Bec08e1-01 A4

BEC08E1-01
MACHINE MODEL SERIAL NO.

FG35ZT/40ZT-7 100001 and up
FG35T/40T/45T-7 100001 and up
FG50AT-7 100001 and up
FD35ZT/40ZT-8 110001 and up
FD40ZW-8 110001 and up
FD35T/40T/45T-8 110001 and up
FD35W/40W/45W-8 110001 and up
FD50AT-8 110001 and up
CX-Series 00-1
SECTION INDEX
00. FOREWORD
10. GENERAL AND SPECIFICATIONS
20. TESTING AND ADJUSTING
30. REMOVAL AND INSTALLATION
40. DISASSEMBLY AND ASSEMBLY
50. MAINTENANCE STANDARD
60. STRUCTURE AND FUNCTION
70. TROUBLESHOOTING
80. CHECK ITEMS FOR EACH EQUIPMENT
00-2 CX-Series
FOREWORD
For a machine and its components to maintain their performance for a long time, it is nec-
essary to carry out appropriate operation, preventive maintenance, troubleshooting, and
service to prevent failures or problems before they occur.
Of these operations, this shop manual gives information mainly on operations carried out
at a repair shop. These include an outline needed for service and maintenance operations,
together with details of the structure and function, inspection and maintenance, installation
and removal, disassembly and assembly, maintenance standards, troubleshooting, and
periodic inspection and adjustment of components for the machine. The units given for
tightening torques in this manual use the SI units as the standard, so a conversion table
is given at the end of the section 10.
This shop manual has been prepared with the target of making materials that will help you
to gain proper knowledge of the product, its structure and function, and proper methods for
maintenance, to use proper judgement and remedies when there is a failure or problem
with the machine, and to improve the quality of maintenance.
Always be sure that you fully understand the contents of this manual together with the Op-
eration and Maintenance Manual, and make full use of it when handling the machine.
CX-Series 00-3
PRECAUTIONS WHEN PERFORMING THE SERVICE WORK
Always pay attention to "Safety" before starting any work – this is important.
Never attempt any work where danger to yourself or to other persons.
Whenever work requiring safety precautions are described in this manual, a flag
mark inserted, always make double sure that safety measures are taken.
Other unmarked work, should always be performed after studying and using your
common sense to prevent accidents.
DESCRIPTION OF THE SYMBOLS

The symbols described below are used in this manual for convenience and better understanding
Symbol Item Description
Special safety precautions are needed to perform the

Safety
work.
a Note
Special technical precautions are needed to perform the
work.
Fastening parts that require specified tightening force

Tightening torque
when assembling.
Weight of parts or systems.

Weight
Places to be coated with adhesives, etc. When assem-

Coat
bling.
00-4 CX-Series
10. GENERAL AND SPECIFICATIONS
Specifications
(FG35ZT-7, FD35ZT-8) ........................ 10- 2
(FG35T-7, FD35T-7, FD35W-7) ........... 10- 4
(FG40ZT-7, FD40ZT-8, FD40ZW-8)..... 10- 6
(FG40T-7, FD40T-7, FD40W-7) ........... 10- 8
(FG45T-7, FD45T-7, FD45W-7) ........... 10-10
(FG50AT-7, FD50AT-7)........................ 10-12
(EU SPEC.: FD35T-8, FD35W-8)......... 10-14
(EU SPEC.: FD40T-8, FD40W-8)......... 10-16
(EU SPEC.: FD45T-8, FD45W-8)......... 10-18
(EU SPEC.: FD50AT-8)........................ 10-20
Periodic replacement of consumable parts ...... 10-22
Safety items for maintenance........................... 10-23
Standard tightening torque............................... 10-32
How to use loctite............................................. 10-34
Conversion table .............................................. 10-35
CX-Series 10-1
GENERAL AND SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS (FG35ZT-7, FD35ZT-8)

• SPECIFICATION TABLE
Model Manufacturer's designation FG35ZT-7 FD35ZT-8
Power type Electric, diesel, gasoline, LPG, cable Gasoline Diesel
Characteristics
Operation type Pedestrian, driver standing, sitting, order picking Sitting

Rated capacity Q Rated capacity kg 3,500
Load center c Rated load center mm 500
Alternative Capacity Capacity@600mm load center kg 3,250
Load distance x Front axle center to fork face mm 530
Wheelbase y mm 1,800
Service weight kg 5,260 5,430
Front kg 7,795 7,850
Weight
Loaded
Rear kg 965 1,080
Axle loading
Front kg 2,290 2,380
Unloaded
Rear kg 2,970 3,050
Tyre type Cushion, elastic cushion, pneumatic, polyurethane Pneumatic
Front 250-15-16PR(I)
Tyre size
Rear 7.00-12-12PR(I)
Tyre
Number of wheel Front/rear (x=driven) 2x/2

Tread, front b10 mm 1,115
Tread, rear b11 mm 1,120
Tilting angle a/ß degree 6/12
Mast height, lowered h1 mm 2,100
Std. free lift h2 mm 150
Std. lift height h3 mm 3,000
Mast height, extended h4 mm 4,130
Height, overhead guard h6 mm 2,150 2,190
Basic measurement
Length, with Std. forks l1 mm 3,970

Length, to fork face l2 mm 2,900
Width, at tyre b1 mm 1,350
Forks s/e/l Thickness/width/length mm 50x150x1,070
Fork carriage class ISO 2328, Type A/B Class 3, Type A
Width, fork carriage b3 mm 1,190
m1 Under mast mm 140
Ground clearance
m2 At center of wheelbase mm 175 185
Ast With 1,000 x 1,200 pallet mm 4,060
Right angle stacking aisle
Ast With 1,200 x 800 pallet mm 4,260
Turning radius Wa mm 2,530
Loaded,1st/2nd/3rd km/h 18.5
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 19.5
Lifting speed Loaded/unloaded mm/s 450/480 530/570
Performance
Lowering speed Loaded/unloaded mm/s 480/550

Drawbar pull Loaded at 1.5 km/h kN{kgf} 25{2,550} 28{2,860}
Gradeability Loaded at 1.5 km/h % 29 34
Service brake Operation/control Foot/hydraulic
Parking brake Operation/control Hand/mechanical
Steering Type Hydraulic power steering
Battery Voltage/capacity at 5-hour rating V/Ah 12/48 24/56
Make/model NISSAN/TB42 KOMATSU/S6D102E
Engine
Output SAE gross kW{HP}rpm 64{84}2,100 70{94}2,150

Max. torque (SAE gross) Nm{kgf•m}/rpm 275{28}/1,900 372{38}1,000
No. of cylinder/displacement No. of cyl./l{cc} 6/4.169{4,169} 6/5.880{5,880}
Fuel tank capacity l 80 90
Relief pressure for attachment MPa{kgf/cm2} 17.5{178}
Others
Tank capacity l 55
Clutch Torque converter
Transmission TORQFLOW
10-2 CX-Series
• OUTSIDE VIEW DRAWINGS
CX-Series 10-3
SPECIFICATIONS (FG35T-7, FD35T-7, FD35W-7)

Model Manufacturer's designation FG35T-7 FD35T-7 FD35W-7
Characteristics

Service weight kg 5,645 5,835 5,775
Front kg 8,070 8,165 8,120
Weight
Loaded
Rear kg 1,075 1,170 1,155
Axle loading
Front kg 2,520 2,615 2,570
Unloaded
Rear kg 3,125 3,220 3,205
Front 8.25-15-12PR(I)
Tyre size
Rear 7.00-12-12PR(I)
Tyre

Height, overhead guard h6 mm 2,240
Basic measurement

Ground clearance
m2 At center of wheelbase mm 230
Loaded,1st/2nd/3rd km/h 18.5 18.5 8.5/18.5
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 19.5 19.5 9.0/19.5
Performance

Drawbar pull Loaded at 1.5 km/h kN{kgf} 24{2,450} 28{2,860} 27{2,750}
Gradeability Loaded at 1.5 km/h % 27 31 25
Make/model NISSAN/TB42 KOMATSU/6D102E
Engine

Fuel tank capacity l 100
Others
Tank capacity l 55
Clutch Torque converter Torque converter Wet
Transmission TORQFLOW TORQFLOW Synchromesh
10-4 CX-Series
CX-Series 10-5
SPECIFICATIONS (FG40ZT-7, FD40ZT-8, FD40ZW-8)

Model Manufacturer's designation FG40ZT-7 FD40ZT-8 FD40ZW-8
Characteristics

Front kg 8,505 8,555 8,510
Weight
Loaded
Rear kg 1,075 1,195 1,180
Axle loading
Front kg 2,215 2,295 2,250
Unloaded
Rear kg 3,365 3,455 3,440
Tyre size
Rear 7.00-12-12PR(I)
Tyre

