MBX50 Service Manual (PF17183 SM160-MBX)

SM160
SERVICE MANUAL BEB16E1-06
MBX50 SERIES LIFT TRUCKS

Federal Environmental Protection Agency (EPA) Emission-Control Compliant
S/N 200001A~
Gasoline & LP G20/25/28/30/32(S)(H)T-16
G35AHT-16
Diesel D20/25/28/30/32T-16
D35AT-16
MBX50
WARNING
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory-installed guards and shields are properly
secured in place.
PF17183 ISSUED: February 2007

The information and specifications contained herein were accurate at the time of
publication, but may change without notice as required for product improvements.
Neither Copyright 2007 Komatsu Forklift USA, Inc. Used With Permission, nor its parent
company nor any of its subsidiaries will be held responsible for damages due to misuse
or inappropriate use of its products.
Requests for information, comments and other inquiries should be sent to:
Copyright 2007 Komatsu Forklift USA, Inc. Used With Permission

Hamech Lift Trucks
44 S. Washington Street
New Bremen, Ohio 45869
Tel: (419) 629-2311

Fax: (419) 629-3796
www.hamech.com
© Copyright 2007 Komatsu Forklift USA, Inc. Used With Permission All rights reserved.
No part of this document may be photocopied or reproduced in any way without prior
written consent of Copyright 2007 Komatsu Forklift USA, Inc. Used With Permission.
CONTENTS
Page No.
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EMISSION CONTROL STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MODEL TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
00. SAFETY
SAFETY MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
SAFE TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
LOADING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-14
SAFETY IN PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-19
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-25
STRUCTURE AND STABILITY OF THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-29
SAFETY LABEL ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-35
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-36
GENERAL AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10. GENERAL AND SPECIFICATIONS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
PERIODIC REPLACEMENT OF CONSUMABLE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
STANDARD TIGHTENING TORQUE FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
20. TESTING & ADJUSTING

SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
GASOLINE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
DIESEL ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
ADJUSTMENT OF IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
ADJUSTMENT OF FUEL INJECTION TIMING (4D94LE DIESEL ENGINE) . . . . . . . . . . . . . . . 20-14
MEASUREMENT OF COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
ADJUSTMENT OF VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
TORQUING OF CYLINDER HEAD MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
TORQFLOW TRANSMISSION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
DIFFERENTIAL CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
HYDRAULIC TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
MEASURE HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . 20-22
ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORQFLOW MODEL) . . . . . . . . . . . . . . . 20-24
ADJUSTMENT OF ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
ADJUST PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
DESIGNATED FUEL AND LUBRICATING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
30. REMOVAL & INSTALLATION

WEIGHT TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
ALIGNMENT OF POWER TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
STEERING AXLE AND POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
40. DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
TORQFLOW TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-16
DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25
DIFFERENTIAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31
WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-35
BRAKE MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-37
COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
POWER STEERING CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-56
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-71
FORK CARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-77
FLOW DIVIDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-77
RESERVOIR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-81
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-86
MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
50. MAINTENANCE STANDARD

TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-3
TORQFLOW TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
BRAKE MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12
BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-15
POWER STEERING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-16
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18
MAST, FORK CARRIAGE AND FORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-25
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26
FLOW DIVIDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
60. STRUCTURE AND FUNCTION

TORQUE CONVERTER, GEAR PUMP & CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3
BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-12
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-13
VEHICLE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15
HYDRAULIC CIRCUIT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22
P-PORT OIL PRESSURE MEASURING PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24
PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
4
80. PERIODIC INSPECTION
CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
90. CONVERSION TABLES

ENGINE MANUALS AND APPENDICES
SM300 - K21/K25 ENGINE SERVICE MANUAL
SM197 - 4D94LE ENGINE SERVICE MANUAL
APPENDIX 1 - MAST SERVICE MANUALS

E SERIES MD MASTS - FULL FREE LIFT 2-STAGE
E SERIES MS MASTS - LIMITED FREE LIFT 2-STAGE
E SERIES MT MASTS - FULL FREE LIFT 3-STAGE
35D/45D/55D-MQ QUAD MAST SERVICE MANUAL
APPENDIX 2 - ELECTRICAL DIAGRAMS

MBX50 EPA TORQFLOW - GASOLINE ENGINE
MBX50 EPA TORQFLOW - LPG ENGINE
MBX50 EPA TORQFLOW - UL-EE LP ENGINE
MBX50 EPA TORQFLOW - GAS/LP DUAL-FUEL ENGINE
MBX50 EPA TORQFLOW - DIESEL ENGINE
5
INTRODUCTION
This Service Manual has been developed as an information resource to help the reader learn
about, understand, repair and maintain the MBX50 Series lift trucks, and the various equipment,
systems, inspections, sensors, diagnostic procedures and diagnostic equipment utilized to main-
tain, adjust and troubleshoot these systems. Although reference is made to maintenance proce-
dures necessary to perform servicing of this vehicle, you should refer to the applicable Operation
and Maintenance Manual for these lift trucks for more complete maintenance information.
Hamech is involved in a concentrated and highly technical program of designing and developing
cleaner burning, more efficient and more powerful engines for use in the industrial truck market.
As a result, new computerized sensors, systems and diagnostic monitors have been created to
make the job of maintaining and repairing these systems simple and easy.
Read this manual carefully, refer to it often and learn the repair, testing and adjustment proce-
dures to the best of your ability. Please note that some illustrations are generic and may not look
exactly like your unit in every detail.
Ensure that, when you are working on or around industrial trucks, Safety is priority Number
One. Read, understand and obey all WARNINGS and CAUTIONS.
Follow the instructions and procedures presented in this manual when working on these lift
trucks and their systems. Damage to the equipment, and possible injury to yourself or others,
may result if these procedures are not adhered to carefully.
Keep this manual nearby and accessible for use when necessary. If this book becomes dirty,
worn or illegible, contact Hamech for a replacement. The procedures outlined in this manual will
be updated periodically. Be sure that you have the latest revision in order to learn the newest
information available. Revision dates will be clearly displayed on the lower left hand corner of the
cover page.
This will aid in maintaining your equipment in excellent condition and in ensuring that these lift
trucks will operate safely at maximum efficiency.
ENGINE SERIAL NUMBER LOCATION

The K21/K25 engine serial number is stamped on an
angled and machined pad on the right side of the
engine block in the center just beneath the valve cover.
The machined boss is split vertically by a groove. The
Engine Model number is on the left pad and the Engine
Serial number is on the right pad.
7
EMISSION CONTROL STATEMENTS
CALIFORNIA/FEDERAL EMISSION CONTROL STATEMENT FOR

OFF-ROAD LSI (NON-DIESEL) ENGINES (K21 AND K25 ENGINES)
This section presents information concerning the correct labeling, warranty, parts and maintenance of K21 and K25
engines in order to comply with the EPA and CARB off-road, large-spark-ignition (LSI) engine regulations.
LABELS REQUIRED AND LABEL LOCATIONS

All “K” series engines will display the required identification label as follows.
Location on K21/K25 Series engines:
Emission compliance label (sample):
8
WARRANTY
The following statement is required to be provided by regulations of the California Air Resources Board.
YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board is pleased to explain the emission control system warranty on your 2007
engine. In California, new off-road large spark-ignition (LSI) engines must be designed, built and equipped to meet
the state's stringent anti-smog standards.
Copyright 2007 Komatsu Forklift USA, Inc. Used With Permission. Hamech must warrant the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the carburetor, regulator or fuel-injection system, ignition
system, engine computer unit (ECM), catalytic converter and air induction system.
Also included may be sensors, hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, an Authorized Hamech Dealer will repair your LSI engine at no cost to you
including diagnosis, parts and labor.
MANUFACTURER'S WARRANTY COVERAGE

The 2007 off-road large spark-ignition engines are warranted for the time periods as listed below.
If any emission-related part on your engine is defective, the part will be repaired or replaced by an Authorized
Hamech Dealer.
OWNER'S WARRANTY RESPONSIBILITIES

As the off-road LSI engine owner, you are responsible for the performance of the required maintenance listed in
your Operation and Maintenance Manual.
Hamech recommends that you retain receipts covering maintenance on your off-road engine, but Hamech cannot
deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled
maintenance.
As the off-road large spark-ignition engine owner, you should however be aware that Hamech may deny you
warranty coverage if your off-road large spark-ignition engine or a part thereof has failed due to abuse, neglect,
improper maintenance or unapproved modifications.
Your engine is designed to operate on gasoline or LPG fuel. Use of any other fuel may result in your engine no
longer operating in compliance with California's emissions requirements.
You are responsible for initiating the warranty process. The ARB suggests that you present your off-road large
spark-ignition engine to an Authorized Hamech Dealer as soon as a problem exists.
The warranty repairs should be completed by the Dealer as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, you should contact Hamech's
Product Support Department at 1-419-629-2311.
EMISSION CONTROL WARRANTY - 36 MONTHS or 2,500 HOURS FOR GENERAL PARTS

For the first 2,500 operating hours or for a period of thirty-six months from the date of the first use by the original
purchaser from an Authorized Hamech Dealer, whichever occurs first, Hamech warrants the following emission-
related parts.
• Oxygen sensor • PCV valve
• Water temperature sensor • Gasoline injector
• LPG injector • LPG pressure sensor
• LPG solenoid • Mass air flow sensor
• Throttle chamber • Ignition coil
9
• Crankshaft position sensor • Camshaft position sensor

• Spark plugs • Exhaust tube from manifold to catalytic converter
• Gasoline fuel hose • Gasoline fuel cap
EMISSION CONTROL WARRANTY - 36 MONTHS or 4,000 HOURS FOR POWER TRAIN PARTS
• Intake manifold
• Exhaust manifold
LONG-TERM EMISSION CONTROL WARRANTY - 60 MONTHS or 3,500 HOURS FOR GENERAL PARTS
• ECM
• Catalytic converter
• Vaporizer
Follow the instructions in the Operations Manual concerning any other maintenance programs not
required for EPA compliance.
For questions and additional information concerning EPA Diesel Engine Exhaust Regulations, contact:

Hamech Lift Trucks
Tel: (419) 629-2311

Fax: (419) 629-3796
www.hamech.com
10
FEDERAL EPA EMISSION CONTROL STATEMENT FOR

OFF-ROAD DIESEL ENGINES (4D94E ENGINES)
Exhaust emissions produced by diesel engines are regulated by the United States Environmental Protection
Agency (EPA). This section presents information concerning the correct labeling, warranty, parts and maintenance
of 4D94E diesel engines in order to comply with current EPA regulations.
LABELS REQUIRED AND LABEL LOCATIONS

All certified 4D94E diesel engines will display the required identification label as follows:
• 4D94E diesel engines: Labels will be affixed to all appropriate engines on Hamech production trucks.
Location on 4D94E Series diesel engines:
11
WARRANTY
The following statement is hereby provided as required by regulations of the United States Environmental
Protection Agency (EPA).
YOUR WARRANTY RIGHTS AND OBLIGATIONS

The Federal EPA and Hamech are pleased to explain the emission control system warranty on your 2004 or later
Diesel heavy duty off-road engine. All new, heavy-duty off-road engines must be designed, built and equipped to
meet the EPA’s stringent anti-smog standards. Hamech must warrant the emission control system on your engine
for the period of time listed below, provided there has been no abuse, damage, neglect or improper maintenance of
your engine.
Your emission control system may include parts such as fuel injection pump. Also included may be hoses, belts,
connectors and other emission-related assemblies.
Where a warrantable condition exists, an authorized Hamech dealer will repair the heavy-duty off-road engine at no
cost to the owner, including diagnosis, parts and labor.
Now, Hamech hereby certifies that diesel engines for lift trucks produced in 2004 model year and after shall be
regulated by Federal EPA exhaust gaseous regulations. The difference between current and EPA-certified engines
is only the label attached on the engine. See available drawing and/or illustration of emission label and its location.
MANUFACTURER’S WARRANTY COVERAGE

Beginning January 1, 2004 heavy-duty off-road EPA engines are warranted for a period of five (5) years, or three-
thousand (3,000) hours of operation, whichever occurs first. If any emission-related part on your engine is
defective, the part will be repaired or replaced by at an authorized Hamech dealer.
EMISSION-RELATED PARTS
• Fuel injection pump
• Fuel injection nozzles
• Turbocharger
OWNER’S WARRANTY RESPONSIBILITIES

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance
listed in owner's manual (Instruction Manual). Hamech recommends that you retain all receipts and records
covering the maintenance on your engine, but Hamech cannot deny warranty solely for the lack of receipts and
records or for your failure to ensure the performance of all scheduled maintenance. For your reference, the
following is an emission control maintenance schedule for certified Diesel engines.
• Check oil level and coolant level Every day

• Change of lubricating oil Every 200 hours
• Change lubricating oil filter Every 200 hours
• Initial adjustment of valve clearance Every 200 hours
• Change fuel filter Every 500 hours
• Check turbocharger, rebuild or replace if necessary Every 2,000 hours
• Adjust valve clearance Every 2,000 hours
• Check fuel injection nozzles, replace if necessary Every 2,000 hours
12
Keep records to show proof of compliance with the required maintenance practices and intervals.
• As the heavy-duty off-road engine owner you should, however, be aware that Hamech may deny your warranty
coverage if your heavy-duty off-road engine or part has failed due to abuse, damage, neglect, improper main-
tenance or disapproved modifications.
• Your engine is designed to operate on commercial diesel fuel only. Use of any other fuel in our engine will
result in the engine operating in non-compliance with the Federal EPA regulations.
You are responsible for initiating the warranty process. It is suggested that you present your heavy duty off-
road engine to an authorized Hamech dealer as soon as you become aware that problem exists. The warranty
repair should be completed by the dealer as expeditiously as possible.
• If you have any questions regarding your warranty rights and responsibilities, you should contact the autho-
rized Hamech dealer.
LIMITATIONS
Hamech is not responsible for resultant damages to an emission-related part or component resulting from:
• Any application or installation Hamech deems improper as explained in the Instruction Manual.
• Attachments, accessory items or parts not authorized for use by Hamech.
• Improper off-road engine maintenance, repair or abuse.
• Owner's unreasonable delay in making the product available after being notified of a potential product problem.
This warranty is in addition to the Hamech standard warranty applicable to the off-road engine product involved.
Remedies under this warranty are limited to the provision of material and services as specified herein. Hamech is
not responsible for incidental or consequential damages, such as downtime or lost use of the lift truck.
CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEMS WARRANTY

Hamech aims to ensure that the Emission Control Systems Warranty is properly administered. In the event that
you do not receive the warranty service to which you believe you are entitled under the Emission Control Systems
Warranty, call or write to your Hamech Dealer.
Authorized dealers are recommended for major maintenance and repair work, as they are staffed with trained
personnel, proper tools and are aware of the latest maintenance methods and procedures. Owners and others who
desire to perform their own work should purchase a service manual and obtain current service information from
their Hamech engine dealer.
Follow the instructions in the Operations Manual concerning any other maintenance programs not
required for EPA compliance.
For questions and additional information concerning EPA Diesel Engine Exhaust Regulations, contact:

Hamech Lift Trucks
Tel: (419) 629-2311

Fax: (419) 629-3796
www.hamech.com
13
MODEL TABLE
MODEL TABLE
LIFT TRUCKS COVERED IN THIS PUBLICATION
GASOLINE, LPG AND DUAL-FUEL ENGINE MODELS

CUSHION TIRE
G20ST-16 4,000 lb. capacity, K21 gasoline engine, cushion tires
G20STLS-16 4,000 lb. capacity, K21 LPG engine, cushion tires, “LPS”
G20SHT-16 4,000 lb. capacity, K25 gasoline engine, cushion tires
G20SHTLS-16 4,000 lb. capacity, K25 gasoline engine, cushion tires, “LPS”
G25ST-16 5,000 lb. capacity, K21 gasoline engine, cushion tires
G25STLS-16 5,000 lb. capacity, K21 LPG engine, cushion tires, “LPS”
G25SHTLS-16 5,000 lb. capacity, K25 LPG engine, cushion tires, “LPS”
PNEUMATIC TIRE
G20T-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires
G20TUS-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires, “GS”
G20TLS-16 4,000 lb. capacity, K21 LPG engine, pneumatic tires, “LPS”
G20HT-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires
G20HTUS-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires, “GS”
G20HTLS-16 4,000 lb. capacity, K25 LPG engine, pneumatic tires, “LPS”
G25T-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires
G25TUS-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires, “GS”
G25TLS-16 5,000 lb. capacity, K21 LPG engine, pneumatic tires, “LPS”
14
MODEL TABLE
LIFT TRUCKS COVERED IN THIS PUBLICATION (Continued)

G35AHT-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires
G35AHTUS-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires, “GS”
G35AHTLS-16 7,000 lb. capacity, K25 LPG engine, pneumatic tires, “LPS”
DIESEL ENGINE MODELS

D20T-16 4,000 lb. capacity, 4D94E diesel engine, pneumatic tires
D20TUS-16 4,000 lb. capacity, 4D94E diesel engine, pneumatic tires, “DS”
D28TUS-16 5,500 lb. capacity, 4D94E diesel engine, pneumatic tires. “DS”
D30TUS-16 6,000 lb. capacity, 4D94E diesel engine, pneumatic tires. “DS”
D35AT-16 7,000 lb. capacity, 4D94E diesel engine, pneumatic tires
D35ATUS-16 7,000 lb. capacity, 4D94E diesel engine, pneumatic tires, “DS”
15
MODEL TABLE
16
SAFETY
SAFETY
00. SAFETY
SAFETY MANAGEMENT ................................................................................................. 0-3
SAFE TRAVEL.................................................................................................................. 0-6
LOADING OPERATIONS ............................................................................................... 0-14
SAFETY IN PERIODIC MAINTENANCE........................................................................ 0-19
TOWING ......................................................................................................................... 0-25
STRUCTURE AND STABILITY OF THE LIFT TRUCK .................................................. 0-26
SAFETY LABELS ........................................................................................................... 0-29
SAFETY LABEL ORDERING INFORMATION ............................................................... 0-35
OPTIONAL EQUIPMENT ............................................................................................... 0-36
0-1
SAFETY MANAGEMENT
SAFETY MANAGEMENT
FOLLOW THE INSTRUCTIONS IN THE OPERATION AND MAINTENANCE MANUAL AS WELL AS ON THE
SAFETY LABELS
• Read the instructions in this manual and the safety labels attached to various parts of the lift truck, and make
sure that you understand and follow them. If you do not understand or do not follow the instructions, this will lead
to improper operation which may result in personal injury or damage.
• Be sure that you understand the proper method of using the lift truck and the procedure for carrying out an
inspection, and ensure that they are carried out safely.
• Read this manual and safety labels again from time to time. If the Operation and Maintenance Manual or safety
labels have been lost or have become dirty and cannot be read, obtain replacements from your Hamech Lift
Truck Dealer and attach the safety labels in the specified positions.
• See “SAFETY LABELS” on page 29.
MAKE SAFETY PLANS BEFOREHAND

• Before operation, establish an operating plan and hold a meeting to discuss operating safety.
• In confined areas, position a signal person and carry out operations in accordance with his/her instructions.
FOLLOW THE SAFETY RULES IN PLACE

• Do not operate the lift truck if you are fatigued, or when you have been drinking or have taken any medication
which can make you sleepy.
• When carrying out operation, inspection, or maintenance of the lift truck, always follow all work shop rules,
safety regulations and precautions.
• During operation, always pay attention to safety and be careful of pedestrians and other surrounding conditions.
ENSURE SAFETY AT THE WORKING AREA

• Always work on level surfaces and wipe up all oil or grease from the ground.
• When working on quays, platforms, or docks, or other places where there is danger of falling, set up blocks to
prevent the lift truck from going over the edge.
• Put warning signs up in dangerous places to warn the operator not to approach.
• Mark the travel areas clearly and maintain the road surface in good condition.
• Put up signs to prevent unauthorized lift trucks from entering areas where lift trucks are being operated.
• Ensure that there is adequate lighting to enable safe operations to be performed.
WEAR SAFETY CLOTHES WHILE IN OPERATION

• Avoid loose clothing, jewelry, and loose long hair, which can
catch on controls or in moving parts and cause serious injury or
death.
• Depending on the working conditions, wear other safety
equipment such as a hard hat and safety boots when required.
KEEP THE OPERATOR'S COMPARTMENT CLEAN AND CLEAR

• Keep the operator's compartment clean and tidy. Be sure to
clean up all oil or mud. If the operator's hand or foot slips it could lead to a serious accident.
• Do not leave tools or spare parts lying around in the operator's compartment; always keep them in the tool box
when not being used. They may damage or obstruct the control levers or pedals.
• Do not drive the lift truck if your hands are wet or covered with oil. Your hands will slip on the work equipment
control levers or directional lever and could cause a serious accident.
0-3
SAFETY MANAGEMENT
REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT

• The permissible load for lift trucks equipped with any attachment is lower than the permissible load for the
standard lift truck, the reasons being:
1. The overall permissible load is lowered by as much as the weight of an attachment itself.
2. The load center shifts toward the front due to the thickness of an attachment.
• Follow the load limit as indicated in the load capacity chart on the nameplate.
• On some detachable-type attachments and inserting-type attachments, there is an additional load capacity chart
or attachment weight label provided at a certain place. Follow the instructions in the chart or the label when
installing such an attachment.
UNAUTHORIZED MODIFICATION
• Do not install any additional equipment, parts or the like on the lift truck, or modify the lift truck without prior
written consent from Hamech Lift Truck. An additional counterweight or unauthorized modification of the lift truck
can bring about a negative effect on the stability or strength of the lift truck, and can also impair its safety.
• Do not install any equipment or parts which obstruct or limit the operator's view.
DON'T REMOVE THE OVERHEAD GUARD AND LOAD BACKREST

• The overhead guard is installed to protect the operator from falling objects. It is designed to withstand the force
of light boxes or small packages. It is not designed to withstand every possible impact.
• Always be careful to prevent damage or injury from falling objects.
• Do not use a Hamech lift truck when it is equipped with a non-genuine overhead guard or load backrest.
Note: Hamech lift trucks are usually equipped with the optimum overhead guard and load backrest when they
are shipped out of Hamech lift truck plants.
DON'T USE A LIFT TRUCK THAT IS NOT WORKING

PROPERLY- USE LOCK-OUT TAG-OUT PROCEDURES
• Remove the key from the faulty lift truck and hang signs in the
operator's compartment to prevent its use.
• If the lift truck has suffered a failure and the lift truck must be
parked without lowering the forks, put markers on the tips of the
forks and take steps to prevent pedestrians or other vehicles
from hitting the forks.
• Select a parking place where people or vehicles do not pass,
and stop the lift truck so that it is difficult for anyone to go under the forks. (The area under the forks is a danger
zone.)
ENGINE EXHAUST GAS IS POISONOUS

Do not leave the engine running where there is poor ventilation. The
engine exhaust gas contains carbon monoxide, which can cause
gas poisoning and result in serious injury or death.
0-4
SAFETY MANAGEMENT
FIRE IS STRICTLY PROHIBITED DURING REFUELING

Fuel is extremely flammable and can cause fires and explosions.
• Carry out refueling away from flames or sparks.
• Stop the engine when refueling.
• After refueling, tighten the gas cap securely and wipe up any
spilled fuel.
FIRE, FIRST AID AND GENERAL SAFETY

• When you feel something unusual occurring with the lift truck,
promptly stop working, move the lift truck to a safe place for
parking and stop the engine for safety. Then report to the
supervisor.
• Be sure that fire extinguishers have been provided and that you
read the labels to ensure that you know how to use them.
• Know what to do in the event of a fire.
• Be sure that you know the phone numbers of persons you
should contact in case of an emergency.
• Provide a first aid kit at the storage point.
• If a fuel leak is discovered, do not operate the lift truck. Be sure to make repairs, stopping the leak before
starting the operation again, while reporting the trouble to the supervisor.
0-5
SAFE TRAVEL
SAFE TRAVEL
JUMPING ON AND OFF THE LIFT TRUCK IS STRICTLY

PROHIBITED
• When getting in or out of the lift truck, be sure to first stop the
truck and use the handrails (assist grip) as well as the step to
hold yourself securely.
• Do not hold on to or pull yourself up with the control levers or
steering wheel when getting on or off the lift truck.
• Keep the handrails (assist grip) clean all the time, and repair any
damage.
DON'T TRY TO OPERATE THE LIFT TRUCK FROM OUTSIDE

THE OPERATORS COMPARTMENT
• Always keep your body under the overhead guard.
• Do not put your hand or foot out of the overhead guard.
• You must be properly seated in the operator’s seat when
operating any function of the lift truck.
MAINTAIN PROPER POSTURE WHILE OPERATING

Travel Interlock (power transmission cutoff) and Lift Interlock
(Option)
• If you operate the lift truck when you are not seated properly or
off the seat, an accident may happen unexpectedly. To forestall
such a possible accident, the truck is provided with Travel
Interlock and Lift Interlock that make travel and truck operation
impossible if you are not seated properly (Operator Presence
System).
• If you operate the lift truck in such a posture that your weight is
not properly applied to the seat, like standing up or leaning forward or sideways, the Travel Interlock begins to
alarm in approximately three seconds and cuts off the transmission of engine power. Then the truck will not
move, even if you depress the accelerator pedal or operate the Forward/Reverse lever.
• Additionally, Lift Interlock locks lifting/lowering and tilting operations. Even if you operate the lift lever or tilt lever,
these functions will not work. (The lever for an attachment is not equipped with this function.)
0-6
SAFE TRAVEL
DON'T ALLOW A PASSENGER ON THE TRUCK

• Never allow any other person to ride with you on the lift truck.
• Do not use anyone for a makeshift human counterweight.
BE SURE TO WEAR THE SAFETY SEAT BELT

• Always fit your seat belt correctly when operating. If your seat
belt is fitted incorrectly, there is danger of serious personal injury
if the lift truck should tip over.
• Always check the seat belt mounts and check for any damage to
the seat belt. If any abnormality is found, repair or replace the
seat belt immediately.
CHECK THE SURROUNDINGS FOR SAFETY BEFORE

STARTING UP THE ENGINE
• Before stating the engine, check that the parking brake is set,
and that the directional and speed levers are in the neutral
position.
• Adjust the operator's seat and the steering wheel before starting
the engine. Always lock them in position after adjusting.
Adjusting the seat or steering wheel during operation is
dangerous as it may cause you to lose your balance or operate
the lift truck in an unsafe manner.
• Before starting the engine, first check that the surrounding area
is safe, and sit securely in the operator's seat.
• Sound the horn before starting the engine to warn people around
you.
• Do not attempt to start the engine by intentionally short-circuiting
the engine starting circuit.
• Do not attempt to jump-start the lift truck.
CHECK AND ADJUST THE REAR VIEW MIRROR AND LAMPS

• When reversing, never depend on the rear view mirror. The operator must visually check behind him. Also,
adjust the rear view mirror so that the operator can check from the operator's seat that the area behind the lift
truck is safe. Always keep the surface of the mirror clean. If the mirror is broken, replace it with a new one.
• Check that all lamps light up correctly. Replace any broken bulbs (for lift trucks equipped with lamps).
0-7
SAFE TRAVEL
PERFORM A SAFETY CHECK BEFORE STARTING THE LIFT

TRUCK
• Before starting the lift truck, check that the surrounding area is
safe.
• Before moving the lift truck, raise the forks [approximately 15 -
20 cm (6 - 8 in) from the ground surface], and tilt the mast back.
• When ready to move, release the parking brake.
A SUDDEN SHIFT OF THE F-R LEVER IS DANGEROUS

To change the travel direction, stop the lift truck completely and then operate the F-R lever.
BE SAFETY CONSCIOUS WHILE DRIVING

• Keep a clear view of the path of travel and watch for other traffic, personnel, and safe clearances.
• When passing oncoming vehicles, reduce speed and keep a safe distance from the other vehicle.
• In places where there are speed limits, observe the speed limit
and maintain a safe distance from other vehicles.
• When traveling, always pay careful attention to the area around
your lift truck, particularly in the direction of travel or when
turning.
• Do not attempt to pass another lift truck or vehicle on a narrow
path or on a spot of limited view like a crossing.
• When passing through an area of limited view, like a crossing or
when running into a narrow path, sound the horn and check the
surroundings for safety.
• Even if you sound the horn, not everyone in the surrounding
area will necessarily hear it. Always pay careful attention to the
movements of people in the surrounding area.
• When crossing a passage or turning at a corner, stop the lift truck once to confirm the safety around.
• Always pay careful attention to the movements of people in the surrounding area, and take steps to prevent
people from entering the working area.
• When traveling on a slope or through a crowded spot, always give way (yield) to a loaded lift truck.
DO NOT DRIVE ON ROUGH GROUND OR SURFACE

• Avoid traveling in places which are flooded or where there are
holes.
• Do not try to drive the lift truck on soft ground.
• Avoid curbs, rails, ditches, or other obstacles, and do not travel
directly over them.
• Do not travel on slippery road surfaces.
• When entering buildings, check the weight limit of the floor and
be careful not to exceed the limit.
0-8
SAFE TRAVEL
DRIVING ON A ROAD SHOULDER IS STRICTLY PROHIBITED

• There is a danger that soft road shoulders may collapse, so do
not go near them.
• Always maintain a safe distance from the edge of road shoulders
and platforms.
WHEN DRIVING INTO A RAILWAY CAR, TRUCK OR

CONTAINER, EXERCISE EXTRA CARE
• Do not travel on the edge of docks. There is a danger that the lift
truck may fall, which may result in serious injury or death.
• Before starting operations, check the load limit for the dock
plates, and do not use them if they do not have ample strength to
take the weight of the lift truck when loaded.
• Apply the brakes on the truck and block the wheels before
driving the forklift into the truck.
• When driving into trailers, use jacks and take steps to prevent
the trailer from sinking when the forklift truck travels on it.
• When driving the forklift inside trucks, reduce speed when
backing out and be sure to check that the gangplanks are safe.
• Be careful of pedestrians.
• Tell the truck driver not to move the truck until the operation is
completed.
• If there is some system to secure the truck to the dock, always
use this system. Secure the dock plates so that they do not slip
and fall.
0-9
SAFE TRAVEL
BE AWARE OF THE LIFT TRUCK'S MAXIMUM HEIGHT AND

WIDTH
• Ensure that there is ample height and width for the lift truck to
pass.
• Do not extend your hands or legs outside the operator's
compartment or the area covered by the overhead guard (safe
area).
• Check that the surrounding area is safe.
• Be careful of electric wires and other obstacles inside and
outside the building.
WHEN DRIVING UP OR DOWN A SLOPE, EXERCISE EXTRA

CARE
• Do not turn, or travel across or at an angle on slopes. There is
danger that the lift truck will tip over.
• Before starting to drive up a slope, stop the lift truck and adjust
the clearance between the ground surface and the bottom of the
forks so that the bottom of the forks or pallet do not contact the
ground surface or the tip of the fork does not stick into the
ground when traveling.
• For safe travel on slopes:
When Travel forward up the slope, and in reverse
loaded: down the slope with the load upgrade.
Travel in reverse up the slope and forward down
When
the slope with the load-engaging means down-
unloaded:
grade.
• On a downslope, drive down slowly and use the foot brake.

• When starting on slopes, the lift truck may start to move down
the slope depending on the amount the pedals are depressed.
Always leave ample room in front of and behind the lift truck
when starting on slopes.
• Be careful of the truck sliding downhill if Travel Interlock is
engaged while traveling uphill or on a slope. Stay securely in the
operator’s seat!
0-10
SAFE TRAVEL
WHEN MAKING A TURN, BE CAREFUL OF THE SWINGING

COUNTERWEIGHT
• Remember that a lift truck steers with the rear wheels, not the
front wheels. It will not drive like an automobile.
• When turning while traveling forward, the counterweight will
swing far out. Keep an ample clearance from walls to ensure
safety.
• When turning, travel slowly and be careful that the front or rear
wheels do not come off the ground.
When turning on soft road shoulders, there is danger that the
rear wheels may come off the road shoulder and cause the lift
truck to tip.
ANY OPERATION THAT MIGHT OVERTURN THE LIFT TRUCK IS

STRICTLY PROHIBITED
• If the load-engaging means or load is raised, the center of gravity
of the lift truck will also rise and increase the danger of the lift
truck tipping. Do not turn the lift truck when the forks are raised
high.
• Do not suddenly raise the forks or tilt the mast to the front or rear
when the forks are loaded. There is danger that the lift truck will
tip.
• Reduce speed before turning the lift truck.
In particular, when traveling unloaded, the rear of the lift truck is
heavy. If the lift truck is turned at high speed, there is a greater
chance of tipping than when traveling with the forks loaded.
WHEN BACKING UP THE LIFT TRUCK, VISUALLY CHECK

BEHIND THE TRUCK
• Before backing the lift truck, make sure that there is no one
behind the truck before starting to travel.
• The rear view mirror is simply an aid for checking the rear. When
driving in reverse, do not use the rear view mirror. Turn to face
the rear and check the area directly behind the lift truck for safe
unobstructed travel.
• Even if you sound the backup buzzer, the people behind the
truck may not necessarily hear it. Always check that there is no
one behind the truck before driving the truck. (For lift trucks
equipped with backup buzzer)
WHEN CARRYING A HIGH LOAD, USE A SIGNAL PERSON OR

DRIVE BACKWARDS
• If the view to the front is obstructed by the load, turn to the rear
and drive the lift truck in reverse.
• When driving in reverse with a high load, use a signal person to
ensure the safety of the load and the safety in the surrounding
area.
0-11
SAFE TRAVEL
PAY SPECIAL ATTENTION TO THE REAR VIEW WITH AN LPG CYLINDER-INSTALLED (GASOLINE ENGINE)
LIFT TRUCK
• The installed LP gas cylinder may partially block your rear view and could pose a danger of hitting people,
product, or nearby objects if you do not exercise caution. Before starting in reverse, make sure the area behind
you is clear. Get off the truck and look if necessary. Sound your horn. When travleing in reverse, watch around
you to make sure your path of travel is clear. If appropriate for your application, consider, installing backup
warning devices (backup alarm, rotating warning lamp, etc.) or backup safety devices such as a rear view mirror
but always check for safe conditions in the area of the truck.
• When installing optional warning devices, call your Hamech Lift Truck Dealer for details.
APPLY THE BRAKES CORRECTLY WHILE RUNNING
• Do not stop the engine while the truck is in motion. When the engine is not running, the operating efforts for
power steering and power brakes (if present) increase. Thus it is dangerous to stop the engine while running.
• If the inching pedal is depressed, the braking effect of the engine will be lost.
• Do not use the brakes unnecessarily or too frequently. If your lift truck is a TORQFLOW transmission type and
you rest your foot on the inching pedal during operations, the multiple clutch plates of the transmission will
overheat, deforming the clutch plates and causing them to malfunction, in the worst case.
REQUIRED BRAKING DISTANCE DIFFERS DEPENDING ON THE ROAD CONDITIONS

• When traveling downhill, it requires a longer distance for the lift truck to stop than when traveling on level
ground.
• When traveling downhill, reduce the speed and make sure that you have ample room at the bottom of the slope
to stop.
• Traveling on wet surfaces requires a longer distance to stop than when traveling on normal road surfaces.
Always leave ample room to stop.
0-12
SAFE TRAVEL
FOLLOW THESE STEPS FOR PARKING

CHECK ITEMS WHEN PARKING
1. Stop the lift truck on level ground.
2. Apply the parking brake securely to make sure that the lift truck
cannot move.
3. Set the directional lever and speed lever to neutral.
4. Tilt the mast forward and lower the fork to the floor.
5. Turn the starting switch to the OFF position.
6. Pull out the starting switch key and leave the lift truck.
PARK THE LIFT TRUCK IN A SAFE PLACE

• Park the lift truck in the specified place.
• Park the lift truck on a firm surface.
• Do not park near any emergency exit, stairway, fire extinguisher,
or other safety equipment. Park the lift truck in a place where it
will not obstruct pedestrians or other vehicles.
• Never park the lift truck near any flammable object.
• If there is no way to avoid parking on a slope, immobilize the lift truck by putting blocks under the tires in addition
to normal parking procedures.
SHOULD THE LIFT TRUCK BECOME INOPERATIVE IN A DANGEROUS PLACE LIKE A RAILROAD
CROSSING, LET ALL PEOPLE AROUND KNOW IMMEDIATELY
• If engine trouble occurs on a railroad crossing and the lift truck does not move, it is impossible to push start the
motor as can be done on a standard-shift automobile. (This is because a neutral safety switch is installed.)
• In such an emergency, light a flare or smoke candle to warn approaching trains and people in the area that there
is a broken-down truck on the tracks.
DON'T USE A LIFT TRUCK TO TOW ANOTHER BROKEN-DOWN LIFT TRUCK

If there is any problem with the brakes or steering system of your lift truck, do not use another lift truck to tow it as
there is danger that the lift truck may run out of control.
DON'T USE THE DRAWBAR PIN FOR OTHER THAN IT’S

INTENDED PURPOSE
• Do not use the drawbar pin for any other towing purpose than to
bail out a stuck lift truck, or to be towed by another lift truck or to
be hoisted.
• The towing pin at the back of the counterweight is provided to
pull out the lift truck when it has gotten stuck in dirt or a ditch as
well as when it is being loaded on a truck.
0-13
LOADING OPERATIONS
LOADING OPERATIONS
PRECAUTIONS FOR LOADING AND UNLOADING

• If you operate the lift truck in such a posture that your weight is
not properly applied to the seat, like standing up or leaning
forward or sideways, Travel Interlock begins to alarm in
approximately three seconds and cuts off the transmission of
engine power. Then the truck does not move even if you depress
the accelerator pedal or operate the Forward/Reverse lever.
The truck will slide downhill if Travel Interlock activates on an
uphill grade or a slope.
• Select flat and solid ground for loading and unloading. Avoid a
road shoulder or a place near a cliff.
• Use ramps of sufficient length, width and strength. Moreover, set them securely so that they will not shift or be
displaced.
• Always operate the mast and forks from the operator's compartment. Be careful not to operate the lever by
mistake. There is danger that the forks or work equipment may cause serious injury.
KEEP UNAUTHORIZED PEOPLE OUT OF WORKING AREA AND ENSURE A SIGNAL PERSON IS ON DUTY
• Do not allow anyone in the working area except the signal person.
• Do not let any person or other lift truck come close during operation.
• When working with a signal person, always follow their instructions.
NEVER GO BENEATH RAISED FORKS

The space under a lifted fork is an area of danger, so never allow
anyone to go under the fork. There is a danger of personal injury to
any person who could be crushed under the forks when they come
down.
STANDING ON THE FORK(S) IS STRICTLY PROHIBITED

• Do not let anyone place a load on the forks.
• Do not let anyone directly remove the load from the forks.
• Standing on the forks is dangerous because the forks are
slippery and the load may move.
• Do not use anyone to keep the load stable. The lift truck may
move unexpectedly, causing the load to fall and crush the
person.
0-14
LOADING OPERATIONS
BE CAREFUL NOT TO GET CAUGHT IN THE MAST

STRUCTURE
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.
DON'T CLIMB ON THE MAST OR LOAD BACKREST

If you climb on the mast or load backrest, there is a danger that you
could get caught up in the moving parts or fall off.
USE A PALLET OR SKID OF SUFFICIENT STRENGTH

• Always be sure that the pallets and skids have ample strength. If broken or damaged pallets or skids are used,
there is a risk that the load may fall.
• Always check that the load is positioned securely and safely on the pallet before moving the truck.
HANDLE A LONG OR WIDE LOAD WITH EXTRA CARE

• Be extremely careful when carrying long or wide loads. Raise the
load slowly and be careful not to touch anything in the
surrounding area.
• Keep the load as low as possible and be sure to maintain the
balance.
• When turning, operate slowly and be careful not to let the load
shift or move.
0-15
LOADING OPERATIONS
WATCH OUT OVERHEAD

• As the fork goes up, the mast height increases. Be mindful of this
fact during the operation.
• Take care so that the mast or the overhead guard will not hit
electric wiring, piping, sprinklers, beams in the ceiling, and so on.
If such contact occurs, there is the danger that the load on the
fork may fall off or the lift truck may tip over.
OVERLOADING IS STRICTLY PROHIBITED

