PDF Shop Manual Komatsu AE50 AM50 Series Electric Lift Truck - 2 MB
Keep your Komatsu AE50 and AM50 Series electric lift trucks in top working condition with this complete shop manual.
It contains all the necessary information for service, repair, and troubleshooting.
From battery maintenance to hydraulic system repairs, every procedure is explained in detail.
This manual empowers technicians to perform jobs correctly and efficiently, minimizing downtime in your material handling operations.
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BBA12C1-04
ELECTRIC LIFT TRUCK
AE50/AM50 Series
FB15U/15FU-12 837898 and up
FB18U/18FU/20AU/20AFU-12 837898 and up
FB15MU/15MFU-12 826828 and up
FB18MU/18MFU/20MU/20MFU-12 826828 and up
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GENERAL AND SPECIFICATIONS SPECIFICATIONS
FB18MU-12 FB20MU-12
Electric Electric
Sitting Sitting
1570 [3461] 1800 [3968]
600 [23.6] 600 [23.6]
405 [15.9] 425 [16.7]
1390 [54.7] 1485 [58.5]
3470 [7650] 3900 [8598]
4250 [9367] 4860 [10714]
790 [1742] 840 [1852]
1620 [3572] 1900 [4189]
1850 [4079] 2000 [4409]
Elastic Cushion Elastic Cushion
18x7-8 200/50-10
15x4 1/2-8 15x4 1/2-8
2*/2 2*/2
940 [37.0] 950 [37.4]
170 [6.7] 170 [6.7]
6/10 6/10
1995 [78.5] 2110 [83.1]
140 [5.5] 150 [5.9]
3300 [130.0] 3300 [130.0]
4255 [167.5] 4270 [168.1]
2070 [81.5] 2070 [81.5]
3070 [120.9] 3185 [125.4]
2000 [78.7] 2115 [83.3]
1110 [43.7] 1160 [45.7]
35x100x1070 36x122x1070
[1.4x3.9x42.1] [1.4x4.8x42.1]
Class 2, Type A Class 2, Type A
970 [38.2] 970 [38.2]
95 [3.7] 95 [3.7]
125 [4.9] 125 [4.9]
2995 [117.9] 3115 [122.6]
3195 [125.8] 3315 [130.5]
1590 [62.6] 1690 [66.5]
15.0/17.0 [10/11] 14.0/16.0 [9/10]
320/600 [63/118] 280/500 [55/98]
450/550 [89/108] 370/440 [73/87]
9560 [2150] 9045 [2033]
16 14
Foot/Hydraulic Foot/Hydraulic
Hand/Mechanical Hand/Mechanical
FHPS FHPS
4.5x2 4.5x2
9.0 9.0
48 48
600 600
950 [2094.4] 950 [2094.4]
Transistor Transistor
176 176
[17.6, 180, 2560] [17.6, 180, 2560]
23 [6.1] 23 [6.1]
AE50/AM50 Series 10-7
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GENERAL AND SPECIFICATIONS HOW TO USE LOCTITE
HOW TO USE LOCTITE
Procedure for using LOCTITE
4. Assembly
After applying LOCTITE, tighten the screw or fit the
Male side
shaft to the hole as usual. (When using LOCTITE
Degreasing Air drying for structures or LOCTITE of instant glue type, press
Female the mating parts lightly (about 49 kPa {0.5 kgf/cm2}).
side
Removal of parts
Leaving Applying
Assembly When screws and shafts are secured with LOC-
LOCTITE
TITE, they usually can be removed with common
tools such as spanners, wrenches, pulley pullers,
etc. If LOCTITE is so strong that a part may be bro-
1. Degreasing and cleaning ken when it is removed, heat it (to 200 β 250Β°C) with
1) Clean the parts in trichloroethylene, acetone, a soldering iron, gas torch, etc., and you can
ether, alkaline solution, etc. which are highly remove it easily. It is generally difficult to dissolve
volatile. LOCTITE in chemical solutions.
2) Degrease the parts as perfectly as possible.
