KOMATSU SHOP MANUAL FG10/15/18-20 FG15H/18H-20 FD10/15/18-20 FG20/25/30-16 FG20H/25H/-16 FG20N/25N/30N-16 FG35A-16 FD20/25/30-16 FD20H/25H/30H-16 FD20N/25N/30N-16 FD35A-16 KOMATSU FORKLIFTPRECAUTIONS WHEN PERFORMING THE SERVICE WORK says py anton "Sab aoe staring ary wk —ns is npontant Now tang ony wv bers cnet Yuta her paren ‘hero wok ecu bafsy pecutone we doeed he mara fog mark howe, aay nae dnb at exe ease rake Cie unmaied wr, shoul anays be parted ater Sayan sha your connin ents prov aers DESCRIPTION OF THE SYMBOLS ‘The eymbols described below are used in tia manual fe eonvenionce ana better understanding. Symbol tem Desception A Safety ‘Special safety precautions are needed to perform the work, * Note ‘Special technical precautions are needed to perform the Work G1 | Tlttoingtongn | Fasting pate ase speci hein ace when asebng SS |e Witt pas or aston KDXe [om Plce ob contd wth adhesives, when seeing AXSOIBXS0 Series00. 10. 20. 30. 40. 50. 60. 80. 90. SECTION INDEX FOREWORD GENERAL AND SPECIFICATIONS TESTING AND ADJUSTMENT REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD STRUCTURE AND FUNCTION CRITERIA FOR PERIODICAL INSPECTION AND JUDGMENT CONVERSION TABLE ‘AXSOIBXSO Series10. GENERAL AND SPECIFICATIONS SPECIFICATIONS 102 PERIODIC REPLACEMENT OF CONSUMABLE PARTS sora SAFETY ITEMS FOR MAINTENANCE 1019 STANDARO TIGHTENING TORQUE Hi FoR Bors. 1021 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS 1022 ‘AXSOIBXSO Series 10-1‘SPECIFICATIONS. GENERAL AND SPECIFICATIONS SPECIFICATIONS 950 (1.01.0 Serie — — = =a (== —— | fc ieteesss ——fresreamar a va co Peo Se = a = aes ;z a + 3 peels Fee i ‘e_| em | aos | io vetoed [Fes i Tae i ane % a a ==EE ras == se (ee + = — et a = ee 5 | an og Er oed—| asta Se as a7 eg Oras a 1 Lergh wh Se Fes [Cong Fone ra {wasr ay oo a a [Fae Tse WETS [Fa Caos es [1502 Ro ae WwiFok aa rae at ae Sura ne [Fo ipa »/2}3}3}3} 8] §|5}3/3]3}3}4)=] |2|3}3}3]a)=|ala3 5 21 [iaciseesrno) SR a 52 |Liteg Speed — g sade | e2 [town cpm Sane onaetny [teams a Soe ae Sata ria sit ranma ee Tapes = se or aaa Ca ATE | VE = ma ao te = 10-2 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS [SPECIFICATIONS RS | [S| TE FO FO [ P| PO PSS PTE | OE ‘Stig Sig ‘Seng ‘Sig ‘ig hg wae ee re 7 a7 Eo TS PRTG —|— Serer —| a ToT] —| — Sar wr] —| 6 o PAT Tosser) —|— 600.5 ean —| — bo oPRN | — saweoPaT) —| — 500 6 oP Teatyaike —| —TeaTnascte | —TeatTyanle | —TeatTyiste —| — Teobde | Teste TR [Weal [ RAT | enV [Wa [RAL [| TORN | Marae TOR | a ‘AXS0/BXS0 Series 10-3‘SPECIFICATIONS. GENERAL AND SPECIFICATIONS 1BX50 (2.0-2.5ton) Series — aE TTR TE = SSS Sara — =, = = B [1s rer capacity aoa Capac a 000 00, a re = === = i ie = Se te a ee eee BE oan i 7 ‘so-so —|—-s | io ad Front te x % i z us ee as oto Cs iE = meee | ee Ss ee ee ae a = = a = te ates, —taeeees te a =e oe =e See = 4 [ee erg rare = a —— a = 2 pnsnansaee fmeetaeneae te ss [weno =e ar 2 [inet tase = se 22 [Lowi a Lee a = ep eee tees ertets a See te aa a ae ees = $$$ a ne ie ee bis aT aE sa ee oe Sees — ae ie etheie saa es ere 10-4 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS SPECIFICATIONS ta a Taat = Tat mae Tama Fae — eee Taoeame | ratte —| rare cine | rao ew —| ro ee [rao a SE a Fearamae —| — roars —_ ream | — Porm To Hao ane | TOROFLoR [OR wea ‘AXS0/BXS0 Series 10-5‘SPECIFICATIONS GENERAL AND SPECIFICATIONS 1BX50 (2.0-3.5ton) Series ~— aT TT ae Sena — =, = a B [1s rer capacity aoa Capac a 000 000, == = Oe = i ie = = 2 =e === BE coats i i ‘or —| aa ——— a Er eam fe — 5S —-- = cae = te Stan eae rere — we —————_ = = Sater — a = te a nr a =e ae = et See == 4 [ee erg rare = Sr see = a = = 2 pnsnansaee fmeetaeneae te = ss [weno =e ar 2 [inet tase = = 22 [Lowi a Lee a cad eee hee ertets a Se Se ee = = ae a bis aT aa {et ee Sea ie etheie ass 10-6 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS 2 ea re rar a see Raa SEEETOPAT SRT PAI [ eT PAT Fa Fao | “Fe ToRrToW | — vara —| “Tororo —| “Toran ‘AXS0/BXS0 Series SPECIFICATIONS 10-7‘SPECIFICATIONS GENERAL AND SPECIFICATIONS 100 Series Tr ATS —T aT Sa rae toes ae a § ftomaetion ier | [israel ——_ fraser a at [i reomme es = } [iat aseartnesy —[emsyonome treo —[ ty Pa = aE rat a BE coats ia ic rar = : er as = a ai ae 4 resort romeo 2 Eo ST a 2 [neste seed — [sag —— aa taps [Sang eT no a nesta bara [ae ba a =e age esa fe [oes wa Po =e 4 [ee erg rare = Le — fae (wan into = Sr akkeone Era —t st inelemeeny = econ ite = 22 [lowing ges a Sr wooo — [ser = sr [enero a ae Sr rau Sores i = areas | vor re abe co an bis aT sa 2 ares mee eae Tee Pea = oe 5 raters] = : es T TSR Toma 10-8 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS SPECIFICATIONS ae a Te aa Fears — | Foto | Fett | Fear 8 oR FORA ‘AXS0/BXS0 Series 10-9‘SPECIFICATIONS GENERAL AND SPECIFICATIONS Outside view 1.0t0n 15t0n 2 2 Em E it i © oweamenten © oweerenem 1800 zoo are 200 2s E ww 5 ie ac 2 LOAD CENTER imp LOND CENTER im) 10-10 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS 25109 SPECIFICATIONS SUBERE CAPACITY 63) 6 LOAD CENTER (rn) EUREEE ‘CAPACITY Go) 5 LOAD CENTER i) 3500 CAPACITY ta) 88 LOAD CENTER (mm) ‘AXS0/BXS0 Series 10-11PERIODIC REPLACEMENT OF CONSUMABLE PARTS GENERAL AND SPECIFICATIONS PERIODIC REPLACEMENT OF CONSUMABLE PARTS For opetation safety, never fal to perorm peridle main: tenance or make period replacement of the consum: able pats lated nthe folowing ‘These parts may deteriorate in time and are susceptible to wear. Rie cout to eatimate the degree of wear at time of periode maintenance; therefore, even ino appat= lent wear is found, always replace wth new pats win the prescribed period of replacement (or eatlerf rouble 's found) [Note that periodc replacement has nothing to do with qarantee service, No. Part name rene tee 1__| Master ojinder and wheel cyinder cups dustseas_[ Every 1 year 2 _| Rubber pars of brake booster Brey tyear 2 [Brake hose ortibe Every ayaa 4 [Resenoirtankendtube——~—~S~*~*~*~*S*S*«*~d my ya 3 | Power steering hose Every years @ | Stop arp ewich (Oil pressure ype) Every years 7 | Fuethose Every 2 years @_| Rubber pants of power stoning Every 2 years [Utena Every 3 years 10 | Hose oflead handing Every 2 years 10-12 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS [SAFETY ITEMS FOR MAINTENANCE ‘SAFETY ITEMS FOR MAINTENANCE FOR SAFETY OPERATION “A. Use Quauirieo PERSONNEL FOR INSPECTION AND MAINTENANGE ‘= Only persons authorized by the owner or operator of the equipment and having proper certification (ocal or national) may catty out inspection, maintenance and repairs of the it truck inspection, maintenance, or repair work is carried out incorrectly i is very dangerous. A. wanrenance Locarion “+ When carrying out inspection and maintenance, use a level, dry, dust-ree area. the work is carried out inside a building, make sure that there is ample ventilation, “A. PRECAUTIONS FOR INSPECTION AND MAINTENANCE ‘+ To be propared in the event of a fire, have a fre extinguisher nearby and make sure that you know ow to use it ‘+ Betore canying out inspection, lower the forks to the ground and stop the machine, ‘+ Do not run the engine unless it is necessary + Place the directional lever, speed lever, and work equipment control levers in neutral “A. PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE ‘+ Wipe off any oll or grease. Immediately wipe up any oll that has loaked. Ite tit truck is dirty, t becomes dificut or impossibe to find cracks or other problems. Always clean the lit truck before starting inspection, ‘+ Do not smoke or allow any flame to exist under any circumstances. Do not use any cloth which is soaked in fuel, ol, or grease. There Is danger that it may catch fe, ‘+ Wear suitable clothes forthe job. ‘+ Use suitable safely and protective equipment (hard hat, safety boots, safely glasces, gloves) for the Jeb ‘+ Whon working on top ofthe lit ruck, be careful not to fall, ‘+ Do.not put your foot under the forks, ‘+ When opening oF closing the floor plate or engine hood, be carelul not to gat your hands or body ‘caught ‘+ When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and mast from dropping, ‘+ When carying out job with another worker, decide who isthe leader and carry out the job in accor ‘dance with instructions from that person. ‘+ After repairing, make sure that the trouble has been corrected by performing atrial run. ‘During the trial run, starvoperate the lit ruck carefully because its possible that the trouble has not been fully corrected or that detective parts have not been removed. ‘AXS0/BXS0 Series 10-13‘SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS A. Use suTaate Toots + Always use tools that are suited for inspection and maintenance, Itis extremely dangerous to use broken toots or tools designed for another purpose. x eros (A. PEPLAGE SAFETY CRITICAL PARTS PERIODICALLY + Evenif no abnormality is found, always replace salety critical parts periodically. ‘As time passes, these parts deteriorate and may cause fir of fallue in the work equipment system. *+ However, it these parts show any abnormality belore the replacement interval has passed, they ‘should be repaired or replaced immediately. TAL PrecauTions with rich TEMPERATURE COOLANT + Immediately after using the fit ruck, the engine coolant is at high temperature and high pressure. Do not remove the radiator cap under these conditions. Hot water may spurt out and cause burns. ‘+ When removing the radiator cap, turn it slowly to release the internal pressure. ‘+ When checking tne cootant level, stop the engine and walt for the engine and radiator to cool down before x checking, For i rks equppes wth a stank or a resort; chock the love inthe eubtank. walt. «Won ading wat on tt wk oquppad with ub —_ tank, add the water to the subtank. 10-14 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS [SAFETY ITEMS FOR MAINTENANCE [AL PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE O1L + immediatly ater sing thei trek the oa high temperature. Do net dain theo or place the ftr wn th iho. Ht ol may spurt ot ae cause burs + Wen caring out rapecton and maintenance vitor theo temperature to go down, and cary cut the operation fn the oder given in this mana x + Doro orget that he werk equipment its are ‘hays under pressure, Dont ao cain ol or carry out mahtnanoe or inepecion bel com- pletey releasing te ternal presse + Wil sleaing under high pressure from small holes, tis dangerous tho jt of high-pressure ol Its your skin or ees, Avaya wear salt lasses ae thick gov, ac Use a place of cardboard or ‘shoo of pjvood chek ol aakage + Pease te interna pressure before checking the scour ping, + tyou are fy tt igh prossure ol, cont a clecor mediate + When removing the ast and ho finer bo sare deompees tho taut pn 1) Slop the vehicle Lower he fork tothe round 2) Stop tw orgne 3) Tum he ky to ACC potion, 4) Be seated onthe seat and operat the Mt ae evers back aed forth 45 tes respectively fo decompress tho ydraule ping. (BY Usinss you sce vente on the seat at operte te lever, the hye piping cannot be decom pressed TAL rorarwa raw ano Bett + It is extremely dangerous if you of any too! touches or gets caught inthe fan or fan belt when the fan is rotating. Never touch the fan when itis rotating. + Alvays stop the engine before inspecting rotating parts. ‘+ When inspecting the areas around rotating parts, do not allow anything to come close which may get caught. ‘AXS0/BXS0 Series 10-15 12008.9.20(1)‘SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS 1A BE CAREFUL NoT To GET CAUGHT OR FALL + Never put your hands or feet into the mast structure ‘There is danger that you wll get caught in mewing parts ‘and be serious injured + Donnot use the mast asa ladder. you sip, thereis dan- DX ‘ger that you wl fal. A. CHECKING AND INFLATING TIRES + Ifthe tire inflation pressure i lw, It wil affect truck stably, However, do not Inflate the tres immed ately The inflation pressure may have gone down because of damage to the rim. I the rim is dam- aged or cracked and the tives are inflated, there is danger thatthe rim will break when the tr is under high pressure, and this may cause personal injury or death For safely, when checking tre pressure, place your body in front ofthe tread face ofthe tire. Do not check from the side face of the tr, + Suitable qualifications are needed for tre inflation work ‘Always have the work carried out by properly qualified personnel + The tire inflation pressure on a forklift truck is several times higher than the pressure on an automobile. When the tres are being inflated, there is danger that dirt or dust may be thrown up by the compressed air and enter your eyes, so always wear safety glasses, 10-16 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS [SAFETY ITEMS FOR MAINTENANCE ‘A tanounc nes Disassembly and assembly of tres shouki be carried out by tre dealer. ‘The tie inflation pressure is extremely high, 50 caution is needed when handing tires, ‘+ The wheelis fited with mounting nuts It also has rim nuts and bolts used to join the rim halves. When removing the tire rom the lit truck, do not loosen the rim nuts and bolts. The tire is under high pres ‘sure, and there isa significant risk that the rim nuts and bolts may fly ff. Relief ie inflation pressure betore removing, ‘+ When the ties have been replaced, carry out atest drive and check again for any loose mounting ruts. Ifthe tightening torque is low, tighten to the specified torque, (A. JeCKING UP LIFT TRUCK (when checking or replacing tires)| + Do not go under the forklift truck when itis jacked up. '+ Check the following before jacking up the it truck, 41) Cheok that there is no one on the it truck. 2) Check that there is no load on the forks. ‘+ Whon jacking up, stop when the tires come off tho ground surface. Put blocks under both sides of tho ‘rame to prevent te lift truck from coming down, ‘+ Put blocks under any tres contacting the ground to provent the lift ruck from moving (AX UFTING LIFT TRUCK (when checking tires) ‘+ Littruck slinging work should be carried out by a ‘qualified person who has comploted course in ‘correct iting methods. + Fitwire ropes tothe specified Iting points, ‘+ When titing the lit truck, check that the wire ropes have ample strength and are not damaged + Block the tires contacting the ground to prevent the lit truck from moving, ‘+ Insert blocks to prevent the truck from coming own, + Do not go under the lit truck during the titing ‘operation ‘+ Ifthe specified liting point is the counterweight, ‘check that the counterweight mounting bolts are tightened to the specified torque betore carrying ‘out the liting operation. check also that there is no ‘damage tothe ling portion on the counterweight. ‘AXS0/BXS0 Series 10-17‘SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS (A. BATTERY HAZARD PREVENTION ‘+ When removing the battery, remove the cable from the negative © terminal first. When installing the battery, install the cable to the postive ® terminal firs. + Avoid short-ciruiting the battery terminals through ‘accidental contact with tools or other metal objects ‘across the torminals.Tighten tho battery terminals ‘securely. Loose terminals can generate sparks and load to an explosion. + When removing or Instaling the battery, confirm hich isthe positive @ terminal and negative © ter- minal, Be careful not to conneet the cables to the ‘opposite terminals + Tighten the battery caps securely + When cleaning the battery, leave the battery caps tightened. *+ Battery electrolyte contains sulfuric acid and can quickly bum the skin and eat holes in clothing. If you pil electrolyte on yourself, immediately flush the area with a large quantity of water. + Battery electrolyte can cause blindness it splashed into the eyes. I electrolyte gets into your eyes, flush them immediately wit large quantities of water and consult a doctor at once. + Ifyou accidentally crnk electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite ‘oF vegetable oil, Cal a doctor or poison prevention center immediately, + When working with batteries, ALWAYS wear safety glasses or goggles. * Batteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a ‘small spark or flame, Do not smoke or create any spark near the battery. + Before working with batteries, stop the engine and turn the starting switch to the OFF position. ® ‘and start a fe, ‘A. 00 not PUT METAL OBJECTS ON TOP OF BATTERY + Never place any metal objects ontop ofthe battery. There is danger that they will cause a short crcut 10-18 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS [SAFETY ITEMS FOR MAINTENANCE “A. Precaurions wien cHancina "When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical ‘change. To prevent the danger of gas explosion, always do as folows. + Carry out the charging operation in a well-ventilated place. + Dornot smoke or allow any flame, ‘+ Start the charging operation when the temperature ofthe battery electrolyte is below 35°C (95 °F ) (it the temperature goes above 50°C (122°F) during the charging operation, wait for itto go down below 35°C (95°F) before starting charging operation again.) + When using a battery charger to charge the battery, take the battery caps oft. ‘A. stantina wrra Booster castes + ALWAYS wear safety glasses or goggles when staring the it truck with booster cables. + When starting using the battery of another lit ruck, donot allow the two lit trucks to touch. For details ‘of the order of operations when using a booster cable. + Stop the engine before connecting the cables. + extremely caroful not to let the cables got caught in the fan or fan bel ‘+ Connect the battaries in paralle: positive to postive and negative to negative. Never connect postive tonegatve {A conor push starr ‘+ Do.not push the lit truck to start the engine. There is danger that the lit truck may suddenly start and ‘operate unexpectedly. A. Hanounc BRAKE FLUID It is dangerous lf the brakes do not work because in this condition, the lif truck cannot be stopped. Always do the fllowing, ‘Check the level ofthe brake fluid periodical, + Aays use the specified brake fluid ‘Check that the breather of the brake fluid reserve tank isnot clogged. + Be careful not to lt dit or dust get into the brake flud reserve tank, ‘AXS0/BXS0 Series 10-19‘SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS A. Hanoune anTiFReEze + Antiteeze can be a flammable, Keep away from flame when handling. + Antitteeze is poisonous, so do not drink it. you drink it by mistake, drink large amounts of water, Vomit itout, and get medical attention immediately. Folow safety precautions on container. (A. waste mareRiALs ‘+ Obey appropriate laws and regulations when disposing ‘of harmful objects such as oil, fuel, solvent, fiters, and batteries, 10-20 ‘AXSO/BXS0 Series(GENERAL AND SPECIFICATIONS ‘STANDARD TIGHTENING TORQUE FOR BOLTS STANDARD TIGHTENING TORQUE FOR BOLTS For unspected bolts and nuts, use the torques spectiad inhi it, Select a proper torque corresponding to the width across fats () of bots and nus, ‘When replacing bots and nuts, aways use genuine Komatsu Forklift pars the same size as the previous Thread dameter | Wath acrose Tishioring ore ‘obo (ne). iat (rm). ‘@ o Nov Kom Bh e 10 2a Te Tas = O16 O73 = 105 8 3 Bia 2 28 32203 232224 10 w 057 2 68 67 07 495 = 50 9 n22 98 6210 26 = 72 “ 2 219 180 2 20 qe 4 16 = Wo = ms = 5 206 = 2 1 a 989 + 90 mea 282 = 20 2 ey 549 2 58 26 405 2 43 2 2 745 2 78 meee 549 2 58 24 6 srs 98 945 + 10 e842 72 a a 1320 = 140 7 2 6 978 = 100 30 46 1720 2 190 175 2 20 s270 = 140 2 0 2210 = 240 25 = 25 1620 = 100 28 5 2780 + 290 280 + 20 2000 + 210 2 6 2280 + 340 25 2 95 220 = 260 ‘AXS0/BXS0 Series 10-21‘STANDARD TIGHTENING TORQUE FOR PIPE JOINTS GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS Elbows, nipples and unions Comer z = = wan = 2 » Taheriaiomie nian) | aewaiea | Taeiee eR) [rmTerelieTeR Fahenrgiomenniam | Serena | meee een : wm 0 ; « High-pressure rubber hoses, pipes and sleeve nuts Tightening torque Nm {kgm} B3) 67) ei) | ti | 8-21) cS, 10-22 ‘AXSO/BXS0 Series‘AXSOIBXS0 Series 20. TESTING AND ADJUSTING SERVICE DATA. 202 HOW TO DECOMPRESS THE HYDRAULIC PIPING 2004 GASOLINE ENGINE. 20-10 DIESEL ENGINE. 20-12 AIR CLEANER 2054 [ADJUSTMENT OF IGNITION TIMING. 20.16 [ADJUSTMENT OF FUEL INJECTION TIMING. (2047 MEASUREMENT OF COMPRESSION. 2048 ADJUSTMENT OF VALVE CLEARANCE 20.18 TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS. 20-20, REPLACEMENT OF CLUTCH DISC 2021 TORGFLOW TRANSMISSION CASE. (2023 DIFFERENTIAL CASE 20-24 HYDRAULIC TANK. 20-25 MEASUREMENT OF HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS. 20-26 [ADJUSTMENT OF CLUTCH AND BRAKE PEDAL 2027 [ADJUSTMENT OF INCHING AND BRAKE PEDAL. (2028 [ADJUSTMENT OF ACCELERATOR PEDAL "2028 ADJUSTMENT OF PARKING BRAKE LEVER 2031 [ADJUSTMENT OF CABLES OF THE FORWARD AND BACKWARD CONTAOL LEVER AND THEHIGH AND LOW SPEED LEVER... 2031-1 WHEEL BRAKE 2092 BLEEDING AIR (2083 DESIGNATED FUEL AND LUBRICATING OIL 20-96 20-1 12008.9.20(1)SERVICE DATA, SERVICE DATA Gasoline-Powered Forklift Truck (1.0 to 1.75 ton) TESTING AND ADJUSTING Tae Te Fa Ta FORTE ae kan Ti Ke Neen Ka ing epee om 7a oo0 Ta Ene ax Sed vom | Be s0%0 7a 3000 corpresen 1 (Engine Speed: 200 rpm) katie? 