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

7
7.13.8 ASSEMBLE HYDRAULIC PUMP - FRONT PUMP SECTION - GASOLINE (CUSHION)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-152
7.13.9 INSPECTION AND REPAIR - HYDRAULIC PUMP - GASOLINE (CUSHION) . 7-153
7.14 HYDRAULIC PUMP - DIESEL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-154
HYDRAULIC PUMP - FRONT UNIT - DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . 7-154
7.14.1 DISASSEMBLE HYDRAULIC PUMP - FRONT PUMP UNIT - DIESEL . . . . . . . 7-155
7.14.2 INSPECT AND REPAIR HYDRAULIC PUMP - DIESEL . . . . . . . . . . . . . . . . . . 7-156
7.14.3 REASSEMBLE HYDRAULIC PUMP FRONT PUMP UNIT - DIESEL . . . . . . . . 7-157
HYDRAULIC PUMP - OIL SEAL INSTALLATION JIG DIAGRAM . . . . . . . . . . 7-160
HYDRAULIC PUMP - REAR UNIT - DIESEL - PARTS BREAKDOWN . . . . . . 7-161
7.14.4 DISASSEMBLE HYDRAULIC PUMP REAR PUMP UNIT - DIESEL . . . . . . . . . 7-162
7.14.5 INSPECT AND REPAIR HYDRAULIC PUMP - DIESEL . . . . . . . . . . . . . . . . . . 7-162
7.14.6 REASSEMBLE HYDRAULIC PUMP - REAR PUMP UNIT - DIESEL. . . . . . . . . 7-164
7.15 TEST HYDRAULIC PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-167
7.16 HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-169
7.16.1 ASSEMBLE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-169
7.16.2 SET PRESSURE ON WORK PORT RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-170
7.16.3 SERVICING AND REPAIR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-170
7.16.4 SHUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-171
7.16.5 SERVICE INFORMATION COMBINATION WORK PORT RELIEF/ANTI-VOID UNIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-172
7.17 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-173
TILT CYLINDER - PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-173
7.17.1 DISASSEMBLE TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-174
7.17.2 INSPECT TILT CYLINDER PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-174
7.17.3 ASSEMBLE TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-175
7.18 SIDESHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-176
7.19 COMBINATION SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-177
COMBINATION SWITCH PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . 7-177
7.19.1 REPLACE COMBINATION SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 7-178
7.19.2 REPLACE LIGHTING AND F/R SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-179
8. TROUBLESHOOTING
8.1 ENGINE TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 TORQFLOW TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 TORQUE CONVERTER TROUBLESHOOTING CHART - CUSHION TRUCKS . . . . . . 8-9
8.4 TORQUE CONVERTER TROUBLESHOOTING CHART - PNEUMATIC TRUCKS . . . . 8-11
8.5 TORQFLOW CONTROL VALVE TROUBLESHOOTING CHART -
CUSHION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.6 TORQFLOW CONTROL VALVE TROUBLESHOOTING CHART -
PNEUMATIC 8-14
8.7 ELECTRICAL SYSTEM TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.8 STEERING SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.9 POWER STEERING VALVE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . 8-18
8.10 BRAKE SYSTEM TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.11 HYDRAULIC SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.12 HYDRAULIC PUMP TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

8
9. 80D/100D/110D - MS 2-STAGE MAST
10. 80D/100D/110D - MT 3-STAGE MAST
11. CONVERSION TABLES
11.1 MILLIMETERS TO INCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53
11.2 INCHES TO MILLIMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53
11.3 CUBIC METERS TO CUBIC YARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-54
11.4 CUBIC YARDS TO CUBIC METERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-54
11.5 LITER TO U.S. GALLON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55
11.6 U.S. GALLON TO LITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55
11.7 KILOGRAM TO POUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56
11.8 POUND TO KILOGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56
11.9 KILOGRAMS PER SQUARE CENTIMETER TO POUNDS PER SQUARE INCH . . . . 11-57
11.10 KILOGRAM TO FOOT POUNDS OF FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-58
11.11 TEMPERATURE - FAHRENHEIT TO CENTIGRADE CONVERSION . . . . . . . . . . . . . 11-59
A. SERVICE DIAGRAMS
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
ELECTRICAL ASSEMBLY DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-24
TRANSMISSION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-35
DRIVE AXLE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-43
STEERING AXLE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-53
FRAME DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-57
PIPING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-63
CONTROL VALVE DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-75
B. E-SERIES SIDESHIFTER
C. D-SERIES SIDESHIFTER