• Do not load the lift truck over the maximum capacity shown in the
load capacity chart, otherwise there is the danger that the rear
wheels may come off the ground, the operator may lose control
of the lift truck; and the truck may tip over. Moreover the load on
the forks can collapse.
• Never exceed the max. load shown in the load capacity chart on
the nameplate. (See “LOAD CENTER AND ACTUAL
CAPACITY” on page 27.)
DON'T HANDLE A LOAD IN AN INSECURE MANNER

• Make sure that the center of gravity of the load is in line with the
center of the lift truck. Do not carry loads off-center. There is
danger that unbalanced loads may cause the lift truck to tip.
• Place the load so that it contacts the load backrest.
• Do not handle unstable loads. If there is danger that the load
may fall off, secure it in position and take steps to prevent the
load from collapsing or falling.
DON'T HANDLE A LOAD EXCEEDING THE LOAD BACKREST

HEIGHT
Keep the height of the load within the height of the load backrest. Do
not carry any load that is higher than the load backrest. If the load is
higher than the load backrest, there is danger that it will fall back on
top of the operator, resulting in serious injury or death.
0-16
LOADING OPERATIONS
BE CAREFUL OF THE FORK TIPS

• Do not allow the tips of the forks to get close to people. The tips
of the forks are pointed, so there is a risk that they may cause
injury.
• Do not attempt to hook something with the tips of the fork,
otherwise the hooked object can suddenly come off the tip, and
the reaction can cause danger to the lift truck as well as to the
hooked object.
DON'T USE THE FORK TO PUSH OR PULL A LOAD

There is a risk that the load will be damaged or fall.
DON'T TILT THE MAST FORWARD WITH A LOAD ON THE

FORK.
• Do not tilt the mast forward with the load raised. Do not raise the
load when the mast is tilted forward. There is danger of the load
falling or the truck tipping over.
• Do not travel with the mast tilted forward.
• Do not load and unload on slopes.
BE CAREFUL OF SLACK IN THE HOIST CHAINS

• If there is any slack in the chain, the mast rail or forks may catch
in the load or a shelf, and there is danger that the load may fall
and the lift truck tip.
• Always be careful that there is no slack in the chain when pulling
the forks out from pallet or shelf.
0-17
LOADING OPERATIONS
DON'T USE THE LIFT TRUCK IMPROPERLY

• Do not use the lift truck for any other purpose than was originally
intended (the loading work using the fork or attachments).
• Do not use the forks to open or close the doors of railroad cars or
warehouses.
• Do not push any other vehicle.
• Do not hook ropes on the forks and use the forks to lift loads.
• Do not use the drawbar pin for towing operations.
0-18
SAFETY IN PERIODIC MAINTENANCE
PERIODIC MAINTENANCE WORK MUST BE CARRIED OUT BY QUALIFIED PERSONNEL

Only persons authorized by the owner or operator of the equipment and having proper certification (local or
national) may carry out inspection, maintenance and repairs of the lift truck. If inspection, maintenance, or repair
work is carried out incorrectly, it may create a hazardous condition.
DESIGNATE A LOCATION FOR PERIODIC MAINTENANCE WORK

• When carrying out inspection and maintenance, use a level, dry, dust-free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.
PRECAUTIONS BEFORE PERIODIC MAINTENANCE WORK

• Read rules and regulations for safety control, safe driving, and loading and unloading operation carefully and
understand them fully.
• To be prepared for a fire, have a fire extinguisher nearby and make sure that you know how to use it.
• Before carrying out inspection, lower the forks to the ground and stop the machine.
• Before starting the inspection and maintenance work, turn the engine starting switch to the OFF position and
keep the engine at a standstill.
• Keep the engine starting switch in the OFF position except when otherwise required in order to keep the engine
at a standstill.
• Set the MAINTENANCE IN PROGRESS sign in a place in the operator's compartment or near the control panel
where it is easy to see.
• Set the Forward/Reverse lever, high/low speed lever, and work equipment lever each to the neutral position.
• Apply the parking brakes and put stoppers (chocks) both before and behind the tires.
PRECAUTIONS DURING PERIODIC MAINTENANCE WORK

• 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 oil, or grease. There is danger that it may catch fire.
• Wear adequate working clothes and protective equipment (hard hat, safety shoes, goggles and gloves).
• 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.
• Before starting the inspection and maintenance work, disconnect the cable from the battery negative (-)
terminal.
• 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 finishing repair work, perform a test drive of the lift truck.
• 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.
PERIODIC INSPECTION OF CRITICAL REPLACEMENT PARTS

Replace critical safety parts with a new one periodically even if no defect is found. Parts tend to deteriorate as time
goes by, and can cause fire or 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.
0-19
USE OF PROPER TOOLS AND EQUIPMENT

Always use tools that are suited for inspection and maintenance. It is extremely dangerous to use broken tools or
tools designed for another purpose.
BE CAREFUL OF BOILING ENGINE COOLING WATER

• 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 as 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 engine and radiator to cool down before checking.
BE CAREFUL OF HIGH PRESSURE AND HIGH TEMPERATURE

HYDRAULIC 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 as hot oil may spurt out and cause burns.
• Wait for the truck temperature to go down before carrying out the
inspection and maintenance work.
• Do not forget that the work equipment circuits are always under
pressure. 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.
• If you are hit by a jet of high-pressure oil, consult a doctor
immediately.
BE CAREFUL OF THE ROTATING COOLING FAN AND BELT

• It is extremely dangerous if part of your body or a tool in your
hand gets caught up in the rotating fan or fan belt. Never touch
them in rotation.
• When inspecting rotating parts, do so only after the engine
comes to a stop.
• When inspecting the areas around rotating parts, do not allow
anything to come close which may get caught.
0-20
AVOID THE DANGER OF GETTING CAUGHT UP OR FALLING

OFF
• 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.
INSPECTION AND INFLATION OF 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, resulting in 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, so
exercise caution when handling tires.
• 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 TIRES
• Disassembly and assembly of tires should be carried out by a
qualified tire dealer.
• The tire inflation pressure is extremely high, so caution is
needed when handling tires.
• When removing a tire, do so only after the internal air is
released. Loosen hub nut (1) to remove the tire from the chassis.
If rim nuts (2) are installed, never loosen them because it is very
dangerous to do so.
• After replacing the tires, make a trial run to make sure that there
are no loose hub nuts. If the tightening torque is not sufficient, further tighten the hub nuts to the specified
torque.
0-21
JACKING-UP THE LIFT TRUCK FOR INSPECTION AND

REPLACEMENT OF 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 coming down.
• Put a tire stopper behind the tires in contact with the floor so that
the lift truck will not move freely.
SAFE HANDLING OF BATTERIES

• Battery electrolyte contains sulfuric acid, and can quickly burn the skin and eat holes in clothing. If you spill
battery electrolyte on yourself, immediately shed the clothes, flush the part with a large quantity of tap water and
then consult a doctor.
• Should battery electrolyte get into your eyes, flush them
immediately with fresh tap water for 10 to 15 minutes and then
consult a doctor at once.
• Should you drink battery electrolyte by accident, either drink a
large quantity of water or milk mixed with beaten egg white or
salad oil, and then consult a doctor at once.
• Be sure to wear goggles, safety gloves and rubber-soled shoes
at the time of battery maintenance.
• Do not smoke or create any spark near the battery. Batteries
generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE,
and is easily ignited with a small spark or flame.
• When inspecting or handling the battery, do so only after turning the engine starting switch key to the OFF
position and stopping the engine.
• When disconnecting the battery cables, disconnect the cable of the negative (-) terminal first. Conversely, when
connecting them again, connect the cable of 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 connecting the disconnected battery cables again, be sure which is the positive (+) terminal and which is
the negative (-) terminal in order to avoid improper connection.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps tightened.
• Do not put a metallic tool or plate on the battery terminals by accident. There is danger that such a metallic
object could cause short-circuiting leading to a fire.
PRECAUTIONS WHEN CHARGING BATTERIES

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.
• Before charging the battery, check that the battery electrolyte level stays within the specified range. If the
electrolyte is found insufficient, add distilled or purified water without fail.
• Carry out the charging operation in a well-ventilated place.
• Do not smoke or allow any flame or ignition source.
• Start to charge the battery when the battery electrolyte temperature is below 35ºC (95ºF). If the electrolyte
temperature is above 50ºC (122ºF), wait until it goes below 35ºC (95ºF).
• When using a battery charger to charge the battery, take the battery caps off.
0-22
PRECAUTIONS WHEN USING BOOSTER (JUMPER) 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.
• Stop the engine before connecting the cables.
• Be extremely careful not to let the cables get caught in the fan or fan belt.
• Ensure that the cables are hooked up correctly - positive-to-positive and negative-to-negative. Never let the
positive (+) and negative (-) terminals contact each other.
JUMP- STARTING THE ENGINE IS PROHIBITED.

Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and operate
unexpectedly.
SAFE HANDLING OF BRAKE OIL

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.
SAFE HANDLING OF ANTI-FREEZE

• 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.
SAFE HANDLING OF WASTES FROM LIFT TRUCK

Obey appropriate laws and regulations when disposing of harmful
objects such as oil, filters, and batteries.
PRECAUTIONS FOR WASHING LIFT TRUCK WITH WATER

• If water gets into the electrical system (controller, sensor,
connectors, etc.), there is the hazard that it will cause
malfunctions or operational failure. Do not wash the electrical
system with water or high-pressure steam.
• For more details on the washing method, see “LIFT TRUCK
WASHING PROCEDURE” on page 3-35.
0-23
HOISTING LIFT TRUCK

• Never lift the truck by the overhead guard.
If the truck has to be lifted frequently, it is necessary to install
special lifting equipment, so please contact your Hamech
Forklift dealer.
• 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.
• Never go under the lifted truck.
• If the specified lifting point is the counterweight, check that the
counterweight 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.
• When using the hooks on the counterweight to hoist the lift truck,
check beforehand that the counterweight mounting bolts are
tightened to the specified torque and that there is no abnormality
on the hooks.
0-24
TOWING
TOWING
HOW TO MOVE A DISABLED LIFT TRUCK

Use extra care when towing a lift truck if there is a problem with any the following;
a. Brakes do not operate correctly.
b. Steering does not operate correctly.
c. Tires are damaged.
d. Traction conditions are poor.
e. The lift truck must be moved on a steep grade.
If the steering pump motor does not operate, steering control of the lift truck can be slow. This can make the control
of the lift truck difficult. If there is no power, there is no power steering.
DO NOT tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to
slide. Steep grades will require additional brake force to stop the lift truck.
Never carry a disabled lift truck unless the lift truck MUST be moved and cannot be towed. The lift truck used to
carry the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck.
The capacity must be for a load center equal to half the width of the disabled lift truck. See the nameplate of the
approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of the
disabled lift truck on the forks and be careful not to the damage the under side of the lift truck.
HOW TO TOW THE LIFT TRUCK

1. The towed lift truck must have an operator.
2. Tow the lift truck slowly.
3. Raise the carriage and mast channels and secure from moving.
4. If another lift truck is used tow the disabled lift truck, that lift truck must have an equal or larger capacity than
the disabled lift truck. Install an approximate half-capacity load on the forks of the lift truck that is being used to
tow the disabled lift truck. This half-capacity load will increase the traction of the lift truck. Keep the load as low
as possible.
5. Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks.
0-25
STRUCTURE AND STABILITY OF THE LIFT TRUCK

To operate the lift truck safely, it is important to understand the structure and stability of the lift truck.
This section will educate the operator in methods to prevent tipping-over the lift truck.
STRUCTURE OF LIFT TRUCK

Forklift trucks basically consist of a lifting mechanism (fork and
mast) and a main body (vehicle). The front wheels act as a fulcrum
and the center of gravity of the lift truck and that of the load are kept
in balance. The relationship between the positions of these two
centers of gravity plays a very important role for the safety of the lift
truck.
CENTER OF GRAVITY OF LOAD

The loads carried by forklift trucks come in various shapes from
boxes to planks and long objects. To judge the stability of the lift
truck, it is important to distinguish the position of the center of
gravity for loads of various shapes.
CENTER OF GRAVITY AND STABILITY

The stability of the lift truck is determined by the position of a
combined center of gravity resulting from combining the centers of
gravity of the lift truck and the load. When the lift truck is carrying no
load, the center of gravity of the lift truck remains unchanged. On
the other hand, when it is carrying a load, the center of gravity of the
lift truck shifts to a combined center of gravity from the centers of
gravity of both the lift truck and the load. The position of the center
of gravity of a load changes as the mast is tilted back or forth, or it is
raised or lowered. The position of the combined center of gravity
also changes depending on the following factors.
• Size, weight, shape of load
• Lifting height
• Tilting angle of mast
• Inflation pressure of tires
• Acceleration, deceleration, turning radius
• Condition of road surface, angle of road
• Type of attachments
0-26
STABLE RANGE OF CENTER OF GRAVITY

For the lift truck to remain stable, the combined center of gravity of
the lift truck must come within a stable range of the center of gravity,
i.e. a triangle formed by three points of the right and left front wheels
in contact with the floor and the center of the rear axle.
When a position of the combined center of gravity shifts beyond the
front axle, the lift truck will tip over in the forward direction with the
front wheels acting as a fulcrum. On the other hand, when a position
of the combined center of gravity shifts outside of a stable range of
the center of gravity, the lift truck will overturn in the direction of
shifting.
ACTUAL CAPACITY
The horizontal distance from the position of the center of gravity of a
load on the fork to the upright load backrest of the fork is called a
load center.
Actual capacity means the maximum weight of a load that can be
loaded at a certain load center.
A load capacity chart is given in the name plate. The chart shows
the relationship between the actual capacity and a load center.
As a load center shifts toward the fork tips, so does the position of
the combined center of gravity, too. Therefore, the load has to be
decreased accordingly in the actual operation.
When the lift truck is equipped with an attachment, or when the mast is raised high, the actual capacity is reduced.
Take this fact into consideration in such a case.
LOAD CAPACITY CHART

In the load capacity chart, capacity is shown in relation to load center.
Capacity values are determined according to each model on the
condition of the specifications shown on the plate.
Before proceeding to loading a load, make sure that the load center and
the load are well within the confines of capacity.
When the load is in a complex shape, pull the load closer to the load
backrest so that the heaviest portion of the load comes to the fork center.
Should a load be loaded beyond the confines of capacity, it would pose a serious danger to the lifting truck as the
rear wheels (for steering) are likely to lift off the ground, causing the operator to lose control of steering.
To make the things still worse, the lift truck will likely tip over while in operation. Therefore, always make sure that
the load is absolutely within the confines of capacity.
LOAD CENTER AND ACTUAL CAPACITY

An example nameplate is shown at right. During actual operations,
follow the instructions on a nameplate of the actual lift truck.
This example shows a nameplate for a lift truck with a mast of max.
fork height of 3.0 m (9.8 ft) and which is not equipped with any
attachment.
Capacity: 2,500 kg
When the load center is 500 mm (19.7 in)
(5500 lbs)
Capacity: 2,250 kg
When the load center is 600 mm (23.6 in)
(4950 lbs)
Capacity: 1,620 kg
When the load center is 1,000 mm (39.4 in)
(3564 lbs)
Even when the load center is shorter than 500 mm (19.7 in), the actual capacity is 2,500 kg (5500 lbs).
0-27
It is required to replace the present nameplate with a new one when the present nameplate is broken or has
become difficult to read. In that case, call your Hamech Lift Truck Dealer asking for a new replacement nameplate.
SPEED AND ACCELERATION

If a stationary object is not subjected to external force, it will remain stationary. In the same way, if a moving object
is not subjected to external force, it will continue to move at the same speed. This is called inertia.
Because of inertia, a force is applied towards the rear when the lift truck starts to move, and is applied towards the
front when the lift truck stops. If the brakes are applied suddenly, there is danger of a large force being applied
towards the front which may make the lift truck tip or the load to be expelled.
When the lift truck is turned, a centrifugal force is applied to the outside from the center of the turn.
This force pushes the lift truck to the outside and makes it tip. The range of stability to the left and right is
particularly small, so it is necessary to reduce speed when turning, in order to prevent the lift truck from tipping. If
the lift truck is traveling with a raised load, the position of the overall center of gravity is high, so the danger of
tipping to the front, left, or right becomes greater.
0-28
SAFETY LABELS
SAFETY LABELS
Keep safety and other labels clean. If a label comes off, stick it on again or replace with a new one.
Overhead guard
On dash to right On engine inside right
of steering column 8 Overhead guard
1 11 2 inside left
Right side 9
13 Inside rear
of bonnet
right stay
Outside both 5
outer masts
12 Outside rear
Rear outer 7 left stay
mast stay
3 Inside front
left stay
4
Outside both 10 Inside rear
front stays tire rims
6 Top of radiator shroud
Details and ordering information for labels are given in the following sections.
0-29
SAFETY LABELS
1. Jump start prohibited. Start the engine only after sitting down in the
operator's seat. Do not attempt to start the engine by short-circuit-
ing the engine starting circuit. Such an act may cause serious
bodily injury or fire.
2. Avoiding danger if lift truck overturns during operations.
Tip-over can occur even when unloaded. In case of

Don't risk injury or death. tip-over
Slow down before turning! Buckle seatbelt
Follow these
instructuions: Don't jump Hold on tight Brace feet Lean away WARNING
3EB-96-A5111
(a) (b) (c) (d) (e)
If the steering is operated suddenly during operations, there is danger that the lift truck may lose its balance
and tip over. To avoid this danger, always observe the following precautions strictly.
(a) Always wear your seat belt during operations.
(b) Never jump off the lift truck.
(c) Hold on tight to avoid falling out and having the lift truck fall on top of you.
(d) Brace yourself with both feet to support your body.
(e) Lean in the opposite direction from the direction in which the lift truck is tipping.
Items (b) through (e) are instructions for when the lift truck tips over.
3. Using the parking brake.
WARNING
• Pull parking brake to locked position and shut off power before
leaving seat.
• When parked with the power on, place high-low and forward-reverse
lever in neutral.
• If force required to engage brake is low (less than 44 lbs.), chock
wheels when parking truck and contact forklift dealer for service.
See manual for details.
3EB-96-A5821
0-30
SAFETY LABELS
4. Seating capacity – No passengers allowed.
5. Prohibit the operator from riding on the forks and lifting/lowering himself.
Never enter the area under the forks.
WARNING
3EB-96-A5920
0-31
SAFETY LABELS
6. Use caution to avoid getting hand caught.
7. Use caution to avoid getting hand caught.
WARNING
3EB-96-A5940
8. Caution before operating machine.
0-32
SAFETY LABELS
9. Warning for operation.
WARNING
SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS!
Before Operating
• Do not operate or repair truck unless trained and authorized. • Do not handle unstable loads or loosely stacked loads.
• Read and understand all warnings and instructions in manuals • Do not handle loads higher than load backrest.
and on truck before operating. • Space forks as far as load permits.
• Dealers have replacement manuals. • Be sure load is centered and forks are completely under load.
• Check truck before use. If truck is in need of repair, do not • Never tilt load with mast tilted forward.
operate until restored to safe condition. • Do not tilt forward when elevated except to pick
• Do not start truck if fuel is leaking or has leaked. up or deposit load.
• Use attachments for intended purpose only. • Travel load or lifting mechanism low and tilted back.
• Tipover can occur if operated improperly.
• Do not jump if truck begins to tipover.
While Operating Hold on firmly and lean away from point of impact.
• Operate truck only from operator's seat. Avoid being trapped between truck and ground.
• Sit firmly in the seat with good posture while driving.
Leaving the seat or sitting improperly for approximately 3 General Precautions
seconds may cause the drive system to disengage. • Allow no one to stand or pass under or near load or
Unintended truck movement like rolling on an incline may occur. lifting mechanism.
• Keep truck under control at all times. • Never place any part of body into mast structure, between
• Do not overload truck. Check capacity plate for load weight mast and truck or outside truck.
and load center. • Do not carry passengers on any part of truck.
• Avoid any sudden starts, stops, turn or change of direction. • Lift no one under any circumstances.
• Obey traffic safety rules. Yield right-of-way to pedestrians. • Do not operate without overhead guard and load backrest.
• Keep clear view of travel path. If load being carried blocks • Fill fuel or charge battery only in specified place.
forward view, travel with load trailing. • Stop engine when fueling and avoid open flame or sparks,
• Slow down and sound horn when vision is blocked. and provide adequate ventilation.
• Watch clearances, especially forks, mast, overhead guard and • Keep vent caps clear when charging battery.
tailswing area. • Disconnect battery during servicing.
• Slow down for turns and on uneven or slippery surfaces.
• Avoid running over loose objects.
• Never angle or turn on incline. After Operating
• Travel with load uphill when loaded. • Before getting off truck, shift F-R lever and high-low
• Travel with lifting mechanism downhill when empty. lever (clutch type) to neutral position, fully lower
• Secure dockboard or bridgeplate properly. lifting mechanism and pull parking lever securely.
• Do not exceed rated capacity. • Shut off power when leaving truck unattended.
• Use special care when operating on dockboard or bridgeplate. • Block wheels when parking on incline.
3EB-96-A6120
10. Warning for use of split rim (pneumatic tires only).
0-33
SAFETY LABELS
11. Replace overhead guard if damaged.
WARNING REPLACE IF DAMAGED!

This overhead guard offers reasonable protection to operator
from falling objects but cannot protect against every possible impact.
Impact test rating: 16000 foot pounds.
37B-1QT-A030
12. Tire pressure (pneumatic tires only).

Bar
7 7
37A-2BK-A020
13. Method of hoisting the lift truck. Never use the overhead guard to
lift the truck. 3EB-96-25520
14. Warning for handling LPG/FLAMMABLE GAS (on LP tank

bracket, not shown).
15. Maintenance schedule (front outside dashboard, not shown), P/N 3EB-96-A7110.
0-34
SAFETY LABEL ORDERING INFORMATION
SAFETY LABEL ORDERING INFORMATION

Use the chart below to order the safety labels described in the previous section.
LABEL# ORDER PART NO.
1 09842-A0481
2 3EB-96-A5111
3 3EB-96-A5821
4 3EB-96-A5910
5 3EB-96-A5920
6 3EB-96-A5930
7 3EB-96-A5940
8 3EB-96-A5960
9 3EB-96-A6120
10 3EB-96-A5970
11 37B-1QT-A030
12 37A-2BK-A020
13 3EB-96-25520
14 3EB-96-A5950
15 3EB-96-A7110
0-35
OPTIONAL EQUIPMENT
OPTIONAL EQUIPMENT
Various safety devices are available as options. If operating conditions demand it, please install these devices. The
devices listed below are only examples. Various other devices are also available. For details, please contact your
Hamech Lift truck Dealer.
REAR LAMP
Install this when carrying out operations at night which require the rear area to be lighted.
(The law demands that sufficient lighting be provided to ensure safety.)
HIGH LOAD BACKREST

This improves the support for high loads and improves the stability of the load.
WIDE FORK CARRIAGE

This improves the support for wide load and improves the stability.
AUDIBLE SPEED ALARM

When the lift truck exceeds the preset speed, a buzzer sounds to warn the operator.
WARNING LAMPS
The following warning lamps may be added to the instrument panel.
• Battery electrolyte level warning lamp
• Air cleaner element clogging warning lamp
• Radiator cooling water level warning lamp
0-36
GENERAL AND SPECIFICATIONS
GENERAL AND SPECIFICATIONS
10. GENERAL AND SPECIFICATIONS
SPECIFICATIONS.......................................................................................................... 10-3
PERIODIC REPLACEMENT OF CONSUMABLE PARTS ........................................... 10-15
STANDARD TIGHTENING TORQUE FOR BOLTS ..................................................... 10-16
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS........................................... 10-17
10-1
SPECIFICATIONS
SPECIFICATIONS
TRUCK DATA – 2-TON PNEUMATIC TIRE LIFT TRUCKS (OUTDOOR)
Manufacturer’s Designation Unit G20T-16 D20T-16 G20HT-16
GENERAL
Power Type Gasoline Diesel Gasoline
Operation Type Sit Down Sit Down Sit Down
Capacity@24 in. (600 mm) Load Center* lbs. (kg) 4,000 (1,810) 4,000 (1,810) 4,000 (1,810)
Load Distance: Center Axle to Fork Face in. (mm) 17.9 (455) 17.9 (455) 17.9 (455)
Wheelbase in. (mm) 65.0 (1,650) 65.0 (1,650) 65.0 (1,650)
WEIGHT
Service Weight (inc. 2-Stage STD Mast/Forks lbs. (kg) 7,180 (3,255) 7,290 (3,310) 7,180 (3,255)
Axle Loading - LOADED lbs. (kg) Fr 9,880 (4,480) Fr 9.980 (4,485) Fr 9,880 (4,480)
Axle Loading - LOADED lbs. (kg) Rr 1,300 (590) Rr 1,410 (640) Rr 1,300 (590)
Axle Loading - UNLOADED lbs. (kg) Fr 3,270 (1,485) Fr 3,280 (1,490) Fr 3,270 (1,485)
Axle Loading - UNLOADED lbs. (kg) Rr 3,900 (1,770) Rr 4,010 (1,820) Rr 3,900 (1,770)
TIRES
Tire Type Pneumatic Pneumatic Pneumatic
Tire Size-Front 7.00-12-12PR (I) 7.00-12-12PR (I) 7.00-12-12PR (I)
Tire Size-Rear 6.00-09-10PR (I) 6.00-09-10PR (I) 6.00-09-10PR (I)
Number of Wheels-Front/Rear += Driven 2x/2 2x/2 2x/2
38.0 (966)/37.8 38.0 (966)/37.8 38.0 (966)/37.8
Tread (Center of Tires)-Front/Rear in. (mm)
(960) (960) (960)
DIMENSIONS
Tilting Angle, Forward/Backward ° 6/12 6/12 6/12
Mast Height-Lowered-2-Stage Std. Mast ** in. (mm) 85.4 (2,170) 85.4 (2,170) 85.4 (2,170)
Mast Height-Extended-2-Stage Mast ** in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Height Overhead Guard in. (mm) 83.1 (2,110) 83.1 (2,110) 83.1 (2,110)
Length with Std. Forks in. (mm) 141.5 (3,595) 141.5 (3,595) 141.5 (3,595)
Length to Fork Face in. (mm) 99.4 (2,525) 99.4 (2,525) 99.4 (2,525)
Overall Width at Drive Tires (Single) in. (mm) 45.3 (1,150) 45.3 (1,150) 45.3 (1,150)
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42 (40+100+1,070)
Carriage Width/ITA Class in. (mm) 40.9 (1,040)/II 40.9 (1,040)/II 40.9 (1,040)/II
Ground Clearance under Mast in. (mm) 5.0 (127) 5.0 (127) 5.0 (127)
Ground Clearance-Center of Wheelbase in. (mm) 6.2 (158) 6.2 (158) 6.2 (158)
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 101.6 (2,580) 101.6 (2,580) 101.6 (2,580)
Turning Radius-Outside in. (mm) 86.2 (2,190) 86.2 (2,190) 86.2 (2,190)
PERFORMANCE
Travel Speed, Forward-Loaded (1st/2nd) mph (k/hr.) 11.2 (18.0) 11.5 (18.5) 11.2 (18.0)
Travel Speed, Forward-Unloaded (1st/2nd) mph (k/hr.) 11.8 (19.0) 11.8 (19.0) 11.8 (19.0)
Lifting Speed-Loaded fpm (mm/s) 120.0 (610) 124.0 (630) 120.0 (610)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 130.0 (660) 124.0 (630)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Maximum Drawbar Pull-Loaded lbs/f (kN) 3,960 (17.6) 4,072 (18.1) 4,720 (21.0)
10-3
SPECIFICATIONS
Manufacturer’s Designation Unit G20T-16 D20T-16 G20HT-16

Maximum Gradeability-Loaded % 32 36 40
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
Steering Type FHPS FHPS FHPS
DRIVE
Battery Voltage/Capacity (5 hour rating) V/Ah 12/33 12/64 12/33
Engine Model K21 4D94LE K25
Rated Output (SAE Gross) HP (kW)@rpm 56.0 (41)@2,700 65.0 (48)@2,450 60.0 (44)@2,700
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 119 (160)@1,600 141 (191)@1,800 142 (193)@1,600
No. of Cylinders/Displacement cu. in. (cm3 ) 4/126 (2,065) 4/187 (3,062) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58)
OTHER
Relief Pressure-Maximum psi (bar) 2,630 (181) 2,630 (181) 2,630 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34) 8.98 (34) 8.98 (34)
Transmission PowerShift PowerShift PowerShift
NOTE: Most values shown in this publication are rounded. Therefore, direct conversion between metric and English or
Imperial may be slightly different than displayed in this table. The performance of the machines is affected by the con-
dition of the vehicle and how it is equipped as well as the nature and condition of the operating area. If these specifica-
tions are critical or if your needs exceed the specifications shown here, discuss the proposed application with your
authorized dealer.
* Optional masts, attachments, longer load dimensions and higher lifting heights may result in derating of the capacity.
Contact your authorized dealer.
** Other mast heights available. Contact your authorized dealer.
10-4
SPECIFICATIONS
TRUCK DATA – 2.5/2.8-TON PNEUMATIC TIRE LIFT TRUCKS (OUTDOOR)

Manufacturer’s Designation Unit G25T-16 D25T-16 G25HT-16 G28HT-16
GENERAL
Power Type Gasoline Diesel Gasoline Gasoline
Operation Type Sit Down Sit Down Sit Down Sit Down
Capacity@24 in. (600 mm) Load
lbs. (kg) 5,000 (2,267) 5,000 (2,267) 5,000 (2,267) 5,500 (2,495)
Center*
Load Distance: Center Axle to Front
in. (mm) 17.9 (455) 17.9 (455) 17.9 (455) 19.1 (485)
Face
Wheelbase in. (mm) 65.0 (1,650) 65.0 (1,650) 65.0 (1,650) 66.9 (1,700)
WEIGHT
Service Weight (inc. 2-Stage STD
lbs. (kg) 7,941 (3,605) 8,060 (3,660) 7,941 (3,605) 8,888 (4,035)
Mast/Forks
Axle Loading - LOADED lbs. (kg) Fr 11,360 (5,155) Fr 11,440 (5,195) Fr 11,360 (5,155) 12,590 (5,710)
Axle Loading - LOADED lbs. (kg) Rr 1,590 (720) Rr 1,620 (735) Rr 1,590 (720) 1,810 (820)
Axle Loading - UNLOADED lbs. (kg) Fr 3,110 (1,410) Fr 3,190 (1,450) Fr 3,110 (1,410) 3,510 (1,590)
Axle Loading - UN LOADED lbs. (kg) Rr 4,840 (2,195) Rr 4,870 (2,210) Rr 4,840 (2,195) 5,390 (2,445)
TIRES
Tire Type Pneumatic Pneumatic Pneumatic Pneumatic
Tire Size-Front 7.00-12-12PR (I) 7.00-12-12PR (I) 7.00-12-12PR (I) 28+9-15-12PR (I)
Tire Size-Rear 6.00-09-10PR (I) 6.00-09-10PR (I) 6.00-09-10PR (I) 6.50-10-10PR
Number of Wheels-Front/Rear += Driven 2x/2 2x/2 2x/2 2x/2
40.4 (1,025)/38.0
Tread (Center of Tires)-Front/Rear in. (mm) 38.0 (966)/37.8 (960)
(965)
DIMENSIONS
Tilting Angle, 2-Stage Masts, Forward/
° 6/12 6/12 6/12 6/12
Backward
Mast Height-Lowered-2-Stage Std.
in. (mm) 85.4 (2,170) 85.4 (2,170) 85.4 (2,170) 85.0 (2,160)
Mast
Mast Height-Extended-2-Stage Mast† in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Height Overhead Guard in. (mm) 83.1 (2,110) 83.1 (2,110) 83.1 (2,110) 83.9 (2,130)
Length to Fork Face in. (mm) 102.4 (2,600) 102.4 (2,600) 102.4 (2,600) 104.3 (2,650)
Overall Width at Drive Tires (Single) in. (mm) 45.3 (1,150) 45.3 (1,150) 45.3 (1,150) 48.6 (1,1235)
2+4.9+42
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42.0 (40+100+1,070)
(50+125+1,070)
Carriage Width/ITA Class in. (mm) 40.9 (1,040)/II 40.9 (1,040)/II 40.9 (1,040)/II 41.0 (1,041)/II
Ground Clearance under Mast in. (mm) 5.0 (127) 5.0 (127) 5.0 (127) 7.3 (186)
Ground Clearance-Center of
in. (mm) 6.2 (158) 6.2 (158) 6.2 (158) 5.0 (127)
Wheelbase
Right Angle Stacking Aisle (2-Stage
in. (mm) 106.5 (2,705) 106.5 (2,705) 106.5 (2,705) 110.1 (2,796)
Mast)
Turning Radius-Outside in. (mm) 88.2 (2,240) 88.2 (2,240) 88.2 (2,240) 90.9 (2,310)
PERFORMANCE
Travel Speed, Forward-Loaded (1st/
mph (k/hr.) 11.2 (18.0) 11.5 (18.5) 11.2 (18.0) 11.5 (18.5)
2nd)
Travel Speed, Forward-Unloaded (1st/
mph (k/hr.) 11.8 (19.0) 11.8 (19.0) 12.1 (19.5) 12.1 (19.5)
2nd)
10-5
SPECIFICATIONS
Manufacturer’s Designation Unit G25T-16 D25T-16 G25HT-16 G28HT-16

Lifting Speed-Loaded fpm (mm/s) 120.0 (610) 124.0 (630) 120.0 (610) 112 (570)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 130.0 (660) 124.0 (630) 124 (630)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98 (500)
Maximum Drawbar Pull-Loaded lbs/f (kN) 3,960 (17.6) 4,072 (18.1) 4,720 (21.0) 4,630 (20.6)
Maximum Gradeability-Loaded % 27 31 34 30
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/ Hand/ Hand/
Parking Brake-Operation/Control Hand/Mechanical
Mechanical Mechanical Mechanical
Steering Type FHPS FHPS FHPS FHPS
DRIVE
Battery Voltage/Capacity (20 hour
V/Ah 12/33 12/64 12/33 12/100
rating)
Engine Model K21 4D94LE K25 K25
Rated Output (SAE Gross) HP (kW)@rpm 56.0 (41)@2,700 65.0 (48)@2,450 60.0 (44)@2,700 60.0 (44)@2,700
lb.ft 141 141
Maximum Torque (SAE Gross) 119 (160)@1,600 142 (193)@1600
(Nm)@rpm (191)@1,600 (191)@1,800
No. of Cylinders/Displacement cu. in. (cm3 ) 4/126 (2,065) 4/187 (3,052) 4/152 (2,488) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58) 15.3 (58)
OTHER
Relief Pressure-Maximum psi (bar) 2,650 (181) 2,650 (181) 2,650 (181) 2,650 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34) 8.98 (34) 8.98 (34) 8.98 (34)
Transmission PowerShift PowerShift PowerShift PowerShift
authorized dealer.
10-6
SPECIFICATIONS

Manufacturer’s Designation D28T-16 G30HT-16 D30T-16
GENERAL
Power Type Gasoline Gasoline Diesel
Capacity@24 in. (600 mm) Load Center* lbs. (kg) 5,500 (2,495) 6,000 (2,722) 6,000 (2,722)
Load Distance from Center Axle (2-Stage) in. (mm) 19.1 (485) 19.1 (485) 19.1 (485)
Wheelbase in. (mm) 66.9 (1,700) 66.9 (1,700) 66.9 (1,700)
WEIGHT
Axle Loading - LOADED lbs. (kg) Fr 12,640 (5,740) Fr 13,510 (6,130) Fr 13,590 (6,170)
Axle Loading - LOADED lbs. (kg) Rr 1,770 (805) Rr 1,910 (865) Rr 1,890 (8600)
Axle Loading - UN LOADED lbs. (kg) Rr 5,350 (2,430) Rr 5,810 (2,635) Rr 5,790 (2,630)
TIRES
Tire Type Pneumatic Pneumatic Pneumatic
Tire Size-Front 28+9-15-12PR (I) 28+9-15-12PR (I) 28+9-15-12PR (I)
Tire Size-Rear 6.50-10-10PR 6.50-10-10PR 6.50-10-10PR
Tread (Center of Tires)-Front/Rear in. (mm) 40.4 (1,025)/38.0 (965)
DIMENSIONS
Tilting Angle, 2-Stage (FV) Masts, Forward/Backward ° 6/12 6/12 6/12
Mast Height-Lowered-2-Stage Mast in. (mm) 85.5 (2,160) 85.5 (2,160) 85.5 (2,160)
Mast Height-Extended-2-Stage Mast in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Maximum Fork Height-2-Stage STD Mast** in. (mm) 128.0 (3,250) 128.0 (3,250) 128.0 (3,250)
Free Lift Height-2-Stage STD Mast in. (mm) 5.5 (140) 5.5 (140) 5.5 (140)
Length to Fork Face-2-Stage Mast in. (mm) 104.3 (2,705) 106.5 (2,705) 106.5 (2,705)
Overall Width at Drive Tires in. (mm) 48.6 (1,235) 48.6 (1,235) 48.6 (1,235)
Carriage Width/ITA Class in. (mm) 41.0 (1,040)/II 41.0 (1,040)/III 41.0 (1,040)/III
PERFORMANCE
12.1 (19.5)/11.2 11.2 (18.0)/12.1 11.8 (19.0)/12.1
Travel Speed, Forward-Loaded/Unloaded mph (k/hr.)
(18.0) (19.0) (19.5)
118 (600)/128 104 (530)/124 104 (530)/128
Lifting Speed-Loaded/Unloaded (2-Stage) fpm (mm/s)
(650) (630) (650)
Lowering Speed-Loaded/Unloaded (2-Stg) fpm (mm/s) 98 (500)/98 (500)
Maximum Gradeability-Loaded % 27 27 25
10-7
SPECIFICATIONS
Manufacturer’s Designation D28T-16 G30HT-16 D30T-16

DRIVE
Engine Model 4D94LE K25 4D94LE
Rated Output (SAE Gross) HP (kW)@rpm 65.0 (48)@2,450 60.0 (44)@2,700 65.0 (48)@2,450
No. of Cylinders/Displacement cu. in. (cm3) 4/187 (3,062) 4/152 (2,488) 4/187 (3,062)
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58)
OTHER
Transmission PowerShift Powershift
authorized dealer.
10-8
SPECIFICATIONS