Basic measurement

Ground clearance
m2 At center of wheelbase mm 175 185
Travel speed (FWD)
Performance

Make/model NISSAN/TB42 KOMATSU/S6D102E
Engine

Fuel tank capacity l 80 90
Others
Tank capacity l 55
10-6 CX-Series
CX-Series 10-7

Characteristics

Front kg 8,830 8,925 8,880
Weight
Loaded
Rear kg 1,240 1,335 1,320
Axle loading
Front kg 2,480 2,575 2,530
Unloaded
Rear kg 3,590 3,685 3,670
Tyre size
Rear 7.00-12-12PR(I)
Tyre

Basic measurement

Ground clearance
Travel speed (FWD)
Performance

Engine

Others
Tank capacity l 55
10-8 CX-Series
CX-Series 10-9

Characteristics

Front kg 9,885 9,950 9,905
Weight
Loaded
Rear kg 1,270 1,365 1,350
Axle loading
Front kg 2,690 2,785 2,740
Unloaded
Rear kg 3,935 4,030 4,015
Tyre size
Rear 7.00-12-12PR(I)
Tyre

Basic measurement

Ground clearance
Loaded,1st/2nd/3rd km/h 15.5/23.0 15.5/23.0 8.5/18.5
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 16.5/24.0 16.5/24.0 9.0/19.5
Performance

Engine

Others
Tank capacity l 55
10-10 CX-Series
CX-Series 10-11
SPECIFICATIONS (FG50AT-7, FD50AT-7)

Model Manufacturer's designation FG50AT-7 FD50AT-7
Characteristics

Alternative Capacity Capacity@600mm load center kg —
Wheelbase y mm 2,000 2,200
Front kg 10,820 10,705
Weight
Loaded
Rear kg 1,420 1,300
Axle loading
Front kg 2,880 3,035
Unloaded
Rear kg 4,360 3,970
Tyre size
Rear 7.00-12-14PR(I) 7.00-12-12PR(I)
Tyre

Basic measurement
Length, with Std. forks l1 mm 4,435 4,605

Length, to fork face l2 mm 3,215 3,385
Ground clearance
Ast With 1,000 x 1,200 pallet mm 4,425 4,625
Ast With 1,200 x 800 pallet mm 4,625 4,825
Turning radius Wa mm 2,850 3,050
Loaded,1st/2nd/3rd km/h 15.5/23.0
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 16.5/24.0
Performance

Engine

Max. torque (SAE gross) Nm{kgf•m}/rpm 275{28}1,900 343{35}1,500
Others
Tank capacity l 55
10-12 CX-Series
CX-Series 10-13
SPECIFICATIONS (EU SPEC.: FD35T-8, FD35W-8)

Model Manufacturer's designation FD35T-8 FD35W-8
Power type Electric, diesel, gasoline, LPG, cable Diesel
Characteristics

Front kg 8,135 8,090
Weight
Loaded
Rear kg 1,200 1,185
Axle loading
Front kg 2,585 2,450
Unloaded
Rear kg 3,250 3,235
Front 8.25-15-12PR(I)
Tyre size
Rear 7.00-12-12PR(I)
Tyre

Basic measurement

Ground clearance
Loaded,1st/2nd/3rd km/h 18.5 8.5/18.5
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 19.5 9.0/19.5
Lifting speed Loaded/unloaded mm/s 530/570
Performance

Battery Voltage/capacity at 5-hour rating V/Ah 24/56
Make/model KOMATSU/S6D102E
Engine
Output SAE gross kW{HP}rpm 70{44}2,150

Max. torque (SAE gross) Nm{kgf•m}/rpm 372{38}1,000
No. of cylinder/displacement No. of cyl./l{cc} 6/5.880{5,880}
Others
Tank capacity l 55
Clutch Torque converter Wet
Transmission TORQFLOW Synchromesh
10-14 CX-Series
CX-Series 10-15

Characteristics

Front kg 8,910 8,865
Weight
Loaded
Rear kg 1,375 1,360
Axle loading
Front kg 2,560 2,515
Unloaded
Rear kg 3,725 3,710
Tyre size
Rear 7.00-12-12PR(I)
Tyre

Basic measurement

Ground clearance
Loaded,1st/2nd/3rd km/h 18.5 8.5/18.5
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 19.5 9.0/19.5
Performance

Engine

Others
Tank capacity l 55
10-16 CX-Series
CX-Series 10-17

Characteristics

Front kg 9,930 9,885
Weight
Loaded
Rear kg 1,410 1,395
Axle loading
Front kg 2,770 2,720
Unloaded
Rear kg 4,070 4,060
Tyre size
Rear 7.00-12-12PR(I)
Tyre

Basic measurement

Ground clearance
Loaded,1st/2nd/3rd km/h 15.5/23.0 8.5/18.5
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 16.5/24.0 9.0/19.5
Performance

Engine

Others
Tank capacity l 55
10-18 CX-Series
CX-Series 10-19
SPECIFICATIONS (EU SPEC.: FD50AT-8)

Model Manufacturer's designation FD50AT-8
Characteristics

Alternative Capacity Capacity@600mm load center kg —
Service weight kg 7,030
Front kg 10,690
Weight
Loaded
Rear kg 1,340
Axle loading
Front kg 3,020
Unloaded
Rear kg 4,010
Tyre size
Rear 7.00-12-12PR(I)
Tyre

Basic measurement

Ground clearance
Loaded,1st/2nd/3rd km/h 15.5/23.0
Travel speed (FWD)
Unloaded,1st/2nd/3rd km/h 16.5/24.0
Performance

Drawbar pull Loaded at 1.5 km/h kN{kgf} 33{3,370}
Gradeability Loaded at 1.5 km/h % 28
Engine

Others
Tank capacity l 55
10-20 CX-Series
CX-Series 10-21
GENERAL AND SPECIFICATIONS PERIODIC REPLACEMENT OF CONSUMABLE PARTS
PERIODIC REPLACEMENT OF CONSUMABLE PARTS

For operation safety, never fail to perform period-
ic maintenance or make periodic replacement of
the consumable parts listed in the following.
These parts may deteriorate in time and are sus-
ceptible to wear. It is dificult to estimate the de-
gree of wear at time of periodic maintenance;
therefore, even if no apparent wear is found, al-
ways replace with new parts within the prescribed
period of replacement (or earlier if trouble is
found).
Note that periodic replacement has nothing to do
with guarantee service.
No. Part name Period of replacement
1 Master cylinder and wheel cylinder caps, dust seals Every 1 year
2 Brake hose or tube Every 2 years
3 Brake reservoir tank and tube Every 2 to 4 years
4 Power steering hose Every 2 years
5 Stop lamp switch (Oil pressure type) Every 2 years
6 Fuel hose Every 2 years
7 Rubber parts of power steering Every 2 years
8 Lift chain Every 3 years
9 Hose of laod handling Every 2 years
10-22 CX-Series
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
SAFETY ITEMS FOR MAINTENANCE

FOR SAFETY OPERATION
INSPECTION AND MAINTENANCE SHALL BE PERFORMED BY PERSONS WHO

HAVE BOTH SKILL AND EXPERIENCE IN MAINTENANCE.
• Inspection, maintenance, and repair of the vehicle shall be performed by persons who have sufficient knowl-
edge and experience in maintenance and repair.
• When inspecting and maintaining a new model or a new component, fully understand its structure, function,
and mechanism in advance.
THE SPECIFIC FREE INSPECTIONS SHALL BE PERFORMED BY QUALIFIED

PERSONS.
• The specific free inspections of the fork lift shall be performed by the "Fork lift inspectors".
PLACE FOR INSPECTION AND MAINTENANCE

• Perform inspection and maintenance on a flat, dry, and dustless place.
• When working in a warehouse, ventilate well.
• Keep the inside of the maintenance shop arranged well and work safely.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE WORK

• Prepare a fire extinguisher against a fire and learn how to use it.
• Before starting inspection work, lower the fork to the ground.
• Before starting inspection work, stop the engine.
• Run the engine only when necessary.
• Set the directional lever, high/low speed lever, and work equipment control lever in neutral.
• Pull the parking brake lever and put chocks in front and rear of the front and rear tires.
CX-Series 10-23
PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE

• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the
lift truck before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.
• Wear suitable clothes for the job.
• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the job.
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks
and mast from dropping.
• When carrying out job with another worker, decide who is the leader and carry out the job in accordance
with instructions from that person.
• After repairing, make sure that the trouble has been corrected by performing a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been
fully corrected or that defective parts have not been removed.
REPLACE SAFETY CRITICAL PARTS PERIODICALLY

