00 Bx50 Shop Training Manual

NOTES:
FORKLIFT TRUCKS
COVERED IN THIS PUBLICATION
BX50 S/N 200001A~
KOMATSU MODEL
DESCRIPTION
DESIGNATION
Gasoline, LPG and Dual-Fuel Engine Models
FG20ST-16 4,000 lb. capacity, K21 gasoline engine, cushion tires
FG20STLS-16 4,000 lb. capacity, K21 LPG engine, cushion tires, “LPS”
FG20SHT-16 4,000 lb. capacity, K25 gasoline engine, cushion tires
FG20SHTLS-16 4,000 lb. capacity, K25 gasoline engine, cushion tires, “LPS”
FG20T-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires
FG20TUS-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires, “GS”
FG20TLS-16 4,000 lb. capacity, K21 LPG engine, pneumatic tires, “LPS”
FG20HT-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires
FG20HTUS-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires, “GS”
FG20HTLS-16 4,000 lb. capacity, K25 LPG engine, pneumatic tires, “LPS”
FG25ST-16 5,000 lb. capacity, K21 gasoline engine, cushion tires
FG25STLS-16 5,000 lb. capacity, K21 LPG engine, cushion tires, “LPS”
FG25SHTLS-16 5,000 lb. capacity, K25 LPG engine, cushion tires, “LPS”
FG25T-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires
FG25TUS-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires, “GS”
FG25TLS-16 5,000 lb. capacity, K21 LPG engine, pneumatic tires, “LPS”
Table Continued on Next Page
3
BX50 S/N 200001A~
KOMATSU MODEL
DESCRIPTION
DESIGNATION
FG32HT-16 6,500 lb. capacity, K25 gasoline engine, cushion tires
FG35AHT-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires
FG35AHTUS-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires, “GS”
FG35AHTLS-16 7,000 lb. capacity, K25 LPG engine, pneumatic tires, “LPS”
Diesel Engine Models
FD20T-16 4,000 lb. capacity, 4D94E diesel engine, pneumatic tires
FD20TUS-16 4,000 lb. capacity, 4D94E diesel engine, pneumatic tires, “DS”
FD28TUS-16 5,500 lb. capacity, 4D94E diesel engine, pneumatic tires. “DS”
FD30TUS-16 6,000 lb. capacity, 4D94E diesel engine, pneumatic tires. “DS”
FD35AT-16 7,000 lb. capacity, 4D94E diesel engine, pneumatic tires
FD35ATUS-16 7,000 lb. capacity, 4D94E diesel engine, pneumatic tires, “DS”
4
FORKLIFT TRUCKS COVERED
IN THIS PUBLICATION
BX50 S/N 200001A~
TUSK MODEL DESCRIPTION
Gasoline, LPG and Dual-Fuel Engine Models

CUSHION TIRE
400CG-16 4,000 lb. capacity, K21 gasoline engine, cushion tires
400CGL-16 4,000 lb. capacity, K21 LPG engine, cushion tires, “LPS”
400CGH-16 4,000 lb. capacity, K25 gasoline engine, cushion tires
400CGLS-16 4,000 lb. capacity, K25 gasoline engine, cushion tires, “LPS”
500CG-16 5,000 lb. capacity, K21 gasoline engine, cushion tires
500CGL-16 5,000 lb. capacity, K21 LPG engine, cushion tires, “LPS”
500CGLH-16 5,000 lb. capacity, K25 LPG engine, cushion tires, “LPS”
PNEUMATIC TIRE
400PG-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires
400PGS-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires, “GS”
400PGL-16 4,000 lb. capacity, K21 LPG engine, pneumatic tires, “LPS”
400PGH-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires
400PGSH-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires, “GS”
400PGLH-16 4,000 lb. capacity, K25 LPG engine, pneumatic tires, “LPS”
500PG-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires
500PGS-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires, “GS”
500PGL-16 5,000 lb. capacity, K21 LPG engine, pneumatic tires, “LPS”
vii
BX50 S/N 200001A~
TUSK MODEL DESCRIPTION
Diesel Engine Models

400PD-16 4,000 lb. capacity, 4D94E diesel engine, pneumatic tires
400PDS-16 4,000 lb. capacity, 4D94E diesel engine, pneumatic tires, “DS”
550PDS-16 5,500 lb. capacity, 4D94E diesel engine, pneumatic tires. “DS”
600PDS-16 6,000 lb. capacity, 4D94E diesel engine, pneumatic tires. “DS”
viii
SPECIFICATIONS GENERAL AND SPECIFICATIONS
SPECIFICATIONS
AX50 (1.0 - 1.8ton) Series
1.2 Model Manufacturer's Designation FG10T-20 FG10C-20 FD10T-20 FD10C-20
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 910 910
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 2095 2180 2195
2.2 Front kg 2725 2735 2760 2765
Weight
Loaded
2.2.1 Rear kg 355 360 420 430
Axle Loading
2.3 Front kg 1065 1075 1095 1105
Unloaded
2.3.1 Rear kg 1015 1020 1085 1090
3.1 Tyre Type Pneumatic Pneumatic
3.2 Tyre Size Front 6.50-10-10PR(I) 6.50-10-10PR(I)
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 2030 2030
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 Class 2
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
4.35 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
5.6 Max. Drawbar Pull Loaded KN 10 11 13 14
5.8 Max. Gradeability Loaded % 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
I.C Engine
7.2 Rated Output, SAE gross KW 27@2500 35@2450

7.3 Rated RPM min-1 2500 2450
7.3.1 Max. Torque, SAE gross 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
Others
8.2 Relief Pressure for Attachment bar 172 172

8.7 Transmission TORQFLOW Manual TORQFLOW Manual
10-2 AX50/BX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS
FG15T-20 FG15C-20 FD15T-20 FD15C-20 FG15HT-20 FG15HC-20 FG18T-20 FG18C-20 FD18T-20 FD18C-20 FG18HT-20 FG18HC-20
Gasoline Diesel Gasoline Gasoline Diesel Gasoline
Sitting Sitting Sitting Sitting Sitting Sitting
1500 1500 1500 1750 1750 1750
500 500 500 500 500 500
1360 1360 1360 1590 1590 1590
405 405 405 405 405 405
1400 1400 1400 1400 1400 1400
2450 2465 2550 2565 2450 2465 2645 2660 2745 2760 2645 2660
3500 3510 3530 3540 3500 3510 3870 3880 3900 3910 3870 3880
450 455 520 525 450 455 525 530 595 600 525 530
1005 1015 1035 1045 1005 1015 960 970 990 1000 960 970
1445 1450 1515 1520 1445 1450 1685 1690 1755 1760 1685 1690
Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic
6.50-10-10PR(I) 6.50-10-10PR(I) 6.50-10-10PR(I) 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) 5.00- 8- 8PR(I) 5.00-8-8PR(I) 5.00- 8- 8PR(I)
2*/2 2*/2 2*/2 2*/2 2*/2 2*/2
890 890 890 890 890 890
895 895 895 895 895 895
6/10 6/10 6/10 6/10 6/10 6/10
1995 1995 1995 1995 1995 1995
140 140 140 140 140 140
3000 3000 3000 3000 3000 3000
3955 3955 3955 3955 3955 3955
2030 2030 2030 2030 2030 2030
3160 3160 3160 3200 3200 3200
2240 2240 2240 2280 2280 2280
1070 1070 1070 1070 1070 1070
35x100x920 35x100x920 35x100x920 35x100x920 35x100x920 35x100x920
Class 2 Class 2 Class 2 Class 2 Class 2 Class 2
970 970 970 970 970 970
120 120 120 120 120 120
130 130 130 130 130 130
3360 3360 3360 3395 3395 3395
3560 3560 3560 3595 3595 3595
1955 1955 1955 1990 1990 1990
18.5 8.5/18.5 18.5 8.5/19.0 18.5 8.5/18.5 18.5 8.5/18.5 18.5 8.5/18.5 18.5 8.5/18.5
19.0 9.0/19.0 19.0 8.5/19.5 19.0 9.0/19.0 19.0 9.0/19.0 19.0 8.5/19.0 19.0 9.0/19.0
570 620 590 570 620 590
640 670 640 640 670 640
500 500 500 500 500 500
550 550 550 550 550 550
10 11 13 14 15 14 10 11 13 14 15 14
26 27 33 31 37 35 25 24 29 28 33 32
Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical
FHPS FHPS FHPS FHPS FHPS FHPS
12/33 12/64 12/33 12/33 12/64 12/33
NISSAN K15 Komatsu 4D92E NISSAN K21 NISSAN K15 Komatsu 4D92E NISSAN K21
27@2500 35@2450 35@2450 27@2500 35@2450 35@2450
2500 2450 2450 2500 2450 2450
113@1600 142@1800 152@1600 113@1600 142@1800 152@1600
4-1486 4-2659 4-2065 4-1486 4-2659 4-2065
40 40 40 40 40 40
172 172 172 172 172 172
TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual
AX50/BX50 Series 10-3

BX50 (2.0 - 2.5ton) Series

Characteristics

2.2 Front kg 4670 4680 4700 4720
Weight
Loaded
2.2.1 Rear kg 550 550 610 610
Axle Loading
2.3 Front kg 1480 1480 1510 1520
Unloaded
2.3.1 Rear kg 1740 1750 1800 1810
3.2 Tyre Size Front 7.00-12-12PR(I) 7.00-12-12PR(I)
Tyres
3.3 Rear 6.00-09-10PR(I) 6.00-09-10PR(I)

Dimensions

Ground Clearance
Loaded, 1st/2nd km/h 18.5 8.5/18.5 18.5 8.5/18.5
Loaded mm/s 545 630
5.2 Lifting Speed
Performance
Loaded mm/s 450 450

5.3 Lowering Speed
7.1 Maker Model NISSAN K21 Komatsu 4D94LE
I.C Engine

7.3 Rated RPM min-1 2450 2450
Others


FG20HT-16 FD20HT-16 FD20HC-16 FG25T-16 FG25C-16 FD25T-16 FD25C-16 FG25HT-16 FD25HT-16 FD25HC-16
Gasoline Diesel Gasoline Diesel Gasoline Diesel
Sitting Sitting Sitting Sitting Sitting Sitting
2000 2000 2500 2500 2500 2500
500 500 500 500 500 500
1810 1810 2270 2270 2270 2270
460 460 465 465 465 465
1650 1650 1650 1650 1650 1650
3220 3310 3330 3590 3600 3680 3700 3590 3680 3700
4670 4700 4720 5420 5430 5460 5470 5420 5460 5470
550 610 610 670 670 720 730 670 720 730
1480 1510 1520 1430 1430 1460 1470 1430 1460 1470
1740 1800 1810 2160 2170 2220 2230 2160 2220 2230
Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic Pneumatic
2*/2 2*/2 2*/2 2*/2 2*/2 2*/2
965 965 965 965 965 965
960 960 960 960 960 960
6/12 6/12 6/12 6/12 6/12 6/12
1995 1995 1995 1995 1995 1995
150 150 155 155 155 155
3000 3000 3000 3000 3000 3000
4050 4050 4050 4050 4050 4050
2070 2070 2070 2070 2070 2070
3450 3450 3655 3655 3655 3655
2530 2530 2585 2585 2585 2585
1150 1150 1150 1150 1150 1150
36x122x920 36x122x920 40x122x1070 40x122x1070 40x122x1070 40x122x1070
Class 2 Class 2 Class 2 Class 2 Class 2 Class 2
1020 1020 1020 1020 1020 1020
115 115 115 115 115 115
160 160 160 160 160 160
3650 3650 3775 3775 3775 3775
3850 3850 3905 3905 3905 3905
2190 2190 2240 2240 2240 2240
19.0 18.5 8.0/18.5 18.5 8.5/18.5 18.5 8.5/18.5 19.0 18.5 8.0/18.5
19.5 19.0 8.5/19.0 19.0 9.0/19.0 19.0 8.5/19.0 19.5 19.0 8.5/19.0
620 660 545 630 620 660
670 710 600 685 670 710
450 450 450 450 450 450
500 500 500 500 500 500
19 22 21 14 14 18 17 19 22 21
38 45 44 23 22 31 29 32 37 37
Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical
FHPS FHPS FHPS FHPS FHPS FHPS
12/33 12/64 12/33 12/64 12/33 12/64
NISSAN K25 Komatsu 4D98E NISSAN K21 Komatsu 4D94LE NISSAN K25 Komatsu 4D98E
43@2400 53@2400 35@2450 46@2450 43@2400 53@2400
2400 2400 2450 2450 2400 2400
186@1600 216@1700 152@1600 186@1800 186@1600 216@1700
4-2488 4-3318 4-2065 4-3052 4-2488 4-3318
58 58 58 58 58 58
181 181 181 181 181 181
TORQFLOW TORQFLOW Manual TORQFLOW Manual TORQFLOW Manual TORQFLOW TORQFLOW Manual

BX50 (3.0 - 3.5ton) Series

Characteristics

2.2 Front kg 6390 6400 6430 6440
Weight
Loaded
2.2.1 Rear kg 820 830 880 880
Axle Loading
2.3 Front kg 1600 1610 1640 1650
Unloaded
2.3.1 Rear kg 2610 2620 2670 2670
3.2 Tyre Size Front 28x9-15-12PR(I) 28x9-15-12PR(I)
Tyres
3.3 Rear 6.50-10-10PR(I) 6.50-10-10PR(I)

Dimensions

Ground Clearance
Loaded, 1st/2nd km/h 18.5 8.5/18.5 19.0 8.5/18.5
Loaded mm/s 450 520
5.2 Lifting Speed
Performance
Loaded mm/s 400 420

5.3 Lowering Speed
I.C Engine

7.3 Rated RPM min-1 2400 2450
Others


FD30HT-16 FD30HC-16 FG35A-16 FD35A-16

Diesel Gasoline Diesel
Sitting Sitting Sitting
3000 3500 3500
500 500 500
2720 3180 3180
490 505 505
1700 1700 1700
4310 4320 4910 5010
6430 6440 7440 7480
880 880 970 1030
1640 1650 1820 1860
2670 2670 3090 3150
Pneumatic Pneumatic Pneumatic
28x9-15-12PR(I) 250-15-16PR(I) 250-15-16PR(I)
6.50x10-10PR(I) 6.50x10-12PR(I) 6.50x10-12PR(I)
2*/2 2*/2 2*/2
1005 1060 1060
965 965 965
6/12 6/12 6/12
2070 2100 2100
160 145 145
3000 3000 3000
4275 4280 4280
2090 2105 2105
3775 3865 3865
2705 2795 2795
1235 1290 1290
44x122x1070 50x150x1070 50x150x1070
Class 3 Class 3 Class 3
1060 1060 1060
135 135 135
185 185 185
3930 4055 4055
4060 4185 4185
2370 2480 2480
18.5 8.0/18.5 18.0 18.0
19.0 8.5/19.0 19.0 19.0
550 410 450
595 450 490
420 400 420
500 400 400
21 21 16 20
30 30 20 26
Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/Mechanical Hand/Mechanical Hand/Mechanical
FHPS FHPS FHPS
12/64 12/33 12/64
Komatsu 4D98E NISSAN K25 Komatsu 4D98E
53@2400 43@2400 53@2400
2400 2400 2400
216@1700 186@1600 216@1700
4-3318 4-2488 4-3318
58 58 58
181 181 181
TORQFLOW Manual TORQFLOW TORQFLOW

109 Series
1.2 Model Manufacturer's Designation FG20NT-16 FD20NT-16
Characteristics

2.1 Service Weight kg 3230 3330
2.2 Front kg 4600 4630
Weight
Loaded
2.2.1 Rear kg 630 700
Axle Loading
2.3 Front kg 1250 1280
Unloaded
2.3.1 Rear kg 1980 2050
3.2 Tyre Size Front 22 1/4x7 1/2-15/5.50 22 1/4x7 1/2-15/5.50
Tyres
3.3 Rear 17 3/4x6 1/2 -10/5.00 17 3/4x6 1/2 -10/5.00

Dimensions

Ground Clearance
Loaded, 1st/2nd km/h 17.0 17.0
Unloaded, 1st/2nd km/h 16.5 16.5
Loaded mm/s 545 630
5.2 Lifting Speed
Performance
Loaded mm/s 450 450

5.3 Lowering Speed
5.6 Max. Drawbar Pull Loaded KN 14 17
5.8 Max. Gradeability Loaded % 27 34
I.C Engine

7.3 Rated RPM min-1 2450 2450
Others

8.7 Transmission TORQFLOW TORQFLOW

FG25NT-16 FD25NT-16 FG30NT-16 FD30NT-16

Gasoline Diesel Gasoline Diesel
Sitting Sitting Sitting Sitting
2500 2500 3000 3000
500 500 500 500
2270 2270 2720 2720
435 435 440 440
1400 1400 1450 1450
3630 3730 4070 4170
5350 5380 6250 6240
780 850 820 930
1140 1170 1260 1250
2490 2560 2810 2920
Pneumatic Pneumatic Pneumatic Pneumatic
22 1/4x7 1/2-15/5.50 22 1/4x7 1/2-15/5.50 22 1/4x7 1/2-15/5.50 22 1/4x7 1/2-15/5.50
17 3/4x6 1/2 -10/5.00 17 3/4x6 1/2 -10/5.00 17 3/4x6 1/2 -10/5.00 17 3/4x6 1/2 -10/5.00
2*/2 2*/2 2*/2 2*/2
900 900 900 900
885 885 885 885
6/10 6/10 6/10 6/10
1995 1995 2070 2070
155 155 160 160
3000 3000 3000 3000
4050 4050 4275 4275
2025 2025 2025 2025
3475 3475 3535 3535
2405 2405 2465 2465
1090 1090 1090 1090
40x122x1070 40x122x1070 44x122x1070 44x122x1070
Class 2 Class 2 Class 3 Class 3
960 960 940 940
105 105 105 105
115 115 115 115
3555 3555 3620 3620
3685 3685 3750 3750
2050 2050 2110 2110
16.5 16.5 16.0 16.0
16.5 16.5 16.0 16.0
545 630 515 520
600 685 550 555
450 450 420 420
500 500 500 500
14 17 16 16
23 29 24 24
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 K21 Komatsu 4D94LE NISSAN K25 Komatsu 4D94LE
35@2450 46@2450 43@2400 46@2450
2450 2450 2400 2450
152@1600 186@1800 186@1600 186@1800
4-2065 4-3052 4-2488 4-3052
40 40 40 40
181 181 181 181
TORQFLOW TORQFLOW TORQFLOW TORQFLOW

