPS FHPS FHPS FHPS

12/33 12/64 12/33 12/64

NISSAN K21 Komatsu 4D94LE NISSAN K25 Komatsu 4D94LE

35@2450 46@2450 43@2400 46@2450

2450 2450 2400 2450

152@1600 186@1800 186@1600 186@1800

4-2065 4-3052 4-2488 4-3052

40 40 40 40

181 181 181 181

TORQFLOW TORQFLOW TORQFLOW TORQFLOW

SPECIFICATIONS

AX50/BX50 Series 10-9

SPECIFICATIONS

Outside view

b2 b4 b3 b1

GENERAL AND SPECIFICATIONS

L2 L3

Load Capacity chart

1.0 ton

1900

1700

1500

1300

1100

900

CAPACITY (kg)

700

500

0 500 600 800 1000 1200

LOAD CENTER (mm)

3m, 3.5m, 4m Mast

4.5m Mast 5m Mast

1.5 ton

3m, 3.5m, 4m Mast *4.5m Mast

1900

1700

1500

1300

1100

900

CAPACITY (kg)

700

500

0 500 600 800 1000 1200

*5m Mast

LOAD CENTER (mm)

1.8 ton

3m, 3.5m, 4m Mast *4.5m Mast

1900

1700

1500

1300

1100

900

CAPACITY (kg)

700

500

0 500 600 800 1000 1200

*5m Mast

LOAD CENTER (mm)

2.0 ton

~4m Mast

4.3m~4.5m Mast

3000 2800 2600 2400 2200 2000 1800 1600 1400

CAPACITY (kg)

1200 1000

800

0 500 600 800 1000 1200 1400 1500

4.7~5m Mast

LOAD CENTER (mm)

10-10 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

SPECIFICATIONS

2.5 ton

3.5 ton

~4m Mast

4.3m~4.5m Mast

3000 2800 2600 2400 2200 2000 1800 1600 1400

CAPACITY (kg)

1200 1000

800

0 500 600 800 1000 1200 1400 1500

4.7~5m Mast

LOAD CENTER (mm)

~4.5m Mast

3500 3300 3100 2900 2700 2500 2300 2100 1900

CAPACITY (kg)

1700 1500 1300

0 500 600 800 1000 1200 1400 1500

4.7m~5m Mast

LOAD CENTER (mm)

3.0 ton

~4m Mast

4.3m~4.5m Mast

3000 2800 2600 2400 2200 2000 1800 1600 1400

CAPACITY (kg)

1200 1000

800

0 500 600 800 1000 1200 1400 1500

4.7~5m Mast

LOAD CENTER (mm)

AX50/BX50 Series 10-11

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

GENERAL AND SPECIFICATIONS

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance; therefore, even if no apparent wear is found, always replace with new parts within the prescribed period of replacement (or earlier if trouble is found). Note that periodic replacement has nothing to do with guarantee service.

No. Part name

1 Master cylinder and wheel cylinder cups, dust seals Every 1 year

2 Rubber parts of brake booster Every 1 year

3 Brake hose or tube Every 2 years

4 Reservior tank and tube Every 2 years

5 Power steering hose Every 2 years

6 Stop lamp switch (Oil pressure type) Every 2 years

7 Fuel hose Every 2 years

8 Rubber parts of power steering Every 2 years

9 Lift chain Every 3 years

10 Hose of load handing Every 2 years

Period of

replacement

10-12 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

FOR SAFETY OPERATION

USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE

• 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 is very dangerous.

MAINTENANCE LOCATION

• When carrying out inspection and maintenance, use a level, dry, dust–free area.

• If the work is carried out inside a building, make sure that there is ample ventilation.

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

• To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know

how to use it.

• Before carrying out inspection, lower the forks to the ground and stop the machine.

• Do not run the engine unless it is necessary.

• Place the directional lever, speed lever, and work equipment control levers in neutral.

PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE

• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.

If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean

the lift truck before starting inspection.

• Do not smoke or allow any flame to exist under any circumstances.

Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.

• Wear suitable clothes for the job.

• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the

job.

• When working on top of the lift truck, be careful not to fall.

• Do not put your feet under the forks.

• When opening or closing the floor plate or engine hood, be careful not to get your hands or body

caught.

• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the

forks and mast from dropping.

• When carrying out job with another worker, decide who is the leader and carry out the job in accor-

dance with instructions from that person.

• After repairing, make sure that the trouble has been corrected by performing a trial run.

• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not

been fully corrected or that defective parts have not been removed.

AX50/BX50 Series 10-13

SAFETY ITEMS FOR MAINTENANCE

USE SUITABLE TOOLS

• Always use tools that are suited for inspection and

maintenance.

It is extremely dangerous to use broken tools or tools

designed for another purpose.

REPLACE SAFETY CRITICAL PARTS PERIODICALLY

• Even if no abnormality is found, always replace safety critical parts periodically.

As time passes, these parts deteriorate and may cause fire of 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.

GENERAL AND SPECIFICATIONS

PRECAUTIONS WITH HIGH TEMPERATURE COOLANT

• Immediately after using the lift truck, the engine coolant is at high temperature and high pressure. Do

not remove the radiator cap under these conditions.

Hot water may spurt out and cause burns.

• When removing the radiator cap, turn it slowly to

release the internal pressure.

• When checking the coolant level, stop the engine and

wait for the engine and radiator to cool down before

checking. For lift trucks equipped with a subtank or

reservoir, check the level in the subtank.

• When adding water on lift trucks equipped with a sub-

tank, add the water to the subtank.

10-14 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE 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. Hot oil may spurt out and cause burns.

• When carrying out inspection and maintenance,

wait for the oil temperature to go down, and carry

out the operation in the order given in this manual.

• Do not forget that the work equipment circuits are

always under pressure. Do not add oil, drain oil, or

carry out maintenance or inspection before com-

pletely releasing the internal pressure.

• If oil is leaking under high pressure from small

holes, it is dangerous if the jet of high–pressure oil

hits your skin or eyes. Always wear safety glasses

and thick gloves, and use a piece of cardboard or

a sheet of plywood to check for oil leakage.

• Release the internal pressure before checking the

accumulator piping.

• If you are hit by a jet of high pressure oil, consult a

doctor immediately.

ROTATING FAN AND BELT

• It is extremely dangerous if you or any tool

touches or gets caught in the fan or fan belt when

the fan is rotating. Never touch the fan when it is

rotating.

• Always stop the engine before inspecting rotating

parts.

• When inspecting the areas around rotating parts,

do not allow anything to come close which may

get caught.

AX50/BX50 Series 10-15

SAFETY ITEMS FOR MAINTENANCE

BE CAREFUL NOT TO GET CAUGHT OR FALL

• Never put your hands or feet into the mast structure.

There is danger that you will get caught in moving parts

and be serious injured.

• Do not use the mast as a ladder. If you slip, there is dan-

ger that you will fall.

GENERAL AND SPECIFICATIONS

CHECKING AND INFLATING TIRES

• If the tire inflation pressure is low, it will affect truck stability. However, do not inflate the tires immedi-

ately. The inflation pressure may have gone down because of damage to the rim. If the rim is dam-

aged or cracked and the tires are inflated, there is danger that the rim will break when the tire is under

high pressure, and this may cause personal injury or death.For safety, when checking tire pressure,

place your body in front of the tread face of the tire. Do not check from the side face of the tire.

• Suitable qualifications are needed for tire inflation work.

Always have the work carried out by properly qualified

personnel.

• The tire inflation pressure on a forklift truck is several

times higher than the pressure on an automobile. When

the tires are being inflated, there is danger that dirt or

dust may be thrown up by the compressed air and enter

your eyes, so always wear safety glasses.

10-16 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

HANDLING TIRES

Disassembly and assembly of tires should be carried out by tire dealer.

The tire inflation pressure is extremely high, so caution is needed when handling tires.

• The wheel is fitted with mounting nuts. It also has rim nuts and bolts used to join the rim halves. When

removing the tire from the lift truck, do not loosen the rim nuts and bolts. The tire is under high pres-

sure, and there is a significant risk that the rim nuts and bolts may fly off. Relief tire inflation pressure

before removing.

• When the tires have been replaced, carry out a test drive and check again for any loose mounting

nuts. If the tightening torque is low, tighten to the specified torque.

JACKING UP LIFT TRUCK (when checking or replacing tires)

• Do not go under the forklift truck when it is jacked up.

• Check the following before jacking up the lift truck.

1) Check that there is no one on the lift truck.

2) Check that there is no load on the forks.

• When jacking up, stop when the tires come off the

ground surface. Put blocks under both sides of the

frame to prevent the lift truck from coming down.

• Put blocks under any tires contacting the ground

to prevent the lift truck from moving.

LIFTING LIFT TRUCK (when checking tires)

• Lift truck slinging work should be carried out by a

qualified person who has completed a course in

correct lifting methods.

• Fit wire ropes to the specified lifting points.

• When lifting the lift truck, check that the wire ropes

have ample strength and are not damaged.

• Block the tires contacting the ground to prevent

the lift truck from moving.

• Insert blocks to prevent the truck from coming

down.

• Do not go under the lift truck during the lifting

operation.

• If the specified lifting point is the counterweight,

check that the counterweight mounting bolts are

tightened to the specified torque before carrying

out the lifting operation. check also that there is no

damage to the lifting portion on the counterweight.

AX50/BX50 Series 10-17

SAFETY ITEMS FOR MAINTENANCE

BATTERY HAZARD PREVENTION

• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you

spill electrolyte on yourself, immediately flush the area with a large quantity of water.

• Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes,

flush them immediately with large quantities of water and consult a doctor at once.

• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite

or vegetable oil. Call a doctor or poison prevention center immediately.

• When working with batteries, ALWAYS wear safety glasses or goggles.

• Batteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a

small spark or flame. Do not smoke or create any spark near the battery.

• Before working with batteries, stop the engine and turn the starting switch to the OFF position.

• When removing the battery, remove the cable from

the negative terminal first. When installing the

battery, install the cable to the positive terminal

first.

• Avoid short–circuiting the battery terminals through

accidental contact with tools or other metal objects

across the terminals.Tighten the battery terminals

securely. Loose terminals can generate sparks and

lead to an explosion.

• When removing or installing the battery, confirm

which is the positive terminal and negative ter-

minal. Be careful not to connect the cables to the

opposite terminals.

• Tighten the battery caps securely.

