БАСТРЫЙ СЕРВИС TU-Quik - Serv - 050704

QSBKAC001
QUIK-SERV
Service Reference Manual
Quik-Serv Contents
KAC-BT ELECTRICS
ND30B / NR35-45B / NS40 50B
WF45B 24 Volt 300A
WF65-80B 24 Volt 300A
WA60-80B 24 Volt 400A
SIT-DOWN ELECTRICS
ET30/35 24 Volt GE EV100
E30/35 36/48 Volt GE EV100 LX
E40/50/60BBX 36/48 Volt GE EV100 LXT
E30/35ABX 36/48 Volt GE EV100LXT
E40/50/60BBX 36/48 Volt GE EV100 ZX
ABX (Supplement)
E30/35ABX SCR Hydraulics
BBX (Supplement)
E40/50/60BBX SCR Hydraulics
IC 30-35
C/P30-35 NISSAN H20 -II
C/P30-35B TOYOTA 5K
C/P30-35B NISSAN H20
C/P30-35AX NISSAN H20-II
IC 40-60
C/P40-60 NISSAN H20
C/P40-60B NISSAN H20
C/P40-60B HERCULES G1600
C/P40-60 KOMATSU 4D95S
C/P40-60B KOMATSU 4D95S-W
C/P40-60BX NISSAN H20-II
C/P40-60BXH NISSAN H25
C/P40-60BXD KOMATSU 4D94E
IC 80-100
P80-100G NISSAN P40
P80-100D KOMATSU 6D95L
C/P80-100B NISSAN P40
P80-100B NISSAN TB42
C/P80-100BD KOMATSU 6D95L
C/P80-100CXG NISSAN TB42
P80-100CXD KOMATSU 6D102E
i
IC 110-350
DX
P110-150G NISSAN P40
P110-150D KOMATSU 6D95L
P150BG NISSAN TB42
P150BD KOMATSU 6D95L
P155DX NISSAN TB42
P155-180DXD KOMATSU 6D102E
EX
P220/250/300/330/350EXD ISUZU 6BG1-T
MISCELLANEOUS
Quick Reference — Gas & LPG Engine Spark Plug Wire Sets
Recommended Fluid Changes
C/P30-35B Transmission Test Ports
C/P40-60B Transmission Test Ports
C/P30-60AX/BX Series Transmission Test Ports
C/P80-100B Type T1 Transmission Test Ports
C/P80-100B Type T2 Transmission Test Ports
C/P80-100CX Indoor Transmission Pressure Ports
C/P80-100CX Outdoor T1 Transmission Pressure Ports
P150-180DX with Torqflow 2 Transmission
LPG Carburetor Adjustment
Overheating Troubleshooting
ii
Microfiche 493-493A Microfiche 493-493A
QUIK - SERV QUIK - SERV QUIK - SERV
MODELS ND30B / NR35-45B / NS40-50B MODELS ND30B / NR35-45B / NS40-50B
Warning Codes Without Registering Warning Codes With Registering (Cont.)

Error No Error Code Name Comment Error N Error Code Name Comment
10 Pump Chopper Lim 100 Pump Temp Pump Chopper Over Or Under Temp
11 Steer Chopper Lim Steer Chopper Current Limit 101 Pump Curr
12 Wheel Ind Error 102 Drive Chopper Drive Chopper Internal Error
13 Height Ind Error Height Counter Error 110 P Brake Pot Ref Pedal/Parking Brake POT Supply Voltage
16 Pump Brush Error Worn Pump Motor Brush 111 P Brake Pot Pedal/Park Brake POT Adjustment Or Failure
17 Drive Brush Error Worn Drive Motor Brush 112 P Brake Sw Pedal/Park Brake Switch Adjustment Or Failure
18 Nov Ram Error 113 P Brake Out Shorted Or Open Parking Brake Output
19 Default Par 115 Spd Sens Drive Motor Speed Sensor Failure
20 Pump Voltage Error 116 Dir Sens Drive Motor Direction Sensor Failure
21 Lift Pot Z Error Lift Pot Not Centered @ Key On 117 Rev Signal Drive Chopper Reversing Signal Failure
22 Tilt Pot Z Error Tilt Pot Not Centered @ Key On 120 Steer Data Control Module internal Error
23 Reach Pot Z Error Reach Pot Not Centered @ Key On 121 Steer Chopper Steer Chopper Error
24 Sideshfter Pot Error Sideshifter Pot Not Centered @ Key On 122 Steer Temp Steer Chopper Over Temperature
27 Bat Measure Error Low Battery Voltage Detected 123 Steer Volt
28 Motor Overtemp Drive Motor Overtemperature 124 Steer Curr
125 Steer Tach Steer Tach Motor Error (Too Quick Movement of
Warning Codes With Registering Steering Wheel)
Error NoError Code Name Comment 126 Steer Conn Opened S/Motor Output-Motor Or Connection Failure
52 O Lift Error Shorted Or Open Lift Valve Output 127 Steer Comm Control Module internal Error
130 Slave Comm Control Module internal Error
131 Sec Rel Error 1 Security Relay Error 1(Inside Card-Normally Low
53 O Tilt Error Shorted Or Opened Tilt Valve Output Charge Condition
54 O Dir A Error Shorted Or Open Dir A Valve Output 132 Steer Pwr Steer Chopper Supply Voltage Under Voltage
55 O Dir B Error Shorted Or Open Dir B Valve Output 133 Sec Rel Security Relay Error 2
56 O Sideshfter Shorted Or Open S/Shifter Valve Output 140 Check Sum Control Module internal Error
57 O Spare In Error Unused Output/Input
58 O Spare Out Error Unused Output
59 O Reach In Error Shorted Or Open Reach In Valve Output
60 O Reach Out Error Shorted Or Open Reach Out Valve Output
61 O Lower Prop Error Shorted Or Open Lower Proportional Valve
O Forward Contactor
63 Shorted Or Open Forward Contactor
Error
O Backward Contactor
64 Shorted Or Open Backward Contactor
Error
90 Lift Pot Error Shorted Or Opened Lift Pot. Input
91 Lift Pot Error Shorted Or Opened Lift Pot. Input
92 Reach Pot Error Shorted Or Opened Reach Pot. Input
93 Sideshfter Shorted Or Opened S/Shifter Pot Input
95 Pot Ref Error Potentiometer Supply Voltage
Rev 12/2003
PAGE 1 Rev 12/2003 PAGE 2
Microfiche 493-493A Microfiche 493-493A
QUIK - SERV QUIK - SERV
Models ND30B / NR35-45B / NS40-50B Models ND30B / NR35-45B / NS40-50B
CURRENT CONSUMPTION
Spinner Knob (Steering) 8734196
Spinner Retaining Nut 8733658
NR35B ND30B NR45B Spinner Knob Cap 8734195
Driving Without Rated 24V-140A Brake Shoe (2 ea) 8730015
36V-150A 36V-150A
Load 36V-140A D/Tire (Rubber 13.5x5.5x8) 8735631
Driving With Rated 24V-160A Stabilizing Wheel 8733981
36V-170A 36V-170A
Load 36V-165A Load Wheel (4"x3") 2 ea 8731798
Load Wheel (5"x4") 2 ea 8731340
Lifting Without Rated 24V-36V Load Wheel (5"x3") 2 ea 8734185
36V-320A 36V-320A
Load 240A L/Wheel (10.5"x3.5") 2 ea 8734187
Lifting With Rated 24V-36V Horn 24V 8730167
36V-570A 36V-570A
Load 415A Horn 36V 8730972
Speed Cut Back Limit Switch
Mechanical Switch (Old) 8735007
Note: Performance may vary up to 10% due to motor and Sensor Style (New Style) 8734979
system efficiency tolerance. Micro Switch (Lights & Fan) 8734262
Key Switch Assy 8733984
Key-Set Of Two 8736081
Actuator, Emergency Stop 8735663
Drive Motor Brush Set 8734091 Switch, Emergency Stop 8735664 & 8735663
Drive Motor Spring Set 8734092 Fuse, 0.25A Control 8736285
Pump Motor Brush Set (NR35B) 8735652 Fuse, 15A (Control) To S/N 27135_000 8733968
Pump Moter Spring Set (NR35B) 8735653 Fuse, 30A (Steering) To S/N 27135-000 8733969
Pump Motor Brush Set (8 ea.) (NR45B/ND30B) 8735000 Fuse, 10A (Control) S/N 27135-001-UP 8736286
Pump Motot Spring Set (8 ea.) (NR45B/ND30B) 8730401 Fuse, 30A (Steering) S/N 27135-001-UP 8736287
Static Strap (Frame-Static To Floor) 8735475 Fuse, 250A 8733970
Switch, Horn Button 8735237 Fuse, 425A 8733971
Lift Bypass Contactor Tip Kit 36V 8734228 Fuse, 355A 8733972
Bat Cut Out/Plug Contactor Kit 24v 8735633 Fuse, 500A 8736377
Bat Cut Out/Plug Contactor Kit 36v 8734228 Sensor, 180º 8734279
Bat Cut Out/Plug Con. Kit 36V (With Bridge) 8735637 Sensor, Direction/Blue Plug 8734280
FWD/REV Contactor Tip Set (2 ea.) 8734259 Sensor, Direction/Grey Plug 8734281
Potentiometer 8733983 Sensor, Direction/Male Plug 8734285
Thumb Knob-Accelerator 8734245 Sensor, Direction/Female Plug 8734288
Hyd. Tank Breather 8735018 Switch, Right Foot 8731205
Hyd. Tank Filter (NR35B) 8734365 Switch, Brake 8731205
Hyd. Tank Filter (NR45B/ND30B) 8736324 Reach & Carriage Sensor 8734979
Rev 12/2003
Page 3 Rev 12/2003 Page 4
Microfiche 494 Microfiche 494
MODELS WF45B 24V 300A MODELS WF45B 24V 300A
CONTROLLER PARAMETER SETTINGS CURRENT DRAWS - 24 VOLT
(PMC SepEx 1242 Controler)
M1 Drive Current Limit 300 Travel/No Load 35 Amps ± 10%
M2 Drive Current Limit 300 Lift/Rated Load 135 Amps ± 10%
M3 Drive Current Limit 300
M1 Brake Current Limit 300
M3 Brake Current Limit 300 NOTE: CURRENT DRAW TO BE TAKEN WITH WARM OIL
M1 Neutral Brake % 0 QUIK REF PART NUMBERS
M2 Neutral Brake % 0 Switch, Lift 8733093
M3 Neutral Brake % 0 Switch, Lower 8733092
M4 Neutral Brake % 0 Switch, Rearward 8734824
M1 Acceleration Rate 0.5 Switch, Forward 8734824
M2 Acceleration Rate 0.5 Reverser Assembly-2 wire 8733400
M4 Acceleration Rate 0.5 Drive Motor Brush-24 Volt (2 EA) 8735806
M1 Maximum Speed Maximum Setting 66 Spring For Above (2 EA) 8735807
M1 Maximum Speed Maximum Setting 66 Brake Shoe (2 EA) 8730015
M1 Maximum Speed Maximum Setting 66 Tire (Rubber) 10.5x5x6.5 8730044
M1 Maximum Speed Maximum Setting 66 Tire (Urethane) 10.5x5x6.5 8730045
EMR REV C/Limit 300 Amps Tire (Non-Marking xlc) 10.5x5x6.5 8730749
All Settings Are Made Through PMC Handset Tire (Traction Lug) 10.5x5x6.5 8730750
Load Wheel 8730186
Load Wheel Bearing 8730185
Potentiometer Settings Handle Grip Fixed 8730610
Static 5500 ± 100 Ohms Handle GripTwist 8730584
Full Speed Below 50 Ohms Connector-Grey (SB-175) 8730325
Horn 24 Volt 8730167
Line Contactor 24 Volt 8730162
Key Switch 8730617
Switch, Brake Interlock 8730061
ACCELERATOR POT 8735476
Control Fuse 10 Amp 8732486
Circuit Breaker 8730335
HYDRAULIC SPECS Pump Motor Brushes & Spring (Set) 8730096
TANK CAPACITY Approximately 1 Qt Pump Solinoid 8733937
RELIEF PRESSURE 3200 PSI Lowering Valve & Coil (24 Volt) 8730289
Flow 1.6 cc/REV Lowering Valve Coil (24 Volt) 8730424
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS WF65-80B 24V 300A MODELS WF65-80B 24V 300A
M1 Maximum Speed Maximum Setting 66 Sealed Load Wheel Bearings 8730185
EMR REV C/Limit 300 Amps No-Seal Load Wheel Bearings 8730465
Guard, String 8730462
All Settings Are Made Through PMC Handset Load Wheel WA/WF65B 8730461
Hand Set P/N 8736731 Load Wheel WA/WF80B 8730467
Cable P/N 8734946 Stablilizer Wheel 8730487
Potentiometer Settings Stablilizer Wheel-Bearing 8730185
Stablilizer Wheel-Spacer 8730486
Static 5500 ± 100 Ohms Horn 24 Volt 8730167
Full Speed Below 50 Ohms Line Contactor Tip Set-Fixed (2 EA) 8734712
Line Contactor Tip Set-Moving(1 EA ) 8734710
Directional Contactor Tip Set-Kit 8734710
Breaker-Contol Circuit (12 Amp) 8730651
Breaker-Pump Circuit (105 Amp) 8735559
HYDRAULIC SPECS Breaker-Drive Circuit (150Amp) 8735561
TANK CAPACITY Approximately 1 Qt Pump Motor Brushes & Spring (Set) 8730096
RELIEF PRESSURE 4000 PSI Pump Contator 8733937
Flow .8 cc/REV Lowering Valve 8730289
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS WA60-80B 24V 400A MODELS WA60-80B 24V 400A
M1 Maximum Speed Maximum Setting 90 Sealed Load Wheel Bearings 8730185
M1 Brake Rate 0.5 No-Seal Load Wheel Bearings 8730465
M2 Brake Rate 0.5 Guard, String 8730462
M3 Brake Rate 0.5 Load Wheel MWL/MWE31 8730461
M4 Brake Rate 0.5 Load Wheel MWL/MWE36 8730467
Potentiometer Settings Stablilizer Wheel 8730487
Static 5500 ± 100 Ohms Stablilizer Wheel-Bearing 8730185
Full Speed Below 50 Ohms Stablilizer Wheel-Spacer 8730486
Horn 24 Volt 8730167
Hand Set P/N 8736731 Line Contactor Tip Set-Fixed (2 EA) 8734712
Cable P/N 8734946 Line Contactor Tip Set-Moving(1 EA ) 8734710
All Settings Are Made Through PMC Handset Directional Contactor Tip Set-Kit 8730647
Breaker-Contol Circuit (12 Amp) 8730651
Breaker-Pump Circuit (105 Amp) 8735559
HYDRAULIC SPECS Breaker-Drive Circuit (150Amp) 8735561
TANK CAPACITY Approximately 1 Qt Pump Motor Brushes & Spring (Set) 8730096
RELIEF PRESSURE 4000 PSI Pump Contator 8733937
Flow .8 cc/REV Lowering Valve 8730289
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MICROFICHE 470 MICROFICHE 470
MODELS ET30/35 24 VOLT W/EV100 MODELS ET30/35 24 VOLT W/EV100
CONTROL CARD TUNE UP SPECS CURRENT DRAWS
CREEP VOLTAGE (PREFERENCE) 0.2V TO 1.5V 1A FREE WHEELING 100 - 105 AMPS
CURRENT LIMIT (BOTH MOTORS) 220 AMPS PUMP MOTOR (NEUTRAL) 130 - 140 AMPS
BATTERY CURRENT PUMP MOTOR (BYPASS) 480 AMPS
CONTROLLED ACCELERATION < 0.5 SECONDS POWER STEER (NEUTRAL) 12 - 15 AMPS
1A TIME (PREFERENCE) 1 - 2 SECONDS POWER STEER (BYPASS) 50 AMPS
1A DROP OUT 825 AMPS NOTE: CURRENT DRAW TO BE TAKEN WITH WARM OIL
PLUGGING (PREFERENCE) 13 - 23 FT
FULL LOAD & IN 1A QUIK REF PART NUMBERS
CONTACTOR SPECS F/R CONTACT TIP KIT 8761138

