Komatsu Forklift Truck FG20C-16

Warning: Only trained personnel should perform this procedure.

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

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

Check the oil level after refilling.

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.

If TORQFLOW type, inspect and replace the TORQFLOW transmission case in addition to those of the differential case.

Sign off on the oil replacement procedure.

• 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.

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

Open the floor plate to check the oil level with the oil level gauge

Fix the pressure plate with the pressure plate mounting bolt

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

Push the shaft toward the transmission

Remove the pressure plate mounting bolt (3) and slide the pressure plate

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

Sign off on the clutch disc replacement

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

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

Turn the adjustment bolt (3) and adjust the lever control force at the initial extension of the cable

Set the lever control force for standard brake between 147 – 196N {15 – 20 kgf}

Set the lever control force for power brake between 245 – 294N {25 – 30 kgf}

Sign off on the brake lever adjustment