SM160 BX50 FG25T-16 Jun 2014 PDF

SM160
SERVICE MANUAL BEB16E1-06
BX50 SERIES FORKLIFT TRUCKS
FG20/25/28/30/32(S)(H)T-16 GASOLINE/LPG
FG35AHT-16 S/N 200001A~ EPA Tier 1
S/N 210001A~ EPA Tier 2
S/N 750875 - 751862 EPA Tier 2
S/N A224001~ EPA Tier 2/CARB 2010
S/N 751863~ CARB 2010
FD20/25/28/30/32T-16 DIESEL
FD35AT-16 S/N 200001A~/210001A~ EPA Tier 2
S/N A223001~/750875~ EPA Interim Tier 4
BX50
Read and observe all warnings on this unit

before operating it.
DO NOT operate this equipment unless all
factory-installed guards and shields are properly
secured in place.
REVISED: JUNE 2014

The information and specifications contained herein were accurate at the time of
publication, but may change without notice as required for product improvements.
Neither Komatsu Forklift U.S.A. nor its parent company nor any of its subsidiaries will be
held responsible for damages due to misuse or inappropriate use of its products.
© Copyright 2013, Komatsu Forklift U.S.A., LLC. All rights reserved. No part of this
document may be photocopied or reproduced in any way without prior written consent of
Komatsu Forklift U.S.A.
CONTENTS
FOREWORD
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIRECTION OF TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FORKLIFT TRUCKS COVERED IN THIS PUBLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS SERIAL NUMBER RANGES BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ANSI/ITSDF B56.1-2012 COMPLIANCE SERIAL NUMBER BREAKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
K21/K25 ENGINE SERIAL NUMBER BREAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EPA COMPLIANCE SERIAL NUMBER BREAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. SAFETY
1.1 BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 FIRE PREVENTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.3 SAFETY CHECKS BEFORE STARTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4 SAFE TRAVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.5 STOPPING, PARKING AND TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.6 LOADING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.7 SAFETY IN INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.8 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.9 STRUCTURE AND STABILITY OF THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.10 SAFETY LABELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
1.11 OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
2. SPECIFICATIONS AND GENERAL INFORMATION

2.1 GENERAL ASSEMBLY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 LUBRICANT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 GASOLINE/LPG MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 DIESEL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 PERIODIC REPLACEMENT OF CONSUMABLE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4.1 2-TON PNEUMATIC (OUTDOOR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4.2 2.5-TON PNEUMATIC (OUTDOOR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
3
CONTENTS
2.4.7 2.0/2.5-TON CUSHION (INDOOR)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.4.8 2.8/3.0/3.2-TON CUSHION (INDOOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.5 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.5.1 PNEUMATIC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.5.2 CUSHION MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.6 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.7.1 ELBOWS, NIPPLES AND UNIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.7.2 HIGH-PRESSURE RUBBER HOSES, PIPES AND SLEEVE NUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
3. OPERATOR COMPARTMENT
3.1 STRUCTURE AND FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.1 VEHICLE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.2 KOMATSU OPERATOR PRESENCE SYSTEM (KOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.3 CONTROLLER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.1.4 ISO CONTROLLER TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.1 TRAVELING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.2 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.3 ROD LINK, CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.4 CHASSIS FRAME, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.5 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.6 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.7 DEVICES FOR GETTING ON/OFF TRUCK, ANTI-SLIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.8 DISPLAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.9 OVERHEAD GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.10 BACKREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.11 LIGHTS, GAUGES, WARNING DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.12 REAR VIEW MIRROR, REFLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.13 LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.14 FUNCTION OF EACH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.1 ADJUST INCHING AND BRAKE PEDAL (TORQFLOW MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.2 ADJUST STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.3 ADJUST ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.3.4 ADJUST PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3.5 COMBINATION SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
INSPECT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3.4 REMOVAL AND INSTALLATION - PARKING BRAKE CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.4.1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.4.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4
CONTENTS
3.6 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4. ENGINE
4.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 ENGINE START, NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 ENGINE REVOLUTION, EXHAUST EMISSION COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.3 IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.4 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.5 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.6 VALVE CLEARANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.7 COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.8 FUEL INJECTION STARTING PRESSURE (DIESEL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.9 FUEL INJECTION STATE (DIESEL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.10 TURBOCHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.11 ENGINE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.12 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.13 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.14 HIGH-PRESSURE GAS FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.15 BLOW-BY GAS RETURN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.16 RADIATOR COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.17 FAN, FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.18 DISTRIBUTOR (GASOLINE EXPORT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.19 SPARK PLUG, IGNITION TIMING (GASOLINE MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.20 BATTERY CHARGING SYSTEM, WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.1 GASOLINE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.2 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.3 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.3.4 ADJUST IGNITION TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.5 ADJUST FUEL INJECTION TIMING (DIESEL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.6 ADJUST NO-LOAD ROTATING SPEED (DIESEL MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.3.7 MEASURE COMPRESSION PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
CAUSES FOR INSUFFICIENT COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.3.8 TORQUE CYLINDER HEAD MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
K21/K25 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4D94LE AND 4D98E ENGINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.3.9 ADJUST VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.4 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.4.1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.4.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
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CONTENTS
5. TORQUE CONVERTER
5.1.1 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.2 GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.3 TORQUE CONVERTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
HYDRAULIC CIRCULATING ROUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5.2.1 CHECK OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.2.2 REPLACE OIL, INSPECT AND CLEAN STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.2.3 REPLACE LINE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5.1 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5.2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.5.3 CHECK FOR CORRECT OIL LEVEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.5.4 TIGHTENING TORQUE FOR BOLTS AND PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
6. TORQFLOW TRANSMISSION
6.3.1 CHECK OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.2 REPLACE OIL, INSPECT AND CLEAN STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.3 REPLACE LINE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.5.1 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.5.2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.5.3 SOLENOID VALVE DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
6.6.1 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.6.2 TRANSMISSION CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
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CONTENTS
7. DRIVE AXLE
7.2.1 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.2 FRONT AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.3 TIRES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.4 WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.5 BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2.6 OIL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.7 BRAKE BOOSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.8 BRAKE SHOE LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.9 BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.10 BACK PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.11 PARKING BRAKE DRUM, LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.3.1 INSPECT OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.3.2 REPLACE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.3.3 GREASE CROSS BEARING OF PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3.4 ADJUST PINION SHAFT ASSEMBLY WITH SHIM(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.3.5 ADJUST PINION GEAR CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.3.6 INSPECT PINION BEARING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.3.7 ADJUST DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.4.1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.4.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
8. STEERING SYSTEM
8.2.1 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.2 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.3 STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.4 KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.5 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.6 POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.2.7 RIGHT AND LEFT TURNING RADIUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.2.8 DIRECTIONAL CONTROL VALVE (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.2.9 DIRECTIONAL CONTROL VALVE (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
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CONTENTS

8.4.1 STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
8.4.2 POWER STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12
8.4.3 STEERING AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
INSTALLATION - STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
8.5.1 STEERING VALVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.5.2 DISMANTLE PRESSURE RELIEF VALVE (OSPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.5.3 DISMANTLE PRESSURE RELIEF VALVE CARTRIDGE (OSPC) (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . 8-22
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-23
8.5.4 ASSEMBLE PRESSURE RELIEF VALVE (OSPC) (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.5.5 ASSEMBLE SHOCK VALVES (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.5.6 POWER STEERING CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
PNEUMATIC TIRE FORKLIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-34
CUSHION TIRE FORKLIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-35
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-36
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-37
8.5.7 STEERING AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
STEERING AXLE ASSEMBLY DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-40
8.6 MAINTENANCE STANDARD - STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
9. WHEEL BRAKE
9.1.1 WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.3 BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.1 TRAVELING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.2 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.3 ROD LINK, CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.4 BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.5 PARKING BRAKE DRUM, LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.2.6 OIL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.2.7 BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.2.8 BRAKE SHOE LINING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.2.9 BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.2.10 BACK PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.3.1 INSPECT BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.3.2 ADJUST BRAKE SHOE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
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CONTENTS
9.3.3 BLEED AIR FROM BRAKE PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9.4.1 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.4.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.5.1 WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.5.2 BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.6 MAINTENANCE STANDARD - MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
10. HYDRAULIC SYSTEM

10.1 STRUCTURE AND FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.2.1 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.2.2 PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.2.3 PIPING OF WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.2.4 HYDRAULIC DRIFT OF LIFT CYLINDER AND TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.2.5 DIRECTIONAL CONTROL VALVE (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.6 DIRECTIONAL CONTROL VALVE (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.7 SOLENOID VALVE, STEERING PRESSURE PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.8 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.9 FLOW DIVIDER (FOR P/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.10 OIL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.11 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.12 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.13 REACH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.2.14 WORK EQUIPMENT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.3 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.3.1 SERVICE HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.3.2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.4 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.4.1 REMOVE HYDRAULIC PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.4.2 INSTALL HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.5 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.5.1 FLOW DIVIDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.5.2 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
9
CONTENTS
10.6 HYDRAULIC PUMP MAINTENANCE STANDARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
11. WORK EQUIPMENT

11.1 STRUCTURE AND FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.1.1 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
BASIC FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
FUNCTION OF EACH SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
PISTON SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4
11.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.2.1 FORK (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.2.2 FORK (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.2.3 MAST (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.2.4 MAST (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.2.5 FORK CARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.2.6 LIFT CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.2.7 CHAIN WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.2.8 WORK EQUIPMENT SYSTEM (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.2.9 WORK EQUIPMENT SYSTEM (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.2.10 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.2.11 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.2.12 REACH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.2.13 WORK EQUIPMENT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.2.14 HYDRAULIC DRIFT OF LIFT CYLINDER AND TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.3 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.3.1 MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9
11.3.2 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10
11.4 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
11.4.1 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12
GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12
GENERAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-16
INSPECTION AFTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-19
11.4.2 TILT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-21
PARTS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-21
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-22
10
CONTENTS
11.4.3 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27
REPLACE LIP SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27
CHANGE SPOOL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28
11.4.4 CYLINDER SEAL SERVICE KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29
DISPLACEMENT DESIGN WITH PISTON SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29
PISTON DESIGN WITH NO DOWNSTROKE CUSHIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30
11.4.5 SIDESHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33
REPLACE CYLINDER HEAD O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34
SERVICE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47
11.5 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
11.5.1 CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
11.5.2 LIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
12. MASTS
E-MS SERIES LIMITED FREE LIFT 2-STAGE MAST
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
PERIODIC MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
E-MD SERIES FULL FREE LIFT 2-STAGE MAST

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46
E-MT SERIES FULL FREE LIFT 3-STAGE MAST

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-72
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-91
35D/45D/55D MQ QUAD MASTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-118
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-119
11
CONTENTS
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-135
13. CONVERSION TABLES

MILLIMETERS TO INCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3
INCHES TO MILLIMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3
CUBIC METERS TO CUBIC YARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3
CUBIC YARDS TO CUBIC METERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
LITER TO U.S. GALLON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
U. S. GALLON TO LITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
LITER TO U.K. GALLON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-5
U. K. GALLON TO LITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-5
KILOGRAM TO POUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-5
POUND TO KILOGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-6
KG/CM2 TO LB/IN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-6
KGM TO FT. LB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-7
TEMPERATURE (FAHRENHEIT/CENTIGRADE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-8
ELECTRICAL DIAGRAMS
BX50 TIER 2 DIESEL (4D94LE ENGINE) S/N 200001A - 215882A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
BX50 INTERIM TIER 4 DIESEL (4D98E ENGINE) S/N 215883A - 219999A / 750875~ / A223001~. . . . . . . . . . . . . . . A-3
BX50 TIER 1 GASOLINE (K21/K25 ENGINE) S/N 200001A - 205849A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
BX50 TIER 2 GASOLINE (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~. . . . . . . . . . . . A-7
BX50 TIER 1 LPG (K21/K25 ENGINE) S/N 200001A - 205849A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
BX50 TIER 2 LPG (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~ . . . . . . . . . . . . . . . . . A-11
BX50 CARB 2010 LPG (K21/K25 ENGINE) S/N 751863~ / A224001~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
BX50 CARB 2010 LPG (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . A-15
BX50 TIER 1 LPS (K21/K25 ENGINE) S/N 200001A - 205849A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
BX50 TIER 2 LPS (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~ . . . . . . . . . . . . . . . . . A-19
BX50 TIER 1 DUAL FUEL (K21/K25 ENGINE) S/N 200001A - 205849A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
BX50 TIER 2 DUAL FUEL (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~ . . . . . . . . . . . A-23
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) S/N 751863~ / A224001~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM . . . . . . . . . . . . . . . . A-27
12
LIST OF FIGURES
1. SAFETY
SAFETY LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40

LUBRICANTS - DUAL FUEL/LPG MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
LUBRICANTS - DIESEL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
OUTLINE VIEW OF LIFT TRUCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
INCHING AND BRAKE PEDAL (TORQFLOW MODEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
ACCELERATOR PEDAL - K21/K25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
ACCELERATOR PEDAL - DIESEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
COMBINATION SWITCH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
COMBINATION SWITCH CONNECTOR PINOUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
4. ENGINE
ENGINE WIRING CONNECTIONS - K21/K25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4D94LE/4D98E TOP VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
K21/K25 TOP VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4D94LE/4D98E RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
K21/K25 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
5. TORQUE CONVERTER
TORQUE CONVERTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
POWER TRANSMISSION PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
HYDRAULIC PRESSURE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
TORQUE CONVERTER ASSEMBLY - HYDRAULIC PRESSURE PORT LOCATION . . . . . . . . . . . . . . . . . . . .5-8
TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
TORQUE CONVERTER MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
TRANSMISSION CROSS-SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
TRANSMISSION CONTROL VALVE ASSEMBLY - HYDRAULIC PRESSURE PORT LOCATION . . . . . . . . . .6-4
ENGINE WIRING CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
TRANSMISSION ORDER OF ASSEMBLY AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
SOLENOID VALVE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
SOLENOID VALVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
TRANSMISSION MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
TRANSMISSION CONTROL VALVE MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
7. DRIVE AXLE
DRIVE AXLE AND WHEEL HUB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
PROPELLER SHAFT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
DIFFERENTIAL ASSEMBLY (2.0 - 3.5 TON TRUCKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
PINION SHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
DIFFERENTIAL TORQUES AND SEALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
DIFFERENTIAL TORQUES AND SEALS (2.0 - 3.0 TON TRUCKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
DRIVE AXLE ASSEMBLY (2.0 - 2.5 TON TRUCKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
13
CONTENTS
DRIVE AXLE ASSEMBLY (3.0 - 3.5 TON TRUCKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

DIFFERENTIAL MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
8. STEERING SYSTEM
STEERING HYDRAULIC CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
STEERING VALVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
STEERING AXLE AND POWER STEERING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
TROUBLESHOOTING STEERING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
STEERING VALVE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
STEERING VALVE COMPONENTS AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
STEERING AXLE ASSEMBLY AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
STEERING AXLE - OVERHEAD VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
STEERING AXLE - REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
9. WHEEL BRAKE
WHEEL BRAKE STRUCTURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
BRAKE BOOSTER STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
MASTER CYLIINDER STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
WHEEL BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

HYDRAULIC CIRCUIT - POWER BRAKE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
HYDRAULIC CIRCUIT - STANDARD BRAKE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
FLOW DIVIDER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
HYDRAULIC PUMP COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
HYDRAULIC PUMP MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
11. WORK EQUIPMENT

LIFT CYLINDER COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
TILT CYLINDER ASSEMBLY (2.0 - 3.5 TON TRUCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
SIDESHIFTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33
LIFT CYLINDER MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
14
FOREWORD
FOREWORD
INTRODUCTION
This Service Manual has been developed as an information resource to help the reader learn about, understand,
repair and maintain the BX50 Series forklift trucks, and the various equipment, systems, inspections, sensors,
diagnostic procedures and diagnostic equipment utilized to maintain, adjust and troubleshoot these systems.
Although reference is made to maintenance procedures necessary to perform servicing of this vehicle, you should
refer to the applicable Operation and Maintenance Manual for these lift trucks for more complete maintenance
information.
Komatsu is involved in a concentrated and highly technical program of designing and developing cleaner burning,
more efficient and more powerful engines for use in the industrial truck market. As a result, new computerized
sensors, systems and diagnostic monitors have been created to make the job of maintaining and repairing these
systems simple and easy.
Read this manual carefully, refer to it often and learn the repair, testing and adjustment procedures to the best of
your ability. Please note that some illustrations are generic and may not look exactly like your unit in every detail.
Ensure that, when you are working on or around industrial trucks, Safety is priority Number One. Read,
understand and obey all WARNINGS and CAUTIONS.
Follow the instructions and procedures presented in this manual when working on these lift trucks and their
systems. Damage to the equipment, and possible injury to yourself or others, may result if these procedures are
not adhered to carefully.
Keep this manual nearby and accessible for use when necessary. If this book becomes dirty, worn or illegible,
contact Komatsu for a replacement. The procedures outlined in this manual will be updated periodically. Be sure
that you have the latest revision in order to learn the newest information available. Revision dates will be clearly
displayed on the lower left hand corner of the cover page.
This will aid in maintaining your equipment in excellent condition and in ensuring that these lift trucks will operate
safely at maximum efficiency.
DIRECTION OF TRUCK
This manual uses the directions left, right, front and rear as they are seen from the operator's seat.
RIGHT
FRONT REAR
LEFT
1
FOREWORD
ENGINE SERIAL NUMBER LOCATION

The K21/K25 engine serial number is stamped on an angled
and machined pad on the right side of the engine block in the
center just beneath the valve cover.
The machined boss is split vertically by a groove. The Engine
Model number is on the left pad and the Engine Serial
number is on the right pad.
The 4D94LE/4D98E engine model and serial number are

stamped on the block below the exhaust manifold. The
engine model number is followed by the five digit engine
serial number. EMIS
THIS
FOR ENGINE
LOW
ENGINE
SION
M.
COMPLIESCON
SULFUR Y. NONROAD
ENGINE FAMILYFUEL
OR
WITH TROL
U. S.
/OFF-ROA EPA INFO
FUEL MODEL : ULTRA AND
D DIESELCALIFORN RMAT
REFERRATE : LOW
SULFUR ENGINES.IA
ADJUSTM TO : REGULATI ION
OWNER'SMM 3 FUEL
ENTS /STROKE DISPLACE
MANUAL @ ONLY ONS
EMISSION MENT
FOR kW / CONTROL:
MAINTENA
RPM LITERS
NCE SYSTEM
SPECIFICA :
TIONS
AND
Engine
serial number
location
0001102D-01
2
FOREWORD
FORKLIFT TRUCKS COVERED IN THIS PUBLICATION

MODEL DESCRIPTION
BX50 Gasoline, LPG and Dual Fuel Models

FG20ST-16 4,000 lb. capacity, K21 gasoline engine, cushion tires
FG20STLS-16 4,000 lb. capacity, K21 LPG engine, cushion tires, LPS
FG20SHT-16 4,000 lb. capacity, K25 gasoline engine, cushion tires
FG20SHTLS-16 4,000 lb. capacity, K25 gasoline engine, cushion tires, LPS
FG20T-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires
FG20TUS-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires, GS
FG20TLS-16 4,000 lb. capacity, K21 LPG engine, pneumatic tires, LPS
FG20HT-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires
FG20HTUS-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires, GS
FG20HTLS-16 4,000 lb. capacity, K25 LPG engine, pneumatic tires, LPS
FG25ST-16 5,000 lb. capacity, K21 gasoline engine, cushion tires
FG25STLS-16 5,000 lb. capacity, K21 LPG engine, cushion tires, LPS
FG25SHTLS-16 5,000 lb. capacity, K25 LPG engine, cushion tires, LPS
FG25T-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires
FG25TUS-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires, GS
FG25TLS-16 5,000 lb. capacity, K21 LPG engine, pneumatic tires, LPS
3
FOREWORD
MODEL DESCRIPTION
FG35AHT-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires
FG35AHTUS-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires, GS
FG35AHTLS-16 7,000 lb. capacity, K25 LPG engine, pneumatic tires, LPS
BX50 Diesel Models

FD20T-16 4,000 lb. capacity, 4D94E or 4D98E diesel engine, pneumatic tires
FD20TUS-16 4,000 lb. capacity, 4D94E or 4D98E diesel engine, pneumatic tires, DS
FD35AT-16 7,000 lb. capacity, 4D94E or 4D98E diesel engine, pneumatic tires
FD35ATUS-16 7,000 lb. capacity, 4D94E or 4D98E diesel engine, pneumatic tires, DS
4
FOREWORD
CHASSIS SERIAL NUMBER RANGES BY MODEL

MODEL CHASSIS SERIAL NUMBER RANGE
FD25T-16 200001A~ / 210001A~ / A223001 - A223400 / 750875~
FD30T-16 200001A~ / 210001A~ / A223401 - A223900 / 750875~
FD32T-16 200001A~ / 210001A~ / A223901 - A224000 / 750875~
FG20T-16 200001A~ / 210001A~ / A224001 - A224100 / 750875~
FG25T-16 200001A~ / 210001A~ / A224101 - A230000 / 750875~
FG25HT-16 200001A~ / 210001A~ / A230001 - A230500 / 750875~
FG30HT-16 200001A~ / 210001A~ / A230501 - A231500 / 750875~
FG32HT-16 200001A~ / 210001A~ / A231501 - A233000 / 750875~
FG20ST-16 200001A~ / 210001A~ / A233001 - A233300 / 750875~
FG25ST-16 200001A~ / 210001A~ / A233301 - A240000 / 750875~
FG25SHT-16 200001A~ / 210001A~ / A240001 - A240300 / 750875~
FG30SHT-16 200001A~ / 210001A~ / A240301 - A241300 / 750875~
FG32SHT-16 200001A~ / 210001A~ / A241301 - A243000 / 750875~
ANSI/ITSDF B56.1-2012 COMPLIANCE SERIAL NUMBER BREAKS

Models in these ranges were factory-installed with Mast/Attachment (Auxiliary) Lockout.
MODEL CHASSIS SERIAL NUMBER RANGE

FG20ST-16 A233132 - A233139 / A280000 - A299999
FG20T-16 A224023 - A224026 / A400000 - A409999
FG25HT-16 A230096 - A230156 / A260000 - A269999
FG25SHT-16 A240058 - A240087 / A470000 - A479999
FG25ST-16 A234854 - A235148 / A450000 - A469999
FG25STLS-16 A243008 - A243012 / A250000 - A259999
FG25T-16 A225994 - A226379 / A250000 - A259999
FG25TLS-16 A243308 - A499999
FG30HT-16 A231327 - A249999 / A410000 - A429999
FG30SHT-16 A240524~
FG32HT-16 A231553 - A231561 / A270000 - A279999
FG32SHT-16 A241429 - A241436 / A480000 - A489999
5
FOREWORD
K21/K25 ENGINE SERIAL NUMBER BREAKS

To identify your engine serial number, see the EPA/CARB label on the engine valve cover.
EPA TIER 1
MODEL YEAR LPG DUAL GASOLINE
K21-K14398~ K21-K14814~ K21-K14462~
2005
K25-K10903~ K25-K11051~ K25-K11279~
K21-K32097~ K21-K32278~ K21-K32280~
2006
K25-K24078~ K25-K24117~ K25-K24711~
EPA TIER 2
K21-023868~ K21-023873~ K21-024907~
K25-049259~ K25-049112~ K25-050425~
2007
K21-K48924~ K21-K49292~ K21-K50077~
K25-K36577~ K25-K37465~ K25-K37661~
K21-046637~ K21-046682~ K21-046895~
2008/2009
K25-067269~ K25-067294~ K25-067505~
EPA/CARB 2010
K21-086329~ K21-086298~ K21-089021~
2010
K25-107691~ K25-107784~ K25-110042~
K21-099450~ K21-K60485~
2011 —
K25-120623~ K25-K46021~
K21-122060~ K21-K64052~
2012 —
K25-145609~ K25-K48250~
K21-145683~ K21-K65966~
2013 —
K25-171085~ K25-K49595~
6
FOREWORD
EPA COMPLIANCE SERIAL NUMBER BREAKS

ENGINE EPA COMPLIANCE CHASSIS SERIAL NUMBER RANGE
4D94LE Tier 2 (2004 - 2007) 200001A - 215882A

4D98E Interim Tier 4 (2008) 215883A - 219999A / 750875~ / A223001~
Tier 1 (2004 - 2006) 200001A - 205849A
Tier 2 (2007 - 2009) 210001A - 219999A / 750875 - 751862 / A224001~
FG25T-16 ............... K21 DUAL...... A226028~
FG20ST-16............. K21 LP ........... A233117~
FG20T-16 ............... K21 LP ........... A224023~
FG25ST-16............. K21 LP ........... A234706~
FG25T-16 ............... K21 LP ........... A225867~
FG25STLS-16 ........ K21 UL-S ....... A243013~
K21/K25 FG25TLS-16 .......... K21 UL-S ....... A243317~
FG25HT-16 ............ K25 DUAL...... A230083~
EPA / CARB 2010
FG30HT-16 ............ K25 DUAL...... A230985~
FG25HT-16 ............ K25 LP ........... A230077~
FG25SHT-16 .......... K25 LP ........... A240053~
FG30HT-16 ............ K25 LP ........... A231078~
FG30SHT-16 .......... K25 LP ........... A240451~
FG32HT-16 ............ K25 LP ........... A231550~
FG32SHT-16 .......... K25 LP ........... A241398~
All Japan import models................. 751863~
7
1. SAFETY
1. SAFETY
1.1 BASIC PRECAUTIONS

FOLLOW THE INSTRUCTIONS IN THE OPERATION
AND MAINTENANCE MANUAL AS WELL AS ON
THE SAFETY LABELS
• Read the instructions in this manual and the safety labels
attached to various parts of the lift truck, and make sure that
you understand and follow them. If you do not understand or
do not follow the instructions, this will lead to improper
operation which may result in personal injury or damage.
• Be sure that you understand the proper method of using the lift
truck and the procedure for carrying out an inspection, and
ensure that they are carried out safely.
• Read this manual and safety labels again from time to time. If the Operation and Maintenance Manual or safety
labels have been lost or have become dirty and cannot be read, obtain replacements from your Komatsu Forklift
dealer and attach the safety labels in the specified positions.
• See “SAFETY LABELS” on page 1-40.
FOLLOW THE SAFETY RULES IN PLACE

• Before operation, establish an operating plan and hold a
meeting to discuss operating safety.
• In confined areas, position a signal person and carry out
operations in accordance with his/her instructions.
• Only trained and qualified persons are allowed to operate this
lift truck.
• During operation, safety must be your primary responsibility
ensuring the safety of those you are working around, the lift
truck, yourself, and other property in the work area.
• Do not operate the lift truck if you are fatigued, ill or mentally unstable, or when you have been drinking or have
taken any medication which can make you sleepy.
• When carrying out operation, inspection, or maintenance of the lift truck, always follow all work shop rules, safety
regulations and precautions.
• During operation, always pay attention to safety and be careful of pedestrians and other surrounding conditions.
DON'T USE A DEFECTIVE LIFT TRUCK

USE LOCK-OUT TAG-OUT PROCEDURES AS FOLLOWS
• If any abnormality is detected during start-up inspection or
operation (noise, vibration, odor, maladjusted gauge, smoke,
oil leak, or erroneous indication of warning device or monitor),
report it to the administrator immediately and take adequate
corrective actions.
• Do not operate the lift truck until the abnormality is corrected
• Remove the key from the faulty lift truck and hang signs in the
operator's compartment to prevent its use.
• If the lift truck has suffered a failure and the lift truck must be parked without lowering the forks, put markers on
the tips of the forks and take steps to prevent pedestrians or other vehicles from hitting the forks.
• Select a parking place where people or vehicles do not pass, and stop the lift truck so that it is difficult for anyone
to go under the forks. The area under the forks is a danger zone.
1-3
1. SAFETY
SECURE SAFETY AT THE WORKING AREA

• Working on rough surfaces can result in bodily injuries such as
backache.
Always keep passages and work areas flat and smooth without
bumps.
• Wipe up all spilled oil or grease from the ground to prevent tip-
over or collision due to slipping.
• When working on platforms, docks, quays, or other places
where there is danger of falling, set up blocks to prevent the lift
truck from going over the edge.
• Put warning signs up in dangerous places to warn the operator
not to approach those places.
• Mark traffic areas clearly, and establish a clear traffic rule such
as temporary stop line, speed limit, and no-entry area for other
vehicles and pedestrians.
• Provide adequate lighting for safe operations.
WEAR SAFETY CLOTHES WHILE IN OPERATION

• Avoid loose clothing, jewelry, and loose long hair, which can
catch on controls or in moving parts and cause serious injury or
death.
• Always wear a hard hat and safety boots.
• Depending on the working conditions, wear other safety
equipment in addition to the hard hat and safety boots.
FIRE, FIRST AID AND GENERAL SAFETY

• When you feel something unusual occurring with the lift truck,
promptly stop working, move the lift truck to a safe place for
parking, stop the engine for safety. Then report to the
supervisor.
• Be sure that fire extinguishers have been provided and that
you read the labels to ensure that you know how to use them.
• Know what to do in the event of a fire.
• Be sure that you know the phone numbers of persons you
should contact in case of an emergency.
• Provide a first aid kit at the storage point.
• If a fuel leak is discovered, do not operate the lift truck. Be sure to make repairs, stopping the leak before starting
the operation again, while reporting the trouble to the supervisor.
1-4
1. SAFETY
CAUTIONS FOR SAFETY-RELATED EQUIPMENT

• Confirm that all protective guards, covers, and mirrors are properly mounted. Repair them immediately when
broken.
• Be sure that you fully understand the usage of safety-related equipment.
• Never remove the safety-related equipment and keep fully functional at all times.
• Do not operate this lift truck if the overhead guard or load backrest has been or appears to have been damaged
or loosened until repairs have been made by your authorized Komatsu Forklift dealer.
PRACTICE SUFFICIENTLY BEFORE OPERATION

• Take sufficient time for practice until you become familiar with the operation of each component before starting
actual operations.
• Even after you become familiar with the components, operate with caution and avoid harsh operation to avoid
bodily injury or damage.
• Each lift truck is more or less peculiar in the performance of the brake, accelerator, and load handling device
even when it is the same model type. When you change lift trucks, understand the peculiarity of each lift truck
before stating operation. Be especially careful with the brake, since its performance varies by individual lift truck.
JUMPING ON AND OFF THE LIFT TRUCK IS

STRICTLY PROHIBITED
• Never jump on or off the lift truck as it is extremely dangerous.
• Even when the lift truck accidentally starts to move without the
operator onboard, never attempt to stop the truck by jumping
on it.
• Always mount and dismount the lift truck from the left side.
• While mounting and dismounting the lift truck, always support
yourself securely with your hands and feet at three locations
(three-point stance):
1. Grab the assist grip (handrail) with your left hand,
2. put your left foot on the step, then
3. grab the backrest or hip support of the seat with your right hand.
• Do not hold on the control levers or steering wheel when mounting or dismounting the lift truck.
KEEP THE OPERATOR'S COMPARTMENT CLEAN AND CLEAR

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

• If water gets into the electrical system (controller, sensor,
connectors, etc.), there is the hazard that it will cause
malfunctions or operational failure. Do not wash the electrical
system with water or high-pressure steam.
• For more details on the washing method, see “LIFT TRUCK
WASHING PROCEDURE” on page 3-35.
1-5
1. SAFETY
DO NOT MODIFY THE LIFT TRUCK

• Contact your Komatsu Forklift dealer in advance for any
modification (installation, removal and modification) of the lift modify
truck, attachment or option. Some modifications may cause
safety hazards and violate the law.
• Do not install any equipment or parts which obstruct or limit the
operator's view.
• Komatsu Forklift will not be responsible for any bodily injury,
damage or failure which results from modifications made
without consent of Komatsu Forklift in writing.
DON'T REMOVE THE OVERHEAD GUARD AND

LOAD BACKREST
• The overhead guard is installed to protect the operator from
falling objects. It is designed to withstand the force of light
boxes or small packages. It is not designed to withstand every
possible impact.
• Always be careful to prevent damage or injury from falling
objects.
• Do not use a Komatsu lift truck when it is equipped with a non-
genuine overhead guard or load backrest.
Note: Komatsu lift trucks are usually equipped with the
optimum overhead guard and load backrest when they are shipped out of Komatsu Forklift plants.
REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT

• The permissible load for lift trucks equipped with any attachment is lower than the permissible load for the
standard lift truck, the reasons being:
- The overall permissible load is lowered by as much as the weight of an attachment itself.
- The load center shifts toward the front due to the thickness of an attachment.
• Follow the load limit as indicated in the load capacity chart on the data plate.
• On some detachable-type attachments and inserting-type attachments, there is an additional load capacity chart
or attachment weight label provided at a certain place. Follow the instructions in the chart or the label when
installing such an attachment.
ENGINE EXHAUST GAS IS POISONOUS

Do not leave the engine running where there is poor ventilation.
The engine exhaust gas contains carbon monoxide, which can
cause gas poisoning and result in serious injury or death.
ASBESTOS CAUTION
• Non-Genuine Parts (unspecified parts of Komatsu Forklift) such as the clutch disc, brake lining, gaskets and
packing may contain asbestos.
• Use Komatsu genuine parts. All the parts used in this lift truck are asbestos-free.
1-6
1. SAFETY
WINDOW WASHER CAUTION

• Use window washer which contains ethyl alcohol.
• Never use window washer that contains methanol, as it is harmful to the eyes.
FIRE IS STRICTLY PROHIBITED DURING

REFUELING
Fuel is extremely flammable and can cause fires and explosions.
• Carry out refueling away from flames or sparks.
• Stop the engine when refueling.
• After refueling, tighten the gas cap securely and wipe up any
spilled fuel.
PRECAUTIONS WHEN REFUELING LPG TRUCKS

• Only trained and authorized personnel may change LPG cylinders.
• LPG is heavier than air and will sink to the lowest area possible. Avoid parking near areas near floor drains,
lubrication pits, or other areas where escaped fuel may collect.
• After changing, ensure that the replacement cylinder is securely mounted.
• If you smell LPG odor or there is frost on the fuel cylinder:
- do not start the engine;
- close the fuel valve at the LPG cylinder;
- park and tag the truck and have qualified personnel inspect and repair the fuel system.
• For additional information, consult the National Fire Protection Association pamphlet 58 for the safe storage and
handling of liquefied petroleum gases.
1-7
1. SAFETY
LPG FUEL SYSTEM SAFETY

• Testing of the LPG fuel system and repairs are to be performed by qualified personnel only.
• Accidents involving fuel systems are always dangerous and can cause fire and explosion, serious injury, death
and property damage. Keep the following points in mind when working with fuel systems.
- LPG is heavier than air and will sink to the lowest area possible. Avoid parking truck in areas near floor drains
or lubrication pits where escaped fuel may collect.
- Store all LPG cylinders OUTDOORS in a secured area and safe from any vehicle traffic.
- NEVER WELD ON AN LPG PRESSURE VESSEL, STORAGE TANK OR CYLINDER.
- Ensure that the fuel tank is properly mounted.
- Always use a UL-listed LPG tank.
• Before testing or repairing the LPG fuel system:
- Read, understand and remember relevant information in standard 58 of the NATIONAL FIRE PROTECTION
AGENCY (NFPA).
- Ensure you are wearing proper personal protective equipment.
- Ensure there are NO SOURCES OF IGNITION nearby.
- Ensure your work area is adequately ventilated.
- Keep in mind that LPG is stored under high pressure and ensure that the LPG fuel storage container valve is
turned OFF (closed), and pressure is released from the lines.
- Disconnect the battery and fuel hose coupling.
- Test for fuel leaks. DO NOT work on the system if the fuel storage container is filled with fuel past the 80%
liquid level. Before testing, make sure the system gas pressure is greater than 90 psi (621 kPa). Test all
connections, container, valves and fittings with soap and water or equivalent solution.
• When replacing LPG fuel system components, always use Komatsu genuine parts.
1-8
1. SAFETY
1.2 FIRE PREVENTION

ENGINE FIRE PREVENTION - CHECKS BEFORE STARTING
Always check the following points before starting the lift truck engine. If you find a loosely connected battery
terminal, secure it. Also, clean any accumulations of dirt, tree waste or paper. If any problem persists, do not
hesitate to contact your Komatsu Forklift dealer for servicing.
1. Check around the engine
• Accumulation of tree waste or paper around the hot engine area and its circumference
• Oil leakage or fuel leakage around the engine
• Damage or gas leakage of muffler or exhaust pipe
• Loosen or damaged electrical wiring or clamps around the engine
2. Check around battery
• Loose or corroded battery terminals, connectors or clamps
• Accumulation of tree waste, paper or entry of metals around battery
• Damaged cable or wiring harness
3. Check oil or fuel leakage
• Oil leakage from hydraulic piping or fuel leakage from
fuel tank (1)
• Accumulation of tree waste or paper around fuel tank (1)

or hydraulic oil tank (2)
• Accumulation of dirt under the frame (engine or

transmission system)
In particular, dirt or paper may accumulate easily on a lift
truck with an undercover. Carefully check for such
accumulation.
4. Check the inside of the operator’s cab (for cab models) for
accumulation of cigarettes and other flammables
1-9
1. SAFETY
FIRE FROM FAULTY ELECTRICAL WIRING

Short-circuiting of the electrical wiring may cause a fire.
• Clean all electrical wiring connections and firmly secure them.
• Check wiring daily for looseness, wear and damage. Retighten loose connectors and wiring clamps. Damaged
wiring must be repaired or replaced by your Komatsu Forklift dealer.
FIRE FROM FUEL OR OIL

Fuel, oil, antifreeze, and window washer fluid are flammable, so
keep them away from open flame. Strictly follow these
instructions:
• Do not smoke or allow any flame near fuel, oil, coolant or
window washer fluid, or clothes soaked with them.
• Stop the engine before refueling.
• Do not leave the area while refilling fuel or oil.
• Tighten the fuel cap and oil cap securely.
• Do not spill fuel on overheated surfaces or electrical system
components.
• Store fuel and oil in a designated, well-ventilated, dark and cool
place away from unauthorized personnel.
• Wipe off any spilled fuel, oil, and grease after refilling.
• Put clothes soaked in oil and other flammable objects in a
secure container and store them in a safe place.
• When inspecting or servicing the lift truck using devices and
equipment, be cautious and take measures to avoid igniting
fires with a spark or flame.
Failure to comply with these safety policies may result in serious injury or death.
FIRE FROM FAULTY PIPING

Ensure clamps, guards and cushions of hoses and tubes are fixed securely. Loose hoses or tubes damaged by
vibration during operation or by rubbing against other parts can cause eruption of high pressure fluid, fire and
bodily injury.
IF A FIRE BREAKS OUT

• If a fire breaks out, turn the starting switch to the OFF ( ) position to stop the engine.
• Do not jump off the lift truck in a rush. Support yourself securely with handrails and use steps to evacuate.
AVOID BURN INJURY

HIGH TEMPERATURE COOLANT
Immediately after the lift truck is used, the coolant is still very hot,
so there is always a danger of burns when you open the radiator
cap, as steam or boiling water may spurt out. After the coolant
temperature has gone down sufficiently, turn the radiator cap
slowly to release the remaining pressure.
1-10
1. SAFETY
HIGH TEMPERATURE PARTS AND OIL

To prevent burns from high temperature parts or by spurting oil,
carry out inspection and maintenance work after these parts cool
down and can be touched safely with bare hands.
CLEANING
After operating, use an air blower or similar device to clean off
any dirt, tree waste, and paper that has accumulated on the lift
truck.
• Around the engine.
Carefully clean the circumference of the exhaust manifold.
• Under the frame.
In particular, dirt or paper may accumulate easily on a lift truck
with an undercover. Carefully clean such accumulation.
• On the floor plate.
• Around the muffler.
1-11
1. SAFETY
1.3 SAFETY CHECKS BEFORE STARTING OPERATION

ALWAYS CONDUCT A START-UP INSPECTION IN THE BEGINNING OF THE DAY FOR
SAFE OPERATION OF THE LIFT TRUCK
• Do not operate a lift truck before completing start-up inspection.
• Report any abnormality immediately to the administrator. Never operate the lift truck in question until repairs are
completed.
CHECK AND ADJUSTMENT BEFORE STARTING ENGINE

Check the following before starting the engine:
• Check for coolant level, fuel level, oil level in the engine oil pan, and hydraulic oil level.
• Adjust the seat (seat position, backrest angle), steering wheel position and center mirror, and make sure the
locks are secured.
PRECAUTIONS BEFORE STARTING THE ENGINE

Before starting the engine:
• Check that the parking brakes are set, and that the electric
forward/reverse lever is in the neutral position.
• Check that the surrounding area is safe, then sit in the
operator's seat.
• Sound the horn to warn people nearby.
DO NOT START THE ENGINE BY SHORT-CIRCUITING OR PUSHING

• Do not start the engine by short-circuiting the starting circuit.
• Starting the engine by pushing the vehicle is not possible
because this is a hydrostatic transmission type vehicle.
Forcibly pushing the vehicle can cause failure of the hydraulic
components.
CAUTION WHEN CHECKING SAFETY FUNCTION

• To check the safety function, apply travel interlock, lift interlock, neutral start, and parking brake warning.
• Before the check, secure sufficient space in case of unexpected movement of the vehicle, and perform the
check after confirming no people or obstacles are nearby.
CAUTION IN COLD WEATHER

• Allow sufficient time for warming-up the lift truck in cold weather. If the lift truck is insufficiently warmed-up, it may
move slowly or change its motion suddenly, which can result in an accident.
• Know where to find safety salt, ice melter or oil absorbent.
1-12
1. SAFETY
1.4 SAFE TRAVEL

DON'T TRY TO OPERATE THE LIFT TRUCK FROM
OUTSIDE
• Always keep your body under the overhead guard.
• Do not put your hand or foot out of the overhead guard.
• You must be properly seated in the operator’s seat when
operating any function of the lift truck.
BE SURE TO WEAR THE SAFETY SEAT BELT

• Always fit your seat belt correctly when operating. If your seat
belt is fitted incorrectly, there is danger of serious personal
injury if the lift truck should tip over.
• Always check the seat belt mounts and check for any damage
to the seat belt. If any abnormality is found, repair or replace
the seat belt immediately.
MAINTAIN PROPER POSTURE WHILE OPERATING

TRAVEL INTERLOCK (POWER TRANSMISSION CUTOFF)
AND MAST/ATTACHMENT INTERLOCK
• If you operate the lift truck when you are not seated properly or
off the seat, an accident can occur. To prevent such an
accident, this lift truck has Travel Interlock and Mast/
Attachment Interlock safety features that make travel and truck
operation impossible if you are not seated properly (Operator
Presence System).
• If you operate the lift truck in so that your weight is not properly
applied to the seat, like standing up or leaning forward or
sideways out of the seat, Travel Interlock begins to alarm in about three seconds and cuts off the transmission of
engine power. Then the truck will not move, even if you depress the accelerator pedal or operate the forward-
reverse lever.
• Additionally, Mast/Attachment Interlock disables lifting/lowering, tilting and attachment functions. Even if you
operate the lift, tilt or attachment levers, these functions will not work.
CHECK AND ADJUST THE REAR VIEW MIRROR AND LAMPS

• When reversing, never depend on the rear view mirror. The operator must visually check behind him. Also,
adjust the rear view mirror so that the operator can check from the operator's seat that the area behind the lift
truck is safe. Always keep the surface of the mirror clean. If the mirror is broken, replace it with a new one.
• Check that all lamps light up correctly. Replace any broken bulbs (for lift trucks equipped with lamps).
A SUDDEN SHIFT OF THE F-R LEVER IS DANGEROUS

To change the travel direction, stop the lift truck completely and then operate the F-R lever.
1-13
1. SAFETY
DON'T ALLOW A PASSENGER ON THE TRUCK

• Never allow any other person to ride with you on the lift truck.
• Do not use anyone for a makeshift human counterweight.
NEVER TURN OFF THE STARTING SWITCH WHILE TRAVELING

When the starting switch is turned to OFF while traveling, the operating efforts for power steering and power brakes
may increase.
DO NOT REST YOUR FOOT ON THE INCHING PEDAL WHILE TRAVELING

• Keep your foot off the inching pedal while traveling to prevent the brake from overheating and losing braking
effect.
• Depressing the pedal engages the clutch halfway, which makes the engine brake ineffective.
• This can also cause the transmission to overheat, leading to wear or seizure of the multiple clutch plates.
CHECK THE SURROUNDINGS FOR SAFETY

BEFORE STARTING UP THE ENGINE
• Before stating the engine, check that the parking brake is set,
and that the directional and speed levers are in the neutral
position.
• Adjust the operator's seat and the steering wheel before
starting the engine. Always lock them in position after
adjusting. Adjusting the seat or steering wheel during operation
is dangerous as it may cause you to lose your balance or
operate the lift truck in an unsafe manner.
• Before starting the engine, first check that the surrounding area
is safe, and sit securely in the operator's seat.
• Sound the horn before starting the engine to warn people
around you.
• Do not attempt to start the engine by intentionally short-
circuiting the engine starting circuit.
• Do not attempt to jump start the lift truck.
1-14
1. SAFETY
PERFORM A SAFETY CHECK BEFORE STARTING

THE LIFT TRUCK
• Before starting the lift truck, check that the surrounding area is
safe.
• Before moving the lift truck, raise the forks [approximately 15 to
20 cm (6 - 8 in.) from the ground surface], and tilt the mast
back.
• When ready to move, release the parking brake.
BE SAFETY CONSCIOUS WHILE DRIVING

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

SURFACE
• Avoid traveling in places which are flooded or where there are
holes.
• Do not try to drive the lift truck on soft ground.
• Avoid curbs, rails, ditches, or other obstacles, and do not travel
directly over them.
• Do not travel on slippery road surfaces.
• When entering buildings, check the weight limit of the floor and
be careful not to exceed the limit.
1-15
1. SAFETY
DRIVING ON A ROAD SHOULDER IS STRICTLY

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

RAILWAY CAR, TRUCK OR CONTAINER,
• Do not travel on the edge of docks. There is a danger that the
lift truck may fall, which may result in serious injury or death.
• Before starting operations, check the load limit for the
gangplanks, and do not use them if they do not have ample
strength to take the weight of the lift truck when loaded.
• Apply the brakes on the truck and block the wheels before
driving the forklift into the truck.
• When driving into trailers, use jacks and take steps to prevent
the trailer from sinking when the forklift truck travels on it.
• When driving the forklift inside trucks, reduce speed when
backing out and be sure to check that the gangplanks are safe.
• Be careful of pedestrians.
• Tell the truck driver not to move the truck until the operation is
completed.
• If there is some system to secure the truck to the dock, always
use this system. Secure the gangplanks so that they do not slip
and fall.
1-16
1. SAFETY
BE AWARE OF THE LIFT TRUCK'S MAXIMUM

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

EXERCISE EXTRA CARE
• Do not turn, or travel across or at an angle on slopes. There is
danger that the lift truck will tip over.
• Before starting to drive up a slope, stop the lift truck and adjust
the clearance between the ground surface and the bottom of
the forks so that the bottom of the forks or pallet do not contact
the ground surface or the tip of the fork does not stick into the
ground when traveling.
• For safe travel on slopes:
- When loaded: Travel forward up the slope, and in reverse
down the slope with the load upgrade.
- When unloaded: Travel in reverse up the slope and forward
down the slope with the load-engaging means downgrade.
• On a downslope, drive down slowly and use the foot brake.
• When starting on slopes, the lift truck may start to move down
the slope depending on the amount the pedals are depressed.
Always leave ample room in front of and behind the lift truck
when starting on slopes.
• Be careful of the truck sliding downhill if Travel Interlock is
engaged while traveling uphill or on a slope. Stay securely in
the operator’s seat!
1-17
1. SAFETY
WHEN MAKING A TURN, BE CAREFUL OF THE

SWINGING COUNTERWEIGHT
• Remember that a fork lift truck steers with the rear wheels, not
the front wheels. It will not drive like an automobile.
• When turning while traveling forward, the counterweight will
swing far out. Keep an ample clearance from walls to ensure
safety.
• When turning, travel slowly and be careful that the front or rear
wheels do not come off the ground.
• When turning on soft road shoulders, there is danger that the
rear wheels may come off the road shoulder and cause the lift
truck to tip.
NEVER JUMP OFF THE LIFT TRUCK WHEN THE LIFT TRUCK APPEARS TO BE TIPPING
OVER
• Always fasten your seat belt during operations for your safety should the lift truck tip over.
• To avoid tipping over and other accidents, carry out proper operation, inspection and maintenance of the lift
truck, and read and understand this Operation and Maintenance Manual.
• When the lift truck appears to be tipping over:
- Do not jump off the lift truck or you may be crushed by it.
- Lean in the opposite direction to the direction the lift truck is tipping.
- Grip the steering wheel tightly.
- Brace yourself with both feet to support your body.
• Practice this series of actions from time to time to master how to act in emergency situations.
Tip-over can occur even when unloaded. In case of

Don't risk injury or death. tip-over
Slow down before turning! Buckle seatbelt
Follow these
instructuions: Don't jump Hold on tight Brace feet Lean away WARNING
3EB-96-A5111
(a) (b) (c) (d) (e)
DO NOT TRAVEL WITH THE FORKS RAISED HIGH

• If the load-engaging means or load is raised, the center of
gravity of the lift truck will also rise and increase the danger of
the lift truck tipping. Do not turn the lift truck when the forks are
raised high. During travel, keep the forks about 15 to 20 cm (6 -
8 in.) above the ground with the mast tilted back.
• Do not suddenly raise the forks or tilt the mast to the front or
rear when the forks are loaded. There is danger that the lift
truck will tip.
• Reduce speed before turning the lift truck.
• In particular, when traveling unloaded, the rear of the lift truck
is heavy. If the lift truck is turned at high speed, there is a
greater chance of tipping than when traveling with the forks
loaded.
1-18
1. SAFETY
WHEN BACKING UP THE LIFT TRUCK, VISUALLY

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

PERSON OR DRIVE BACKWARDS
• If the view to the front is obstructed by the load, turn to the rear
and drive the lift truck in reverse.
• When driving in reverse with a high load, use a signal person
to ensure the safety of the load and the safety in the
surrounding area.
APPLY THE BRAKES CORRECTLY WHILE RUNNING

• Do not stop the engine while the truck is in motion. When the engine is not running, the operating efforts for
power steering and power brakes (if present) increase. Thus it is dangerous to stop the engine while running.
• If the inching pedal is depressed, the braking effect of the engine will be lost.
• Do not use the brakes unnecessarily or too frequently. If your lift truck is a TORQFLOW transmission type and
you rest your foot on the inching pedal during operations, the multiple clutch plates of the transmission will
overheat, deforming the clutch plates and causing them to malfunction, in the worst case.
SHOULD THE LIFT TRUCK BECOME INOPERATIVE IN A DANGEROUS PLACE LIKE A

RAILROAD CROSSING, LET ALL PEOPLE AROUND KNOW IMMEDIATELY
• If engine trouble occurs on a railroad crossing and the lift truck does not move, it is impossible to use the starting
motor as can be done on a standard-shift automobile. (This is because a neutral safety switch is installed.)
• In such an emergency, light a flare or smoke candle to warn approaching trains and people in the area that there
is a broken-down truck on the tracks.
REQUIRED BRAKING DISTANCE DIFFERS DEPENDING ON THE ROAD CONDITIONS

• Allow plenty of time for brake operation depending on the situation, as the road surface and weight of the load
affect the stopping distance. Longer braking distance is required for heavy loads and stopping on downhill
slopes and wet or slippery surfaces.
• When traveling downhill, reduce the speed and make sure that you have ample room at the bottom of the slope
to stop.
OBSERVE THE WEIGHT LIMIT

Do not exceed the weight limit on floors and roads where the weight limit is specified.
1-19
1. SAFETY
DO NOT TRAVEL DIRECTLY OVER OBSTACLES

ON THE ROAD
Avoid clutter, curbs, rails, ditches, or other obstacles, and do not
travel directly over them. Also, the impact applied when traveling
over obstacles can result in bodily injuries such as backache.
EMERGENCY ACTION AT A RAILWAY CROSSING

When the lift truck becomes disabled at a railway crossing or similar place due to engine trouble, the lift truck
cannot be moved with the neutral start function of the cell motor as it can on a passenger vehicle. In such an
emergency, burn a safety flare or take similar action to warn the approaching train of the failure.
PAY SPECIAL ATTENTION TO THE REAR VIEW IN LIFT TRUCK WITH LPG CYLINDER
INSTALLED
• The installed LP gas cylinder partially blocks the rear view and poses a danger of hitting people, piled
commodities, or contact with nearby objects. Therefore, install backup warning devices (backup alarm buzzer,
rotating warning lamp, etc.) or backup safety checking devices such as a rear view mirror in order to warn people
nearby and check for safe conditions in the area of the truck.
• When installing optional warning devices, call your Komatsu Forklift dealer for details.
1-20
1. SAFETY
1.5 STOPPING, PARKING AND TOWING

PARK THE LIFT TRUCK IN A SAFE PLACE
• Park the lift truck in the specified place.
• Park the lift truck on a firm surface.
• Do not park near any emergency exit, stairway, fire extinguisher, or other safety equipment. Park the lift truck in
a place where it will not obstruct pedestrians or other vehicles.
• Never park the lift truck near heat, ignition sources, or any flammable object.
• If there is no way to avoid parking on a slope, immobilize the lift truck by putting blocks under the tires in addition
to normal parking procedures.
• LPG trucks: LPG is heavier than air and will sink to the lowest area possible. Avoid parking near areas near floor
drains or lubrication pits where escaped fuel may collect.
FOLLOW THESE STEPS FOR PARKING

1. Stop the lift truck on level ground.
2. Apply the parking brake securely to make sure that the lift
truck cannot move.
3. Set the directional lever and speed lever to neutral.
4. Tilt the mast forward and lower the fork to the floor.
5. Turn the starting switch to the OFF position.
6. Pull out the starting switch key and leave the lift truck.
7. LPG trucks: close fuel valve on fuel cylinder after parking the
lift truck.
BE CAREFUL WHEN USING THE DRAWBAR PIN

• Do not use the drawbar pin for any other towing purpose than
to bail out a stuck lift truck, or to be towed by another lift truck
or to be hoisted.
• The towing pin at the back of the counterweight is provided to
pull out the lift truck when it has gotten stuck in dirt or a ditch as
well as when it is being loaded on a truck.
DON'T USE A LIFT TRUCK TO TOW ANOTHER BROKEN-DOWN LIFT TRUCK

If there is any problem with the brakes or steering system of your lift truck, do not use another lift truck to tow it as
there is danger that the lift truck may run out of control.
1-21
1. SAFETY
1.6 LOADING OPERATIONS

PRECAUTIONS FOR LOADING AND UNLOADING
• If you operate the lift truck in such a posture that your weight is
not properly applied to the seat, like standing up or leaning
forward or sideways, Travel Interlock begins to alarm in
approximately three seconds and cuts off the transmission of
engine power. Then the truck does not move even if you
depress the accelerator pedal or operate the forward-reverse
lever.
The truck will slide downhill if Travel Interlock activates on an
uphill grade or a slope.
• Select flat and solid ground for loading and unloading. Avoid a
road shoulder or a place near a cliff.
• Use ramps of sufficient length, width and strength. Moreover, set them securely so that they will not shift or be
displaced.
• Always operate the mast and forks from the operator's compartment. Be careful not to operate the lever by
mistake. There is danger that the forks or work equipment may cause serious injury.
KEEP UNAUTHORIZED PEOPLE OUT OF WORKING AREA AND ENSURE A SIGNAL

PERSON IS ON DUTY
• Do not allow anyone in the working area except the signal person.
• Do not let any person or other lift truck come close during operation.
• When working with a signal person, always follow their instructions.
NEVER GO BENEATH RAISED FORK

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

STRICTLY PROHIBITED
• Do not manually place a load on the forks or manually remove
a load from the forks.
• Do not stand on the forks to support a load as the load may slip
off the forks and fall on the person below.
• Do not try to move or adjust any part of the load, the forklift or
the surroundings while on the forklift.
1-22
1. SAFETY
BE CAREFUL NOT TO GET CAUGHT IN THE MAST

STRUCTURE
Never put your hands or feet into the mast structure. There is
danger that you will get caught in moving parts and be seriously
injured.
DON'T CLIMB ON THE MAST OR LOAD

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

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

CARE
• Be extremely careful when carrying long or wide loads. Raise
the load slowly and be careful not to touch anything in the
surrounding area.
• Keep the load as low as possible and be sure to maintain the
balance.
• When turning, operate slowly and be careful not to let the load
shift or move.
BE CAREFUL OF THE FORK TIPS

• Do not allow the tips of the forks to get close to people. The tips
of the forks are pointed, so there is a risk that they may cause
injury.
• Do not attempt to hook something with the tips of the fork,
otherwise the hooked object can suddenly come off the tip, and
the reaction can cause danger to the lift truck as well as to the
hooked object.
1-23
1. SAFETY
WATCH OUT OVERHEAD

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

• Do not load the lift truck over the maximum capacity shown in
the load capacity chart, otherwise there is the danger that the
rear wheels may come off the ground, the operator may lose
control of the lift truck; and the truck may tip over. Moreover the
load on the forks can collapse.
• Never exceed the max. load shown in the load capacity chart
on the data plate. (See “LOAD CENTER AND ACTUAL
CAPACITY” on page 1-38.)
DON'T HANDLE A LOAD IN AN INSECURE

MANNER
• Make sure that the center of gravity of the load is in line with
the center of the lift truck. Do not carry loads off-center. There
is danger that unbalanced loads may cause the lift truck to tip.
• Place the load so that it contacts the load backrest.
• Do not handle unstable loads. If there is danger that the load
may fall off, secure it in position and take steps to prevent the
load from collapsing or falling.
DO NOT LOAD AND UNLOAD ON SLOPES

Loading or unloading on the slopes may cause the lift truck to
lose balance and tip over.
DO NOT LOWER LOADED FORKS HASTILY

Do not operate the forks roughly or make sudden stops. Sudden lowering may cause the load to collapse and fall,
and the lift truck may lose balance and tip over.
1-24
1. SAFETY
DON'T HANDLE A LOAD THAT EXCEEDS THE

LOAD BACKREST HEIGHT
Keep the height of the load within the height of the load backrest.
Do not carry any load that is higher than the load backrest. If the
load is higher than the load backrest, there is danger that it
will fall back on top of the operator, resulting in serious
injury or death.
DO NOT PRY LOAD WITH THE TIPS OF THE FORK

If you pry a load with the tips of the fork, the load may be
damaged or snagged. A snagged load can suddenly come off the
tip and cause damage to the lift truck as well as the load.
DON'T USE THE FORK TO PUSH OR PULL A

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

ON THE FORK
• Do not tilt the mast forward with the load raised. Do not raise
the load when the mast is tilted forward. There is danger of the
load falling or the truck tipping over.
• Do not travel with the mast tilted forward.
• Do not load and unload on slopes.
1-25
1. SAFETY
BE CAREFUL OF SLACK IN THE HOIST CHAINS

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

• Do not use the lift truck for any other purpose than was
originally intended (the loading work using the fork or
attachments).
• Do not use the forks to open or close the doors of railroad cars
or warehouses.
• Do not push any other vehicle.
• Do not hook ropes on the forks and use the forks to lift loads.
• Do not use the drawbar pin for towing operations.
1-26
1. SAFETY
1.7 SAFETY IN INSPECTION AND MAINTENANCE

ALWAYS PERFORM THE START-UP INSPECTION
• This Operation and Maintenance Manual provides only simple
inspection and maintenance information that operators can
perform relatively easily. For inspection and maintenance that
requires qualified trained and skilled personnel, contact your
Komatsu Forklift dealer.
• Do not operate the lift truck before completing start-up
inspection.
• Report abnormality, if any, immediately to the administrator. Do
not operate a faulty lift truck until repairs are completed.
• Incorrect inspection, maintenance and repair services may
cause a critical accident or shorten lift truck service life. For your safety, contact Komatsu Forklift dealer for
inspection, maintenance and repair services.
PUT UP A WARNING SIGN DURING INSPECTION

AND MAINTENANCE
• Put up a warning sign on the steering wheel or load handling
lever during inspection and maintenance work. If necessary,
put up the sign around the lift truck.
• Do not let any person other than the inspector or maintenance
staff start the engine or touch the load handling lever during
inspection and maintenance, or serious injuries may result.
When jointly making inspection or maintenance with other
personnel, name the leader and follow their instructions.
KEEP THE WORK AREA CLEAN, TIDY AND VENTILATED

• Perform work on level surfaces with ample space.
• Keep the working area clean and tidy. Get obstacles out of the way. Wipe off any grease or oil.
• If the work is carried out inside a building, keep it well-ventilated.
1-27
1. SAFETY
PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE

• Arrange for a fire extinguisher. Know its location and how to use it.
• Wear adequate working clothes and protective items:
- safety helmet and shoes
- protective eyeglasses and gloves
• Before any inspection and maintenance work, always do the following:
- lower the forks to the floor
- pull the parking brake lever toward the rear of the lift truck to engage the brake
- set all levers to neutral
- turn the starting switch to OFF to stop the engine
• Check the front and rear tires.
KEEP UNAUTHORIZED PERSONNEL OFF THE TRUCK

No unauthorized person is allowed near the lift truck under maintenance service.
USE PROPER TOOLS AND EQUIPMENT

Always use tools that are suited for inspection and maintenance. It is extremely dangerous to use broken tools or
tools designed for another purpose.
CAUTIONS WHEN WORKING UNDER WORK

EQUIPMENT
When performing the inspection and maintenance work while
forks are raised, block the forks and mast to prevent them from
falling and causing a serious accident.
CAUTIONS WHEN REPLACING THE SEAT

• The seat is equipped with important safety functions:
• Seat belt and support to the operator’s body
• Travel and lift interlock function switches
• Storage case for instruction manual
Always use a Genuine Seat for replacement.
PERIODIC MAINTENANCE WORK MUST BE CARRIED OUT BY QUALIFIED PERSONNEL

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

• When carrying out inspection and maintenance, use a level, dry, dust-free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.
1-28
1. SAFETY
PRECAUTIONS BEFORE PERIODIC MAINTENANCE WORK

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

• Wipe off any oil or grease. Immediately wipe up any oil that has leaked. If the lift truck is dirty, it becomes difficult
or impossible to find cracks or other problems.
• Always clean the lift truck before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
• Do not use any cloth which is soaked in oil, or grease. There is danger that it may catch fire.
• Wear adequate working clothes and protective equipment (hard hat, safety shoes, goggles and gloves).
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and
mast from dropping.
• Before starting the inspection and maintenance work, disconnect the cable from the battery negative (-) terminal.
• When carrying out job with another worker, decide who is the leader and carry out the job in accordance with
instructions from that person.
• After finishing repair work, perform a test drive of the lift truck.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been fully
corrected or that defective parts have not been removed.
PERIODIC INSPECTION OF SAFETY CRITICAL PARTS

• To ensure the safety and long service life of the lift truck, be sure to perform lubrication, inspection and
maintenance regularly. Safety critical parts especially must be replaced regularly.
The quality of these parts may change over time from wear or fatigue, or deteriorate as they are repeatedly
used, thereby introducing the possibility of serious bodily injury and damage from accidents. Furthermore, the
remaining service life of such parts is usually hard for operators to determine during visual inspection.
• Replace safety critical parts with new ones periodically even if no abnormality is found.
• Replace safety critical parts immediately when any abnormality is found, even if the replacement interval has not
passed yet.
• This Operation and Maintenance Manual does not detail how to inspect or replace safety critical parts.
Inspection and replacement of safety critical parts and refilling of greases must be done by a Komatsu Forklift
dealer.
1-29
1. SAFETY
SAFE HANDLING OF BRAKE OIL

It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped. Always do the
following.
• Check the level of the brake fluid periodically.
• Always use the specified brake fluid.
• Check that the breather of the brake fluid reserve tank is not clogged.
• Be careful not to let dirt or dust get into the brake fluid reserve tank.
BE CAREFUL OF BOILING ENGINE COOLANT

• Immediately after using the lift truck, the engine coolant is at
high temperature and high pressure. Do not remove the
radiator cap under these conditions as hot water may spurt out
and cause burns.
• When removing the radiator cap, turn it slowly to release the
internal pressure.
• When checking the coolant level, stop the engine and wait for
the engine and radiator to cool down before checking.
BE CAREFUL OF HIGH PRESSURE AND HIGH

TEMPERATURE HYDRAULIC OIL
• Immediately after using the lift truck, the oil is at high
temperature. Do not drain the oil or replace the filter when the
oil is hot as hot oil may spurt out and cause burns.
• Wait for the truck temperature to go down before carrying out
the inspection and maintenance work.
• Do not forget that the work equipment circuits are always under
pressure. Do not add oil, drain oil, or carry out maintenance or
inspection before completely releasing the internal pressure.
• If oil is leaking under high pressure from small holes, it is
dangerous if the jet of high-pressure oil hits your skin or eyes.
Always wear safety glasses and thick gloves, and use a piece
of cardboard or a sheet of plywood to check for oil leakage.
• If you are hit by a jet of high-pressure oil, consult a doctor
immediately.
BE CAREFUL OF THE ROTATING COOLING FAN

AND BELT
• It is extremely dangerous if part of your body or a tool in your
hand gets caught up in the rotating fan or fan belt. Never touch
them when rotating.
• When inspecting rotating parts, do so only after the engine
comes to a stop.
• When inspecting the areas around rotating parts, do not allow
anything to come close which may get caught.
1-30
1. SAFETY
JUMP STARTING THE ENGINE IS PROHIBITED

Do not push the lift truck to start the engine. There is danger that the lift truck may unexpectedly start and operate.
CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM

When repairing the electrical system, disconnect the cable of the negative (-) terminal to stop power supply.
CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING

• If compressed air is used for cleaning, the airborne dust particles can cause serious bodily injury.
• Always wear protective gears such as safety eyeglasses, dust mask, and gloves when you clean elements,
radiator, and other components with compressed air.
AVOID THE DANGER OF GETTING CAUGHT UP IN

OR FALLING OFF THE MAST
• Do not put your hands, feet, or other body parts into the mast
structure. If the mast moves accidentally there is the danger
that you may get caught and be seriously injured.
• Do not use the mast as a ladder. If you slip, there is danger that
you will fall.
• Do not stand between mast and operator’s compartment as
you can be crushed or killed.
• Do not climb on the mast or load backrest or on top of the

dashboard. You may slip and fall or get caught in the moving
parts. Use a stepladder for inspection and maintenance at an
elevated level.
1-31
1. SAFETY
JACKING-UP THE LIFT TRUCK FOR INSPECTION

AND REPLACEMENT OF TIRES
• Do not go under the forklift truck when it is jacked up.
• Check the following before jacking up the lift truck.
1. Check that there is no one on the lift truck.
2. Check that there is no load on the forks.
• When jacking up, stop when the tires come off the ground
surface. Put blocks under both sides of the frame to prevent
the lift truck from coming down.
• Put a tire stopper behind the tires in contact with the floor so
that the lift truck will not move freely.
INSPECTION AND INFLATION OF TIRES

The lift truck tires are very highly pressurized with air. Do not
mishandle or the tires may burst, be damaged or the rim may
break into pieces causing a serious injury. For your safety, follow
the instructions below.
• Do not disassemble/assemble tire, tube or rim, nor inflate
removed tires with air.
• For safety, when filling a tire with air or replacing it, place your
body in front of the tread face of the tire (see the figure at right).
Do not work from the side of the tire.
• When removing the tire with divided rim from the lift truck,
always loosen the hub nuts (1) after depressurizing the tire. Do
not loosen the rim bolt (irregular shape) (2) of the divided rim.
• Always use the specified tire of Komatsu Forklift and observe
the specified tire inflation pressure.
• When filling up the tires, make sure no one is nearby and use a
clip-on air chuck that can be fixed to the air valve.
• Fill the tire while checking with an air gauge to avoid over
inflation.
• The rim will not “fit” the tire if either the tire or rim is defective,
or if it is not properly assembled. To fit, the rim must contact the
tire evenly around the circumference. If this is not the case, contact your Komatsu Forklift dealer.
PRECAUTIONS WHEN USING BOOSTER (JUMPER) CABLES

• ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.
• When starting using the battery of another lift truck, do not allow the two lift trucks to touch.
• Stop the engine before connecting the cables.
• Be extremely careful not to let the cables get caught in the fan or fan belt.
• Ensure that the cables are hooked up correctly - positive-to-positive and negative-to-negative. Never let the
positive (+) and negative (-) terminals contact each other.
1-32
1. SAFETY
SAFE HANDLING OF WASTES FROM LIFT TRUCK

Obey appropriate laws and regulations when disposing of harmful
objects such as oil, filters, and batteries.
SAFE HANDLING OF ANTI-FREEZE

• Antifreeze can be a flammable. Keep away from flame when handling.
• Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water, vomit it out,
and get medical attention immediately. Follow safety precautions on container.
SAFE HANDLING OF BATTERIES

• Battery electrolyte contains sulfuric acid, and can quickly burn
the skin and eat holes in clothing. If you spill battery electrolyte
on yourself, immediately shed the clothes, flush the part with a
large quantity of tap water and then consult a doctor.
• Should battery electrolyte get into your eyes, flush them
immediately with fresh tap water for 10 to 15 minutes and then
consult a doctor at once.
• Should you drink battery electrolyte by accident, either drink a
large quantity of water or milk mixed with beaten egg white or
salad oil, and then consult a doctor at once.
• Be sure to wear goggles, safety gloves and rubber-soled shoes
at the time of battery maintenance.
• Do not smoke or create any spark near the battery. Batteries
generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE,
and is easily ignited with a small spark or flame.
• When inspecting or handling the battery, do so only after
turning the engine starting switch key to the OFF position and
stopping the engine.
• When disconnecting the battery cables, disconnect the cable
of the negative (-) terminal first. Conversely, when connecting
them again, connect the cable of the positive (+) terminal first.
• Avoid short-circuiting the battery terminals through accidental contact with tools or other metal objects across the
terminals.
• Tighten the battery terminals securely. Loose terminals can generate sparks and lead to an explosion.
• When connecting the disconnected battery cables again, be sure which is the positive (+) terminal and which is
the negative (-) terminal in order to avoid improper connection.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps tightened.
• Do not put a metallic tool or plate on the battery terminals by accident. There is danger that such a metallic
object could cause short-circuiting leading to a fire.
• Wash hands after handling battery.
1-33
1. SAFETY
PRECAUTIONS WHEN CHARGING BATTERIES

When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change. To
prevent the danger of gas explosion, always do as follows.
• Before charging the battery, check that the battery electrolyte level stays within the specified range. If the
electrolyte is found insufficient, add distilled or purified water without fail.
• Carry out the charging operation in a well-ventilated place.
• Do not smoke or allow any flame or ignition source.
• Start to charge the battery when the battery electrolyte temperature is below 35ºC (95ºF). If the electrolyte
temperature is above 50ºC (122ºF), wait until it goes below 35ºC (95ºF).
• When using a battery charger to charge the battery, take the battery caps off.
STRICTLY FOLLOW THESE INSTRUCTIONS TO AVOID GENERATION OF SPARKS

• Do not place tools or other metal objects on the battery. They may accidentally short the positive (+) and
negative (-) terminals of the battery.
• When disconnecting the battery cables, always disconnect the cable of the negative (-) terminal first.
Conversely, when connecting them again, connect the cable of the positive (+) terminal first.
CAUTION AFTER INSPECTION AND REPAIR

• Wipe off spilled oil and grease immediately. If the lift truck is dirty, it becomes difficult or impossible to find cracks
or other problems.
• Test the lift truck upon completion of the repair to ensure there is no abnormality.
1-34
1. SAFETY
1.8 TOWING
CAUTION WHEN HOISTING THE LIFT TRUCK
• Never lift up by the overhead guard.
• Before lifting-up, check that the mounting bolts of mast and
counterbalance-weight are tightened to the specified torque.
• To hoist the lift truck, hook on the holes on the top of the outer
mast for the front, and the hole on the top of the
counterbalance- weight for the rear.
• Do not go under the lifted truck.
• If the lift truck has to be lifted frequently, it is necessary to
install special lifting equipment, so please contact your
PRECAUTIONS FOR LOADING AND UNLOADING

THE LIFT TRUCK
Loading and unloading a lift truck to and from a trailer always
involve a hazard of the lift truck tipping over or falling off by
handling error. Follow the instructions below:
• Stop the trailer on level, flat road. Always apply parking brake.
Apply blocks to the tires.
• Use ramps or dock plate of appropriate length, width and
strength. Secure it tightly to prevent it from being dislocated or
disengaged.
• Take a right posture on the seat while operating.
• If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like standing up
or leaning forward or sideways, travel interlock activates to cut off the transmission of engine power. Then the lift
truck may slither down even if the accelerator pedal is stepped on or an uphill. Operate the lift truck assisted by
a signal person if necessary so that you don't have to stand up or lean forward or sideways to watch.
• When using the ramps, set them in gentle gradient, align the center of both the trailer and the lift truck and lock
securely to prevent misalignment.
• Do not change the course of the lift truck while on the ramps. If course change is needed, move off the ramps
once and make another uphill travel on them in right direction.
HOW TO MOVE A DISABLED LIFT TRUCK

Use extra care when towing a lift truck if there is a problem with any the following;
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are poor.
• The lift truck must be moved on a steep grade.
If the steering pump motor does not operate, steering control of the lift truck can be slow. This can make the control
of the lift truck difficult. If there is no power, there is no power steering.
DO NOT tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to
slide. Steep grades will require additional brake force to stop the lift truck.
Never carry a disabled lift truck unless the lift truck MUST be moved and cannot be towed. The lift truck used to
carry the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck.
The capacity must be for a load center equal to half the width of the disabled lift truck. See the data plate of the
approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of the
disabled lift truck on the forks and be careful not to the damage the under side of the lift truck.
1-35
1. SAFETY
HOW TO TOW THE LIFT TRUCK

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

• Never lift the truck by the overhead guard. If the truck has to be
lifted frequently, it is necessary to install special lifting
equipment, so please contact your Komatsu Forklift dealer.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes have ample
strength and are not damaged.
• Never go under the lifted truck.
• If the specified lifting point is the counterweight, check that the
counterweight mounting bolts are tightened to the specified
torque before carrying out the lifting operation. Check also that
there is no damage to the lifting portion on the counterweight.
• When using the hooks on the counterweight to hoist the lift
truck, check beforehand that the counterweight mounting bolts
are tightened to the specified torque and that there is no
abnormality on the hooks.
1-36
1. SAFETY
1.9 STRUCTURE AND STABILITY OF THE LIFT TRUCK

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

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

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

The stability of the lift truck is determined by the position of a
combined center of gravity resulting from combining the centers
of gravity of the lift truck and the load. When the lift truck is
carrying no load, the center of gravity of the lift truck remains
unchanged. On the other hand, when it is carrying a load, the
center of gravity of the lift truck shifts to a combined center of
gravity from the centers of gravity of both the lift truck and the
load. The position of the center of gravity of a load changes as
the mast is tilted back or forth, or it is raised or lowered. The
position of the combined center of gravity also changes
depending on the following factors.
• Size, weight, shape of load
• Lifting height
• Tilting angle of mast
• Inflation pressure of tires
• Acceleration, deceleration, turning radius
• Condition of road surface, angle of road
• Type of attachments
1-37
1. SAFETY
STABLE RANGE OF CENTER OF GRAVITY

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

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

The data plate shown at right is an example. In actual operation,
follow the instructions on the data plate of the actual lift truck.
This example shows a data plate for a lift truck with a mast of
maximum fork height of 3.0 m and which is not equipped with any
attachment.
• When load center (1) = 500 mm, Capacity (2) = 2,500 kg
• When load center (1) = 600 mm, Capacity (2) = 2,250 kg
• When load center (1) = 1,000 mm, Capacity (2) = 1,620 kg
1-38
1. SAFETY
Even when the load center is shorter than 500 mm, the actual capacity is 2,500 kg (2).
It is required to replace the present data plate with a new one when the present data plate is broken or has become
difficult to read. In that case, call your Komatsu Forklift dealer asking for a new replacement data plate.
SPEED AND ACCELERATION

If a stationary object is not subjected to external force, it will remain stationary. In the same way, if a moving object
is not subjected to external force, it will continue to move at the same speed. This is called inertia.
Because of inertia, a force is applied towards the rear when the lift truck starts to move, and is applied towards the
front when the lift truck stops. If the brakes are applied suddenly, there is danger of a large force being applied
towards the front which may make the lift truck tip or the load to be expelled.
When the lift truck is turned, a centrifugal force is applied to the outside from the center of the turn.
This force pushes the lift truck to the outside and makes it tip. The range of stability to the left and right is
particularly small, so it is necessary to reduce speed when turning, in order to prevent the lift truck from tipping. If
the lift truck is traveling with a raised load, the position of the overall center of gravity is high, so the danger of
tipping to the front, left, or right becomes greater.
1-39
1. SAFETY
1.10 SAFETY LABELS

Keep safety and other labels clean. If a label comes off, reattach it or replace with a new one.
Overhead guard
On dash to right On engine inside right
of steering column 8 Overhead guard
1 11 2 inside left
Right side 9
12 Inside rear
of bonnet
right stay
Outside both 5
outer masts
13
Rear outer 7
mast stay
15
3 Inside front
left stay
4 14
Outside both 10 Inside rear
front stays tire rims
6 Top of radiator shroud
Safety Label Locations
Details and ordering information for labels are given in the following sections.
1-40
1. SAFETY
Label Description Part No.
1 Jump start prohibited 09842-A0481

2 Avoiding danger if lift truck overturns 3EB-96-A5111
3 Using the parking brake 3EB-96-A5821
4 No passengers allowed 3EB-96-A5910
5 No standing on the forks 3EB-96-A5920
6 Avoid getting hand caught in fan 3EB-96-A5931
7 Avoid getting hand caught in pinch-point 3EB-96-A5940
8 Caution before operating 3EB-96-A5960
9 Warning for operation 3EB-96-A6120
10 Warning for use of split rim 3EB-96-A5970
11 Replace overhead guard if damaged 37B-1QT-A030
12 Method of hoisting 3EB-96-25520
13 Warning for handling LPG/FLAMMABLE GAS 3EB-96-A5951
14 Slide seat forward prior to opening bonnet 3EB-96-A7560
a: 37B-1QA-3010 (GAS)
15 Fuel type b: 37B-1QB-3010 (DIESEL)
c: 09652-31251 (DIESEL)
1. Jump start prohibited. Start the engine only after sitting down
in the operator's seat. Do not attempt to start the engine by
short-circuiting the engine starting circuit. Such an act may
cause serious bodily injury or fire.
2. Avoiding danger if lift truck overturns during operations.
Tip-over can occur even when unloaded. In case of

Don't risk injury or death. tip-over
Slow down before turning! Buckle seatbelt
Follow these
instructuions: Don't jump Hold on tight Brace feet Lean away WARNING
3EB-96-A5111
(a) (b) (c) (d) (e)
If the steering is operated suddenly during operations, there is danger that the lift truck may lose its balance
and tip over. To avoid this danger, strictly observe the following precautions.
a. Always wear your seat belt during operations.
b. Never jump off the lift truck.
c. Hold on tight to avoid falling out and having the lift truck fall on top of you.
d. Brace yourself with both feet to support your body.
e. Lean in the opposite direction from the direction in which the lift truck is tipping.
Items (b) through (e) are instructions for when the lift truck tips over.
1-41
1. SAFETY
6. Using the parking brake.
WARNING
• Pull parking brake to locked position and shut off power before
leaving seat.
• When parked with the power on, place high-low and forward-reverse
lever in neutral.
• If force required to engage brake is low (less than 44 lbs.), chock
wheels when parking truck and contact forklift dealer for service.
See manual for details.
3EB-96-A5821
7. No passengers allowed.
8. No standing on the forks.

Never enter the area under the forks.
WARNING
3EB-96-A5920
1-42
1. SAFETY
9. Use caution to avoid getting hand caught in fan (not shown) (P/N 3EB-96-A5931).
10. Use caution to avoid getting hand caught in pinch-point.
WARNING 3EB-96-A5940
11. Caution before operating machine.
12. Warning for operation.
WARNING
SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS!
Before Operating
• Do not operate or repair truck unless trained and authorized. • Do not handle unstable loads or loosely stacked loads.
• Read and understand all warnings and instructions in manuals • Do not handle loads higher than load backrest.
and on truck before operating. • Space forks as far as load permits.
• Dealers have replacement manuals. • Be sure load is centered and forks are completely under load.
• Check truck before use. If truck is in need of repair, do not • Never tilt load with mast tilted forward.
operate until restored to safe condition. • Do not tilt forward when elevated except to pick
• Do not start truck if fuel is leaking or has leaked. up or deposit load.
• Use attachments for intended purpose only. • Travel load or lifting mechanism low and tilted back.
• Tipover can occur if operated improperly.
• Do not jump if truck begins to tipover.
While Operating Hold on firmly and lean away from point of impact.
• Operate truck only from operator's seat. Avoid being trapped between truck and ground.
• Sit firmly in the seat with good posture while driving.
Leaving the seat or sitting improperly for approximately 3 General Precautions
seconds may cause the drive system to disengage. • Allow no one to stand or pass under or near load or
Unintended truck movement like rolling on an incline may occur. lifting mechanism.
• Keep truck under control at all times. • Never place any part of body into mast structure, between
• Do not overload truck. Check capacity plate for load weight mast and truck or outside truck.
and load center. • Do not carry passengers on any part of truck.
• Avoid any sudden starts, stops, turn or change of direction. • Lift no one under any circumstances.
• Obey traffic safety rules. Yield right-of-way to pedestrians. • Do not operate without overhead guard and load backrest.
• Keep clear view of travel path. If load being carried blocks • Fill fuel or charge battery only in specified place.
forward view, travel with load trailing. • Stop engine when fueling and avoid open flame or sparks,
• Slow down and sound horn when vision is blocked. and provide adequate ventilation.
• Watch clearances, especially forks, mast, overhead guard and • Keep vent caps clear when charging battery.
tailswing area. • Disconnect battery during servicing.
• Slow down for turns and on uneven or slippery surfaces.
• Avoid running over loose objects.
• Never angle or turn on incline. After Operating
• Travel with load uphill when loaded. • Before getting off truck, shift F-R lever and high-low
• Travel with lifting mechanism downhill when empty. lever (clutch type) to neutral position, fully lower
• Secure dockboard or bridgeplate properly. lifting mechanism and pull parking lever securely.
• Do not exceed rated capacity. • Shut off power when leaving truck unattended.
• Use special care when operating on dockboard or bridgeplate. • Block wheels when parking on incline.
3EB-96-A6120
1-43
1. SAFETY
13. Warning for use of split rim (pneumatic tires only).
14. Replace overhead guard if damaged.
WARNING REPLACE IF DAMAGED!