PUMP AMPERAGE 300 AMPS 1A CONTACT TIP KIT 8761133
COIL RESISTANCE 33.3 OHM PUMP CONTACT TIP KIT 8761133
RATED VOLTAGE 24 V POWER STEER CONTACT TIP KIT 8769380
FUSE #1 - 500 A 4966760
F/R AMPERAGE 150 AMPS FUSE #2 - 500 A 4966760
COIL RESISTANCE 10 - 14 OHMS FUSE #3 - 90 A 4943865
RATED VOLTAGE 24 V FUSE #4 - 15 A 8769416
DRIVE MOTOR BRUSH - 4 EA 4943752
1A AMPERAGE 300 AMPS PUMP MOTOR BRUSH - 4 EA 4943752
COIL RESISTANCE 10 - 14 OHMS STEER MOTOR BRUSH - 4 EA 4943775
RATED VOLTAGE 24 V SUMP BREATHER 4941268
HYD SUMP FILTER 8767442
"D" AMPERAGE 100 A EV100 LOGIC CARD 8766501
COIL RESISTANCE 27 - 30 OHMS #1 SCR - KIT 4966939
RATED VOLTAGE 24 V #2 SCR 4966925
#5 SCR 8772172
POWER STEER AMPERAGE N/A #3 & #4 RECS 4966911
COIL RESISTANCE 22 OHMS ACCELERATOR 8764812
RATED VOLTAGE 24 V ACCELERATOR POT 4969803
SEAT SWITCH 4944157
HYDRAULIC SPECS F/R SWITCHES 8764513
TANK CAPACITY 4 GALLONS KEY SWITCH 4944052
RELIEF PRESSURE 2450 PSI SERVICE BRAKE SWITCH 4944146
STEER RELIEF PRESSURE 1140 PSI PARKING BRAKE SWITCH 4967868
HORN SWITCH 8764513
GEAR CASE HYD VLV SWITCH 4944092
GEAR OIL TYPE SAE 90 W
GEAR CASE CAPACITY 5 PINTS
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS E30/35 W/EV100LX MODELS E30/35 W/EV100LX
CONTROL CARD / HANDSET SPECS CURRENT DRAWS - 36 / 48 VOLT
FAULT CODE 1 1A FREE WHEELING 70 / 80 AMPS

CREEP SPEED 2 35 PUMP MOTOR (NEUTRAL) 67 / 81 AMPS
C/A & 1A TIME 3 12 PUMP MOTOR (BYPASS) 250 / 220 AMPS
CURRENT LIMIT 4 15 POWER STEER (NEUTRAL) 10 / 13 AMPS
PLUGGING 5 180 POWER STEER (BYPASS) 35 / 30 AMPS
1A DROP OUT 6 62 CURRENT LIMIT - BATTERY 200 / 180 AMPS
NOTE: CURRENT DRAW TO BE TAKEN WITH WARM OIL
OPTIONS: F. W. PICK UP 7 17
F. W. DROP OUT 8 19 QUIK REF PART NUMBERS
REGEN CURRENT LIMIT 9 56
REGEN START 10 44 F/R CONTACT TIP KIT 8761138
1A CONTACT TIP KIT 8761132
INT. RES. COMP 14 12 PUMP CONTACT TIP KIT 8761133
BATTERY VOLTS 15 200 POWER STEER CONTACT TIP KIT 8761134
CARD TYPE 17 7 FUSE #1 - 275 A 4967620
STEER PUMP DELAY 18 134 FUSE #2 - 400 A 4967622
FUSE #3 - 10 A 4944153
CONTACTOR SPECS FUSE #4 - 35 A 4967621
PUMP AMPERAGE 300 AMPS DRIVE MOTOR BRUSH 4967928
COIL RESISTANCE 33.3 OHM PUMP MOTOR BRUSH 4967795
RATED VOLTAGE 36 / 48 V STEER MOTOR BRUSH 4968003
SUMP BREATHER 4941268
F/R AMPERAGE 150 AMPS HYD SUMP FILTER 8767442
COIL RESISTANCE 14 OHMS EV100 LOGIC CARD 4967627
RATED VOLTAGE 24 V #1 SCR - KIT 4966939
#2 SCR 4966925
1A AMPERAGE 300 AMPS #5 SCR 8772172
COIL RESISTANCE 14 OHMS #3 & #4 RECS 4966911
RATED VOLTAGE 24 V ACCELERATOR 8764812
POWER STEER AMPERAGE 150 A SEAT SWITCH 4944157
COIL RESISTANCE 14 OHMS F/R SWITCHES 4968512
RATED VOLTAGE 24 V KEY SWITCH 4944052
SERVICE BRAKE SWITCH 4968161
HYDRAULIC SPECS PARKING BRAKE SWITCH 4967868
TANK CAPACITY 7.9 GALLONS HORN SWITCH 4968511
RELIEF PRESSURE 2550 PSI HYD VLV SWITCH 4967890
STEER RELIEF PRESSURE 1350 PSI TMM2 CARD 4967629
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS E40/50/60BBX W/EV100LXT MODELS E40/50/60BBX W/EV100LXT
FAULT CODE 1 F/W FREE WHEELING 85 / 95 AMPS