FORKLIFT TRUCKS COVERED IN THIS PUBLICATION
9
FORKLIFT TRUCKS
COVERED IN THIS PUBLICATION
S/N 130001A~
KOMATSU MODEL
DESIGNATION DESCRIPTION ENGINE
Gasoline and LPG Trucks
FG35ST-8 8,000 lb. capacity, cushion tire truck, 1-speed transmission TB45
FG35BCS-8 8,000 lb. capacity, cushion tire truck, Box Car Special (BCS), 1-spd. trans. TB45
FG40ZT-8 8,000 lb. capacity, pneumatic tire truck, compact wheelbase, 1-spd. trans. TB45
FG40ZT2-8 8,000 lb. capacity, pneumatic tire truck, compact wheelbase, 2-spd trans. TB45
FG40T-8 9,000 lb. capacity, pneumatic tire truck, long wheelbase, 1-spd. trans. TB45
FG40T2-8 9,000 lb. capacity, pneumatic tire truck,long wheelbase, 2-spd. trans. TB45
FG45T-8 10,000 lb. capacity, pneumatic tire truck, long wheelbase, 1-spd. trans. TB45
FG45T2-8 10,000 lb. capacity, pneumatic tire truck, long wheelbase, 2-spd. trans. TB45
FG45ST-8 10,000 lb. capacity, cushion tire truck, long wheelbase, 1-spd. trans. TB45
FG45BCS-8 10,000 lb. capacity, cushion tire truck, Box Car Special (BCS), 1-spd. trans. TB45
FG50AT2-8 11,000 lb. capacity, pneumatic tire truck, long wheelbase, 2-spd. trans. TB45
Diesel Trucks
FD40ZT-8 8,000 lb. capacity, pneumatic tire truck, compact wheelbase, 1-spd. trans. S6D102E
FD40ZT2-8 8,000 lb. capacity, pneumatic tire truck, compact wheelbase, 2-spd. trans. S6D102E
FD40T-8 9,000 lb. capacity, pneumatic tire truck, long wheelbase, 1-spd. trans. S6D102E
FD40T2-8 9,000 lb. capacity, pneumatic tire truck, long wheelbase, 2-spd. trans. S6D102E
FD45T-8 10,000 lb. capacity, pneumatic tire truck, long wheelbase, 1-spd. trans. S6D102E
FD45T2-8 10,000 lb. capacity, pneumatic tire truck, long wheelbase, 2-spd. trans. S6D102E
FD50AT2-8 11,000 lb. capacity, pneumatic tire truck, long wheelbase, 2-spd. trans. S6D102E

FEDERAL EPA EMISSION CONTROL STATEMENT
11
FEDERAL EPA EMISSION CONT ROL STATEMENT
FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (TB45E ENGINES)
This section presents information concerning the correct labeling, warranty, parts and maintenance of TB45E
engines in order to comply with the EPA off-road, large-spark-ignition (LSI) engine regulations.
1. LABELS REQUIRED AND LABEL LOCATIONS
All engines will display the required identification label as follows. Note that decal content will vary between gaso-
line, LP and Dual-Fuel engines.
Location on TB45E Series engines: (Includes TB45D, TB45G and TB45L Series)
Emission compliance label (DUAL-FUEL (D) SAMPLE shown below)