128 (13.0) 128 (128) Taga Fan Geter _ 7 ols | reer canon | 8 nis 2) tate na inake | mm 038 038 8) "RES | vevecieaanee WW) System Exhaust | mm 038 038 Dover Pon Gop mm | eae 0a cae oa eattcal | Spark Pug Type - FREAD (NGK) FRZA.D (NGK) Fae Bak co pny _| oe ‘ 2 pin Or v802 ea Fo wor oir c Tie Air pressure “ f Teo ada) wa Tae 4 Fail | TTB | aa aT | tent | Tahonna tre arm kg | e167 @S=1) [69 ATS —Troway nme [Cregeen woes] ees OTe Fim Belt) Tiottaring Torqus Rear [Nm kgm) ‘59-74 (60-75) ‘59-74 (60-75) 20-2 AXSO/BXS0 SeriesTESTING AND ADJUSTING SERVICE DATA Davee Ceeaken Oar Fa FaaTeH ‘Sieerng scorn [pay mn 30-60 20-00 , [Cusn Peas Pay on ona on4 a m BT oy Pe ona ona | Pe econneied Sroke om wena ary 3 Pay mm ona oa 8 crake pec] ____| : Pedal Height Wren Depressed] mm 70-98 76-96 o ‘More than ‘More than oman |Paaraisteopeming ere] Nat | er MESH 20y | ar 86 (18-20) Barc MouiraBok |aum wg] 176-796 (18-20), 176 ~198 (18-20) ‘Ten ras more tan 28 §| Fon | cknes ot Fork Base mn {Brine more nen 9 A {Foam ore ta 99 @| onan [Lengo 7 ins wm | tess man e765 (ess than 2755 3 sae z 3 Hysiauie aera Proscure ey 172 078) 172 (175) ‘AXSOIBXS0 SeriesSERVICE DATA, TESTING AND ADJUSTING Gasoline-Powered Forklift Truck (2.0 to 3.5 ton) Davee Check om [URES] FRR | FERN | PROTO wakanoge =| Nn Kat | Wiseantas | Nissan2t | Nisan KOS icing Speed vom | 750-800 | 750-900 | 750-900 | 760-00 Engine ni | Max. Speed tpm | 2,840-3,040 | 2,720 -2,920 | 2,640 -3,040 | 2,860-3,060 eonpresen we io , , fexgreSrees | yglete | s29cr28) | zrc0 | tascam) | trio Taba |Fan Sok Tesion snd Gouin | ge Pressure om fonts | sats | eis | ss0 Sra | Geto nat 8 ate ana inske | mm | 088 038 ose oe 5 vate | Gttaust clearance 8) Sion Exhaust] mm | 038 038 o3e 038 Diswbuor Poin Gao | mm | 026-045 | 028-045 | oas-oas | o9s—oas Spank Pg Gap mm | oe-09 | o@-09 | 08-00 | on-oo Steere! [Spar Pug pe =| reo | Feo | frexo | Fano Sjcon Taso Tg Broo ge Speed 2 ° 2 ° ei 1pm) degrees: eon Order yeaa | ves | vee | 0se a Sar 600 Front evorra) | ev0iro) - ewe wwe a tahter®) | $9070} 70) 51en- 65085) ro |arpressure ve Stor 600171 ewe sora) | 600470) - — Seeeorray . tegen] 801791 ay asen eo) Fama | eae ao | asa= za | Bea = 480 g| Heena lrorque Fear [Nmion) TSZ=2ES | TST=2S | T7=2a8 | 187 2as & tie=a5) | ema) | eas) | We 2sh = 6-254 FO~, ny From | Nm tkom} (Excl 2.78 ton and 3 ton forklift trucks) imaot |Titoring Tot gm) BSE | wae Bas ea [inion] Say | es | - | ee 20-4 AXSO/BXS0 SeriesTESTING AND ADJUSTING SERVICE DATA Davee Check am Tak] FSROES | FRR | FRRNTEN | FERRE Stearn seer | pay mm | s0-e0 | s0-e0 | 30-60 | 30-00 caer Fae [Py mm | Ona on = ona fi may mm [ee [ee foe BY notin 2) Bea i Intrcomectedsroxe | mm | s6-40 | s6-40 | c6-a0 g Pay mm | one on4 aoa 2| Poss Pedal aight When i ee mm | 2-02 | coco | coco | ee2 var=se | vars | var i96 | tar i06 Parka Grake Operating | wagy | tig-2o) | tig-2n | tame | ttexz Brake © a a ci BeaxPate Momnina Bor wm gm] Wenge | Were | wen | Wee rehtening Toru caz2o | azz | es2o) | 8-20) Zion was move han SBS | Fork |ThicknessofFomBase | mm 2B tontwck more han 38 & Stontuse more han S08 1B] Chain |Length of 17 Links mm Seg eae ace then 320 5 | Hyaraulc | Relief Pressure geaten)| 180185) 18 (185) 18185) 181185) Notes +: Apply 245 ~ 204 N (2530 ka) for FGQSA and okt tucks equipped wih pow brake -AXSOIBXSO Series 20-5SERVICE DATA TESTING AND ADJUSTING Diesel Powered Fork Tuck 1.01.75 ton) Devoe Cheah ters One rororare waked Vora a002E Tang Speed om 70600 Engine Max Speed om 7650-2700 oneresion ay 204 }250 aa [eae aae , 2 | "Sydow? | SaPftonst 2 é laten Tring ae ‘voce Fuel Syatem | riton Order - 1342 ‘ation Pressure nea 123-193 925 — 195) Wonks and vase | mm oe KEIN | vave clearance ‘System Exhaust | mm 02 ron | ay e079) thes |ArPresure ode fee [agi 00m Front |_Nm tard 167 = 248 96-28) upnu_| ngtaningTorave ear | Nmiier 7 e518) Font | Nmiter wet pO-12H Fim Bot} Toning Tove Rew | Nmitar == T4(80-75) 20-6 AXSO/BX50 Series 2006.9.20(1)TESTING AND ADJUSTING SERVICE DATA Devices Tepes tome un roioiee gene? ay mm 30-0 « [oucn pean] ray a on g Pi on ©) eager nm - B) Pe Tieconoted Soke mm we40 & Play mm o-4 2 orate Ped ; Depressed recainagne | mm 75-06 Paning Brae Operaing Foe | Ng a7 199 1520) erie Beagrie Fang Bet Ns ar) 1761901820) ore ian 28 FOTS g| rom | rickree a Fon Base mm more ian Soto Bova and FDIS, 4 ‘more than 33 for FD18 @| chan [lenge Tone mm Less than 2788 4 Dgaaae TP Taga [peter resare wae rane ‘AXSOIBXS0 SeriesSERVICE DATA, Diesel-Powered Forklift Truck (2.0 -3.5 ton) TESTING AND ADJUSTING FORTE] —FDSORENT Device Cheek tes tone] Foeoase0 | POSER ane Makanodet =) Remaisy4D94LE | Komatsu 40986 | Komatsu 4DS4LE Tang Speed om 75005 | 760-000 | 705-605 Engine Max. Spo0a pm | 2650-2700 | 2650-2700 | 2660-2700 Compression nee | 298080) 298 20) 296 20) Labzzaton [Tension of Fan Bat anootng | (Enger Sreasure mm 10-15 10-15 10-15 4g | “Syeon® | Sentionsh 5 lantion Timing Aime, 8 6 6 Fue System gon Order ~ 1842 1342 1342 wpa, | 23-13] aaa | eas tation Pressure clon) | ttae—Ta8) | teeta) | teeta) vaaae ane | intake [mm 02 02 oa Ephaust | SeSance Syaom Exhaust] mm 02 oz 02 ve | a 2=sien ewo TT] ee larpreene mm | wstere | °° Farrar acores) tos [Ae Prete ae one [Ester B9017ay « tigen?) 70 [aston ssoea i Bago | aoe —a0 | — aaa =| gupwa [Tattering | Pet | Neamt | je0-E0y {60-5} (e050) 2 rtque new | mgm) | =z | pais] tesa é (2-25) (20-251 {20-281 com | Nm am 196 — 76 0-3, ~ ramaoe |Fatterng | Fent | Ne ttar (Cecing Son wok) mon | Torque ae 123 ‘68 = 123 few | Netto) | emis | e128) = 20-8 AXSOIBXSO Series 2006.9.20(1)TESTING AND ADJUSTING SERVICE DATA Devices inepeotoniems | unm ] Foovesco | FOREST | FOEuEEN Steering [pray mm 20-60 20-60 30-60 iach Poca Pay mm ont ona = i Pay om one ona ona Ini o| Peco? Sion: 86—40 $ Imoreannecte Soke mm | 36-40 30-40 i ae a= 8 ay mm one ona one 3 orate Pea! 2 DepressedPedainegre | mm | co—w ew wee @ 147-196 147-196 147-196 Parking Brake Operating §— | wyiagty | {18 = 20) (15-20) (i529) Brake ow a a BackPae Fama B® umagn) We= me | e=S| es Fanning Tore ts-2y | Gece | eae Tio tan es rz on aS | rom [rncinessatronctase | mm tore han 382 Stone, § Tore than 98S for sen ae é B[_ ome [sorarrine ™ Rae cen a peta | 808 1 (85) v0 (85) Notes "1 Apply 245 ~ 204 N (2590 kgf for FDSSA and fork trucks equipped with power brake, ‘AXSOIBXS0 SeriesHOW TO DECOMPRESS THE HYDRAULIC PIPING TESTING AND ADJUSTING HOW TO DECOMPRESS THE HYDRAULIC PIPING Awernn ‘When deoompressing he hycraul piping, be sure to be coated onthe eat and operate the levers, Ifyou operate the levers without being seated on the ‘seat, the shut va of hydraulic piping is shut and the hyeraulie piping cannot be decompressed HOW To DECOMPRESS ON 11. Stop the vehicle, Lowe the fork tothe ground, a0, 2 Stop the engine, » 3, Tumthe key ACC postion. OFF} 4. Wile siting on the seat, operate the It and fit levers back and fortn 4 to § times respectively to decompress the hycraule piping 20-9-1 AXSO/BXS0 Series 2006.9.20(1)GASOLINE ENGINE TESTING AND ADJUSTING GASOLINE ENGINE Awesnine Botore stating maintenance of the engin, stop the ‘engine and wal unl cooing down completly. 1. CHANGE OF ENGINE OL 1) Removing the drain plug, eran the oll and tighten the plug again ater eraining, 2) Filthe engine ol up tothe speci love. 8) Check the engine of level with the ol evel gauge. Refill Engine Ol Level “Bree | ar —eitrone [388 etree [sa 2, REPLACEMENT OF ENGINE OIL FILTER 1) Remove the cartridge with the iter wrench 2) Clean the fiter mounting up and apply the ‘ngine ol to the thead a6 wel as the seal ot the now caridge before instalation, ‘After intaling the cartridge, start the engine and chock to make sure thet there is no oil eakage from the fiter mounting surtace. 20-10 AXSO/BXS0 SeriesTESTING AND ADJUSTING 3. REPLACEMENT OF FUEL FILTER 1) Loceen the nut to remove the cover and take the er out 2) Clean the cit at the bottom and drain the 3) Replace witha new tite. Fr any damage is found on the gasket of the cover, replace wth anew one + ter replacement, check the hose fitng area for no fuel leakage 4. INSPECTION OF SPARK PLUG 1) Remove the spark plug wth the special plug wrench 2) Clean the carbon up stuck on he plug head andthe suroundings. 53) Measure the plug gap A as shown on the ils tratlon on the right wth the pug gap gave. Plug gap A: 07 t0 0.8 mm © Good ® No good: The sutace of insulator becomes ently white and the burn-outs (deposits are stuck othe insu lator ike specks, Ir burnt exceseWey, the elec trode wal met. ® No good Carbons are stuck to the ns tor and electrode, Maker and Mode! Name of Spark Plug T_T FROAD ‘AXSOIBXSO Series GASOLINE ENGINEDIESEL ENGINE DIESEL ENGINE 4092, ADS4E and 4098E ENGINE 4. CHANGE OF ENGINE OIL 1) Drain the engine ol removing the drain plog ‘and tighten tagain 2) Remove the ol ove gauge 3) Reflthe engine ol up tothe specified level. Be Carell not ot overtow. 4) Check the of level wih the engine ol eve gauge Fetil Engine Ol Level wom tngne TSE aosateengne | TSE oss Engine | 20-12 * TESTING AND ADJUSTING REPLACEMENT OF ENGINE OIL FILTER 1) Pemove the cartridge wit the iter wrench 2) Clean the fter mounting and apply the engine oll onthe thread as wel as he seal ofthe new FIywneet side AXSO/BXS0 SeriesTESTING AND ADJUSTING TORGFLOW TRANSMISSION CASE Avernns ——_ ‘The temperature of the ol is very high immecsatey ater stop operation of the tuck Be sure to start Inspection ater coofng down completely INSPECTION OF OIL LEVEL 1. Open the lor plate to check he cil level wth the cil level gauge, 2. Ret me oli neceseary, REPLACEMENT OF OIL, INSPECTION AND CLEANING OF STRAINER 1. Remove the cain plug to cain the ol. Tighten the stain plug ater draining. 2. lomove the mounting bl to take cut the strainer or ‘laning wih ushing ol 3. Alter cleanin, blow dry compressed a om inside tw ouside ofthe sainet an inetall when completely ay, ke any damage or clogs i found on the anor, replace wih anew one 4. Reine oil as spected, 5, Check the ol level ater refiing, oplacemert Oi Lovet: “FisiSpead [8 here netuding torque (ira) Model verter Be sure to always use the Komatsu genuine cil *FED10-CD" forthe engine ol. REPLACEMENT OF LINE FILTER 4. Tui the tne titer counterclockwise for removal. 2. Install a new tne fiter. When instaling, check to make sure that te 2ea ofthe line iter touched the ‘ase iting face and then tighten tby another three. quart tuning ‘AXSOIBXS0 Series TORGFLOW TRANSMISSION CASE 20-23 :2008.9.20(1)DIFFERENTIAL CASE DIFFERENTIAL CASE Awesnine “The temperature of he oi ie very high immedkately ‘after stop operation of the truck Be sure to start Inspection aftr ts cooled down completely OL LEVEL CHECK 1. Remove the oil level plug! filer port plug and cheok the of level, Ill files at the level of lower ne near the pag hole, the ovale norma Ino, reil ot REPLACEMENT OF OIL 1. Remove the of filer plug and ean te ol exough the erin plus. 2 Alter craining, tighten the cain plug and refilthe ol as specited 3. Cheokthe oll level ater refiing, Replacement i Lovet: ae [as 20-25% | 607 eT IMNPORTANT] Be sure fo always use the Komatsu genuine oil "F090" for the gear oll Fe nan wed a he rd cae ane ‘fects at ea bonp ives mt nes fons Sroniornsrorariowope Thee he TOROPLOW ype ets hago and Toonerow be TORGACOW tari ch Sonumsnoreal bet cn 20-24 2006.9.20(1) TESTING AND ADJUSTING il ievel check ana cl filing combination plug AXSO/BXS0 SeriesTESTING AND ADJUSTING HYDRAULIC TANK HYDRAULIC TANK REPLACEMENT OF HYDRALIC OIL REPLACEMENT OF LINE FILTER CLEANING OF STRAINER ‘CLEANING OF INSIDE HYDRAULIC TANK Avorn The temperate of the ol fs very high immedately ater stop operation of the truck Be sure to stat Inepecton ater eootng down complete, 1. Remove the dain plug located atthe bottom ofthe hydraulic tank for raining. Then, uncover the hyraulc tank and remove the strainer. Clean the strainer up with Mashing ol 2. Alter cleaning inside hyraul tank, instal the cain Piva 3. Alte cleaning the strainer, blow cry compressed air trom inside to outside ofthe strainer unt iti co pletely ry ‘4 Romove thelne titer and replace it wth anew ono. “Then, instal he tank cover 5. Rell he hycraule ol through the bresther hole Check the aleve wth the ol level gauge, Foplacemert Oi Love: 1 178m aoe Bo=30- [5S ortho aancard moses and ton [20 forthe compact models 6 Start the engine and operate the mast with tting and ting until stroke-en for several times s0 as to blood the a ‘Always Be sure to use the Komatsu genuine hydrau- We oll ‘AXSOIBXS0 Series reater Drain is 20-25 :2008.9.20(1)MEASUREMENT OF HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS TESTING AND ADJUSTING. MEASUREMENT OF HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS A. Precautions 1. Never alow aryone to stand or pass under the raised forks or the load. oop your hands and legs away form te iting mechanism inctuding the mast stay orth dashbcard area, which wl keep your hands and log safe fom harm or injury caught in the mast. Alvays prepare a ladder or a stand that I ‘rong enough to us for your inspection, 3, Checkto make sure thatthe hycraule ol levels noemal, notty and not ited wih any other kindof 44. Park tne truck on an even eurface. The menaurement must be cared outin font fa loadng platform strong enough to support the ruck even It should tip over othe font METHOD OF MEASUREMENT 4. Hold he frit tuck at $00 mm in ant of te plat Sv vat ee 2a ig gst ey ZN) = hows gan 4. cata us one ns nese cere ont on J \I| hres 4. Lift the forks about 1, 500 mm and keep the mast wort {Hydrauile Drift of Litt Cylinder] NT] 8. Waltfor3 minutes and place a ruler against the pis ton rod ofthe liteyiner. Then, make @ mark ic ie 16. Measure the hycrauilo dit over the next 18 minutes. = he raul 175 ton: within 75 mm 2: onder Pyare [.0~ 1.78 ton: within 75 on ‘SZitinctes” [20~3.0%0n: within 60 mm Hydraulic Drift of Tt Cylinder] 7. Waitfor3 minutos and place a ruler against the pis- ton rod ofthe tt eynder. Then, make a mark B" on & 8. Measure the hydraulic dit over the newt 15 mit Ryde orRormm Gfindor For 18 Minutes ‘winin 4S mm 20-26 AXSO/BXS0 SeriesTESTING AND ADJUSTING ADJUSTMENT OF CLUTCH AND BRAKE PEDAL ADJUSTMENT OF CLUTCH AND BRAKE PEDAL (CLUTCH MODEL) Stop amp switch 1. PROCEDURE FOR ADJUSTMENT OF CLUTCH AND BRAKE PEDAL (CLUTCH MODEL) 1) Brake pedal stoke aie | sisi0mm x10 mm KET the brake pedal stroke is more than the standard, check the brake show for weat 12) Adjust the height ofthe brake pec withthe stopper Bol (1) to make it approximately 127 mm trom the foor pate 3) Adjust the height ofthe lutch pedal with the stopper bolt (2) to make it approximately 153 mm from the foot pate 2 PROCEDURE FOR ADJUSTMENT OF STOP LAMP SWITCH ‘Alte justin the height of brake pedal, aust he dimension °C" to 0 to 1.5mm. ‘AXSOIBXS0 Series 20-27 :2008.9.20(1)‘ADJUSTMENT OF INCHING AND BRAKE PEDAL TESTING AND ADJUSTING ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORQFLOW MODEL) Inching pedal Brake pedal Aust an Inching Cable for play of able end tobe 0-05 mm. {No pul the Spec!) 1. PROCEDURE FOR ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORGFLOWMODEL) 1) Brake pedal stroke “Fa 18ten | sisionm 2-3 Ssionm Het brake pedal stoke is more than the standard, check the brake shoe for wear. 2) Adjust the height of tre brake pedal wih the stopper bot (1) to make it approximately 137 mm tom the floor plate. 3) Adjust the height of he inching pedal withthe stopper bot (2) to make kt approximately 159 mm from the oor plate 4) Adjust adjusting screw (8) so thatthe inching pedal can interconnect withthe brake pedal with the its stroke Inthe range of 36 mm through 40 mm aocordinghy 2, PROCEDURE FOR ADJUSTNENT OF STOP LAMP SWITCH ‘After acting the height of brake pedal, aust the dimension “C" to 0 to 1.5mm. 20-28 AXSO/BXS0 Series 2006.9.20(1)TESTING AND ADJUSTING ADJUSTMENT OF ACCELERATOR PEDAL ADJUSTMENT OF ACCELERATOR PEDAL K15/K21/K25 ENGINE MODEL am aru ) PROCEDURE FOR ADJUSTMENT OF ACCELERATOR PEDAL 1. Setthe stopper bot (1) temporary with the height of 65mm 2. Alter assembing the eable, adjust the outer easing mount of the cable to allow the pedal play of 2to 3 sm ‘3. Adjust the height of stopper bol (1) again to alow the engine fll ttle when foring the accelerator peda i ‘AXSOIBXS0 Series 20-29 12008.9.20(1)ADJUSTMENT OF ACCELERATOR PEDAL TESTING AND ADJUSTING ‘40925 /4D94L.E/4D98E ENGINE MODEL Fut gaa a ‘agement 16 | PROCEDURE FOR ADJUSTMENT OF ACCELERATOR, PEDAL 1. Setthe stopper bot (1) temporaiy with he height ot 55 mn, 2 Alter assembling the cable, aust the outer casing ‘mountof the cable to alow the pedal play between 2 team, 3. Adjust the height of stopper bot (1) agaln to allow the engine ful notte when flooring the accelerator pedal 20-30 AXSO/BXS0 Series 2006.9.20(1)TESTING AND ADJUSTING ADJUSTMENT OF PARKING BRAKE LEVER, ADJUSTMENT OF PARKING BRAKE LEVER Dy cots sang acsiment check © make sure fval ofoom fort and rer aret ofa brit tuck hasten wn oper epee, 1. Roloase the parking brake by pushing the parking brake lever 2) forward to the release postion (B) while pressing the push butlon (1), 2 Tun the aglustment bolt (8) and adjust the lever contol ore a the nial extension of the cable tobe set as flows: ‘+ Forstandars brake 47 ~ 196N (15 ~ 20 kgf) 1+ Forpower brake: 245 —204N (25-30 kgf) ‘AXSOIBXS0 Series 20-31WHEEL BRAKE TESTING AND ADJUSTING ADJUSTMENT OF CABLES OF THE FORWARD AND BACKWARD CONTROL LEVER AND THE HIGH AND LOW SPEED LEVER (CLUTCH MODEL) 1. Loosen the adusting nut and adjust the height of cables, ke the waterprot caver is improperly installed Water may saepe from the water-proct cover ‘and the Inside wil be rusted. Aer the work instal te water-proof cover to the corect pos: he AL the circulating check of new vehicle andthe rmonthy Inspection, confirm that the water root covers inetd in the caret positon 20-31-1 2006.9.20(1) “Tighten ator connecting the cables Forward and backwar onto lever cable High and low — speed lever cab ‘Gonect Postion ——_Incoeect Position ater seepsin. Wala pooh Foor Rust Incomectly assembled Correctly assembled AXSOIBX0 SeriesTESTING AND ADJUSTING Awonne ——— Forte frmara an acta once lesan te hgh an ew apes tar (2uoh mos, be pion cable adopt art oh aca of sting and aig Une the gener ea, neste ppl cable trent nane t tn catn ke When transporting or storing the cable, keep it aight If bent inadvertenty and the bend i not restored as shown in right figure, replace the cable with 2 new one. “ke Won insaling the cable, rove the flor plate at the front side to reserve the space enough for replacement and instal the cable staighty without bending as possibi as you can. ‘AXSOIBXS0 Series BLEEDING AIR a Flor plat at the ont side 20-31-2 2008.9.20(1)WHEEL BRAKE TESTING AND ADJUSTING WHEEL BRAKE PROCEDURE FOR ADJUSTMENT OF BRAKE SHOE CLEARANCE 1. Release the parking brake while fosting the wheels ‘up above the ground 2 Remove the rubber cap (2). 3. Turn the goar (1) in the dvecton (A) 0° toward the brake shoes repeatedly wih a sorewotWer untl the brake choos ehould touch the brake drum, Tuning of every notch makes sound of leks. IMPORTANT: Turn the wheels by hand to foe braking ait bit 4 Prepare two sorowervers. The first screwdriver should be used for mcly pushing the lever (2) and have it miss each gear noth, Be careful nat o push strongly. The second one should be used for turing the gear (1) toward the dfectin (B) courting by twenty-one (21) notches while the tone is stil on duty. It counts 30 notches for one turning of the gear IMPORTANT: Since no cicks are made avalace here, count the numberof notches watching through the hole ofthe rubber cap () fr carrying out the agustment, 5. natal the rubber cap () 6. Tum the wheels by hands and check to make sure that thera eno brake cragging, IMPORTANT: ‘The clearance between the brake shoe ang brake rum can be adjusted approximatay to 0.55 mm (@oarance of diameter) wih tis adjustment 20-32 2006.9.20(1) AXSO/BXS0 SeriesTESTING AND ADJUSTING BLEEDING AIR BRAKE PIPING Avene ——_ + Bebe staring Deed a, act he rake sow clearance ft pected 4010 086 me (Sane. trot te ope) + From tine om, rel he brake it preven th rae hed teresa fan ere carying ot a Being You shoul cay ou te ispecton ag om te begin beaise ts coll be ibd oe te tn Beco ones 1. Remove the eap trom the ar bleed plug (1) ofthe brake whee! oyindet. Insta one end of a plato. hose @ for al bleecing othe plug and put the other endo the hase ina container ofthe brake id ke The color ofthe plastic hose should be trans- patent a8 much as possible, 2. inspectors only one, connect a string ora wire to the upper arm of brake pedal (2) and lat the other fend of sting or wire @ lose fee in approximately ‘300 mm through the space between the frame (8) ‘andthe dashboard (), 3. Stowy pull out the sting or the wire @ connected with the brake pedal (2) arm trom the font ofthe fork 20 a8 to compress the air inside the orake piping and hot a ke I ngpector Is more than two, one inspector ‘should pres the brake pedal 4. Loosen the aibaed pg (1) of ne brake whee! cy Inder approximately 3/ turns to the let anc depress the brake podal to bie tho alr in the piping along ith the brake fic. Then, tighten the bled plug (1) hile bleeng the brake ful ke inthis stage, keep pling the sting or the we fora whi, 5. Altar tightening the bleed pg, relaase the brake pecia ‘AXSOIBXS0 Series BLEEDING AIR 20-33 12008.9.20(1)BLEEDING AIR, TESTING AND ADJUSTING ©, Repeat the step 3, 4, and § of the above unt no ‘more bubbles come out from the hose. 7. After completing one ste of brake austment, cary fut the other side of aqustment wih the same steps 18. Then, repeat the air bleeding ofthe brake and check again to make sure that no more ar lt inthe brake Ping 8, Depress the brake pedal to check ft for normal response. Then, depress the brake pedal wih depressing force of 196 Nor 20 kal to maasute the cal stroke (a). Check to make sure that te pedal ‘Stroke (a) a wihin 55 mm to 75 mm when depress: Ing the pedal Pedal Stoke: Pedal stroke @) [2-78 ten | A181 mmm when depresses. | 3=a ton | S75 mm Pray Tey =a 10. Remove the hose (D trom the air bleed plug (1), Tighten again the both side ofthe airbieed plug and Insta the ea. FEI Nibleseplug'5 9-88 Nm (08 -0.9kgm) 11, fil tho brake tue up to the MAX tne (C) on the seive tank (5) of upper master cylinder, which shows the species thi eve 12, Remove nesting or the wre @ connected wih the brake pedal arm, 20-34 2006.9.20(1) AXSO/BXS0 SeriesTESTING AND ADJUSTING BLEEDING AIR CLUTCH PIPING 4. Remove the cap from the air bled plug. Then, ft lone end of the plastic hose to the plug and put the ater end of the hose in a container ot me Brake ul 2. Loosen the air bleed pig approximately 9/4 tus and depress the brake pedal 3. Tighten the air bleed plug, Then, release the lich pedal 4. apeattne step 2 and Sunt no more bubbles come outro the hose, '5. When all the alr has been completely removed, ‘ighton the plug and instal the cap, UFT CYLINDER 1. Starthe engine and run tat low ing 2. Litup and down the mast Ik Ty to stop ling at about 100 mm betore reaching to the maximum iting and lowering height. 