Manufacturer’s Designation Unit G32HT-16 D32T-16 G35AHT-16 D35AT-16
GENERAL
Power Type Gasoline Diesel Gasoline Diesel
Capacity@24 in. (600 mm) Load Center * lbs. (kg) 6,500 (2,948) 6,500 (2,948) 7,000 (3,175) 7,000 (3,175)
Load Distance from Center Axle (2-Stage) in. (mm) 19.1 (485) 19.1 (485) 19.9 (505) 19.9 (505)
Wheelbase in. (mm) 66.9 (1,700) 66.9 (1,700) 66.9 (1,700) 66.9 (1,700)
WEIGHT
Service Weight (inc. 2-Stage STD Mast/
lbs. (kg) 9,791 (4,445) 9,930 (4,510) 10,793 (4,900) 10,970 (4,980)
Forks
Fr 14,200 Fr 14,380
Axle Loading - LOADED lbs. (kg) Fr 15,610 (7,080) Fr 15,700 (7,130)
(6,440) (6,530)
Axle Loading - LOADED lbs. (kg) Rr 2,110 (965) Rr 2,050 (930) Rr 2,200 (1,000) Rr 2,270 (1,030)
Axle Loading - UNLOADED lbs. (kg) Fr 3,480 (1,580) Fr 3,680 (1,670) Fr 3,970 (1,800) Fr 4,060 (1,845)
Axle Loading - UN LOADED lbs. (kg) Rr 6,320 (2,865) Rr 6,260 (2,840) Rr 6,830 (3,100) Rr 6,910 (3,135)
TIRES
Tire Type Pneumatic Pneumatic Pneumatic Pneumatic
28+9-15- 28+9-15-
Tire Size-Front 250+15+16PR(I) 250+15+16PR(I)
12PR(I) 12PR(I)
Tire Size-Rear 650+10+10PR 650+10+10PR 650+10+12PR 650+10+12PR
Tread (Center of Tires)-Front/Rear in. (mm) 40.4 (1,025)/38.0 (965) 41.7 (1,060)/38.0 (965)
DIMENSIONS
Tilting Angle, 2-Stage (FV) Masts, Forward/
° 6/12 6/12 6/12 6/12
Backward
Mast Height-Lowered-2-Stage Mast in. (mm) 88.6 (2,250) 88.6 (2,250) 89.2 (2,265) 89.2 (2,265)
Mast Height-Extended-2-Stage Mast in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Maximum Fork Height-2-Stage STD Mast
in. (mm) 128.0 (3,250) 128.0 (3,250) 132.3 (3,360) 132.3 (3,360)
**
Free Lift Height-2-Stage STD Mast in. (mm) 5.5 (140) 5.5 (140) 5.5 (140) 5.5 (140)
Length to Fork Face-2-Stage Mast in. (mm) 108.5 (2,755) 108.5 (2,755) 110.0 (2,795) 110.0 (2,795)
Overall Width at Drive Tires in. (mm) 48.6 (1,235) 48.6 (1,235) 50.8 (1,290) 50.8 (1,290)
Carriage Width/ITA Class in. (mm) 42.1 (1,070)/III 42.1 (1,070)/III 41.7 (1,060)/III 41.7 (1,060)/III
Ground Clearance-Center of Wheelbase in. (mm) 5.0 (127) 5.0 (127) 5.5 (140) 5.5 (140)
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 114.4 (2,906) 114.4 (2,906) 117.6 (2,987) 117.6 (2,987)
PERFORMANCE
10.9 (17.5)/11.5 11.2 (18.0)/11.8 10.9 (17.5)/11.5 11.2 (18.0)/11.5
Travel Speed, Forward-Loaded/Unloaded mph (k/hr.)
(18.5) (19.0) (18.5) (18.5)
104 (530)/114 98 (500)/112
Lifting Speed-Loaded/Unloaded (2-Stage) fpm (mm/s) 89 (450)/91 (460) 87 (440)/91(460)
(580) (570)
98 (500)/98 98 (500)/98
Lowering Speed-Loaded/Unloaded (2-Stg) fpm (mm/s) 79 (400)/79 (400) 79 (400)/79 (400)
(500) (500)
10-9
SPECIFICATIONS
Manufacturer’s Designation Unit G32HT-16 D32T-16 G35AHT-16 D35AT-16

Hand/ Hand/
Parking Brake-Operation/Control Hand/Mechanical
Mechanical Mechanical
DRIVE
Engine Model K25 4D94LE K25 4D94LE
60.0 65.0
Rated Output (SAE Gross) HP (kW)@rpm 60. (45)@2,950 65.0 (48)@2,450
(44)@2,700 (48)@2,450
lb.ft 142 141 142 141
Maximum Torque (SAE Gross)
(Nm)@rpm (193)@1,600 (191)@1,800 (193)@1,600 (191)@1,800
No. of Cylinders/Displacement cu. in. (cm3) 4/152 (2,488) 4/187 (3,062) 4/152 (2,488) 4/187 (3,062)
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58) 15.3 (58)
OTHER
Relief Pressure-Maximum psi (bar) 2,630 (181) 2,630 (181) 2,630 (181) 2,630 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34) 8.98 (34) 8.98 (34) 8.98 (34)
Transmission Powershift
authorized dealer.
10-10
SPECIFICATIONS
TRUCK DATA – 2.0/2.5-TON CUSHION TIRE LIFT TRUCKS (INDOOR)

Manufacturer’s Designation Unit G20ST-16 G20SHT-16 G25ST-16 G25SHT-16
GENERAL
Power Type Gasoline Gasoline Gasoline Gasoline
Capacity@24 in. (600 mm) Load
lbs. (kg) 4,000 (1,810) 4,000 (1,810) 5,000 (2,267) 5,000 (2,267)
Center*
Load Distance: Center Axle to Fork
in. (mm) 16.9 (430) 16.9 (430) 16.9 (430) 16.9 (430)
Face
Wheelbase in. (mm) 55.1 (1,400) 55.1 (1,400) 55.1 (1,400) 55.1 (1,400)
WEIGHT
Service Weight (inc. 2-Stage STD Mast/
lbs. (kg) 7,300 (3,310) 7,300 (3,310) 8,180 (3,710) 8,180 (3,710)
Forks
Fr 11,330
(5,140)
Axle Loading - LOADED lbs. (kg) Rr 1,480 (670) Rr 1,480 (670) Rr 1,850 (840) Rr 1,850 (840)
Axle Loading - UNLOADED lbs. (kg) Fr 2,820 (1,280) Fr 2,820 (1,280) Fr 2,600 (1,180) Fr 2,600 (1,180)
Axle Loading - UNLOADED lbs. (kg) Rr 4,480 (2,030) Rr 4,480 (2,030) Rr 5,580 (2,530) Rr 5,580 (2,530)
TIRES
Tire Type Cushion Cushion Cushion Cushion
Tire Size-Front 21+7+15 21+7+15 21+7+15 21+7+15
Tire Size-Rear 16.25+5+11.25 16.25+5+11.25 16.25+5+11.25 16.25+5+11.25
Number of Wheels-Front/Rear +=
2x/2 2x/2 2x/2 2x/2
Driven
34.6 (879)/35.4 34.6 (879)/35.4 34.6 (879)/35.4 34.6 (879)/35.4
(900) (900) (900) (900)
DIMENSIONS
Tilting Angle, Forward/Backward ° 6/8 6/8 6/8 6/8
Mast Height-Lowered-2-Stage Std.
in. (mm) 85.5 (2,170) 85.5 (2,170) 85.5 (2,170) 85.5 (2,170)
Mast **
Mast Height-Extended-2-Stage Mast ** in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Length with Std. Forks in. (mm) 132.9 (3,595) 132.9 (3,595) 135.4 (3,440) 135.4 (3,440)
Length to Fork Face in. (mm) 90.8 (2,305) 90.8 (2,305) 93.3 (2,370) 93.3 (2,370)
Overall Width at Drive Tires (Single) in. (mm) 42.1 (1,070) 42.1 (1,070) 42.1 (1,070) 42.1 (1,070)
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42 (40+100+1,070) 1.6+4+42 (40+100+1,070)
Carriage Width/ITA Class in. (mm) 37.0 (940)/II 37.0 (940)/II 37.0 (940)/II 37.0 (940)/II
Ground Clearance-Center of
in. (mm) 3.9 (100) 3.9 (100) 3.9 (100) 3.9 (100)
Wheelbase
Right Angle Stacking Aisle (2-Stage
in. (mm) 92.6 (2,355) 92.6 (2,355) 94.6 (2,405) 94.6 (2,405)
Mast)
PERFORMANCE
Travel Speed, Forward-Loaded (1st/
mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
2nd)
Travel Speed, Forward-Unloaded (1st/
mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
2nd)
10-11
SPECIFICATIONS
Manufacturer’s Designation Unit G20ST-16 G20SHT-16 G25ST-16 G25SHT-16

Lifting Speed-Loaded fpm (mm/s) 120.0 (610) 124.0 (630) 120.0 (610) 120.0 (610)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 124.0 (630) 124.0 (630) 124.0 (630)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98.0 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98.0 (500)
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/ Hand/
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical
Mechanical Mechanical
DRIVE
Engine Model K21 K25 K21 K25
56.0 56.0
Rated Output (SAE Gross) HP (kW)@rpm 60.0 (44)@2,700 60.0 (44)@2,700
(41)@2,700 (41)@2,700
119 119
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 142 (193)@1,600 142 (193)@1,600
(160)@1,600 (160)@1,600
No. of Cylinders/Displacement cu. in. (cm3) 4/126 (2,065) 4/152 (2,488) 4/126 (2,065) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4)
OTHER
Transmission PowerShift PowerShift PowerShift PowerShift
authorized dealer.
10-12
SPECIFICATIONS
TRUCK DATA – 2.8/3.0/3.2-TON CUSHION TIRE LIFT TRUCKS (INDOOR)

Manufacturer’s Designation Unit G28SHT-16 G30SHT-16 G32SHT-16
GENERAL
Power Type Gasoline Gasoline Gasoline
Capacity@24 in. (600 mm) Load Center * lbs. (kg) 5,500 (2,495) 6,000 (2,722) 6,500 (2,948)
Load Distance: Center Axle to Fork Face in. (mm) 17.3 (440) 17.3 (440) 17.3 (440)
Wheelbase in. (mm) 57.1 (1,450) 57.1 (1,450) 57.1 (1,450)
WEIGHT
Axle Loading - LOADED lbs. (kg) Rr 2,000 (905) Rr 2,180 (990) Rr 2,430 (1,100)
Axle Loading - UNLOADED lbs. (kg) Rr 6,020 (2,730) Rr 6,570 (2,980) Rr 7,180 (3,255)
TIRES
Tire Type Cushion Cushion Cushion
Tire Size-Front 21+8+15 21+8+15 21+8+15
Tire Size-Rear 16.25+6+11.25 16.25+6+11.25 16.25+6+11.25
35.2 (895)/34.7 35.2 (895)/34.7 35.2 (895)/34.7
(880) (880) (880)
DIMENSIONS
Tilting Angle, Forward/Backward ° 6/8 6/8 6/8
Mast Height-Lowered-2-Stage Std. Mast ** in. (mm) 85.5 (2,170) 86.5 (2,197) 85.6 (2,250)
Mast Height-Extended-2-Stage Mast ** in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Length with Std. Forks in. (mm) 136.6 (3,470) 137.8 (3,500) 139.2 (3,535)
Length to Fork Face in. (mm) 94.5 (2,400) 95.7 (2,430) 97.1 (2,465)
Overall Width at Drive Tires (Single) in. (mm) 43.3 (1,100) 43.3 (1,100) 43.3 (1,100)
1.6+4+42 2+4+42 2+4+42
Forks-Thickness+Width+Length in. (mm)
(40+100+1,070) (50+125+1,070) (50+125+1,070)
Carriage Width/ITA Class in. (mm) 37.0 (940)/II 37.0 (940)/III 37.0 (940)/III
PERFORMANCE
Travel Speed, Forward-Loaded (1st/2nd) mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
Travel Speed, Forward-Unloaded (1st/2nd) mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
Lifting Speed-Loaded fpm (mm/s) 112.0 (570) 104.0 (530) 104.0 (530)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 124.0 (630) 108.0 (550)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Maximum Gradeability-Loaded % 33 31 28.5
10-13
SPECIFICATIONS
Manufacturer’s Designation Unit G28SHT-16 G30SHT-16 G32SHT-16

DRIVE
Engine Model K25 K25 K25
Rated Output (SAE Gross) 60.0 (44)@2,700 60.0 (44)@2,700 60.0 (44)@2,700
No. of Cylinders/Displacement cu. in. (cm3) 4/152 (2,488) 4/152 (2,488) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4)
OTHER
Transmission PowerShift PowerShift PowerShift
authorized dealer.
Outline View
b2 b4 b3 b1
Wa
h3
h1
h2 h4
L2 L3
L1
10-14
PERIODIC REPLACEMENT OF CONSUMABLE PARTS
PERIODIC REPLACEMENT OF CONSUMABLE PARTS

For operation safety, never fail to perform periodic maintenance or perform periodic replacement of the
consumable parts listed in the following table.
These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of
wear at the time of periodic maintenance; therefore, even if no apparent wear is found, always replace with
new parts within the prescribed period of replacement (or earlier if trouble is found).
Note that periodic replacement has no relationship to warranty service.
Period of
No. Part name
replacement
1 Master cylinder and wheel cylinder cups, dust seals Every 1 year
2 Rubber parts of brake booster Every 1 year
3 Brake hose or tube Every 2 years
4 Reservoir tank and tube Every 2 years
5 Power steering hose Every 2 years
6 Stop lamp switch (Oil pressure type) Every 2 years
7 Fuel hose Every 2 years
8 Rubber parts of power steering Every 2 years
9 Lift chain Every 3 years
10 Load handing hoses Every 2 years
10-15
STANDARD TIGHTENING TORQUE FOR BOLTS
STANDARD TIGHTENING TORQUE

FOR BOLTS
For unspecified bolts and nuts, use the torques spec-
ified in this table.
Select a proper torque corresponding to the width
across flats (b) of bolts and nuts.
When replacing bolts and nuts, always use genuine
Hamech Lift Truck parts the same size as the previ-
ous items.
Thread diameter Width across Tightening Torque

of bolt (mm) flat (mm)
(a) (b) Nm Kgm lbft
6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.03
8 13 31.4 ± 2.9 3.2 ± 0.3 23.2 ± 2.1
10 17 65.7 ± 6.8 6.7 ± 0.7 48.5 ± 5.0
12 19 112 ± 9.8 11.5 ± 1.0 82.6 ± 7.2
14 22 177 ± 19 18.0 ± 2.0 131 ± 14
16 24 279 ± 29 28.5 ± 3 206 ± 21
18 27 383 ± 39 39 ± 3 282 ± 29
20 30 549 ± 58 56 ± 6 405 ± 43
22 32 745 ± 78 76 ± 8 549 ± 58
24 36 927 ± 98 94.5 ± 10 684 ± 72
27 41 1320 ± 140 135 ± 15 973 ± 100
30 46 1720 ± 190 175 ± 20 1270 ± 140
33 50 2210 ± 240 225 ± 25 1630 ± 180
36 55 2750 ± 290 280 ± 30 2030 ± 210
39 60 3280 ± 340 335 ± 35 2420 ± 250
10-16
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

Elbows, nipples and unions
Torque Units Nm kgm lb/ft
Width across flats B (mm) 22 30 36
Width D (mm) 19 22 30
Tightening torque 21.7 - 28.9 57.9 - 75.9 86.8 - 119 (117.7 -

ft/lb (Nm) (kgm) (29.4 - 39.2) (3 - 4) (78.5 - 103) (8 - 10.5) 161.8) (12 - 16.5)
Port size (inch) 3/4 - 16UNF 7/8 - 14UNF –
Tightening torqueNm {kgm} 68.6 - 73.6 {7 - 7.5} 78.5 - 83.3 {8 - 8.5} –
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
14.5 - 21.7 21.7 - 50.6 43.4 - 72.3 79.6 - 123 108 - 152
Tightening torque
(19.6 - 29.4) 23.5 - 68.6 58.8 - 98.1 108 - 167 147 - 206
ft/lb (Nm) (kgm)
(2 - 3) (3 - 7) (6 - 10) (11 - 17) (15 - 21)
10-17
NOTES:
TESTING AND ADJUSTING
TESTING AND ADJUSTING
20. TESTING & ADJUSTING
SERVICE DATA.............................................................................................................. 20-3

GASOLINE ENGINE ...................................................................................................... 20-9
DIESEL ENGINE...........................................................................................................20-11
AIR CLEANER ............................................................................................................. 20-12
ADJUSTMENT OF IGNITION TIMING......................................................................... 20-13
ADJUSTMENT OF FUEL INJECTION TIMING (4D94LE DIESEL ENGINE)............... 20-14
MEASUREMENT OF COMPRESSION PRESSURE................................................... 20-15
ADJUSTMENT OF VALVE CLEARANCE .................................................................... 20-16
TORQUING OF CYLINDER HEAD MOUNTING BOLTS............................................. 20-18
TORQFLOW TRANSMISSION CASE.......................................................................... 20-19
DIFFERENTIAL CASE ................................................................................................. 20-20
HYDRAULIC TANK ...................................................................................................... 20-21
MEASURE HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS.............................. 20-22
ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORQFLOW MODEL)............... 20-24
ADJUSTMENT OF ACCELERATOR PEDAL............................................................... 20-26
ADJUST PARKING BRAKE LEVER............................................................................. 20-28
WHEEL BRAKE ........................................................................................................... 20-29
BLEEDING AIR ............................................................................................................ 20-30
DESIGNATED FUEL AND LUBRICATING OIL............................................................ 20-34
20-1
SERVICE DATA
SERVICE DATA
MBX50 GASOLINE ENGINE LIFT TRUCK – PNEUMATIC TIRE
Component Inspection item Unit G20/25T-16 G20/25HT-16
Engine model — K21 K25
Idling engine speed rpm 750 - 900
Engine
Max. engine speed rpm 2900 - 3100 2720 - 2920
Compression PSI (kgf/cm2)/rpm 177.8 (12.5) /250 185 (13.0) /250
11 - 13 (0.43 - 0.51)
Cooling system Fan belt deflection mm (in)
[finger pressure: 98 N (10 kgf)]
Injection timing deg-BTDC — —
Fuel system Injection order — — —

Engine
Injection pressure PSI (kgf/cm2) — —
Valve Intake mm (in) 0.38 (0.015) [Warm]

Intake, exhaust system
clearance Exhaust mm (in) 0.38 (0.015) [Warm]
Distributor point gap mm (in) — —
Spark plug gap mm (in) 0.8 - 0.9 (0.031 - 0.035)
Electric system Spark plug type — FR2A-D
Ignition timing deg-BTDC/rpm 2/850 0/850
Firing order — 1-3-4-2
Tire inflation Front wheels 100 (7.0)

Tires
pressure PSI (kgf/cm2)
Rear wheels 100 (7.0)
Travel system
Tightening Front wheels 22 - 37 (30 - 50)

Hub (lug) nuts ft/lbs (kgfm)
torque Rear wheels 12 - 18 (16 - 25)

Rim mating nuts ft/lbs (kgfm)
torque Rear wheels 88 - 123 (9 - 12.5)
Steering wheel Play mm (in) 10 - 30 (0.4 - 1.2)
Clutch pedal Play mm (in) — —
Steering, Braking System
Play mm (in) 0 - 4 (0 - 0.158)

Inching pedal
Interconnected travel mm (in) 35 - 41 (1.38 - 1.61)
Play mm (in) 0 - 4 (0 - 0.158)
Brake pedal Pedal height when pedal is
mm (in) 62 - 82 (2.4 - 3.2)
depressed
Parking brake operating force lbf (kgf) 33 - 44 (15 - 20)*
Brake Tightening torque for back ft/lbs. (kgfm) 13 - 14.8 (18 - 20)
plate mounting bolts
1.58-inch fork: Min. 1.42 (36)
Loading Equipment
Forks Fork thickness (at base) in (mm) 1.75-inch fork: Min. 1.58 (40)
Chain Length over 17 links mm (in) 2 - 2.5 ton lift truck: Max. 330 (13.0)
Hydraulic system Relief pressure PSI (kgf/cm2) 2,630 (185)
* When a lift truck is equipped with power brakes, this value is 55 - 66 lbf (25 - 30 kgf).
20-3
SERVICE DATA
MBX50 GASOLINE ENGINE LIFT TRUCK – PNEUMATIC TIRE (CONT’D)

Component Inspection item Unit G28HT-16 G30HT-16
Engine Max. engine speed rpm 2720 - 2920
2
Compression PSI (kgf/cm )/ 185 (13.0)/250
rpm
11 - 13 (0.43 - 0.51)
Cooling system Fan belt deflection mm (in) [finger pressure: 98 N (10 kgf)]
Engine
Intake, exhaust Intake mm (in) 0.38 (0.015) [Warm]

Valve clearance
system Exhaust mm (in) 0.38 (0.015) [Warm]
Ignition timing deg-BTDC/rpm 0/850
Tire inflation Front wheels 100 (7.0)

Tires
pressure PSI (kgf/cm2)
Rear wheels 100 (7.0)
Travel system

Hub (lug) nuts ft/lbs (kgfm)
torque Rear wheels 12 - 18 (16 - 25)
Tightening Front wheels 14.8 - 22(20 - 30) —

Rim mating nuts ft/lbs (kgfm)
torque Rear wheels 6.6 - 9.2(9 - 12.5) —
Play mm (in) 0 - 4 (0 - 0.158)

Inching pedal
Play mm (in) 0 - 4 (0 - 0.158)
depressed mm (in) 62 - 82 (2.4 - 3.2)

Brake Tightening torque for back plate
ft/lbs. (kgfm) 13 - 14.8 (18 - 20)
mounting bolts
1.58-inch fork: Min.
1.42 (36) 1.8-inch fork: Min.
Loading Equipment
Forks Fork thickness (at base) in (mm) 1.75-inch fork: Min. 1.80 (45)
1.58 (40)
3 ton lift truck:
2 - 2.5 ton lift truck: Max. 550 (21.7)
Chain Length over 17 links mm (in) Max. 330 (13.0) 3.5 ton lift truck: Max.
440 (17.3)
20-4
SERVICE DATA
MBX50 GASOLINE ENGINE LIFT TRUCK – PNEUMATIC TIRE (CONT’D)

Component Inspection item Unit G32HT-16 G35AHT-16
Engine model — NISSAN K25 NISSAN K25
Idling speed rpm 750 - 900
Engine
Max. speed rpm 2720 - 2920
Compression 2 185 (13.0)/250

PSI (kgf/cm )/rpm
Cooling system Fan belt deflection mm (in) 11 - 13 (0.43 - 0.51)


Engine
Intake, exhaust Intake mm (in) 0.38 (0.015) [Warm]

system Valve clearance
Exhaust mm (in) 0.38 (0.015) [Warm]
Electric system Spark plug type — FR2A-D FR2A-D
Ignition timing deg-BTDC/rpm 0/850
Front wheels 2) 100 (7.0) 121 (8.5)

Tire inflation PSI (kgf/cm
Tires
pressure 2
Travel System
Rear wheels PSI (kgf/cm ) 100 (7.0) 128 (9.0)
Tightening Front wheels Nm (kgfm) 22 - 37 (30 - 50)

Hub (lug) nuts torque Rear wheels Nm (kgfm) 12 - 18 (16 - 25)
Tightening Front wheels Nm (kgfm) — —

Rim mating nuts torque Rear wheels Nm (kgfm) — —
Play mm (in) 0 - 4 (0 - 0.158)

Inching pedal
Interconnected travel mm (in) 35 - 41 (1.38 - 1.61) 40 - 46 (1.58 - 1.81)
Play mm (in) 0 - 4 (0 - 0.158)
depressed mm (in) 62 - 82 (2.4 - 3.2)

ft/lbs. (kgfm) 13 - 14.8 (18 - 20) 18.4 - 22.1 (25 - 30)
mounting bolts
Forks Fork thickness (at base) in (mm) 2-inch fork: Min. 1.80 (45)
Loading Equip.
Chain Length over 17 links mm (in) 3 ton lift truck: Max. 550 (21.7)
3.5 ton lift truck: Max. 440 (17.3)
Hydraulic
system
Relief pressure PSI (kgf/cm2) 2,630 (185)
20-5
SERVICE DATA
MBX50 GASOLINE ENGINE LIFT TRUCK – CUSHION TIRE

Component Inspection item Unit G20/25ST-16 G28SHT-16
Engine
Max. engine speed rpm 2900 - 3100 2720 - 2920
Compression 2 178 (12.5)/250 185 (13.0)/250

PSI (kgf/cm )/rpm


Engine
Valve Intake mm (in) 0.38 (0.015) [Warm]

Intake, exhaust system clearance Exhaust mm (in) 0.38 (0.015) [Warm]
Ignition timing deg-BTDC/rpm 2/850 0/850
Front wheels ft/lbs. (kgfm) 22 - 37 (30 - 50)
Wheels
Hub (lug) nuts Tightening

torque Rear wheels ft/lbs. (kgfm) N/A N/A

Play mm (in) 0 - 4 (0 - 0.158)

Inching pedal
Play mm (in) 0 - 4 (0 - 0.158)
depressed mm (in) 62 - 82 (2.4 - 3.2)

Brake Tightening torque for back
ft/lbs. (kgfm) 13.2 - 14.8 (18 - 20)
plate mounting bolts
1.58-inch fork: Min. 1.42 (36)
Loading Equip.
Forks Fork thickness (at base) in (mm)

1.75-inch fork: Min. 1.58 (40)
Chain Length over 17 links mm (in) 2 - 2.5 ton lift truck: Max. 330 (13.0)
20-6
SERVICE DATA
MBX50 GASOLINE ENGINE LIFT TRUCK – CUSHION TIRE (CONT’D)

Component Inspection item Unit G30/32SHT-16
Engine model — K25
Engine
Max. engine speed rpm 2720 - 2920
Compression 2 185 (13.0)/250

PSI (kgf/cm )/rpm

Injection timing deg-BTDC —
Fuel system Injection order — —

Engine
Injection pressure PSI (kgf/cm2) —
Intake mm (in) 0.38 (0.015) [Warm]

Intake, exhaust system Valve clearance
Exhaust mm (in) 0.38 (0.015) [Warm]
Distributor point gap mm (in) —
Ignition timing deg-BTDC /rpm 0/850
Front wheels 22 - 37 (30 - 50)
Travel System
Hub (lug) nuts Tightening ft/lbs. (kgfm)

torque Rear wheels N/A

Clutch pedal Play mm (in) —
Play mm (in) 0 - 4 (0 - 0.158)

Inching pedal
Play mm (in) 0 - 4 (0 - 0.158)
depressed mm (in) 62 - 82 (2.4 - 3.2)

ft/lbs. (kgfm) 13.2 - 14.8 (18 - 20)
mounting bolts
Forks Fork thickness (at base) mm (in) 2-inch fork: Min. 1.80 (45)
Loading Equip.
3.5 ton lift truck: Max. 440 (17.3)
20-7
SERVICE DATA
MBX50 DIESEL ENGINE LIFT TRUCK

Component Inspection item Unit ALL MODELS
Engine model — Hamech 4D94LE
Idling speed rpm 785 - 835
Engine proper
Max. speed rpm 2650 - 2750
Compression 2 426.7 (30)/250

PSI (kgf/cm )/rpm
Cooling system Fan belt deflection mm (in) 10 - 15 (0.39 - 0.59 in)

Injection timing deg-BTDC ATDC6
Engine
Fuel system Injection order — 1-3-4-2
Injection pressure PSI (kgf/cm2)/rpm 1,706.8 (120)
Intake, exhaust Intake mm (in) 0.2 (0.0079 in)[Cool]

system Valve clearance
Exhaust mm (in) 0.2 (0.0079 in)[Cool]
Distributor point gap mm (in) —
Spark plug gap mm (in) —
Electric system
Ignition timing deg-BTDC/rpm —
Firing order — —
Front wheels 2) 100 (7.0)

Tire inflation PSI (kgf/cm
Tires
pressure
Rear wheels PSI (kgf/cm2) 100 (7.0)
Travel System
Front wheels ft/lbs. (kgfm) 22.1 - 36.8 (30 - 50)

Hub nuts Tightening torque
Rear wheels ft/lbs. (kgfm) 11.8 - 18.4 (16 - 25)
Front wheels ft/lbs. (kgfm) 14.8 - 22.1(20 - 30)

Rim mating nuts Tightening torque [excluding 3-ton lift truck]
Rear wheels ft/lbs. (kgfm) 6.6 - 9.2 (9 - 12.5)
Clutch pedal Play mm (in) 0 - 4 (0 - 0.158)
Play mm (in) 0 - 4 (0 - 0.158)

Inching pedal
Play mm (in) 0 - 4 (0 - 0.158)
Brake pedal
Pedal height when pedal is depressed mm (in) 62 - 82 (2.4 - 3.2)
Parking brake operating force lbf (kgf) 33 - 44 (15 - 20)**
ft/lbs. (kgfm) 13.2 - 14.8 (18 - 20)
mounting bolts
1.58-inch fork: Min. 1.42 (36)
Loading Equipment
Forks Fork thickness (at base) mm (in) 1.75-inch fork: Min. 1.58 (40)
2-inch fork: Min. 1.80 (45)
2 - 2.5 ton lift truck: Max. 330 (13.0)
3.5 ton lift truck: Min. 440 (17.3)
* In case of D35AT, this value is 40 - 46 mm (1.6 - 1.8 in).

** In case of D35AT or any other lift truck equipped with power brakes, this value is 55 - 66 lbf (25 - 30 kgf).
20-8
GASOLINE ENGINE
GASOLINE ENGINE
Before beginning maintenance of the engine, stop the engine and wait until it cools down com-
pletely.
1. CHANGING ENGINE OIL

1) Removing the drain plug, drain the oil and tighten the plug again after draining.
2) Fill the engine oil up to the specified level.
3) Check the engine oil level with the oil level gauge.
Refill Engine Oil Level
K21 Engine 3.8 liters
K25 Engine 3.8 liters
2. REPLACING ENGINE OIL FILTER

1) Remove the cartridge with the filter wrench.
2) Clean the filter mounting area and apply clean engine oil to the threads, as well as the seal of the
new cartridge, before installation.
IMPORTANT
After installing the cartridge, start the engine and check to make sure that there is no oil leakage from the
filter mounting surface.
3. REPLACING THE FUEL FILTER
1) Loosen the nut to remove the cover and take the filter out.
2) Clean the dirt at the bottom, and drain the water.
3) Replace with a new filter.
IMPORTANT
• If any damage is found on the gasket of the cover, replace it with a new one.
• After replacement, check the hose fitting area for any fuel leakage.
20-9
GASOLINE ENGINE
4. INSPECTING THE SPARK PLUGS

1) Remove the spark plug with an appropriate
plug wrench.
2) Clean off any carbon stuck on the plug head
and the surrounding area.
3) Measure plug gap A as shown on the illus-
tration on the right with a plug gap gauge.
Plug gap A: 0.7 to 0.8 mm
(1) Good
(2) No good
(3) No good
Spark Plugs
NGK FR2A-D
20-10
DIESEL ENGINE
DIESEL ENGINE
4D94LE ENGINE
1. CHANGING ENGINE OIL
1) Drain the engine oil after removing the drain plug,
and then reinstall the plug and tighten.
2) Remove the oil level gauge (dipstick).
3) Refill with engine oil up to the specified level. Be
careful not to overfill.
4) Check oil level with the engine oil level gauge.
Refill Engine Oil Level
4D94LE Engine 7.5 liters
2. REPLACE ENGINE OIL FILTER

1) Remove the cartridge with a filter wrench.
2) Clean the filter mounting area and apply engine oil
on the threads as well as the seal of the new car-
tridge before installation.
IMPORTANT
After installation of the cartridge, start the engine and check the filter-mounting surface for any oil leakage.
3. DRAINING WATER FROM FUEL FILTER

1) Loosen the combination sensor plug (1) and drain the water, as well as any sediment, accumu-
lated at the bottom.
2) Use care as fuel may be mixed with water. Clean up any spillage.
4. REPLACEMENT OF FUEL FILTER

1) Remove the combination sensor plug (4) at the bottom of the cartridge.
2) Remove the cartridge (3) with a filter wrench.
3) Install the combination sensor plug to the new cartridge (3).
4) Fill the new cartridge with fuel and apply a thin layer of engine oil before installation.
5) Loosen the plug (2) and pump the knob (1) up and down until no more bubbles come out with the
fuel.
6) Tighten the plug (2).
20-11
AIR CLEANER
AIR CLEANER
Neither cleaning of the air cleaner nor replace-

ment of the element is allowed while the engine is
running.
Element
IMPORTANT
• Never remove the inner element (Diesel only).
• In case of severe working conditions or environ-
ments, clean or replace the element sooner than
regular maintenance intervals.
[Single Element Type]
CLEANING OF THE ELEMENT Element

1. Remove the element and inspect for condition
and cleanliness. It is no longer recommended
that air filter elements be blown clean with com-
pressed air. If the filter element is damaged or is
not sealing properly, replace with a new filter.
2. Replace inner filter elements on diesel engines
every third time that the outer element is
replaced.
INSPECTION
Visually check the element for damage.
Inner Element
REPLACEMENT OF ELEMENT
1. Remove the outer element from the air cleaner. [Double Element Type]
2. Do not remove the inner element (if equipped).
3. Cover the air connector with clean cloth or tape.
4. Clean the interior of the air cleaner and remove the cover from the air cleaner.
5. Put a new element into the air cleaner. Ensure that the new filter seats and seals properly.
6. Do not force the filter element into place with the housing cover. This will damage the filter and reduce
it’s sealing ability. Ensure the filter is properly seated before installing the cover.
20-12
ADJUSTMENT OF IGNITION TIMING
ADJUSTMENT OF IGNITION TIMING

EPA Model lift trucks are equipped with an Electronic Control Unit (ECU) that controls ignition timing. The
timing is not adjustable on EPA trucks designed for use in the United States.
Lift trucks destined for export are equipped with a standard distributor ignition system and the adjustment
of ignition timing can be performed as follows:
GASOLINE ENGINE (Export only)

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. Glow the timing light (3) and check to make sure
that the indicator and the timing mark stamped
on the crankshaft pulley and flywheel are cor-
rectly aligned.
5. If the timing is not in spec, turn the distributor (4)
to the right or the left for further adjustment.
6. Check that ignition timing advances quickly
when the engine is revved up.
20-13
ADJUSTMENT OF FUEL INJECTION TIMING (4D94LE DIESEL ENGINE)
ADJUSTMENT OF FUEL INJECTION TIMING (4D94LE DIESEL ENGINE)

INSPECTION AND ADJUSTMENT OF
FUEL INJECTION TIMING MARK
WHEN DISASSEMBLING AND ASSEMBLING

1. Match the injection pump with the A mark.
2. Match the top mark B with the ATDC 5 degrees.
3. Make sure that the plunger lift is 1 mm.
4. If the plunger lift is not 1 mm, adjust the angle of
the injection pump mounting.
INSPECTION
Implement the above mentioned items 2, 3 and 4 for
inspection.
20-14
MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF COMPRESSION PRESSURE

1. Warm up the engine to get the coolant tem-
perature at 167-185° F (75 - 85 ° C).
2. Stop the engine and remove all the spark
plugs on gasoline engines or the nozzle hold-
ers on diesel engines as well as the air
cleaner.
3. Disconnect the coil cord from the ignition coil
on the gasoline engine. Set the fuel control
lever to the non-injection position or discon-
nect the wiring of the fuel cut solenoid on die-
sel engines.
4. Fix the adaptor to the nozzle holder mounting
of the cylinder that is to be checked and
tighten to the specified torque on diesel
engines.
5. Install a compression gauge to the cylinder to
be checked.
6. For pneumatic governor, floor the accelerator
pedal and crank the engine with the starter
motor to get the maximum reading of the
gauge.
Take a measurement more than twice on

each engine to avoid measurement errors
and average the values.
Discharge battery may not give sufficient revolutions. Use fully charged battery.
CAUSES FOR INSUFFICIENT COMPRESSION

1. Poor adjustment of valve clearance
2. Pressure leakage from valve seat
3. Seize of valve stems
4. Defective or broken valve spring
5. Pressure leakage from cylinder head gasket
6. Sticking or breakage of piston rings
7. Wear of piston rings or cylinders
20-15
ADJUSTMENT OF VALVE CLEARANCE

1. Remove the cylinder head cover.
2. Turn the crankshaft to match the top mark A of
the crank pulley (1) and the pointer (2). Check to
make sure that the compression upper dead
center is attained with the No.1 cylinder and the
No.4 cylinder.
Upper dead center of the piston can be

checked under the state that both of intake
and exhaust valves are closed, which
means the cylinder that both the rocker
arms are being in free state is at the com-
pression upper dead center.
3. Adjust the clearance beginning with the cylinder

at the compression upper dead center.
When the No.1 cylinder is at the compres-

sion top dead center, adjust the valves
marked with the black circle for clearance
listed on the table and give a turn to the
crankshaft in the positive direction. Then,
adjust the remaining valves marked with the
white circle for clearance.
When the No.4 cylinder is at the compres-

sion top dead center, adjust the valves
marked with the white circle for clearance
and give a turn to the crankshaft in the posi-
tive direction. Then, adjust the remaining
valves marked with the black circle for clear-
ance.
4. Loosen the locknut (3) of the adjusting screw (4) and insert a specified thickness gauge (2) between
the valve stem (6) and the rocker arm (5) to allow the gauge to move smoothly and adjust the gap.
20-16
Then, tighten the locknut to secure the adjustment screw.
20-17
TORQUING OF CYLINDER HEAD MOUNTING BOLTS
TORQUING OF CYLINDER HEAD MOUNTING BOLTS

K21/K25 ENGINE
1. Put the steel plate side of the cylinder head gas-
ket on the cylinder block side. Then, set it on top
of the cylinder block.
2. Set the cylinder head in position, apply engine oil
to the cylinder bolts. Then, tighten in the order
shown in the diagram on the right (1 through 10)
to the specified tightening torque as follows:
torque
Cylinder Head Bolt:
1. 21.6 ft/lbs (29.4 Nm, 3.0 kgm) Tighten

2. 57.8 ft/lbs (78.5 Nm, 8.0 kgm) temporarily
3. 0 ft/lbs (0 Nm, 0 kgm) Loosen
4. 21.6 ft/lbs (29.4 Nm, 3.0 kgm)
Tighten
5. 54.2 - 61.4 ft/lbs
(73.5 - 83.4 Nm, 7.5 - 8.5 kgm) again
4D94LE ENGINE
1. Apply engine oil to the cylinder head mounting
bolts, coating evenly by hand.
2. Tighten twice in sequence as the diagram on the
right (1 through 18) as follows:
torque
Cylinder Head Bolt:

First Time: 43.4 ft/lbs (58.8 Nm, 6 kgm)
Second Time: 86.7 ft/lbs (117.6 Nm, 12 kgm)
20-18
TORQFLOW TRANSMISSION CASE
TORQFLOW TRANSMISSION CASE
The temperature of the oil is very high immediately after stopping operation of the truck. Be sure to
start inspection after cooling down completely.
INSPECTION OF OIL LEVEL

1. Open the floor plate to check the oil level with the Air breather
oil level gauge. for transmission
2. Add oil if necessary.
REPLACEMENT OF OIL, INSPECTION

AND CLEANING OF STRAINER
1. Remove the drain plug to drain the oil. Tighten
the drain plug after draining.
Oil level gauge Line filter
2. Remove the mounting bolt to take out the
strainer for cleaning with flushing oil.
3. After cleaning, blow dry compressed air from inside to outside of the strainer and install when com-
pletely dry.
If any damage or clogs are found on the strainer, replace it with a new one.
4. Refill the oil as specified.