This overhead guard offers reasonable protection to operator
from falling objects but cannot protect against every possible impact.
Impact test rating: 16000 foot pounds.
37B-1QT-A030
15. Method of hoisting the lift truck. Never use the overhead
guard to lift the truck. 3EB-96-25520
16. Warning for handling LPG/FLAMMABLE GAS (on LP tank bracket).
1-44
1. SAFETY
17. Slide seat forward prior to opening bonnet.
18. Fuel type.

a
GASOLINE FUEL
3 7 B -1 QA -3 0 1 0
3 7 B -1 QB -3 0 1 0
1-45
1. SAFETY
1.11 OPTIONAL EQUIPMENT

Various safety devices are available as options. If operating conditions demand it, please install these devices. The
devices listed below are only examples. Various other devices are also available. For details, please contact your
REAR LAMP
Install this when carrying out operations at night which require the rear area to be lighted.
(The law demands that sufficient lighting be provided to ensure safety.)
HIGH LOAD BACKREST

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

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

When the lift truck exceeds the preset speed, a buzzer sounds to warn the operator.
WARNING LAMPS
The following warning lamps may be added to the instrument panel.
• Battery electrolyte level warning lamp
• Air cleaner element clogging warning lamp
• Radiator cooling water level warning lamp
1-46
2. SPECIFICATIONS
AND GENERAL
INFORMATION
2.1 GENERAL ASSEMBLY DIAGRAM
6 - 7.5 kgfm
torque 59 - 74 Nm
43.4 - 54.2 lbf.ft
45 - 65 kgfm
torque
442 - 638 Nm
325 - 470 lbf.ft
Exhaust pipe mounting torque:

19.6 - 25.5 Nm (2.0 - 2.6 kgfm)
35 - 43.5 kgfm
torque
344 - 427 Nm
253 - 315 lbf.ft Muffler securing nut torque:
59 - 74 Nm (6.0 - 7.5 kgfm)
2-3
2.2 LUBRICANT LIST

2.2.1 GASOLINE/LPG MODELS
MODELS FG20/25/28/30/32(S)(H)T-16 & FG35AHT-16
• Always use genuine Komatsu Forklift oil and grease.

• Oil and grease are available from your Komatsu Forklift
dealer.
• Never use fuel mixed with kerosene as it can damage the
fuel injection system.
• Never use the wrong type of brake fluid.
LUBRICANTS - DUAL FUEL/LPG MODELS
Ambient Temperature
Location Type of Fluid -4 14 32 50 68 86 104°F Capacity
-20 -10 0 10 20 30 40°C
Engine oil (including filter)

Engine oil pan
(SAE10W-30SJ) 1.0 U.S. gal. / 3.8 L
TORQFLOW Transmission fluid

2.54 U.S. gal. / 9.6 L
transmission case (TO10)
2 - 3.2T I/D, 2 - 2.5T O/D:

Gear oil 1.59 U.S. gal. / 6.0 L
Differential case
(GO80W90)
3 - 3.5T O/D:
1.53 U.S. gal. / 5.8 L
Hydraulic oil
Hydraulic tank 14.53 U.S. gal. / 55.0 L
(HO32R)
Gasoline: 87 octane 2 - 3.2T I/D:

(recommended) 10.57 U.S. gal. / 40.0 L
Fuel tank
LPG: HD-5 grade 2 - 3.5T O/D:
propane 15.32 U.S. gal. / 58.0 L
Brake fluid (DOT 3) 3.88 oz. / 0.115 L
Brake reservoir
(SAE7OR-3) 10.14 oz. / 0.30 L (Rebuild)
Lithium grease
Greasing points —
(NLGI No. 2)
Non-amine (AF-NAC)
Cooling system 2.4 U.S. gal. / 9.1 L
engine coolant
2-4
2.2.2 DIESEL MODELS

MODELS FD20/25/28/30/32T-16 & FD35AT-16
• Always use genuine Komatsu Forklift oil and grease.

• Oil and grease are available from your Komatsu Forklift
dealer.
• Never use fuel mixed with kerosene as it can damage the
EPA REGULATION
fuel injection system.
USE LOW SULFUR
• Never use the wrong type of brake fluid. FUEL OR ULTRA LOW
SULFUR FUEL ONLY
NOTE: Use low sulfur or ultra- low sulfur diesel fuel only. AE80369C
LUBRICANTS - DIESEL MODELS

Ambient Temperature
Location Type of Fluid -22 -4 14 32 50 68 86 104°F Capactities
-30 -20 -10 0 10 20 30 40°C
Engine oil
SAE10W-30CH (including filter)
Engine oil pan
1.98 U.S. gal. / 7.5 L
SAE30W-30CH
TORQFLOW Transmission fluid

2.54 U.S. gal. / 9.6 L
transmission case (TO10)
2 - 2.5 ton:
1.59 U.S. gal. / 6.0 L
Differential case Gear oil (GO80W90)
3 - 3.5 ton:
1.53 U.S. gal. / 5.8 L
Hydraulic oil 2 - 3.5 ton:

Hydraulic tank (HO32R) 14.53 U.S. gal. / 55.0 L
Diesel 2 - 2.5 ton:

ASTM Grade No. 2-D 10.57 U.S. gal. / 40.0 L
S15
Fuel tank
3 - 3.5 ton:
ASTM Grade No. 1-D 15.32 U.S. gal. / 58.0 L
S15
Brake fluid (DOT 3) 3.88 oz. / 0.115 L
Brake Reservoir
(SAE7OR-3) 10.14 oz. / 0.30 L (rebuild)
Lithium grease
Greasing points —
(NLGI No. 2)
Cooling system Non-amine (AF-NAC) 2.4 U.S. gal. / 9.1 L

engine coolant
2-5
2.3 PERIODIC REPLACEMENT OF CONSUMABLE PARTS

For operation safety, never fail to perform periodic maintenance or perform periodic replacement of the
consumable parts listed in the following table.
These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at the
time of periodic maintenance; therefore, even if no apparent wear is found, always replace with new parts within
the prescribed period of replacement (or earlier if trouble is found).
Note that periodic replacement has no relationship to warranty service.
Period of
No. Part name
replacement
Master cylinder and wheel cylinder cups, dust

1 Every 1 year
seals
2 Rubber parts of brake booster Every 1 year
3 Brake hose or tube Every 2 years
4 Reservoir tank and tube Every 2 years
5 Power steering hose Every 2 years
6 Stop lamp switch (Oil pressure type) Every 2 years
7 Fuel hose Every 2 years
8 Rubber parts of power steering Every 2 years
9 Lift chain Every 3 years
10 Load handing hoses Every 2 years
2-6
2.4 SPECIFICATIONS
Most values shown in this publication are rounded, so direct conversion between metric and English or Imperial
may be slightly different than what is displayed in these tables. The performance of the machines is affected by the
condition of the vehicle and how it is equipped as well as the nature and condition of the operating area. If these
specifications are critical or if your needs exceed the specifications shown here, discuss the proposed application
with your authorized dealer.
2.4.1 2-TON PNEUMATIC (OUTDOOR)

Manufacturer’s
Unit FG20T-16 FD20T-16 FG20HT-16
Designation
GENERAL
Power Type Gasoline Diesel Gasoline
Operation Type Sit Down Sit Down Sit Down
Capacity@24 in. (600 mm) Load

lbs. (kg) 4,000 (1,810) 4,000 (1,810) 4,000 (1,810)
Center*
Load Distance: Center Axle to

in. (mm) 17.9 (455) 17.9 (455) 17.9 (455)
Fork Face
Wheelbase in. (mm) 65.0 (1,650) 65.0 (1,650) 65.0 (1,650)
WEIGHT
Service Weight (incl. 2-Stage STD
lbs. (kg) 7,180 (3,255) 7,290 (3,310) 7,180 (3,255)
Mast/Forks
Axle Loading - LOADED lbs. (kg) Fr 9,880 (4,480) Fr 9.980 (4,485) Fr 9,880 (4,480)
Axle Loading - LOADED lbs. (kg) Rr 1,300 (590) Rr 1,410 (640) Rr 1,300 (590)
Axle Loading - UNLOADED lbs. (kg) Fr 3,270 (1,485) Fr 3,280 (1,490) Fr 3,270 (1,485)
Axle Loading - UNLOADED lbs. (kg) Rr 3,900 (1,770) Rr 4,010 (1,820) Rr 3,900 (1,770)
TIRES
Tire Type Pneumatic Pneumatic Pneumatic
Tire Size-Front 7.00-12-12PR (I) 7.00-12-12PR (I) 7.00-12-12PR (I)
Tire Size-Rear 6.00-09-10PR (I) 6.00-09-10PR (I) 6.00-09-10PR (I)
Number of Wheels-Front/Rear +=
2x/2 2x/2 2x/2
Driven
Tread (Center of Tires)-Front/ 38.0 (966)/37.8 38.0 (966)/37.8

in. (mm) 38.0 (966)/37.8 (960)
Rear (960) (960)
DIMENSIONS
Tilting Angle, Forward/Backward ° 6/12 6/12 6/12
Mast Height-Lowered-2-Stage
in. (mm) 85.4 (2,170) 85.4 (2,170) 85.4 (2,170)
Std. Mast **
Mast Height-Extended-2-Stage
in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Mast **
Height Overhead Guard in. (mm) 83.1 (2,110) 83.1 (2,110) 83.1 (2,110)
Length with Std. Forks in. (mm) 141.5 (3,595) 141.5 (3,595) 141.5 (3,595)
Length to Fork Face in. (mm) 99.4 (2,525) 99.4 (2,525) 99.4 (2,525)
2-7
Manufacturer’s
Designation
Overall Width at Drive Tires

in. (mm) 45.3 (1,150) 45.3 (1,150) 45.3 (1,150)
(Single)
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42 (40+100+1,070)
Carriage Width/ITA Class in. (mm) 40.9 (1,040)/II 40.9 (1,040)/II 40.9 (1,040)/II
Ground Clearance under Mast in. (mm) 5.0 (127) 5.0 (127) 5.0 (127)
Ground Clearance-Center of
in. (mm) 6.2 (158) 6.2 (158) 6.2 (158)
Wheelbase
Right Angle Stacking Aisle (2-

in. (mm) 101.6 (2,580) 101.6 (2,580) 101.6 (2,580)
Stage Mast)
Turning Radius-Outside in. (mm) 86.2 (2,190) 86.2 (2,190) 86.2 (2,190)
PERFORMANCE
Travel Speed, Forward-Loaded
mph (k/hr.) 11.2 (18.0) 11.5 (18.5) 11.2 (18.0)
(1st/2nd)
Travel Speed, Forward-Unloaded

mph (k/hr.) 11.8 (19.0) 11.8 (19.0) 11.8 (19.0)
(1st/2nd)
Lifting Speed-Loaded fpm (mm/s) 120.0 (610) 124.0 (630) 120.0 (610)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 130.0 (660) 124.0 (630)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Maximum Drawbar Pull-Loaded lbs/f (kN) 3,960 (17.6) 4,072 (18.1) 4,720 (21.0)
Maximum Gradeability-Loaded % 32 36 40
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
Steering Type FHPS FHPS FHPS
DRIVE
Battery Voltage/Capacity (5 hour
V/Ah 12/33 12/64 12/33
rating)
Engine Model K21 4D94LE 4D98E K25
Rated Output (SAE Gross) HP (kW)@rpm 56.0 (41)@2,700 65.0 (48)@2,450 96.5 (72)@2,400 60.0 (44)@2,700
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 119 (160)@1,600 141 (191)@1,800 159 (215.6)@1,700 142 (193)@1,600
No. of Cylinders/Displacement cu. in. (cm3 ) 4/126 (2,065) 4/187 (3,062) 4/ 202 (3318) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58)
OTHER
Relief Pressure-Maximum psi (bar) 2,630 (181) 2,630 (181) 2,630 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34) 8.98 (34) 8.98 (34)
Transmission PowerShift PowerShift PowerShift
* Optional masts, attachments, longer load dimensions and higher lifting heights may result in derating of the capacity.
Contact your authorized dealer.
** Other mast heights available. Contact your authorized dealer.
2-8
2.4.2 2.5-TON PNEUMATIC (OUTDOOR)

Manufacturer’s
Designation
GENERAL
Power Type Gasoline Diesel Gasoline
Capacity@24 in. (600 mm) Load

lbs. (kg) 5,000 (2,267) 5,000 (2,267) 5,000 (2,267)
Center*
Load Distance: Center Axle to

in. (mm) 17.9 (455) 17.9 (455) 17.9 (455)
Front Face
Wheelbase in. (mm) 65.0 (1,650) 65.0 (1,650) 65.0 (1,650)
WEIGHT
Service Weight (incl. 2-Stage STD
lbs. (kg) 7,941 (3,605) 8,060 (3,660) 7,941 (3,605)
Mast/Forks
Axle Loading - LOADED lbs. (kg) Fr 11,360 (5,155) Fr 11,440 (5,195) Fr 11,360 (5,155)
Axle Loading - LOADED lbs. (kg) Rr 1,590 (720) Rr 1,620 (735) Rr 1,590 (720)
Axle Loading - UN LOADED lbs. (kg) Rr 4,840 (2,195) Rr 4,870 (2,210) Rr 4,840 (2,195)
TIRES
Tire Type Pneumatic Pneumatic Pneumatic
Tire Size-Front 7.00-12-12PR (I) 7.00-12-12PR (I) 7.00-12-12PR (I)
Tire Size-Rear 6.00-09-10PR (I) 6.00-09-10PR (I) 6.00-09-10PR (I)
Number of Wheels-Front/Rear += Driven 2x/2 2x/2 2x/2
Tread (Center of Tires)-Front/Rear in. (mm) 38.0 (966)/37.8 (960)
DIMENSIONS
Tilting Angle, 2-Stage Masts,
° 6/12 6/12 6/12
Forward/Backward
Mast Height-Lowered-2-Stage
in. (mm) 85.4 (2,170) 85.4 (2,170) 85.4 (2,170)
Std. Mast
Mast Height-Extended-2-Stage
in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Mast†
Overall Width at Drive Tires

in. (mm) 45.3 (1,150) 45.3 (1,150) 45.3 (1,150)
(Single)
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42.0 (40+100+1,070)
Carriage Width/ITA Class in. (mm) 40.9 (1,040)/II 40.9 (1,040)/II 40.9 (1,040)/II
Ground Clearance-Center of
in. (mm) 6.2 (158) 6.2 (158) 6.2 (158)
Wheelbase
2-9
Manufacturer’s
Designation
Right Angle Stacking Aisle (2-

in. (mm) 106.5 (2,705) 106.5 (2,705) 106.5 (2,705)
Stage Mast)
PERFORMANCE
Travel Speed, Forward-Loaded
mph (k/hr.) 11.2 (18.0) 11.5 (18.5) 11.2 (18.0)
(1st/2nd)
Travel Speed, Forward-Unloaded

mph (k/hr.) 11.8 (19.0) 11.8 (19.0) 12.1 (19.5)
(1st/2nd)
Maximum Gradeability-Loaded % 27 31 34
DRIVE
Battery Voltage/Capacity (20 hour
V/Ah 12/33 12/64 12/33
rating)
Engine Model K21 4D94LE 4D98E K25
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 119 (160)@1,600 141 (191)@1,600 159 (215.6)@1,700 141 (191)@1,800
No. of Cylinders/Displacement cu. in. (cm3 ) 4/126 (2,065) 4/187 (3,052) 4/ 202 (3318) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58)
OTHER
2-10

Manufacturer’s Designation Unit FG28HT-16 FD28T-16
GENERAL
Power Type Gasoline Diesel
Operation Type Sit Down Sit Down
Capacity@24 in. (600 mm) Load Center* lbs. (kg) 5,500 (2,495) 5,500 (2,495)
Load Distance from Center Axle (2-Stage) in. (mm) 19.1 (485) 19.1 (485)
Wheelbase in. (mm) 66.9 (1,700) 66.9 (1,700)
WEIGHT
Service Weight (incl. 2-Stage STD Mast/Forks lbs. (kg) 8,888 (4,035) 8,920 (4,050)
Axle Loading - LOADED lbs. (kg) 12,590 (5,710) Fr 12,640 (5,740)
Axle Loading - LOADED lbs. (kg) 1,810 (820) Rr 1,770 (805)
Axle Loading - UNLOADED lbs. (kg) 3,510 (1,590) Fr 3,570 (1,620)
Axle Loading - UN LOADED lbs. (kg) 5,390 (2,445) Rr 5,350 (2,430)
TIRES
Tire Type Pneumatic Pneumatic
Tire Size-Front 28+9-15-12PR (I) 28+9-15-12PR (I)
Tire Size-Rear 6.50-10-10PR 6.50-10-10PR
Number of Wheels-Front/Rear += Driven 2x/2 2x/2
40.4 (1,025)/38.0
Tread (Center of Tires)-Front/Rear in. (mm) 40.4 (1,025)/38.0 (965)
(965)
DIMENSIONS
Tilting Angle, 2-Stage (FV) Masts, Forward/
° 6/12 6/12
Backward
Mast Height-Lowered-2-Stage Mast in. (mm) 85.0 (2,160) 85.5 (2,160)
Mast Height-Extended-2-Stage Mast in. (mm) 176.0 (4,470) 176.0 (4,470)
Maximum Fork Height-2-Stage STD Mast** in. (mm) 83.9 (2,130) 128.0 (3,250)
Free Lift Height-2-Stage STD Mast in. (mm) 104.3 (2,650) 5.5 (140)
Height Overhead Guard in. (mm) 48.6 (1,1235) 83.9 (2,130)
2+4.9+42
Length to Fork Face-2-Stage Mast in. (mm) 104.3 (2,705)
(50+125+1,070)
Overall Width at Drive Tires in. (mm) 41.0 (1,041)/II 48.6 (1,235)
Forks-Thickness+Width+Length in. (mm) 7.3 (186) 2.0+5.0+42.0 (50+125+1,070)
Carriage Width/ITA Class in. (mm) 5.0 (127) 41.0 (1,040)/II
Ground Clearance under Mast in. (mm) 110.1 (2,796) 7.3 (186)
Ground Clearance-Center of Wheelbase in. (mm) 90.9 (2,310) 5.0 (127)
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 110.1 (2,796)
Turning Radius-Outside in. (mm) 11.5 (18.5) 90.9 (2,310)
2-11
PERFORMANCE
Travel Speed, Forward-Loaded/Unloaded mph (k/hr.) 112 (570) 12.1 (19.5)/11.2 (18.0)
Lifting Speed-Loaded/Unloaded (2-Stage) fpm (mm/s) 124 (630) 118 (600)/128 (650)
Lowering Speed-Loaded/Unloaded (2-Stg) fpm (mm/s) 98 (500) 98 (500)/98 (500)
Maximum Drawbar Pull-Loaded lbs/f (kN) 98 (500) 4,072 (18.1)
Maximum Gradeability-Loaded % 4,630 (20.6) 27
Service Brake-Operation/Control 30 Foot/Hydraulic
Parking Brake-Operation/Control Foot/Hydraulic Hand/Mechanical
Steering Type Hand/Mechanical FHPS
DRIVE
Engine Model 4D94LE 4D98E
Rated Output (SAE Gross) HP (kW)@rpm 12/100 65.0 (48)@2,450 96.5 (72)@2,400
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm K25 141 (191)@1,800 159 (215.6)@1,700
No. of Cylinders/Displacement cu. in. (cm3) 60.0 (44)@2,700 4/187 (3,062) 4/ 202 (3318)
Fuel Tank Capacity U.S. gal. (liters) 142 (193)@1600 15.3 (58)
OTHER
Relief Pressure-Maximum psi (bar) 15.3 (58) 2,630 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34)
Transmission 2,650 (181) PowerShift
2-12

GENERAL
Capacity@24 in. (600 mm) Load Center* lbs. (kg) 6,000 (2,722) 6,000 (2,722)
Wheelbase in. (mm) 66.9 (1,700) 66.9 (1,700)
WEIGHT
Axle Loading - LOADED lbs. (kg) Fr 13,510 (6,130) Fr 13,590 (6,170)
Axle Loading - LOADED lbs. (kg) Rr 1,910 (865) Rr 1,890 (8600)
Axle Loading - UNLOADED lbs. (kg) Fr 3,600 (1,635) Fr 3,700 (1,680)
Axle Loading - UN LOADED lbs. (kg) Rr 5,810 (2,635) Rr 5,790 (2,630)
TIRES
Tire Size-Front 28+9-15-12PR (I) 28+9-15-12PR (I)
Tire Size-Rear 6.50-10-10PR 6.50-10-10PR
Tread (Center of Tires)-Front/Rear in. (mm)
DIMENSIONS
° 6/12 6/12
Backward
Maximum Fork Height-2-Stage STD Mast** in. (mm) 128.0 (3,250) 128.0 (3,250)
Free Lift Height-2-Stage STD Mast in. (mm) 5.5 (140) 5.5 (140)
Length to Fork Face-2-Stage Mast in. (mm) 106.5 (2,705) 106.5 (2,705)
Overall Width at Drive Tires in. (mm) 48.6 (1,235) 48.6 (1,235)
Forks-Thickness+Width+Length in. (mm)
Carriage Width/ITA Class in. (mm) 41.0 (1,040)/III 41.0 (1,040)/III
Ground Clearance under Mast in. (mm) 7.3 (186) 7.3 (186)
Ground Clearance-Center of Wheelbase in. (mm) 5.0 (127) 5.0 (127)
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 112.6 (2,860) 112.6 (2,860)
Turning Radius-Outside in. (mm) 93.3 (2,370) 93.3 (2,370)
2-13
PERFORMANCE
Travel Speed, Forward-Loaded/Unloaded mph (k/hr.) 11.2 (18.0)/12.1 (19.0) 11.8 (19.0)/12.1 (19.5)
Lifting Speed-Loaded/Unloaded (2-Stage) fpm (mm/s) 104 (530)/124 (630) 104 (530)/128 (650)
Lowering Speed-Loaded/Unloaded (2-Stg) fpm (mm/s)
Maximum Drawbar Pull-Loaded lbs/f (kN) 4,630 (20.6) 3,937 (17.5)
Maximum Gradeability-Loaded % 27 25
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical
Steering Type FHPS FHPS
DRIVE
Engine Model K25 4D94LE 4D98E
Rated Output (SAE Gross) HP (kW)@rpm 60.0 (44)@2,700 65.0 (48)@2,450 96.5 (72)@2,400
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 142 (193)@1,600 141 (191)@1,800 159 (215.6)@1,700
No. of Cylinders/Displacement cu. in. (cm3) 4/152 (2,488) 4/187 (3,062) 4/ 202 (3318)
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58)
OTHER
Relief Pressure-Maximum psi (bar) 2,630 (181) 2,630 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34) 8.98 (34)
Transmission Powershift
2-14

GENERAL
Capacity@24 in. (600 mm) Load Center * lbs. (kg) 6,500 (2,948) 6,500 (2,948)
Wheelbase in. (mm) 66.9 (1,700) 66.9 (1,700)
WEIGHT
Axle Loading - LOADED lbs. (kg) Rr 2,110 (965) Rr 2,050 (930)
TIRES
Tire Size-Front 28+9-15-12PR(I) 28+9-15-12PR(I)
Tire Size-Rear 650+10+10PR 650+10+10PR
DIMENSIONS
° 6/12 6/12
Backward
Maximum Fork Height-2-Stage STD Mast ** in. (mm) 128.0 (3,250) 128.0 (3,250)
Forks-Thickness+Width+Length in. (mm) 2.0+4.9+42.0 (50+125+1,070)
2-15
PERFORMANCE
Lifting Speed-Loaded/Unloaded (2-Stage) fpm (mm/s) 104 (530)/114 (580) 98 (500)/112 (570)
Lowering Speed-Loaded/Unloaded (2-Stg) fpm (mm/s) 98 (500)/98 (500) 98 (500)/98 (500)
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical
DRIVE
Rated Output (SAE Gross) HP (kW)@rpm 60.0 (44)@2,700 65.0 (48)@2,450 96.5 (72)@2,400
OTHER
Transmission Powershift
2-16

Manufacturer’s Designation Unit FG35AHT-16 FD35AT-16
GENERAL
Capacity@24 in. (600 mm) Load Center * lbs. (kg) 7,000 (3,175) 7,000 (3,175)
Wheelbase in. (mm) 66.9 (1,700) 66.9 (1,700)
WEIGHT
Axle Loading - LOADED lbs. (kg) Rr 2,200 (1,000) Rr 2,270 (1,030)
TIRES
Tire Size-Front 250+15+16PR(I) 250+15+16PR(I)
Tire Size-Rear 650+10+12PR 650+10+12PR
Number of Wheels-Front/Rear += Driven 2x/2
DIMENSIONS
° 6/12 6/12
Backward
Maximum Fork Height-2-Stage STD Mast ** in. (mm) 132.3 (3,360) 132.3 (3,360)
2-17
Manufacturer’s Designation Unit FG35AHT-16 FD35AT-16
PERFORMANCE
Lifting Speed-Loaded/Unloaded (2-Stage) fpm (mm/s) 89 (450)/91 (460) 87 (440)/91(460)
Lowering Speed-Loaded/Unloaded (2-Stg) fpm (mm/s) 79 (400)/79 (400) 79 (400)/79 (400)
Service Brake-Operation/Control Foot/Hydraulic
Parking Brake-Operation/Control Hand/Mechanical
DRIVE
Rated Output (SAE Gross) HP (kW)@rpm 60. (45)@2,950 65.0 (48)@2,450 96.5 (72)@2,400
OTHER
Transmission
2-18
2.4.7 2.0/2.5-TON CUSHION (INDOOR))

Manufacturer’s Designation Unit FG20ST-16 FG20SHT-16 FG25ST-16 FG25SHT-16
GENERAL
Power Type Gasoline Gasoline Gasoline Gasoline
Operation Type Sit Down Sit Down Sit Down Sit Down
Capacity@24 in. (600 mm) Load Center* lbs. (kg) 4,000 (1,810) 4,000 (1,810) 5,000 (2,267) 5,000 (2,267)
Load Distance: Center Axle to Fork Face in. (mm) 16.9 (430) 16.9 (430) 16.9 (430) 16.9 (430)
Wheelbase in. (mm) 55.1 (1,400) 55.1 (1,400) 55.1 (1,400) 55.1 (1,400)
WEIGHT
Service Weight (incl. 2-Stage STD Mast/
lbs. (kg) 7,300 (3,310) 7,300 (3,310) 8,180 (3,710) 8,180 (3,710)
Forks
Axle Loading - LOADED lbs. (kg) Fr 9,820 (4,455) Fr 9,820 (4,455) Fr 11,330 (5,140) Fr 11,330 (5,140)
Axle Loading - LOADED lbs. (kg) Rr 1,480 (670) Rr 1,480 (670) Rr 1,850 (840) Rr 1,850 (840)
Axle Loading - UNLOADED lbs. (kg) Fr 2,820 (1,280) Fr 2,820 (1,280) Fr 2,600 (1,180) Fr 2,600 (1,180)
Axle Loading - UNLOADED lbs. (kg) Rr 4,480 (2,030) Rr 4,480 (2,030) Rr 5,580 (2,530) Rr 5,580 (2,530)
TIRES
Tire Type Cushion Cushion Cushion Cushion
Tire Size-Front 21+7+15 21+7+15 21+7+15 21+7+15
Tire Size-Rear 16.25+5+11.25 16.25+5+11.25 16.25+5+11.25 16.25+5+11.25
Number of Wheels-Front/Rear += Driven 2x/2 2x/2 2x/2 2x/2
34.6 (879)/35.4 34.6 (879)/35.4 34.6 (879)/35.4 34.6 (879)/35.4

(900) (900) (900) (900)
DIMENSIONS
Tilting Angle, Forward/Backward ° 6/8 6/8 6/8 6/8
Mast Height-Lowered-2-Stage Std. Mast

in. (mm) 85.5 (2,170) 85.5 (2,170) 85.5 (2,170) 85.5 (2,170)
**
Mast Height-Extended-2-Stage Mast ** in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Height Overhead Guard in. (mm) 80.9 (2,055) 80.9 (2,055) 80.9 (2,055) 80.9 (2,055)
Length with Std. Forks in. (mm) 132.9 (3,595) 132.9 (3,595) 135.4 (3,440) 135.4 (3,440)
Length to Fork Face in. (mm) 90.8 (2,305) 90.8 (2,305) 93.3 (2,370) 93.3 (2,370)
Overall Width at Drive Tires (Single) in. (mm) 42.1 (1,070) 42.1 (1,070) 42.1 (1,070) 42.1 (1,070)
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42 (40+100+1,070) 1.6+4+42 (40+100+1,070)
Carriage Width/ITA Class in. (mm) 37.0 (940)/II 37.0 (940)/II 37.0 (940)/II 37.0 (940)/II
Ground Clearance under Mast in. (mm) 5.5 (140) 5.5 (140) 5.5 (140) 5.5 (140)
Ground Clearance-Center of Wheelbase in. (mm) 3.9 (100) 3.9 (100) 3.9 (100) 3.9 (100)
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 92.6 (2,355) 92.6 (2,355) 94.6 (2,405) 94.6 (2,405)
Turning Radius-Outside in. (mm) 75.6 (1,920) 75.6 (1,920) 77.6 (1,970) 77.6 (1,970)
2-19
Manufacturer’s Designation Unit FG20ST-16 FG20SHT-16 FG25ST-16 FG25SHT-16
PERFORMANCE
Travel Speed, Forward-Loaded (1st/2nd) mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
Travel Speed, Forward-Unloaded (1st/

mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
2nd)
Lifting Speed-Loaded fpm (mm/s) 120.0 (610) 124.0 (630) 120.0 (610) 120.0 (610)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 124.0 (630) 124.0 (630) 124.0 (630)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98.0 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98.0 (500)
Maximum Drawbar Pull-Loaded lbs/f (kN) 4,343 (19.3) 5,513 (24.5) 4,343 (19.3) 5,513 (24.5)
Maximum Gradeability-Loaded % 36 47 30 39
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical
Steering Type FHPS FHPS FHPS FHPS
DRIVE
Engine Model K21 K25 K21 K25
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 119 (160)@1,600 142 (193)@1,600 119 (160)@1,600 142 (193)@1,600
No. of Cylinders/Displacement cu. in. (cm3) 4/126 (2,065) 4/152 (2,488) 4/126 (2,065) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4)
OTHER
Transmission PowerShift PowerShift PowerShift PowerShift
2-20
2.4.8 2.8/3.0/3.2-TON CUSHION (INDOOR)

Manufacturer’s Designation Unit FG28SHT-16 FG30SHT-16 FG32SHT-16
GENERAL
Power Type Gasoline Gasoline Gasoline
Capacity@24 in. (600 mm) Load Center * lbs. (kg) 5,500 (2,495) 6,000 (2,722) 6,500 (2,948)
Load Distance: Center Axle to Fork Face in. (mm) 17.3 (440) 17.3 (440) 17.3 (440)
Wheelbase in. (mm) 57.1 (1,450) 57.1 (1,450) 57.1 (1,450)
WEIGHT
Service Weight (incl. 2-Stage STD Mast/Forks lbs. (kg) 8,840 (4,010) 9,440 (4,280) 9,920 (4,500)
Axle Loading - LOADED lbs. (kg) Fr 12,360 (6,015) Fr 13,260 (6,015) Fr 14,000 (6,350)
Axle Loading - LOADED lbs. (kg) Rr 2,000 (905) Rr 2,180 (990) Rr 2,430 (1,100)
Axle Loading - UNLOADED lbs. (kg) Rr 6,020 (2,730) Rr 6,570 (2,980) Rr 7,180 (3,255)
TIRES
Tire Type Cushion Cushion Cushion
Tire Size-Front 21+8+15 21+8+15 21+8+15
Tire Size-Rear 16.25+6+11.25 16.25+6+11.25 16.25+6+11.25
Number of Wheels-Front/Rear += Driven 2x/2 2x/2 2x/2
35.2 (895)/34.7 35.2 (895)/34.7 35.2 (895)/34.7

(880) (880) (880)
DIMENSIONS
Tilting Angle, Forward/Backward ° 6/8 6/8 6/8
Mast Height-Lowered-2-Stage Std. Mast ** in. (mm) 85.5 (2,170) 86.5 (2,197) 85.6 (2,250)
Mast Height-Extended-2-Stage Mast ** in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Length with Std. Forks in. (mm) 136.6 (3,470) 137.8 (3,500) 139.2 (3,535)
Overall Width at Drive Tires (Single) in. (mm) 43.3 (1,100) 43.3 (1,100) 43.3 (1,100)
1.6+4+42 2+4+42 2+4+42

(40+100+1,070) (50+125+1,070) (50+125+1,070)
Carriage Width/ITA Class in. (mm) 37.0 (940)/II 37.0 (940)/III 37.0 (940)/III
Ground Clearance-Center of Wheelbase in. (mm) 3.9 (100) 3.9 (100) 3.9 (100)
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 97.0 (2,464) 98.9 (2,515) 100.1 (2,543)
2-21
Manufacturer’s Designation Unit FG28SHT-16 FG30SHT-16 FG32SHT-16
PERFORMANCE
Travel Speed, Forward-Loaded (1st/2nd) mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
Travel Speed, Forward-Unloaded (1st/2nd) mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
Maximum Gradeability-Loaded % 33 31 28.5
DRIVE
Engine Model K25 K25 K25
Rated Output (SAE Gross) 60.0 (44)@2,700 60.0 (44)@2,700 60.0 (44)@2,700
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 142 (193)@1,600 142 (193)@1,600 142 (193)@1,600
No. of Cylinders/Displacement cu. in. (cm3) 4/152 (2,488) 4/152 (2,488) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4)
OTHER
2-22
OUTLINE VIEW OF LIFT TRUCK
b2 b4 b3 b1
Wa
h3
h1
h2 h4
L2 L3
L1
2-23
2.5 WEIGHT TABLE

2.5.1 PNEUMATIC MODELS
Description 2 ton 2.5 ton 2.8 ton 3.0 ton 3.2 ton 3.5 ton
K21 320 (145) –
Engine K25 320 (145)
4D94LE/4D98E 498 (226)
Torque Converter 66 (30)
Transmission TORQFLOW 148 (67) 150 (68)
Drive Axle 505 (229) 531 (241) 597 (271)
Steering Axle 87 (40) 93 (42) 96 (43)
Front 77 (35)
Wheel
Rear 33 (15)
Overhead Guard 245 (111)
2,470 3,236 3,746 4,123 4,522 4,967

Counterweight Standard
(1,120) (1,472) (1,699) (1,870) (2,051) (2,253)
Mast (including fork) w/ 2-stage 128” MFH 1,613 1,717 1,823 2,175
1,493 (677)
Mast (120” on 3.5T) (732) (779) (827) (987)
Lift 55 (25) 70 (32) 73 (33)
Cylinder Tilt 26 (12) each 30 (14) each
Power Steering 39 (18)
221 270
Fork Carriage 190 (86) 213 (96)
(100) (122)
Fork (42” pair) 220 (110) 322 (146)
Backrest 91 (41.3)
Pump 19 (8.5) 20 (9)
Control Valve (2 valves) 17.6 (8)
Steering system 48 (22)
2-24
2.5.2 CUSHION MODELS
Description 2 ton 2.5 ton 2.8 ton 3.0 ton 3.2 ton
K21 320 (145) –

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

Counterweight Standard
(1,122) (1,517) (1,737) (1,924) (2,133)
Mast (including fork) w/ 2-stage

1,455 (660) 1,562 (708) 1,666 (756) 1,772 (804)
128” MFH Mast (120” on 3.5T)
70 (32)
Lift 55 (25)
Cylinder
Tilt 26 (12) each 30 (14) each
Power Steering 35 (16)
Fork Carriage 181 (82) 202 (92) 211 (95) 260 (118)
Fork (42” pair) 220 (110) 322 (146)
Backrest 91 (41.3)
Pump 19 (8.5)
Control Valve (2-spool) 17.6 (8)
Steering system 48 (22)
2-25
2.6 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
For unspecified bolts and nuts, use the torques specified in

this table.
Select a proper torque corresponding to the width across flats
(b) of bolts and nuts.
When replacing bolts and nuts, always use genuine Komatsu
Forklift parts the same size as the previous items.
Thread diameter Width across Tightening Torque

of bolt (mm) flat (mm)
(a) (b) Nm Kgm lbft
6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.03
8 13 31.4 ± 2.9 3.2 ± 0.3 23.2 ± 2.1
10 17 65.7 ± 6.8 6.7 ± 0.7 48.5 ± 5.0
12 19 112 ± 9.8 11.5 ± 1.0 82.6 ± 7.2
14 22 177 ± 19 18.0 ± 2.0 131 ± 14
16 24 279 ± 29 28.5 ± 3 206 ± 21
18 27 383 ± 39 39 ± 3 282 ± 29
20 30 549 ± 58 56 ± 6 405 ± 43
22 32 745 ± 78 76 ± 8 549 ± 58
24 36 927 ± 98 94.5 ± 10 684 ± 72
27 41 1320 ± 140 135 ± 15 973 ± 100
30 46 1720 ± 190 175 ± 20 1270 ± 140
33 50 2210 ± 240 225 ± 25 1630 ± 180
36 55 2750 ± 290 280 ± 30 2030 ± 210
39 60 3280 ± 340 335 ± 35 2420 ± 250
2-26
2.7 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS

2.7.1 ELBOWS, NIPPLES AND UNIONS
Torque Units Nm kgm lb/ft
Width across flats B (mm) 22 30 36
Width D (mm) 19 22 30
Tightening torque 21.7 - 28.9 57.9 - 75.9 86.8 - 119 (117.7 -

ft/lb (Nm) (kgm) (29.4 - 39.2) (3 - 4) (78.5 - 103) (8 - 10.5) 161.8) (12 - 16.5)
Port size (inch) 3/4 - 16UNF 7/8 - 14UNF –
Tightening torqueNm {kgm} 68.6 - 73.6 {7 - 7.5} 78.5 - 83.3 {8 - 8.5} –
2.7.2 HIGH-PRESSURE RUBBER HOSES, PIPES AND SLEEVE NUTS
Width across flats B (mm) 19 24 27 32 36
Bore A (mm) 14 18 22 24 30
14.5 - 21.7 21.7 - 50.6 43.4 - 72.3 79.6 - 123 108 - 152
Tightening torque
(19.6 - 29.4) 23.5 - 68.6 58.8 - 98.1 108 - 167 147 - 206
ft/lb (Nm) (kgm) (2 - 3) (3 - 7) (6 - 10) (11 - 17) (15 - 21)
2-27
NOTES:
3. OPERATOR
COMPARTMENT
3.1 STRUCTURE AND FUNCTION

The Operator Compartment is where the operator controls all the functions of the truck. It includes the steering
column, dashboard, and engine controls.
3.1.1 VEHICLE CONTROLLER

The BX50 Series is equipped with a vehicle controller (interlock box) conforming to ISO3691 Standard, which
includes functions to enhance safety of the vehicle.
3.1.2 KOMATSU OPERATOR PRESENCE SYSTEM (KOPS)

Trucks made after November 22, 2005 are equipped with a Forward-Reverse Interlock to prevent travel without an
operator sitting in the seat (ASME B56.1 2004) and a Load Handling Interlock to prevent lift and tilt operation
without an operator sitting in the seat.
In addition, trucks made after March 2013 have an expanded Load Handling Interlock (ANSI/ITSDF B56.1-2012) to
prevent attachment operation (both auxiliary 1 and 2) without an operator sitting in the seat.
1. TRAVEL INTERLOCK FUNCTION: This prevents the malfunction of the vehicle. When
an operator leaves the seat, the switch under the seat is activated to disable the travel of
the vehicle. To restart travel, it is necessary to reset the Forward / Reverse lever. Users
can check operation status by the TRAVEL LOCK LAMP on the monitor panel. If the
operator leaves the seat with the lever set to F or R, the TRAVEL LOCK LAMP blinks,
showing that travel is disabled. When an operator gets on the seat again and returns
the lever to N (resets), the TRAVEL LOCK LAMP turns off and travel of the vehicle can
be restarted. The TRAVEL LOCK LAMP is also used as a neutral lamp.
2. LOAD HANDLING INTERLOCK FUNCTION: When an operator leaves the seat, the
switch under the seat is activated to disable the load handling with work equipment.
Users can check the operation status by the LOAD HANDLING LOCK LAMP on the
meter panel. If an operator is not seated properly, the LOAD HANDLING LOCK LAMP
blinks showing that load handling is disabled. When an operator is seated properly, the
LOAD HANDLING LOCK LAMP turns off and the load handling can be restarted.
3. FAILURE DETECTION:
• Seat switch failure detection.
• Relay output transistor failure detection.
• Forward / Reverse lever failure detection.
• CPU failure detection.
1 2 3
Check
Engine
3-3
3.1.3 CONTROLLER TROUBLESHOOTING
3-4
3.1.4 ISO CONTROLLER TROUBLESHOOTING CHART

NOTE: “N” lamp lights when F/R lever is set to Neutral.
ERROR LAMP
(No. of blinks)
MAST
N-LAMP
Symptom LAMP Failure Remedy Reset
status
status
Travel operation and work 1 Blinking1 Blinking SEAT-SW failure from Examine SEAT-SW cir- Normal return1
equipment do not work disconnection or short- cuit, and repair it if nec-
circuit essary.
Travel operation does not 2 Blinking1 – F/R lever failure from Examine F/R lever cir- Normal return2
short-circuit cuit, and repair it if nec-
work
essary.
N-LAMP, MAST-LAMP Abnormal output of N- Examine lamps and Key/OFF

LAMP or MAST-LAMP lamp circuit, and repair
• N-LAMP does not light from disconnection or them if necessary.
even when F/R lever is set short-circuit
to neutral.
• N-LAMP does not turn
.OFF even when F/R lever
is set to F or R position.
• MAST-LAMP does not light
for a certain time when the
key is turned ON.
• MAST-LAMP does not turn
OFF after the key is turned
ON.
Only work equipment does 4 – Blinking • Abnormal output of Examine MAST-RELAY Normal return or
work equipment inter- and relay circuit, and key/OFF
not work lock relay from dis- repair them if neces-
connection or short- sary.
circuit
• Controller output Tr
open or relay discon-
nection
Travel operation and work 4 Blinking1 Blinking Controller output Tr Examine MAST- Key/OFF
short-circuit or any of RELAY, F-RELAY, R-
equipment do not work MAST-RELAY, F- RELAY & relay circuit,
RELAY, R-RELAY and repair them if nec-
short-circuit essary.
Only travel operation does 5 Blinking1 – • Abnormal output of Examine F-RELAY, Normal return or
work equipment inter- R-RELAY & relay cir- key/OFF
not work
lock relay from dis- cuit, and repair them if
connection or short- necessary.
circuit
• Controller output Tr
open or relay discon-
nection
Travel operation and work 5 Blinking1 Blinking1 Controller output Tr Examine MAST- Key/OFF
short-circuit or any of RELAY, F-RELAY, R-
equipment do not work
MAST-RELAY, F- RELAY, & relay circuit,
RELAY, R-RELAY and repair if necessary.
short-circuit
Travel operation and work 6 Blinking1 Blinking Abnormal output of Examine MAIN-RELAY Key/OFF
equipment do not work MAIN-RELAY from dis- and relay circuit, and
connection, short-circuit repair them if neces-
sary.
Travel operation and work 7 Blinking1 Blinking Controller failure • Examine power cir- Key/OFF
equipment do not work cuit, and repair it if
necessary.
• Replace controller.
3-5
1Seat Switch Logic

Input Output
Remarks
SEAT_SW1 SEAT_SW2 ERROR-LAMP
OFF OFF Error No.1 Open

OFF ON OFF Normal
ON OFF OFF Normal
ON ON Error No.1 Short
2
F/R Lever Logic
Input Output
Remarks
F_SW1 R_SW2 ERROR-LAMP
OFF OFF OFF Normal (Neutral)

ON OFF OFF Normal (F)
OFF ON OFF Normal (R)
ON ON Error No.2 Abnormal
3-6
3.2 PERIODIC INSPECTION AND MAINTENANCE CHECK POINTS

3.2.1 TRAVELING BRAKE
1. Brake pedal
a. Pedal height (stroke)
1.61 - 2.4 in. (41 - 61 mm)
b. Play
0 - .157 in. (0 - 4 mm)

137 mm
2. Braking efficiency
Select dry and even surface road, drive at full speed and stop abruptly
to check the following:
a. Pulling of steering wheel
b. Dragging of brakes
c. Abnormal noise
d. Stopping distance
Unloaded within 14.7 ft (4.5 m) (at max. speed)

Loaded within 6.6 ft (2.0 m) (at 10 km/h)
3.2.2 PARKING BRAKES

1. Parking brake lever
Lever control force Standard brake: 33 - 44 lb/f (147 - 196 Nm) (15 - 20
kgm)
Power brake: 55 - 66 lb/f
(245 - 294 Nm) (25 - 30 kgm)
2. Braking force
Check if the truck can maintain braking on the following slope:
Unloaded slope of 11.2 degrees and over

Loaded slope of 8.5 degrees and over
3.2.3 ROD LINK, CABLE

• Scratches, looseness or play
• Breakage of cotter pin
3.2.4 CHASSIS FRAME, CHASSIS

• Cracks or deformation
• Looseness or coming off of mounting bolt
3.2.5 CAB
• Cracks or deformation
• Corrosion or rain leakage
• Opening/closing of door, lock play or breakage
3.2.6 SEAT
• Actuation
• Looseness of mounting bolt
3-7
3.2.7 DEVICES FOR GETTING ON/OFF TRUCK, ANTI-SLIP

• Cracks, damage or deformation
3.2.8 DISPLAY PANEL

• Damage
• Mounting condition
3.2.9 OVERHEAD GUARD

• Looseness of mounting
• Deformation, cracks or damage
3.2.10 BACKREST
• Deformation, cracks or damage
3.2.11 LIGHTS, GAUGES, WARNING DEVICES

• Lighting up of lamps
• Mounting condition, breakage or leakage of water
• Actuation of gauges
3.2.12 REAR VIEW MIRROR, REFLECTOR

• Dirt or damage
• Reflection
3.2.13 LUBRICATION
• Oil, greasing condition
• Actuation of auto-greasing system
3.2.14 FUNCTION OF EACH SYSTEM

Carry out travel, operation test to check.
3-8
3.3 TESTING AND ADJUSTING

INCHING AND BRAKE PEDAL (TORQFLOW MODEL)
Stop lamp switch

2
3
c
159 mm
137 mm
Inching pedal
Brake pedal
Adjust Inching Cable end play

to be 0 - 0.5 mm
(No pull the Spool)
Cable end
0 - 0.5 mm
Spool
3.3.1 ADJUST INCHING AND BRAKE PEDAL (TORQFLOW MODEL)

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

Set measurement “C” in the range of 0.02 - 0.06 in. (0.5 - 1.5 mm) after adjusting brake pedal height.
3-9
3.3.3 ADJUST ACCELERATOR PEDAL

ACCELERATOR PEDAL - K21/K25
1. Adjust lo-idle position.

a. Adjust voltage using Stopper Bolt “A” ensuring that the bolt does not contact the Spring Pin.
b. Use Turnbuckle to set pedal height at 5.19 in. (130 mm).
c. Adjust Stopper Bolt “A” to permit contact with Spring Pin, then return by more than 90° and secure in place.
d. Check that the voltage is in the correct range as shown in the following table.
2. Adjust hi-idle position.
Using Stopper Bolt “B”, adjust voltage to table values.
POSITION ACCELERATOR OUTPUT VOLTAGE

Measurement points Between GNDA - APS1 GNDA2 - APS2
Target 0.77V Target 0.38V
Released Pedal (Lo-Idle Position)
Range: 0.67-0.86V Range: 0.14-0.63V
Target 4.55V Target 2.28V
Full Pedal (Hi-Idle Position)
Range: 4.46-4.65V Range: 2.03-2.52V
3-10
ACCELERATOR PEDAL - DIESEL
3. Adjust accelerator pedal.

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

lever (2) forward to release position (B) while pressing the
push button (1).
2. Turn adjustment bolt (3) and adjust the lever control force
at the initial extension of the cable to be set as follows:
Standard brake: 33 - 44 lbf (147 - 196N)

{15 - 20 kgf}
Power brake: 55 - 66 lbf. (245 - 294N)
{25 - 30 kgf}
1
B
A
3-12
3.3.5 COMBINATION SWITCH

COMBINATION SWITCH COMPONENTS
2 3
1. F/R Switch
2. Screw
3. Cover
4. Body
5. Cover
6. Screw
7. Turn Signal Switch
3-13
 INSPECT SWITCHES 1 2
1. Remove the connection between the 8-pin coupler of the
combination switch cord and the main wiring harness. 262522232124 51 52
2. Check continuity of electric current between the terminals NS10MW-X C04MB-X
at each position to make sure that there is continuity
between the 0 to the 0.
3
3. Insulating resistance: greater than 10 at each terminal
with a 500V meg/ohm meter.
a. F/R switch connector
b. Horn contact connector
c. Protective plate
d. Lighting connector
e. Lighting and turn signal switch connector
5 4
67
28913 11 5 1012
NS08MBR-X NS04MBR-X
COMBINATION SWITCH CONNECTOR PINOUTS
Horn Switch Circuit (Conn. 2) Position of F/R Switch (Conn. 1)

(TORQFLOW Type)
No. Connect to
No. F N R Connect to
51
52 21 Earth
22 Relay
Position of Turn Signal Switch (Conn. 5) 23 Relay
No. R N L Connect to 24 Relay
1 Power Source 25 Power Source
2 3/1 Lamp 26 Relay
3 3/1 Lamp When switching between F←→N←→R,
F←→N and N←→R do not overlap.
Position of Lighting Switch (Conn. 4, 5) (Conn. 4, 5)
Twist Up and Down
No. Connect to No. Connect to
OFF 1 2 A B C
11 Power Source Power Source
12 Tail Lamp 6 H/Lamp Main
7 H/Lamp Main
5 5 Power Source
Power Source
8 9 H/Lamp
10 H/Lamp Dimmer
8 Power Source
When switching between A←→B←→C,
A←→B and B←→C overlap.
Returns automatically to C→B.
3-14
3.4 REMOVAL AND INSTALLATION - PARKING BRAKE CABLE

IMPORTANT
Always use Komatsu genuine parts when replacing parts.
3.4.1 REMOVAL
1. Park the truck in a flat and level location.
2. Block the back wheels to prevent the truck
from moving.
3. Raise the front of the truck enough to allow
the drive wheels to clear the ground.
4. Place blocks under the frame to hold the
truck off the ground.
5. Remove the wheels and brake drums.
6. Remove the adjustment lever (10).
7. Pull back on the retaining spring and
disconnect the parking brake cable (13).
8. Pull the parking brake cable out of the
wheel.
9. Remove the clips attaching the brake cable
to the frame.
10. Remove the cotter pin and the pin securing
the cable to the parking brake handle.
11. Loosen and remove the locknut securing
the parking brake cable to the mounting
bracket.
12. Pull the cable out of the mounting bracket.
13. Repeat for the other side if necessary.
3.4.2 INSTALLATION
1. Route the cable along the frame and secure with clips and bolts.
NOTE: Be sure the tang end of the cable is at the parking brake lever and the spring clip end is at the wheel. Do
not tighten the clips at this point to allow slight adjustment when attaching the cable ends to the wheel and
parking brake handle.
2. Thread the cable and the sheath end through the mounting bracket on the parking brake handle.
3. Secure the sheath to the mounting bracket with the lock nut.
4. Secure the end of the cable to the parking brake handle with the pin and cotter pin.
5. Thread the spring clip into the wheel as shown in the previous illustration.
6. Secure the cable end to the parking brake mechanism.
7. Replace the adjustment lever.
8. Replace the brake drum.
9. Replace the wheel.
10. Test the parking brake and adjust as necessary.
3-15
3.5 DISASSEMBLY AND ASSEMBLY

There are no specific disassembly and assembly procedures for operator compartment items.
3.6 MAINTENANCE STANDARD

There are no specific maintenance standards for operator compartment items.
3-16
4. ENGINE
4. ENGINE

The engine, diesel or gas, provides the power for all functions of the BX50. Propulsion is provided through the
Torqflow transmission and a PTO driven hydraulic pump provides power to the power steering and material
handling equipment.
For detailed shop information on the engines, see the service manuals for the K21/K25 (gas) or 4D94(L)E/
4D98E (diesel) series.

4.2.1 ENGINE START, NOISE
Position F/R lever in neutral, pull the parking brake lever down, and start the engine to check the following:
1. Check engine for smooth starting
2. Check engine for abnormal noise
3. Check pre-heating valve for proper functioning
4. Check acceleration pedal and control levers for smooth functioning
4.2.2 ENGINE REVOLUTION, EXHAUST EMISSION COLOR

Press accelerator pedal to check the following:
1. Check engine for combustion instability
2. Check engine for abnormal noise
3. Check engine for abnormal explosion or backfire
4. Check engine for irregular engine vibration
5. Check engine revolution for smooth speed up
6. Check engine for leakage of exhaust emission
7. Check engine for exhaust emission color
When idling no color

When pedal pressed faint black color
4.2.3 IDLING SPEED

Warm up the engine and maintain idle to check the following:
1. Idling speed
FG20 - 30 750 - 900 rpm

FG20H - 30H 750 - 900 rpm
FG35A 750 - 900 rpm
FD20 - 30 785 - 835 rpm
FD35A 785 - 835 rpm
2. Maximum speed
Gas models 2,720 - 2,920 rpm

Diesel models 2,650 - 2,750 rpm
4.2.4 AIR CLEANER

1. Check the air cleaner and element for the following:
2. Check air cleaner for cracks or scratches
3. Check air cleaner for looseness of air cleaner mounting
4. Check element for dirt or scratches
NOTE: See “AIR CLEANER” on page 4-10 for cleaning and replacement of element.
4-3
4. ENGINE
4.2.5 CYLINDER HEAD

Check cylinder head for loose mounting bolts
NOTE: See “TORQUE CYLINDER HEAD MOUNTING BOLTS” on page 4-13 for tightening torque of cylinder
head mounting bolts.
4.2.6 VALVE CLEARANCE

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

FG20 - 30 K21 0.15 (0.38) (Warm) 0.15 (0.38) (Warm)
FG20H - 25H K25 0.15 (0.38) (Warm) 0.15 (0.38) (Warm)
FG30H/32/35A K25 0.15 (0.38) (Warm) 0.15 (0.38) (Warm)
4D94LE/ 0.001-0.002 (0.035-0.065) 0.002-0.003
Diesel models
4D98E (Cool) (0.045-0.075) (Cool)
NOTE: See “ADJUST VALVE CLEARANCE” on page 4-14 for adjusting method.
4.2.7 COMPRESSION
Unit: PSI (MPa) (kgcm2)/rpm
Model Engine Standard Limit

FG20 - 30 K21 178 (1.23) {12.5}/300 149 (1.03) {10.5}/300
FG20H - 25H K25 185 (1.28) {13.0}/300 158 (1.09) {11.0}/300
FG30H/32/35A K25 185 (1.28) {13.0}/300 158 (1.09) {11.0}/300
4D94LE/ 412-441 (2.84-3.04)
Diesel models 340 (2.35) {24}/200
4D98E {29-31}/250
NOTE: See “MEASURE COMPRESSION PRESSURE” on page 4-12 for measuring method
4.2.8 FUEL INJECTION STARTING PRESSURE (DIESEL MODELS)

Set nozzle tester to check the following:
Unit: PSI (MPa) (kgcm2)
1,784-1,929
Injection 4D94LE/
(12.3-13.3)
Pressure 4D98E
{125-135}
Adjustment: Apply adjusting screw.
4.2.9 FUEL INJECTION STATE (DIESEL MODELS)

Check injection nozzle for proper injection
Faulty nozzle: Remove the nozzle from the holder. Remove carbon stuck to the nozzle and wash in diesel oil.
4.2.10 TURBOCHARGER
Exclusively for 2 - 3.5 ton models
1. Check turbocharger for abnormal vibration
2. Check turbocharger for abnormal noise
3. Check turbocharger for gas leakage
4-4
4. ENGINE
4.2.11 ENGINE MOUNT

1. Check bracket for cracks or deformation
2. Check mounting bolt and nut for looseness or coming off
3. Check anti-vibration rubber for scratches or deterioration
4.2.12 LUBRICATION SYSTEM

1. Engine Oil
a. Capacity
Check with oil level gauge and add oil if necessary.
K21/K25 Engines 4 qt. / 3.8 liter

4D94LE/ 4D98E Engines 7.9 qt. / 7.5 liter
b. Deterioration
No judgment can be made with visual check. Need periodic replacement.
c. Oil Leakage
2. Engine Oil Filter
No judgment can be made with visual check. Need periodic replacement.
4.2.13 FUEL SYSTEM

1. Check fuel leakage.
2. Check scratches or deterioration of hose and pipes.
3. Check fuel filter for proper functioning .
4. No judgment can be made with visual check. Need periodic replacement.
4.2.14 HIGH-PRESSURE GAS FUEL SYSTEM

1. Gas leakage
2. Cracks/damage of conduit
3. Looseness/damage of gas cylinder fixture
4.2.15 BLOW-BY GAS RETURN SYSTEM

1. Check valve for proper functioning.
2. Check piping for clogging or scratches.
4.2.16 RADIATOR COOLANT

1. Check coolant for proper level amount .
2. Check hose for water leakage.
3. Check hose for cracks or heat hardening.
4. Check radiator cap for damage.
• Never remove the radiator cap when the engine cool-

ant is still at high temperature. Extremely hot water
may spurt out and cause injury.
• Wait for engine and coolant to cool down before checking. When removing the radiator cap, turn it
slowly to release the internal pressure.
4-5
4. ENGINE
a. Pressure Adjusting Valve

Check the cap spring for proper tension when push-
ing it down with your finger.
b. Negative Pressure Valve
Check the valve for proper functioning.
NOTE: In case of damaged packing, replace radiator cap .
4.2.17 FAN, FAN BELT

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

K21/K25 engines
(11 - 13 mm)
.39 - .59 in.
4D94LE/4D98E engines
(10 - 15 mm)
Adjustment: Loosen the alternator mounting nut and
adjust bar bolt to slide the position of the alternator for
your adjustment.
3. Fan, Fan Cover (Shroud)
a. Check fan for cracks or deformation.
b. Check fan mounting bolt for loosening.
c. Check shroud for cracks or deformation.
d. Check shroud mounting bolt for loosening.
4.2.18 DISTRIBUTOR (GASOLINE EXPORT MODELS)

1. Check cap for cracks.
2. Check cable for scratches.
3. Check air gap for proper functioning or damage.
Air gap (Full-transistor ignition) (Export only) .014 - .017 in. (0.35 - 0.45 mm)
4-6
4. ENGINE
4.2.19 SPARK PLUG, IGNITION TIMING (GASOLINE MODELS)

NOTE: EPA Models are equipped with electronically controlled ignition systems and are not adjustable.
Export trucks are equipped with distributor ignition systems and are adjustable.
1. Spark Plug
a. Gap
Remove the plug with a plug wrench and measure the
gap with a gauge.
Plug Gap A: .027-.031 in. (0.7-0.8 mm)
NOTE: Replace the spark plug if it does not meet the specifi-
cation above or is burned
b. Cleaning
Remove the carbon stuck around the plug tip and its
surroundings
2. Ignition Timing
a. Start the engine and idle
b. Check the injection timing applying the timing light at
the timing mark of front cover and crank pulley.
Adjustment: Turn the distributor to adjust (Export only)
Ignition Timing: K21 2/850

(BTDC degrees/rpm) K25 0/850
4.2.20 BATTERY CHARGING SYSTEM, WIRING

1. Check battery gravity for charging.
Battery
Charge Need for
Electrolyte
Condition Charging
Gravity
1.280 Fully charged
No
1.240 1/4 discharged
1.210 1/2 discharged
Yes
1.130 Fully discharged
NOTE: In case of insufficient charging, check the alternator.
2. Check battery electrolyte for proper amount level.
3. Check battery terminals for loosening or corrosion.
4. Check wiring connection for loosening.
5. Check wiring for damage.
4-7
4. ENGINE

4.3.1 GASOLINE ENGINE
Before beginning maintenance of the engine, stop the engine and wait until it cools down completely.
1. Change engine oil.

a. Removing the drain plug and drain the oil into an suit-
able container.
b. Replace and tighten the plug again after draining.
c. Dispose of the used oil properly.
d. Fill the engine oil up to the specified level.
e. Check the engine oil level with the oil level gauge.
K21/K25 Engine 4 quarts (3.8 liters)
2. Replace engine oil filter.

a. Remove the cartridge with the filter wrench.
b. Clean the filter mounting area.
c. Apply clean engine oil to the threads, as well as the
seal of the new cartridge.
d. Install the new cartridge and tighten 1/3 turn after
contact with seat.
IMPORTANT
After installing the cartridge, start the engine and check to make sure that there is no oil leakage from the filter
mounting surface.
3. Replace the fuel filter.
a. Loosen the nut to remove the cover.
b. Take the filter out.
c. Clean the dirt from the bottom.
d. Drain the water.
e. Replace with a new filter.
IMPORTANT
• If any damage is found on the gasket of the cover, replace it with a new one.
• After replacement, check the hose fitting area for any fuel leakage.
4. Inspect spark plugs.

a. Remove the spark plug with an appropriate plug
wrench.
b. Clean off any carbon stuck on the plug head and the
surrounding area.
c. Measure plug gap A as shown on the illustration on
the right with a plug gap gauge.
Plug gap A: 0.7 to 0.8 mm
(1) Good
(2) No good
4-8
4. ENGINE
(3) No good
NGK FR2A-D
4.3.2 DIESEL ENGINE

1. Change engine oil.
a. Remove the drain plug and drain the engine oil into
an suitable container.
b. Dispose of the used oil properly.
c. Reinstall the plug and tighten.
d. Remove the oil level gauge (dipstick).
e. Refill with engine oil up to the specified level.
NOTE: Be careful not to overfill.
f. Check oil level with the engine oil level gauge.
4D94LE / 4D98E Engines 7.9 quarts (7.5 liters)
2. Replace engine oil filter.

a. Remove the cartridge with the filter wrench.
b. Clean the filter mounting area.
c. Apply clean engine oil to the threads, as well as the seal of the new cartridge.
d. Install the new cartridge and tighten 1/3 turn after contact with seat.
IMPORTANT
After installing the cartridge, start the engine and check to make sure that there is no oil leakage from the filter
mounting surface.
3. Drain water from fuel filter.
a. Loosen the combination sensor plug (1) and drain the
water, as well as any sediment, accumulated in the
bottom of the filter.
b. Clean up any spillage.
NOTE: Use care as fuel may be mixed with water.
4. Replace fuel filter.

a. Remove the combination sensor plug (4) at the bot-
tom of the cartridge.
b. Remove the cartridge (3) with a filter wrench.
c. Install the combination sensor plug to the new car-
tridge (3).
d. Fill the new cartridge with fuel and apply a thin layer
of engine oil before installation.
e. Loosen the plug (2) and pump the knob (1) up and
down until no more bubbles come out with the fuel.
f. Tighten the plug (2).
4-9
4. ENGINE
5. Bleed air from fuel piping (Diesel models). 2

a. Loosen plug (1) and move the knob (2) up and down
until no more bubbles come out with the fluid. 1
b. Tighten the plug (1) after completely bleeding the air.
Cartridge
Sensor and
filter plug
4.3.3 AIR CLEANER
Neither cleaning of the air cleaner nor replacement of the element is allowed while the engine is running.
IMPORTANT
• Never remove the inner element (Diesel only).
• In case of severe working conditions or environments, clean or replace the element sooner than regular main-
tenance intervals.
1. Clean the element.

Element
a. Remove the element and inspect for condition and
cleanliness.
If the filter element is damaged or is not sealing properly,

replace with a new filter.
b. Replace inner filter elements on diesel engines every

third time that the outer element is replaced.
2. Visually check the element for damage.
3. Replace element.
a. Remove the outer element from the air cleaner.
Inner Element
b. Do not remove the inner element (if equipped).
c. Cover the air connector with clean cloth or tape. [Double Element Type]
d. Clean the interior of the air cleaner and remove the
cover from the air cleaner.
e. Put a new element into the air cleaner.
f. Ensure that the new filter seats and seals properly.
Do not force the filter element into place with the housing cover. This will damage the filter and reduce it’s
sealing ability. Ensure the filter is properly seated before installing the cover.
4-10
4. ENGINE
4.3.4 ADJUST IGNITION TIMING

EPA Model lift trucks are equipped with an Electronic Control Unit (ECU) that controls ignition timing. The timing is
not adjustable on EPA trucks designed for use in the United States.
Lift trucks destined for export are equipped with a distributor ignition system and the adjustment of ignition timing is
performed as follows:
1. Connect the timing advance tester (1) as shown in the
diagram on the right.
2. Turn the power switch on and adjust the timing position of
the advance adjustment knob (2).
3. Start the engine and run at the specified idling speed.
4. Glow the timing light (3) and check to make sure that the
indicator and the timing mark stamped on the crankshaft
pulley and flywheel are correctly aligned.
5. If the timing is not in spec, turn the distributor (4) to the
right or the left for further adjustment.
6. Check that ignition timing advances quickly when the

engine is revved up.
4.3.5 ADJUST FUEL INJECTION TIMING (DIESEL MODELS)

1. Set cylinder No. 1 to TDC on the compression stroke.
2. Match the injection pump with the A mark.
3. Match the top mark B with the ATDC 4 degrees for
4D94LE engines and ATDC 6 degrees for 4D98E
engines.
4. Make sure that the plunger lift is 1 mm.
5. If the plunger lift is not 1 mm, adjust the angle of the
injection pump mounting.
4-11
4. ENGINE
4.3.6 ADJUST NO-LOAD ROTATING SPEED (DIESEL MODELS)

1. Warm up the engine prior to making this adjustment.
2. No-load Maximum Rotating Speed
Loosen a maximum rotating speed stopper bolt to No-load Maximum No-load Minimum
adjust. Speed Stopper Bolt Speed Stopper Bolt
Max. Speed 2,700-2,750 rpm
IMPORTANT
Do not adjust no-load maximum rotating speed beyond
the specified value.
3. No-load Minimum Rotating Speed
Loosen a minimum rotating speed stopper bolt to
adjust.
4D94LE 845 ± 25 rpm

Min. Speed
4D98E 810 ± 25 rpm
04-0027
4.3.7 MEASURE COMPRESSION PRESSURE

1. Warm up the engine to get the coolant temperature at
167-185° F (75 - 85 °C).
2. Stop the engine and remove all the spark plugs on
gasoline engines or the nozzle holders on diesel
engines as well as the air cleaner.
3. Disconnect the coil cord from the ignition coil on the
gasoline engine.
4. Set the fuel control lever to the non-injection position
or disconnect the wiring of the fuel cut solenoid on
diesel engines.
5. Fix the adaptor to the nozzle holder mounting of the
cylinder that is to be checked and tighten to the
specified torque.
6. Install a compression gauge to the cylinder to be
checked.
7. For pneumatic governor, floor the accelerator pedal
and crank the engine with the starter motor to get the
maximum reading of the gauge.
NOTE: Take a measurement more than twice on each cyl-
inder to avoid measurement errors and average
the values.
Use fully charged battery. Discharged battery may
not give sufficient revolutions.
4-12
4. ENGINE
COMPRESSION PRESSURE DISPERSION

PSI (kgf/cm2) at 250rpm AMOUNG
ENGINE MODEL CYLINDERS
STANDARD REPAIR LIMIT PSI (kgf/cm2)
4D94LE/4D98E 412.5 - 441 (29-31) 341.4 (24) 28.4 - 42.7 (2-3)
K21 178 (12.5)
K25 178 (12.5)
 CAUSES FOR INSUFFICIENT COMPRESSION

• Poor adjustment of valve clearance • Pressure leakage from cylinder head gasket
• Pressure leakage from valve seat • Sticking or breakage of piston rings
• Seize of valve stems • Wear of piston rings or cylinders
• Defective or broken valve spring
4.3.8 TORQUE CYLINDER HEAD MOUNTING BOLTS

K21/K25 ENGINE
1. Put the steel plate side of the cylinder head gasket
against the cylinder block.
2. Set the cylinder head in position.
3. Apply engine oil to the cylinder bolts.
4. Tighten in the order shown in the diagram on the right (1
through 10) to the specified tightening torque as follows:
torque
Cylinder Head Bolt:
1. 21.6 ft/lbs (29.4 Nm, 3.0 kgm)

Tighten temporarily
2. 57.8 ft/lbs (78.5 Nm, 8.0 kgm)
3. 0 ft/lbs (0 Nm, 0 kgm) Loosen
4. 21.6 ft/lbs (29.4 Nm, 3.0 kgm)
5. 54.2 - 61.4 ft/lbs Tighten again
(73.5 - 83.4 Nm, 7.5 - 8.5 kgm)
4D94LE AND 4D98E ENGINES

1. Put the steel plate side of the cylinder head gasket
against the cylinder block.
2. Set the cylinder head in position.
3. Apply engine oil to the cylinder head mounting bolts,
coating evenly by hand.
4. Tighten twice in sequence as the diagram on the right (1
through 18) as follows:
torque
Cylinder Head Bolt:

First Time: 36.1 - 43.4 ft/lbs (49 - 58.8 Nm, 5 - 6 kgm)
Second Time: 75.9 - 83.1 ft/lbs (102.9 - 112.7 Nm, 10.5 - 11.5kgm)
4-13
4. ENGINE
4.3.9 ADJUST VALVE CLEARANCE

1. Remove the cylinder head cover.
2. Turn the crankshaft to match the top mark A of the crank
pulley (1) and the pointer (2).
3. Check to make sure that the compression top dead
center is attained with the No.1 cylinder or the No.4
cylinder.
NOTE: At compression top dead center of the piston both of
intake and exhaust valves are closed, which means
that both the rocker arms are in free state.
4. Adjust the clearance beginning with the cylinder at the

compression top dead center.
NOTE: When the No.1 cylinder is at the compression top
dead center, adjust the valves marked with the black
circle for clearance listed on the table and turn the
crankshaft one full turn in the positive direction. Then,
adjust the remaining valves marked with the white cir-
cle for clearance.
When the No.4 cylinder is at the compression top
dead center, adjust the valves marked with the white
circle for clearance and turn the crankshaft one full
turn in the positive direction. Then, adjust the remain-
ing valves marked with the black circle for clearance.
5. Loosen the locknut (3) of the adjusting screw (4) and
insert a specified thickness gauge (2) between the valve
stem (6) and the rocker arm (5) to allow the gauge to
move smoothly and adjust the gap.
6. Tighten the locknut to secure the adjustment screw.
4-14
4. ENGINE
4.4 REMOVAL AND INSTALLATION

4.4.1 REMOVAL
Check to make sure that the mast, including forks and

attachment, are fully lowered to the ground or removed
from the truck.
1. Remove the overhead guard.

2. Remove the engine hood.
3. Remove the counterweight.
4. Remove the wiring and battery.
ENGINE WIRING CONNECTIONS - K21/K25
Seat Switch Wiring Harness

Starter B Terminal
Starter S Terminal
Operator Presence
Controller
Fuse Box Engine Wiring Harness
5. Remove the accelerator wire.
4-15
4. ENGINE
6. Remove hydraulic pump piping, torque converter piping, radiator hose, air cleaner hose, and fuel hose.
The left figure below shows diesel engine forklift truck (TORQFLOW type equipped with 4D94LE or 4D98E) and
the figure on the right shows the TORQFLOW type equipped with K21 or K25 engine.
4D94LE/4D98E TOP VIEW K21/K25 TOP VIEW
7. Remove radiator and shroud

8. Disconnect exhaust pipe.
4D94LE/4D98E RADIATOR K21/K25 RADIATOR
4-16
4. ENGINE
9. Place a wooden block under the transmission case.

10. Lift the engine slightly using a crane and hold it.
11. For TORQFLOW type trucks, remove the bolts mounting
the torque converter case.
12. Remove the left and right hand engine mounting bolts.
13. Remove the engine.
4.4.2 INSTALLATION
1. Loosen the engine mounting bolts located at the trans-
mission side.
2. Mount the engine carefully to place it in the center of the

truck frame.
4-17
4. ENGINE
3. Ensure that gap A between fan and shroud is equal.

4. Tighten engine mounting bracket bolts. A A
torque
Bracket to frame bolts:

43.5 - 54.6 ft/lbs (59 - 74 Nm) {6 - 7.5 kgm}
Engine to block side:
72 - 90 ft/lbs (98 - 122Nm) {10 - 12.5 kgm}
5. Tighten torque converter case mounting bolt.
torque
43.5 - 54.6 ft/lbs. (59 - 74 Nm) {6 - 7.5 kgm}
6. Tighten torque for engine mount bolt at transmission side.

torque
115.7 - 144.5 ft/lbs. (157 - 196 Nm) {16 - 20 kgm}

7. Align power train.
8. Tighten hydraulic piping connections.
torque
See “STANDARD TIGHTENING TORQUE FOR PIPE

JOINTS” on page 2-27.
9. Install accelerator wiring.
10. Tighten counterweight mounting bolts

torque
325 - 471 ft/lbs (441 - 639 Nm) {45 - 65 kgm}


4-18
5. TORQUE
CONVERTER
5. TORQUE CONVERTER

5.1.1 TORQUE CONVERTER
Size: 10.5 in. (265 mm)
Type: 3-Element, 1-Stage, 2-Phase Type (equipped with one-
way clutch)
5.1.2 GEAR PUMP

Capacity
Theoretical Output: 15.93 cc/rev
Actual Output:
Speed (rpm) Output (per min)

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

Oil Temperature: 149 + 41° F (65 ± 5° C)
Type: Inner contact type gear pump
• Ensure that no dirt or debris enters the hydraulic circuit openings on the transmission mounting side.
• Check to make sure each mounting bolt and plug is properly torqued prior to assembly.
• When assembling with engine, make sure to insert torque converter tip boss slowly along flywheel
center.
• After completing assembly with engine, check to ensure that gear pump oil level is correct after rotat-
ing torque converter for about one minute at the time of initial oil filling.
5.1.3 TORQUE CONVERTER ASSEMBLY

See drawing of “TORQUE CONVERTER ASSEMBLY” on page 5-4 for structure, which consists of following
elements.
• Torque Converter Circuit
• Gear Pump
• Housing
• Power Joint (Input Plate, Turbine Hub)
• Oil Filter
• Relief Valve (Main, Torque Converter Inlet Port, Lubrication)
• Strainer Assembly
1. Torque Converter Circuit

Torque converter circuit is 3-element 1-stage 2-phase type consisting of the following parts.
a. Impeller: connected with input plate through front cover
b. Stator: secured with housing through one-way clutch
a. Turbine: connected with turbine shaft through turbine hub
5-3
5. TORQUE CONVERTER
TORQUE CONVERTER ASSEMBLY

1
2
3
4
7 5
Mar
Part Name Qty
k
1 Oil Filter 1
Torque
2 Turbine 1 Converter
3 Stator 1 Circuit
4 Impeller 1
5 Turbine Shaft 5
6 Gear Pump 5
7 Turbine Hub 1
8 Input Plate 1
9 Housing 1
5-4
5. TORQUE CONVERTER
2. Gear Pump
It is an inner contact gear type pump driven with the
impeller tip fin, which supplies the oil to the transmission
and the torque converter.
3. Housing
Inside housing, it contains valves as described below:
• Torque converter inlet port relief valve to control or
prevent torque converter inner pressure from rising.
• Main relief valve to adjust clutch pressure
• Lubrication relief valve to control or prevent
lubrication pressure from rising.
4. Power Joint
a. Input Plate
The outside circumference is connected to the engine side flywheel and the inside circumference is con-
nected to the front cover of the torque converter, which transmits engine torque to the torque converter.
b. Turbine Hub
Combines the turbine shaft and the spline at transmission side and transmits the torque converter output to
the transmission.
5. Oil Filter
It is located on the hydraulic circuit at the torque converter outlet port and filters oil to prevent foreign bodies
from flowing with the oil toward the transmission side.
6. Relief Valve
a. Main Relief Valve
Being contained inside the housing, it adjusts the oil coming from the pump to supply it to the control valve
of the transmission. Thus, it also supplies the relieved oil here to the torque converter.
b. Torque Converter Inlet Port Relief Valve
Being contained inside the housing, it relieves the inner oil pressure from the torque converter to control or
protect the torque converter from escalating inner pressure.
c. Lubrication Relief Valve
Being contained inside the housing, it relieves or drains the oil for hydraulic pressure of the truck side lubri-
cation circuit so as not to exceed the specified level in order to control or prevent the inside lubrication cir-
cuit from escalating hydraulic pressure.
7. Strainer Assembly
Being located at the pump suction circuit, the strainer stops any foreign body with mesh so as to filter the oil
flow to the inside of the oil circuit.
5-5
5. TORQUE CONVERTER
POWER TRANSMISSION PATH
a. Engine rotation is transmitted to the impeller (3) through the input plate (1). Through centrifugal force, the
oil inside of the impeller flows out along the impeller fins.
b. Being pushed out from the impeller, the oil hits the turbine (2) blades and transfers its generated force
through the turbine shaft (5).
c. Coming through the turbine (2), the oil changes the direction of flow with assistance of the stator (4), which
alters the flowing angle to match the blade lines of the impeller.
Constantly repeating steps 1) through 3) above, engine power is transmitted to the transmission side. Driven by the
fins of the impeller hub tip, the gear pump is always rotating in synchronization with the engine.
 HYDRAULIC CIRCULATING ROUTE

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

B. Torque Converter Inlet Port Pressure b. Level Gauge Mounting Port
Gauge Port c. To Oil Cooler
C. Lubrication Pressure Check Port d. Drain
e. To Valve on Transmission side
f. Strainer Assembly
5-8
5. TORQUE CONVERTER
Before performing this inspection, be sure to place the wheel stoppers at each wheel and apply the park-
ing brake.
1. Clutch Oil Pressure: Select F/R lever from either direction of forward or reverse and press the pedal for mea-
suring the oil pressure.
Clutch Oil Pressure 132 - 190 PSI (0.91 - 1.31 MPa) (9.3 - 13.4 kgf/cm2)
2. Stall Speed: Select F/R lever from either direction of forward or reverse and floor the pedal to the maximum
speed for measuring the engine speed.
K21 engine 1900 ± 150 rpm/1850 ± 150 rpm

K25 & Diesel engines 2000 ± 150 rpm
Be careful to keep inspection time brief as it may raise the temperature of the oil in the torque converter.
Torque Converter Inlet Port Pressure 72.5 - 101.5 PSI (0.5 - 0.7 MPa) (5 - 7 kgf/cm2)
3. Torque Converter Outlet Port Pressure

4. Torque Converter Assembly Oil Pressure Port Location
A. Torque Converter Inlet Oil Pressure Measuring Port (101
PSI)
B. Main Oil Pressure Measuring Port (217 PSI)
C. Lubrication Oil Pressure Measuring Port (84.1 PSI Max)
B A
5. Control Valve Assembly Oil Pressure Port Location

C1. Forward Clutch Oil Pressure Measuring Port (PT1/8z) P1
(132 - 190 PSI)
C2. Reverse Clutch Oil Pressure Measuring Port
P1. Main Oil Pressure Measuring Port
C2
The temperature of the oil is very high immediately after stop-
ping operation of the truck. Be sure to start inspection after it C1
has cooled down completely.
5-9
5. TORQUE CONVERTER
5.2.1 CHECK OIL LEVEL

1. Open the floor plate to check the oil level with the oil level Air breather
gauge. for transmission
2. Add oil if necessary.
Oil level gauge Line filter
5.2.2 REPLACE OIL, INSPECT AND CLEAN STRAINER

1. Remove the drain plug to drain the oil into a suitable container.
2. Dispose of the old oil properly.
3. Replace and tighten the drain plug after draining.
4. Remove the mounting bolt and remove the strainer.
5. Cleaning the filter with flushing oil.
6. Blow dry compressed air from inside to outside of the strainer.
7. Install the strainer when it is completely dry.
8. Secure the filter with the mounting bolt.
NOTE: If any damage or clogs are found on the strainer, replace it with a new one.
9. Refill the oil as specified.
10. Check the oil level after refilling.
First Speed 10 quarts (9.5 liters) including

(F1/R1) Model torque converter
IMPORTANT
Be sure to always use Komatsu genuine oil FED10-CD for the transmission oil.
5.2.3 REPLACE LINE FILTER Air breather for transmission

1. Turn the line filter counterclockwise for removal. Air breather
for differential
2. Install a new line filter.
3. Check to make sure that the seal of the line filter touches the
case fitting face and then tighten it by another three-quarter
turn.
Strainer Drain plug
5-10
5. TORQUE CONVERTER

Troubleshooting Table
Problem Cause Remedy
No hydraulic pressure
Lack of oil Add oil
Disassemble and check. Replace with new
Damage of gear pump or drive device
parts or whole assembly if necessary.
Damage of piping or joint
No power
transmission Breakage of piston in inlet port relief valve or
Disassemble and replace with new parts.
broken spring
Mechanical Breakage Disassemble and replace with new parts.
Damage of input plate Disassemble and replace with new parts.
Damage of shaft or gear Disassemble and replace with new parts.
Damage of spline Disassemble and replace with new parts.
Hydraulic pressure is too low
Lack of oil Add oil
Check joint and gasket. Replace with new
Leakage of air from suction piping
parts if necessary.
Drop in efficiency of gear pump
parts if necessary.
Deteriorated spring in inlet port relief valve or Disassemble and check. Replace with new
faulty movement of piston parts if necessary.
Engine output
Wear or damage of seal ring Disassemble and replace with new parts.
drop
Check and wash strainer. Replace with new
Clogging of strainer
parts if necessary.
Mechanical breakage
Damage or deformation of impeller Disassemble and replace with new parts.
Deformation of input plate Disassemble and replace with new parts.
Other
Use of incorrect oil Replace with correct oil
Cavitations caused by leakage of air from Add oil and check and replace with new
suction pipe or lack of oil parts if necessary.
Failure of gear pump
parts or whole assembly if necessary.
Contact caused by deformed impeller
parts if necessary.
Abnormal sound Breakage of input plate Disassemble and replace with new parts.
Breakage of gear Disassemble and replace with new parts.
Wear or breakage of bearings Disassemble and replace with new parts.
Wear of spline Disassemble and replace with new parts.
Tighten again and replace with new parts if
Looseness of bolts
necessary.
5-11
5. TORQUE CONVERTER
Oil seal
Wear or breakage of lip Disassemble and replace with new parts.
Intake of foreign body through dust
parts if necessary
Wear or scratches of bearings Repair or replace with new parts.
Hardening or deterioration of rubber
Disassemble and replace with new parts.
because of abnormal rise in oil temperature
O-ring
Breakage of o-ring Disassemble and replace with new parts.
Scratches on mating surface Repair or replace with new parts.
Hardening or deterioration of rubber
Oil leak Disassemble and replace with new parts
because of abnormal rise in oil temperature
Sudden use in extremely cold temperature
Warm up engine before operation.
(below minus 15°C)
Joint surfaces with gasket
Looseness of bolts Tighten again.
Damage of gasket Replace with new parts
Scratches on joint surfaces Replace with new parts
Plug and screw
Looseness of screw Tighten again.
Damage of screw Replace with new parts
Cracks on mating hole Replace with new parts
IMPORTANT
Inspection and maintenance should be performed by qualified personnel.
5-12
5. TORQUE CONVERTER

1. Remove the torque converter from the truck by following the engine/transmission removal procedure.
2. Remove the transmission/torque converter assembly from the engine.
3. Removal of Torque Converter Assembly
a. Drain the oil from inside transmission.
b. Remove the torque converter assembly from the
engine and the transmission.
M24 × 1.5 Drain Plug
12 mm Socket Wrench
5-13
5. TORQUE CONVERTER

5.5.1 DISASSEMBLY
1. Remove the oil filter (20) from the housing with a special
tool.
20
2. Remove the torque converter (1) slowly from the housing.
Be careful not to damage the oil seal and the sealing of

1
the gear pump.
3. Removal of Gear Pump

a. Remove the bolts mounting the gear pump.
(M8 × 1.25 Bolt: 5 pcs.)
(Socket Wrench 12 mm)
b. Remove the gear pump (2).
5-14
5. TORQUE CONVERTER
c. Remove the o-ring, if it remains inside the housing. 2
4. Removal of Strainer
a. Remove all the bolts mounting the cover of the
strainer.
b. Remove the cover (11) and the gasket (12).
(M8 × 1.25 Hexagon Head Bolt with Flange: 8 pcs.)
(Offset Wrench 13 mm) 11,12
c. Pull the strainer assembly (13) out of the housing.
13
Be careful not to damage the o-ring for the strainer
assembly.
5. Removal of Main Relief Valve

a. Remove the main relief valve plug.
(M24 × 1.5 Plug)
(Socket Wrench12mm)
Use care. The plug is under spring pressure and may pop
out of the valve.
5-15
5. TORQUE CONVERTER
b. Pull the piston and the spring out of the valve.

