SEN05692-00

FG10/15/18-21
FG15H/18H-21
FD10/15/18-21
FG20/25/30-17
FG20H/25H/-17
FG20N/25N/30N-17
FG35A-17
FD20/25/30-16
FD20H/25H/30H-16
FD20N/25N/30N-16
FD35A-16
 PRECAUTIONS WHEN PERFORMING THE SERVICE WORK

Always pay attention to “Safety” before starting any work — this is important.
Never attempt any work where danger to yourself or to other persons.
Whenever work requiring safety precautions are described in this manual, a flag mark
inserted, always make double sure that safety measures are taken.
Other unmarked work, should always be performed after studying and using your
common sense to prevent accidents.

DESCRIPTION OF THE SYMBOLS

The symbols described below are used in this manual for convenience and better understanding.

Symbol Item Description

Safety Special safety precautions are needed to perform the work.

Note Special technical precautions are needed to perform the work

Tightening torque Fastening parts that require specified tightening force when assembling.

Weight Weight of parts or systems

Coat Places to be coated with adhesives, etc. when assembling

00-2 AX50/BX50 Series

 SECTION INDEX

00. FOREWORD

10. GENERAL AND SPECIFICATIONS

20. TESTING AND ADJUSTMENT

30. REMOVAL AND INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

80. CRITERIA FOR PERIODICAL INSPECTION AND JUDGMENT

90. CONVERSION TABLE

AX50/BX50 Series 00-3

 10. GENERAL AND SPECIFICATIONS

SPECIFICATIONS .....................................................10-2
PERIODIC REPLACEMENT OF
CONSUMABLE PARTS ..........................................10-16
SAFETY ITEMS FOR MAINTENANCE ...................10-17
STANDARD TIGHTENING TORQUE
FOR BOLTS.............................................................10-25
STANDARD TIGHTENING TORQUE
FOR PIPE JOINTS ..................................................10-26

AX50/BX50 Series 10-1

SPECIFICATIONS GENERAL AND SPECIFICATIONS

SPECIFICATIONS
AX50 (1.0 - 1.8ton) Series
1.2 Model Manufacturer's Designation FG10T-21 FG10C-21 FD10T-21 FD10C-21
1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel
Characteristics

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 1000 1000
1.6 Load Center Rated Load Center mm 500 500
1.6.1 Alternative Capacity Capacity@600mm Load Center kg 900 900
1.8 Load Distance Front Axle Center to Fork Face mm L2 400 400
1.9 Wheelbase mm L3 1400 1400
2.1 Service Weight kg 2080 2120 2180 2220
2.2 Front kg 2725 2760 2760 2790
Weight

Loaded
2.2.1 Rear kg 355 360 420 430
Axle Loading
2.3 Front kg 1065 1100 1095 1130
Unloaded
2.3.1 Rear kg 1015 1020 1085 1090
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 6.50-10-10PR(I) 6.50-10-10PR(I)
Tyre Size
Tyres

3.3 Rear 5.00- 8- 8PR(I) 5.00-8-8PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2
3.6 Tread, Front mm b4 890 890
3.7 Tread, Rear mm b3 895 895
4.1 Tilting Angle Forward/Backward degree 6/10 6/10
4.2 Mast Height, Lowered 2-stage Mast mm h2 1995 1995
4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 135 135
4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000
4.5 Mast Height, Extended 2-stage Std. Mast mm h3 3955 3955
4.7 Height, Overhead Guard mm h4 2070 2070
4.19 Length, with Std. Forks mm L1 2965 2965
Dimensions

4.20 Length, to Fork Face mm 2195 2195

4.21 Width, at Tyre Single mm b1 1070 1070
4.22 Forks Thickness x Width x Length mm 31x100x770 31x100x770
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2, Type A Class 2, Type A
4.24 Width, Fork Carriage mm 970 970
4.31 Under Mast mm 120 120
Ground Clearance
4.32 at Center of Wheelbase mm 130 130
4.33 with L1000 x W1200 pallet mm 3315 3315
Right Angle Stacking Aisle
4.34 with L1200 x W800 pallet mm 3515 3515
4.35 Turning Radius mm Wa 1915 1915
Loaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.5 8.5/19.5
Loaded mm/s 580 620
5.2 Lifting Speed
Unloaded mm/s 640 670
Performance

Loaded mm/s 500 500

5.3 Lowering Speed
Unloaded mm/s 550 550
5.6 Max. Drawbar Pull Loaded, 1.5 km/h, 3 min rating KN 10 11 13 14
5.8 Max. Gradeability Loaded, 1.5 km/h, 3 min rating % 34 38 49 41
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery Voltage/ Capacity at 5-hour rating V/ah 12/33 12/64
7.1 Maker Model NISSAN K15 Komatsu 4D92E
7.2 Rated Output, SAE net KW 27.2@2500 34.6@2450
I.C Engine

7.3 Rated RPM min-1 2500 2450

7.3.1 Max. Torque, SAE net Nm@min-1 113@1600 142@1800
7.4 No. of Cylinder/Displacement cm3 4-1486 4-2659
7.6 Fuel Tank Capacity Ltr 40 40
8.2 Relief Pressure for Attachment bar 172 172
Others

8.6 Clutch T/C Dry T/C Dry

8.7 Transmission TORQFLOW Synchromesh TORQFLOW Synchromesh

10-2 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS

FG15T-21 FG15C-21 FD15T-21 FD15C-21 FG15HT-21 FG15HC-21

Gasoline Diesel Gasoline
Sitting Sitting Sitting
1500 1500 1500
500 500 500
1350 1350 1350
405 405 405
1400 1400 1400
2450 2490 2550 2590 2450 2490
3500 3535 3530 3565 3500 3535
450 455 520 525 450 455
1005 1040 1035 1070 1005 1040
1445 1450 1515 1520 1445 1450
Pneumatic Pneumatic Pneumatic
6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I)
5.00- 8- 8PR(I) 5.00-8-8PR(I) 5.00- 8- 8PR(I)
2*/2 2*/2 2*/2
890 890 890
895 895 895
6/10 6/10 6/10
1995 1995 1995
140 140 140
3000 3000 3000
3955 3955 3955
2070 2070 2070
3160 3160 3160
2240 2240 2240
1070 1070 1070
35x100x920 35x100x920 35x100x920
Class 2, Type A Class 2, Type A Class 2, Type A
970 970 970
120 120 120
130 130 130
3360 3360 3360
3560 3560 3560
1955 1955 1955
18.5 8.5/18.5 18.5 8.5/19.0 18.5 8.5/18.5
19.0 9.0/19.0 19.0 8.5/19.5 19.0 9.0/19.0
570 620 590
640 670 640
500 500 500
550 550 550
10 11 13 14 15 14
26 27 33 31 37 35
Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/Mechanical Hand/Mechanical Hand/Mechanical
FHPS FHPS FHPS
12/33 12/64 12/33
NISSAN K15 Komatsu 4D92E NISSAN K21
27.2@2500 34.6@2450 34.6@2450
2500 2450 2450
113@1600 142@1800 152@1600
4-1486 4-2659 4-2065
40 40 40
172 172 172
T/C Dry T/C Dry T/C Dry
TORQFLOW Synchromesh TORQFLOW Synchromesh TORQFLOW Synchromesh

AX50/BX50 Series 10-3

SPECIFICATIONS GENERAL AND SPECIFICATIONS

1.2 Model Manufacturer's Designation FG18T-21 FG18C-21 FD18T-21 FD18C-21

1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel
Characteristics

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 1750 1750
1.6 Load Center Rated Load Center mm 500 500
1.6.1 Alternative Capacity Capacity@600mm Load Center kg 1570 1570
1.8 Load Distance Front Axle Center to Fork Face mm L2 405 405
1.9 Wheelbase mm L3 1400 1400
2.1 Service Weight kg 2645 2685 2745 2785
2.2 Front kg 3870 3905 3900 3935
Weight

Loaded
2.2.1 Rear kg 525 530 595 600
Axle Loading
2.3 Front kg 960 995 990 1025
Unloaded
2.3.1 Rear kg 1685 1690 1755 1760
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 6.50-10-10PR(I) 6.50-10-10PR(I)
Tyre Size
Tyres

3.3 Rear 5.00- 8- 8PR(I) 5.00-8-8PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2
3.6 Tread, Front mm b4 890 890
3.7 Tread, Rear mm b3 895 895
4.1 Tilting Angle Forward/Backward degree 6/10 6/10
4.2 Mast Height, Lowered 2-stage Mast mm h2 1995 1995
4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 140 140
4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000
4.5 Mast Height, Extended 2-stage Std. Mast mm h3 3955 3955
4.7 Height, Overhead Guard mm h4 2070 2070
4.19 Length, with Std. Forks mm L1 3200 3200
Dimensions

4.20 Length, to Fork Face mm 2280 2280

4.21 Width, at Tyre Single mm b1 1070 1070
4.22 Forks Thickness x Width x Length mm 35x100x920 35x100x920
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2, Type A Class 2, Type A
4.24 Width, Fork Carriage mm 970 970
4.31 Under Mast mm 120 120
Ground Clearance
4.32 at Center of Wheelbase mm 130 130
4.33 with L1000 x W1200 pallet mm 3395 3395
Right Angle Stacking Aisle
4.34 with L1200 x W800 pallet mm 3595 3595
4.35 Turning Radius mm Wa 1990 1990
Loaded, 1st/2nd km/h 18.5 8.5/18.5 18.5 8.5/18.5
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0
Loaded mm/s 570 620
5.2 Lifting Speed
Unloaded mm/s 640 670
Performance

