Bee08e1 01 PDF

BEE08E1-01
SHOP MANUAL
FD100/115-8
FD100/115/135/150E/160E-8
FD135/150E/160E-8
2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan
Printed in Japan
FD100/115-8
FD135/150E/160E-8
LIFT TRUCK MODEL SERIAL No. ENGINE

FD100/115-8 M246-7001 and up SAA6D107E-1-A
FD135/150E/160E-8 M247-7001 and up SAA6D107E-1-A
SECTION INDEX
00. FOREWORD
10. GENERAL AND SPECIFICATIONS
20. TESTING AND ADJUSTING
30. REMOVAL AND INSTALLATION
40. DISASSEMBLY AND ASSEMBLY
50. MAINTENANCE STANDARD
60. STRUCTURE AND FUNCTION
70. TROUBLESHOOTING
80. CHECK ITEMS FOR EACH EQUIPMENT
90. CONVERSION TABLE

FOREWORD
To retain the machine and engine in good working conditions for an

extended period of time and prevent troubles, appropriate operation, main-
tenance inspection, troubleshooting and repair services must be conducted.
This shop manual mainly describes, among those works, the outline,
inspection and maintenance, removal and installation, disassembly and
assembly, maintenance standards, structure and functions, troubleshoot-
ing, and the annual inspection criteria.
For the engine main body, see Engine Shop Manual 6D107E-BE1.
This shop manual is intended for providing service staff with correct product
knowledge and method of repair work to improve repair quality by correctly
judging the machine conditions. Fully understand the content of this manual
and make the most use of it.
EX50 Series 00-5

PRECAUTIONS WHEN PERFORMING THE SERVICE WORK
Always pay attention to “Safety” before starting any work — this is important.
Never attempt any work where danger to yourself or to other persons.
Whenever work requiring safety precautions are described in this manual, a flag mark
inserted, always make double sure that safety measures are taken.
Other unmarked work, should always be performed after studying and using your
common sense to prevent accidents.
DESCRIPTION OF THE SYMBOLS

The symbols described below are used in this manual for convenience and better understanding.
Symbol Item Description
Safety Special safety precautions are needed to perform the work.
Note Special technical precautions are needed to perform the work
Tightening torque Fastening parts that require specified tightening force when assembling.
Weight Weight of parts or systems
Coat Places to be coated with adhesives, etc. when assembling
00-6 EX50 Series

10. GENERAL AND SPECIFICATIONS
Specifications ..........................................................10- 2
Periodic replacement of consumable parts .............10- 6
Safety items for maintenance .................................10- 7
Standard tightening torque......................................10-16
How to use LOCTITE..............................................10-18
EX50 Series 10-1

SPECIFICATIONS GENERAL AND SPECIFICATIONS
SPECIFICATIONS
1.2 Model Manufacturer's Designation FD100-8 FD115-8 FD135-8
1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel Diesel
Characteristics
1.4 Operation Type Sitting Sitting Sitting

1.5 Rated Capacity Q kg(lb) 10000(22,000) 11500(25,000) 13500(30,000)
1.6 Load Center c mm(in) 600(24) 600(24) 600(24)
1.8 Load Distance x Front Axle Center to Fork Face mm(in) 695(27.4) 715(28.1) 740(29.1)
1.9 Wheelbase y mm(in) 2800(110.2) 2800(110.2) 3100(122.0)
2.1 Service Weight kg(lb) 12980(28,620) 14360(31,660) 15480(34,130)
2.2 Front kg(lb) 20860(45,990) 23490(51,790) 26450(58,310)
Weight
Loaded
2.2.1 Rear kg(lb) 2120(4,670) 2370(5,220) 2530(5,580)
Axle Loading
2.3 Front kg(lb) 6230(13,730) 6590(14,530) 7110(15,670)
Unloaded
2.3.1 Rear kg(lb) 6750(14,880) 7770(17,130) 8370(18,450)
3.1 Tyre Type Pneumatic Pneumatic Pneumatic
3.2 Front 9.00-20-14PR(I) 10.00-20-14PR(I) 11.00-20-14PR(I)
Tyre Size
3.3 Rear 9.00-20-14PR(I) 10.00-20-14PR(I) 11.00-20-14PR(I)
Tyres
3.5 Number of Wheels Front/Rear (x=driven) 4x/2 4x/2 4x/2

3.6 Tread, Front b10 mm(in) 1700(66.9) 1700(66.9) 1770(69.7)
3.7 Tread, Rear b11 mm(in) 1900(74.8) 1890(74.4) 1890(74.4)
4.1 Tilting Angle Forward/Backward degree 6/12 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm(in) 2890(113.8) 3160(124.4) 3170(124.8)
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm(in) 0(0.0) 0(0.0) 0(0.0)
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm(in) 3000(118) 3000(118) 3000(118)
4.5 Mast Height, Extended h4 2-stage Std. Mast mm(in) 4400(173.2) 4670(183.9) 4680(184.3)
4.7 Height, Overhead Guard h6 mm(in) 2780(109.4) 2800(110.2) 2810(110.6)
4.19 Length, with Std. Forks L1 mm(in) 5465(215.2) 5505(216.7) 5860(230.7)
Dimensions
4.20 Length, to Fork Face L2 mm(in) 4245(167.1) 4285(168.7) 4640(182.7)

4.21 Width, at Tyre b1 Single mm(in) 2280(89.8) 2310(90.9) 2410(94.9)
75x170x1220 75x185x1220 80x185x1220
4.22 Forks s/e/l Thickness x Width x Length mm(in)
(3.0x6.7x48.0) (3.0x7.3x48.0) (3.1x7.3x48.0)
4.23 Fork Carriage Class Pin Mount Pin Mount Pin Mount
4.24 Width, Fork Carriage b2 mm(in) 2140(84.3) 2140(84.3) 2210(87.0)
4.31 m1 Under Mast mm(in) 250(9.8) 250(9.8) 260(10.2)
Ground Clearance
4.32 m2 at Center of Wheelbase mm(in) 325(12.8) 345(13.6) 350(13.8)
4.33 Right Angle Stacking Aisle Ast plus load length mm(in) 4695(184.8) 4725(186.0) 5090(200.4)
4.35 Turning Radius Wa mm(in) 4000(157.5) 4010(157.9) 4350(171.3)
8.5/18/28 8.5/19/28 9/19.5/27.5
Loaded,1st/2nd/3rd km/h(mph)
(5.3/11.2/17.4) (5.3/11.8/17.4) (5.6/12.1/17.1)
5.1 Travel Speed (FWD)
9/20/32 9/21/32 9.5/21/32
Unloaded,1st/2nd/3rd km/h(mph)
(5.6/12.4/19.9) (5.6/13.0/19.9) (5.9/13.0/20.2)
5.2 Lifting Speed Loaded/Unloaded mm/s(fpm) 470/500(93/98) 430/450(85/89) 350/375(69/74)
Performance
5.3 Lowering Speed Loaded/Unloaded mm/s(fpm) 400/500(79/98) 400/500(79/98) 400/500(79/98)

5.6 Max. Drawbar Pull Loaded, 1.5km/h, 3min rating kN(Ib) 89(20,010) 87(19,610) 85(19,150)
5.8 Max. Gradeability Loaded, 1.5km/h, 3min rating % 40 34 28
Foot/Hydraulic, Foot/Hydraulic, Foot/Hydraulic,
5.10 Service Brake Operation/Control
Powered Powered Powered
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
Hydraulic Power Hydraulic Power Hydraulic Power
5.12 Steering Type
Steering Steering Steering
6.4 Battery Voltage/ Capacity at 5-hour rating V/Ah 24/80 24/80 24/80
KOMATSU KOMATSU KOMATSU
7.1 Maker Model
SAA6D107E-1 SAA6D107E-1 SAA6D107E-1
7.2 Rated Output, SAE net kW(HP) 122(164) 122(164) 122(164)
I.C Engine
7.3 Rated RPM min-1 2200 2200 2200

7.3.1 Max. Torque, SAE net Nm@min-1 575(424)@1600 575(424)@1600 575(424)@1600
No. of Cylinder/
7.4 cm3(cu.in) 6/6690(408) 6/6690(408) 6/6690(408)
Displacement
7.6 Fuel Tank Capacity l (US Gal) 260(69) 260(69) 280(74.0)
Relief Pressure for
8.2 bar(psi) 215(3,100) 215(3,100) 215(3,100)
Attachment
Others
8.2.1 Hydraulic Tank Capacity l (US Gal) 170(45) 170(45) 200(53)

8.6 Clutch Torque Converter Torque Converter Torque Converter
8.7 Transmission TORQFLOW TORQFLOW TORQFLOW
Specifications are subject to change without notice.

The performance values indicated herein represent nominal values obtained under typical operating conditions.
10-2 EX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS
1.2 Model Manufacturer's Designation FD150E-8 FD160E-8

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

1.5 Rated Capacity Q kg(lb) 15000(33,000) 16000(35,000)
1.6 Load Center c mm(in) 600(24) 600(24)
1.8 Load Distance x Front Axle Center to Fork Face mm(in) 750(29.5) 750(29.5)
1.9 Wheelbase y mm(in) 3100(122.0) 3100(122.0)
2.1 Service Weight kg(lb) 16570(36,530) 17200(37,920)
2.2 Front kg(lb) 28740(63,360) 30140(66,450)
Weight
Loaded
2.2.1 Rear kg(lb) 2830(6,240) 3060(6,750)
Axle Loading
2.3 Front kg(lb) 7210(15,900) 7170(15,810)
Unloaded
2.3.1 Rear kg(lb) 9360(20,640) 10030(22,110)
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 11.00-20-16PR(I) 12.00-20-16PR(I)
Tyre Size
3.3 Rear 11.00-20-16PR(I) 12.00-20-16PR(I)
Tyres
3.5 Number of Wheels Front/Rear (x=driven) 4x/2 4x/2

3.6 Tread, Front b10 mm(in) 1770(69.7) 1770(69.7)
3.7 Tread, Rear b11 mm(in) 1890(74.4) 1870(73.6)
4.1 Tilting Angle Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Std. Mast mm(in) 3270(128.7) 3290(129.5)
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm(in) 0(0.0) 0(0.0)
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm(in) 3000(118) 3000(118)
4.5 Mast Height, Extended h4 2-stage Std. Mast mm(in) 4780(188.2) 4800(189.0)
4.7 Height, Overhead Guard h6 mm(in) 2810(110.6) 2830(111.4)
4.19 Length, with Std. Forks L1 mm(in) 5920(233.1) 6020(237.0)
Dimensions
4.20 Length, to Fork Face L2 mm(in) 4700(185.0) 4800(189.0)

4.21 Width, at Tyre b1 Single mm(in) 2410(94.9) 2480(97.6)
85x190x1220 85x210x1220
4.22 Forks s/e/l Thickness x Width x Length mm(in)
(3.3x7.5x48.0) (3.3x8.3x48.0)
4.23 Fork Carriage Class Pin Mount Pin Mount
4.24 Width, Fork Carriage b2 mm(in) 2210(87.0) 2210(87.0)
4.31 m1 Under Mast mm(in) 250(9.8) 270(10.6)
Ground Clearance
4.32 m2 at Center of Wheelbase mm(in) 350(13.8) 370(14.6)
4.33 Right Angle Stacking Aisle Ast plus load length mm(in) 5150(202.8) 5250(206.6)
4.35 Turning Radius Wa mm(in) 4400(173.2) 4500(177.2)
9/19.5/27.5 9.5/20/28
Loaded,1st/2nd/3rd km/h(mph)
(5.6/12.1/17.1) (5.9/12.4/17.4)
5.1 Travel Speed (FWD)
9.5/21/32 10/21.5/32
Unloaded,1st/2nd/3rd km/h(mph)
(5.9/13.0/20.2) (6.2/13.4/20.5)
5.2 Lifting Speed Loaded/Unloaded mm/s(fpm) 325/350(64/69) 320/345(63/68)
Performance
5.3 Lowering Speed Loaded/Unloaded mm/s(fpm) 400/400(79/79) 400/400(79/79)

5.6 Max. Drawbar Pull Loaded, 1.5km/h, 3min rating kN(Ib) 80(18,160) 80(18,030)
5.8 Max. Gradeability Loaded, 1.5km/h, 3min rating % 25 23
Foot/Hydraulic, Foot/Hydraulic,
5.10 Service Brake Operation/Control
Powered Powered
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
Hydraulic Power Hydraulic Power
5.12 Steering Type
Steering Steering
6.4 Battery Voltage/ Capacity at 5-hour rating V/Ah 24/80 24/80
KOMATSU KOMATSU
7.1 Maker Model
SAA6D107E-1 SAA6D107E-1
7.2 Rated Output, SAE net kW(HP) 122(164) 122(164)
I.C Engine
7.3 Rated RPM min-1 2200 2200

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

8.6 Clutch Torque Converter Torque Converter
8.7 Transmission TORQFLOW TORQFLOW
EX50 Series 10-3

SPECIFICATIONS GENERAL AND SPECIFICATIONS
10-4 EX50 Series

GENERAL AND SPECIFICATIONS SPECIFICATIONS
EX50 Series 10-5

PERIODIC REPLACEMENT OF CONSUMABLE PARTS GENERAL AND SPECIFICATIONS
PERIODIC REPLACEMENT OF CONSUMABLE PARTS

For operation safety, never fail to perform periodic main-
tenance or make periodic replacement of the consum-
able 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 appar-
ent 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 converter) 2
13 Engine high-pressure piping clamp
Every 8000 hours
14 Fuel spray prevention cap
10-6 EX50 Series

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
SAFETY ITEMS FOR MAINTENANCE

FOR SAFETY OPERATION
USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE
• 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 is very dangerous.
MAINTENANCE LOCATION
• 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 FOR INSPECTION AND MAINTENANCE
• To be prepared in the event of 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.
• Do not run the engine unless it is necessary.
• Place the directional lever, speed lever, and work equipment control levers in neutral.
PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE
• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean
the lift truck before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.
• Wear suitable clothes for the job.
• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the
job.
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body
caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the
forks and mast from dropping.
• When carrying out job with another worker, decide who is the leader and carry out the job in accor-
dance with instructions from that person.
• After repairing, make sure that the trouble has been corrected by performing a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not
been fully corrected or that defective parts have not been removed.
EX50 Series 10-7

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS
WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS
• Avoid loose clothing, jewelry, and loose long hear.

They can catch control 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.
USE SUITABLE TOOLS
• Always use tools that are suited for inspection and

maintenance.
It is extremely dangerous to use broken tools or tools
designed for another purpose.
REPLACE SAFETY CRITICAL PARTS PERIODICALLY
• Even if no abnormality is found, always replace safety critical parts periodically.

As time passes, these parts deteriorate and may cause fire of failure in the work equipment system.
• However, if these parts show any abnormality before the replacement interval has passed, they
should be repaired or replaced immediately.
PRECAUTIONS WITH HIGH TEMPERATURE COOLANT
• Immediately after using the lift truck, the engine coolant is at high temperature and high pressure. Do
not remove the radiator cap under these conditions.
Hot water may spurt out and cause burns.
• When removing the radiator cap, turn it slowly to
release the internal pressure.
• When checking the coolant level, stop the engine and
wait for the engine and radiator to cool down before
checking. For lift trucks equipped with a subtank or
reservoir, check the level in the subtank.
• When adding water on lift trucks equipped with a sub-
tank, add the water to the subtank.
10-8 EX50 Series

PROHIBIT WELDING OF FUEL TANK
• Never weld the fuel tank as it may explode.
PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL
• Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the
filter when the oil is hot. Hot oil may spurt out and cause burns.
• When carrying out inspection and maintenance,
wait for the oil temperature to go down, and carry
out the operation in the order given in this manual.
• Do not forget that the work equipment circuits are
always under pressure. Do not add oil, drain oil, or
carry out maintenance or inspection before com-
pletely releasing the internal pressure.
• If oil is leaking under high pressure from small
holes, it is dangerous if the jet of high–pressure oil
hits your skin or eyes. Always wear safety glasses
and thick gloves, and use a piece of cardboard or
a sheet of plywood to check for oil leakage.
• Release the internal pressure before checking the
accumulator piping.
• If you are hit by a jet of high pressure oil, consult a
doctor immediately.
• When removing a mast or a lift cylinder, always
depressurize the hydraulic piping.
1) Stop the forklift truck. Lower the fork to the ground.
2) Stop the engine.
3) Turn the starting switch to the ACC position.
4) Sit on the seat. Operate the lift lever and tilt lever forward and backward 4 to 5 times each to
depressurize the hydraulic piping.
No depressurization can be effected by lever operation without sitting on the seat.
EX50 Series 10-9

ROTATING FAN AND BELT
• It is extremely dangerous if you or any tool

touches or gets caught in the fan or fan belt when
the fan is rotating. Never touch the fan when it is
rotating.
• Always stop the engine before inspecting rotating
parts.
• When inspecting the areas around rotating parts,
do not allow anything to come close which may
get caught.
BE CAREFUL NOT TO GET CAUGHT OR FALL
• Never put your hands or feet into the mast structure.

There is danger that you will get caught in moving parts
and be serious injured.
• Do not use the mast as a ladder. If you slip, there is dan-
ger that you will fall.
10-10 EX50 Series

CHECKING AND INFLATING TYRES
• If the tyre inflation pressure is low, it will affect truck stability. However, do not inflate the tyres immedi-
ately. The inflation pressure may have gone down because of damage to the rim. If the rim is dam-
aged or cracked and the tyres are inflated, there is danger that the rim will break when the tyre is
under high pressure, and this may cause personal injury or death.
• For safety, when checking tyre pressure, place your body in front of the tread face of the tyre. Do not
check from the side face of the tyre.
• Suitable qualifications are needed for tyre inflation work.
Always have the work carried out by properly qualified
personnel.
• The tyre inflation pressure on a forklift truck is several
times higher than the pressure on an automobile.
• When the tyres 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 TYRES
Have a specialist disassemble and assemble the tyre.

Since the tyre inflation pressure is very high, handle the
tyre with extreme care.
• Release all the inflation pressure and then remove the
tyre.
Remove hub nuts (1) and remove the tyre from the
machine.
• After replacing the tyre, carry out a test run and then
check the mounting nuts for looseness again. If the nuts
are not tightened sufficiently, retighten them to the specified torque.
• Tightening torque: See "Chapter 20, Testing and adjusting, Service data".
EX50 Series 10-11

JACKING UP LIFT TRUCK (when checking or replacing tyres)
• Do not go under the forklift truck when it is jacked up.

• Check the following before jacking up the lift truck.
1) Check that there is no one on the lift truck.
2) Check that there is no load on the forks.
• When jacking up, stop when the tyres come off the
ground surface. Put blocks under both sides of the
frame to prevent the lift truck from coming down.
• Put blocks under any tyres contacting the ground
to prevent the lift truck from moving.
LIFTING LIFT TRUCK (when checking tyres)
• Lift truck slinging work should be carried out by a

qualified person who has completed a course in
correct lifting methods.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes
have ample strength and are not damaged.
• Block the tyres contacting the ground to prevent
the lift truck from moving.
• Insert blocks to prevent the truck from coming
down.
• Do not go under the lift truck during the lifting
operation.
• If the specified lifting point is the counterweight,
check that the 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.
10-12 EX50 Series

BATTERY HAZARD PREVENTION
• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you
spill electrolyte on yourself, immediately flush the area with a large quantity of water.
• Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes,
flush them immediately with large quantities of water and consult a doctor at once.
• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite
or vegetable oil. Call a doctor or poison prevention center immediately.
• When working with batteries, ALWAYS wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a
small spark or flame. Do not smoke or create any spark near the battery.
• Before working with batteries, stop the engine and turn the starting switch to the OFF position.
• When removing the battery, remove the cable from
the negative terminal first. When installing the
battery, install the cable to the positive terminal
first.
• Avoid short–circuiting the battery terminals through
accidental contact with tools or other metal objects
across the terminals.Tighten the battery terminals
securely. Loose terminals can generate sparks and
lead to an explosion.
• When removing or installing the battery, confirm
which is the positive terminal and negative ter-
minal. Be careful not to connect the cables to the
opposite terminals.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps
tightened.
DO NOT PUT METAL OBJECTS ON TOP OF BATTERY
• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit
and start a fire.
EX50 Series 10-13

PRECAUTIONS WHEN CHARGING
When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical
change. To prevent the danger of gas explosion, always do as follows.
• Carry out the charging operation in a well–ventilated place.
• Do not smoke or allow any flame.
• Start the charging operation when the temperature of the battery electrolyte is below 35°C (95 ). (If
the temperature goes above 50°C (122°F) during the charging operation, wait for it to go down below
35°C (95°F) before starting charging operation again.)
• When using a battery charger to charge the battery, take the battery caps off.
STARTING WITH BOOSTER CABLES
• ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.
• When starting using the battery of another lift truck, do not allow the two lift trucks to touch. For details
of the order of operations when using a booster cable.
• Stop the engine before connecting the cables.
• e extremely careful not to let the cables get caught in the fan or fan belt.
• Connect the batteries in parallel: positive to positive and negative to negative. Never connect positive
to negative.
DO NOT PUSH START
• Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and
operate unexpectedly.
10-14 EX50 Series

HANDLING ANTIFREEZE
• Antifreeze can be a flammable. Keep away from flame when handling.

• Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water,
vomit it out, and get medical attention immediately. Follow safety precautions on container.
WASTE MATERIALS
• Comply with appropriate laws and regulations when

disposing of hazardous objects such as oil, fuel, cool-
ant, solvent, filters, batteries and CFCs (refrigerant).
EX50 Series 10-15

STANDARD TIGHTENING TORQUE GENERAL AND SPECIFICATIONS
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
10-16 EX50 Series

GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE
Elbows, nipples and unions
Width across flats B (mm) 22 30 36
Width D (mm) 19 22 30
Tightening 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
19.6–29.4 23.5–68.6 58.8–98.1 108–167 147–206
Tightening torque Nm {kgm} {2–3} {3–7} {6–10} {11–17} {15–21}
EX50 Series 10-17

HOW TO USE LOCTITE GENERAL AND SPECIFICATIONS
HOW TO USE LOCTITE

Procedure for using LOCTITE
4. Assembly
Male side After applying LOCTITE, tighten the screw or fit the
shaft to the hole as usual. (When using LOCTITE for
Degreasing Air drying
structures or LOCTITE of instant glue type, press the
Female
side mating parts lightly (about 49 kPa {0.5 kgf/cm2}).
Applying Removal of parts

Leaving Assembly When screws and shafts are secured with LOCTITE,
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
1. Degreasing and cleaning
when it is removed, heat it (to 200 - 250°C) with a
1) Clean the parts in trichloroethylene, acetone,
soldering iron, gas torch, etc., and you can remove it
ether, alkaline solution, etc. which are highly vol-
easily. It is generally difficult to dissolve LOCTITE in
atile.
chemical solutions.
2) Degrease the parts as perfectly as possible.
3) Since gasoline, light oil, kerosene, etc. are not
When assembling again
highly volatile, they are not recommended. If it is
1) If a LOCTITE film on threads is broken, it is left as
obliged to use them, dry them completely.
white powder on the threads. In this case, you can
4) If the mating parts are made of thermosetting
apply LOCTITE again to the threads without remov-
resin, treat them with LOQUICK PRIMER after
ing the white powder.
degreasing them.
2) If shafts or flanges secured with LOCTITE are dis-
connected, LOCTITE remaining on them may need
2. Air drying
to be removed to maintain dimensional accuracy.
1) Wait until the cleaning fluid dries out.
You can remove the remaining LOCTITE easily,
2) If the parts are treated with LOQUICK PRIMER,
however, with a wire brush, etc.
do not wipe them but dry them in air for 5 - 10
3) If plates secured with LOCTITE need to be assem-
minutes. (If LOCTITE is used before LOQUICK
bled again after they are separated, be sure to
PRIMER dries out, its effect is lowered.)
remove all the hardened LOCTITE and roughen the
mating surfaces with sandpaper.
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads or the
shaft and hole to be fitted by amount to fill the clear-
ance 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
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
10-18 EX50 Series

20. TESTING AND ADJUSTING
Service data .............................................................20- 2

How to depressurize hydraulic system ....................20- 4
Engine oil/engine oil filter replacement ....................20- 5
Replacement of fuel filters .......................................20- 6
Cleaning inside the cooling system..........................20- 9
Air cleaner................................................................20-10
Adjusting valve clearance ........................................20-11
Checking compression pressure..............................20-11
Tightening torque for the cylinder head
mounting bolts ................................................20-11
Differential case .......................................................20-12
TORQFLOW transmission case...............................20-13
Hydraulic tank ..........................................................20-14
Brake cooling oil.......................................................20-15
Measuring hydraulic draft/tilt of cylinder...................20-16
Adjusting brake/inching pedal operation ..................20-17
Accumulator for brake..............................................20-19
Adjusting accelerator pedal operation......................20-27
Adjusting parking brake ...........................................20-27
Bleeding air ..............................................................20-28
Checking wear of brake disc....................................20-30
Steering axle ............................................................20-31
Inspecting the air conditioner (option)......................20-32
Battery......................................................................20-34
Oil and greasing chart..............................................20-35
Lubricant list.............................................................20-36
EX50 Series 20-1

SERVICE DATA TESTING AND ADJUSTING
SERVICE DATA
Component Inspection item Unit FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8
Engine model – KOMATSU SAA6D107E-1-A
Idling speed rpm 700–750
Max. speed rpm 2,375–2,475

Engine proper
Torque converter stall speed rpm 2,000
MPa
Compression Min. 24 {Min. 246} / 250–280
{kgf/cm²}/ rpm
Engine
Capacity of engine oil 20.3

Lubricating and
cooling system
Capacity of engine coolant 12.8 (Exhaust capacity of radiator)
Injection order – 1–5–3–6–2–4

Fuel system
Capacity of fuel tank 260 280
Intake mm 0.25 (in cold state)

Intake and
Valve clearance
exhaust system
Exhaust mm 0.51 (in cold state)
Specific gravity of battery elec-

Electric system – Min. 1.24 (20°C)
trolyte
Stall speed rpm 2,000
MPa
Torque converter Inlet oil pressure {kgf/cm²} 1.2–1.5 {12–15}
MPa
Outlet oil pressure {kgf/cm²} 0.6–0.73 {6–7.4}
Power train
MPa
Relief pressure {kgf/cm²} 1.96 {20}
Clutch actuating pressure MPa 1.35–1.65 {13–16}

{kgf/cm²}
TORQFLOW
transmission
Lubrication oil pressure MPa 0.6–0.73 {6–7.4}
{kgf/cm²}
Capacity of oil 37–40

(including capacity of torque converter, oil cooler and oil pipes)
Differential Capacity of oil 20
kPa 735 690 660 760 690

Front wheel
{kgf/cm²} {7.5} {7.0} {6.75} {7.75} {7.0}
Tyre inflation
Travel device
Tyre
pressure
Rear wheel kPa 735 690 660 760 690
{kgf/cm²} {7.5} {7.0} {6.75} {7.75} {7.0}
Front wheel Nm {kgfm} 441–539 {45–55}

Tightening
Hub nuts torque Rear wheel Nm {kgfm} 441–539 {45–55}
20-2 EX50 Series

TESTING AND ADJUSTING SERVICE DATA
Component Check item Unit FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8
Steering wheel Play mm 30–60
Rear axle Turning radius mm 4,000 4,010 4,350 4,400 4,500
Stroke mm 83
Inching pedal
Interlocking stroke mm 50
Steering and braking device
Play mm 1–4
Brake pedal
Stroke mm 76
Cooling oil tank (Wet disc type) 14.5
Operating effort of parking Nm Min. 196

brake lever {kgfm} {Min 20}
Gas pressure of brake accu- MPa 4.9

Brake mulator (Hydraulic drum type) {kgf/cm²} {50}
Gas pressure of brake accu- MPa 3.4

mulator (Wet disc type) {kgf/cm²} {35}
Tightening torque of back plate Nm 147–245 147–196

mounting bolt {kgfm} {15–25} {15–20}
Thickness of base mm Min. 70 Min. 75 Min. 80
Fork Height difference mm 20

Material–handling device
Opening at tip mm 50
Chain Length of 17 links mm Max. 660 Max. 770
Hydraulic drift mm/15 min 50

Cylinder
Hydraulic forward tilt mm/15 min 40
MPa 21.6
Relief pressure
Hydraulic {kgf/cm2} {220}
system
Quantity of oil 170 200
EX50 Series 20-3

HOW TO DEPRESSURIZE HYDRAULIC SYSTEM TESTING AND ADJUSTING
HOW TO DEPRESSURIZE HYDRAULIC SYSTEM

CAUTION
When depressurizing the hydraulic system, always

seat yourself on the operator seat before operating
the lever. Or, the shut valve of the hydraulic piping
will be closed, disabling depressurization.
HOW TO DEPRESSURIZE
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. Operate the lift lever and tilt lever for-
ward and backward 4 to 5 times each to depressur-
ize the hydraulic system.
20-4 EX50 Series

TESTING AND ADJUSTING ENGINE OIL/ENGINE OIL FILTER REPLACEMENT
ENGINE OIL/ENGINE OIL FILTER REPLACEMENT
CAUTION
Service the engine always after it is stopped completely and the temperature fully lowered.
CHANGE ENGINE OIL REPLACE OF ENGINE OIL FILTER

1. Remove the drain plug and drain the oil. After drain- 1. Remove the filter cartridge with a filter wrench.
ing the all oil, tighten the drain plug. 2. Clean the filter stand. Apply engine oil to the seal
2. Supply engine oil by the specified quantity. and threads of a new cartridge, then install the latter.
3. Check the oil level with the oil level gauge.
Oil capacity for replacement:
20.3 l (5.36 US gal, 4.47 UK gal) NOTICE
After installing the cartridge, start the engine and

check the filter mounting face for oil leakage.
Oil gauge
Oil filler port
Filters
Drain plug
EX50 Series 20-5

REPLACEMENT OF FUEL FILTERS TESTING AND ADJUSTING
REPLACEMENT OF FUEL FILTERS

The fuel filters of this truck consist of pre-filter cartridge
and main filter cartridge.
CAUTION
• 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.
NOTICE
• Special filter of high-efficiency filtration property is adopted for the genuine Komatsu Utility fuel filter car-
tridges.
Always use genuine Komatsu Utility parts for replacement.
• The common rail fuel injection system adopted for the engine is configured with components of higher accu-
racy 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 mat-
ters than before. Attached dirt, if any, must be fully washed off using engine oil.
REPLACEMENT OF 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).
Water separator
3. Apply the filter wrench to cartridge (3) to remove it by (*REF)
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 func-
tion for the inferior fuel.
20-6 EX50 Series

TESTING AND ADJUSTING REPLACEMENT OF FUEL FILTERS
NOTICE
• 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 car-
tridge.
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.
• If over-tightened, the filter cartridge may cause
fuel leakage because of damaged packing. Con-
versely, 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.
9. After replacing the fuel main filter cartridge (every
1000 hours), always bleed the air from the cartridge.
(See the section of BLEEDING OF AIR FROM
FUEL PRE-FILTER).
10. Start the engine. Check the filter-sealed surface for
fuel leakage. Keep operating the engine for about 10
minutes at low idling speed.
BLEEDING OF 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.
Operate it forward and backward.
• The plug on the side of the fuel pre-filter head
need not to be removed.
• Keep operating the pump until the knob (2) starts
meeting resistance.
3. When bleeding of the air is completed, push back
and tighten the feed pump knob (2).
EX50 Series 20-7

REPLACEMENT OF FUEL FILTERS TESTING AND ADJUSTING
REPLACEMENT OF 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.
NOTICE
• 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 car-

tridge.
5. Remove the filter cartridge cap (A) and mount it to
the filter holder.
6. To mount the cap, tighten it 3/4 turn after the packing
surface makes contact with the sealed surface of the
filter holder.
• If over-tightened, the filter cartridge may cause
fuel leakage because of damaged packing. Con-
versely, 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.
7. After replacing the fuel main filter cartridge, always
bleed the air from the cartridge. (See the section of
BLEEDING OF AIR FROM FUEL PRE-FILTER).
8. After completing the bleeding of the air, start the
engine, and check the filter sealed surface for oil
leakage. If oil leakage is detected, check the filter
cartridge and give it extra tightening. If oil leakage
persists, remove the filter cartridge following the
steps 1 to 2 and check the packing surface for any
damage or biting of foreign matters. If any damage or
foreign matters detected, replace the cartridge with a
new part and repeat the steps 3 to 7.
BLEEDING AIR FROM FUEL MAIN FILTER

Bleed the air by seeing the section of BLEEDING OF AIR
FROM FUEL PRE-FILTER.
20-8 EX50 Series

TESTING AND ADJUSTING CLEANING INSIDE THE COOLING SYSTEM
CLEANING INSIDE THE COOLING SYSTEM

CAUTION
• 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.
CLEANING THE RADIATOR

Park the machine on a level ground before cleaning.
1. Drain coolant by opening the drain levers at the bot-
tom of the radiator and the engine cylinder block.
2. Close the drain levers. Apply water (supply water)
and the radiator detergent from the water filler port.
Operate the engine at low idling speed for about 15
minutes.
3. Stop the engine. Drain the water from the drain port.
Keep feeding supply 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.
4. Stop the engine. Drain water from the drain port.
Close the drain lever and fill the radiator with supply NOTICE
water and super coolant.
Incomplete bleeding of the air upon replacing the coolant
(See the section of LUBRICANT LIST.)
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.
EX50 Series 20-9

AIR CLEANER TESTING AND ADJUSTING
AIR CLEANER
CAUTION
• 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.
NOTICE
• If attached with oil, grease or carbon, apply spe-

cial cleaner for the element according to the
descriptions on the cleaner.
• Clean or replace the cleaner earlier when under O-ring
adverse working environment or conditions.
CLEANING
1. Remove element (3). Blow the element from inside
to outside with dry, compressed air of 0.68 MPa {7
kgf/cm²} all around the element.
2. Install cleaned element (3).
CHECKING
Visually check the element for any damage.
REPLACING THE 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.
20-10 EX50 Series

ADJUSTING VALVE CLEARANCE, CHECKING COMPRESSION PRESSURE,
TESTING AND ADJUSTING TIGHTENING TORQUE FOR THE CYLINDER HEAD MOUNTING BOLTS
ADJUSTING VALVE CLEARANCE

For how to adjust valve clearance, see Engine Shop Manual 6D107E-BE1.
CHECKING COMPRESSION PRESSURE

For how to check the compression pressure, see Engine Shop Manual 6D107E-BE1.
TIGHTENING TORQUE FOR THE CYLINDER HEAD MOUNTING BOLTS

For the tightening torque for the cylinder head mounting bolts, see Engine Shop Manual 6D107E-BE1.
EX50 Series 20-11

DIFFERENTIAL CASE TESTING AND ADJUSTING
DIFFERENTIAL CASE
CAUTION
Oil is in high temperature immediately after the engine
operation.
Start working on it after the temperature is lowered.
OIL LEVEL CHECKING

1. Remove the level plug to check. If the oil is close to
the lower line of the plug hole, the level is normal.
If in short, remove the oil filler port plug to replenish
oil.
OIL REPLACEMENT
1. Remove the oil filler port plug first. Then remove the
drain plug to drain oil.
2. After draining, tighten the drain plug and fill oil to the
specified level through the oil filler port.
3. Check the oil level after filling oil.
20 l (5.28 US gal, 4.40 UK gal)
NOTICE
Always use Komatsu Utility-designated oil for the

gear.
20-12 EX50 Series

TESTING AND ADJUSTING TORQFLOW TRANSMISSION CASE
TORQFLOW TRANSMISSION CASE

CAUTION
Oil is in high temperature immediately after the engine
operation.
Start working on it after the temperature is lowered.
OIL LEVEL CHECKING OIL REPLACEMENT AND STRAINER

1. Open the inspection window of the floor plate to CLEANING
check the level with the oil gauge. 1. Remove the drain plug to drain oil. Tighten the drain
2. If the level is low, remove the oil filler port cap and plug after draining oil.
replenish oil. 2. Remove the pipe to remove the strainer. Wash it with
cleaning oil.
3. After cleaning, blow the strainer with the air from
inside to outside. Dry it completely before installation.
4. Fill oil from the oil filler port to the specified level.
5. Check the oil level after filling oil.
40 l (10.57 US gal, 8.80 UK gal)
NOTICE
Always use Komatsu Utility-designated oil for the

engine. (See the section of LUBRICANT LIST.)
Oil filler cap Oil gauge
Correct
Drain plug range
Strainer
EX50 Series 20-13

HYDRAULIC TANK TESTING AND ADJUSTING
HYDRAULIC TANK
REPLACEMENT OF OIL IN THE HYDRAULIC TANK
CLEANING THE HYDRAULIC TANK STRAINER
CLEANING INSIDE THE HYDRAULIC TANK
REPLACEMENT OF HYDRAULIC OIL LINE FILTER CARTRIDGE
CAUTION
Oil is in high temperature immediately after the opera-
tion.
Do not replace oil immediately after operation.
Replace after the oil is cooled.
1. After draining oil from the drain plug at the bottom of

the oil tank, remove the cover to remove the strainer.
Wash it with cleaning oil.
2. Install the drain plug after cleaning inside of the tank.
3. After cleaning, blow the strainer with the air from
inside to outside. Install the strainer after drying it
completely. Install the cover.
4. Remove the line filter cartridge. Install a new car-
tridge.
5. Fill the hydraulic tank to the specified level through
the hydraulic oil filler port. Check the level through
the inspection window.
OIL CAPACITY FOR REPLACEMENT:
FD100/115 170 l (44.9 US gal, 37.4 UK gal)
FD135/150E/160E 200 l (52.84 US gal, 44.0 UK gal)
6. Start the engine. Operate the cylinders (lifting, tilting

and power steering) to the stroke end 5 to 6 times,
then bleed the air.
NOTICE
Always use Komatsu Utility-designated hydraulic oil.
20-14 EX50 Series

TESTING AND ADJUSTING BRAKE COOLING OIL
BRAKE COOLING OIL

(WET DISC BRAKE TYPE)
REPLACEMENT
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)
5. Start the engine.

The brake chamber is filled with cooling oil from the
tank. The oil level in the tank drops.
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. Hold it running at low idling

speed for 3 minutes or over and then stop the
engine.
8. Check if the oil is up to the specified level. Replenish
it, if necessary.
NOTICE
Always use Komatsu Utility-designated oil for cool-

ing the brake.
EX50 Series 20-15

MEASURING HYDRAULIC DRAFT / TILT OF CYLINDER TESTING AND ADJUSTING
MEASURING HYDRAULIC DRAFT / TILT OF CYLINDER

CAUTION
1. When measuring, never let anyone go under the load.
2. Do not put your feet on the mast stays or dashboard and climb up when measuring the hydraulic drift of the lift cylin-
der. 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.
3. 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.
4. 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.
METHOD OF MEASURING
1. Stop the lift truck 500 mm in front of the platform.
2. Operate the lift and tilt repeatedly to set the hydraulic Set must
oil temperature to 50° (122 ). perpendicular
3. Set the rated load on the forks and secure it to the

fork carriage with wire.
Approx
1500 mm
4. Raise the load approx. 1500 mm (59 in) and set the
mast perpendicular.
[Hydraulic draft of lift cylinder]

5. Wait for 3 minutes, then place a ruler against the lift
cylinder piston rod and make a mark.
6. Measure the hydraulic drift over the next 15 minutes.
[Hydraulic draft of tilt cylinder]

7. Wait for 3 minutes, then place a ruler against the tilt
cylinder piston rod and make a mark.
8. Measure the hydraulic drift over the next 15 minutes.
20-16 EX50 Series

TESTING AND ADJUSTING ADJUSTING BRAKE/INCHING PEDAL OPERATION
ADJUSTING BRAKE/INCHING PEDAL OPERATION

(HYDRAULIC DRUM BRAKE TYPE)
BRAKE PEDAL
1. Pedal height (from floor plate)
Adjust with stopper bolt (1). Pedal play 1- 4 mm
Pedal height (h1) 231 mm (9.1 in) 1

h1
2. Pedal play
After adjusting the brake pedal height, adjust the
cable length so that the play of the brake pedal 2
becomes 1 to 4mm. (The play at the end of cable is 0
to 0.5mm.)
But, do not pull the linkage. (The connection pins at
both ends of cable should be smoothly moved by
hand.)
Cable 0 - 0.5 mm
Pedal play 1–4 mm (0.04–0.16 in) end
INCHING PEDAL
Adjust with stopper bolt (3).
Pedal height (h2) 231 mm (9.1 in)
2. Protrusion of inching spool

5 3 4
After adjusting the pedal height, adjust with linkage h2
(4).
Protrusion (a) 24.5 mm (0.97 in)
3. Interconnected stroke
Adjust with bolt (5) so that the inching pedal and
brake pedal are interconnected for the travel shown
below when the inching pedal is depressed.
Interconnected stroke 50 mm (1.97 in)
Detail (a)
50 mm
The depressed inching
pedal travels at a distance
as shown until the brake
pedal starts to move.
EX50 Series 20-17

ADJUSTING BRAKE/INCHING PEDAL OPERATION TESTING AND ADJUSTING
ADJUSTING BRAKE/INCHING PEDAL OPERATION

BRAKE PEDAL
Adjust with stopper bolt (1).
2. Play of valve clearance and the pedal

After adjusting the pedal height, use bolt (2) to press
the valve spool in for 1 to 1.5 mm for adjusting the
play.
Play of the pedal 2 – 6 mm (0.08 – 0.24 in)
INCHING PEDAL
Adjust with stopper bolt (3)
2. Protrusion of inching spool

After adjusting the pedal height, adjust with linkage
(4).
3. Interconnected stroke * The dimension with which the

Adjust with bolt (5) so that the inching pedal and brake pedal starts moving as the
inching pedal is stepped on.
brake pedal are interconnected for the travel shown
below when the inching pedal is depressed.
Interconnected 28.5 – 33.5 mm

stroke (b) (1.12 – 1.32 in)
20-18 EX50 Series

TESTING AND ADJUSTING ACCUMLATOR FOR BRAKE
ACCUMLATOR FOR BRAKE

CAUTION
• 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-pres-
sure gas is required for charging the nitrogen gas.
PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS

1. Remove accumulator (1) shown in the following figure.
Brake valve
EX50 Series 20-19

ACCUMLATOR FOR BRAKE TESTING AND ADJUSTING
2. Charging accumulator with nitrogen gas How to connect accumulator and nitrogen gas cylinder
1) Since the thread of gas valve (25) of the accu-
mulator is TV8, install the joint assembly to the
charging assembly.
2) Turn handle (23) of charging assembly (00) to
the left until it stops.
3) Turn handle (24) of the bleed plug to the left to
open the plug.
4) Remove the cap of the accumulator and install
charging assembly (21) to the gas valve of the
accumulator.
5) Connect nitrogen gas cylinder (2) and charging
assembly (21) by hose assembly (29).
a There are 2 types of threads of gas cylinders, 1. Accumulator
W22-14 thread (mail screw, type A) and W23-
2. Nitrogen gas cylinder
14 thread (female screw, type B). When using
3. Charging assembly
type-B gas cylinder, use the attached reducer
4. Hose assembly
(30).
6) Open the valve of nitrogen gas cylinder (2) a lit-
tle 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.
Then, the gas comes out of handle (24). At this
time, turn the handle to the right to prevent the
gas from escaping.
7) Turn handle (23) of charging assembly to the
right to lead the nitrogen gas to the accumulator.
At this time, stop handle (23) when you feel a
light reaction so that the gas valve piston will not
be damaged.
a If the handle is turned too strongly, the core
will be broken. Take care.
8) Open the gas cylinder valve gradually further to
charge the accumulator with the nitrogen gas.
While doing so, close the gas cylinder valve
sometimes and read pressure gauge (28) of the
charging assembly when it is stabilized.
Charge gas pressure: 4.9 MPa ± 0.2 {50 ± 2 kg/
cm²}
9) After the accumulator is charged to the specified
pressure, close the valve of nitrogen gas cylin-
der securely.
If the pressure in the accumulator is too high,
turn handle (24) to the left and release the nitro-
gen gas gradually.
10) Turn handle (23) to the left until it stops, and
then turn handle (24) to the left to open it and
discharge the gas remaining in the charging
assembly and hose.
11) Remove charging assembly (21) from the accu-
mulator.
12) Apply water or soap water to the gas valve of the
accumulator to check that the gas is not leaking,
and then install the cap.
3. Install the accumulator to the lift truck.
20-20 EX50 Series

Charging Ass'y
No. Part No. Part name Q’ty Remarks

00 3EE-38-21700 Charging Ass’y 1
21 3EE-38-21710 • Charging Ass’y 1
22 3EE-38-21720 • • Charging valve, Body 1
23 3EE-38-21730 • • Adjust screw, handle 1
24 3EE-38-21740 • • Bleed plug, handle 1
25 3EE-38-21750 • • Gas, Valve 1
26 3EE-38-21760 • • Nut 1
27 3EE-38-21770 • • Joint 1
28 3EE-38-21780 • • Pressure, Gauge 1 0 – 15 MPa {0 – 153 kgf/cm²}
29 3EE-38-21790 • Hose Ass’y 1 L = 4,000 mm
30 3EE-38-21810 • Reducer 1 JIS N2 gas cylinder
Joint Ass'y

3EE-38-21900 Joint Ass’y 1
31 • Joint 1
32 • Gasket 1
33 • Seal washer 1
EX50 Series 20-21

PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS

1. Remove accumulator (1) shown in the following figure.
Accumulator charge valve
2. Charging accumulator with nitrogen gas How to connect accumulator and nitrogen gas cylinder
1) Since the thread of gas valve (25) of the accu-
mulator is TV8, install the joint assembly to the
charging assembly.
2) Turn handle (23) of charging assembly (00) to
the left until it stops.
3) Turn handle (24) of the bleed plug to the left to
open the plug.
4) Remove the cap of the accumulator and install
charging assembly (21) to the gas valve of the
accumulator.
5) Connect nitrogen gas cylinder (2) and charging
assembly (21) by hose assembly (29).
a There are 2 types of threads of gas cylinders, 1. Accumulator
W22-14 thread (mail screw, type A) and W23- 2. Nitrogen gas cylinder
14 thread (female screw, type B). When using 3. Charging assembly
type-B gas cylinder, use the attached reducer 4. Hose assembly
(30).
20-22 EX50 Series

6) Open the valve of nitrogen gas cylinder (2) a lit-

tle 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.
Then, the gas comes out of handle (24). At this
time, turn the handle to the right to prevent the
gas from escaping.
7) Turn handle (23) of charging assembly to the
right to lead the nitrogen gas to the accumulator.
At this time, stop handle (23) when you feel a
light reaction so that the gas valve piston will not
be damaged.
a If the handle is turned too strongly, the core
will be broken. Take care.
8) Open the gas cylinder valve gradually further to
charge the accumulator with the nitrogen gas.
While doing so, close the gas cylinder valve
sometimes and read pressure gauge (28) of the
charging assembly when it is stabilized.
Charge gas pressure: 3.4 MPa ± 0.2 {35 ± 2 kg/
cm²}
9) After the accumulator is charged to the specified
pressure, close the valve of nitrogen gas cylin-
der securely.
If the pressure in the accumulator is too high,
turn handle (24) to the left and release the nitro-
gen gas gradually.
10) Turn handle (23) to the left until it stops, and
then turn handle (24) to the left to open it and
discharge the gas remaining in the charging
assembly and hose.
11) Remove charging assembly (21) from the accu-
mulator.
12) Apply water or soap water to the gas valve of the
accumulator to check that the gas is not leaking,
and then install the cap.
3. Install the accumulator to the lift truck.
EX50 Series 20-23

