Komatsu CX20 Series User manual

Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory-installed guards and shields are properly
secured in place.
WARNING
SERVICE MANUAL
CX Forklift Truck
Federal Environmental Protection Agency (EPA) Emission-Control Compliant
S/N 130001A~
CX20
ISSUED: APRIL 2008
SM202
Gasoline & LP FG35/45ST-8
FG40/45T(2)-8
FG35/45BCS-8
FG50AT2-8
FG40ZT(2)-8
Diesel FD40/45T(2)-8
FD50AT2-8
FD40ZT(2)-8
Komatsu Forklift USA, Inc.

The information and specifications contained herein were accurate at the time of
publication, but may change without notice as required for product improvements.
Neither Komatsu Forklift USA, Inc., nor its parent company nor any of its subsidiaries will
be held responsible for damages due to misuse or inappropriate use of its products.
Requests for information, comments and other inquiries should be sent to:
Komatsu Forklift USA, Inc.
14481 Lochridge Blvd., Bldg. #2
Covington, Georgia 30014-4908
Voice phone: [phone]
Fax phone: [phone]
© Copyright 2008, Komatsu Forklift USA, Inc. All rights reserved. No part of this
document may be photocopied or reproduced in any way without prior written consent of
Komatsu Forklift USA, Inc.

3
INTRODUCTION
This Service Manual has been developed as an information resource to help the reader
learn about, understand, repair and maintain the CX20 Series forklift trucks, and the var-
ious equipment, systems, inspections, sensors, diagnostic procedures and diagnostic
equipment utilized to maintain, adjust and troubleshoot these systems. Although refer-
ence is made to maintenance procedures necessary to perform servicing of this vehicle,
you should refer to the applicable Operation and Maintenance Manual for these lift trucks
for more complete maintenance information.
Komatsu is involved in a concentrated and highly technical program of designing and
developing cleaner burning, more efficient and more powerful engines for use in the
industrial truck market. As a result, new computerized sensors, systems and diagnostic
monitors have been created to make the job of maintaining and repairing these systems
simple and easy.
Read this manual carefully, refer to it often and learn the repair, testing and adjustment
procedures to the best of your ability. Please note that some illustrations are generic and
may not look exactly like your unit in every detail.
Ensure that, when you are working on or around industrial trucks, Safety is priority
Number One. Read, understand and obey all WARNINGS and CAUTIONS.
Follow the instructions and procedures presented in this manual when working on these
lift trucks and their systems. Damage to the equipment, and possible injury to yourself or
others, may result if these procedures are not adhered to carefully.
Keep this manual nearby and accessible for use when necessary. If this book becomes
dirty, worn or illegible, contact Komatsu for a replacement. The procedures outlined in
this manual will be updated periodically. Be sure that you have the latest revision in order
to learn the newest information available. Revision dates will be clearly displayed on the
lower left hand corner of the cover page.
This will aid in maintaining your equipment in excellent condition and in ensuring that
these lift trucks will operate safely at maximum efficiency.

4
ENGINE SERIAL NUMBER LOCATION
The TB45E series engine serial number is
stamped on a flat machined, painted pad on the
right side of the engine block just behind the dis-
tributor. The right side is determined by the opera-
tor’s right side when seated on the lift truck.
The serial number faces upwards for ease of iden-
tification.
The S6D102E series engine serial number is
stamped on the left side of the engine to the left of
the oil filter.
NOTICE
For EPA TB45E(D)(G)(L) engine-related troubleshooting,
refer to the following manual:
• TM100 - “EPA Engine Training Manual”
NOTICE
For EPA S6D102E engine-related troubleshooting, refer
to the following manual:
• SM140 - “S6D102E Service Manual”

1
CONTENTS
Page No.
