SM228 Ex50 May2008 - 061308

SM228
SERVICE MANUAL
EX Forklift Truck
Federal Environmental Protection Agency (EPA) Emission-Control Compliant
S/N 7001~
Diesel FD100/115-8
FD135/150E/160E-8
EX50
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.
ISSUED: JUNE 2008 Komatsu Forklift USA, Inc.

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

14481 Lochridge Blvd., Bldg. #2
Covington, Georgia 30014-4908
Voice phone: (770) 385-4815

Fax phone: (770) 385-4838
© Copyright 2008, Komatsu Forklift USA, Inc. All rights reserved. No part of this
document may be photocopied or reproduced in any way without prior written consent of
CONTENTS
Page No.
1. SAFETY
1.1. SAFETY MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2. SAFE TRAVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3. LOADING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.4. SAFETY IN PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.5. TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.6. STRUCTURE AND STABILITY OF THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
2. GENERAL INFORMATION & SPECIFICATIONS

2.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 PERIODIC REPLACEMENT OF CONSUMABLE PARTS. . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3 STANDARD TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4 HOW TO USE LOCTITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3. SERVICE DATA
4. TESTING & ADJUSTING
4.1 DEPRESSURIZE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 REPLACE ENGINE OIL/ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 CHANGE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 REPLACE ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 REPLACE FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.1 REPLACE FUEL PRE-FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.2 BLEED AIR FROM FUEL PRE-FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.3 REPLACE FUEL MAIN FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 BLEED AIR FROM FUEL MAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 CLEAN INSIDE THE COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.1 CLEAN THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.5 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.5.1 CLEAN FILTER ELEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.5.2 CHECK FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.5.3 REPLACE FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 ADJUST VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7 CHECK COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.8 TIGHTEN CYLINDER HEAD MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.9 DIFFERENTIAL CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.9.1 CHECK OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.9.2 REPLACE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.10 TORQFLOW TRANSMISSION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.10.1 CHECK OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.10.2 REPLACE OIL AND CLEAN STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.11 SERVICE HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.12 REPLACE BRAKE COOLING OIL (WET DISC BRAKE TYPE) . . . . . . . . . . . . . . . . . . . 4-10
4.13 MEASURE HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS . . . . . . . . . . . . . . . . . 4-11
3
4.14 ADJUST BRAKE/INCHING PEDAL OPERATION (HYDRAULIC DRUM BRAKE TYPE) 4-12
4.14.1 ADJUST BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.14.2 ADJUST INCHING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.15 ADJUST BRAKE/INCHING PEDAL OPERATION (WET DISC BRAKE TYPE) . . . . . . . 4-14
4.15.1 ADJUST BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.15.2 INCHING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.16 ACCUMLATOR FOR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.16.1 CHARGE ACCUMULATOR WITH NITROGEN GAS (HYDRAULIC DRUM BRAKE
TYPE) 4-15
4.17 CHARGE ACCUMULATOR WITH NITROGEN GAS (WET DISC BRAKE TYPE) . . . . . 4-18
4.18 MEASURE ACCUMULATOR CHARGE VALVE PRESSURE (WET DISC BRAKE TYPE) 4-19
4.19 ADJUST ACCUMULATOR CHARGE VALVE PRESSURE (WET DISC BRAKE TYPE) 4-19
4.20 ADJUST ACCELERATOR PEDAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.21 ADJUST PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.21.1 ADJUST THE LEVER OPERATING EFFORT . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.21.2 ADJUST PARKING BRAKE SHOE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.22 BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.22.1 BRAKE PIPING (HYDRAULIC DRUM BRAKE TYPE) . . . . . . . . . . . . . . . . . . . . 4-21
4.22.2 LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.22.3 BRAKE (WET DISC BRAKE TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.23 CHECK WEAR OF BRAKE DISC (WET DISC BRAKE TYPE) . . . . . . . . . . . . . . . . . . . . 4-22
4.24 ADJUST STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.24.1 ADJUST TURNING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.25 INSPECT THE AIR CONDITIONER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.26 INSPECT BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.27 OIL AND GREASING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.28 LUBRICANT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
5. INSPECTION
5.1 GENERAL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 CHECK ITEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 REMOVAL AND INSTALLATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.5 REMOVAL AND INSTALLATION FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.6 MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.6.1 MAST REMOVAL - TYPICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.6.2 MAST INSTALLATION - TYPICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.6.3 BLEED AIR FROM LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.7 POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.7.1 REAR AXLE SUPPORT BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.7.2 CENTER DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.7.3 CENTER ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.7.4 WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.7.5 TIRE CLAMP TIGHTENING INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.7.6 ADJUST RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.8 BRAKE SYSTEM (HYDRAULIC DRUM BRAKE TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.8.1 METHOD OF BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.8.2 METHOD OF REMOVING HIGH PRESSURE OIL . . . . . . . . . . . . . . . . . . . . . . 5-31
4
5.9 WORK EQUIPMENT CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
6. DISASSEMBLY AND ASSEMBLY

6.1 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.1 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2 TORQFLOW TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.1 CONTROL VALVE (SOLENOID VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.2.2 DISASSEMABLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.2.3 DISASSEMBLY OF CLUTCH PACK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.2.4 PRECAUTIONS WHEN ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.2.5 CONNECTORS FOR SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.2.6 ASSEMBLY OF F/R (INPUT SHAFT) SHAFT SUB ASSEMBLY . . . . . . . . . . . . 6-20
6.2.7 ASSEMBLY OF 1ST/2ND SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.2.8 ASSEMBLY OF 3RD (OUTPUT SHAFT) SHAFT SUB ASSEMBLY . . . . . . . . . 6-24
6.2.9 CLUTCH SHAFT SUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.3 HYDRAULIC PUMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.3.1 WORK EQUIPMENT PUMP AND POWER STEERING PUMP . . . . . . . . . . . . . 6-28
6.3.2 TORQUE CONVERTER CHARGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.3.3 WORK EQUIPMENT, POWER STEERING, BRAKE, AND BRAKE COOLING
HYDRAULIC PUMPS 6-29
6.4 DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.4.1 FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.4.2 DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.4.3 ADJUST PINION SHAFT SHIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6.4.4 DIFFERENTIAL SUPPORT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6.5 STEERING AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6.6 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.7 WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6.8 BRAKE / INCHING PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
6.9 BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
6.9.1 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
6.9.2 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
6.10 POWER STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
6.11 POWER STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
6.12 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
6.12.1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
6.13 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
6.13.1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
6.13.2 DISASSEMBLE LIFT AND TILT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
6.13.3 ASSEMBLE LIFT AND TILT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
6.14 POWER STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
6.14.1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
6.15 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
6.15.1 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
6.16 MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
6.16.1 SHIM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
6.16.2 ADJUST CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
6.17 TABLE OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
6.18 TABLE OF SPECIAL TOOLS FOR POWER STEERING CYLINDER. . . . . . . . . . . . . . . 6-97
5
7. MAINTENANCE STANDARD
7.1 ENGINE AND ELECTRICAL PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 SPEEDOMETER SENSOR (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 LOCATION OF SWITCHES AND SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.7 TRANSMISSION CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.8 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.9 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.10 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.10.1 HYDRAULIC DRUM BRAKE TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.10.2 WET DISC BRAKE TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.11 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.12 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.13 FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.14 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.15 BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.16 FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7.17 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.18 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.19 PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7.20 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7.21 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7.22 POWER STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7.23 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
7.23.1 ADJUST CHAIN LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
8. STRUCTURE AND FUNCTION

8.1 POWER TRAIN DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2.1 PTO DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.1 HYDRAULIC CIRCUIT (OUTLINE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.5.2 MECHANISM OF CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.6 INCHING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
6
8.7 AUTOMATIC TRANSMISSION (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.1 BASIC SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.2 AUTO/MANUAL SELECTOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.8 DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.9 STEERING AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.10 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.10.1 HYDRAULIC CIRCUIT DIAGRAMS OF STEERING SYSTEM AND CYLINDER 8-23
8.11 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.11.2 PRINCIPLE OF OPERATION OF BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.11.3 HYDRAULIC CIRCUIT DIAGRAMS OF BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.12 HYDRAULIC CIRCUIT DIAGRAMS OF BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.13 HYDRAULIC PUMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.14 TORQUE CONVERTER CHARGING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.15 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
8.16 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
8.17 METER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
9. TROUBLESHOOTING
9.1 FUNCTIONS OF TROUBLESHOOTING TOOL AND CHECK OF FAILURE CODE . . . 9-2
9.1.1 FUNCTIONS OF TROUBLESHOOTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.2 INDICATING FAILURE CODE WITH TROUBLESHOOTING TOOL . . . . . . . . . 9-3
9.1.3 INDICATING FAILURE CODE WITH METER PANEL . . . . . . . . . . . . . . . . . . . . 9-5
9.1.4 FAILURE CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.3 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
10. CONVERSION TABLES

10.1 MILLIMETERS TO INCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2 INCHES TO MILLIMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3 CUBIC METERS TO CUBIC YARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.4 CUBIC YARDS TO CUBIC METERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.5 LITER TO U.S. GALLON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
10.6 U.S. GALLON TO LITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
10.7 KILOGRAM TO POUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.8 POUND TO KILOGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.9 KILOGRAMS PER SQUARE CENTIMETER TO POUNDS PER SQUARE INCH . . . . 10-6
10.10 KILOGRAM TO FOOT POUNDS OF FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.11 TEMPERATURE - FAHRENHEIT TO CENTIGRADE CONVERSION . . . . . . . . . . . . . 10-8
7
NOTES:
INTRODUCTION
This Service Manual has been developed as an information resource to help the reader learn
about, understand, repair and maintain the EX50 Series forklift trucks, and the various equip-
ment, systems, inspections, sensors, diagnostic procedures and diagnostic equipment utilized
to maintain, adjust and troubleshoot these systems. Although reference is made to mainte-
nance procedures necessary to perform servicing of this vehicle, you should refer to the appli-
cable Operation and Maintenance Manual for these lift trucks for more complete maintenance
information.
Komatsu is involved in a concentrated and highly technical program of designing and develop-
ing 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 Komatsu for a replacement. The procedures outlined in this manual
will be updated periodically. Be sure that you have the latest revision in order to learn the new-
est 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.
0-9
ENGINE MOUNTED IN THIS TRUCK
The engine mounted in this truck is approved by the following diesel engine exhaust gas control
standards:
STAGE3 provided in Directive 2004/26/EC (for EU)
TIER3 provided in40CFR1039/EPA (for USA and Canada)
0-10
1. SAFETY
1.1. 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
Komatsu Forklift dealer and attach the safety labels in the specified positions.
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.
• Always wear a hard hat and safety boots.
• Depending on the working conditions, wear other safety
equipment in addition to the hard hat and safety boots.
1-2
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.
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 Komatsu Forklifts. 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 Komatsu lift truck when it is equipped with a non-genuine overhead guard or load backrest.
Note: Komatsu lift trucks are usually equipped with the optimum overhead guard and load backrest when they
are shipped out of Komatsu Forklift plants.
DON'T USE A DEFECTIVE LIFT TRUCK - 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.
1-3
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.
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.
1-4
1.2. SAFE TRAVEL
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, 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.
1.2. 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.
AJM00003
DON'T TRY TO OPERATE THE LIFT TRUCK FROM

OUTSIDE
• 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/Tilt 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/Tilt 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
1-5
1.2. SAFE TRAVEL
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/Tilt 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.)
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.
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.
1-6
1.2. SAFE TRAVEL
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).
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
to 20 cm (6 - 8 in) from the ground surface], and tilt the mast
back.
• When ready to move, release the parking brake.
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.
1-7
1.2. SAFE TRAVEL
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.
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.
1-8
1.2. SAFE TRAVEL
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
gangplanks, 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 gangplanks so that they
do not slip and fall.
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.
1-9
1.2. SAFE TRAVEL
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.
When Travel in reverse up the slope and forward
unloaded: down the slope with the load-engaging
means downgrade.
• 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!
WHEN MAKING A TURN, BE CAREFUL OF THE

SWINGING COUNTERWEIGHT
• Remember that a fork 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.
1-10
1.2. SAFE TRAVEL
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.)
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.
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.
1-11
1.2. SAFE TRAVEL
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.
FOLLOW THESE STEPS FOR 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 heat, ignition sources, or 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.
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1.2. SAFE TRAVEL
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 use the
starting 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 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.
1-13
1.3. 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.
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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.
1-15
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.
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.
1-16
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.
1-17
1.4. SAFETY IN PERIODIC MAINTENANCE
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.
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.
1-18
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.
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.
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.
1-19
BE CAREFUL OF BOILING ENGINE COOLANT

• Immediately after using the lift truck, the engine coolant is at
high temperature and high pressure. Do not remove the
radiator cap under these conditions 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 when rotating.
• 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.
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.
1-20
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 before checking the rims for
damage. If a rim is damaged or cracked when a tire is
inflated, there is danger that the rim will break under the high
pressure of the tire, 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.
• Always have tire inflation 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. Never loosen rim nuts (2) if installed 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.
1-21
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.
• Check that there is no one on the lift truck.
7. 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.
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.
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”.
1-22
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.
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.
1-23
1.5. TOWING
1.5. 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.
a. 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.
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 Komatsu 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.
1-24
1.6. 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
1-25
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

A nameplate shown at right is just an example. In the actual
operation, follow the instructions on a nameplate of the actual lift
truck.
An example here shows a nameplate for a lift truck which has a
mast of max. fork height of 3.0 m and which is not equipped with any
attachment.
(1) When the load center is 500 mm (2) Capacity: 2,500 kg
(1) When the load center is 600 mm (2) Capacity: 2,250 kg
(1) When the load center is 1,000 mm (2) Capacity: 1,620 kg
Even when the load center is shorter than 500 mm, the actual capacity is 2,500 kg (2).
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 Komatsu Forklift dealer asking for a new replacement nameplate.
1-26
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.
1-27
NOTES:
2. GENERAL
INFORMATION &
SPECIFICATIONS
2.1 SPECIFICATIONS
Model Manufacturer's Designation FD100-8 FD115-8 FD135-8
Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel Diesel
Characteristics
Operation Type Sitting Sitting Sitting

Rated Capacity Q kg(lb) 10,000 (22,000) 11,500 (25,000) 13,500
(30,000)
Load Center c mm(in) 600 (24) 600 (24) 600 (24)
Load Distance x Front Axle Center to mm(in) 695 (27.4) 715 (28.1) 740 (29.1)
Fork Face
Wheelbase y mm(in) 2,800 (110.2) 2,800 (110.2) 3,100 (122.0)
Service Weight kg(lb) 12,980 (28,620) 14,360 (31,660) 15,480
(34,130)
Axle Loading Loaded Front kg(lb) 20,860 (45,990) 23,490 (51,790) 26,450
Weight
(58,310)
Rear kg(lb) 2,120 (4,670) 2,370 (5,220) 2,530 (5,580)
Unloaded Front kg(lb) 6,230 (13,730) 6,590 (14,530) 7,110 (15,670)
Rear kg(lb) 6,750 (14,880) 7,770 (17,130) 8,370 (18,450)
Tyre Type Pneumatic Pneumatic Pneumatic
Tyre Size Front 9.00-20-14PR(I) 10.00-20-14PR(I) 11.00-20-
14PR(I)
Rear 9.00-20-14PR(I) 10.00-20-14PR(I) 11.00-20-
Tires
14PR(I)
Number of Wheels Front/Rear (x=driven) 4x/2 4x/2 4x/2
Tread, Front b10 mm(in) 1,700 (66.9) 1,700 (66.9) 1,770 (69.7)
Tread, Rear b11 mm(in) 1,900 (74.8) 1,890 (74.4) 1,890 (74.4)
2-2
Tilting Angle Forward/Backward degree 6/12 6/12 6/12

Mast Height, h1 2-stage Mast mm(in) 2,890 (113.8) 3,160 (124.4) 3,170 (124.8)
Lowered
Std. Free Lift h2 2-stage Std. Mast, mm(in) 0(0.0) 0(0.0) 0(0.0)
from Ground
Std. Lift Height h3 2-stage Std. Mast, mm(in) 3,000 (118) 3,000 (118) 3,000 (118)
from Ground
Mast Height, h4 2-stage Std. Mast mm(in) 4,400 (173.2) 4,670 (183.9) 4,680
Extended (184.3)
Height, Overhead h6 mm(in) 2,780 (109.4) 2,800 (110.2) 2,810 (110.6)
Guard
Length, with Std. L1 mm(in) 5,465 (215.2) 5,505 (216.7) 5,860 (230.7)
Forks
Dimensions
Length, to Fork L2 mm(in) 4,245 (167.1) 4,285 (168.7) 4,640 (182.7)

Face
Width, at Tyre b1 Single mm(in) 2,280 (89.8) 2,310 (90.9) 2,410 (94.9)
Forks s/e/l Thickness x Width x mm(in) 75x170x1,220 75x185x1,220 80x185x1,220
Length (3.0x6.7x48.0) (3.0x7.3x48.0) (3.1x7.3x48.0)
Fork Carriage Pin Mount Pin Mount Pin Mount
Class
Width, Fork b2 mm(in) 2,140 (84.3) 2,140 (84.3) 2,210 (87.0)
Carriage
Ground Clearance m1 Under Mast mm(in) 250(9.8) 250(9.8) 260(10.2)
m2 at Center of mm(in) 325(12.8) 345(13.6) 350(13.8)
Wheelbase
Right Angle Ast plus load length mm(in) 4,695 (184.8) 4,725 (186.0) 5,090 (200.4)
Stacking Aisle
Turning Radius Wa mm(in) 4,000 (157.5) 4,010 (157.9) 4,350 (171.3)
Travel Speed Loaded,1st/2nd/3rd km/ 8.5/18/28 8.5/19/28 9/19.5/27.5
(FWD) h(mph) (5.3/11.2/17.4) (5.3/11.8/17.4) (5.6/12.1/17.1)
Unloaded,1st/2nd/3rd km/ 9/20/32 9/21/32 9.5/21/32
h(mph) (5.6/12.4/19.9) (5.6/13.0/19.9) (5.9/13.0/20.2)
Lifting Speed Loaded/Unloaded mm/ 470/500 (93/98) 430/450 (85/89) 350/375
s(fpm) (69/74)
Lowering Speed Loaded/Unloaded mm/ 400/500 (79/98) 400/500 (79/98) 400/500
Performance
s(fpm) (79/98)
Max. Drawbar Pull Loaded, 1.5km/h, 3min kN(Ib) 89 (20,010) 87 (19,610) 85 (19,150)
rating
Max. Gradeability Loaded, 1.5km/h, 3min % 40 34 28
rating
Service Brake Operation/Control Foot/Hydraulic, Foot/Hydraulic, Foot/Hydraulic,
Powered Powered Powered
Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/
Mechanical
Steering Type Hydraulic Power Hydraulic Power Hydraulic
Steering Steering Power Steering
Battery Voltage/ Capacity at 5-hour V/Ah 24/80 24/80 24/80
rating
2-3
Maker Model KOMATSU KOMATSU KOMATSU

SAA6D107E-1 SAA6D107E-1 SAA6D107E-1
Rated Output, kW(HP) 122 (164) 122 (164) 122 (164)
SAE net
I.C Engine
Rated RPM min-1 2,200 2,200 2,200

Max. Torque, SAE Nm@mi 575 (424)@1600 575 (424)@1600 575
net n-1 (424)@1600
No. of Cylinder/ cm3(cu.i 6/6,690 (408) 6/6,690 (408) 6/6,690 (408)
Displacement n)
Fuel Tank Capacity l (US 260(69) 260(69) 280(74.0)
Gal)
Relief Pressure for bar(psi) 215(3,100) 215(3,100) 215(3,100)
Attachment
Hydraulic Tank l (US 170(45) 170(45) 200(53)
Others
Capacity Gal)
Clutch Torque Converter Torque Converter Torque
Converter
Transmission TORQFLOW TORQFLOW TORQFLOW
Specifications are subject to change without notice.
The performance values indicated herein represent nominal values obtained under typical operating conditions.
2-4
Model Manufacturer's Designation FD150E-8 FD160E-8

Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel
Characteristics
Operation Type Sitting Sitting

Rated Capacity Q kg(lb) 15,000 (33,000) 16,000 (35,000)
Load Center c mm(in) 600 (24) 600 (24)
Load Distance x Front Axle Center to Fork mm(in) 750 (29.5) 750 (29.5)
Face
Wheelbase y mm(in) 3,100 (122.0) 3,100 (122.0)
Service Weight kg(lb) 16,570 (36,530) 17,200 (37,920)
Axle Loading Loaded Front kg(lb) 28,740 (63,360) 30,140 (66,450)
Weight
Rear kg(lb) 2,830 (6,240) 3,060 (6,750)

Unloaded Front kg(lb) 7,210 (15,900) 7,170 (15,810)
Rear kg(lb) 9,360 (20,640) 10,030 (22,110)
Tyre Type Pneumatic Pneumatic
Tyre Size Front 11.00-20-16PR(I) 12.00-20-16PR(I)
Rear 11.00-20-16PR(I) 12.00-20-16PR(I)
Number of Wheels Front/Rear (x=driven) 4x/2 4x/2
Tyres
Tread, Front b1 mm(in) 1,770 (69.7) 1,770 (69.7)

0
Tread, Rear b1 mm(in) 1,890 (74.4) 1,870 (73.6)
1
Tilting Angle Forward/Backward degree 6/12 6/12
Mast Height, Lowered h1 2-stage Std. Mast mm(in) 3,270 (128.7) 3,290 (129.5)
Std. Free Lift h2 2-stage Std. Mast, from mm(in) 0 (0.0) 0 (0.0)
Ground
Std. Lift Height h3 2-stage Std. Mast, from mm(in) 3,000 (118) 3,000 (118)
Ground
Mast Height, h4 2-stage Std. Mast mm(in) 4,780 (188.2) 4,800 (189.0)
Extended
Height, Overhead h6 mm(in) 2,810 (110.6) 2,830 (111.4)
Guard
Dimensions
Length, with Std. L1 mm(in) 5,920 (233.1) 6,020 (237.0)

Forks
Length, to Fork Face L2 mm(in) 4,700 (185.0) 4,800 (189.0)
Width, at Tyre b1 Single mm(in) 2,410 (94.9) 2,480 (97.6)
Forks s/ Thickness x Width x mm(in) 85x190x1,220 85x210x1,220
e/l Length (3.3x7.5x48.0) (3.3x8.3x48.0)
Fork Carriage Class Pin Mount Pin Mount
Width, Fork Carriage b2 mm(in) 2,210 (87.0) 2,210 (87.0)
Ground Clearance m1 Under Mast mm(in) 250 (9.8) 270 (10.6)
m2 at Center of Wheelbase mm(in) 350 (13.8) 370 (14.6)
Right Angle Stacking Ast plus load length mm(in) 5,150 (202.8) 5,250 (206.6)
Aisle
Turning Radius Wa mm(in) 4,400 (173.2) 4,500 (177.2)
2-5
Travel Speed (FWD) Loaded,1st/2nd/3rd km/ 9/19.5/27.5 9.5/20/28

h(mph) (5.6/12.1/17.1) (5.9/12.4/17.4)
Unloaded,1st/2nd/3rd km/ 9.5/21/32 10/21.5/32
h(mph) (5.9/13.0/20.2) (6.2/13.4/20.5)
Lifting Speed Loaded/Unloaded mm/ 325/350 (64/69) 320/345 (63/68)
s(fpm)
Performance
Lowering Speed Loaded/Unloaded mm/ 400/400 (79/79) 400/400 (79/79)

s(fpm)
Max. Drawbar Pull Loaded, 1.5km/h, 3min rating kN(Ib) 80 (18,160) 80 (18,030)
Max. Gradeability Loaded, 1.5km/h, 3min rating % 25 23
Service Brake Operation/Control Foot/Hydraulic, Foot/Hydraulic,
Powered Powered
Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
Steering Type Hydraulic Power Hydraulic Power
Steering Steering
Battery Voltage/ Capacity at 5-hour V/Ah 24/80 24/80
rating
Maker Model KOMATSU KOMATSU
SAA6D107E-1 SAA6D107E-1
Rated Output, SAE kW(HP) 122 (164) 122 (164)
net
I.C Engine
Rated RPM min-1 2,200 2,200

Max. Torque, SAE net Nm@mi 575 (424)@1600 575 (424)@1600
n-1
No. of Cylinder/ cm3(cu.i 6/6690 (408) 6/6690 (408)
Displacement n)
Fuel Tank Capacity l (US 280(74.0) 280(74)
Gal)
Relief Pressure for bar(psi) 215 (3,100) 215 (3,100)
Attachment
Others
Hydraulic Tank l (US 200 (53) 200 (53)

Capacity Gal)
Clutch Torque Converter Torque Converter
Transmission TORQFLOW TORQFLOW
2-6
2-7
2-8
2.2 PERIODIC REPLACEMENT OF CONSUMABLE PARTS
For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable
parts listed in the following.
These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time
of periodic maintenance; therefore, even if no 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 nothing to do with guarantee service.
No. Part name Years elapsed
1 Fuel hose (fuel tank - fuel pre-filter) 2
2 Fuel hose (fuel pre-filter - supply pump) 2
3 Fuel hose (supply pump - fuel main filter) 2
4 Fuel hose (fuel main filter - supply pump) 2
5 Fuel hose (supply pump - common rail overflow) 2
6 Fuel hose (engine - fuel tank) 2
7 Brake hose or tube 2
8 Power steering hose 2
9 Stop lamp switch (hydraulic type switch) 2
10 Rubber parts inside power steering system 2
11 Lift chain 2–4
12 Hydraulic hose (for travel, loading & unloading and torque 2

converter)
13 Engine high-pressure piping clamp Every 8,000 hours
14 Fuel spray prevention cap
2-9
2.3 STANDARD TIGHTENING TORQUE
Bolts
For unspecified bolts and nuts, use the torques specified in this list.
Select a proper torque corresponding to the width across flats

(b) of bolts and nuts.
When replacing bolts and nuts, always use genuine Komatsu
Forklift parts the same size as the previous ones.
Thread diameter Width across Tightenng 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
2-10
Elbows, Nipples And Unions
Width across flats B (mm) 22 30 36
Width D (mm) 19 22 30
Tightening torqueNm {kgm} 29.4–39.2 {3–4} 78.5–103 {8–10.5} 117.7–161.8 {12–16.5}
Port size (inch) 3/4–16UNF 7/8–14UNF –
Tightening 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
Tightening torque Nm 19.6–29.4 23.5–68.6 58.8–98.1 108–167 147–206

{kgm} {2–3} {3–7} {6–10} {11–17} {15–21}
2-11
2.4 HOW TO USE LOCTITE
Procedure for using LOCTITE
Male side
Degreasing Air drying
Female
side
Applying
Leaving Assembly
LOCTITE
1. Degreasing and cleaning

a. Clean the parts in trichloroethylene, acetone, ether, alkaline solution, etc. which are highly volatile.
b. Degrease the parts as perfectly as possible.
c. Since gasoline, light oil, kerosene, etc. are not highly volatile, they are not recommended. If it is obliged to
use them, dry them completely.
d. If the mating parts are made of thermosetting resin, treat them with LOQUICK PRIMER after degreasing
them.
2. Air drying
a. Wait until the cleaning fluid dries out.
b. If the parts are treated with LOQUICK PRIMER, do not wipe them but dry them in air for 5 - 10 minutes. (If
LOCTITE is used before LOQUICK PRIMER dries out, its effect is lowered.)
3. Applying LOCTITE
a. Apply LOCTITE to either or both of the threads or the shaft and hole to be fitted with an amount to fill the
clearance between them by one of the following methods.
• Applying directly from LOCTITE container nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving pan.)
• Sponge
• Automatic applier
NOTE: Do not mix metallic foreign matter in LOCTITE or return LOCTITE used in a pan to the container.
4. Assembly
After applying LOCTITE, tighten the screw or fit the shaft to the hole as usual. (When using LOCTITE for
structures or LOCTITE instant glue type, press the mating parts lightly (about 49 kPa {0.5 kgf/cm2}).
5. Removal of parts
When screws and shafts are secured with LOCTITE, they usually can be removed with common tools such as
spanners, wrenches, pulley pullers, etc. If LOCTITE is so strong that a part may be broken when it is removed,
heat it (to 200 - 250 C) with a soldering iron, gas torch, etc., and you can remove it easily. It is generally
difficult to dissolve LOCTITE in chemical solutions.
6. When reassembling
If a LOCTITE film on threads is broken it is left as white powder on the threads. In this case, you can apply
LOCTITE again to the threads without removing the white powder.
2-12
If shafts or flanges secured with LOCTITE are disconnected, LOCTITE remaining on them may need to be
removed to maintain dimensional accuracy. You can remove the remaining LOCTITE easily, however, with a
wire brush, etc.
If plates secured with LOCTITE need to be assembled again after they are separated, be sure to remove all
the hardened LOCTITE and roughen the mating surfaces with sandpaper.
NOTES:
3. SERVICE DATA
3. SERVICE DATA
Component Inspection item Unit FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8

Engine Engine model – KOMATSU SAA6D107E-1-A
proper Idling speed rpm 700–750
Max. speed rpm 2,375–2,475
Torque converter stall rpm 2,000
speed
Compression psi Min.348 (24)/ 250–280
(MPa)/
rpm
Engine
Lubricating Capacity of engine oil gal (L) 5.4 (20.3)

and cooling Capacity of engine gal (L) 3.4 (12.8) (Exhaust capacity of radiator)
system coolant
Fuel system Injection order – 1–5–3–6–2–4
Capacity of fuel tank gal (L) 68.7 (260) 74 (280)
Intake and Valve Intake mm 0.01 (0.25) (in cold state)
exhaust clearance Exhaust in (mm) 0.02 (0.51) (in cold state)
system
Electric Specific gravity of – Min. 1.24 (20°C)
system battery electrolyte
Torque Stall speed rpm 2,000
converter Inlet oil pressure MPa 1.2–1.5 {12–15}
{kgf/cm²}
Outlet oil pressure MPa 0.6–0.73 {6–7.4}
{kgf/cm²}
TORQFLOW Relief pressure MPa 1.96 {20}
Power train
transmission {kgf/cm²}
Clutch actuating MPa 1.35–1.65 {13–16}
pressure {kgf/cm²}
Lubrication oil pressure MPa 0.6–0.73 {6–7.4}
{kgf/cm²}
Capacity of oil gal (L) 9.8-10.6 (37–40)
(including capacity of torque converter, oil cooler and oil
pipes)
Differential Capacity of oil gal (L) 5.3 (20)
Tire Tire inflation Front psi (kPa) 106.6 100 95.7 110.3 (760) 100 (690)
pressure wheel (735) (690) (660)
Travel device
Rear psi (kPa) 106.6 100 95.7 110.3 (760) 100 (690)
wheel (735) (690) (660)
Hub nuts Tightening Front lbf-ft 325.3-398 (441–539)
torque wheel (Nm)
Rear lbf-ft 325.3-398 (441–539)
wheel (Nm)
3-2
3. SERVICE DATA
Component Check item Unit FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8

Steering Play in (mm) 1.2-2.4 (30–60)
wheel
Rear axle Turning radius in (mm) 157.5 157.9 171.3 173.2 177.2
(4,000) (4,010) (4,350) (4,400) (4,500)
Inching pedal Stroke in (mm) 3.3 (83)
Interlocking stroke in (mm) 2 (50)
Steering and braking device
Brake pedal Play in (mm) 0.04-0.2 (1–4)

Stroke in (mm) 3.0 (76)
Brake Cooling oil tank (Wet gal (L) 3.8 (14.5)
disc type)
Operating effort of lbf-ft Min. 145 (196)
parking brake lever (Nm)
Gas pressure of brake MPa 4.9
accumulator (Hydraulic {kgf/cm²} {50}
drum type)
Gas pressure of brake MPa 3.4
accumulator (Wet disc {kgf/cm²} {35}
type)
Tightening torque of lbf-ft 108-181 (147–245) 108-145 (147–196)
back plate mounting (Nm)
bolt
Fork Thickness of base in (mm) Min.2.8 (70) Min. 2.9 Min. 3.1 (80)
(75)
Material–handling device
Height difference in (mm) 0.8 (20)

Opening at tip in (mm) 2.0 (50)
Chain Length of 17 links in (mm) Max.26 Max. 30.3 (770)
(660)
Cylinder Hydraulic drift in (mm)/ 2.0 (50)
15 min
Hydraulic forward tilt in (mm)/ 1.6 (40)
15 min
Hydraulic Relief pressure MPa 21.6
system {kgf/cm2} {220}
Quantity of oil gal (L) 44.9 (170) 52.8 (200)
3-3
NOTES:
4. TESTING &
ADJUSTING
4.1 DEPRESSURIZE HYDRAULIC SYSTEM
When depressurizing the hydraulic system, always seat yourself on the operator seat before operating the
lever. Or, the shut valve (operator present) of the hydraulic piping will be closed, disabling depressuriza-
tion.
1. Stop the forklift truck. Lower the fork to the ground.

2. Stop the engine.
3. Turn the starting switch to the ON (2) position.
4. Sit on the seat.

5. Operate the lift lever and tilt lever forward and backward 4
to 5 times each to depressurize the hydraulic system.
4-2
4.2 REPLACE ENGINE OIL/ENGINE OIL FILTER
Service the engine always after it is stopped completely and the temperature fully lowered.
4.2.1 CHANGE ENGINE OIL

1. Remove the drain plug and drain the oil. After draining the all oil, tighten the drain plug.
2. Supply engine oil by the specified quantity.
3. Check the oil level with the oil level gauge.
NOTE: Oil capacity for replacement:
5.36 US gal. ( 20.3 l, 4.47 UK gal)
4.2.2 REPLACE ENGINE OIL FILTER

1. Remove the filter cartridge with a filter wrench.
2. Clean the filter stand. Apply engine oil to the seal and threads of a new cartridge, then install the latter.
NOTE: After installing the cartridge, start the engine and check the filter mounting face for oil leakage.
Oil gauge
Oil filler port
Filters
Drain plug
4-3
4.3 REPLACE FUEL FILTERS

The fuel filters of this truck consist of pre-filter cartridge and main filter cartridge.
• Engine parts are in high temperature immediately after the engine is stopped. Do not replace filters
immediately. Replace only after the engine is cooled.
• When replacing filters, wait till the inner pressure lowers. Replace the filters 30 seconds or more after
the engine stopped.
• Keep fire away when replacing filters.
NOTE:
• Special filter of high-efficiency filtration property is adopted for the genuine Komatsu Utility fuel filter
cartridges.
Always use genuine Komatsu Utility parts for replacement.
• The common rail fuel injection system adopted for the engine is configured with components of higher
accuracy compared with conventional injection pumps and nozzles. Using other fuel filter cartridges
than genuine Komatsu Utility parts may cause mixing of foreign matters, leading to a failure of
injection system. Never use substitute part.
• For inspection and maintenance of the fuel system, more care should be given for the mixing of
foreign matters than before. Attached dirt, if any, must be fully washed off using engine oil.
4.3.1 REPLACE FUEL PRE-FILTER CARTRIDGE

Arrange for the filter wrench.
1. Remove the cover on the left side of the machine.
2. Set an oil-receiving container under filter cartridge (3).
3. Apply the filter wrench to cartridge (3) to remove it by turning counterclockwise.
4. Clean the filter holder.
* REF (Reliable-Extra-Filtration)
This specification provides an additional main filter and a filter
with the water separation function for the inferior fuel. Water separator
(*REF)
• When filling the filter cartridge with fuel, always keep the cap
(A) attached.
• Cap (A) is provided to prevent dirt from entering the filter
cartridge.
5. Fill new filter cartridge with clean fuel through eight small
holes (B) on the cartridge.
6. Apply oil to the packing surfaces of the filter cartridge.
7. Remove the filter cartridge cap (A) and mount it to the
filter holder.
8. To mount the cap, tighten it 3/4 turn after the packing
surface makes contact with the sealed surface of the filter
holder.
NOTE: If over-tightened, the filter cartridge may cause fuel

leakage because of damaged packing. Conversely, if
loosely tightened, the fuel may leak through the gap
4-4
of the packing. Always tighten it to correct tightening angle.

When using the filter wrench, be careful not to cause damage or dents to the filter.
9. Bleed the air from the cartridge. (See the section of BLEED AIR FROM FUEL PRE-FILTER).
10. Start the engine.
11. Check the filter-sealed surface for fuel leakage.
12. Operate the engine for about 10 minutes at low idling speed.
4.3.2 BLEED AIR FROM FUEL PRE-FILTER

1. Fill up the fuel tank to full.
2. Loosen and pull out the knob (2) of the feed pump.
3. Operate the knob forward and backward.
NOTE: The plug on the side of the fuel pre-filter head need
not to be removed.
4. Operate the pump until the knob (2) starts meeting

resistance.
5. Push back and tighten the feed pump knob (2) when
bleeding of the air is completed.
4.3.3 REPLACE FUEL MAIN FILTER CARTRIDGE

Arrange for the filter wrench.
1. Open the engine hood.
2. Apply the filter wrench to the filter cartridge to remove it by turning counterclockwise.
3. Clean the filter holder.
NOTE: Do not fill the filter cartridge with fuel.

Cap (A) is provided to prevent dirt from entering
the filter cartridge.
4. Apply oil to the packing surfaces of the filter cartridge.

5. Remove the filter cartridge cap (A) and mount it to the
filter holder.
6. To mount the cartridge.
7. Tighten it 3/4 turn after the packing surface makes
contact with the sealed surface of the filter holder.
NOTE: If over-tightened, the filter cartridge may cause fuel

leakage because of damaged packing. Conversely, if
loosely tightened, the fuel may leak through the gap
of the packing. Always tighten it to correct tightening angle.
When using the filter wrench, be careful not to cause damage or dents to the filter.
8. Bleed the air from the cartridge. (See the section of BLEED AIR FROM FUEL PRE-FILTER).
10. Check the filter sealed surface for oil leakage.
11. Check the filter cartridge and give it extra tightening if oil leakage is detected.
12. Remove the filter cartridge following the steps 1 to 2 and check the packing surface for any damage or biting of
foreign matter if oil leakage persists.
13. Replace the cartridge with a new part and repeat the steps 3 to 7 if any damage or foreign matter is detected.
4-5
4.3.4 BLEED AIR FROM FUEL MAIN FILTER

Bleed the air by seeing the section of BLEED AIR FROM FUEL PRE-FILTER.
4.4 CLEAN INSIDE THE COOLING SYSTEM
• Engine parts are in high temperature after operation. Drain the coolant after the engine is cooled, or
you may burn yourself with hot coolant.
• Never enter under the machine body for cleaning while the engine is running, or serious accident may
occur if the machine started moving suddenly.
• When the radiator temperature is high, do not remove the radiator cap, or scalding hot water may blow
out. Remove the cap after the coolant temperature is lowered. Remove it by turning slowly while
allowing the pressure to escape gently.
• Incomplete bleeding of the air upon replacing the coolant or radiator may cause the engine to overheat.
Always bleed the air completely from the coolant.
4.4.1 CLEAN THE RADIATOR

1. Park the machine on a level ground before cleaning.
2. Drain coolant by opening the drain levers at the bottom of
the radiator and the engine cylinder block.
3. Close the drain levers.
4. Pour water and the radiator detergent into the water filler
port.
5. Operate the engine at low idling speed for about 15
minutes.
6. Stop the engine.
7. Drain the water from the drain port.
8. Keep adding water with the drain lever in open position
and run the engine at idling speed (for 5 to 10 minutes)
until clean water comes out of the drain port.
9. Stop the engine.
10. Drain water from the drain port.
11. Close the drain lever and fill the radiator with supply water and super coolant.(See the section of LUBRICANT
LIST.)
NOTE: Incomplete bleeding of the air upon replacing the coolant may cause the engine to overheat. Always bleed
the air completely from the coolant.
CAUTION WHEN REPLACING THE COOLANT
• Rapidly filling the coolant through the hose, etc. causes the bubbles to be mixed. Fill slowly.
• To check the coolant level after initial filling, run the engine at idling speed for 5 to 10 minutes with the radiator
cap removed to bleed the air inside the engine. Stop the engine and check the level again.
• Fill the reservoir tank with the coolant to the specified level.
4-6
4.5 AIR CLEANER
• Do not clean or replace the air cleaner while the engine is running.
When cleaning the elements with compressed air, dirt may be scattered to get into the eye. Put on the
protective glasses for evading the danger.
NOTE: If attached with oil, grease or carbon, apply special cleaner for the element according to the
descriptions on the cleaner.
Clean or replace the cleaner earlier when under adverse working environment or conditions.
4.5.1 CLEAN FILTER ELEMENT

1. Remove element (3).
O-ring
2. Blow the element from inside to outside with dry,

compressed air of 0.68 MPa {7 kgf/cm²} all around the
element.
3. Install cleaned element (3).
4.5.2 CHECK FILTER ELEMENT

1. Visually check the element for any damage.
4.5.3 REPLACE FILTER ELEMENT

1. Remove element (3).
2. Install the cover on the side of the air connector using a
clean piece of cloth or tape.
3. Clean the inside of the body and remove the cover installed in step 2.
4. Install new element.
4.6 ADJUST VALVE CLEARANCE
For how to adjust valve clearance, see Engine Shop Manual 6D107E-BE1 (SM229).
4.7 CHECK COMPRESSION PRESSURE
For how to check the compression pressure, see Engine Shop Manual 6D107E-BE1 (SM229).
4.8 TIGHTEN CYLINDER HEAD MOUNTING BOLTS
For the tightening torque for the cylinder head mounting bolts, see Engine Shop Manual 6D107E-BE1 (SM229).
4-7
4.9 DIFFERENTIAL CASE
Oil is in high temperature immediately after the engine operation.

Start working on it after the temperature is lowered
4.9.1 CHECK OIL LEVEL

1. Remove the level plug to check oil level.
NOTE: If the oil is close to the lower line of the plug hole, the
level is normal.
2. Remove the oil filler port plug to replenish oil if is low.
4.9.2 REPLACE OIL

1. Remove the oil filler port plug first.
2. Remove the drain plug to drain oil.
3. Tighten the drain plug after draining.
4. Fill oil to the specified level through the oil filler port.
5. Check the oil level after filling oil.
NOTE: Oil capacity for replacement: 5.28 US gal. (20 l,

4.40 UK gal)
IMPORTANT
Always use Komatsu designated oil for the gear.
(See the section of LUBRICANT LIST.)

4.10 TORQFLOW TRANSMISSION CASE
Oil is at a high temperature immediately after the engine operation.

Start working on it after the temperature is lowered.
4.10.1 CHECK OIL LEVEL

1. Open the inspection window of the floor plate to check the level with the oil gauge.
2. Remove the oil filler port cap and replenish oil if the level is low.
4.10.2 REPLACE OIL AND CLEAN STRAINER

1. Remove the drain plug to drain oil.
2. Tighten the drain plug after draining oil.
3. Remove the pipe to remove the strainer.
4. Wash the strainer with cleaning oil.
5. Blow the strainer with the air from inside to outside.
6. Dry it completely before installation.
7. Fill oil from the oil filler port to the specified level.
8. Check the oil level after filling oil.
NOTE: Oil capacity for replacement: 10.57 US gal (40 l, 8.80 UK gal)
4-8
IMPORTANT
Always use Komatsu designated oil for the engine. (See the section of LUBRICANT LIST.)
Oil filler cap Oil gauge
Correct
Drain plug range
Strainer
4-9
4.11 SERVICE HYDRAULIC TANK
• Oil is at a high temperature immediately after the operation.

• Do not replace oil immediately after operation.
• Replace after the oil is cooled.
1. Drain oil from the drain plug at the bottom of the oil tank.
2. Remove the cover.
3. Remove the strainer.
4. Wash the strainer with cleaning oil.
5. Clean the inside of the tank.
6. Install the drain plug.
7. Blow the strainer with the air from inside to outside.
8. Install the strainer after drying it completely.
9. Install the cover.
10. Remove the line filter cartridge.
11. Install a new cartridge.
12. Fill the hydraulic tank to the specified level through the
hydraulic oil filler port.
13. Check the level through the inspection window.
OIL CAPACITY FOR REPLACEMENT:
FD100/115 44.9 US gal (170 l, 37.4 UK gal)
FD135/150E/160E 52.84 US gal (200 l, 44.0 UK gal)

15. Operate the cylinders (lifting, tilting and power steering) to the stroke end 5 to 6 times to bleed the air.
NOTE: Always use Komatsu Utility-designated hydraulic oil.
4.12 REPLACE BRAKE COOLING OIL (WET DISC BRAKE TYPE)

1. Stop the engine.
2. Remove cooling oil drain plug (2) at the bottom of the L.H.
and R.H. brake cylinders (1).
3. When the cooling oil is completely drained, tighten the
drain plug (2).
4. Fill the cooling oil tank inside the side cover on the L.H.
side of the machine to the specified level.
Cooling oil tank 14.5 l

oil level (3.83 US gal, 3.19 UK gal)
Oil capacity inside 9l
the front axle (2.83 US gal, 1.98 UK gal)
Oil capacity of piping 6l
(1.59 US gal, 1.32 UK gal)
The brake chamber is filled with cooling oil from the tank. The oil level in the tank drops.
4-10
6. Stop the engine and replenish oil to the tank to the specified level.
Specified oil level At the center of the gauge on

the side of the tank
7. Start the engine again.
8. Hold it running at low idling speed for 3 minutes or over and then stop the engine.
9. Check if the oil is up to the specified level.
10. Replenish it, if necessary.
NOTE: Always use Komatsu -designated oil for cooling the brake. (See the section of LUBRICANT LIST.)
4.13 MEASURE HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS
• When measuring, never let anyone go under the load.

• Do not put your feet on the mast stays or dashboard and climb up when measuring the hydraulic drift
of the lift cylinder. If you measure the hydraulic drift when doing this, there is danger that you may get
your hands or feet caught in the mast.
• Always use a strong, stable stand when measuring.
• Before measuring, check that the hydraulic oil level is correct and that hydraulic oil is not dirty or
mixed with any other brand of oil.
• Always carry out the measurement on flat horizontal ground in front of a strong platform which will
support the truck if it should tip over to the front.
1. Stop the lift truck 500 mm in front of the platform.

2. Operate the lift and tilt repeatedly to set the hydraulic oil
temperature to 122°F (50°C).
3. Set the rated load on the forks and secure it to the fork Set must
carriage with wire. perpendicular
4. Raise the load approx. 59 in (1500 mm) and set the mast
perpendicular.
5. Wait for 3 minutes.
Approx
1500 mm
6. Place a ruler against the lift cylinder piston rod and make
a mark.
7. Measure the hydraulic drift over the next 15 minutes.
8. Wait for 3 minutes.
4-11
9. Place a ruler against the tilt cylinder piston rod and make
a mark.
10. Measure the hydraulic drift over the next 15 minutes.
4.14 ADJUST BRAKE/INCHING PEDAL OPERATION (HYDRAULIC DRUM

BRAKE TYPE)
4.14.1 ADJUST BRAKE PEDAL
1. Adjust stopper bolt (1) so that the pedal height (h1) is 9.1
in (231mm).
2. Adjust the cable length so that the play of the brake pedal Pedal play 1- 4 mm
becomes 0.04-0.16in (1 to 4mm). 1
3. Adjust the cable position so that the play at the end of h1
cable is 0 to 0.5mm.
NOTE: Do not pull the linkage. (The connection pins at both

ends of cable should be smoothly moved by hand.) 2
Cable 0 - 0.5 mm
end
4-12
4.14.2 ADJUST INCHING PEDAL

1. Adjust with stopper bolt (3) so that the pedal height (h2) is
9.1 in (231mm).
2. Adjust linkage (4) so that the inching spool protrusion (a)
is 0.97in (24.5mm).
5 3 4
h2
Detail (a)
3. Adjust bolt (5) so that the inching pedal and brake pedal
are interconnected for the travel shown below when the 50 mm
inching pedal is depressed. The depressed inching
pedal travels at a distance
as shown until the brake
Interconnected stroke 50 mm (1.97 in) pedal starts to move.
4-13
4.15 ADJUST BRAKE/INCHING PEDAL OPERATION (WET DISC BRAKE

TYPE)
4.15.1 ADJUST BRAKE PEDAL
1. Adjust stopper bolt (1) so that the brake pedal height (h1)
is 9.1in (231mm) above the floor plate.
2. Use bolt (2) to press the valve spool in for 1 to 1.5 mm to

adjusting the play.
Play of the pedal 0.08 – 0.24 in (2 – 6 mm)
4.15.2 INCHING PEDAL

1. Adjust stopper bolt (3) so that the inching pedal height
(h2) is 9.1 in. (231mm) above the floor plate.
2. Protrusion of inching spool

2. Adjust linkage (4) so the protrusion of the inching spool
(a) is 0.97in. (24.5mm).
4-14
3. Adjust bolt (5) so that the inching pedal and brake pedal
* The dimension with which the
are interconnected for the travel shown below when the
brake pedal starts moving as the
inching pedal is depressed. inching pedal is stepped on.
Interconnected 28.5 – 33.5 mm

stroke (b) (1.12 – 1.32 in)
4.16 ACCUMLATOR FOR BRAKE
• Park the machine on a flat place. Lower the work equipment completely to the ground. Apply chocks
to the tyres.
• High-pressure nitrogen gas is charged with the brake accumulator. Proper certification of handling the
high-pressure gas is required for charging the nitrogen gas.
4.16.1 CHARGE ACCUMULATOR WITH NITROGEN GAS (HYDRAULIC DRUM BRAKE

TYPE)
1. Remove accumulator (1) as shown in the following figure.
Brake valve
4-15
2. Since the thread of gas valve (25) of the accumulator is TV8, install the joint assembly to the charging
assembly. (See Charging Assembly and Joint Assembly illustrations on the following pages.)
3. Turn handle (23) of charging assembly (00) to the left until it stops.
4. Turn handle (24) of the bleed plug to the left to open the plug.
5. Remove the cap of the accumulator and install charging assembly (21) to the gas valve of the accumulator.
6. Connect nitrogen gas cylinder (2) and charging assembly
(21) by hose assembly (29).
NOTE: There are 2 types of threads of gas cylinders, W22-

14 thread (male screw, type A) and W23-14 thread
(female screw, type B). When using type-B gas cylin-
der, use the attached reducer (30).
7. Open the valve of nitrogen gas cylinder (2) a little so that

the gas will be discharged at pressure of 0.2 – 0.3 MPa {2
– 3 kg/cm²}, taking care not to discharge the gas quickly.
NOTE: Then, the gas comes out of handle (24). At this time,
turn the handle to the right to prevent the gas from
escaping.
8. Turn handle (23) of charging assembly to the right to lead the nitrogen gas to the accumulator.
9. Stop handle (23) when you feel a light reaction so that the gas valve piston will not be damaged.
If the handle is turned too strongly, the core will be broken. Take care.
10. Open the gas cylinder valve gradually further to charge the accumulator with the nitrogen gas. While doing so,
close the gas cylinder valve sometimes and read pressure gauge (28) of the charging assembly when it is
stabilized.
11. Charge gas pressure: 4.9 MPa ± 0.2 {50 ± 2 kg/cm²}
12. After the accumulator is charged to the specified pressure, close the valve of nitrogen gas cylinder securely.
NOTE: If the pressure in the accumulator is too high, turn handle (24) to the left and release the nitrogen gas grad-
ually.
13. Turn handle (23) to the left until it stops, and then turn handle (24) to the left to open it and discharge the gas
remaining in the charging assembly and hose.
14. Remove charging assembly (21) from the accumulator.
15. Apply water or soap water to the gas valve of the accumulator to check that the gas is not leaking, and then
install the cap.
16. Install the accumulator to the lift truck.
4-16
Charging Assembly
No. Part name Q’ty Remarks
00 Charging Ass’y 1
21 • Charging Ass’y 1
22 • • Charging valve, Body 1
23 • • Adjust screw, handle 1
24 • • Bleed plug, handle 1
25 • • Gas, Valve 1
26 • • Nut 1
27 • • Joint 1
28 • • Pressure, Gauge 1 0 – 15 MPa {0 – 153 kgf/cm²}
29 • Hose Ass’y 1 L = 4,000 mm
30 • Reducer 1 JIS N2 gas cylinder
4-17
Joint Assembly
No. Part name Q’ty Remarks
Joint Ass’y 1
31 • Joint 1
32 • Gasket 1
33 • Seal washer 1
4.17 CHARGE ACCUMULATOR WITH NITROGEN GAS (WET DISC BRAKE

TYPE)
1. Remove accumulator (1) shown in the following figure.
Accumulator charge valve
4-18
2. Charge the accumulator as described in the previous section.

4.18 MEASURE ACCUMULATOR CHARGE VALVE PRESSURE (WET DISC
BRAKE TYPE)
1. Stop the engine.
2. Step on the brake pedal 10 times or more to depressurize the accumulator circuit.
3. Remove the floor cover.
4. Remove plug (1) from the accumulator charge valve.
5. Install the measuring nipple (PT1/8).
6. Install the oil pressure gauge (39.2 MPa {400 kgf/cm²})
7. Measure the accumulator charge cut-in pressure.
a. Start the engine and run it at low idling speed.
b. Measure the oil pressure when the sound of brake oil
pressure-warning buzzer ends.
+0.49 +5
Cut-in pressure 5.88 0 MPa {60 0 kgf/cm²}
8. Measure the accumulator charge cut-out pressure.

a. Note the oil pressure when rising oil pressure gauge
indicator reading suddenly changes to falling after cutting the accumulator charge in.
+0.98 +10
Cut-out pressure 9.8 0 MPa {100 0 kgf/cm²}
9. Remove the equipment used and restore the original conditions.

4.19 ADJUST ACCUMULATOR CHARGE VALVE PRESSURE (WET DISC
BRAKE TYPE)
NOTE: Adjusting the accumulator charge cut-out pressure also changes the cut-in pressure.
1. Loosen lock nut (5) of cut-out valve (4).

2. Adjust by turning adjust screw (6).
NOTE: Adjust screw
Turn clockwise Pressure rises
Turn counterclockwise Pressure lowers
NOTE: Adjustment per turn of the adjust screw: 811psi (5.59

MPa) {57 kgf/cm²}
torque 7.2-11.8 lbf-ft (9.8 – 11.8 Nm) {1.0 – 1.2

kgm}
4-19
3. After completing adjustment, measure the accumulator

cut-in pressure and cut-out pressure again.
4.20 ADJUST ACCELERATOR PEDAL OPERATION

Since the accelerator pedal installed to this machine is electrical, no adjustment is required.
4.21 ADJUST PARKING BRAKE
4.21.1 ADJUST THE LEVER OPERATING EFFORT
1. Use adjust bolt to adjust the maximum parking lever oper-
Adjustment bolt
ating effort reads 196 Nm {20 kgm} at the center of the
grip.
4-20
4.21.2 ADJUST PARKING BRAKE SHOE CLEARANCE

1. Turn the adjust wheel (1) in the shoe expanding direction to have the lining made contact with the brake drum.
2. Turn the adjust wheel (1) so that the clearance between
the drum and lining (points X and Y in the diagram to the
right) reads 0.1 to 0.25 mm.
torque
157 – 196 Nm
{16 – 20 kgm}
NOTE: Turning the adjust wheel by 11 notches adjusts the
clearance by 0.25 mm. 2 Loctite #271
4.22 BLEEDING AIR

4.22.1 BRAKE PIPING (HYDRAULIC DRUM BRAKE TYPE)
1. Remove the cap from the air bleed plug.
2. Fit one end of a vinyl hose over the air bleed plug.
3. Put the other end of the vinyl hose in a container of brake
fluid.
4. Loosen the air bleed plug approx. 3/4 turns.
5. Depress the brake pedal.
6. Tighten the air bleed plug.
7. Release the brake pedal.
8. Repeat Steps 4 to 7 until no more bubbles come out from
the hose.
9. Tighten the plug and install the cap.
10. Add brake fluid as necessary.
4.22.2 LIFT CYLINDER

1. Start the engine and run at low idling.
2. Raise and lower the mast.
NOTE: Stop the mast approx. 4 in (100 mm) before reaching the max. lifting height and max. lowering position.
3. Repeat Step 2 4–5 times.

4. Raise and lower the mast to the maximum lifting height and maximum lowering position.
4-21
5. Repeat Step 4 4–5 times.
4.22.3 BRAKE (WET DISC BRAKE TYPE)
Carry out the work by two (2) persons. One person steps on the brake pedal and other bleeds the air from
the bleeder screw.
1. Remove the bleeder cap on top of the brake cylinder.