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

a. Remove all of the bolts mounting the valve cover.
b. Remove the cover (9) and the gasket (10).
(M6 × 1 Hexagon Head Bolt with Hole: 4 pcs.)
(Hexagon Wrench 5 mm)
Be sure to keep pressure on the cover while removing

the bolts to prevent the plug from springing out from
inside the valve.
c. Pull out the piston (7) and the springs (5)(8) from
16 5 7
each valve.
9,10 8 7
5-16
5. TORQUE CONVERTER
7. Removal of Gear Pump

a. Remove the o-ring and disassemble the gear pump.
b. Remove the screw for disassembly as shown.
(M5 × 0.8 Screw)
Disassembly of the gear pump must be minimized as

much as possible.
Gear Case
Stator Support
Driven Gear
O-Ring
Drive Gear
Assembly
5-17
5. TORQUE CONVERTER
COMPONENT PARTS
16 24
25 20
5 18
19 27
4
6
7
9
1 10
8
7 28
1-1
18
1-2
23
22
1-3
12
11
13
3
17
26
2
15
2-7 2-5
14
2-6
2-3
2-2
2-1
2-9
2-8
2-4
5-18
5. TORQUE CONVERTER
NOTE: The numbers shown in the left column of the table correspond to those on the component parts drawing.
5-19
5. TORQUE CONVERTER
5.5.2 ASSEMBLY
Carry out assembly work in the reverse order to disassembly work.
IMPORTANT
• Wash all the removed or disassembled parts with clean oil to remove dirt and debris completely. In par-
ticular, wash the oil groove and oil circuit with care.
• Replace such parts as the o-ring, the oil seal and the gasket with new ones after disassembly.
• Be careful to assemble correctly. For details, see the check items in “Maintenance Standard” on
page 5-22.
• When replacing the oil seal with a new one, apply a semi-dry gasket sealant (THREE BOND No.1211 or
No.1104 for example) on the outside circumference of the oil seal. However, never apply it to the lip or
the sliding surface of the shaft.
8. Gear Pump
a. Insert a pair of the gears (2-2) (2-3) in the gear casing (2-1) and insert the stator support (2-6).
b. Tighten the countersunk head screw and check to make sure that the gear rotates smoothly. If it does not
rotate, disassemble it and start to assemble again.
torque
Countersunk Head Screw: 8.7 - 26 in/lbs (0.98 - 2.94) Nm (0.1 - 0.3 kgm)
9. Main Relief Valve
a. Insert the spring and the piston to the relief valve
b. Secure in place with the plug.
c. Check the piston for proper positioning when assembling.
torque
Bolt: 44 - 59 ft/lbs (60 - 80 Nm, 6.1 - 8.2 kgm)

10. Torque Converter Inlet Port Valve
a. Insert the piston and the spring into the valve.
b. Apply the gasket and the cover.
c. Secure cover in place with bolts.
torque
Bolt: 6.3 - 8.1 ft/lbs (8.5 - 11 Nm, 0.9 - 1.1 kgm)

11. Main Relief Valve
a. Insert the piston and the spring into the valve.
b. Apply the gasket and the cover.
c. Secure valve in place with valve plug.
12. Gear Pump
a. Install o-ring (1) to the corner of the housing (2) to
hold it in place.
b. Check to make sure that the o-ring is correctly
installed without any slack.
c. Insert the gear pump (3) into the housing slowly and
vertically.
13. Secure it with the bolts.
torque
Bolt: 14.7 - 19.1 ft/lbs (20 - 26 Nm, 2.0 - 2.7 kgm)

14. Torque Converter
a. Insert the torque converter in the pump into the housing slowly.
5-20
5. TORQUE CONVERTER
Be careful not to damage the oil seal and seal ring.
b. Fill the area between the oil seal lip up to 1/3 to 1/2 level with lithium grease, or apply clean hydraulic oil to
the oil seal.
c. Assemble the torque converter assembly with the transmission and the engine.
5.5.3 CHECK FOR CORRECT OIL LEVEL PRESSURE

15. Input engine speed: 2,000 rpm
Oil temperature: 175°F (80°C)
Torque converter outlet port pressure: 43.5 PSI (0.3 MPa)
Hydraulic Port
Check Item Pressure PSI (MPa)
Position
Main Pressure 160 - 303 (1.1 - 1.4) A
Torque Converter Inlet Port Pressure 72.5 - 101.5 (0.5 - 0.7) B
5.5.4 TIGHTENING TORQUE FOR BOLTS AND PLUGS

Tightening Torque
Tightening Location Screw Specifications Size Ref. No.
ft/lbs. (Nm)
Input Plate Hexagon Head Bolt M8 × 1.25 × 12 22.1 - 28.0 (30 – 38) 1-3
Gear Pump Assembly Hexagon Head Bolt M8 × 1.25 × 12 14.7 - 19.1 (20 – 26) 14
Valve Cover Hexagon Socket Head Bolt M6 × 1 × 20 6.3 - 8.1 (8.5 – 11) 16
Strainer Cover Hexagon Bolt M8 × 1.25 × 12 14.7 - 19.1 (20 – 26) 17
Pressure Pick-up Port Blind Plug Hexagon Socket Head Bolt R 1/4 9.6 - 12.5 (13 – 17) 18
Oil Filter Oil Filter 3/4-16UNF 7.3 - 11.0 (10 – 15) 20
Drain Plug Drain Plug M24 × 1.5 44.2 - 59.0 (60 – 80) 22
Main Valve Plug M24 × 1.5 44.2 - 59.0 (60 – 80) 24
Pressure Pick-up Ports Hexagon Socket Head Plug R 3/8 15.1 - 21.0 (20.5 – 28.5) 27
Blind Plug Plug M22 × 1.5 44.2 - 59.0 (60 – 80) 28
Gear Pump Stator Support Countersunk Head Screw M5 × 0.8 × 16 .722 - 2.16 (0.98 – 2.94) 2-5
5-21
5. TORQUE CONVERTER

TORQUE CONVERTER MAINTENANCE STANDARD
1
2
3
4
Mark Part Name Qty

1 Oil Filter 1
2 Turbine 1
3 Stator 1 Torque
4 Impeller 1 Converter
Circuit
5 Turbine Shaft 1
6 Gear Pump 1
7 Turbine Hub 1 7 5
8 Input Plate 1
9 Housing 1 6
5-22
5. TORQUE CONVERTER
NOTE: The numbers shown in the mark column of the table refer to the location of the component parts shown in
the diagram.
Criteria [in. (mm)]

Check Item Mark
Standard Limit
Piston (Shaft) and Torque Converter Housing (Hole)
B A
Torque Converter Housing Piston
A: Piston Outside Diameter Ø21.972 - Ø21.985mm – 4
Main Relief Valve B: Hole inside Diameter Ø22.000 - Ø22.021mm – 3
Clearance: in. (mm) .0006-.002 (.015 -.049) .003 (0.080) –

Torque Converter Inlet
B: Hole inside Diameter Ø14.000 - Ø14.018mm – 3
Port Valve
Clearance: in. (mm) .001-.002 (.030 -.058) .003 (0.080) –
Lubrication Relief Valve B: Hole inside Diameter Ø14.000 - Ø14.018mm – 3
Clearance: in. (mm) .001-.002 (.030 -.058) .003 (0.080) –
Pressure Spring
D
E
C: Free Length 3.61 (91.8) – 6
D: Mount Length 3.11 (79.1) – –

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

Torque Converter inlet
D: Mount Length 3.06 (77.6) – –
Port Valve
E: Mount Load N 10.7 lb/f (47.8 N) ± 5% 9.67 lb/f (43.0 N) –
5-23
5. TORQUE CONVERTER
Criteria [in. (mm)]

Check Item Mark
Standard Limit
C: Free Length 2.38 (60.5) – 8
Lubrication Relief Valve D: Mount Length 1.90 (48.2) – –
E: Mount Load N 13.2 lb/f (58.8 N) ± 5% 11.9 lb/f (52.9 N) –
Oil Seal and Torque Converter Impeller
F:– 1.63 (41.5)

G: 1.650 - 1.652 1.65
F
(41.915 - 41.965) (41.815)

G
Oil Seal Impeller
Seal Ring and Seal Ring Groove

H
H:.0746 -.0748
.063 (1.600)
(1.895 - 1.900)
I:.0736 -.0815
I
.0657 (1.670)
(1.870 - 2.070)
J:.0787 -.0885
K
.0905 (2.30)
J (2.000 - 2.250)
K: 1.657 - 1.658
1.663 (42.25)
(42.10 - 42.13)
Seal Ring Seal Ring Groove
Bushing and Stator Support
L: 1.279 - 1.280
–
(32.500 - 32.525)
M: 1.277 - 1.278
–
(32.450 - 32.470)
Clearance:
L
.0011 -.0029
.0039 (0.100)
(0.030 - 0.075)
Bushing Stator Support
5-24
6. TORQFLOW
TRANSMISSION

The torqflow transmission is located between the torque converter and the drive axle. It is a single speed two
direction transmission. The transmission is controlled by a solenoid valve which receives signals from the F/R lever
mounted on the steering column.
TRANSMISSION CROSS-SECTION
6-3
TRANSMISSION CONTROL VALVE ASSEMBLY - HYDRAULIC PRESSURE PORT LOCATION
a
(On T/M Case)
g
e
f
h
a. Pump O/P Measure Port

b. FWD Clutch Measure Port
c. REVERSE Clutch Measure Port
d. To REVERSE Clutch
e. To FWD Clutch
f. Drain
g. Drain
h. From Pump
6-4

1. Check the following by operating the F/R lever:
a. No clatter at each position
b. Smooth shifting
N
2. Check transmission for abnormal sound.
3. Check transmission for oil leakage.

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

Air breather
for differential
Strainer Drain plug
5. Inching Pedal (TORQFLOW type)

a. Inching spool stroke
Stroke A .96 in. (24.5 mm)
NOTE: Be very careful that the cable does not press the inching
pedal when it is released A
Initial set
Reference: 13 mm
6-5
b. Interconnected Stroke
Adjust stroke with adjusting screw to interlock the brake pedal
with the inching pedal at the specified value
Adjusting screw
2.0 - 3.0 ton
1.41 - 1.57 in. (36 - 40 mm)
3.5 ton
Inching pedal
c. Pedal Stroke
2.0 - 3.0 ton 3.54 - 4.57 in. (90 - 116 mm)

3.5 ton 3.15 - 4.17 in. (80 - 106 mm)
d. Play: 0 - .157 in. (0 - 4 mm)

159 mm
6-6

6.3.1 CHECK OIL LEVEL
1. Open the floor plate to check the oil level with the oil level Air breather
gauge. for transmission
The temperature of the oil is very high immediately after stop-

ping operation of the truck. Be sure to start inspection after it
has cooled down completely.
6.3.2 REPLACE OIL, INSPECT AND CLEAN STRAINER

1. Remove the drain plug to drain the oil into a suitable container.
2. Dispose of the old oil properly.
3. Replace and tighten the drain plug after draining.
4. Remove the mounting bolt and remove the strainer.
5. Cleaning the filter with flushing oil.
6. Blow dry compressed air from inside to outside of the strainer.
7. Install the strainer when it is completely dry.
8. Secure the filter with the mounting bolt.
NOTE: If any damage or clogs are found on the strainer, replace it with a new one.
9. Refill the oil as specified.
10 quarts (9.5 liters) including

F1/R1 Model
torque converter
IMPORTANT
Be sure to always use Komatsu genuine oil FED10-CD for the transmission oil.
6.3.3 REPLACE LINE FILTER

Air breather for transmission
1. Turn the line filter counterclockwise for removal. Air breather
2. Install a new line filter. for differential
3. Check to make sure that the seal of the line filter touches the
case fitting face and then tighten it by another three-quarter
turn.
Strainer Drain plug
6-7

6.4.1 REMOVAL
Ensure that the mast, including forks and attachment, are fully
lowered to the ground or removed from the mast.
1. Remove Counterweight
a. Connect a crane to the counterweight.
b. Remove the bolts securing the counterweight to the frame.
c. Lift the counterweight up and away from the truck frame.
2. Remove Overhead Guard
a. Remove the four bolts and washers securing the overhead guard to the frame.
b. Disconnect the lighting harness connectors at each corner of the overhead guard frame.
c. Secure a crane to the overhead guard and lift straight up to remove.
3. Remove Engine Hood
a. Lift the engine hood.
b. Disconnect the operator presence switch harness from the seat switch.
c. Remove the hairpin clips and pins securing the stay and the locking brace to the frame.
d. Remove the bolts securing the engine hood hinges to the frame.
4. Disconnect battery cables and remove battery.
5. Disconnect engine and transmission wiring.
ENGINE WIRING CONNECTIONS
Seat Switch Wiring Harness

Starter B Terminal
Starter S Terminal
Operator Presence
Controller
Fuse Box Engine Wiring Harness
6. Disconnect the inching cable.
6-8
7. Remove piping and hoses

a. Disconnect hydraulic pump piping at the pump.
b. Disconnect torque converter piping.
c. Remove radiator hoses.
d. Remove air cleaner hose.
e. Disconnect fuel hose.
8. Disconnect exhaust pipe.
9. Remove radiator shroud.
In the illustration below the diesel engine configuration is on the left and K21/K25 engines on the right.
10. Rig the engine with a crane and hold it.

11. Place a jack as shown in the illustration on the right and
support two unit assemblies.
6-9
12. Remove the bolts mounting the propeller shaft and

remove the propeller shaft.
13. Remove the bolts mounting the engine at the

transmission side.
14. Lift the engine and transmission using the crane.
6-10
6.4.2 INSTALLATION
When installing the power train (front axle or Transmission/engine), always be sure to perform an align-
ment between the front axle and the transmission.
1. Install Engine/Transmission Assembly

a. Loosen the bolts mounting the engine located at the
transmission side.
b. Mount the engine carefully to place it in the center of

the truck frame.
c. Check that gap A between fan and shroud is equal.

d. Remove the inching valve and check that gaps are parallel.
2. Tighten Torque Converter Case Mounting Bolt.
torque
43.5 - 54.6 ft/lbs. (59 - 74 Nm) {6 - 7.5 kgm} Mounting bolt
6-11
Tightening torque for engine mount bolt at transmission

side:
torque
115.7 - 144.5 ft/lbs. (157 - 196 Nm) {16 - 20 kgm}
3. Install propeller shaft.

torque
24 - 28ft/lbs (32.4 - 38.2 Nm) {3.3 - 3.6 kgm}
4. Align power train.

a. Prepare the tools shown below.
Special tool for remove/install back lamp/Neutral switch

for manual transmission. (Not applicable on TorqFlow
models)
L-Type block for Axle
Electric Water level Meter
6-12
b. Remove oil level plug from front axle and install the l-type block using the plug.
c. Place the electric water level meter and measure the leaning angle (tilt) of the front axle.
d. Measure leaning angle (tilt) of engine/transmission
e. Remove transmission control valve.
f. Place electric water level meter on the machined sur-
face of transmission as above.
g. Read the leaning angle of transmission.
IMPORTANT
Service limit of leaning angle of Transmission and Front axle:
Maximum 0.5 degrees between Transmission/Axle
measurement.
When angle of leaning (tilt) is more than 0.5 degrees, this
indicates an incorrect position in either the front axle or
engine/transmission.
h. Adjust the engine mounting and axle mounting as necessary.
IMPORTANT
All pipe threaded fittings should be installed using an approved sealing compound.
5. Attach and tighten piping and hoses.
a. Connect hydraulic pump piping at the pump.
b. Connect torque converter piping.
c. Install radiator hoses.
d. Attach air cleaner hose.
e. Connect fuel hose.
IMPORTANT
Fuel lines should be supported by clamps to minimize chafing and wear.
See “STANDARD TIGHTENING TORQUE FOR PIPE JOINTS” on page 2-27.
6. Install accelerator cable (see “ADJUST ACCELERATOR PEDAL” on page 3-10).
6-13
7. Install engine hood.

a. Align hinges and secure with bolts.
b. Lift engine hood and hold in place.
c. Secure stay in place with pins and hairpin clips.
d. Secure locking bar in place with pins and hairpin clips.
e. Attach seat switch cable to seat switch.
8. Install overhead guard frame.
a. Position overhead guard frame in place and secure with bolts.
b. Attach lighting harness at each overhead guard frame corner.
9. Install counterweight.
a. Use crane to lift counterweight into place.
b. Install and tighten counterweight mounting bolt.
torque
325 - 471 ft/lbs (441 - 639 Nm, 45 - 65 kgm)
6-14

6.5.1 DISASSEMBLY
1. Remove bolt (1) and remove the transmission control
valve. 1
2. Remove the drain plug and drain the oil inside the
transmission case.
3. Remove the propeller shaft.
4. Place wooden blocks to support the transmission case

assembly and set it facing in the direction shown in the 1
diagram on the right.
5. Remove bolt (1) connecting the torque converter and the
transmission case to separate the torque converter.
6-15
6. Remove bolt (1).

7. Remove the bearing (2), the gear (3), the bearing (4), the
seal (5) and the spacer (6) in turn. 1
8. Pull the output shaft (7) out from the lower side of the
transmission case.
2
9. Pull out the intermediate shaft sub-assembly.
6-16
10. Pull the input shaft sub-assembly (with the clutch pack
assembly) out of the transmission case.
11. Remove bolt (1) from the transmission case (7).

12. Remove plate (2). 4
13. Remove the strainer (3). 1 7
14. Remove the oil level plug (4). 2
15. Remove cap (5) and the blind plug (6). 3
16. Disassemble the clutch pack assembly by removing the

parts in the order indicated in the following illustration. 6
6-17
TRANSMISSION ORDER OF ASSEMBLY AND DISASSEMBLY
a
b
13
11
3 10
9
5
6
7 17
8 15
12
14
1 4 31
16
a 18
29
21 28
27
23
20
24
25 35
26 33
30
32
19 22
34
b
36
6-18
6.5.2 ASSEMBLY
1. Blow out all machined holes of the transmission case with 4
air.
2. Install blind plug (6), the cap (5) and the breather (4) to 1
2
the transmission case. 3
3. Install drain plug (7).
torque 6 7
Tightening Torque for Drain Plug:
37.4 - 57.8 ft/lbs. (50.8 - 78.4 Nm) {6.0 - 8.0 kgm}
4. Fit the o-ring to the strainer (3) and insert it inside the
transmission case.
5. Then, install the plate (2) with the gasket and tighten it 5
with bolt (1).
6. Insert spacer (6), seal (5), bearing (4), the gear (3) and
the bearing (2) in the output shaft and secure it with the 1
washer and bolt (1).
torque 2
Tightening Torque for Bolt:
72.2 - 90.7 ft/lbs. (98 - 123 Nm) {10 - 12.5 kgm}
3
LOCTITE #271 (Hole Thread) 4
6-19
7. Install the intermediate shaft sub-assembly into the

transmission case.
8. Fit seal (2) and seal (3) to the piston (4).

9. Assemble the input shaft assembly (1) into the piston. 3 4 5 6 7 1
10. Install spring (5) and the washer (6).
11. Secure with snap ring (7).
12. Assemble bearing (8) and secure with snap ring (8-1).
13. Assemble the clutch discs (10) and the plates (9) and 14 10 9 11 8
secure with ring (11).
14. Install forward gear
a. Insert the bearing in gear (14) and assemble it to the
shaft.
b. Assemble the bearing and the spacer.
c. Secure with the snap ring.
15. Install reverse gear
a. Assemble the washer, the gear, the bearing and the
washer.
b. Secure with the snap ring.
6-20
16. Install the seal ring to the input shaft sub-assembly and
assemble inside the transmission.
17. Apply Liquid gasket to the torque converter contact face

of the transmission case and install the torque converter 2
(2) and the transmission case (3) with bolt (1).
18. Fit the transmission control valve gasket in place.

19. Secure the transmission control valve with bolts (1).
1
torque
Tightening torque for control valve mounting bolts:

19.9 - 25.0 ft/lbs. (27 - 34 Nm) {2.8 - 3.5 kgm}
20. Install the oil filter and the piping.
6-21
6.5.3 SOLENOID VALVE DISASSEMBLY AND ASSEMBLY

SOLENOID VALVE DISASSEMBLY
15
3
13
9
12 1
11
2
7
5
4
6
13
8
10
14
1. Body
2. Solenoid Guide
3. Spool
4. Solenoid Coil
5. Plug
6. Spacer
7. Spring
8. Nut
9. Retainer A
10. O-ring
11. Retainer B
12. O-ring
13. Parallel Pin
14. O-ring
6-22
SOLENOID VALVE COMPONENTS
11 12 9 8 6 15 4 5 7 10 2 1 14
13
SOL.b SOL.a
3
See also figure at left.
6-23
DISASSEMBLY
1. Remove the nut (11) with 27 mm box end wrench.
2. Remove the O-ring (12). Then, remove the solenoid coil 15
(9).
NOTE: Be careful not to damage the spool hole because the
clearance between the body (1) and the spool (2) is
extremely small. 9
3. Remove the O-ring (15) inserted in the solenoid coil (9). 12
11
4. Remove the solenoid guide (8) with the 27 mm box end

wrench. 2
5. Remove the O-ring (13) from the solenoid guide (8). 7
5
4
6
13
6. Loosen the plug (3) with a spanner (3.5 mm pin-spanner

with 12.5 mm pitch) and remove it.
7. Remove the O-ring (13) from the plug (3). 1
8. Remove the O-ring (14) from the body (1).
3
Never attempt to remove the spacer, it is pressed into the 13
body.
14
6-24
ASSEMBLY
1. Insert the O-ring (14) into the body (1).
NOTE: All of the O-rings should be replaced with new ones.
2. Insert the O-ring (13) in the plug (3). 1
3. Assemble plug (3) to the body (1) with the pin spanner
(3.5 mm pin-spanner with 12.5 mm pitch).
3
torque
14.8 - 18.4 ft/lbs. (20 - 25 Nm) {2.0 - 2.6 kgm} 13
4. Insert O-ring (12) into the solenoid guide (8)
14
5. Assemble O-ring (13), retainer B (6), spring (4), retainer

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

7. Insert the solenoid coil (9) into the solenoid guide (8). 15
8. Insert O-ring (12) into the solenoid coil (9).
9. Install the nut (11) with a 27 mm box end wrench.
torque
9
6 - 7.4 ft/lbs. 8 - 10 Nm {0.8 - 1.0 kgm}
12
11
6-25

6.6.1 TRANSMISSION
TRANSMISSION MAINTENANCE STANDARD
F1
D1
C1
D2 C2 A1 A2
6-26
Criteria [in. (mm)]

Mark Check Item Remedy
Standard Limit
.123 -.128
A1 Thickness of Drive Plate (3.13 - 3.27) .0114 (2.9)
A Plate .092 (2.35) Replace
.098 -.104
A2 Thickness of Driven Plate (Oil groove width:
(2.50 - 2.65) min..0059 (0.15))
B1 Clearance at End Gap when .0141 -.0220 –

inserting piston (0.36 - 0.56)
.0059 -.0137 Oil groove Replace with
B Seal Ring B2 Depth of Oil Groove in side face every
(0.15 - 0.35) must be there. disassembly
.1023 -.1043
(D1) Width of Insertion Groove (2.60 - 2.65) .110 (2.8)
C1 Inside Diameter of Seal Ring 1.378 - 1.379 1.385 (35.2)

Contact Face (35.025 - 35.050)
C Piston
Width of Seal Ring .1220 -.1226
C2 .1338 (3.4)
Insertion Groove (3.1 - 3.2)
Width of Seal Ring .1023 -.1047
D1 Insertion Groove (2.60 - 2.65) .1102 (2.8)
D Drive Shaft
D2 Width of Seal Ring .1023 -.1043 .1102 (2.8)
Insertion Groove (2.60 - 2.65)
E1 Clearance at End Gap when .0078 -.0157 .0393 (1.0)

inserting clutch case (0.2 - 0.4)
.1169 -.1185
E Seal Ring E2 Width (2.77)
(2.97 - 3.01)
Replace
.1220 -.1259
(C2) Width of Insertion Groove (3.1 - 3.2) .1338 (3.4)
F Clutch Case F1 Inside Diameter of Seal Ring 3.936 - 3.939 3.948 (100.3)
Contact Face (100 - 100.054)
Clearance at End Gap when .0141 -.0220
H1 –
inserting cap (0.36 - 0.56)
.0059 -.0137 Oil groove
H Seal Ring H2 Depth of Oil Groove in side face (0.15 - 0.35) must be there.
(D2) Width of Insertion Groove .1023 -.1043 .1102 (2.8)

(2.60 - 2.65)
.0031 -.0110
– Gears – Backlash –
(0.08 - 0.28)
Replace with
Gasket, O-ring and new parts on
– – –
Seals disassembly
and assembly
6-27
6.6.2 TRANSMISSION CONTROL VALVE

TRANSMISSION CONTROL VALVE MAINTENANCE STANDARD
23
19
22
21
1
8
18 10
11
15
7
17
20 5
16
4
2
13 14
12
1. Valve Body 9. Spring 17. Gasket

2. Spool 10. Spring 18. Plug
3. Valve 11. Pin 19. Plug
4. Spring 12. Plate 20. Orifice
5. Spacer 13. Gasket 21. Oil Seal
6. Spring Pin 14. Bolt 22. Plate
7. Spring 15. Piston 23. Bolt
8. Piston 16. Plug
6-28
The numbers shown in the mark column refer to the callouts in the component parts diagram.
Criteria [in. (mm)]
Check Item Remedy Mark
Standard Limit
Piston or Spool and Body Hole
A: Valve Body Inside Diameter
B: Piston Spool Outside Diameter
– – –
A B
1.1011 - 1.1015
(27.97 - 27.98)
Piston Outside Diameter 1.1023 - 1.1031 14
Accumulator Body Inside Diameter .0031 (0.080) 1
Clearance (28 - 28.021)
.0007 -.0020
(0.020 - 0.051)
.7858 -.7866
Piston Outside Diameter (19.96 - 19.98) 15
Regulator Body Inside Diameter .7873 -.7882 (20 - 20.021) .0031 (0.080) 1
Clearance .0007 -.0024
(0.020 - 0.061)
.7858 -.7866
Piston Outside Diameter (19.96 - 19.98) 15
Lubrication Relief Body Inside Diameter .7873 -.7882 (20 - 20.021) .0031 (0.080) 1
(0.020 - 0.061)
.7862 -.7866
Spool Outside Diameter (19.97 - 19.98) 2
Inching Spool Body Inside Diameter .7873 -.7882 (20 - 20.021) .1127 (0.070) 1
(0.020 - 0.051)
.7862 -.7866
Small Piston Piston Outside Diameter (19.97 - 19.98) .1127 (0.070) 3
Clearance .0007 -.0020 Replace
(0.020 - 0.051)
Spring
C: Free Length
D: Mount Length –
E: Mount Load
C
D
E
Free Length 1.739 (44.18)
Accumulator Large Spring Mount Length 1.129 (28.70) 11
Mount Load 287.3 N {29.3 kgf} ± 5% 258.6 N {26.4 kgf}
Accumulator Small Spring Mount Length 3.295 (83.7) 12
Free Length 4.372 (111.07)
Regulator Large Spring Mount Length 2.941 (74.7) 16
Free Length 4.859 (123.43)
Regulator Small Spring Mount Length 3.807 (96.7) 17
Mount Load 206 N {21.0 kgf} ± 5% 185.4 N {18.9 kgf}
Lubrication Relief Mount Length 1.885 (47.9) 19
Mount Load 138 N {14.1 kgf} ± 5% 124.5 {12.7 kgf}
Inching Spool Mount Length 1.889 (48.0) 7
Small Piston Mount Length .8661 (22.0) 4
6-29
NOTES:
7. DRIVE AXLE
7. DRIVE AXLE

The drive axle is located at the front of the truck and consists of the differential, wheel hub, and brake system.
DRIVE AXLE AND WHEEL HUB COMPONENTS
7-3
7. DRIVE AXLE
DIFFERENTIAL
7-4
7. DRIVE AXLE

7.2.1 DIFFERENTIAL
1. Abnormal noise when traveling
2. Oil level in differential casing
3. Dirt or stain with oil (see “DIFFERENTIAL TORQUES
AND SEALS” on page 7-19 for checking oil level and
replacing).
4. Oil leakage from differential casing
7.2.2 FRONT AXLE

1. Deformation, cracks or scratches: Visual check on and
around the frame and mounting bolt or welded area Oil level check and
Drain plug
2. Looseness of mounting bolt: Tightening torque of oil filling combination plug
mounting bolt
2.0 - 3.0 ton trucks 361 - 448 ft/lbs. (490 - 608 Nm) (50.0 - 62.0 kgm)
torque
3.2, 3.5 ton trucks 488 - 611 ft/lbs. (662 - 829 Nm) (67.5 - 84.5 kgm)
7.2.3 TIRES
1. Air pressure A
B
2.0 - 3.0 ton Front
trucks 100 PSI (690 kPa) {7.0 kgf/cm2}
Rear
2
3.2, 3.5 ton Front 123 PSI (850 kPa) {8.5 kgf/cm }
more than1.6 mm
trucks Rear 129 PSI (890 kPa) {9.0 kgf/cm2}
2. Cracks in tread or sidewall: Replace with a new one if

necessary.
3. Depth of tread: Measure the groove depth at a quarter of
the tread width, it must be at least 1.6 mm.
4. Abnormal wear
5. Eccentric wear or stepped wear
6. Metal pieces stuck in tire
7.2.4 WHEEL
1. Tightening torque for hub nut
Front 217 - 361 ft/lbs. (294 - 490 Nm) {30 - 50 kgm}

2.0 - 3.5 ton
Rear 116 - 180 ft/lbs. (157 - 245 Nm) {16 - 25 kgm}
2. Deformation or cracks of side link: Check visually or by the crack detection method.
3. Tightening torque for rim mating nut
Front 144 - 217 ft/lbs. (196 - 294 Nm) {20 - 30 kgm} excluding 3 ton truck
2.0 - 3.5 ton
Rear 65 - 90 ft/lbs. (88 - 123 Nm) {9 - 12.5 kgm}
7.2.5 BRAKE PIPING

1. Visual check on piping, hoses and joints
2. Scratches
3. Oil leakage
4. Evidence of interference or contact
5. Deterioration of hose
7-5
7. DRIVE AXLE
6. Loosening of mounting bolt
7.2.6 OIL BRAKE

1. Master cylinder and wheel cylinder
a. Check the following by operating the brake pedal
b. Pressure (feel) when pedal depressed
c. Fluctuation of pressure or pedal height
d. Fluctuation of pedal position when maintaining pedal
pressure
e. Return of the pedal when releasing the pedal
NOTE: If you feel a change while pressing the pedal with no
oil leakage, the brake valve is defective
2. Brake reservoir
a. Oil level amount. Applicable limit A: 18 mm
b. Fluid stain from oil or oil leakage
3. Deterioration of wheel cylinder
Clearance between < .006 in.

cylinder and piston (0.15 mm)
7.2.7 BRAKE BOOSTER

Oil leakage
7.2.8 BRAKE SHOE LINING

1. Brake shoe
Check proper functioning, rust or wear
2. Peeling off, scratches or wear of brake lining
Thickness of lining > .039 in. (1 mm)

3. Corrosion of anchor pin
4. Deterioration of return spring
Free length < 4.13 in. (105 mm)

Thickness of hook > .078 in. (2.0 mm)
7.2.9 BRAKE DRUM

Cracks scratches or wear of brake drum
Measure the following dimensions, and check whether they are allowable values.
Inside diameter of drum (all models) < 12.28 in. (312 mm)
7.2.10 BACK PLATE

1. Deformation, cracks or scratches
2. Tightening torque for mounting bolt
LOCTITE #271 (thread hole)
torque
130 - 144 ft/lbs. (176 - 196 Nm)
{18.0 - 20.0 kgm}
7.2.11 PARKING BRAKE DRUM, LINING

Common with the travel brake drum, lining (see “Parking Brakes” on page 9-6).
7-6
7. DRIVE AXLE

7.3.1 INSPECT OIL LEVEL
The temperature of the oil is very high immediately after

stop operation of the truck. Be sure to start inspection
after it is cooled down completely.
1. Remove the oil level check plug to check that the oil is
nearly up to the lower level of the plug-hole.
7.3.2 REPLACE OIL

1. Remove the oil filler plug and drain plug.
2. Drain the oil into a suitable container.
3. Dispose of the oil properly.
Drain plug
4. Replace and tighten the drain plug. Oil level check and
5. Refill the oil as specified. oil filling combination plug
2.0 - 2.5 ton 6.34 qt. (6.0 liters)
3.0 - 3.5 ton 6.13 qt. (5.8 liters)
IMPORTANT
• Be sure to always use Komatsu genuine oil FG090 for the gear oil. The same oil is used in the differential case
and the transmission case on clutch models.
• The TORQFLOW type truck requires inspection and oil replacement of the TORQFLOW transmission case in
addition to the oil of the differential case.
7-7
7. DRIVE AXLE
7.3.3 GREASE CROSS BEARING OF PROPELLER SHAFT

Typical lubrication cycle: 1200 hours
1. Supply grease to the grease nipple attached to the cross bearing.
2. Press a grease gun to the end of the nipple, and supply grease until it comes out of all four shafts.
3. Wipe overflowing grease completely to prevent adhesion of dirt and dust.
PROPELLER SHAFT COMPONENTS
7-8
7. DRIVE AXLE
7.3.4 ADJUST PINION SHAFT ASSEMBLY WITH SHIM(S)

1. Determine clearances
a. Read the indication (a) at the pinion shaft tip.
b. Read the stamp (b) on the case.
c. Measure clearance (c) and express it in 1/100-unit
bases against the standard size 1.16 in. (29.50 mm). Set No. a
c = .59 in. (15 mm)
#7
20
NOTE: The clearance can be determined by calculation con-
sidering the accuracy of the bearing and following
value shall be applicable. If no proper tooth contact is b
found, assemble it again.
2. Calculation of Shim Thickness S1

a. Apply clearances (a), (b) and (c), obtained as shown
above, to the formula shown below to calculate the 15680 -
thickness of the shim S1. 23250 N
(1600 -
S 1 = 0.7 + A +b+c+d 2400 kgf)
-------------------------------- Set this face
100
to the
b. Round the figure to two decimal places. differential (Equivalent to
when bearing preload)
IMPORTANT assembling.
Check to make sure there is no clearance between the gear

c
and the shim when pressing the gear for installation.
7.3.5 ADJUST PINION GEAR CLEARANCE

1. Clearance (b)
a. Fix the pinion shaft pushing from the bottom. 1 d
b. Take an alignment to the shaft with the jig.
c. Turn the bearing about 10 times each to right and left
to check its smooth movement.
d. Measure the clearance (d).
IMPORTANT
Check to make sure that step (1) above has no clearance.
2. Calculation of Shim Thickness S2
a. Calculate shim thickness S2 1 Fixed
S 2 = 2.354 – d
applying the clearance (d) measured above.
b. Select the shim so as to meet the S2 of the clearance.
c. Measure the starting torque and adjust the shim thickness S2.
Make sure to measure the starting torque without the coupling shaft.
d. Starting Torque for Pinion Bearing
torque
Starting Torque: 6.49 - 9.75 (8.8 - 13.2 Nm, 90 - 135 kgcm)
7-9
7. DRIVE AXLE
7.3.6 INSPECT PINION BEARING CLEARANCE

1. Apply Komatsu Forklift genuine oil to the inner race face
and edge (1) when assembling.
2. Check to make sure that no clearance exists (2) when
inserting the outer race. 2 1
3. Check to make sure that the inner race large rim has no
clearance (3) when pressing the inner race for
installation.
4. After tightening the nut with specified torque, turn the
bearing about 20 times each to the left and right to check
its smooth movement. 3
5. If the starting torque cannot match the specified torque as
shown below, disassemble and adjust the shim thickness
again.
torque
Starting Torque: 6.49 - 9.75 ft/lbs. (8.8 - 13.2 Nm, 90 - 135 kgcm)
• If the starting torque T is greater than 9.7 ft/lbs. (13.2 Nm, 135 kgcm), increase the shim thickness.
• If the starting torque T is less than 6.5 ft/lbs. (8.8 Nm, 90 kgcm), reduce the shim thickness.
7.3.7 ADJUST DIFFERENTIAL

1. Assembly of Differential Assembly
a. Assemble the differential assembly and install adjust-
ment screw (1). 2
b. Apply LOCTITE #271 to the hole of the cap (2) and 1
tighten with bolt (3) temporarily.
LOCTITE #271
2. Adjust Backlash
Use special tool A for tightening the adjustment screw (1). 1
Special Tool A 34B-97-99110

a. Set the dial gauge and slightly tighten the adjustment
screw at the (B) side until the backlash goes to zero.
7-10
7. DRIVE AXLE
b. Loosen the adjustment screw at the (B) side until

backlash goes to .006 - .009 in. (0.15 - 0.23 mm)
Backlash between Ring .006 - .009 in.

Gear and Pinion Gear (0.15 - 0.23 mm)
IMPORTANT
If the backlash is above the limits specified, make the adjust- A B
ment again.
3. Adjust Tooth Contact Forward

a. Apply red lead thinly and evenly to the tooth surface
of the bevel gear.
b. Turn the bevel gear forward and reverse several
times.
c. Check the tooth contact pattern left on the surface for
condition of tooth contact.
d. If the tooth contact is not correct, adjust it using the
shim thickness S1.
4. Adjust Tooth Contact Reverse
5. Correct Tooth Contact (No Load)

The pattern must be located in the center of the tooth
contact, which covers 40 to 70% of the overall length of
the tooth showing weak contact at both ends of the 1
2
pattern.
• In case of strong contact at the tooth top (1), increase
the shims.
• In case of strong contact at the tooth bottom (2),
reduce the shims.
6. Adjust the tooth contact correctly both forward and

reverse.
NOTE: Run-out of Bevel Gear: less than .004 in. (0.1 mm).
7-11
7. DRIVE AXLE
7. Correction of Tooth Contact

a. Increase the shims at the pinion shaft to move the
protrusion of the pinion in the direction of the (A).
b. Next, move the bevel gear away from the pinion in
the direction of the (B) to adjust the backlash.
c. Reduce the shims at the pinion shaft to decrease the

d. Next, move the bevel gear closer to the pinion in the
direction of the (B) to adjust the backlash.
e. Reduce the shims at the pinion shaft to decrease the

f. Next, move the bevel gear closer to the pinion in the
direction of the (B) to adjust the backlash.
g. Increase the shims at the pinion shaft to move the

protrusion of the pinion in the direction of (A).
h. Next, move the bevel gear away from the pinion in
the direction of (B) to adjust the backlash.
7-12
7. DRIVE AXLE

7.4.1 REMOVAL
When removing such devices as the torque converter, the transmission and the drive axle, remove the
counterweight first to prevent the truck from overturning. Then hoist the truck frame in the front with a
crane
1. Put blocks under the front and rear wheels.

2. Disconnect the parking brake cable at the drive axle.
3. Disconnect the brake piping and cap hydraulic lines to prevent dirt from entering the sysem.
4. Remove the overhead guard.
5. Remove the engine hood.
6. Remove mast.
NOTE: See Chapter 11 “WORK EQUIPMENT”.
7. Remove counter weight.
8. Place blocks under the bottom of the truck frame to keep

the frame about 4 in. (10 mm) above the ground.
9. Rig the engine/transmission as shown and support them
with crane.
10. Place a carriage as shown in the illustration on the right to
support the front axle.
7-13
7. DRIVE AXLE
11. Mark (A) (B) and (C) to match the differential and the front
axle both on the left and the right.
D
NOTE: For normal removal/installation (except for replace- A
ment of front-wheel support), remove the front-wheel
bolts (E) only.
12. Remove the bolts securing the propeller shaft and remove the propeller shaft.
7-14
7. DRIVE AXLE
13. Remove the support for the front axle from the frame and
pull out the front axle using a pallet jack or dolly.
7.4.2 INSTALLATION
1. Install the drive axle to the matching marks on the equip-
ment marked at the time of removal. D
A
2. Remove the level plug, and check leveling with an
appropriate tool and a level
torque
Tightening Torque for Front Axle Support Bolts

2.0 - 3.0 ton: 361-448 ft/lbs (490-608 Nm)(50.0-62.0 kgm)
3.2, 3.5 ton: 488-611 ft/lbs (662-829 Nm)(67.5-84.5 kgm)
NOTE: See “Align power train.” on page 6-12.
If no matching marks can be found, tighten temporar-
ily the front bolts to the front axle.
Then tighten the two mounting bolts on the support E
side and check the remaining two bolts for the correct
positioning toward the center.
7-15
7. DRIVE AXLE
3. Install propeller shaft.
torque
Tightening Torque for Propeller Shaft Mounting Bolts

24 - 28 ft/lbs (32.4 - 38.2 Nm) {3.3 - 3.6 kgm}
4. Install brake piping.
5. Bleed air from brake lines.
6. Install parking brake cable.
7. Install counterweight and tighten counter weight bolt.
torque
Tightening Torque for Counter Weight Bolt

325 - 471 ft/lbs (441 - 639 Nm) {45 - 65 kgm}
8. Install mast and tighten mast cap mounting bolts.

torque
Tightening Torque for Mast Cap Mounting Bolts:
2.8 - 3.2T (55/65 series mast) 32 kgfm target, 33 - 41 kgfm

2.0 - 2.5T O/D (50 series mast) 23.5 kgfm target, 23.5 - 29.5 kgfm
2.0 - 2.5T I/D (50 series mast) 32 kgfm target, 33 - 41 kgfm
3.5T (70 series mast) 47 kgfm target, 46.5 - 58 kgfm
45D/55D-MQ series mast 32 kgfm target, 33 - 41 kgfm
7-16
7. DRIVE AXLE

DIFFERENTIAL ASSEMBLY (2.0 - 3.5 TON TRUCKS)
83 - 97 ft/lbs.
torque 113 - 132 Nm
{11.5 - 13.5 kgm}
LOCTITE #271
LOCTITE #271
7-17
7. DRIVE AXLE
PINION SHAFT ASSEMBLY
83 - 97 ft/lbs.
torque 113 - 132 Nm
{11.5 - 13.5 kgm}
7-18
7. DRIVE AXLE
DIFFERENTIAL TORQUES AND SEALS
.006 - .008 in. Gear Oil

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

Run-out
on dial gauge
253 ft/lbs.
torque 343 Nm
{35 kgm}
G2-L1
(Seal Lip)
torque
72.3 ft/lbs.
98 Nm {10 kgm}
LOCTITE #271
(Thread Hole)
torque
72.3 ft/lbs.
98 Nm {10 kgm} .006 - .008 in. LG-7 (Seal Outer
Backlash
LOCTITE #271 0.15 - 0.20 mm Circumference)
(Thread Hole)
43 - 55 ft/lbs.
torque 59 - 74 Nm
{6 - 7.5 kgm}
43 - 55 ft/lbs.
torque 59 - 74 Nm
{6 - 7.5 kgm}
7-19
7. DRIVE AXLE
DIFFERENTIAL TORQUES AND SEALS (2.0 - 3.0 TON TRUCKS)
72.3 - 91 ft/lbs.
torque 98 - 123 Nm
{10 - 12.5 kgm}
LOCTITE #271
(Thread Hole)
20 - 25 ft/lbs.
torque 27 - 34 Nm
{2.8 - 3.5 kgm}
< .004 in. (0.1 mm) 253 ft/lbs.

Run-out 343 Nm
on dial gauge torque
{35 kgm}
Gear Oil
GO90
(Thread)
G2-L1
(Seal Lip)
72.3 - 91 ft/lbs.
torque 98 - 123 Nm
{10 - 2.5 kgm}
LOCTITE #271 LG-7 (Seal Outer
(Thread Hole) Circumference)
6.5 - 9.7 ft/lbs. .006 - .008 in.

Starting Backlash
8.8 - 13.2 Nm 0.15 - 0.20 mm
Torque
{90 - 135 kgcm}
43 - 55 ft/lbs.
torque 59 - 74 Nm
{6 - 7.5 kgm}
253 ft/lbs.
torque 343 Nm
{35 kgm} 83 - 97 ft/lbs.
LOCTITE #271 torque 113 - 132 Nm
(Thread Hole) {11.5 - 13.5 kgm}
7-20
7. DRIVE AXLE
DRIVE AXLE ASSEMBLY (2.0 - 2.5 TON TRUCKS)
87 - 119 ft/lbs.
118 - 162 Nm
{12 - 16.5 kgm}
72 - 93 ft/lbs.
98 - 127 Nm
{10 - 13.5 kgm}
7-21
7. DRIVE AXLE
DRIVE AXLE ASSEMBLY (3.0 - 3.5 TON TRUCKS)
87 - 119 ft/lbs.
torque 118 - 162 Nm
{12 - 16.5 kgm}
235 - 315 ft/lbs.

torque 319 - 427 Nm
{32.5 - 43.5 kgm}
72 - 93 ft/lbs.
torque 98 - 127 Nm
{10 - 13.5 kgm}
7-22
7. DRIVE AXLE

DIFFERENTIAL MAINTENANCE STANDARD
Criteria [in. (mm)]

Standard Limit
Replace (Excl. Bevel
Differential Pinion Gear and Differential In case of damaged
A – Gear and Pinion be
Side Gear tooth face
replaced in a set.)
.9826 -.9834 .9744
B Outside Diameter of Spider
(24.959 - 24.980) (24.75)
Inside Diameter of Differential Pinion .9842 -.9881 .9921
C
Gear (25.0 - 25.1) (25.2)
.0763 -.0811 .0669
D Thickness of Bushing Replace
(1.94 - 2.06) (1.7)
.0598 -.0661 .0511
E Thickness of Bushing
(1.52 - 1.68) (1.3)
12.204 - 12.2125 12.283
– Inside Diameter of Brake Drum
(310.0 - 310.2) (312)
Replace with new
– Gaskets, O-rings & Seals – – parts when disassem-
bly and assembly
7-23
NOTES:
8. STEERING SYSTEM
8. STEERING SYSTEM

The steering system receives hydraulic pressure from the hydraulic pump through the steering priority valve. As a
safety feature, the steering priority valve directs hydraulic pressure to the steering system before allowing pressure
to the material handling system. The pressure is controlled through the steering valve to the power steering
cylinder mounted on the steering axle.
STEERING HYDRAULIC CIRCUIT DIAGRAMS
13.5 to 17.3 L /min

To Work Equip.
FLOW DIVIDER
PS RELIEF PRE.
2 to 3 ton: 1711 psi (11.8 MPa)
BLEEDING VALVE
M
P2 P1
From Work Equip.
FILTER 20 m
STRAINER 105 m
8-3
8. STEERING SYSTEM
STEERING VALVE COMPONENTS
8-4
8. STEERING SYSTEM
No. Part name Qty Remarks

1 Screw 7 Size: 5/16-24UNF
2 Spring pin 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
No spacer or two spacers are used depending on specifications.
6 (Spacer) (1)
7 Spacer plate 1
8 Drive 1
9 Control parts assembly 1 Including part numbers 10 to 12
10 Housing (1)
11 Sleeve (1)
12 Spool (1)
13 Pin 1
14 Centering spring 6 For standard input specifications
4 For standard low input specifications
4 For standard ultra-low input specifications
15 (Flat spring) 2 For standard ultra-low input specifications only
16 EPACS controller (if applicable) 1
17 Cross recessed countersunk head screw 2 Size: M3, width across flats: .06 in. (1.5mm)
18 Rotor
19 Hexagon socket head setscrew 1 Size: M3
21 Race bearing 2
22 Thrust needle 1
23 O-ring 1
24 Oil seal 1
25 Dust seal 1
26 Retaining ring 1
27 Seal ground bushing 1
28 O-ring 2
29 O-ring 1
30 Ball 1
31 Face seal (or plug) 1 For low slip specifications only
32 O-ring 1 For low slip specifications only
33 Nameplate 1
34 Rivet 2
36 Valve block 1
37 Spool 1
40 Tube assembly 1
41 Nut 1
42 Coil with connector 1
43 O-ring 4
44 O-ring 1
45 Hexagon head bolt 2 M10 x P1.5 x shank: 35mm, width across flats: 8mm
46 Spring 1
47 Core 1
48 (Hexagon socket head plug) 1 No plug is used depending on specifications.
50 O-ring 1
52 (Orifice plug) 1 Check valve is used depending on specifications.
54 Adapter screw 1
55 (Check valve assembly) 1 No assembly is used depending on specifications.
8-5
8. STEERING SYSTEM
STEERING AXLE AND POWER STEERING TORQUES
253 - 315 lbf.ft

torque 343 - 427 Nm
{35 - 43.5 kgfm}
116 - 180 lbf.ft

torque 157 - 245 Nm
{16 - 25 kgfm}
24 - 28 lbf.ft
torque 32 - 38 Nm
{3.2 - 3.8 kgfm}
8-6
8. STEERING SYSTEM

8.2.1 REAR AXLE
1. Deformation, cracks or scratches: Check visually
2. Play of center pin
3. Clearance of thrust
Clearance (a) < .02 in. (0.5 mm)

Adjustment: If 2.0 mm or over, adjust with shims to less
than 0.5 mm.
Tightening torque for mounting bolt (1).
torque 361 - 448 PSI (490 - 608 Nm, 50 - 62.9 kgm)
4. Looseness of cap mounting bolt
8.2.2 STEERING WHEEL

1. Shaking, pulling or dragging
2. Steering force (Control force)
3. Play at engine idle:
Play L 1.18 - 2.36 in. (30 - 60 mm)

Adjustment: Adjust at gearbox.
4. Interference between wheel and other part of truck.
8.2.3 STEERING VALVE

1. Oil leakage
2. Looseness of mounting bolt
8.2.4 KNUCKLE
1. Wheel bearing. Jack up the truck for inspection.
a. Play: Check the play by holding the tire by hand at its top and bottom and rocking the wheel.
b. Noise: Check abnormal sound by turning the tire by hand.
2. King pin
a. Play
b. Noise
3. Knuckle: Check for damage visually or check with a crack detection method.
8.2.5 STEERING WHEEL

1. Loose or missing stopper bolt
2. Interference between wheel and other part of truck
8.2.6 POWER STEERING

1. Power steering cylinder and hose oil leakage
2. Scratches or deterioration of hose
3. Loose or missing mounting bolt
4. Interference with truck body
8-7
8. STEERING SYSTEM
8.2.7 RIGHT AND LEFT TURNING RADIUS

Measure minimum turning radius
1. Have an assistant drive truck and make minimum turning radius
2. Draw a circle with a chalk affixed to outside end of the counterweight
3. Measure the circle drawn on the ground.
4. Make turns to right and left.
2.0 ton 86.2 in. (2,190 mm) ± less than 5%

2.5, 2.8 ton 88.1 in. (2,240 mm) ± less than 5%
3.0 ton 93.3 in. (2,370mm) ± less than 5%
3.2, 3.5 ton 97.6 in. (2,480 mm) ± less than 5%
Difference R/L: < 3.95 in. (< ±100 mm)
Adjustment: Adjust with the stopper bolt.
8.2.8 DIRECTIONAL CONTROL VALVE (1)

1. Actuation and oil leakage

Measure relief pressure
1. Install an oil pressure gauge to port (A).
A: Control valve relief pressure measurement port
2. Lift the forks to the maximum lifting height, measure the
oil pressure when the oil is relieved, and check it for
specified level.
Relief set pressure
1.5 - 2.0 ton 2,525 PSI (17.4 MPa) (177.5 kgf/cm2)
8-8
8. STEERING SYSTEM

Most steering problems can be corrected if the problem is properly diagnosed. The entire steering system should
be evaluated before removing any components. The steering control unit is generally not the cause of most
steering problems. The following list of common steering problems along with possible causes and suggested
corrective action will be helpful in diagnosing any unusual steering conditions.
Troubleshooting Steering Problems
Problem Possible Cause Corrective Action
Worn or malfunctioning hydraulic
Replace pump
pump
Overloaded steer axle Reduce load
Slow steering, hard steering or loss Check lines and reroute or replace
of power assist Kinked or pinched hydraulic line
as necessary
Malfunctioning relief valve allowing
the system pressure to be less than Replace relief valve
specified
Air in the system due to low fluid
level, cavitating pump, leakage or Correct condition and add fluid
pinched hose
Wander - Tendency of vehicle path Worn steering linkage Repair or replace
to deviate from the direction the
Bending of linkage or cylinder rod Repair or replace
operator steers the truck
Loose cylinder piston Repair or replace
Severe wear in steering control
Replace the steering control valve
valve
Drift - Deviation of vehicle path, Cylinder rod end slowly extends
Minor extension may be normal
without driver input, from expected without turning the steering wheel
path of travel Worn or damaged steering linkage Replace linkage and align front end
Slip - A slow movement of the Leakage of cylinder piston seals Replace seals
steering wheel fails to cause and
movement of steered wheels Worn steering valve Replace valve
Temporary hard steering or hang-up
- A momentary increase in steering Check unit for proper operation and
Thermal shock*
wheel torque during steering cause of thermal shock
reversal or initial driver input
Air in system due to low fluid level,
Correct condition and add fluid
leaky fittings, pinched hose
Erratic steering
Loose cylinder piston Replace cylinder
Thermal shock damage* Replace steering control valve
Air in hydraulic system. Most likely
Bleed air out of system
“Spongy” or soft steering air trapped in cylinders or lines
Low fluid level Add fluid and check for leaks
Steering column upper shaft is loose Tighten steering wheel nut and
or damaged check brackets
Lower splines of shaft may be
Repair or replace column
Free wheeling - Steering wheel turns damaged or broken
freely with no feeling of pressure and No fluid flow to steering valve
no movement of steered wheels caused by: Add fluid and check for leaks
• Low fluid level Replace hose
• Ruptured hose Replace the unit
• Damaged steering valve
8-9
8. STEERING SYSTEM
Troubleshooting Steering Problems

Problem Possible Cause Corrective Action
Free wheeling - Steering wheel turns
Determine cause
with slight resistance but results in Piston seal blown out
Correct and replace seal
little or no steered wheel movement
Loose steering wheel nut. Steering
Excessive free play at steering Repair or replace steering wheel
column shaft worn or damaged.
wheel connection or column
There should be very little free play.
Check for loose fitting bearings and
Broken or worn linkage between anchor points in steering linkage
Excessive free play at steered cylinder and steered wheels between cylinder and steered
wheels wheels
Leaky cylinder seals Replace cylinder seals
Binding or misalignment in steering Align column pilot and spline to
column or splined input connection steering control unit
Binding or poor centering of steering
wheel High back pressure in tank line can
cause slow return to center. Should Revise circuit return line
not exceed 300 psi.
Clean the unit and filter the fluid. If a
Binding or poor centering of steering Debris can cause binding between component has failed creating the
wheel (continued) spool and sleeve debris, flush the system while
bypassing the control unit
Large debris in steering valve Clean the unit
Insufficient hydraulic power Check hydraulic power supply
Steering unit locks up
Severe wear and/or broken pin Replace the unit
Thermal shock* Replace the unit
Steering wheel oscillates or turns by Parts assembled incorrectly Steering Correct timing
itself, either side of neutral, after unit improperly timed
operator has ceased input Lines connected to wrong ports Reconnect lines correctly
Steered wheels turn in wrong
Lines connected to incorrect cylinder
direction when operator turns Reconnect lines correctly
ports
steering wheel
Kick - momentary kick-back of No inlet check valve in steering
Install a check valve
steering wheel at start of steering control unit
Air in lines Check inlet fittings. Bleed lines
Instability - fluid-born oscillation
Plumbing Bleed all lines
* Thermal Shock - A condition caused when the hydraulic system is operated for some time without turning the steering
wheel so that fluid in the reservoir and system has become hot and the steering valve is relatively cool (more than 50° F
temperature differential) . When the steering wheel is turned quickly, the result is temporary seizure and damage to the
steering valve internal parts. The seizure may be followed by total free-wheeling.
8-10
8. STEERING SYSTEM

IMPORTANT
Inspection and maintenance should be performed by qualified personnel.
8.4.1 STEERING VALVE

Steering Valve Connections
 REMOVAL
1. Remove the bolts securing the steering column brace.
2. Remove the bolts securing the steering column to the steering valve and the mounting flange.
3. Remove the steering column from the steering valve.
4. Remove bolts securing the steering valve piping flange to the steering valve.
5. Remove the steering valve from the mounting flange.
6. Remove all o-rings and discard them.
 INSTALLATION
1. Mount the steering valve to the mounting flange.
2. Insert the steering column to the steering valve aligning the mounting holes.
3. Secure the steering column to the mounting flange with bolts.
4. Secure the steering column brace with bolts.
5. Place new o-rings on the steering valve piping ports.
6. Secure the steering valve piping flange to the steering valve.
8-11
8. STEERING SYSTEM
8.4.2 POWER STEERING CYLINDER

 REMOVAL
NOTE: Lower the mast, forks and any attachments to the ground before removing counterweight.
1. Raise rear portion of frame with crane.
2. Place wooden blocks under left and right side of frame.
3. Raise counterweight slightly with crane just enough to take the
load off the mounting bolts.
4. Remove mounting bolts.
5. Lift counterweight away from truck.
6. Remove hoses (A) and (B) as shown in illustration.

7. Plug cylinder oil ports to prevent leakage and entry of dirt into
hydraulic system.
8. Remove the bolts securing the steering cylinder to the right and
left knuckles.
9. Remove mounting bolts and remove the cylinder.
 INSTALLATION
The power steering cylinder can be installed by reversing the steps utilized during removal.
Pay particular attention to the following details:
Coat the counterweight retaining bolts with molybdenum disulfide.

torque
Power Steering Cylinder mounting bolt torque: 108 - 228 lbs./ft (147 - 309 Nm) (15 - 31.5 kgfm)
Steering Linkage bolt torque: 180 - 288 lbs./ft (245 - 309 Nm) (25 - 31.5 kgfm)
Counterweight retaining bolt torque: 361.4 lbs./ft (490 Nm) (50kgfm)
8-12
8. STEERING SYSTEM
8.4.3 STEERING AXLE

 REMOVAL
NOTE: Lower the mast, forks and any attachments to the ground before removing counterweight.
1. Raise rear portion of frame with crane.
2. Place wooden blocks under left and right side of frame.
3. Raise counterweight slightly with crane just enough to take the
load off the mounting bolts.
4. Remove mounting bolts.
5. Lift counterweight away from truck.
6. Remove hoses (A) and (B) as shown in illustration.

7. Plug cylinder oil ports to prevent leakage and entry of dirt into
hydraulic system.
8. Support steering axle with pallet jack or dolly.

9. Remove 2 support bolts each for front and rear axle.
10. Carefully slide the steering axle out from under the lift truck
towards the rear of the chassis.
8-13
8. STEERING SYSTEM
 INSTALLATION - STEERING LINKAGE

The steering axle assembly can be installed into the lift truck chassis by reversing the steps utilized during removal.
Pay particular attention to the following details:
torque
Power Steering Cylinder mounting bolt torque: 108 - 228 lbs./ft (147 - 309 Nm) (15 - 31.5 kgfm)
Steering Linkage bolt torque: 180 - 288 lbs./ft (245 - 309 Nm) (25 - 31.5 kgfm)
Counterweight retaining bolt torque: 361.4 lbs./ft (490 Nm) (50kgfm)
1. Adjust shims so that clearance is less than 0.02 in. (0.5mm).
2. Install the bushing so that the hole is facing up.
3. Connect hoses at position (A) and (B) in diagram on right.
4. Install counterweight on the lift truck.
Coat the retaining bolts with molybdenum disulfide.
torque
Torque bolts to 361.4 lbs./ft (490 Nm) (50kgfm).
8-14
8. STEERING SYSTEM

8.5.1 STEERING VALVE DISASSEMBLY
STEERING VALVE COMPONENTS AND ASSEMBLY
NOTE: Special tools are necessary for the disassembly and reassembly of this valve.
8-15
8. STEERING SYSTEM
1. Place the steering valve in a holding tool or padded vice.

2. Remove the 7 bolts from the end cover (6 standard and 1 special bolt).
3. Remove the end cover by sliding it off sideways.
4. Lift the gear wheel set (with spacer if fitted) off of the unit.
5. Remove the two o-rings.
6. Remove the cardan shaft.
8-16
8. STEERING SYSTEM
7. Remove the distributor plate.
8. Unscrew and remove the threaded bushing over the

check valve.
9. Remove the o-ring.
10. Shake out the check valve ball and suction valve pins and
balls.
NOTE: On some OSPC pins there are two springs. Replace the pins prior to
reassembly.
8-17
8. STEERING SYSTEM
IMPORTANT
Keep the cross pin in the sleeve and spool horizontal.
NOTE: The pin can be seen through the open end of the spool.
11. Press the spool inwards.
NOTE: The sleeve, ring, bearing races and needle bearing will be pushed out
of the housing together.
12. Remove the ring, bearing races and needle bearing from
the sleeve and spool assembly.
NOTE: The outer (thin) bearing race can sometimes “stick” in the housing.
Check and be sure it has come out.
13. Press out the cross pin using the special bolt from the
end cover.
IMPORTANT
A small mark has been inscribed on both the spool and sleeve close to one of
the slots for the neutral position springs. This was done with a pumice stone
at the factory. If this mark is not easily seen, mark the sleeve and spool clearly
before the neutral position springs are removed.
8-18
8. STEERING SYSTEM
14. Gently press the spool out of the sleeve.
15. Press the neutral position springs out of their slots in the
spool.
16. Remove the dust seal and o-ring/kin-ring/Roto-Glyde.
17. Remove plugs from shock valves using a 6mm allen

wrench.
8-19
8. STEERING SYSTEM
18. Remove 2 seal washers.
19. Remove the set screws using a 6mm allen wrench.
20. Shake out the 2 springs and 2 valve balls into your hand.
NOTE: The valve seats are bonded onto the housing and cannot be
removed.
The shock valves have now been disassembled.
8-20
8. STEERING SYSTEM
8.5.2 DISMANTLE PRESSURE RELIEF VALVE (OSPC)

1. Remove the plug using an 8mm Allen wrench.
2. Remove seal washers.
3. Unscrew the set screw with an 8mm Allen wrench.
4. Shake out spring and piston.

NOTE: The valve seat is bonded into the housing and cannot be removed.
The pressure relief valve is now fully dismantled.
8-21
8. STEERING SYSTEM
8.5.3 DISMANTLE PRESSURE RELIEF VALVE CARTRIDGE (OSPC) (IF EQUIPPED)

1. Remove the pressure relief valve using an 8mm allen wrench.
2. Remove the seal ring.
IMPORTANT
If the valve is defective, it must be replaced.
3. The pressure relief valve is now fully diassembled.
NOTE: The OSPC power steering valve is now completely

disassembled.
All models contain all parts shown.
8-22
8. STEERING SYSTEM
 ASSEMBLY
1. Clean all parts thoroughly. Do not leave lint or dirt on any parts.
2. Replace all seals and washers.
3. Check all parts carefully for wear or damage.
4. Lubricate all parts with hydraulic oil prior to assembly.
5. Place the 2 neutral position springs in their slot.
6. Place the curved springs between the flat ones and press
them into place.
7. Line up the spring set.
8. Guide the spool onto the sleeve.

9. Line up the marks made previously.
10. Insert the spool into the sleeve.
8-23
8. STEERING SYSTEM
11. Press the springs together and push the neutral position springs into
place in the sleeve.
12. Line up the springs and center them.
13. Guide the ring down over the sleeve.

NOTE: The ring should be able to move free of the springs.
14. Fit the cross pin into the spool/sleeve assembly.
15. Fit the bearing races and needle bearing.
8-24
8. STEERING SYSTEM
16. Assemble the parts in compliance with the following diagram
17. Turn the steering valve until the bore is horizontal.

18. Guide the outer part of the assembly tool into the bore of the spool/sleeve
assembly.
19. Grease o-ring and kin-ring/Roto-Glyde with hydraulic oil

and place them on the tool.
20. Hold the outer part of the assembly tool in the bottom of
the steering unit housing and guide the inner part of the tool fully to the
bottom.
8-25
8. STEERING SYSTEM
21. Press and turn the o-ring/kin-ring into position in the housing.
22. Draw the inner and outer parts of the assembly tool out of
the steering unit bore, leaving the guide from the inner part inside the
bore.
23. Lubricate the lip seal with hydraulic oil and place it on the
assembly tool.
24. Guide the assembly tool all the way to the bottom.
25. Press and turn the lip seal into the housing.
8-26
8. STEERING SYSTEM
26. With a gentle turning movement, guide the spool and sleeve into the bore.
NOTE: Fit the spool set while holding the cross pin horizontal.
27. The spool set will push out the assembly tool guide.
NOTE: The o-ring and kin-ring/Roto-Glyde are now in position.
28. Turn the steering unit around until the bore is vertical
again.
29. Place the check valve ball into the hole indicated by the arrow.
30. Screw the threaded bushing lightly into the check valve
bore.
IMPORTANT
The top of the bushing must lie just below the housing surface. It must not
protrude above the surface.
31. Place a ball in each of the 2 holes indicated by arrows.
8-27
8. STEERING SYSTEM
32. Place one new pin in each of the same 2 holes.

NOTE: In some cases, a spring must be placed over the pins before assem-
bly. Check disassembled parts. If springs were present on the pins
when disassembled, be sure and reinstall them upon assembly.
33. Lubricate the o-ring with mineral oil and place in groove.
34. Place the distributor plate so that the channel holes

match the holes in the housing.
35. Guide the cardan shaft down into the bore so that the slot
is parallel with the connection flange.
36. Place the cardan shaft as shown so it is held in position

by the mounting fork.
8-28
8. STEERING SYSTEM
37. Lubricate the 2 o-rings with mineral oil and place them in the 2 grooves in
the gear rim.
38. Fit the gear wheel and rim on the cardan shaft.
39. Fit the gear wheel (rotor) and cardan shaft so that a tooth
base in the rotor is positioned in relation to the shaft slot as shown.
40. Turn the gear rim so that the 7 through-holes match the holes in the
housing.
41. Fit the spacer in place (if equipped).
42. Place the end cover in position as shown.
8-29
8. STEERING SYSTEM
43. Place a washer over the special bolt and place it in the hole shown at
right.
44. Place washers over the 6 remaining bolts and insert them in the bolt
holes. Use a criss-cross pattern to tighten the bolts and the rolled pin with
a torque value of 26.5 ± 5.31 lbs./in (3.0 ± 0.6 Nm).
8-30
8. STEERING SYSTEM
8.5.4 ASSEMBLE PRESSURE RELIEF VALVE (OSPC) (IF EQUIPPED)

1. Fit the piston into the opening.
2. Insert the spring as shown.

3. Reinstall the set screw with an 8mm Allen wrench.
4. Adjust the pressure setting on the vehicle.
5. Screw plug with dust seal into the housing using an 8mm
Allen wrench.
torque
Torque to 44.25 lbs./in. (5 ± 1 Nm).
8-31
8. STEERING SYSTEM
8.5.5 ASSEMBLE SHOCK VALVES (IF EQUIPPED)

1. Place a ball into the two holes indicated by arrows.
2. Place springs and valve cones over the two balls.

NOTE: The blue spring applies to 1,305 - 2,610 PSI (90 - 180 bar). The
uncolored spring applies to 2,465 - 3,770 PSI (170 - 260 bar).
3. Install the two set screws using an 6mm Allen wrench.
8-32
8. STEERING SYSTEM
4. Screw plugs with seal rings into the two shock valve openings.
torque
Torque to 26.5 lbs./in. (3 ± 1 Nm).
5. Place the dust seal ring in the housing.
IMPORTANT
Install the dust seal ring in only after the pressure relief valve and shock valve
parts have been installed.
6. Fit the dust seal gently in place with a driver and a plastic
hammer.
NOTE: When placing plastic plugs in connection ports (for storage or ship-
ping), press then in. DO NOT HAMMER THEM IN.
7. The OSPC Power Steering Valve can now be function tested.
8-33
8. STEERING SYSTEM
8.5.6 POWER STEERING CYLINDER ASSEMBLY

 PNEUMATIC TIRE FORKLIFT TRUCK
Ref. No. Part Name Qty Ref. No. Part Name Qty
1 Cylinder 1 7 Backup Ring 2
2 Cylinder Rod Sub-Assembly 1 8 Packing 2
3 Cylinder Head 2 9 Backup Ring 2
4 Bushing 2 10 Dust Seal 2
5 Packing 1 11 Tie Rod 2
6 O-ring 2 12 Nut 4
8-34
8. STEERING SYSTEM
 CUSHION TIRE FORKLIFT TRUCK
Ref. No. Part Name Qty Ref. No. Part Name Qty
1 Cylinder 1 7 Backup Ring 2
2 Cylinder Rod Sub-Assembly 1 8 Packing 2
3 Cylinder Head 2 9 Backup Ring 2
4 Bushing 2 10 Dust Seal 2
5 Packing 1 11 Tie Rod 2
6 O-ring 2 12 Nut 4
8-35
8. STEERING SYSTEM
 DISASSEMBLY
1. Secure the outer tube of the cylinder (1) with clamps.
Clamp cylinder tube outer diameter.

1
2. Remove the 4 cylinder head nuts (12).

3. Remove the tie-rods (11).
12
11
4. Pull the cylinder head (3) on the right and left hand out
slowly. 3
NOTE: Be careful not to damage the packing when pulling

out the cylinder head.
5. Pull the cylinder rod sub-assembly (2) straight out.

