Komatsu Forklift Truck FD20C-16

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.

Replace Master cylinder and wheel cylinder cups, dust seals

Replace Rubber parts of brake booster;

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

Power switch turned on and timing position of the advance adjustment knob (2) adjusted.

Engine started and running at the specified idling speed.

Timing light (3) glowed and indicator and timing mark stamped on the crankshaft pulley and flywheel correctly aligned.

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

Ignition timing advances quickly when the engine is revved up.

Sign off on the gasoline engine adjustment

Warning: This replacement procedure requires trained personnel with PPE!

Issues found during the replacement

Sign off on the forklift truck replacement

Warning: Prepare a container to catch the drained water possibly mixed with the fuel.

Warning: Always make sure to wipe up spilled fuel if any.

Loosen the combination sensor plug (1)

Drain the water as well as sediment accumulated at the bottom

Upload a photo of the drained water and sediment

Sign off on the draining process

• 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.

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 cylinder 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.