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 Reservior 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

NOTES:
SERVICE DATA TESTING AND ADJUSTING
SERVICE DATA
Gasoline-Powered Forklift Truck (1.0 to 1.75 ton)
Device Check Item Unit FG10/14/15/18 FG15H/18H
Make/Model – Nissan K15 Nissan K21
Idling Speed rpm 750 – 900 750 – 900

Engine
Max. Speed rpm 2,840 – 3,040 2,840 – 3,040
Compression MPa
(Engine Speed: 300 rpm) {kgf/cm2} 1.28 {13.0} 1.23 {12.5}
Lubrication
and Cooling Fan Belt Tension mm 11 – 13 11 – 13
(Finger Pressure: 98 N {10 kgf})
System
Engine
Intake and Intake mm 0.38 0.38

Exhaust Valve Clearance
System Exhaust mm 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
Electrical Spark Plug Type – FR2A-D (NGK) FR2A-D (NGK)

System
Ignition Timing BTDC 4 2
(Engine Speed: 850 rpm) degrees
Ignition Order 1-3-4-2 1-3-4-2
kPa
Front 690 {7.0} 690 {7.0}
{kgf/cm2}
Tire Air pressure
kPa
Drive system
Rear 790 {8.0} 790 {8.0}

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

TESTING AND ADJUSTING SERVICE DATA
Device Check Item Unit FG10/14/15/18 FG15H/18H
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
More than More than

Parking Brake Operating Force N {kgf} 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 MPa
Relief Pressure 17.2 {175} 17.2 {175}
System {kgf/cm2}

Gasoline-Powered Forklift Truck (2.0 to 3.5 ton)

Device Check Item Unit FG20/25 FG20H/25H FG20N/25N FG30/30N/35A
Make/Model – Nissan K21 Nissan K25 Nissan K21 Nissan K25
Idling Speed rpm 750 – 900 750 – 900 750 – 900 750 – 900
Engine
Max. Speed rpm 2,840 – 3,040 2,720 – 2,920 2,840 – 3,040 2,860 – 3,060
Compression MPa
(Engine Speed: 1.23 {12.5} 1.27 {13.0} 1.23 {12.5} 1.27 {13.0}
{kgf/cm2}
300 rpm)
Lubrication Fan Belt Tension
and Cooling (Finger Pressure: mm 11 – 13 11 – 13 11 – 13 11 – 13
System 98 N {10 kgf})
Engine
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
Distributor Point Gap mm 0.35 – 0.45 0.35 – 0.45 0.35 – 0.45 0.35 – 0.45
Spark Plug Gap mm 0.8 – 0.9 0.8 – 0.9 0.8 – 0.9 0.8 – 0.9
Electrical Spark Plug Type – FR2A-D FR2A-D FR2A-D FR2A-D

System
Ignition Timing BTDC
(Engine Speed: 2 0 2 0
degrees
850 rpm)
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
294 – 490 294 – 490 294 – 490 294 – 490

Front Nm {kgm}
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}
Tightening (Excl. 2.75 ton and 3 ton forklift trucks)
Rim Bolt Torque 88 – 123 88 – 123 88 – 123
Rear Nm {kgm} –
{9 – 12.5} {9 – 12.5} {9 – 12.5}

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
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
147 – 196 147 – 196 147 – 196 147 – 196
Parking Brake Operating N {kgf} {15 – 20} {15 – 20} {15 – 20} {15 – 20}
Force
Brake (*1) (*1) (*1) (*1)
Back Plate Mounting Bolt 176 – 196 176 – 196 176 – 196 176 – 196
Nm {kgm}
Tightening Torque {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
2 - 2.5 ton truck: less than 330
Chain Length of 17 Links mm 3 ton truck: less than 550
Hydraulic Relief Pressure MPa 18 {185} 18 {185} 18 {185} 18 {185}
System {kgf/cm2}
Notes
*1: Apply 245 – 294 N (25 – 30 kgf) for FG35A and forklift trucks equipped with power brake.

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}
BTDC
Ignition Timing BTDC4
degrees
Fuel System Ignition Order – 1-3-4-2
MPa
Ignition Pressure {kgf/cm2} 12.3 – 13.3 {125 – 135}
Intake and Intake mm 0.2

Exhaust Valve Clearance
System Exhaust mm 0.2
kPa 690 {7.0}

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

Devices Inspection Items Unit FD10/15/18
Steering Play mm 30 – 60
Wheel
Clutch Pedal Play mm 0–4

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

Diesel-Powered Forklift Truck (2.0 – 3.5 ton)

FD20H/25H/ FD20N/25N/
Device Check Items Unitþ FD20/25/30 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
MPa
Compression 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}
ATDC
Ignition Timing 4 6 4
degrees
Fuel System Ignition Order – 1-3-4-2 1-3-4-2 1-3-4-2
MPa
Ignition Pressure 11.8 {120} 11.8 {120} 11.8 {120}
{kgf/cm2}
Intake and Intake mm 0.2 0.2 0.2

Valve
Exhaust Clearance
System Exhaust mm 0.2 0.2 0.2
kPa 2 – 3 ton: 690 {7.0}

Front 690 {7.0} –
{kgf/cm2} 3.5 ton: 850 {8.5}
Tires Air Pressure
kPa 2 – 3 ton: 690 {7.0}
Rear 690 {7.0} –
{kgf/cm2} 3.5 ton: 890 {9.0}
Drive system
294 – 490 294 – 490 294 – 490

Front Nm {kgm}
Tightening {30 – 50} {30 – 50} {30 – 50}
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} –
Tightening (Excluding 3-ton trucks)
Rim Bolt Torque 88 – 123 88 – 123
Rear Nm {kgm} –
{9 – 12.5} {9 – 12.5}

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 –

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
Brake (*1) (*1) (*1)
Back Plate Fixing Bolt 176 – 196 176 – 196 176 – 196
Tightening Torque Nm {kgm} {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 MPa
Relief Pressure 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.

1
EXPLAIN POINTS
11
17
12
21
38
39
42
43
44
46
47
48
49
51
52
53
54
58
61
OPERATION
GENERAL VIEW
GENERAL VIEW
GENERAL VIEW OF LIFT TRUCK
1 2 3 4 5
17
8
16
15
14
10
11
12
13
1. Mast 10. Rear wheel

2. Lift cylinder 11. Engine hood
3. Head lamp 12. Tilt cylinder
4. Turn signal lamp 13. Front wheel
5. Overhead guard 14. Fork
6. Assist grip 15. Fork carriage
7. Operator's seat 16. Load backrest
8. Counterweight 17. Lift chain
9. Fuel filter
3-2
GENERAL VIEW
OPERATOR'S COMPARTMENT
The numbered items in the illustration below are described in the "OPERATION" section starting on page 3-14.
1 2 3 4 5
12 11 10 9 8 7
1. FORWARD/REVERSE lever 8. Starting switch

2. Horn button 9. Brake pedal
3. Combination switch 10. Inching pedal
(turn signal lamp and lamp switch) This pedal is used for fine control when driving the
4. Lift lever lift truck slowly forward or in reverse for loading or
5. Tilt lever unloading.
6. Tiltable steering wheel lock lever 11. Parking brake lever
7. Accelerator pedal 12. Brake oil reservoir tank
3-3
GENERAL VIEW
METER PANEL INSTRUMENTS AND CONTROLS

The numbered items in the illustration below are described in the next section.
(for Diesel Engine truck)
5 6
1 2 3 4 7 8 9 10
Check
Engine
1. Fuel gauge 7. Lift Interlock indicator lamp

2. Neutral / Travel Interlock indicator lamp 8. Check engine lamp (gas engine truck)
3. Engine oil pressure warning lamp Sedimenter warning lamp (diesel engine truck)
4. Charge warning lamp 9. Maintenance lamp (gas engine truck)
5. Operation indicator Glow indicator (diesel engine truck)
6. Hour meter 10. Water temperature gauge
3-4
EXPLANATION OF METER PANEL COMPONENTS

The following is an explanation of the devices employed to operate the lift truck as illustrated on page 3-4.
To carry out suitable operations correctly and safely, it is important to understand fully the method of operating the
equipment and the meanings of the displays.
NOTICE
CHECK WARNING LAMPS FOR BLOWN BULBS
• Check that each warning lamp lights up when the engine starting switch key is turned ON.
• If there is any warning lamp that does not light up, check if the bulb is blown.
• Do not climb on top of the dashboard. There is the danger that your foot may slip and you fall off.
(1) FUEL GAUGE

Fuel gauge (1) displays the level of the remaining fuel with a needle
indicator.
Check the remaining fuel level with the engine starting switch key in
the ON position.
Position (A): indicates that the fuel level is low.
Position (B): indicates that the fuel tank is full.
Do not use up all the fuel. Fill the fuel tank before the fuel runs out.
(2) NEUTRAL INDICATOR AND TRAVEL

INTERLOCK INDICATOR LAMP
This lift truck is equipped with KOPS Plus (Komatsu Operator
Presence System Plus), which includes the neutral indicator, the
Travel Interlock indicator, and the Lift Interlock indicator. For details
on Lift Interlock, see “LIFT INTERLOCK” on page 3-23.
The neutral indicator ensures that the operator starts the lift truck in
neutral, while the Travel Interlock indicator ensures that the operator
stays in the operator’s seat and sits using good posture.
The neutral lamp functions as both the neutral indicator and the
Travel Interlock indicator, and blinks when either safety feature is activated.
Neutral Indicator
Normal starting operation: When the operator turns the key switch on with the forward/reverse lever in the neutral
position, the neutral indicator lamp (2) turns on steady. After the engine starts and the operator puts the lift truck
into forward or reverse, the lamp turns off.
Improper starting and neutral safety activated: When the operator attempts to start the lift truck in forward or
reverse, the neutral lamp starts blinking and the engine will not start.
To clear the indicator and resume travel:
• Put the forward/reverse lever into neutral (neutral lamp steady on). The lift truck is now ready for travel.
• Start the engine and put the lift truck into forward or reverse (neutral lamp off).
Travel Interlock Indicator

With the key switch turned ON and the engine running: When the operator sits improperly or leaves the operator’s
seat for three seconds or more, Travel Interlock disables the transmission of engine power, the lamp starts blinking,
and travel stops.
To clear the indicator and resume travel:
• Sit in the operator’s seat using good posture.
• Return the forward/reverse lever to the neutral position (neutral lamp steady on).
• The lift truck is now ready for travel. Put the lift truck into forward or reverse (neutral lamp off). It is not neces-
sary to recycle the key switch, as the engine will continue to run after Travel Interlock has activated.
See “TRAVEL INTERLOCK (ENGINE POWER CUTOFF)” on page 3-19 for more details.
3-5
3-6
KOPS Plus (Komatsu Operator Presence System Plus)
Meter Panel Indicators
Check
Engine
Travel Interlock Indicator Lift Interlock Indicator

When Travel Interlock indicator is blinking, When Lift Interlock indicator is blinking,
power to transmission is disabled and forklift power to hydraulic control valve is
cannot travel. disabled and lift and tilt functions are
disabled.
To clear blinking Travel Interlock or Lift Interlock indicators and resume truck operations:
- Sit securely in the operator’s seat using good posture.
- Place the Forward/Reverse lever in neutral.
If warning lamp(s) continue to blink, contact your local dealer.
WARNING
Lift Interlock disables only the lift and tilt levers, and not the attachment levers. Some attachments will still
move when their lever is operated, regardless of whether Lift Interlock is engaged or not. Additionally, even
when the key switch is in the ON position, or when the engine is not running, some attachments will move
under their own weight or the load weight when their lever is operated.
KOPS01
(3) ENGINE OIL PRESSURE WARNING LAMP

Engine oil pressure warning lamp (3) acts to indicate whether the
engine lubrication oil pressure is normal or not.
This lamp lights up when the engine starting switch key is turned to
the ON position and goes off after the engine startup. Then it is
functioning normally.
Should the lamp light up during operation, stop operations
immediately and check the engine lubrication system for any
abnormality.
(4) CHARGE WARNING LAMP

Battery charging warning lamp (4) indicates how the alternator is
generating power.
This lamp lights up when the engine starting switch key is turned to
the ON position and goes off after the engine startup. Then it is
functioning normally.
Should the lamp light up during operation, check the electrical
system for any abnormality.
(5) OPERATION INDICATOR

Operation indicator (5) acts to indicate that the hourmeter is
functioning.
While the engine starting switch key is in the ON position, an
"hourglass" mark on the left side of the hourmeter keeps flashing.
(6) HOUR METER

Hourmeter (6) begins to work when the engine starting switch key is
turned to the ON position, and indicates the cumulative value of
operating hours. (While the hourmeter is in operation, the operation
indicator keeps flashing.)
The last digit advances by 1 (meaning 0.1 hour) when the engine
starting switch key is kept in the ON position for 6 minutes, or when
it is turned to the START position.
3-7
(7) LIFT INTERLOCK INDICATOR LAMP

Lift interlock indicator lamp (7) begins to flash when the Lift Interlock
is activated, indicating that all lifting and tilting functions are
disabled.
When you seat yourself properly on the operator's seat, the lamp
stops flashing and the lift truck is now ready to operate again.
For more details on the function of Lift Interlock, see illustration on
facing page and “LIFT INTERLOCK” on page 3-23.
Lift Interlock disables only the lift and tilt levers, and not the attachment levers. Some attachments will
still move when their lever is operated, regardless of whether Lift Interlock is engaged or not.
Additionally, even when the key switch is in the ON position, or when the engine is not running, some
attachments will move under their own weight or the load weight when their lever is operated.
(8) CHECK ENGINE LAMP

(GASOLINE ENGINE TRUCK)
When the Check Engine lamp (8) lights up, it is a warning that the
self-diagnostic system has detected a malfunction or failure. When
this occurs, contact your local authorized dealer for service.
Check
Engine
9JL00854
(8) SEDIMENT WARNING/MAINTENANCE LAMP

(DIESEL ENGINE TRUCK)
This lamp is a Sediment warning lamp and, in the diesel engine lift
truck, is used in combination with the Maintenance lamp (see
“MAINTENANCE LAMP (GASOLINE ENGINE TRUCK)” below).
The Sediment warning lamp indicates that water has accumulated
in the fuel filter.
When functioning normally, this lamp lights up when the engine
starting switch key is turned to the ON position and goes off after the
engine startup.
When the lamp lights up during operations, drain water
accumulation in the fuel filter is indicated. If water is left inside the
fuel filter, the fuel injection pump and injection nozzle function will
likely be impaired.
For the water draining method, refer to “MAINTENANCE OF ENGINE” on page 4-28.
3-8
(9) MAINTENANCE LAMP

(GASOLINE ENGINE TRUCK)
NOTICE
If the lamp begins to flash, stop operations promptly and report
the trouble to the administrator, or call your Komatsu Forklift
dealer for technical assistance.
The Maintenance lamp (8) begins to flash when some abnormality

has occurred in the control system.
(9) GLOW INDICATOR (DIESEL ENGINE TRUCK)

Glow indicator (9) indicates the preheating condition of the engine.
The lamp lights up when the engine starting switch key is turned to
the ON position and goes off when engine preheating is finished.
Lamp ON: the glow plug is heating the engine.
Lamp OFF: the glow plug has finished heating the engine.
The lamp goes off in approximately 8 seconds regardless of the

ambient temperature.
(10) WATER TEMPERATURE GAUGE
NOTICE
If the indicator enters the red range, stop operations
immediately and park the truck in a safe place. (See “DON'T
USE A DEFECTIVE LIFT TRUCK - USE LOCK-OUT TAG-OUT
PROCEDURES” on page 2-13.) Then take corrective actions
against engine overheating. (See “ACTIONS WHEN ENGINE
HAS OVERHEATED” on page 3-28.)
Engine cooling water temperature gauge (10) indicates the engine coolant temperature with a needle.
White range: the coolant temperature is normal.
Red range: the coolant is overheated.
(10) DIGITAL LOAD METER (OPTION)

Digital load meter (10) measures a load on the fork in a simple way
and displays the value.
When this meter is installed, the water temperature gauge, a
standard part, is moved to an optional meter location.
3-9
OPTION METER
When the following meters and gauges are installed in the lift truck
as an optional part, they are installed in the location indicated by the
arrow in the figure at right.
• Speedometer
• Ampere meter (ammeter)
• TORQFLOW transmission oil temperature gauge
• Engine cooling water temperature gauge (when the lift truck is equipped with a digital type load meter)
A maximum of two optional meters and gauges can be installed.
3-10
REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY
Remove the support bolts only

when replacing the support.
490 – 608 Nm
{50 – 62 kgfm}
196 – 245 Nm
{20 – 25 kgfm}
294 – 490 Nm
{30 – 50 kgfm}

WEIGHT TABLE REMOVAL AND INSTALLATION
WEIGHT TABLE
1.0 – 1.75 ton Forklift Trucks
Devices 1 ton 1.5 ton 1.75 ton Remarks

K15 Engine 145
Engine K21 Engine 145
Assembly
4D92E engine 230
Clutch Assembly 45
Torque Converter Assembly 30
Clutch Type 35
Transmission
TORQFLOW Type 43
Front 158
Axle
Rear 70
Front 23
Wheel
Rear 12
Overhead Guard 100
Counterweight 430 790 980
Mast Standard (3.0 m) 453 464
Lift 26 For 3 m mast

Cylinder Tilt 10
Power Steering 12
Fork Carriage 70 74
Fork 28 34
Backrest 21
Pump 3.5
Control Valve 10
Steering system 15

REMOVAL AND INSTALLATION WEIGHT TABLE
2.0 - 3.5 ton Forklift Trucks
Name of Devices 2 ton 2.5 ton 3 ton 3.5 ton Remarks

K15 Engine 145 –
K21 Engine 145 –

Engine K25 Engine 145
Assembly
4D94LE Engine 226 –
4D98E Engine 226

Clutch Assembly 45 –
Toque Converter Assembly 30

Clutch Type 35 –
Transmission
Assembly TORQFLOW Type 43
Drive Axle 207 219 261
Steering Axle 84
Front 35/45 35/–
Wheel
(Standard type/compact type) Rear 15/30 15/–
Overhead Guard Assembly 111

Standard Type 1,131 1,480 1,875 2,272
Counterweight
Compact Type 1,170 1,557 1,900 –
Mast Assembly (Incl. Forks) 644 663 773 969
Lift 25 32 33
Cylinder Tilt 12
Power Steering 16
Fork Carriage 95 120
Fork 42 50 62 90
Backrest 20 27
Pump 10
Control Valve (2 valves) 8
Steering system 22

TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER
After washing the outside of the torque converter, carry
out disassembling in a clean place as follows:
DISASSEMBLY
1. Removal of Torque Converter Assembly
Drain the oil from inside transmission. Then, remove
the torque converter assembly from the engine and
the transmission.
(M24 × 1.5 Drain Plug)
(12 mm Socket Wrench)
2. Removal of Oil Filter

Remove the oil filter (20) from the housing with the
special tool.
20
3. Removal of Torque Converter

Remove the torque converter (1) slowly from the
housing.
Be careful not to damage the oil seal and the
1
sealing of the gear pump.