3, Ropoatthe step 2 ofthe above our tot times, 4 Lit up and down the mast tothe maximum liting and lowering hegnt. 5, Ropeatthe step 4 of the above four to fhe times FUEL PIPING (Diesel Engine Forklift Truck) 1. Loosen the plug (1) an move the knob (2) up and ‘down uni no more buboles come out wth he Mule 2 Tighten the plug (1) aftr completely blessing the ‘AXSOIBXS0 Series Release ovindor Air blood plug Canidge ‘Sensor and ‘iter piog 20-35 12008.9.20(1)DESIGNATED FUEL AND LUBRICATING OIL DESIGNATED FUEL AND LUBRICATING OIL GASOLINE ENGINE FORKLIFT TRUCKS Foionanse ForsHieH Fo20725080 FazoHi2sHa0H FaZ0w2sNa0n Fa6A ‘Always make sure to use exclusively Komatsu gent ine lubricating oi (Ol, grease and anti-sreeze are ave sistrbutors.) ble at Komatsu TESTING AND ADJUSTING Avrens Never we he wong pe fake fd aber enpeaiae Lubrton rit weooums [BZ ee 0 we TEE % % FS 8 BR Engine 01 Pan SAETONESH Engr 08 TOROFLOW Tannen Case SAEIOWED eet Case Gew ot Tasoae Trams Case (ote) vou Tn Engine on SAEOWED Fuel Tank assine Brake Reson Brake Fu SARTORT GAETORA, BOTS hich Resevoir resing Pont iia Gresse MiSiNee Goning yan aon AF NAG) APS 20-36 2006.9.20(1) AXSOIBX0 SeriesTESTING AND ADJUSTING DESIGNATED FUEL AND LUBRICATING OlL. 1.9~1.75 ton Forklift Tucks TOROFLOW cuuTer area [OE [sano | Omen | Pee Tow om] SEBm32 | otis | “ * i =| ons 08 Sams 25-2ston Foun et Engine OH Pan | qf ORES OMe | ran ctast case | Dire Case] Hydrauio Tank oma] REL engre 33 | nt To 48 | seoPssen | cSiae Picts FT| a oR — ca AXSO/BX5O Series. 20-37 :2008.9.20(1)DESIGNATED FUEL AND LUBRICATING OIL DIESEL ENGINE FORKLIFT TRUCKS Fororiaisii8 Fo2028/30 FozoHeSH'S0H FD20N25N/S0N FD25A, ‘Never use fuel mixed with Kerosene because ‘may damage fuel injection system, + Always make sure to use oxclusively Komatsu ‘genuine lubrication oil, (Ol, grease and anti freeze are available at Komatsu distributors.) Deeonine Never use the wrong ype of brake fu TESTING AND ADJUSTING Abert Tenperaiae Lubrication Point Twpeotouruis | a 4a 0 ge TONE SB % 10 9 0 fo ‘toe Engine O1 Pan ‘SAET0Ws0GD Engine OF ‘TOROFLOW Transmission Case ‘SAEVOWCD Diferential Case Gear ol SAEDOGLA Transmission Case (etch) yaroute Tank Engine O1 ‘GAEIOWCD —o ‘ASTM D975 No2 Fuel Tank Diesel fuel au rake Reservoir Brake Fi 'SAETOR1, SAE7ORS, DOTS Coton Reservoir Greasing Points Lithium Grease NUGINO2 Cooling System ‘Coolant (FAF-NAC) AR-NAG 20-38 2006.9.20(1) AXSOIBX0 SeriesTESTING AND ADJUSTING DESIGNATED FUEL AND LUBRICATING OlL. 1.9~1.75 ton Forklift Tucks TOROFLOW cLUTCH, Engh OF Pan] TORO OW || ATE aay | iron Caso | _ryeauto Tank Copasiy|_ gona eran | gna Ewe 7” we wm te |78 Severe) Fae Tata Fasano — | — cuir Resenar — | —coara yaa oo 42 0.15 015, AD92E Engine: 9.2 220-20 on Fore Trucks Engh OF Pan] 7 TORGELOWL | AUTEN. | rental Caso | _Pyeaute Tank Coram Egre TS) Gea Equ 7” 0 STO Type te) | SoeeE noe 7S | nt Tome s8(ed 3st) | coma peo Fa Tank Trae Recover | cua Resewor | — Soares Cae] —— STD Type «8 oe ons WDReLe Engne 92 te) | _ cama Re ‘Bone ene #2 ‘AXSOIBXS0 Series 20-39‘AXS0/BXS0 Series 30. REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY 302 WEIGHT TABLE, 204 MAST. 208 LUFT CYLINDER 207 POWER LINE. 208 DRIVE AXLE AND TRANSFER. 20-14 ALIGNMENT OF POWER LINE (1) 3048 ALIGNMENT OF POWER LINE (2) 3023 STEERING AXLE AND POWER STEERING......90.25, WHEEL BRAKE 20-28 30-1 12008.9.20(1)OVERALL DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY ‘The folowing figure shows a torque converter lype unless otherwise specties 30-2 38-27Nm \as= 43's gimp SS ein | (es es agi Suen pe ‘AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. OVERALL DISASSEMBLY AND ASSEMBLY Remove the support bots only ‘when replacing the suppert ‘AXS0/BXS0 Series 30-3WEIGHT TABLE, REMOVAL AND INSTALLATION WEIGHT TABLE 110-175 ton Forklit Trucks ‘Davos Tien isto T7500 Remar Kis Erare 1 Fae, [aT Ene 1 AD92E engine 220 itch Assemy s Torque Convener Assembly 20 Transmission [MEY He = FTOROFLOW Type 2 Front 18 axle Rear 70 Front Ey We! Fear a Gvethead Guard 10 Countenight Ey 730 380 Mast Sandaa(som) 3 ue = Forammast covinder Tx 0 Powe Stating 2 Fork Garage 74 Fo 28 Bao zi Pune 35 Ceonrol Vai 10 ‘Steenng system 6 30-4 ‘AXSO/BXS0 SeriesREMOVAL AND INSTALLATION, WEIGHT TABLE 20-5 on Forklift Trucks Tame of Devons Zon] bem [sen | osm | pena IS Engre 1s = ret Engine = = Srane, Tas erie 7 ADSLE Ergo 2s = ADe8E Engine ae Guach Assert 6 = “Toque Converter Assonbhy 2 Transmission _|Slu'eh Type 38 = assem” [TORORLOW Type 2 Dive Ane 207 20 | Soong Ao a“ ‘neu Fron mas = (Suda ypecomeact ype) [Rear 7580 ie ‘Gvetead Guard Asem 1H camereign [STE ver] taso[ ee | ae Compost Type x70 | 15571900 = Twas Asser (hel. Fork) ca | ea] 78 |e tt 35 z = cinder Tk 1% Powe Seeing 7 Fok Cariage % 72 Fok 2 3 @ % Backer 20 2 Pune 10 ‘Contol Valve @ vale) @ ‘Seeing yaen 2 ‘AXS0/BXS0 Series 30-5MAST MAST REMOVAL 41. Putblocke under the fron an the rear whee 2. Li the fork caage with the erane to remove the yeraut peng 8, Remove tne torks 4. Putblocks under the fork carage 5, After decompressing the hycraule pling, remove the piping fe eterto Chapter 20 HOW TO DECOMPRESS ‘THE HYDRAULIC PIPING. ke Altar removing the piping, the bind plug Immediately to prevent the hydraule ol from flowing out andto prevent dt or dust rom get- ting in 8. Lit up the fork cariageslgnty with the crane and remove te Blocks, 7. Uttdown the fork cartage 8. Fethe crane tothe mast. 8. Remove the titpin, 10, Tit the mast forward slighty and remove the cfr ‘ential mounting ap bot WARNING: Ifthe masts kept being tte backward, you are In danger thatthe mast may fal ver ‘Mast cap installing bolts 10-1750 | Rea 255 — 308 Nn Bo-esten | (25~315 kam) REMOVAL AND INSTALLATION 2 son astn | S27 Nm (Compact Type)_| (05 ~ 43.5 kam) 490-608 Nm {60 €2 kam} 35 t0n 30-6 ‘AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. MAST. 1. Remove te ast. WARNING: When caryng te removed mast hozontaly, ‘ secie the over sty and th ak caiage bythe anreatng wre wn tes) AA Pt 8024 under te bot of he masta ay = the mast assem horizontally so thatthe fork ew csrragels 0 op a = Je Cary outnataton na ever ercer tremor AXSOTBXSO Series 30-6-1 2008.9.20(1)LIFT CYLINDER von Sonu pee 6. Ater decompressing the hyctaulic piping, remove 3 the piping 3k Refer to Chapter 20 ‘HOW TO DECOMPRESS: THE HYDRAULIC PIPING’ ke After removing the piping ft the bind plug Immediately to prevent the nycaule of trem ‘owing cut and to prevent ator aust trom get ting 7. Crane the eyinder with sling bao remove INSTALLATION 1. tthe mast up tothe maximum iting helt 2. Check the mast forthe play on both side 8, Adjust the shime so that the both side ofthe on ors are synchronized wth each other at the max: mum ting height Reger |] oa a oyinder “Regjedio wight [Insert shims into ha right cyinder ar ai ‘AXS0/BXS0 Series Un oytnger 30-7 12008.9.20(1)POWER LINE REMOVAL AND INSTALLATION POWER LINE REMOVAL 4. Overhead Guard (Ceiling) Engine Hood CCounteeght By. cre mat sr ta te mast ining tks tr atachmer¢ mst e lowered ot dom t tre gourd or ramevedtom ne mest 2 Wiring and Battery ‘The figure below shows a gasoline model ‘Sheet Swiich Wiing Hamese Starter 8 Terninal Engine Wing Harmoss Fuse Box 3. Accelerator Wire Femave the accelerator wie 4. Piping and Hoses Hydraule Pump Piping, Torque Comverer Piping, Radator Hose, A Cleaner Hose, Fuel Hose 5. Radiator, Shroud and Exhaust Pipe 30-8 ‘AXSO/BXS0 Series 2006.9.20(1)REMOVAL AND INSTALLATION. POWER LINE 6. Power ine 1) Hoist te powerline with the cane and hold it 2) Remove the engine mount nuts rom the let and right sides of engine 3) Remove the mount nuts ftom the transmission, 4) Move the power line backward while hosting the power ine with the crane. ‘AXS0/BXS0 Series 30-9 12008.9.20(1)POWER LINE REMOVAL AND INSTALLATION 5) Draln out olin he transmission case 8) Lower slowly he power ine on the work bench ‘and detach the power ine trom the crane 30-10 2006.9.20(1) ‘AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. POWER LINE 71) Remove the universal jot. Do not remove the joint of spline, Remove the Universal joint only FFemove the bots and separate the torque con verter from the tansmisson, (Torque converter mods!) ‘counterpart ‘AXS0/BXS0 Series 30-11 2008.9.20(1)POWER LINE INSTALLATION 1 Installation of power line Insert the aligning jig C int the i B and install the ig B tothe power ine, ke Use the supplied &mm bots Gength: Ssmm pitch: tm), “ke There two types of jg. The long one is for AX vehicle. The short one is for BX vice 1) Lower slowty the power ne to mount Hon the center of engine tame, 2) Ate locaton ofthe engine mounts, aust the power line by hoisting R again so that the ‘mensions A at right and left sides become ‘mim to Sm. ke Asthe engine mount made of rubber does not slp, the powerline mounted on the engine mounts cannot be austed. Adjust ‘the power ine by hoisting again 30 that the dimensions A at right and let become equal, (Insert your hand from top and judge the equilibrium by touching the engine mounts by rand) 2. Alignment of power ine ke For lignment of power tne, reer Allgnment ‘oF power in ke Perform ater iting the body wit he er 30-12 2006.9.20(1) REMOVAL AND INSTALLATION ‘AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. POWER LINE 3, Tightening ofthe transmission mount nuts 4. Tightening of the right and left engine mount ts Tightening torque for mount nut Gn _ | Se= 12 Nm (10-125 Ka 5, Tightening ofthe hydraulle piping ler to Chapter 10 “TIGHTENING em | Tonave woz, 6. Installation of cable Installation of accelerator cable ke eter to Chapter 20 "ADUUSTMENT OF ACCELERATOR PEDAL’ Installaton of inching cable. (Tertiow model) “hetero Chapter 20 ADJUSTMENT OF INCHING ‘AND BRAKE PEDAL" (TORGFLOW MODEL), 7. Installation of the bonnet and the head guard 8, Tightening of counter-weight installing bolts ‘AXS0/BXS0 Series 30-13 :2008.9.20(1)DRIVE AXLE AND TRANSFER, DRIVE AXLE AND TRANSFER REMOVAL, 4. Remove the mast. fe Ratorto the kam MAST 2. Drive axle and Transter Incase of normal emovalnstallaton (except replacement ot support of tnt axe) remove the front ave instaling bots (B). Do not remove the suppor bots (A) of front ave 1) To keep the frame about 10mm above the ‘ground, place the blocks under the frame. 2) Place the carrier as shown in ight figure to hold he front axl, 3) Mark the markings (C) and (0) on the support of ifeential and the trot axle for aligning he Marke at bot at and ight sides 3. Remove the brake pip. 30-14 /2006.9.20(1) REMOVAL AND INSTALLATION ‘AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. 4. Remove the parking brake cable. ‘AXS0/BXS0 Series DAIVE AXLE AND TRANSFERDRIVE AXLE AND TRANSFER, INSTALLATION 1. Drive axle 1) Insta the aligning jg Ato the cient. Insert the aligning ig B ito the algning jg © and instal the ig B to the pow ine 2) Install the ctve ae, aging it withthe mark: ings ¢ and. (The markings © and D are marked when removed.) Tighten! 3) Algn the power ne. “ke For alignment of powerline, refer tothe tom “ALIGNMENT OF POWER LINE? 2. Universal joint Tightening of universal joint installing bolts 30-16 2006.9.20(1) REMOVAL AND INSTALLATION ‘AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. 3, Tighten the transmission mount bots. 4. Brake pipe Tightening of brake pipe Gm_[ 24-382 NBS-38K9M) Fe loosing air tom tne brake fer to "20. TESTING AND ADJUSTMENT (20 38) BLEEDING AIR" te Pedal Aqustment Refer to "20. TESTING AND ADJUSTMENT (20 28) PEDAL ADJUSTMENT’ DAIVE AXLE AND TRANSFER 5 Mast Mast cap installing bolts yoni 7m) 17a 1860 = 175ton | (re—zokgm Doubs "245 309 Nm =25t0n | (25—Si Skah Bo-BSton —|_38-2TNm (Compact Type) | (25-438 kgm) “490 608 Nm 3510 {60-82 kgm} ‘AXS0/BXS0 SeriesREMOVAL AND INSTALLATION. ALIGNMENT OF POWER LINE ALIGNMENT OF POWER LINE (1) he When removing *Drve Ale + Tiansfr" or Power Line, be sure to algn the power ine MEASUREMENT OF ALIGNMENT SHIFT 1. Make the jigs shown below. 4) Drive ase side (A) 2) Transmission side jg (®) 3) Jig() AX voile: 115mm BX vehicle: 7omm Special bot & mm X 35 mm Unit nm ‘AXS0/BXS0 Series 30-19 12008.9.20(1)ALIGNMENT OF POWER LINE 2. Inatalth jo (A) tthe ve ane sie, 3. Insert the jg (B) In the jg (C) and then install te fo (8) to the transmission side ke stall the jigs win the supplied mm bots {Length a5mm,pich 1mm). Keep them notto los, ke There are two types of jig (C). The long one Is for AX vehicle. The short one i for BX vehicle, 4 Slice the ja (C) toward the jg (A) ane measure the (9 (a) andthe dterence (b) Judging reference Cap@pewean ta Mae) | goog Diference (b) between fg (A) ahd piles atosmm Jk When measured wit jos, the value is more than mm, the power line Is not properly insted Holst tne power ine with crane again and re instal the pote ine tobe property acusted ALIGNMENT PROCEDURE 1. When there is a gap at upper ot lower side: ‘Cause: Worn-out mount rubbers at ront and rear Countermeasure: Replace the mount rubbers at front and rear sides with new “ke Atter replacing the mount rubbers, he gap cannot be eiminatod, creck the installed state of dive axle If any loose bot i found, adust the instaling pos tion of dive ale (A shim cannot be used for acust ment) 2. Won there ie the shit at upper oF lower side (Cause: Worn-out mount rubbers at ront and reat Countermeasure: Replace the mount rubbers at front and rear sides with new “ke_AMtor replacing the mount rubbers, tthe shit cannot be corrected, cneok the installed state of cive axle If any loose bot i ound, aust the netting pos: tion of criva ale. (A shim cannot be used for aust ment) 30-20 2006.9.20(1) REMOVAL AND INSTALLATION oA | Kk yy © Lee Jig mt, Joa Side 08 Jac “Dive ae side ———_‘Tranamissionside-+ wa 29S AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. ALIGNMENT OF POWER LINE 3. When there is a gap at lft or right side: Cause: Countermeasure The mounting postion at the engine side or the transmission side is shied (Especiay engine side) Holat the power tne with crane again and reinstall to tat the dimensions A at the engine ‘mounts are oto Sm, 4. When there the shift at let or right side: couee: Countermeasure ‘AXS0/BXS0 Series The mounting pesiton at the {engine side or the vansmission cide ie eed, (Especialy transmission side) When adjusting the postion of ‘mount hole at the wanemission ‘sid, do not move for, Hoist the power line with crane again and reinstall the power line tobe property acted, b009| e000, 30-21 12008.9.20(1)REMOVAL AND INSTALLATION. ALIGNMENT OF POWER LINE ALIGNMENT OF POWER LINE (2) “ke Winen removing the powertrain ont axle or Transmission/engine), always be sure to take an alignment between the ‘ront axle and the tansmisson, Measurement of Alignment 1. Prepare the tools as shown bellows (@) Special tool fer removerinstall back lamp/Neutal itch for manual ransmission (&) Block for Water level meter for manual ransmission (@) Liypebicek tor axe (© occ Water love! Meter oe & {@) Special too for Neuraback lamp ston (0) Blook for Water tvel moter — (©) L-type biook or Axe (@) Electric Water Level Met ‘AXS0/BXS0 Series 30-23 :2008.9.20(1)ALIGNMENT OF POWER LINE REMOVAL AND INSTALLATION 2. Remove Oi Level Plug fom Front Ale and instal the L type block by Pug, ‘Then put Eletic water lvel meter and measure leaning angle of rot axe 8. Measure leaning angle of Engine/Transmission + Manual Tansmision Remove the Neutral site! Back lamp swith from vansmissin. + Automatic Fansmission Remove transmission contil valve ‘Then put electric water level meter onthe machining surace of ransmisson as above. ‘And reaing the leaning angle of transmission. 4 Service limit of leaning angle of Tansmission and Front axle, Maximum 0.5degree between Transmission/Axle leaning 5. When angle of leaning Is more than 05 degree, ts shows wrong postion in ether the trent axle or enginatransmission CCheckhe engine mounting and axle mounting. 30-24 (for Manual ransmission) AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. STEERING AXLE AND POWER STEERING STEERING AXLE AND POWER STEERING TST BSN {16-25 kgm} ‘AXS0/BXS0 Series 30-25WHEEL BRAKE REMOVAL AND INSTALLATION WHEEL BRAKE REMOVAL 11. Front Axle and Torque Shaft 1) Apply the whee! stopper tothe rear wheal 2) Place the wooden blocks under the bettom of the truck rama to lit the front wheels. 3) Apply he parking brake 4) Remove the hub aut and then the torque shat [ 10-1.75 ton @. 5) Release the parking brake. 20-80t0n 30-26 ‘AXSO/BXS0 Series 2006.9.20(1)REMOVAL AND INSTALLATION. WHEEL BRAKE 2 Hub 1) Remove the bot (4 2) Remove the lock nut (6) with a special oo (80 mm double face bor) 18) Remove the hub not to be twisted upside down 75ten 20-a0t0n INSTALLATION 1. Back Plate (when removed) ‘Apply the Lotte tothe mounting Bok (1) and tightan leith tightening terque specited as follows: Gam | 78196 nme 2O KER Sa = ‘AXS0/BXS0 Series 30-27WHEEL BRAKE REMOVAL AND INSTALLATION 2 Hub 1} Install anew ol soa, ke Apply the grease G2Lt on the ip sutace of the ol seal 2) Fil me grease G2-L1 in the bear Instal tothe hub) 3) Remove drt or fat anol inthe inside face of the brake crum (@) competey. 4) Install the hub to the shat tube 5) Tighten the locknut (6) 50 that the staring torque of the hub ean conform to the folowing, 9 (7) and Gang Seana | .1—15:7 nm (625-160ka) 18) Tighten the bot (4) after appiing the Loctite Ks (ostte #271 30-28 10-1 78t0n ° \ ; : i : , “8 A gy ‘ ‘AXSO/BXS0 SeriesREMOVAL AND INSTALLATION. WHEEL BRAKE 3. Front Axle and Torque Shaft 1) Install the torque shat (3) and tighten the bolt (2) wt gttering torque specie as follows: i ec) 2) neta he font asl and ghtan the hub cut (1) wit tghtening torque spectid as folous. 294 490 Nm (8050 Kar) ‘AXS0/BXS0 Series 10-1760 20-a0t0n 30-29‘AXS0/BXS0 Series 40. DISASSEMBLY AND ASSEMBLY cure CLUTCH MASTER CYLINDER, CLUTCH BOOSTER ASSEMBLY. CLUTCH TRANSMISSION. TORQUE CONVERTER TOROFLOW TRANSMISSION DIFFERENTIAL DIFFERENTIAL ASSEMBLY DRAWING. WHEEL BRAKE [BRAKE MASTER CYLINDER, COMBINATION SWITCH SOLENOID VALVE STEERING VALVE. STEERING AXLE POWER STEERING CYLINDER ASSEMBLY. LUFT CYLINDER TILT CYLINDER, CONTROL VALVE, MAST. FORK CARRIAGE. FLOW DIVIDER RESERVOIR ASSEMBLY HYDRAULIC PUMP, UNIVERSAL JOINT. 402 40-4 408 4013 4028 40-41 40-50 4058 40-84 4087 4071 4073 407 40-78 40-96 40.92 40-99 40-101 4oeit2 40-178 40-122 40-126 40-127 40-158 40-1CLUTCH DISASSEMBLY AND ASSEMBLY CLUTCH DISASSEMBLY AND ASSEMBLY "1. Applya tin layer ofthe MOLY-PASTE wen assombing °2. Apply the Iithium grease (G21) to the lp STN (6-754gm) 40-2 ‘AXSO/BXS0 Series 2006.9.20(1)DISASSEMBLY AND ASSEMBLY CLUTCH CLUTCH ASSEMBLY DRAWING ‘1: Bolt Thread +2: Remove the bal ater nctaliation, A] @u xe) SU AN | later) iNe| MOLY PASTE ‘AXS0/BXS0 Series 40-3 12008.9.20(1)CLUTCH MASTER CYLINDER DISASSEMBLY AND ASSEMBLY CLUTCH MASTER CYLINDER COMPONENT PARTS et. Ne. Part Name oy 1 | evinder 1 2 _| Piston Assembly 1 3 | Sup Pie 1 4 | Snap Ring 1 s_| Beet 7 8 | Push Roa 7 7 | Ne fl 8 | vow 1 9 | Bushing 1 10 _| Filer Union 1 1 ° 10 2 & 3 4 6 ® z 8 Unt mm No ‘Check Kem ‘Standard Sze epairuime] Remedy | Ref. No |_| learance between Gylinder and Te 1 Replacement |, Piston 0016 -0.088 18 | (oyinger Ascemby) | 12 ‘ghening Atowance ot Gap | limary side: approx. 0.8 ¢ Replacement 2 [Tightening Alowance of Cup | Seconaary sie: approx.09 | (Paton Assomey) |? [Spring Free Length 75 as Replacement 2 40-4 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY 1. DISASSEMBLY 1) Remove the bushing rod and the boot 2) Remove the snap ing, 3) Remove the stop pate and the piston assem: by 2. Disassembly of Filler Union +) Litup the filer union hosing the hose connec: ton, 2) Insert the screw ver (negative type) between the bushing (2) and the cylinder (1) to remover the bushing —— Avrrwina + Be caretu not to damage the cylinder, te pston ot the cup. + When earring out sassombly. make sure that you fuly understand the structure ofthe cylinder eo that you can layout the csassemblad parts inorder. + Never sisasserble the piston assembly. + Never push tne surface ofthe evince mth a vise ‘AXS0/BXS0 Series CLUTCH MASTER CYLINDER, 40-5CLUTCH MASTER CYLINDER DISASSEMBLY AND ASSEMBLY INSPECTION AND ADJUSTMENT Part Name (Check tem Remedy n | __|* Remove emal scratches wth sancpaper oyinder Seratches, uneven waar o > ertealacratones are found o affect adversely the cup, corresion of nets curtace replace it with a new eylinder assembly, Seratehes, uneven wear corrosion of aang section = Remove aml scaiohes with oetone, ifemieal scratches are found to affect adversely the inner fae of eytnaer or te cup, replace i with a new piston ‘ese. Piston Clearance between cynder ana |* {He clearances eae than the ep nit epace th Peton Pepair UE OTS vatches on + Even tthe scratches are very small, replace i wit a new Scratches on fe piston assembly > harmful piting found, replace witha new piston ting ofp base rm iting ; Pl soln + abnormal deterioration, wear or weling is found replace cup Wear or sweling twit 3 new piston assembly, Tightening lowsnce [its beet pari ope Wiha e paon sneete [Aero bio ote paste repcne pia ou ache ot sch LE es Cynder Assembly Vaive roa ave cup Spring Detormaton, sratches or wear ot imble + abnormal deformation, scratches or wea is found, replace Itwitn a new piston assembly, 1. ease 2 up 3. Base 4 Up 40-6 AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY CLUTCH MASTER CYLINDER Pat hae Tpecion on = Goaucs ew > Te fn be en apne ‘Spring [> ‘Those of below the repair limit must be replaced with a Freeing mone sonny caste o gunvoanon Thee fous oa iron aban mun noa Goan doamaton Teste amon ne co Gace dmagporsoatine | Tiepel gs enape or ovens rib arand soot Titra atowarce bowen |» Those ofr taoning wovanc ay exvoney ie ans ares aang ican Bus be apace wee ew a mene > Even oass ae enone al pe twine Fier non eoncaion Theta seorton mabe rpeawina Beaches Thos of elches must oped wh anew oe AW TENANce STANDARD nem 7 check Saad Soe Repu Lint Taree | eran bowen oder ard Fepaceren 0016-0088 oss: ston (yinder Assemoyy) ring Clearance o Cu Primary side: approx. 