• Even if no abnormality is found, always replace safety critical parts periodically.
As time passes, these parts deteriorate and may cause fire of failure in the work equipment system.
• However, if these parts show any abnormality before the replacement interval has passed, they should be
repaired or replaced immediately.
USE SUITABLE TOOLS

• Always use tools that are suited for inspection and maintenance.
It is extremely dangerous to use broken tools or tools designed for an-
other purpose.
10-24 CX-Series
PRECAUTIONS WITH HIGH TEMPERATURE COOLANT

• Immediately after using the lift truck, the engine coolant is at high temperature and high pressure. Do not
remove the radiator cap under these conditions.
Hot water may spurt out and cause burns.
• When removing the radiator cap, turn it slowly to release the internal
pressure.
• When checking the coolant level, stop the engine and wait for the en-
gine and radiator to cool down before checking. For lift trucks equipped
with a subtank or reservoir, check the level in the subtank.
• When adding water on lift trucks equipped with a subtank, add the wa-
ter to the subtank.
PROHIBITION OF WELDING OF FUEL TANK

• Never weld the fuel tank since it can explode.
PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL

• Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the filter
when the oil is hot. Hot oil may spurt out and cause burns.
• When carrying out inspection and maintenance, wait for the oil temper-
ature to go down, and carry out the operation in the order given in this
manual.
• Do not forget that the work equipment circuits are always under pres-
sure. 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.
• Release the internal pressure before checking the accumulator piping.
• If you are hit by a jet of high pressure oil, consult a doctor immediately.
CX-Series 10-25
ROTATING FAN AND BELT

• It is extremely dangerous if you or any tool touches or gets caught in
the fan or fan belt when the fan is rotating. Never touch the fan when it
is rotating.
• Always stop the engine before inspecting rotating parts.
• When inspecting the areas around rotating parts, do not allow anything
to come close which may get caught.
BE CAREFUL NOT TO GET CAUGHT OR FALL

• Never put your hands or feet into the mast structure. There is danger
that you will get caught in moving parts and be seriously injured.
• Do not use the mast as a ladder. If you slip, there is danger that you
will fall.
10-26 CX-Series
CHECKING AND INFLATING TIRES

• If the tire inflation pressure is low, it will affect truck stability. However, do not inflate the tires immediately.
The inflation pressure may have gone down because of damage to the rim. If the rim is damaged or cracked
and the tires are inflated, there is danger that the rim will break when the tire is under high pressure, and
this may cause personal injury or death.
• For safety, when checking tire pressure, place your body in front of the
tread face of the tire. Do not check from the side face of the tire.
• Suitable qualifications are needed for tire inflation work. Always have
the work carried out by properly qualified personnel.
• The tire inflation pressure on a forklift truck is several times higher than
the pressure on an automobile.
• When the tires are being inflated, there is danger that dirt or dust may
be thrown up by the compressed air and enter your eyes, so always
wear safety glasses.
HANDLING OF TIRE
Leave disassembly and assembly of each tire to a specialist.
Since the tire inflation pressure is very high, you must steering wheel the
tire carefully.
• Before removing the tire, release the inflation pressure completely. To
remove the tire from the chassis, loosen hub nuts (2).
• Never touch rim nuts (1), since they are dangerous.
• After replacing the tire, perform a test run, then check the mounting
nuts for looseness. If the tightening torque of the nuts is insufficient,
retighten the nuts to the specified torque.
• See the section of tightening torque: [20. TESTING AND ADJUSTING,
Service data].
CX-Series 10-27
JACKING UP LIFT TRUCK (when checking or replacing 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 com-
ing down.
• Put blocks under any tires contacting the ground to prevent the lift truck
from moving.
LIFTING LIFT TRUCK (when checking tires)

• Lift truck slinging work should be carried out by a qualified person who has completed a course in correct
lifting methods.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes have ample
strength and are not damaged.
• Block the tires contacting the ground to prevent the lift truck from mov-
ing.
• Insert blocks to prevent the truck from coming down.
• Do not go under the lift truck during the lifting operation.
• If the specified lifting point is the counterweight, check that the coun-
terweight 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.
SLINGING VEHICLE (for loading it on trailer, etc.)

• Never sling the vehicle by the head guard.
If the vehicle needs to be slung often, a special sling device is neces-
sary. In this case, consult your distributor.
• The vehicle shall be slung by a person who has completed a course of
slinging work.
• Install wires to the specified sling parts.
• Use wires which is free of defect and has sufficient strength to sling the
vehicle.
10-28 CX-Series
BATTERY HAZARD PREVENTION

• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill
electrolyte on yourself, immediately flush the area with a large quantity of water.
• Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes, flush them
immediately with large quantities of water and consult a doctor at once.
• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite or
vegetable oil. Call a doctor or poison prevention center immediately.
• When working with batteries, ALWAYS wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a small
spark or flame. Do not smoke or create any spark near the battery.
• Before working with batteries, stop the engine and turn the starting switch to the OFF position.
• When removing the battery, remove the cable from the negative (–) ter-
minal first. When installing the battery, install the cable to the positive
(+) terminal first.
• Avoid short-circuiting the battery terminals through accidental contact
with tools or other metal objects across the terminals.
• Tighten the battery terminals securely. Loose terminals can generate
sparks and lead to an explosion.
• When removing or installing the battery, confirm which is the positive
(+) terminal and negative (–) terminal. Be careful not to connect the ca-
bles to the opposite terminals.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps tightened.
DO NOT PUT METAL OBJECTS ON TOP OF BATTERY

• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit and
start a fire.
CX-Series 10-29
PRECAUTIONS WHEN CHARGING

When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change.
To prevent the danger of gas explosion, always do as follows.
• Carry out the charging operation in a well-ventilated place.
• Do not smoke or allow any flame.
• Start the charging operation when the temperature of the battery electrolyte is below 35°C. (If the tempera-
ture goes above 50°C during the charging operation, wait for it to go down below 35°C before starting charg-
ing operation again.)
• When using a battery charger to charge the battery, take the battery caps off.
STARTING WITH BOOSTER CABLES

• ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.
• When starting using the battery of another lift truck, do not allow the two lift trucks to touch.
For details of the order of operations when using a booster cable.
• Stop the engine before connecting the cables.
• Be extremely careful not to let the cables get caught in the fan or fan belt.
• Connect the batteries in parallel: positive to positive and negative to negative. Never connect positive to neg-
ative.
HANDLING BRAKE FLUID

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.
10-30 CX-Series
HANDLING ANTIFREEZE
• Antifreeze can be a flammable. Keep away from flame when handling.
• Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water, vomit it
out, and get medical attention immediately. Follow safety precautions on container.
WASTE MATERIALS
• Obey appropriate laws and regulations when disposing of harmful ob-
jects such as oil, fuel, solvent, filters, and batteries.
CX-Series 10-31
GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

BOLT
For unspecified bolts and nuts, use the torques spec-
ified in this list.
Select a proper torque corresponding to the width
across flats (b) of bolts and nuts.
When replacing bolts and nuts, always use genuine
Komatsu Forklift parts the same size as the previous
ones.
Thread diameter Width across Tightening torque (Nm {kgf•m})

of bolt (a) flat (b)
(mm) (mm) Target value Range
6 10 13 {1.35} 12 – 15 {1.2 – 1.5}
8 13 31 {3.2} 27 – 34 {2.8 – 3.5}
10 17 66 {6.7} 59 – 74 {6.0 – 7.5}
12 19 113 {11.5} 98 – 123 {10.0 – 12.5}
14 22 177 {18.0} 157 – 196 {16.0 – 20.0}
16 24 279 {28.5} 245 – 309 {25.0 – 31.5}
18 27 382 {39.0} 343 – 427 {35.0 – 43.5}
20 30 549 {56.0} 490 – 608 {50.0 – 62.0}
22 32 745 {76.0} 662 – 829 {67.0 – 84.5}
24 36 927 {94.5} 824 – 1,030 {84.0 – 105.0}
27 41 1,324 {135.0} 1,177 – 1,471 {120.0 – 150.0}
30 46 1,716 {175.0} 1,520 – 1,912 {155.0 – 195.0}
33 50 2,206 {225.0} 1,961 – 2,452 {200.0 – 250.0}
36 55 2,746 {280.0} 2,452 – 3,040 {250.0 – 310.0}
39 60 3,285 {335.0} 2,893 – 3,628 {295.0 – 370.0}
10-32 CX-Series
GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE
ELBOWS, NIPPLES AND UNIONS
Width across flats B mm 22 30 36
Width D mm 19 22 30
Tightening torque Nm {kgf•m} 29.4 – 39.2 {3 – 4} 78.5 – 103 {8 – 10.5} 117.7 – 161.8 {12 – 16.5}
Port size inch 3/4-16UNF 7/8-14UNF —
Tightening torque Nm {kgf•m} 68.6 – 73.6 {7 – 7.5} 78.5 – 83.3 {8 – 8.5} —
Union Elbow
HIGH-PRESSURE RUBBER HOSES, PIPES AND SLEEVE NUTS
Width across flats B mm 19 24 27 32 36
Bore A mm 14 18 22 24 30
19.6 – 29.4 23.5 – 68.6 58.8 – 98.1 107.9 – 166.7 147– 206
Tightening torque Nm {kgf•m} {2 – 3} {3 – 7} {6 – 10} {11 – 17} {15–21}
CX-Series 10-33
GENERAL AND SPECIFICATIONS HOW TO USE LOCTITE
HOW TO USE LOCTITE 4. Assembly