FEDERAL EPA EMISSION CONTROL STATEMENT
12
2. WARRANTY
The following statement is hereby provided as required by regulations of the United States Environmental Protec-
tion Agency (EPA).
YOUR WARRANTY RIGHTS AND OBLIGATIONS
All off-road large spark-ignition (LSI) engines must be designed, built and equipped to meet the Federal EPA’s
stringent anti-smog standards.
Komatsu Forklift USA, Inc. (“”) must warrant the emission control system on your engine for the periods of time
listed below provided there has been no abuse, damage, neglect or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor, regulator or fuel-injection system, ignition
system, engine computer unit (ECM), catalytic converter and air induction system.
Also included may be sensors, hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, an Authorized Dealer will repair your LSI engine at
no cost to you, including diagnosis, parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
Beginning January 1, 2004 off-road large spark-ignition EPA engines are warranted for the time periods listed
below. If any emission-related part on your engine is defective, the part will be repaired or replaced by an Autho-
rized Komatsu Forklift Dealer.
OWNER’S WARRANTY RESPONSIBILITIES
As the off-road LSI engine owner, you are responsible for the performance of the required maintenance listed in
your Operation and Maintenance Manual.
KFI recommends that you retain receipts covering maintenance on your off-road engine, but KFI cannot deny war-
ranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
As the off-road large spark-ignition engine owner, you should be aware, however, that KFI may deny you warranty
coverage if your off-road large spark-ignition engine, or a part thereof, has failed due to abuse, damage, neglect,
improper maintenance or unapproved modifications.
Your engine is designed to operate on gasoline and/or LPG fuel. Use of any other fuel may result in your engine no
longer operating in compliance with the Federal EPA’s emissions requirements.
You are responsible for initiating the warranty process. It is suggested that you present your off-road large spark-
ignition engine to an Authorized Komatsu Dealer as soon as you become aware that a problem exists. The war-
ranty repairs should be completed by the dealer as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, you should contact the Komatsu
Product Support Dept. at 1-770-385-4815.
In addition to the standard warranty periods, the components listed below are covered by the following specific
warranty periods.

FEDERAL EPA EMISSION CONTROL STATEMENT
13
EMISSION CONTROL WARRANTY – 36 MONTHS OR 2,500 HOURS FOR GENERAL PARTS
For the first 2,500 operating hours, or for a period of thirty-six months from the date of the first use by the original
purchaser from an Authorized Komatsu Forklift Dealer, whichever occurs first, KFI warrants the following emission-
related parts:
EMISSION CONTROL WARRANTY – 36 MONTHS OR 4,000 HOURS FOR POWER TRAIN PARTS
• Intake manifold
• Exhaust manifold
EMISSION CONTROL WARRANTY – 60 MONTHS OR 3,500 HOURS FOR GENERAL PARTS
• ECM
• Catalytic converter
• Vaporizer
Follow the instructions in the Operations Manual concerning any other maintenance programs not
required for EPA compliance.
For questions and additional information concerning EPA Gasoline Engine Exhaust Regulations, contact:
Komatsu Forklift USA, Inc.
14481 Lochridge Blvd., Bldg. #2
Covington, GA 30014-4908
Voice phone: [phone]
Fax phone: [phone]
• Oxygen sensor • PCV valve
• Water temperature
sensor • Gasoline injector
• LPG injector • LPG pressure sensor
• LPG solenoid • LPG switching module
• Mass air flow sensor • Throttle chamber
• Ignition coil • Crankshaft position sensor
• Camshaft position sensor • Distributor
• Spark plugs
NOTICE

FEDERAL EPA EMISSION CONTROL STATEMENT
14
FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD DIESEL ENGINES
(S6D102E ENGINES)
Exhaust emissions produced by diesel engines are regulated by the United States Environmental Protection
Agency (EPA). This section presents information concerning the correct labeling, warranty, parts and maintenance
of S6D102E diesel engines in order to comply with current EPA regulations.
1. LABELS REQUIRED AND LABEL LOCATIONS
All certified S6D102E diesel engines will display the required identification labels (4) as follows:
• S6D102E diesel engines: Labels will be affixed to all appropriate engines on KFI production trucks.
Locations on S6D102E Series diesel engines:
1.1 EPA/EC CERTIFICATION DECAL (2 LOCATIONS) (SEE ITEM #1 IN PRECEEDING ILLUSTRATION)
1.2 EPA/EC CERTIFICATION ASSISTANCE PLATE (SEE ITEM #2 IN PRECEEDING ILLUSTRATION)
1.3 EPA/EC CERTIFICATION DATA PLATE (SEE ITEM #3 IN PRECEEDING ILLUSTRATION)

FEDERAL EPA EMISSION CONTROL STATEMENT
15
2. WARRANTY
The following statement is hereby provided as required by regulations of the United States Environmental Protec-
tion Agency (EPA).
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The Federal EPA and Komatsu Forklift USA, Inc. (hereinafter referred to as “KFI”) are pleased to explain the emis-
sion control system warranty on your 2004 or later Diesel heavy duty off-road engine. All new, heavy-duty off-road
engines must be designed, built and equipped to meet the EPA’s stringent anti-smog standards. KFI must warrant
the emission control system on your engine for the period of time listed below, provided there has been no abuse,
damage, neglect or improper maintenance of your engine.
Your emission control system may include parts such as fuel injection pump. Also included may be hoses, belts,
connectors and other emission-related assemblies.
Where a warrantable condition exists, an authorized Komatsu dealer will repair the heavy-duty off-road engine at
no cost to the owner, including diagnosis, parts and labor.
Now, KFI hereby certifies that diesel engines for lift trucks produced in 2004 model year and after shall be regu-
lated by Federal EPA exhaust gaseous regulations. The difference between current and EPA-certified engines is
only the labels attached on the engine. See available drawing and/or illustration of emission label and its location.