0.9 a Replacement 2 |Tiamtening Clerance ot Cup | Secondary side approx. 0.9, °. (piston Assomby) | Spring Free Length 75 ors: Replacement ‘AXS0/BXS0 Series 40-7CLUTCH MASTER CYLINDER ASSEMBLY 1. Assombly of Master Cylinder 1) Use aleoho! of brake fluid to wash al the parts Never soak such parts asthe cup or other rub ber parts for more than 30 seconde when ‘washing inal 2) Apply rubber grease or brake thi evenly othe inside face ofthe eyiner and the outer ctcur ference ofthe pleton 3) Install the plston assembly and the stopper plate in the oyinder. 4) Install the snap rng while pushing the piston 5) Assemble the boot ard nut in tur to the push 6) Assembly of Fir Union ‘+ Apply rubber grease or brake fluid to the bushing (8) and push Icinto the fing pos ‘on ofthe cyinder (1). Then, push the iter union (10) into te fing hoe of te bushing @, ‘+ Push the lr unin (10) into mounting hole of he bush (). Avance DISASSEMBLY AND ASSEMBLY “+ Never use any ful of char tnan alcohol or rake Fuld to wasn the parts. n particular, never use mineral oll auen 25 petroleum and gasoline. I mineral of sticks onthe rubber part, they may swell and become unusable, ‘+ Koop the pars ina clean place to prevent the parts rom sticking dit or dust after washing. ‘+ Aways keep such parts asthe cyinder, the piston or the cup away tom any foreign matters that may damage those parts serious. 40-8 AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. CLUTCH BOOSTER ASSEMBLY CLUTCH BOOSTER ASSEMBLY ‘COMPONENT PARTS Pt, No Pat Name oy Ret. No Pan Name oy 7 [Booater Seay 1 a7 |e 2 2 | Piston 7 18 |Yore 7 3 |Snapring 1 18 [Washer 2 4 [seal 7 20 [Backup Ring 7 5 [O-Ring 1 21 [Spring 7 6 |Seina 1 22 [Serna 1 7 [Picton Guide 7 23 [ovinder T 8 [Snap ing 7 24 [Filer Union 7 ° low 1 25 [Busting 7 10 [O-Ring 7 6 [Sud Bor 2 a1 |¥Packng 3 27 [Piston Assemiy 7 32 [O-Ring 1 28 [Master Cyinder Assembly | 1 18 | Washer 7 28 [valve Assemby 1 74 /Pin 7 30 [Booster Pkton Assembly | 1 18 [Boot 1 ai [Ring 7 16 | Push Roa 1 22 |Steei Ban 7 ‘AXS0/BXS0 Series 40-9CLUTCH BOOSTER ASSEMBLY DISASSEMBLY 41 Loosen and remove the Boks mounting the booster anc the master cylinder “fee careful not to mix he Mud being usec for nese art asthe fuld tiers each other, 2 Disasserbiy of Master Cylinder: 1) Remove the piston assembly trom the cylinder 2) WF ie hard to remove the platon assemby, apply a shoot of Board on the side of cyinder ‘and add low-pressure ar fom the filer union cup gradual Aisne ‘+ Be careful not to damage the oyinde, the piston and the cup with scratches, '+ Never disassemble the piston assembly ‘+ Never soak such parts as the cup or other rubber parts for more tnan 90 seconds when washing 9 Aloo. 3, Disassembly of Booster 1) Remove the boot andthe pushrod 2) Remove the snap tng 3) Push the rod from the connection side ofthe master eynder anc remove te nner pat. Avrora + Be careful not to damage the cylinder, the piston or ‘the cup with sozatches, ‘winencarying out zascemby, make cute that You fully understand he suctue of the cyinder so that yuan lay out the disascombled parts inorder. ‘+ Never push the surtace ofthe cylinder witha vise, + Never remove the seal ofthe piston of the valves, which must be replaced on assembly basis 40-10 DISASSEMBLY AND ASSEMBLY ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY CLUTCH BOOSTER ASSEMBLY (CHECK AND INSPECTION Arnis “+ Never use any other than alcoho or brake fc ta wash or clean the parts. In partoular, never use mineral euch as pevoleum and gasoline. it mineral ol stoke on the ruober parts, they may swe and become unusable “+ Never soak such parts asthe cup or ater rubber parts for more than 30 seconds when washing in alcohol. + Koop the pats in @cean place to prevent the pars from sticking dt or dust aftr washing. ‘+ Atways keep such parts as the cylinder, the piston or the cup away rom any foreign body that may damage those parts seriously (eX) m\ /4 4. Spring 8. Rear Custion Piston 2 Bushing 10. Cup 3. Filler Union M1. Peli! Vave: 4 Oyinder Body 12. Oytinder 5. Powor Piston 13, Pod 6 Boot Packing 7. Push Rod 15. Piston Assembly 8 YoKe ‘AXS0/BXS0 Series 40-11 /2006.9.20(1)CLUTCH BOOSTER ASSEMBLY DISASSEMBLY AND ASSEMBLY Booster Side: No | PatName Check term ‘Gheck Paint Femecy | Ref No. 7 |evinaer [Scratches on __Exremely small scratches mustbe [Replacement | 12 siting face or wear |removed with sancpaper. Those ct [withthe booster Raving eitea scratches to alfect” [assembly versely tothe seal must be replaced with te eyinder assem. Clearance between [Those of being below the lint must be eyinder andpiston [replaced win a new one 2 [Power Piston [Scratches on [Extremely small scratches mustbe [Replacement | 5: Assemoy sicing fae or wear |remavee with sancpaper wih tne booster Piston assembly [Damage of seal [Those ot having damages or remarkable wear on te Seal mustbe replaced wih anew one 3 [Retet vate Scratches on [Exiemely small scratches mustbe [Replacement | 11 ‘Assomby sicing face or wear | removed with sandpaper wih tne Booster ston ascorbly [Damage ofsesl [These ot having damages or remarkable wear on te seal mustbe replaced win anew one “4 [RearGustion Piston [Scratches on [Extremely smallscatches mustbe [Replacement | 9 ‘Ascomoy sicang face or wear | removed with sancpaper wth the Booster ston assembly [Damage ofeeal [Those of having camages or remarkable wear on te coal mustbe replaced win anew one 5 [sping Scratches, [Those of having remarkable soratches [Replacement | 1 wear ota or wear must be replaced with a now Free length These of being below the lt must be replaced win anew one © [fos [Scratches on [Extremely small scratches mustbe [Replacement | 13 siding fae or wear [removed with sandpaper. Those of having erica scratches fo aft versal othe seal must be replaced ith te cylinder assembly 7 [Y-Packing, Cup, [Damage of seal | Those of having damages or Replacement | 10, 14 O-Ring remarkable wear on te sea! mustbe replaced wen anew one [Push Roa Deformation and [Those ofhaving deformation or [Replacement | 7 wear remarkable wear mustbe replaced wth 9 [Boot racks | These othavingeracks mustbe [Replacement | 6 replaced win arew one rghening These of having any tighening alowance between boot and eyiner clearance must be replaced win anew 40-12 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. [Master Cylinder Side:$ CLUTCH BOOSTER ASSEMBLY No | PatName ‘Check tem Check Point Femedy | Ret No. + [evinder [Scratches on __[Exremeiy small scratches mustbe [Replacement | 12 siding face or wear |removedwith sandpaper IThaving [wth the master erlcl scratches to affed adversely to foylinder the seal, replace Rvth the cyineer [assembly fasserbly. [Coarance benwoen | Those of beng below the lit must be ender and plston [replaced witha new one 2 [Piston Assembly [Scratches on [Extemely smallscraiches mustbe [Replacement | 15 icing face or wear |removedt itn sandpaper. ih the piston fassemby [Scratches on SP |Thase ot having sratches on te lp Jeupand wear" |mus be replaced wih anew one. Tightening [Those of beng below the limit must be clearance between |replaced with a new one ston and.cup | Tightening clearance: 04 mm) [Sertohes on vane [Those ot having damages or ow remarkable wear on the seal must be replaced witha new one 3 [Spring [Sertches, wear or [Those of having remarkable scratches [Replacement | 1 ai or woar mustbe replaced wih anew Free nat Those of bing Below the lit must be replaced with a new one “| Filer Union, Sushing |Soratcies crash or | Those of having scratches, crash or [Replacement | 2.9 scoloraton| femarkable cotoraton must Be replaced witha new one “ke The refecence numbers in the rghmest colurm ofthe table show the pat names in the figures on the previous page. ‘AXS0/BXS0 Series 40-13CLUTCH BOOSTER ASSEMBLY MAINTENANCE STANDARD (Clutch Booster Assembly yy DISASSEMBLY AND ASSEMBLY ios Ua Citra par Lin No | check tam Remedy Sandra Repair Standard Size | Shaft Hole Clearance | Clearance erence between cam | soa | oaao— 7 Joytinder and piston 0254 0.053 0 0.105, 9.780 lerance between oa | voase | oma 2 | cyinder and piston 022.22 0.053 oO 0.105, 0.180 Free eng | Fig length | Fing load N ks Freleng 2 | Detention of sping epacamect 22 738 eam) 25 @ [Deterortion ofapeng | 108 e Bea ws © [Dstrormionatapeng | 148 10 rare 8 © [Deterioration at pring | 736 a8 242) @ Eira 7 | Tightening torque -20—90Nm (2.1 —3.1 kgm) lightening 40-14 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY ‘ASSEMBLY 1. Assombly of Mastor Cylinder 1) Us alcohol or brake fd to wash or clean all the pars tobe reused [Never soak such parts asthe eup or other rub ber parts for more than 30 seconds when ‘washing in leohol 2) Apply rubber grease or brake fut evenly tthe Inside surtace ofthe cylinder and the cutside ‘ereumerenee ofthe piston, 13) Assombio the olinder with the piston assom: bly, where no engp rng ean be used, Avreons ‘+ Novor use any fd ol othr than alcohol or brake fluid to wash or lean the parts. In paricular, never use mineral ol such as petolsum and gasoine, I mineral cil sticks on the rubber parts, they may ‘wel and become unusable ‘+ Keop the parts ina clean place to proventthe parts from stoking dt or dust ster washing, ‘+ Avways hoop such parts as th cylinder, te piston or the cup away ftom any foreign body that may damage those parts serous ‘AXS0/BXS0 Series CLUTCH BOOSTER ASSEMBLY 40-15CLUTCH BOOSTER ASSEMBLY DISASSEMBLY AND ASSEMBLY 2 Assembly of Booster 1) Use fusing ol or mineral hysraue ole wash athe pats tobe reused Use mineral hydraue ol to wash the rubber parts. Never use petroleum or gasotne to wash the rubber pars. 2) Assembling the rear cushion piston: + Assemble te O-ring and the backup plate ‘withthe rear cushion piston, 1+ While matohing te eit vas hole wth the rear cushion piston hole, push the roliet vale int the rear cushion piston. Check to make sure that the both holes are matched “Then, inser the pi, 3) Assembling the power piston sub-assembly ‘+ Apply the nycrau oto the bocstor piston ‘assembly and the rear cushion piston. “Theo, instalthe spring othe booster piston and inset the rear cushion piston into the booster piston ‘+ Incort the ring am the side and assemble wth te snap ing, 44) Assembling the piston guide: ‘+ Apply the grease tothe cup the O-ring and the Y-packing, Then, assemble them with the piston guide. Make suro not to make a mistake in aspembling decton, 40-16 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. 5) Assembling the ¥packing to the plston guid: + Api the grease to the Y.packing. Then assemble t wth the plson guide, Make {10 not to make a mistake on ts assem- bing erecton. 6) Assembling the power piston assembly: ‘+ Apply the hydrauke olf the Inner face of the boey and outer surroundings of the ower piston. Insert te spring and the ower piston assembly int the cylinder. ‘+ Pushing the pston guide into the rear cush- lon piston, check to make sure thatthe ps- ton 8 ready for assembling. Then, ‘ascemble it wth the snap tng. 7) Assembling the boo: ‘+ Pushing te rear cushion piston by hand, check to make sure that moves smoothly, ‘Then, assemble Rwith the boot. 8) Putthe pushrod and assemble wth the boot, ‘he nt andthe yoke in tun a= | T2Nm (08-12 Kam) CLUTCH BOOSTER ASSEMBLY parts serious, Awonne + Never ae any doer nan ho! or bake a to wash or ean he pan parte never emia tuch ae peleun and gaelne mineral ol eit on the tbe pat, fey may evel and become unable + Keop the parts na clean place to preventhe pars om steking tor st ar washing {nay eps parts ah yr, he tno cp ay om ary feign bd hal may damage those ‘AXS0/BXS0 Series 40-17CLUTCH BOOSTER ASSEMBLY DISASSEMBLY AND ASSEMBLY 3, Assembling the master cylinder: 1) Assomble the booster body with the master cy Inder assembly and tighten It withthe nut (1) ‘spectied as flows: Gan | 2 -Wiin eto eT 40-18 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY CLUTCH TRANSMISSION DISASSEMBLY +. Cuteh case 1) Remove the clic release eyinder (2). 2) Remove the bolts (8) connecting the clutch ‘case and the transmission case to separate the clutch case 2. Shifter Yoke Lover Remove the bot to take the shifter yoke shalt out Then, remove the shiter yoke lever. 3. Drive Shatt 1), Femove the snap ring (10) and pin (11) being ttsed to hol the ve salt a the input nat 2) Pulte orve shaft (12) out ‘AXS0/BXS0 Series CLUTCH TRANSMISSION — 40-19 12008.9.20(1)CLUTCH TRANSMISSION 4 Output shatt Aone ‘A LOCTITE appt the bot (1), be sre ute the otaton topper remove the bat) DISASSEMBLY AND ASSEMBLY 1) Remove the bol (1). Then, remove the bearing (2) the gear @), the bearing (), the sea (6) ‘andthe spacer (6) In tun, Filly, remove the ‘output shat (7) from tho botom of te case. 5, lor Shaft and Shifter Yoke Pall ut the idler shat assembly (6) from the case together wth the shiter yoke assembly 40-20 2006.9.20(1) 1. tock ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY CLUTCH TRANSMISSION 66. Input Shaft and Shite Yoke Pull out the input shat assembly from te case. 7. Shiter Yoke Remove the snap ring (7) and the bot (8) from the ‘shaft (6). Then, row the yoke (8). ‘AXS0/BXS0 Series : 1 Block 40-21 /2006.9.20(1)CLUTCH TRANSMISSION DISASSEMBLY AND ASSEMBLY ASSEMBLY 1. Shifter Yoke ‘Assemble the shifter yoke reversing the steps taken for disassembling Tightening Torque for Bote: Gan | 27-34Nm 20-3 5km) oNs | WOCTITE A271 (Thread of Hole) 2. Idler Shatt Assembly 1) Secure the bearing postoning at botn ends of ‘the ier shar wth te holder ana the bot Tightoning Torque fr Bots: ep | 27-34Nm@e-asKon) Poe | LOCTITE #277 (Thread o Hole) 2) Install he ile shat assembly and the shiter yoke assembly inside the case. 40-22 2006.9.20(1) ia — Block ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY CLUTCH TRANSMISSION 3. Input Shaft Install the input shalt inside te case. 4. Output Shatt Avernne When tightening the Bok (1), be sure to use the rote ton etopper Jo eo that other gears engaged do not Rotation stopper ig 1) Insert the spacer (6), the seal (5), the bearing (4), ho gear (3) and the Bearing 2) to he out put shaft and secure withthe washer and the bot (1) Tightening Torque for Bots: Gael | 68~ 128 Nm (T0~ 125 Kam) PoRe | LOGTITE #271 ead of Hole) 2) Insert the shaft (7) and secure wath te pln (8) and the snap ring) ke Apply the shaft with the MOLY PASTE nen ascembing ke After assembling, move the shat in the ‘vil retion to make sure that is held inpostion securely ‘AXS0/BXS0 Series Block 40-23 12008.9.20(1)CLUTCH TRANSMISSION 5. Clutch Case 1) Insert the ange (1) to the input shaft. Then, ‘secure othe clatch ase wit the bois (2). 2) Inset the cage (8) inthe clutch case hole located atthe upper ier shaft. Then, secure wth he bo). 3) Apply the fld gasket tothe contact face with the clutch case ofthe tansmission case and ‘connect the clutch case wth the bots, 4) Insta the cto release oyinder (5), 5) Thread the shit yoke lover shat in the shit yoke ever an tighten I wth the bot. Tightening torque for shaft yoke lever shaft Ge |= TANmIe-7 Kom ‘Appl thinly clean lium grease (32-11) tothe lip of oll seal ‘when inetaling the ol seala, enant them 96 ‘shown in ght igure. Press-insert the of-seals with cauton not to ‘damage the ip and be bas. ‘Appi lithium grease (G21) to the suriace where ne ever contacts, + + tH 40-24 2006.9.20(1) DISASSEMBLY AND ASSEMBLY Contacting sure ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY CLUTCH TRANSMISSION ©) Install the neural switch and the back lamp wen Back lamp owt Tightening torque Neutral site 26 -383Nn 23-34 kG) ‘AXS0/BXS0 Series 40-24-41 /2006.9.20(1)DISASSEMBLY AND ASSEMBLY CLUTCH TRANSMISSION (CROSS SECTION DRAWING OF CLUTCH TRANSMISSION + Move te shaft in the axial rection to make sure thats ned in postion securely. AX [MOLY PASTE : J a 22 | es-sskgm «Ds LOcTITE #271 Xe | MOLY-PASTE aim - a oe | AS | ai8-162Nm oe | 2 teskam ADS | loorrewr ‘AXS0/BXS0 Series 40-25‘TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER [Aker washing the outside ofthe torque convertr, cary ‘out elsassemoling na clean place as follows: DISASSEMELY 1 Removal of Torque Converter Assembly Drain the ol ftom inside vansmisson, Then, rove the torque converter assembly from the engine and the transmission (4241.5 Drain Pug) (12:mm Socket Wreneh) 2. Removal of Oi Fiter Femove the ol special too, 3. Removal of Torque Converter Remove the torque converter (1) slowly trom the housing “fe Be carful not to damage the of seal and the ‘sealing of the gear pump. 40-26 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY 4. Removal of Gear Pump 1) Pemove the bats mounting the gear pump. (Mx 1.25 Bott pes) (Socket Wrench 12 mm) 2) Remove the gear pump (2). Then, remove the (O-ting iit remains nse the housing 5. Removal of Strainer 1) Remove all the bots mounting the cover ofthe strainer. Then, remove the cover (11) and the gasket (12) (Ms x 1.25 Hexagon Head Bot with Fange: 8 2) Pull out the stsiner assembly (12) from the housing, He Be caret not to damage the Oxtng for the sraner aszemby. ‘AXS0/BXS0 Series TORQUE CONVERTER 40-27‘TORQUE CONVERTER 6. Removal of Main Rellet Valve 1) Remove the main rl vale plug (428 «15 Plug) (Socket Wiench2mm) Awirrna Be careful for he plug that may be jumping out freed bythe sping rom inside the valve. 2) Pull out the piston and the spring trom the vane, 7. Removal of Inlet Port Reliet Valve 1) Remove all of the bolls mounting the valve cover. Then, remove the cover (9) and the gas ket (10), (U6 + 1 Hexagon Head Bott uth Hole: 4 pes) (Hexagon Wrench § mm Awernins Alay be sure to press the cover while removing the bots to prevent the plug from spring out from inside the vate 2) Pullout the piston (7) and the springs (618) from each valve. 