3) Since gasoline, light oil, kerosene, etc. are not When assembling again
highly volatile, they are not recommended. If it
1) If a LOCTITE film on threads is broken, it is left
is obliged to use them, dry them completely.
as white powder on the threads. In this case,
4) If the mating parts are made of thermosetting you can apply LOCTITE again to the threads
resin, treat them with LOQUICK PRIMER after without removing the white powder.
degreasing them.
2) If shafts or flanges secured with LOCTITE are
disconnected, LOCTITE remaining on them
2. Air drying may need to be removed to maintain dimen-
sional accuracy. You can remove the remain-
1) Wait until the cleaning fluid dries out.
ing LOCTITE easily, however, with a wire
2) If the parts are treated with LOQUICK brush, etc.
PRIMER, do not wipe them but dry them in air
3) If plates secured with LOCTITE need to be
for 5 - 10 minutes. (If LOCTITE is used before
assembled again after they are separated, be
LOQUICK PRIMER dries out, its effect is low-
sure to remove all the hardened LOCTITE and
ered.)
roughen the mating surfaces with sandpaper.
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads or
the shaft and hole to be fitted by amount to fill the
clearance between them by one of the following
methods.
β’ Applying directly from LOCTITE container nozzle
β’ Dipping (For threads. Use receiving pan.)
β’ Tumbling
β’ Brushing (For shaft and hole. Use receiving
pan.)
β’ Sponge
β’ Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
AE50/AM50 Series 10-17
--- Page 5 ---
TESTING AND ADJUSTING BATTERY
BATTERY
Check of Battery Solution
Check the battery electrolyte level. If battery electrolyte is below the standard level, refill distilled water or purified water.
a For information about inspecting and refilling of battery electrolyte, see βOperation & Maintenance Manualβ attached
to the battery.
Check of specific gravity of battery electrolyte
As the specific gravity of battery electrolyte changes, along with the
temperature, read the specific gravity and electrolyte temperature
and convert it to the value equivalent at 20Β°C [68Β°F], using the con-
version table.
Check of battery structure
Confirm bracket (1) and stay (2) are installed on the battery. (The
fire prevention/retaining plug system)
1. Bracket (3BA-55-71260)
2. Stay (3BA-08-73130)
a Bracket (1) and stay (2) are sent with the vehicle.
AE50/AM50 Series 20-9
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TESTING AND ADJUSTING MAST
MAST (2.0 TON VEHICLE)
Roller Choice and Shim Adjustment
Outer Main Roller
1. Choice of Roller Size
a Outer main roller Choose the roller size (NS, NM) so that the clearances "a" at
the left and right sides are equal.
b
c
2. Shim Adjustment
2 Insert the shims (1) with identical thickness at the right and left
sides so that b = 0 β 0.3 mm [0 β 0.012 in] is achieved.
Insert the shim (2) so that c = 0.1 β 0.4 mm [0.004 β 0.016 in]
is achieved all along the rail when pushing the roller to the rail.
(The target is 0.1 mm [0.004 in].)
1
Outer main roller
Inner Main Roller
1. Choice of Roller Size
Choose the roller size (S, M, L) so that d = 0.2 β 0.7 mm [0.008
Inner main roller β 0.028 in] is achieved.
d
e
2. Shim Adjustment
Adjust by inserting the shim (3) so that e = 0 β 0.5 mm [0 β
0.020 in] (when lifted up to the maximum) is achieved.