After applying LOCTITE, tighten the screw or fit
the shaft to the hole as usual. (When using LOC-
1. PROCEDURE FOR USING LOCTITE
TITE for structures or LOCTITE of instant glue
type, press the mating parts lightly (about 49 kPa
Male side {0.5 kgf/cm2}).
Degreasing Air drying
2. REMOVAL OF PARTS
Female
side
When screws and shafts are secured with LOC-
TITE, they usually can be removed with common
tools such as spanners, wrenches, pulley pull-
Applying
Leaving Assembly ers, etc. If LOCTITE is so strong that a part may
LOCTITE
be broken when it is removed, heat it (to 200 –
250°C) with a soldering iron, gas torch, etc., and
1. Degreasing and cleaning you can remove it easily. It is generally difficult
(a) Clean the parts in trichloroethylene, ace- to dissolve LOCTITE in chemical solutions.
tone, ether, alkaline solution, etc. which are
highly volatile. 3. WHEN ASSEMBLING AGAIN
(b) Degrease the parts as perfectly as possible. (a) If a LOCTITE film on threads is broken, it is
(c) Since gasoline, light oil, kerosene, etc. are left as white powder on the threads. In this
not highly volatile, they are not recommend- case, you can apply LOCTITE again to the
ed. If it is obliged to use them, dry them threads without removing the white powder.
completely. (b) If shafts or flanges secured with LOCTITE
(d) If the mating parts are made of thermoset- are disconnected, LOCTITE remaining on
ting resin, treat them with LOQUICK PRIM- them may need to be removed to maintain
ER after degreasing them. dimensional accuracy. You can remove the
remaining LOCTITE easily, however, with a
2. Air drying wire brush, etc.
(a) Wait until the cleaning fluid dries out. (c) If plates secured with LOCTITE need to be
(b) If the parts are treated with LOQUICK PRIM- assembled again after they are separated,
ER, do not wipe them but dry them in air for be sure to remove all the hardened LOC-
5 – 10 minutes. (If LOCTITE is used before TITE and roughen the mating surfaces with
LOQUICK PRIMER dries out, its effect is sandpaper.
lowered.)
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads
or the shaft and hole to be fitted by amount to fill
the clearance between them by one of the fol-
lowing methods.
• Applying directly from LOCTITE container
nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving
pan.)
• Sponge
• Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
10-34 CX-Series
GENERAL AND SPECIFICATIONS CONVERSION TABLE
CONVERSION TABLE
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.229 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Inches to millimeters
1 in = 25.4 mm
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0 0.254 0.508 0.762 1.016 1.270 1.524 1.778 2.032 2.286
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.141 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
CX-Series 10-35
Liter to U.S. gallon

1 = 0.2642 U.S. gal
0 1 2 3 4 5 6 7 8 9
0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
U.S. gallon to liter

1 U.S. gal = 3.7854
0 1 2 3 4 5 6 7 8 9
3.79 7.57 11.36 15.14 18.93 22.71 26.50 30.28 34.07
10 37.85 41.64 45.43 49.21 53.00 56.78 60.57 64.35 68.14 71.92
20 75.71 79.49 83.28 87.06 90.85 94.64 98.42 102.21 105.99 109.78
30 113.56 117.35 121.13 124.92 128.70 132.49 136.27 140.06 143.85 147.63
40 151.42 155.20 158.99 162.77 166.56 170.34 174.13 177.91 181.70 185.49
50 189.27 193.06 196.84 200.63 204.41 208.20 211.98 215.77 219.55 223.34
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 253.62 257.41 261.19
70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05
80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90
90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76
10-36 CX-Series
Litter to U.K. gallon

1 = 0.21997 U.K. gal
0 1 2 3 4 5 6 7 8 9
0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
U.K. gallon to liter

1 U.K. gal = 4.5461
0 1 2 3 4 5 6 7 8 9
4.55 9.09 13.64 18.18 22.73 27.28 31.82 36.37 40.92
10 45.64 50.01 54.55 59.10 63.65 68.19 72.74 77.28 81.83 86.38
20 90.92 95.47 100.01 104.56 109.11 113.65 118.20 112.74 127.29 131.84
30 136.28 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76
50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22
60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68
70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14
80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60
90 409.15 413.69 418.24 422.79 427.33 341.88 436.42 440.97 445.52 450.06
CX-Series 10-37
Kilogram to pound
1 kg = 2.2046 Ib
0 1 2 3 4 5 6 7 8 9
2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Pound to kilogram
1 Ib = 0.4536 kg
0 1 2 3 4 5 6 7 8 9
0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082
10 4.536 4.990 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154
30 13.608 14.061 14.515 14.969 15.422 15.876 16.329 16.783 17.237 17.690
40 18.144 18.597 19.051 19.505 19.958 20.412 20.865 21.319 21.772 22.226
50 22.680 23.133 23.587 24.040 24.494 24.948 25.401 25.855 26.308 26.762
60 27.216 27.699 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298
70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843
80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906
10-38 CX-Series
kgf/cm² to lb/in²
1 kgf/cm² = 14.2233 lb/in²
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 996.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1123 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
CX-Series 10-39
kgf•m to ft. lb
1 kgf.m = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.6 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
10-40 CX-Series
TEMPERATURE
Fahrenheit-Centigrade Conversion. –A simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column
of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.3 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.2 16.1 61 141.8 35.6 96 204.8

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

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 265.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
CX-Series 10-41
20. TESTING AND ADJUSTING
Service data ..................................................... 20- 2

Gasoline engine ............................................... 20- 4
Diesel engine ................................................... 20- 6
Air cleaner ........................................................ 20- 8
Method of adjusting ignition timing................... 20- 9
Method of adjusting injection timing ................. 20-10
Measuring method for compression................. 20-12
Adjustment method for valve clearance ........... 20-13
Tightening torque for cylinder head
mounting bolts............................................. 20-14
Adjusting accelerator pedal
(TB42 Engine Truck) ................................... 20-17
Adjusting accelerator pedal
(S6D102E Engine Truck) ............................ 20-18
Adjusting power-assist-type clutch/brake pedal
(Clutch truck)............................................... 20-19
Adjusting inching/brake pedal
(Torque converter truck).............................. 20-20
Wheel brake ..................................................... 20-21
Adjusting parking brake lever ........................... 20-22
TORQFLOW transmission case
(Only torque converter truck) ...................... 20-23
Differential case ............................................... 20-24
Hydraulic tank .................................................. 20-25
Measuring hydraulic drift of lift cylinder,
tilt cylinder ................................................... 20-26
Adjusting mast.................................................. 20-27
Adjusting finger bar .......................................... 20-29
Cooling system................................................. 20-31
Bleeding air ...................................................... 20-32
Specified fuel, lubricating oil, and fluid ............. 20-34
Lubricating table............................................... 20-36
CX-Series 20-1
TESTING AND ADJUSTING SERVICE DATA
SERVICE DATA
FG35ZT/40ZT-7 FD35ZT/40ZT-8
Component Check item Unit FG35T/40T/45T-7 FD35T/40T/45T/50AT-8
Engine model — Nissan TB42 Komatsu S6D102E
Idling speed rpm 850 – 900 675 – 725
Engine proper Max. speed rpm 2,300 – 2,400
Torque converter stall speed rpm 1,970 2,090

MPa
Compression {kgf/cm²}/rpm Min. 1.2 {12} / 200 3.35 {36} / 280 – 320
Engine oil capacity l 8 11.5

Lubricating,
cooling system Coolant capacity l 17 16
Fan belt tension mm 15 – 17 / 98N {10kgf} —

Finger pressure
ATDC1 [Injection pump
Injection timing BTDC° — cam lift 1mm point]
Injection order — — 1-5-3-6-2-4

Engine
Fuel system
Injection pressure MPa — 21.6 {220}
{kgf/cm²}
FD35ZT/40ZT-7 : 80 FD35ZT/40ZT-8 : 90
Fuel tank capacity l FG35T/40T/45T-7: 100 FD35T/40T/45T/50AT-8 : 100
Intake mm 0.38 (Warm) 0.25 (Cold)
Intake, exhaust
system Valve clearance
Exhaust mm 0.38 (Warm) 0.51 (Cold)
Distributor point gap mm — —
Ignition plug gap mm 0.7 – 0.8 —
Type of ignition plug — B-4ES, L47W, BPR-4ES —