40-28 DISASSEMBLY AND ASSEMBLY oJ mamp 8 7 8.10 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY ‘8. Removal of Gear Pump 1) Pomove the Oving and disassemble the goar ume. 2) Remove the screw at one place for cisassem- ‘AXS0/BXS0 Series TORQUE CONVERTER 40-29‘TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY ‘COMPONENT PARTS 40-30 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. TORQUE CONVERTER Pat Ne Pat Name oy | [Rene Pan Name oy + [Torque Converter Circa 7 @ [Covera 1 1-1 _[Torave Converter Sub-Ci 7 10 [Gasket A 7 12 [input Plate Assembly 7 11 [overs 7 1-3 [Hexagon Head Bor 048) 3 12 [asker 7 2 [Gear Pump Assomoiy 1 12 | Sirainer Ascombiy 7 21 |GearGasing 7 14 [Hexagon Bot (Ma) 5 22 [Dive Gear 7 16 [aesket 5 23, |Drven Gear 7 16 [Hexagon Head Bot (we) 4 24 [ousear 1 17__[ Hexagon Head Bot (46) 8 25 [Countersunk Head Serow 1 13 [Hexagon Socket Head Piug RIM) |S 26 | Stator Suppon 7 19 [Nepie 7 27 [orn 1 20_ [or Fiter 1 28 [Inner Fing| 1 21 _[INSULOK TIE 7 209, [Sealing 7 22 [Drain Pug 2a) 7 3 [Housing 1 23 [o-ring 7 [Piston 7 24 [Pug (may 7 [Pressure Spring 7 25 [o-ring 1 6 [Pressure Spring 1 26 [cater 7 7_[Pison 2 27 [Hexagon Socket Head Pug (RSM) | 2 @ [Pressure Spring 7 28 [Pug (wen) 7 ‘AXS0/BXS0 Series 40-31‘TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY INSPECTION wns mm Grier No Check tem Ret. No. Siandard Sas. Repair Lint Piston Shaft and Torque Converter Housing Hole Zz —, ' <| 2 7 JA: Piston Outward Fam | 021.972 021.985 = 4 141 |Main Reet Vane [B:Hole Inner Diameter | 022.000- 022.021 = 3 Ctearance 0.015 0.088 0.080 = JA:Piston Outward Fom | 14960-01497 = 7 ‘12 | Torque Converter inet Por a = 2 | Forgua conv Br HoleInerDiameter | 014000- 014018 3 tearance 0.080 0.088 0.080 = [A:Praton Outward Form | 014860- 014.970 = 7 113 | Lubrication Rotet ave [B:Hele mer Diameter | 914.000 o14018 = 3 [iearance 0.080 0.058 (0.080 = Pressure Spring 2 [C:Free Length 918 = 6 24 [Main Relist Vane Dining Length 734 = = Fixing Load N 105425% 1669N) = [o:Free Length 1036 = 5 “Toque Converter Inlet Port 7 z= Z ae | rogue con D: Fixing Length 6 E: Fixing Load N 47825% 480N = [o:Free Length 605 = 3 2.8 {Lubrication Relit Valve |: Fxg Length 482 = = [E: Fixing Load N 50825% a20N = 40-32 ‘AXSO/BXS0 SeriesTORQUE CONVERTER DISASSEMBLY AND ASSEMBLY Unit: mm Crier No Check tem Ret, No Grandard See Repar Unit (O1'Seal and Torque Converter Impaler Hub a ro 15 26 6 41.915 41.965 aieis | ia ‘Seal Fing and Sealing Groove Hy ot H : 1.898 ~ 1.600 3.800 29 s Ht Pi te%—2070 4870 | 3 : 2000-2250 2.350 ot x ik 24210-4213 42.25 4 ‘Seal Fing and Sealing Groove L$ 92500 —92.505 oo a: 82.450 ~ 32.470 6 Clearance: 28 t ‘00-0075 0100 , | “ke The numbers shown in the column on the let hand ofthe above table should ele to thase onthe component parts rawing respectively ‘AXS0/BXS0 Series 40-33‘TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY ‘ASSEMBLY Canty ut assembly work in the reverse order to csassembly work IMPORTANT: ‘+ Wash all the removed or dsassembied parts with clean ol to remove foreign bodies completely. n par ticular, wash the of groove and ol cul wih care. + Replace such pars as the O-ng the oll seal and the gasket wth new ones after dsassemby + Be careul to assemble conecty For deta, s2e the check tems spected inthe maintenance standard + When replacing the oll eal with anew one, apply @ semicry gasket sealant (THREE BOND No.1211 or 'No.1104for example) onthe outside circumference of the oll seal, However, never apply It tothe lp ofthe siding surace ofthe shat, 1. Assembly of Gear Pump Inset s pair of the gears (3) (4) in the gear casing (@) and reverse the stator support (5) to assemble in the same stops taken for csassemely Tighton the countersunk head sorew and check to ‘make sue thatthe gear rotates smoothly ft does not rotate, isassemble It and start to assemble again 0.98 2.94 Nm {610.3 kgm) 2. Assembly of Main Relet Valve Insert the spring and the pston to the roll valve fan tighten Ie wth the plug. Check the piston for Proper postioning when assembing, ‘Gi (Plug) | 60-80 Nm {61-82 kgm) 3. Assembly of Torque Converter Inlot Port Valve ‘nd Lubrication Relet Valve Insert the piston and the spring to the valve. Then, Inert the gasket and tighton the cover. There are ‘wo types of the valve and the spring is dierent from the torque converter inlet port valve and the lubreation rele! vale, Be sure to assemble them correct othe original poston Gm ee | 8s TN (09— 1.1 Ka) 40-34 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY 4 ‘Assembly of Gear Pump Inctall the Oxing (1) tothe comer ofthe housing (2) te prevent item being loosed. Check to make sure that the O-ing is correctly installed without loose: ness, Then, Insert the gear pump (3) othe housing ‘Slowly and vertally ana tighten withthe bot: a Oa | 20-26 0-27 Kg] ‘Assembly of Torque Convertsr Insert the torque converter in the pump inside the housing slowly. Be careful not to damage the ol seal ‘and sealing, Fil he area between the ol sel Ip up to 1/3 to 1/2 lave withthe thivm grease, oF apply ‘the clean hydraulic ol to the ol seal Assembly of Torque Converter Assembly Assemble the torque converter assembly wth the ‘wanamigson and the engine ‘AXS0/BXS0 Series TORQUE CONVERTER 40-35‘TORQUE CONVERTER MAINTENANCE STANDARD 41. Check or Ol Pressure. Input Engine Speed: 2,000 rpm Temperature: 80°C ‘Torque Converter Outlet Port Pressure: 03 MPa DISASSEMBLY AND ASSEMBLY Ne. [__Ghecknon | Presure Pa) _[ Fyauie Por Poston 1 [Wan Prema iaata a Tague convener inst 2 | Port Pressure 08-07 8 2._Titening Torque for Bots ad Page e,_[_Tehenng eaten | Sew Seceatos Tsien Tern im] Pet Na 7 Fragen fendtot |wextasxve | 0-38 = 2 evagonfeadBok|wextasxre | @=28 a Heragon Socket Head 7” 3 ee oct 20 osm ‘8 a [Sinner Cove engentat—|wextasxve | eo=8 7 Pressure Pop Poa Bind |Hexagn Soca Head | 5 s [ee ee aie we? 8 @ [earner outer eon Da = 7 [oan Pug Bram Pg wat wo-80 z 2 [Man Vaive Fis wants wn80 2 9 [pressure FickspPons _ |pipragen Secret Head |e ae 205-265 ar 70 [BaP Pug weaxte wo-20 = 11 [cearPunpsntorsippon [Samiesnttead Tye coaxre | ooe-ese | os 40-36 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. ‘TORQUE CONVERTER ASSEMBLY ‘AXS0/BXS0 Series TORQUE CONVERTER et No, Pan Name oy OW Fiker Turbine ‘Stator Impelier “Torque Converter reult Turbine Shalt (Gear Pump Turbine Hu Input ate Housing 40-37‘TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY ‘TORQUE CONVERTER ASEMBLY HYDRAULIC PORT POSITION, 6 0 S ©. © @ 6 Li, of. A i. i oS 2 ° Q 0 at 0 OLE ! 3 fs Man Pres Check Pot a: Breather Peep Port Er Tew comeror in Por PrsrChsokPo al Gauge Pa Pat 6: Luteten Pat Gack Pe © wotceoer & Dan oF Temi ae veh 1 Sraer ecm 40-38 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY TORQUE CONVERTER HYDRAULIC ciRCUTT To Tansmisston side Lubrication 4. ol Tank 2. Suction Fitter (100 mesh) 3. Torque Converter Assembly ‘3A Torque Converter 38.0 Fiter ‘3C-Torque Converter Port Rel! Valve ‘30.Gear Pump Assembly ‘3€ Lubeeation Rll Valve ‘SFRegulator Vane 4. Olleooier ‘AXS0/BXS0 Series 40-39‘TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY CAUSE Ato REMEDY FoR PROBLEM wParam [ona Fee eee ama rrnne 2 Sap tow pur or ave) 3) Seo, ee ow 3 Stra ctgomasrgn | acai aaapit rane 3 BEE ASPIS toon 3} Bein ta pase senso ose Sas? 8 "Snape ta 2 Sesnct tn etc wt oun gSoabgaes. |} beacuse apie secs 3 Sona arn 3 Besse esas oe 7 ligmoma | ARizogepewermoR | ren | EEE arron sco | Space: hapr wh owas 2) Dopnemconytgarpure |) blatant ea Rc ww 4 toca seg w ut por | ELEHOSERSY cra rape row iat ve o uly moverer f Piston 15) Wear or damage of sealing 8) Clogging of srainer Mechanica breakage 1) Damage or deformation of impeber 23) Deformation f input pats E:omer Use of wrong ol patts necessary. 5) Dlsassemble and replace wih new parts. 8) Chook ang wasn sane" Repco. with now pare tnecessay. Olsasserte and epace wih new pats } ‘Bicascemete and replace ith Mew pas. Disassemble and replace with new ar Gavtaions enused by fe arom ucon ppe or lack ool Falure of gear pure 8) Contact caused by deformed impeter 44) Breakage of input plate 8) Breakage of gear 8) Wear o breakage of bearings 2 Wear ot spine. 8} Leoseneds a bots @ [Aerormaicouna | generating 2 Adio and check and replace wih new pars 2) Bisasconble and check, Replace with new parts whe asm maces. jesasombie and oveek Replace wih new its necessary Bissssembie and pace wth new pars. 5} lsassortie and epiace wen new pars §} Blssssonble and pace win new pars 3 Bassemele and eplace Wren new pas 3} Tigrten aga and tepiace wih ew Parts i nessa KOseat 1) ‘Wear o: breakage of ip 2) Intake otforeign body rough dust @ [on eaking 3) Wear o scratches of beatings 4) Hardening "or catetoration of "bbe betase of sonoma sein clitemperature rn ) ‘Breskape of Ong 2 Scrat on mat sutace 3 3} Harsening or cateroration of Fibber because of sonormal en alitemperature 4) SSIs ip exiemety, ot temperature (belo minus 15% dont uraces wth gasket 3 Damage gasket mage of gs 3) Scratches on int surfaces 8: Fagland screw 1) Lateonose of sxow 2) Damage et sere 5) Crh on mating hole 1) Dicassemble and replace with new parts. 2} Disassemble and neck Replace with new pare tracey 3) Ppa or replace wity new parts. 4) Oetassombie and replace wih new pats 4) Disassemble and replace wih new pats 2}, epar replace wiry now parts 5} Bilasemase and replace win ew pats 4) Warm up engine betore operation, Tighten again Feplace nth new pats Replace wth ew parts “Tighten again Fepince uth new parts 5) eplace wit ew arts 40-40 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY TORGFLOW TRANSMISSION TORGFLOW TRANSMISSION DISASSEMBLY 4. Transmission Vaive Remove the bot (1) and dsassemble the transmis on valve, 2. Transmission Case Remove the craln plug and drain olin the case, 3. Torque Converter 1) Place the transmission assemely on the ‘wooden blocks as shown in ight gure 2) Remove the bolts (1) joing the toque con verter andtranemission cas, 3) Screw bot in two tapping holes for extraction and detach the torque converter fom the trans: mission case, IK Wien pecting off the fd gasket, use the gas kot romover orth plastic seraper asthe gasket Is subject to seratch ‘AXS0/BXS0 Series Ligation of tap for extracting the counterpart 40-41 /2006.9.20(1)‘TORGFLOW TRANSMISSION 4 Output shatt DISASSEMBLY AND ASSEMBLY Aone ‘A LOCTITE appt the bot (1), be sre ute the otaton topper remove the bat) Rolaton sopperig 1) Remove the bolt (1) fist. Then, remove the bearing (2), the gear (3), the bearing (4, the ‘seal (6) andthe space (6) In tur. Pl the out put shat (7) out trom lower side ofthe trans: 5, Imermediate Shaft Sub-Assembly 1) Pullthe intermediate chat eub-aseembly ou 40-42 2006.9.20(1) Ss ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY TORGFLOW TRANSMISSION 6. Input Shaft Sub-Assembiy Poll te Input shaft sub-assembly (wih the clutch pack assembly) out from the transmission case 7. Strainer 1) Remove the bot (1) rom th (7), Then, remove the plate 2, 2) Remove the stainr (3). 8. OilLevet Plug Remove the of level pug (4), 9. Capand Blind Plug Remove the cap (5) andthe bind pg (6) ‘AXS0/BXS0 Series 40-43‘TORGFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY 10, Disassembly of Clutch Pack Assembly “The numbers put onthe diagram show the order for disassembly, sep-r-séoa0 YU Calan 3E8-37-99010 Hower ‘3€8-47-99000 40-44 ‘AXSO/BXS0 Series 2006.9.20(1)DISASSEMBLY AND ASSEMBLY ASSEMBLY 1. Cleaning and Air Blowing of Transmission Caso 1) Remove the cap when cleaning the transmis sion case because the LOCTITE is applied to ‘the cap tightening bots 2) Blow the machined hole of the transmission ‘case with a. 2, Installation of Blind Plug to Transmission Case Instal tho bina plug (6), the cap (6) and the breather (@ to he wansmission case 3. _ntalition of Drain Plug Insta te dain plvg (7) “Tightening Torque for Oran Plug: Gan | @8-Teatim@o-eoKgm 4. Installation of Strainer Fi the O-ring tothe strainer (8) andineert in inside the tanemission case, Then, install the plate (2) withthe gasket and tighten itwiththe bot (1), ‘AXS0/BXS0 Series TORGFLOW TRANSMISSION 40-45TOROFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY 5 Input hat Sub-Assomby 1) Fhe seal) andthe sea toe piston eager 3 Then, asele the out shal assenby (1) wi tein ; 2) insane apn (5) anne wasne (6) Then, \ few Be eo ng) a | oO i 3) Assmbe the bean (andi wth the snap tinge 4) Assembe the cuch se (10) and he plate) anath wstb g (). 5) Intaaon of Forard ear Inset th beating in the gar (14) and assem: bie tothe sha, Asore fe bering and tre spacer Then, wth he sep hg 6) satan of Revere Gow Assemble the washer, te gear the beating athe wash. Thanh th the nan, 6 Instatation of put Sha Sub-Assembly Ia he sal ng toe mt at sub-set ang asain he vain 40-46 AXSO/EXS0 Series 2006.9.20(1)DISASSEMBLY AND ASSEMBLY 7. Installation of Intermediate Shaft Sub-Assombly ‘Accemble the intermediate shat cub-assembly Inside the transmission case, 8. Output shart TORGFLOW TRANSMISSION Avernne \Winen tightening the Bok (1), be sure to use the rote ton stopper Jo eo that other gears engaged do not Insert the spacer (6) the sea (5) the beaing the gar (9) an he baring 2) in he op hat aneeeue win te washer andthe bok (1 Tightening Torque for Bol: Gam | 8 eNm io 12S kan) oNe | LOGTITE W271 (Hole Threaa ‘AXS0/BXS0 Series Rotation scpper ig 40-47 /2006.9.20(1)‘TORGFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY 8, Installation of Torque Converter ‘Apply tho Liquefid gasket to the torque converter contact face ofthe transmision case and assemble the torque converter (2) and the transmission case (@) itn tne Bot (1), 410, Installation of Transmission Valve Fit the gasket and install wth the bo (1). Tightoning Torque for Bot: Ga | 8-MNme8-35 tam) Installation of Toque Converter Cooler Filter Inatal the ol iter and he pong 40-48 2006.9.20(1) ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY TORGFLOW TRANSMISSION ‘TORFLOW TRANSMISSION ASSEMBLY DRAWING LOSTITE W271 ae ‘AXS0/BXS0 Series 40-49DIFFERENTIAL DISASSEMBLY AND ASSEMBLY DIFFERENTIAL DISASSEMBLY AND ASSEMBLY (1.0 ~ 1.75 ton Forklift Trucks) 40-50 ‘AXSO/BXS0 Series‘AXSOIBXS0 Seri jes 40-51DIFFERENTIAL DISASSEMBLY AND ASSEMBLY 40-52 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY DIFFERENTIAL ADJUSTMENT METHOD OF PINION SHAFT ASSEMBLY SHIM 4. Clearance () Fead the inicaton (a) atthe pinion shat ti. 2. Clearance (o) Read ine stamp (b) onthe case, 3. Clearance (e) Measure the clearance (e) and indicate the clear ance on 1100-uni bases agains! the stancard size 29.50.mm, ke The clsarance can be fixed for calculation con: sidering fom the accuracy ofthe bearing and folowing value shall be appicaie. Kno proper tooth contact i found, assemble again e= 15mm Caleulation of Shim Thickness $1 Appl the clearances (a, (b) and (e) obtained trom 15680 the above tothe formula shown below to calculate 28250 18 ofthe chin S Se ‘he thickness ofthe chin S 200 ka) Arbrerd Set this ace si-o7 Aibeerd the ‘00 ‘Serena st doomak fren (Equivalent to Round the figure attwo places of decimals Weng. Sediing preload) IMPORTANT: Check to make sure of no clearance between the gear ‘anc the shim when pressing the gear for instalaton ‘AXS0/BXS0 Series 40-53DIFFERENTIAL DISASSEMBLY AND ASSEMBLY ADJUSTMENT OF PINION GEAR CLEARANCE 4. Clearance (b) 2. Fixthe pinion shaft pushing trom the bottom, 1) Take an abgnmentto the shat wh the i. 2) Tum the bearing about 10 tmes each to right ‘andi to chook te smooth movement. 3) Measure the clearance () He Check to make sure the step (1 of the above forne clearance 3. Caloulation of Shim Thickness Se 1) Caloulate the chim theknese S appiying the Clearance (f) measured by the step 13 ofthe above 2 ea The Shim so as to meet the Se of the 3) Measure the starting torque and adjust the him thickness &, ‘Starting Torque for Pinion Bearing ‘Starting Torque: 88 = 19.2 Nm {90 195 kgemp ke Make sure to measure the starting torque wih ‘out the coupling shat INSPECTION OF PINION BEARING CLEARANCE 1. Apply the KOMATSU FORKLIFT genuine olf the Inne aoe big brim (1) when assembling 2. Check to make sure for no clearance (2) whan Inserting te ote race 3, Cheok to make sxe he Inner race big brim for no clearance (3) when pressing the inner race for Inctalaton, 4. Alter ghtening the nut uth spected toque, turn the Bearing about 20 times each to the et and the rig to chock ts eooth movement 5, Ifthe starting torque cannot gat the spected torque ‘as shown below, disassemble and adjust the shim thickness again. Starting Torque: 2Ni (00 195 kgemp Ke ihe starting torque Ti greater than 13.2Nm (135 gen, increase the shim thickness. ke the starting torque Tis less than 8.8 Nm (90, kgom), edie the anim thickness 40-54 es Fixed AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY DIFFERENTIAL ADJUSTMENT OF DIFFERNTIAL Assembly of Differential Assembly 1) Assemble the iferental assembly and install the acjustment sorew (1). 2) Apply the LOCTITE #271 tothe hole of th cap (2) and ign with bok (3) temporary Adjustment of Backlash ke Use the special toot A for tghtening the asst: ment screw (1). ‘Special Tool [340-07-00170 1), Set the dial gauge and sighty tighten the adjustment screw athe (B) side until the beck lash goes to zero. 2) Loosen the adustment serew atthe (B) side ntl backlash goes to 0.15 0.23 mm. ‘Backing between Ring Gear and Pinion Gear |018— 9:28 mm ke I the backlash is beyond the crtaria of the above, take an acuetment again ‘AXS0/BXS0 Series LooTiTE W277 40-55DIFFERENTIAL 3, Adjustment of Tooth Contact 1) Apply tho red lead thinly tothe tooth surface of the bevel gear 2) Turn the bevel gear forward and reverse sev: ceraitines 3) Check the root contact pattern let onthe sur face for cnation of teat contact, 4) Ite tooth contact isnot come, adjust wth the shim thickness St + Correct Tooth Contact (No Load) ‘The pattern must be looted inthe center ofthe tooth contact, which eovers 40 to 70 % of the ‘overall length ofthe toth being in weak contact atthe both ends ofthe pattern he Incase of strong contact atthe tooth top (1), increase the him. “ke Incase of strong contact atthe tooth top (2), reduce the shims, ke Adjust the tooth contact corectly both forward andreverse Runout of Bevel Gear: less than 0.1 mm 40-56 Forward DISASSEMBLY AND ASSEMBLY AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. DIFFERENTIAL 4. Correction of Tooth Contact Increase the stims athe pinion shaft to imorove the protrusion ofthe pinion in the ection ofthe a. Nex, move the bevel gear away from the pinion Inthe ection ofthe (B) to adjust the backlash, Reduce the shins at the pinion shalt to Gecrease the protrusion of the pinion in the ection ofthe (A) Next, move the bevel gear closer to the pinion in the decton of the (B) to acust the backiash, Reduce the shims at the pinion shalt to ecrease the protusion of the pinion in the iraction ofthe (A) Next, move the bevel gear closer tothe pinion in the dtecton of the (B) to acust the backlash, Increase the shims at the pinion shaft to improve the protrusion of the pinion in the sirection ofthe @. Next, move the bovel gear away from the pinion Inthe rection ofthe (B) to adjust the backlash ‘AXS0/BXS0 Series a ilk =P 40-57DIFFERENTIAL ASSEMBLY DRAWING DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY DRAWING 4.0~ 1.75 ton Forklift Trucks occ Backiaon | 020mm Tasman oy am Flun-out | on gia gauge Se Sz | Bian) a q ADS] callie, SS g = (10 kgm} are Ds | Greece) LST wearouercr ADXo | csitoreney 3m = (rong) Backs [018020 mm | tomes — pobroeemm DS | Ghreastioe [2-7 em | e-75kam 40-58 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. 2.0-3.0ton Forklift Trucks DIFFERENTIAL ASSEMBLY DRAWING om oe naa RTE f SS = | 36 kgm} ee ADs [Thread ao Wy ADs | cea) Se) EES ee = ym) LG-7 (Seal Outer ee ats AN [Saiiteesl Oo | Woearian) woos | ooh [Seewnerres) “Baring | 88-132Nm Food [Soham ee a ocrre wat Os (Thread Hole) ‘AXS0/BXS0 Series 40-59DIFFERENTIAL ASSEMBLY DRAWING DISASSEMBLY AND ASSEMBLY 4.0- 1.75 ton Forklift Truck =| 40-60 9=7aNm (60-75 5om) ‘AXSO/BXS0 SeriesDISASSEMBLYAND ASSEMBLY DIFFERENTIAL ASSEMBLY DRAWING ‘AXSOIBXS0 Seri jes 40-61DIFFERENTIAL ASSEMBLY DRAWING DISASSEMBLY AND ASSEMBLY 2.02.5 ton Forklift Truck [aieteaN oN a | 2 teskam B= 187 Nm {10135 kgm) = 40-62 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY DRAWING 3.0 - 35 ton Forklift Truck | 319-27 Nm (252435 kam) 38 — 127 hm mm | 10-15 tam ‘AXS0/BXS0 Series 40-63WHEEL BRAKE DISASSEMBLY AND ASSEMBLY WHEEL BRAKE 1.0- 1.75 ton Forklift Truck "1. entealseratches are found to act adversely the cp, canesion of nner surface replaoe it wih anew oylnder assembly. Remove email cratanes wih olltone Scratches, uneven wear or Hertel seralches are found to afoct adversely the inet comes.on ‘08 of eyinder othe cup, replace wih new piston Piston assembly. eararce between onde ana [* fe Seance amb he repaint apaco wn ston opal Limit: 0.15 mm Soraches on Eu soe reversal pce Fw a ew 1 harmful ping i found, replace kwh anew piston Piting o base pam abnormal deterioration, wear or sweling is found, replace Wear or sweling tania nev plier eee cw ith anew by Clearance Titi below the repair mt, replace it wth a new piston ‘accor Fepai Limit: 0.4 mn Note: “The cup belongs othe parts tobe replaced periodical. In era, Rie recommended that such parte be replaced ‘Whenever disassembled, Picton Assembly Deformation, coraiches or wear of valve od, valve cup, spring ane mele + abnormal deformation, scratches or wears found replace itwith a new piston assem Base Up ase up pene ‘AXS0/BXS0 Series 40-69BRAKE MASTER CYLINDER DISASSEMBLY AND ASSEMBLY Pai None Chek lem Para Gouna wear has areca ratios msibeepesewine Spina roe alow hepa atrusibeeplced wih anew Free lenath Hs Fa Lint: 70mm mnroa aud ov aucoaon as ctoenor latin mead wih anew st daageorenacies [skal an8s cage arenes mate pane Boot Frghening atovance between [Tove on ehenng alowanoe or an xray le Spor bared hang ovarce ste opacad wih oe ome Event cack a exer sal epee Fier urion Oeoowaxon es en anand wih ew seas Those fares muatbeopased wih an Oe Tras of sacs ete dteoratin mst be replaced ting creck or detroraon nave orcas MAINTENANCE STANDARD Unt: mm Ne ‘Check tem ‘Standard Sze Repair Umit Remedy |_| Clearance between oyinder and mon placement piston 9.020-0.105 ons (Oyinder Assemovy ening Clearance of Gu Primary side approx. 7.0 oe Replacement 2 [Tightening Cesrance ot Cup | secondary side approx. 1.2 (oyinder Assemoy) | Spring Free Length 788 70 Replacement 40-70 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY COMBINATION SWITCH COMBINATION SWITCH ‘COMPONENT PARTS FIR Switch Serow Cover Boay cover Serow “uin Signal Switch ‘AXS0/BXS0 Series 40-71COMBINATION SWITCH Inspection of Switches. 4. Remove the connection of the @pin coupler between the combination switch cord and the main wiring haress, 2 Check contnuty of electie curent bemeen the tr minals at each poston to make sure that there I continu between the 0 tothe 0 18, Insulating reietance’ More than 10 Gat enen termi nal with 2500 V mogohm meter. 1) FIR svtch connecter 2) Hotn contact connector 3) Protective pate 44) Lighting connector 5) Lighting and tun signal swizn connector Pocono Tun Signal Such Connection DISASSEMBLY AND ASSEMBLY stone. GB coaB.x wo R[N | t | coma +10) over Sune z16 2h are 3 ae ston ct Lang Sc Connect ve mT cenee | fmf 228° care 710] [0 fever saure O10 [rer saael ef) [OT tits 16 iano sin o Ho Sn = é 5 over ox o Poe ous n é 4 fe amp 7a Taran Fostn oi Oth Comecon a Poe Sa onarow ie) Vion hr wer AB wel F [6 | m| comaw ovriosbeea ood zfol [oO] eam sorely cB zo oy 2 = Hom Sich Chet a Stes e-] —_Joowecr [10] pvr sauce sO | 16 Rew 2/0 ‘hen anne Semcen FN [bent veep between FN and 40-72 AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY SOLENOID VALVE ‘SOLENOID VALVE DISASSEMBLY DRAWING n ‘AXS0/BXS0 Series 40-73‘SOLENOID VALVE, DISASSEMBLY AND ASSEMBLY ‘COMPONENT PARTS no ° 6 sous\ _\soue V at No Pan Name Spina Retainer A Fomine: Paral! Ps Selencid Guide Soenaid Gor Space 7 Rut 2 ORG 3 (ORing 74 (ORing 5 (ORing 40-74 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY DISASSEMBLY 4. amove the nut (14) withthe spanner (27 mm). 2. Remove the Oxing (12). Then, emove the solenoid cal (9). 