Charging Ass'y

00 3EE-38-21700 Charging Ass’y 1
21 3EE-38-21710 • Charging Ass’y 1
22 3EE-38-21720 • • Charging valve, Body 1
23 3EE-38-21730 • • Adjust screw, handle 1
24 3EE-38-21740 • • Bleed plug, handle 1
25 3EE-38-21750 • • Gas, Valve 1
26 3EE-38-21760 • • Nut 1
27 3EE-38-21770 • • Joint 1
28 3EE-38-21780 • • Pressure, Gauge 1 0 – 15 MPa {0 – 153 kgf/cm²}
29 3EE-38-21790 • Hose Ass’y 1 L = 4,000 mm
30 3EE-38-21810 • Reducer 1 JIS N2 gas cylinder
Joint Ass'y

3EE-38-21900 Joint Ass’y 1
31 • Joint 1
32 • Gasket 1
33 • Seal washer 1
20-24 EX50 Series

MEASURING ACCUMULATOR CHARGE VALVE PRESSURE

MEASUREMENT
k With the engine stopped, step on the brake pedal
for 100 times or more to depressurize the accu-
mulator circuit.
1. Remove the floor cover.
2. Remove plug (1) from the accumulator charge valve.
3. Install the measuring nipple (PT1/8). Install the oil
pressure gauge (39.2 MPa {400 kgf/cm²})
4. Measure the accumulator charge cut-in pressure.
a Start the engine and run it at low idling speed.
Measure the oil pressure when the sound of
brake oil pressure-warning buzzer ends.
Cut-in +0.49 +5
5.88 0 MPa {60 0 kgf/cm²}
pressure
5. Measure the accumulator charge cut-out pressure.

a Measure the oil pressure when thus far rising oil
pressure gauge indicator reading suddenly
changes to falling after cutting the accumulator
charge in.
Cut-out +0.98 +10

9.8 0 MPa {100 0 kgf/cm²}
pressure
6. When the work is completed, remove the equipment

used and restore the original conditions.
EX50 Series 20-25

ADJUSTING ACCUMULATOR CHARGE VALVE PRESSURE

a Adjusting the accumulator charge cut-out pres-
sure also changes the cut-in pressure in propor-
tion to the bubble area ratio.
1. Loosen lock nut (5) of cut-out valve (4). Adjust by
turning adjust screw (6).
a Adjust screw
Turn clockwise Pressure rises
Turn counterclockwise Pressure lowers
a Adjustment per turn of the adjust screw

: 5.59 MPa {57 kgf/cm²}
9.8 – 11.8 Nm {1.0 – 1.2 kgm}
2. After completing adjustment, measure the accumula-

tor cut-in pressure and cut-out pressure again.
20-26 EX50 Series

ADJUSTING ACCELERATOR PEDAL OPERATION,
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE
ADJUSTING ACCELERATOR PEDAL OPERATION

Since the accelerator pedal installed to this machine is electrical, no adjustment is required.
ADJUSTING PARKING BRAKE

ADJUSTING THE LEVER OPERATING Adjustment bolt
EFFORT
Use adjust bolt to adjust the maximum parking lever
operating effort reads 196 Nm {20 kgm} at the center of
the grip.
ADJUSTING CLEARANCE
1. Turn the adjust wheel (1) in the shoe expanding
direction to have the lining made contact with the
brake drum. 157 – 196 Nm
2. Turn the adjust wheel (1) so that the clearance {16 – 20 kgm}
between the drum and lining (points X and Y in the 2 Loctite #271
diagram to the right) reads 0.1 to 0.25 mm.
(Returning the adjust wheel by 11 notches adjusts
the clearance by 0.25 mm)
EX50 Series 20-27

BLEEDING AIR TESTING AND ADJUSTING
BLEEDING AIR
BRAKE PIPING
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.
LIFT CYLINDER
1. Start the engine and run at low idling.
2. Raise and lower the mast.

Stop the mast approx. 100 mm before reaching
the max. lifting height and max. lowering posi-
tion.
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.
20-28 EX50 Series

TESTING AND ADJUSTING BLEEDING AIR
BRAKE (WET DISC BRAKE TYPE)
CAUTION
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 Vinyl hose Bleeder
screw
other end to inside the container.
3. Start the engine, and then step on the brake pedal.
4. Loosen the bleeder screw slowly. 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.
5. Repeat the same process with other brake to bleed
the air.
6. When the air bleeding is completed with the L.H. and
R.H. brakes, check the hydraulic tank level. Replen-
ish oil, if necessary.
a Care should be taken to keep dirt and foreign
matters away from the brake during assembly.
CAUTION
Since high-pressure oil is stored inside the piping con-
necting the accumulator and brake valve after the
engine stopped, remove the piping according to the fol-
lowing method:
HOW TO REMOVE
1. Stop the engine.
2. Step on the brake pedal 100 times and over to drain
the high-pressure oil inside the piping to the hydrau-
lic tank.
3. Remove the piping.
EX50 Series 20-29

CHECKING WEAR OF BRAKE DISC TESTING AND ADJUSTING
CHECKING WEAR OF BRAKE DISC

CAUTION
• 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.
1. Start the engine. Store pressure in the brake accu-

mulator with the forward/rear travel lever in neutral
position.
2. Stop the engine.
3. Check that no other brake than the parking brake is
applied.
4. Step on the brake pedal.
5. Remove cap nut (1) from the disc wear sensor (2).
6. Push the disc wear sensor (2) in till it contacts with
the piston to check on wear volume.
a 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.
a 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.
7. Install the cap nut (1) of the disc wear sensor.
Cap nut (1) tightening torque
19.6 Nm {2.0 kgm}
20-30 EX50 Series

TESTING AND ADJUSTING STEERING AXLE
STEERING AXLE
Adjusting alignment
Toe–in mm
Camber deg
0
Castor deg
King pin angle deg
1,900 (10 t)
Tread mm 1,890 (11.5 t–15 t)
1,870 (16 t)
Toe–in L1 = L2
Tyre turning angle

1. Adjust the left and right stopper bolts so that turning
angle is 76° ± 30'.
2. After adjusting the turning angle, operate the cylinder
in and out and check that there is no scuffing at the
link connection or any other part.
EX50 Series 20-31

INSPECTING THE AIR CONDITIONER (OPTION) TESTING AND ADJUSTING
INSPECTING THE AIR CONDITIONER (OPTION)
CAUTION
• 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.
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 con-
ditioner 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).
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 refriger-
ant, then it turns light opaque
white.
b : Refrigerant volume ... In short. Bubbles are continu-
ally noticed after the air condi-
tioner is turned ON.
X : Flow state of refrigerant
Y : State of the sight glass
x : Bubbles are present. Refrigerant in liquid and gas-
eous state is mixed.
y : Bubbles are gone and all the refrigerant is in trans-
parent liquid state.
z : White turbid oil and refrigerant are in separated con-
dition in light opaque white.
20-32 EX50 Series

TESTING AND ADJUSTING INSPECTING THE AIR CONDITIONER (OPTION)
Inspection and maintenance and its timing
Timing for inspection and maintenance

Check points Check item
Start-up inspection 6 months Replacement 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
EX50 Series 20-33

BATTERY TESTING AND ADJUSTING
BATTERY
CAUTION
Cautions for handling batteries
• First-aid treatment for exposure to battery electrolyte
If your eyes, skin or clothes is attached 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 bat-
tery.
1. Charge the battery. After completing the charging,

replenish battery electrolyte to normal level, if neces-
sary.
2. Use a specific gravity meter and temperature gauge
to measure specific gravity of the battery electrolyte
and the temperature.
3. 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
4. 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
20-34 EX50 Series

TESTING AND ADJUSTING OIL AND GREASING CHART
OIL AND GREASING CHART

(OIL, GREASE LOCATIONS ANDINSPECTION AND MAINTENANCE INTERVALS)
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)
Caution
Symbol Type of fluid
1. Check and add fluid if necessary
EO Diesel engine oil 2. Change or add oil
MO Engine oil 3. The figure in indicates the number of oil or greas-
GO Gear oil ing locations.
4. The intervals for checking the oil level, adding oil,
HO Hydraulic oil
and greasing are every day, every two weeks, every
G Lithium grease one month, every three months, and every six
months, or according to the hourmeter reading.
* Always use Komatsu Utility-designated oil for the
diesel engine.
EX50 Series 20-35

LUBRICANT LIST TESTING AND ADJUSTING
LUBRICANT LIST
NOTICE:
• 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
20-36 EX50 Series

30. REMOVAL AND INSTALLATION
General locations ....................................................30- 2
Weight table ............................................................30- 4
Removal and installation of unit ..............................30- 6
Flow chart ...............................................................30- 8
Mast ........................................................................30- 9
Power train ..............................................................30-10
Brake system ..........................................................30-13
Work equipment control lever..................................30-14
EX50 Series 30-1

GENERAL LOCATIONS REMOVAL AND INSTALLATION
GENERAL LOCATIONS
30-2 EX50 Series

REMOVAL AND INSTALLATION GENERAL LOCATIONS
Page for disassembly/ Pages related to inspection,

No. Name of equipment
assembly maintenance and other
1 Mast 40–92 30–9 80-18
2 Lift cylinder 40–76 20–16, 50-31, 60-39 80-20
3 Tilt cylinder 40–78 80-20, 50-32, 60-39
4 Brake valve 40–50 20-18, 60-24
5 Control valve 40–88 50-28 80-21
6 Front wheel – 30-7, 30-10 80-11
7 Fork – 80-17
8 Wheel brake 40–46 20–19, 30-13, 50-23 80-16
9 Drive axle 40–32 30-7, 60-17
10 Differential gear 40–38 20–12, 50-12
11 Parking brake 40–45 20–27, 50-26
12 Drive shaft – 50-11 80–10
13 Transmission 40–8 50-9 80-7
14 Torque converter 40–2 50-8, 60-4, 70-10 80-9
15 Air cleaner – 20–10
16 Engine – 20–5, 20-11
17 Hydraulic pump 40–30 60-38
18 Rear wheel – 30-7 80-11
19 Steering axle 40–44 20-31, 50-16, 60-18 80-11
20 Power steering cylinder 40–86 50-33 80-14
21 Muffler – 30-7
22 Radiator – 30-7
23 Counterweight – 30-6
24 Parking lever – 20–27 80-15
25 Power steering valve 40–57 –
26 Battery (on the R.H. side of the lift truck) 20-34, 80-6
27 Pedal – 20-17, 20-27, 50-2, 50-19
Brake cooling oil tank

28 – –
(wet disc brake type)
29 Aftercooler – –
Brake cooling oil cooler

30 – –
(wet disc brake type)
31 Torque converter cooler – 30-7, 30-8
EX50 Series 30-3

WEIGHT TABLE REMOVAL AND INSTALLATION
WEIGHT TABLE
Unit: kg
FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8 Remaks
Engine assembly 535
Transmission assembly 360 Dry
Front 785 820 Excluding frontwheel

Axle
Rear 425 560 Excluding power
steering cylinder
Front 80 95 105 110 115 With rim

Wheel (each)
Rear 70 85 95 95 105 With rim
Over head guard 131
Counterweight 4,260 5,220 5,700 6,590 7,100
Lift cylinder 85 90 105 110 110 Lift high 3 m (each)
Tilt cylinder 50 Each
Power steering cylinder assembly 45 55
Must 1,700 1,940 2,050 2,100 2,100 Lift high 3 m Excluding

fork, fork carriage
Fork carriage assembly 785 870 1,010 1,135 1,135 Excluding fork
Fork (each) 175 200 220 240 260 Length: 1,220 mm
30-4 EX50 Series

REMOVAL AND INSTALLATION OF UNIT REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION OF UNIT
30-6 EX50 Series

REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION OF UNIT
EX50 Series 30-7

30-8
Front wheel Torque shaft differential Brake
FLOW CHART
Tilt cylinder Mast Brake piping Front axle
Lift cylinder Parking brake cable

FLOW CHART
Radiator hose
Torque converter Torque converter Shroud
cooler hose cooler Radiator Aftercooler
Aftercooler hose Brake cooler
Brake cooler hose
Muffler
REMOVAL AND INSTALLATION
Engine hood
Pedal link
F.R. lever link

Completed
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
Parking brake cable
Air cleaner
Rear wheel P.S. pipings P.S. cylinder
Joint
Rear axle
Disassembly Counterweight Assembly
EX50 Series
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION MAST
MAST
Support with wooden blocks to prevent fork carriage from dropping.
2 54–118 Nm
{5.5–12 kgm} Method for bleeding air from lift cylinder
(1) Start the engine and run at low idling.
(2) Raise and lower the mast.
Inner mast Stop the mast approx. 100 mm before reaching
the max. lifting height and max. lowering posi-
tion.
Shims
(3) Repeat Step (2) 4–5 times.
(4) Raise and lower the mast to the maximum lifting
height and maximum lowering position.
Cylinder
rod (5) Repeat Step (4) 4–5 times.
Tightening torque for the mast mounting bolts.

Outer mast
824 – 1,030 Nm {84 – 105 kgm}
Moves to left Insert shim to left cylinder
Moves to right Insert shim to right cylinder
Adjust with shims so that the left and right cylinders

are synchronized at the maximum lifting height.
EX50 Series 30-9

POWER TRAIN REMOVAL AND INSTALLATION
POWER TRAIN
2. Centering of drive shaft
1. Rear axle support busing
Direct oil hole

of bushing up.
5 mm max. (in both vertical and

Deviation lateral directions)
3. Centering of engine mount
Deviation 5 mm max. (in both vertical and

lateral directions)
4. Installation of wheel
k When hub nut (1) was removed for replacing

the wheel, etc. and again installed back on,
always tighten the hub additionally after trav- Clamp
Spacer
eling 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 install-
ing the wheels.
(See the section of TYRE CLAMP TIGHTEN-
ING INSTRUCTION.)
Tyres
Tightening torque
441 – 539.5 Nm {45 – 55 kgm}
30-10 EX50 Series

REMOVAL AND INSTALLATION POWER TRAIN
5. Tyre clamp tightening instruction
CAUTION
• Park the lift truck on a level and safe place before starting the work.
• 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.
1. Tighten the hub nuts in the order of (1) to (16).

Tightening torque
245 – 343 Nm {25 – 35 kgm}
2. Retain the tyre in floated condition. Adjust the maxi-

mum difference in the runout of the tyre to within the
specified value by adjusting it with clamps at 8 loca-
tions.
Adjusting runout
1) Locate the gauge at a right angle to the side face
of the tyre and apart 10 mm from it.
2) Rotate the tyre with no load in the forward 1st
gear and find out a point that the gauge tip con-
tacted, 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.
EX50 Series 30-11

POWER TRAIN REMOVAL AND INSTALLATION
4) Check the runout again. If outside the specified

range, make another adjustment.
Runout of tyre 10 mm or less (0.39 in)
3. Tighten the hub nuts in the order of (1) to (16).

Tightening torque
490 Nm {50 kgm}
4. Tighten the hub nuts again in the order of (1) to (16).

Tightening torque
490 Nm {50 kgm}
5. Measure the tightening torque of (1) and (2) and

check that they are within the range of specified
value.
If outside, tighten the hub nuts additionally as
instructed in step 3.
Specified values for the tightening torque
441 – 539.5 Nm {45 – 55 kgm}
6. Check the tyre 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.
7. 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.
8. Repeat the procedure of step 7 for a period of
approx. 50 hours after installation.
30-12 EX50 Series

REMOVAL AND INSTALLATION BRAKE SYSTEM
BRAKE SYSTEM
Method of bleeding air

(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 bub-
bles come out from the hose.
(5) After completely bleeding the air, tighten the
plug and install the cap.
Bleed the air from the bottom cylinder first,
then bleed the air from the top cylinder.
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.
Method of removing
(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.
EX50 Series 30-13

WORK EQUIPMENT CONTROL LEVER REMOVAL AND INSTALLATION
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
mm
S1 S2
Lift lever 126 126
Tilt lever 130 130
30-14 EX50 Series

40. DISASSEMBLY AND ASSEMBLY
Torque converter ......................................................40- 2
TORQFLOW transmission .......................................40- 8
Drive axle .................................................................40-32
Differential ................................................................40-38
Steering axle ............................................................40-44
Parking brake ...........................................................40-45
Wheel brake .............................................................40-46
Brake / inching pedal................................................40-49
Brake valve...............................................................40-51
Power steering valve ................................................40-57
Lift cylinder...............................................................40-76
Tilt cylinder...............................................................40-78
Power steering cylinder ............................................40-86
Control valve ............................................................40-88
Mast .........................................................................40-92
Table of special tools................................................40-96
EX50 Series 40-1

TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER
The numbers show the order for disassembly
40-2 EX50 Series

DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
EX50 Series 40-3

ASSEMBLY
1. Assembly of idler gear and shaft

Assemble bearing (2) to idler gear (1), then set in the
case.
Assemble idler shaft (3) to the idler gear. Secure the
idler shaft to the case with lock plate (4) and bolt (5).
35.3–44.1 Nm {3.6–4.5kgm}
2. Stator shaft
1) Install pump boss gear (1) to stator shaft (2).
40-4 EX50 Series

2) Installation of stator shaft

Using tightening bolt (1) [M12, P1.75], mesh the
idler gear and pump boss gear and install to the
case.
67.6–78.4 Nm {6.9–8 kgm}
3. PTO driven gear

1) Assemble bearing (1).
2) Mesh driven gear (2) with the idler gear and
assemble.
3) Using bolt (4) as a guide, install the bearing
retainer.
4) Tighten bolt (4) to secure in position.
67.6–78.4 Nm {6.9–8 kgm}
4. Pump
1) Assemble the pump.
Align the pump boss spline and pump gear
spline and assemble the pump.
EX50 Series 40-5

5. Stator
1) Assemble the collar, trust washers (1) and (2),
stator, and thrust washers (3) and (4) in turn.
2) Set the tab of lock washer (5) facing the outside,
and insert.
3) Secure the stator with ring nut (6). (Check that
the stator rotates lightly when doing this.)
4) Secure the ring nut with the tab of the lock
washer.
6. Turbine, drive cover assembly

1) Assemble O–ring (3) to the pump.
2) Assemble the turbine and drive cover assembly
(A) to the pump.
3) Tighten the pump and drive cover assembly with
bolt (1) and nut (2).
27.4–33.3 Nm {2.8–3.4 kgm}
7. Pilot, flexible plate

1) Install pilot (1) and flexible plate (2) to the drive
cover.
2) Tighten with bolt (3).
35.3–44.1 Nm {3.6–4.5 kgm}
40-6 EX50 Series

8. Hydraulic pump (torque converter charge pump)

1) Install hydraulic pump (1) (FAL3–045).
35.3–44.1 Nm {3.6–4.5 kgm}
9. Oil strainer
1) Assemble the oil strainer in the case.

35.3–44.1 Nm {3.6–4.5 kgm}
EX50 Series 40-7

TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY
TORQFLOW TRANSMISSION
Hydraulic pump Torque converter pump
40-8 EX50 Series

DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
Gasket
Transmission
Torque converter
59–73.5 Nm
{6–7.5 kgm}
EX50 Series 40-9

CONTROL VALVE (SOLENOID VALVE)
Protrusion inching spool 24.5 mm (0.97 in)
(Solenoid valve)
Actuating voltage (V)
Standard 24 V
Range 22–26 V
(Inching spool)
Torque converter
Mounting bolts
Insufficient tightening: Oil leakage
Over tightening: Defective operation of spool
40-10 EX50 Series

Main pressure pick-up port
EX50 Series
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
DISASSEMBLY AND ASSEMBLY
M16 = 1.5 pick-up port

Torque converter oil PT1/8
outlet-cum-lubricant
regulator valve
0.45 ± 0.15 MPa
HYDRAULIC SYSTEM DIAGRAM
Inching
valve
Solenoid valve
for F/R Accumulator
for speed
Solenoid valve for

1st speed Speed pressure
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
40-11
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
40-12 EX50 Series

DISASSEMABLY
1. TORQFLOW transmission
After completion of the operation for removing the Lifting equipment
TORQFLOW transmission assembly from the chas-
sis, wash the case and the area surrounding the
accessory parts, then remove the following parts.
• Sending unit
• Oil
(1) Remove the lifting equipment from the eyebolts

and install it to the transmission case mount
bracket, then raise slowly so that the torque con-
verter case is at the bottom. Lifting equipment
(2) Lower the TORQFLOW transmission assembly
slowly and set in position on wooden blocks
(250–300 mm) placed on the floor, or lower on to
a special work stand.
• Use 3 or 4 wooden blocks and support the
TORQFLOW transmission stably and securely.
Stand
EX50 Series 40-13

(3) Disassemble the torque converter case and

transmission case.
• Loosen all the bolts connecting the cases (a
clearance of 2–3 mm is generated when the Lifting equipment
case is disconnected).
• Raise the lifting equipment slightly to apply
tension to the wires of the lifting equipment
(do not raise the assembly from the ground).
• Hit the outside of the torque converter case
lightly with a wooden hammer or plastic ham-
(Bolt)
mer.
• Check that the connection between the 2
cases is completely separated, then lower the
lifting equipment and remove all the bolts.
• Raise the lifting equipment and disconnect
the transmission case.
Leave the shaft assemblies for F/R, 1st/2nd, and

3rd remaining inside the torque coverter case.
40-14 EX50 Series

2. Clutch shaft sub assembly

1) Remove the 1st/2nd and 3rd clutch shaft sub (Hoist)
assemblies.
• Set the special tools to the shaft sub assem-
blies.
• Fit the lifting tool to the eyebolts. Lifting equipment
• Pull up the 1st/2nd and 3rd clutch shaft sub
assemblies together.
• After removing, lower the assemblies on top
Lifting up together
of a work stand.
Special tool-1
The operation is easier to carry out if the 1st/2nd
and 3rd clutch shaft sub assemblies are pulled Special tool-2
up at the same time.
If they are removed separately, there will be
twisting and gouging, or damage to the case.
3rd
1/2nd
Torque converter
M10 x 1.5 L=35

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.
EX50 Series 40-15

2) Remove the FORWARD/REVERSE clutch shaft sub

assembly
(Remove the 1st/2nd and 3rd clutch shaft sub
assemblies first.)
• Wind a wire around the reverse clutch shaft. (Hoist)
• Fit the lifting equipment to the wire.
• Lifting up the FORWARD/REVERSE clutch shaft
sub assembly slowly with the hoist.
• After removing, lower the shaft sub assembly
slowly on the top of a work stand.
For safety reasons, do not pull up the shaft by
Lifting equipment
hand. Always use lifting equipment.
It is possible to remove the FORWARD/REVERSE
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 F/R
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
40-16 EX50 Series

DISASSEMBLY OF CLUTCH PACK ASSEMBLY

(Example: 1st/2nd)
Numbers indicate the order of assembly.
To disassemble, start with the greater number.
k CAUTION
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.
Special tool 3EC–97–99000
• Collar inner diameter: φ65–69 mm (2.56–2.71 in)
When removing snap rings 13 and 14, always use

the above special tool.
EX50 Series 40-17

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
NOTICE
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.
40-18 EX50 Series

A. k Caution
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)
Clutch pack for 1st/2nd speed Clutch pack for F/R

Warping of camber plate Warping of camber plate
: 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
B. Number of plate disc (per pack)
F/R 1st/2nd speed 3rd speed
Qty. Part No Qty. Part No Qty. Part No
Plate 8 30E-15-11190 7 30E-15-11190 4 30E-15-11120
Disc 7 30E-15-11180 6 30E-15-11170 4 30E-15-11110
Camber plate 1 30E-15-11210 1 30E-15-11210 — —
Pressure plate 1 30E-15-11220 1 30E-15-13420 1 30E-15-11130
EX50 Series 40-19

PRECAUTIONS WHEN ASSEMBLING
1. Clutch pack assembly

Blow compressed air into the oil hole to check
the operation of the drive plate and driven plate.
Air pressure 5 kg/cm2
Must move to the

Stroke stroke end.
2. Solenoid valve
1 4
Tighten the mounting bolts in the order shown in
the diagram on the right.
3 2
When assembling, check the operation of the
spool.
Insufficient tightening: Oil leakage
Overtightening: Defective operation
3. Seal ring
After assembling, coat the seal ring with grease.
40-20 EX50 Series

CONNECTORS FOR SOLENOIDVALVES
CONNECTING DWG.
F: 3(+), 4(-)
FR VALVE 4 1
R: 1(+), 2(-)
3 2
1st/2nd
1(+), 2(-)
VALVE 1 2
3rd VALVE 1(+), 2(-)

1 2
F R 1st 2nd 3rd

ON OFF 1st/2nd VALVE ON OFF OFF
FR VALVE
OFF ON 3rd VALVE OFF OFF ON
Solenoid valve Inching spool
F/R
1, 2 speed
3rd, output
EX50 Series 40-21

ASSEMBLY OF F/R (INPUT SHAFT) SHAFT SUB ASSEMBLY

(Reassemble in the opposite order to disassembly.)
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)
40-22 EX50 Series

6 5 4 1 2 2 1 9 10 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
EX50 Series 40-23

ASSEMBLY OF 1ST/2ND SHAFT ASSEMBLY

Coat the seal ring with grease.
(1st end)
Transmission case
Torque converter
(2nd end)
40-24 EX50 Series

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
EX50 Series 40-25

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
40-26 EX50 Series

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
EX50 Series 40-27

2. Clutch shaft sub assembly

1) Assemble the 1st/2nd and 3rd clutch shaft sub (Hoist)
assemblies.
Assemble the 1st/2nd and 3rd clutch shaft
sub assemblies together as a set.
• Set the special tools to the shaft sub assemblies.
Lifting equipment
• Fit the lifting equipment to the eyebolts.
• Set so that the 1st/2nd and 3rd clutch shaft sub
assemblies mesh at the respective gear position.
• Raise slowly and set in position above the torque
converter case.
• Check that the position of each gear is aligned
as shown in the diagram on the right (the vertical
position should be meshed within the range of
the gear width).
• Check that the busing has entered the 3rd shaft
3rd
hole at the torque converter case end.
• Lower the assembly slowly and check that the tip
of each shaft is facing the shaft hole in the
torque converter case. 1/2nd
• In addition, be careful of the position of the seal
ring.
• There is a washer on the 3rd shaft, so check that
it is not at an angle.
• Lower the assembly to set the 1st/2nd and 3rd
clutch shaft sub assemblies completely in posi-
k For safety reasons, always use a hoist.

tion.
Torque converter
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 eas-
ily. Never try to push in by force.
40-28 EX50 Series

2) Assemble the F/R clutch shaft sub assembly.