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FORKLIFT TRUCKS COVERED IN THIS PUBLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FEDERAL EPA EMISSION CONTROL STATEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1. SAFETY
1.1. SAFETY MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2. SAFE TRAVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3. LOADING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.4. SAFETY IN PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.5. TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1.6. STRUCTURE AND STABILITY OF THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.7. SAFETY LABELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1.8. OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.8.1 REAR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.8.2 HIGH LOAD BACKREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.8.3 WIDE FORK CARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.8.4 AUDIBLE SPEED ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.8.5 WARNING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
2. GENERAL INFORMATION & SPECIFICATIONS
2.1 SPECIFICATIONS - MAST DATA & FEATURES - INDOOR (CUSHION) TRUCK. . . . . 2-2
2.2 SPECIFICATIONS - MAST DATA & FEATURES - OUTDOOR (PNEUMATIC) TRUCKS 2-5
2.3 TRUCK DATA - CUSHION TIRE LIFT TRUCKS (INDOOR) . . . . . . . . . . . . . . . . . . . . . . 2-8
2.4 TRUCK DATA - PNEUMATIC TIRE LIFT TRUCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
3. SERVICE DATA
3.1 SERVICE DATA - GASOLINE ENGINE TRUCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 SERVICE DATA - DIESEL ENGINE TRUCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4. TESTING, ADJUSTING AND MEASURING
4.1 CHECK ENGINE OIL (TB45E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 ADJUST ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 ADJUST IGNITION TIMING (TB45E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 ADJUST SPARK PLUG GAP (TB45E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 ADJUST VALVE CLEARANCE (TB45E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6 ADJUST VALVE CLEARANCE (S6D102E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.7 ADJUSTMENT OF ENGINE DRIVE BELTS (TB45E) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7.1 BELTS IN SERVICE ON ENGINE - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7.2 INSTALL NEW BELT(S) - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.8 MEASURE ENGINE CYLINDER COMPRESSION (TB45E) . . . . . . . . . . . . . . . . . . . . . . 4-8
4.9 MEASURE HYDRAULIC DRIFT ON LIFT & TILT CYLINDERS . . . . . . . . . . . . . . . . . . . 4-10

2
4.10 ADJUST - TYPICAL MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.10.1 OUTER MAIN ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.10.2 INNER MAIN ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.10.3 FORK CARRIAGE - TYPICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.10.4 ADJUST CLEARANCE - THRUST PAD AND RAIL . . . . . . . . . . . . . . . . . . . . . . 4-13
4.10.5 CHANGE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.10.6 ADJUST CLEARANCE BETWEEN INNER MAST AND FORK CARRIAGE . . . 4-13
4.10.7 ADJUST CLEARANCE BETWEEN INNER MAST AND INTERMEDIATE MAST 4-14
4.11 ADJUST PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.12 ADJUST ACCELERATOR PEDAL (TB45E ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.13 ACCELERATOR PEDAL POSITION SENSOR - TB45 ENGINE . . . . . . . . . . . . . . . . . . 4-17
4.14 ADJUST ACCELERATOR PEDAL (S6D102E ENGINE). . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.15 MEASURE BRAKE STOPPING DISTANCE (BRAKING EFFECT). . . . . . . . . . . . . . . . . 4-19
4.16 ADJUST INCHING/BRAKE PEDAL (TORQFLOW TRUCKS) . . . . . . . . . . . . . . . . . . . . 4-19
4.16.1 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.16.2 INCHING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.16.3 INCHING PEDAL/BRAKE PEDAL INTERCONNECTED TRAVEL. . . . . . . . . . . 4-20
4.17 ADJUST STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.18 ADJUST WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.19 CHECK OPERATION OF THE AUTOMATIC ADJUSTMENT DEVICE . . . . . . . . . . . . . 4-23