Loaded mm/s 500 500

5.3 Lowering Speed
Unloaded mm/s 550 550
5.6 Max. Drawbar Pull Loaded, 1.5 km/h, 3 min rating KN 10 11 13 14
5.8 Max. Gradeability Loaded, 1.5 km/h, 3 min rating % 25 24 29 28
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery Voltage/ Capacity at 5-hour rating V/ah 12/33 12/64
7.1 Maker Model NISSAN K15 Komatsu 4D92E
7.2 Rated Output, SAE net KW 27.2@2500 34.6@2450
I.C Engine

7.3 Rated RPM min-1 2500 2450

7.3.1 Max. Torque, SAE net Nm@min-1 113@1600 142@1800
7.4 No. of Cylinder/Displacement cm3 4-1486 4-2659
7.6 Fuel Tank Capacity Ltr 40 40
8.2 Relief Pressure for Attachment bar 172 172
Others

8.6 Clutch T/C Dry T/C Dry

8.7 Transmission TORQFLOW Synchromesh TORQFLOW Synchromesh

10-4 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS

FG18HT-21 FG18HC-21
Gasoline
Sitting
1750
500
1570
405
1400
2645 2685
3870 3905
525 530
960 995
1685 1690
Pneumatic
6.50-10-10PR(I)
5.00- 8- 8PR(I)
2*/2
890
895
6/10
1995
140
3000
3955
2070
3200
2280
1070
35x100x920
Class 2, Type A
970
120
130
3395
3595
1990
18.5 8.5/18.5
19.0 9.0/19.0
590
640
500
550
15 14
33 32
Foot/Hydraulic
Hand/Mechanical
FHPS
12/33
NISSAN K21
34.6@2450
2450
152@1600
4-2065
40
172
T/C Dry
TORQFLOW Synchromesh

AX50/BX50 Series 10-5

SPECIFICATIONS GENERAL AND SPECIFICATIONS

BX50 (2.0 - 2.5ton) Series

1.2 Model Manufacturer's Designation FG20T-17 FG20C-17 FD20T-16 FD20C-16
1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel
Characteristics

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 2000 2000
1.6 Load Center Rated Load Center mm 500 500
1.6.1 Alternative Capacity Capacity@600mm Load Center kg 1810 1810
1.8 Load Distance Front Axle Center to Fork Face mm L2 460 460
1.9 Wheelbase mm L3 1650 1650
2.1 Service Weight kg 3220 3255 3310 3355
2.2 Front kg 4670 4705 4700 4745
Weight

Loaded
2.2.1 Rear kg 550 550 610 610
Axle Loading
2.3 Front kg 1480 1505 1510 1545
Unloaded
2.3.1 Rear kg 1740 1750 1800 1810
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 7.00-12-12PR(I) 7.00-12-12PR(I)
Tyre Size
Tyres

3.3 Rear 6.00-09-10PR(I) 6.00-09-10PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2
3.6 Tread, Front mm b4 965 965
3.7 Tread, Rear mm b3 960 960
4.1 Tilting Angle Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered 2-stage Mast mm h2 1995 1995
4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 150 150
4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000
4.5 Mast Height, Extended 2-stage Std. Mast mm h3 4050 4050
4.7 Height, Overhead Guard mm h4 2110 2070
4.19 Length, with Std. Forks mm L1 3450 3450
Dimensions

4.20 Length, to Fork Face mm 2530 2530

4.21 Width, at Tyre Single mm b1 1150 1150
4.22 Forks Thickness x Width x Length mm 36x122x920 36x122x920
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2, Type A Class 2, Type A
4.24 Width, Fork Carriage mm 1020 1020
4.31 Under Mast mm 115 115
Ground Clearance
4.32 at Center of Wheelbase mm 160 160
4.33 with L1000 x W1200 pallet mm 3650 3650
Right Angle Stacking Aisle
4.34 with L1200 x W800 pallet mm 3850 3850
4.35 Turning Radius mm Wa 2190 2190
Loaded, 1st/2nd km/h 18.5 8.5/18.5 18.5 8.5/18.5
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.0 9.0/19.0 19.0 8.5/19.0
Loaded mm/s 545 630
5.2 Lifting Speed
Unloaded mm/s 600 685
Performance

Loaded mm/s 450 450

5.3 Lowering Speed
Unloaded mm/s 500 500
5.6 Max. Drawbar Pull Loaded, 1.5 km/h, 3 min rating KN 14 14 18 17
5.8 Max. Gradeability Loaded, 1.5 km/h, 3 min rating % 28 27 36 34
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery Voltage/ Capacity at 5-hour rating V/ah 12/33 12/64
7.1 Maker Model NISSAN K21 Komatsu 4D94LE
7.2 Rated Output, SAE net KW 34.6@2450 46.3@2450
I.C Engine

7.3 Rated RPM min-1 2450 2450

7.3.1 Max. Torque, SAE net Nm@min-1 152@1600 186@1800
7.4 No. of Cylinder/Displacement cm3 4-2065 4-3052
7.6 Fuel Tank Capacity Ltr 58 58
8.2 Relief Pressure for Attachment bar 181 181
Others

8.6 Clutch T/C Dry T/C Dry

8.7 Transmission TORQFLOW Synchromesh TORQFLOW Synchromesh

10-6 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS

FG20HT-17 FD20HT-16 FD20HC-16 FG25T-17 FG25C-17 FD25T-16

Gasoline Diesel Gasoline Diesel
Sitting Sitting Sitting Sitting
2000 2000 2500 2500
500 500 500 500
1810 1810 2260 2260
460 460 465 465
1650 1650 1650 1650
3220 3310 3355 3590 3625 3680
4670 4700 4745 5420 5455 5460
550 610 610 670 670 720
1480 1510 1545 1430 1455 1460
1740 1800 1810 2160 2170 2220
Pneumatic Pneumatic Pneumatic Pneumatic
7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I)
6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I) 6.00-09-10PR(I)
2*/2 2*/2 2*/2 2*/2
965 965 965 965
960 960 960 960
6/12 6/12 6/12 6/12
1995 1995 1995 1995
150 150 155 155
3000 3000 3000 3000
4050 4050 4050 4050
2110 2070 2110 2070
3450 3450 3655 3655
2530 2530 2585 2585
1150 1150 1150 1150
36x122x920 36x122x920 40x122x1070 40x122x1070
Class 2, Type A Class 2, Type A Class 2, Type A Class 2, Type A
1020 1020 1020 1020
115 115 115 115
160 160 160 160
3650 3650 3775 3775
3850 3850 3905 3905
2190 2190 2240 2240
19.0 18.5 8.0/18.5 18.5 8.5/18.5 18.5
19.5 19.0 8.5/19.0 19.0 9.0/19.0 19.0
620 660 545 630
670 710 600 685
450 450 450 450
500 500 500 500
19 22 21 14 14 18
38 45 44 23 22 31
Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical
FHPS FHPS FHPS FHPS
12/33 12/64 12/33 12/64
NISSAN K25 Komatsu 4D98E NISSAN K21 Komatsu 4D94LE
42.6@2400 53.0@2400 34.6@2450 46.3@2450
2400 2400 2450 2450
186@1600 216@1700 152@1600 186@1800
4-2488 4-3318 4-2065 4-3052
58 58 58 58
181 181 181 181
T/C T/C Dry T/C Dry T/C
TORQFLOW TORQFLOW Synchromesh TORQFLOW Synchromesh TORQFLOW

AX50/BX50 Series 10-7

SPECIFICATIONS GENERAL AND SPECIFICATIONS

1.2 Model Manufacturer's Designation FG25HT-17 FD25HT-16 FD25HC-16

1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel
Characteristics

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 2500 2500
1.6 Load Center Rated Load Center mm 500 500
1.6.1 Alternative Capacity Capacity@600mm Load Center kg 2260 2260
1.8 Load Distance Front Axle Center to Fork Face mm L2 465 465
1.9 Wheelbase mm L3 1650 1650
2.1 Service Weight kg 3590 3680 3725
2.2 Front kg 5420 5460 5495
Weight

Loaded
2.2.1 Rear kg 670 720 730
Axle Loading
2.3 Front kg 1430 1460 1495
Unloaded
2.3.1 Rear kg 2160 2220 2230
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 7.00-12-12PR(I) 7.00-12-12PR(I)
Tyre Size
Tyres

3.3 Rear 6.00-09-10PR(I) 6.00-09-10PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2
3.6 Tread, Front mm b4 965 965
3.7 Tread, Rear mm b3 960 960
4.1 Tilting Angle Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered 2-stage Mast mm h2 1995 1995
4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 155 155
4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000
4.5 Mast Height, Extended 2-stage Std. Mast mm h3 4050 4050
4.7 Height, Overhead Guard mm h4 2110 2070
4.19 Length, with Std. Forks mm L1 3655 3655
Dimensions

4.20 Length, to Fork Face mm 2585 2585

4.21 Width, at Tyre Single mm b1 1150 1150
4.22 Forks Thickness x Width x Length mm 40x122x1070 40x122x1070
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2, Type A Class 2, Type A
4.24 Width, Fork Carriage mm 1020 1020
4.31 Under Mast mm 115 115
Ground Clearance
4.32 at Center of Wheelbase mm 160 160
4.33 with L1000 x W1200 pallet mm 3775 3775
Right Angle Stacking Aisle
4.34 with L1200 x W800 pallet mm 3905 3905
4.35 Turning Radius mm Wa 2240 2240
Loaded, 1st/2nd km/h 19.0 18.5 8.0/18.5
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.5 19.0 8.5/19.0
Loaded mm/s 620 660
5.2 Lifting Speed
Unloaded mm/s 670 710
Performance