CREEP SPEED 2 50 PUMP MOTOR (NEUTRAL/HI-SPEED) 210 / 230 AMPS
C/A & 1A TIME 3 9 PUMP MOTOR (BYPASS/HI-SPEED) 475 / 450 AMPS
F. W. PICK UP 7 80 NOTE: CURRENT DRAW TO BE TAKEN WITH WARM OIL
F. W. DROP OUT 8 87
REGEN CURRENT LIMIT 9 255 QUIK REF PART NUMBERS
REGEN START 10 30 F/R CONTACT TIP KIT 8767364
INT. RES. COMP 14 21 1A / PUMP / REGEN CONTACT TIP KIT 8761133
BATTERY VOLTS 15 200 FIELD WEAKENING CONTACT TIP KIT 8761133
PEDAL PLUG 16 200 POWER STEER CONTACT TIP KIT 8761134
CARD TYPE 17 47 FUSE #1 - 500 A 8769418
FUSE #3 - 15 A 8769416
CONTACTOR SPECS FUSE #4 - 80 A 8769419
DRIVE MOTOR BRUSH- 4 EA 8772170
PUMP A/B AMPERAGE 300 AMPS PUMP MOTOR BRUSH - 4 EA 4967968
COIL RESISTANCE 33.3 OHM STEER MOTOR BRUSH - 4 EA 4968003
RATED VOLTAGE 36 / 48 V SUMP BREATHER 4941268
HYD SUMP FILTER 8767442
F&R AMPERAGE 300 AMPS EV100 LOGIC CARD 4974188
COIL RESISTANCE 12.5 OHMS #1 SCR - KIT 4966939
#5 SCR 8772172
1A / REGEN AMPERAGE 300 AMPS #3 & #4 RECS 4966911
COIL RESISTANCE 12.5 OHMS #7 REC 4967670
RATED VOLTAGE 24 V PA / PB TIME DELAY 4974316
PA / PB DRIVER 4968098
PWR STEER / FW AMPERAGE 150 A ACCELERATOR 8764812
COIL RESISTANCE 12.5 OHMS ACCELERATOR POT 4969803
RATED VOLTAGE 24 V SEAT SWITCH 4968186
F/R SWITCHES 8764513
HYDRAULIC SPECS KEY SWITCH 4944052
TANK CAPACITY 8.2 GALLONS SERVICE BRAKE SWITCH 4968187
RELIEF PRESSURE 2550 PSI PARKING BRAKE SWITCH 4968186
STEER RELIEF PRESSURE 1250 PSI HYD VLV SWITCH 4968204
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS E30/35ABX W/EV100LXT MODELS E30/35ABX W/EV100LXT
FAULT CODE 1 1A FREE WHEELING 80 / 90 AMPS
CREEP SPEED 2 160 PUMP MOTOR (NEUTRAL) 110 / 130 AMPS
C/A & 1A TIME 3 9 PUMP MOTOR (BYPASS) 350 / 325 AMPS
NOTE: CURRENT DRAW TO BE TAKEN WITH WARM OIL
OPTIONAL: F. W. PICK UP 7 90
F. W. DROP OUT 8 120 QUIK REF PART NUMBERS
F/R CONTACT TIP KIT 8761138
REGEN CURRENT LIMIT 9 240 1A / FIELD WKNG. CONTACT TIP KIT 8761132
REGEN START 10 30 PUMP / REGEN CONTACT TIP KIT 8761133
INT. RES. COMP 14 21 POWER STEER CONTACT TIP KIT 8761134
BATTERY VOLTS 15 200 FUSE #1 - 500 A 8769418
PEDAL PLUG 16 200 FUSE #2 - 400 A 8770094
CARD TYPE 17 43 FUSE #3 - 15 A 8769416
DRIVE MOTOR BRUSH - 4 EA 8772170
CONTACTOR SPECS PUMP MOTOR BRUSH - 4 EA 4974164
PUMP AMPERAGE 300 AMPS STEER MOTOR BRUSH - 4 EA 4968003
COIL RESISTANCE 33.3 OHM SUMP BREATHER 4941268
RATED VOLTAGE 36 / 48 V HYD SUMP FILTER 8767442
EV100 LOGIC CARD 4974188
F/R AMPERAGE 300 AMPS #1 SCR - KIT 4966939
COIL RESISTANCE 12.5 OHM #2 SCR 4966925
#3 & #4 RECS 4966911
1A / FIELD WEAKENING AMPERAGE 150 AMPS #7 REC 4967670
COIL RESISTANCE 12.5 OHM PA / PB TIME DELAY 4974316
RATED VOLTAGE 24 V PA / PB DRIVER 4968098
ACCELERATOR 8764812
POWER STEER AMPERAGE 100 AMPS ACCELERATOR POT 4969803
COIL RESISTANCE 12.5 OHM SEAT SWITCH 4968186
RATED VOLTAGE 24 V F/R SWITCHES 8764513
KEY SWITCH 4944052
HYDRAULIC SPECS SERVICE BRAKE SWITCH 4968187
TANK CAPACITY 6.6 GALLONS PARKING BRAKE SWITCH 4974268
RELIEF PRESSURE 2500 PSI HYD VLV SWITCH 4968204
STEER RELIEF PRESSURE 1065 PSI TMM2 CARD 4967629
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS E40/50/60 BBX W/EV100ZX MODELS E40/50/60 BBX W/EV100ZX
SCR CONTROL CARD SETTINGS - SEE PAGES 3 & 4
CONTACTOR SPECS QUIK REF PART NUMBERS
PUMP A/B AMPERAGE 300 AMPS F/R CONTACT TIP KIT 8767364
COIL RESISTANCE 33.3 OHM 1A / PUMP / REGEN CONTACT TIP KIT 8761133
RATED VOLTAGE 36 / 48 V FIELD WEAKENING CONTACT TIP KIT 8761132 (SH Only)
POWER STEER CONTACT TIP KIT 8761134
F&R AMPERAGE 300 AMPS FUSE #1 - 500 A 8769418
COIL RESISTANCE 12.5 OHMS FUSE #2 - 500 A 8769418
RATED VOLTAGE 24 V FUSE #3 - 15 A 8769416
FUSE #4 - 80 A 8769419
1A / REGEN AMPERAGE 300 AMPS 11" DRIVE MOTOR BRUSH- 4 EA 8772170
COIL RESISTANCE 12.5 OHMS 9" DRIVE MOTOR BRUSH- 4 EA 8767448
RATED VOLTAGE 24 V 8" PUMP MOTOR BRUSH - 4 EA 8769390
9" PUMP MOTOR BRUSH - 4 EA 8772171
POWER STEER / FW AMPERAGE 150 A STEER MOTOR BRUSH - 1 EA 4968003
COIL RESISTANCE 12.5 OHMS SUMP BREATHER 4941268
RATED VOLTAGE 24 V HYD SUMP FILTER 4941243
EV100ZX LOGIC CARD 8767360
HYDRAULIC SPECS #1 SCR - KIT 4966939
TANK CAPACITY 8.2 GALLONS #2 SCR 4966925
RELIEF PRESSURE 2550 PSI #5 SCR 8772172
STEER RELIEF PRESSURE 1250 PSI #3 & #4 RECS 4966911
#7 REC 4967670
PA / PB TIME DELAY 4967620
PA / PB DRIVER 4967625
CURRENT DRAWS - 36 / 48 VOLT ACCELERATOR 8772173
F/W FREE WHEELING 85 / 95 AMPS SEAT SWITCH (STD SEAT) 8766933
PUMP MOTOR (NEUTRAL/HI-SPEED) 210 / 230 AMPS SEAT SWITCH (OPT. SEAT) 8767576
PUMP MOTOR (BYPASS/HI-SPEED) 475 / 450 AMPS F/R SWITCHES 8764513
POWER STEER (NEUTRAL) 6 / 8 AMPS KEY SWITCH 4944052
POWER STEER (BYPASS) 39 / 36 AMPS SERVICE BRAKE SWITCH 4968187
CURRENT LIMIT - BATTERY 240 / 200 AMPS PARKING BRAKE SWITCH 4974268
NOTE: CURRENT DRAW TO BE TAKEN WITH WARM OIL HYD VLV SWITCH 4968204
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS E30/35ABX W/SCR HYDRAULICS MODELS E40/50/60BBX W/SCR HYDRAULICS
QUIK-SERV SUPPLEMENT QUIK-SERV SUPPLEMENT
HYDRAULIC PUMP HYDRAULIC PUMP

CONTROL CARD / HANDSET SPECS CONTROL CARD / HANDSET SPECS
FAULT CODE 1 FAULT CODE 1

INT. RES. COMP. START 2 21 CREEP SPEED 2 50
C/A 3 10 CONTROLLED ACCELERATION 3 10 (BBX), 9 (BBXH)
CURRENT LIMIT 4 200 CURRENT LIMIT 4 5
SPEED LIMIT #1(AUXILIARY) 11 150 PLUGGING DISTANCE 5 111 (BBX), 128 (BBXH)
SPEED LIMIT #2 (TILT) 12 90 1A DROP OUT CURRENT 6 110 (BBX), 232 (BBXH)
SPEED LIMIT #3 (LIFT A) 13 180 FIELD WEAKENING
SPEED LIMIT #4 (LIFT B) 14 180 PICK-UP CURRENT 7 0 (BBX), 80 (BBXH)
BATTERY VOLTS 15 200 FIELD WEAKENING
INT. RES. COMPENSATION 16 20 DROP-OUT CURRENT 8 0 (BBX), 87 (BBXH)
CARD TYPE 17 58 REGENERATIVE BRAKING C/L 9 30 (BBX), 255 (BBXH)
REGEN START 10 30
SPEED LIMIT #1(AUXILIARY) 11 0
SPEED LIMIT #2 (TILT) 12 0
SPEED LIMIT #3 (LIFT A) 13 0
QUIK-REF PART NUMBERS INTERNAL RESISTANCE COMP. 14 21
BATTERY VOLTS 15 200
EV100 LOGIC CARD 4974187 PEDAL POSITION PLUG 16 200
#1 SCR - KIT 4966938 CARD TYPE 17 47
STEERING PUMP TIME DELAY 18 132
MAINT. CODE
(10'S & UNIT HRS SET) 19 99
MAINT. CODE
(1000'S & 100'S HRS SET) 20 99
MAINT. CODE SPEED LIMIT 21 0
10'S & UNIT HRS SET 29 0
100'S & 100'S HRS SET 30 0
EV100 LOGIC CARD 8767360
#1 SCR - KIT 4966939
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS C/P30-35 W/NISSAN H20 MODELS C/P30-35 W/NISSAN H20
ENGINE COOLING SYSTEM SPECS
MAKE/MODEL NISSAN H20 SYSTEM CAPACITY 1.8 GALLONS
CYLINDERS 4 OPERATING TEMPERATURE 180 DEGREES
DISPLACEMENT 121 CU.IN. FAN BELT DEFLECTION 1/2" @ 22 LBS
HORSEPOWER 46 @ 2300 RPM SYSTEM PRESSURE 14 PSI
OIL CAPACITY W/ FILTER 4.5 QUARTS ELECTRICAL SYSTEM
OIL TYPE SAE 10W30 VOLTAGE 12 VDC
ALTERNATOR OUTPUT 25 AMPS
TUNE UP SPECS CRANKING VOLTAGE (MIN.) 9.5 VDC
FIRING ORDER 1-3-4-2 CHARGING VOLTAGE MAX 15.0 VDC
AIR GAP 0.018" - 0.022" DIFFERENTIAL SPECS
PLUG GAP 0.028"-0.031" OIL TYPE SAE 90 W
RPM TO TIME 650 RPM CASE CAPACITY-TORQFLOW 1.3 GALLONS
TIMING GAS 8 DEG BTDC CASE CAPACITY-CLUTCH 2.6 GALL0NS
TIMING LPG 10 DEG BTDC FUEL TANK SPECS
IDLE RPM 550-650 RPM TANK CAPACITY (S / H) 6.9 / 10.0 GALLONS
NO LOAD GOV RPM 2700-2900 RPM RECOMMENDED OCTANE 87
HYDRAULIC BYPASS RPM 2100-2200 RPM LPG SPECS
STEERING BYPASS RPM 2600 RPM MANUFACTURE IMPCO
CONVERTER STALL RPM 1600-1900 RPM MAX TANK PRESSURE 250 PSI
COMPRESSION @ 300 RPM 156 PSI DRY GAS PRESSURE 1.5-2 PSI
HEAD BOLT TORQUE 65-70 FT/LBS QUICK REF PART NUMBERS
VALVE CLEARANCE WARM SPARK PLUG 8763178
INTAKE 0.015" TUNE UP KIT 4900739
EXHAUST 0.015" ELECTRONIC IGNITION KIT 4918908
TRANSMISSION SPECS DISTRIBUTOR CAP 4942508
OIL DEXRON ATF ROTOR 4942380
CASE CAPACITY 2.0 GALLON ENGINE OIL FILTER 8763179
PUMP PRESSURE 100-200 PSI HYDRAULIC OIL FILTER 8767442
CONVERTER INLET 30-100 PSI TRANSMISSION OIL FILTER 4940471
CONVERTER OUTLET 30-60 PSI FUEL FILTER (GASOLINE) 4948580
FOR/REV PACK 100-200 PSI AIR FILTER 4907794
LUBE PRESSURE (MAX) 64 PSI HYDRAULIC TANK BREATHER CAP 4941268
INCHING SPOOL PROTRUSION 0.78 IN OR 20 MM FAN BELT 4942361
HYDRAULIC SPECS ALTERNATOR BELT 4942145
TANK CAPACITY (S / H) 6.1 / 7.1 GALLONS THERMOSTAT 4942370
PUMP TYPE GEAR TYPE RADIATOR CAP 4940755
FLOW @ GOV RPM 15.8 GPM
FLOW @ HYD BY-PASS 12.5 GPM
RELIEF PRESSURE 2500 PSI
STEER RELIEF PRESSURE 1050 PSI
PAGE 1 Rev 3/2003 PAGE 2 Rev 3/2003

