SM Forklift Komatsu PDF

BED08E1-01
MACHINE MODEL SERIAL NO.
FG50/60/70-7 40001 and up
FD50/60/70/80-8 46001 and up
DX-Series 00-1
SECTION INDEX
00. FOREWORD
10. GENERAL AND SPECIFICATIONS
20. TESTING AND ADJUSTING
30. REMOVAL AND INSTALLATION
40. DISASSEMBLY AND ASSEMBLY
50. MAINTENANCE STANDARD
60. STRUCTURE AND FUNCTION
70. TROUBLESHOOTING
80. CHECK ITEMS FOR EACH EQUIPMENT
90. —
00-2 DX-Series
FOREWORD
For a machine and its components to maintain their performance for a long time, it is nec-
essary to carry out appropriate operation, preventive maintenance, troubleshooting, and
service to prevent failures or problems before they occur.
Of these operations, this shop manual gives information mainly on operations carried out
at a repair shop. These include an outline needed for service and maintenance operations,
together with details of the structure and function, inspection and maintenance, installation
and removal, disassembly and assembly, maintenance standards, troubleshooting, and
periodic inspection and adjustment of components for the machine. The units given for
tightening torques in this manual use the SI units as the standard, so a conversion table
is given at the end of the section 10.
This shop manual has been prepared with the target of making materials that will help you
to gain proper knowledge of the product, its structure and function, and proper methods for
maintenance, to use proper judgement and remedies when there is a failure or problem
with the machine, and to improve the quality of maintenance.
Always be sure that you fully understand the contents of this manual together with the Op-
eration and Maintenance Manual, and make full use of it when handling the machine.
DX-Series 00-3
PRECAUTIONS WHEN PERFORMING THE SERVICE WORK
Always pay attention to "Safety" before starting any work – this is important.
Never attempt any work where danger to yourself or to other persons.
Whenever work requiring safety precautions are described in this manual, a flag
mark inserted, always make double sure that safety measures are taken.
Other unmarked work, should always be performed after studying and using your
common sense to prevent accidents.
DESCRIPTION OF THE SYMBOLS

The symbols described below are used in this manual for convenience and better understanding
Symbol Item Description
Special safety precautions are needed to perform the

Safety
work.
a Note
Special technical precautions are needed to perform the
work.
Fastening parts that require specified tightening force

Tightening torque
when assembling.
Weight of parts or systems.

Weight
Places to be coated with adhesives, etc. When assem-

Coat
bling.
00-4 DX-Series
10. GENERAL AND SPECIFICATIONS
Specifications (FG50-7, FD50-8) ..................... 10- 2

Specifications (FD80-8).................................... 10- 8
Periodic replacement of consumable parts ...... 10-10
Safety items for maintenance........................... 10-11
Standard tightening torque............................... 10-20
How to use loctite............................................. 10-22
Conversion table .............................................. 10-23
DX-Series 10-1
GENERAL AND SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS (FG50-7, FD50-8)

• SPECIFICATION TABLE
Model Manufacturer's designation FG50-7 FD50-8
Characteristics
Power type Electric, diesel, gasoline, LPG, cable Gasoline Diesel

Operation type Pedestrian, driver standing, sitting, order picking Sitting Sitting
Rated capacity Q Rated capacity kg 5,000
Load center c Rated load center mm 600
Load distance x Front axle center to fork face mm 570
Wheelbase y mm 2,300
Service weight kg 7,340 7,645
Front kg 11,105 11,225
Weight
Loaded
Rear kg 1,235 1,420
Axle loading
Front kg 3,560 3,685
Unloaded
Rear kg 3,780 3,960
Tyre type Cushion, elastic cushion, pneumatic, polyurethane Pneumatic
Front 300-15-18PR(I)
Tyre size
Rear 8.25-15-12PR(I)
Tyre
Number of wheel Front/rear (x=driven) 2x/2

Tread, front b10 mm 1,580
Tread, rear b11 mm 1,640
Tilting angle a/ß degree 6/12
Mast height, lowered h1 mm 2,500
Std. free lift h2 mm 210
Std. lift height h3 mm 3,000
Mast height, extended h4 mm 4,350
Basic measurement
Height, overhead guard h6 mm 2,440

Length, with Std. forks l1 mm 4,690
Length, to fork face l2 mm 3,470
Width, at tyre b1 mm 1,880
Forks s/e/l Thickness/width/length mm 55x150x1,220
Fork carriage class Class IV, Type A
Width, fork carriage b3 mm 1,700
m1 Under mast mm 225
Ground clearance
m2 At center of wheelbase mm 280
Right angle stacking aisle Ast With 1,000 x 1,200 pallet, lateral mm 3,820
Turning radius Wa mm 3,250
Loaded,1st/2nd/3rd km/h 11.0/28.0 11.0/30.0
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 12.0/31.0 12.0/32.0
Lifting speed Loaded/unloaded mm/s 420/430 530/560
Performance
Lowering speed Loaded/unloaded mm/s 550/580

Max. drawbar pull Loaded at 1.5 km/h kN{kgf} 55{5,610} 49{5,000}
Max. gradeability Loaded at 1.5 km/h % 52 43
Service brake Operation/control Foot/hydraulic
Parking brake Operation/control Hand/mechanical
Steering Type Hydraulic power steering
Battery Voltage/capacity at 5-hour rating V/Ah 12/48 24/56
Make/model NISSAN/TB42 KOMATSU/S6D102E
Rated output (SAE gross) kW(HP) 66(88) 77(103)
Engine
Rated RPM rpm 2,300 2,250

Max. torque (SAE gross) Nm{kgf•m}/rpm 275{28}/1,900 392{40}1,600
No. of cylinder/displacement No. of cyl./l{cc} 6/4.169{4,169} 6/5.880{5,880}
Fuel tank capacity l 140
Relief pressure for attachment MPa{kgf/cm2} 17.5{178}
Others
Tank capacity l 70
Clutch Torque converter
Transmission TORQFLOW
10-2 DX-Series
• OUTSIDE VIEW DRAWINGS
DX-Series 10-3

Characteristics

Front kg 12,705 12,795
Weight
Loaded
Rear kg 1,495 1,650
Axle loading
Front kg 3,640 3,730
Unloaded
Rear kg 4,560 4,715
Front 8.25-15-12PR(I)
Tyre size
Rear 8.25-15-12PR(I)
Tyre

Basic measurement

Ground clearance
Travel speed (FWD)
Performance

Engine

Max. torque (SAE gross) Nm{kgf•m}/rpm 275{28}/1,900 392{40}/1,600
Others
Tank capacity l 70
10-4 DX-Series
DX-Series 10-5

Characteristics

Front kg 14,225 14,330
Weight
Loaded
Rear kg 1,775 1,915
Axle loading
Front kg 3,620 3,725
Unloaded
Rear kg 5,380 5,520
Front 8.25-15-14PR(I)
Tyre size
Rear 8.25-15-14PR(I)
Tyre

Basic measurement

Ground clearance
Travel speed (FWD)
Performance

Engine

Max. torque (SAE gross) Nm{kgf•m}/rpm 275{28}/1,900 392{40}/1,600
Others
Tank capacity l 70
10-6 DX-Series
DX-Series 10-7
SPECIFICATIONS (FD80-8)
Model Manufacturer's designation FD80-8
Characteristics
Power type Electric, diesel, gasoline, LPG, cable Diesel

Operation type Pedestrian, driver standing, sitting, order picking Sitting
Service weight kg 10,870
Front kg 16,820
Weight
Loaded
Rear kg 2,050
Axle loading
Front kg 4,740
Unloaded
Rear kg 6,130
Front 9.00-20-12PR(I)
Tyre size
Rear 9.00-20-12PR(I)
Tyre

Basic measurement

Fork carriage class Class 4, Type A
Ground clearance
Loaded,1st/2nd/3rd km/h 12.0/28.0
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 12.0/32.0
Lifting speed Loaded/unloaded mm/s 455/500
Performance

Max. drawbar pull Loaded at 1.5 km/h kN{kgf} 67{6,830}
Max. gradeability Loaded at 1.5 km/h % 39
Battery Voltage/capacity at 5-hour rating V/Ah 24/56
Make/model KOMATSU/SA6D102E
Rated output (SAE gross) kW(HP) 96(130)
Engine
Rated RPM rpm 2,250

Max. torque (SAE gross) Nm{kgf•m}/rpm 431{44}/1600
No. of cylinder/displacement No. of cyl./l{cc} 6/5.880{5,880}
Others
Tank capacity l 70
10-8 DX-Series
DX-Series 10-9
GENERAL AND SPECIFICATIONS PERIODIC REPLACEMENT OF CONSUMABLE PARTS
PERIODIC REPLACEMENT OF CONSUMABLE PARTS

For operation safety, never fail to perform period-
ic maintenance or make periodic replacement of
the consumable parts listed in the following.
These parts may deteriorate in time and are sus-
ceptible to wear. It is dificult to estimate the de-
gree of wear at time of periodic maintenance;
therefore, even if no apparent wear is found, al-
ways 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.
No. Part name Period of replacement
1 Master cylinder and wheel cylinder caps, dust seals Every 1 year
2 Brake hose or tube Every 2 years
3 Brake reservoir tank and tube Every 2 to 4 years
4 Power steering hose Every 2 years
5 Stop lamp switch (Oil pressure type) Every 2 years
6 Fuel hose Every 2 years
7 Rubber parts of power steering Every 2 years
8 Lift chain Every 3 years
9 Hose of laod handling Every 2 years
10-10 DX-Series
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
SAFETY ITEMS FOR MAINTENANCE

FOR SAFETY OPERATION
INSPECTION AND MAINTENANCE SHALL BE PERFORMED BY PERSONS WHO

HAVE BOTH SKILL AND EXPERIENCE IN MAINTENANCE.
• Inspection, maintenance, and repair of the vehicle shall be performed by persons who have sufficient knowl-
edge and experience in maintenance and repair.
• When inspecting and maintaining a new model or a new component, fully understand its structure, function,
and mechanism in advance.
THE SPECIFIC FREE INSPECTIONS SHALL BE PERFORMED BY QUALIFIED

PERSONS.
• The specific free inspections of the fork lift shall be performed by the "Fork lift inspectors".
PLACE FOR INSPECTION AND MAINTENANCE

• Perform inspection and maintenance on a flat, dry, and dustless place.
• When working in a warehouse, ventilate well.
• Keep the inside of the maintenance shop arranged well and work safely.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE WORK

• Prepare a fire extinguisher against a fire and learn how to use it.
• Before starting inspection work, lower the fork to the ground.
• Before starting inspection work, stop the engine.
• Run the engine only when necessary.
• Set the directional lever, high/low speed lever, and work equipment control lever in neutral.
• Pull the parking brake lever and put chocks in front and rear of the front and rear tires.
DX-Series 10-11
PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE

• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the
lift truck before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.
• Wear suitable clothes for the job.
• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the job.
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks
and mast from dropping.
• When carrying out job with another worker, decide who is the leader and carry out the job in accordance
with instructions from that person.
• After repairing, make sure that the trouble has been corrected by performing a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been
fully corrected or that defective parts have not been removed.
REPLACE SAFETY CRITICAL PARTS PERIODICALLY

• Even if no abnormality is found, always replace safety critical parts periodically.
As time passes, these parts deteriorate and may cause fire of failure in the work equipment system.
• However, if these parts show any abnormality before the replacement interval has passed, they should be
repaired or replaced immediately.
USE SUITABLE TOOLS

• Always use tools that are suited for inspection and maintenance.
It is extremely dangerous to use broken tools or tools designed for an-
other purpose.
10-12 DX-Series
PRECAUTIONS WITH HIGH TEMPERATURE COOLANT

• Immediately after using the lift truck, the engine coolant is at high temperature and high pressure. Do not
remove the radiator cap under these conditions.
Hot water may spurt out and cause burns.
• When removing the radiator cap, turn it slowly to release the internal
pressure.
• When checking the coolant level, stop the engine and wait for the en-
gine and radiator to cool down before checking. For lift trucks equipped
with a subtank or reservoir, check the level in the subtank.
• When adding water on lift trucks equipped with a subtank, add the wa-
ter to the subtank.
PROHIBITION OF WELDING OF FUEL TANK

• Never weld the fuel tank since it can explode.
PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL

• Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the filter
when the oil is hot. Hot oil may spurt out and cause burns.
• When carrying out inspection and maintenance, wait for the oil temper-
ature to go down, and carry out the operation in the order given in this
manual.
• Do not forget that the work equipment circuits are always under pres-
sure. Do not add oil, drain oil, or carry out maintenance or inspection
before completely releasing the internal pressure.
• If oil is leaking under high pressure from small holes, it is dangerous if
the jet of high-pressure oil hits your skin or eyes. Always wear safety
glasses and thick gloves, and use a piece of cardboard or a sheet of
plywood to check for oil leakage.
• Release the internal pressure before checking the accumulator piping.
• If you are hit by a jet of high pressure oil, consult a doctor immediately.
DX-Series 10-13
ROTATING FAN AND BELT

• It is extremely dangerous if you or any tool touches or gets caught in
the fan or fan belt when the fan is rotating. Never touch the fan when it
is rotating.
• Always stop the engine before inspecting rotating parts.
• When inspecting the areas around rotating parts, do not allow anything
to come close which may get caught.
BE CAREFUL NOT TO GET CAUGHT OR FALL

• Never put your hands or feet into the mast structure. There is danger
that you will get caught in moving parts and be seriously injured.
• Do not use the mast as a ladder. If you slip, there is danger that you
will fall.
10-14 DX-Series
CHECKING AND INFLATING TIRES

• If the tire inflation pressure is low, it will affect truck stability. However, do not inflate the tires immediately.
The inflation pressure may have gone down because of damage to the rim. If the rim is damaged or cracked
and the tires are inflated, there is danger that the rim will break when the tire is under high pressure, and
this may cause personal injury or death.
• For safety, when checking tire pressure, place your body in front of the
tread face of the tire. Do not check from the side face of the tire.
• Suitable qualifications are needed for tire inflation work. Always have
the work carried out by properly qualified personnel.
• The tire inflation pressure on a forklift truck is several times higher than
the pressure on an automobile.
• When the tires are being inflated, there is danger that dirt or dust may
be thrown up by the compressed air and enter your eyes, so always
wear safety glasses.
HANDLING OF TIRE
Leave disassembly and assembly of each tire to a specialist.
Since the tire inflation pressure is very high, you must steering wheel the
tire carefully.
• Before removing the tire, release the inflation pressure completely. To
remove the tire from the chassis, loosen hub nuts (2).
• Never touch rim nuts (1), since they are dangerous.
• After replacing the tire, perform a test run, then check the mounting
nuts for looseness. If the tightening torque of the nuts is insufficient,
retighten the nuts to the specified torque.
• See the section of tightening torque: [20. TESTING AND ADJUSTING,
Service data].
DX-Series 10-15
JACKING UP LIFT TRUCK (when checking or replacing tires)

• Do not go under the forklift truck when it is jacked up.
• Check the following before jacking up the lift truck.
1) Check that there is no one on the lift truck.
2) Check that there is no load on the forks.
• When jacking up, stop when the tires come off the ground surface. Put
blocks under both sides of the frame to prevent the lift truck from com-
ing down.
• Put blocks under any tires contacting the ground to prevent the lift truck
from moving.
LIFTING LIFT TRUCK (when checking tires)

• Lift truck slinging work should be carried out by a qualified person who has completed a course in correct
lifting methods.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes have ample
strength and are not damaged.
• Block the tires contacting the ground to prevent the lift truck from mov-
ing.
• Insert blocks to prevent the truck from coming down.
• Do not go under the lift truck during the lifting operation.
• If the specified lifting point is the counterweight, check that the coun-
terweight mounting bolts are tightened to the specified torque before
carrying out the lifting operation. check also that there is no damage to
the lifting portion on the counterweight.
SLINGING VEHICLE (for loading it on trailer, etc.)

• Never sling the vehicle by the head guard.
If the vehicle needs to be slung often, a special sling device is neces-
sary. In this case, consult your distributor.
• The vehicle shall be slung by a person who has completed a course of
slinging work.
• Install wires to the specified sling parts.
• Use wires which is free of defect and has sufficient strength to sling the
vehicle.
10-16 DX-Series
BATTERY HAZARD PREVENTION

• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill
electrolyte on yourself, immediately flush the area with a large quantity of water.
• Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes, flush them
immediately with large quantities of water and consult a doctor at once.
• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite or
vegetable oil. Call a doctor or poison prevention center immediately.
• When working with batteries, ALWAYS wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a small
spark or flame. Do not smoke or create any spark near the battery.
• Before working with batteries, stop the engine and turn the starting switch to the OFF position.
• When removing the battery, remove the cable from the negative (–) ter-
minal first. When installing the battery, install the cable to the positive
(+) terminal first.
• Avoid short-circuiting the battery terminals through accidental contact
with tools or other metal objects across the terminals.
• Tighten the battery terminals securely. Loose terminals can generate
sparks and lead to an explosion.
• When removing or installing the battery, confirm which is the positive
(+) terminal and negative (–) terminal. Be careful not to connect the ca-
bles to the opposite terminals.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps tightened.
DO NOT PUT METAL OBJECTS ON TOP OF BATTERY

• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit and
start a fire.
DX-Series 10-17
PRECAUTIONS WHEN CHARGING

When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change.
To prevent the danger of gas explosion, always do as follows.
• Carry out the charging operation in a well-ventilated place.
• Do not smoke or allow any flame.
• Start the charging operation when the temperature of the battery electrolyte is below 35°C. (If the tempera-
ture goes above 50°C during the charging operation, wait for it to go down below 35°C before starting charg-
ing operation again.)
• When using a battery charger to charge the battery, take the battery caps off.
STARTING WITH BOOSTER CABLES

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

It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped. Always do
the following.
• Check the level of the brake fluid periodically.
• Always use the specified brake fluid.
• Check that the breather of the brake fluid reserve tank is not clogged.
• Be careful not to let dirt or dust get into the brake fluid reserve tank.
10-18 DX-Series
HANDLING ANTIFREEZE
• Antifreeze can be a flammable. Keep away from flame when handling.
• Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water, vomit it
out, and get medical attention immediately. Follow safety precautions on container.
WASTE MATERIALS
• Obey appropriate laws and regulations when disposing of harmful ob-
jects such as oil, fuel, solvent, filters, and batteries.
DX-Series 10-19
GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

BOLT
For unspecified bolts and nuts, use the torques spec-
ified in this list.
Select a proper torque corresponding to the width
across flats (b) of bolts and nuts.
When replacing bolts and nuts, always use genuine
Komatsu Forklift parts the same size as the previous
ones.
Thread diameter Width across Tightening torque (Nm {kgf•m})

of bolt (a) flat (b)
(mm) (mm) Target value Range
6 10 13 {1.35} 12 – 15 {1.2 – 1.5}
8 13 31 {3.2} 27 – 34 {2.8 – 3.5}
10 17 66 {6.7} 59 – 74 {6.0 – 7.5}
12 19 113 {11.5} 98 – 123 {10.0 – 12.5}
14 22 177 {18.0} 157 – 196 {16.0 – 20.0}
16 24 279 {28.5} 245 – 309 {25.0 – 31.5}
18 27 382 {39.0} 343 – 427 {35.0 – 43.5}
20 30 549 {56.0} 490 – 608 {50.0 – 62.0}
22 32 745 {76.0} 662 – 829 {67.0 – 84.5}
24 36 927 {94.5} 824 – 1,030 {84.0 – 105.0}
27 41 1,324 {135.0} 1,177 – 1,471 {120.0 – 150.0}
30 46 1,716 {175.0} 1,520 – 1,912 {155.0 – 195.0}
33 50 2,206 {225.0} 1,961 – 2,452 {200.0 – 250.0}
36 55 2,746 {280.0} 2,452 – 3,040 {250.0 – 310.0}
39 60 3,285 {335.0} 2,893 – 3,628 {295.0 – 370.0}
10-20 DX-Series
GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE
ELBOWS, NIPPLES AND UNIONS
Width across flats B mm 22 30 36
Width D mm 19 22 30
Tightening torque Nm {kgf•m} 29.4 – 39.2 {3 – 4} 78.5 – 103 {8 – 10.5} 117.7 – 161.8 {12 – 16.5}
Port size inch 3/4-16UNF 7/8-14UNF —
Tightening torque Nm {kgf•m} 68.6 – 73.6 {7 – 7.5} 78.5 – 83.3 {8 – 8.5} —
Union Elbow
HIGH-PRESSURE RUBBER HOSES, PIPES AND SLEEVE NUTS
Width across flats B mm 19 24 27 32 36
Bore A mm 14 18 22 24 30
19.6 – 29.4 23.5 – 68.6 58.8 – 98.1 107.9 – 166.7 147– 206
Tightening torque Nm {kgf•m} {2 – 3} {3 – 7} {6 – 10} {11 – 17} {15–21}
DX-Series 10-21
GENERAL AND SPECIFICATIONS HOW TO USE LOCTITE
HOW TO USE LOCTITE 4. Assembly

After applying LOCTITE, tighten the screw or fit
the shaft to the hole as usual. (When using LOC-
1. PROCEDURE FOR USING LOCTITE
TITE for structures or LOCTITE of instant glue
type, press the mating parts lightly (about 49 kPa
Male side {0.5 kgf/cm2}).
Degreasing Air drying
2. REMOVAL OF PARTS
Female
side
When screws and shafts are secured with LOC-
TITE, they usually can be removed with common
tools such as spanners, wrenches, pulley pull-
Leaving Applying
Assembly ers, etc. If LOCTITE is so strong that a part may
LOCTITE
be broken when it is removed, heat it (to 200 –
250°C) with a soldering iron, gas torch, etc., and
1. Degreasing and cleaning you can remove it easily. It is generally difficult
(a) Clean the parts in trichloroethylene, ace- to dissolve LOCTITE in chemical solutions.
tone, ether, alkaline solution, etc. which are
highly volatile. 3. WHEN ASSEMBLING AGAIN
(b) Degrease the parts as perfectly as possible. (a) If a LOCTITE film on threads is broken, it is
(c) Since gasoline, light oil, kerosene, etc. are left as white powder on the threads. In this
not highly volatile, they are not recommend- case, you can apply LOCTITE again to the
ed. If it is obliged to use them, dry them threads without removing the white powder.
completely. (b) If shafts or flanges secured with LOCTITE
(d) If the mating parts are made of thermoset- are disconnected, LOCTITE remaining on
ting resin, treat them with LOQUICK PRIM- them may need to be removed to maintain
ER after degreasing them. dimensional accuracy. You can remove the
remaining LOCTITE easily, however, with a
2. Air drying wire brush, etc.
(a) Wait until the cleaning fluid dries out. (c) If plates secured with LOCTITE need to be
(b) If the parts are treated with LOQUICK PRIM- assembled again after they are separated,
ER, do not wipe them but dry them in air for be sure to remove all the hardened LOC-
5 – 10 minutes. (If LOCTITE is used before TITE and roughen the mating surfaces with
LOQUICK PRIMER dries out, its effect is sandpaper.
lowered.)
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads
or the shaft and hole to be fitted by amount to fill
the clearance between them by one of the fol-
lowing methods.
• Applying directly from LOCTITE container
nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving
pan.)
• Sponge
• Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
10-22 DX-Series
GENERAL AND SPECIFICATIONS CONVERSION TABLE
CONVERSION TABLE
MILLIMETERS TO INCHES
1 mm = 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 1.229 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 1.811 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 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
INCHES TO MILLIMETERS
1 in = 25.4 mm
0 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 10.141 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
DX-Series 10-23
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
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 253.62 257.41 261.19
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
10-24 DX-Series
LITER TO U.K. GALLON

1 = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0.220 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 9.09 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
30 136.28 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
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
90 409.15 413.69 418.24 422.79 427.33 341.88 436.42 440.97 445.52 450.06
DX-Series 10-25
KILOGRAM TO POUND
1 kg = 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 = 0.4536 kg
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 27.699 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
10-26 DX-Series
KGF/CM² TO LB/IN²
1 kgf/cm² = 14.2233 lb/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
70 996.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1123 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 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 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 3214 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
DX-Series 10-27
KGF • M TO FT. LB
1 kgf.m = 7.233 ft.lb
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
120 868.0 875.2 882.4 889.7 896.6 904.1 911.4 918.6 925.8 933.1
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 1200.7 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
10-28 DX-Series
TEMPERATURE
Fahrenheit-Centigrade Conversion. –A simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade 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 to 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.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -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 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-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 33.3 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 78.2 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 54.4 130 265.0

-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
-15.6 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 44 111.2 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
DX-Series 10-29
20. TESTING AND ADJUSTING
Service data ..................................................... 20- 2

Gasoline engine ............................................... 20- 6
Diesel engine ................................................... 20- 8
Air cleaner ........................................................ 20-10
Method of adjusting ignition timing................... 20-11
Method of adjusting injection timing ................. 20-12
Measuring method for compression................. 20-14
Adjustment method for valve clearance ........... 20-15
Tightening torque for cylinder head
mounting bolts............................................. 20-16
Adjusting accelerator pedal.............................. 20-17
Adjusting brake/inching pedal .......................... 20-18
Wheel brake ..................................................... 20-19
Accumulator for brake ...................................... 20-21
Adjusting parking brake.................................... 20-25
TORQFLOW transmission case....................... 20-26
Differential case ............................................... 20-27
Hydraulic tank .................................................. 20-28
Measuring hydraulic drift of lift cylinder,
tilt cylinder ................................................... 20-29
Adjusting mast.................................................. 20-30
Adjusting finger bar .......................................... 20-32
Cooling system................................................. 20-34
Bleeding air ...................................................... 20-35
Specified fuel, lubricating oil, and fluid ............. 20-36
Lubricating table............................................... 20-38
DX-Series 20-1
TESTING AND ADJUSTING SERVICE DATA
SERVICE DATA
Component Check item Unit FG50 FG60 FG70
Engine model — TB42
Idling speed rpm 825 – 875 850 – 900
Engine proper Max. speed rpm 2,400 – 2,500 2,440 – 2,540
Torque converter stall speed rpm 1,650 – 1,850
Compression MPa Min. 1.18 {12} / 200

{kgf/cm²}/rpm
Engine oil capacity l 8.5
Lubricating, Coolant capacity l 15

cooling system
Engine
Fan belt tension mm 15 – 17

(98N {10kgf})
Ignition timing BTDC° 7° / 700rpm
Ignition order — 1-5-3-6-2-4

Fuel system
Clearance between spark plug mm 0.7 – 0.8
Intake mm 0.38 (Warm)

Intake, exhaust Valve clearance
system
Exhaust mm 0.38 (Warm)
Electrical system Battery electrolyte specific gravity — 1.28 (20°C)
Stall speed rpm 1,650 – 1,850
Torque MPa
converter Inlet port oil pressure {kgf/cm²} 0.6 – 0.8 {6 – 8}
MPa
Outlet port oil pressure {kgf/cm²} 0.1 – 0.67 {1 – 6.7}
Power train
MPa
Relief pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 16.7}
MPa
Clutch actuation pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 16.7}
TORQFLOW
transmission MPa
Lubricating oil pressure {kgf/cm²} 0.42 – 0.66 {5.3 – 5.7}
Oil capacity l 20
Differential Oil capacity l 12.5
Front MPa
wheel {kgf/cm²} 0.78 {8.0} 0.69 {7.0} 0.78 {8.0}
Travel system
Tires Inflation pressure

Rear MPa
wheel {kgf/cm²} 0.69 {7.0} 0.78 {8.0}
Front Nm
wheel {kgf•m} 294 – 490 {30 – 50}
Hub nut Tightening torque
Rear Nm
wheel {kgf•m} 294 – 490 {30 – 50}
20-2 DX-Series
Component Check item Unit FG50 FG60 FG70
Steering wheel Play mm 30 – 60
Rear axle Min. turning radius mm 3,088 – 3,412 3,183 – 3,517
Play mm 2–3
Steering, braking system
Inching pedal
Interconnected travel mm 23 – 28
Play mm 2–6
Brake pedal
Pedal height when depressed mm 103 – 113
Brake fluid capacity l 0.05
Brake Parking brake operating effort Nm {kgf} Min. 98 {10} (Center grip)
Tightening torque for back plate Nm {kgf•m} 157 – 196 {16 – 20}
mounting bolt
Thickness at fork root mm Min. 55 Min. 60 Min. 65
Fork Difference in height mm Max. 15
Amount of opening at tip mm Max. 35
Lifting hight mm Max. 440

Power train
3m
Chain Length of 17 links Max. 550
Lifting hight
Min 3m mm Max. 550
Hydraulic drift (lift cylinder) mm/15min Max. 50 (cylinder) or 100 (fork)

Cylinder
Hydraulic drift (tilt cylinder) mm/15min 33
Relief pressure MPa {kgf/cm²} 18 {185}

Hydraulic
system
Oil capacity l 70
DX-Series 20-3
Component Check item Unit FD50 FD60 FD70 FD80
Engine model — S6D102E SA6D102E
Idling speed rpm 625 – 675
Engine proper Max. speed rpm 2,400 – 2,500
Torque converter stall speed rpm 1,800 – 2,000 1,750 – 1,950
Compression MPa Min. 2.41 {24.6} / 250 – 280

{kgf/cm²}/rpm
Engine oil capacity l 16.5
Lubricating, Coolant capacity l 15 20

cooling system
Engine
Fan belt tension mm Auto tentioner

10°
3° (Injection
Injection timing BTDC° (Injection pump cam lift 1mm point) pump cam lift
1mm point)
Fuel system Injection order — 1-5-3-6-2-4
MPa
Injection pressure {kgf/cm²} 21.6 {220} 22 {224}
Intake, Intake mm 0.25 (Cold)

exhaust Valve clearance
system Exhaust mm 0.51 (Cold)
Electrical Battery electrolyte specific

system gravity — 1.28 (20 °C)
Stall speed rpm 1,800 – 2,000 1,750 – 1,950
Torque MPa
converter Inlet port oil pressure {kgf/cm²} 0.6 – 0.8 {6 – 8}
MPa
Outlet port oil pressure {kgf/cm²} 0.1 – 0.67 {1 – 6.7}
Power train
MPa
Relief pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 16.7}
MPa
Clutch actuation pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 16.7}
TORQFLOW
transmission MPa
Lubricating oil pressure {kgf/cm²} 0.42 – 0.66 {5.3 – 5.7}
Oil capacity l 20
Differential Oil capacity l 12.5 15
Front MPa
wheel {kgf/cm²} 0.78 {8.0} 0.69 {7.0} 0.78 {8.0} 0.66 {6.5}
Travel system
Tires Inflation pressure

Rear MPa
wheel {kgf/cm²} 0.69 {7.0} 0.69 {7.0} 0.78 {8.0} 0.66 {6.5}
Front Nm 294 – 490 {30 – 50} 539 – 637

wheel {kgf•m} {55 – 65}
Hub nut Tightening torque
Rear Nm 294 – 490 {30 – 50} 441 – 539
wheel {kgf•m} {45 – 55}
20-4 DX-Series
Component Check item Unit FD50 FD60 FD70 FD80
Steering Play mm 30 – 60
wheel
Rear axle Min. turning radius mm 3,088 – 3,412 3,183 – 3,517 3,420 – 3,780
Play mm 2–3
Steering, braking system
Inching
pedal
Interconnected travel mm 23 – 28
Play mm 2–6
Brake pedal
Pedal height when depressed mm 103 – 113 115 – 125
Brake fluid capacity l 0.05 (*1)
Brake Parking brake operating effort Nm Min. 98 {10} (Center grip)

{kgf}
Tightening torque for back plate Nm 157 – 196 {16 – 20} 245 – 309
mounting bolt {kgf•m} {25 – 31.5}
Thickness at fork root mm Min. 55 Min. 60 Min. 65
Fork Difference in height mm Max. 15
Amount of opening at tip mm Max. 35
Lifting hight mm Max. 440

Power train
3m
Chain Length of 17 links Max. 550 Max. 660
Lifting hight
Min 3m mm Max. 550
Hydraulic drift (lift cylinder) mm/15min Max. 50 (cylinder) or 100 (fork)

Cylinder
Hydraulic drift (tilt cylinder) mm/15min 33 39
MPa
Relief pressure {kgf/cm²} 18 {185}
Hydraulic
system
Oil capacity l 70 77
*1. FD80 is equipped with a fully hydraulic brake system.
DX-Series 20-5
TESTING AND ADJUSTING GASOLINE ENGINE
GASOLINE ENGINE
TB42
k Maintain the engine when the engine stops and after the temperature has completely dropped.
1. REPLACEMENT OF FUEL FILTER 2. CHANGE OF ENGINE OIL

1. Loosen the clamp to remove the hose and then 1. Drain engine oil filter removing the drain plug.
remove the cartridge from the bracket.
2. Fill the specified amount of engine oil.
2. Put a new cartridge to the fuel pipe. Oil amount to replace: 7.8 l
a Make sure of no fuel leaking from the pipe.
3. Check on engine oil by use of an oil gauge.
20-6 DX-Series
TESTING AND ADJUSTING GASOLINE ENGINE
3. REPLACEMENT OF ENGINE OIL FILTER

1. Remove the cartridge by use of a filter wrench.
2. Clean the filter face and coat a new cartridge
(both the seal and the screw) with engine oil be-
fore fixing it.
a After fixing the new cartridge, start the engine to
check on any oil leakage.
4. CHEKING ON SPARK PLUG

1. Remove the plug by the special plug wrench.
2. Clean carbon off the top and its vicinity of the
plug.
3. Measure the plug gap by a gauge.
Normal plug gap A: 0.7 – 0.8 mm
[1] Normal
[2] Badly burnt
[3] Sooty
Brand plug
NGK plug B-4ES
Hitachi plug L47W
NGK plug BPR-4ES (noiseproof type)
5. CHANGE OF GOVERNOR OIL

1. Remove the drain plug (3) to drain oil and tighten
the plug (3) after draining.
2. Remove the oil filler port (1) and level plugs (2).
3. Fill oil from the oil filler port (1) until it flows out of
the level plug (2) port.
a Use the same oil as that for the oil pan
(capacity: 35 to 40 cc).
4. Tighten the oil filler port (1) and level plugs (2).
DX-Series 20-7
TESTING AND ADJUSTING DIESEL ENGINE
DIESEL ENGINE
S6D102E/SA6D102E
k Maintain the engine when the engine stops and after the temperature has completely dropped.
1. CHANGE OF ENGINE OIL 2. REPLACEMENT OF ENGINE OIL FILTER

1. Remove the drain plug, drain the oil, then tighten 1. Using a filter wrench, remove the cartridge.
the plug again.
2. Clean the filter holder, coat the thread and the
2. Remove the dipstick. seal of the new cartridge with engine oil, then in-
stall.
3. Add the specified amount of engine oil, and be a After installing the cartridge, start the engine and
careful not to let it overflow. check that there is no leakage of oil from the filter
Oil amount to replace: 11.5 l mounting surface.
4. Check the oil level with the dipstick.
20-8 DX-Series
TESTING AND ADJUSTING DIESEL ENGINE
3. DRAIN WATER FROM FUEL FILTER

1. Loosen the combination sensor plug (1) and drain
the water and sediment accumulated at the bot-
tom.
a Fuel is drained out at the same time, so prepare
a container to catch it.
a Always be sure to wipe up any spilled fuel.
4. REPLACEMENT OF FUEL FILTER

1. Remove the combination sensor plug (4) at the
bottom of the cartridge.
2. Using a filter wrench, remove the cartridge (3).
3. Install the combination sensor plug (4) to the new
cartridge (3).
4. Fill the new cartridge with fuel, coat the packing
surface thinly with engine oil, then install.
5. Loosen plug (2) and pump knob (1) up and down
until no more bubbles come out with the fuel.
6. Tighten plug (2).
k Be sure to use a pan for catching fuel
drained when draining water from the fuel fil-
ter or bleeding air after replacing cartridges
and wipe off any spilled fuel. Otherwise, fire
may occur.
DX-Series 20-9
TESTING AND ADJUSTING AIR CLEANER
AIR CLEANER
CLEANING OF ELEMENT
1. Remove and clean (inside to outside) the element
over by dry compressed air (0.69 MPa {7 kg/
cm²}).
2. Put the cleaned element back to the air cleaner.
k When compressed air is used for cleaning, a
pair of safety glasses must be put on.
a In case of severer working conditions and envi-
ronments, clean or replace the element as early
as possible.
a When any grease or carbon is found on the ele-
ment, clean it with a special cleaner prescribed in
the instruction for the air cleaner.
REPLACEMENT OF ELEMENT Single element type
1. Element
2. Nut
3. Internal tube element
4. Dust evacuater
1. Remove the element (1) from the air cleaner.