5. Check the oil level after refilling.
Replacement Oil Level
First Speed 9.5 liters including torque

(F1/R1) Model converter
IMPORTANT
Be sure to always use Hamech genuine oil for the engine oil.
REPLACEMENT OF LINE FILTER Air breather for transmission

Air breather
1. Turn the line filter counterclockwise for removal.
for differential
2. Install a new line filter. When installing, check to
make sure that the seal of the line filter touches
the case fitting face and then tighten it by
another three-quarter turn.
Strainer Drain plug
20-19
DIFFERENTIAL CASE
DIFFERENTIAL CASE
INSPECTION OF OIL LEVEL
The temperature of the oil is very high immediately after stop operation of the truck. Be sure to
start inspection after it is cooled down completely.
Remove the oil level check plug to check that the oil is nearly up to the lower level of the plug-hole. Refill
the oil, if necessary.
REPLACEMENT OF OIL
1. Remove the oil filler plug and drain the oil through the drain plug.
2. After draining, tighten the drain plug and refill the oil as specified.
3. Check the oil level after refilling.
2.0 - 2.5 ton 6.34 qt. (6.0 liters)
3.0 - 3.5 ton 6.13 qt. (5.8 liters)
IMPORTANT
Be sure to always use Hamech genuine oil for the gear oil.
IMPORTANT
• The same oil is being used in the differential
case and the transmission case on clutch mod-
els.
• The TORQFLOW type truck requires inspection
and oil replacement of the TORQFLOW trans-
mission case in addition to the oil of the differen-
tial case.
Drain plug
Oil level check and
oil filling combination plug
20-20
HYDRAULIC TANK
HYDRAULIC TANK
REPLACEMENT OF HYDRAULIC OIL AND LINE FILTER, AND CLEANING OF
STRAINER AND INSIDE HYDRAULIC TANK
The temperature of the oil is very high immediately after stop operation of the truck. Be sure to
start inspection after cooling down completely.
1. Remove the drain plug located at the bottom of the hydraulic tank for draining. Then, uncover the
hydraulic tank and remove the strainer. Clean the strainer with flushing oil.
2. After cleaning inside hydraulic tank, install the
drain plug. Breather
3. After cleaning the strainer, blow dry compressed Cover
air from inside to outside of the strainer until it is
completely dry.
4. Remove the line filter and replace it with a new
one. Then, install the tank cover.
5. Refill the hydraulic oil through the breather hole.
Check the oil level with the oil level gauge.
8.98 gallons
2.0 - 3.5 ton
(34 liters)
Strainer
6. Start the engine and operate the mast, lifting and

tilting until stroke-end for several cycles so as to Line filter
bleed the air.
IMPORTANT
Always be sure to use Hamech genuine hydraulic oil.
Drain plug
20-21
MEASURE HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS
• Never allow anyone to stand or pass under the raised forks or the load.
• Keep your hands and legs away form the lifting mechanism including the mast stay and the
dashboard area, which will keep your hands and legs safe from harm or injury caught in the
mast. Always prepare a ladder or a stand that is strong enough to use for your inspection.
• Check to make sure that the hydraulic oil level is normal, not dirty and not mixed with any
other kind of oil.
• Park the truck on an even surface. The measurement must be carried out in front of a loading
platform strong enough to support the truck even if it should tip over to the front.
METHOD OF MEASUREMENT
1. Stop the lift truck 20 in. (500 mm) in front of the
platform. 1: Keep mast uprigh
2. Repeat lifting and tilting to set the hydraulic oil

temperature to about 122° F (50 °C).
3. Set the rated load on the forks and secure it to
the fork carriage.
4. Lift the forks about 60 in. (1,500 mm) and keep
H Approx.
the mast upright. 1,500 mm
Hydraulic Drift of Lift Cylinder

A Ruler
5. Wait for 3 minutes and place a ruler against the
piston rod of the lift cylinder. Then, make a mark
"A" on it.
6. Measure the hydraulic drift over the next 15 min-
utes.
Hydraulic Drift of 2.0 - 3.5 ton: within

Lift Cylinder For
2 in. (50 mm)
15 Minutes 2: Lift cylinder
Hydraulic Drift of Tilt Cylinder

7. Wait for 3 minutes and place a ruler against the piston rod of the tilt cylinder. Then, make a mark "B"
on it.
20-22
8. Measure the hydraulic drift over the next 15 min-

utes Ruler 3: Tilt cylinder
Hydraulic Drift of Tilt within 1.8 in.

Cylinder For 15 Minutes (45 mm)
20-23
ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORQFLOW MODEL)
Stop lamp switch

2
3
159 mm
1
Inching pedal
Brake pedal 137 mm
Adjust inching cable for play

of cable end to be 0 - 0.5 mm.
(do not pull the spool)
Cable end
0 - 0.5 mm
Spool
1. PROCEDURE FOR ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORQFLOW MODEL)

1) Brake pedal stroke
2 - 3.5 ton 2.56 ± 0.4 in. (65 ±10 mm)
If the brake pedal stroke is more than the standard, check the brake shoe for wear.
2) Adjust the height of the brake pedal with the stopper bolt (1) to make it approximately 5.4 in. (137
mm) from the floor plate.
20-24
3) Adjust the height of the inching pedal with the stopper bolt (2) to make it approximately 6.26 in.
(159 mm) from the floor plate.
4) Adjust the adjusting screw (3) so that the inching pedal can interconnect with the brake pedal with
the its stroke in the range of 1.4 - 1.6 in. (36 - 40 mm) accordingly.
2. PROCEDURE FOR ADJUSTMENT OF STOP LAMP SWITCH

Set measurement “C” in the range of 0.02 - 0.06 in. (0.5 - 1.5 mm) after adjusting brake pedal height.
20-25
ADJUSTMENT OF ACCELERATOR PEDAL

K21/K25 ENGINE MODEL
1. PROCEDURE FOR LO-IDLE POSITION ADJUSTMENT

1) Adjust voltage using Stopper Bolt “A” ensuring that the bolt does not contact the Spring Pin.
2) Use Turnbuckle to set pedal height at 5.19 in. (130 mm).
3) Adjust Stopper Bolt “A” to permit contact with Spring Pin, then return by more than 90° and secure
in place.
4) Check that the voltage is in the correct range as shown in the following table.
2. PROCEDURE FOR HI-IDLE POSITION ADJUSTMENT

Using Stopper Bolt “B”, adjust voltage to table values.
POSITION ACCELERATOR OUTPUT VOLTAGE

Measurement
Between GNDA - APS1 GNDA2 - APS2
points
Target 0.77V Target 0.38V
Released Pedal (Lo-Idle Position)
Range: 0.67-0.86V Range: 0.14-0.63V
Target 4.55V Target 2.28V
Full Pedal (Hi-Idle Position)
Range: 4.46-4.65V Range: 2.03-2.52V
20-26
4D94LE ENGINE MODEL

1
PROCEDURE FOR ADJUSTMENT OF ACCELERATOR PEDAL

1) Set the stopper bolt (1) temporarily with a height of 2.56 in. (65 mm).
2) After assembling the cable, adjust the outer casing mount of the cable to allow the pedal play
between .08 - .11 in. (2 - 3 mm).
3) Adjust the height of stopper bolt (1) again to allow engine full throttle when flooring the accelerator
pedal.
20-27
ADJUST PARKING BRAKE LEVER
ADJUST PARKING BRAKE LEVER
Before starting adjustment, check to make sure that both front and rear wheels of the forklift truck
have locked with stoppers respectively.
1. Release the parking brake by pushing the park-

ing brake lever (2) forward to release position (B)
while pressing the push button (1).
2. Turn adjustment bolt (3) and adjust the lever
control force at the initial extension of the cable
to be set as follows:
Standard brake: 33 - 44 lbf

(147 - 196N) {15 - 20 kgf}
Power brake: 55 - 66 lbf.
(245 - 294N) {25 - 30 kgf}
1
B
A
20-28
WHEEL BRAKE
WHEEL BRAKE
PROCEDURE FOR ADJUSTMENT OF BRAKE SHOE CLEARANCE
1. Release the parking brake while raising the wheels up off the ground.
2. Remove the rubber cap.
3. Turn gear (1) in direction (A) or toward the brake shoes repeatedly with a screwdriver until the brake
shoes touch the brake drum. Turning of each notch makes a clicking sound.
IMPORTANT
Turn the wheels by hands to feel braking effect.
4. Prepare two screwdrivers. The first screwdriver

should be used for gently pushing the lever (2)
and have it miss each gear notch. Be careful not
to push too strongly. The second one should be
used for turning the gear (1) toward direction (B)
counting by twenty-one (21) notches while the
first one is still engaged. It counts 30 notches for
one turning of the gear.
IMPORTANT
Since no clicks are made here, count the number of
notches watching through the hole of the rubber cap
(3) for carrying out the adjustment.
5. Install the rubber cap (3).

6. Turn the wheels by hand and check to make sure that there is no brake dragging.
IMPORTANT
The clearance between the brake shoe and brake drum can be adjusted approximately to 0.02 in.
(0.55 mm) (clearance of diameter) with this adjustment.
20-29
BLEEDING AIR
BLEEDING AIR
BRAKE PIPING
• Before starting to bleed air, adjust the brake shoe clearance to the specified .016 - .022 in. (0.40
- 0.56 mm).
• From time to time, refill the brake fluid to prevent the brake fluid in the reserve tank from emp-
tying while carrying out air bleeding. If air is drawn into the system from an empty reservoir
during bleeding, start the procedure over again keeping the brake fluid filled.
1. Remove the cap from the air bleed plug (1) of the
brake wheel cylinder. Install one end of a plastic
hose for air bleeding to the plug and put the
other end of the hose into a container of brake
fluid.
The color of the plastic hose should be

transparent.
2. If inspector is alone, connect a string or a wire to

the upper arm of brake pedal (2) and let the
other end of string or wire loose free in approxi-
mately 300 mm through the space between the
frame (3) and the dashboard (4).
3. Slowly pull out the string or the wire ¡ connected
with the brake pedal (2) arm from the front of the
forklift so as to compress the air inside the brake
piping and hold it as is.
If more than one person is present, one

inspector should press the brake pedal. 2
2
4. Loosen the air bleed plug (1) of the brake wheel cylinder approximately 3/4 turns to the left and
depress the brake pedal to bleed the air in the piping along with the brake fluid. Then, while holding
the pedal down, tighten the bleed plug (1) while bleeding the brake fluid.
In this stage, keep pulling the string or the wire for a while.
20-30
BLEEDING AIR
5. After tightening the bleed plug, release the brake pedal.
20-31
NOTES:
2
2
6. Repeat the step 3, 4, and 5 of the above until no

more bubbles come out of the hose.
7. After completing one side of brake adjustment,
carry out the other side adjustment with the
same steps.
8. Then, repeat air bleeding of the brake and check
again to make sure that no more air left in the b
brake piping.
a
9. Depress the brake pedal to check it for normal

response. Then, depress the brake pedal with
depressing force of 196 N or 20 kgf to measure
the pedal stroke (a). Check to make sure that the
pedal stroke (a) is within 2.17 - 2.95 in. (55 - 75
mm) when depressing the pedal.
Pedal Stroke
Pedal stroke (a) 2.17 - 2.95 in.
2 - 3.5 ton
when depressed (55 - 75 mm)
Play
Play (b) 0 - 0.16 in. (0 - 4 mm)
10. Remove the hose from the air bleed plug (1). Tighten again the both side of the air bleed plug and
install the cap.
torque
Air bleed plug: 4.3 - 6.5 ft/lbs. (5.9 - 8.8 Nm) {0.6 - 0.9 kgm}
11. Refill the brake fluid up to the MAX line (C) on the reserve tank (5) of upper master cylinder, which
shows the specified fluid level.
12. Remove the string or the wire connected to the brake pedal arm.
BLEEDING AIR
LIFT CYLINDER
Start the engine and run it at low idling.
1. Raise and lower the mast.
Try to stop lifting about 3.9 in. (100 mm) before reaching to the maximum lifting and lowering
height.
2. Repeat step 2 of the above four to five times.

3. Raise and lower the mast to the maximum lifting and lowering height.
4. Repeat step 4 of the above four to five times.
FUEL PIPING (Diesel Engine Lift Truck)

1. Loosen plug (1) and move the knob (2) up and
down until no more bubbles come out with the
fluid.
2. Tighten the plug (1) after completely bleeding the
air.
20-33
DESIGNATED FUEL AND LUBRICATING OIL

GASOLINE ENGINE LIFT TRUCKS
• Always make sure to use exclusively Hamech

genuine lubricating oil.
• Oil, grease and anti-freeze are available at
Hamech dealers.
• Never use the wrong type of brake fluid.
Ambient Temperature
Lubrication Point Type of Oil/Fluid -22 -4 14 32 50 68 86 104°F
-30 -20 -10 0 10 20 30 40°C
Engine Oil Pan SAE10W30SH

Engine Oil
TORQFLOW Transmission Case DEXRON III
Differential Case Gear Oil SAE90GL4
Hydraulic Tank Engine Oil ISO32
Fuel Tank Gasoline
Brake Reservoir
Brake Fluid SAE70R-1, SAE70R-3, DOT3
Clutch Reservoir
Greasing Points Lithium Grease NLGI No.2
Cooling System Coolant GLYCOL BASED
CAPACITY OF 2.0 - 3.5 TON LIFT TRUCKS

TORQFLOW
Engine Oil Pan Differential Case Hydraulic Tank
Transmission Case
1.6 gal (6 L)
K21/K25: 2.5 gal (9.5 L)
3.0-3.5 ton: 8.98 gal (34 L)
4 qt. (3.8 L) (Incl. T/C @ .82 gal (3.1 L)
1.53 gal (5.8 L)
Fuel Tank Brake Reservoir Cooling System
K21/K25 Engine:
15.3 gal (58 L) 5.07 oz. (0.15 L)
2.4 gal (9.1 L)
20-34
DIESEL ENGINE LIFT TRUCKS
• Never use fuel mixed with kerosene because

it may damage the fuel injection system.
• Always make sure to use exclusively Hamech
genuine lubrication oil.
• Oil, grease and anti-freeze are available at
Hamech dealers.
• Never use the wrong type of brake fluid.
Ambient Temperature
Lubrication Point Type of Oil/Fluid -22 -4 14 32 50 68 86 104°F
-30 -20 -10 0 10 20 30 40°C
Engine Oil Pan SAE10W30CD

Engine Oil
TORQFLOW Transmission Case Trans Fluid DEXRON III
Differential Case Gear Oil SAE90GL4
Hydraulic Tank Hydraulic Fluid ISO32
ASTM D975 No.2

Fuel Tank Diesel fuel
ASTM
D975 No.1
Brake Reservoir
Brake Fluid SAE70R-1, SAE70R-3, DOT3
Clutch Reservoir
Greasing Points Lithium Grease NLGI No.2
Cooling System Coolant Glycol Based Antifreeze
CAPACITY OF 2.0 - 3.5 TON LIFT TRUCKS

TORQFLOW
Engine Oil Pan Differential Case Hydraulic Tank
Transmission Case
2.0-2.8 ton:
4D94LE Engine: 2.5 gal (9.5 L) 1.6 gal (6.0 L)
8.98 gal (34 L)
2.0 gallons (7.5 L) (Incl. T/C.82 gal (3.1 L)) 3.0-3.5 ton:
1.5 gal (5.8 L)
Fuel Tank Brake Reservoir Cooling System
4D94LE Engine:
15.3 gal (58 L) 5.07 oz (0.15 L)
2.43 gal (9.2 L)
20-35
20-36
REMOVAL AND INSTALLATION
30. REMOVAL & INSTALLATION
WEIGHT TABLES........................................................................................................... 30-4

MAST ............................................................................................................................. 30-6
LIFT CYLINDER............................................................................................................. 30-8
ENGINE.......................................................................................................................... 30-9
TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE .................................. 30-14
30-1
The following figure shows a torque converter type truck unless otherwise specified.
43.4 – 54.2 ft/lb

torque
{6 – 7.5 kgfm}
torque
325 – 470 ft/lb
{45 – 65 kgfm}
253 – 315 ft/lb

torque
{35 – 43.5 kgfm}
30-3
WEIGHT TABLES
WEIGHT TABLES
2.0 - 3.5 ton Lift Trucks - Pneumatic - lbs. (kg)
2.5 2.8 3.0

Name of Device 2 ton 3.2 ton 3.5 ton
ton ton ton
K21 Engine 320 (145) –

Engine
K25 Engine 320 (145)
Assembly
4D94LE Engine 498 (226)
Torque Converter Assembly 66 (30)
Transmission
TORQFLOW Type 148 (67) 150 (68)
Assembly
Drive Axle 505 (229) 531 (241) 597 (271)
Steering Axle 87 (40) 93 (42) 96 (43)
Front 77 (35)
Wheel
Rear 33 (15)
Overhead Guard Assembly 245 (111)
2,470 3,236 3,746 4,123 4,522 4,967

Counterweight Standard Type
(1,120) (1,472) (1,699) (1,870) (2,051) (2,253)
Mast Assembly (Incl. Forks) w/ 2-stage 1,613 1,717 1,823 2,175

1,493 (677)
128” MFH Mast (120” on 3.5T) (732) (779) (827) (987)
Lift 55 (25) 70 (32) 73 (33)
Cylinder Tilt 26 (12) each 30 (14) each
Power Steering 39 (18)
213 221 270

Fork Carriage 190 (86)
(96) (100) (122)
Fork (42” pair) 220 (110) 322 (146)
Backrest 91 (41.3)
Pump 19 (8.5) 20 (9)
Control Valve (2 valves) 17.6 (8)
Steering system 48 (22)
30-4
WEIGHT TABLES
2.0 - 3.2 ton Lift Trucks - Cushion - lbs. (kg)
Name of Device 2 ton 2.5 ton 2.8 ton 3.0 ton 3.2 ton
Engine K21 Engine 320 (145) –

Assembly K25 Engine 320 (145)
Torque Converter Assembly 66 (30)
Transmission
TORQFLOW Type 148 (67) 150 (68)
Assembly
Drive Axle 496 (225)
Steering Axle 92 (42) 94 (43)
Front 77 (35)
Wheel
Rear 33 (15)
Overhead Guard Assembly 245 (111)
2,474 3,344 3,829 4,242 4,702

Counterweight Standard Type
(1,122) (1,517) (1,737) (1,924) (2,133)
Mast Assembly (Incl. Forks) w/ 2-stage 1,562 1,666 1,772

1,455 (660)
128” MFH Mast (120” on 3.5T) (708) (756) (804)
Lift 55 (25) 70 (32)
Cylinder Tilt 26 (12) each 30 (14) each
Power Steering 35 (16)
Fork Carriage 181 (82) 202 (92) 211 (95) 260 (118)
Fork (42” pair) 220 (110) 322 (146)
Backrest 91 (41.3)
Pump 19 (8.5)
Control Valve (2-spool) 17.6 (8)
Steering system 48 (22)
30-5
MAST
MAST
REMOVAL
1. Put blocks under the front and the rear wheels
2. Lift the fork carriage with the crane to remove the
hydraulic piping.
3. Remove the forks.
4. Put blocks under the fork carriage.
5. Operate the work equipment control levers sev-

eral times to release any remaining pressure in
the hydraulic piping. Then, the remove the pip-
ing.
After removing the piping, fit the blind plug

immediately to prevent the hydraulic oil from
flowing out and to prevent dirt or dust from
getting in.
6. Lift up the fork carriage slightly with a crane and

remove the blocks.
7. Let the fork carriage down.
8. Hook the crane to the mast.

9. Remove the tilt pins.
10. Tilt the mast forward slightly and remove the dif-
ferential mounting cap bolt.
If the mast is being tilted backward, there is a

danger the mast may fall over.
30-6
MAST
11. Remove the mast.
When carrying the removed mast horizontally,

secure the lower stay and the fork carriage with a
twisted annealing wire (A).
Put blocks under the bottom of the mast and lay

the mast assembly horizontally so that the fork
carriage is at the top.
Carry out installation in the reverse order of removal.
30-7
LIFT CYLINDER
LIFT CYLINDER
Also see correct Mast Service Manual in Appendix 1 at back of this publication.
REMOVAL
1. Place the mast upright.
2. Remove the stopper bolt.
3. Hoist the mast by a crane.
4. Put blocks under the inner mast.
5. Remove the cylinder clamp. Stopper bolt
6. Operate the work equipment control levers sev-
eral times to release remaining pressure in the
hydraulic piping. Then, the remove piping.
After removing the piping, fit the blind plug

immediately to prevent the hydraulic oil from
flowing out and to prevent dirt or dust from
getting in.
7. Crane the cylinder with a sling belt to remove it.
INSTALLATION
8. Lift the mast up to the maximum lifting height.
Lift Cylinder
9. Check the mast for play on both sides.

10. Adjust the shims so that both sides of the cylin- 21.7 - 36.1 ft/lbs.
ders are synchronized with each other at the torque (29.4 - 49 Nm)
maximum lifting height. {3 - 5 kgm}
Insert shims into the left
Angled to left
cylinder Inner
mast
Insert shims into the
Angled to right
right cylinder
Shim
Cylinder
rod
Outer
mast
30-8
ENGINE
ENGINE
REMOVAL
1. Overhead Guard
Engine Hood
Counterweight
Check to make sure that the mast, including forks

and attachment, are fully lowered to the ground
or removed from the mast.
2. Wiring and Battery

The figure below shows a gasoline model.
Sheet Switch Wiring Harness

Starter B Terminal
Starter S Terminal
Controller
Fuse Box Engine Wiring Harness
3. Accelerator Wire
Remove the accelerator wire.
4. Piping and Hoses

Hydraulic Pump Piping, Torque Converter Piping, Radiator Hose, Air Cleaner Hose, Fuel Hose
30-9
ENGINE
Diesel Engine Lift Truck (TORQFLOW type equipped with 4D94LE)
Gasoline Engine Lift Truck (TORQFLOW type equipped with K21 and K25)
30-10
ENGINE
5. Radiator, Shroud and Exhaust Pipe
4D94LE K21, K25
6. Engine
1) Place a wooden block under the transmis-
sion case.
2) Crane the engine and hold it.
3) For TORQFLOW type trucks, remove the
bolts mounting the torque converter case.
4) Remove the left and right hand bolts mount-
ing the engine.
30-11
ENGINE
INSTALLATION
7. Installation of Engine
1) Loosen the bolts mounting the engine
located at the transmission side
2) Mount the engine carefully to place it in the

center of the truck frame.
3) Check that gap A between fan and shroud is

equal. A A
4) For torque converter models, remove the
inching valve and check that gaps are paral-
lel.
30-12
ENGINE
8. Tightening Torque Converter Case Mounting Bolt.

torque
43.5 - 54.6 ft/lbs. (59 - 74 Nm) {6 - 7.5 kgm}
9. Tightening Torque for Engine Mount Bolt at

Transmission Side
torque
115.7 - 144.5 ft/lbs. (157 - 196 Nm) {16 - 20 kgm}
10. Alignment of Power Train
See “ALIGNMENT OF POWER TRAIN” on

page 30-23.
11. Tightening Hydraulic Piping

torque
See “STANDARD TIGHTENING TORQUE FOR

PIPE JOINTS” on page 10-17.
12. Installation of Accelerator Wiring

See “ADJUSTMENT OF ACCELERATOR PEDAL” on page 20-26.
13. Tightening Counterweight Mounting Bolts

torque
325 - 471 ft/lbs (441 - 639 Nm) {45 - 65 kgm}
30-13
TORQUE CONVERTER, TRANSMISSION AND DRIVE AXLE

REMOVAL
14. Overhead Guard
Engine Hood
Counterweight
When dismantling such devices as the torque

converter, the transmission and the drive axle,
remove the counterweight first to prevent the
truck from overturning. Then hoist the truck
frame in the front with a crane.
Check to make sure that the mast, including forks

and attachment, are lowered to the ground or
removed from the mast.
15. Mast
See “MAST” on page 30-6.
16. Accelerator Cable
30-14
17. Brake Master Cylinder

Brake Piping
Parking Brake Lever
10.1 oz (0.30 L) (Brake Fluid)
18. Inching Cable (TORQFLOW type)
30-15
19. Pedal Assembly
20. Not Used
21. Torque Converter Cooler Piping
30-16
22. Piping
23. Wiring
The figure below shows a gasoline model
Sheet Switch Wiring Harness

Starter B Terminal
Starter S Terminal
Controller
Fuse Box Engine Wiring Harness
30-17
24. Drive Axle

For normal removal/installation (except for
replacement of front-wheel support), remove the
front-wheel bolts (E) only.
1) Place blocks under the bottom of the truck
frame to keep the frame about 4 in. (10 mm)
above the ground.
2) Place a carriage as shown in the illustration
on the right to support the front axle.
3) Mark (A) (B) and (C) to match the differential

and the front axle both on the left and the
right. D
A
C B
30-18
4) Remove the bolts mounting the propeller

shaft and remove the propeller shaft.
5) Remove the support for the front axle from

the frame and pull out the front axle using a
pallet jack or dolly.
30-19
25. Torque Converter, Transmission and Drive Axle

1) Hoist the engine with a crane and hold it.
2) Place a jack as shown in the illustration on
the right and support two unit assemblies.
3) Remove the bolts mounting the torque con-
verter case. (TORQFLOW type).
4) Remove the bolts mounting the engine at

the transmission side and pull out the two
unit assemblies using the jack.
INSTALLATION
Apply the reverse order for removal. Pay attention on the following:
26. Tightening Torque for Torque Converter Case

Mounting Bolt (TORQFLOW).
Tightening Torque for Mounting Bolts: Mounting bolt
torque
43.5 - 54.6 ft/lbs (59 - 74 Nm) {6 - 7.5 kgm}
30-20
27. Tightening Torque for Engine Mounting Bolt

(Transmission side)
Tightening Torque for Mounting Bolt:
torque
115.8 - 144.6 ft/lbs (157 - 196 Nm) {016 -

20 kgm}
Ensure the engine is centered on the engine

mounting, both left and right, at the engine
side properly. Then, tighten the bolt mount-
ing the engine at the transmission side.
28. Drive Axle

1) Install the drive axle to the matching marks
on the equipment marked at the time of
removal.
2) Remove the level plug, and check leveling
with an appropriate tool and a level
torque
Tightening Torque for Front Axle Support Bolts

253 - 315 ft/lbs (343 - 427 Nm) {35 - 43.5 kgm}
See “Alignment of Power Train” on

page 30-13.
If no matching marks can be found, tighten

temporarily the front bolts to the front axle.
Then tighten the two mounting bolts on the support side and check the remaining two bolts for the
correct positioning toward the center.
29. Propeller Shaft

torque
Tightening Torque for Propeller Shaft Mounting Bolts
30-21
24 - 28 ft/lbs (32.4 - 38.2 Nm) {3.3 - 3.6 kgm}
30. Pedal Assembly

Brake Piping
Bleeding Air: See “BLEEDING AIR” on page 20-30.
Adjustment of Pedal: See “ADJUSTMENT OF INCHING AND BRAKE PEDAL (TORQFLOW
MODEL)” on page 20-24.
31. Counterweight
torque
Tightening Torque for Counterweight Mounting

Bolts
325 - 471 ft/lbs (441 - 639 Nm) {45 - 65 kgm}
32. Mast
torque
Tightening Torque for Mast Cap Mounting Bolts:
180 - 228 ft/lbs

2.0 - 2.5 ton (245 - 309 Nm)
{25 - 31.5 kgm}
253 - 315 ft/lbs
2.8, 3.0 ton (343 - 427 Nm)
{35 - 43.5 kgm}
361 - 448 ft/lbs
3.2, 3.5 ton (490 - 608 Nm)
{50 - 62 kgm}
30-22
ALIGNMENT OF POWER TRAIN
ALIGNMENT OF POWER TRAIN

When removing the power train (front axle or Transmission/engine), always be sure to perform an
alignment between the front axle and the transmission.
Measurement of Alignment
1. Prepare the tools as shown below.
1) Special tool for remove/install back lamp/
Neutral switch for manual transmission. (Not
applicable on TorqFlow models).
2) L-Type block for Axle
3) Electric Water level Meter
2. Remove Oil Level Plug from Front Axle and

install the L-type block by Plug.
Then place the Electric water level meter and
measure the leaning angle (tilt) of the front axle.
3. Measure leaning angle (tilt) of Engine/Transmis-

sion
• Automatic Transmission: Remove transmis-
sion control valve.
Then place electric water level meter on the
machined surface of transmission as above.
Read the leaning angle of transmission.
4. Service limit of leaning angle of Transmission
and Front axle:
Maximum 0.5 degree between Transmission/
Axle measurement.
5. When angle of leaning (tilt) is more than 0.5
degrees, this exhibits an incorrect position in either the front axle or engine/transmission.
Check the engine mounting and axle mounting.
30-23
STEERING AXLE AND POWER STEERING
STEERING AXLE AND POWER STEERING
253 - 315 ft/lbs

torque
343 - 427 Nm
{35 - 43.5 kgfm}
116 - 180 ft/lbs

torque
157 - 245 Nm
{16 - 25 kgfm}
torque 26 - 46 ft/lbs
35 - 63 Nm
{3.6 - 6.4 kgfm}
30-24
WHEEL BRAKE
WHEEL BRAKE
REMOVAL
6. Front Axle and Torque Shaft
1) Chock or block the rear wheels.
2) Place wooden blocks under the bottom of
the truck frame to lift the front wheels.
3) Apply the parking brake.
4) Remove the hub nut and the torque shaft

2.0 - 3.0 ton
(3).
5) Release the parking brake.
7. Hub
2.0 - 3.0 ton
1) Remove the bolts (4).
2) Remove the lock nut (5) with a special tool 4
(80 mm double face box).
3) Remove the hub (do not twist upside down).
30-25
WHEEL BRAKE
INSTALLATION
8. Back Plate (when removed)
2.0 - 3.0 ton
Apply Loctite to the mounting bolts (1) and
tighten with tightening torque specified as fol-
lows:
torque
130 - 145 ft/lbs 176 - 196 Nm {18 - 20 kgm}
LOCTITE #271
1
9. Hub
1) Install a new oil seal.
2.0 - 3.0 ton
6
Apply the grease G2-L1 on the lip surface of 9
the oil seal.
2) Fill the grease G2-L1 in the bearing (7) and

install it to the hub (8).
3) Remove dirt and oil in the inside face of the
brake drum (9) completely.
7
4) Install the hub to the shaft tube.
5) Tighten locknut (5) so that the starting 8
torque of the hub will conform to the follow-
ing:
torque
Starting Torque: 4.5 - 11.6 ft/lbs (6.1 - 15.7 Nm) {62.5 - 160 kgm}
6) Tighten bolt (4) after applying the Loctite.
2.0 - 3.0 ton
Loctite #271 4
30-26
WHEEL BRAKE
10. Front Axle and Torque Shaft

1) Install the torque shaft (3) and tighten the
2.0 - 3.5 ton
bolts (2) to tightening torque specified
below:
torque
72.3 - 93.7 ft/lbs 98 - 127 Nm {10 - 13 kgm} 2

2) Install the front axle and tighten the hub nuts
(1) with tightening torque specified below: 1
torque
217 - 361 ft/lbs 294 - 490 Nm {30 - 50 kgm}
30-27
NOTES:
DISASSEMBLY AND ASSEMBLY
40. DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY.................................................................................. 40-1

TORQUE CONVERTER................................................................................................. 40-3
TORQFLOW TRANSMISSION .................................................................................... 40-16
DIFFERENTIAL ............................................................................................................ 40-25
DIFFERENTIAL ASSEMBLY DRAWING ..................................................................... 40-31
WHEEL BRAKE ........................................................................................................... 40-35
BRAKE MASTER CYLINDER ...................................................................................... 40-37
COMBINATION SWITCH ............................................................................................. 40-41
SOLENOID VALVE....................................................................................................... 40-44
STEERING VALVE ....................................................................................................... 40-48
STEERING AXLE ......................................................................................................... 40-50
POWER STEERING CYLINDER ASSEMBLY ............................................................. 40-56
LIFT CYLINDER........................................................................................................... 40-59
TILT CYLINDER ........................................................................................................... 40-67
CONTROL VALVE........................................................................................................ 40-71
FORK CARRIAGE........................................................................................................ 40-77
FLOW DIVIDER ........................................................................................................... 40-77
RESERVOIR ASSEMBLY ............................................................................................ 40-80
HYDRAULIC PUMP ..................................................................................................... 40-81
PROPELLER SHAFT ................................................................................................... 40-86
40-1
TORQUE CONVERTER
TORQUE CONVERTER
After cleaning the outside of the torque converter, perform disassembly in a clean area as follows:
DISASSEMBLY
1. Removal of Torque Converter Assembly
Drain the oil from inside transmission. Then,
remove the torque converter assembly from the
engine and the transmission.
(M24 × 1.5 Drain Plug)
(12 mm Socket Wrench)
2. Removal of Oil Filter

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

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

the sealing of the gear pump.
40-3
TORQUE CONVERTER
4. Removal of Gear Pump

1) Remove the bolts mounting the gear pump.
(M8 × 1.25 Bolt: 5 pcs.)
(Socket Wrench 12 mm)
2) Remove the gear pump (2). Then, remove

2
the O-ring, if it remains inside the housing.
5. Removal of Strainer
2
1) Remove all the bolts mounting the cover of
the strainer. Then, remove the cover (11)
and the gasket (12).
(M8 × 1.25 Hexagon Head Bolt with Flange:
8 pcs.)
(Offset Wrench 13 mm)
11,12
40-4
TORQUE CONVERTER
2) Pull out the strainer assembly (13) from the

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

strainer assembly.
6. Removal of Main Relief Valve

1) Remove the main relief valve plug.
(M24 × 1.5 Plug)
(Socket Wrench 12mm)
Use care. The plug is under spring pressure and

may pop out of the valve.
2) Pull out the piston and the spring from the

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

1) Remove all of the bolts mounting the valve
cover. Then, remove the cover (9) and the
gasket (10).
(M6 × 1 Hexagon Head Bolt with Hole:
4 pcs.)
(Hexagon Wrench 5 mm)
Always be sure to press the cover while removing

the bolts to prevent the plug from springing out
from inside the valve.
40-5
TORQUE CONVERTER
2) Pull out the piston (7) and the springs (5)(8)

from each valve. 16 5 7
9,10 8 7
8. Removal of Gear Pump

1) Remove the O-ring and disassemble the
gear pump.
2) Remove the screw for disassembly as
shown.
(M5 × 0.8 Screw)
Disassembly of the gear pump must be mini-

mized as much as possible.
Gear Case
Stator Support
Driven Gear
O-Ring
Drive Gear
Assembly
40-6
TORQUE CONVERTER
COMPONENT PARTS
16 24
25 20
5 18
19 27
4
6
7
9
1 10
8
7 28
1-1
18
1-2
23
22
1-3
12
11
13
3
17
26
2
15
2-7 2-5
14
2-6
2-3
2-2
2-1
2-9
2-8
2-4
40-7
TORQUE CONVERTER
INSPECTION
The numbers in the left column refer to the callouts in the component parts drawing on the previous
page.
Criteria (in. (mm))

No Check Item Ref. No.
Standard Size Repair Limit
Piston Shaft and Torque Converter Housing Hole
1
A
B
A: Piston Outward Form .8650 - .8655 (21.972 - 21.985) – 4
1-1 Main Relief Valve B: Hole Inner Diameter .8661 - .8669 (22.000 - 22.021) – 3
Clearance .0006 - .0019 (0.015 - 0.049) .003 (.080) –
1-2 Torque Converter Inlet Port B: Hole Inner Diameter .5511 - .5518 (14.000 - 14.018) – 3
Relief Valve
Clearance .0011 - .0022 (0.030 - 0.058) .003 (.080) –
1-3 Lubrication Relief Valve B: Hole Inner Diameter .5511 - .5518 (14.000 - 14.018) – 3
Clearance .0011 - .0022 (0.030 - 0.058) .003 (.080) –
Pressure Spring
2
C
D
E
C: Free Length 3.614 (91.8) – 6
2-1 Main Relief Valve D: Fixing Length 3.114 (79.1) – –
E: Fixing Load N 7.299 (185.4) ± 5% 166.9 N –
C: Free Length 4.070 (103.4) – 5
Toque Converter Inlet Port
2-2 D: Fixing Length 3.055 (77.6) – –
Relief Valve
E: Fixing Load N 1.881 (47.8) ± 5% 43.0 N –
C: Free Length 60.5 – 8
2-3 Lubrication Relief Valve D: Fixing Length 48.2 – –
E: Fixing Load N 58.8 ± 5% 52.9 N –
40-8
TORQUE CONVERTER
in. (mm)
Criteria
No Check Item Ref. No.
Oil Seal and Torque Converter Impeller Hub
F : – 1.633 (41.5) 2-4

3 G : 1.650 - 1.652 1.646 1-1
(41.915 - 41.965) (41.815)
F
G
Seal Ring and Seal Ring Groove
H
H : .0746 - .0748 .0629
(1.895 - 1.900) (1.600)
I : .0736 - .0814 .0657
(1.870 - 2.070) (1.670) 2-9
5
J : .0787 - .0814 .0925 2-1
I
(2.000 - 2.250) (2.350)

K
K : 1.657 - 1.658 1.663

J (42.10 - 42.13) (42.25)
L : 1.279 - 1.280
–
(32.500 - 32.525) –
M : 1.277 - 1.278 2-2
6 (32.450 - 32.470) – 2-6
–
Clearance: .0039
: .0011 - .0029
(0.030 - 0.075) (0.100)
M
L
40-9
TORQUE CONVERTER
ASSEMBLY
Carry out assembly work in the reverse order to disassembly work.
IMPORTANT:
• Wash all the removed or disassembled parts with clean oil to remove dirt and debris completely. In par-
ticular, wash the oil groove and oil circuit with care.
• Replace such parts as the O-ring, the oil seal and the gasket with new ones after disassembly.
• Be careful to assemble correctly. For details, see the check items specified in the maintenance stan-
dard.
• When replacing the oil seal with a new one, apply a semi-dry gasket sealant (THREE BOND No.1211
or No.1104 for example) on the outside circumference of the oil seal. However, never apply it to the lip
or the sliding surface of the shaft.
1. Assembly of Gear Pump

Insert a pair of the gears (3) (4) in the gear cas-
ing (2) and reverse the stator support (5) to
assemble in the same steps taken for disassem-
bly.
Tighten the countersunk head screw and check
to make sure that the gear rotates smoothly. If it
does not rotate, disassemble it and start to
assemble again.
torque
Countersunk Head Screw:

8.7 - 26 in/lbs (0.98 - 2.94) Nm {0.1 - 0.3 kgm}
2. Assembly of Main Relief Valve

Insert the spring and the piston to the relief valve and tighten it with the plug. Check the piston for
proper positioning when assembling.
torque
Plug: 44 - 59 ft/lbs (60 - 80 Nm) {6.1 - 8.2 kgm}
3. Assembly of Torque Converter Inlet Port Valve and Lubrication Relief Valve
Insert the piston and the spring to the valve. Then, insert the gasket and tighten the cover. There are
two types of valves and the spring is different from the torque converter inlet port valve and the lubrica-
tion relief valve. Be sure to assemble them correctly to their original position.
torque
Bolt: 6.3 - 8.1 ft/lbs (8.5 - 11 Nm) {0.9 - 1.1 kgm}
4. Assembly of Gear Pump

Install O-ring (1) to the corner of the housing (2)
to hold it in place. Check to make sure that the
O-ring is correctly installed without any slack.
Then, insert the gear pump (3) to the housing
slowly and vertically and tighten it with the bolts.
torque
Bolt: 14.7 - 19.1 ft/lb (20 - 26 Nm) {2.0 - 2.7 kgm}
5. Assembly of Torque Converter

Insert the torque converter in the pump into the
housing slowly. Be careful not to damage the oil
40-10
TORQUE CONVERTER
seal and seal ring. Fill the area between the oil seal lip up to 1/3 to 1/2 level with lithium grease, or
apply clean hydraulic oil to the oil seal.
6. Assembly of Torque Converter Assembly

Assemble the torque converter assembly with the transmission and the engine.
MAINTENANCE STANDARD
1. Check for Oil Pressure
Input Engine Speed: 2,000 rpm - Oil Temperature: 175°F (80°C)
Torque Converter Outlet Port Pressure: 43.5 PSI (0.3 MPa)
No. Check Item Pressure PSI (MPa) Hydraulic Port Position

1 Main Pressure 160 - 303 (1.1 - 1.4) A
Torque Converter Inlet
2 72.5 - 101.5 (0.5 - 0.7) B
Port Pressure
2. Tightening Torque for Bolts and Plugs
Tightening
Screw
No. Tightening Location Size Torque ft/lbs. Ref. No.
Specifications
(Nm)
22.1 - 28.0
1 Input Plate Hexagon Head Bolt M8x1.25x12 1-3
(30 - 38)
14.7 - 19.1
2 Gear Pump Assembly Hexagon Head Bolt M8x1.25x12 14
(20 - 26)
Hexagon Socket 6.3 - 8.1
3 Valve Cover M6x1x20 16
Head Bolt (8.5 - 11)
14.7 - 19.1
4 Strainer Cover Hexagon Bolt M8x1.25x12 17
(20 - 26)
Pressure Pick-up Port Hexagon Socket 9.6 - 12.5
5 R 1/4 18
Blind Plug Head Bolt (13 - 17)
6 Oil Filter Oil Filter 3/4-16UNF 7.3 - 11.0 (10 - 15) 20
44.2 - 59.0
7 Drain Plug Drain Plug M24x1.5 22
(60 - 80)
44.2 - 59.0
8 Main Valve Plug M24x1.5 24
(60 - 80)
Hexagon Socket 15.1 - 21.0
9 Pressure Pick-up Ports R 3/8 27
Head Plug (20.5 - 28.5)
44.2 - 59.0
10 Blind Plug Plug M22x1.5 28
(60 - 80)
Gear Pump Stator Countersunk Head .722 - 2.16
11 M5x0.8x16 2-5
Support Screw (0.98 - 2.94)
40-11
TORQUE CONVERTER
TORQUE CONVERTER ASSEMBLY