8. Remove the O-ring (18) inserted in the solenoid col ® 4. move the solenoid guide (8) with the 27 mm spamer, ke Be carelul not to damage the spool hole because the clearance between the body (1) and the spool (2) extremely sal '5. Romove the O-1ing (18) rom the solenoid gue (8) 66. Loosen the plug (3) wih the spanner (& 5 mm pln spanner wih 12.5 mm pch) and remove i 7. Remove the O-ting (18) from the plug (3) 8. Remove the O-ring (14) rom the body (1). ke Nover remove the spacer because was Pressed nto the body ‘AXS0/BXS0 Series SOLENOID VALVE 40-75‘SOLENOID VALVE, ASSEMBLY 4. Inert te O-ring (14) inthe body (1), ke All ofthe Ovings shall be replaced wath a new 2. Insert ne O-ring (19) nthe pg (2) '3, Assemble the plug (9) tothe body (1) with the pin spanner (3.5 mm pl-spanner with 12.5 mm pt) Gan | 2-28Nm 20-26 %9m) 4 Insert te O-ring (12) nthe solenoid guide (8) 5. Assemble the Oving (18), the retainer B (6), the spting (), the retainer A (8), the spool 2) and the paral in (7) the salenoid quid (8), which insert to the body (1) ana assembie withthe spanner (24 ‘mm spanne. Insert the O-ing (1) Inthe solonid col (8). Inger the solenoid col () in the solenoid guide (8) Insert the O-ing (12) inthe sotonod col (8). Instal the nu (1) withthe spanner (27 mm span- nen. B= TNT (08-10 Kar) 40-76 DISASSEMBLY AND ASSEMBLY ye © ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. STEERING VALVE ‘STEERING VALVE Knob correction valve ORBITROL + EPACS controller @ = & @ © we HS, ety doomed Ne = eee ee ee =a a oa 7 = era ; or Tsao] bles 7 James a seme = [os 3 oe t + aes ey 2 [eanormamen | LB = | ; a 7 oc : Ter = ee : 13 [Pn + 20 [Tube assert 7 + Ee ae : 1 |ommetasns + [ssa +3 [or z a |awon Tfeaesaeer |] [= snmmnm |» [iaarbe Te [EPACS conclor 7 $6 [Soa + [Saree | = [ER + lemonoeamens| so [Berane waarn008 | Toe 2 [ng ={ pee [ove + [En a - [Rear soe z aa : Omxemecoy | 1 [Se ‘AXS0/BX50 Series 40-77 12008.9.20(1)‘STEERING VALVE DISASSEMBLY AND ASSEMBLY REPLACEMENT OF SEAL OF KNOB CORRECTION VALVE Before removing the piping clean the exterior (around port and joint) and perform as follows ina washed area, Disassembly Awrrrns (De notpush strongly the outer wal witha vise. 1. Remove the nut (41) and the coll wit» connector 2), 2, Remove the tube ascembiy (4). ke The spring (46) and the core (47) may come of Koop them for ater use 3, Remove two hexagon socket head bolts (45) and the vave block (96) rom the housing. 4. Rlomove the © ting (50) ftom the tube assembly 40), 5. Flemove one O rng (44) and four O rings (43) rom the vave block (36), 40-77-1 2006.9.20(1) ‘Assembly He Replace all of the O tings wth new ones 2 Insert the Oring (50) in the tube assembly (40. Insert one © ring (#4) and four © rings (48) inthe vale book (36) Insta the tube assembly (40), S4= 40 Nm S— 4 Fa) = | Install he coll ith connector (42) and Nght t with te nut). Nn (05t aT kam Install the vane bloc (96) tothe housing (10) with ‘two hexagon socket head bots (48), =| 4-44 im GS-45 kgm) ke When insating, be careful for © ring not o be caught ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY ‘ORBITROL: REPLACEMENT OF SEAL AT THE SHAFT SIDE STEERING VALVE Belore removing the piping, clean te exterior (around port and jin) and perform as follows in acean ave. Disassembly 1. Remove two screws (ooss-ecessed fat head screw) (17) and then EPACS contoler 16) 2 Remove the dust seal (25) from the EPACS conto ter (16) 3, Remove the fixing sorew (hexagon socket head crew) (19) and then the rotor (18) from the speo| (12), ke As the LOCTITE Is applied to the fixing serew (hexagon ead screw) (19), it may not be removed. 20, repace the ORBITROL. ke Keop the fing serew (hexagon socket head s2rew) (19) later use 4. Remove the retaining ting (26) trom the housing 0) Awesnins “The retaining ting (26) may pop fom the housing (1). Bo sure to woar the protoction glasses. 5. Remove the seal grand bushing @7) and then theo eal (24. 6 Ramove the Oring (29) ‘AXS0/BXS0 Series (ORAITROL: shat block 40-77-2 12008.9.20(1)‘STEERING VALVE, DISASSEMBLY AND ASSEMBLY ‘Assembly “he Feplace allo the sings and oi seals wth new ones. er 4. Insertthe O ring (29 2, natal th ot seat (28. ke Orient the of ccarolul for oll seal nat to be twisted or deformed, in the correct direction, 86 3, Inetall te seal grand bushing (27) to the housing (10) and hen te retalning (25), ke Widen the groove of housing (10) with a flat blade screwdriver o thatthe entra crcumar ‘ence of retaining ring can be securely Installed inthe groove Awonne The etaning ring my pop om the hong, ba sre wea ne proacton aren 4. Align the seraw hole of rotor (18) withthe hole of spocl (12). 5. Apply LOCTITE tthe ig sorew (hexagon sooket head sere) Install the rotor (18) to the spool! (12) wih the fixing serew (hexagon socket head screw). 6. Install the EPAGS controler (16) tothe housing (10) with wo screws (coss-recessed ta ead coe). 40-77-3 ‘AXSO/BXS0 Series 2006.9.20(1)DISASSEMBLY AND ASSEMBLY CORBITROL: Replacement of seal at the gerator STEERING VALVE Belore removing the piping, clean the exterior (around port and jen) and perform as follows in acean area. Disassembly /ABNING Do not push strongly the outer wall witha vi 1. Fixthe housing, facing the end cap up. 2. Ramove seven sorews (1). 8. Remove the end cap (8) and hen the O ng (28) 4. Remove the spacer (6) from the spline bck in the star of geroto (4). ke Depending on the specication, two pleces of spacer (6) oF sone of them are used, 5. Romove the gorotor and ton the © rng 28). ke Be cautous not to drop the star rom the cuter ‘crcumterence of gerotor (4. 16. Romove the O ring (92) of grotor star. ke The O ring le the low sip specication. Do not use it for standard specication, 7. Remove the cvs (@) 8 move the spacer pate (7). 9. Remove the Oring of housing (10). He The © ring (28) and the © ring (29) afer In ‘iz. Decrminate them ‘AXS0/BXS0 Series 40-77-4 /2006.9.20(1)‘STEERING VALVE, ‘Assembly ke Replace all of tho © rings and oll seals with new He The 0 ring (28) and the © ring (28) fer in size Discriminate them. 1. Inger the © rng (22) ke The Oring (82) ste low sip specication. Do not use ier standard specication. 2. Incerthe O rng (28. 3, Inset te O ing (28) inthe housing (10). 4 Place the space pate (7) on the housing (10) and align the postions of bot noes. ke Discriminate the bot hole trom the ol hole as their amotes iter 5. Inset the cive (8) and engage the yoke of eve wath he pin (13). “ke To secure the postioning, mark the tne onthe ‘end surface of chive (8) in parallel withthe pin (9), (Perform this work precely as tis importante meet ne vale ming ) 6. Install the gerotor (4) withthe © ring side placed at the spacer plate (7) side, algnng the teth-shaped valey of gerotor star with the ne marked. At this moment, corm thet the pn, the marked te onthe ve (8) and the vale of rotor star are in paral as shawn in figure 7. Keeping the dive (8) engaged withthe gerotor star, algn the bot hoes by rotating the gerotor ring. Awonns “The incomect aligning may lead to the serious ‘operation touble. Ensure to pertorm the postoning 40-77-5 2006.9.20(1) DISASSEMBLY AND ASSEMBLY ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY {stall he spacer (6) tothe spline inthe gerotr star “ke Depending on the speciation, two pieces of space (6) or none of them ae used, 9. Place the end cap (3) on the gerotor (4) and align the posttons of bot hoes. 10. Apply Iovicant to the serewed portions of seven screws (1) and install the end cap @) AN thst, tight evenyy each scvew wth tottening torque of 14:7 Nm (1.5 kg) “Then, tighten sorewe with torque shown below. a. Tiohten screws in orders shown in gue STEERING VALVE scneavon |, Yolme | Tightening Tore Spee pumpadout | Nm kan Stone 28129) tana . suas. [Bwarenia| Sea) More than sient iov 20129) Below St onview | 25185) spect ore han Srectsaton | Stentor 21005) 11, Install the handle to the ep00 (12), ke Confem tat the spool (12) rotates. ‘AXS0/BXS0 Series 40-77-6 :2008.9.20(1)‘STEERING AXLE DISASSEMBLY AND ASSEMBLY STEERING AXLE DISASSEMBLY DRAWING 1.0-1,78ton Forkit Truck Note: Press in wth igs 40-78 ‘AXSO/BXS0 Series40-79 SeriesDISASSEMBLY AND ASSEMBLY [STEERING AXLE ASSEMBLY DRAWING 1. Assembly of Ball Socket ‘When assembling the ball socket othe bel lamp, check to make sure each tapered section i tree rom sticking ol or paint. 1.0~1.78 to Fort Tuck 2.02.0 ton Forklift Truck 2 Grease -AppIy the Itium grease (241) forthe grease ripple and greasing to the hub ‘AXS0/BXS0 Series 40-81 12008.9.20(1)DISASSEMBLY AND ASSEMBLY ‘STEERING AXLE DETAILS OF STEERING AXLE 1.0~1.78 ton Forkit Truck 4. Bellclamp 1) Lock Pate (1) 2) Snap Ring (2) ke Check to make sure the anap ring for being secured in the ring groove. 2 ing Pin 1) Match the needle Bearing (3) end face to the boss (4) end face inthe distance of 6 mm, 2) Match the needle bearing (6) end face tothe oss (6) ena tae, 8) Adjust the knee (7) t0 minimize ‘between top and bottom. ‘Standard space (a) inthe dagram on the right: 0.05 - 0.2mm space 40-82 20-80 ton Fort Truck Po BooKr A oy — An 110=1,75 ton Fork Trck =e se Ns ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. 3. Link 1) Make sure to bene! the cote pin (8) corey 4 Hu 1) Fil enough grease (G2:L1) to the hub bearing (9) upto the hal to one titd of the hub space ‘capacty inthe both side, 2) When assembing the hub, apply the grease (G2L1) tothe lp ofthe sea (10) 3) ter adusing starting torque, make sure to bed the cotter pn (11) corecty ‘AXS0/BXS0 Series 1.01.75 ton Fort Truck STEERING AXLE a] eH eeu 40-83 12008.9.20(1)‘STEERING AXLE DISASSEMBLY AND ASSEMBLY s. ‘Adjustment of Hub Rotating Stating Power 1) Tighlen the lock nut unt ti geting hard to tum by hand. Then, reverse I turing by one ‘quater from that positon. Apply spring bal: ‘ance 1 the hub bolt and gWve the tper rer bearng pre-pressure while adjuting the nur (12) to wake rotating staring power reach to the flowing value ‘Staring power [196 -293N (2-34 Kgl) ‘tating torque [254 400 Nm (9550 kgem) 2) After completing the adjustment of the above step, Insert the cote pin to stop loosening in the place where the holes of both the nut and the shaft are matched. Then, bend for sure, ‘Adjustment of Steering Wheel Angle ‘Act te storing wheel angle fn te falling pro Ccadure go thatthe relation between steering kn postion and steering angle becomes constant. 40-84 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY STEEANG ANE mal seTTHe Wonk Proceounes NO. wor Termnai] GLE, | __ chester ere 1 [ERSTE SPM | coma] rash] MPRA i, [Seba 7 EEE coma oa Se EN foo rT > |ray wen OFF amet [Tuma In ravelng soa fonara 3a 4 |esteerg whet inosalthe” | Connect “Tumott |Wieelelsteoring whee! po \Whselestecring whee! PO- | close terminal, open. starting pol. ar WaT Sa conraer 5 |key switch ON Ccomneat| 1 FLASH check LED (or 1 FLASH [OIE cis auty contol er or wheel sensor eran TRASH ‘Check } ELASHforchange | Under reset controle ital 6 | Remove the terminals pen Teal SLASH 9° | Under ese Won LED changod ie FLASH, 7 [Baie wie com i ado Under int st: contort memorize steering speed and storing angle. ‘Sto0r surly to ne onc 2 FLASH | Stcing oboe 80m) Normal node, 1G on, ab- oral tun of. Stay in 2 tat set(%), 2 | Check LED for lighting ‘open | Tuinon |CheckLED forturn on | Dotmal tun of Stay in 2 reset rom No. n mon |Gheckto make sure steer 2 [Fins Open | Tein on ling knob postion corrected LED Display No. Content ‘Terminal LED ONOFF nal set mode + (under osm 1+ [intal sep orincompete nt-| rast | fs A Int setmoge 2 ese 2 | inser aching eras eet to 3 [emornawmeetsonsor | ortash | 4 | woe sensor enor aFLAsH (compte mal set) Conte ero or contaer 5 | Sontoter anor Tummof ) gep «6 [Under normal operation | tm on «Sa [Note *1: An incompl inital set means intial set isnot corey completed under normal mode. It needs to operate ‘steering wheel to turn more than one and ha times in right and left om the state of raving srlghtforars under teaching mode. ‘AXS0/BXS0 Series 40-85POWER STEERING CYLINDER ASSEMBLY DISASSEMBLY AND ASSEMBLY POWER STEERING CYLINDER ASSEMBLY 1.0~ 1.75 ton Forklift Truck COMPONENT PARTS Pel No. Pat Name ay | [Rette. PartName oy 7 [ovina Tube 7 6 [Rea Packing 2 Ba [Prston Roa 7 7 [Backup Ang 2 22 [Piston 7 3 [ovine 2 3 [ed Guide z © _[Pston Packing 2 @_ [Te oa 2 70 [Round Bushing 2 5 [DustSeal 2 11_[SmallFange Nut a 40-86 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. DISASSEMBLY 1. Clamp the outer diameter of the oyiner tube (1) and secure 2. Loosen 4 pieces ofthe nut (1) and remeve the te re), 2, Pulthe right and let 06 guide (2) out slowy. he Be Careful not to damage the packing when paling out 4. Pulthe piston rod (2) straight (finder Inner Diameter Standard Size: 75 mm Cynder inner Diameter Repair Limit: 75.2:mm od Outer Diameter Standard Size: 60mm FRod Outer Diameter RepairLimit: 49.92 mm od Outer Diameter Bed Limit 05mm ‘AXS0/BXS0 Series POWER STEERING CYLINDER ASSEMBLY Clamp oyinder tube outer carter 40-87POWER STEERING CYLINDER ASSEMBLY ASSEMBLY 41. Assembly work sal be takon to reverse the proce: dre of sassembly Aweonns + Apply grease or hydraulic oil to the lip surfaces of Cig a al and ping wan aston bese pars + Batre gong, mate srt wpe of od rose catetlyromteas ote or see + Wan to th pactng ft ater lo 80°) protonation tothe eng 40-88 DISASSEMBLY AND ASSEMBLY ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. 2.03.0 ton Forklift Truck POWER STEERING CYLINDER ASSEMBLY deans le 7 Pee : Li - Compact Mode! ‘AXS0/BXS0 Series THREE BOND vise 78.989 4 10 40-89 2008.9.20(1)POWER STEERING CYLINDER ASSEMBLY DISASSEMBLY 1. Seoue the outer Woe of the onder (1) with cams. 2. Loose the nut (12) of 4 pleces and remove the te 00 (19), 3. ul the oyinder head 2) on the right and et hand out stom. ke Be caret not to damage the packing when puling out the evince head 4. Pullthe cylinder rod sub-assembly (2) out straight Cylinder Inner ameter Standard Size: 75 mm Wear Limit Cylinder Rod Outer Osameter ‘Standard Sie: 50 mm Wear Limit: 49:92 mm Bend Lim: 0.5 mm 40-90 DISASSEMBLY AND ASSEMBLY Clamp cylinder tubo outer diametor ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY ASSEMBLY 1. Assombly work shal be taken to reverse the proce: hive of cisassemby,. Avena + penis otra ol be Ip stacs of ving st seal ac pking when sensing these prs + enfreaping he THREE BOND #1964, mato sue wpe fo ree crt fom teat votre + mute packing 0 hl war low 80°) prt tlio tthe eng ‘AXS0/BXS0 Series POWER STEERING CYLINDER ASSEMBLY 40-91LIFTCYLINDER, DISASSEMBLY AND ASSEMBLY LIFT CYLINDER COMPONENT PARTS _Drain pipe QQ OO: 1. Oyfinder 9. Backup ring 2. Piston rod assembly 10. Bush 3. Oylinder ead 11. Cushion eating 4 Bush 12, Snap ing 5. Using Spacer 8. Wioer ring 14. Ong 7 O-rng 15, Wear tng 8 Uting 40-92 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. LIFT CYLINDER, Disassembly reparation Prepare the folowing belore stating disassembly 1. Workbench Prepare a sol, stable workbench that Is large lenough to pu parts and prevents hem from moving fling during work ‘Tools and materials Prepare tole and materats shown on te folowing age, feral Precautions Clean the oylnder belorehand to remove sol, drt and cat 2. Since the cyinder Is composed of precision pars, hance very careful, Do not imp or drop parts during work 3. Do not nt or tamper pats fori. This may cause burrs or damage, which may deable reassembling cause ol leakage or deterioration, Perform dsas- semblingreassembing careuly and patient. 4 ithe cyinder is lot alone cisassombled or inthe idle of disassembly, parts may rust due to humid or diidust. When disassombing & unavoldably suspended, be careful to quard the cyincer against rust and dust ‘Maintenance Standard Replace siding parts and seal parts according to the folowing. Inspection after Reassembly Nowoad [Check for smooth mavement wit no poration check | abnormaly through ful soko witout oat fwe mas, Dimension cheek | Check the most contracted leh and stroke specres nthe drawing Pressure check | Check fr no looseness, permanent storion, or external eakage when the test pressure (spoctiecin the srawing) is appt tothe croke ond ors mates ¢ more. WARNING: Be cure to mebilize the iftcyiner during checking, Exterral leakage | Check the volume ofclleakage fom check the ro, [ete to te folowing page) Intemaleakage | Oilleakage volume shall be 3 mor cheek ess for 10 mintes, Ciera for ol leakage trom rod Determine by the ol ting condition ater reciprocating 20 times with an oltemperature of 20 to 40°C. Ol ring Athats outa order means abnormal state. Take proper action refering to Section 6 Troubleshooting Buches | Roplane when 1/4 ercurterence for total Jongih of te bush worn n bronze colt, Replace cealpars wih new ones whenever ‘Sealpats | ne cyinder is dsassemcied etn roa [Depa When abend 10 5 rmper meer "Note: The bush onthe cylinder head is preset wih the cylinder head Use "Cylinder head Kt for parts replacement to replace the bush. (Cylinder head Kt A pats replacement kt where a buch i press-fit oyinder head. ‘AXS0/BXS0 Series 40-93LIFTCYLINDER, DISASSEMBLY AND ASSEMBLY Toole 1. Goneral tools No Toei Javenty] + | Fiatlade sorevetrver 2 | hoxagon wonoh cr ost 3 Vee 1 4 | Torque wrench vest 5 | Plastic hammer 1 6 | Monkey wrench 1 7 | Spatula test «| eok woe (~~. 1 2 Special tools ‘The following tools are helpful or dsassembiinglreassembling the cylinder, Too! ‘Simpifed figure Picton seal press tool 40-94 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. Disassembling Procedure 1. Blood oi 2 Loosen cylinder head (). Loosen eyinder nead (2) wth @ hook wrench, anc remove rom cylinder tube assembly (1). Put an oil pan under the ylinder tube assembly as ‘the remahning ol may leak 2. Pullouteylinder head (2). Cartuty pull out the cylinder head straint Awesnins ‘The piston ring may touch otner parts right ater ts ule out ftom ie rod depencing on the shape ofthe fend of piston rod assembly (2). Be very earful when pulling the cylinder head ‘4. Pullout piston rod assombiy @). Careful pul out the piston rod assembly horizon taly, and put Rona crosste, Awesnins “The peton rod assembly may touch the thread portion ‘feline tube assembly (1) right ae itis pulled out cormay fall and damage othet parts. This is mote risky for tt cylinders with long conractes length Be very ‘caretlto avoid damage 5. Pullout spacer (19). Poul out te spacer ftom piston rod assembly (2). However, spacer with wear ring (16) cannot be removed, as is nonisassembly par. “The wear ing can be removed easly by hand. ©. Disassembling piston assembly Remove Uing (8), backup rng (), bush (10), and cushion bearing (11), Note: The piston rod and piston cannot be sas semble, 1) Use a spat or serewever to pul out the U: fing and backup ring 2) Remove bush (10) while widening the mating face using a srowiver. ‘The removed seal parts cannot be reused. 9) Remove snap rng (12) trom the groove with a ‘sharp tool, and then pull ou the cushion bearing (1). ‘AXS0/BXS0 Series LIFT CYLINDER, 40-95LIFTCYLINDER, Disassembling seal parts in cylinder head (8) Remove Using (8), wiper ring (6), and O-ing (7), 1) Use a spatula or sorewerver to remove the U: ving 2) Since the wiper rng fs preset, pull tout by hiting the rubber from the bush side with a ‘creer ora ami too 3) (Remove the Oring using a spatula or screw diver inthe same way as the Uting ‘The removed seal parts cannot be reused, (Cleaning and storage 1} Clean the removed pars with white kerosene, _appy hyckaulic ol to them, ard then store them wth a cover 2) ithe removes pars are et, the cylincer can: not exhib ts performance well alter reassem bling due to rst or dust Reassembling Procedure Awenns Coating of paris may pel of and fal inside when reassembing hem. Be very cart 80 tet cosh materais my not tito the nde. TA may cause oeakage Feassembling cylinder head (9) Prepare the cisassomtled oyinder head or “yinder head kt Coan them wall belore reassembing, 1) Instaling Using (6) Pressdt the Using nto the Using groove of coylncer head (3). Use a spatula to avoid cam: age to the Using. I the Using is heated at ‘approx. 70°C, it can be instaled easly. Be c’eatetl not to get bumed {Check that there is no permanent deformation ‘50ch as wrinkles ater instalation 2) nstaing wiper ing (6) Instaling the wper ring using a too. Push the wiper ring wih a press machine or the tke, 40-96 2006.9.20(1) DISASSEMBLY AND ASSEMBLY Push with sprosemactie SL Tool Wiper ring oyindor noas | ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. 3) Insaling O-ing (7) Install the O-xing paying attention not to dam age oreut it Check that there is no ] 0] 0/0) 0] a] ol ol >| o| otelteleetelseteltele ates -fela bl ele lag e}s]e}e] 2]e)e) a) 3/2) e]alnlele sl Fig. 408 ‘AXS0/BXS0 Series 40-103CONTROL VALVE DISASSEMBLY AND ASSEMBLY 1 Loceen socket head bok (11) to remove cap (6), and pull spool) out of valve housing (1) as a eubae- ‘sembly, Remove the spool together wth seal plate (@), Oring (4, and wiper (5) onthe cap side. 2 Remove screw (10) on the opposte side, and remove seal plat (3), Ong (@), and wiper (6) 3. Remove the hexagon socket head bok of solenoid ave (16), ancpulof the col. Then remove the ron cote. Remove solenoid valve (33) in tho same way Be careful so tha the wave washers do not all 4. Remove plugs (26), (27), and take out spring (24, steel bal (23), sp00! 22), and sping (23), 5, Remove plugs (82), (95, and take out spring (20) ‘ane poppet (1). 