Komatsu CX20 Gasoline & LP FG35/45ST-8 FG35/45BCS-8 FG40ZT(2)-8 FG40/45T(2)-8 FG50AT2-8 Diesel FD40ZT(2)-8 FD40/45T(2)-8 FD50AT2-8 Service Manual SM202 – PDF

Description

Komatsu CX20 Gasoline & LP FG35/45ST-8 FG35/45BCS-8 FG40ZT(2)-8 FG40/45T(2)-8 FG50AT2-8 Diesel FD40ZT(2)-8 FD40/45T(2)-8 FD50AT2-8 ForkLift Truck Service Manual SM202 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu CX20 Gasoline & LP FG35/45ST-8 FG35/45BCS-8 FG40ZT(2)-8 FG40/45T(2)-8 FG50AT2-8 Diesel FD40ZT(2)-8 FD40/45T(2)-8 FD50AT2-8 ForkLift Truck Service Manual SM202 – PDF DOWNLOAD

S/N 130001A – 134999A EPA Tier 1
S/N 135001A~ EPA Tier 2

Komatsu CX20 Gasoline & LP FG35ST-8 FG45ST-8 FG35BCS-8 FG45BCS-8 FG40ZT(2)-8 FG40T(2)-8 FG45T(2)-8 FG50AT2-8 Diesel FD40ZT(2)-8 FD40T(2)-8 FD45T(2)-8 FD50AT2-8 ForkLift Truck Service Manual SM202 – PDF DOWNLOAD

INTRODUCTION:

• This Service Manual has been developed as an information resource to help the reader learn
  about, understand, repair and maintain the CX20 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.

TABLE OF CONTENTS:

Komatsu CX20 Gasoline & LP FG35/45ST-8 FG35/45BCS-8 FG40ZT(2)-8 FG40/45T(2)-8 FG50AT2-8 Diesel FD40ZT(2)-8 FD40/45T(2)-8 FD50AT2-8 ForkLift Truck Service Manual SM202 – PDF DOWNLOAD

CONTENTS 3
INTRODUCTION 11
ENGINE SERIAL NUMBER LOCATION 12
FORKLIFT TRUCKS COVERED IN THIS PUBLICATION 13
FEDERAL EPA EMISSION CONTROL STATEMENTS 14
1 LABELS REQUIRED AND LABEL LOCATIONS 14
2 WARRANTY 15
1 LABELS REQUIRED AND LABEL LOCATIONS 17
2 WARRANTY 19
SAFETY MANAGEMENT 24
SAFE TRAVEL 28
LOADING OPERATIONS 36
SAFETY IN PERIODIC MAINTENANCE 41
TOWING 47
STRUCTURE AND STABILITY OF THE LIFT TRUCK 48
SAFETY LABELS 51
OPTIONAL EQUIPMENT 57
1 8 1 REAR LAMP 57
1 8 2 HIGH LOAD BACKREST 57
1 8 3 WIDE FORK CARRIAGE 57
1 8 4 AUDIBLE SPEED ALARM 57
1 8 5 WARNING LAMPS 57
2 GENERAL INFORMATION & SPECIFICATIONS 59
2 1 SPECIFICATIONS – MAST DATA & FEATURES – INDOOR (CUSHION) TRUCK 60
2 2 SPECIFICATIONS – MAST DATA & FEATURES – OUTDOOR (PNEUMATIC) TRUCKS 62
2 3 TRUCK DATA – CUSHION TIRE LIFT TRUCKS (INDOOR) 64
2 4 TRUCK DATA – PNEUMATIC TIRE LIFT TRUCKS 68
2 5 PERIODIC REPLACEMENT OF CONSUMABLE PARTS 78
2 6 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS 79
2 7 STANDARD TIGHTENING TORQUE FOR BOLTS 80
3 SERVICE DATA 81
3 1 SERVICE DATA – GASOLINE ENGINE TRUCKS 82
3 2 SERVICE DATA – DIESEL ENGINE TRUCKS 85
4 TESTING, ADJUSTING AND MEASURING 89
4 1 CHECK ENGINE OIL (TB45E) 90