2. Attach an end of the vinyl hose to the screw and other
end to inside the container.
Vinyl hose Bleeder
3. Start the engine, and then step on the brake pedal. screw
4. Loosen the bleeder screw slowly.
5. When the bubbles stop coming out of the hose, fully step
on the brake and tighten the bleeder screw while the oil is
coming out.
6. Repeat the same process with other brake to bleed the
air.
7. When the air bleeding is completed with the L.H. and
R.H. brakes, check the hydraulic tank level.
8. Replenish oil, if necessary.
IMPORTANT
Care should be taken to keep dirt and foreign matter away from the brake during assembly.
4.23 CHECK WEAR OF BRAKE DISC (WET DISC BRAKE TYPE)
• When the disc approaches the wear limit, check the disc frequently.
• Carry on the work by two (2) persons. One person steps on the brake pedal and other checks the wear
of the disc.
2. Store pressure in the brake accumulator with the forward/rear travel lever in neutral position.
3. Stop the engine.
4. Check that no other brake than the parking brake is applied.
5. Step on the brake pedal.
6. Remove cap nut (1) from the disc wear sensor (2).
7. Push the disc wear sensor (2) in till it contacts with the
piston to check on wear volume.
NOTE: New truck has the rod end face (a) protruded from
the plug (3). Do not loosen the plug (3) for other than
checking the disc wear.
When the rod end face (a) of disc wear sensor is
below the plug (3) housing surface, the disc has
reached the wear limit. Replace whole the brake disc
assembly.
8. Install the cap nut (1) of the disc wear sensor.
torque
Cap nut (1) tightening torque 14.5lbft-ft (19.6 Nm) {2.0 kgm}
4-22
4.24 ADJUST STEERING AXLE

Adjusting alignment
Toe–in mm
Camber deg
0
Castor deg
King pin angle deg
Tread mm 1,900 (10 t)

1,890 (11.5 t–15 t)
1,870 (16 t)
Toe–in L1 = L2
4.24.1 ADJUST TURNING ANGLE

1. Adjust the left and right stopper bolts so that turning angle
is 76° ± 30'.
2. Operate the cylinder in and out and check that there is no
scuffing at the link connection or any other part.
4.25 INSPECT THE AIR CONDITIONER (OPTION)
• Never touch refrigerant. Never loosen the parts on the refrigerant circuit as well. Eyesight may be lost
or hand may be frostbitten if contacting with refrigerant gas.
• Keep fire away from the leaking point of refrigerant gas if any.
1. Start the engine and set the speed to about 1,500 rpm.
4-23
2. Press main power switch (1) of the air conditioner and

turn the power ON.
3. Press the fan switch (2) to set the flow rate to H.
4. Press the temperature control switch (3) to set the display
monitor to the COOL side (A).
5. Open all the doors and windows.
6. Press the air conditioner switch (4) to set the air
conditioner ON.
7. Check the state of refrigerant (Freon 134a) flowing inside

the refrigerant circuit through the sight glass (6)
(inspection window) on the receiver dryer (5).
NOTE: The table indicates the refrigerant level.
A:Refrigerant capacity
B:State of the sight glass
a:Correct: After the air conditioner is turned ON, some
bubbles are noticed in the flow of refrigerant, then it turns
light opaque white.
b:Refrigerant volume low: Bubbles are continually noticed
after the air conditioner is turned ON.
X:Flow state of refrigerant
Y:State of the sight glass
x:Bubbles are present. Refrigerant in liquid and gaseous state
is mixed.
y:Bubbles are gone and all the refrigerant is in transparent
liquid state.
z:White turbid oil and refrigerant are in separated condition in
light opaque white.
Inspection and maintenance table
Timing for inspection and maintenance

Check points Check item
Start-up Replacement
6 months
inspection intervals
Filters Clogging, contamination Check 2 years
Condenser Clogging, contamination Check
Belts Loosening, damage Check 2 years
Refrigerant gas Filling volume Check
Piping Loosening, damage, leakage Check
Receiver dryer — 2 years
4-24
4.26 INSPECT BATTERY
• First-aid treatment for exposure to battery electrolyte

If your eyes, skin or clothes are contaminated with battery electrolyte, wash it off with large amount of
water. If it gets into your eyes, immediately see an eye doctor.
• Keep fire away
Avoid short circuit and/or sparks to be generated near the battery. Keep a lit cigarette or other fire
away from the battery.
1. Charge the battery.
2. Replenish battery electrolyte to normal level, if necessary.
3. Use a specific gravity meter and temperature gauge to
measure specific gravity of the battery electrolyte and the
temperature.
4. Substitute the calculating formula with the values
measured in steps 1 and 2 above to calculate S20.
S20 = St + 0.0007 (t-20)
S20:Specific gravity at 20°C

St:Specific gravity at t°C (measured value)
t:Temperature of battery electrolyte (measured value)
Normal value: S20 = 1.27 – 1.29
5. Charge, if necessary.
Specific gravity Necessity for

Charged state
of electrolyte charging
1.280 Fully charged None

1.240 Discharged 1/4
1.210 Discharged 1/2 Charging

1.130 Fully discharged necessary
4-25
4.27 OIL AND GREASING CHART
Fork slide shaft Differential case
Lift chain Tilt cylinder pin
TORQFLOW
Mast support
transmission
Pedal pin Engine oil pan
Brake cooling oil

Hydraulic tank
tank (Wet disc type)
Power steering
Center pin, King pin
cylinder pin
Daily inspection
Once every 2 week (100 hours)
Monthly (200 hours)
Every 2 months (400 hours)
Symbol Type of fluid
EO Diesel engine oil
MO Engine oil
GO Gear oil
HO Hydraulic oil
G Lithium grease
1. Check and add fluid if necessary

2. Change or add oil
3. The figure in indicates the number of oil or greasing locations.
4. The intervals for checking the oil level, adding oil, and greasing are every day, every two weeks, every one
month, every three months, and every six months, or according to the hourmeter reading.
IMPORTANT
Always use Komatsu -designated oil for the diesel engine.
4-26
4.28 LUBRICANT LIST
IMPORTANT
Never use fuel mixed with kerosene.
Ambient temperature
Lubrication
point Type of fluid -22 -4 14 32 50 68 86 140 °F
-30 -20 -10 0 10 20 30 40 °C
SAE J300 0W30 (*1)
SAE J300 5W40 (*1)
Diesel
Engine oil pan engine oil SAE J300 10W30 (*1)
SAE J300 15W40 (*1)
SAE J300 30 (*1)
TORQFLOW
transmission Engine oil SAE 10W (*2)
case
SAE 80
Differential
case Gear oil
SAE 90
SAE 5W (*2)
Hydraulic Hydraulic oil
system
SAE 10W (*2)
ASTM Grade No.1-D S15

Fuel tank Diesel fuel
Brake cooling oil SAE 10W (*2)

(option) Engine oil
Greasing Lithium
G2-LI
points grease
Cooling system Super FAF-NAC

coolant
*1 Use API CF-4 or higher grade oil. SAE : Society of Automotive Engineers
*2 Use API CD or higher grade oil. ASTM: American Society of Testing and Material
API : American Petroleum Institute
4-27
NOTES:
5. INSPECTION
5. INSPECTION
5.1 GENERAL LOCATIONS
No. Name of equipment No. Name of equipment

1 Mast 17 Hydraulic pump
2 Lift cylinder 18 Rear wheel
3 Tilt cylinder 19 Steering axle
4 Brake valve 20 Power steering cylinder
5 Control valve 21 Muffler
6 Front wheel 22 Radiator
7 Fork 23 Counterweight
8 Wheel brake 24 Parking lever
9 Drive axle 25 Power steering valve
10 Differential gear 26 Battery (on the R.H. side of the lift truck)
11 Parking brake 27 Pedal
12 Drive shaft 28 Brake cooling oil tank
(wet disc brake type)
13 Transmission 29 Aftercooler
14 Torque converter 30 Brake cooling oil cooler
(wet disc brake type)
16 Engine 31 Torque converter cooler
5-2
5. INSPECTION
5.2 WEIGHT TABLE

Unit: lb. (kg)
FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8 Remaks
Engine assembly 1,180 (535)
Transmission assembly 794 (360) Dry
Axle Front 1,731 (785) 1,808 (820) Excluding frontwheel
Rear 937(425) 1,235 (560) Excluding power
steering cylinder
Wheel (each) Front 176 (80) 209 (95) 231 (105) 242 (110) 253 (115) With rim
Rear 154 (70) 187 (85) 209 (95) 209 (95) 231 (105) With rim
Over head guard 289 (131)
Counterweight 9,392 11,508 12,280 14,528 15,653
(4,260) (5,220) (5,700) (6,590) (7,100)
Lift cylinder 187 (85) 198 (90) 231 (105) 242 (110) 242 (110) Lift hight 118 in (3 m)
(each)
Tilt cylinder 110 (50) Each
Power steering cylinder 99 (45) 121 (55)
assembly
Mast 3,748 4,277 4,519 4,630 4,630 Lift hight 118 in (3 m)
(1,700) (1,940) (2,050) (2,100) (2,100) Excluding fork, fork
carriage
Fork carriage assembly 1,731 1,918 2,227 2,502 2,502 Excluding fork
(785) (870) (1,010) (1,135) (1,135)
Fork (each) 386 (175) 441 (200) 485 (220) 529 (240) 573 (260) Length: 48in (1,220
mm)
5-3
5. INSPECTION
5.3 CHECK ITEMS
Compo
Inspection item Nature of inspection
nent
1. Startup condition Pull back the parking lever. Set the F/R travel lever to neutral, then start
and abnormal sound engine and check the following:
1. Does engine start smoothly?
2. Is there any abnormal noise?
3. Does glow plug operate normally?
4.Do the accelerator pedal and lever operate smoothly?
2. Rotating condition, Step on the accelerator pedal and inspect the following:
exhaust color, etc. 1. Does engine rotation increase smoothly?
2. Is exhaust gas color normal?
During idling Colorless

When stepping down on the pedal Light black
3. Is exhaust sound normal?

4. Is there any leakage of exhaust gas?
3. Engine speed Check the following after warming-up the engine:

Engine
1. Idling speed
FD100/115
FD135/150E 700–750 rpm
FD160E
2. Max. speed
FD100/115
FD135/150E 2,375–2,475 rpm
FD160E
4. Air cleaner Check the following on the air cleaner:

1. Cracks and deformation of air cleaner
2. Loosening of air cleaner mount
3. Contamination and damage of the elements
NOTE: For the cleaning and replacement method of the element, see
the section of TESTING AND ADJUSTING.
5-4
5. INSPECTION
Compo
nent
5. Cylinder head Loosening of cylinder head mounting bolts
NOTE: For the tightening method and torque for the cylinder head
mounting bolts, see Engine Shop Manual 6D107E-BE1.
6. Valve clearance Valve clearance
Exhaust
Model Engine Intake valve
valve
FD100/115 SAA6D107-1-A 0.0098 (0.25) 0.020 (0.51)

FD135/150E (Komatsu) (Cold) (Cold)
FD160E
NOTE: For how to adjust valve clearance, see Engine Shop Manual
6D107E-BE1.
Engine
7. Compression Compression
pressure Unit: psi (MPa) {kgf/cm2}/rpm
FD100/115
FD135/150E Min. 349.9 (2.41) {24.6}/ 250 – 280
FD160E
NOTE: For how to measure the compression, see Engine Shop Manual
6D107E-BE1.
8. Injection pressure — Not applicable to this truck model —
9. Spray condition and — Not applicable to this truck model —

injection timing
10. Turbocharger Check the turbocharger for the following points:

1) Abnormal vibration
2) Abnormal noise
3) Gas leakage
5-5
5. INSPECTION
Compo
nent
11. Engine mount Check the engine mount for the following points:
1) Cracks and deformation of bracket
2) Loosening and falling of mount bolts and nuts
3) Damage and degradation of vibration absorbing rubber
12. Lubrication system 1. Engine oil

1) Oil level
Check the level with the oil level gauge. Replenish it if in shortage.
SAA6D107E-1-A
20.3 l
(Komatsu)
2) Discoloration and degradation
Replace it if degraded.
NOTE: For the oil changing method, see the section of TESTING AND
ADJUSTING.
3) Oil leakage
2. Engine oil filter
Engine
Periodically replace filters since their condition is not determined by

visual inspection.
NOTE: For the oil filter replacement method, see the section of TEST-
ING AND ADJUSTING.
13. Fuel system Check the fuel system for the following points:
1) Fuel leakage
2) Damage and degradation of hoses and pipes
3) Fuel filters
Periodically replace filters since their condition is not determined by visual
inspection.
NOTE: For the fuel filter replacement method, see the section of TEST-
ING AND ADJUSTING.
14. High pressure gas — Not applicable to this truck model —

fuel system
15. Blow-by gas — Not applicable to this truck model —

reducing device
5-6
5. INSPECTION
Compo
nent
16. Coolant, radiator 1. Coolant level

Check the level with the reservoir
tank.
2. Water leakage from hose
3. Crack and thermal hardening of
hose
4. Radiator cap
Do not remove the radiator cap when the coolant temperature is

high. Or the scalding water may blow out.
After the coolant temperature has gone down, turn the cap slowly to
release the pressure before completely removing it.
1) Pressure-regulating valve
Check the cap spring for appropriate tension
when it is depressed with fingertip.
2) Negative pressure valve
Check that the valve closes when it is pulled
and released.
If packing is damaged, replace the radiator
cap assembly.
Engine
17. Fan, fan belt 1. Fan belt

1) Wear and damage of fan belt
• Also check the inside of the belt.
• If the lower portion of a pulley is shiny, replace the pulley as it is prone to
start slipping.
2. Deflection
Since the fan belt is equipped with an automatic tensioner, measuring and
adjustment of flexure are not required.
2. Fan, fan cover (shroud)
1. Cracks and deformation of fan
2) Loosening of fan mounting bolts
3) Cracks and deformation of shroud
4) Loosening of shroud mounting bolts
18. Distributor — Not applicable to this truck model —

(Gasoline engine lift
truck)
19. Spark plug — Not applicable to this truck model —

Ignition timing
(Gasoline engine lift
truck)
5-7
5. INSPECTION
Compo
nent
20. Alternator, wring Check the following.

1. Specific gravity of battery electrolyte
Be careful when handling the battery
electrolyte. If it is handled mistakenly, it
may catch fire or explode.
• Flames, sparks from short cir-

cuits, or lighted cigarettes are
dangerous.
• Use or charge batteries in a
well–ventilated area.
• When using a booster cable,
check that there is no danger
in the method of handling. Bat-
tery electrolyte (dilute sulphu-
ric acid) may cause burns or
loss of sight. If the electrolyte
Engine
gets in your eyes, on your

skin, or on your clothes, wash
it off immediately with large
amounts of water.
• If the electrolyte gets in your
eyes, wash your eyes with
water, then get medical atten-
tion.
2. Check battery electrolyte level for
batteries other than maintenance–free
batteries.
If the battery electrolyte is not within
the specified range, add distilled water
to upper limit line (A).
Clean the terminals and battery cap
breather.
3. Loose, corroded battery terminals
4. Loose wiring connections
5. Damaged wiring
21. Clutch — Not applicable to this truck model —

(Clutch type lift truck)
5-8
5. INSPECTION
Compo
nent
22. Transmission 1. Directional lever

1) Check that there is no play at the
neutral position.
2) Check ease of shifting gear, check
for play at gear position.
2. Speed lever
1) Check for ease of shifting to each
speed position.
2) Check for play at each speed
position.
3. Transmission
1) Check for any abnormal noise
2) Check for oil leakage
If the oil forms drops, replace the
packing.
3) Check oil level
Stop the truck in a level place and
check with the oil level gauge.
Power train
Oil filler cap Oil level gauge
Correct
Drain plug range
Strainer
5-9
5. INSPECTION
Compo
nent
22.Transmission 4. Inching pedal

(continued) 1) Protrusion of inching spool
Protrusion (a) 1.0 in (24.5 mm)
For details of the method of adjustment,

a
see TESTING AND ADJUSTING.
2) Interconnected travel
Adjust with adjustmentbolt so that the
inching pedal and brake pedal are
interconnected for the travel shown Adjustment bolt
Power train
below when the inching pedal is

depressed.
Interconnected 1.97 in (50 mm)

stroke
3) Pedal height
Pedal height (h) 9.1 in (231 mm)
5-10
5. INSPECTION
Compo
nent
23. Torque converter
For the following inspection, block the wheels of the lift truck and
apply the parking securely.
1. Clutch actuation pressure

Place the directional lever at FORWARD or REVERSE, depress the
accelerator pedal, and measure the pressure.
Clutch F/R 196.3–239psi(1.35–1.65 MPa) {13.8–

actuation 1st and 2nd 16.8 kgf/cm2}
pressure
3rd 173.5–217.6psi (1.20–1.50 MPa)
{12.2–15.3 kgf/cm2}
Torque converter inlet port pressure: 170.7–213.4psi (1.2–1.5 MPa)

{12–15 kgf/cm2}
Torque converter outlet port pressure: 85.3–105.3psi (0.6–0.75 MPa)
{6–7.4 kgf/cm2}
From line filter Main pressure T/C oil oressure To cooler F/R clutch
1 1/16-12 UNF measurement port measurement port 7/8-14 UNF pressure port
Power train
1, 2, 3 speed
clutch pressure
port
Oil level
gauge
Oil filler cap

To line filter
PF 3/4
2. Stall speed
Place the directional lever at FORWARD and REVERSE, run the engine at
maximum speed, and measure the engine speed at this point.
SAA6D107E-1-A
2,000 rpm
(Komatsu)
The torque converter oil temperature will rise, so do not continue

this operation for a long time.
5-11
5. INSPECTION
Compo
nent
24. Drive shaft 1. Oil leakage from seal of connecting part (case)
2. Play, damage to shaft and spider
3. Loose, damaged, missing spider connecting bolts
25. Differential 1. Abnormal noise when traveling

2. Oil level in differential case
3. Dirty oil
NOTE: For details of the method of

checking the oil level and
changing the oil, see TEST-
ING AND ADJUSTING.
Power train
4. Oil leakage from case

5. Loose mounting bolts
26. Final drive 1. Abnormal noise when traveling

2. Oil level
Check that there is ample oil inside the planetary gear.
3. Dirty oil
4. Oil leakage from case
5-12
5. INSPECTION
Compo
nent
27. Front axle 1. Deformation, cracks, damage

Check visually or use the crack detector method.
(Be particularly careful to check the weld and area around the mounting
bolts with the main frame.)
Tightening torque for bolts mounting to frame
torque 1446.6–1808 lbf/ft (1,961–2,452 Nm)

{200–250 kgm}
28. Rear axle 1. Deformation, cracks, damage

Check visually or use the crack detector
method.
2. Play of center pin (clearance from
bushing)
3. Loose cap, support mounting bolts
Bolts 1,2 361.6–448.4lbf/ft 1 2

Cap
(490–608 Nm)
Wheel center Support
Travel system
torque {50.0–62.0 kgm}
29. Tire 1. Inflation pressure

Unit: psi (kPa) {kgf/cm2}
Model Front wheel Rear wheel
FD100 106.7 (735) {7.5} 106.7 (735) {7.5}
FD115 99.6 (690) {7.0} 99.6 (690) {7.0}
FD135 96 (660) {6.75} 96 (660) {6.75}
FD150E 110.2 (760) {7.75} 110.2 (760) {7.75}
FD160E 99.6 (690) {7.0} 99.6 (690) {7.0}
2. Cracks, damage to tread, side wall

If the damage is serious, replace the Tire.
3. Depth of groove (wear amount)
Check the groove for whether it has reached the slip sign (wear limit mark).
4. Abnormal wear
Check for uneven or stepped wear.
5. Pieces of metal stuck in Tire
5-13
5. INSPECTION
Compo
nent
30. Wheel 1. Loose hub nut

Hub nut tightening torque
Unit: lbf/ft (Nm) {kgm}
Front wheel Rear wheel
Travel system
325.5–397.8 (441.5–539.5) 325.5–397.8 (441.5–539.5)

{45–55} {45–55}
2. Deformation, cracks in rim, side ring

Check visually or use the crack detector method.
31. Steering wheel 1. Shaking, pulling, dragging

2. Operating effort
Play
30–60 mm {1.2–2.4 in}

Play (At engine idling)
Adjustment: Adjust at gear box

3. Looseness, play
32. Steering valve 1. Oil leakage

2. Tightening torque for mounting bolts
Steering system
33. Steering linkage 1. Cracks, damage, curvature

2. Missing, broken split pins
3. Loose, missing mounting bolts
4. Play in movable parts, connections
34. Knuckle 1. Wheel bearing

Jack up and check for the following.
1) Play
Use your hands to move the Tire at the top and bottom to check.
2) Abnormal noise, rotate the Tire by hand to check.
2. King pin
1) Play
2) Cracks, damage
3. Knuckle
Damage
Check visually or check with the crack detection method.
5-14
5. INSPECTION
Compo
nent
35. Left, right turning Minimum turning radius

radius 1) Have an assistant operate the truck and turn it so that the turning radius
is the minimum.
2) Fit chalk to a stick, put the stick in contact with the outermost portion of
the counterweight, and draw a circle on the road surface.
3) Measure the circle on the road surface.
4) Carry out this operation for both turning to the left and turning to the
right.
FD100 Within 157.6 in (4,000 mm) ± 5 %

FD115
FD135 Within 171.4 in (4,350 mm) ± 5 %
FD150E Within 173.4 in (4,400 mm) ± 5 %
FD160E Within 177.3 in (4,500 mm) ± 5 %
Difference between left and right Within ± 3.9 in (100 mm)
Adjustment: Adjust with the stopper bolt.

Steering system
36. Steering wheel 1. Loose, missing stopper bolt

2. Contact between wheel and other part
37. Power steering 1. Oil leakage from power steering cylinder and hose
system 2. Damaged, deteriorated hose
3. Loose, missing mounting bolt
4. Interference with chassis
5. Oil pressure
Remove plug (1) in the diagram on
the right, install an oil pressure
gauge, and measure the oil pressure
when the steering wheel is turned
fully.
1850± 35 psi
FD100/115 (12.7 MPa ± 0.25)
Oil {130 ± 2.5 kgf/cm2}
pressure 2133±35 psi
FD135–160E (14.7 MPa ± 0.25)
{150 ± 2.5 kgf/cm2}
38. Steering chain — Not applicable to this truck model —
5-15
5. INSPECTION
Compo
nent
39. Travel brake 1. Brake pedal

1) Pedal height
Height When free (h) 9.1 in (231 mm)

h
2) Pedal play
Pedal play 0.04–0.16 in (1–4 mm)
2. Braking performance
Drive the lift truck on a flat, dry, paved road
surface at full speed, then apply the brake suddenly and check for the
following.
1) Pulling of steering wheel to one side
2) Braking on one side only
3) Abnormal noise
4) Stopping distance (braking performance)
When unloaded Within 5 m

(when traveling at 20 km/h)
Braking system
When loaded Within 2.5 m

(when traveling at 10 km/h)
3. Stop lamp switch

Check that the switch is actuated when the pedal is depressed
40. Parking brake 1. Parking brake lever

1) Operating effort of lever
44.1 lbf (196 N) {20 kgf}
2) Parking brake performance
Check that it can hold the lift truck stopped
on the slope below.
When unload Slope of min, 11.2°

When loaded Slope of min. 8.5°
41. Rod, link, cables 1. Damage, looseness, play

2. Damage to split pin
42. Brake piping Check the pipes, hoses, and joints visually for the following.
1. Oil leakage, air leakage 2. Damage
3. Deteriorated hoses 4. Loose mounting bolts
5. Interference with chassis
5-16
5. INSPECTION
Compo
nent
43. Oil brake 1. Actuation of air master, wheel cylinder

Operate the brake pedal and check following.
1) Operating effort when depressing brake
2) Changes in operating effort
3) Change in position of pedal when pedal is kept depressed
4) Return of pedal when it is released
2. Brake reservoir tank
1) Oil level
2) Dirty oil, oil leakage
3. Wheel cylinder
Clearance
FD100/115
between cylinder Within 0.0047 in (0.12 mm)
FD135/150E/160E
and piston
44. Air brake — Not applicable to this truck model —
45. Brake booster Check operation of valve and other equipment, check for leakage of
hydraulic oil
Braking system
46. Brake shoe, lining 1. Brake shoe

Check operating condition, check for rust, wear
2. Peeling, damage, wear of lining
FD100/115
Lining thickness FD135/150E/ Within 0.22 in (5.5 mm)
160E
3. Corrosion of anchor pin

4. Deterioration of return spring
Item FD100/115 FD135/150E/160E

Free Standard dimension: Standard dimension:
length 3.66 in (93 mm) 6.67 in (169.5 mm)
Spring Min. 72 ± 7.2 lbf Min. 110 ± 11 lbf
(1) (323 ± 32 N) (490 ± 49 N) {50 ± 5 kgf}
Strength
{33 ± 3.3 kgf} when L=(178 mm)
when L=(103.5 mm)
Free – Standard dimension:
Spring length 5.82 in (148 mm)
(2) – Min. (412 ± 39 N) {42 ±
Strength
4 kgf} when L=159 mm
5-17
5. INSPECTION
Compon
ent
47. Brake drum Cracks, damage, wear of drum

Measure the following dimensions and check that they are within the
service limit.
Item FD100/115 FD135/150E/
160E
Inside diameter of Within 15.49 in Within 17.24 in
Wheel drum (393.7 mm) (438 mm)
brake Clearance between 0.008–0.02 in 0.012–0.04 in
drum and lining (0.2–0.5 mm) (0.3–0.6 mm)
48. Back plate 1. Deformation, cracks, damage

2. Tightening torque of mounting bolts
Item FD100/115 FD135/150E/160E

torque 180.8–227.8lbf/ft 72.3–90.4lbf/ft
(Wheel brake) (245–309 Nm) (98–123 Nm)
{25–31.5 kgm} {10–12.5 kgm}
Loctite #271 (tap hole)
(Wheel brake)
49. — Not applicable to this truck model —

Braking system
Parking brake disc, pad
50.
51. Parking brake 1. Peeling, damage, wear of lining

lining, back plate
Lining thickness Min. 0.13 in (33 mm)
2. Deterioration of return spring
Strength (when L=2.0 in (50 mm)) Min. (137 N) {14

kgf}
Free length b: Standard dimension 2.15 in (54.7 mm)
3. Deformation, cracks, damage to back plate
4. Tightening torque of back plate mounting bolt
torque 180.7–227.9lbf/ft (245–309 Nm)

(Parking brake) {25–31.5 kgm}
52. Parking brake drum Cracks, damage, wear of drum

Measure the following dimensions and check that they are within the
service limit.
Item FD100–FD160E
Inside diameter of drum Within 8.5 in (216 mm)
Parking
Clearance between drum 0.004–0.008 in (0.1–0.2 mm)
brake
and lining
5-18
5. INSPECTION
Compo
nent
53. Fork (1) 1. Deformation, cracks, wear at fork stopper pin

2. Check that the opening of the fork tips and
difference in height are within the specified
range.
Opening Within 0.197 in (50 mm)

Difference in height Within 0.079 in (20 mm)
54. Fork (2) 1. Cracks, wear at upper hook, lower hook portion
2. Cracks, wear at fork root
Check that the thickness of the fork
root is within the specified value.
FD100 Min. 2.8 in (70 mm)

FD115 Min. 2.8 in (70 mm)
FD135 Min. 3.0 in (75 mm)
FD150E Min. 3.2 in (80 mm)
FD160E Min. 3.2 in (80 mm)
NOTE: From time to time, use the crack detection method to check the
Loading system
fork root and hook, where stress is concentrated.
55. Mast (1) 1. Deformation, cracks, damage to mast

Check the following places visually or check with the crack detection
method.
Mast stay
Tilt cylinder bracket
Roller shaft weld
2. Wear, play in mast roller, cracks in roller shaft
Set the mast perpendicular, raise the forks approx. 10 cm from the ground,
then check that the following clearances are within the specified value.
Clearance between Left–to–right Within 0.118 in (3.0 mm)

outer mast and Front–to–rear Within 0.197 in (5.0 mm)
inner mast
Clearance between Left–to–right Within 0.079 in (2.0 mm)
inner mast and fork Front–to–rear Within 0.197 in (5.0 mm)
carriage
56. Mast (2) 1. Play in mast support

Check that there is an oil groove in the bushing at the mast support.
2. Loose mast cap mounting bolts.
Tightening torque
torque
607.7–759.7lbf/ft (824–1,030 Nm) {84–105 kgm}
5-19
5. INSPECTION
Compo
nent
57. Fork carriage 1.Deformation, cracks, damage to fork carriage

2.Wear, play in roller
3.Cracks in roller shaft
58. Lift chain 1.Tension

Set the mast perpendicular, raise the forks approx. 10 cm from the ground,
then push the lift chain at the mid point with your finger and check that
there is no difference in the tension.
Adjustment: Adjust with the chain stopper
2.Elongation
Measure the length between 17 links and check that it is within the
specified value.
Length FD100 FD115/135/150E/160E

Loading system
of 17 Within 26.0 in Within 30.3 in (770 mm)

links (660 mm)
3.Cracks, deformation, damage, corrosion

4.Stopper bolt thread
59. Chain wheel Deformation, damage, play in wheel

Check contact surface with chain visually.
Turn by hand and check for play in the bearing.
60. Attachment (1) 1. Installation to chassis

2. Loose bolts, nuts
61. Attachment (2) 1. Cracks, deformation, damage, wear at all parts

2. Actuation, abnormal noise at all parts
5-20
5. INSPECTION
Compo
nent
62. Hydraulic tank 1. Oil leakage

2. Oil level
Check the oil level with the oil
level gauge and add oil if
necessary. (Check the
dirtiness of the oil also.)
3. Clean strainer
4. Replace line filter
(Fitted to outside of tank)
Hydraulic system
63. Chassis piping 1. Cracks, damage, deterioration, twisting of piping

2. Oil leakage
3. Loose mounting bolts, nuts
64. Attachment piping 1. Cracks, damage, deterioration, twisting of piping

2. Oil leakage
3. Loose mounting bolts, nuts
65. Hydraulic pump 1. Oil leakage

2. Abnormal vibration
3. Abnormal noise
66. Oil motor — Not applicable to this truck model —
67. Lift cylinder 1. Actuation, oil leakage

2. Dents, cracks, curvature, scratches on rod
5-21
5. INSPECTION
Compo
nent
68. Tilt cylinder 1. Actuation, oil leakage

2. Dents, cracks, curvature, scratches on rod
70. Attachment 1. Actuation, oil leakage

cylinders 2. Dents, cracks, curvature, scratches on rod
3. Looseness of mounting bolts
71. Hydraulic drift of lift Load the forks with the maximum
cylinder, tilt cylinder payload, set the mast perpendicular,
raise the forks approx. 1 m from the
ground, then check that the hydraulic
drift is within the specified value given
below.
Hydraulic When Within 4 in

drift of lift measured (100 mm)
cylinder at fork (for 15 min)
When Within 4 in
measured (100 mm)
at cylinder (for 15 min)
Hydraulic system
Hydraulic Within 1.6 in (40 mm)

drift of lift (for 15 min)
cylinder
Adjustment:
Replace the control valve, cylinder
packing
72. Directional control 1. Actuation, oil leakage

valve (1) 2. Loose mounting bolts
73. Directional control Measure relief pressure

valve (2) 1) Install an oil pressure gauge to relief
pressure measurement port (1).
2) Raise the forks to the maximum
lifting height, measure the oil pressure
when the oil is relieved, and check that
it is within the specified pressure.
Unit: psi MPa {kgf/cm2}

Relief set pressure 3129 (21.6) {220}
5-22
5. INSPECTION
Compo
nent
74. Solenoid valve 1. Actuation, abnormal noise

Hydraulic system
2. Abnormal generation of heat

3. Oil leakage
75. Chassis frame, 1. Cracks, deformation

chassis 2. Loose, missing mounting bolts, nuts
76. Cab 1. Cracks, deformation

2. Corrosion, leakage of rain
3. Opening/closing of door, lock, play, breakage
77. Seat 1. Actuation

78. Equipment for 1. Cracks, damage, deformation

getting on/off lift truck, 2. Loose mounting blots
Chassis, safety system
anti–slip devices
79. Display panel 1. Damage

2. Mounting condition
80. Overhead guard 1. Loose mount

2. Deformation, cracks, damage
81. Backrest 1. Loose mounting bolts

2. Cracks, deformation, damage
82. Lights, gauges, 1. Lighting up of lamps

warning devices 2. Mounting condition, breakage, entry of water
3. Actuation of gauges
83. Rear view mirror, 1. Dirt, damage

reflectors 2. Reflection
84. Oil, grease 1. Oil, greasing condition

2. Actuation of auto–greasing system
85. Function of all Carry out travel, operation test to check

Overrall test
system
5-23
5. INSPECTION
5.4 REMOVAL AND INSTALLATION OF COMPONENTS
5-24
5. INSPECTION
5-25
5.5
Front wheel Torque shaft differential Brake
Tilt cylinder Mast Brake piping Front axle

5. INSPECTION
Lift cylinder Parking brake cable
Radiator hose
Torque converter Torque converter Shroud
cooler hose cooler Radiator Aftercooler
Aftercooler hose Brake cooler
Brake cooler hose
Muffler
Engine hood
Pedal link
F.R. lever link

Completed
5-26
forklift
Control valve link Engine accessory Engine
+
Floor plate Wire harness Overhead guard Piping Torque converter
+
Drive train ass'y
Torque converter
P.S. pipings piping
REMOVAL AND INSTALLATION FLOW CHART
Parking brake cable
Air cleaner
Rear wheel P.S. pipings P.S. cylinder
Joint
Rear axle
Disassembly Counterweight Assembly
5. INSPECTION
5.6 MAST
For mast maintenance see the suitable mast manual included in this manual.
5.6.1 MAST REMOVAL - TYPICAL

1. Place blocks under front and rear tires.
2. Lift fork carriage with crane so that hydraulic piping can be
removed.
3. Remove forks.
4. Place block under fork carriage.
5. Operate work equipment control levers several times to release
remaining pressure in hydraulic piping.
6. Disconnect mast piping.
7. Plug the openings to prevent spillage of hydraulic fluid and
possible entry of dirt and foreign matter into the hydraulic system.
8. Raise fork carriage slightly with crane and remove the block set in
place in step 4.
9. Lower the fork carriage.
10. Attach crane to the mast.
11. Remove the tilt pins.
12. Tilt the mast slightly forward from the vertical position.
13. Remove the cap bolts from the front axle.
If the mast cap is removed with the mast tilted back there is dan-
ger that the mast may fall over.
14. Lift the mast enough that the mast support comes off of the axle
and move the mast towards the front of the truck to remove it.
NOTE: When carrying the removed mast horizontally, secure the

lower stay and the finger bar with wire or straps.
15. Place blocks under the bottom of the mast.

16. Lay the mast assembly horizontally so that the fork carriage faces
upwards.
5-27
5. INSPECTION
5.6.2 MAST INSTALLATION - TYPICAL

1. Raise and block the front end of the truck about 1 foot (30.5cm)
from the ground or place the truck over a service pit.
2. Install the bearings (bushings) (A) on the lower axle mounts.
3. Lubricate the bearing surfaces of the tilt cylinder and lower axle
mounting surfaces with chassis grease.
4. Use an overhead hoist to lift the mast with chain hooks attached
to the cheek plate lifting holes.
5. Position the mast lower axle mounts on the truck axle.
6. Install the mounting caps and capscrews (B).
torque
Torque the capscrews to 608 - 760 lbs./ft (824 - 1030 Nm) (84 - 105
kgfm).
7. Make sure the tilt cylinders “bottom” evenly.

8. Adjust the tilt cylinders to prevent “racking” during tilting.
9. Connect the lift truck hose (C) to the mast valve.
NOTE: The mast valve may appear differently on your vehicle.
10. Connect the tilt cylinders to the mast anchor brackets with the two
tilt pins (D).
torque
Torque the tilt pin capscrews (E) to 43.5 - 54.6 ± 5.0 lbs./ft (59 - 74 ±
6.8 Nm).
• Use as few fittings as possible. Use 45° fittings instead of

90° fittings.
• Keep hose lengths to the minimum required for effective
operation.
• Avoid sharp bends or pinch points when routing the hoses.
5.6.3 BLEED AIR FROM LIFT CYLINDER

1. Start the engine and run at low idling.
2. Raise and lower the mast.
NOTE: Stop the mast approx. 4 in (100 mm) before reaching the max. lifting height and max. lowering position.
3. Repeat Step (2) 4–5 times.

4. Raise and lower the mast to the maximum lifting height and maximum lowering position.
5. Repeat Step (4) 4–5 times.
torque
Tightening torque for the mast mounting bolts.
608-760lbf-ft (824 – 1,030 Nm) {84 – 105 kgm}
5-28
5. INSPECTION
5.7 POWER TRAIN

5.7.1 REAR AXLE SUPPORT BUSHING
1. Install the rear axle support bushing with the oil hole up.
5.7.2 CENTER DRIVE SHAFT

1. Use special tool 3EE-97-99110 to check centering of drive shaft.
2. Adjust as necessary.
Deviation 5mm max. ( in both vertical and lateral directions)
5.7.3 CENTER ENGINE MOUNTS

1. Center engine mounts within specifications.
Deviation 5mm max. ( in both vertical and lateral directions)
5.7.4 WHEEL INSTALLATION

When hub nut (1) was removed for replacing the wheel, etc. and
again installed back on, always tighten the hub additionally after Spacer Clamp
traveling the machine for 30 to 60 minutes to break in each contact
surfaces.
Particularly, the front wheels have more number of contact portions
than the rear wheels, taking longer time for break-in. Accordingly,
repeat additional tightening of the hub nut during first 50 hours after
installing the wheels.
(See the section of TIRE CLAMP TIGHTENING INSTRUCTION.)
• Park the lift truck on a level and safe place before starting the
work.
Tires
Jack can be dangerous if it is disengaged. Person may be caught by it and seriously injured. Always check
that the jack is safely engaged during the tightening work. Also remember never get under the machine.
5-29
5. INSPECTION
torque
Tightening torque
325 - 398lbf-ft 441 – 539.5 Nm {45 – 55 kgm}
5.7.5 TIRE CLAMP TIGHTENING INSTRUCTION
1. Tighten the hub nuts in the order of (1) to (16).
245 – 343 Nm {25 – 35 kgm}

2. Retain the Tire in floated condition. Adjust the maximum difference in the runout of the Tire to within the
specified value by adjusting it with clamps at 8 locations.
5.7.6 ADJUST RUNOUT

1. Locate the gauge at a right angle to the side face of the
Tire and apart 10 mm from it.
2. Rotate the Tire with no load in the forward 1st gear and
find out a point that the gauge tip contacted, and then
loosen the hub nut opposite to that point.
3. Tighten the hub nut at the point that the gauge tip
contacted to adjust.
4. Check the runout again. If outside the specified range,
make another adjustment.
Runout of Tire 10 mm or less (0.39 in)

5. Tighten the hub nuts in the order of (1) to (16).
490 Nm {50 kgm}
5-30
5. INSPECTION
6. Tighten the hub nuts again in the order of (1) to (16).
490 Nm {50 kgm}

7. Measure the tightening torque of (1) and (2) and check that they are within the range of specified value.
8. If outside, tighten the hub nuts additionally as instructed in step 3.
441 – 539.5 Nm {45 – 55 kgm}

9. Check the Tire runout as instructed in step 2. If it is not within the range of specified values, loosen the hub
nuts to adjust, then tighten them as instructed in step 3.
10. Tighten the hub nuts additionally in the order of (1) to (16) after traveling the machine (maybe for actual
operation) for about 30 to 60 minutes.
11. Repeat the procedure of step 7 for a period of approx. 50 hours after installation.
5.8 BRAKE SYSTEM (HYDRAULIC DRUM BRAKE TYPE)
5.8.1 METHOD OF BLEEDING AIR
NOTE: Bleed the air from the bottom cylinder first, then
bleed the air from the top cylinder.
1. Remove the cap from the air bleed plug, fit one end of
a vinyl hose, and put the other end of the vinyl hose in
a container of brake fluid.
2. Loosen the air bleed plug approx. 3/4 turns, then
depress the brake pedal.
3. Tighten the air bleed plug, then release the brake
pedal.
4. Continue Steps (2) and (3) until no more bubbles
come out from the hose.
5. After completely bleeding the air, tighten the plug and
install the cap.
When assembling, be careful not to let any dirt or dust

get in.
High–pressure oil is stored in the piping connecting the accumulator and brake valve even after the engine
has been stopped, so do as follows when removing.
5.8.2 METHOD OF REMOVING HIGH PRESSURE OIL

1. Stop the engine.
2. Depress the brake pedal repeatedly at least 10 times to drain all the high–pressure oil from the piping to the
tank.
3. Remove the piping.
5-31
5. INSPECTION
5.9 WORK EQUIPMENT CONTROL LEVER

1. Connect the yoke portion of link (A) and the control valve with pin (F). Insert a cotter pin into the pin and bend
it to hold in position. (Link length: 484 mm)
2. Align both the lift and tilt levers with bracket (B), insert support pin (C), then tighten bolt (D).
3. Connect the lever yoke and the end of link (A) with a pin. Insert a cotter pin into the pin and bend it to hold in
position.
4. Install bracket (B) of the lever to the bracket at the chassis end with the bolt.
5. Lever travel
S1 S2
Lift lever 126mm 126mm
Tilt lever 130mm 130mm
5-32
6. DISASSEMBLY AND
ASSEMBLY
6.1 TORQUE CONVERTER

NOTE: The numbers show the order for disassembly
6-2
6.1.1 ASSEMBLY
1. Assembly of idler gear and shaft.
a. Assemble bearing (2) to idler gear (1), then set in the
case.
b. Assemble idler shaft (3) to the idler gear. Secure the
idler shaft to the case with lock plate (4) and bolt (5).
torque 26–32.5lbf/ft (35.3–44.1 Nm) {3.6–4.5kgm}
2. Stator shaft
a. Install pump boss gear (1) to stator shaft (2).
6-3
b. Installation of stator shaft.

Using tightening bolt (1) [M12, P1.75], mesh the idler gear
and pump boss gear and install to the case.
torque 50–57.9lbf/ft (67.6–78.4 Nm)

{6.9–8 kgm}
3. PTO driven gear.

a. Assemble bearing (1).
b. Mesh driven gear (2) with the idler gear and assem-
ble.
c. Using bolt (4) as a guide, install the bearing retainer.
d. Tighten bolt (4) to secure in position.
torque 50–57.9lbf/ft (67.6–78.4 Nm)

{6.9–8 kgm}
4. Pump
a. Align the pump boss spline and pump gear spline
and assemble the pump.
6-4
5. Stator
a. Assemble the collar, trust washers (1) and (2), stator,
and thrust washers (3) and (4) in turn.
b. Set the tab of lock washer (5) facing the outside, and
insert.
c. Secure the stator with ring nut (6). (Check that the
stator rotates lightly when doing this.)
d. Secure the ring nut with the tab of the lock washer.
6. Turbine, drive cover assembly

a. Assemble O–ring (3) to the pump.
b. Assemble the turbine and drive cover assembly (A) to
the pump.
c. Tighten the pump and drive cover assembly with bolt
(1) and nut (2).
torque 20.3–24.6lbf/ft (27.4–33.3 Nm)

{2.8–3.4 kgm}
7. Pilot, flexible plate

a. Install pilot (1) and flexible plate (2) to the drive cover.
b. Tighten with bolt (3).
torque 26–32.5lbf/f (35.3–44.1 Nm)

{3.6–4.5 kgm}
6-5
8. Hydraulic pump (torque converter charge pump)

a. Install hydraulic pump (1) (FAL3–045).
torque 26–32.5lbf/ft (35.3–44.1 Nm)

{3.6–4.5 kgm}
9. Oil strainer
a. Assemble the oil strainer in the case.
torque 26–32.5lbf/ft (35.3–44.1 Nm)

{3.6–4.5 kgm}
6-6
6.2 TORQFLOW TRANSMISSION
Hydraulic pump Torque converter pump
6-7
TORQUE CONVERTER TRANSMISSION ASSEMBLY
Gasket
Transmission
Torque converter
427- 532lbf/ft (59–73.5 Nm)

{6–7.5 kgm}
6-8
6.2.1 CONTROL VALVE (SOLENOID VALVE)
Protrusion inching spool 0.97 in (24.5 mm)
(Solenoid valve)
Actuating voltage (V)

Standard 24 V
Range 22–26 V
(Inching spool)
Torque converter
NOTE: Mounting bolts

Insufficient tightening: Oil leakage
Over tightening: Defective operation of spool
6-9
Main pressure pick-up port
Main pressure regulator valve

1.5 MPa {15.3 kg/cm²}
F/R
Line filter pressure
pick-up port
Oil tempera- Oil
ture gauge T/C cooler Accumulator for F/R
take-out slot pressure
M16 = 1.5 pick-up port
Torque converter oil PT1/8
outlet-cum-lubricant
regulator valve
0.45 ± 0.15 MPa
Inching
valve
Solenoid valve
for F/R Accumulator
for speed
6-10
Solenoid valve for
1st speed Speed pressure
HYDRAULIC SYSTEM DIAGRAM
pick-up port
Solenoid valve for

2nd/3rd speed
Strainer
1st 2nd 3rd F R
1st-2nd VALVE ON OFF OFF ON OFF

FWD-REV VALVE
3rd VALVE OFF OFF ON OFF ON
TORQFLOW TRANSMISSION EXTERNAL VIEW

From line filter
1 1/16-12 UNF Main pressure T/C oil pressure To cooler F/R clutch
measurement port measurement port 7/8-14 UNF pressure port
1, 2, 3 speed
clutch pressure
port
Oil level
Air breather gauge
Oil filler cap

To line filter
PF 3/4
Eye bolt From cooler
Torque converter
pump
Torque converter
Flexible plate
Oil level
Drain plug Oil temperature

gauge pick-up port
6.2.2 DISASSEMABLY
1. After completion of the operation for removing the TORQFLOW transmission assembly from the chassis, wash
the case oil.
6-11
2. Remove the lifting equipment from the eyebolts and

install it to the transmission case mount bracket, then
raise slowly so that the torque converter case is at the
bottom.
Lifting equipment
3. Lower the TORQFLOW transmission assembly slowly

and set in position on wooden blocks (10-12 in 250–300
mm) placed on the floor, or lower on to a special work
stand.
Lifting equipment
NOTE: Use 3 or 4 wooden blocks and support the TORQ-
FLOW transmission stably and securely.
Stand
6-12
4. Remove the 1st/2nd and 3rd clutch shaft sub assemblies.

M10 x 1.5 L=35
a. Set the special tools to the shaft sub assemblies.
Clutch shaft lifting tool 1
M10 x 1.5 L=50
Clutch shaft lifting tool 2
3rd 1st/2nd
Using the special tools, lifting up the 1st/2nd and

3rd clutch shaft together.
b. Fit the lifting tool to the eyebolts.
c. Pull up the 1st/2nd and 3rd clutch shaft sub assem- (Hoist)
blies together.
d. After removing, lower the assemblies on top of a
work stand.
Lifting equipment
IMPORTANT
The operation is easier to carry out if the 1st/2nd and 3rd
clutch shaft sub assemblies are pulled up at the same time.
Lifting up together
Special tool-1
Special tool-2
If they are removed separately, there will be twisting and
gouging, or damage to the case.
3rd
1/2nd
Torque converter
6-13
5. Remove the FORWARD/REVERSE clutch shaft sub

assembly.
NOTE: Remove the 1st/2nd and 3rd clutch shaft sub assem-
blies first.
(Hoist)
a. Wind a wire around the reverse clutch shaft.
b. Fit the lifting equipment to the wire.
c. Lifting up the FORWARD/REVERSE clutch shaft sub
assembly slowly with the hoist.
d. After removing, lower the shaft sub assembly slowly
on the top of a work stand.
Lifting equipment
For safety reasons, do not pull up the shaft by hand.

Always use lifting equipment.
NOTE: It is possible to remove the FORWARD/REVERSE F/R

clutch shaft sub assembly first before removing the
1st/2nd and 3rd clutch shaft sub assemblies. The
important point is always remove the 1st/2nd and 3rd
shaft sub assemblies together.
If force is used to remove the 1st/2nd and 3rd clutch

shaft sub assemblies separately, damage may be caused
to the transmission case seal ring contact surface or
shaft.
Torque converter
6-14
6.2.3 DISASSEMBLY OF CLUTCH PACK ASSEMBLY

(Example: 1st/2nd)
Numbers indicate the order of assembly.
To disassemble, start with the greater number.
If the snap rings (15 and 27 in diagram above) used to hold the piston
and return spring are removed, the force of the spring will be brought to
bear and this will cause a dangerous condition. Always use the special
tool to remove them.
NOTE: Collar inner diameter: φ 2.56–2.71 in (65–69 mm)
6-15
CLUTCH PACK DETAIL (EXAMPLE: 1ST SPEED/2ND SPEED)

Camber plate* Camber plate*
Snap ring
Snap ring Plate
Plate Plate
Spacer Seal Spacer

Seal
Snap ring Piston Snap ring
Piston ring
Spring
Spring
Disc
NOTE: Clutch pack for 1st and 2nd speed has a camber plate (*) installed on the side of snap ring. Clutch pack for
F/R has the camber plate (*) installed on the side of piston.
When removing the snap ring for holding the piston return spring, the spring tension may cause injuries.
Always apply a special tool for removing snap ring. (3EC-97-99000)
6-16
Clutch pack for 1st/2nd speed Clutch pack for F/R
Install the warped side to the snap ring side. Install the warped side to the piston side.
Piston
Plate
Camber plate
Camber plate
Snap
ring Plate
Number of plate disc (per pack)
1st/
3rd
F/R 2nd
speed
speed
Plate 8 7 4
Disc 7 6 4
Camber plate 1 1 —
Pressure plate 1 1 1
6.2.4 PRECAUTIONS WHEN ASSEMBLING
1. Clutch pack assembly
6-17
a. Blow compressed air into the oil hole to check the

operation of the drive plate and driven plate.
Air pressure 71psi (5 kg/cm2 )
Stroke Must move to

the stroke end.
2. Solenoid valve
a. Tighten the mounting bolts in the order shown in the
diagram on the right. 1 4
b. When assembling, check the operation of the spool.
NOTE: Insufficient tightening: Oil leakage 3 2

Overtightening: Defective operation
3. Seal ring
a. After assembling, coat the seal ring with grease.
6-18
6.2.5 CONNECTORS FOR SOLENOID VALVES
CONNECTOR DWG.
FR VALVE F: 3(+), 4(-)

R: 1(+), 2(-)
4 1
3 2
1st/2nd 1(+), 2(-)

VALVE
1 2
3rd VALVE 1(+), 2(-)
1 2
1st 2nd 3rd F R
1st/2nd VALVE ON OFF OFF ON OFF

FR VALVE
Solenoid valve Inching spool
F/R
1, 2 speed
3rd, output
6-19
6.2.6 ASSEMBLY OF F/R (INPUT SHAFT) SHAFT SUB ASSEMBLY

Reassemble in the opposite order to disassembly.
NOTE: Soak the clutch plates and discs in clean oil before assembly.
Coat the seal ring with grease. 12
13
(Reverse end)
14
16
17
18 15
19
20
21
22
23
26
25
6
5
4
3
2
1
A
1
2
8
9
10
11
38
37
36
35
34
33
32
31 39
30
29
Torque converter
27
28 (Forward end)
6-20
F/R (INPUT SHAFT)

6 5 4 1 2 2 1 9 1 0 11
(Forward end) (Reverse end)
23
39 38 37 36 35 34 31 32 33 30 29 28 27 26 25 3 8 12 13 14 16 17 15 18 19 20 21 22
Order Main F/R shaft A

of
assembly (FORWARD end) (REVERSE end)
1 Assemble seal to shaft assembly (F/R)

2 Install seal ring to piston (F/R)
3 Assemble piston to drum while checking concave
4 Assemble spring
5 Assemble spacer
6 Fix with snap ring
7 Reverse shaft assembly
Clutch pack
8 Assemble piston to drum while checking concave (8)

9 Assemble spring (9)
10 Assemble spacer (10)
11 Fix with snap ring (11)
12 Assemble plate (12)
13 Assemble camber plate (13)
14 Assemble clutch discs and plates alternately (14)
15 Discs (7), plates (8) (15)
16 Assemble plate (t=6) (16)
17 Fix with ring (17)
18 Assemble washer (18)
19 Assemble gear (Z=30) (19)
20 Assemble two bearings (20)
22 Assemble plate (22)
23 Assemble bearing (23)
24 Reverse shaft assembly (24)
25 Assemble plate
26 Assemble camber plate
27 Assemble clutch discs and plates alternately
Clutch
28 Discs (7), plates (8)

29 Assemble plate (t=6)
30 Fix with ring
31 Fix with ring
32 Assemble washer
33 Assemble gear (Z=46)
34 Assemble bearing
35 Assemble washer
36 Assemble plate
37 Install bearing (outer rim to casing side)
38 Fix with ring
39 Install seal ring
Main F/R shaft A sub-assembly
6-21
6.2.7 ASSEMBLY OF 1ST/2ND SHAFT ASSEMBLY

Coat the seal ring with grease.
(1st end)
Transmission case
Torque converter
(2nd end)
6-22
1ST/2ND SHAFT
6 5 4 1 3 2 2 8 1 9 10 11
(2nd end) (1st end)
38 37 36 34 35 33 32 31 30 29 28 27 26 25 12 13 141516 1718 19 20 21 22 23
Order Main 1st/2nd shaft B

of
assembly (2nd end) (1st end)
1 Assemble seal to shaft assembly (1st/2nd)

2 Install seal ring to piston (1st/2nd)
3 Assemble piston to drum
4 Assemble spring
5 Assemble spacer
Clutch pack
7 Reverse shaft assembly

8 Assemble piston to drum (8)
9 Assemble spring (9)
10 Assemble spacer (10)
11 Fix with snap ring (11)
12 Assemble clutch discs and plates alternately (12)
13 Discs (6), plates (7) (13)
14 Assemble camber plate (14)
15 Assemble plate (t=6) (15)
24 Reverse shaft assembly (24)
Clutch
27 Asseble camber plate

29 Fix with ring
30 Assemble washer
32 Assemble bearing
33 Assemble washer
34 Fix with ring
35 Assemble washer
37 Assemble bearing
Main 1st/2nd shaft B sub-assembly
6-23
6.2.8 ASSEMBLY OF 3RD (OUTPUT SHAFT) SHAFT SUB ASSEMBLY

Coat the seal ring with grease.
Coat the oil seal and lip portion with grease.
13
14
15
16
17
Transmission case 18
19
1
2
3
4
5
6
7
9
10
11
12
8
(3rd end)
21
20
C Torque converter
6-24
3RD, OUTPUT SHAFT

21 20 2 3 1 7 9 10 4 5 6 11 1213 14 15 16 17 18 19
Order Main 3rd shaft C

of
assembly
1 Assemble seal to shaft
2 Install seal ring to piston
3 Assemble piston to drum
4 Assemble spring
Clutch pack
5 Assemble spacer
10 Fix with ring
11 Assemble washer
13 Assemble bearing
14 Assemble washer
15 Fix with ring
17 Assemble spacer
19 Assemble bearing
20 Assemble bearing
Main 3rd shaft C sub-assembly
6-25
6.2.9 CLUTCH SHAFT SUB ASSEMBLY

1. Assemble the 1st/2nd and 3rd clutch shaft sub assem- (Hoist)
blies.
IMPORTANT
Assemble the 1st/2nd and 3rd clutch shaft sub assemblies Lifting equipment
together as a set.
a. Set the special tools to the shaft sub assemblies.

b. Fit the lifting equipment to the eyebolts.
c. Set so that the 1st/2nd and 3rd clutch shaft sub
assemblies mesh at the respective gear position.
d. Raise slowly and set in position above the torque
converter case.
e. Check that the position of each gear is aligned as
shown in the diagram on the right (the vertical posi-
tion should be meshed within the range of the gear
width). 3rd
f. Check that the busing has entered the 3rd shaft hole
at the torque converter case end.
g. Lower the assembly slowly and check that the tip of 1/2nd
each shaft is facing the shaft hole in the torque con-
verter case.
h. In addition, be careful of the position of the seal ring.
i. There is a washer on the 3rd shaft, so check that it is
not at an angle.
j. Lower the assembly to set the 1st/2nd and 3rd clutch
shaft sub assemblies completely in position.
Torque converter
For safety reasons, always use a hoist.
IMPORTANT
If it is difficult to insert the shafts in the torque converter case, raise the shaft slightly then lower again. In this case,
the shafts should enter easily. Never try to push in by force.
6-26
2. Assemble the F/R clutch shaft sub assembly.
IMPORTANT
Assemble the 1st/2nd and 3rd clutch shaft sub assemblies
first, then assemble the F/R clutch shaft sub assembly. (Hoist)
a. Wind a wire around the reverse clutch shaft.

b. Fit the lifting equipment to the eyebolt.
c. Raise slowly and set in position above the torque
converter case.
d. Lower the assembly slowly and check that the tip of
the shaft sub assembly is facing the center of the
Lifting equipment
shaft hole in the torque converter case.
e. Be careful of the position of the seal ring, and insert
(lower) the sub assembly shaft into the stator shaft.
f. Be careful to mesh with the gears of the 1st/2nd shaft
sub assembly, and insert the sub assembly fully at
the point where the gears mesh. F/R
For safety reasons, always use a hoist.
Torque converter
6-27
6.3 HYDRAULIC PUMPS

6.3.1 WORK EQUIPMENT PUMP AND POWER STEERING PUMP
Hydraulic drum brake type
The hydraulic pump and power steering pump are connected as a unit (1), and are driven by the torque converter
PTO system.
Work
Item Unit Steering
equipment
Name of pump – SAR–90 SAR–40
Relief pressure psi (MPa) {kg/cm2} 3130 (21.6) {220} 1850 (12.7) {130}
Discharge cc/rev 90.0 40.0
Rated speed rpm 2,200 2,200
Torque converter
2
6.3.2 TORQUE CONVERTER CHARGE PUMP

The torque converter charge pump (2) is driven by the torque converter PTO system.
Item Unit
Name of pump — FAL3–045
Relief pressure MPa {kgf/cm2} 1.5 {14.7 }
Discharge cc/rev 43.7
Rated speed rpm 2,200
6-28
6.3.3 WORK EQUIPMENT, POWER STEERING, BRAKE, AND BRAKE COOLING

HYDRAULIC PUMPS
Wet disc brake type
Pumps for work equipment, power steering, brake and brake cooling are combined into a unit, which is driven by
PTO system of torque converter.
Work
Item Unit Power steering Brake Brake cooling
equipment
Name of pump — Pump No. 1 Pump No. 2 Pump No. Pump No. 4
3
Relief pressure psi (MPa) {kgf/ 3130 (21.6) {220} 1850 (12.7) {130} (FD100 1422 (9.8) 50 (0.34) {3.5}
cm²} – 115) {100}
2134 (14.7) {150} (FD135

– 160E)
Discharge cc/rev 49.8 50.1 20.4 18.1
Rated revolution rpm 2,500 2,500 2,500 2,500
Torque converter
6-29
6.4 DRIVE AXLE

HYDRAULIC DRUM BRAKE TYPE
Coat sliding portion of
490.5 -- 605 Nm oil seal with grease.
{50 -- 62 kgm}
* After adjusting, fit lock 343 -- 426 Nm

bolt stopper securely. {35 -- 43.5 kgm}
441.5 -- 539.5 Nm
{45 -- 55 kgm}
Be extremely careful not to get

grease or oil on the inside surface
of the brake drum.
Hub starting 20 -- 39 Nm
friction torque: {200 -- 400 kgcm}
490.5 -- 605 Nm
{50 -- 62 kgm}
FD135/
FD100 FD115 FD160E
150E
Type Fixed single shaft full–floating type
Reduction Planetary gear

gear type
Reduction 6.4
ratio
Tread 1,700 1,700 1,770 1,770
6-30
WET DISC BRAKE TYPE

Coat sliding portion of
oil seal with grease.
490.5 -- 605 Nm
{50 -- 62 kgm}
10.8 -- 14.7 Nm
{1.1 -- 1.5 kgm}
245 -- 309 Nm 343 -- 427 Nm
Loctite #572 {25 -- 31.5 kgm} {35 -- 43.5 kgm}
441 -- 539 Nm
{45 -- 55 kgm}
490.5 -- 605 Nm
{50 -- 62 kgm}
FD135/
FD100 FD115 FD160E
150E
Type Fixed single shaft full–floating type
Reduction Planetary gear

gear type 9JL01913
Reduction 6.4
ratio
Tread 1,700 1,700 1,770 1,770
6-31
6.4.1 FRONT HUB

NOTE: Hub starting friction torque: 20–39 Nm {200–400 kgcm}
6-32
WET DISC BRAKE TYPE
* Install oil seal using a jig.
G2-LI
Apply liquid gasket to the inner

circumferential face. Press-fit oil seal.
Wipe off liquid gasket extruded.
After adjustment, apply a

stopper securely.
Gear
Hub
Shaft nut
Gear Clamp
Bearing
1. Tighten the nut until the bearing has 441 -- 539 Nm

no play. Then loosen the nut. {45 -- 55 kgm}
Case
2. Manually tighten the nut and
measure the start-up frictional torque
of the hub (A).
3. Tighten the hub nuts to the above Cover

torque (A)+20 to 39 Nm {2.0 to 4.0
kgm}.
343 -- 427 Nm
{35 -- 43.5 kgm}
Loctite #271
6-33
6-34
WET DISC BRAKE TYPE

Hub
1,961 -- 2,452 Nm
{200 -- 250 kgm}
Loctite #271
Differential case
Frame connecting
bolt
Cap
G2-LI
490.5 -- 605 Nm
Stud {50 -- 62 kgm}
Tube
490.5 -- 605 Nm
{50 -- 62 kgm}
Hub
6-35
6.4.2 DIFFERENTIAL
245 -- 309 Nm
{25 -- 31.5 kgm}
Loctite #271
* Be extremely careful
not to get grease or oil
on the inside surface of
the brake drum.
Backlash 0.2 -- 0.28 mm
Special tool 3ED-97-99600
Backlash 0.15 -- 0.20 mm
343 -- 427 Nm
{35 -- 43.5 kgm}
Loctite #271
Special tool 34B–97–

99110
Run out Max. 0.1 with dial

gauge
9JL01914
157 -- 196 Nm
{16 -- 20 kgm}
6-36
6.4.3 ADJUST PINION SHAFT SHIM
1. Calculate values of dimensions (a), (b), (c), and (d).

a. Read value (a) displayed at the tip of the pinion shaft
b. Measure dimension t when the preload on bearing is
58,840 N {6,000 kgf} and subtract 31.5 to obtain
value (b) in units of 1/100.
Example: When measured value is 31.6
b= (31.6 – 31.5) x 100 =10
c. Read value (c) indicated by the arrow on case.
d. Read value (d) stamped on differential case.
2. Calculating shim thickness

a. Insert values (a) to (d) calculated above in the for-
mula below to calculate the necessary shim thick-
ness (s).
a+b+c+d
(s) = Round the 2nd place of
100
decimal.
3. Installing shim combination
a. Combine shims (t=0.3) and (t=0.2) so that the total is
value (s) calculated above, then install the set of
shims.
4. Pinion shaft, bearing preload
a. After installing the shim, apply a preload to the bear-
ing so that the set staring torque of the pinion shaft is
392–784.5 Ncm (40–80 kgcm) when tightening the
bolt.
6-37
6.4.4 DIFFERENTIAL SUPPORT BEARING
1. Adjust the backlash of the ring gear and pinion gear.
Backlash 0.008–0.011 in (0.20–0.28 mm)
NOTE: Assemble to make the backlash 0.2 mm, cons-

iclesing it will increase during the initial running in
period.
PROCEDURE FOR ADJUSTING BACKLASH

1. To adjust the backlash, loosen one adjustment screw
1 notch and tighten the other screw 1 notch. Gradually
move the differential case in this way, and watch the
indicator of the dial gauge to adjust to the correct
value.
Special tool 34B–97–99110
2. After adjusting, tighten nut (1) and adjust so that the

starting torque of the ring gear and pinion shaft set is
as follows.
Starting 22.4–41.2lbf/ft (3040–5590 Ncm)

torque {310–570 kgcm}
3. Measure the backlash again and check that it is within

the specified range.
6-38
CHECKING TOOTH CONTACT

1. Coat the tooth face of the bevel pinion lightly with red
lead (minimum).
2. Rotate the bevel gear forward and backward.
3. Inspect the pattern left on the teeth.
4. If the result of the inspection shows that the correct
tooth contact is not being obtained, adjust again as
follows.
Adjust shims at pinion shaft
Adjust backlash of bevel gear
Adjust preload of bevel gear side bearing
• Tooth contact should be checked with no load on the

bevel pinion. The tooth contact pattern should cover
about 40–75 % of the length of the tooth, with weak
contact at both ends. It should be in the center of the
tooth height.
NOTE: The tooth contact should be correct on both the

FORWARD and REVERSE sides of the teeth.
However, if it is impossible to adjust both sides
correctly, the FORWARD side must be correct.
Swing of within 0.004 in (0.1 mm)

bevel gear
6-39
ADJUSTING TOOTH CONTACT

1. Inspect the shim thickness at the pinion shaft to move
the pinion in direction A closer to the bevel gear. Then
move the bevel gear away from the pinion gear in
direction B.
2. Adjust the backlash again.
1. Reduce the shim thickness at the pinion shaft to move

the pinion in direction A away from the bevel gear.
Then move the bevel gear close to the pinion gear in
direction B.
1. Reduce the shim thickness at the pinion shaft to move

the pinion in direction A away from the bevel gear.
Then move the bevel gear closer to the pinion gear in
direction B.
1. Increase the shim thickness at the pinion shaft to

move the pinion in direction A closer to the bevel gear.
Then move the bevel gear away from the pinion gear
in direction B.
6-40
Differential carrier
245 -- 309 Nm
{25 -- 31.5 kgm}
49 -- 73.5 Nm Loctite #271
{5 -- 7.5 kgm}
Pinion shaft
Loctite #271
Shim
Coat with
grease
(G2-LI)
Shim Coat oil seal contact

surface with grease (G2-LI)
157 -- 196 Nm Runout of rear face of gear:

{16 -- 20 kgm} Max. 0.1 (dial gauge reading)
After adjusting backlash, tighten so that starting torque of ring gear 9JL01915
and pinion shaft is 3,040 -- 5,590 Ncm {310 -- 570 kgcm}
Reduction gear type Hypoid bevel gear
Reduction ratio 4.375
Oil capacity 20
6-41
6.5 STEERING AXLE
6-42
6.6 PARKING BRAKE
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
A Lining Thickness 0.22 (5.45mm) 0.13 (3.3mm) Replace
B Shoe return spring Strength 34.2lbf (152 N) 30.9lbf (137 N)

{15.5 kgf} {14 kgf}
[L = 1.97 (50mm) [L = 1.97 (50mm)
Free length 2.15 (54.7mm)
6-43
6.7 WHEEL BRAKE

HYDRAULIC DRUM BRAKE TYPE (FD100/115)
Judgement standard
B Shoe return spring Strength 33 ± 3.3 kgf 33 ± 3.3 kgf

[L= 4.078 [L= 4.078
(103.5mm)] (103.5mm)]
Free length: 93 (3.664) (Reference)
C Wheel cylinder Clearance 0.001–0.005 0.001–0.005

between piston (0.025–0.126mm) (0.025–0.126)
and cylinder
Clacks, chips, rust
D Back plate Damage, bending
Inside diameter of brake drum 15.512 (393.7) 15.622 (396.5)
6-44
FD135/150E/160E
Judgement standard
B Shoe return spring Strength 50 ± 5 kgf 42 ± 4 kgf

[L= 7.013 (178mm)] [L=6.265 (159mm)]
Free length: 6.678 (Reference)

(169.5mm)
5.838
(148mm)
C Wheel cylinder Clearance 0.001–0.005 0.001–0.005 (0.025–

between piston (0.025–0.126mm) 0.126mm)
and cylinder
Clacks, chips, rust
D Back plate Damage, bending
Inside diameter of brake drum 17.257 (438mm) 17.336 (440)
6-45
WET DISC BRAKE TYPE
10.8 -- 14.7 Nm
{1.1 -- 1.5 kgm}
Loctite #572
245 -- 309 Nm
{25 -- 31.5 kgm}
373 -- 426 Nm
{38 -- 43.5 kgm}
Loctite #271
157 -- 196 Nm
{16 -- 20 kgm}
* Install oil seal using a jig.
Loctite #271 Loctite #271
9JL01916
6-46
6.8 BRAKE / INCHING PEDAL

Brake pedal
Torque converter
Brake valve
Inching pedal
6-47
WET DISC BRAKE TYPE
Brake pedal Torque converter
Inching pedal
Brake valve
6-48
6.9 BRAKE VALVE

the accumulator circuit is under high hydraulic pressure. It is therefore very dangerous to loosen any con-
nections before releasing this pressure. When removing the accumulator, first stop the engine, then
repeatedly (at least 10 times) depress the brake pedal fully. After completely releasing the pressure in the
accumulator, disconnect the pipes.
6-49
6.9.1 DISASSEMBLY
1. Fix body (1) in a vice and remove plug (2).
When fixing in the vice, be careful not to

hold the flow divider mounting face.
NOTE: Parts marked * are supplied in the parts kit.
2. Remove bolt (2) from body (1) using a

hexagonal bar wrench.
3. Remove snap ring (3).
4. Pull out washer (4) and input piston assembly
(5) carefully.
FD100/115 only
• Turn hole on disassembled side of body to
face down and spring (8) will come out.
IMPORTANT
When disassembling cup (6), be careful not to
scratch piston.
NOTE: If nut (7) is loosened, the stroke of piston or

hydraulic pressure must be adjusted.
5. Insert a bar to spool hole (1) to remove guide (2)

and valve assembly (3).
NOTE: Do not push hard.
NOTE: Outside diameter of hole: 13 mm (0.5 in).
6-50
6. Remove O–ring (7) from valve sub–assembly (3) with

fingers.
7. Remove O–ring (8) from guide (2) with fingers.
8. Remove O–ring (9), back–up ring (10) and O–ring (11)
from reaction piston with fingers or a hair–pin.
6.9.2 ASSEMBLY
IMPORTANT
Clean all parts and dry thoroughly.
1. Coat the O–rings and cup with silicon grease supplied

with O–ring kit.
2. Follow the method shown in Fig. A when installing cup
(2).
Wind the outside of the spring with vinyl tape and

make a guide to install the cup.
The cup must be faced as shown in Fig. A.
3. Install input piston sub–assembly (2) and washer (3) in

body (1) and fix with snap ring.
4. Assemble sub–assembly with spool (5), reaction
piston (6) and guide (7).
FD100/115 only
• Install spring (8) in hole in spool (5).
• Install sub–assembly with spool (5).
NOTE: Coat spool (5) with engine oil.
SAE10W
Standard depth of guide 40 (1.6)
6-51
5. Install retainer (2) securely on tip of piston (1).