Loaded mm/s 450 450

5.3 Lowering Speed
Unloaded mm/s 500 500
5.6 Max. Drawbar Pull Loaded, 1.5 km/h, 3 min rating KN 19 22 21
5.8 Max. Gradeability Loaded, 1.5 km/h, 3 min rating % 32 37 37
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery Voltage/ Capacity at 5-hour rating V/ah 12/33 12/64
7.1 Maker Model NISSAN K25 Komatsu 4D98E
7.2 Rated Output, SAE net KW 42.6@2400 53.0@2400
I.C Engine

7.3 Rated RPM min-1 2400 2400

7.3.1 Max. Torque, SAE net Nm@min-1 186@1600 216@1700
7.4 No. of Cylinder/Displacement cm3 4-2488 4-3318
7.6 Fuel Tank Capacity Ltr 58 58
8.2 Relief Pressure for Attachment bar 181 181
Others

8.6 Clutch T/C T/C Dry

8.7 Transmission TORQFLOW TORQFLOW Synchromesh

10-8 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS

BX50 (3.0 - 3.5ton) Series

1.2 Model Manufacturer's Designation FG30T-17 FG30C-17
1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline
Characteristics

1.4 Operation Type Sitting

1.5 Rated Capacity Rated Capacity kg 3000
1.6 Load Center Rated Load Center mm 500
1.6.1 Alternative Capacity Capacity@600mm Load Center kg 2720
1.8 Load Distance Front Axle Center to Fork Face mm L2 490
1.9 Wheelbase mm L3 1700
2.1 Service Weight kg 4210 4255
2.2 Front kg 6390 6425
Weight

Loaded
2.2.1 Rear kg 820 830
Axle Loading
2.3 Front kg 1600 1635
Unloaded
2.3.1 Rear kg 2610 2620
3.1 Tyre Type Pneumatic
3.2 Front 28x9-15-12PR(I)
Tyre Size
Tyres

3.3 Rear 6.50-10-10PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2
3.6 Tread, Front mm b4 1005
3.7 Tread, Rear mm b3 965
4.1 Tilting Angle Forward/Backward degree 6/12
4.2 Mast Height, Lowered 2-stage Mast mm h2 2070
4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 160
4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000
4.5 Mast Height, Extended 2-stage Std. Mast mm h3 4275
4.7 Height, Overhead Guard mm h4 2130
4.19 Length, with Std. Forks mm L1 3775
Dimensions

4.20 Length, to Fork Face mm 2705

4.21 Width, at Tyre Single mm b1 1235
4.22 Forks Thickness x Width x Length mm 44x122x1070
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 3, Type A
4.24 Width, Fork Carriage mm 1060
4.31 Under Mast mm 135
Ground Clearance
4.32 at Center of Wheelbase mm 185
4.33 with L1000 x W1200 pallet mm 3930
Right Angle Stacking Aisle
4.34 with L1200 x W800 pallet mm 4060
4.35 Turning Radius mm Wa 2370
Loaded, 1st/2nd km/h 18.5 8.5/18.5
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.5 9.0/19.5
Loaded mm/s 515
5.2 Lifting Speed
Unloaded mm/s 550
Performance

Loaded mm/s 420

5.3 Lowering Speed
Unloaded mm/s 500
5.6 Max. Drawbar Pull Loaded, 1.5 km/h, 3 min rating KN 18 18
5.8 Max. Gradeability Loaded, 1.5 km/h, 3 min rating % 26 25
5.10 Service Brake Operation/Control Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical
5.12 Steering Type FHPS
6.4 Battery Voltage/ Capacity at 5-hour rating V/ah 12/33
7.1 Maker Model NISSAN K25
7.2 Rated Output, SAE net KW 42.6@2400
I.C Engine

7.3 Rated RPM min-1 2400

7.3.1 Max. Torque, SAE net Nm@min-1 186@1600
7.4 No. of Cylinder/Displacement cm3 4-2488
7.6 Fuel Tank Capacity Ltr 58
8.2 Relief Pressure for Attachment bar 181
Others

8.6 Clutch T/C Dry

8.7 Transmission TORQFLOW Synchromesh

AX50/BX50 Series 10-9

SPECIFICATIONS GENERAL AND SPECIFICATIONS

1.2 Model Manufacturer's Designation FD30T-16 FD30C-16 FD30HT-16 FD30HC-16

1.3 Power Type Electric, Diesel, Gasoline, LPG Diesel Diesel
Characteristics

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 3000 3000
1.6 Load Center Rated Load Center mm 500 500
1.6.1 Alternative Capacity Capacity@600mm Load Center kg 2720 2720
1.8 Load Distance Front Axle Center to Fork Face mm L2 490 490
1.9 Wheelbase mm L3 1700 1700
2.1 Service Weight kg 4310 4345 4310 4345
2.2 Front kg 6430 6465 6430 6465
Weight

Loaded
2.2.1 Rear kg 880 880 880 880
Axle Loading
2.3 Front kg 1640 1675 1640 1675
Unloaded
2.3.1 Rear kg 2670 2670 2670 2670
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 28x9-15-12PR(I) 28x9-15-12PR(I)
Tyre Size
Tyres

3.3 Rear 6.50-10-10PR(I) 6.50x10-10PR(I)

3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2
3.6 Tread, Front mm b4 1005 1005
3.7 Tread, Rear mm b3 965 965
4.1 Tilting Angle Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered 2-stage Mast mm h2 2070 2070
4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 160 160
4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000
4.5 Mast Height, Extended 2-stage Std. Mast mm h3 4275 4275
4.7 Height, Overhead Guard mm h4 2090 2090
4.19 Length, with Std. Forks mm L1 3775 3775
Dimensions

4.20 Length, to Fork Face mm 2705 2705

4.21 Width, at Tyre Single mm b1 1235 1235
4.22 Forks Thickness x Width x Length mm 44x122x1070 44x122x1070
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 3, Type A Class 3, Type A
4.24 Width, Fork Carriage mm 1060 1060
4.31 Under Mast mm 135 135
Ground Clearance
4.32 at Center of Wheelbase mm 185 185
4.33 with L1000 x W1200 pallet mm 3930 3930
Right Angle Stacking Aisle
4.34 with L1200 x W800 pallet mm 4060 4060
4.35 Turning Radius mm Wa 2370 2370
Loaded, 1st/2nd km/h 19.0 8.5/18.5 18.5 8.0/18.5
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.5 9.0/19.0 19.0 8.5/19.0
Loaded mm/s 520 550
5.2 Lifting Speed
Unloaded mm/s 555 595
Performance

Loaded mm/s 420 420

5.3 Lowering Speed
Unloaded mm/s 500 500
5.6 Max. Drawbar Pull Loaded, 1.5 km/h, 3 min rating KN 18 17 21 21
5.8 Max. Gradeability Loaded, 1.5 km/h, 3 min rating % 25 23 30 30
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery Voltage/ Capacity at 5-hour rating V/ah 12/64 12/64
7.1 Maker Model Komatsu 4D94LE Komatsu 4D98E
7.2 Rated Output, SAE net KW 46.3@2450 53.0@2400
I.C Engine

7.3 Rated RPM min-1 2450 2400

7.3.1 Max. Torque, SAE net Nm@min-1 186@1800 216@1700
7.4 No. of Cylinder/Displacement cm3 4-3052 4-3318
7.6 Fuel Tank Capacity Ltr 58 58
8.2 Relief Pressure for Attachment bar 181 181
Others

8.6 Clutch T/C Dry T/C Dry

8.7 Transmission TORQFLOW Synchromesh TORQFLOW Synchromesh

10-10 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS

FG35AT-17 FD35AT-16
Gasoline Diesel
Sitting Sitting
3500 3500
500 500
3180 3180
505 505
1700 1700
4910 5010
7440 7480
970 1030
1820 1860
3090 3150
Pneumatic Pneumatic
250-15-16PR(I) 250-15-16PR(I)
6.50x10-12PR(I) 6.50x10-12PR(I)
2*/2 2*/2
1060 1060
965 965
6/12 6/12
2100 2100
145 145
3000 3000
4280 4280
2145 2105
3865 3865
2795 2795
1290 1290
50x150x1070 50x150x1070
Class 3, Type A Class 3, Type A
1060 1060
135 135
185 185
4055 4055
4185 4185
2480 2480
18.0 18.0
19.0 19.0
410 450
450 490
400 420
400 400
16 20
20 24
Foot/Hydraulic Foot/Hydraulic
Hand/Mechanical Hand/Mechanical
FHPS FHPS
12/33 12/64
NISSAN K25 Komatsu 4D98E
42.6@2400 53.0@2400
2400 2400
186@1600 216@1700
4-2488 4-3318
58 58
181 181
T/C T/C
TORQFLOW TORQFLOW

AX50/BX50 Series 10-11

SPECIFICATIONS GENERAL AND SPECIFICATIONS

109 Series
1.2 Model Manufacturer's Designation FG20NT-17 FD20NT-16 FG25NT-17
1.3 Power Type Electric, Diesel, Gasoline, LPG Gasoline Diesel Gasoline
Characteristics

1.4 Operation Type Sitting Sitting Sitting

1.5 Rated Capacity Rated Capacity kg 2000 2000 2500
1.6 Load Center Rated Load Center mm 500 500 500
1.6.1 Alternative Capacity Capacity@600mm Load Center kg 1800 1800 2250
1.8 Load Distance Front Axle Center to Fork Face mm L2 430 430 435
1.9 Wheelbase mm L3 1400 1400 1400
2.1 Service Weight kg 3230 3330 3630
2.2 Front kg 4600 4630 5350
Weight