1
2
3
4
7 5
Ref.No. Part Name Qty

1 Oil Filter 1
2 Turbine 1
3 Stator 1
4 Impeller 1
5 Turbine Shaft 1
Torque
6 Gear Pump 1 Converter Circuit
7 Turbine Hub 1
8 Input Plate 1
9 Housing 1
40-12
TORQUE CONVERTER
TORQUE CONVERTER ASSEMBLY - HYDRAULIC PORT POSITION

a
A B
e d c
f d C
A: Main Pressure Check Port

B: Torque Converter Inlet Port Pressure Check Port
C: Lubrication Pressure Check Port
40-13
TORQUE CONVERTER
HYDRAULIC CIRCUIT
3A 3B
To Transmission
side Lubrication
B
3C
C
3E
A
3F
To T/M
3D
1. Oil Tank
2. Suction Filter (100 mesh)
3. Torque Converter Assembly

3A. Torque Converter
3B. Oil Filter
3C. Torque Converter Port Relief Valve
3D. Gear Pump Assembly
3E. Lubrication Relief Valve
3F. Regulator Valve
4. Oil cooler
40-14
TORQUE CONVERTER
SYMPTOM AND REMEDY FOR PROBLEM

No. Problem Cause Remedy
A: No hydraulic pressure 1. Add oil
1. Lack of oil 2. Disassemble and check. Replace with new parts or
2. Damage of gear pump or drive device whole assembly if necessary.
3. Damage of piping or joint 3. Disassemble and replace with new parts.
4. Breakage of piston in inlet port relief 4. Disassemble and replace with new parts.
1 No power
transmitting valve or broken spring
B: Mechanical Breakage 1. Disassemble and replace with new parts.
1. Damage of input plate 2. Disassemble and replace with new parts.
2. Damage of shaft or gear 3. Disassemble and replace with new parts.
3. Damage of spline
A: Hydraulic pressure is too low 1. Add oil
1. Lack of oil 2. Check joint and gasket. Replace with new parts if
2. Leakage of air from suction piping necessary.
3. Drop in efficiency of gear pump 3. Disassemble and check. Replace with new parts if
4. Deteriorated spring in inlet port relief necessary.
valve or faulty movement of piston 4. Disassemble and check. Replace with new parts if
5. Wear or damage of seal ring necessary.
Engine output 6. Clogging of strainer 5. Disassemble and replace with new parts.
2 dropping 6. Check and wash strainer. Replace with new parts if
necessary.
B: Mechanical breakage 1. Disassemble and replace with new parts.
1. Damage or deformation of impeller 2. Disassemble and replace with new parts.
2. Deformation of input plate
C: Other
Disassemble and replace with new parts.
Use of wrong oil
1. Cavitations caused by leakage of air 1. Add oil and check and replace with new parts if nec-
from suction pipe or lack of oil essary.
2. Failure of gear pump 2. Disassemble and check. Replace with new parts or
3. Contact caused by deformed impeller whole assembly if necessary.
4. Breakage of input plate 3. Disassemble and check. Replace with new parts if
Abnormal sound 5. Breakage of gear necessary.
3 4. Disassemble and replace with new parts.
generating 6. Wear or breakage of bearings
7. Wear of spline 5. Disassemble and replace with new parts.
8. Looseness of bolts 6. Disassemble and replace with new parts.
7. Disassemble and replace with new parts.
8. Tighten again and replace with new parts if neces-
sary.
A: Oil seal 1. Disassemble and replace with new parts.
1. Wear or breakage of lip 2. Disassemble and check. Replace with new parts if
2. Intake of foreign body through dust necessary
3. Wear or scratches of bearings 3. Repair or replace with new parts.
4. Hardening or deterioration of rubber 4. Disassemble and replace with new parts.
because of abnormal rise in oil temper-
ature
B: O-ring 1. Disassemble and replace with new parts.
1. Breakage of O-ring 2. Repair or replace with new parts.
2. Scratches on mating surface 3. Disassemble and replace with new parts
3. Hardening or deterioration of rubber 4. Warm up engine before operation.
4 Oil leaking because of abnormal rise in oil temper-
ature
4. Sudden use in extremely cold tempera-
ture (below minus 15°C)
C: Joint surfaces with gasket 1. Tighten again.
1. Looseness of bolts 2. Replace with new parts
2. Damage of gasket 3. Replace with new parts
3. Scratches on joint surfaces
D: Plug and screw 1. Tighten again.
1. Looseness of screw 2. Replace with new parts
2. Damage of screw 3. Replace with new parts
3. Cracks on mating hole
40-15
TORQFLOW TRANSMISSION
1
DISASSEMBLY
1. Transmission Valve
Remove bolt (1) and disassemble the transmis-
sion valve.
2. Transmission Case
1) Remove the drain plug and drain the oil
inside the transmission case.
2) Disassemble the propeller shaft.
3. Torque Converter
1) Place wooden blocks to support the trans- 1
mission case assembly and set it facing in
the direction shown in the diagram on the
right.
2) Remove bolt (1) connecting the torque con-
verter and the transmission case to separate
the torque converter.
40-16
4. Output Shaft
1
Remove bolt (1) first. Then, remove the bearing
(2), the gear (3), the bearing (4), the seal (5) and
the spacer (6) in turn. Pull the output shaft (7) out 2
from the lower side of the transmission case.
3
5. Intermediate Shaft Sub-Assembly

Pull the intermediate shaft sub-assembly out.
40-17
6. Input Shaft Sub-Assembly

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

Remove cap (5) and the blind plug (6).
40-18
10. Disassembly of Clutch Pack Assembly
The numbers in the diagram show the order for disassembly.
a
b
13
11
3 10
9
5
6
7 17
8 15
12
14
1 4 31
16
a 18
29
21 28
27
23
20
24
25 35
26 33
30
32
19 22
34
b
36
40-19
ASSEMBLY
1. Cleaning and Air Blowing of Transmission Case
1) Remove the cap when cleaning the transmission case because LOCTITE is applied to the cap
tightening bolts.
2) Blow out the machined hole of the transmission case with air.
2. Installation of Blind Plug to Transmission

Case 4
Install blind plug (6), the cap (5) and the breather
(4) to the transmission case. 1
2
3
3. Installation of Drain Plug
Install drain plug (7). 6 7
torque
Tightening Torque for Drain Plug:

37.4 - 57.8 ft/lbs. (50.8 - 78.4 Nm) {6.0 - 8.0 kgm}
4. Installation of Strainer 5
Fit the O-ring to the strainer (3) and insert it
inside the transmission case. Then, install the
plate (2) with the gasket and tighten it with bolt
(1).
5. Output Shaft
Insert spacer (6), seal (5), bearing (4), the gear
1
(3) and the bearing (2) in the output shaft and
secure it with the washer and bolt (1).
2
torque
Tightening Torque for Bolt:

72.2 - 90.7 ft/lbs. (98 - 123 Nm) {10 - 12.5 kgm} 3
4
LOCTITE #271 (Hole Thread)
5
40-20
6. Installation of Intermediate Shaft Sub-Assem-

bly
Assemble the intermediate shaft sub-assembly
inside the transmission case.
7. Input Shaft Sub-Assembly

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

ring (8-1). 14 10 9 11 8
4) Assemble the clutch disc (10) and the plate
(9) and secure with ring (11).
5) Installation of Forward Gear
Insert the bearing in gear (14) and assemble
it to the shaft. Assemble the bearing and the
spacer. Then, secure with the snap ring.
6) Installation of Reverse Gear
Assemble the washer, the gear, the bearing
and the washer.
Then, secure with the snap ring.
40-21
8. Installation of Input Shaft Sub-Assembly

Install the seal ring to the input shaft sub-assem-
bly and assemble inside the transmission.
9. Installation of Torque Converter

2
Apply Liquid gasket to the torque converter con-
tact face of the transmission case and assemble
the torque converter (2) and the transmission
case (3) with bolt (1).
40-22
10. Installation of Transmission Valve

Fit the gasket and install with bolts (1).
1
torque
Tightening Torque for Bolts:

19.9 - 25.0 ft/lbs. (27 - 34 Nm) {2.8 - 3.5 kgm}
11. Installation of Torque Converter Cooler Filter

Install the oil filter and the piping.
40-23
TORQFLOW TRANSMISSION ASSEMBLY DRAWING
72 - 90 ft/lbs.
torque 98 - 123 Nm
{10 - 12.5 kgm}
LOCTITE #271
40-24
DIFFERENTIAL
DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY (2.0 - 3.5 ton Lift Trucks)
83 - 97 ft/lbs.
torque 113 - 132 Nm
{11.5 - 13.5 kgm}
LOCTITE #271
LOCTITE #271
40-25
DIFFERENTIAL
ADJUSTING PINION SHAFT ASSEMBLY WITH SHIM(S)
83 - 97 ft/lbs.
torque 113 - 132 Nm
{11.5 - 13.5 kgm}
1. Clearance (a)
Read the indication (a) at the pinion shaft tip.
2. Clearance (b)
Read the stamp (b) on the case. Set No. a
#7
20
3. Clearance (c)
Measure the clearance (c) and indicate the clear-
ance in 1/100-unit bases against the standard
b
size 1.16 in. (29.50 mm).
The clearance can be determined by calcu-

lation considering the accuracy of the bear-
ing and following value shall be applicable. If
no proper tooth contact is found, assemble it
again. c = .59 in. (15 mm)
40-26
DIFFERENTIAL
4. Calculation of Shim Thickness S1

Apply clearances (a), (b) and (c), obtained from
the above, to the formula shown below to calcu- 15680 -
late the thickness of the shim S1. 23250 N
(1600 -
a+b+c+d 2400 kgf)
S 1 = 0.7 + -------------------------------- Set this face
100
Round the figure to two places of decimals. to the
differential (Equivalent to
when bearing preload)
assembling.
IMPORTANT
Check to make sure there is no clearance between c
the gear and the shim when pressing the gear for
installation.
ADJUSTMENT OF PINION GEAR

CLEARANCE
1. Clearance (b) 1 d
2. Fix the pinion shaft pushing from the bottom.

1) Take an alignment to the shaft with the jig.
2) Turn the bearing about 10 times each to
right and left to check its smooth movement.
3) Measure the clearance (d).
Check to make sure that step (1) of the

above has no clearance.
1 Fixed
3. Calculation of Shim Thickness S2
1) Calculate the shim thickness S2 applying the clearance (d) measured by steps 1 - 3 of the instruc-
tions.
2) S 2 = 2.354 – d Select the shim so as to meet the S2 of the clearance.
3) Measure the starting torque and adjust the shim thickness S2.
torque
Starting Torque for Pinion Bearing: 6.49 - 9.75 (8.8 - 13.2 Nm) {90 - 135 kgcm}
Make sure to measure the starting torque without the coupling shaft.
INSPECTION OF PINION BEARING

CLEARANCE
1. Apply Hamech Forklift genuine oil to the inner 1
2
race face and edge (1) when assembling.
2. Check to make sure that no clearance exists (2)
when inserting the outer race.
3. Check to make sure that the inner race large rim
has no clearance (3) when pressing the inner
race for installation. 3
4. After tightening the nut with specified torque, turn
the bearing about 20 times each to the left and
right to check its smooth movement.
5. If the starting torque cannot match the specified
torque as shown below, disassemble and adjust the shim thickness again.
40-27
DIFFERENTIAL
torque
Starting Torque: 6.49 - 9.75 ft/lbs. (8.8 - 13.2 Nm) {90 - 135 kgcm}
If the starting torque T is greater than 9.7 ft/lbs. (13.2 Nm) {135 kgcm}, increase the shim thick-
ness.
If the starting torque T is less than 6.5 ft/lbs. (8.8 Nm) {90 kgcm}, reduce the shim thickness.
ADJUSTMENT OF DIFFERENTIAL
1. Assembly of Differential Assembly
1) Assemble the differential assembly and 2
install adjustment screw (1).
2) Apply LOCTITE #271 to the hole of the cap 1
(2) and tighten with bolt (3) temporarily.
3
LOCTITE #271
2. Adjustment of Backlash
1
Use special tool A for tightening the adjust-
ment screw (1).
Special Tool A 34B-97-99110
1) Set the dial gauge and slightly tighten the

adjustment screw at the (B) side until the
backlash goes to zero. A
2) Loosen the adjustment screw at the (B) side
until backlash goes to .006 - .009 in. (0.15 -
0.23 mm)
Backlash between Ring .006 - .009 in.

Gear and Pinion Gear (0.15 - 0.23 mm)
If the backlash is beyond the limits above,

make the adjustment again.
A B
40-28
DIFFERENTIAL
3. Adjustment of Tooth Contact Forward

1) Apply red lead thinly and evenly to the tooth
surface of the bevel gear. Forward
2) Turn the bevel gear forward and reverse
several times.
3) Check the tooth contact pattern left on the
surface for condition of tooth contact.
4) If the tooth contact is not correct, adjust it
using the shim thickness.
Correct Tooth Contact (No Load)

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

increase the shims. 1
2
In case of strong contact at the tooth top (2),

reduce the shims.
Adjust the tooth contact correctly both for-

ward and reverse.
Run-out of Bevel Gear: less than .004 in.

(0.1 mm)
40-29
DIFFERENTIAL
4. Correction of Tooth Contact

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

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

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

move the protrusion of the pinion in the direc-
tion of (A).
• Next, move the bevel gear away from the
pinion in the direction of (B) to adjust the
backlash.
40-30
DIFFERENTIAL ASSEMBLY DRAWING
.006 - .008 in.

Backlash
0.15 - 0.20 mm Gear Oil
GO90
(Thread)
Run- < .004 in. (0.1 mm)

out on dial gauge 253 ft/lbs.
torque 343 Nm
{35 kgm}
G2-L1
(Seal Lip)
72.3 ft/lbs.
torque
98 Nm {10 kgm}
LOCTITE #271
(Thread Hole)
LG-7 (Seal Outer

Circumference)
72.3 ft/lbs.
torque
98 Nm {10 kgm} .006 - .008 in.
Backlash
0.15 - 0.20 mm
LOCTITE #271
(Thread Hole)
43 - 55 ft/lbs.
torque 59 - 74 Nm
{6 - 7.5 kgm}
43 - 55 ft/lbs.
torque 59 - 74 Nm
{6 - 7.5 kgm}
40-31
2.0 - 3.0 ton Lift Trucks

72.3 - 91 ft/lbs.
torque 98 - 123 Nm
{10 - 12.5 kgm}
LOCTITE #271
(Thread Hole) 20 - 25 ft/lbs.
torque 27 - 34 Nm
{2.8 - 3.5 kgm}
Run- < .004 in. (0.1 mm)
out on dial gauge 253 ft/lbs.
torque 343 Nm
{35 kgm}
Gear Oil
GO90
(Thread)
G2-L1
(Seal Lip)
72.3 - 91 ft/lbs.
torque 98 - 123 Nm
{10 - 2.5 kgm}
LG-7 (Seal Outer
LOCTITE #271 Circumference)
(Thread Hole) .006 - .008 in.
Backlash
0.15 - 0.20 mm
6.5 - 9.7 ft/lbs.
Starting
8.8 - 13.2 Nm
Torque
{90 - 135 kgcm} 43 - 55 ft/lbs.
torque 59 - 74 Nm
{6 - 7.5 kgm}
253 ft/lbs.
torque 343 Nm
{35 kgm} 83 - 97 ft/lbs.
torque 113 - 132 Nm
LOCTITE #271 {11.5 - 13.5 kgm}
(Thread Hole)
40-32
2.0 - 2.5 ton Lift Truck
87 - 119 ft/lbs.
torque 118 - 162 Nm
{12 - 16.5 kgm}
72 - 93 ft/lbs.
torque 98 - 127 Nm
{10 - 13.5 kgm}
40-33
87 - 119 ft/lbs.
torque 118 - 162 Nm
{12 - 16.5 kgm}
235 - 315 ft/lbs.

torque 319 - 427 Nm
{32.5 - 43.5 kgm}
72 - 93 ft/lbs.
torque 98 - 127 Nm
{10 - 13.5 kgm}
40-34
WHEEL BRAKE
WHEEL BRAKE
13 - 19.5 ft/lbs.
torque 17.6 - 26.4 Nm
{1.8 - 2.7 kgm}
5 (*1)
*1
A
1 2
torque
*1. Tightening Torque for Back Plate Mounting Bolt: 130 - 144 ft/lbs. (176 - 196 Nm) (18 - 20 kgfm)
Lubrication for Back Plate Mounting Bolt: LOCTITE #291
Item Unit Wheel Brake

Type – Front wheel internal expanding hydraulic type
Structure – Duo servo
Brake Drum Inner Diameter in. (mm) 12.2 (310.0)
Lining Material – Resin molded (Adhesive type)
Width in. (mm) 2.36 (60.0)
Thickness in. (mm) .224 (5.7)
Wheel Cylinder Inner Diameter in. (mm) 1.25 (28.58)
40-35
WHEEL BRAKE
1. Adjustment of Shoe Clearance

See “WHEEL BRAKE” on page 20-29.
2. Test After Adjustment

Pull cable (1) by finger in the direction shown by
the arrow in the diagram on right causing the
lever to engage with the next tooth. Release the
cable and the lever returns to the original posi-
tion after clicking one notch.
When the lever fails to function properly,

check the lever for position above the
adjuster screw.
Right Position of Lever

The lever is designed to contact the adjuster wheel
with clearance (a) between 0.20 - 0.28 in. (5 - 7 mm)
from the center of the adjuster screw.
When the lever position is incorrect, the lever

cannot mesh with the wheel and the wheel may
fail to function even if the lever operates.
Remedy for Malfunction

1) Check to make sure that the cable guide fits
properly to the specified hole on the second-
ary shoe.
2) Check to make sure that the adjuster spring can properly fit to the specified hole on the primary
shoe.
3) Replace the cable with a new one, if necessary.
4) Replace the lever with a new one, if necessary.
5) Replace the adjuster assembly, if necessary.
40-36
BRAKE MASTER CYLINDER

COMPONENT PARTS
No. Part Name Qty No. Part Name Qty
1 Cylinder 1 10 Bleeder Valve 1
2 Piston Assembly 1 11 Bleeder Cap 1

3 Snap Ring 1 12 Valve Spring 1
4 Boot 1 13 Seat 1
5 Push Rod 1 14 Valve Rubber 1
6 Nut 1 15 Gasket 1
7 Yoke 1 16 Bolt 1
8 Bushing 1 17 Valve Assembly 1
9 Filler Union 1
11
9 10
8
2 1
4 12
13
5
17
6 14
7
15
16
Repair
No. Check Item Standard Size Limit Remedy Ref. No.
in. (mm)
in. (mm)
Clearance between Cylinder and .0008 - .0040 Replacement

1 .006 (0.15) 1.2
Piston (0.020 - 0.105) (Cylinder Assembly)
Primary: approx. .04 (1.0) Replacement
2 Tightening Clearance of Cup .016 (0.4) 2
Secondary: approx. .047 (1.2) (Cylinder Assembly)
3 Free Length for Spring 3.1 (78.8) 2.76 (70) Replacement 2
The numbers shown in the Ref. No. on the right refer to those in the diagram of the component parts.
40-37
DISASSEMBLY
1. Remove the yoke and boot.
2. Remove stopper pin (1) with a flat-headed
screwdriver.
When it is hard to remove the stopper pin, push

on the push rod (2) lightly.
3. Remove the stopper wire (3) from the cylinder

(4) with a flat-headed screwdriver.
4. Remove the piston assembly, the spring, the
check valve and valve seat.
• Be careful not to damage the cylinder, the piston or the cup.

• When carrying out disassembly, make sure that you understand the structure of the cylinder
well in advance. Then, it is recommended that all the disassembled parts be put in order
according to the disassembly procedures.
• Never disassemble the piston assembly.
• Be careful not to squeeze the outer surface of the cylinder with a vise.
1. Base
2. Lip
3. Base
4. Lip
40-38
INSPECTION AND ADJUSTMENT

Part Name Check Item Remedy
Remove small scratches with sandpaper.
Scratches, uneven wear or
Cylinder If there are critical scratches that adversely affect the
corrosion of inner surface
cup, replace with a new cylinder assembly.
Remove small scratches with oilstone.
Scratches, uneven wear or If there are critical scratches that adversely affect the
corrosion inner face of cylinder or the cup, replace with a new
Piston piston assembly.
If the clearance is greater than the repair limit, replace
Clearance between cylinder
it with a new one.
and piston
Repair Limit: 0.15 mm
Even if the scratches are very small, replace if with a
Scratches on lip
new piston assembly.
If there is harmful pitting, replace with a new piston
Pitting of base
assembly.
If there is abnormal deterioration, wear or swelling,
Wear or swelling
Cup replace with a new piston assembly.
If below the repair limit, replace with a new piston
assembly.
Repair Limit: 0.4 mm
Clearance
Note: The cup belongs to the group of parts to be
replaced periodically. In general, it is recommended
that such parts be replaced whenever disassembled.
Deformation, scratches or
If there is abnormal deformation, scratches or wear,
Piston Assembly wear of valve rod, valve cup,
replace with a new piston assembly.
spring and thimble
Springs showing critical scratches must be replaced
Scratches, wear or fall
with new ones.
Spring Those below the repair limit must be replaced with a
Free length new one.
Repair Limit: 2.76 in. (70 mm)
Those bent or deformed must be replaced with a new
Push Rod Bend or deformation
one.
Those with cracks, damage or scratches must be
Cracks damage or scratches
replaced with a new one.
Boot Those with no tightening allowance, or an extremely
Tightening allowance between
little tightening allowance, must be replaced with a
cylinder and rod
new one.
Even if the cracks are extremely small, replace with a
Cracks
new part.
Those with critical discoloration must be replaced with
Filler Union Discoloration
a new one.
Those with scratches must be replaced with a new
Scratches
one.
Bushings displaying cracks or critical deterioration
Bushing Cracks or deterioration
must be replaced with a new one.
40-39
Unit: in. (mm)
No. Check Item Standard Size Repair Limit Remedy

Clearance between cylinder .0008 - .004 Replacement
1 .006 (0.15)
and piston (0.020 - 0.105) (Cylinder Assembly)
Primary side:
approx. .004 (1.0) Replacement
2 Tightening Clearance of Cup .016 (0.4)
Secondary side: (Cylinder Assembly)
approx. .047 (1.2)
3 Spring Free Length 3.1 (78.8) 2.76 (70) Replacement
40-40
COMBINATION SWITCH
COMBINATION SWITCH
COMPONENT PARTS
2 3
1. F/R Switch
2. Screw
3. Cover
4. Body
5. Cover
6. Screw
7. Turn Signal Switch
40-41
COMBINATION SWITCH
Inspection of Switches
1. Remove the connection between the 8-pin cou- 1 2
pler of the combination switch cord and the main
wiring harness. 262522232124 51 52
NS10MW-X C04MB-X
2. Check continuity of electric current between the
terminals at each position to make sure that
there is continuity between the 0 to the 0. 3
3. Insulating resistance: More than 10 Ω at each

terminal with a 500 V meg/ohm meter.
1) F/R switch connector
2) Horn contact connector
3) Protective plate
4) Lighting connector
5) Lighting and turn signal switch connector
5 4
67
28913 11 5 1012
NS08MBR-X NS04MBR-X
40-42
COMBINATION SWITCH
Position of Turn Signal Switch Connection

No. R N L Connect to
1 Power Source
2 3/1 Lamp
3 3/1 Lamp
Position of Lighting Switch Connection

Twist Up and Down
No. Connect to No. Connect to
OFF 1 2 A B C
11 Power Source Power Source
12 Tail Lamp 6 H/Lamp Main
7 H/Lamp Main
5 5 Power Source
Power Source
8 9 H/Lamp
10 H/Lamp Dimmer
Position of F/R Switch Connection 8 Power Source

(TORQFLOW Type)
No. F N R Connect to
21 Earth
22 Relay
Horn Switch Circuit
23 Relay
24 Relay No. Connect to
25 Power Source 51
26 Relay 52
40-43
SOLENOID VALVE
SOLENOID VALVE
DISASSEMBLY DRAWING
15
3
13
9
12 1
11
2
7
5
4
6
13
8
10
14
See Parts Legend on next page
40-44
SOLENOID VALVE
COMPONENT PARTS
11 12 9 8 6 15 4 5 7 10 2 1 14
13
SOL.b SOL.a
3
Ref.
Part Name Qty
No.
1 Body 1
2 Spool 1
3 Plug 1
4 Spring 1
5 Retainer A 1
6 Retainer B 1
7 Parallel Pin 8
8 Solenoid Guide 1
9 Solenoid Coil 1
10 Spacer 4
11 Nut 1
12 O-Ring 1
13 O-Ring 1
14 O-Ring 1
15 O-Ring 1
40-45
SOLENOID VALVE
DISASSEMBLY 15
1. Remove the nut (11) with the spanner (27 mm).
2. Remove the O-ring (12). Then, remove the sole-
noid coil (9).
9
3. Remove the O-ring (15) inserted in the solenoid
coil (9). 12
11
4. Remove the solenoid guide (8) with the 27 mm

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

(8).
6. Loosen the plug (3) with a spanner (3.5 mm pin-

spanner with 12.5 mm pitch) and remove it.
1
7. Remove the O-ring (13) from the plug (3).
8. Remove the O-ring (14) from the body (1).
3
Never remove the spacer because it is pressed 13
into the body.
14
40-46
SOLENOID VALVE
ASSEMBLY
1. Insert the O-ring (14) into the body (1). 1
All of the O-rings shall be replaced with new

ones.
3
2. Insert the O-ring (13) in the plug (3). 13
3. Assemble plug (3) to the body (1) with the pin
spanner (3.5 mm pin-spanner with 12.5 mm
pitch).
torque
14.8 - 18.4 ft/lbs. (20 - 25 Nm) {2.0 - 2.6 kgm}

4. Insert O-ring (12) in the solenoid guide (8). 14
5. Assemble O-ring (13), retainer B (6), spring (4),

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

15
7. Insert the solenoid coil (9) into the solenoid guide
(8).
8. Insert O-ring (12) into the solenoid coil (9).
9
9. Install the nut (11) with the spanner (27 mm
spanner).
12
torque
11
6 - 7.4 ft/lbs. 8 - 10 Nm {0.8 - 1.0 kgm}
40-47
STEERING VALVE
STEERING VALVE
If any seal is replaced at a service shop, the manufacturer’s warranty becomes invalid.
Be sure to send seals to the manufacturer for replacement as an assembly unit.
No. Part name Qty Remarks
1 Screw 7 Size: 5/16-24UNF

2 Spring pin 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
No spacer or two spacers are used depending on specifications.
6 (Spacer) (1)
7 Spacer plate 1
8 Drive 1
9 Control parts assembly 1 Including part numbers 10 to 12
10 Housing (1)
11 Sleeve (1)
12 Spool (1)
13 Pin 1
6 For standard input specifications
14 Centering spring 4 For standard low input specifications
4 For standard ultra-low input specifications

15 (Flat spring) 2 For standard ultra-low input specifications only
16 EPACS controller 1
17 Cross recessed countersunk head screw 2 Size: M3, width across flats: .06 in. (1.5mm)
18 Rotor
19 Hexagon socket head setscrew 1 Size: M3
21 Race bearing 2
40-48
STEERING VALVE
22 Thrust needle 1
23 O-ring 1
24 Oil seal 1
25 Dust seal 1
26 Retaining ring 1
27 Seal ground bushing 1
28 O-ring 2
29 O-ring 1
30 Ball 1
31 Face seal (or plug) 1 For low slip specifications only
32 O-ring 1 For low slip specifications only

33 Nameplate 1
34 Rivet 2
36 Valve block 1
37 Spool 1
40 Tube assembly 1
41 Nut 1
42 Coil with connector 1

43 O-ring 4
44 O-ring 1
45 Hexagon head bolt 2 M10 x P1.5 x shank: 35mm, width across flats: 8mm
46 Spring 1
47 Core 1
48 (Hexagon socket head plug) 1 No plug is used depending on specifications.

50 O-ring 1
52 (Orifice plug) 1 Check valve is used depending on specifications.
54 Adapter screw 1
55 (Check valve assembly) 1 No assembly is used depending on specifications.
40-49
STEERING AXLE
STEERING AXLE
DISASSEMBLY DRAWING
Note: Press in with jigs
40-50
STEERING AXLE
ASSEMBLY DRAWING
1. Adjustment of Stops
The stops are internal to the steering cylinder on the MBX50 truck as opposed to earlier models where
the stops were externally adjustable.
+0.3
+0.1
+2
+1
2. Assembly of Ball Socket

When assembling the ball socket to the bell clamp, check to make sure each tapered section is free
from sticking oil or paint.
40-51
STEERING AXLE
3. Grease
Apply lithium grease (G2-L1) for the grease nipple and greasing to the hub.
STEERING AXLE DETAILS

1. Bell Clamp
1
1) Lock Plate (1)
2) Snap Ring (2)
29K7
Check to make sure the snap ring is secured
in the ring groove.
2
A-A
40-52
STEERING AXLE
2. King Pin
1) Match needle bearing (3) end face to the 6
boss (4) end face for a distance of 0.24 in. (6
mm).
2) Match needle bearing (5) end face to the
boss (6) end face.
3) Adjust knuckle (7) to minimize the space
between top and bottom. 5
Standard space (a) in the diagram on the
right: 7
6
B-B 4 3
3. Link
Make sure to bend the cotter pin (8) correctly.
4. Hub
1) Fill enough grease (G2-L1) in the hub bear- torque G2-L1
ing (9) up to half to one third of the hub 10
space capacity in the both sides.
2) When assembling the hub, apply grease
(G2-L1) to the lip of the seal (10).
3) After adjusting starting torque, make sure to 11
bend the cotter pin (11) completely.
40-53
STEERING AXLE
5. Adjustment of Hub Rotating Starting Power

1) Tighten the lock nut until it becomes hard to
turn by hand. Then, reverse it turning by one
quarter from that position. Apply a spring
balance to the hub bolt and give the taper
roller bearing pre-pressure while adjusting
the nut (12) to make rotating starting power
reach the following value.
12
Starting 4.4 - 7.5 lb/f
power 19.6 - 33.3 N {2 - 3.4 kgf}
Starting 217 - 361 ft/lbs
torque 294 - 490 Nm {35 - 50 kgcm}
2) After completing adjustment in the above step, insert the cotter pin to secure it in place where the
holes of both the nut and the shaft are matched. Then, bend it completely.
6. Adjustment of Steering Wheel Angle

Adjust the steering wheel angle in the following procedure so that the relation between steering knob
position and steering angle becomes constant.
40-54
STEERING AXLE
INITIAL SETTING WORK PROCEDURES

LED
NO. Work Terminal Display Check Item Remarks
Rest steering for 5 times to bleed After bleeding air, check Stop engine. No smooth
1 air inside circuit Connect 1 FLASH steering wheel for no play. steering is available.
Key switch ON: travel straight State of traveling straight Controller: initial setting mode
2 forward and stop. Connect 1 FLASH forward 1.
3 Key switch OFF Connect Turn off
In traveling straight forward, set the Wheels/steering wheel

4 steering wheel knob at the starting Connect Turn off Close terminal, if open.
point. position: terminals closed
Under initial set: controller

mode 1
5 Key switch ON Connect 1 FLASH Check LED for 1 FLASH
3 or 4 FLASH: faulty controller
or wheel sensor error
1 FLASH Check 1 FLASH for change Under reset: controller initial

6 Remove the terminals Open ↓
2 FLASH to 2 FLASH set mode 2
When LED changed to 2FLASH,

1) steer to right end, Steer surely to the end Under initial set: controller to
7 Open 2 FLASH memorize steering speed and
2) steer to left end, (Steering speed: 60 rpm) steering angle.
3) return to neutral and over.
Normal mode: turn on,

abnormal: turn off. Stay in 2
8 Check LED for lighting Open Turn on Check LED for turn on
FLASH: close terminals and
reset from No.1.
9 Finish Open Turn on Check to make sure steering

knob position corrected
LED Display
NO. Content Terminal LED ON/OFF
Initial set mode 1
0.5s 3s
(under initial set) or
1 1 FLASH
incomplete initial set*
(*1)
0.5s 0.5s 0.5s 3s

Initial set mode 2
2 2 FLASH
(under teaching)
Steering wheel sensor

3 3 FLASH
error
4 Wheel sensor error 4 FLASH
Controller error or
5 controller under initial Turn off OFF
set
Under normal
6 operation (complete Turn on ON
initial set)
* An incomplete initial setting means initial setting is not fully completed under normal mode. It needs to operate steering
wheel to turn more than one and half times to the right and left from the straight forward position in teaching mode.
40-55
POWER STEERING CYLINDER ASSEMBLY

Pneumatic Tire Lift Truck
Ref. No. Part Name Qty Ref. No. Part Name Qty
1 Cylinder 1 7 Backup Ring 2
2 Cylinder Rod Sub-Assembly 1 8 Packing 2
3 Cylinder Head 2 9 Backup Ring 2
4 Bushing 2 10 Dust Seal 2
5 Packing 1 11 Tie Rod 2
6 O-Ring 2 12 Nut 4
40-56
Cushion Tire Lift Truck

Ref. No. Part Name Qty Ref. No. Part Name Qty
1 Cylinder 1 7 Backup Ring 2
2 Cylinder Rod Sub-Assembly 1 8 Packing 2
3 Cylinder Head 2 9 Backup Ring 2
4 Bushing 2 10 Dust Seal 2
5 Packing 1 11 Tie Rod 2
6 O-Ring 2 12 Nut 4
DISASSEMBLY
1. Secure the outer tube of the cylinder (1)
with clamps.
Clamp cylinder tube outer diameter.

1
40-57
2. Loosen the 4 nuts (12) and remove the tie-rod

(11).
12
11
3. Pull the cylinder head (3) on the right and left

hand out slowly. 3
Be careful not to damage the packing when

pulling out the cylinder head.
4. Pull the cylinder rod sub-assembly (2) out

straight. 2
Cylinder Inner Diameter
Standard Size 2.95 in. (75 mm)
Wear Limit 2.96 in. (75.2 mm)
Cylinder Rod Outer Diameter
Standard Size 1.97 in. (50 mm)
Wear Limit 1.96 in. (49.92 mm)
Bend Limit 0.02 in. (0.5 mm)
ASSEMBLY
Assembly work shall be the reverse of the disassembly procedure.
• Apply grease or hydraulic oil to the lip surfaces of O-ring, dust seal and packing when assem-
bling these parts.
• Before applying the THREE BOND #1344, make sure to wipe off old grease carefully from
thread of bolts or screws.
• Warm up the packing in hot water (below 176° F (80°C)) prior to installation to the engine.
40-58
LIFT CYLINDER
LIFT CYLINDER
COMPONENT PARTS
1. Rod/Plunger 11. Retaining Ring

2. Spacer 12. Check Valve
3. Back-up Ring 13. O-Ring
4. Pull-in Wire 14. Washer
5. Roll Pin 15. Retaining Ring
6. Shell 16. Wear Ring
7. Wiper 17. Nylon Ring
8. Rod Seal 18. Piston Seal
9. Piston 19. O-Ring
10. Sleeve 20. Retainer
40-59
LIFT CYLINDER
Disassembly
Service requiring disassembly should be performed by the manufacturer.
Preparation
Prepare the following before starting disassembly.
1. Workbench
Prepare a solid, stable workbench that is large enough to support parts and prevent them from moving
or falling during the work.
2. Tools and materials

Prepare tools and materials shown on the following page.
General Precautions
1. Clean the cylinder beforehand to remove soil, dirt and dust.
2. Since the cylinder is composed of precision parts, handle it very carefully. Do not bump or drop parts
during work.
3. Do not hit or tamper with parts forcibly. This may cause burrs or damage, which may disable reassem-
bling or cause oil leakage or deterioration. Perform disassembling/reassembling carefully and
patiently.
4. If the cylinder is left alone disassembled or in the middle of disassembly, parts may rust due to humid-
ity or dirt/dust. When disassembling is unavoidably suspended, be careful to guard the cylinder
against rust and dust.
Maintenance Standard
Replace sliding parts and seal parts according to the following.
Replace when 1/4 circumference for total length of

Bushings
the bush is worn in bronze color.
Replace seal parts with new ones whenever the
Seal parts
cylinder is disassembled.
Piston rod Replace when there is a bend of 0.5 mm per meter.
Note: The bushing on the cylinder head is press-fit with the cylinder head.
Use “Cylinder head Kit” for parts replacement to replace the bushing.
(Cylinder head Kit: A parts replacement kit where a bushing is press-fit with cylinder head.)
40-60
LIFT CYLINDER
Inspection after Reassembly

Check for smooth movement with no abnormality through full stroke without
No-load operation check
load five times.
Dimension check Check the most contracted length and stroke specified in the drawing.
Check for tightness, permanent distortion, or external leakage when the test
pressure (specified in the drawing) is applied to the stroke end for 3 minutes
Pressure check
or more.
WARNING: Be sure to immobilize the lift cylinder during checking.
Check the volume of oil leakage from the rod.
External leakage check
(Refer to the following page.)
Internal leakage check Oil leakage volume shall be 3 ml or less for 10 minutes.
Criteria for oil leakage from rod

Determine by the oil ring condition after cycling 20 times with an oil temperature of 68 - 104° F (20 - 40°C).
Take proper action referring to Section on Troubleshooting.
40-61
LIFT CYLINDER
3. General tools
No. Tool Qty
1 Flat-blade screwdriver 1
2 Hexagon wrench 1 set
3 Vise 1
4 Torque wrench 1 set
5 Plastic hammer 1
6 Monkey wrench 1
7 Spatula 1 set
8 Hook wrench 1
4. Special tools
The following tools are helpful for disassembling/reassembling the cylinder.
Tool Simplified figure
Wiper ring press-fit

tool
Piston seal press tool
40-62
LIFT CYLINDER
Disassembling Procedure
1. Bleed oil.
2. Loosen cylinder head.

Loosen cylinder head with a hook wrench, and
remove it from cylinder tube assembly.
Put an oil pan under the cylinder tube assembly
as the remaining oil may leak out
3. Pull out cylinder head.

Carefully pull out the cylinder head straight.
The piston ring may touch other parts right after it

is pulled out from the rod depending on the
shape of the end of piston rod assembly. Be very
careful when pulling the cylinder head.
4. Pull out piston rod assembly.

Carefully pull out the piston rod assembly hori-
zontally, and put it on a crosstie.
The piston rod assembly may touch the thread

portion of cylinder tube assembly right after it is
pulled out or may fall and damage other parts.
This is more risky for lift cylinders with long con-
tracted length. Be very careful to avoid damage.
5. Pull out spacer.