Inner main
roller
3
AE50/AM50 Series 20-19
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REMOVAL AND INSTALLATION UNIT MASS
UNIT MASS (4-WHEEL VEHICLE)
Unit: kg [lb]
Model FB15U-12 FB18U-12 FB20U-12 Remark
Unit FB15FU-12 FB18FU-12 FB20AFU-12
Drive Axle (Total) 165 [363.8] 165 [363.8] 165 [363.8]
Drive Motor 40 [88.2] 40 [88.2] 40 [88.2]
Transfer 125 [275.6] 125 [275.6] 125 [275.6]
Pump Motor 40 [88.2] 40 [88.2] 40 [88.2]
Rear Axle 90 [198.4] 90 [198.4] 90 [198.4]
Front Wheel 20 [44.1] 20 [44.1] 40 [88.2]
Rear Wheel 15 [33.1] 15 [33.1] 25 [55.1]
Head Guard 85 [187.4] 85 [187.4] 85 [187.4]
Counterweight 790 [1741.6] 990 [2182.6] 1270 [2799.8]
Mast (3 m, inner and outer masts only) 300 [661.4] 300 [661.4] 365 [804.7]
Lift Cylinder (For 3 m mast) 26 [57.3] 26 [57.3] 25 [55.1]
Tilt Cylinder 17 [37.5] 17 [37.5] 17 [37.5]
Finger Bar 75 [165.3] 75 [165.3] 85 [187.4]
Fork 75 [165.3] 75 [165.3] 85 [187.4]
Backrest 20 [44.1] 20 [44.1] 20 [44.1]
Hydraulic Pump 5 [11.0] 5 [11.0] 5 [11.0]
Tank and Grease 30 [66.1] 30 [66.1] 30 [66.1]
Control Valve + Lever 20 [44.1] 20 [44.1] 20 [44.1]
Steering Gear Box 20 [44.1] 20 [44.1] 20 [44.1] Column included
a The values show the standard specification.
Battery
Capacity Max. Mass
Model (Ah) (kg) Voltage
FB15U-12, FB15FU-12, FB18U-12, FB18FU-12 600 935 [2061.3]
48 V
FB20U-12, FB20AFU-12 600 935 [2061.3]
a Confirm the battery capacity by reading the manufacturer plate on the front of battery case.
AE50/AM50 Series 30-3
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REMOVAL AND INSTALLATION LIFT CYLINDER
LIFT CYLINDER
Removal
The removal of lift cylinder at one side is explained as an example.
1. Erect the mast (1) vertically and place the wheel stoppers at
the front and rear wheels.
1 2. Lift up the finger bar with the crane by 300 mm [11.8 in].
2
3. Remove the cotter pin (3) and pull out the pin (4). Then, sepa-
rate the chain and remove the chain from the chain roller.
4. By operating the lift lever, lift up the mast.
a When performing the traveling and cargo operation, be
seated correctly on the operator's seat.
Unless an operator is correctly seated on the operator's
seat or is out of the seat, the traveling and cargo operation
cannot be performed.
AE50/AM50 Series 30-13
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REMOVAL AND INSTALLATION REAR AXLE
REAR AXLE
Removal
1. Lift up the lower side of counterweight rear with the crane and
place the wooden blocks (1) under the right and left frames.
2. Place the fork (2) (Something movable up and down) under
rear axle.
1
2
3. Remove the power steering piping (3).
3
4. Remove four plate fixing bolts (4).
4
5. Remove two plates (5).
5
AE50/AM50 Series 30-23
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DISASSEMBLY AND ASSEMBLY DRIVE AXLE
Judging Standard Unit: mm [in]
Criteria
Mark Part Check Item Remedy
Standard Limit
Dimension allowed
A Diameter of piston shaft 19.96 β 19.98 19.9
[0.786 β 0.787] [0.783]
B Inner diameter of piston shaft sliding part of cover 20 β 20.033 20.1
[0.787 β 0.789] [0.791]
C Inner diameter of piston sliding part 35 β 35.039 35.1
[1.378 β 1.379] [1.382]
D Brake Outer diameter of sliding part of cover and piston 34.950 β 34.975 34.9
(In drive axle) [1.376 β 1.377] [1.374]
E Thickness of wet type disc 2.32 β 2.47 2.1 Replacing parts
[0.091 β 0.097] [0.083]
F Thickness of plate * 1.7 β 1.8 β
[0.067 β 0.071]
G Free length of spring 29.5 β 30.5 28
[1.16 β 1.20] [1.10]
H Thrust washer a 0.95 β 1.05 0.85
[0.037 β 0.041] [0.033]
I Thrust washer b 2.23 β 2.37 2.13
Drive Axle [0.088 β 0.093] [0.084]
Replace with a new
J O-ring, seals β β one at disassembly/as-
sembly.