Electrical
system
Ignition timing BTDC°/ rpm 7/700 —
Ignition order — 1-5-3-6-2-4 —
Electrolyte specific gravity — 1.27 – 1.29
Stall speed rpm 1,970 2,090
Torque Inlet port oil pressure MPa 0.49 – 0.69 {5 – 7}

converter {kgf/cm²}
MPa
Outlet port oil pressure {kgf/cm²} —
Relief pressure MPa 1.01 – 1.25 {10.3 – 12.7}

{kgf/cm²}
Power train
MPa
Clutch actuation pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 12.7}
TORQFLOW
transmission MPa
Lubricating oil pressure {kgf/cm²} 0.34 – 0.58 {4.3 – 4.7}
Oil capacity l 16 ( Including torque converter 3.5 l)

Torque con-
verter truck l 13
Differential Oil capacity
Clutch truck l 25
20-2 CX-Series
TESTING AND ADJUSTING SERVICE DATA
Component Check item Unit FG35ZT/40ZT-7 FD35ZT/40ZT-8

FG35T/40T/45T-7 FD35T/40T/45T/50AT-8
250-15-16PR : 830 {8.5}
Front kPa 8.25-15-12PR : 690 {7.0}
wheel {kgf/cm²} 300-15-18PR : 780 {8.0}
Inflation pressure
Tires Rear kPa
wheel {kgf/cm²} 830 {8.5}
Travel system
Depth of pattern mm Min. 1.6 (at 1/4 of tread width)
Front Nm
wheel {kgf•m} 294 – 490 {30 – 50}
Hub nut Tightening torque
Rear Nm 294 – 490 {30 – 50}
wheel {kgf•m}
Front Nm —
wheel {kgf•m}
Rim nut Tightening torque
Rear Nm 196 – 294 {20 – 30}
wheel {kgf•m}
Belt tension mm —
Power steering
system MPa
Relief pressure 100 – 105 {1,020 – 1,071}
{kgf/cm²}
Steering wheel Play mm 30 – 60 (Engine idling state)
FG(D)35ZT:2,530±150 FG(D)35T:2,730±150 FG(D)45T:2,820±150

Min. turning radius mm FG(D)40ZT:2,580±150 FG(D)40T:2,770±150 FD50AT :3,050±150
Rear axle
Support thrust clearance mm Max. 0.7
Steering, braking system
Clutch pedal Play mm 3–5
Play mm 2–3
Inching pedal
Interconnected travel mm 35 – 41
Play mm 3–7
Brake pedal
Pedal height when depressed mm 90 – 100
Brake fluid capacity l 0.15
Parking brake operating effort N {kgf} Min. 20 {2.0}

Brake
Tightening torque for back plate Nm {kgf•m} FD35ZT/40ZT : 157 – 196 {16 – 20}
mounting bolt FD35T/40T/45T/50AT : 245 – 309 {25 – 31.5}
Lining thickness mm Min. 2.0
Thickness at fork root mm 3.25 ton : Min. 48 4.0 ton : Min. 50

3.5 ton : Min. 48 4.5 ton : Min. 50
Fork Difference in height mm Max. 15
Amount of opening at tip mm Max. 35

Power train
Chain Length of 17 links mm Max. 440
cylinder Max. 50
Hydraulic drift (lift cylinder) mm/15min
Cylinder fork Max. 100
Hydraulic drift (tilt cylinder) mm/15min Max. 45 (cylinder)
Relief pressure MPa 18 {185}

Hydraulic {kgf/cm²}
system
Oil capacity l 55
CX-Series 20-3
TESTING AND ADJUSTING GASOLINE ENGINE
GASOLINE ENGINE
TB42
k Maintain the engine when the engine stops and after the temperature has completely dropped.
1. REPLACEMENT OF FUEL FILTER 2. CHANGE OF ENGINE OIL

1. Loosen the clamp to remove the hose and then 1. Drain engine oil filter removing the drain plug.
remove the cartridge from the bracket.
2. Fill the specified amount of engine oil.
2. Put a new cartridge to the fuel pipe. Oil amount to replace: 8 l
a Make sure of no fuel leaking from the pipe.
3. Check on engine oil by use of an oil gauge.
20-4 CX-Series
TESTING AND ADJUSTING GASOLINE ENGINE
3. REPLACEMENT OF ENGINE OIL FILTER

1. Remove the cartridge by use of a filter wrench.
2. Clean the filter face and coat a new cartridge
(both the seal and the screw) with engine oil be-
fore fixing it.
a After fixing the new cartridge, start the engine to
check on any oil leakage.
4. CHEKING ON SPARK PLUG

1. Remove the plug by the special plug wrench.
2. Clean carbon off the top and its vicinity of the
plug.
3. Measure the plug gap by a gauge.
Normal plug gap A: 0.7 – 0.8 mm
[1] Normal
[2] Badly burnt
[3] Sooty
Brand plug
NGK plug B-4ES
Hitachi plug L47W
NGK plug BPR-4ES (noiseproof type)
5. CHANGE OF GOVERNOR OIL

1. Remove the drain plug (3) to drain oil and tighten
the plug (3) after draining.
2. Remove the oil filler port (1) and level plugs (2).
3. Fill oil from the oil filler port until it flows out of the
level plug (2) port.
a Use the same oil as that for the oil pan
(capacity: 35 to 40 cc).
4. Tighten the oil filler port (1) and level plugs (2).
CX-Series 20-5
TESTING AND ADJUSTING DIESEL ENGINE
DIESEL ENGINE
S6D102E
k Maintain the engine when the engine stops and after the temperature has completely dropped.
1. CHANGE OF ENGINE OIL 2. REPLACEMENT OF ENGINE OIL FILTER

1. Remove the drain plug, drain the oil, then tighten 1. Using a filter wrench, remove the cartridge.
the plug again.
2. Clean the filter holder, coat the thread and the
2. Remove the dipstick. seal of the new cartridge with engine oil, then in-
stall.
3. Add the specified amount of engine oil, and be a After installing the cartridge, start the engine and
careful not to let it overflow. check that there is no leakage of oil from the filter
Oil amount to replace: 11.5 l mounting surface.
4. Check the oil level with the dipstick.
20-6 CX-Series
TESTING AND ADJUSTING DIESEL ENGINE
3. DRAIN WATER FROM FUEL FILTER

1. Loosen the combination sensor plug (1) and drain
the water and sediment accumulated at the bot-
tom.
a Fuel is drained out at the same time, so prepare
a container to catch it.
a Always be sure to wipe up any spilled fuel.
4. REPLACEMENT OF FUEL FILTER

1. Remove the combination sensor plug (4) at the
bottom of the cartridge.
2. Using a filter wrench, remove the cartridge (3).
3. Install the combination sensor plug (4) to the new

cartridge (3).
4. Fill the new cartridge with fuel, coat the packing

surface thinly with engine oil, then install.
5. Loosen plug (2) and pump knob (1) up and down

until no more bubbles come out with the fuel.
6. Tighten plug (2).
k Be sure to use a pan for catching fuel

drained when draining water from the fuel fil-
ter or bleeding air after replacing cartridges
and wipe off any spilled fuel. Otherwise, fire
may occur.
CX-Series 20-7
TESTING AND ADJUSTING AIR CLEANER
AIR CLEANER
k • Do not clean or replace the air cleaner
while the engine is running.
• When using compressed air to clean the
element, put on protective glasses to pro-
tect your eyes from dirt.
CLEANING OF ELEMENT
a If oil, grease, or carbon sticks to the element,
clean it with special element cleaner accord-
ing to the instruction manual for the air clean-
er.
a If the working environment or condition is
bad, clean and replace a little earlier than usu-
al.
1. Remove the element and clean its all surface by

blowing compressed dry air (0.69 MPa {7 kgf/
cm2}) from its inside.
2. Install the cleaned element.
CHECK OF ELEMENT
Check the element visually for damage.
REPLACEMENT OF ELEMENT
1. Remove cover (1) and element (2). Double element type
2. Remove inner element (3).
3. Cover the air connector in body (4) with clean

cloth tapes.
4. Clean the inside of body (4) and remove the cover

installed in 3.
5. Install a new element.
20-8 CX-Series
TESTING AND ADJUSTING METHOD OF ADJUSTING IGNITION TIMING
METHOD OF ADJUSTING IGNITION TIMING