MODELS C/P30-35B W/ TOYOTA 5K MODELS C/P30-35B W/ TOYOTA 5K
s/n 312001A & up
MAKE/MODEL TOYOTA 5K SYSTEM CAPACITY 2.0 GALLONS
CYLINDERS 4 OPERATING TEMPERATURE 180-190 DEGREES
DISPLACEMENT 91 CU IN. FAN BELT DEFLECTION 1/2" @ 22 LBS
HORSEPOWER 38 HP @ 2500 RPM SYSTEM PRESSURE 14 PSI
TUNE UP SPECS ALTERNATOR OUTPUT 35 AMPS
FIRING ORDER 1-3-4-2 CRANKING VOLTAGE (MIN) 9.5 VDC
AIR GAP (ELECT IGN) 0.008" CHARGING VOLTAGE 13.5 - 14.5 VDC
PLUG GAP 0.028"-0.031" DIFFERENTIAL SPECS
RPM TO TIME 700 RPM OIL TYPE SAE 90 W
TIMING GAS 10 DEG BTDC CASE CAPACITY-TORQFLOW 1.3 GALLONS
TIMING LPG 18 DEG BTDC CASE CAPACITY-CLUTCH 2.6 GALL0NS
IDLE RPM 650-750 RPM FUEL TANK SPECS
NO LOAD GOV RPM 2800-2900 RPM TANK CAPACITY 9.5 GALLONS
HYDRAULIC BYPASS RPM 2500-2600 RPM RECOMMENDED OCTANE 87
STEERING BYPASS RPM 2650-2700 RPM LPG SPECS
CONVERTOR STALL RPM 2300 RPM MANUFACTURE IMPCO
COMPRESSION @ 250 RPM 180 PSI MAX TANK PRESSURE 250 PSI
HEAD BOLT TORQUE 43 FT/LBS DRY GAS PRESSURE 1.5-2 PSI
VALVE CLEARANCE HYDRAULIC QUICK REF PART NUMBERS
SPARK PLUG 8760171
TRANSMISSION SPECS ELEC. IGN. 8760183
OIL DEXRON ATF ROTOR 8760174
TORQFLOW CASE CAPACITY 2.0 GALLON DISTRIBUTOR CAP 8760179
PUMP PRESSURE 100-200 PSI ENGINE OIL FILTER 8760118
CONVERTER INLET 70-100 PSI HYDRAULIC OIL FILTER 8767442
CONVERTOR OUTLET 30-60 PSI TRANSMISSION OIL FILTER 4940471
FOR/REV PACK 120-180 PSI FUEL FILTER (GASOLINE) 8760250
LUBE PRESSURE (MAX) 64 PSI AIR FILTER 4907794
INCHING SPOOL PROTRUSION 0.9 IN. OR 23 MM HYDRAULIC TANK BREATHER CAP 4941268
WATER PUMP/FAN BELT 8760137
THERMOSTAT 8760140
HYDRAULIC SPECS RADIATOR CAP 4949074
TANK CAPACITY 10.8 GALLON
PUMP TYPE GEAR TYPE
FLOW @ HYD BY-PASS 14.2 GPM
PAGE 1 Rev 11/2003 PAGE 2 Rev 11/2003

MODELS C/P30-35B W/ NISSAN H20 MODELS C/P30-35B W/ NISSAN H20
FIRING ORDER 1-3-4-2 CRANKING VOLTAGE 9.5 VDC
POINT GAP 0.018"-0.022" CHARGING VOLTAGE 13.5-14.75 VDC
RPM TO TIME 600-700 RPM OIL TYPE SAE 90 W
IDLE RPM 550 - 650 RPM FUEL TANK SPECS
HYDRAULIC BYPASS RPM 2300 RPM RECOMMENDED OCTANE 87
STEERING BYPASS RPM 2600 RPM LPG SPECS
CONVERTOR STALL RPM 1600-1700 RPM MANUFACTURE IMPCO
VALVE CLEARANCE WARM QUICK REF PART NUMBERS
INTAKE 0.015" SPARK PLUG - LPG 8763178
EXHAUST 0.015" CONDENSOR 4949012
TRANSMISSION SPECS ELECTRONIC IGNITION KIT 4900739
OIL DEXRON ATF * CLIP DOWN DIST CAP 4949023
CASE CAPACITY 2.0 GALLON * CLIP DOWN CAP - ROTOR 4949021
PUMP PRESSURE 100-200 PSI ** SCREW DOWN DIST CAP 4969894
CONVERTER INLET 70-100 PSI ** SCREW DOWN CAP - ROTOR 4969893
CONVERTOR OUTLET 30-60 PSI ELECTRONIC IGNITION - PERLUX 4900666
FOR/REV PACK 120-180 PSI ENGINE OIL FILTER 8763179
LUBE PRESSURE (MAX) 64 PSI HYDRAULIC OIL FILTER 8767442
INCHING SPOOL PROTRUSION 0.9 IN OR 23 MM TRANSMISSION OIL FILTER 4940471
FUEL FILTER (GASOLINE) 4948580
HYDRAULIC SPECS AIR FILTER 4907794
TANK CAPACITY 10.8 GALLON HYDRAULIC TANK BREATHER CAP 4941268
PUMP TYPE GEAR TYPE FAN BELT 4942361
FLOW @ GOV RPM 15.8 GPM WATER PUMP BELT 4942145
FLOW @ HYD BY-PASS 14.2 GPM THERMOSTAT 4942370
RELIEF PRESSURE 2500 PSI RADIATOR CAP 4949074
STEER RELIEF PRESSURE 1070 PSI * EARLY H20 - S/N S...........J
** LATE H20 - S/N K...........X
PAGE 1 Rev 11/2003 PAGE 2 Rev 11/2003
MODELS C/P30-35AX W/ NISSAN H20-II MODELS C/P30-35AX W/ NISSAN H20-II
MAKE/MODEL NISSAN H20-II SYSTEM CAPACITY 2.4 GALLONS
CYLINDERS 4 OPERATING TEMPERATURE 180 - 190 DEGREES
DISPLACEMENT 121 CU.IN. FAN BELT DEFLECTION 0.43- 0.51 in.
HORSEPOWER 48.5 @ 2450 RPM SYSTEM PRESSURE 13 PSI
AIR GAP 0.0138" - 0.0177" CHARGING VOLTAGE 13.7 - 14.25 VDC
PLUG GAP 0.031" - 0.035" DIFFERENTIAL SPECS
TIMING GAS 4 DEG BTDC CASE CAPACITY-TORQFLOW 1.59 Gallons
TIMING LPG 12 DEG BTDC CASE CAPACITY-CLUTCH TYPE 3.43 Gallons
HYDRAULIC BYPASS RPM 2630 PSI RECOMMENDED OCTANE 87
STEERING BYPASS RPM 1050-1150 PSI LPG SPECS
CONVERTER STALL RPM 1760-2000 RPM MANUFACTURE IMPCO
COMPRESSION @ 350 RPM 185 psi MAX TANK PRESSURE 250 PSI
HEAD BOLT TORQUE 54 - 64 ft/lbs DRY GAS PRESSURE 1.5-2 PSI
INTAKE 0.015 in. SPARK PLUG - LPG 8763178
EXHAUST 0.015 in. DISTRIBUTOR CAP 8762078
TRANSMISSION SPECS ROTOR 8762079
OIL DEXRON ATF IGNITOR 8762083
CASE CAPACITY 12.5 QUARTS ENGINE OIL FILTER 8763179
PUMP PRESSURE @ 2000 RPM 135-185 PSI HYDRAULIC OIL FILTER 8761853
FOR/REV PACK @ 600 RPM 70-150 PSI TRANSMISSION OIL FILTER 8761343
FOR/REV PACK @ 2000 RPM 130-180 PSI TRANSMISSION SUMP SCREEN 8761359
LUBE PRESSURE @ 600 RPM 10-20 PSI FUEL FILTER (GASOLINE) 4948580
LUBE PRESSURE @ 2000 RPM 30-80 PSI AIR FILTER (S/N 600000A-652023A(E)) 4907794
AIR FILTER (FROM S/N 652024A(E)) 8767408
HYDRAULIC TANK BREATHER CAP 8761850
HYDRAULIC SPECS WATER PUMP/FAN BELT 8761967
TANK CAPACITY 5.0 GALLONS THERMOSTAT 4942370
PUMP TYPE Drive Type RADIATOR CAP 8761209
FLOW @ GOV RPM 15 GPM

MODELS C/P40-60 W/ NISSAN H20 MODELS C/P40-60 W/ NISSAN H20
FIRING ORDER 1-3-4-2 CRANKING VOLTAGE (MIN.) 9.5 VDC
AIR GAP 0.018" - 0.022" CHARGING VOLTAGE 12.5-15.25 VDC
NO LOAD GOV RPM 2700-2900 RPM TANK CAPACITY (S / H) 9.8 / 16.0 GALLONS
STEERING BYPASS RPM 2600 RPM LPG SPECS
HEAD BOLT TORQUE 65-70 FT/LBS DRY GAS PRESSURE 1.5-2 PSI
INTAKE 0.015" SPARK PLUG 8763178
EXHAUST 0.015" CONDENSOR 8772179
TRANSMISSION SPECS IGNITION POINTS 8772180
OIL DEXRON ATF ELECTRONIC IGNITION-PERLUX 4918908
CASE CAPACITY (T1 / T2) 2.0 / 2.8 GALLON DISTRIBUTOR CAP 4942508
PUMP PRESSURE 130-200 PSI ROTOR 8772182
CONVERTER INLET 35 - 100 PSI ENGINE OIL FILTER 8763179
CONVERTOR OUTLET 30-60 PSI HYDRAULIC OIL FILTER 8767442
FOR/REV PACK T1 / T2 130-200 / 110-175 PSI TRANSMISSION OIL FILTER 4940471
LUBE PRESSURE (MAX) 64 PSI FUEL FILTER (GASOLINE) 4948580
INCHING SPOOL PROTRUSION 2.12 IN. OR 54 MM AIR FILTER 4907794
HYDRAULIC TANK BREATHER CAP 4941268
HYDRAULIC SPECS FAN BELT 4942361
TANK CAPACITY (S / H) 7.4 / 10.0 GALLONS ALT & WATER PUMP BELT 4942145
PUMP TYPE GEAR TYPE POWER STEER BELT 4941442
FLOW @ GOV RPM 16.5 GPM THERMOSTAT 4942370
FLOW @ HYD BY-PASS MIN 13.0 GPM RADIATOR CAP 4940755
PAGE 1 Rev 11/2003 PAGE 2 Rev 11/2003

MODELS C/P40-60B W/ NISSAN H20 MODELS C/P40-60B W/ NISSAN H20
RPM TO TIME 600-700 RPM OIL TYPE SAE 90 W
TIMING GAS 8 DEG BTDC CASE CAPACITY 1.3 GALLONS
IDLE RPM 550-650 RPM TANK CAPACITY 9.5 GALLONS
CONVERTER STALL RPM 1650-1850 RPM MAX TANK PRESSURE 250 PSI
HEAD BOLT TORQUE 68 FT/LBS QUICK REF PART NUMBERS
VALVE CLEARANCE WARM SPARK PLUG - LPG 8763178
INTAKE 0.015" CONDENSOR 4949012
EXHAUST 0.015" *CLIP DOWN DIST. CAP 4949023
TRANSMISSION SPECS *CLIP DOWN CAP - ROTOR 4949021
OIL DEXRON ATF **SCREW DOWN DIST. CAP 4969894
CASE CAPACITY T1/T2 2.6 / 2.8 GALLON **SCREW DOWN CAP - ROTOR 4969893
PUMP PRESSURE 154-212 PSI ELECTRONIC IGNITION - PERLUX 4900666
CONVERTOR INLET 35-100 PSI ENGINE OIL FILTER 8763179
CONVERTOR OUTLET 30-60 PSI HYDRAULIC OIL FILTER 8767442
FOR/REV PACK-1ST/2ND SPEED 154-212 / 125-189 PSI TRANSMISSION OIL FILTER 4940471
LUBE PRESSURE 15-60 PSI FUEL FILTER (GASOLINE) 4948580
INCHING SPOOL PROTRUSION 1.3 IN. OR 33 MM AIR FILTER 4907794
HYDRAULIC SPECS HYDRAULIC TANK BREATHER CAP 4949685
TANK CAPACITY: CUSHION-TIRE 9.8 GALLON FAN BELT 4942361
TANK CAPACITY: PNEUMATIC-TIRE 12.0 GALLON WATER PUMP BELT 4942145
PUMP TYPE GEAR TYPE THERMOSTAT 4942370
FLOW @ GOV RPM 17.5 GPM RADIATOR CAP 4949074
FLOW @ HYD BY-PASS 14 GPM * EARLY H20 - S/N S........J
RELIEF PRESSURE 2630 PSI ** LATE H20 - S/N K........X
PAGE 1 Rev 11/2003 PAGE 2 Rev 11/2003