4 2 ADJUST ENGINE OIL LEVEL 90
4 3 ADJUST IGNITION TIMING (TB45E) 91
4 4 ADJUST SPARK PLUG GAP (TB45E) 92
4 5 ADJUST VALVE CLEARANCE (TB45E) 92
4 6 ADJUST VALVE CLEARANCE (S6D102E) 94
4 7 ADJUST ENGINE DRIVE BELTS (TB45E) 96
4 7 1 Belts in Service on Engine – General 96
4 7 2 Install New Belt(s) – General 96
4 8 MEASURE ENGINE CYLINDER COMPRESSION (TB45E) 97
4 9 MEASURE HYDRAULIC DRIFT ON LIFT & TILT CYLINDERS 99
4 10 ADJUST TYPICAL MAST 100
4 10 1 Outer Main Roller 100
4 10 2 Inner Main Roller 100
4 10 3 Fork Carriage – Typical 101
4 10 4 Adjust Clearance – Thrust Pad And Rail 102
4 10 5 Change Pad 102
4 10 6 Adjust Clearance Between Inner Mast and Fork Carriage 102
4 10 7 Adjust Clearance Between Inner Mast and Intermediate Mast 103
4 11 ADJUST PARKING BRAKE LEVER 104
4 12 ADJUST ACCELERATOR PEDAL (TB45E Engine) 104
4 13 TESTING, ADJUSTING AND MEASURINGTHROTTLE POSITION SENSOR SYSTEM 105
4 14 ACCELERATOR PEDAL POSITION SENSOR – TB45 Engine 106
4 15 ADJUST ACCELERATOR PEDAL (S6D102E Engine) 108
4 16 MEASURE BRAKE STOPPING DISTANCE (BRAKING EFFECT) 109
4 17 ADJUST INCHING / BRAKE PEDAL (TORQFLOW TRUCKS) 109
4 17 1 Brake Pedal 109
4 17 2 Inching Pedal 109
4 17 3 Inching Pedal/Brake Pedal Interconnected Travel 110
4 18 ADJUST STOP LAMP SWITCH 111
4 19 ADJUST WHEEL BRAKE 112
4 20 CHECK OPERATION OF THE AUTOMATIC ADJUSTMENT DEVICE 113
4 21 CHECK TORQFLOW CLUTCH ACTUATION PRESSURE – PNEUMATIC TIRE 113
4 22 CHECK TORQUE CONVERTER STALL SPEED 114
4 23 CHECK TORQFLOW CLUTCH ACTUATION PRESSURE – CUSHION TIRE 114
4 24 CHECK TORQUE CONVERTER STALL SPEED 115
4 25 ADJUST INCHING VALVE / SPOOL 115
4 26 TEST SPECIFIC GRAVITY OF BATTERY ELECTROLYTE 116
4 27 CHECK TIRES AND ADJUSTING PNEUMATIC TIRE PRESSURE 117
4 28 MEASURE MINIMUM LEFT AND RIGHT TURNING RADIUS 118
4 29 ADJUST TURNING RADIUS 119
4 30 ADJUST REAR AXLE – THRUST CLEARANCE 120
5 INSPECTION 121
5 1 INSPECT ENGINE STARTING OPERATION 122
5 2 INSPECT ENGINE RUNNING CONDITION 122
5 3 INSPECT AIR CLEANER ASSEMBLY 122
5 4 INSPECT THE FILTER ELEMENT 123
5 5 INSPECT / RE-TORQUE CYLINDER HEAD MOUNTING BOLTS (TB45E) 123
5 6 INSPECT / RE-TORQUE CYLINDER HEAD BOLTS (S6D102E) 124
5 7 INSPECT ENGINE MOUNTS 125
5 8 INSPECT THE ENGINE LUBRICATING SYSTEM 125
5 9 INSPECT ENGINE FUEL SYSTEM 125
5 10 INSPECT DIESEL FUEL INJECTION NOZZLES 126
5 11 INSPECT LPG VAPORIZER FOR TAR BUILDUP (TB45E) 126
5 12 INSPECT BLOW-BY GAS RECIRCULATION SYSTEM (TB45E) 127