2
Cylinder Inner Diameter
Standard Size 2.95 in. (75 mm)
Wear Limit 2.96 in. (75.2 mm)
Cylinder Rod Outer Diameter
Standard Size 1.97 in. (50 mm)
Wear Limit 1.96 in. (49.92 mm)
Bend Limit 0.02 in. (0.5 mm)
8-36
8. STEERING SYSTEM
 ASSEMBLY
Assembly work shall be the reverse of the disassembly procedure.
• Apply grease or hydraulic oil to the lip surfaces of o-ring, dust seal and packing when assembling
these parts.
• Before applying the THREE BOND #1344, make sure to wipe off old grease carefully from thread of
bolts or screws.
• Warm up the packing in hot water (below 176° F (80°C)) prior to installation to the engine.
8-37
8. STEERING SYSTEM
8.5.7 STEERING AXLE

STEERING AXLE ASSEMBLY AND DISASSEMBLY
8-38
8. STEERING SYSTEM
STEERING AXLE - OVERHEAD VIEW
+0.3
+0.1
+2
+1
STEERING AXLE - REAR VIEW
1. Adjust stops
The stops are internal to the steering cylinder on the BX50.
2. Assemble ball socket
When assembling the ball socket to the bell clamp, check to make sure each tapered section is free from oil or
paint.
3. Grease
Apply lithium grease (G2-L1) for the grease nipple and greasing to the hub.
8-39
8. STEERING SYSTEM
 STEERING AXLE ASSEMBLY DETAILS

1. Bell clamp
a. Lock Plate (1) 1
b. Snap Ring (2)

29K7
NOTE: Check to make sure the snap ring is secured in the
ring groove.
A-A
2. King pin
a. Match needle bearing (3) end face to the boss (4) 6
end face for a distance of 0.24 in. (6 mm).
b. Match needle bearing (5) end face to the boss (6)
end face.
c. Adjust knuckle (7) to minimize the space between top
and bottom.
5
NOTE: Standard space (a) in the diagram on the right:
7
a
6
B-B 4 3
3. Link
Make sure to bend the cotter pin (8) correctly.
8-40
8. STEERING SYSTEM
4. Hub
a. Fill enough grease (G2-L1) in the hub bearing (9) up torque G2-L1
to half to one third of the hub space capacity in the 10
both sides.
b. When assembling the hub, apply grease (G2-L1) to
the lip of the seal (10).
11
c. After adjusting starting torque, make sure to bend the
cotter pin (11) completely.
5. Adjust hub rotating starting power.

a. Tighten the lock nut until it becomes hard to turn by
hand.
b. Reverse it turning by one quarter from that position.
c. Apply a spring balance to the hub bolt and give the
taper roller bearing pre-pressure while adjusting the
nut (12) to make rotating starting power reach the fol-
lowing value. 12
Starting 4.4 - 7.5 lb/f
power 19.6 - 33.3 N {2 - 3.4 kgf}
Starting 2.1 - 3.6 lbf ft
torque 294 - 490 N cm {35 - 50 kg cm}
d. After completing adjustment in the above step, insert the cotter pin to secure it in place where the holes of
both the nut and the shaft are matched. Then, bend it completely.
6. Adjust steering wheel angle
Adjust the steering wheel angle in the following procedure so that the relation between steering knob position
and steering angle becomes constant.
INITIAL SETTING WORK PROCEDURES
LED
Work Terminal Check Item Remarks
Display
After bleeding air,
Rest steering for 5 times to Stop engine. No smooth steering
Connect 1 FLASH check steering wheel
bleed air inside circuit is available.
for no play.
Key switch ON: travel State of traveling
Connect 1 FLASH Controller: initial setting mode 1.
straight forward and stop. straight forward
Key switch OFF Connect Turn off
In traveling straight forward, Wheels/steering wheel
set the steering wheel knob Connect Turn off position: terminals Close terminal, if open
at the starting point. closed
Under initial set: controller mode
Check LED for 1
Key switch ON Connect 1 FLASH 1, 3 or 4 FLASH: faulty controller
FLASH
or wheel sensor error
1 FLASH
Check 1 FLASH for Under reset: controller initial set
Remove the terminals Open 
change to 2 FLASH mode 2
2 FLASH
8-41
8. STEERING SYSTEM
LED
Work Terminal Check Item Remarks
Display
When LED changed to
2FLASH,
Steer surely to the end Under initial set: controller to
1) steer to right end,
Open 2 FLASH (Steering speed: 60 memorize steering speed and
2) steer to left end,
rpm) steering angle
3) return to neutral and
over.
Normal mode: turn on, abnormal:
turn off.
Check LED for lighting Open Turn on Check LED for turn on
Stay in 2 FLASH: close terminals
and reset from No.1.
Check to make sure
Finish Open Turn on steering knob position –
corrected
LED DISPLAY
Content Terminal LED ON/OFF
0.5s 3s
Initial set mode 1 (under initial
1 FLASH
set) or incomplete initial set *
Initial set mode 2 0.5s 0.5s 0.5s 3s

2 FLASH
(under teaching)
Steering wheel sensor

3 FLASH
error
Wheel sensor error 4 FLASH
Controller error or controller

Turn off OFF
under initial set
Under normal operation (com-

Turn on ON
plete initial set)
* An incomplete initial setting means initial setting was not correctly completed under normal mode. It needs to operate
steering wheel to turn more than one and half times in right and left from the state of traveling straight forward under teach-
ing mode.
8-42
8. STEERING SYSTEM
8.6 MAINTENANCE STANDARD - STEERING AXLE
Unit: in. (mm)
Criteria
Standard Size Repair Limit
A Diameter of King Pin 1.102 (28) 1.094 (27.8) Replace
Shim
B Deterioration of Knuckle Up/Down – .0078 (0.2)
Adjustment
C Diameter of Bell Crank Pin .8661 (22) .8582 (21.8)
D Diameter of Center Pin 1.96 (50) 1.948 (49.5)

Replace
Cracks
Steering Axle, Hub, Knuckle, Bear-
– Scratches or Pealing-off
ing
Seizure, Faulty Revolving or Abnormal Noise
8-43
NOTES:
9. WHEEL BRAKE
9. WHEEL BRAKE

9.1.1 WHEEL BRAKE
WHEEL BRAKE STRUCTURE
5 (*1)
*1
A
1 2
Item Unit Wheel Brake

Type – Front wheel internal expanding hydraulic type
Structure – Duo servo
Brake Drum Inner Diameter in. (mm) 12.2 (310.0)
Lining Material – Resin molded (Adhesive type)
Width in. (mm) 2.36 (60.0)
Thickness in. (mm) .224 (5.7)
Wheel Cylinder Inner Diameter in. (mm) 1.25 (28.58)
9-3
9. WHEEL BRAKE
9.1.2 BRAKE BOOSTER

BRAKE BOOSTER STRUCTURE
13 12 5 A 6 7
2 1 11 10 B 3 4 9 8
1. Reservoir 6. Reaction Piston 11. Hydraulic Tank

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

MASTER CYLIINDER STRUCTURE
11
9 10
8
2 1
4 12
13
5
17
6 14
7
15
16
1. Cylinder 8. Bleeder Valve

2. Piston Assembly 9. Bleeder Cap
3. Snap Ring 10. Valve Spring
4. Boot 11. Seat
5. Push Rod 12. Valve Rubber
6. Nut 13. Gasket
7. Yoke 14. Bolt
Repair
Standard Size
Check Item Limit Remedy Ref. No.
in. (mm)
in. (mm)
Clearance between Cylinder .0008 - .0040 Replacement
.006 (0.15) 1.2
and Piston (0.020 - 0.105) (Cylinder Assembly)
Primary: approx. .04 (1.0) Replacement
Tightening Clearance of Cup .016 (0.4) 2
Secondary: approx. .047 (1.2) (Cylinder Assembly)
Free Length for Spring 3.1 (78.8) 2.76 (70) Replacement 2
NOTE: The numbers shown in the Ref. No. on the right refer to those in the diagram of the component parts.
9-5
9. WHEEL BRAKE

9.2.1 TRAVELING BRAKE
1. Brake pedal
a. Pedal height (stroke)
2.0 - 3.0 ton 2.16 - 2.95 in. (55 - 75 mm)

3.5 ton 1.77 - 2.56 in. (45 - 65 mm)
b. Play
Standard model 0 - .157 in. (0 - 4 mm)

137 mm
2. Braking efficiency
Select dry and even surface road, drive at full speed and
stop abruptly to check the following:
a. Pulling of steering wheel
b. Dragging of brakes
c. Abnormal noise
d. Stopping distance
Unloaded within 14.7 ft (4.5 m) (at max. speed)

Loaded within 6.6 ft (2.0 m) (at 10 km/h)
9.2.2 PARKING BRAKES

1. Parking brake lever
Lever control force Standard brake:
33 - 44 lb/f (147 - 196 Nm) (15 - 20 kgm)
Power brake: 55 - 66 lb/f
(245 - 294 Nm) (25 - 30 kgm)
2. Braking force
Check if the truck can maintain braking on the following
slope:
Unloaded slope of 11.2 degrees and over

Loaded slope of 8.5 degrees and over
9.2.3 ROD LINK, CABLE

1. Scratches, looseness or play
2. Breakage of cotter pin
9.2.4 BRAKE PIPING

1. Visual check on piping, hoses and joints
2. Scratches
3. Oil leakage
4. Evidence of interference or contact
5. Deterioration of hose
9.2.5 PARKING BRAKE DRUM, LINING

Common with the travel brake drum, lining. See “Brake Booster” on page 9-7.
9-6
9. WHEEL BRAKE
9.2.6 OIL BRAKE

1. Master cylinder and wheel cylinder
Check the following by operating the brake pedal
a. Pressure (feel) when pedal depressed
b. Fluctuation of pressure or pedal height
c. Fluctuation of pedal position when maintaining pedal pressure
d. Return of the pedal when releasing the pedal
NOTE: If you feel a change while pressing the pedal with no
oil leakage, the brake valve is defective.
2. Brake reservoir
a. Oil level amount
Applicable limit A: 18 mm
b. Fluid stain from oil or oil leakage
3. Deterioration of wheel cylinder
Clearance between < .006 in.

cylinder and piston (0.15 mm)
9.2.7 BRAKE BOOSTER

Oil leakage
9.2.8 BRAKE SHOE LINING

1. Brake shoe
Check proper functioning, rust or wear
2. Peeling off, scratches or wear of brake lining
Thickness of lining > .039 in. (1 mm)

3. Corrosion of anchor pin
4. Deterioration of return spring
Free length < 4.13 in. (105 mm)

Thickness of hook > .078 in. (2.0 mm)
9.2.9 BRAKE DRUM

Cracks scratches or wear of brake drum:
Measure the following dimensions, and check whether they are allowable values.
Inside diameter of drum (all models) < 12.28 in. (312 mm)
9.2.10 BACK PLATE

1. Deformation, cracks or scratches
2. Tightening torque for mounting bolt
LOCTITE #271 (thread hole)
torque
130 - 144 ft/lbs. (176 - 196 Nm)
{18.0 - 20.0 kgm}
9-7
9. WHEEL BRAKE

9.3.1 INSPECT BRAKE ASSEMBLY
1. Adjust shoe clearance.
2. Test wheel brake adjustment.
a. Pull cable (1) by finger in the direction shown by the
arrow in the diagram on right causing the lever to
engage with the next tooth.
b. Release the cable and the lever returns to the original
position after clicking one notch.
NOTE: When the lever fails to function properly, check
the lever for position above the adjuster screw.
The lever is designed to contact the adjuster wheel with

clearance (a) between 0.20 - 0.28 in. (5 - 7 mm) from the
center of the adjuster screw.
NOTE: When the lever position is incorrect, the lever cannot
mesh with the wheel and the wheel may fail to func-
tion even if the lever operates.
3. Remedy for Malfunction
a. Check to make sure that the cable guide fits properly
to the specified hole on the secondary shoe.
b. Check to make sure that the adjuster spring can
properly fit to the specified hole on the primary shoe.
c. Replace the cable with a new one, if necessary.
d. Replace the lever with a new one, if necessary.
e. Replace the adjuster assembly, if necessary.
9.3.2 ADJUST BRAKE SHOE CLEARANCE

1. Chock the rear wheels.
2. Raise the front, drive wheels, up off the ground.
3. Position blocks under the frame to support the truck.
4. Release the parking brake.
5. Remove the rubber cap to access the adjustment gear.
6. Turn gear (1) in direction (A) or toward the brake shoes repeatedly with a screwdriver until the brake shoes
touch the brake drum. Turning of each notch makes a clicking sound.
7. Turn the wheels by hands to feel braking effect.
8. Obtain two screwdrivers.
9. Gently push the lever (2) so that it will miss each gear
notch using one screwdriver.
NOTE: Be careful not to push too hard.
10. Turn the gear (1) toward direction (B) counting by twenty-
one (21) notches with the second screwdriver while the
first one is still holding the lever.
9-8
9. WHEEL BRAKE
IMPORTANT
Since no clicks are made here, count the number of notches watching through the hole of the rubber cap (3) for
carrying out the adjustment.
11. Install the rubber cap (3).
12. Turn the wheels by hand and check to make sure that there is no brake dragging.
IMPORTANT
The clearance between the brake shoe and brake drum should be adjusted approximately to 0.02 in. (0.55 mm)
(clearance of diameter) with this adjustment.
9.3.3 BLEED AIR FROM BRAKE PIPING

IMPORTANT
• Before starting to bleed air, adjust the brake shoe clearance to the specified .016 - .022 in. (0.40 - 0.56 mm).
• From time to time, refill the brake fluid to prevent the brake fluid in the reserve tank from emptying while carry-
ing out air bleeding. If air is drawn into the system from an empty reservoir during bleeding, start the procedure
over again keeping the brake fluid filled.
1. Remove the cap from the air bleed plug (1) of the brake
wheel cylinder.
2. Install one end of a plastic hose (2) for air bleeding to the
plug and put the other end of the hose into a container of
brake fluid.
NOTE: The plastic hose should be transparent.
3. If inspector is alone, connect a string or a wire (3) to the

upper arm of brake pedal (4).
2
2
9-9
9. WHEEL BRAKE
4. Let the other end of string or wire (3) loose free in

approximately 12 inches through the space between the
frame (4) and the dashboard (5).
5. Slowly pull out the string or the wire (3) connected with
the brake pedal (4) arm from the front of the forklift so as
to compress the air inside the brake piping and hold it.
NOTE: If more than one person is present, one inspector
should press the brake pedal.
6. Loosen the air bleed plug (1) of the brake wheel cylinder
approximately 3/4 turn to the left and depress the brake
pedal to bleed the air in the piping along with the brake
fluid. Then, while holding the pedal down, tighten the
bleed plug (1) while bleeding the brake fluid.
NOTE: In this stage, keep pulling the string or the wire for a while.
7. After tightening the bleed plug, release the brake pedal.
8. Repeat the step 3, 4, and 5 of the above until no more
bubbles come out of the hose.
9. Carry out the other side adjustment with the same steps.
10. Repeat air bleeding of the brake and check again to
make sure that no more air left in the brake piping.
11. Depress the brake pedal to check it for normal response.
12. Depress the brake pedal with force of 196 N or 20 kgf to b
measure the pedal stroke (a). Check to make sure that
the pedal stroke (a) is within 2.17 - 2.95 in. (55 - 75 mm)
when depressing the pedal. a
2.17 - 2.95 in.

Pedal stroke (a) when depressed
(55 - 75 mm)
0 - 0.16 in.
Play (b)
(0 - 4 mm)
13. Remove the hose (2) from the air bleed plug (1).
14. Tighten the air bleed plug and install the cap.
torque
Air bleed plug: 4.3 - 6.5 ft/lbs. (5.9 - 8.8 Nm) {0.6 - 0.9 kgm}
15. Refill the brake fluid up to the MAX line (C) on the reserve
tank (5) of upper master cylinder, which shows the
specified fluid level.
16. Remove the string or the wire (3) connected to the brake
pedal arm.
9-10
9. WHEEL BRAKE

9.4.1 REMOVAL
1. Chock or block the rear wheels.
2. Place wooden blocks under the bottom of the truck frame
to lift the front wheels.
3. Apply the parking brake.
4. Remove the hub nut and the torque shaft (3).

5. Release the parking brake.
6. Remove the bolts (4).

7. Remove the lock nut (5) with a special tool (80 mm
double face box). 4
8. Remove the hub (do not twist upside down).
9-11
9. WHEEL BRAKE
9.4.2 INSTALLATION
1. Install back plate (when removed)
a. Apply Loctite to the mounting bolts (1).
LOCTITE #271
b. Tighten as follows:
torque
130 - 145 ft/lbs (176 - 196 Nm) {18 - 20 kgm}

1
2. Install hub
6
a. Install a new oil seal. 9
NOTE: Apply G2-L1 grease to the lip surface of the oil
seal.
b. Fill G2-L1 grease in the bearing (7) and install it to the
hub (8).
c. Remove any dirt and oil from the inside face of the
7
brake drum (9) completely.
d. Install the hub to the shaft tube. 8
e. Tighten locknut (5) so that the starting torque of the

hub will conform to the following:
4
torque
Starting Torque: 4.5 - 11.6 ft/lbs (6.1 - 15.7 Nm) {62.5 -

160 kgm}
f. Apply Loctite to bolt (4) and tighten.
Loctite #271
3. Install front axle and torque shaft.

a. Install the torque shaft (3).
b. Tighten the bolts (2) and tighten as specified below:
torque
72.3 - 93.7 ft/lbs 98 - 127 Nm {10 - 13 kgm} 2
c. Install the front axle.

1
d. Tighten the hub nuts (1) and tighten as specified
below:
torque
217 - 361 ft/lbs 294 - 490 Nm {30 - 50 kgm} 3
9-12
9. WHEEL BRAKE

9.5.1 WHEEL BRAKE
WHEEL BRAKE ASSEMBLY
13 - 19.5 ft/lbs.
torque 17.6 - 26.4 Nm
{1.8 - 2.7 kgm}
5 (*1)
*1
A
1 2
torque
*1. Tightening Torque for Back Plate Mounting Bolt: 130 - 144 ft/lbs. (176 - 196 Nm) (18 - 20 kgfm)
Lubrication for Back Plate Mounting Bolt: LOCTITE #291
Item Unit Wheel Brake

Type – Front wheel internal expanding hydraulic type
Structure – Duo servo
Brake Drum Inner Diameter in. (mm) 12.2 (310.0)
Lining Material – Resin molded (Adhesive type)
Width in. (mm) 2.36 (60.0)
Thickness in. (mm) .224 (5.7)
Wheel Cylinder Inner Diameter in. (mm) 1.25 (28.58)
9-13
9. WHEEL BRAKE
9.5.2 BRAKE MASTER CYLINDER

MASTER CYLINDER ASSEMBLY
11
9 10
8
2 1
4 12
13
5
17
6 14
7
15
16

4. Boot 11. Seat
6. Nut 13. Gasket
7. Yoke 14. Bolt
9-14
9. WHEEL BRAKE
 DISASSEMBLY
1. Remove the yoke and boot.
2. Remove stopper pin (1) with a flat-headed screwdriver.
NOTE: When it is hard to remove the stopper pin, push on
the push rod (2) lightly.
3. Remove the stopper wire (3) from the cylinder (4) with a
flat-headed screwdriver.
4. Remove the piston assembly, the spring, the check valve
and valve seat.
• Be careful not to damage the cylinder, the piston or

the cup.
• When carrying out disassembly, make sure that you
understand the structure of the cylinder well in
advance. Then, it is recommended that all the disas-
sembled parts be put in order according to the disas-
sembly procedures.
• Never disassemble the piston assembly.
• Be careful not to squeeze the outer surface of the cyl-
inder with a vise.
1 - Base 2 - Lip 3 - Base 4 - Lip
9-15
9. WHEEL BRAKE
 INSPECTION AND ADJUSTMENT

Part Name Check Item Remedy
Remove small scratches with sandpaper.
Scratches, uneven wear or corro-
Cylinder If there are critical scratches that adversely affect the cup,
sion of inner surface
replace with a new cylinder assembly.
Remove small scratches with oilstone.
Scratches, uneven wear or corro- If there are critical scratches that adversely affect the inner
sion face of cylinder or the cup, replace with a new piston
Piston assembly.
If the clearance is greater than the repair limit, replace it
Clearance between cylinder and
with a new one.
piston
Repair Limit: 0.15 mm
Even if the scratches are very small, replace if with a new
Scratches on lip
piston assembly.
If there is harmful pitting, replace with a new piston
Pitting of base
assembly.
If there is abnormal deterioration, wear or swelling,
Wear or swelling
Cup replace with a new piston assembly.
If below the repair limit, replace with a new piston assem-
bly.
Repair Limit: 0.4 mm
Clearance
Note: The cup belongs to the group of parts to be replaced
periodically. In general, it is recommended that such parts
be replaced whenever disassembled.
Deformation, scratches or wear
If there is abnormal deformation, scratches or wear,
Piston Assembly of valve rod, valve cup, spring
replace with a new piston assembly.
and thimble
Springs showing critical scratches must be replaced with
Scratches, wear or fall
new ones.
Spring Those below the repair limit must be replaced with a new
Free length one.
Repair Limit: 2.76 in. (70 mm)
Push Rod Bend or deformation Those bent or deformed must be replaced with a new one.
Those with cracks, damage or scratches must be replaced
Cracks damage or scratches
with a new one.
Boot
Tightening allowance between Those with no tightening allowance, or an extremely little
cylinder and rod tightening allowance, must be replaced with a new one.
Even if the cracks are extremely small, replace with a new
Cracks
part.
Filler Union Those with critical discoloration must be replaced with a
Discoloration
new one.
Scratches Those with scratches must be replaced with a new one.
Bushings displaying cracks or critical deterioration must
Bushing Cracks or deterioration
be replaced with a new one.
9-16
9. WHEEL BRAKE
 ASSEMBLY
1. Wash all parts to be reused in alcohol or brake fluid.
• Cleanliness is essential when working with brake parts.

• Do not soak rubber parts, such as cups, boot, etc., in alcohol for more than 30 seconds.
• Do not use any fluid other than alcohol or brake fluid when cleaning parts.
• Never use mineral oil, petroleum or gasoline. Mineral oil will cause the rubber parts to swell up and
become unusable.
• After washing the parts, keep them in a clean place to prevent contamination by dirt or dust.
• Ensure no dirt or dust gets on or into the parts during assembly.
• Do not damage the cylinder, piston or cup.
2. Coat inside surface of cylinder and outside circumference of piston evenly with rubber grease or brake fluid.
3. Assemble the valve seat and the check valve to the cylinder housing.
4. Assemble the spring to the piston assembly.
11
9 10
8
2 1
4 12
13
5
17
6 14
7
15
16
5. Insert the piston assembly into the cylinder.

NOTE: When doing this, align the direction of the piston groove with the direction of the stop pin hole in the cylin-
der.
6. Fit the gasket and o-ring to the stop pin.
7. Push in piston and install to the cylinder.
torque
Torque the stop pin to 22.1 - 30.1 lbs./in (2.5 - 3.4 Nm).
8. Insert stop plate, push in piston lightly with a finger, and secure to cylinder with stop wire.
9. Insert push rod.
10. Attach the boot, nut and yoke in order to the push rod.
torque
Torque nut to 69.0 - 104.4 lbs./in (7.8 - 11.8 Nm).
9-17
9. WHEEL BRAKE
9.6 MAINTENANCE STANDARD - MASTER CYLINDER
11
9 10
8
2 1
4 12
13
5
17
6 14
7
15
16

4. Boot 11. Seat
6. Nut 13. Gasket
7. Yoke 14. Bolt
Repair
Standard Size
Check Item Limit Remedy Ref. No.
in. (mm)
in. (mm)
Clearance between Cylinder .0008 - .0040 Replacement
.006 (0.15) 1.2
and Piston (0.020 - 0.105) (Cylinder Assembly)
Primary: approx. .04 (1.0) Replacement
Tightening Clearance of Cup .016 (0.4) 2
Secondary: approx. .047 (1.2) (Cylinder Assembly)
Free Length for Spring 3.1 (78.8) 2.76 (70) Replacement 2
NOTE: The numbers shown in the Ref. No. on the right refer to those in the diagram of the component parts.
9-18
10. HYDRAULIC
SYSTEM

The hydraulic system consists of the hydraulic pump mounted on the engine, the material handling control valves
and cylinders, and the steering priority valve and the power steering cylinder.
HYDRAULIC CIRCUIT - POWER BRAKE MODELS
10-3
HYDRAULIC CIRCUIT - STANDARD BRAKE MODELS
Lift height 3.7 m or less

Lift height 4.0 m or more
B2
A2
TILT CYLINDER
LIFT CYLINDER A1
DOWN SAFTY
VALVE
MAIN RELIEF
KL PRE.
2625 psi
13.5 to 17.3 /min G1 P T

KPF
KP
FLOW DIVIDER
PS RELIEF PRE.
1711 psi
BLEEDING VALVE
M
P2 P1
POWER
STEERING
CYLINDER
FILTER 20 m
STRAINER 105 m
10-4

10.2.1 HYDRAULIC TANK
Breather
1. Oil leakage Cover
2. Oil level amount
Check with oil level gauge and add oil if necessary.
(Also check for oil contamination)
3. Cleaning of strainer
4. Replacement of line filter
10.2.2 PIPING
1. Cracks, scratches, deterioration or twist of piping
Strainer
2. Oil leakage
3. Loosening of mounting bolt and nut Line filter
10.2.3 PIPING OF WORK EQUIPMENT

1. Cracks, scratches, deterioration or twist of piping
2. Oil leakage
3. Loosening of mounting bolt and nut Drain plug
10.2.4 HYDRAULIC DRIFT OF LIFT CYLINDER AND TILT CYLINDER

1. Load the forks with maximum payload and set the mast
(1) upright, lift the forks approx. 59 in. (1,500 mm) from
the ground. 1
2. Match a straight measure (1) on the piston rod of the lift
cylinder (2) and put the mark (A) for measurement,
3. Match a straight measure (2) on the piston rod of the tilt
cylinder (3) and put the mark (B) for measurement,
H
When measured 3.95 in. (100 mm)/
Hydraulic drift of at fork within 15 min
lift cylinder When measured 1.96 in. (50 mm) /
at cylinder within 15 min A
Hydraulic drift of
1.18 in. (30 mm) / 15 min
tilt cylinder
Adjustment: Replace control valve and cylinder packing
10-5

1. Actuation and oil leakage

Measure relief pressure
1. Install an oil pressure gauge to port (A).
A: Control valve relief pressure measurement port
2. Lift the forks to the maximum lifting height, measure the
oil pressure when the oil is relieved, and check it for spec-
ified level.
Relief set pressure: 2,567 - 2,697 PSI (17.7 - 18.6 MPa)
{180 - 190 kgf/cm2}
10.2.7 SOLENOID VALVE, STEERING PRESSURE PORT

1. Actuation, abnormal noise
2. Abnormal generation of heat
3. Oil leakage
10.2.8 HYDRAULIC PUMP

1. Oil leakage
2. Abnormal vibration
3. Noise
4. Abnormal wear of spline
10.2.9 FLOW DIVIDER (FOR P/S)

1. Oil leakage
2. Noise
P-port
10.2.10 OIL MOTOR Oil pressure measuring port
RC 1/8
1. Oil leakage
2. Noise
10.2.11 LIFT CYLINDER

1. Actuation, oil leakage
2. Dents, cracks, curvature or scratches
10.2.12 TILT CYLINDER

10.2.13 REACH CYLINDER

Not applicable for this model
10.2.14 WORK EQUIPMENT CYLINDER

10-6

10.3.1 SERVICE HYDRAULIC TANK
The temperature of the oil is very high immediately after stop operation of the truck. Be sure to start
inspection after it has cooled down completely.
1. Remove the drain plug located at the bottom of the

hydraulic tank and drain the oil into a suitable container. Breather
2. Dispose of the old oil properly. Cover
3. Remove the hydraulic tank cover.
4. Remove the strainer.
5. Clean the strainer with flushing oil.
6. Blow dry compressed air from inside to outside of the
strainer until it is completely dry.
7. Clean the inside of the hydraulic tank.
8. Install and tighten the drain plug.
9. Remove the line filter and replace it with a new one.
10. Install the tank cover.
11. Refill the hydraulic oil through the breather hole. Strainer
8.98 gallons (34 liters) Line filter

12. Check the oil level with the oil level gauge.
13. Start the engine and operate the mast, lifting and tilting
until stroke-end for several cycles to bleed the air.
IMPORTANT
Always be sure to use Komatsu genuine hydraulic oil. Drain plug
10-7
10.3.2 TROUBLESHOOTING
Add hydraulic oil to the specified level of

Low oil level
No oil available amount.
from gear pump Blocked or clogged suction piping or Clean up immediately. In case of dirty oil,
strainer replace with new oil or filter it.
Excessive wear of bushing at (3), (4), (5)

and (6)
Replace with a new part.
Defective bushing seal (14), packing (15)
and (16), plate seal (20) and backup (21)
No pressure Add pressure to the specified level with pres-

Relief valve with faulty adjustment
available from sure gauge.
gear pump
Repair any loose suction piping.
Add oil to the specified level.
Sucking air Check oil seal at gear pump.
Stop operation until bubble goes out from
tank.
Cavitations caused with damaged suction

Remove dirt from piping or strainer.
piping or clogged strainer
Sucking air because of loosened joint of

Tightening again each joint.
suction piping
Noise from gear Replace with new oil with proper viscosity.
pump Cavitations due to high viscosity of oil Operate forklift truck with proper oil tempera-
ture.
Improper alignment between gear pump

Perform correct alignment.
and shaft from engine
Bubble in hydraulic oil Determine cause and correct.
Defective oil seal (18) of gear pump

Oil leakage from Replace with a new part.
Defective body seal (13)
gear pump
Oil being stuck with dirt Check gear pump again.
Check disassembled parts for damage or discoloration. Wash and clean those parts with light-oil. However, never
soak rubber parts in light-oil. Check all the parts again. Repair or replace them with new ones if necessary.
10-8

10.4.1 REMOVE HYDRAULIC PUMP
Allow the hydraulic system to cool to avoid getting burned from hot fluids.
1. Place a suitable container under the pump to catch any spills.

2. Remove the bolts securing the supply line to the pump and disconnect the line.
3. Remove the o-ring from the pump flange and discard it.
4. Loosen the fitting securing the discharge line to the pump and disconnect the line.
5. Remove the bolt securing the pump to the engine.
6. Pull the pump off of the engine mounting flange.
7. Remove the o-ring from the pump flange and remove.
10.4.2 INSTALL HYDRAULIC PUMP

1. Place a new o-ring on the pump mounting flange.
2. Mount the pump to the engine engaging the shaft with the engine PTO.
3. Secure the pump in place with the bolt.
4. Place a new o-ring on the suction line flange.
5. Secure the suction line to the pump with bolts.
6. Secure the discharge line to the pump.
10-9

10.5.1 FLOW DIVIDER
FLOW DIVIDER COMPONENTS
2
1
4 5 3
1. Body
2. Spool
3. Bolt
4. Spring
5. O-ring
OUT port
IN port Oil flow rate

control port
10-10
 DISASSEMBLY
1. Loosen the bolt (3) and remove.
2. Remove and discard o-ring (5).
3. Remove the spring (4).
4. Remove the spool (2).
Be careful not to damage the circumference of the spool.

1
NOTE: Before carrying out disassembly, make sure that you
understand the structure of the flow divider and lay
the disassembled parts out in order.
2
• Never use any fluid oil other than alcohol or brake

fluid to wash or clean the parts. In particular, never
use mineral oil such as petroleum and gasoline. If
mineral oil sticks on the rubber parts, they may swell
and become unusable.
• Keep the parts in a clean place to prevent the parts
from dirt or dust after washing.
• Always keep such parts as the cylinder, the piston or
the cup away from any foreign body that may damage
those parts.
4 3
 ASSEMBLY
1. Wash or clean metal parts to be reused with flushing oil or
brake fluid.
NOTE: Always use mineral hydraulic oil to wash or clean
rubber parts. Never use flushing oil and petroleum or
gasoline for rubber parts.
Make sure to prevent the spool (2) circumference
from getting scratched or dirty.
2. Assemble the spring (4) as shown in the diagram on the
right.
2 4
3. Slip new o-ring (5) on the bolt (3).

5 3
10-11
4. Tighten the bolt (3) .

torque
3
Bolt: 72 - 79 ft/lbs. (98 - 107 Nm) {10 - 11 kgm}
Be careful not to damage the circumference of the spool.
5. Check to make sure the spool functions smoothly after

assembly.
10-12
10.5.2 HYDRAULIC PUMP

HYDRAULIC PUMP COMPONENTS
3.2/3.5 TON K25 PUMP SHOWN BELOW
Front drive gear

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

comes to gear side.
The face chamfered along outer circumfer-
ence comes to the bottom.
Section A-A Section B-B Section A-A
1. Front body assembly 10. Side plate 19. Seal plate

2. Bushing BR assembly (front pump) 11. Mounting flange 20. Seal Backup
3. Bushing BL assembly (front pump) 12. Body seal 21. Isolation plate
4. Bushing ER assembly (center pump) 13. Bush seal 22. Center plate
5. Bushing EL assembly (center pump) 14. Packing ring R 23. Rear body assembly
6. Front drive gear (front pump) 15. Packing ring L 24. Rear drive gear
7. Driven gear (front pump) 16. Hexagon bolt with flange 25. Rear driven gear
8. Rear drive gear (center pump) 17. Oil seal 26. Bushing ER assembly (rear pump)
9. Driven gear (center pump) 18. Snap ring 27. Bushing EL assembly (rear pump)
10-13
 DISASSEMBLY
IMPORTANT
• Clean any dirt stuck on the surface of the pump and the driving shaft, before carrying out disassembly.
• Put the disassembled parts on clean paper or cloth so as to prevent such parts from getting damaged.
• Lay all of the disassembled parts out in order for ease of identification of such parts before disassembly
1. Place the flange side of the hydraulic pump face downward.

2. Clamp the flange (11) with a vise and secure it.
NOTE: Apply any soft material such as wooden piece, aluminum or copper to protect the vise.
3. Remove the flange bolt (16).
When loosening the bolt, be careful not to drop the hydraulic pump from the vise. Always make sure to
loosen the bolt gradually.
Always use a proper tool (wrench) in good condition.
4. Remove the hydraulic pump together with the center plate (22) straight in the direction toward the shaft.
NOTE: If the pump is hard to remove, tap the side of rear body (23) lightly with a plastic hammer.
5. Remove the center plate (22) from the rear pump.
6. Remove the seals (12), (13), (14) and (15) in turn.
7. Pull out the spline of the rear drive gear (24).
8. Remove the bushings (26), (27) and the gears (24) (25) from the rear body.
9. Remove the side plate (10) located at the bottom of the rear body hole.
10. Remove the hydraulic pump from the vise.
11. Hold the pump by hand to prevent dropping and place it on the work stand with the front pump side on facing
upwards.
12. Pull the flange (11) out straight in the direction toward the shaft.
13. Remove the seals (12), (13). (14) and (15) in turn.
14. Pull the spline of the front drive gear (6) up slightly.
15. Remove the flange side bushings of (2) (3) and gears of (6) (7) from the front body (1).
16. Remove the parts located at the bottom of the front body, including the side plate (10), the plate seat (19), the
backup seal (20) and the isolation plate (21).
17. Turn the front body and repeat the steps 12 thru 15 to remove the gears (8) (9), the bushings (4) (5), the side
plate (10), the plate seal (19), the backup seal (20) and the isolation plate (21) in return.
NOTE: If it is hard to remove them, push out the gear end of the rear pump from the bearing hole of the front pump
side.
18. Remove snap ring (18) from flange (11).
19. Remove oil seal (17) with a flat-headed screwdriver “A” in
the direction indicated by the arrow in the diagram. 12 A
20. Lay all the disassembled parts out in order for ease of
assembly.
10-14
 ASSEMBLY
A
21
20
Check to make sure that all the disassembled parts have
been cleaned up and dried with compressed air before
beginning assembly.
1. Put the front body (1) on the work stand facing the front
pump side or the flange side on the top.
2. Install the isolation plate (21) at the body bottom hole.
Then, insert the plate seal (19) and backup seal (20). 19
NOTE: Pay careful attention to the direction of the suction
side (A) and the discharge side (B). B
As for the isolation plate, set the face (C) on the out-
side circumference downward or face it to the bottom
hole side.
21
3. Set the copper alloy surface of the side plate (10) to the
top (the gear side).
4. Insert the side plate (10) to the body bottom hole.

NOTE: Pay careful attention to the direction of the suction A
10
side (A) and the discharge side (B).
Copper alloy
surface B
5. Insert the front drive gear (6) and driven gear (7).
NOTE: Match the gear teeth to each other properly.
Be careful that the front pump has the reversed tooth face.
6. Assemble the bushing (2) and (3).
7. Insert the bushing to the body (1) paying attention to the direction.
8. Assemble the body seal (12), the bushing seal (13) and the packing of (14) (15) respectively.
9. Assemble the flange (11) on top of front body (1).
NOTE: The alignment has been made on the shaft at the factory. Be careful not to damage the hole for the shaft.
10. Hold the flange to prevent the assembled parts from coming out.
11. Reverse the body and secure with a vise.
12. Assemble the parts with the center pump using the same procedures taken in steps 2 and 3 above.
13. Insert the rear drive gear (8) and the driven gear (9).
NOTE: Check to make sure both splines of the rear drive gear (8) and the front drive gear (6) match properly.
10-15
14. Insert the bushing (4) and (5) using the same procedure
taken in steps 6 and 7 above.
15. Assemble the body seal (12), bushing seal (13) and the
packing of (14) and (15).
16. Put the rear body (23) on the work stand setting the gear
hole side to the top and insert the side plate (10) in the
hole bottom.
17. Pay attention to the turning direction of the gear.
18. Insert the rear drive gear (24) and the driven gear (25).
19. Insert the bushing of (26) and (27) with the same Front drive gear turning direction
procedure taken in step 5 above.
20. Insert the seal of (12), (13), (14) and (15) in turn with the
same procedure taken in step 6 above.
21. Install the center plate (22) on top of rear body.
22. Install the rear pump assembled with the procedures Suction side
taken in steps 12 through 16 above on the top of the front
body (19).
NOTE: Check to make sure both splines of the rear drive
gear (8) and the front drive gear (6) match properly.
23. Tighten the bolt with the flange.
torque
34 - 36 ft/lbs. 46.1 - 48.6 Nm {4.7 - 5.0 kgm}
Discharge side
Always tighten the bolt with the specified torque.

If tightening torque is greater or smaller than the speci-
fied torque, it may result in damage to the bolt or cause trouble blowing the hydraulic oil out from the
matching face of the hydraulic pump.
24. Remove the pump from the vise and assemble the flange
(11) with the oil seal (17) and the snap ring (18).
Gear shaft 18
NOTE: Apply a thin layer of clean lithium grease to the oil
seal. Dust lip
See the direction for installing the oil seal (17).
When installing the oil seal with compressor, make
sure to install it straight so as not to damage the lip.
Protect the front drive gear end with tape to prevent Inside pump Shaft end
the lip from getting damaged and remove the tape
after installation.
25. Turn the drive shaft end with a tool. Lip
NOTE: If it turns lightly by hand, you can assume it is clean 17
internally. If it does not turn easily, carry out disas-
sembly and assembly again because either dirt or bit
of seal could be causing the problem.
26. Install the pump on the truck.
Pay attention to the following points:
• Check to make sure that no scratches can be found at the in-line boss part, which is a standard for
alignment.
• Check to make sure that neither scratches nor dirt can be found on the fitting surface of flange (11). In
particular, carefully check after tightening too strongly with the vise.
• Check to make sure that neither scratches nor dirt can be found on the flange face of the piping.
NOTE: Remove scratches or dirt with fine oilstones.
10-16
10.6 HYDRAULIC PUMP MAINTENANCE STANDARD

HYDRAULIC PUMP MAINTENANCE STANDARD
Front drive gear

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

The face chamfered along outer circumference gear side.
comes to the bottom.
Section A-A Section B-B Section C-C
10-17
1. Front Body and Rear Body

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

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

(18.035 mm), replace with a new gear assembly.
10-18
3. Bushing
An ideal bushing condition is when the inside diameter
d
sliding section of the bushing has no rough surface and
shining contact can be seen in half of the suction side. It
is normal if the side face contact (D) is strong at suction Inlet
side showing dark gray color while contact at high
pressure side is weak and quite minimal.
Replace with a new part for the following conditions
described below: c Outlet
• The contact can be seen all over the inside diameter D
sliding surface of the bushing and your fingernail can
catch rough surfaces on it.
• Many scratches can be seen toward circumference at
the bushing side face and your fingernail can catch
rough surfaces on it.
• The scoring marks of a foreign body can be seen at the inside diameter sliding surface and side surface of
the bushing.
Each repair limit size for the bushing are as follows:
If sizes (c) or (d) exist, replace with a new bushing assembly together with a new gear.
Inside diameter (a) Overall length (b)

Type
in. (mm) in. (mm)
For center pump and rear c >.7528 d <.5814

pump (4), (5), (26) and (27) (19.123) (14.768)
c >.7528 d < 1.039

For front pump (2) and (3)
(19.123) (26.411)
4. Side Plate
It is normal if the sliding surface (copper alloy) contact (D)
of the side plate is strong at suction side while such D
contact is weak at high-pressure side.
• If many scratches can be seen toward circumference
and your fingernail can catch in them, replace with a A
new one.
• If the thickness of the side plate is less than .0767 in.
(1.95 mm), replace it with a new one.
Make sure to replace such parts as push seal, body seal,

B
packing ring, plate seal, backup, oil seal and snap ring
with new parts after disassembly.
10-19
NOTES:
11. WORK EQUIPMENT
11. WORK EQUIPMENT

The work equipment consists of the mast and any material handling equipment attached to the mast. The mast is
mounted on the front of the truck.
6 3 4 5 2
1. Cylinder Head Assembly 4. Bushing

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

• The cylinder head assembly (1) functions as a bearing of the piston rod (2) by way of inserting the bushing (4)
with pressure to the inside diameter of the cylinder head (3). Also, inserting the U-ring (5) to the inside diameter
of the cylinder head, it prevents oil leakage to the outside. Additionally, it functions to supply and exhaust high
pressure oil from inside of the cylinder tube to the port.
• The U-ring (5) is located between the bushing (4) and hydraulic pressure to seal the hydraulic pressure of inside
cylinder. Moreover, it forms a moderate oil membrane on the surface of the piston rod, which works to prevent
the piston rod from getting rusty.
• Being inserted to the inner face of the cylinder head with pressure, the bushing (4) contacts the piston rod.
Sharing a horizontal load given to the piston rod through the piston, it functions as a straight-line movement on
the high-pressure surface against the piston rod. Moreover, it supports one end of the piston rod to minimize any
eccentricity which would affect the sealing function adversely.
• The wiper ring (6) is located at the mouth of inlet and outlet for the piston rod from the cylinder, which prevents
the U-ring rod seal of the inside cylinder from getting dusty or leaking water from the outside. Moreover, it
functions to remove the mud stuck on the rod surface with the movement of the piston rod.
11-3
11. WORK EQUIPMENT
 PISTON SECTION
2.0 - 2.5 ton 3.0 - 3.5 ton
14 13 14 13 15
Fig. 1 Fig. 2
The piston section is provided with the packing (13) for the center of the piston and prevents the hydraulic pressure
from flowing from right of left either side of the piston chamber to the other side of the chamber.
• Packing (13)
Being located in the center of the piston, the packing has an equivalent sealing function with the U-packing
because of its special one-ring seal lip for both face pressure usage, which seals the clearance between the
piston and the cylinder tube utilizing its tensity and forms the chambers of high-pressure side and constant
pressure side bounded by the piston.
• Backup Ring (14) in Fig. 1
A combination bearing with insertion-type backup ring, which protects the piston from deterioration and
improves durability and resistance to the oil pressure of the packing (13).
• Backup Ring (14) in Fig. 2
It stops the packing (13) from protruding and improves durability and resistance to the oil pressure. The bearing
(15) protects the piston from seizure or deterioration.
11-4
11. WORK EQUIPMENT

11.2.1 FORK (1)
1. Deformation, cracks or wear of fork stopper pin
2. Opening or difference in height of fork tips
Opening (a): within 35 mm
Opening (a) within 1.37 in. (35 mm)

Difference in height (b) within 0.59 in.(15 mm) b
11.2.2 FORK (2)

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

3.0 ton > 1.58 in. (40.0 mm) Min.
3.5 ton > 1.80 in. (45.0 mm) Min.
NOTE: Check the fork base/root and the hooks, where stress is concentrated, by the crack detection method
11.2.3 MAST (1)

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

1. Play in mast support
Check mast support for oil groove of bushing
2. Loosening of mast cap mounting bolt
2.5 ton 180 - 228 ft/lbs. (245 - 309 Nm) {25.0 - 31.5 kgm}
torque 3.0 ton 253 - 315 ft/lbs. (343 - 427 Nm) {35.0 - 43.5 kgm}
3.5 ton 361 - 448 ft/lbs. (490 - 608 Nm) {50.0 - 62.0 kgm}
11.2.5 FORK CARRIAGE

1. Deterioration, cracks or scratches of fork carriage
2. Wear or play in roller
3. Play in roller shaft
11-5
11. WORK EQUIPMENT
11.2.6 LIFT CHAIN

1. Chain tension
Put the mast straight vertically and lift the forks about 4.0 in. (10 cm) from the ground to check lift chain for
proper tension with your finger.
Adjustment should be made with chain stopper.
2. Elongation
Check chain elongation over specified length (L) of
17 links L
2 - 2.5 ton within 13.0 in. (330 mm)

2.8 - 3 ton within 21.6 in. (550 mm)
3.2 - 3.5 ton within 17.3 in. (440 mm)
3. Anchor bolt threads
Make visual check
11.2.7 CHAIN WHEEL

Deformation, scratches or play in wheel
1. Check visually chain and its contact surface
2. Turn by hand and check wheel for play in bearing
11.2.8 WORK EQUIPMENT SYSTEM (1)

1. Check work equipment for proper installation to the truck
2. Check each bolt and nut for proper tightening
11.2.9 WORK EQUIPMENT SYSTEM (2)

1. Check work equipment for cracks, scratches or wear of each section
2. Check work equipment for proper functioning and abnormal noise of each section


11.2.12 REACH CYLINDER

Not applicable for this model
11.2.13 WORK EQUIPMENT CYLINDER

11-6
11. WORK EQUIPMENT
11.2.14 HYDRAULIC DRIFT OF LIFT CYLINDER AND TILT CYLINDER

1. Load the forks with maximum payload and set the mast
(1) upright, lift the forks about 59 in. (1,500 mm) from the
ground. 1
2. Match a straight measure (1) on the piston rod of the lift
cylinder (2) and put the mark (A) for measurement.
3. Match a straight measure (2) on the piston rod of the tilt
cylinder (3) and put the mark (B) for measurement.
H
When measured at 3.95 in. (100 mm)/
Hydraulic drift fork within 15 min
of lift cylinder When measured at 1.96 in. (50 mm) /
cylinder within 15 min A
Hydraulic drift
1.18 in. (30 mm) / 15 min
of tilt cylinder
Adjustment: Replace control valve and cylinder packing
11-7
11. WORK EQUIPMENT

11.3.1 MAST
 REMOVAL
1. Put blocks under the front and the rear wheels.
2. Support the fork carriage with a crane.
3. Remove the forks.
4. Put blocks under the fork carriage.
5. Operate the work equipment control levers several times

to release any remaining pressure in the hydraulic piping.
6. Disconnect the piping.
7. Fit the blind plugs immediately to prevent the hydraulic oil
from flowing out and to prevent dirt or dust from getting in.
8. Lift the fork carriage slightly with a crane.
9. Remove the blocks.
10. Let the fork carriage down.
11. Hook the crane to the mast.

12. Remove the tilt pins.
13. Tilt the mast forward slightly and remove the differential
mounting cap bolt.
If the mast is being tilted backward, there is a danger the

mast may fall over.
11-8
11. WORK EQUIPMENT
14. Remove the mast.
When carrying the removed mast horizontally, secure the

lower stay and the fork carriage with a twisted annealing
wire (A).
Put blocks under the bottom of the mast and lay the mast
assembly horizontally so that the fork carriage is at the
top.
 INSTALLATION
Carry out installation in the reverse order of removal.
11-9
11. WORK EQUIPMENT

Also see Chapter 12, “MASTS”.
 REMOVAL
1. Place the mast upright.
2. Remove the stopper bolt.
3. Hoist the mast by a crane.
4. Put blocks under the inner mast.
5. Remove the cylinder clamp.
6. Operate the work equipment control levers several times Stopper bolt
to release remaining pressure in the hydraulic piping.
7. Disconnect the piping.
8. Fit the blind plugs immediately to prevent the hydraulic oil
from flowing out and to prevent dirt or dust from getting in.
9. Lift the cylinder with a crane and sling to remove it.
Lift Cylinder
 INSTALLATION
1. Lift the mast up to the maximum lifting height.
2. Check the mast for play on both sides.
3. Adjust the shims so that both sides of the cylinders are 21.7 - 36.1 ft/lbs.
synchronized with each other at the maximum lifting torque (29.4 - 49 Nm)
height. {3 - 5 kgm}
Angled to left Insert shims into the left cylinder

Angled to right Insert shims into the right cylinder
Inner
mast
Shim
Cylinder
rod
Outer
mast
11-10
11. WORK EQUIPMENT

LIFT CYLINDER COMPONENTS
1. Rod/Plunger 11. Retaining Ring

2. Spacer 12. Check Valve
3. Back-up Ring 13. O-ring
4. Pull-in Wire 14. Washer
5. Roll Pin 15. Retaining Ring
6. Shell 16. Wear Ring
7. Wiper 17. Nylon Ring
8. Rod Seal 18. Piston Seal
9. Piston 19. O-ring
10. Sleeve 20. Retainer
11-11
11. WORK EQUIPMENT
IMPORTANT
Service requiring disassembly should be performed by the manufacturer.
 PREPARATION
Before starting disassembly:
• Prepare a solid, stable workbench that is large enough to support parts and prevent them from moving or falling
during the work.
• Prepare tools and materials shown on the following page.
 GENERAL PRECAUTIONS
• Clean the cylinder beforehand to remove soil, dirt and dust.
• Since the cylinder is composed of precision parts, handle it very carefully. Do not bump or drop parts during
work.
• Do not hit or tamper with parts forcibly. This may cause burrs or damage, which may disable reassembling or
cause oil leakage or deterioration. Perform disassembling/reassembling carefully and patiently.
• If the cylinder is left alone disassembled or in the middle of disassembly, parts may rust due to humidity or dirt/
dust. When disassembling is unavoidably suspended, be careful to guard the cylinder against rust and dust.
11-12
11. WORK EQUIPMENT
 GENERAL TOOLS
Tool Qty
Flat-blade screwdriver 1
Hexagon wrench 1 set
Vise 1
Torque wrench 1 set
Plastic hammer 1
Adjustable wrench 1
Spatula 1 set
Hook wrench 1
 SPECIAL TOOLS
The following tools are helpful for disassembling/reassembling the cylinder.
Tool Simplified figure
Wiper ring press-fit tool
Piston seal press tool
11-13
11. WORK EQUIPMENT
 DISASSEMBLY
1. Bleed oil.
2. Loosen cylinder head with a hook wrench, and remove it
from cylinder tube assembly.
NOTE: Put an oil pan under the cylinder tube assembly as
the remaining oil may leak out
3. Carefully pull out the cylinder head straight.
The piston ring may touch other parts right after it is

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

5. Put it on a crosstie.
The piston rod assembly may touch the thread portion of

cylinder tube assembly right after it is pulled out or may
fall and damage other parts. This is more risky for lift cyl-
inders with long contracted length. Be very careful to
avoid damage.
6. Disassemble piston assembly.

a. Pull out the spacer from piston rod assembly.
NOTE: Spacer with wear ring cannot be removed, as it is
non-disassembly part.
b. The wear ring can be removed easily by hand.
c. Remove U-ring, backup ring, bushing, and cushion
bearing.
NOTE: The piston rod and piston cannot be disassembled.
d. Use a spatula or screwdriver to pull out the U-ring
and backup ring.
e. Remove bushing while widening the mating face
using a screwdriver.
NOTE: The removed seal parts cannot be reused.
f. Remove snap ring from the groove with a sharp-tip tool, and then pull out the cushion bearing.
11-14
11. WORK EQUIPMENT
7. Disassemble seal parts in cylinder head

a. Use a spatula or screwdriver to remove the U-ring.
b. Since the wiper ring is press-fit, pull it out by hitting
the rubber from the bush side with a screwdriver or a
similar tool.
c. (Remove the o-ring using a spatula or screwdriver in
the same way as the U-ring.
IMPORTANT
The removed seal parts cannot be reused.
8. Clean and store removed parts.
a. Clean the removed parts with white kerosene.
b. Apply hydraulic oil to removed parts.
c. Then store parts with a cover.
IMPORTANT
If the removed parts are left unprotected, the cylinder cannot exhibit its performance well after reassembling due to
rust or dust.
11-15
11. WORK EQUIPMENT
 ASSEMBLY
Coating of parts may peel off and fall inside when reassembling them. Be very careful so that coating
materials may not fall into the cylinder. This may cause oil leakage.
1. Reassemble cylinder head

a. Prepare the disassembled cylinder head or “cylinder
head kit”.
b. Clean parts well before reassembling.
c. Press-fit the U-ring into the U-ring groove of cylinder
head.
NOTE: Use a spatula to avoid damage to the U-ring.
If the U-ring is heated to approx. 158°F (70°C), it can
be installed easily. Be careful not to get burned.
d. Check that there is no permanent deformation such
as wrinkles after installation.
e. Install the wiper ring using a tool.
f. Push the wiper ring with a press machine or the like.
g. Install the o-ring paying attention not to damage or

cut it.
h. Check that there is no distortion after installation.
11-16
11. WORK EQUIPMENT
2. Reassemble piston assembly

a. Clean the piston and the surrounding area well
before reassembling.
b. Install the U-ring to the U-ring groove of the piston
while expanding it.
NOTE: Pay attention to its orientation. If hydraulic oil is
applied to the U-ring, it can be installed easily. An
insertion tool as shown in the figure will make the
installation safe.
c. Install backup ring to the back of U-ring (see the fig-

ure).
NOTE: If installed incorrectly, the backup ring will not function
normally and damage U-ring, which may inhibit nor-
mal cylinder operation.
d. Install the bushing to the bush groove of the piston

while widening its mating face (see the figure).
11-17
11. WORK EQUIPMENT
e. Insert the cushion bearing into the piston irrespective

of its orientation.
f. Fit snap ring into the snap ring groove of the piston to
secure the cushion bearing.
3. Reassemble cylinder tube assembly, piston rod
assembly, and cylinder head
a. Secure the cylinder tube assembly horizontally.
b. Insert the spacer into piston rod assembly.
c. Press-fit o-ring into the o-ring groove around the pis-
ton rod, and then insert the spacer from the end of
the piston rod until the spacer touches the piston.
NOTE: If the fitting is not smooth, apply hydraulic oil to the o-
ring.
d. When non-disassembly type spacer with a wear ring
is used, install the wear ring into the wear ring groove
of the spacer.
e. Insert the piston rod assembly into cylinder tube
assembly 1 completely.
When inserting piston rod assembly 2, it may touch the

thread portion of cylinder tube assembly, causing dam-
age to the piston seal or other parts. Carefully insert the
piston rod assembly while holding it horizontally.
f. Press and insert cylinder head into the piston rod

assembly from the end of the piston rod assembly.
g. Then insert the cylinder head into the threaded por-
tion of the cylinder tube assembly.
h. Tighten the cylinder head with a hook wrench to the
torque specified in the assembly drawing.
4. Mount the cylinder to the main body.
5. Actuate the switch valve.
6. Perform full-stroke operation 8 times.
NOTE: The cylinder is now filled with oil.
IMPORTANT
Do not start the cylinder suddenly. Doing so may cause aeration of the hydraulic oil.
11-18
11. WORK EQUIPMENT
 INSPECTION AFTER REASSEMBLY
Check for smooth movement with no abnormality through full stroke without load
No-load operation check
five times.
Dimension check Check the most contracted length and stroke specified in the drawing.
Check for tightness, permanent distortion, or external leakage when the test
pressure (specified in the drawing) is applied to the stroke end for 3 minutes or
more.
Pressure check
Be sure to immobilize the lift cylinder during checking.
Check the volume of oil leakage from the rod.

External leakage check
(Refer to the following page.)
Internal leakage check Oil leakage volume shall be 3 ml or less for 10 minutes.
11-19
11. WORK EQUIPMENT

TILT CYLINDER ASSEMBLY (2.0 - 3.5 TON TRUCK)
1. Cylinder Sub-Assy 8. Nut 15. Back-up Ring

2. Piston Rod 9. Head 16. Gasket (Packing)
3. Spacer 10. O-ring 17. Head
4. Piston 11. Dust Seal 18. Bushing
5. Gasket (Packing) 12. Bushing 19. Snap Ring
6. Back-up Ring 13. Washer 20. Bushing
7. O-ring 14. O-ring 21. Snap Ring
NOTE: Before disassembling, protect threaded portion of the cylinder rod with tape to ensure neither the lip seal
nor the packing will be damaged.
11-20
11. WORK EQUIPMENT
 DISASSEMBLY
1. Remove tilt cylinder from lift truck.
2. Remove the yoke end from the piston rod.
3. Remove spacer from piston rod (if equipped).
4. Remove the head from the cylinder.
a. Hold the cylinder securely.
Do not clamp or vise the cylinder tube to avoid damage.
b. Remove the head from the cylinder by turning counterclockwise.
Special Tool OSTBX-1 is required to remove the head.

The use of incorrect tools may damage the head or cylinder and may void the warranty.
c. Remove the head/piston rod/piston assembly from the cylinder.
Using compressed air to remove the head/piston rod/piston assembly from the cylinder may cause the
assembly to be ejected with great force. Use extreme care when removing these assemblies.
5. Disassemble the head/piston rod/piston assembly.

a. Securely hold the piston rod so that the piston nut may be loosened.
NOTE: Special Tool OSTBX-2 is recommended to hold the piston rod. The use of incorrect tools may damage the
piston rod and could void the warranty.
b. Remove the piston nut by turning clockwise.
The piston nut is of the staked type. Significant difficulty may be encountered when the nut is removed
from the piston rod.
c. Remove the piston from the piston rod.
d. Remove the head by sliding toward the piston end of the rod.
e. Remove all internal and external seals from the piston.
f. Remove all internal and external seals from the head.
NOTE: Pay close attention to location of original parts for ease of reassembly.
 PARTS INSPECTION
1. Inspect cylinder sub-assembly.
a. Inspect cylinder sub-assembly for scratches or scoring on the interior surface.
If scratches or scoring exist on the interior surface of the cylinder sub-assembly, replace the sub-assembly.
b. Inspect the internal threads for damage or scoring.
If the threads are damaged or scored, replace the sub-assembly.
2. Inspect piston rod.
a. Inspect the piston rod chrome surface (30.0 mm diameter) for damage or scratches.
If the chrome surface is scratched, gouged, dented, rusted or scored, replace the piston rod.
b. Measure the piston rod chrome surface at the piston locating shoulder.
The maximum diameter of the piston rod chrome surface is 29.98mm. If the measurement is larger than
this value, replace the piston rod.
c. Inspect the threaded portions of the piston rod for damage or scoring.
If damage is discovered during inspection, replace the piston rod.
3. Inspect the piston for dents, damage or scoring. If damage is found, replace the piston.
11-21
11. WORK EQUIPMENT
4. Inspect the head.

a. Inspect the threaded portion of the head for damage or scoring. If damage is found, replace.
b. Inspect the piston rod guide bushing for scratches or scoring. Replace the head if damage is discovered.
 ASSEMBLY
1. Obtain the proper seal kit and a new piston nut.
2. Thoroughly clean all parts to remove any possible contamination.
NOTE: Foreign matter that enters the cylinder can cause scratches, scoring and seal leakage. Do not permit any
foreign matter to enter the cylinder.
3. Assemble head.
a. Inspect head for absolute cleanliness.
b. Install new seals in head.
c. Ensure that all seals are installed in their proper locations.
Failure to use new seals, or installing seals improperly, may cause a sudden loss of pressure in the cylin-
der which may result in injury or property damage.
4. Assemble piston
a. Inspect piston for absolute cleanliness.
b. Install new seals in piston.
c. Ensure that seals are installed in their proper locations and are correctly oriented.
5. Assemble head/piston rod/piston assembly
a. Securely hold the piston rod so that the piston nut may be tightened.
Special tool OSTBX-2 is recommended to hold the piston rod.

The use of incorrect tools may damage the piston rod and could void the warranty.
b. Install the head onto the piston rod. Take care not to damage the seals or guide bushing.
Scratches on the seals or guide bushing can cause seal leakage or rod damage.
c. Install piston onto piston rod.
NOTE: Apply a small amount of grease on the rod to ease installation.
d. Install a new piston nut onto the piston rod.
torque
Torque piston rod nut to 290 lbs./ft (392 Nm).
Torque the new piston nut to 290 ± 43.5 lbs./ft (392 ± 59 Nm). Failure to use a new piston nut may cause the
piston nut to loosen. A loose nut may allow the piston rod/piston assembly to come apart resulting in cyl-
inder failure. Always use a new nut and torque the nut as specified.
6. Assemble tilt cylinder.

a. Inspect cylinder sub-assembly for cleanliness.
b. Hold the cylinder securely.
NOTE: Do not clamp or vise the cylinder tube as damage will occur.
c. Ensure that the head/piston rod/piston assembly is cleaned with solvent and dried.
NOTE: Do not use rags or paper towels to dry. Gentle drying with compressed air is recommended.
11-22
11. WORK EQUIPMENT
d. Apply clean hydraulic oil to the piston and inside the cylinder.
e. Install the head/piston rod/piston assembly into the cylinder sub-assembly.
NOTE: Use care not to damage the threaded portion of the cylinder. Damaged threads will prevent the head from
fully seating in its proper location.
f. Apply medium strength thread locking agent to the threaded portion of the head.
g. Thread the head into the cylinder taking care to align the threads properly.
torque
Torque the head to 360 + 55 lbs./ft (490 + 75 Nm).

NOTE: Special tool OSTBX-1 is required to install the head. The use of incorrect tools may damage the head
and could void the warranty.
Failure to properly torque the head can result in cylinder leakage or cylinder damage and could void
the warranty.
h. Install the spacer, if needed, and yoke end onto the piston rod.
7. Install the tilt cylinder assembly onto the lift truck.
For models FG(D)20(S)(H)(T) and FG(D)25(S)(H)(T), use a wet torque method to prevent potential disen-
gagement of the tilt cylinder rod end from the tilt cylinder rod.
See Technical Bulletin TB2010-011FC for details.
8. Cycle the tilt cylinder and check for function and leakage after it is fully installed.
11-23
11. WORK EQUIPMENT
11.4.3 CONTROL VALVE

CONTROL VALVE ASSEMBLY
1. Nut (4)
2. Nut (2)
3. Housing
4. Through Bolt (2) (small)
5. Through Bolt (1) (larger)
6. Housing
7. Spring
8. Poppet
9. O-ring
11-24
11. WORK EQUIPMENT
 DISASSEMBLY
Pay attention to the following when disassembling parts:
• Place the target forklift horizontally with all forks grounded. Stop the engine and release the pressure off the
actuator. If disassembling is performed with pressure confined, high-pressure oil may spray out or parts may
jump off suddenly possibly causing injury.
• Bleed air from the pressure tank.
• Clean the target parts and the surrounding area to prevent foreign matter from entering the valve when
disassembling.
• Distinguish each disassembled part with a tag or the like for correct reassembling.
• Replace all the removed seal parts (o-rings, backup rings, etc.) with new ones.
• Since spools are engaged in accordance with the management of clearance with the valve housing, they cannot
be replaced for quality reasons. Do not bump or drop any spool.
• Since the mating face of sections is a sealed surface, do not bump or scratch it.
• Clearance of spools is precisely managed to minimize internal oil leakage. Replace spools as a spool section
assembly, as they may be deformed during disassembling or reassembling.
1. Remove main relief valve from the valve housing.
IMPORTANT
The relief valve should be replaced as an assembly. Therefore do not disassemble the relief valve unless a defect
is found. Refer to the relief valve maintenance manual when disassembling it. Distinguish each disassembled part
for correct reassembly.
2. Remove tie rod nuts (1), (2) at the end, and disassemble the spool assemblies from each section one by one.
3. Loosen and remove tie rods (through bolts) (4), (5) from the lift spool section.
NOTE: Be careful not to misplace the poppets, springs, and o-rings inserted in the mating faces of sections.
4. Wash all the disassembled parts completely with clean mineral oil.
5. Dry all the disassembled parts completely with compressed air and put them on clean paper or lint-free cloth
for inspection.
6. Check all disassembled parts for burrs, scratches, flaws or any other defects on any surface.
a. Check that no scratch or dent is present on the outer surfaces of spools. If slight scratches are found,
remove them with an oilstone or cloth dampened with lapping agent.
b. Check that all sliding parts move smoothly, and that no foreign matter is left in any groove or path.
c. Replace spring if it is damaged, deformed or worn.
d. Check that seal grooves of the valve housing are smooth with no dirt/dust, dent or rust.
e. If any dent and/or scratches are found on the check seat surfaces of the valve housing, remove them by
lapping while paying attention not to leave lapping agent in the valve.
7. Check it according to the relief valve maintenance manual when the relief valve does not work normally.
8. Check that no paint scrap is left near the plug seats or holes of the machine body when any cap or plug is
detached.
If paint scraps enter the valve, they may cause catching or clogging, which may result in a malfunction or
oil leakage.
11-25
11. WORK EQUIPMENT
 ASSEMBLY
Pay attention to the following when handling o-rings.
• Do not use o-rings with a molding defect or scratches.
• Apply grease or hydraulic oil to o-rings and their installation places for adequate lubrication.
• Do not expand any o-ring to an extent where it is permanently deformed.
• When installing an o-ring, do not roll it. Once it is distorted, the distortion cannot be corrected naturally. This may
cause oil leakage after installation of the o-ring.
Pay attention to the following when handling spools.
• Always observe the specified torques. Excessive torque on tightening screws may cause spool malfunction.
• Put spools, springs, and spool ends in the same combinations as those before disassembling.
Pay attention to the following when reassembling section assemblies and valve assemblies.
• Slowly insert the spool straight to the hole. If the spool does not move smoothly by hand after it is inserted, it
may malfunction.
• Check that the o-ring at the mating face is fitted within the o-ring groove.
• Check that no washing oil or hydraulic oil is remaining at the following places before reassembling:
• Outer surface of the o-ring groove at the mating face of each section
• Outer surface of the o-ring groove at the cap installation face
NOTE: If reassembling is performed with oil remaining at these places, the oil may be misdiagnosed as oil
leakage during operation.
1. Mount the spool subassembly onto the valve housing at the same position and in the same orientation as
before disassembly, and then attach cap with socket head bolt.
2. Mount connector assembly onto the lift section.
3. Tighten the iron cores of solenoid valves to the lift section, install the coil, and then tighten the hexagon socket
head bolts, while paying attention to the internal wave washers.
4. Mount the port relief valve and main relief valve.
5. When reassembling is completed, recheck that all the disassembled parts are securely installed. Loose
installation of parts may cause oil leakage.
6. Adjust pressure settings.
a. Attach an accurate pressure gauge to the entrance of the circuit.
b. Run the pump at the rated speed.
c. Switch the control valve spool, and read the pressure gauge at the time of cylinder stroke end.
d. Turn the adjuster clockwise until necessary pressure is obtained.
The pressure increases 2,277 PSI (15.7) MPa by one turn of the adjuster (reference value).
e. When pressure reached the specified value, hold the adjuster to prevent it from turning and tighten the lock
nut.
torque
20 - 23 ft/lbs. 27 - 31 Nm {2.8 - 3.2 kgfm}

f. Increase the pressure again and check that the pressure is the specified value.
 INSTALLATION
Pay attention to the following for installation.
• Be careful so that excessive stress is not applied to the valves through piping.
• Tighten all bolts evenly.
• When performing welding near a valve, be careful not to damage seal parts by excessive heat or spatters.
• To prevent dust or foreign matter from entering, do not detach protective materials of ports until piping is
installed.
11-26
11. WORK EQUIPMENT
 OPERATION
• Check that the valves are correctly arranged and that hydraulic oil is clean, and then check that no oil is leaking
outside while increasing the pressure gradually (by inching operation at low idle).
• Use hydraulic oil with an aniline point of 82°F to 113°F.
• Use relief valves within the specified set pressure.
• Perform adequate warm-up run before starting work.
When starting the machine with a low hydraulic oil temperature or low valve temperature, be careful of the following
to prevent sticking due to spool's heat shock:
• Do not suddenly activate the main relief valve or overload relief valve continuously during warm-up run. Operate
the machine so that hydraulic oil in each actuator can circulate and that each section warms up evenly.
• Do not perform fine operation or combined operation suddenly under a low temperature. This may cause partial
heating due to throttle control in each section.
 REPLACE LIP SEALS

1. Remove cap screws, spool cap, seal plate, spring and spring seats from
spool.
NOTE: Hold the spool by the tang end to prevent rotation. This can be done
with valve on or off the lift truck depending upon the valve location.
Identify spools so they can be reinstalled in the same bore if the
spools are to be removed from the valve.
2. Remove all foreign material from the spool and seal cavities.
3. Remove screws and seal plate from the opposite end of the spool.
4. Locate the spool in its neutral position.
NOTE: Be careful not to move the spool when installing both seals.
Use the installation tools shown in the illustration at right.
5. Lubricate the seal (B) and wiper (C) with Mobilith SHC PM or equivalent
and place on top of tool driver as shown.
NOTE: Use the tool driver to press the seal into the spool housing counter-
bore using steps 6 through 12 below.
Use hand force only. Repeat for each seal.
6. Install wiper ring (C) on the end of tool driver (D) with smaller O.D. of ring
into the driver.
7. Put seal (B) on top of wiper ring with the larger O.D. of the seal away from wiper ring.
NOTE: Lip end of sleeve (A) I.D. is cone shaped to compress seal and wiper
ring for installation. See illustration.
8. Carefully slide sleeve (A) over seal (B), wiper ring (C) and driver (D).
Next, lube the end of the spool and spool counter-bore on the valve.
9. Put tool assembly over end of spool with raised lip of sleeve (A) into
counter-bore of valve section.
10. Push driver (D) with slow steady motion to install seal and wiper ring into
valve housing.
11. Ensure that all threads are clean and dry, apply Loctite # 242 (red), 1 or 2
drops to spool end screw and assemble spring seats and spring. Torque
screw to spool end between 6 - 8 ft/lbs for both 5,000 lb. and 6,000 lb.
valves.
12. Reassemble seal plates, spring, spring seats, spool cap and mounting
screws.
torque
Torque mounting screws to 7 ft/lbs. each.
11-27
11. WORK EQUIPMENT
 CHANGE SPOOL SEALS

1. Remove the control valve from the lift truck.
2. Clean entire valve prior to disassembly to prevent dirt or debris from entering valve orifices or getting onto
sealing surfaces.
3. Disassemble tang and cap end without removing spool from housing.
4. Remove original o-ring and wiper from tang and cap end.
5. Clean seal cavities (tang and cap end) with clean solvent.
6. Lubricate lip seal with oil or light grease.
7. Install new lip seals per diagram with fingers or blunt tool using caution to avoid damage to the outside and
inside diameters of the critical edges as the seal enters the seal cavity.
8. Install new wipers as per diagram.
9. Reassemble tang and cap end mechanism.
10. Apply Loctite # 271 to spool end screw.
torque
Torque spool end screw and socket head screws to 7 ft/lbs.

Torque machine screw RD. HD. to 4 ft/lbs.
11. Check all spools for ‘sticking’ before reinstalling on lift truck.
NOTE: If the spools stick or will not move smoothly, the lip seals may be improperly installed. Repeat the above
procedure.
11-28
11. WORK EQUIPMENT
11.4.4 CYLINDER SEAL SERVICE KITS

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

using a screwdriver with smooth edges. Use great care not to
scratch the seal grooves.
4. Clean the plunger, piston, retainer and cylinder bore and then
inspect for nicks and burrs. Minor nicks and burrs can be removed
with 400 grit emery cloth.
IMPORTANT
Minor nicks are those which will not allow oil to bypass under pressure.
If nicks can still be felt with a fingernail after using the emery cloth,
replace the part to avoid leakage under pressure.
11-29
11. WORK EQUIPMENT
5. Replace the seals, backup rings, o-rings and wear ring. Note the
correct seal directions. The cylinder will not operate properly if the
seals are installed incorrectly.
6. Place the loader in the cylinder shell. The loader must cover all the
threads, but not contact the thread relief chamfer.
7. Apply a film of clean hydraulic oil to the cylinder bore, loader and
piston seals. Insert the plunger/piston assembly through the loader
and into the cylinder shell. If resistance is encountered, tap the
plunger with a rubber mallet. Remove the loader and ensure that
the plunger is fully inserted.
8. Install the retainer and tighten to the recommended torque as
shown in the table below.
TORQUE SPECIFICATIONS
Bore Dia. Torque Bore Dia. Torque

40mm 140-160 ft/lbs. 70mm 260-280 ft/lbs.
45mm 160-180 ft/lbs. 75mm 280-300 ft/lbs.
50mm 180-200 ft/lbs. 85mm 320-340 ft/lbs.
55mm 200-220 ft/lbs. 90mm 340-360 ft/lbs.
60mm 220-240 ft/lbs. 95mm 360-380 ft/lbs.
64mm 236-256 ft/lbs. 105mm 400-420 ft/lbs.
 PISTON DESIGN WITH NO DOWNSTROKE CUSHIONING

Please follow these directions carefully to ensure that the seals are not
damaged upon installation.
1. Make sure that the disassembly area, tools and cylinder are clean
prior to disassembly. This will reduce the amount of potential con-
taminants that may enter the system during seal installation. Use a
soft jawed vise or some other fixing method to hold the cylinder
during this procedure. Do not crush or bend the cylinder while hold-
ing stationary for the work.
2. Use a claw type spanner wrench to remove the retainer. Pull the
plunger/piston assembly from the shell.
11-30
11. WORK EQUIPMENT
3. Carefully remove the seals from the piston and retainer using a
screwdriver with smooth edges. Use great care not to scratch
the seal grooves.
4. Clean the plunger, piston, retainer and cylinder bore and then inspect for nicks and burrs. Minor nicks and
burrs can be removed with 400 grit emery cloth.
IMPORTANT
Minor nicks are those which will not allow oil to bypass under pressure. If nicks can still be felt with a fingernail after
using the emery cloth, replace the part to avoid leakage under pressure.
5. Replace the seals, backup rings, o-ring and wear ring. Note the correct seal directions. The cylinder will not
operate correctly if the seals are installed improperly.
6. To replace the o-ring on the internal check valve, you must first
remove the retaining ring and washer. Use a hook or screwdriver to
remove the check valve from the piston. Replace the o-ring and
insert the check valve back into the piston, followed by the washer
and retaining ring.
Ensure that the arrow on the check valve is pointing in the correct
direction.
11-31
11. WORK EQUIPMENT
7. Place the loader in the cylinder shell. The loader must cover all the
threads, but not contact the thread relief chamfer.
8. Apply a film of clean hydraulic oil to the cylinder bore, loader and
piston seals. Insert the plunger/piston assembly through the loader
and into the cylinder shell. If resistance is encountered, tap the
plunger with a rubber mallet. Remove the loader and ensure that
the plunger is fully inserted.
9. Install the retainer and tighten to the recommended torque as
shown in the table below.
TORQUE SPECIFICATIONS
Bore Dia. Torque Bore Dia. Torque

40mm 140-160 ft/lbs. 70mm 260-280 ft/lbs.
45mm 160-180 ft/lbs. 75mm 280-300 ft/lbs.
50mm 180-200 ft/lbs. 85mm 320-340 ft/lbs.
55mm 200-220 ft/lbs. 90mm 340-360 ft/lbs.
60mm 220-240 ft/lbs. 95mm 360-380 ft/lbs.
64mm 236-256 ft/lbs. 105mm 400-420 ft/lbs.
11-32
11. WORK EQUIPMENT
11.4.5 SIDESHIFTER
SIDESHIFTER ASSEMBLY
Item Quantity Description Item Quantity Description

A 1 Carriage Assembly 8 2 Lower Carriage Claw
B 1 Spline Weldment 9 2 Chain Anchor
C 1 Carriage Frame 10 3 Spine Bar Wear Pad
D 2 Sideshift Rod 11 2 Chain Anchor Pin
E 2 Fitting 12 3 Top Wear Pad
1 2 O-ring 13 1 Face Wear Pad
2 2 Rod Seal 14 2 Rod Wiper
3 6 Cap Screw 15 4 Cotter Pin
4 4 Load Roller 16 2 Cotter Pin
5 2 Cylinder Head 17 2 Nut
6 3 Grease Fitting 18 16 Load Roller Shim
7 3 Grease Fitting
11-33
11. WORK EQUIPMENT
 REPLACE CYLINDER HEAD O-RINGS

Tool Requirements
• O-ring replacement kit, which includes two o-rings • Cylinder Head removal/installation socket and 3/16
and one thread cover dowel pin
• Loctite 243 for cylinder head/cylinder block and • 1/2 inch or 3/8 inch drive ratchet
lower carriage claw bolts • Torque wrench with minimum torque value of 170 ft/
• 3/4 inch socket lbs for 1/2 inch socket
• 8mm Allen socket head wrench • Oil drain pan
• Floor dry • Clean white rags
• Brake cleaner or isopropyl alcohol • High temperature grease
• 90 degree pick tool
1. Remove the backrest from the carriage per manufacturer's instructions.

2. Remove forks from the carriage per manufacturer's instructions.
3. Raise carriage on the mast to eye level.
WARNING: YOU MUST PUSH THE TWO CYLINDER RODS INTO THE CYLINDER BLOCK PER THE FOL-
LOWING STEPS TO AVOID INJURY. PRIOR TO PUSHING THE RODS INTO THE CYLINDER BLOCK THEY
ARE UNDER HIGH PRESSURE!
4. Push the cylinder rods into the cylinder block through the cylinder heads as shown in the following photo.
a. With the truck engine turned off, stand on the right side of the truck and push the third function lever up
while pushing the front frame to the left.
b. Pull the lever down while pulling the frame to the right.
11-34
11. WORK EQUIPMENT
5. Remove the six lower carriage claw bolts from the front frame lower bar and claws with 8mm Allen wrench.
6. Lower carriage to ground level until it stops.
7. Remove the front frame by lifting it out and upwards away from the front of the mast channels.
8. Place the front frame flat down on pallet or blocks to prevent damage to the paint.
11-35
11. WORK EQUIPMENT
9. Check for presence of the wear pads to ensure none were removed during disassembly.
NOTE: Three upper wear pads are to be on top of the cylinder block, two face wear pads on the face of the cylin-
der block and 3 lower wear pads on the face of the lower spine bar. If any are missing, review front frame
to see if they are attached to the front frame inner surface.
10. Place oil drain pan under the lower spine bar directly below one of the cylinder heads.
11. Place a white rag on top of the lower spine bar to reduce oil spill during removal of the cylinder head.
12. Place the cylinder head removal/installation socket onto the cylinder head and align the holes of the socket and
the cylinder head.
11-36
11. WORK EQUIPMENT
13. Insert the dowel pin in the hole ensuring it is seated completely.
14. Use the 3/4 inch socket and cylinder head socket tool to remove the cylinder head from the cylinder block.
15. Let oil drain into the oil pan.

16. Remove the cylinder head assembly from the cylinder block.
11-37
11. WORK EQUIPMENT
IMPORTANT
Be sure not to scratch the cylinder rod on the cylinder block
17. Repeat the steps for the other side.
18. Rest the cylinder rod on a piece of wood and push the cylinder head all the way down the cylinder rod towards
the taper end.
Do not take the cylinder head off the cylinder rod as it may damage the inner seals.
19. Stand the cylinder rod up so the threaded side of the cylinder head is facing up.
20. Use the 90 degree pick tool to remove the o-ring from the cylinder head.
NOTE: Discard the o-ring after removal.

21. Clean the cylinder head threads with brake cleaner or isopropyl alcohol and a white rag to completely remove
oil film from the cylinder head threads.
11-38
11. WORK EQUIPMENT
22. Place the black rubber protective sleeve over the threads of the cylinder head to protect the o-ring from
damage during installation.
23. Lubricate the new o-ring and install over the protective sleeve cover.
Be sure not to damage the o-ring.
24. Ensure the new o-ring is completely seated on the cylinder head.
25. Repeat the same steps for the other cylinder head.
11-39
11. WORK EQUIPMENT
26. Remove any paint on the mating surfaces of the cylinder head and cylinder block if necessary ensuring no
metal is removed in the process.
NOTE: The mating surfaces between the cylinder head and cylinder block must be free from paint build up.
27. Blow out the cylinder block bore with an air gun and clean the cylinder block threads and bore with brake
cleaner or isopropyl alcohol and white rags.
IMPORTANT
All threads must be free from oil.
11-40
11. WORK EQUIPMENT
28. Inspect the threads and o-ring seating surface.
IMPORTANT
The chamfer machined surface on the cylinder block must be free of burrs or filings. Remove if necessary.
11-41
11. WORK EQUIPMENT
29. Place a drop of Loctite 243 onto the outer most thread of the cylinder block.
NOTE: Size of the drop should be approximately 1/4 inch.
IMPORTANT
Do not apply Loctite onto the cylinder head threads.
30. Insert the cylinder rod/cylinder head assembly into the cylinder block.
NOTE: Be sure the alignment of the threads is correct to avoid cross threading. (Prior to installation ensure the o-
ring is still lubricated.
11-42
11. WORK EQUIPMENT
31. Tighten the cylinder head/cylinder rod assembly until the cylinder head is completely seated on cylinder block.
32. Push the cylinder rod completely into the cylinder block.
33. Use the removal/installation socket tool and dowel pin to torque the cylinder head.
torque
TORQUE THE CYLINDER HEAD TO 170 FT/LBS ± 10 FT/LBS FOR PROPER REPAIR.
11-43
11. WORK EQUIPMENT
IMPORTANT
Be sure you align the holes of the socket tool with the cylinder head and that the dowel pin is completely seated in
the holes.
34. Repeat the same steps for the other side.
35. Clean all external surfaces of the rear spine frame of any hydraulic oil.
36. Grease the inner surface of the front frame upper and lower carriage bars with high temperature grease.
11-44
11. WORK EQUIPMENT
37. Inspect the presence of all wear pads before re-installing the front frame onto the rear spine.
NOTE: If any pads are loose, apply a small amount of grease onto the back side of the pads to hold them in place
during assembly.
38. Install the front frame onto the rear spine frame using the steps of removal in reverse.
39. Ensure the front frame is properly seated onto the rear spline frame.
11-45
11. WORK EQUIPMENT
40. Install the lower carriage claws onto the front frame lower bar.
NOTE: Apply Loctite 243 to the carriage claw bolts before installation.
torque
The bolts installed should be tightened to about 25 ft/lbs.

41. Install the carriage backrest per manufacturer's instructions.
42. Install the two forks onto the carriage per manufacturer's instructions.
Assembly of unit is now complete.
43. Inform the End User of the following Start Up steps:

a. Do not use the sideshifter for three (3) hours.
b. After 3 hours, slowly push the third function lever to allow cylinder block to fill with oil and push the rod out
of the cylinder block until it contacts the front frame.
c. Repeat this process for the other side.
11-46
11. WORK EQUIPMENT
 SERVICE CYLINDER HEAD

Tool Requirements
• O-ring replacement kit. This kit includes two o-rings, • Cylinder Head removal/installation socket and 3/16
two U-cup seals, and one thread cover. dowel pin.
• Loctite 243 for cylinder head/cylinder block and • 1/2 inch or 3/8 inch drive ratchet.
lower carriage claw bolts. • Torque wrench with minimum torque value of 170 ft/
• 3/4 inch socket. lbs for 1/2 inch socket.
• 8mm Allen socket head wrench. • Oil drain pan.
• Floor dry. • Clean white rags.
• Brake cleaner or isopropyl alcohol. • High temperature grease.
• 90 degree pick tool.
1. Remove the backrest from the carriage per manufacturer's

instructions.
2. Remove forks from the carriage per manufacturer's instructions.
3. Raise carriage on the mast to eye level.
THE CYLINDER RODS ARE UNDER HIGH PRESSURE! TO AVOID INJURY, PERFORM THE FOLLOWING
STEPS TO PUSH THE TWO CYLINDER RODS INTO THE CYLINDER BLOCK.
4. Push the cylinder rods into the cylinder block through the cylinder heads as shown in the following photo.
a. With the truck engine turned off, stand on the right side of the truck and push the third function lever up
while pushing the front frame to the left.
b. Pull the lever down while pulling the frame to the right.
11-47
11. WORK EQUIPMENT
5. Remove the six lower carriage claw bolts from the front frame lower bar and claws with 8mm Allen wrench.
6. Lower carriage to ground level until it stops.
7. Remove the front frame by lifting it out and upwards away from the front of the mast channels.
11-48
11. WORK EQUIPMENT
8. Place the front frame flat down on pallet or blocks to prevent damage to the paint.
9. Check for presence of the wear pads to ensure none were removed during disassembly.
NOTE: Three upper wear pads are to be on top of the cylinder block, two face wear pads on the face of the cylin-
der block and 3 lower wear pads on the face of the lower spine bar. If any are missing, review front frame
to see if they are attached to the front frame inner surface.
10. Place oil drain pan under the lower spine bar directly below one of the cylinder heads.
11. Place a white rag on top of the lower spine bar to reduce oil spill during removal of the cylinder head.
12. Place the cylinder head removal/installation socket onto the cylinder head and align the holes of the socket and
the cylinder head.
11-49
11. WORK EQUIPMENT
13. Insert the dowel pin in the hole ensuring it is seated completely.
14. Use the 3/4 inch socket and cylinder head socket tool to remove the cylinder head from the cylinder block.
15. Let oil drain into the oil pan.

16. Remove the cylinder head assembly from the cylinder block.
11-50
11. WORK EQUIPMENT
IMPORTANT
Be sure not to scratch the cylinder rod on the cylinder block
17. Repeat the steps for the other side.
18. Rest the cylinder rod on a piece of wood and push the cylinder head all the way down the cylinder rod towards
the rounded end and remove the cylinder head from the rod.
19. Use the 90 degree pick tool to remove the o-ring, wiper, and seal from the cylinder head.
Discard the parts after removal.
20. Clean the cylinder head threads with brake cleaner or isopropyl alcohol and a white rag to completely remove
oil film from the cylinder head threads.
21. Place the blank cylinder head on a flat surface and place the black rubber protective sleeve over the threads of
the cylinder head to protect the o-ring from damage during installation.
22. Lubricate the new o-ring and install over the protective sleeve cover.
Be sure not to damage the o-ring.
11-51
11. WORK EQUIPMENT
23. Ensure the new o-ring is completely seated on the cylinder head.
24. Repeat the same steps for the other cylinder head.
25. Place the cylinder head on a flat surface with the threads facing up.
26. Install the seal into the first slot from the threaded side of the cylinder head with the groove in the seal facing
upwards toward the threads.
11-52
11. WORK EQUIPMENT
27. Turn the cylinder head over and ensure the seal is properly seated in the slot.
28. Place the cylinder head on a flat surface with the threads facing downwards.
29. Install the cylinder wiper in the first slot on the cylinder head with the lip facing upwards.
11-53
11. WORK EQUIPMENT
30. Ensure it is completely seated.
31. Lubricate the installed U cup and wiper seal.

