Komatsu FG-FD-All-16-20-Serie Forklift Truck Service Repair Workshop Manual (AX50/BX50 Series)

BEB16E1-02 FG10/15/18-20 FG15H/18H-20 FD10/15/18-20 FG20/25/30-16 FG20H/25H-16 FG20N/25N/30N-16 FG35A-16 FD20/25/30-16 FD20H/25H/30H-16 FD20N/25N/30N-16 FD35A-16 Printed in Japan 01-05(YC)01001 SHOP MANUAL AX50/BX50 Series

FG10/15/18-20 FG15H/18H-20 FD10/15/18-20 FG20/25/30-16 FG20H/25H/-16 FG20N/25N/30N-16 FG35A-16 FD20/25/30-16 FD20H/25H/30H-16 FD20N/25N/30N-16 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

GENERAL AND SPECIFICATIONS 10-2 AX50/BX50 Series 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 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 Axle Loading Loaded Front kg 2725 2735 2760 2765 2.2.1 Rear kg 355 360 420 430 2.3 Unloaded Front kg 1065 1075 1095 1105 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*/2 2*/2 3.6 Tread, Front mm b4 890 890 3.7 Tread, Rear mm b3 895 895 4.1 Tilting Angle Forward/Backward degree 6/10 6/10 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 Under Mast mm 120 120 4.32 at Center of Wheelbase mm 130 130 4.33 Right Angle Stacking Aisle with L1000 x W1200 pallet mm 3315 3315 4.34 with L1200 x W800 pallet mm 3515 3515 4.35 Turning Radius mm Wa 1915 1915 5.1 Travel Speed (FWD) Loaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0 Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.5 8.5/19.5 5.2 Lifting Speed Loaded mm/s 580 620 Unloaded mm/s 640 670 5.3 Lowering Speed Loaded mm/s 500 500 Unloaded mm/s 550 550 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 12/33 12/64 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 Nm@min-1 113@1600 142@1800 7.4 No. of Cylinder/Displacement cm3 4-1486 4-2659 7.6 Fuel Tank Capacity Ltr 40 40 8.2 Relief Pressure for Attachment bar 172 172 8.7 Transmission TORQFLOW Manual TORQFLOW Manual Characteristics Weight Tyres Dimensions Performance I.C Engine Others SPECIFICATIONS

GENERAL AND SPECIFICATIONS AX50/BX50 Series 10-3 FG15T-20 FG15C-20 FD15T-20 FD15C-20 FG15HT-20 FG15HC-20 FG18T-20 FG18C-20 FD18T-20 FD18C-20 FG18HT-20 FG18HC-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 TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual SPECIFICATIONS

GENERAL AND SPECIFICATIONS 10-4 AX50/BX50 Series 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 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 Axle Loading Loaded Front kg 4670 4680 4700 4720 2.2.1 Rear kg 550 550 610 610 2.3 Unloaded Front kg 1480 1480 1510 1520 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*/2 2*/2 3.6 Tread, Front mm b4 965 965 3.7 Tread, Rear mm b3 960 960 4.1 Tilting Angle Forward/Backward degree 6/12 6/12 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 Under Mast mm 115 115 4.32 at Center of Wheelbase mm 160 160 4.33 Right Angle Stacking Aisle with L1000 x W1200 pallet mm 3650 3650 4.34 with L1200 x W800 pallet mm 3850 3850 4.35 Turning Radius mm Wa 2190 2190 5.1 Travel Speed (FWD) Loaded, 1st/2nd km/h 18.5 8.5/18.5 18.5 8.5/18.5 Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0 5.2 Lifting Speed Loaded mm/s 545 630 Unloaded mm/s 600 685 5.3 Lowering Speed Loaded mm/s 450 450 Unloaded mm/s 500 500 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 12/33 12/64 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 Nm@min-1 152@1600 186@1800 7.4 No. of Cylinder/Displacement cm3 4-2065 4-3052 7.6 Fuel Tank Capacity Ltr 58 58 8.2 Relief Pressure for Attachment bar 181 181 8.7 Transmission TORQFLOW Manual TORQFLOW Manual Characteristics Weight Tyres Dimensions Performance I.C Engine Others SPECIFICATIONS

GENERAL AND SPECIFICATIONS AX50/BX50 Series 10-5 FG20HT-16 FD20HT-16 FD20HC-16 FG25T-16 FG25C-16 FD25T-16 FD25C-16 FG25HT-16 FD25HT-16 FD25HC-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*/2 2*/2 2*/2 2*/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 TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual TORQFLOW TORQFLOW Manual SPECIFICATIONS

Komatsu FG-FD-All-16-20-Serie Forklift Truck Service Repair Workshop Manual (AX50/BX50 Series)

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