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
4. Removal of Gear Pump

1) Remove the bolts mounting the gear pump.
(M8 × 1.25 Bolt: 5 pcs.)
(Socket Wrench 12 mm)
2) Remove the gear pump (2). Then, remove the 2
O-ring if it remains inside the housing.
5. Removal of Strainer
1) Remove all the bolts mounting the cover of the
strainer. Then, remove the cover (11) and the
gasket (12).
(M8 × 1.25 Hexagon Head Bolt with Flange: 8 11,12
pcs.)
(Offset Wrench 13 mm)
2) Pull out the strainer assembly (13) from the

housing. 13
Be careful not to damage the O-ring for
the strainer assembly.

6. Removal of Main Relief Valve

1) Remove the main relief valve plug.
(M24 × 1.5 Plug)
(Socket Wrench12mm)
WARNING
Be careful for the plug that may be jumping out forced
by the spring from inside the valve.
2) Pull out the piston and the spring from the

valve.
O-Ring
Plug Spring Piston
7. Removal of Inlet Port Relief Valve

1) Remove all of the bolts mounting the valve
cover. Then, remove the cover (9) and the gas-
ket (10).
(M6 × 1 Hexagon Head Bolt with Hole: 4 pcs.)
(Hexagon Wrench 5 mm)j
WARNING
Always be sure to press the cover while removing the
bolts to prevent the plug from spring out from inside
the valve.
2) Pull out the piston (7) and the springs (5)(8)

16 5 7
from each valve.
9,10 8 7

8. Removal of Gear Pump

1) Remove the O-ring and disassemble the gear
pump.
2) Remove the screw at one place for disassem-
bly.
(M5 × 0.8 Screw)
WARNING
Disassembly of the gear pump must be minimized as
much as possible.
Gear Case
Stator Support
Driven Gear
O-Ring
Drive Gear
Assembly

COMPONENT PARTS
16 24
25 20
5 18
19 27
4
6
7
9
1 10
8
7 28
1-1
18
1-2
23
22
1-3
12
11
13
3
17
26
2
15
2-7 2-5
14
2-6
2-3
2-2
2-1
2-9
2-8
2-4

Ref. No. Part Name Q'ty Ref. No. Part Name Q'ty
1 Torque Converter Circuit 1 9 Cover A 1
1-1 Torque Converter Sub-Circuit 1 10 Gasket A 1
1-2 Input Plate Assembly 1 11 Cover B 1
1-3 Hexagon Head Bolt (M8) 8 12 Gasket B 1
2 Gear Pump Assembly 1 13 Strainer Assembly 1
2-1 Gear Casing 1 14 Hexagon Bolt (M8) 5
2-2 Drive Gear 1 15 Gasket 5
2-3 Driven Gear 1 16 Hexagon Head Bolt (M6) 4
2-4 Oil Seal 1 17 Hexagon Head Bolt (M8) 8
2-5 Countersunk Head Screw 1 18 Hexagon Socket Head Plug (R1/4) 3
2-6 Stator Support 1 19 Nipple 1
2-7 O-Ring 1 20 Oil Filter 1
2-8 Inner Ring 1 21 INSULOK-TIE 1
2-9 Seal Ring 1 22 Drain Plug (M24) 1
3 Housing 1 23 O-Ring 1
4 Piston 1 24 Plug (M24) 1
5 Pressure Spring 1 25 O-Ring 1
6 Pressure Spring 1 26 Collar 1
7 Piston 2 27 Hexagon Socket Head Plug (R3/4) 2
8 Pressure Spring 1 28 Plug (M22) 1

INSPECTION
Unit: mm
Criteria
No Check Item Ref. No.
Standard Size Repair Limit
Piston Shaft and Torque Converter Housing Hole
1
A
B
A: Piston Outward Form Ø21.972 – Ø21.985 – 4
1-1 Main Relief Valve B: Hole Inner Diameter Ø22.000 – Ø22.021 – 3
Clearance 0.015 – 0.049 0.080 –

Torque Converter Inlet Port
1-2 B: Hole Inner Diameter Ø14.000 – Ø14.018 – 3
Relief Valve
Clearance 0.030 – 0.058 0.080 –
1-3 Lubrication Relief Valve B: Hole Inner Diameter Ø14.000 – Ø14.018 – 3
Clearance 0.030 – 0.058 0.080 –
Pressure Spring
2
C
D
E
C: Free Length 91.8 – 6
2-1 Main Relief Valve D: Fixing Length 79.1 – –
E: Fixing Load N 185.4 ±5 % 166.9 N –

Toque Converter Inlet Port
2-2 D: Fixing Length 77.6 – –
Relief Valve
E: Fixing Load N 47.8 ±5 % 43.0 N –
2-3 Lubrication Relief Valve D: Fixing Length 48.2 – –
E: Fixing Load N 58.8 ±5 % 52.9 N –

Unit: mm
Criteria
No Check Item Ref. No.
Standard Size Repair Limit
Oil Seal and Torque Converter Impeller Hub
F :– 41.5 2-4
3
G : 41.915 – 41.965 41.815 1-1
F
G
Seal Ring and Seal Ring Groove
H : 1.895 – 1.900 1.600

2-9
I : 1.870 – 2.070 1.670
5
J : 2.000 – 2.250 2.350
2-1
I
K : 42.10 – 42.13 42.25

K
Seal Ring and Seal Ring Groove
L : 32.500 – 32.525 –
2-2
M : 32.450 – 32.470 –
6 2-6
Clearance:
: 0.030 – 0.075 0.100
M
L
The numbers shown in the column on the left hand of the above table should refer to those on the component parts
drawing respectively.

ASSEMBLY
Carry out assembly work in the reverse order to
disassembly work.
IMPORTANT:
• Wash all the removed or disassembled parts with
clean oil to remove foreign bodies completely. In par-
ticular, wash the oil groove and oil circuit with care.
• Replace such parts as the O-ring, the oil seal and the
gasket with new ones after disassembly.
• Be careful to assemble correctly. For details, see the
check items specified in the maintenance standard.
• When replacing the oil seal with a new one, apply a
semi-dry gasket sealant (THREE BOND No.1211 or
No.1104 for example) on the outside circumference of
the oil seal. However, never apply it to the lip or the
sliding surface of the shaft.
1. Assembly of Gear Pump

Insert s pair of the gears (3) (4) in the gear casing
(2) and reverse the stator support (5) to assemble in
the same steps taken for disassembly.
Tighten the countersunk head screw and check to
make sure that the gear rotates smoothly. If it does
not rotate, disassemble it and start to assemble
again.
0.98 – 2.94
(Countersunk Head Screw) Nm {0.1 – 0.3 kgm}
2. Assembly of Main Relief Valve

Insert the spring and the piston to the relief valve
and tighten it with the plug. Check the piston for
proper positioning when assembling.
(Plug) 60 – 80 Nm {6.1 – 8.2 kgm}
3. Assembly of Torque Converter Inlet Port Valve

and Lubrication Relief Valve
Insert the piston and the spring to the valve. Then,
insert the gasket and tighten the cover. There are
two types of the valve and the spring is different
from the torque converter inlet port valve and the
lubrication relief valve. Be sure to assemble them
correctly to their original position.
(Bolt) 8.5 – 11 Nm {0.9 – 1.1 kgm}

4. Assembly of Gear Pump

Install the O-ring (1) to the corner of the housing (2)
to prevent it from being loosed. Check to make sure
that the O-ring is correctly installed without loose-
ness. Then, insert the gear pump (3) to the housing
slowly and vertically and tighten it with the bolts.D
(Bolt) 20 – 26 Nm {2.0 – 2.7 kgm}
5. Assembly of Torque Converter

Insert the torque converter in the pump inside the
housing slowly. Be careful not to damage the oil seal
and seal ring. Fill the area between the oil seal lip up
to 1/3 to 1/2 level with the lithium grease, or apply
the clean hydraulic oil to the oil seal.
6. Assembly of Torque Converter Assembly

Assemble the torque converter assembly with the
transmission and the engine.

MAINTENANCE STANDARD
1. Check for Oil Pressure
Input Engine Speed: 2,000 rpm
Oil Temperature: 80°C
Torque Converter Outlet Port Pressure: 0.3 MPa
No. Check Item Pressure (MPa) Hydraulic Port Position
1 Main Pressure 1.1 – 1.4 A
Torque Converter Inlet

2 0.5 – 0.7 B
Port Pressure
2. Tightening Torque for Bolts and Plugs
No. Tightening Location Screw Specifications Tightening Torque (Nm) Ref. No.
1 Input Plate Hexagon Head Bolt M8 × 1.25 × 12 30 – 38 1-3
2 Gear Pump Assembly Hexagon Head Bolt M8 × 1.25 × 12 20 – 26 14
Hexagon Socket Head

3 Valve Cover M6 × 1 × 20 8.5 – 11 16
Bolt
4 Strainer Cover Hexagon Bolt M8 × 1.25 × 12 20 – 26 17
Pressure Pick-up Port Blind Hexagon Socket Head

5 R 1/4 13 – 17 18
Plug Bolt
6 Oil Filter Oil Filter 3/4-16UNF 10 – 15 20
7 Drain Plug Drain Plug M24 × 1.5 60 – 80 22
8 Main Valve Plug M24 × 1.5 60 – 80 24
Hexagon Socket Head

9 Pressure Pick-up Ports R 3/8 20.5 – 28.5 27
Plug
10 Blind Plug Plug M22 × 1.5 60 – 80 28
Countersunk Head
11 Gear Pump Stator Support M5 × 0.8 × 16 0.98 – 2.94 2-5
Screw

TORQUE CONVERTER ASSEMBLY
1
2
3
4
7 5
Ref.No. Part Name Q'ty
1 Oil Filter 1
2 Turbine 1
3 Stator 1
Torque Converter
4 Impeller 1 Circuit
5 Turbine Shaft 1
6 Gear Pump 1
7 Turbine Hub 1
8 Input Plate 1
9 Housing 1

TORQUE CONVERTER ASEMBLY HYDRAULIC PORT POSITION

a
A B
e d c
f d C
A: Main Pressure Check Port a: Breather Pick-up Port

B: Torque Converter Inlet Port Pressure Check Port b: Level Gauge Pick-up Port
C: Lubrication Pressure Check Port c: to Oil Cooler
d: Drain
e: to Transmission side valve
f: Strainer Assembly

HYDRAULIC CIRCUIT
3A 3B
To Transmission
side Lubrication
B
3C
C
3E
A
3F
To T/M
3D
1. Oil Tank
2. Suction Filter (100 mesh)
3. Torque Converter Assembly
3A.Torque Converter
3B.Oil Filter
3C.Torque Converter Port Relief Valve
3D.Gear Pump Assembly
3E.Lubrication Relief Valve
3F.Regulator Valve
4. Oil cooler

CAUSE AND REMEDY FOR PROBLEM
No. Problem Cause Remedy
1 No power A: No hydraulic pressure

transmitting 1) Lack of oil 1) Add oil
2) Damage of gear pump or drive 2) Disassemble and check. Replace with new
device parts or whole assembly if necessary.
3) Damage of piping or joint 3) Disassemble and replace with new parts.
4) Breakage of piston in inlet port 4) Disassemble and replace with new parts.
relief valve or broken spring
B: Mechanical Breakage
1) Damage of input plate 1) Disassemble and replace with new parts.
2) Damage of shaft or gear 2) Disassemble and replace with new parts.
3) Damage of spline 3) Disassemble and replace with new parts.
2 Engine output A: Hydraulic pressure is too low.

dropping 1) Lack of oil 1) Add oil
2) Leakage of air from suction piping 2) Check joint and gasket. Replace with new parts
if necessary.
3) Drop in efficiency of gear pump 3) Disassemble and check. Replace with new
parts if necessary.
4) Deteriorated spring in inlet port 4) Disassemble and check. Replace with new
relief valve or faulty movement of parts if necessary.
piston
5) Wear or damage of seal ring 5) Disassemble and replace with new parts.
6) Cloggingof sstrainer 6) Check and wash strainer. Replace with new
parts if necessary.
B: Mechanical breakage
1) Damage or deformation of impeller 1) Disassemble and replace with new parts.
2) Deformation of input plate 2) Disassemble and replace with new parts.
C: Other
Use of wrong oil Disassemble and replace with new parts.
3 Abnormal sound 1) Cavitations caused by leakage of 1) Add oil and check and replace with new parts if
generating air from suction pipe or lack of oil necessary.
2) Failure of gear pump 2) Disassemble and check. Replace with new
parts or whole assembly if necessary.
3) Contact caused by deformed 3) Disassemble and check. Replace with new
impeller parts if necessary.
4) Breakage of input plate 4) Disassemble and replace with new parts.
5) Breakage of gear 5) Disassemble and replace with new parts.
6) Wear or breakage of bearings 6) Disassemble and replace with new parts.
7) Wear of spline 7) Disassemble and replace with new parts.
8) Looseness of bolts 8) Tighten again and replace with new parts if
necessary.
4 Oil leaking A: Oil seal

1) Wear or breakage of lip 1) Disassemble and replace with new parts.
2) Intake of foreign body through dust 2) Disassemble and check. Replace with new
parts if necessary
3) Wear or scratches of bearings 3) Repair or replace with new parts.
4) Hardening or deterioration of 4) Disassemble and replace with new parts.
rubber because of abnormal rise in
oil temperature
B: O-ring
1) Breakage of O-ring 1) Disassemble and replace with new parts.
2) Scratches on mating surface 2) Repair or replace with new parts.
3) Hardening or deterioration of 3) Disassemble and replace with new parts
rubber because of abnormal rise in
oil temperature
4) Sudden use in extremely cold 4) Warm up engine before operation.
temperature (below minus 15°C)
C: Joint surfaces with gasket
1) Looseness of bolts 1) Tighten again.
2) Damage of gasket 2) Replace with new parts
3) Scratches on joint surfaces 3) Replace with new parts
D: Plug and screw
1) Looseness of screw 1) Tighten again.
2) Damage of screw 2) Replace with new parts
3) Cracks on mating hole 3) Replace with new parts

DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
DISASSEMBLY
1. Transmission Valve
1
Remove the bolt (1) and disassemble the transmis-
sion valve.
2. Transmission Case
1) Remove the drain plug and drain the oil inside
the transmission case.
2) Disassemble the propeller shaft.
3. Torque Converter 1
1) Place the wooden blocks to support the trans-
mission case assembly and make it set facing
in the direction shown in the diagram on the
right.
2) Remove the bolt (1) connecting the torque con-
verter and the transmission case to separate
the torque converter.

TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY
4. Output Shaft
1) Remove the bolt (1) first. Then, remove the 1
bearing (2), the gear (3), the bearing (4), the
seal (5) and the spacer (6) in turn. Pull the out- 2
put shaft (7) out from lower side of the trans-
mission case. 3
5. Intermediate Shaft Sub-Assembly

1) Pull the intermediate shaft sub-assembly out.

6. Input Shaft Sub-Assembly

Pull the input shaft sub-assembly (with the clutch
pack assembly) out from the transmission case.
7. Strainer
1) Remove the bolt (1) from the transmission case 4
(7). Then, remove the plate (2).
1 7
2) Remove the strainer (3). 2
3
8. Oil Level Plug
Remove the oil level plug (4). 6
9. Cap and Blind Plug

Remove the cap (5) and the blind plug (6).

10. Disassembly of Clutch Pack Assembly

The numbers put on the diagram show the order for disassembly.
a
b
13
11
3 10
9
5
6
7 17
8 15
12
14
1 4 31
16
a 18
29
21 28
27
23
20
24
25 35
26 33
30
32
19 22
34
b
36

ASSEMBLY
1. Cleaning and Air Blowing of Transmission Case
1) Remove the cap when cleaning the transmis-
sion case because the LOCTITE is applied to
the cap tightening bolts.
2) Blow the machined hole of the transmission
case with air.
2. Installation of Blind Plug to Transmission Case

Install the blind plug (6), the cap (5) and the breather 4
(4) to the transmission case.
1
2
3. Installation of Drain Plug 3
Install the drain plug (7).
Tightening Torque for Drain Plug: 6 7
50.8 – 78.4 Nm {6.0 – 8.0 kgm}
4. Installation of Strainer 5
Fit the O-ring to the strainer (3) and insert it in inside
the transmission case. Then, install the plate (2)
with the gasket and tighten it with the bolt (1).

5. Output Shaft
Insert the spacer (6), the seal (5), the bearing (4),
the gear (3) and the bearing (2) in the output shaft 1
and secure it with the washer and the bolt (1).
2
Tightening Torque for Bolt:
98 – 123 Nm {10 – 12.5 kgm}

3
LOCTITE #271 (Hole Thread)
4
6. Installation of Intermediate Shaft Sub-Assembly

Assemble the intermediate shaft sub-assembly
inside the transmission case.

7. Input Shaft Sub-Assembly

1) Fit the seal (2) and the seal (3) to the piston (4). 3 4 5 6 7 1
Then, assemble the input shaft assembly (1)
with the piston.
2) Install the spring (5) and the washer (6). Then,
fix with the snap ring (7).
3) Assemble the bearing (8) and fix with the snap

ring (8-1). 14 10 9 11 8
4) Assemble the clutch disc (10) and the plate (9)
and fix with the ring (11).
5) Installation of Forward Gear
Insert the bearing in the gear (14) and assem-
ble it to the shaft. Assemble the bearing and
the spacer. Then, fix with the snap ring.
6) Installation of Reverse Gear
Assemble the washer, the gear, the bearing
and the washer.
Then, fix with the snap ring.
8. Installation of Input Shaft Sub-Assembly

Install the seal ring to the input shaft sub-assembly
and assemble inside the transmission.