FEDERAL EPA EMISSION CONTROL STATEMENT
16
MANUFACTURER’S WARRANTY COVERAGE
Beginning January 1, 2004 heavy-duty off-road EPA engines are warranted for a period of five (5) years, or three-
thousand (3,000) hours of operation, whichever occurs first. If any emission-related part on your engine is defec-
tive, the part will be repaired or replaced by at an authorized Komatsu Forklift dealer.
EMISSION-RELATED PARTS
• Fuel injection pump
• Fuel injection nozzles
• Turbocharger
OWNER’S WARRANTY RESPONSIBILITIES
As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance
listed in owner's manual (Instruction Manual). KFI recommends that you retain all receipts and records covering the
maintenance on your engine, but KFI cannot deny warranty solely for the lack of receipts and records or for your
failure to ensure the performance of all scheduled maintenance. For your reference, the following is an emission
control maintenance schedule for certified Diesel engines.
• Check oil level and coolant level – Every day
• Change of engine oil– Every 200 hours
• Change lubricating oil filter – Every 200 hours
• Initial adjustment of valve clearance – Every 200 hours
• Change fuel filter – Every 500 hours
• Check turbocharger, rebuild or replace if necessary – Every 3,000 hours
• Adjust valve clearance – Every 1,000 hours
• Check fuel injection nozzles, replace if necessary – Every 3,000 hours
Keep records to show proof of compliance with the required maintenance practices and intervals.
• As the heavy-duty off-road engine owner you should, however, be aware that KFI may deny your war-
ranty coverage if your heavy-duty off-road engine or part has failed due to abuse, damage, neglect,
improper maintenance or disapproved modifications.
• Your engine is designed to operate on commercial diesel fuel only. Use of any other fuel in our engine
will result in the engine operating in non-compliance with the Federal EPA regulations.
You are responsible for initiating the warranty process. It is suggested that you present your heavy duty
off-road engine to an authorized Komatsu dealer as soon as you become aware that problem exists.
The warranty repair should be completed by the dealer as expeditiously as possible.
• If you have any questions regarding your warranty rights and responsibilities, you should contact the
authorized KFI dealer.
LIMITATIONS
KFI is not responsible for resultant damages to an emission-related part or component resulting from:
• Any application or installation KFI deems improper as explained in the Instruction Manual.
• Attachments, accessory items or parts not authorized for use by KFI.
• Improper off-road engine maintenance, repair or abuse.
• Owner's unreasonable delay in making the product available after being notified of a potential product
problem.
This warranty is in addition to the KFI standard warranty applicable to the off-road engine product involved.
Remedies under this warranty are limited to the provision of material and services as specified herein. KFI is not
responsible for incidental or consequential damages, such as downtime or lost use of the forklift truck.

FEDERAL EPA EMISSION CONTROL STATEMENT
17
CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEMS WARRANTY
Komatsu Forklift aims to ensure that the Emission Control Systems Warranty is properly administered. In the event
that you do not receive the warranty service to which you believe you are entitled under the Emission Control Sys-
tems Warranty, call or write to your Komatsu Forklift Dealer.
Authorized dealers are recommended for major maintenance and repair work, as they are staffed with trained per-
sonnel, proper tools and are aware of the latest maintenance methods and procedures. Owners and others who
desire to perform their own work should purchase a service manual and obtain current service information from
their KFI engine dealer.
Follow the instructions in the Operations Manual concerning any other maintenance programs not
required for EPA compliance.
For questions and additional information concerning EPA Diesel Engine Exhaust Regulations, contact:
Komatsu Forklift USA, Inc.
14481 Lochridge Blvd., Bldg. #2
Covington, GA 30014-4908
Voice phone: [phone]
Fax phone: [phone]
NOTICE