6. Install spring (3), valve sub–assembly (4) and plug (5) in order.
7. Tighten plug (5) by hand.
8. Fix brake valve in vice and tighten plug (5) again.
torque Plug (5) 49–79lbf/ft (690–

1,100 kgcm)
9. Install boot (1) in groove of body (2) and groove of nut (3).
10. Adjust brake pressure.
a. Set the oil pressure gauge.
b. Run the engine at low idling speed.
IMPORTANT
Do not operate TILT, LIFT or ATTACHMENT lever.
c. Depress brake pedal slowly and brake pressure comes to the

specified value below, turn locknut (2) so that it is in contact
with washer (3).
FD100/115 1850 ± 43psi

Wheel cylinder oil (130 ± 3 kg/cm2)
pressure FD135–160E 1850 ± 43psi
(130 ± 3 kg/cm2)
torque
36–58lbf/ft (500–800 kgcm)
IMPORTANT
If adjustment cannot be made with this procedure, adjust as follows.
a. Adjust so that the distance A (a + b) between washer (3) and

locknut (2) is the valve below.
b. Remove snap ring (4) and pull out input piston (1), and mea-
sure the depth a.
FD100/115 156.5 ± 4.3 psi

(11 ± 0.3 kg/cm2)
a+b
FD135–160E 138 ± 4.3psi
(9.7 ± 0.3 kg/cm2)
torque
36–58lbf/ft (500–800 kgcm)
6-52
WET DISC BRAKE TYPE
1.Seat 11.Piston 21.Holder

2.Stopper (pedal) 12.Seal (oil) 22.Cylinder Ass’y
3.Boot 13.Flange Ass’y 23.Retainer
4.Bolt 14.O-ring 24.Snapring
5.Nut 15.Retainer 25.Spring
6.Braket 16.Retainer 26.O-ring
7.Pin (snap) 17.Snapring 27.Nut (end)
8.Pin 18.Spring
9.Pin 19.Spring
10.Bolt 20.Spring
6-53
CAUTIONS BEFORE DISASSEMBLY

Remove mud, dirt, oil, grease, water attached to the surfaces with a brush, compressed air, etc.
Care should be taken not to allow those infiltrate the brake valve.
Put a match mark to the joint of each part for assembling convenience.
Arrange individual parts in orderly manner for correct assembly with ease. Take full care not to have the parts
damaged, dented or bent.
6-54
6.10 POWER STEERING VALVE

No. Part name Remarks No. Part name Remarks
1 Screw 16 Race bearing
2 — 17 Thrust needle bearing
3 End cap 18 O-ring
4 Gerotor Gerotor ring and star 19 Oil seal
5 Spacer 20 Dust seal
6 — 21 Snap ring
7 Spacer plate 22 Seal grand bushing
8 Drive 23 O-ring
9 Control parts assembly Items 10 to 12 included 24 O-ring
10 Housing 25 Adapter screw
11 Sleeve 26 Ball
12 Spool 27 O-ring
13 Pin 28 Seat
14 Centering spring 29 O-ring
15 Flat spring 30 Screw
6-55
DISASSEMBLY PROCEDURES
1. Remove the column assembly.
a. Hold the flange of a column assembly with a vise.
b. Loosen the bolts to remove the column assembly.
2. Remove the gerotor assembly.

a. Hold the housing (10) with the vise with the gerotor
side facing upward.
b. Loosen the screw (1).
c. Lift the end cap (3), gerotor (4) and plate (7) as a unit.
Remove the gerotor assembly.
NOTE: When lifting them in the unit, hold the plate with fin-
gertips.
3. Disassemble control valve assembly.

a. Hold the assembly lightly with the vise with the col-
umn mount side facing upward.
b. Remove the snap ring (21).
IMPORTANT
Apply a flat wooden block under the assembly to prevent the
Housing
sleeve and spool assembly from being damaged.
6-56
4. Remove the snap ring (21).

5. Remove the seal grand bushing (22) and O-ring (18).
6. Push out the sleeve and spool assembly to remove the
bearing assembly (B).
7. Fix the housing (10) with the port face facing downward.
8. Pull out the sleeve and spool assembly (A) from the front
(mount plate) side.
IMPORTANT
• When pulling out the assembly, care should be taken not
to have the straight pin (13) dropped into the groove of
the housing to be caught there. If it is caught in the
groove, adjust the straight pin position with fingertip, turn
it slowly to pull out.
• Never forcibly pull it out since the clearance with the
housing is narrow.
9. Loosen the check valve assemblies (25), (26), (27), (28),

(29) and (30), which are screwed into the housing.
10. Pull out the straight pin (13) from the sleeve and spool
assembly (A).
11. Pull out the spool as shown in the figure to the right, and
push out the centering springs (14) and (15).
NOTE: Clearance between the sleeve and spool is narrow.

Pull the spool out carefully by turning it slowly.
6-57
12. Disassemble of column assembly.

a. Hold the flange of a column assembly with the vise.
b. Remove the handle.
c. Remove the snap ring on the column and flange side.
13. Pull out the shaft (14) from the flange.
NOTE: Bearing (15) is press-fitted to the shaft. Do not disas-

semble it unless it has any defect.
14. Hold the outside diameter section of column (16) with the
vise.
15. Pull out the column bushing by pushing in the protrusion
at 2 locations on the column bushing (17).
INSPECTION AND CLEANING

1. Check the sealing parts for any damage, wear or other abnormality.
2. When re-assembling, replace all seals with new parts.
3. Check the sliding surfaces of individual parts for excessive flaws, wear or breakage due to dirt.
NOTE: Main functional parts are selectively combined and cannot be supplied as a single unit. In the case of
excessive damage, replace the parts by assembly.
Washing metal parts

Wash metal parts using volatile metal cleaning solvents (Trichloroethane, methylene chloride, etc.).
Cleaning rubber parts
Dust rubber parts with compressed air, and immerse in hydraulic oil before using.
IMPORTANT
Never wash rubber parts in metal washing solvent.
6-58
ASSEMBLY PROCEDURES
1. Assemble control valve assembly.
a. Place the housing on a flat wooden block with the
front side (steering column side) facing upward.
b. Install O-ring (18) to the check valve assembly and
screw it in to the housing.
torque 60 – 80 kgcm
c. Insert spool (12) to the sleeve (11) from the spline

side.
d. Apply clean hydraulic oil to the spool and insert by
turning it lightly.
e. Turn the spool lightly with fingertips by an end (spline
side) and check for smooth rotation.
f. Align the spring groove positions on the spool and

sleeve.
g. Insert springs (14) and (15) to the spool and sleeve
using a spring insertion jig.
Spring insertion jig 3BA-97-99220
a. Lay each three (3) leaves of spring to one side.

b. Put both sides of the spring back-to-back.
c. Hold the notched side facing downward.
d. Hold one end with the spring insertion jig while hold-
ing the other end bent with fingertips.
e. Press the springs in this condition in the direction of insertion.
f. Pull out the insertion jig with the spring until the spring fits inside the groove.
g. Correct the position of the spring insertion jig and spring.
h. Align them by preventing protrusion.
i. Insert straight pin (13) to the sleeve and spool
assembly (A).
6-59
j. Fix the housing (10) with the port face facing down-
ward or sideway. Insert the sleeve and spool assem-
bly (A) to the bore from the spline side of the spool.
NOTE: When inserting the assembly, care should be taken

not to have the straight pin (13) dropped into the
groove of the housing to be caught there. If it is
caught in the groove, adjust the straight pin position
with fingertip.
k. Apply clean hydraulic oil to the spool and insert by

turning it little by little, carefully avoiding slanted
insertion.
l. Turn the spool lightly with fingertips by an end and
check for smooth rotation.
m. Insert bearing assembly (B).
n. Install the race bearing (16) on both sides of the
thrust needle bearing (17) so that the curved side (R)
will be to the opposite of the bearing.
o. Insert dust seal (20) and wheel seal (19) to the seal
grand bushing (22), and O-ring (18).
p. Smoothly slide in the assembly. Further push it in
slowly and stop it with snap ring (21).
NOTE: Be careful and avoid catching the O-ring (18) during

insertion.
To prevent the bearing assembly (B) from being
locked, check that the housing and mounting plate
are closely in contact.
q. Apply thin layer of grease to outer circumference of

the seal before press-fitting.
r. Fill the lip portion with grease.
6-60
2. Assemble gerotor assembly

a. Hold the mounting plate with the vise with the rear side of the control valve assembly facing upward.
b. Insert O-ring (24) to the groove on the housing.
c. Place the spacer plate (7) on the assembly and align

the bolt hole positions.
NOTE: The bolt hole and oil hole have different pitch circle
diameter. (The bolt hole pitch circle diameter is
greater than that of the oil hole.)
d. Insert drive (8) and have the drive yoke section

engaged to pin (13).
e. To ensure correct positioning, draw a line on the end
face of the drive (8) in parallel with the pin (13) using
a felt-tip marker pen.
f. Hold the side of gerotor star having greater spline

Parallel relation
chamfer to the side of spacer plate (7).
g. Align the tooth-shaped root of the gerotor star to the
felt-tipped marker line.
h. Insert O-ring (23) and install gerotor (4).
i. At this time, check that A: star root, B: felt-tipped line
on the drive (8) and C: pin (13) are in parallel relation
mutually as the figure shows.
Align positions correctly. Wrong combination may cause malfunction, leading to a serious accident.
j. Install the spacer (5).
k. Install the O-ring (23) and the end cap (3).
6-61
l. Install 7 screws (1) to the end cap (3).
NOTE: When installing the screw (1), check that the spring
pin (2) is installed to the end of screw hole at the
position indicated in the figure.
m. Tighten the screws at 7 locations in advance by

applying torque of about 11 lbf/ft (15 Nm) {1.5 kgm}.
n. Tighten them to the tightening torque indicated in the
table below in the order shown in the figure to the
right.
torque 18–21.7 lbf/ft (24.5 – 29.4 Nm)

{2.5 – 3.0 kgm}
If spring pin (2) is not installed, malfunction may occur, causing a serious accident.
3. Assemble column assembly.

a. Hold the outside diameter section of the column with
the vise.
b. Apply grease to the outer circumference of the col-
umn bushing and push it inside the column.
NOTE: Care should be taken to have the protrusions at 2

locations to fit the holes at 2 places correctly.
c. Fill the lip of column bushing with grease.

d. Insert the shaft from the flange side to the bore of the
column. Push it until the end face of the bearing
makes contact with the prescribed position.
e. Install the snap ring correctly to the groove to com-
plete the assembling of the column.
f. Check the shaft for smooth revolution.
6-62
g. Seal in grease (bearing grease No. 2 containing

(molybdenum disulfide) to the spline joint of the col-
umn assembly and install to the steering valve main
unit.
h. Tighten 4 bolts to complete assembly.
torque 21.7– 25.3lbf/ft (29.4 – 34.3 Nm)

{3 – 3.5 kgm}
6-63
6.11 POWER STEERING VALVE

WET DISC BRAKE TYPE
No. Part name Remarks No. Part name Remarks
1 Screw 16 Race bearing
2 Spring pin 17 Thrust needle bearing
3 End cap 18 O-ring
4 Gerotor Gerotor ring and star 19 Oil seal
5 Spacer 20 Dust seal
6 — 21 Retaining ring
7 Spacer plate 22 Seal grand bushing
8 Drive 23 O-ring
6-64
9 Control parts Items 10 to 12 included 24 O-ring

assembly
10 Housing 25 Adapter screw
11 Sleeve 26 Ball
12 Spool
13 Pin
14 Centering spring
15 Flat spring Not installed with USA spec.
DISASSEMBLY PROCEDURES
1. Remove the column assembly
a. Hold the flange of a column assembly with a vise,
loosen the bolts to remove the column assembly.
2. Remove the gerotor assembly.

a. Hold the housing (10) with the vise with the gerotor
side facing upward.
b. Loosen the screw (1).
c. Lift the end cap (3), gerotor (4) and plate (7) as a unit.
Remove the gerotor assembly.
NOTE: When lifting them in the unit, hold the plate with fin-
gertips.
6-65
3. Disassemble control valve assembly.

a. Hold the assembly lightly with the vise with the col-
umn mount side facing upward.
b. Remove the retaining ring (21).
c. Apply a flat wooden block under the assembly to pre-
vent the sleeve and spool assembly from being dam-
aged.
Housing
d. Remove the retaining ring (21).

e. Remove the seal grand bushing (22) and O-ring (18).
f. Push out the sleeve and spool assembly to remove
the bearing assembly (B).
g. Fix the housing (10) with the port face facing down-
ward.
h. Pull out the sleeve and spool assembly (A) from the
front (mount plate) side.
NOTE: When pulling out the assembly, care should be taken

with fingertip, turn it slowly to pull out.
Never forcibly pull it out since the clearance with the
housing is narrow.
i. Loosen the check valve assemblies (25) and (26),

which are screwed into the housing.
6-66
j. Pull out the straight pin (13) from the sleeve and
spool assembly (A).
k. Pull out the spool as shown in the figure to the right.
l. Push out the centering springs (14) and (15).
NOTE: Clearance between the sleeve and spool is narrow.

Pull the spool out carefully by turning it slowly.
4. Disassemble column assembly.

a. Hold the flange of a column assembly with the vise.
Remove the handle, then remove the snap ring on
the column and flange side.
b. Pull out the shaft (14) from the flange.
NOTE: Bearing (15) is press-fitted to the shaft. Do not disas-

semble it unless it has any defect.
c. Hold the outside diameter section of column (16) with

the vise.
d. Pull out the column bushing by pushing in the protru-
sion at 2 locations on the column bushing (17).
6-67
INSPECTION AND CLEANING

1. Check the sealing parts for any damage, wear or other abnormality.
2. When re-assembling, replace all seals with new parts.
3. Check the sliding surfaces of individual parts for excessive flaws, wear or breakage due to dirt.
NOTE: Main functional parts are selectively combined and cannot be supplied as a single unit. In the case of
excessive damage, replace the parts by assembly.
Washing metal parts

Wash metal parts using volatile metal cleaning solvents (Trichloroethane, methylene chloride, etc.).
Cleaning rubber parts
Dust rubber parts with compressed air, and immerse in hydraulic oil before using.
IMPORTANT
Never wash rubber parts in metal washing solvent.
ASSEMBLY PROCEDURES
1. Assemble control valve assembly.
a. Place the housing on a flat wooden block with the
front side (steering column side) facing upward.
b. Install O-ring (18) to the check valve assembly and
screw it in to the housing.
torque 43.4 –57.9lbf/ft

(60 – 80 kgcm)
c. Insert spool (12) to the sleeve (11) from the spline

side.
d. Apply clean hydraulic oil to the spool and insert by
turning it lightly.
e. Turn the spool lightly with fingertips by an end (spline
side) and check for smooth rotation.
6-68
f. Align the spring groove positions on the spool and

sleeve.
g. Insert springs (14) and (15) to the spool and sleeve
using a spring insertion jig.
Spring insertion jig 3BA-97-99220
a. Lay each three (3) leaves of spring to one side.

b. Put both sides of the spring back-to-back.
c. Hold the notched side facing downward.
d. Hold one end with the spring insertion jig while hold-
ing the other end bent with fingertips.
e. Press the springs in this condition in the direction of insertion.
f. Pull out the insertion jig with the spring until the spring fits inside the groove.
g. Correct the position of the spring insertion jig and spring.
h. Align them by preventing protrusion.
i. Insert straight pin (13) to the sleeve and spool
assembly (A).
j. Fix the housing (10) with the port face facing down-
ward or sideway. Insert the sleeve and spool assem-
bly (A) to the bore from the spline side of the spool.
NOTE: When inserting the assembly, care should be taken

with fingertip.
k. Apply clean hydraulic oil to the spool and insert by

turning it little by little, carefully avoiding slanted
insertion.
l. Turn the spool lightly with fingertips by an end and
check for smooth rotation.
m. Insert bearing assembly (B).
n. Install the race bearing (16) on both sides of the
thrust needle bearing (17) so that the curved side (R)
will be to the opposite of the bearing.
6-69
o. Insert dust seal (20) and wheel seal (19) to the seal
grand bushing (22), and O-ring (18).
p. Smoothly slide in the assembly. Further push it in
slowly and stop it with snap ring (21).
NOTE: Be careful and avoid catching the O-ring (18) during

insertion.
To prevent the bearing assembly (B) from being
locked, check that the housing and mounting plate
are closely in contact.
q. Apply thin layer of grease to outer circumference of

the seal before press-fitting.
r. Fill the lip portion with grease.
2. Assemble gerotor assembly
a. Hold the mounting plate with the vise with the rear
side of the control valve assembly facing upward.
b. Insert O-ring (24) to the groove on the housing.
c. Place the spacer plate (7) on the assembly and align

the bolt hole positions.
NOTE: The bolt hole and oil hole have different pitch circle
diameter. (The bolt hole pitch circle diameter is
greater than that of the oil hole.)
d. Insert drive (8) and have the drive yoke section

engaged to pin (13).
e. To ensure correct positioning, draw a line on the end
face of the drive (8) in parallel with the pin (13) using
a felt-tip marker pen.
6-70
f. Hold the side of gerotor star having greater spline

Parallel relation
chamfer to the side of spacer plate (7).
g. Align the tooth-shaped root of the gerotor star to the
felt-tipped marker line.
h. Insert O-ring (23) and install gerotor (4).
i. At this time, check that A: star root, B: felt-tipped line
on the drive (8) and C: pin (13) are in parallel relation
mutually as the figure shows.
Align positions correctly. Wrong combination may cause malfunction, leading to a serious accident.
j. Install the spacer (5).
k. Install the O-ring (23) and the end cap (3).
3. Assemble column assembly.

a. Hold the outside diameter section of the column with
the vise.
b. Apply grease to the outer circumference of the col-
umn bushing and push it inside the column.
NOTE: Care should be taken to have the protrusions at 2

locations to fit the holes at 2 places correctly.
c. Fill the lip of column bushing with grease.

d. Insert the shaft from the flange side to the bore of the
column. Push it until the end face of the bearing
makes contact with the prescribed position.
e. Install the snap ring correctly to the groove to com-
plete the assembling of the column.
f. Check the shaft for smooth revolution.
6-71
g. Seal in grease (bearing grease No. 2 containing

(molybdenum disulfide) to the spline joint of the col-
umn assembly and install to the steering valve main
unit.
h. Tighten 4 bolts to complete assembly.
torque 21.7– 25.3lbf/ft (29.4 – 34.3 Nm)

{3 – 3.5 kgm}
6-72
6.12 LIFT CYLINDER
1. Cylinder
2. Piston rod
3. Piston ring
4. Wear ring
5. Cylinder head
6. O-ring
7. Dust seal
8. Rod packing
9. Wear ring
10. Collar
11. O-ring
6-73
(Lifting height: 3 m)
FD135/
Item Unit FD100 FD115 160E
150E
Cylinder (inside diameter × outside mm 95 × 110 100 × 113 110 × 124 120 × 136
diameter)
Stroke mm 1510
Outside diameter of rod mm 65 70 75
Weight kg 85 90 105 110
6.12.1 INSPECTION
in (mm)
Judgement standard
Symb. Inspection item Remedy
A FD100 0.004–0.014 0.026 (0.666)

Clearance (0.097–0.366) Replace
between piston
FD115/135/150E/ 0.004–0.016 0.027 (0.695) bushing
rod and bushing
160E (0.107–0.395)
B Scratches that catch finger nail, dents,

Piston rod
hollows
C Piston ring Scratches that catch finger nail Replace
D Cylinder Scratches that catch finger nail,

hollows
6-74
6.13 TILT CYLINDER
1. Cylinder 9. Backup ring
2. Piston rod 10. O–ring
3. Cylinder head 11. Piston ring
4. Snap ring 12. Wear ring
5. Dust seal 13. Bushing
6. O–ring 14. Rod head
7. Bushing 15. Lock washer
8. Rod packing 16. Nut
6-75
(lifting height: 3 m)
Item Unit FD100–160E
Cylinder (inside diameter × outside mm 125 × 142

diameter)
Stroke mm 240
Outside diameter of rod mm 60
Three Bond # 1901
910–1110 Nm {93–113.3
kgm}
6.13.1 INSPECTION
in (mm)
Judgement standard
A Clearance between piston rod 0.001–0.011 0.022 (0.567)

and bushing (0.036–0.267)
B Piston rod Scratches that catch finger nail, dents,

hollows Replace
C Piston ring Scratches that catch finger nail
D Cylinder Scratches that catch finger nail, hollows
6-76
6.13.2 DISASSEMBLE LIFT AND TILT CYLINDERS

1. Remove cylinder head assembly.
a. Use a wrench to remove the cylinder head assembly.
Wrench For lift Outside diameter φ100–

cylinder 120 (FD100,115)
Outside diameter φ125–

130 (FD135, 150E)
Outside diameter φ140

(FD160E)
For tilt Outside diameter φ140

cylinder (FD100–160E)
2. Remove of piston rod assembly.

a. Remove the piston rod and cylinder head assembly
from the cylinder.
• When lifting with wire rope, put a cloth between the

wire and the rod to prevent damage to the rod.
• When pulling out, prepare a can to catch the hydrau-
lic oil that comes out from the cylinder.
• If the assembly will not come out smoothly, turn the
piston rod while pulling out.
• When removing, be careful not to damage the piston
seal with the thread of the cylinder.
3. Disassemble piston rod assembly.

a. Remove the piston rod head. (Tilt cylinder only)
b. Remove the cylinder head from the piston rod
assembly.
IMPORTANT
Be careful not to damage the cylinder head seal with the
thread of the piston rod.
3) Remove the wear ring.

4) Remove the piston ring.
NOTE: If the rings are not damaged, do not remove them. If they are removed, replace them with new parts.
6-77
4. Disassemble cylinder head assembly.
NOTE: If the seals are not damaged, do not disassemble

them. If they are disassembled, replace them with
new parts.
a. Remove the snap ring (tilt cylinder only), then remove

the dust seal.
b. Use a screwdriver to remove the U–packing.
IMPORTANT
Be careful not to damage any other place when removing the
U–packing.
6.13.3 ASSEMBLE LIFT AND TILT CYLINDERS

1. Assemble cylinder head assembly.
a. To prevent damage to the seal, use an oilstone to
remove any burrs or flashes at the places marked
in the diagram on the right.
b. Coat the inside diameter of the cylinder head and the

mounting groove of the packing and O–ring with
grease or hydraulic oil.
6-78
2. Compress the U–packing and push in until it enters

groove B.
NOTE: Use a jig made of copper, aluminum or plastic and

check that there are no burrs or flashes on the U–
packing contact surface.
It is better to push in as far as possible by hand and
not use a jig.
c. Push the inside circumference of the U–packing by

hand towards the outside circumference and check
that there is no abnormality on the inside circumfer-
ence lip and that the U–packing is fitted securely in
the groove.
d. Soak the backup ring in hot water at 30–50 C for 2–

3 minutes.
e. Take the backup ring out of the hot water, and expand
it to assemble it to the cylinder head.
IMPORTANT
When assembling the cylinder head assembly in the cylinder,
check first that the backup ring has cooled and is contracted
to its original size.
f. Assemble the O–ring.
6-79
g. Use a press–fitting tool to press fit the dust seal, then

install the snap ring (tilt cylinder only).
3. Assemble piston assembly

a. To prevent damage to the seal, use an oilstone to
remove any burrs of flashes at the places marked O
in the diagram on the right.
b. Coat top portion of the piston taper surface with

grease or hydraulic oil.
c. Insert one end of the piston ring into the groove first,
then push the other side along the taper surface by
hand to expand and install it.
6-80
d. Assemble the wear ring.
Assemble piston rod assembly
a. Assemble the piston rod assembly to the cylinder.
Be careful not to damage the piston rod assembly seals

with the thread of the cylinder.
4. Assemble cylinder head assembly

a. Using a wrench, assemble the cylinder head to the
cylinder and tighten it.
lbf/ft (Nm) {kgm}
521–637 (706–863) {72–88}

(FD100)
For lift 618–752 (838–1,020) {85.5–104.5}

cylinder (FD115)
torque 651–797 (883–1,080) {90–110}
(FD135/160E)
618–752 (838–1,020) {85.5–104.5}

For tilt (FD100/115)
cylinder 687–833 (932–1,130) {95–115}
(FD135/160E)
6-81
6.14 POWER STEERING CYLINDER
1. Cylinder 9. Rod cover
2. Piston rod 10. O–ring
3. Bushing 11. Retainer ring
4. Piston 12. Dust wiper
5. O–ring 13. U–packing
6. Stopper seal 14. Bushing
7. Retainer ring 15. O–ring
8. Ring 16. Dust cap
6-82
(lifting height: 3 m)
Item Unit FD100–115 FD135–160E
Cylinder (inside diameter x outside diameter) mm φ 90 x φ 102 φ 100 x φ 115
Stroke mm 312 312
Outside diameter of rod mm φ 60 φ 70
6.14.1 INSPECTION
in (mm)
Judgement standard
A Clearance between cylinder and 0.002–0.010 0.016 (0.4)

piston rod (0.05–0.25)
B Clearance between piston and 0.001–0.007 (0.012) (0.3)

busing (0.03–0.18)
Replace
C Piston ring Scratches that catch finger nail, dents,
hollows
D Cylinder Scratches that catch finger nail, dents,

hollows
6-83
6.15 CONTROL VALVE

6.15.1 DISASSEMBLY AND ASSEMBLY
This section describes disassembling and assembling procedures of the representative 3-port relief model. When
disassembling or assembling work varies according to the number of port reliefs or their presence/absence,
additional instructions are given in [ ].
Disassembling and assembling units should be conducted at the manufacturer's factory in principle. If this is
impossible, ask a service shop with in-depth knowledge of hydraulic machines for the disassembling/assembling
work. Since precision-made hydraulic machines form many small gaps inside, conduct disassembly and assembly
in the following procedures, while paying attention to the handling of the machine in a clean, dust-free place. Do
not hit any part even if it does not work smoothly.
NECESSARY TOOLS
• Hexagon key wrench
(width across flats: 4, 5, 6, 8, 12 mm)
• Spanner (width across flats: 10, 24, 27, 32 mm)
• Torque wrench
• Scriber
• Vice
DISASSEMBLY
1. Spool
a. Remove two hexagonal socket head bolts (40) using an 8 mm hexagon key wrench. [This work is required
for all port reliefs.]
b. Remove cap (3) and O-ring (51). [This work is required for all port reliefs.]
c. Pull out lift spool (27) from body (37) with parts (26), (28) and (41) united.
d. Pull out tilt spool (31) in the same way.
e. Pull out spool (29) in the same way.
[Dual-port relief model: not necessary, 4/5-port relief model: in the same way.]
IMPORTANT
Since clearance is controlled for body (37) and spool (29), check the combination of spool when disassembling,
and reassemble it at its original position.
2. Spool assembly
a. Detach button bolt (41) from lift spool (27) using a 6 mm hexagon key wrench.
b. Remove spring (26) and spring holder (28).
c. Detach button bolt (41) from tilt spool (31) using a 6 mm hexagon key wrench.
d. Remove spring (26) and spring holder (28).
e. Remove head spool (20) using a 10 mm spanner.
f. Remove O-ring (53) using a scriber.
g. Pull out spring (22) and plunger (21).
h. Since orifice (24) is caulked, it cannot be disassembled.
i. Detach button bolt (41) from spool (29) using a 6 mm hexagon key wrench.
[Dual-port relief model: not necessary, 4/5-port relief model: in the same way]
j. Remove spring (26) and spring holder (28).
3. Main relief assembly
a. Remove sleeve (33) as an assembly using a 24 mm spanner, while holding cap nut (5) and locknut (7) to
prevent the set pressure from varying.
IMPORTANT
Do not disassemble the main relief. It has been set to the specified pressure.
4. Port relief assembly
6-84
a. Remove pilot sleeve (16) as an assembly using a 27 mm spanner, while holding cover (17) to prevent the
set pressure from varying.
IMPORTANT
Do not disassemble the port relief. It has been set to the specified pressure.
5. Plug, oil seal

a. Remove three plugs (19) using a 6 mm hexagon key wrench.
b. Remove three O-rings (58) using a scriber.
c. Remove socket head plug (59) using a 5 mm hexagon key wrench.
d. Remove sleeve (23) using a 32 mm spanner.
e. Remove O-ring (54) using a scriber.
f. Remove two hexagonal socket head bolts (39) using a 4 mm hexagon key wrench.
[This work is required for all port reliefs.]
g. Remove seal holder (36) and oil seal (46).
6. Plunger
a. Remove two plugs (1) using a 12 mm hexagon key wrench.
b. Remove O-ring (57) using a scriber.
c. Pull out two sets of spring (2) and plunger (4).
IMPORTANT
Check the combination of these parts when disassembling, and reassemble them at their original positions.
NOTE: Since steel balls (44) are press-fit into body (37), it cannot be disassembled.
Since plate name (35) is riveted with rivet screws (43), it cannot be disassembled.
ASSEMBLY
Before starting reassembly, adequately wash and degrease disassembled parts and prepare new oil seals.
1. Plunger
a. Install two sets of plunger (4) and spring (2) to body (37) with the same combination as that during disas-
sembling.
b. Tighten two plugs (1) together with O-rings (57) to body (37) using a 12 mm hexagon key wrench.
torque 46.8–57.2lbf/ft (63.5–77.6

Nm) {6.5–7.9 kgm}
2. Sleeve
a. Tighten two sleeves (23) together with O-rings (54) to body (37) using a 32 mm spanner.
torque 57.8–70.6lbf/ft (78.3–95.7

Nm) {8.0–10.1 kgm}
3. Plug, oil seal

a. Install oil seal (46) to body (37). [This work is required for all port reliefs.]
b. Tighten seal holder (36) with two hexagonal socket head bolts (39) using a 4 mm hexagon key wrench.
6-85
torque 4.1–5lbf/ft (5.6–6.8 Nm) {0.6–

0.7 kgm}
c. Tighten three plugs (19) together with O-rings (58) to body (37) using a 6 mm hexagon key wrench.
torque 21.2–26lbf/ft (28.8–35.2 Nm)

{2.9–3.6 kgm}
4. Main relief assembly

a. Tighten sleeve (33) assembly to body (37) using a 24 mm spanner.
torque 65–79.5lbf/ft (88.2–107.8 Nm)

{9.0–11.0 kgm}
5. Socket head plug

a. Wind seal tape around socket head plug (59) and tighten it using a 5 mm hexagon key wrench.
torque 5.8–7.2lbf/ft (7.9–9.7 Nm)

{0.8–10.0 kgm}
6. Port relief assembly

a. Tighten pilot sleeve (16) assembly to body (37) using a 27 mm spanner.
torque 46.8–57.2lbf/ft (63.5–77.6 Nm)

{6.5–7.9 kgm}
7. Spool assembly
a. Hold the width across flats (10 mm) of lift spool (27) in a vice.
b. Install spring holder (28), spring (26), and spring holder (28) in this order to the held lift spool, and then
tighten button bolt (41) using a 6 mm hexagon key wrench.
torque 19.5–23.8lbf/ft (26.5–32.3 Nm)

{2.7–3.3 kgm}
NOTE: Since button bolt (41) is a microcapsuled product, prepare a new one or apply Loctite #242 (or the equiva-
lent) to the threaded portion when installing the disassembled button bolt. (When Loctite #242 is applied,
leave the button bolt at ordinary temperature for at least four hours.)
c. Pass a rod through the 6 mm hole at the end of tilt spool (31), and hold the tilt spool in a vice.
d. Insert plunger (21) and spring (22) into the held tilt spool, and tighten head spool (20) and O-ring (53) (with
Loctite #242 applied to the threaded portion) using a 10 mm spanner.
torque 19.5–23.8lbf/ft (26.5–32.3 Nm)

{2.7–3.3 kgm}
e. Hold the width across flats of the installed head spool in a vice.
6-86
f. Install parts (28), (26) and (41) to tilt spool (31) in the same way as step 2).
g. Hold spool (29) in a vice in the same way as step 1).
h. Install parts (28), (26) and (41) to spool (29) in the same way as step 2).
i. Insert assembled lift spool (27) into body (37).
j. Insert assembled tilt spool (31) into body (37).
k. Insert assembled spool (29) into body (37).
[For 4- or 5-port relief model, install the spool to its original position.]
l. Tighten cap (3) including O-ring (51) with two hexagonal socket head bolts (40) using an 8 mm hexagon
key wrench. [This work is required for all port reliefs.]
torque 19.5–23.8lbf/ft (26.5–32.3 Nm)

{2.7–3.3 kgm}
6-87
1 Plug
2 Spring
3 Cap
4 Plunger
5 Cap nut
6 Adjusting screw
7 Locknut
8 Needle valve
9 Circlip
6-88
10 Wire
11 Spring 31 Tilt spool
12 Spring 32 Seat
13 Spring holder 33 Sleeve
14 Spring 34 Seat
15 Plunger 35 Plate name
16 Pilot sleeve 36 Seal holder
17 Cover 37 Body
18 Adjusting screw 38
19 Plug 39 Hexagonal socket head bolt
20 Head spool 40 Hexagonal socket head bolt
21 Plunger 41 Button bolt
22 Spring 42 Nut 51 O-ring
23 Sleeve 43 Rivet screw 52 O-ring
24 Orifice 44 Steel ball 53 O-ring
25 Wire 45 Steel ball 54 O-ring
26 Spring 46 Oil seal 55 O-ring
27 Lift spool 47 O-ring 56 O-ring
28 Spring holder 48 O-ring 57 O-ring
29 Spool 49 O-ring 58 O-ring
30 Gasket 50 O-ring 59 Socket head plug
6.16 MAST
When removing the mast and transporting it horizontally, secure

the fork carriage and lower stay of the outer mast with wire
before transporting.
Set wooden blocks under the mast and lay the mast assembly
horizontally with the fork carriage at the top.
6-89
6.16.1 SHIM ADJUSTMENT

1. Strip shim
a 0–0.5 mm
a. Adjust with shims so that when the main roller is pressed against the rail, dimen-
sion a=0–0.5 mm along the whole inner rail.
2. Outer main roller
b 0.5–1.0 mm
a. Insert the same shim thickness on the left and right to adjust so that clearance c between
the rounded portion of the roller and the rounded portion of the rail is 0.5–1.0 mm when
the rail is 0.5–1.0 mm when the rail is pushed against the roller.
3. Inner roller
c 0.5–1.0 mm
a. Insert the same shim thickness on the left and right to adjust so that clearance b between
the rounded portion of the roller and the rounded portion of the rail is 0.5–1.0 mm.
6-90
FORK CARRIAGE
4.10–ton truck upper roller.
a.No shim adjustment is needed for the upper
roller or lower roller on trucks other than the 10–
ton truck. (Held with snap ring).
5.Side roller
(10–ton only)
d 0.5–1.0 mm
a.Adjust with shims so that clearance d between the roller and rail is 0.5–1.0
mm at the highest point of the inner rail.
6.Side roller
(other than 10–ton)
e 0.5–1.0 mm
a.Adjust with shims so that clearance e

between the roller and rail is 0.5–1.0 mm at the
highest point of the inner rail.
7.Lower roller
(10 ton only)
f 0.5–1.0 mm
a.Insert the same thickness of shim on the left and right to adjust so that
clearance f between the rail and roller is 0.5–1.0 mm at maximum lifting
height.
6-91
6.16.2 ADJUST CHAIN

1. Chain length
a. Adjust with the chain stopper so that the bottom face of the
fork is 15 mm below the ground level when the forks are
lowered fully.
2. Tighten chain stopper locknut
torque 607.7–760lbf/ft (824–1030Nm)

{84–105 kgfm}
INSPECTION
in (mm)
Judgement standard
Inspection item Remedy
Clearance between outer Left–right 0.020–0.039 Within 0.118 (3.0) Adjust with
mast and inner mast (0.5–1.0) shim
Front–rear 0.020–0.039 Within 0.197 (5.0) Replace roller

(0.5–1.0)
Clearance between inner Left–right 0.020–0.039 Within 0.079 (2.0) Adjust with
mast and fork carriage (0.5–1.0) shim

(0.5–1.0)
Depth of busing oil groove at mast support 0.197 (5.0) There must be oil
portion groove
Fork thickness (root of fork) FD100 3.0 (75) Min. 2.8 (70)
FD115 3.0 (75) Min. 2.8 (70) Replace

FD135 3.2 (80) Min.3.0 (75)
FD150E 3.3 (85) Min. 3.2 (80)
FD160E 3.3 (85) Min. 3.2 (80)
6-92
Elongation of chain FD100 648 (25.5) Max. 660 (26.0)

(length of 17 links)
FD115 756 (29.8) Max. 770 (30.3)
FD135 756 (29.8) Max. 770 (30.3) Replace
FD150E 756 (29.8) Max. 770 (30.3)
FD160E 756 (29.8) Max. 770 (30.3)
6-93
6.17 TABLE OF SPECIAL TOOLS
Driving in differential pinion shaft oil seal Tightening differential adjusting screw nut
3ED-97-99590 34B-97-99110
Centering drive shaft Rotating differential ring gear
3EE-97-99110 3EB-97-99960
Measuring starting torque of front hub Tightening front axle lock nut
3ED-97-99570 308-968-9110
6-94
Measuring starting torque of differential pinion shaft Compressing clutch pack return spring
3ED-97-99600 3EC-97-99000
Inserting clutch pack piston Holding, tightening differential pinion shaft
a 3ED-97-99151 b 3ED-97-99180
3EC-97-99030
Driving in transmission output shaft bearing, oil seal Inserting steering valve leaf spring
3EE-97-99110 3BA-97-99220
Driving in bearing Assembling steering valve Y-packing
3EB-97-99210 3BA-97-99210
6-95
Driving in transmission F shaft, R shaft bearing 1st/2nd clutch ligting

Lifting tool 1
170
16 138 (16)
60
30
15
2-φ11 M16x2.0 or φ15
16
φ30
Lifting tool 2
15
3EE-97-99190 f11
6-96
6.18 TABLE OF SPECIAL TOOLS FOR POWER STEERING CYLINDER
1. Removing and installing bottom assembly screw 2. Press fitting dust wiper
Material: SS41
Material: SCM435
Heat treatment: Quenching, tempering
3. Piston inserting guide (for FD100) 4. Piston insertion guide (for FD115/135/150E)
1. There must be no burrs or flashes.

2. Finish with paper so that corner A joins smoothly. 1. There must be no burrs or flashes.
3. Remove any sharp edge from corner B. 2. Finish with paper so that corner A joins smoothly.
3. Remove any sharp edge from corner B.
Material: STKM12–13 or S45C
Material: STKM12–13 or S45C
6-97
5. Piston rod cap
Material: C3602, C3604
6. Caulking pin rod tip
Material: SK3
Heat treatment: Quenching, tempering
6-98
7. MAINTENANCE
STANDARD
7.1 ENGINE AND ELECTRICAL PARTS

For the engine and electrical maintenance standards, see Engine Shop Manual 6D107-BE1.
7.2 ACCELERATOR PEDAL
Symbol Inspection item New lift truck standard values
— Pedal pressing efforts 24.5 – 58.8 Nm {2.5 – 6.0 kgm}
— Pedal angle Neutral (a1) 45 ± 2
Maximum (a2) 17 ± 2
* Carry out inspection when starting engine.
7-2
7.3 SPEEDOMETER SENSOR (OPTION)
Speedometer sensor
Bracket
Front
axle
Parking brake drum
in (mm)
Judgement standard
Clearance between sensor and 0.059 (1.5)

drum.
a Screw in sensor and check that it
contacts drum lightly, then turn back
three turns and lock in position.
Replace
Tightening torque
1 Sensor locknut 36.1lbf/ft (49 Nm) {5.0 kgm}
2 Sensor bracket mounting bolt 72.3–90.7lbf/ft (98–123 Nm) {10.0–12.5 kgm}
7-3
7.4 LOCATION OF SWITCHES AND SENSORS

Combination switch
Forward / reverse lever (Turn signal switch and light switch)
Gearshift lever
1. Engine coolant temperature gauge 9. Lift Interlock warning lamp (option)
2. Hour meter 10. Engine warning lamp
3. Torque converter oil temperature gauge 11. Failure indicator
4. Fuel gauge 12. Air cleaner element warning lamp
5. Neutral indicator lamp / Travel interlock warning lamp 13. Radiator coolant level warning lamp
(option)
6. Parking brake warning lamp 14. Glow indicator
7. Charge warning lamp 15. Speedometer (option)
8. Operation indicator
7-4
Coolant level SW
Stop lamp SW Fuel level sensor
Air cleaner sensor
Coolant temperature
sensor
Speedometer sensor Accumulator low

(Option) Automatic T/M pressure SW T/C temperature sensor
(Option)
7-5
Parking brake SW
F/R SW Combination SW
H/L SW
Starting SW
Parking
brake SW
Parking brake SW
Dashboard
Automatic transmission SW
(Option)
Low pressure SW
T/C oil
temperature
sensor
To air cleaner
and sheet SW
Coolant level SW
Automatic transmission
Coolant
temperature
sensor
Top of engine
Rear of engine 9JL01917
7-6
7-7
in (mm)
Judgement standard
Symbol Inspection item
A Wear of pilot tip 0.985 (25) 0.979 (24.85)
B Inside diameter of pump boss 3.152 (80) 3.158 (80.15)

(seal ring contact surface)
C Seal ring Width 0.112–0.114 (2.83–2.9) 0.104 (2.65)
End gap when installed 0.002–0.010 (0.05–0.25) –
D Idler gear shaft mounting bolt 26–32.5lbf/ft (35.3–44.1 Nm) –

(tightening torque) {3.6–4.5 kgm}
E Stator shaft mounting bolt 49.9–57.9lbf/ft (67.7–78.5 Nm) –

(tightening torque) {6.9–8 kgm}
F Pump, drive cover mating bolt 20.3–24.6lbf/ft (27.5–33.3 Nm) –

G Pilot, flexible plate tightening bolt 26–32.5lbf/ft (35.3–44.1 Nm) –

– Max. engine speed (no load) 2,375–2,475 rpm
– Engine stall speed 2,000 rpm
– Torque converter pump relief pressure 196.3–239psi (1.35–1.65 MPa) {13.8–16.8 kgf/cm2}
(main pressure)
– Torque converter outlet port pressure 44.1–86.8psi (0.3–0.6 MPa) {3.1–6.1 kgf/cm2}
7-8
7.6 TORQFLOW TRANSMISSION

F / R / 1st / 2nd 196.3–239lbf/ft (1.35–1.65 MPa) {13.8–16.8 kgf/cm²}
Clutch actuating pressure
3rd 170.7–213.3lbf/ft (12.0–15.0 MPa) {12.2 – 15.3 kgf/cm²}
7-9
in (mm)
Judgement standard
Symbol Inspection item Standard Remedy
Repair limit
size
A Wear of pilot boss (tip) 0.985 (25) 0.979 (24.85)
B Pump boss inner diameter (seal ring contact surface) 3.152 (80) 3.158 (80.15)
C Seal ring Width 0.118 (3.0) 0.115 (2.93)
Thickness 0.126 (3.2) 0.097 (2.45)
D Stator shaft inner diameter (seal ring contact surface) 1.773 (45) 1.779 (45.15)
E Seal ring (4 points) Width 0.099 (2.5) 0.076 (1.93)
Thickness 0.079 (2.0) 0.060 (1.52)
F Converter inner diameter (seal ring contact surface) 1.379 (35) 1.385 (35.15) Replace
G Seal ring (5 points) Width 0.099 (2.5) 0.076 (1.93)
Thickness 0.079 (2.0) 0.060 (1.52)
H Clutch piston inner diameter 1.970 (50) 1.976 (50.15)
(piston ring contact surface) (4 points)
J Clutch piston inner diameter (piston ring contact 1.970 (50) 1.976 (50.15)
surface)
K Piston ring (5 points) Width 0.099 (2.5) 0.076 (1.93)
Thickness 0.079 (2.0) 0.060 (1.52)
7-10
7.7 TRANSMISSION CONTROL VALVE
Inching spool
7-11
in (mm)
Judgement standard
Regulator (1) Set value for relief pressure 217.6psi (1.5 MPa) –
valve (main pressure) {15.3 kgf/cm2}
(2) Clutch F/R 196.3–239psi –

actuating 1st / 2nd (1.35–1.65 MPa)
pressure {13.8–16.8 kgf/cm2}
3rd 173.5–217.6psi –
A (1.20–1.50 MPa)
{12.2–15.3 kgf/cm2}
(3) Inner valve of valve There must be no dents or uneven wear of

outside circumference, end face
(4) Valve mounting bolt 13.7–18.1lbf/ft –

(tightening torque) (18.6–24.5 Nm) {1.9–
2.5 kgm}
Inching (1) Outside diameter of spool (seal 0.7861–0.7866 –

valve contact portion) (19.967–19.98)
(2) Free length of valve spring 2.916 (74) –
(3) Installed length of valve spring 2.325 (59) –

B
(a) Protrusion of inching spool 0.965 (24.5) –
(when assembled)
(4) Valve base mounting bolt 13.7–18.1lbf/ft –

2.5 kgm}
Solenoid (1) Actuating voltage 24 V 22–26 V

valve
C (2) Mounting bolt 13.7–18.1lbf/ft –
2.5 kgm}
7-12
7.8 DRIVE SHAFT
Differential Mission
in (mm)
Judgement standard
A Misalignment of drive shaft 0.197 (5) 0.197 (5)
B Inside diameter of mating portion — —

of bearing and drive shaft
C Outside diameter, seal contact 2.758 (70) 2.754 (69.9) There must be
surface at joint boss no scratches
on contact
surface
D Outside diameter, seal contact 2.167 (55) 2.163 (54.9) There must be
surface at brake drum boss no scratches
on contact
surface
E (Tightening torque) 43.4–50.6lbf/ft —

Spider, bearing support (58.8–68.6 Nm)
mounting bolts {6–7 kgm}
7-13
7.9 DIFFERENTIAL
7-14
in (mm)
Judgement standard
A Differential Backlash 0.006–0.008 0.006–0.008

and pinion (0.15–0.2) (0.15–0.2)
B Outside diameter of spider, pin portrion 0.982–0.984 0.975 (24.75)

(24.929–24.98)
C Inside diameter of pinion gear 0.985–0.986 0.990 (25.12)

(25.0–25.021)
D Pinion gear Thickness of busing 0.060–0.066 0.051 (1.3)

(1.52–1.68)
Width x depth of busing 0.012–0.035 Depth: 0.028

oil groove (0.3 × 0.9) (0.7)
E Side gear Thickness of bushing 0.076–0.081 0.067 (1.7)

(1.94–2.06)
Width x depth of busing 4×1 Depth: 0.032

oil groove (0.158–0.039) (0.8)
F Differential Inside diameter of 2.362 (60 +0.030 ) 2.366 (60.05)

0
case side mating portion
gear boss
Width x depth of busing 4×1 Depth: 0.032
oil groove (0.157–0.039) (0.8)
G Outside diameter of differential case 2.953 (75 +0.030 ) 2.953 (75 +0.030 )
+0.011 +0.011
boss
H Backlash between bevel and pinion gear 0.0079–0.011 0.011 (0.28)

(0.2–0.28)
I Runout of rear face of bevel gear Max. 0.0039 Max. 0.0039

(0.1) (0.1)
J Outside diameter of drum boss portion, 2.165 (55) There must be no

seal contact surface scratches
K Inside diameter of parking brake drum 8.5–8.51 8.59 (218.2)

(216.0–216.2)
L Differential case tightening bolt 36.1–54.2lbf/ft (49–73.5 Nm) Coat thread

{5–7.5 kgm} with Loctite
M Bevel gear mounting bolt 115.8–144.6lbf/ft (157–196 Nm)

{16–20 kgm}
N Differential carrier support tightening bolt 253–314.9lbf/ft (343–427 Nm)

{35–43.5 kgm}
O Bevel pinion shaft case tightening bolt 72.3–90.7lbf/ft (98–123 Nm)

{10–12.5 kgm}
7-15
P Differential housing tightening bolt 180.7–227.9lbf/ft (245–309 Nm)

{25–31.5 kgm}
Q Parking brake drum tightening bolt 180.7–227.9lbf/ft (245–309 Nm) Coat thread
{25–31.5 kgm} with Locite
* Replace damaged gear, if any (replace the bevel gear and pinion gear in set).
7-16
7.10 FINAL DRIVE

7.10.1 HYDRAULIC DRUM BRAKE TYPE
in (mm)
Judgement standard
1 Inside diameter of housing, dowel pin 0.709 (18) 0.709 (18)

hole
2 Outside diameter of housing, dowel 0.709 (18) 0.709 (18))

pin
3 Outside diameter of mast support 6.698 (170) 6.698 (170))

mount
4 Outside diameter of housing, seal 7.683 (195) 7.683 (195)

retainer mating portion
5 Inside diameter of hub inner bearing 5.122 (130) 5.122 (130)

mating portion
6 Outside diameter of ring gear boss 5.516 (140) 5.516 (140)
7 Hub Outer diameter of inside 5.122 (130) 5.122 (130)

bearing waiting portion
Outer diameter of outside 7.683 (195) 7.683 (195)

bearing waiting portion
8 Inside diameter of drum, seal mating 9.062 (230) 9.062 (230)

portion
7-17
9 Inside diameter of drum inner 7.880 (200) 7.880 (200)

bearing mating portion
Hub
10 Inside diameter of drum outer 8.274 (210) 8.274 (210)
bearing mating portion
11 Starting torque of front hub 14.7–28.8lbf/ft (20–39 Nm)

{200–400 kgcm}
(Tightening torque)
12 Lock bolt (for hub nut) 43.4–54.2lbf/ft (58.8–73.5 Nm) Fix in

{6–7.5 kgm} position
(install cotter
pin)
13 Axle pipe connecting bolt 361.7–446.2lbf/ft (490.5–605 Nm)

{50–62 kgm}
14 Gear case mounting bolt 253–314.2lbf/ft (343–426.5 Nm)

{35–43.5 kgm}
15 Wheel clip nut 325.3–398lbf/ft (441.5–539.5 Nm)

{45–55 kgm}
7-18
7.10.2 WET DISC BRAKE TYPE
in (mm)
Judgement standard
1 Housing, dowel pin inside diameter 0.709 (18) 0.709 (18)
2 Housing, dowel pin outside diameter 0.709 (18) 0.709 (18)
3 Outside diameter, mast support 6.698 (170) 6.678 (169.5)

mounting base
4 Housing, outside diameter, seal 5.122 (130) —

retainer engaging portion
5 Hub Outside diameter, inner 7.880 (200) —

bearing engaging portion
6 Outside diameter, outer 8.274 (210) —

7 Seal retainer Inside diameter 130 (5.122) No flaw allowed
Outside diameter 170 (6.698) No flaw allowed

(seal contact face)
8 Hub Inside diameter, inner 5.122 (130) —

9 Inside diameter, outer 140 (5.516) —

7-19
10 Front hub starting torque 14.7–28.8lbf/ft (20 – 39 Nm) {200 – 400

kgcm}
(Tightening torque)
11 Lock bolt (for hub nut) See the part for Lock the bolt
disassembly and securely
assembly (Use a cotter pin)
12 Shaft tube joint bolt 361.7–446.2lbf/ft (490.5–605 Nm)

{50–62 kgm}
13 Gear case mount bolts 253–314.2lbf/ft (343–426.5 Nm)

{35–43.5 kgm}
14 Wheel clip nut 325.3–398lbf/ft (441.5–539.5 Nm)

{45–55 kgm}
15 Disc wear sensor mounting plug 8–10.8lbf/ft (10.8–14.7 Nm) {1.1–1.5 kgm}
7-20
7.11 REAR AXLE
in (mm)
Judgement standard
1 Axle king pin Hole inside diameter (bearing 2.835 (72–0.018 —

+0.012 )
boss engaging section)
2 Inner height 8.35 ± 0.008 (212 ± 0.2) 8.327 (211.5)
3 Height of knuckle king pin boss 6.89 ± 0.020 (175 ± 0.5) 6.850 (174)
4 Clearance for assembling axle king pin boss 0.004 – 0.012 (0.1 – 0.3) 0.020 (0.5)
and knuckle
5 PS cylinder, rod end, pin hole inside diameter 0.984 (25 +0.25 —
+0.05 )
6 PS cylinder link, pin hole inside diameter Upper 1.181 (30 +0.1 —
0 )
Lower 0.984 (25 +0.1

0 )
7 PS cylinder link, pin hole outside diameter 0.984 (25 –0.025 —

–0.048 )
8 Knuckle arm, pin hole inside diameter 1.968 (50 –0.008 —

–0.003 )
9 Axle center pin outside diameter 3.150 (80 –0.060 3.130 (79.5)
–0.106 )
* Tire operating angle (adjusted using the 76° ± 30’

stopper bolt)
10 Rear hub starting torque 5–7.2lbf/ft (7 – 10 Nm) {0.7 – 1.0 kgm}
(Tightening torque)
7-21
* Center pin, support mounting bolts 361.7– 448.4lbf/ft (490–608 Nm)

{50 – 62 kgm}
11 Steering cylinder mounting bolt 542.5–610.5lbf/ft (735.5 – 828.5 Nm)

(Loctite application) {75 – 84.5 kgm}
12 Wheel clip nut 325.5–397.8lbf/ft (441.5 – 539.5 Nm)

{45 – 55 kgm}
7-22
7.12 STEERING
2°
2°
65°
in (mm)
Judgement standard
Steering wheel play (when idling) 1.182–2.364 1.182–2.364

(30–60) (30–60)
Steering wheel tilt angle 2° 2°
Steering wheel lock lever, lock 65° 65°

angle
Operating effort of steering wheel 2.2lbf (9.8 N)

(at knob) {1.0 kgf}
Set pressure of FD100/115 1850psi (12.7 MPa) {130 kgf/cm2}

hydraulic relief
valve FD135–160E 2134psi (14.7 MPa) {150 kgf/cm2}
7-23
7.13 FRAME
in (mm)
Judgement standard
A Inside dimension between rear 14.18 (360) 14.38 (365)

axle and center support
B Size of center support bushing 3.15 × 3.66 × 3.15 (80 × 93 × 80)

inside diameter x outside
diameter x length
(Tightening torque)
1 Front axle mounting bolt 1446–1808lbf/ft (1961–2452 Nm) {200–250 Coat with
kgm} Loctite #271
2 Center support 361–448lbf/ft (490–608 Nm) {50–62 kgm}