2. Remove the nut (2) and the internal tube element
(3) (single element type).
3. Cove the air connector with clean cloth or tape.
4. Clean the interior of the air cleaner and remove
the cover from the air connector.
5. Install new internal tube element (2) and element
(1). Double element type
a Do not clean or replace the air cleaner while
the engine is running.
20-10 DX-Series
TESTING AND ADJUSTING METHOD OF ADJUSTING IGNITION TIMING
METHOD OF ADJUSTING IGNITION TIMING

1. Connect the timing advance tester (1) as shown
in the diagram on the right.
2. Turn the power switch ON, and adjust the timing
position of the advance adjustment knob (2).
3. Start the engine and run at the specified idling
speed.
4. Shin the timing light (3) and check that the indica-
tor and timing mark stamped on the crankshaft
pulley and flywheel are aligned.
5. If the timing is misaligned, turn the distributor (4)
to the right or left to adjust.
6. Check that the ignition timing advances quickly
when the engine speed is raised.
DX-Series 20-11
TESTING AND ADJUSTING METHOD OF ADJUSTING INJECTION TIMING
METHOD OF ADJUSTING INJECTION TIMING

There are following two methods. 2. Measuring device method
1. Counter mark alignment method Used when repairing or replacing the injection
Used when installing the injection pump in the pump.
original engine without repair.
a Inspect and adjust the truck after placing the

No. 1 cylinder at the compression top dead
center (see the section “Adjusting method of
valve clearance”.
1. Counter mark alignment method

1. Check that stamp line “a” on the injection pump
side aligns stamp line “b” on the timing gear case
side.
2. If not, loosen nut (1) to move the injection pump
to align them and then tighten the nut.
2. Measuring device method

Adjust the timing so that the injection pump cam
lift is set at the specified value when the No. 1 cyl-
inder is placed at the compression top dead cen-
ter.
1. Turn the No. 1 cylinder by 25 to 30 degrees in the
opposite direction from the compression top dead
center (place the plunger at the bottom dead cen-
ter).
2. Remove the distributor head bolt (2) from the in-
jection pump.
3. Set a dial gauge [2] on the plunger stroke mea-
sure [1] (ND95095-10172) and mount it on the in-
jection pump (3).
a Make sure that the end of the plunger stroke
measure tracer comes in contact with the
plunger head.
4. Set the dial gauge [2] pointer at 0.
a Make sure that the pointer stably indicates 0
even if slightly turning the crankshaft.
20-12 DX-Series
TESTING AND ADJUSTING METHOD OF ADJUSTING INJECTION TIMING
5. Turn the crankshaft in the normal direction and

read the dial gauge [2] when V-groove C of the
crankshaft pulley (4) (see below) corresponds to
the pointer (5).
Standard value 0.97 – 1.03 mm
a Gauge reading ± 0.03 mm corresponds to injec-

tion timing ± 0.5 degree.
a Be sure to turn the crankshaft in the normal direc-
tion.
a V-groove position
V-groove BTDC degree
A 10°
B 8°
C 6°
D 0°
6. If the dial gauge reading is not within the standard

range, turn the injection pump (6) to adjust it.
Mark side : Less than standard value
Mark side : More than standard value
7. Tighten the pump mounting bolt.
8. Remove the plunger stroke measure [1] to install

the distributor head bolt (2).
a Replace the copper washer of the distributor
head bolt with a new one.
DX-Series 20-13
TESTING AND ADJUSTING MEASURING METHOD FOR COMPRESSION
MEASURING METHOD FOR COMPRESSION

1. Warm up the engine to get the coolant tempera- Gasoline engine
ture of 75 – 85 °C.
2. Stop the engine, then remove all the spark plugs
(on gasoline engines) or nozzle holders (on die-
sel engines) and the air cleaner.
3. Disconnect the coil cord from the ignition coil (on
gasoline engines). Set the fuel control lever to
the non-injection position or disconnect the wiring
of the fuel cut solenoid (on diesel engines).
4. Fit the adapter to the nozzle holder mounting of
the cylinder which is to be checked and tighten to
the specified torque (on diesel engines).
5. Install a compression gauge [1] to the cylinder to
be checked.
6. For pneumatic governor, press the accelerator
pedal fully to the floor and crank the engine with
the starter motor to get the maximum reading of
the gauge.
a Take measurements more than two times on
each engine to avoid measurement errors
and average the values.
a Discharged battery will not give sufficient rev-
olutions. Use fully charged battery.
Diesel engine
Causes for insufficient compression
1. Poor adjustment of valve clearance
2. Pressure leakage from the valve seat
3. Seize of valve stems
4. Defective or broken valve springs
5. Pressure leakage from the cylinder head gasket
6. Sticking or breakage of piston rings
7. Wear of piston rings or cylinders
20-14 DX-Series
TESTING AND ADJUSTING ADJUSTMENT METHOD FOR VALVE CLEARANCE
ADJUSTMENT METHOD FOR VALVE CLEARANCE

1. Remove the cylinder head cover.
2. Rotate the crankshaft to match top mark [1] of
crank pulley (1) to pointer (2) and see which of the
pistons of the No. 1 and No. 6 cylinders is at the
compression top dead center.
a If the piston of a cylinder is at the compres-
sion top dead center, both intake valve and
exhaust valve of that cylinder are closed, or
both of the rocker arms are free.
3. Adjust the valve clearance of the cylinder in which
the piston is at the compression top dead center.
a When the piston of the No. 1 cylinder is at the
compression top dead center
Adjust the valve clearance of the valves
marked with q in the table, then rotate the
crankshaft forward by 1 turn and adjust the
valve clearance of the valves marked with Q.
a When the piston of the No. 6 cylinder is at the
compression top dead center
Adjust the valve clearance of the valves
marked with Q in the table, then rotate the
crankshaft forward by 1 turn and adjust the
valve clearance of the valves marked with q.
4. Loosen locknut (4) of adjustment screw (3) and

insert feeler gauge [2] of the specified clearance
between valve stem (6) and rocker arm (5). Ad-
just the clearance to a degree that you can move
the feeler gauge lightly, and then tighten the lock-
nut to fix the adjustment screw.
DX-Series 20-15
TESTING AND ADJUSTING TIGHTENING TORQUE FOR CYLINDER HEAD MOUNTING BOLTS
TIGHTENING TORQUE FOR CYLINDER HEAD MOUNTING BOLTS

1. Nissan engine TB42
a When tightening the cylinder head, apply engine
oil to the bolt screws and seat surface.
a Set the washer so that the non-chamfered sur-
face faces the cylinder head.
a Tighten the bolts in the order shown in the figure
on the right.
[Angle tightening]
Procedure for tightening cylinder head bolts
1) Tighten by 29.4 Nm {3 kgf•m}.
2) Tighten by 57 to 66 Nm {5.3 to 6.8 kgf•m}.
3) Loosen to 0 Nm {0 kgf•m}.
4) Tighten by 29.4 Nm {3 kgf•m} again.
5) Retighten by “69 +50 degrees” from the position in
4)
a When no angle tightening wrench is available

Wind a wire around the wrench extension bar to
make an indicator (the stability of the indicator
can be improved by winding nylon tape around
the bar several times and putting a wire for an in-
dicator on it).
Next, set a readily-available protractor under the
extension bar indicator set on the applicable bolt
and tighten it by the specified torque. Tighten it
further from the position by using the point having
the torque value as 0 and reading the protractor
scale by referring to the degree written in the
maintenance standard.
20-16 DX-Series
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
ADJUSTING ACCELERATOR PEDAL

1. Pedal height (from the upper surface of the
floor plate)
Use stopper bolt (1) to adjust the height.
Unit : mm
Stopper bolt
Model Pedal height (B) height (A)
FG50/60/70 129.5 14.5
FD50/60/70 129.5 14.5
FD80 130 15
2. Pedal stroke D
Unit : mm
Model Stopper bolt height (C)
FG50/60/70 62
FD50/60/70 51
FD80 71
3. Locknut tightening torque

Stopper bolt (1):
3.43 to 4.41 Nm (0.35 to 0.45 kgf•m) S6D102
Stopper bolt (2):
27.44 to 34.3 Nm (2.8 to 3.5 kgf•m)
4. Engine side lever

After mounting the cable, adjust the stopper bolt
(2) so that the lever (4) at the engine end can be
fully opened when the pedal is fully stepped on.
a Use adjust nut (3) on the cable set part to adjust
the idling speed of the engine.
TB42 SA6D102E
DX-Series 20-17
TESTING AND ADJUSTING ADJUSTING BRAKE/INCHING PEDAL
ADJUSTING BRAKE/INCHING PEDAL

5 – 7 ton
BRAKE PEDAL
1. Pedal height (from the upper end of the pedal
bracket)
Unit : mm
Engine type Pedal height (A1) Pedal stroke (B)
5, 6, 7 ton 333 80
8 ton 311 67
8 ton
INCHING PEDAL
1. Pedal height (from the upper end of the pedal
bracket)
Unit : mm
Engine type Pedal height (A2) Pedal stroke (C)
5, 6, 7 ton 333 105
8 ton 311 107
5 – 7 ton
2. Inching spool protrusion amount
Use cable (3) to adjust the protrusion amount af-
ter adjusting the pedal height.
Projection of spool 31 mm
Clearance e: 0 – 0.5 mm
(Spool must not be pushed, however.)
3. Interlocking stroke
Adjust using bolt (4) so that the inching pedal will
interlock with the brake pedal in the following
stroke. 8 ton
Interlocking stroke 25 mm
4. Adjustment of stop lamp switch (8 ton model)

After adjusting the brake pedal height, set dimen-
sion D to 0.5 – 1.5 mm.
20-18 DX-Series
TESTING AND ADJUSTING WHEEL BRAKE
WHEEL BRAKE
ADJUSTING WHEEL BRAKE
Although the clearance between the drum and the lin-
ing is automatically adjusted, it can also be manually
adjusted as follows:
a Manually adjust the clearance of the 8 ton truck
on two places (top and bottom).
1. Lift the truck body using a jack to turn the adjuster

wheel gear (2) using an adjustment screwdriver
so that the lining will completely come in contact
with the drum.
Return the adjuster wheel gear (2) for 20 to 25
teeth (or 5 to 7 teeth for the 8 ton truck) from the
position where the lining completely comes in
contact with the drum. Adjust the clearance be-
tween the lining and drum to the specified value
while checking it with a thickness gauge.
a Set shoe clearance value
5 to 7 ton truck : 0.4 to 0.6 mm
8 ton truck : 0.24 to 0.3 mm
a After adjusting the brake, be sure to check its
operation. If brakes of one side operate
stronger than those of the other side, be sure
to readjust them.
5 – 7 ton 5 – 7 ton
2. Checking of automatic adjuster operation
With the brake shoe assembly properly installed,
pressing the wire center of spring assembly (1) in
the arrow direction pulls lever (3) upward, feed
the wheel gear by one tooth and extend the shoe
(by one tooth).
3. Correct lever position

Lever (3) is in contact with the adjuster wheel
gear at the position 7.8 to 8.2 mm away from the
adjuster screw center.
A different contact position will cause wrong en-
gagement between the lever and the wheel gear,
disabling the wheel gear from being fed even if
the lever is operated, thereby causing improper
automatic adjustment.
DX-Series 20-19
TESTING AND ADJUSTING WHEEL BRAKE
8 ton
4. Adjustment method for clearance
1) Turn adjustment screw (1) in shoe expanding
direction A to fit the shoe to the drum.
2) Return adjustment screw (1) by 4 – 5 notch-
es.
After the above work, clearance a is set to
0.24 – 0.30 mm.
20-20 DX-Series
TESTING AND ADJUSTING ACCUMULATOR FOR BRAKE
ACCUMULATOR FOR BRAKE

FOR ONLY 8 TON MODEL
INSPECTION OF ACCUMULATOR
Stop vehicle on level and safe place and

pull parking brake lever.
Start engine and keep pressing brake

pedal for about 10 seconds.
Stop engine and set starting switch in

position ACC.
Press brake pedal repeatedly.
Buzzer sounds when brake Buzzer sounds when brake pedal Buzzer does not sound even if brake
pedal is pressed 9 times or less. is pressed 10 times or more. pedal is pressed 40 times or more.
Gas pressure in accumulator is Normal Buzzer or pressure switch

low or pressure switch is broken. is broken.
INSPECTION AND MAINTENANCE

1) Service data
Gas pressure in
accumulator 3.4 MPa {35 kgf/cm²}
2) Inspection and maintenance list
Inspection and maintenance interval

Maintenance
period by
Accumulator for brake Check operating
before 2 weeks 1 month 3 months 6 months 1 year 2 years hours (hours)
starting
• Inspection of accumulator
• Inspection of gas pressure Q Q 2,400
and charging with gas
DX-Series 20-21
PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS

1. Stop the vehicle on a flat place, lower the work equipment to the ground, stop the engine, set the control le-
vers in neutral, and put chocks under the tires.
2. Remove accumulator (1) shown in the following figure.
3. Charging accumulator with nitrogen gas

1) Since the thread of gas valve (25) of the ac- How to connect accumulator and nitrogen gas
cumulator is TV8, install the joint assembly to cylinder
the charging assembly.
2) Turn handle (23) of charging assembly (00) to
the left until it stops.
3) Turn handle (24) of the bleed plug to the left
to open the plug.
4) Remove the cap of the accumulator and in-
stall charging assembly (21) to the gas valve
of the accumulator.
5) Connect nitrogen gas cylinder (2) and charg-
ing assembly (21) by hose assembly (29).
a There are 2 types of threads of gas cylin-
ders, W22-14 thread (mail screw, type A)
and W23-14 thread (female screw, type
B). When using type-B gas cylinder, use
the attached reducer (30). 1. Accumulator
2. Nitrogen gas cylinder
3. Charging assembly
4. Hose assembly
20-22 DX-Series
6) Open the valve of nitrogen gas cylinder (2) a

little so that the gas will be discharged at
pressure of 0.2 – 0.3 MPa {2 – 3 kg/cm²}, tak-
ing care not to discharge the gas quickly.
Then, the gas comes out of handle (24). At
this time, turn the handle to the right to pre-
vent the gas from escaping.
7) Turn handle (23) of charging assembly to the
right to lead the nitrogen gas to the accumu-
lator.
At this time, stop handle (23) when you feel a
light reaction so that the gas valve piston will
not be damaged.
a If the handle is turned too strongly, the
core will be broken. Take care.
8) Open the gas cylinder valve gradually further
to charge the accumulator with the nitrogen
gas. While doing so, close the gas cylinder
valve sometimes and read pressure gauge
(28) of the charging assembly when it is sta-
bilized.
Charge gas pressure: 3.4 MPa {35 kgf/cm²}
9) After the accumulator is charged to the spec-
ified pressure, close the valve of nitrogen gas
cylinder securely.
If the pressure in the accumulator is too high,
turn handle (24) to the left and release the ni-
trogen gas gradually.
10) Turn handle (23) to the left until it stops, and
then turn handle (24) to the left to open it and
discharge the gas remaining in the charging
assembly and hose.
11) Remove charging assembly (21) from the ac-
cumulator.
12) Apply water or soap water to the gas valve of
the accumulator to check that the gas is not
leaking, and then install the cap.
4. Install the accumulator to the vehicle.
DX-Series 20-23
Charging Ass’y
No. Part No. Part name Q’ty Remarks

00 3EE-38-21700 Charging Ass’y 1
21 3EE-38-21710 • Charging Ass’y 1
22 3EE-38-21720 • • Charging valve, Body 1
23 3EE-38-21730 • • Adjust screw, handle 1
24 3EE-38-21740 • • Bleed plug, handle 1
25 3EE-38-21750 • • Gas, Valve 1
26 3EE-38-21760 • • Nut 1
27 3EE-38-21770 • • Joint 1
28 3EE-38-21780 • • Pressure, Gauge 1 0 – 15 MPa {0 – 153 kgf/cm²}
29 3EE-38-21790 • Hose Ass’y 1 L = 4,000 mm
30 3EE-38-21810 • Reducer 1 JIS N2 gas cylinder
Joint Ass’y
No. Part No. Part name Q’ty Remarks

3EE-38-21900 Joint Ass’y 1
31 • Joint 1
32 • Gasket 1
33 • Seal washer 1
20-24 DX-Series
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE
ADJUSTING PARKING BRAKE

ADJUSTING CLEARANCE
1. Turn the adjustment wheel to the shoe expansion
direction so that the lining can completely come
into contact with the drum.
2. Turn the adjustment wheel so that the clearance
between the drum and lining (points X and Y in
the right figure) can be set to 0.1 to 0.25 mm
(when the adjustment wheel is turned for 11
notches, the clearance is adjusted for 0.25 mm).
ADJUSTING LEVER OPERATING EFFORT

1. Release the parking brake (push the lever for-
ward).
2. Use a screwdriver to push in adjustment button
(1) in direction G, then to keep it push and rotate
in to adjust the operating effort of the lever.
Lever operating effort

(Grip center) Min. 98 N {10 kgf}
3. Adjust and insert the hexagonal portion of adjust-

ment button (1) to the hexagonal hole on the tip
of grip (2), then pull the screwdriver.
DX-Series 20-25
TESTING AND ADJUSTING TORQFLOW TRANSMISSION CASE
TORQFLOW TRANSMISSION CASE

k After operating the engine, the oil is at a high
temperature. Start working after the oil tem-
perature sufficiently drops.
OIL LEVEL CHECK

1. Open the inspection window on the floor plate
and check the oil level with the dipstick (1).
(Mast be in range of L)
2. If the oil level is insufficient, open the oil filler cap
(2) and fill the oil.
CHANGING OIL, CLEANING STRAINER

1. Remove the drain plug (3), then tighten it after
draining.
2. Remove the pipe, take out the strainer (4), and
clean it with the flushing oil.
3. After cleaning, blow dry compressed air from the
inside of the strainer (4) to outside and install it
when it is completely dry.
4. Add specified amount of oil from the oil filler port.
5. Check the oil level after changing the oil.
Oil amount to replace: 20 l
a Be sure to use the genuine TORQFLOW trans-

mission oil for Komatsu Forklifts (FE010-CD).
(See the section "Specified fuel, lubricating
oil, and fluid.")
20-26 DX-Series
TESTING AND ADJUSTING DIFFERENTIAL CASE
DIFFERENTIAL CASE
k After the engine is operated, the oil is at a
high temperature. Start working after the oil
temperature sufficiently drops.
CHECKING OIL LEVEL

1. Pull out the dipstick and check the oil level (1). If
the oil is filled to nearby the lower line of the plug
hole, the oil level is normal.
If the oil level is too low, remove the oil filler port
plug (2) and fill the oil.
CHANGING OIL
1. Remove the oil filler port plug (2), and drain the oil
through the drain plug (3).
2. After draining the oil, tighten the drain plug (3)
and refill the specified amount of oil.
3. Check the oil level after filling.
Oil amount to replace:
5, 6, 7 ton 12.5 l
8 ton 15 l
a Be sure to use the genuine differential case

oil for Komatsu Forklifts (FG090).
(See the section "Specified fuel, lubricating
oil, and fluid.")
Supplementary explanation
The differential case and TORQFLOW transmission
case of the torque converter type truck use exclusive
types of oil. When the differential case oil is checked
and changed, the TORQFLOW transmission case oil
also need to be checked and changed.
DX-Series 20-27
TESTING AND ADJUSTING HYDRAULIC TANK
HYDRAULIC TANK
CHANGING HYDRAULIC OIL
CLEANING HYDRAULIC TANK STRAINER
CLEANING INSIDE HYDRAULIC TANK
REPLACING HYDRAULIC LINE FILTER
k The oil temperature is still high just after the
operation is stopped. Accordingly, start the
work after the oil temperature lowers.
1. After draining the oil from the drain plug (4) on the
bottom of the tank, remove the cover (3) to take
out the strainer and clean the strainer (5) with the
flushing oil.
2. After cleaning inside of the tank, mount the drain
plug (4).
3. After cleaning strainer (5), blow air from its inside
to dry well, and then install it and cover (3).
4. Remove the line filter (1) and mount a new one.
5. Pour specified amount of oil through breather
hole. Check the oil level from the inspection win-
dow.
Oil amount to replace:
5, 6, 7 ton 70 l
8 ton 77 l
6. Start the engine and bleed air by moving the cyl-

inders (lift, tilt, and power steering) to the stroke
end five to six times.
a Be sure to use the genuine hydraulic oil for
Komatsu Forklifts.
20-28 DX-Series
TESTING AND ADJUSTING MEASURING HYDRAULIC DRIFT OF LIFT CYLINDER, TILT CYLINDER
MEASURING HYDRAULIC DRIFT OF LIFT CYLINDER, TILT CYLINDER

k PRECAUTIONS AT MEASUREMENT
1. During measurement, never let anyone go under the load.
2. Do not put your feet on the mast stays or dashboard and climb up when measuring the hydraulic drift of the
cylinder. If this rule is violated, your hands or feet may be caught in the mast. Always use a strong, stable
stand at measurement.
3. Before start the measurement, check that the hydraulic oil level is correct and that the hydraulic oil is not dirty
or mixed with any other brand of oil.
4. Always carry out the measurement on flat horizontal ground in front of strong platform which will support the
truck if it should tilt over to the front.
MEASUREMENT
1. Stop the lift truck 500 mm in front of the platform.
2. Operate the lift and tilt repeatedly to set the hy-
draulic oil temperature to 50°
3. Set the rated load on the forks and secure it to the
fork carriage with a wire rope.
4. Raise the load height H for about 1,500 mm and
set the mast (1) perpendicular.
Hydraulic drift of lift cylinder

5. Wait for three minutes, then place a ruler [1]
against the lift cylinder (2) piston rod and draw a
mark A.
6. Measure the hydraulic drift for 15 minutes.
Hydraulic drift of lift cylinder 50 mm / 15 min
Hydraulic drift of tilt cylinder

7. Wait for three minutes, then place a ruler [2]
against the tilt cylinder (3) piston rod and draw a
mark B.
8. Measure the hydraulic drift for 15 minutes.
5, 6, 7 ton 33 mm / 15 min
8 ton 39 mm / 15 min
DX-Series 20-29
TESTING AND ADJUSTING ADJUSTING MAST
ADJUSTING MAST
SYNCHRONOUS ADJUSTMENT
(SHIM ADJUSTMENT)
1. Mast stay
2. Shim
3. Lift cylinder
1. Lift the mast to the maximum height.

2. Check the mast play in the horizontal direction.
3. Adjust the mast using shims (2) (t = 0.1 mm) so
that the left and right cylinders synchronize when
the mast is lifted to the maximum height.
When the mast sways to the left

(at maximum height)
Put a shim (2) on the left cylinder.
When the mast sways to the right

(at maximum height)
Put a shim (2) on the right cylinder.
SELECTING ROLLER AND SHIM

ADJUSTMENT
1. OUTER ROLLER
1) Selecting roller
Select a roller so that dimension V at the strip
do not differ between left and right.
2) Shim adjustment
Put shims of the same thickness to the left
and right so that clearance f between R of the
rail and the roller will be 0 to 0.5 mm when the
mast is lifted to the maximum height.
20-30 DX-Series
TESTING AND ADJUSTING ADJUSTING MAST
2. INNER ROLLER
1) Selecting roller
Select a roller so that clearance a between
the rail and the roller will be 0.2 to 0.9 mm.
2) Shim adjustment
and right so that clearance c between R of the
rail and the roller will be 0 to 0.5 mm when the
mast is lifted to the maximum height and the
rail is engaged with the roller.
3. STRIP
1) Shim adjustment
Put a shim so that clearance b between the
strip and the rail exists at every position along
the inner rail when the main roller is engaged
with the rail.
Clearance b : 0.1 to 0.4 mm
Standard : 0.3 mm
DX-Series 20-31
TESTING AND ADJUSTING ADJUSTING FINGER BAR
ADJUSTING FINGER BAR

SELECTING ROLLER AND SHIM
ADJUSTMENT
1. Lower main roller
1) Selecting roller
Select a roller so that the clearance a be-
tween the rail and the roller will be 0.2 to 0.9
mm.
2) Shim adjustment
and right so that the clearance c between the
rail and the roller can be 0.01 to 0.1 mm when
the finger bar is lifted to the maximum height.
Standard shim thichness b : 5.8 mm
2. Upper and intermediate main rollers

1) Selecting roller
Select a roller so that the clearance d be-
mm.
2) Shim adjustment
Standard shim thickness : 1 mm
3. Upper side roller

1) Shim adjustment
Adjust using shims so that clearance e be-
mm when the finger bar is located at the high-
est position.
Standard shim thickness f : 1.5 mm
4. Lower side roller

1) Shim adjustment
Put a shim thinner by 0.3 mm than that for the
upper side roller.
20-32 DX-Series
TESTING AND ADJUSTING ADJUSTING FINGER BAR
5. Roller engagement
Check the engagement A between the upper (1)
and lower (2) side rollers all along the inner rail by
tilting the finger bar.
6. Lower main roller protrusion

1) Install a lift chain on the outer mast and adjust
so that the tension is the same for both left
and right.
2) Adjust the lower main roller (3) protrusion g
from the lower edge of the inner mast to the
set value when the lift is lowered to the lowest
height using the locknut of the chain stopper.
Locknut 820 – 1,030 Nm

{84 – 105 kgf•m}
Protrusion g
5 ton 60 mm
6 ton 50 mm
7 ton 49 mm
8 ton 62.5 mm
a Engage the backrest with the board side and

tighten them using a bolt (4).
DX-Series 20-33
TESTING AND ADJUSTING COOLING SYSTEM
COOLING SYSTEM
CLEANING RADIATOR
1. Drain water by opening the drain cocks of the low-
er part of the radiator and the engine cylinder
block.
2. Close the drain cock, fill pure water (tap water)
and radiator detergent liquid from the water filler
port and idle the truck for approximately 15 min-
utes.
3. Stop the engine and drain water from the drain
cock. Idle the truck by pouring pure water until
clean water flows out of the cock (for 5 to 10 min-
utes).
4. Stop the engine and drain water from the drain
cock. After closing the cock, fill pure water and
long-life coolant in the radiator.
Amount of coolant:
5 – 7 ton : 15 l
8 ton : 21 l
a Fill long-life coolant when it is cold.

a Fill radiator anti-rust fluid when not using
long-life coolant.
a Clean the radiator at a flat place.
a Use Komatsu genuine coolant, anti-rust fluid
and long-life coolant.
CLEANING RADIATOR FIN
1. Clean it by blowing air, steam or water.
Air pressure : Max. 0.98 MPa {10 kgf/cm²}

Steam pressure : Max. 0.39 MPa {4 kgf/cm²}
a Clean it by positioning the air or steam nozzle

at right angles to the radiator.
20-34 DX-Series
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
FUEL PIPING (DIESEL ENGINE MODEL)
1. Loosen plug (2) at the top of fuel filter cartridge (3)
and move knob (1) up and down until bubbles do
not come out any more.
2. After bleeding all air, tighten plug (2).
BRAKE PIPING
1. Brake drum cover 4. Brake fluid
2. Air bleed plug 5. Brake drum
3. Vinyl hose 6. Lining
1. Remove the cap from the air bleeding plug (2), fit
one end of a vinyl hose (3) to the plug, and put the
other end of the hose in a container of brake fluid
(4).
2. Step on the brake pedal and loosen the air bleed-
ing plug (2) for about 3/4 turns to drain the brake
fluid containing air.
3. Tighten the air bleeding plug (2), then release the
brake pedal.
4. Repeat Steps 2 and 3 until no more bubbles
come out of the hose. (3)
5. When all the bubbles of air have been completely
removed, tighten the plug (2) and install the cap.
6. After bleeding all air, remove cap (7) and the in-
ner cap from brake reservoir tank (8) and check
the oil level. Add oil by the quantity reduced by
the air bleeding work and check that the oil level
is in the proper range (25 – 45 mm).
LIFT CYLINDER
1. Start the engine and run it at low idling.
2. Raise and lower the mast.
a Stop the mast about 100 mm before the max-
imum height and the lowest position.
3. Repeat Step 2 four or five times.
4. Raise and lower the mast to the maximum height
and lowest position.
5. Repeat Step 4 four or five times.
DX-Series 20-35
TESTING AND ADJUSTING SPECIFIED FUEL, LUBRICATING OIL, AND FLUID
SPECIFIED FUEL, LUBRICATING OIL, AND FLUID

GASOLINE ENGINE TRUCK
Engine : TB42
Ambient temperature ( C)
Lubrication point Type of fluid Capacity (l)
-30 -20 -10 0 10 20 30 40
Engine oil pan SAE 30-CD 8.5
Engine oil
TORQFLOW SAE 10W-CD 20

transmission case
SAE 80
Differential case Gear oil 12.5
SAE 90
SAE
5W-CD
Hydraulic oil tank Hydraulic oil 65
SAE 10W-CD
Fuel tank Gasoline 140
Brake reservoir tank Brake fluid SAE 70R-1, SAE 70R-3, DOT3 0.05
Lithium
Greasing points grease NLGI No.2
Cooling system Coolant Add antifreeze 15
a Use CD or upper grade oil.

a Be sure to use genuine oil for Komatsu Forklifts
(Komatsu Forklift dealers provide oil, grease, and antifreeze).
20-36 DX-Series
TESTING AND ADJUSTING SPECIFIED FUEL, LUBRICATING OIL, AND FLUID
DIESEL ENGINE TRUCK

Engine : S6D102E, SA6D102E
Ambient temperature ( C)
Lubrication point Type of fluid Capacity (l)
-30 -20 -10 0 10 20 30 40
SAE 10W-CD
Engine oil pan 16.5
SAE 30-CD
Engine oil
TORQFLOW
SAE 10W-CD 20
transmission case
SAE 80 FD50 -- 70 : 12.5

Differential case Gear oil
SAE 90 FD80 : 15
SAE
5W-CD FD50 -- 70 : 65
Hydraulic oil tank Hydraulic oil
SAE 10W-CD FD80 : 72
ASTM D975 No. 2

Diesel fuel 140
Fuel tank (*1) ASTM
D975 No. 1
Brake reservoir tank (*2) Brake fluid SAE 70R-1, SAE 70R-3, DOT3 0.05
Lithium
Greasing points NLG1 No.2
grease
FD50 -- 70 : 15
Cooling system Coolant Add antifreeze
FD80 : 20
*1. Do not use fuel containing kerosene.