Assemble the 1st/2nd and 3rd clutch shaft
sub assemblies first, then assemble the F/R
clutch shaft sub assembly.
• Wind a wire around the reverse clutch shaft. (Hoist)
• Fit the lifting equipment to the eyebolt.
• Raise slowly and set in position above the torque
converter case.
• Lower the assembly slowly and check that the tip
of the shaft sub assembly is facing the center of
the shaft hole in the torque converter case.
• Be careful of the position of the seal ring, and Lifting equipment
insert (lower) the sub assembly shaft into the
stator shaft.
• Be careful to mesh with the gears of the 1st/2nd
shaft sub assembly, and insert the sub assembly
F/R
fully at the point where the gears mesh.
k For safety reasons, always use a hoist.
Torque converter
EX50 Series 40-29

HYDRAULIC PUMP
1. Hydraulic pump and power steering pump

(Hydraulic drum brake type)
The hydraulic pump and power steering pump are
connected as a unit, and are driven by the torque
converter PTO system.
Item Unit Work Steering

equipment
Name of pump – SAR–90 SAR–40
2
Relief pressure MPa {kg/cm } 21.6 {220} 12.7 {130}
Discharge cc/rev 90.0 40.0
Rated speed rpm 2,200 2,200
Torque converter
2
2. Torque converter charge pump

The torque converter charge pump 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
40-30 EX50 Series

HYDRAULIC PUMP
1. Hydraulic pump
(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.
Item Unit Work equipment Power steering Brake Brake cooling
Name of pump — Pump No. 1 Pump No. 2 Pump No. 3 Pump No. 4
12.7 {130} (FD100 – 115)

Relief pressure MPa {kgf/cm²} 21.6 {220} 9.8 {100} 0.34 {3.5}
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
EX50 Series 40-31

DRIVE AXLE DISASSEMBLY AND ASSEMBLY
DRIVE AXLE
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}
FD100 FD115 FD135/150E FD160E
Type Fixed single shaft full–floating type
Reduction gear
type Planetary gear
Reduction ratio 6.4
Tread 1,700 1,700 1,770 1,770
40-32 EX50 Series

DISASSEMBLY AND ASSEMBLY DRIVE AXLE
DRIVE AXLE
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}
FD100 FD115 FD135/150E FD160E
Type Fixed single shaft full–floating type
Reduction gear
type Planetary gear
Reduction ratio 6.4 9JL01913
Tread 1,700 1,700 1,770 1,770
EX50 Series 40-33

FRONT HUB
Hub starting friction torque: 20–39 Nm {200–400 kgcm}
40-34 EX50 Series

FRONT HUB
* 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
EX50 Series 40-35

FRONT AXLE
40-36 EX50 Series

FRONT AXLE
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
EX50 Series 40-37

DIFFERENTIAL DISASSEMBLY AND ASSEMBLY
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
Run out Max. 0.1 with dial

gauge
9JL01914
157 -- 196 Nm
{16 -- 20 kgm}
Special tool 34B–97–99110
40-38 EX50 Series

DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
ADJUSTING PINION SHAFT SHIM
1. Calculate values of dimensions (a), (b), (c),

and (d).
1) Read value (a) displayed at the tip of the pinion
shaft.
2) Measure dimension t when the preload on bear-
ing 06002–30311 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
3) Read value (c) indicated by the arrow on case
3FE–21–15130.
4) Read value (d) stamped on differential case
3FE–21–15120.
2. Calculating shim thickness

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

Combine shims 3FE–21–15160 (t=0.3) and 3FE–
21–15170 (t=0.2) so that the total is value (s) calcu-
lated above, then install the set of shims.
4. Pinion shaft, bearing preload

After installing the shim, apply a preload to the bear-
ing (06002–30311) so that the set staring torque of
the pinion shaft is 392–784.5 Ncm (40–80 kgcm)
when tightening the bolt (01011-81605).
EX50 Series 40-39

DIFFERENTIAL SUPPORT BEARING
1. Adjust the backlash of the ring gear and pinion gear.
0.20–0.28 mm
Backlash (0.008–0.011 in)
Assemble to make the backlash 0.2 mm, cons-

iclesing it will increase during the initial running
in period.
Procedure for adjusting backlash

To adjust the backlash, loosen one adjustment screw
1 notch and tighten the other screw 1 notch. Gradu-
ally 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.
3040–5590 Ncm
Starting torque {310–570 kgcm}
3. Measure the backlash again and check that it is

within the specified range.
40-40 EX50 Series

Checking tooth contact

1) Coat the tooth face of the bevel pinion lightly with red FORWARD side
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.
The tooth contact should be correct on both the
FORWARD and REVERSE sides of the teeth. REVERSE side
However, if it is impossible to adjust both sides
correctly, the FORWARD side must be correct.
Swing of within 0.1 mm (0.004 in)

bevel gear
EX50 Series 40-41

Adjusting tooth contact

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.
Adjust the backlash again.
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.
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.
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 direc-
tion B.
40-42 EX50 Series

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
EX50 Series 40-43

STEERING AXLE DISASSEMBLY AND ASSEMBLY
STEERING AXLE
40-44 EX50 Series

DISASSEMBLY AND ASSEMBLY PARKING BRAKE
PARKING BRAKE
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
A Lining Thickness 5.45 (0.22) 3.3 (0.13)
152 N {15.5 kgf} 137 N {14 kgf}

Strength Replace
B Shoe return spring [ = 50 (1.97)] [ = 50 (1.97)]
Free length 54.7 (2.15)
EX50 Series 40-45

WHEEL BRAKE DISASSEMBLY AND ASSEMBLY
WHEEL BRAKE
FD100/115
mm (in)
Judgement standard
33 ± 3.3 kgf 33 ± 3.3 kgf

B Shoe return spring Strength [ = 103.5 (4.078)] [ = 103.5 (4.078)]
Free length: 93 (3.664) (Reference)
Clearance 0.025–0.126 0.025–0.126 Replace

C Wheel cylinder between piston (0.001–0.005) (0.001–0.005)
and cylinder
Clacks, chips, rust
D Back plate Damage, bending
Inside diameter of brake drum 393.7 (15.512) 396.5 (15.622)
40-46 EX50 Series

DISASSEMBLY AND ASSEMBLY WHEEL BRAKE
FD135/150E/160E
mm (in)
Judgement standard
50 ± 5 kgf 42 ± 4 kgf
[ =178 (7.013)] [ =159 (6.265)]
B Shoe return spring Strength
169.5 (6.678)
Free length: (Reference)
148 (5.831)
0.025–0.126 0.025–0.126 Replace
Clearance
C Wheel cylinder between piston (0.001–0.005) (0.001–0.005)
and cylinder
Clacks, chips, rust
D Back plate Damage, bending
Inside diameter of brake drum 438 (17.257) 440 (17.336)
EX50 Series 40-47

WHEEL BRAKE DISASSEMBLY AND ASSEMBLY
WHEEL BRAKE
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
40-48 EX50 Series

DISASSEMBLY AND ASSEMBLY BRAKE / INCHING PEDAL
BRAKE / INCHING PEDAL

Brake pedal
Torque converter
Brake valve
Inching pedal
EX50 Series 40-49

BRAKE / INCHING PEDAL DISASSEMBLY AND ASSEMBLY
BRAKE / INCHING PEDAL

Brake pedal Torque converter
Inching pedal
Brake valve
40-50 EX50 Series

DISASSEMBLY AND ASSEMBLY BRAKE VALVE
BRAKE VALVE
Warning
The accumulator circuit is under high hydraulic
pressure. It is therefore very dangerous to loosen
any connections 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, discon-
nect the pipes.
EX50 Series 40-51

BRAKE VALVE DISASSEMBLY AND ASSEMBLY
1. Fix body (1) in a vice and remove plug (2).

Use a hexagonal bar wrench.
Width across flats: 17 mm (0.67 in).
• Remove O–ring (3) with fingers.

When fixing in the vice, be careful not to hold the
flow divider mounting face.
Parts marked *are supplied in the parts kit.
2. Remove bolt (2) from body (1) and then remove snap
ring (3).
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.
When disassembling cup (6), be careful not to
scratch piston.
Nut (7)
If it is loosened, the stroke of piston or hydraulic
pressure must be adjusted.
3. Insert a bar to spool hole (1) to remove guide (2) and

valve assembly (3).
Outside diameter of hole: 13 mm (0.5 in).
Do not push hard.
40-52 EX50 Series

• Remove O–ring (7) from valve sub–assembly (3)

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

plied with O–ring kit.
2. Cup (2)
• Follow the method shown in Fig. A when install-
ing.
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.
• Install input piston sub–assembly (2) and washer

(3) in body (1) and fix with snap ring.
• 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).
Coat spool (5) with engine oil.
SAE10W
mm (in)
Standard depth of guide 40 (1.6)
EX50 Series 40-53

4. Install retainer (2) securely on tip of piston (1).

• Install spring (3), valve sub–assembly (4) and plug
(5) in order.
Plug (5) 690–1,100 kgcm
• Tighten plug (5) by hand.

• Fix brake valve in vice and tighten plug (5) again.
5. Install boot (1) in groove of body (2) and groove of

nut (3).
6. Adjustment of brake pressure.
• Set the oil pressure gauge.
• Run the engine at low idling speed.
Do not operate TILT, LIFT or ATTACHMENT lever.
• 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).
FD100/115 130 ± 3 kg/cm2

Wheel cylinder
oil pressure
FD135–160E 130 ± 3 kg/cm2
500–800 kgcm
If adjustment cannot be made with this procedure,

adjust as follows.
• Adjust so that the distance A (a + b) between

washer (3) and locknut (2) is the valve below.
Measuring distance a.
• Remove snap ring (4) and pull out input piston (1),
and measure the depth a.
FD100/115 11 ± 0.3 kg/cm2

a+b
FD135–160E 9.7 ± 0.3 kg/cm2
500–800 kgcm
40-54 EX50 Series

BRAKE VALVE
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 assem-
bling convenience.
Arrange individual parts in orderly manner for correct
assembly with ease. Take full care not to have the
parts damaged, dented or bent.
EX50 Series 40-55

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
40-56 EX50 Series

DISASSEMBLY AND ASSEMBLY POWER STEERING VALVE
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
EX50 Series 40-57

POWER STEERING VALVE DISASSEMBLY AND ASSEMBLY
DISASSEMBLY PROCEDURES
1. Removing the column assembly
Hold the flange of a column assembly with a vise,
loosen the bolts to remove the column assembly.
2. Removing the gerotor assembly

1) Hold the housing (10) with the vise with the gero-
tor side facing upward. Loosen the screw (1).
2) Lift the end cap (3), gerotor (4) and plate (7) as a
unit. Remove the gerotor assembly.
a When lifting them in the unit, hold the plate
with fingertips.
3. Disassembly of control valve assembly

1) Hold the assembly lightly with the vise with the
column mount side facing upward. Remove the
snap ring (21).
a Apply a flat wooden block under the assembly
to prevent the sleeve and spool assembly
from being damaged.
Housing
40-58 EX50 Series

2) After removing the snap ring (21), remove the

seal grand bushing (22) and O-ring (18). Push
out the sleeve and spool assembly to remove
the bearing assembly (B).
3) Fix the housing (10) with the port face facing

downward. Pull out the sleeve and spool assem-
bly (A) from the front (mount plate) side.
a 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.
a Never forcibly pull it out since the clearance
with the housing is narrow.
4) Loosen the check valve assemblies (25), (26),

(27), (28), (29) and (30), which are screwed into
the housing.
5) After pulling out the straight pin (13) from the

sleeve and spool assembly (A), pull out the
spool as shown in the figure to the right, and
push out the centering springs (14) and (15).
a Clearance between the sleeve and spool is
narrow. Pull the spool out carefully by turning
it slowly.
EX50 Series 40-59

4. Disassembly of column assembly

1) Hold the flange of a column assembly with the
vise. Remove the handle, then remove the snap
ring on the column and flange side.
2) Pull out the shaft (14) from the flange.

a Bearing (15) is press-fitted to the shaft. Do
not disassemble it unless it has any defect.
3) Hold the outside diameter section of column (16)

with the vise. Pull out the column bushing by
pushing in the protrusion at 2 locations on the
column bushing (17).
INSPECTION AND CLEANING

• After disassembly, check the sealing parts for any • Washing metal parts
damage, wear or other abnormality. Wash metal parts using volatile metal cleaning sol-
a When re-assembling, replace all of those seals vents (Trichloroethane, methylene chloride, etc.).
with new parts.
• Check the sliding surfaces of individual parts for • Cleaning rubber parts
excessive flaws, wear or breakage due to dirt. Dust rubber parts with compressed air, and immerse
a Main functional parts are selectively combined in hydraulic oil before using.
and cannot be supplied as a single unit. In the a Never wash rubber parts in metal washing sol-
case of excessive damage, replace the parts by vent.
assembly.
Part No. for seal kit 3FE-34-11170

Part No. for bearing kit 3ED-34-41760
40-60 EX50 Series

ASSEMBLING PROCEDURES
1. Assembling control valve assembly
1) Place the housing on a flat wooden block with
the front side (steering column side) facing
upward. Install O-ring (18) to the check valve
assembly and screw it in to the housing.
60 – 80 kgcm
2) Insert spool (12) to the sleeve (11) from the

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

and sleeve. 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. Put both sides of the spring back-to-
back. Hold the notched side facing down-
ward. Hold one end with the spring insertion
jig while holding the other end bent with fin-
gertips. Press the springs in this condition in
the direction of insertion. Pull out the insertion
jig with the spring until the spring fits inside
the groove.
a Correct the position of the spring insertion jig
and spring. Align them by preventing protru-
sion.
4) Insert straight pin (13) to the sleeve and spool

assembly (A).
EX50 Series 40-61


downward or sideway. Insert the sleeve and
spool assembly (A) to the bore from the spline
side of the spool.
a When inserting the assembly, care should be
taken not to have the straight pin (13)
adjust the straight pin position with fingertip.
insert by turning it little by little, carefully
avoiding slanted insertion.
and check for smooth rotation.
6) Insert bearing assembly (B).

a 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.
7) Insert dust seal (20) and wheel seal (19) to the

seal grand bushing (22), and O-ring (18).
Smoothly slide in the assembly. Further push it
in slowly and stop it with snap ring (21).
a Be careful and avoid catching the O-ring (18)
during insertion.
a To prevent the bearing assembly (B) from
being locked, check that the housing and
mounting plate are closely in contact.
a Apply thin layer of grease to outer circumfer-
ence of the seal before press-fitting. Then fill
the lip portion with grease.
40-62 EX50 Series

2. Assembling gerotor assembly

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

align the bolt hole positions.
a 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.)
3) Insert drive (8) and have the drive yoke section

engaged to pin (13).
4) 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.
5) Hold the side of gerotor star having greater Parallel relation

spline chamfer to the side of spacer plate (7).
Align the tooth-shaped root of the gerotor star to
the felt-tipped marker line. Insert O-ring (23) and
install gerotor (4).
a 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.
k Warnings
Align positions correctly. Wrong combination may
cause malfunction, leading to a serious accident.
EX50 Series 40-63

6) Install the spacer (5).
7) Install the O-ring (23) and the end cap (3).
8) Install 7 screws (1) to the end cap (3).

a 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.
a Tighten the screws at 7 locations in advance
by applying torque of about 15 Nm(1.5 kgm).
Then tighten them to the tightening torque
indicated in the table below in the order
shown in the figure to the right.
Tightening torque
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
k Warnings
If spring pin (2) is not installed, malfunction may
occur, causing a serious accident.
40-64 EX50 Series

3. Assembling column assembly

1) Hold the outside diameter section of the column
with the vise. Apply grease to the outer circum-
ference of the column bushing and push it inside
the column.
a Care should be taken to have the protrusions
at 2 locations to fit the holes at 2 places cor-
rectly.
2) Fill the lip of column bushing with grease. 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.
3) Install the snap ring correctly to the groove to
complete the assembling of the column.
a After assembly, check the shaft for smooth
revolution.
4) Seal in grease (bearing grease No. 2 containing

(molybdenum disulfide) to the spline joint of the
column assembly and install to the steering
valve main unit.
5) Tighten 4 bolts to complete assembly.
29.4 – 34.3 Nm {3 – 3.5 kgm}
EX50 Series 40-65

POWER STEERING VALVE

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
9 Control parts assembly Items 10 to 12 included 24 O-ring
10 Housing 25 Adapter screw
11 Sleeve 26 Ball
12 Spool
13 Pin
14 Centering spring
15 Flat spring Not installed with USA spec.
40-66 EX50 Series

DISASSEMBLY PROCEDURES
1. Removing the column assembly
Hold the flange of a column assembly with a vise,
loosen the bolts to remove the column assembly.
2. Removing the gerotor assembly

1) Hold the housing (10) with the vise with the gero-
tor side facing upward. Loosen the screw (1).
2) Lift the end cap (3), gerotor (4) and plate (7) as a
unit. Remove the gerotor assembly.
a When lifting them in the unit, hold the plate
with fingertips.
3. Disassembly of control valve assembly

1) Hold the assembly lightly with the vise with the
column mount side facing upward. Remove the
retaining ring (21).
a Apply a flat wooden block under the assembly
to prevent the sleeve and spool assembly
from being damaged.
Housing
EX50 Series 40-67

2) After removing the retaining ring (21), remove

the seal grand bushing (22) and O-ring (18).
Push out the sleeve and spool assembly to
remove the bearing assembly (B).

downward. Pull out the sleeve and spool assem-
bly (A) from the front (mount plate) side.
a When pulling out the assembly, care should
be taken not to have the straight pin (13)
adjust the straight pin position with fingertip,
turn it slowly to pull out.
a Never forcibly pull it out since the clearance
with the housing is narrow.
4) Loosen the check valve assemblies (25) and

(26), which are screwed into the housing.
5) After pulling out the straight pin (13) from the

sleeve and spool assembly (A), pull out the
spool as shown in the figure to the right, and
push out the centering springs (14) and (15).
a Clearance between the sleeve and spool is
narrow. Pull the spool out carefully by turning
it slowly.
40-68 EX50 Series

4. Disassembly of column assembly

1) Hold the flange of a column assembly with the
vise. Remove the handle, then remove the snap
ring on the column and flange side.
2) Pull out the shaft (14) from the flange.

a Bearing (15) is press-fitted to the shaft. Do
not disassemble it unless it has any defect.
3) Hold the outside diameter section of column (16)

with the vise. Pull out the column bushing by
pushing in the protrusion at 2 locations on the
column bushing (17).
INSPECTION AND CLEANING

• After disassembly, check the sealing parts for any • Washing metal parts
damage, wear or other abnormality. Wash metal parts using volatile metal cleaning sol-
a When re-assembling, replace all of those seals vents (Trichloroethane, methylene chloride, etc.).
with new parts.
• Check the sliding surfaces of individual parts for • Cleaning rubber parts
excessive flaws, wear or breakage due to dirt. Dust rubber parts with compressed air, and immerse
a Main functional parts are selectively combined in hydraulic oil before using.
and cannot be supplied as a single unit. In the a Never wash rubber parts in metal washing sol-
case of excessive damage, replace the parts by vent.
assembly.
Part No. for seal kit EABA 0363A

Part No. for bearing kit EA 64009
EX50 Series 40-69

ASSEMBLING PROCEDURES
1. Assembling control valve assembly
1) Place the housing on a flat wooden block with
the front side (steering column side) facing
upward. Install O-ring (18) to the check valve
assembly and screw it in to the housing.
60 – 80 kgcm
2) Insert spool (12) to the sleeve (11) from the

spline side.
insert by turning it lightly.
(spline side) and check for smooth rotation.
3) Align the spring groove positions on the spool

and sleeve. 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. Put both sides of the spring back-to-
back. Hold the notched side facing down-
ward. Hold one end with the spring insertion
jig while holding the other end bent with fin-
gertips. Press the springs in this condition in
the direction of insertion. Pull out the insertion
jig with the spring until the spring fits inside
the groove.
a Correct the position of the spring insertion jig
and spring. Align them by preventing protru-
sion.
4) Insert straight pin (13) to the sleeve and spool

assembly (A).
40-70 EX50 Series


downward or sideway. Insert the sleeve and
spool assembly (A) to the bore from the spline
side of the spool.
a When inserting the assembly, care should be
taken not to have the straight pin (13)
adjust the straight pin position with fingertip.
insert by turning it little by little, carefully
avoiding slanted insertion.
and check for smooth rotation.
6) Insert bearing assembly (B).

a 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.
7) Insert dust seal (20) and wheel seal (19) to the

seal grand bushing (22), and O-ring (18).
Smoothly slide in the assembly. Further push it
in slowly and stop it with retaining ring (21).
a Be careful and avoid catching the O-ring (18)
during insertion.
a To prevent the bearing assembly (B) from
being locked, check that the housing and
mounting plate are closely in contact.
a Apply thin layer of grease to outer circumfer-
ence of the seal before press-fitting. Then fill
the lip portion with grease.
EX50 Series 40-71