Rear mounting bolt (F)
3 axle Center support 361–448lbf/ft (490–608 Nm) {50–62 kgm}

mounting bolt (R)
4 Counterweight mounting bolt 723–1012lbf/ft (980.5–1373 Nm) {100–140

kgm}
7-24
7.14 BRAKE PEDAL

in (mm)
Judgement standard
(Brake)
A Brake pedal height (when free) 9.1 (231) —
B Brake stroke 3.0 (76) —
D Inching stroke 3.3 (83) —
E Interlocking point with the 1.97 (50) —

inching brake pedal
(Brake oil pressure)
Set pressure of relief valve See Priority Valve
Oil leakage from oil circuit and Operate brake valve and check that there
connections is no leakage or oozing of oil from brake
piping or connections
(Brake, inching pedal)
Pedal anchor bushing (outside 1.02 × 0.79 × 0.79 (26 × 20 × 20)

diameter x inside diameter x
width)
Inching rod link lever bushing 0.63 × 0.55 × 0.79 (16 × 14 × 20)
(outside diameter x inside
diameter x width)
Small collar for brake valve link 0.51 × 0.41 × 0.59 (12.9 × 10.5 × 15)
diameter x width)
Large collar for brake valve link 0.51 × 0.41 × 1.14 (12.9 × 10.5 × 29)
diameter x width)
7-25
(Brake piping)
Joints of elbows, nipples, etc. Apply gasket sealant
Tightening 8 {0.315 in} 10.8–25.3lbf/ft (14.7–34.3 Nm) {1.5–3.5

torque of kgm}
respective
sleeve nuts for 10 {0.394 in} 14.5–32.5lbf/ft (19.6–44.1 Nm) {2.0–4.5
brake pipe kgm}
12 {0.472 in} 36.2–50.6lbf/ft (49–68.6 Nm) {5.0–7.0

kgm}
7-26
in (mm)
Judgement standard
(BRAKE)
A Brake pedal height (when free) 9.1 (231) —
B Brake stroke 1.85 (47) —
C Height of pedal when depressed Approx. 2.56 (65) —
D Inching stroke 2.96 (75) —
E Interlocking point with the inching brake 1.12 – 1.32 (28.5 – 33.5) —
pedal
Leakage from joints Each joint shall have no oil smear or leakage upon
applying brake.
(Brake inching pedal)
Pedal anchor bushing (outside diameter × 1.02 × 0.79 × 0.79 (26 × 20 × 20)
inside diameter × width)
Inching rod link lever bushing (outside 0.63 × 0.55 × 0.79 (16 × 14 × 20)
diameter × inside diameter × width)
(Brake piping)
Joints of elbows, nipples, etc. Apply gasket sealant
7-27
Tightening torque of 8 mm 10.8–25.3lbf/ft (14.7–34.3 Nm) {1.5–3.5 kgm}

respective sleeve nuts for
brake pipe 10 mm 14.5–32.5lbf/ft (19.6–44.1 Nm) {2.0–4.5 kgm}
12 mm 36.1–50.6lbf/ft (48–68.6 Nm) {5.0–7.0 kgm}
Pipe outside
4.76 6.35 8 10 12 15
diameter (mm)
lbf/ft 9.4 – 13 11.6 – 17.4 21.7 – 28.9 28.9 – 36.2 43.4 – 57.9 50.6 – 68.7
Tightening
Nm 12.7 – 17.6 15.7 – 23.5 29.4 – 39.2 39.2 – 49.0 58.8 – 78.4 68.6 – 93.1
torque
{kgm} 1.3 – 1.8 1.6 – 2.4 3.0 – 4.0 4.0 – 5.0 6.0 – 8.0 7.0 – 9.5
7-28
7.15 BRAKE VALVE

7-29
in (mm)
Judgement standard
Standard size Repair Limit
A Clearance between input piston – 0.006 (0.16)

and diameter of body mating
portion
B Clearance between spool and – 0.001 (0.032)

diameter of body mating portion
C Clearance between reaction – 0.006 (0.16)

piston and diameter of guide
mating portion
D Piston, spool sliding surface of – If there is damage,

body uneven wear, rust
E Input piston outside diameter –

sliding surface
F Reaction piston outside diameter –

sliding surface
G Spool outside diameter sliding – Replace

surface
H Reaction piston sliding surface of –

guide
I Reaction piston spring dimension 0 0

a (a in diagram below)
J Deterioration of spring J1 – 0.926 (23.5)

(free length)
J2 – 0.788 (20)
7-30
in (mm)
Criterion
Tolerance
Reference dimmensions
No. Inspection item limit Action
Mounting
Free length Mounting load Free length
length
1 (*) Control spring 1.340 (340) 1.320 (33.5) 0.86lbf (3.82 N) —

{0.39 kgf}
2 Control spring 1.824 (46.3) 1.812 (46) 2.87lbf (12.8 N) —

{1.3 kgf}
Replacement
3 Return spring 3.396 (86.2) 2.285 (58) 13.7lbf (60.8 N) —
{6.2 kgf}
4 Return spring 1.241 (31.5) 0.768 (19.5) 3.75lbf (16.7 N) —

{1.70 kgf}
* FD100 to 135 are not installed with the control spring (1).
7-31
7.16 FRONT BRAKE

FD 100, 115
in (mm)
Judgement standard
A Inside diameter of drum 15.49–15.51 (393.5–393.9) 15.61 (396.5)
B Thickness of lining 0.5 (12.7) 0.22 (5.5)
C Inside diameter of wheel cylinder 1.626 (41.3) There must be no scratches
D Outside diameter of piston – on sliding surface
E Outside diameter of piston cup – There must be no scratches
or deterioration
F Clearance between piston and 0.00098–0.0049 (0.025–0.126) 0.00098–0.0049
cylinder (0.025–0.126)
G Strength of return spring 72.7 ± 7.2lbf (324 ± 32.4 N) 72.7 ± 7.2lbf (324 ± 32.4 N)
( = 103.5 mm) {33 ± 3.3 kgf} {33 ± 3.3 kgf}
Free length of return spring 3.66 (93) 3.66 (93)
(reference)
(Tightening torque)
H Hub plate tightening bolts, nuts 180.8–227.8lbf/ft (245–309 Nm) —
(x 6) {25–31.5 kgm}
I Wheel cylinder tightening bolt 27.5–36.2lbf/ft (37.29–49.03 Nm) —
{3.8–5.0 kgcm}
7-32
FD135, 150E, 160E
in (mm)
Judgement standard
A Inside diameter of drum 17.24 (438) 17.32 (440)
B Thickness of lining 0.5 (12.7) 0.22 (5.5)
C Inside diameter of wheel cylinder 1.875 (47.62) There must be no

scratches on sliding surface
D Outside diameter of piston
E Outside diameter of piston cup There must be no

scratches or deterioration
F Clearance between piston and 0.0010–0.005 (0.025–0.126) 0.0010–0.005 (0.025–

cylinder 0.126)
G Strength of return spring 1 110 ± 11lbf (490 ± 49 N) 110 ± 11lbf (490 ± 49 N)

{50 ± 5 kgf} ( = 7 (178)) {50 ± 5 kgf} ( = 7 (178))
Free length of return spring 6.67 (169.5) 6.67 (169.5)

(reference)
H Strength of return spring 2 92.6 ± 9.3lbf (412 ± 39 N) {42 ± 4 92.6 ± 9.3lbf (412 ± 39 N)
kgf} ( = 6.26 (159)) {42 ± 4 kgf}
( = 6.26 (159))
Free length of return spring 5.83 (148) 5.83 (148)

(reference)
I Inside diameter of dowel pin hole 0.551 (14) 0.551 (14)
J Outside diameter of dowel pin 0.551 (14) 0.551 (14)
(Tightening torque)
K Back plate tightening bolts, nuts 72.3–90.4lbf/ft (98–123 Nm) —

(x 6) {10–12.5 kgm}
L Wheel cylinder tightening bolt 13–19.5lbf/ft (17.65–26.46 Nm) —

{1.8–2.7 kgm}
7-33
in (mm)
Criterion
Inspection
Symbol Remedy
item Reference
Tolerance Tolerance limit
dimensions
A Plate 0.095 (2.4) 0.091 – 0.099 (2.3 – 2.5) 0.087 (2.2)
B Disc thickness 0.201 (5.1) 0.197 – 0.205 (5.0 – 5.2) 0.181 (4.6)
Depth of lining 0.020 (0.5) (min) — 0.010 (0.25)

groove
Lining thickness 0.039 (1) 0.024 (0.6) (min) — Replace
C Spring load Reference dimensions Tolerance limit
Mounting height Mounting load Mounting load

lbf/ft (N {kgf}) lbf/ft (N {kgf})
2.39 (60.7) 102.7 (456.7) {46.6} 92.4 (411.0) {41.9}
7-34
7.17 PARKING BRAKE
in (mm)
Judgement standard
Inspection item
Lining thickness 0.215 (5.45) 0.130 (3.3)
Shoe return spring Strength 34.2lbf (152 N) {15.5 kgf} 30.9lbf (137 N) {14 kgf}
( = 1.97 (50)) ( = 1.97 (50))
Free length 2.15 (54.7)
Clearance between drum and lining 0.0039–0.0098 (0.1–0.25)

After bringing lining into tight contact with drum,
turn adjuster back 11 notches to adjust
clearance to 0.0098 (0.25)
Max. operating effort of parking lever (at center 44.1lbf (196 N) {20 kgf}
of grip)
7-35
7.18 CONTROL VALVE
Measure control valve relief pressure

1. Remove the plug (control valve body, left side) and install a pressure gauge.
2. Raise the forks to the maximum lifting height, and measure the oil pressure when the circuit is relieved.
Relief pressure 3129 psi (21.6 MPa) {220 kgf/cm2}
in (mm)
Judgement standard
A Return spring Free length 2.25 (57) 2.16 (55)

(20)
Installed length 1.41 (35.8) –
Install load 37.3 lbf (165 N) 33–41.9 lbf (147–186 N)

{16.9 kgf} {15–19 kgf}
B Tilt lock spring Free length 2.76 (70) 2.64 (67)

(13)
Installed length 2.52 (64) –
Replace
Install load 11 lbf (49 N) {5 kgf} 9.9–12.1 lbf (44–53 N)
{4.5–5.5 kgf}
C Check valve Free length 1.89 (48) 1.73 (44)

(2) spring
Installed length 1.60 (40.8) –
Install load 2.2 lbf (9.8 N) 2–2.4 lbf (8.8–10.7 N)

{1 kgf} {0.9–1.1 kgf}
7-36
TOP SURFACE OF CONTROL VALVE
Judgement standard
Standard size
(tightening torque)
31 Coat thread of spool return set bolt with Locite #242. 18.1–25.3lbf/ft (25–34.3 Nm)
{2.5–3.5 kgm}
4 Return spring cover mounting bolt 25.3–32.5lbf/ft (35–44.1 Nm)

{3.5–4.5 kgm
12 Coat tightening thread of tilt spool head with Loctite #242. 18.1–25.3lbf/ft (25–34.3 Nm)
{2.5–3.5 kgm}
45 Tightening of relief valve assembly 39.1–47.7lbf/ft (53.0–64.7 Nm)

{5.4–6.6 kgm}
14 Tightening of sleeve (top of relief V) 58.6–71.6lbf/ft (79.4–97.0 Nm)

{8.1–9.9 kgm}
43 Plug of load check valve 58.6–71.6lbf/ft (79.4–97.0 Nm)

{8.1–9.9 kgm}
Nipple (return pipe) mounting bolt 25.3–32.5lbf/ft (35–44.1 Nm)

{3.5–4.5 kgm
7-37
Tightening of plug (nominal 27) 45.6–55.7lbf/ft (62–75.5 Nm)

{6.3–7.7 kgm}
(hexagonal socket 6 18.1–25.3lbf/ft (25–34.3 Nm)

mm) {2.5–3.5 kgm}
(hexagonal socket 5 9.4–12.3lbf/ft (13.0–16.7 Nm)

mm) {1.3–1.7 kgm}
Operating effort of control Lift RAISE 4.9lbf (22 N) {2.2 kgf}

15 lever
Lift LOWER 4.9lbf (22 N) {2.2 kgf}
Tilt back 4.9lbf (22 N) {2.2 kgf}
Tilt forward 4.9lbf (22 N) {2.2 kgf}
Stroke of control lever Forward Backward
Lift lever 4.96 (126) 4.96 (126)
Tilt lever 5.12 (130) 5.12 (130)
7-38
7.19 PRIORITY VALVE
1 12
7
7
11
10
9
8
6
5
4
3
2
16 : Standard
16
15 16
14
13
or
18
16
19 20 : For Dynamic signal
Set pressure
FD100/115 1850 psi (12.7 MPa) {130 kgf/cm²}
FD135/150E/160E 2133 psi (14.7 MPa) {150 kgf/cm²}
7-39
7.20 LIFT CYLINDER
(Lifting height: 118 in (3m))
FD135/
Item Unit FD100 FD115 160E
150E
Cylinder (inside diameter x in (mm) 3.74 x 4.33 3.93 x 4.45 4.33 x 4.88 4.72 x 5.35
outside diameter) (95 × 110) (100 × 113) (110 × 124) (120 × 136)
Stroke in (mm) 59.4 (1510)
Outside diameter of rod in (mm) 2.56 (65) 2.75 (70) 2.95 (75)
Weight lb (kg) 187.4 (85) 198.4 (90) 231.5 (105) 242.5 (110)
mm (in)
Judgement standard
A Clearance FD100 0.004–0.014 0.026 (0.666)

between (0.097–0.366)
piston rod and Replace bushing
bushing FD115/135/ 0.004–0.016 0.027 (0.695)
150E/160E (0.107–0.395)
B Piston rod Scratches that catch finger nail, dents,

hollows
Replace
(Tightening torque)
E Cylinder head FD100 488–597lbf/ft (662–808 Nm)

{67.5–82.5 kgm}
FD115 521–636lbf/ft (706–862 Nm) {72–88 kgm}
FD135–150E 618–756lbf/ft (838–1024 Nm)

{85.5–104.5 kgm}
FD160E 651–796lbf/ft (882–1078 Nm)

{90–110 kgm}
7-40
7.21 TILT CYLINDER
(Lifting height: 118in (3 m))
Cylinder (inside diameter x outside diameter) in (mm) 4.92 x 5.59 (125 × 142)
Stroke of rod in (mm) 9.45 (240)
Outside diameter of rod in (mm) 2.36 (60)
in (mm)
Judgement standard
A Clearance between piston rod 0.001–0.011 (0.036–0.267) 0.022 (0.567)

and bushing
B Piston rod Scratches that catch finger nail, dents, hollows Replace
Tightening torque
E Rod head locknut 709–890lbf/ft (98–123 Nm) {10.0–12.5 kgm}
F Set bolt for rod head mounting 709–890lbf/ft (98–123 Nm) {10.0–12.5 kgm}
pin
G Set bolt for cylinder bottom 709–890lbf/ft (98–123 Nm) {10.0–12.5 kgm}
mounting pin
H Tightening of cylinder head 672–819lbf/ft (910–1110 Nm) {93–113.3 kgm}
7-41
7.22 POWER STEERING CYLINDER
(Lifting height: 118in (3 m))
Item Unit FD100–FD115 FD135–FD160E
Cylinder (inside diameter x outside in (mm) 3.54 x 4.02 (90 × 102) 3.94 x 4.53 (100 × 115)
diameter)
Stroke in (mm) 12.28 (312) 12.28 (312)
Outside diameter of rod in (mm) 2.36 (60) 2.76 (70)
in (mm)
Judgement standard
A Clearance between cylinder 0.002–0.010 0.016 (0.4)

and piston (0.05–0.25)
B Clearance between piston rod 0.001–0.007 0.012 (0.3)

and bushing (0.03–0.18)
Replace
C Piston ring Scratches that catch finger nail, dents, streaks,
hollows
D Inside surface of cylinder Scratches that catch finger nail, dents, streaks,
hollows
(Tightening torque)
1 Tightening of Cylinder head 325–398lbf/ft (441–539 Nm) {45–55 kgm} Coat thread
with Loctite
2 Cylinder mounting bolt (rear 542–611lbf/ft (735.5–828.5 Nm) {75–84.5 kgm}

axle)
7-42
7.23 WORK EQUIPMENT

7.23.1 ADJUST CHAIN LENGTH
1. Adjust with the chain stopper so that the bottom face of the fork is 0.6 in (15 mm) below the ground level when
the forks are lowered fully.
Tightening torque for chain stopper locknut
torque 607–759lbf/ft (824–1030 Nm)

{84–105 kgm}
Tightening torque for mast support cap mounting bolt
torque 607–759lbf/ft (824–1030 Nm)

{84–105 kgm}
7-43
mm (in)
Judgement standard
Inspection item Remedy
Clearance between outer mast Left–right 0.020–0.039 Within 0.118 (3.0) Adjust with shim
and inner mast (0.5–1.0)

(0.5–1.0)
Clearance between inner mast Left–right 0.020–0.039 Within 0.079 (2.0) Adjust with shim
and fork carriage (0.5–1.0)

(0.5–1.0)
Clearance between side roller and rail 0.020–0.039 Within 0.118 (3.0) Adjust with shim
(0.5–1.0)
Depth of bushing oil groove at mast support 0.197 (5.0) There must be oil
portion groove
Fork thickness (root of fork) FD100 3.0 (75) Min. 2.8 (70) Replace
FD115 3.0 (75) Min. 2.8 (70)
FD135 3.2 (80) Min. 3.0 (75)
FD150E 3.3 (85) Min. 3.2 (80)
FD160E 3.3 (85) Min. 3.2 (80)
Elongation of chain FD100 25.5 (648) Max. 26.0 (660)

(length of 17 links)
FD115 29.8 (756) Max. 30.3 (770)
FD135 29.8 (756) Max. 30.3 (770)
FD150E 29.8 (756) Max. 30.3 (770)
FD160E 29.8 (756) Max. 30.3 (770)
7-44
8. STRUCTURE AND
FUNCTION
8.1 POWER TRAIN DIAGRAM

8-2
Engine
Torque converter
Transmission
Front wheel Drive shaft
Parking brake
Reduction gear
(No. 2)
Main brake Differential Reduction gear

(No. 1)
8-3

8.2.1 PTO DRIVE
A PTO drive is installed to the torque converter to drive the torque converter charging pump, power steering pump,
and hydraulic pump.
TORQUE CONVERTER COOLER

The torque converter cooler is built into the radiator.
PTO gear
Item Unit Okamura Ltd.
Type – MN 16
Structure – 3 elements, 1 stage and 2 phases
Stall torque ratio – 2.51 ± 0.15
Stall speed rpm 2,000
Oil pressure inside Inlet oil pressure psi (MPa) 152–196psi (1.05–1.35) {10.7–13.8}
torque converter {kg/cm2}
Outlet oil pressure 0.3–0.6 {3.1–6.1}
8-4
8.3 TORQFLOW TRANSMISSION (1/3)
No. 1 shaft Input shaft with F/R clutch pack
No. 2 shaft Shaft with 1st/2nd clutch pack
No. 3 shaft Output shaft with 3rd clutch pack
Torque converter case
No. 1 shaft
No. 2 shaft
No. 3 shaft
Structure Wet, multiple disc clutch, hydraulic type
Reduction ratio F1: 1.795 F2: 0.757 F3: 0.457

R1: 1.777 R2: 0.749 R3: 0.452
Clutch actuating pressure F/R 196–239psi (1.35–1.65 MPa) {13.8–16.8 kgf/cm2}

1st / 2nd
3rd 173.5–217.6psi (1.20–1.50 MPa) {12.2–15.3 kgf/cm2}
Oil capacity 29.6–33.8qt (28–32l)

(including torque converter, cooler and pipes)
8-5
Idller gear
R F
Input shaft
1st-2nd shaft
1ST 2ND
Output shaft
3RD
(Transmission case) (Torque converter case)
8-6

Regulator valve relief pressure: 1.96 MPa {20 kgf/cm2}
From line filter

1, 2, 3 speed
pressure port
Main pressure
measurement port
T/C oil pressure

measurement port
F/R clutch pressure port To cooler

Eye bolt From cooler
Inching spool
Drain plug Oil temperature gauge
8-7
8.5.1 HYDRAULIC CIRCUIT (OUTLINE)

1. When the engine is started, the charging pump is driven to intake and deliver oil to and from the transmission
case via strainer.
2. Oil discharged from the gear pump is examined by the main regulator valve via line filters and then fills the
accumulator.
3. When the solenoid valve switches the circuit to forward or rear travel (each in 1st to 3rd speed), oil inside the
accumulator is fed to the hydraulic clutch circuit.
4. After the clutch is operated, the oil on the side of hydraulic circuit flows in to the clutch side while filling the
accumulator. This raises the pressure in the clutch gradually, realizing smooth power transfer.
5. Throttle valve is provided at the entrance to the torque converter and the torque converter regulator valve at
the exit to control the pressure rise in the torque converter to 0.73 MPa {7.4 kgf/cm²} maximum.
6. Oil cooled with the oil cooler is fed to inside the transmission to lubricate and cool individual components. It
then returns to the transmission case. (See the hydraulic circuit diagram in the next page onward.)
8.5.2 MECHANISM OF CLUTCH OPERATION

DURING MANUAL SHIFT TRANSMISSION
1. When the lever is set to forward or reverse 1st speed, the solenoid valves for F or R and 1st speed are turned
ON and the oil pressure works on the forward or reverse travel and the 1st speed clutch.
2. When F/R lever is set to forward or reverse travel and the 2nd speed, the solenoid valve for F or R is turned
ON, and the oil pressure works for the forward or reverse travel. As to 2nd speed clutch, oil pressure works for
forward or reverse travel clutch in 2nd speed via the solenoid valves for 1st and 3rd speed (in OFF state).
3. When the lever is set to forward or reverse 3rd speed, the solenoid valves for F or R and 3rd speed are turned
ON and the oil pressure works on the forward or reverse travel and the 3rd speed clutch.
(See the hydraulic circuit diagram on the next page.)
8-8

1.5 MPa {15.3 kg/cm²}
F/R
pressure
Line filter pick-up port
Oil tempera- Oil
regulator valve
0.45 ± 0.15 MPa
Inching
valve
Solenoid valve Accumulator
for F/R for speed
8-9
HYDRAULIC CIRCUIT DIAGRAM
Solenoid valve for

pick-up port
Solenoid valve for

2nd/3rd speed
Strainer
1st 2nd 3rd F R

FWD-REV VALVE
8.6 INCHING VALVE

This is interconnected with the pedal, and controls the oil pressure to the multiple disc clutch according to the
amount that the pedal is depressed.
Full stroke
F/R clutch pressure port
Inching spool
Protrusion
8-10
8.7 AUTOMATIC TRANSMISSION (OPTION)

Automatic transmission automatically changes gear for forward or reverse travel through microcomputer control.
This relieves operator from tedious operation during gearshift, enabling him/her to concentrate to work equipment
operation. In addition, newly developed controller and 3-shift forward-reverse transmission provide optimal speed
through automatic gear shift.
8.7.1 BASIC SYSTEM CONFIGURATION
F/R lever
H/L lever
1st F clutch
3rd
Auto/Manual Inching R clutch
Controller SW valve
1st clutch
3rd clutch
Power
Adjustment cut relay
volume 3rd 2nd clutch
Vehicle speed
Input pulse
Truble
Speed detecter
sensor F/R
ACC fuse cut relay
Speed can be shifted using the volume switch. Troubleshooting function provides ease of servicing.
Controller mounting location LED indicator for monitoring
Monitoring LED (green)
Volume switch
Controller
Monitoring LED (red)
8-11
8.7.2 AUTO/MANUAL SELECTOR SWITCH

The switch for selecting automatic or manual transmission
Pushing the switch downward changes transmission to automatic, and upward to manual transmission using the
lever for 1st, 2nd and 3rd speed.
MANUAL
AUTO
TROUBLE INDICATOR
If any abnormality occurs to the automatic transmission system, requiring inspection and maintenance service, the
red and green LED in the monitor LED indicator on the bottom of the controller flashes and informs the content of
trouble with the flashing pattern.
In such a state, stop the engine, return the shift lever to neutral position and re-start the engine. The controller then
resets the abnormality to enable operation.
If LED persists flashing after resetting the system, the trouble may be caused by any machine problem. See
TROUBLESHOOTING TABLE for appropriate repair.
• Select forward-reverse travel after the machine comes to complete stop.

• During high speed travel on AUTO mode, do not select the 1st speed fixing position.
• For safety purpose, shifting the gear down to 1st speed is disabled when travel at 9 km/h or higher.
• When welding the machine body, remove the controller in advance. Or the controller may be damaged
by the current during welding.
• Never splash the controller, resistor and other electrical parts with strong water current during steam
washing.
8-12
TROUBLESHOOTING TABLE
Trouble indicator
(LED)
Content of Truck body Resetting
Repair Method
Number trouble behavior method
Color of LED
flashing
Red One time 1st speed solenoid Disabled to travel Check the 1st speed Reset by turning
in short circuit solenoid and replace it. key switch
Red Two times 3rd speed solenoid Disabled to travel Check the 3rd speed Reset by turning
in short circuit solenoid and replace it. key switch
Red Three 1st speed solenoid Disabled to travel Check the controller and Reset by turning
times drive of the replace it. key switch
controller in short
circuit
1st speed solenoid Holding 2nd Check the controller and

drive of the speed replace it.
controller is open.
Red Four times 3rd speed solenoid Disabled to travel Check the controller and Reset by turning
drive of the replace it. key switch
controller in short
circuit
3rd speed solenoid Holding 2nd Check the controller and

drive of the speed replace it.
controller is open.
Red Five times Power supply cut Holding 2nd Check the short circuit Reset by turning
relay contact in speed and replace the power key switch
short circuit supply cut relay contact.
F/R cut relay Check the short circuit

contact in short and replace the F/R cut
circuit relay contact.
Power supply cut Check the grounding

relay solenoid and replace the power
grounded supply cut relay
solenoid.
F/R cut relay Check the grounding

solenoid grounded and replace the F/R cut
relay solenoid.
Relay drive Check the controller and

transistor in short replace it.
circuit
Red Six times Shift lever (H-L Gear shift holding Check the short circuit Reset by turning
switch) contacts and replace the shift key switch
turn ON lever (H-L switch)
simultaneously. contact.
8-13
Trouble indicator
(LED)
Repair Method
Color of LED
flashing
Red Seven 1st speed solenoid Disabled to travel Check the opening and Reset by turning
times harness is open. replace the 1st speed key switch
solenoid harness.
1st speed solenoid Check the opening and

is open. replace the 1st speed
solenoid.
1st speed solenoid Check the grounding

is grounded. and replace the 1st
speed solenoid.
Power supply cut Check the opening and

relay is grounded replace the power
and open. supply cut relay contact.
F/R cut relay Check the opening and

contact is open. replace the F/R cut relay
contact.

relay solenoid is replace the power
open. supply cut relay
solenoid.
F/R cut relay Check the opening and

solenoid is open. replace the F/R cut relay
solenoid.
Relay drive Check the controller and

transistor is open. replace it.
8-14
Trouble indicator
(LED)
Repair Method
Color of LED
flashing
Check the opening and

3rd speed solenoid
replace the 3rd speed
harness is open.
solenoid harness.

3rd speed solenoid is
open.
solenoid.
Check the grounding and

3rd speed solenoid is
grounded.
solenoid.

Power supply cut
replace the power supply
relay contact is open. Reset by turning
Red Eight times Disabled to travel cut relay contact.
key switch
F/R cut relay contact
replace the F/R cut relay
is open.
contact.

relay solenoid is replace the power supply
open. cut relay solenoid.

F/R cut relay sole-
replace the F/R cut relay
noid is open.
solenoid.
Relay drive transistor Check the controller and

is open. replace it.

Travel speed sensor
replace the travel speed
is open.
sensor.
Check the short circuit and

Travel speed sensor
in short circuit
sensor.
Red Nine times Gear shift holding
Travel speed sensor
harness is open.
sensor harness.
Travel speed sensor Check the short circuit and

harness in short cir- replace the travel speed
cuit sensor harness.
Check the controller and

Green ON Defective controller Disabled to travel
replace it.
8-15
Trouble indicator
(LED)
Repair Method
Color of LED
flashing
Trouble indicator lamp (red LED) flashes as follows:

1 CYCLE 3.0 SEC
0.5 0.5
LIST OF TROUBLES NOT DETECTABLE BY THE TROUBLESHOOTING FUNCTION
Truck body
No. Content of trouble Repair method
behavior
1 1 Controller power supply line is Disabled to travel 1 Check the power line and replace the
open. harness.
2 Defective controller 2 Check the controller and replace it.
2 1 F/R switch power supply line is Disabled to travel 1 Check the F/R switch and replace it.
open or grounded.
2 F/R switch is open. 2 Check the truck body harness and

replace it.
3 Flown fuse 3 Check the fuse and replace it.
4 F or R solenoid in short circuit 4 Check the F or R solenoid and replace

it.
3 1 F solenoid is open. Disabled to travel 1 Check the F solenoid and replace it.
forward
2 F switch signal line is 2 Check the F switch signal line and
disconnected. replace the harness.
3 F switch contact is open. 3 Check the F/R switch and replace it.
4 1 R solenoid is open. Disabled to travel 1 Check the R solenoid and replace it.
reverse
2 R switch signal line is 2 Check the R switch signal line and
3 R switch contact is open. 3 Check the F/R switch and replace it.
5 1 F switch contact is open. 1st speed 1 Check the shift lever (H-L switch) and
holding not replace it.
functioning
2 F switch signal line is 2 Check the F switch signal line and
8-16
Truck body
No. Content of trouble Repair method
behavior
6 1 F switch contact is open. Disabled to shift 1 Check the shift lever (H-L switch) and
to 3rd speed replace it.
2 F switch contact line is 2 Check the F switch signal line and

7 1 AUTO/MANUAL switch Automatic or 1 Check the AUTO/MANUAL switch and

abnormal manual replace it.
transmission
function is
disabled.
8 1 Adjustment volume switch is Gear shift speed 1 Check the correction volume switch
open. does change and replace it.
when the volume
2 Adjustment volume switch (5 switch is turned. 2 Check the power supply short circuit of
V) in short circuit the correction volume switch and
replace the volume switch.
3 Adjustment volume switch is 3 Check the grounding of correction

grounded. volume switch and replace it.
4 Adjustment volume switch 4 Check the opening and replace the

harness is open. volume harness
Remarks For repair method, implement measures in

the order of the descriptions.
8-17
8.8 DRIVE AXLE

1. Differential
Item Unit FD100/115 FD135–160E
Reduction gear type – Hypoid bevel gear
Reduction ratio – 4,375
Outside diameter of torque shaft mm 42 42
Oil capacity (including final drive) 20 20
2. Final Drive
Item Unit FD100/115 FD135–160E
Type – Fixed single shaft full–floating type
Reduction gear type – Planetary gear type
Reduction ratio – 5.4 5.4
Tread mm 1700 1770
8-18
8.9 STEERING AXLE

This has a thick steel plate welded integrated structure with a built–in 2–rod type power steering cylinder.
Specifications
Item FD100 FD115–150E FD160E
Type Center pin support, Center pin support, Center pin support,
single–shaft type single–shaft type single–shaft type
Structure of knuckle Elliot type Elliot type Elliot type
Alignment None None None
Swing angle 5° 5° 5°
Tire turning angle (inside) 76° ± 30’ 76° ± 30’ 76° ± 30’
Tire turning angle (outside) 53° 53° 53°
Tread 1900 mm 1890 mm 1870 mm
8-19
8.10 STEERING SYSTEM

Full hydraulic power steering (FHPS)
Compared with semi–integral power steering, full hydraulic power steering is superior in straight travel stability,
there is no kick back, and it is also easier to carry out inspection and maintenance.
STEERING VALVE
Structure
Power steering system using full hydraulic power steering basically consist of a hydraulic pump, full hydraulic
power steering body, and power steering cylinder.
The internal structure of the full hydraulic power steering body can be divided into the control valve and metering
device. The control valve consists of the No. 1 rotating valve (called the spool), and the No. 2 rotating valve (called
the sleeve). The metering device consists of a special gear set called a Gerotor.
In addition, a feedback link is installed to provide feedback of the metering flow in the metering device to the control
valve.
Model FD100-160E
Discharge 230 cc/rev
Relief pressure 12.7 MPa {130 kg/cm2}
Inlet flow 22.7 /min
Valve Open center non–reaction

characteristic type
8-20
PRINCIPLE OF OPERATION
At Neutral
The pressure oil entering pump port (P) of the power steering
from the hydraulic pump passes through passage (11), goes
through spool groove (15) and passage (14), then returns to the
oil tank from tank port (T).
When this happens, cylinder port (R) is blocked inside the
sleeve, so the power steering cylinder is kept in the same
condition and the machine travels in a straight line or at the set
turning angle.
Turning Right
When the steering wheel is turned to the right, the spool also
rotates to the right and an oil passage is formed between the
spool and sleeve. The passage to (11)–(15) is throttled and a
passage is formed to (11)–(16) and (17). At the same time, a
passage is formed from Gertor chambers (D), (E), and (F)
through passages (18), (19), and (12) to cylinder port *R*. The
hydraulic oil sent from the pump to the cylinder all passes
through the metering mechanism and is sent to the cylinder.
The oil discharged from the cylinder goes from cylinder port (L)
through passage (13), (15), and (14) and returns from tank port
(T) to the oil tank.
When the hydraulic oil discharged from the hydraulic pump
passes through the metering mechanism, it rotates external
tooth trochoid gear (23) to the right. This rotation is transmitted
to the sleeve by the feedback link, so the sleeve also rotates in
the same direction as the spool. When the relative position of
the sleeve and spool returns to the neutral condition, the flow of
oil to the metering mechanism is shut off, and the oil from the
pump all passes through passages (15) and (14) and returns
from port (T) to the tank.
8-21
Steering When There Is Failure In Hydraulic Pump

Even if the hydraulic pump breaks down and no hydraulic oil is supplied, the full hydraulic power steering is
designed so that the steering equipment can be operated manually.
In other words, if the steering wheel is turned, the spool of the full hydraulic power steering is turned by the shaft,
contacts the cross pin, and rotates the drive shaft.
When the drive shaft rotates, the rotor, which is meshed by a spline, also rotates, so the Gerotor acts as hand
pump to send oil to the cylinder. When this happens, the check valve between the tank port and pump port opens,
the oil from the tank side flows to the pump side, and this makes it possible to operate the steering manually in
emeragencies.
• The full hydraulic power steering (FHPS) is a type of hydraulic direction selector valve. There is no
drag link or other mechanical connection with the rear axle, so if the steering is turned fully to the lock
position, there is leakage of hydraulic oil inside the valve. This means that the position of the steering
wheel knob when traveling in a straight line may become different.
NOTE: It is possible to correct the position of the steering wheel knob as follows, but it is difficult to prevent this
change in position from occurring.
Method Of Correction
1. Set the rear wheels facing straight.
2. Turn the starting switch OFF.
3. Check that the engine has stopped.
4. Turn the steering wheel and set the steering wheel knob to the specified position.
5. Bleed all the air from the piping between the FHPS valve and power steering cylinder. (This causes abnormal
noise and play in the steering wheel.)
For safety reasons, always replace the hose between the FHPS valve and power steering cylinder once
every two years.
8-22
8.10.1 HYDRAULIC CIRCUIT DIAGRAMS OF STEERING SYSTEM AND CYLINDER

8-23
WET DISC BRAKE TYPE
8-24
8.11 BRAKE
Wheel Brake
Model FD100/115 FD135/150E/160E
Brake specifications Type 2–leading type
Inside diameter of drum 15.499 in (393.7 mm) 17.008 in (432 mm)
Lining material Non–asbestos
Lining size (width x thickness) 4.92 x 0.516 in 4.92 x 0.472 in

(125 mm × 13.1 mm) (125 mm × 12 mm)
Inside diameter of wheel cylinder 1.63 in (41.3 mm) 1.87 in (47.62 mm)
Brake valve Regulated pressure 1850 psi (12.7 MPa) {130 kg/cm2}
Piston stroke 0.43 in (11 mm)
Inlet flow 6.6 gpm (25l/min)
Accumulator Oil pressure at max. pressure 1991 psi(13.7 MPa) {140 kg/cm2}
storage
Pressure storage capacity 0.84 oz (290 cc)
Brake Valve
1. Body 3”. Spring 7. Ball valve
2. Input piston 4. Spool 8. Nut (for pressure adjustment)
3. Spring 5. Reaction piston 9. Return spring
3’. Spring 6. Valve rod 10. Push rod
When the brake pedal is operated, the hydraulic oil in the power steering hydraulic circuit is adjusted to a pressure
that matches the amount that the pedal is depressed, and this actuates the wheel cylinder. If the engine stalls and
the flow of oil from the hydraulic pump stops, the pressure stored in the accumulator makes it possible to carry out
braking operations several times.
8-25
8.11.2 PRINCIPLE OF OPERATION OF BRAKE VALVE

When Pedal Is Not Depressed
When spool (4) is at the position in the diagram above and the downstream equipment (power steering, etc.) is
operated, the oil pressure at pump port (P) rises. However, pump ports (P) and (11) are blocked by normally–
closed valve (b), so the pressure oil does not flow to the control pressure chamber. Therefore, even if the
downstream equipment is operated, the brake is naturally not applied.
When Pedal Is Depressed
When the brake pedal is depressed, push rod (10) and input piston (2) move to the left, spool (4) and reaction
piston (5) are pushed by springs (3), (3’), and (3Åh), push return spring (9) and move to the left. When spool (4)
moves to the left, the circuit between (11) and reservoir port (R) is blocked by valve (a), and the control pressure
chamber is shut off from reservoir port (R). Next, normally–closed valve (b) opens, forms a circuit between (P) and
(11), and pump port (P) and the control pressure chamber are connected.
From this condition, if spool (4) is moved further to the left, valve (C) is throttled, and the oil pressure at pump port
(P) rises. For this reason, the oil pressure in control pressure chamber connected to pump port (P) also rises, so
the oil pressure in the wheel cylinder also rises.
The pressure in the control pressure chamber pushes reaction piston (5) to the right (it is returned by the hydraulic
reaction force), so the condition is balanced with the amount that the pedal is depressed by the operator.
If the brake pedal is depressed fully, nut (8) contacts stopper (14), so the input piston cannot move further to the left
from this position, and the oil pressure in the control pressure chamber becomes the maximum in this condition.
8-26
When disassembling, do not loosen nut (8) unless the input piston is to be replaced.
Spool (4)
Valve (b) of spool (4) must control the flow of a small amount of oil, so
it has a ring orifice as shown in the diagram on the right.
When Supply Of Pressure Oil Stops
If the pump stops (if the engine stalls, etc.), it is possible to use the oil pressure stored in the accumulator to
operate the emergency brake.
When the brake is depressed, push rod (10), input piston (2), and spool (4) move to the left. When spool (4) moves
to the left, valve (a) closes, normally–closed valve (b) opens, and valve (c) is throttled, but no oil pressure is
generated in the control pressure chamber while the pump is stopped.
If the brake pedal is further depressed, spool (4) and reaction piston (5) move to the left, the tip of reaction piston
(5) contacts valve rod (6), valve (d) closes, and the circuit between (13) and the control pressure chamber is
blocked. If the brake pedal is depressed even further, spool (4), reaction piston (5), and valve rod (6) move as one
unit to the left, push open ball valve (7), and a circuit is formed between accumulator port (A) and the control
pressure chamber.
As a result, the pressure oil stored inside the accumulator goes to the control pressure chamber, and raises the
pressure inside the wheel cylinder. At the same time, the oil pressure in the control pressure chamber applies a
reaction force to reaction piston (5), so the system is balanced with the amount that the operator depresses the
brake pedal.
8-27
When the brake pedal is released, spool (4), reaction piston (5), and valve rod (6) move to the right, ball valve (7)
returns to the valve seat, and blocks the passage between the accumulator (A) and the control pressure chamber.
Valve rod (6) then moves partially, and reaction piston (5) moves further to the right, so valve (d) opens, and forms
a passage between (13) and the control pressure chamber. Pressure oil flows, so the oil pressure in the wheel
cylinder goes down. If spool (4) moves further to the right, valve (a) opens, and a circuit is formed between (11) and
reservoir port (R), so the oil pressure in the wheel cylinder goes down completely.
8-28
8.11.3 HYDRAULIC CIRCUIT DIAGRAMS OF BRAKE

8-29

BRAKE VALVE
to the tank
From the to the brake

brake pump
1. Control spring(*)
2. Control spring
3. Return spring
4. Return spring
*FD100 to 135 do not include the control spring (1).
8-30
WHEN OPERATING
Stepping on the pedal transfers the operating efforts to spool From the pump
(3) via rod (2) and spring (4). When the spool (3) is lowered,
the drain port (a) closes, and the oil from the pump and
accumulator flows from the port (A) to port (C) to operate the Accumulator
brake cylinder.
To brake cylinder
WHEN RELEASING
When the pressure to the pedal is reduced and the pedal
operating efforts are removed from the top of the spool, the
back pressure from the brake cylinder and the spool return
spring move the spool (3) upward to release the drain port Accumulator
(a). Oil from the brake cylinder then returns to the hydraulic
tank and flows to the circuit to release the brake
From the brake cylinder
8-31
ACCUMULATOR CHARGE VALVE
A : To the tank
ACC : To the brake valve
P : From the brake pump
PP : To the brake valve
T : To the tank
FUNCTION
The accumulator charge valve operates to maintain oil pressure from the pump at specified pressure level and
stores the pressure in the accumulator.
When the pressure exceeds the specified level, the oil from the pump is led to the drain circuit to reduce the pump
load.
8-32
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. Relief valve (R2)
5. Relief valve (H1)
6. Filter
8-33
OPERATIONS
1. When no oil is supplied to the accumulator (cut out
state)
Tank
• Because the pressure of port (B) is higher than the set
pressure of relief valve (R1), piston (8) is forcibly pushed
upward by the oil pressure from port (B) to open poppet
(6), thus short-circuiting ports (C) and (T).
• Since the spring chamber at the right end of spool (15) is
connected with port (C) of relief valve (R1), the pressure
level of spring chamber is equal to that of the brake oil Pilot
pressure of
tank. accumulator
• Oil from the pump enters port (P) and pushes spool (15) to
the right with low pressure equivalent to the load of spring
(14), flowing to the tank from port (A).
• At the same time, the oil also flows to the tank via orifices
(17), (18) and (16).
To
accumu-
lator
2. When oil is supplied to the accumulator

1. Cut in state
Tank
• When the pressure of port (B) reaches the set pressure
for relief valve (R1) or lower, spring (5) returns piston (8)
downward. The valve seat (7) and poppet (6) are in
contact and cut port (C) from port (T).
• Right hand spring chamber of spool (15) is also cut off
from port (T). Likewise the pressure of port (P) rises.
• When the pressure of port (P) reaches a level higher than Pilot
t h a t o f p o r t ( B) ( a c c u m u l a t o r ) , o i l s u p p l y t o t h e pressure of
accumulator
accumulator starts at this point. In this case, fixed quantity
determined by the size (area) of orifice (17) and the
pressure difference generated before and after the oil
supply to the accumulator (equivalent to the load of spring
(14)) is supplied to the accumulator irrespective of engine
speed, and the remaining oil flows to port (A).
To
accumu-
lator
8-34
2. When the cut-out pressure is reached

• When port (B) pressure (accumulator pressure) reaches Tank
the set pressure level for relief valve (R1), poppet (6) is
separated from valve seat (7), forming the oil flow to
operate relieving.
• With the start of relief operation, pressure difference is
generated between the top and bottom of piston (8). This
makes the piston (8) move upward, forcing the poppet (6)
to open and short-circuiting ports (C) and (T).
Pilot
• Since the spring chamber at the right end of spool (15) is pressure of
connected with port (C) of relief valve (R1), the pressure accumulator
level of spring chamber is equal to that of the brake oil
tank.
• Likewise, the pressure of port (P) drops to the level
equivalent to the load of spring (14), stopping oil supply to
port (B).
To
accu-
mulator
3. Main relief valve (R3)

• When the pressure of port (P) (pump pressure) reaches Tank
the set pressure level of relief valve (R3), oil from the
pump pushes up ball (11) against the force of spring (3) to
allow the oil to flow to the tank circuit. This controls the
maximum brake circuit pressure to protect the circuit.
BRAKE
Pilot
pressure of
accumulator
To
accu-
mulator
8-35
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc
8-36
FUNCTION
• The brake has wet type multiple disc structure.
• Stepping on the brake pedal causes the pressured oil
from the brake valve to move brake piston (4) to the right
direction and bring the disc (8) and plate (7) to close con-
tact. As the result, frictional force is generated between
the disc and plate. As the wheel turns with the disc, this
friction causes the machine to decelerate and stop.
• Releasing the brake pedal releases the pressure on the

back of the brake piston (4), and the force of return
spring (2) moves the piston to the left and the brake is
released.
8-37
8.12 HYDRAULIC CIRCUIT DIAGRAMS OF BRAKE

WET DISC BRAKE TYPE
8-38
8.13 HYDRAULIC PUMPS

The pump for the work equipment and the pump for the power steering (brake) are a parent–child type and are
driven by the torque converter PTO.
1. Hydraulic drum brake type
Item Unit FD100/115/135/150E/160E
Type – Work equipment: SAR90 Power steering and brake:

SAR40
Relief set pressure psi (MPa) 3130 (21.6) {220} 1850 (12.7) {130}
{kgf/cm²}
Discharge cc/rev 90.0 40.0
Rated speed rpm 2200 2200
2. Wet disc brake type
Work Brake
Item Unit Power steering Brake
equipment cooling
Name of — Pump No. 1 Pump No. 2 Pump No. 3 Pump No. 4

pump
1850 (12.7) {130}

Relief psi (MPa) 3130 (21.6) (FD100 – 115) 1422 (9.8) 50 (0.34)
pressure {kgf/cm²} {220} 2133 (14.7) {150} {100} {3.5}
(FD135 – 160E)
Discharge cc/rev 49.8 50.1 20.4 18.1
Rated rpm 2,500 2,500 2,500 2,500

revolution
8.14 TORQUE CONVERTER CHARGING PUMP

The torque converter charging pump is driven by the torque converter PTO.
Item Unit FD100/115/135/150E/160E
Type –
Relief set pressure psi (MPa) 209.1 (1.5) {14.7}

{kgf/cm²}
Discharge cc/rev 43.7
Rated speed rpm 2200
8-39
8.15 LIFT CYLINDER
FD150E/
Item Unit FD100 FD115 FD135
160E
Outside diameter of in (mm) 4.33 (110) 4.45 (113) 4.88 (124) 5.35 (136)
cylinder
Inside diameter of cylinder in (mm) 3.74 (95) 3.94 (100) 4.33 (110) 4.72 (120)
Diameter of piston rod in (mm) 2.56 (65) 2.76 (70) 2.95 (75) 2.95 (75)
Stroke in (mm) 3 m: 1510 3 m: 1510 3 m: 1510 3 m: 1510
Seal type – U–packing, U–packing, U–packing, U–packing,

piston ring piston ring piston ring piston ring
Weight lb (kg)/each 187.4 (85) 198.4 (90) 231.5 (105) 242.5 (110)
8.16 TILT CYLINDER
Outside diameter of cylinder in (mm) 5.59 (142)
Inside diameter of cylinder in (mm) 4.92 (125)
Diameter of piston rod in (mm) 2.36 (60)
Stroke in (mm) 0.94 (24)
Seal type – U–packing, piston ring
Weight lb (kg)–each 110.2 (50)
8-40
8.17 METER PANEL

Integrated meter panel with safety checkers
The integrated meter panel with safety checkers informs the operator of vehicle status that is monitored by many
sensors installed in the units of the vehicle and then immediately processed for display.
(1) Engine coolant temperature gauge (8) Operation indicator
(2) Hour meter (9) Lift Interlock warning lamp (option)
(3) Torque converter oil temperature gauge (10) Engine warning lamp
(4) Fuel gauge (11) Failure indicator
(5) Neutral indicator lamp / Travel interlock warning (12) Air cleaner element warning lamp
lamp (option)
(6) Parking brake warning lamp (13) Radiator coolant level warning lamp
(7) Charge warning lamp (14) Glow indicator
(15) Speedometer (option)
8-41
Indication
Cat. No. Symbol Indicated item Indication method
(range)
1 Engine cooling Indicates the temperature of engine

water cooling water.
temperature White range: Normal
Red range: May indicate overheating
2 Hour meter 0 to 999999/h Operates upon turning the switch ON.

indication Indicates accumulated operating hours.
Meter
3 Torque converter Indicates the temperature of torque

oil temperature converter oil.
White range: Normal
Red range: Abnormal
4 Fuel Indicates unused balance of fuel if the

key switch is turned OFF (Stitch type).
5 Neutral indication During operation When F/R lever is in neutral: Lights up

Travel- During travel-interlocked operation:
interlocked Flashes
operation
6 Parking brake in During operation When parking brake is applied: Lights

operation up
Safety checker
7 Battery charged When not fully Key switch ON: Lights up

state charged After engine start: Turns OUT (normal)
After engine start: Turns ON (abnormal)
8 Operation During operation Flashes during operation

indicator
Hour meter
operation
9 Material During operation During material handling-interlocked

handling- operation: Flashes
interlocked
operation
8-42
Indication
Cat. No. Symbol Indicated item Indication method
(range)
10 Engine When the engine Key switch ON: Lights up

abnormality is in abnormal When in normal conditions: Turns OFF
conditions 4 seconds after the key switch is turned
ON
During abnormal conditions and when
failure lamp selection connector is
connected: Flashes
11 Abnormality of When the engine Key switch ON: Lights up

engine control is in abnormal When in normal conditions: Turns OFF
system conditions 4 seconds after the key switch is turned
ON
During abnormal conditions and when
failure lamp selection connector is
connected: Flashes
Safety checker
12 Air cleaner When clogged: When the clogging of air cleaner is near
element clogging the limit: Lights up
13 Radiator cooling Below proper Indicated when the starter switch is ON

water level quantity while the engine has stopped.
When normal : Turns OUT
When abnormal: Lights up
Indicated during engine revolution
When normal: Turns OUT
When abnormal: Lights up
14 Preheating During preheating Lights up during preheating
15 Travel speed
Meter
8-43
NOTES:
HYDRAULIC CIRCUIT DIAGRAMS OF WORK EQUIPMENT, STEERING SYSTEM, AND BRAKES
8-45
BLANK PAGE
WET DISC BRAKE TYPE
8-47
BLANK PAGE
SCHEMATIC - 6D102E DIESEL ENGINE
8-49
BLANK PAGE
SCHEMATIC - 6D102E DIESEL ENGINE, UL-S
8-51
BLANK PAGE
WIRING DIAGRAM - TB42 GASOLINE ENGINE
8-53
BLANK PAGE
WIRING DIAGRAM - TB42 GASOLINE ENGINE, UL-S
8-55
BLANK PAGE
WIRING DIAGRAM - 6D102E DIESEL ENGINE
8-57
BLANK PAGE
WIRING DIAGRAM - 6D102E DIESEL ENGINE, UL-S
8-59
BLANK PAGE
TRANSMISSION DIAGRAM - TORQFLOW F1/R1, PNEUMATIC TIRE
8-61
BLANK PAGE
TRANSMISSION DIAGRAM - TORQFLOW F2/R1, PNEUMATIC TIRE
8-63
BLANK PAGE
9. TROUBLESHOOTING
9. TROUBLESHOOTING
9.1 FUNCTIONS OF TROUBLESHOOTING TOOL AND CHECK OF FAILURE

CODE
9.1.1 FUNCTIONS OF TROUBLESHOOTING TOOL
The electronically controlled engine controller of this machine indicates a failure code when a trouble occurs. The
failure code can be checked by the following 2 methods.
Check of failure code with troubleshooting tool
Check of failure code by blinking lamp of meter panel
Tools For Troubleshooting
Part name (part

Symbol Remarks
No.)
A CD-ROM for Common parts for diesel

troubleshooting engine and gasoline engine
software trucks
(3EB-97-50030) Windows 2000,Windows XP,
Windows Vista compatible
Troubleshooting Personal computer

software (Provided by KOMATSU
(CD-ROM) FORKLIFT distributor)
B Intermediate cable For diesel engine lift truck

(3EA-55-38880) only
C Communication Kvaser-made CANBUS

cable (Common part with FB-12/
(3BA-97-71220) FBR-14)
The troubleshooting tool has the following functions.

1. Indication of failure code
2. Deletion of failure code
3. Indication of repair procedure
9-2
9. TROUBLESHOOTING
9.1.2 INDICATING FAILURE CODE WITH TROUBLESHOOTING TOOL

NOTE: Install troubleshooting software A from the CD-ROM to a personal computer (PC) in advance.
1. Turn the key switch OFF.

3. Disconnect cap (1A) (having a short circuit wiring
harness) from connector (1) of the wiring harness on the
right side of the lift truck and connect communication
cable (C) of troubleshooting software (A) and
intermediate cable (B).
NOTE: Machine in this photo is different from actualmachine.
4. Start the installed software and check the failure code.
NOTE: The method of using the software is shown in the CD-

ROM.
9-3
9. TROUBLESHOOTING
Example of indication of failure code
9-4
9. TROUBLESHOOTING
9.1.3 INDICATING FAILURE CODE WITH METER PANEL

Interchange cap (1A) (having a short circuit wiring harness) of connector (1) and cap (2A) (having no short circuit
wiring harness) of connector (2). By this work, the circuit of connector (1) is disconnected and that of connector (2)
is shorted and the failure code can be indicated by the blinking patterns of engine abnormality warning lamp (3)
and abnormality warning lamp (4) of the meter panel.
• Interchange of respective caps (1A) and (2A) of connector
(1) and (2): Failure code indication function ON
• Non-interchange (Normal state) of respective caps (1A)
and (2A) of connector (1) and (2): Failure code indication
function OFF.
NOTE: When starting or running the engine normally, do not interchange caps (1A) and (2A).
9-5
9. TROUBLESHOOTING
1. Indication in normal state

When the key switch is turned ON, engine abnormality warning lamp (3) and abnormality warning lamp (4) are
turned ON or OFF as shown below.
In position "A", the indication varies with the following condition.
• Failure lamp indication selector connector is not connected:
Warning lamps (3) and (4) are turned OFF.
• Failure lamp indication selector connector is connected and in trouble:
Warning lamps (3) and (4) blink to indicate trouble.
2. Indication when trouble occurs

A generated failure code is indicated under the following conditions.
• Condition (1): Engine is stopped
• Condition (2): Key switch is in ON position
• Condition (3): Respective caps (1A) and (2A) of connector (1) and (2) are interchanged.
Example 1: Failure code "244"
9-6
9. TROUBLESHOOTING
Example 3: Simultaneous indication of failure codes "112" and "244"
9-7
9. TROUBLESHOOTING
9.1.4 FAILURE CODE TABLE
Failure code of
troubleshooting Trouble Place of description
tool
111 Abnormality in engine controller
115 Abnormality in engine NE and Bkup speed sensors
122 Abnormally high level in charge pressure sensor
123 Abnormally low level in charge pressure sensor
131 Abnormally high level in throttle sensor
132 Abnormally low level in throttle sensor
143 Torque derating by low engine oil pressure
144 Abnormally high level in coolant temperature sensor
145 Abnormally low level in coolant temperature sensor
146 Engine overheating
153 Abnormally high level in charge temperature sensor
154 Abnormally low level in charge temperature sensor
187 Abnormally low level in sensor power supply 2 circuit
221 Abnormally high level in atmospheric pressure sensor Troubleshooting of

electrical system
222 Abnormally low level in atmospheric pressure sensor (E-mode)
227 Abnormally high level in sensor power supply 2 circuit
234 Engine overspeed
238 Abnormality in Ne speed sensor power supply
271 Short circuit in IMV
272 Disconnection in IMV
322 Disconnection or short circuit in injector #1 (L/B #1) system
342 Matching error in engine controller data
351 Abnormality in injector drive circuit
9-8
9. TROUBLESHOOTING
Failure code of
troubleshooting Trouble Place of description
tool
415 Rotation derating by low engine oil pressure
418 Water mixed in fuel
428 Abnormally high level in water sensor
429 Abnormally low level in water sensor
431 Abnormality in idle validation switch
432 Abnormality in processing of idle validation
435 Abnormality in engine oil pressure switch
441 Abnormally low power supply voltage
442 Abnormally high power supply voltage
449 Abnormally high common rail pressure 2
451 Abnormally high level in common rail pressure sensor

Troubleshooting of
452 Abnormally low level in common rail pressure sensor electrical system
(E-mode)
488 Derating of torque by abnormally high charge temperature
559 No-pressure feed by supply pump 1
689 Abnormality in engine Ne speed sensor
731 Abnormality in engine Bkup speed sensor phase
757 Loss of all data in engine controller
778 Abnormality in engine Bkup speed sensor
2185 Abnormally high level in throttle sensor power supply
2186 Abnormally low level in throttle sensor power supply
2311 Abnormality in IMV solenoid
2555 Disconnection in intake air heater relay
2556 Short circuit in intake air heater relay
9-9
9. TROUBLESHOOTING

CAUSES AND REMEDIES FOR FAILURES
Problem Cause Remedy
Power is not A. No hydraulic pressure

transmitted 1) Lack of oil Add oil
2) Damaged gear pump or drive portion Disassemble and check, replace
with new parts or replace whole
assembly
3) Damaged piping or joint Disassemble and replace
4) Broken piston in regulator valve or Disassemble and replace
broken spring
B. Mechanical breakage
1) Broken input plate Disassemble and replace
2) Broken shaft, gear Disassemble and replace
3) Broken spline Disassemble and replace
Output drops A. Hydraulic pressure is too low

1) Lack of oil Add oil
2) Leakage of air from suction piping Check joint, gasket, replace parts
if necessary
3) Drop in efficiency of gear pump Disassemble and replace,
replace parts if necessary
4) Deteriorated spring in regulator valve Disassemble and replace,
or defective operation of piston replace parts if necessary
5) Worn or broken seal ring Disassemble and replace

B. Mechanical breakage
1) Broken or deformed impeller Disassemble and replace
2) Deformed input plate Disassemble and replace
C. Other
1) Non–specified oil is being used Change to specified oil
Oil pressure rises 1) Incorrect oil level Add or drain oil

abnormally high 2) Contact of impeller Disassemble and replace,
3) Wear or seizure of bearing Disassemble and replace,
4) Wear or damage of gear pump Disassemble and replace,
9-10
9. TROUBLESHOOTING
Abnormal noise is 1) Cavitation caused by leakage of air Add oil or check and replace parts
generated from suction piping or lack of oil if necessary
2) Failure of gear pump Disassemble and replace parts or
whole assembly
3) Contact caused by deformed Disassemble and replace,
impeller replace parts if necessary
4) Breakage of input plate Disassemble and replace
5) Breakage of gear Disassemble and replace
6) Wear or breakage of bearing Disassemble and replace
7) Wear of spline Disassemble and replace
8) Loose bolts Tighten, replace if necessary
Oil oozes out or leaks A. Oil seal

1) Worn or damaged lip Disassemble and replace
2) Dirt caught Disassemble and replace,
3) Worn or scratched shaft Correct or replace
4) Hardening or deterioration of rubber Disassemble and replace
because of abnormal rise in oil
temperature
B. O–ring
1) Broken O–ring Disassemble and replace
2) Scratched mating surface Correct or replace
3) Hardening or deterioration of rubber Disassemble and replace
because of abnormal rise in oil
temperature
4) Sudden use in extremely cold Carry out warming–up operation
temperatures (below–15 C)
C. Plug, screw
1) Loose screw Tighten
2) Broken screw Replace
3) Cracked hole Replace
9-11

1.5 MPa {15.3 kg/cm²}
F/R
pressure
Line filter pick-up port
Oil tempera- Oil
9. TROUBLESHOOTING

regulator valve
0.45 ± 0.15 MPa
Inching
valve
Solenoid valve
for F/R Accumulator
for speed
9-12
Solenoid valve for
pick-up port
Solenoid valve for

2nd/3rd speed
Strainer
1st 2nd 3rd F R

FWD-REV VALVE
9. TROUBLESHOOTING
9.3 CONTROL VALVE

TROUBLESHOOTING
External oil leakage • Damage/deformation/ • Replace with a new O-ring.

disengagement of O-ring
• Flaws on O-ring seal • Correct flaws with oilstone.
• Damage of oil seal • Replace with a new oil seal.
• Loosened bolt or plug due to • Check machine pressure.

excessive pressure
Pressure fluctuation or • Damage of needle valve or oil seat • Replace relief assembly.
low pressure of relief
valve • Stuck foreign matter
Lift elevation speed or • Relief set pressure drop and • Replace relief assembly.
tilting speed down cracking pressure drop
Speed down (only when • Malfunction of plunger (21) • Replace valve assembly.
forward tilting)
Large natural drop • Excessive wear of lift spool (27) • Replace valve assembly.
Large natural tilting • Excessive wear of plunger (21) • Replace valve assembly.
coupling portion
• Excessive wear of tilt spool (31)
Mast descends when • Malfunction of plunger (4) • Disassemble, wash and

lever is returned after (due to stuck foreign matter) reinstall the plunger.
elevation
• Defect of spring (2) • Disassemble and correct the spring
or replace it with a new one.
Spool does not • Foreign matter remaining in the • Remove the foreign matter or
move smoothly. spool sliding area. replace valve assembly.
9-13
9. TROUBLESHOOTING
1 Plug
2 Spring
3 Cap
4 Plunger
5 Cap nut
6 Adjusting screw
7 Locknut
9-14
8 Needle valve
9 Circlip
10 Wire
11 Spring 31 Tilt spool
12 Spring 32 Seat
13 Spring holder 33 Sleeve
14 Spring 34 Seat
15 Plunger 35 Plate name
16 Pilot sleeve 36 Seal holder
17 Cover 37 Body
18 Adjusting screw 38
19 Plug 39 Hexagonal socket head bolt
20 Head spool 40 Hexagonal socket head bolt
21 Plunger 41 Button bolt
22 Spring 42 Nut 51 O-ring
23 Sleeve 43 Rivet screw 52 O-ring
24 Orifice 44 Steel ball 53 O-ring
25 Wire 45 Steel ball 54 O-ring
26 Spring 46 Oil seal 55 O-ring
27 Lift spool 47 O-ring 56 O-ring
28 Spring holder 48 O-ring 57 O-ring
29 Spool 49 O-ring 58 O-ring
30 Gasket 50 O-ring 59 Socket head plug
10. CONVERSION
TABLES
CONVERSION TABLES
10.1 MILLIMETERS TO INCHES

1MM = 0.03937 IN.
10.2 INCHES TO MILLIMETERS
10-2
CONVERSION TABLES
10.3 CUBIC METERS TO CUBIC YARDS

1M3 = 1.308 CUBIC YARDS
10.4 CUBIC YARDS TO CUBIC METERS
10-3
CONVERSION TABLES
10.5 LITER TO U.S. GALLON

1 L = 0.2642 U.S. GALLON
10.6 U.S. GALLON TO LITER

1 U.S. GALLON = 3.7854 L
10-4
CONVERSION TABLES
10.7 KILOGRAM TO POUND

1 kg = 2.2046 lb.
10.8 POUND TO KILOGRAM

1 LB. = 0.4536 KG
10-5
CONVERSION TABLES
10.9 KILOGRAMS PER SQUARE CENTIMETER TO POUNDS PER SQUARE

INCH
1kg/cm2 = 14.2233 lb./in2
10-6
CONVERSION TABLES
10.10KILOGRAM TO FOOT POUNDS OF FORCE

1 Kgm = 7.233 lbf./ft
10-7
CONVERSION TABLES
10.11 TEMPERATURE - FAHRENHEIT TO CENTIGRADE CONVERSION

A simple way to convert a Fahrenheit temperature reading into a Centigrade (Celsius) reading, or vice versa, is to
utilize the table below. The table is divided into groupings of 3 columns each. Use the center “FIND” column of
each group as either a F° or C° reading and look to the left or right to find the other temperature reading you are
seeking.
10-8
NOTES:
KOMATSU FORKLIFT USA, INC.
Covington, GA 30014-4908
VOICE PHONE: (770) 385-4815

FAX : (770) 385-4838
SM229
SERVICE MANUAL
SAA6D107E-1-A SERIES FORKLIFT TRUCK ENGINES
TRUCK MODEL SERIAL NUMBER TRUCK MODEL SERIAL NUMBER

FD100-8 7001 AND UP FD150E-8 7001 AND UP
FD115-8 7001 AND UP FD160E-8 7001 AND UP
FD135-8 7001 AND UP
SAA6D107E-1-A
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.
ISSUED: JUNE 2008 Komatsu Forklift USA, Inc.

