6
7.22.1 Disassemble Torqflow Transmission Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-847.22.2 Assemble Torqflow Transmission Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-847.22.3 Remove Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-857.22.4 Disassemble Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-867.22.5 Assemble Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-867.22.6 Disassemble Main Shaft And Clutch Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-877.22.7 Assemble Main Shaft And Clutch Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-877.22.8 Assemble Forward And Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-887.22.9 Measure Torqflow Transmission - Clutch Pack End Gap . . . . . . . . . . . . . . . . . . . . 7-897.22.10 Disassemble Clutch Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-907.22.11 Assemble Clutch Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-907.22.12 Disassemble Output Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-917.22.13 Assemble Output Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-917.22.14 Remove Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-917.22.15 Install Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-917.22.16 Remove Transmission Case Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-927.22.17 Install Transmission Case Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
7.23 TORQFLOW TRANSMISSION - CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
7.23.1 Disassemble Torqflow Transmission - Control Valve . . . . . . . . . . . . . . . . . . . . . . . 7-997.23.2 Assemble Torqflow Transmission - Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
7.24 HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1037.25 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104
7.25.1 Dissassemble Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1047.25.2 Replace Hydraulic Pump Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1067.25.3 Replace Front And Rear E-seal And Back-up Ring . . . . . . . . . . . . . . . . . . . . . . . . 7-1067.25.4 Replace O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1077.25.5 Assemble Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107
7.26 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
7.26.1 Disassemble Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1087.26.2 Inspect Tilt Cylinder Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1097.26.3 Assemble Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110
7.27 REMOVE MAST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1117.28 INSTALL MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1127.29 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113
7.29.1 Remove Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1137.29.2 Install Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1137.29.3 Disassemble Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1147.29.4 Assemble Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-118
7.30 CYLINDER SEAL SERVICE KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121
7.30.1 Displacement Design with Piston Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1217.30.2 Piston Design with No Downstroke Cushioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123
7.31 SIDESHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
7.31.1 Replace Cylinder Head O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1267.31.2 Service Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-138
8.
MASTS
35/40/50/55/60D-MD SERIES 2-STAGE MASTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-230/35/40/50/55/60D-MS 2-STAGE MASTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3530/35/40/50/55/60D-MT 3-STAGE MASTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
9.
APPENDICES AND ENGINE MANUAL
APPENDIX 1 - SCHEMATICSAPPENDIX 2 - HYDRAULIC CIRCUIT DIAGRAMAPPENDIX 3 - PEDAL ADJUSTMENT DIAGRAMAPPENDIX 4 - TROUBLESHOOTING DIAGRAMSM300 - K21/25 ENGINE SERVICE MANUAL
Страница 1: ...l factory installed guards and shields are properly secured in place WARNING SERVICE MANUAL AX20 SERIES FORKLIFT TRUCKS Federal Environmental Protection Agency EPA Emission Control Compliant S N 67000...
Страница 2: ...ponsible for damages due to misuse or inappropriate use of its products Requests for information comments and other inquiries should be sent to Komatsu Forklift USA Inc 14481 Lochridge Blvd Bldg 2 Cov...
Страница 3: ...PLUG GAP 4 3 4 3 ADJUST VALVE CLEARANCE 4 3 4 4 ADJUST FAN BELT TENSION 4 4 4 5 MEASURE ENGINE CYLINDER COMPRESSION 4 4 4 6 ADJUST THE PARKING BRAKE LEVER 4 5 4 7 MEASURE HYDRAULIC DRIFT ON LIFT TILT...
Страница 4: ...10 5 23 INSPECT BRAKE DRUMS 5 10 5 24 INSPECT BRAKE BACKING PLATES 5 11 5 25 INSPECT LOAD FORKS 5 11 5 26 INSPECT MAST 5 11 5 27 INSPECT FORK CARRIAGE 5 12 5 28 INSPECT LIFT CHAINS 5 12 5 29 INSPECT C...
Страница 5: ...AXLE LUBRICATION AND ADJUSTMENTS 7 22 7 11 1 Steering Axle Lubrication 7 22 7 11 2 Hub Bearing Preload Adjustment 7 22 7 11 3 Toe in Specification Cushion Tire Truck 7 22 7 11 4 Turning Angle Adjustme...
Страница 6: ...MP 7 104 7 25 1 Dissassemble Hydraulic Pump 7 104 7 25 2 Replace Hydraulic Pump Seals 7 106 7 25 3 Replace Front And Rear E seal And Back up Ring 7 106 7 25 4 Replace O ring 7 107 7 25 5 Assemble Hydr...
Страница 7: ...arefully refer to it often and learn the repair testing and adjustment procedures to the best of your ability Please note that some illustrations are generic and may not look exactly like your unit in...
Страница 8: ...block in the center just beneath the valve cover The machined boss is split vertically by a groove The Engine Model number is on the left pad and the Engine Serial number is on the right pad NOTICE F...
Страница 9: ...l Pneumatic Tire FG15ST 17 3 000 lb capacity K21 Engine Torqflow Spec Cushion Tire FG15STLS 17 3 000 lb capacity K21 Engine Torqflow Spec LP Special Cushion Tire FG18HT 17 3 500 lb capacity K21 Engine...
Страница 10: ...10 NOTES...
Страница 11: ...ect labeling warranty parts and maintenance of K21 and K25 engines in order to comply with the EPA off road large spark ignition LSI engine regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All K seri...
Страница 12: ...aler OWNER S WARRANTY RESPONSIBILITIES As the off road LSI engine owner you are responsible for the performance of the required maintenance listed in your Operation and Maintenance Manual KFI recommen...
Страница 13: ...RS FOR GENERAL PARTS ECM Catalytic converter Vaporizer Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance For questions and addi...
Страница 14: ...NOTES...