5 13 INSPECT COOLING SYSTEM AND RADIATOR 128
5 14 INSPECT COOLANT SUB-TANK LEVEL 128
5 15 INSPECT FAN ASSEMBLY 128
5 16 INSPECT CHARGING SYSTEM WIRING 128
5 17 INSPECT FRONT AXLE AND RE-TORQUE MOUNTING BOLTS 129
5 18 INSPECT REAR AXLE AND RE-TORQUE MOUNTING BOLTS 129
5 19 INSPECT WHEELS 129
5 20 INSPECT RIM SIDE RING 129
5 21 INSPECT WHEEL BEARINGS 130
5 22 INSPECT STEERING AXLE 130
5 23 INSPECT STEERING WHEEL 130
5 24 INSPECT LIGHTING / TURN SIGNAL SWITCH – W/O DIMMER SWITCH 131
5 25 INSPECT LIGHTING / TURN SIGNAL SWITCH – WITH DIMMER SWITCH 132
5 26 INSPECT LIGHTING / TURN SIGNAL SWITCH 133
5 27 INSPECT F/R SWITCH 134
5 28 INSPECT POWER STEERING SYSTEM 134
5 29 INSPECT BRAKE SYSTEM RODS, CABLES AND LINKS 135
5 30 INSPECT BRAKE PIPING AND CONNECTIONS 135
5 31 INSPECT BRAKE MASTER AND WHEEL CYLINDERS 135
5 32 INSPECT BRAKE SHOES AND ASSOCIATED PARTS 136
5 33 INSPECT BRAKE DRUMS 136
5 34 INSPECT BRAKE BACKING PLATES 136
5 35 INSPECT LOAD FORKS 137
5 36 INSPECT MAST 137
5 37 INSPECT FORK CARRIAGE 137
5 38 INSPECT LIFT CHAINS 138
5 39 INSPECT CHAIN WHEELS 138
5 40 INSPECT ATTACHMENTS 138
5 41 INSPECT HYDRAULIC TANK 139
5 42 INSPECT CHASSIS AND ATTACHMENT PIPING 139
5 43 INSPECT HYDRAULIC PUMP 139
5 44 INSPECT LIFT CYLINDER 139
5 45 INSPECT TILT CYLINDERS 139
5 46 INSPECT ATTACHMENT CYLINDERS (IF EQUIPPED) 139
5 47 INSPECT LIFT TRUCK CHASSIS AND FRAME 140
5 48 INSPECT CAB (IF EQUIPPED) 140
5 49 INSPECT OPERATOR’S SEAT 141
5 49 1 Vehicle Controller 141
5 49 2 Komatsu Operator PresenCE System (KOPS) 141
5 49 3 Controller Troubleshooting 142
5 50 INSPECT EQUIPMENT USED FOR ACCESSING THE LIFT TRUCK 145
5 51 INSPECT DISPLAY PANEL 145
5 52 INSPECT OVERHEAD GUARD 145
5 53 INSPECT LIGHTS, GAUGES AND WARNING DEVICES 145
5 54 INSPECT REAR VIEW MIRROR AND REFLECTORS 145
6 MAINTENANCE OPERATIONS 147
6 1 LUBRICANT LIST – GASOLINE ENGINE LIFT TRUCKS 148
6 2 LUBRICANT LIST – DIESEL ENGINE LIFT TRUCKS 149
6 3 OIL AND GREASING CHART 154
6 4 CHANGE OIL AND FILTER IN GASOLINE ENGINES 155
6 5 CHANGE OIL AND FILTER IN DIESEL ENGINES 157
6 6 CHANGE GEAR OIL IN DIFFERENTIAL CASE 158
6 6 1 Check Differential Oil Level 158
6 6 2 Change Differential Oil 158
6 7 CHANGE TRANSMISSION FLUID IN TORQFLOW TRANSMISSION CASE 159
6 7 1 Check TORQFLOW Transmission Fluid Level 159
6 7 2 Change TORQFLOW Transmission Fluid and Clean the Strainer 159
6 8 CHANGE OIL IN HYDRAULIC TANK 160
6 9 REPLACE FUEL FILTER – GASOLINE ENGINES 161