• When cleaning the battery, leave the battery caps

tightened.

GENERAL AND SPECIFICATIONS

DO NOT PUT METAL OBJECTS ON TOP OF BATTERY

• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit

and start a fire.

10-18 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

PRECAUTIONS WHEN CHARGING

When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical

change. To prevent the danger of gas explosion, always do as follows.

• Carry out the charging operation in a well–ventilated place.

• Do not smoke or allow any flame.

• Start the charging operation when the temperature of the battery electrolyte is below 35

°C (95 ). (If

the temperature goes above 50°C (122°F) during the charging operation, wait for it to go down below

35°C (95°F) before starting charging operation again.)

• When using a battery charger to charge the battery, take the battery caps off.

STARTING WITH BOOSTER CABLES

• ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.

• When starting using the battery of another lift truck, do not allow the two lift trucks to touch. For details

of the order of operations when using a booster cable.

• Stop the engine before connecting the cables.

• e extremely careful not to let the cables get caught in the fan or fan belt.

• Connect the batteries in parallel: positive to positive and negative to negative. Never connect positive

to negative.

DO NOT PUSH START

• Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and

operate unexpectedly.

HANDLING BRAKE FLUID

It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped.

Always do the following.

• Check the level of the brake fluid periodically.

• Always use the specified brake fluid.

• Check that the breather of the brake fluid reserve tank is not clogged.

• Be careful not to let dirt or dust get into the brake fluid reserve tank.

AX50/BX50 Series 10-19

SAFETY ITEMS FOR MAINTENANCE

HANDLING ANTIFREEZE

• Antifreeze can be a flammable. Keep away from flame when handling.

• Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water,

vomit it out, and get medical attention immediately. Follow safety precautions on container.

WASTE M ATERIALS

• Obey appropriate laws and regulations when disposing

of harmful objects such as oil, fuel, solvent, filters, and

batteries.

GENERAL AND SPECIFICATIONS

10-20 AX50/BX50 Series

GENERAL AND SPECIFICATIONS

STANDARD TIGHTENING TORQUE FOR BOLTS

For unspecified bolts and nuts, use the torques specified in this list. Select a proper torque corresponding to the width across flats (b) of bolts and nuts. When replacing bolts and nuts, always use genuine Komatsu Forklift parts the same size as the previous ones.

Thread diameter

of bolt (mm)

(a)

6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.03

8 13 31.4 ± 2.9 3.2 ± 0.3 23.2 ± 2.1

10 17 65.7 ± 6.8 6.7 ± 0.7 48.5 ± 5.0

12 19 112 ± 9.8 11.5 ± 1.0 82.6 ± 7.2

14 22 177 ± 19 18.0 ± 2.0 131 ± 14

16 24 279 ± 29 28.5 ± 3 206 ± 21

18 27 383 ± 39 39 ± 3 282 ± 29

20 30 549 ± 58 56 ± 6 405 ± 43

22 32 745 ± 78 76 ± 8 549 ± 58

24 36 927 ± 98 94.5 ± 10 684 ± 72

27 41 1320 ± 140 135 ± 15 973 ± 100

30 46 1720 ± 190 175 ± 20 1270 ± 140

33 50 2210 ± 240 225 ± 25 1630 ± 180

36 55 2750 ± 290 280 ± 30 2030 ± 210

39 60 3280 ± 340 335 ± 35 2420 ± 250

Width across

flat (mm)

(b)

Tightenng torque

Nm Kgm lbft

AX50/BX50 Series 10-21

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

GENERAL AND SPECIFICATIONS

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

Elbows, nipples and unions

Width across flats B (mm) 22 30 36

Width D (mm) 19 22 30

Tightening torqueNm {kgm} 29.4–39.2 {3–4} 78.5–103 {8–10.5} 117.7–161.8 {12–16.5}

Port size (inch) 3/4–16UNF 7/8–14UNF –

Tightening torqueNm {kgm} 68.6–73.6 {7–7.5} 78.5–83.3 {8–8.5} –

High–pressure rubber hoses, pipes and sleeve nuts

Width across flats B (mm) 19 24 27 32 36

Bore A (mm) 14 18 22 24 30

Tightening torque Nm {kgm}

19.6–29.4 {2–3}

23.5–68.6 {3–7}

58.8–98.1 {6–10}

108–167

{11–17}

147–206

{15–21}

10-22 AX50/BX50 Series

20. TESTING AND ADJUSTING

SERVICE DATA .....................................................................................20-2

GASOLINE ENGINE ............................................................................20-10

DIESEL ENGINE..................................................................................20-12

AIR CLEANER .....................................................................................20-14

ADJUSTMENT OF IGNITION TIMING.................................................20-16

ADJUSTMENT OF FUEL INJECTION TIMING ...................................20-17

MEASUREMENT OF COMPRESSION ...............................................20-18

ADJUSTMENT OF VALVE CLEARANCE ............................................20-19

TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS..20-20

REPLACEMENT OF CLUTCH DISC ...................................................20-21

TORQFLOW TRANSMISSION CASE..................................................20-23

DIFFERENTIAL CASE.........................................................................20-24

HYDRAULIC TANK...............................................................................20-25

MEASUREMENT OF HYDRAULIC DRIFT OF

LIFT AND TILT CYLINDERS ................................................................20-26

ADJUSTMENT OF CLUTCH AND BRAKE PEDAL .............................20-27

ADJUSTMENT OF ACCELERATOR PEDAL .......................................20-29

ADJUSTMENT OF PARKING BRAKE LEVER ....................................20-31

WHEEL BRAKE ...................................................................................20-32

BLEEDING AIR ....................................................................................20-33

DESIGNATED FUEL AND LUBRICATING OIL ....................................20-36

AX50/BX50 Series 20-1

SERVICE DATA

TESTING AND ADJUSTING

SERVICE DATA

Gasoline-Powered Forklift Truck (1.0 to 1.75 ton)

Device Check Item Unit FG10/14/15/18 FG15H/18H

Make/Model – Nissan K15 Nissan K21

Idling Speed rpm 750 – 900 750 – 900

Engine

Max. Speed rpm 2,840 – 3,040 2,840 – 3,040

Compression (Engine Speed: 300 rpm)

Lubrication

and Cooling

System

Intake and

Exhaust

Engine

System

Electrical

System

Tire Air pressure

Hub Nut Tightening Torque

Drive system

Rim Bolt Tightening Torque

Fan Belt Tension (Finger Pressure: 98 N {10 kgf})

Valve Clearance

Distributor Point Gap mm 0.35 – 0.45 0.35 – 0.45

Spark Plug Gap mm 0.8 – 0.9 0.8 – 0.9

Spark Plug Type – FR2A-D (NGK) FR2A-D (NGK)

Ignition Timing (Engine Speed: 650 rpm)

Ignition Order 1-3-4-2 1-3-4-2

MPa

{kgf/cm

Intake mm 0.38 0.38

Exhaust mm 0.38 0.38

degrees

Front

Rear

Front Nm {kgm} 157 – 245 {16 – 25} 157 – 245 {16 – 25}

Rear Nm {kgm} 83 – 147 {8.5 – 15} 83 – 147 {8.5 – 15}

Front Nm {kgm} 88 – 123 {9.0 – 12.5} 88 – 123 {9.0 – 12.5}

Rear Nm {kgm} 59 – 74 {6.0 – 7.5} 59 – 74 {6.0 – 7.5}

{kgf/cm

}

mm 11 – 13 11 – 13

BTDC

kPa

}

kPa

}

1.28 {13.0} 1.23 {12.5}

690 {7.0} 690 {7.0}

790 {8.0} 790 {8.0}

20-2 AX50/BX50 Series

TESTING AND ADJUSTING

Device Check Item Unit FG10/14/15/18-18 FG15H/18H-18

SERVICE DATA

Steering

Wheel

Clutch Pedal Play mm 0 – 4 0 – 4

Inching

Pedal

Brake Pedal

Steering and Brake SystemLoading System

Brake

Fork Thickness of Fork Base mm

Chain Length of 17 Links mm Less than 275.5 Less than 275.5

Hydraulic

System

Play mm 30 – 60 30 – 60

Play mm 0 – 4 0 – 4

Interconnected Stroke mm 35 – 41 35 – 41

Play mm 0 – 4 0 – 4

Pedal Height When Depressed mm 76 – 96 76 – 96

Parking Brake Operating Force N {kgf}

Back Plate Mounting Bolt Tightening Torque

Relief Pressure

Nm {kgm} 176 – 196 {18 - 20} 176 – 196 {18 - 20}

MPa

{kgf/cm

More than

147 – 196 {15 – 20}

1-ton truck: more than 26

1.5-ton truck: more than 30

1.75 ton-truck: more than 33

}

17.2 {175} 17.2 {175}

More than

147 – 196 {15 – 20}

AX50/BX50 Series

20-3

SERVICE DATA

Gasoline-Powered Forklift Truck (2.0 to 3.5 ton)

TESTING AND ADJUSTING

Device Check Item Unit FG20/25 FG20H/25H FG20N/25N

Make/Model – Nissan K21 Nissan K25 Nissan K21 Nissan K25

Idling Speed rpm 750 – 900 750 – 900 750 – 900 750 – 900

Engine

Lubrication

and Cooling

System

Intake and

Exhaust

Engine

System

Electrical

System

Max. Speed rpm 2,840 – 3,040 2,720 – 2,920 2,840 – 3,040 2,860 – 3,060

Compression (Engine Speed: 300 rpm)

Fan Belt Tension (Finger Pressure: 98 N {10 kgf})

Valve Clearance

Distributor Point Gap mm 0.35 – 0.45 0.35 – 0.45 0.35 – 0.45 0.35 – 0.45

Spark Plug Gap mm 0.8 – 0.9 0.8 – 0.9 0.8 – 0.9 0.8 – 0.9

Spark Plug Type –

Ignition Timing (Engine Speed: 650 rpm)