The information and specifications contained herein were accurate at the time of publication, but may
change without notice as required for product improvements. Neither Komatsu Forklift USA, Inc., Komatsu
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:

Covington, Georgia 30014-4908
Voice phone: (770) 385-4815

Fax phone: (770) 385-4838
© Copyright 2008, Komatsu Forklift USA, Inc. All rights reserved. No part of this document may be
photocopied or reproduced in any way without prior written consent of Komatsu Forklift USA, Inc.
CONTENTS
Page No.
1. General Information
1.1 SAFETY NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 HOW TO READ THE SHOP MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . 1-10
1.4 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS . . . . . . . 1-11
1.5 HANDLING OF CONNECTORS NEWLY USED FOR ENGINES . . . . . . . . . . . . . . . . . . 1-18
1.6 HOW TO READ ELECTRIC WIRE CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.7 PRECAUTIONS WHEN CARRYING OUT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1.8 METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER . 1-28
1.9 STANDARD TIGHTENING TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.10 CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
2. SPECIFICATIONS
2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 DIMENSIONS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 ENGINE PERFORMANCE CURVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

3.1 AIR INTAKE AND EXHAUST UNITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 TURBOCHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5 LUBRICATING OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.6 COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7.1 INJECTORS AND FUEL LINES - OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.8 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.9 CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.10 CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.11 PISTON, PISTON RING AND PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.12 CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.13 VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.14 TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.15 VALVE AND VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.16 ROCKER ARM, SHAFT AND TAPPET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.17 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.18 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.19 FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.20 OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.21 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
1
3.22 FUEL SUPPLY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.23 WATER PUMP DRIVE AND FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
4. STANDARD VALUE TABLE

4.1 STANDARD VALUE TABLE FOR TESTING, ADJUSTING AND TROUBLESHOOTING 4-2
4.2 RUN-IN STANDARD AND PERFORMANCE TEST CRITERIA . . . . . . . . . . . . . . . . . . . 4-3
5. TESTING AND ADJUSTING

5.1 TESTING AND ADJUSTING TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 TESTING AIR BOOST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 ADJUSTMENT OF VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 TESTING COMPRESSION PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 TESTING BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.6 TESTING ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7 HANDLING FUEL SYSTEM PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.8 RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.9 TESTING FUEL PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.10 REDUCED CYLINDER MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.11 NO-INJECTION CRANKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.12 TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR
5-18
5.13 BLEEDING AIR FROM FUEL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.14 TESTING FUEL SYSTEM FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.15 REPLACING THE FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.16 HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.17 FUNCTIONS OF TROUBLESHOOTING TOOL AND CHECK OF FAILURE CODE . . . 5-24
5.17.1 FUNCTIONS OF TROUBLESHOOTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.17.2 METHOD OF INDICATING FAILURE CODE WITH TROUBLESHOOTING TOOL
5-24
5.17.3 METHOD OF INDICATING FAILURE CODE WITH METER PANEL. . . . . . . . . 5-26
6. TROUBLESHOOTING
6.1 GENERAL INFORMATION ON TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 FAILURE CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 INFORMATION IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
2
6.5 TROUBLESHOOTING FOR MECHANICAL SYSTEM (S MODE) . . . . . . . . . . . . . . . . . 6-10
6.5.1 S-1 STARTING PERFORMANCE IS POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.5.2 S-2 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.5.3 S-3 ENGINE DOES NOT PICK UP SMOOTHLY . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.5.4 S-4 ENGINE STOPS DURING OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.5.5 S-5 ENGINE DOES NOT ROTATE SMOOTHLY . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.5.6 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) . . . . . . . . . . . . . . . . . . . . 6-21
6.5.7 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) . . . . . . . . . 6-23
6.5.8 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) . 6-25
6.5.9 S-9 OIL BECOMES CONTAMINATED QUICKLY . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.5.10 S-10 FUEL CONSUMPTION IS EXCESSIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.5.11 S-12 OIL PRESSURE DROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.5.12 S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL) . . . . . . . . . . . . . . . 6-30
6.5.13 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING). . 6-31
6.6 TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E MODE) . . . . . . . . . . . . . . . . . . 6-36
6.6.1 E-1 FAILURE CODE [111] ABNORMALITY IN ENGINE CONTROLLER . . . . . 6-36
6.6.2 E-2 FAILURE CODE [115] ENGINE NE OR BKUP SPEED SENSOR ERROR. 6-36
6.6.3 E-3 FAILURE CODE [122] ABNORMALLY HIGH LEVEL IN CHARGE PRESSURE
SENSOR 6-37
6.6.4 E-4 FAILURE CODE [123] ABNORMALLY LOW LEVEL IN CHARGE PRESSURE
SENSOR 6-39
6.6.5 E-5 FAILURE CODE [131] THROTTLE SENSOR HIGH ERROR . . . . . . . . . . . 6-40
6.6.6 E-6 FAILURE CODE [132] THROTTLE SENSOR LOW ERROR. . . . . . . . . . . . 6-42
6.6.7 E-7 FAILURE CODE [143] (TORQUE DERATING BY LOW ENGINE OIL PRESSURE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6.6.8 E-8 FAILURE CODE [144] ABNORMALLY HIGH LEVEL IN COOLANT
TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6.6.9 E-9 FAILURE CODE [145] ABNORMALLY LOW LEVEL IN COOLANT
TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6.6.10 E-10 FAILURE CODE [146] (ENGINE OVERHEATING) . . . . . . . . . . . . . . . . . . 6-50
6.6.11 E-11 FAILURE CODE [153] ABNORMALLY HIGH LEVEL IN CHARGE
TEMPERATURE SENSOR 6-52
6.6.12 E-12 FAILURE CODE [154] ABNORMALLY LOW LEVEL IN CHARGE
TEMPERATURE SENSOR 6-54
6.6.13 E-13 FAILURE CODE [187] ABNORMALLY LOW LEVEL IN SENSOR POWER
SUPPLY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
6.6.14 E-14 FAILURE CODE [221] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC
PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
6.6.15 E-15 FAILURE CODE [222] ABNORMALLY LOW LEVEL IN ATMOSPHERIC
PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
6.6.16 E-16 FAILURE CODE [227] ABNORMALLY HIGH LEVEL IN SENSOR POWER
SUPPLY 2 6-62
6.6.17 E-17 FAILURE CODE [234] ENGINE OVERSPEED . . . . . . . . . . . . . . . . . . . . . 6-63
6.6.18 E-18 FAILURE CODE [238] ABNORMAL LEVEL IN NE SPEED SENSOR POWER
SUPPLY 6-64
6.6.19 E-19 FAILURE CODE [271] SHORT CIRCUIT IN IMV. . . . . . . . . . . . . . . . . . . . 6-65
6.6.20 E-20 FAILURE CODE [272] DISCONNECTION IN IMV. . . . . . . . . . . . . . . . . . . 6-66
6.6.21 E-21 FAILURE CODE [322] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO.
1 (L/B NO. 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
6.6.22 E-22FAILURE CODE [323] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO.
5 (L/B NO. 5) 6-70
3
3 (L/B NO. 3) 6-72
6 (L/B NO. 6) 6-73
2 (L/B NO. 2) 6-75
4 (L/B NO. 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
6.6.27 E-27 FAILURE CODE [342] MATCHING ERROR IN ENGINE CONTROLLER DATA
6-79
6.6.28 E-28 FAILURE CODE [351] ABNORMALITY IN INJECTOR DRIVE CIRCUIT . 6-80
SUPPLY 1 6-82
SUPPLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
6.6.31 E-31 FAILURE CODE [415] (ROTATION DERATING BY LOW ENGINE OIL
PRESSURE) 6-85
6.6.32 E32 FAILURE CODE [418] WATER MIXED IN FUEL . . . . . . . . . . . . . . . . . . . . 6-85
6.6.33 E-33 FAILURE CODE [428] ABNORMALLY HIGH LEVEL IN WATER SENSOR 6-86
6.6.34 E-34 FAILURE CODE [429] ABNORMALLY LOW LEVEL IN WATER SENSOR 6-88
6.6.35 E-35 FAILURE CODE [431] IDLE VALIDATION SWITCH ERROR . . . . . . . . . . 6-89
6.6.36 E-36 FAILURE CODE [432] IDLE VALIDATION ACTION ERROR . . . . . . . . . . 6-92
6.6.37 E-37 FAILURE CODE [435] ABNORMALITY IN ENGINE OIL PRESSURE SWITCH
6-94
6.6.38 E-38 FAILURE CODE [441] ABNORMALLY LOW POWER SUPPLY VOLTAGE 6-95
6.6.39 E-39 FAILURE CODE [442] ABNORMALLY HIGH POWER SUPPLY VOLTAGE 6-98
6.6.40 E-40 FAILURE CODE [449] ABNORMALLY HIGH COMMON RAIL PRESSURE 2
6-100
6.6.41 E-41 FAILURE CODE [451] ABNORMALLY HIGH LEVEL IN COMMON RAIL
PRESSURE SENSOR 6-101
6.6.42 E-42 FAILURE CODE [452] ABNORMALLY LOW LEVEL IN COMMON RAIL
PRESSURE SENSOR 6-103
6.6.43 E-43 FAILURE CODE [488] DERATING OF TORQUE BY ABNORMALLY HIGH
CHARGE TEMPERATURE 6-104
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105
6.6.45 E-45 FAILURE CODE [559] NO-PRESSURE FEED BY SUPPLY PUMP 1. . . . 6-106
6.6.46 E-46 FAILURE CODE [689] ABNORMALITY IN ENGINE NE SPEED SENSOR 6-107
6.6.47 E-47 FAILURE CODE [731] ABNORMALITY IN ENGINE BKUP SPEED SENSOR
PHASE 6-110
6.6.48 E-48 FAILURE CODE [757] LOSS OF ALL DATA IN ENGINE CONTROLLER 6-111
6-112
6.6.50 E-50 FAILURE CODE [2185] THROTTLE SENSOR SUPPLY VOLTAGE HIGH
ERROR 6-115
6.6.51 E-51 FAILURE CODE [2186] THROTTLE SENSOR POWER SUPPLY LOW ERROR
6-116
6.6.52 E-52 FAILURE CODE [2249] NO-PRESSURE FEED BY SUPPLY PUMP 2. . . 6-117
6.6.53 E-53 FAILURE CODE [2311] ABNORMALITY IN IMV SOLENOID . . . . . . . . . . 6-118
6.6.54 E-54 FAILURE CODE [2555] DISCONNECTION IN INTAKE AIR HEATER RELAY
6-120
6.6.55 E-55 FAILURE CODE [2556] SHORT CIRCUIT IN INTAKE AIR HEATER RELAY
6-122
4
7.1 HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 REMOVAL AND INSTALLATION OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . 7-3
7.2 COATING MATERIALS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3 SPECIAL TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.4 GENERAL DISASSEMBLY OF ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.5 GENERAL ASSEMBLY OF ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
5
NOTES:
1. GENERAL
INFORMATION
1. GENERAL INFORMATION
1.1 SAFETY NOTICE

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe. Some of
these techniques require the use of tools specially designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or
may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
1. General precautions
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully
before operating the machine.
a. Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the loca-
tions of the safety plates and detailed explanation of precautions, see the Operation and Maintenance
Manual.
b. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in
their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on
the floor. Smoke only in the areas provided for smoking. Never smoke while working.
c. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes,
or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.

• Always wear safety glasses when grinding parts with a grinder, etc.
d. When carrying out any operation with 2 or more workers, always agree on the operating procedure before
starting. Always inform your fellow workers before starting any step of the operation. Before starting work,
hang UNDER REPAIR warning signs in the operator's compartment.
e. Only qualified workers must carry out work and operation which require license or qualification.
f. Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them.
Before starting work, thoroughly check the tools, machine, lift truck , service car, etc.
g. If welding repairs are needed, always have a trained and experienced welder carry out the work. When
carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes
suited for welding work.
1-2
h. Before starting work, warm up your body thoroughly to start work under good condition.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
Prohibition of operation and handling by
5
unlicensed workers
6 Safety check before starting work
Wearing protective goggles
7
(for cleaning or grinding work)
Wearing shielding goggles and protectors
8
(for welding work)
9 Good physical condition and preparation
Precautions against work which you are
10
not used to or you are used to too much
2. Preparations for work

a. Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking
brake and block the wheels or tracks to prevent the machine from moving.
b. Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang warning signs on them.
c. When disassembling or assembling, support the machine with blocks, jacks, or stands before starting
work.
d. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the
handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is
impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
3. Precautions during work

a. Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure
completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from spurting out.
b. The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded.
Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.
c. Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the
engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts.
d. Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) ter-
minal first.
e. When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check
that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component
from hitting any other part. Do not work with any part still raised by the hoist or crane.
f. When removing a cover which is under internal pressure or under pressure from a spring, always leave 2
bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then
remove the cover.
g. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may
cause electrical fires.
1-3
h. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up
immediately. Fuel or oil on the floor can cause you to slip and can even start fires.
i. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.
j. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged
by contact with other parts when the machine is operated.
k. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous,
so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting
parts are correctly installed.
l. When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to
check that they are installed correctly.
m. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a
hole.
n. When measuring hydraulic pressure, check that the measuring tools are correctly assembled.
o. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poi-
soning. Accordingly, open the windows and doors to ventilate well.
4. Precautions for sling work and making signs

a. Only one appointed worker must make signs and co-workers must communicate with each other fre-
quently. The appointed sign maker must make specified signs clearly at a place where he is seen well from
the operator's seat and where he can see the working condition easily. The sign maker must always stand
in front of the load and guide the operator safely.
• Do not stand under the load.

• Do not step on the load.
b. Check the slings before starting sling work.
c. Keep putting on gloves during sling work. (Put on leather gloves, if available.)
d. Measure the weight of the load by the eye and check its center of gravity.
e. Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used
to sling a light load, the load may slip and fall.
f. Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of
the rope from its original winding position on the load, which can result in a dangerous accident.
g. Limit the hanging angle to 60°, as a rule.

h. Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
i. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging
angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes,
each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2
ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is
reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000
kg}.
1-4
j. When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
k. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.
l. Apply wire ropes to the middle portion of the hook.
Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the
maximum strength at the middle portion.
m. Do not use twisted or kinked wire ropes.

n. When lifting up a load, observe the following.
• Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do
not grasp them but press them from above. If you grasp them, your fingers may be caught.
• After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes,
and pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load slantingly.
o. When lifting down a load, observe the following.
1-5
• When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the
specified place.
5. Precautions for using mobile crane

a. Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane
safely.
6. Precautions for using overhead hoist crane
When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight
of a part heavier than 25 kg is indicated after the mark of 4.
a. Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric
shock prevention earth leakage breaker, crane collision prevention device, and power application warning
lamp, and check safety.
b. Observe the signs for sling work.
c. Operate the hoist at a safe place.
d. Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons
without fail.
e. Do not sling a load slantingly. Do not move the crane while the slung load is swinging.
f. Do not raise or lower a load while the crane is moving longitudinally or laterally.
g. Do not drag a sling.
h. When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up.
i. Consider the travel route in advance and lift up a load to a safe height.
j. Place the control switch on a position where it will not be an obstacle to work and passage.
k. After operating the hoist, do not swing the control switch.
l. Remember the position of the main switch so that you can turn off the power immediately in an emergency.
m. If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which
was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to
that switch are not in operation state.
n. If you find an obstacle around the hoist, stop the operation.
o. After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the
floor. Do not leave the sling installed to the hook.
1-6
7. Selecting wire ropes

a. Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes
(Standard “Z” twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal diameter of rope Allowable load
mm kN ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
a The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
8. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
a. Disconnection
IMPORTANT
Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance.
• Ask professional traders for collecting and filling operation of refrigerant (R134a).
• Never release the refrigerant (R134a) to the atmosphere.
If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or
filling it, you must be qualified for handling the refrigerant and put on protective goggles.
b. Connection
• When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter
them.
• When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.
• Check that each O-ring is not damaged or deteriorated.
• When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.
1-7
Example of O-ring (Fitted to every joint of hoses and tubes)
c. For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
1.2 HOW TO READ THE SHOP MANUAL
• Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
• Materials and specifications are subject to change without notice.
• Shop manuals are divided into the “Chassis” and “Engine”.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For ease
of understanding, the manual is divided into the following sections.
00. General Information

This section explains the shop manuals list, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component. The
structure and function sub-section explains the structure and function of each component. It serves not
only to give an understanding of the structure, but also serves as reference material for troubleshooting.
The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjust-
ing and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting are
explained in Testing and adjusting.
40. Troubleshooting
1-8
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by
failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and quantity
and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to Komatsu Utility Co., Ltd.
FORKLIFT COMPANY or your KOMATSU FORKLIFT distributor. Get the most up-to-date
information before you start any work.
3. Symbols
Important safety and quality portions are marked with the following symbols so that the shop
manual will be used practically.
Symbol Item Remarks
Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

Caution
dards are necessary when performing work.
Weight of parts of component or parts. Caution necessary when

Weight
selecting hoisting wire, or when working posture is important, etc.
torque Tightening Places that require special attention for tightening torque during
torque assembly.
Coat Places to be coated with adhesives, etc. during assembly.
Oil, coolant Places where oil, etc. must be added, and capacity.
Drain Places where oil, etc. must be drained, and quantity to be drained.
4. Units
In this shop manual, the units are indicated with International System of units (SI). For reference,
conventionally used Gravitational System of units is indicated in parentheses { }.
1-9
1.3 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard values necessary for judgment of products and parts are described by the following
terms.
1. Standard size and tolerance

• To be accurate, the finishing size of parts is a little different from one to another.
• To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size
is indicated.
• The above size set temporarily is called the “standard size” and the range of difference from the standard size
is called the “tolerance”.
• The tolerance with the symbols of + or – is indicated on the right side of the standard size.
Example:
Standard size Tolerance
–0.022
120
–0.126
The tolerance may be indicated in the text and a table as

[standard size (upper limit of tolerance/lower limit of
tolerance)].
Example) 120 (–0.022/–0.126)
• Usually, the size of a hole and the size of the shaft to be

fitted to that hole are indicated by the same standard size
and different tolerances of the hole and shaft. The tight-
ness of fit is decided by the tolerance.
• Indication of size of rotating shaft and hole and relation-
ship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
2. Standard clearance and standard value

• The clearance made when new parts are assembled is
called the “standard clearance“, which is indicated by the
range from the minimum clearance to the maximum
clearance.
• When some parts are repaired, the clearance is gener-
ally adjusted to the standard clearance.
• A value of performance and function of new products or
equivalent is called the “standard value“, which is indi-
cated by a range or a target value.
• When some parts are repaired, the value of performance/function is set to the standard value.
3. Standard interference
• When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that
of the mating shaft, the difference between those diameters is called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the
hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “stan-
dard interference”.
• After repairing or replacing some parts, measure the size of their hole and shaft and check that the interfer-
ence is in the standard range.
1-10
4. Repair limit and allowable value

• The size of a part changes because of wear and deformation while it is used. The limit of changed size is
called the “repair limit”.
• If a part is worn to the repair limit must be replaced or repaired.
• The performance and function of a product lowers while it is used. A value below which the product can be
used without causing a problem is called the “allowable value”.
• If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is esti-
mated from various tests or experiences in most cases, however, it must be judged after considering the oper-
ating condition and customer's requirement.
5. Clearance limit
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those
parts cannot be used is called the “clearance limit”.
• If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6. Interference limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled
is called the “interference limit”.
• The interference limit shows the repair limit of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
1.4 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPO-

NENTS
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality
of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment”
(particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting one
component to another component, connectors used for
connecting and disconnecting one wire from another
wire, and protectors or tubes used for protecting the
wiring.
Compared with other electrical components fitted in
boxes or cases, wiring harnesses are more likely to be
affected by the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection and repair
operations, they are frequently removed and installed
again, so they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely careful
when handling wiring harnesses.
2. Main failures occurring in wiring harness
a. Defective contact of connectors (defective contact
between male and female)
Problems with defective contact are likely to occur
because the male connector is not properly inserted
into the female connector, or because one or both of
the connectors is deformed or the position is not cor-
rectly aligned, or because there is corrosion or oxi-
dization of the contact surfaces. The corroded or
oxidized contact surfaces may become shiny again
(and contact may become normal) by connecting
and disconnecting the connector about 10 times.
1-11
3. Defective crimping or soldering of connectors

The pins of the male and female connectors are in
contact at the crimped terminal or soldered portion, but if
there is excessive force brought to bear on the wiring, the
plating at the joint will peel and cause improper
connection or breakage.
4. Disconnections in wiring
If the wiring is held and the connectors are pulled apart,
or components are lifted with a crane with the wiring still
connected, or a heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be
damaged, or the wiring may be broken.
5. High-pressure water entering connector

The connector is designed to make it difficult for water to
enter (drip-proof structure), but if high-pressure water is
sprayed directly on the connector, water may enter the
connector, depending on the direction of the water jet.
Accordingly, take care not to splash water over the
connector. The connector is designed to prevent water
from entering, but at the same time, if water does enter, it
is difficult for it to be drained. Therefore, if water should
get into the connector, the pins will be short-circuited by
the water, so if any water gets in, immediately dry the
connector or take other appropriate action before passing
electricity through it.
6. Oil or dirt stuck to connector

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and
female pins, the oil will not let the electricity pass, so
there will be defective contact. If there is oil or grease
stuck to the connector, wipe it off with a dry cloth or blow
it dry with compressed air and spray it with a contact
restorer.
• When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
• If there is oil or water in the compressed air, the contacts
will become even dirtier, so remove the oil and water
from the compressed air completely before cleaning with
compressed air.
1-12
7. Removing, installing, and drying connectors and

wiring harnesses
a. Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the con-
nectors. For connectors held by a screw, loosen the
screw fully, then hold the male and female connec-
tors in each hand and pull apart. For connectors
which have a lock stopper, press down the stopper
with your thumb and pull the connectors apart.
Never pull with one hand.
2) When removing from clips

Both of the connector and clip have stoppers, which
are engaged with each other when the connector is
installed.
When removing a connector from a clip, pull the con-

nector in a parallel direction to the clip for removing
stoppers.
If the connector is twisted up and down or to the left or

right, the housing may break.
3) Action to take after removing connectors

After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from get-
ting in the connector portion.
If the machine is left disassembled for a long time, it is

particularly easy for improper contact to occur, so always
cover the connector.
1-13
b. Connecting connectors
1) Check the connector visually.
Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
Check that there is no deformation, defective con-
tact, corrosion, or damage to the connector pins.
Check that there is no damage or breakage to the
outside of the connector.
IMPORTANT
• If there is any oil, water, or dirt stuck to the connector,
wipe it off with a dry cloth. If any water has got inside the
connector, warm the inside of the wiring with a dryer, but
be careful not to make it too hot as this will cause short circuits.
• If there is any damage or breakage, replace the connector.
2) Fix the connector securely.
Align the position of the connector correctly, and
then insert it securely. For connectors with the lock
stopper, push in the connector until the stopper
clicks into position.
3) Correct any protrusion of the boot and any mis-
alignment of the wiring harness.
For connectors fitted with boots, correct any protru-

sion of the boot. In addition, if the wiring harness is
misaligned, or the clamp is out of position, adjust it
to its correct position.
IMPORTANT
• If the connector cannot be corrected easily, remove the
clamp and adjust the position.
• If the connector clamp has been removed, be sure to
return it to its original position. Check also that there are
no loose clamps.
c. Heavy duty wire connector (DT 8-pole, 12-pole)

Disconnection (Left figure)
While pressing both sides of locks (a) and (b),
pull out female connector (2).
Connection (Right figure)
1] Push in female connector (2) horizontally until
the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set com-
pletely, push in female connector (2) while mov-
ing it up and down until the locks are set
normally.
Arrow: 1), 2), 3)
1-14
Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely.
(1):Male connector
(2):Female connector
(a), (b): Locks
d. Drying wiring harness
If there is any oil or dirt on the wiring harness, wipe it
off with a dry cloth. Avoid washing it in water or using
steam. If the connector must be washed in water, do
not use high-pressure water or steam directly on the
wiring harness. If water gets directly on the connec-
tor, do as follows.
1) Disconnect the connector and wipe off the water
with a dry cloth.
IMPORTANT
If the connector is blown dry with compressed air, there is the
risk that oil in the air may cause defective contact, so remove
all oil and water from the compressed air before blowing with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry
the connector.
Hot air from the dryer can be used, but regulate the time
that the hot air is used in order not to make the connector
or related parts too hot, as this will cause deformation or
damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected
and carry out a continuity test to check for any short
circuits between pins caused by water.
After completely drying the connector, blow it with
contact restorer and reassemble.
1-15
8. Handling controller
a. The controller contains a microcomputer and elec-
tronic control circuits. These control all of the elec-
tronic circuits on the machine, so be extremely
careful when handling the controller.
b. Do not place objects on top of the controller.
c. Cover the control connectors with tape or a vinyl bag.
Never touch the connector contacts with your hand.
d. During rainy weather, do not leave the controller in a

place where it is exposed to rain.
e. Do not place the controller on oil, water, or soil, or in
any hot place, even for a short time. (Place it on a
suitable dry stand).
f. Precautions when carrying out arc welding
g. When carrying out arc welding on the body, discon-
nect all wiring harness connectors connected to the
controller. Fit an arc welding ground close to the
welding point.
9. Points to remember when troubleshooting electric

circuits
a. Always turn the power OFF before disconnecting or connecting connectors.
b. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
1) Disconnect and connect the related connectors several times to check.
c. Always connect any disconnected connectors before going on to the next step.
1) If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will
be generated.
d. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading of
the tester.
1) If there is any change, there is probably defective contact in that circuit.
1-16
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or repairing
the machine in rain or high winds, or places where there
is a lot of dust.
2. Disassembly and maintenance work in the field

If disassembly or maintenance work is carried out on
hydraulic equipment in the field, there is danger of dust
entering the equipment. It is also difficult to check the
performance after repairs, so it is desirable to use unit
exchange. Disassembly and maintenance of hydraulic
equipment should be carried out in a specially prepared
dustproof workshop, and the performance should be
checked with special test equipment.
3. Sealing openings
After any piping or equipment is removed, the openings
should be sealed with caps, tapes, or vinyl bags to
prevent any dirt or dust from entering. If the opening is left
open or is blocked with a rag, there is danger of dirt
entering or of the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain oil out
onto the ground, but collect it and ask the customer to
dispose of it, or take it back with you for disposal.
4. Do not let any dirt or dust get in during refilling

operations
Be careful not to let any dirt or dust get in when refilling
with hydraulic oil. Always keep the oil filler and the area
around it clean, and also use clean pumps and oil
containers. If an oil cleaning device is used, it is possible
to filter out the dirt that has collected during storage, so
this is an even more effective method.
5. Change hydraulic oil when the temperature is high
When hydraulic oil or other oil is warm, it flows easily. In
addition, the sludge can also be drained out easily from
the circuit together with the oil, so it is best to change the
oil when it is still warm. When changing the oil, as much
as possible of the old hydraulic oil must be drained out.
(Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If
any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the
hydraulic oil.
1-17
6. Flushing operations
After disassembling and assembling the equipment, or
changing the oil, use flushing oil to remove the
contaminants, sludge, and old oil from the hydraulic
circuit. Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump, control
valve, etc.) or when running the machine, carry out oil
cleaning to remove the sludge or contaminants in the
hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that the filter
built in the hydraulic equipment cannot remove, so it is an
extremely effective device.
1.5 HANDLING OF CONNECTORS NEWLY USED FOR ENGINES

Mainly, following engines are object for following connectors.
• 107E-1
• 114E-3
• 125E-5
• 140E-5
• 170E-5
• 12V140E-3
1. Slide lock type

(FRAMATOME-3, FRAMATOME-2)
• 107 – 170, 12V140 engines
• Various pressure sensors and NE speed sensor
Examples)
Intake air pressure in intake manifold: PIM(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing: NE(107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
1-18
Disconnect connector (1) according to the following

procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1)
toward you.
3) Even if lock (L2) is pressed, connector (1) cannot
be pulled out toward you, if part A does not float.
In this case, float part A with a small screwdriver
while press lock (L2), and then pull out connector
(1) toward you.
2. Pull lock type (PACKARD-2)

• 107 – 170, 12V140 engine
• Various temperature sensors
Example)
Intake air temperature sensor in intake mani-
fold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR, etc.
Disconnect the connector by pulling lock (B) (on the
wiring harness side) of connector (2) outward.
3. Push lock type

• 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector (3) in the direction of the arrow.
114 engine
1-19
107 engine
NOTE: If the lock is on the underside, use flat-head screw-

driver [1] since you cannot insert your fingers.
1) While pressing up lock (C) of the connector with

flat-head screwdriver [1], pull out connector (3) in
the direction of the arrow.
107, 114 engine

Example)
Intake air pressure/temperature sensor in intake
manifold
(SUMITOMO-04)
1) While pressing lock (D), pull out connector (4) in

the direction of the arrow.
125 – 170, 12V140 engine

1) While pressing lock (E) of the connector, pullout
connector (5) in the direction of the arrow.
Example)
Fuel pressure in common rail: PFUEL etc.
(AMP-3)
1-20
Example)
Injection pressure control valve of fuel supply pump:
PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
1) Pull the connector straight up.
4. Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CAN-
NON-04): PIM etc.
a. Disconnect connector (6) according to the following

procedure.
1) Turn housing (H1) in the direction of the arrow.
a When connector is unlocked, housing (H1)
becomes heavy to turn.
2) Pull out housing (H1) in the direction of the arrow.
3) Housing (H1) is left on the wiring harness side.
b. Connect the connector according to the following pro-

cedure.
1) Insert the connector to the end, while setting its
groove.
2) Turn housing (H1) in the direction of the arrow until
it “clicks”.
1-21
1.6 HOW TO READ ELECTRIC WIRE CODE

• The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The
electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness
and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Type Symbol Material temperature Example of use
range (°C)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for auto- AV appliance
(Nominal No. 5 and above)
mobile Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric –30 to +60
Conductor
low-voltage appliance General wiring
AVS
wire for auto- (Nominal No. 3 and below)
mobile Insulator Soft polyvinyl chloride
Heat-resis- Annealed copper for electric
Conductor General wiring in extremely cold
tant low-volt- appliance
AEX –50 to +110 district, wiring at high-tempera-
age wire for Heat-resistant crosslinked
Insulator ture place
automobile polyethylene
1-22
1. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
Conductor strand
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cover
AV Standard – – – – – – – 4.6
D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
Conductor strand
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cover
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
1-23
2. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
3. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
1-24
1.7 PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnect-
ing the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
a. Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
1-25
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with
2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt
or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
b. When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

a. Refilling with coolant, oil and grease
• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the
engine to circulate the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after
reassembling the parts.
• For details, see Testing and adjusting, “Bleeding air”.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
1-26
b. Checking cylinder head and manifolds for looseness

1) Check the cylinder head and intake and exhaust manifold for looseness.
2) If any part is loosened, retighten it.
3) For the tightening torque, see “Disassembly and assembly”.
c. Checking engine piping for damage and looseness
1) Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction
and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
2) Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
3) Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
d. Checking muffler and exhaust pipe for damage and looseness
1) Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2) Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
If any bolt or nut is loosened, retighten it.
e. Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and
assembly”.
1-27
1.8 METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE

COUPLER
• Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
• Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the
hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
a. Hold adapter (1) and push hose joint (2) into mating
adapter (3). (Fig. 1)
• The adapter can be pushed in about 3.5 mm.
• Do not hold rubber cap portion (4).
b. After hose joint (2) is pushed into adapter (3), press
rubber cap portion (4) against adapter (3) until it
clicks. (Fig. 2)
c. Hold hose adapter (1) or hose (5) and pull it out. (Fig.
3)
• Since some hydraulic oil flows out, prepare an oil
receiving container.
1-28
2. Connection
a. Hold hose adapter (1) or hose (5) and insert it in mat-
ing adapter (3), aligning them with each other. (Fig. 4)
• Do not hold rubber cap portion (4).
b. After inserting the hose in the mating adapter per-
fectly, pull it back to check its connecting condition.
(Fig. 5)
• When the hose is pulled back, the rubber cap portion
moves toward the hose about 3.5 mm. This does not
indicate abnormality, however.
Type 2
1. Disconnection
a. Hold the tightening portion and push body (7) straight
until sliding prevention ring (6) contacts contact sur-
face (a) of the hexagonal portion at the male end.
(Fig. 6)
b. While holding the condition of Step 1), turn lever (8)
to the right (clockwise). (Fig. 7)
c. While holding the condition of Steps 1) and 2), pull
out whole body (7) to disconnect it. (Fig. 8)
1-29
2. Connection
face (a) of the hexagonal portion at the male end.
(Fig. 9)
Type 3
1. Disconnection
face (b) of the hexagonal portion at the male end.
(Fig. 10)
b. While holding the condition of Step 1), push cover
(10) straight until it contacts contact surface (b) of the
hexagonal portion at the male end. (Fig. 11)
c. While holding the condition of Steps 1) and 2), pull
out whole body (9) to disconnect it. (Fig. 12)
2. Connection
until the sliding prevention ring contacts contact sur-
face (b) of the hexagonal portion at the male end.
(Fig. 13)
1-30
1.9 STANDARD TIGHTENING TORQUE TABLE

1. Table of tightening torques for bolts and nuts
Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque
wrench)
The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Fig. A Fig. B
1-31
2. Table of tightening torques for split flange bolts

Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
1-32
5. Table of tightening torques for hoses (taper seal type and face seal type)
Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below.
Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. - Thread
No. of across Thread size Number of diameter
hose flats Range Target
(mm) threads, type of (mm)
thread (Reference)
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the
torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the
torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
1-33
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to
the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
1.10 CONVERSION TABLE

Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the method of
using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.
a. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line
from (A).
b. Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from
(B).
c. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millime-
ters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

a. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
b. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
c. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 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 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
1-34
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 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 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 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
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 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
1-35
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 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
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 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
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
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 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
1-36
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
1-37
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 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
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
1-38
2. SPECIFICATIONS
2. SPECIFICATIONS
2.1 GENERAL
1. Applicable machine
Engine Serial No. Applicable machine

FD100-8, FD115-8,
SAA6D107E-1-A Lift truck
FD135-8, FD150E-8, FD160E-8
2.2 SPECIFICATIONS
Engine SAA6D107E-1-A
FD100-8, FD115-8,
Applicable model
FD135-8, FD150E-8, FD160E-8
No. of cylinders – Bore × Stroke mm 6 – 107 × 124
Total piston displacement l {cc} 6.69 {6,690}
Firing order — 1–5–3–6–2–4
Overall length in (mm) 44.8 (1,138)
Dimensions
Overall width in (mm) 32.1 (815)

Overall height (excluding exhaust pipe) in (mm) 44.3 (1,126)
Overall height (including exhaust pipe) in (mm) —
128.7 {173.0}/2,200
Flywheel horsepower kW{HP}/rpm
(Gross)
lbf/ft
Performance
435 (590) {60.2}/1,600

Max. torque (Nm){kgm}/
(Gross)
rpm
High idle speed rpm 2,425 ± 50
Low idle speed rpm 725 ± 25
g/kW·h
Min. fuel consumption ratio 238 {177}
{g/HP·h}
Dry weight kg 525
Fuel injection system HPCR
—
Fuel injection system control Electronic control type
Lubricating oil amount (refill capacity) l 22.6 (20.3)
Coolant amount l 8.4
Alternator — 24V, 35A
Starting motor — 24V, 4.5kW
Battery — 12V, 110Ah × 2
Turbocharger — HOLSET HX35W
Air compressor — —
Others — —
2-2
2. SPECIFICATIONS
2.3 GENERAL VIEW

SAA6D107E-1-A (Left side view of engine)
Machine model: FD100-8, FD115-8, FD135-8, FD150E-8, FD160E-8
1. Crankshaft center
2. Flywheel housing rear surface
2-3
2. SPECIFICATIONS
SAA6D107E-1-A (Right side view of engine)

2. Flywheel housing rear surface
2-4
2. SPECIFICATIONS
SAA6D107E-1-A (Front view of engine)

2. Cylinder center
2-5
2. SPECIFICATIONS
SAA6D107E-1-A (Rear view of engine)

2. Cylinder center
2-6
2. SPECIFICATIONS
2.4 DIMENSIONS TABLE

Unit: mm
Dimension of each part
Engine Machine model
A B C D
FD100-8, FD115-8,
SAA6D107E-1-A FD135-8, FD150E-8, 1,138 1,126 390 816
FD160E-8
These dimensions are given for reference when the engine is set on a test bench.
2-7
2. SPECIFICATIONS
2.5 ENGINE PERFORMANCE CURVE

SAA6D107E-1-A
Rated output: 128.7 kW {173 HP}/2,200 rpm (Gross)
Max. torque: 590 Nm {60.2 kgm}/1,600 rpm (Gross)
2-8
3. STRUCTURE AND
FUNCTION
3.1 AIR INTAKE AND EXHAUST UNITS

SAA6D107E-1-A
NOTE: The shape is subject to applicable machines.
A - Air inlet
B - Front side of cylinder block
1. Air connector
2. Electrical intake air heater
3. Turbocharger
4. Exhaust manifold
3-2
3-3
3.2 INTAKE SYSTEM

General Information
1. Intake air inlet to turbocharger

2. Turbocharger air to charge air cooler
3. Charge air cooler
4. Intake manifold
(integral part of the cylinder head)
5. Intake valve
Air is drawn through the air cleaner into the compressor side of the turbocharger. It is then forced through the
charge air cooler piping to the charge air cooler, the intake air heater (if applicable), and into the intake manifold.
From the intake manifold, air is forced into the cylinders and used for combustion.
3-4
3.3 EXHAUST SYSTEM

General Information
1. Exhaust valve
2. Exhaust manifold
3. Turbocharger
4. Turbocharger exhaust outlet
The turbocharger uses exhaust gas energy to turn the turbine
wheel. The turbine wheel drives the compressor impeller,
which provides pressurized air to the engine for combustion.
The additional air provided by the turbocharger allows more
fuel to be injected to increase the power output from the
engine.
The turbine and compressor wheels share a common shaft

(referred to as a rotor assembly), which is supported by two
rotating bearings in the bearing housing. Passages in the
bearing housing direct filtered, pressurized engine oil to the
shaft bearings and thrust bearings. The oil is used to lubricate
and cool the rotating components. Oil then drains from the
bearing housing to the engine sump through the oil drain line.
3-5
Lubricating Oil Consumption and Leaks

Engine lubricating oil is used to lubricate the bearings and
provide some cooling for the turbocharger. The lubricating oil
supplied to the turbocharger through the supply line is at
engine operating pressure. A return line connected to the
bottom of the turbocharger routes the lubricating oil back to
the engine lubricating oil pan.
Seal rings are used on each end of the rotor assembly. The
primary function of the seals is to prevent exhaust gases and
compressed air from entering the turbocharger housing.
Lubricating oil leakage from the seals is rare, but it can occur.
NOTE: Excessive crankcase pressure will not allow the

oil to drain from the turbocharger. This will load
the bearing housing and allow lubricating oil to
leak past the seal rings and into the engine and
exhaust.
If turbine seal leakage into the exhaust occurs on engines

with a catalyst, check the exhaust restriction during the repair.
3-6
3.4 TURBOCHARGER
Air-cooled type
Model: HOLSET HX35W
3-7
A: Air inlet
B: Air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
1. Turbine housing
2. Adapter gasket
3. Retainer ring
4. Adjusting link end
5. Plain washer
6. Bolt
7. Bracket (Actuator)
8. Bolt
9. Nut
10. Actuator
11. Compressor housing
12. Bearing housing
13. Bolt
14. Clamping plate
15. Split ring seal
16. Heat shield
17. Turbine wheel and shaft assembly
18. Adapter connection
19. Bolt
20. Retainer ring
21. Bearing
22. Thrust collar
23. Thrust bearing
24. Retainer ring
25. Compressor wheel
26. Locknut
27. Oil slinger
28. Split ring seal
29. Baffle
30. Retainer ring
Specifications
Model: HOLSET HX35W (Air-cooled)
Applicable exhaust temperature: Max. 700°C (inlet)
Rotation direction: Clockwise (seen from blower side)
3-8
Unit:in (mm)
No. Check item Criteria Remedy

Replace bearing
1 Radial play (Play in radial direction) 0.013 –0.020 (0.329 – 0.501)
parts
2 End play (Play in axial direction) 0.0014 – 0.0036 (0.038 – 0.093) Replace thrust parts
Tightening torque of turbine housing Target lbf/ft (Nm) {kgm})
3 Retighten
bolt 19.2 (26 {2.6}
3-9
3.5 LUBRICATING OIL SYSTEM

General Information
1. Gerotor lubricating oil pump 8. Filter bypass valve
2. From lubricating oil pump 9. Filter bypass valve closed
3. Pressure regulating valve closed 10. Filter bypass valve open
4. Pressure regulating valve open 11. To lubricating oil filter
5. To lubricating oil cooler 12. Full-flow lubricating oil filter
6. To oil pan 13. From lubricating oil filter
7. Lubricating oil cooler 14. Main lubricating oil rifle
3-10
Lubrication for the turbocharger
1. Turbocharger lubricating oil supply

2. Turbocharger lubricating oil drain
3-11
Lubrication for the power components
1. From lubricating oil cooler

2. Main lubricating oil rifle
3. To valve train
4. From main lubricating oil rifle
5. To piston-cooling nozzle
6. To camshaft
7. Crankshaft main journal
8. Oil supply to rod bearings
9. Directed piston-cooling nozzle
10. To internal lubrication of air compressor
3-12
Lubrication for the overhead components
1. Main lubricating oil rifle

2. Rocker lever support
3. Transfer slot
4. Rocker lever shaft
5. Rocker lever bore
6. Rocker lever
3-13
Lubrication for the accessory drive
1. Oil feed from block

2. Oil supply to accessory drive
NOTE: Oil returns to pan through the gear housing.
3-14
3.6 COOLING SYSTEM

Flow Diagram
1. Coolant inlet
2. Pump impeller
3. Coolant flow past lubricating oil cooler
4. Coolant flow past cylinders
5. Coolant flow from cylinder block to cylinder head
6. Coolant flow between cylinders
7. Coolant flow to thermostat housing
8. Coolant bypass passage
9. Coolant flow back to radiator
10. Bypass open
11. Coolant bypass in cylinder head
12. Coolant flow to water pump inlet
3-15
3.7 FUEL SYSTEM

General Information
Without electric lift pump
1. From fuel supply tank

2. Water/fuel separator (not mounted on engine)
3. ECM cooling plate
4. To fuel gear pump
5. To fuel filter
6. Fuel filter head
7. Fuel filter
8. To high-pressure pump
9. High-pressure pump
10. To fuel rail
11. Fuel rail
12. To injectors
13. High-pressure connector
14. Injector
15. Fuel return from injectors and fuel rail to fuel filter head
16. Fuel return from high-pressure pump to fuel filter head
17. Fuel return manifold
18. To fuel supply tank
3-16
3.7.1 INJECTORS AND FUEL LINES - OVERVIEW

General Information
The fuel system is a high-pressure common rail electronically controlled fuel system. The high-pressure common
rail system consists of four main components: Fuel pump gear pump, high-pressure pump, fuel rail, and injectors.
The high-pressure pump supplies high-pressure fuel to the fuel rail independent of engine speed. The high-
pressure fuel is then accumulated in the fuel rail. High-pressure fuel is constantly supplied to the injectors by the
fuel rail. The electronic control module (ECM) controls the fueling and timing of the engine by actuating the
injectors.
A suction side fuel/water separating filter is required. This filter is located off of the engine and contains a hand
priming pump. Fuel enters the engine at the ECM cooling plate, if equipped, and then flows to the fuel pump gear
pump. Using fuel pump gear pump pressure (approximately 42.6 – 189 psi (0.3 – 1.3 MPa) {3.0 – 13.3 kg/cm 2}),
fuel is filtered using an on-engine or remotely mounted fuel filter prior to entering the high-pressure fuel pump.
The fuel that enters the high-pressure fuel pump is pressurized between 25 and 180 MPa [255 to 1,837 kg/cm2] by
three radial pumping chambers. An M-Prop valve, or EFC valve, at the inlet to the three radial pumping chambers
regulates the volume of fuel that is allowed to enter the pumping chambers. By regulating the volume of fuel that is
pressurized, the M-Prop valve uses signals from the ECM to maintain the pressure in the fuel rail at a desired level.
Fuel that is not allowed to enter the three radial pumping chambers is directed through the Cascade Overflow
Valve. The Cascade Overflow Valve directs a certain amount of pressure to the lube channels of the high pressure
pump and then returns the fuel to the fuel tank.
The fuel rail acts as a fuel manifold accumulating and distributing fuel to each of the injector supply lines. Within the
fuel rail, there is a fuel rail pressure sensor that monitors the pressure provided to the fuel rail from the high-
pressure fuel pump.
Pressure measured by the fuel rail pressure sensor is used by the ECM to adjust the fuel output of the high-
pressure pump. The fuel rail also contains a fuel rail pressure relief valve. The fuel rail pressure relief valve is a
safety valve used to bleed off excess pressure if the rail pressure exceeds a preset threshold. Fuel bled off by the
fuel rail pressure relief valve is returned to the fuel tank through a fuel drain line connected to the fuel rail.
High-pressure common rail fuel systems use solenoid-actuated injectors. High-pressure fuel flows into the side of
the injector. When the solenoid is activated, an internal needle lifts and fuel is injected. The clearances in the
nozzle bore are extremely small and any dirt or contaminants will cause the injector to stick. This is why it is
important to clean around all fuel connections before servicing the fuel system. Also, cap or cover any open fuel
connections before a fuel system repair is performed.
3-17
High-pressure fuel is supplied to the injector from the fuel rail

by an injector supply line and a fuel connector. The fuel
connector pushes against the injector body when the fuel
connector nut is tightened. The injector supply line is then
connected to the fuel connector.
The torque on this fuel connector and the injector supply lines
is critical. If the nut or line is undertightened, the surfaces will
not seal and a high-pressure fuel leak will result. If the nut is
overtightened, the connector and injector will deform and
cause a high-pressure fuel leak. This leak will be inside the
head and will not be visible. The result will be a fault code,
low power, or no-start.
The fuel connector contains an edge filter that breaks up

small contaminants that enter the fuel system. The edge filter
uses the pulsating high pressure to break up any particles so
that they are small enough to pass through the injector.
NOTE: The edge filters are not a substitute for cleaning

and covering all fuel system connections during
repair. Edge filters are not a substitute for main-
taining the recommended engine mounted fuel fil-
ter.
All injectors feed into a common return circuit contained within

the cylinder head. Any excess fuel is returned to the tank via
this drilling in the cylinder head and return line attached to the
rear of the cylinder head. A back-pressure valve is located on
the back of the cylinder head where the drain line attaches.
The fuel drain lines may have either a quick-disconnect fitting
or a banjo fitting at ends of the fuel drain lines.
Each of the fuel drain lines combine together at the fuel return
manifold.
The electronic control module (ECM) controls the fueling and
timing of the engine by actuating the solenoids on the injector.
An electronic pulse is sent to the solenoids to lift the needle
and start the injection event. By electronically controlling the
injectors, there is a more precise and accurate control of
fueling quantity and timing. Also, multiple injection events can be achieved by electronically controlling the
injectors.
3-18
3.8 CYLINDER HEAD

SAA6D107E-1-A
1. Cylinder head Specifications Valve seat
2. Head cover Cylinder head • Press-fitted valve seat insert for both intake and
exhaust valves
3. Oil filler cap • Direct injection type
4. Head bolt • One-unit type Injector
5. Injector assembly • 4-valve type • Installation: Dry type (without sleeve)
3-19
3-20
Unit: mm
End-to-End Max. 0.305 Correct by

Strain of cylinder head mounting
1 grinding or
face Side-to-Side Max. 0.076 replace
Procedure Target lbf/ft (Nm) {kgm}

Tightening torque for cylinder
head mounting bolt 1st stage 66.3 (90) {9.2} Tighten and
2
(Apply molybdenum disulfide or 2nd stage 66.3 (90) {9.2} retighten
engine oil to threaded part)
3rd stage Retighten 90°
Replace noz-
3 Projection of nozzle 2.45 – 3.15
zle or gasket
Tightening torque for injector Target lbf/ft (Nm) {kgm}

4
holder mounting bolt 6.6 (8) {0.8}
Tighten
Tightening torque for head cover
5 17.7 (24) {2.4}
mounting bolt
3-21
3.9 CYLINDER BLOCK
3-22
Unit: in (mm)
Strain of cylinder head mount- End-to-End Max. 0.075 Correct by grind-

1
ing face Side-to-Side Max. 0.075 ing or replace
Replace main
Diameter of main bearing
2 3.463 – 3.464 (87.982 – 88.008) bearing metal
metal mounting hole
cap
Inside diameter of main bear-

3 3.269 – 3.271 (83.041 – 83.109)
ing metal Replace bearing
Thickness of main bearing metal
4 0.966 – 0.970 (2.456 – 2.464)
metal
Diameter of cam bushing Correct or

5 Max.: 2.333 (59.248)
mounting hole replace block
Inside diameter of cam bush- Replace cam

6 Max.: 2.132 (54.164)
ing bushing

Tightening torque for main cap 1st stage 44.3 (60) {6.1} Tighten and
7 mounting bolt
2nd stage 59.0 (80) {8.2} retighten
(Apply engine oil to threads)
Tightening torque for oil pan Target lbf/ft (Nm) {kgm}

8
mounting bolt 20.6 (28) {2.8}
Tighten and
retighten
Tightening torque for crank-
9 1st stage 36.9 50 {5.1}
shaft pulley mounting bolt
2nd stage Retighten 90°
Inside diameter of cylinder 4.212 – 4.123 (106.990 – 107.010)

Correct by over-
Roundness of inside of cylin-
10 Repair limit: 0.0015 (0.038) size or replace
der
cylinder block
Taper of inside of cylinder Repair limit: 0.0030 (0.076)
3-23
3.10 CRANKSHAFT
3-24
Unit: in (mm)
Replace thrust bearing

1 End play (A) 0.002 – 0.017 (0.065 – 0.432) metal or use oversize
metal
Outside diameter of main journal 3.266 – 3.268 (82.962 – 83.013)

Use undersize journal or
Roundness of main journal Repair limit: 0.002 (0.050)
replace
2 Taper of main journal Repair limit: 0.001 (0.013)
Replace main bearing

Clearance of main journal 0.0016 – 0.0047 (0.04 – 0.12)
metal
Outside diameter of crank pin jour-

2.715 – 2.717 (68.962 – 69.013) Use undersize journal or
nal
replace
3 Roundness of crank pin journal Repair limit: 0.002 (0.050)
Replace connecting rod

Clearance of crank pin journal 0.0016 – 0.0047 (0.04 – 0.12)
bearing metal
Outside diameter of crankshaft gear

4 2.779 – 2.780 (70.59 – 70.61)
journal Use undersize crank-
Inside diameter of crankshaft gear shaft or replace
5 2.776 – 2.777 (70.51 – 70.55)
journal
3-25
3.11 PISTON, PISTON RING AND PISTON PIN
Unit: in (mm)
Outside diameter of piston

1 4.222 – 4.223 (107.255 – 107.273) Replace piston
(at right angles to boss)
Top ring 0.013 – 0.017 (0.33 – 0.43)

Clearance at piston ring end
2 2nd ring 0.021 – 0.033 (0.55 – 0.85)
gap
Replace piston
Oil ring 0.010 – 0.019 (0.25 – 0.50)
ring or piston
2nd ring 0.001 – 0.004 (0.040 – 0.110)
3 Clearance of piston ring
Oil ring 0.001 – 0.003 (0.040 – 0.085)
4 Outside diameter of piston pin 1.5746 – 1.5749 (39.997 – 40.003)

Replace piston
Inside diameter of piston pin or piston pin
5 1.5750 –1.5754 (40.006 – 40.012)
bore
3-26
3.12 CONNECTING ROD
Unit: in (mm)
Replace bushing
Inside diameter of connecting
(spare part is
1 rod bushing (when bushing is 1.575 – 1.576 (40.019 – 40.042)
semi-finished
installed)
part)
Inside diameter of connecting

2 2.718 – 2.720 (69.05 – 69.10)
rod bearing Replace connect-
Thickness of connecting rod ing rod bearing
3 0.0769 – 0.0774 (1.955 – 1.968)
bearing
3-27
Inside diameter of connecting Replace connect-

4 72.99 – 73.01
rod bearing mounting hole ing rod

Tightening torque for connect-
ing rod cap mounting bolt 1st stage 22.1 (30) {3.1} Tighten and
5
(Coat thread of bolt nut with 2nd stage 44.2 (60) {6.1} retighten
engine oil)
Side clearance of connecting Replace connect-

6 0.0039 – 0.0129 (0.10 – 0.33)
rod ing rod
3.13 VIBRATION DAMPER
Unit: mm

Tightening torque of vibration Tighten and
1 1st stage 36.9 (50) {5.1}
damper retighten
2nd stage Retighten 90°
3-28
3.14 TIMING GEAR
Unit: in mm
Backlash of oil 0.0067 – 0.012

A
pump gear (0.170 – 0.300)
Backlash of cam- 0.0030 – 0.0110

B
shaft gear (0.076 – 0.280)
– Backlash of each gear Backlash of oil 0.0067 – 0.012 Replace
C
pump idler gear (0.170 – 0.300)
Backlash of fuel
0.0009 – 0.0057
D injection pump
(0.022 – 0.146)
gear
3-29
Camshaft 1
3-30
Unit: in (mm)
Replace
1 End play 0.0039 – 0.0141 (0.100 – 0.360)
thrust plate
Outside diameter of camshaft Correct or

2 2.090 – 2.128 (53.095 – 54.045)
bearing journal replace
Intake 1.857 – 1.884 (47.175 – 47.855)

3 Height of cam
Exhaust 1.797 – 1.823 (45.632 – 46.312)
Replace
Thickness of camshaft thrust
4 0.370 – 0.378 (9.40 – 9.60)
plate
Tightening torque of cam- Target lbf/ft (Nm {kgm})

5 shaft thrust plate mounting
bolt 17.7 (24) {2.4}
Tighten
Tightening torque of cam-
6 26.6 (36) {3.7}
shaft gear mounting bolt
3-31
3.15 VALVE AND VALVE GUIDE
3-32
Unit: in (mm)
Intake 0.0230 – 0.0423 (0.584 – 1.092) Replace

1 Sunk depth (A) of valve valve or
Exhaust 0.0378 – 0.0578 (0.965 – 1.473) valve seat
2 Thickness (B) of valve head Min. 0.0311 (0.79) Replace
Valve Angle Repair limit Correct or

replace
3 Angle of valve seat Intake 30° Judge condition of contact valve, valve
Exhaust 45° surface with vacuum test seat
Outside diameter of valve

4 0.274 – 0.276 (6.96 – 7.01)
stem Replace
5 Diameter of valve guide bore 0.2766 – 0.2786 (7.027 – 7.077)
Replace
Clearance between valve
6 0.0007 – 0.0046 (0.017 – 0.117) valve or
guide and valve stem
valve guide
Depth of valve insert bore

7 1.3719 – 1.3726 (34.847 – 34.863) Replace
(standard insert)
3-33
3.16 ROCKER ARM, SHAFT AND TAPPET
3-34
Unit: in (mm)
Outside diameter of rocker arm Replace rocker

1 Min. 0.8647 (21.965)
shaft arm shaft
Inner diameter of rocker arm Replace rocker

2 Max. 0.8672 (22.027)
shaft hole arm
Clearance between rocker arm Replace rocker

3 Max. 0.0024 (0.062)
shaft and rocker arm arm or shaft
Tightening torque of locknut for Target lbf/ft (Nm) {kgm}

4 Tighten
rocker arm adjustment screw 17.7 (24) {2.4}
Valve Repair limit
5 Valve clearance (cold) Intake 0.0098 (0.25) Adjust
Exhaust 0.0200 (0.51)
6 Outside diameter of tappet 0.6274 – 0.6298 (15.936 – 15.977) Replace tappet
Replace cylinder
7 Inside diameter of tappet hole 0.6299 – 0.6321 (16.000 – 16.055)
block
Clearance between tappet and Replace tappet or

8 0.0009 – 0.0047 (0.023 – 0.119)
tappet hole cylinder block
Tightening torque of rocker Target lbf/ft (Nm) {kgm}

9 Tighten
arm mounting bolt 26.5 (36) {3.7}
3-35
3-36
Unit: mm
1 Face runout of flywheel housing Repair limit: 0.008 (0.20) Reassemble,

2 Radial runout of flywheel housing Repair limit: 0.008 (0.20) correct
Target lbf/ft (Nm) {kgm}

Tightening torque of flywheel
3 M10: 36.1 (49) {5.0} Tighten
housing mounting bolt
M12: 62.7 (85) {8.7}
Flywheel Repair limit

4 Face runout of flywheel For torque Diameter (actual measurement) × Reassemble,
converter 0.0005 correct
5 Radial runout of flywheel Repair limit: (0.13)
Tightening torque of flywheel Target (Nm) {kgm}