6 10 REPLACE FUEL FILTER – DIESEL ENGINES 162
6 11 REPLACE AIR CLEANER ELEMENT 163
6 12 CLEAN RADIATOR 165
6 13 CLEAN RADIATOR FINS 166
6 14 BLEED AIR FROM BRAKE SYSTEM 167
7 REMOVAL, DISASSEMBLY, ASSEMBLY, INSTALLATION 169
7 1 UNIT INSTALLATION POSITIONS DIAGRAM 170
7 2 OVERALL DISASSEMBLY / ASSEMBLY FLOW CHART 171
7 3 WEIGHT TABLE – COMPONENT ASSEMBLIES AND PARTS 172
7 4 MAST 173
7 4 1 Mast Removal – Typical 173
7 4 2 Mast Installation – Typical 174
7 5 ENGINE 175
7 5 1 Engine Removal From Chassis 175
7 5 2 Engine Disassembly / Assembly 176
7 5 3 Engine Installation 176
7 6 TRANSMISSION AND DRIVE AXLE 178
7 6 1 Remove Torque Converter, Transmission, And Drive Axle 178
7 6 2 Torque Converter Installation 180
7 6 3 Transmission And Drive Axle Installation 180
7 6 4 Drive Axle Support Mounting Bolts And Nuts 180
7 6 5 Install Counterweight 180
7 7 TORQUE CONVERTER / TRANSMISSION CONTROL VALVE – PNEUMATIC TRUCKS 181
7 7 1 Overview 181
7 7 2 Torque Converter Assembly 182
7 7 3 Control Valve Assembly 183
7 7 4 Transmission Hydraulic Fluid Circulation Path 183
7 7 5 TORQUE CONVERTER ASSEMBLY – FLUID DIAGRAM 184
7 7 6 TRANSMISSION CONTROL VALVE ASSEMBLY EXTERNAL VIEW 185
7 7 7 TRANSMISSION CONTROL VALVE INTERNAL VIEW 185
7 7 8 POSITION OF CONTROL VALVE HYDRAULIC PORTS 186
7 7 9 TRANSMISSION CONTROL VALVE – PARTS BREAKDOWN 187
7 7 10 TRANSMISSION CONTROL VALVE – SPECIFICATIONS 188
7 7 11 HYDRAULIC CHARACTERISTICS OF THE INCHING VALVE 190
7 7 12 Remove Transmission Control Valve 191
7 7 13 Install Transmission Control Valve 191
7 7 14 POSITION OF TORQUE CONVERTER HOUSING HYDRAULIC PORTS 192
7 7 15 TORQUE CONVERTER – TORQUE SPECIFICATIONS 193
7 7 16 TORQUE CONVERTER PARTS BREAKDOWN 194
7 7 17 TORQUE CONVERTER – PART STANDARD 195
7 7 18 GEAR PUMP ASSEMBLY – PARTS BREAKDOWN 196
7 7 19 Disassemble Torque Converter (Pneumatic) 197
7 7 20 Assemble Torque Converter (Pneumatic) 198
7 7 21 ASSEMBLED TORQUE CONVERTER 199
7 7 22 Test F1/r1 Transmission (Single Speed) 200
7 7 23 F1/R1 TRANSMISSION – PART STANDARD 201
7 7 24 Test F2/r1 Transmission (Two Speed) 202
7 7 25 F2/R1 TRANSMISSION – PART STANDARD 203
7 7 26 Disassemble Torqflow Transmission (Pneumatic Trucks) 204
7 7 27 Disassemble Input Shaft Clutch Pack 207
7 7 28 Disassemble Intermediate Shaft Clutch Pack 209
7 7 29 Assemble F1/r1 And F2/r1 Transmission – Input Shaft 211
7 7 30 ASSEMBLED F1/R1 AND F2/R1 TRANSMISSION – INPUT SHAFT 213
7 7 31 Assemble F2/r1 Transmission – Intermediate Shaft (2nd Speed) 214