Intake mm 0.38 0.38 0.38 0.38

Exhaust mm 0.38 0.38 0.38 0.38

MPa

{kgf/cm

mm 11 – 13 11 – 13 11 – 13 11 – 13

BTDC

degrees

1.23 {12.5} 1.27 {13.0} 1.23 {12.5} 1.27 {13.0}

}

FR2A-D FR2A-D FR2A-D FR2A-D

2020

FG30/30N/35A

Tire Air pressure

Hub Nut

Drive system

Rim Bolt

Ignition Order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

3 ton: 690 {7.0}

3.5 ton: 850 {8.5}

3 ton: 690 {7.0}

3.5 ton: 890 {9.0}

294 – 490

{30 – 50}

157 – 245

{16 – 25}

88 – 123

{9 – 12.5}

Tightening Torque

Front

Rear

Front Nm {kgm}

Rear Nm {kgm}

Front Nm {kgm}

Rear Nm {kgm}

kPa

{kgf/cm2}

kPa

{kgf/cm

690 {7.0} 690 {7.0} –

}

294 – 490

{30 – 50}

157 – 245

{16 – 25}

88 – 123

{9 – 12.5}

294 – 490

{30 – 50}

157 – 245

{16 – 25}

196 – 294 {20 – 130}

(Excl. 2.75 ton and 3 ton forklift trucks)

88 – 123

{9 – 12.5}

294 – 490

{30 – 50}

157 – 245

{16 – 25}

–

20-4 AX50/BX50 Series

TESTING AND ADJUSTING

SERVICE DATA

Device Check Item Unit FG20/25 FG20H/25H

Steering

Wheel

Clutch

Pedal

Inching

Pedal

Brake

Pedal

Steering and Brake SystemLoading System

Brake

Fork Thickness of Fork Base mm

Chain Length of 17 Links mm

Hydraulic

System

Play mm 30 – 60 30 – 60 30 – 60 30 – 60

Play mm 0 – 4 0 – 4 – 0 – 4

Play mm 0 – 4 0 – 4 0 – 4 0 – 4

Interconnected Stroke mm 35 – 41 35 – 41 35 – 41

Play mm 0 – 4 0 – 4 0 – 4 0 – 4

Pedal Height When Depressed

Parking Brake Operating Force

Back Plate Mounting Bolt Tightening Torque

Relief Pressure

mm 62 – 82 62 – 82 62 – 82 62 – 82

N {kgf}

Nm {kgm}

MPa

{kgf/cm2}

147 – 196

{15 – 20}

(*1)

176 – 196

{18 – 20}

18 {185} 18 {185} 18 {185} 18 {185}

147 – 196

{15 – 20}

(*1)

176 – 196

{18 – 20}

2 ton truck: more than 32.5

2.5 ton truck: more than 36 3 ton truck: more than 39.5

2 - 2.5 ton truck: less than 330 3 ton truck: less than 550

FG20N/25N

147 – 196

{15 – 20}

(*1)

176 – 196

{18 – 20}

FG30/30N/35A

3 ton: 35 – 41

3.5 ton: 40 – 46

147 – 196

{15 – 20}

(*1)

176 – 196

{18 – 20}

Notes

*1: Apply 245 – 294 N (25 – 30 kgf) for FG35A and forklift trucks equipped with power brake.

AX50/BX50 Series

20-5

SERVICE DATA

Diesel-Powered Forklift Truck (1.0 – 1.75 ton)

Device Check Items Unitþ FD10/15/18

Make/Model – Komatsu 4D92E

Idling Speed rpm 750 – 800

Engine

Max. Speed rpm 2,650 – 2,700

TESTING AND ADJUSTING

Compression

Lubrication

and Cooling

System

Engine

Fuel System

Intake and

Exhaust

System

Tires Air Pressure

Hub Nut Tightening Torque

Drive system

Rim Bolt Tightening Torque

Tension of Fan Belt (Finger Pressure: 98N {10kgf}

Ignition Timing

Ignition Order – 1-3-4-2

Ignition Pressure

Valve Clearance

MPa

{kgf/cm

degrees

{kgf/cm

Intake mm 0.2

Exhaust mm 0.2

Front

Rear

Front Nm {kgm} 157 – 245 {16 – 25}

Rear Nm {kgm} 83 – 147 {8.5 – 15}

Front Nm {kgm} 88 – 123 {9.0 – 12.5}

Rear Nm {kgm} 59 – 74 {6.0 – 7.5}

{kgf/cm

}

mm 10 – 15

BTDC

MPa

}

kPa

}

kPa

}

2.94 {30}/250

ATDC4

12.3 – 13.3 {125 – 135}

690 {7.0}

790 {8.0}

20-6 AX50/BX50 Series

TESTING AND ADJUSTING

Devices Inspection Items Unit FD10/15/18

SERVICE DATA

Steering

Wheel

Clutch Pedal Play mm 0 – 4

Inching

Pedal

Brake Pedal

Steering and Brake System

Brake

Fork Thickness at Fork Base mm

Chain Length of 17 Links mm Less than 275.5

Hydraulic

Loading System

System

Play mm 30 – 60

Play mm 0 – 4

Interconnected Stroke mm 35 – 41

Play mm 0 – 4

Depressed Pedal Height mm 76 – 96

Parking Brake Operating Force N {kgf} 147 – 196 {15 – 20}

Back Plate Fixing Bolt Tightening Torque

Relief Pressure

Nm {kgm} 176 – 196 {18 – 20}

More than 26 for FD10,

more than 30 for FD14 and FD15,

more than 33 for FD33

MPa

{kgf/cm

}

17.2 {175}

AX50/BX50 Series

20-7

SERVICE DATA

Diesel-Powered Forklift Truck (2.0 – 3.5 ton)

TESTING AND ADJUSTING

Device Check Items Unitþ FD20/25/30

Make/Model – Komatsu 4D94LE Komatsu 4D98E Komatsu 4D94LE

Idling Speed rpm 785 – 835 750 – 800 785 – 835

Engine

Max. Speed rpm 2,650 – 2,700 2,650 – 2,700 2,650 – 2,700

Lubrication

and Cooling

System

Engine

Fuel System

Intake and

Exhaust

System

Tires Air Pressure

Hub Nut

Drive system

Rim Bolt

Compression

Tension of Fan Belt (Finger Pressure: 98N {10kgf}

Ignition Timing

Ignition Order – 1-3-4-2 1-3-4-2 1-3-4-2

Ignition Pressure

Valve Clearance

Tightening Torque

Intake mm 0.2 0.2 0.2

Exhaust mm 0.2 0.2 0.2

Front

Rear

Front Nm {kgm}

Rear Nm {kgm}

Front Nm {kgm}

Rear Nm {kgm}

MPa

{kgf/cm

degrees

{kgf/cm2}

{kgf/cm

}

mm 10 – 15 10 – 15 10 – 15

ATDC

MPa

kPa

}

kPa

}

2.94 {30} 2.94 {30} 2.94 {30}

11.8 {120} 11.8 {120} 11.8 {120}

690 {7.0}

294 – 490

{30 – 50}

196 – 245

{20 – 25}

88 – 123

{9 – 12.5}

FD20H/25H/

30H/35A

464

2 – 3 ton: 690 {7.0}

3.5 ton: 850 {8.5}

2 – 3 ton: 690 {7.0}

3.5 ton: 890 {9.0}

294 – 490

{30 – 50}

196 – 245

{20 – 25}

196 – 294 {20 – 30}

(Excluding 3-ton trucks)

88 – 123

{9 – 12.5}

FD20N/25N/

30N

–

294 – 490

{30 – 50}

196 – 245

{20 – 25}

–

20-8 AX50/BX50 Series

TESTING AND ADJUSTING

SERVICE DATA

Devices Inspection Items Unit FD20/25/30

Steering

Wheel

Clutch Pedal Play mm 0 – 4 0 – 4 –

Inching

Pedal

Brake Pedal

Steering and Brake System

Brake

Fork Thickness at Fork Base mm

Chain Length of 17 Links mm

Hydraulic

Loading System

System

Play mm 30 – 60 30 – 60 30 – 60

Play mm 0 – 4 0 – 4 0 – 4

Interconnected Stroke mm 35 – 41 35 – 41 35 – 41

Play mm 0 – 4 0 – 4 0 – 4

Depressed Pedal Height mm 62 – 82 62 – 82 62 – 82

Parking Brake Operating Force

Back Plate Fixing Bolt Tightening Torque

Relief Pressure

N {kgf}

Nm {kgm}

MPa

{kgf/cm

147 – 196

{15 – 20}

(*1)

176 – 196

{18 – 20}

More than 32.5 for 2-ton trucks, more than 36 for 2.5 ton trucks,

more than 39.5 for 3-ton trucks

Less than 330 for 2 - 2.5 ton trucks,

less than 550 for 3-ton trucks

18 {185} 18 {185} 18 {185}

}

FD20H/25H/

30H/35A

147 – 196

{15 – 20}

(*1)

176 – 196

{18 – 20}

FD20N/25N/

30N

147 – 196

{15 – 20}

(*1)

176 – 196

{18 – 20}

Notes *1: Apply 245 – 294 N (25 – 30 kgf) for FD35A and forklift trucks equipped with power brake.

AX50/BX50 Series

20-9

GASOLINE ENGINE

WARNING

Before starting maintenance of the engine, stop the engine and wait until cooling down completely.

1. CHANGE OF ENGINE OIL

1) Removing the drain plug, drain the oil and tighten the plug again after draining.

2) Fill the engine oil up to the specified level.

3) Check the engine oil level with the oil level gauge.

Refill Engine Oil Level

K15 Engine 3.8

K21 Engine 3.8

K25 Engine 3.8

TESTING AND ADJUSTING

2. REPLACEMENT OF ENGINE OIL FILTER

1) Remove the cartridge with the filter wrench.

2) Clean the filter mounting up and apply the engine oil to the thread as well as the seal of the new cartridge before installation.

IMPORTANT

After installing the cartridge, start the engine and

check to make sure that there is no oil leakage from

the filter mounting surface.

20-10 AX50/BX50 Series

TESTING AND ADJUSTING

3. REPLACEMENT OF FUEL FILTER

1) Loosen the nut to remove the cover and take the filter out.

2) Clean the dirt at the bottom and drain the water.

3) Replace with a new filter.

IMPORTANT

• If any damage is found on the gasket of the cover, replace it with a new one.

• After replacement, check the hose fitting area for no fuel leakage.

4. INSPECTION OF SPAK PLUG

1) Remove the spark plug with the special plug wrench.

2) Clean the carbon up stuck on the plug head and the surroundings.

3) Measure the plug gap A as shown on the illustration on the right with the plug gap gauge. Plug gap A: 0.7 to 0.8 mm

Good No good No good

GASOLINE ENGINE

Maker and Model Name of Spark Plug

NGK FR2A-D

AX50/BX50 Series

20-11

DIESEL ENGINE

4D92E, 4D94E and 4D98E ENGINE

TESTING AND ADJUSTING

1. CHANGE OF ENGINE OIL

1) Drain the engine oil removing the drain plug and tighten it again.