9. Installation of Torque Converter

Apply the Liquefied gasket to the torque converter 2
contact face of the transmission case and assemble
the torque converter (2) and the transmission case
(3) with the bolt (1).
10. Installation of Transmission Valve

Fit the gasket and install with the bolt (1).
Tightening Torque for Bolt: 1
27 – 34 Nm {2.8 – 3.5 kgm}
11. Installation of Toque Converter Cooler Filter

Install the oil filter and the piping.

TORQFLOW TRANSMISSION ASSEMBLY DRAWING
98 – 123 Nm
{10 – 12.5 kgm}
LOCTITE #271

DIFFERENTIAL DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY (1.0 – 1.75 ton Forklift Trucks)
113 – 132 Nm
{11.5 – 13.5 kgm}
LOCTITE #271
LOCTITE #271

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY (2.0 – 3.5 ton Forklift Trucks)
113 – 132 Nm
{11.5 – 13.5 kgm}
LOCTITE #271
LOCTITE #271

113 – 132 Nm
{11.5 – 13.5 kgm}

ADJUSTMENT METHOD OF PINION SHAFT ASSEMBLY SHIM

1. Clearance (a)
Read the indication (a) at the pinion shaft tip.
2. Clearance (b)
Read the stamp (b) on the case. Set No. a
#7
20
3. Clearance (c)
Measure the clearance (c) and indicate the clear-
ance on 1/100-unit bases against the standard size b
29.50 mm.
The clearance can be fixed for calculation con-
sidering from the accuracy of the bearing and
following value shall be applicable. If no proper
tooth contact is found, assemble it again.
c = 15 mm
4. Calculation of Shim Thickness S1

Apply the clearances (a), (b) and (c) obtained from
15680 -
the above to the formula shown below to calculate 23250 N
the thickness of the shim S1. (1600 -
2400 kgf)
A+b+c+d Set this face
S1 = 0.7 + to the
100
differential (Equivalent to
Round the figure at two places of decimals. when bearing preload)
assembling.
IMPORTANT:
c
Check to make sure of no clearance between the gear
and the shim when pressing the gear for installation.

ADJUSTMENT OF PINION GEAR CLEARANCE

1. Clearance (b)
2. Fix the pinion shaft pushing from the bottom.
1) Take an alignment to the shaft with the jig.
2) Turn the bearing about 10 times each to right 1 d
and left to check its smooth movement.
3) Measure the clearance (d).
Check to make sure the step (1) of the above
for no clearance.
3. Calculation of Shim Thickness S2

1) Calculate the shim thickness S2 applying the
clearance (d) measured by the step 1 – 3 of the
above. 1 Fixed
S2 = 2.354 - d
2) Select the shim so as to meet the S2 of the
clearance.
3) Measure the starting torque and adjust the
shim thickness S2.
Starting Torque for Pinion Bearing
Starting Torque: 8.8 – 13.2 Nm {90 – 135 kgcm}
Make sure to measure the starting torque with-
out the coupling shaft.
INSPECTION OF PINION BEARING CLEARANCE

1. Apply the KOMATSU FORKLIFT genuine oil to the
inner race big brim (1) when assembling.
2. Check to make sure for no clearance (2) when 2 1
inserting the outer race.
3. Check to make sure the inner race big brim for no
clearance (3) when pressing the inner race for
installation.
4. After tightening the nut with specified torque, turn
the bearing about 20 times each to the left and the 3
right to check its smooth movement.
5. If the starting torque cannot get the specified torque
as shown below, disassemble and adjust the shim
thickness again.
Starting Torque: 8.8 – 13.2 Nm {90 – 135 kgcm}
If the starting torque T is greater than 13.2 Nm
{135 kgcm}, increase the shim thickness.
If the starting torque T is less than 8.8 Nm {90
kgcm}, reduce the shim thickness.

ADJUSTMENT OF DIFFERNTIAL
1. Assembly of Differential Assembly
1) Assemble the differential assembly and install
the adjustment screw (1). 2
2) Apply the LOCTITE #271 to the hole of the cap 1
(2) and tighten with bolt (3) temporarily.
LOCTITE #271
2. Adjustment of Backlash
1
Use the special tool A for tightening the adjust-
ment screw (1).
Special Tool A 34B-97-99110
1) Set the dial gauge and slightly tighten the

adjustment screw at the (B) side until the back-
lash goes to zero. A
2) Loosen the adjustment screw at the (B) side
until backlash goes to 0.15 – 0.23 mm.
Backlash between Ring

0.15 – 0.23 mm
Gear and Pinion Gear
If the backlash is beyond the criteria of the

above, take an adjustment again.
A B

3. 3. Adjustment of Tooth Contact Forward

1) Apply the red lead thinly to the tooth surface of
the bevel gear.
2) Turn the bevel gear forward and reverse sev-
eral times.
3) Check the tooth contact pattern left on the sur-
face for condition of tooth contact.
4) If the tooth contact is not correct, adjust it with
the shim thickness S1.
• Correct Tooth Contact (No Load)

The pattern must be located in the center of the
tooth contact, which covers 40 to 70 % of the Reverse
overall length of the tooth being in weak contact
at the both ends of the pattern.
In case of strong contact at the tooth top (1),

increase the shims.
In case of strong contact at the tooth top (2), 1
2
reduce the shims.
Adjust the tooth contact correctly both forward
and reverse.
Run-out of Bevel Gear: less than 0.1 mm

4. Correction of Tooth Contact

• Increase the shims at the pinion shaft to improve
the protrusion of the pinion in the direction of the
(A).
Next, move the bevel gear away from the pinion
in the direction of the (B) to adjust the backlash.
• Reduce the shims at the pinion shaft to

decrease the protrusion of the pinion in the
direction of the (A).
Next, move the bevel gear closer to the pinion in
the direction of the (B) to adjust the backlash.
• Reduce the shims at the pinion shaft to

decrease the protrusion of the pinion in the
direction of the (A).
Next, move the bevel gear closer to the pinion in
the direction of the (B) to adjust the backlash.
• Increase the shims at the pinion shaft to improve

the protrusion of the pinion in the direction of the
(A).
Next, move the bevel gear away from the pinion
in the direction of the (B) to adjust the backlash.

DIFFERENTIAL ASSEMBLY DRAWING DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL ASSEMBLY DRAWING

0.15 –
Backlash 0.20 mm Gear Oil GO90
(Thread)
Run-out Less than 0.1 mm

on dial gauge
343 Nm
{35 kgm}
G2-L1
(Seal Lip)
98 Nm
{10 kgm}
LOCTITE #271
(Thread Hole)
LG-7 (Seal Outer Cir-

cumference)
98 Nm
{10 kgm}
Backlash 0.15 – 0.20 mm
LOCTITE #271
(Thread Hole)
59 – 74 Nm
{6 – 7.5 kgm}
59 – 74 Nm
{6 – 7.5 kgm}

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY DRAWING
98 – 123 Nm
{10 – 12.5 kgm}
LOCTITE #271
(Thread Hole)
27 – 34 Nm
{2.8 – 3.5 kgm}
Run-out Less than 0.1 mm

on dial gauge
343 Nm
{35 kgm}
Gear Oil GO90

(Thread)
G2-L1
(Seal Lip)
98 – 123 Nm
{10 – 2.5 kgm} LG-7 (Seal Outer
Circumference)
LOCTITE #271 0.15 –
(Thread Hole) Backlash 0.20 mm
Starting 8.8 – 13.2 Nm

Torque {90 – 135 kgcm}
59 – 74 Nm
{6 – 7.5 kgm}
343 Nm
{35 kgm} 113 – 132 Nm
LOCTITE #271 {11.5 – 13.5 kgm}
(Thread Hole)

1.0 – 1.75 ton Forklift Truck
118 – 162 Nm
{12 – 16.5 kgm}
59 – 74 Nm
{6.0 – 7.5 kgm}

109 Series Forklift Truck
118 – 162 Nm
{12 – 16.5 kgm}
98 – 127 Nm
{10 – 13.5 kgm}

118 – 162 Nm
{12 – 16.5 kgm}
98 – 127 Nm
{10 – 13.5 kgm}

118 – 162 Nm
{12 – 16.5 kgm}
319 – 427 Nm
{32.5 – 43.5 kgm}
98 – 127 Nm
{10 – 13.5 kgm}

DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
SOLENOID VALVE
DISASSEMBLY DRAWING
15
3
13
9
12 1
11
2
7
5
4
6
13
8
10
14

SOLENOID VALVE DISASSEMBLY AND ASSEMBLY
COMPONENT PARTS
11 12 9 8 6 15 4 5 7 10 2 1 14
13
SOL.b SOL.a
3
Ref. No. Part Name Q'ty

1 Body 1
2 Spool 1
3 Plug 1
4 Spring 1
5 Retainer A 1
6 Retainer B 1
7 Parallel Pin 8
8 Solenoid Guide 1
9 Solenoid Coil 1
10 Spacer 4
11 Nut 1
12 O Ring 1
13 O Ring 1
14 O Ring 1
15 O Ring 1

DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
DISASSEMBLY
1. Remove the nut (11) with the spanner (27 mm). 15
2. Remove the O-ring (12). Then, remove the solenoid
coil (9).
3. Remove the O-ring (15) inserted in the solenoid coil
9
(9).
12
11
4. Remove the solenoid guide (8) with the 27 mm

spanner. 2
Be careful not to damage the spool hole 7
because the clearance between the body (1) 5
4
and the spool (2) is extremely small.
6
13
5. Remove the O-ring (13) from the solenoid guide (8).
8
6. Loosen the plug (3) with the spanner (3.5 mm pin-

spanner with 12.5 mm pitch) and remove it. 1
7. Remove the O-ring (13) from the plug (3).
8. Remove the O-ring (14) from the body (1).
Never remove the spacer because it was 3
pressed into the body. 13
14

SOLENOID VALVE DISASSEMBLY AND ASSEMBLY
ASSEMBLY
1. Insert the O-ring (14) in the body (1).
1
All of the O-rings shall be replaced with a new
one,
2. Insert the O-ring (13) in the plug (3). 3
3. Assemble the plug (3) to the body (1) with the pin
13
spanner (3.5 mm pin-spanner with 12.5 mm pitch).
20 – 25 Nm {2.0 – 2.6 kgm}
4. Insert the O-ring (12) in the solenoid guide (8).

5. Assemble the O-ring (13), the retainer B (6), the
spring (4), the retainer A (5), the spool (2) and the
14
parallel pin (7) to the solenoid guide (8), which insert
to the body (1) and assemble with the spanner (24
mm spanner).
2
7
5
4
6
13
6. Insert the O-ring (15) in the solenoid coil (9).

7. Insert the solenoid coil (9) in the solenoid guide (8). 15
8. Insert the O-ring (12) in the solenoid coil (9).
9. Install the nut (11) with the spanner (27 mm span-
ner). 9
8 – 10 Nm {0.8 – 1.0 kgm} 12

11

DISASSEMBLY AND ASSEMBLY STEERING VALVE
STEERING VALVE
If any seal is replaced at a service shop, the manufacturer’s warranty becomes invalid.
Be sure to send seals to the manufacturer for replacement as an assembly unit.
No. Part name Q’ty Remarks No. Part name Q’ty Remarks
1 Screw 7 Size: 5/16-24UNF 24 Oil seal 1
2 Spring pin 1 25 Dust seal 1
3 End cap 1 26 Retaining ring 1
4 Gerotor 1 27 Seal ground bushing 1
5 Spacer 1 No spacer or two spacers are 28 O-ring 2
used depending on
6 (Spacer) (1) specifications. 29 O-ring 1
7 Spacer plate 1 30 Ball 1
8 Drive 1 31 Face seal (or plug) 1 For low slip specifications only
Including part numbers 10 to 32 O-ring 1 For low slip specifications only

9 Control parts assembly 1 12 33 Nameplate 1
10 Housing (1) 34 Rivet 2
11 Sleeve (1) 36 Valve block 1
12 Spool (1) 37 Spool 1
13 Pin 1 40 Tube assembly 1
6 For standard input 41 Nut 1
specifications
42 Coil with connector 1
14 Centering spring For standard low input
4 specifications 43 O-ring 4
For standard ultra-low input 44 O-ring 1
4 specifications
45 Hexagon head bolt 2 M10 x P1.5 x shank: 35mm,
15 (Flat spring) 2 For standard ultra-low input width across flats: 8mm
specifications only
46 Spring 1
16 EPACS controller 1
47 Core 1
Cross recessed Size: M3, width across flats:
17 2 No plug is used depending on
countersunk head screw 1.5mm 48 (Hexagon socket head plug) 1
specifications.
18 Rotor
50 O-ring 1
Hexagon socket head
19 1 Size: M3 Check valve is used
setscrew 52 (Orifice plug) 1 depending on specifications.
21 Race bearing 2
54 Adapter screw 1
22 Thrust needle 1
55 (Check valve assembly) 1 No assembly is used
23 O-ring 1 depending on specifications.

STEERING AXLE DISASSEMBLY AND ASSEMBLY
STEERING AXLE
DISASSEMBLY DRAWING
Note: Press in with jigs

DISASSEMBLY AND ASSEMBLY STEERING AXLE
Note: Press in with jigs

FLOW DIVIDER DISASSEMBLY AND ASSEMBLY
FLOW DIVIDER
COMPONENT PARTS
Ref. No. Part Name Q'ty

1 Body 1
2 Spool 1
3 Bolt 1
4 Spring 1
5 O-Ring 1
2
1
4 5 3
OUT port
IN port Oil flow rate

control port

DISASSEMBLY AND ASSEMBLY FLOW DIVIDER
DISASSEMBLY
1. Loosen the bolt (3) to remove.
2. Remove the spring (4).
3. Remove the spool (2).
4 3
WARNING
• Be careful not to damage the circumference of the
spool.
• Before carrying out disassembly, make sure that
you understand the structure of the flow divider and
lay the disassembled parts out in order.

FLOW DIVIDER DISASSEMBLY AND ASSEMBLY
CHECK AND INSPECTION
WARNING
• Never use any fluid oil other than alcohol or brake fluid to wash or clean the parts. In particular, never use mineral oil
such as petroleum and gasoline. If mineral oil sticks on the rubber parts, they may swell and become unusable.
• Keep the parts in a clean place to prevent the parts from sticking dirt or dust after washing.
• Always keep such parts as the cylinder, the piston or the cup away from any foreign body that may damage those
parts seriously.
2
1
4 5 3
COMPONENT PARTS
1. 1. Body
2. 2. Spool
3. 3. Bolt
4. 4. Spring
5. 5. O-ring
No. Part Name Check Item Check Point Remedy Ref. No.
Extremely small scratches must be

removed with sandpaper. Those of
Scratches or wear Replacement in
1 Cylinder having critical scratches to affect 1
on sliding surface assembly
adversely to the seal must be
replaced with the cylinder assembly.
Those of having critical scratches or

Scratched, wear or
2 Spring wear and those of below the repair Replacement 4
fall
limit must be replaced with a new one.
Extremely small scratches must be

Scratches or wear removed with sandpaper. Those of
3 Flow divider spool Replacement 2
on sliding surface having critical scratches or wear must
be replaced with a new one.
Those of having scratches on the seal

4 O-ring or having critical wear must be Replacement 5
replaced with a new one.
The number shown in the Ref. No. on the right hand in the above table refers to those shown with the arrow in the dia-
gram of the component parts respectively.

DISASSEMBLY AND ASSEMBLY FLOW DIVIDER
ASSEMBLY
1. Assembly of Spool
1) Those parts to be reused must be washed or
cleaned with the flushing oil or brake fluid.
Always use mineral hydraulic oil to wash or
clean rubber parts. Never use flushing oil and
petroleum or gasoline for rubber parts.
2) Make sure to keep the spool (2) circumference
away from getting scratches or sticking dirt.
3) Check to make sure the spool for smooth func-
tion after assembly.
2. Assembly of Spring
1) Assemble the spring (4) as shown in the dia-
gram on the right. 2 4
3. Tightening of Bolt
1) Assemble the bolt (3) to the O-ring (5).
5 3
2) Tighten the bolt (3) with the following torque.
(Bolt) 98 – 107 Nm {10 – 11 kgm} 3
WARNING
• Be careful not to damage the circumference of the
spool.
• Before carrying out disassembly, make sure that
you understand the structure of the flow divider and
lay the disassembled parts out in order.

DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
HYDRAULIC PUMP
DISASSEMBLY AND ASSEMBLY
Front drive gear

Engaged-gear view
Enlarged Enlarged
view of D view of E
The copper alloy face

comes to gear side.
The face chamfered along outer
circumference comes to the bottom.
Section A-A Section B-B Section A-A
1 Front body assembly 15 Packing ring L

2 Bush BR assembly (for front pump) 16 Bolt with hexagon flange
3 Bush BL assembly (for front pump) 17 Oil seal
4 Bush ER assembly (for center pump) 18 Snap ring
5 Bush EL assembly (for center pump) 19 Plate seal
6 Front drive gear (for front pump) 20 Backup
7 Driven gear (for front pump) 21 Isolation plate
8 Rear drive gear (for center pump) 22 Center plate
9 Driven gear (for center pump) 23 Rear body assembly
10 Side plate 24 Rear drive gear
11 Flange 25 Driven gear
12 Body seal 26 Bush ER assembly (for rear pump)
13 Bush seal 27 Bush ER assembly (for rear pump)
14 Packing ring R

DISASSEMBLY AND ASSEMBLY PROPELER SFAFT
PROPELER SFAFT
The propeller shaft can be supplied as a drive shaft assemble.
Typical lubrication cycle: 1200 hours

MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
COMPONENT PARTS
Mark Part Name Q'ty

1 Oil Filter 1
2 Turbine 1
Torque
3 Stator 1 Converter
4 Impeller 1 Circuit
5 Turbine Shaft 1
6 Gear Pump 1
7 Turbine Hub 1
8 Input Plate 1
9 HousingHousing 1
1
2
3
4
7 5

TORQUE CONVERTER MAINTENANCE STANDARD
Unit: mm
Criteria
NO. Check Item Mark
Standard Limit
1 Piston (Shaft) and Toque Converter Housing (Hole)
A B
Torque Converter Housing Piston
1-1 Main Relief Valve A: Piston Outside Diameter Ø21.972 – Ø21.985 – 4

B: Hole inside Diameter Ø22.000 – Ø22.021 – 3
Clearance: mm 0.015 – 0.049 0.080 –
1-2 Torque Converter inlet Port A: Piston Outside Diameter Ø14.960 – Ø14.970 – 7
Valve
Clearance: mm 0.030 – 0.058 0.080 –
1-3 Lubrication Relief Valve A: Piston Outside Diameter Ø14.960 – Ø14.970 – 7
Clearance: mm 0.030 – 0.058 0.080 –
2 Pressure Spring
D
E
2-1 Main Relief Valve C: Free Length 91.8 – 6

D: Mount Length 79.1 – –
E: Mount Load N 185.4 ±5 % 166.9 N –
2-2 Torque Converter inlet Port C: Free Length 103.4 – 5
Valve
E: Mount Load N 47.8 ±5 % 43.0 N –
2-3 Lubrication Relief Valve C: Free Length 60.5 – 8
E: Mount Load N 58.8 ±5 % 52.9 N –
The numbers shown in the mark column of the table refer to the location of the component parts shown in the dia-
gram.

MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
Criteria
NO. Check Item Mark
Standard Limit
3 Oil Seal and Torque Converter Impeller
F: – 41.5
F
G: 41.915 – 41.965 41.815
G
Oil Seal Impeller
4 Seal Ring and Seal Ring Groove
H
I
H: 1.895 – 1.900 1.600

I: 1.870 – 2.070 1.670
K
J: 2.000 – 2.250 2.30

J K: 42.10 – 42.13 42.25
Seal Ring Seal Ring Groove
5 Bushing and Stator Support
L: 32.500 – 32.525 –
M: 32.450 – 32.470 –
Clearance:
L
0.030 – 0.075 0.100

M
Bushing Stator Support
gram.

TORQFLOW TRANSMISSION MAINTENANCE STANDARD
TORQFLOW TRANSMISSION
F1
D1
C1
D2 C2 A1 A2

MAINTENANCE STANDARD TORQFLOW TRANSMISSION
Unit: mm
Criteria
Mark Check Item Remedy
Standard Limit
A1 Thickness of Drive Plate 3.13 – 3.27 2.9

A Plate 2.35 Replace
A2 Thickness of Driven Plate 2.50 – 2.65 (Oil groove width:
min. 0.15)
Clearance at End Gap
B1 0.36 – 0.56 –
when inserting piston
Depth of Oil Groove in side Oil groove Replace in
B Seal Ring B2 0.15 – 0.35 every
face must be there.
disassembly
(D1) Width of Insertion Groove 2.60 – 2.65 2.8
Inside Diameter of Seal

C1 35.025 – 35.050 35.2
Ring Contact Face
C Piston
Width of Seal Ring
C2 3.1 – 3.2 3.4
Insertion Groove
Width of Seal Ring
D1 2.60 – 2.65 2.8
Insertion Groove
D Drive Shaft
Width of Seal Ring
D2 2.60 – 2.65 2.8
Insertion Groove
E1 0.2 – 0.4 1.0
when inserting clutch case
E Seal Ring E2 Width 2.97 – 3.01 2.77

Replace
(C2) Width of Insertion Groove 3.1 – 3.2 3.4
Inside Diameter of Seal

F Clutch Case F1 100 – 100.054 100.3
Ring Contact Face
H1 0.36 – 0.56 –
when inserting cap
Depth of Oil Groove in side Oil groove
H Seal Ring H2 0.15 – 0.35
face must be there.
(D2) Width of Insertion Groove 2.60 – 2.65 2.8
– Gears – Backlash 0.08 – 0.28 –
Replace with
new parts
Gasket, O-ring and
– – – when disas-
Seals sembly and
assembly

TRANSMISSION CONTROL VALVE MAINTENANCE STANDARD
TRANSMISSION CONTROL VALVE

COMPONENT PARTS
Mark Part Name Q'ty Mark Part Name Q'ty

1 Valve Body 1 13 Gasket 1
2 Spool 1 14 Bolt 1
3 Valve Body 1 15 Piston 1
4 Spring 1 16 Plug 1
5 Spacer 1 17 Gasket 1
6 Spring Pin 1 18 Plug 1
7 Spring 1 19 Plug 1
8 Piston 1 20 Orifice 1
9 Spring 1 21 Oil Seal 1
10 Spring 1 22 Plate 1
11 Pin 1 23 Bolt 1
12 Plate 1
23
19
22
21
1
8
18 10
11
15
7
17
20 5
16
4
2
13 14
12

MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
Criteria
Mark Check Item Remedy Mark
Standard Limit
Piston or Spool and Body Hole
A: Valve Body Inside Diameter
B: Piston Spool Outside Diameter
– – – –
A B
Accumulator Piston Outside Diameter 27.97 – 27.98 14

1 Body Inside Diameter 28 – 28.021 1
Clearance 0.020 – 0.051 0.080 Replace
Regulator Piston Outside Diameter 19.96 – 19.98 15
Clearance 0.020 – 0.061 0.080
Lubrication Relief Piston Outside Diameter 19.96 – 19.98 15
Clearance 0.020 – 0.061 0.080
Inching Spool Spool Outside Diameter 19.97 – 19.98 2
Body Inside Diameter 20 – 20.021 1
4 Clearance 0.020 – 0.051 0.070
Small Piston Piston Outside Diameter 19.97 – 19.98 3
Clearance 0.020 – 0.051 0.070
Spring
C: Free Length
– D: Mount Length – –
E: Mount Load
C
D
E
Accumulator Large Free Length 44.18 11

Spring Mount Length 28.70
Mount Load 287.3 N {29.3 kgf} ± 5 % 258.6 N {26.4 kgf}
5
Accumulator Small Free Length 98.14 12
Regulator Large Free Length 111.07 Replace 16
6
Regulator Small Free Length 123.43 17
Mount Load 206 N {21.0 kgf} ± 5 % 185.4 N {18.9 kgf}
Lubrication Relief Free Length 64.65 19
7 Mount Length 47.9
Mount Load 138 N {14.1 kgf} ± 5 % 124.5 {12.7 kgf}
Inching Spool Free Length 73.97 7
Mount Length 48.0 31.4 N {3.2 kgf}
Mount Load 34.3 N {3.5 kgf} ± 5 %
8
Small Piston Free Length 30.79 4
Mount Length 22.0
gram.

DIFERENTIAL MAINTENANCE STANDARD
DIFERENTIAL
Unit: mm
Criteria
Standard Limit
Replace (Excl. Bevel
Differential Pinion Gear and Differential Side In case of dam-
A – Gear and Pinion be re-
Gear aged tooth face placed in a set.)
B Outside Diameter of Spider 21.959 – 21.980 21.75
C Inside Diameter of Differential Pinion Gear 22.0 – 22.025 22.12
D Thickness of Bushing 1.54 – 1.66 1.3 Replace
E Thickness of Bushing 1.54 – 1.66 1.3
– Inside Diameter of Brake Drum 254.0 – 254.2 256
Gasket Replace with new parts

– O-ring – – when disassembly and
Seals assembly

MAINTENANCE STANDARD DIFERENTIAL
Unit: mm
Criteria
Standard Limit
Replace (Excl. Bevel
Differential Pinion Gear and Differential Side In case of dam-
A – Gear and Pinion be re-
Gear aged tooth face placed in a set.)
B Outside Diameter of Spider 24.959 – 24.980 24.75
C Inside Diameter of Differential Pinion Gear 25.0 – 25.1 25.2
D Thickness of Bushing 1.94 – 2.06 1.7 Replace
E Thickness of Bushing 1.52 – 1.68 1.3
– Inside Diameter of Brake Drum 310.0 – 310.2 312
Gasket Replace with new parts

– O-ring – – when disassembly and
Seals assembly

MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
Front drive gear

Engaged-gear view
Enlarged Enlarged
view of D view of E
The copper alloy face

comes to gear side.
The face chamfered along outer
circumference comes to the bottom.
Section A-A Section B-B Section C-C
1. ÉtÉçÉìÉgÉ{ÉfÉBAss'y 21. ÉAÉCÉ\ÉåÅ[ÉVÉáÉìÉvÉåÅ[Ég

2. ÉuÉbÉVÉÖBR Ass'yÅiÉtÉçÉìÉgÉ|ÉìÉvópÅj 22. ÉZÉìÉ^Å[ÉvÉåÅ[Ég
3. ÉuÉbÉVÉÖBL Ass'yÅiÉtÉçÉìÉgÉ|ÉìÉvópÅj 23. ÉäÉÑÉ{ÉfÅ[Ass'y
4. ÉuÉbÉVÉÖER Ass'yÅiÉZÉìÉ^Å[É|ÉìÉvópÅj 24. ÉäÉÑÉhÉâÉCÉuÉMÉÑÅ[
5. ÉuÉbÉVÉÖEL Ass'yÅiÉZÉìÉ^Å[É|ÉìÉvópÅj 25. ÉhÉäÉuÉìÉMÉÑÅ[
6. ÉtÉçÉìÉgÉhÉâÉCÉuÉMÉÑÅ[ÅiÉtÉçÉìÉgÉ|ÉìÉvópÅj 26. ÉuÉbÉVÉÖER Ass'yÅiÉäÉÑÉ|ÉìÉvópÅj
7. ÉhÉäÉuÉìÉMÉÑÅ[ÅiÉtÉçÉìÉgÉ|ÉìÉvópÅj 27. ÉuÉbÉVÉÖER Ass'yÅiÉäÉÑÉ|ÉìÉvópÅj
8. ÉäÉÑÉhÉâÉCÉuÉMÉÑÅ[ÅiÉZÉìÉ^Å[É|ÉìÉvópÅj
9. ÉhÉäÉuÉìÉMÉÑÅ[ÅiÉZÉìÉ^Å[É|ÉìÉvópÅj
10. ÉTÉCÉhÉvÉåÅ[Ég
11. ÉtÉâÉìÉW
12. É{ÉfÅ[ÉVÅ[Éã
13. ÉuÉbÉVÉÖÉVÅ[Éã
14. ÉpÉbÉLÉìÉäÉìÉOR
15. ÉpÉbÉLÉìÉäÉìÉOL
16. òZäpÉtÉâÉìÉWïtÉ{ÉãÉg
17. ÉIÉCÉãÉVÅ[Éã
18. ÉXÉiÉbÉvÉäÉìÉO
19. ÉvÉåÅ[ÉgÉVÅ[Éã
20. ÉoÉbÉNÉAÉbÉv

TORQUE CONVERTER, GEAR PUMP AND CONTROL VALVE STRUCTURE AND FUNCTION
TORQUE CONVERTER ASSEMBLY DRAWING
1
2
3
4
7 5
COMPONENT PARTS
Mar Part Name Q'ty

k
1 Oil Filter 1
2 Turbine 1 Torque
Converter
3 Stator 1 Circuit
4 Impeller 1
5 Turbine Shaft 5
6 Gear Pump 5
7 Turbine Hub 1
8 Input Plate 1
9 Housing 1

STRUCTURE AND FUNCTION TORQUE CONVERTER, GEAR PUMP AND CONTROL VALVE
2) Gear Pump
It is an inner contact gear type pump driven
with the impeller tip fin, which supplies the oil to
the transmission and the torque converter.
3) Housing
Inside housing, it contains such valves as
described below:
• Torque converter inlet port relief valve to
control or prevent torque converter inner
pressure from rising.
• Main relief valve to adjust clutch pressure
• Lubrication relief valve to control or prevent
lubrication pressure from rising.
6) Relief Valve
4) Power Joint
a. Main Relief Valve
a. Input Plate
Being contained inside the housing, it
The outside circumference is connected
adjusts the oil coming from the pump so
to the engine side flywheel and the inside
as to supply it to the control valve of the
circumference is connected to the front
transmission. Thus, it also supplies the
cover of the torque converter, which trans-
relieved oil here to the torque converter.
mits engine torque to the torque con-
b. Torque Converter Inlet Port Relief Valve
verter.
b. Turbine Hub
relieves or drains the oil for the torque
It combines the turbine shaft and the
converter inner pressure not to exceed
spline at transmission side and transmits
specified level so as to control or prevent
the torque converter output to the trans-
the torque converter from rising inner
mission.
pressure.
c. Lubrication Relief Valve
5) Oil Filter
It is located on the hydraulic circuit at the
relieves or drains the oil for hydraulic pres-
torque converter outlet port and filters oil to
sure of truck side lubrication circuit not to
prevent foreign body to flow toward the trans-
exceed the specified level so as to control
mission side.
or prevent inside the lubrication circuit
from rising hydraulic pressure.
7) Strainer Assembly
Being located at the pump suction circuit, the
strainer stops foreign body with mesh not to
flow to the inside of the oil circuit.

2. Control Valve Assembly 1. Valve Body

The solenoid valve provides speed selection of one 2. Solenoid Valve
each forward and reverse. It also provides with the 3. Inching Spool
inching mechanism to release the hydraulic clutch 4. Accumulator (Modulation Valve)
when stopping the engine and the modulation
mechanism (accumulator) to relieve shocks occur-
ring at the time of stating truck and shifting speed.

3. Power Transmitting Route
1) Engine rotation is transmitted to the impeller (3) Repeating such steps 1) through 3) of the above, engine
through the input plate (1). Receiving centrifu- power is transmitted to transmission side.
gal force, the oil inside of the impeller flows out
along the impeller fins. Driven by the fins of the impeller hub tip, the gear pump is
always rotating synchronized with the engine.
2) Being pushed out from the impeller, the oil hits
the turbine (2) by the blade and outputs its gen-
erated force through the turbine shaft (5).
3) Coming through the turbine (2), the oil

changes the direction of flow with assistance of
the stator (4), which meets to flowing angle
suitable to the blade lines of the impeller.

4. Hydraulic Circulating Route

1) When starting the engine, the fins of the impel-
ler hub tip of the torque converter drives the
gear pump. Then, the oil inside the transmis-
sion flows to the gear pump through the
strainer installed with torque converter assem-
bly, which is impressed to deliver to the inner
contact gear inside the gear pump.
2) Flowing out of the gear pump, the oil is

adjusted clutch pressure 1.1 to 1.5 MPa (11.2
to 15.5 kgf/cm2) by the main relief valve. The
adjusted oil is supplied to the hydraulic clutch
of transmission side.
3) On the other hand, the oil removed from the

main relief valve is supplied to the torque con-
verter.
4) At the torque converter port, the torque con-

verter inlet port relief valve is provided to con-
trol an increase in pressure inside the torque
converter to maximum 0.7 MPa (7 kgf/cm2)
5) Flowing out of the toque converter outlet port,

the oil is filtered with the oil filter and supplied
to the oil cooler. The lubrication relied valve is
provided at the torque converter outlet port so
as to control an increase in pressure inside the
cooling and lubrication circuit to maximum 0.58
MPa (6.0 kgf/cm2).
6) Cooling down in the oil cooler, the oil is sup-

plied inside the transmission for lubricating and
cooling each section as required and then
returns to inside the transmission case.
See the hydraulic circuit diagram and each port location

on and after next pages.

HYDRAULIC PRESSURE CIRCUIT DRAWING
3A 3B
To lubrication of
transmission side
B
3C
C
3E
A
3F
To T/M
3D
1. Oil Tank
2. Suction Filter (100 mesh)
3. Torque Converter Assembly
3A. Torque Converter
3B. Oil Filter
3C. Torque Converter Inlet Port Relief Valve
3D. Gear Pump Assembly
3E. Lubrication Relief Valve
3F. Regulator Valve
4. Oil Cooler

TORQUE CONVERTER ASSEMBLY HYDRAULIC PRESSURE PORT LOCATION
A B
e d c
f d C
A: Main Pressure Check Port a: Breather Mounting Port

B: Torque Converter Inlet Port Pressure Gauge Port b: Level Gauge Mounting Port
C: Lubrication Pressure Check Port c: To Oil Cooler
d: Drain
e: To Valve of Transmission side
f: Strainer Assembly

CONTROL VALVE ASSEMBLY HYDRAULIC PRESSURE PORT LOCATION
a
(On T/M Case)
g
e
f
h
a: Pump O/P Measure Port

b: F Clutch Measure Port
c: R Clutch Measure Port
d: To R Clutch
e: To F Clutch
f: Drain
g: Drain
h: From Pump

BRAKE BOOSTER STRUCTURE AND FUNCTION
BRAKE BOOSTER
13 12 5 A 6 7
2 1 11 10 B 3 4 9 8
1. Reservoir 6. Reaction Piston 11. Hydraulic Tank

2. Wheel Cylinder 7. Push Rod 12. Piston
3. Pump 8. Spring 13. Return Spring
4. Flow Divider 9. Control Valve
5. Booster Piston 10. Valve sear
1. A certain amount of the oil is supplied to the brake 5. With such an increase in hydraulic pressure in the
booster from the pump (3) through the flow divider power chamber (A), the hydraulic pressure affects to
(4). The oil enters to the power chamber (A) inside the right side of the booster piston (5) so as to push
the brake booster and flows to the hydraulic tank the return spring (13) away and move the piston (12)
(11) via the isle hole of the booster piston (5) after to the left.
passing through the space (B) being formed
between the control valve (9) and valve (10) respec- 6. Also, the hydraulic pressure in the power chamber
tively. (A) should push the rear piston (6) back to the right
(generating an anti-hydraulic force), which could bal-
2. When the brake booster is off, the oil has no resis- ance with brake pedal control force.
tance in passing through inside the booster includ-
ing large space (B), which makes no hydraulic 7. Therefore, it becomes the receiving pressure area
pressure available inside the booster. ratio or servo of the booster piston (5) and the reac-
tion piston (6). However, when the force to push the
3. When brake pedal is pressed down, the reaction pis- valve seat (10) back to the right due to the increased
ton (6) is pushed out to the left by the push rod so as hydraulic pressure in the power chamber (A) is
to squeeze the space (B). stronger than the spring (8), the space (B) cannot
be squeezed and the increase in pressure in the
4. With squeezed space (B), the oil has resistance power chamber (A) should stop.
when passing through the space (B), which should
increase the hydraulic pressure in the power cham- 8. In case of problem of the pump or engine stall, the
ber (A). reaction piston (6), the booster piston (5) and the
piston (12) should mechanically engaged, which
could enable you to operate manually.