AE50/AM50 Series 40-5
--- Page 11 ---
DISASSEMBLY AND ASSEMBLY TRANSFER (BRAKE)
5. Tighten fully the bolts with the flat blade screwdriver and turn
them back by 1/2 turns.
6. Remove the special jig and confirm that the gap A is 6 Β± 0.3
mm (at three locations).
A
7. Apply LOCTITE (#271) to the screwed portions and tighten the
LOCTITE nuts with specific torque.
8.8 β 10.8 Nm
{0.9 β 1.1 kgm}
[6.5 β 8.0 ft. lb]
AE50/AM50 Series 40-15
--- Page 12 ---
DISASSEMBLY AND ASSEMBLY BRAKE WHEEL CYLINDER
BRAKE WHEEL CYLINDER
11
9
2
3
5
4
6
10
12
7
8
1
1. Cylinder 5. Spring 9. Cup
2. Boot 6. Holder A 10. Cup
3. Piston 7. Holder B 11. Backup Ring
4. Snap Ring 8. Dust Seal 12. Backup Ring
Judging Standard Unit: mm [in]
No. Check Item Standard Value Limit allowed Remedy
Inner diameter of cylinder:
ο¦ο 40.0 β 40.062 [1.575 β 1.577]
1 Clearance between cylinder Outer diameter of piston: 0.2 [0.0079] at
and piston ο¦ο 39.911 β 39.950 [1.571 β 1.573] the maximum
Clearance:
0.05 β 0.151 [0.002 - 0.006]
Inner diameter of holder A/B:
ο¦ο 12.0 β 12.043 [0.472 β 0.474]
2 Clearance between holder and Outer diameter of rod: 0.15 [0.006] at Replace individual
piston rod part ο¦ο 11.957 β 11.984 [0.471 β 0.472] the maximum part or cylinder as-
Clearance: sembly.
0.016 β 0.086 [0.001 β 0.006]
3 Interference of cup About 1.7 β 1.8 [0.067 β 0.071] 0.75 [0.030]
(large diameter)
4 Interference of cup About 1.0 β 1.2 [0.039 β 0.047] 0.40 [0.016]
(small diameter)
5 Free length of spring 25.8 [1.016] Β± 3 % 22.5 [0.886]
(25.03 β 26.57 [0.985 β 1.046])
AE50/AM50 Series 40-25
--- Page 13 ---
DISASSEMBLY AND ASSEMBLY ORBITROL
ORBITROL
44 36 42 37 44 31 41 32 39 38
30 34
43 33
40
35
27
20 45
23 2
17
13 5*
16
12
4
22
15
21
14 24 18 19 28 29 11 8 9 10 7 26 6 25 3 1
*: 4 wheel vehicle only
No. Part Name No. Part Name No. Part Name
1 Screw 16 Rotor 31 Spool
Hexagon Socket Head Stopper Screw
2 Retainer Screw Assembly 17 (Tip of stick) 32 Tube Assembly
3 Roll End Cap 18 Race Bearing 33 Nut
4 Gerotor 19 Thrust Needle 34 Coil with connector
5 Spacer 20 O-ring 35 O-ring
6 Spacer Plate 21 Oil Seal (Y Packing) 36 O-ring
7 Drive 22 Dust Seal 37 Hexagon Socket Head Bolt
8 Housing 23 Retaining Ring 38 Spring
9 Sleeve 24 Seal Ground Bushing 39 Core
10 Spool 25 O-ring 40 Plug with hexagon hole
11 Pin 26 O-ring 41 O-ring
12 Centering Spring 27 Ball 42 Check Valve Assembly
13 Flat Spring 28 Name Plate 43 Relief Valve Cartridge
14 Handle Angle Sensor 29 Rivet 44 O-ring
Cross-Recessed Flat Head
15 Screw 30 Valve Block 45 Check Valve Assembly
AE50/AM50 Series 40-35
--- Page 14 ---
DISASSEMBLY AND ASSEMBLY STEERING AXLE
Procedure of Shim Adjustment
1. Tighten tentatively the plate (10) with the center bolt (11) with-
out shim.