Loaded
2.2.1 Rear kg 630 700 780
Axle Loading
2.3 Front kg 1250 1280 1140
Unloaded
2.3.1 Rear kg 1980 2050 2490
3.1 Tyre Type SSCT SSCT SSCT
22 1/4x7 1/2-15/ 22 1/4x7 1/2-15/ 22 1/4x7 1/2-15/
3.2 Front
5.50 5.50 5.50
Tyre Size
Tyres

17 3/4x6 1/2 -10/ 17 3/4x6 1/2 -10/ 17 3/4x6 1/2 -10/

3.3 Rear
5.00 5.00 5.00
3.5 Number of Wheel Front/Rear (x=driven) 2*/2 2*/2 2*/2
3.6 Tread, Front mm b4 900 900 900
3.7 Tread, Rear mm b3 885 885 885
4.1 Tilting Angle Forward/Backward degree 6/10 6/10 6/10
4.2 Mast Height, Lowered 2-stage Mast mm h2 1995 1995 1995
4.3 Std. Free Lift 2-stage Std. Mast, from Ground mm 150 150 155
4.4 Std. Lift Height 2-stage Std. Mast, from Ground mm h1 3000 3000 3000
4.5 Mast Height, Extended 2-stage Std. Mast mm h3 4050 4050 4050
4.7 Height, Overhead Guard mm h4 2065 2025 2065
4.19 Length, with Std. Forks mm L1 3260 3260 3475
Dimensions

4.20 Length, to Fork Face mm 2340 2340 2405

4.21 Width, at Tyre Single mm b1 1090 1090 1090
4.22 Forks Thickness x Width x Length mm 36x122x920 36x122x920 40x122x1070
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class 2, Type A Class 2, Type A Class 2, Type A
4.24 Width, Fork Carriage mm 960 960 960
4.31 Under Mast mm 105 105 105
Ground Clearance
4.32 at Center of Wheelbase mm 115 115 115
4.33 with L1000 x W1200 pallet mm 3410 3410 3555
Right Angle Stacking Aisle
4.34 with L1200 x W800 pallet mm 3610 3610 3685
4.35 Turning Radius mm Wa 1980 1980 2050
Loaded, 1st/2nd km/h 17.0 17.0 16.5
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 16.5 16.5 16.5
Loaded mm/s 545 630 545
5.2 Lifting Speed
Unloaded mm/s 600 685 600
Performance

Loaded mm/s 450 450 450

5.3 Lowering Speed
Unloaded mm/s 500 500 500
5.6 Max. Drawbar Pull Loaded, 1.5 km/h, 3 min rating KN 14 17 14
5.8 Max. Gradeability Loaded, 1.5 km/h, 3 min rating % 27 34 23
5.10 Service Brake Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS FHPS
6.4 Battery Voltage/ Capacity at 5-hour rating V/ah 12/33 12/64 12/33
7.1 Maker Model NISSAN K21 Komatsu 4D94LE NISSAN K21
7.2 Rated Output, SAE net KW 34.6@2450 46.3@2450 34.6@2450
I.C Engine

7.3 Rated RPM min-1 2450 2450 2450

7.3.1 Max. Torque, SAE net Nm@min-1 152@1600 186@1800 152@1600
7.4 No. of Cylinder/Displacement cm3 4-2065 4-3052 4-2065
7.6 Fuel Tank Capacity Ltr 40 40 40
8.2 Relief Pressure for Attachment bar 181 181 181
Others

8.6 Clutch T/C T/C T/C

8.7 Transmission TORQFLOW TORQFLOW TORQFLOW

10-12 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS

FD25NT-16 FG30NT-17 FD30NT-16

Diesel Gasoline Diesel
Sitting Sitting Sitting
2500 3000 3000
500 500 500
2250 2720 2720
435 440 440
1400 1450 1450
3730 4070 4170
5380 6250 6240
850 820 930
1170 1260 1250
2560 2810 2920
SSCT SSCT SSCT
22 1/4x7 1/2-15/ 22 1/4x7 1/2-15/ 22 1/4x7 1/2-15/
5.50 5.50 5.50
17 3/4x6 1/2 -10/ 17 3/4x6 1/2 -10/ 17 3/4x6 1/2 -10/
5.00 5.00 5.00
2*/2 2*/2 2*/2
900 900 900
885 885 885
6/10 6/10 6/10
1995 2070 2070
155 160 160
3000 3000 3000
4050 4275 4275
2025 2065 2025
3475 3535 3535
2405 2465 2465
1090 1090 1090
40x122x1070 44x122x1070 44x122x1070
Class 2, Type A Class 3, Type A Class 3, Type A
960 940 940
105 105 105
115 115 115
3555 3620 3620
3685 3750 3750
2050 2110 2110
16.5 16.0 16.0
16.5 16.0 16.0
630 515 520
685 550 555
450 420 420
500 500 500
17 16 16
29 24 24
Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/Mechanical Hand/Mechanical Hand/Mechanical
FHPS FHPS FHPS
12/64 12/33 12/64
Komatsu 4D94LE NISSAN K25 Komatsu 4D94LE
46.3@2450 42.6@2400 46.3@2450
2450 2400 2450
186@1800 186@1600 186@1800
4-3052 4-2488 4-3052
40 40 40
181 181 181
T/C T/C T/C
TORQFLOW TORQFLOW TORQFLOW

AX50/BX50 Series 10-13

SPECIFICATIONS GENERAL AND SPECIFICATIONS

Outside view

D D D D

9C

q q

J
J
J J

. .
.

Load Capacity chart

1.0 ton 1.5 ton

3m, 3.5m, 4m Mast 3m, 3.5m, 4m Mast

4.5m Mast *4.5m Mast
5m Mast *5m Mast
1900 1900

1700 1700
CAPACITY (kg)
CAPACITY (kg)

1500 1500

1300 1300

1100 1100

900 900

700 700

500 500
0 500 600 800 1000 1200 0 500 600 800 1000 1200

LOAD CENTER (mm) LOAD CENTER (mm)

1.8 ton 2.0 ton

3m, 3.5m, 4m Mast ~4m Mast

*4.5m Mast 4.3m~4.5m Mast
*5m Mast 4.7~5m Mast
1900 3000
2800
1700
CAPACITY (kg)

CAPACITY (kg)

2600
1500 2400
2200
1300 2000
1100 1800
1600
900 1400
1200
700
1000
500 800
0 500 600 800 1000 1200 0 500 600 800 1000 1200 1400 1500

LOAD CENTER (mm) LOAD CENTER (mm)

10-14 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS

2.5 ton 3.0 ton

~4m Mast ~4m Mast

4.3m~4.5m Mast 4.3m~4.5m Mast
4.7~5m Mast 4.7~5m Mast
3000 3000
2800 2800
CAPACITY (kg)

CAPACITY (kg)
2600 2600
2400 2400
2200 2200
2000 2000
1800 1800
1600 1600
1400 1400
1200 1200
1000 1000
800 800
0 500 600 800 1000 1200 1400 1500 0 500 600 800 1000 1200 1400 1500

LOAD CENTER (mm) LOAD CENTER (mm)

3.5 ton

~4.5m Mast
4.7m~5m Mast
3500
3300
CAPACITY (kg)

3100
2900
2700
2500
2300
2100
1900
1700
1500
1300
0 500 600 800 1000 1200 1400 1500

LOAD CENTER (mm)

AX50/BX50 Series 10-15

PERIODIC REPLACEMENT OF CONSUMABLE PARTS GENERAL AND SPECIFICATIONS

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

For operation safety, never fail to perform periodic main-
tenance or make periodic replacement of the consum-
able parts listed in the following.
These parts may deteriorate in time and are susceptible
to wear. It is difficult to estimate the degree of wear at
time of periodic maintenance; therefore, even if no appar-
ent wear is found, always replace with new parts within
the prescribed period of replacement (or earlier if trouble
is found).
Note that periodic replacement has nothing to do with
guarantee service.
Period of
No. Part name replacement
1 Master cylinder and wheel cylinder cups, dust seals Every 1 year
2 Rubber parts of brake booster Every 1 year
3 Brake hose or tube Every 2 years
4 Reservoir tank and tube Every 2 years
5 Power steering hose Every 2 years
6 Stop lamp switch (Oil pressure type) Every 2 years
7 Fuel hose Every 2 years
8 Rubber parts of power steering Every 2 years
9 Lift chain Every 3 years
10 Hose of load handing Every 2 years

10-16 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE

SAFETY ITEMS FOR MAINTENANCE

FOR SAFETY OPERATION

USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE

• Only persons authorized by the owner or operator of the equipment and having proper certification
(local or national) may carry out inspection, maintenance and repairs of the lift truck.
If inspection, maintenance, or repair work is carried out incorrectly, it is very dangerous.

MAINTENANCE LOCATION

• When carrying out inspection and maintenance, use a level, dry, dust–free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

• To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know
how to use it.
• Before carrying 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.

PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE

• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean
the lift 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, oil, or grease. There is danger that it may catch fire.
• Wear suitable clothes for the job.
• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the
job.
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get 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 carrying out job with another worker, decide who is the 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 a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not
been fully corrected or that defective parts have not been removed.

AX50/BX50 Series 10-17

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS

USE SUITABLE TOOLS

• Always use tools that are suited for inspection and

maintenance.
It is extremely dangerous to use broken tools or tools
designed for another purpose.