MODELS C/P40-60B W/ HERCULES G1600 MODELS C/P40-60B W/ HERCULES G1600
MAKE/MODEL HERCULES G1600 SYSTEM CAPACITY 2.4 GALLONS
OIL CAPACITY W/ FILTER 6 QUARTS ELECTRICAL SYSTEM
AIR GAP 0.008" CHARGING VOLTAGE 12.5-14.0 VDC
PLUG GAP 0.035" DIFFERENTIAL SPECS
TIMING GAS 6 DEG BTDC CASE CAPACITY 1.3 GALLONS
IDLE RPM 800 RPM TANK CAPACITY 9.5 GALLONS
CONVERTER STALL RPM T1 / T2 2050 RPM / 1850 RPM MAX TANK PRESSURE 250 PSI
HEAD BOLT TORQUE 60-65 FT/LBS QUICK REF PART NUMBERS
VALVE CLEARANCE WARM SPARK PLUG 4948894
INTAKE 0.015" * EARLY DISTRIBUTOR CAP 4948883
EXHAUST 0.015" ** LATE DIST. CAP (CLIP-DOWN) 4967583
TRANSMISSION SPECS * EARLY ROTOR 4966007
OIL DEXRON ATF ** LATE ROTOR 4967584
CASE CAPACITY T1/T2 2.6 / 2.8 GALLON * EARLY ELECTRONIC IGNITION 4948884
PUMP PRESSURE 150-210 PSI ** LATE ELECTRONIC IGNITION 4967585
CONVERTOR INLET 35-100 PSI * EARLY ENGINE OIL FILTER 4948738
CONVERTOR OUTLET 30-60 PSI ** LATE ENGINE OIL FILTER 4966684
FOR/REV PACK-1ST/2ND SPEED 150-210 / 125-190 PSI HYDRAULIC OIL FILTER 8767442
LUBE PRESSURE (MAX) 15-60 PSI TRANSMISSION OIL FILTER 4940471
INCHING SPOOL PROTRUSION 1.3 IN. OR 33 MM FUEL FILTER (GASOLINE) 4948754
TANK CAPACITY: CUSHION-TIRE 9.8 GALLON HYDRAULIC TANK BREATHER CAP 4941268
TANK CAPACITY: PNEUMATIC-TIRE 12.0 GALLON FAN / WATER PUMP BELT 4948673
PUMP TYPE GEAR TYPE THERMOSTAT 4948796
FLOW @ GOV RPM 17.5 GPM RADIATOR CAP 4949074
FLOW @ HYD BY-PASS 14 GPM
RELIEF PRESSURE 2630 PSI * EARLY STYLE G1600 NON-VACUUM ADVANCE-TYPE DISTRIBUTOR
STEER RELIEF PRESSURE 1350 PSI ** LATE STYLE HAS VACUUM ADVANCE-TYPE DISTRIBUTOR
PAGE 1 Rev 11/2003 PAGE 2 Rev 11/2003

MODELS C/P40-60 W/ KOMATSU 4D95S MODELS C/P40-60 W/ KOMATSU 4D95S
MAKE/MODEL KOMATSU 4D95S-1 SYSTEM CAPACITY 2.5 GALLONS
OIL CAPACITY W/ FILTER 5.8 QUARTS
OIL TYPE SAE 15W40 ELECTRICAL SYSTEM
VOLTAGE 12 VDC
RPM TO TIME 700 RPM CHARGING VOLTAGE 12.5 - 15.25 VDC
TIMING 6 DEG BTDC
IDLE RPM 600 - 700 RPM DIFFERENTIAL SPECS
NO LOAD GOV RPM 2600 - 2700 RPM OIL TYPE SAE 90 W
HYDRAULIC BYPASS RPM 2300 - 2500 RPM CASE CAPACITY-TORQFLOW 1.6 GALLONS
STEERING BYPASS RPM N/A
CONVERTER STALL RPM 1650 - 1950 RPM FUEL TANK SPECS
COMPRESSION @ 300 RPM 427 PSI TANK CAPACITY 9.8 / 16.0 GALLONS
HEAD BOLT TORQUE 110 FT/LBS RECOMMENDED OCTANE DIESEL FUEL
VALVE CLEARANCE COLD
INTAKE 0.014" QUICK REF PART NUMBERS
EXHAUST 0.020" ENGINE OIL FILTER 4947978
HYDRAULIC OIL FILTER 4941711
TRANSMISSION SPECS TRANSMISSION OIL FILTER 4940471
OIL DEXRON ATF FUEL FILTER (DIESEL) 4947983
CASE CAPACITY 2.3 / 2.8 GALLON AIR FILTER 4943271
PUMP PRESSURE 130 - 200 PSI HYDRAULIC TANK BREATHER CAP 4943267
CONVERTOR INLET 35 - 100 PSI FAN BELT 4965293
CONVERTOR OUTLET 30 - 60 PSI THERMOSTAT 4934169
FOR/REV PACK T1 / T2 130-200 / 110-175 PSI RADIATOR CAP 4940755
LUBE PRESSURE (MAX) 64 PSI
INCHING SPOOL PROTRUSION 2.12 IN. (55 mm)
HYDRAULIC SPECS
TANK CAPACITY (S / H) 7.4 / 10.0 GALLONS
PUMP TYPE GEAR TYPE
FLOW @ GOV RPM
FLOW @ HYD BY-PASS