STRUCTURE AND FUNCTION FLOW DIVIDER
FLOW DIVIDER
Fig. 1. Pump OFF Fig. 2. Pump ON
4 5 3 6 7 8
A a B
1 2
1. Pump 4. Damper Orifice 7. Spring

2. Brake Booster 5. Orifice 8. Body
3. Brake Booster or Hydraulic Tank 6. Spool
As to the control type of flow amount dividing, the flow 4. Then, the oil at the inlet port should flow to the
divider is so-called a "certain amount control type" or a hydraulic tank (3) from the first chamber (A) in pass-
"preference distribution type", which keeps constant ing through the space (a). (The shift from pump ON
control over the flow amount almost against the to the state of the Fig. 2 should be made instanta-
fluctuation of flow amount at the inlet port. neously.)
1. The Fig. 1.shows non-operation state with the pump 5. At the state of the Fig. 2, the spool (6) with the force
OFF. The spool (6) moves to the left in maximum pushing to the right due to the difference of the pres-
from the spring (7). sure in the first chamber and the second chamber
should balance with the force pushing to the left due
2. When the oil is supplied to the port from the pump to the spring (7), which should result in almost con-
(1), the oil at the port is supplied from the damper stant control over the difference in pressure between
orifice (4) of the spool (6) to the first chamber (A), the first chamber (A) and the second chamber (B).
then passing through the orifice (5) and the second
chamber (B) flows to the brake booster (2). How- 6. This pressure difference is the same as the case of
ever, the oil pressure in the first chamber (A) should the orifice (5). The amount of oil to flow to the brake
increase due to flow resistance caused by orifice booster (2) passing through the orifice (5) should be
(5). controlled almost constantly. (The space (a) and (b)
should keep constant control over the difference in
3. Since the hydraulic pressure in the first chamber (A) pressure between the spool as described above
should affect to the left side of the spool (6) to over- despite the changes of hydraulic pressure at the
come the spring (7), it moves the spool (6) to the each outlet port.)
right, which turns to the sate of the Fig.2. of the
pump ON and the space (a) and (b) is made avail-
able between the body (8) groove and the spool (6)
accordingly.

STRUCTURE AND FUNCTION VEHICLE CONTROLLER
VEHICLE CONTROLLER
The AX50/BX0 Series is equipped with a vehicle controller (interlock box) conforming to ISO3691 Standard, which has
functions to enhance safety of the vehicle.
1. Travel interlock function 3. Parking brake warning

(torque converter vehicles only) When an operator leaves operator's seat without applying
When an operator leaves operator's seat, the switch the parking brake, the buzzer sounds to warn the
under the seat is activated to disable travel of the operator to apply the parking brake.
vehicle. To restart travel, it is necessary to reset the
forward/reverse lever. This prevents malfunction of 4. Failure detection
the vehicle. 1) Sear switch failure detection
Users can check operation status by the travel lock 2) Relay output transistor failure detection
lamp on the meter panel. 3) Forward/reverse lever failure detection
If an operator leaves operator's seat with the for- 4) CPU failure detection
ward/reverse lever set to F or R, the lamp blinks When any of these failures is detected, the alarm
showing that travel is disabled. lamp on the meter panel blinks to warn users.
When the operator takes seat again and returns the
lever to N (resets), the lamp turns off and travel of
the vehicle can be restarted.
The travel lock lamp is also used as neutral lamp.
(Gasoline vehicle)
Travel lock lamp
2. Load handling interlock function

When an operator leaves operator's seat, the switch
under the seat is activated to disable load handling (Diesel vehicle: Together with sedimenta alarm lamp)
with work equipment. Alarm lamp
Users can check operation status by the load han-
dling lock lamp on the meter panel.
If an operator is not seated properly, the lamp blinks
showing that load handling is disabled.
When the operator is seated properly, the lamp
turns off and load handling can be restarted.
Load handling lock lamp

VEHICLE CONTROLLER STRUCTURE AND FUNCTION
SYSTEM OVERVIEW
- Provision of essential functions

- Pursuit of safety
Off the seat
Travel and load handling disabled while operator is off the seat
F
F/R switch
Transmission Travel disabled

Seated
Travel interlock
F/R solenoid OFF
Directly open/close travel circuit
F
Seat switch
Neutral reset is required

Seated
Controller N
Detects F/R switch failure
Detects output circuit failure
(Transistor, relay)
Control valve
Load handling interlock

Unload solenoid OFF Travel enabled
Seated
Lift lock solenoid OFF
Two switches

CONTROLLER SYSTEM CONFIGURATION
60A 40A 100A

ALTERNATER
OFF
START
ON
10A L TERMINAL
10A
GLOW TIMER (Disel)
15A
STARTER
RELAY
F/R LEVER
(T)
N F R
RELAY
To R_RELAY
All relays have a coil resistor
Coil resistor: 96 ohms
To F_RELAY
CONTROLLER Built-in resistor: 705 ohms
POWER Lamp: 12v,1.4w
13: 12v,24w 24 23 N_LAMP
3
SEAT_SW1 (NO)
ERROR_LAMP
11 15 MAIN RELAY
MAST_LAMP ACM32221
9 Coil: 12v,1.7w
SEAT_SW2 (NC) SW: 14v,35A
17 1: MAIN_RELAY
4: MAIN_BACK R_RELAY (T)

R_SW
ACM32221
Coil: 12v,1.7w
20: R_RELAY SW: 14v,35A
F_SW
BACK-LAMP SW
F_RELAY (T)
(C)
ACM32221
Coil:12v,1.7w
14: F_RELAY
SW: 14v,35A
22: R_BACK
CONTROLLER
16: F_BACK L R
Interlock-Box
(ISO3691)
BACK BACK
F_SOL R_SOL LAMP BUZZER
(T) (T) Lamp: 12v,8w
Solenoid: 12v,2A BUZZ: 12v,50mA Battery
L-GND: 7
MAST_RELAY
L-GND: 26 ACM32221 Parking_SW
8: MAST_RELAY Coil:12v,1.7w (Reset: ON)
SW: 14v,35A
10: MAST_BACK PARKING
P-GND: 6 _RELAY
LIFT-LOCK UNLOAD (B CONTACT)
P-GND: 12
SOL SOL ACM12221
P-GND: 18 Coil: 12v,1.7w
Solenoid: 12v. 1A SW: 14v,20A
P-GND: 25
2: PARKING_RELAY
PK_BUZZER
Rated: 12v,25mA
MaxA: 500mA

VEHICLE CONTROLLER STRUCTURE AND FUNCTION
Troubleshooting
1. ISO Controller
ERROR
_LAMP N_LAMP MAST_
LAMP
No. Symptom blinking status
status
Failure Remedy Reset Remarks
times “N”
“L”
“1”
SEAT_SW failure 1) Examine
Travel operation and work Blinking (disconnection or SEAT_SW circuit, Normal return
1 1 Blinking short-circuit) Refer to Remark Table 1
equipment do not work. *1 and repair it if
necessary.
F/R lever failure 1) Examine F/R lever
Travel operation does not Blinking
2 2 –– (short-circuit) circuit, and repair it Normal return Refer to Remark Table 2
work. *1 if necessary.
1) Parking brake warning 1) Abnormal output of 1) Parking brake 1) Parking brake
buzzer parking brake warning buzzer warning
1-1)Buzzer does not stop warning buzzer Examine buzzer:
even when parking (disconnection or PARKING_RELAY Normal return
brake is activated. short-circuit) and buzzer
1-2)Buzzer does not stop circuits, and repair
even when operator them if necessary.
left the seat with
parking brake
released.
2) N_LAMP, MAST_LAMP 2) Abnormal output of 2) Lamps 2) Lamp:
2-1)N_LAMP does not N_LAMP or Examine lamps Key/OFF
3 light even when F/R 3 –– –– MAST_LAMP and lamp circuit,
lever is set to neutral. (disconnection or and repair them if
2-2)N_LAMP does not short-circuit) necessary.
turn OFF even when
F/R lever is set to F or
R position.
2-3)MAST_LAMP does
not light for a certain
time when the key is
turned ON.
2-4)MAST_LAMP does
not turn OFF after the
key is turned ON.
Abnormal output of
work equipment
interlock relay
(disconnection or
short-circuit)
1) Only work equipment 1) – – 1) Controller output 1) Work equipment 1) Normal return
does not work. Tr open only or key/OFF
or relay Examine
disconnection MAST_RELAY
and relay circuit,
4 4 Blinking and repair them if
necessary.
2) Travel operation and 2) Blink- 2) Controller output 2) Travel/work 2) Key/OFF
work equipment do not ing *1 Tr short-circuit equipment
work. or any of Examine
MAST_RELAY, MAST_RELAY,
F_RELAY, F_RELAY,
R_RELAY short- R_RELAY, and
circuit relay circuit, and
repair them if
necessary.
Abnormal output of
work equipment
interlock relay
(disconnection or
short-circuit)
1) Only travel operation 1) – – 1) Controller output1) Travel only 1) Normal return
does not work. Tr open or relay Examine or key/OFF
disconnection F_RELAY,
R_RELAY and
relay circuit, and
5 5 Blinking repair them if
2) Travel operation and *1
2) Blink- 2) Controller output necessary. 2) Key/OFF
work equipment do not ing *1 Tr short-circuit 2) Travel/work
work. or any of equipment
MAST_RELAY, Examine
F_RELAY, MAST_RELAY,
R_RELAY short- F_RELAY,
circuit R_RELAY, and
relay circuit, and
repair them if
necessary.
Abnormal output of Examine
MAIN_RELAY and
6 Travel operation and work 6 Blinking Blinking MAIN_RELAY
equipment do not work. *1 (disconnection, short- relay circuit, and Key/OFF
circuit) repair them if
necessary.
1) Examine power
Travel operation and work Blinking Blinking circuit, and repair it Return the controller and
7 7 Controller failure Key/OFF
equipment do not work. *1 if necessary. examine it.
2) Replace controller.
*1: N_LAMP lights when F/R lever is set to neutral.

2. Knob Displacement Correction System

No. Symptom Controller LED status Failure Remedy Remarks
1) Examine controller power circuit,
Knob position
1 OFF Controller failure and repair it if necessary.
deviates.
2 Repeats blinking 3 times. Steering wheel sensor failure Replace controller.
Tire sensor failure

• Disconnection or short-circuit 1) Examine tire sensor (including
installation), and repair it if
3 Repeats blinking 4 times. (signal line - GND)
• Improper installation (orientation) necessary.
of tire angle sensor 2) Examine tire sensor circuit, and
repair it if necessary.
1) Perform initial setting from the
beginning.
2) Examine tire sensor installation,
Initial setting in progress and repair it if necessary.
4 Repeats blinking twice.
(Not always a failure) 3) Check whether orbit roll rotor is
loose, and repair it if necessary.
Secure it by tightening screws or
locking.
1) Check terminals of the controller.
5 Repeats blinking once. Initial setting not completed (Open (disconnected) normally)
2) Perform initial setting
1) Examine tire sensor (including
(1) Tire sensor short-circuit installation), and repair it if
(power line - signal line) necessary.
2) Examine tire sensor circuit, and
1) Check whether valve turns ON/
(2) Electromagnetic valve (for cor- OFF during steering.
rection) failure 2) Examine valve harness, and
6 ON 1) Check whether rotor is loose, and
(3) Orbit roll rotor idle rotation
Secure it by tightening screws or
locking.
(4) Failure of controller valve drive 1) Perform remedy for (2).
circuit 2) Replace controller.
1) Examine whether initial setting is
(5) Steering wheel sensor short-cir- available.
cuit 2) Perform remedy for (1).
Remark Table 1
Input Output
Remarks
SEAT_SW1 SEAT_SW2 ERROR-LAMP
OFF OFF Error No.1 Open
OFF ON OFF Normal
ON OFF OFF Normal
ON ON Error No.1 Short
Remark Table 2
Input Output
Remarks
F_SW1 R_SW2 ERROR-LAMP
OFF OFF OFF Normal (Neutral)
ON OFF OFF Normal (F)
OFF ON OFF Normal (R)
ON ON Error No.2 Abnormal

HYDRAULIC CIRCUIT DRAWING STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT DRAWING

Standard model: 1.0 to 1.8 ton
Lift height 3.7 m or less

Lift height 4.0 m or more
B2
A2
TILT CYLINDER
LIFT CYLINDER A1
DOWN SAFTY
VALVE
KL
FLOW DIVIDER
8 to 11 /min PS
RELIEF PRE.
1 to 1.8 ton:
7.4 MPa
{75 kg/cm2}
MAIN RELIEF PRE.

17.2 MPa
{175 kg/cm2}
KP
M
POWER P1
STEERING
CYLINDER
FILTER 20 µ
PUMP DISPLACEMENT (cm /rev) 3 STRAINER 105 µ
G, GH D
20.8 23.3

2006.3.27(1)
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DRAWING
Standard model: 2.0 ton to 3.0 ton
Lift height 3.7 m or less

Lift height 4.0 m or more
B2
A2
TILT CYLINDER
LIFT CYLINDER A1
DOWN SAFTY
VALVE
MAIN RELIEF
KL PRE.
18.1 MPa
13.5 to 17.3 /min G1 P T

KPF
KP
FLOW DIVIDER
PS RELIEF PRE.
2 to 3 ton: 11.8 MPa {120 kg/cm2}
BLEEDING VALVE
M
P2 P1
POWER
STEERING
CYLINDER
FILTER 20 µ
STRAINER 105 µ

2006.3.27(1)
HYDRAULIC CIRCUIT DRAWING STRUCTURE AND FUNCTION
Power Brake Truck: 2.0 to 3.0 ton, 3.5 ton
CONTROL VALVE
B2
A2
TILT CYLINDER
LIFT CYLINDER
A1
DOWN SAFTY
VALVE
MAIN RELIEF
KL
PRE.
18.1 MPa
G1 P T
KP
KPF 13.5 to 17.3 /min FLOW DIVIDER
PS
BRAKE BOOSTER BLEEDING RELIEF
VALVE PRE.*
MASTER
CYLINDER 6.9 MPa
1.3 /min
POWER M
FLOW DIVIDER
STEERING P3 P2 P1
CYLINDER
FILTER
20 µ
STRAINER
105 µ
* : PS RELIEF PRE.
2 to 3 ton: 11.8 MPa {120 kg/cm2}
3.5 ton: 13.2 MPa {135 kg/cm2}

2006.3.27(1)
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DRAWING
P-PORT OIL PRESSURE MEASURING PORT
㪧㪄㫇㫆㫉㫋
㪦㫀㫃㩷㫇㫉㪼㫊㫊㫌㫉㪼㩷㫄㪼㪸㫊㫌㫉㫀㫅㪾㩷㫇㫆㫉㫋
㪩㪚㩷㪈㪆㪏㩷
AX50/BX50 Series 60-28-1

60-29
2006.3.27(1)
ELECTRICAL CIRCUIT DRAWING STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DRAWING

1. GASOLINE POWERED FORKLIFT TRUCK
1.25RG 0.85RG 0.85LW
1 2
1 2 3 4 5
HEAD LAMP (55W) 1.25RB 0.85RB 0.85GY
0.85RL 0.5 LY
0.85G 0.85L
0.85RG 0.85B
1 2 3
1
2
DRIVING LAMP (8W) 3
4
5
6
WINKER LAMP (23W)
3EB-55
48160
LIFT LOCK SOL
0.85 B
1 2
UNLOAD SOL 0.85YB

DIODE
0.85 B 0.85 B
1 2
a 1
0.85YB 0.85YB
0.85YR
1 3 5 6 8 10 12
7 9 11
0.5 BR
SOLENOID
2 4
0.5 YB
VALVE(T MODEL)
0.5 RB
F R
0.85B
1 2 3 4
0.85B
0.85G
0.85GW
3.0 G
1 2 3 4
M 0.5 BY
ST
STARTING SW B 3.0 W
0.85GW
1 2 3
G 0.85B
0.85G
0.5LW
1 2
STOP LAMP
0.5RW DIODE
SW
N LAMP
0.85YB
L
2 1
FLASHER UNIT 0.85GW

B BACK LAMP
SW (C)
CHARGE
0.85YB
2 1
0.85GW
OIL
PRESSURE L R
COMBINATION SW 0.85G
2 1
0.85B
0.5 BR
(B)
0.85L
FUEL GAUGE NEUTRAL
1 2 3 4 5 6 7 8
F Center Center Center Center

0.85GR
0.85YG
SWITCH (C) FOR T/C MODEL
B E
0.85GW
T
Hi Lo Hi Lo Hi Lo Hi Lo 0.85RL
FOR CLUTCH MODEL
CLUTCH WIRE
0.85LW T/C WIRE
HOUR METER
OFF 1 2 OFF 1 2 OFF 1 2 0.85GY
HOUR METER FOR FOR
(A)
SW 3EB-55 C MODEL 3EB-55 T MODEL
0.5 RW 5511B 5531C
1 2 3 4
0.85GR
0.85R
0.5 LY
WATER TEMP
0.85GW
0.85GW
0.5 GW
0.85 G
0.5 YB
0.85G
0.85B
0.85B
W 0.5 BY
18 20 22
0.85 B
14 16 17 19 21
B E
T 0.5 GY
0.5 LY
0.5 RG 1 2 3 4 5 6 1 2 3 4 5 6
13 15
0.5 L
HORN T/C OR
SW 3EB-55 D/B HARNESS CLUTCH WIRE 1 2 3 4 5 6
(T MODEL) 0.5 YG 56110
1 2 3 4
0.85GW
0.5 YB
0.5RG
0.85G
0.5 B 0.85B
3EB-55 ENG.HARNESS
F R 0.5 RG 56210
1 2 3 4 5 6 7 8 9 10
0.85B
F-R SWITCH 0.5 WL
0.5 YR 0.5 YR 7
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
0.85YB
0.5 YR
0.5 GW 0.5 GW 8
0.5 YG 0.5 YG 9
0.5 RB
R 0.5 RB 10
0.5 GY 0.5 GY 11
12
0.5 L 0.5 L 13
0.5 RG 0.5 RG 14
0.5 YR 0.5 YR 15
0.5 WL 0.5 WL 16
0.5 BY 0.5 BY
17
0.5 YL 0.5 YL 18
11 10 9 8 7 6 5 4 3 2 1
0.5 LW 0.5 LW 19
0.85GR 0.85GR 20
0.85YB 0.85 Y 21
0.85RL 0.85RL 22
0.5 RW 0.5 RW 23
0.85GW 0.85GW
1.25YG 1.25YG
3.0B 3.0 B 24
3.0W 3.0 W 25
3.0 G 3.0 WG 26
27
28
1.25RB 0.85RB 0.85YG