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. Shin the timing light (3) and check that the indica-
tor and timing mark stamped on the crankshaft
pulley and flywheel are aligned.
5. If the timing is misaligned, turn the distributor (4)

to the right or left to adjust.
6. Check that the ignition timing advances quickly

when the engine speed is raised.
CX-Series 20-9
TESTING AND ADJUSTING METHOD OF ADJUSTING INJECTION TIMING
METHOD OF ADJUSTING INJECTION TIMING

There are following two methods. 2. Measuring device method
1. Counter mark alignment method Used when repairing or replacing the injection
Used when installing the injection pump in the pump.
original engine without repair.
a Inspect and adjust the truck after placing the

No. 1 cylinder at the compression top dead
center (see the section “ADJUSTING METH-
OD OF VALVE CLEARANCE”.
1. Counter mark alignment method

1. Check that stamp line a on the injection pump
side aligns stamp line b on the timing gear case
side.
2. If not, loosen nut (1) to move the injection pump
to align them and then tighten the nut.
2. Measuring device method

Adjust the timing so that the injection pump cam
lift is set at the specified value when the No. 1 cyl-
inder is placed at the compression top dead cen-
ter.
1. Turn the No. 1 cylinder by 25 to 30 degrees in the
opposite direction from the compression top dead
center (place the plunger at the bottom dead cen-
ter).
2. Remove the distributor head bolt (2) from the in-
jection pump.
3. Set a dial gauge [2] on the plunger stroke mea-
sure [1] (ND95095-10172) and mount it on the in-
jection pump (3).
a Make sure that the end of the plunger stroke
measure tracer comes in contact with the
plunger head.
4. Set the dial gauge [2] pointer at 0.
a Make sure that the pointer stably indicates 0
even if slightly turning the crankshaft.
20-10 CX-Series
TESTING AND ADJUSTING METHOD OF ADJUSTING INJECTION TIMING
5. Turn the crankshaft in the normal direction and

read the dial gauge [2] when V-groove C of the
crankshaft pulley (4) (see below) corresponds to
the pointer (5).
Standard value 0.97 – 1.03 mm
a Gauge reading ± 0.03 mm corresponds to injec-

tion timing ± 0.5 degree.
a Be sure to turn the crankshaft in the normal direc-
tion.
a V-groove position
V-groove BTDC degree
A 10°
B 8°
C 6°
D 0°
6. If the dial gauge reading is not within the standard

range, turn the injection pump (6) to adjust it.
Mark side : Less than standard value
Mark side : More than standard value
7. Tighten the pump mounting bolt.
8. Remove the plunger stroke measure [1] to install

the distributor head bolt (2).
a Replace the copper washer of the distributor
head bolt with a new one.
CX-Series 20-11
TESTING AND ADJUSTING MEASURING METHOD FOR COMPRESSION
MEASURING METHOD FOR COMPRESSION

1. Warm up the engine to get the coolant tempera- Gasoline engine
ture of 75 – 85 °C.
2. Stop the engine, then remove all the spark plugs
(on gasoline engines) or nozzle holders (on die-
sel engines) and the air cleaner.
3. Disconnect the coil cord from the ignition coil (on
gasoline engines). Set the fuel control lever to
the non-injection position or disconnect the wiring
of the fuel cut solenoid (on diesel engines).
4. Fit the adapter to the nozzle holder mounting of
the cylinder which is to be checked and tighten to
the specified torque (on diesel engines).
5. Install a compression gauge [1] to the cylinder to
be checked.
6. For pneumatic governor, press the accelerator
pedal fully to the floor and crank the engine with
the starter motor to get the maximum reading of
the gauge.
a Take measurements more than two times on
each engine to avoid measurement errors
and average the values.
a Discharged battery will not give sufficient rev-
olutions. Use fully charged battery.
Causes for insufficient compression Diesel engine

1. Poor adjustment of valve clearance
2. Pressure leakage from the valve seat
3. Seize of valve stems
4. Defective or broken valve springs
5. Pressure leakage from the cylinder head gasket
6. Sticking or breakage of piston rings
7. Wear of piston rings or cylinders
20-12 CX-Series
TESTING AND ADJUSTING ADJUSTMENT METHOD FOR VALVE CLEARANCE
ADJUSTMENT METHOD FOR VALVE CLEARANCE

1. Remove the cylinder head cover.
2. Rotate the crankshaft to match top mark [1] of
crank pulley (1) to pointer (2) and see which of the
pistons of the No. 1 and No. 6 cylinders is at the
compression top dead center.
a If the piston of a cylinder is at the compres-
sion top dead center, both intake valve and
exhaust valve of that cylinder are closed, or
both of the rocker arms are free.
3. Adjust the valve clearance of the cylinder in which
the piston is at the compression top dead center.
a When the piston of the No. 1 cylinder is at the
compression top dead center
Adjust the valve clearance of the valves
marked with q in the table, then rotate the
crankshaft forward by 1 turn and adjust the
valve clearance of the valves marked with Q.
a When the piston of the No. 6 cylinder is at the
compression top dead center
Adjust the valve clearance of the valves
marked with Q in the table, then rotate the
crankshaft forward by 1 turn and adjust the
valve clearance of the valves marked with q.
4. Loosen locknut (4) of adjustment screw (3) and

insert feeler gauge [2] of the specified clearance
between valve stem (6) and rocker arm (5). Ad-
just the clearance to a degree that you can move
the feeler gauge lightly, and then tighten the lock-
nut to fix the adjustment screw.
CX-Series 20-13
TESTING AND ADJUSTING TIGHTENING TORQUE FOR CYLINDER HEAD MOUNTING BOLTS
TIGHTENING TORQUE FOR CYLINDER HEAD MOUNTING BOLTS

1. Nissan engine TB42
a When tightening the cylinder head, apply engine
oil to the bolt screws and seat surface.
a Set the washer so that the non-chamfered sur-
face faces the cylinder head.
a Tighten the bolts in the order shown in the figure
on the right.
[Angle tightening]
Procedure for tightening cylinder head bolts
1) Tighten by 29.4 Nm {3 kgf•m}.
2) Tighten by 57 to 66 Nm {5.3 to 6.8 kgf•m}.
3) Loosen to 0 Nm {0 kgf•m}.
4) Tighten by 29.4 Nm {3 kgf•m} again.
5) Retighten by “69 +50 degrees” from the position in
4)
a When no angle tightening wrench is available

Wind a wire around the wrench extension bar to
make an indicator (the stability of the indicator
can be improved by winding nylon tape around
the bar several times and putting a wire for an in-
dicator on it).
Next, set a readily-available protractor under the
extension bar indicator set on the applicable bolt
and tighten it by the specified torque. Tighten it
further from the position by using the point having
the torque value as 0 and reading the protractor
scale by referring to the degree written in the
maintenance standard.
20-14 CX-Series
2. S6D102E engine
a Make sure that no dirt or foreign matter exists on
the cylinder head mounting surface or inside the
cylinder.
1) Set cylinder head gasket (41) on the cylinder
block.
a Make sure that the gasket is properly en-
gaged with the block holes.
2) Lift cylinder head assembly (40) to set it on

the cylinder block.
3) Install push rod (39).

Apply engine oil (15W-40) to the push
rod socket.
4) Install rocker arm assembly (38) and tighten

the mounting bolts by hand.
a Make sure that the adjust screw ball is
completely engaged with the push rod
socket.
Apply engine oil (15W-40) to the 8-
and 12-mm mounting bolt screws and
seat surface.
CX-Series 20-15
5) Tighten the cylinder head mounting bolts in

the order shown in the figure on the right.
Apply engine oil (15W-40) to the
mounting bolt screws and seat sur-
face.
Cylinder head mounting bolts:
1. Tighten by 90 ± 5 Nm {9.18 ± 0.51 kgf•m}
in the order from [1] to [26].
2. Tighten by 120 ± 5 Nm {12.24 ± 0.51
kgf•m} in the order from [3] to [6], [11],
[14], [19] to [22].
3. i) When using tool A
• Retighten the bolts by 90 degrees us-
ing the angle tightening wrench (tool
A) in the order from [1] to [26].
ii) When not using tool A
• Retighten the bolts by 90 degrees af-
ter marking the bolts and heads with
a marker, etc.
6) Tighten the rocker arm assembly mounting

bolt (8 mm).
Rocker arm mounting bolt:
24 ± 4 Nm {2.25 ± 0.41 kgf•m}
a Nozzle holder assembly:
60 ± 9 Nm {6.12 ± 0.92 kgf•m}
a Head cover mounting bolt:
24 ± 4 Nm {2.25 ± 0.41 kgf•m}
20-16 CX-Series
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL (TB42 ENGINE TRUCK)
ADJUSTING ACCELERATOR PEDAL (TB42 ENGINE TRUCK)
PROCEDURE FOR ADJUSTING PEDAL

