Komatsu Forklift Truck FG20NT-16

WARNING: 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.

Remove the cap from the air bleed plug 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.

If inspector is only one, connect a string or a wire to the upper arm of brake pedal and let the other end of string or wire loose free in approximately 300 mm through the space between the frame and the dashboard.

Slowly pull out the string or the wire connected with the brake pedal arm from the front of the forklift so as to compress the air inside the brake piping and hold it as is.

Loosen the air bleed plug 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.

Tighten the bleed plug while bleeding the brake fluid.

Warning: This procedure requires trained personnel with PPE!

Loosen the nut to remove the cover and take the filter out.

Clean the dirt at the bottom and drain the water.

If any damage is found on the gasket of the cover, replace it with a new one.

After replacement, check the hose fitting area for no fuel leakage.

Sign off on the fuel filter replacement

Remove the spark plug with the special plug wrench

Clean the carbon up stuck on the plug head and the surroundings

Measure the plug gap A as shown on the illustration on the right with the plug gap gauge. Plug gap A: 0.7 to 0.8 mm

Sign off on the spark plug replacement

1. PROCEDURE FOR ADJUSTMENT OF CLUTCH AND BRAKE PEDAL (CLUTCH MODEL)

If the brake pedal stroke is more than the standard, check the brake shoe for wear.

2) Adjust the height of the brake pedal with the stopper bolt (1) to make it approximately 137 mm from the floor plate.

3) Adjust the height of the clutch pedal with the stopper bolt (2) to make it approximately 153 mm from the floor plate.

2. PROCEDURE FOR ADJUSTMENT OF STOP LAMP SWITCH

Set the measurement "C" at the range of 0.5 mm through 1.5 mm after adjustment of the brake pedal height.;

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.

Drain plug removed and hydraulic tank uncovered

Strainer removed and cleaned with flushing oil

Drain plug installed after cleaning inside hydraulic tank

Strainer dried with compressed air from inside to outside until completely dry

Line filter replaced with a new one and tank cover installed

Hydraulic oil refilled through the breather hole. Enter the oil level as per the oil level gauge.

Engine started and mast operated with lifting and tilting until stroke-end for several times to bleed the air

Komatsu genuine hydraulic oil used