*2. FD80 does not use the brake reservoir tank since it is equipped with a fully hydraulic brake system.
a Use CD or upper grade oil.

a Be sure to use genuine oil for Komatsu Forklifts
(Komatsu Forklift dealers provide oil, grease, and antifreeze).
DX-Series 20-37
TESTING AND ADJUSTING LUBRICATING TABLE
LUBRICATING TABLE
LUBRICATING PARTS AND INSPECTION AND MAINTENANCE CYCLES
Notes Symbol. Type of fluid

E : Check, then add if necessary.
Q : Replace or add oil/grease. Gasoline engine oil
T : Number of lubrication parts. EO
Diesel engine oil
MO Engine oil
GO Gear oil
HO Hydraulic oil
BF Brake fluid
G Grease
20-38 DX-Series
30. REMOVAL AND INSTALLATION
Unit assembly position ..................................... 30- 2

Weight table ..................................................... 30- 3
Removal and installation flowchart................... 30- 5
Overall disassembly and assembly drawing .... 30- 6
Lift cylinder ....................................................... 30- 8
Mast ................................................................. 30-11
Engine .............................................................. 30-12
Torque converter + transmission...................... 30-19
Drive axle ......................................................... 30-23
Steering axle and power steering..................... 30-25
Wheel brake ..................................................... 30-28
Standard tightening torque............................... 30-32
How to use loctite............................................. 30-34
DX-Series 30-1
REMOVAL AND INSTALLATION UNIT ASSEMBLY POSITION
UNIT ASSEMBLY POSITION
1. Meter panel 12. Starting motor

2. Steering wheel 13. Hydraulic pump
3. Head guard 14. Clutch or torque converter
4. Operator seat 15. Transmission
5. Radiator 16. Front axle
6. Weight 17. Front wheel
7. Muffler 18. Fork
8. PS cylinder 19. Control valve
9. Rear wheel 20. Tilt cylinder
10. Rear axle 21. Lift cylinder
11. Engine 22. Mast
30-2 DX-Series
REMOVAL AND INSTALLATION WEIGHT TABLE
WEIGHT TABLE
Unit: kg
FG50 FG60 FG70 Remarks
Engine assembly 320 320 320
Radiator assembly 17 17 17
Torque converter assembly 110 110 110
Transmission assembly 130 130 130
Front 435 435 435 Excluding the front wheel.

Axle
Rear 370 370 370 Excluding the PS cylinder.
Front 100 135 135 Including the rim (on one side
alone).
Wheel (a single wheel)
Rear 50 70 70
Head guard 165 165 165
Counter weight 2,275 2,465 3,705
Hydraulic pump 17 17 17
Control valve 27 27 27
Steering valve 6 6 6
Lifting height 3 m (mass of a

Lift cylinder assembly 58 58 60 single assembly)
Tilt cylinder assembly 25 25 25 Weight of a single assembly
PS cylinder assembly 40 40 40
Lifting height 3 m. Excluding the

Mast assembly 1,075 1,075 1,100 fork carriage and fork.
Finger bar assembly 325 325 325 Excluding the fork.
Fork assembly 115 125 135 1,220 mm long.
Note: The single-tire specification is employed for the front wheels of the FG50.
DX-Series 30-3
REMOVAL AND INSTALLATION WEIGHT TABLE
Unit: kg
FD50 FD60 FD70 FD80 Remarks
Engine assembly 470 470 470 480
Radiator assembly 22 22 22 31
Torque converter assembly 110 110 110 110
Transmission assembly 130 130 130 130
Front 435 435 435 535 Excluding the front wheel.

Axle
Rear 370 370 370 400 Excluding the PS cylinder.
Including the rim (on one side

Front 100 135 135 170 alone).
Wheel (a single wheel)
Rear 50 70 70 70
Head guard 170 170 170 170
Counter weight 2,270 2,980 3,700 4,475
Hydraulic pump 17 17 17 17
Control valve 27 27 27 27
Steering valve 6 6 6 6
Lifting height 3 m (mass of a

Lift cylinder assembly 58 58 60 68 single assembly)
Tilt cylinder assembly 25 25 25 35 Weight of a single assembly
PS cylinder assembly 40 40 40 40
Lifting height 3 m. Excluding the

Mast assembly 1,075 1,075 1,100 1,440 fork carriage and fork.
Finger bar assembly 325 325 325 500 Excluding the fork.
Fork assembly 115 125 135 160 1,220 mm long.
Note: The single-tire specification is employed for the front wheels of the FD50.
30-4 DX-Series
Front wheel Torque shaft Differential Brake
DX-Series
Tilt cylinder Mast Brake piping Front axle
Lift cylinder Parking

brake cable
Muffler Propeller shaft

REMOVAL AND INSTALLATION
Radiator hose Shroud Radiator
Engine hood
Pedal link
Completed
machine Head guard
Forward-reverse
lever link
Engine
Hydraulic
accessories
control valve Engine
+
Floor plate Wire harness Torque
converter
+
Parking Transmission
Master back Torque converter
brake lever
piping
Hydraulic
REMOVAL AND INSTALLATION FLOWCHART
Handle
piping
Hydraulic pump
Rear wheel Power Power

steering piping steering cylinder
Steering link
Rear axle
Counter-
Removal weight Installation
REMOVAL AND INSTALLATION FLOWCHART
30-5
REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY DRAWING
OVERALL DISASSEMBLY AND ASSEMBLY DRAWING
30-6 DX-Series
REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY DRAWING
DX-Series 30-7
REMOVAL AND INSTALLATION LIFT CYLINDER
LIFT CYLINDER
REMOVAL
1) Erect the mast straight up.
2) Remove the stopper bolt.
3) Lift the mast using the crane.
4) Apply the block under the inner mast.
5) Remove the cylinder clamp.
6) Operate the work equipment control lever several
times to bleed pressure remaining in the piping.
Then, remove the piping.
a After removing the piping, attach the blind plug
immediately so that flow out of hydraulic oil or en-
try of dusts may be prevented.
7) Lift up and then remove the cylinder using the
spring belt.
• Place a piece of square timber under the
mast assembly (1), then place the assembly
horizontally so that the finger bar comes up-
per side.
• Secure part A with wires.
30-8 DX-Series
INSTALLATION
Installation operation is essentially performed in the
reverse order of removal. Then, the synchronous ad-
justment of the mast and cylinder is done along with
air bleeding of the lift cylinder air.
1. Synchronization of masts
1. Inner mast
2. Cylinder rod
3. Outer mast
4. Shim (Right side)
5. Shim (Left side)
(1) Raise the masts to the maximum lifting
height.
(2) Check the lateral play of the masts.
(3) Adjust the shims so that the masts will be syn-
chronized with the right and left cylinders
when they are at the maximum lifting height.
Tilting to left Put shim (5) in left cylinder.

Tilting to right Put shim (4) in right cylinder.
2. Bleeding air from the lift cylinder

(1) Start the engine, then turn on the low idling
state.
(2) Move the mast up and down.
a Up and down move of the mast should be
stopped at a position approximately 100
mm away from the maximum lifting height
and the lowering position, respectively.
(3) Repeat above step (2) operation several
times.
(4) Move the mast to the maximum lifting height
and lowering position.
(5) Repeat above step (4) operation several
times.
DX-Series 30-9
30-10 DX-Series
REMOVAL AND INSTALLATION MAST
MAST
REMOVAL
1. Apply blocks to the front and rear wheels.
2. Remove the fork.
3. Lift the finger bar using the crane to dismount the

hydraulic piping.
4. Place a block under the finger bar.
5. Operate the work equipment control lever several

times to bleed pressure remaining in the piping,
then remove the piping.
a After removing the piping, attach the blind plug

immediately so that flow out of hydraulic oil and
entry of dusts may be prevented.
6. Lift the finger bar slightly using the crane, then re-
move the block.
7. Lower the finger bar.
8. Hold the mast with the crane.
9. Remove the tilt pin.
10. Tilt the mast slightly forward, then remove the

catch bolt fixing the differential.
k • If you try to remove the catch bolt with the
mast being tilted backward or excessively
forward, the mast can suddenly fall down
or disengage.
• Space in front of the mast be evacuated.
11. Dismount the mast.

Note: Before carrying the laid mast, the lower
stay and finger bar on the outer mast
must be fixed with a wire.
k The mast assembly is placed horizontally on
a piece of square timber so that the finger
bar may come to the upper side.
a Installation of the mast is done in the reverse or-
der of removal.
DX-Series 30-11
REMOVAL AND INSTALLATION ENGINE
ENGINE
REMOVAL
1. Head guard (at the ceiling)
Bonnet (first, remove the interlocking cable for
the steering wheel spring-up mechanism).
Counter weight
k Before starting the disassembly, the fork
and attachment must be placed on the
ground or removed.
The truck falls if the counter weight is re-
moved while the mast attachment are lifted.
2. Wiring and battery

Whenever removing the wiring or battery, the (–)
terminal and (–) lead wire must be removed first.
1) FG50/60/70
30-12 DX-Series
2) FD50/60/70
3) FD80
DX-Series 30-13
3. Axle wire
Remove the axle wire.
4. Piping (for hydraulic system and torque converter) and hose (for radiator, air cleaner and fuel)
Remove the piping and hoses.
1) FG50/60/70
2) FD50/60/70
30-14 DX-Series
3) FD80
DX-Series 30-15
S6D102E
5. Radiator, shroud and exhaust pipe
SA6D102E
6. Flexible plate mounting bolt
7. Engine
1) Place a wooden block under the transmission
case.
2) Using the crane, lift the engine and hold it in
that position.
3) Remove the clutch case mounting bolt (for
the machine employing the clutch).
Remove the torque converter mounting bolt
(for the machine employing the torque con-
verter).
30-16 DX-Series
INSTALLATION
Installation is done in the reverse order of removal.
Care must be paid to the following points.
1. Tightening of the engine mounting bolt

The shim shown in the figure to the right is used
for adjusting clearance of the frame side mount.
The shim may be used on either of the left or right
side.
49 – 88 Nm {5.5 – 9.0 kgf•m}
Shim: 0.5 mm, 1.0 mm
2. Tightening of the torque converter case

mounting bolt
59 – 74 Nm {6 – 7.5 kgf•m}
3. Tightening of the flexible plate mounting bolt

(with torque converter)
59 – 74 Nm {6 – 7.5 kgf•m}
DX-Series 30-17
4. Tightening of the hydraulic piping

k • After removing the hydraulic piping or
parts used on the hydraulic system, make
sure to attach the blind plug immediately.
• Care must be exercised when you open the
hydraulic tank cap or radiator cap immedi-
ately after an operation is over. Hot gas or
steam may burst out.
• Bleeding Oil Pressure
1. Lower the work equipment to the ground
level.
2. Stop the engine, then operate the con-
trol lever two or three times.
3. Open the oil filler port cap gradually.
Elbow, nipple and union tightening torque
Width across mm 22 30 36
flats B
Width D mm 19 22 30
Tightening Nm 30 – 39 79 – 103 118 – 162
torque {kgf•m} {3 – 4} {8 – 105} {12 – 16.5}
3/4-16 13/16-12 15/16-12
Port size inch UNF UNF UNF
Tightening Nm 69 – 74 118 – 162 108 – 147
torque {kgf•m} {7 – 7.5} {12 – 16.5} {11 – 15}
High pressure rubber hose, pipe and sleeve nut

tightening torque
Width across
flats B mm 19 24 27 32 36
Inside diame- mm 14 18 22 24 30
ter A
Tightening Nm 20 – 30 30 – 69 56 – 98 108 – 167 147 – 206
torque {kgf•m} {2 – 3} {3 – 7} {6 – 10} {11 – 17} {15 – 21}
5. Tighten the counter weight mounting bolt.

882 – 1,176 Nm {90 – 120 kgf•m}
30-18 DX-Series
REMOVAL AND INSTALLATION TORQUE CONVERTER + TRANSMISSION
TORQUE CONVERTER + TRANSMISSION

REMOVAL
1. Head guard (at the ceiling)
Bonnet (steering wheel spring-up mecha-
nism)
a Battery whenever removing the battery or wiring,
make sure to remove the (–) terminal and vehicle
grounding wire first.
a The TORQUEFLOW transmission can be dis-
mounted either by lifting it up toward the front side
of the vehicle or toward rear side of the vehicle.
Whatever approach you may select, make sure to
exercise reasonable care to prevent accidents or
personal injuries.
Considering ease of positioning of the transmis-
sion and centering of the propeller shaft during
assembly work, this document employs the ap-
proach of dismounting this assembly toward the
latter approach (lifting it toward rear side of the
vehicle).
k • Every dismounting operation must be done
according to the instructions provided
from the group supervisor. And, always
make sure that the safety comes first.
• Lifting operations are allowed only to those
who have successfully completed the
crane and slinging work training program.
• Wires used in the lifting must be free from
damages and provided with sufficient
strength.
2. Floor plate
Reservoir tank
Floor stay and accelerator pedal
Wiring
Meter panel
Steering wheel (including the column, valve)
Hydraulic piping
k • After removing the hydraulic piping, make
sure to attach the blind plug immediately so
that flow our of hydraulic oil and entry of
dusts may be prevented.
• When assembling the steering valve pip-
ing, attach numbered tags to the four pipes
(hoses) so that the assembly may not devi-
ate from specified procedure.
• Whenever attaching or detaching the con-
nector for the meterpenal wiring, do it hold-
ing the connector body. Don’t try to
disconnect the connector holding the cord.
DX-Series 30-19
3. Torque converter cooler piping
4. Pedal
Inching cable
Master back link rod
Solenoid valve wiring
5. Flexible cable mounting bolt Flexible plate

Propeller shaft
a Remove the top cover on the torque convert-

er case, then remove the flexible plate mount-
ing bolt.
30-20 DX-Series
6. Lifting tool set

Transmission mount
a Adjustment shims (3) are inserted between trans-

mission mount (1) and bracket (2) on the frame
side. When they are removed, do not disassem-
ble them but bind them for the right side and left
side respectively.
a Set the lifting tool set on the torque converter side

lifting bolt (5) and the transmission side bracket
(4), lift the transmission until it is almost detached
from the current position, then remove the trans-
mission mount and torque converter tightening
bolt (6).
7. Torque converter and transmission assembly

• Remove the bolts (6) connecting the engine and
torque converter (the bolt provided on each side
must be maintained at 15 mm above the original
position so that they may not fall off unnoticed),
then swing the transmission slightly to separate
the engine from the torque converter.
• Remove the remained bolts (one for each side),

move the torque converter and transmission as-
sembly slowly forward until the mount bracket on
the transmission and frame is completely disen-
gaged. After making sure that the bracket is dis-
engaged, lift and then place them gently on the
carriage prepared in the pit.
• Then, using the crane, lift the torque converter

and transmission assembly out the pit.
DX-Series 30-21
INSTALLATION
Installation is done in the reverse order of removal.
Care must be paid to the following points.
1. Tightening of the torque converter case

mounting bolt
59 – 74 Nm {6 –7.5 kgf•m}
2. Tightening of the flexible plate mounting bolt

59 – 74 Nm {6 – 7.5 kgf•m}
3. Pedal assembly
Brake piping
a Bleeding the brake air

Refer to the section describing the "AIR BLEED-
ING PROCEDURE".
a Pedal adjustment
Refer to the section describing the "PEDAL AD-
JUSTMENT PROCEDURE".
FD80 is equipped with a fully hydraulic brake sys-
tem.
30-22 DX-Series
REMOVAL AND INSTALLATION DRIVE AXLE
DRIVE AXLE
REMOVAL
1. Mast
(Refer to the section describing the "MAST".)
2. Lift front side of the vehicle.

Using the crane, lift front side of the vehicle until
front wheels are detached from the ground.
Then, using the block applied under the frame,
adjust height the front wheels to 50 to 100 mm
from the ground level.
3. Brake pipe
Disconnect the brake pipe from the master cylin-
der at the T block (disconnection of the brake
k A pan should be prepared to receive brake

pipe).
fluid that comes out of the pipe. Don’t allow

the brake fluid to spill on the floor. Spilt fluid
must be wiped off.
4. Parking brake cable

Drive out the snap pin (1), then remove the pin (2)
situated at the cable end to disconnect the cable
(4) from the lever (3).
5. Propeller shaft
Remove the propeller shaft mounting bolts (6)
(one each on the transmission side and parking
brake side) to dismount the propeller shaft.
6. Front axle
• Place the carriage under the front axle, then re-
move the frame mounting bolt (5).
• Lower the carriage slowly, then after making sure
that the front axle has been detached from the
frame, take out the front axle through the front
side of the vehicle.
DX-Series 30-23
REMOVAL AND INSTALLATION DRIVE AXLE
INSTALLATION
Installation is done essentially in the reverse order of
removal. Care must be paid to the following points.
1. Tightening of the frame front axle connecting

bolt
1,127 – 1,911 Nm {115 – 195 kgf•m}
a Rusts or dusts on the mating face of the
frame and front axle must be cleaned before-
hand.
2. Propeller shaft radial runout and tightening

torque
(1) Radial runout between A and B should be 2.5
mm maximum.
a An excessive radial runout on the propel-
ler shaft can cause abnormal noise, oil
leakage or shaft damage.
Such inappropriate radial runout must be
corrected from the transmission mount or
engine mount.
(2) Tightening torque of the mounting bolt (6)
59 – 74 Nm {6.0 – 7.5 kgf•m}
3. Parking brake clearance adjustment

Clearance must be adjusted to 0.1 to 0.25 mm.
a Make sure that the snap pin (2) is positively
inserted.
4. Air bleeding on the service brake (vacuum hy-

draulic)
[Refer to the section describing the testing and
adjustment procedure "AIR BLEEDING"]
5. Tightening torque of the mast support cap

mounting bolt
5 to 7 ton 490 – 608 Nm {50 – 62 kgf•m}
8 ton 824 –1,030 Nm {84 –105 kgf•m}
a For the air bleeding on the hydraulic cylinder,
refer to the section describing the testing and
adjustment "AIR BLEEDING".
30-24 DX-Series
REMOVAL AND INSTALLATION STEERING AXLE AND POWER STEERING
STEERING AXLE AND POWER STEERING

REMOVAL
1. Counter weight
1) Lift the counter weight slightly using the
crane, then remove the mounting bolt to dis-
mount the counter weight.
2) Lift rear side of the frame using the crane,
place a wooden block under both sides of the
frame.
2. PS cylinder rod link

Hydraulic piping
Remove the PS cylinder rod link provided on both
sides, then remove the hydraulic piping.
3. Steering axle
1) Support the steering axle using the carriage.
2) Remove the 4 rear side axle support bolts,
then drive the steering axle approximately 85
mm backward.
3) After making sure that the center pin is driven
out of the front side support (welded), lower
the carriage slowly to move the steering axle
(with the PS cylinder) out of the vehicle.
4. Power steering cylinder

• When removing the PS cylinder alone
After removing the weight, PS cylinder rod link
and hydraulic piping, set the carriage and remove
the mounting bolt. Then, lower the carriage
slouchy and, before the PS cylinder rod contacts
against the protector, drive the PS cylinder out
through front side of the vehicle.
DX-Series 30-25
INSTALLATION
1. Tightening of the steering axle support bolt (1)

5 to 7 ton 157 – 225 Nm {16 – 23 kgf•m}
8 ton 343 – 426 Nm {35 – 43.5 kgf•m}
a Using shims, adjust the clearance a to 0.5
mm or less.
a The bushing must be mounted in such that
the bushing hole may face up.
2. Tightening of the PS cylinder mounting bolt (2)

662 – 829 Nm {67.5 – 84.5 kgf•m}
Coat the threaded portion with loctite # 271
3. Steering linkage
• The cotter pin must be positively bent.
30-26 DX-Series
4. Adjustment procedure for steering angle

1) Adjust the steering angle so that left stopper
bolts (5) and (4) and right stopper bolt (3) and
(6) always come in contact simultaneously
when the tires are set to the maximum steer-
ing angle.
2) After adjusting the steering angle, reciprocate
the PS cylinder and check that the link joints
are free from scuffing.
5. Tightening of the counter weight mounting

bolt
882 – 1,176 Nm {90 – 120 kgf•m}
Molybdenum disulfide
a Prior to tightening of the bolt, coat it with mo-
lybdenum disulfide.
DX-Series 30-27
REMOVAL AND INSTALLATION WHEEL BRAKE
WHEEL BRAKE
REMOVAL
1. Front wheels and torque shaft
1) Apply chocks to the rear wheels.
2) Place a block under the frame to lift the front
wheels.
3) Apply the parking brake.
4) Remove the hub nut (1) to dismount the front

wheels.
5) Remove the bolt (2) and cover (3).
6) Remove the bolt (4).
7) Release the parking brake.
8) Remove the planet carrier assembly (5).
9) Drive out the torque shaft (6).
a Remove the torque shaft by attaching the
pulling bolt [10 ø × P 1.5, l = 100 (threaded
portion = 15 mm)] to the screw hole (10E× P
1.5, 20 mm deep) provided at the shaft end.
2. Hub
1) Remove the bolt (7).
2) Remove the lock nut (8).
3) Remove the hub while paying attention so
that it may not be twisted.
4) Remove the inch lace (10) on the hub inner
bearing.
5) Remove the retainer (11).
30-28 DX-Series
5 – 7 ton
3. Brake drum
1) 5 – 7 ton
(1) Remove the bolt (1).
(2) Remove the brake drum (2).
8 ton
2) 8 ton
(1) Remove the nut (3).
(2) Remove the brake drum (4).
a The bolt assembled to the brake drum
and that on the nut are united hub and
bolt type.
5 – 7 ton
4. Back plate and brake shoe assembly
1) 5 – 7 ton
(1) Remove the sleeve nut on the brake pipe.
a Receive the brake fluid using a pan.
Don’t forget to clean the spilt fluid.
(2) Remove the bolts (1) and (2).
Bolt (1): Four bolts are provided on the
wheel cylinder side.
Bolt (2): Three bolts are provided on the
adjuster side.
a Care must be used to avoid
confusion between them.
(3) Remove the back plate and shoe assem-
bly. 8 ton
2) 8 ton
(1) Remove the sleeve nut on the brake pipe.
a Receive the brake fluid using a pan.
Don’t forget to clean the spilt fluid.
(2) Remove the nut (1) and bolt (2).
(3) Remove the back plate and shoe assem-
bly.
DX-Series 30-29
5 – 7 ton
INSTALLATION
1. Tightening torque of the back plate mounting

bolt
1) 5 – 7 ton
157 – 196 Nm {16 – 20 kgf•m}
Coat the threaded portion with Loctite
#271.
Bolt (1): Four reamer bolts are provided on the
wheel cylinder side.
8 ton
Bolt (2): A KES bolt.
a Care must be used to avoid confusion be-
tween them.
2) 8 ton
245 – 309 Nm {25 – 31.5 kgf•m}
Coat the threaded portion with Loctite
#271.
2. Tightening torque of the brake drum mount- 5 – 7 ton

ing bolt
1) 5 – 7 ton
196 – 309 Nm {20 – 31.5 kgf•m}
8 ton
2) 8 ton (Nut is tightened to hub bolt)
319 – 490 Nm {32.5 – 50 kgf•m}
a After tightening the nut to the hub bolt,
cross caulk them.
30-30 DX-Series
5 – 7 ton
3. Adjusting the front hub and brake
1) Front hub starting torque
14.7 – 29.4 Nm {1.5 – 3 kgf•m}
a Tighten the lock nut (1), then adjust the start-
ing torque to the specified level.
a After the starting torque adjustment is com-
plete, tighten the lock bolt (2) and then attach
the cotter pin. The cotter pin must be posi-
tively bent.
a When assembly and adjustment of the hub
are over, double check the starting torque
value. If it is not conforming to the specified
value, the adjustment must be repeated.
2) Bleeding the brake air

Refer to the section describing the "BLEED-
ING AIR".
3) Adjusting the brake

Clearance between the brake drum and lin-
ing:
Standard clearance 0.4 – 0.6 mm
a Auto adjuster’s per notch adjusting volume:
5 – 7 ton: 0.016 mm
8 ton: 0.04 – 0.12 mm
8 ton
DX-Series 30-31
REMOVAL AND INSTALLATION STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

BOLT
For unspecified bolts and nuts, use the torques spec-
ified in this list.
Select a proper torque corresponding to the width
across flats (b) of bolts and nuts.
When replacing bolts and nuts, always use genuine
Komatsu Forklift parts the same size as the previous
ones.
Thread diameter Width across Tightening torque (Nm {kgf•m})

of bolt (a) flat (b)
(mm) (mm) Target value Range
6 10 13 {1.35} 12 – 15 {1.2 – 1.5}
8 13 31 {3.2} 27 – 34 {2.8 – 3.5}
10 17 66 {6.7} 59 – 74 {6.0 – 7.5}
12 19 113 {11.5} 98 – 123 {10.0 – 12.5}
14 22 177 {18.0} 157 – 196 {16.0 – 20.0}
16 24 279 {28.5} 245 – 309 {25.0 – 31.5}
18 27 382 {39.0} 343 – 427 {35.0 – 43.5}
20 30 549 {56.0} 490 – 608 {50.0 – 62.0}
22 32 745 {76.0} 662 – 829 {67.0 – 84.5}
24 36 927 {94.5} 824 – 1,030 {84.0 – 105.0}
27 41 1,324 {135.0} 1,177 – 1,471 {120.0 – 150.0}
30 46 1,716 {175.0} 1,520 – 1,912 {155.0 – 195.0}
33 50 2,206 {225.0} 1,961 – 2,452 {200.0 – 250.0}
36 55 2,746 {280.0} 2,452 – 3,040 {250.0 – 310.0}
39 60 3,285 {335.0} 2,893 – 3,628 {295.0 – 370.0}
30-32 DX-Series
REMOVAL AND INSTALLATION STANDARD TIGHTENING TORQUE
ELBOWS, NIPPLES AND UNIONS
Width across flats B mm 22 30 36
Width D mm 19 22 30
Tightening torque Nm {kgf•m} 29.4 – 39.2 {3 – 4} 78.5 – 103 {8 – 10.5} 117.7 – 161.8 {12 – 16.5}
Port size inch 3/4-16UNF 7/8-14UNF —
Tightening torque Nm {kgf•m} 68.6 – 73.6 {7 – 7.5} 78.5 – 83.3 {8 – 8.5} —
Union Elbow
HIGH-PRESSURE RUBBER HOSES, PIPES AND SLEEVE NUTS
Width across flats B mm 19 24 27 32 36
Bore A mm 14 18 22 24 30
19.6 – 29.4 23.5 – 68.6 58.8 – 98.1 107.9 – 166.7 147– 206
Tightening torque Nm {kgf•m} {2 – 3} {3 – 7} {6 – 10} {11 – 17} {15–21}
DX-Series 30-33
REMOVAL AND INSTALLATION HOW TO USE LOCTITE
HOW TO USE LOCTITE 4. Assembly

After applying LOCTITE, tighten the screw or fit
the shaft to the hole as usual. (When using LOC-
1. PROCEDURE FOR USING LOCTITE
TITE for structures or LOCTITE of instant glue
type, press the mating parts lightly (about 49 kPa
Male side {0.5 kgf/cm2}).
Degreasing Air drying
2. REMOVAL OF PARTS
Female
side
When screws and shafts are secured with LOC-
TITE, they usually can be removed with common
tools such as spanners, wrenches, pulley pull-
Leaving Applying
Assembly ers, etc. If LOCTITE is so strong that a part may
LOCTITE
be broken when it is removed, heat it (to 200 –
250°C) with a soldering iron, gas torch, etc., and
1. Degreasing and cleaning you can remove it easily. It is generally difficult
(a) Clean the parts in trichloroethylene, ace- to dissolve LOCTITE in chemical solutions.
tone, ether, alkaline solution, etc. which are
highly volatile. 3. WHEN ASSEMBLING AGAIN
(b) Degrease the parts as perfectly as possible. (a) If a LOCTITE film on threads is broken, it is
(c) Since gasoline, light oil, kerosene, etc. are left as white powder on the threads. In this
not highly volatile, they are not recommend- case, you can apply LOCTITE again to the
ed. If it is obliged to use them, dry them threads without removing the white powder.
completely. (b) If shafts or flanges secured with LOCTITE
(d) If the mating parts are made of thermoset- are disconnected, LOCTITE remaining on
ting resin, treat them with LOQUICK PRIM- them may need to be removed to maintain
ER after degreasing them. dimensional accuracy. You can remove the
remaining LOCTITE easily, however, with a
2. Air drying wire brush, etc.
(a) Wait until the cleaning fluid dries out. (c) If plates secured with LOCTITE need to be
(b) If the parts are treated with LOQUICK PRIM- assembled again after they are separated,
ER, do not wipe them but dry them in air for be sure to remove all the hardened LOC-
5 – 10 minutes. (If LOCTITE is used before TITE and roughen the mating surfaces with
LOQUICK PRIMER dries out, its effect is sandpaper.
lowered.)
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads
or the shaft and hole to be fitted by amount to fill
the clearance between them by one of the fol-
lowing methods.
• Applying directly from LOCTITE container
nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving
pan.)
• Sponge
• Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
30-34 DX-Series
40. DISASSEMBLY AND ASSEMBLY
Disassembly drawing ...................................... 40- 2

Torque converter............................................. 40- 4
TORQFLOW transmission .............................. 40- 10
Propeller shaft ................................................. 40- 36
Differential ....................................................... 40- 38
Drive axle (Front axle)..................................... 40- 45
Wheel brake .................................................... 40- 50
Parking brake .................................................. 40- 54
Steering axle (Rear axle) ................................ 40- 56
Brake pedal ..................................................... 40- 59
Combination switch ......................................... 40- 61
Master back and master cylinder assembly .... 40- 66
Brake valve ..................................................... 40- 71
Steering valve ................................................. 40- 78
Hydraulic pump ............................................... 40- 94
Control valve ................................................... 40- 98
Hydraulic cylinder........................................... 40-100
Mast ............................................................... 40-112
Special tool list ............................................... 40-119
DX-Series 40-1
DISASSEMBLY AND ASSEMBLY DISASSEMBLY DRAWING
DISASSEMBLY DRAWING
40-2 DX-Series
DISASSEMBLY AND ASSEMBLY DISASSEMBLY DRAWING
No. Part name No. Part name
1 Snap ring 31 Bearing
2 Snap ring 32 Seal ring
3 Turbine shaft 33 Bolt washer
4 Bearing 34 Retainer
5 Seal 35 Oil seal
6 Bolt washer 36 Packing
7 Flexible plate 37 Pump boss gear
8 Pilot boss 38 Bearing
9 O-ring 39 Bolt washer
10 Snap ring 40 Shaft
11 Nut 41 Bolt washer
12 Bolt washer 42 Retainer
13 Drive cover 43 O-ring
14 Bearing 44 Driven gear
15 Plug washer 45 Bearing
16 O-ring 46 Bearing
17 Turbine 47 Bolt washer
18 Ring nut 48 Plate
19 Lock washer 49 Idler shaft
20 Thrust washer 50 Idler gear
21 Thrust washer 51 Bearing
22 Stator 52 Bearing
23 One-way clutch 53 Sleeve
24 Hub 54 Bolt
25 Spacer 55 Seal
26 Pump 56 Spring
27 Bolt washer 57 Valve
28 Pump boss 58 Elbow
29 O-ring 59 Adapter
30 Snap ring 60 Breather
• The number allocated to each part roughly indicates the order in which they are disassembled.
• Parts of No. 27, 28 and 29 are normally not disassembled.
DX-Series 40-3
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
TORQUE CONVERTER
40-4 DX-Series
ASSEMBLY SEQUENCE OVERVIEW

Whenever assembling rotary parts such as gear and bearing, they must be immersed in oil prior to the assembly.
No. Part name Mounting bolt Tightening torque Remarks
1 Idle gear — — Bearing: 2 are provided in the gear.
35.2 – 44.1 Nm
2 Idle shaft A {3.6 – 4.5 kgf•m} —
67.6 – 78.4 Nm Assembled with the seal ring, then coated with
3 Stator shaft B {6.9 – 8.0 kgf•m} small amount of grease.
4 PTO driven shaft — — Bearing: One each is provided on the case side
and gear side.
The O-ring is first assembled and coated with

5 Retainer C 67.6 – 78.4 Nm grease. Then, the bolt (C) is assembled to the
{6.9 – 8.0 kgf•m} guide.
6 Pump boss gear — — Bearing: 2 are provided in the gear.
7 Seal retainer D 18.6 – 24.5 Nm The seal is first assembled to the retainer. The
{1.9 – 2.5 kgf•m} lip is coated with small amount of grease.
8 Pump — — * The pump and pump boss are normally not

separated.
Make sure that the one-way clutch operates

9 Stator — — normally.
10 Thrust washer — — —
11 Thrust washer — — —
12 Lock plate — — * Assemble the ring nut (13), then bend the
washer claw at 2 points to lock.
13 Ring nut — — It is used for fixing the stator.