32. Install the assembled cylinder heads on the cylinder rods by sliding them over the rounded end of the rods.
IMPORTANT
Do not install the cylinder head over the tapered end of the rod.
11-54
11. WORK EQUIPMENT
33. Remove any paint on the mating surfaces of the cylinder head and cylinder block if necessary, ensuring no
metal is removed in the process.
NOTE: The mating surfaces between the cylinder head and cylinder block must be free from paint build up.
34. Blow out the cylinder block bore with an air gun and clean the cylinder block threads and bore with brake
cleaner or isopropyl alcohol and white rags.
11-55
11. WORK EQUIPMENT
IMPORTANT
All threads must be free from oil.
35. Inspect the threads and o-ring seating surface.
IMPORTANT
The chamfer machined surface on the cylinder block must be free of burrs or filings. Remove if necessary.
11-56
11. WORK EQUIPMENT
36. Place a drop of Loctite 243 onto the outer most thread of the cylinder block.
NOTE: Size of the drop should be approximately ¼ inch.
IMPORTANT
Do not apply Loctite onto the cylinder head threads.
37. Insert the cylinder rod/cylinder head assembly into the cylinder block.
NOTE: Be sure the alignment of the threads is correct to avoid cross threading. (Prior to installation ensure the o-
ring is still lubricated.
11-57
11. WORK EQUIPMENT
38. Tighten the cylinder head/cylinder rod assembly until the cylinder head is completely seated on the cylinder
block.
39. Push the cylinder rod completely into the cylinder block.
40. Use the removal/installation socket tool and dowel pin to torque the cylinder head.
11-58
11. WORK EQUIPMENT
IMPORTANT
Be sure you align the holes of the socket tool with the cylinder head and that the dowel pin is completely seated in
the holes.
torque
Torque the cylinder head to 170 ft/lbs ± 10 ft/lbs for proper repair.
41. Repeat the same steps for the other side.
42. Clean all external surfaces of the rear spine frame of any hydraulic oil.
43. Grease the inner surface of the front frame upper and lower carriage bars with high temperature grease.
11-59
11. WORK EQUIPMENT
44. Inspect the presence of all wear pads before re-installing the front frame onto the rear spine.
NOTE: If any pads are loose, apply a small amount of grease onto the back side of the pads to hold them in place
during assembly.
45. Install the front frame onto the rear spine frame using the steps of removal in reverse.
46. Ensure the front frame is properly seated onto the rear spline frame.
11-60
11. WORK EQUIPMENT
47. Install the lower carriage claws onto the front frame lower bar.
NOTE: Apply Loctite 243 to the carriage claw bolts before installation.
torque
The bolts installed should be tightened to approximately 25 ft/lbs.

48. Install the carriage backrest per manufacturer's instructions.
49. Install the two forks onto the carriage per manufacturer's instructions.
Assembly of unit is now complete.
50. Inform the end user of the following start up steps:

a. Do not use the sideshifter for three (3) hours.
b. After 3 hours, slowly push the third function lever to allow cylinder block to fill with oil and push the rod out
of the cylinder block until it contacts the front frame.
c. Repeat this process for the other side.
11-61
11. WORK EQUIPMENT

11.5.1 CYLINDERS
Replace sliding parts and seal parts according to the following.
Replace when 1/4 circumference for total length of

Bushings
the bush is worn in bronze color.
Replace seal parts with new ones whenever the cyl-
Seal parts
inder is disassembled.
Piston rod Replace when there is a bend of 0.5 mm per meter.
NOTE: The bushing on the cylinder head is press-fit with the cylinder head.
Use “Cylinder head Kit” for parts replacement to replace the bushing.
(Cylinder head Kit: A parts replacement kit where a bushing is press-fit with cylinder head.)
Criteria for oil leakage from rod

Determine by the oil ring condition after cycling 20 times with an oil temperature of 68 - 104° F (20 - 40°C). Take
proper action referring to “Troubleshooting Steering Problems” on page 8-9.

LIFT CYLINDER MAINTENANCE STANDARD
PART NUMBER
11-62
11. WORK EQUIPMENT
Symptom Related parts Possible causes Remedy

• Remove the scratches with an oilstone to smooth the
surface (0.4a or less). If oil leakage still occurs, the
scratches may damage the seal of U-ring. In that case,
Scratches/rust are present disassemble and check the part.
on the sliding surface
• If the scratch or rust cannot be removed with an oilstone,
Piston rod replace the piston rod, seals of U-ring/wiper ring, and
shaft support material of piston rod.
• Apply re-plating or replace the piston rod.
Plating is separated • If seals and/or shaft support material of piston rod are
damaged, replace the defective parts.
Foreign matter is clogged in • Remove the foreign matter.
the gap between piston and
cylinder • Replace the packing if damaged.
Oil contamination at the Scratches on sliding Replace the scratched part.

piston rod sliding portion surfaces
Rod packing • Packing is worn out due
(U-ring) • Replace the packing.
to loss of rubber elasticity
of packing • Before replacing the packing, check whether it reaches
the end of life or overheats partially.
• The lip is missing
• Replace the packing.
Remarkable protrusion of
packing heel • Check the piston seal as excessive pressure may be
affecting the packing.
Foreign matter is clogged in
Remove the foreign matter.
the lip
Wiper ring • The lip is damaged
• Other substantial dam- Replace the defective part.
age is present
The gap from the piston rod Replace the shaft support material.
is out of the allowable range
Shaft support
material Scratches/damage are • Replace the shaft support material.
present on the sliding
surface • Check the piston rod when replacing.
Oil contamination at the
piston rod sliding portion Cylinder head
Cylinder head with • Remove the scratches/rust with an oilstone.
scratches/rust at its seal
position is directly used as • If the scratches/rust still remain, replace the cylinder
piston rod sliding part head.
• Remove the foreign matter.

• Foreign matter is clogged • Replace the O-ring if damaged.
in the gap between pis- • Check the inner surface of tube. Smooth the surface with
O-ring ton and cylinder an oilstone if scratches/rust are present.
• O-ring is damaged • Check the cylinder head O-ring groove. Replace the O-
ring if damaged.
Oil leakage from the cylinder • Disassemble the cylinder head to check the O-ring.
head mating portion Replace the O-ring if damaged.
Cylinder head Loose parts are present. • Then tighten the loose part to the specified tightening
torque. Refer to the tightening torque specified in the
assembly drawings.
• Replace the cylinder tube with a new one.
Cylinder tube Abnormal swelling • Oil leakage from the mating portion may be caused by
excessive pressure. Check the cylinder tube for swelling,
deformation, and for system pressure.
• Replace the piston rod with a new one.
• Piston rod Substantial bend exceeding
• Cylinder tube specified bend distortion • Check the seals and sliding materials for damage.
Replace them if damaged.
• Abnormal operation • Replace the cylinder tube with a new one.

Cylinder tube A bend is present.
• Mechanical parts do not • Check the seals and sliding materials for damage.
move smoothly Remarkable wear/damage • Replace the defective part with a new one.
• Piston rod to sliding surfaces, foreign • Check the seals and sliding materials for damage.
• Cylinder tube matter clogged in the
piston, cylinder head sliding • Remove the foreign matter.
• Sliding materials
portion • Check the seals and sliding materials for damage
11-63
11. WORK EQUIPMENT
Symptom Related parts Possible causes Remedy

Damage such as scratch • Replace the piston seal with a new one.
• Internal oil leakage Piston seal
and wear is present • Check the cylinder tube inner surface for damage.
• Expansion or contraction
while piston rod is working • Remove scratched/rust with a honing or oilstone to
• Specified speed is not Scratches or rust on the smooth the surface. If scratched/rust cannot be
Cylinder tube removed, replace the cylinder tube with a new one.
obtained during operation inner surface
• Replace the piston seal with a new one.
Bleed the air:
• Cylinder with no air bleeder: Bleed the air by reciproca-
tion several times with low pressure and low speed.
• Cylinder with an air bleeder: Remove the load to prevent
Operation is not stable Air Air is remaining in the inner pressure from high temperature, and then loosen
cylinder the air bleeder to bleed air.
The cylinder expands or contracts in some cases when it
stops suddenly. This is due to compression characteristics
of hydraulic oil. This phenomenon is likely to occur with
long-stroke cylinders.
Hydraulic oil expands or contracts with the change of temperature and pressure. Be careful that this is not
internal oil leakage. Be sure to check internal oil leakage under constant temperature and pressure.
11-64
E-MS SERIES LIMITED
12. MASTS
FREE LIFT 2-STAGE

MAST
12. MASTS
INTRODUCTION
Section 1Introduction
1.1
Introduction
This manual provides the installation instruction, periodic
maintenance, troubleshooting and service procedures for
the Komatsu Series masts.
In any communication about the mast, refer to the mast

serial number stamped in the nameplate. If the nameplate
is missing, these numbers are also stamped on the
left side identification plate. See Figure 4a.
WARNING: Do not install a Komatsu Mast on a
truck with a capacity greater than the truck rated
capacities shown below
TRUCK CAPACITY AT 24IN.

(610 mm) LOAD CENTER
EV40 EV50 EV60
ES30 ES40
E40 E50 E60 E65 E50-MS-001
3000 lbs. 4000 lbs. 5000 lbs. 6000 lbs. 6500 lbs.
(1361 kg) (1814 kg) (2268 kg) (2718 kg) (2948 kg)
Mast Serial Number
Stamped Here
Modifications and additions which affect capacity or safe

operation shall not be performed without prior written
approval from Komatsu Forklift per ANSI B56. 1.
1.2
Special Definitions
WARNING
A statement preceded by WARNING is information
that should be acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION
A statement preceded by CAUTION is information that
should be acted upon to prevent machine damage.
IMPORTANT
A statement preceded by IMPORTANT that
possesses special significance.
NOTE
A statement preceded by NOTE is information that is handy MA2808.eps
Figure 4a. Serial Mast Number Location
12-2
12. MASTS
INSTALLATION INSTRUCTIONS
Section 2 Installation Instructions

2.1
Truck System Requirements
To achieve maximum lifting capacity of the mast, the
truck relief valve should be set to relieve at the pressure
indicated in the chart below. This chart also indicates the
hose fitting size to use between the truck control valve
and masts valve.
Valve Inlet Port
3/4 in. SAE O-ring OR
TRUCK SUPPLY REQUIREMENTS
Relief Fitting*
Komatsu Mast Hose Size
Pressure Size
ES/EV/E 13/32 in.
2600 psi No. 8 min.
30/40/50/60/65 Orifice MA1152.eps
* Valve inlet port is 3/4 in. SAE O-ring. See Figure 5a.
WARNING: For proper truck stability or to
prevent interference, tilt restriction may be
Valve Inlet Port
required. Contact Komatsu Forklift. 3/4 in. SAE O-ring
IMPORTANT: Komatsu Masts are compatible with SAE 10W Figure 5a. Valve inlet Port.
petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104
B only. Use of synthetic or aqueous base hydraulic oil is not
recommended. If fire resistant hydraulic oil must be used,
contact Komatsu Forklift.
2.2 Mounting Bracket Truck Cowl

A
B
Installation C
D
If it is 1necessary to install mounting brackets and cross-
members to fit your lift truck, consult with the nearest
Komatsu Forklift dealer. Front View
You must supply dimensions A through F shown in
Figure 5b. Failure to install the correct brackets and cross-
Tilt Cylinders
members can result in mast structural failure, bodily injury
and loss of warranty.
WARNING: Failure to install the correct
brackets and crossmembers can result in
mast structural failure, bodily injury and
loss of warranty. E
Side View
MA0031.eps
Figure 5b. Determining Mounting Bracket Location.
12-3
12. MASTS

2.3
1
Mast Installation
1. Raise and block the front end of the truck 1ft. (30 cm) per
ANSI B56.1 or drive the truck over a service pit.
2. Install the bearings to lower the axle mounts.
3. Lubricate the bearing surfaces of the lower axle and tilt

cylinder mounting brackets with chassis grease.
4. Lift the mast using an overhead hoist with a lifting strap

routed under all the upper crossmembers. Position the mast
onto the axle mounts on the truck axle. Install
4
the mount caps and capscrews. Tighten the capscrews
to the torque specifications.
5. Connect the lift truck hose to the mast valve.
IMPORTANT: Prior to connecting the tilt cylinders to the

mast.Refer to your truck service manual for procedures.
NOTE: Use as few fittings as possible and always use 45o

fittings instead of 90o fittings. Keep the hose lengths to a
minimum. Avoid sharp bends or pinch points when routing
the hose.
6. Connect the tilt cylinders to the mast anchor brackets.

Tighten the pin capscrews to the torque specifications.
Contact Komatsu Forklift if

additional fittings are required.
MA2809.eps
FiFigure 6a. Mast Installation.
12-4
12. MASTS

2.4 Inspection and
Adjustments *3 in. *5 in.
2.4-1 Chain Inspection and Underclearance Underclearance
Tension Outer Upright

and Carriage
The hoist Chains have been factory lubricated using heat and Flush Outer
Upright
pressure to force the lubricant thoroughly into the chain links.
Avoid removal or contamination of this factory applied
Carriage 2 in.
lubricant. Do not wash, sand blast, etch, steam clean, or Below Outer
paint the chains for internal mast installation. Upright
MA2778.eps
The chains must be adjusted with equal tension to ensure *NOTE: Underclearance is based on mast
proper load distribution and mast operation. To determine production series, actual mast
equal tension, extend the unloaded mast to put the chains underclearance may vary by truck model.
under tension. Press the center of a strand of chain with your
thumb, then press at the same place on the other chain of the Figure 7a. Upright and Carriage Position.
pair. Each chain in a pair should have equal “give”. If they
do not have equal tension, preform the hoist chain adjust-
ments described below.
2.4-2 Hoist Chain adjustment

SEE SECTION 5.6-3.
Main Lift
Adjusting
Nuts
2.4-3
Upright Rail Lubrication Figure 7b. Main Lift Chains.
MA2659.eps
Lubricate the full length of each upright rail with chassis lube
or Kendall SR-12X as shown in Figure 7c.
Load Upright
Rollers Channels
2.4-4 Cylinder Bleeding

SEE SECTION 5.2-11.
2.4-5 Mast Skewing MA606.eps
Lubricate only where indicated

by the heavy line for the full
length of each upright.
SEE SECTION 5.5-6.
Figure 7c. Channel lubrication.
12-5
12. MASTS

2.5
Internal Reeving Installation
1. Install carriage hose bracket.
Note: 2. Install the 90o fittings to the carriage bracket. Install the
hoses to the carriage fittings. Leave the fittings loose.
Double Internal Hose Reeving is shown.
Single Internal Hose Reeving can be
installed on either the right or left hand 3. Install the hoses and sheaves to the hoist chain shaft.
Tighten the capscrew to a torque of 65 ft.-lbs. (88 Nm).
side as required.
Washer (part no. CC683794) may be required to add
clearance between the sheave and crossmember.
4. Pull hoses down to the middle crossmember. Attach the

hoses to the bracket fittings. Leave the fittings loose on
the bracket.
5. Pull down on the hoses to remove slack. Attach the

bracket to the front side of the crossmember. See the
bracket and fitting assembly options below. Tighten the
capscrew to a torque of 38 ft.-lbs. (51 Nm).
6. Raise and lower the mast several times to make sure the
hoses are tracking correctly. Use the white lines on the
hoses to detect twisting. Adjust the hose ends if re-
quired. Tighten fittings making sure they do not twist.
Figure 9a.Internal Reeving Installation

MA2810.eps
12-6
12. MASTS
PERIODIC MAINTENANCE
Section 3 Periodic Maintenance

3.1
Periodic Maintenance
For proper operation and an extended service life, your
Komatsu Mast should be inspected and serviced regularly
as part of your normal lift truck maintenance schedule accord-
ing to the following outlines and ANSI B56.1 procedures.
The recommended intervals are for masts operating under
normal conditions. If the mast is operating in severe conditions
or corrosive atmospheres, the inspections should be per-
formed more frequently.
WARNING: Never work on the mast with a load
on the forks or attachment, in the raised position
without supports or while anyone is near the lift
truck control handles per ANSI B56.1
3.1-1 Daily Inspection
Perform the following at the beginning of each work shift:
1. Extend the carriage a few inches off the ground and make
sure the chains are under equal tension. Refer to Section
5.6-3 for chain adjustment.
2. Extend the mast to its fullest height to make sure the mast rails
and carriage extend freely without binding.
3. While the mast is extended, inspect the upright rails for
proper lubrication. Refer to Section 2.4-3 for rail
lubrication.
4. Make sure the internal reeving hoses (if equipped) travel
evenly in the hose guides. Adjust the hose ends if re-
quired. Tighten the fittings making sure they do not twist.
100 Hour Inspection Pry Here

Load Roller
After each 100 hours of lift truck operation, and in addition to
the daily inspection:
1. Inspect and lubricate the full length of the chains with SAE
40 wt. oil or Bowman Heavy Load Red Grease.
CAUTION: The chains must be coated with a film of lubricant X
X
X
at all times.
500 Hour Inspection

.06 in.
the Daily and 100 Hour Inspection: (1.5 mm)
Max.
1. Each pair of load rollers on the uprights and carriage
should be shimmed so that a total side to side clearance
no greater than 1/16 in. (1.5 mm) occurs at the tightest
point throughout the travel of the member. Pry between
the upright and load roller so that the opposite load roller
is tight against the upright. Measure the clearance for the
pair of rollers at XXX shown. See Figure 10a.
MA2645.eps
2. Check the chains for wear and stretch. Refer to Section

Figure 10a. Load Roller Clearances.
5.6-1 for complete chain inspection.
12-7
12. MASTS
TROUBLESHOOTING
Section 4 Troubleshooting
The following table lists problems that may be encountered on your Komatsu Mast, the probable causes and rec-
ommended corrective action that should be taken to restore the mast to normal operating condition.
PROBLEM PROBABLE CAUSE SOLUTION

Cylinders don’t lift load or won’t move
Empty a) Plugged inlet hose a) Unplug hose or replace.
b) Insufficient oil. b) Check the truck hydraulic system for
correct oil level in tank, defective pump or
pump drive, leaks in the lines or
disconnect control valve linkage. Repair
or replace as necessary.
c) Bent or jammed plunger. c) Repair or replace as necessary.
WARNING: Extreme care should be used when working on a unit
when the carriage (with or without a load) is in the raised position.
Loaded a) Plugged piston check valve. a) Unplug check valve or replace.
b) Truck relief valve setting low. b) Raise truck relief setting to specified level.
c) Over capacity. c) Reduce load to specified capacity.
d) Mechanical bind due to bent plunger d) Remove mechanical bind by
or bad rollers. replacing/freeing plunger and rollers.
Cylinders drift- a) External leak in pressure line. a) Tighten or replace as necessary.
b) Truck valve defective-cycle to full b) Repair or replace truck valve.
lift height to verify.
c) External leaks at retainer. c) Replace all cylinder seals.
d) Piston check valve leaking. d) Replace check valve.
Spongy or jerky action- a) Sticky or defective truck relief valve. a) remove and check the truck relief valve. If
contaminated oil caused the malfunction,
drain and flush the system, change the
filter and refill with fresh oil.
b) Bent or damaged cylinder plunger. b) Disassemble, check and repair cylinder
assembly.
c) Load rollers not properly adjusted c) Adjust or repair as necessary.
or defective.
d) Mast channels improperly lubricated. d) Lubricate mast.
e) Low Battery charge. e) Charge battery.
f) Low pump volume. f) Install accumulator.
g) Low oil level. g) Fill oil reservoir.
h) Insufficient hydraulic tank capacity h) Install larger tank baffles
or baffles.
Other. Contact Komatsu Forklift
12-8
12. MASTS
SERVICE
Section 5 Service
5.1
Mast Removal
1. Raise and block the front end of the truck 1ft. (30cm) per ANSI 56.1 or
drive the truck over a service pit.
2. Attach overhead hoist strap as shown in Figure 11a.

Take up slack in the chain.
WARNING: Do not stand on or near the mast

while suspended by the hoist.
3 6
3. Disconnect the tilt cylinders (if applicable) from the
mast anchor brackets.
4. Disconnect the lift truck supply hose from the mast

valve. Plug the hose end and cap the valve fitting.
5. Disconnect the mast lower mounts (if applicable).
6. Lift away the mast.
7. For mast installation, refer to Section 2.3.
WARNING: Do not stand the mast upright

unless it is chained to a support.
MA2811.eps
Figure 11a. Mast Removal
12-9
12. MASTS
Section 5 Service
5.2 Cylinders
5.2-1 Main Lift Cylinder Description Retainer
The main lift cylinders are single stage piston type cylin-
ders. They consist of a shell and a telescoping plunger/
piston assembly. During extension oil pressure is acting
against the full piston area. The truck hoist control valve
holds the cylinder in place once extension has stopped.
The shell is internally threaded at the top end to hold the

retainer. The retainer seals provide a high-pressure
hydraulic seal against the plunger. The retainer also limits
the upward stroke of the plunger.
Plunger / Piston
A piston is attached to the bottom end of the plunger. The Assembly
piston seal provides a high-pressure hydraulic seal against
the shell. A check valve is located in the bottom of the
piston. The check valve allows residual oil between the
shell and plunger to escape when the cylinder is extending.
A hydraulic fuse valve is located in the right hand cylinder inlet

port. In case of a hose failure between the lowering control Shell
valve and cylinders, the fuse limits the lowering speed of the
cylinder. Down stroke cushioning is provided in the main lift
cylinder. This function cushions the piston as the cylinder
nears the fully lowered position.
Check Valve
External Hydraulic Fuse

( RIGHT HAND SIDE ONLY )
MA1178.eps
Figure 13a. Main Lift Cylinder
12-10
12. MASTS
Section 5 Service
5.2-2
Cylinder Operation
Cylinders Raising
1. When the truck hoist control valve is actuated, oil enters
the lowering control valve through the inlet port and
flows unrestricted through the lowering control car-
tridge.
2. Oil flows to the cylinder inlet ports.
3. Oil flows through the hydraulic fuse valve or fitting to the

bottom of the piston. Lifting force is created against the
bottom of the piston causing the plunger to raise. Oil in the
area between the plunger and shell is allowed to
escape through the check valve in the piston as the
plunger raises.
5. When oil flow from the truck hoist control valve is

discontinued, the cylinders are held in position by the
closed center spool of the truck valve.
Main Lift Cylinder Main Lift Cylinder
Cylinders Lowering
1. When the truck hoist control valve is actuated, the main
lift retract fully then the free lift cylinder plunger lowers,
forcing oil out through the hydraulic fuse valve.
Shell
NOTE: The restriction setting of each hydraulic fuse is
higher (allows more oil flow) than the setting of the
lowering control valve. The hydraulic fuses restrict flow
only in the instance of a lowering control valve or hose
failure. Plunger
2. Oil flows to the lowering control valve where it is re-

stricted at a controlled speed determined by the load
being handled.
3. As the main lift cylinder pistons lower over the spear in Piston
the bottom of the shell, a high pressure area is devel-
oped between the piston and shell which engages the Hydraulic Fuse/
Cushion Valve
cushion valve to restrict flow. This slows the piston/
plunger just prior to bottoming providing a smooth
transition to the free lift cylinder lowering.
Lowering
Control Valve
Figure 14a. Cylinder Operation
Inlet Port
To Truck Valve
12-11
12. MASTS
Section 5 Service
5.2-3 Main Lift Cylinder Removal-
Mast on Floor
1. Remove the mast from the truck as described in
Section 5.1
2. Lay the mast down on wooden blocks as shown. Extend

inner rails to expose the lower fittings on the main lift cylinders.
3. Disconnect the cylinder supply hoses from the cylinder

inlet ports. Remove the fittings from the
cylinder ports and install plug fittings.
4. Remove the bolts fastening the cylinder rods to

the intermediate upright. Remove the bolts at the base of the
cylinders that attach the cylinders to the lower outer crossmember.
5. Pull the inner upright outward as required

to allow the main lift cylinders to be removed.
6. Lift the cylinder from the base mount and angle inward
to remove.
7. Note the number of shims (if equipped) on each

cylinder rod.
8. For reassembly, reverse the above procedures except

6 as follows:
WARNING: Main lift cylinders must be bled to

remove trapped air prior to returning the mast
to operation. Refer to Section 5.2-6.
4 6 4
7
3
MA2812.eps
Figure 15a. Cylinder Removal.
12-12
12. MASTS
Section 5 Service
5.2-4 Main Lift Cylinder Service
1. Remove the cylinder from the mast as described in
Section 5.2-3.
2. Use a claw type spanner wrench

2 8 Retainer
to remove the retainer. See Figure 16a.
3. Remove the plunger/piston assembly from the shell.
4. Remove the Hydraulic Fuse or fitting as equipped.
5. Inspect all components for nicks or burrs. Minor nicks

or burrs can be removed with 400 grit emery cloth.
NOTE: Minor nicks are those that will not bypass oil
when under pressure. If they cannot be removed with
emery cloth, replace the part. If the piston requires re-
placing, refer to Section 5.2-5.
6. Replace the retainer and piston seals, back-up rings

O-rings and bearing. Lubricate the new seals with
petroleum jelly prior to installation. Note the correct
3 Plunger / Piston
Assembly
seal directions. The cylinder will not operate correctly

if the seals are installed backwards.
7. When replacing the piston check valve O-ring, make

sure the check valve is reinstalled with the arrow
pointed in the correct direction. Shell
8. Install the plunger retainer on the plunger. Install the

plunger/piston assembly into the cylinder shell.
Tighten the retainer to the torque value listed below
using the claw spanner wrench and a strap wrench.
EV/E-40/50/60 - 180-200 ft.-lbs. (244-271 Nm)
7 Check Valve
4 ( RIGHT HAND SIDE ONLY )
MA0071.eps
Figure 16a. Claw Type Spanner Wrench.
MA1178.eps
Figure 16b. Cylinder Service.
12-13
12. MASTS
Section 5 Service
5.2-5
Piston Removal
1. Remove the plunger/piston assembly from the cylinder
shell as described in Section 5.2-4.
2. Use a strap wrench and 400
grit emery cloth to secure the plunger while turning the
piston with a pin type spanner wrench.
3. Turn the piston until the snap wire end is visible through
the hole. Use a screwdriver to start the wire end out the
hole. Turn the piston to feed the wire out.
4. Pull the piston from the plunger.
as follows:
MA0677.eps
*Install a new snap wire when installing the piston.
5.2-6 Cylinder Bleeding Figure 17a. Piston Removal.
WARNING: The cylinders must be bled to

remove air. Air in the cylinders will compress
on the first extension which could rupture the
cylinders causing serious bodily injury and
property damage.
After repair, the cylinders may have air trapped in them that
must removed. To bleed air refer to Section 5.2-6.
5.3
Valve
5.3-1
Valve Cartridge Service
1. Completely lower the mast.
2. Remove the truck supply hose from the valve car-
tridge. See Figure 40. Plug the hose.
3. Remove the valve cartridge from the valve. Note the
3
stamped part no. on the Cartridge for ordering a
replacement. 2
WARNING: Replacing the valve cartridge with
a different part no. cartridge may cause the
mast to malfunction.
4. For reassembly, reverse the above procedures.
MA2812.eps
Figure 17b. Valve Cartridge Service.
12-14
12. MASTS
Section 5 Service
5.4
Carriage
5.4-1
Description
The carriage shown below is the structure to which hook-type
forks or attachments are attached. The carriage travels
within the rails of the mast inner upright on four (or six
optional) rollers. On a four roller carriage, all four rollers are
shim adjustable , where as only the bottom four rollers on a
six roller carriage are shim adjustable. Carriage rollers are
interchangeable on a four roller carriage. A pair of chain
anchors are used to connect the carriage chains to the carriage.
Carriage Weldment
Shim
Load
Roller
Chain Anchor
Chain Pin
Cotter
Pins
Self-Locking Nut
MA2648.eps
Cotter Pin
IMPORTANT: The chain anchor

nuts must be replaced with new
self-locking nuts and cotter pins if
removed or adjusted.
Figure 18a. Carriage Service.
12-15
12. MASTS
Section 5 Service
5.4-2
Carriage Removal-Mast on Truck
1. Raise the mast high enough to place a 20 in. (50 cm) WARNING: The inner upright
long, 4X4 in. (10 X 10cm) wood block between the must be supported by angle iron
inner lower crossmember and the ground.
to avoid possible injury.
2. Attach an overhead hoist to the carriage. Raise the
carriage to slacken the carriage chains. WARNING: The carriage must
3. Remove the chain anchor nuts and cotter pins. be supported by a block to
avoid possible injury.
Note: Nuts and cotter pins must be replaced
with new nuts and cotter pins after removal.
4. Disconnect the internal reeving hoses from the

carriage fittings (if equipped). Plug the hose ends.
5. Using the overhead hoist, lower the carriage to the

bottom of the mast to remove.
6. Note the number of shims behind each load roller for

reassembly.

as follows:
*inspect the carriage as described in Section 5.4-4.
*Lubricate the inner upright rails with chassis lube or 2

Kendall SR-12X.
See Figure 19a.
*Assemble shims and load rollers on the stub shafts.

The shims should be installed ( none on top rollers
of a six roller carriage) to provide a total side to side
clearance no looser than 1/16 in. (1.5 mm) at the
tightest point throughout the travel of the carraige.
Use an equal amount of shims side to side.
2
*Install chain anchors to carriage using new self-locking
nuts and ensuring cotter pins are installed in the bottom
hole of each chain anchor.
Load Upright
Rollers Channels
3
5
1
MA606.eps MA2814.eps

length of each upright. Some components are not shown for clarity.
Figure 19a.Rail Lubrication. Figure 19b. Carriage Service.
12-16
12. MASTS
Section 5 Service
5.4-3 Carriage Removal - Mast on Floor
1. Remove mast from truck as described in Section 5.1.
2. Remove chain anchor nuts and cotter pins. Note: Install new self-locking
chain anchor nuts and cotter pins during reassembly. Remove the chain
anchors. 5
3. Disconnect the internal reeving hoses for the carriage
fittings (if equipped). Plug the hose ends.
4. Roll the carriage to the bottom of the mast.
5. Attach an overhead hoist to the carriage fork bars.

5
Remove the carriage through the bottom of the mast.
6. Note the number of shims located behind each load

roller for reassembly.
MA2815.eps
Figure 20a. Mast On Floor.
2
SOME COMPONENTS ARE NOT SHOWN FOR CLARITY.
Load Upright
Rollers Channels
7. For Reassembly, reverse the above procedures except
as follows:
*Lubricate the inner upright rails with chassis lube or
Kendall SR-12X . See Figure 20b.
*Assemble shims and load rollers on the carriage stub
shafts. The shims should be installed to provide a
total side to side clearance no looser than 1/16 in.
(1.5 mm) at the tightest point throughout the travel of
the carriage. Use an equal amount of shims side to
side. MA606.eps
*Install new self-locking nuts and cotter pins on carriage chain anchors
if nuts are remove or adjusted.
*Check and adjust the main lift chains as described in length of each upright.
Section 5.6-3.
Figure 20b.Rail Lubrication.
12-17
12. MASTS
Section 5 Service
5.4-4
Carriage Inspection
1. Inspect the rollers for excessive wear or damage.
Rollers with visible flat spots or cracks should be re-
placed.
2. Inspect the roller bearings by turning the rollers on their
shafts. Rollers with roughness or noticeable restrictions
to turning should be replaced.
3. Inspect all welds between the carriage side plates and
the carriage fork bars. If any welds are cracked,
replace the carriage.
4. Inspect the roller stub shafts. If they are damaged or if
there are cracks at the base of the stub shafts, the
carriage must be replaced or repaired. Contact
Komatsu Forklift for repair procedures.
Carriage Weldment
Shim
Load
Roller
Chain Anchor
Chain Pin
Cotter
Pins
Self-Locking Nut
MA2648.eps
Cotter Pin
Figure 21a. Carriage Service.

self-locking nuts and cotter pins if
removed or adjusted.
12-18
12. MASTS
Section 5 Service
5.5
Mast Uprights
5.5-1 Upright Description
Outer Upright Assembly
The outer upright assembly is mounted to the truck. A pair
of shim adjustable load rollers are attached to stub shafts Wear Plug
Cylinder
Shim Chain Anchor
located near the top of the upright. A pair of adjustable and Shim
hoist chain anchors are located on the top of each rail. A
pair of shim adjustable wear plugs are located near the top
of the outer. The main lift cylinder are secured to the outer
by retaining bolts located near bottom of the outer.
Inner Upright Assembly

Chain
The inner upright assembly Sheave
telescopes within the outer
upright assembly.
A pair of shim adjustable load
rollers are attached to stub shafts
located at the bottom of the
upright.
Cylinder Retainer
Bolt
Cylinder Retainer
MA2816.eps
Capscrew
Shims
Load Rollers
Figure 22a. Mast Uprights .
12-19
12. MASTS
Section 5 Service
5.5-2
Upright Operation Inner
Upright
Outer
Upright
Fully Lowered
Chain Sheaves
The hoist chains are anchored to the outer upright top Main Lift
Chains
crossmember. The chains travel over the inner upright Main Lift
chain sheaves and attach to the carriage anchors. Cylinders
Extension Carriage
Activating the truck hoist valve causes the hoist cylinders

to extend the inner upright. The extension of the upright
causes the chains to raise the carriage.
MA2653.eps
Lowering of the mast is a reversal of extension.
Figure 23a. Uprights Operation.
12-20
12. MASTS
Section 5 Service
5.5-3
Upright Disassembly
NOTE Remove the internal hose reeving sheave and
hoses (if equipped) prior to mast removal.
1. Remove the mast assembly from the truck as
de scribed in Section 5.1.
2. Remove the main lift cylinders from the mast as
described in Section 5.2-3.
3. Remove the pins fastening the main 8
lift chains to the carriage
chain anchors. Remove the carriage
from the mast as described in
Section 5.4-3.
CAUTION: The chain anchor nuts and

cotter pins should be used one time only
and be replaced after removal. 8
MA2817.eps
Figure 24a. Uprights Disassembly.
7
5. Pull the main lift

chains back through the chain
sheaves.
6. Remove the main lift chain sheaves.
7. Roll the inner upright downward to expose the inner
and outer upright load rollers. Remove the load
rollers. Note the number of shims behind each load
roller.
8. Attach an overhead hoist to the inner upright. Remove
the inner upright through the top of the outer
upright.
12-21
12. MASTS
Section 5 Service
5.5-4 Upright Inspection 4
1. Inspect the load rollers for excessive wear or damage.
Rollers with visible flat spots or cracks should be
replaced. See Figure 25a.
2. Inspect the load roller bearings by turning the rollers on

their shafts. Rollers with roughness or noticeable 1
restrictions to turning should be replaced. MA1192.eps
3. Inspect the load roller stub shafts. If they are damaged

or have cracks at the base, the upright mast must be re-
placed or repaired.
4. Inspect the outer upright thrust plugs.

If the wear surface is worn to less than 1/16 in. (1.5 mm),
they should be replaced.
Figure 25a. Wear Plug - bearing Inspec-
5. Inspect the hoist chains as described in Section
tion.
5.6-1.
12-22
12. MASTS
Section 5 Service
5.5-5
Uprights Reassembly Upright
Rail
1. Lubricate the outer upright rails with chassis lube or
Kendall SR-12X. See Figure 26a Rail Lubrication.
2. Attach an overhead hoist to the inner upright.
Install the inner uptight through the top of the
outer upright and through the outer upright to
expose the load roller shafts below the outer.
3. Install the thrust plugs to the outer uprights.
4. Assemble shims and load rollers to the outer upright
1
and lower inner upright stub shafts. The shims
should be installed to provide a total side to side
tightest point throughout the travel in the upright. Use MA0629.eps
an equal amount of shims side to side. NOTE: Roll
the upright past the thrust plugs before checking roller
clearances.
5. Lubricate the inner upright rails with chassis Lubricate only where indicated
lube or Kendall SR-12X. See Figure 26a. by the heavy lines for the full
length of each upright
2 Figure 26a. Rail Lubrication.
4
Outer
Upright
Inner
Upright
MA2818.eps
4
3 Figure 26b. Upright Reassembly.
4 SOME COMPONENTS ARE NOT SHOWN FOR CLARITY.
12-23
12. MASTS
Section 5 Service
5.5-6
Uprights Reassembly - Continued
6. Install the main lift chain anchors (long anchors) and chains to the
outer upright crossmember.
7. Install the carriage as described in Section 5.4-2 and 5.4-3.
8. Install the main lift cylinders as described in Section 5.2-3.
9. Install the mast to the truck as described in Section 2.4.
10. Adjust the main lift chains as described in Sections 5.6-3 . Check
for mast skewing as described in Section 5.5-6.
11. Install the internal reeving sheave and hoses (if equipped) as
described in Section 2.5.
12-24
12. MASTS
Section 5 Service
5.5-7
Mast Skewing WARNING: The inner upright must be
1. Extend the mast to the full lift height. supported to avoid possible injury.
*If the mast kicks to the right at full extension, a shim

(part no. 200524) needs to be installed to the right
hand main lift cylinder rod.
*If the mast kicks to the left at full extension, a shim

(part no. 200524) needs to be installed to the left
2. Place a 4 X 4 X 20 in. (10 X 10 X 50 cm) wood block

between the upper inner and the upper outer
crossmembers. Lower the mast onto the block.
3. Remove the bolt from the cylinder to be adjusted.

Open the truck valve to allow the center (free lift)
cylinder to fully retract. Tap the main lift cylinder rod
down past the cylinder mount to install the shim.
4. Slowly hydraulically power the main lift cylinder back

into the cylinder mount and reinstall the bolt.
5. Repeat steps 3 through 4 until skewing is removed.
Right Hand
Bolt Left Hand
Main Lift
Main Lift
Cylinder
Cylinder
Shim
Main Lift Cylinder
MA2819.eps
MA2657.eps
Figure 28a.Shim Installation. Figure 28b.Extended Upright.
12-25
12. MASTS
Section 5 Service
5.6
Chains
5.6-1 Inspection and Tension
Each pair of chains has been factory-lubricated using heat
and pressure to force the lubricant thoroughly into the chain
links. Avoid removal or contamination of this factory Cracked Side Plates
applied lubricant. Do not wash, sand blast, etch, steam
clean, or paint the chains on initial mast installation.
The chains must be adjusted with equal tension to ensure

proper load distribution and mast operation. To determine
equal tension, extend the unloaded mast to put the chains
under tension. Press the center of a strand of chain with
your thumb, then press at the same place on the other
chain of the pair. Each chain in a pair should have equal
“give”. If tension is not equal, adjust the chains as de-
scribed in Chain Adjustment.
Inspect the chains. If inspection reveals that one strand of

a pair of chains requires replacement, both strands of the Tight Pin Joints
pair should be replaced.
*Check for rust and corrosion.
*Check for cracked side plates. If you find cracked side

plates, replace both strands of chain.
*Check for tight joints. If tight joints are caused by rust or

corrosion, loosen them with SAE 40 wt. oil or penetrating
oil. If they cannot be loosened, or if the tight joints are
caused by bent pins or plates or by peened plate edge,
replace both strands of the chain. Peened Plate Edges
*Check for protruding or turned pins. Replace both

strands of the chain.
*Check for chain side wear. If pins and outside plates

show signs of wear, check for misalignment os sheaves,
anchors or other components. Correct the misalignment.
If wear is excessive, replace both strands of chain.
*Check for worn, broken or misaligned chain anchors. Protruding Pins

Replace or adjust as required.
*Lubricate the full length of the chains with SAE 40 wt. oil
or Bowman Heavy Load Red Grease.
MA0633.eps
Turned Pins
Figure 29a.Chain Inspection.
12-26
12. MASTS
Section 5 Service
5.6-2
Measuring Chain Stretch
A
A
Regular inspection and lubrication of the chains will
increase their service life and reduce downtime.
Chain
If the chains stretch beyond the recommended amount, Wear
they should be replaced in pairs. Chain stretch can be Scale
measured with chain wear scale. Measure
the chains according to the instructions printed on the chain
wear scale, without a load on the carriage.
*To check the free lift chains, raise the carriage 1 ft.
(30 cm) off the ground to put tension on the chains.
*To check the main lift chains, raise the mast until the inner
upright starts to extend putting tension on the chains.
A
A
MA0634.eps
New Chain Stretched Chain

5.6-3 Main Lift Chain Adjustment Figure 30a.Measuring Chain Stretch.
The main lift chains should be adjusted so that when the
unloaded mast is fully lowered, the uprights are positioned *3 in. *5 in.
Underclearance Underclearance
as shown in figure 30b.
1. Adjust one chain to achieve the correct upright position

when fully lowered. See Figure 30b. Outer Upright
and Carriage
Flush Outer
2. Adjust the other chain to achieve equal chain tension. Upright
Tighten the nuts together to a torque of 50-70 ft.-lbs.
(98-96 Nm).
Carriage 2 in.
3. Raise and lower the mast several times to confirm the Below Outer
Upright
adjustments. MA2778.eps
*NOTE: Underclearance is based on mast

production series, actual mast
underclearance may vary by truck model.
Figure 30b.Upright and Carriage Position.
Main Lift
Adjusting
Nuts
MA2659.eps
Figure 30c.Main Lift Chains.
12-27
12. MASTS
Section 5 Service
5.6-4 Main Lift Chain Service
WARNING: The inner upright must be

supported avoid possible injury.
1. Raise the inner upright 3 ft. (90 cm). Place a 3 ft. (90
cm) block under the inner rail chanrel, then lower the
inner rail channel onto the block. The main lift chains
should be slack.
2. Remove the cotter pins and chain pins from the chain
anchors. Remove the chains.
3. Inspect the chain anchors for cracks. Replace as

required.
4. For reassembly, reverse the above procedures. Adjust

the chains as described in Section 5.6-3.
MA2658.eps
Figure 31a.Main Chains.
12-28
E-MD SERIES FULL
FREE LIFT 2-STAGE
MAST
12. MASTS
INTRODUCTION
Section 1 Introduction
1.1
Introduction
the Komatsu E-Series roller masts. E50-MD-001

is missing, these numbers are also stamped on a Mast Serial Number
Stamped Here
plate on the left-hand side of the mast. See Figure 1.
WARNING: Do not install a Komatsu Mast

on a truck with a capacity greater than the
truck rated capacities shown below
EV40 EV50 EV60
ES30 ES40
E40 E50 E60 E65
(1361 kg) (1814 kg) (2268 kg) (2718 kg) (2948 kg)

operation shall not be performed without prior written
1.2
Special Definitions
WARNING
CAUTION
IMPORTANT
A statement preceded by IMPORTANT is information that
NOTE
A statement preceded by NOTE is information that is handy
to know and may make your job easier.
MA2823.eps
Figure 1. Mast Serial Number Location
12-30
12. MASTS

2.1
Truck System
Requirements
and masts valve.
Valve Inlet Port
TRUCK SUPPLY REQUIREMENTS 3/4 in. SAE O-ring OR
Relief Fitting*
Pressure Size
ES/EV/E 13/32 in.
2600 psi No. 8 min.
30/40/50/60/65 Orifice
MA1152.eps
* Valve inlet port is 3/4 in. SAE O-ring. See Figure 2.

required. Contact Komatsu Forklift.
Valve Inlet Port
3/4 in. SAE O-ring
IMPORTANT: Komatsu Masts are compatible with SAE 10W
petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104 FigFigure 2. Valve inlet Port.

A
Installation B
C
1 If it is necessary to install mounting brackets and cross- D
Komatsu dealer.
Front View
Figure 3. Failure to install the correct brackets and cross-
members can result in mast structural failure, bodily injury Tilt Cylinders
loss of warranty. E
Side View
MA0031.eps
Figure 3. Determining Mounting Bracket Location.
12-31
12. MASTS

2.3
Mast Installation
1
The following instructions and illustrations are typical
for most trucks. If your truck does not match,
4
2. Install the bearings to the lower the axle mounts.
3. Lubricate the bearing surfaces of lower axle and tilt cylinder

mounting brackets with chassis grease.

attached under all of the upper crossmembers. Position the
mast by lowering the axle mounts onto the truck axle. Install
the mounting caps and capscrews. Tighten the capscrews to
the truck torque specifications.
IMPORTANT: Prior to connecting the tilt cylinders to

the mast, make sure the cylinders “bottom” evenly.
Adjust the tilt cylinders to prevent the mast from
“racking” during tilting. Refer to your truck service
manual for procedures.
6. Connect the tilt cylinders to the mast anchor brackets. Tighten

the pin capscrews to the truck torque specifications.
NOTE: Use as few fittings as possible and always

use 45o fittings instead of 90o fittings. Keep the hose
lengths to a minimum. Avoid sharp bends or pinch
points when routing the hose.

MA2824.eps
FiFigure 4. Mast Installation.
12-32
12. MASTS

2.4
Inspection and
Adjustments
2.4-1 Chain Inspection and Tension
*3 in. *5 in.
The hoist Chains have been factory lubricated using heat and
pressure to force the lubricant thoroughly into the chain links.
Avoid removal or contamination of this factory applied Outer Upright
and Carriage
lubricant. Do not wash, sand blast, etch, steam clean, or Flush Outer
paint the chains for internal mast installation. Upright
The chains must be adjusted with equal tension to ensure Carriage 2 in.
Below Outer
proper load distribution and mast operation. To determine Upright
equal tension, extend the unloaded mast to put the chains MA2778.eps
under tension. Press the center of a strand of chain with your *NOTE: Underclearance is based on mast
thumb, then press at the same place on the other chain of the production series, actual mast
pair. Each chain in a pair should have equal “give”. If they underclearance may vary by truck model.
ments described in Sections 5.6-3 and 5.6-4. Figure 5. Upright and Carriage Position.
Free Lift
MA1155.eps Adjusting
Nuts
Figure 6. Free Lift Chains.
12-33
12. MASTS

2.4-5 Upright Rail Lubrication
Upright
Lubricate the full length of each upright rail with chassis lube Rails
or Kendall SR-12X as shown in Figure 7.

remove air. Air in the cylinders will compress on
the first extension which could rupture the
property damage.
When new or after repair, the cylinders may have air trapped MA0389.ill
in them that must be removed. To bleed air do the following:
LUBRICATE ONLY WHERE INDICATED
1. Without a load extend the free lift cylinder and continue to BY THE HEAVY LINE FOR THE FULL
LENGTH OF EACH UPRIGHT
extend the main lift cylinders to 90% of full stroke. Retract all
cylinders completely. Repeat three times. Figure 7. Channel lubrication.
2. Extend the cylinders without a load at 50% full engine speed

then build full system pressure at the end of the main lift
cylinder stroke. Electric trucks limit the control valve move-
ment to achieve 50% speed. Retract all cylinders. Repeat
four times.
3. Cycle the mast with a half load (50% mast rated capacity)
through full cylinder extension several times. The cylinders
should extend smoothly. Repeat the steps if cylinder exten-
sion is not smooth.
2.4-7 Mast Skewing

Check for mast skewing as described in Section 5.5-6.
12-34
12. MASTS

2.5
Single Function Internal Reeving
Installation
1. Install fittings and caps to the carriage termination bracket and install bracket to carriage as shown.
2. Assemble crosshead components as shown.
MA2834.eps
1
Figure 8. Crosshead and Carriage IHR assembly.
12-35
12. MASTS

2.5
Installation (Continued)
3. Install inner guide bracket on middle inner crossmember.
4. Install one clamp piece on upper clamp of the inner guide bracket as shown.
5. Install lower clamp piece on inner guide as shown.
Figure 9. Inner IHR brackets.

MA2835.eps
12-36
12. MASTS

2.5
6. Install the outer guide bracket as shown. Do not tighten upper clamp.
7. Install the outer clamp to the outer cylinder support as shown.
8. Install the middle outer termination bracket to the outer middle crossmember as shown.
9. Install lower truck supply line bracket as shown.
6
8
MA2836.eps
Figure 10. Outer IHR components.
12-37
12. MASTS

2.5
9. Attach hoses to fittings on carriage termination bracket.
10. Route hoses over crosshead and down over the middle
crossmember.
MA2837.eps
Figure 11. Hose Routing Front View.
12-38
12. MASTS

2.5
11. Route hoses through clamp piece on top inner
guidebracket and install second clamp piece, coverplate
and bolts loosely.
12. Pull hoses to proper tension and tighten clamp bolt.
13. Route hoses to lower clamp bracket on inner guide and

tighten clamp bolt.
14. Route hoses up to the outer guide bracket with gentle

loop making sure that the hose is positioned between the
top hose clamp peice and the guide tray.
15. Route hoses through clamp piece on upper outer bracket

and install second clamp piece.
16. Pull hoses to proper tension and tighten clamp bolts.
17. Tighten the outer guide bracket clamps.
18. Install hose ends to the middle outer termination bracket.
19. Check hose clearances and twist. Make any nessecary

adjustment and tighten hose ends.
20. Route truck IHR supply hoses through lower outer

bracket and attach to mast IHR hoses.
hoses are tracking correctly in the guides. Check for any
hose twist and adjust as required.
MA2838.eps
Figure 12. Hose Routing Rear View.
12-39
12. MASTS

2.5
Double Function Internal Reeving
Installation
1. Install fittings and caps to the carriage termination bracket and install bracket on carriage as shown.
2. Assemble crosshead sheaves and new guards as shown.
8 2
9 5
MA2839.eps
Figure 13. Crosshead Assembly.

1
12-40
12. MASTS

2.5
3. Install inner guide bracket on middle inner crossmember.
4. Install one clamp piece on each of the upper clamps of the inner guide bracket as shown.
5. Install lower clamp pieces on inner guide as shown.
6. Install the outer guide bracket as shown. Do not tighten upper clamps.
7. Install the outer clamps to the outer cylinder support as shown.
8. Install the middle outer termination brackets to the outer middle crossmemeber as shown.
9. Install lower truck supply line brackets as shown.
12-41
12. MASTS

2.5
10. Route hoses over crosshead and down over the middle
crossmember.
11. Route hoses through clamp piece on top inner guidebracket

and install second clamp pieces, coverplates and bolts
loosely.
13. Route hoses to lower clamp brackets on inner guide and

tighten clamps.
14. Route hoses up to the outer guide brackets with gentle loop
making sure that the hoses are positioned between the top
hose clamp peices and the guide trays.
MA2840.eps
Figure 14. Hose Routing Front View.
12-42
12. MASTS

2.5
15. Route hoses through clamp pieces on upper outer
brackets and install second clamp pieces.
17. Tighten the outer guide bracket clamps.
18. Install hose ends to the middle outer termination brackets.
19. Check hose clearances and twist. Make any nessecary

adjustment and tighten hose ends.
20. Route truck IHR supply hoses through lower outer

bracket and attach to mast IHR hoses.
hoses are tracking correctly in the guides. Check for any
hose twist and adjust as required.
Figure 15. Hose Routing Rear View.
12-43
12. MASTS

3.1
For proper operation and an extended service life, your
Komatsu mast should be inspected and serviced regularly
5.6-3 and 5.6-4 for chain adjustment.
proper lubrication. Refer to Section 2.4-5 for rail
lubrication.
evenly and for twisting . Adjust the hose ends to remove twist, if re-
Pry Here
Load Roller
100 Hour Inspection
the daily inspection:
1. Inspect and lubricate the full length of the chains with SAE X
40 wt. oil or Bowman Heavy Load Red Grease. X

X
CAUTION: The chains must be coated with a film of lubricant

at all times.
500 Hour Inspection

After each 500 hours of lift truck operation, and in addition to .06 in.
the Daily and 100 Hour Inspection: (1.5 mm)
1. Each pair of load rollers on the uprights and carriage Max.
pair of rollers at XXX shown. See Figure 16.
2. Check the chains for wear and stretch. Refer to Section MA2669.eps
5.6-1 for complete chain inspection.

Figure 16. Load Roller Clearances.
12-44
12. MASTS
TROUBLESHOOTING
The following table lis is problems that may be encountered on your Komatsu Mast, the probable causes and rec-
Cylinders don’t lift load or won't move
assembly.
or defective.
or baffles.
12-45
12. MASTS
SERVICE
Section 5 Service
5.1
Mast Removal

3 6
WARNING: Do not stand on or near the mast
3. Attach overhead hoist strap as shown in Figure 17.



MA2825.eps
Figure 17. Mast Removal
12-46
12. MASTS
Section 5 Service
Left Hand Cyliner
Right Hand Cyliner
5.2
Cylinders
5.2-1 Main Lift Cylinder Description Retainer
ders. They consist of a shell and a telescoping plunger/

retainer. The retainer seals provide a high-pressure Shell
the upward stroke of the plunger.
A piston is attached to the bottom end of the plunger. The

shell and plunger to escape when the cylinder is extending.

port. In case of a hose failure between the lowering control Piston/Plunger
valve and cylinders, the fuse limits the lowering speed of the Assembly
MA2671.eps
Figure 18. Mainlift Cylinder
12-47
12. MASTS
Section 5 Service
5.2-2
Free Lift Cylinder Description
The free lift cylinder is a single stage piston type cylinders.

It consists of a shell and a plunger/piston assembly.
During extension the oil pressure is acting
Retainer
The shell is internally threaded at the top end to hold the re-
tainer. The retainer seal provide a high-pressure hydraulic
seal against the plunger. The retainer also limits the upward
stroke of the plunger.
A piston is attached to the bottom end of the plunger. The

the shell. A check valve is located in the bottom on the pis-
ton. The check valve allows residual oil between the shell
Shell
and plunger to escape when the cylinder is extending.
Upstroke cushioning is provided in the free lift cylinder. This
cushions the cylinder when the cylinder nears the fully
extended position. Piston/Plunger
Assembly
A hydraulic fuse/cushion valve is located in the cylinder port.
In case of a hose failure between the lowering control valve
and cylinder, the fuse limits the lowering speed of the cylin-
der.
Check Valve
(free flow in
Hydraulic Fuse direction of arrow)
Assembly
MA2672.eps
Figure 19. Free Lift Cylinder
12-48
12. MASTS
Section 5 Service
5.2-4 Cylinder Operation
Cylinders Raising Cylinders Lowering
1. When the truck hoist control valve is actuated, oil 1. When the truck hoist control valve is actuated,
enters the lowering control valve through the inlet the main lift retract fully then the free lift cylinder
port and flows unrestricted through the lowering plunger lowers, forcing oil out through the
control cartridge. hydraulic fuse valve.
NOTE: The restriction setting of each hydraulic
2. Oil flows to the cylinder inlet ports. Due to the larger
fuse is higher (allows more oil flow) than the
bore diameter of the free lift cylinder compared to
setting of the lowering control valve. The hydrau-
both main lift cylinders, the free lift cylinder will raise
lic fuses restrict flow only in the instance of a
completely before the main lift cylinders raise.
lowering control valve or hose failure
3. Oil flows through the free lift cylinder hydraulic fuse 2. Oil flows to the lowering control valve where it is
valve to the bottom of the piston. Lifting force restricted at a controlled speed determined by
is created against the bottom of the piston causing the load being handled.
the plunger to raise. Oil in the area between the
plunger and shell is allowed to escape through the 3. As the main lift cylinder pistons lower over the
check valve in the piston as the plunger raises to the spear in the bottom of the shell, a high pressure
end of its stroke. area is devel oped between the piston and shell
which engages the cushion valve to restrict flow.
4. Oil flows through the hydraulic fuse valve or fitting to This slows the piston/plunger just prior to
the bottom of the piston. Lifting force is created bottoming providing a smooth transition to the
against the bottom of the piston causing the plunger free lift cylinder lowering.
to raise. Oil in the area between the plunger and Main Lift Cylinder Main Lift Cylinder
shell is allowed to escape through the check valve in Hose
the piston as the plunger raises.

Tube
Free Lift Cylinder

discontinued, the cylinders are held in position by Shell
theclosed center spool of the truck valve. Shell
Plunger
Plunger
Ckeck
Valve
Piston
Piston
Hydraulic Fuse/
Cushion Valve
Lowering
Control Valve
Inlet Port
Figure 20. Cylinder Operation
To Truck Valve
12-49
12. MASTS
Section 5 Service
Mast on Floor
1. Remove the mast from the truck as described in Section 5.1
2. Lay the mast down on wooden blocks as shown. Extend inner
rails to expose the lower fittings on the main lift cylinders.
3. Disconnect the cylinder supply hoses from the cylinder inlet
ports. Remove the fittings from the cylinder ports and install
plug fittings.
4. Remove the bolts fastening the cylinder rods to the inner
upright. Remove the bolts at the base of the cylinders that
attach the cylinders to the lower outer crossmember.
5. Pull the inner upright outward as required to allow the main lift
cylinders to be removed.
6. Lift the cylinder from the base mount and angle inward to
remove.
7. Note the number of shims (if equipped) on each cylinder rod.
8. For reassembly, reverse the above procedures except as
6 follows:

4 2
3
MA2673.eps
4
Figure 21. Cylinder Removal.
12-50
12. MASTS
Section 5 Service
5.2-6 Free Lift Cylinder Removal-
Mast on Floor
Section 5.1.
2. Lay the mast down as shown.
3. Roll the carriage toward the center of the cylinder to
slacken the chains and internal reeving hoses (if
equipped).
4. Disconnect the hose from the cylinder 45o fitting. Cap
the fitting and plug the hose.
5. Remove the chain guards from the crosshead. For
reassembly, tighten the capscrews to a torque of 48-52
ft.-lbs. (65-70 Nm).
6. Remove the snap ring fastening the crosshead to the
cylinder rod.
7. Pull the crosshead with chains and hoses (if equipped)
off the cylinder rod.
8. Remove the cylinder mounting bolts the keeping shims for reassembly.
9. Remove the cylinder from the mast.
10. For reassembly, reverse the above procedures. nuts on the carriage must be
replaced with new self-locking
nuts if removed or adjusted.
4
6
MA2674.eps
5 Figure 22. Cylinder Removal.
12-51
12. MASTS
Section 5 Service
Mast on Truck
1. Completely lower the carriage. Remove forks or
attachment if equipped. Make sure the free lift cylinder
is completely retracted. Attach an overhead hoist to
the top carriage bar.
WARNING: The carriage must be supported
by a block while removing the cylinder to
2. Raise the carriage to the center of the cylinder to
equipped). Block the carriage in place using a 4 X 4 X
24 in. (10 X 10 X 60 cm) wood block between the lower
carriage bar and the floor.
1
ft.-lbs. (65-70 Nm).

cylinder rod. 4
5. A. Pull the crosshead with chains and hoses
(if equipped) off the cylinder rod and lay
over upper carriage bar.
5 6
B. Remove cylinder mounting bolts, keeping
the shims for reassembly.
6. Pry the cylinder up out of the support casting to gain

access to the cylinder hose fitting. Remove the hose
from the 45o fitting. Cap the fitting and plug the hose.
2
7. Remove the cylinder from the mast from the top.
8. For reassembly, reverse the above procedures. 3 2

7
MA2826.eps
12-52
12. MASTS
Section 5 Service
Left Hand Cyliner

Section 5.2-5. Right Hand Cyliner
2. Use a claw type spanner wrench to remove the

retainer. See Figure 24.
5. Inspect all components for nicks or burrs. Minor nicks 2 8 Retainer

emery cloth, replace the part. If the piston requires
replacing, refer to Section 5.2-10.

Shell
seal directions. The cylinder will not operate cor-
rectly if the seals are installed backwards.

3 Piston/Plunger
Assembly
EV/E-40/50/60 - 180-200 ft.-lbs. (244-271 Nm)
4
MA0071.eps
Figure 24. Claw Type Spanner Wrench..
MA2676.eps
Figure 25. Cylinder Service.
12-53
12. MASTS
Section 5 Service
5.2-9 Free Lift Cylinder Service
1. Remove the cylinder from the mast as described in Section 5.2-6

or 5.2-7.
2. Use a claw type spanner wrench to remove the retainer. See

Figure 26.
4. Remove the hydraulic fuse.
5. Inspect all components for nicks or burrs. Minor nicks or burrs can
be removed with 400 grit emery cloth. NOTE: Minor nicks are
2 8
Retainer
those that will not bypass oil when under pressure. If they cannot
be removed with emery cloth, replace the part. If the piston
requires replacing, refer to Section 5.2-10.
6. Replace the retainer and piston seals, back-up rings, O-rings and
bearing. Lubricate the new seals with petroleum jelly prior to
installation. Note the correct seal directions. The cylinder will
not operate correctly if the seals are installed backwards. Shell
7. When replacing the piston check valve O-ring, make sure the
3
Piston/Plunger
check valve is reinstalled with the arrow pointed in the correct Assembly
direction.
8. Install the plunger retainer on the plunger. Install the plunger/

piston assembly into the cylinder shell. Pour 25 - 30cc hydraulic
oil into the cylinder cavity between the shell and rod. Tighten the
retainer to a torque of 280-300 ft.-lbs. (380-407 Nm) using the
claw spanner wrench and a strap wrench.
Check Valve
4 (free flow in
direction of arrow)
Hydraulic Fuse
MA0071.eps Assembly
MA2672.eps
12-54
12. MASTS
Section 5 Service
5.2-10
Piston Removal
1. Remove the plunger/piston assembly from the cylinder
shell as described in Section 5.2-8 or 5.2-9.
2. Use a strap wrench and 400 grit emery cloth to secure
the plunger while turning the piston with a pin type
spanner wrench.
3. Turn the piston until the snap wire end is visible through
as follows: MA0677.eps

Figure 28. Piston Removal.
property damage.
1
3
5.3
Valve 2
5.3-1 Valve Cartridge Service
2. Remove the truck supply hose from the valve cartridge. See
Figure 29. Plug the hose.
3. Remove the valve cartridge from the valve. Note the stamped part
no. on the Cartridge for ordering a replacement.

mast to malfunction. MA2827.eps

Figure 29. Valve Cartridge Service.
Typical Illustration
12-55
12. MASTS
Section 5 Service
5.4
Carriage
5.4-1 Description

optional) rollers. On a four roller carriage, all four rollers
are shim adjustable, whereas only the bottom four on a
six roller carriage are shim adjustable. Carriage rollers
are interchangeable on a four roller carriage. A
pair of chain anchors are used to connect the carriage
chains to the carriage.
Carriage
Weldment
Cotter Pins
Chain
Pin
Shim
Chain Load
Anchor Roller
SELF-LOCKING Nut MA1184.eps
Cotter Pin
Figure 30. Carriage Service.

self-locking nuts if removed or
adjusted.
12-56
12. MASTS
Section 5 Service
5.4-2 Carriage Removal-Mast on Truck
1. Raise the mast high enough to place a 20 in. (50 cm) long,
4X4 in. (10 X 10cm) wood block between the inner lower
crossmember and the ground. Lower the carriage to be even
with the bottom of the inner upright.
2. Attach an overhead hoist to the carriage. Raise the carriage to
slacken the carriage chains.
3. Remove the chain anchor nuts. Note: Nuts must be re-
placed with new nuts after removal.
2
4. Disconnect the internal reeving hoses from the carriage
5. Using the overhead hoist, lower the carriage to the bottom of
the mast to remove.
6. Note the number of shims behind each load roller for reas-
sembly.
7. For reassembly, reverse the above procedures except as
follows:
2
Kendall SR-12X. See Figure 31.
*Assemble shims and load rollers on the stub shafts. The
shims should be installed (except the top two rollers of a
six roller carriage) to provide a total side to side clearance
no looser than 1/16 in. (1.5 cm) at the tightest point
throughout the travel of the carriage. Use an equal amount
of shims side to side.
nuts and ensuring cotter pins are installed in the bottom 3
5
*Check and adjust the free lift chains as described in
Section 5.6-4 and 5.6-6. Upright
Rails
MA2828.eps
MA0389.ill

BY THE HEAVY LINE FOR THE FULL
Figure 32. Carriage Removal.
Figure 31.Rail Lubrication.
12-57
12. MASTS
Section 5 Service
5.4-3
Carriage Removal-Mast on Floor
2. Remove chain anchor nuts. Note install new self-locking chain
anchor nuts during reassembly. Remove the chain anchors.
3. Disconnect the internal reeving hoses for the carriage fittings 5
(if equipped). Plug the hose ends.
4. Roll the carriage to the bottom of the mast.
5. Attach an overhead hoist to the carriage fork bars. Remove
the carriage through the bottom of the mast.
6. Note the number of shims located behind each load roller for
reassembly.
2
MA2829.eps

Upright
Rails
7. For Reassembly, reverse the above procedures except as

follows:
Kendall SR-12X . See Figure 34.
shafts. The shims should be installed (except on the top
two rollers on a six roller carriage) to provide a total side
to side clearance no looser than 1/16 in. (1.5 mm) at the
tightest point throughout the travel of the carriage. Use an
equal amount of shims side to side. MA0389.ill
*Install new self-locking nuts on carriage chain anchors if LUBRICATE ONLY WHERE INDICATED
nuts are remove or adjusted. BY THE HEAVY LINE FOR THE FULL
Section 5.6-4 and 5.6-6. Figure 34. Rail Lubrication.
12-58
12. MASTS
Section 5 Service
5.4-4
Carriage Inspection
1. Inspect the rollers for excessive wear or damage. Rollers with visible
flat spots or cracks should be replaced.
2. Inspect the roller bearings by turning the rollers on their shafts. Rollers
with roughness or noticeable restrictions to turning should be re-
placed.
3. Inspect all welds between the carriage side plates and the carriage
fork bars. If any welds are cracked, replace the carriage.
4. Inspect the roller stub shafts. If they are damaged or if there are
cracks at the base of the stub shafts, the carriage must be replaced
or repaired. Contact Komatsu Forklift for repair procedures.
Carriage
Weldment
Cotter Pins
Chain
Pin
Shim
Chain Load
Anchor Roller
Cotter Pin
Figure 35. Carriage .

adjusted.
12-59
12. MASTS
Section 5 Service
5.5
Mast Uprights Outer Upright Assembly
5.5-1 Upright Description of shim adjustable load rollers are attached to the stub
shafts located near the top of the upright. A pair of shim
adjustable wear plugs are located near the top of the outer.
The main lift cylinders are secured to the outer by retaining
bolts located near the bottom of the outer.
Wear Plug The inner upright assembly telescopes within the outer
and upright assembly. A pair of shim adjustable load rollers are
Shim
attached to stub shafts located at the bottom of the upright.
The free lift chain anchors are attached to the center
mounting block of the free lift cylinder. The free lift cylinder
rests on a cradle which is integral with the cylinder and
Mainlift Cylinder secure by bolts to the middle crossmember.
Bolt
Inner
Weldment
Outer
Weldment
Chain
Anchor
MA2830.eps
Load
Roller Shim
Jam Nut
Figure 36. Mast Uprights .
Full Nut
12-60
12. MASTS
Section 5 Service
5.5-2
Upright Operation
Outer Upright
Inner
Upright
Main Lift
Cylinders
Chain Sheaves
Free Lift Chains

Free Lift
Cylinder
Fully Lowered
The free lift chains are anchored to the inner upright Carriage
center crossmember then travel over the free lift

cylinder chain sheaves and attach to the carriage
chain anchors.
Free Lift
Actuating the truck hoist valve causes the free lift
cylinder to raise which draws the carriage to the top of
the inner upright.
Full Extension
When the free lift cylinder reaches the end of its
stroke the main lift cylinders begin to raise. The
extension of the cylinders causes the inner upright to
raise.
Lowering
Lowering of the mast is a reversal of extension.
MA2681.eps
Figure 37. Upright Operation .
12-61
12. MASTS
Section 5 Service
5.5-3 Upright Disassembly
NOTE Remove the internal hose reeving sheave and
1. Remove the mast assembly from the truck as de-

scribed in Section 5.1.
2. Remove the main lift cylinders from the mast as

described in Section 5.2-5. 12
3. Remove the free lift cylinder from the mast as de-
scribed in Section 5.2-6.
4. Remove the carriage from the mast as described in 11

Section 5.4-3.
Outer
7 8
Upright
11
Inner
Upright MA2831.eps
Figure 38. Upright Disassembly .
5. Remove the pins fastening the free lift chains to the inner
upright chain anchors. Pull the free lift chains back through the
chain sheaves.
CAUTION: The chain anchor nuts should be used one time
only and be replaced after removal.
6. Remove the free lift chain anchors (long anchors) from the
inner upright middle crossmember. Tag the anchors for
reassembly.
7. Roll the inner upright downward to expose the inner and outer
upright load rollers. Remove the load rollers. Note the number
of shims behind each load roller.
9. Attach an overhead hoist to the inner upright. Remove the

inner upright through the top of the outer upright.
12-62
12. MASTS
Section 5 Service
5.5-4 Upright Inspection
1. Inspect the load rollers for excessive wear or damage. Rollers with
visible flat spots or cracks should be replaced. See Figure 39.
2. Inspect the load roller bearings by turning the rollers on their shafts.
Rollers with roughness or noticeable restrictions to turning should be
replaced.
3. Inspect the load roller stub shafts. If they are damaged or have cracks
at the base, the upright mast must be replaced or repaired.
4. Inspect the outer upright thrust plugs. If the wear surface is worn to
less than 1/16 in. (1.5 mm), they should be replaced.
5. Inspect the hoist chains as described in Section 5.6-1.
1
MA1192.eps
Figure 39. Upright Inspection .
12-63
12. MASTS
Section 5 Service
5.5-5
Upright Reassembly
1. Lubricate the outer upright rails with chassis lube or Kendall Upright
SR-12X. See Figure 40 Rail Lubrication. Rail
2. Attach an overhead hoist to the inner upright. Install the inner

uptight through the top of the outer upright.
3. Install the thrust plugs to the outer upright.
4. Assemble shims and load rollers to the outer upright and

lower inner upright stub shafts. The shims should be installed 1 5
to provide a total side to side clearance no looser than 1/16
in. (1.5 mm) at the tightest point throughout the travel in the
upright. Use an equal amount of shims side to side. NOTE:
Roll the upright past the thrust plugs before checking roller
clearances. MA2352.eps
5. Lubricate the inner upright rails with chassis lube or Kendall

SR-12X. See Figure 40.
by the heavy lines for the full
2
Figure 40. Rail Lubrication
Outer
Upright 4
Inner
Upright
MA2832.eps
10
4 SOME COMPONENTS ARE NOT SHOWN FOR CLARITY.
Figure 41. Mast Reassembly
12-64
12. MASTS
Section 5 Service
5.5-5
Upright Reassembly (Continued)
9. Install the free lift cylinder as described in Section 5.2-6.
10. Install the chain anchors (long anchors) to the back side of the
freelift cylinder mounting block using new nuts.
11. Pull the free lift chains over the chain sheaves and install on the
free lift cylinder chain anchors using new nuts.
12. Install the carriage as described in Section 4.5-3.
13. Install the main lift cylinders as described in Section 5.2-5.
15. Adjust the free lift chains as described in Sections 5.6-3. Check
for mast skewing as described in Section 5.5-6.
16. Install the internal reeving sheave and hoses (if equipped) as
12-65
12. MASTS
Section 5 Service
5.5-6 Mast Skewing WARNING: The inner upright must be
supported by angle iron to avoid possible injury.
1. Extend the mast to the full lift height.


2. Place a 4 X 4 X 20 in. (10 X 10 X 50 cm) wood block between

3
the upper iner and the upper outer crossmembers. Lower the
mast onto the block.
3. Remove the bolt from the cylinder to be adjusted. Open the

4 valve to allow the center (free lift) cylinder to fully
truck Freelift
retract. Tap the main lift cylinder rod down past the cylinder Cylinder
mount to install the shim.
5
4. Slowly hydraulically power the main lift cylinder back into the
cylinder mount and reinstall the bolt.
Right Hand
Left Hand
Main Lift
Main Lift
Cylinder
Bolt Cylinder
Shim
Main Lift Cylinder
MA2685.eps
MA2683.eps
Figure 42.Shim Installation. Figure 43.Extended Upright.

12-66
12. MASTS
Section 5 Service
5.6
Chains
links. Avoid removal or contamination of this factory CRACKED SIDE PLATES


TIGHT PIN JOINTS
a pair of chains requires replacement, both strands of the


PEENED PLATE EDGES
replace both strands of the chain.


PROTRUDING PINS
*Check for worn, broken or misaligned chain anchors.
MA0633.eps
TURNED PINS
Figure 44.Chain Inspection.
12-67
12. MASTS
Section 5 Service
5.6-2
A
A
If the chains stretch beyond the recommended amount, Chain
they should be replaced in pairs. Chain stretch can be Wear
the chains according to the instructions printed on the chain Scale
*to check the free lift chains, raise the carriage 1 ft.
5.6-3 Free Lift Chain Adjustment
A
A
MA0634.eps
The free lift chains should be adjusted so that when the New Chain Stretched Chain
unloaded mast is fully lowered, the upright channels and
carriage are positioned as shown in Figure 46. Figure 45.Measuring Chain Stretch.
*3 in. *5 in.
1. Locate the threaded chain anchors on the front side of Underclearance Underclearance
the inner upright crossmember on each side of the
cylinder. Adjust one chain to achieve the correct
upright position when fully lowered. See Figure 61.
Outer Upright
and Carriage
2. Adjust the each pair to achieve equal chain tension. Flush Outer
Tighten the nuts together to a torque of 50-70 ft.-lbs. Upright
(68095 Nm).
Carriage 2 in.
3. Raise and lower the mast several times to confirm the Below Outer
adjustments. Upright
MA2778.eps
*NOTE: Underclearance is based on mast

underclearance may vary by truck model.
Figure 46.Upright and Carriage Position.
Free Lift
Nuts
Figure 47.Free Lift Chains.
12-68
12. MASTS
Section 5 Service
5.6-4 Free Lift Chain Service
by a block to avoid possible injury.
1. Raise the carriage 12 in. (30 cm). Place a 12 in. (30

cm) block under the carriage, then lower the carriage
onto the block. The free lift chains should be slack.
See Figure 48.
3. Inspect the chain anchors for cracks. Replace as

required. If lower chain nut is removed, it must be
replaced with a new self-locking nut.

1 2
MA2833.eps
12-69
NOTES:
E-MT SERIES FULL
FREE LIFT 3-STAGE
MAST
12. MASTS
INTRODUCTION
Section 1 Introduction
1.1
Introduction
the Komatsu E-Series roller masts.

is missing, these numbers are also stamped on a
plate on the left-hand side of the mast. See Figure 1.
WARNING: Do not install a Komatsu Mast

on a truck with a capacity greater than the
truck rated capacities shown below
EV40 EV50 EV60
ES30 ES40
E40 E50 E60 E65
(1361 kg) (1814 kg) (2268 kg) (2718 kg) (2948 kg)

operation shall not be performed without prior written E50-MT-001

1.2
Special Definitions Mast Serial Number
Stamped Here
WARNING
CAUTION
IMPORTANT
A statement preceded by IMPORTANT is information that
NOTE
to know and may make your job easier.
MA2348.eps
12-72
12. MASTS

2.1
Truck System
Requirements
and masts valve.
Valve Inlet Port
3/4 in. SAE O-ring OR
TRUCK SUPPLY REQUIREMENTS
Relief Fitting*
Pressure Size
ES/EV/E 13/32 in.
2600 psi No. 8 min.
30/40/50/60/65 Orifice MA1152.eps

Valve Inlet Port
required. Contact Komatsu Forklift. 3/4 in. SAE O-ring
IMPORTANT: Komatsu Masts are compatible with SAE 10W FigFigure 2. Valve inlet Port.
petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104
Installation A
B
1 If it is necessary to install mounting brackets and cross- C

members to fit your lift truck, consult with the nearest D
Front View
and loss of warranty. Tilt Cylinders

loss of warranty.
E
Side View MA0031.eps
12-73
12. MASTS

2.3
1
Mast Installation
The following instructions and illustrations are typical
for most trucks. If your truck does not match,
4
2. Install the bearings to the lower the axle mounts.
3. Lubricate the bearing surfaces of lower axle and tilt


attached under all of the upper crossmembers. Position the mast
by lowering the axle mounts onto the truck axle. Install the
mounting caps and capscrews. Tighten the capscrews to the
truck torque specifications.

mast, make sure the cylinders “bottom” evenly. Adjust the tilt
cylinders to prevent the mast from “racking” during tilting.
Refer to your truck service manual for procedures.

Tighten the pin capscrews to the truck torque specifications.
NOTE: Use as few fittings as possible and always use

45o fittings instead of 90o fittings. Keep the hose lengths
to a minimum. Avoid sharp bends or pinch points when
routing the hose.

MA2349.eps
FiFigure 4. Mast Installation.
12-74
12. MASTS

2.4
Inspection and
Adjustments
*3 in. *5 in.
2.4-1 Chain Inspection and Tension Underclearance Underclearance
The hoist Chains have been factory lubricated using heat and Outer Upright
pressure to force the lubricant thoroughly into the chain links. and Carriage
Flush Outer
Avoid removal or contamination of this factory applied Upright
lubricant. Do not wash, sand blast, etch, steam clean, or

paint the chains for internal mast installation. Carriage 2 in.
Below Outer
Upright
If the mast has been cleaned using a pressure washer or MA2778.eps
heavy detergents that may rinse the chain lubrication *NOTE: Underclearance is based on mast
out from within the links, then the recommended method production series, actual mast
for reestablishing chain lubrication is to soak the chains underclearance may vary by truck model.
in SAE 40wt oil for at least 8 hours, preferably with the
oil heated to 100o F to 120o F to facilitate complete Figure 5. Upright and Carriage Position.
lubricatant penetration. Excess oil may be wiped off prior
to installation.

under tension. Press the center of a strand of chain with your Main Lift
thumb, then press at the same place on the other chain of the Chain Anchors
pair. Each chain in a pair should have equal “give”. If they
ments described in Sections 5.6-3 and 5.6-4.
Main Lift
Adjusting Nuts
MA1156.eps
Figure 6. Main Lift Chains.
Free Lift
Nuts
Figure 7. Free Lift Chains.
12-75
12. MASTS

2.4-4 Free lift Cylinder Supply
Hose Tracking Adjustment
Make sure the cylinder supply hose is not twisted and travels
evenly in the hose sheave. Check the hose to be sure it is not
scuffing. Adjust the hose by loosening the hose clamp on the
outer upright as shown in figure 8 and twisting the hose.
Tighten the clamp while holding the hose in place. Tension
Free Lift
on the hose can be adjusted by sliding the hose through the Hose Clamp
loosened clamp as required.
MA1157.eps
2.4-5
Upright Rail Lubrication Figure 8. Free Lift Cylinder Supply Hose Adjustment.
Lubricate the full length of each upright rail with chassis lube
or Kendall SR-12X as shown in Figure 9.

Upright
Rails
remove air. Air in the cylinders will compress on
the first extension which could rupture the
property damage.
When new or after repair, the cylinders may have air trapped
in them that must be removed. To bleed air do the following:
1. Without a load extend the free lift cylinder and continue

to extend the main lift cylinders to 90% of full stroke.
Retract all cylinders completely. Repeat three times.
MA0941.eps
2. Extend the cylinders without a load at 50% full engine
speed then build full system pressure at the end of the
main lift cylinder stroke. Electric trucks limit the control BY THE HEAVY LINE FOR THE FULL
valve movement to achieve 50% speed. Retract all LENGTH OF EACH UPRIGHT
cylinders. Repeat four times.

Figure 9. Channel lubrication.
3. Cycle the mast with a half load (50% mast rated
capacity) through full cylinder extension several times.
The cylinders should extend smoothly. Repeat the
steps if cylinder extension is not smooth.
2.4-7 Mast Skewing

Check for mast skewing as described in Section 5.5-6.
12-76
12. MASTS

2.5
Installation
1. Install fittings and caps to the carriage termination bracket and install bracket to carriage as shown.
2. Assemble crosshead sheaves and new chain guards as shown.
NOTE:
4
Old Chain Guard
2 is not reused
MA1158.eps
1
Figure 10. Crosshead and Carriage IHR assembly.
12-77
12. MASTS

2.5
3. Install bracket on middle inner crossmember (E-Series Only).
4. Install upper bracket and one clamp piece on lower inner crossmember as shown.
5. Install lower bracket and one clamp piece on lower inner crossmember as shown.
3
E-Series Only
3
EV-Series Only
4 EV-Series Only
4 E-Series Only
5
MA1160.eps
12-78
12. MASTS

2.5
6. Install guard and sheave onto upper intermediate stubshaft as shown.
MA1162.eps
MA1161.eps
Figure 12. Upper intermediate sheave.

Figure 13. Outer tab.
7. Install bracket and one clamp piece

on outer tab as shown.
8. Install guide bracket to middle

crossmember as shown.
MA1163.eps
Figure 14. Outer guide bracket.
12-79
12. MASTS

2.5
10. Route hoses over crosshead and down over the middle crossmember guard.
14
15 16
17
10
10
MA1164.eps
11 12
13
Figure 15. Hose Routing. 9

12-80
12. MASTS

2.5
11. Route hoses through clamp piece on top lower inner bracket and install second
clamp piece, coverplate and bolts loosely.
12. Pull hoses to proper tension and tighten clamp bolt.
13. Route hoses to second bracket on lower inner (right hose to outboard slot on clamp
piece and left hose to inboard slot on clamp piece) with gentle loop and install
second clamp piece, coverplate and bolt tightly.
14. Route hoses up through sheave on upper intermediate.
15. Route hoses through clamp piece on outer bracket and install second clamp piece.
17. Route truck IHR supply hoses through lower outer bracket and attach to mast IHR hoses.
12-81
12. MASTS

2.5
Installation
1. Install fittings and caps to the carriage termination bracket and install bracket on carriage as shown.
2. Assemble crosshead sheaves and guards as shown.
NOTE:
2 Old Chain Guard

is not reused
MA1165.eps
1
Figure 16. Crosshead Assembly.
12-82
12. MASTS

2.5
3. Install bracket on middle inner crossmember as shown (E-Series Only). For the EV-Series, Install the
roll pins and caps in the top holes of the middle inner crossmenber.
4. Install upper bracket and one clamp piece on lower inner crossmember as shown.
5. Install lower bracket and one clamp piece on lower inner crossmember as shown.
3
E-Series Only
3
EV-Series Only
4 EV-Series Only
4 E-Series Only
5
MA1160.eps
12-83
12. MASTS

2.5
Installation (Continued) 7
6. Install guard and sheave onto upper intermediate stubshaft as shown.
MA1162.eps
Figure 19. Outer tab.