2. Assembling gerotor assembly

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

align the bolt hole positions.
a 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.)
3) Insert drive (8) and have the drive yoke section

engaged to pin (13).
4) 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.
5) Hold the side of gerotor star having greater Parallel relation

spline chamfer to the side of spacer plate (7).
Align the tooth-shaped root of the gerotor star to
the felt-tipped marker line. Insert O-ring (23) and
install gerotor (4).
a 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.
k Warnings
Align positions correctly. Wrong combination may
cause malfunction, leading to a serious accident.
40-72 EX50 Series

6) Install the spacer (5).
7) Install the O-ring (23) and the end cap (3).
8) Install 7 screws (1) to the end cap (3).

a 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.
a Tighten the screws at 7 locations in advance
by applying torque of about 15 Nm(1.5 kgm).
Then tighten them to the tightening torque
indicated in the table below in the order
shown in the figure to the right.
Tightening torque
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
k Warnings
If spring pin (2) is not installed, malfunction may
occur, causing a serious accident.
EX50 Series 40-73

3. Assembling column assembly

1) Hold the outside diameter section of the column
with the vise. Apply grease to the outer circum-
ference of the column bushing and push it inside
the column.
a Care should be taken to have the protrusions
at 2 locations to fit the holes at 2 places cor-
rectly.
2) Fill the lip of column bushing with grease. 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.
3) Install the snap ring correctly to the groove to
complete the assembling of the column.
a After assembly, check the shaft for smooth
revolution.
4) Seal in grease (bearing grease No. 2 containing

(molybdenum disulfide) to the spline joint of the
column assembly and install to the steering
valve main unit.
5) Tighten 4 bolts to complete assembly.
29.4 – 34.3 Nm {3 – 3.5 kgm}
40-74 EX50 Series

LIFT CYLINDER DISASSEMBLY AND ASSEMBLY
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
40-76 EX50 Series

DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
(Lifting height: 3 m)
Item Unit FD100 FD115 FD135/150E 160E
Cylinder (inside diameter × outside diameter) mm 95 × 110 100 × 113 110 × 124 120 × 136
Stroke mm 1510
Outside diameter of rod mm 65 70 75
Weight kg 85 90 105 110
INSPECTION
mm (in)
Judgement standard
0.097–0.366 0.666
Clearance between FD100 (0.004–0.014) (0.026)
A piston rod and Replace bushing
bushing 0.107–0.395 0.695
FD115/135/150E/160E (0.004–0.016) (0.027)
B Piston rod Scratches that catch finger nail, dents, hollows
C Piston ring Scratches that catch finger nail Replace
D Cylinder Scratches that catch finger nail, hollows
EX50 Series 40-77

TILT CYLINDER DISASSEMBLY AND ASSEMBLY
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
40-78 EX50 Series

DISASSEMBLY AND ASSEMBLY TILT CYLINDER
(lifting height: 3 m)
Item Unit FD100–160E
Cylinder (inside diameter × outside diameter) mm 125 × 142
Stroke mm 240
Outside diameter of rod mm 60
Three Bond # 1901
910–1110 Nm {93–113.3 kgm}
INSPECTION
mm (in)
Judgement standard
Clearance between piston rod and 0.036–0.267 0.567

A bushing (0.001–0.011) (0.022)

Replace
C Piston ring Scratches that catch finger nail
EX50 Series 40-79

DISASSEMBLY LIFT, TILT CYLINDER
1. Removal of cylinder head assembly

Use a wrench to remove the cylinder head assembly.
Outside diameter φ100–120

(FD100,115)
For lift Outside diameter φ125–130

cylinder (FD135, 150E)
Wrench
Outside diameter φ140
(FD160E)
For tilt Outside diameter φ140

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

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
hydraulic 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 pis-
ton seal with the thread of the cylinder.
3. Disassembly of piston rod assembly

1) Remove the piston rod head. (Tilt cylinder only)
2) Remove the cylinder head from the piston rod
assembly.
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.
If the rings are not damaged, do not remove
them. If they are removed, replace them with
new parts.
40-80 EX50 Series

4. Disassembly of cylinder head assembly

If the seals are not damaged, do not disassemble
them. If they are disassembled, replace them with
new parts.
1) Remove the snap ring (tilt cylinder only), then
remove the dust seal.
2) Use a screwdriver to remove the U–packing.

Be careful not to damage any other place
when removing the U–packing.
ASSEMBLY OF LIFT, TILT CYLINDER
1. Assembly of cylinder head assembly

1) 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.
2) Coat the inside diameter of the cylinder head

and the mounting groove of the packing and O–
ring with grease or hydraulic oil.
EX50 Series 40-81

3) Compress the U–packing and push in until it enters

groove .
When using a jig to push in
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.
4) 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.
5) Soak the backup ring in hot water at 30–50 °C for 2–

3 minutes.
6) Take the backup ring out of the hot water, and

expand it to assemble it to the cylinder head.
When assembling the cylinder head assembly in
the cylinder, check first that the backup ring has
cooled and is contracted to its original size.
7) Assemble the O–ring.
40-82 EX50 Series

8) Use a press–fitting tool to press fit the dust seal, then

install the snap ring (tilt cylinder only).
2. Assembly of piston assembly

1) 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.
2) Coat top portion of the piston taper surface with

grease or hydraulic oil.
3) 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.
EX50 Series 40-83

4) Assemble the wear ring.
3. Assembly of piston rod assembly

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. Assembly of cylinder head assembly

Using a wrench, assemble the cylinder head to the
cylinder and tighten it.
Nm {kgm}
706–863 {72–88}
(FD100)
For lift 838–1,020 {85.5–104.5}

cylinder (FD115)
883–1,080 {90–110}
(FD135/160E)
838–1,020 {85.5–104.5}
(FD100/115)
For tilt
cylinder 932–1,130 {95–115}
(FD135/160E)
40-84 EX50 Series

POWER STEERING CYLINDER DISASSEMBLY AND ASSEMBLY
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
40-86 EX50 Series

DISASSEMBLY AND ASSEMBLY POWER STEERING CYLINDER
(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
INSPECTION
mm (in)
Judgement standard
A Clearance between cylinder and 0.05–0.25 0.4

piston rod (0.002–0.010) (0.016)
B Clearance between piston and 0.03–0.18 0.3

busing (0.001–0.007) (0.012) Replace
C Piston ring Scratches that catch finger nail, dents, hollows
D Cylinder Scratches that catch finger nail, dents, hollows
EX50 Series 40-87

CONTROL VALVE DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
This section describes disassembling and assembling 2. Spool assembly
procedures of the representative 3-port relief model. 1) Detach button bolt (41) from lift spool (27) using
When disassembling or assembling work varies accord- a 6 mm hexagon key wrench.
ing to the number of port reliefs or their presence/ 2) Remove spring (26) and spring holder (28).
absence, additional instructions are given in [ ]. 3) Detach button bolt (41) from tilt spool (31) using
Disassembling and assembling units should be con- a 6 mm hexagon key wrench.
ducted at the manufacturer's factory in principle. If this is 4) Remove spring (26) and spring holder (28).
impossible, ask a service shop with in-depth knowledge 5) Remove head spool (20) using a 10 mm span-
of hydraulic machines for the disassembling/assembling ner.
work. Since precision-made hydraulic machines form 6) Remove O-ring (53) using a scriber.
many small gaps inside, conduct disassembly and 7) Pull out spring (22) and plunger (21).
assembly in the following procedures, while paying atten- 8) Since orifice (24) is caulked, it cannot be disas-
tion to the handling of the machine in a clean, dust-free sembled.
place. Do not hit any part even if it does not work 9) Detach button bolt (41) from spool (29) using a 6
smoothly. mm hexagon key wrench.
[Dual-port relief model: not necessary, 4/5-port
NECESSARY TOOLS relief model: in the same way]
• Hexagon key wrench 10) Remove spring (26) and spring holder (28).
(width across flats: 4, 5, 6, 8, 12 mm)
• Spanner (width across flats: 10, 24, 27, 32 mm) 3. Main relief assembly
• Torque wrench 1) Remove sleeve (33) as an assembly using a 24
• Scriber mm spanner, while holding cap nut (5) and lock-
• Vice nut (7) to prevent the set pressure from varying.
Do not disassemble the main relief. It has
DISASSEMBLY been set to the specified pressure.
1. Spool
1) Remove two hexagonal socket head bolts (40) 4. Port relief assembly
using an 8 mm hexagon key wrench. [This work 1) Remove pilot sleeve (16) as an assembly using
is required for all port reliefs.] a 27 mm spanner, while holding cover (17) to
2) Remove cap (3) and O-ring (51). [This work is prevent the set pressure from varying.
required for all port reliefs.] Do not disassemble the port relief. It has
3) Pull out lift spool (27) from body (37) with parts been set to the specified pressure.
(26), (28) and (41) united.
4) Pull out tilt spool (31) in the same way.
5) Pull out spool (29) in the same way.
[Dual-port relief model: not necessary, 4/5-port
relief model: in the same way]
Since clearance is controlled for body (37) and
spool (29), check the combination of spool when
disassembling, and reassemble it at its original
position.
40-88 EX50 Series

DISASSEMBLY AND ASSEMBLY CONTROL VALVE
5. Plug, oil seal ASSEMBLY

1) Remove three plugs (19) using a 6 mm hexagon Before starting reassembly, adequately wash and
key wrench. degrease disassembled parts and prepare new oil seals.
2) Remove three O-rings (58) using a scriber.
3) Remove socket head plug (59) using a 5 mm 1. Plunger
hexagon key wrench. 1) Install two sets of plunger (4) and spring (2) to
4) Remove sleeve (23) using a 32 mm spanner. body (37) with the same combination as that
5) Remove O-ring (54) using a scriber. during disassembling.
6) Remove two hexagonal socket head bolts (39) 2) Tighten two plugs (1) together with O-rings (57)
using a 4 mm hexagon key wrench. to body (37) using a 12 mm hexagon key
[This work is required for all port reliefs.] wrench.
7) Remove seal holder (36) and oil seal (46).
63.5–77.6 Nm {6.5–7.9 kgm}
[This work is required for all port reliefs.]
6. Plunger 2. Sleeve
1) Remove two plugs (1) using a 12 mm hexagon 1) Tighten two sleeves (23) together with O-rings
key wrench. (54) to body (37) using a 32 mm spanner.
2) Remove O-ring (57) using a scriber. 78.3–95.7 Nm {8.0–10.1 kgm}
3) Pull out two sets of spring (2) and plunger (4).
Check the combination of these parts when
disassembling, and reassemble them at 3. Plug, oil seal
their original positions. 1) Install oil seal (46) to body (37). [This work is
4) Since steel balls (44) are press-fit into body (37), required for all port reliefs.]
it cannot be disassembled. 2) Tighten seal holder (36) with two hexagonal
5) Since plate name (35) is riveted with rivet screws socket head bolts (39) using a 4 mm hexagon
(43), it cannot be disassembled. key wrench.
[This work is required for all port reliefs.]
5.6–6.8 Nm {0.6–0.7 kgm}
3) Tighten three plugs (19) together with O-rings

(58) to body (37) using a 6 mm hexagon key
wrench.
28.8–35.2 Nm {2.9–3.6 kgm}
4. Main relief assembly

1) Tighten sleeve (33) assembly to body (37) using
a 24 mm spanner.
88.2–107.8 Nm {9.0–11.0 kgm}
5. Socket head plug

1) Wind seal tape around socket head plug (59)
and tighten it using a 5 mm hexagon key wrench.
7.9–9.7 Nm {0.8–10.0 kgm}
EX50 Series 40-89

CONTROL VALVE DISASSEMBLY AND ASSEMBLY
6. Port relief assembly

1) Tighten pilot sleeve (16) assembly to body (37)
using a 27 mm spanner.
63.5–77.6 Nm {6.5–7.9 kgm}
7. Spool assembly
1) Hold the width across flats (10 mm) of lift spool
(27) in a vice.
2) 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 hexa-
gon key wrench.
26.5–32.3 Nm {2.7–3.3 kgm}
Since button bolt (41) is a microcapsuled

product, prepare a new one or apply Loctite
#242 (or the equivalent) to the threaded por-
tion when installing the disassembled button
bolt.
(When Loctite #242 is applied, leave the but-
ton bolt at ordinary temperature for at least
four hours.)
3) Pass a rod through the 6 mm hole at the end of
tilt spool (31), and hold the tilt spool in a vice.
4) 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.
26.5–32.3 Nm {2.7–3.3 kgm}
5) Hold the width across flats of the installed head

spool in a vice.
6) Install parts (28), (26) and (41) to tilt spool (31) in
the same way as step 2).
7) Hold spool (29) in a vice in the same way as step
1).
8) Install parts (28), (26) and (41) to spool (29) in
the same way as step 2).
9) Insert assembled lift spool (27) into body (37).
10) Insert assembled tilt spool (31) into body (37).
11) Insert assembled spool (29) into body (37).
[For 4- or 5-port relief model, install the spool to
its original position.]
12) 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.]
26.5–32.3 Nm {2.7–3.3 kgm}
40-90 EX50 Series

EX50 Series
1 Plug
2 Spring
3 Cap
4 Plunger
5 Cap nut
6 Adjusting screw
7 Locknut
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
40-91
CONTROL VALVE
MAST DISASSEMBLY AND ASSEMBLY
MAST
When removing the mast and transporting it horizon-

tally, 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.
40-92 EX50 Series

DISASSEMBLY AND ASSEMBLY MAST
SHIM ADJUSTMENT
(1) Strip shim (3) Inner roller
a 0–0.5 mm c 0.5–1.0 mm
Adjust with shims so that Insert the same shim

when the main roller is thickness on the left and
pressed against the rail, right to adjust so that
dimension a=0–0.5 mm clearance b between the
along the whole inner rounded portion of the
rail. roller and the rounded
portion of the rail is 0.5–
1.0 mm.
(2) Outer main roller
b 0.5–1.0 mm
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.
EX50 Series 40-93

MAST DISASSEMBLY AND ASSEMBLY
FORK CARRIAGE
Shim adjustment
(4) 10–ton truck upper roller

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
Adjust with shims so that clear-

ance 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
Adjust with shims so that clear-

ance 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
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 maxi-
mum lifting height.
40-94 EX50 Series

DISASSEMBLY AND ASSEMBLY MAST
ADJUSTING CHAIN
1. Chain length
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.
Tightening torque for chain stopper locknut
824–1030Nm {84–105 kgfm}
INSPECTION
mm (in)
Judgement standard
Inspection item Remedy
Left–right 0.5–1.0 Within 3.0 (0.118) Adjust with shim

Clearance between outer mast (0.020–0.039)
and inner mast
Front–rear 0.5–1.0 Within 5.0 (0.197) Replace roller
(0.020–0.039)

Clearance between inner mast (0.020–0.039)
and fork carriage
Front–rear 0.5–1.0 Within 5.0 (0.197) Replace roller
(0.020–0.039)
Depth of busing oil groove at mast support portion 5.0 (0.197) There must be oil
groove
FD100 75 (3.0) Min. 70 (2.8)
FD115 75 (3.0) Min. 70 (2.8)
Fork thickness (root of fork) FD135 80 (3.2) Min.75 (3.0)
FD150E 85 (3.3) Min. 80 (3.2)

Replace
FD160E 85 (3.3) Min. 80 (3.2)
FD100 648 (25.5) Max. 660 (26.0)

FD115 756 (29.8) Max. 770 (30.3)
Elongation of chain
(length of 17 links) FD135 756 (29.8) Max. 770 (30.3)
FD150E 756 (29.8) Max. 770 (30.3)
FD160E 756 (29.8) Max. 770 (30.3)
EX50 Series 40-95

TABLE OF SPECIAL TOOLS DISASSEMBLY AND ASSEMBLY
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
Measuring starting torque of differential pinion shaft Compressing clutch pack return spring
3ED-97-99600 3EC-97-99000
40-96 EX50 Series

DISASSEMBLY AND ASSEMBLY TABLE OF SPECIAL TOOLS
Inserting clutch pack piston Holding, tightening differential pinion shaft
a 3ED-97-99151
3EC-97-99030 b 3ED-97-99180
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
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
EX50 Series 40-97

TABLE OF SPECIAL TOOLS DISASSEMBLY AND ASSEMBLY
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. 1. There must be no burrs or flashes.

2. Finish with paper so that corner A joins smoothly. 2. Finish with paper so that corner A joins smoothly.
3. Remove any sharp edge from corner B. 3. Remove any sharp edge from corner B.
Material: STKM12–13 or S45C Material: STKM12–13 or S45C
40-98 EX50 Series

DISASSEMBLY AND ASSEMBLY TABLE OF SPECIAL TOOLS
5. Piston rod cap
Material: C3602, C3604
6. Caulking pin rod tip

Material: SK3
Heat treatment:
Quenching, tempering
EX50 Series 40-99

50. MAINTENANCE STANDARD
Engine and electrical parts ......................................50- 2

Accelerator pedal .....................................................50- 2
Speedometer sensor (Option)..................................50- 3
Location of switches and sensors ............................50- 4
Transmission control valve .......................................50-10
Drive shaft................................................................50-11
Differential ................................................................50-12
Final drive ................................................................50-14
Rear axle..................................................................50-16
Steering....................................................................50-17
Frame.......................................................................50-18
Brake peadl ..............................................................50-19
Brake valve...............................................................50-21
Front brake ...............................................................50-23
Parking brake ...........................................................50-26
Control valve ............................................................50-28
Priority valve.............................................................50-30
Lift cylinder...............................................................50-31
Tilt cylinder...............................................................50-32
Power steering cylinder ............................................50-33
Work equipment .......................................................50-34
EX50 Series 50-1

ENGINE AND ELECTRICAL PARTS / ACCELERATOR PEDAL MAINTENANCE STANDARD
ENGINE AND ELECTRICAL PARTS

For the engine and electrical maintenance standards, see Engine Shop Manual 6D107-BE1.
ACCELERATOR PEDAL
Symbol Inspection item New lift truck standard values Remedy
— Pedal pressing efforts 24.5 – 58.8 Nm {2.5 – 6.0 kgm} —
Neutral (a1) 45 ± 2 ° —
— Pedal angle
Maximum (a2) 17 ± 2 ° —
* Carry out inspection when starting engine.
50-2 EX50 Series

MAINTENANCE STANDARD SPEEDOMETER SENSOR (OPTION)
SPEEDOMETER SENSOR (OPTION)
Speedometer sensor
Bracket
Front
axle
Parking brake drum
mm (in)
Judgement standard
Clearance between sensor and
drum
a Screw in sensor and check that 1.5 (0.059)
it contacts drum lightly, then
turn back three turns and lock in
position. Replace
(Tightening torque)
1 Sensor locknut 49 Nm {5.0 kgm}
2 Sensor bracket mounting bolt 98–123 Nm {10.0–12.5 kgm}
EX50 Series 50-3

LOCATION OF SWITCHES AND SENSORS MAINTENANCE STANDARD
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 (option) 13. Radiator coolant level warning lamp
6. Parking brake warning lamp 14. Glow indicator
7. Charge warning lamp 15. Speedometer (option)
8. Operation indicator
50-4 EX50 Series

MAINTENANCE STANDARD LOCATION OF SWITCHES AND SENSORS
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)
EX50 Series 50-5

LOCATION OF SWITCHES AND SENSORS MAINTENANCE STANDARD
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
50-6 EX50 Series

TORQUE CONVERTER MAINTENANCE STANDARD
TORQUE CONVERTER
mm (in)
Judgement standard
A Wear of pilot tip 25 (0.985) 24.85 (0.979)
B Inside diameter of pump boss 80 (3.152) 80.15 (3.158)

(seal ring contact surface)
Width 2.83–2.9 2.65 (0.104)

(0.112–0.114)
C Seal ring
0.05–0.25
End gap when installed (0.002–0.010) –
D Idler gear shaft mounting bolt 35.3–44.1 Nm –

(tightening torque) {3.6–4.5 kgm}
E Stator shaft mounting bolt 67.7–78.5 Nm –

(tightening torque) {6.9–8 kgm}
Pump, drive cover mating bolt 27.5–33.3 Nm
F (tightening torque) {2.8–3.4 kgm} –
G Pilot, flexible plate tightening bolt 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 1.35–1.65 MPa {13.8–16.8 kgf/cm2}

(main pressure)
– Torque converter outlet port pressure 0.3–0.6 MPa {3.1–6.1 kgf/cm2}
50-8 EX50 Series

MAINTENANCE STANDARD TORQFLOW TRANSMISSION
F / R / 1st / 2nd 1.35 – 1.65 MPa {13.8 – 16.8 kgf/cm²}
Clutch actuating pressure
3rd 12.0 – 15.0 MPa {12.2 – 15.3 kgf/cm²}
mm (in)
Judgement standard
A Wear of pilot boss (tip) 25 (0.985) 24.85 (0.979)

B Pump boss inner diameter (seal ring contact surface) 80 (3.152) 80.15 (3.158)
Width 3.0 (0.118) 2.93 (0.115)
C Seal ring
Thickness 3.2 (0.126) 2.45 (0.097)
D Stator shaft inner diameter (seal ring contact surface) 45 (1.773) 45.15 (1.779)
Width 2.5 (0.099) 1.93 (0.076)
E Seal ring (4 points)
Thickness 2.0 (0.079) 1.52 (0.060)
F Converter inner diameter (seal ring contact surface) 35 (1.379) 35.15 (1.385) Replace
Width 2.5 (0.099) 1.93 (0.076)

G Seal ring (5 points)
Thickness 2.0 (0.079) 1.52 (0.060)
Clutch piston inner diameter
H (piston ring contact surface) (4 points) 50 (1.970) 50.15 (1.976)
J Clutch piston inner diameter (piston ring contact surface) 50 (1.970) 50.15 (1.976)
Width 2.5 (0.099) 1.93 (0.076)
K Piston ring (5 points)
Thickness 2.0 (0.079) 1.52 (0.060)
EX50 Series 50-9

TRANSMISSION CONTROL VALVE MAINTENANCE STANDARD
TRANSMISSION CONTROL VALVE
Inching spool
mm (in)
Judgement standard
(1) Set value for relief pressure 1.5 MPa

(main pressure) {15.3 kgf/cm2} –
F/R 1.35–1.65 MPa

{13.8–16.8 kgf/cm2} –
Clutch 1st / 2nd
(2) actuating
A Regulator pressure
3rd
1.20–1.50 MPa
{12.2–15.3 kgf/cm2} –
valve
There must be no dents or uneven wear of outside circumference,

(3) Inner valve of valve end face
Valve mounting bolt 18.6–24.5 Nm

(4) (tightening torque) {1.9–2.5 kgm} –
Outside diameter of spool

(1) 19.967–19.98 –
(seal contact portion)
(2) Free length of valve spring 74 (2.916) –
B Inching (3) Installed length of valve 59 (2.325) –

valve spring
(a) Protrusion of inching spool 24.5 (0.965) –

(when assembled)
Valve base mounting bolt 18.6–24.5 Nm

(4) –
(1) Actuating voltage 24 V 22–26 V

Solenoid
C valve
Mounting bolt 18.6–24.5 Nm
(2) (tightening torque) {1.9–2.5 kgm} –
50-10 EX50 Series

MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
Differential Mission
mm (in)
Judgement standard
A Misalignment of drive shaft 5 (0.197) 5 (0.197)
B Inside diameter of mating portion of — —

bearing and drive shaft
Outside diameter, seal contact There must be

C surface at joint boss 70 (2.758) 69.9 (2.754) no scratches on
contact surface
There must be
D Outside diameter, seal contact 55 (2.167) 54.9 (2.163) no scratches on
surface at brake drum boss contact surface
(Tightening torque) 58.8–68.6 Nm
E Spider, bearing support mounting {6–7 kgm} —
bolts
EX50 Series 50-11