2) Remove the oil level gauge.

3) Refill the engine oil up to the specified level. Be careful not to let it overflow.

4) Check the oil level with the engine oil level gauge.

Refill Engine Oil Level

4D92E Engine 7.5

4D94LE Engine 7.5

4D98E Engine 7.5

2. REPLACEMENT OF ENGINE OIL FILTER

1) Remove the cartridge with the filter wrench.

2) Clean the filter mounting and apply the engine oil on the thread as well as the seal of the new cartridge before installation.

After installation of the cartridge, start the engine and check the filter-mounting surface for no oil leakage.

20-12 AX50/BX50 Series

TESTING AND ADJUSTING

3. DRAINING OF WATER FROM FUEL FILTER

1) Loosen the combination sensor plug (1) and drain the water as well as sediment accumulated at the bottom.

IMPORTANT

• Prepare a container to catch the drained water

possibly mixed with the fuel.

• Always make sure to wipe up spilled fuel if any.

4. REPLACEMENT OF FUEL FILTER

1) Remove the combination sensor plug (4) at the bottom of the cartridge.

2) Remove the cartridge (3) with the filter wrench.

3) Install the combination sensor plug to the new cartridge (3).

4) Fill the new cartridge with the fuel and apply the thin layer of engine oil before installation.

5) Loosen the plug (2) and pump the knob (1) up and down until no more bubbles come out with the fuel.

6) Tighten the plug (2).

DIESEL ENGINE

As for draining the water from the fuel filter and bleeding the air after replacement of the cartridge, the fuel may come out mixed with draining water and bleeding air. Always make sure to prepare the container for receiving those matters and wipe up spilled fuel if any, because it may be in danger to cause fire if fuel sticks here and there.

AX50/BX50 Series

20-13

AIR CLEANER

AIR CLEANER (1.0 – 1.75 TON)

WARNING

• Neither cleaning of the air cleaner nor replacement of the element is allowed while the engine is in motion.

• Always put the safety glasses on to protect your eyes when using the compressed air for cleaning the element up.

IMPORTANT

• If any grease or carbon is found stuck on the ele-

ment, clean it up with a special cleaner according

to the instruction for the air cleaner.

• In case of sever working conditions or environ-

ments, clean or replace the element earlier than

regular maintenance.

TESTING AND ADJUSTING

Element

[Single Element Type]

CLEANING OF ELEMENT

1. Remove the element and blow the dry compressed

air ( 0.69 MPa {7 kgf/cm the element for cleaning the whole element.

2. Put the cleaned element back to the air cleaner.

}) from inside to outside of

INSPECTION

Visually check the element for damage.

REPLACEMENT OF ELEMENT

1. Remove the element from the air cleaner.

2. Cover the air connector with clean cloth or tape.

3. Clean the interior of the air cleaner and remove the

cover from the air cleaner.

4. Put a new element into the air cleaner.

20-14 AX50/BX50 Series

TESTING AND ADJUSTING

AIR CLEANER (2 TON)

WARNING

• Neither cleaning of the air cleaner nor replacement of the element is allowed while the engine is in motion.

• Always put the safety glasses on to protect your eyes when using the compressed air for cleaning the element up.

IMPORTANT

• If any grease or carbon is found stuck on the ele-

ment, clean it up with a special cleaner according

to the instruction for the air cleaner.

• Never remove the inner element.

[FD20 (H) – FD30 (H)]

• In case of sever working conditions or environ-

ments, clean or replace the element earlier than

regular maintenance.

AIR CLEANER

Element

[Single Element Type]

Element

CLEANING OF ELEMENT

1. Remove the element and blow the dry compressed

air ( 0.69 MPa {7 kgf/cm the element for cleaning the whole element.

2. Put the cleaned element back to the air cleaner.

}) from inside to outside of

INSPECTION

Visually check the element for damage.

REPLACEMENT OF ELEMENT

1. Remove the element from the air cleaner.

2. Remove the inner element.

3. Cover the air connector with clean cloth or tape.

4. Clean the interior of the air cleaner and remove the

cover from the air cleaner.

5. Put a new element into the air cleaner.

Inner Element

[Double Element Type]

AX50/BX50 Series

20-15

ADJUSTMENT OF IGNITION TIMING

GASOLINE ENGINE

1. Connect the timing advance tester (1) as shown in

the diagram on the right.

2. Turn the power switch on and adjust the timing position of the advance adjustment knob (2).

3. Start the engine and run at the specified idling speed.

4. Glow the timing light (3) and check to make sure that the indicator and the timing mark stamped on the crankshaft pulley and flywheel are correctly aligned.

5. If the timing is wrong, turn the distributor (4) to the right or the left for further adjustment.

TESTING AND ADJUSTING

6. Check that ignition timing advances quickly when the engine is revved up.

20-16 AX50/BX50 Series

TESTING AND ADJUSTING

ADJUSTMENT OF FUEL INJECTION TIMING

DIESEL ENGINE (4D92E, 4D94LE and 4D98E)

INSPECTION AND ADJUSTMENT OF FUEL

INJECTION TIMING MARK

WHEN DISASSEMBLING AND ASSEMBLING

1. Match the injection pump with the A mark.

2. Match the top mark B with the ATDC 5 degrees.

3. Make sure that the plunger lift is in 1 mm.

4. If the plunger lift is not in 1 mm, adjust the angle of

the injection pump mounting.

INSPECTION

Implement the above mentioned items 2, 3 and 4 for inspection.

AX50/BX50 Series

20-17

MEASUREMENT OF COMPRESSION

TESTING AND ADJUSTING

1. Warm up the engine to get the coolant temperature at 75 – 85 °C.

2. Stop the engine and remove all the spark plugs on gasoline engines or the nozzle holders on diesel engines as well as the air cleaner.

3. Disconnect the coil cord from the ignition coil on the gasoline engine. Set the fuel control lever to the non-injection position or disconnect the wiring of the fuel cut solenoid on diesel engines.

4. Fix the adaptor to the nozzle holder mounting of the cylinder that is to be checked and tighten to the specified torque on diesel engines.

5. Install the compression gauge to the cylinder to be checked.

6. For pneumatic governor, floor the accelerator pedal and crank the engine with the starter motor to get the maximum reading of the gauge.

Take a measurement more than twice on each engine to avoid measurement errors and average the values. Discharge battery may not give sufficient revolutions. Use fully charged battery.

Gasoline Engine

Diesel Engine

CAUSES FOR INSUFFICIENT COMPRESSION

1. Poor adjustment of valve clearance

2. Pressure leakage from valve seat

3. Seize of valve stems

4. Defective or broken valve spring

5. Pressure leakage from cylinder head gasket

6. Sticking or breakage of piston rings

7. Wear of piston rings or cylinders

20-18 AX50/BX50 Series

TESTING AND ADJUSTING

ADJUSTMENT OF VALVE CLEARANCE

1. Remove the cylinder head cover.

2. Turn the crankshaft to match the top mark A of the

crank pulley (1) and the pointer (2). Check to make sure that the compression upper dead center is attained with the No.1 cylinder and the No.4 cylinder.

Upper dead center of the piston can be checked under the state that both of intake and exhaust valves are closed, which means the cylinder that both the locker arms are being in free state is at the compression upper dead center.

ADJUSTMENT OF VALVE CLEARANCE

3. Adjust the clearance beginning with the cylinder at the compression upper dead center.

When the No.1 cylinder is at the compression top dead center, adjust the valves marked with

for clearance listed on the table and give a turn to the crankshaft in the positive direction. Then, adjust the remaining valves marked with

for clearance. When the No.4 cylinder is at the compression top dead center, adjust the valves marked with

for clearance and give a turn to the crankshaft in the positive direction. Then, adjust the remaining valves marked with for clearance.

4. Loosen the locknut (3) of the adjusting screw (4) and insert the specified thickness gauge between the valve stem (6) and the locker arm (5) to allow the gauge to move smoothly and adjust the gap. Then, tighten the locknut to fix the adjustment screw.

Engine with ignition sequence of 1-2-4-3

1Cylinder No. 2 3 4

Exhaust

valve

Intake

valve

Engine with ignition sequence of 1-3-4-2

1Cylinder No. 2 3 4

Exhaust

valve

Intake

valve

AX50/BX50 Series

20-19

TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS

TESTING AND ADJUSTING

TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS

K15/K21/K25 ENGINE

1. Put the steel plate side of the cylinder head gasket

on the cylinder block side. Then, set it on top of the cylinder block.

2. Set the cylinder head in position, apply the engine oil to the cylinder bolts. Then, tighten in the order shown in the diagram on the right ( through ) to the specified tightening torque as follows:

Cylinder Head Bolt:

1) 29.4 Nm {3.0 kgm}

2) 78.5 Nm {8.0 kgm}

3) 0 Nm {0 kgm} Loosen

4) 29.4 Nm {3.0 kgm}

5) 73.5 – 83.4 Nm {7.5 – 8.5 kgm}

Tighten temporarily

Tighten again

4D92E, 4D94LE and 4D98E ENGINE

1. Apply the engine oil to the cylinder head mounting

bolts coating evenly by hand.

2. Tighten twice in the order in the diagram on the right ( through ) as follows:

Cylinder Head Bolt: Fist Time:58.8 Nm {6 kgm} Second Time:117.6 Nm {12 kgm}

20-20 AX50/BX50 Series

TESTING AND ADJUSTING

REPLACEMENT OF CLUTCH DISC

REMOVAL OF CLUTCH DISC

1. Open the clutch case cover.

2. Fix the pressure plate with the pressure plate

mounting bolt.

Fixing Bolt:

Part Name 01010-51065

Size M10

Pitch × Length 1.5 × 65

3. Slide the snap ring (1) and remove the pin (2).

REPLACEMENT OF CLUTCH DISC

4. Push the shaft toward the transmission.

5. Remove the pressure plate mounting bolt (3) and

slide the pressure plate. Then, remove the clutch disc.

Be careful not to damage the spring when sliding the pressure plate.

AX50/BX50 Series

20-21

REPLACEMENT OF CLUTCH DISC

INSTALLATION OF CLUTCH DISC

1. Install the clutch disc.

Put the flat side of the clutch disc to face toward the flywheel when assembling. Apply the thin layer of grease paste to the spline (a).