4.20 CHECK TORQFLOW CLUTCH ACTUATION PRESSURE - PNEUMATIC TIRE . . . . . . 4-24
4.21 CHECK TORQUE CONVERTER STALL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.22 CHECK TORQFLOW CLUTCH ACTUATION PRESSURE - CUSHION TIRE . . . . . . . . 4-25
4.23 CHECK TORQUE CONVERTER STALL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.24 ADJUST INCHING VALVE/SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.25 TEST SPECIFIC GRAVITY OF BATTERY ELECTROLYTE . . . . . . . . . . . . . . . . . . . . . . 4-26
4.26 CHECK TIRES AND ADJUSTING PNEUMATIC TIRE PRESSURE. . . . . . . . . . . . . . . . 4-27
4.27 MEASURE MINIMUM LEFT AND RIGHT TURNING RADIUS . . . . . . . . . . . . . . . . . . . . 4-28
4.28 ADJUST TURNING RADIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.29 ADJUST REAR AXLE - THRUST CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
5. INSPECTION
5.1 INSPECT ENGINE STARTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 INSPECT ENGINE RUNNING CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 INSPECT AIR CLEANER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 INSPECT THE FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.5 INSPECT/RE-TORQUE CYLINDER HEAD MOUNTING BOLTS (TB45E) . . . . . . . . . . 5-3
5.6 INSPECT / RE-TORQUE CYLINDER HEAD BOLTS (S6D102E) . . . . . . . . . . . . . . . . . . 5-4
5.7 INSPECT ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.8 INSPECT THE ENGINE LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.9 INSPECT ENGINE FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.10 INSPECT DIESEL FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.11 INSPECT LPG VAPORIZER FOR TAR BUILDUP (TB45E) . . . . . . . . . . . . . . . . . . . . . . 5-6
5.12 INSPECT BLOW-BY GAS RECIRCULATION SYSTEM (TB45E). . . . . . . . . . . . . . . . . . 5-7
5.13 INSPECT COOLING SYSTEM AND RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.14 INSPECT COOLANT SUB-TANK LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

3
5.15 INSPECT FAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.16 INSPECT CHARGING SYSTEM WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.17 INSPECT FRONT AXLE AND RE-TORQUE MOUNTING BOLTS . . . . . . . . . . . . . . . . . 5-9
5.18 INSPECT REAR AXLE AND RE-TORQUE MOUNTING BOLTS . . . . . . . . . . . . . . . . . . 5-9
5.19 INSPECT WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.20 INSPECT RIM SIDE RING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.21 INSPECT WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.22 INSPECT STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.23 INSPECT STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.24 INSPECT LIGHTING/TURN SIGNAL SWITCH - W/O DIMMER SWITCH . . . . . . . . . . . 5-10
5.25 INSPECT LIGHTING/TURN SIGNAL SWITCH - WITH DIMMER SWITCH . . . . . . . . . . 5-11
5.26 INSPECT LIGHTING/TURN SIGNAL SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.27 INSPECT F/R SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.28 INSPECT POWER STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.29 INSPECT BRAKE SYSTEM RODS, CABLES AND LINKS . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.30 INSPECT BRAKE PIPING AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.31 INSPECT BRAKE MASTER AND WHEEL CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.32 INSPECT BRAKE SHOES AND ASSOCIATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.33 INSPECT BRAKE DRUMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.34 INSPECT BRAKE BACKING PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.35 INSPECT LOAD FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.36 INSPECT MAST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.37 INSPECT FORK CARRIAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.38 INSPECT LIFT CHAINS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.39 INSPECT CHAIN WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.40 INSPECT ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.41 INSPECT HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.42 