MODELS C/P40-60B W/ KOMATSU 4D95S-W MODELS C/P40-60B W/ KOMATSU 4D95S-W
* ENGINE COOLING SYSTEM SPECS
MAKE/MODEL KOMATSU 4D95S-W SYSTEM CAPACITY 2.6 GALLONS
HORSEPOWER 50 / 57 @ 2450 RPM SYSTEM PRESSURE 13 PSI
* OIL CAPACITY W/ FILTER 6.0 / 8.5 QUARTS
VOLTAGE 12 VDC
* TUNE UP SPECS ALTERNATOR OUTPUT 35 AMPS
* TIMING 6 DEG BTDC / 12 DEG ATDC
* NO LOAD GOV RPM 2650 / 2750 RPM OIL TYPE SAE 90 W
HYDRAULIC BYPASS RPM CASE CAPACITY-TORQFLOW 2.9 GALLONS
STEERING BYPASS RPM
* CONVERTER STALL RPM 2150 / 1950 RPM FUEL TANK SPECS
COMPRESSION @ 300 RPM 427 PSI TANK CAPACITY 14.5 GALLONS
CASE CAPACITY T1 / T2 2.6 / 2.8 GALLON AIR FILTER INNER 4949208
PUMP PRESSURE 154 - 212 PSI AIR FILTER OUTER 4949706
CONVERTOR INLET 35 - 100 PSI HYDRAULIC TANK BREATHER CAP 4949685
CONVERTOR OUTLET 30 - 60 PSI FAN BELT 4965293
FOR/REV PACK T1 / T2 154-212 / 125-189 PSI THERMOSTAT 4934169
LUBE PRESSURE 15-60 PSI RADIATOR CAP 4949074
INCHING SPOOL PROTRUSION 1.3 IN. or 33 MM
HYDRAULIC SPECS
TANK CAPACITY 12.4 GALLONS
PUMP TYPE GEAR TYPE
FLOW @ GOV RPM
FLOW @ HYD BY-PASS
*4D95S-W = EARLY SN 37058 - 104548 / LATE SN 104549 & UP
PAGE 1 Rev 11/2003 PAGE 2 Rev 11/2003
Fiche 530-530D Fiche 530-530D
MODELS C/P40-60BX W/ NISSAN H20-II MODELS C/P40-60BX W/ NISSAN H20-II
MAKE/MODEL NISSAN H20-II SYSTEM CAPACITY 2.4 GALLONS
HORSEPOWER 48.5 @ 2450 RPM SYSTEM PRESSURE 13 PSI
FIRING ORDER 1-3-4-2 CRANKING VOLTAGE 9.5 VDC MIN
PLUG GAP 0.031" - 0.035" DIFFERENTIAL SPECS
TIMING GAS 4 DEG BTDC CASE CAPACITY-TORQFLOW 6 QUARTS
TIMING LPG 12 DEG BTDC CASE CAPACITY-CLUTCH TYPE 14 QUARTS
EXHAUST 0.015" DISTRIBUTOR CAP 8762078
FOR/REV PACK @ 600 RPM 128 PSI TRANSMISSION OIL FILTER 8761343
FOR/REV PACK @ 2000 RPM 185 PSI TRANSMISSION SUMP SCREEN 8761359
AIR FILTER, S/N 010001A-558381A(E) 4907794
HYDRAULIC SPECS AIR FILTER, FROM S/N 558382A(E) 8767408
TANK CAPACITY: CUSHION-TIRE 10.0 GALLONS HYDRAULIC TANK BREATHER CAP 8761850
TANK CAPACITY: PNEUMATIC-TIRE 14.0 GALLONS WATER PUMP/FAN BELT 8761967
PUMP TYPE Gear Type THERMOSTAT 4942370
FLOW @ GOV RPM 23cc PER PUMP REV RADIATOR CAP 8761209
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS C/P40-60BXH W/ NISSAN H25 MODELS C/P40-60BXH W/ NISSAN H25
FIRING ORDER 1-3-4-2 CRANKING VOLTAGE 9.5 VDC MIN
TIMING GAS 4 DEG BTDC CASE CAPACITY-TORQFLOW 6 QUARTS
TIMING LPG 12 DEG BTDC CASE CAPACITY-CLUTCH TYPE 14 QUARTS
EXHAUST 0.015" DISTRIBUTOR CAP 8762078
FOR/REV PACK @ 600 RPM 128 PSI TRANSMISSION OIL FILTER 8761343
FOR/REV PACK @ 2000 RPM 185 PSI TRANSMISSION SUMP SCREEN 8761359
AIR FILTER, S/N 010001A-558381A(E) 4907794
AIR FILTER, FROM S/N 558382A(E) 8767408
TANK CAPACITY: CUSHION-TIRE 10.0 GALLONS WATER PUMP/FAN BELT 8761967
TANK CAPACITY: PNEUMATIC-TIRE 14.0 GALLONS THERMOSTAT 4942370
PUMP TYPE GEAR TYPE RADIATOR CAP 8761209
FLOW @ GOV RPM 23cc PER PUMP REV
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS P40-60BXD W/ KOMATSU 4D94E MODELS P40-60BXD W/ KOMATSU 4D94E
MAKE/MODEL YANMAR 4D94E SYSTEM CAPACITY 2.5 GALLONS
OIL CAPACITY W/ FILTER 8 QUARTS
VOLTAGE 12 VDC
FIRING ORDER 1-3-4-2 CRANKING VOLTAGE (MIN.) 9.5 VDC MIN
TIMING 6 DEG ATDC CHARGING VOLTAGE 13.5 - 14.5 VDC
IDLE RPM 675-725 RPM
NO LOAD GOV RPM 2650-2750 RPM DIFFERENTIAL SPECS
HYDRAULIC BYPASS RPM 2125-2225 RPM OIL TYPE SAE 90 W
STEERING BYPASS RPM 2400-2500 RPM CASE CAPACITY-TORQFLOW 6 QUARTS
CONVERTER STALL RPM 2050-2250 RPM CASE CAPACITY-CLUTCH TYPE 14 QUARTS
COMPRESSION (PSI )@ 250 RPM 412-441 (340min)
HEAD BOLT TORQUE 1ST STEP 1st TIME @ 43 ft-lb FUEL TANK SPECS
HEAD BOLT TORQUE 2ND STEP 2nd TIME @ 86 ft-lb TANK CAPACITY 14.5 GALLONS
VALVE CLEARANCE COLD RECOMMENDED OCTANE DIESEL FUEL
INTAKE 0.008"
EXHAUST 0.008" QUICK REF PART NUMBERS
ENGINE OIL FILTER 8762282
TRANSMISSION SPECS HYDRAULIC OIL FILTER 8761853
OIL DEXRON ATF TRANSMISSION OIL FILTER 8761343
CASE CAPACITY 12.5 QUARTS TRANSMISSION SUMP SCREEN 8761359
PUMP PRESSURE @ 2000 RPM 135-185 PSI FUEL FILTER (DIESEL) 8762405
FOR/REV PACK @ 600 RPM 128 PSI AIR FILTER INNER 4949208
FOR/REV PACK @ 2000 RPM 185 PSI AIR FILTER OUTER 4949706
LUBE PRESSURE 30-50 PSI HYDRAULIC TANK BREATHER CAP 8761850
FAN BELT 8762497
THERMOSTAT 8762501
HYDRAULIC SPECS RADIATOR CAP 8761209
PUMP TYPE GEAR TYPE
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS P80-100G W/ NISSAN P40 MODELS P80-100G W/ NISSAN P40
MAKE/MODEL NISSAN P40 SYSTEM CAPACITY 3.7 GALLONS
DISPLACEMENT 3.95 LITERS FAN BELT DEFLECTION 1/2" @ 22 LBS
FIRING ORDER 1-5-3-6-2-4 CRANKING VOLTAGE (MIN.) 9.5 VDC
POINT GAP 0.018" - 0.022" CHARGING VOLTAGE 12.5-15.25 VDC
NO LOAD GOV RPM 2300-2400 RPM TANK CAPACITY (S / Z / PNUE) 13 / 18 / 24 GALLONS
INTAKE 0.015" SPARK PLUG - GAS 8772178
EXHAUST 0.015" SPARK PLUG - LPG 8763178
TRANSMISSION SPECS CONDENSOR 8772179
OIL DEXRON ATF IGNITION POINTS 8772180
CASE CAPACITY (T1 & T2) 3.8 GALLON ELECTRONIC IGNITION-PERLUX 8772181
PUMP PRESSURE 130-200 PSI DISTRIBUTOR CAP 4947919
CONVERTER INLET 35 - 100 PSI ROTOR 8772182
CONVERTER OUTLET 30-60 PSI ENGINE OIL FILTER 8772183
FOR/REV PACK T1 / T2 130-200 / 130-200 PSI HYDRAULIC OIL FILTER 4942657
LUBE PRESSURE (MAX) 64 PSI TRANSMISSION OIL FILTER 4941456
INCHING SPOOL PROTRUSION T1 / T2 1.85" / 1.9" FUEL FILTER (GASOLINE) 8765003
AIR FILTER 8772184
TANK CAPACITY (S / H) 14.0 GALLONS FAN BELT 4942503
PUMP TYPE GEAR TYPE WATER PUMP BELT 8772185
FLOW @ GOV RPM 31 GPM THERMOSTAT 4942505
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS P80-100D W/ KOMATSU 6D95L MODELS P80-100D W/ KOMATSU 6D95L
MAKE/MODEL KOMATSU 6D95L SYSTEM CAPACITY 3.7 GALLONS
VOLTAGE 24 VDC
TIMING 12 DEG BTDC
NO LOAD GOV RPM 2350 RPM OIL TYPE SAE 90 W
HYDRAULIC BYPASS RPM 1900 - 2100 RPM CASE CAPACITY-TORQFLOW 2.4 GALLONS
STEERING BYPASS RPM N/A
COMPRESSION @ 300 RPM 427 PSI TANK CAPACITY Z / PNUE 18.5 / 24.0 GALLONS
CASE CAPACITY T1 & T2 3.8 GALLON AIR FILTER 4945160
PUMP PRESSURE 130 - 200 PSI HYDRAULIC TANK BREATHER CAP 4942522
CONVERTER INLET 35 - 100 PSI FAN BELT 4947601
CONVERTER OUTLET 30 - 60 PSI THERMOSTAT 4947987
FOR/REV PACK T1 / T2 130-200 / 130-200 PSI RADIATOR CAP 4940755
INCHING SPOOL PROTRUSION 1.85" / 1.9"
HYDRAULIC SPECS
PUMP TYPE GEAR TYPE
FLOW @ GOV RPM
FLOW @ HYD BY-PASS
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS C/P80-100B W/ NISSAN P40 MODELS C/P80-100B W/ NISSAN P40
FIRING ORDER 1-5-3-6-2-4 CRANKING VOLTAGE (MIN) 9.5 VDC
TIMING GAS 8 DEG BTDC TORQFLOW CASE CAPACITY 2.4 GALLONS
TIMING LPG 10 DEG BTDC CLUTCH CAPACITY 5.8 GALLONS
NO LOAD GOV RPM 2300-2400 RPM TANK CAPACITY (S/Z/PNUEMATIC) 13 gal / 18 gal / 24 gal
HYDRAULIC BYPASS RPM 2100 RPM RECOMMENDED OCTANE 87
EXHAUST 0.015" SPARK PLUG - GAS 8772178
CASE CAPACITY 15 QUARTS ELECTRONIC IGNITION - PERLUX 8772181
PUMP PRESSURE 160-200 PSI DIST. CAP 4947919
CONVERTER INLET 70-100 PSI ROTOR 4942380
CONVERTER OUTLET 30-60 PSI ENGINE OIL FILTER 4942494
FOR/REV PACK - 1ST/2ND SPEED 130-200 / 133-200 PSI HYDRAULIC OIL FILTER 4942657
LUBE PRESSURE (MAX) 15-60 PSI TRANSMISSION OIL FILTER 4941456
INCHING SPOOL PROTRUSION T1/T2 47MM / 48MM FUEL FILTER (GASOLINE) 8765003
TANK CAPACITY 14 GALLON HYDRAULIC TANK BREATHER CAP 4942522
FLOW @ GOV RPM 31 GPM THERMOSTAT 4942505
FLOW @ HYD BY-PASS 24.8 GPM RADIATOR CAP 4966704
POWER BRAKE PRESSURE 880 PSI
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS P80-100B W/ NISSAN TB42 MODELS P80-100B W/ NISSAN TB42
MAKE/MODEL NISSAN TB42 SYSTEM CAPACITY 3.7 GALLONS
DISPLACEMENT 254 cu in. FAN BELT DEFLECTION 1/2" @ 22 LBS
HORSEPOWER 85 @ 2100 RPM ALTERNATOR BELT DEFLECTION 5/8" @ 22 LBS
OIL CAPACITY W/ FILTER 8.25 QUARTS GOVERNOR BELT DEFLECTION 3/4" @ 22 LBS
OIL TYPE SAE 10W30 SYSTEM PRESSURE 13 PSI
TUNE UP SPECS ELECTRICAL SYSTEM
FIRING ORDER 1-5-3-6-2-4 VOLTAGE 12 VDC
AIR GAP (ELECT IGN) ALTERNATOR OUTPUT 35 AMPS
PLUG GAP 0.028"-0.032" CRANKING VOLTAGE (MIN) 9.5 VDC
RPM TO TIME 600-650 RPM CHARGING VOLTAGE 13.5-14.7 VDC
TIMING GAS 7 DEG BTDC DIFFERENTIAL SPECS
TIMING LPG 12 DEG BTDC OIL TYPE SAE 90 W
IDLE RPM 600-700 RPM CASE CAPACITY (C / T) 5.8 / 2.4 GALLONS
NO LOAD GOV RPM 2400-2500 RPM
HYDRAULIC BYPASS RPM 2100 RPM FUEL TANK SPECS
STEERING BYPASS RPM 2200-2250 RPM TANK CAPACITY (S / H) 13.2 / 24 GALLONS
CONVERTOR STALL RPM 1500-1950 RPM RECOMMENDED OCTANE 87
COMPRESSION @ 200 RPM 170 PSI LPG SPECS
HEAD BOLT TORQUE 47 - 54 FT/LBS MANUFACTURE IMPCO
VALVE CLEARANCE WARM MAX TANK PRESSURE 250 PSI
INTAKE 0.015" DRY GAS PRESSURE 1.5-2 PSI
TRANSMISSION SPECS SPARK PLUG 8763178
OIL DEXRON ATF ELECTRONIC IGNITION 4968820
CASE CAPACITY 15 QUARTS DISTRIBUTOR CAP 4968832
PUMP PRESSURE 130-200 PSI ROTOR 4968831
CONVERTER INLET 70-100 PSI ENGINE OIL FILTER 8763270
CONVERTER OUTLET 30-60 PSI HYDRAULIC OIL FILTER 4942657
FOR/REV PACK - 1ST/2ND SPEED 130-200 / 130-200 PSI TRANSMISSION OIL FILTER 4941456
INCHING SPOOL PROTRUSION T1/T2 47MM / 48MM AIR FILTER 4942587
TANK CAPACITY 14 GALLON FAN BELT 4968643
PUMP TYPE GEAR TYPE ALTERNATOR BELT 4968642
FLOW @ GOV RPM 32.3 GPM GOVERNOR BELT 4968641
FLOW @ HYD BY-PASS 25.8 THERMOSTAT 4968819
RELIEF PRESSURE 2630 PSI RADIATOR CAP (C ONLY) 4966704
STEER RELIEF PRESSURE 1495 PSI RADIATOR CAP 4941972
POWER BRAKE PRESSURE 880 PSI
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS C/P80-100BD W/ KOMATSU 6D95L MODELS C/P80-100BD W/ KOMATSU 6D95L
MAKE/MODEL KOMATSU 6D95L-1 SYSTEM CAPACITY 3.7 GALLONS
VOLTAGE 24 VDC
TIMING 6 DEG BTDC
NO LOAD GOV RPM 2300 - 2400 RPM OIL TYPE SAE 90 W
STEERING BYPASS RPM
COMPRESSION @ 300 RPM 427 PSI TANK CAPACITY Z / PNUE 18.0 / 24.0 GALLONS
CASE CAPACITY T1 & T2 3.8 GALLON AIR FILTER - ASSY 4969311
PUMP PRESSURE 130 - 200 PSI AIR FILTER - INNER 8765033
CONVERTER INLET 35 - 100 PSI AIR FILTER - OUTER 4966488
CONVERTER OUTLET 30 - 60 PSI HYDRAULIC TANK BREATHER CAP 4942522
FOR/REV PACK T1 / T2 130-200 / 130-200 PSI FAN BELT 4947601
LUBE PRESSURE (MAX) 65 PSI THERMOSTAT 4967446
INCHING SPOOL PROTRUSION 1.85" / 1.89" RADIATOR CAP 4966704
HYDRAULIC SPECS
PUMP TYPE GEAR TYPE
FLOW @ GOV RPM
FLOW @ HYD BY-PASS
STEER RELIEF PRESSURE
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS C/P80-100CXG W/ NISSAN TB42 MODELS C/P80-100CXG W/ NISSAN TB42
CYLINDERS 6 OPERATING TEMPERATURE 180° -190° F
RPM TO TIME 700 RPM CHARGING VOLTAGE 13.5-14.7 VDC
IDLE RPM 600-700 RPM CASE CAPACITY (C / T) 13.7 QTS
NO LOAD GOV RPM 2,300-2,400
STEERING BYPASS RPM 2080 RPM TANK CAPACITY (40Z,40/45) 21, 26.5 GALLONS
CONVERTOR STALL RPM 1985 ± 150 RPM RECOMMENDED OCTANE 87
HEAD BOLT TORQUE 47 - 54 FT/LBS MANUFACTURE AFS
CASE CAPACITY 17 QUARTS DISTRIBUTOR CAP 4968832
PUMP PRESSURE 164 ± 17 PSI ROTOR 4968831
CONVERTER INLET 101 ± 17 PSI ENGINE OIL FILTER 8763270
CONVERTER OUTLET 64 ± 17 PSI SPIN-ON HYDRAULIC OIL FILTER 4942657
FOR/REV PACK - F1/R1/F2 164 ± 17 PSI IN-LINE TRANSMISSION OIL FILTER 8763122
LUBE PRESSURE (MAX) 64 ± 17 PSI SPIN-ON TRANSMISSION OIL FILTER 8765222
FUEL FILTER (GASOLINE) 8765003
TANK CAPACITY(40Z, 40/45) 11, 8.7 GALLONS RADIATOR CAP 8764959
HYD. FLOW @ GOV RPM 34 GPM ALTERNATOR BELT 4968642
STEER FLOW (Flow Divider) 5 GPM GOVERNOR BELT 4968641
HYD. RELIEF PRESSURE 2630 ± 70 PSI THERMOSTAT 4968819
STEER RELIEF PRESSURE 1495(+70/-0) PSI HYD TANK BREATHER CAP-FG40Z 8765645
HYD. BYPASS 2130 ± 50 PSI HYD. TANK BREATHER (FG40/45) 8765646
POWER BRAKE 995 ± 142 PSI
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003
MODELS P80-100CXD W/ KOMATSU 6D102E MODELS P80-100CXD W/ KOMATSU 6D102E