TESTING AND ADJUSTING

Flywheel side

2. Return the shaft to the flywheel side and push it into the flywheel through the spline of the clutch disc.

3. Tighten the pressure plate fixing-bolt (3).

27 – 34 Nm {2.8 – 3.5 kgm}

4. Fix the pin (2) with the snap ring.

If any damage is found at the snap ring, replace it with a new one.

5. Remove the pressure plate fixing-bolt.

6. Install the clutch case cover.

20-22 AX50/BX50 Series

TESTING AND ADJUSTING

TORQFLOW TRANSMISSION CASE

WARNING

The temperature of the oil is very high immediately after stop operation of the truck. Be sure to start inspection after cooling down completely

INSPECTION OF OIL LEVEL

1. Open the floor plate to check the oil level with the oil

level gauge.

2. Refill the oil if necessary.

TORQFLOW TRANSMISSION CASE

Air breather for transmission

Oil level gauge

Line filter

REPLACEMENR OF OIL, INSPECTION AND

CLEANING OF STRAINER

1. Remove the drain plug to drain the oil. Tighten the

drain plug after draining.

2. Remove the mounting bolt to take out the strainer for cleaning with flushing oil.

3. After cleaning, blow dry compressed air from inside to outside of the strainer and install when completely dry.

If any damage or clogs is found on the strainer, replace it with a new one.

4. Refill the oil as specified.

5. Check the oil level after refilling.

Replacement Oil Level:

First Speed (F1/R1) Model

IMPORTANT

Be sure to always use the Komatsu genuine oil

"FED10-CD" for the engine oil.

9.5 liters including torque converter

REPLACEMENT OF LINE FILTER

1. Turn the line filter counterclockwise for removal.

2. Install a new line filter. When installing, check to

make sure that the seal of the line filter touched the case fitting face and then tighten it by another threequarter turning.

Air breather for transmission

Strainer

Drain plug

Air breather for differential

AX50/BX50 Series

20-23

DIFFERENTIAL CASE

WARNING

The temperature of the oil is very high immediately after stop operation of the truck. Be sure to start inspection after it is cooled down completely

INSPECTION OF OIL LEVEL

1. Remove the oil level check plug to check that the oil

is nearly up to the lower level of the plug-hole. Refill the oil, if necessary.

TESTING AND ADJUSTING

REPLACEMENR OF OIL

1. Remove the oil filler plug and drain the oil through

the drain plug.

2. After draining, tighten the drain plug and refill the oil as specified.

3. Check the oil level after refilling.

Replacement Oil Level:

1.0 – 1.75 ton

2.0 – 3.0 ton

IMPORTANT

Be sure to always use the Komatsu genuine oil

"FG090" for the gear oil.

IMPORTANT

The same oil is being used at the differential case and the transmission case for the clutch model, while the specifications of the oil being used at those devices differs for the TORQFLOW type. Therefore, the TORQFLOW type requires inspection and replacement of the TORQFLOW transmission case in addition to those of the differential case.

10 liters for clutch model and 6 liters for the TORQFLOW type.

12.5 liters for clutch model and 7 liters for the TORQFLOW type.

Oil level check and

Drain plug

oil filling combination plug

20-24 AX50/BX50 Series

TESTING AND ADJUSTING

HYDRAULIC TANK

REPLACEMENT OF HYDRALIC OIL

REPLACEMENT OF LINE FILTER

CLEANING OF STRAINER

CLEANING OF INSIDE HYDRAULIC TANK

WARNING

The temperature of the oil is very high immediately after stop operation of the truck. Be sure to start inspection after cooling down completely.

1. Remove the drain plug located at the bottom of the hydraulic tank for draining. Then, uncover the hydraulic tank and remove the strainer. Clean the strainer up with flushing oil.

2. After cleaning inside hydraulic tank, install the drain plug.

3. After cleaning the strainer, blow dry compressed air from inside to outside of the strainer until it is completely dry.

Breather

Cover

Strainer

Line filter

Drain plug

4. Remove the line filter and replace it with a new one. Then, install the tank cover.

5. Refill the hydraulic oil through the breather hole. Check the oil level with the oil level gauge.

Replacement Oil Level:

1.0 –

1.75 ton

2.0 – 3.0 ton

6. Start the engine and operate the mast with lifting and tilting until stroke-end for several times so as to bleed the air.

IMPORTANT

Always be sure to use the Komatsu genuine hydrau-

lic oil.

52 for the standard models and 34 for the compact models.

AX50/BX50 Series

20-25

MEASUREMENT OF HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS

TESTING AND ADJUSTING

MEASUREMENT OF HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS

PRECAUTIONS

1. Never allow anyone to stand or pass under the raised forks or the load.

2. Keep your hands and legs away form the lifting mechanism including the mast stay or the dashboard area, which will

keep your hands and legs safe from harm or injury caught in the mast. Always prepare a ladder or a stand that is strong enough to use for your inspection.

3. Check to make sure that the hydraulic oil level is normal, not dirty and not mixed with any other kind of oil.

4. Park the truck on an even surface. The measurement must be carried out in front of a loading platform strong enough

to support the truck even if it should tip over to the front.

METHOD OF MEASUREMENT

1. Hold the forklift truck at 500 mm in front of the plat-

form.

2. Repeat lifting and tilting to set the hydraulic oil temperature to 50 °C.

1: Keep mast uprig

3. Set the rated load on the forks and secure it to the fork carriage with wire.

4. Lift the forks about 1, 500 mm and keep the mast upright.

[Hydraulic Drift of Lift Cylinder]

5. Wait for 3 minutes and place a ruler against the pis-

ton rod of the lift cylinder. Then, make a mark "A" on it.

6. Measure the hydraulic drift over the next 15 minutes.

Hydraulic Drift of Lift Cylinder For 15 Minutes

[Hydraulic Drift of Tilt Cylinder]

7. Wait for 3 minutes and place a ruler against the pis-

ton rod of the tilt cylinder. Then, make a mark "B" on it.

8. Measure the hydraulic drift over the next 15 minutes

Hydraulic Drift of Tilt Cylinder For 15 Minutes

1.0 – 1.75 ton: within 75 mm

2.0 – 3.0 ton: within 50 mm

within 45 mm

Approx. 1,500 mm

Ruler

2: Lift cylinder

3: Tilt cylinder

20-26 AX50/BX50 Series

TESTING AND ADJUSTING

ADJUSTMENT OF CLUTCH AND BRAKE PEDAL

ADJUSTMENT OF CLUTCH AND BRAKE PEDAL (CLUTCH MODEL)

Stop lamp switch

Clutch pedal

Brake pedal

153 mm

1. PROCEDURE FOR ADJUSTMENT OF CLUTCH AND BRAKE PEDAL (CLUTCH MODEL)

1) Brake pedal stroke

1 – 1.8 ton 51 ±10 mm

2 – 3 ton 65 ±10 mm

If the brake pedal stroke is more than the standard, check the brake shoe for wear.

2) Adjust the height of the brake pedal with the stopper bolt (1) to make it approximately 137 mm from the floor plate.

3) Adjust the height of the clutch pedal with the stopper bolt (2) to make it approximately 153 mm from the floor plate.

137 mm

2. PROCEDURE FOR ADJUSTMENT OF STOP LAMP SWITCH Set the measurement "C" at the range of 0.5 mm through 1.5 mm after adjustment of the brake pedal height.

AX50/BX50 Series

20-27

ADJUSTMENT OF INCHING AND BRAKE PEDAL

TESTING AND ADJUSTING

ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORQFLOW MODEL)

Stop lamp switch

159 mm

Inching pedal

Brake pedal

137 mm

1. PROCEDURE FOR ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORQFLOWMODEL)

1) Brake pedal stroke

1 – 1.8 ton 51 ±10 mm

2 – 3 ton 65 ±10 mm

If the brake pedal stroke is more than the standard, check the brake shoe for wear.

2) Adjust the height of the brake pedal with the stopper bolt (1) to make it approximately 137 mm from the floor plate.

3) Adjust the height of the inching pedal with the stopper bolt (2) to make it approximately 159 mm from the floor plate.

4) Adjust the bolt (3) so that it can gear with the brake pedal with the inching pedal stroke in the range of 55 mm through 61 mm accordingly.

2. PROCEDURE FOR ADJUSTNENT OF STOP LAMP AWITCH Set the measurement "C" in the range of 0.5 mm through 1.5 mm after adjustment of the brake pedal height.

20-28 AX50/BX50 Series

TESTING AND ADJUSTING

ADJUSTMENT OF ACCELERATOR PEDAL

K15/K21/K25 ENGINE MODEL

ADJUSTMENT OF ACCELERATOR PEDAL

PROCEDURE FOR ADJUSTMENT OF ACCELERATOR

PEDAL

1. Set the stopper bolt (1) temporarily with the height of

65 mm.

2. After assembling the cable, adjust the outer casing mount of the cable to allow the pedal play of 2 to 3 mm.

3. Adjust the height of stopper bolt (1) again to allow the engine full throttle when flooring the accelerator pedal.

AX50/BX50 Series

20-29

ADJUSTMENT OF ACCELERATOR PEDAL

4D92E/4D94LE/4D98E ENGINE MODEL

TESTING AND ADJUSTING

PROCEDURE FOR ADJUSTMENT OF ACCELERATOR

PEDAL

1. Set the stopper bolt (1) temporarily with the height of

65 mm.

2. After assembling the cable, adjust the outer casing mount of the cable to allow the pedal play between 2 to 3 mm.

3. Adjust the height of stopper bolt (1) again to allow the engine full throttle when flooring the accelerator pedal.

20-30 AX50/BX50 Series

TESTING AND ADJUSTING

ADJUSTMENT OF PARKING BRAKE LEVER

Before starting adjustment, check to make sure that all of both front and rear wheels of the forklift truck has locked with stoppers respectively

1. Release the parking brake by pushing the parking brake lever (2) forward to the release position (B) while pressing the push button (1).

2. Turn the adjustment bolt (3) and adjust the lever control force at the initial extension of the cable to be set as follows:

• For standard brake147 – 196N {15 – 20 kgf}

• For power brake: 245 – 294N {25 – 30 kgf}

AX50/BX50 Series

20-31

WHEEL BRAKE

PROCEDURE FOR ADJUSTMENT OF BRAKE SHOE

CLEARANCE

1. Release the parking brake while floating the wheels

up above the ground.

