Komatsu Forklift Truck FG25NT-16

Ensure all front and rear wheels of the forklift truck are locked with stoppers

Parking brake released by pushing the parking brake lever forward to the release position while pressing the push button

Lever control force at the initial extension of the cable

Sign off on the parking brake lever adjustment

Ensure all front and rear wheels of the forklift truck are locked with stoppers

Parking brake released by pushing the parking brake lever forward to the release position while pressing the push button

Lever control force at the initial extension of the cable for standard brake

Lever control force at the initial extension of the cable for power brake

Sign off on the parking brake lever adjustment

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 from the bottom of the hydraulic tank

Hydraulic tank uncovered and strainer removed

Strainer cleaned with flushing oil

Drain plug installed after cleaning inside hydraulic tank

Strainer cleaned and dried with compressed air

Line filter replaced with a new one

Hydraulic oil level after refill

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

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 (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.

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).

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.

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.

After tightening the bleed plug, release the brake pedal.

Repeat the step 3, 4, and 5 of the above until no more bubbles come out from the hose.

After completing one side of brake adjustment, carry out the other side of adjustment with the same steps.