6 mounting bolt Tighten
(Coat bolt thread with engine oil) 101 (137) {14.0}
3.17 OIL PUMP
Unit: mm
Clearance of rotor in axial

1 Max. 0.0050 (0.127)
direction Replace oil
Clearance between outer pump
2 Max. 0.0070 (0.178)
rotor and inner rotor

Tightening torque of oil pump Tighten and
3 1st stage 5.9 (8) {0.8}
mounting bolt retighten
2nd stage 17.7 (24) {2.4}
3-37
3.18 OIL PAN

SAA6D107E-1-A
1. Oil level gauge

2. Oil suction pipe
3. Oil pan
4. Drain plug
3-38
3.19 FLYWHEEL AND FLYWHEEL HOUSING
1. Flywheel housing
2. Starting motor
3. Ring gear (Number of teeth: 127)
4. Flywheel
5. Rear seal
3-39
Specifications
Rear seal
• For dry type: Single lip with dust seal
3-40
3.20 OIL FILTER
1. Filter cartridge
2. Filter head
3-41
3.21 OIL COOLER
1. Regulator valve
2. Oil cooler core assembly
3. Oil pump
4. Safety valve
Specifications
Oil cooler
• Number of element stages: 7
3-42
3.22 FUEL SUPPLY PUMP
1. Fuel injection pipe (No. 1) Specifications

2. Fuel injection pipe (No. 2) Fuel supply pump
3. Fuel injection pipe (No. 3) • Type: Rotary plunger feed type
4. Fuel injection pipe (No. 4) • Lubrication method: Lubrication
with fuel
5. Fuel injection pipe (No. 5)
6. Fuel injection pipe (No. 6)
7. Common rail
8. Fuel filter
9. Feed pump
10. Fuel supply pump
3-43
3.23 WATER PUMP DRIVE AND FAN DRIVE
Y: To radiator 1. V-belt 4. Water pump

Z: From radiator 2. Crankshaft pulley 5. Alternator
3. Tension pulley 6. Fan pulley
a, b, c, d, e: Outside diameter of pulley
Outside diameter of pulley Unit: in (mm)
Applicable a (Water b
Engine c (Tension) d. (Crankshaft) e. (Fan)
model pump) (Alternator)
FD100-8,
FD115-8,
SAA6D107
FD135-8, 3.46 (88) 3.07 (78) 2.87 (73) 6.85 (174) 7.2 (183)
E-1-A
FD150E-8,
FD160E-8
3-44
4. STANDARD VALUE
TABLE
4.1 STANDARD VALUE TABLE FOR TESTING, ADJUSTING AND TROU-

BLESHOOTING
FD100-8, FD115-8,
Applicable machine
FD135-8, FD150E-8, FD160E-8
Standard value
Cate-
gory
Item Measurement conditions Unit for new Permissible value

machine
High idle speed rpm 2,425 ± 50 2,425 ± 50

Performance
Engine speed
Low idle speed rpm 725 ± 25 725 ± 25
Necessary start- At 0°C rpm — —

ing speed At –20°C rpm — —
psi Max. 0.54 1.08

Intake resistance At all speed kPa (Max. 3.73) (7.45)
{mmH2O} {Max. 380} {760}
psi 21.3 16.4

Intake pressure
At rated horsepower kPa (Min. 147) (113)
(Aftercooler inlet)
{mmHg} {Min. 1,100} {850}
Air intake and exhaust system
Exhaust pressure
kPa
(Turbine inlet At rated horsepower — —
{mmHg}
press.)
Exhaust tempera-
ture
At all speed (at 20°C) °C Max. 690 740
(Turbine outlet
temp.)
At rated horsepower % Max. 12 22

Exhaust gas color Quick acceleration
% Max. 25 35
(Low idle o high idle)
0.0060 – 0.0150
Intake valve in. (mm) 0.0098 (0.25)
(0.152 – 0.381)
Valve clearance
0.0150 – 0.0230
Exhaust valve in. (mm) 0.020 (0.51)
(0.381 – 0.762)
Oil temperature: 40 – 60°C psi Min. 34.28 24.04

Compression pres- (MPa)
Engine speed: 250 – 280 (Min. 2.41) (1.69)
sure
{kg/cm2}
Body
rpm {Min. 24.6} {17.2}
kPa Max. 0.98 1.96

Blow-by pressure At rated horsepower
{mmH2O} {Max. 100} {200}
4-2
FD100-8, FD115-8,
Applicable machine
FD135-8, FD150E-8, FD160E-8
At rated horsepower psi Min. 42.67 35.56

(Oil temperature: Min. (MPa) (Min. 0.29) (0.25)
80°C)
SAE15W-40 {kg/cm2} {Min. 3.0} {2.5}
Lubrication system
Oil pressure
At low idle psi Min. 14.2 9.95
(Oil temperature: Min. (MPa) (Min. 0.10) (0.07)
80°C)
SAE15W-40 {kg/cm2} {Min. 1.0} {0.7}
At all speed 176 – 230

Oil temperature °F (°C) 248 (120)
(Oil in oil pan) (80 – 110)
Oil consumption At continuous rated

% Max. 0.15 0.3
ratio (Ratio to fuel consumption)
Radiator pressure Opening pressure kPa

Cooling system
— —
valve (Differential pressure) {kg/cm2}
Fan speed At rated engine speed rpm 2,110 2,110
Fan and alternator Deflects when pushed with

mm Auto-tensioner Auto-tensioner
belt tension a force of 98 N {10 kg}
4.2 RUN-IN STANDARD AND PERFORMANCE TEST CRITERIA

Run-in standard
Applicable machine FD100-8, FD115-8, FD135-8, FD150E-8, FD160E-8
Procedure
Item
1 2 3 4 5
Running time min 2 10 2 3 3
Engine speed rpm 725 1,000 1,200 1,600 2,200
lb (N) 216 (98) 540 (245) 970 (440) 1720 (780)

Dynamometer load 0 {0}
{kg} {10} {25} {45} {80}
kW
Output 0 {0} 7.4 {10} 22 {29.5} 53 {71} 129 {173}
{HP}
• The table gives the standard values for machines without fan.
• The loads for the dynamometer are at an arm’s length of28.2 in. (716 mm).
4-3
Performance test criteria
Applicable machine FD100-8, FD115-8, FD135-8, FD150E-8, FD160E-8
High idle Low idle

Test item Rated horsepower Max. torque
speed speed
128.7 ± 6.4 kW/ 590 ± 29.5 Nm/

Specification 2,200 rpm 1,600 ± 100 rpm 2,425 ± 50 725 ± 25
—
value (Gross) {173 ± 8.7 HP/ {60.2 ± 3.0 kgm/ rpm rpm
2,200 rpm} 1,600 ± 100 rpm}
Speed rpm 2,200 1,600 ± 100 2,425 ± 50 725 ± 25
Dynamometer lb (N) 1720 (780) 1817 (824)

— —
load {kg} {80} {84}
kW 129
Output (Gross) — — —
{HP} {173}
435.1
lbf/ft Nm
Torque (Gross) — (590) — —
{kgm}
{60.2}
sec/
Fuel consumption 30 — — —
300cc
Coolant tempera- 167 – 201 167 – 201

°F (°C) 167 – 201 (75 – 94) 167 – 201 (75 – 94)
ture (75 – 94) (75 – 94)
Lubricating oil 176 – 230 176 – 230 176 – 230 176 – 230
°F (°C)
temperature (80 –110) (80 – 110) (80 – 110) (80 – 110)
psi (kPa) Min. 37.98 Min. 28.01 Min. 37.98 Min. 7.98
Lubricating oil
Min. 261.8 (Min. 193.2) (Min. 261.8) (Min. 54.9)
pressure {kg/cm2} {Min. 2.67} {Min. 1.97} {Min. 2.67} {Min. 0.56}
Exhaust tempera- Max.1202 Max.1274

°F (°C) — —
ture Max. 650 Max. 690
• This table shows the standard values using the JIS correction factor.
• The output and torque values in the table are the standard values with the fan removed, so they are different
from the specification values.
• This table shows the standard values with an air cleaner installed, muffler installed, alternator under no load.
• The dynamometer load shows the value for an arm length of 716 mm.
• Use ASTM D975 diesel oil as the fuel.
• Use SAE15W-40 as the lubricating oil.
4-4
5. TESTING AND
ADJUSTING
5.1 TESTING AND ADJUSTING TOOLS LIST

Testing and
Symbol Part No. Part name Q'ty Remarks
adjusting item
–101 – 200 kPa {–760 – 1,500
Testing air boost 799-201-2202 Boost gauge kit 1
A mmHg}
pressure
799-401-2220 Hose 1 I-coupler type (if necessary)
1 795-799-1131 Gear 1
Adjusting valve
C Commercially
clearance 2 Clearance gauge 1
available
1 795-799-6700 Puller 1
Testing compres- 2 795-502-1590 Gauge assembly 1
D
sion pressure 3 795-790-4410 Adapter 1
4 6754-11-3130 Gasket 1
Testing blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
2 790-301-1230 Nipple 1
Testing oil pres- 3 799-101-5160 Nipple 1
F
sure
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Digital hydraulic Pressure gauge: 60 MPa {600 kg/
790-261-1204 1
tester cm2}
Testing fuel pres- 6732-81-3170 Adapter 1 10 × 1.0 mm o PT1/8
G
sure 2
6215-81-9710 O-ring 1
3 799-401-2320 Hydraulic tester 1
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
1 795-790-4700 Tester kit 1
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Commercially
4 Measuring cylinder 1
available
Testing leakage
from pressure Commercially
H 5 Stopwatch 1
limiter and return available
rate from injector Hose
Commercially
6 (Inside diameter: ø14 1
available
mm)
Hose
Commercially
7 (Inside diameter: ø8 1
available
mm)
Common to diesel and gasoline
Troubleshooting soft- machines
1 3EB-97-50030 1
ware (Applicable to Windows 2000/XP/
Check of failure Vista)
J
code
2 3EA-55-38880 Intermediate cable 1
CANBUS manufactured by KVASER
3 3BA-97-71220 Communication cable 1
Same as cable for FB-12/FBR-14
5-2
Testing and
Symbol Part No. Part name Q'ty Remarks
adjusting item
Measuring volt-
Commercially
age and resis- — Circuit tester 1
available
tance
Removal and
installation of
Commercially Hexlobe (TORX) 3.26 mm Hexlobe (TORX) wrench
booster pres- — 1
available wrench (KTC Q4T15 or equivalent)
sure and temper-
ature sensors
Removal and
installation of Commercially
— Deep socket 1 27 mm deep socket
engine oil pres- available
sure sensor
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-40 (5 pins)
799-601-7360 Adapter 1 Relay (5 pins)
799-601-7310 T-adapter 1 AWP (12 poles)
799-601-7070 T-adapter 1 AWP (16 poles)
799-601-4100 T-adapter assembly 1 Connected with engine
Diagnosis sen- 799-799-5530 T-adapter 1 Engine coolant temperature
—
sor and harness 799-601-4230 T-adapter 1 Boost temperature/pressure sensor
799-601-4130 T-adapter 1 Ne sensor, CAM sensor
799-601-4160 T-adapter 1 Hydraulic pressure sensor
799-601-4211 T-adapter 1 Controller (50 poles)
799-601-4140 T-adapter 1 Atmosperic pressure sensor
799-601-4340 T-adapter 1 Pump actuator
799-601-4190 T-adapter 1 Common rail pressure sensor
5.2 TESTING AIR BOOST PRESSURE

TESTING TOOLS FOR AIR BOOST PRESSURE
Symbol Part No. Part name

799-201-2202 Boost gauge kit
A
799-401-2220 Hose
Be careful not to touch any hot part when removing or installing the testing tools.
NOTE: The test point is subject to machine models.
5-3
1. Remove air boost pressure pickup plug (1).
2. Install nipple [1] of boost gauge kit A and connect it to

gauge [2].
3. Run the engine at the rated output and test the air boost
pressure.
IMPORTANT
When testing with the engine mounted on the machine, test
on the condition described in the shop manual for the
machine.
4. After finishing testing, remove the measuring tools and

return the removed parts.
5.3 ADJUSTMENT OF VALVE CLEARANCE

VALVE CLEARANCE ADJUSTING TOOLS

1 795-799-1131 Gear
C Commercially
2 Clearance gauge
available
5-4
1. Remove cylinder head cover (1).
2. Remove plug (2) from the starting motor top and install
tool C1.
NOTE: The shape in the figure may be a little different

from the actual machine.
3. Rotate the crankshaft forward with tool C1 and set wide

slit (b) on the disc having the revolution sensor slits at the
rear of the crankshaft pulley to projection top (a) of the
front cover.
a Seen from the air intake manifold side, set projection
top (a) into wide slit (b).
NOTE: The shape in the figure may be little different from the
actual machine.
After this positioning, each cylinder is not set to the top

dead center. Take care. (Each cylinder is set 76 – 88°
before the top dead center.)
• No. 1 cylinder or No. 6 cylinder
4. Adjust the valve clearance according to the following procedure.
5-5
NOTE: If you cannot move the rocker arms of the exhaust

valves (on the EX side) with the hand, adjust the
valves marked with open circle in the valve arrange-
ment drawing.
If you can move the rocker arms of the exhaust
valves (on the EX side) with the hand by the valve
clearance, adjust the valves marked with filled circle
in the valve arrangement drawing.
a. Insert clearance gauge C2 in the clearance between

rocker arm (3) and crosshead (4).
b. Loosen locknut (5) and adjust the valve clearance
with adjustment screw (6).
c. With the clearance gauge inserted, turn the adjust-
ment screw to a degree that you can move the clear-
ance gauge lightly.
d. While fixing adjustment screw (6), tighten locknut (5).
torque
Locknut: 14.7 – 20.7 lbf/ft (20 – 28 Nm) {2.04 – 2.86

kgm}
e. After tightening the locknut, check the valve clear-
ance again.Rotate the crankshaft forward by 1 turn
with tool C1 and set wide slit (b) to projection top (a) according to step 3.
5. Adjust the other valve clearances according to step 4.
NOTE: If the valves marked with open circle in the valve arrangement drawing were adjusted in step 4, adjust the
valves marked with closed circle.
6. After finishing adjustment, remove the adjusting tools and return the removed parts.
Remove tool C1 without fail.
torque
Cylinder head cover mounting nut: 14.7 – 20.7 lbf/ft (20 – 28 Nm) {2.04 – 2.86 kgm}
5.4 TESTING COMPRESSION PRESSURE

TESTING TOOLS FOR COMPRESSION PRESSURE

1 795-799-6700 Puller
2 795-502-1590 Gauge assembly
D
3 795-790-4410 Adapter
4 6754-11-3130 Gasket
When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muf-
fler, etc. or get caught in a rotating part.
5-6
IMPORTANT
Measure the compression pressure after the engine is warmed up.
(Engine oil temperature: 104 – 140°F (40 – 60°C)).

1. Remove cylinder head cover (1).
2. Disconnect injector harness connectors (2) (at 6 places)
and move the harnesses.
3. Disconnect fuel high-pressure tube (3).
4. Loosen injector terminal nut (4) and remove the terminal

from the injector.
5. Move the cylinder to be tested to the compression top dead center.
NOTE: See “Adjusting valve clearance”.
6. Remove rocker arm assembly (5).
5-7
7. Remove retainer (6) and disconnect fuel inlet connector

(7).
8. Remove holder (8).
9. Remove injector (9).
NOTE: Remove the injector using puller D1 and the impact of

slide hammer.
Do not unclench the upper part of the injector.
10. Install gasket D4 to the tip of adapter D3 and connect it to

the injector mount.
11. Fix adapter D3 with the injector holder.
a. Tighten the holder mounting bolts alternately.
torque
Holder mounting bolt:5.9 ± 0.59 lbf/ft (8 ± 0.8 Nm) {0.8 ±

0.08 kgm}
12. Connect gauge assembly D2 to adaptor D3.

a. Apply a little amount of engine oil to the connecting
parts of the adapter and gauge so that air will not leak
easily.
13. Install rocker arm assembly (5).
torque
Rocker arm assembly mounting bolt: 26.5 ± 3.7 lbf/ft (36 ± 5

Nm) {3.67 ± 0.51 kgm}
14. Adjust valve clearance.
NOTE: See “Adjusting valve clearance”.
15. Disconnect all the injector wiring harness connectors.
• If the connectors are not disconnected, the engine will start during measurement and that will be dan-
gerous. Accordingly, be sure to disconnect them.
• If the crankshaft is rotated without turning on the controller, the common rail is damaged. Accord-
ingly, be sure to check that the controller is turned ON.
• Cover the disconnected connectors with a vinyl sheet etc. to prevent electric leakage and grounding
fault.
16. Rotate the engine with the starting motor and measure the compression pressure.
NOTE: Read the pressure gauge pointer when it is stabilized.
5-8
17. After finishing testing, remove the testing tools and return
the removed parts.
18. Install the injector and fuel high-pressure tube according
to the following procedure.
a. Mate protrusion (a) of the injector with notch (b) of
the holder, and set the injector to the cylinder head.
NOTE: Set the injector with the above mating position toward
the fuel inlet connector insertion side.
b. Tighten injector holder mounting bolt (10) 3 to 4

threads.
c. Set fuel inlet connector (7).
NOTE: Press it in until you feel the O-ring clicks in.
d. Alternately tighten injector holder mounting bolt (10).

torque
Holder mounting bolt :5.9±.6 lbf/ft (8 ± 0.8 Nm)

{0.8 ± 0.08 kgm}
e. Tighten retainer (6) of the fuel inlet connector.
torque
Retainer: 36.9±3.7 lbf/ft (50 ± 5 Nm) {5.1 ± 0.5 kgm}

f. Tighten the sleeve nut of the fuel high-pressure tube
(3) in order of the head side and common rail side.
torque
Sleeve nut: 25.8±2.6 lbf/ft (35 ± 3.5 Nm) {3.6 ± 0.4 kgm}
19. After installing the rocker arm assembly, adjust the valve
clearance.
NOTE: For details, see “Adjusting valve clearance”.
torque
Rocker arm assembly mounting bolt: 26.5±3.7 lbf/ft (36 ± 5

Nm) {3.67 ± 0.51 kgm}
20. Tighten the injector terminal nut with the following torque.
torque
Terminal nut:1.1±.2 lbf/ft (1.5 ± 0.25 Nm) {0.15 ± 0.025 kgm}
Check that the injector wiring harness does not interfere with the rocker arm.
21. Tighten the head cover mounting nuts to the following torque.
torque
Head cover mounting nut:17.7±2.9 lbf/ft (24 ± 4 Nm) {2.45 ± 0.41 kgm}
5-9
5.5 TESTING BLOW-BY PRESSURE

a Testing tool for blow-by pressure

E 799-201-1504 Blow-by checker
1. Install adaptor [1] of blow-by checker E to the tip of blow-by hose (1).
2. Connect hose [2], and then connect it to adaptor [1] and
gauge [3].
3. Run the engine at the rated output and test the blow-by
pressure.
NOTE: When testing with the engine mounted on the

machine, test on the condition described in the shop
manual for the machine.

5.6 TESTING ENGINE OIL PRESSURE

TESTING TOOLS FOR ENGINE OIL PRESSURE

2 790-301-1230 Nipple
F 3 799-101-5160 Nipple
4 799-401-2320 Gauge
5-10
1. Remove oil pressure pickup plug (1).
actual machine.
2. Install the nipples to the plug mount in order of F2 and F3,

and connect it to gauge F4.
actual machine.
3. Run the engine at the rated output and low idle and test
the oil pressure.
NOTE: When testing with the engine mounted on the

machine, test on the condition described in the shop
manual for the machine.

5.7 HANDLING FUEL SYSTEM PARTS

1. Precautions for testing and maintaining fuel system
The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection
pump and nozzle. If foreign matter enters this system, it can cause a trouble.
When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part,
wash that part thoroughly with clean fuel.
2. Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel
injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it.
If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such
a filter.
5-11
5.8 RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM

1. Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine
is running.
Low-pressure circuit:
Feed pump – Fuel filter – Fuel supply pump
High-pressure circuit:
Fuel supply pump – Common rail – Fuel injector
2. The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30
seconds after the engine is stopped.
3. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be
released completely. Accordingly, observe the following.
Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine
until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the
engine since there is residual pressure.)
5.9 TESTING FUEL PRESSURE

TESTING TOOLS FOR FUEL PRESSURE

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
6732-81-3170 Adapter (10 × 1.0 mm o PT1/8)
2
G 6215-81-9710 O-ring
3 799-401-2320 Hydraulic tester
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit
IMPORTANT
Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply
pump and in the return circuit from the supply pump through the common rail and the injector to the fuel tank.
Since the pressure in the high-pressure circuit from the fuel supply pump through the common rail to the
injector is very high, it cannot be measured.
1. Testing fuel low-pressure circuit pressure
5-12
a. Remove fuel pressure pickup plug (1) from the fuel

main filter fuel inlet.
actual machine.
b. Install adapter G2 and nipple [1] of hydraulic tester

G1 and connect it to oil pressure gauge [2].
NOTE: Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.

The shape in the figure may be little different from the
actual machine.
c. Run the engine at low idle and test the fuel low-pres-
sure circuit pressure.
NOTE: If the fuel low-pressure circuit pressure is in the fol-

lowing range, it is normal.
72.5 –189.2 psi (0.5 – 1.3 MPa)

Low idle
{5.1 – 13.3 kg/cm2}
44.1 – 160.3 psi (0.3 – 1.1 MPa)
Cranking
{3.1 – 11.3 kg/cm2}
When the engine cannot run, you may test it by cranking the engine with the starting motor. To protect the
starting motor, do not continuously crank the engine 20 seconds or more.
d. After finishing testing, remove the testing tools and return the removed parts.
torque
Fuel pressure pickup plug:7.4 ± 1.5 lbf/ft (10 ± 2 Nm) {1 ± 0.2 kgm}
2. Checking fuel return circuit pressure
5-13
a. Remove fuel pressure pickup plug (2) from the fuel

return block.
b. Connect nipples [3] and [1] of hydraulic tester G1

there and connect hydraulic tester G3.
NOTE: Nipple [3]: 790-301-1181, 07002-11223
c. Run the engine at low idle and test the fuel return circuit pressure.
NOTE: If the fuel return circuit pressure is in the following range, it is normal.
Low idle
Max. 2.7 psi (0.02 MPa){ 0.19 kg/cm2}
Cranking
When the engine cannot run, you may test it by cranking the engine with the starting motor. To protect the
starting motor, do not continuously crank the engine 20 seconds or more.
d. After finishing testing, remove the testing tools and return the removed parts.
torque
Fuel pressure pickup plug:17.7 ± 2.9 lbf/ft (24 ± 4 Nm) {2.4 ± 0.4 kgm}
3. Measuring fuel negative-pressure circuit pressure
5-14
a. Remove joint bolt (2) of fuel hose (1) between the

prefilter and supply pump (3).
b. Connect fuel hose (1) to supply pump (3) by tool J1

instead of joint bolt (2).
NOTE: When installing tool J1, fit the gaskets to both sides
of the fuel hose joint.
torque
Tool J1: 14.5 – 21.7lbf/ft (19.6 – 29.4 Nm) {2.0 – 3.0

kgm}
c. Connect tool J2 to tool J1.
d. Run the engine and measure the circuit negative

pressure at high idle.
Circuit standard negative pressure:
Max. – 7.35 lb/in2 (–50.7 kPa) {–380 mmHg}
e. If the negative pressure is higher than the standard pressure, the fuel prefilter may be clogged. In this
case, replace the fuel prefilter and measure again.
f. After finishing measurement, remove the measuring instruments and return the removed parts.
torque
Joint bolt (2):14.5 - 21.7 lbf/ft (19.6 – 29.4 Nm) {2.0 – 3.0 kgm}
5-15
5.10 REDUCED CYLINDER MODE OPERATION

Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled
electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows.
1. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is
abnormal).
2. When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not
change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects.
The possible defects are as follows.
• Leakage through cylinder head gasket
• Defective injection
• Defective piston or piston ring
• Defective valve mechanism
(Moving valve system)
• Defect in electrical system
3. Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator
can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder.
• Perform the reduced cylinder mode operation with the engine mounted on the machine or connected to
troubleshooting tool.
Before performing, see Testing method in the shop manual for the machine or troubleshooting tool.
5.11 NO-INJECTION CRANKING

No-injection cranking means to crank the engine with the starting motor while all the injections are stopped
electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the machine has been stored for a long period, the no-injection cranking is
performed to lubricate the engine parts and protect them from seizure.
Perform the no-injection cranking mode operation with the engine mounted on the machine or connected to
Before performing, see Testing method in the shop manual for the machine or troubleshooting tool.
5-16
5.12 TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURN RATE

FROM INJECTOR
TESTING TOOLS FOR LEAKAGE FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR

1 795-790-4700 Tester kit
6754-71-5340 Connector
3
6754-71-5350 Washer
H 4 Commercially available Measuring cylinder
5 Commercially available Stopwatch
6 Commercially available Hose (Inside diameter: 14 mm)
7 Commercially available Hose (Inside diameter: 8 mm)
NOTE: Prepare a receiver of 5.2 gal. (20 l) for fuel leakage during testing.
1. Measuring supply pump delivery

a. Loosen clamp (2) of discharge tube (1) of the supply
pump and disconnect tube (1).
b. Install test hose H6 to the nipple on the discharge

side of the supply pump.
c. Fix the hose with a wire etc.
d. Adjust the route of the test hose so that it will not
slacken and put its end in an oil receiving pan.
5-17
e. Crank the engine for 30 seconds and measure the

delivery with measuring cylinder H4.
f. Adjust the route of the test hose so that it will not
Do not crank the engine for more than 30 seconds to pro-

tect the starting motor in any case other than this mea-
surement.
NOTE: If the supply pump delivery is in the following stan-

dard range, it is normal.
At cranking speed (125 rpm) Min. 75 cc

At cranking speed (150 rpm) Min. 90 cc
g. After finishing measurement, remove the measuring instruments and return the removed parts.
torque
Tube sleeve nut: 25.8 ± 2.9 lbf/ft (35 ± 4 Nm) {3.6 ± 0.4 kgm}
torque
Clamp mounting bolt: (10 ± 2 Nm) {1.0 ± 0.2 kgm}

2. Measuring supply pump return rate
a. Disconnect return hose (1) of the supply pump.
b. Install connector H3 and cap nut [1] of tester kit H1 to

the return hose to stop the fuel from flowing out.
c. Connect test hose [2] of tester kit H1 to the supply
pump.
d. Adjust the route of the test hose so that it will not
5-18
e. Run the engine at low idle and measure the return

rate from the supply pump with measuring cylinder
H4.
NOTE: If the return rate from the supply pump is in the fol-
Low idle Max. 400 cc/25 sec
f. After finishing testing, remove the testing tools and

3. Measuring leakage from pressure limiter

a. Disconnect return hose (2) of the pressure limiter.
NOTE: Keep the seal washer installed to the connector bolt.
b. Install removed joint bolt (3) and cap nut [1] of tester
kit H1 to the return hose to prevent the fuel from flow-
ing out.
c. Install connector H3 to the common rail and connect
test hose [2] of tester kit H1.
d. Set the test hose so that it will not slack and put its
end in the receiving pan.
e. Run the engine at low idle and measure the leakage

in 1 minute with measuring cylinder H4.
NOTE: If the leakage from the pressure limiter is in the fol-

Low idle 0 cc (No leakage)
f. After finishing testing, remove the testing tools and

torque
Joint bolt: 17.7 ± 2.9lbf/ft (24 ± 4 Nm) {2.4 ± 0.4 kgm}
5-19
4. Testing return rate from injector

a. Disconnect return hose (4) from the cylinder head.
b. Fit the seal washer to the connector bolt.
c. Install connector H3 to the cylinder head and connect

test hose [2] of tester kit H1 and put its end in an oil
receiving pan.
d. Install removed connector bolt (5) and cap nut [1] of
tester kit H1 to the return hose to prevent fuel leak-
age.
e. Run the engine at low idle and test the return rate
from the injector with measuring cylinder H4.
NOTE: If the return rate from the injector is in the following

range, it is normal.
Low idle Max. 180 cc/min.

Cranking Max. 90 cc/min.
When the engine cannot run, you may test it by cranking

the engine with the starting motor. To protect the starting
motor, do not continuously crank the engine 20 seconds or more.
f. After finishing testing, remove the testing tools and return the removed parts.
torque
Joint bolt: 17.7 ± 2.9lbf/ft (24 ± 4 Nm) {2.4 ± 0.4 kgm}
5.13 BLEEDING AIR FROM FUEL CIRCUIT

If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the
following procedure.
When the priming pump and fuel filter is remote mounted, bleed air by operating the priming pump at the remote
side.
5-20
1. Loosen the knob of the priming pump (1) (remote mount

side) and move it back and forth.
actual machine.
2. Continue moving the knob until it becomes hard to move.

(If the main filter is empty, move the knob 60 – 70 times,
and the air is bled.)
3. Start the engine with the starting motor.
NOTE: The air in the high-pressure circuit is bled automati-

cally if the engine is cranked.
If the engine does not start, air may not be bled from
the low-pressure circuit. In this case, repeat the above work.
5.14 TESTING FUEL SYSTEM FOR LEAKAGE
• Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the
engine is running, it is dangerous since it can catch fire.
• After testing the fuel system or removing its parts, test it for fuel leakage according to the following
procedure.
IMPORTANT
Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.
1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-
pressure piping.
2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel leakage.
a. Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage.
b. If any fuel leakage is detected, repair it and inspect again from step 1.
4. Run the engine at low idle.
6. Run the engine at high idle.
8. Run the engine at high idle and load it.
a. When checking while the components to be checked are mounted on the machine, stall the torque con-
verter or relieve the hydraulic pump.
c. If no fuel leakage is detected, check is completed.
5.15 REPLACING THE FAN BELT

The auto-tensioner is provided for the fan belt. Thus, testing and adjustment of the belt is usually no necessary.
1. Disconnect air conditioner compressor belt before replacing the fan belt.
5-21
2. Insert a wrench to the portion (A) (width across flats T

12.7 mm) of the tensioner assembly (3), and rotate it to
the opposite to the winding-up direction to decrease the
fan belt (2) tension.
• Make sure that the wrench is secured at the portion

(A) before rotating it. (The spring of the tensioner
assembly (3) is strong. If the wrench is loosely
inserted, the wrench may accidentally come off while
being rotated and it is extremely dangerous.)
• After removing the fan belt (2), return the tensioner
assembly (3) slowly with care.
• Be careful not to get your fingers caught between the
pulley and fan belt (2) during work.
3. Replace the fan belt (2).
4. Check each pulley for breakage and crack.
5.16 HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT
The engine controller uses a high-voltage circuit to drive the fuel injector. Accordingly, the high-voltage
circuit is connected to the wiring harnesses and connectors between the engine controller and injector.
Normally, the engine controller keeps outputting the high voltage to the injector only while the engine is running and
stops outputting when the engine stops.
If you touch the high-voltage circuit directly, you may get an electric shock. To avoid this, observe the fol-
lowing precautions when testing.
1. The following connectors are used in the high-voltage circuit.

• Engine controller connector: J1
• Injector intermediate connector:
INJ CYL 1&2, INJ CYL 3&4, INJ CYL 5&6
• Injector head terminal (in head cover)
2. When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting
switch OFF.
5-22
3. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting,
do not start the engine.
IMPORTANT
You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
5.17 FUNCTIONS OF TROUBLESHOOTING TOOL AND CHECK OF FAILURE

CODE
CHECK OF FAILURE CODE
1 3EB-97-50030 Troubleshooting software
J 2 3EA-55-38880 Intermediate cable
3 3BA-97-71220 Communication cable
5.17.1 FUNCTIONS OF TROUBLESHOOTING TOOL

The electronically controlled engine controller of this machine indicates a failure code when a trouble occurs. The
failure code can be checked by the following 2 methods.
• Check of failure code with troubleshooting tool
• Check of failure code by blinking lamp of meter panel
The troubleshooting tool has the following functions.
1. Indication of failure code
2. Deletion of failure code
3. Indication of repair procedure
5.17.2 METHOD OF INDICATING FAILURE CODE WITH TROUBLESHOOTING TOOL

Install troubleshooting software J1 from the CD-ROM to a personal computer (PC) in advance.
1. Turn the key switch OFF.
3. Disconnect cap (1A) (having a short circuit wiring
harness) from connector (1) of the wiring harness on the
left side of the machine and connect communication
cable J3 of troubleshooting software J1 and intermediate
cable J2.
NOTE: Machine in this photo is different from actual machine
5-23
4. Start the installed software and check the failure code.
NOTE: The method of using the software is shown in the CD-

ROM.
5-24
Example of indication of failure code
5.17.3 METHOD OF INDICATING FAILURE CODE WITH METER PANEL

1. Interchange cap (1A) (having a short circuit wiring har-
ness) of connector (1) and cap (2A) (having no short cir-
cuit wiring harness) of connector (2). By this work, the
circuit of connector (1) is disconnected and that of con-
nector (2) is shorted and the failure code can be indicated
by the blinking patterns of engine abnormality warning
lamp (3) and abnormality warning lamp (4) of the meter
panel.
• Interchange of respective caps (1A) and (2A) of connector
(1) and (2): Failure code indication function ON
• Non-interchange (Normal state) of respective caps (1A)
and (2A) of connector (1) and (2): Failure code indication
function OFF
NOTE: When starting or running the engine ordinarily, do not

interchange caps (1A) and (2A).
5-25
5-26
2. Indication in normal state

When the key switch is turned ON, engine abnormality warning lamp (3) and abnormality warning lamp (4) are
turned ON or OFF as shown below.
In position "A", the indication varies with the following condition.
• Failure lamp indication selector connector is not connected: Warning lamps (3) and (4) are turned OFF.
• Failure lamp indication selector connector is connected and in trouble: Warning lamps (3) and (4) blink to
indicate trouble.
3. Indication when trouble occurs

A generated failure code is indicated under the following conditions.
• Condition (1): Engine is stopped
• Condition (2): Key switch is in ON position
• Condition (3): Respective caps (1A) and (2A) of connector (1) and (2) are interchanged.
5-27
Example 3: Simultaneous indication of failure codes "112" and "244"
5-28
6. TROUBLESHOOTING
6. TROUBLESHOOTING
6.1 GENERAL INFORMATION ON TROUBLESHOOTING
• Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely
fitted.
• When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do
not allow any unauthorized person to come near.
• If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
• Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
• When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
• When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it prop-
erly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the
structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to
form some idea of possible causes of the failure that would produce the reported symptoms.
1. Do not rush at disassembling the machine even if a failure occurs.

Otherwise,
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry
out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Questions to users and operators
a. Have any other problems occurred apart from the problem that has been reported?
b. Was there anything strange about the machine before the failure occurred?
c. Did the failure occur suddenly, or were there problems with the machine condition before this?
d. Under what conditions did the failure occur?
e. Had any repairs been carried out before the failure? When were these repairs carried out?
f. Has the same kind of failure occurred before?
3. Inspections before troubleshooting
a. Is there any sign of irregularities of the machine?
b. Make checks before starting day's work.
c. Make checks of other items.
d. Check other maintenance items which can be visually checked and are considered necessary.
4. Confirmation of failure
Confirm the degree of failure on your own to verify if it is a real failure and the machine is handled or operated
improperly.
a. When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation
or measurement that may make the problem worse.
5. Troubleshooting
Pinpoint high possibility causes according to the results of examinations and inspections of items 2 to 4, and
find the failure location based on the troubleshooting table or troubleshooting flow (chart).
a. The basic procedure for troubleshooting is as follows.
• Start from the simple points.
• Start from the most likely points.
• Investigate other related parts or information.
6. Radical countermeasures against failure cause
Even if the immediate problem is removed, a similar failure will reoccur unless its root cause is removed. To
prevent reoccurence, examine the reason of the failure cause occurrence and remove the root cause.
6-2
6. TROUBLESHOOTING
6.2 FAILURE CODE TABLE
Failure code of
Place of
troubleshooting Trouble
description
tool
111 Abnormality in engine controller
115 Abnormality in engine NE and Bkup speed sensors
122 Abnormally high level in charge pressure sensor
123 Abnormally low level in charge pressure sensor
131 Abnormally high level in throttle sensor
132 Abnormally low level in throttle sensor
143 Torque derating by low engine oil pressure
144 Abnormally high level in coolant temperature sensor
145 Abnormally low level in coolant temperature sensor
146 Engine overheating
153 Abnormally high level in charge temperature sensor
154 Abnormally low level in charge temperature sensor
221 Abnormally high level in atmospheric pressure sensor
222 Abnormally low level in atmospheric pressure sensor
234 Engine overspeed
Troubleshooting of
238 Abnormality in Ne speed sensor power supply electrical system
271 Short circuit in IMV (E-mode)
272 Disconnection in IMV

342 Matching error in engine controller data
351 Abnormality in injector drive circuit
415 Rotation derating by low engine oil pressure
418 Water mixed in fuel
428 Abnormally high level in water sensor
429 Abnormally low level in water sensor
431 Abnormality in idle validation switch
6-3
6. TROUBLESHOOTING
Failure code of
Place of
troubleshooting Trouble
description
tool
432 Abnormality in processing of idle validation
435 Abnormality in engine oil pressure switch
441 Abnormally low power supply voltage
442 Abnormally high power supply voltage
451 Abnormally high level in common rail pressure sensor
452 Abnormally low level in common rail pressure sensor
488 Derating of torque by abnormally high charge temperature
Troubleshooting of
559 No-pressure feed by supply pump 1 electrical system
689 Abnormality in engine Ne speed sensor (E-mode)
731 Abnormality in engine Bkup speed sensor phase
757 Loss of all data in engine controller
778 Abnormality in engine Bkup speed sensor
2185 Abnormally high level in throttle sensor power supply
2186 Abnormally low level in throttle sensor power supply
2311 Abnormality in IMV solenoid
2555 Disconnection in intake air heater relay
2556 Short circuit in intake air heater relay
Failure code of troubleshooting tool:

3- or 4-digit failure code displayed on troubleshooting tool when a failure occurrence condition is confirmed using
6.3 INFORMATION IN TROUBLESHOOTING TABLE

The following information is summarized in the troubleshooting table and the related electrical circuit diagram.
Before carrying out troubleshooting, understand that information fully.
Failure code Failure code
Display on Display on Trouble Problem that appears on engine

troubleshooting applicable
tool machine
Contents of
Contents of trouble detected by engine controller
trouble
Action of Action taken by engine controller to protect system or devices when engine controller detects
controller trouble
Problem that
appears Problem that appears on engine as result of action taken by engine controller (shown above)
on machine
Related
Information related to detected trouble or troubleshooting
information
6-4
6. TROUBLESHOOTING
Causes Standard value in normal state/Remarks on troubleshooting

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1 <Troubles in wiring harness>
Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
Ground fault
Wiring harness which is not connected to chassis ground cir-
cuit is in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each other
Possible abnormally.
causes and stan- Possible causes of trouble
dard value (Given numbers are refer-
in normal state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1)Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
If connector No. has no marks of “male” and “female“, discon-
nect connector and insert T-adapters in both male side and
female side.
If connector No. has marks of “male” and “female”, discon-
nect connector and connect T-adapter to only male side or
female side.
(2)Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise speci-
4 fied.
Connect positive (+) lead to pin No. or wiring harness entered
on front side.
Connect negative (–) lead to pin No. or wiring harness
entered on rear side.
6-5
6. TROUBLESHOOTING
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
6-6
6. TROUBLESHOOTING
6.4 METHOD OF USING TROUBLESHOOTING CHARTS

The troubleshooting chart consists of the “questions”, “check
items”, “causes”, and “troubleshooting” blocks.
The questions and check items are used to pinpoint high
probability causes by simple inspection or from phenomena
without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to
check the narrowed causes in order from the most probable
one to make final confirmation according to the
troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the right.
The items in A are basic ones.
The items in B can be drawn from the user or operator,
depending on their level.
[Check items]:
Items to be simply checked by the serviceman to narrow
down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and check
items.
The serviceman narrows down the probable causes from
A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed down causes
are undoubtedly the real causes using the
troubleshooting tools and direct inspections.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
When narrowing the “causes“, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes
cannot be narrowed, however, you may apply them.)
6-7
6. TROUBLESHOOTING
Example of troubleshooting: Exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have causal
relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air
cleaner clogging caution lamp is flashing].
6-8
6. TROUBLESHOOTING
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
6-9
6. TROUBLESHOOTING
6.5 TROUBLESHOOTING FOR MECHANICAL SYSTEM (S MODE)

6.5.1 S-1 STARTING PERFORMANCE IS POOR
General causes why starting performance is poor Causes
• Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
• Insufficient supply of fuel
Defective alternator (generator section)

Defective alternator (regulator section)
• Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system

• Improper selection of fuel
Defective or deteriorated battery

• The common rail fuel injection system (CRI) controls the fuel
Clogged air cleaner element

injection timing electrically. Accordingly, even if the starting
Clogged fuel filter, element

operation is carried out, the engine may not start until the
Worn piston ring, cylinder

crankshaft revolves 2 turns at maximum. This phenomenon
does not indicate a trouble, however.
Defective injector
Confirm recent repair history
Degree of use of
Operated for long period E E E
machine
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Shop Manual w w Q Q
Oil must be added more frequently w
When engine is preheated or when temperature is low, blow indicator does
w
not indicate normally (if meter panel is installed)
Charge warning lamp is lighting while engine is running (if meter panel is
w w
installed)
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
While engine is If air bleeding plug of fuel filter is removed, fuel does
w
cranked with starting not flow out
motor, Much fuel returns from the injector w
Check items
When exhaust manifold is touched immediately after starting engine, tem-

w
perature of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
6-10
6. TROUBLESHOOTING
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Carry out troubleshooting according to “No-pressure feed by supply pump
Troubleshooting
q
(*1)” in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine
q
speed does not change
When starting switch is turned to HEAT, intake air heater mount does not
q
become warm
Is voltage 20 – 30 V between alternator terminal B and termi- Yes q
nal E with engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured,
q
they are low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
*1: Troubleshooting for failure codes [559] and [2249] in E mode
6-11
6. TROUBLESHOOTING
6.5.2 S-2 ENGINE DOES NOT START

A. Engine does not turn Causes
General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

• Seized parts inside engine
• See “S-4 Engine stops during operations”
• Defective electrical system
Defective or deteriorated battery
Defective steering circuit wiring

• Problem in drive devices on applicable machine side
• Carry out troubleshooting for devices on applicable machine
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Defective safety relay

Degree of use of
Questions
Operated for long period E E

machine
Condition of horn when Horn does not sound Q Q w
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q

When specific gravity of electrolyte and voltage of battery are measured, they are
q
low
Carry out troubleshooting
There is not voltage (20 – 30 V) between battery relay ter-
q on applicable machine
Troubleshooting
minal B and terminal E

When terminal B and terminal C of starting switch are con-
q
Turn starting switch nected, engine starts
OFF, connect cord, and When terminal B and terminal C at safety relay outlet are
q
carry out troubleshoot- connected, engine starts
ing at ON Even if terminal B and terminal C at safety relay outlet are
q
connected, engine does not start
When terminal at safety switch and terminal B at starting
q
motor are connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
6-12
6. TROUBLESHOOTING
B) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke comes

out
Defective common rail pressure limiter

• Fuel is not being supplied
Defective operation of overflow valve

Seized, abnormally worn feed pump
• Supply of fuel is extremely small

• Improper selection of fuel (particularly in winter)
Defective supply pump MPROP

Clogged fuel filter element
Broken supply pump shaft

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
(Does not close)

Degree of use of
Questions
machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E
Fuel other than specified one is used w
Replacement of filters has not been carried out according to Shop Man-
w E Q
ual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

If air bleeding plug of fuel filter is removed, fuel
While engine is Q Q w Q
does not flow out
cranked with starting
motor, If spill hose from injector is disconnected, little
Q w w w Q
fuel spills

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply
q q
pump (*1)” in E-mode
Carry out troubleshooting according to “Abnormality in supply pump PCV
q
(*2)” in E-mode
Inspect pressure relief valve directly q
Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy

6-13
6. TROUBLESHOOTING
C) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
not start
• Lack of rotating force due to defective electrical system
Leaking or clogged fuel system, entry of air

Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery
Clogging of fuel filter

Use of improper fuel
Degree of use of
machine
Questions
Suddenly failed to start w w Q

Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Shop Manual w w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate normally (if monitor is installed)
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder
w
head
Check items
If air bleeding plug of fuel filter is removed, fuel

Q w
While engine is cranked does not flow out
with starting motor, If spill hose from injector is disconnected, little fuel
w
spills
6-14
6. TROUBLESHOOTING

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting
Inspect fuel filter directly q

Carry out troubleshooting according to “No-pressure feed by supply pump
q
(*1)” in E-mode
When specific gravity of electrolyte and voltage of battery are measured,
q
they are low
Coolant temperature gauge does not indicate normally (if coolant tempera-
q
ture gauge is installed)
When starting switch is turned to HEAT, intake air heater mount does not
q
become warm
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
6-15
6. TROUBLESHOOTING
6.5.3 S-3 ENGINE DOES NOT PICK UP SMOOTHLY

General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

• Defective condition of fuel injection


• Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electrical system)

Clogged injector, defective spray

Improper valve clearance

Degree of use of
Operated for long period E E E E
machine
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Shop Manual w w
Rust and water are found when fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, tempera-
Q w
ture of some cylinders is low
Blue under light load w
Color of exhaust gas is
Black w Q w w
Check items
When engine is cranked, abnormal sound is generated around cylinder head w

When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w
applied
There is hunting from engine (rotation is irregular) Q Q Q
6-16
6. TROUBLESHOOTING

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)”
q
in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
6-17
6. TROUBLESHOOTING
6.5.4 S-4 ENGINE STOPS DURING OPERATIONS

General causes why engine stops during opera- Causes
tions
Broken dynamic valve system (valve, rocker arm, etc.)

• Internal parts of engine seized
Broken auxiliary equipment (pump, compressor, etc.)

Defective engine controller power supply wiring

• There is overheating
• Problem in drive devices on applicable machine side

• Carry out troubleshooting for devices on
Broken, seized piston, connecting rod

applicable machine

Broken, seized crankshaft bearing
Clogging feed pump gauze filter
Defective starting switch wiring

Clogging of fuel filter, strainer
Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train
Degree of use of
machine
Abnormal noise was heard and
w w w w Q w Q w w
engine stopped suddenly
Questions
Condition when engine Engine overheated and stopped w Q Q Q Q

stopped Engine stopped slowly w Q Q Q Q
There was hunting and engine
w Q Q Q Q
stopped
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to
w w
Shop Manual
Fuel gauge indicates low level w
Rust and water are found when fuel tank is drained w w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w
6-18
6. TROUBLESHOOTING
Carry out troubleshooting on applicable machine.

Inspect piston, connecting rod directly q
Inspect crankshaft bearing directly q
Inspect gear train directly q
Inspect feed pump gauze filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by
q q
supply pump (*1)” in E-mode
Engine rotates when pump auxiliary equipment (pump, com-
q
pressor, etc.) is removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
—
6-19
6. TROUBLESHOOTING
6.5.5 S-5 ENGINE DOES NOT ROTATE SMOOTHLY

General causes why engine does not rotate smoothly Causes
• Air in fuel system
Clogged injector, defective spray (dirt in injector)

• Defective speed sensor (Error at degree that it is not indicated)
Defective Ne speed sensor, wiring harness

Defective G speed sensor, wiring harness


Degree of use of
Operated for long period E
machine
Questions
Occurs at a certain speed range Q Q

Occurs at low idle Q Q Q Q Q
Hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Shop Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” in E-mode q
Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” in E-
q
mode
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Troubleshooting for failure code [689] in E mode

*2: Troubleshooting for failure code [778] in E mode
6-20
6. TROUBLESHOOTING
6.5.6 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)

General causes why engine lacks output Causes
Clogged injector, defective spray (dirt in injector)
Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor

Defective drive of injector (signal, solenoid)



• See “S-14 Coolant temperature becomes too
Air leakage from air intake piping

high (Overheating)“
Leaking, clogged fuel piping

(limiting injection rate (output) because of an error in

electrical system)
Clogged fuel spill piping

(air leakage)
Degree of use of
machine
Questions
Suddenly Q w Q Q Q Q
Power was lost
Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
Replacement of filters has not been carried out according to
w w
Shop Manual
Oil must be added more frequently Q Q
Dust indicator is red (if indicator is installed) w w
Air breather hole of fuel tank cap is clogged w w
Output becomes insufficient after short stop of operation w
Black w w
When exhaust manifold is touched immediately after starting
w w
engine, temperature of some cylinders is low
When engine is cranked, interference sound is generated
w
around turbocharger
Check items
When engine is cranked, abnormal sound is generated

w
around cylinder head
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly
Q w Q Q
drops when load is applied
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w
6-21
6. TROUBLESHOOTING

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
When compression pressure is measured, it is found to be
q q
low
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to “No-pressure feed by
q
supply pump (*1)” in E-mode
When a cylinder is cut out for reduced cylinder mode opera-
q q
tion, engine speed does not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in boost
q
pressure sensor (*2)” in E-mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

6-22
6. TROUBLESHOOTING
6.5.7 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head

Defective coolant temperature sensor, wiring harness


• See “S-14 Coolant temperature becomes too high
(Overheating)“

(limiting injection rate (output) because of an error in

electrical system)
Improper fuel injection pressure


Crushed, clogged muffler
Abnormally worn injector

Improper injection timing
Clogged, seized injector
Degree of use of
machine
Suddenly became black w w Q Q Q
Questions
Color of exhaust gas is Gradually became black w Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine,
Q w
temperature of some cylinders is low
When engine is cranked, interference sound is generated around tur-
w
bocharger
Check items

w
head
Torque converter stall speed or pump relief speed is high (Fuel is
Q
injected excessively)
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Much fuel returns from the injector w
6-23
6. TROUBLESHOOTING

When turbocharger is rotated by hand, it is fount to be heavy q
Troubleshooting
When muffler is removed, exhaust sound improves q

Carry out troubleshooting according to “No-pressure feed by supply
q q
pump (*1)” in E-mode
q
Carry out troubleshooting according to “Abnormality in coolant temper-
q
ature sensor (*2)” in E-mode
Confirm with troubleshooting tool or with monitoring function on appli-
q q
cable machine side
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

6-24
6. TROUBLESHOOTING
6.5.8 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)

General causes why oil consumption is excessive Causes
• Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

• Long-time operation of engine at low idle or high idle
Worn, damaged valve (stem, guide, seal)

(Do not run engine at idle for more than 20 minutes
continuously)
Dust sucked in from intake system

• External leakage of oil
Clogged breather, breather hose

• Wear of pats in lubrication system
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
Questions

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnor-
q
mally
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
6-25
6. TROUBLESHOOTING
6.5.9 S-9 OIL BECOMES CONTAMINATED QUICKLY

General causes why oil becomes contaminated quickly Causes
• Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
• Clogging of lubrication passage
• Use of improper fuel
• Use of improper oil
Clogged breather, breather hose

• Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions
Degree of use of
machine
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q

Inspect oil cooler directly q See S-7
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
6-26
6. TROUBLESHOOTING
6.5.10 S-10 FUEL CONSUMPTION IS EXCESSIVE

General causes why fuel consumption is excessive Causes
• Leakage of fuel
Fuel leakage from fuel filter, piping,

Defective fuel supply pump oil seal
• Defective condition of fuel injection (fuel pressure, injection timing)
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective coolant temperature

• Excessive injection of fuel
Defective operation of injector

Defective spray by injector
Improper injection timing
sensor,wiring harness
Degree of use of
Questions

machine
More than for other machines of same model Q Q Q Q
Condition of fuel con-
Gradually increased Q Q
sumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect fuel supply pump oil seal directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)”
q
Troubleshooting
in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
Much fuel returns from the injector q
Carry out troubleshooting according to “Abnormality in coolant temperature sen-
q
sor (*2)” in E-mode
Confirm with troubleshooting tool or with monitoring function on applicable
q q
machine side
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

6-27
6. TROUBLESHOOTING
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT

LEVEL GOES DOWN) 1
General causes why oil is in coolant Causes
• Internal leakage in lubrication system
Broken cylinder head, head gasket
power train oil cooler on applicable

• Internal leakage in cooling system
Broken oil cooler core, O-ring
Broken hydraulic oil cooler or

Cracks inside cylinder block
Holes caused by pitting
machine side
Degree of use of
Questions

machine
Suddenly rose Q Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w
When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q Carry out

Trouble-
Inspect cylinder block directly q q troubleshooting

on applicable
Pressure-tightness test of oil cooler shows there is leakage q machine
Replace
Replace
Replace
Replace
Remedy
—
6-28
6. TROUBLESHOOTING
6.5.11 S-12 OIL PRESSURE DROPS

General causes why oil pressure drops Causes
• Leakage, clogging, wear or lubrication system
Leaking, crushed, clogged hydraulic piping

• Defective oil pressure control
• Improper selection of fuel (improper viscosity)
• Deterioration of oil due to overheating
Clogged, broken pipe in oil pan

Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Questions
machine
Engine trouble warning lamp lights because of oil pressure reduction (if meter
Q w
panel is installed)
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Shop Manual w
Indicates pressure drop at low idle w
Engine trouble warning lamp lights because of oil pres-
Oil pressure monitor sure reduction while engine is running at low idle or high Q w w w Q
(if installed) idle
Indicates pressure drop on slopes w
Sometimes indicates pressure drop w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of regulator valve are fatigued, damaged q
Inspect oil filter directly q
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy
—
6-29
6. TROUBLESHOOTING
6.5.12 S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)

General causes why oil level rises Causes
• Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

• Fuel in oil (smells diluted diesel fuel)
• If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Defects in supply pump

Broken injector, O-ring
Questions
Degree of use of
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of
w Q
Check items
bubbles appears, or coolant spurts back

Exhaust smoke is white Q
Oil level in clutch chamber or damper chamber is low w
Oil level in hydraulic tank of machine is low w

Remove injector and inspect O-ring. q
Troubleshooting
Inspect cylinder block directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
6-30
6. TROUBLESHOOTING
6.5.13 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)

General causes why coolant temperature becomes too Causes
high
temperature on applicable machine side

• Lack of cooling air (deformation, damage of fan)
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

• Drop in heat dissipation efficiency
Defective operation of thermostat

• Problem in coolant circulation system
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
• Rise in oil temperature in torque converter
Rise in torque converter oil

• o Carry out troubleshooting on applicable machine
Clogged, broken oil cooler
Broken fan pulley bearing

Clogged radiator core

Lack of coolant
Degree of use of
machine
Questions
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q Q w w Q
Coolant temperature Rises quickly Q Q w
gauge
(if meter panel is Does not go down from red range w
installed)
Engine oil level has risen, oil is milky w w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are

w w
clogged with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
torque converter oil temperature enters red range faster than engine
w
coolant temperature (if meter panel is installed)
6-31
6. TROUBLESHOOTING

Inspect cylinder block directly q q
Inspect oil cooler directly q
Carry out troubleshooting

on applicable machine
Temperature difference between upper and lower radiator tanks is
q
Troubleshooting
large
When operation of thermostat is carried out, it does not open at crack-
q
ing temperature
Temperature difference between upper and lower radiator tanks is
q
slight
Inspect radiator core directly q
When operation of radiator cap is carried out, cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
6-32
6. TROUBLESHOOTING
S-15 ABNORMAL NOISE IS MADE 1

General causes why abnormal noise is made Causes
• Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

• Abnormal combustion
Defective inside of muffler (dividing board out of position)

Leakage of air between turbocharger and cylinder head
• Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

• Judge if the noise is an internal noise or an external noise
Broken dynamic valve system (valve, rocker lever)

before starting troubleshooting.
Interference of turbocharger, seized turbocharger
temperature sensor, boost temperature sensor)

• The engine is operated in the low-temperature mode while it
is not warmed up sufficiently. Accordingly, the engine sound
becomes a little larger. This does not indicate abnormality,
however.
Excessive wear of piston ring, cylinder

• When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little larger for up
to about 3 seconds. This does not indicate abnormality,
Improper gear train backlash

however.
Removed, seized bushing

Clogged, seized injector

Dirt caught in injector
Degree of use of
Operated for long period E
machine
Questions
Condition of abnormal Gradually occurred Q Q

noise Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around tur-
w
bocharger
w w
head
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine,

w Q
temperature of some cylinders is low
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
6-33
6. TROUBLESHOOTING
When turbocharger is rotated by hand, it is found to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
q q
Abnormal noise is heard only when engine is started q
Confirm with troubleshooting tool q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
6-34
6. TROUBLESHOOTING
S-16 VIBRATION IS EXCESSIVE 1

General causes why vibration is excessive Causes
• Defective parts (abnormal wear, breakage)
Improper fuel injection timing (abnormality in coolant

• Misalignment between engine and chassis
Stuck dynamic valve system (valve, rocker lever)

• Abnormal combustion
temperature sensor, boost temperature sensor)

Loose engine mounting bolts, broken cushions
Misalignment between engine and devices on
• If abnormal noise is made and vibration is excessive, carry out
Worn main bearing, connecting rod bearing

troubleshooting for “S-15 Abnormal noise is made“, too.
Broken output shaft, parts in damper on

Improper gear train backlash
applicable machine side
applicable machine side

Worn camshaft bushing
Degree of use of
Questions

machine
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with troubleshooting tool q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
6-35
6. TROUBLESHOOTING
6.6 TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E MODE)

6.6.1 E-1 FAILURE CODE [111] ABNORMALITY IN ENGINE CONTROLLER
Failure code Abnormality in engine Controller
Trouble
111 (Engine controller system)
Contents of trouble • Abnormality occurred in memory of engine controller or power supply circuit.
Action of controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on
• The engine does not start or operate normally.
machine
Related information • Method of reproducing failure code: Start engine
Possible causes and Causes Standard value in normal state/Remarks on troubleshooting

standard value in normal
state Carry out troubleshooting of failure code [757].
6.6.2 E-2 FAILURE CODE [115] ENGINE NE OR BKUP SPEED SENSOR ERROR
Failure code Engine Ne or Bkup speed sensor error
Trouble
• Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed
Contents of trouble
sensor circuit.
Action of controller • None in particular
Problem that appears • Engine stops.
on machine • The engine does not start.
Related information • Method of reproducing failure code: Start engine

Defective Ne speed Ne speed sensor can be defective.
1
Possible causes and sensor Carry out troubleshooting of failure code [689].
standard value in nor- Defective Bkup speed Bkup speed sensor can be defective.
mal state 2
sensor Carry out troubleshooting of failure code [778].
Defective connection of Check Ne speed sensor and Bkup speed sensor directly for
3
sensor connector defective connection (wrong connection).
6-36
6. TROUBLESHOOTING
6.6.3 E-3 FAILURE CODE [122] ABNORMALLY HIGH LEVEL IN CHARGE PRESSURE
SENSOR
Failure code
Trouble Abnormally high level in charge pressure sensor
122
Contents of • High voltage is detected in pressure signal circuit of boost pressure sensor and temperature
trouble sensor.
Action of • None in particular
controller
Problem that • Engine output drops.
appears on
machine
Related • Method of reproducing failure code: Starting switch ON.
information

Defective sensor power sup- If failure code [227] is indicated simultaneously, carry out trou-
1
ply 2 circuit bleshooting for it first.
Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective [pressure signal BOOST PRESS & IMT Voltage
2 circuit] of boost pressure Between (2) – (4) Power supply 4.75 – 5.25 V
sensor, temperature sensor
Voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and control-
ler, too, for another cause of trouble, and then judge.
Hot short (Short circuit with 5 and carry out troubleshooting.
3 V, 24 V circuit) in wiring har-
ness Wiring harness between J1 (female) (44)
Voltage Max. 1 V
Possible – BOOST PRESS & IMT (female) (1)
causes and Prepare with starting switch OFF, then carry out troubleshoot-
standard value ing without turning starting switch ON.
in normal state Short circuit in wiring har-
4 ness Wiring harness between J1 (female) (44)
(with another wiring harness) – BOOST PRESS & IMT (female) (1) Resis- Min.
and J1 (female) (37) – BOOST PRESS tance 100 kz
& IMT (female) (2)
Connecting parts among boost pressure sensor, temperature
sensor, engine wiring harness, and engine controller are sus-
Defective wiring harness pected. Inspect them directly.
5
connector • Loose connector, broken lock, broken seal
• Corrosive, bent, broken, forced-in, or extended pin
• Humidity in connector, entry of dirt or dust, poor insulation
6 Defective engine controller J1 Voltage
Between (37) –
Power supply 4.75 – 5.25 V
(47)
6-37
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO BOOST PRESSURE, TEMPERATURE SENSOR (COMBI-