2. Remove the rubber cap.

3. Turn the gear (1) in the direction (A) or toward the

brake shoes repeatedly with a screwdriver until the brake shoes should touch the brake drum. Turning of every notch makes sound of clicks.

IMPORTANT:

Turn the wheels by hands to feel braking a little bit.

4. Prepare two screwdrivers. The first screwdriver should be used for mildly pushing the lever (2) and have it miss each gear notch. Be careful not to push strongly. The second one should be used for turning the gear (1) toward the direction (B) counting by twenty-one (21) notches while the fist one is still on duty. It counts 30 notches for one turning of the gear.

IMPORTANT:

Since no clicks are made available here, count the number of notches watching through the hole of the rubber cap (3) for carrying out the adjustment.

TESTING AND ADJUSTING

5. Install the rubber cap (3).

6. Turn the wheels by hands and check to make sure

that there is no brake dragging.

IMPORTANT:

The clearance between the brake shoe and brake drum can be adjusted approximately to 0.55 mm (clearance of diameter) with this adjustment.

20-32 AX50/BX50 Series

TESTING AND ADJUSTING

BLEEDING AIR

BRAKE PIPING

WARNING

• Before starting bleeding air, adjust the brake shoe clearance to the specified 0.40 to 0.56 mm (diameter of the space).

• From time to time, refill the brake fluid to prevent the brake fluid in the reserve tank from empty for carrying out air bleeding. You should carry out the inspection again just from the beginning because air could be mixed in once the tank becomes empty.

1. Remove the cap from the air bleed plug (1) of the brake wheel cylinder. Install one end of a plastic hose for air bleeding to the plug and put the other end of the hose in a container of the brake fluid.

The color of the plastic hose should be transparent as much as possible.

BLEEDING AIR

2. If inspector is only one, connect a string or a wire to the upper arm of brake pedal (2) and let the other end of string or wire loose free in approximately 300 mm through the space between the frame (3) and the dashboard (4).

3. Slowly pull out the string or the wire connected with the brake pedal (2) arm from the front of the forklift so as to compress the air inside the brake piping and hold it as is.

If inspector is more than two, one inspector should press the brake pedal.

4. Loosen the air bleed plug (1) of the brake wheel cyl- inder approximately 3/4 turns to the left and depress the brake pedal to bleed the air in the piping along with the brake fluid. Then, tighten the bleed plug (1) while bleeding the brake fluid.

In this stage, keep pulling the string or the wire for a while.

5. After tightening the bleed plug, release the brake pedal.

AX50/BX50 Series

20-33

BLEEDING AIR

6. Repeat the step 3, 4, and 5 of the above until no more bubbles come out from the hose.

7. After completing one side of brake adjustment, carry out the other side of adjustment with the same steps.

8. Then, repeat the air bleeding of the brake and check again to make sure that no more air left in the brake piping.

9. Depress the brake pedal to check it for normal response. Then, depress the brake pedal with depressing force of 196 N or 20 kgf to measure the pedal stroke (a). Check to make sure that the pedal stroke (a) is within 55 mm to 75 mm when depressing the pedal.

Pedal Stroke:

TESTING AND ADJUSTING

Pedal stroke (a)

when depressed

Play:

Play (b) 0 – 4 mm

10. Remove the hose from the air bleed plug (1). Tighten again the both side of the air bleed plug and install the cap.

Air bleed plug: 5.9 – 8.8 Nm {0.6 – 0.9 kgm}

11. Refill the brake fluid up to the MAX line (C) on the reserve tank (5) of upper master cylinder, which shows the specified fluid level.

12. Remove the string or the wire connected with the brake pedal arm.

1 – 1.8 ton 41 – 61 mm

2 – 3 ton 55 – 75 mm

20-34 AX50/BX50 Series

TESTING AND ADJUSTING

CLUTCH PIPING

1. Remove the cap from the air bleed plug. Then, fit

one end of the plastic hose to the plug and put the other end of the hose in a container of the brake fluid.

2. Loosen the air bleed plug approximately 3/4 turns and depress the brake pedal.

3. Tighten the air bleed plug. Then, release the brake pedal.

BLEEDING AIR

Release cylinder Air bleed plug

4. Repeat the step 2 and 3 until no more bubbles come out from the hose.

5. When all the air has been completely removed, tighten the plug and install the cap.

LIFT CYLINDER

1. Start the engine and run it at low idling.

2. Lift up and down the mast.

Try to stop lifting at about 100 mm before reaching to the maximum lifting and lowering height.

3. Repeat the step 2 of the above four to five times.

4. Lift up and down the mast to the maximum lifting

and lowering height.

5. Repeat the step 4 of the above four to five times.

FUEL PIPING (Diesel Engine Forklift Truck)

1. Loosen the plug (1) and move the knob (2) up and

down until no more bubbles come out with the fluid.

Clutch lever

2. Tighten the plug (1) after completely bleeding the air.

AX50/BX50 Series

20-35

DESIGNATED FUEL AND LUBRICATING OIL

GASOLINE ENGINE FORKLIFT TRUCKS

FG10/14/15/18 FG15H/18H FG20/25/30 FG20H/25H/30H FG20N/25N/30N FG35A

IMPORTANT

Always make sure to use exclusively Komatsu genu-

ine lubricating oil.

(Oil, grease and anti-freeze are available at Komatsu

distributors.)

WARNING

Never use the wrong type of brake fluid.

TESTING AND ADJUSTING

Lubrication Point Type of Oil/Fluid

Engine Oil Pan

Engine Oil

TORQFLOW Transmission Case

Differential Case Gear Oil

Hydraulic Tank Engine Oil

Fuel Tank Gasoline

Brake Reservoir

Brake Fluid

Clutch Reservoir

Greasing Points Lithium Grease

Cooling System

Coolant (FAF-NAC)

Ambient Temperature

-22 14 32 50 68 86

-30

-4

-20 -10 0 10 20 30

SAE10W30SH

SAE10WCD

SAE90GL4

SAE10WCD

SAE70R-1, SAE70R-3, DOT3

NLGI No.2

AF-NAC

104˚F

40˚C

20-36 AX50/BX50 Series

TESTING AND ADJUSTING

1.0 – 1.75 ton Forklift Trucks

DESIGNATED FUEL AND LUBRICATING OIL

Engine Oil Pan

Capacity

()

Capacity

()

2.0 – 2.5 ton Forklift Truck

Capacity

()

Capacity

()

K15 Engine: 3.8 K21 Engine: 3.8

Fuel Tank Brake Reservoir Clutch Reservoir Cooling System

42 0.15 0.1

Engine Oil Pan

K15 Engine: 3.8 K21 Engine: 3.8 K25 Engine: 3.8

Fuel Tank Brake Reservoir Clutch Reservoir Cooling System

STD Type: 63

Compact Type: 42

TORQFLOW

Transmission Case

(

Incl. Torque Converter 3.1

Transmission Case

(

Incl. Torque Converter 3.1

9.5

TORQFLOW

9.5

0.15 0.1

Differential Case Hydraulic Tank

TORQFLOW Type: 4

)

Clutch Type: 10

(

Incl. Transmission Case 6

Differential Case Hydraulic Tank

TORQFLOW Type: 7

Clutch Type: 12.5

(

Incl. Transmission Case 5.5

)

K15 Engine: 9.1 K21 Engine: 9.1

STD Type: 52

Compact Type: 34

)

K15 Engine: 9.1 K21 Engine: 9.1 K25 Engine: 9.1

AX50/BX50 Series

20-37

DESIGNATED FUEL AND LUBRICATING OIL

DIESEL ENGINE FORKLIFT TRUCKS

FD10/14/15/18 FD20/25/30 FD20H/25H/30H FD20N/25N/30N FD35A

IMPORTANT

• Never use fuel mixed with kerosene because it

may damage fuel injection system.

• Always make sure to use exclusively Komatsu

genuine lubrication oil. (Oil, grease and anti-

freeze are available at Komatsu distributors.)

WARNING

Never use the wrong type of brake fluid.

Lubrication Point Type of Oil/Fluid

TESTING AND ADJUSTING

Ambient Temperature

-22 14 32 50 68 86

-30

-4

-20 -10 0 10 20 30

104˚F

40˚C

Engine Oil Pan

Engine Oil

TORQFLOW Transmission Case

Differential Case Gear Oil

Hydraulic Tank Engine Oil

Fuel Tank Diesel fuel

Brake Reservoir

Brake Fluid

Clutch Reservoir

Greasing Points Lithium Grease

Cooling System

Coolant (FAF-NAC)

SAE10W30CD

SAE10WCD

SAE90GL4

SAE10WCD

ASTM D975 No.2

ASTM

D975 No.1

SAE70R-1, SAE70R-3, DOT3

NLGI No.2

AF-NAC

20-38 AX50/BX50 Series

TESTING AND ADJUSTING

1.0 – 1.75 ton Forklift Trucks

DESIGNATED FUEL AND LUBRICATING OIL

Engine Oil Pan

Capacity

()

Capacity

()

2.0 - 3.0 ton Forklift Trucks

Capacity

()

Capacity

()

4D92E Engine: 7.5

Fuel Tank Brake Reservoir Clutch Reservoir Cooling System

42 0.15 0.1 4D92E Engine: 9.2

Engine Oil Pan

4D94LE Engine: 7.5

4D98E Engine: 7.5

Fuel Tank Brake Reservoir Clutch Reservoir Cooling System

STD Type: 63

Compact Type: 42

TORQFLOW

Transmission Case

(

Incl. Torque Converter 3.1

Transmission Case

(

Incl. Torque Converter 3.1

9.5

TORQFLOW

9.5

0.15 0.1

Differential Case Hydraulic Tank

TORQFLOW Type: 4

)

Clutch Type: 10

(

Incl. Transmission Case 6

Differential Case Hydraulic Tank

TORQFLOW Type: 7

Clutch Type: 12.5

Incl. Transmission Case 5.5

(

)

Compact Type: 34

)

4D94LE Engine: 9.2 4D98E Engine: 9.2

STD Type: 52

AX50/BX50 Series

20-39

30. REMOVAL AND INSTALLATION

OVERALL DISASSEMBLY AND ASSEMBLY ............30-2

WEIGHT TABLE.........................................................30-4

MAST .........................................................................30-6

LIFT CYLINDER ........................................................30-7

ENGINE .....................................................................30-8

CLUTCH AND TORQUE CONVERTER,

TRANSMISSION AND DRIVE AXLE.......................30-13

ALIGNMENT OF POWER TRAIN............................30-23

STEERING AXLE AND POWER STEERING ..........30-25

WHEEL BRAKE .......................................................30-26

AX50/BX50 Series 30-1

OVERALL DISASSEMBLY AND ASSEMBLY

The following figure shows a torque converter type unless otherwise specified.