REPLACE SAFETY CRITICAL PARTS PERIODICALLY

• Even if no abnormality is found, always replace safety critical parts periodically.

As time passes, these parts deteriorate and may cause fire of failure in the work equipment system.
• However, if these parts show any abnormality before the replacement interval has passed, they
should be repaired or replaced immediately.

PRECAUTIONS WITH HIGH TEMPERATURE COOLANT

• Immediately after using the lift truck, 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 the coolant level, stop the engine and
wait for the engine and radiator to cool down before
checking. For lift trucks equipped with a subtank or
reservoir, check the level in the subtank.
• When adding water on lift trucks equipped with a sub-
tank, add the water to the subtank.

10-18 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE

PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL

• Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the
filter when the oil is hot. Hot oil may spurt out and cause burns.
• When carrying out inspection and maintenance,
wait for the oil temperature to go down, and carry
out the operation in the order given in this manual.
• Do not forget that the work equipment circuits are
always under pressure. Do not add oil, drain oil, or
carry out maintenance or inspection before com-
pletely releasing the internal pressure.
• If oil is leaking under high pressure from small
holes, it is dangerous if the jet of high–pressure oil
hits your skin or eyes. Always wear safety glasses
and thick gloves, and use a piece of cardboard or
a sheet of plywood to check for oil leakage.
• Release the internal pressure before checking the
accumulator piping.
• If you are hit by a jet of high pressure oil, consult a
doctor immediately.
• When removing the mast and the lift cylinder, be
sure to decompress the hydraulic piping first.
1) Stop the vehicle. Lower the fork to the ground.
2) Stop the engine.
3) Turn the key to ACC position.
4) Be seated on the seat and operate the lift and tilt levers back and forth 4 to 5 times respectively to
decompress the hydraulic piping.

Unless you are seated on the seat and operate the levers, the hydraulic piping cannot be decom-
pressed.

ROTATING FAN AND BELT

• It is extremely dangerous if you or any tool

touches or gets caught in the fan or fan belt when
the fan is rotating. Never touch the fan when it is
rotating.
• Always 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.

AX50/BX50 Series 10-19

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS

BE CAREFUL NOT TO GET CAUGHT OR FALL

• Never put your hands or feet into the mast structure.

There is danger that you will get caught in moving parts
and be serious injured.
• Do not use the mast as a ladder. If you slip, there is dan-
ger that you will fall.

CHECKING AND INFLATING TIRES

• If the tire inflation pressure is low, it will affect truck stability. However, do not inflate the tires immedi-
ately. The inflation pressure may have gone down because of damage to the rim. If the rim is dam-
aged or cracked and the tires are inflated, there is danger that the rim will break when the tire is under
high pressure, and this may cause personal injury or death.For safety, when checking tire pressure,
place your body in front of the tread face of the tire. Do not check from the side face of the tire.
• Suitable qualifications are needed for tire 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 tires 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.

10-20 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE

HANDLING TIRES

Disassembly and assembly of tires should be carried out by tire dealer.

The tire inflation pressure is extremely high, so caution is needed when handling tires.
• The wheel is fitted with mounting nuts. It also has rim nuts and bolts used to join the rim halves. When
removing the tire from the lift truck, do not loosen the rim nuts and bolts. The tire is under high pres-
sure, and there is a significant risk that the rim nuts and bolts may fly off. Relief tire inflation pressure
before removing.
• When the tires have been replaced, carry out a test drive and check again for any loose mounting
nuts. If the tightening torque is low, tighten to the specified torque.

JACKING UP LIFT TRUCK (when checking or replacing tires)

• Do not go under the forklift truck when it is jacked up.

• Check the following before jacking up the lift truck.
1) Check that there is no one on the lift truck.
2) Check that there is no load on the forks.
• When jacking up, stop when the tires come off the
ground surface. Put blocks under both sides of the
frame to prevent the lift truck from coming down.
• Put blocks under any tires contacting the ground
to prevent the lift truck from moving.

LIFTING LIFT TRUCK (when checking tires)

• Lift truck slinging work should be carried out by a

qualified person who has completed a course in
correct lifting methods.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes
have ample strength and are not damaged.
• Block the tires contacting the ground to prevent
the lift truck from moving.
• Insert blocks to prevent the truck from coming
down.
• Do not go under the lift truck during the lifting
operation.
• If the specified lifting point is the counterweight,
check that the counterweight mounting bolts are
tightened to the specified torque before carrying
out the lifting operation. check also that there is no
damage to the lifting portion on the counterweight.

AX50/BX50 Series 10-21

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS

BATTERY HAZARD PREVENTION

• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you
spill electrolyte on yourself, immediately flush the area with a large quantity of water.
• Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes,
flush them immediately with large quantities of water and consult a doctor at once.
• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite
or vegetable oil. Call 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.
• When removing the battery, remove the cable from
the negative terminal first. When installing the
battery, install the cable to the positive terminal
first.
• Avoid short–circuiting the battery terminals through
accidental contact with tools or other metal objects
across the terminals.Tighten the battery terminals
securely. Loose terminals can generate sparks and
lead to an explosion.
• When removing or installing the battery, confirm
which is the positive terminal and negative ter-
minal. Be careful not to connect the cables to the
opposite terminals.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps
tightened.

DO NOT PUT METAL OBJECTS ON TOP OF BATTERY

• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit
and start a fire.

10-22 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE

PRECAUTIONS WHEN CHARGING

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 follows.
• Carry out the charging operation in a well–ventilated place.
• Do not smoke or allow any flame.
• Start the charging operation when the temperature of the battery electrolyte is below 35°C (95 ). (If
the temperature goes above 50°C (122°F) during the charging operation, wait for it to 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 off.

STARTING WITH BOOSTER CABLES

• ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.
• When starting using the battery of another lift truck, do not allow the two lift trucks to touch. For details
of the order of operations when using a booster cable.
• Stop the engine before connecting the cables.
• e extremely careful not to let the cables get caught in the fan or fan belt.
• Connect the batteries in parallel: positive to positive and negative to negative. Never connect positive
to negative.

DO NOT PUSH START

• Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and
operate unexpectedly.

HANDLING BRAKE FLUID

It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped.
Always do the following.
• Check the level of the brake fluid periodically.
• Always use the specified brake fluid.
• Check that the breather of the brake fluid reserve tank is not clogged.
• Be careful not to let dirt or dust get into the brake fluid reserve tank.

AX50/BX50 Series 10-23

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS

HANDLING ANTIFREEZE

• Antifreeze can be a flammable. Keep away from flame when handling.

• Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water,
vomit it out, and get medical attention immediately. Follow safety precautions on container.

WASTE MATERIALS

• Obey appropriate laws and regulations when disposing

of harmful objects such as oil, fuel, solvent, filters, and
batteries.

CAUTION AT THE INSTALLATION OF THE WIRELESS EQUIPMENT

When installing the wireless equipment, be careful of the items below. Otherwise, it may affect the elec-
tronic control system, depending on the installing location.
• Install the wireless antenna, keeping it away from the electronic control system as far possible.
• Lay out the wireless antenna feeder wire, keeping the distance of more than 20 cm from the electronic
control equipment.
• To eliminate the radio interference, adjust the antenna and the feeder wire.

10-24 AX50/BX50 Series

GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR BOLTS

STANDARD TIGHTENING TORQUE FOR BOLTS

For unspecified bolts and nuts, use the torques specified
in this list.
Select a proper torque corresponding to the width across
flats (b) of bolts and nuts.
When replacing bolts and nuts, always use genuine
Komatsu Forklift parts the same size as the previous
ones.

Thread diameter Width across Tightening torque

of bolt (mm) flat (mm)
(a) (b) Nm Kgm lbft
6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.03
8 13 31.4 ± 2.9 3.2 ± 0.3 23.2 ± 2.1
10 17 65.7 ± 6.8 6.7 ± 0.7 48.5 ± 5.0
12 19 112 ± 9.8 11.5 ± 1.0 82.6 ± 7.2
14 22 177 ± 19 18.0 ± 2.0 131 ± 14
16 24 279 ± 29 28.5 ± 3 206 ± 21
18 27 383 ± 39 39 ± 3 282 ± 29
20 30 549 ± 58 56 ± 6 405 ± 43
22 32 745 ± 78 76 ± 8 549 ± 58
24 36 927 ± 98 94.5 ± 10 684 ± 72
27 41 1320 ± 140 135 ± 15 973 ± 100
30 46 1720 ± 190 175 ± 20 1270 ± 140
33 50 2210 ± 240 225 ± 25 1630 ± 180
36 55 2750 ± 290 280 ± 30 2030 ± 210
39 60 3280 ± 340 335 ± 35 2420 ± 250

AX50/BX50 Series 10-25

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS GENERAL AND SPECIFICATIONS

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

Elbows, nipples and unions

Width across flats B (mm) 22 30 36

Width D (mm) 19 22 30

Tightening torque Nm {kgm} 29.4–39.2 {3–4} 78.5–103 {8–10.5} 117.7–161.8 {12–16.5}

Port size (inch) 3/4–16UNF 7/8–14UNF –

Tightening torque Nm {kgm} 68.6–73.6 {7–7.5} 78.5–83.3 {8–8.5} –

High–pressure rubber hoses, pipes and sleeve nuts

Width across flats B (mm) 19 24 27 32 36

Bore A (mm) 14 18 22 24 30
19.6–29.4 23.5–68.6 58.8–98.1 108–167 147–206
Tightening torque Nm {kgm} {2–3} {3–7} {6–10} {11–17} {15–21}