DIFFERENTIAL MAINTENANCE STANDARD
DIFFERENTIAL
50-12 EX50 Series

MAINTENANCE STANDARD DIFFERENTIAL
mm (in)
Judgement standard
A Differential Backlash 0.15–0.2 0.15–0.2

and pinion (0.006–0.008) (0.006–0.008)
24.929–24.98 24.75
B Outside diameter of spider, pin portrion (0.982–0.984) (0.975) 3EE-21-21530
C Inside diameter of pinion gear 25.0–25.021 25.12 3EB-21-11340

(0.985–0.986) (0.990)
Thickness of busing 1.52–1.68 1.3

(0.060–0.066) (0.051)
D Pinion gear 3FE-21-15310
Width x depth of busing oil 0.3 × 0.9 Depth: 0.7
groove (0.012–0.035) (0.028)
Thickness of bushing 1.94–2.06 1.7

(0.076–0.081) (0.067)
E Side gear 3FE-21-15340
Width x depth of busing oil 4×1 Depth: 0.8 (0.032)
groove (0.158–0.039)
Inside diameter of mating +0.030 60.05
Differential portion 60 0 (2.366)
F case side 3FE-21-00010
gear boss Width x depth of busing oil 4×1 Depth: 0.8 (0.032) (3FE-21-15410)
groove (0.157–0.039) (3EB-21-11420)
G Outside diameter of differential case boss 75 +0.030 75 +0.030
+0.011 +0.011
0.2–0.28 0.28
H Backlash between bevel and pinion gear (0.0079–0.011) (0.011)
I Runout of rear face of bevel gear Max. 0.1 Max. 0.1

(0.0039) (0.0039)
J Outside diameter of drum boss portion, seal 55 There must be no

contact surface (2.165) scratches
3FE-21-31110
216.0–216.2 218.2
K Inside diameter of parking brake drum (8.5–8.51) (8.59)
Coat thread
L Differential case tightening bolt 49–73.5 Nm {5–7.5 kgm} with Loctite
M Bevel gear mounting bolt 157–196 Nm {16–20 kgm}
N Differential carrier support tightening bolt 343–427 Nm {35–43.5 kgm}
O Bevel pinion shaft case tightening bolt 98–123 Nm {10–12.5 kgm} 01010-81245
P Differential housing tightening bolt 245–309 Nm {25–31.5 kgm}
Coat thread
Q Parking brake drum tightening bolt 245–309 Nm {25–31.5 kgm} with Locite
* Replace damaged gear, if any (replace the bevel gear and pinion gear in set).
EX50 Series 50-13

FINAL DRIVE MAINTENANCE STANDARD
FINAL DRIVE
mm (in)
Judgement standard
1 Inside diameter of housing, dowel pin hole 18 (0.709) 18 (0.709)
2 Outside diameter of housing, dowel pin 18 (0.709) 18 (0.709)
3 Outside diameter of mast support mount 170 (6.698) 170 (6.698)
4 Outside diameter of housing, seal 195 (7.683) 195 (7.683)

retainer mating portion
Inside diameter of hub inner bearing
5 mating portion 130 (5.122) 130 (5.122)
6 Outside diameter of ring gear boss 140 (5.516) 140 (5.516)

Outer diameter of inside bearing 130 (5.122) 130 (5.122)
waiting portion
7 Hub
Outer diameter of outside bear-
ing waiting portion 195 (7.683) 195 (7.683)
Inside diameter of drum, seal mating

8 portion 230 (9.062) 230 (9.062)
9 Inside diameter of drum inner 200 (7.880) 200 (7.880)

bearing mating portion
Hub
Inside diameter of drum outer
10 bearing mating portion 210 (8.274) 210 (8.274)
11 Starting torque of front hub 20–39 Nm {200–400 kgcm}

(Tightening torque)
Fix in position
12 Lock bolt (for hub nut) 58.8–73.5 Nm {6–7.5 kgm} (install cotter pin)
13 Axle pipe connecting bolt 490.5–605 Nm {50–62 kgm}
14 Gear case mounting bolt 343–426.5 Nm {35–43.5 kgm}
15 Wheel clip nut 441.5–539.5 Nm {45–55 kgm}
50-14 EX50 Series

MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
mm (in)
Judgement standard
1 Housing, dowel pin inside diameter 18 (0.709) 18 (0.709)
2 Housing, dowel pin outside diameter 18 (0.709) 18 (0.709)
Outside diameter, mast support mounting
3 170 (6.698) 169.5 (6.678)
base
Housing, outside diameter, seal retainer
4 130 (5.122) —
engaging portion
Outside diameter, inner bearing
5 200 (7.880) —
engaging portion
Hub
Outside diameter, outer bearing
6 210 (8.274) —
engaging portion
Inside diameter 130 (5.122) No flaw allowed
7 Seal retainer Outside diameter (seal
170 (6.698) No flaw allowed
contact face)
Inside diameter, inner bearing
8 130 (5.122) —
engaging portion
Hub
Inside diameter, outer bearing
9 140 (5.516) —
engaging portion
10 Front hub starting torque 20 – 39 Nm {200 – 400 kgcm}
(Tightening torque)
See the part for disas- Lock the bolt securely
11 Lock bolt (for hub nut)
sembly and assembly (Use a cotter pin)
12 Shaft tube joint bolt 490.5 – 605 Nm {50 – 62 kgm}
13 Gear case mount bolts 343 – 427 Nm {35 – 43.5 kgm}
14 Wheel clip nut 441.5 – 539.5 Nm {45 – 55 kgm}
15 Disc wear sensor mounting plug 10.8 – 14.7 Nm {1.1 – 1.5 kgm}
EX50 Series 50-15

REAR AXLE MAINTENANCE STANDARD
REAR AXLE
mm (in)
Judgement standard
Hole inside diameter (bear- +0.018
1 Axle king pin ing engaging section) 72 –0.012 —
boss
2 Inner height 212 ± 0.2 211.5
3 Height of knuckle king pin boss 175 ± 0.5 174
Clearance for assembling axle king pin
4 0.1 – 0.3 0.5
boss and knuckle
PS cylinder, rod end, pin hole inside diam-
5 25 +0.25 —
eter +0.05
Upper 30 +0.1
0
6 PS cylinder link, pin hole inside diameter —
Lower 25 +0.1
0
–0.025
7 PS cylinder link, pin hole outside diameter 25 –0.048 —
–0.008
8 Knuckle arm, pin hole inside diameter 50 –0.003 —
–0.060
9 Axle center pin outside diameter 80 –0.106 79.5
Tyre operating angle (adjusted using the
* 76 ° ± 30’
stopper bolt)
10 Rear hub starting torque 7 – 10 Nm {0.7 – 1.0 kgm}
(Tightening torque)
* Center pin, support mounting bolts 490 – 608 Nm {50 – 62 kgm}
Steering cylinder mounting bolt
11 735.5 – 828.5 Nm {75 – 84.5 kgm}
(Loctite application)
12 Wheel clip nut 441.5 – 539.5 Nm {45 – 55 kgm}
50-16 EX50 Series

MAINTENANCE STANDARD STEERING
STEERING
2°
2°
65°
mm (in)
Judgement standard
Steering wheel play (when idling) 30–60 (1.182–2.364) 30–60 (1.182–2.364)
Steering wheel tilt angle 2° 2°
Steering wheel lock lever, lock angle 65° 65°
Operating effort of steering wheel 9.8 N {1.0 kgf}
(at knob)
Set pressure of hy- FD100/115 12.7 MPa {130 kgf/cm2}

draulic relief valve FD135–160E 14.7 MPa {150 kgf/cm2}
EX50 Series 50-17

FRAME MAINTENANCE STANDARD
FRAME
mm (in)
Judgement standard
Inside dimension between rear axle
A and center support 360 (14.18) 365 (14.38)
Size of center support bushing 80 × 93 × 80

B inside diameter x outside diameter x (3.15 × 3.66 × 3.15)
length
(Tightening torque)
Coat with
1 Front axle mounting bolt 1961–2452 Nm {200–250 kgm} Loctite #271
2 Center support 490–608 Nm {50–62 kgm}

mounting bolt (F)
Rear axle
Center support
3 mounting bolt (R) 490–608 Nm {50–62 kgm}
4 Counterweight mounting bolt 980.5–1373 Nm {100–140 kgm}
50-18 EX50 Series

MAINTENANCE STANDARD BRAKE PEDAL
BRAKE PEDAL
mm (in)
Judgement standard
(Brake)
A Brake pedal height (when free) 231 (9.1) —
B Brake stroke 76 (3.0) —
D Inching stroke 83 (3.3) —
Interlocking point with the inching
E brake pedal 50 (1.97) —
(Brake oil pressure)

Set pressure of relief valve See p. 50-29
Operate brake valve and check that there is no
Oil leakage from oil circuit and con- leakage or oozing of oil from brake piping or
nections connections
(Brake, inching pedal)
Pedal anchor bushing (outside di- 26 × 20 × 20
ameter x inside diameter x width) (1.02 × 0.79 × 0.79) 3FE–36–11520
Inching rod link lever bushing (out-

side diameter x inside diameter x 16 × 14 × 20 3EB–35–14120
width) (0.63 × 0.55 × 0.79)
Small collar for brake valve link 12.9 × 10.5 × 15

(outside diameter x inside diameter (0.51 × 0.41 × 0.59) 3FE–36–11420
x width)
Large collar for brake valve link 12.9 × 10.5 × 29
(outside diameter x inside diameter (0.51 × 0.41 × 1.14) 3FE–36–11430
x width)
(Brake piping)
Joints of elbows, nipples, etc. Apply gasket sealant
Tightening 8 {0.315 in} 14.7–34.3 Nm {1.5–3.5 kgm}
torque of re-
spective sleeve 10 {0.394 in} 19.6–44.1 Nm {2.0–4.5 kgm}
nuts for brake
pipe 12 {0.472 in} 49–68.6 Nm {5.0–7.0 kgm}
EX50 Series 50-19

BRAKE PEDAL MAINTENANCE STANDARD
BRAKE PEDAL
mm (in)
Judgement standard
(BRAKE)
A Brake pedal height (when free) 231 (9.1) —
B Brake stroke 47 (1.85) —
C Height of pedal when depressed Approx. 65 (2.56) —
D Inching stroke 75 (2.96) —
Interlocking point with the inching 28.5 – 33.5
E —
brake pedal (1.12 – 1.32)
Each joint shall have no oil smear or leakage
Leakage from joints
upon applying brake.
(Brake inching pedal)
Pedal anchor bushing (outside diam-
26 × 20 × 20 (1.02 × 0.79 × 0.79) 3EE-36-11520
eter × inside diameter × width)
Inching rod link lever bushing (out-
side diameter × inside diameter × 16 × 14 × 20 (0.63 × 0.55 × 0.79) 3EE-36-31250
width)
(Brake piping)
Joints of elbows, nipples, etc. Apply gasket sealant
8 mm 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
Tightening torque of
respective sleeve nuts for 10 mm 19.6 – 44.1 Nm {2.0 – 4.5 kgm}
brake pipe
12 mm 48 – 68.6 Nm {5.0 – 7.0 kgm}
Pipe outside diameter (mm) 4.76 6.35 8 10 12 15

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
50-20 EX50 Series

MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
mm (in)
Judgement standard
Standard size Standard size
A Clearance between input piston and – 0.16 (0.006)

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

eter of body mating portion
Clearance between reaction piston
C and diameter of guide mating por- – 0.16 (0.006)
tion
D Piston, spool sliding surface of body –
E Input piston outside diameter sliding –

surface
If there is damage,
Reaction piston outside diameter uneven wear, rust
F sliding surface –
G Spool outside diameter sliding sur- –

face Replace
H Reaction piston sliding surface of –
guide
Reaction piston spring dimension a
(a in diagram below) 0 0
Deterioration of spring J1 – 23.5 (0.926)

J (free length) J2 – 20 (0.788)
EX50 Series 50-21

BRAKE VALVE MAINTENANCE STANDARD
BRAKE VALVE
mm (in)
Criterion
No. Inspection item Reference dimmensions Tolerance limit Action
Free length Mounting length Mounting load Free length
1 (*) Control spring 340 (1.340) 33.5 (1.320) 3.82 N {0.39 kgf} —
2 Control spring 46.3 (1.824) 46 (1.812) 12.8 N {1.3 kgf} —
Replacement
3 Return spring 86.2 (3.396) 58 (2.285) 60.8 N {6.2 kgf} —
4 Return spring 31.5 (1.241) 19.5 (0.768) 16.7 N {1.70 kgf} —
* FD100 to 135 are not installed with the control spring (1).
50-22 EX50 Series

MAINTENANCE STANDARD FRONT BRAKE
FRONT BRAKE
FD 100, 115
mm (in)
Judgement standard
A Inside diameter of drum 393.5–393.9 396.5 (15.61)

(15.49–15.51)
B Thickness of lining 12.7 (0.5) 5.5 (0.22)
C Inside diameter of wheel cylinder 41.3 (1.626) There must be no
scratches on sliding
D Outside diameter of piston – surface
There must be no
E Outside diameter of piston cup – scratches or deterio-
ration
Clearance between piston and
F cylinder 0.025–0.126 0.025–0.126
Strength of return spring 324 ± 32.4 N 324 ± 32.4 N

( = 103.5 mm) {33 ± 3.3 kgf} {33 ± 3.3 kgf}
G
Free length of return spring 93 (3.66) 93 (3.66)
(reference)
(Tightening torque)
H Hub plate tightening bolts, nuts (x 6) 245–309 Nm —

{25–31.5 kgm}
I Wheel cylinder tightening bolt 37.29–49.03 Nm —

{3.8–5.0 kgcm}
EX50 Series 50-23

FRONT BRAKE MAINTENANCE STANDARD
FD135, 150E, 160E
mm (in)
Judgement standard
A Inside diameter of drum 438 (17.24) 440 (17.32)
B Thickness of lining 12.7 (0.5) 5.5 (0.22)
C Inside diameter of wheel cylinder 47.62 (1.875) There must be no
scratches on sliding
D Outside diameter of piston surface
There must be no
E Outside diameter of piston cup scratches or deteriora-
tion
F Clearance between piston and cylinder 0.025–0.126 0.025–0.126
Strength of return spring 1 490 ± 49 N {50 ± 5 kgf} 490 ± 49 N {50 ± 5 kgf}

( = 178) ( = 178)
G
Free length of return spring
(reference) 169.5 169.5
412 ± 39 N {42 ± 4 kgf} 412 ± 39 N {42 ± 4 kgf}

Strength of return spring 2 ( = 159) ( = 159)
H
Free length of return spring 148 148
(reference)
I Inside diameter of dowel pin hole 14 (0.551) 14 (0.551)
J Outside diameter of dowel pin 14 (0.551) 14 (0.551)
(Tightening torque)
98–123 Nm
K Back plate tightening bolts, nuts (x 6) {10–12.5 kgm} —
17.65–26.46 Nm
L Wheel cylinder tightening bolt {1.8–2.7 kgm} —
50-24 EX50 Series

MAINTENANCE STANDARD FRONT BRAKE
FRONT BRAKE
mm (in)
Criterion
Reference dimensions Tolerance Tolerance limit
2.3 – 2.5
A Plate 2.4 (0.095) 2.2 (0.087)
(0.091 – 0.099)
5.0 – 5.2
Disc thickness 5.1 (0.201) 4.6 (0.181)
(0.197 – 0.205)
B
Depth of lining groove 0.5 (min) (0.020) — 0.25 (0.010)
Replacement
Lining thickness 1 (0.039) 0.6 (min) (0.024) —
Reference dimensions Tolerance limit
C Spring load Mounting height Mounting load (N {kgf}) Mounting load (N {kgf})
60.7 (2.39) 456.7 {46.6} 411.0 {41.9}
EX50 Series 50-25

PARKING BRAKE MAINTENANCE STANDARD
PARKING BRAKE
mm (in)
Judgement standard
Lining thickness 5.45 (0.215) 3.3 (0.130)
152 N {15.5 kg} 137 N {14 kg}
Shoe return Strength ( = 50) ( = 50)
spring
Free length 54.7 (2.15)
Clearance between drum and lining
After bringing lining into tight
contact with drum, turn adjuster 0.1–0.25
back 11 notches to adjust clear- (0.0039–0.0098)
ance to 0.25
Max. operating effort of parking
lever (at center of grip) 196 N {20 kgf}
50-26 EX50 Series

CONTROL VALVE MAINTENANCE STANDARD
CONTROL VALVE
Measuring 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 21.6 MPa {220 kgf/cm2}
mm (in)
Judgement standard
Free length 57 (2.25) 55 (2.16)
A
(20) Return spring Installed length 35.8 (1.41) –
Install load 165 N {16.9 kgf} 147–186 N {15–19 kgf}
Free length 70 (2.76) 67 (2.64)
B
(13) Tilt lock spring Installed length 64 (2.52) – Replace
Install load 49 N {5 kgf} 44–53 N {4.5–5.5 kgf}
Free length 48 (1.89) 44 (1.73)
C Check valve
(2) spring Installed length 40.8 (1.60) –
Install load 9.8 N {1 kgf} 8.8–10.7 N {0.9–1.1 kgf}
50-28 EX50 Series

MAINTENANCE STANDARD CONTROL VALVE
(Top surface of control valve)
mm (in)
Judgement standard
(tightening torque)
Coat thread of spool return set bolt 25–34.3 Nm
31 with Locite #242. {2.5–3.5 kgm} —
4 Return spring cover mounting bolt 35–44.1 Nm —

{3.5–4.5 kgm
Coat tightening thread of tilt spool 25–34.3 Nm
12 head with Loctite #242. {2.5–3.5 kgm} —
53.0–64.7 Nm
45 Tightening of relief valve assembly {5.4–6.6 kgm} —
14 Tightening of sleeve (top of relief V) 79.4–97.0 Nm —

{8.1–9.9 kgm}
61.7–75.5 Nm
43 Plug of load check valve {8.1–9.9 kgm} —
34.3–44.1 Nm
Nipple (return pipe) mounting bolt {3.5–4.5 kgm} —
(nominal 27) 62–75.5 Nm —

{6.3–7.7 kgm}
Tightening of (hexagonal 24.5–34.3 Nm
plug socket 6 mm) {2.5–3.5 kgm} —
(hexagonal 13.0–16.7 Nm
socket 5 mm) {1.3–1.7 kgm} —
Lift RAISE 22 N {2.2 kgf} —

15
Operating effort Lift LOWER 22 N {2.2 kgf} —
of control lever Tilt back 22 N {2.2 kgf} —
Tilt forward 22 N {2.2 kgf} —
Forward Backward
Stroke of control Lift lever 126 (4.96) 126 (4.96)
lever
Tilt lever 130 (5.12) 130 (5.12)
EX50 Series 50-29

PRIORITY VALVE MAINTENANCE STANDARD
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 12.7 MPa {130 kgf/cm²}
FD135/150E/160E 14.7 MPa {150 kgf/cm²}
50-30 EX50 Series

MAINTENANCE STANDARD LIFT CYLINDER
LIFT CYLINDER
(Lifting height: 3m)
Item Unit FD100 FD115 FD135/150E 160E

Cylinder (inside diameter x outside diameter) mm 95 × 110 100 × 113 110 × 124 120 × 136
Stroke mm 1510
Outside diameter of rod mm 65 70 75
Weight kg 85 90 105 110
INSPECTION
mm (in)
Judgement standard
Clearance 0.097–0.366 0.666

FD100 (0.004–0.014) (0.026)
A between piston Replace bushing
rod and
bushing FD115/135/ 0.107–0.395 0.695
150E/160E (0.004–0.016) (0.027)
C Piston ring Scratches that catch finger nail Replace
(Tightening torque)
FD100 662–808 Nm {67.5–82.5 kgm}
FD115 706–862 Nm {72–88 kgm}
E Cylinder head
FD135–150E 838–1024 Nm {85.5–104.5 kgm}
FD160E 882–1078 Nm {90–110 kgm}
EX50 Series 50-31

TILT CYLINDER MAINTENANCE STANDARD
TILT CYLINDER

Cylinder (inside diameter x outside diameter) mm 125 × 142
Stroke of rod mm 240
Outside diameter of rod mm 60
INSPECTION
mm (in)
Judgement standard
Clearance between piston rod and 0.036–0.267 0.567
A bushing (0.001–0.011) (0.022)
B Piston rod Scratches that catch finger nail, dents, hollows Replace
C Piston ring Scratches that catch finger nail
(Tightening torque)
E Rod head locknut 98–123 Nm {10.0–12.5 kgm}
F Set bolt for rod head mounting pin 98–123 Nm {10.0–12.5 kgm}
Set bolt for cylinder bottom mount- 01010-81230
G ing pin 98–123 Nm {10.0–12.5 kgm}
H Tightening of cylinder head 910–1110 Nm {93–113.3 kgm}
50-32 EX50 Series

MAINTENANCE STANDARD POWER STEERING CYLINDER
POWER STEERING CYLINDER
Item Unit FD100–FD115 FD135–FD160E

Cylinder (inside diameter x outside diameter) mm φ 90 × φ 102 φ 100 × φ 115
Stroke mm 312 312
Outside diameter of rod mm φ 60 φ 70
INSPECTION
mm (in)
Judgement standard
Clearance between cylinder and 0.05–0.25 0.4
A piston (0.002–0.010) (0.016)
B Clearance between piston rod and 0.03–0.18 0.3

bushing (0.001–0.007) (0.012)
Replace
C Piston ring Scratches that catch finger nail, dents, streaks,
hollows
Scratches that catch finger nail, dents, streaks,
D Inside surface of cylinder hollows
(Tightening torque)
1 Tightening of Cylinder head 441–539 Nm {45–55 kgm} Coat thread with

Loctite
2 Cylinder mounting bolt (rear axle) 735.5–828.5 Nm {75–84.5 kgm}
EX50 Series 50-33

WORK EQUIPMENT MAINTENANCE STANDARD
WORK EQUIPMENT
ADJUSTING CHAIN
1. Chain length
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.
Tightening torque for chain stopper locknut
824–1030 Nm {84–105 kgm}
2. Mast support cap mounting bolt
824–1030 Nm {84–105 kgm}
INSPECTION
mm (in)
Judgement standard
Inspection item Remedy

Clearance between outer mast (0.020–0.039)
and inner mast 0.5–1.0
Front–rear (0.020–0.039) Within 5.0 (0.197) Replace roller
0.5–1.0
Left–right (0.020–0.039) Within 2.0 (0.079) Adjust with shim
Clearance between inner mast
and fork carriage 0.5–1.0
Front–rear Within 5.0 (0.197) Replace roller
(0.020–0.039)
0.5–1.0
Clearance between side roller and rail (0.020–0.039) Within 3.0 (0.118) Adjust with shim
Depth of bushing oil groove at mast support There must be oil

portion 5.0 (0.197) groove
FD100 75 (3.0) Min. 70 (2.8)
FD115 75 (3.0) Min. 70 (2.8)
Fork thickness (root of fork) FD135 80 (3.2) Min. 75 (3.0)
FD150E 85 (3.3) Min. 80 (3.2)
FD160E 85 (3.3) Min. 80 (3.2)
Replace
FD100 648 (25.5) Max. 660 (26.0)
FD115 756 (29.8) Max. 770 (30.3)
Elongation of chain FD135 756 (29.8) Max. 770 (30.3)
(length of 17 links)
FD150E 756 (29.8) Max. 770 (30.3)
FD160E 756 (29.8) Max. 770 (30.3)
50-34 EX50 Series

60. STRUCTURE AND FUNCTION
Power train diagram .................................................60- 2
Automatic transmission (option)...............................60-11
Drive axle .................................................................60-17
Steering axle ............................................................60-18
Steering system .......................................................60-19
Brake........................................................................60-24
Hydraulic pumps ......................................................60-38
Torque converter charging pump .............................60-38
Lift cylinder...............................................................60-39
Tilt cylinder...............................................................60-39
Meter panel ..............................................................60-40
Hydraulic circuit diagrams of work equipment,
steering system and brake ................................60-43
Electrical circuit diagram ..........................................60-47
EX50 Series 60-1