MAKE/MODEL 6D102E SYSTEM CAPACITY 4.75 GALLONS
CYLINDERS 6 OPERATING TEMPERATURE 180 - 190° F
VOLTAGE 24 VDC
TIMING 1º ATDC ± 1
NO LOAD GOV RPM 2300-2400 RPM OIL TYPE SAE 90 W
CASE CAPACITY-TORQFLOW 13.7QTS
CONVERTOR STALL RPM 1850 ± 150 RPM FUEL TANK SPECS

COMPRESSION @ 300 RPM 512 PSI TANK CAPACITY 40Z, 40/45 23, 26 GALLONS
HEAD BOLT TORQUE See Shop Manual SM180 for Procedure RECOMMENDED OCTANE DIESEL FUEL
SPIN-ON HYDRAULIC OIL FILTER 4942657
CASE CAPACITY 17 QTS AIR FILTER - INNER 8764816
PUMP PRESSURE 164 ± 17 PSI AIR FILTER - OUTER 8764821
CONVERTER INLET 101 ± 17 PSI HYDRAULIC TANK BREATHER CAP 8766137
CONVERTER OUTLET 64 ± 17 PSI HYD.TNK BRTHR CAP (FD45-7) 8765646
FOR/REV PACK T1 / T2 164 ± 17 PSI FAN BELT 8766129
LUBE PRESSURE (MAX) 64 ± 17 PSI THERMOSTAT 8771463
RADIATOR CAP 4941972
HYDRAULIC SPECS
TANK CAPACITY (40Z, 40/45) 11.0, 8.7 GAL. Total Hyd.System Capacity 14.5 Gallons
PUMP TYPE GEAR TYPE Aux Valve Bypass 2130 ±50 PSI
HYD. RELIEF FLOW 34 GPM
STEER RELIEF FLOW 5 GPM
RELIEF PRESSURE 2630 ± 70 PSI
STEER RELIEF PRESSURE 1495(+70/-0 PSI)
HYD. BYPASS 2150 ± 50 PSI
POWER BRAKE 995 ± 142 PSI
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003
MODELS P110-150G W/ NISSAN P40 MODELS P110-150G W/ NISSAN P40
POINT GAP 0.018" - 0.022" CHARGING VOLTAGE 12.5-15.25 VDC
TIMING GAS 8 DEG BTDC CASE CAPACITY-TORQFLOW 3 GALLONS
TIMING LPG 10 DEG BTDC
NO LOAD GOV RPM 2300-2400 RPM TANK CAPACITY 32 GALLONS
CONVERTER STALL RPM 2000 RPM MANUFACTURE IMPCO
INTAKE 0.015" SPARK PLUG - GAS 8772178
EXHAUST 0.015" SPARK PLUG - LPG 8763178
CASE CAPACITY 3.2 GALLON ELECTRONIC IGNITION-PERLUX 8772181
PUMP PRESSURE 170 PSI DISTRIBUTOR CAP 4947919
CONVERTER INLET 170 PSI ROTOR 8772182
CONVERTER OUTLET 70 PSI ENGINE OIL FILTER 8772183
FOR/REV PACK T1 / T2 170 / 170 PSI HYDRAULIC OIL FILTER 4945742
LUBE PRESSURE (MAX) 142 PSI TRANSMISSION OIL FILTER 4940471
INCHING SPOOL PROTRUSION 2.16" OR 55 mm FUEL FILTER (GASOLINE) 8765003
AIR FILTER 8772184
TANK CAPACITY (S / H) 17.2 GALLONS FAN BELT 4942503
PUMP TYPE GEAR TYPE WATER PUMP BELT 8772185
FLOW @ GOV RPM 35.5 GPM THERMOSTAT 4942505
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS P110-150D W/ KOMATSU 6D95L MODELS P110-150D W/ KOMATSU 6D95L
MAKE/MODEL KOMATSU 6D95L SYSTEM CAPACITY 4.2 GALLONS
VOLTAGE 24 VDC
TIMING 14 DEG BTDC
IDLE RPM 600-700 RPM DIFFERENTIAL SPECS
HYDRAULIC BYPASS RPM 2200-2375 RPM CASE CAPACITY-TORQFLOW 3 GALLONS
STEERING BYPASS RPM 2300-2325 RPM
CONVERTER STALL RPM 2050 RPM FUEL TANK SPECS
COMPRESSION @ 300 RPM 427 PSI TANK CAPACITY 32 GALLONS
VALVE CLEARANCE WARM
CASE CAPACITY 3.2 GALLON AIR FILTER 4945160
PUMP PRESSURE 170 PSI HYDRAULIC TANK BREATHER CAP 4945740
CONVERTER INLET 170 PSI FAN BELT 4947601
CONVERTER OUTLET 70 PSI THERMOSTAT 4947987
FOR/REV PACK T1 / T2 170 / 170 PSI RADIATOR CAP 4941972
INCHING SPOOL PROTRUSION 2.16" OR 55 mm
HYDRAULIC SPECS
TANK CAPACITY (S / H) 17.2 GALLONS
PUMP TYPE GEAR TYPE
FLOW @ HYD BY-PASS MIN 28.5 GPM
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODEL P150BG W/ NISSAN TB42 MODEL P150BG W/ NISSAN TB42
IDLE RPM 600-700 RPM CASE CAPACITY 3.0 GALLONS
STEERING BYPASS RPM 2200-2250 RPM TANK CAPACITY 13.2 / 24 GALLONS
CONVERTER STALL RPM 1500-1950 RPM RECOMMENDED OCTANE 87
CASE CAPACITY 13 QUARTS DIST. CAP 4968832
PUMP PRESSURE 170 PSI ROTOR 4968831
CONVERTER INLET 170 PSI ENGINE OIL FILTER 8763270
CONVERTER OUTLET 70 PSI SPIN-ON HYDRAULIC OIL FILTER 4942657
FOR/REV PACK - 1ST/2ND SPEED 170/170 PSI TRANSMISSION OIL FILTER 4941456
INCHING SPOOL PROTRUSION 55 MM AIR FILTER 4969046
TANK CAPACITY 17.2 GALLON FAN BELT 4968640
PWR BRAKE PRESSURE (50-70 / 80) 140 / 285 PSI
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODEL P150BD W/ KOMATSU 6D95L MODEL P150BD W/ KOMATSU 6D95L
MAKE/MODEL KOMATSU 6D95L-1 SYSTEM CAPACITY 4.2 GALLONS
VOLTAGE 24 VDC
TIMING 8 DEG BTDC
HYDRAULIC BYPASS RPM CASE CAPACITY-TORQFLOW 3 GALLONS
STEERING BYPASS RPM
CASE CAPACITY 3.2 GALLON AIR FILTER - INNER 4969311
PUMP PRESSURE 170 PSI AIR FILTER - OUTER 4969312
CONVERTER INLET 170 PSI HYDRAULIC TANK BREATHER CAP 4942522
CONVERTER OUTLET 70 PSI FAN BELT 4947601
FOR/REV PACK T1 / T2 170 / 170 PSI THERMOSTAT 4967446
LUBE PRESSURE (MAX) 142 PSI RADIATOR CAP 4941972
HYDRAULIC SPECS
PUMP TYPE GEAR TYPE
FLOW @ GOV RPM
FLOW @ HYD BY-PASS
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

Manual Only Manual Only
MODELS P155DX W/ NISSAN TB42 MODELS P155DX W/ NISSAN TB42
IDLE RPM 600-700 RPM CASE CAPACITY 3.0 GALLONS
STEERING BYPASS RPM 2200-2250 RPM TANK CAPACITY 13.2 / 24 GALLONS
CONVERTOR STALL RPM 1500-1950 RPM RECOMMENDED OCTANE 87
CASE CAPACITY 13 QUARTS DIST. CAP 4968832
PUMP PRESSURE 170 PSI ROTOR 4968831
CONVERTER INLET 170 PSI ENGINE OIL FILTER 8763270
CONVERTER OUTLET 70 PSI SPIN-ON HYDRAULIC OIL FILTER 4942657
FOR/REV PACK - 1ST/2ND SPEED 170/170 PSI TRANSMISSION OIL FILTER 4941456
INCHING SPOOL PROTRUSION 55 MM AIR FILTER 4969046
TANK CAPACITY 18 GALLONS FAN BELT 4968640
PWR BRAKE PRESSURE (50-70 / 80) 140 / 285 PSI
PAGE 1 Rev 11/2003 PAGE 2 Rev 11/2003

MODEL P155-180DXD W/ KOMATSU 6D102E MODEL P155-180DXD W/ KOMATSU 6D102E
MAKE/MODEL KOMATSU 6D102E SYSTEM CAPACITY 6.3 GALLONS
VOLTAGE 24 VDC
TIMING 14 DEG BTDC
STEERING BYPASS RPM
CASE CAPACITY 3.2 GALLON AIR FLTR (INNER & OUTER) 4969311
PUMP PRESSURE 170 PSI HYD TANK BREATHER CAP 8763133
CONVERTER INLET 170 PSI FAN BELT 8763118
CONVERTER OUTLET 70 PSI THERMOSTAT 8771463
FOR/REV PACK T1 / T2 170 / 170 PSI RADIATOR CAP 4941972
HYDRAULIC SPECS
TANK CAPACITY 18 GALLONS
PUMP TYPE GEAR TYPE
FLOW @ GOV RPM
FLOW @ HYD BY-PASS
STEER RELIEF PRESSURE
PAGE 1 Rev 12/2003 PAGE 2 Rev 12/2003

MODELS P220/250/300/330/350EXD W/ ISUZU 6BG1-T MODELS P220/250/300/330/350EXD W/ ISUZU 6BG1-T
MAKE/MODEL ISUZU 6BG1-T SYSTEM CAPACITY 7.4 GALLONS
DISPLACEMENT 396 CU IN. FAN BELT DEFLECTION 0.50 IN. @ 13 LBS
HORSEPOWER 160 @ 2200 RPM SYSTEM PRESSURE
OIL TYPE SAE 15W40-CD ELECTRICAL SYSTEM
VOLTAGE 24 VDC
INJECTION TIMING 12 DEG BTDC CHARGING VOLTAGE 25.5-29.25 VDC
IDLE RPM 600-700 RPM
NO LOAD GOV RPM 2350-2450 RPM DIFFERENTIAL SPECS
CONVERTER STALL RPM 2000 RPM OIL TYPE SAE 90 W
COMPRESSION @ 200 RPM 369.8 PSI CASE CAPACITY-TORQFLOW 21 QUARTS
HEAD BOLT TORQUE SEE SHOP MANUAL LUG BOLT TORQUE 400 FT/LBS
INTAKE 0.016" FUEL TANK SPECS
EXHAUST 0.016" TANK CAPACITY 58 GALLONS
RECOMMENDED OCTANE DIESEL FUEL
TRANSMISSION SPECS QUICK REF PART NUMBERS