Make sure that the stator rotates smoothly.
14 Turbine —
98 – 118 Nm * The turbine and drive cover are normally not
{10 – 12 kgf•m} separated.
The O-ring is assembled to a position between

15 Drive cover E 27.4 – 33.3 Nm the pump and cover, then coated with small
{2.8 – 3.4 kgf•m} amounted of grease.
16 Pilot boss — — The O-ring is assembled first and then coated

with small amount of grease.
35.2 – 44.1 Nm
17 Flexible plate F {3.6 – 4.5 kgf•m} —
35.2 – 44.1 Nm
18 Charging pump G {3.6 – 4.5 kgf•m} Coat the pump drive spline axis with grease.
19 Turbine shaft — — Previously assemble the seal ring to the turbine

shaft and thinly coat it with grease.
20 Snap ring — — —
Disassembly is done essentially in the reverse order of assembly.
DX-Series 40-5
CHECK AND INSPECTION
Unit : mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
A Wear on the pilot tip 20 19.85
Pump boss inner diameter

B (seal ring contact surface) 68 68.15
C1 Width 2.5 1.93

C Seal ring
C2 Thickness 2.0 1.52 Replace
Converter case inner diameter

D (seal ring contact surface) 48 48.15
Width 2.5 1.93

E Seal ring
Thickness 2.7 2.22
40-6 DX-Series
ASSEMBLY
a Assembly is done essentially in the reverse order
of disassembly.
a Before starting the assembly, clean inside and
outside of the case as well as the components.
Make sure that they are free from foreign sub-
stance.
1. Idle gear and stator shaft

1) Assemble the sleeve (1) to the case.
2) Set the idle gear (2) in the case, then assem-
ble the idle shaft (3).
3) Using the plate (4) and bolt (5), fix the idle
shaft to the case.
• The bolt used: M10 × P 1.5 and l =
22 mm.
35.2 – 44.1 Nm {3.6 – 4.5 kgf•m}
4) Assemble the stator shaft (6) to the case,

then fix it with the bolt.
• The bolt used: M12 × P 1.75 and l =
30 mm.
67.6 – 78.4 Nm {6.9 – 8.0 kgf•m}
2. PTO driven gear

1) Assemble the bearing (1).
2) Engage the driven gear (2) with the idle gear,
then assemble.
3) Assemble the bearing (3).
4) Assemble the O-ring (5) to the bearing retain-
er (4), then assemble them using the bolt (6)
as the guide and fix them using the bolt.
• The bolt used: M12 × P 1.75, l = 40 mm.
67.6 – 78.4 Nm {6.9 – 8.0 kgf•m}
DX-Series 40-7
3. Pump boss gear and seal retainer

1) Assemble the bearing [(1) × 2] to the pump
boss gear (2), engage them with the idle gear,
then assemble them to the stator shaft.
2) Assemble the oil seal (3) to the seal retainer
(5), combine them with the packing [(4) coat-
ed with Loctite #572)], then assemble them to
the case.
3) Fix the seal retainer using the bolt (6).
18.6 – 24.5 Nm {1.9 – 2.5 kgf•m}
4) Assemble the seal ring (7). (Coat it with small

amount of grease G2-LI.)
4. Pump and stator

1) Assemble the bearing [(1) × 2] to inside the
hub of the pump (2), hold it using the snap
ring, then assemble the pump assembly to
the stator shaft.
a Care must be exercised in assembling
the pump so that the seal ring on the sta-
tor shaft may not be damaged.
2) Assemble the hub and one-way clutch (3). [It
comprises the roller, spring and cap among
others] to the stator (4). Then, assemble
them to the stator shaft.
a Use care to direction of the hub. The hub
spacer must be situated on the pump
side.
3) Assemble the thrust washers (5) and (6), then
assemble them to the lock washer so that its
claw faces outward.
4) Assemble the ring nut (8) on the lock washer
(7), then fix the stator.
a Set the ring nut. This setting position
must ensure smooth rotation of the stator
and also prevent its play in the axial direc-
tion.
5) Bend the lock washer claw (at two positions
minimum), then fix the ring nut.
40-8 DX-Series
5. Turbine, drive cover and pilot boss

1) Assemble the O-ring (1) to the pump.
2) Assemble the turbine (3) and drive cover (4)
[combine the turbine and drive cover via the
bearing (2) and fix them with the snap ring] to
the pump.
3) Fix the assembly using the bolt and nut.
27.4 – 33.3 Nm {2.8 – 3.4 kgf•m}
4) Assemble the pilot boss (5) and flexible plate

(6) (assemble the O-ring to the pilot boss).
5) Fix them using the bolt.
35.2 – 44.1 Nm {3.6 – 4.5 kgf•m}
6. Gear pump and turbine shaft

1) Assemble the O-ring (1) to the gear pump.
2) Coat the pump drive spline with grease, then
assemble the gear pump (2) to the case.
3) Fix the gear pump with the bolt.
• The bolt used: M10 × 1.5, l = 20 mm.
35.2 – 44.1 Nm {3.6 – 4.5 kgf•m}
4) Assemble the turbine shaft (3).

5) Fix it using the snap ring (4).
7. Piping
Attach the piping (hose and nipple).
DX-Series 40-9
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
40-10 DX-Series
DX-Series 40-11
PRESSURE CONTROL VALVE

Main relief pressure: 1.01 – 1.25 Mpa {10.3 – 12.7 kgf/cm²}
40-12 DX-Series
CONTROL VALVE (SOLENOID VALVE)
Inching spool protrusion 31 mm
• Solenoid valve operating voltage

a Mounting bolt.
Model Standard Range Improper tightening can cause the following trou-
bles:
Gasoline machine 12V 10 – 14V Insufficient tightening : Oil leakage.
Over tightening : Improper spool action.
Diesel machine 24V 22 – 26V
DX-Series 40-13
HYDRAULIC CIRCUIT DIAGRAM
40-14 DX-Series
TORQFLOW TRANSMISSION DISASSEMBLY DRAWING

a The number attached to each part represents thier disassembly order.
40-16 DX-Series
DX-Series 40-17
a Inspection port, pipe and control valve must be

removed beforehand.
a It is dangerous to remove snap rings (11) and

(16) without using a special tool, since the spring
tension is applied. Be sure to use special tool A.
Special tool A 3EC-97-99000
a Drive plate and driven plate

Prior to the assembly, immerse the drive plate
and driven plate in engine oil.
40-18 DX-Series
DISASSEMBLY
1. TORQFLOW transmission
After the TORQFLOW transmission assembly
has been dismounted from the machine body,
clean the case and accessories. Then, remove
the following parts:
• Oil and oil temperature sensor.
• Torque converter oil gauge, pipe and hose.
• Torque converter pump, hose and pipe.
• Work equipment hydraulic pump.
• Solenoid valve and plate.
• Control valve.
• Output shaft flange, and retainer pipe on in-
put and shafts.
1) Disengage the lifting tool from the eyebolt

and transmission bracket, then apply it to the
torque converter case (a jig is used). Then,
lift the case gradually.
2) Place and set the TORQFLOW transmission

assembly on the wooden blocks (each 200 to
300 mm square) or special work bench pro-
vided on the floor.
• 3 to 4 wooden blocks should be used to
stabilize the TORQFLOW transmission
assembly.
DX-Series 40-19
3) Separation of the torque converter and trans-

mission
• Loosen all bolts connecting the case.
Loosen them so that the clearance made
after removing the case is 2 to 3 mm.
a Remove two of them first.
• Raise the lifting tool slightly to tense the
wire of the lifting tool (donít try to lift the
torque converter).
• Bolt holes for the pulling bolts are provid-
ed near to the knock pin hole on the
torque converter case (one each on is
provided diagonally on both sides of the
case). Attach each of the two removed
bolts into the hole, then tighten them uni-
formly by alternately rotating each of
them a half turn at a time. When the bolt
touched the transmission case, rotate the
bolt more turn to detach the torque con-
verter case. If this operation does not
separate the case connection block,
strike outer surface of the case lightly us-
ing a plastic hammer.
• After making sure that the case connec-
tion block is completely separated, lower
the lifting tool and then remove all remain-
ing bolts.
• Raise the lifting tool to remove the torque
converter.
Front view of the transmission
(after separation)
40-20 DX-Series
CONNECTOR FOR SOLENOID VALVE
DX-Series 40-21
DETAIL OF CLUTCH PACK
Number of plate discs used per unit (For 1 forklift)
Type Clutch pack
Part name or No. For For For For

F1 F2 F3 F4
Plate [1] 3EC-15-31290 2 2 2 2
Disc 3EC-15-31270 7 7 7
Disc 3FD-15-21470 7
Plate 3EC-15-31280 6 6 6 6
Plate [2] 3FD-15-21320 1 1 1 1
40-22 DX-Series
CLUTCH PACK ASSEMBLY PROCEDURE
Code Part name Assembly procedure
1 Seal 1
2 Piston ring 2
3 Piston 3
4 Plate [1] 4
5 Disk 5 7 9 11 13 15 17
6 Plate 6 8 10 12 14 16
7 Plate [2] 18
8 Plate [3] 19
9 Ring 20
10 Spring 21
11 Spacer 22
12 Snap ring 23
13 Boss gear 24
a Assembly is done in the reverse order of disassembly.
CLUTCH PACK ASSEMBLY (DETAIL)

1. Install the seal to the shaft in the drum. 24. Assemble the gear.
2. Install seal ring to the piston. a After the piston has been assembled, you
3. Install the piston to the cylinder in the drum. may assemble the clutch pack in the order of
4. Install the plate (t = 4.5 ± 0.1). (Both sides are the the spring, spacer and snap ring in stead of
same.) the above order of the plate and disc. It is al-
5. Install the disc (3EC-15-31270). (Both sides are lowed to employ the procedure you are ac-
the same.) customed to.
a The disc of F2 is made of sintered alloy (3FD- a Use a special tool A for tightening the snap
15-21470). ring on the piston return spring.
6. Install the plate (3EC-15-31280).
Special tool A 3EC-97-99000
a In the following procedures, install the disc
and plate alternately.
17. Install the disc (3EC-15-31270). (Both sides are
the same.)
18. Install the plate (the same as the one in No. 4, t =
4.5 ± 0.1).
19. Install the plate (warped, t = 2 ± 0.07).
a Install this plate with the warped side out
(Warp: 1.8 ± 0.1).
20. Fix the plate with the ring.
21. Install the spring.
22. Install the spacer.
23. Fix the spacer with the snap ring.
DX-Series 40-23
ASSEMBLY OF INPUT SHAFT (R1/R2) SUB-ASSEMBLY

(Assembly is done essentially in the reverse order of disassembly.)
a The clutch plate and disc are immersed in oil prior to the assembly.
a Coat the seal ring with grease.
40-24 DX-Series
Assembling
sequence
R1/R2 shaft
(R1 side) (R2 side)
1 Assemble the seal to the shaft. Assemble the seal to the shaft.
2 Assemble the seal ring to the piston. Assemble the seal ring to the piston.
3 Assemble the piston to the drum. Assemble the piston to the drum.
4 Assemble the spring. Assemble the spring.
5 Assemble the spacer. Assemble the spacer.

Clutch pack
6 Secure it with the snap ring. Secure it with the snap ring.
7 Assemble the plate (t = 4.5 ± 0.1 mm). Assemble the plate (t = 4.5 ± 0.1 mm).
8 Assemble the clutch disk and plate (6). Assemble the clutch disk and plate (6).
9 Disc (7) and plate (6). Disc (7) and plate (6).
Assemble the plate (t = 2 ± 0.07 mm) Assemble the plate (t = 2 ± 0.07 mm)
11
(with the warped surface facing outside). (with the warped surface facing outside).
12 Fix them using the ring. Fix them using the ring.
13 Assemble a washer. Assemble a washer.
14 Assemble the bearing to the boss gear, then Assemble the bearing to the boss gear, then
15 assemble the boss gear to the drum (Z3 = 25). assemble the boss gear to the drum (Z2 = 43).
16 Assemble the washer. Assemble the washer.
17 Fix the washer using the snap ring. Assemble the gear (Z1 = 45).
18 Assemble the ball bearing. Assemble the ball bearing.
Fix it using the snap ring. Fix it using the snap ring.
Assemble the seal ring.
R1/R2 (input shaft) sub-assembly
DX-Series 40-25
ASSEMBLY OF INTERMEDIATE SHAFT (F1/F2)

(Assembly is done essentially in the reverse order of disassembly.)
a The clutch pate and disc are immersed in oil prior to the assembly.
a Coat the seal ring with grease.
40-26 DX-Series
Assembling
sequence
F1/F2 shaft
(F1 side) (F2 side)
1 Assemble the seal to the shaft. Assemble the seal to the shaft.
2 Assemble the seal ring to the piston. Assemble the seal ring to the piston.
3 Assemble the piston to the drum. Assemble the piston to the drum.
4 Assemble the spring. Assemble the spring.
5 Assemble the spacer. Assemble the spacer.

Clutch pack
6 Fix them with the snap ring. Fix them with the snap ring.
8 Assemble the clutch disk and plate alternately. Assemble the clutch disk and plate alternately.
9 Disc (7) and plate (6). Disc (7) and plate (6).
11 Assemble the plate (t = 2±0.07 mm). Assemble the plate (t = 2 ± 0.07 mm).
12 Fix them using the ring. Fix them using the ring.
13 Assemble a washer. Assemble a washer.
14 Assemble the bearing to the boss gear, then Assemble the bearing to the boss gear, then
15 assemble the boss gear to the drum (Z3 = 25). assemble the boss gear to the drum (Z2 = 43).
16 Assemble the washer. Assemble the washer.
17 Fix the washer using the snap ring. Assemble the gear (Z1 = 45).
18 Assemble the ball bearing. Assemble the ball bearing.
19 Fix it using the snap ring. Fix it using the snap ring.
20 Assemble the seal ring.
F1/F2 (intermediate shaft) sub-assembly
DX-Series 40-27
PRECAUTIONS ON THE ASSEMBLY

1. Clutch pack assembly
a Check action of the drive plate and driven
plate by blowing air into the oil hole.
Air pressure 0.49 MPa {5 kgf/cm²}
Stroke 2.2 mm
2. Solenoid valve
Solenoid valve (1) : For F1, F2
Solenoid valve (2) : For R1
a Tighten the mounting bolts in the order of [1]
– [4] shown in the figure at right.
1.96 Nm {0.2 kgf•m}
a Check action of the spool after the assembly.

Insufficient tightening: Oil leakage.
Over-tightening: Not smooth spool action.
3. Seal ring
a It must be coated with grease prior to the as-
sembly.
40-28 DX-Series
PRESSURE CONTROL VALVE AND SOLENOID VALVE

Main relief pressure: 1.01 – 1.25 MPa {10.3 – 12.9 kgf/cm²}
Inching spool projection: 31 mm (Stroke: 24 mm)
DX-Series 40-29
ASSEMBLY
a Before starting the assembly, inside and outside
of the transmission, oil route and bolt holes must
be sufficiently cleaned to prevent contamination
by foreign substances.
1. Filter
1) Attach the O-ring (2) to the filter (1), then as-
semble them.
2) Assemble the gasket (3) and plate (4), then
tighten them with the bolt.
27.44 – 34.3 Nm {2.8 – 3.5 kgf•m}
Threaded portion must be coated with Loctite

#271.
2. Dumper
1) Assemble the piston (6), spring (7) and collar
(8), then assemble the plate (9). Tighten
them using the bolt.
27.44 – 34.3 Nm {2.8 – 3.5 kgf•m}
Threaded portion must be coated with Loctite

#242.
3. Plug, oil temperature sensor and oil cap

Assemble the plugs [(11) × 6], oil temperature
sensor (12) and coil cap (13).
4. Large gear for the output shaft

1) Place the large gear (Z5 = 45) in the transmis-
sion case.
a You must place this large gear in the trans-
mission case first because it canít be inserted
after the intermediate shaft and such have
been assembled
40-30 DX-Series
5. Intermediate shaft sub-assembly (for F1/F2)

1) Assemble the intermediate shaft sub-assem-
bly to the transmission case.
a Insert the intermediate shaft sub-assem-
bly gradually through the sub-assembly
hole prepared on the torque converter
side.
2) Fit the bearing (3) to the intermediate shaft,
then assemble them to the case.
3) Fix the assembled bearing (3) using the snap
ring (4).
a Make sure that the snap ring is positively
held in the groove.
• Torque converter side

1. Suction filter
2. Hole prepared for the output shaft
3. Hole prepared for the input shaft
4. Dumper
5. Hole prepared for the intermediate shaft
DX-Series 40-31
6. Input shaft sub-assembly (for R1/R2)

1) Assemble the input shaft sub-assembly into
the transmission case.
a Insert the input shaft sub-assembly grad-
ually through the hole prepared on the
torque converter side while maintaining
its engagement with the gear on the inter-
mediate shaft sub-assembly.
2) Fit the bearing (6) to the input shaft, then as-
semble them to the case.
3) Using the snap ring (7), fix the bearing (6) as-
sembled with the input shaft.
a Make sure that the snap ring is positively
held in the groove.
40-32 DX-Series
7. Seal ring and retainer

1) Assemble the seal ring (1) to the input shaft.
2) Assemble the gasket (2) to the retainer (3)
with the gasket seal side being faced toward
the retainer.
3) Assemble the retainer to the transmission
case routing it over the input shaft.
4) Tighten the assembly using the bolt (4).
a Assemble the intermediate side seal ring
and retainer employing the same proce-
dure.
8. Pipe
1) Using the bolt (6), assemble the pipe (5) to
the input shaft and intermediate shaft side re-
tainer.
a If alignment between the retainer (3) bolt
hole and pipe (5) mounting hole is lost
and thus you can’t tighten the bolt (6),
loosen the retainer mounting bolt (4), then
tighten the pipe amounting bolt first.
Then, tighten the retainer mounting bolt.
9. Cage
1) Assemble the cage (7) between the transmis-
sion case and intermediate shaft.
DX-Series 40-33
10. Output shaft

1) Assemble the bearing (6) to the output shaft,
fix it using the snap ring (7).
2) Place the small gear (2) and collar (3) in the
transmission case.
3) Insert the output shaft (9) into the case
through the propeller shaft side, then assem-
ble the large gear (1), collar (3) and small
gear (2), in this order.
4) Assemble the bearing (4), then fix it using the
snap ring (5).
5) Assemble the oil seal (8).
11. Plate
1) Mate the gasket (10) with the transmission
while facing the gasket seal toward the plate,
then fix it using the bolt (12).
40-34 DX-Series
DX-Series 40-35
DISASSEMBLY AND ASSEMBLY PROPELLER SHAFT
PROPELLER SHAFT
DISASSEMBLY DRAWING
ASSEMBLY DRAWING
Misalignment of shafts A and B: Max. 2.5 mm
40-36 DX-Series
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DIFFERENTIAL
40-38 DX-Series
TESTING AND INSPECTION
Unit : mm
Criteria
A Backlash 0.15 – 0.20 — Replace (*1)
B Spider outer diameter 24.929 – 24.980 24.75
C Inner diameter of differential pinion gear 25.000 – 25.021 25.12
D 1.52 – 1.68 1.3 Replace

Bushing thickness
E 1.94 – 2.06 1.7
F Inner diameter of parking brake drum 216.0 – 216.2 218.2
*1. Replace when damages recognized the tooth flank (bevel gears or pinion gears must be replaced as a set).
DX-Series 40-39
PINION SHAFT ADJUSTING PROCEDURE

1. Determine difference of dimensions at a, b, c and
d.
1) Record the reading a obtained at tip of the
pinion shaft.
2) Determine the difference b between the actu-
al measurement and dimension “t” up to the
second decimal place [the dimension “t”
(31.5) results when a load of 58,840 N {600
kgf} is applied to the bearing 06002-30311).
An example of when an actual measurement
is 31.60 mm:
b = (31.6 – 31.5) × 100 = 10 mm.
3) Read the case 3FD-21-21130 value indicated
by the arrow head.
4) Read the value d marked on the differential
case.
2. Calculating the shim thickness

Using difference in dimensions a, b, c and d that
have been determined in the above, calculate re-
quired shim thickens s in the following manner:
a+b+c+d
s = 0.5 + The result is rounded
100 up at the second deci-
mal place.
3. Combining and installing the shims

Combine the shim 3FD-21-21170 (t = 0.3) and
3FD-21-21160 (t = 0.2) appropriately so that their
combined thickness meets the required value s.
4. Pressurizing the pinion shaft and bearing

shaft
1) After installing the shims and tightening the
nut (3ED-21-41250)
2) Using torque wrench [1], give a pre-load to
bearing (06002-30311) so that the set start-
ing torque of the pinion shaft will be 3.92 –
7.84 Nm {0.4 – 0.8 kgf•m}.
Special tool 3FD-97-99600
5. Bending the lock washer

After adjusting the pinion shaft, tighten nut (1).
a Bend lock washer (2) securely toward both
sides.
40-40 DX-Series
DIFFERENTIAL SUPPORT BEARING

1. Using dial gauge [2], adjust the backlash between
the ring gear and pinion gear.
Backlash 0.20 – 0.28 mm
a Considering initial running-in, 0.2 mm should

be targeted in the assembly.
ADJUSTING THE BACKLASH

1. Referencing pointer on the dial gauge [2], adjust
the backlash returning one end of the adjusting
screw (3) by 1 notch and advancing the other end
by 1 notch to tighten.
Special tool [3] 34B-97-99110
2. Tighten the adjusting screw (3) so that the start-

ing torque of the ring gear and pinion gear is set
to the following value.
Starting torque 30.4 – 55.9Nm {3.1 – 5.7 kgf•m}
3. Double check if the set backlash conforms to the

specified range.
DX-Series 40-41
CHECKING THE TOOTH CONTACT Foward side
1) Coat the bevel gear tooth surface with small

amount of red lead.
2) Turn the bevel gear forward and reverse several
times.
3) Check appropriateness of the tooth contact refer-
encing the pattern left on the tooth surface.
4) If correct tooth contact is not present, check and
adjust the following points:
• Shims used for the pinion shaft.
• Backlash of the bevel gear.
• Bearing pre-load on the bevel gear side.
Reverse side
• Appropriate Tooth Contact (no-load)
You can be sure that an appropriate tooth contact
is obtained if the pattern is situated at center of
the tooth surface, shares 40 to 70% of the overall
tooth length and contact becomes weaker at both
ends of the pattern.
a Tooth contact for both the forward and reverse

move must be correctly adjusted. If, however,
that is not practicable, the forward side alone
should be adjusted as specified.
Radial runout of the bevel gear: Max. 0.1 mm
40-42 DX-Series
CORRECTING THE TOOTH CONTACT

• Increase shims used for the pinion shaft to in-
crease protrusion of the pinion (in direction A).
Then, move the bevel gear away from the pinion
(in direction B) to adjust the backlash.
• Reduce shims used for the pinion shaft to de-

crease projection of the pinion (in direction A).
Then, move the bevel gear toward the pinion (in
direction B) to adjust the backlash.
• Reduce shims used for the pinion shaft to de-

crease projection of the pinion (in direction A).
Then, move the bevel gear toward the pinion (in
direction B) to adjust the backlash.
• Increase shims used for the pinion shaft to in-

crease protrusion of the pinion (in direction A).
Then, move the bevel gear away from the pinion
(in direction B) to adjust the backlash.
DX-Series 40-43
Reduction gear model Hypoid bevel gear set
Reduction ratio 4.375
5 – 7 ton 12.5 l
Amount of oil
8 ton 15 l
40-44 DX-Series
DISASSEMBLY AND ASSEMBLY DRIVE AXLE (FRONT AXLE)
DRIVE AXLE (FRONT AXLE)

5 – 7 ton
DX-Series 40-45
5 – 7 ton
40-46 DX-Series
8 ton
DX-Series 40-47
8 ton
40-48 DX-Series
DISASSEMBLY AND ASSEMBLY WHEEL BRAKE
WHEEL BRAKE
5 – 7 ton
40-50 DX-Series
Unit : mm
Criteria
Sym- Check item Remedy
bol
A Lining Thickness 10 5.2
294N {30kgf} (l = 101.2mm) 265N {27kgf} (l = 101.2mm)
Free length: 90 mm
Return
B spring Strength
245N {25kgf} (l = 101.2mm) 221N {22.5kgf} (l = 101.2mm)
Free length: 93 mm
0.025 – 0.126 0.15

C Wheel Clearance between
cylinder piston and cylinder
Crack or chipping on the body and rust inside the body.
Replace
Length D1 97.6 ± 0.15 98
D Link Outer diameter a D2 4 3.75
Crush or wear.
inner diam- 4.7 ± 0.1 5.0

eter b
E Lever Toggle hole
Crush or wear.
F Back plate Deformation or crack.
— Brake drum inner diameter 317.5 320.5
— Clearance between lining and drum 0.4 – 0.6 0.4 – 0.6 Testing and
adjusting
DX-Series 40-51
8 ton
40-52 DX-Series
Unit : mm
Criteria
bol
A Lining Thickness 12.7 5.5
324N {33kgf} (l = 103.5mm) 294N {30kgf} (l = 103.5mm)

B Return spring Strength
Free length: 93mm
0.080 – 0.181 0.2 Replace

Clearance between
C Wheel cylinder piston and cylinder
Crack or chipping on the body,
or rust inside the body.
D Back plate Deformation or crack.
— Brake drum inner diameter 393.7 396
Testing and
— Clearance between lining and drum 0.3 – 0.5 0.3 – 0.5 adjusting
When assembling the brake shoe

Insert a 0.25 mm and 0.15 mm thickness gauge to the
position G and F respectively, tighten nut E, then in-
sert the cotter pin to the nut.
If it is difficult to insert the cotter pin, rewind the nut E
by 1/6 turn and then retry.
DX-Series 40-53
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
PARKING BRAKE
Unit : mm
Criteria
bol
Strength 152N {15.5kgf} (l = 50mm) 137N {14kgf} (l = 50mm)

B Shoe return Replace
spring
Free length 54.7
— Drum Inner diameter 216 217.5
Clearance between lining and

— drum 0.1 – 0.25 0.1 – 0.25
Operator of brake lever Min. 196 N {20 kgf} Min. 196 N {20 kgf}
Check that the vehicle is kept stopped on following slopes.

Adjust or repair
When not loaded Slope sharper than 20% (11.2 deg.)
—
Braking force When loaded Slope sharper than 15% (8.5 deg.)
If there is not proper slope, drive at low speed with

extreme care for safety and check effect of parking brake.
40-54 DX-Series
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
ADJUSTING PARKING BRAKE
Adjusting clearance
1. Turn the adjustment wheel to the shoe expansion
direction so that the lining can completely come
into contact with the drum.
2. Turn the adjustment wheel so that the clearance
between the drum and lining (points X and Y in
the right figure) can be set to 0.1 to 0.25 mm
(when the adjustment wheel is turned for 11
notches, the clearance is adjusted for 0.25 mm).
Adjusting lever operating effort

1. Release the parking brake (push the lever for-
ward).
2. Use a screwdriver to push in adjustment button
(1) in direction G, then to keep it push and rotate
in to adjust the operating effort of the lever.
Lever operating effort

(Grip center) Min. 98 N (10 kgf)
3. Adjust and insert the hexagonal portion of adjust-

ment button (1) to the hexagonal hole on the tip
of grip (2), then pull the screwdriver.
DX-Series 40-55
DISASSEMBLY AND ASSEMBLY STEERING AXLE (REAR AXLE)
STEERING AXLE (REAR AXLE)
40-56 DX-Series
DX-Series 40-57

5 – 7 ton
Unit : mm
Criteria
A1 Outer diameter 60 59.5

A Center pin
A2 Bushing inner diameter 60 60.5
B King pin outer diameter 40 39.8 Replace
C PS cylinder pin outer diameter 20 19.9
D1 Mounting pin outer diameter 25 24.9
D Knuckle D2 Play in vertical direction — 0.2 Adjusting shim
D3 Inner diameter of mounting pin bushing 20 20.5 Replace
8 ton
Unit : mm
Criteria

A Center pin
40-58 DX-Series
DISASSEMBLY AND ASSEMBLY BRAKE PEDAL
BRAKE PEDAL
5 – 7 ton
DX-Series 40-59
DISASSEMBLY AND ASSEMBLY BRAKE PEDAL
8 ton
40-60 DX-Series
DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH
COMBINATION SWITCH
COMPONENTS
1. Lighting/turn signal light switch 5. Screw

2. Forward/reverse switch 6. Screw
3. Cover 7. Dash board harness
4. Boots 8. Engine harness
DX-Series 40-61
CHECKING THE LIGHTING/TURN

SIGNAL LIGHT SWITCH
(WITH DIMMER SWITCH)
1. Disconnect the 8P coupler (1) situated between
the combination switch cord and main wire har-
ness.
2. Check the line between the terminals at each po-
sition for continuity and confirm that only the lines
marked with Q–Q shown in the following table
have continuity.
3. Insulation resistance must be 10 Mz when tested
with the 500V megger.
Circuit diagram
Lighting switch connection position
Circuit 1 2 3 4 5
Position
OFF Q
1st stage Q Q Q
2nd stage Q Q Q
DIMMER Q Q Q
Circuit diagram
Turn signal light switch connection position
Circuit 6 7 8
Position
R Q Q
Intermediate
L Q Q
40-62 DX-Series
CHECKING THE F/R SWITCH

1. Disconnect the 6P coupler (1) and 2P coupler (2)
situated between the combination switch cord
and main wire harness.
2. Check conduction between each terminal to
make sure that between Q and Q shown in the
following table alone is conducted.
F/R switch Circuit diagram

Circuit 1 2 3 4 5 6 7
Position
Starter
and N Q Q
F1 Q Q
F/R
switch R1 Q Q
F2 Q Q
R2 Q Q
DX-Series 40-63
REPLACING THE COMBINATION SWITCH

1. Remove 4 screws (5), steering column upper cover (1), and lower cover (4).
2. Disconnect 8P coupler (3), 6P coupler (6), and 2P coupler between the switch cable of combination switch
(2) and the main wiring harness.
3. Remove 2 screws (8) of band (9) which is fixing steering shaft (7) and combination switch, and then remove
the switch.
4. Assembly is done in the reverse order of disassembly.
40-64 DX-Series
REPLACING THE LIGHTING AND F/R SWITCH

1. Remove 4 screws (5), steering column upper cover (1), and lower cover (4).
2. Disconnect 8P coupler (3), 6P coupler (6), and 2P coupler between the switch cable of combination switch
(2) and the main wiring harness.
3. Remove 2 screws (8) of band (11) which is fixing steering shaft (7) and combination switch, and then remove
the switch.
4. Remove 2 mounting screws (9) of lighting switch (10) and cable fixing plastic band, and then remove the
switch.
5. Assembly is done in the reverse order of disassembly.
DX-Series 40-65
DISASSEMBLY AND ASSEMBLY MASTER BACK AND MASTER CYLINDER ASSEMBLY
MASTER BACK AND MASTER CYLINDER ASSEMBLY

5 – 7 ton
• Amount of master cylinder brake fluid : 0.05 l.
1. Master cylinder assembly 6. Silencer

2. Master back assembly 7. Filter
Master back replacement parts 8. Seal
3. Retainer 9. Retainer
4. Guard 10. Seal
5. Filter
a Make sure that the filter is not clogged.
40-66 DX-Series
MASTER CYLINDER
5 – 7 ton
1. Indicator assembly 13. • O-ring

2. Cylinder 14. • Valve rubber
3. Clamp 15. Snap ring
4. Reservoir tank Piston assembly
5. Cap 16. • Piston
6. Baffle plate 17. • Snap ring
Valve assembly 18. • Retainer
7. • Snap ring 19. • P cup
8. • Valve case 20. • Spacer
9. • Stopper 21. • R cup
10. • Spring guide 22. • Spring
11. • Valve spring
12. • Steel ball
DX-Series 40-67
DISASSEMBLY AND CHECKING PROCEDURE
Part name Check item Remedy
Scratches, eccentric wear or • Eliminate minor scratches using a sand paper.