NATION SENSOR)
6-38
6. TROUBLESHOOTING
6.6.4 E-4 FAILURE CODE [123] ABNORMALLY LOW LEVEL IN CHARGE PRESSURE
SENSOR
Failure code
Trouble Abnormally low level in charge pressure sensor
123
Contents of • Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature
trouble sensor.
Action of • Fixes charge pressure and continues operation.
controller
appears
on machine
information

Defective sensor power If failure code [187] is indicated simultaneously, carry out trou-
1
supply 2 circuit bleshooting for it first.
Defective [pressure signal BOOST PRESS & IMT Voltage
2 circuit] of boost pressure Between (2) – (4) Power supply 4.75 – 5.25 V
sensor, temperature sensor
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Grounding fault in wiring Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Contact with ground cir- Wiring harness between J1 (female) (44) Resis- Min.
Possible cuit) – BOOST PRESS & IMT (female) (1) tance 100 kz
causes and
standard value Prepare with starting switch OFF, then carry out troubleshooting
in normal state Short circuit in wiring har- without turning starting switch ON.
4
(with another wiring har- and BOOST PRESS & IMT (female) (1) Resis- Min.
ness) and J1 (female) (47) and BOOST PRESS tance 100 kz
& IMT (female) (4)
5
connector Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
6 Defective engine controller
J1 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
6-39
6. TROUBLESHOOTING

NATION SENSOR)
6.6.5 E-5 FAILURE CODE [131] THROTTLE SENSOR HIGH ERROR

Failure code Throttle sensor high error
Trouble
Contents of • High voltage was detected in the throttle sensor signal circuit.
trouble
Action of con- • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is
troller ON.
Problem that • The engine does not reach full throttle.
appears
on machine
Related infor- • Method of reproducing failure code: Turn the starting switch ON.
mation
6-40
6. TROUBLESHOOTING

Defective throttle sensor If failure code [2185] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
Accelerator pedal
Accelerator pedal Voltage
connector
All range
Defective accelerator pedal Between (1) and (3) (Power supply) 4.75 – 5.25 V
2
(Internal trouble)
When released 0.50 – 0.80 V
Between (2) and (3)
When pressed 3.70 – 4.00 V
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller for another cause of trouble before judgment.
Hot short (Short circuit with and carry out troubleshooting.
3 5V, 24V circuit) in wiring har- Wiring harness between J2 (female) (9) –
Possible ness accelerator pedal connector (female) (2) Voltage Max. 1 V
causes and and chassis ground
standard value
in normal state Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring har- without turning starting switch ON.
ness Wiring harness between J2 (female) (9) –
4
(with another wiring har- accelerator pedal connector (female) (2), Resis- Min.
ness) J2 (female) (22) – accelerator pedal con- tance 1 Mz
nector (female) (1)
Connecting parts among accelerator pedal, engine unit wiring
harness, and engine controller are suspected. Inspect them
Defective wiring harness directly.
5
J2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range
4.75 – 5.25 V
(23) (Power supply)
Between (9) and When released 0.50 – 0.80 V
(23) When pressed 3.70 – 4.00 V
6-41
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO THROTTLE SENSOR
6.6.6 E-6 FAILURE CODE [132] THROTTLE SENSOR LOW ERROR

Failure code Throttle sensor low error
Trouble
Contents of • Low voltage was detected in the throttle sensor signal circuit.
trouble
Action of con- • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it
troller is ON.
appears
on machine
mation
6-42
6. TROUBLESHOOTING

Defective throttle sensor If failure code [2186] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
Accelerator pedal
Accelerator pedal Voltage
connector
All range
Defective accelerator pedal Between (1) and (3) (Power supply) 4.75 – 5.25 V
2
(Internal trouble)
When released 0.50 – 0.80 V
Between (2) and (3)
When pressed 3.70 – 4.00 V
Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring har- without turning starting switch ON.
ness
3 Wiring harness between J2 (female) (9) –
(Short circuit with ground Resis- Min.
Possible accelerator pedal connector (female) (2)
circuit) tance 1 Mz
causes and and chassis ground
standard value
4
(with another wiring har- accelerator pedal connector (female) (2), Resis- Min.
ness) J2 (female) (23) – accelerator pedal con- tance 1 Mz
nector (female) (3)
5
J2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range
4.75 – 5.25 V
(23) (Power supply)
Between (9) and When released 0.50 – 0.80 V
(23) When pressed 3.70 – 4.00 V
6-43
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO THROTTLE SENSOR
6-44
6. TROUBLESHOOTING
6.6.7 E-7 FAILURE CODE [143] (TORQUE DERATING BY LOW ENGINE OIL
PRESSURE)
Failure code Torque derating by low engine oil pressure
Trouble
Contents of • While engine is run, engine oil pressure became lower than operating range.
trouble
Action of con- • Limits output and continues operation (Limits fuel injection rate and engine speed).
troller
Problem that • Engine output lowers.
appears
on machine
Related infor- • Method of reproducing failure code: Start engine.
mation

Low engine oil pressure
Engine oil has potentially gone low. Check the pressure and if it
1 (When the system is nor-
is below the specified level, locate and eliminate the cause.
mal)
Defective engine oil pres- without turning starting switch ON.
2 sure switch
OIL PRESSURE SWITCH Resistance
(Internal trouble)
Between (1) and (2) Max. 10 z
Possible
causes and
without turning starting switch ON.
standard value Disconnection in wiring
in normal state 3 harness Wiring harnesses between J1 (female) Resis-
Max. 1 z
(Disconnection or defec- (17) – OIL PRESSURE SWITCH tance
tive contact in connector)
Wiring harnesses between OIL PRES- Resis-
Max. 1 z
SURE SWITCH – chassis ground tance
4 Defective engine controller J1 Resistance
Between (17) and chassis
Max. 10 z
ground
CIRCUIT DIAGRAM RELATED TO ENGINE OIL PRESSURE SWITCH
6-45
6. TROUBLESHOOTING
6.6.8 E-8 FAILURE CODE [144] ABNORMALLY HIGH LEVEL IN COOLANT

TEMPERATURE SENSOR
Failure code
Trouble Abnormally high level in coolant temperature sensor
144
Contents of • High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of • Fixes coolant temperature and continues operation.
controller
Problem that • Engine does not start easily at low temperature.
appears • Exhaust smoke is white.
on machine • Overheat prevention function does not function.
information

Defective coolant tempera-
1
ture sensor COOLANT TEMP (Male) Resistance
Between (A) – (B) 0.18 – 160 kz
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between J1 (female) (15) Resis-
2 (Disconnection in wiring or Max. 10 z
– COOLANT TEMP (female) (B) tance
defective contact in con-
nector) Wiring harness between J1 (female) (38) Resis-
Max. 10 z
– COOLANT TEMP (female) (A) tance
Possible Prepare with starting switch OFF, then carry out troubleshooting
causes and Short circuit in wiring har- without turning starting switch ON.
standard value ness Wiring harness among all pins between
in normal state 3 (with another wiring har- J1 (female) (15) – J1 (female) Resis- Min.
ness) (With all connectors of wiring harness distance 100 kz
connected)
Connecting parts among coolant temperature, engine wiring
4
J1 (Female) Resistance
Between (15) – (38) 0.18 – 160 kz
6-46
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO COOLANT TEMPERATURE SENSOR
6-47
6. TROUBLESHOOTING
6.6.9 E-9 FAILURE CODE [145] ABNORMALLY LOW LEVEL IN COOLANT

TEMPERATURE SENSOR
Failure code
Trouble Abnormally low level in coolant temperature sensor
145
Contents of
• Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes coolant temperature and continues operation.
controller
Problem that • Engine does not start easily at low temperature.
appears • Exhaust smoke is white.
on machine • Overheat prevention function does not function.
Related
• Method of reproducing failure code: Starting switch ON.
information

Defective coolant tempera- COOLANT TEMP (Male) Resistance
1
ture sensor
Between (A) – (B) 0.18 – 160 kz
Between (B) – chassis ground Min. 100 kz
Ground fault in wiring har- Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
2
(Short circuit with ground Wiring harness between J1 (female) (15) Resis- Min.
circuit) – COOLANT TEMP (female) (B) tance 100 kz
Possible Short circuit in wiring har- without turning starting switch ON.
causes and 3 ness Wiring harness among all pins between
standard value (with another wiring har- J1 (female) (15) – J1 (female) Resis- Min.
in normal state ness) (With all connectors of wiring harness distance 100 kz
connected)
Connecting parts among coolant temperature, engine wiring
4
5 Defective engine controller J1 (Female) Resistance
Between (15) – (38) 0.18 – 160 kz
Between (15) – chassis ground Min. 100 kz
6-48
6. TROUBLESHOOTING
6-49
6. TROUBLESHOOTING
6.6.10 E-10 FAILURE CODE [146] (ENGINE OVERHEATING)

Failure code Engine overheating
Trouble
Contents of
• While the engine is run, the engine coolant temperature exceeded the operating range.
trouble
Action of con-
• Limits output and continues operation.
troller
Problem that
appears • Engine output lowers.
on machine
Related infor-
• Method of reproducing failure code: Start engine.
mation

Engine coolant overheat
Overheating of engine coolant can be suspected. Check the
1 (When the system is nor-
temperature to locate and eliminate the cause.
mal)
Defective coolant tempera- without turning starting switch ON.
2 ture sensor
COOLANT TEMP (male) Resistance
(Internal trouble)
Between (A) and (B) 0.18 – 160 kz
Possible
causes and
standard value Disconnection in wiring
in normal state 3 harness Wiring harness between J1 (female) (15) Resis-
Max. 1 z
(Disconnection or defec- – COOLANT TEMP (female) (B) tance
tive contact in connector)
Wiring harness between COOLANT Resis-
Max. 1 z
TEMP (female) (A) – J1 (female) (38) tance
4 Defective engine controller J1 (male) Resistance
Between (15) and chassis
0.18 – 160 kz
ground
6-50
6. TROUBLESHOOTING
6-51
6. TROUBLESHOOTING
6.6.11 E-11 FAILURE CODE [153] ABNORMALLY HIGH LEVEL IN CHARGE

TEMPERATURE SENSOR
Failure code
Trouble Abnormally high level in charge temperature sensor
153
Contents of • High voltage is detected in temperature signal circuit of boost pressure sensor and
trouble temperature sensor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that • Exhaust smoke is white.
appears
on machine • Boost temperature-based engine protection function does not function.
Related
information

Defective [temperature sig-
nal circuit] of boost pres-
1
sure sensor, temperature BOOST PRESS & IMT (Male) Resistance
sensor
Between (3) – (4) 0.18 – 160 kz
harness
– BOOST PRESS & IMT (female) (3) tance
Max. 10 z
– BOOST PRESS & IMT (female) (4) tance
standard value ness Wiring harness among all pins between J1
in normal state 3 (with another wiring har- (female) (23) – J1 (female) Resis- Min.
connected)
4
Between (23) – (47) 0.18 – 160 kz
6-52
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO BOOST PRESSURE, TEMPERATURE SENSOR (COM-

BINATION SENSOR)
6-53
6. TROUBLESHOOTING
6.6.12 E-12 FAILURE CODE [154] ABNORMALLY LOW LEVEL IN CHARGE

TEMPERATURE SENSOR
Failure code
Trouble Abnormally low level in charge temperature sensor
154
Contents of • Low voltage is detected in temperature signal circuit of boost pressure sensor and
trouble temperature sensor.
Action of • Fixes charge temperature and continues operation.
controller
Problem that • Exhaust smoke is white.
appears • Boost temperature-based engine protection function does not function.
on machine
information

Defective [temperature sig- without turning starting switch ON.
nal circuit] of boost pres- BOOST PRESS & IMT (Male) Resistance
1
sure sensor, temperature
sensor Between (3) – (4) 0.18 – 160 kz
2
circuit) and BOOST PRESS & IMT (female) (3) tance 100 kz
causes and 3 ness Wiring harness among all pins between J1
standard value (with another wiring har- (female) (23) – J1 (female) Resis- Min.
connected)
4
Between (23) – (47) 0.18 – 160 kz
6-54
6. TROUBLESHOOTING

NATION SENSOR)
6-55
6. TROUBLESHOOTING
SUPPLY 2
Failure code
Trouble Abnormally low level in sensor power supply 2 circuit
187
Contents of
• Low voltage is detected in sensor power supply 2 circuit.
trouble
Action of • Fixes boost pressure and charge temperature, and continues operation.
controller • Limits output and continues operation.
Problem that
appears • Engine output drops.
on machine
Related
information

Disconnect connector with starting switch OFF, then turn start-
ing switch ON and carry out troubleshooting.
Disconnect devices Boost pressure,
BOOST PRESS &
at right in order. temperature
IMT
If failure code dis- sensor
Defective sensor or wiring
1 appears after repro-
harness Common rail
duction operation is FUEL RAIL PRESS
pressure sensor
Possible conducted,
causes and that device or Bkup sensor CAM SENSOR
standard value wiring harness has a Engine wiring
in normal state defect in it. J1
harness
Connecting parts among each sensor, engine wiring harness,
and engine controller are suspected. Inspect them directly.
Defective wiring harness
2 Loose connector, broken lock, broken seal
connector
If causes 1 and 2 are not detected, engine controller may be
3 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
6-56
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO SENSOR POWER SUPPLY 2
6-57
6. TROUBLESHOOTING
6.6.14 E-14 FAILURE CODE [221] ABNORMALLY HIGH LEVEL IN ATMOSPHERIC

PRESSURE SENSOR
Failure code
Trouble Abnormally high level in atmospheric pressure sensor
221
Contents of
• High voltage is detected in atmospheric pressure sensor
trouble
Action of
• Fixes atmospheric pressure and continues operation.
controller
Problem that • Starting performance is poor.
appears
on machine • Engine output drops.
Related
information

1
AMBAIR PRESSURE Voltage
Defective atmospheric
2 Between (1) – (2) Power supply 4.75 – 5.25 V
pressure sensor
3 5 V, 24 V circuit) in wiring
harness Wiring harness between J1 (female) (3) –
Possible Voltage Max. 1 V
AMBAIR PRESSURE (female) (3)
causes and
4
(with another wiring har- AMBAIR PRESSURE (female) (3) and J1 Resis- Min.
ness) (female) (33) – AMBAIR PRESSURE tance 100 kz
(female) (1)
Connecting parts among atmospheric pressure sensor, engine
wiring harness, and engine controller are suspected. Inspect
Defective wiring harness them directly.
5
J1 Voltage
6-58
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO ATMOSPHERIC PRESSURE SENSOR
6-59
6. TROUBLESHOOTING
6.6.15 E-15 FAILURE CODE [222] ABNORMALLY LOW LEVEL IN ATMOSPHERIC

PRESSURE SENSOR
Failure code
Trouble Abnormally low level in atmospheric pressure sensor
222
Contents of • Low voltage is detected in atmospheric pressure sensor
trouble
Action of • Fixes atmospheric pressure and continues operation.
controller
on machine
information

1
AMBAIR PRESSURE Voltage
Defective atmospheric
pressure sensor
3
(Short circuit with ground Wiring harness between J1 (female) (3) – Resis- Min.
Possible circuit) AMBAIR PRESSURE (female) (3) tance 100 kz
causes and
4
(with another wiring har- AMBAIR PRESSURE (female) (3) and J1 Resis- Min.
ness) (female) (38) – AMBAIR PRESSURE tance 100 kz
(female) (2)
5
J1 Voltage
6-60
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO ATMOSPHERIC PRESSURE SENSOR
6-61
6. TROUBLESHOOTING
SUPPLY 2
Failure code
Trouble Abnormally high level in sensor power supply 2
227
Contents of
• High voltage is detected in sensor power supply 2 circuit.
trouble
Action of • Fixes boost pressure and charge temperature, and continues operation.
controller • Limits output and continues operation.
Problem that
on machine
Related
information

Possible Defective wiring harness
causes and connector
standard value
in normal state
If cause 1 is not detected, engine controller may be defective.
2 Defective engine controller (Since trouble is in system, troubleshooting cannot be carried
out.)
6-62
6. TROUBLESHOOTING
6.6.17 E-17 FAILURE CODE [234] ENGINE OVERSPEED

Failure code
Trouble Engine overspeed
234
Contents of
• Engine speed is above upper control limit.
trouble
Action of
• Stops injection of injector until engine speed drops to normal level.
controller
Problem that
appears • Engine speed fluctuates.
on machine
Related
• Method of reproducing failure code: Start engine and run it at high idle.
information

1 Use of improper fuel Check fuel used directly (for high viscosity).
Possible
causes and 2 Way of use may be improper. Teach proper way of use to opera-
Improper way of use
standard value tor.
in normal state If causes 1 and 2 are not detected, engine controller may be
carried out.)
6-63
6. TROUBLESHOOTING
6.6.18 E-18 FAILURE CODE [238] ABNORMAL LEVEL IN NE SPEED SENSOR POWER
SUPPLY
Failure code
Trouble Abnormality in Ne speed sensor power supply
238
Contents of
• Low voltage is detected in engine Ne speed sensor power supply circuit.
trouble
Action of
• Controls Ne speed sensor with signals of Bkup speed sensor.
controller
appears
on machine • There is hunting from engine.
Related
information

Disconnect devices
at right in order.
Defective sensor or wiring If failure code dis- Ne speed sensor CRANK SENSOR
1 appears after repro-
Possible harness
causes and duction operation is
standard value conducted,
in normal state that device or Engine wiring
J1
wiring harness has a harness
defect in it.
connector
CIRCUIT DIAGRAM RELATED TO ENGINE NE SPEED SENSOR
6-64
6. TROUBLESHOOTING
6.6.19 E-19 FAILURE CODE [271] SHORT CIRCUIT IN IMV
Failure code
Trouble Short circuit in IMV
271
Contents of
• There is short circuit in supply pump actuator drive circuit.
trouble
Action of
• None in particular.
controller
Problem that • Engine speed does not rise from low idle.
on machine • Common rail fuel pressure is above command value.
Related
information

Defective supply pump
1 CP3 PUMP REGULATOR
actuator Resistance
(Male)
Ground fault in wiring Prepare with starting switch OFF, then carry out troubleshooting
haress without turning starting switch ON.
2
circuit) CP3 PUMP REGULATOR (female) (1) tance 100 kz
Possible Short circuit in wiring without turning starting switch ON.
causes and haress
standard value 3 Wiring harness among all pins between J1
(with another wiring (female) (2) – J1 (female) Resis- Min.
in normal state haress) (With all connectors of wiring harness distance 100 kz
connected)
Connecting parts among supply pump actuator, engine wiring
4
6-65
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO SUPPLY PUMP ACTUATOR (METERING UNIT)
6.6.20 E-20 FAILURE CODE [272] DISCONNECTION IN IMV

Failure code
Trouble Disconnection in IMV
272
Contents of
• There is disconnection in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that • Engine speed runs, but in unstable condition.
appears
on machine • Common rail fuel pressure is above command value.
Related
information
6-66
6. TROUBLESHOOTING

Prepare with starting switch OFF, then carry out trouble-
shooting without turning starting switch ON.
Defective supply pump
1 CP3 PUMP REGULATOR
actuator Resistance
(Male)
Between (1) – (2) Max. 5 z
Disconnection in wiring
Wiring harness between J1 (female) (2)
harness Resis- Max. 10
– CP3 PUMP REGULATOR (female)
2 (Disconnection in wiring tance z
(1)
or defective contact in
connector) Wiring harness between J1 (female)
Resis- Max. 10
(32) – CP3 PUMP REGULATOR
tance z
(female) (2)
Prepare with starting switch OFF, then turn starting switch
Possible
Hot short (Short circuit ON and carry out troubleshooting.
causes and
standard 3 with 24V circuit) in wiring Wiring harness between J1 (female) (2)
value harness – CP3 PUMP REGULATOR (female) Voltage Max. 3 V
in normal (1)
state Prepare with starting switch OFF, then carry out trouble-
Short circuit in wiring har- shooting without turning starting switch ON.
ness Wiring harness among all pins between
4
(with another wiring har- J1 (female) (2) – J1 (female) Resis- Min.
ness) (With all connectors of wiring harness tance 100 kz
disconnected)
Connecting parts among supply pump actuator, engine wir-
ing harness, and engine controller are suspected. Inspect
5
Defective engine control-
6
ler J1 (Female) Resistance
6-67
6. TROUBLESHOOTING
1 (L/B NO. 1)
Failure code
Trouble Disconnection, short circuit in injector No. 1 (L/B No. 1)
322
Contents of
• There is disconnection or short circuit in drive circuit of injector No. 1.
trouble
Action of
controller
Problem that • There is irregular combustion or hunting.
appears
Related
information
6-68
6. TROUBLESHOOTING

1 Defective injector No. 1 INJ CYL 1 & 2 (Male) Resistance
harness
Wiring harness between J1 (female) (45) –
2 (Disconnection in wiring Resistance Max. 2 z
INJ CYL 1 (female) (3)
or defective contact in
connector) Wiring harness between J1 (female) (53) –
Resistance Max. 2 z
Ground fault in wiring Prepare with starting switch OFF, then carry out troubleshooting
haress without turning starting switch ON.
3
(Short circuit with ground Wiring harness between J1 (female) (45) –
circuit) Resistance Max. 2 z
Possible
causes and Prepare with starting switch OFF, then carry out troubleshooting
standard without turning starting switch ON.
value Short circuit in wiring Wiring harness among all pins between J1
in normal Min.
haress (female) (45) – J1 (female)(With all con- Resistance
state 4 100 kz
(with another wiring har- nectors of wiring harness disconnected)
ness)
Wiring harness among all pins between J1
Min.
(female) (53) – J1 (female)(With all con- Resistance
100 kz
nectors of wiring harness disconnected)
Connecting parts among injector No. 1, engine wiring harness, and
engine controller are suspected. Inspect them directly.
connector
Defective injector or wir-
If failure codes for troubles in multiple injectors, carry out trouble-
6 ing harness of another
shooting for those codes.
cylinder
Defective engine control- J1 (Female) Resistance
7
ler
Between (45) – (53) Max. 2 z
CIRCUIT DIAGRAM RELATED TO INJECTOR NO. 1
6-69
6. TROUBLESHOOTING
6.6.22 E-22FAILURE CODE [323] DISCONNECTION, SHORT CIRCUIT IN INJECTOR NO.

5 (L/B NO. 5)
Failure code
323
Contents of • There is disconnection or short circuit in drive circuit of injector No. 5.
trouble
Action of • None in particular.
controller
on machine
Related • Method of reproducing failure code: Start engine.
information
6-70
6. TROUBLESHOOTING

harness
– INJ CYL 5 (female) (3) tance
Max. 2 z
3
(Short circuit with ground Wiring harness between J1 (female) (46) Resis-
circuit) Max. 2 z
causes and without turning starting switch ON.
standard value Wiring harness among all pins between J1
in normal state Short circuit in wiring har-
(female) (46) – J1 (female) Resis- Min.
ness
4 (With all connectors of wiring harness distance 100 kz
(with another wiring har-
connected)
ness)
Resis- Min.
(female) (60) – J1 (female)(With all con-
tance 100 kz
Connecting parts among injector No. 5, engine wiring harness,
connector
Defective another cylinder If multiple failure codes are displayed for injector malfunction,
6
injector or wiring harness carry out troubleshooting for them, too.
Between (46) – (60) Max. 2 z
6-71
6. TROUBLESHOOTING
3 (L/B NO. 3)
Failure code
324
trouble
controller
on machine
information
harness
Max. 2 z
3
circuit) Max. 2z
standard value
in normal state Short circuit in wiring har- Wiring harness among all pins between J1
Resis- Min.
ness (female) (55) – J1 (female)(With all con-
4 tance 100 kz
ness) Wiring harness among all pins between J1
Resis- Min.
tance 100 kz
connector
6
Between (55) – (52) Max. 2 z
6-72
6. TROUBLESHOOTING
6 (L/B NO. 6)
Failure code
325
trouble
controller
on machine
information
6-73
6. TROUBLESHOOTING

harness
Max. 2 z
3
circuit) Max. 2 z
standard value
Resis- Min.
4 tance 100 kz
ness) Wiring harness among all pins between J1
Resis- Min.
tance 100 kz
connector
6
Between (57) – (59) Max. 2 z
6-74
6. TROUBLESHOOTING
2 (L/B NO. 2)
Failure code
331
Contents of
• There is disconnection or short circuit in drive circuit of injector No. 2.
trouble
Action of
controller
appears
Related
information
6-75
6. TROUBLESHOOTING

harness
Max. 2 z
3
circuit) Max. 2 z
standard value
Resis- Min.
4 tance 100 kz
ness)
Resis- Min.
tance 100 kz
connector
6
Between (54) – (51) Max. 2 z
6-76
6. TROUBLESHOOTING
4 (L/B NO. 4)
Failure code
332
trouble
controller
on machine
information
6-77
6. TROUBLESHOOTING

harness
Max. 2 z
3
circuit) Max. 2 z
standard value
Resis- Min.
4 tance 100 kz
ness)
Resis- Min.
tance 100 kz
connector
6
Between (56) – (58) Max. 2 z
6-78
6. TROUBLESHOOTING
6.6.27 E-27 FAILURE CODE [342] MATCHING ERROR IN ENGINE CONTROLLER DATA
Failure code Matching error in engine controller data
Trouble
Contents of trouble • Matching error occurred in engine controller data.
Action of controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears • Continues the normal operation.
on machine • Engine stops or does not start.
Related information • Method of reproducing failure code: Turn the starting switch ON.
Possible causes and Standard value in normal state/Remarks on troubleshoot-

Causes
standard value in nor- ing
mal state Carry out troubleshooting of failure code [757].
6-79
6. TROUBLESHOOTING
6.6.28 E-28 FAILURE CODE [351] ABNORMALITY IN INJECTOR DRIVE CIRCUIT

Failure code
Trouble Abnormality in injector drive circuit
351
Contents of • Abnormality occurred in injector drive power supply circuit.
trouble
Action of • Limits output and continues operation.
controller
• Engine does not start.
Problem that • Exhaust smoke is black.
appears
on machine • There is irregular combustion.
• Engine output drops.
information
If another failure code is indicated, carry out troubleshooting for
1 Defective related system
it.
2 Defective fuse No. (r) (30A) If fuse is burnt out, circuit probably has ground fault.
without turning switch ON.
Pwm (male) Resistance
Defective relay (Pwm) for Between (85) – (86) 200 – 400 z
3 engine controller power
supply and carry out troubleshooting.
Possible
Replace relays for engine controller power supply (Pwm) with
causes and other relays. If failure code disappears after reproduction opera-
standard value tion is conducted, that relay has a defect.
in normal state
Disconnection in wiring Wiring harness between fuse No. (r) (30A) Resis- Max.
harness – Pwm (female) (30) tance 0.5 z
4 (Disconnection in wiring or
defective contact in con- Wiring harness between Pwm (female) Resis- Max.
nector) (87) – J3 (female) (3) (4) tance 0.5 z
Wiring harness between J3 (female) (1) Resis- Max.
(2) – chassis ground tance 10 z
If causes 1 – 4 are not detected, engine controller may be defec-
5 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
ried out.)
6-80
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO ENGINE CONTROLLER POWER SUPPLY
6-81
6. TROUBLESHOOTING
SUPPLY 1
Failure code
Trouble Abnormally low level in sensor power supply 1
352
Contents of • Low voltage is detected in sensor power supply 1 (5V) circuit.
trouble
Action of • Fixes atmospheric pressure and continues operation.
controller
on machine
information

Disconnect devices
at right in order. Atmospheric AMBAIR PRES-
Defective sensor or wiring If failure code dis- pressure sensor SURE
1 appears after
harness
reproduction opera-
tion is conducted,
Possible Engine wiring
that device or J1
causes and harness
wiring harness has a
standard value
defect in it.
in normal state
2
carried out.)
6-82
6. TROUBLESHOOTING
6-83
6. TROUBLESHOOTING
SUPPLY 1
Failure code
Trouble Abnormally high level in sensor power supply 1
386
Contents of
• High voltage is detected in sensor power supply 1 (5V) circuit.
trouble
Action of
• Fixes atmospheric pressure and continues operation.
controller
appears
Related
information

Connecting parts among atmospheric pressure sensor,
Possible engine wiring harness, and engine controller are suspected.
causes and Defective wiring harness Inspect them directly.
1
standard connector Loose connector, broken lock, broken seal
value Corrosive, bent, broken, forced-in, or extended pin
in normal Humidity in connector, entry of dirt or dust, poor insulation
state If cause 1 is not detected, engine controller may be defec-
2 tive. (Since trouble is in system, troubleshooting cannot be
ler
carried out.)
6-84
6. TROUBLESHOOTING
6.6.31 E-31 FAILURE CODE [415] (ROTATION DERATING BY LOW ENGINE OIL
PRESSURE)
Failure code Rotation derating by low engine oil pressure
Trouble
Contents of • While engine is run, engine oil pressure became lower than operating range.
trouble
Action of • Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that • Engine output lowers.
appears
on machine
information
Possible Causes Standard value in normal state/Remarks on troubleshooting

causes and
standard
value Carry out troubleshooting of failure code [143].
in normal
state
6.6.32 E32 FAILURE CODE [418] WATER MIXED IN FUEL

Failure code
Trouble Water mixed in fuel
418
Contents of • Water separator is full of water.
trouble
Action of • Turns the centralized warning lamp ON.
controller
Problem that • Normal operation is continued.
appears
on machine
Related • Method of reproducing failure code: Turn starting switch ON.
information

causes and
standard
value Water separator which is a part of fuel prefilter is full of water. Drain water according to
in normal operation manual.
state
6-85
6. TROUBLESHOOTING
6.6.33 E-33 FAILURE CODE [428] ABNORMALLY HIGH LEVEL IN WATER SENSOR
Failure code
Trouble Abnormally high level in water sensor
428
Contents of • High voltage occurred in fuel water sensor
trouble
controller
Problem that • —
appears
on machine
information

1 Defective fuel water sensor
E06 (male) Resistance
Between (1) – (2) 10 – 100 kz
harness
– E06 (female) (1) tance
Max. 10 z
– E06 (female) (2) tance
standard value ness Wiring harness among all pins between J1
in normal state 3 (With another wiring har- (female) (14) – J1 (female) Resis- Min.
connected)
Connecting parts among fuel water sensor, engine wiring har-
ness, and engine controller are suspected. Inspect them
4
Between (14) – (47) 10 – 100 kz
6-86
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO FUEL WATER SENSOR
6-87
6. TROUBLESHOOTING
6.6.34 E-34 FAILURE CODE [429] ABNORMALLY LOW LEVEL IN WATER SENSOR
Failure code
Trouble Abnormally low level in water sensor
429
Contents of • Low voltage occurred in fuel water sensor
trouble
controller
appears
on machine
information

1 Defective fuel water sensor E06 (male) Resistance
Between (1) – chassis ground 10 – 100 kz
2
circuit) – E06 (female) (1) and chassis ground tance 100 kz
causes and 3 ness Wiring harness among all pins between J1
standard value (With another wiring har- (female) (14) – J1 (female) Resis- Min.
connected)
Connecting parts among fuel water sensor, engine wiring har-
4
Between (14) – (47) 10 – 100 kz
6-88
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO FUEL WATER SENSOR
6.6.35 E-35 FAILURE CODE [431] IDLE VALIDATION SWITCH ERROR

Failure code Idle validation switch error
Trouble
Contents of • Abnormality occurred in idle validation switch circuit.
trouble
Action of con- • Operates at position of throttle of throttle sensor.
troller
appears
on machine
mation
6-89
6. TROUBLESHOOTING

Accelerator pedal
Signal name Voltage
connector
Defective accelerator pedal
1 Between (5) and (4) Signal 1 See Fig. 1 on the
(Internal trouble)
Between (6) and (4) Signal 2 next page
Disconnection in wiring Wiring harness between J2 (female) (11) – Resis-
Max. 10 z
harness accelerator pedal connector (female) (5) tance
2
(Disconnection or defecive Wiring harness between J2 (female) (1) – Resis-
contact in connector) Max. 10 z
accelerator pedal connector (female) (6) tance
Possible Wiring harness between J2 (female) (32) Resis-
Max. 10 z
causes and – accelerator pedal connector (female) (4) tance
in normal state without turning starting switch ON.
Resis- Min.
(female) (11) – J2 (female) (accelerator
tance 100 kz
pedal connector, too, is disconnected.)
Short circuit in wiring Wiring harness among all pins between J2
Resis- Min.
haress (female) (1) – J2 (female) (accelerator
3 tance 100 kz
(with another wiring pedal connector, too, is disconnected.)
haress)
Between J2 (female) (11) – J3 (female) (3)
Resis- Min.
(accelerator pedal connector, too, is dis-
tance 100 kz
connected.)
Resis- Min.
(accelerator pedal connector, too, is dis-
tance 100 kz
connected.)
4
Possible
causes and J2 (female) Signal name Voltage
standard value 5 Defective engine controller Between (11) and
in normal state Signal 1
(32)
See Fig. 1
Between (1) and
Signal 2
(32)
6-90
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO ACCELERATOR PEDAL
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x (Voltage when pedal
pressed – Voltage when pedal opened)
B: Voltage when pedal opened + 0.1 x (Voltage when pedal
6-91
6. TROUBLESHOOTING
6.6.36 E-36 FAILURE CODE [432] IDLE VALIDATION ACTION ERROR

Failure code Idle validation action error
Trouble
Contents of
• Signals from the idle validation switch and throttle sensor do not agree (they are contradictory)
trouble
1.When the idle validation switch recognized the accelerator pedal is OFF and the throttle sensor,
on the contrary, recognized the accelerator pedal is ON: Control the opening ratio of the throttle to
0% after the accelerator pedal is OFF and then control the opening ratio of the throttle to 50% while
Action of after the accelerator pedal is ON.
controller 2.When the idle validation switch recognized the accelerator pedal is ON and the throttle sensor, on
the contrary, recognized the accelerator pedal is OFF: Control the opening ratio of the throttle to 0%
(fix to the low idle).
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears • Engine speed does not rise from low idle.
on machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Defective accelerator Accelerator pedal con- Signal name Voltage
1 nector
pedal
Between (5) and (4) Signal 1 See Fig. 1 on the
Between (6) and (4) Signal 2 next page
Disconnection in wir- without turning starting switch ON.
ing harness
Wiring harness between J2 (female) (22) – Resis- Max.
2 (Disconnection or
accelerator pedal connector (female) (1) tance 10 z
defective contact in
connector) Wiring harness between J2 (female) (9) – Resis- Max.
accelerator pedal connector (female) (2) tance 10 z
standard Short circuit in wiring Wiring harness among all pins between J2
value in nor- Resis- Min.
haress (female) (22) – J2 (female) (accelerator pedal
mal state 3 tance 100 kz
(with another wiring connector, too, is disconnected.)
haress) Wiring harness among all pins between J2
Resis- Min.
(female) (9) – J2 (female) (accelerator pedal
tance 100 kz
connector, too, is disconnected.)
Defective wiring directly.
4
haress connector Loose connector, broken lock, broken seal
Defective engine con- J2 (female) Accelelator pedal Voltage
5
troller
Between (11) and (32) Signal 1
See Fig. 1
Between (1) and (32) Signal 2
6-92
6. TROUBLESHOOTING
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A:Voltage when pedal opened + 0.03 x (Voltage when pedal
B:Voltage when pedal opened + 0.1 x (Voltage when pedal
6-93
6. TROUBLESHOOTING
6.6.37 E-37 FAILURE CODE [435] ABNORMALITY IN ENGINE OIL PRESSURE SWITCH
Failure code
Trouble Abnormality in engine oil pressure switch
435
Contents of • Abnormality occurred in engine oil pressure switch signal circuit.
trouble
controller
Problem that • Engine oil pressure switch-based engine protection function does not function.
appears
on machine
Related • Method of reproducing failure code: Starting switch ON or start engine
information

Defective engine oil pres-
1 OIL PRESSURE SWITCH
sure switch Resistance
(Male)
Between (1) – body Max. 10 z
Disconnection in wiring Prepare with starting switch OFF, then carry out troubleshooting
defective contact in con- Wiring harness between J1 (female) (17) Resis-
Max. 10 z
nector) – OIL PRESSURE SWITCH (female) (1) tance
Troubleshoot with starting switch OFF, then carry out trouble-
Possible
Short circuit in wiring shooting without turning starting switch ON.
causes and
standard value 3 haress Wiring harness among all pins between J1
in normal state (With another wiring (female) (17) – J1 (female) Resis- Min.
haress) (With all connectors of wiring harness distance 100 kz
connected)
Connecting parts among engine oil pressure switch, engine wir-
ing harness, and engine controller are suspected. Inspect them
4
Between (17) – chassis ground Max. 10 z
6-94
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO ENGINE OIL SWITCH
6.6.38 E-38 FAILURE CODE [441] ABNORMALLY LOW POWER SUPPLY VOLTAGE
Failure code
Trouble Abnormally low power supply voltage
441
Contents of • Low voltage occurred in controller power supply circuit.
trouble
controller
Problem that • Engine stops.
appears • Starting performance is poor.
on machine
information
6-95
6. TROUBLESHOOTING

Loose, corroded battery
1 Inspect battery terminal directly for loose and corrosion.
terminal
Prepare with starting switch OFF, then turn starting switch OFF
and START and carry out troubleshooting.
2 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) OFF Min. 12 V
terminals START Min. 6.2 V
3 Defective fuse No. (r) (30A) If fuse is burnt out, circuit probably has ground fault. (See cause6.)
Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective relay for engine
4 Replace relays for engine controller power supply (Pwm) with
controller power supply
other relays. If failure code disappears after reproduction opera-
tion is conducted, that relay has a defect.
Disconnection in wiring Wiring harness between Fuse No. (r) (30A) Resis-
Possible harness Max. 10 z
causes and 5 – Pwm (female) (30) tance
(Disconnection in wiring or
standard defective contact in con- Wiring harness between Pwm (female) (87) Resis-
value Max. 10 z
nector) – J3 (female) (3) tance
in normal
state Wiring harness between J3 (female) (1) – Resis-
Max. 10 z
chassis ground (T12) tance
Ground fault in wiring har-
ness Wiring harness between Fuse No. (r) (30A) Resis- Min.
6
(Short circuit with ground – Pwm (female) (30) and chassis ground tance 100 kz
circuit) Wiring harness between Pwm (female) (87) Resis-
Max. 10 z
– J3 (female) (3) and chassis ground tance
Resis- Min.
(female) (3) (2) – J3 (female) (1) (2)
Short circuit in wiring har- tance 100 kz
(With battery terminal disconnected)
ness
7 Wiring harness among all pins between J3
(With another wiring har- Resis- Min.
ness) (female) (3) (2) – J2 (female)
tance 100 kz
Resis- Min.
(female) (1) (2) – J2 (female)
tance 100 kz
6-96
6. TROUBLESHOOTING

Connecting parts among fuse No. (r) (30A), engine unit wiring har-
ness, and engine controller are suspected. Inspect them directly.
8 • Loose connector, broken lock, broken seal
connector
Possible • Corrosive, bent, broken, forced-in, or extended pin
causes and • Humidity in connector, entry of dirt or dust, poor insulation
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and START and carry out troubleshooting.
9 Defective engine controller J3 (Female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
6-97
6. TROUBLESHOOTING
6.6.39 E-39 FAILURE CODE [442] ABNORMALLY HIGH POWER SUPPLY VOLTAGE
Failure code
Trouble Abnormally high power supply voltage
442
Contents of • High voltage (min. 36V) occurred in controller power supply circuit.
trouble
controller
Problem that • Engine may stop.
appears
on machine
information

1 Defective battery voltage
Battery Voltage
Between (+) – (–) terminals Max. 32 V
Prepare with starting switch OFF, then start the engine and carry
Possible out troubleshooting.
causes and
standard value 2 Alternator connec-
Defective alternator Engine speed Voltage
in normal state tor (Male)
Between (2) – chas-
Min. medium speed 27.5 – 29.5 V
sis ground
J3 (Female) Voltage
Between (3) (4) – (1) (2) Max. 32 V
6-98
6. TROUBLESHOOTING
6-99
6. TROUBLESHOOTING
Failure code
Trouble Abnormally high common rail pressure 2
449
Contents of • Pressure (2) in common rail circuit is abnormally high.
trouble
controller
Problem that • Engine sound becomes larger under no load or light load.
on machine
information

it.
Inspect it for air entry directly according to the following proce-
dure.
1)Remove pressure pickup plug (outlet side) from fuel main fil-
2 Air in low-pressure circuit ter.
2)Operate feed pump of fuel pre-fuel filter.
3)Inspect fuel and air from pressure pickup plug for leakage
level.
For check of pressure in fuel return circuit, see TESTING AND
ADJUSTING, Testing fuel pressure.
Defective fuel return circuit
Possible 3 At low idle
device Fuel return circuit Max. 0.02 MPa
causes and or
pressure
cranking {Max. 0.19 kg/cm2}
standard value
in normal state Prepare with starting switch ON, then carry out troubleshooting
without turning starting switch OFF.
Defective common rail Monitoring on
4 Monitoring information
pressure sensor troubleshooting tool
Common rail Condition when 0 ± 0.39 MPa
pressure engine stopped {0 ± 4 kg/cm2}
For testing of leakage from pressure limiter, see TESTING AND
ADJUSTING, Testing leakage from pressure limiter and return
5 Defective pressure limiter rate from injector.
Leakage
At low idle 0 cc (No leakage)
from pressure limiter
6 Defective supply pump If causes 1 – 5 are not detected, supply pump may be defective.
6-100
6. TROUBLESHOOTING
6.6.41 E-41 FAILURE CODE [451] ABNORMALLY HIGH LEVEL IN COMMON RAIL
PRESSURE SENSOR
Failure code
Trouble Abnormally high level in common rail pressure sensor
451
Contents of • High voltage occurred in common rail pressure sensor.
trouble
controller
Problem that • Engine does not start.
appears • Engine speed or output drops.
on machine
information

1
FUEL RAIL PRESS Voltage
Defective common rail
pressure sensor
3 5V, 24V circuit) in wiring Wiring harness between J1 (female) (25)
harness – FUEL RAIL PRESS (female) (2) and Voltage Max. 1 V
Possible
causes and chassis ground
standard value Troubleshoot with starting switch OFF, then carry out trouble-
in normal state Short circuit in wiring har- shooting without turning starting switch ON.
4
(With another wiring har- – FUEL RAIL PRESS (female) (2) and J1 Resis- Min.
ness) (female) (37) – FUEL RAIL PRESS tance 100 kz
(female) (3)
Connecting parts among common rail pressure sensor, engine
5
J1 Voltage
6-101
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO COMMON RAIL PRESSURE SENSOR
6-102
6. TROUBLESHOOTING
6.6.42 E-42 FAILURE CODE [452] ABNORMALLY LOW LEVEL IN COMMON RAIL
PRESSURE SENSOR
Failure code
Trouble Abnormally low level in common rail pressure sensor
452
Contents of • Low voltage occurred in common rail pressure sensor.
trouble
controller
Problem that • Engine does not start.
appears • Engine speed or output drops.
on machine
information

1
FUEL RAIL PRESS Voltage
Defective common rail
pressure sensor
Ground fault in wiring har- and carry out troubleshooting.
ness
3 Wiring harness between J1 (female) (25)
Possible circuit) – FUEL RAIL PRESS (female) (2) and
tance 100 kz
causes and chassis ground
standard value Troubleshoot with starting switch OFF, then carry out trouble-
in normal state Short circuit in wiring har- shooting without turning starting switch ON.
4
(With another wiring har- – FUEL RAIL PRESS (female) (2) and J1 Resis- Min.
ness) (female) (47) – FUEL RAIL PRESS tance 100 kz
(female) (1)
Connecting parts among common rail pressure sensor, engine
5
J1 Voltage
6-103
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO COMMON RAIL PRESSURE SENSOR
6.6.43 E-43 FAILURE CODE [488] DERATING OF TORQUE BY ABNORMALLY HIGH

CHARGE TEMPERATURE
Failure code
Trouble Derating of torque by abnormally high charge temperature
488
Contents of • Temperature signal of boost pressure sensor and temperature sensor is above upper control
trouble limit.
controller
appears
on machine
information

Inspect following directly.
Drop in cooling perfor- Loose, broken fan belt
1
Possible mance of aftercooler. Lack of cooling air
causes and Clogged aftercooler fin
standard value Abnormally high tempera-
in normal state 2 ture at turbocharger outlet
Inspect related parts directly.

carried out.)
6-104
6. TROUBLESHOOTING
Failure code
Trouble Abnormally high common rail pressure 1
553
Contents of • Voltage (1) in common rail circuit is abnormally high.
trouble
controller
Problem that • Engine sound becomes larger under no load or light load.
on machine
information

If another failure code is indicated, carry out troubleshooting
Possible for it.
causes and Inspect following directly for connection of ground terminal.
standard Ground terminal (battery (–)) of machine main unit.
value Defective connection of
2 Ground terminal of engine
in normal ground terminal
Ground terminal of engine controller
state Ground terminal of starting motor
Broken O-ring of supply
3 Inspect O-ring directly for breakage.
pump actuator
6-105
6. TROUBLESHOOTING
6.6.45 E-45 FAILURE CODE [559] NO-PRESSURE FEED BY SUPPLY PUMP 1

Failure code
Trouble No-pressure feed by supply pump 1
559
Contents of
• No-pressure feed (1) occurred in common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start or starting performance is poor.
appears • Exhaust smoke is black.
Related
information
1 Use of improper fuel Fuel used may be improper. Check it directly.
For contents of troubleshooting, see “Note 1”. For measure-
ment of pressure in fuel low-pressure circuit, see TESTING
AND ADJUSTING, “Measurement of fuel pressure”.
Fuel supply pump
At high idle
inlet negative pres- Max. –50.7 kPa
(When engine can
sure (Fuel prefilter {Max. –380 mmHg}
Defective fuel low-pres- be started)
2 outlet side)
sure circuit parts
During cranking 0.3 – 1.1 MPa
(When engine can-
{3.1 – 11.3 kg/cm2}
Fuel main filter inlet not be started)
pressure At low idle 0.5 – 1.3 MPa
(When engine can
be started) {5.1 – 13.3 kg/cm2}
For testing of leakage from pressure limiter, see TESTING AND

Possible 3 Defective pressure limiter rate from injector.
causes and Leakage
standard value At low idle 0 cc (No leakage)
from pressure limiter
in normal state
For testing of return rate from injector, see TESTING AND
rate from injector.
Defective injector At cranking
4 (High-pressure piping in (When engine Max. 90 cc/min.
head included) Return rate from cannot be started)
injector At low idle
(When engine Max. 180 cc/min.
can be started)
For testing of return rate from supply pump, see TESTING AND
rate from injector.
At cranking
5 Defective supply pump (When engine Max. 140 cc/min.
Return rate from cannot be started)
supply pump At low idle
(When engine Max. 1,000 cc/min.
can be started)
6-106
6. TROUBLESHOOTING
Note 1. If fuel low-pressure circuit parts seem to be defective, check the following items.
1. Fuel level
2. Clogging of fuel tank breather
3. Leaking or clogging of fuel low-pressure piping
4. Clogging of fuel prefilter
5. Clogging of fuel main filter
6.6.46 E-46 FAILURE CODE [689] ABNORMALITY IN ENGINE NE SPEED SENSOR

Failure code
Trouble Abnormality in engine Ne speed sensor
689
Contents of
Abnormality occurred in signals from engine Ne speed sensor.
trouble
Action of
Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that Starting performance is poor.
appears There is hunting from engine.
on machine Engine output drops.
Related
Method of reproducing failure code: Start engine.
information
6-107
6. TROUBLESHOOTING

Defective engine Ne speed
If failure code [238] is indicated simultaneously, carry out trou-
1 sensor power supply sys-
bleshooting for it first.
tem
CRANK SENSOR Voltage
Defective engine Ne speed
sensor
Broken engine Ne speed
3 sensor or defective clear- Inspect engine Ne speed sensor for breakage or clearance.
ance
Broken rotation sensing
4 Inspect it for breakage directly.
flywheel
Possible harness without turning starting switch ON.
causes and 5 (Disconnection in wiring or
Wiring harness between J1 (female) (27) – Resis- Max.
standard value defective contact in con-
nector) CRANK SENSOR (female) (3) tance 10 z
in normal state
ness
6 Wiring harness between J1 (female) (27) –
circuit) CRANK SENSOR (female) (3) and chassis
tance 100 kz
ground
7 5 V, 24 V circuit) in wiring Wiring harness between J1 (female) (27) –
harness Max. 1
CRANK SENSOR (female) (3) and chassis Voltage
V
ground
Short circuit in wiring har- Wiring harness between J1 (female) (27) –
Resis- Min.
ness CRANK SENSOR (female) (3) and J1
8 tance 100 kz
(With another wiring har- (female) (16) – CRANK SENSOR (female) (1)
ness) Wiring harness between J1 (female) (27) –
Resis- Min.
CRANK SENSOR (female) (3) and J1
tance 100 kz
(female) (48) – CRANK SENSOR (female) (2)
6-108
6. TROUBLESHOOTING

Connecting parts among engine Ne speed sensor, engine wiring har-
Defective wiring harness con-
Possible 9 • Loose connector, broken lock, broken seal
nector
causes and stan- • Corrosive, bent, broken, forced-in, or extended pin
dard value • Humidity in connector, entry of dirt or dust, poor insulation
in normal state a Prepare with starting switch OFF, then turn starting switch ON and
J1 Voltage
CIRCUIT DIAGRAM RELATED TO ENGINE NE SPEED SENSOR
6-109
6. TROUBLESHOOTING
PHASE
Failure code
Trouble Abnormality in engine Bkup speed sensor phase
731
Contents of • Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed
trouble sensor.
Action of
• Controls with signals of engine Ne speed sensor.
controller
Problem that • Engine does not start or is difficult to start.
appears • Idle speed is unstable.
on machine • Exhaust smoke is black.
Related
information

Broken engine Ne speed
1 Inspect engine Ne speed sensor for breakage directly.
sensor
Broken engine Bkup speed
2 Inspect engine Bkup speed sensor for breakage directly.
sensor
Inspect it for defect or breakage according to the following pro-
cedure.
Defective or broken mount
1)Set No. 1 cylinder to compression top dead center (align
3 of rotation sensing fly-
stamping mark).
wheel on crankshaft side
2)If tip of Ne speed sensor is aligned with center of oblong hole
of rotation sensing flywheel, it is mounted normally.
Possible
causes and Inspect it for defect or breakage according to the following pro-
standard value cedure.
in normal state Defective or broken mount 1)Set No. 1 cylinder to compression top dead center (align
4 of rotation sensing ring on stamping mark).
camshaft side 2)Remove Bkup speed sensor.
3)If 2 grooves (1 thread) of rotation sensing ring can be seen
through sensor mounting hole, it is mounted normally.
Defective timing between
5 Inspect crankshaft and camshaft for timing directly.
crankshaft and camshaft
Inspect following directly for connection of ground terminal.
Ground terminal (battery (–)) of machine main unit.
Defective connection of
6 Ground terminal of engine
ground terminal
Ground terminal of engine controller
Ground terminal of starting motor
6-110
6. TROUBLESHOOTING
6.6.48 E-48 FAILURE CODE [757] LOSS OF ALL DATA IN ENGINE CONTROLLER
Failure code
Trouble Loss of all data in engine controller
757
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears • Engine stops and sometimes cannot be started.
on machine
Related
information
it.
Loose or corroded battery
2 Inspect battery terminal directly for loose and corrosion.
terminal
Prepare with starting switch OFF, then turn starting switch OFF
3 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) OFF Min. 12 V
terminals START Min. 6.2 V
Defective fuse No. (r)
4 If fuse is burnt out, circuit probably has ground fault.
(30A)
Defective relay for engine
5 Replace relays for engine controller power supply (Pwm) with
controller power supply
other relays. If failure code disappears after reproduction opera-
Possible tion is conducted, that relay has a defect.
causes and Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state
Disconnection in wiring Wiring harness between fuse No. (r) (30A) Resis-
harness Max. 10 z
– Pwm (female) (30) tance
defective contact in con- Wiring harness between Pwm (female) Resis-
Max. 10 z
nector) (87) – J3 (female) (3) tance
Wiring harness between J3 (female) (1) – Resis-
Max. 10 z
chassis ground tance
Connecting parts among fuse No. (r) (30A) – Pwm (female) (30),
engine unit wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
7
8 Defective engine controller J3 (Female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
6-111
6. TROUBLESHOOTING
Failure code
Trouble Abnormality in engine Bkup speed sensor
778
Contents of
Continues control according to engine Ne speed sensor signals.
trouble
Action of
Controls with signals of Ne speed sensor.
controller
Problem that
Starting performance is poor.
appears
Engine output drops.
on machine
Related
Method of reproducing failure code: Start engine.
information
6-112
6. TROUBLESHOOTING

1
CAM SENSOR Voltage
Defective engine Bkup
speed sensor
Broken engine Bkup speed
Inspect engine Bkup speed sensor directly for breakage or
3 sensor or defective
clearance.
clearance
Broken rotation sensing
4 Inspect it for breakage directly.
ring
Possible defective contact in con- Wiring harness between J1 (female) (26) Resis- Max.
causes and nector) – CAM SENSOR (female) (3) tance 10 z
standard value
ness
circuit) – CAM SENSOR (female) (3) and chassis
tance 100 kz
ground
7 5 V, 24 V circuit) in wiring Wiring harness between J1 (female) (26)
harness – CAM SENSOR (female) (3) and chassis Voltage Max. 1 V
ground
Wiring harness between J1 (female) (26)
Short circuit in wiring har- – CAM SENSOR (female) (3) and J1 Resis- Min.
ness (female) (37) – CAM SENSOR (female) tance 100 kz
8
(With another wiring har- (1)
ness) Wiring harness between J1 (female) (26)
– CAM SENSOR (female) (3) and J1 Resis- Min.
(female) (47) – CAM SENSOR (female) tance 100 kz
(2)
6-113
6. TROUBLESHOOTING

Connecting parts among engine Bkup speed sensor, engine wiring har-
Defective wiring harness con-
Possible 9 • Loose connector, broken lock, broken seal
nector
causes and stan- • Corrosive, bent, broken, forced-in, or extended pin
dard value • Humidity in connector, entry of dirt or dust, poor insulation
in normal state a Prepare with starting switch OFF, then turn starting switch ON and
J1 Voltage
CIRCUIT DIAGRAM RELATED TO ENGINE BKUP SPEED SENSOR
6-114
6. TROUBLESHOOTING
6.6.50 E-50 FAILURE CODE [2185] THROTTLE SENSOR SUPPLY VOLTAGE HIGH
ERROR
Failure code Throttle sensor supply voltage high error
Trouble
Contents of • High voltage (min. 5.25V) occurred in throttle sensor power supply circuit.
trouble
troller is ON.
appears on
machine
mation
Short circuit in wiring Wiring harness among all pins between J2
Resis- Min.
haress (female) (22) – J2 (female) (accelerator
1 tance 100 kz
(with another wiring pedal connector, too, is disconnected.)
haress)
Possible Resis- Min.
(Accelerator pedal connector, too, is dis-
causes and tance 100 kz
connected.)
standard value
in normal state Connecting parts among accelerator pedal connector, engine
unit wiring harness, and engine controller are suspected.
2
ried out.)
6-115
6. TROUBLESHOOTING
6.6.51 E-51 FAILURE CODE [2186] THROTTLE SENSOR POWER SUPPLY LOW ERROR
Failure code Throttle sensor power supply voltage low error
Trouble
Contents of
• Low voltage occurred in throttle sensor power supply circuit.
trouble
troller is ON.
Problem that
appears on • The engine does not reach full throttle.
machine
Related infor-
• Method of reproducing failure code: Turn the starting switch ON.
mation
ness
(Contact with ground cir- Resis- Min.
cuit) – accelerator pedal connector (female) (1)
tance 100 kz
and chassis ground
Possible ness
2 Wiring harness among all pins between J2
causes and (with another wiring har- Resis- Min.
ness) (female) (9) – J2 (female) (Accelerator
standard value tance 100 kz
pedal connector, too, is disconnected.)
in normal state
Connecting parts among accelerator pedal connector, engine
unit wiring harness, and engine controller are suspected.
3
ried out.)
6-116
6. TROUBLESHOOTING
6.6.52 E-52 FAILURE CODE [2249] NO-PRESSURE FEED BY SUPPLY PUMP 2

Failure code
Trouble No-pressure feed by supply pump 2
2249
Contents of • No-pressure feed (2) occurred in common rail circuit.
trouble
controller
Problem that • Starting performance is poor
appears • Exhaust smoke is black
on machine • Output drops.
information

causes and
standard value 1 Carry out troubleshooting for failure code [559].
in normal state
6-117
6. TROUBLESHOOTING
6.6.53 E-53 FAILURE CODE [2311] ABNORMALITY IN IMV SOLENOID

Failure code
Trouble Abnormality in IMV solenoid
2311
Contents of
• Resistance in supply pump actuator is abnormally high or low.
trouble
Action of
controller
Problem that
on machine
Related
information

it.
Defective supply pump CP3 PUMP REGULATOR
2 Resistance
actuator (Male)
harness
Wiring harness between J1 (female) (2) – Resis-
CP3 PUMP REGULATOR (female) (1) tance
Possible nector) Wiring harness between J1 (female) (32) Resis-
causes and Max. 5 z
– CP3 PUMP REGULATOR (female) (2) tance
standard value
in normal state Ground fault in wiring har- Prepare with starting switch OFF, then carry out troubleshooting
4
circuit) CP3 PUMP REGULATOR (female) (1) tance 100 kz
Connecting parts among supply pump actuator, engine wiring
5
6-118
6. TROUBLESHOOTING
6-119
6. TROUBLESHOOTING
6.6.54 E-54 FAILURE CODE [2555] DISCONNECTION IN INTAKE AIR HEATER RELAY
Failure code
Trouble Disconnection in intake air heater relay
2555
Contents of • There is disconnection in intake air heater relay.
trouble
controller
Problem that • Intake air heater does not function (Poor starting performance, white exhaust smoke at low
appears temperature)
on machine
Related • Method of reproducing failure code: Starting switch ON when coolant temperature is –4°C or
information less.

without turning starting switch ON. (Test relay unit).
Heater relay terminal Resistance
Defective heater relay Between coil terminal 300 – 600 z
1
(Internal disconnection) Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
Replace heater relay with new one and perform reproduction
method. If failure code goes off at this time, relay is defective.
harness
Wiring harness between J2 (female) (40) Resis- Max.
– heater relay terminal tance 10 z
Possible defective contact in con-
causes and nector) Between heater relay primary side – Resis- Max.
standard value ground tance 10 z
in normal state Troubleshoot with starting switch OFF, then carry out trouble-
Short circuit in wiring har- shooting without turning starting switch ON.
ness Wiring harness among all pins between J2
3
(With another wiring har- (female) (40) – J2 (female) Resis- Min.
ness) (With also heater relay terminal discon- tance 100 kz
nected)
Connecting parts among heater relay, engine unit wiring har-
4
carried out.)
6-120
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO PREHEATING ENGINE
6-121
6. TROUBLESHOOTING
6.6.55 E-55 FAILURE CODE [2556] SHORT CIRCUIT IN INTAKE AIR HEATER RELAY
Failure code
Trouble Short circuit in intake air heater relay
2556
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function.
appears
(Poor starting performance, white exhaust smoke at low temperature)
on machine
Related • Method of reproducing failure code: Starting switch ON when coolant temperature is –
information 4°C or less.

shooting without turning starting switch ON. (Test relay unit).
Heater relay terminal Resistance
Between (1) – (2) 300 – 600 z
Defective heater relay Prepare with starting switch OFF, then turn starting switch
1
(Internal disconnection)
ON and carry out troubleshooting. (Test by replacing relay
unit.)
Replace heater relay with new one and perform reproduction
method. If failure code goes off at this time, relay is defec-
tive.
Ground fault in wiring har- Prepare with starting switch OFF, then carry out trouble-
Possible ness shooting without turning starting switch ON.
causes and 2
(Short circuit with ground Wiring harness between J2 (female) Resis- Min.
standard circuit)
value (40) – heater relay terminal (female) (1) tance 100 kz
in normal Prepare with starting switch OFF, then carry out trouble-
state Short circuit in wiring har- shooting without turning starting switch ON.
ness Wiring harness among all pins between
3
(With another wiring har- J2 (female) (40) – J2 (female) Resis- Min.
ness) (With also heater relay terminal discon- tance 100 kz
nected)
Connecting parts among heater relay, engine unit wiring har-
4
5 defective. (Since trouble is in system, troubleshooting can-
ler
not be carried out.)
6-122
6. TROUBLESHOOTING
CIRCUIT DIAGRAM RELATED TO PREHEATING ENGINE
6-123
NOTES:
7. DISASSEMBLY AND
ASSEMBLY
7.1 HOW TO READ THIS MANUAL

7.1.1 REMOVAL AND INSTALLATION OF ASSEMBLIES
Special tools
• Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1
etc. and their part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.
1. Necessity
t: Special tools that cannot be substituted and should always be used (installed).
q: Special tools that will be useful if available and are substitutable with commercially available tools.
2. Distinction of new and existing special tools
N: Tools newly developed for this model. They respectively have a new part number.
R: Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank Tools already available for other models. They can be used without any modification.
3. Circle mark Q in sketch column:
• The sketch of the special tool is presented in the section of "Sketches of special tools".
• This mark means part No. of special tools starting with 79 T-
from Komatsu in Japan (i.e. locally made parts).
* *** ****- and that they can not be supplied
Removal
• The “Removal” section contains procedures and precautions for implementing the work, know-how and the
amount of oil or coolant to be drained.
• General tools that are necessary for removal are described as [1], [2]•••etc. and their part names, part numbers
and quantities are not described.
• Various symbols used in the “Removal” section are explained and listed below.
This mark indicates safety-related precautions that must be followed when implementing the work.
Know-how or precautions for the work

[*1] This mark shows that there are instructions or precautions for installing parts.
This mark shows the amount of oil or coolant to be drained.
Weight of part or component
Installation
• Except where otherwise instructed, installation of parts is done in the reverse order of removal.
• Instructions and precautions for installing parts are shown with [*1] mark in the “Installation” section, identifying
which step the instructions are intended for.
• General tools that are necessary for installation are described as [1], [2]•••etc. and their part names, part
numbers and quantities are not described.
• Marks shown in the “Installation” section stand for the following.
Precautions related to safety in execution of the work.
NOTE: This mark gives guidance or precautions when doing the procedure.
Type of coating materials
7-2
torque
Tightening torque
Quantity of oil or coolant to be added
Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.
7.1.2 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES

Special tools
• Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1
etc. and their part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.
1. Necessity
t: Special tools that cannot be substituted and should always be used (installed).
q: Special tools that will be useful if available and are substitutable with commercially available tools.
2. Distinction of new and existing special tools
N: Tools newly developed for this model. They respectively have a new part number.
R: Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank Tools already available for other models. They can be used without any modification.
3. Circle mark Q in sketch column:
• The sketch of the special tool is presented in the section of "Sketches of special tools".
• This mark means part No. of special tools starting with 79 T-
from Komatsu in Japan (i.e. locally made parts).
* *** ****- and that they can not be supplied
Disassembly
• In “Disassembly” section, the work procedures, precautions and know-how for carrying out those procedures,
and quantity of the oil and coolant drained are described.
• General tools that are necessary for disassembly are described as [1], [2]•••etc. and their part names, part
numbers and quantities are not described.
• The meanings of the symbols used in “Disassembly” section are as follows.
This mark indicates safety-related precautions that must be followed when implementing the work.
Know-how or precautions for the work

[*1] This mark shows that there are instructions or precautions for installing parts.
This mark shows the amount of oil or coolant to be drained.
Assembly
• In "Assembly" section, the work procedures, precautions and know-how for carrying out those procedures, and
quantity of the oil and coolant added are described.
• General tools that are necessary for assembly are described as [1], [2]•••etc. and their part names, part numbers
and quantities are not described.
• The meanings of the symbols used in “Assembly” section are as follows.
Precautions related to safety in execution of the work.
NOTE: This mark gives guidance or precautions when doing the procedure.
7-3
Type of coating materials
torque
Tightening torque
Quantity of oil or coolant to be added
Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.
7-4
7.2 COATING MATERIALS LIST

(Rev. 2007.06)
• The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly
and assembly are listed below.
• For coating materials not listed below, use the equivalent of products shown in this manual.
Cate Komatsu
Part number Q'ty Container Main features and applications
gory code
Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
Used for plastic (except polyethylene,
Polyethyl- polypropylene, tetrafluoroethylene and vinyl
20 g
LT-1B 790-129-9050 ene con- chloride), rubber, metal, and non-metal parts
(2 pcs.)
tainer which require immediate and strong adhe-
sion.
Polyethyl-
Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g ene con-
Used to fix and seal bolts and plugs.
tainer
790-129-9060
Adhesive: 1 kg
(Set of adhe- Used to stick and seal metal, glass, and plas-
LT-3 Hardener: 500 Can
sive and hard- tics.
g
ener)
Adhesive
Polyethyl-
LT-4 790-129-9040 250 g ene con- Used to seal plugs.
tainer
Holtz MH
790-129-9120 75 g Tube Heat-resistant seal used to repair engines.
705
Quick-setting adhesive.
Polyethyl-
ThreeBond Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g ene con-
1735 Used mainly to stick metals, rubbers, plastics,
tainer
and woods.
Quick-setting adhesive.
Polyethyl- Quick-setting type.
Aron-alpha
790-129-9130 2g ene con- (max. strength is obtained after 30 minutes)
201
tainer Used mainly to stick rubbers, plastics, and
metals.
Polyethyl- Features: Resistance to heat and chemicals.
Loctite
79A-129-9110 50 cc ene con- Used for fitted portions used at high tempera-
648-50
tainer tures.
7-5
Used to stick or seal gaskets and packings of

LG-1 790-129-9010 200 g Tube
power train case, etc.
Used to seal various threaded portions, pipe
Polyethyl-
joints, and flanges.
LG-5 790-129-9080 1 kg ene con-
Used to seal tapered plugs, elbows, and nip-
tainer
ples of hydraulic piping.
Gasket Sealant
Features: Silicon-based heat and cold-resis-

tant sealant.
LG-6 790-129-9020 200 g Tube Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
Used to seal transfer case, etc.
Used for rough surfaces such as the circle
LG-9 gear top seal which does not need to be
ThreeBond 790-129-9310 200 g Tube clamped, water resistance of the clearance at
1206D the welded area, etc.
Can be coated with paint.
Gasket sealant
LG-10 Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E Can be coated with paint.
LG-11 Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube Gasket sealant used to repair engine.
1211
Molybdenum
Used to prevent scuffing and seizure of

disulfide
press-fitted portions, shrink-fitted portions,

LM-P 09940-00040 200 g Tube
and threaded portions.
Used to lubricate linkages, bearings, etc.
Feature: Seizure and scuffing prevention

prevention
LC-G compound with metallic super-fine-grain, etc.