REMOVAL AND INSTALLATION

59 – 74 Nm

{6 – 7.5 kgfm}

343 – 427 Nm

{35 – 43.5 kgfm}

441 – 639 Nm

{45 – 65 kgfm}

Clutch type

30-2 AX50/BX50 Series

REMOVAL AND INSTALLATION

OVERALL DISASSEMBLY AND ASSEMBLY

Remove the support bolts only

when replacing the support.

294 – 490 Nm {30 – 50 kgfm}

490 – 608 Nm {50 – 62 kgfm}

196 – 245 Nm

{20 – 25 kgfm}

AX50/BX50 Series 30-3

WEIGHT TABLE

1.0 – 1.75 ton Forklift Trucks

Devices 1 ton 1.5 ton 1.75 ton Remarks

K15 Engine 145

Engine Assembly

Clutch Assembly 45

Torque Converter Assembly 30

K21 Engine 145

4D92E engine 230

REMOVAL AND INSTALLATION

Transmission

Axle

Wheel

Overhead Guard 100

Counterweight 430 790 980

Mast Standard (3.0 m) 453

Cylinder

Fork Carriage 70 74

Fork 28

Backrest 21

Pump 3.5

Control Valve 10

Steering system 15

Clutch Type 35

TORQFLOW Type 43

Front 158

Rear 70

Front 23

Rear 12

464

Lift 26 For 3 m mast

Tilt 10

Power Steering 12

30-4 AX50/BX50 Series

REMOVAL AND INSTALLATION

2.0 - 3.5 ton Forklift Trucks

Name of Devices 2 ton 2.5 ton 3 ton 3.5 ton Remarks

K15 Engine 145

K21 Engine 145

Engine Assembly

Clutch Assembly 45

Toque Converter Assembly 30

Transmission Assembly

Drive Axle

Steering Axle

Wheel (

Standard type/compact type

K25 Engine 145

4D94LE Engine 226

4D98E Engine 226

Clutch Type 35

TORQFLOW Type 43

207 219 261

Front 35/45

)

Rear 15/30

WEIGHT TABLE

–

35/–

15/–

Overhead Guard Assembly 111

Counterweight

Mast Assembly (Incl. Forks) 644

Cylinder

Fork Carriage 95

Fork 42 50

Backrest 20

Pump 10

Control Valve (2 valves) 8

Steering system 22

Standard Type 1,131 1,480 1,875 2,272

Compact Type 1,170 1,557 1,900 –

663 773 969

Lift 25

Tilt 12

Power Steering 16

32 33

120

62 90

AX50/BX50 Series 30-5

MAST

REMOVAL

1. Put blocks under the front and the rear wheels

2. Lift the fork carriage with the crane to remove the

hydraulic piping.

3. Remove the forks.

4. Put blocks under the fork carriage.

5. Operate the work equipment control levers several

times to release remaining pressure in the hydraulic

piping. Then, the remove the piping.

After removing the piping, fit the blind plug

immediately to prevent the hydraulic oil from

flowing out and to prevent dirt or dust from get-

ting in.

REMOVAL AND INSTALLATION

6. Lift up the fork carriage slightly with the crane and

remove the blocks.

7. Lift down the fork carriage.

8. Fit the crane to the mast.

9. Remove the tilt pin.

10. Tilt the mast forward slightly and remove the differ-

ential mounting cap bolt.

WARNING:

If the mast is kept being tilted backward, you are in

danger that the mast may fall over.

11. Remove the mast.

WARNING:

When carrying the removed mast horizontally,

secure the lower stay and the fork carriage by the

annealing wire with twisted (A).

Put blocks under the bottom of the mast and lay

the mast assembly horizontally so that the fork

carriage is at the top.

Carry out installation in the reverse order to removal.

30-6 AX50/BX50 Series

REMOVAL AND INSTALLATION

LIFT CYLINDER

REMOVAL

1. Upright the mast.

2. Remove the stopper bolt.

LIFT CYLINDER

3. Hoist the mast by the crane.

4. Put blocks under the inner mast.

5. Remove the cylinder clamp.

6. Operate the work equipment control levers several

times to release remaining pressure in the hydraulic

piping. Then, the remove piping.

After removing the piping, fit the blind plug

immediately to prevent the hydraulic oil from

flowing out and to prevent dirt or dust from get-

ting in.

7. Crane the cylinder with sling belt to remove it.

INSTALLATION

1. Lift the mast up to the maximum lifting height.

2. Check the mast for the play on both side.

3. Adjust the shims so that the both side of the cylin-

ders are synchronized with each other at the maxi-

mum lifting height.

Stopper bolt

Lift Cylinder

29.4 – 49 Nm {3 – 5 kgm}

Inner mast

Angled to left Insert shims into the left cylinder

Angled to right Insert shims into the right cylinder

Outer mast

Shim

Cylinder rod

AX50/BX50 Series 30-7

ENGINE

REMOVAL

1. Overhead Guard (Ceiling)

Engine Hood

Counterweight

Check to make sure that the mast including forks

and attachment must be lowered or lift down to

the ground or removed from the mast.

2. Wiring and Battery

The figure below shows a gasoline model.

REMOVAL AND INSTALLATION

Sheet Switch Wiring Harness

Starter B Terminal

Starter S Terminal

Fuse Box

Controller

Engine Wiring Harness

30-8 AX50/BX50 Series

REMOVAL AND INSTALLATION

3. Accelerator Wire

Remove the accelerator wire.

4. Piping and Hoses

Hydraulic Pump Piping, Torque Converter Piping, Radiator Hose, Air Cleaner Hose, Fuel Hose

• Diesel Engine Forklift Truck (TORQFLOW type equipped with 4D94LE)

ENGINE

• Gasoline Engine Forklift Truck (TORQFLOW type equipped with K15, K21 and K25)

AX50/BX50 Series 30-9

ENGINE

5. Radiator, Shroud and Exhaust Pipe

4D92E, 4D94LE, 4D98E K15, K21, K25

REMOVAL AND INSTALLATION

6. Engine

1) Place a wooden block under the transmission

case.

2) Crane the engine and hold it.

3) For clutch type trucks, remove the bolts mount-

ing the clutch case.

For TORQFLOW type trucks, remove the bolts

mounting the torque converter case.

Clutch Type Forklift Truck

TORQFLOW Type Forklift Truck

4) Remove the left and right hand bolts mounting

the engine.

30-10 AX50/BX50 Series

REMOVAL AND INSTALLATION

INSTALLATION

1. Installation of Engine

1) Loosen the bolts mounting the engine located

at the transmission side

2) Mount the engine slowly to put it on the center

of the truck frame.

ENGINE

3) Check that the gap A between fan and shroud

is even.

4) For torque converter models, remove the inch-

ing valve and check the parallelism with a level.

For clutch models, remove the back buzzer and

neutral switch, and then check the parallelism

of the surfaces with a level.

AX50/BX50 Series 30-11

ENGINE

2. Tightening Clutch Case Mounting Bolt (Clutch

Type)

Tightening Torque Converter Case Mounting Bolt

(TORQFLOW Type)

59 – 74 Nm {6 – 7.5 kgm}

Note: The illustration on the right is for clutch type.

3. Tightening Torque for Engine Mount Bolt at

Transmission Side

157 – 196 Nm {16 – 20 kgm}

REMOVAL AND INSTALLATION

Mounting bolt

4. Alignment of Power Train

See 30-00: Alignment of Power Train

5. Tightening Hydraulic Piping

See 10-22 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

6. Installation of Accelerator Wiring

See 20-29 ADJUSTMENT OF ACCELERATOR

PEDAL

7. Tightening Counterweight Mounting Bolts

441 – 639 Nm {45 – 65 kgm}

30-12 AX50/BX50 Series

REMOVAL AND INSTALLATION

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

REMOVAL

1. Overhead Guard (Ceiling)

Engine Hood

Counterweight

When dismantling such devices as the clutch, the

toque converter, the transmission and the drive axle,

remove the counterweight first to prevent the truck

from overturn. Then hoist the truck frame in the front

with the crane

Check to make sure that the mast including forks

and attachment must be lowered or lift down to

the ground or removed from the mast.

2. Mast

See 30-6: Mast

AX50/BX50 Series 30-13

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

3. Acceleration Cable

REMOVAL AND INSTALLATION

30-14 AX50/BX50 Series

REMOVAL AND INSTALLATION

4. Brake Master Cylinder

Brake Piping

Clutch Master Cylinder

Clutch Piping

Parking Brake Lever

0.30 (Brake Fluid)

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

5. Inching Cable (TORQFLOW type)

6. Pedal Assembly

AX50/BX50 Series 30-15

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

7. Forward/Reverse Control Lever, High/Low Speed

Control Lever (Clutch Type)

High/Low Speed Cable

Forward/Reverse Cable

8. Torque Converter Cooler Piping

REMOVAL AND INSTALLATION

9. Piping

30-16 AX50/BX50 Series

REMOVAL AND INSTALLATION

10. Wiring

The figure below shows a gasoline model

Starter S Terminal

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

Sheet Switch Wiring Harness

Starter B Terminal

Controller

Fuse Box

Engine Wiring Harness

AX50/BX50 Series 30-17

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

11. Drive Axle

For normal removal/installation (except for replace-

ment of front-wheel support), remove the front-

wheel bolts (E) only.

1) Place blocks under the bottom of the truck

frame to keep the frame about 10 mm above

the ground.

2) Place a carriage as shown in the illustration on

the right to support the front axle.

REMOVAL AND INSTALLATION

3) Mark (A) (B) and (C) to match the differential

and the front axle both on the left and the right.

30-18 AX50/BX50 Series

REMOVAL AND INSTALLATION

4) Remove the bolts mounting the propeller shaft

and remove the propeller shaft.

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

5) Remove the support for the front axle from the

frame and pull out the front axle placing on the

carriage.