1. Locsen the nuts and setserews of shut! valve (0), ‘andloosen the plgto remove R 7. Remove plugs (14, (1) ontop ofthe housing, and takeout spring (19) and poppet (12), 8 lemove plugs 17), (18) onthe side ofthe housing 8. Loosen and remove plugs (17), (18) on the botlom ofthe housing, and take out spring (20) and poppet 9), 10. Grip spoo! (2) Ina vise win hard wood blocks on both sides to protect the spool from damage. Locsen cap screw (8), dlsassembe spring seat (7) land spring (8) to remove Oving (8) and wipe (5) Be earful so that any part does not mp due to repulsion force of te sing 40-104 Precautions when pulling out spool Pull out each spool straight to avoid bumping or seraches. II bumped or scratched, the spcol may damage the holes of the main unt ot may not be ited Properly when is reassembled. Even ifthe spool Is fited, a matuncton may be caused, Distinguish each spect by tag ot the lke for correct reassembling. It reassembled wrongly, the actuator may mafunstion, TNS Is very dangerous. 30-40 24 aan ou 70-200 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. CONTROL VALVE Disassembling tt spool section assembly 17 16-45, — Fora a eatery Meera Pare sapped apa Kt ohich rant A {bere en ‘Seaccemsing Pars aupled as compose pat or 8 reason quay aeeuonce or Searing Pars aupled os angle pa [Pa at carnetbe evppied Parra ow ane nose peat Seale Sang Weer cao rea Sng seat [oap seem “fs 7 Fig. oa 1. Remove Oxing (12), poppet (10), and spring (11) from the mating face. 2. Detach eap (6) by loosening socket head bok (14), and pul poo! 2) out of valve housing (1) as sub assemby. Remove the spool together with seal plate (2), O-ring (), and wiper (6) onthe cap ede 3. Remove screw (13) on the opposite side, and remove seal plate (8), Oving 4), and wpe (5), ‘AXS0/BXS0 Series elo] fo] o] =] ] »] [eel Spr ere 10" | Porpet (heck vay [Spring (hack va) 7 [o-me. 1 [vane 18 [Serna 17 [omg lp 9p00! (2) na vise with hard wood blocks on both sides to protect the epodl from damage. Loosen cap screw (8), isassemtle spring seat (7) and spring (8) to remove Oring (8) and wiper (5), Be careful so that any part does not jump due to repusion free ofthe spring, Remove spring (16) from inside the spool, and pull vale (15) out ofthe spool using the Ma screw at the end 40-105,CONTROL VALVE DISASSEMBLY AND ASSEMBLY Disassembling atachment spool section assembly 2 10 Ropar aaning Pa sepled separa ich mast 1k |berepiaged when dusszerbing! reasienting eo [rameneehansay sctoancer a3 oeerbing | Parsauppela ange nar Pare tat cannot be supped Parra low 7 [Vane ous Sesot Seal ie Sang Wer Fig. 40-5 4. Remove Oxing (12), poppet (10), and spring (11) fromthe mating face 2. Detach cap (6) by loosening sockat head bot (14), ‘an pul spoct (2) ou of vaive housing (1) as a sub- assembly. Remove the spool together with seal plate (8), Oxing (8), and wiper (5) on the cap side, 3. Remove screw (13) on the opposite side, and ove seal pat (3), O-ring (@), and wiper) 40-106 Soin eat ap seem Serna ea 0 Poppet (chee) | Spang (heck wah) 72 [ome 3 6 [cap eee 3 2 of o|>[o] 4] 0] o]]o]>]>| 0] ofolag 4. Grip spool @2 in a vise wit hard wood blocks on both sides to protect the spool from damage. Loosen eap serew (8), disassemble spring seat (7) ‘and spring (9) to remove Oving (4) and wiper (6) Be careful so that any part does not jump due to ‘epuleon force ofthe spring, Distinguish and manage the parts disassembled in the ‘above procedures fer each section using tage or he he 50 that you can quickly understand where to reassemble them. ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. CONTROL VALVE Cleaning Wash all the ccassembied par completely with clean ‘mineral ot ‘Then dy them wth compressed air and put them on ean paper or lth for inspection, Inspection Check al cisassembled pats for burs, seratches, flaws ‘orany other detects on ary surface 4. Check hat no sertch or dents present on the cuter ‘surfaces of spools. It slight soratches are foun, remove them wih an ollstone or cloth dampened wit lapping agent. 2 Check that al siting parts move smoothy, and that no foreign matters etin any groove or path 3. Replace soring itis damages, deformed or worn 4 Check that seal grooves of the vale housing are ‘sooth wih no dtlsut, dent or ust. 5. lary dont andor seratches are found onthe check seat surfaces of the valve housing, remove them by lapping whie paying attention not to leave lapping agent inthe vane, 6. When the rele valve doe not work normaly, check t according tothe ree vane maintenance manual 7. When replacing O-tings or backup rings, always replace them with new ones. 8. When any cap or pug is detached, check that no paint scrap is lft near the plug seas or holes ofthe machine body. I pant seraps enter the valve, they may cause catching or loging, which may eautin ‘a mauncton or ol eskage. ‘AXS0/BXS0 Series ASSEMBLY 1. Pay atlonton to the following when harsding O- tings. 1) Do not use O-rings wih a moliing defect or scrtones 2) Apply grease oF hydraulic oll 10 O-ings and their instalation places for adequate lubrica- 3} Do not expand any Oxing oan extent where it 's permanent deformed 4) When instaling an O-ing, do not ot. Once it Is distorted, the distorton cannot bo corrected raturay. This may cause oll leakage afer instalation of the O-ring Pay attention tothe flowing when handing spooks, 1) Always observe the specified torques. Over- torque for tightening screws may cause spoo! rmattunction 2) Put spools, springs, and spool ends in the ‘same combinations as those belorecisasee bing. 3. Pay attention to the following when reassembling seetlon assemoles and vaNe assembles 1) heck that te Oring atthe mating face & ft ted within te O-ring groove 2) Check that no washing oll or hycraulc oi is remaining at the folowing places betorereas- sembing + Outer surface of the O-ring groove at the ‘mating face of each section + Outer surface of the O-ing groove at the cap instalation face it eeassembiing is pertormes with ol remaining at these places, the oil may be micunderstood as ol leakage during operation Valve housing 1. Assemble poppet (10), sring (11), and O-ting (12) to be Inserted into the mating tae of sections 2. [Fig. 40-1] Scrow to rode (2), (4) fly into the tt section, and then instal the valve housings of each section one by one. Then tighten the te rods wth ‘nuts (1), (8) to the spected torque. Be caret so that spring (11) at the mating face & not caught K For doutle-vale models, tighten the tit hous lng to the lit housing wit bots (1), (3) and washers @), 40-107CONTROL VALVE DISASSEMBLY AND ASSEMBLY 3, Inthe attached pars lots Fig. 40°, Fig. 40-4 and Fig. 405, insert Oxing (4) and wiper (8) into the ‘seal groove on the spool head sde, and then tighten ‘seal pate (3) with screw 10) oF (13), Lt spool section assembly Feferenes number ie desorbed inthe parts lt Fig. 40-3 41. Install Oxings to each plug 2. Inset poppet (19) and spring (20) ino the botom Plate, and then tighten plug (17) 3. Tighten plug (17) onthe side panel. 4 Insert poppet (81) and spring (20) into the side panel, and then tighten plug (82). 5. Insert poppet (12) and spring (1) ito the top pat, anithen tighten plug (14) 6. Insert sping (21, spool (22), steel ball (23), and spting (24) sequently Into the tp plate, and then Yighton plug (26). Grease these parts so that the spting can be securely installed together with the lug (6). 7. Tighten and instal the plug to vate housing (1) wih the poppet of shuttt valve (30) press-fited, and then push the setscrew so tha the peppet is seated atthe vale edge. Then tighten the nu. ‘Spool subassembly In Fig. 403, Fig. 40-4 and Fig. 405, insert Ong (4), wiper (5), and seal plate (9) sequential into spool (2), put sping (9) Between spring seats (7), and secure onto 001 (2) wth cap serew (8). Grip spool (2) na vise ih hard wood blocks (Fig, 2-1) on both sides to protect, the spool from damage. Grease the outer surface of spting (9). Be careful ofthe orientation ofthe wpe o-ing Spool_~ Seaipiate Value housing 40-108 {Fig 40-4] Insert valve (18) and spring (18) into poo! (2) of tit section only, and then install Oxing (12) to cap screw (8) fo assemble the sp00 Inaert check vale (29) into spool (28) and tighten plug (20), Grip spool 28) ina vise wih hard wood blocks on bath sides to protec he spool from damage. Be careful ofthe orientation ofthe check vale Final reassembling and checking 41. Mount the spe0! cubaseembly ont te valve hous ing a the same postion and inthe game orientation as belre csassembly, and ten atach cap (8) with socket heat bot (14) oF (1), 2. Mount connector assemby (30) ont the lit seston. 3, Tighten the iron cores of solencid valves (18), (90) tothe ft section, install he col and then tighten the hexagon socket head bolts, while paying attention to the internal wave washers. 4. Mount te port ree valve and main relict vale. Precautions when inserting spoo! Slowly Insert the spocl straight to the hole. Ifthe spon! oes not move smoothly by hand after ts inserted, t ‘may mafunetion Precautions when assembling When reassembling 's competes, recheck tht all the Glsassombled parts are soouroy Installed, Loose Installation of pats may cause ol leakage. ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. (MAIN RELIEF CONTROL VALVE 1. Disassembling Remove plug (2), sieeve (2), main poppet (4), and sxring(). Loosen adjuster Kt (7) and take out plot poppet (6) and spring (8). Do nat dlsassemble plot seat (6) a8 ts crimped at tho plug ond ke Raliot valve should be replaced as an assombly in principle, Therefore do not disassemble i unless @ defects found. 2 Cleaning and inspection ‘iach all the disassembled parts completly with clean mineral ol Dry them wn compressed alr and then perform the following 1) Check that seat surfaces of each poppet and Plug are even wih no defect. 2) Check that main poppet (4) and stove (8) ‘move Iightly and smoothly, and that no scraich ‘or damage s present on the main poppet cuter ‘surface andthe sleeve inner surtace. 8) Check that spring (@) is not damaged, elormed or worn 4) Check thatthe holes of the main poppet and pilot seat are not logge with foreign matters, '5) stings and backup rings stall not be reused and be replaced wih new ones. Wien slight sratches or laws are found dur ing this inspection, remove them by lapping It there is any detective pat, replace tas eet valve assembly. ‘AXS0/BXS0 Series ‘Assembling 1) Insert main poppet (4) and spring (@) nto sleeve (3), and pu tem over pilot seat (6) that 's assembled with O-ring (10) and backup ring a9). 2) tach Ovngs to eap (1) nd plug (2) 3) Insert pot poppet (6) and epring (8) into plug (2), and tomporary assemble adjuster kt (7) with an Orting attached. Then install the assembly tothe cap, 44) Assemble the cap assembly tothe vane hous- Ing, and then portorm pressure agustment stings and backup rings shall not be roused and be replaced with new ones Pressure adjustment procedure 1) tach an accurate pressure gauge to the fentranee ofthe cou 2) Runthe pump atthe rated speed, 3). Switch the contel valve spool, and read the pressure gauge atthe time of cylinder stroke ond. 4) Turn the aduster clockus pressures obtained. ‘The prassur increases 17.7 MPa by one turn cof he adjuster (reterence valve). 5) When pressure reached the spectieg valve, hola the cluster to prevent it from tuning and Ughton te lock nut unt! necessary 6) mreaee the prasoute again and check thatthe pressure isthe specified value 40-109CONTROL VALVE DISASSEMBLY AND ASSEMBLY PORT RELIEF ke tthe set pressure is higher than the main rellet valve pressure, do not adjust the port relat but replace the installed reli valve assembly. 4. Disassembing Remove plug (2), and disassemble wave washer (16), sleove (3), poppet (4, plton (6), and sping a Remove adjuster kt (8) by losering the nus, and take out plot poppet (6) and spring (8), Ke Relief valve should be replaced as an assembly In principle. Therefore do not disassemble it unless a defect fe found, 2. Cleaning and inspection Wash all ne cisassemoled parts completely with clean mineral of Dry them with compressed air and then perform the folowing 1) Check that seat surfaces ofeach poppet and lug are even with no detect 2) Check that poppet (4) and sleeve (3) move Ughty and smoothy, and that no scratch or ‘damage is present on the main poppet outer surface and the sleeve ane surface, 3) Cheek that springs (7), (8) are not damages, ‘etormed or worn, 4) Check that the orilos of pston (6) 12 not logged with foreign matt, 5) O-rings and backup rings shall not be reused nde repiaced wih new ones, “he When slight seratches or faws are found dur ing hs inepecton, remove them by lapping, Ir there is any defective part, replace as rel vave assembly 40-110 ‘Assembling 1) Fit poppet (4) that ls assembled with O-ring (10) and backup ig (11) into sieeve (8), Inert piston (6) and spring 7 into poppet). (Assembiy A) 2) Insert pot poppet (6) and spring (8) nto plug (2), and tomporariy assemble adjuster bt (9) wit an O-ring atached, 3) Fit O-ing (14) and wave washer (16) ito plug {2), and then install Oxing (12) and backup ing (13). (Assembly B) 4) natal O-ring (1) © plug (1), Insert assembly At plug (1), and then install assembly B. Gm | B= 7m 70-8 aM (o-ings and backup rings shall notbe reused and be replaced with new ones, ‘Operation check after assembling Push sleeve (3) inside ater assembling, and check that piston (6) canbe rotated ight wth finger. it does no rotate, replace tas rele valve assemby ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. CONTROL VALVE 5, Pressure adjustment procedure 1) Attach an accurate pressure gauge to the entrance ofthe clout. 2) Runthe pump atthe rated speed 9) Swtah the contl vale epeo), and read the pressure gauge atthe time of ylinder stroke end 4) Tur the adjuster clockwise unth necessary pressures obaine. ‘The pressure increases 15.7 MPa by one turn of ho adustr (reference vale) 5) When pressure reached the spectied value, hold the adjuster to prevent it from tring and tighten the lock nt Gas PNB ©) Inorease the pressure again and check thatthe Pressures the epectied value. INSTALLATION Pay attention tothe flowing for netalaon. ‘Be careful so that excessive stess is not applied to the valves trough piping + Tighten all bots evenly. + When performing welding near a valve, be careul not to damage seal pats by excessive heat or spattars. ‘+ To prevent dust or foelgn mates from entering, do not detach protective materia of pets until piping ‘OPERATION ‘+ Cheok tat te valves are conecty arranged ans that Iydrauite ol clean, and then check that no oll is leaking ouside while increasing the pressute gradu- aly (by inching operation at ow ie). “+ Use ryraulie of wn an anne point of 6210 113 ° ‘+ Uso relat vas wiin the specie set pressure. + Perform adequate warm-up run Detoe starting Work When starting the machine with @ low hyseaulc of temperature or low valve temperature, be caretl of the folowing to prevent tick due to apoo's heat shook. + Domnot operate sucdenly the main elit valve oF over load relist vaNe continuously during warm-up run ‘Operate the machine s0 that hydraule ol in each ‘actuator can exeulate and that each section warms up evenly ‘+ Do not perform tne operation or combined operation ‘suddenly under a low temperature. Tis may cause partial heating due to thote conto in each section ‘AXS0/BXS0 Series 40-111MAST DISASSEMBLY AND ASSEMBLY MAST 1.0~ 1.75 ton Forklift Truck Inner mast chain Fork carriage || ‘835-7 {e5~120kom) Te7= EN S| (ie-20hgm) 40-112 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY ADJUSTMENT (1.0 - 1.75 ton) 1. Outer Main Roller » Selection of Foter Size Select the rollers (8, M, Land 0) to make no aiference between right and left atthe clear ance (a) ofthe mast sip Adjustment wih Shir Pt the same thieknass of the shims (1) on right ans fet to agust the clearanos at (b) as follows: 01 bS 04 ut the same thickness of the shims (2) on Fight and lef to adust the clearance a () as follows: 0.1 Ses 05 2. Inner Main Roller » a Selection of Rofer Size Select the roles (8, M, Land ©) to make the clesrance (a) as flows: 01S 8S 0.7 Adjustment wih Shim Put the same thikness of the shime (1) on Fight and left to aust the clearance at (b) as follows: 0156505 ‘AXS0/BXS0 Series to te 40-113MAST DISASSEMBLY AND ASSEMBLY 2.02.0 ton Forklift Truck “1000 | Inner mast ul Lum evinder Chain Fork camiage | star Km ‘Outer mast = | (10-18 kgm e=1a7 Nm em | flo- 1S49m) 40-114 ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY ADJUSTMENT (2.5 - 3.0 ton) 1. Selection of Main Roller 1) Section AA Select the roles (S, M and L) to make no ot ference between right and le tthe clearance (b) ofthe mast stip 2) Secton B-5 Select the rolls to make the clearance between the mast all andthe roller as follows: 028 bS0.7mm ‘Adjustment with Shim (Sections A-A and B+ Put he same thickvess ofthe shims on right ad et to adjust tne clearance at a) as flows: 0S aS05 rm, which makes such a state thatthe A section of the mast rail and roller may contact each other slighty when the rollr Is pushed toward the mast ral 3. Strip Shim (Section A-A) Put the same thickness of he shims on right anda to adjust he clearance Between the mast etrp and the mast all evenly ver the nner mast rll when the main oles pushed toward the masta. The lear- ance should be adjusted to 0.1 eS 04mm, ‘AXS0/BXS0 Series tekness: 13 mm Stand shim Standard shim thiekness 1.5 ym I standard shim icknees: 13 mm F Cor 40-115,MAST ‘ADJUSTMENT (25 ~3.5 ton Triple Mast) 41. Selection of Main Roller 1) Sections AA and C6 ‘Select the rollers (S, M and L) to make no dt ference between right and let atthe clearance (b) ofthe mast sip. 2) Sections 8-8 and D:D ‘Select the rollers to make the clearance bbetwoen the mast ral andthe roller as follows: 025bS07mm 2 Adjustment with Shim (Geotions A-A,B-B, C-C and DD) Putthe same thickness ofthe shims on right andlen to adjust the clearance a a) as follows: 0 aS 05 rm, which makes such state that the Rsecton of the mast rail and roller may contact each other slightly when the roller Is pushed toward the mast ral. 3, ‘Strip Shim (Sections A-A and C-C) Putte came thickness of te ahims on right anda to adjust the clearance between the mast stip and the masta evenly ver the inner mast all when the ‘main roller is pushed toward the mast ral, The clear ance shouldbe adjusted o 0.1 $¢$0.4mm, 40-116 DISASSEMBLY AND ASSEMBLY ticks: 13 mm Istandard shim ‘Standard shim thickness: 1.8 mm | rand enim riknecs: 1.3 mn Cc Cy Standars shim tickness: 2.3 mm - Standard shim thickness: 1-3 mm 5 ss i ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY 1. Section E (Cylinder Clamp) 1) Inert the top ofthe ft ying inthe nner cy: Inder 0 as to acjust it wt shim (a, Standard Thickness of Stim 2a 3mm ‘aot 1mm aa a7 mm ‘Standard Thickness of Shim (Tible Mast) Bat 5mm ‘at 55mm 2. Adjustment of Lif Cylinder Stroke End “a Put te shim 1) to aust the clearance othe it cy Inder stoke end sos to synchronize right and ltt Int eyiinders when extending theif eylinders to the maximum fork height, Avrnes ——__ Chacko make sre hatte ences ae bog secured ty wh topper ‘AXS0/BXS0 Series 40-117FORK CARRIAGE FORK CARRIAGE 1.0~ 1.75 ton Forklift Truck “ke Tiahton the bot pushing toward the backrest board he 1. Section 8-8 (Exclusively for 2-Rolle Type) 1) Select such shims as to make the clearance at" tobe 03 t03.1 mm 2) Use the shims of the same thickness to make the elearance "bY to be 04 to 0.7 mm inthe tight and let at the top ofthe fork carriage 40-118 DISASSEMBLY AND ASSEMBLY ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY 2. Section c-c » 2 Select such shime ac to make the clearance “az tob203t0 11 mn. Use the shims ofthe same thickness fo make the clearance *b2" tobe 4 to 0.7 mm for 2 roller type and 0.1 to 04 mm for llr ype ln ‘the right and ft at he top ofthe fork eariags, 3. Section D-0 » a Select such shims as to make the clearance “ast tobe 03t611 mm, Use the shime ofthe same thickness to make the clearance "bs" 10 be 0 t0 0.2 mm In the Hight anit atthe top ofthe fork carage 4. Protrusion “A* (Lowered Height) » Lower the fork tothe ground and measure the ‘amencion “A” between the lower end of inner rmaet (1) andthe ower side ral (2) of fnger bat Distance "A ‘StandardTee | Coupe Mode! pout vg | va) FORK CARRIAGE Ta a78t0n | 29mm | 2mm | 1 mm ‘AXS0/BXS0 Series 40-119 12008.9.20(1)FORK CARRIAGE 2.02.0 ton Forklift Truck “ke Tiahton the bot pushing toward the backrest board i ‘Always make sure to use the ig the roler to prevent the seal trom getting any damage when assembling 1. Section BB 1) Seloct such shims as to make the clearance tobe 021007 mm, 2) The standard thickness of the clearance *b* should be 0 mm, 3) The atandard thickness of the clearance “e" should be 1.8 mm, 40-120 DISASSEMBLY AND ASSEMBLY TF (Goer of Seat Black olor of Sea! Blue olor of Seal: Black Color of Sak lace ‘oor af Sea: Bue (Color of Seal: Black ‘AXSO/BXS0 SeriesDISASSEMBLY AND ASSEMBLY. FORK CARRIAGE 2. Section c-c 1) Select such shim as to make the clearance to be 07t0 12mm, 2) Use the shims ofthe same thickness to make 2 ‘he clearance “eto be Oto 0.2 mm inthe right and et atthe top of he fork cartlage. 3) The standard thickness of the clearance “bt should be 3.8 mm, ke Use the same size of roses as used in upper and lower ones oy 3. Section 0-0 1) Select such shims as to make the clearance at tobe 02t0 0.7 mm, 2) Use the shims ofthe same thickness to make ‘the clearance "tobe 0 100.1 mm inte right and eat the top of he fork cartage. 3) The standard thickness of the clearance “bt shouldbe 5.1 me, 4. Section EE 1) Use the shims ofthe same thickness to make ‘he clearance "gto bs 0 10 0.2mm inte right and ot atthe top of he fork cartage. 2) The standard thickness of the clearance should be 2.0 mm, “ke Never use more than 2 pieces ofthe shims of 105.and.0 (thickness of 05 mm and 1.0 mm) ‘Aways make sure to use the spacer of 2 (thickness of 3.2:mm) 5. Protrusion “A* (Lowered Height) Lower the fork to the ground and measure the