Cylinder corrosion on the inner surface. • When scratches can adversely affect the cups, replace the
cylinder assembly.
Scratches, eccentric wear or • Eliminate minor scratches using an oil stone.

corrosion on the sliding part. • When scratches can adversely affect the cylinder inner
surface or cups, replace the piston assembly.
Piston
Clearance between the cylinder • When the clearance exceeds the tolerable limit, replace the
and piston. piston.
Scratches on the lip • When scratches are minor, replace the piston assembly.
Exposed base substrate • When the base is bared seriously, replace the piston
assembly.
Cup Wear and swelling • If excessive fatigue, wear or swelling is present, replace
the piston assembly.
Interference • When the interference is within the tolerable limit, replace

the piston assembly.
Note: Cup is one of the parts to be replaced on a regular
basis. It is recommended to replace the cup when-
ever disassembly takes place.
Deformation, scratches or wear • If excessive deformation, scratches or wear is present,

Piston assembly on the valve rod, valve cup, spring replace the piston assembly.
or thimble.
Scratches, wear or collapse • Replace the spring suffered from excessive scratches or
wear.
Spring
Free length • Replace the spring if its free length exceeds the tolerable
limit.
Scratches, deformation or • Replace the check valve if it is suffered from serious

Check valve swelling scratches, deformation or swelling.
Scratches, deformation or • Replace the valve seat if it is suffered from serious

Valve seat swelling scratches, deformation or swelling.
Crack • When a crack is present, replace the cylinder assembly

irrespective of its seriousness.
Discoloring • If serious discoloring is present, replace the cylinder

Reservoir assembly.
Scratches • When scratches are present, replace the cylinder

assembly.
Alarm action • Move the float up and down. If the alarm lamp is not
Indicator assembly activated, replace the indicator assembly.
40-68 DX-Series
DISASSEMBLY PROCEDURE
(Master Cylinder for 5 to 7 ton)

(1) Remove the indicator assembly.
(2) Remove the reservoir tank.
(3) Remove the valve assembly.
(4) Remove the snap ring assembly.
(5) Take out the piston assembly.
(6) Take out the spring.
a Assembly is done essentially in the reverse order of disassembly.
PRECAUTIONS ON THE DISASSEMBLY AND ASSEMBLY

• Use of alcohol or brake fluid alone is permitted for cleaning the parts. Use of mineral oil (such as kerosene
and gasoline) is strictly prohibited. (Mineral oil attached on rubber-made parts can cause swelling and thus
make them unusable.)
When cleaning rubber parts such as cups, they must not be placed in alcohol for more than 30 seconds.
• Parts after cleaning must be kept in a clean place so that they may not be contaminated by foreign substance.
• Disassembly and assembly must be done paying reasonable care to contamination by foreign substance or
potential damages on the cylinder, piston and cups, among others.
• When disassembling the cylinder, it is recommended to understand well how it is structured so that this
knowledge may be utilized in the assembly operation.
• The piston assembly may not be disassembled.
• It is prohibited to push outer wall of the cylinder using the vise.
• When assembling, inner surface of the cylinder and peripherals of the piston must be uniformly coated with
sufficient amount of rubber grease or brake fluid.
DX-Series 40-69
MASTER CYLINDER MAINTENANCE STANDARD

5 – 7 ton
Unit: mm
Check item Standard value Repair limit Remedy
Clearance between the cylinder Replace

1 and piston 0.020 – 0.105 0.15 (Cylinder assembly)
2 Cup interference Primary side: Approx. 0.6 0.3 Replace

Secondary side: Approx. 1.5 0.4 (Piston assembly)
3 Spring free length 89 80 Replace
1.47 – 2.45 Nm
4 Clamp tightening torque {0.15 – 0.25 kgf•m} — —
Master cylinder and master back 8.82 – 13.72 Nm

5 tightening torque {0.9 – 1.4 kgf•m} — —
– Master back clevis tightening 15.68 – 21.56 Nm — —

torque {1.6 – 2.2 kgf•m}
– Torque for tightening master back 13.72 – 17.64 Nm — —

to machine body {1.4 – 1.8 kgf•m}
40-70 DX-Series
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
BRAKE VALVE
8 ton
a When working, do not grip faces P of the valve body.
DX-Series 40-71
DISASSEMBLY
k When removing the brake valve from the ve-
hicle, stop the engine and press the brake
pedal repeatedly more than 10 times to re-
lease the pressure, and then disconnect the
piping.
a Parts marked with (*) in the figure at right are the

kit parts.
1. Grip body (1) in a vise and remove plug (2) with a

hexagon jig A having the width across flats of 17
mm (an ordinary hexagon rod cut to about 30 mm
will do), and then remove O-ring (3) with your fin-
gers.
a Set protectors B (made of aluminum or cloth)
to the vise.
a When gripping the body in the vise, take care
not to tighten flow divider mounting faces P.
2. Remove bellows (2) from body (1) and remove

snap ring (3), and then pull out washer (4) and in-
put piston sub-assembly (5) slowly.
a When removing cup (6), take care not to dam-

age the piston. (Pull the outside lip with pliers
and cut with a knife.)
a Remove nuts (7) only when replacing the pis-
ton. (If they are removed, the stroke or oil
pressure needs to be adjusted.)
40-72 DX-Series
3. Press the bottom of the hole of spool (1) 13 mm

in diameter with a screwdriver to remove guide
(2) and valve sub-assembly (3). Then, reaction
piston (4), retainer (5), and spring (6) are re-
moved simultaneously.
a Set the body on protector C (cloth).
a Take care not to press the screwdriver too
strongly.
4. Remove O-ring (7) from valve sub-assembly with

your fingers, and then remove O-ring (8) from
guide (2) with your fingers. Remove O-ring (9),
backup ring (10), and O-ring (11) from reaction
piston (4) with your fingers or a hairpin.
DX-Series 40-73
ASSEMBLY
a When installing the O-rings and cup, apply suffi-
cient amount of silicone grease (SHINETSU KA-
GAKU G40M) prepared in the kit to them.
a Take care of installing direction of cup (2).
1. Using jig D, install input piston sub-assembly (1)

to cup (2) by pushing in a, b, and c in order.
When the jig is not available

1) Wind vinyl tape E onto the spring to form a
guide, and then install cup (2) in the direction
of the arrow.
2) After installing the cup, remove vinyl tape E.
2. Install input piston sub-assembly (2) and washer

(3) to body (1) and fix them with snap ring (4).
3. Assemble spool (5), reaction piston (6), and

guide (7), and then insert them in the body with jig
G (17-mm socket wrench).
a Be sure to install all the O-rings.

a Check depth d of guide (7).
Depth d of guide (7) 40 mm
a When installing spool (5), apply hydraulic oil

to its outside.
40-74 DX-Series
4. 1) Set the body vertically.

2) Set the center hole of retainer (2) to the end
shaft of reaction piston (1) securely and in-
stall spring (3), valve sub-assembly (4), and
plug (5) in order, and then tighten plug (5).
Plug (5) 68 – 108 Nm

{690 – 1,100 kgf•cm}
a Tighten plug (5) with your fingers as much

as possible.
a Set retainer (2) to the end of reaction pis-
ton (1) securely.
5. Set bellows (1) to the grooves of body (2) and nut

(3) securely.
6. If locknut (2) of input piston sub-assembly (1) was

removed, perform the following adjustment.
ADJUSTMENT PROCEDURE WITH

WHEEL CYLINDER OIL PRESSURE
1) Run the engine (Turn the hydraulic pump ON)
and press the brake pedal.
2) When the wheel cylinder oil pressure is set in
the following range, set locknut (2) in contact
with washer (3) and tighten it to the following
torque.
Wheel cylinder oil 11.8 ± 0.3 MPa

pressure {120 ± 3 kgf/cm²}
49 – 78 Nm
Locknut (2) {500 – 800 kgf•cm}
a While adjusting the oil pressure, run the en-

gine at idling and do not operate other hy-
draulic equipment.
DX-Series 40-75
SIMPLE ADJUSTMENT PROCEDURE

The above method is the best. If it cannot be applied
for some reason, however, adjust according to the
following procedure.
1) Remove snap ring (4), pull out input piston (1), re-
move only washer, and measure dimension e.
2) While pressing input piston (1) in the direction of
the arrow with your finger, measure dimension f.
3) Adjust dimension (e + f) to the following value,
and then tighten locknut (2) to the following
torque.
Dimension (e + f) 11 ± 0.3 mm
Locknut (2) 49 – 78 Nm
{500 – 800 kgf•cm}
40-76 DX-Series
Unit : mm
Criteria
Sym- Inspection item Remedy
bol
A Diameter clearance of fitting parts of input piston and body — 0.16
B Diameter clearance of fitting parts of spool and body — 0032
C Diameter clearance of fitting parts of reaction piston and guide — 0.16
D Sliding surfaces of piston of body and spool —
E Sliding surfaces of outside of input piston — When there is

flaw, uneven
F Sliding surfaces of outside of reaction piston — wear, or rust
G Sliding surfaces of outside of spool —
H Sliding surfaces of reaction piston of guide — —

Replace
Dimension a of input piston spring 0 0
K Fatigue of spring (Free length) — 20
DX-Series 40-77
DISASSEMBLY AND ASSEMBLY STEERING VALVE
STEERING VALVE
Valve model Open center, non road reaction type
Rated flow rate 22.7 l/min
Displacement 184 cc/rev 3BA-97-99210

Special tool No.
Max. pressure 17.2 MPa {175 kgf/cm²} 3BA-97-99220
40-78 DX-Series
1. Bolt 11. Plate 21. Bearing race

2. Bolt 12. O-ring 22. Straight pin
3. Retainer bolt 13. Adapter bolt 23. Centering spring
4. End cap 14. Ball 24. Spool
5. O-ring 15. Dust seal 25. Sleeve
6. Spacer 16. Ground seal bushing 26. O-ring
7. Spacer 17. Oil seal 27. Housing
8. Gerotor 18. Snap ring
9. O-ring 19. Bearing lace A. Thrust bearing assembly
10. Drive shaft 20. Thrust needle B. Spool sleeve assembly
DX-Series 40-79
CAUSE OF TROUBLE AND COUNTERMEASURE
No. Type of troubles Possible causes Countermeasures
1. Hydraulic system
a. Insufficient hydraulic pressure on the PS Checking, adjustment and repair.
circuit.
b. Insufficient hydraulic pump delivery. Checking and repair.
c. Oil leakage in the PS cylinder. Checking and repair.
2. PS valve
a. Foreign substance is entrapped Checking, repair and part replace-
between the spool and sleeve or sleeve ment.
and housing.
b. An excessive torque is used for tighten- Tighten the ball uniformly according to
1 Smooth steering wheel ing the end cap tightening bolt. the specified torque.
operation is not available c. The ball on the emergency steering Assemble the ball.
check valve have not been assembled.
3. Hydraulic pump
a. Wear or damages on the gear body. Checking, repair and replacement.
b. Wear or damages on the drive shaft Checking, repair and replacement.
spline.
4. Machine body
a. Scuffing or seize on the steering link or Checking, repair and part replace-
bushing. ment.
1. PS valve
a. Foreign substance is entrapped Checking, repair and part replace-
Leaving my hands off the between the spool and sleeve valve, or ment.
2 steering wheel does not seize on that part.
return it to the neutral. b. Damages or cracks on the centering Checking, repair and part replace-
spring. ment.
c. Scuffing between the column shaft and Checking, repair and part replace-
bushing. ment.
1. Hydraulic system
a. Air is mixed into the system. Check and repair the piping and tank.
b. Cavitation has occurred. Check and repair the filter and tank.
c. Insufficient pump delivery. Check, repair and replace (if neces-
sary) the pump.
When steering wheel is

turned, the cylinder does 2. PS valve
not follow properly or a. Wear on the internal parts. Checking, repair and part replace-
3 does not follow at all, or ment.
excessive wheel slip b. Insufficient tightening torque is Tighten the bolt uniformly according to
occurs. employed for the end cap fastening bolt. the specified torque.
c. The driver or spacer has not been Assemble the part as specified.
assembled.
3. PS cylinder
a. Damages, wear or scuffing on the piston Checking, repair and part replace-
cylinder seal. ment.
40-80 DX-Series
No. Type of troubles Possible causes Countermeasures
1. Hydraulic system
a. Improper piping is done for the 4th port. Checking and repair.
Steering wheel turns in
4 the direction opposite to
my intention. Or, wheel 2. PS valve
kick occurs. a. Improper valve timing is set (after re- Checking and repair.
assembly)
1. Hydraulic system
a. Air is mixed into the system. Check and repair (as necessary) the
piping and tank.
5 Vibrations occur
2. Machine body
a. Wear or backlash on the steering link. Checking and part replacement.
b. Backlash on the wheel bearing or hub. Checking and adjustment.
1. Hydraulic system
a. Sounds are generated from the control Checking, adjustment and repair.
valve.
b. Sounds are generated from the hydrau- Checking, adjustment and repair.
lic pump.
c. Sounds are generated from the piping or Checking, adjustment and repair.
Abnormal sounds (includ- tank.
6 ing abnormal relief
sounds) occurs.
2. PS valve
a. Sounds are generated from the spool or Checking and repair.
sleeve assembly.
b. Sounds are generated from the gerotor Checking and repair.
or drive.
1. PS valve
[Wear or damages on the shaft (spool)
oil seal]
a. Hydraulic oil is contaminated. Replace hydraulic oil or filter.
b. Rusts on the spool surface. Replace the assembly.
c. Damages due to disassembly or assem- Replace the part.
bly.
7 Oil leak [Damages on the O-ring used on the
mating surface (gerotor)]
a. The O-ring was pinched during disas- Replace the part.
sembly or assembly work.
b. Damages on the O-ring groove. Replace the part.
c. Insufficient tightening torque is Tighten the bolt uniformly according to
employed for the end cap fastening bolt. the specified torque.
DX-Series 40-81
DISASSEMBLY
1. Disassembling the steering valve assembly
1) Remove the bolt (1) by holding the flange of
the column assembly with the vise, then re-
move the steering valve assembly (now you
can separate the column from the valve).
k • Care must be exercised so that you may

not be injured by machined part of the
sleeve, spool or housing.
• Care is also required in handling the as-
sembly so that it may not be dented or
scratched.
2. Disassembly of the gerotor valve

1) Face the end cover upward, then hold the
flange mounting portion on the housing (27)
with the vise.
2) Remove the six bolts (2) and a retainer bolt

(3).
3) Remove the end cap (4).
4) Remove the O-ring (5) on the end gear.
5) Remove the spacers (6) and (7) contained in

the spline of the star situated in the gerotor
(8).
6) Remove the gerotor (8).
a Use care so that you may not drop the
star provided on the gerotor outside pe-
rimeter.
7) Remove the O-ring (9) from the gerotor.
40-82 DX-Series
8) Take out the drive (10).

9) Remove the spacer plate (11).
10) Remove the O-ring (12) from the housing.
11) Remove the adapter bolt (13) using a bladed

screw driver.
12) Disengage the housing from the vise, then
turn it upside down to remove the ball (14).
a Use care so that the ball may not be
dropped and lost.
3. Disassembly of the control valve

1) Place the housing on the work bench facing
its flanged surface upward. Prior to this oper-
ation, spread a piece of clean cloth on the
work bench so that the gerotor mounting face
may not be damaged.
2) Using the bladed screw drier, pull up the snap
ring (15) end to remove it from the housing.
a When pulling up the snap ring end, cover
the ring with a piece cloth and hold it with
your hand.
k The snap ring can spring out of the housing

unexpectedly. Thus, you must wear protec-
tive goggles before starting this operation.
DX-Series 40-83
3) Place the housing in such that it is horizontal

in axial direction of the body.
• Set the straight pin (22) to horizontal po-
sition turning the spool/sleeve assembly.
Then, slightly push the spool/sleeve as-
sembly forward to remove the ground
seal bushing (16).
4) Remove the oil seal (17) from the ground seal

bushing. Then, remove the dust seal (18) us-
ing the bladed screw driver.
a Use case so that the ground seal bushing
may not be damaged.
5) Remove the thrust bearing assembly

• Remove the bearing (19), thrust needle
(20) and bearing lace (21), in this order.
40-84 DX-Series
6) Drive out the spool/sleeve assembly (B)

through the opposite side of the flanged part
on the housing. When driving the assembly
out, push it forward using your thumb. Make
sure to push it slowly so that the sleeve outer
perimeter may not gall the housing bore.
a If direction of the sleeve and spool is
changed by 180 degrees in combining
them during re-assembly, normal per-
formance of the assembly may not be
expected. Thus, you are advised to
apply a match mark on the spool/
sleeve assembly at this stage using an
oil felt pen.
7) Drive the straight pin (22) out of the spool/

sleeve assembly.
k The snap ring can spring out of the housing

unexpectedly. Thus, you must wear protec-
8) Push the spool inside the sleeve slightly for-

ward, then carefully remove the centering
spring (23) from the spool using your hands.
a Combination of centering springs
• Centering spring C : 4
• Centering spring F : 2
9) Drive the spool (24) out of the sleeve (25)

(rotate the sleeve gently to when removing
the spool).
10) Remove the O-ring (26) from the housing.
DX-Series 40-85
4. Disassembly of the column

1) Remove the snap ring (13) holding the
flanged portion with the vise.
2) Drive the shaft (14) through the flange side.

a The bearing (15) is press fitted to the
shaft. Disassembly is permitted only
when any trouble has occurred.
3) Drive out the column (16) bushing (17) by

holding the outer perimeter with the vise and
pushing two projections on it inward.
CHECK AND CLEANING

• After disassembly, check the seals for damages, • Cleaning of metal parts
wear or other failures. Volatile metal cleaning solvent, available in the
a When re-assembling, all seals are replaced market, may be used for cleaning metal parts.
with new ones.
• Check sliding surface of each part for serious • Cleaning of rubber parts
scratches due to dusts, wear or other damages. Before using rubber dusts, blow off dusts settled
a Major functional parts are selectively com- on them using compressed air, then place and
bined, thus they can’t be supplied on a single wash them in hydraulic oil.
part basis. If a serious damage is found on a a It is strictly prohibited to clean rubber parts in
part, the assembly comprising the part must metal cleaning solvent.
be replaced.
40-86 DX-Series
ASSEMBLY
a Joints of every part must be checked. Parts with scratches or burrs resulting from disassembly operation
must be replaced with new one. Otherwise, oil leakage can occur.
a Parts are cleaned with commercially available detergents and then dried with air blow. Don’t try to wipe
cleaned parts with a piece of cloth or paper, otherwise they can be contaminated by foreign substance.
a It is prohibited to file or sand the parts.
a When assembling, consumable parts such as O-rings and seals must be replaced with new ones and, after
assembly, they must be coated with the grease (G2-LI).
a O-rings (5), (9) and (12) are very similar in their size, so reasonable care must be exercised to prevent con-
fusion between them.
k Care must be used in the assembly operation so that you may not be injured by machined edges
and such of the sleeve/spool assembly or housing.
1. Assembly of the control valve

1) Slowly turning the spool (24), insert it into the
sleeve (25).
a Coat the spool with clean hydraulic oil,
then insert it turning slowly.
a After insertion, make sure that the spool
rotates smoothly by turning the spline
side end of the spool with your fingers.
2) • Match the 2 spring grooves at 180 de-
grees of the spool and sleeve and erect
them on a level plate.
• Put spring inserting tool (3BA-97-99220)
E in the spring groove.
• Install centering spring C to the inserting
tool so that cuts Q at both ends will be on
the down side (sleeve side).
a At this time, if you raise the spool a lit-
tle from the sleeve, you can insert the
spring easily.
a Improper combination can result in
generating an uneven steering wheel
control force between the left and
right side.
DX-Series 40-87
3) • Lift the spool (24) slightly off the sleeve

(25), then insert the centering spring into
the spool/sleeve groove. When inserting
the centering spring, compress its other
end with your finger (the insertion jig is
drawn through the other side).
• Align ends of the spring to the sleeve out-
er perimeter.
a Referencing the match marks applied
in the Disassembly Procedure Step 3,
6), check the spool (24) and sleeve
(25) positions to make P sure they are
not 180 degrees dislocated. If the po-
sition is incorrect, align the position
again.
k The centering spring can spring out of the

spool unexpectedly, thus you must wear
protective goggles before starting the oper-
ation.
4) Align both ends of the spring to the sleeve

outer perimeter by inserting the straight pin
(22) into the spool/sleeve assembly.
5) • Set the housing body (27) horizontal in

axial direction, then insert the spool/
sleeve assembly (with the spool spline
side at the head) into the bore from the
gerotor and end cover side.
• Stop insertion as the spool end face
comes to the housing end face (flanged
portion). This completes the insertion op-
eration.
a Insert the spool/sleeve assembly by rotating
the horizontally held straight pin clockwise
and counterclockwise.
a When the straight pin is caught on something
during the insertion, don’t try to forcibly move
it. Undo the interference using your finger tip.
a Make sure that the spool/sleeve assembly ro-
tates smoothly at the insertion end position.
40-88 DX-Series
6) Place the housing (27) vertically (with the

spool spline facing above), assemble the O-
ring (26).
a Coat the O-ring with grease (G2-LI).
7) Assemble the bearing lace (21), thrust nee-

dle (20) and bearing lace (19).
a For combination of the thrust bearing as-
sembly, refer to the figure to the right.
a Coat them with the grease (G2-LI).
8) Assemble the dust seal (18) to the ground

seal bushing (16).
a Coat the lip with the grease (G2-LI).
a Make sure the lip direction is correct.
9) Assemble the oil seal (17) to the ground seal

bushing (16).
a Take care so that the oil seal may not be
deformed.
a Apply the grease (G2-LI).
10) Rotating the ground seal bushing assembly

(28), insert it into the spool. Then, assemble
them to the housing.
a Use a plastic hammer as needed to place
the assembly in the specified position.
11) Assemble the snap ring (15) to the housing.

a When assemble the snap ring, stretch it
using a bladed screw driver so that its en-
tire body is positively fitted into the snap
ring groove.
k The snap ring can jump out of the housing

unexpectedly, thus you must wear protec-
DX-Series 40-89
(Assembly of gland seal bushing)

• Install dust seal (15), oil seal (17), and O-ring (26)
to gland seal bushing (16), and then install them
to housing (27).
• Fix the above parts with snap ring (18).
2. Assembly of the gerotor valve

1) Hold the flanged portion of the housing using
the vise.
a Attach a copper plate F or equivalent on
the vise so that the flanged portion may
not be excessively tightened.
2) Among 7 holes provided on the housing end

face, insert the ball (14) to the hole shown in
the figure to the right.
a Take care so that the ball may not be
dropped and lost.
3) After inserting the ball, assemble the adapter

bolt (13).
a Effective screw depth : approx. 10 mm.
(Insert the bolt until it is stopped.)
a This ball insertion hole is used for attach-
ing a retainer (3) when assembling the
end cover.
• End of housing
G. Bolt hole ( 5/16-24UNF)
H. Oil hole ( 6.4)
J. Ball insertion hole ( 11 × P1.0)
40-90 DX-Series
4) Assemble the O-ring (12) to the housing.

a Apply grease (G2-LI) ton O-ring (12) thin-
ly.
5) Place the spacer plate (11) on the O-ring,

then align bolt holes of the housing and plate.
a Pitch and diameter of the bolt and oil
holes are not identical.
6) Turn the spool and sleeve assembly so that

prolonged line K of straight pin (29) will be in
parallel with prolonged line L of the port sur-
face of the housing.
Insert drive shaft (10) and fit its yoke to
straight pin (29).
a For accurate positioning, draw a line par-
allel with straight pin (29) on end face M
of drive shaft (10) with oil ink in advance.
7) Assemble the O-ring (9) to the gerotor (8).

a Coat it with the grease (G2-LI) O-ring (9).
DX-Series 40-91
8) Set the O-ring side of the gerotor end face to

spacer plate (11) side and install it, matching
the roots of the gerotor teeth N to the line of
straight pin (22).
a At this time, check that lines R, S, T, and
U are in parallel.
9) Rotate the gerotor to align holes on the gero-

tor ring, plate and the housing bolt holes.
a Rotate the gerotor ring until it fits into the
bolt hole while maintaining engagement
of the drive shaft (10) and gerotor.
10) Install spacer (6) to the internal spline of the

gerotor star.
• Thickness of spacer (6): Approx. 53.7 mm
11) Assemble the O-ring (5) to the end cap (4),

place them on the gerotor (8), then align the
bolt holes.
12) Assemble the end cap (4) using six bolts (2)
and a retainer bolt (3).
a Coat threaded portion on each bolt with
oil.
a For the tightening sequence, refer to the
numbers provided in the figure to the
right.
a Make sure that the hole [7] contains the
ball (14) and adapter bolt (13). Assemble
the adapter bolt (3) to this hole.
1st time 14.7 Nm {1.5 kgf•m}
2nd time 28 Nm {2.9 kgf•m}
40-92 DX-Series
3. Assembly of the column

1) Hold the column (30) outer diameter portion
with the vise, coat outer perimeter of the col-
umn bushing (31) with grease and then push
it into the column.
a Make sure that two projections are posi-
tively fitted into the two holes provided on
the column.
2) Fill the column bushing lip with grease, the in-

sert the shaft (32) into the column bore from
the flange side until the bearing end face
reaches the specified position.
a After assembling, make sure that the
shaft rotates smoothly.
3) Install the snap ring (33) to the groove. Make
sure the snap ring is securely held in place.
4. Assembling the steering valve column

assembly
1) Charge the grease (Bearing grease No. 2
containing molybdenum disulfide) to the shaft
spline connection on the column assembly,
then assemble it to the steering valve body.
2) Tighten four bolts (1) to complete the assem-

bly.
34.4 – 44.1 Nm {3.5 – 4.5 kgf•m}
DX-Series 40-93
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
HYDRAULIC PUMP
FG50/60/70
No. Part name No. Part name No. Part name
1 Snap ring 8 Backup ring 15 Seal ring
2 Oil seal 9 Side plate 16 O-ring
3 Plate 10 Drive gear 17 Bracket
4 Bolt 11 Driven gear
5 Cover 12 Pump case
6 O-ring 13 Side plate
7 Seal ring 14 Backup ring
40-94 DX-Series
Item Oil pressure setup (control valve)

Pump
model Delivery Rotating direction
Model Main relief pressure Port relief pressure
FG50/60/70 SAL56 56.5/rev Counterclockwise 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
Unit: mm
Criteria
A Clearance between shaft hole inner 0.06 – 0.148 0.15

diameter and gear shaft outer diameter
Clearance between gear case and

B bushing gear 0.10 – 0.15 0.18
Contact area (circumference) between Replace

C gear and body 1/3 – 1/2 Min. 3/4
D Contact between gear and side plate/ Contact face shall be free from
body scratches or streaks on claw.
E Seal ring and backup ring Shall be free from scuffing or tears.
Tightening torque of pump body

F assembly bolt 98.1 – 122.6 Nm {10 – 12.5 kgf•m} Retighten
DX-Series 40-95
FD50/60/70
FD80
No. Part name No. Part name No. Part name

(2nd pump) 13 Backup ring 25 Carrier
1 Bolt 14 Seal ring 26 O-ring
2 O-ring 15 O-ring 27 Seal ring
3 Bolt 16 Bracket 28 Backup ring
4 Cover 17 Bolt 29 Side plate
5 O-ring 18 Plate 30 Drive gear
6 Seal ring 19 O-ring 31 Driven gear
7 Backup ring (1st plate) 32 Pump case
8 Side plate 20 Snap ring 33 Side plate
9 Drive gear 21 Oil seal 34 Backup ring
10 Driven gear 22 Plate 35 Seal ring
11 Pump case 23 Coupling 36 O-ring
12 Side plate 24 Bolt 37 Bracket
40-96 DX-Series
Item Delivery Oil pressure setup (control valve)

Pump model
Model 1st pump 2nd pump Main relief pressure Port relief pressure
FD50/60/70 SAL40+28 40.2 cc/rev 28.0 cc/rev 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
FD80 SAL40+36 40.2 cc/rev 36.1 cc/rev 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
a Each pump rotates in counterclockwise.

Unit: mm
Criteria

B Clearance between gear case and 0.10 – 0.15 0.18

bushing gear
Contact area (circumference) between

C gear and body 1/3 – 1/2 Min. 3/4 Replace
Contact between gear and side plate/ Contact face shall be free from
D body scratches or streaks on claw.
F Tightening torque of pump body 98.1 – 122.6 Nm {10 – 12.5 kgf•m}

assembly bolt
Retighten
Tightening torque of bracket and carrier
G coupling bolt 58.8 – 73.5 Nm {6 – 7.5 kgf•m}
DX-Series 40-97
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
a Before assembling the parts, parts must be Assembly of tilt spool

cleaned well, removed of detergents or dusts by 1. Install tilt lock spool (2) to tilt spool (1) in the direc-
air blow and coated with hydraulic oil. tion of the arrow.
a It is not allowed to use cloth for cleaning deter- a Install tilt lock spool (2) as shown in the figure.
gent or dusts.
a Kerosene or trichlene alone should be used for
cleaning detergents. Cleaning must be done in a
place free from fire.
a Prior to assembly, dust seals, U-packing and O-
rings must be replaced with new ones.
40-98 DX-Series
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

Unit: mm
Criteria
A1 Return spring 78 66 – 90
A2 Tilt lock spring 36.2 31

A Spring free length
A3 Check valve 31.8 27 Replace
A4 Inlet 46.4 39
— Spool and housing Burrs or scratches
Measuring the control valve relief pressure

1. Remove the plug (3), then attach the manometer.
2. Measure oil pressure at the time when the fork is
driven to the maximum lift position.
Relief pressure 18.88 MPa {185 kgf/cm²}
Measuring the power steering relief pressure

1. Remove the plug (4), then attach the manometer.
2. Measure the pressure at the time when the steer-
ing wheel is fully turned clockwise or counter-
clockwise.
a The main relief valve on the control valve
must not be open when the above measure-
ment is done. A1 : To lift cylinder bottom
A2 . To tilt cylinder head
B2 : To tilt cylinder bottom
Note PF : To steering valve
A: When P1 alone is used (1-pump type) P1 : From hydraulic pump #1
• FG50/60/70: SAL56 P2 : From hydraulic pump #2
B: When P1 and P2 are used (2-pump type) T : To hydraulic tank
• FD50/60/70: SAL40 (P1) + SAL28 (P2)
• FD80: SAL40 (P1) + SAL36 (P2)
DX-Series 40-99
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
LIFT CYLINDER
*1. For mast 1.45 – 6 m
1. Cylinder head 8. O-ring

2. O-ring 9. Collar
3. Dust seal 10. Piston ring
4. Rod packing 11. Wear ring
5. Bushing
6. Cylinder
7. Piston rod
40-100 DX-Series
Item Unit 5 – 6 ton 7 ton 8 ton Remarks
Cylinder
(inner diam. × outer diam.) mm 80 × 90 85 × 90 90 × 102 —
Stroke mm 1,505 1,505 1,505 Lifting height: 3 m
Rod outer diameter mm 60 60 (65) 60 (65) Lifting height within paren-

theses is 4.5 m minimum.

