Komatsu FG15/18ST(LS)-17 FG15HC-17 FG15/18HT(LS)-17 AX20 Series Forklift Trucks Service Manual SM123 – PDF DOWNLOAD

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Komatsu FG15/18ST(LS)-17 FG15HC-17 FG15/18HT(LS)-17 AX20 Series Forklift Trucks Service Manual SM123 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu FG15/18ST(LS)-17 FG15HC-17 FG15/18HT(LS)-17 AX20 Series Forklift Trucks Service Manual SM123 – PDF DOWNLOAD

INTRODUCTION:

• This Service Manual has been developed as an information resource to help the reader
  learn about, understand, repair and maintain the AX20 Series forklift trucks, and the various
  equipment, systems, inspections, sensors, diagnostic procedures and diagnostic
  equipment utilized to maintain, adjust and troubleshoot these systems. Although reference
  is made to maintenance procedures necessary to perform servicing of this vehicle,
  you should refer to the applicable Operation and Maintenance Manual for these lift trucks
  for more complete maintenance information.
• Komatsu is involved in a concentrated and highly technical program of designing and
  developing cleaner burning, more efficient and more powerful engines for use in the
  industrial truck market. As a result, new computerized sensors, systems and diagnostic
  monitors have been created to make the job of maintaining and repairing these systems
  simple and easy.
• Read this manual carefully, refer to it often and learn the repair, testing and adjustment
  procedures to the best of your ability. Please note that some illustrations are generic and
  may not look exactly like your unit in every detail.

TABLE OF CONTENTS:

Komatsu FG15/18ST(LS)-17 FG15HC-17 FG15/18HT(LS)-17 AX20 Series Forklift Trucks Service Manual SM123 – PDF DOWNLOAD