POWER TRAIN DIAGRAM STRUCTURE AND FUNCTION
POWER TRAIN DIAGRAM

60-2 EX50 Series

STRUCTURE AND FUNCTION POWER TRAIN DIAGRAM
POWER TRAIN DIAGRAM

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

(No. 1)
EX50 Series 60-3

TORQUE CONVERTER STRUCTURE AND FUNCTION
TORQUE CONVERTER
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 1.05–1.35 {10.7–13.8}

torque converter MPa {kg/cm2}
Outlet oil pressure 0.3–0.6 {3.1–6.1}
60-4 EX50 Series

STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION
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

F1: 1.795 F2: 0.757 F3: 0.457
Reduction ratio R1: 1.777 R2: 0.749 R3: 0.452
F/R 1.35–1.65 MPa {13.8–16.8 kgf/cm2}
Clutch actuating pressure 1st / 2nd
3rd 1.20–1.50 MPa {12.2–15.3 kgf/cm2}
28–32
Oil capacity (including torque converter, cooler and pipes)
EX50 Series 60-5

TORQFLOW TRANSMISSION STRUCTURE AND FUNCTION
Idller gear
R F
Input shaft
1st-2nd shaft
1ST 2ND
Output shaft
3RD
(Transmission case) (Torque converter case)
60-6 EX50 Series

STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION

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
EX50 Series 60-7

HYDRAULIC CIRCUIT (OUTLINE)

1. When the engine is started, the charging pump is
driven to intake and deliver oil to and from the trans-
mission 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 for-

ward 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} maxi-
mum.
6. Oil cooled with the oil cooler is fed to inside the trans-
mission to lubricate and cool individual components.
It then returns to the transmission case. (See the
hydraulic circuit diagram in the next page onward.)
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 for-
ward 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 pres-
sure 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 for-
ward or reverse travel and the 3rd speed clutch.
(See the hydraulic circuit diagram on the next page
onward.)
60-8 EX50 Series

EX50 Series
1.5 MPa {15.3 kg/cm²}
F/R
pressure
Line filter pick-up port
Oil tempera- Oil
ture gauge cooler Accumulator for F/R
STRUCTURE AND FUNCTION
T/C
regulator valve
0.45 ± 0.15 MPa
HYDRAULIC CIRCUIT DIAGRAM
Inching
valve
Solenoid valve Accumulator
for F/R for speed
Solenoid valve for

pick-up port
Solenoid valve for

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

FWD-REV VALVE
60-9
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
60-10 EX50 Series

STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (OPTION)
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.
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)
EX50 Series 60-11

AUTOMATIC TRANSMISSION (OPTION) STRUCTURE AND FUNCTION
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
MANUAL
lever for 1st, 2nd and 3rd speed.
TROUBLE INDICATOR AUTO

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 con-
tent 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.
CAUTIONS
1. Select forward-reverse travel after the machine
comes to complete stop.
2. 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.)
3. When welding the machine body, remove the con-

troller in advance.
(Or the controller may be damaged by the current
during welding.)
4. Never splash the controller, resistor and other electri-

cal parts with strong water current during steam
washing.
60-12 EX50 Series

TROUBLESHOOTING TABLE
Trouble indicator
(LED) Truck body
No. Content of trouble Repair method Resetting method
Number of behavior
Color
LED flashing
1st speed solenoid in Check the 1st speed sole- Reset by turning
1 Red One time 1 Disabled to travel 1
short circuit noid and replace it. key switch
3rd speed solenoid Check the 3rd speed sole- Reset by turning
2 Red Two times 1 Disabled to travel 1
in short circuit noid and replace it. key switch
1st speed solenoid
Check the controller and
1 drive of the controller Disabled to travel 1
replace it.
in short circuit Reset by turning
3 Red Three times
1st speed solenoid key switch
1 drive of the controller Holding 2nd speed 1
replace it.
is open.
3rd speed solenoid
1 drive of the controller Disabled to travel 1
replace it.
in short circuit Reset by turning
4 Red Four times
3rd speed solenoid key switch
1 drive of the controller Holding 2nd speed 1
replace it.
is open.
Power supply cut Check the short circuit and
1 relay contact in short 1 replace the power supply
circuit cut relay contact.
Check the short circuit and
F/R cut relay contact
2 2 replace the F/R cut relay
in short circuit
contact.
Power supply cut Check the grounding and Reset by turning
5 Red Five times Holding 2nd speed
3 relay solenoid 3 replace the power supply key switch
grounded cut relay solenoid.
Check the grounding and
F/R cut relay sole-
noid grounded
solenoid.
Relay drive transistor Check the controller and
5 5
in short circuit replace it.
Shift lever (H-L Check the short circuit and
Reset by turning
6 Red Six times 1 switch) contacts turn Gear shift holding 1 replace the shift lever (H-L
key switch
ON simultaneously. switch) contact.
EX50 Series 60-13

Trouble indicator
(LED) Truck body
Number of behavior
Color
LED flashing
Check the opening and
1st speed solenoid
1 1 replace the 1st speed
harness is open.
solenoid harness.
1st speed solenoid is
open.
solenoid.
1st speed solenoid is
grounded.
solenoid.
Power supply cut Check the opening and
4 relay is grounded 4 replace the power supply
Reset by turning
7 Red Seven times and open. Disabled to travel cut relay contact.
key switch
is open.
contact.
6 relay solenoid is 6 replace the power supply
open. cut relay solenoid.
F/R cut relay sole-
noid is open.
solenoid.
8 8
is open. replace it.
3rd speed solenoid
1 1 replace the 3rd speed
harness is open.
solenoid harness.
3rd speed solenoid is
open.
solenoid.
3rd speed solenoid is
grounded.
solenoid.
Power supply cut
4 4 replace the power supply
relay contact is open. Reset by turning
8 Red Eight times Disabled to travel cut relay contact.
key switch
is open.
contact.
6 relay solenoid is 6 replace the power supply
open. cut relay solenoid.
F/R cut relay sole-
noid is open.
solenoid.
8 8
is open. replace it.
60-14 EX50 Series

Trouble indicator
(LED) Truck body
Number of behavior
Color
LED flashing
Travel speed sensor
1 1 replace the travel speed
is open.
sensor.
Check the short circuit and
Travel speed sensor
in short circuit
sensor.
9 Red Nine times Gear shift holding
Travel speed sensor
harness is open.
sensor harness.
Travel speed sensor Check the short circuit and
4 harness in short cir- 4 replace the travel speed
cuit sensor harness.
10 Green ON 1 Defective controller Disabled to travel 1
replace it.
Trouble indicator lamp (red LED) flashes as follows: For repair method, implement measures in the
1 CYCLE 3.0 SEC
order of the descriptions.
Remarks
0.5 0.5
EX50 Series 60-15

LIST OF TROUBLES NOT DETECTABLE BY THE TROUBLESHOOTING FUNCTION
No. Content of trouble Truck body behavior Repair method

Controller power supply line is Check the power line and replace the har-
1 1
1 open. Disabled to travel ness.
2 Defective controller 2 Check the controller and replace it.
F/R switch power supply line is
1 1 Check the F/R switch and replace it.
open or grounded.
2 2 F/R switch is open. Disabled to travel 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.
1 F solenoid is open. 1 Check the F solenoid and replace it.
Disabled to travel Check the F switch signal line and replace
3 2 F switch signal line is disconnected. 2
forward the harness.
3 F switch contact is open. 3 Check the F/R switch and replace it.
1 R solenoid is open. 1 Check the R solenoid and replace it.
R switch signal line is discon- Disabled to travel Check the R switch signal line and replace
4 2 2
nected. reverse the harness.
3 R switch contact is open. 3 Check the F/R switch and replace it.
Check the shift lever (H-L switch) and
1 F switch contact is open. 1
1st speed holding replace it.
5
not functioning Check the F switch signal line and replace
2 F switch signal line is disconnected. 2
the harness.
Check the shift lever (H-L switch) and
1 F switch contact is open. 1
Disabled to shift to replace it.
6
F switch contact line is discon- 3rd speed Check the F switch signal line and replace
2 2
nected. the harness.
Automatic or man-
Check the AUTO/MANUAL switch and
7 1 AUTO/MANUAL switch abnormal ual transmission 1
replace it.
function is disabled.
Check the correction volume switch and
1 Adjustment volume switch is open. 1
replace it.
Check the power supply short circuit of the
Adjustment volume switch (5 V) in Gear shift speed
2 2 correction volume switch and replace the
short circuit does change when
8 volume switch.
the volume switch is
Adjustment volume switch is Check the grounding of correction volume
3 turned. 3
grounded. switch and replace it.
Adjustment volume switch harness Check the opening and replace the volume
4 4
is open. harness
For repair method, implement measures in the
Remarks
order of the descriptions.
60-16 EX50 Series

STRUCTURE AND FUNCTION DRIVE AXLE
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
EX50 Series 60-17

STEERING AXLE STRUCTURE AND FUNCTION
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°
Tyre turning angle (inside) 76° ± 30’ 76° ± 30’ 76° ± 30’
Tyre turning angle (outside) 53° 53° 53°
Tread 1900 mm 1890 mm 1870 mm
60-18 EX50 Series

STRUCTURE AND FUNCTION STEERING SYSTEM
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.
1. STEERING VALVE
Structure
Power steering system using full hydraulic power steering
basically consist of a hydraulic pump, full hydraulic power Model FD100-160E
steering body, and power steering cylinder.
Discharge 230 cc/rev
The internal structure of the full hydraulic power steering
body can be divided into the control valve and metering Relief pressure 12.7 MPa {130 kg/cm2}
device. The control valve consists of the No. 1 rotating Inlet flow 22.7 /min
valve (called the spool), and the No. 2 rotating valve
Valve charac- Open center non–reaction type
(called the sleeve). The metering device consists of a teristic
special gear set called a Gerotor.
In addition, a feedback link is installed to provide feed-
back of the metering flow in the metering device to the
control valve.
EX50 Series 60-19

STEERING SYSTEM STRUCTURE AND FUNCTION
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 cylin-
der all passes through the metering mechanism and
is sent to the cylinder.
The oil discharged from the cylinder goes from cylin-
der 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 feed-
back 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 pas-
sages (15) and (14) and returns from port (T) to the
tank.
60-20 EX50 Series

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.
Precautions
1. 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.
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.
2. 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.)
3. For safety reasons, always replace the hose between the FHPS valve and power steering cylinder once every two
year.
EX50 Series 60-21

STEERING SYSTEM STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT DIAGRAMS OF STEERING SYSTEM AND CYLINDER

60-22 EX50 Series

HYDRAULIC CIRCUIT DIAGRAMS OF STEERING SYSTEM AND CYLINDER

EX50 Series 60-23

BRAKE STRUCTURE AND FUNCTION
BRAKE
Wheel brake
Model FD100/115 FD135/150E/160E

Type 2–leading type
Inside diameter of drum 393.7 mm 432 mm
Brake specifications Lining material Non–asbestos
Lining size (width x thickness) 125 mm × 13.1 mm 125 mm × 12 mm
Inside diameter of wheel cylinder 41.3 mm 47.62 mm
Regulated pressure 12.7 MPa {130 kg/cm2}
Brake valve Piston stroke 11 mm
Inlet flow 25 /min
Oil pressure at max. pressure storage 13.7 MPa {140 kg/cm2}
Accumulator
Pressure storage capacity 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.
60-24 EX50 Series

STRUCTURE AND FUNCTION BRAKE
PRINCIPLE OF OPERATION OF BRAKE VALVE
1. 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.
2. 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 pres-
sure 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 reac-
tion force), so the condition is balanced with the amount that the pedal is depressed by the operator.
EX50 Series 60-25

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.
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.
3. 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) con-
tacts 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.
60-26 EX50 Series

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.
EX50 Series 60-27

HYDRAULIC CIRCUIT DIAGRAMS OF BRAKE

60-28 EX50 Series

BRAKE
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 are not installed with the control spring (1).
EX50 Series 60-29

WHEN OPERATING
Stepping on the pedal transfers the operating efforts to
spool (3) via rod (2) and spring (4). When the spool (3) is From the pump
lowered, the drain port (a) closes, and the oil from the
pump and accumulator flows from the port (A) to port (C)
Accumulator
to operate the 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
Accumulator
drain port (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
60-30 EX50 Series

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.
EX50 Series 60-31

1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. Relief valve (R2)
5. Relief valve (H1)
6. Filter
60-32 EX50 Series

OPERATIONS
1. When no oil is supplied to the accumulator (cut 2. When oil is supplied to the accumulator
out state) 1) Cut in state
• Because the pressure of port (B) is higher than the • When the pressure of port (B) reaches the set pres-
set pressure of relief valve (R1), piston (8) is forcibly sure for relief valve (R1) or lower, spring (5) returns
pushed upward by the oil pressure from port (B) to piston (8) downward. The valve seat (7) and poppet
open poppet (6), thus short-circuiting ports (C) and (6) are in contact and cut port (C) from port (T).
(T). • Right hand spring chamber of spool (15) is also cut
• Since the spring chamber at the right end of spool off from port (T). Likewise the pressure of port (P)
(15) is connected with port (C) of relief valve (R1), rises.
the pressure level of spring chamber is equal to that • When the pressure of port (P) reaches a level higher
of the brake oil tank. than that of port (B) (accumulator), oil supply to the
• Oil from the pump enters port (P) and pushes spool accumulator starts at this point. In this case, fixed
(15) to the right with low pressure equivalent to the quantity determined by the size (area) of orifice (17)
load of spring (14), flowing to the tank from port (A). and the pressure difference generated before and
At the same time, the oil also flows to the tank via ori- after the oil supply to the accumulator (equivalent to
fices (17), (18) and (16). the load of spring (14)) is supplied to the accumulator
irrespective of engine speed, and the remaining oil
flows to port (A).
Tank
Tank
Pilot
pressure of
accumulator
Pilot
pressure of
accumulator
To
accumu-
lator
To
accumu-
lator
EX50 Series 60-33

2) When the cut-out pressure is reached 3. Main relief valve (R3)

• When port (B) pressure (accumulator pressure) • When the pressure of port (P) (pump pressure)
reaches the set pressure level for relief valve (R1), reaches the set pressure level of relief valve (R3), oil
poppet (6) is separated from valve seat (7), forming from the pump pushes up ball (11) against the force
the oil flow to operate relieving. of spring (3) to allow the oil to flow to the tank circuit.
• With the start of relief operation, pressure difference This controls the maximum brake circuit pressure to
is generated between the top and bottom of piston protect the circuit.
(8). This makes the piston (8) move upward, forcing
the poppet (6) to open and short-circuiting ports (C)
and (T). Tank
• 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 tank.
• Likewise, the pressure of port (P) drops to the level
equivalent to the load of spring (14), stopping oil sup- Pilot
ply to port (B). pressure of
accumulator
Tank
Pilot
pressure of
accumulator
To
accu-
mulator
To
accu-
mulator
60-34 EX50 Series

BRAKE
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc
EX50 Series 60-35

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 contact. As the result, frictional force is gen-
erated 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.
60-36 EX50 Series

HYDRAULIC CIRCUIT DIAGRAMS OF BRAKE

EX50 Series 60-37

HYDRAULIC PUMPS, TORQUE CONVERTER CHARGING PUMP STRUCTURE AND FUNCTION
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 MPa {kgf/cm²} 21.6 {220} 12.7 {130}
Discharge cc/rev 90.0 40.0
Rated speed rpm 2200 2200
2. Wet disc brake type
Item Unit Work equipment Power steering Brake Brake cooling
Name of pump — Pump No. 1 Pump No. 2 Pump No. 3 Pump No. 4
12.7 {130} (FD100 – 115)

Relief pressure MPa {kgf/cm²} 21.6 {220} 9.8 {100} 0.34 {3.5}
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 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 MPa {kgf/cm²} 1.5 {14.7}
Discharge cc/rev 43.7
Rated speed rpm 2200
60-38 EX50 Series

STRUCTURE AND FUNCTION LIFT CYLINDER, TILT CYLINDER
LIFT CYLINDER
Item Unit FD100 FD115 FD135 FD150E/160E
Outside diameter of cylinder mm 110 113 124 136
Inside diameter of cylinder mm 95 100 110 120
Diameter of piston rod mm 65 70 75 75
Stroke 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 kg/each 85 90 105 110
TILT CYLINDER
Outside diameter of cylinder mm 142
Inside diameter of cylinder mm 125
Diameter of piston rod mm 60
Stroke mm 24
Seal type – U–packing, piston ring
Weight kg–each 50
EX50 Series 60-39

METER PANEL STRUCTURE AND FUNCTION
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) (13) Radiator coolant level warning lamp
(6) Parking brake warning lamp (14) Glow indicator
(7) Charge warning lamp (15) Speedometer (option)
60-40 EX50 Series

STRUCTURE AND FUNCTION METER PANEL
Cate-
No. Symbol Indicated item Indication (range) Indication method
gory
Indicates the temperature of engine cooling

Engine cooling water water.
1
temperature White range : Normal
Red range : May cause overheat
0 to 999999/h Operates upon turning the switch ON. Indi-

2 Hour meter
indication cates accumulated operating hours.
Meter
Indicates the temperature of torque converter

Torque converter oil oil.
3
temperature White range : Normal
Red range : Abnormal
Indicates unused balance of fuel if the key

4 Fuel
switch is turned OFF (Stitch type).
Neutral indication • When F/R lever is in neutral: Lights up

5 Travel-interlocked During operation • During travel-interlocked operation:
operation Flashes
Parking brake in
6 During operation When parking brake is applied: Lights up
operation
• Key switch ON: Lights up

Battery charged When not fully
7 • After engine start: Turns OUT (normal)
state charged
• After engine start: Turns ON (abnormal)
Operation indicator
8 During operation Flashes during operation
Hour meter operation
Safety checker
Material handling- During material handling-interlocked opera-

9 During operation
interlocked operation tion: Flashes

• When in normal conditions: Turns OFF 4
When the engine is in seconds after the key switch is turned ON
10 Engine abnormality
abnormal conditions • During abnormal conditions and when fail-
ure lamp selection connector is con-
nected: Flashes
• When in normal conditions: Turns OFF 4
Abnormality of
When the engine is in seconds after the key switch is turned ON
11 engine control sys-
abnormal conditions • During abnormal conditions and when fail-
tem
ure lamp selection connector is con-
nected: Flashes
Air cleaner element When the clogging of air cleaner is near the
12 When clogged:
clogging limit: Lights up
EX50 Series 60-41

METER PANEL STRUCTURE AND FUNCTION
Cate-
No. Symbol Indicated item Indication (range) Indication method
gory
• Indicated when the starter switch is ON
while the engine has stopped.
When normal : Turns OUT
Radiator cooling
13 Below proper quantity When abnormal: Lights up
Safety checker
water level
• Indicated during engine revolution
When normal: Turns OUT
When abnormal: Lights up
14 Preheating During preheating Lights up during preheating

Meter
15 Travel speed
60-42 EX50 Series

STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAMS OF WORK EQUIPMENT, STEERING SYSTEM AND BRAKE
HYDRAULIC CIRCUIT DIAGRAMS OF WORK EQUIPMENT, STEERING SYSTEM AND BRAKE

EX50 Series 60-43

STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAMS OF WORK EQUIPMENT, STEERING SYSTEM AND BRAKE
HYDRAULIC CIRCUIT DIAGRAMS OF WORK EQUIPMENT, STEERING SYSTEM AND BRAKE

EX50 Series 60-45

STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

ISO 3691-1
BRAKE TYPE TRANSMISSION TYPE
(With OPS system)
Hydraulic drum Manual —
EX50 Series 60-47


ISO 3691-1
(With OPS system)
Hydraulic drum Auto —
EX50 Series 60-49


ISO 3691-1
(With OPS system)
Hydraulic drum Manual Q
EX50 Series 60-51


ISO 3691-1
(With OPS system)
Hydraulic drum Auto Q
EX50 Series 60-53


ISO 3691-1
(With OPS system)
Wet disc Manual —
EX50 Series 60-55


ISO 3691-1
(With OPS system)
Wet disc Auto —
EX50 Series 60-57


ISO 3691-1
(With OPS system)
Wet disc Manual Q
EX50 Series 60-59


ISO 3691-1
(With OPS system)
Wet disc Auto Q
EX50 Series 60-61

70. TROUBLESHOOTING
Functions of troubleshooting tool and

check of failure code ...........................................70-2
Failure code table ......................................................70-8
Torque converter ........................................................7-10
Control valve ............................................................70-13
EX50 Series 70-1

FUNCTIONS OF TROUBLESHOOTING TOOL AND CHECK OF FAILURE CODE TROUBLESHOOTING
FUNCTIONS OF TROUBLESHOOTING TOOL AND CHECK OF FAILURE

CODE
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
a Arrange for necessary tools for troubleshooting.
Symbol Part name (part No.) Remarks
CD-ROM for trouble- • Common parts for diesel

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

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

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

C cable (Common part with FB-12/FBR-
(3BA-97-71220) 14)
70-2 EX50 Series

TROUBLESHOOTING FUNCTIONS OF TROUBLESHOOTING TOOL AND CHECK OF FAILURE CODE
• The troubleshooting tool has the following functions.

