Factory Shop Manual For Komatsu Forklift Truck. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 956
Number: SM160
Bookmarks: Yes
Searchable: Yes
Hydraulic Diagrams: Yes
Model
Komatsu Forklift Truck
BX50 Series
FG20-16
FG25-16
FG28-16
FG30-16
FG32-16
FG35-16
FD20-16
FD25-16
FD28-16
FD30-16
FD32-16
FD35-16
SN 200001A And Up
Contents
INTRODUCTION
FED. EPA STATEMENT – K21/K25 ENGINES
FED. EPA STATEMENT – 4D94LE ENGINES
FORKLIFT MODEL TABLE
-SAFETY
Safety Management
Safe Travel
Loading Operations
Stopping & Parking
Inspection & Maintenance
-GENERAL DATA & SPECIFICATIONS
Spec. Tables – Pneumatic Trucks
Spec. Tables – Cushion Trucks
Periodic Replacement – Consumable Parts
Torque Table – Bolts
Torque Table – Pipe Joints
-TESTING & ADJUSTING
Service Data Table – Gasoline Pneumatic
Service Data Table – Gasoline Cushion
Service Data – Diesel Pneumatic
Gasoline Engines
Diesel Engine
Air Cleaner Servicing
Ignition Timing
Fuel Injection Timing
Compression – Measuring
Valve Clearance – Adjusting
Cyl. Head Bolts – Torque
Torqflow Transmission Case
Differential Case
Hydraulic Tank
Hydraulic Drift – Lift & Tilt Cyl.
Inching & Brake Pedals – Adjustment
Accelerator Pedal – K21/K25 Gasoline
Accelerator Pedal – 4D94Le Diesel
Parking Brake Lever – Adjust
Wheel Brake – Adjust
Bleeding Air
Fuel & Lube Oil Chart – Gasoline
Fuel & Lube Oil Chart – Diesel
-REMOVAL & INSTALLATION
Exploded View – BX50
Weight Tables – Components
Mast Removal
Lift Cylinder
Engine
Torque Conv. Trans. Drive Axle
Power Train – Alignment
Steering Axle & Power Steering
Wheel Brakes
-DISASSEMBLY & ASSEMBLY
Torque Converter
Torqflow Transmission
Differential
Wheel Brakes
Brake Master Cylinder
Combination Switch
Solenoid Valve
Steering Valve
Steering Axle
Power Steering Cylinder
Lift Cylinder
Tilt Cylinder
Control Valve
Fork Carriage
Flow Divider
Reservoir Assembly
Hydraulic Pump
Propeller Shaft
-MAINTENANCE STANDARD
Torque Converter
Torqflow Transmission
Differential
Wheel Brakes
Brake Master Cylinder
Brake Booster
Steering Axle
Power Steering Valve
Lift Cylinder
Mast, Fork Carriage, Forks
Hydraulic Pump
Propeller Shaft
-STRUCTURE & FUNCTION
Torque Conv., Gear Pump, Control Valve
Hyd. Pressure Circuit Dwg.
Pressure Port Location
Brake Booster
Flow Divider
Tilt Cylinder
Vehicle Controller
Hydraulic Circuit Drawing
P-Port Oil Pressure Measuring Port
-PERIODIC INSPECTION
Inspection Chart
CONVERSION TABLES
-K21 AND K25 ENGINE SHOP MANUAL
Introduction
Contents
Overview Of Improvements
Abbreviations – Common
Lift Truck Model Table
General Information
Engine Mechanical
Engine Fuel System
Engine Lubrication & Cooling System
Engine Systems & Diagnostics
-4D94LE DIESEL ENGINES Shop Manual
Safety
General Description
Adjustment Of Engine
Troubleshooting
Engine Body
Lubrication System
Cooling System
Fuel Injection / Speed Controller
Starting System
Charging System – Alternator W/ Built-In Fan
Special Purpose Service Tools
Maintenance Standard
-E SERIES MD MAST
Special Definitions
Introduction
Truck System
Requirements
Mounting Bracket
Installation
Mast Installation
Chain Inspection and Tension
Upright Rail Lubrication
Cylinder Bleeding
Mast Skewing
Single Function Internal Reeving
Double Function Internal Reeving
Periodic Maintenance
Daily Inspection
100 Hour Inspection
500 Hour Inspection
Section 4 Troubleshooting
Mast Removal
Main Lift Cylinder Description
21
Free Lift Cylinder Description
Cylinder Operation
Main Lift Cylinder Removal
Free Lift Cylinder Removal
Main Lift Cylinder Service
Free Lift Cylinder Service
Cylinder Bleeding
Valve Cartridge Service
Piston Removal
Carriage
Carriage Removal-Mast on Truck
Carriage Removal-Mast on Floor
Carriage Inspection
Upright Description
Upright Disassembly
Upright Inspection
Upright Reassembly
Mast Skewing
Chains
Inspection and Tension
Measuring Chain Stretch
Free Lift Chain Adjustment
Free Lift Chain Service
-E SERIES MS MAST
Introduction
Special Definitions
Truck System Requirements
Mounting Bracket Installation
Mast Installation
Chain Inspection and Tension
Internal Reeving Installation
Periodic Maintenance
Daily Inspection
100 Hour Inspection
500 Hour Inspection
Mast Removal
Main Lift Cylinder Description
Cylinder Operation
Main Lift Cylinder Removal
Main Lift Cylinder Service
Cylinder Bleeding
Valve Cartridge Service
Piston Removal
Carriage Description
Carriage Removal-Mast on Truck
Carriage Removal – Mast on Floor
Carriage Inspection
Upright Description
Upright Operation
Upright Disassembly
Upright Inspection
Uprights Reassembly
Mast Skewing
Chain Inspection and Tension
Measuring Chain Stretch
Main Lift Chain Adjustment
Main Lift Chain Service
-E SERIES MT MAST
Special Definitions
Introduction
Truck System
Requirements
Mounting Bracket
Installation
Mast Installation
Chain Inspection and Tension
Free lift Cylinder Supply
Upright Rail Lubrication
Cylinder Bleeding
Mast Skewing
Single Function Internal Reeving
Double Function Internal Reeving
Periodic Maintenance
Daily Inspection
100 Hour Inspection
500 Hour Inspection
Mast Removal
Main Lift Cylinder Description
Free Lift Cylinder Description
Cylinder Operation
Main Lift Cylinder Removal-
Free Lift Cylinder Removal-
Main Lift Cylinder Service
Free Lift Cylinder Service
Cylinder Bleeding
Valve Cartridge Service
Piston Removal
Carriage
Carriage Removal-Mast on Truck
Carriage Removal-
Mast on Floor
Carriage Inspection
Upright Description
Upright Operation
Upright Disassembly
Upright Inspection
Upright Reassembly
Mast Skewing
Chains
Inspection and Tension
Measuring Chain Stretch
Main Lift Chain Adjustment
Free Lift Chain Adjustment
Free Lift Chain Service
Main Lift Chain Service
-D-MQ QUAD MAST
Introduction
Installation
Periodic Maintenance
Troubleshooting
Service
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