INTRODUCTION 7
APPLICABLE AX20 !EPA” LIFT TRUCK MODELS 9
FEDERAL EPA EMISSION CONTROL STATEMENTS 11
1 SAFETY
1 1 SAFETY MANAGEMENT 1-2
1 2 SAFE TRAVEL 1-7
1 3 LOADING OPERATIONS 1-15
1 4 STOPPING AND PARKING 1-21
1 5 INSPECTION AND MAINTENANCE 1-22
1 6 STRUCTURE AND STABILITY OF THE LIFT TRUCK 1-29
2 GENERAL INFORMATION AND SPECIFICATIONS
2 1 SPECIFICATIONS – MAST DATA & FEATURES – INDOOR & OUTDOOR TRUCKS 2-2
2 2 TRUCK DATA – PNEUMATIC TIRE LIFT TRUCKS (OUTDOOR) 2-4
2 3 TRUCK DATA – CUSHION TIRE LIFT TRUCKS 2-6
2 4 PERIODIC REPLACEMENT OF CONSUMABLE PARTS 2-8
2 5 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS 2-9
2 6 STANDARD TIGHTENING TORQUE FOR BOLTS 2-10
3 SERVICE DATA
3 1 GASOLINE ENGINE TRUCKS – PNEUMATIC 3-2
3 2 GASOLINE ENGINE LIFT TRUCKS – CUSHION 3-4
4 TESTING, ADJUSTING AND MEASURING
4 1 ADJUST IGNITION TIMING 4-2
4 2 ADJUST SPARK PLUG GAP 4-3
4 3 ADJUST VALVE CLEARANCE 4-3
4 4 ADJUST FAN BELT TENSION 4-4
4 5 MEASURE ENGINE CYLINDER COMPRESSION 4-4
4 6 ADJUST THE PARKING BRAKE LEVER 4-5
4 7 MEASURE HYDRAULIC DRIFT ON LIFT & TILT CYLINDERS 4-5
4 8 ADJUST THE ACCELERATOR PEDAL 4-6
4 9 THROTTLE POSITION SENSOR SYSTEM 4-7
4 10 ACCELERATOR PEDAL POSITION SENSOR 4-8
4 11 CHECK BRAKE FLUID 4-9
4 12 MEASURE BRAKE STOPPING DISTANCE (BRAKING EFFECT) 4-10
4 13 ADJUST THE STOP LAMP SWITCH 4-10
4 14 ADJUST THE INCHING/BRAKE PEDAL (TORQFLOW TRUCKS) 4-10
4 14 1 Brake Pedal 4-10
4 14 2 Inching Pedal 4-10
4 14 3 Inching Pedal/Brake Pedal Interconnected Travel 4-11
4 15 CHECK TORQFLOW CLUTCH ACTUATION PRESSURE 4-13
4 16 CHECK TORQUE CONVERTER STALL SPEED 4-13
4 17 TESTING SPECIFIC GRAVITY OF BATTERY ELECTROLYTE 4-14
4 18 CHECK TIRES AND ADJUST PNEUMATIC TIRE PRESSURE 4-15
4 19 MEASURING MINIMUM LEFT AND RIGHT TURNING RADIUS 4-15
4 20 MEASURE HYDRAULIC CONTROL VALVE RELIEF PRESSURE 4-16
5 INSPECTION
5 1 INSPECT ENGINE STARTING OPERATION 5-2
5 2 INSPECT ENGINE RUNNING CONDITION 5-2
4
5 3 INSPECT AIR CLEANER ASSEMBLY 5-2
5 3 1 Cleaning the Filter Element 5-2
5 4 INSPECT FOR LOOSE CYLINDER HEAD MOUNTING BOLTS & RE-TORQUE 5-3
5 5 INSPECT ENGINE MOUNTS 5-3
5 6 INSPECT THE ENGINE LUBRICATING SYSTEM 5-3
5 7 INSPECT ENGINE FUEL SYSTEM 5-3
5 8 INSPECT LPG VAPORIZER FOR TAR BUILDUP (EVERY MONTH) 5-4
5 9 INSPECT THE BLOW-BY GAS RECIRCULATION SYSTEM 5-4
5 10 INSPECT COOLING SYSTEM AND RADIATOR 5-5
5 11 INSPECT CHARGING SYSTEM WIRING 5-5
5 12 INSPECT LPG VAPORIZER FOR TAR BUILDUP (EVERY MONTH) 5-5
5 13 INSPECT THE BLOW-BY GAS RECIRCULATION SYSTEM 5-6
5 14 INSPECT COOLING SYSTEM AND RADIATOR 5-7
5 15 INSPECT CHARGING SYSTEM WIRING 5-7
5 16 INSPECT STEERING 5-8
5 17 INSPECT STEERING WHEEL 5-8
5 18 INSPECT THE POWER STEERING SYSTEM 5-8
5 18 1 Power Steering Oil Pressure 5-8
5 19 INSPECT BRAKE SYSTEM RODS, CABLES AND LINKS 5-8
5 20 INSPECT BRAKE PIPING AND CONNECTIONS 5-9
5 21 INSPECT BRAKE MASTER AND WHEEL CYLINDERS 5-10