Unit: mm
Criteria
Rod outer-dimeter
0.097 – 0.366 0.666
60
A Clearance between pis- Replace the
ton rod and bushing Rod outer-dimeter bushing
0.107 – 0.395 0.695
65
B Piston rod Scratches, dents or

concave on the claw
C Piston ring Scratches on the claw Replace
D Cylinder Scratches or concave on the claw
DX-Series 40-101
TILT CYLINDER
1. Nut 8. O-ring 15. Nut

2. Spring washer 9. Wiper ring 16. Piston
3. Bolt 10. U-ring 17. Packing
4. Rod head 11. Bushing (8 ton) 18. Cylinder
5. Bushing 12. Piston rod 19. Bushing
6. Cylinder head 13. Screw (8 ton)
7. O-ring 14. Steel ball (8 ton)
40-102 DX-Series
Item Unit 5 – 7 ton 8 ton
Cylinder
(inner diam. × outer diam.) mm 100 × 116 110 × 129
Stroke mm 200 234
Rod outer diameter mm 50 50

Unit: mm
Criteria
A Piston rod and cylinder head (bushing) 0.036 – 0.267 0.567

concave on the claw
Replace
C Piston ring Scratches on the claw
DX-Series 40-103
DISASSEMBLY OF LIFT AND TILT CYLIN-

DER
1. Removing the cylinder head assembly

Remove the cylinder head assembly using the
wrench.
For outer diameter

80 – 90 mm FG, D50 – 60
For lift For outer diameter

cylinder 85 – 90 mm FG, D70
Wrench
For outer diameter FD80

90 – 105 mm
For outer diameter

100 – 120 mm FG, D50 – 70
For tilt
cylinder
For outer diameter
110 – 130 mm FD80
2. Removing the piston rod assembly

Drive the piston rod and cylinder head assem-
blies out of the cylinder.
a When hanging the piston rod with wires, put
cloth between the piston rod and wires so that
the piston rod will not be damaged.
a When the cylinder rod is pulled out, hydraulic
oil in the cylinder flows out. Accordingly, pre-
pare an oil can to receive the oil.
a If the piston rod cannot be pulled out easily,
turn it.
a When pulling out the cylinder rod, take care
not to damage the piston seal with the
threads of the cylinder.
a Support the piston rod and cylinder head as-
sembly with a tool shown in the figure and
loosen the piston nut with a power wrench
and a socket.
a For the torque of the power wrench and the
width across flats of the socket, see MAINTE-
NANCE STANDARD.
40-104 DX-Series
3. Disassembling the piston rod assembly

1) Remove the piston rod head (tilt cylinder
alone).
2) Remove the cylinder head assembly from the
piston rod assembly.
a Care must be used so that the seal on the
cylinder head may not be damaged by
threaded portion on the piston rod.
3) Remove the wear ring.
4) Remove the piston ring.
a Undamaged rings may not be removed.
A removed ring must be replaced with a
new one.
4. Disassembling the cylinder head

a Undamaged seals may not be disassembled.
A disassembled seal must be replaced with a
new one.
1) Remove the snap ring (tilt cylinder alone),
then remove the dust seal.
2) Remove the U-packing using a screw driver.

a Use care so that adjacent parts may not
be damaged.
DX-Series 40-105
ASSEMBLY OF THE LIFT AND TILT

CYLINDER
1. Assembling the cylinder head assembly

1) If burrs or sharp edges are present in the cir-
cled positions P in the figure to right, remove
them with an oil stone Z so that the seal may
not be damaged by them.
2) Coat the cylinder head inner diameter portion

and packing as well as the O-ring installation
groove A with grease or hydraulic oil.
3) Collapse the U-packing and push it into the

groove B.
a When a jig is used pushing
The jig used must be made of copper,
aluminum or plastics and free from burrs
or sharp edges on its contact surface.
a It is advised to use your hands for push-
ing in the U-packing in stead of using the
jig.
4) Check if there is any failure on the inner diam-

eter lip and if it is appropriately fitted to the
groove by pushing inner perimeter of the U-
packing toward outer perimeter with your
hands.
40-106 DX-Series
5) Attach the dust seal by press fitting it with the

jig.
6) Assemble the O-ring.
2. Assembling the piston assembly

1) If burrs or sharp edges are present in the cir-
cled positions in the figure to right P, remove
them with an oil stone Z so that the seal may
not be damaged by them.
2) Coat the tapered surface on the piston A with

grease or hydraulic oil.
DX-Series 40-107
3) Place one end the piston ring in the groove,

stretch the other end along the tapered sur-
face, then assemble it.
4) Assemble the wear ring.
3. Assembling the piston rod assembly

Assemble the piston rod assembly to the cylinder.
a Use care so that the seal on the piston rod as-
sembly may not be damaged by threaded
portion on the cylinder.
40-108 DX-Series
4. Assembling the cylinder head assembly

Assemble the cylinder head assembly with the
cylinder using the wrench, then tighten them.
5 – 6 ton 529 – 647 Nm

{54 – 66 kgf•m}
573.5 – 700.5 Nm
For lift cylinder 7 ton {58.5 – 71.5 kgf•m}
661.5 – 808.5 Nm
8 ton {67.5 – 82.5kgf•m}
5 – 7 ton 392 – 686 Nm

{40 – 70 kgf•m}
For tilt cylinder
834 Nm
8 ton {25 kgf•m}
DX-Series 40-109
POWER STEERING CYLINDER
1. Cylinder head 6. U-packing 11. Stopper

2. O-ring 7. Bushing 12. Piston
3. O-ring 8. Cylinder 13. O-ring
4. Ring 9. Piston rod 14. O-ring
5. Dust seal 10. Ring 15. Bushing
40-110 DX-Series
a After installing the piston head, caulk along the periphery (on both right and left sides).
INSPECTION
Unit : mm
Criteria
Symbol Inspection item Remedy
A Clearance between cylinder and 0.03 – 0.18 0.30 Replace piston ring
piston ring
Clearance between piston rod and

B bushing 0.05 – 0.25 0.40 Replace bushing
C Piston rod Flaw, bruise, scratch, or dent felt with finger
D Cylinder Flaw, bruise, scratch, or dent felt with finger Replace
• Local wear deeper than 0.15 mm

E Bushing • Wear of red copper color over 1/4 of
circumference
F Outside diameter of cylinder 102
G Inside diameter of cylinder 90
H Diameter of piston rod 60 —
J Stroke 282
K Tightening torque of head 118 – 147 Nm {12 – 15 kgf•m}

mounting nut
DX-Series 40-111
DISASSEMBLY AND ASSEMBLY MAST
MAST
1. Strip shim
2. Outer main roller
3. Inner roller
*1. Used for mast having lifting height of 4 m or higher
40-112 DX-Series
k Place the mast assembly on wood blocks

(about 200 mm high) with the finger bar up.
ADJUSTING SHIM
1. Strip shim (1)
Dimension a 0 – 0.5 mm
1) Press the main roller against the rail.

2) Adjust the shim so that dimension a will be 0
– 0.4 mm through the inner rail. (The target
distance is 0.3 mm.)
2. Outer main roller (2)
Dimension b 0 – 0.5 mm
1) Set the mast to the maximum lifting height.

2) Insert the shims of the same thickness to the
right and left so that clearance b between the
round parts of the rail and roller will be 0 – 0.5
mm.
DX-Series 40-113
3. Inner roller (3)
Dimension c 0 – 0.5 mm

2) Press the rail against the roller and insert the
shims of the same thickness to the right and
left so that clearance c between the round
parts of the rail and roller will be 0 – 0.5 mm.
40-114 DX-Series
FINGER BAR
1. Roller on F side
2. Side roller
1. Roller on F side (1)
Dimension a 0.5 – 1.0 mm

2) Insert the shims of the same thickness to the
right and left so that clearance a between the
rail and roller will be 0.5 – 1.0 mm.
2. Side roller (2)
Dimension b 0 – 0.5 mm
Insert the shims of the same thickness to the right

and left so that clearance b between the roller
and rail will be 0 – 0.5 mm at the top of the inner
rail.
40-116 DX-Series
ADJUSTING CHAIN
1. Length of chain
1) Lower the mast to the lowest position.
2) Adjust the length of the chain so that projec-
tion A of the bottom of inner rail (1) from lower
roller (2) of finger bar (3) will be as follows.
Projection A
Unit : mm
5 ton 60
6 ton 55
7 ton 49
8 ton 62.5
DX-Series 40-117
Unit : mm
Criteria
A1 Axial 0.1 – 1.0 3.0 Adjusting shim

A Clearance between outer and inner
masts
A2 Radial 0.1 – 3.4 5.0 Replace
B1 Axial 0.1 – 0.5 2.0 Adjusting shim

Clearance between inner mast and
B finger bar
B2 Radial 0.1 – 3.4 5.0
Oil groove is
C Depth of bushing oil groove on mast support 1.5 provided
5 ton 55 50
Replace
6 ton 60 55
D Fork thickness (at root)
7 ton 65 60
8 ton 65 60
40-118 DX-Series
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Item Tool No. Drawing
For driving the differential pinion shaft oil 3ED-97-99590

seal
For measuring the differential pinion

pre-load 3FD-97-99940
For measuring the front hub starting 3ED-97-99570

torque
For measuring the differential pinion shaft 3ED-97-99600

starting torque
DX-Series 40-119
For tightening the differential adjusting

screw nut 34D-97-99110
For turning the differential ring gear 3ED-97-99960
For tightening the front axle locknut 308-968-9110
For compressing the clutch pack return

spring 3EC-97-99000
40-120 DX-Series
For inserting the clutch pack piston 3EC-97-99030
For driving the transmission output shaft

bearing and oil seal 3ED-97-99110
For propeller shaft centering 3ED-97-99500

(between transmission – differntial)
For stopping and tightening the differential A 3ED-97-99151

pinion shaft B 3ED-97-99181
DX-Series 40-121
For driving the transmission F and R shaft

bearing 3ED-97-99190
For steering valve (obitroll)

Assembly of centering spring 3BA-97-99220
40-122 DX-Series
CAULKING JIG A
CAULKING JIG B
Notes
1. For the part marked , harden and temper 5 mm from the end (normalizing is also acceptable).
2. Chamfer C0.5 to 1.0 mm at the corner.
3. Material: S45C
DX-Series 40-123
50. MAINTENANCE STANDARD
Torque converter.............................................. 50- 2

Transmission.................................................... 50- 4
Transmission control valve............................... 50- 6
Propeller shaft .................................................. 50- 8
Differential ........................................................ 50-10
Final drive......................................................... 50-12
Steering axle (Rear axle) ................................. 50-16
Master back and master cylinder assembly ..... 50-17
Brake valve ...................................................... 50-19
Wheel brake ..................................................... 50-20
Parking brake ................................................... 50-24
Hydraulic pump (Single type) ........................... 50-25
Hydraulic pump (Tanden type)......................... 50-26
Power steering cylinder.................................... 50-27
Lift cylinder ....................................................... 50-28
Tilt cylinder ....................................................... 50-29
Mast ................................................................. 50-30
Control valve .................................................... 50-31
DX-Series 50-1
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Unit : mm
Criteria
A Wear on tip of pilot 20 19.85
B Inside diameter of pump boss (seal ring engaging surface) 68 68.15
C1 Width 2.5 1.93
C Seal ring
C2 Thickness 2.0 1.52 Replace
D Inside diameter of converter case (seal ring engaging surface) 48 48.15
Width 2.5 1.93
E Seal ring
Thickness 2.7 2.22
1 Idling shaft mounting bolt tightening torque 67.6 – 78.4 Nm {6.9 – 8.0 kgf•m}
2 PTO bearing retainer mounting bolt tightening torque 67.6 – 78.4 Nm {6.9 – 8.0 kgf•m}
3 Seal retainer mounting bolt tightening torque 18.6 – 24.5 Nm {1.9 – 2.5 kgf•m}
Retighten
4 Pump case mounting bolt tightening torque 27.4 – 33.3 Nm {2.8 – 3.4 kgf•m}
5 Pilot boss and flexible plate mounting bolt tightening torque 35.2 – 44.1 Nm {3.6 – 4.5 kgf•m}
6 Charging pump mounting bolt tightening torque 35.2 – 44.1 Nm {3.6 – 4.5 kgf•m}
50-2 DX-Series
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
50-4 DX-Series
MAINTENANCE STANDARD TRANSMISSION
TESTING AND CHECKING

Unit : mm
Criteria
Sym- Check item Remedy Remarks
bol
A1 Thickness for F1, R1, and R2 2.5 – 2.7 2.3

Clutch disk —
A2 Thickness for F2 2.5 – 2.7 2.3
A3 Thickness for F1, R1, and R2 1.93 – 2.07 1.7

A Clutch plate
A4 Thickness for F2 1.93 – 2.07 1.7 Oil groove
depth:
Plate x A5 Thickness — — Min. 0.05
Plate y A6 Thickness with warp — —
Abutment joint clearance —

B1 (when inserting piston) (Bias cut) —
Seal ring B2 Width 2.45 – 2.55 2.25

B in 1- or 2-
axis clutch Inside diameter of seal ring
B3 engaging surface of piston 45.00 – 45.025 45.30
Seal ring insertion groove

B4 width 2.6 – 2.65 2.8
Abutment joint clearance

C1 (when inserting piston) 0.3 – 0.5 1.20
Replace
C2 Width 4.47 – 4.49 4.25
Piston ring
C in 1- or 2- Inside diameter of piston ring
axis clutch C3 engaging surface of clutch 145.00 – 45.063 145.300
case
Piston ring insertion groove
C4 width 4.55 – 4.65 4.85 —
D1 1st plate thickness — —

D Thrust
D2 2nd plate thickness — —
Abutment joint clearance —

E1 (when inserting piston) (Bias cut) —
E2 Width 2.47 – 2.49 2.25

E Seal ring
(retainer) Inside diameter of seal ring
E3 engaging surface of cap 35.00 – 35.025 35.20
Seal ring insertion groove

E4 width 2.60 – 2.65 2.80
F Spacer width (output axis) 118.2 – 118.3 118.0
Backlash 0.14 – 0.41 — If a tooth sur-

face is dam-
— Gear aged, replace —
Thrust clearance 0.15 – 0.60 — the gear.
T1 T/C, T/M tightening torque 58.8 – 73.5 Nm {6 – 7.5 kgf•m}
T Tightening T2 Retainer mounting bolt 27.44 – 34.3 Nm {2.8 – 3.5 kgf•m} —

torque
T3 Pipe mounting bolt 34.3 – 44.1 Nm {3.5 – 4.5 kgf•m}
DX-Series 50-5
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
A. Pressure regulator valve

B. Inching valve
C. Accumulator valve
D. Solenoid valve
• Gasoline engine model: 12 V
• Diesel engine model: 24 V
E. Filter
F. O-ring
50-6 DX-Series
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit : mm
Criteria
Sym-
No. Check item bol Remedy
Piston or spool and body hole
A: Inside diameter of valve body
B: Outside diameter of piston and spool
— — —
Outside diameter of piston 29.97 – 27.98

1 Accumulator Inside diameter of body 28.00 – 28.021 10
(damper) Clearance 0.02 – 0.051 0.08
—
2 Regulator valve Inside diameter of body 20.00 – 20.021 1
Clearance 0.02 – 0.061 0.08
3 Lubrication Inside diameter of body 10.00 – 10.015 5
relief valve Clearance 0.013 – 0.037 0.08
Outside diameter of valve 19.98 – 19.99
Inching sleeve Inside diameter of body 20.00 – 20.021
4 valve Clearance 0.01 – 0.041 7
Inside diameter of sleeve 10.00 – 10.022 0.08
Outside diameter of spool 9.978 – 9.787
5 Inching spool Clearance 0.013 – 0.044 0.08 6
Spring
— — — —
C: Free length
D: Installed length
E: Installed load
Free length 83
6 Accumulator Spring Installed length 80 11
(large) Installed load 34.3 – 38.2 N {3.5 – 3.9 kgf} 33 N {3.4 kgf}
Free length 107
7 Accumulator Spring Installed length 100 12
(small) Installed load 69.87 – 7.22 N {7.13 – 7.88kgf} 66 N {6.7 kgf}
Free length 73.8
8 Regulator Spring Installed length 37 3
Free length 55.5
9 Regulator Spring Installed length 36 2 —
(small) Installed load 41.2 – 45.1 N {4.2 – 4.6 kgf} 39 N {3.9 kgf}
Free length 34.5
10 Lubrication relief Valve Installed length 29 4
spring Installed load 29.4 – 32.3 N {3 – 3.3kgf} 28 N {2.8 kgf}
Free length 74
11 Inching Spring Installed length 54 9
Free length 28
12 Inching Spring Installed length 24.5 8
(small) Installed load 6.3 – 6.86 N {0.64 – 0.7 kgf} 5.9 N {0.6 kgf}
• The symbols at the right end of the table correspond to Nos. of NAME OF COMPONENT PARTS (1).
DX-Series 50-7
MAINTENANCE STANDARD PROPELLER SHAFT
PROPELLER SHAFT
Unit : mm
Sym- Criteria
Check item Remedy
bol Standard size Repair limit
A Shift amount of propeller shaft core 2.5 2.5 —
Inside diameter of propeller shaft and There must be

B bearing mating hole — — no backlash.
C Outside diameter of seal engaging sur- 60 59.9 There must be

face of joint boss no flaw on the
Outside diameter of seal engaging sur- engaging sur-
D 55 54.9 face.
face of brake drum boss
Spider and bearing support mounting
E bolt tightening torque 59 – 74 Nm {6 – 7.5 kgf•m} Retighten
50-8 DX-Series
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
50-10 DX-Series
MAINTENANCE STANDARD DIFFERENTIAL
Unit : mm
Sym- Criteria
Check item Remedy
Set starting torque — —

A Differential 3FE-21-15000
pinion
Backlash 0.15 – 0.2 0.15 – 0.2
B Outside diameter of spider and pin 24.929 – 24.98 24.75 3EE-21-21530
C Inside diameter of pinion gear 25.0 – 25.021 25.12 3EB-21-11340
Bushing thickness 1.52 – 1.68 1.3 3EB-21-11370

D Pinion gear
Bushing oil groove — — —
width by depth
Bushing thickness 1.94 – 2.06 1.7 34B-21-12141

E Side gear
Oil groove width by
depth — — —
Inside diameter of 60.00 – 60.03 — —

Differential mating hole
F case side
gear boss Oil groove width by
depth 3.0 × 1 — —
Outside diameter of differential case

G boss 75.011 – 75.030 75 —
H Bevel pinion gear backlash 0.2 – 0.28 0.28 —
I Runout on back of bevel gear Max. 0.1 Max. 0.1 —
J Outside diameter of seal engaging sur- 54.97 – 55.00 There must be no flaw. 3FD-21-21310
face of drum boss
K Inside diameter of parking brake and 216.0 – 216.2 218.2 3FD-21-21310

drum
L Differential case tightening torque 49 – 74 Nm {5 – 7.5 kgf•m} Loctite on thread
M Bevel gear mounting bolt 157 – 196 Nm {16 – 20 kgf•m} —
Differential carrier and support cap

N tightening bolt 343 – 427 Nm {35 – 43.5 kgf•m} —
O Bevel pinion shaft locknut (W) 196 – 392 Nm {20 – 40 kgf•m} —
P Bevel pinion shaft case tightening bolt 98 – 123 Nm {10.0 – 12.5 kgf•m} 01010-81245
Q Differential housing tightening bolt 157 – 196 Nm {16 – 20 kgf•m} —
R Parking brake drum tightening bolt 196 – 245 Nm {20 – 25 kgf•m} Loctite on thread
DX-Series 50-11
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
5 – 7 ton
50-12 DX-Series
Unit : mm
Sym- Criteria
Check item Remedy
1 Inside diameter of housing and knock pin 14 14 —
2 Outside diameter of housing and knock pin 14 14 —
3 Outside diameter of mast support mounting 160 0

159.5 —
portion – 0.2
4 Outside diameter of housing and seal 105 –– 0.012 — —

retainer mating hole 0.047
Outside diameter of bearing mating hole in

5 housing 105 –– 0.012
0.047 — —
6 Outside diameter of ring gear bearing mat- 100 –– 0.012 — —

ing hole 0.047
Inside diameter 105 There must be no flaw. —

Seal
7 retainer Outside diameter 135 There must be no flaw. —
(seal engaging surface)
8 Inside diameter of hub seal mating hole 165 There must be no flaw. —
9 Inside diameter of internal 160 –– 0.028 — —

bearing mating hole 0.068
Hub
10 Inside diameter of external 180 –– 0.028 — —
11 Front hub start torque 14.7 – 29.4 Nm {1.5 – 3.0 kgf•m} —
Hub and ring gear tightening nut

12 tightening torque (Front hub start torque adjustment) —
Be sure to stop
13 Lock bolt (for ring nut) tightening torque 58.8 – 73.5 Nm {6 – 7.5 kgf•m} rotation (mount
the cotter pin).
14 Axis pipe connection bolt tightening torque 196 – 309 Nm {20 – 31.5 kgf•m} —
15 Gear case mounting bolt tightening torque 157 – 196 Nm {16 – 20 kgf•m} Apply Locktite
#271 on the
threaded portion.
16 Brake drum mounting bolt tightening torque 196 – 309 Nm {20 – 31.5 kgf•m}
Cross-caulk the
17 Hub bolt mounting nut tightening torque 441 – 588 Nm {45 – 60 kgf•m} bolt.
18 Wheel and clip (hub) nut tightening torque 294 – 490 Nm {30 – 50 kgf•m} —
DX-Series 50-13
8 ton
50-14 DX-Series
Unit : mm
Sym- Criteria
Check item Remedy
1 Inside diameter of housing and knock pin 14 14 —
2 Outside diameter of housing and knock pin 14 14 —
3 Outside diameter of mast support mounting 160 0

159.5 —
portion – 0.2
4 Outside diameter of housing and seal 105 –– 0.012 — —

retainer mating hole 0.047
Outside diameter of bearing mating hole in

5 housing 105 –– 0.012
0.047 — —
6 Outside diameter of ring gear bearing mat- 120 –– 0.012 — —

ing hole 0.047
Inside diameter 105 There must be no flaw. —

Seal
7 retainer Outside diameter 135 There must be no flaw. —
(seal engaging surface)
8 Inside diameter of hub seal mating hole 165 There must be no flaw. —
9 Inside diameter of internal 160 –– 0.028 — —

Hub
10 Inside diameter of external 180 –– 0.028 — —
11 Front hub start torque 14.7 – 29.4 Nm {1.5 – 3.0 kgf•m} —
Hub and ring gear tightening nut tightening

12 torque (Front hub start torque adjustment) —
Be sure to stop
13 Lock bolt (for hub nut) tightening torque 58.8 – 73.5 Nm {6 – 7.5 kgf•m} rotation (mount
the cotter pin).
14 Axis pipe connection bolt tightening torque 196 – 309 Nm {20 – 31.5 kgf•m} —
Apply Locktite
15 Gear case mounting bolt tightening torque 196 – 309 Nm {20 – 31.5 kgf•m} #271 on the
threaded portion.
16 Brake drum mounting nut (also used to 319 – 490 Nm {32.5 – 50 kgf•m} Cross-caulk the
mount hub bolt) tightening torque bolt.
Wheel cap nut (hub nut A) tightening

17 torque 539 – 637 Nm {55 – 65 kgf•m} —
Wheel and clip (hub) nut B tightening

18 torque 539 – 637 Nm {55 – 65 kgf•m} —
DX-Series 50-15
MAINTENANCE STANDARD STEERING AXLE (REAR AXLE)
STEERING AXLE (REAR AXLE)

5 – 7 ton
Unit : mm
Criteria
A1 Outer diameter 60 59.5 Replace

A Center pin
B King pin outer diameter 40 39.8
8 ton
Unit : mm
Criteria

A Center pin
50-16 DX-Series
MAINTENANCE STANDARD MASTER BACK AND MASTER CYLINDER ASSEMBLY
MASTER BACK AND MASTER CYLINDER ASSEMBLY

5 – 7 ton
• Amount of master cylinder brake fluid : 0.05 l.
1. Master cylinder assembly 6. Silencer

2. Master back assembly 7. Filter
Master back replacement parts 8. Seal
3. Retainer 9. Retainer
4. Guard 10. Seal
5. Filter
a Make sure that the filter is not clogged.
DX-Series 50-17
MAINTENANCE STANDARD MASTER BACK AND MASTER CYLINDER ASSEMBLY
5 – 7 ton
(Master cylinder)
Unit : mm
No. Check item Standard value Repair limit Remedy
1 Clearance between cylinder and piston 0.020 – 0.105 0.15 Replace

(cylinder assembly)
Primary side:
2 Interference of cup About 0.6 0.3 Replace
Secondary side: (pistonassembly)
About 1.5 0.4
3 Spring free length 89 80 Replace
4 Clamp tightening torque 1.47 – 2.45 Nm — —

{0.15 – 0.25 kgf•m}
5 Master cylinder and master back tighten- 8.82 – 13.72 Nm — —

ing torque {0.9 – 1.4 kgf•m}
15.68 – 21.56 Nm
– Master back clevis tightening torque {1.6 – 2.2 kgfm} — —
– Torque of tightening master back on truck 13.72 – 17.64 Nm — —

body {1.4 – 1.8 kgf•m}
50-18 DX-Series
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
8 ton
Unit : mm
Criteria
Sym-
bol Inspection item Remedy
A Diameter clearance of fitting parts of input piston and body — 0.16
B Diameter clearance of fitting parts of spool and body — 0032
C Diameter clearance of fitting parts of reaction piston and guide — 0.16
D Sliding surfaces of piston of body and spool —
E Sliding surfaces of outside of input piston — When there is

flaw, uneven
F Sliding surfaces of outside of reaction piston — wear, or rust
G Sliding surfaces of outside of spool —
H Sliding surfaces of reaction piston of guide — —

Replace
Dimension a of input piston spring 0 0
K Fatigue of spring (Free length) — 20
DX-Series 50-19
MAINTENANCE STANDARD WHEEL BRAKE
WHEEL BRAKE
5 – 7 ton
50-20 DX-Series
Unit : mm
Criteria
bol
A Lining Thickness 10 5.2
294N {30kgf} (l = 101.2mm) 265N {27kgf} (l = 101.2mm)
Free length: 90 mm
Return
B spring Strength
245N {25kgf} (l = 101.2mm) 221N {22.5kgf} (l = 101.2mm)
Free length: 93 mm
0.025 – 0.126 0.15

C Wheel Clearance between
cylinder piston and cylinder
Crack or chipping on the body and rust inside the body.
Replace
Length D1 97.6 ± 0.15 98
D Link Outer diameter a D2 4 3.75
Crush or wear.
inner diam- 4.7 ± 0.1 5.0

eter b
E Lever Toggle hole
Crush or wear.
F Back plate Deformation or crack.
— Brake drum inner diameter 317.5 320.5
— Clearance between lining and drum 0.4 – 0.6 0.4 – 0.6 Testing and
adjusting
DX-Series 50-21
8 ton
50-22 DX-Series
Unit : mm
Criteria
Sym-
bol Check item Remedy
324N {33kgf} (l = 103.5mm) 294N {30kgf} (l = 103.5mm)

B Return spring Strength
Free length: 93mm
0.080 – 0.181 0.2 Replace

C Wheel cylinder Clearance between
piston and cylinder
Crack or chipping on the body,
or rust inside the body.
D Back plate Deformation or crack.
— Brake drum inner diameter 393.7 396
Testing and
— Clearance between lining and drum 0.3 – 0.5 0.3 – 0.5 adjusting
When assembling the brake shoe

Insert a 0.25 mm and 0.15 mm thickness gauge to the
position G and F respectively, tighten nut E, then in-
sert the cotter pin to the nut.
If it is difficult to insert the cotter pin, rewind the nut E
by 1/6 turn and then retry.
DX-Series 50-23
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
Unit : mm16
Criteria
bol
Strength 152N {15.5kgf} (l = 50mm) 137N {14kgf} (l = 50mm)

B Shoe return Replace
spring
Free length 54.7
— Drum Inner diameter 216 217.5
Clearance between lining and

— drum 0.1 – 0.25 0.1 – 0.25
Operator of brake lever Min. 196 N {20 kgf} Min. 196 N {20 kgf}
Check that the vehicle is kept stopped on following slopes.

Adjust or repair
When not loaded Slope sharper than 20% (11.2 deg.)
—
Braking force When loaded Slope sharper than 15% (8.5 deg.)
If there is not proper slope, drive at low speed with

extreme care for safety and check effect of parking brake.
50-24 DX-Series
MAINTENANCE STANDARD HYDRAULIC PUMP (SINGLE TYPE)
HYDRAULIC PUMP (SINGLE TYPE)
Item Oil pressure setup (control valve)

Pump Delivery Rotating direction
Model model Main relief pressure Port relief pressure
FG50/60/70 SAL56 56.5/rev Counterclockwise 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
Unit: mm
Criteria
Clearance between shaft hole inner
A diameter and gear shaft outer diameter 0.06 – 0.148 0.15
Clearance between gear case and

B bushing gear 0.10 – 0.15 0.18
Contact area (circumference) between Replace

C gear and body 1/3 – 1/2 Min. 3/4
Tightening torque of pump body
F assembly bolt 98.1 – 122.6 Nm {10 – 12.5 kgf•m} Retighten
DX-Series 50-25
MAINTENANCE STANDARD HYDRAULIC PUMP (TANDEN TYPE)
HYDRAULIC PUMP (TANDEN TYPE)
Item Delivery Oil pressure setup (control valve)

Pump model
Model 1st pump 2nd pump Main relief pressure Port relief pressure
FD50/60/70 SAL40+28 40.2 cc/rev 28.0 cc/rev 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
FD80 SAL40+36 40.2 cc/rev 36.1 cc/rev 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
a Each pump rotates in counterclockwise.

Unit: mm
Criteria

B Clearance between gear case and 0.10 – 0.15 0.18

bushing gear
Contact area (circumference) between

C gear and body 1/3 – 1/2 Min. 3/4 Replace
F Tightening torque of pump body 98.1 – 122.6 Nm {10 – 12.5 kgf•m}

assembly bolt
Retighten
Tightening torque of bracket and carrier
G coupling bolt 58.8 – 73.5 Nm {6 – 7.5 kgf•m}
50-26 DX-Series
MAINTENANCE STANDARD POWER STEERING CYLINDER
POWER STEERING CYLINDER
a After installing the piston head, caulk along the periphery (on both right and left sides).
INSPECTION
Unit : mm
Criteria
Symbol Inspection item Remedy
Clearance between cylinder and

A piston ring 0.03 – 0.18 0.30 Replace piston ring
Clearance between piston rod and

B bushing 0.05 – 0.25 0.40 Replace bushing
C Piston rod Flaw, bruise, scratch, or dent felt with finger
D Cylinder Flaw, bruise, scratch, or dent felt with finger Replace
• Local wear deeper than 0.15 mm

E Bushing • Wear of red copper color over 1/4 of
circumference
F Outside diameter of cylinder 102
G Inside diameter of cylinder 90
H Diameter of piston rod 60 —
J Stroke 282
Tightening torque of head

K mounting nut 118 – 147 Nm {12 – 15 kgf•m}
DX-Series 50-27
MAINTENANCE STANDARD LIFT CYLINDER
LIFT CYLINDER
Item Unit 5 – 6 ton 7 ton 8 ton Remarks
Cylinder mm 80 × 90 85 × 90 90 × 102 —
(inner diam. × outer diam.)
Stroke mm 1,505 1,505 1,505 Lifting height: 3 m
Lifting height within paren-

Rod outer diameter mm 60 60 (65) 60 (65) theses is 4.5 m minimum.
Unit: mm
Criteria
Rod outer-dimeter
0.097 – 0.366 0.666
60
Clearance between pis- Replace the
A ton rod and bushing bushing
Rod outer-dimeter
0.107 – 0.395 0.695
65

concave on the claw
C Piston ring Scratches on the claw Replace
50-28 DX-Series
MAINTENANCE STANDARD TILT CYLINDER
TILT CYLINDER
Item Unit 5 – 7 ton 8 ton
Cylinder mm 100 × 116 110 × 129

(inner diam. × outer diam.)
Stroke mm 200 234
Rod outer diameter mm 50 50
Unit: mm
Criteria
A Piston rod and cylinder head (bushing) 0.036 – 0.267 0.567

concave on the claw
Replace
C Piston ring Scratches on the claw
DX-Series 50-29
MAINTENANCE STANDARD MAST
MAST
Unit : mm
Criteria
A1 Axial 0.1 – 1.0 3.0 Adjusting shim

Clearance between outer and inner
A masts
A2 Radial 0.1 – 3.4 5.0 Replace
B1 Axial 0.1 – 0.5 2.0 Adjusting shim

B Clearance between inner mast and
finger bar
B2 Radial 0.1 – 3.4 5.0
Oil groove is
C Depth of bushing oil groove on mast support 1.5 provided
5 ton 55 50
Replace
6 ton 60 55
D Fork thickness (at root)
7 ton 65 60
8 ton 65 60
50-30 DX-Series
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Unit : mm
Sym- Criteria
bol Check item Remedy
A1 Return spring 78 66 – 90
A2 Tilt lock spring 36.2 31

Free length of
A spring
A3 Check valve 31.8 27 Replace
A4 Inlet 46.4 39
— Spool and housing Scratches, burrs
DX-Series 50-31
60. STRUCTURE AND FUNCTION
Power train ...................................................................................................................... 60- 2

Torque converter and transmission control valve............................................................ 60- 3
Work equipment control valve ......................................................................................... 60-12
Hydraulic circuit diagram ................................................................................................. 60-16
Brake system................................................................................................................... 60-18
Master back, master cylinder .......................................................................................... 60-20
Brake valve...................................................................................................................... 60-25
Assembly drawings
Accelerator pedal (FG50/60/70-7 (TB42 engine)) ........................................................ 60-30
Accelerator pedal (FD50/60/70-8 (6D102E engine)) .................................................... 60-31
Accelerator pedal (FD80-8 (SA6D102E engine)) ......................................................... 60-32
Brake and inching pedal (5 – 7 ton) ............................................................................. 60-34
Brake and inching pedal (8 ton) ................................................................................... 60-36
Parking brake ............................................................................................................... 60-38
Torque converter .......................................................................................................... 60-39
TORQFLOW transmission ........................................................................................... 60-40
Differential .................................................................................................................... 60-42
Front axle (5 – 7 ton) .................................................................................................... 60-43
Front axle (8 ton) .......................................................................................................... 60-44
Steering axle (5 – 7 ton) ............................................................................................... 60-45
Steering axle (8 ton) ..................................................................................................... 60-46
Brake piping (FD50/60/70-8) ........................................................................................ 60-47
Brake piping (FD80-8) .................................................................................................. 60-48
Work equipment hydraulic piping diagrams (FD50/60/70-8) ........................................ 60-49
Work equipment hydraulic piping diagrams (FD80-8) .................................................. 60-50
Mast.............................................................................................................................. 60-51
Electrical (5 – 7 ton) ..................................................................................................... 60-52
Electrical (8 ton) ........................................................................................................... 60-53
Electrical circuit diagram (Gasoline engine truck (TB42 engine)) ................................ 60-55
Electrical circuit diagram (Diesel engine truck (S6D102E engine, FD50, 60, 70-8)) .... 60-57
Electrical circuit diagram (Diesel engine truck (SA6D102E engine, FD80-8)) ............. 60-59
Speedometer (option)................................................................................................... 60-61
Hinged fork (For 5 – 6 ton models, fixed guard type: HFF607) .................................... 60-62
Side shift (For 5 – 6 ton models: FSE607) ................................................................... 60-63
Clamp base (For 5 – 6 ton models: CBW607) ............................................................. 60-64
DX-Series 60-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1. Engine 6. Parking brake