Pull out the spacer from piston rod assembly.
However, spacer with wear ring cannot be
removed, as it is non-disassembly part.
The wear ring can be removed easily by hand.
6. Disassembling piston assembly

Remove U-ring, backup ring, bushing, and cush-
ion bearing.
The piston rod and piston cannot be disas-

sembled.
1) Use a spatula or screwdriver to pull out the U-ring and backup ring.
2) Remove bushing while widening the mating face using a screwdriver.
The removed seal parts cannot be reused.
3) Remove snap ring from the groove with a sharp-tip tool, and then pull out the cushion bearing.
40-63
LIFT CYLINDER
7. Disassembling seal parts in cylinder head

Remove U-ring, wiper ring, and O-ring.
1) Use a spatula or screwdriver to remove the
U-ring.
2) Since the wiper ring is press-fit, pull it out by
hitting the rubber from the bush side with a
screwdriver or a similar tool.
3) (Remove the O-ring using a spatula or
screwdriver in the same way as the U-ring.
The removed seal parts cannot be reused.
8. Cleaning and storage

1) Clean the removed parts with white kerosene,
apply hydraulic oil to them, and then store them
with a cover.
2) If the removed parts are left, the cylinder cannot
exhibit its performance well after reassembling
due to rust or dust.
Reassembling Procedure
Coating of parts may peel off and fall inside when

reassembling them. Be very careful so that coat-
ing materials may not fall into the cylinder. This
may cause oil leakage.
1. Reassembling cylinder head

Prepare the disassembled cylinder head or “cyl-
inder head kit”.
Clean them well before reassembling.
1) Installing U-ring
Press-fit the U-ring into the U-ring groove of cyl-
inder head. Use a spatula to avoid damage to
the U-ring. If the U-ring is heated to approx.
158°F (70°C), it can be installed easily. Be care-
ful not to get burned.
Check that there is no permanent deformation
such as wrinkles after installation.
2) Installing wiper ring
Installing the wiper ring using a tool. Push the wiper ring with a press machine or the like.
40-64
LIFT CYLINDER
3) Installing O-ring
Install the O-ring paying attention not to damage
or cut it.
Check that there is no distortion after installation.
2. Reassembling piston assembly

Clean the piston and the surrounding area well
before reassembling.
1) Installing U-ring
Install the U-ring to the U-ring groove of the pis-
ton while expanding it. Pay attention to its orien-
tation. If hydraulic oil is applied to the U-ring, it
can be installed easily. An insertion tool as
shown in the figure will make the installation
safe.
2) Installing backup ring

Install backup ring to the back of U-ring (see the
figure).
If installed incorrectly, the backup ring will not
function normally and damage U-ring, which may
inhibit normal cylinder operation.
3) Installing bushing
Install the bushing to the bush groove of the pis-
ton while widening its mating face (see the fig-
ure).
40-65
LIFT CYLINDER
4) Installing cushion bearing

Insert the cushion bearing into the piston irre-
spective of its orientation. Then fit snap ring into
the snap ring groove of the piston to secure the
cushion bearing.
3. Reassembling cylinder tube assembly, piston

rod assembly, and cylinder head
1) Fixing cylinder tube assembly
Secure the cylinder tube assembly horizontally.
2) Inserting spacer (installing wear ring)
Insert the spacer into piston rod assembly.
Press-fit O-ring into the O-ring groove around the
piston rod, and then insert the spacer from the
end of the piston rod until the spacer touches the
piston. If the fitting is not smooth, apply hydraulic
oil to the O-ring.
When non-disassembly type spacer with a wear
ring is used, install the wear ring into the wear
ring groove of the spacer.
3) Inserting piston rod assembly
Insert the piston rod assembly into cylinder tube
assembly 1 completely.
When inserting piston rod assembly 2, it may

touch the thread portion of cylinder tube assem-
bly, causing damage to the piston seal or other parts. Carefully insert the piston rod assembly
while holding it horizontally.
4) Installing cylinder head

Press and insert cylinder head into the piston rod
assembly from the end of the piston rod assem-
bly. Then insert the cylinder head into the
threaded portion of the cylinder tube assembly,
and tighten the cylinder head with a hook wrench
to the torque specified in the assembly drawing
Test run
Mount the cylinder to the main body, actuate the
switch valve, and then perform full-stroke operation 8
times. The cylinder is now filled with oil.
Do not start the cylinder suddenly. Doing so may
cause aeration of the hydraulic oil.
40-66
TILT CYLINDER
TILT CYLINDER
1. Cylinder Sub-Assy 8. Nut 15. Back-up Ring

2. Piston Rod 9. Head 16. Gasket (Packing)
3. Spacer 10. O-ring 17. Head
4. Piston 11. Dust Seal 18. Bushing
5. Gasket (Packing) 12. Bushing 19. Snap Ring
6. Back-up Ring 13. Washer 20. Bushing
7. O-ring 14. O-ring 21. Snap Ring
Before disassembling, protect threaded portion of the cylinder rod with tape to ensure neither the lip
seal nor the packing will be damaged.
40-67
TILT CYLINDER
TILT CYLINDER - DISASSEMBLY

1. Remove tilt cylinder from lift truck.
2. Remove the yoke end from the piston rod. Remove spacer from piston rod (if equipped).
3. Remove the head from the cylinder.
a. Hold the cylinder securely. Do not clamp or vise the cylinder tube to avoid damage.
b. Remove the head from the cylinder by turning counterclockwise.
Special Tool OSTBX-1 is required to remove the head. The use of incorrect tools may damage the
head or cylinder and may void the warranty.
c. Remove the head/piston rod/piston assembly from the cylinder.
Using compressed air to remove the head/piston rod/piston assembly from the cylinder may cause
the assembly to be ejected with great force. Use extreme care when removing these assemblies.
4. Disassemble the head/piston rod/piston assembly.

a. Securely hold the piston rod so that the piston nut may be loosened.
Special Tool OSTBX-2 is recommended to hold the piston rod. The use of incorrect tools may
damage the piston rod and could void the warranty.
b. Remove the piston nut by turning clockwise.
The piston nut is of the staked type. Significant difficulty may be encountered when the nut is
removed from the piston rod.
c. Remove the piston from the piston rod.

d. Remove the head by sliding toward the piston end of the rod.
e. Remove all internal and external seals from the piston.
f. Remove all internal and external seals from the head. Pay close attention to location of original
parts for ease of reassembly.
TILT CYLINDER PARTS INSPECTION

1. Cylinder sub-assembly inspection
a. Inspect cylinder sub-assembly for scratches or scoring on the interior surface.
If scratches or scoring exist on the interior surface of the cylinder sub-assembly, the sub-assem-
bly must be replaced.
b. Inspect the internal threads for damage or scoring. If the threads are damaged or scored, replace
the sub-assembly.
2. Piston Rod inspection
a. Inspect the piston rod chrome surface (30.0 mm diameter) for damage or scratches.
If the chrome surface is scratched, gouged, dented, rusted or scored, the piston rod must be
replaced.
b. Measure the piston rod chrome surface at the piston locating shoulder.
40-68
TILT CYLINDER
The maximum diameter of the piston rod chrome surface is 29.98 mm. If the measurement is
larger than this value, replace the piston rod.
c. Inspect the threaded portions of the piston rod for damage or scoring.
If damage is discovered during inspection, replace the piston rod.
3. Piston inspection
Inspect the piston for dents, damage or scoring. If damage is found, replace the piston.
4. Head inspection
a. Inspect the threaded portion of the head for damage or scoring. If damage is found, replace.
b. Inspect the piston rod guide bushing for scratches or scoring. Replace the head if damage is dis-
covered.
TILT CYLINDER REASSEMBLY

1. Obtain the proper seal kit and a new piston nut.
2. Thoroughly clean all parts to remove any possible contamination.
Foreign matter that enters the cylinder can cause scratches, scoring and seal leakage. Do not permit
any foreign matter to enter the cylinder.
3. Reassemble head
a. Inspect head for absolute cleanliness.
b. Install new seals in head. Ensure that all seals are installed in their proper locations.
Failure to use new seals, or installing seals improperly, may cause a sudden loss of pressure in the
cylinder which may result in injury or property damage.
4. Reassemble piston
a. Inspect piston for absolute cleanliness.
b. Install new seals in piston. Ensure that seals are installed in their proper locations and are cor-
rectly oriented.
5. Reassemble head/piston rod/piston assembly
a. Securely hold the piston rod so that the piston nut may be tightened.
Special tool OSTBX-2 is recommended to hold the piston rod. The use of incorrect tools may
damage the piston rod and could void the warranty.
b. Install the head onto the piston rod. Take care not to damage the seals or guide bushing.
Scratches on the seals or guide bushing can cause seal leakage or rod damage.
c. Install piston onto piston rod. Apply a small amount of grease on the rod to ease installation.
d. Install a new piston nut onto the piston rod. and torque to 290 lbs./ft (392 Nm).
40-69
TILT CYLINDER
Torque the new piston nut to 290 + 43.5 lbs./ft (392 + 59 Nm). Failure to use a new piston nut may
cause the piston nut to loosen. A loose nut may allow the piston rod/piston assembly to come
apart resulting in cylinder failure. Always use a new nut and torque the nut as specified.
6. Reassemble tilt cylinder

a. Inspect cylinder sub-assembly for cleanliness.
b. Hold the cylinder securely. Do not clamp or vise the cylinder tube as damage will occur.
c. Ensure that the head/piston rod/piston assembly is cleaned with solvent and dried. Do not use
rags or paper towels to dry. Gentle drying with compressed air is recommended.
d. Apply clean hydraulic oil to the piston and inside the cylinder.
e. Install the head/piston rod/piston assembly into the cylinder sub-assembly.
NOTE: Use care not to damage the threaded portion of the cylinder. Damaged threads will pre-
vent the head from fully seating in its proper location.
f. Apply medium strength thread locking agent to the threaded portion of the head.
g. Thread the head into the cylinder taking care to align the threads properly.
h. Torque the head to 360 + 55 lbs./ft (490 + 75 Nm).
NOTE: Special tool OSTBX-1 is required to install the head. The use of incorrect tools may dam-
age the head and could void the warranty.
NOTE: Failure to properly torque the head can result in cylinder leakage or cylinder damage and
could void the warranty.
i. Install the spacer, if needed, and yoke end onto the piston rod.
j. Install the tilt cylinder assembly onto the lift truck.
k. After fully installed, cycle the tilt cylinder and check for function and leakage.
40-70
CONTROL VALVE
CONTROL VALVE
1. Nut (4)
2. Nut (2)
3. Housing
4. Through Bolt (2) (small)
5. Through Bolt (1) (larger)
6. Housing
7. Spring
8. Poppet
9. O-Ring
40-71
CONTROL VALVE
Disassembly - Disassembling valve assembly

Pay attention to the following when disassembling parts:
• Place the target forklift horizontally with all forks grounded. Stop the engine and release the pressure
off the actuator. If disassembling is performed with pressure confined, high-pressure oil may spray out
or parts may jump off suddenly possibly causing injury.
• Bleed air from the pressure tank.
• Clean the target parts and the surrounding area to prevent foreign matter from entering the valve when
disassembling.
• Distinguish each disassembled part with a tag or the like for correct reassembling.
• Replace all the removed seal parts (O-rings, backup rings, etc.) with new ones.
• Since spools are engaged in accordance with the management of clearance with the valve housing,
they cannot be replaced for quality reasons. Do not bump or drop any spool.
• Since the mating face of sections is a sealed surface, do not bump or scratch it.
• Clearance of spools is precisely managed to minimize internal oil leakage. Replace spools as a spool
section assembly, as they may be deformed during disassembling or reassembling.
1. Remove main relief valve from the valve housing.

Precautions when disassembling relief:
The relief valve should be replaced as an assembly. Therefore do not disassemble the relief valve
unless a defect is found. Refer to the relief valve maintenance manual when disassembling it. Distin-
guish each disassembled part for correct reassembly.
2. Remove tie rod nuts (1), (2) at the end, and disassemble the spool assemblies of each section
one by one. Loosen and remove tie rods (through bolts) (4), (5) from the lift spool section.
Be careful not to misplace the poppets, springs, and O-rings inserted in the mating faces of sections.
Cleaning
Wash all the disassembled parts completely with clean mineral oil.
Then dry them with compressed air and put them on clean paper or lint-free cloth for inspection.
Inspection
Check all disassembled parts for burrs, scratches, flaws or any other defects on any surface.
1. Check that no scratch or dent is present on the outer surfaces of spools. If slight scratches are found,
remove them with an oilstone or cloth dampened with lapping agent.
2. Check that all sliding parts move smoothly, and that no foreign matter is left in any groove or path.
3. Replace spring if it is damaged, deformed or worn.
4. Check that seal grooves of the valve housing are smooth with no dirt/dust, dent or rust.
5. If any dent and/or scratches are found on the check seat surfaces of the valve housing, remove them
by lapping while paying attention not to leave lapping agent in the valve.
6. When the relief valve does not work normally, check it according to the relief valve maintenance man-
ual.
7. When replacing O-rings or backup rings, always replace them with new ones.
8. When any cap or plug is detached, check that no paint scrap is left near the plug seats or holes of the
machine body. If paint scraps enter the valve, they may cause catching or clogging, which may result
in a malfunction or oil leakage.
40-72
CONTROL VALVE
Assembly
1. Pay attention to the following when handling O-rings.
1) Do not use O-rings with a molding defect or scratches.
2) Apply grease or hydraulic oil to O-rings and their installation places for adequate lubrication.
3) Do not expand any O-ring to an extent where it is permanently deformed.
4) When installing an O-ring, do not roll it. Once it is distorted, the distortion cannot be corrected nat-
urally. This may cause oil leakage after installation of the O-ring.
2. Pay attention to the following when handling spools.

1) Always observe the specified torques. Excessive torque on tightening screws may cause spool
malfunction.
2) Put spools, springs, and spool ends in the same combinations as those before disassembling.
3. Pay attention to the following when reassembling section assemblies and valve assemblies.
1) Check that the O-ring at the mating face is fitted within the O-ring groove.
2) Check that no washing oil or hydraulic oil is remaining at the following places before reassem-
bling.
• Outer surface of the O-ring groove at the mating face of each section
• Outer surface of the O-ring groove at the cap installation face
If reassembling is performed with oil remaining at these places, the oil may be misdiagnosed as
oil leakage during operation.
Final reassembling and checking

1. Mount the spool subassembly onto the valve housing at the same position and in the same orientation
as before disassembly, and then attach cap with socket head bolt
2. Mount connector assembly onto the lift section.
3. Tighten the iron cores of solenoid valves to the lift section, install the coil, and then tighten the hexa-
gon socket head bolts, while paying attention to the internal wave washers.
4. Mount the port relief valve and main relief valve.
Precautions when inserting spool

Slowly insert the spool straight to the hole. If the spool does not move smoothly by hand after it is inserted,
it may malfunction.
Precautions when assembling

When reassembling is completed, recheck that all the disassembled parts are securely installed. Loose
installation of parts may cause oil leakage.
1. Pressure adjustment procedure
1) Attach an accurate pressure gauge to the entrance of the circuit.
2) Run the pump at the rated speed.
3) Switch the control valve spool, and read the pressure gauge at the time of cylinder stroke end.
4) Turn the adjuster clockwise until necessary pressure is obtained.
The pressure increases 2,277 PSI (15.7) MPa by one turn of the adjuster (reference value).
5) When pressure reached the specified value, hold the adjuster to prevent it from turning and
tighten the lock nut.
torque
20 - 23 ft/lbs. 27 - 31 Nm {2.8 - 3.2 kgfm}

6) Increase the pressure again and check that the pressure is the specified value.
40-73
CONTROL VALVE
Installation
Pay attention to the following for installation.
• Be careful so that excessive stress is not applied to the valves through piping.
• Tighten all bolts evenly.
• When performing welding near a valve, be careful not to damage seal parts by excessive heat or spat-
ters.
• To prevent dust or foreign matter from entering, do not detach protective materials of ports until piping
is installed.
Operation
• Check that the valves are correctly arranged and that hydraulic oil is clean, and then check that no oil
is leaking outside while increasing the pressure gradually (by inching operation at low idle).
• Use hydraulic oil with an aniline point of 82 to 113 °
• Use relief valves within the specified set pressure.
• Perform adequate warm-up run before starting work.
When starting the machine with a low hydraulic oil temperature or low valve temperature, be careful of the
following to prevent sticking due to spool's heat shock:
• Do not suddenly activate the main relief valve or overload relief valve continuously during warm-up
run. Operate the machine so that hydraulic oil in each actuator can circulate and that each section
warms up evenly.
• Do not perform fine operation or combined operation suddenly under a low temperature. This may
cause partial heating due to throttle control in each section.
Field Replacement Instructions for Lip Seals

1. Remove cap screws, spool cap, seal plate, spring and spring
seats from spool. Hold the spool by the tang end to prevent rota-
tion. This can be done with valve on or off the lift truck depending
upon the valve location.
2. Identify spools so they can be reinstalled in the same bore if the
spools are to be removed from the valve.
3. Remove all foreign material from the spool and seal cavities.
4. Remove screws and seal plate from the opposite end of the
spool. Locate the spool in its neutral position. Be careful not to
move the spool when installing both seals. Use the installation
tools shown in the illustration at right.
5. Lubricate the seal (B) and wiper (C) with Mobilith SHC PM or
equivalent and place on top of tool driver as shown. Use the tool
driver to press the seal into the spool housing counter-bore using
steps 6 through 12 below. Hand force only. Repeat for each seal.
6. Install wiper ring (C) on the end of tool driver (D) with smaller
O.D. of ring into the driver.
7. Put seal (B) on top of wiper ring with the larger O.D. of the seal
away from wiper ring.
NOTE: Lip end of sleeve (A) I.D. is cone shaped to compress seal and wiper ring for installation. See
illustration.
40-74
CONTROL VALVE
8. Carefully slide sleeve (A) over seal (B), wiper ring (C) and driver
(D). Next, lube the end of the spool and spool counter-bore on
the valve.
9. Put tool assembly over end of spool with raised lip of sleeve (A)
into counter-bore of valve section.
10. Push driver (D) with slow steady motion to install seal and wiper
ring into valve housing.
11. Ensure that all threads are clean and dry, apply Loctite # 242
(red), 1 or 2 drops to spool end screw and assemble spring seats
and spring. Torque screw to spool end between 6 - 8 ft/lbs for
both 5,000 lb. and 6,000 lb. valves.
12. Reassemble seal plates, spring, spring seats, spool cap and
mounting screws. Torque mounting screws to 7 ft/lbs. each.
Changing Spool Seals on Hydraulic Control Valves

1. Remove the control valve from the lift truck.
2. Clean entire valve prior to disassembly to prevent dirt or debris from entering valve orifices or getting
onto sealing surfaces.
3. Disassemble tang and cap end without removing spool from housing.
4. Remove original O-Ring and wiper from tang and cap end.
5. Clean seal cavities (tang and cap end) with clean solvent.
6. Lubricate lip seal with oil or light grease.
7. Install new lip seals per diagram with fingers or blunt tool using caution to ovoid damage to the outside
and inside diameters of the critical edges as the seal enters the seal cavity.
40-75
CONTROL VALVE
8. Install new wipers as per diagram.

9. Reassemble tang and cap end mechanism. Apply Loctite # 271 to spool end screw and torque to 7 ft/
lbs. Also torque socket head screws to 7 ft/lbs. Torque machine screw RD. HD. to 4 ft/lbs.
10. Check all spools for ‘sticking’ before reinstalling on lift truck. If the spools stick or will not move
smoothly, the lip seals may be improperly installed. Repeat the above procedure.
40-76
FORK CARRIAGE
FORK CARRIAGE
See applicable Mast Service Manual in Appendix 1.
FLOW DIVIDER
COMPONENT PARTS
Ref. No. Part Name Qty

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

control port
40-77
FLOW DIVIDER
DISASSEMBLY
1. Loosen the bolt (3) to remove.
2. Remove the spring (4).
3. Remove the spool (2).
• Be careful not to damage the circumference

of the spool.
1
• Before carrying out disassembly, make sure
that you understand the structure of the flow
divider and lay the disassembled parts out in
order. 2
CHECK AND INSPECTION 4 3
• Never use any fluid oil other than alcohol or brake fluid to wash or clean the parts. In particular,
never use mineral oil such as petroleum and gasoline. If mineral oil sticks on the rubber parts,
they may swell and become unusable.
• Keep the parts in a clean place to prevent the parts from dirt or dust after washing.
• Always keep such parts as the cylinder, the piston or the cup away from any foreign body that
may damage those parts.
ASSEMBLY
1. Assembly of Spool
1) Those parts to be reused must be washed
or cleaned with flushing oil or brake fluid.
Always use mineral hydraulic oil to wash or

clean rubber parts. Never use flushing oil
and petroleum or gasoline for rubber parts.
2) Make sure to prevent the spool (2) circum-

ference from getting scratches or adhered
dirt.
3) Check to make sure the spool functions
smoothly after assembly.
2 4
40-78
FLOW DIVIDER
2. Assembly of Spring
Assemble the spring (4) as shown in the diagram on the right.
3. Tightening of Bolt
1) Assemble the bolt (3) to the O-ring (5). 5 3
2) Tighten the bolt (3) with the following torque.

torque
Bolt: 72 - 79 ft/lbs. 98 - 107 Nm {10 - 11 kgm} 3
• Be careful not to damage the circumference

of the spool.
• Before carrying out disassembly, make sure
that you understand the structure of the flow
divider and lay the disassembled parts out in
order.
40-79
RESERVOIR ASSEMBLY
RESERVOIR ASSEMBLY
COMPONENT PARTS
Ref No. Part Name Qty

3
1 Reservoir 1
2 Baffle Plate 1
3 Reservoir Cap 1

Carry out disassembly and assembly following the diagram shown above.
Make sure to assemble the baffle plate to the cap beforehand. Then, install it to the reservoir.
40-80
HYDRAULIC PUMP
HYDRAULIC PUMP
3.2/3.5 TON K25 PUMP SHOWN BELOW
Front drive gear
Enlarged Enlarged
The copper alloy face

The face chamfered along outer comes to gear side.
circumference comes to the bottom.
Section A-A Section B-B Section A-A
1. Front body assembly 11. Flange 21. Isolation plate

2. Bush BR assembly (for front pump) 12. Body seal 22. Center plate
3. Bush BL assembly (for front pump) 13. Bush seal 23. Rear body assembly
4. Bush ER assembly (for center pump) 14. Packing ring R 24. Rear drive gear
5. Bush EL assembly (for center pump) 15. Packing ring L 25. Driven gear
6. Front drive gear (for front pump) 16. Bolt with hexagon flange 26. Bush ER assembly (for rear pump)
7. Driven gear (for front pump) 17. Oil seal 27. Bush ER assembly (for rear pump)
8. Rear drive gear (for center pump) 18. Snap ring
9. Driven gear (for center pump) 19. Plate seal
10. Side plate 20. 0 Backup
40-81
HYDRAULIC PUMP
DISASSEMBLY
• Clean any dirt stuck on the surface of the pump and the driving shaft, when carrying out disas-
sembly.
• Put the disassembled parts on clean paper or cloth so as to prevent such parts from getting
damaged.
• Lay all of the disassembled parts out in order for ease of identification of such parts before dis-
assembly
1. Placing the flange side of the hydraulic pump face downward, clamp the flange (11) with a vise and
secure it.
Apply any soft material such as wooden piece, aluminum or copper to protect the vise.
2. Remove the flange bolt (16).
• When loosening the bolt, be careful not to drop the hydraulic pump from the vise. Always
make sure to loosen the bolt gradually.
• Always use a proper tool (wrench) in good condition.
3. Remove the hydraulic pump together with the center plate (22) straight in the direction toward the
shaft.
If it is hard to remove, tap the side of rear body (23) lightly with a plastic hammer.
4. Remove the center plate (22) from the rear pump. Then, remove the seal of (12), (13), (14) and (15) in
turn.
5. Pull the spline of the rear drive gear (24) out. Then, remove the bushing of (26), (27) and the gear of
(24) (25) from the rear body.
6. Remove the side plate (10) located at the bottom of the rear body hole.
7. Remove the hydraulic pump from the vise. Hold it by hand to prevent dropping and place it on the
work stand with the front pump side on facing upwards.
8. Pull the flange (11) out straight in the direction toward the shaft. Then, remove the seal of (12), (13).
(14) and (15) in turn.
9. Pull the spline of the front drive gear (6) up slightly. Then, remove the flange side bushings of (2) (3)
and gears of (6) (7) from the front body (1).
10. Remove the parts located at the bottom of the front body such as the side plate (10), the plate seat
(19), the backup seal (20) and the isolation plate (21).
11. Turn the front body and apply the same procedures of the steps 9 and 10 of the above steps to
remove the gear of (8) (9), the bushing of (4) (5), the side plate (10), the plate seal (19), the backup
seal (20) and the isolation plate (21) in return.
If it is hard to remove them, push out the gear end of the rear pump from the bearing hole of the
front pump side.
40-82
HYDRAULIC PUMP
12. Remove snap ring (18) from the flange (11).

Then remove the oil seal (17), which can be
removed with a flat-headed screwdriver “A” in 12 A
the direction toward the arrow mark shown in the
diagram.
13. Make sure to lay all the disassembled parts out
in order for ease of assembly.
JUDGEMENT OF PARTS
See 50. MAINTENANCE STANDARD.
ASSEMBLY
A
21
20
Check to make sure that all the disassembled
parts have been cleaned up and dried with com-
pressed air before beginning assembly.
1. Put the front body (1) on the work stand facing

the front pump side or the flange side on the top.
2. Install the isolation plate (21) at the body bottom
hole. Then, insert the plate seal (19) and backup 19
seal (20).
B
Pay careful attention to the direction of the
suction side (A) and the discharge side (B).
As for the isolation plate, set the face (C) on
the outside circumference downward or face 21
it to the bottom hole side.
3. Set the copper alloy surface of the side plate (10)

to the top (the gear side). Then, insert the side A
plate (10) to the body bottom hole. 10
Pay careful attention to the direction of the

suction side (A) and the discharge side (B).
Copper alloy
surface B
40-83
HYDRAULIC PUMP
4. Insert the front drive gear (6) and driven gear (7).
Match the gear teeth to each other properly.
Be careful that the front pump has the

reversed tooth face.
5. Assemble the bushing (2) and (3). Then, insert it

to the body (1) paying attention to the direction.
6. Assemble the body seal (12), the bushing seal
(13) and the packing of (14) (15) respectively. Front drive gear turning direction
7. Assemble the flange (11) on top of front body (1).
The alignment has been made on the shaft

at the factory. Be careful not to damage the
hole for the shaft. Suction side
8. Hold the flange to prevent the assembled parts

from coming out. Then, reverse the body and
secure with a vise.
9. Assemble the parts with the center pump using
the same procedures taken in steps 2 and 3
above. Then, insert the rear drive gear (8) and
the driven gear (9).
Check to make sure both splines of the rear Discharge side

drive gear (8) and the front drive gear (6)
match properly.
10. Insert the bushing (4) and (5) using the same procedure taken in step 5 above.
11. Assemble the body seal (12), bushing seal (13) and the packing of (14) and (15).
12. Put the rear body (23) on the work stand setting the gear hole side to the top and insert the side plate
(10) in the hole bottom.
13. Pay attention to the turning direction of the gear.
Then, insert the rear drive gear (24) and the
driven gear (25). Gear shaft 18
14. Insert the bushing of (26) and (27) with the same Dust lip
procedure taken in step 5 above.
15. Insert the seal of (12), (13), (14) and (15) in turn
with the same procedure taken in step 6 above. Inside pump Shaft end
16. Install the center plate (22) on top of rear body.
17. Install the rear pump assembled with the proce-
dures taken in steps 12 through 16 above on the Lip
top of the front body (19).
17
Check to make sure both splines of the rear
drive gear (8) and the front drive gear (6)
match properly.
18. Tighten the bolt with the flange.

torque
34 - 36 ft/lbs. 46.1 - 48.6 Nm {4.7 - 5.0 kgm}
40-84
HYDRAULIC PUMP
• Always tighten the bolt with the specified torque.

• If tightening torque is greater or smaller than the specified torque, it may result in damage to
the bolt or cause trouble blowing the hydraulic oil out from the matching face of the hydraulic
pump.
19. Remove the pump from the vise and assemble the flange (11) with the oil seal (17) and the snap ring
(18).
Apply a thin layer of clean lithium grease to the oil seal.

As to the direction for installing the oil seal (17), see the diagram.
When installing the oil seal with compressor, make sure to install it straight so as not to damage
the lip. Protect the front drive gear end with tape to prevent the lip from getting damaged and
remove the tape after installation.
20. Turn the drive shaft end with a tool. If it turns lightly by hand, you can assume it is clean internally. In
case of turning roughly, carry out disassembly and assembly again because either dirt or bit of seal
could be found.
21. Check the assembled pump again for correct assembly method and turning direction. Then, assemble
it to the truck. Pay attention to the following points:
1) Check to make sure that no scratches can be found at the in-line boss part, which is a standard
for alignment.
2) Check to make sure that neither scratches nor dirt can be found on the fitting surface of flange
(11). In particular, carefully check after tightening too strongly with the vise.
3) Check to make sure that neither scratches nor dirt can be found on the flange face of the piping.
Remove scratches or dirt with fine oilstones.
For such component parts as body, gear and bushing, make sure to assemble them in the same
position and direction as they were originally, when carrying out assembly again after disassembly.
40-85
PROPELLER SHAFT
PROPELLER SHAFT
The propeller shaft can be supplied as a drive shaft assembly.
Typical lubrication cycle: 1200 hours
40-86
50. MAINTENANCE STANDARD
MAINTENANCE STANDARD......................................................................................... 50-1

TORQUE CONVERTER................................................................................................. 50-3
TORQFLOW TRANSMISSION ...................................................................................... 50-6
TRANSMISSION CONTROL VALVE ............................................................................. 50-8
DIFFERENTIAL ............................................................................................................ 50-10
WHEEL BRAKE ............................................................................................................50-11
BRAKE MASTER CYLINDER ...................................................................................... 50-12
BRAKE BOOSTER....................................................................................................... 50-13
STEERING AXLE ......................................................................................................... 50-15
POWER STEERING VALVE ........................................................................................ 50-16
LIFT CYLINDER........................................................................................................... 50-18
MAST, FORK CARRIAGE AND FORK ........................................................................ 50-25
HYDRAULIC PUMP ..................................................................................................... 50-26
FLOW DIVIDER ........................................................................................................... 50-30
PROPELLER SHAFT ................................................................................................... 50-32
50-1
TORQUE CONVERTER
TORQUE CONVERTER
COMPONENT PARTS
1
2
3
4
Mark Part Name Qty

1 Oil Filter 1
2 Turbine 1
3 Stator 1 Torque
Converter
4 Impeller 1 Circuit
5 Turbine Shaft 1
7 5
6 Gear Pump 1
7 Turbine Hub 1
6
8 Input Plate 1
9 Housing 1 8
50-3
TORQUE CONVERTER
The numbers shown in the mark column of the table refer to the location of the component parts shown in
the diagram.
Criteria [in. (mm)]

NO. Check Item Mark
Standard Limit
Piston (Shaft) and Torque Converter Housing (Hole)
1 A B
Torque Converter Housing Piston
A: Piston Outside Diameter Ø21.972 - Ø21.985mm – 4

1-1 Main Relief Valve B: Hole inside Diameter Ø22.000 - Ø22.021mm – 3
Clearance: in. (mm) .0006-.002 (.015 -.049) .003 (0.080) –
Torque Converter Inlet Port
1-2 B: Hole inside Diameter Ø14.000 - Ø14.018mm – 3
Valve
Clearance: in. (mm) .001-.002 (.030 -.058) .003 (0.080) –
1-3 Lubrication Relief Valve B: Hole inside Diameter Ø14.000 - Ø14.018mm – 3
Clearance: in. (mm) .001-.002 (.030 -.058) .003 (0.080) –
Pressure Spring
2
C
D
E
C: Free Length 3.61 (91.8) – 6

D: Mount Length 3.11 (79.1) – –
2-1 Main Relief Valve
37.5 lb/f (166.9
E: Mount Load N 41.4 lb/f (185.4 N) ± 5% N) –
C: Free Length 4.07 (103.4) – 5

2-2 Torque Converter inlet Port D: Mount Length 3.06 (77.6) – –
Valve
E: Mount Load N 10.7 lb/f (47.8 N) ± 5% 9.67 lb/f (43.0 N) –
C: Free Length 2.38 (60.5) – 8
2-3 Lubrication Relief Valve D: Mount Length 1.90 (48.2) – –
E: Mount Load N 13.2 lb/f (58.8 N) ± 5% 11.9 lb/f (52.9 N) –
50-4
TORQUE CONVERTER
Criteria [in. (mm)]

NO. Check Item Mark
Standard Limit
Oil Seal and Torque Converter Impeller
F:– 1.63 (41.5)

3 G: 1.650 - 1.652 1.65
F
G
(41.915 - 41.965) (41.815)
Oil Seal Impeller
H:.0746 -.0748
.063 (1.600)
(1.895 - 1.900)
I
I:.0736 -.0815
(1.870 - 2.070) .0657 (1.670)
4
K
J:.0787 -.0885 .0905 (2.30)

J (2.000 - 2.250)
K: 1.657 - 1.658
1.663 (42.25)
(42.10 - 42.13)
Seal Ring Seal Ring Groove
Bushing and Stator Support
L: 1.279 - 1.280 –
(32.500 - 32.525)
M: 1.277 - 1.278
–
5 (32.450 - 32.470)
Clearance:
.0011 -.0029
L
.0039 (0.100)
(0.030 - 0.075)
Bushing Stator Support
50-5
F1
D1
C1
D2 C2 A1 A2
50-6
Criteria [in. (mm)]

Mark Check Item Remedy
Standard Limit
.123 -.128
A1 Thickness of Drive Plate .0114 (2.9)
(3.13 - 3.27)
A Plate .092 (2.35) Replace
.098 -.104
A2 Thickness of Driven Plate (Oil groove width:
(2.50 - 2.65) min..0059 (0.15))
Clearance at End Gap when .0141 -.0220
B1 –
inserting piston (0.36 - 0.56)
Replace with
B Seal Ring B2 Depth of Oil Groove in side .0059 -.0137 Oil groove every
face (0.15 - 0.35) must be there.
disassembly
.1023 -.1043
(D1) Width of Insertion Groove (2.60 - 2.65) .110 (2.8)
Inside Diameter of Seal Ring 1.378 - 1.379

C1 1.385 (35.2)
Contact Face (35.025 - 35.050)
C Piston
C2 Width of Seal Ring .1220 -.1226 .1338 (3.4)
Insertion Groove (3.1 - 3.2)
Width of Seal Ring .1023 -.1047
D1 Insertion Groove (2.60 - 2.65) .1102 (2.8)
D Drive Shaft
Width of Seal Ring .1023 -.1043
D2 .1102 (2.8)
Insertion Groove (2.60 - 2.65)
E1 inserting clutch case (0.2 - 0.4) .0393 (1.0)
.1169 -.1185
E Seal Ring E2 Width (2.77)
(2.97 - 3.01)
Replace
(C2) Width of Insertion Groove .1220 -.1259 .1338 (3.4)
(3.1 - 3.2)
Inside Diameter of Seal Ring 3.936 - 3.939
F Clutch Case F1 Contact Face (100 - 100.054) 3.948 (100.3)

H1 –
inserting cap (0.36 - 0.56)
H Seal Ring H2 Depth of Oil Groove in side .0059 -.0137 Oil groove
face (0.15 - 0.35) must be there.
.1023 -.1043
(D2) Width of Insertion Groove (2.60 - 2.65) .1102 (2.8)
.0031 -.0110
– Gears – Backlash –
(0.08 - 0.28)
Replace with
Gasket, O-ring and new parts on
– Seals – – disassembly
and assembly
50-7
TRANSMISSION CONTROL VALVE

COMPONENT PARTS
23
19
22
21
1
8
18 10
11
15
7
17
20 5
16
4
2
13 14
12
1. Valve Body 9. Spring 17. Gasket

2. Spool 10. Spring 18. Plug
3. Valve Body 11. Pin 19. Plug
4. Spring 12. Plate 20. Orifice
5. Spacer 13. Gasket 21. Oil Seal
6. Spring Pin 14. Bolt 22. Plate
7. Spring 15. Piston 23. Bolt
8. Piston 16. Plug
50-8
The numbers shown in the mark column refer to the callouts in the component parts diagram.
Criteria [in. (mm)]
Mark Check Item Remedy Mark
Standard Limit
Piston or Spool and Body Hole
A: Valve Body Inside Diameter
B: Piston Spool Outside Diameter
– – – –
A B
1.1011 - 1.1015
(27.97 - 27.98)
Piston Outside Diameter 1.1023 - 1.1031 14
1 Accumulator Body Inside Diameter .0031 (0.080) 1
Clearance (28 - 28.021)
.0007 -.0020
(0.020 - 0.051)
.7858 -.7866
Piston Outside Diameter (19.96 - 19.98) 15
2 Regulator Body Inside Diameter .7873 -.7882 (20 - 20.021) .0031 (0.080) 1
Clearance .0007 -.0024
(0.020 - 0.061)
.7858 -.7866
Piston Outside Diameter (19.96 - 19.98) 15
3 Lubrication Relief Body Inside Diameter .7873 -.7882 (20 - 20.021) .0031 (0.080) 1
(0.020 - 0.061)
.7862 -.7866
Spool Outside Diameter (19.97 - 19.98) 2
Inching Spool Body Inside Diameter .7873 -.7882 (20 - 20.021) .1127 (0.070) 1
4 (0.020 - 0.051)
.7862 -.7866
Small Piston Piston Outside Diameter (19.97 - 19.98) .1127 (0.070) 3
Clearance .0007 -.0020 Replace
(0.020 - 0.051)
Spring
C: Free Length
– D: Mount Length –
E: Mount Load
C
D
E
Free Length 1.739 (44.18)
Accumulator Large Mount Length 1.129 (28.70) 258.6 N {26.4 11
Spring kgf}
Mount Load 287.3 N {29.3 kgf} ± 5%
5
Accumulator Small
Spring Mount Length 3.295 (83.7) 75.7 N {7.7 kgf} 12
Mount Load 84.1 N {8.6 kgf} ± 5%
Regulator Large Free Length 4.372 (111.07) 147.1 N {15.0

Mount Length 2.941 (74.7) 16
Spring Mount Load 163.8 N {16.7 kgf} ± 5% kgf}
6
Free Length 4.859 (123.43)
Regulator Small Mount Length 3.807 (96.7) 185.4 N {18.9 17
Spring kgf}
Mount Load 206 N {21.0 kgf} ± 5%
7 Lubrication Relief Mount Length 1.885 (47.9) 124.5 {12.7 kgf} 19
Mount Load 138 N {14.1 kgf} ± 5%
Inching Spool Mount Length 1.889 (48.0) 31.4 N {3.2 kgf} 7
8
Small Piston Mount Length .8661 (22.0) 62.6 N {6.4 kgf} 4
50-9
DIFFERENTIAL
DIFFERENTIAL
Criteria [in. (mm)]

Standard Limit
In case of Replace (Excl. Bevel
Differential Pinion Gear and Differential
A – damaged tooth Gear and Pinion be
Side Gear
face replaced in a set.)
.9826 -.9834 .9744
B Outside Diameter of Spider
(24.959 - 24.980) (24.75)
Inside Diameter of Differential Pinion .9842 -.9881 .9921
C
Gear (25.0 - 25.1) (25.2)
.0763 -.0811 .0669
D Thickness of Bushing Replace
(1.94 - 2.06) (1.7)
.0598 -.0661 .0511
E Thickness of Bushing
(1.52 - 1.68) (1.3)
12.204 - 12.2125 12.283
– Inside Diameter of Brake Drum
(310.0 - 310.2) (312)
Replace with new
parts when
– Gaskets, O-rings & Seals – –
disassembly and
assembly
50-10
WHEEL BRAKE
WHEEL BRAKE
13.0 - 19.5 ft/lbs.

torque 17.6 - 26.4 Nm
{180 - 270 kgm}
5 (*1)
*1
A
1 2
*1.
torque Back Plate Mounting Bolt: 129.8 - 144.5 ft/lbs. (176 -196 Nm) (18 - 20 kgm)
Back Plate Mounting Bolt: LOCTITE #271
Criteria [in. (mm)]

No. Check Item Remedy
Standard Limit
1 Thickness of Lining .2244 (5.7) .0393 (1.0)
Free Length:
2 Primary side 5.272 (134)
Deterioration of Return 120
Spring Free Length:
3 Secondary side 5.724 (145.4)
120
.0025 -.0059 (0.065 - 0.150) Replace
4 Clearance between Piston and Cylinder No damage including scratches,
deterioration or rust
5 Back Plate No deformation or cracks
12.204 (310) 12.283 (312)
– Inside Diameter of Brake Drum
No scratches or uneven wear
50-11

COMPONENT PARTS
11
9 10
8
2 1
4 12
13
5
17
6 14
7
15
16
The numbers in the mark column of the table below refer to the callouts in the component parts diagram.
Unit: in. (mm)
No. Check Item Standard Limit Remedy Mark

Replace
Clearance between Cylinder and .0007 -.0041 .0059
1 (Cylinder 1, 2
Piston (0.020 - 0.105) (0.15)
Assembly)
Replace
Primary side: approx. 1.0 .0157
2 Allowance of Cup (Piston 2
Secondary side: approx. 1.2 (0.4)
Assembly)
2.755
3 Free Length of Spring 3.102 (78.8) Replace 2
(70)
1. Cylinder 10. Bleeder Valve

2. Piston Assembly 11. Bleeder Cap
3. Snap Ring 12. Valve Spring
4. Boot 13. Valve Seat
5. Pushrod 14. Valve Rubber
6. Nut 15. Gasket
7. Yoke 16. Bolt
8. Bushing 17. Valve Assembly
9. Filler Union
50-12
BRAKE BOOSTER
BRAKE BOOSTER
COMPONENT PARTS
33
17
34
35 19
36 27
37
28 23
38
39
24
25
14 10 9 11 15
26 11 31 32 1 6 30 4 5 22 29 21 20 12 2 13 3 7 8 16 17 18
1. Booster Body 14. Pin 27. Piston Assembly

2. Piston 15. Boot 28. Cylinder Assembly
3. Snap Ring 16. Pushrod 29. Valve Assembly
4. Seal 17. Nut 30. Booster Piston Assy
5. O-ring 18. Yoke 31. Stop Pin
6. Spring 19. Washer 32. Steel Ball
7. Piston Guide 20. Backup Ring 33. Bolt
8. Snap Ring 21. Spring 34. Gasket
9. Cup 22. Spring 35. Valve Rubber
10. O-ring 23. Cylinder 36. Seal
11. Y-packing 24. Bushing 37. Valve Spring
12. O-ring 25. Filler Union 38. Bleeder Valve
13. Washer 26. Stud Bolt 39. Bleeder Cap
50-13
BRAKE BOOSTER
6 2 7 4 5 1 3
Unit: in. (mm)

Standard Allowance
No. Check Item Remedy
STD Repair
STD Size Shaft Hole Clearance Limit
-.0007
+.002 .0007 -.0041
1 Clearance between 1.00 (0.020) (0.052) (0.020 - .006
Cylinder and Piston Ø(25.4) -.0020 (0.150)
(0.053) 0 0.105)
-.0007
Clearance between 1.00 (0.020) +.002 .0007 -.0041 .006
2 (0.052) (0.020 -
Cylinder and Piston Ø(25.4) -.0020 0 0.105) (0.150)
(0.053)
Replace
Free Length Mount Mount Load N (kgf) Free Length
Length
3 Deterioration of Spring
.913 (23.2) .759 (19.5) 65 {6.6} .866 (22.0)
4 Deterioration of Spring 2.89 (73.6) 2.48 (63) 23.5 {2.4} 2.59 (66.0)
5 Deterioration of Spring .583 (14.8) .394 (10) 41.1 {4.2} .512 (13.0)
6 Deterioration of Spring 2.52 (64.1) 1.78 (45.4) 49 {5.0} 2.26 (57.5)

Extra
7 Tightening Torque 14.75 - 22.12 ft/lbs. (20 - 30 Nm) {2.1 - 3.1 kgm}
Tightening
50-14
STEERING AXLE
STEERING AXLE
2.0-ton Lift Truck
Unit: in. (mm)
Criteria
A Diameter of King Pin 1.102 (28) 1.094 (27.8) Replace
Shim
B Deterioration of Knuckle Up/Down – .0078 (0.2)
Adjustment
C Diameter of Bell Crank Pin .8661 (22) .8582 (21.8)
D Diameter of Center Pin 1.96 (50) 1.948 (49.5)
Replace
Cracks
Steering Axle, Hub, Knuckle,
– Scratches or Pealing-off
Bearing
Seizure, Faulty Revolving or Abnormal Noise
50-15
POWER STEERING VALVE

INITIAL SETTING WORK PROCEDURES
LED
NO. Work Terminal Check Item Remarks
Display
After bleeding air, Stop engine. No
Rest steering for 5 times to
1 Connect 1 FLASH check steering wheel smooth steering is
bleed air inside circuit
for no play. available.
Key switch ON: travel State of traveling Controller: initial setting
2 Connect 1 FLASH
straight forward and stop. straight forward mode 1.
3 Key switch OFF Connect Turn off
In traveling straight
Wheels/steering
forward, set the steering
4 Connect Turn off wheel position: Close terminal, if open
wheel knob at the starting
terminals closed
point.
Under initial set:
controller mode 1, 3 or
Check LED for 1
5 Key switch ON Connect 1 FLASH 4 FLASH: faulty
FLASH
controller or wheel
sensor error
1 FLASH
Check 1 FLASH for Under reset: controller
6 Remove the terminals Open ↓
change to 2 FLASH initial set mode 2
2 FLASH
When LED changed to
2FLASH, Under initial set:
Steer surely to the end
1) steer to right end, controller to memorize
7 Open 2 FLASH (Steering speed: 60
2) steer to left end, steering speed and
rpm)
3) return to neutral and steering angle
over.
Normal mode: turn on,
abnormal: turn off.
8 Check LED for lighting Open Turn on Check LED for turn on Stay in 2 FLASH: close
terminals and reset
from No.1.
Check to make sure
9 Finish Open Turn on steering knob position –
corrected
50-16
LED Display
No. Content Terminal LED ON/OFF
Initial set mode 1 0.5s 3s

1 (under initial set) or 1 FLASH
incomplete initial set *
0.5s 0.5s 0.5s 3s

Initial set mode 2
2 2 FLASH
(under teaching)
Steering wheel sensor

3 3 FLASH
error
4 Wheel sensor error 4 FLASH
Controller error or
5 controller under initial Turn off OFF
set
Under normal
6 operation (complete Turn on ON
initial set)
* An incomplete initial setting means initial setting was not correctly completed under normal mode. It
needs to operate steering wheel to turn more than one and half times in right and left from the state of
traveling straight forward under teaching mode.
50-17
LIFT CYLINDER
LIFT CYLINDER
Item Symptom Related parts Possible causes Remedy
Remove the scratches with an oilstone to smooth

the surface (0.4a or less). If oil leakage still occurs,
Scratches/rust are the scratches may damage the seal of U-ring. In
present on the sliding that case, disassemble and check the part.
surface. If the scratch or rust cannot be removed with an
Piston rod oilstone, replace the piston rod, seals of U-ring/
wiper ring, and shaft support material of piston rod.
Apply re-plating or replace the piston rod.