MA1166.eps
8
Figure 18. Upper intermediate sheave.

on outer tab as shown.
8. Install lower left bracket and one clamp

on lower inner crossmember as shown.
MA2003.eps
Figure 20. Lower Left bracket.
12-84
12. MASTS

2.5
9. Install bracket on the upper intermediate crossmember as shown.
10
9
EV-Series E-Series
MA2353.eps MA2362.eps
Figure 21. Upper Intermed. bracket. Figure 22. Upper Outer bracket.
10. Install bracket and one clamp piece to the
bottom of the upper outer crossmember as shown.
on outer tab as shown. 11
12. Install guides to middle crossmember as shown.
12
MA1170.eps
MA1171.eps
Figure 23. Middle Outer bracket. Figure 24. Middle Outer bracket.
12-85
12. MASTS

2.5
13. Attach hoses to the carriage termination bracket fittings as shown in Figure 25a for E-Series and 25b for EV-
Series.
14. Route outside hoses over outside sheaves on the crosshead and route middle hoses over sheaves above
crosshead.
15. Route middle hoses over middle inner guard (E-Series Only). For the EV-Series, route the two outside hoses
outside of the roll pins on the middle inner crossmemeber and the two inside hoses to the inside of the roll
pins.
16. Route hoses through clamp piece on top lower inner bracket and install second clamp piece, coverplate and
bolts loosely.
18. Pull outside hoses down to middle inner crossmember, place hose clamps on hoses, slightly above the
middle crossmember (E-Series Only).
19. Pull hoses to proper tension and attach clamps to middle inner crossmember (E-Series Only).
20. Route the outside right hose in front of the lower crossmember and middle right hose behind the lower to
second bracket on lower inner ( middle hose to inboard slot on clamp piece and outside hose to outboard
slot on clamp piece ) with gentle loop and install second clamp piece, coverplate and bolt tightly.
21. Route hoses down through sheave on the upper intermediate.
22. Route hoses up through clamp piece on outer bracket and install second clamp piece, coverplate and bolts
loosely.
24. At lower inner crossmember, route the outside left hose in front of the lower crossmember and the middle left
hose behind the lower crossmember to left side bracket on lower inner ( middle hose to inboard slot on
clamp piece and outside hose to outboard slot on clamp piece ) with gentle loop and install second clamp
piece, coverplate and bolt tightly.
25. Route hoses up to the sheave at the upper intermediate crossmember shown in Figure 25a and 25b (install
hoses onto sheave prior to installing stubshaft and sheave on bracket ).
26. Route hoses down to bracket attached to upper outer crossmember. Tension hoses and clamp using parts
as shown in Figure 22.
27. Route hoses through guide bar on the bracket and down to clamp piece on outer bracket and install second
clamp piece, cover plate and bolts loosely. Orient hoses so they follow an orderly path from upper bracket to
clamp.
28. Route truck IHR supply hoses through the lower bracket attached to the middle outer crossmember and
attach them to the mast IHR hoses.
12-86
12. MASTS

2.5
Shortest Shortest
Hose Hose
Middle
Longest
Length
Hose
Hose
26
25
27
MA1172.eps
Figure 25a. Carriage Termination bracket.
21
27
22
23
28
14
18 15
19
MA1173.eps
16 17
20 24
Figure 26a. Hose Routing - E-Series Only.

13
12-87
12. MASTS

2.5
Installation (Continued) Shortest Shortest
Hose Hose
Middle
Longest
Length
Hose
Hose
26
25
27
MA1172.eps
Figure 25b. Carriage Termination bracket.
21
27
22
23
14
18 15
19
MA2998.eps
16 17
20 24
13
Figure 26b. Hose Routing - EV-Series Only.
12-88
12. MASTS

3.1
For proper operation and to extended service life, your
Komatsu Mast should be inspected and serviced regularly
5.6-3 and 5.6-4 for chain adjustment.
proper lubrication. Refer to Section 5.5-5 steps 1 and 5 for rail
lubrication.
5. In applications with high humidity or condensation, chain
lubrication as described under Item 1 of the 100 hour
inspection may be needed more frequently to reduce the Pry Here
Load Roller
risk of corrosion.
100 Hour Inspection
the daily inspection: X
X
1. Inspect and lubricate the full length of the chains with SAE X
40 wt. oil or equivalent.

CAUTION: The chains must be coated with a film of lubricant
at all times.
500 Hour Inspection .06 in.
After each 500 hours of lift truck operation, and in addition to (1.5 mm)
Max.
the Daily and 100 Hour Inspection:

1. Each pair of load rollers on the uprights and carriage
pair of rollers at XXX shown. See Figure 13.
MA1174.eps

5.6-1 for complete chain inspection. Figure 27. Load Roller Clearances.
12-89
12. MASTS
TROUBLESHOOTING
The following table lists problems that may be encountered on your Komatsu Mast, the probable causes and rec-
WARNING: Extreme care should be used when working on a unit when the carriage (with or without a
load) is in the raised position.

b) Truck relief valve setting low. b) Raise truck relief setting to specified level
or bad rollers . replac ing/ f reeing plunger and rollers.
Cylinders drift a) External leak in pressure line. a) Tighten or replace as necessary.
Spongy or jerky action a) Sticky or defective truck relief valve. a) remove and check the truck relief valve. If
assembly.
c) Load rollers not properly adjusted c) Adjust or replace as necessary.
or defective.
or baffles.
Weldments banging a) Insufficient cushion oil exists on top a) Open top of Free Lift cylinder and add oil
during exit from Free of the Free Lift cylinder to properly as described in Step 8 of Section 5.2.9.
Lift (Lifting) dampen the weldment transition. If the problem persists, or reoccurs
frequently, then replacement of the Free
Lift cylinder seals is recommended.
Weldments banging a) Insufficient cushion oil exists on top a) Replace Main Lift cylinder seal.
during entry into Free of the Free Lift cylinder to properly
Lift (Lowering) dampen the weldment transition.
12-90
12. MASTS
SERVICE
Section 5 Service
5.1
Mast Removal

WARNING: Do not stand on or near the mast 3 6

3. Attach overhead hoist strap as shown in Figure 28.



MA2350.eps
Figure 28. Mast Removal
12-91
12. MASTS
Section 5 Service
5.2
Cylinders
5.2-1
Main Lift Cylinder Description Retainer
ders. They consist of a shell and a telescoping rod/

hydraulic seal against the rod. The retainer also limits
Rod/ Piston
the upward stroke of the rod. Assembly
A piston is attached to the bottom end of the rod. The

shell and rod to escape when the cylinder is extending.
Shell
port. In case of a hose failure between the lowering control
valve and cylinders, the fuse limits the lowering speed of the
Check Valve

MA1178.eps
Figure 29. Main Lift Cylinder
12-92
12. MASTS
Section 5 Service
5.2-2
Free Lift Cylinder Description
The free lift cylinder is a single stage piston type cylinders.

It consists of a shell and a rod/piston assembly.
During extension the oil pressure is acting
Retainer
The shell is internally threaded at the top end to hold the re-
tainer. The retainer seal provide a high-pressure hydraulic
seal against the rod. The retainer also limits the upward
stroke of the rod.
A piston is attached to the bottom end of the rod. The

piston seal provides a high-pressure hydraulic seal against Rod / Piston
the shell. A check valve is located in the bottom on the pis- Assembly
ton. The check valve allows residual oil between the shell
and rod to escape when the cylinder is extending.
Upstroke cushioning is provided in the free lift cylinder. This
cushions the cylinder when the cylinder nears the fully
extended position. Shell
A hydraulic fuse/cushion valve is located in the cylinder port.

In case of a hose failure between the lowering control valve
and cylinder, the fuse limits the lowering speed of the cylin-
der.
Check Valve
Hydraulic Fuse Assembly
MA1177.EPS
Figure 30. Free Lift Cylinder
12-93
12. MASTS
Section 5 Service
Cylinders Raising
1. When the truck hoist control valve is actuated, oil enters
the lowering control valve through the inlet port and
flows unrestricted through the lowering control car-
tridge.
2. Oil flows to the cylinder inlet ports. Due to the larger
bore diameter of the free lift cylinder compared to both
main lift cylinders, the free lift cylinder will raise com-
pletely before the main lift cylinders raise.
3. Oil flows through the free lift cylinder hydraulic fuse

valve to the bottom of the piston. Lifting force
is created against the bottom of the piston causing the
rod to raise. Oil in the area between the rod
and shell is allowed to escape through the check valve
in the piston as the rod raises to the end of its
stroke.
4. Oil flows through the hydraulic fuse valve or fitting to the

bottom of the piston. Lifting force is created against the
bottom of the piston causing the rod to raise. Oil in the
area between the rod and shell is allowed to
escape through the check valve in the piston as the
rod raises.

discontinued, the cylinders are held in position by the
closed center spool of the truck valve.
Cylinders Lowering
1. When the truck hoist control valve is actuated, the main
lift retract fully then the free lift cylinder rod lowers,
forcing oil out through the hydraulic fuse valve.
NOTE: The restriction setting of each hydraulic fuse is
higher (allows more oil flow) than the setting of the
only in the instance of a lowering control valve or hose
failure.
2. Oil flows to the lowering control valve where it is re-
stricted at a controlled speed determined by the load
being handled.
3. As the main lift cylinder pistons lower over the spear in
the bottom of the shell, a high pressure area is devel-
oped between the piston and shell which engages the
cushion valve to restrict flow. This slows the piston/
rod just prior to bottoming providing a smooth
transition to the free lift cylinder lowering.
12-94
12. MASTS
Section 5 Service
Triple Mast (MT) Hydraulic Schematic

R.H. Main Lift Cylinder L.H. Main Lift Cylinder
Free Lift Cylinder
Shell
Shell
Rod
Rod
Ckeck
Valve
Piston Piston
Hydraulic Fuse/
Cushion Valve
Lowering
Control Valve
Inlet Port
To Truck Valve
Figure 31. Cylinder Operation
12-95
12. MASTS
Section 5 Service
Mast on Floor
Section 5.1
2. Lay the mast down on wooden blocks as shown. Extend
inner and intermediate rails to expose the lower fittings
on the main lift cylinders.
3. Disconnect the cylinder supply hoses from the cylinder
inlet ports. Remove the fittings from the
cylinder ports and install plug fittings.
4. A.Remove the bolts fastening the cylinder rods to
the intermediate upright. Remove the bolts at the base of the
cylinders that attach the cylinders to the lower outer crossmember.
B. Remove nuts from chain mounts. Remove mount from
cylinder and lay over carriage.
5. Pull the inner and intermediate upright outward as required
to allow the main lift cylinders to be removed.
6. Lift the cylinder from the base mount and angle inward
to remove.
cylinder rod.
as follows:
3
3 4
MA1179.eps
The mast is shown from the underside for clarity

12-96
12. MASTS
Section 5 Service
Mast on Floor
Section 5.1.
2. Lay the mast down as shown.
3. Roll the carriage toward the center of the cylinder to
equipped).
4. Disconnect the hose from the cylinder 45o fitting. Cap
the fitting and plug the hose.
ft.-lbs. (65-70 Nm).
cylinder rod.
7. Pull the crosshead with chains and hoses (if equipped)
off the cylinder rod.
8. Remove the cylinder mounting bolts the keeping shims for reassembly. IMPORTANT: The chain anchor
nuts on the carriage must be
9. Remove the cylinder from the mast.
replaced with new self-locking
10. For reassembly, reverse the above procedures. nuts if removed or adjusted.
5 4
6 7
8
MA1180.eps
12-97
12. MASTS
Section 5 Service
Mast on Truck
1. Completely lower the carriage. Remove forks or
attachment if equipped. Make sure the free lift cylinder
is completely retracted. Attach an overhead hoist to
the top carriage bar.
2. Raise the carriage to the center of the cylinder to
equipped). Block the carriage in place using a 4 X 4 X
24 in. (10 X 10 X 60 cm) wood block between the lower
carriage bar and the floor. 1
ft.-lbs. (65-70 Nm).

cylinder rod. 4
5. A. Pull the crosshead with chains and hoses
(if equipped) off the cylinder rod and lay
over upper carriage bar.
5 6
B. Remove cylinder mounting bolts, keeping
the shims for reassembly.
2
6. Pry the cylinder up out of the support casting to gain 3
access to the cylinder hose fitting. Remove the hose
from the 45o fitting. Cap the fitting and plug the hose.
7. Remove the cylinder from the mast from the top.

2
MA1181.eps
12-98
12. MASTS
Section 5 Service
Section 5.2-5.

2 8 Retainer
to remove the retainer. See Figure 35.

emery cloth, replace the part. If the piston requires re-
placing, refer to Section 5.2-10.

3 Rod/ Piston
Assembly
seal directions. The cylinder will not operate correctly


sure the check valve is reinstalled with the arrow
pointed in the correct direction. Shell

EV/E-40/50/60 - 180-200 ft.-lbs. (244-271 Nm)
7 Check Valve
4
MA0071.eps
MA1178.eps
12-99
12. MASTS
Section 5 Service
Section 5.2-6 or 5.2-7.

to remove the retainer. See Figure 37.
3. Remove the rod/piston assembly from the shell.
4. Remove the hydraulic fuse.

2 8
or burrs can be removed with 400 grit emery cloth. Retainer
6. Replace the retainer and piston seals, back-up rings,

O-rings and bearing. Lubricate the new seals with 3
petroleum jelly prior to installation. Note the correct Plunger / Piston
seal directions. The cylinder will not operate correctly Assembly

sure the check valve is reinstalled with the arrow Shell
pointed in the correct direction.
8. Install the rod retainer on the rod. Install the

rod/piston assembly into the cylinder shell. Pour
75 - 80cc hydraulic oil into the cylinder cavity
between the shell and rod. Tighten the retainer to a
torque of 280-300 ft.-lbs. (380-407 Nm) using the claw
spanner wrench and a strap wrench.
Check Valve
4
Hydraulic Fuse Assembly
MA0071.eps
MA1182.EPS
12-100
12. MASTS
Section 5 Service
5.2-10
Piston Removal
1. Remove the rod/piston assembly from the cylinder
shell as described in Section 5.2-8 or 5.2-9.
2. Use a strap wrench and 400
grit emery cloth to secure the rod while turning the
piston with a pin type spanner wrench.
. 3. Turn the piston until the snap wire end is visible through
4. Pull the piston from the rod.
as follows: MA0677.eps
Figure 39. Piston Removal.

property damage.
1
5.3
Valve
2. Remove the truck supply hose from the valve car-
tridge. See Figure 40. Plug the hose.
3. Remove the valve cartridge from the valve. Note the 3
stamped part no. on the Cartridge for ordering a
replacement.
2
mast to malfunction.
MA2351.eps
Figure 40. Valve Cartridge Service.

Typical Illustration
12-101
12. MASTS
Section 5 Service
5.4 Carriage
5.4-1 Description

optional) rollers. On a four roller carriage, all four rollers are
shim adjustable, whereas only the bottom four rollers on a six
roller carriage are shim adjustable. Carriage rollers are
interchangeable on a four roller carriage. A pair of chain
anchors are used to connect the carriage chains to the carriage.
Carriage
Weldment
Cotter Pins
Chain
Pin
Shim
Chain Load
Anchor Roller
SELF-LOCKING Nut
MA1184.eps
Cotter Pin
Figure 41. Carriage Service.

adjusted.
12-102
12. MASTS
Section 5 Service
5.4-2 Carriage Removal-Mast on Truck
1 1. Raise the mast high enough to place a 20 in. (50 cm)
long, 4X4 in. (10 X 10cm) wood block between the
intermediate lower crossmember and the ground. Lower
the carriage to be even with the bottom of the inner
upright.
2. Attach an overhead hoist to the carriage. Raise the
carriage to slacken the carriage chains.
3. Remove the chain anchor nuts. Note: Nuts must be
replaced with new nuts after removal.
5. Using the overhead hoist, lower the carriage to the
bottom of the mast to remove.
6. Note the number of shims behind each load roller for
reassembly. 2
as follows:
Kendall SR-12X.
See Figure 42.
*Assemble shims and load rollers on the stub shafts.
The shims should be installed (none to top rollers if six
roller carriage) to provide a total side to side clearance
no looser than 1/16 in. (1.5 mm) at the tightest point
throughout the travel of the carriage. Use an equal
2
amount of shims side to side.
*Check and adjust the free lift chains as described in 3

Section 5.6-4 and 5.6-6.
nuts and ensuring cotter pins are installed in the bottom
Upright
Rails
5
1
MA1186.eps
MA0941.eps

BY THE HEAVY LINE FOR THE FULL
Some components are not shown for clarity.
Figure 42.Rail Lubrication. Figure 43. Carriage Removal.
12-103
12. MASTS
Section 5 Service
5.4-3 Carriage Removal-
Mast on Floor 5
2. Remove chain anchor nuts. Note install new self-locking

chain anchor nuts during reassembly. Remove the chain
anchors.
3. Disconnect the internal reeving hoses for the carriage

4. Roll the carriage to the bottom of the mast. 5

5. Attach an overhead hoist to the carriage fork bars.
Remove the carriage through the bottom of the mast.
6. Note the number of shims located behind each load

roller for reassembly.
MA1187.eps
7. For Reassembly, reverse the above procedures except

as follows:
Kendall SR-12X . See Figure 45.
shafts. The shims should be installed (except on the top
two roller on a six roller carriage) to provide a
total side to side clearance no looser than 1/16 in.
(1.5 mm) at the tightest point throughout the travel of
the carriage. Use an equal amount of shims side to side.
*Install new self-locking nuts on carriage chain anchors
if nuts are remove or adjusted.
Section 5.6-4 and 5.6-6. Figure 45. Rail Lubrication.
12-104
12. MASTS
Section 5 Service
5.4-4
Carriage Inspection
Rollers with visible flat spots or cracks should be re-
placed.
2. Inspect the roller bearings by turning the rollers on their
Komatsu Forklift for repair procedures.
Carriage
Weldment
Cotter Pins
Chain
Pin
Shim
Chain Load
Anchor Roller
Cotter Pin
Figure 46. Carriage .

adjusted.
12-105
12. MASTS
Section 5 Service
5.5
Mast Uprights
Outer Upright Assembly
of shim adjustable load rollers are attached to stub shafts
located near the top of the upright. A pair of adjustable
hoist chain anchors are located on the top of each rail. A
pair of shim adjustable wear plugs are located near the top
of the outer. The main lift cylinder are secured to the outer
by retaining bolts located near bottom of the outer.
Intermediate Upright Assembly

The intermediate upright assembly telescopes within the
outer upright assembly. A pair of shim adjustable load
Chain Anchor
rollers are attached to stub shafts located at the top and Wear Plug
and Shim
bottom of the upright. A free lift hose sheave and a pair of
chain sheaves are located near the top of the upright to
provide a rolling surface for the main lift chains. The main lift
cylinders are secured to the intermediate using retaining
bolts located on the cylinder mounting block.
Cylinder Retainer Free Lift
Hose Clamp
Bolt
Inner Upright Assembly Chain
Sheave
The inner upright assembly telescopes within the Free Lift
intermediate upright assembly. A pair of shim Hose Sheave
adjustable load rollers are attached to stub shafts

located at the bottom of the upright. The main lift
chain anchors are attached on mounts welded to the
back of the rail sections. The free lift cylinder is
Cylinder
attached to the middle
Shim
crossmember. The free lift
cylinder rests on the lower
crossmember.
Cylinder Retainer
Capscrew
Free Lift Cotter Pins Shims

Hose Clamp Load Rollers
Chain Pin
Chain Anchor
ChainAnchor Nuts
Figure 47. Mast Uprights .

Cotter Pin
MA1188.eps
12-106
12. MASTS
Section 5 Service
5.5-2
Upright Operation Intermediate Upright
Inner
Outer Upright
Upright
Fully Lowered Chain Sheaves Main Lift

Chains
The main Lift chains are anchored to the outer upright top
Main Lift
crossmember then travel over the intermediate upright chain Cylinders
sheaves and attach to the inner upright anchors. Free Lift Chains
Carriage
Free Lift
The free lift chains are anchored to the free lift cylinder Cylinder
then travel over the free lift cylinder chain sheaves and
attach to the carriage chain anchors.
Free Lift
Actuating the truck hoist valve causes the free lift cylinder to
raise which draws the carriage to the top of the inner
upright.
Full Extension
When the free Lift cylinder nears the end of its stroke the
main lift cylinders begin to rise. The extension of the
cylinders causes the intermediate and inner uprights to
raise.
Lowering
The two main lift cylinders lower at the same time. As the
main lift cylinders near bottoming out, the free lift cylinder
begins to lower resulting in the lowering of the carriage.
MA1189.eps
Figure 48. Upright Operation .
12-107
12. MASTS
Section 5 Service
5.5-3 Upright Disassembly
NOTE Remove the internal hose reeving sheave and 12
1. Remove the mast assembly from the truck as de-

scribed in Section 5.1.
2. Remove the main lift cylinders from the mast as de-

11
3. Remove the free lift cylinder from the mast as de-
4. Remove the carriage from the mast as described in

Section 5.4-3.
Inner 7 8
Upright 11
Outer
Upright
Intermediate
Upright
MA1190.eps
10
11
7
11
5. Remove the pins fastening the main 10 Figure 49. Upright Disassembly .
lift chains to the inner upright
chain anchors. Pull the main lift
chains back through the chain
sheaves.
CAUTION: The chain anchor nuts should be used one time

only and be replaced after removal.
6. Remove the main lift chain anchors (long anchors)
from the inner upright lower back side. Tag the
anchors for reassembly.
7. Remove the free lift cylinder supply hose and sheave.
Remove the main lift chain sheaves.
8. Roll the inner upright downward to expose the inner
and intermediate upright load rollers. Remove the load
rollers. Note the number of shims behind each load
roller.
9. Attach an overhead hoist to the inner upright. Remove
the inner upright through the top of the intermediate
upright.
12-108
12. MASTS
Section 5 Service
5.5-3
Upright Disassembly (Continued)
CAUTION: The chain anchor nuts should be used one
time only and be replaced after removal.
10. Remove the main lift chain anchors (long anchors) and
chains from the outer upright crossmember. Tag the
anchors for reassembly. 15
11. Roll the inner upright downward to expose the
intermediate and outer upright load rollers.
Remove the load rollers. Note the number of
shims behind each load roller.
12. Attach an overhead hoist to the intermediate upright.
Remove the intermediate upright through the top 14
of the outer upright.
14
14
MA1191.eps
14
14 13

Figure 50. Upright Disassembly .
5.5-4 Upright Inspection
1. Inspect the load rollers for excessive wear or damage. 4
replaced. See Figure 51.
2. Inspect the load roller bearings by turning the rollers on

their shafts. Rollers with roughness or noticeable
restrictions to turning should be replaced.
1
3. Inspect the load roller stub shafts. If they are damaged MA1192.eps
or have cracks at the base, the upright mast must be re-

placed or repaired.
4. Inspect the outer and intermediate upright thrust plugs.

If the wear surface is worn to less than 1/16 in. (1.5 mm),
they should be replaced.
5. Inspect the hoist chains as described in Section

5.6-1. Figure 51. Upright Inspection .
12-109
12. MASTS
Section 5 Service
5.5-5
Upright Reassembly
1. Lubricate the outer upright rails with chassis lube or
Upright
Kendall SR-12X. See Figure 52 Rail Lubrication. Rail
2. Attach an overhead hoist to the intermediate upright.

Install the intermediate uptight through the top of the
outer upright.
3. Install the thrust plugs to the uprights.
4. Assemble shims and load rollers to the outer upright

and lower intermediate upright stub shafts. The shims 1 5
should be installed to provide a total side to side
tightest point throughout the travel in the upright. Use
MA2352.eps
clearances.
5. Lubricate the intermediate upright rails with chassis

lube or Kendall SR-12X. See Figure 52.
by the heavy lines for the full
15
Figure 52. Rail Lubrication
4
Outer
Upright
Intermediate
Upright
MA1193.eps
4
3
4 Figure 53. Mast Reassembly
12-110
12. MASTS
Section 5 Service
5.5-5
Upright Reassembly
(Continued)
6. Attach an overhead hoist to the inner upright. Install
the inner upright through the top of the intermediate
upright. Adjust thrust plugs with shims as required.
7. Assemble shims and load rollers to the intermediate
upright top and inner upright lower stub shafts. The
shims should be installed to provide a total side
clearance no loosest than 1/16 in. (1.5 mm) at the
tightest point throughout the travel in the upright. Use
clearances.
6
8. Install the chain sheaves and free lift hose sheave to the
intermediate upright. Tighten the capscrew to a
torque of 26-30 ft.-lbs. (35-40 Nm).
9. Install the main lift chain anchors (long anchors) and

chains to the outer upright crossmember using
new nuts.
6
Inner
Upright 7
Outer
Upright
Intermediate
Upright
MA1194.eps
8
7
9
7
8
8
8 Figure 54. Mast Reassembly
12-111
12. MASTS
Section 5 Service
5.5-5
Upright Reassembly (Continued)
9. Install the chain anchors (long anchors) to the back
side of the inner upright lower crossmember using new nuts.
10. Pull the main lift chains over the chain sheaves and
attach to the lower inner upright chain anchors.
11. Install the free lift cylinder supply hose clamp

on the outer upright and route hose over the
sheave on the intermediate top upright.
12. Install the carriage as described in Section 5.4-2 and 5.4-3.
13. Install the free lift cylinder as described in Section

5.2-6.
14. Install the main lift cylinders as described in Section

5.2-5.
18. Adjust the main lift and free lift chains as described in
Sections 5.6-3 and 5.6-4. Check for mast skewing as
described in Section 5.5-6.
17. Install the internal reeving sheave and hoses (if

equipped) as described in Section 2.5.
10
9
MA1195.eps
10
Figure 55. Upright Reassembly.
10
12-112
12. MASTS
Section 5 Service
5.5-6 Mast Skewing WARNING: The intermediate upright must be
1. Extend the mast to the full lift height. supported by angle iron to avoid possible injury.


2. Place a 4 X 4 X 20 in. (10 X 10 X 50 cm) wood block

between the upper intermediate and the upper outer Freelift
crossmembers. Lower the mast onto the block. Cylinder
3.3Remove the bolt from the cylinder to be adjusted.

Open the truck valve to allow the center (free lift)
cylinder to fully retract. Tap the main lift cylinder rod
down past the cylinder mount to install the shim.
4
4. Slowly hydraulically power the main lift cylinder back
into the cylinder mount and reinstall the bolt.
5 Repeat steps 3 through 4 until skewing is removed.
5.
Bolt
Shim
Right Hand
Left Hand Main Lift
Main Lift Cylinder
Main Lift Cylinder Cylinder
MA2004.eps
MA2005.eps
Figure 56.Shim Installation. Figure 57.Extended Upright.

12-113
12. MASTS
Section 5 Service
5.6
Chains
links. Avoid removal or contamination of this factory
CRACKED SIDE PLATES


a pair of chains requires replacement, both strands of the TIGHT PIN JOINTS


replace both strands of the chain. PEENED PLATE EDGES


PROTRUDING PINS
*Check for worn, broken or misaligned chain anchors.
MA0633.eps
TURNED PINS
Figure 58.Chain Inspection.
12-114
12. MASTS
Section 5 Service
5.6-2
A
A
If the chains stretch beyond the recommended amount, Chain
they should be replaced in pairs. Chain stretch can be
Wear
the chains according to the instructions printed on the chain Scale
*to check the free lift chains, raise the carriage 1 ft.
*To check the main lift chains, raise the mast until the inner
upright starts to extend ensuring tension on the chains.
5.6-3 Main Lift Chain Adjustment

A
A
MA0634.eps
unloaded mast is fully lowered, the uprights are positioned
New Chain Stretched Chain
as shown in figure 60.
1. Adjust one chain to achieve the correct upright position Figure 59.Measuring Chain Stretch.
when fully lowered. See Figure 62. *3 in. *5 in.
2. Adjust the each pair to achieve equal chain tension.
(98-96 Nm). Ensure cotter pins are installed in the hole
at the bottom of each chain anchor. Outer Upright
and Carriage
3. Raise and lower the mast several times to confirm the Flush Outer
Upright
adjustments.
5.6-4
Free Lift Chain Adjustment Carriage 2 in.
Below Outer
The free lift chains should be adjusted so that when the Upright
MA2778.eps
unloaded mast is fully lowered, the upright channels and
carriage are positioned as shown in Figure 60. *NOTE: Underclearance is based on mast
1. Locate the threaded chain anchors on the front side of underclearance may vary by truck model.
the inner upright crossmember on each side of the
cylinder. Adjust one chain to achieve the correct Figure 60.Upright and Carriage Position.
upright position when fully lowered. See Figure 61.
2. Adjust the each pair to achieve equal chain tension.
(68095 Nm).
3. Raise and lower the mast several times to confirm the
adjustments.
Main Lift
Chain Anchors
Main Lift
Adjusting Nuts
MA1156.eps
Free Lift
Figure 62.Main Lift Chains. Nuts
12-115
12. MASTS
Section 5 Service
5.6-5 Main Lift Chain Service
WARNING: The intermediate upright must be
supported by a block to avoid possible injury.
1. Raise the inner upright 3 ft. (90 cm). Place a 3 ft. (90
cm) block under the free lift cylinder support casting,
then lower the cylinder support onto the block. The
main lift chains should be slack.
3. Inspect the chain anchors for cracks or turned pins.
Replace as required.
MA2000.eps
5. If the mast has been cleaned using a pressure washer or
heavy detergents that may rinse the chain lubrication
Figure 63.Main Chains.
out from within the links, then the recommended method
for reestablishing chain lubrication is to soak the chains
oil heated to 100o F to 120o F to facilitate complete
lubrication penetration. Excess oil can be wiped off prior
to installation.
5.6-6 Free Lift Chain Service
1. Raise the carriage 12 in. (30 cm). Place a 12 in. (30

cm) block under the carriage, then lower the carriage 2
onto the block. The free lift chains should be slack.
See Figure 64.
3. Inspect the chain anchors for cracks or turned pins. 2
Replace as required. If lower chain nut is removed,
it must be replaced with a new self-locking nut.
the chains as described in Section 5.6-4. 1
5. If the mast has been cleaned using a pressure washer or

heavy detergents that may rinse the chain lubrication
out from within the links, then the recommended method MA2001.eps
for reestablishing chain lubrication is to soak the chains

oil heated to 100o F to 120o F to facilitate complete
lubrication penetration. Excess oil can be wiped off prior
to installation.
12-116
35D/45D/55D MQ QUAD
MASTS
12. MASTS
INTRODUCTION
ntroduction
I
1.1 Introduction
This manual provides the installation Instructions, periodic
maintenance requirements, troubleshooting and service 45D-MQ-001-00025-M
procedures for the Komatsu Series Quad roller masts. Stamped

Serial
Numbers
These masts provide excellent visibility for the lift truck OR
driver. The mast carriage and upright channels are all Left-Hand
roller-mounted which provides smooth operation and long 45D-MQ-001-00025-M
Side of
service life. Outer
In any communication about the mast, refer to the mast Upright
MA2781.eps
is missing, these numbers are also stamped on the Example:
left-hand upper cheekplate. See Figure 1. 45D–MQ–001–00025–M
Figure 1. Serial Mast Number Location
1.2 Special Definitions

WARNING
CAUTION
IMPORTANT
A statement preceded by IMPORTANT that
NOTE
1.3 Tool Requirements

Listed below are the minimum tools needed to work on a mast.
METRIC
17, 19, 24 mm Open End or Socket Wrench
INCH
3/4, 13/16, 7/8, 15/16, 1.0, 1-1/16 in Open End or
Socket Wrench.
1/8 in. Allen Wrench
Snap Ring Pliers
Claw Type Spanner Wrench
Strap Wrench
Torque Wrench
2 lb. Dead Blow Hammer
12-118
12. MASTS
INSTALLATION
nstallation
I
2.1
Truck System
Requirements
and masts valve.
Relief Hose Fitting*

Pressure Size Size
No. 8 min.
2600 psi No. 8 min. 13/32 in. Orifice
MA0022.eps
required. Contact Komatsu Forklift.
IMPORTANT: Komatsu Masts are compatible with SAE 10W Valve Inlet Port
petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104 3/4 in. SAE O-ring
B only. Use of synthetic or aqueous base hydraulic oil is not FigFigure 2. Valve inlet Port.
2.2
Mounting Bracket
Installation Truck Cowl
A
If it is necessary to install mounting brackets and cross- B
C
Komatsu Forklift dealer. D
Front View
Tilt Cylinders
loss of warranty.
E
Side View
MA0031.eps
12-119
12. MASTS
nstallation
I
2.3
Mast Installation
2. Install the bearings to lower the axle mounts.
3. Lubricate the bearing surfaces of the lower axle and tilt 4

4. Lift the mast using an overhead hoist with chain hooks

attached to the upper outer crossmember. Position the mast
lower the axle mounts on the truck axle. Install the mount
caps and capscrews. Tighten the capscrews to the truck
manufacturer’s torque specifications.

mast, make sure the cylinders “bottom” evenly. Adjust the tilt
cylinders to prevent the mast from “racking” during tilting.
Refer to your truck service manual for procedures.
5. Connect the lift truck supply hose to the mast valve.

Tighten the pin capscrews to the torque specifications.
5
NOTE: Use as few fittings as possible and always use 45 o
6
fittings instead of 90o fittings. Keep the hose lengths to a
minimum. Avoid sharp bends or pinch points when routing
the hose.
7. Check the hydraulic fluid level in the truck hydraulic

tank when the Mast is fully lower. Fill if required.
MA0016.eps
4
2 3
additional fittings are FiFigure 4. Mast Installation.
required.
12-120
12. MASTS
nstallation
I
2.4 Mast Inspection *3 in. *5 in.
Check each of the following before using the Mast for the Underclearance Underclearance
first time.
CAUTION: The factory-set adjustments may not be Outer Upright

and Carriage
correct for your truck. Flush Outer
Upright
1. Inspect all chains for lubrication.

Carriage 2 in.
Below Outer
Upright
2. Inspect all chains for any visible damage. MA2777.eps
NOTE: Underclearance is based on mast

3. Inspect the main lift chain adjustment for proper production series, actual mast
tension and upright position. underclearance may vary by truck
model.
4. Inspect the free lift chain adjustment for proper
tension and carriage position. Figure 5. Mast side view showing correct
position for uprights and carriage.
5. Inspect for lubrication in the Mast upright channels.
6. Check for Mast skewing.
2.4-1
Chain Lubrication
The main and free lift chains have been factory lubricated
Outer Main
using heat and pressure to force the lubrication thoroughly Lift Chain
Inner Main
Adjusting Nuts
into the chain links. Avoid removal or contamination of Lift Chain
Adjusting
this factory-applied lubrication. Do not wash, sand blast, Nuts
etch, steam clean, or paint the chains for initial Mast
installation. If chains need lubrication, refer to
Section 5.6. Chain Service
2.4-2
Upright and Carriage
Position, Chain Tension Free Lift Chains
Adjusting Nuts

unloaded Mast is fully lowered, the uprights are flush at
the bottom (see Figure 5). The free lift chains should be
adjusted so that when the unloaded Mast is fully lowered,
the carriage is properly positioned depending on the truck
type (see figure 6).
CONTINUED ON NEXT PAGE MA0015.eps
Figure 6. Adjusting Chain Anchor

Location (driver’s view).
12-121
12. MASTS
nstallation
I
2.4-2
Upright and Carriage Upright
Rails
Position, Chain Tension

( Continued )
All chains should also be adjusted for equal tension of the
Lubrication
pairs to ensure proper load distribution and mast opera-
tion. Chains are adjusted at the chain anchors (see
Figure 6 ). To determine equal tension, extend the
MA0028.eps
unloaded mast to put the chains under tension. Then press
the center of the strand with your thumb. Then press
at the same place on the other chain of the pair. Each Figure 7. Lubricating upright channels.
chain in a pair should have equal “give”.
If the uprights or carriage are not in correct adjust-
ment, of if the chain pairs do not have equal tension,
perform the Main Lift and Free Lift Chain Adjustments
as described in Section 5.6-3 and 5.6-4.
2.4-3
Channel Lubrication Free Lift
Cylinder
Inspect the upright channels for lubrication. If necessary,
lubricate the full length of each upright channel with
chassis lube or Kendall SR-12X (see Figure 7).
2.4-4
Mast Skewing
Extend the mast to full lift height and inspect for mast
skewing (see Figure 8).
* If the mast bends to the right at full extension, a shim(s)
needs to be removed from the left main lift cylinder rod.
* If the mast bends to the left at full extension, a shim(s)
needs to be installed on the left main lift cylinder rod.
To adjust the Mast to eliminate skewing, perform the Mast
Skewing Adjustment as described in Section 5.5-6.
Left Hand Right Hand

Outer Main Lift
Intermediate
Main Lift
Upright Cylinder Cylinder
Snap
Ring 4 X 4 in.
( 10 X 10 cm)
Wood Block
Outer
Upright
Shim
MA0020.eps
MA0017.eps
Figure 9. Blocking upright to retract LH main lift cylinder rod. Figure 8. Extending Mast to check for
skewing (driver’s view).
12-122
12. MASTS
nstallation
I
2.4-2
Internal Reeving
1
STANDARD
1. Install the shaft, tires and hose guards to the

crosshead center plate (see Figure 10). Leave the
capscrew and nut finger-tight to allow for hose
installation.
MA0222.eps
NOTE: For PIDs 45D-MQ-001 through
45D-MQ3233 the crosshead was a six sheave
design. The current crosshead design uses
two sheaves for improved service life. Figure 10. Installing shaft, tires and hose guards on
When replacing the crosshead components crosshead.
on the above PIDs, the six sheave crosshead
should be converted to two sheave
crosshead design. Contact Komatsu Forklift parts
for conversion kit part numbers.
2. Install the carriage hose bracket to the center tab

on the lower carriage bar.
3. Install the fittings to the bracket (see Figure 11).
* Single Function - Install the fittings to the

left or right side location. Tighten the
fittings finger-tight. 3
* Double Function - Install the fittings to the 2

left and right side location. Tighten the
fittings finger-tight.
MA0255.eps
4. Make up two hose assemblies by connection the
two oses to the two long hoses.
OR
3
SINGLE DOUBLE
FUNCTION FUNCTION
MA0256.eps
Figure 11. Installing hose bracket and fittings on carriage.
12-123
12. MASTS
nstallation
I
2.4-2
Internal Reeving
STANDARD ( Continued )
5. Install the shaft, sheave(s), shim and hardware to 8. Loosen the crosshead coverplate capscrew. Route
the inner intermediate upright chain sheave shaft. the hoses up over the crosshead rollers.
Tighten the capscrew to 37 ft-lbs. (50 Nm).
9. Completly lower the carriage. Route the hoses
6. Route the hose ends over the inner intermediate down behind the carriage bar to the carriage
upright sheave(s) down to the inner upright bracket fittings. Connect the hose ends to the
bracket. fittings leaving the hose ends finger tight.
NOTE: The short hose routes over the
cylinder crosshead.
7. Position the hoses with the tabs on the inner 13

upright bracket as shown in figure 13.
Outer
Outer 14
Upright
Intermediate
Upright
Inner
Intermediate
Upright
Upper
Hose
14 Guide
5 Double
Function 14
Single
Function
11
10
Lower
Hose
Guide
MA0225.eps
Figure 12.Installing internal hose reeving components on uprights.
12-124
12. MASTS
nstallation
I
2.4-2
Internal Reeving
STANDARD 6
16
8
( Continued )
Inner
Intermediate
Upright Sheave
SINGLE DOUBLE
FUNCTION FUNCTION
Long
Hose
Upper
8 12 Hose
Short Guide
Hose
15
17
7 Lower
Hose
Guide
Connect
4 hoses
SINGLE DOUBLE
FUNCTION FUNCTION
FRONT VIEW
Inner
Upright
Bracket
7 MA0257.eps
9
Carriage
Bracket
Fittings
SINGLE DOUBLE
FUNCTION FUNCTION
SINGLE DOUBLE
FUNCTION FUNCTION BACK VIEW
Figure 13. Installing internal hose reeving on uprights.

10. Install the lower hose guide and spacer to the outer 13. Install the upper hose guide to the outer upright.
intermediate upright. Tighten the capscrews to a Tighten the capscrew to 37 ft.-lbs. (50 Nm).
torque of 37 ft.-lbs. (50 Nm). 14. Install the hose clamps to the upper hose guide.
11. Install the hose clamps to the lower hose guide. Leave the capscrews finger tight.
Leave the capscrews finger tight. 15. Route the hoses up into the upper hose guide.
12. Route hoses down to the lower hose guide. Place 16. Route the hoses under the hose clamps at the
hoses under the hose clamp at the top of the lower top of the upper hose guide. Tighten the cap-
hose guide. Pull downward on the hoses with 20 screws finger tight.
lbs. force. Tighten clamp capscrews enough to 17. Route the hoses under the hose clamps at the
stop hose movement. bottom of the upper hose guide. Do not tighten
the clamp capscrews.
12-125
12. MASTS
nstallation
I
2.4-2
Internal Reeving
STANDARD ( Continued ) 4
1. Tighten the crosshead coverplate capscrew to a

torque of 30-33 ft.-lbs. (40-45 Nm). 4
2. Align the hoses by twisting the hose ends to travel

centered in the crosshead on the natural curve of the
hose. The hoses should travel parallel to each other.
Hold the hoses while tightening the fittings to keep the
hoses from twisting.
3. Loosen the hose clamps at the top of the lower hose Upper
guide. Pull down on the hoses with 40 lbs. of force. Hose
Guide
Tighten the hose clamp capscrews to 7-11 ft.-lbs.
(10-15 Nm).
4. Loosen the hose clamps on the upper hose guide. 1

Adjust the hoses to the natural hose bend and align
evenly spaced in the guide rails. Tighten the hose 3 4
clamp capscrews to 7-11 ft.-lbs. (10-15 Nm). Crosshead
5. Raise and lower the Mast slowly through several cycles

and check for proper hose alignment, clearances and
hose tracking in the guides.
Lower
Hose
Guide
MA0258.eps
12-126
12. MASTS
nstallation
I
2.4-2
Internal Reeving
Hi-VIS
1. Install the shafts, sheaves and hose guards to the 1
crosshead center plate. Leave the capscrew and nut
finger tight to allow hose installation.
NOTE: For PIDs 45D-MQ-001 through

45D-MQ3233 the crosshead was a six sheave
design. The current crosshead design uses MA0514.eps
two sheaves for improved service life.

When replacing the crosshead components
on the above PIDs, the six sheave crosshead
should be converted to two sheave
crosshead design. Contact Komatsu Forklift
parts for conversion kit part numbers.
2. SINGLE FUNCTION- Install the carriage bracket to

the center tab on the lower carriage bar. Tighten the
center tab nut to a torque of 37-40 ft.-lbs. (50-54 Nm). 2
DOUBLE FUNCTION – Do not install carriage
bracket.
1) Route the hoses down and behind the upper fork 3
bar.
2) Start all hose fittings on the bulkhead fittings of the
MA0515.eps
carriage termination bracket.
3) Install the carriage termination bracket and torque
nut to 37-40 ft.lbs. (50-54 Nm).
4) Tighten the hose fittings and jam nuts.
5) Check the outer bulkhead/hose fittings are not 3
misaligned where the fittings will create interference
OR
with the chain ends.
3. Install fittings to the carriage bracket.

SINGLE FUNCTION – Install the fittings pointing left
MA0523.eps
or right as required. Tighten the fittings finger tight. Double
Single
DOUBLE FUNCTION – Install the fittings to the left Function Function
and right side location. Tighten the fittings finger tight.
12-127
12. MASTS
nstallation
I
2.4-2
Internal Reeving Hi-VIS (continued)
4. Install the bracket and sheaves to the inner interme- 35D DOUBLE FUNCTION: The No. 4 hoses
diate upright. Tighten capscrews to 37 ft.-lbs. (50 connect to the two right fittings (viewed from the
Nm). drivers seat).
SINGLE FUNCTION: Install sheaves to the top 7. Route the hoses over the crosshead sheaves.
shafts. Tighten the cover capscrew to a torque of 63 ft.-lbs.
5. Install the middle hose guide to the outer intermedi- (85 Nm).
ate upright. Tighten capscrews to a torque of 37 ft.- 8. Route the hoses down between the freelift cyinder
lbs. (50 Nm). and crossmember. Position the hoses in their natural
6. Connect the short hoses to the carriage bracket curve over the crosshead sheaves. Tighten the hose
fittings. Hand tighten the fittings. ends at the carriage bracket.
9. Connect the long hoses to the short hoses behind
the freelift cyinder.
Single Function IHR DOUBLE FUNCTION: The right side hoses (viewed
from the drivers seat) are approximately 14 in. (355
mm) longer than the left side hoses.
Upper Sheave Bracket

and Components
Upper Hose Guide

and Components
MA2331.eps
Crosshead and Components
Carriage Termination Bracket

and Components
Middle Hose Guide

and Components
Lower Inner Bracket
and Components
12-128
12. MASTS
nstallation
I
Double Function IHR
Upper Sheave Bracket

and Components
Upper Hose Guide

and Components
MA2332.eps
Crosshead and Components
Middle Hose Guide Carriage Termination Bracket

and Components and Components
Lower Inner Bracket
and Components
12-129
12. MASTS
nstallation
I
2.4-2
18
19
12
21 21
19
17
4 3
12 34
12
13
Single Double
Function Function
15
7
20
12 3412 3412
14
8
16
8 10
MA2123.eps
2 24
21 4321
8 1 13
10
1 4
1
2 2 3
11
Single
6 Double
Single Double
Function Function
Function Function
10. Pull down on the hoses with approximately 30 lbs. 15. Install the upper hose guide to the tapped bar on the
force. Clamp the hoses to the lower bracket at- outer upright. Leave the capscrews loose.
tached to the inner upright crossmember. Tighten 16. Loop the hoses 5 in. (125 mm) below the bottom of
the clamp capscrew to a torque of 11 ft.-lbs. (15 Nm). the middle hose guide and route upward into the
11. Route hoses up to the left through the guide. upper hose guide.
Position the hoses in the guide as indicated. Install 17. Feed the hose ends up between the chain anchors.
the retainer bar with the end in the bracket slot. Install the hose retainer bar at the top of the upper
12. Route hoses up and over the upper bracket hose guide. Tighten the capscrews to a torque of
sheaves, then down to the middle hose guide. 11 ft.-lbs. (15 Nm).
13. Pull down on the hoses with 40 lbs. force. Clamp 18. Install the guide bar between the upper hose guide
the hoses to the top of the middle hose guide. and tapped bar on the outer upright. Route the
Tighten the clamp capscrews to a torque of 11 ft.- hoses to the right of the guide bar. Tighten the
lbs. (15 Nm). guide capscrews to a torque of 36 ft.-lbs. (50 Nm).
14. Clamp the hoses to the lower location on the middle 19. Clamp the hoses to the guide bar. Tighten the
hose guide. Arrange the hoses in the clamps as capscrews to a torque of 11 ft.-lbs. (15 Nm).
shown. Tighten the capscrews to a torque of 11 ft.- 20. Clamp hoses to the back side of the upper hose guide.
lbs. (15 Nm). Tighten capscrews to a torque of 11 ft. lbs. (15 Nm)
12-130
12. MASTS
I nstallation
2.4-2
Hose and Bracket Adjustment
1. Raise the mast slowly checking all guides and 3
brackets for proper clearances and alignment.
2. Check for a sufficient length of hose between the
middle and upper hose guides at full extension.
3. Check the hoses for proper tracking over the
sheaves. 5
4. Check the hoses for even tracking in the hose
guides.
5. Raise and lower the mast slowly through several
cycles for a final check. Check all clamp capscrew
torque values and retighten if necessary to 11 ft.-lbs.
(15 Nm).
3 5
2 4
NOTE:
Left Hand IHR is installed the same
as Right Hand IHR with the exception
that the IHR hoses route left to
right from the lower inner bracket
to the back of the mast.
MA2179.eps
12-131
12. MASTS
P eriodic Maintenance
3.1
For proper operation and an extended service lift, the quad
Mast should be inspected and serviced regularly as part of
your normal lift truck maintenance schedule according to
the following outlines and ANSI B56.1 procedures.
The recommended intervals are for Masts operating under
normal conditions. If operation is in severe conditions or
corrosive atmospheres, inspect the Mast more frequently,
WARNING: Never work on a raised mast with

a load without supports, or while anyone is near
the lift truck control handles per ANSI B56.1.
3.1-1
Daily Inspection
1. Extend the carriage a few inches off the ground and
make sure the chains are under equal tension and that
the tops of intermediate-inner and inner weldments are
flush within 3mm of the intermediate-outer weldment.
Refer to Sections 5.6-3 and 5.6-4 for chain adjustment. Pry Here Load
Rollers
2. Extend the Mast to full height to make sure the uprights
3. While the Mast is extended, inspect the upright rails for
lubrication. Refer to Section 5.5-5, Step 1 for lubrication.
quired. Tighten loose fittings, avoid any hose twist.
3.1-2 100 - Hour Inspection .06 in.

(1.5 mm)
Max.
the Daily inspection:
1. Inspect and lubricate the full length of the chains with

SAE 40 wt. oil or Bowman Heavy Load Red Grease.
CAUTION: The chains must be coated with a film of

lubricant at all times.
Thrust Thrust
3.1-3
500 - Hour Inspection
Plugs Block
the Daily and 100 - Hour Inspections:
1. Measure load roller clearances in the carriage and Mast

uprights. Pry between the upright and load roller so that
the opposite load roller is tight against the upright (see .06 in.
Figure 14 ). Total side-to-side clearance should be 1/16 (1.5 mm)
MA0227.eps
Max.
in. (1.5 mm) max. across the tightest point throughout the
travel of the upright. If shimming is required, refer to
Section 5.4-2, Carriage Removal for carriage rollers, or Figure 14. Measuring Load Roller and Thrust
Section 5.5-3, Upright Disassembly. Plug Clearances.
12-132
12. MASTS
P eriodic Maintenance
3.1-3
500 - Hour Inspection (Continued)
2. Measure thrust plug/block clearances in the Mast
uprights. Pry between the upright upper crossmembers
( see Figure 14 ). Clearance should be 1/16in. (1.5 mm)
max.. If thrust plug/block replacement is required, refer to
Section 5.5-3, Upright Disassembly.

5.6. Chains for complete chain service.
4. Check the backrest capscrews for tightness. Tighten

capscrews to 145 ft.-lbs. ( 195 Nm ).
12-133
12. MASTS
TROUBLESHOOTING
rouble Shooting
T
4.1
Troubleshooting Chart
The Following Table lists problems that may be encountered on your Quad Mast, the probable causes, and the
recommended corrective action that should be taken to restore the Mast to normal operating condition.

assembly.
or defective.
or baffles.
12-134
12. MASTS
SERVICE
ervice
S
5.1
Mast Removal
1. Raise and block the front end of the truck up 1 ft. ( 30
cm ) or drive the truck over a service pit.
2. Disconnect the lift truck supply hose from the Mast

WARNING: Do not stand on or near the Mast

while it is suspended by an overhead hoist.
3
3. Attach overhead hoist chains to the outer upright

crossmember. Take up slack in the chains.
4. Disconnect the tilt cylinders from the mast anchor

brackets, For reassembly, tighten the pin capscrews to
the torque specifications.
5. Disconnect the Mast lower mounts. For reassembly,

tighten the capscrews to the torque specifications.
6. Lift the Mast away from the truck.
7. To install the mast, refer to Section 2.2, Mast Installation.
WARNING: Do not stand the Mast up vertically

2
4
MA0228.eps
Figure 15. Removing Mast from Truck.
12-135
12. MASTS
ervice
S
5.2 Cylinders
5.2-1 This Illustration applies to
Main Lift Cylinder 45D-MQ6359 Thru Present
Description 55D-MQ-001 Thru Present
The main lift cylinders (see Figure
16) are single stage displacement
type cylinders consisting of a shell Fitting
and a telescoping plunger/piston
assembly. During extension Rod End
hydraulic pressure is acting O-Ring
against the plunger outer diameter
due to the internal porting through Install with LOCTITE 242
Torque to 50 ft-lbs MIN.
the piston. The piston seals do not
affect cylinder extension. The Wiper
truck hoist control valve holds the
cylinders in place once extension Rod Seal
has stopped.
O-Ring
The shell is internally threaded at
the top end to hold the retainer.
The retainer seals provide a high-
Retainer
Torque to 100 ft-lbs MIN
pressure hydraulic seal against

the plunger. The retainer also
limits the upward stroke of the Shell
plunger. Rod
A piston is attached to the bottom Hydraulic
end of the plunger. The piston Tube
seal provides a high-pressure
hydraulic seal against the shell Spacer
that engages the cushion valve (If required)
when the cylinder is fully lowered. Install with

Loctite 242
Torque to:
A hydraulic fuse/cushion valve is 50 ft-lbs MIN.
located in the LH cylinder’s inlet
port. In case of a hose failure Piston
between the lowering control valve
and the cylinders, the fuse limits
the lowering speed of the Piston Seal
cylinder.
Wear Ring
External Fuse Plug
Retaining Ring
Fitting
MA2178.eps
Left Hand Main Lift Cylinder Right Hand Main Lift Cylinder
TYPICAL ILLUSTRATION
Figure 16a. Main Lift Cylinders.
12-136
12. MASTS
ervice
S Free Lift
Cylinder
Connection
This page applies to PIDs

45D-MQ-001 Thru 45D-MQ4724 and
the individual PIDs listed below.
45D-MQ 4726 45D-MQ 4844
45D-MQ 4727 45D-MQ 4845
45D-MQ 4736 45D-MQ 4845
45D-MQ 4741 45D-MQ 4848
45D-MQ 4751 45D-MQ 4850
45D-MQ 4757 45D-MQ 4853
45D-MQ 4760 45D-MQ 4856 Retainer
Seals
45D-MQ 4761 45D-MQ 4857
45D-MQ 4762 45D-MQ 4858
45D-MQ 4769 45D-MQ 4864
45D-MQ 4770 45D-MQ 4869
45D-MQ 4771 45D-MQ 4872
45D-MQ 4772 45D-MQ 4873
45D-MQ 4776 45D-MQ 4874
45D-MQ 4778 45D-MQ 4875
45D-MQ 4780 45D-MQ 4876
45D-MQ 4781 45D-MQ 4879
45D-MQ 4782 45D-MQ 4881 Outer
Shell
45D-MQ 4783 45D-MQ 4882
45D-MQ 4788 45D-MQ 4885
45D-MQ 4789 45D-MQ 4886
45D-MQ 4790 45D-MQ 4893
45D-MQ 4792 45D-MQ 4896
45D-MQ 4793 45D-MQ 4897
Plunger/Piston
45D-MQ 4795 45D-MQ 4899 Assembly
45D-MQ 4797 45D-MQ 4905
45D-MQ 4801 45D-MQ 4906
45D-MQ 4803 45D-MQ 4924
45D-MQ 4804 45D-MQ 4925
45D-MQ 4805 45D-MQ 4927
Check Valve
45D-MQ 4816 45D-MQ 4930 Used on Later
45D-MQ 4817 45D-MQ 4931 Production
45D-MQ 4822 45D-MQ 4932 Cylinders
45D-MQ 4825 45D-MQ 4936 Piston
45D-MQ 4826 45D-MQ 4939 Seal
45D-MQ 4829 45D-MQ 4940
45D-MQ 4835 45D-MQ 5207 Check
45D-MQ 4837 45D-MQ 5368 Valve
45D-MQ 4843
Used on Early
Production
Inlet
Cylinders
Inlet MA0229.eps
Hydraulic Fuse/Cushion Valve
Figure 16b. Main Lift Cylinders.
12-137
12. MASTS
ervice
S
This page applies to
45D-MQ 4725 45D-MQ 4821 45D-MQ 4891 FREE LIFT
CYLINDER
45D-MQ 4728 45D-MQ 4823 45D-MQ 4892
CONNECTION
Thru 45D-MQ 4824 45D-MQ 4994 PORT
45D-MQ 4740 45D-MQ 4827 45D-MQ 4895
45D-MQ 4742 45D-MQ 4828 45D-MQ 4898
Thru 45D-MQ 4830 45D-MQ 4900
RETAINER
45D-MQ 4750 45D-MQ 4831 45D-MQ 4901
SEALS
45D-MQ 4752 45D-MQ 4832 45D-MQ 4902
Thru 45D-MQ 4833 45D-MQ 4903
45D-MQ 4759 45D-MQ 4834 45D-MQ 4904
45D-MQ 4764 45D-MQ 4836 45D-MQ 4907 RETAINER
Thru 45D-MQ 4838 Thru
45D-MQ 4768 45D-MQ 4839 45D-MQ 4923
45D-MQ 4773 45D-MQ 4840 45D-MQ 4926
45D-MQ 4774 45D-MQ 4841 45D-MQ 4928
PLUNGER/PISTON
45D-MQ 4775 45D-MQ 4842 45D-MQ 4929
ASSEMBLY
45D-MQ 4779 45D-MQ 4847 45D-MQ 4933
45D-MQ 4784 45D-MQ 4849 45D-MQ 4934
45D-MQ 4785 45D-MQ 4851 45D-MQ 4935
45D-MQ 4786 45D-MQ 4852 45D-MQ 4937
45D-MQ 4787 45D-MQ 4854 45D-MQ 4938
45D-MQ 4791 45D-MQ 4855 45D-MQ 4941
45D-MQ 4794 45D-MQ 4859 Thru
45D-MQ 4796 45D-MQ 4861 45D-MQ 5206
45D-MQ 4798 45D-MQ 4862 45D-MQ 5208
45D-MQ 4799 45D-MQ 4863 Thru
45D-MQ 4800 45D-MQ 4865 45D-MQ 5367
45D-MQ 4802 45D-MQ 4866 45D-MQ 5369
45D-MQ 4806 45D-MQ 4867 Thru
45D-MQ 4807 45D-MQ 4838 45D-MQ 6358
45D-MQ 4808 45D-MQ 4870
45D-MQ 4809 45D-MQ 4871
45D-MQ 4810 45D-MQ 4878
45D-MQ 4811 45D-MQ 4880
45D-MQ 4812 45D-MQ 4883
45D-MQ 4813 45D-MQ 4884 PISTON
45D-MQ 4815 45D-MQ 4887 SEAL
45D-MQ 4818 45D-MQ 4888
45D-MQ 4819 45D-MQ 4889
45D-MQ 4820 45D-MQ 4890
INLET
INLET
PORT
PORT
MA0992.eps
Figure 16c. Main Lift Cylinders.
12-138
12. MASTS
ervice
S This Illustration applies to
5.2-2 Free Lift Cylinder 45D-MQ6359 Thru Present
Description 55D-MQ-001 Thru Present
Snap Ring
The free lift cylinder (see Figure 17) is a single stage piston
type cylinder consisting of a shell and plunger/piston
assembly. During extension hydraulic pressure is acting
against the fill piston area. The truck hoist control valve
The shell is internally threaded at the top end to hold the Retainer
O-Ring
the upward stroke of the plunger. Wiper
A piston is attached to the bottom end of the plunger. The Back-Up Rod Seal
piston seal provides a high-pressure seal against Ring
the shell. A check valve located in the bottom of the piston
O-Ring
allows residual oil between the shell and plunger to escape
when the cylinder is extending (except for figure 17c).
A hydraulic fuse/cushion valve is located in the cylinder

inlet port. In case of hose failure between the lowering
control valve and the cylinder, the fuse limits the lowering Shell
speed of the cylinder.
Add 80ml +/- 15 ml of oil

to this area before installing
retainer.
Hydraulic Tube
Install with
Loctite 242
Part Number
Rod Stamped Here
Retaining Ring
Piston Check Valve
Piston Seal O-Ring
Install O-ring onto vlave
before assembly - valve
Wear Ring Plug orientaion critical
Install with
Loctite 242
Fitting
MA2180.eps
Figure 17a. Free Lift Cylinder.
12-139
12. MASTS
ervice
S
This page applies to PIDs
45D-MQ-001 Thru 45D-MQ4724 and
45D-MQ 4726 45D-MQ 4844
45D-MQ 4727 45D-MQ 4845
45D-MQ 4736 45D-MQ 4845
45D-MQ 4751 45D-MQ 4850 Seals

45D-MQ 4760 45D-MQ 4856
45D-MQ 4761 45D-MQ 4857
45D-MQ 4762 45D-MQ 4858
45D-MQ 4763 45D-MQ 4860
45D-MQ 4769 45D-MQ 4864
45D-MQ 4770 45D-MQ 4869
45D-MQ 4771 45D-MQ 4872
45D-MQ 4772 45D-MQ 4873 Outer
Shell
45D-MQ 4776 45D-MQ 4874
45D-MQ 4778 45D-MQ 4875
45D-MQ 4780 45D-MQ 4876
45D-MQ 4781 45D-MQ 4879
Plunger/Piston
45D-MQ 4782 45D-MQ 4881 Assembly
45D-MQ 4783 45D-MQ 4882
45D-MQ 4788 45D-MQ 4885
45D-MQ 4789 45D-MQ 4886
45D-MQ 4790 45D-MQ 4893
45D-MQ 4792 45D-MQ 4896
45D-MQ 4793 45D-MQ 4897 Piston
45D-MQ 4795 45D-MQ 4899 Seal
45D-MQ 4797 45D-MQ 4905 Check
45D-MQ 4801 45D-MQ 4906 Valve
45D-MQ 4803 45D-MQ 4924

Inlet
45D-MQ 4804 45D-MQ 4925
45D-MQ 4805 45D-MQ 4927
45D-MQ 4816 45D-MQ 4930
45D-MQ 4817 45D-MQ 4931
45D-MQ 4822 45D-MQ 4932
45D-MQ 4825 45D-MQ 4936
45D-MQ 4826 45D-MQ 4939 Hydraulic Fuse/Cushion Valve
45D-MQ 4829 45D-MQ 4940 MA0230.eps
45D-MQ 4835 45D-MQ 5207

45D-MQ 4837 45D-MQ 5368 TYPICAL ILLUSTRATION
45D-MQ 4843 Figure 17b. Free Lift Cylinder.
12-140
12. MASTS
ervice
S
This page applies to

45D-MQ 4725 45D-MQ 4821 45D-MQ 4891
45D-MQ 4728 45D-MQ 4823 45D-MQ 4892
Thru 45D-MQ 4824 45D-MQ 4994
45D-MQ 4740 45D-MQ 4827 45D-MQ 4895
Thru 45D-MQ 4830 45D-MQ 4900 SEALS
45D-MQ 4752 45D-MQ 4832 45D-MQ 4902
Thru 45D-MQ 4833 45D-MQ 4903
45D-MQ 4759 45D-MQ 4834 45D-MQ 4904
45D-MQ 4764 45D-MQ 4836 45D-MQ 4907
Thru 45D-MQ 4838 Thru
45D-MQ 4768 45D-MQ 4839 45D-MQ 4923 OUTER
45D-MQ 4773 45D-MQ 4840 45D-MQ 4926 SHELL
45D-MQ 4774 45D-MQ 4841 45D-MQ 4928
45D-MQ 4775 45D-MQ 4842 45D-MQ 4929
45D-MQ 4779 45D-MQ 4847 45D-MQ 4933
45D-MQ 4784 45D-MQ 4849 45D-MQ 4934
45D-MQ 4785 45D-MQ 4851 45D-MQ 4935
45D-MQ 4786 45D-MQ 4852 45D-MQ 4937 PLUNGER/PISTON
45D-MQ 4787 45D-MQ 4854 45D-MQ 4938 ASSEMBLY
45D-MQ 4791 45D-MQ 4855 45D-MQ 4941
45D-MQ 4794 45D-MQ 4859 Thru
45D-MQ 4796 45D-MQ 4861 45D-MQ 5206
45D-MQ 4798 45D-MQ 4862 45D-MQ 5208
45D-MQ 4799 45D-MQ 4863 Thru
45D-MQ 4800 45D-MQ 4865 45D-MQ 5367
45D-MQ 4802 45D-MQ 4866 45D-MQ 5369 PISTON
45D-MQ 4806 45D-MQ 4867 Thru SEAL
45D-MQ 4807 45D-MQ 4838 45D-MQ 6358
45D-MQ 4808 45D-MQ 4870
45D-MQ 4809 45D-MQ 4871
45D-MQ 4810 45D-MQ 4878
45D-MQ 4811 45D-MQ 4880 INLET
PORT
45D-MQ 4812 45D-MQ 4883
45D-MQ 4813 45D-MQ 4884
45D-MQ 4815 45D-MQ 4887 MA0991.eps
45D-MQ 4818 45D-MQ 4888

45D-MQ 4819 45D-MQ 4889
45D-MQ 4820 45D-MQ 4890
Figure 17c. Free Lift Cylinder.
12-141
12. MASTS
ervice
S
Cylinder Raising
1. Actuating the truck hoist control valve to raise Quad Mast (MQ) Hydraulic Schematic
causes hydraulic fluid to enter the lowering
control valve through the inlet port where it
flows unrestricted through the lowering
control cartridge. Left Hand Main Right Hand Main
Lift Cylinder
Lift Cylinder
2. Hydraulic fluid flows to the cylinder inlet ports. Free Lift Cylinder
Due to the larger bore diameter of the free

lift cylinder compared to both main lift Shell
cylinders, the free lift cylinders raise first. Shell
3. Hydraulic fluid flows through the free lift cylinder

Plunger
hydraulic fuse/cushion valve to the bottom of the Plunger
piston. Lifting force is created against the bottom

of the piston causing the plunger to raise.
Hydraulic fluid in the areas between the plunger
and the shell is allowed to escape through the Piston Piston
Check valve in the piston as the plunger raises Hydraulic Fuse/

to the end of its stroke. Cushion Valve
4. Hydraulic fluid flows through the hydraulic fuse/

cushion valve to the bottom of the pistons as the Lowering
Control Valve
free lift cylinder has fully extended, lifting force is
created against the bottom of the main lift cylinder
pistons causing their plungers to raise. Hydraulic
fluid in the area between the plunger and the shell
is allowed to escape through the check valve in
the piston as the plunger raises. Inlet Port
5. When hydraulic fluid flow from the truck hoist control To Truck Valve
valve is discontinued, the cylinders are held in

position by the closed center spool of the truck valve. Figure 18. Quad Mast Hydraulic Schematic.
Cylinder Lowering
1. Actuating the truck hoist control valve to lower the
mast causes the main lift cylinder plungers then free lift
cylinder plunger to lower, forcing hydraulic fluid out
through the hydraulic fuse/cushion valves.
Note: The restriction setting of each hydraulic fuse is

lower (allows more flow) than the setting of the
only during failure of a lowering control valve or hose.
2. Hydraulic fluid flows to the lowering control valve

where it is restricted at a controlled speed determined
by the load being handled.
3. As the main lift cylinder pistons lower over the spear in

the bottom of the shell, a high pressure area is
developed between the piston and the shell which
engages the cushion valva to restrict flow. This allows
the plunger/piston just prior to bottoming, providing a
smooth transition to free lift cylinder lowering.
12-142
12. MASTS
ervice
S
5.2-4 Main Lift Cylinder Removal - Mast on Floor
Section 5.1.
2. Insert a 2 X 4 in. ( 5 X 10 cm ) wood block between the
lower crossmembers of the outer upright and outer
intermediate upright to prevent uprights from moving
out the bottom of the Mast.
3. Lay the Mast face-down on wood blocks (Figure 19).
Block under each end of the outer upright so the Mast
is level, and the inner uprights and carriage are free to
move.
4. Using a 1-in. wrench, disconnect the cylinder supply
hoses from the cylinder inlet ports. Using a 1-in.
socket, remove the special long fittings from the
cylinder ports and install plugs.
5. Remove the snap ring from the top of the LH cylinder
rod, and the tube and fitting from the top of the RH
cylinder rod. Plug the cylinder port.
6. Roll the uprights through the top of the Mast 1 - 2 ft.
( 30-60 cm), disengage the cylinder rods from the
outer intermediate upright.
7. Lift the cylinder from its base mounting boss in the
outer upright and angle inward. Remove the cylinders
through the sides of the uprights.
4
2 Snap
Ring
7
Shim
7
MA0233.eps
3
5 8

MA0232.eps
cylinder rod.
5 8
Figure 19. Removing Main Lift Cylinders.
12-143
12. MASTS
ervice
S
5.2-5 Free Lift Cylinder Removal -
Mast on Floor
Section 5.1.
2. Lay the Mast face-up, blocking under the lower
mounts so the Mast is level ( see Figure 20).
3. Roll the carriage upward to slacken the free lift
chains and internal reeving (if equipped).
cylinder rod.
5. Pull the crosshead with chains and hoses (if
equipped) of the cylinder rod.
6. Roll the carriage above the free lift cylinder.
7. Using a 1-in. wrench, disconnect the tube from the
cylinder fitting. Cap the cylinder fitting and plug
the tube.
8. Using a 5-mm Allen wrench, remove the cylinder
strap.
9. Remove the cylinder from the Mast.
7
4 5
9
2 6
Figure 20. Removing Free lift Cylinder Mast

on Floor.
MA0074.eps
12-144
12. MASTS
ervice
S
5.2-6 Free Lift Cylinder Removal -
Mast on Truck
1. Completely lower the carriage. Remove the forks or
other attachment if equipped. Make sure the free lift
cylinder is completely retracted.
4
2. Attach an overhead hoist to the top carriage bar and

raise the carriage to the center of the cylinder. Block
the carriage in place using a 4 X 4 X 24 in. long (10
X 10 X 60 cm) wood block between the lower carriage
bar and the floor.

cylinder rod.
4. Pull the crosshead with chains and hoses (if

equipped) off the cylinder rod.
5. Using a 1-in. wrench, disconnect the tube from the

cylinder fitting. Cap the cylinder and plug the 3 4
tube. 2
6. Using a 5-mm Allen wrench, remove the cylinder
mounting strap.
7. Remove the cylinder from the Mast.
2 5
MA0267.eps
Figure 21. Removing Free lift Cylinder Mast

on Truck.
12-145
12. MASTS
ervice
S
1. Remove the cylinder from the Mast as described in
Section 5.2-4.
2. Use a claw-type spanner wrench and a strap wrench

to remove the retainer from the shell (see Figure 24).
6
5
or burrs can be removed with 400-grit emery cloth.
2

O-rings, and bearing. Lubricate the new seals with 3
seal directions. The seal lip always points toward
the pressure side of cylinder. The cylinder will not
operate correctly if the seals are installed backwards.

plunger/piston assembly into the cylinder shell. Using
the claw spanner and strap wrenches, tighten the
retainer to 95-125 ft.-lbs. (129-169 Nm).
MA0993.eps
Figure 23. RH Main Lift Cylinder.
Figure 22. LH Main Lift Cylinder.
12-146
12. MASTS
ervice
S
1. Remove the cylinder from the Mast as described in
Section 5.2-4.
2. Use a claw-type spanner wrench and a strap wrench

to remove the retainer from the shell (see Figure 24).
3. Remove the plunger/piston assembly from the shell. 6

or burrs can be removed with 400-grit emery cloth.
5
emery cloth, replace the part. If the piston requires 2

O-rings, and bearing.
Lubricate the new seals with petroleum jelly prior to
installation. Note the correct seal directions. The 3
seal lip always points toward the pressure side of
cylinder. The cylinder will not operate correctly if the
seals are installed backwards.

plunger/piston assembly into the cylinder shell. Pour
1/2 cup (120 ml) hydraulic fluid into the cylinder
cavity between the shell and rod. Using the claw
spanner and strap wrenches, tighten the
retainer to 95-125 ft.-lbs. (129-169 Nm).
Cylinder
Shell
5
Claw-Type
Spanner
Strap
Wrench
MA0235.eps
Piston
Retainer
MA0994.eps
Figure 24. Removing or installing plunger/

piston using a claw-type spanner and strap TYPICAL ILLUSTRATION
wrench.
Figure 25. Free Lift Cylinder.
12-147
12. MASTS
ervice
S
5.2-9 Piston Removal
1. Remove the plunger/piston assembly from the
cylinder shell as described in Section 5.2-7 or 5.2-8.
3
2. Using a strap wrench and 400-grit emery cloth to
secure the plunger while turning the piston with
a pin-type spanner wrench (see Figure 26).
3. Turn the piston until the snap wire end is visible

through the hole. Use a screwdriver to start the wire
2 2
end out of the hole. Turn the piston to feed the wire out.
MA0069.eps

as follows:
Figure 26. Removing piston from plunger.
* Install a new snap wire when installing the piston.
5.3 Valve
1. Completely lower the Mast. 3
2. Remove the truck supply hose from the valve cart- 2
tridge (see Figure 27). Plug the hose.
3. Remove the valve cartridge from the lowering control

valve. Note the stamped part number on the cartridge
when ordering a replacement.
WARNING: Replacing the valve cartridge

with a different part number may cause the
Mast to malfunction.
MA0238.eps
Figure 27. Removing the truck supply line.
12-148
12. MASTS
ervice
S
5.4
Carriage
5.4-1
Carriage Description
The carriage (see Figure 28) is the Mast structure that
hook-type forks or attachments are mounted on. The
carriage travels within the rails of the Mast inner upright
on four (six optional) rollers. On a four roller carriage,
all four rollers are shim adjustable, whereas only the
bottom four on a six roller carriage are shim adjustable.
Carriage rollers are interchangeable on a four roller carriage.
There are four side thrust rollers to transfer carriage side loading to the
inner rails. These rollers are held in place by a capscrew
and are adjustable via their eccentric mounting bases. A
pair of adjustable chain anchors connect the carriage free
lift chains to the carriage.
Carriage
Face
Carriage
Rails
Roller
Shims
Thrust
Rollers
(4)
Chain Load
Anchor Pins Rollers
(6)
Chain
Anchors
(2)
Chain Anchor MA0239.eps

Adjustment Nuts
Figure 28. Carriage ( 6-roller version ).
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5.4-2
Carriage Removal - WARNING: The inner intermediate upright
must be supported by blocks while removing
Mast on Truck chain pins to avoid possible injury.
1. Raise the Mast high enough to place two 4 X 4 X 20 in.
long (10 X 10 X 50 cm) wood blocks under the inner 2
intermediate upright (see Figure 30).
2. Attach an overhead hoist to the carriage and raise it
slightly to slacken the free lift chains.
6
3. Remove the pins fastening the free lift chains to the
carriage chain anchors.
5. Remove the Allen-head stops on the inner upright
lower crossmember. Tightened to 80 ft.-lbs. ( 110 Nm).
6. Using the overhead hoist, remove the carriage by
lowering it through the bottom end of the inner upright.
7. Remove the load rollers, noting the number of shims
behind each roller for reassembly.
8. For reassembly, reverse the above procedures except as follows:
* Inspect the carriage as described in Section 5.4-4.
* Lubricate the inner upright rails with chassis lube or
Kendall SR-12X where indicated by the heavy line
for the full length of the upright (see Figure 29).
* Assemble shims and load rollers on the carriage.
Roller Shimming - Install shims (none on top
3
rollers of six roller carriage) to provide a total
side-to-side clearance of 1/16 in. (1.5 mm) max. at
the tightest point throughout the travel of the carriage.
Use equal numbers of shims on each side.
* Adjust carriage side thrust rollers for unrestricted
clearance along the travel of the carriage. Turn
the eccentric mount base of each roller toward
the upright rail to decrease clearance. Tighten the
mount capscrews to 79-80 ft.-lbs. (95-110 Nm).
* Inspect and adjust the free lift chains as described
in Section 5.6-1 and 5.6-4.
5
Carriage
Load
Roller
Shims
Upright
Rails Lube
.06 in.
(1.5 mm)
Max.
1
MA0079.eps
Carriage
Side
Thrust
Rollers (4) Figure 30. Removing carriage - Mast on
MA0240.eps
Truck.
Figure 29. Adjusting load and thrust rollers on carriage.
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5.4-3 Carriage Removal -
Carriage
Mast on Floor Load
Roller
Shims
1. Remove Mast from truck as described in Section 5.1.
Upright
Rails Lube
2. Remove the pins fastening the free chains to the
carriage chain anchors.
.06 in.
3. Disconnect the internal reeving hoses from the (1.5 mm)
carriage fittings (if equipped). Plug the hose ends. Max.
4. Remove the Allen-headed stops on the inner upright

lower crossmember. For reassembly, tighten to 80 Carriage
ft.-lbs. (110 Nm). Side
Thrust
Rollers (4)
5. Roll the carriage to the bottom end of the Mast.
MA0240.eps
6. Attach an overhead hoist to the carriage side bars
and remove the carriage through the bottom end of
the Mast. Figure 32. Adjusting load and thrust rollers on carriage.
5 6 2
Figure 31. Removing carriage - Mast on Floor.

7. Remove the load rollers, noting the number of shims
behind each roller for reassembly.
as follows:
* Inspect the carriage as described in Section 5.4-4. MA0080.eps
* Lubricate the inner upright rails with chassis lube or

Kendall SR-12X where indicated by the heavy line * Adjust carriage side thrust rollers for unrestricted
for the full length of the upright (see Figure 32). clearance along the travel of the carriage. Turn
* Assemble shims and load rollers on the carriage. the eccentric mount base of each roller toward
Roller Shimming - Install shims to provide a total the upright rail to decrease clearance. Tighten the
side-to-side clearance of 1/16 in. (1.5 mm) max. at mount capscrews to 79-80 ft.-lbs. (95-110 Nm).
the tightest point throughout the travel of the carriage. * Inspect and adjust the free lift chains as described
Use equal numbers of shims on each side. in Section 5.6-1 and 5.6-4.
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5.4-4 Carriage Inspection
replaced.
2. Inspect the load roller bearings by turning the rollers on their



Lift Technologies for repair procedures.
5. Inspect the chain anchors for wear or damage.
IMPORTANT: The chain anchors nuts must be installed

as shown to function correctly (see Figure 33).
4 Load
Rollers
1 2
Thrust
Rollers
1 2
Chain
Anchors 3
5
MA0241.eps
Thin Thick
Jam Nut Jam Nut
MA0242.eps
Figure 33. Mast carriage - (6 roller version).
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5.5
Mast Uprights
Outer Upright Assembly Inner Intermediate Upright Assembly
The outer upright assembly is mounted to the truck. A pair The inner intermediate upright assembly telescopes within
of shim-adjustable load rollers are attached to stub shafts the outer intermediate upright assembly. A pair of shim-
located near the top of the upright. A pair of adjustable adjustable load rollers are attached to stub shafts located
main lift chain anchors attached to bosses on each inner side at the top and bottom of the upright. A pair of chain
of the upright. Two main lift cylinders, one on each side, sit sheaves are located near the top of the upright to provide a
in bosses on the back of the upright, rolling surface for the inner main lift chains. A hose sheave
is located next to the chain sheave to provide a rolling
surface for the free lift cylinder supply hose.
Outer Intermediate Upright Assembly
The outer intermediate upright assembly telescopes
within the outer upright assembly. A pair of shim- The inner upright assembly telescopes within the inner
adjustable load rollers are attached to stub shafts located intermediate upright assembly. A pair of shim-adjustable
at the top and bottom of the upright. A pair of chain load rollers are attached to stub shafts located at the
sheaves are located near the top of the upright to provide bottom of the upright. The free lift chain anchors are
a rolling surface for the outer main lift chains. attached to the center crossmember and the main lift chain
anchors are attached to the lower end of each of the upright rails.
The free lift cylinder sits on a platform which is intergal with
the lower crossmember. The free lift chain crosshead and
sheaves mount on top of the free lift cylinder.
Outer
Upright
Outer Chain
Intermediate Chain Load Anchor
Inner Upright Roller
Intermediate Sheave
Upright Hose
Inner
Upright Sheave
Crosshead
MA0243.eps
Figure 34. Exploded View of Mast Uprights.
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S Inner Main
Lift Chains
Outer Main
Lift Chains
5.5-2 Upright Operation
Fully Lowered
The outer main lift chains are anchored to the outer
upright top crossmember then travel over the outer
intermediate upright chain sheaves and attach to the Free Lift
Chains
bottom of the inner intermediate upright. The inner main
lift chains are anchored to the outer intermediate upright
top crossmember then travel over the inner intermediate
upright chain sheaves and attach to the bottom of the
inner upright.
Free lift
Actuating the truck valve to raise the Mast causes the free
lift cylinder on the inner upright to raise, which moves the
carriage to the top of the inner upright.
Free Lift
Cylinder
Full Extension
When the free lift cylinder reaches the end of its stroke
the main lift cylinders on the outer upright begin to raise.
Due to the interconnection of the upright by the chains,
extension of the main lift cylinders causes both intermedi-
ate uprights and the inner to raise simultaneously.
Lowering
Actuating the truck valve to lower the Mast causes all
cylinders to lower at the same time resulting in a smooth
lowering of the carriage and load.
Main Lift
Cylinders (2)
MA0247.eps
Figure 35. Upright Operation.
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5.5-3
Upright Disassembly
The Quad Mast uprights require complete disassembly in 8. Disconnect the free lift cylinder hose from the tube and
order to service the load rollers, thrust plugs/blocks, and remove the stop/hose bracket/tube assembly.
chain/hose sheaves.
1. Remove the internal hose reeving from the Mast (if 9. Disconnect the inner main chain anchors from the lower
equipped) while it is on the truck. end of the inner upright and the upper end of the outer
intermediate upright.
2. Remove the Mast assembly from the truck as described
in Section 5.1.
10. Move the inner upright downward. Remove the free lift
3. Remove the main lift cylinders from the Mast as hose sheave, hose and main chain sheaves at the top
described in Section 5.2-4. of the inner intermediate upright.
4. Using an overhead chain hoist, turn the Mast over NOTE: The lower end of the inner upright must be
(face up). raised slightly to clear the inner intermediate upright
lower crossmember.
5. Remove the free lift cylinder from the Mast as described
in Section 5.2-5.
11. Remove the inner main lift chains and tag for
6. Remove the carriage from the Mast as described in reassembly.
Section 5.4-3.
12. Remove the load rollers from the lower end of the inner
7. Remove the free lift chain anchors and chains from the upright. Remove the load rollers and thrust plugs from
inner upright center crossmember and tag for the upper end of the inner intermediate upright. Note
reassembly. the number of shims behind each for reassembly.
8 Inner 12 12
Intermediate
Upright
9
10
Thrust
7 Plug
Inner 10 Thrust
Plug
Main Lift Shim
Chains
11
10
12 9
10
MA0244.eps
7 12
Free Lift
Chains
MA0078.eps
Figure 36. Mast preparation for upright disassembly.
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5.5-3
Upright Disassembly
(continued)
13. Attach an overhead hoist to the inner upright and
remove it through the top end of the inner intermediate
upright.
NOTE: The stub shafts on the lower end of the inner

upright come out of the inner intermediate upright
between the rail cutout and the stub shaft (see Figure 37).
13
Inner
Intermediate
Upright
Inner
Upright
MA0245.eps
Inner
Upright
MA0077.eps
Figure 37. Removing inner upright.
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5.5-3
Upright Disassembly
(continued)
14. Remove the outer main lift chain anchors from the lower
end of the inner intermediate upright and the top end of
the outer upright. Set the chains aside and tag for
reassembly.
15. Remove the lower stop from the outer intermediate

upright.
16. Remove the chain sheaves from the outer intermediate

upright.
17. Roll the inner intermediate upright downward and

remove the lower rollers. Remove the upper rollers and
thrust plugs from the outer intermediate upright. Note
the number of shims behind each roller for reassembly.
18. Attach an overhead hoist to the inner intermediate

upright and remove it through the top end of the outer
intermediate upright.
15 17
18
17
17
16
Outer Main
Lift Chain 14
Anchors
Inner
MA0076.eps
Intermediate
Upright
Figure 38. Removing inner intermediate upright.
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5.5-3
Upright Disassembly
(continued)
19. Roll the outer intermediate upright downward and remove
the lower rollers. Remove the upper rollers and thrust
blocks from the outer upright. Note the number of shims
behind each roller and thrust block for reassembly.
20. Attach an overhead hoist to the outer intermediate upright
and remove it through the top end of the outer upright.
19
Thrust
20 19 Block
19
Thrust
Plug
Thrust
Plug
MA0075.eps Shim
5.5-4
Upright Inspection Outer
Intermediate
1. Inspect the load for excessive wear or Upright
damage. Rollers with visible flat spots or cracks
should be replaced.
Figure 39. Removing outer intermediate upright.
2. Inspect the load roller bearings by turning the rollers
on their shafts. Rollers with roughness or noticeable
restrictions to turning should be replaced.
3. Inspect the load roller stub shafts. IF they are
damaged or have cracks at the base, the upright
must be replaced or repaired.
4. Inspect the outer and intermediate upright thrust
blocks and plugs. If the wear surface is worn to less
than 1/16 in. (1.5 mm) thickness, they should be
replaced as described in Section 5.5-5.
5. Inspect the free and main lift chains as described in
Section 5.6-1.
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5.5-5
Upright Reassembly 1 4 Lube
1. Lubricate the full length of the outer upright rails with
chassis lube or Kendall SR-12X (see Figure 39).
2. Attach an overhead hoist to the outer intermediate Upright
Rails
upright and install it through the top of the outer
upright. Position it out the lower end of the outer upright
about 6 in. (15 cm).
3. Assemble shims, load rollers and thrust blocks to the
upper end of the outer upright. Assemble shims and
load rollers to the lower end of the outer intermediate
upright.
Roller Shimming - Install shims to provide a total side-
to-side clearance of 1/16 in. (1.5 mm) max. at the Upright
tightest point throughout the travel of the upright (see Rail
Figure 40). Pry between the upright and the load roller so Shim
that the opposite load roller is tight against the upright.
Measure the clearance for the pair of rollers at the XXX Load
shown. Use an equal number of shims on each side. Rollers
NOTE: Roll the uprights past installed thrust plugs/

blocks before checking load roller clearance.
3
Thrust Plug/Block Replacement - Install thrust plugs/ .06 in.
blocks to provide a clearance of 1/16 in. (1.5 mm) max. (1.5 mm)
between an upright and its corresponding thrust plug/ Max. MA0259.eps
block (see Figure 41). Pry between the upright upper
crossmembers. Measure the clearance at the XXX Figure 40. Channel lubrication area, load roller clearance
shown to determine which thickness thrust plug/block to measurement.
use. Thrust plugs/blocks may be shimmed as required.
4. Lubricate the full length of the outer intermediate 3
upright rails with chassis lube or Kendall SR-12X
Thrust Thrust
(see Figure 40). Plugs Block
2
.06 in.
(1.5 mm)
Max.
2 Thrust
Block
Inside
of Rail
Outer
3 Upright
MA0246.eps
Figure 41. Installing outer intermediate upright.