2. Torque converter 7. Final drive (differential)
3. TORQFLOW transmission 8. Front axle (planetary gear)
4. Propeller shaft 9. Brake drum
5. Parking brake drum 10. Wheel brake
60-2 DX-Series
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE

SECTIONAL VIEW OF TORQUE CONVERTER ASSEMBLY
DX-Series 60-3
1. Torque converter assembly
1) Configuration
It is configured as shown in the sectional view and
the components are roughly classified as follows:
(1) Torque converter
(2) Gear pump
(3) Housing
(4) Power combining portion (input plate and
turbine shaft)
(1) Torque converter

The torque converter is the 3-component, 1-
step, 2-phase type and consists of as follows:
a. Pump impeller
Combined with the input plate
b. Stator
Fit with the stator support via the one-way
clutch using the spline
c. Turbine
Combined with the turbine shaft
60-4 DX-Series
(2) Gear pump

This circumscribed-type gear pump is designed to supply oil to the transmission and the torque converter
and be driven by the PTO gear of the torque converter.
(3) Housing
A torque converter inlet relief valve is built in the housing in order to restrain internal torque converter
pressure from rising.
(4) Power combining portion

a. Input plate
The outer circumference is combined with the flywheel on the engine side and the inner circumfer-
ence is combined with the torque converter pump (impeller) to transmit the engine torque to the
torque converter.
b. Turbine shaft
The one side is combined with the torque converter turbine and the other is combined with the trans-
mission input portion in order to transmit the torque converter output torque to the transmission side.
DX-Series 60-5
2) Function
(1) The rotation from the engine is transmitted to the impeller via the input plate.
The oil in the impeller is discharged along the impeller blades by centrifugal force.
(2) The oil drained from the impeller hits the turbine blade train. At this time, power is generated, which is
output via the turbine shaft.
(3) The direction of the oil drained from the turbine is changed by the stator so that it will re-enter in a desired
angle against the impeller blade train.
By repeating procedures (1) to (3) above, the engine torque is transmitted to the transmission side.
The gear pump is driven by the PTO gear.
60-6 DX-Series
2. Torque converter performance curve diagrams
3. TORQFLOW transmission hydraulic circuit diagram
DX-Series 60-7
4. Hydraulic circulation route
1) After starting the engine, the gear pump is driven by the PTO gear of the torque converter and the oil in the
transmission enters the gear pump via the strainer to be forcefully fed.
2) The pressure of the oil drained from the gear pump is adjusted to the relief pressure (1.01 – 1.25 MPa (10.3
– 12.7 kgf/cm²)) by the regulator valve in the control valve and the adjusted oil is supplied to the solenoid
valve in the hydraulic clutch circuit.
3) The accumulator is released when the circuit is switched to the forward or reverse travel by the solenoid valve
and the oil in the accumulator is supplied to the circuit to the hydraulic clutch.
4) Power is smoothly transmitted since the pressure in the clutch gradually rises after clutch starts operation
since the oil on the hydraulic circuit side flows into the clutch side while filling the accumulator.
5) The oil drained from the regulator valve, on the other hand, is supplied to the torque converter.
6) There is a relief valve at the torque converter inlet for retaining the pressure in the torque converter at 0.59
to 0.78 MPa {6 to 8 kgf/cm²}.
7) Part of the oil drained from the torque converter is used to set the coolant and lubrication flow loads so that
the pressure in the lubrication circuit will be retained at 0.42 to 0.66 MPa {4.3 to 6.7 kgf/cm²} by the lubrication
relief valve in the control valve and the rest is fed to the oil cooler.
8) The oil cooled in the oil cooler is returned to the transmission case alter lubricating or cooling each part of the
transmission via the filter.
The following pages show the hydraulic circuit diagrams and the positions of each port.
5. Hydraulic characteristics of inching valve

Measuring condition: P1 port pressure : 1.25 MPa {12.7 kgf/cm²}
Point Lower limit value Upper limit value
MPa {kgf/cm²} 0.10 {1.0} 0.69 {7.0}

A
Stroke (mm) 3.4 4.1
MPa {kgf/cm²} 0.04 {0.4} 0.14 {1.4}

B
Stroke (mm) 7.6 5.5
MPa {kgf/cm²} — 0.07 {0.7}

C
Stroke (mm) — 10.2
60-8 DX-Series
6. Position of the TORQFLOW transmission hydraulic port
(1) TORQUE CONVERTER HOUSING
DX-Series 60-9
(2) TRANSMISSION
60-10 DX-Series
7. Control valve assembly
The speed steps are forward travel 2-step and reverse travel 2-step and switched by the solenoid valve.
It is equipped with the inching function for releasing the hydraulic clutch when the truck stops and the mod-
ulation function for reducing shock generated when the truck starts moving or changes the speed.
Sectional view of control valve assembly
DX-Series 60-11
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL VALVE
WORK EQUIPMENT CONTROL VALVE
60-12 DX-Series
COMPOUND VALVE UNIT

The control valve consists of lift valve (4), tilt valve
(3), main relief valve (1), and attachment valve (2). In
addition, PS relief valve (5), flow divider with PS load
sensing valve (6), and engine stall prevention valve
(7).
LOAD SENSING VALVE

With the PS load sensing valve, while the steering
wheel is in neutral, most of the oil for the PS is sup-
plied for the work equipment. Accordingly, the work
equipment speed is increased and the operator can
work efficiently.
PRINCIPLE OF OPERATION OF LOAD

SENSING VALVE
• While the steering wheel is in neutral
As shown in the figure at right, flow divider (8) is
balanced by the differential pressure between the
front and rear sides of hole a. Accordingly, a little
amount of the hydraulic oil flows through hole a to
PS valve (10) and most hydraulic oil flows in con-
trol valve (11) to move the work equipment.
• When the steering wheel is turned

If the steering wheel is turned, load sensing valve
(9) is pushed up by the pressure from PS valve
(10) and hole b opens. Since flow divider (8) is
balanced by the differential pressure between the
front and rear sides of holes a and b, the flow di-
vider lowers less. Accordingly, the oil flowing in
control valve (11) is reduced and the oil neces-
sary to the PS flows in PS valve (10).
DX-Series 60-13
ENGINE STALL PREVENTION VALVE

The engine stall prevention valve is installed in the
control valve inlet to improve operability when an at-
tachment is installed.
1. Structure of engine stall prevention valve
2. Function Pressure wave form when engine stall preven-

When pressure is applied to the work equipment, tion valve is installed
the flow divider increases the open area on the
work equipment. Since the valve responds slow-
ly at this time, the oil flow does not follow up the
pressure for a moment. Accordingly, generation
of the peak pressure is delayed and the engine
does not stall.
60-14 DX-Series
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

5 – 7 ton
Hydraulic pumps by engine type
Hydraulic setting
Engine type Classification Pump type
[1] Main relief pressure [2] Port relief pressure
FG50/60/70 P1 SAL56
18.88 MPa {185 kgf/cm²} 10.71 MPa {105 kgf/cm²}
FD50/60/70 P1 + P2 SAL40 + 28
60-16 DX-Series
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
8 ton
Hydraulic pumps by engine type
Hydraulic setting
Engine type Classification Pump type
[1] Main relief pressure [2] Port relief pressure
FD80 P1 + P2 SAL40 + 36 18.88 MPa {185 kgf/cm²} 10.71 MPa {105 kgf/cm²}
DX-Series 60-17
STRUCTURE AND FUNCTION BRAKE SYSTEM
BRAKE SYSTEM
5 – 7 ton
Vacuum tank
• Vacuum level : Max. 91 kPa {680 mmHg}
• Alarm level : 60 kPa {450 mmHg} (during vacuum switch operation)
60-18 DX-Series
STRUCTURE AND FUNCTION BRAKE SYSTEM
8 ton
Accumulator
• Volume for accumulation: 300 cc
• Alarm level: Operates at 6.3 – 6.9 MPa {64 – 70 kgf/cm²}
DX-Series 60-19
STRUCTURE AND FUNCTION MASTER BACK, MASTER CYLINDER
MASTER BACK, MASTER CYLINDER

5 – 7 ton
60-20 DX-Series
OPERATION OF THE MASTER BACK

(Master back, master cylinder assembly)
1. Non-operating state
When not stepping on the brake pedal
The negative pressure from the vacuum pump via
the vacuum tank is guided on both sides of the di-
aphragm with the vacuum valve set to ON
(opened) and the air valve set to OFF (closed).
The master back will not move because no pres-
sure difference is generated.
2. Intermediate load state

When slightly stepping on the pedal
When slightly pushing the push rod, both the vac-
uum valve and air valve are set to OFF and the di-
aphragm is retained at a fixed place only by slight
movement.
When stopping the pedal halfway to maintain the
state, both the vacuum valve and air valve are set
to this position.
DX-Series 60-21
3. During full load

Stepping on the brake pedal
When stepping on the pedal, the operating rod
pushes the valve body to the push rod (master
cylinder). Accordingly, the air valve opens with
the vacuum valve remaining closed and the air
valve opens to allow the air to enter the air cham-
ber. Hence, the pressure difference before and
behind the diaphragm (the vacuum chamber and
air chamber) increase and the diaphragm moves
to the push rod side (vacuum chamber) to apply
force (boosting operation).
The stepping-on force of the pedal is transmitted
via the operating rod, plunger, and reaction disk.
4. During return
Releasing the brake pedal
When releasing the brake pedal, the plunger
head drops until it touches the key. Then, be-
cause the air valve closes and the vacuum valve
opens, the air in the air chamber is discharged via
the vacuum valve. Consequently, the diaphragm
moves to the rear (right side) by the force of the
spring and the push rod returns to the original po-
sition, and then the brake is released.
60-22 DX-Series
OPERATION OF THE FAST FILL VALVE,

MASTER CYLINDER
1. When starting stepping on the brake pedal
When stepping on the brake pedal, the piston is
pushed via the push rod of the master back. For
the same piston travel, the pressure (P2) of the
large-diameter chamber is larger than the pres-
sure (P1) of the small chamber (because the ca-
pacity of the large-diameter chamber decreases
by the piston actuation). At this time, the brake
fluid in the small-diameter chamber flows in the
gap between the primary cup and cylinder and
the hole of the piston.
Consequently, the pressure inside the cylinder
can increase in a short stroke.
2. When further stepping on the brake pedal

After having further stepped on the brake pedal,
if each pressure inside the cylinder reaches
P1 = P2 = 0.98 MPa {10 kgf/cm²}
(Cracking pressure of the check valve),
the ball valve is operated and the fluid in the
large-diameter flows in the reservoir tank, and
then the pressure in the small-diameter chamber
rises in the same manner as before.
DX-Series 60-23
3. When releasing the brake pedal

When releasing the brake pedal, the piston is
pushed back by the force of the return spring.
At this time, the pressure inside the cylinder
reaches the negative pressure, the fluid inside
the reservoir tank pushes to open the seal of the
fast fill valve and flows in the cylinder.
60-24 DX-Series
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
8 ton
SPECIFICATIONS
Type Leading type
Inside diameter of drum 393.7 mm
Specifications of brake Material of lining Resin mold
Size of lining (Width × thickness) 125 mm × 13.1 mm
Inside diameter of wheel cylinder 41.3 mm
Adjustment pressure 11.8 MPa {120 kgf/cm²}
Brake pedal Piston stroke 11 mm
Flow rate at inlet 25 l/min
Oil pressure at max. accumulation pressure 13.7 MPa {140 kgf/cm²}

Accumulator
Volume for accumulation 0.3 l {300 cc}
STRUCTURE OF BRAKE VALVE
1. Ball valve 7. Input piston A: From accumulator

2. Valve rod 8. Stopper B: To wheel cylinder
3. Return spring 9. Nut (For adjusting pressure) C: From pump
4. Reaction piston 10. Push rod D: To hydraulic tank
5. Spool 11. Spring E: To downstream devices
6. Body Relationship of valves
a<b<c<d
• The brake valve regulates the oil pressure in the brake oil circuit according to the pressing distance of the
brake pedal and operates the wheel cylinder. Even if the oil from the hydraulic pump stops because of an
engine stall, etc., the brake can be operated several times with the oil pressure saved in the accumulator.
DX-Series 60-25
PRINCIPLE OF OPERATION OF BRAKE VALVE

1. While the brake pedal is released
• If a downstream device (power-assisted steering system, etc.) is operated while spool (5) is in the position
shown above, the oil pressure in pump port C rises. Since pump port C and port F are blocked by normally-
closed valve b, however, the hydraulic oil does not flow in control oil chamber G. Accordingly, the brake does
not work by itself, even if a downstream device is operated.
2. When the brake pedal is pressed
• If the brake pedal is pressed, push rod (10) and input piston (7) move to the left and spool (5) and reaction
piston (4) are pushed by spring (11) to push and move return spring (3) to the left. As spool (5) moves to the
left, the pass between port F and drain port D is blocked by valve a and control pressure chamber G is dis-
connected from drain port D. Then, normally-closed valve b opens and forms the pass between ports C and
F. As a result, pump port c is connected to control oil chamber G.
• If spool (5) is moved further to the left, valve c is closed and the oil pressure in pump port C rises. Accord-
ingly, the oil pressure in control pressure chamber G connected to port C rises and the oil pressure in the
wheel cylinder also rises.
• Since the oil pressure in control pressure chamber G presses reaction piston (4) to the right (which is returned
by the reaction force to the oil pressure), it is balanced with the pressing force of the operator.
60-26 DX-Series
• If the brake pedal is pressed to the stroke end, nut (9) touches stopper (8) and input piston (7) cannot move
to the left any more. Accordingly, the oil pressure in control pressure chamber becomes highest at this time.
k Loosen nut (9) only when replacing input piston (7).
Movement of spool (5)

1) Valve b of spool (5) is a ring orifice as shown in
the figure at right, since it must be control the little
oil flow.
3. When hydraulic oil is not supplied
• Even if the pump stops (because of an engine stall, etc.), the emergency brake can be operated with the pres-
sure saved in the accumulator.
If the brake pedal is pressed, push rod, (10), input piston (7), and spool (5) move to the left. As spool (5)
moves to the left, valve a closes and normally-closed valve b open and valve c closes. While the pump is
stopped, however, no oil pressure is generated in control pressure chamber G.
• If the brake pedal is pressed further, spool (5) and reaction piston (4) move to the left. Accordingly, the end
of reaction piston (4) touches valve rod (2) and valve d is closed and the pass between port H and control
pressure chamber G is blocked. If the brake pedal is pressed further, spool (5), reaction piston (4), and valve
rod (2) move to the left as 1 unit. Accordingly, ball valve (1) is pushed open and the pass is formed between
accumulator port A and control pressure chamber G. As a result, the oil pressure saved in the accumulator
is led into control pressure chamber G to raise the pressure in the wheel cylinder.
• Since the oil pressure in control pressure chamber G gives a reaction force to reaction piston (4), it is bal-
anced with the pressing force of the operator.
DX-Series 60-27
• If the brake pedal is released, spool (5), reaction piston (4), and valve rod (2) move to the right and ball valve
(1) returns to the valve seat to block the pass between accumulator A and control pressure chamber G.
• Valve rod (2) stops halfway but reaction piston (4) moves further to the right. Accordingly, valve d opens to
form the pass between port H and control pressure chamber G, then the hydraulic oil flows and the oil pres-
sure in the wheel cylinder lowers. If spool (5) moves further to the right, valve a opens and the pass is formed
between port F and drain port D, then the oil pressure in the wheel cylinder lowers completely.
Oil flow in valve

1) There is a hole having a filter net on the cover of
the ball valve (1) and the hydraulic oil from the ac-
cumulator flows through that hole.
2) There is clearance between valve rod (2) and
valve body (6) and the hydraulic oil from the ac-
cumulator flows through that clearance.
60-28 DX-Series
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
ACCELERATOR PEDAL
FG50/60/70-7 (TB42 engine)
Accelerator pedal adjusting procedure

1. Set the pedal height to 129.5 mm with the stopper
bolt (1).
2. Temporarily set the height of the stopper bolt (2)
to 52.2 mm.
3. After having assembled the cable (4), adjust the
outer casing mounting part (5) of the cable so that
the play of 1 to 2 mm can be obtained in the pedal
(3).
4. Adjust and set the height of the stopper bolt (2) so
that the engine side lever (6) can be fully opened
on the pedal stroke end.
5. After having adjusted it, accurately tighten and
lock the locknut of the stopper bolts (1) and (2).
Cable stroke 46.3 mm
a Coat each sliding portion with lithium grease

(G2-LI) during assembly.
60-30 DX-Series
ACCELERATOR PEDAL
FD50/60/70-8 (S6D102E engine)
Accelerator pedal adjust procedure

1. Set the pedal height to 129.5 mm with the stopper
bolt (1).
to 61 mm.
outer casing (5) mounting part of the cable so that
(3).

(G2-LI) after assembly.
DX-Series 60-31
ACCELERATOR PEDAL
FD80-8 (SA6D102E engine)
Accelerator pedal adjusting procedure

1. Set the pedal height to 130 mm with the stopper
bolt (1).
to 71 mm.
outer casing mounting part (3) of the cable so that
(5).
Between points a – b 189 mm

(G2-LI) after assembly.
60-32 DX-Series
BRAKE AND INCHING PEDAL

5 –7 ton
a Coat each sliding portion with lithium grease (G2-LI) during assembly.
60-34 DX-Series
DX-Series 60-35
BRAKE AND INCHING PEDAL

8 ton
a Coat each sliding part with lithium grease (G2-LI) during assembly.
60-36 DX-Series
DX-Series 60-37
PARKING BRAKE
60-38 DX-Series
70. TROUBLESHOOTING
Engine .............................................................. 70- 2

Electrical system .............................................. 70- 3
TORQFLOW system ........................................ 70- 4
Steering system ............................................... 70- 7
Brake system ................................................... 70- 9
Hydraulic system.............................................. 70-11
DX-Series 70-1
TROUBLESHOOTING ENGINE
ENGINE
Problem Major cause Remedy
• Lowered oil level in the oil pan. • Fill oil.

The oil pressure warning light • Clogging of oil filter element. • Replace the element.
does not go out. • Oil leakage due to the loose or worn oil • Check and repair it.
pipe joint.
• Insufficient coolant or water leakage. • Fill coolant or repair it.

Steam is blown out of the radiator • Loose fan belt. • Adjust the belt tension.
pressure valve. • Dirt or scale in the cooling system. • Replace coolant or clean the cooling
system.
• Clogged or broken radiator fin. • Clean or repair it.

The water temperature gauge • Failed thermostat or water temperature • Replace it.
pointer indicates the black range gauge.
on the right. • Loose radiator filler cap. • Retighten the cap or replace the pack-
ing.
The water temperature gauge • Failed thermostat. • Replace it.

pointer indicates the black range • Failed water temperature gauge. • Replace it.
on the left.
• Insufficient fuel. • Fill fuel.

• Air entering in the fuel system. • Repair it.
The engine does not start even • Failed fuel injection pump or nozzle. • Replace it.
after turning the starting motor • Slow revolution of the starting motor. • Refer to "ELECTRICAL SYSTEM".
on. • Insufficient engine compression.
• Improper adjustment of the valve clear- • Adjust the clearance.
ance.
• Excessive oil in the oil pan. • Decrease oil.

White or blue exhaust gas.
• Wrong fuel. • Replace it with specified fuel.
Black exhaust gas. • Clogging of air cleaner element. • Clean or replace the element.
Irregular fuel noise. • Failed fuel pump. • Replace it.
• Wrong fuel used. • Replace it with specified fuel.

• Overheat. • Refer to the section "STEAM IS
Noise occurs (due to burning or BLOWN OUT OF THE RADIATOR
mechanism). PRESSURE VALVE" above.
• Broken muffler. • Replace it.
• Excessive valve clearance. • Adjust the clearance.
70-2 DX-Series
TROUBLESHOOTING ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
The light is dark even when the • Wrong wiring. • Check if there is any loose terminal or
engine revolves at the highest disconnection.
speed. • Wrong alternator. • Check and repair it.
• Improper belt tension. • Adjust the belt tension

The light flickers during engine (TB42).
operation. • Wrong auto tension. • Check and repair it
(S6D102E, SA6D102E).
The charge lamp does not come • Failed charge lamp. • Replace it.
on even after the engine starts • Wrong wiring. • Check and repair it.
normal operation.
The alternator generates abnor- • Failed alternator. • Replace it.

mal sound.
The starting motor does not • Wrong wiring. • Check and repair it.
revolve even after turning the • Low battery voltage. • Charge it.
starting switch on.
The starting motor pinion repeat- • Low battery voltage. • Charge it.
edly comes in and goes out. • Failed holding coil. • Check and repair it.
The revolution speed of the start- • Low battery voltage. • Charge it.
ing motor is too low. • Failed starting motor. • Replace it.
The starting motor stops before • Wrong wiring. • Check and repair it.
the engine starts operation. • Low battery voltage. • Charge it.
The heater signal is not turned • Wrong wiring. • Check and repair it.
red. • Broken glow plug. • Replace it.
The engine oil pressure warning • Failed warning lamp. • Replace it.
lamp does not come on even • Failed warning lamp switch. • Replace it.
after the engine stops (with the
starting switch turned on).
DX-Series 70-3
TROUBLESHOOTING TORQFLOW SYSTEM
TORQFLOW SYSTEM
• Improper oil amount. • Check the amount and fill or drain oil.
• Contact of the vane wheel. • Check oil by draining it from the oil
tank or transmission and replace it.
• Air is taken in. • Check the joint or piping on the inlet
1. Oil temperature rise side and retighten it or replace the
1) Torque converter gasket.
• Water entering the transmission case. • Drain oil and check or replace it.
• Worn or seized bearings. • Repair or replace it after disassem-
bling and checking.
• Failed meter. • Check and replace it.
• Clutch dragging. • Check if the truck operates by setting it

in the neutral state and replace the
2) Transmission clutch plate.
• Worn or seized bearings. • Replace it after disassembling and
checking.
• Cavitation. • Replace oil or parts where air leaks.

• Broken flexible plate. • Check the revolution sound at low
speed and replace the flexible plate.
• Broken or worn bearings. • Replace after disassembling and
checking.
• Broken gear. • Replace after disassembling and
checking.
2. Noise occurs. • Contact of the vane wheel. • Replace after checking it or draining oil
1) Torque converter to check whether foreign matter has
entered or not.
• Loose bolt. • Retighten or replace after disassem-
bling and checking.
• Worn spline. • Replace after disassembling and
checking.
• Gear pump noise. • Replace after disassembling and
checking.
• Dragging noise due to seized clutch. • Check if the truck operates by setting
the transmission in the neutral state
and replace the clutch plate.
• Worn or seized bearings. • Replace after disassembling and
checking.
2) Transmission • Broken gear. • Replace after disassembling and
checking.
• Loose bolt. • Retighten or replace after disassem-
bling and checking.
• Worn spline. • Replace after disassembling and
checking.
Low oil pressure

• (1) Insufficient oil • Check the amount and fill oil.
3. Lowered horsepower
• (2) Air is taken in from the intake side. • Check each joint and pipe and
1) Torque converter
retighten them or replace the packing.
• (3) Clogged oil filter. • Check and replace it.
70-4 DX-Series
• (4) Worn oil pump (decreased discharge • Check the oil pressure and replace the
amount) pump.
• (5) Deformed coil spring of the regulator • Check the spring tension and replace
valve. it.
• (6) Proper spool operation of the control • Repair or replace it after disassem-
1) Torque converter
valve. bling and checking.
• (7) Worn or broken seal ring. • Replace the seal ring.
• Deformed flexible plate. • Replace the flexible plate.
• Breakage or contact of the vane wheel. • Check if foreign matter has entered by
draining oil and replace it.
• Improper oil used or bubbling • Check and replace it.

• (1) Air is taken in from the intake side. • Check each joint and valve and
retighten or replace them.
• (2) Bubbling occurs due to excessively • Check the oil pressure.
low torque converter pressure.
• (3) Water mixes oil. • Drain oil to check and replace it.
• (4) Improper adjustment of the inching • Check and adjust it.
rod or slipped clutch.
2) Transmission
• (1) Decreased oil. • Check the oil pressure.
• (2) Worn piston ring or O-ring. • Replace it after disassembling, check-
ing and measuring.
• (3) Broken clutch or piston. • Replace it after disassembling and
checking.
• (4) Seized and dragged clutch plate. • Check if the truck operates by setting it
in the neutral state and replace the
clutch plate.
• Control valve malfunction. • (1) Replace the valve after checking

whether the spool operates or not.
• (2) Check if the small hole of the valve
4. Abnormal oil pressure body is clogged or not and clean or
1) High pressure repair it.
• When cold (high viscosity). • Replace it if the ambient temperature
is lower than 0°C (recheck after raising
the oil temperature to 60 to 80°C).
• Improper oil used. • Check and replace it.

• Failed (worn) gear pump. • Replace it after disassembling and
checking.
• Excessively leaked oil.
• (1) Failed coil spring of the control valve. • Check the spring tension (refer to the
spring standard) and replace it.
2) Low pressure
• (2) Failed control valve spool. • Repair or replace the valve after disas-
sembling and checking.
• Air is taken in. • Check each joint and pipe and
retighten them or replace the packing.
• Insufficient oil. • Check the oil level and fill oil.
• Clogged oil filter. • Check and replace it.
• Excessive leakage. • Replace it after disassembling and

3) Transmission checking (wear of the piston ring and
O-ring, etc.).
DX-Series 70-5
• Broken clutch plate. • Check the revolution sound at low

speed and replace it.
• Failed driving system of the oil pump. • Replace worn pump, gear, shaft or
5. Power is not transmitted. spline after disassembling and check-
1) Torque converter ing.
• Broken shaft. • Check and replace it.
• No oil pressure. • Check oil, pump and gear wear to see
whether the inlet side has inlet force
and replace them.

• Dislocated inching valve and link lever. • Adjust it after checking and measuring.
• Dislocated forward/reverse travel spool • Adjust it after checking.
and link lever.
The clutch works for both.
• (1) Failed piston ring of the clutch case. • Replace it after disassembling and
checking.
• (2) Pulled-out plug of the main shaft. • Repair or replace it after disassem-
bling and checking.
• Seized clutch. • Check if the truck operates (travels) by
setting the transmission in the neutral
2) Transmission
state and replace the clutch.
• Broken shaft. • Replace it after disassembling and
checking (main shaft, etc.).
• Broken clutch dram (snap ring groove). • Replace it after disassembling and
checking.
• Broken snap ring of the clutch drum. • Replace it after disassembling and
checking.
• Foreign matter entering the oil passage • Repair or replace it after disassem-
to the clutch. bling and checking.
• Worn shaft or spline. • Replace it after disassembling and
checking.
• From the oil seal. • Disassemble and check wear of the

seal lip and the sliding surface of its
counterpart (pump, boss, coupling,
etc.) and replace oil seal, pump boss,
coupling, etc.
• From the case mating surface. • Check and retighten them or replace
• From each joint or pipe. the packing. After checking, repair it
or replace the pipe gasket.
• From the drain plug. • Check and retighten it or replace the
6. Oil leakage (transmission/ gasket.
torque converter) • Crack. • Check and replace it.
• Oil is blown out of the transmission case. • (1) Check if water is contained in oil by
draining it (white if oil contained)
and replace it.
• (2) Check if air is taken in from the inlet
joint and retighten it or replace the
packing.
• (3) Check the air hole of the air
breather and repair it.
• Excessive oil. • Check the oil level and drain the oil.
70-6 DX-Series
TROUBLESHOOTING STEERING SYSTEM
STEERING SYSTEM
1. Hydraulic system
a. Insufficient oil pressure of PS circuit Check, adjust, or repair it.
b. Insufficient hydraulic pump delivery Check or repair it.
c. Oil leak in PS cylinder Check or repair it.
2. PS valve
a. Contaminant being caught between Check or repair it and replace the parts.
spool sleeves or between the sleeve
and housing
b. Large tightening torque of end cap Uniformly tighten it at a regular tighten-
1. The steering wheel operation tightening bolt ing torque.
is heavy. c. Failed ball incorporation of check Incorporate the ball.
valve for emergency steering
3. Hydraulic pump
a. Wear and damage of gear body Check, repair, or replace it.
b. Wear and damage of drive shaft Check, repair, or replace it.
spline
4. Truck body
a. Scuffing and baking of steering link Check or repair it or replace the parts.
and bushings
1. PS valve
a. Contaminant being caught between Check or repair it and replace the parts.
2. Even the steering wheel is spool sleeve valves, scuffing, or bak-
released, it does not return to ing
neutral. b. Damage of center ring spring Check or repair it or replace the parts.
c. Scuffing of column shaft and bush- Check or repair it or replace the parts.
ings
1. Hydraulic system
a. Mixing in of air Check or repair the piping and tank.
b. Generation of cavitation Check or repair the piping, filter, and
tank.
c. Insufficient pump delivery Check, repair, or replace the pump.
3. The follow-up performance of
the cylinder is bad or ineffec- 2. PS valve
tive for the steering wheel rota- a. Wear of internal parts Check or repair it or replace the parts.
tion. b. Small tightening torque of bolt for end Uniformly tighten it at a regular torque.
Otherwise, the wheel slip is cap tightening
abnormally large. c. Failed incorporation of drive or Assemble it regularly.
spacer
3. PS cylinder
a. Damage, wear, and scuffing of piston Check or repair it or replace the parts.
ring seal
DX-Series 70-7
TROUBLESHOOTING STEERING SYSTEM
1. Hydraulic system
4. The steering wheel is turned in a. Wrong piping mounting on four ports Check or repair it.
the reserve direction, or a
wheel kick symptom is gener- 2. PS valve
ated. a. Incorrect valve timing (after re- Check or repair it.
assembly)
1. Hydraulic system
a. Mixing in of air Check or repair the piping and tank.
5. Vibration is generated.
2. Truck body
a. Wear of steering link with backlash Check it or replace the parts.
b. Backlash of wheel bearing or hub Check or adjust it.
1. Hydraulic system
a. Noise from control valve Check, adjust, or repair it.
b. Noise from hydraulic pump Check, adjust, or repair it.
6. An abnormal noise (including a c. Noise from piping and tank Check, adjust, or repair it.
relief noise) is generated.
2. PS valve
a. Noise from spool sleeve assembly Check or repair it.
b. Noise from gerotor and drive Check or repair it.
1. PS valve
[Damage of wear of spool part oil seal]
a. Stain of hydraulic oil Replace the hydraulic oil and filter.
b. Rust of spool seal surface Replace the assembly.
c. Damage during disassembly and Replace the parts.
assembly
7. Oil leakage [Damage of O-ring of mating face
(gerotor part)]
a. Being caught during disassembly Replace the parts.
and assembly
b. Damage of O-ring groove part Replace the parts.
c. Insufficient tightening torque of bolt Uniformly tighten the end cap at a regu-
for end cap tightening lar tightening torque.
70-8 DX-Series
TROUBLESHOOTING BRAKE SYSTEM
BRAKE SYSTEM
• Oil leakage in the hydraulic system. • Repair it and fill fluid.

• Air entering the hydraulic system. • Bleed air.
• Water or oil adhering to the lining sur- • Clean or replace it.
face.
• Hardened lining surface or wrong • Grind and repair or replace it.
engagement.
• Worn lining. • Replace it.
1. Insufficient braking force.
• Master back wheel • Check, correct or repair it.
• Clogged hydraulic system. • Clean it.
• Air intake from the vacuum hose joint • Check or repair it.
• Defective vacuum pump (5 – 7 ton) • Check or replace it.
• Clogging of master back filter (5 – 7 ton) • Check, repair or replace it.
• Improper adjustment of brake valve (8 ton) • Check, repair or replace it.
• Defective accumulator (8 ton) • Check, repair or replace it.
• Improper adjustment of the tire air pres- • Adjust the air pressure.
sure.
• Improper adjustment of the brake. • Adjust it.
• Water or oil adhering to the lining sur- • Clean or replace it.
face.
• Earth or sand entering the brake drum. • Clean it.
• Hardened lining surface. • Grind and repair or replace it.
• Wrong lining engagement. • Grind and repair it.
2. Brake pull
(the steering wheel becomes
• Partially worn or broken (distorted) brake • Repair or replace it.
uncontrollable when braking).
drum.
• Wheel or cylinder malfunction. • Repair or replace it.
• Wrong sliding of the shoe. • Adjust it.
• Loose back plate mounting bolt. • Retighten or replace it.
• Deformed back plate. • Replace it.
• Improper adjustment of the wheel bear- • Adjust or replace it.
ing.
• Clogged hydraulic system. • Clean it.
• No play of the pedal. • Adjust it.

• Wrong sliding of the shoe. • Adjust it.
• Wheel cylinder malfunction. • Repair or replace it.
• Failed piston cup. • Replace it.
• Deformed or broken return spring. • Replace it.
3. Brake dragging • Improper return or adjustment of the • Repair or replace it.
parking brake.
• Clogged brake valve or return port. • Check or repair it.
• Failed piston return of master cylinder. • Clean it.
• Improper adjustment of the wheel or • Adjust or replace it.
bearing.
DX-Series 70-9
TROUBLESHOOTING BRAKE SYSTEM
• Brake dragging. • Refer to the section on brake dragging

above.
4. Brake noise
• Improper piston return. • Replace it.
(cheeping)
• Changed lining surface. • Grind and repair or replace it.
• Changed lining surface. • Grind and repair or replace it.