Plating is separated. If seals and/or shaft support material of piston rod
are damaged, replace the defective parts.
Foreign matter is
clogged in the gap Remove the foreign matter.
between piston and Replace the packing if damaged.
cylinder.
Oil contamination at
1 the piston rod sliding Scratches on sliding Replace the scratched part.
portion surfaces
Rod packing
(U-ring) Packing is worn out due Replace the packing.
to loss of rubber
elasticity of packing. Before replacing the packing, check whether it
reaches the end of life or overheats partially.
The lip is missing.
Replace the packing.
Remarkable protrusion
of packing heel Check the piston seal as excessive pressure may
be affecting the packing.
Foreign matter is Remove the foreign matter.

clogged in the lip.
Wiper ring
The lip is damaged.
Other substantial Replace the defective part.
damage is present.
50-18
LIFT CYLINDER
Item Symptom Related parts Possible causes Remedy
The gap from the piston

rod is out of the Replace the shaft support material.
allowable range.
Shaft support
material
Scratches/damage are
Oil contamination at present on the sliding Replace the shaft support material.
2 the piston rod sliding Check the piston rod when replacing.
portion surface.
Cylinder head with
Remove the scratches/rust with an oilstone.
Cylinder head scratches/rust at its seal If the scratches/rust still remain, replace the
position is directly used
as piston rod sliding part. cylinder head.
Remove the foreign matter.

Foreign matter is Replace the O-ring if damaged.
clogged in the gap Check the inner surface of tube. Smooth the
O-ring between piston and surface with an oilstone if scratches/rust are
cylinder. present.
O-ring is damaged. Check the cylinder head O-ring groove. Replace
the O-ring if damaged.
Oil leakage from the
3 cylinder head mating Disassemble the cylinder head to check the O-ring.
Replace the O-ring if damaged.
portion Cylinder head Loose parts are present. Then tighten the loose part to the specified
tightening torque. Refer to the tightening torque
specified in the assembly drawings.
Replace the cylinder tube with a new one.

Oil leakage from the mating portion may be caused
Cylinder tube Abnormal swelling by excessive pressure. Check the cylinder tube for
swelling, deformation, and for system pressure.
Piston rod Substantial bend Replace the piston rod with a new one.
exceeding specified Check the seals and sliding materials for damage.
Cylinder tube bend distortion Replace them if damaged.
Replace the cylinder tube with a new one.

Abnormal operation Cylinder tube A bend is present. Check the seals and sliding materials for damage.
Mechanical parts do
not move smoothly. Remarkable wear/
damage to sliding Replace the defective part with a new one.
Piston rod
Cylinder tube surfaces, foreign matter Check the seals and sliding materials for damage.
4 clogged in the piston, Remove the foreign matter.
Sliding materials cylinder head sliding Check the seals and sliding materials for damage
portion
Internal oil leakage Damage such as scratch Replace the piston seal with a new one.
Piston seal
Expansion or and wear is present. Check the cylinder tube inner surface for damage.
contraction while
piston rod is working Remove scratched/rust with a honing or oilstone to
Specified speed is not Cylinder tube Scratches or rust on the smooth the surface. If scratched/rust cannot be
obtained during inner surface. removed, replace the cylinder tube with a new one.
operation. Replace the piston seal with a new one.
Bleed the air.

Cylinder with no air bleeder
Bleed the air by reciprocation several times with
low pressure and low speed.
Cylinder with an air bleeder
Operation is not Air is remaining in the Remove the load to prevent inner pressure from
Air high temperature, and then loosen the air bleeder
stable. cylinder. to bleed air.
(Reference)
The cylinder expands or contracts in some cases
5 when it stops suddenly. This is due to compression
characteristics of hydraulic oil. This phenomenon
is likely to occur with long-stroke cylinders.
Hydraulic oil expands or contracts with the change of temperature and pressure. This
causes the cylinder to expand or contract. Be careful that this is not internal oil leakage. Be
sure to check internal oil leakage under constant temperature and pressure.
50-19
LIFT CYLINDER
Cylinder Seal Service Kits - Installation Instructions
Displacement Design with Piston Seal

Please follow these directions carefully to ensure that the seals are not damaged upon installation.
1. Make sure that the disassembly area, tools and cylinder
are clean prior to disassembly. This will reduce the amount
of potential contaminants that may enter the system during
seal installation. Use a soft jawed vise or some other fix-
turing method to hold the cylinder during this procedure.
Do not crush or bend the cylinder while holding stationary
for the work.
2. Use a claw type spanner wrench to remove the retainer.
Pull the plunger/piston assembly from the shell.
3. Carefully remove the seals from the piston and retainer

using a screwdriver with smooth edges. Use great care
not to scratch the seal grooves.
4. Clean the plunger, piston, retainer and cylinder bore and
then inspect for nicks and burrs. Minor nicks and burrs can
be removed with 400 grit emery cloth.
Minor nicks are those which will not allow oil to bypass
under pressure. If nicks can still be felt with a fingernail
after using the emery cloth, replace the part to avoid leak-
age under pressure.
50-20
LIFT CYLINDER
5. Replace the seals, backup rings, O-rings and wear ring.

Note the correct seal directions. The cylinder will not oper-
ate properly if the seals are installed incorrectly.
6. Place the loader in the cylinder shell. The loader must
cover all the threads, but not contact the thread relief
chamfer.
7. Apply a film of clean hydraulic oil to the cylinder bore,
loader and piston seals. Insert the plunger/piston assem-
bly through the loader and into the cylinder shell. If resis-
tance is encountered, tap the plunger with a rubber mallet.
Remove the loader and ensure that the plunger is fully
inserted.
8. Install the retainer and tighten to the recommended torque
as shown in the table below.
TORQUE SPECIFICATIONS
Bore Dia. Torque Bore Dia. Torque
40 mm 140-160 ft/lbs. 70 mm 260-280 ft/lbs.
45 mm 160-180 ft/lbs. 75 mm 280-300 ft/lbs.
50 mm 180-200 ft/lbs. 85 mm 320-340 ft/lbs.
55 mm 200-220 ft/lbs. 90 mm 340-360 ft/lbs.
60 mm 220-240 ft/lbs. 95 mm 360-380 ft/lbs.
64 mm 236-256 ft/lbs. 105 mm 400-420 ft/lbs.
50-21
LIFT CYLINDER
Cylinder Seal Service Kits - Installation Instructions
Piston Design with No Downstroke Cushioning

Please follow these directions carefully to ensure that the seals
are not damaged upon installation.
1. Make sure that the disassembly area, tools and cylinder
are clean prior to disassembly. This will reduce the amount
of potential contaminants that may enter the system during
seal installation. Use a soft jawed vise or some other fix-
turing method to hold the cylinder during this procedure.
Do not crush or bend the cylinder while holding stationary
for the work.
2. Use a claw type spanner wrench to remove the retainer.
Pull the plunger/piston assembly from the shell.
3. Carefully remove the seals from the piston and retainer

using a screwdriver with smooth edges. Use great care
not to scratch the seal grooves.
4. Clean the plunger, piston, retainer and cylinder bore and
then inspect for nicks and burrs. Minor nicks and burrs can
be removed with 400 grit emery cloth.
Minor nicks are those which will not allow oil to bypass
under pressure. If nicks can still be felt with a fingernail
after using the emery cloth, replace the part to avoid leak-
age under pressure.
5. Replace the seals, backup rings, O-ring and wear ring.

Note the correct seal directions. The cylinder will not oper-
ate correctly if the seals are installed improperly.
50-22
LIFT CYLINDER
6. To replace the O-ring on the internal check valve, you

must first remove the retaining ring and washer. Use a
hook or screwdriver to remove the check valve from the
piston. Replace the O-ring and insert the check valve back
into the piston, followed by the washer and retaining ring.
Ensure that the arrow on the check valve is pointing in the

correct direction.
7. Place the loader in the cylinder shell. The loader must

cover all the threads, but not contact the thread relief
chamfer.
8. Apply a film of clean hydraulic oil to the cylinder bore,
loader and piston seals. Insert the plunger/piston assem-
bly through the loader and into the cylinder shell. If resis-
tance is encountered, tap the plunger with a rubber mallet.
Remove the loader and ensure that the plunger is fully
inserted.
9. Install the retainer and tighten to the recommended torque
as shown in the table below.
50-23
LIFT CYLINDER
TORQUE SPECIFICATIONS
Bore Dia. Torque Bore Dia. Torque
40 mm 140-160 ft/lbs. 70 mm 260-280 ft/lbs.
45 mm 160-180 ft/lbs. 75 mm 280-300 ft/lbs.
50 mm 180-200 ft/lbs. 85 mm 320-340 ft/lbs.
55 mm 200-220 ft/lbs. 90 mm 340-360 ft/lbs.
60 mm 220-240 ft/lbs. 95 mm 360-380 ft/lbs.
64 mm 236-256 ft/lbs. 105 mm 400-420 ft/lbs.
50-24
MAST, FORK CARRIAGE AND FORK
MAST, FORK CARRIAGE AND FORK

Unit: in. (mm)
Criteria
Check Item Remedy
.0196 -.0393 Min..0984

Right and Left (0.5 - 1.0) (2.5) Shim Adjustment
Clearance between Outer Mast and Inner Mast
Roller
.0078 -.0275 Min..0787 Replace with
Front and Rear (0.2 - 0.7) (2.0) oversized roller
.0196 -.0393 Min..0984

Right and Left (0.5 - 1.0) (2.5) Shim Adjustment
Clearance between Inner Mast and Fork
Carriage Roller
.0078 -.0275 Min..0787 Replace with
Front and Rear (0.2 - 0.7) (2.0) oversized roller
Bushing Oil Groove at Mast Support Part Grooved Grooved? Replace bushing
T 1.417 Max. 1.279

(36) (32.5)
2.0 ton
K 1.574 Max. 1.417
(40) (36)
1.574 Max. 1.417

Thickness of Fork A (at the base) 2.5 ton (40) (36) Replace
T 1.732
(44)
Max. 1.555
3.0 ton (39.5)
K 1.771
(45)
3.5 ton Lift Truck

Unit: in. (mm)
Criteria
Check Item Remedy
.0196 -.0393 Min..0984
Right and Left Shim Adjustment
Clearance between Outer Mast and Inner Mast (0.5 - 1.0) (2.5)
Roller .0078 -.0275 Min..0787 Replace with
Front and Rear
(0.2 - 0.7) (2.0) oversized roller
.0196 -.0393 Min..0984
Right and Left Shim Adjustment
Clearance between Inner Mast and (0.5 - 1.0) (2.5)
Fork Carriage Roller .0078 -.0275 Min..0787 Replace with
Front and Rear
(0.2 - 0.7) (2.0) oversized roller
Bushing Oil Groove at Mast Support Part Grooved Grooved? Replace bushing
Thickness of Fork A (at the base) 1.968 (50) 1.771 (45) Replace
50-25
HYDRAULIC PUMP
HYDRAULIC PUMP
Front drive gear

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

to gear side.
The face chamfered along outer circumference
comes to the bottom.
Section A-A Section B-B Section C-C
50-26
HYDRAULIC PUMP
TROUBLESHOOTING
Problem Cause Remedy
Add hydraulic oil to the specified level of
No oil Low oil level
amount.
available from
gear pump Blocked or clogged suction piping or Clean up immediately. In case of dirty oil,
strainer replace with new oil or filter it.
Excessive wear of bushing at (3), (4), (5)
and (6)
Replace with a new part.
Defective bushing seal (14), packing (15)
and (16), plate seal (20) and backup (21)
No pressure Add pressure to the specified level with
Relief valve with faulty adjustment
available from pressure gauge.
gear pump
Repair any loose suction piping.
Add oil to the specified level.
Sucking air Check oil seal at gear pump.
Stop operation until bubble goes out from
tank.
Cavitations caused with damaged suction
Remove dirt from piping or strainer.
piping or clogged strainer
Sucking air because of loosened joint of
Tightening again each joint.
suction piping
Noise from Replace with new oil with proper viscosity.
gear pump Cavitations due to high viscosity of oil Operate forklift truck with proper oil
temperature.
Improper alignment between gear pump
Perform correct alignment.
and shaft from engine
Bubble in hydraulic oil Determine cause and correct.
Oil leakage Defective oil seal (18) of gear pump

Replace with a new part.
from gear Defective body seal (13)
pump Oil being stuck with dirt Check gear pump again.
Check disassembled parts for damage or discoloration. Wash and clean those parts with light-oil. However,
never soak rubber parts in light-oil. Check all the parts again. Repair or replace them with new ones if nec-
essary.
50-27
HYDRAULIC PUMP
1. Front Body and Rear Body

The Gear pump is designed to have gear tooth
tip contact the inner wall of gear hole when rotat-
ing for improvement in pump efficiency. There-
fore, the contact mark of the tooth tip (A) can be
seen around the suction port of the pump, if it
was ever operated. If the contact mark (A) cov- A
ers less than half of the inner wall of gear hole,
then it is normal. It is also normal that the depth
(a) of contact mark (A) is approximately .002 in.
(0.05 mm). When such depth (a) is more than
.006 in. (0.15 mm), replace with a new gear
pump assembly.
2. Drive Gear and Driven Gear

The gear shaft and gear side face should have a a
smooth surface if hydraulic oil is clean. However,
if your fingernail can catch on any rough surface
either on the gear shaft or the gear side face,
and also if abnormal wear of the tooth face can
be seen, replace with a new one. A
Suction
chamber
When diameter of the shaft (b) is less than .7100

in. (18.035 mm), replace with a new gear assem-
bly.
50-28
HYDRAULIC PUMP
3. Bushing
An ideal bushing condition is when the inside d
diameter sliding section of the bushing has no
rough surface and shining contact can be seen
in half of the suction side. It is normal if the side Inlet
face contact (D) is strong at suction side showing
dark gray color while contact at high pressure
side is weak and quite minimal. Outlet
c
Replace with a new part for the following condi-
D
tions described below:
1) The contact can be seen all over the inside
diameter sliding surface of the bushing and
your fingernail can catch rough surfaces on
it.
2) Many scratches can be seen toward circumference at the bushing side face and your fingernail
can catch rough surfaces on it.
3) The scoring marks of a foreign body can be seen at the inside diameter sliding surface and side
surface of the bushing.
Each repair limit size for the bushing are as follows:
If sizes (c) or (d) exist, replace with a new bushing assembly together with a new gear.
Inside diameter (a) Overall length (b)

Type
in. (mm) in. (mm)
For center pump and rear c >.7528 d <.5814
pump (4), (5), (26) and (27) (19.123) (14.768)
c >.7528 d < 1.039
For front pump (2) and (3)
(19.123) (26.411)
4. Side Plate
It is normal if the sliding surface (copper alloy)
contact (D) of the side plate is strong at suction D
side while such contact is weak at high-pressure
side.
• If many scratches can be seen toward cir- A
cumference and your fingernail can catch in
them, replace with a new one,
• In case the thickness of the side plate is less
than .0767 in. (1.95 mm), replace it with a
new one. B
Make sure to replace such parts as push seal, body seal, packing ring, plate seal, backup, oil seal
and snap ring with new parts after disassembly.
50-29
FLOW DIVIDER
FLOW DIVIDER
Fig. 1. Pump OFF Fig. 2. Pump ON
4 5 3 6 7 8 A a B
1 2
1. Pump 5. Orifice
2. Brake Booster 6. Spool
3. Brake Booster or Hydraulic Tank 7. Spring
4. Damper Orifice 8. Body
As for the control of the divided flow, the flow divider is called a “certain amount control type” or a “prefer-
ence distribution type”, which keeps constant control over the flow amount against the fluctuation of flow
volume at the inlet port.
1. Fig. 1 shows non-operation state with the pump OFF. The spool (6) moves to the maximum left from
the spring (7).
2. When oil is supplied to the port from the pump (1), the oil at the port is supplied from the damper ori-
fice (4) of the spool (6) to the first chamber (A), then passing through the orifice (5) and the second
chamber (B) flows to the brake booster (2). However, the oil pressure in the first chamber (A) should
increase due to flow resistance caused by orifice (5).
3. Since the hydraulic pressure in the first chamber (A) should press to the left side of the spool (6) to
overcome the spring (7), it moves the spool (6) to the right, which turns to the pump ON state (Fig. 2)
and the space (a) and (b) is made available between the body (8) groove and the spool (6) accord-
ingly.
50-30
FLOW DIVIDER
4. Then, the oil at the inlet port should flow to the hydraulic tank (3) from the first chamber (A) in passing
through space (a). (The shift from pump ON to the state of Fig. 2 should be made instantaneously.)
5. At the ON state of Fig. 2, the spool (6), with the force pushing to the right due to the difference of the
pressure in the first chamber and the second chamber, should balance with the force pushing to the
left due to the spring (7), which should result in almost constant control over the difference in pressure
between the first chamber (A) and the second chamber (B).
6. This pressure difference is the same at the orifice (5). The amount of oil flow to the brake booster (2)
passing through the orifice (5) should be controlled almost constantly. (The space (a) and (b) should
keep constant control over the difference in pressure between the spool as described above despite
the changes of hydraulic pressure at the each outlet port.)
50-31
PROPELLER SHAFT
PROPELLER SHAFT
Typical lubrication cycle: 1200 hours
Greasing cross bearing:

Supply grease to the grease nipple attached to the cross bearing. Press a grease gun to the end of the nip-
ple, and supply grease until it comes out of all four shafts. Wipe overflowing grease completely to prevent
adhesion of dirt and dust.
50-32
STRUCTURE AND FUNCTION
STRUCTURE AND FUNCTION
60. STRUCTURE AND FUNCTION
STRUCTURE AND FUNCTION ..................................................................................... 60-1

TORQUE CONVERTER, GEAR PUMP & CONTROL VALVE ....................................... 60-3
BRAKE BOOSTER....................................................................................................... 60-12
TILT CYLINDER ........................................................................................................... 60-13
VEHICLE CONTROLLER ............................................................................................ 60-15
HYDRAULIC CIRCUIT DRAWING............................................................................... 60-22
P-PORT OIL PRESSURE MEASURING PORT........................................................... 60-24
60-1
TORQUE CONVERTER, GEAR PUMP & CONTROL VALVE

OUTLINE
1. Torque Converter
Size: 10.5 in. (265 mm)
Type: 3-Element, 1-Stage, 2-Phase Type
(equipped with one-way clutch)
2. Gear pump
Capacity
Theoretical Output: 15.93 cc/rev
Actual Output:
Speed (rpm) Output (per min)

600 > 1.3 gal (5 L)
2,000 > 8.4 gal (32 L)
Output Pressure: 217.5 PSI (1.5 MPa) {15 kgf/cm2}

Oil Temperature: 149 + 41° F (65 ± 5° C)
Type: Inner contact type gear pump
• Ensure that no dirt or debris enters the hydraulic circuit openings on the transmission mount-
ing side.
• Check to make sure each mounting bolt and plug is properly torqued prior to assembly.
• When assembling with engine, make sure to insert torque converter tip boss slowly along fly-
wheel center.
• After completing assembly with engine, check to ensure that gear pump oil level is correct
after rotating torque converter for about one minute at the time of initial oil filling.
STRUCTURE
See Torque Converter Assembly drawing for structure, which consists of following elements.
• Torque Converter Circuit
• Gear Pump
• Housing
• Power Joint (Input Plate, Turbine Hub)
• Oil Filter
• Relief Valve (Main, Torque Converter Inlet Port, Lubrication)
• Strainer Assembly
1) Torque Converter Circuit
Torque converter circuit is 3-element 1-stage 2-phase type consisting of following parts.
a) Impeller
To be connected with input plate through front cover.
b) Stator
To be secured with housing through one-way clutch.
c) Turbine
To be connected with turbine shaft through turbine hub.
60-3
TORQUE CONVERTER ASSEMBLY DRAWING
COMPONENT PARTS
1
2
3
4
7 5
Mark Part Name Qty

1 Oil Filter 1
2 Turbine 1 Torque
3 Stator 1 Converter
Circuit
4 Impeller 1
5 Turbine Shaft 5
6 Gear Pump 5
7 Turbine Hub 1
8 Input Plate 1
9 Housing 1
60-4
2) Gear Pump
It is an inner contact gear type pump driven
with the impeller tip fin, which supplies the
oil to the transmission and the torque con-
verter.
3) Housing
Inside housing, it contains valves as
described below:
• Torque converter inlet port relief valve to
control or prevent torque converter inner
pressure from rising.
• Main relief valve to adjust clutch pres-
sure
• Lubrication relief valve to control or prevent lubrication pressure from rising.
4) Power Joint
a) Input Plate
The outside circumference is connected to the engine side flywheel and the inside circumfer-
ence is connected to the front cover of the torque converter, which transmits engine torque to
the torque converter.
b) Turbine Hub
Combines the turbine shaft and the spline at transmission side and transmits the torque con-
verter output to the transmission.
5) Oil Filter
It is located on the hydraulic circuit at the torque converter outlet port and filters oil to prevent for-
eign bodies from flowing with the oil toward the transmission side.
6) Relief Valve
a) Main Relief Valve
Being contained inside the housing, it adjusts the oil coming from the pump to supply it to the
control valve of the transmission. Thus, it also supplies the relieved oil here to the torque con-
verter.
b) Torque Converter Inlet Port Relief Valve
Being contained inside the housing, it relieves the inner oil pressure from the torque converter
to control or protect the torque converter from escalating inner pressure.
c) Lubrication Relief Valve
Being contained inside the housing, it relieves or drains the oil for hydraulic pressure of the
truck side lubrication circuit so as not to exceed the specified level in order to control or pre-
vent the inside lubrication circuit from escalating hydraulic pressure.
7) Strainer Assembly
Being located at the pump suction circuit, the strainer stops any foreign body with mesh so as to
filter the oil flow to the inside of the oil circuit.
2. Control Valve Assembly

The solenoid valve provides speed selection for one each forward and reverse. It also provides the
inching mechanism with pressure to release the hydraulic clutch when stopping the engine and the
modulation mechanism (accumulator) to relieve shocks occurring at the time of starting truck and shift-
ing speed.
60-5
1. Valve body
2. Solenoid valve
3. Inching spool
4. Accumulator (modulation valve)
60-6
3. Power Transmitting Route
1) Engine rotation is transmitted to the impeller (3) through the input plate (1). Through centrifugal
force, the oil inside of the impeller flows out along the impeller fins.
2) Being pushed out from the impeller, the oil hits the turbine (2) blades and transfers its generated
force through the turbine shaft (5).
3) Coming through the turbine (2), the oil changes the direction of flow with assistance of the stator
(4), which alters the flowing angle to match the blade lines of the impeller.
Constantly repeating steps 1) through 3) above, engine power is transmitted to the transmission side.
Driven by the fins of the impeller hub tip, the gear pump is always rotating in synchronization with the
engine.
4. Hydraulic Circulating Route

1) When starting the engine, the fins of the impeller hub tip of the torque converter drives the gear
pump. Then, the oil inside the transmission flows to the gear pump through the strainer installed
with torque converter assembly, which then delivers oil to the inner contact gear inside the gear
pump.
2) Flowing out of the gear pump, the oil adjusts clutch pressure 160 - 246 PSI (1.1 - 1.5 MPa) (11.2 -
15.5 kgf/cm2) by way of the main relief valve. The regulated oil is supplied to the hydraulic clutch
on the transmission side.
3) On the other hand, the oil removed from the main relief valve is supplied to the torque converter.
4) At the torque converter port, the torque converter inlet port relief valve is there to control an
increase in pressure inside the torque converter to maximum 101.5 PSI (0.7 MPa) (7 kgf/cm2)
60-7
5) Flowing out of the torque converter outlet port, the oil is filtered through the oil filter and supplied
to the oil cooler. The lubrication relief valve is provided at the torque converter outlet port so as to
control an increase in pressure inside the cooling and lubrication circuit to a maximum of 84.1 PSI
(0.58 MPa) (6.0 kgf/cm2).
6) Cooling in the oil cooler, the oil is supplied inside the transmission for lubricating and cooling each
section as required and then returns to inside the transmission case.
See the hydraulic circuit diagram and each port location on the following pages.
60-8
HYDRAULIC PRESSURE CIRCUIT DRAWING
3A 3B
To lubrication of
transmission side
B
3C
C
3E
A
3F
To T/M
3D
1. Oil Tank
2. Suction Filter (100 mesh)
3A. Torque Converter
3B. Oil Filter
3C. Torque Converter Inlet Port Relief Valve
3D. Gear Pump Assembly
3E. Lubrication Relief Valve
3F. Regulator Valve
4. Oil Cooler
60-9
TORQUE CONVERTER ASSEMBLY - HYDRAULIC PRESSURE PORT LOCATION
A B
e d c
f d C
A. Main Pressure Check Port a. Breather Mounting Port

B. Torque Converter Inlet Port Pressure b. Level Gauge Mounting Port
Gauge Port c. To Oil Cooler
C. Lubrication Pressure Check Port d. Drain
e. To Valve on Transmission side
f. Strainer Assembly
60-10
CONTROL VALVE ASSEMBLY - HYDRAULIC PRESSURE PORT LOCATION
a
(On T/M Case)
g
e
f
h
a. Pump O/P Measure Port

b. FWD Clutch Measure Port
c. REVERSE Clutch Measure Port
d. To REVERSE Clutch
e. To FWD Clutch
f. Drain
g. Drain
h. From Pump
60-11
BRAKE BOOSTER
BRAKE BOOSTER
13 12 5 A 6 7
2 1 11 10 B 3 4 9 8
1. Reservoir 6. Reaction Piston 11. Hydraulic Tank

2. Wheel Cylinder 7. Push Rod 12. Piston
3. Pump 8. Spring 13. Return Spring
4. Flow Divider 9. Control Valve
5. Booster Piston 10. Valve sear
1. A certain amount of oil is supplied to the brake booster from the pump (3) through the flow divider (4).
The oil enters to the power chamber (A) inside the brake booster and flows to the hydraulic tank (11)
via the hole of the booster piston (5) after passing through the space (B) being formed between the
control valve (9) and valve (10) respectively.
2. When the brake booster is off, the oil sees no resistance in passing through inside the booster includ-
ing chamber (B), which makes no hydraulic pressure inside the booster.
3. When the brake pedal is pressed down, the reaction piston (6) is pushed out to the left by the push rod
so as to pressurize space (B).
4. With space (B) under pressure, the oil encounters resistance when passing through the space (B),
which should increase the hydraulic pressure in the power chamber (A).
5. With such an increase in hydraulic pressure in the power chamber (A), the hydraulic pressure presses
to the right side of the booster piston (5) so as to push the return spring (13) away and move the piston
(12) to the left.
6. Also, the hydraulic pressure in the power chamber (A) should push the rear piston (6) back to the right
(generating an anti-hydraulic force), which should balance with the brake pedal control force.
7. Therefore, it becomes the receiving pressure area or servo of the booster piston (5) and the reaction
piston (6). However, when the force to push the valve seat (10) back to the right due to the increased
hydraulic pressure in the power chamber (A) is stronger than the spring (8), the space (B) cannot be
compressed and the increase in pressure in the power chamber (A) should stop.
8. In case of a problem at the pump or engine stall, the reaction piston (6), the booster piston (5) and the
piston (12) should be mechanically engaged, which would enable you to operate manually.
60-12
TILT CYLINDER
TILT CYLINDER
6 3 4 5 2
1. Cylinder Head Assembly 4. Bushing

2. Piston Rod 5. U-ring
3. Cylinder Head 6. Wiper Ring
1. BASIC FUNCTION
The tilt cylinder is a kind of hydraulic actuator, which changes the energy being supplied from the
hydraulic pump to the forceful power of a straight line movement through the piston, and then switches
the direction of hydraulic pressure to the movement of pulling out and pulling back by way of operating
the lever of the control valve. Thus, these three functions generate a great deal of power. A straight
line movement and switching of operating direction is the basic function of the tilt cylinder.
2. FUNCTION OF EACH SECTION

1) The cylinder head assembly (1) functions as a bearing of the piston rod (2) by way of inserting the
bushing (4) with pressure to the inside diameter of the cylinder head (3). Also, inserting the U-ring
(5) to the inside diameter of the cylinder head, it prevents oil leakage to the outside. Additionally, it
functions to supply and exhaust high pressure oil from inside of the cylinder tube to the port.
2) The U-ring (5) is located between the bushing (4) and hydraulic pressure to seal the hydraulic
pressure of inside cylinder. Moreover, it forms a moderate oil membrane on the surface of the pis-
ton rod, which works to prevent the piston rod from getting rusty.
3) Being inserted to the inner face of the cylinder head with pressure, the bushing (4) contacts the
piston rod. Sharing a horizontal load given to the piston rod through the piston, it functions as a
straight-line movement on the high-pressure surface against the piston rod. Moreover, it supports
one end of the piston rod to minimize any eccentricity which would affect the sealing function
adversely.
4) The wiper ring (6) is located at the mouth of inlet and outlet for the piston rod from the cylinder,
which prevents the U-ring rod seal of the inside cylinder from getting dusty or leaking water from
the outside. Moreover, it functions to remove the mud stuck on the rod surface with the movement
of the piston rod.
60-13
TILT CYLINDER
3. PISTON SECTION
2.0 - 2.5 ton 3.0 - 3.5 ton
14 13 14 13 15
Fig. 1 Fig. 2
The piston section is provided with the packing (13) for the center of the piston and prevents the hydraulic
pressure from flowing from right of left either side of the piston chamber to the other side of the chamber.
1) Packing (13)
Being located in the center of the piston, the packing has an equivalent sealing function with the
U-packing because of its special one-ring seal lip for both face pressure usage, which seals the
clearance between the piston and the cylinder tube utilizing its tensity and forms the chambers of
high-pressure side and constant pressure side bounded by the piston.
2) Backup Ring (14) in Fig. 1
A combination bearing with insertion-type backup ring, which protects the piston from deteriora-
tion and improves durability and resistance to the oil pressure of the packing (13).
3) Backup Ring (14) in Fig. 2
It stops the packing (13) from protruding and improves durability and resistance to the oil pres-
sure. The bearing (15) protects the piston from seizure or deterioration.
60-14
VEHICLE CONTROLLER
VEHICLE CONTROLLER
The MBX50 Series is equipped with a vehicle controller (interlock box) conforming to ISO3691 Standard,
which includes functions to enhance safety of the vehicle.
1. Travel interlock function (Torque Converter vehicles only)
When an operator leaves the operator's seat, the switch under the seat is activated to disable travel of
the vehicle. To restart travel, it is necessary to reset the forward/reverse lever. This prevents malfunc-
tion of the vehicle.
Operators can check operation status by the travel lock lamp on the meter panel.
If an operator leaves operator's seat with the forward/reverse lever set to F or R, the lamp blinks show-
ing that travel is disabled.
When the operator takes seat again and returns the lever to N (resets), the lamp turns off and travel of
the vehicle can be restarted.
The travel lock lamp is also used as neutral lamp.
Travel lock lamp
2. Load handling interlock function

When an operator leaves the operator's seat, the switch under the seat is activated to disable load
handling with work equipment.
Operators can check operation status by the load handling lock lamp on the meter panel.
If an operator is not seated properly, the lamp blinks showing that load handling is disabled.
When the operator is seated properly, the lamp turns off and load handling can be restarted.
Load handling lock lamp
3. Parking brake warning

When an operator leaves the operator's seat without applying the parking brake, the buzzer sounds to
warn the operator to apply the parking brake.
60-15
VEHICLE CONTROLLER
4. Failure detection
1) Seat switch failure detection
2) Relay output transistor failure detection
3) Forward/reverse lever failure detection
4) CPU failure detection
When any of these failures is detected, the alarm lamp on the meter panel blinks to warn users.
Maintenance alarm lamp

(gasoline vehicle)
Maintenance alarm lamp with

sedimenter alarm lamp (diesel vehicle)
60-16
VEHICLE CONTROLLER
System Overview
- Provision of essential functions

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

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

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

Unload solenoid OFF Travel enabled
Seated
Lift lock solenoid OFF
Two switches
60-17
VEHICLE CONTROLLER
Controller System Configuration
60A 40A 100A

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

R_SW
ACM32221
Coil: 12v,1.7w
20: R_RELAY
SW: 14v,35A
F_SW
BACK-LAMP SW
F_RELAY (T)
(C)
ACM32221
Coil:12v,1.7w
14: F_RELAY
SW: 14v,35A
22: R_BACK
CONTROLLER
16: F_BACK L R
Interlock-Box
(ISO3691) BACK BACK
F_SOL R_SOL LAMP BUZZER
(T) (T) Lamp: 12v,8w
Solenoid: 12v,2A BUZZ: 12v,50mA Battery
L-GND: 7
MAST_RELAY
L-GND: 26 ACM32221 Parking_SW
8: MAST_RELAY Coil:12v,1.7w (Reset: ON)
SW: 14v,35A
10: MAST_BACK PARKING
P-GND: 6 _RELAY
LIFT-LOCK UNLOAD (B CONTACT)
P-GND: 12
SOL SOL ACM12221
P-GND: 18 Coil: 12v,1.7w
Solenoid: 12v. 1A SW: 14v,20A
P-GND: 25
2: PARKING_RELAY
PK_BUZZER
Rated: 12v,25mA
MaxA: 500mA
60-18
VEHICLE CONTROLLER
Troubleshooting
1. ISO Controller (NOTE *1: “N” lamp lights when F/R lever is set to Neutral)
No. of blinks “1”
N-LAMP status
ERROR LAMP
LAMP status
Symptom Failure Remedy Reset Remarks
MAST
“N”
“L”
Travel operation and work equipment do not work.
SEAT-SW failure Examine SEAT- Normal return Refer to Remark
1 Blinking *1 Blinking (disconnection or SW circuit, and Table 1
short-circuit) repair it if
necessary.
Travel operation does not work.
F/R lever failure 1) Examine F/R Normal return Refer to Remark
(short-circuit) lever circuit, and Table 2
2 Blinking *1 –
repair it if
necessary.
1. Parking brake warning buzzer
• Buzzer does not stop Abnormal output Parking brake Parking brake
even when parking of parking brake warning buzzer warning buzzer:
brake is activated. warning buzzer Examine Normal return
• Buzzer does not stop (disconnection or PARKING-
3 – – short-circuit) RELAY and
even when operator
left the seat with park- buzzer circuits,
ing brake released. and repair them if
necessary.
2. N-LAMP, MAST-LAMP
• N-LAMP does not Abnormal output Lamps Lamp:
light even when F/R of N-LAMP or Examine lamps Key/OFF
lever is set to neutral. MAST-LAMP and lamp circuit,
• N-LAMP does not turn (disconnection or and repair them if
OFF even when F/R short-circuit) necessary.
lever is set to F or R
position.
3
• MAST-LAMP does
not light for a certain
time when the key is
turned ON.
• MAST-LAMP does
not turn OFF after the
key is turned ON.
1. Only work equipment does not work.
Abnormal output Work equipment Normal return
of work only or key/OFF
equipment Examine MAST-
interlock relay RELAY and relay
4 – Blinking (disconnection or circuit, and repair
short-circuit) them if
Controller output necessary.
Tr open or relay
disconnection
2. Both travel operation and work equipment do not work.
Abnormal output Travel/work Key/OFF
of work equipment
interlock relay RELAY,
(disconnection or F-RELAY,
short-circuit) R-RELAY & relay
4 Blinking *1 Blinking Controller output circuit, and repair
Tr short-circuit or them if
any of MAST- necessary.
RELAY,
F-RELAY,
R-RELAY short-
circuit
60-19
VEHICLE CONTROLLER
1. ISO Controller (NOTE *1: “N” lamp lights when F/R lever is set to Neutral) (Continued)
No. of blinks “1”
N-LAMP status
ERROR LAMP
LAMP status
Symptom Failure Remedy Reset Remarks
MAST
“N”
“L”
1. Only travel operation does not work.
Abnormal output Travel only Normal return
of work Examine or key/OFF
equipment F-RELAY,
interlock relay R-RELAY & relay
5 Blinking *1 – (disconnection or circuit, and repair
Controller output necessary.
Tr open or relay
disconnection
2. Both travel operation and work equipment do not work.
Abnormal output Travel/work Key/OFF
of work equipment
interlock relay RELAY,
(disconnection or F-RELAY,
short-circuit) R-RELAY, & relay
5 Blinking *1 Blinking *1 Controller output circuit, and repair
Tr short-circuit or if necessary.
any of MAST-
RELAY,
F-RELAY,
R-RELAY short-
circuit
Abnormal output Examine MAIN- Key/OFF
of MAIN-RELAY RELAY and relay
6 Blinking *1 Blinking (disconnection, circuit, and repair
necessary.
Controller failure • Examine power Key/OFF Return the
circuit, and controller and
repair it if nec- examine it.
7 Blinking *1 Blinking essary.
• Replace con-
troller.
60-20
VEHICLE CONTROLLER
2. Knob Displacement Correction System