INSPECT CHASSIS AND ATTACHMENT PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.43 INSPECT HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.44 INSPECT LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.45 INSPECT TILT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.46 INSPECT ATTACHMENT CYLINDERS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.47 INSPECT LIFT TRUCK CHASSIS AND FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.48 INSPECT CAB (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.49 INSPECT OPERATOR’S SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.49.1 VEHICLE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.49.2 TUSK OPERATOR PRESENT SYSTEM (TOPS) . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.49.3 CONTROLLER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.50 INSPECT EQUIPMENT USED FOR ACCESSING THE LIFT TRUCK . . . . . . . . . . . . . . 5-24
5.51 INSPECT DISPLAY PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.52 INSPECT OVERHEAD GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.53 INSPECT LIGHTS, GAUGES AND WARNING DEVICES . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.54 INSPECT REAR VIEW MIRROR AND REFLECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

4
6. MAINTENANCE OPERATIONS
6.1 LUBRICANT LIST - GASOLINE ENGINE LIFT TRUCKS . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 LUBRICANT LIST - DIESEL ENGINE LIFT TRUCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 OIL AND GREASING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4 CHANGE OIL AND FILTER IN GASOLINE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.5 CHANGE OIL AND FILTER IN DIESEL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.6 CHANGE GEAR OIL IN DIFFERENTIAL CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.6.1 CHECK DIFFERENTIAL OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.6.2 CHANGE DIFFERENTIAL OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.7 CHANGE TRANSMISSION FLUID IN TORQFLOW TRANSMISSION CASE . . . . . . . . 6-13
6.7.1 CHECK TORQFLOW TRANSMISSION FLUID LEVEL . . . . . . . . . . . . . . . . . . . 6-13
6.7.2 CHANGE TORQFLOW TRANSMISSION FLUID AND CLEAN THE STRAINER 6-13
6.8 CHANGE OIL IN HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.9 REPLACE FUEL FILTER - GASOLINE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.10 REPLACE FUEL FILTER - DIESEL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.11 REPLACE AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.12 CLEAN RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.13 CLEAN RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.14 BLEED AIR FROM BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
7. REMOVAL, DISASSEMBLY, ASSEMBLY, INSTALLATION
UNIT INSTALLATION POSITIONS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
OVERALL DISASSEMBLY/ASSEMBLY FLOW CHART. . . . . . . . . . . . . . . . . 7-3
WEIGHT TABLE - COMPONENT ASSEMBLIES AND PARTS . . . . . . . . . . . . 7-4
7.1 MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.1.1 MAST REMOVAL - TYPICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.1.2 MAST INSTALLATION - TYPICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2.1 ENGINE REMOVAL FROM CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2.2 ENGINE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2.3 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.3 TRANSMISSION AND DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.3.1 REMOVE TORQUE CONVERTER, TRANSMISSION, AND DRIVE AXLE . . . . 7-11
7.3.2 TORQUE CONVERTER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.3.3 TRANSMISSION AND DRIVE AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . 7-13
7.3.4 DRIVE AXLE SUPPORT MOUNTING BOLTS AND NUTS . . . . . . . . . . . . . . . . 7-13
7.3.5 INSTALL COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.4 TORQUE CONVERTER/TRANSMISSION CONTROL VALVE - PNEUMATIC TRUCKS 7-14
7.4.1 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.4.2 TRANSMISSION HYDRAULIC FLUID CIRCULATION PATH . . . . . . . . . . . . . . 7-17