11
15 Nm
{1.53 kgm}
10 [11.1 ft. lb]
2. Pull out the center bolt (11) and remove the plate (10).
9 Measure the height from the end face of pinion shaft to the end
face of bearing inner race by the unit of 5/100.
(Dimension = ο‘)
3. Calculate the clearance S.
S = ο‘ β 4.8 (mm)
4. According to the table below, determine the thickness and
quantity of shim. Then, install the shims.
Clearance S Thickness and quantity of shim
(mm) t = 0.2 (mm) t = 0.3 (mm) t = 1.0 (mm)
1.04 β 1.13 1
1.14 β 1.23 1 3
1.24 β 1.33 1 1
1.34 β 1.43 1 1
1.44 β 1.53 2 1
1.54 β 1.63 1 1 1
1.64 β 1.73 2 1
1.74 β 1.83 2 1 1
1.84 β 1.93 1 2 1
1.94 β 2.03 3 1
2.04 β 2.13 2
2.14 β 2.23 1 3 1
2.24 β 2.33 1 2
2.34 β 2.43 1 2
2.44 β 2.53 2 2
AE50/AM50 Series 40-45
--- Page 15 ---
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
6. Disassembly of Piston Block
Remove the U-ring (8), backup ring (9), bushing (10) and cush-
ion bearing (11).
a Do not disassemble the piston rod and piston.
1) Draw out the U-ring (8) and backup ring (9) with knife or
screwdriver.
2) Remove the bushing (10) with the screwdriver while wid-
ening the joint.
a Do not re-use the seal removed.
3) Remove the snap ring (12), and draw out the cushion
bearing (11). Draw the snap ring (12) out of the groove
with the tool of sharp tip.
7. Disassembly of seal in cylinder head (3) block
Remove the U-ring (5), wiper ring (6) and O-ring (7).
1) Remove the U-ring (5) with the knife or screwdriver.
2) As the wiper ring is press-fitted, stick the screwdriver in
the rubber from the bushing side and pull out by hitting.
3) In the same manner, remove the O-ring (7) and U-ring (5)
with the knife or screwdriver.
a Do not re-use the seal removed.
8. Scrubbing and store
1) After scrubbing the removed parts with kerosene, apply
the hydraulic oil to them and store them, being covered.
2) If the disassembled parts are left as are, due to rust and
dust, they may not function well after assembled.
AE50/AM50 Series 40-55
--- Page 16 ---
DISASSEMBLY AND ASSEMBLY TILT CYLINDER
3. Assembly of piston block seal
1) Install the O-ring in the installation groove with caution not
to twist the O-ring.
2) Install the backup ring in the installation groove with the
knife.
a To make it easier to install the O-ring, warm it up to
80Β°C [176Β°F].
a When the backup spring is installed, it is stretched.
Therefore, after installed, correct it with the correction jig.
Confirm that the correction jig and the tip of knife are
flawless, clean and smooth.
4. Installation of cylinder head
1) Wind the tape around the screwed portion of piston rod.
A
2) Insert the cylinder head with caution to prevent the wiper
ring of cylinder head and lip portion of U-ring from being
scratched by the screwed portion of piston rod.
a Fix the tube with the vice horizontally or vertically.
3) Insert the piston rod in the tube.
When the piston block and cylinder block are inserted in
the tube, insert them with caution for seals not to be
damaged by the inner screw portion of tube.
Screw portion
AE50/AM50 Series 40-65
--- Page 17 ---
DISASSEMBLY AND ASSEMBLY PUMP MOTOR
PUMP MOTOR
Name of each block
1. Frame 6. Temperature Sensor
2. Stator 7. Speed Sensor
3. Rotor 8. Bracket (Opposite to the connection side)
4. Bracket (Connection side) 9. Tube
5. Shaft 10. NOMEX Paper
AE50/AM50 Series 40-75
--- Page 18 ---