10-26 AX50/BX50 Series

 20. TESTING AND ADJUSTING

SERVICE DATA .....................................................................................20-2

HOW TO DECOMPRESS THE HYDRAULIC PIPING .........................20-10
GASOLINE ENGINE ............................................................................20-11
DIESEL ENGINE..................................................................................20-13
AIR CLEANER .....................................................................................20-15
ADJUSTMENT OF IGNITION TIMING.................................................20-17
ADJUSTMENT OF FUEL INJECTION TIMING ...................................20-18
MEASUREMENT OF COMPRESSION ...............................................20-19
ADJUSTMENT OF VALVE CLEARANCE ............................................20-20
TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS..20-21
REPLACEMENT OF CLUTCH DISC ...................................................20-22
TORQFLOW TRANSMISSION CASE..................................................20-24
DIFFERENTIAL CASE .........................................................................20-25
HYDRAULIC TANK...............................................................................20-26
MEASUREMENT OF HYDRAULIC DRIFT OF
LIFT AND TILT CYLINDERS................................................................20-27
ADJUSTMENT OF CLUTCH AND BRAKE PEDAL .............................20-28
ADJUSTMENT OF INCHING AND BRAKE PEDAL.............................20-29
ADJUSTMENT OF ACCELERATOR PEDAL .......................................20-30
ADJUSTMENT OF PARKING BRAKE LEVER ....................................20-33
ADJUSTMENT OF CABLES OF THE FORWARD AND BACKWARD
CONTROL LEVER AND THE HIGH AND LOW SPEED LEVER .........20-34
WHEEL BRAKE ...................................................................................20-36
BLEEDING AIR ....................................................................................20-37
DESIGNATED FUEL AND LUBRICATING OIL ....................................20-40
LIST OF LUBRICANT AND GREASE..................................................20-44

AX50/BX50 Series 20-1

SERVICE DATA TESTING AND ADJUSTING

SERVICE DATA
Gasoline-Powered Forklift Truck (1.0 to 1.75 ton)
FG09/18
Device Check Item Unit FG10/14/15/18 FG15H/18H (Electronic Control Engine)

Nissan
Make/Model – Nissan K21 Nissan K21 Electronic Control
K21

Engine Idling Speed rpm 700 – 800 750 – 900 700 – 800

Max. Speed rpm 2,840 – 3,040 2,840 – 3,040 2,650 – 2,750

Compression MPa
(Engine Speed: 300 rpm) {kgf/cm2} 1.28 {13.0} 1.23 {12.5} 1.45 {14.8}

Lubrication Fan Belt Tension

and Cooling (Finger Pressure: 98 N mm 11 – 13 11 – 13 11 – 13
System {10 kgf})
Engine

Intake and Intake mm 0.38 0.38 0.38

Valve
Exhaust Clearance
System Exhaust mm 0.38 0.38 0.38

Distributor Point Gap mm 0.35 – 0.45 0.35 – 0.45 –

Spark Plug Gap mm 0.8 – 0.9 0.8 – 0.9 0.8 – 0.9

Electrical FR2A-D (NGK) FR2A-D (NGK) FR2A-D (NGK)

Spark Plug Type – FR2B-D (NGK) FR2B-D (NGK) FR2B-D (NGK)
System

Ignition Timing BTDC 4 2 0

(Engine Speed: 850 rpm) degrees

Ignition Order 1-3-4-2 1-3-4-2 1-3-4-2

kPa
Front {kgf/cm2} 690 {7.0} 690 {7.0} 690 {7.0}
Tire Air pressure
kPa
Rear 790 {8.0} 790 {8.0} 790 {8.0}
Drive system

{kgf/cm2}
Tightening Front Nm {kgm} 157 – 245 {16 – 25} 157 – 245 {16 – 25} 157 – 245 {16 – 25}
Hub Nut Torque Rear Nm {kgm} 83 – 147 {8.5 – 15} 83 – 147 {8.5 – 15} 83 – 147 {8.5 – 15}
88 – 123 88 – 123 88 – 123
Tightening Front Nm {kgm} {9.0 – 12.5} {9.0 – 12.5} {9.0 – 12.5}
Rim Bolt
Torque
Rear Nm {kgm} 59 – 74 {6.0 – 7.5} 59 – 74 {6.0 – 7.5} 59 – 74 {6.0 – 7.5}

20-2 AX50/BX50 Series

TESTING AND ADJUSTING SERVICE DATA

Device Check Item Unit FG10/15/18 FG15/18 (CNG)

Steering Play mm 30 – 60 30 – 60
Wheel

Clutch Pedal Play mm 0–4 0–4

Steering and Brake System

Play mm 0–4 0–4

Inching
Pedal
Interconnected Stroke mm 36 – 40 36 – 40

Play mm 0–4 0–4

Brake Pedal
Pedal Height When Depressed mm 76 – 96 76 – 96

Parking Brake Operating Force N {kgf} More than More than

147 – 196 {15 – 20} 147 – 196 {15 – 20}
Brake
Back Plate Mounting Bolt Nm {kgm} 176 – 196 {18 - 20} 176 – 196 {18 - 20}
Tightening Torque
1-ton truck: more than 26
Loading System

Fork Thickness of Fork Base mm 1.5-ton truck: more than 30

1.75 ton-truck: more than 33

Chain Length of 17 Links mm Less than 275.5 Less than 275.5

Hydraulic Relief Pressure MPa 17.2 {175} 17.2 {175}

System {kgf/cm2}

AX50/BX50 Series 20-3

SERVICE DATA TESTING AND ADJUSTING

Gasoline-Powered Forklift Truck (2.0 to 3.5 ton)

FG20N/25N
Device Check Item Unit FG20/25 FG20H/25H (Electronic FG30/30N/35A
Control 30N)

Make/Model – Nissan K21 Nissan K25 Nissan K21 Nissan K25

Carburetor rpm 750 – 900 750 – 900 750 – 900 750 – 900
Idling Speed
Electronic rpm 700 – 800 700 – 800 700 – 800 700 – 800
Control
Engine
Carburetor rpm 2,840 – 3,040 2,720 – 2,920 2,840 – 3,040 2,860 – 3,060
Max. Speed
Electronic rpm 2,650 – 2,750 2,650 – 2,750 2,650 – 2,750 2,650 – 2,750
Control
Compression MPa
(Engine Speed: {kgf/cm2} 1.45 {14.8} 1.51 {15.3} 1.45 {14.8} 1.51 {15.3}
300 rpm)
Lubrication Fan Belt Tension
Engine

and Cooling (Finger Pressure: mm 11 – 13 11 – 13 11 – 13 11 – 13

System 98 N {10 kgf})

Intake and Intake mm 0.38 0.38 0.38 0.38

Valve
Exhaust Clearance
System Exhaust mm 0.38 0.38 0.38 0.38

Spark Plug Gap mm 0.8 – 0.9 0.8 – 0.9 0.8 – 0.9 0.8 – 0.9

Spark Plug Type – FR2A-D FR2A-D FR2A-D FR2A-D

Electrical Ignition BTDC

Timing Carburetor degrees 2 0 2 0
System
(Engine
Speed: Electronic BTDC 0 0 0 0
850 rpm) Control degrees

Ignition Order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

kPa 3 ton: 690 {7.0}

Front 690 {7.0} 690 {7.0} –
{kgf/cm2} 3.5 ton: 850 {8.5}
Tire Air pressure
kPa 3 ton: 690 {7.0}
Rear 690 {7.0} 690 {7.0} –
{kgf/cm2} 3.5 ton: 890 {9.0}
Drive system

Front Nm {kgm} 294 – 490 294 – 490 294 – 490 294 – 490
Tightening {30 – 50} {30 – 50} {30 – 50} {30 – 50}
Hub Nut
Torque 157 – 245 157 – 245 157 – 245 157 – 245
Rear Nm {kgm} {16 – 25} {16 – 25} {16 – 25} {16 – 25}
196 – 294 {20 – 30}
Front Nm {kgm} (Excl. 2.75 ton and 3 ton forklift trucks)
Tightening
Rim Bolt Torque 88 – 123 88 – 123 88 – 123
Rear Nm {kgm} {9 – 12.5} {9 – 12.5} – {9 – 12.5}

20-4 AX50/BX50 Series

TESTING AND ADJUSTING SERVICE DATA

Device Check Item Unit FG20/25 FG20H/25H FG20N/25N FG30/30N/35A

Steering Play mm 30 – 60 30 – 60 30 – 60 30 – 60
Wheel

Clutch Play mm 0–4 0–4 – 0–4

Pedal
Steering and Brake System

Play mm 0–4 0–4 0–4 0–4

Inching
Pedal 3 ton: 36 – 40
Interconnected Stroke mm 36 – 40 36 – 40 36 – 40
3.5 ton: 40 – 46

Play mm 0–4 0–4 0–4 0–4

Brake
Pedal Pedal Height When mm 62 – 82 62 – 82 62 – 82 62 – 82
Depressed

Parking Brake Operating 147 – 196 147 – 196 147 – 196 147 – 196
Force N {kgf} {15 – 20} {15 – 20} {15 – 20} {15 – 20}
Brake (*1) (*1) (*1) (*1)
Back Plate Mounting Bolt 176 – 196 176 – 196 176 – 196 176 – 196
Tightening Torque Nm {kgm} {18 – 20} {18 – 20} {18 – 20} {18 – 20}
2 ton truck: more than 32.5
Loading System

Fork Thickness of Fork Base mm 2.5 ton truck: more than 36

3 ton truck: more than 39.5

Chain Length of 17 Links mm 2 - 2.5 ton truck: less than 330

3 ton truck: less than 550
Hydraulic MPa
System Relief Pressure {kgf/cm2} 18 {185} 18 {185} 18 {185} 18 {185}

Notes
*1: Apply 245 – 294 N (25 – 30 kgf) for FG35A and forklift trucks equipped with power brake.