TORQUE CONVERTER ASSEMBLY - FLUID DIAGRAM . . . . . . . . . . . . . . . . 7-18
TRANSMISSION CONTROL VALVE ASSEMBLY EXTERNAL VIEW. . . . . . . 7-19
TRANSMISSION CONTROL VALVE INTERNAL VIEW. . . . . . . . . . . . . . . . . . 7-19
TRANSMISSION CONTROL VALVE - PARTS BREAKDOWN . . . . . . . . . . . . 7-21
TRANSMISSION CONTROL VALVE - SPECIFICATIONS. . . . . . . . . . . . . . . . 7-23
HYDRAULIC CHARACTERISTICS OF THE INCHING VALVE . . . . . . . . . . . . 7-25
7.4.3 REMOVE TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.4.4 INSTALL TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.4.5 TORQUE CONVERTER (PNEUMATIC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

5
POSITION OF TORQUE CONVERTER HOUSING HYDRAULIC PORTS . . . . 7-28
TORQUE CONVERTER - TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . 7-29
TORQUE CONVERTER PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . 7-30
TORQUE CONVERTER - PART STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
GEAR PUMP ASSEMBLY - PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . 7-32
7.4.6 DISASSEMBLE TORQUE CONVERTER (PNEUMATIC) . . . . . . . . . . . . . . . . . 7-33
7.4.7 ASSEMBLE TORQUE CONVERTER (PNEUMATIC) . . . . . . . . . . . . . . . . . . . . 7-34
ASSEMBLED TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.4.8 TEST F1/R1 TRANSMISSION (SINGLE SPEED) . . . . . . . . . . . . . . . . . . . . . . . 7-36
F1/R1 TRANSMISSION - PART STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7.4.9 TEST F2/R1 TRANSMISSION (TWO SPEED). . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
F2/R1 TRANSMISSION - PART STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7.4.10 DISASSEMBLE TORQFLOW TRANSMISSION (PNEUMATIC TRUCKS) . . . . 7-42
7.4.11 DISASSEMBLE INPUT SHAFT CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . 7-45
7.4.12 DISASSEMBLE INTERMEDIATE SHAFT CLUTCH PACK . . . . . . . . . . . . . . . . 7-47
7.4.13 ASSEMBLE F1/R1 AND F2/R1 TRANSMISSION - INPUT SHAFT . . . . . . . . . . 7-49
ASSEMBLED F1/R1 AND F2/R1 TRANSMISSION - INPUT SHAFT . . . . . . . . 7-51
7.4.14 ASSEMBLE F2/R1 TRANSMISSION - INTERMEDIATE SHAFT (2ND SPEED) 7-52
ASSEMBLED F2/R1 TRANSMISSION - INTERMEDIATE SHAFT (2ND SPEED)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7.4.15 ASSEMBLE OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
7.4.16 ASSEMBLE F1/R1 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
ASSEMBLED F1/R1 TRANSMISSION - TORQFLOW TRANSMISSION . . . . . 7-62
7.4.17 ASSEMBLE F2/R1 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
7.5 TORQFLOW TRANSMISSION W/ TORQUE CONVERTER - CUSHION TRUCKS . . . . 7-67
TRANSMISSION CONTROL VALVE - PARTS BREAKDOWN . . . . . . . . . . . . 7-67
TRANSMISSION CONTROL VALVE - SPECIFICATIONS. . . . . . . . . . . . . . . . 7-68
7.5.1 DISASSEMBLE TRANSMISSION CONTROL VALVE (CUSHION TRUCKS) . . 7-69
TORQUE CONVERTER PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . 7-70
TORQUE CONVERTER - PARTS SPECIFICATION . . . . . . . . . . . . . . . . . . . . 7-71
HYDRAULIC CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
TORQUE CONVERTER PRESSURE TESTING PORTS . . . . . . . . . . . . . . . . . 7-73
7.5.2 SERVICE AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
7.5.3 DISASSEMBLE TORQFLOW TRANSMISSION (CUSHION TRUCKS). . . . . . . 7-75
7.5.4 DISASSEMBLE REVERSE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
7.5.5 DISASSEMBLE THE FORWARD MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 7-80
7.5.6 ASSEMBLE REVERSE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
ASSEMBLED MAIN SHAFT (REVERSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
7.5.7 ASSEMBLE FORWARD MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
ASSEMBLED MAIN SHAFT (FORWARD).. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
7.5.8 ASSEMBLE THE OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
7.5.9 ASSEMBLE TORQFLOW TRANSMISSION (CUSHION TRUCKS). . . . . . . . . . 7-88
7.6 DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
DRIVE AXLE - PARTS BREAKDOWN (PNEUMATIC). . . . . . . . . . . . . . . . . . . 7-93
DRIVE AXLE - TORQUE CHART (PNEUMATIC) . . . . . . . . . . . . . . . . . . . . . . . 7-94