1. Indication of failure code
2. Deletion of failure code
3. Indication of repair procedure
Method of indicating failure code with

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

2. Open the engine hood.
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 communi-
cation cable (C) of troubleshooting software (A) and
intermediate cable (B).
<Machine in this photo is different from actualmachine>
4. Start the installed software and check the failure

code.
a The method of using the software is shown in
the CD-ROM.
EX50 Series 70-3

Example of indication of failure code
70-4 EX50 Series

Method of 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
a When starting or running the engine ordinarily, do

not interchange caps (1A) and (2A).
EX50 Series 70-5

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.
a 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"
70-6 EX50 Series

Example 2: Failure code "112"
Example 3: Simultaneous indication of failure codes "112" and "244"
EX50 Series 70-7

FAILURE CODE TABLE TROUBLESHOOTING
FAILURE CODE TABLE
Failure code of
Trouble Place of description
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
222 Abnormally low level in atmospheric pressure sensor
227 Abnormally high level in sensor power supply 2 circuit

Troubleshooting of
234 Engine overspeed electrical system
(E-mode)
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
352 Abnormally low level in sensor power supply 1 circuit
386 Abnormally high level in sensor power supply 1 circuit
415 Rotation derating by low engine oil pressure
418 Water mixed in fuel
428 Abnormally high level in water sensor
70-8 EX50 Series

TROUBLESHOOTING FAILURE CODE TABLE
Failure code of
Trouble Place of description
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
452 Abnormally low level in common rail pressure sensor
488 Derating of torque by abnormally high charge temperature
553 Abnormally high common rail pressure 1 Troubleshooting of

electrical system
559 No-pressure feed by supply pump 1 (E-mode)
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
2249 No-pressure feed by supply pump 2
2311 Abnormality in IMV solenoid
2555 Disconnection in intake air heater relay
2556 Short circuit in intake air heater relay
a Failure code of troubleshooting tool:

3- or 4-digit failure code displayed on troubleshooting tool when a failure occurrence condition is confirmed using trou-
bleshooting tool.
EX50 Series 70-9

TORQUE CONVERTER TROUBLESHOOTING
TORQUE CONVERTER
1. Causes and remedies for failures
No. Problem Cause Remedy
1 Power is not transmitted A No hydraulic pressure

1) Lack of oil Add oil
2) Damaged gear pump or drive por- Disassemble and check, replace
tion 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
2 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 Disassemble and replace, replace
valve or defective operation of pis- parts if necessary
ton
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
3 Oil pressure rises 1) Incorrect oil level Add or drain oil

abnormally high 2) Contact of impeller Disassemble and replace, replace
parts if necessary
3) Wear or seizure of bearing Disassemble and replace, replace
parts if necessary
4) Wear or damage of gear pump Disassemble and replace, replace
parts if necessary
70-10 EX50 Series

TROUBLESHOOTING TORQUE CONVERTER
No. Problem Cause Remedy
4 Abnormal noise is 1) Cavitation caused by leakage of air Add oil or check and replace parts if
generated
from suction piping or lack of oil necessary
2) Failure of gear pump Disassemble and replace parts or
whole assembly
3) Contact caused by deformed impel- Disassemble and replace, replace
ler 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
5 Oil oozes out or leaks A Oil seal

1) Worn or damaged lip Disassemble and replace
2) Dirt caught Disassemble and replace, replace
parts if necessary
3) Worn or scratched shaft Correct or replace
4) Hardening or deterioration of rubber Disassemble and replace
because of abnormal rise in oil tem-
perature
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 tem-
perature
4) Sudden use in extremely cold tem- Carry out warming–up operation
peratures (below–15°C)
C Plug, screw
1) Loose screw Tighten
2) Broken screw Replace
3) Cracked hole Replace
EX50 Series 70-11

70-12
1.5 MPa {15.3 kg/cm²}
F/R
TORQUE CONVERTER
pressure
Line filter pick-up port
Oil tempera- Oil
ture gauge T/C cooler Accumulator for F/R
regulator valve
0.45 ± 0.15 MPa
Inching
valve
Solenoid valve
for F/R Accumulator
for speed
Solenoid valve for

pick-up port
Solenoid valve for

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

FWD-REV VALVE
EX50 Series
TROUBLESHOOTING
TROUBLESHOOTING CONTROL VALVE
CONTROL VALVE
Troubleshooting
Problem Cause Remedy
External oil leakage • Damage/deformation/disengagement of • Replace with a new O-ring.
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 excessive • Check machine pressure.
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 cracking • Replace relief assembly.
tilting speed down 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) coupling • Replace valve assembly.
portion
• Excessive wear of tilt spool (31)
Mast descends when lever • Malfunction of plunger (4) • Disassemble, wash and
is returned after elevation (due to stuck foreign matter) reinstall the plunger.
• Defect of spring (2) • Disassemble and correct the spring or
replace it with a new one.
Spool does not • Foreign matter remaining in the spool • Remove the foreign matter or replace
move smoothly. sliding area. valve assembly.
EX50 Series 70-13

70-14
CONTROL VALVE
1 Plug
2 Spring
3 Cap
4 Plunger
5 Cap nut
6 Adjusting screw
7 Locknut
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
EX50 Series
TROUBLESHOOTING
80. CHECK ITEMS FOR EACH EQUIPMENT
Engine......................................................................80- 2
Power train...............................................................80- 7
Travel system...........................................................80-11
Steering system .......................................................80-13
Braking system ........................................................80-15
Loading system........................................................80-18
Hydraulic system......................................................80-20
Chassis, safety system ............................................80-23
Overrall test..............................................................80-23
EX50 Series 80-1

ENGINE CHECK ITEMS FOR EACH EQUIPMENT
CHECK ITEMS FOR EACH EQUIPMENT
Com- Inspection item Nature of inspection

ponent
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:

1. Idling speed
Engine
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
For the cleaning and replacement method of the element, see the sec-
tion of TESTING AND ADJUSTING.
80-2 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
ponent Inspection item Nature of inspection
5. Cylinder head Loosening of cylinder head mounting bolts

For the tightening method and torque for the cylinder head mounting
bolts, see Engine Shop Manual 6D107E-BE1.
6. Valve clearance Valve clearance
Model Engine Intake valve Exhaust valve

FD100/115 SAA6D107-1-A
FD135/150E (Komatsu) 0.25 (Cold) 0.51 (Cold)
FD160E
For how to adjust valve clearance, see Engine Shop Manual

6D107E-BE1.
7. Compression Compression
Engine
pressure Unit: MPa {kgf/cm2}/rpm

FD100/115
FD135/150E Min. 2.41 {24.6} / 250 – 280
FD160E
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
EX50 Series 80-3

Com-
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
(Komatsu) 20.3 l
2) Discoloration and degradation

Replace it if degraded.
a For the oil changing method, see the section of TESTING AND
ADJUSTING.
3) Oil leakage
2. Engine oil filter

Periodically replace filters since their condition is not determined by visual
inspection.
a For the oil filter replacement method, see the section of TESTING AND
Engine
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.
a For the fuel filter replacement method, see the section of TESTING
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
80-4 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
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
k Do not remove the radiator
cap when the coolant tem-
perature is high.
Or the scalding water may blow out.
k 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 fin-
gertip.
2) Negative pressure valve
Check that the valve closes when it is
pulled and released.
a 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)
EX50 Series 80-5

Com-
20. Alternator, wring Check the following.

1. Specific gravity of battery electrolyte
Be careful when handling the bat-
tery electrolyte. If it is handled mis-
takenly, 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.
Battery electrolyte (dilute sul-
phuric acid) may cause burns
or loss of sight. If the electro-
lyte gets in your eyes, on your
skin, or on your clothes, wash
it off immediately with large
Engine
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)
80-6 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT POWER TRAIN
Com-
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.
Oil filler cap Oil level gauge

Power train
Correct
Drain plug range
Strainer
EX50 Series 80-7

POWER TRAIN CHECK ITEMS FOR EACH EQUIPMENT
Com-
22. Transmission 4. Inching pedal

(continued) 1) Protrusion of inching spool
For details of the method of a

adjustment, see TESTING AND
ADJUSTING.
2) Interconnected travel
Adjust with adjustmentbolt so that
the inching pedal and brake pedal
Adjustment bolt
are interconnected for the travel
shown below when the inching
pedal is depressed.
Interconnected 50 mm (1.97 in)

stroke
3) Pedal height
Power train
Pedal height 231 mm

(h) (9.1 in)
80-8 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT POWER TRAIN
Com-
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.
F/R
Clutch actuation 1st and 2nd 1.35–1.65 MPa {13.8–16.8 kgf/cm2}
pressure
3rd 1.20–1.50 MPa {12.2–15.3 kgf/cm2}
Torque converter inlet port pressure: 1.2–1.5 MPa {12–15 kgf/cm2}

Torque converter outlet port pressure: 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
1, 2, 3 speed
clutch pressure
port
Oil level
gauge
Oil filler cap

To line filter
PF 3/4
Power train
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
(Komatsu) 2,000 rpm
The torque converter oil temperature will rise, so do not continue this
operation for a long time.
EX50 Series 80-9

POWER TRAIN CHECK ITEMS FOR EACH EQUIPMENT
Com-
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
For details of the method of check-
ing the oil level and changing the
oil, see TESTING AND ADJUST-
ING.
4. Oil leakage from case
5. Loose mounting bolts

Power train
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
80-10 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT TRAVEL SYSTEM
Com-
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
1,961–2,452 Nm
{200–250 kgm}
28. Rear axle 1. Deformation, cracks, damage

Check visually or use the crack detec-
tor
method.
2. Play of center pin (clearance from
bushing)
3. Loose cap, support mounting bolts
Cap 1 2
Bolts 1,2 Wheel center Support
490–608 Nm
{50.0–62.0 kgm}
Travel system
29. Tyre 1. Inflation pressure

Unit: kPa {kgf/cm2}
Model Front wheel Rear wheel

FD100 735 {7.5} 735 {7.5}
FD115 690 {7.0} 690 {7.0}
FD135 660 {6.75} 660 {6.75}
FD150E 760 {7.75} 760 {7.75}
FD160E 690 {7.0} 690 {7.0}
2. Cracks, damage to tread, side wall

If the damage is serious, replace the tyre.
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 tyre
EX50 Series 80-11

TRAVEL SYSTEM CHECK ITEMS FOR EACH EQUIPMENT
Com-
30. Wheel
1. Loose hub nut
Hub nut tightening torque
Unit: Nm {kgm}
Front wheel Rear wheel
441.5–539.5 {45–55} 441.5–539.5 {45–55}
2. Deformation, cracks in rim, side ring

Check visually or use the crack detector method.
Travel system
80-12 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT STEERING SYSTEM
Com-
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
33. Ssteering linkage 1. Cracks, damage, curvature

Steering system
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 tyre at the top and bottom to check.
2) Abnormal noise, rotate the tyre by hand to check.
2. King pin
1) Play
2) Cracks, damage
3. Knuckle
Damage
Check visually or check with the crack detection method.
EX50 Series 80-13

STEERING SYSTEM CHECK ITEMS FOR EACH EQUIPMENT
Com-
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
FD115 Within 4,000 mm (157.6 in) ± 5 %
FD135 Within 4,350 mm (171.4 in) ± 5 %

FD150E Within 4,400 mm (173.4 in) ± 5 %
FD160E Within 4,500 mm (177.3 in) ± 5 %
Difference between left and right Within ± 100 mm (3.9 in)
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 pres-
sure when the steering wheel is
turned fully.
12.7 MPa ± 0.25

FD100/115
Oil {130 ± 2.5 kgf/cm2}
pressure 14.7 MPa ± 0.25
FD135–160E
{150 ± 2.5 kgf/cm2}
38. Steering chain — Not applicable to this truck model —
80-14 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT BRAKING SYSTEM
Com-
39. Travel brake 1. Brake pedal

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

(9.1 in) h
2) Pedal play
1–4 mm
Pedal play (0.04–0.16 in)
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)
Within 2.5 m
When loaded (when traveling at 10 km/h)
Braking system
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
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
EX50 Series 80-15

BRAKING SYSTEM CHECK ITEMS FOR EACH EQUIPMENT
Com-
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 between FD100/115

cylinder and piston Within 0.12 mm (0.0047 in)
FD135/150E/160E
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 Within 5.5 mm (0.22 in)
FD135/150E/160E
3. Corrosion of anchor pin
4. Deterioration of return spring
Item FD100/115 FD135/150E/160E
Free length Standard dimension: Standard dimension:

93 mm 169.5 mm
Spring (1)
Strength Min. 323 ± 32 N {33 ± 3.3 kgf} Min. 490 ± 49 N {50 ± 5 kgf}
when =103.5 mm when =178 mm
Standard dimension:
Free length – 148 mm
Spring (2)
Strength – Min. 412 ± 39 N {42 ± 4 kgf}
when =159 mm
80-16 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT BRAKING SYSTEM
Com-
47. Brake drum Cracks, damage, wear of drum

Measure the following dimensions and check that they are within the ser-
vice limit.
Item FD100/115 FD135/150E/160E

Inside diame- Within 393.7 mm Within 438 mm
Wheel ter of drum (Within 15.49 in) (Within 17.24 in)
brake Clearance between 0.2–0.5 mm 0.3–0.6 mm
drum and lining (0.008–0.02 in) (0.012–0.04 in)
48. Back plate 1. Deformation, cracks, damage

2. Tightening torque of mounting bolts
Item FD100/115 FD135/150E/160E
(Wheel brake) 245–309 Nm 98–123 Nm

{25–31.5 kgm} {10–12.5 kgm}
(Wheel brake) Loctite #271 (tap holem)
49. Parking brake — Not applicable to this truck model —

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

ing, back plate
Lining thickness Min. 33 mm (Min. 0.13 in)
2. Deterioration of return spring
Strength (when =50 mm) (2.0 in) Min. 137 N {14 kgf}
Free length b: Standard dimension 54.7 mm (2.15 in)
3. Deformation, cracks, damage to back plate
4. Tightening torque of back plate mounting bolt
(Parking brake) 245–309 Nm {25–31.5 kgm}
52. Parking brake drum Cracks, damage, wear of drum

Measure the following dimensions and check that they are within the ser-
vice limit.
Item FD100–FD160E
Inside diameter of Within 216 mm
Parking drum (Within 8.5 in)
brake Clearance between 0.1–0.2 mm
drum and lining (0.004–0.008 in)
EX50 Series 80-17

LOADING SYSTEM CHECK ITEMS FOR EACH EQUIPMENT
Com-
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 50 mm (0.197 in)

Difference in height Within 20 mm (0.079 in)
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. 70 mm (2.8 in)

FD115 Min. 70 mm (2.8 in)
FD135 Min. 75 mm (3.0 in)
FD150E Min. 80 mm (3.2 in)
FD160E Min. 80 mm (3.2 in)
From time to time, use the crack detection method to check the fork
Loading system
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 outer Left–to–right Within 3.0 mm (0.118 in)

mast and inner mast Front–to–rear Within 5.0 mm (0.197 in)
Clearance between inner Left–to–right Within 2.0 mm (0.079 in)

mast and fork carriage Front–to–rear Within 5.0 mm (0.197 in)
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
824–1,030 Nm {84–105 kgm}
80-18 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT LOADING SYSTEM
Com-
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 speci-
fied value.
Length FD100 FD115/135/150E/160E

between Within 660 mm Within 770 mm
17 links (26.0 in) (30.3 in)
Loading system
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
EX50 Series 80-19

HYDRAULIC SYSTEM CHECK ITEMS FOR EACH EQUIPMENT
Com-
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)
63. Chassis piping 1. Cracks, damage, deterioration, twisting of piping
2. Oil leakage
Hydraulic system
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
80-20 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT HYDRAULIC SYSTEM
Com-
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 pay-
cylinder, tilt cylinder load, 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.
When measured Within 100 mm

Hydraulic at fork (4 in) (for 15 min)
drift of lift
cylinder When measured Within 50 mm
at cylinder (4 in) (for 15 min)
Hydraulic
drift of lift Within 40 mm (1.6 in) (for 15 min)
cylinder
Hydraulic system
Adjustment:
Replace the control valve, cylinder
packing
72. Directional control 1. Actuation, oil leakage

valve (1)
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: MPa {kgf/cm2}

Relief set pressure 21.6 {220}
EX50 Series 80-21

HYDRAULIC SYSTEM CHECK ITEMS FOR EACH EQUIPMENT
Com-
74. Solenoid valve 1. Actuation, abnormal noise
2. Abnormal generation of heat
3. Oil leakage
Hydraulic system
80-22 EX50 Series

CHECK ITEMS FOR EACH EQUIPMENT CHASSIS, SAFETY SYSTEM
Com-
ponent Check item Details of check
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 get- 1. Cracks, damage, deformation

ting on/off lift truck, 2. Loose mounting blots
anti–slip devices
Chassis, safety system
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 sys- Carry out travel, operation test to check
tem
Overrall test
EX50 Series 80-23

90. CONVERSION TABLE
Millimenters to Inches ................................................90-2

Inches to Millimeters ..................................................90-2
Cubic meters to Cubic yards......................................90-3
Cubic yards to Cubic meters......................................90-3
Liter to U.S. Gallon.....................................................90-4
U.S. Gallon to Liter.....................................................90-4
Liter to U.K. Gallon.....................................................90-5
U.K. Gallon to Liter.....................................................90-5
Kilogram to Pound .....................................................90-6
Pound to Kilogram .....................................................90-6
Kg/cm2 to Ib/in2 ..........................................................90-7
Kgm to Ft Ib ...............................................................90-8
Temperature...............................................................90-9
EX50 Series 90-1

Millimeters to Inches
Inches To Millimeters CONVERSION TABLE
CONVERSION TABLE
Millimeters to Inches 1mm=0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.881 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 2.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Inches to Millimeters
0.1 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0 0.254 0.508 0.762 1.016 1.270 1.524 1.778 2.032 2.286
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
90-2 EX50 Series

Cubic meters to Cubic yards
CONVERSION TABLE Cubic yards to Cubic meters
Cubic meters to Cubic yards 1m3= 1.308 cu.yd
0 1 2 3 4 5 6 7 8 9
1.31 2.62 3.92 5.23 6.54 7.85 9.16 10.46 11.77
10 13.08 14.39 15.70 17.00 18.31 19.62 20.93 22.24 36.62 24.85
20 26.16 27.47 28.78 30.08 31.39 32.70 34.01 35.32 36.62 27.93
30 39.24 40.55 41.86 43.16 44.47 45.78 47.09 48.40 49.70 51.01
40 52.32 53.63 54.94 56.24 57.55 58.86 60.17 61.48 62.78 64.09
50 65.40 66.71 68.02 69.32 70.63 71.94 73.24 74.56 75.86 77.17
60 78.48 79.79 81.10 82.40 83.71 85.02 86.33 87.64 88.94 90.25
70 91.56 92.87 94.18 95.48 96.79 98.10 99.41 100.72 102.02 103.33
80 104.64 105.95 107.26 108.56 109.87 111.18 112.49 113.80 115.10 116.41
90 117.72 119.03 120.34 121.64 122.95 124.26 125.57 126.88 128.18 129.49
Cubic yards to Cubic meters
0 1 2 3 4 5 6 7 8 9
0.76 1.53 2.29 3.06 3.82 4.59 5.35 6.12 6.88
10 7.65 8.41 9.18 9.94 10.70 11.47 12.23 13.00 13.76 14.53
20 15.29 16.06 16.82 17.59 18.35 19.12 19.88 20.64 21.41 22.17
30 22.94 23.70 24.47 25.23 26.00 26.76 27.53 28.29 29.05 29.82
40 30.58 31.35 32.11 32.88 33.64 34.41 35.17 35.94 36.70 37.47
50 38.23 38.99 39.76 40.52 41.29 42.05 42.82 43.58 44.35 45.11
60 45.88 46.64 47.41 48.17 48.93 49.70 50.46 51.23 51.99 52.76
70 53.52 54.29 55.05 55.82 56.58 57.35 58.11 58.57 59.64 60.40
80 61.17 61.93 62.70 63.46 64.23 64.99 65.76 66.52 67.28 68.05
90 68.81 69.58 70.34 71.11 71.87 72.64 73.40 74.17 74.93 75.70
EX50 Series 90-3

Liter to U.S Gallon
U.S. Gallon to Liter CONVERSION TABLE
Liter to U.S. Gallon 1 = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
U. S. Gallon to Liter 1 U.S. Gal = 3.7854
0 1 2 3 4 5 6 7 8 9
3.79 7.57 11.36 15.14 18.93 22.71 26.50 30.28 34.07
10 37.85 41.64 45.43 49.21 53.00 56.78 60.57 64.35 68.14 71.92
20 75.71 79.49 83.28 87.06 90.85 94.64 98.42 102.21 105.99 109.78
30 113.56 117.35 121.13 124.92 128.70 132.49 136.27 140.06 143.85 147.63
40 151.42 155.20 158.99 162.77 166.56 170.34 174.13 177.91 181.70 185.49
50 189.27 193.06 196.84 200.63 204.41 208.20 211.98 215.77 219.55 223.34
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 353.62 257.41 261.19
70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05
80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90
90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76
90-4 EX50 Series

Liter to U.K Gallon
CONVERSION TABLE U.K. Gallon to Liter
Liter to U.K. Gallon 1 = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0.200 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
U. K. Gallon to Liter 1 U.K. Gal = 4.5461
0 1 2 3 4 5 6 7 8 9
4.55 90.09 13.64 18.18 22.73 27.28 31.82 36.37 40.92
10 45.64 50.01 54.55 59.10 63.65 68.19 72.74 77.28 81.83 86.38
20 90.92 95.47 100.01 104.56 109.11 113.65 118.20 112.74 127.29 131.84
30 136.38 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76
50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22
60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68
70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14
80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60
90 409.15 413.69 418.24 422.79 427.33 431.88 436.42 440.97 445.52 450.06
EX50 Series 90-5

Kilogram to Pound
Pound to Kilogram CONVERSION TABLE
Kilogram to Pound 1Kg = 2.2046 Ib
0 1 2 3 4 5 6 7 8 9
2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Pound to Kilogram 1 Ib = 0.4536Kg
0 1 2 3 4 5 6 7 8 9
0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082
10 4.536 4.990 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154
30 13.608 14.061 14.515 14.969 15.422 15.876 16.329 16.783 17.237 17.690
40 18.144 18.597 19.051 19.505 19.958 20.412 20.865 21.319 21.772 22.226
50 22.680 23.133 23.587 24.040 24.494 24.948 25.401 25.855 26.308 26.762
60 27.216 27.669 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298
70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843
80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906
90-6 EX50 Series

CONVERSION TABLE Kg/cm2 to Ib /in2
Kg/cm2 to Ib/in2 1Kg/cm2 = 14.2233 Ib/in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1644 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1946 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 223 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2360 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3124 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
EX50 Series 90-7

Kgm to Ft. Ib CONVERSION TABLE
Kgm to Ft. Ib 1Kg.m = 7.233 ft. Ib
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1220.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
90-8 EX50 Series

CONVERSION TABLE Temperature
Temperature
Fahrenheit–Centigrade Conversion. –A simple way to convert a Fahrenheit temperture reading into a Centigraqde
temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired it convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures abd read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
velues, and read the corresponding Fahrenheit temperature on the right.
–40.4 –40 –40.9 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.6 17 62.6 11.1 52 125.6 30.6 84 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.8 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 112.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
EX50 Series 90-9

FD100/160E-08 FORKLIFT TRUCK
Form No. BEE08E1-01
PRINTED IN JAPAN

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2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan

LIFT TRUCK MODEL SERIAL No. ENGINE

10. GENERAL AND SPECIFICATIONS

20. TESTING AND ADJUSTING

30. REMOVAL AND INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

80. CHECK ITEMS FOR EACH EQUIPMENT

90. CONVERSION TABLE

To retain the machine and engine in good working conditions for an

EX50 Series 00-5

DESCRIPTION OF THE SYMBOLS

Symbol Item Description

Safety Special safety precautions are needed to perform the work.

Note Special technical precautions are needed to perform the work

Weight Weight of parts or systems

Coat Places to be coated with adhesives, etc. when assembling

00-6 EX50 Series

EX50 Series 10-1

1.4 Operation Type Sitting Sitting Sitting

3.5 Number of Wheels Front/Rear (x=driven) 4x/2 4x/2 4x/2

4.20 Length, to Fork Face L2 mm(in) 4245(167.1) 4285(168.7) 4640(182.7)

5.3 Lowering Speed Loaded/Unloaded mm/s(fpm) 400/500(79/98) 400/500(79/98) 400/500(79/98)

7.3 Rated RPM min-1 2200 2200 2200

8.2.1 Hydraulic Tank Capacity l (US Gal) 170(45) 170(45) 200(53)

Specifications are subject to change without notice.

10-2 EX50 Series

1.2 Model Manufacturer's Designation FD150E-8 FD160E-8

1.4 Operation Type Sitting Sitting

3.5 Number of Wheels Front/Rear (x=driven) 4x/2 4x/2

4.20 Length, to Fork Face L2 mm(in) 4700(185.0) 4800(189.0)

5.3 Lowering Speed Loaded/Unloaded mm/s(fpm) 400/400(79/79) 400/400(79/79)

7.3 Rated RPM min-1 2200 2200

8.2.1 Hydraulic Tank Capacity l (US Gal) 200(53) 200(53)

EX50 Series 10-3

10-4 EX50 Series

EX50 Series 10-5

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

10-6 EX50 Series

SAFETY ITEMS FOR MAINTENANCE

USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE

EX50 Series 10-7

WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS

• Avoid loose clothing, jewelry, and loose long hear.

USE SUITABLE TOOLS

• Always use tools that are suited for inspection and

REPLACE SAFETY CRITICAL PARTS PERIODICALLY

• Even if no abnormality is found, always replace safety critical parts periodically.

PRECAUTIONS WITH HIGH TEMPERATURE COOLANT

10-8 EX50 Series

PROHIBIT WELDING OF FUEL TANK

• Never weld the fuel tank as it may explode.

PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL

EX50 Series 10-9

ROTATING FAN AND BELT

• It is extremely dangerous if you or any tool

BE CAREFUL NOT TO GET CAUGHT OR FALL

• Never put your hands or feet into the mast structure.

10-10 EX50 Series