AX50/BX50 Series 20-5

SERVICE DATA TESTING AND ADJUSTING

Diesel-Powered Forklift Truck (1.0 – 1.75 ton)

Device Check Items Unitþ FD10/15/18

Make/Model – Komatsu 4D92E

Idling Speed rpm 750 – 800

Engine
Max. Speed rpm 2,650 – 2,700

MPa
Compression {kgf/cm2} 2.94 {30}/250

Lubrication Tension of Fan Belt

and Cooling (Finger Pressure: mm 10 – 15
Engine

System 98N {10kgf}

Ignition Timing BTDC ATDC6

degrees

Fuel System Ignition Order – 1-3-4-2

Ignition Pressure MPa 12.3 – 13.3 {125 – 135}

{kgf/cm2}

Intake and Intake mm 0.2

Exhaust Valve Clearance
System Exhaust mm 0.2

Front kPa 690 {7.0}

{kgf/cm2}
Tires Air Pressure
Rear kPa 790 {8.0}
{kgf/cm2}
Drive system

Front Nm {kgm} 157 – 245 {16 – 25}

Hub Nut Tightening Torque
Rear Nm {kgm} 83 – 147 {8.5 – 15}

Front Nm {kgm} 88 – 123 {9.0 – 12.5}

Rim Bolt Tightening Torque
Rear Nm {kgm} 59 – 74 {6.0 – 7.5}

20-6 AX50/BX50 Series

TESTING AND ADJUSTING SERVICE DATA

Devices Inspection Items Unit FD10/15/18

Steering
Wheel Play mm 30 – 60

Clutch Pedal Play mm 0–4

Steering and Brake System

Play mm 0–4
Inching
Pedal
Interconnected Stroke mm 36 – 40

Play mm 0–4
Brake Pedal
Depressed Pedal Height mm 76 – 96

Parking Brake Operating Force N {kgf} 147 – 196 {15 – 20}

Brake
Back Plate Fixing Bolt Nm {kgm} 176 – 196 {18 – 20}
Tightening Torque
More than 26 for FD10,
Loading System

Fork Thickness at Fork Base mm more than 30 for FD14 and FD15,
more than 33 for FD18

Chain Length of 17 Links mm Less than 275.5

Hydraulic MPa
System Relief Pressure {kgf/cm2} 17.2 {175}

AX50/BX50 Series 20-7

SERVICE DATA TESTING AND ADJUSTING

Diesel-Powered Forklift Truck (2.0 – 3.5 ton)

Device Check Items Unitþ FD20/25/30 FD20H/25H/ FD20N/25N/

30H/35A 30N

Make/Model – Komatsu 4D94LE Komatsu 4D98E Komatsu 4D94LE

Idling Speed rpm 785 – 835 750 – 800 785 – 835

Engine
Max. Speed rpm 2,650 – 2,700 2,650 – 2,700 2,650 – 2,700

Compression MPa 2.94 {30} 2.94 {30} 2.94 {30}

{kgf/cm2}
Lubrication Tension of Fan Belt
and Cooling (Finger Pressure: mm 10 – 15 10 – 15 10 – 15
Engine

System 98N {10kgf}

Ignition Timing ATDC 6 6 6

degrees

Fuel System Ignition Order – 1-3-4-2 1-3-4-2 1-3-4-2

Ignition Pressure MPa 12.3 – 13.3 12.3 – 13.3 12.3 – 13.3

{kgf/cm2} {125 – 135} {125 – 135} {125 – 135}

Intake and Intake mm 0.2 0.2 0.2

Exhaust Valve
System Clearance
Exhaust mm 0.2 0.2 0.2

kPa 2 – 3 ton: 690 {7.0}

Front {kgf/cm2} 690 {7.0} –
3.5 ton: 850 {8.5}
Tires Air Pressure
kPa 2 – 3 ton: 690 {7.0}
Rear {kgf/cm2} 690 {7.0} –
3.5 ton: 890 {9.0}
Drive system

294 – 490 294 – 490 294 – 490

Front Nm {kgm} {30 – 50} {30 – 50} {30 – 50}
Tightening
Hub Nut Torque 196 – 245 196 – 245 196 – 245
Rear Nm {kgm} {20 – 25} {20 – 25} {20 – 25}
196 – 294 {20 – 30}
Front Nm {kgm} (Excluding 3-ton trucks) –
Tightening
Rim Bolt Torque 88 – 123 88 – 123
Rear Nm {kgm} {9 – 12.5} {9 – 12.5} –

20-8 AX50/BX50 Series

TESTING AND ADJUSTING SERVICE DATA

FD20H/25H/ FD20N/25N/
Devices Inspection Items Unit FD20/25/30 30H/35A 30N
Steering Play mm 30 – 60 30 – 60 30 – 60
Wheel

Clutch Pedal Play mm 0–4 0–4 –

Steering and Brake System

Play mm 0–4 0–4 0–4

Inching
Pedal 3 ton: 36 – 40
Interconnected Stroke mm 36 – 40 36 – 40
3.5 ton: 40 – 46

Play mm 0–4 0–4 0–4

Brake Pedal
Depressed Pedal Height mm 62 – 82 62 – 82 62 – 82

147 – 196 147 – 196 147 – 196

Parking Brake Operating N {kgf} {15 – 20} {15 – 20} {15 – 20}
Force (*1) (*1) (*1)
Brake
Back Plate Fixing Bolt Nm {kgm} 176 – 196 176 – 196 176 – 196
Tightening Torque {18 – 20} {18 – 20} {18 – 20}
More than 32.5 for 2-ton trucks,
Fork Thickness at Fork Base mm more than 36 for 2.5 ton trucks,
Loading System

more than 39.5 for 3-ton trucks

Less than 330 for 2 - 2.5 ton trucks,
Chain Length of 17 Links mm less than 550 for 3-ton trucks
Hydraulic Relief Pressure MPa 18 {185} 18 {185} 18 {185}
System {kgf/cm2}

Notes
*1: Apply 245 – 294 N (25 – 30 kgf) for FD35A and forklift trucks equipped with power brake.

AX50/BX50 Series 20-9

HOW TO DECOMPRESS THE HYDRAULIC PIPING TESTING AND ADJUSTING

HOW TO DECOMPRESS THE HYDRAULIC PIPING

WARNING
When decompressing the hydraulic piping, be sure to
be seated on the seat and operate the levers.
If you operate the levers without being seated on the
seat, the shut valve of hydraulic piping is shut and the
hydraulic piping cannot be decompressed.

HOW TO DECOMPRESS
1. Stop the vehicle. Lower the fork to the ground.
2. Stop the engine.
3. Turn the key to ACC position.

4. While sitting on the seat, operate the lift and tilt

levers back and forth 4 to 5 times respectively to
decompress the hydraulic piping.

20-10 AX50/BX50 Series

TESTING AND ADJUSTING GASOLINE ENGINE

GASOLINE ENGINE

WARNING
Before starting maintenance of the engine, stop the
engine and wait until cooling down completely.

5. CHANGE OF ENGINE OIL

1) Removing the drain plug, drain the oil and
tighten the plug again after draining.
2) Fill the engine oil up to the specified level.
3) Check the engine oil level with the oil level
gauge.

Refill Engine Oil Level

K15 Engine 3.8
K21 Engine 3.8
K25 Engine 3.8

6. REPLACEMENT OF ENGINE OIL FILTER

1) Remove the cartridge with the filter wrench.
2) Clean the filter mounting up and apply the
engine oil to the thread as well as the seal of
the new cartridge before installation.

IMPORTANT
After installing the cartridge, start the engine and
check to make sure that there is no oil leakage from
the filter mounting surface.

AX50/BX50 Series 20-11

GASOLINE ENGINE TESTING AND ADJUSTING

7. REPLACEMENT OF FUEL FILTER

1) Loosen the nut to remove the cover and take
the filter out.
2) Clean the dirt at the bottom and drain the
water.
3) Replace with a new filter.

IMPORTANT
• If any damage is found on the gasket of the cover,
replace it with a new one.
• After replacement, check the hose fitting area for no
fuel leakage.

8. INSPECTION OF SPARK PLUG

1) Remove the spark plug with the special plug A
wrench.
2) Clean the carbon up stuck on the plug head
and the surroundings.
3) Measure the plug gap A as shown on the illus-
tration on the right with the plug gap gauge.
Plug gap A: 0.7 to 0.8 mm
Good
No good: The surface of insulator becomes
entirely white and the burn-outs
(deposits) are stuck to the insu-
lator like specks.
If burnt excessively, the elec-
trode will melt. 1
No good: Carbons are stuck to the insula-
tor and electrode.

Maker and Model Name of Spark Plug 2 3

NGK FR2A-D

20-12 AX50/BX50 Series

TESTING AND ADJUSTING DIESEL ENGINE

DIESEL ENGINE
4D92E, 4D94E and 4D98E ENGINE

1. CHANGE OF ENGINE OIL 2. REPLACEMENT OF ENGINE OIL FILTER

1) Drain the engine oil removing the drain plug 1) Remove the cartridge with the filter wrench.
and tighten it again. 2) Clean the filter mounting and apply the engine
2) Remove the oil level gauge. oil on the thread as well as the seal of the new
3) Refill the engine oil up to the specified level. Be cartridge before installation.
careful not to let it overflow. After installation of the cartridge, start the engine
4) Check the oil level with the engine oil level and check the filter-mounting surface for no oil leak-
gauge. age.