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

ON ON Error No.2 Abnormal
60-21
HYDRAULIC CIRCUIT DRAWING

Standard model: 2.0 ton to 3.0 ton
Lift height 3.7 m or less

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

KPF
KP
FLOW DIVIDER
PS RELIEF PRE.
2 to 3 ton: 11.8 MPa {120 kg/cm2}
BLEEDING VALVE
M
P2 P1
POWER
STEERING
CYLINDER
FILTER 20 m
STRAINER 105 m
60-22
Power Brake Truck: 2.0 to 3.0 ton, 3.2 & 3.5 ton
CONTROL VALVE
B2
A2
TILT CYLINDER
LIFT CYLINDER
A1
DOWN SAFTY
VALVE
MAIN RELIEF
KL
PRE.
18.1 MPa
G1 P T
KP
KPF 13.5 to 17.3 /min FLOW DIVIDER
PS
BRAKE BOOSTER RELIEF
BLEEDING
VALVE PRE.*
MASTER
CYLINDER 6.9 MPa
1.3 /min
POWER M
FLOW DIVIDER
STEERING P3 P2 P1
CYLINDER
FILTER
20 m
STRAINER
105 m
* : PS RELIEF PRE.
2 to 3 ton: 11.8 MPa {120 kg/cm2}
3.5 ton: 13.2 MPa {135 kg/cm2}
60-23
P-PORT OIL PRESSURE MEASURING PORT
P-PORT OIL PRESSURE MEASURING PORT
P-port
Oil pressure measuring port
RC 1/8
60-24
PERIODIC INSPECTION
PERIODIC INSPECTION
80. PERIODIC INSPECTION
ENGINE.......................................................................................................................... 80-3
POWER TRAIN .............................................................................................................. 80-9
TRAVEL SYSTEM ........................................................................................................ 80-12
STEERING SYSTEM ................................................................................................... 80-13
BRAKE SYSTEM ......................................................................................................... 80-15
WORK EQUIPMENT .................................................................................................... 80-17
HYDRAULIC SYSTEM ................................................................................................. 80-19
CHASSIS AND SAFETY SYSTEM .............................................................................. 80-21
80-1
PERIODIC INSPECTION
Check Item Check Point

1. Engine Start, Position F/R lever in neutral, pull the parking brake lever down, and start
Noise the engine to check the following:
1. Check engine for smooth starting
2. Check engine for abnormal noise
3. Check pre-heating valve for proper functioning
4. Check acceleration pedal and control levers for smooth function-
ing
2. Engine Revolu- Press accelerator pedal to check the following:
tion, Exhaust 1. Check engine for combustion instability
Emission Color
2. Check engine for abnormal noise
3. Check engine for abnormal explosion or bacHamechre
4. Check engine for irregular engine vibration
5. Check engine revolution for smooth speed up
6. Check engine for leakage of exhaust emission
7. Check engine for exhaust emission color
When idling no color

When pedal pressed faint black color
ENGINE
3. Idling Speed Warm up the engine and maintain idle to check the following:
1. Idling speed
G20 - 30 750 - 900 rpm

G20H - 30H 750 - 900 rpm
G35A 750 - 900 rpm
D20 - 30 785 - 835 rpm
D35A 785 - 835 rpm
2. Maximum speed
Gas models 2,720 - 2,920 rpm

Diesel models 2,650 - 2,750 rpm
4. Air Cleaner 1. Check the air cleaner and element for the following:
2. Check air cleaner for cracks or scratches
3. Check air cleaner for looseness of air cleaner mounting
4. Check element for dirt or scratches
See “AIR CLEANER” on page 20-12 for cleaning and replacement of
element.
5. Cylinder Head Check cylinder head for loose mounting bolts
See “TORQUING OF CYLINDER HEAD MOUNTING BOLTS” on
page 20-18 for tightening torque of cylinder head mounting bolts.
80-3
PERIODIC INSPECTION

6. Valve Clearance Unit: in. (mm)
Model Engine Intake Valve Exhaust Valve

G20 - 30 K21 0.15 (0.38) (Warm) 0.15 (0.38) (Warm)
G20H - 25H K25 0.15 (0.38) (Warm) 0.15 (0.38) (Warm)
G30H/32/35A K25 0.15 (0.38) (Warm) 0.15 (0.38) (Warm)
Diesel models 4D94LE 0.008 (0.20) (Cool) 0.008 (0.20) (Cool)
See “ADJUSTMENT OF VALVE CLEARANCE” on page 20-16 for

adjusting method.
7. Compression Unit: PSI (MPa) (kgcm2)/rpm
Model Engine Standard Limit

G20 - 30 K21 178 (1.23) {12.5}/300 149 (1.03) {10.5}/30
G20H - 25H K25 185 (1.28) {13.0}/300 158 (1.09) {11.0}/30
G30H/32/35A K25 185 (1.28) {13.0}/300 158 (1.09) {11.0}/30
Diesel models 4D94LE 426 (2.94) {30}/250 340 (2.35) {24}/200
ENGINE
See “MEASUREMENT OF COMPRESSION PRESSURE” on

page 20-15 for measuring method
8. Fuel Injection Set nozzle tester to check the follow-
Starting Pressure ing:
(Diesel Engine
Unit: PSI (MPa) (kgcm2)
Model)
Injection 1,706 (11.8)
4D94LE
Pressure {120}
Adjustment: Apply adjusting screw.

9. Fuel Injection Check injection nozzle for proper
State (Diesel injection
Model) Faulty nozzle: Remove the nozzle
from the holder. Remove carbon stuck
to the nozzle and wash in diesel oil.
10. Turbocharger Exclusively for 2 - 3.5 ton models
1. Check turbocharger for abnormal vibration
2. Check turbocharger for abnormal noise
3. Check turbocharger for gas leakage
11. Engine Mount 1. Check bracket for cracks or deformation
2. Check mounting bolt and nut for looseness or coming off
3. Check anti-vibration rubber for scratches or deterioration
80-4
PERIODIC INSPECTION

12. Lubrication Sys- 1. Engine Oil
tem 1) Capacity
Check with oil level gauge and add oil if necessary.
K21 Engine 4 qt. / 3.8 liter

K25 Engine 4 qt. / 3.8 liter
4D94LE Engine 7.9 qt. / 7.5 liter
2) Deterioration
No judgment can be made with visual check. Need periodic
replacement.
ENGINE
3) Oil Leakage
2. Engine Oil Filter
No judgment can be made with visual check. Need periodic replacement.
13. Fuel System 1. Check fuel leakage
2. Check scratches or deterioration of hose and pipes
3. Check fuel filter for proper functioning
No judgment can be made with visual check. Need periodic replacement.
14. High-Pressure 1. Gas leakage
Gas Fuel System
2. Cracks/damage of conduit
3. Looseness/damage of gas cylinder fixture
15. Blow-by Gas 1. Check valve for proper functioning
Return System
2. Check piping for clogging or scratches
80-5
PERIODIC INSPECTION

16. Coolant, Radia- 1. Check coolant for proper level
tor amount
2. Check hose for water leakage
3. Check hose for cracks or heat
hardening
4. Check radiator cap for damage
• Never remove the radiator cap when the engine coolant is still at
high temperature. Extremely hot water may spurt out and cause
injury.
• Wait for engine and coolant to cool down before checking. When
ENGINE
removing the radiator cap, turn it slowly to release the internal

pressure.
1) Pressure Adjusting Valve
Check the cap spring for proper
tension when pushing it down
with your finger.
2) Negative Pressure Valve

Check the valve for proper func-
tioning.
In case of damaged packing,
replace it with radiator cap
assembly.
80-6
PERIODIC INSPECTION

17. Fan, Fan Belt 1. Fan Belt
• Check inside of fan belt for damage
• In case of shining pulley at the bottom, replace with a new one to
avoid slips.
2. Fan Belt Deflection
Check belt for proper deflection
pressing at a point midway between
the fan pulley and the alternator
with your finger.
Finger pressure: 22 lb/f / 98 Nm (10
kgf)
K21 engine .43 - .51 in.

K25 engine (11 - 13 mm)
.39 - .59 in.
4D94LE engine
ENGINE
(10 - 15 mm)
Adjustment: Loosen the alternator

mounting nut and adjust bar bolt to slide the position of the alternator
for your adjustment.
3. Fan, Fan Cover (Shroud)
1) Check fan for cracks or deformation
2) Check fan mounting bolt for loosening
3) Check shroud for cracks or deformation
4) Check shroud mounting bolt for loosening
18. Distributor (Gas- 1. Check cap for cracks
oline Export
2. Check cable for scratches
Model)
3. Check air gap for proper functioning or damage
Air gap .014 - .017 in.

(Full-transistor ignition) (Export only) (0.35 - 0.45 mm)
80-7
PERIODIC INSPECTION

19. Spark Plug, Igni- EPA Models are equipped with electronically controlled ignition sys-
tion Timing Gas- tems and are not adjustable.
oline Model) Export trucks are equipped with distributor ignition systems and are
adjustable.
1. Spark Plug
1) Gap
Remove the plug with a plug
wrench and measure the gap with
a gauge.
Plug Gap A: .027-.031 in. (0.7-
0.8 mm)
Normal
Badly burned
Sooty
Replace the spark plug if it does not meet the specification above or is
burned
2) Cleaning
Remove the carbon stuck around
the plug tip and its surroundings
2. Ignition Timing
1) Start the engine and idle
ENGINE
2) Check the injection timing

applying the timing light at
the timing mark of front cover
and crank pulley.
Adjustment: Turn the distributor
to adjust (Export only)
Ignition Timing: K21 2/850

(BTDC degrees/rpm) K25 0/850
20. Battery Charg- 1. Check battery gravity for charging

ing System, Wir-
ing Battery
Charge Need for
Electrolyte Condition Charging
Gravity
1.280 Fully charged
1.240 1/4 discharged No
1.210 1/2 discharged

Yes
1.130 Fully discharged
In case of insufficient charging,

check the alternator.
2. Check battery electrolyte for proper amount level
3. Check battery terminals for loosening or corrosion
4. Check wiring connection for loosening
5. Check wiring for damage
80-8
PERIODIC INSPECTION

21. Clutch Not applicable
22. Transmission 1. Check the following by operat-
ing the F/R lever
1) No clatter at each position
2) Smooth shifting N
2. Check transmission for abnor-

mal sound
POWER TRAIN
3. Check transmission for oil

Air breather
leakage for transmission
Replace the packing if oil stains
become oil droplets.
4. Check transmission oil for
proper amount level
Park the truck on flat and even
ground surface and check with
oil level gauge. Oil level gauge Line filter
Air breather for transmission

Air breather
for differential
Strainer Drain plug
80-9
PERIODIC INSPECTION

23. Transmission 5. Inching Pedal (TORQFLOW
(continued) type)
1) Inching spool stroke
Stroke A .96 in. (24.5 mm)

A
Be very careful that the cable
does not press the inching
pedal when it is released
Initial set
Reference: 13 mm
2) Interconnected Stroke
Adjust stroke with adjusting
screw to interlock the brake pedal
POWER TRAIN
Adjusting screw
with the inching pedal at the
specified value
2.0 - 3.0 ton 1.41 - 1.57 in.

3.5 ton (36 - 40 mm)
Inching pedal
3) Pedal Stroke
3.54 - 4.57 in.

2.0 - 3.0 ton
(90 - 116 mm)
3.15 - 4.17 in.
3.5 ton
(80 - 106 mm) 159 mm
4) Play
Play 0 - .157 in. (0 - 4 mm)
80-10
PERIODIC INSPECTION

24. Torque Con-
verter
Make sure to place the wheel stoppers at each wheel and apply the
parking brake prior to following inspection
1. Clutch Oil Pressure
Select F/R lever from either direction of forward or reverse and press
the pedal for measuring the oil pressure
132 - 190 PSI (0.91 - 1.31 MPa)

Clutch Oil Pressure
(9.3 - 13.4 kgf/cm2)
2. Stall Speed
Select F/R lever from either direction of forward or reverse and floor
the pedal to the maximum speed for measuring the engine speed.
K21 engine 1900 ± 150 rpm/1850 ± 150 rpm

K25 engine 2000 ± 150 rpm
4D94LE engine 2000 ± 150 rpm
Be careful to keep inspection time brief as it may raise the temperature

of the oil in the torque converter
Torque Converter Inlet Port Pressure: 72.5 - 101.5 PSI (0.5 - 0.7 MPa) (5 -
POWER TRAIN
7 kgf/cm2)
3. Torque Converter Outlet Port
Pressure
4. Torque Converter Assembly Oil
Pressure Port Location
A. Torque Converter Inlet Oil
Pressure Measuring Port (101
B A
PSI)
B. Main Oil Pressure Measuring
Port (217 PSI)
C. Lubrication Oil Pressure Mea-
suring Port (84.1 PSI Max)
Control Valve Assembly Oil Pressure

Port Location P1
C1. Forward Clutch Oil Pressure
Measuring Port (PT1/8z) (132
- 190 PSI)
C2. Reverse Clutch Oil Pressure
Measuring Port
P1. Main Oil Pressure Measuring C2
Port C1
25. Propeller Shaft Play, scratches, looseness of mounting bolt, damage, coming off
80-11
PERIODIC INSPECTION

26. Differential 1. Abnormal noise when traveling
2. Oil level in differential casing
3. Dirt or stain with oil
POWER TRAIN
See “DIFFERENTIAL CASE” on

page 20-20 for checking oil level
and replacing.
4. Oil leakage from differential
casing
Drain plug
Oil level check and
oil filling combination plug
27. Front Axle 1. Deformation, cracks or scratches

Visual check on and around the main frame and mounting bolt or
welded area
2. Looseness of mounting bolt
Tightening torque for mounting bolt
361 - 448 ft/lbs. (490 - 608 Nm)

2.0 - 3.0 ton forklift trucks
(50.0 - 62.0 kgm)
torque
488 - 611 ft/lbs. (662 - 829 Nm)
3.2, 3.5 ton forklift trucks
(67.5 - 84.5 kgm)
TRAVEL SYSTEM
28. Rear Axle 1. Deformation, cracks or scratches

Check visually
2. Play of center pin
3. Clearance of thrust
< .02 in.

Clearance (a)
(0.5 mm)
Adjustment: If 2.0 mm or over,

adjust with shims to less than
0.5 mm.
Tightening torque for mounting
bolt (1).
torque 361 - 448 PSI (490 - 608 Nm) (50 - 62.9 kgm)
4. Looseness of cap mounting bolt
80-12
PERIODIC INSPECTION

29. Tires 1. Air pressure
A
2.0 - 3.0 ton Front 100 PSI (690 kPa)
B
lift trucks 2
Rear {7.0 kgf/cm }
123 PSI (850 kPa)
Front more than1.6 mm
3.2, 3.5 ton {8.5 kgf/cm2}
lift trucks 129 PSI (890 kPa)
Rear
{9.0 kgf/cm2}
2. Cracks in tread or sidewall

Replace with a new one if necessary
TRAVEL SYSTEM
3. Depth of tread
Measure the groove depth at a quarter of the tread width, and check
that the depth is at least 1.6 mm.
4. Abnormal wear
5. Eccentric wear or stepped wear
6. Metal pieces stuck in tire
30. Wheel 7. Tightening torque for hub nut
Front 217 - 361 ft/lbs. (294 - 490 Nm) {30 - 50 kgm}

2.0 - 3.5 ton
Rear 116 - 180 ft/lbs. (157 - 245 Nm) {16 - 25 kgm}
8. Deformation or cracks of side link

Check visually or by the crack detection method.
9. Tightening torque for rim mating nut
144 - 217 ft/lbs. (196 - 294 Nm) {20 - 30 kgm}

Front
2.0 - 3.5 ton excluding 3 ton forklift truck
Rear 65 - 90 ft/lbs. (88 - 123 Nm) {9 - 12.5 kgm}
31. Steering Wheel 1. Shaking, pulling or dragging

2. Steering force (Control force)
STEERING SYSTEM
3. Play
1.18 - 2.36 in.

Play L
(30 - 60 mm) (at engine idle)
Adjustment: Adjust at gearbox.

4. Looseness or play
32. Steering Valve 1. Oil leakage
80-13
PERIODIC INSPECTION

33. Knuckle 1. Wheel bearing
Jacking up the truck for inspection
1) Play
Check the play by holding the tire by hand at its top and bottom
and rocking the wheel
2) Noise
Check abnormal sound by turning the tire by hand.
2. King pin
1) Play
2) Noise
3. Knuckle
Check for damage visually or check with a crack detection method
34. Right and left Measuring minimum turning radius
turning radius
STEERING SYSTEM
1. Have an assistant drive truck and make minimum turning radius

2. Draw a circle with a chalk affixed to outside end of the counterweight
3. Measure the circle drawn on the ground.
4. Make turns to right and left.
2.0 ton 86.2 in. (2,190 mm) ± less than 5%

2.5, 2.8 ton 88.1 in. (2,240 mm) ± less than 5%
3.0 ton 93.3 in. (2,370mm) ± less than 5%

3.2, 3.5 ton 97.6 in. (2,480 mm) ± less than 5%
Difference R/L < 3.95 in. (< ±100 mm)
Adjustment: Adjust with the stopper bolt.

35. Steering wheel 1. Loose or missing stopper bolt
2. Interference between wheel and other part of truck
36. Power steering 1. Power steering cylinder and hose oil leakage
2. Scratches or deterioration of hose
3. Loose or missing mounting bolt
4. Interference with truck body
80-14
PERIODIC INSPECTION

37. Traveling Brake 1. Brake pedal
1) Pedal height (stroke)
2.16 - 2.95 in.

2.0 - 3.0 ton
(55 - 75 mm)
137 mm
1.77 - 2.56 in.
3.5 ton
(45 - 65 mm)
2) Play
0 - .157 in
Standard model
(0 - 4 mm)
2. Braking efficiency
Select dry and even surface road, drive at full speed and stop abruptly
to check the following:
1) Pulling of steering wheel
2) Dragging of brakes
3) Abnormal noise
4) Stopping distance
Unloaded within 14.7 ft (4.5 m) (at max. speed)

BRAKE SYSTEM
Loaded within 6.6 ft (2.0 m) (at 10 km/h)
38. Parking Brakes 1. Parking brake lever

Lever control force Standard
brake: 33 - 44 lb/f (147 - 196 Nm)
(15 - 20 kgm)
Power brake: 55 - 66 lb/f
(245 - 294 Nm) (25 - 30 kgm)
2. Braking force
Check if the truck can maintain
braking on the following slope:
slope of 11.2
Unloaded
degrees and over
slope of 8.5 degrees
Loaded
and over
39. Rod link, cable 1. Scratches, looseness or play

2. Breakage of cotter pin
40. Brake piping Visual check on piping, hoses and joints
1. Scratches
2. Oil leakage
3. Evidence of interference or contact
4. Deterioration of hose
5. Loosening of mounting bolt
80-15
PERIODIC INSPECTION

41. Oil Brake 1. Master cylinder and wheel cylinder
1) Check the following by operating the brake pedal
2) Pressure (feel) when pedal depressed
3) Fluctuation of pressure or pedal height
4) Fluctuation of pedal position when maintaining pedal pressure
5) Return of the pedal when releasing the pedal
If you feel a change while pressing the pedal with no oil leakage,
the brake valve is defective
2. Brake reservoir
1) oil level amount
Applicable limit A: 18 mm
2) Fluid stain from oil or oil leak-
age
3. Deterioration of wheel cylinder

BRAKE SYSTEM
Clearance between < .006 in.

cylinder and piston (0.15 mm)
42. Air Brake Not applicable to this model.

43. Brake Booster Oil leakage
44. Brake Shoe Lin- 1. Brake shoe
ing Check proper functioning, rust or wear
2. Peeling off, scratches or wear of brake lining
Thickness of lining > .039 in. (1 mm)
3. Corrosion of anchor pin

4. Deterioration of return spring
Free length < 4.13 in. (105 mm)

Thickness of hook > .078 in. (2.0 mm)
45. Brake Drum Cracks scratches or wear of brake drum

Measure the following dimensions, and check whether they are allow-
able values.
Inside diameter of drum (all models) < 12.28 in. (312 mm)
80-16
PERIODIC INSPECTION

46. Back Plate 1. Deformation, cracks or scratches
2. Tightening torque for mounting
bolt
BRAKE SYSTEM
LOCTITE #271 (thread

hole)
130 - 144 ft/lbs. (176 - 196
torque
Nm) {18.0 - 20.0 kgm}
47. Brake Disc Pad Not applicable to this model

48. Parking Brake Common with the travel brake drum, lining. See No. 44 and 45.
Drum, Lining
49. Fork (1) 1. Deformation, cracks or wear of
fork stopper pin
2. Opening or difference in height of
fork tips
Opening (a): within 35 mm
within 1.37 in. b

Opening (a)
(35 mm)
WORK EQUIPMENT
a
Difference in within 0.59 in.
height (b) (15 mm)
50. Fork (2) 1. Cracks or wear of upper and lower hooks

2. Cracks or wear of fork base/root
Check fork base thickness (C) for
specified size
2 ton > 1.42 in. (36.0 mm) Min.

C
2.5 ton > 1.42 in. (36.0 mm) Min.
3.0 ton > 1.58 in. (40.0 mm) Min.
3.5 ton > 1.80 in. (45.0 mm) Min.
Check the fork base/root and the hooks, where stress is concentrated,
by the crack detection method
80-17
PERIODIC INSPECTION

51. Mast (1) 1. Deformation, cracks or wear of mast
Check the following visually or by the crack detection method
• mast stay
• tilt cylinder bracket
• roller shaft weld
2. Wear or play in mast roller and cracks in roller shaft
Upright the mast and lift about 10 cm from the ground to check follow-
ing clearance:
Clearance between outer Right and left within .078 in. (2.0 mm)
mast and inner mast Front and rear within .098 in. (2.5 mm)
Clearance between inner Right and left within .078 in. (2.0 mm)
mast and fork carriage Front and rear within .098 in. (2.5 mm)
52. Mast (2) 1. Play in mast support

Check mast support for oil groove of bushing
2. Loosening of mast cap mounting bolt
WORK EQUIPMENT
2.5 ton 180 - 228 ft/lbs. (245 - 309 Nm) {25.0 - 31.5 kgm}
torque 3.0 ton 253 - 315 ft/lbs. (343 - 427 Nm) {35.0 - 43.5 kgm}
3.5 ton 361 - 448 ft/lbs. (490 - 608 Nm) {50.0 - 62.0 kgm}
53. Fork Carriage 1. Deterioration, cracks or scratches of fork carriage

2. Wear or play in roller
3. Play in roller shaft
54. Lift Chain 1. Chain tension
Put the mast straight vertically and lift the forks about 4.0 in. (10 cm)
from the ground to check lift chain for proper tension with your finger.
Adjustment should be made with chain stopper.
2. Elongation
Check chain elongation over specified
length (L) of 17 links
L
2 - 2.5 ton within 13.0 in. (330 mm)
2.8 - 3 ton within 21.6 in. (550 mm)
3.2 - 3.5 ton within 17.3 in. (440 mm)
3. Anchor bolt threads

Make visual check
55. Chain Wheel Deformation, scratches or play in wheel
1. Check visually chain and its contact surface
2. Turn by hand and check wheel for play in bearing
80-18
PERIODIC INSPECTION

56. Work Equipment 1. Check work equipment for proper installation to the truck
WORK EQUIPMENT
System (1)
2. Check each bolt and nut for proper tightening
57. Work Equipment 1. Check work equipment for cracks, scratches or wear of each sec-
System (2) tion
2. Check work equipment for proper functioning and abnormal noise
of each section
58. Hydraulic Tank 1. Oil leakage

Breather
2. Oil level amount Cover
Check with oil level gauge

and add oil if necessary.
(Also check for oil contami-
nation)
3. Cleaning of strainer
4. Replacement of line filter
See “HYDRAULIC TANK” Strainer
on page 20-21 for check-
ing oil level and replac- Line filter
ing.
HYDRAULIC SYSTEM
Drain plug
59. Piping 1. Cracks, scratches, deterioration or twist of piping

2. Oil leakage
3. Loosening of mounting bolt and nut
60. Piping of Work 1. Cracks, scratches, deterioration or twist of piping
Equipment
2. Oil leakage
3. Loosening of mounting bolt and nut
61. Hydraulic Pump 1. Oil leakage
2. Abnormal vibration
3. Noise
4. Abnormal wear of spline
5. Loosening of mounting bolt
62. Flow Divider (For 1. Oil leakage
P/S)
2. Noise
63. Oil Motor 1. Oil leakage
2. Noise
80-19
PERIODIC INSPECTION

64. Lift Cylinder 1. Actuation, oil leakage
2. Dents, cracks, curvature or scratches
65. Tilt Cylinder 1. Actuation, oil leakage
66. Reach Cylinder Not applicable for this model
67. Work Equipment 1. Actuation, oil leakage
Cylinder
68. Hydraulic drift of 1. Load the forks with maximum
lift cylinder and payload and set the mast (1)
tilt cylinder upright, lift the forks approx. 59 1
in. (1,500 mm) from the ground.
2. Match a straight measure (1) on
the piston rod of the lift cylinder
HYDRAULIC SYSTEM
(2) and put the mark (A) for

measurement, H
3. Match a straight measure (2) on

the piston rod of the tilt cylinder
(3) and put the mark (B) for
measurement, A
When 3.95 in.

measured at (100 mm)/
Hydraulic fork within 15 min
drift of lift
cylinder When 1.96 in.
measured at (50 mm) /
cylinder within 15 min
Hydraulic 1.18 in.
drift of tilt
cylinder (30 mm) / 15 min
2
Adjustment:
Replace control valve and cylinder
packing 3
69. Directional Con- 1. Actuation and oil leakage

trol Valve (1)
80-20
PERIODIC INSPECTION

70. Directional Con- Measure relief pressure
trol Valve (2) 1. Install an oil pressure gauge to
port (A).
2. Lift the forks to the maximum lift-
ing height, measure the oil pres-
sure when the oil is relieved, and
check it for specified level.
Relief set pressure
2,567 - 2,697 PSI

2.0 - (17.7 - 18.6 MPa)
3.0 ton
{180 - 190 kgf/cm2}
HYDRAULIC SYSTEM
A: Control valve relief pressure measurement port

71. Solenoid Valve, 1. Actuation, abnormal
Steering Pres- noise
sure Port
2. Abnormal generation of
heat
3. Oil leakage
P-port
Oil pressure measuring port
RC 1/8
72. Chassis frame, 1. Cracks or deformation

CHASSIS AND SAFETY SYSTEM
chassis
2. Looseness or coming off of mounting bolt
73. Cab 1. Cracks or deformation
2. Corrosion or rain leakage
3. Opening/closing of door, lock play or breakage
74. Seat 1. Actuation
75. Devices for get- 1. Cracks, damage or deformation
ting on/off fork-
lift truck, anti-slip 2. Looseness of mounting bolt
76. Display panel 1. Damage
2. Mounting condition
80-21
PERIODIC INSPECTION

77. Overhead Guard 1. Looseness of mounting
CHASSIS AND SAFETY SYSTEM
2. Deformation, cracks or damage

78. Backrest 1. Looseness of mounting bolt
2. Deformation, cracks or damage
79. Lights, gauges, 1. Lighting up of lamps
Warning devices
2. Mounting condition, breakage or leakage of water
3. Actuation of gauges
80. Rear view mir- 1. Dirt or damage
ror, reflector
2. Reflection
81. Lubrication 1. Oil, greasing condition
2. Actuation of auto-greasing system
82. Function of each Carry out travel, operation test to check.
system
80-22
CONVERSION TABLES
CONVERSION TABLES
90. CONVERSION TABLES
MILLIMETERS TO INCHES ........................................................................................... 90-3

INCHES TO MILLIMETERS ........................................................................................... 90-3
CUBIC METERS TO CUBIC YARDS............................................................................. 90-3
CUBIC YARDS TO CUBIC METERS............................................................................. 90-4
LITER TO U.S. GALLON................................................................................................ 90-4
U. S. GALLON TO LITER............................................................................................... 90-4
LITER TO U.K. GALLON................................................................................................ 90-5
U. K. GALLON TO LITER............................................................................................... 90-5
KILOGRAM TO POUND ................................................................................................ 90-5
POUND TO KILOGRAM ................................................................................................ 90-6
KG/CM2 TO LB/IN2........................................................................................................ 90-6
KGM TO FT. LB.............................................................................................................. 90-7
TEMPERATURE (FAHRENHEIT/CENTIGRADE).......................................................... 90-8
90-1
CONVERSION TABLES
Add the value in the heading row to the major unit value in the left most column in order to interpolate
between the major units, and then cross-reference to the converted value. For example, in the first table
below, 2 mm + 10 mm = 12 mm = 0.472 inches.
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 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.881 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 2.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Inches to Millimeters
0.1 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0 0.254 0.508 0.762 1.016 1.270 1.524 1.778 2.032 2.286
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
Cubic meters to Cubic yards

1 m3 = 1.308 cu. yd
0 1 2 3 4 5 6 7 8 9
0 1.31 2.62 3.92 5.23 6.54 7.85 9.16 10.46 11.77
10 13.08 14.39 15.70 17.00 18.31 19.62 20.93 22.24 36.62 24.85
20 26.16 27.47 28.78 30.08 31.39 32.70 34.01 35.32 36.62 27.93
30 39.24 40.55 41.86 43.16 44.47 45.78 47.09 48.40 49.70 51.01
40 52.32 53.63 54.94 56.24 57.55 58.86 60.17 61.48 62.78 64.09
50 65.40 66.71 68.02 69.32 70.63 71.94 73.24 74.56 75.86 77.17
60 78.48 79.79 81.10 82.40 83.71 85.02 86.33 87.64 88.94 90.25
70 91.56 92.87 94.18 95.48 96.79 98.10 99.41 100.72 102.02 103.33
80 104.64 105.95 107.26 108.56 109.87 111.18 112.49 113.80 115.10 116.41
90 117.72 119.03 120.34 121.64 122.95 124.26 125.57 126.88 128.18 129.49
90-3
CONVERSION TABLES
Cubic yards to Cubic meters

0 1 2 3 4 5 6 7 8 9
0.76 1.53 2.29 3.06 3.82 4.59 5.35 6.12 6.88
10 7.65 8.41 9.18 9.94 10.70 11.47 12.23 13.00 13.76 14.53
20 15.29 16.06 16.82 17.59 18.35 19.12 19.88 20.64 21.41 22.17
30 22.94 23.70 24.47 25.23 26.00 26.76 27.53 28.29 29.05 29.82
40 30.58 31.35 32.11 32.88 33.64 34.41 35.17 35.94 36.70 37.47
50 38.23 38.99 39.76 40.52 41.29 42.05 42.82 43.58 44.35 45.11
60 45.88 46.64 47.41 48.17 48.93 49.70 50.46 51.23 51.99 52.76
70 53.52 54.29 55.05 55.82 56.58 57.35 58.11 58.57 59.64 60.40
80 61.17 61.93 62.70 63.46 64.23 64.99 65.76 66.52 67.28 68.05
90 68.81 69.58 70.34 71.11 71.87 72.64 73.40 74.17 74.93 75.70
Liter to U.S. Gallon

1 liter = 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 liters
0 1 2 3 4 5 6 7 8 9
3.79 7.57 11.36 15.14 18.93 22.71 26.50 30.28 34.07
10 37.85 41.64 45.43 49.21 53.00 56.78 60.57 64.35 68.14 71.92
20 75.71 79.49 83.28 87.06 90.85 94.64 98.42 102.21 105.99 109.78
30 113.56 117.35 121.13 124.92 128.70 132.49 136.27 140.06 143.85 147.63
40 151.42 155.20 158.99 162.77 166.56 170.34 174.13 177.91 181.70 185.49
50 189.27 193.06 196.84 200.63 204.41 208.20 211.98 215.77 219.55 223.34
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 353.62 257.41 261.19
70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05
80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90
90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76
90-4
CONVERSION TABLES
Liter to U.K. Gallon

1 liter = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0.200 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
U. K. Gallon to Liter
1 U.K. Gal = 4.5461 liters
0 1 2 3 4 5 6 7 8 9
4.55 90.09 13.64 18.18 22.73 27.28 31.82 36.37 40.92
10 45.64 50.01 54.55 59.10 63.65 68.19 72.74 77.28 81.83 86.38
20 90.92 95.47 100.01 104.56 109.11 113.65 118.20 112.74 127.29 131.84
30 136.38 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76
50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22
60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68
70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14
80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60
90 409.15 413.69 418.24 422.79 427.33 431.88 436.42 440.97 445.52 450.06
Kilogram 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
90-5
CONVERSION TABLES
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 27.669 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298
70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843
80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906
Kg/cm2 to lb/in2
1 Kg/cm2 = 14.2233 Ib/in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1644 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1946 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 223 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2360 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3124 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
90-6
CONVERSION TABLES
Kgm to ft. lb
1 kg.m = 7.233 ft. Ib
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1220.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
90-7
CONVERSION TABLES
Temperature (Fahrenheit/Centigrade)
Select a value from the Convert column, which can be read as either Fahrenheit or Centigrade degrees,
and find the corresponding converted value in the left (°C) or right (°F) column.
To convert from Fahrenheit to Centigrade degrees, consider the Convert column as Fahrenheit values and
read the corresponding Centigrade temperature in the left column.
To convert from Centigrade to Fahrenheit degrees, consider the Convert column as Centigrade values and
read the corresponding Fahrenheit temperature in the right column.
°C Convert °F °C Convert °F °C Convert °F °C Convert °F

-40.4 -40 -40.9 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.6 17 62.6 11.1 52 125.6 30.6 84 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.8 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 112.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
90-8
CONTENTS
SM300 - K21/K25 ENGINE SERVICE MANUAL
SM197 - 4D94LE ENGINE SERVICE MANUAL
APPENDIX 1 - MAST SERVICE MANUALS

E Series MD Masts - Full Free Lift 2-Stage
E Series MS Masts - Limited Free Lift 2-Stage
E Series MT Masts - Full Free Lift 3-Stage
35D/45D/55D-MQ Quad Mast Service Manual
APPENDIX 2 - ELECTRICAL DIAGRAMS

MBX50 EPA Torqflow - Gasoline Engine
MBX50 EPA Torqflow - LPG Engine
MBX50 EPA Torqflow - UL-EE LP Engine
MBX50 EPA Torqflow - Gas/LP Dual-Fuel Engine
MBX50 EPA Torqflow - Diesel Engine

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SM160

SERVICE MANUAL BEB16E1-06

MBX50 SERIES LIFT TRUCKS

PF17183 ISSUED: February 2007

Copyright 2007 Komatsu Forklift USA, Inc. Used With Permission

Tel: (419) 629-2311

10. GENERAL AND SPECIFICATIONS

20. TESTING & ADJUSTING

30. REMOVAL & INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

90. CONVERSION TABLES

SM300 - K21/K25 ENGINE SERVICE MANUAL

SM197 - 4D94LE ENGINE SERVICE MANUAL

APPENDIX 1 - MAST SERVICE MANUALS

APPENDIX 2 - ELECTRICAL DIAGRAMS

ENGINE SERIAL NUMBER LOCATION

CALIFORNIA/FEDERAL EMISSION CONTROL STATEMENT FOR

LABELS REQUIRED AND LABEL LOCATIONS

Location on K21/K25 Series engines:

Emission compliance label (sample):

YOUR WARRANTY RIGHTS AND OBLIGATIONS

MANUFACTURER'S WARRANTY COVERAGE

OWNER'S WARRANTY RESPONSIBILITIES

The warranty repairs should be completed by the Dealer as expeditiously as possible.

EMISSION CONTROL WARRANTY - 36 MONTHS or 2,500 HOURS FOR GENERAL PARTS

• Crankshaft position sensor • Camshaft position sensor

Copyright 2007 Komatsu Forklift USA, Inc. Used With Permission

Tel: (419) 629-2311

FEDERAL EPA EMISSION CONTROL STATEMENT FOR

LABELS REQUIRED AND LABEL LOCATIONS

Location on 4D94E Series diesel engines:

YOUR WARRANTY RIGHTS AND OBLIGATIONS

MANUFACTURER’S WARRANTY COVERAGE

OWNER’S WARRANTY RESPONSIBILITIES

• Check oil level and coolant level Every day

CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEMS WARRANTY

Copyright 2007 Komatsu Forklift USA, Inc. Used With Permission

Tel: (419) 629-2311

LIFT TRUCKS COVERED IN THIS PUBLICATION

GASOLINE, LPG AND DUAL-FUEL ENGINE MODELS

G20ST-16 4,000 lb. capacity, K21 gasoline engine, cushion tires

G20SHT-16 4,000 lb. capacity, K25 gasoline engine, cushion tires

G25ST-16 5,000 lb. capacity, K21 gasoline engine, cushion tires

G25SHT-16 5,000 lb. capacity, K25 gasoline engine, cushion tires

G28SHT-16 5,500 lb. capacity, K25 gasoline engine, cushion tires

G30SHT-16 6,000 lb. capacity, K25 gasoline engine, cushion tires

G32SHT-16 6,500 lb. capacity, K25 gasoline engine, cushion tires

G20T-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires

G20HT-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires

G25T-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires

G25HT-16 5,000 lb. capacity, K25 gasoline engine, pneumatic tires

G28HT-16 5,500 lb. capacity, K25 gasoline engine, pneumatic tires

LIFT TRUCKS COVERED IN THIS PUBLICATION (Continued)

G30HT-16 6,000 lb. capacity, K25 gasoline engine, pneumatic tires

G32HT-16 6,500 lb. capacity, K25 gasoline engine, pneumatic tires

G35AHT-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires

DIESEL ENGINE MODELS

D25T-16 5,000 lb. capacity, 4D94E diesel engine, pneumatic tires

D28T-16 5,500 lb. capacity, 4D94E diesel engine, pneumatic tires

D30T-16 6,000 lb. capacity, 4D94E diesel engine, pneumatic tires

D32T-16 6,500 lb. capacity, 4D94E diesel engine, pneumatic tires

D35AT-16 7,000 lb. capacity, 4D94E diesel engine, pneumatic tires