1 2
1 2 3 4 5
1.25RG 0.85RB 0.85R

HEAD LAMP (55W)
0.85RL 0.5 YL
1.25 YG
1.25 YB
0.85GR
3.0 WG
0.5 RW
5.0 WR
0.85G
0.5 BY
0.5 BY
0.85RL
0.85Y
0.5 G
0.85RG 0.85B
1 2 3
a
b
DRIVING LAMP (8W)
c
d
e 15A
3EB-55 f 10A
WINKER LAMP (23W)
48160 g 10A
h
i
j 10A
0.5 B
HORN k 15A
0.5 GW 10A
l
m 3A
n
o
p
q
r
FUSE BOX

STRUCTURE AND FUNCTION P-PORT OIL PRESSURE MEASURING PORT
LICENSE LAMP (10W)

REAR LAMP (R)
2 1
TAIL LAMP
(8W)
2 1 STOP LAMP
(23W)
0.5 YL
0.5 B
1 0.5 YL 1.25RL WINKER LAMP
(23W)
6 5 4 3 2 1
2 0.5 LW 1.25GW
3 0.85L 1.25G
4 0.85GW 1.25Y
5 BACK UP LAMP
6 0.85B 1.25B (10W)
3.0B
STARTING SWITCH CONNECTION
CIRCUIT M B G ST
OPERATION
3
OFF
1
2
WINKER SWITCH CONNECTION
3.0WL
0.85YB
TERMINAL 5(B) 4(B) 8(B)
OPERATION
STARTING MOTOR
LEFT
NEUTRAL
B
RIGHT
20B
LAMP SWITCH CONNECTION

CARBURETOR
SOLENOID-VALVE
TERMINAL 4(A) 1(A) 3(A) INT.
7(B) INT.
3EB-55 E OPERATION TERMINAL1 TERMINAL2
43240 TWIST OFF

ENG.EARTH LOW
CABLE
DISTRIBUTOR
SECOND
37B-1LK
4020
BATTERY TERMINAL 3(A) 1(B) 2(B) INT.
7(B) 2(A) 6(B) INT.
CABLE(+) SPARK PLUG OPERATION TERMINAL1 TERMINAL2
0.85B
UP/ UP
DOWN NEUTRAL
DOWN
+ -
IGNITION COIL
STARTER HEATER
1 2
RELAY RELAY
0.5 Y ALTERNATER
WATER TEMP
OIL PRESS SENSOR BACK
SW L BUZZER
0.5 YR
1 2
0.5 WR
S
86 30 87 85 87B 1 2 3 4 5 5.0 WR B
1 2
1
1 2
IC-REGULATOR
E
3.0 WB
3.0 WL
0.5 RG
0.5 YR
0.5 BY
0.5 Y
0.5GW
0.5 B
0.5 RB
0.5 L
8
9
10
11
12
13
14
15
16
TAIL LAMP
17 (8W)
18 0.5 YL 1.25RL
6 5 4 3 2 1
19 0.5 LW 1.25GW STOP LAMP

20 0.85RL 1.25G (23W)
21 0.85GW 1.25Y
22
23 0.85B 1.25B WINKER LAMP
(23W)
24
25
26 BACK UP LAMP
(10W)
27
0.5 GY
0.5 B
REAR LAMP (R)

28
1 2 3
FUEL LEVEL
0.85GW
0.5 GW
5.0 WR
3.0 WB
0.5 BW
0.85BY
0.5 YG
0.5 WL
SENSOR
0.85 R
0.85 R
0.5 YL
0.85G
3.0 W
0.5 G
0.5 G
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
100A
60A
BATTERY
40A + -
20B 20B
F RELAY R RELAY HORN RELAY
S.B FUSE 8.0 W
SLOW BLOW FUSE & RELAY BOX

34B19R BATTERY
32C24R
37B-1LH EARTH CABLE
4020

ELECTRICAL CIRCUIT DRAWING STRUCTURE AND FUNCTION
2. DIESEL POWERED FORKLIFT TRUCK
3EB-55
48160
1
1.25RG 0.85RG 0.85LW 2
1 2
1 2 3 4 5
HEAD LAMP (55W) 1.25RB 0.85RB 0.85GY 3
0.85RL 0.5 YL 4
0.85G 0.85L 5
0.85RG 0.85BW 6
1 2 3
7
DRIVING LAMP (8W)
WINKER LAMP (23W)

LIFT LOCK SOL
0.85 B
1 2
UNLOAD SOL 0.85GY
DIODE
0.85 B 0.85 B
1 2
a 1
0.85GY 0.85GY
0.85YR
6 8 10 12
7 9 11
0.5 BR
0.5 RY
0.5 LW
5
0.5 Y
4
3
0.5 RB
2
1
1.4W
1.4W
3.0 G
GLOW
1 2 3 4
M 0.5 BY
ST
B 3.0 W
STARTING SW
1.4W G
SEDI
MENTOR
0.5 LW
1 2
STOP LAMP SW 0.5 RW

1.4W
N LAMP
0.85Y
L
2 1
FLASHER UNIT 0.85GW

B
1.4W
CHARGE
TURN SIGNAL
COMBINATION SW N
1.4W
OIL
PRESSURE L R
(B)
0.85L
FUEL GAUGE
1 2 3 4 5 6 7 8
0.85GR
F Hi Lo Hi Lo Hi Lo Hi Lo 0.85YG
B E
T 0.85GW 0.5 BR
0.85RL
0.85LW
HOUR METER
OFF 1 2 OFF 1 2 OFF 1 2 0.85GY
(A)
0.5 RW
1 2 3 4
0.85GR 0.5 BY
0.85R
1.4W 0.5 YL
1.4W
WATER TEMP
W
18 20 22
0.85 BY
14 16 17 19 21
B
T
E
0.5 GY 3EB-55 D/B HARNESS
0.5 YL 57210
0.5 RG
13 15
0.5 L
HORN 3EB-55 ENG.HARNESS

SW
(T MODEL) 0.5 YG 57220
1 2 3 4
0.5 BY
F R 0.5 RG
1 2 3 4 5 6 7 8 9 10
0.85BY
F-R SWITCH 0.5 WL
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
0.85Y
0.85YR
0.5GL 0.5GL 8
0.5YG 0.5YG 9
0.5RB 0.5RB 10
0.5GY 0.5GY 11
0.5LW 0.5LW 12
0.5RY 0.5RY 13
0.5L 0.5L 14
0.5RG 0.5RG 15
0.85YR 0.85YR 16
0.5WL 0.5WL 17
0.5BY 0.5BY
0.5YL 0.5YL 18
11 10 9 8 7 6 5 4 3 2 1
0.5LW 0.5LW 19
0.85GR 0.85GR 20
1.25Y 1.25Y
0.85RL 0.85RL 21
1.25RW 1.25RW
0.5GW 0.5GW
1.25YG 1.25YG 22
3.0B 3.0B 23
3.0W 3.0W 24
3.0G 3.0G 25
26
1.25RB 0.85RB 0.85YG

1 2
1 2 3 4 5
1.25RG 0.85RB 0.85R 27

HEAD LAMP (55W)
0.85RL 0.5 YL
0.85G 0.85RL
1.25RW
0.85GR
1.25YG
0.85YB
0.5 BY
0.85RG
3.0WR
0.85BW
1.25Y
0.5BY
0.5 G
1 2 3
3.0G
DRIVING LAMP (8W) a

b
c
d
WINKER LAMP (23W) 3EB-55 e
f
15A
10A
48160 g 10A
h
i
j 10A
0.5 BY
k 15A
HORN 0.5 GL
l 10A
m 3A
n
o
p
q
r
FUSE BOX

STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DRAWING
37B-1EB
1 4510
2
3
4
5
6
7 REAR LAMP (R)
2 1
TAIL LAMP
(8W)
LICENSE LAMP (10W)

1 2 STOP LAMP
(23W)
0.5 YL
0.5 B
1.25RL WINKER LAMP
0.5 YL (23W)
6 5 4 3 2 1
0.5 LW 1.25GW STARTING SWITCH CONNECTION
0.85L 1.25G
0.85GW 1.25Y CIRCUIT M B G ST
BACK UP LAMP OPERATION
0.85B 1.25B (10W)
3
OFF
1
2
8.0 WR
WINKER SWITCH CONNECTION
3EB-55
TERMINAL
3EB-55 41420 OPERATION
5(B) 4(B) 8(B)
SOLENOID
VALVE(T MODEL)
5225A LEFT
3.0B
F R
ALTERNATER B NEUTRAL
0.85B RIGHT
1 2 3 4
0.85B 3.0 WL
0.85G
0.85YR
0.85GW LAMP SWITCH CONNECTION
0.85Y
L
TERMINAL 4(A) 1(A) 3(A)
2 1
INT. INT.
STARTING MOTOR 7(B)
0.85GW R OPERATION TERMINAL1 TERMINAL2
1 2 3
TWIST OFF
0.85B B
R
20B
0.85G
S
L LOW
SECOND
F
DIODE
E
TERMINAL 3(A) 1(B) 2(B) INT.

7(B) 2(A) 6(B) INT.
BACK LAMP
SW (C)
FOR CLUTCH MODEL OPERATION TERMINAL1 TERMINAL2
3EB-55
41431 UP/ UP
2 1
DOWN NEUTRAL
0.85YB
GLOW PLUGS DOWN
0.85GW
0.85G
2 1
0.85B
8.0W
GLOW RELAY
NEUTRAL FOR T/C MODEL & TIMER
SWITCH (C)
8.0W
1 2
8.0WR WATER TEMP SENSOR
CLUTCH WIRE T/C WIRE

FOR FOR
1 2 3 4 5 6
0.85B FUEL CUT SOLENOID

3EB-55 C MODEL 3EB-55 T MODEL 0.5 LW
BACK
TIMER BUZZER
5511B 5531C CIRCLE 0.5 BY
OIL PRESS SW
0.5 YB
SEDIMENTOR
0.85GW
0.85GW
SENS0R
0.5 GW
0.85 G
0.5 YB
0.85G
0.85B
0.85B
86 30 87 85 87a
0.5 RG
3.0 WL 1 2
1 2 3 4 5 6 1 2 3 4 5 6
STARTER 3.0 WB
RELAY 0.5 YB
0.5GW
0.5B
0.5 RB
T/C OR
CLUTCH WIRE 1 2 3 4 5 6 2 1
0.85 YB
0.85GW
0.5 YB
0.5 GW
0.5 RG
0.5 L
0.5 YB
a 1
0.85G
0.85B
0.5 BY
0.5 RY
DIODE
0.5 B
8
9
10
11
12
13
14
15
16
17
TAIL LAMP
(8W)
0.5YL 1.25RL
6 5 4 3 2 1
18 0.5LW 1.25GW STOP LAMP

19 0.85RL 1.25G (23W)
20 0.85GW 1.25Y
21 0.85B 1.25B WINKER LAMP

(23W)
22
23
24 BACK UP LAMP
25 (10W)
REAR LAMP (L)

0.5 GY
0.5 B
26
1 2 3
FUEL LEVEL
SENSOR
27
37B-1EB
0.85GW
0.5 BW
0.5 WL
0.5 BY
0.5 YR
0.85 R
0.85 R
0.5 YG
8.0WR
0.5 GL
3.0WB
0.85G
4510
0.5 G
0.5 G
3.0W
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
120A
8.0W
60A
5.0W
+ -
40B 40B
F RELAY R RELAY HORN RELAY 40A

3.0W 8.0W
95D31R
S.B FUSE BATTERY

3.
0.85Y
LPG LPG
(ONLY) LAMP BUZZER 0.85Y
1.25YG
LPG RELAY1
R WIPER SWITCH 0.85YW
F WIPER MOTOR 0.5 BR
1 2 3 4 5 6
60-34
1 2 3
60-33-1
1 2 3 4
0.5 LY
1 2 3
0.5 LR
0.5 YW
0.5 BR LPG RELAY2
2006.4.11(1)
1 2 3 4 5 6 1 2 0.85Y
0.5L
1.25 L
1.25 Y
1.25 L
1.25 LB
LPG SWITCH 0.5YR
1 2 3 4
1.25 WB
1.25 LW
1.25 YW
0.5 LY
0.5 LY
0.5 GR
ASIST LAMP SW
0.5 GW
(DUAL)
ASIST LAMP SW
or BECON LAMP SW
or BECON LAMP SW
F WIPER SWITCH
(+WORKING WITH ACC)
(+WORKING WITH R GIAR)

1 2 3
1 2 3 1 2 3 4
F.ASIST
1.25 WB
LAMP (R)
F.ASIST
1.25 L
LAMP (L)
ACC
1.25 LW
1.25 YW
1.25 P
1.25 LB
1.25 YB
1.25 GB
1.25 BW
1.25 WB
1.25 WB
1 2 1.25 L 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 1 2 3 4 5 6 1 2
STARTER
BATT
0.5 Y
0.85B
0.85B
0.85R
0.85R
0.5 LY
0.5 GR
0.85LY
0.85LR
0.5 RW
0.85RY
0.85RY
0.5 RW
0.5 GW
ROOM LAMP
1.25GB
1.25LW
1.25 LB
0.85YW
1.25GB
1.25LW
1.25 LO
1.25 YG
1.25 WB a
0.5 BY
4 3 2 1
5.0 WR
3.0 WG
b
c
d
LPG POWERED FORKLIFT TRUCK
e 15A
f 10A
g 10A
h
i
j 10A
k 15A
l 10A
m 3A
1.25 P
1.25 LB
1.25 LB
1.25 GB
1.25 LB
1.25 LB
1.25 BW
1.25 GB
1.25 GY
1.25 YB
1.25 BW
n
1 a B. ASSIST LAMP SW. o
1 2 3 4 1 2 3 4 5 6 p
q
r
DIODE
FUSE BOX
F PUMP RELAY F WIPER RELAY 1 2 3 4 5 6
CONNECTOR (8P) 1 CONNECTOR (5P)

TERMINAL 8
0.85 R
0.85 R
TERMINAL
0.85 BY
0.85 GW
0.5 B
1 2 3 5 4 3 2 1 TERMINAL
0.85 R
0.85LY
0.5 GR
0.85LR
0.85RY
1.25YG
1.25GB
1.25LW
4 5 6 7 8 CONNECTOR (4P)
AI01 0.5 L
AT01 3.0 B
FE01 0.5 G
AP01 0.5 Y
AQ01 0.5 R
AV01 3.0 W
AK01 0.85Y
AW01 3.0 G
FC01 0.5 YL
EB01 0.5 GL
AS01 0.5 RL
AB01 0.5 RB
AU01 0.5 BY
FD01 0.5 RG
AC01 0.5 GY
AU01 0.5 YR
AH01 0.5 RY
AF01 0.85RL
AE01 0.5 LW
AR01 0.5 YG
AN01 0.5 WL
FB01 0.5 GW
FA01 0.85GY
AJ01 0.85GR
AG01 0.5 LW
DA01 0.85YR
AA01 0.5 GW
AO01 0.5 BW
AM01 0.85YB
GA01 1.25YG
AL01 0.85RW
1 2 3 4 5 6
1 2 3 4
0.5 Y
0.5 Y
1.25 LB
1.25 LO
1.25 YG
1.25 GY
0.85B
1.25 WB
1.25 WB
0.85R
0.85R
0.5 RW
0.5 GW
11 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 1 2 3 4 5 4 3 2 1
CONNECTOR (5P)
E/G HARNESS E/G HARNESS E/G HARNESS
GND ACC OIL PRESS ALT TERMINAL
SW (CAB) (LPG) (OP LAMP)
BATT
R GEAR E/G HARNESS
D/B HARNESS D/B HARNESS PRESSURE SW

D/B HARNESS PRESSURE SW
CONNECTOR (8P) 1 (LPG) (LPG)
STEEL CAB TERMINAL 6 3 2 1 (CAB) 1 2 3 4 5
1 2 3 4 5 1 2 3 4 5
8 7 6 5 4 1 2 3 4 5 6 7 8
0.5 GB 0.5 GB
0.5 BY
0.5 BY
WINDOW VALVE-SOL(GAS) VALVE-SOL(LPG)
WASHER
0.5 LR 0.85LY
(TANK) 0.5 G
1.25 YW 1.25 L
1 2
1.25 LW 1.25 LW
1.25 WB 1.25 YW
VALVE-SOL(LPG)
1.25 L 1.25 WB 1.25 WB 1.25 WB VALVE-SOL(VAPO)
1 2 3 4
1 2 3 4
1.25 G 1.25 G 0.85LY
1 2
1 2
10A 10A
0.85LY
0.85G
1 2
R WIPER MOTOR
1.25 WB
VALVE-SOL(VAPO) VALVE-SOL(VAC)
0.5 Y
1.25 L
ST ST
1.25 YR
1.25 WB
(FUSE, i) 0.85LY (FUSE, i) 0.85LY
1 2 3 4
1.25 YR
0.85G 0.85G
1 2
1 2
EARTH
LPG (DUAL) LPG (ONLY)
20A VALVE-SOL(VAC)
0.85LY
0.85G
1 2
BATTERY R WIPER RELAY

STRUCTURE AND FUNCTION
AX50/BX50 Series
CRITERIA FOR PERIODICAL INSPECTION AND JUDGMENT POWER TRAIN
Device Check Item Check Point

22. Transmission 2) Check transmission for oil leakage
(To be continued) Replace the packing if stained oil becomes oil droplets.
3) Check transmission oil for proper amount level
Park the truck on flat and even surface ground and check with oil lever gauge.
Air Breather for Transmission Air Breather for Transmission

Air Breather for
Differential
Oil Level Gauge Line Filter

Strainer Drain Plug
4. Inching Pedal (TORQFLOW type)