OIL SAE10W-CD ENGINE OIL FILTER 1-13240-168-1
CASE CAPACITY 10.5 GALLON BYPASS FILTER 1-13240-161-2
PUMP PRESSURE 284 PSI HYDRAULIC OIL FILTER 3ED-66-11331
CONVERTER INLET N/A HYDRAULIC OIL STRAINER 3EE-66-11161
CONVERTER OUTLET N/A TRANSMISSION OIL FILTER 3ED-66-1330
FOR/REV PACK T1 / T2 203 PSI TRANSMISSION OIL STRAINER OKX52313
LUBE PRESSURE (MAX) N/A FUEL FILTER (DIESEL) 1-13240-068-0
AIR FILTER (OUTER ELEMENT) 3EF-02-46530
AIR FILTER (INNER ELEMENT) 3EF-02-46540
HYDRAULIC SPECS HYDRAULIC TANK BREATHER CAP 3FE-66-11380
TANK CAPACITY (S / H) 39.68 GALLONS FAN BELT 1-13671-404-0
PUMP TYPE GEAR TYPE THERMOSTAT 1-13770-070-0
RELIEF PRESSURE 3130 PSI RADIATOR CAP 3EE-04-21331
BRAKE RELIEF PRESSURE 1850 PSI
Please fax orders for the above listed parts to 770-385-4836
PAGE 1 Added 12/2003 PAGE 2 Added 12/2003

Quick Reference — Gas & LPG Engine Spark Plug Wire Sets
Engine Type Plug Wire Set Notes
H20 4942394 S & K SERIES ENGINE
P40 4947928
TB42 8760967
8760768 WITH VACUUM ADVANCE

G1600
4948877 WITHOUT VACUUM ADVANCE
5K
TJ191017812071
H20-II
22450-50K50
H25
12/2003
RECOMMENDED FLUID CHANGES ALL MODELS
HYDRAULIC FLUID 6 MONTHS OR EVERY 1200 HR

( 10 WT HYD OIL)
TRANSMISSION FLUID 6 MONTHS OR EVERY 1200 HRS
(DEXRON II)
BRAKE FLUID 6 MONTHS OR EVERY 1200 HRS
(DOT 3)
DIFFERENTIAL FLUID 6 MONTHS OR EVERY 1200 HRS
(SAE 90 WT)
CLUTCH CASE 6 MONTHS OR EVERY 1200 HRS
(SAE 90 WT)
ANTIFREEZE ONCE A YEAR
(NAME BRAND)
ENGINE OIL EVERY 200 HRS
(10W30)
GREASE FITTINGS EVERY 200 HRS
WHEN SEVERE CONDITIONS EXIST,

REPLACE ALL FLUIDS MORE OFTEN
Rev 12/2003
C/P30-35B TRANSMISSION TEST PORTS
PLACE BLOCKS TO THE WHEELS AND APPLY PARKING BRAKE BEFORE

CHECKING PRESSURES
Clutch Operating Pressure and Torque Converter Pressure
NOTE: Shift the F-R lever to either forward or reverse position and bring engine up to 1,500 rpm
before checking pressure.
Check Pressure Range

Check Item
Spot
Torque converter inlet
h 3 – 7 kg/cm2
pressure
(4P) 7.2 – 11.3 kg/cm2

(102 – 161 psi)
Clutch operating pressure P3 and P4
(H20) 9.6 – 13.7 kg/cm2
(137 – 195 psi)
Stall Engine Speed
NOTE: Shift the F-R lever to either forward or reverse position and increase engine speed to
fullest to check on engine speed at the maximum.
To prevent excessive oil temperature, long checking is not allowed.
4P 2,350 + 150 rpm

5K 2,400 + 150 rpm
H20 1,750 + 150 rpm
12/2003
C/P40-60B TRANSMISSION TEST PORTS

CHECKING PRESSURES
TC inlet
2.2 ~ 4 kg/cm2 (31 – 56 psi)
TC outlet
P1 main relief
10.8 ~ 14.9 kg/cm2 (154 – 212 psi)
P2 inch valve
P3 mod valve
P4 lube relief 4.5 kg/cm2 (64 psi)
12/2003
C/P30-60AX/BX SERIES TRANSMISSION TEST PORTS

CHECKING PRESSURES
Clutch Pressure 92 – 142 psi @ 1,000 rpm

128 – 178 psi @ 2,000 rpm
Forward/Reverse Pack 71 – 126 psi @ 600 rpm

127 – 178 psi @ 2,000 rpm
Stall Speed H20-II 1,760 – 2,000 rpm

H25 2,000 – 2,200 rpm
4D94E 2,080 – 2,300 rpm
12/2003
C/P80-100B TYPE T1 TRANSMISSION TEST PORTS

CHECKING PRESSURES
12/2003
C/P80-100B TYPE T2 TRANSMISSION TEST PORTS

CHECKING PRESSURES
12/2003
C/P80-100CX INDOOR TRANSMISSION PRESSURE PORTS
PAGE 1 12/2003
PAGE 2 12/2003
LPG CARBURETOR ADJUSTMENT
Idle Mixture
Turning the idle air screw in will make the fuel mixture richer.
Turing the idle air screw out will make the fuel mixture leaner.
The idle air fuel mixture is best adjusted only with an engine CO exhaust
analyzer and the mixture should be adjusted to 0.30 to 0.70 percent
carbon monoxide.
Alternate Method:
• Adjust idle to 400-500 rpm
• Turn idle air screw out until engine
starts to run rough.
• Turn idle air screw in approximately
¼ turn to ½ turn or until engine
smoothes out.
Idle Speed Adjustment

Turn the idle speed screw until the idle
speed of the engine is within
specification.
Power Adjustment
This setting is preset at the factory and should not require further
adjustment. This adjustment controls the mixture when the gas metering
valve is withdrawn from the jet. It is only effective when the engine is near
a full-load condition. This can only be set with the engine loaded or at a
close to its rated governed rpm.
If adjustment is needed, follow these steps:
• Set parking brake and block the drive wheels

• Connect a tachometer to engine.
• Accelerate engine to full governed rpm.
• Pull backward on tilt lever until pump reaches hydraulic relief bypass.
The rpm should drop according to the spec for hydraulic bypass on
your Quik-Serv cards (typically a 250-500 rpm drop). If the rpm does
not drop, check and adjust the hydraulic pressure before you continue.
• Turn the power mixture valve until the highest engine rpm is reached at
0.30 to 0.70 percent carbon monoxide.
12/2003
OVERHEATING
TROUBLESHOOTING
HOW LONG DOES IT TAKE FOR THE ENGINE TO OVERHEAT?
IF APPROXIMATELY 30 MINUTES OR LESS, DO THE
FOLLOWING.
1. COMPRESSION TEST
2. CYLINDER LEAKAGE TEST
3. RADIATOR GAS TEST (NAPA STORE)
4. CHECK THE THERMOSTAT FOR OPENING PROBLEMS
5. CHECK FOR FAULTY TEMPERATURE GAUGE AND/OR FAULTY
SENDING UNIT
ITEMS #1, #2, & #3 - CHECK FOR BLOWN HEADGASKET

AND/OR CRACKS IN THE CYLINDER HEAD OR BLOCK.
IF OVERHEATING TAKES PLACE OVER A LONG PERIOD
OF TIME, INSPECT THE ITEMS LISTED BELOW
1. TUNE-UP COMPONENTS IN GOOD CONDITION AND ADJUSTED

PROPERLY
2. ENGINE IGNITION TIMING TOO FAR ADVANCED OR THE
DISTRIBUTOR ADVANCE PLATE STUCK IN THE FULL ADVANCE
POSITION
3. CARBURETOR MIXTURE TOO LEAN (GASOLINE)
4. LOW COOLANT LEVELS DUE TO LEAKS
5. FAN BELT TENSION TOO LOOSE ALLOWING SLIPPAGE
6. DOES RADIATOR HAVE GOOD INTERNAL FLOW (TUBES NOT
CLOGGED)
7. RADIATOR FINS ARE CLEAN OF DIRT AND/OR DEBRIS
8. RADIATOR HOSES ARE NOT COLLAPSED
9. WATER PUMP IMPELLER SPINNING FREE OR BROKEN
10. RADIATOR CAP HAS BAD, BROKEN OR MISSING SEAL
11. FAN BLADE IS IN POOR CONDITION (ESPECIALLY PLASTIC) OR
INSTALLED BACKWARDS
PAGE 1 12/2003
OVERHEATING
TROUBLESHOOTING
LISTED ARE COMPONENTS THAT CAN MAKE A FORKLIFT

OVERHEAT DUE TO A CONSTANT LOAD BEING PUT ON THE
ENGINE
TRANSMISSION
1. INCHING SPOOL OUT OF ADJUSTMENT, ALLOWING THE CLUTCH

PACKS TO SLIP. THIS ADDS HEAT TO RADIATOR THROUGH
TRANSCOOLER IN RADIATOR.
2. TRANSMISSION CLUTCH PACKS SLIPPING DUE TO LOW
PRESSURE FROM PUMP ON THE TRANSMISSION CONTROL
VAVLE
3. HIGH TORQUE CONVERTER PRESSURES
4. LOW TRANSMISSION FLUID LEVELS
BRAKES
1. EMERGENCY BRAKE CABLES ADJUSTED TOO TIGHT

2. SERVICE BRAKES DRAGGING
HYDRAULICS
1. MAIN HYDRAULIC RELIEF PRESSURE SET TOO HIGH ON THE

CONTROL VAVLE
2. AUXILIARY PRESSURES SET TOO HIGH ON THE CONTROL
VALVE
APPLICATIONS REQUIRING VERY FAST TIMES OF THE FORKLIFT

CAN OVERHEAT THE UNIT. THIS TYPE OF OVERHEATING TAKES
A LONG PERIOD OF TIME (APPROX. THREE TO FOUR HOURS).
HIGH USAGE OF THE INCHING PEDAL IN A SHORT TIME OR HIGH
USAGE OF HYDRAULICS (INCLUDING ATTACHMENTS) CAN
ALSO CONTRIBUTE TO AN OVERHEATING PROBLEM.
PAGE 2 12/2003

БАСТРЫЙ СЕРВИС TU-Quik - Serv - 050704

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БАСТРЫЙ СЕРВИС TU-Quik - Serv - 050704

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Copyright:

Available Formats

QSBKAC001

Recommended Fluid Changes

C/P30-35B Transmission Test Ports

C/P40-60B Transmission Test Ports

C/P30-60AX/BX Series Transmission Test Ports

C/P80-100B Type T1 Transmission Test Ports

C/P80-100B Type T2 Transmission Test Ports

C/P80-100CX Indoor Transmission Pressure Ports

C/P80-100CX Outdoor T1 Transmission Pressure Ports

P150-180DX with Torqflow 2 Transmission

LPG Carburetor Adjustment

Warning Codes Without Registering Warning Codes With Registering (Cont.)

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CONTACTOR SPECS F/R CONTACT TIP KIT 8761138

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FAULT CODE 1 1A FREE WHEELING 70 / 80 AMPS

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FAULT CODE 1 F/W FREE WHEELING 85 / 95 AMPS

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SCR CONTROL CARD SETTINGS - SEE PAGES 3 & 4

CONTACTOR SPECS QUIK REF PART NUMBERS

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HYDRAULIC PUMP HYDRAULIC PUMP

FAULT CODE 1 FAULT CODE 1

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ENGINE COOLING SYSTEM SPECS

CONVERTOR STALL RPM 1850 ± 150 RPM FUEL TANK SPECS

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TRANSMISSION SPECS QUICK REF PART NUMBERS

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8760768 WITH VACUUM ADVANCE

HYDRAULIC FLUID 6 MONTHS OR EVERY 1200 HR

WHEN SEVERE CONDITIONS EXIST,

PLACE BLOCKS TO THE WHEELS AND APPLY PARKING BRAKE BEFORE

Clutch Operating Pressure and Torque Converter Pressure

Check Pressure Range

(4P) 7.2 – 11.3 kg/cm2

Stall Engine Speed

To prevent excessive oil temperature, long checking is not allowed.

4P 2,350 + 150 rpm