You might also like

• The Subtle Art of Not Giving a F*ck: A Counterintuitive Approach to Living a Good Life

  

  From Everand

  The Subtle Art of Not Giving a F*ck: A Counterintuitive Approach to Living a Good Life

  Mark Manson

  Rating: 4 out of 5 stars

  4/5 (5820)
• The Gifts of Imperfection: Let Go of Who You Think You're Supposed to Be and Embrace Who You Are

  

  From Everand

  The Gifts of Imperfection: Let Go of Who You Think You're Supposed to Be and Embrace Who You Are

  Brené Brown

  Rating: 4 out of 5 stars

  4/5 (1093)
• Never Split the Difference: Negotiating As If Your Life Depended On It

  

  From Everand

  Never Split the Difference: Negotiating As If Your Life Depended On It

  Chris Voss

  Rating: 4.5 out of 5 stars

  4.5/5 (845)
• • Magazines
  • Podcasts
  • Sheet music
• Principles: Life and Work

  

  From Everand

  Principles: Life and Work

  Ray Dalio

  Rating: 4 out of 5 stars

  4/5 (609)
• The Glass Castle: A Memoir

  

  From Everand

  The Glass Castle: A Memoir

  Jeannette Walls

  Rating: 4.5 out of 5 stars

  4.5/5 (1717)
• Grit: The Power of Passion and Perseverance

  

  From Everand

  Grit: The Power of Passion and Perseverance

  Angela Duckworth

  Rating: 4 out of 5 stars

  4/5 (590)
• Sing, Unburied, Sing: A Novel

  

  From Everand

  Sing, Unburied, Sing: A Novel

  Jesmyn Ward

  Rating: 4 out of 5 stars

  4/5 (1104)
• Hidden Figures: The American Dream and the Untold Story of the Black Women Mathematicians Who Helped Win the Space Race

  

  From Everand

  Hidden Figures: The American Dream and the Untold Story of the Black Women Mathematicians Who Helped Win the Space Race

  Margot Lee Shetterly

  Rating: 4 out of 5 stars

  4/5 (898)
• Shoe Dog: A Memoir by the Creator of Nike

  

  From Everand

  Shoe Dog: A Memoir by the Creator of Nike

  Phil Knight

  Rating: 4.5 out of 5 stars

  4.5/5 (540)
• The Perks of Being a Wallflower

  

  From Everand

  The Perks of Being a Wallflower

  Stephen Chbosky

  Rating: 4.5 out of 5 stars

  4.5/5 (2104)
• The Hard Thing About Hard Things: Building a Business When There Are No Easy Answers

  

  From Everand

  The Hard Thing About Hard Things: Building a Business When There Are No Easy Answers

  Ben Horowitz

  Rating: 4.5 out of 5 stars

  4.5/5 (349)
• Bad Feminist: Essays

  

  From Everand

  Bad Feminist: Essays

  Roxane Gay

  Rating: 4 out of 5 stars

  4/5 (1018)
• Elon Musk: Tesla, SpaceX, and the Quest for a Fantastic Future

  

  From Everand

  Elon Musk: Tesla, SpaceX, and the Quest for a Fantastic Future

  Ashlee Vance

  Rating: 4.5 out of 5 stars

  4.5/5 (474)
• The Outsider: A Novel

  

  From Everand

  The Outsider: A Novel

  Stephen King

  Rating: 4 out of 5 stars

  4/5 (1867)
• Her Body and Other Parties: Stories

  

  From Everand

  Her Body and Other Parties: Stories

  Carmen Maria Machado

  Rating: 4 out of 5 stars

  4/5 (822)
• The Sympathizer: A Novel (Pulitzer Prize for Fiction)

  

  From Everand

  The Sympathizer: A Novel (Pulitzer Prize for Fiction)

  Viet Thanh Nguyen

  Rating: 4.5 out of 5 stars

  4.5/5 (122)
• Angela's Ashes: A Memoir

  

  From Everand

  Angela's Ashes: A Memoir

  Frank McCourt

  Rating: 4.5 out of 5 stars

  4.5/5 (441)
• The Emperor of All Maladies: A Biography of Cancer

  

  From Everand

  The Emperor of All Maladies: A Biography of Cancer

  Siddhartha Mukherjee

  Rating: 4.5 out of 5 stars

  4.5/5 (271)
• Brooklyn: A Novel

  

  From Everand

  Brooklyn: A Novel

  Colm Toibin

  Rating: 3.5 out of 5 stars

  3.5/5 (1947)
• The Little Book of Hygge: Danish Secrets to Happy Living

  

  From Everand

  The Little Book of Hygge: Danish Secrets to Happy Living

  Meik Wiking

  Rating: 3.5 out of 5 stars

  3.5/5 (401)
• A Man Called Ove: A Novel

  

  From Everand

  A Man Called Ove: A Novel

  Fredrik Backman

  Rating: 4.5 out of 5 stars

  4.5/5 (4771)
• The World Is Flat 3.0: A Brief History of the Twenty-first Century

  

  From Everand

  The World Is Flat 3.0: A Brief History of the Twenty-first Century

  Thomas L. Friedman

  Rating: 3.5 out of 5 stars

  3.5/5 (2259)
• Steve Jobs

  

  From Everand

  Steve Jobs

  Walter Isaacson

  Rating: 4.5 out of 5 stars

  4.5/5 (808)
• The Yellow House: A Memoir (2019 National Book Award Winner)

  

  From Everand

  The Yellow House: A Memoir (2019 National Book Award Winner)

  Sarah M. Broom

  Rating: 4 out of 5 stars

  4/5 (98)
• Devil in the Grove: Thurgood Marshall, the Groveland Boys, and the Dawn of a New America

  

  From Everand

  Devil in the Grove: Thurgood Marshall, the Groveland Boys, and the Dawn of a New America

  Gilbert King

  Rating: 4.5 out of 5 stars

  4.5/5 (266)
• A Tree Grows in Brooklyn

  

  From Everand

  A Tree Grows in Brooklyn

  Betty Smith

  Rating: 4.5 out of 5 stars

  4.5/5 (1929)
• The Art of Racing in the Rain: A Novel

  

  From Everand

  The Art of Racing in the Rain: A Novel

  Garth Stein

  Rating: 4 out of 5 stars

  4/5 (4208)
• Yes Please

  

  From Everand

  Yes Please

  Amy Poehler

  Rating: 4 out of 5 stars

  4/5 (1903)
• Team of Rivals: The Political Genius of Abraham Lincoln

  

  From Everand

  Team of Rivals: The Political Genius of Abraham Lincoln

  Doris Kearns Goodwin

  Rating: 4.5 out of 5 stars

  4.5/5 (234)
• A Heartbreaking Work Of Staggering Genius: A Memoir Based on a True Story

  

  From Everand

  A Heartbreaking Work Of Staggering Genius: A Memoir Based on a True Story

  Dave Eggers

  Rating: 3.5 out of 5 stars

  3.5/5 (231)
• The Woman in Cabin 10

  

  From Everand

  The Woman in Cabin 10

  Ruth Ware

  Rating: 3.5 out of 5 stars

  3.5/5 (2522)
• Fear: Trump in the White House

  

  From Everand

  Fear: Trump in the White House

  Bob Woodward

  Rating: 3.5 out of 5 stars

  3.5/5 (738)
• Wolf Hall: A Novel

  

  From Everand

  Wolf Hall: A Novel

  Hilary Mantel

  Rating: 4 out of 5 stars

  4/5 (3973)
• John Adams

  

  From Everand

  John Adams

  David McCullough

  Rating: 4.5 out of 5 stars

  4.5/5 (2409)
• On Fire: The (Burning) Case for a Green New Deal

  

  From Everand

  On Fire: The (Burning) Case for a Green New Deal

  Naomi Klein

  Rating: 4 out of 5 stars

  4/5 (74)
• The Light Between Oceans: A Novel

  

  From Everand

  The Light Between Oceans: A Novel

  M.L. Stedman

  Rating: 4.5 out of 5 stars

  4.5/5 (789)
• Manhattan Beach: A Novel

  

  From Everand

  Manhattan Beach: A Novel

  Jennifer Egan

  Rating: 3.5 out of 5 stars

  3.5/5 (792)
• The Constant Gardener: A Novel

  

  From Everand

  The Constant Gardener: A Novel

  John le Carré

  Rating: 3.5 out of 5 stars

  3.5/5 (104)
• The Unwinding: An Inner History of the New America

  

  From Everand

  The Unwinding: An Inner History of the New America

  George Packer

  Rating: 4 out of 5 stars

  4/5 (45)
• Rise of ISIS: A Threat We Can't Ignore

  

  From Everand

  Rise of ISIS: A Threat We Can't Ignore

  Jay Sekulow

  Rating: 3.5 out of 5 stars

  3.5/5 (137)
• Little Women

  

  From Everand

  Little Women

  Louisa Alcott

  Rating: 4 out of 5 stars

  4/5 (104)