1) Inching spool stroke
Stroke A 24.5
Be very careful so that the cable do not

press the inching pedal when it is A
released
Initial set
Power Train
Reference: 13 mm
2) Interconnected Stroke
Adjust the stroke with the adjusting
screw so as to interlock with the brake Adjusting screw
pedal with the inching pedal being
specified value
1.0 – 3.0 ton

36 – 40 mm
3.5 ton
Inching pedal
3) Pedal Stroke
1.0 – 1.75 ton 76 – 102 mm
2 .0 – 3.0 ton 90 – 116 mm
3.5 ton 80 – 106 mm Pedal stroke
159 mm
4) Play
Play 0 – 4 mm

2006.2.20(1)
POWER TRAIN CRITERIA FOR PERIODICAL INSPECTION AND JUDGMENT
Device Check Item Check Point

23. Torque Make sure to place the wheel stoppers at each wheel and apply the parking
Converter brake for sure prior to following inspection
1. Clutch Oil Pressure
Select F/R lever from either direction of forward or reverse and press the pedal for
measuring the oil pressure
Clutch Oil Pressure 0.19 – 1.13 Nm (9.3 – 13.4 kgf/cm2)
2. Stall Speed
Select F/R lever from either direction of forward or reverse and floored the pedal to
the maximum speed for measuring the engine speed.
K15 engine 2200 ± 150 prm
K21 engine (1 ton H type/2 ton) 1900 ± 150 prm/1850 ± 150 prm
K25 engine 2000 ± 150 prm
4D92E engine 1850 ± 150 prm
4D94LE engine 2000 ± 150 prm
4D98E engine 2200 ± 150 prm
Be careful not to operate too long for the inspection as it may increase in temperature
of the oil in the torque converter
3. Torque Converter Inlet Port Pressure: 0.5 – 0.7 MPa (5 – 7 kgf/cm2)
4. Torque Converter Outlet Port Pressure

Power Train
Torque Converter Assembly Oil Pres-

sure Port Location
A. Torque Converter Inlet Oil Pres-
sure Measuring Port
B A
B. Main Oil Pressure Measuring Port
C. Lubrication Oil Pressure Measur-
ing Port
Control Valve Assembly Oil Pressure Port

Location P1
C1. Forward Clutch Oil Pressure Mea-
suring Port (PT1/8z)
C2. Reverse Clutch Oil Pressure Mea-
suring Port
P1. Main Oil Pressure Measuring Port C2
C1

2005.5.13(1)
90. CONVERSION TABLE
MILLIMETERS TO INCHES ......................................90-2

INCHES TO MILLIMETERS ......................................90-2
CUBIC METERS TO CUBIC YARDS ........................90-3
CUBIC YARDS TO CUBIC METERS ........................90-3
LITER TO U.S. GALLON ...........................................90-4
U.S. GALLON TO LITER ...........................................90-4
LITER TO U.K. GALLON ...........................................90-5
U.K. GALLON TO LITER ...........................................90-5
KILOGRAM TO POUND ............................................90-6
POUND TO KILOGRAM ............................................90-6
KG/CM2 TO IB/IN2 .....................................................90-7
KGM TO FT IB ...........................................................90-8
TEMPERATURE ........................................................90-9

MILLIMETERS TO INCHES
INCHES TO MILLIMETERS CONVERSION TABLE
CONVERSION TABLE
Millimeters to Inches 1mm=0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.881 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 2.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Inches to Millimeters
0.1 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0 0.254 0.508 0.762 1.016 1.270 1.524 1.778 2.032 2.286
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146

CUBIC METERS TO CUBIC YARDS
CONVERSION TABLE CUBIC YARDS TO CUBIC METERS
Cubic meters to Cubic yards 1m3= 1.308 cu.yd
0 1 2 3 4 5 6 7 8 9
1.31 2.62 3.92 5.23 6.54 7.85 9.16 10.46 11.77
10 13.08 14.39 15.70 17.00 18.31 19.62 20.93 22.24 36.62 24.85
20 26.16 27.47 28.78 30.08 31.39 32.70 34.01 35.32 36.62 27.93
30 39.24 40.55 41.86 43.16 44.47 45.78 47.09 48.40 49.70 51.01
40 52.32 53.63 54.94 56.24 57.55 58.86 60.17 61.48 62.78 64.09
50 65.40 66.71 68.02 69.32 70.63 71.94 73.24 74.56 75.86 77.17
60 78.48 79.79 81.10 82.40 83.71 85.02 86.33 87.64 88.94 90.25
70 91.56 92.87 94.18 95.48 96.79 98.10 99.41 100.72 102.02 103.33
80 104.64 105.95 107.26 108.56 109.87 111.18 112.49 113.80 115.10 116.41
90 117.72 119.03 120.34 121.64 122.95 124.26 125.57 126.88 128.18 129.49
Cubic yards to Cubic meters
0 1 2 3 4 5 6 7 8 9
0.76 1.53 2.29 3.06 3.82 4.59 5.35 6.12 6.88
10 7.65 8.41 9.18 9.94 10.70 11.47 12.23 13.00 13.76 14.53
20 15.29 16.06 16.82 17.59 18.35 19.12 19.88 20.64 21.41 22.17
30 22.94 23.70 24.47 25.23 26.00 26.76 27.53 28.29 29.05 29.82
40 30.58 31.35 32.11 32.88 33.64 34.41 35.17 35.94 36.70 37.47
50 38.23 38.99 39.76 40.52 41.29 42.05 42.82 43.58 44.35 45.11
60 45.88 46.64 47.41 48.17 48.93 49.70 50.46 51.23 51.99 52.76
70 53.52 54.29 55.05 55.82 56.58 57.35 58.11 58.57 59.64 60.40
80 61.17 61.93 62.70 63.46 64.23 64.99 65.76 66.52 67.28 68.05
90 68.81 69.58 70.34 71.11 71.87 72.64 73.40 74.17 74.93 75.70

LITER TO U.S GALLON
U.S. GALLON TO LITER CONVERSION TABLE
Liter to U.S. Gallon 1 = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
U. S. Gallon to Liter 1 U.S. Gal = 3.7854
0 1 2 3 4 5 6 7 8 9
3.79 7.57 11.36 15.14 18.93 22.71 26.50 30.28 34.07
10 37.85 41.64 45.43 49.21 53.00 56.78 60.57 64.35 68.14 71.92
20 75.71 79.49 83.28 87.06 90.85 94.64 98.42 102.21 105.99 109.78
30 113.56 117.35 121.13 124.92 128.70 132.49 136.27 140.06 143.85 147.63
40 151.42 155.20 158.99 162.77 166.56 170.34 174.13 177.91 181.70 185.49
50 189.27 193.06 196.84 200.63 204.41 208.20 211.98 215.77 219.55 223.34
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 353.62 257.41 261.19
70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05
80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90
90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76

LITER TO U.K GALLON
CONVERSION TABLE U.K. GALLON TO LITER
Liter to U.K. Gallon 1 = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0.200 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
U. K. Gallon to Liter 1 U.K. Gal = 4.5461
0 1 2 3 4 5 6 7 8 9
4.55 90.09 13.64 18.18 22.73 27.28 31.82 36.37 40.92
10 45.64 50.01 54.55 59.10 63.65 68.19 72.74 77.28 81.83 86.38
20 90.92 95.47 100.01 104.56 109.11 113.65 118.20 112.74 127.29 131.84
30 136.38 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76
50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22
60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68
70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14
80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60
90 409.15 413.69 418.24 422.79 427.33 431.88 436.42 440.97 445.52 450.06

KILOGRAM TI POUND
POUND TO KILOGRAM CONVERSION TABLE
Kilogram to Pound 1Kg = 2.2046 Ib
0 1 2 3 4 5 6 7 8 9
2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Pound to Kilogram 1 Ib = 0.4536Kg
0 1 2 3 4 5 6 7 8 9
0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082
10 4.536 4.990 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154
30 13.608 14.061 14.515 14.969 15.422 15.876 16.329 16.783 17.237 17.690
40 18.144 18.597 19.051 19.505 19.958 20.412 20.865 21.319 21.772 22.226
50 22.680 23.133 23.587 24.040 24.494 24.948 25.401 25.855 26.308 26.762
60 27.216 27.669 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298
70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843
80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906

CONVERSION TABLE KG/CM2 TO IB /IN2
Kg/cm2 to Ib/in2 1Kg/cm2 = 14.2233 Ib/in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1644 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1946 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 223 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2360 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3124 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

KGM TO FT. IB CONVERSION TABLE
Kgm to ft. Ib 1Kg.m = 7.233 ft. Ib
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1220.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

CONVERSION TABLE TEMPERATURE
Temperature
Fahrenheit–Centigrade Conversion. –A simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired it convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
–40.4 –40 –40.9 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.6 17 62.6 11.1 52 125.6 30.6 84 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.8 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 112.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

NOTES:
MASTS - 50/55/60-MS & MT MASTS
Measuring Chain Stretch

Regular inspection and lubrication of the chains will
increase their service life and decrease down-time.
If the chains stretch beyond the recommended specifica-

tion, they should be replaced in pairs. Chain stretch can
be measured with a chain wear scale, Part Number
CC661923. Measure the chains according to the instruc-
tions printed on the chain wear scale, without a load on
the carriage.
• To check hoist chains, raise the carriage 1 foot
(30cm) off the ground to put tension on the chains.
See the figure at right.
Hoist Chain Adjustment

The hoist chains should be adjusted so that when the
unloaded mast is fully lowered, the carriage is in position
as shown at right.
To adjust the hoist chains:

• Adjust one chain to achieve the correct carriage posi-
tion when fully lowered. See two illustrations at right.
• Adjust the other chain to achieve chain tension.
08-15
Section 2 Installation Instructions
2.4
Inspection and
Adjustments
2.4-1 Chain Inspection and
Tension
The hoist Chains have been factory lubricated using heat and
CUSHION TIRE PNEUMATIC TIRE
pressure to force the lubricant thoroughly into the chain links. 3 in. Underclearance 5 in. Underclearance
Avoid removal or contamination of this factory applied
lubricant. Do not wash, sand blast, etch, steam clean, or
paint the chains for internal mast installation. Uprights and
Carriage
Flush
The chains must be adjusted with equal tension to ensure Uprights
Flush
proper load distribution and mast operation. To determine
equal tension, extend the unloaded mast to put the chains Carriage 2 in.
under tension. Press the center of a strand of chain with your Below Uprights
thumb, then press at the same place on the other chain of the
MA1154.eps
pair. Each chain in a pair should have equal “give”. If they
Figure 5. Upright and Carriage Position.
do not have equal tension, preform the hoist chain adjust-
ments described in Sections 5.6-3 and 5.6-4.
Main Lift
Chain Anchors
Main Lift
Adjusting Nuts
MA1156.eps
Figure 6. Main Lift Chains.
Free Lift
MA1155.eps Adjusting
Nuts
Figure 7. Free Lift Chains.
7
MASTS - 35D/45D QUAD MAST
9.6 CHAINS
Lubrication, Adjustments and Wear
Regular lubrication and adjustments of the chains will
increase their service life and decrease mast downtime.
The chains should be covered with a thin film of lubri-
cant at all times. If the chains are dry, lubricate the full
length of the chains with SAE 40 wt. oil.
The chains should be adjusted for:

1. Correct upright and carriage position
2. Equal tension to ensure proper load distribution
and mast operation
If the carriage and uprights are not in the proper posi-
tion, or if chain tension is not equal, adjust the chains as
described in Sections 9.8 and 9.9.
The chains should be free of any of the damage shown

at right. If inspection reveals that one strand of a pair of
chains requires replacement, both strands of the pair
should be replaced.
• Check for rust.
• Check for cracked side plates. If damage is found,

replace both strands of chain.
• Check for tight joints. If tight points are caused by

rust or corrosion, loosen them with SAE 40 wt. oil or
penetrating oil. If they cannot be loosened, or if the
tight joints are caused by bent pins or plates or by
peened plate edges, replace both strands of the
chain pair.
• Check for protruding or turned pins. If damage is

found, replace both strands of the chain pair.
• Check for side wear. If pins or outside plates show

signs of wear, check for misalignment of sheaves,
anchors or other components. Correct the misalign-
ment. If wear is excessive, replace both strands of
the chain pair.
• Check for worn, broken or misaligned chain

anchors. Replace or adjust as required.
08-70
MASTS - 35D/45D QUAD MAST
9.7 MEASURING CHAIN STRETCH

Chain stretch can be measured with a Chain
Wear Scale. Measure the chains according to
the instructions printed on the scale, without a
load on the carriage. If the chains are stretched
beyond the recommended amount, they should
be replaced in pairs.
• To check the free lift chains, raise the car-
riage 1 ft. (30cm) off the ground to put ten-
sion on the chains.
• To check the main lift chains, raise the mast
until the inner upright starts to extend to
place tension on the chains.
9.8 OUTER AND INNER MAIN LIFT CHAIN ADJUSTMENT

The main lift chains should be adjusted so that
when the unloaded mast is fully lowered, the
uprights are flush at the bottom.
1. Locate the four main lift threaded chain anchors
on the back side top of the outer and outer inter-
mediate uprights on each side of the main lift cyl-
inders.
2. Adjust one anchor of the outer main lift chain pair
first to achieve a flush inner intermediate upright
position with the mast outer uprights.
3. Adjust the other anchor of the pair to achieve
equal chain tension. Repeat Steps 1 and 2 for
the inner main lift chain pair to achieve a flush
inner upright position with the mast intermediate
uprights. Tighten the chain anchor nuts to 50 - 70
lbf./ft (68 - 95 Nm).
4. Raise and lower the mast several times to con-
firm the adjustments.
9.9 FREE LIFT CHAIN ADJUSTMENT

The free lift chains should be adjusted so that
when the unloaded mast is fully lowered, the car-
riage is properly positioned.
1. Locate the threaded chain anchors on the front
side of the inner upright crossmember on each
side of the free lift cylinder.
2. Adjust one anchor to achieve the correct carriage
position when lowered.
3. Adjust the other anchor to achieve equal chain
tension. Tighten the chain anchor nuts to 50- 70
lbf./ft (68 - 96 Nm).
4. Raise and lower the carriage several times to confirm the adjustments.
08-71
NOTES:
NOTES:
NOTES:
NOTES:
NOTES:
KOMATSU FORKLIFT USA, INC.
14481 Lochridge Blvd., Bldg. # 2
Covington, GA 30014-4908
TUSK LIFT TRUCKS

14481 Lochridge Blvd., Bldg. # 2
Covington, GA 30014-4908
(770) 385-4815 (Phone)

(770) 385-4838 (Fax)

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Gasoline, LPG and Dual-Fuel Engine Models

FG20ST-16 4,000 lb. capacity, K21 gasoline engine, cushion tires

FG20SHT-16 4,000 lb. capacity, K25 gasoline engine, cushion tires

FG20T-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires

FG20HT-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires

FG25ST-16 5,000 lb. capacity, K21 gasoline engine, cushion tires

FG25SHT-16 5,000 lb. capacity, K25 gasoline engine, cushion tires

FG25T-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires

FG25HT-16 5,000 lb. capacity, K25 gasoline engine, pneumatic tires

FG28SHT-16 5,500 lb. capacity, K25 gasoline engine, cushion tires

FG28HT-16 5,500 lb. capacity, K25 gasoline engine, pneumatic tires

Table Continued on Next Page

FG30SHT-16 6,000 lb. capacity, K25 gasoline engine, cushion tires

FG30HT-16 6,000 lb. capacity, K25 gasoline engine, pneumatic tires

FG32HT-16 6,500 lb. capacity, K25 gasoline engine, cushion tires

FG32HT-16 6,500 lb. capacity, K25 gasoline engine, pneumatic tires

FG35AHT-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires

Diesel Engine Models

FD20T-16 4,000 lb. capacity, 4D94E diesel engine, pneumatic tires

FD25T-16 5,000 lb. capacity, 4D94E diesel engine, pneumatic tires

FD28T-16 5,500 lb. capacity, 4D94E diesel engine, pneumatic tires

FD30T-16 6,000 lb. capacity, 4D94E diesel engine, pneumatic tires

FD32T-16 6,500 lb. capacity, 4D94E diesel engine, pneumatic tires

FD35AT-16 7,000 lb. capacity, 4D94E diesel engine, pneumatic tires

TUSK MODEL DESCRIPTION

Gasoline, LPG and Dual-Fuel Engine Models

400CG-16 4,000 lb. capacity, K21 gasoline engine, cushion tires

400CGH-16 4,000 lb. capacity, K25 gasoline engine, cushion tires

500CG-16 5,000 lb. capacity, K21 gasoline engine, cushion tires

500CGH-16 5,000 lb. capacity, K25 gasoline engine, cushion tires

550CGH-16 5,500 lb. capacity, K25 gasoline engine, cushion tires

600CGH-16 6,000 lb. capacity, K25 gasoline engine, cushion tires

650CGH-16 6,500 lb. capacity, K25 gasoline engine, cushion tires

400PG-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires

400PGH-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires

500PG-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires

500PGH-16 5,000 lb. capacity, K25 gasoline engine, pneumatic tires

TUSK MODEL DESCRIPTION

550PGH-16 5,500 lb. capacity, K25 gasoline engine, pneumatic tires

600PGH-16 6,000 lb. capacity, K25 gasoline engine, pneumatic tires

650PGH-16 6,500 lb. capacity, K25 gasoline engine, pneumatic tires

700PGH-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires

Diesel Engine Models

500PD-16 5,000 lb. capacity, 4D94E diesel engine, pneumatic tires

550PD-16 5,500 lb. capacity, 4D94E diesel engine, pneumatic tires

600PD-16 6,000 lb. capacity, 4D94E diesel engine, pneumatic tires

650PD-16 6,500 lb. capacity, 4D94E diesel engine, pneumatic tires

700PD-16 7,000 lb. capacity, 4D94E diesel engine, pneumatic tires

1.4 Operation Type Sitting Sitting

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

4.20 Length, to Fork Face mm 2195 2195

Loaded mm/s 500 500

7.2 Rated Output, SAE gross KW 27@2500 35@2450

8.2 Relief Pressure for Attachment bar 172 172

10-2 AX50/BX50 Series

AX50/BX50 Series 10-3

BX50 (2.0 - 2.5ton) Series

1.4 Operation Type Sitting Sitting