Seizure
NEVER- — — Can Used for the mounting bolt in the high temper-
SEEZ ature area of the exhaust manifold and the
turbocharger, etc.
7-6
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI Feature: Lithium grease with extreme pres-
G0-LI
SYGA-160CNLI Various Various sure lubrication performance.
*: For cold
SYG0-400LI-A General purpose type.
district
(*)
SYG0-160CNLI
(*)
Used for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g x 10 Bellows-type Do not apply grease to rolling bearings like
fide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2- SYGA-16CNM 16 kg Can The grease should be applied to work equip-
M) ment pins at their assembly only, not applied
for greasing afterwards.
SYG2-400T-A
Hyper White Seizure resistance, heat resistance and water
Grease
SYG2-16CNT
Grease G2- 400 g Bellows-type resistance higher than molybdenum disulfide
SYG0-400T-A
T, G0-T (*) container grease.
(*)
*: For cold 16 kg Can Not conspicuous on machine since color is
SYG0-16CNT
district white.
(*)
Biogrease
G2-B, G2-BT
SYG2-400B
(*)
SYGA-16CNB 400 g Bellows-type Since this grease is decomposed by natural
*: For use at
SYG2-400BT container bacteria in short period, it has less effects on
high temper-
(*)SYGA- 16 kg Can microorganisms, animals, and plants.
ature and
16CNBT (*)
under high
load
Feature: Silicone grease with wide using tem-
perature range, high resistance to thermal-
G2-S
oxidative degradation and performance to
ThreeBond — 200 g Tube
prevent deterioration of rubber and plastic
1855
parts.
Used for oil seals of the transmission, etc.
7-7
Cate Komatsu
Part Number Q’ty Container Main features and applications
gory Code
SUNSTAR
Used as primer for cab side.
PAINT Glass con-
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 tainer
facture)
SUPER
417-926-3910
SUNSTAR
Used as primer for glass side.
GLASS Glass con-
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 tainer
Adhesive for cab glass

facture)
SUPER
SUNSTAR Used as primer for painted surface on cab
PAINT Glass con- side.
Primer
22M-54-27230 20 ml
PRIMER 435- tainer (Using limit: 4 months after date of manu-
95 facture)
Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR
Used as primer for sash (Almite).
SASH Glass con-
22M-54-27250 20 ml (Using limit: 4 months after date of manu-
PRIMER GP- tainer
facture)
402
SUNSTAR “S” is used for high-temperature season
PENGUINE Polyethyl- and “W” for low-temperature season as
SEAL 580 417-926-3910 320 ml ene con- adhesive for glass.
SUPER “S” or tainer (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
Polyethyl- Used as adhesive for glass.

Sika Japan,
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manu-
Sikaflex 256HV
Adhesive for cab glass
tainer facture)
SUNSTAR Ecocart Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Polyethyl- Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manu-
SEAL No. 2505 tainer facture)
Caulking material
SEKISUI SILI- Polyethyl- Used to seal front window.

CONE SEAL- 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manu-
ANT tainer facture)
Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
7-8
7.3 SPECIAL TOOLS LIST

• Tools with part number 79QT - QQQ - QQQQ cannot be supplied (they must be locally manufactured)
• Necessity:t ------ Cannot be substituted, should always be installed (used)
: q ------ Extremely useful if available, can be substituted with commercially available part
• New / Remodel:NTools newly developed for this model and given new part Nos.
:RTools remodeled from tools already available for other models and given upgraded part Nos.
:BlankTools already available for other models, usable without any modification
• Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools
(See Sketches of special tools)
• Nos. in the upper line of the Part No. column are KOMATSU part Nos. and those in the lower line are CUMMINS
part Nos.
New/Remodel
Necessity
Sketches
Sym
Q'ty
Work item Part No. Part name Remarks
bol
790-501-2001
A Repair stand t 1
795-799-1150
Disassembly and assembly Specialized for Komatsu
of engine assembly — N
repair stand
B Adapter t 1
Specialized for CUM-
795-799-7210 N
MINS repair stand
Removal and installation of 795-102-2103
air intake and exhaust C Spring pusher q 1
valves 795-799-8800 N
Removal and installation of
D 795-100-2800 Piston ring tool t 1
piston ring
Installation of piston E 795-921-1100 Piston holder t 1 φ75 – 175 mm
Removal of injector F 795-799-6700 Puller t 1 N
G 795-799-6500 Seal driver q 1 N
rear seal
H 795-799-6400 Seal driver q 1 N
front seal
790-331-1120 Wrench (angle)
Angle tightening of bolt J q 1
795-799-2240 Angle gauge
Commercially
Adjusting valve clearance K Clearance gauge q 1
available
Adjusting gear backlash Commercially
L Dial gauge and stand q 1
and end play available
Removal of fuel inlet con-
M 795-799-8150 Remover q 1 N
nector
Removal and installation of Remover and
U 795-799-2270 q 1
main bearing installer
Rotation of crankshaft V 795-799-1131 Barring tool q 1
Tightening of injector har-
W 795-799-7110 Torque wrench q 1 N
ness nut
Measurement of cylinder
X 795-790-4510 Gauge q 1 N
head bolt length
7-9
7.4 GENERAL DISASSEMBLY OF ENGINE
IMPORTANT
This disassembly manual is a general disassembly manual for the SAA6D107E-1-A engine. Since the shapes,
numbers, locations, etc. of the parts depend on each applicable machine, check them before starting the work.
1. Preparation work
Before disassembling the engine, check its parts for cracking, damage, etc. and clean it generally and carefully for
accurate inspection of its parts and quick disassembly and assembly.
Before cleaning the engine, carefully seal or remove the openings, electric parts, and wiring connectors so
that water will not enter them.
a. Prepare stable 2 engine stands (Blocks [1]) for the right and left and secure the engine assembly on them
so that it will not tip over.
b. Remove oil gauge assembly (2).
2. Installation to engine repair stand

a. Install tool B to engine assembly (1).
Mounting bolt on engine side M12 x 1.75
torque
Mounting bolt: 56.8 ± 8.8 lbf/ft (77 ± 12 Nm) {7.9 ± 1.2 kgm}
b. Sling engine assembly (1) and install it to tool A.
Engine assembly: Approx. 1146lb (520 kg)

(Weight depends on each applicable machine)
c. Drain the engine coolant and engine oil.

Engine oil: Approx. 23.3 qt (23 l)
7-10
3. Starting motor assembly

a. Remove mounting bolt (1) and then remove starting
motor assembly (2).
4. Engine sling bracket on rear side

a. Remove rear engine sling bracket (1) from the cylin-
der head.
5. Fan pulley
a. Remove fan belt (1).
1) Insert a wrench to the portion (A) (width across
flats T 12.7 mm) of the tensioner assembly (2), and
rotate it to the opposite to the winding-up direction
to decrease the fan belt (1) tension, then remove.

(A) before rotating it. (The spring of the tensioner
assembly (2) is strong. If the wrench is loosely
inserted, the wrench may accidentally come off while
being rotated and it is extremely dangerous.)
• After removing the fan belt (1), return the tensioner
assembly (2) slowly with care.
• Be careful not to get your fingers caught between the pulley and fan belt (1) during work.
b. Remove bolt (3) and then remove fan pulley (4).
7-11
6. Vibration damper
a. Remove bolts (1) and vibration damper (2).
7. Belt tensioner
a. Remove bolt (1) and then remove belt tensioner (2).
8. Fan hub
a. Remove 4 bolts (1) and then remove fan hub (2).
9. Alternator
a. Remove plate (1).
b. Remove bolt (2) and then remove alternator (3).
7-12
j. Remove alternator bracket (4) and front side sling

bracket (5).
11. Thermostat
a. Remove coolant outlet connector (1).
b. Remove thermostat (2).
12. Water pump

a. Remove coolant inlet connector (1).
b. Remove water pump (2).
7-13
13. Turbocharger and exhaust manifold

a. Remove turbocharger lubricating oil inlet tube (1) and
drain tube (2).
b. Remove turbocharger assembly (3) and exhaust

manifold (4).
14. Fuel filter assembly

a. Disconnect hoses (1) and (2) from the filter.
b. Disconnect drain hose (3) from filter bracket (4).
c. Remove fuel filter assembly (5).
1) Removal of hose
While pressing the adapter (by the right and left
sides) at the hose end, pry off the hose end face with
a screwdriver.
The internal parts of the adapter may be damaged when

the hose is removed. Accordingly, do not reuse the
adapter but use new one when installing the hose again,
as a rule.
7-14
15. Harness assembly

a. Disconnect the harness from the sensor and control-
ler, and then remove the clamp to remove harness
assembly (1).
16. Fuel high-pressure piping and common rail

a. Remove boots (9) of high-pressure pipings (1) to (7)
and then remove the high-pressure pipings.
b. Remove fuel drain hose (8).
c. Remove common rail (10).
1) Removal of hose
Remove the hose by prying the hose end face with
screwdriver while pushing the mouthpiece (on both
sides) of the hose termination.
Do not use the hose again, because inside of the mouth-

piece may be damaged when the hose is removed. Use a
new hose when assembling.
17. Air intake manifold cover

a. Remove tube (1) and electrical intake air heater (2).
b. Remove manifold covers (3) and (4).
18. Head cover and rocker housing

a. Remove duct (1).
b. Remove nuts (2) and then remove head cover (3).
7-15
c. Remove nuts (4) of the harness from injector.

Harness installation position
Color of cable Cylinder No.
White 1, 3, 5
Black 2, 4, 6
d. Remove bolt (5) and then remove rocker housing

assembly (6).
19. Rocker arm assembly and crosshead

a. Remove bolts (1) and rocker arm assembly (2).
1) Loosen the locknut and then loosen the adjustment
screw fully so that the tension of the valve spring
will not be applied to the rocker arm assembly
mounting bolts.
b. Remove crosshead (3).
c. Record the position of the crosshead and the shapes

of holes "a" and "b" (to install the crosshead in the
same direction again).
20. Push rod

a. Remove push rods (1).
7-16
21. Fuel injector assembly

a. Remove retainer (5) and then remove 6 inlet connec-
tors (1).
NOTE: Use tool M when removing the inlet connector.
b. Remove mounting bolts (3) of injector (2) and then

remove holder (4).
c. Remove injector (2).
d. Lift and remove the injector using tool F. (Don't try to

pry the top of the injector.)
22. Cylinder head assembly

a. Remove bolts (1) and cylinder head assembly (2).
Cylinder head assembly: 154 lb (70 kg)
7-17
b. Disassemble the cylinder head assembly according

to the following procedure.
1) Using tool C, compress valve spring (3) to remove
valve cotter (4).
2) Remove upper seat (5) and valve spring (3).

3) Raise the cylinder head assembly, pull and remove
valve (6) and then remove valve seal (7).
4) Apply a marking to valve (6) to make it identifiable

to which cylinder head it should be combined.
23. Oil cooler

a. Remove oil filter (1). (When filter is installed to
engine)
7-18
b. Remove mounting bolts (6), cover (2) and cover gas-

ket (3).
c. Remove oil cooler (4) and cooler gasket (5).
24. Engine controller

a. Remove engine controller (1).
b. Disconnect ground cable (2).
c. Remove cooling plate (3).

a. Remove hose (1).
b. Remove 3 nuts (2) and then remove supply pump (3).
7-19
26. Flywheel
a. Install guide bolt [1] and then remove flywheel (1).
Flywheel: 77 lb (35 kg)
Take care in this operation so that your fingers may not be damaged by the flywheel that can fall off from
the shallow spigot joint.
27. Rear oil seal

a. Install tool G to the crankshaft.
b. Screw in tapping screw [1] of tool G to the seal carrier
section of rear oil seal (1).
c. Turn the handle counterclockwise to remove rear oil

seal (1).
7-20
28. Flywheel housing

a. Remove bolts (1) and then remove flywheel housing
(2).
29. Oil pan

a. Remove bolts (1) and then remove oil pan (2).
b. Remove suction tube (3).

c. Remove plate (4) and 3 plates (5).
30. Front cover

a. Remove bolts (1) and then remove front cover (2).
b. Remove front seal (3).
7-21
31. Oil pump assembly

a. Remove bolts (1) and then remove oil pump assem-
bly (2).
32. Camshaft
a. Rotate the crankshaft to align punch mark A on cam-
shaft gear (1) to the chamfered tooth of crankshaft
gear (4) (preventing of interference with the connect-
ing rod when removing the camshaft).
b. Remove gear (1).
c. Remove thrust plate (2).
7-22
d. Rotate camshaft (3) when removing the plate.
33. Gear housing

a. Remove bolts (1) and then remove gear housing (2).
34. Piston and connecting rod assembly

a. Rotate the crankshaft and bring the piston to be
removed to the bottom dead center.
b. Scrub the carbon off the top wall of the cylinder liner
with fine sandpaper.
c. Apply a marking to each of connecting rod cap (1)
assembly position on respective cylinders.
NOTE: Before removing the piston and connecting rod

assembly, measure the side clearance between the
connecting rod and crankshaft using tool K.
d. Remove bolt (2).

e. Hit connecting rod cap (1) with a plastic hammer
lightly, and remove connecting rod cap (1) and con-
necting rod bearing as a unit.
Keep the connecting rod and connecting rod cap so that

their mating faces will not be damaged.
If their mating faces are damaged, replace them.
7-23
f. Push in and remove the piston and connecting rod

assembly with a wood bar, etc. from the oil pan side,
while supporting piston (6) on the cylinder head side.
Take care in the removal so that inner surface of the cyl-

inder liner may not be damaged by corners of the con-
necting rod.
NOTE: Make a cylinder No. mark on the piston.
g. Remove the other piston and connecting rod assem-

blies according to the above procedure.
Take care not to damage the sliding portions of the pistons and bearings.
h. Disassemble the piston and connecting rod assembly

according to the following procedure.
1) Remove snap ring (3).
2) Separate piston (6) from connecting rod by pulling
out piston pin (5) while supporting connecting rod
(4) with hand.
3) Remove the snap ring on the opposite side.
4) Using tool D, remove piston ring (7).
IMPORTANT
Keep the piston, connecting rod, connecting rod bearing, pis-
ton rings, and piston pin by cylinder.
7-24
35. Crankshaft
IMPORTANT
Before removing the crankshaft, measure its end play X with
dial gauge.
a. Remove mounting bolts (2) of main cap (1).

b. Insert the bolts in the bolt holes of main cap (1) and
remove the cap, while shaking it.
NOTE: Installation position numbers are marked on the main

cap. No. 1 starts from the front side of the cylinder
block.
c. Check that the position No. of the main cap (stamped

at part A) is directed toward the oil cooler.
d. Remove bottom lower bearing (3) from main cap (1).

e. Mark the installation position number on claw (A) of
the removed bearing.
(Don't apply the number on the sliding surface of the
bearing.)
7-25
f. Lift off crankshaft (4) using the nylon sling.
• When lifting and removing the crankshaft, take care

not to damage it by bumping against the cylinder
block.
• Keep the crankshaft in a safe place so that its sliding
portions will not be damaged.
Crankshaft: 132lbs (60 kg)
g. Remove upper thrust bearing (5) and upper bearings

(6).
IMPORTANT
Mark the assembly position on the main cap, upper bearing and upper thrust bearing (in the claw of the bearing). It
is advised to maintain the bearings of a main cap separately from that for another main cap. And take care not to
damage these parts.
36. Piston cooling nozzle

a. Remove bolt (1) and then remove piston cooling noz-
zles (2).
7-26
37. Tappet
a. Remove tappets (1) and then mark the installation
position on them.
NOTE: When reusing the camshafts and tappets, be sure to

install them in the original position.
38. Cylinder block

a. Remove cylinder block (1) from tool A.
Cylinder block: 306 lbs (140 kg)
7-27
7.5 GENERAL ASSEMBLY OF ENGINE

a This document describes the general assembly procedure of SAA6D107E-1-A. The shapes, quantity, loca-
tions, etc. of the parts depend on each applicable machine. Take care.
a When reusing a part, be sure to install it to its original position.
1. Preparation work
a. Install tool B.
b. Install cylinder block (1) to tool A.
torque
Mounting bolt: 56.8 ± 8.8 lbf/ft(77 ± 12 Nm) {7.9 ± 1.2 kgm}
Cylinder block: 306 lbs (140 kg)
2. Tappet
a. Apply engine oil to tappets (1).
Tappet: Engine oil (EO15W-40)
3. Install tappets (1).
IMPORTANT
• When reusing the camshafts and tappets, be sure to
install them in the original position.
• Don't invert the cylinder block by 90° or more. Otherwise,
the tappet may fall off from the mounting hole during
assembly.
7-28
4. Piston cooling nozzle

a. Set piston cooling nozzles (2) and then tighten them
using mounting bolt (1).
torque
Mounting bolt: 11 ± 1.5 lbf/ft (15 ± 2 Nm) {1.5 ± 0.2 kgm}
5. Crankshaft
a. Install upper bearings (6) and an upper thrust bearing
(5).
1) Set the projection of each bearing to the notch of
the cylinder block.
2) When installing the bearings, check that their back
sides are free from foreign matter.
3) Apply engine oil to inner surface of metal. Don't
apply the oil to the backside.
Inside of bearing: Engine oil (EO15W-40)
IMPORTANT
When reusing the bearings, check the marks made on them when removed and install them to their original posi-
tions.
6. Using a nylon sling, lift up and install crankshaft (4).
When installing, take care so that the upper thrust bear-

ing may not be damaged.
Crankshaft: 132 lbs (60 kg)
7-29
7. Fit lower bearing (3) to the main cap, matching the

projection of the former to the notch of the latter.
8. Make sure ring dowel (7) is installed on the main cap.
9. Apply engine oil (EO15W-40) to the journal surfaces of

the crankshaft.
10. Before installation, check the No. stamped on main cap (1).
IMPORTANT
Installation shall start from the front side of the cylinder block
in a numerical order.
11. In the installation, make sure the stamped No. (section A)

is faced to the oil cooler.
12. Push in each main cap by hitting it lightly with a plastic
hammer or rubber hammer.
7-30
13. Before tightening the main cap mounting bolt (2), check
the following.
a. Using tool X, measure stem length (a) of every bolt
and check that it is less than the using limit.
Using limit length of bolt stem: Less than 120.0 mm
IMPORTANT
If a bolt is longer than the using limit, do not reuse it but
replace it.
14. Tightening procedure of main cap mounting bolts (2).

a. Apply engine oil to the bolts.
Main cap mounting bolt: Engine oil (EO15W-40)

b. Tighten the bolts in the order [1] to [14] shown in the figure.
torque
Main cap mounting bolt

When current bolts are used again:
1. 44 ± 3.7 lbf/ft (60 ± 5 Nm) {6.1 ± 0.5 kgm}

2. 59 ± 3.7 lbf/ft (80 ± 5 Nm) {8.2 ± 0.5 kgm}
3. 90° ± 5° (When angle tightening tool J is used)
When new bolts are used:

1. 88.5 ± 3.7 lbf/ft (120 ± 5 Nm) {12.2 ± 0.5 kgm}
2. Loosen by 360°
3. 44 ± 3.7 lbf/ft (60 ± 5 Nm) {6.1 ± 0.5 kgm}
4. 62.7 ± 3.7 lbf/ft (85 ± 5 Nm) {8.7 ± 0.5 kgm}
7-31
c. When tool J is not used:

1) Mark the main cap and each bolt with paint and
then tighten the bolt by 90° ± 5° (when the bolt is
reused) or 120° ± 5° (when a new bolt is used).
15. After tightening the bolts, make sure that the crankshaft
turns smoothly.
16. Measure the end play of the crankshaft with a dial gauge.
NOTE: End play X: 0.0094 ± 0.0068 in (0.24 ± 0.175 mm)
17. Piston and connecting rod assembly

a. Using tool D, fit piston rings (7) to the piston.
b. Installation of oil ring
NOTE: Set the oil ring (9) so that its abutment joint comes in
a position at 180° to the end of expander (8).
7-32
c. Fit second ring (10) with the stamp of “TOP” near the
abutment joint up.
d. Fit top ring (11) with the “dot” mark near the abutment
joint up.
e. When fitting each ring, set the abutment joint off the
thrust, anti-thrust, and piston axis directions.
f. Apply engine oil (EO15W-40) to piston ring and pis-
ton skirt.
g. Set the piston and connecting rod.
IMPORTANT
When “FRONT” mark of piston (6) head is set at the top, con-
necting rod (4) must be facing to the direction shown in the
figure.
h. Apply engine oil to the piston pin hole and piston pin.
Piston pin and pin hole: Engine oil (EO15W-40)
i. Insert piston pin (5) and then assemble piston (6) to

connecting rod (4).
j. Install snap ring (3) to both sides.
k. Install the bearing to the connecting rod and connect-

ing rod cap.
l. Check that the back side of the bearing is free from
foreign matter.
7-33
m. Fit the bearing to the connecting rod and cap, match-

ing the projection of the former to the notch of the
connecting rod and cap.
n. Set the crankshaft to the bottom dead center of the

cylinder to install the piston and apply engine oil to the inside of the cylinder.
Inside of cylinder: Engine oil (EO15W-40)

18. Insert the piston and connecting rod assembly setting
“FRONT” mark of piston (6) to the front side of the
cylinder.
a. Check the directions of the abutment joints of the pis-
ton rings again.
b. When inserting the connecting rod, take care not to
damage the wall of the cylinder.
c. When installing the assembly, take care so that it may
hit the cooling nozzle.
d. Using tool E, reduce the piston rings and push in the

piston head with a wood bar, etc.
7-34
19. Install connecting rod cap (2) by tightening bolt (1) in the
a. Apply engine oil to the threaded portions of the bolts
and inside of the connecting rod bearings.
Threaded portions of bolts: Engine oil (EO15W-40)

Inside of connecting rod bearings: Engine oil (EO15W-
40)
b. Tighten the bolts with angle tightening tool J (wrench

and angle gauge).
torque
Mounting bolts (Tighten both bolts alternately):

1. 22 ± 2.2 lbf/ft (30 ± 3 Nm) {3.06 ± 0.31 kgm}
2. 44 ± 3.7 lbf/ft (60 ± 5 Nm) {6.12 ± 0.51 kgm}
c. When not using tool J

1) Make marks on the main cap and bolt with paint
and then tighten the bolt by 60° ± 5°.
20. After installing the piston and connecting rod assembly,

rotate the crankshaft to make sure that it turns smoothly without getting hung up.
21. Measure the side clearance between the connecting rod
and crankshaft with tool K.
NOTE: Side clearance: 0.0039 – 0.0130 in (0.10 – 0.33 mm)
7-35
22. Gear housing

a. Apply gasket sealant to part A of the mounting face of
housing (2).
Housing: Gasket sealant (LG-7)
IMPORTANT
• Diameter of gasket sealant line shall be 1 – 2 mm.
• If too much gasket sealant is applied near blow-by oil
groove B, the groove may be clogged. Accordingly, keep
the gasket sealant line diameter strictly.
b. Make sure that each of the dowel ring of the gear
housing is correctly inserted to the dowel hole at both the top and bottom (indicated with ∗ mark). Other-
wise, they can be damaged when bolt-tightened.
c. Press the gear housing against the cylinder block so that its entire mating surface with the cylinder block is
closely contacted.
NOTE: Don't apply torque to the mounting bolts until the entire mating surface is closely contacted.
d. Tighten the mounting bolts.

1) Bolts tightening procedure
IMPORTANT
• Tighten the bolts according to the numbers [1] to [10]
shown in the figure.
• 4 types of bolts are used. Make sure when tightening that
specified torque is applied.
torque
Mounting bolt:
1. M12: 56.8 ± 5.7 lbf/ft (77 ± 7 Nm) {7.9 ± 0.7 kgm}

(No marking)
2. M10: 31.7 ± 3.7 lbf/ft (43 ± 5 Nm) {4.4 ± 0.5 kgm}
(Q mark l = 30, T mark l = 50)
3. M8: 17.7 ± 2.9 lbf/ft (24 ± 4 Nm) {2.5 ± 0.4 kgm}
(E mark)
7-36
23. Camshaft
a. Rotate the crankshaft to set the No. 1 cylinder to the
top dead center.
b. Apply engine oil (EO15W-40) to the camshaft bore,
camshaft journal and lobed surface. Then lightly push
in and rotate camshaft (3) to install.
Sliding surfaces of camshaft: Engine oil (EO15W-40)
c. Install thrust plate (2).

torque
Mounting bolt: 17.7 ± 2.9 lbf/ft (24 ± 4 Nm) {2.4 ± 0.4

kgm}
d. When installing, fit in the thrust plate to timing mark A

on camshaft gear (1) as well as to the chamfered
tooth (a single location) of crankshaft gear (4).
torque
Mounting bolt: 26.5 ± 2.9 lbf/ft (36 ± 4 Nm)

{3.7 ± 0.4 kgm}
e. Measure the end play and backlash of the camshaft

with a dial gauge.
• End play: 0.0039 – 0.0142 in (0.10 – 0.36 mm)
NOTE: The end play is determined by thickness of the thrust

plate and groove of the camshaft.
• Backlash: 0.0030 – 0.011 in. (0.076 – 0.280 mm)
7-37
24. Flywheel housing

a. Install flywheel housing (2) using bolt (1).
Apply gasket sealant (LG-7) to the flanged housing

installation surface as well as circumference of the
mounting bolt hole. Diameter of gasket sealant line shall
be 1 – 3 mm.
Flywheel housing: Gasket sealant (LG-7)
b. Tighten the mounting bolts in the numeric order [1] to

[20] shown in the figure.
• 2 types of bolts are used. Make sure when tightening
that the specified torque is used.
torque
M12: 62.7 ± 7.4 lbf/ft (85 ± 10 Nm) {8.7 ± 1.0 kgm}

(E mark)
torque
M10: 36.1 ± 3.7 lbf/f (49 ± 5 Nm) {5.0 ± 0.5 kgm}

(T mark)
c. After installing the flywheel housing, measure the

radial runout and facial runout with tool L.
• Radial runout: Max. 0.0079 in (0.20 mm)
• Facial runout: Max. 0.0079 in (0.20 mm)
d. Measurement of radial runout
1) Install tool L to the crankshaft end face.
2) Contact the probe of the dial gauge at right angle
against part of the spigot joint of the flywheel hous-
ing.
3) Set graduations of the dial gauge to “0” and then
rotate the crankshaft by a turn to measure differ-
ences in the maximum deflections of the gauge
pointer.
4) Make sure after rotating the crankshaft by a turn that the gauge pointer is returned to the position where
it had situated when the crankshaft was started to turn.
e. Measurement of facial runout
1) Like in measurement of the radial runout, contact
the probe of the dial gauge at right angle against
the end face of the flywheel housing.
2) Before conducting the measurement, move the
crankshaft either in the front or rear side in order to
prevent errors due to the end play.
3) Set graduations of the dial gauge to “0” and then
rotate the crankshaft by a turn to measure the dif-
ference in the maximum deflections of the gauge
pointer.
7-38
25. Rear oil seal

a. Insert pilot [2] to rear oil seal (4).
NOTE: Before inserting the pilot, clean, degrease and dry the
oil seal lip surface.
b. Insert oil seal (4), together with pilot [2], to the crank-
shaft and then push in the seal carrier of oil seal (4) to
the flywheel housing (1).
NOTE: Before inserting the oil seal, clean, degrease and dry
the surface where the seal is contacted against the
crankshaft.
c. Pull out pilot [2] and then further push in oil seal (4).
d. Using tool G, insert the oil seal until it is flush with the
flywheel housing end face.
IMPORTANT
When pushing in the oil seal, make sure that the seal carrier
is free from bending.
NOTE: Installed dimension X = Max. 0.38 mm
7-39
26. Flywheel
a. Install guide bolt [1] and flywheel (1).
Apply gasket sealant to the circumference of the bolt

hole (8 locations) on the mounting surface of the crank-
shaft. Diameter of gasket sealant line shall be 1 – 3 mm.
Flywheel mounting surface: Gasket sealant (LG-7)
Flywheel assembly: 77 lbs (35 kg)
b.Tighten the mounting bolts in the order indicated in

the figure.
torque
Mounting bolt: 101 ± 5.2 lbf/ft (137 ± 7 Nm)

{14.0 ± 0.7 kgm}
c. After installing the flywheel, measure the radial

runout and facial runout with tool L.
• Radial runout: Max. 0.0051 in (0.13 mm)
• Facial runout: Max. 0.0079 in (0.20 mm)
d. Measurement of radial runout
1) Install tool L to the flywheel housing.
2) Contact the probe of the dial gauge at right angle
against section (a) of the spigot joint or periphery
of the flywheel housing.
3) Rotate the flywheel by a turn to measure the differ-
ences in the maximum deflections of the dial
gauge pointer.
4) Make sure after rotating the flywheel by a turn that
the dial gauge pointer is returned to the position where it had situated when the flywheel was started to
turn.
e. Measurement of facial runout
1) Like in measurement of the radial runout, contact the probe of the dial gauge at right angle against end
face (b) situated near the periphery of the flywheel housing.
2) Before conducting the measurement, move the crankshaft either in the front or rear side in order to pre-
vent errors due to the end play.
3) Rotate the flywheel by a turn to measure the differences in the maximum deflections of the dial gauge
pointer.
7-40
27. Oil pump assembly

a. Fill up the oil pump rotor space and the idler shaft
bore with engine oil (EO15W-40) and then rotate the
rotor by two turns.
b. Install oil pump assembly (2) with bolts (1).
c. Tighten the mounting bolts in the order indicated in

the figure.
torque
Mounting bolt:
1st time: 5.9 ± 0.7lbf/ft
(8 ± 1 Nm) {0.8 ± 0.1 kgm} (Fig.a)
2nd time: 17.7 ± 2.9 lbf/ft
(24 ± 4 Nm) {2.4 ± 0.4 kgm} (Fig.b)
d. Measurement of backlash
1) Stop move of a gear of either side and then mea-
sure backlash (C) of the pump and idler gear.
• Total amount of backlash (C): 0.2 ± 0.05 mm
7-41
28. Front cover

a. Apply gasket sealant to installation surface (A) of
cover (2).
Front cover: Gasket sealant (LG-7)

Diameter of gasket sealant line shall be 1 – 2 mm.
b. Tighten the mounting bolts according to the numbers

[1] to [13] shown in the figure.
torque

{2.4 ± 0.4 kgm}
c. Using tool H, install front seal (3).

d. Before installing the seal, check that the end corners
and lip sliding surfaces of the crankshaft are free from
flaw, burr, and rust of the housing.
e. When installing the seal, do not apply oil or grease to
the shaft and seal lip. Wipe off the oil from the shaft.
7-42
IMPORTANT
The deviation of seal (3) from cover (2) must be as follows:
• Extrusion (x): Max. 0.015 in. (0.38 mm)

• Facial runout (TIR) (y): Max. 0.010 in. (0.25 mm)
29. Oil pan

a. Install plate (4) and 3 plates (5).
torque

{4.4 ± 0.5 kgm}
b. Install suction tube (3).
torque
Flange mounting bolt: 17.7 ± 2.9 lbf/ft (24 ± 4 Nm)

{2.4 ± 0.4 kgm}
c. Apply gasket sealant to installation surface (A).
Oil pan: Gasket sealant (LG-7)

Diameter of gasket sealant line: Straight line: 3 mm,
curved line: 1 mm
d. Install oil pan (2) with bolts (1).
7-43
e. Tighten the mounting bolts according to the numbers

torque

{2.9 ± 0.2 kgm}
f. Application procedure for gasket sealant when install-

ing oil pan
1) Remove the excessive gasket projected onto the
underside of the portion between block (2) and
front cover (1) and that between block (2) and gear
housing (3) with a scraper.
2) Apply gasket sealant (LG-7) to oil pan mounting
face, the border between block (2) and front cover
(1) and that between block (2) and gear housing
(3) (4 portions marked with a).
7-44
g. When replacing only oil pan

1) Remove the excessive gasket projected onto the
underside of the portion between block (2) and
front cover (1) and that between block (2) and gear
housing (3) with a scraper.
2) Remove the old gasket sealant packed between
block (2) and front cover (1) and that packed
between block (2) and gear housing (3) (4 portions
marked with a) with the scraper.
3) Apply gasket sealant (LG-7) to oil pan mounting
face, the border between block (2) and front cover
(1) and that between block (2) and gear housing
(3) (4 portions marked with a).
1. Cylinder block
2. Gear housing
3. Oil pan
7-45
30. Vibration damper

a. Install vibration damper by fitting in their knock holes
to dowel pin (a) of the crankshaft.
b. Bolt (1) tightening procedure
torque
Mounting bolt:
1) Tighten the bolt's opposing corner sequentially with
40.6 ± 3.7 lbf/ft (55 ± 5 Nm) {5.6 ± 0.5 kgm}.
2) Loosen the bolt by 180°.
1) Tighten the bolt's opposing corner sequentially with
40.6 ± 3.7 lbf/ft (55 ± 5 Nm) {5.6 ± 0.5 kgm}.
2) 90° ± 5° (When angle tightening tool J is used)
c. When not using angle tightening tool:

1) Make marks on the crankshaft pulley or vibration
damper and each bolt with paint and then tighten
the bolt by 90° ± 5°.

a. Install supply pump (3) with 3 nuts (2).
• If grease is applied too much to the O-ring when the

supply pump is installed, it will ooze out during oper-
ation. Accordingly, do not apply grease too much.
(Apply grease to O-ring groove area A.)
• When removing and installing the supply pump
mounting stud bolts of the gear housing, apply
LOCTITE to the root side.
torque
Mounting nut: 17.7 ± 2.9 lbf/ft (24 ± 4 Nm) {2.4 ± 0.4 kgm}
b. Install new hose (1).
The internal parts of the adapter may be damaged when

the hose is removed. Accordingly, do not reuse the
adapter but use new one when installing the hose again,
as a rule.
7-46
32. Engine controller

a. Install cooling plate assembly (2) and tighten mount-
ing bolts (4).
torque

{2.4 ± 0.4 kgm}
b. Install engine controller (1) and tighten mounting

bolts (5).
torque

{2.4 ± 0.4 kgm}
c. Install ground wire (3).
33. Oil cooler

a. Install gaskets (5) and (3), oil cooler (4) and cover (2)
with bolts (6).
b. Tighten the bolts in the numeric order shown in the

figure.
torque

{2.4 ± 0.4 kgm}
7-47
c. Install oil filter (1).
Apply engine oil to the seal. Engine oil (EO15W-40)

torque
Filter: 9.6 ± 1.5 lbf/ft (13 ± 2 Nm) {1.3 ± 0.2 kgm}

Or tighten 3/4 turns after contacting mating part.
34. Cylinder head assembly

a. Assemble the cylinder head assembly according to
the following procedure.
1) Install valve seal (7).
2) Apply engine oil to the valve stem and inside of
valve guide and install valve (6).
Valve stem and valve guide: Engine oil (EO15W-40)
3) Raise the cylinder head and install valve spring (3)

and upper seat (5).
4) Using tool C, compress valve spring (3) to install

valve collet (4).
5) Hit the valve stem lightly with a plastic hammer to
make sure that the valve collet is positively fitted to
the groove of the valve stem.
7-48
b. Before tightening the cylinder head mounting bolt,

check the following.
1) Measure stem length (a) of every bolt to make sure
that they are within the using limit.
IMPORTANT
• Using limit length of bolt stem (a): Max. 132.1 mm
• If a bolt is longer than the using limit, do not reuse it but
replace it.
c. Check that the cylinder head mounting face and

inside of the cylinder are free from foreign matter and
then set cylinder head gasket (8).
d. Make sure that the gasket is fitted in the hole on the
cylinder head.
e. Set cylinder head assembly (2) on the cylinder block

and then tighten it using mounting bolts (1).
f. First, tighten the mounting bolts by 2 – 3 turns or

more by hand, and then tighten them according to the
Apply engine oil (EO15W-40) to the threaded portion and

head seat of each bolt.
torque
Mounting bolt: Tighten the bolts 3 times in the order

1. 66.4 ± 2.2 lbf/ft (90 ± 3 Nm) {9.2 ± 0.3 kgm}
2. 66.4 ± 2.2 lbf/ft (90 ± 3 Nm) {9.2 ± 0.3 kgm}
3. 90° ± 5° (When tightened with angle tightening tool
J)
7-49
g. When the angle tightening tool J is not used:

1) After applying a paint marking to the cylinder head
and bolt, tighten the bolt by 90° ± 5°.
35. Fuel injector assembly
IMPORTANT
• When replacing the injector, replace the inlet connector,
too.
• Make sure that the injector sleeve is free from damages or
dirt.
a. Attach the gasket (6) and O-ring (7) to injector (2).
b. Apply engine oil (EO15W-40) to the O-ring (7) of
injector (2) as well as the head side.
c. Insert injector (2) to the cylinder head while directing
its fuel inlet hole to the manifold.
d. Install holder (4) and then tighten bolt (3) 3 to 4
threads.
e. Check the inlet connector for the following items. If it
is defective, replace it.
1) There is a burr or a worn part at front end (a) or
rear end (b) of the inlet connector.
2) There is foreign matter in the edge filter at rear end
(c) of the inlet connector.
3) The O-ring at upper part (d) of the inlet connector
is cracked or deteriorated.
4) There is a worn part or an uneven seat contact

mark on seat surface (e) at the front end of the inlet
connector.
NOTE: If high-pressure fuel leaks through the inlet connec-

tor, the seat surface has fine streaks or flaws.
7-50
Apply engine oil (EO15W-40) to the O-ring of inlet connector (1) as well as the head side.
f. Insert inlet connector (1) in the mounting hole of
injector (2) and tighten retainer (5) temporarily.
torque
Retainer: 11 ± 3.7 lbf/ft (15 ± 5 Nm) {1.5 ± 0.5 kgm}
NOTE: The above tightening torque is for temporarily tight-

ening. Tighten the retainer permanently in step h).
g. Tighten bolts (3) alternately.

torque
Bolt: 5.9 ± .6 lbf/ft (8 ± 0.8 Nm) {0.8 ± 0.08 kgm}

h. Tighten retainer (5).
torque
Retainer: 36.9 ± 3.7 lbf/ft (50 ± 5 Nm) {5.1 ± 0.5 kgm}

36. Push rod
a. Install push rod (1).
1) Check that the push rod is fitted in the tappet.
2) Refill the push rod socket with engine oil (EO15W-
40).
37. Rocker arm assembly

a. Install crosshead (3).
b. Install rocker arm assembly (2) and tighten bolts (1).
c. Before tightening the mounting bolts, check that the
ball of the adjustment screw is fitted to the socket of
the push rod.
torque
Bolt: 26.5 ± 3.7 lbf/ft (36 ± 5 Nm) {3.7 ± 0.5 kgm}
7-51
IMPORTANT
Shape of the holes (a) and (b) on the crosshead is not identi-
cal. Thus when using this part again, the same air intake and
exhaust valves must be assembled in the same direction.
38. Adjusting valve clearance

As for the valve clearance, adjust the clearance between the crosshead and rocker arm to the following value.
Valve clearance (when cold)
Unit: mm
Air intake valve Exhaust valve
0.25 ± 0.05 0.51 ± 0.05
a. Remove plug (1) on the top of the starting motor and

install tool V.
NOTE: The position of plug (1) depends on the applicable

machine.
The shape in the figure is a little different from the actual

machine.
b. Rotate the crankshaft forward with tool V and set

wide slit (b) on the disc having the revolution sensor
slits at the rear of the crankshaft pulley to projection
top (a) of the front cover.
NOTE: Seen from the air intake manifold side, set projection
top (a) into the range of wide slit (b).
Note that the following cylinder is not at the top dead

center (but at 76 – 88° before the top dead center) when
the projection top is set as above.
No. 1 cylinder or No. 6 cylinder

Reference: A part of the damper corresponding to wide slit (b) is painted white.
7-52
c. Adjust the valve clearance according to the following

procedure.
• If you cannot move the rocker arms of the exhaust
valves (on the EX side) with the hand, adjust the
valves marked with an open circle in the valve
arrangement drawing.
• If you can move the rocker arms of the exhaust
valves (on the EX side) with the hand by the valve
clearance, adjust the valves marked with closed
circle in the valve arrangement drawing.
1) Insert clearance gauge K in the clearance between

rocker arm (3) and crosshead (4).
2) Loosen locknut (5) and adjust the valve clearance
with adjustment screw (6).
3) With the clearance gauge inserted, turn the adjust-
ment screw to a degree that you can move the
clearance gauge lightly.
4) While fixing adjustment screw (6), tighten locknut
(5).
torque
Locknut: 14.8 – 20.7 lbf/ft (20 – 28 Nm)

{2.04 – 2.86 kgm}
5)
After tightening the locknut, check the valve clear-
ance again.
6) Rotate the crankshaft forward by 1 turn with tool V and set wide slit (b) to projection top (a) according to
step 2.
7) Adjust the other valve clearances according to steps 3 – 5.
• If the valves marked with open circle in the valve arrangement drawing were adjusted in the previous step,
adjust the valves marked with closed circle. If the valves marked with closed circle were adjusted, adjust
the valves marked with the open circle.
39. Rocker housing and head cover

a. Install rocker housing assembly (6) with bolt (5).
torque

kgm}
b. Install nuts (4) of the harness.
Harness installation position
Color of cable Cylinder No.

White 1, 3, 5
Black 2, 4, 6
torque
Mounting nut: 1.1 ± 0.2 lbf/ft (1.5 ± 0.25 Nm) {0.15 ± 0.03 kgm}
c. Check that the wiring harness does not interfere with the rocker arm.
7-53
d. Fit the gasket and then install head cover (3) using
nut (2).
torque
Mounting nut: 17.7 ± 2.9 lbf/ft (24 ± 4 Nm)

{2.4 ± 0.4 kgm}
e. Install duct (1).
40. Air intake manifold cover

a. Fit the gasket and then install manifold covers (3) and
(4).
b. Fit the gasket and then install tube (1) and electrical
intake air heater (2).
torque
Tube mounting bolt:17.7 ± 2.9 lbf/ft (24 ± 4 Nm)

{2.4 ± 0.4 kgm}
41. Fuel pressure sensor and relief valve

a. Replace fuel pressure sensor (2), if necessary,
according to the following procedure.
IMPORTANT
• Do not remove fuel pressure sensor (2) from common rail
(1) for a purpose other than replacement.
• Once the fuel pressure sensor is removed from the
common rail, be sure to replace it.
1) Before removing the fuel pressure sensor, remove
mud etc. from around it thoroughly and clean it.
2) Remove the fuel pressure sensor.
3) Check the fuel pressure sensor connector for crack, breakage, damage of the seal, foreign matter on
the pin and corrosion, bend and breakage of the pin.
4) Install a new fuel pressure sensor.
Threaded part of fuel pressure sensor: Gear oil (#90)

torque
Fuel pressure sensor: 51.6 ± 3.7 lbf/ft (70 ± 5 Nm) {7.1 ± 0.5 kgm}
5) Connect the engine wiring harness. At this time, take care not to connect the wiring harness in reverse.
6) Start the engine and check that fuel does not leak.
For the testing procedure, see Testing and adjusting, "Testing fuel system for leakage".
7-54
b. Replace relief valve (3), if necessary, according to the

1) Before removing the relief valve, remove mud etc.
from around it thoroughly and clean it.
2) Remove the relief valve.
3) If the leakage from the relief valve exceeds the
specified value, do not reuse it.
4) Check that high-pressure seal surfaces (A) of the
relief valve and rail are free from damage.
5) Install the relief valve.
torque
Threaded part of relief valve: Gear oil (#90)

torque
Relief valve: 73.8 ± 2.9 lbf/ft (100 ± 4 Nm) {10.2 ± 0.4 kgm}
IMPORTANT
Excessive tightening can cause leakage. Take care not to tighten too strongly.
6)
Start the engine and check that fuel does not leak.
For the testing procedure, see Testing and adjusting, "Testing fuel system for leakage".
42. Common rail and fuel high-pressure piping
• It is prohibited to bend high-pressure pipings used.

• The clamps used for fixing high-pressure pipings must be the genuine part. And the specified
tightening torque must be strictly observed.
• A clearance of 10 mm minimum must be provided between the installed high-pressure piping and
harness.
Fuel leakage can occur on a high-pressure piping that has
visible lengthwise slits (b) or dents such as patchy damages
(c) on its taper seal of the piping connection (part (a): 2 mm
space from the tip). The same holds true for a high-pressure
piping that catches claw because of fatigued steps in part (d)
(end of the taper seal: a 2 mm space from the tip). Such high-
pressure piping must be replaced.
a. Temporarily install common rail (10) and high-pressure pipings (1) to (7).
torque
Sleeve nut and mounting bolt 0.15 – 0.59 lbf/ft (0.2 – 0.8 Nm) {0.02 – 0.08 kgm}
(Temporary tighten):
b. Tighten high-pressure pipings (1) to (7) according to the following procedure.

torque
Sleeve nut: 25.8 ± 2.6 lbf/ft (35 ± 3.5 Nm) {3.57 ± 0.36 kgm}
7-55
1) Head side of high-pressure pipings (6) and (1)

2) Rail side of high-pressure pipings (6) and (1)
3) Head side of high-pressure pipings (2) o (3) o (4) o
(5)
4) Rail side of high-pressure pipings
(2) o (3) o (4) o (5)
5) Pump side of high-pressure piping (7) and then its
rail side
c. Tighten the clamp of high-pressure piping (7).
torque

{1.0 ± 0.2 kgm}
d. Tighten common rail (10) with 4 bolts.
Apply sealant (LG-7) to the threaded part of 2 bolts inside the engine.
torque
Mounting bolt: 17.7 ± 2.9 lbf/ft (24 ± 4 Nm) {2.4 ± 0.4 kgm}
e. Install boots (9).
Set the slits of each boots out and down.
The boots are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for
some reason.
f. Install fuel return hose (8).
torque
Joint bolt: 17.7 ± 2.9 lbf/ft (24 ± 4 Nm) {2.4 ± 0.4 kgm}
43. Harness assembly
a. Connect harness assembly (1) to the controller and
sensor and then fix it to the engine.
Before connecting the harness connector, clean sands,

dusts or water in the controller side connector.
7-56
44. Fuel filter assembly

a. Install filter bracket assembly (4).
b. Install drain hose (3) to the filter bracket.
c. Install filter inlet hose (1) and outlet hose (2).
d. Install fuel filter (5).
NOTE: As the gasket touched the filter head, tighten the fuel
filter 1/2 turn to install it.
45. Exhaust manifold

a. Fit a new gasket and then install exhaust manifold (4)
to the cylinder head. Tighten the mounting bolts
according to the numbers shown in the figure.
torque
Mounting bolts tightening procedure:

1. Tighten every bolt with 17.7 ± 2.9 lbf/ft (24 ± 4 Nm)
{2.4 ± 0.4 kgm}.
2. Tighten every bolt with 39.1 ± 4.4 lbf/ft (53 ± 6 Nm)
{5.4 ± 0.6 kgm}.
3. Tighten [1] to [4] bolts alone in the figure in this
order with 39 ± 4 lbf/ft (53 ± 6 Nm) {5.4 ± 0.6 kgm}.
46. Turbocharger assembly

a. Fit the gasket and install turbocharger assembly (3)
to exhaust manifold (4).
torque
Mounting nut: 31.7 ± 4 lbf/ft (43 ± 6 Nm) {4.4 ± 0.6 kgm}

b. Tighten the mounting nuts in the diagonal order.
c. Install the turbocharger assembly oil feed tube.

torque
Mounting nut on oil cooler side: 17.7 ± 2.9 lbf/ft (24 ± 4 Nm) {2.4 ± 0.4 kgm}
Mounting nut on turbocharger side: 26.5 ± 3.6 lbf/ft (36 ± 5 Nm) {3.6 ± 0.5 kgm}
7-57
d. Fit the gasket to the turbocharger assembly and

install oil return tube (2).
torque
Oil return tube mounting bolt: 17.7 ± 2.9 lbf/ft 24 ± 4 Nm

{2.4 ± 0.4 kgm}
47. Water pump

a. Attach the seal ring and then install water pump (2).
b. Attach the seal ring and then install coolant inlet con-
nector (1).
torque

{4.4 ± 0.6 kgm}
48. Thermostat
a. Install thermostat (2).
b. Install coolant outlet connector (1).
7-58
49. Alternator
a. Install front side sling bracket (5) and alternator
bracket (4).
torque
Mounting bolt:17.7 ± 2.9 lbf/ft (24 ± 4 Nm) {2.4 ± 0.4

kgm}
b. Install alternator (3) temporarily using mounting bolt

(2).
c. Install plate (1).
d. Tightening alternator mounting bolt (2).
50. Fan hub

a. Install fan hub (2) with mounting bolt (1).
torque

kgm}
51. Belt tensioner

a. Install tensioner (2) with mounting bolt (1).
torque

{4.4 ± 0.6 kgm}
b. Check visually or using a ruler, that the belt mounts of
the tensioner pulley and alternator pulley are parallel.
7-59
52. Fan pulley

a. Install fan pulley (4) with mounting bolt (3).
torque

kgm}
b. Install fan belt (1).
1) Insert a wrench to the portion (A) (width across
flats T 12.7 mm) of the tensioner assembly (2), and
rotate it to the opposite to the winding-up direction
to decrease the fan belt (1) tension, then install.

(A) before rotating it. (The spring of the tensioner assembly (2) is strong. If the wrench is loosely
inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.)
• After removing the fan belt (1), return the tensioner assembly (2) slowly with care.
• Be careful not to get your fingers caught between the pulley and fan belt (1) during work.
53. Engine sling bracket on rear side
a. Install engine sling bracket (1) to the cylinder bracket.
54. Starting motor assembly

a. Fit the gasket and then install starting motor assem-
bly (2) with bolt (1).
Apply 1 mm wide gasket sealant (LG-7) to the entire cir-

cumference of the front and back sides of the gasket.
7-60
55. Removal from engine repair stand

a. Lift engine assembly (1) temporarily and then sepa-
rate it from tool A.
Engine assembly: Approx. 1146 lbs (520 kg)

(The weight depends on the applicable machines.)
b.Remove tool B.
c. Set engine assembly (1) on stable engine stand [1]
provided on both sides.
d. Install oil gauge assembly (2).

56. Refilling with oil
a. Check that the engine oil drain plug is tightened.
b. Add oil through the oil filler to the specified level.
Engine oil pan: Approx. 24.3 qt. (23 l)
7-61
KOMATSU FORKLIFT USA, INC.
Covington, GA 30014-4908
VOICE PHONE: (770) 385-4815

FAX : (770) 385-4838

SM228 Ex50 May2008 - 061308

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SM228

ISSUED: JUNE 2008 Komatsu Forklift USA, Inc.

Komatsu Forklift USA, Inc.

Voice phone: (770) 385-4815

2. GENERAL INFORMATION & SPECIFICATIONS

6. DISASSEMBLY AND ASSEMBLY

8. STRUCTURE AND FUNCTION

10. CONVERSION TABLES

FOLLOW THE INSTRUCTIONS IN THE OPERATION AND MAINTENANCE MANUAL AS WELL AS

MAKE SAFETY PLANS BEFOREHAND

FOLLOW THE SAFETY RULES IN PLACE

ENSURE SAFETY AT THE WORKING AREA

WEAR SAFETY CLOTHES WHILE IN OPERATION

KEEP THE OPERATOR'S COMPARTMENT CLEAN AND CLEAR

REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT

DON'T REMOVE THE OVERHEAD GUARD AND LOAD BACKREST

DON'T USE A DEFECTIVE LIFT TRUCK - USE LOCK-

ENGINE EXHAUST GAS IS POISONOUS

FIRE IS STRICTLY PROHIBITED DURING REFUELING

FIRE, FIRST AID AND GENERAL SAFETY

JUMPING ON AND OFF THE LIFT TRUCK IS

DON'T TRY TO OPERATE THE LIFT TRUCK FROM

MAINTAIN PROPER POSTURE WHILE OPERATING

A SUDDEN SHIFT OF THE F-R LEVER IS DANGEROUS

DON'T ALLOW A PASSENGER ON THE TRUCK

BE SURE TO WEAR THE SAFETY SEAT BELT

CHECK THE SURROUNDINGS FOR SAFETY BEFORE

CHECK AND ADJUST THE REAR VIEW MIRROR AND LAMPS

PERFORM A SAFETY CHECK BEFORE STARTING

BE SAFETY CONSCIOUS WHILE DRIVING

DO NOT DRIVE ON ROUGH GROUND OR SURFACE

DRIVING ON A ROAD SHOULDER IS STRICTLY

WHEN DRIVING INTO A RAILWAY CAR, TRUCK OR

BE AWARE OF THE LIFT TRUCK'S MAXIMUM HEIGHT

WHEN DRIVING UP OR DOWN A SLOPE, EXERCISE

• On a downslope, drive down slowly and use the foot brake.

WHEN MAKING A TURN, BE CAREFUL OF THE

ANY OPERATION THAT MIGHT OVERTURN THE LIFT

WHEN BACKING UP THE LIFT TRUCK, VISUALLY

DON'T USE A LIFT TRUCK TO TOW ANOTHER BROKEN-DOWN LIFT TRUCK

WHEN CARRYING A HIGH LOAD, USE A SIGNAL

APPLY THE BRAKES CORRECTLY WHILE RUNNING

REQUIRED BRAKING DISTANCE DIFFERS DEPENDING ON THE ROAD CONDITIONS

FOLLOW THESE STEPS FOR PARKING

PARK THE LIFT TRUCK IN A SAFE PLACE

SHOULD THE LIFT TRUCK BECOME INOPERATIVE IN A DANGEROUS PLACE LIKE A

DON'T USE THE DRAWBAR PIN FOR OTHER THAN

PRECAUTIONS FOR LOADING AND UNLOADING

NEVER GO BENEATH RAISED FORKS

STANDING ON THE FORK(S) IS STRICTLY

BE CAREFUL NOT TO GET CAUGHT IN THE MAST

DON'T CLIMB ON THE MAST OR LOAD BACKREST

USE A PALLET OR SKID OF SUFFICIENT STRENGTH

HANDLE A LONG OR WIDE LOAD WITH EXTRA

WATCH OUT OVERHEAD

OVERLOADING IS STRICTLY PROHIBITED

DON'T HANDLE A LOAD IN AN INSECURE MANNER

DON'T HANDLE A LOAD EXCEEDING THE LOAD

BE CAREFUL OF THE FORK TIPS

DON'T USE THE FORK TO PUSH OR PULL A LOAD

DON'T TILT THE MAST FORWARD WITH A LOAD ON

BE CAREFUL OF SLACK IN THE HOIST CHAINS

DON'T USE THE LIFT TRUCK IMPROPERLY