AX50/BX50 Series 30-19

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

12. Clutch, Torque Converter, Transmission and

Drive Axle

1) Hoist the engine with a crane and hold it.

2) Place a carriage as shown in the illustration on

the right and support two unit assemblies.

3) Remove the bolts mounting the clutch case.

(Clutch Type)

Remove the bolts mounting the torque con-

verter case. (TORQFLOW Type)

4) Remove the bolts mounting the engine at the

transmission side and pull out the two unit

assemblies placing on the carriage.

REMOVAL AND INSTALLATION

30-20 AX50/BX50 Series

REMOVAL AND INSTALLATION

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

INSTALLATION

Apply the reverse order for removal. Pay attention on the

followings:

1. Tightening Torque for Clutch Case Mounting

Bolt (Clutch Type)

Tightening Torque for Torque Converter Case

Mounting Bolt (TORQFLOW Type)

Tightening Torque for Mounting Bolt:

59 – 74 Nm {6 – 7.5 kgm}

2. Tightening Torque for Engine Mounting Bolt

(Transmission side)

Tightening Torque for Mounting Bolt:

157 – 196 Nm {016 – 20 kgm}

Mounting bolt

Check the engine for placing on the center of

engine mounting both left and right at the

engine side properly. Then, tighten the bolt

mounting the engine at the transmission side.

AX50/BX50 Series 30-21

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

3. Drive Axle

1) Install the drive axle following to the matching

marks on the equipment marked at the time of

removal.

2) Remove the level plug, and check levelness

with a dedicated tool and a level

Tightening Torque for Front Axle Support Bolts

343 – 427 Nm {35 – 43.5 kgm}

Alignment of Power Train: See 30-28

If no matching marks can be found, tighten

temporarily the front fix bolts with the front axle.

Then tighten the two mounting bolts on the

support side and check the remaining two bolts

for the correct positioning toward the center

accordingly.

REMOVAL AND INSTALLATION

4. Propeller Shaft

Tightening Torque for Propeller Shaft Mounting

Bolts

32.4 – 38.2 Nm {3.3 – 3.6 kgm}

5. Pedal Assembly

Brake Piping

Bleeding Air: See 20-35

Adjustment of Pedal: See 20-26

6. Counterweight

Tightening Torque for Counterweight Mounting

Bolts

441 – 639 Nm {45 – 65 kgm}

7. Mast

Tightening Torque for Mast Cap Mounting Bolts

1.0 – 1.75 ton

2.5 ton

2.5 ton (Compact Type)

3.0 ton

3.5 ton

157 – 196 Nm

{16 – 20 kgm}

245 – 309 Nm

{25 – 31.5 kgm}

343 – 427 Nm

{35 – 43.5 kgm}

490 – 608 Nm

{50 – 62 kgm}

30-22 AX50/BX50 Series

REMOVAL AND INSTALLATION

ALIGNMENT OF POWER TRAIN

When removing the power train (front axle or Transmission/engine), always be sure to take an alignment between the

front axle and the transmission.

Measurement of Alignment

1. Prepare the tools as shown bellows.

(a) Special tool for remove/install back lamp/Neutral switch for manual transmission.

(b) Block for Water level meter for manual transmission

(d) Electric Water level Meter

(a) Special tool for Neutral/back lamp switch

(b) Block for Water level meter

(d) Electric Water Level Meter

AX50/BX50 Series 30-23

ALIGNMENT OF POWER TRAIN

2. Remove Oil Level Plug from Front Axle and install

the L type block by Plug.

Then put Electric water level meter and measure

leaning angle of front axle.

3. Measure leaning angle of Engine/Transmission.

• Manual Transmission

Remove the Neutral switch/ Back lamp switch

from transmission.

• Automatic Transmission

Remove transmission control valve.

REMOVAL AND INSTALLATION

Then put electric water level meter on the machining

surface of transmission as above.

And reading the leaning angle of transmission.

4. Service limit of leaning angle of Transmission and

Front axle.

Maximum 0.5degree between Transmission/Axle

leaning.

5. When angle of leaning is more than 0.5 degree, its

shows wrong position in either the front axle or

engine/transmission.

Check he engine mounting and axle mounting.

(for Manual transmission)

30-24 AX50/BX50 Series

REMOVAL AND INSTALLATION

STEERING AXLE AND POWER STEERING

343 – 427 Nm

{35 – 43.5 kgfm}

STEERING AXLE AND POWER STEERING

157 – 245 Nm

{16 – 25 kgfm}

35 – 63 Nm

{3.6 – 6.4 kgfm}

AX50/BX50 Series 30-25

WHEEL BRAKE

REMOVAL

1. Front Axle and Torque Shaft

1) Apply the wheel stopper to the rear wheels.

2) Place the wooden blocks under the bottom of

the truck frame to lift the front wheels.

3) Apply the parking brake.

REMOVAL AND INSTALLATION

4) Remove the hub nut and then the torque shaft

(3).

5) Release the parking brake.

1.0 – 1.75 ton

2.0 – 3.0 ton

30-26 AX50/BX50 Series

REMOVAL AND INSTALLATION

2. Hub

1) Remove the bolt (4).

2) Remove the lock nut (5) with a special tool (80

mm double face box).

3) Remove the hub not to be twisted upside down.

WHEEL BRAKE

1.0 – 1.75 ton

2.0 – 3.0 ton

INSTALLATION

1. Back Plate (when removed)

Apply the Loctite to the mounting bolt (1) and tighten

it with tightening torque specified as follows:

176 – 196 Nm {18 – 20 kgm}

LOCTITE #271

1.0 – 1.75 ton

2.0 – 3.0 ton

AX50/BX50 Series 30-27

WHEEL BRAKE

2. Hub

1) Install a new oil seal.

Apply the grease G2-L1 on the lip surface of

the oil seal.

2) Fill the grease G2-L1 in the bearing (7) and

install it to the hub (8).

3) Remove dirt or fat and oil in the inside face of

the brake drum (9) completely.

4) Install the hub to the shaft tube.

5) Tighten the locknut (5) so that the starting

torque of the hub can conform to the following.

1.0 – 1.75 ton

REMOVAL AND INSTALLATION

Starting

Torque

6) Tighten the bolt (4) after applying the Loctite.

6.1 – 15.7 Nm {62.5 – 160 kgm}

Loctite #271

2.0 – 3.0 ton

1.0 – 1.75 ton

2.0 – 3.0 ton

30-28 AX50/BX50 Series

REMOVAL AND INSTALLATION

WHEEL BRAKE

3. Front Axle and Torque Shaft

1) Install the torque shaft (3) and tighten the bolt

(2) with tightening torque specified as follows:

98 – 127 Nm {10 – 13 kgm}

2) Install the front axle and tighten the hub nut (1)

with tightening torque specified as follows.

294 – 490 Nm {30 – 50 kgm}

1.0 – 1.75 ton

2.0 – 3.0 ton

AX50/BX50 Series 30-29

40. DISASSEMBLY AND ASSEMBLY

CLUTCH ....................................................................40-2

CLUTCH MASTER CYLINDER .................................40-4

CLUTCH Booster assembly.......................................40-9

CLUTCH TRANSMISSION ......................................40-19

TORQUE CONVERTER ..........................................40-26

TORQFLOW TRANSMISSION ................................40-41

DIFFERENTIAL .......................................................40-50

DIFFERENTIAL ASSEMBLY DRAWING .................40-58

WHEEL BRAKE .......................................................40-64

BRAKE MASTER CYLINDER..................................40-67

COMBINATION SWITCH .........................................40-71

SOLENOID VALVE...................................................40-73

STEERING VALVE ...................................................40-77

STEERING AXLE ....................................................40-78

POWER STEERING CYLINDER ASSEMBLY .........40-86

LIFT CYLINDER ......................................................40-92

TILT CYLINDER .......................................................40-99

CONTROL VALVE..................................................40-101

MAST .....................................................................40-112

FORK CARRIAGE .................................................40-118

FLOW DIVIDER .....................................................40-122

RESERVOIR AASEMBLY ......................................40-126

HYDRAULIC PUMP...............................................40-127

PROPELER SFAFT ...............................................40-133

AX50/BX50 Series 40-1

CLUTCH

DISASSEMBLY AND ASSEMBLY

*1. Apply a thin layer of the MOLY-PASTE

when assembling.

27 – 34 Nm

{2.8 – 3.5 kgm}

Clutch release cylinder

G2-L1

Sleeve

Yo k e

Disk

Pressure plate

Engine

40-2 AX50/BX50 Series

DISASSEMBLY AND ASSEMBLY

CLUTCH ASSEMBLY DRAWING

Loctite #271 (

CLUTCH

*1: Bolt Thread

*2: Remove the bolt after installation.

G2-L1

MOLY-PASTE

G2-L1

AX50/BX50 Series

40-3

Komatsu FG10, FG15, FG18, FG15H, FG18H Shop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION INDEX

10. GENERAL AND SPECIFICATIONS

SPECIFICATIONS

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

SAFETY ITEMS FOR MAINTENANCE

STANDARD TIGHTENING TORQUE FOR BOLTS

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

20. TESTING AND ADJUSTING

SERVICE DATA

GASOLINE ENGINE

DIESEL ENGINE

AIR CLEANER

ADJUSTMENT OF IGNITION TIMING

ADJUSTMENT OF FUEL INJECTION TIMING

MEASUREMENT OF COMPRESSION

ADJUSTMENT OF VALVE CLEARANCE

TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS

REPLACEMENT OF CLUTCH DISC

TORQFLOW TRANSMISSION CASE

DIFFERENTIAL CASE

HYDRAULIC TANK

MEASUREMENT OF HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS

ADJUSTMENT OF CLUTCH AND BRAKE PEDAL

ADJUSTMENT OF INCHING AND BRAKE PEDAL

ADJUSTMENT OF ACCELERATOR PEDAL

ADJUSTMENT OF PARKING BRAKE LEVER

WHEEL BRAKE

BLEEDING AIR

DESIGNATED FUEL AND LUBRICATING OIL

30. REMOVAL AND INSTALLATION

OVERALL DISASSEMBLY AND ASSEMBLY

WEIGHT TABLE

MAST

LIFT CYLINDER

ENGINE

CLUTCH AND TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

ALIGNMENT OF POWER TRAIN

STEERING AXLE AND POWER STEERING

WHEEL BRAKE

40. DISASSEMBLY AND ASSEMBLY

CLUTCH