DRIVE AXLE - PARTS BREAKDOWN (CUSHION) . . . . . . . . . . . . . . . . . . . . . 7-95
DRIVE AXLE - TORQUE CHART (CUSHION) . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
7.7 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
DIFFERENTIAL - TORQFLOW TRANSMISSION - PARTS BREAKDOWN . . 7-97
DIFFERENTIAL - TORQFLOW TRANSMISSION - SPECIFICATIONS . . . . . . 7-98
7.7.1 ADJUST DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
7.8 BRAKE BOOSTER AND MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104
BRAKE MASTER CYLINDER - PARTS BREAKDOWN. . . . . . . . . . . . . . . . . . 7-104

6
BRAKE MASTER CYLINDER/BRAKE BOOSTER DIAGRAM . . . . . . . . . . . . 7-106
7.8.1 BRAKE MASTER CYLINDER - DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 7-107
7.8.2 DISASSEMBLE BRAKE BOOSTER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
BRAKE BOOSTER & MASTER CYLINDER - SPECIFICATIONS . . . . . . . . . . 7-109
BRAKE BOOSTER & MASTER CYLINDER - INSPECTION & TESTING . . . . 7-110
7.8.3 ASSEMBLE BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
7.8.4 BRAKE BOOSTER - ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113
7.9 WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115
7.9.1 WHEEL BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115
WHEEL BRAKE - STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117
WHEEL BRAKE - DISASSEMBLY/ASSEMBLY DRAWING - CUSHION . . . . 7-119
WHEEL BRAKE - DISASSEMBLY/ASSEMBLY DRAWING - PNEUMATIC . . 7-120
7.9.2 INSTALL WHEEL BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121
7.9.3 INSTALL PEDAL ASSEMBLY - BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . 7-121
7.9.4 BRAKE SYSTEM - BLEEDING AIR FROM LINES. . . . . . . . . . . . . . . . . . . . . . . 7-122
7.10 STEERING AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123
7.10.1 REMOVE STEERING AXLE AND POWER STEERING CYLINDER . . . . . . . . . 7-123
POWER STEERING CYLINDER - STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . 7-124
STEERING AXLE BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
STEERING AXLE - LUBRICATION AND TORQUE VALUES . . . . . . . . . . . . . 7-126
STEERING AXLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
7.10.2 STEERING AXLE AND POWER STEERING CYLINDER INSTALLATION . . . . 7-128
7.11 POWER STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129
POWER STEERING CYLINDER - PARTS BREAKDOWN. . . . . . . . . . . . . . . . 7-129
7.12 POWER STEERING VALVE (ORBITAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130
POWER STEERING VALVE - PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . 7-130
7.12.1 REMOVE POWER STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131
7.12.2 DISASSEMBLE POWER STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131
7.12.3 CLEAN POWER STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136
7.12.4 ASSEMBLE POWER STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136
7.12.5 INSTALL POWER STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145
7.13 HYDRAULIC PUMP - GASOLINE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-146
HYDRAULIC PUMP - GASOLINE ENGINE (PNEUMATIC) PARTS BREAKDOWN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-146
7.13.1 DISASSEMBLE HYDRAULIC PUMP - REAR PUMP SECTION - GASOLINE
(PNEUMATIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147
7.13.2 DISASSEMBLE HYDRAULIC PUMP - FRONT PUMP SECTION - GASOLINE
(PNEUMATIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147
7.13.3 ASSEMBLE HYDRAULIC PUMP - REAR PUMP SECTION - GASOLINE
(PNEUMATIC) 7-147
7.13.4 ASSEMBLE HYDRAULIC PUMP - FRONT PUMP SECTION - GASOLINE
(PNEUMATIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-148
HYDRAULIC PUMP - GASOLINE ENGINE (CUSHION) PARTS BREAKDOWN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150
7.13.5 DISASSEMBLE HYDRAULIC PUMP - REAR PUMP SECTION - GASOLINE
(CUSHION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-151
7.13.6 DISASSEMBLE HYDRAULIC PUMP - FRONT PUMP SECTION - GASOLINE
(CUSHION) 7-151
7.13.7 ASSEMBLE HYDRAULIC PUMP - REAR PUMP SECTION - GASOLINE (CUSHION)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-151