5 22 INSPECT BRAKE SHOES AND ASSOCIATED PARTS 5-10
5 23 INSPECT BRAKE DRUMS 5-10
5 24 INSPECT BRAKE BACKING PLATES 5-11
5 25 INSPECT LOAD FORKS 5-11
5 26 INSPECT MAST 5-11
5 27 INSPECT FORK CARRIAGE 5-12
5 28 INSPECT LIFT CHAINS 5-12
5 29 INSPECT CHAIN WHEELS 5-13
5 30 INSPECT ATTACHMENTS 5-13
5 31 INSPECT HYDRAULIC TANK 5-13
5 32 INSPECT CHASSIS AND ATTACHMENT PIPING 5-13
5 33 INSPECT HYDRAULIC PUMP 5-13
5 34 INSPECT LIFT CYLINDER 5-13
5 35 INSPECT TILT CYLINDERS 5-13
5 36 INSPECT ATTACHMENT CYLINDERS (IF EQUIPPED) 5-14
5 37 INSPECT LIFT TRUCK CHASSIS AND FRAME 5-14
5 38 INSPECT CAB (IF EQUIPPED) 5-14
5 39 INSPECT THE OPERATOR!S SEAT 5-14
5 39 1 Vehicle Controller 5-14
5 39 2 Tusk Operator Present System TOPS) 5-14
5 39 3 Controller Troubleshooting 5-16
5 40 INSPECT EQUIPMENT USED FOR ACCESSING THE LIFT TRUCK 5-18
5 41 INSPECT DISPLAY PANEL 5-18
5 42 INSPECT OVERHEAD GUARD 5-18
5 43 INSPECT LIGHTS, GAUGES AND WARNING DEVICES 5-18
5 44 INSPECT REAR VIEW MIRROR AND REFLECTORS 5-18
6 MAINTENANCE OPERATIONS
6 1 LUBRICANT LIST 6-2
6 2 CHANGE ENGINE OIL AND FILTER – GASOLINE/LP ENGINES 6-4
6 3 DIFFERENTIAL CASE 6-5
6 3 1 Checking Differential Oil Level 6-5
6 3 2 Changing Differential Oil 6-5
6 4 TORQFLOW TRANSMISSION CASE 6-5
5
6 4 1 Checking TORQFLOW Transmission Fluid Level 6-6
6 4 2 Changing TORQFLOW Transmission Fluid and Cleaning the Strainer 6-6
6 5 CHANGE OIL IN HYDRAULIC TANK 6-7
6 6 REPLACE THE FUEL FILTER 6-8
6 7 CLEAN AND/OR REPLACING AIR CLEANER ELEMENT 6-8
7 REMOVAL, DISASSEMBLY, ASSEMBLY, INSTALLATION
7 1 OVERALL ASSEMBLY DRAWING 7-2
7 2 WEIGHT TABLE – COMPONENT ASSEMBLIES AND PARTS 7-4
7 3 ENGINE 7-5
7 3 1 Engine Removal 7-5
7 3 2 Engine Disassembly And Assembly 7-6
7 3 3 Engine Installation 7-6
7 4 TRANSMISSION AND DRIVE AXLE 7-8
7 4 1 Torque Converter, Transmission, Drive Axle Removal 7-8
7 5 INSTALL TORQUE CONVERTER 7-10
7 6 INSTALL TRANSMISSION AND DRIVE AXLE 7-11
7 7 INSTALL PEDAL ASSEMBLY & BRAKE PIPING 7-11
7 8 BRAKE MASTER CYLINDER 7-11
7 8 1 Disassemble Brake Master Cylinder 7-13
7 8 2 Assemble Brake Master Cylinder 7-14
7 9 BLEED AIR FROM BRAKE SYSTEM LINES 7-15
7 10 STEERING AXLE 7-17
7 10 1 STEERING AXLE SPECIFICATIONS 7-17
7 10 2 Steering Axle Removal 7-17
7 10 3 Install STEERING AXLE 7-21
7 11 STEERING AXLE – LUBRICATION AND ADJUSTMENTS 7-22
7 11 1 Steering Axle Lubrication 7-22
7 11 2 Hub Bearing Preload Adjustment 7-22
7 11 3 Toe-in Specification – Cushion Tire Truck 7-22
7 11 4 Turning Angle Adjustment 7-23
7 12 POWER STEERING VALVE (OSPC) 7-26
7 13 POWER STEERING VALVE – TROUBLESHOOTING CHART 7-27
7 13 1 Remove Power Steeering Pump 7-29
7 13 2 Disassemble Power Steering Valve 7-29
7 13 3 Assemble Power Steering Valve 7-36
7 13 4 Install Power Steering Valve 7-48
7 14 POWER STEERING CYLINDER 7-49
7 15 WHEEL BRAKE 7-50
7 15 1 Wheel Brake Removal 7-50
7 15 2 Wheel Brake Disassembly 7-51