7 7 32 ASSEMBLED F2/R1 TRANSMISSION – INTERMEDIATE SHAFT (2nd speed) 216
7 7 33 Assemble Output Shaft 217
7 7 34 Assemble F1/r1 Transmission 219
7 7 35 ASSEMBLED F1/R1 TRANSMISSION – TORQFLOW TRANSMISSION 224
7 7 36 Assemble F2/r1 Transmission 225
7 8 TORQFLOW TRANSMISSION W/ TORQUE CONVERTER – CUSHION TRUCKS 229
7 8 1 TRANSMISSION CONTROL VALVE – PARTS BREAKDOWN 229
7 8 2 TRANSMISSION CONTROL VALVE – SPECIFICATIONS 230
7 8 3 Disassemble Transmission Control Valve (Cushion Trucks) 231
7 8 4 TORQUE CONVERTER PARTS BREAKDOWN 232
7 8 5 TORQUE CONVERTER – PARTS SPECIFICATION 233
7 8 6 HYDRAULIC CIRCUIT DIAGRAM 234
7 8 7 TORQUE CONVERTER PRESSURE TESTING PORTS 235
7 8 8 Service And Inspection 236
7 8 9 Disassemble Torqflow Transmission (Cushion Trucks) 237
7 8 10 Disassemble Reverse Main Shaft 241
7 8 11 Disassemble The Forward Main Shaft 242
7 8 12 Assemble Reverse Main Shaft 243
7 8 13 ASSEMBLED MAIN SHAFT (REVERSE) 244
7 8 14 Assemble Forward Main Shaft 245
7 8 15 ASSEMBLED MAIN SHAFT (FORWARD) 246
7 8 16 Assemble The Output Shaft 247
7 8 17 Assemble Torqflow Transmission (Cushion Trucks) 249
7 9 DRIVE AXLE 253
7 9 1 DRIVE AXLE – PARTS BREAKDOWN (PNEUMATIC) 253
7 9 2 DRIVE AXLE – TORQUE CHART (PNEUMATIC) 254
7 9 3 DRIVE AXLE – PARTS BREAKDOWN (CUSHION) 255
7 9 4 DRIVE AXLE – TORQUE CHART (CUSHION) 256
7 10 DIFFERENTIAL 257
7 10 1 DIFFERENTIAL – TORQFLOW TRANSMISSION – PARTS BREAKDOWN 257
7 10 2 DIFFERENTIAL – TORQFLOW TRANSMISSION – SPECIFICATIONS 258
7 10 3 Adjust Differential 260
7 10 4 Adjusting Tooth Contact 261
7 11 BRAKE BOOSTER AND MASTER CYLINDER 263
7 11 1 BRAKE MASTER CYLINDER – PARTS BREAKDOWN 263
7 11 2 BRAKE MASTER CYLINDER / BRAKE BOOSTER DIAGRAM 265
7 11 3 Brake Master Cylinder – Disassembly 266
7 11 4 Disassemble Brake Booster Unit 267
7 11 5 BRAKE BOOSTER & MASTER CYLINDER – SPECIFICATIONS 268
7 11 6 BRAKE BOOSTER & MASTER CYLINDER – INSPECTION & TESTING 268
7 11 7 Assemble Brake Master Cylinder 270
7 11 8 Brake Booster – Assembly 271
7 12 WHEEL BRAKE 274
7 12 1 Wheel Brake Removal 274
7 12 2 WHEEL BRAKE – STRUCTURE 275
7 12 3 WHEEL BRAKE – DISASSEMBLY / ASSEMBLY DRAWING – CUSHION 277
7 12 4 WHEEL BRAKE – DISASSEMBLY / ASSEMBLY DRAWING – PNEUMATIC 278
7 12 5 Install Wheel Brake 279
7 12 6 Install Pedal Assembly – Brake Piping 279
7 12 7 Brake System – Bleeding Air From Lines 280
7 13 STEERING AXLE 281
7 13 1 Remove Steering Axle And Power Steering Cylinder 281