1. Set stopper bolt (1) so that the pedal height is 137
mm.
2. Set stopper bolt (2) temporarily to a height of 35.7
mm.
3. After assembling the cable, adjust the outer cas-
ing mount of the cable so that the pedal has a
play of 1 to 2 mm.
4. Adjust the height of stopper bolt (2) again so that
the lever at the engine end is fully open when the
pedal is fully depressed.
Standard pedal stroke 86.1 mm
Cable stroke 44.0 mm
Dimension of clearance 169.8 mm

point a to b
CX-Series 20-17
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL (S6D102E ENGINE TRUCK)
ADJUSTING ACCELERATOR PEDAL (S6D102E ENGINE TRUCK)
PROCEDURE FOR ADJUSTING PEDAL

1. Set stopper bolt (1) so that the pedal height is 132
mm.
2. Set stopper bolt (2) temporarily to a height of 57.5
mm.
3. After assembling the cable, adjust the outer cas-
ing mount of the cable so that the pedal has a
play of 1 to 2 mm.
4. Adjust the height of stopper bolt (2) again so that
the lever at the engine end is fully open when the
pedal is fully depressed.
Standard pedal stroke 46.2 mm
Cable stroke 29.0 mm
Dimension of clearance 111.3 mm

point a to b
20-18 CX-Series
TESTING AND ADJUSTING ADJUSTING POWER-ASSIST-TYPE CLUTCH/BRAKE PEDAL
ADJUSTING POWER-ASSIST-TYPE CLUTCH/BRAKE PEDAL

(CLUTCH TRUCK)
ADJUSTING CLUTCH PEDAL

1. Set the pedal so that the height from the upper
edge of bracket (S) will be 243 mm using stopper
bolt (1).
2. After setting the height, adjust the length of the
clutch booster push rod (loosen locknut (2) to turn
the rod) and set the clutch pedal play at 3 to 5
mm.
3. After adjustment, properly tighten locknut (2).
ADJUSTING BRAKE PEDAL

bolt (3).
2. After setting the height, adjust the length of the
brake booster push rod (loosen locknut (4) to turn
the rod) and set the brake pedal play at 3 to 7
mm.
3. After adjustment, properly tighten locknut (4).
CX-Series 20-19
TESTING AND ADJUSTING ADJUSTING INCHING/BRAKE PEDAL (TORQUE CONVERTER TRUCK)
ADJUSTING INCHING/BRAKE PEDAL (TORQUE CONVERTER TRUCK)
ADJUSTING BRAKE PEDAL

bolt (1).
2. Adjust the length of the brake booster rod (loosen
locknut (2) to turn the rod) and set the pedal play
at 3 to 7 mm.
ADJUSTING INCHING PEDAL

bolt (3).
2. Adjust using bolt (4) so that the pedal stroke will
be 35 to 41 mm and it will interlock the brake ped-
al.
Interlocking point FG(D)35ZT/40ZT: 20 – 30 mm

FG(D)35T – 45T: 0 – 5 mm
20-20 CX-Series
TESTING AND ADJUSTING WHEEL BRAKE
WHEEL BRAKE
ADJUSTING WHEEL BRAKE
Although the clearance between the drum and the lin-
ing is automatically adjusted, it can also be manually
adjusted as follows:
1. Lift the truck body using a jack to turn the adjuster

wheel gear (2) using an adjustment driver so that
the lining completely comes in contact with the
drum.
Return the adjuster wheel gear by 10 to 11 teeth
from the position where the lining completely
comes in contact with the drum. This position al-
lows an appropriate clearance between them.
a Set shoe clearance value:
a After adjusting the brake, be sure to check its
operation.
2. Checking of automatic adjuster operation

With the brake shoe assembly properly installed,
pressing the wire center of spring assembly (1) in
the arrow direction pulls lever (3) upward, feed
the wheel gear by one tooth and extend the shoe
(by one tooth).
3. Correct lever position

Lever (3) is in contact with the adjuster wheel
gear at the position 7.8 to 8.2 mm away from the
adjuster screw center.
A different contact position will cause wrong en-
gagement between the lever and the wheel gear,
disabling the wheel gear from being fed even if
the lever is operated, thereby causing improper
automatic adjustment.
CX-Series 20-21
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE LEVER
ADJUSTING PARKING BRAKE LEVER

1. Release the parking brake (push the lever for-
ward).
2. Using a screwdriver, push in adjustment button

(1) in direction G, then keep it pushed in and ro-
tate in to adjust the operating effort of the lever to
245 N {25 kgf}.
3. Align the direction of the hexagonal portion of ad-

justment button (1) to match the hexagonal hole
in the tip of grip (2), then remove the screwdriver.
20-22 CX-Series
TESTING AND ADJUSTING TORQFLOW TRANSMISSION CASE (ONLY TORQUE CONVERTER TRUCK)
TORQFLOW TRANSMISSION CASE

(ONLY TORQUE CONVERTER TRUCK)
k After operating the engine, the oil is at a high
temperature. Start working after the oil tem-
perature sufficiently drops.
OIL LEVEL CHECK

1. Open the inspection window on the floor plate
and check the oil level with the dipstick (1).
(Mast be in range of L)
2. If the oil level is insufficient, open the oil filler cap

(2) and fill the oil.
CHANGING OIL, CLEANING STRAINER

1. Remove the drain plug (3), then tighten it after
draining.
2. Remove the pipe, take out the strainer (4), and

clean it with the flushing oil.
3. After cleaning, blow dry compressed air from the

inside of the strainer (4) to outside and install it
when it is completely dry.
4. Add specified amount of oil from the oil filler port.
5. Check the oil level after changing the oil.

Oil amount to replace: 16 l
a Be sure to use the genuine TORQFLOW trans-

mission oil for Komatsu Forklifts (FEO10-CD).
(See the section "SPECIFIED FUEL, LUBRI-
CATING OIL, AND FLUID.")
CX-Series 20-23
TESTING AND ADJUSTING DIFFERENTIAL CASE
DIFFERENTIAL CASE
k After the engine is operated, the oil is at a
high temperature. Start working after the oil
temperature sufficiently drops.
CHECKING OIL LEVEL

1. Pull out the dipstick and check the oil level (1). If
the oil is filled to nearby the lower line of the plug
hole, the oil level is normal.
If the oil level is too low, remove the oil filler port
plug (2) and fill the oil.
CHANGING OIL
1. Remove the oil filler port plug (2), and drain the oil
through the drain plug (3).
2. After draining the oil, tighten the drain plug (3)
and refill the specified amount of oil.
3. Check the oil level after filling.
Oil amount to replace:
Clutch truck 25 l
Torque converter truck 13 l
a Be sure to use the genuine differential case

oil for Komatsu Forklifts (FG090).
(See the section "SPECIFIED FUEL, LUBRI-
CATING OIL, AND FLUID.")
Remarks
a The same oil is used for the differential case and
transmission case of the clutch model, but differ-
ent oils are used respectively for those cases of
the torque converter model.
Accordingly, when inspecting the torque convert-
er model, check/replace the oil in the TORQ-
FLOW transmission case as well as the oil in the
differential case.
a There are 2 level plugs (4) on the front side of the
differential case.
Embossed letter C: For clutch model
Embossed letter T : For torque converter model
20-24 CX-Series
TESTING AND ADJUSTING HYDRAULIC TANK
HYDRAULIC TANK
CHANGING HYDRAULIC OIL
CLEANING HYDRAULIC TANK STRAINER
CLEANING INSIDE HYDRAULIC TANK
REPLACING HYDRAULIC LINE FILTER
k The oil temperature is still high just after the
operation is stopped. Accordingly, start the
work after the oil temperature lowers.
1. After draining the oil from the drain plug (5) on the
bottom of the tank, remove the cover (1) to take
out the strainer and clean the strainer (4) with the
flushing oil.
2. After cleaning inside of the tank, mount the drain

plug (5).
3. After cleaning strainer (4), blow air from its inside

to dry well, and then install it and cover (1).
4. Remove the line filter (3) and mount a new one.
5. Pour specified amount of oil through breather

hole. Check the oil level from the inspection win-
dow.
Oil amount to replace: 55 l
6. Start the engine and bleed air by moving the cyl-

inders (lift, tilt, and power steering) to the stroke
end five to six times.
a Be sure to use the genuine hydraulic oil for