Refill Engine Oil Level

4D92E Engine 7.5
4D94LE Engine 7.5
4D98E Engine 7.5

AX50/BX50 Series 20-13

DIESEL ENGINE TESTING AND ADJUSTING

3. DRAINING OF WATER FROM FUEL FILTER

1) Loosen the combination sensor plug (1) and
drain the water as well as sediment accumu-
lated at the bottom.

IMPORTANT
• Prepare a container to catch the drained water
possibly mixed with the fuel.
• Always make sure to wipe up spilled fuel if any.

4. REPLACEMENT OF FUEL FILTER

1) Remove the combination sensor plug (4) at the
bottom of the cartridge.
2) Remove the cartridge (3) with the filter wrench.
3) Install the combination sensor plug to the new
cartridge (3).
4) Fill the new cartridge with the fuel and apply
the thin layer of engine oil before installation.
5) Loosen the plug (2) and pump the knob (1) up
and down until no more bubbles come out with
the fuel.
6) Tighten the plug (2).

As for draining the water from the fuel filter and

bleeding the air after replacement of the cartridge,
the fuel may come out mixed with draining water
and bleeding air. Always make sure to prepare the
container for receiving those matters and wipe up
spilled fuel if any, because it may be in danger to
cause fire if fuel sticks here and there.

20-14 AX50/BX50 Series

TESTING AND ADJUSTING AIR CLEANER

AIR CLEANER (1.0 – 1.75 TON)

WARNING
• Neither cleaning of the air cleaner nor replacement
of the element is allowed while the engine is in
motion.
• Always put the safety glasses on to protect your
eyes when using the compressed air for cleaning
the element up. Element

IMPORTANT
• If any grease or carbon is found stuck on the ele-
ment, clean it up with a special cleaner according
to the instruction for the air cleaner.
[Single Element Type]
• In case of sever working conditions or environ-
ments, clean or replace the element earlier than
regular maintenance.

CLEANING OF ELEMENT
1. Remove the element and blow the dry compressed
air ( 0.69 MPa {7 kgf/cm2}) from inside to outside of
the element for cleaning the whole element.

2. Put the cleaned element back to the air cleaner.

INSPECTION
Visually check the element for damage.

REPLACEMENT OF ELEMENT
1. Remove the element from the air cleaner.

2. Cover the air connector with clean cloth or tape.

3. Clean the interior of the air cleaner and remove the

cover from the air cleaner.

4. Put a new element into the air cleaner.

AX50/BX50 Series 20-15

AIR CLEANER TESTING AND ADJUSTING

AIR CLEANER (2 TON)

WARNING
• Neither cleaning of the air cleaner nor replacement
of the element is allowed while the engine is in
motion.
• Always put the safety glasses on to protect your
eyes when using the compressed air for cleaning
the element up. Element

IMPORTANT
• If any grease or carbon is found stuck on the ele-
ment, clean it up with a special cleaner according
to the instruction for the air cleaner.
[Single Element Type]
• Never remove the inner element.
[FD20 (H) – FD30 (H)]
• In case of sever working conditions or environ- Element
ments, clean or replace the element earlier than
regular maintenance.

CLEANING OF ELEMENT
1. Remove the element and blow the dry compressed
air ( 0.69 MPa {7 kgf/cm2}) from inside to outside of
the element for cleaning the whole element.

2. Put the cleaned element back to the air cleaner.

INSPECTION Inner Element

Visually check the element for damage.
[Double Element Type]
REPLACEMENT OF ELEMENT
1. Remove the element from the air cleaner.

2. Remove the inner element.

3. Cover the air connector with clean cloth or tape.

4. Clean the interior of the air cleaner and remove the

cover from the air cleaner.

5. Put a new element into the air cleaner.

20-16 AX50/BX50 Series

TESTING AND ADJUSTING ADJUSTMENT OF IGNITION TIMING

ADJUSTMENT OF IGNITION TIMING

GASOLINE ENGINE (CNG)
1. Connect the timing advance tester (1) as shown in
the diagram on the right.

2. Turn the power switch on and adjust the timing posi-

tion of the advance adjustment knob (2).

3. Start the engine and run at the specified idling

speed.

4. Glow the timing light (3) and check to make sure that
the indicator and the timing mark stamped on the
crankshaft pulley and flywheel are correctly aligned.

5. If the timing is wrong, turn the distributor (4) to the

right or the left for further adjustment.

6. Check that ignition timing advances quickly when

the engine is revved up.

For Electronic Control Engine, refer to the

Engine Shop Manual.

AX50/BX50 Series 20-17

ADJUSTMENT OF FUEL INJECTION TIMING TESTING AND ADJUSTING

ADJUSTMENT OF FUEL INJECTION TIMING

DIESEL ENGINE (4D92E, 4D94LE and 4D98E)
INSPECTION AND ADJUSTMENT OF FUEL
INJECTION TIMING MARK

WHEN DISASSEMBLING AND ASSEMBLING

1. Match the injection pump with the A mark.
2. Match the top mark B with the ATDC 6 degrees.
3. Make sure that the plunger lift is in 1 mm.
4. If the plunger lift is not in 1 mm, adjust the angle of
the injection pump mounting.

INSPECTION
Implement the above mentioned items 2, 3 and 4 for
inspection.

Precautions for Installing the Injection Pump

For installing the injection pump, it makes install easy by
move the pointer on the check hall and O mark with two
tooth gears as shown in right.

20-18 AX50/BX50 Series

TESTING AND ADJUSTING MEASUREMENT OF COMPRESSION

MEASUREMENT OF COMPRESSION
1. Warm up the engine to get the coolant temperature Gasoline Engine
at 75 – 85 °C.

2. Stop the engine and remove all the spark plugs on

gasoline engines or the nozzle holders on diesel
engines as well as the air cleaner.

3. Disconnect the coil cord from the ignition coil on the

gasoline engine. Set the fuel control lever to the
non-injection position or disconnect the wiring of the
fuel cut solenoid on diesel engines.

4. Fix the adaptor to the nozzle holder mounting of the

cylinder that is to be checked and tighten to the
specified torque on diesel engines.

5. Install the compression gauge to the cylinder to be

checked. Diesel Engine

6. For pneumatic governor, floor the accelerator pedal

and crank the engine with the starter motor to get
the maximum reading of the gauge.
Take a measurement more than twice on each
engine to avoid measurement errors and aver-
age the values.
Discharge battery may not give sufficient revo-
lutions. Use fully charged battery.

CAUSES FOR INSUFFICIENT COMPRESSION

1. Poor adjustment of valve clearance 5. Pressure leakage from cylinder head gasket
2. Pressure leakage from valve seat 6. Sticking or breakage of piston rings
3. Seize of valve stems 7. Wear of piston rings or cylinders
4. Defective or broken valve spring

AX50/BX50 Series 20-19

ADJUSTMENT OF VALVE CLEARANCE TESTING AND ADJUSTING

ADJUSTMENT OF VALVE CLEARANCE

1. Remove the cylinder head cover.

2. Turn the crankshaft to match the top mark A of the

crank pulley (1) and the pointer (2). Check to make
sure that the compression upper dead center is
attained with the No.1 cylinder and the No.4 cylin-
der.
Upper dead center of the piston can be
checked under the state that both of intake and
exhaust valves are closed, which means the
cylinder that both the rocker arms are being in
free state is at the compression upper dead
center.

Engine with ignition sequence of 1-2-4-3

3. Adjust the clearance beginning with the cylinder at Cylinder No. 1 2 3 4
the compression upper dead center. Exhaust
valve
When the No.1 cylinder is at the compression Intake
valve
top dead center, adjust the valves marked with
for clearance listed on the table and give a Engine with ignition sequence of 1-3-4-2
turn to the crankshaft in the positive direction. Cylinder No. 1 2 3 4
Then, adjust the remaining valves marked with Exhaust
valve
for clearance. Intake
valve
When the No.4 cylinder is at the compression
top dead center, adjust the valves marked with
for clearance and give a turn to the crank-
shaft in the positive direction. Then, adjust the
remaining valves marked with for clearance.

4. Loosen the locknut (3) of the adjusting screw (4) and

insert the specified thickness gauge between the
valve stem (6) and the locker arm (5) to allow the
gauge to move smoothly and adjust the gap. Then,
tighten the locknut to fix the adjustment screw.

20-20 AX50/BX50 Series

TESTING AND ADJUSTING TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS

TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS

K21/K25 ENGINE
1. Put the steel plate side of the cylinder head gasket
on the cylinder block side. Then, set it on top of the
cylinder block.

2. Set the cylinder head in position, apply the engine

oil to the cylinder bolts. Then, tighten in the order
shown in the diagram on the right ( through ) to
the specified tightening torque as follows:
Cylinder Head Bolt:
1) 29.4 Nm {3.0 kgm}
Tighten temporarily
2) 78.5 Nm {8.0 kgm}
3) 0 Nm {0 kgm} Loosen
4) 29.4 Nm {3.0 kgm}
Tighten
5) 73.5 – 83.4 Nm {7.5 – 8.5 kgm}
again

4D92E, 4D94LE and 4D98E ENGINE

1. Apply the engine oil to the cylinder head mounting
bolts coating evenly by hand.

2. Tighten twice in the order in the diagram on the right

( through ) as follows:
Cylinder Head Bolt:
Fist Time:58.8 Nm {6 kgm}
Second Time:117.6 Nm {12 kgm}

AX50/BX50 Series 20-21