Outer
Intermediate
Upright
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5.5-5
Upright Reassembly
(continued)
5. Attach an overhead hoist to the inner intermediate 8. Install the outer main lift chain anchors (long anchors) to
upright and install it through the top end of the outer the lower end of the inner intermediate upright.
intermediate upright. Position it out the lower end of the 9. Install the lower stop on the outer intermediate upright.
outer intermediate upright about 6 in. (15 cm). Tighten the capscrew to 81-88 ft.-lbs. (110-120 Nm).
6. Install shims and load rollers to the lower end of the 10. Install the main chain sheaves and free lift sheaves and
inner intermediate upright. Install shims, load rollers hose in the inner intermediate upright. Tighten the
and thrust plugs to the upper end of the outer interme- retainer capscrews to 26-30 ft.-lbs. (35-40 Nm).
diate upright. Refer to step 3 for roller shimming and
thrust plug clearance measurement. 11. Install the upper inner main chain anchors to the outer
intermediate upright. Install the free lift hose bracket
7. Install the chains sheaves to the upper end of the outer and tube.
intermediate upright. Install the outer main lift chain
anchors and chains over the outer intermediate upright 12. Lubricate the inner intermediate upright rails with
chain sheaves. chassis lube or Kendall SR-12X (see Figure 39).
5
10
5
9
10
10 MA0250.eps
6
7
6
8
Inner Main 6 Load Roller,

Chain Anchor Thrust Plug
11 MA0248.eps
Thrust
15
Plug
Thrust
Plug
Shim Inner
Intermediate
Upright
11
Free Lift
Hose
Bracket Tube
Figure 42. Installing inner intermediate upright.
Outer Intermediate
Upright MA0249.eps
12-160
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5.5-5
Upright Reassembly
(continued)
13. Attach an overhead hoist to the inner upright and install
through the top of the inner intermediate upright.
Position it out the lower end of the inner intermediate
upright about 6 in. (25 cm).
14. Assemble shims and load roller to the lower end of the
inner upright. Assemble shims, load rollers and thrust
plugs to the upper end of the inner intermediate upright.
Refer to Step 3 for roller shimming and thrust plug
clearance measurement.
15. Install the inner main lift chain anchors (long anchors)
on the back side, lower end of the inner upright and
connect the inner main lift chains.
16. Install the stop/hose bracket/tube assembly on the

lower end of the inner upright. Tighten the capscrews
to 81-88 ft.-lbs. (110-120 Nm).
13
14
15
13 Thrust
Plug
Thrust
Plug
Shim
MA0269.eps
14
14
Inner
Upright
16
MA0251.eps
MA0252.eps
Figure 43. Installing inner upright.

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5.5-5
Upright Reassembly
(continued)
17. Install the free lift chain anchors (short anchors) and
chains to the inner upright center crossmember.
18. Install the free lift cylinder supply hose to the free lift
cylinder tube. Leave the tubing clamp loose. 22 21
19. Install the carriage as described in Section 5.4-3.
20. Install the free lift cylinder as described in Section

5.2-5. Connect the tube to the cylinder fitting and
MA0254.eps
tighten the tubing clamp.
21. Place a 2 X 4 in. (5 X 10 cm) wood block between the Figure 44. Blocking uprights before turning Mast over.
outer and outer intermediate lower crossmembers to
prevent upright movement.
22. Turn the Mast over (face down), rotating it on its lower 24. Install the Mast to the truck as described in Section 2.2.
end. Make sure the Mast is re-blocked in a level
position (see Figure 44). * Install the internal hose reeving (if equipped) as
23. Install main lift cylinders as described in Section 5.2-4. * Adjust the main and free lift chains as described
in Sections 5.6-3 and 5.6-4.
* Check the Mast for skewing as described in
18 Section 5.5-6.
17
Figure 45. Final assembly of Mast.
MA0253.eps
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5.5-6
Mast Skewing Adjustment
1. Extend the mast to full lift height (see Figure 47).
* If the mast bends to the right at full extension, 1
a shim(s) needs to be removed from the left
main lift cylinder rod.
* If the mast bends to the lift at full extension,
a shim(s) needs to be installed on the left
main lift cylinder rod.
WARNING: The upright must be supported

Free Lift
2. Place a 4 X 4 X 20 in. (10 X 10 X 50 cm) wood block Cylinder
between the outer intermediate and outer upright
crossmembers (see Figure 46). Lower the Mast
uprights onto the block.
3. Remove the snap ring from the left-hand cylinder rod. 1 1
Open the truck valve to allow the cylinder rod to retract.
Tap the cylinder rod down past the outer intermediate’s
top crossmember. Install or remove shim(s) on the
cylinder rod, below the crossmember (see Figure 46).
Shim are listed below:
Shim Thickness Part No.
.010 in. (.25 mm) 205198
.031 in. (.79 mm) 205199
.062 in. (1.57 mm) 205196
.092 in. (2.36 mm) 205197
4. Slowly hydraulically power the main lift cylinder rod up

into the crossmember and reinstall the snap ring.
Outer Left Hand Right Hand

Intermediate Main Lift Main Lift
Upright Cylinder Cylinder
3 Snap
Ring 4 x 4 in.
2 (10 x 10 cm)
Wood Block
Outer
Upright
Shim 4
MA0261.eps
Figure 47. Extending Mast to check

MA0260.eps for skewing (driver’s side).
Figure 46. Blocking upright to retract

LH main lift cylinder rod.
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5.6 Chains
5.6-1
Lubrication, Adjustments
and Wear
Regular lubrication and adjustment of the chains will
increase their service life and reduce Mast downtime. The
chains should be covered with a thin film of lubricant at all
times. If the chains are dry, lubricate the full length of the
chains with SAE 40 wt. oil or Bowman Heavy Load Red
Grease.
The chains should be adjusted for: 1) correct upright and

carriage position and 2) equal tension to ensure proper
load distribution and mast operation (Refer to Section 2.3,
Mast Inspection). If the uprights or carriage are not on
the proper position, or if chain tension is not equal, adjust
the chains as described in Sections 5.6-3 and 5.6-4.
The chains should be free of any of the damage shown (see

Figure 48). If inspection reveals that one strand of a pair of
chains requires replacement, both strands of the pair
should be replaced.
* Check for rust.
* Check for cracked side plates. If damage is found

replace both strands of the chain.
* Check for tight joints. If tight joints are caused by rust or

caused by bent pins or plates or by peened plate edges,
replace both strands of the chain pair.
* Check for protruding or turn pins. If damage is found,

replace both strands of the chain pair.
* Check for chain side wear. If pins and outside plates

show signs of wear, check for misalignment of sheaves,
If wear is excessive, replace both strands of the chain pair.
* Check for worn, broken or misaligned chain anchors.

Figure 48. Damage requiring chain replace-

ment.
12-164
12. MASTS
ervice
S Weldments are to be flush within 3mm for
notes 2 and 3 in Section 5.6-3.
5.6-2 Measuring Chain Stretch *3 in.
Underclearance
*5 in.
Underclearance
Chain stretch can be measured with Chain Wear Scale.
Measure the chains according to the instruction printed
on the scale, without a load on the carriage. If the chains Outer Upright
are stretched beyond the recommended amount, they and Carriage
should be replaced in pairs. Flush Outer
Upright
* To check the free lift chains, raise the carriage 1 ft.
(30 cm) off the ground to out tension on the chains.
Carriage 2 in.
* To check the main lift chains, raise the mast until the Below Outer
inner upright starts to extend to put tension on the Upright
MA2777.eps
chains.
NOTE: Underclearance is based on mast
5.6-3 Outer and Inner Main Lift production series, actual mast
Chain Adjustment underclearance may vary by truck
model.
Figure 49. Mast showing correct retracted
unloaded Mast is fully lowered, the uprights are flush at the
bottom (see Figure 49). position of uprights and carriage.
1. Locate the four main lift threaded chain anchors on the
back side top of the outer and outer intermediate
uprights, on each side of the main lift cylinders (see
Figure 50).
2. Adjust one anchor of the outer main lift chain pair first to
achieve a flush inner intermediate upright position with
the Mast outer uprights (see Figure 49).
1 2 3
3. Adjust the other anchor of the pair to achieve equal Inner Main Outer Main
chain tension. Repeat steps 1 and 2 for the inner Lift Chain Lift Chain
Adjusting Adjusting Nuts
main lift chain pair to achieve a flush inner upright Nuts
position with the Mast intermediate uprights. Tighten
the chain anchor nuts to 50-70 ft.-lbs. (68-95 Nm)
(see Figure 49).
4. Raise and lower the Mast several times to confirm the
adjustments.
5.6-4 Free Lift Chain Adjustment
The free lift chains should be adjusted so that when the
unloaded mast is fully lowered, the carriage is properly 1 2 3
positioned (see Figure 49). Free Lift Chain
Adjusting Nuts
1. Locate the threaded chain anchors on the front side of
the inner upright crossmember on each side of the free
lift cylinder (see Figure 50).
2. Adjust one anchor to achieve the correct carriage

position when lowered.
3. Adjust the other anchor to achieve equal chain tension.

Tighten the chain anchor nuts to 50-70 ft.-lbs.
(68-95 Nm). MA0262.eps
4. Raise and lower the carriage several times to confirm

the adjustments.
Figure 50. Adjustable chain anchor location (driver’s
view).
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5.6-5 Outer Main Lift Chain 5.6-6 Inner Main Lift Chain
Replacement Replacement
WARNING: The inner intermediate WARNING: The inner upright must
upright must be supported by blocks be supported by a block to avoid
to avoid possible injury. possible injury.
1. Raise the inner intermediate upright and place a 1. Raise the inner upright and place a 2ft. (60 cm) long
2 ft. (60 cm) long block under each of the upright’s block under the free lift cylinder support casting.
rails. Lower the upright onto the blocks. The outer Lower the upright onto the block. The inner main lift
main lift chains should be slack (see Figure 51). chains should be slack (see Figure 52).
2. Remove the cotter pins and chains from the 2. Remove the cotter pins and chain pins from the
chain anchors. Remove the chains. chain anchors. Remove the chains
3. Inspect the chain anchors for cracks or other 3. Inspect the chain anchors for cracks or other
damage as described in Section 5.6-1. damage as described in Section 5.6-1.
4. For reassembly, reverse the above procedures. 4. For reassembly, reverse the above procedures.
Adjust the outer main lift chains as described in Adjust the inner main lift chains as described in
Section 5.6-3. Section 5.6-3.
2
Upper Chain
Anchor on
Outer Upright
2
Upper Chain
Anchor on
Inner Outer Intermediate
Main Lift Upright
Outer Main
Lift Chains (2) 2 Chains (2)
2
Lower Chain Lower Chain
Anchor on Inner Anchor on Inner
Intermediate Upright
Upright
1
1 MA0264.eps
MA0263.eps
Figure 51. Replacing outer main chains (RH chain Figure 52. Replacing inner main chains (LH chain
shown). shown).
12-166
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5.6-7 Free Lift Chain
Replacement
WARNING: The carriage must be
supported by a block to avoid pos-
sible injury.
1. Raise the carriage and place a 4 X 4 12 in. (10 X

10 X 30 cm) block under the carriage lower
crossmember. Lower the carriage onto the block. The
free lift chains should be slack (see Figure 53).
anchors. Remove the chains
3. Inspect the chain anchors for cracks or other damage

as described in Section 5.6-1.

the free lift chains as described in Section 5.6-4.
Free Lift
Chains (2)
Chain Anchor
on Inner
Upright
2
2
Chain Anchor
on Carriage
MA0265.eps
Figure 53. Replacing free lift chains.
12-167
NOTES:
ELECTRICAL
DIAGRAMS
BX50 TIER 2 DIESEL (4D94LE ENGINE) S/N 200001A - 215882A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
BX50 INTERIM TIER 4 DIESEL (4D98E ENGINE) S/N 215883A - 219999A / 750875~ / A223001~. . . . . . . . . .A-3
BX50 TIER 1 GASOLINE (K21/K25 ENGINE) S/N 200001A - 205849A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
BX50 TIER 2 GASOLINE (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~ . . . . . . .A-7
BX50 TIER 1 LPG (K21/K25 ENGINE) S/N 200001A - 205849A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
BX50 TIER 2 LPG (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~ . . . . . . . . . . . A-11
BX50 CARB 2010 LPG (K21/K25 ENGINE) S/N 751863~ / A224001~. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-13
BX50 CARB 2010 LPG (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM. . . . . . . . . . . . . . . . .A-15
BX50 TIER 1 LPS (K21/K25 ENGINE) S/N 200001A - 205849A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-17
BX50 TIER 2 LPS (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~. . . . . . . . . . . .A-19
BX50 TIER 1 DUAL FUEL (K21/K25 ENGINE) S/N 200001A - 205849A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-21
BX50 TIER 2 DUAL FUEL (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~ . . . . .A-23
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) S/N 751863~ / A224001~ . . . . . . . . . . . . . . . . . . . . . . . . .A-25
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM . . . . . . . . . .A-27
BX50 TIER 2 DIESEL (4D94LE ENGINE) S/N 200001A - 215882A
BX50 TIER 2 DIESEL (4D94LE ENGINE) S/N 200001A - 215882A
HEAD LAMP (55W) OP TAIL LAMP (8W)
AWG16B AWG18LW AWG18LW
STOP LAMP (23W) REAR
1 2
1 2 3 4 5
AWG18GY AWG18GY AWG18GY
AWG20YR AWG20YR REAR LAMP(R)
DRIVING LAMP (8W) AWG16B
AWG18L
AWG16B
AWG18L
AWG16B
OP WINKER LAMP (23W) COMBI
1 2 3
AWG20YR AWG20YR 1.25G
6 5 4 3 2 1
AWG18L AWG18LW 1.25W
AWG16B
WINKER LAMP (23W) AWG12B AWG16B
AWG18L
AWG18GW
1.25Y
1.25BR
BACK UP LAMP (10W) LAMP
AWG14B AWG16B 1.25B
AWG12B
AWG20RB
SPOOL LOCK SOL(TILT)
1 2 3 4 5 6 7 8
AWG18B AWG20YG
1 2
AWG18GY AWG20B
AWG18YB OP
AWG16R
SPOOL LOCK SOL(LIFT) AWG18B AWG16YB L.O.P.
BACK BUZZER
AWG18B
1 2
AWG18GY AWG20B OP
AWG20L
OP
BUZZER AWG20B AWG18GW
+-
1 2 3
1 2
AWG20GW AWG18B
LF1 AWG16BY
AWG18G
AWG16BY
AWG20R
AWG20B
DIODE
AWG20RY
AWG20LY
AWG20B
AWG20B
AWG14B
AWG12B
AWG20RY
1 2 3 4 5 6 7 8 9 10 11 12
T/C OIL TEMP.
AWG20LY AWG18B 2 1
AIR FILTER
a 1
BRAKE OIL AWG20L AWG18GY
OP
COM AWG20RW 2 1 2 1
COOLANT
AWG18YR
OP
2 1
1 DISPLAY
AWG18Y
COOLANT AWG20R
GLOW AWG20R OP
GND AWG20B
GND OP
POWER AWG20Y
T/C OIL TEMP AIR FILTER 2 1
POWER(+) AWG20LW
OUT PUT(+) AWG20WR
OP
1DISPLAY
1 2
AWG18RW
POWER(+B)
OP
POWER(+) AWG20LW B
LIFT
1 2 3
OUT PUT(+) AWG20WR
COM AWG20RW
OIL PS
1
R
2
(AWG4B)
B
R
S L
E
E
E
STARTING MOTOR ALTERNATOR
GLOW PLUGS
FUSE BOX
L2
F20 F19
AWG8WR
SLOW BLOW FUSE & RELAY BOX
F18 F17 F16

10A AWG18G
10A AWG16RW
AWG20R
AWG18YR
1 3 5 6 8 10 12
15A AWG16GR
7 9 11
AWG20BR
AWG20YL
MAIN RLY
F15 F14 F13 F12 F11

AWG20LY
AWG20W
AWG18Y
AWG20W S.B FUSE PARKING MAST LOCK AUX
2 4
AWG20RB AWG10W
F RELAY R RELAY HORN RELAY RELAY RELAY MAIN RELAY

40A
AWG12WG
WATER
F10
AWG10W
TEMP
1 2 3
ST AWG16BY AWG16YB
F9 F8 F7 F6
IGN 15A
B AWG12W
AWG20LW AWG16Y
ACC AWG20LR 60A 10A
10A
10A
AWG18YG
AWG18GY SENSOR
STOP LAMP SW
AWG16LW AWG8W 4 3 2 1
CONT
1 2
AWG16RW
F5 F4 F3 F2 F1
MAST LOCK 120A
FLASHER UNIT L AWG18Y
EARTH
2 1
B AWG18GW
AWG18RW
AWG18GY
AWG18RY
AWG18B
GLOW 5 4 3 2 1
1 10 9 8 7 6
2 15 14 13 12 11
3 20 19 18 17 16
4 25 24 23 22 21
5 30 29 28 27 26
6
SEAT SW
L1
L R
AWG12WB
AWG8WR
AWG12W
AWG20RW
SEDIMENTER/ (B) AWG20B DIODE
SEAT SW 1
SEAT SW 2
AWG12WG
AWG16L
MAINTENANCE
AWG16RB
AWG20GW
AWG20YG
AWG16RW
AWG20GL
AWG18GY
1 2 3 4 5 6 7 8
AWG18RY
AWG18RY
AWG20BY
AWG16Y
AWG16Y
AWG20GY
AWG18GW
AWG20LY
AWG18RW
AWG18RW
AWG20BW
AWG20G
AWG20G
AWG20WL
AWG16Y
AWG16GR
AWG20YR
AWG20G
AWG20BY
AWG18G
N N N Up N Up
Down AWG18LW
AWG18GW AWG20BR
N LAMP Down Up Up Down Down
AWG16RL HOUR
N.O
N.C
AWG18G
AWG12B
AWG16B
AWG18YG
OFF
1 2 OFF 1 2 OFF 1 2
AWG18GY METER
CHARGE (A)
AWG18RW CUT
1 2 3 4
AWG18GR
R
B
L
AWG18R AWG20B AWG16RW AWG16RW AWG18RW
OIL AWG20YR
AWG8W
1 2 3 4
PRESSURE
COMBINATION SW
AWG20RG
AWG20G
AWG20Y
AWG20Y
F
FUEL GAUGE B
T
E
13 15 18 20 22
AWG18B
14 16 17 19 21
AWG20GR
AWG20YR
HOUR METER AWG20RW
AWG20L
F-R SWITCH HORN SW

AWG20YG
1 2
AWG20B
W
WATER TEMP B
T
E
ILLUMINATION F R N AWG20RL
1 2 3 4 5 6 7 8 9 10
AWG18B
AWG20WL
AWG18Y
AWG18YB
SEAT SW
AWG20Y AWG20Y
1
AWG20G
2
AWG20RG
3
AWG18GW AWG20LR
4
AWG12B AWG12B AWG12B
AWG8W
AWG12WL
AWG20R
AWG20G
AWG12B
AWG16B
AWG18G
WAG20RY
WAG20B
AWG16R
AWG16L
AWG18B
BATTERY AWG18GW
AW
G8
DIODE
W
1 2
+ -
AWG20GW
AWG18RW
AWG20BW
AWG20RG
AWG20WL
AWG22RG
AWG18GY
AWG20GY
AWG18BR
AWG20BR
AWG18BR
AWG20YR
AWG18BR
AWG20RY
AWG20BY
AWG20BY
AWG20YL
AWG20LY
AWG12WB
AWG20RG
AWG12WL
AWG20GW
AWG20G
AWG20G
AWG20YB
AWG20B
AWG20Y
AWG20B
AWG18YG
AWG20GY
AWG20LW
AWG20YB
AWG18BY
AWG18RL
AWG20YL
AWG18GW
AWG12WG
AWG20GW
AWG18GW
AWG16RW
AWG18B
AWG20B
AWG22RG
AWG20RG
AWG20WL
AWG16GR
AWG18GY
AWG20YG
AWG20GY
AWG20LW
AWG20LW
AWG16RB
AWG20YR
AWG20RY
AWG20GL
AWG18BY
AWG16YB
AWG18RL
AWG20LR
AWG20YL
AWG20YL
AWG18G
AWG18B
AWG18B
AWG12W
AWG18G
AWG20G
AWG16R
AWG12B
AWG16Y
AWG16L
(AWG1B) (AWG1B)
87A 87 30 86
FUEL CUT OIL SEDIMENTER 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 1 a
6 5 4 3 2 1
3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
PARKING SOLENOID PRESS SENS0R FUEL
AWG20LW
AWG8WR
AWG18BY
CONTROLLER (INTERLOCK-BOX)
AWG8W
AWG20R
AWG18B
SW LEVEL
AWG12WG
AWG20GW
AWG20RW
BUZZER
AWG18GY
AWG20GB
AWG18GW
AWG16RW
AWG20YG
AWG20GR
AWG20RY
AWG20LW
AWG16GR
AWG20RB
AWG20WL
AWG20RL
AWG20LY
AWG20LW
AWG20YR
AWG16YB
AWG12W
AWG18YB
AWG16BY
AWG18RL
AWG20LR
AWG18G
AWG12B
AWG20R
AWG20L
AWG16G
AWG18Y
SOLENOID SENSOR
AWG20GW
AWG20GW
2 1 6 5 4 3 2 1
CUT VALVE(T) DIODE
R F
TIMER
CIRCLE
QGS (A) QGS (B) OP TAIL LAMP (8W)

STOP LAMP (23W)
REAR
COMBI
AWG16RW
1.25G
1.25W
OP WINKER LAMP (23W)
1.25Y
1.25Br LAMP
1.25B BACK UP LAMP (10W)
OP
OP
AWG12B
PARKING SW
AWG16G
N.O
COM AWG16RW
STROBE LIGHT
2 1
HEAD LAMP (55W) AWG18LW
N.C
AWG16B AWG18GY AWG18YG

AWG16B
1 2
1 2 3 4 5
AWG18GY AWG20YR AWG18R

AWG18L AWG20YR

AWG16B AWG18RL
AWG16B
AWG16B
1 2 3
AWG20YR
AWG18L
WINKER LAMP (23W) HORN
AWG20B
AWG20GB
AWG20L
2 1
AWG18B
OP
BRAKE OIL
A-1
BLANK PAGE
BX50 INTERIM TIER 4 DIESEL (4D98E ENGINE) S/N 215883A - 219999A / 750875~ / A223001~
BX50 INTERIM TIER 4 DIESEL (4D98E ENGINE) S/N 215883A - 219999A / 750875~ / A223001~
A-3
BLANK PAGE
BX50 TIER 1 GASOLINE (K21/K25 ENGINE) S/N 200001A - 205849A
BX50 TIER 1 GASOLINE (K21/K25 ENGINE) S/N 200001A - 205849A
OP TAIL LAMP (8W)
HEAD LAMP (55W)
REAR
STOP LAMP (23W)
1 2
1 2 3 4 5

AWG20YR
AWG18L
AWG16B
AWG20YR
AWG18L
AWG16B
REAR
LAMP(R)
COMBI
1 2 3
LAMP
AWG16B
6 5 4 3 2 1
AWG18L AWG18GL 1.25W
WINKER LAMP (23W) AWG18L
AWG18GW
1.25Y
1.25Br
AWG12B
AWG14B
AWG16B
AWG16B 1.25B BACK UP LAMP (10W)
AWG12B
1 2 3 4 5 6 7 8
AWG18B AWG20YG
1 2
AWG18GY AWG20B
AWG20YB OP
AWG20R
SPOOL LOCK SOL(LIFT) AWG18B AWG18YG L.O.P. BACK
AWG18B
1 2
AWG18GY AWG20B OP
AWG20YR
BUZZER
BUZZER OP AWG18B AWG18GW
+
1 2 3
1 2
AWG20LB AWG18B
LF1 AWG18G -
AWG16BY
STARTING MOTOR
AWG20R
AWG20B
AWG16BY
AWG20RY
DIODE
AWG20LY
AWG20B
AWG20B
AWG14B
AWG12B
AWG20RY
T/C OIL TEMP. B
1 2 3 4 5 6 7 8 9 10 11 12
AWG20LY AWG18B (AWG4B) 2 1
AIR FILTER
a 1
OP BRAKE OIL AWG20L AWG18GY
COM AWG20RW 2 1 2 1
S
2 1
OP
AWG20R
1 DISPLAY COOLANT
LPG LOW FUEL (GLOW) AWG20YB
AWG20B
OP
GND OP
(AWG4B)
COOLANT
GND
AWG20Y
POWER
AVCC(48) AWG20RY
AWG20GW
T/C AIR
SNOW OPE(12)
OIL FILTER
AWG12WL
AWG20LW
POWER(+)
OUTPUT(+) AWG20WR SPEED
OP TEMP SEN UNIT E
EARTH
1 2
AWG18RW
1DISPLAY
SPEED SENSOR(2)
SPEED SENSOR(1)
POWER(+B)
VSP8(33)
VB(119)
GND(1)
GND(1)
OP
POWER(+) AWG20LW
1 2 3
AWG20WR
LIFT OUTPUT(+)
COM AWG20RW
OIL PS 6 5 4 3 2 1
AWG18WR
AWG20GR
AWG20LY
AWG20R
AWG20B
AWG20B
GND
(ISO CONTROLLER) AWG16B
AWG12B
GND
AWG22WR
AWG22BW
AWG22BW
AWG22YR
AWG22L
(ECM CONTROLLER) AWG14B
AWG14B
AWG16W(SH)
AWG22W(SH)
AWG22W(SH)
AWG22R(SH)
AWG22B(SH)
AWG16B(SH)
AWG14B AWG22B
GND-A2(AWU)(83)
6 5 4 3 2 1
APS2(AWU)(98) AWG22BrW 1 2 3 4 5
GND-A(AWU)(82) AWG22B
AVCC2(AWU)(91) AWG22YB
AWG20GY
GND-A(67)
GND-A(67)
CONTROLLER (INTERLOCK-BOX) AWG22LW
1 2 3
AWG20B APS1(AWU)(106)
QA+(51)
AWG22RB
VB(119)
FUEL LEVEL SENSOR AVCC(AWU)(90) 6 5 4 3 21
TA(34)
26 25 24 23 22 21 20 19 18 17 16 1514131211 10 9 8 7 6 5 4 3 2 1
GND-A2(66)
MOTOR1(5)
MOTOR2(4)
AVCC2(47)
TPS1(50)
TPS2(69)
AIR
AWG20GW
AWG20BW
AWG20WL
AWG20RG
AWG20RG
AWG18GY
AWG20GY
AWG18BR
AWG18BR
AWG18BR
AWG18BR
AWG20BY
AWG20BY
AWG20LR
AWG20LR
AWG20YL
AWG20LY
AWG18G
AWG20G
AWG18R
AWG20B
AWG20Y
AWG20B
FLOW
METER THROT
1 2 3 4 5 6
FUEL PUMP AWG14B
AWG18BR
(GAS) CHAMBER
AWG14RB INJ SOL #4 INJ SOL #3 INJ SOL #2 INJ SOL #1 MOTOR &
AWG16B
AWG12B
SENSOR
INJ#4(41)
INJ#3(22)
INJ#2(42)
INJ#1(23)
IGN ACC
IGN ACC
IGN ACC
IGN ACC
AWG20B
2 1 2 1 2 1 2 1
AWG18GB
AWG18RB
AWG18RB
AWG18RB
AWG18GL
AWG18GW
AWG18RB
AWG18G
AWG20BW
AWG20BW
AWG22GL
AWG18LB
AWG18R
AWG22B
4 3 2 1
O2HFR(O2 SENSOR)(24)
O2SFR(O2 SENSOR)(35)
GND-A(O2 SENSOR)(78)
FUSE(O2 HEATER)
SOLENOID
VALVE(T)
R F O2 SENSOR
AWG20GL
AWG20GB 81 IGN#2
80 IGN#4
AWG22B 78 GND-A(O2 SENSOR)
1 2 3 4
AWG18GW
AWG18G
AWG18B
AWG18B
AWG22GL 73 TW(WATER TEMP SENSOR)
AWG16WR
AWG22W(SH) AWG18G
69 TPS2(THROT CHAMBER)
AWG20BW
67 GND-A(SENSOR & DRIVER)
DIODE AWG18B
AWG18GW
AWG22B(SH) 66 GND-A2(THROT CHAMBER)
CONDENSOR
AWG18GW
AWG18G
AWG18B
AWG20GW AWG18WR
AWG20G 62 IGN#1
61 IGN#3
AWG18YR IGN COIL #4 IGN COIL #3 IGN COIL #2 IGN COIL #1
1 3 5 6 8 1012
2 4 7 9 11
AWG20BR
GND (-)
SEAT SW 1
IGN (+)
AWG20GR
AWG20YL
1 2
AWG20R AWG20Y B
AWG20RY N.O
1234
AWG20LR IGN +12(EGI RLY2) AWG18WL AWG20G IGN#3 TrZB (61) IGN +12(EGI RLY2) AWG18WL AWG20GW IGN#1 TrZB (62) AWG20Y L
1 2 3
1 2 3
1 2 3
1 2 3
AWG14WR
AWG18B AWG18B AWG18B AWG18B
AWG18Y
AWG20RB
AWG20LW 54 VARI VSP(TRUCK SPEED RESISTOR) GND TrZE
IGN#4 TrZB (80) AWG20GB AWG18WL GND TrZE
IGN +12(EGI RLY2) 1 2
GND TrZE
IGN#2 TrZB (81) AWG20GL AWG18WL GND TrZE
IGN +12(EGI RLY2)
AWG20G
AWG20RG
R
SEAT SW
AWG22L N.C
51 QA+(AIR FLOW METER)
AWG18WL
ECM (81P CONNECTOR)
AWG22R(SH)
WATER TEMP
AWG18B
AWG22Y 50 TPS1(THROT CHAMBER)
AWG12WG AWG20RY 49 AVCC(FUEL SELECT SW)
48 AVCC(SENSOR) SENSOR
1 2 3
ST AWG16BY AWG22W(SH) SEAT SW 2

B IGN AWG12W 47 AVCC2(THROT CHAMBER)
AWG20B
ACC (TO METER PANEL)
AWG16GL AWG16B AWG16B AWG16B
STOP AWG18GL
1 2
AWG16RW AWG18GB 42 INJ#2SOL(GAS) AWG18RB

41 INJ#4SOL(GAS)
LAMP SW
MAST LOCK FLASHER L AWG18Y AWG20WR
2 1
AWG18GW
AWG20WR
AWG16B
B
UNIT AWG20B AWG22B
MAINTENANCE
AWG22GL
AWG22YR 35 O2SFR(O2 SENSOR) AWG22B
AWG22GL
WATER TEMP
34 TA(AIR TEMP SENSOR) TW(73)
SENSOR
1 2
L R
AWG20LY 33 VSP8(TRUCK SPEED SIGNAL) AWG22BW
AWG22Y GND-A(67)
32 FUELSW2(SELECT GAS)
AWG22RY
(TO ECM)
ERROR LAMP (B)
30 LED(ENG SYS ERROR)
AWG16L ENGINE OIL PRESS SEN
AWG22BrW
1 2 3 4 5 6 7 8
AWG22WR
AWG22WR
AWG16GR
AWG22LY
N N
(TO METER PANEL:E/G H.L-1P)
AWG22B
AWG22B
Down N Up N Up AWG18LW
AWG18GW AWG20BR
AWG16RL AWG18LB
AWG18GW 24 O2HFR(O2 SENSOR)
23 INJ#1SOL(GAS)
OFF 1 2 OFF 1 2 OFF 1 2
AWG18YG
AWG18GY
HOUR METER AWG18G 22 INJ#3SOL(GAS) 6 5 4 3 2 1
CUT
AWG20GY
CHARGE
GND(1)
POS(13)
VB(119)
GND(1)
PHASE(14)
VB(119)
(A) AWG22B 82 GND-A(ACCEL WORK UNIT)
AWG18RW AWG22B 83
1 2 3 4
AWG18GR AWG20B AWG22GY GND-A2(ACCEL WORK UNIT)

AWG18R AWG22YB 84 H/LMT(HEAD LAMP ON)
AWG20YR 85 K-LINE(CONSULT)
OIL PRESSURE AWG22LY 14 PHASE(CAM ANGLE)
AWG22BrW
AWG22GW 13 POS(CRANK ANGLE) CRANK & CAM ANGLE
AWG18YR
COMBINATION SW 12 SNOW SW(ECO) AWG22RB 90 AVCC(ACCEL WORK UNIT) SENSOR
AWG20RG
AWG22YB 91 AVCC2(ACCEL WORK UNIT)
AWG20G
AWG20Y
ECM (40P CONNECTOR)
F
FUEL GAUGE B
T
E
1315 18 20 22
AWG18B
1416 17 19 21
AWG20GY AWG16W(SH) AWG22BrW 1 2 3 4

AWG16B(SH) 5 MOTOR1
98 APS2(ACCEL WORK UNIT)
HOUR METER AWG20YR
AWG20RG AWG16LW 4
3
MOTOR2
V-MOT
AWG20YR
AWG20RG
AWG18GL
AWG20LR
AWG14B 101 BRAKE(FOOT BRAKE ON)
AWG20G
AWG20Y
1 GND AWG22RB
HORN SW 102 NEUT(NEUTRAL SW ON)
F-R SWITCH AWG18BY
AWG20YG 104 MOTRLY(CHAMBER M.RLY)
RELAY BOX2 RELAY BOX1
1 2
AWG20B AWG22LW
W 106 APS1(ACCEL WORK UNIT)
WATER TEMP B
T
E
MAIN RLY
ILLUMINATION AWG18R VRI SPEED REGISTOR(OP) 21 AWG20BW
AWG20LW
SLOW BLOW FUSE & RELAY BOX(TRUCK CONTROL & ISO 3691)
F R N AWG20RG 109 IGN SW(KEY SW IGN ACC) AUX
1 2 3 4 5 6 7 8 9 10
AWG18B AWG18GL
AWG20WL 111 SSOFF(VB POWER ON RLY) NEUT SIGNAL FUEL PUMP ETC MOT EGI EGI HORN R RELAY F RELAY MAIN MAST LOCK PARKING
AWG22BR RELAY RELAY RELAY RELAY2 RELAY1 S.B FUSE 1 RELAY RELAY RELAY RELAY AWG16R
1 2 3 4
AWG18Y 113 FPR(FUEL PUMP M.RLY(GAS)) AWG12W 40A AWG12W AWG18RL
AWG18LR AWG20B
AWG18RY
AWG16B
115 GND S.B FUSE 2
AWG16RW
AWG14B AWG16WB
AWG16GR
AWG16YG
AWG18RB
AWG16RY
AWG18YB
AWG18RL
116 GND AWG12W 60A
AWG18G
AWG18R
AWG18Y
AWG18RG
AWG16R
AWG16WR AWG14R AWG20R
AWG14WR AWG14WR
AWG16WB
119
120
VB
VB
S.B FUSE 3
AWG8W 120A
AWG20B DIODE
121 BATT 8787a30 86 85 8787a308685 8787a 30 86 85 8787a3086 85 8787a 30 86 85 F20 F19F18F17F16F15F14F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 8787a30 86 85 8787a30 86 85 8787a30 86 85 8787a 30 8685 8787a30 86 85 8787a30 86 85 ALTERNATOR
L2
3029 28 27 26 6 25 24 23 22 21 5 20 19 18 17 16 4 3 2 1
10A
10A
10A
10A
10A
10A
15A
L1
10A
10A
10A
15A
10A
10A
10A
L
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 3029 28 27 26 6 25 24 23 22 21 5 20 19 18 17 16 4 15 14 13 12 11 3 10 9 8 7 6 2 5 4 3 2 1 1 AWG18YR
2 1
AWG18WR
S
AWG18GW
AWG20BW
AWG10WR
AWG12WB
FUSE BOX
AWG20WL
AWG20RG
AWG20GB
AWG16LW
AWG20YG
AWG20BY
AWG20GY
AWG22RB
AWG14RB
AWG22BR
AWG18GY
AWG20LR
AWG18BY
AWG20RY
AWG16RY
AWG20RY
AWG18RY
AWG18RY
AWG20BY
AWG20LB
AWG20LY
AWG14WR
AWG16WB
AWG18G
AWG18WL
AWG18RG
AWG20RG
AWG20RG
AWG18R
AWG18R
AWG18G
AWG18G
AWG20G
AWG14R
AWG20R
AWG16R
AWG20R
AWG18GL
AWG18GL
AWG20B
AWG18Y
AWG16R
AWG14B
AWG10WR
AWG12WG
AWG10WR B
AWG10B IC-REGULATOR
E
AWG20RG
AWG14B AWG14B
AWG14B AWG16B
AWG18WR
AWG10WR
1 2
AWG10B
AWG18RB
AWG18RB
AWG20RB
AWG16R
AWG18R AWG16R
AWG18Y AWG20Y
PARKING ENG CHECK
AWG10B
BUZZER (K-LINE)
CUT
1 2 3 4 BATTERY
AWG20WB
AW
AWG20RB
AWG22YB
AWG20B
G8
AWG20LB
AWG20LB
W
- ALTERNATOR E
+
(AWG4B) (AWG4B)
AWG18YR 1 AWG18YR
AWG18GY 2 AWG18GY
AWG20LB 3 AWG20LB
AWG20YL 4 AWG20YL
AWG20RG 5 AWG20RG
AWG20GB 6 AWG20GB
AWG20YG 7 AWG20YG
AWG20RB 8 AWG18RB
AWG20GY 9 AWG20GY
AWG18G 10 AWG18G
AWG20RY 11 AWG22RY
AWG20YR 12 AWG18YR
AWG20RG 13 AWG20RG
AWG20R 14
15 AWG18R OP TAIL LAMP (8W)
AWG20YB AWG18YB
AWG18LR
AWG20WL
AWG16G
16
17
18
19
AWG18LR
AWG20WL
AWG20G
AWG16BY 20 AWG16BY
AWG16RW
AWG20YR 1 AWG20YR AWG20YR 1.25G
6 5 4 3 2 1
AWG20GL 2 AWG20GL AWG18GL 1.25W
AWG16GR 3 AWG16GR AWG18RL 1.25Y
AWG18Y
AWG18RL
AWG16RW
AWG18GW
4
5
6
AWG18Y
AWG18RL
AWG16RW
AWG18GW
AWG18YG
AWG16B
1.25Br
1.25B BACK UP LAMP (10W) LAMP
7 AWG18GW
AWG18YG 8 AWG16YG
AWG20YB
AWG20GW 9
10 AWG22GW HEATER STARTER OP
OP AWG20GY
AWG20RY 11
12
AWG22GY
AWG20RY RELAY RELAY
AWG20LR 13 AWG20LR
AWG12B
AWG14B
14
AWG16G
STROBE LIGHT
2 1
PARKING N.O
COM AWG16RW
HEAD LAMP (55W) SW N.C
AWG12B
AWG12W
1 AWG12B
AWG12W
AWG12B AWG16B
AWG12WG
2 AWG12WG
AWG16B AWG18LW AWG18YG 3
AWG16B
1 2
1 2 3 4 5
AWG18GY AWG18GY AWG18R

AWG20YR AWG20YR 1 2 3 4 5 863087 85 87a
AWG18L
AWG16B
AWG18RL
AWG16B
AWG16B
1 2 3
AWG20YR
AWG18L AWG18Y
AWG12WB
AWG12WL
AWG20RG
AWG16BY
AWG20B AWG18YR
AWG20GB
AWG20L
2 1
AWG18B
OP
BRAKE OIL
A-5
BLANK PAGE
BX50 TIER 2 GASOLINE (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~
BX50 TIER 2 GASOLINE (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~
㧵㧳㧺㧏㧟㨀r㨆㧮㧔㧢㧝㧕㧵㧳㧺㧏㨀r㨆㧮㧔㧢㧕

㧳㧺㧰㨀r㨆㧱㧳㧺㧰㨀r㨆㧱㧳㧺㧰㨀r㨆㧱㧳㧺㧰㨀r㨆㧱
㧵㧳㧺㧏㧠㨀r㨆㧮㧔㧤㧜㧕㧵㧳㧺㧏㨀r㨆㧮㧔㧤㧕
101
102
104
106
109
110
111
113
115
116
118
121
A-7
BLANK PAGE
BX50 TIER 1 LPG (K21/K25 ENGINE) S/N 200001A - 205849A
BX50 TIER 1 LPG (K21/K25 ENGINE) S/N 200001A - 205849A
AWG16B AWG18LW AWG18LW REAR STOP LAMP (23W) REAR
1 2
1 2 3 4 5
AWG20YR
AWG18L
AWG20YR
AWG18L
LAMP(R)
DRIVING LAMP (8W) AWG16B AWG16B AWG16B
1 2 3
AWG16B
6 5 4 3 2 1
WINKER LAMP (23W) AWG18L 1.25Y
AWG12B
AWG14B
AWG16B
AWG18GW
AWG16B
1.25Br
1.25B BACK UP LAMP (10W) LAMP
AWG12B
1 2 3 4 5 6 7 8
AWG18B AWG20YG
1 2
AWG18GY AWG20B
AWG20YB OP
AWG20R
SPOOL LOCK SOL(LIFT) AWG18B AWG18YG L.O.P.
AWG18B
1 2
AWG18GY AWG20B OP
AWG20YR BACK BUZZER
+-
1 2 3
1 2
AWG20LB AWG18B
AWG18G
LF1 AWG16BY STARTING MOTOR
AWG20R
AWG20B
AWG20RY
AWG16BY
AWG20LY
AWG20B
DIODE
AWG20B
AWG14B
AWG12B
T/C OIL TEMP. AWG20RY B
1 2 3 4 5 6 7 8 9 10 11 12
AIR FILTER
a 1
AWG20RW 2 1
COM 2 1 S
2 1
OP
COOLANT AWG20R (AWG4B)
1 DISPLAY LPG LOW FUEL (GLOW)
GND
AWG20YB
AWG20B
OP
OP
COOLANT
POWER
AVCC(48)
AWG20Y
AWG20RY T/C OIL TEMP GND AIR FILTER
SNOW OPE(12) AWG20GW
AWG12WL
POWER(+) AWG20LW
OUTPUT(+) AWG20WR LPG INJ SPEED
OP
DRIVER SEN UNIT EARTH E
1 2
AWG18RW
1DISPLAY
SPEED SENSOR(2)
SPEED SENSOR(1)
FUEEL INJ SOL(+)
LPG INJ PWN(39)

POWER(+B)
LPG INJ B#1(44)

FUEL INJ SOL(-)
LPG INJ A#1(8)

INJ CK#1(72)
GND-A(67)
VSP8(33)
VB(119)
VB(119)
OP
GND(1)
GND(1)
POWER(+) AWG20LW
GND
GND
LIFT
1 2 3
OUTPUT(+) AWG20WR
AWG20RW
OIL PS COM
12 11 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1
AWG16WR
AWG18WR
AWG20BW
AWG16WL
AWG20GR
AWG16BY
AWG20LY
AWG22Gr
AWG22Br
AWG20R
AWG18B
AWG22P
AWG18B
AWG20B
AWG20B
AWG22L
GND AWG16B
(ISO CONTROLLER) AWG12B AWG18B
AWG22WR
AWG22BW
AWG22BW
AWG22YR
AWG22L
GND AWG14B
AWG14B
AWG16W(SH)
AWG22W(SH)
AWG22W(SH)
AWG22R(SH)
AWG22B(SH)
AWG16B(SH)
GND-A2(AWU)(83) AWG22B
5
6 5 4 3 2 1
APS2(AWU)(98) AWG22BrW 1 2 3 4
AWG22YB AWG22BW GND-A(67)
1 3 2
CONTROLLER (INTERLOCK-BOX) AVCC2(AWU)(91) AWG22LW AWG22LB
FUEL PRESS SENSOR(LPG)
GND-A(67)
GND-A(67)
APS1(AWU)(106) AWG22RY LPG PRESS(31)
AWG22RB AVCC(48)
QA+(51)
VB(119)
AVCC(AWU)(90)
TA(34)
26 25 24 23 22 21 20 19 18 17 16 1514131211 10 9 8 7 6 5 4 3 2 1 AWG16WL 6 5 4 32 1
SOL +12 (DRIVE:12)
FUEL INJ SOL(LPG)
2 1
AWG16BY SOL GND(DRIVE:6)
GND-A2(66)
MOTOR1(5)
MOTOR2(4)
AVCC2(47)
AWG20GW
AWG20BW
TPS1(50)
TPS2(69)
AIR FLOW
AWG20WL
AWG20RG
AWG20RG
AWG18WR
AWG18GY
AWG20GY
AWG18BR
AWG18BR
AWG18BR
AWG18BR
AWG20BY
AWG20BY
AWG20LR
AWG20LR
AWG20YL
AWG20LY
VB(119)
FUEL INJ ASIST SOL(LPG)
AWG18G
AWG20G
2 1
AWG18R
AWG20B
AWG20Y
AWG20B
AWG18BR SLOW INJ(11)
METER
THROT CHAMBER
AWG18BR
MOTOR & SENSOR
AWG20WR
AWG20WR
AWG16B
AWG12B
AWG20B
AWG18WR
AWG20BW
AWG20BW
AWG22BW
AWG22GL
AWG18LB
AWG18R
AWG22B
4 3 2 1
FUSE(O2 HEATER)
SOLENOID
VALVE(T)
R F
AWG20GL
AWG20GB 81 IGN#2
80 IGN#4
O2 SENSOR
AWG22GL
AWG22Gr 73 TW(WATER TEMP SENSOR)
72 INJCK#1(DRIVER) 1 2 3 4
AWG22LB
70 FUELSW#1(SELECT LP)
AWG18GW
AWG22W(SH) 69 TPS2(THROT CHAMBER)
AWG18G
AWG18B
AWG18B
AWG20BW
AWG22B(SH) 67 GND-A(SENSOR & DRIVER)
66 GND-A2(THROT CHAMBER)
AWG16WR
AWG18G
AWG20GW
62 IGN#1
DIODE AWG18B
AWG18GW
AWG20G
61 IGN#3
AWG18GW
CONDENSOR
AWG18G
AWG18B
AWG18WR
AWG20LW
AWG18YR 54 VARI VSP(TRUCK SPEED RESISTOR) IGN COIL #4 IGN COIL #3 IGN COIL #2 IGN COIL #1
1 3 5 6 8 1012
2 4 7 9 11
AWG20BR AWG20GR SEAT SW 1

AWG20YL
1 2
AWG20R
GND (-)
IGN (+)
AWG20RY AWG22L AWG20Y B
1234
AWG18WL AWG20GW
ECM (81P CONNECTOR)

AWG20LR AWG22R(SH) IGN +12(EGI RLY2) AWG20G IGN#3 TrZB (61) IGN +12(EGI RLY2) AWG18WL IGN#1 TrZB (62) AWG20Y L N.O
1 2 3
1 2 3
1 2 3
1 2 3
AWG14WR
AWG18B
AWG18Y
AWG20RB
AWG22LB
AWG22RY 49 AVCC(FUEL SELECT SW)
48 AVCC(SENSOR)
GND TrZE
IGN#4 TrZB (80) AWG20GB AWG18WL GND TrZE
IGN +12(EGI RLY2)
GND TrZE
IGN#2 TrZB (81) AWG20GL AWG18WL GND TrZE
IGN +12(EGI RLY2)
AWG20G
AWG20RG
R
SEAT
AWG22W(SH)
47 AVCC2(THROT CHAMBER) 1 2 SW
AWG18WL
N.C
AWG18B
AWG22Br
44 LPGINJB#1(DRIVER)
AWG12WG
WATER TEMP SENSOR
1 2 3
ST AWG16BY
IGN SEAT SW 2
AWG20B
B
ACC
AWG12W
(TO METER PANEL)
AWG22L
39 LPGINJPWM(DRIVER)
STOP LAMP SW
1 2
AWG16RW AWG18RB
AWG16B
AWG22GL 35 O2SFR(O2 SENSOR)
MAST LOCK AWG18Y AWG22YR
AWG20LY 34 TA(AIR TEMP SENSOR) AWG20WR
FLASHER UNIT L
2 1
AWG18GW 33 VSP8(TRUCK SPEED SIGNAL)
AWG20WR
B
AWG22LB AWG20B AWG22B
31 LPGPRES(LPG PRESS SENSOR)
MAINTENANCE
AWG22RY 30 LED(ENG SYS ERROR) AWG22B
AWG22GL
WATER TEMP
TW(73) SENSOR
1 2
L R AWG22BW GND-A(67)
(TO ECM)
ERROR LAMP (B)
AWG16L
AWG18LB
24 O2HFR(O2SENSOR)
ENGINE OIL PRESS SEN
1 2 3 4 5 6 7 8
AWG22BrW
AWG16GR
AWG22WR
AWG22WR
AWG22LY
N N N Up N Up AWG18LW (TO METER PANEL:E/G H.L-1P)
AWG22B
AWG22B
Down
AWG18GW AWG20BR
AWG16RL
AWG18YG 6 5 4 3 2 1
OFF 1 2 OFF 1 2 OFF 1 2 AWG18GY
HOUR METER CUT
CHARGE
GND(1)
POS(13)
VB(119)
GND(1)
PHASE(14)
VB(119)
AWG20GY
(A) AWG22LY 14 PHASE(CAM ANGLE) AWG22B

AWG18RW AWG22Br AWG22B 82 GND-A(ACCEL WORK UNIT)
13 POS(CRANK ANGLE) 83
1 2 3 4
AWG18GR AWG22GW AWG22GY GND-A2(ACCEL WORK UNIT)

AWG18R AWG18BR 12 SNOW SW(ECO) 84 H/LMT(HEAD LAMP ON)
AWG20B 11 SLOW INJ(LPG ASIST SOL) AWG22YB 85 K-LINE(CONSULT)
AWG20YR
OIL PRESSURE AWG22P 8 LPG INJ A#1(DRIVER)
CRANK&CAM
AWG18YR
COMBINATION SW AWG22RB
ANGLE SENSOR
ECM (40P CONNECTOR)

90 AVCC(ACCEL WORK UNIT)
AWG20RG
AWG20G
AWG20Y
F AWG16W(SH)
5 MOTOR1
FUEL GAUGE B
T
E AWG16B(SH)
AWG16LW 4 MOTOR2
3 V-MOT
AWG14B
1
1315 18 20 22
AWG18B GND
1416 17 19 21
AWG20GY AWG22BrW 1 2 3 4
HOUR METER AWG20YR
AWG20RG
AWG20YR
AWG20RG
AWG18GL
AWG20LR
101 BRAKE(FOOT BRAKE ON)
AWG20G
AWG20Y
AWG22RB
HORN SW 102 NEUT(NEUTRAL SW ON)
F-R SWITCH AWG18BY 104 MOTRLY(CHAMBER M.RLY)
AWG20YG
1 2
AWG20B AWG22LW
WATER TEMP B
T
E
ILLUMINATION MAIN RLY
F R N AWG20RG
AWG18R 109 IGN SW(KEY SW IGN ACC) VRI SPEED REGISTOR(OP) 2 AWG20LW
1 AWG20BW
SLOW BLOW FUSE & RELAY BOX (TRUCK CONTROL & ISO 3691) AUX
1 2 3 4 5 6 7 8 9 10
AWG18B AWG18GL
AWG20WL AWG22B 111 SSOFF(VB POWER ON RLY) MAIN/C NEUT SIGNAL ETC MOT EGI RELAY2 EGI HORN R RELAY F RELAY MAIN MAST LOCK PARKING
112 MAIN/C RLY(LPG CUT SOL RLY) S.B FUSE 1 AWG16R
RELAY RELAY RELAY RELAY1 RELAY RELAY RELAY RELAY
1 2 3 4
AWG18Y AWG12W 40A AWG18RL
AWG18LR AWG12W AWG20B
AWG18RY
AWG16B 115 GND S.B FUSE 2
AWG16RW
AWG16GR
AWG16WB
AWG16YG
AWG14B
AWG18RB
AWG16RY
AWG18YB
AWG18RL
116 GND
AWG18G
AWG12W 60A
AWG18R
AWG18Y
AWG18RG
AWG16R
AWG16WR AWG20R
AWG14WR AWG14WR 119 VB S.B FUSE 3 AWG20B DIODE
AWG16WB 120 VB AWG8W 120A
121 BATT 8787a30 86 85 8787a30 86 85 8787a30 86 85 8787a30 86 85 8787a30 86 85 F20F19F18F17F16F15F14F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 8787a30 86 85 8787a30 86 85 8787a 30 86 85 8787a30 8685 8787a30 86 85 8787a30 86 85 ALTERNATOR
L2
6 5 4 3 2 1
10A
10A
10A
10A
10A
10A
15A
L1
6 5 4 3 2 1
10A
10A
10A
15A
10A
10A
10A
3029 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 5 4 3 2 1 AWG18YR L
10 9 8 7 6 5 4 3 2 1 3029 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 1211 10 9 8 7 6
2 1
AWG18WR
S
AWG18WR
AWG20WR
AWG18GW
AWG10WR
AWG12WB
AWG20BW
AWG20RG
AWG16LW
AWG20WL
AWG22RB
AWG20GB
AWG20YG
AWG20GY
AWG18GY
AWG18BY
AWG16RY
AWG20RY
AWG18RY
AWG18RY
AWG20RY
AWG20BY
AWG20BY
AWG20LR
AWG20LB
AWG20LY
AWG14WR
AWG16WB
AWG18WL
AWG18RG
AWG20RG
AWG20RG
AWG16R
AWG20R
AWG18GL
AWG18GL
AWG18G
AWG18G
AWG18G
AWG20G
AWG22B
AWG20B
AWG18Y
AWG18R
AWG18R
AWG16R
AWG18L
AWG14B
AWG10WR
AWG12WG
FUSE BOX AWG10WR B
AWG10B IC-REGULATOR
E
AWG14B AWG14B AWG20RG
AWG14B AWG16B
OP
LPG FUEL
LOW
AWG10WR
1 2
AWG10B
AWG20YB
AWG18L MAIN/C RLY FUEL CUT

SOL
AWG16R
AWG18R AWG16R
AWG18Y AWG20Y
PARKING ENG CHECK

BUZZER
AWG10B
(K-LINE)
CUT
1 2 3 4
BATTERY
AWG20WB
AWG18RB
AWG22YB
AW
AWG20B
G8
AWG20LB
AWG20LB
W
+ - ALTERNATOR E
(AWG4B) (AWG4B)
AWG18YR 1 AWG18YR
AWG18GY 2 AWG18GY
AWG20LB 3 AWG20LB
AWG20YL 4 AWG20YL
AWG20RG 5 AWG20RG
AWG20GB 6 AWG20GB
AWG20YG 7 AWG20YG
AWG20RB 8 AWG18RB
AWG20GY 9
AWG18G 10 AWG18G
AWG20RY 11 AWG22RY
AWG20YR 12 AWG18YR
AWG20RG 13 AWG20RG
AWG20R 14
15 AWG18R OP TAIL LAMP (8W)
AWG20YB
AWG18LR
AWG20WL
16
17
18
AWG18YB
AWG18LR
AWG20WL STOP LAMP (23W) REAR
AWG16G AWG20G
AWG16BY
AWG20YR
19
20 AWG16BY
AWG20YR AWG20YR 1.25G OP WINKER LAMP (23W)
COMBI
1
6 5 4 3 2 1
AWG16RW
AWG20GL
AWG16GR
AWG18Y
2
3
4
AWG20GL
AWG16GR
AWG18Y
AWG18GL
AWG18RL
AWG18GW
1.25W
1.25Y
1.25Br
LAMP
AWG18RL
AWG16RW 5
6
AWG18RL
AWG16RW
AWG18YG
AWG18GW 7 AWG18GW
AWG18YG 8 AWG16YG
AWG20YB
AWG20GW 9
10
AWG20YB
AWG22GW HEATER STARTER OP
OP AWG20GY
AWG20RY 11
12
AWG22GY
AWG20RY RELAY RELAY
AWG20LR AWG20LR
PARKING SW 13
AWG12B
14
AWG16G
STROBE LIGHT
2 1
N.O
COM AWG16RW
HEAD LAMP (55W) N.C AWG12B
AWG12W
AWG12WG
1
2
AWG12B
AWG12W
3 AWG12WG
AWG16B AWG18LW AWG18YG
AWG16B
1 2
1 2 3 4 5

AWG20YR AWG20YR 1 2 3 4 5 863087 85 87a
AWG18L
AWG16B
AWG18RL
AWG16B
AWG16B
1 2 3
AWG20YR
AWG18L AWG18Y
AWG12WB
AWG12WL
AWG20RG
AWG16BY
AWG20B AWG18YR
AWG20GB
AWG20L
2 1
AWG18B
OP
BRAKE OIL
A-9
BLANK PAGE
BX50 TIER 2 LPG (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~
BX50 TIER 2 LPG (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~
A-11
BLANK PAGE
BX50 CARB 2010 LPG (K21/K25 ENGINE) S/N 751863~ / A224001~
BX50 CARB 2010 LPG (K21/K25 ENGINE) S/N 751863~ / A224001~
HEAD LAMP (55W)

TAIL LAMP
1 2
1 2 3 4 5
REAR LAMP(R) STOP LAMP REAR
DRIVING LAMP (8W) COMBI
1 2 3
WINKER LAMP LAMP
6 5 4 3 2 1
WINKER LAMP (23W) BACK UP LAMP (LED TYPE)
SPOOL LOCK
1 2 3 4 5 6 7 8
SOL(TILT)
1 2
OP
SPOOL LOCK
SOL(LIFT)
L.O.P.
1 2
OP
BACK BUZZER
BUZZER OP
+
1 2
1 2 3
BUZZER -
LF1
STARTING MOTOR
DIODE OP T/C
T/C OIL TEMP. TEMP B
1 2 3 4 5 6 7 8 9 10 11 12
AIR FILTER 2 1
a 1
BRAKE OIL
OP COM 2 1 2 1
S
2 1
OP
COOLANT
DELUXE LPG LOW FUEL
GND (GLOW) GND
OP
COOLANT
POWER
PANEL AVCC(48) AIR FILTER
SNOW OPE(12)
POWER(+)
OUT PUT(+)
OP SPEED E
1DISPLAY EARTH
1 2
POWER(+B) SEN UNIT
SPEED SENSOR(2)
SPEED SENSOR(1)
VSP8(33)
VB(121)
OP
GND(1)
GND(1)
POWER(+) CHAMBER MOTOR
1 2 3
LIFT OUT PUT(+) POSITION
SENSOR
COM
OIL PS
6 5 4 3 2 1
S1 S2 THROT CHAMBER
AVCC2(47) MOTOR & SENSOR
1 2 3 4 5 6
TPS1(50)
TPS2(69)
GND-A2(66)
MOTOR2(4)
MOTOR1(5)
GND
(ISO CONTROLLER)
GND-A(67)
1 3 2
GND LPG PRESS(31) FUEL PRESS
AVCC(48) SENSOR(LPG)
(ECM CONTROLLER)
SOL +12 (119) FUEL INJ
2 1
SOL GND(120) SOL(LPG)
GND-A2(AWU)(83)
6 5 4 3 2 1
APS2(AWU)(98)
GND-A(AWU)(82)
CONTROLLER AVCC2(AWU)(91)
APS1(AWU)(106) VB(121) FUEL INJ ASIST
2 1
(INTERLOCK-BOX) AVCC(AWU)(90) SLOW INJ(11) SOL(LPG)
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
4 3 2 1
FUSE(O2 HEATER)
O2 SENSOR O2 SENSOR
1 2 3 4 5 6
AIR FLOW
METER
AIR FLOW METER
SOLENOID
VALVE(T)
R F
IGN#2
IGN#4
GND-A(O2 SENSOR)
TW(WATER TEMP SENSOR)

MAP SENSOR 1 2 3 4
FUELSW#1(SELECT LP)
TPS2(THROT CHAMBER)
GND-A(SENSOR & DRIVER)
GND-A2(THROT CHAMBER)
DIODE
IGN#1
IGN#3
SEAT SW
VARI VSP(TRUCK SPEED RESISTOR)
1 3 5 6 8 10 12
2 4 7 9 11
SEAT SW 1
E C M (81P CONNECTOR)
IGN COIL #2 IGN COIL #1
1 2
QA+(AIR FLOW METER)
4 3 2 1
3 2 1
GND (-)
N.O
IGN (+)
㧵㧳㧺㧏㧟㨀r㨆㧮㧔㧢㧝㧕
1 2 3
1 2 3
1 2 3
1 2 3
TPS1(THROT CHAMBER)
AVCC(FUEL SELECT SW) 㧳㧺㧰㨀r㨆㧱
AVCC(SENSOR) IGN +12(EGI RLY2)
1 2
N.C
WATER TEMP SENSOR
1 2 3
ST SEAT SW 2
B IGN (TO METER PANEL)
ACC STOP
LAMP SW
1 2
O2SFR(O2 SENSOR)
MAST LOCK
FLASHER L TA(AIR TEMP SENSOR)
2 1
B VSP8(TRUCK SPEED SIGNAL)

UNIT
LPGPRES(LPG PRESS SENSOR)
MAINTENANCE L R TW(73)
WATER TEMP
1 2
GND-A(67) SENSOR
(TO ECM)
ERROR
LAMP (B) O2HFR(O2 SENSOR)
1 2 3 4 5 6 7 8
N N N Up N
Down Up (TO METER PANEL:E/G H.L-1P)
Down Up Up Down Down
N LAMP
3 2 1
OFF 1 2 OFF 1 2 OFF 1 2
MAP SENSOR 6 5 4 3 2 1
HOUR METER CUT
GND(1)
POS(13)
VB(121)
GND(1)
PHASE(14)
VB(121)
CHARGE (A) PHASE(CAM ANGLE) GND-A(ACCEL WORK UNIT)
POS(CRANK ANGLE) GND-A2(ACCEL WORK UNIT)
1 2 3 4
SNOW SW(ECO) H/LMT(HEAD LAMP ON)

OIL SLOW INJ(LPG ASIST SOL) K-LINE(CONSULT)
PRESSURE
CRANK & CAM
COMBINATION SW ANGLE SENSOR
AVCC(ACCEL WORK UNIT)
FUEL GAUGE AVCC2(ACCEL WORK UNIT)
F MOTOR1
B
T
E MOTOR2 CRANK & CAM
V-MOT ANGLE SENSOR
GND
GND
13 15 18 20 22
HOUR METER
14 16 17 19 21
1 2 3 4
APS2(ACCEL WORK UNIT)
BRAKE(FOOT BRAKE ON)

HORN NEUT(NEUTRAL SW ON)
SW
F-R SWITCH MOTRLY(CHAMBER M.RLY)
WATER TEMP
1 2
B
W
E
APS1(ACCEL WORK UNIT) RELAY BOX2 RELAY BOX1 MAIN RLY
T ILLUMINATION
N IGN SW(KEY SW IGN ACC) SLOW BLOW FUSE & RELAY BOX (TRUCK CONTROL & ISO 3691) AUX
F R 2
VRI SPEED REGISTOR(OP)
1 2 3 4 5 6 7 8 9 10
BATT 1
SSOFF(VB POWER ON RLY) MAIN MAST LOCK PARKING
HORN RELAY R RELAY F RELAY
MAIN/C RLY(LPG CUT SOL RLY) MAIN/C RELAY NEUT SIGNAL RELAY ETC MOT RELAY EGI RELAY2 EGI RELAY1 S.B FUSE 1 RELAY RELAY RELAY
1 2 3 4
AWG12W
GND 40A
GND S.B FUSE 2
VB
LPG INJ VB#1 60A
LPG INJ -#1 S.B FUSE 3 DIODE
VB F20 F19 F18 F17 F16 F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 ALTERNATOR
6 5 4 3 2 1
L2 L1 120A 6 5 4 3 2 1 L
10A
10A
10A
10A
10A
10A
15A
10A
10A
10A
15A
10A
10A
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2 1
S
FUSE BOX
B
IC-REGULATOR
E
OP
LPG FUEL
LOW(2KG/CM2)
1 2
LPG FUEL
CUT SOL
PARKING ENG CHECK

BUZZER (K-LINE)
CUT
1 2 3 4
+ - ALTERNATOR E
1
2
3
4
5
6
7
8
9
10
11
BATTERY
12
13
14
15
16 TAIL LAMP
17
18
19
STOP LAMP REAR
20 COMBI
1 WINKER LAMP LAMP
6 5 4 3 2 1
2
3
4
5 BACK UP LAMP (LED TYPE)
6
7
8
9
OP 10 STARTER OP
11 RESISTOR RELAY
PARKING 12
13
SW 14
2 1
N.O STROBE LIGHT
COM
AWG12W 1
2
AWG12WG 3
1 2
1 2 3 4 5
1 2
DRIVING LAMP (8W)
1 2 3

2 1
OP
BRAKE OIL
A-13
BLANK PAGE
BX50 CARB 2010 LPG (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM
BX50 CARB 2010 LPG (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM
HEAD LAMP (55W)

AWG16RB AWG16RB AWG18LW TAIL LAMP REAR
12
12345
AWG16RG AWG16RB AWG18GY
AWG16RL AWG20YR STOP LAMP COMBI
DRIVING LAMP (8W) AWG16RG
AWG16G
AWG16RG
AWG18L
AWG16B
REAR LAMP(R) LAMP
123
WINKER LAMP
AWG12B AWG16B
AWG16RL AWG18YR AWG18YR AWG16G
654321
AWG16G AWG18GL AWG16W
AWG18GW
AWG16Y
AWG16Br (LED TYPE)
AWG12B AWG16B BACK UP LAMP
SPOOL LOCK
12345678
AWG18B AWG20YG
12
SOL(LIFT) AWG18GY AWG20B
AWG20YB OP
AWG20R
SPOOL LOCK AWG18B AWG18YG L.O.P.
AWG18B
AWG18B OP
12
12
SOL(TILT) AWG18GY AWG18GY AWG20B
AWG20YR
OP BACK BUZZER
SPOOL LOCK AWG18B BUZZER
12
AWG18B AWG18GW
SOL(ATT1) AWG18GY
+
12
123
AWG20LB AWG18B
AWG18G -
SPOOL LOCK AWG18B LF1
AWG18RY
OP
12
AWG18LY
AWG18R
STARTING MOTOR
AWG18B
AWG18B
AWG16BY
SOL(ATT2)
AWG18B
AWG18GY
AWG14B
AWG12B
AWG16BY
DIODE
AWG18RY T/C B
1 2 3 4 5 6 7 8 9 101112
T/C OIL TEMP. (AWG 4B) 21
AIR FILTER AWG18LY AWG18B OP
TEMP
a1
OP COM AWG20RW 21 21 OP
21
COOLANT AWG18R (AWG 4B) S COOLANT
DELUXE LPG LOW FUEL (GLOW)
GND
AWG20YB
AWG20B OP
POWER AWG20Y DIODE GND
PANEL AVCC(48) AWG20RY AIR FILTER
AWG12WL
AWG20LW AWG18B
a1
POWER(+) AWG18GY
AWG20WR
OUT PUT(+)
SPEED SEN UNIT E
OP EARTH
12
AWG18RW
1DISPLAY
SPEED SENSOR(2)
SPEED SENSOR(1)
POWER(+B)
VSP8(33)
VB(121)
GND(1)
GND(1)
LIFT AWG20LW GND AWG16B
POWER(+) CHAMBER MOTOR POSITION
123
OIL PS OUT PUT(+) AWG20WR
SENSOR
COM AWG20RW (ISO CONTROLLER) AWG12B
OP S1 S2
AWG16B 654321 AWG22W(SH)
AVCC2(47) THROT CHAMBER
1 2 3 4 5 6
AWG18WR
GND AWG22R(SH)
AWG20GR
AWG14B TPS1(50)
AWG20LY
AWG20R
AWG22W(SH)
AWG20B
AWG20B
(ECM CONTROLLER) AWG14B AWG22B(SH) TPS2(69)
GND-A2(66)
MOTOR&SENSOR
AWG16B(SH)
AWG16W(SH) MOTOR2(4)
MOTOR1(5)
ACCEL WORK
AWG18GY
AWG18B
CONTROLLER (ISO) UNIT

AWG22BW
(INTERLOCK-BOX) GND-A(67) FUEL PRESS
132
AWG22LB LPG PRESS(31)
21 AWG22RY AVCC(48) SENSOR(LPG)
WIRE 1
WIRE 2
26 25 24232221201918171615 14 13121110 9 8 7 6 5 4 3 2 1
AWG16WL SOL +12 (119)
FUEL INJ
21
AWG16BY SOL GND(120) SOL(LPG)
AWG20GW
AWG20BW
AWG20RG
AWG20WL
AWG20RG
AWG22B
AWG18B
AWG20GY
AWG18GY
AWG18BR
AWG18BR
AWG18BR
AWG18BR
AWG20BY
AWG20BY
AWG20LR
AWG20LR
AWG20YL
AWG20LY
GND-A2(AWU)(83)
6 5 4 3 2 1
AWG18G
AWG20G
AWG18R
AWG20B
AWG20Y
AWG20B
AWG22BrW
APS2(AWU)(98) AWG22B
GND-A(AWU)(82)
AWG22YB
AVCC2(AWU)(91)
APS1(AWU)(106)
AWG22LW AWG18WR VB(121)
FUEL INJ ASIST
21
AWG22RB AWG18BR
AVCC(AWU)(90) SLOW INJ(11) SOL(LPG)
FUSE 5A
WIRE 1 WIRE 1
AWG16B
AWG12B
SWITCH
21
WIRE 2 WIRE 2 AWG22GL O2SFR(O2 SENSOR)(35)
4321
AWG18R FUSE(O2 HEATER)
AWG18LB O2HFR(O2 SENSOR)(24) O2 SENSOR
AWG22B GND-A(O2 SENSOR)(78)
AWG20WR
AWG20WR
WIRE 1 WIRE 1
21
21
AWG22WR
AWG22BW
AWG22BW
AWG22YR
WIRE 2 WIRE 2
AWG22L
AWG20B
SOLENOID ECM SEALINGS(81P)
AWG18WR
♦X50 PLACES 1 2 3 4 5 6
LAMP(G)
GND-A(67)
GND-A(67)
AWG22BW
AWG20BW
AWG20BW
AWG18 R WIRE 1 AWG20GL
QA+(51)
VB(121)
81 IGN#2
21
6 54 3 21
TA(34)
AWG20GB
STATUS WIRE 2
AWG22B
80 IGN#4
♦
LIGHT AWG18 B 78 GND-A(O2 SENSOR)
♦
♦
♦
AWG22GL ♦
73 TW(WATER TEMP SENSOR)
AWG22LR ♦ AIR FLOW METER
71 MAP SENSOR
AWG22R
AWG22W(SH)
AWG20BW ♦
AWG22B(SH)
♦
♦
AWG20GW ♦
62 IGN#1
AWG20G 61 IGN#3 SOLENOID
♦ VALVE(T)
♦
♦ R F
♦
♦
AWG20LW ♦
54 VARI VSP(TRUCK SPEED RESISTOR)
♦
AWG22L ♦
AWG22R(SH) 50 TPS1(THROT CHAMBER)
AWG22R 49 AVCC(FUEL SELECT SW)
AWG22RY 48 AVCC(SENSOR)
AWG22W(SH) 47 AVCC2(THROT CHAMBER)
♦ 1234
D/B HARNESS
AWG18GW
♦
AWG18G
♦
AWG18B
AWG18B
♦
♦
AWG18WR
♦
♦ AWG18G
♦ DIODE AWG18B
♦ AWG18GW
♦
♦
AWG18GW
AWG18G
AWG18B
AWG22YR
AWG20LY
34
33
TA(AIR TEMP SENSOR)
VSP8(TRUCK SPEED SIGNAL)
♦
AWG18WR
CONDENSOR HARNESS
AWG22LB 31 LPGPRES(LPG PRESS SENSOR) IGN COIL #1
AWG22RY 30 LED(ENG SYS ERROR) IGN COIL #2 SEAT SW
AWG18YR
♦
1 3 5 6 8 1012

2 4 7 9 11
AWG20BR
♦ AWG20GR SEAT SW 1
12
AWG20YL
AWG20RY ♦ AWG20R AWG20Y
GND (-)
♦
IGN (+)
N.O
321
4321
AWG18WL AWG20G AWG18WL AWG20GW
AWG14WR
AWG20LR IGN +12(EGI RLY2) IGN#3 TrZB (61) IGN +12(EGI RLY2) IGN#1 TrZB (62) AWG20G
123
123
123
123
AWG18Y AWG18LB ♦ GND TrZB (80) AWG18B AWG18B GND TrZE GND TrZE AWG18B AWG18B GND TrZE AWG20RG
AWG20RB
24 O2HFR(O2 SENSOR) AWG20GB AWG18WL AWG20GL AWG18WL
♦ IGN#4 TrZB (80) IGN +12(EGI RLY2) IGN#2 TrZB (81) IGN +12(EGI RLY2)
♦ TRUCK SPEED N.C
♦ 12
♦ SENSOR
AWG18WL
AWG18B
AWG12WG ♦
♦ WATER TEMP SENSOR
123
ST AWG16BY
AWG20B
B IGN ♦ SEAT SW 2
AWG12W
♦ (TO METER PANEL)
ACC STOP
AWG22LY ♦
LAMP SW 14 PHASE(CAM ANGLE)
AWG16GL
AWG22BrW
AWG22GW
13 POS(CRANK ANGLE) AWG16B AWG16B AWG16B SEAT SW
12
AWG16RW 12 SNOW SW(ECO) AWG18RB

AWG18BR 11 SLOW INJ(LPG ASIST SOL)
MAST LOCK FLASHER L AWG18Y

♦
♦ AWG20WR HARNESS
21
AWG18GW ♦
AWG16B
UNIT B
♦ AWG20B AWG22B
♦
AWG20WR
AWG16W(SH)
AWG22B
AWG22GL
WATER TEMP
MAINTENANCE TW(73)
12
L R AWG16B(SH)
5
4
MOTOR1
MOTOR2
AWG22BW GND-A(67) SENSOR
AWG16LW 3 V-MOT (TO ECM)
AWG16B 2 GND
ERROR AWG14B
(B) 1 GND
LAMP AWG16L
AWG22WR
AWG22WR
12345 6 78

MAP SENSOR
AWG22LY
AWG16GR
AWG22BrW
AWG22B
AWG22B
N N N Up N
Down Up AWG18LW
AWG18GW AWG20BR
ECM SEALINGS(40P) (TO METER PANEL:E/G H.L-1P)
N LAMP
Down Up Up Down Down
AWG16RL ■X2 PLACE AWG22RY AWG22RY AVCC(48)
321
AWG18YG ♦X17 PLACES AWG22LR MAP SENSOR(71)
OFF 1 2 OFF 1 2 OFF 1 2
AWG22BW GND-A(67) 654321
AWG18GY HOUR METER CUT
GND(1)
POS(13)
VB(121)
GND(1)
PHASE(14)
VB(121)
CHARGE (A) AWG22B
AWG18RW AWG22B
82 GND-A(ACCEL WORK UNIT)
1234
AWG18GR AWG22GY
83 GND-A2(ACCEL WORK UNIT)
AWG20B 84 H/LMT(HEAD LAMP ON)
AWG18R AWG22YB
OIL AWG20YR 85 K-LINE(CONSULT)
♦
PRESSURE ♦
AWG20GY
♦ E/G HARNESS
AWG18YR
COMBINATION SW ♦
AWG20RG
AWG22RB 90 AVCC(ACCEL WORK UNIT)
LP
AWG20G
AWG20Y
FUEL GAUGE AWG22YB 91 AVCC2(ACCEL WORK UNIT)
AWG22BW
F ♦
B E
T
♦
♦
CRANK&CAM
♦ ANGLE SENSOR
♦
1315 182022
AWG18B
14161719 21
HOUR METER AWG20GY AWG22BrW ♦ 1234