7 13 2 POWER STEERING CYLINDER – STRUCTURE 282
7 13 3 STEERING AXLE BREAKDOWN 283
7 13 4 STEERING AXLE – LUBRICATION AND TORQUE VALUES 284
7 13 5 STEERING AXLE SPECIFICATIONS 285
7 13 6 Steering Axle And Power Steering Cylinder Installation 286
7 13 7 POWER STEERING CYLINDER – PARTS BREAKDOWN 287
7 13 8 POWER STEERING VALVE – PARTS BREAKDOWN 288
7 13 9 Remove Power Steering Valve 289
7 13 10 Disassemble Power Steering Valve 290
7 13 11 Clean Power Steering Valve 294
7 13 12 Assemble Power Steering Valve 294
7 13 13 Install Power Steering Valve 302
7 14 HYDRAULIC PUMP – GASOLINE ENGINES 303
7 14 1 HYDRAULIC PUMP – GASOLINE ENGINE (PNEUMATIC) PARTS BREAKDOWN 303
7 14 2 Disassemble Rear Pump Section – Gasoline (Pneumatic) 304
7 14 3 Disassemble Front Pump Section – Gasoline (Pneumatic) 304
7 14 4 Assemble Rear Pump Section – Gasoline (Pneumatic) 304
7 14 5 Assemble Front Pump Section – Gasoline (Pneumatic) 305
7 14 6 HYDRAULIC PUMP – GASOLINE ENGINE (CUSHION) PARTS BREAKDOWN 306
7 14 7 Disassemble Rear Pump Section – Gasoline (Cushion) 307
7 14 8 Disassemble Front Pump Section – Gasoline (Cushion) 307
7 14 9 Assemble Rear Pump Section – Gasoline (Cushion) 307
7 14 10 Assemble Front Pump Section – Gasoline (Cushion) 308
7 14 11 Inspection And Repair – Hydraulic Pump – Gasoline (Cushion) 309
7 15 HYDRAULIC PUMP – DIESEL ENGINES 310
7 15 1 HYDRAULIC PUMP – FRONT UNIT – DIESEL 310
7 15 2 Disassemble Hydraulic Pump – Front Pump Unit – Diesel 311
7 15 3 Inspect And Repair Hydraulic Pump – Diesel 312
7 15 4 Reassemble Hydraulic Pump Front Pump Unit – Diesel 313
7 15 5 HYDRAULIC PUMP – OIL SEAL INSTALLATION JIG DIAGRAM 316
7 15 6 HYDRAULIC PUMP – REAR UNIT – DIESEL – PARTS BREAKDOWN 317
7 15 7 Disassemble Hydraulic Pump Rear Pump Unit – Diesel 318
7 15 8 Inspect And Repair Hydraulic Pump – Diesel 319
7 15 9 Reassemble Hydraulic Pump – Rear Pump Unit – Diesel 320
7 16 TEST HYDRAULIC PUMP 323
7 17 HYDRAULIC CONTROL VALVE 324
7 17 1 Assemble Control Valve 324
7 17 2 Set Pressure On Work Port Relief 325
7 17 3 Servicing And Repair Information 326
7 17 4 Shut-off Valve 326
7 17 5 Combination Work Port Relief / Anti-void Unit 327
7 18 TILT CYLINDER 328
7 18 1 TILT CYLINDER – PARTS BREAKDOWN 328
7 18 2 Disassemble Tilt Cylinder 329
7 18 3 Inspect Tilt Cylinder Parts 329
7 18 4 Assemble Tilt Cylinder 330
7 19 SIDESHIFTER 332
7 20 COMBINATION SWITCH 332
7 20 1 COMBINATION SWITCH PARTS BREAKDOWN 332