• Poor adhesion between the shoe and • Replace it.
the lining.
• Excessively worn shoe and back plate. • Clean the brake and apply grease.
• Foreign matter adhering to the drum slid- • Clean it.
ing surface.
• Broken or dislocated drum sliding sur- • Replace it.
5. Brake noise
face.
(screeching)
• Deformation or wrong mounting of the • Replace or repair it.
shoe.
• Loose back plate mounting bolt. • Retighten it.
• Worn contact of the anchor or other • Replace it.
assembly.
• Improper contact of the lining. • Repair or replace it.
• Improper mounting of the anti-rattle • Repair it.
equipment or spring.
• Rough drum sliding part. • Grind and repair or replace it.

6. Brake noise • Non-centered drum or excessive distor- • Replace it.
(tapping) tion.
• Rough lining surface. • Grind and repair or replace it.
• Improper adjustment of the brake. • Adjust it.

• Air entering the hydraulic system. • Bleed air.
• Fluid leakage from the hydraulic system • Check and repair it and fill fluid.
7. Large pedal stroke. or insufficient fluid.
• Falling or wrong return of the shoe. • Repair it.
• Improper contact of the lining. • Repair it.
• Prying of push rod due to incorrect mas- • Check or adjust it.

ter back mounting
8. The pedal is heavy. • Insufficient vacuum and failed hose joint • Check or repair it.
• Clogging of master back filter (5 – 7 ton) • Check, repair or replace it.
• Insufficient pressure in accumulator (8 ton) • Check, repair or replace it.
• Insufficient vacuum and air intake from • Check or repair it.

the hose
9. The alarm buzzer keeps • Defective vacuum pump (5 – 7 ton) • Check or replace it.
sounding. • Defective vacuum switch (5 – 7 ton) • Check or replace it.
• Defective hydraulic pump • Check or replace it.
• Defective accumulator (8 ton) • Check or replace it.
70-10 DX-Series
TROUBLESHOOTING HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
• Wrong sealing of the control valve. • Replace the spool or valve body.
1. Excessively slow descending
• Oil leakage from the joint or hose. • Replace it.
speed of the fork.
• Wrong sealing of the cylinder. • Replace the packing.
• Backward inclination: Failed check • Clean or replace it.

valve.
2. Excessive hydraulic inclina-
• Forward inclination: Failed tilt lock valve. • Clean or replace it.
tion of the mast.
• Oil leakage from the joint or hose. • Replace it.
• Wrong sealing of the cylinder. • Replace seals.
• Insufficient hydraulic oil. • Fill oil.

• Air entering the hydraulic circuit. • Bleed air.
• Oil leakage from the joint of hose. • Replace it.
• Large oil flow resistance on the suction • Clean the filter.
side of the pump.
• The specified pressure is not maintained • Adjust the relief valve.
by the relief valve.
3. Slow ascending of the fork or • Wrong sealing of the cylinder. • Replace the packing.
slow inclination of the mast. • Excessive viscosity of the hydraulic oil. • Replace it with CD-class SAE10W
engine oil.
• The mast does not move smoothly. • Adjust the clearance between the roll
and the rail.
• Oil leakage from the lift control valve • Replace the spool or the valve body.
spool.
• Oil leakage from the tilt control valve • Replace the spool or the valve body.
spool.
• Large flow resistance on the suction side • Clean the filter.

of the pump.
4. Noise occurs on the hydraulic
• Failed gear or bearing in the work equip- • Replace the gear or bearing.
system.
ment hydraulic pump.
• Worn hydraulic pump spline. • Replace the drive shaft.
• Foreign matter caught between the • Clean them.

5. The control valve lever does spool and the valve body.
not move. • Failed valve body. • Tighten the body mounting bolts in the
same way.
• Insufficient hydraulic oil. • Fill oil.

6. Excessively high oil tempera- • Excessive viscosity of the hydraulic oil. • Replace it with CD-class SAE10W
ture. engine oil.
• Clogged hydraulic oil filter. • Clean the filter.
DX-Series 70-11
80. CHECK ITEMS FOR EACH EQUIPMENT
Engine .............................................................. 80- 2

Power train ....................................................... 80- 8
Travel system................................................... 80-12
Steering system ............................................... 80-14
Braking system................................................. 80-16
Load system..................................................... 80-19
Hydraulic system.............................................. 80-21
Body safety system, Overall test...................... 80-24
DX-Series 80-1
CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
ponent Check item Check contents
1. Starting, noise • Pull the parking brake lever and set the selector lever to neutral, then start the
engine and record the following items:
1. Whether the engine starts smoothly
2. Abnormal noise
3. Whether the glow plug operates normally
4. Whether the accelerator pedal and lever operate smoothly
2. Rotation, exhaust gas • Step on the accelerator pedal and check the following items:
color 1. Whether the engine speed rises smoothly
2. Whether the exhaust gas color is normal
Idling No color
When the pedal is stepped on Thin black
3. Whether the exhaust sound is normal

4. Whether the exhaust gas leaks
3. Engine speed • Check the following items after warming up the engine:
1. Idling speed
Engine
FG50 825 – 875 rpm

TB42
FG60 – FG70 850 – 900 rpm
FD50 – FD70 S6D102E
625 – 675 rpm
FD80 SA6D102E
2. Maximum speed
FG50 2,400 – 2,500 rpm

TB42
FG60 – FG70 2,440 – 2,540 rpm
FD50 – FD70 S6D102E
2,400 – 2,500 rpm
FD80 SA6D102E
4. Air cleaner • Check the following items for the air cleaner:
1. Crack and deformation on the air cleaner
2. Loosening of the air cleaner mounting
3. Stain and damage on the element
a For cleaning and replacing the element, see section "TESTING AND ADJUST-
ING".
80-2 DX-Series
Com-
5. Cylinder head Loosening of the cylinder head mounting bolts

a For tightening the cylinder head mounting bolts of each engine and the tightening
torque, see section "TESTING AND ADJUSTING".
6. Valve clearance Valve clearance

(mm)
Model Engine Intake valve Exhaust valve
FG50/60/70 TB42 0.38 (Warm) 0.38 (Warm)
FD50/60/70 S6D102E
0.25 (Cold) 0.51 (Cold)
FD80 SA6D102E
a For measuring the valve clearance, see section "TESTING AND ADJUSTING".
7. Compression Compression
(Compression pres- (MPa {kgf/cm2}/rpm)
sure)
Model Engine Compression
FG50/60/70 TB42 Min. 1.18 {12}/200
FD50/60/70 S6D102E
Min. 2.41 {24.6}/250 – 280
FD80 SA6D102E
Engine
a For adjusting the compression, see section "TESTING AND ADJUSTING".
8. Injection pressure Injection start pressure

Mount the nozzle on the nozzle tester and check the injection pressure.
(MPa {kgf/cm2})
Manufacturer Engine Injection valve opening

pressure
Komatsu S6D102E 21.6 {220}
Komatsu SA6D102E 22 {224}
Adjustment:
Using the adjustment shim
DX-Series 80-3
Com-
9. Spray status, injec- 1. Spray status

tion timing Check the spray status of the injection nozzle.
If abnormal: Remove the nozzle from the holder, wipe off the carbon, and wash
the holder with diesel fuel oil.
2. Injection timing
Check the fuel injection timing.
S6D102E 3° (BTDC) : Cam lift 1 mm point

SA6D102E 10° (BTDC) : Cam lift 1 mm point
The adjustment is required at ±2°C or more.
a For adjusting the injection nozzle, see section "TESTING ANDADJUSTING".
10. Turbocharger Check the following items:

1. Abnormal vibration
2. Abnormal noise
3. Gas leakage
11. Engine mount Check the following items:

Engine
1. Crack and deformation on the bracket

2. Loosening or missing of the mounting bolts and nuts
3. Damage and deterioration of rubber vibration isolator
12. Lubricating system 1. Engine oil

1) Oil level
Check the oil level with the dipstick and fill the oil if necessary.
S6D102E 16.5 l TB42 8.5 l

SA6D102E 16.5 l
2) Discoloration
If the oil is discolored, change it.
a For changing the oil, see section "TESTING AND ADJUSTING".
3) Oil leakage
2. Engine oil filter

Because the filter cannot be checked visually, periodically replace it.
a For replacing the oil filter, see section "TESTING AND ADJUSTING".
80-4 DX-Series
Com-
13. Fuel system Check the following items:

1. Fuel leakage
2. Damage and deterioration of hoses and pipes
3. Fuel filter
Because the fuel filter cannot be checked visually, periodically replace it.
14. Pressurized gas fuel Check the following items:

system 1. Gas leakage
2. Crack and damage of lead pipe
3. Looseness and damage of gas cylinder fitting
15. Blow-by gas Check the following items:

restoration system 1. Valve operation
2. Clogging in and damage on pipes
16. Coolant, radiator Check the following items:

1. Coolant level
Check the level of the coolant in the
reservoir tank. (Mast be in range of L)
2. Water leakage from the hose
3. Crack on the hose and hose harden-

Engine
ing by heat
4. Radiator cap
k Do not remove the radiator cap

when the coolant temperature is
high. Otherwise, hot water may
k When removing the radiator cap

gush out.
after the coolant temperature

drops, slowly turn the cap to
release the pressure, then
remove it.
1) Pressure adjustment valve

Press the cap spring with your finger
and check that the spring has the
appropriate tension.
2) Negative pressure valve

Pull the valve, then release it, and
check that it is immediately closed.
a If the packing is damaged, replace
the radiator cap assembly.
DX-Series 80-5
Com-
17. Fan, fan belt 1. Fan belt

1) Abrasion and damage on fan belt
• Also check the rear side of the fan
belt.
• If the bottom of the pulley shines,
the belt easily slips. In this case,
replace the fan belt.
2) Deflection amount
Push the centers of fan pulley (1)
and alternator (2) belts with your fin-
ger for check.
Deflection amount a
TB42 15 – 7mm
[98N{10kgf}Finger pressure]
Adjustment: Loosen alternator mounting nut

and adjustment bar bolt and
move the alternator for adjust-
ment.
2. Fan, fan cover (shroud)

1) Crack and deformation on the fan
2) Loosening of the fan mounting
Engine
bolts
3) Crack and deformation on the
shroud
4) Loosening of the shroud mount-
ing bolts
18. Distributor Check the following items:

(gasoline engine truck) 1. Crack and damage on the cap
2. Damage on cables (primary and secondary cables)
3. Insertion of the high tension cables
Remove the coil and plug cables and check rust and connections.
4. Burning and damage on the rear terminal (segment) of the cap
5. Abrasion and burning on the center terminal (center piece) of the cap
Visually check abrasion and burning on the center piece.
Check deterioration of the spring by pushing it with your finger.
80-6 DX-Series
Com-
19. Ignition plug and igni- 1. Ignition plug

tion timing 1) Gap
(Gasoline engine truck) Remove the plug with the plug
wrench and measure the gape with
the gauge.
Plug gap A: 0.7 – 0.8 mm
[1] Normal
[2] Badly burnt
[3] Sooty
a If the plug is burnt or its gap is
out of the specified range,
replace it.
(Model name)
NGK: B4ES, BPR-4ES
(Noise prevention)
HITACHI: L47W
2) Disconnection of plug cable
Set the tester in the 100 kz range
and check the plug cable for discon-
nection.
3) Cleaning
Remove carbon from the tip of the
plug and around it.
2. Ignition timing
1) Run the engine at low idling.
2) Check the ignition timing with the
timing light and timing marks on the
Engine
front cover and crank pulley.

Adjusting: Adjust the ignition timing
by turning the body of
the distributor.
Ignition timing
(BTDC deg/rpm) TB42 7/700
20. Wiring of battery Check the following items.

charger, etc. 1. Electrolyte specific gravity
Electrolyte Charge level Necessity of

specific gravity charge
1.280 Fully charged
1.240 Discharged by 1/4 No
1.210 Discharged by 1/2 Yes

1.130 Fully discharged
a If the battery is not charged suffi-

ciently, check the alternator.
2. Electrolyte level
3. Looseness and corrosion of battery
terminals
4. Looseness of wire connectors
5. Damage of wires
DX-Series 80-7
CHECK ITEMS FOR EACH EQUIPMENT POWER TRAIN
Com-
21. Transmission 1. Selector lever

1) Check backlash on the neutral posi-
tion.
2) Check that the selector lever can

smoothly be switched to any posi-
tion and there is no backlash on any
position.
2. Transmission
1) Abnormal noise
2) Oil leakage
If leaked oil form drops, replace the
packing.
3) Oil level
Place the truck on a horizontal place
and check the oil level with the dip-
stick.
(Mast be in range of L)
1. Oil level gauge
2. Oil filler plug
3. Drain plug
Power train
4. Strainer
80-8 DX-Series
Com-
22. Transmission 3. Inching pedal

(continued) 1) Both-way moving amount of inch-
ing spool
Both-way moving 31 mm
amount (a)
For the adjustment guide, see sec-

tion "TESTING AND ADJUSTING."
a When the pedal is released, the
lever must not push the inching
spool.
2) Interlocking stroke
Adjust adjustment bolt (1) so that the
inching pedal can interlock with the
brake pedal at the specified stroke.
Interlocking stroke 23 – 28 mm
3) Pedal height (when stepped on)
5 – 7 ton 83 – 93 mm
Power train
Height a
8 ton 85 – 95 mm
4) Play
Play b 2 – 3 mm
DX-Series 80-9
Com- Check item Check contents

ponent
23. Torque converter k Check the following items after locking the wheels and operating the
parking brake.
1. Clutch actuation pressure
Switch the selector lever to forward or reverse, step on the accelerator pedal, and
measure the pressure.
Clutch actuation pressure 1.01 – 1.25 Mpa {10.3 – 16.9 kgf/cm²}
Control valve assembly oil pressure port location
C1 R1 clutch
C2 R2 clutch
P1 Main relief pressure
• Inching valve outlet side
P2 • Orifice (ø2 in diameter) inlet
side
P3 F1, F2 clutch
P4 lubrication relief pressure
3 Plug 2.9 – 5.9 Nm {0.3 – 0.6 kgf•m}

Power train
2. Stall speed
Switch the selector lever to forward or reverse, run the engine at the maximum
speed, and measure the engine speed.
S6D102E 1,800 – 2,000 rpm TB42 1,650 – 1,850 rpm

SA6D102E 1,750 – 1,950 rpm
a Because this test raises the temperature of the torque converter oil, do not
execute it for a long time.
3. Torque converter oil inlet pressure A: 0.6 – 0.8 MPa {6 – 8 kgf/cm2)
4. Lubrication relief pressure B: 0.42 – 0.66 MPa (5.3 – 5.7 kgf/cm2)
Torque converter assembly oil

pressure port location
80-10 DX-Series
Com-
24. Propeller shaft 1. Oil leakage from the seal of the connection mating side (case)
2. Backlash and damage of the shaft and spider
3. Loosening, damage, or dropping of spider connection bolts
25. Differential 1. Noise at traveling
2. Oil level in the differential case

1. Oil filler plug
2. Level pulg
3. Drain plig
3. Oil stain
a For checking the oil level and chang-
ing the oil, see section "TESTING
Power train
AND ADJUSTING."
4. Oil leakage from the case
5. Loosening of mounting bolts
26. Final drive 1. Noise at traveling
2. Oil level
Check that the planetary gear case contains the sufficient amount of oil.
3. Oil stain
4. Oil leakage from the case
DX-Series 80-11
CHECK ITEMS FOR EACH EQUIPMENT TRAVEL SYSTEM
Com-
27. Front axle 1. Deformation, crack, damage

Visually check or use the crack search method for checking.
(Specially check the vicinity of bolts mounting the front axle on the mainframe
and welded part.)

Check the tightening torque of bolts mounting the front axle on the frame.
1,127 – 1,911 Nm {115 – 195 kgf•m}
28. Rear axle 1. Deformation, crack, and damage

Visually check or use the crack search
method for checking.
2. Center pin backlash (gap between

the pin and bushing)
3. Loosening of bolts mounting the cap

and support
157 – 225 Nm
Bolt (1) {16 – 23 kgf•m}
Travel system
29. Tires 1. Air pressure (MPa {kgf/cm2})

Model Front wheel Rear wheel
5 ton 0.78 {8.0} 0.69 {7.0}
6 ton 0.69 {7.0} 0.69 {7.0}
7 ton 0.78 {8.0} 0.78 {8.0}
8 ton 0.66 {6.5} 0.66 {6.5}
2. Crack and damage on the tread and sidewall

If the tread or sidewall is extremely cracked or damaged, replace the tire.
3. Tread pattern depth (amount of abrasion)

For a pneumatic (air inflated) tire, measure the B tread pattern depth C at 1/4 of
the tread width and check that the depth C is 1.6 mm or more.
4. Abnormal wear
Partial wear or uneven wear
5. Catching of metal pieces
80-12 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT TRAVEL SYSTEM
Com-
30. Wheel 1. Loosening of hub nuts

Hub nut tightening torque
(Nm {kgf•m})
Model Front wheel Rear wheel
5 ton
6 ton 294 – 490 {30 – 50} 294 – 490 {30 – 50}
7 ton
8 ton 539 – 637 {55 – 65} 441 – 539 {45 – 55}
2. Deformation and crack on the rim and side ring.

Travel system
DX-Series 80-13
CHECK ITEMS FOR EACH EQUIPMENT STEERING SYSTEM
Com-
31. Steering wheel 1. Unstableness, being pulled to one side, returning
2. Steering effort
Play
30 – 60 mm
Play L
(when engine is idling)
3. Loosening and play
32. Steering valve 1. Oil leakage
2. Loosening and dropping of mounting bolts

Steering system
33. Knuckle 1. Wheel bearings

• Using a jack, lift up the truck and check the following items:
1) Backlash
Hold the top and bottom of a tire and shake it to check backlash.
2) Abnormal noise
Turn a tire with your hand to check an abnormal noise.
2. Kingpin
1) Backlash
2) Crack and damage
3. Knuckle
Crack and damage
80-14 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT STEERING SYSTEM
Com-
34. Left and right turning Minimum turning radius

radiuses 1) Make your assistant drive the truck in the minimum turning radius.
2) Apply a rod with a chalk on the end to the outermost part of the counterweight to
draw a circle on the road.
3) Measure the circle on the road.
4) Perform this measurement for both left and right turns.
5, 6 ton 3,088 – 3,412 mm

7 ton 3,183 – 3,517 mm
8 ton 3,420 – 3,780 mm
Difference between
left and right turns Max. ±100 mm
Adjustment: Using the stopper bolt
35. Steering wheel 1. Loosening and dropping of stopper bolts
2. Contact of wheels and other parts

Steering system
36. Power steering 1. Oil leakage from the power steering cylinder and hose
system
2. Damage or deterioration of hose
3. Loosening and dropping of mounting bolts
4. Interference with the truck body
5. Oil pressure
Remove each plug in the right fig-
ure, then mount the hydraulic
gauge and measure the oil pres-
sure when the steering is turned to
the either end.
Oil 10.3 – 10.8 MPa
pressure {105 – 110 kgf/cm2}
DX-Series 80-15
CHECK ITEMS FOR EACH EQUIPMENT BRAKING SYSTEM
Com-
37. Wheel brake 1. Brake pedal

1) Pedal height (Operates pedal)
5 – 7 ton 103 – 113 mm

Height a
8 ton 115 – 125 mm
2) Play
Play b 2 – 6 mm
2. Brake effect
Select a dry and plane road, drive the truck at the maximum speed, then stop it
rapidly and check the following items:
1) Steering unstableness 2) One side braking 3) Abnormal noise
4) Stop range (braking ability)
Unloaded Max. 5 m (at 20 km/h)

Loaded Max. 2.5 m (at 10 km/h)
3. Stop lamp switch

Check that the switch operates when the pedal is stepped on.
Braking system
38. Parking brake 1. Parking brake lever

1) Lever operating effort
Min. 196 N {20 kgf}
2) Parking ability
Check that the truck can maintain
the stop status on the slopes listed
in the table below.
Unloaded 11.2 degrees or

steeper slope
Loaded 8.5 degrees or

steeper slope
39. Rods, links, cables 1. Damage, loosening, backlash
2. Missing of split cotter pins
40. Brake piping Visually check the following items for pipes, hoses, and joints:
1. Oil leakage, air leakage 2. Damages 3. Worn hoses,
4. Mounting bolt loosening 5. Interference with the truck body
80-16 DX-Series
Com-
41. Oil brake 1. Master cylinder, wheel cylinder oper- FG50 – 70, FD50 – 70
ation
Operate the brake pedal and check the
following items:
1) Stepping on effort,
2) Change in the stepping on effort,
3) Change in the pedal position when
the pedal is kept stepping on
4) Return of the pedal when it is
released
2. Brake reservoir tank

1) Oil level
(Must be in range of L)
2) Stained oil and oil leakage
3. Wheel cylinder
Clearance between 5 – 7 ton Max. 0.15 mm

cylinder and piston
42-1. Brake booster Check the vacuum pump, tank and master back pump, and incomplete vacuum.
FG50/60/70 Max. 90 kPa 60 kPa
FD50/60/70 Vacuum Alarm device operating point
{680 mmHg} {450 mmHg}
Braking system
42-2. Brake booster Accumulator for brake

FD80
Volume for accumulation 300 cc
Gas charge pressure 3.4 MPa {35 kgf/cm2}
Alarm operating pressure 6.3 – 6.9 MPa {64 – 70 kgf/cm2}
43. Brake shoe, lining 1. Brake shoe

Operation status, rust, and wear
2. Lining peeling off, damage, and wear
5 – 7 ton Max. 5.2 mm

Lining thickness
8 ton Max. 5.5 mm
3. Anchor pin corrosion
4. Deterioration of return spring
Item 5 – 7 ton 8 ton

Free length Standard size 90 mm Standard size 93 mm
Spring (1) Min. 264.3 N {27 kgf} Min. 293.7 N {30 kgf}
Strength
(when l = 101.2 mm) (when l = 103.5 mm)
Free length Standard size 93 mm —
Spring (2) Min. 220.3 N {22.5 kgf}
Strength —
(when l = 101.2 mm)
DX-Series 80-17
Com-
44. Brake drum Drum crack, damage, and wear

Measure the sizes listed in the table below and check that they are allowable values.

Inside diameter of drum Max. 320.5 mm Max. 396.5 mm
Wheel
brake Clearance between 0.4 – 0.6 mm 0.2 – 0.5 mm
drum and lining
45. Back plate 1. Deformation, crack, and damage

2. Mounting bolt tightening torque

157 – 196 Nm 245 – 309 Nm
(Wheel brake) {16 – 20 kgf•m} {25 – 31.5 kgf•m}
(Wheel brake) Loctite #271 (screw hole)
46. Parking brake lining, 1. Lining peeling off, damage, and wear
back plate
Lining thickness Min. 3.3 mm
Braking system
2. Deterioration of return spring
Strength (when l = 50 mm) Min. 137 N {14 kgf}
Free length: Standard size: 54.7 mm
3. Back plate deformation, crack, and damage
4. Back plate mounting bolt tightening torque
(Parking brake) 196 – 245 Nm {20 – 25 kgf•m}
47. Parking brake Drum crack, damage, and wear

drum Measure the sizes listed in the table below and check that they are allowable values.
Item 5 – 8 ton
Inside diameter of drum Max. 218.2 mm
Parking
brake Clearance between
drum and lining 0.1 – 0.25 mm
80-18 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT LOAD SYSTEM
Com-
48. Fork (1) 1. Deformation, crack, and wear on fork

stopper pin
2. Check that the opening amount of the fork
tip and height difference conform to the
specifications.
Opening amount a Max. 50 mm

Height difference b Max. 20 mm
49. Fork (2) 1. Crack and wear on upper hook and

lower hook
2. Crack and wear on root
Check that the thickness C of the fork root
conforms to the specification.
5 ton Min. 55 mm
6 ton Min. 60 mm
7, 8 ton Min. 65 mm
a Apply the crack search method to check the fork root and hook on which stress is
concentrated at loading.
Load system
a Since the fork thickness varies with the fork length, etc., check the standard value
of the installed fork.
50. Mast (1) 1. Deformation, crack, and damage on mast

Visually check or use the crack search method to check the following parts:
• Mast stay • Tilt cylinder bracket • Roller shaft welded part
2. Wear and backlash of mast roller and crack on roller shaft
Set the mast perpendicular, lift up the fork 100 mm above the ground, and check
that the clearances listed in the table below conform to the specifications.
Clearance between outer Left and right Max. 3.0 mm

mast and inner mast Front and rear Max. 5.0 mm
Clearance between inner Left and right Max. 2.0 mm

mast and finger board Front and rear Max. 5.0 mm
51. Mast (2) 1. Backlash of mast support

Check that the bushing on the mast support has the oil groove.
2. Loosening of mast cap mounting bolts
Tightening torque
5 – 7 ton 490 – 608 Nm {50 – 62 kgf•m}

8 ton 824 – 1,030 Nm {84 – 105 kgf•m}
DX-Series 80-19
CHECK ITEMS FOR EACH EQUIPMENT LOAD SYSTEM
Com-
52. Finger bar 1. Deformation, crack, and damage on finger bar
2. Wear and backlash of roller
3. Crack on roller shaft
53. Lift chain 1. Tension

Set the mast perpendicular, lift up the fork 100 mm above the ground, and push
the center of the lift chain to check that there is no difference in tension.
Adjustment: Using the chain stopper
2. Extension
Measure lengths L between 17 links and check that they conform to the specifi-
cation.
5 – 6 ton 7 ton 8 ton

Max. lift up
height 3.0 m Max. 440 mm Max. 550 mm Max. 660 mm
Min. lift up
height 3.0 m Max. 550 mm Max. 550 mm Max. 660 mm
Load system
3. Crack, deformation, damage, and corrosion
4. Stopper bolt thread

Visually check a fault.
54. Chain wheel Deformation, damage, and backlash on wheel

• Visually check the part where the wheel touches the chain.
• Manually turn the wheel to check the bearing backlash.
55. Attachment unit (1) 1. Mounting status on chassis proper
2. Loosening of bolts and nuts
56. Attachment unit (2) 1. Crack, deformation, damage, and wear on parts
2. Operation and abnormal noise of parts
80-20 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT HYDRAULIC SYSTEM
Com-
57. Hydraulic tank 1. Oil leakage
2. Oil level
Check the oil level with the dipstick and
fill the oil if necessary (also check stain
in the oil).
a For checking the oil level and chang-
ing the oil, see section "INSPEC-
TION AND ADJUSTMENT."
3. Cleaning strainer
4. Replacing line filter (mounted outside

the tank)
1. Line filter
2. Breather
3. Cover
4. Oil cooler
5. Drain plug
6. Strainer
58. Power train piping 1. Crack, damage, deterioration, and bend on piping
2. Oil leakage
Hydraulic system
3. Loosening of mounting bolts and nuts
59. Attachment piping 1. Crack, damage, deterioration, and bend on piping
2. Oil leakage
3. Loosening of mounting bolts and nuts
60. Hydraulic pump 1. Oil leakage
3. Abnormal noise
61. Oil motor 1. Oil leakage
3. Abnormal noise
62. Lift cylinder 1. Operation, oil leakage
2. Trace of dent, crack, bend, and scratch on rod
157 – 196 Nm {16 – 20 kgf•m}
DX-Series 80-21
Com-
63. Tilt cylinder 1. Operation, oil leakage

2. Trace of dent, crack, bend, and scratch
98 – 123 Nm {10 – 12.5 kgf•m}
64. Cylinder for 1. Operation, oil leakage

attachment 2. Trace of dent, crack, bend, and scratch
65. Lowering and forward 1) Apply the permissible load, set mast [1]
tilting by hydraulic vertically, and increase height H to
drift about 1,500 mm.
2) Set rule [1] to the piston rod of lift cylin-
der (2), make mark A, and measure the
hydraulic drift.
3) Set rule [2] to the piston rod of tilt cylin-
der (3), make mark B, and measure the
hydraulic drift.
When
Max. 100
Hydraulic system
measured
Lowering at fork mm/15 min
by hydrau-
lic drift When
measured Max. 50
at cylinder mm/15 min
Forward
tilting by When Max. 40
hydraulic measured mm/15 min
drift at cylinder
Adjustment:Replace the control valve

and packings of the cylinder.
80-22 DX-Series
Com-
66. Direction control 1. Operation, oil leakage

valve (1) 2. Loosening of mounting bolts
67. Direction control Measuring relief pressure

valve (2) 1) Mount the hydraulic gauge on
relief pressure measurement port.
2) Lift up the fork to the maximum
height, measure the oil pressure
when the oil is relieved, and check
that the pressure conform to the
specification.
(MPa {kgf/cm2})
Specified relief
pressure 18 {180}
Hydraulic system
68. Solenoid valve 1. Operation and abnormal noise
2. Abnormal heat dissipation
3. Oil leakage
DX-Series 80-23
CHECK ITEMS FOR EACH EQUIPMENT BODY SAFETY SYSTEM, OVERALL TEST
Com-
69. Frame, body 1. Crack and deformation

2. Loosening and dropping of mounting bolts and nuts
70. Cab 1. Crack and deformation

2. Corrosion and leaking of rain
3. Door opening and closing, lock, backlash, and damage
71. Seat 1. Operation

72. Lift facility, nonskid 1. Crack, damage, and deformation

73. Display panel 1. Damage

Body and safety system
2. Mounting status
74. Head guard 1. Loosening of mounting bolts

2. Deformation, crack, and damage
75. Backrest 1. Loosening of mounting bolts

2. Crack, deformation, and damage
76. Lamps, instruments, 1. Lamp operation

alarm 2. Mounting status, damage, water penetration
3. Instrument operations
77. Rearview mirror, 1. Stain and damage

reflector 2. Reflection
78. Lubrication 1. Lubrication status

2. Automatic lubricator operation
Overall test
69. Component functions Check functions of components by executing the traveling and work tests.
80-24 DX-Series

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BED08E1-01

MACHINE MODEL SERIAL NO.

FG50/60/70-7 40001 and up

FD50/60/70/80-8 46001 and up

10. GENERAL AND SPECIFICATIONS

20. TESTING AND ADJUSTING

30. REMOVAL AND INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

80. CHECK ITEMS FOR EACH EQUIPMENT

DESCRIPTION OF THE SYMBOLS

Symbol Item Description

Special safety precautions are needed to perform the

Fastening parts that require specified tightening force

Weight of parts or systems.

Places to be coated with adhesives, etc. When assem-

Specifications (FG50-7, FD50-8) ..................... 10- 2

SPECIFICATIONS (FG50-7, FD50-8)

Power type Electric, diesel, gasoline, LPG, cable Gasoline Diesel

Number of wheel Front/rear (x=driven) 2x/2

Height, overhead guard h6 mm 2,440

Lowering speed Loaded/unloaded mm/s 550/580

Rated RPM rpm 2,300 2,250

• OUTSIDE VIEW DRAWINGS

SPECIFICATIONS (FG60-7, FD60-8)

Power type Electric, diesel, gasoline, LPG, cable Gasoline Diesel

Number of wheel Front/rear (x=driven) 4x/2

Height, overhead guard h6 mm 2,440

Lowering speed Loaded/unloaded mm/s 550/580

Rated RPM rpm 2,300 2,250

• OUTSIDE VIEW DRAWINGS

SPECIFICATIONS (FG70-7, FD70-8)

Power type Electric, diesel, gasoline, LPG, cable Gasoline Diesel

Number of wheel Front/rear (x=driven) 4x/2

Height, overhead guard h6 mm 2,440

Lowering speed Loaded/unloaded mm/s 500/550

Rated RPM rpm 2,300 2,250

• OUTSIDE VIEW DRAWINGS

Power type Electric, diesel, gasoline, LPG, cable Diesel

Number of wheel Front/rear (x=driven) 4x/2

Height, overhead guard h6 mm 2,610

Lowering speed Loaded/unloaded mm/s 450/500

Rated RPM rpm 2,250

• OUTSIDE VIEW DRAWINGS

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

No. Part name Period of replacement

2 Brake hose or tube Every 2 years

3 Brake reservoir tank and tube Every 2 to 4 years

4 Power steering hose Every 2 years

5 Stop lamp switch (Oil pressure type) Every 2 years

6 Fuel hose Every 2 years

7 Rubber parts of power steering Every 2 years

8 Lift chain Every 3 years

9 Hose of laod handling Every 2 years

SAFETY ITEMS FOR MAINTENANCE

INSPECTION AND MAINTENANCE SHALL BE PERFORMED BY PERSONS WHO

THE SPECIFIC FREE INSPECTIONS SHALL BE PERFORMED BY QUALIFIED

PLACE FOR INSPECTION AND MAINTENANCE

PRECAUTIONS FOR INSPECTION AND MAINTENANCE WORK

PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE

REPLACE SAFETY CRITICAL PARTS PERIODICALLY

USE SUITABLE TOOLS