AWG20YR 98 APS2(ACCEL WORK UNIT)
AWG20RG ♦
AWG20RG
♦
AWG20LR
AWG20YR
AWG20G
AWG18GL
AWG20Y
AWG22RB
102 NEUT(NEUTRAL SW ON)
HORN SW ♦
AWG18BY
F-R SWITCH AWG20YG 104 MOTRLY(CHAMBER M.RLY)
RELAY BOX1
12
♦
WATER TEMP
W
B E
AWG20B
♦
RELAY BOX2 MAIN RLY
T ILLUMINATION ♦
AWG18R VRI SPEED REGISTOR(OP) SLOW BLOW FUSE & RELAY BOX (TRUCK CONTROL & ISO 3691) AUX
IGN SW(KEY SW IGN ACC) 2 AWG20LW
AWG20RG 109
AWG16WB
1 2 3 4 5 6 7 8 9 10
F R N BATT
1 AWG20BW
AWG18B 110
AWG18GL
AWG20WL AWG22B
111 SSOFF(VB POWER ON RLY) MAIN MAST LOCK PARKING
112 MAIN/C RLY(LPG CUT SOL RLY) MAIN/C RELAY NEUT SIGNAL RELAY ETC MOT RELAY EGI RELAY2 EGI RELAY1 HORN RELAY R RELAY F RELAY RELAY RELAY AWG16R
S.B FUSE 1 RELAY
1234
AWG18Y ♦ AWG18RL
AWG18LR AWG12W AWG12W AWG20B
■ AWG18RY
AWG16B 40A
115 GND AWG16WB
AWG14B S.B FUSE 2
AWG16RW
GND
AWG16YG
AWG18RB
AWG16GR
116
AWG18YB
AWG16RY
AWG18RL
AWG18RG AWG12W
AWG18R
AWG18Y
AWG18G
AWG16WR
■ AWG16R
118 VB 60A AWG20R
AWG16WL 119 LPG INJ VB#1
AWG16BY 120 LPG INJ -#1 S.B FUSE 3 AWG20B DIODE
AWG14WR AWG8W
121 VB F20 F19 F18 F17 F16 F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 ALTERNATOR
85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87
120A
10A
10A
10A
10A
10A
10A
15A
10A
10A
10A
15A
10A
10A
6 5 4 3 2 1 L
30 29 28 27 26 25 24 23 22 21 20 19 18 1716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 L2 L1 30 29 28 27 26 6 25 24 23 22 21 5 20 19 18 17 16 4 15 1413 12 11 3 10 9 8 7 6 2 5 4 3 2 1 1 AWG18YR
21
AWG18WR
AWG18GW
AWG10WR
AWG12WB
AWG20BW
AWG20WL
AWG20GB
S
AWG20YG
AWG20GY
AWG18GY
AWG20BY
AWG20RY
AWG14WR
AWG20LR
AWG16RY
AWG20RY
AWG18RY
AWG18RY
AWG20BY
AWG16WB
AWG18WR
AWG20WR
AWG20RG
AWG20LB
AWG20RG
AWG16LW
AWG18WL
AWG18RG
AWG20LY
FUSE BOX
AWG20RG
AWG18GL
AWG18GL
AWG22RB
AWG18BY
AWG18G
AWG18G
AWG18G
AWG18R
AWG20G
AWG18R
AWG16R
AWG16R
AWG20R
AWG20B
AWG22B
AWG18Y
AWG18L
AWG14B
AWG10WR
AWG12WG
APPLICABLE MODELS AWG14B AWG14B
AWG10WR B
AWG10B
E
IC-REGULATOR
FG20ST-16 S/N A233132~

AWG14WR
AWG14B AWG16B WIRE OP
LPG FUEL
AWG18WR
LOW(2KG/CM2)
FG20T-16 S/N A224023~ AWG10WR
12
AWG10B
LPG FUEL
FG25HT-16 S/N A230096~ CUT SOL
FG25SHT-16 S/N A240058~ AWG20YB
AWG18L
AWG16R
FG25ST-16 S/N A234854~ AWG18L
FG25T-16 S/N A225994~

AWG18R AWG16R
FG30HT-16 S/N A231327~ AWG18Y AWG20Y
FG30SHT-16 S/N A240524~ ENG CHECK
AWG10B
PARKING BUZZER (K-LINE)
FG32HT-16 S/N A231553~ CUT
1234
AW
AWG20WB
AWG20RB
AWG22YB
G
AWG20B
AWG20LB
AWG20LB
8W
ALTERNATOR E
+ -
(AWG 4B) (AWG 4B)
AWG18YR AWG18YR
AWG18GY 1 AWG18GY
AWG20LB 2 AWG20LB
AWG20YL 3 AWG20YL
AWG20RG 4 AWG20RG
AWG20GB 5 AWG20GB
AWG20YG 6 AWG20YG
AWG20RB 7 AWG18RB
AWG20GY 8
AWG18G
AWG20RY
9
10
AWG18G
AWG22RY
BATTERY
AWG20YR
AWG20RG
11
12
AWG18YR
AWG20RG
BATTERY
13
AWG20R
AWG20YB
14
15
AWG18R
AWG18YB
CABLE
16
AWG18LR
AWG20WL 17
AWG18LR
AWG20WL
TAIL LAMP
AWG16G 18
19 AWG20G STOP LAMP REAR
AWG16BY
20
AWG16BY
COMBI
AWG16RW
AWG20YR AWG18YR AWG18YR AWG16G WINKER LAMP LAMP
654321
AWG20GL 1
2 AWG20GL AWG18GL AWG16W
AWG16GR AWG16GR AWG18RL AWG16Y
AWG18Y 3
4 AWG18Y AWG18GW AWG16Br (LED TYPE)
AWG18RL 5 AWG18RL AWG18YG BACK UP LAMP
AWG16RW 6 AWG16RW AWG16B AWG16B
AWG18GW AWG18GW
AWG18YG 7 AWG16YG
AWG20YB 8 AWG20YB
PARKING AWG20GW 9
10 AWG22GW STARTER
SW AWG20GY AWG22GY OP
AWG20RY 11
12 AWG20RY RESISTOR RELAY
AWG12B
AWG20LR AWG20LR
OP 13
14
AWG16G
21
N.O
COM AWG16RW
AWG12W
1
AWG12B
AWG12W
2
AWG12WG AWG12WG
AWG16B
AWG16RB AWG16RB AWG18YG

3 STROBE LIGHT
12
12345
AWG16RG AWG16RB AWG18R

AWG16RL AWG20YR 86308785
12
AWG16G
AWG16RG
AWG18RL
AWG16B
AWG12WB
AWG12WL
AWG20RG
123
AWG16BY
AWG16RL
AWG16G AWG18Y
WINKER LAMP (23W) AWG20B AWG18YR
AWG20GB
HORN
AWG18L
21
AWG18B
OP
A-15
BLANK PAGE
BX50 TIER 1 LPS (K21/K25 ENGINE) S/N 200001A - 205849A
BX50 TIER 1 LPS (K21/K25 ENGINE) S/N 200001A - 205849A
STOP LAMP (23W)
1 2
1 2 3 4 5
AWG18GY AWG18GY
AWG20YR
AWG18L
AWG18GY
AWG20YR
AWG18L REAR LAMP(R) REAR
COMBI
1 2 3
AWG16B
6 5 4 3 2 1
WINKER LAMP (23W)
AWG12B AWG16B
AWG18L
AWG18GW
1.25Y
1.25Br LAMP
AWG14B AWG16B 1.25B BACK UP LAMP (10W)
AWG12B
1 2 3 4 5 6 7 8
AWG18B AWG20YG
1 2
AWG18GY AWG20B
AWG20YB OP
AWG20R
SPOOL LOCK SOL(LIFT) AWG18B AWG18YG L.O.P.
AWG18B
1 2
OP
AWG18GY AWG20B
AWG20YR
OP
BACK BUZZER
BUZZER AWG18B AWG18GW
+-
1 2 3
1 2
AWG20LB AWG18B
AWG18G
LF1 AWG16BY
AWG20R
AWG20B
STARTING MOTOR
AWG20RY
AWG16BY
AWG20LY
AWG20B
DIODE
AWG20B
AWG14B
AWG12B
AWG20RY
B
1 2 3 4 5 6 7 8 9 10 11 12
T/C OIL TEMP. AWG20LY AWG18B (AWG4B) 2 1
AIR FILTER
a 1
COM AWG20RW 2 1 2 1
S
2 1
OP
1 DISPLAY COOLANT
LPG LOW FUEL (GLOW)
AWG20R
AWG20YB OP
OP
(AWG4B)
GND AWG20B
AWG20Y T/C GND COOLANT
POWER
AVCC(48) AWG20RY AIR FILTER
SNOW OPE(12) AWG20GW OIL LPG INJ SPEED
AWG12WL
POWER(+) AWG20LW
OUTPUT(+) AWG20WR TEMP DRIVER SEN UNIT
OP
EARTH E
1 2
AWG18RW
1DISPLAY POWER(+B)
SPEED SENSOR(2)
SPEED SENSOR(1)
FUEEL INJ SOL(+)
LPG INJ PWN(39)

LPG INJ B#1(44)
FUEL INJ SOL(-)
LPG INJ A#1(8)

INJ CK#1(72)
GND-A(67)
VSP8(33)
VB(119)
VB(119)
GND(1)
GND(1)
OP
AWG20LW
GND
GND
POWER(+)
1 2 3
AWG20WR
LIFT OUTPUT(+)
COM AWG20RW
OIL PS 12 11 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1
AWG18WR
AWG16WR
AWG20BW
AWG20GR
AWG16WL
AWG16BY
AWG20LY
AWG22Gr
AWG22Br
AWG20R
AWG20B
AWG20B
AWG18B
AWG22P
AWG18B
AWG22L
GND AWG16B
(ISO CONTROLLER) AWG12B AWG18B
AWG22WR
AWG22BW
AWG22BW
GND
AWG22YR
AWG22L
AWG14B
(ECM CONTROLLER)
AWG14B
AWG16W(SH)
AWG22W(SH)
AWG22W(SH)
AWG22R(SH)
AWG22B(SH)
AWG16B(SH)
AWG14B AWG22B
GND-A2(AWU)(83)
6 5 4 3 2 1
APS2(AWU)(98) AWG22BrW 1 2 3 4 5
AWG22YB AWG22BW GND-A(67)
FUEL PRESS SENSOR(LPG)
1 3 2
AVCC2(AWU)(91) AWG22LB
CONTROLLER (INTERLOCK-BOX) AWG22LW
GND-A(67)
GND-A(67)
APS1(AWU)(106) AWG22RY LPG PRESS(31)
AWG22RB AVCC(48)
QA+(51)
VB(119)
AVCC(AWU)(90) 6 5 4 32 1
TA(34)
26 25 24232221 2019181716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 AWG16WL SOL +12 (DRIVE:12)
FUEL INJ SOL(LPG)
2 1
AWG16BY SOL GND(DRIVE:6)
GND-A2(66)
MOTOR1(5)
MOTOR2(4)
AVCC2(47)
TPS1(50)
TPS2(69)
AWG18WR VB(119)
FUEL INJ ASIST SOL(LPG) AIR FLOW
AWG20GW
AWG20BW
2 1
AWG20WL
AWG20RG
AWG20RG
AWG18GY
AWG20GY
AWG18BR
AWG18BR
AWG18BR
AWG18BR
AWG20BY
AWG20BY
AWG20LR
AWG20LR
AWG20YL
AWG18BR
AWG20LY
AWG18G
AWG20G
SLOW INJ(11)
AWG18R
AWG20B
AWG20Y
AWG20B
METER
THROT CHAMBER
AWG18BR MOTOR & SENSOR
AWG16B
AWG20WR
AWG20WR
AWG12B
AWG20B
AWG18WR
AWG20BW
AWG20BW
AWG22BW
AWG22GL
AWG18LB
AWG18R
AWG22B
4 3 2 1
FUSE(O2 HEATER)
SOLENOID
VALVE(T)
R F
AWG20GL
AWG20GB 81
80
IGN#2
IGN#4 O2 SENSOR
AWG22B
78 GND-A(O2 SENSOR)
AWG22GL
72 INJCK#1(DRIVER)
1 2 3 4
AWG22LB
AWG18GW
AWG22W(SH)
AWG18G
69
AWG18B
AWG18B
TPS2(THROT CHAMBER)
AWG20BW
AWG16WR
AWG18G
AWG20GW
62 IGN#1
DIODE AWG18B
AWG18GW
AWG20G
61 IGN#3
AWG18B
AWG18G
AWG18GW
AWG18WR
CONDENSOR
AWG18YR AWG20LW
54 VARIVSP(TRUCKSPEEDRESISTOR)
IGN COIL #4 IGN COIL #3 IGN COIL #2 IGN COIL #1
1 3 5 6 8 1012
2 4 7 9 11

AWG20YL
1 2
AWG20R
GND (-)
AWG22L AWG20Y B
IGN (+)
AWG20RY 51 QA+(AIR FLOW METER)
1234
AWG18WL AWG20G AWG18WL AWG20GW N.O
AWG14WR
AWG22R(SH) AWG20Y L
ECM (81P CONNECTOR)

AWG20LR IGN +12(EGI RLY2) IGN#3 TrZB (61) IGN +12(EGI RLY2) IGN#1 TrZB (62)
1 2 3
1 2 3
1 2 3
1 2 3
AWG22LB 50 TPS1(THROT CHAMBER) AWG18B AWG18B GND TrZE AWG18B AWG18B GND TrZE AWG20G R
AWG18Y 49 AVCC(FUEL SELECT SW) GND TrZE AWG20GB AWG18WL GND TrZE AWG20GL AWG18WL
AWG22RY AWG20RG
AWG20RB
AWG22W(SH) 48
47
AVCC(SENSOR)
AVCC2(THROT CHAMBER)
IGN#4 TrZB (80) IGN +12(EGI RLY2)
1 2
IGN#2 TrZB (81) IGN +12(EGI RLY2)
SEAT SW
AWG18WL
N.C
WATER TEMP
AWG18B
AWG22Br
AWG12WG 44 LPGINJB#1(DRIVER)
SENSOR
1 2 3
ST AWG16BY
B IGN AWG12W SEAT SW 2
AWG20B
ACC
AWG22L
(TO METER PANEL)
STOP LAMP SW
1 2
AWG16RW AWG18RB
AWG22GL
AWG16B
35 O2SFR(O2 SENSOR)
MAST LOCK L AWG18Y AWG22YR
2 1
FLASHER UNIT AWG18GW 33 VSP8(TRUCK SPEED SIGNAL)
AWG20WR
B
AWG22LB AWG20B AWG22B
31
MAINTENANCE
AWG22RY 30
LPGPRES(LPG PRESS SENSOR)
LED(ENG SYS ERROR) AWG22B WATER TEMP
AWG22GL TW(73) SENSOR
1 2
L R AWG22BW GND-A(67)
(TO ECM)
ERROR LAMP (B) AWG18LB
24 O2HFR(O2 SENSOR)
1 2 3 4 5 6 7 8
AWG16GR
AWG22WR
AWG22WR
AWG22LY
N N N Up N Up
AWG22Br
AWG18LW
AWG22B
AWG22B
Down
AWG18GW AWG20BR
N LAMP Down Up Up Down Down AWG16RL
1 2 1 1
AWG18YG HOUR 6 5 4 3 2 1
OFF OFF 2 OFF 2 AWG18GY
METER
AWG20GY
CHARGE
GND(1)
POS(13)
VB(119)
GND(1)
PHASE(14)
VB(119)
AWG22LY
(A)
AWG18RW CUT AWG22BrW 14
13
PHASE(CAM ANGLE)
POS(CRANK ANGLE)
AWG22B
AWG22B 82
83
GND-A(ACCEL WORK UNIT)
1 2 3 4
AWG18GR AWG22GW AWG22GY GND-A2(ACCEL WORK UNIT)

AWG18R AWG18BR 12 SNOW SW(ECO) 84 H/LMT(HEAD LAMP ON)
AWG20B 11 SLOW INJ(LPG ASIST SOL) AWG22YB 85 K-LINE(CONSULT)
AWG20YR
OIL PRESSURE AWG22P
8 LPG INJ A#1(DRIVER)
AWG18YR
COMBINATION SW AWG22RB 90 AVCC(ACCEL WORK UNIT) CRANK&CAM WIRE
AWG20RG
AWG20G
ANGLE SENSOR
AWG20Y
AWG16W(SH)
ECM (40P CONNECTOR)

F 5 MOTOR1
FUEL GAUGE B
T
E AWG16B(SH)
AWG16LW 4 MOTOR2
3 V-MOT
AWG14B
1
1315 18 20 22
AWG18B GND
1416 17 19 21
AWG20GY AWG22BrW 1 2 3 4
HOUR METER AWG20RG
AWG20YR
AWG20RG
AWG18GL
AWG20LR
AWG20G
AWG20Y
AWG22RB 102 NEUT(NEUTRAL SW ON)
F-R SWITCH HORN SW AWG18BY
1 2
AWG20B AWG22LW
WATER TEMP B
T
E
MAIN RLY
ILLUMINATION AWG18R VRI SPEED REGISTOR(OP) 2 AWG20LW SLOW BLOW FUSE & RELAY BOX (TRUCK CONTROL & ISO 3691)
F R N AWG20RG 109 IGN SW(KEY SW IGN ACC) 1 AWG20BW AUX
1 2 3 4 5 6 7 8 9 10
AWG18B AWG18GL
AWG20WL AWG22B 111 SSOFF(VB POWER ON RLY) MAIN/C NEUT SIGNAL ETC MOT EGI EGI HORN R RELAY F RELAY MAIN MAST LOCK PARKING
112 MAIN/C RLY(LPG CUT SOL RLY)
RELAY RELAY RELAY RELAY2 RELAY1 S.B FUSE 1 RELAY RELAY RELAY RELAY AWG16R
1 2 3 4
AWG18Y 40A AWG18RL
AWG18LR AWG12W AWG20B
AWG18RY
AWG16B
AWG14B 115 GND AWG16WB S.B FUSE 2
AWG16RW
AWG16GR
AWG16YG
AWG18RB
AWG16RY
AWG18YB
116
AWG18RL
GND AWG12W 60A
AWG18G
AWG18R
AWG18Y
AWG18RG
AWG16R
AWG16WR AWG20R
AWG14WR AWG14WR 119 VB S.B FUSE 3 AWG20B DIODE
AWG16WB 120 VB AWG8W 120A
121 BATT 8787a30 86 85 8787a30 86 85 8787a30 86 85 87 87a30 86 85 8787a 30 86 85 F20 F19 F18 F17 F16 F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 8787a30 86 85 8787a30 86 85 8787a30 86 85 8787a30 86 85 8787a30 86 85 8787a30 86 85 ALTERNATOR
L2
6 5 4 3 2 1
10A
10A
10A
10A
10A
10A
15A
L1
10A
10A
10A
15A
10A
10A
10A
L
WIRE 30 29 28 27 26 25 24 23 22 21 20 19 18 1716 15 14 13 1211 10 9 8 7 6 5 4 3 2 1 30 29 28 27 26 6 25 24 23 22 21 5 20 19 18 17 16 4 15 1413 12 11 3 10 9 8 7 6 2 5 4 3 2 1 1 AWG18YR
2 1
AWG18WR
S
AWG18WR
AWG20WR
AWG14WR
AWG16WB
AWG20RG
AWG18WL
AWG18RG
AWG20RG
AWG20RG
AWG16LW
AWG22RB
AWG18BY
AWG18GL
AWG18GL
AWG18GW
AWG10WR
AWG12WB
AWG20BW
FUSE BOX
AWG20WL
AWG20GB
AWG20YG
AWG20GY
AWG18GY
AWG16RY
AWG20RY
AWG18RY
AWG18RY
AWG20RY
AWG20BY
AWG20BY
AWG20LR
AWG20LB
AWG20LY
AWG16R
AWG20R
AWG22B
AWG20B
AWG18Y
AWG18L
AWG12W
AWG18G
AWG18G
AWG18G
AWG20G
AWG18R
AWG18R
AWG16R
AWG14B
AWG10W
AWG10WR
AWG12WG
B
AWG10B IC-REGULATOR
E

AWG14B AWG16B
OP
LPG FUEL
AWG18WR
LOW
AWG10WR
1 2
AWG10B
AWG8B
AWG20YB
AWG18L MAIN/C RLY

FUEL CUT
SOL
AWG18R AWG16R
AWG18Y AWG20Y
PARKING ENG CHECK
AWG10B
BUZZER (K-LINE)
CUT 1 2 3 4
AWG20WB
BATTERY
AWG20RB
AWG22YB
AWG20B
AWG20LB
AWG20LB
+ - ALTERNATOR E
(AWG4B) (AWG4B)
AWG18YR 1 AWG18YR
AWG18GY 2 AWG18GY
AWG20LB 3 AWG20LB
AWG20YL 4 AWG20YL
AWG20RG 5 AWG20RG
AWG20GB 6 AWG20GB
AWG20YG 7 AWG20YG
AWG20RB 8 AWG18RB
AWG20GY 9
AWG18G 10 AWG18G
AWG20RY 11 AWG22RY
AWG20YR 12 AWG18YR
AWG20RG AWG20RG
AWG20R
13
14 AWG18R
OP TAIL LAMP (8W)
AWG20YB 15 AWG18YB
AWG18LR 16 AWG18LR
AWG20WL
AWG16G
17
18 AWG20WL
AWG20G
AWG16BY 19 AWG16BY
20
AWG20YR 1.25G OP WINKER LAMP (23W) COMBI
AWG16RW
1 AWG20YR AWG20YR
6 5 4 3 2 1
AWG20GL AWG20GL AWG18GL 1.25W
AWG16GR
AWG18Y
2
3
4
AWG16GR
AWG18Y
AWG18RL
AWG18GW
1.25Y
1.25Br LAMP
AWG18RL
AWG16RW 5
6
AWG18RL
AWG16RW
AWG18YG
AWG18GW 7 AWG18GW
AWG18YG 8 AWG16YG
AWG20YB AWG20YB
OP
AWG20GW
AWG20GY
9
10 AWG22GW
AWG22GY HEATER STARTER OP
AWG20RY 11
12 AWG20RY
AWG20LR RELAY RELAY STROBE LIGHT
PARKING SW AWG20LR 13
AWG12B
14
AWG16G
2 1
N.O
COM AWG16RW
AWG12B AWG12B
HEAD LAMP (55W) N.C
AWG12W
AWG12WG
1
2 AWG12W
AWG12WG
AWG16B AWG18LW AWG18YG 3
AWG16B
1 2
1 2 3 4 5

AWG20YR AWG20YR 1 2 3 4 5 863087 85 87a
AWG18L AWG18RL
AWG16B
1 2 3
AWG20YR
AWG18L AWG18Y
AWG12WB
AWG12WL
AWG20RG
AWG16BY
AWG20B AWG18YR
AWG20GB
AWG20L
2 1
AWG18B
OP
BRAKE OIL
A-17
BLANK PAGE
BX50 TIER 2 LPS (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~
BX50 TIER 2 LPS (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~
A-19
BLANK PAGE
BX50 TIER 1 DUAL FUEL (K21/K25 ENGINE) S/N 200001A - 205849A
BX50 TIER 1 DUAL FUEL (K21/K25 ENGINE) S/N 200001A - 205849A
1 2
1 2 3 4 5
AWG20YR AWG20YR
DRIVING LAMP (8W) AWG18L AWG18L REAR LAMP(R)
1 2 3
AWG16B
6 5 4 3 2 1
AWG18GW
1.25Y
1.25Br LAMP
AWG12B AWG16B
AWG14B AWG16B 1.25B BACK UP LAMP (10W)
AWG12B
1 2 3 4 5 6 7 8
AWG18B AWG20YG
1 2
AWG18GY AWG20B
AWG20YB
AWG20R
OP L.O.P.
SPOOL LOCK SOL(LIFT) AWG18B AWG18YG
AWG18B
1 2
AWG18GY AWG20B OP
AWG20YR
BACK BUZZER
BUZZER OP
AWG18B AWG18GW
+
1 2 3
1 2
AWG20LB AWG18B
LF1
AWG18G -
AWG16BY
STARTING MOTOR
AWG20R
AWG20B
AWG16BY
AWG20RY
DIODE
AWG20LY
AWG20B
AWG20B
AWG14B
AWG12B
AWG20RY
T/C OIL TEMP. B
1 2 3 4 5 6 7 8 9 10 11 12
AIR FILTER AWG20LY AWG18B (AWG4B) 2 1
a 1
OP
COM AWG20RW 2 1 2 1
2 1
1 DISPLAY COOLANT
LPG LOW FUEL(GLOW)
AWG20R
AWG20YB OP
(AWG4B) S OP
GND AWG20B
AWG20Y T/C GND OP
COOLANT
POWER
AVCC(48) AWG20RY AIR
SNOW OPE(12) AWG20GW OIL FILTER
AWG12WL
POWER(+) AWG20LW
OUTPUT(+) AWG20WR TEMP
OP
LPG INJ DRIVER SPEED SEN UNIT EARTH E
1DISPLAY 1 2
AWG18RW
SPEED SENSOR(2)
SPEED SENSOR(1)
FUEEL INJ SOL(+)
LPG INJ PWN(39)

POWER(+B)
LPG INJ B#1(44)

FUEL INJ SOL(-)
LPG INJ A#1(8)

INJ CK#1(72)
GND-A(67)
VSP8(33)
VB(119)
VB(119)
POWER(+)
GND(1)
GND(1)
OP
AWG20LW
GND
GND
1 2 3
LIFT OUTPUT(+) AWG20WR
AWG20RW
OIL PS COM 12 11 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1
AWG18WR
AWG20GR
AWG16WR
AWG20BW
AWG16WL
AWG20LY
AWG16BY
AWG22Gr
AWG22Br
AWG20R
AWG20B
AWG20B
AWG18B
AWG22P
AWG18B
AWG22L
GND AWG16B
GND AWG14B
AWG18B
AWG22WR
AWG22BW
AWG22BW
AWG22YR
AWG22L
AWG14B
AWG16W(SH)
AWG22W(SH)
AWG22W(SH)
AWG22R(SH)
AWG22B(SH)
AWG16B(SH)
GND-A2(AWU)(83) AWG22B
6 5 4 3 2 1
AWG22BrW
FUEL LEVEL SENSOR APS2(AWU)(98)
AWG22YB AWG22BW
1 2 34 5
GND-A(67)
1 3 2
GND-A(67)
GND-A(67)
AWG20GY AVCC2(AWU)(91) AWG22LB
CONTROLLER (INTERLOCK-BOX) AWG22LW LPG PRESS(31) FUEL PRESS SENSOR (LPG)
1 2 3
APS1(AWU)(106)
QA+(51)
AWG20B AWG22RY
VB(119)
AWG22RB AVCC(48)
TA(34)
AVCC(AWU)(90) 6 5 4 32 1
26 25 24 23 22 21 20 19 18 17 16 1514131211 10 9 8 7 6 5 4 3 2 1 AWG16WL SOL +12 (DRIVE:12)
FUEL INJ SOL (LPG)
2 1
AWG16BY
GND-A2(66)
MOTOR1(5)
MOTOR2(4)
SOL GND(DRIVE:6)
AVCC2(47)
TPS1(50)
TPS2(69)
AWG18WR VB(119) AIR FLOW
AWG20GW
FUEL INJ ASIST SOL (LPG)
AWG20BW
AWG20RG
2 1
AWG20WL
AWG20RG
AWG20GY
AWG18GY
AWG18BR
AWG18BR
AWG18BR
AWG18BR
AWG20BY
AWG20BY
AWG20LR
AWG20LR
AWG20YL
AWG18BR
AWG20LY
METER
AWG18G
AWG20G
AWG18R
AWG20B
AWG20Y
AWG20B
SLOW INJ(11)
FUEL PUMP (GAS)
THROT CHAMBER
1 2 3 4 5 6
AWG14B
AWG18BR MOTOR & SENSOR
AWG16B
AWG14RB
AWG20WR
AWG20WR
INJ SOL #4 INJ SOL #3 INJ SOL #2
AWG12B
INJ SOL #1
INJ#4(41)
INJ#3(22)
INJ#2(42)
INJ#1(23)
IGN ACC
IGN ACC
IGN ACC
IGN ACC
AWG20B
AWG18WR
2 1 2 1 2 1 2 1
AWG18GW
AWG18GB
AWG18RB
AWG18RB
AWG18RB
AWG18GL
AWG18RB
AWG18G
AWG20BW
AWG20BW
AWG22BW
AWG22GL
AWG18LB
AWG18R
AWG22B
4 3 2 1
FUSE(O2 HEATER)
SOLENOID
VALVE(T)
R F
AWG20GL
AWG20GB 81
80
IGN#2
IGN#4
O2 SENSOR
AWG22GL
72 INJCK#1(DRIVER)
1 2 3 4
AWG22LB
AWG18GW
AWG22W(SH) 69 TPS2(THROT CHAMBER)
AWG18G
AWG18B
AWG18B
AWG20BW
AWG16WR
AWG18G
AWG20GW
DIODE AWG18B
AWG20G 62 IGN#1 AWG18GW
61 IGN#3
AWG18B
AWG18G
AWG18GW
CONDENSOR
ECM (81P CONNECTOR)

AWG18WR
AWG18YR AWG20LW
54 VARI VSP(TRUCK SPEED RESISTOR)
IGN COIL #4 IGN COIL #3 IGN COIL #2 IGN COIL #1
1 3 5 6 8 1012
2 4 7 9 11

AWG20YL
1 2
AWG22L AWG20R AWG20Y B
GND (-)
AWG20RY
IGN (+)
1234
AWG20LR AWG22R(SH) IGN +12(EGI RLY2) AWG18WL AWG20G IGN#3 TrZB (61) IGN +12(EGI RLY2) AWG18WL AWG20GW IGN#1 TrZB (62) AWG20Y L N.O
AWG14WR
1 2 3
1 2 3
1 2 3
1 2 3
50 TPS1(THROT CHAMBER) AWG18B AWG18B AWG18B AWG18B
AWG18Y
AWG20RB
AWG22R
AWG22RY 49
48
AVCC(FUEL SELECT SW)
AVCC(SENSOR)
GND TrZE
IGN #4 TrZB (80) AWG20GB AWG18WL GND TrZE
IGN +12(EGI RLY2)
GND TrZe
IGN#2 TrZB (81) AWG20GL AWG18WL GND TrZe
IGN +12(EGI RLY2)
AWG20G
AWG20RG
R
SEAT SW
AWG22W(SH)
47 AVCC2(THROT CHAMBER) 1 2
N.C
AWG18WL
AWG22Br
AWG18B
ST AWG12WG 44 LPGINJB#1(DRIVER)
WATER TEMP SENSOR
1 2 3
B IGN AWG16BY AWG18GL

42 INJ#2SOL(GAS) SEAT SW 2
AWG12W AWG18GB
AWG20B
ACC
AWG22L
41 INJ#4SOL(GAS) (TO METER PANEL)
AWG18RB
1 2
STOP LAMP SW AWG16RW

MAST LOCK L AWG18Y AWG22YR
2 1
AWG18GW 33 VSP8(TRUCK SPEED SIGNAL)

FLASHER UNIT AWG22Y
AWG16B
B
AWG22LB 32 FUELSW2(SELECT GAS) AWG20B AWG22B
AWG22RY 31 LPGPRES(LPG PRESS SENSOR)
30 LED(ENG SYS ERROR) AWG22B
MAINTENANCE AWG22GL TW(73) WATER TEMP
1 2
L R AWG22BW
AWG20WR
GND-A(67)
SENSOR
ERROR LAMP (B)
AWG18LB
24 O2HFR(O2 SENSOR) (TO ECM)
AWG16L AWG18GW
23 INJ#1SOL(GAS) ENGINE OIL PRESS SEN
1 2 3 4 5 6 7 8
AWG16GR AWG18G
22 INJ#3SOL(GAS)
N Down N N Up N Up AWG18LW
AWG18GW AWG20BR
(TO METER PANEL: E/G H.L-1P)
AWG22BrW
N LAMP
AWG22WR
AWG22WR
Down Up Up Down Down AWG16RL
AWG22LY
AWG22B
AWG22B
AWG18YG
OFF
1 2
OFF
1 2 1
OFF 2 AWG18GY HOUR METER
AWG20GY
CHARGE (A)
AWG18RW CUT AWG22LY
AWG22BrW 14 PHASE(CAM ANGLE) AWG22B 82 GND-A(ACCEL WORK UNIT) 6 5 4 3 2 1
13 POS(CRANK ANGLE) AWG22B 83
1 2 3 4
AWG18GR AWG20B AWG22GW AWG22GY GND-A2(ACCEL WORK UNIT)

12
GND(1)
POS(13)
VB(119)
GND(1)
PHASE(14)
VB(119)
AWG18R AWG18BR SNOW SW(ECO) 84 H/LMT(HEAD LAMP ON)
11 SLOW INJ(LPG ASIST SOL) AWG22YB 85 K-LINE(CONSULT)
AWG20YR
OIL PRESSURE
ECM (40P CONNECTOR)

AWG22P
8 LPG INJ A#1(DRIVER)
AWG18YR
COMBINATION SW AWG22RB 90 AVCC(ACCEL WORK UNIT)
CRANK&CAM
AWG20RG
AWG20G
AWG20Y
AWG16W(SH)
FUEL GAUGE B
F
T
E AWG16B(SH)
AWG16LW
5
4
MOTOR1
MOTOR2 ANGLE
AWG14B
3 V-MOT SENSOR
1315 18 20 22
AWG18B 1 GND
1416 17 19 21
AWG20GY AWG22Br 1 2 3 4
HOUR METER AWG20RG
AWG20YR
AWG20RG
AWG18GL
AWG20LR
AWG20G
AWG20Y
HORN AWG22RB 102 NEUT(NEUTRAL SW ON)
SW
F-R SWITCH AWG18BY DOWN OFF UP
1 2
AWG20B AWG22LW UP:CLOSE UP:OPEN

W 106 APS1(ACCEL WORK UNIT) DOWN:OPEN DOWN:CLOSE
WATER TEMP B E
T
ILLUMINATION VRI SPEED REGISTOR(OP) AWG20LW
MAIN RLY
AWG18R NEUT FUEL SLOW BLOW FUSE & RELAY BOX (TRUCK CONTROL & ISO 3691)
1
F R N
AWG20RG 109 IGN SW(KEY SW IGN ACC) 2 AWG20BW AUX
1 2 3 4 5 6 7 8 9 10
AWG18B
AWG20WL
AWG18GL 111 SSOFF(VB POWER ON RLY)
MAIN/C SIGNAL PUMP ETC MOT EGI 1
HORN R RELAY F RELAY MAIN MAST LOCK PARKING
AWG22B RELAY RELAY RELAY RELAY RELAY2
112 MAIN/C RLY(LPG CUT SOL RLY) EGI RELAY1 S.B FUSE 1 RELAY RELAY RELAY RELAY AWG16R
4
AWG22BR
1 2 3 4
AWG18Y 113 FPR(FUEL PUMP M.RLY(GAS)) 40A AWG18RL
AWG18RY
AWG16B
115 GND AWG16WB S.B FUSE 2
AWG18RB
AWG16YG
AWG14B
AWG18YB
AWG16RY
AWG16RW
AWG18RL
AWG16GR
116 GND 60A
AWG18R
AWG18Y
AWG18G
AWG18RG AWG12W
AWG20YB
AWG20YB
AWG20LB
AWG16R
AWG20R
AWG20Y
AWG16WR AWG14R AWG20R
AWG14WR AWG14WR
AWG16WB
119
120
VB
VB
S.B FUSE 3
120A
AWG20B DIODE
121 BATT 87 87a30 86 85 8787a30 86 85 8787a30 86 85 8787a30 86 85 87 87a 30 86 85 87 87a 30 86 85 F20 F19F18F17 F16F15 F14 F13 F12 F11 F10F9F8 F7 F6 F5 F4 F3 F2 F1
AWG8W
87 87a 30 86 85 87 87a30 86 85 87 87a 30 86 85 8787a30 8685 87 87a30 86 85 8787a30 86 85 ALTERNATOR
6 5 4 3 2 1 L2
10A
10A
10A
10A
10A
10A
15A
L1
10A
10A
10A
15A
10A
10A
10A
L
6 5 4 3 2 1 3029 28 27 26 25 24 23 22 21 2019 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 3029 28 27 26 6 25 24 23 22 21 5 20 19 18 17 16 4 15 14 13 12 11 3 10 9 8 7 6 2 5 4 3 2 1 1 AWG18YR
2 1
AWG18WR
S
FUSE BOX
AWG18GW
AWG20BW
AWG10WR
AWG12WB
AWG20WL
AWG18WR
AWG20WR
AWG20GB
AWG20YG
AWG20BY
AWG20GY
AWG18GY
AWG16LW
AWG20LR
AWG20RY
AWG16RY
AWG20RY
AWG18RY
AWG20RG
AWG18RY
AWG20BY
AWG14RB
AWG22RB
AWG20LB
AWG22BR
AWG20LY
AWG18BY
AWG18G
AWG14WR
AWG18R
AWG18R
AWG16WB
AWG18G
AWG20RG
AWG18G
AWG20G
AWG20RG
AWG20YB
AWG20YB
AWG18WL
AWG18RG
AWG16R
AWG16R
AWG20R
AWG18GL
AWG22LB
AWG14R
AWG20B
AWG18GL
AWG22B
AWG20R
AWG18L
AWG18Y
AWG22R
AWG22Y
AWG14B
AWG10WR
AWG12WG
AWG10WR B
AWG10B IC-REGULATOR
E
AWG14B AWG16B
LPG FUEL
OP
LOW
AWG18WR
LP FUEL CUT
AWG10WR SOLENOID
1 2
AWG10B (NISSAN P/N)
AWG18RB
AWG18RB
AWG20RB
AWG20YB
AWG16R
AWG18L MAIN/C RLY
FUEL CUT
SOL
AWG18R AWG16R
AWG18Y AWG20Y
PARKING
AWG10B
BUZZER
CUT
1 2 3 4
ENG CHECK BATTERY
AW
AWG20WB
AWG20RB
AWG22YB
AWG20B
G8
AWG20LB
AWG20LB
W
(K-LINE) ALTERNATOR E
+ -
(AWG4B) (AWG4B)
AWG18YR 1 AWG18YR
AWG18GY 2 AWG18GY
AWG20LB 3 AWG20LB
AWG20YL 4 AWG20YL
AWG20RG 5 AWG20RG
AWG20GB 6 AWG20GB
AWG20YG 7 AWG20YG
AWG20RB 8 AWG18RB
AWG20GY 9 AWG20GY
AWG18G 10 AWG18G
AWG20RY 11 AWG22RY
AWG20YR 12 AWG18YR
AWG20RG AWG20RG
AWG20R
13
14 AWG18R
OP TAIL LAMP (8W)
AWG20YB 15 AWG18YB
AWG18LR 16 AWG18LR
17 STOP LAMP (23W)
AWG20WL
AWG16G
AWG16BY
18
19
20
AWG20WL
AWG20G
AWG16BY
REAR
AWG20YR 1 AWG20YR AWG20YR 1.25G OP WINKER LAMP (23W) COMBI
6 5 4 3 2 1
AWG20GL AWG20GL AWG18GL 1.25W
AWG16RW
AWG16GR 2 AWG16GR AWG18RL 1.25Y

AWG18Y
AWG18RL
3
4
5
AWG18Y
AWG18RL
AWG18GW
AWG18YG
1.25Br
BACK UP LAMP (10W) LAMP
AWG16RW 6 AWG16RW AWG16B 1.25B
AWG18GW 7 AWG18GW
AWG18YG 8 AWG16YG
AWG20YB AWG20YB
AWG20GW
AWG20GY
9
10 AWG22GW
AWG22GY
HEATER STARTER OP
OP
AWG20RY 11
12 AWG20RY RELAY RELAY STROBE LIGHT
PARKING SW AWG20LR AWG20LR
AWG12B
13
AWG14B
14
AWG16G
2 1
N.O
COM AWG16RW
AWG12B AWG16B
AWG12W
1
2
AWG12B
AWG12W
AWG12WG 3 AWG12WG
AWG16B AWG18LW AWG18YG
AWG16B
1 2
1 2 3 4 5

AWG20YR AWG20YR 1 2 3 4 5 863087 85 87a
AWG18L
AWG16B
AWG18RL
AWG16B
AWG16B
1 2 3
AWG20YR
AWG18Y
AWG12WB
AWG12WL
AWG20RG
AWG18L
AWG16BY
HORN AWG20GB
AWG20L
2 1
AWG18B
OP
BRAKE OIL
A-21
BLANK PAGE
BX50 TIER 2 DUAL FUEL (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~
BX50 TIER 2 DUAL FUEL (K21/K25 ENGINE) S/N 210001A - 219999A / 750875 - 751863 / A224001~
A-23
BLANK PAGE
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) S/N 751863~ / A224001~
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) S/N 751863~ / A224001~
66
A-25
BLANK PAGE
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM
BX50 CARB 2010 DUAL FUEL (K21/K25 ENGINE) NEW KOPS, S/N AS SHOWN IN DIAGRAM
HEAD LAMP (55W)
AWG16RB AWG16RB AWG18LW TAIL LAMP REAR
12
12345
AWG16RG AWG16RB AWG18GY
REAR LAMP(R) STOP LAMP
AWG16RL
AWG16G
AWG16RG
AWG20YR
AWG18L
AWG16B
COMBI
LAMP
123
AWG16RL AWG18YR AWG18YR AWG16G WINKER LAMP
654321
AWG16B
AWG16G AWG18GL AWG16W
AWG18GW
AWG16Y
AWG16Br (LED TYPE)
AWG12B
AWG14B
AWG16B
AWG16B AWG16B
BACK UP LAMP
AWG12B
12345678
SPOOL LOCK AWG18B AWG20YG
12
SOL(LIFT) AWG18GY AWG20B
AWG20YB OP
OP
SPOOL LOCK AWG18B AWG18B
AWG20R
AWG18YG
L.O.P.
AWG18B
BACK
12
12
SOL(TILT) AWG18GY AWG18GY AWG20B
AWG20YR BUZZER
SPOOL LOCK AWG18B
OP BUZZER
12
SOL(ATT1) AWG18GY AWG18B AWG18GW
+-
12
123
OP AWG20LB AWG18B
AWG18G
SPOOL LOCK AWG18B LF1 AWG16BY
AWG18R
AWG18B
12
AWG18GY AWG16BY
STARTING MOTOR
AWG18LY
SOL(ATT2)
AWG18B
AWG18RY
AWG18B
DIODE
AWG14B
AWG12B
DELUXE AWG18RY T/C B
1 2 3 4 5 6 7 8 9 101112
T/C OIL TEMP. (AWG 4B) 21
AIR FILTER AWG18LY AWG18B OP
PANEL OP TEMP
a1
COM AWG20RW 21 21 COOLANT
21
OP COOLANT AWG18R (AWG 4B) S
LPG LOW FUEL(GLOW) AWG20YB
GND AWG20B
POWER AWG20Y DIODE GND
AVCC(48) AWG20RY OP AIR FILTER
AWG12WL
AWG20LW AWG18B
POWER(+)
a1
AWG20WR AWG18GY
OUT PUT(+)
SPEED SEN UNIT EARTH E
1DISPLAY 12 AWG18RW GND AWG16B
OP POWER(+B)
SPEED SENSOR(2)
SPEED SENSOR(1)
AWG16B
GND AWG14B
VSP8(33)
OP
VB(119)
GND(1)
GND(1)
POWER(+) AWG20LW (ECM CONTROLLER) AWG14B CHAMBER MOTOR POSITION
123
LIFT OUT PUT(+) AWG20WR
AWG20RW SENSOR
OIL PS COM S1 S2
AWG20GY 654321 AWG22W(SH)
AVCC2(47)
THROT CHAMBER
1 2 3 4 5 6
123
AWG20B AWG22R(SH)
TPS1(50) MOTOR & SENSOR
AWG18WR
AWG22W(SH)
AWG20GR
AWG20LY
AWG22B(SH) TPS2(69)
AWG20R
AWG20B
AWG20B
AWG16B(SH) GND-A2(66)
AWG16W(SH) MOTOR2(4)
AWG18GY
MOTOR1(5)
CONTROLLER
AWG18B
ACCEL WORK
(INTERLOCK-BOX) UNIT AWG22BW
GND-A(67) FUEL PRESS
132
FUEL LEVEL AWG22LB
21 AWG22RY LPG PRESS(31)
AVCC(48) SENSOR(LPG)
26 25 24232221 2019181716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 SENSOR
WIRE 1
WIRE 2
FUEL INJ
AWG20GW
123456
AWG20BW
AWG20RG
AWG20WL
AWG20RG
AWG20GY
AWG18GY
AWG18BR
AWG18BR
AWG18BR
AWG18BR
AWG20BY
AWG20BY
AWG20LR
AWG20LR
AWG20YL
AWG16WL
AWG20LY
SOL +12 (119)
AWG18B
AWG18G
AWG20G
21
AWG18R
AWG20B
AWG20Y
AWG20B
AWG14B AWG16BY
AWG22B SOL GND(120) SOL(LPG)
GND-A2(AWU)(83)
6 5 4 3 2 1
APS2(AWU)(98) AWG22BrW
AWG14RB AWG22B
GND-A(AWU)(82) AWG22YB
AVCC2(AWU)(91) AWG22LW AWG18WR FUEL INJ ASIST
APS1(AWU)(106) VB(121)
21
AVCC(AWU)(90) AWG22RB AWG18BR SLOW INJ(11) SOL(LPG) GAS GAS GAS GAS
INJ SOL #4 INJ SOL #3 INJ SOL #2 INJ SOL #1
AWG16B
AWG12B
FUSE 5A
WIRE 1 WIRE 1
21
SWITCH WIRE 2 WIRE 2
INJ#4(41)
INJ#3(22)
INJ#2(42)
INJ#1(23)
IGN ACC
IGN ACC
IGN ACC
IGN ACC
WIRE 1 WIRE 1
FUEL
21
21
WIRE 2 WIRE 2 PUMP 21 21 21 21
AWG18RB
AWG18GL
SOLENOID (GAS)
AWG18GW
AWG18GB
AWG18RB
AWG18RB
AWG18RB
AWG18G
LAMP(G)
ECM SEALINGS(81P)
AWG18 R WIRE 1
21
♦X45 PLACES
6 54 3 21
WIRE 2
STATUS
AWG18 B
LIGHT AWG20GL
AWG20GB 81 IGN#2 AWG22GL O2SFR(O2 SENSOR)(35)
4321
80 IGN#4 AWG18R
AWG22B 79
78
♦
GND-A(O2 SENSOR)
AWG18LB FUSE(O2 HEATER)
O2HFR(O2 SENSOR)(24) O2 SENSOR
AWG22B
77 ♦ GND-A(O2 SENSOR)(78)
76 ♦
75 ♦
AWG22GL 74 ♦
AWG18WR AWG20WR
73 TW(WATER TEMP SENSOR)
AWG20WR
AWG22LR 72 ♦
71 MAP SENSOR
AWG20B
AWG22LB
AWG22WR
AWG22BW
AWG22BW
AWG22W(SH)
AWG22YR
AWG22L
AWG20BW 68 ♦
66 GND-A2(THROT CHAMBER) SOLENOID
65 ♦
64 ♦ VALVE(T)
AWG20BW
AWG20BW
AWG22BW
63 1 2 3 4 5 6
AWG20GW ♦
62 IGN#1 R F
AWG20G
GND-A(67)
GND-A(67)
61 IGN#3
QA+(51)
60
VB(121)
♦
TA(34)
59 ♦
58 ♦
57 ♦
56 ♦
AWG20LW 55
54
♦
VARI VSP(TRUCK SPEED RESISTOR)
AIR FLOW METER
53 ♦ 1234
AWG22L 52 ♦
51 QA+(AIR FLOW MEATER)
D/B HARNESS AWG22R(SH) 50 TPS1(THROT CHAMBER)
AWG18GW
AWG22R 49 AVCC(FUEL SELECT SW)
AWG18G
AWG18B
AWG18B
AWG22RY 48
AWG22W(SH) AVCC(SENSOR)
47 AVCC2(THROT CHAMBER)
AWG18WR
46 ♦
45 ♦
44 ♦ AWG18G
AWG18GL 43 ♦ DIODE AWG18B
AWG18GB 42 INJ#2SOL(GAS) AWG18GW
41 INJ#4SOL(GAS)
CONDENSOR
AWG18GW
40 ♦
AWG18G
AWG18B
39 ♦
38 ♦
37
36
♦
♦
AWG18WR
HARNESS
AWG22GL 35 SEAT SW
AWG22YR O2SFR(O2 SENSOR)
AWG18YR 34 TA(AIR TEMP SENSOR)
1 3 5 6 8 1012
AWG20LY IGN COIL #3 IGN COIL #1

2 4 7 9 11
AWG20BR 33 VSP8(TRUCK SPEED SIGNAL)
GND (-)
IGN (+)
AWG22Y AWG20GR SEAT SW 1
12
AWG20YL AWG22LB 32 FUELSW2(SELECT GAS) AWG20R
AWG20RY 31 LPGPRES(LPG PRESS SENSOR) AWG20Y N.O
321
4321
AWG18WL AWG20G AWG18WL AWG20GW
AWG14WR
AWG20LR AWG22RY 30 LED(ENG SYS ERROR) IGN +12(EGI RLY2) IGN#3 TrZB (61) IGN +12(EGI RLY2) IGN#1 TrZB (62) AWG20G
123
123
123
123
AWG18B AWG18B AWG18B AWG18B AWG20RG
AWG18Y 29 ♦ GND TrZE AWG20GB AWG18WL GND TrZE GND TrZE AWG20GL AWG18WL GND TrZE
AWG20RB 28 ♦ IGN#4 TrZB (80) IGN +12(EGI RLY2) IGN#2 TrZB (81) IGN +12(EGI RLY2)
27 ♦ TRUCK SPEED 12
N.C
AWG18WL
26 ♦
AWG18B
25 ♦
AWG12WG
AWG18LB
AWG18GW 24
23
O2HFR(O2 SENSOR)
INJ#1SOL(GAS)
SENSOR
123
ST AWG16BY AWG18G WATER TEMP SENSOR

22 INJ#3SOL(GAS) SEAT SW 2
AWG20B
B IGN AWG12W 21 ♦
ACC STOP 20 ♦ (TO METER PANEL)
LAMP SW 19 ♦
AWG16GL
18
17
♦
♦
AWG16B AWG16B AWG16B HARNESS
12
AWG16RW AWG18RB
16 ♦
AWG22LY 15 ♦
MAST LOCK FLASHER L AWG18Y AWG22BrW 14 PHASE(CAM ANGLE) AWG20WR
21
B AWG18GW AWG22GW 13 POS(CRANK ANGLE)

UNIT 12 SNOW SW(ECO)
AWG16B
AWG18BR AWG20B AWG22B
11 SLOW INJ(LPG ASIST SOL)
AWG20WR
10 ♦ AWG22B WATER TEMP
MAINTENANCE 9 ♦ AWG22GL
TW(73)
12
L R 8 ♦
♦
AWG22BW GND-A(67) SENSOR
7
6 ♦ (TO ECM)
ERROR AWG16W(SH)
LAMP (B) 5 MOTOR1 ENGINE OIL PRESS SEN
AWG16L AWG16B(SH)
AWG22BrW
AWG22WR
AWG22WR
4 MOTOR2
12345678
AWG22LY
AWG16GR AWG16LW 3 V-MOT (TO METER PANEL:E/G H.L-1P)
AWG22B
AWG22B
N
N
AWG18GW
AWG16B
AWG14B 2 GND ECM SEALINGS(40P) MAP SENSOR
Down Up Up Down Down AWG20BR 1 GND
N LAMP AWG16RL ■X2 PLACES AWG22RY AWG22RY AVCC(48)
321
♦X16 PLACES AWG22LR MAP SENSOR(71)
AWG18YG AWG22BW 654321
OFF 1 2 OFF 1 2
OFF 1 2 AWG18GY HOUR METER CUT GND-A(67)
AWG20GY
GND(1)
POS(13)
VB(119)
GND(1)
PHASE(14)
VB(119)
CHARGE (A) AWG22B GND-A(ACCEL WORK UNIT)
AWG18RW AWG22B
82
1234
AWG18GR AWG20B 83 GND-A2(ACCEL WORK UNIT)

AWG22GY 84 H/LMT(HEAD LAMP ON)
AWG18R AWG22YB
OIL 86 ♦
PRESSURE 87 ♦
E/G HARNESS FUEL SELECT
AWG18YR
88 ♦
COMBINATION SW 89 ♦
AWG20RG
AWG22RB 90 AVCC(ACCEL WORK UNIT) SW
AWG20G
AWG20Y
FUEL GAUGE AWG22YB
GLP
91 AVCC2(ACCEL WORK UNIT)
AWG22BW
F 92 ♦
B E 93 ♦ CRANK&CAM
T 94 ♦
95 ♦ ANGLE SENSOR
96 ♦
1315 18 20 22
HOUR METER AWG18B

1416 17 19 21
AWG20GY 97 ♦ 1234
AWG22BrW 98 APS2(ACCEL WORK UNIT)
AWG20YR
AWG20RG 99 ♦
AWG20RG
♦
AWG20LR
AWG20YR 100
AWG20G
AWG20Y
AWG18GL 101 BRAKE(FOOT BRAKE ON)
HORN AWG22RB 102 NEUT(NEUTRAL SW ON)
F-R SWITCH SW AWG18BY
103 ♦
DOWN OFF UP
WATER TEMP AWG20YG 104 MOTRLY(CHAMBER M.RLY)
RELAY BOX2
UP:CLOSE UP:OPEN
RELAY BOX1
12
AWG20B AWG22LW 105 ♦ DOWN:OPEN DOWN:CLOSE

W 106 APS1(ACCEL WORK UNIT) MAIN RLY
B E 107 ♦
T ILLUMINATION 108 ♦
F R N VRI SPEED REGISTOR(OP) SLOW BLOW FUSE & RELAY BOX(TRUCK CONTROL & ISO 3691) AUX
1
AWG18R
AWG20RG AWG16WB 109 IGN SW(KEY SW IGN ACC) 2 AWG20LW
1 2 3 4 5 6 7 8 9 10
AWG18B 110 BATT 1 AWG20BW

AWG20WL
AWG18GL 111 SSOFF(VB POWER ON RLY) NEUT SIGNAL FUEL PUMP ETC MOT MAIN MAST LOCK PARKING
AWG22B 112 MAIN/C RLY(LPG CUT SOL RLY) MAIN/C RELAY RELAY RELAY RELAY EGI RELAY2 EGI RELAY1 HORN RELAY R RELAY F RELAY RELAY AWG16R
RELAY
4
AWG22BR S.B FUSE 1
1234
AWG18Y 113 FPR(FUEL PUMP M.RLY(GAS)) RELAY AWG18RL
114 ■ AWG18RY
AWG16B 40A
115 GND AWG16WB
AWG16RW
AWG14B S.B FUSE 2
AWG16YG
AWG18RB
AWG16GR
AWG18YB
AWG16RY
AWG18RL
116 GND
AWG18R
AWG18G
AWG18Y
AWG18RG AWG12W
AWG20YB
AWG20YB
AWG20LB
117 ■
AWG20R
AWG20Y
AWG16WR AWG16R
118 VB AWG14R 60A AWG20R
AWG16WL 119 LPG INJ VB#1
AWG16BY AWG20B DIODE
AWG14WR 120 LPG INJ -#1 AWG8W
121 VB F20 F19 F18 F17 F16 F15 F14 F13 F12F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 ALTERNATOR
85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87 85 86 30 87
120A
L
10A
10A
10A
10A
10A
10A
15A
10A
10A
10A
15A
10A
10A
10A
654321 30 29 28 27 26 6 25 24 23 22 21 5 20 19 18 1716 4 15 1413 1211 3 10 9 8 7 6 2 5 4 3 2 1 1 L2 L1 30 29 28 27 26 6 25 24 23 22 21 5 20 19 18 1716 4 15 1413 1211 3 10 9 8 7 6 2 5 4 3 2 1 1 AWG18YR
21
AWG18WR
AWG18GW
AWG10WR
AWG12WB
AWG20BW
AWG20WL
S
AWG20GB
AWG20YG
AWG20GY
AWG18GY
AWG20BY
AWG20RY
AWG16RY
AWG20RY
AWG18RY
AWG20LR
AWG18RY
AWG20BY
AWG18WR
AWG14WR
AWG20WR
AWG20LB
AWG16WB
AWG20LY
AWG20RG
AWG20RG
AWG20RG
AWG16LW
AWG18WL
AWG18RG
AWG14RB
AWG22RB
AWG22BR
AWG18GL
AWG18GL
AWG18BY
AWG18G
AWG18G
AWG18G
AWG18R
AWG18R
AWG20G
AWG16R
FUSE BOX
AWG20YB
AWG20YB
AWG22LB
AWG16R
AWG20R
AWG14R
AWG20R
AWG22B
AWG20B
AWG18Y
AWG18L
AWG22R
AWG22Y
AWG14B
AWG10WR
AWG12WG
AWG10WR B
APPLICABLE MODELS AWG14B AWG14B

AWG20RG
AWG10B
E
IC-REGULATOR
AWG14WR
FG20ST-16 S/N A233132~

AWG14B AWG16B
OP
LPG FUEL
AWG18WR
LOW(2KG/CM2)
FG20T-16 S/N A224023~ AWG10WR
12
AWG10B LPG FUEL
AWG18RB
CUT SOL
FG25HT-16 S/N A230096~ AWG18RB
FG25SHT-16 S/N A240058~
AWG20RB
AWG20YB
AWG18L
AWG16R
FG25ST-16 S/N A234854~ AWG18L
FG25T-16 S/N A225994~ AWG18R AWG16R
FG30HT-16 S/N A231327~ AWG18Y AWG20Y
FG30SHT-16 S/N A240524~
AWG10B
PARKING ENG CHECK
BUZZER (K-LINE)
FG32HT-16 S/N A231553~ CUT

1234
AW
AWG20WB
AWG20RB
AWG22YB
G
AWG20B
AWG20LB
AWG20LB
8W
ALTERNATOR E
+ -
(AWG 4B) (AWG 4B)
AWG18YR AWG18YR
AWG18GY 1 AWG18GY
AWG20LB 2 AWG20LB
AWG20YL 3 AWG20YL
AWG20RG 4 AWG20RG
AWG20GB 5 AWG20GB
AWG20YG 6 AWG20YG
AWG20RB 7 AWG18RB
AWG20GY 8 AWG20GY
AWG18G
AWG20RY
9
10
11
AWG18G
AWG22RY
BATTERY
AWG20YR
AWG20RG 12
13
AWG18YR
AWG20RG BATTERY
14
AWG20R
AWG20YB 15 AWG18R
AWG18YB CABLE
AWG18LR
AWG20WL
16
17 AWG18LR
AWG20WL
TAIL LAMP REAR
AWG16G 18 AWG20G STOP LAMP
AWG16BY 19
20 AWG16BY COMBI
AWG20YR
AWG20GL 1
AWG18YR AWG18YR AWG16G WINKER LAMP LAMP
654321
AWG20GL AWG18GL AWG16W
AWG16RW
AWG16GR 2 AWG16GR AWG18RL AWG16Y

AWG18Y 3 AWG18Y AWG18GW AWG16Br (LED TYPE)
AWG18RL 4 AWG18RL AWG18YG BACK UP LAMP
AWG16RW 5 AWG16RW AWG16B AWG16B
AWG18GW 6 AWG18GW
AWG18YG 7 AWG16YG
AWG20YB 8 AWG20YB
AWG20GW 9 AWG22GW STARTER
OP AWG20GY 10 AWG22GY OP
AWG20RY 11 AWG20RY RESISTOR RELAY
PARKING AWG20LR 12
AWG12B
13 AWG20LR
SW
AWG14B
14
AWG16G
21
N.O
COM AWG16RW
AWG12W 1 AWG12B
AWG12W
AWG12B AWG16B
AWG12WG 2 AWG12WG
3
AWG16RB AWG16RB AWG18YG STROBE
AWG16B
12
12345
AWG16RG AWG16RB AWG18R

AWG16RL AWG20YR 12
86308785 LIGHT
AWG16G
AWG16RG
AWG18RL
AWG16B
AWG12WB
AWG12WL
AWG20RG
123
AWG16BY
AWG16RL
AWG16G AWG18Y
AWG20GB
HORN
AWG18L
21
AWG18B
OP
BRAKE OIL
A-27
BLANK PAGE
CHANGE SUMMARY
JULY 2011
Add model, engine and chassis information tables to Foreword.
Add lubricant lists, weight tables and general assembly diagram.
Add “Bleed air from fuel piping (Diesel models)“ adjustment procedure.
Add CONTROL VALVE ASSEMBLY - HYDRAULIC PRESSURE PORT LOCATION figure.
Add SOLENOID VALVE DISASSEMBLY AND ASSEMBLY.
MAY 2013
Update model and engine serial breaks
Update lubricant tables.
Add lift interlock for ANSI/ITSDF B56.1-2012.
Update mast cap bolt torque values.
Update SAFETY chapter.
Add new KOPS wiring diagram foldouts to Appendix.
JUNE 2014
Update General Assembly Diagram with exhaust pipe and muffler mounting torques.
Update front axle mounting bolt torque.
Update power steering torque.
Correct sideshifter parts list.
Update mast manuals to address banging problems.
KOMATSU FORKLIFT U.S.A.
BX50 TIER 2 DIESEL (4D94LE ENGINE)
S/N 200001A - 215882A
REAR LAMP(R) STOP LAMP (23W) REAR
1 2
1 2 3 4 5
DRIVING LAMP (8W)

AWG20YR AWG20YR
COMBI
AWG18L AWG18L
1 2 3
6 5 4 3 2 1
AWG18L AWG18LW 1.25W
WINKER LAMP (23W)
AWG16B
LAMP
AWG18L 1.25Y
AWG18GW 1.25BR
AWG12B
AWG14B
AWG16B
AWG12B
AWG20RB
1 2 3 4 5 6 7 8
AWG18B AWG20YG
1 2
AWG18GY AWG20B
AWG18YB OP
SPOOL LOCK SOL(LIFT)

AWG16R
L.O.P.
BACK BUZZER
AWG18B AWG16YB
AWG18B
1 2
AWG18GY AWG20B OP
AWG20L
BUZZER +-
OP AWG20B AWG18GW
1 2 3
1 2
AWG20GW AWG18B
LF1 AWG16BY
AWG18G
AWG16BY
DIODE
AWG20R
AWG20B
AWG20RY
AWG20LY
AWG20B
AWG20B
AWG14B
AWG20RY
AWG12B
T/C OIL TEMP.
1 2 3 4 5 6 7 8 9 10 11 12
AWG20LY AWG18B 2 1
AIR FILTER
a 1
COOLANT
OP
COM AWG20RW 2 1 2 1 OP
AWG18YR
1 DISPLAY
2 1
AWG20R
AWG18Y
COOLANT
AWG20R OP
GND
GLOW OP
GND AWG20B
POWER AWG20Y
T/C OIL TEMP AIR FILTER 2 1
POWER(+) AWG20LW
OUT PUT(+) AWG20WR
OP
1DISPLAY
1 2
AWG18RW
POWER(+B)
OP
POWER(+) AWG20LW B
LIFT
1 2 3
OUT PUT(+) AWG20WR

AWG20RW
OIL PS COM
1
R
2
B
(AWG4B)
R
S L
E
E
E
STARTING MOTOR ALTERNATOR
GLOW PLUGS
FUSE BOX
L2
F20 F19
AWG8WR
SLOW BLOW FUSE & RELAY BOX
F18 F17 F16

10A AWG18G
10A AWG16RW
AWG18YR
AWG20R
AWG16GR
1 3 5 6 8 10 12
AWG20BR 15A
7 9 11
AWG20YL
MAIN RLY
S.B FUSE
F15 F14 F13 F12 F11

AWG20LY
AWG20W
AUX
AWG20W
AWG18Y
PARKING MAST LOCK
2 4
AWG20RB AWG10W
F RELAY R RELAY HORN RELAY RELAY RELAY MAIN RELAY

40A
AWG12WG
WATER
TEMP
F10
ST AWG10W
1 2 3
AWG16BY 15A AWG16YB
F9 F8 F7 F6
B IGN AWG12W
ACC
AWG20LW
60A 10A AWG16Y
SENSOR
AWG20LR AWG18YG
10A
AWG18GY
CONT
10A
AWG16LW 4 3 2 1
STOP LAMP SW
AWG8W
1 2
AWG16RW
F5 F4 F3 F2 F1
120A
MAST LOCK
FLASHER UNIT L AWG18Y
EARTH
2 1
B AWG18GW
AWG18RW
AWG18GY
AWG18RY
AWG18B
GLOW 1 2 3 4 5 6
SEAT SW
5 4 3 2 1 10 9 8 7 6 15 14 13 12 11 20 19 18 17 16 25 24 23 22 21 30 29 28 27 26
L1
L R
AWG12WB
AWG8WR
AWG12W
AWG20RW
SEDIMENTER/ (B) AWG20B DIODE
SEAT SW 1
SEAT SW 2
AWG12WG
MAINTENANCE AWG16L
AWG16RB
AWG20GW
AWG20YG
AWG16RW
AWG20GL
AWG18GY
AWG18RY
1 2 3 4 5 6 7 8
AWG18RY
AWG20BY
AWG16Y
AWG16Y
AWG20GY
AWG20LY
AWG18GW
AWG16GR
AWG18RW
AWG18RW
AWG20BW
AWG20G
AWG20G
AWG20WL
AWG16Y
AWG20YR
AWG20G
AWG20BY
N N
AWG18G
HOUR
AWG18GW AWG20BR
AWG16RL
N.O
N.C
AWG18G
AWG12B
AWG16B
OFF
1 2 OFF 1 2 OFF 1 2
AWG18YG
AWG18GY METER
CHARGE (A)
AWG18RW CUT
1 2 3 4
AWG18GR
R
B
L
AWG18R AWG16RW AWG16RW AWG18RW
OIL AWG20YR
AWG20B
AWG8W
1 2 3 4
PRESSURE
COMBINATION SW
AWG20RG
AWG20G
AWG20Y
AWG20Y
F
FUEL GAUGE B
T
E
AWG18B
13 15 18 20 22
14 16 17 19 21
AWG20GR
HOUR METER AWG20YR
AWG20RW
AWG20L
F-R SWITCH HORN SW

AWG20YG
1 2
AWG20B
W
WATER TEMP B
T
E
ILLUMINATION F R N AWG20RL
1 2 3 4 5 6 7 8 9 10
AWG18B
AWG20WL
AWG18Y
AWG18YB
SEAT SW
AWG20Y AWG20Y
1
AWG20G
2
AWG20RG
3
AWG18GW AWG20LR
4
AWG8W
AWG12WL
AWG20R
AWG20G
AWG12B
AWG16B
AWG18G
WAG20RY
WAG20B
AWG16R
AWG16L
AWG18B
BATTERY AWG18GW
AW
G8
DIODE
W
1 2
+ -
AWG20GW
AWG20BW
AWG18RW
AWG20RG
AWG20WL
AWG22RG
AWG18GY
AWG20GY
AWG18BR
AWG20BR
AWG18BR
AWG20YR
AWG18BR
AWG20RY
AWG20BY
AWG20BY
AWG20YL
AWG20LY
AWG12WB
AWG20RG
AWG12WL
AWG20GW
AWG20G
AWG20G
AWG20YB
AWG20B
AWG20Y
AWG20B
AWG18YG
AWG20GY
AWG20LW
AWG20YB
AWG18BY
AWG18RL
AWG20YL
AWG18GW
AWG12WG
AWG20GW
AWG18GW
AWG16RW
AWG18B
AWG20B
AWG22RG
AWG20RG
AWG20WL
AWG16GR
AWG18GY
AWG20YG
AWG20GY
AWG20LW
AWG20LW
AWG16RB
AWG20YR
AWG20RY
AWG20GL
AWG18BY
AWG16YB
AWG18RL
AWG20LR
AWG20YL
AWG20YL
AWG18G
AWG18B
AWG18B
AWG12W
AWG18G
AWG20G
AWG16R
AWG12B
AWG16Y
AWG16L
(AWG1B) (AWG1B)
FUEL CUT OIL SEDIMENTER

87A 87 30 86
1 2 3 4 1 a 3 2 1
SOLENOID PRESS SENS0R

1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
PARKING FUEL CONTROLLER (INTERLOCK-BOX)
AWG20LW
AWG8WR
AWG18BY
AWG8W
AWG20R
AWG18B
BUZZER SW LEVEL
AWG12WG
AWG20GW
AWG20RW
AWG18GY
AWG20GB
AWG18GW
AWG16RW
AWG20YG
AWG20GR
AWG20RY
AWG20LW
AWG16GR
AWG20RB
AWG20WL
AWG20RL
AWG20LY
AWG20LW
AWG20YR
AWG16YB
AWG12W
AWG18YB
AWG16BY
AWG18RL
AWG20LR
AWG18G
AWG12B
AWG20R
AWG20L
AWG16G
AWG18Y
SOLENOID SENSOR
AWG20GW
AWG20GW
CUT VALVE(T)
2 1 6 5 4 3 2 1
DIODE
R F
TIMER
CIRCLE
QGS (A) QGS (B) OP TAIL LAMP (8W)

STOP LAMP (23W)
REAR
COMBI
AWG16RW
1.25G
LAMP
1.25W
1.25Y
1.25Br
1.25B BACK UP LAMP (10W)

OP
OP
PARKING SW
AWG12B
AWG16G
N.O
COM AWG16RW
STROBE LIGHT
2 1
HEAD LAMP (55W) AWG18LW
N.C
AWG16B AWG18GY AWG18YG

AWG16B
1 2 3 4 5
1 2
AWG18GY AWG20YR AWG18R

AWG18L AWG20YR

AWG16B AWG18RL
AWG16B
AWG16B
1 2 3
AWG20YR
AWG18L
AWG20B
AWG20GB
AWG20L
2 1
AWG18B
OP
BRAKE OIL
BX50 INTERIM TIER 4 DIESEL (4D98E ENGINE)
S/N 215883A - 219999A / 750875~ / A223001~
BX50 TIER 1 GASOLINE (K21/K25 ENGINE)
S/N 200001A - 205849A
OP TAIL LAMP (8W)

HEAD LAMP (55W) REAR
STOP LAMP (23W)
COMBI
1 2
1 2 3 4 5
AWG20YR AWG20YR REAR
DRIVING LAMP (8W) AWG18L AWG18L
LAMP(R)
1 2 3
LAMP
AWG16B
6 5 4 3 21
AWG18GW
1.25Y
1.25Br
AWG12B
AWG14B
AWG16B
AWG12B
1 2 3 4 5 6 7 8
AWG18B AWG20YG
1 2
AWG18GY AWG20B
AWG20YB OP
SPOOL LOCK SOL(LIFT) AWG18B

AWG20R
AWG18YG L.O.P. BACK
AWG18B
1 2
AWG18GY AWG20B OP
AWG20YR
BUZZER
+
1 2 3
1 2
LF1
AWG20LB AWG18B
AWG18G -
AWG16BY
STARTING MOTOR
AWG20R
AWG20B
AWG16BY
DIODE
AWG20RY
AWG20LY
AWG20B
AWG20B
AWG14B
AWG12B
T/C OIL TEMP. AWG20RY
B
1 2 3 4 5 6 7 8 9 10 11 12

AIR FILTER
a 1
COM AWG20RW 2 1 2 1
1 DISPLAY S OP
2 1
COOLANT AWG20R (AWG4B)
LPG LOW FUEL (GLOW)
GND
AWG20YB
AWG20B
OP
GND OP COOLANT
POWER
AVCC(48)
AWG20Y
AWG20RY
AWG20GW
T/C AIR
SNOW OPE(12)
AWG20LW OIL FILTER SPEED
AWG12WL
POWER(+)
OUTPUT(+) AWG20WR
OP TEMP SEN UNIT E
1DISPLAY AWG18RW EARTH
1 2
SPEED SENSOR(2)
SPEED SENSOR(1)
POWER(+B)
VSP8(33)
VB(119)
OP
GND(1)
GND(1)
POWER(+) AWG20LW
LIFT
1 2 3
OUTPUT(+) AWG20WR
COM AWG20RW
OIL PS 6 5 4 3 2 1
AWG18WR
AWG20GR
AWG20LY
AWG20R
AWG20B
AWG20B
GND
AWG12B
GND
AWG22WR
AWG22BW
AWG22BW
AWG22YR
(ECM CONTROLLER)
AWG22L
AWG14B
AWG14B
AWG22W(SH)
AWG16W(SH)
AWG22W(SH)
AWG22R(SH)
AWG22B(SH)
AWG16B(SH)
AWG14B AWG22B
GND-A2(AWU)(83)
6 5 4 3 2 1
APS2(AWU)(98) AWG22BrW 1 2 3 4 5
AVCC2(AWU)(91) AWG22YB
CONTROLLER (INTERLOCK-BOX) AWG20GY AWG22LW
GND-A(67)
GND-A(67)
APS1(AWU)(106)
1 2 3
AWG20B AWG22RB
FUEL LEVEL SENSOR
QA+(51)
VB(119)
AVCC(AWU)(90) 6 5 4 3 21
TA(34)
26 25 24 23 22 21 20 19 18 17 16 1514131211 10 9 8 7 6 5 4 3 2 1
GND-A2(66)
MOTOR1(5)
MOTOR2(4)
AVCC2(47)
TPS1(50)
TPS2(69)
AIR
AWG20GW
AWG20BW
AWG20WL
AWG20RG
AWG20RG
AWG18GY
AWG20GY
AWG18BR
AWG18BR
AWG18BR
AWG18BR
AWG20BY
AWG20BY
AWG20LR
AWG20LR
AWG20YL
AWG20LY
FLOW
AWG18G
AWG20G
AWG18R
AWG20B
AWG20Y
AWG20B
METER THROT
1 2 3 4 5 6
FUEL PUMP AWG14B
AWG18BR
(GAS) CHAMBER
AWG14RB INJ SOL #4 INJ SOL #3 INJ SOL #2 INJ SOL #1 MOTOR &
AWG16B
AWG12B
SENSOR
INJ#4(41)
INJ#3(22)
INJ#2(42)
INJ#1(23)
IGN ACC
IGN ACC
IGN ACC
IGN ACC
AWG20B
2 1 2 1 2 1 2 1
AWG18GB
AWG18RB
AWG18RB
AWG18RB
AWG18GL
AWG18GW
AWG18RB
AWG18G
AWG20BW
AWG20BW
AWG22GL
AWG18LB
AWG18R
AWG22B
4 3 2 1
FUSE(O2 HEATER)
SOLENOID
VALVE(T)
R F O2 SENSOR
AWG20GL
AWG20GB 81 IGN#2
80 IGN#4
1 2 3 4
AWG18GW
AWG18G
AWG18B
AWG18B
AWG22GL 73 TW(WATER TEMP SENSOR)
AWG16WR
AWG22W(SH) AWG18G
AWG20BW
DIODE AWG18B
AWG18GW
AWG22B(SH) 66 GND-A2(THROT CHAMBER)
CONDENSOR
AWG18GW
AWG18G
AWG18B
AWG20GW AWG18WR
AWG20G 62 IGN#1
61 IGN#3
AWG18YR IGN COIL #4 IGN COIL #3 IGN COIL #2 IGN COIL #1
1 3 5 6 8 1012
AWG20BR SEAT SW 1
2 4 7 9 11
GND (-)
AWG20GR
IGN (+)
AWG20YL
1 2
AWG20R AWG20Y B
AWG20RY AWG18WL AWG18WL AWG20GW N.O
AWG20G
1234
AWG20LR IGN +12(EGI RLY2) IGN#3 TrZB (61) IGN +12(EGI RLY2) IGN#1 TrZB (62) AWG20Y L
SEAT SW
1 2 3
1 2 3
AWG18B
1 2 3
1 2 3
AWG18B AWG18B
AWG14WR
AWG18Y AWG20LW GND TrZE AWG18B GND TrZE GND TrZE GND TrZE AWG20G R
AWG20RB 54 VARI VSP(TRUCK SPEED RESISTOR) IGN#4 TrZB (80) AWG20GB AWG18WL IGN +12(EGI RLY2) 1 2 IGN#2 TrZB (81) AWG20GL AWG18WL IGN +12(EGI RLY2) AWG20RG
AWG22L N.C
WATER TEMP
AWG18WL
AWG22R(SH)
ECM (81P CONNECTOR)

AWG18B
AWG22Y 49 AVCC(FUEL SELECT SW)
AWG12WG
ST AWG20RY 48 AVCC(SENSOR) SENSOR
1 2 3
AWG16BY AWG22W(SH) SEAT SW 2

IGN AWG12W 47 AVCC2(THROT CHAMBER)
B
(TO METER PANEL)
AWG20B
ACC

STOP AWG16GL AWG18GL
42 INJ#2SOL(GAS) AWG18RB
1 2
AWG16RW AWG18GB
LAMP SW 41 INJ#4SOL(GAS)
MAST LOCK FLASHER L AWG18Y AWG20WR
2 1
AWG18GW
AWG20WR
B
AWG16B
UNIT AWG20B AWG22B
MAINTENANCE
AWG22GL
AWG22YR 35 O2SFR(O2 SENSOR) AWG22B
AWG22GL
WATER TEMP
AWG20LY 34 TA(AIR TEMP SENSOR) TW(73)
SENSOR
1 2
L R 33 VSP8(TRUCK SPEED SIGNAL) AWG22BW GND-A(67)
AWG22Y
32 FUELSW2(SELECT GAS)
(TO ECM)
ERROR LAMP AWG22RY 30 LED(ENG SYS ERROR)
(B)
AWG22BrW
1 2 3 4 5 6 7 8
AWG16GR
AWG22WR
AWG22WR
AWG22LY
N N N Up N AWG18LW
AWG22B
AWG22B
Down Up
AWG18GW AWG20BR
AWG16RL AWG18LB
AWG18GW 24 O2HFR(O2 SENSOR)
OFF 1 2 OFF 1 2 OFF 1 2
AWG18YG
AWG18GY
HOUR METER AWG18G 23 INJ#1SOL(GAS)
22 INJ#3SOL(GAS) 6 5 4 3 2 1
CHARGE CUT
AWG20GY
GND(1)
POS(13)
VB(119)
GND(1)
PHASE(14)
VB(119)
(A) AWG22B 82 GND-A(ACCEL WORK UNIT)
AWG18RW AWG22B 83 GND-A2(ACCEL WORK UNIT)
1 2 3 4
AWG18GR AWG20B AWG22GY

AWG18R AWG22YB 84 H/LMT(HEAD LAMP ON)
OIL PRESSURE AWG22LY 14 PHASE(CAM ANGLE)
AWG22BrW
AWG22GW 13 POS(CRANK ANGLE) CRANK & CAM ANGLE
COMBINATION SW
AWG18YR
12 SNOW SW(ECO) AWG22RB
AWG22YB 90 AVCC(ACCEL WORK UNIT) SENSOR
AWG20RG
91 AVCC2(ACCEL WORK UNIT)
AWG20G
AWG20Y
FUEL GAUGE F
ECM (40P CONNECTOR)

B E
T
AWG18B
1315 18 20 22
AWG16W(SH)
1416 17 19 21
AWG20GY 5 MOTOR1 AWG22BrW 1 2 3 4

HOUR METER AWG20YR
AWG20RG
AWG16B(SH)
AWG16LW 4
3
MOTOR2
V-MOT
AWG20YR AWG18GL
AWG20RG
AWG20LR
AWG14B 101 BRAKE(FOOT BRAKE ON)
AWG20G
1

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SM160

SERVICE MANUAL BEB16E1-06

BX50 SERIES FORKLIFT TRUCKS

Read and observe all warnings on this unit

REVISED: JUNE 2014

2. SPECIFICATIONS AND GENERAL INFORMATION

2.4.7 2.0/2.5-TON CUSHION (INDOOR)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

3.6 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

4.6 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

8.4 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

9.3.3 BLEED AIR FROM BRAKE PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

10. HYDRAULIC SYSTEM

10.6 HYDRAULIC PUMP MAINTENANCE STANDARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

11. WORK EQUIPMENT

11.4.3 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24

E-MD SERIES FULL FREE LIFT 2-STAGE MAST

E-MT SERIES FULL FREE LIFT 3-STAGE MAST

35D/45D/55D MQ QUAD MASTS

13. CONVERSION TABLES

2. SPECIFICATIONS AND GENERAL INFORMATION

DRIVE AXLE ASSEMBLY (3.0 - 3.5 TON TRUCKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

10. HYDRAULIC SYSTEM

11. WORK EQUIPMENT

ENGINE SERIAL NUMBER LOCATION

The 4D94LE/4D98E engine model and serial number are

FORKLIFT TRUCKS COVERED IN THIS PUBLICATION

BX50 Gasoline, LPG and Dual Fuel Models

BX50 Diesel Models

CHASSIS SERIAL NUMBER RANGES BY MODEL

ANSI/ITSDF B56.1-2012 COMPLIANCE SERIAL NUMBER BREAKS

MODEL CHASSIS SERIAL NUMBER RANGE

K21/K25 ENGINE SERIAL NUMBER BREAKS

EPA COMPLIANCE SERIAL NUMBER BREAKS

4D94LE Tier 2 (2004 - 2007) 200001A - 215882A

1.1 BASIC PRECAUTIONS

FOLLOW THE SAFETY RULES IN PLACE

DON'T USE A DEFECTIVE LIFT TRUCK

SECURE SAFETY AT THE WORKING AREA

WEAR SAFETY CLOTHES WHILE IN OPERATION

FIRE, FIRST AID AND GENERAL SAFETY

CAUTIONS FOR SAFETY-RELATED EQUIPMENT

PRACTICE SUFFICIENTLY BEFORE OPERATION

JUMPING ON AND OFF THE LIFT TRUCK IS

KEEP THE OPERATOR'S COMPARTMENT CLEAN AND CLEAR

PRECAUTIONS WHEN WASHING LIFT TRUCK

DO NOT MODIFY THE LIFT TRUCK

DON'T REMOVE THE OVERHEAD GUARD AND

REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT

ENGINE EXHAUST GAS IS POISONOUS

WINDOW WASHER CAUTION

FIRE IS STRICTLY PROHIBITED DURING

PRECAUTIONS WHEN REFUELING LPG TRUCKS

LPG FUEL SYSTEM SAFETY

1.2 FIRE PREVENTION

• Accumulation of tree waste or paper around fuel tank (1)

• Accumulation of dirt under the frame (engine or

FIRE FROM FAULTY ELECTRICAL WIRING

FIRE FROM FUEL OR OIL

FIRE FROM FAULTY PIPING

IF A FIRE BREAKS OUT

AVOID BURN INJURY

HIGH TEMPERATURE PARTS AND OIL

1.3 SAFETY CHECKS BEFORE STARTING OPERATION