7 20 2 Replace Combination Switch Assembly 333
7 20 3 Replace Lighting And F/r Switch 334
8 TROUBLESHOOTING 335
ENGINE 336
TORQFLOW 337
TORQFLOW CONVERTER – CUSHION TRUCKS 340
TORQFLOW CONVERTER – PNEUMATIC TRUCKS 341
CONTROL VALVE – CUSHION TRUCKS 343
CONTROL VALVE – PNEUMATIC TRUCKS 343
ELECTRICAL SYSTEM 344
STEERING SYSTEM 345
POWER STEERING VALVE 346
BRAKE SYSTEM 348
HYDRAULIC SYSTEM 350
HYDRAULIC PUMP 350
9 80D/100D/110D – MS 2-STAGE MAST 353
INTRODUCTION 354
INSTALLATION INSTRUCTIONS 355
PERIODIC MAINTENANCE 360
TROUBLESHOOTING 361
SERVICE 362
10 80D/100D/110D – MT 3-STAGE MAST 381
INTRODUCTION 382
INSTALLATION INSTRUCTIONS 383
PERIODIC MAINTENANCE 398
TROUBLESHOOTING 399
SERVICE 400
11 CONVERSION TABLES 427
11 1 MILLIMETERS TO INCHES 428
11 2 INCHES TO MILLIMETERS 428
11 3 CUBIC METERS TO CUBIC YARDS 429
11 4 CUBIC YARDS TO CUBIC METERS 429
11 5 LITER TO U S GALLON 430
11 6 U S GALLON TO LITER 430
11 7 KILOGRAM TO POUND 431
11 8 POUND TO KILOGRAM 431
11 9 KILOGRAMS PER SQUARE CENTIMETER TO POUNDS PER SQUARE INCH 432
11 10 KILOGRAM TO FOOT POUNDS OF FORCE 433
11 11 TEMPERATURE – FAHRENHEIT TO CENTIGRADE CONVERSION 434
A SERVICE DIAGRAMS 435
CONTENTS 435
Wiring Diagrams 0
TIER 2 GLP (DUAL FUEL) 0
TIER 2 GASOLINE 0
TIER 2 LP 0
TIER 2 LP UL-S 0
TIER 2 DIESEL 0
TB42 GASOLINE ENGINE (PRE KOPS) 0
TB42 GASOLINE ENGINE, UL-S (PRE KOPS) 0
6D102E DIESEL ENGINE (PRE KOPS) 0
6D102E DIESEL ENGINE, UL-S (PRE KOPS) 0
Electrical Assembly Drawings 0
TIER 2 STANDARD GAS 0
TIER 2 COMPACT & LONG UL-S 0
TB42 GASOLINE ENGINE 0
TB42 GASOLINE UL-S 0
6D102E DIESEL ENGINE 0
6D102E DIESEL ENGINE UL-S 0
Transmission Drawings 0
TORQFLOW F1/R1 PNEUMATIC TIRE 0
TORQFLOW F2/R1 PNEUMATIC TIRE 0
TORQFLOW F2/R1 PNEUMATIC TIRE GENERAL VIEW 0
TORQFLOW PINION SHAFT 0
Drive Axle Drawings 0
PNEUMATIC TIRE 0
CUSHION TIRE 0
WHEEL BRAKE – ALL CUSHION 0
WHEEL BRAKE – BOXCAR AND COMPACT WHEELBASE 0
WHEEL BRAKE – PNEUMATIC 0
Steering Axle Drawings 484
PNEUMATIC TIRE 0
CUSHION TIRE 486
Frame Drawings 488
F(G/D)35/40/45(Z)(T) 0
FG35/45(ST)(BCS)-8 490
FG35BCS-8 0
Piping Diagrams 494
HYDRAULIC SYSTEM FD35/40/45(Z)(T)-8 0
HYDRAULIC SYSTEM – FG35ST-8, FG35BCS 496
HYDRAULIC SYSTEM FG35/40/45(Z)(T) 0
POWER STEERING – F(G/D)35/40/45(Z)(T) 500
POWER STEERING – FG35/45ST-8 0
POWER STEERING – FGBCS-8 0
Control Valve Diagram 0
ALL MODELS (PRE KOPS) 0
B E-SERIES SIDESHIFTER 509
C D-SERIES SIDESHIFTER 523

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V