7 15 3 Assemble Wheel Brake 7-53
7 15 4 Axle Shaft And Front Wheel Installation 7-55
7 16 DRIVE AXLE 7-56
7 17 DIFFERENTIAL 7-60
7 17 1 Dissassemble Torqflow Transmission Differential 7-61
7 17 2 Assemble Torqflow Transmission Differential 7-63
7 18 ADJUST RING GEAR BACKLASH 7-67
7 19 TORQFLOW TRANSMISSION W/ TORQUE CONVERTER 7-72
7 19 1 Explanation Of Operation Of Transmission Hydraulic Circuit 7-76
7 20 DISASSEMBLE TORQFLOW TRANSMISSION 7-81
7 21 TORQUE CONVERTER DISASSEMBLY / ASSEMBLY 7-83
7 21 1 Disassemble Torque Converter 7-83
7 21 2 Assemble Torque Converter 7-83
7 22 TORQFLOW TRANSMISSION DISASSEMBLY / ASSEMBLY 7-84
6
7 22 1 Disassemble Torqflow Transmission Oil Pump 7-84
7 22 2 Assemble Torqflow Transmission Oil Pump 7-84
7 22 3 Remove Counter Shaft 7-85
7 22 4 Disassemble Input Shaft 7-86
7 22 5 Assemble Input Shaft 7-86
7 22 6 Disassemble Main Shaft And Clutch Drum 7-87
7 22 7 Assemble Main Shaft And Clutch Drum 7-87
7 22 8 Assemble Forward And Reverse Gear 7-88
7 22 9 Measure Torqflow Transmission – Clutch Pack End Gap 7-89
7 22 10 Disassemble Clutch Return Spring 7-90
7 22 11 Assemble Clutch Return Spring 7-90
7 22 12 Disassemble Output Gear 7-91
7 22 13 Assemble Output Gear 7-91
7 22 14 Remove Oil Filter 7-91
7 22 15 Install Oil Filter 7-91
7 22 16 Remove Transmission Case Magnets 7-92
7 22 17 Install Transmission Case Magnets 7-92
7 23 TORQFLOW TRANSMISSION – CONTROL VALVE 7-94
7 23 1 Disassemble Torqflow Transmission – Control Valve 7-99
7 23 2 Assemble Torqflow Transmission – Control Valve 7-100
7 24 HYDRAULIC CONTROL VALVE 7-103
7 25 HYDRAULIC PUMP 7-104
7 25 1 Dissassemble Hydraulic Pump 7-104
7 25 2 Replace Hydraulic Pump Seals 7-106
7 25 3 Replace Front And Rear E-seal And Back-up Ring 7-106
7 25 4 Replace O-ring 7-107
7 25 5 Assemble Hydraulic Pump 7-107
7 26 TILT CYLINDER 7-108
7 26 1 Disassemble Tilt Cylinder 7-108
7 26 2 Inspect Tilt Cylinder Parts 7-109
7 26 3 Assemble Tilt Cylinder 7-110
7 27 REMOVE MAST 7-111
7 28 INSTALL MAST 7-112
7 29 LIFT CYLINDER 7-113
7 29 1 Remove Lift Cylinder 7-113
7 29 2 Install Lift Cylinder 7-113
7 29 3 Disassemble Lift Cylinder 7-114
7 29 4 Assemble Lift Cylinder 7-118
7 30 CYLINDER SEAL SERVICE KITS 7-121
7 30 1 Displacement Design with Piston Seal 7-121
7 30 2 Piston Design with No Downstroke Cushioning 7-123
7 31 SIDESHIFTER 7-125
7 31 1 Replace Cylinder Head O-rings 7-126
7 31 2 Service Cylinder Head 7-138
8 MASTS
35/40/50/55/60D-MD SERIES 2-STAGE MASTS 8-2
30/35/40/50/55/60D-MS 2-STAGE MASTS 8-35
30/35/40/50/55/60D-MT 3-STAGE MASTS 8-65
9 APPENDICES AND ENGINE MANUAL
APPENDIX 1 – SCHEMATICS
APPENDIX 2 – HYDRAULIC CIRCUIT DIAGRAM
APPENDIX 3 – PEDAL ADJUSTMENT DIAGRAM
APPENDIX 4 – TROUBLESHOOTING DIAGRAM
SM300 – K21/25 ENGINE SERVICE MANUAL

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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