Komatsu Forklifts.
CX-Series 20-25
TESTING AND ADJUSTING MEASURING HYDRAULIC DRIFT OF LIFT CYLINDER, TILT CYLINDER
MEASURING HYDRAULIC DRIFT OF LIFT CYLINDER, TILT CYLINDER

k PRECAUTIONS AT MEASUREMENT
1. During measurement, never let anyone go under the load.
2. Do not put your feet on the mast stays or dashboard and climb up when measuring the hydraulic drift of the
cylinder. If this rule is violated, your hands or feet may be caught in the mast. Always use a strong, stable
stand at measurement.
3. Before start the measurement, check that the hydraulic oil level is correct and that the hydraulic oil is not dirty
or mixed with any other brand of oil.
4. Always carry out the measurement on flat horizontal ground in front of strong platform which will support the
truck if it should tilt over to the front.
MEASUREMENT
1. Stop the lift truck 500 mm in front of the platform.
2. Operate the lift and tilt repeatedly to set the hy-
draulic oil temperature to 50°
3. Set the rated load on the forks and secure it to the
fork carriage with a wire rope.
4. Raise the load height H for about 1,500 mm and
set the mast (1) perpendicular.
Hydraulic drift of lift cylinder

5. Wait for three minutes, then place a ruler [1]
against the lift cylinder (2) piston rod and draw a
mark A.
6. Measure the hydraulic drift for 15 minutes.
Hydraulic drift of lift cylinder 50 mm / 15 min
Hydraulic drift of tilt cylinder

5. Wait for three minutes, then place a ruler [2]
against the tilt cylinder (3) piston rod and draw a
mark B.
6. Measure the hydraulic drift for 15 minutes.
Hydraulic drift of tilt cylinder 45 mm / 15 min
20-26 CX-Series
TESTING AND ADJUSTING ADJUSTING MAST
ADJUSTING MAST
SYNCHRONOUS ADJUSTMENT
(SHIM ADJUSTMENT)
1. Mast stay
2. Shim
3. Lift cylinder
1. Lift the mast to the maximum height.

2. Check the mast play in the horizontal direction.
3. Adjust the mast using shims (2) (t = 0.1 mm) so
that the left and right cylinders synchronize when
the mast is lifted to the maximum height.
When the mast sways to the left

(at maximum height)
Put a shim (2) on the left cylinder.
When the mast sways to the right

(at maximum height)
Put a shim (2) on the right cylinder.
SELECTING ROLLER AND SHIM

ADJUSTMENT
1. OUTER ROLLER
1) Selecting roller
Select a roller so that dimension V at the strip
do not differ between left and right.
2) Shim adjustment
Put shims of the same thickness to the left
and right so that clearance f between R of the
rail and the roller will be 0 to 0.5 mm when the
mast is lifted to the maximum height.
CX-Series 20-27
TESTING AND ADJUSTING ADJUSTING MAST
2. INNER ROLLER
1) Selecting roller
Select a roller so that clearance a between
the rail and the roller will be 0.2 to 0.9 mm.
2) Shim adjustment
and right so that clearance c between R of the
rail and the roller will be 0 to 0.5 mm when the
mast is lifted to the maximum height and the
rail is engaged with the roller.
3. STRIP
1) Shim adjustment
Put a shim so that clearance b between the
strip and the rail exists at every position along
the inner rail when the main roller is engaged
with the rail.
Clearance b : 0.1 to 0.4 mm
Standard : 0.3 mm
20-28 CX-Series
TESTING AND ADJUSTING ADJUSTING FINGER BAR
ADJUSTING FINGER BAR

SELECTING ROLLER AND SHIM
ADJUSTMENT
1. Lower main roller
1) Selecting roller
Select a roller so that the clearance a be-
tween the rail and the roller will be 0.2 to 0.9
mm.
2) Shim adjustment
and right so that the clearance c between the
rail and the roller can be 0.01 to 0.1 mm when
the finger bar is lifted to the maximum height.
Standard shim thichness b : 5.8 mm
2. Upper and intermediate main rollers

1) Selecting roller
Select a roller so that the clearance d be-
mm.
2) Shim adjustment
Standard shim thickness : 1 mm
3. Upper side roller

1) Shim adjustment
Adjust using shims so that clearance e be-
mm when the finger bar is located at the high-
est position.
Standard shim thickness f : 1.5 mm
4. Lower side roller

1) Shim adjustment
Put a shim thinner by 0.3 mm than that for the
upper side roller.
CX-Series 20-29
TESTING AND ADJUSTING ADJUSTING FINGER BAR
5. Roller engagement
Check the engagement A between the upper (1)
and lower (2) side rollers all along the inner rail by
tilting the finger bar.
6. Lower main roller protrusion

1) Install a lift chain on the outer mast and adjust
so that the tension is the same for both left
and right.
2) Adjust the lower main roller (3) protrusion g
from the lower edge of the inner mast to the
set value when the lift is lowered to the lowest
height using the locknut of the chain stopper.
Locknut 392 – 588 Nm

{40 – 60 kgf•m}
Protrusion g: 40 mm
a Engage the backrest with the board side and
tighten them using a bolt (4).
20-30 CX-Series
TESTING AND ADJUSTING COOLING SYSTEM
COOLING SYSTEM
CLEANING RADIATOR
1. Drain water by opening the drain cocks of the low-
er part of the radiator and the engine cylinder
block.
2. Close the drain cock, fill pure water (tap water)
and radiator detergent liquid from the water filler
port and idle the truck for approximately 15 min-
utes.
3. Stop the engine and drain water from the drain
cock. Idle the truck by pouring pure water until
clean water flows out of the cock (for 5 to 10 min-
utes).
4. Stop the engine and drain water from the drain
cock. After closing the cock, fill pure water and
long-life coolant in the radiator.
Amount of coolant
Gasoline engine truck: 17 l
Diesel engine truck: 16 l
a Fill long-life coolant when it is cold.

a Fill radiator anti-rust fluid when not using
long-life coolant.
a Clean the radiator at a flat place.
a Use Komatsu genuine coolant, anti-rust fluid
and long-life coolant.
CLEANING RADIATOR FIN

1. Clean it by blowing air, steam or water.
Air pressure : Max. 0.98 MPa {10 kgf/cm²}

Steam pressure : Max. 0.39 MPa {4 kgf/cm²}
a Clean it by positioning the air or steam nozzle

at right angles to the radiator.
CX-Series 20-31
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
FUEL PIPING
(DIESEL ENGINE LIFT TRUCK)
1. Loosen plug (2) at the top of fuel filter cartridge (3)
and move knob (1) up and down until bubbles do
not come out any more.
2. After bleeding all air, tighten plug (2).
CLUTCH PIPING
1. Remove the cap from the air bleed plug (2), fit
one end of a vinyl hose to the plug, and put the
other end of the hose in a container of brake fluid.
2. Loosen the air bleed plug (2) approx. 3/4 turns

and depress the clutch pedal.
3. Tighten the air bleed plug (2), then release the

clutch pedal.
4. Repeat Steps 2 and 3 unitl no more bubbles

come out from the hose.
5. When all the air has been completely removed,

tighten the plug (2) and install the cap.
6. After air has completely been bled, check the fluid

level by removing the cap and middle rid of the
clutch reservoir tank, fill the same amount
drained while bleeding air and make sure that the
level is within the appropriate range.
20-32 CX-Series
TESTING AND ADJUSTING BLEEDING AIR
BRAKE PIPING
1. Brake drum cover
2. Air bleed plug
3. Vinyl hose
4. Brake fluid
5. Brake drum
6. Lining
1. Remove the cap from the air bleed plug (2), fit
one end of a vinyl hose (3) to the plug, and put the
other end of the hose in a container of brake fluid
(4).
2. Loosen the air bleed plug (2) approx. 3/4 turns

and depress the brake pedal.
3. Tighten the air bleed plug (2), then release the

brake pedal.
4. Repeat Steps 2 and 3 unitl no more bubbles

come out from the hose (3).
5. When all the air has been completely removed,

tighten the plug (2) and install the cap.
6. After air has completely been bled, check the fluid

level by removing the cap and middle rid of the
brake reservoir tank, fill the same amount drained
while bleeding air and make sure that the level is
within the appropriate range.
LIFT CYLINDER
1. Start the engine and run it at low idling.
2. Raise and lower the mast.

a Stop the mast about 100 mm before the max-
imum height and the lowest position.
3. Repeat Step 2 four or five times.
4. Raise and lower the mast to the maximum height

and lowest position.
5. Repeat Step 4 four or five times.
CX-Series 20-33
TESTING AND ADJUSTING SPECIFIED FUEL, LUBRICATING OIL, AND FLUID
SPECIFIED FUEL, LUBRICATING OIL, AND FLUID

GASOLINE ENGINE TRUCK
Engine : TB42
Ambient temperature ( C)
Lubrication point Type of fluid Capacity (l)
-30 -20 -10 0 10 20 30 40
Engine oil pan SAE 30-CD 8
Engine oil
TORQFLOW transmission case SAE 10W-CD 16

(Including torque converter 3.5 l)
Torque
Differential case converter SAE 80 13
(Including transmission truck Gear oil
case 10 l) SAE 90
Clutch truck 25
SAE
Hydraulic oil tank 5W-CD
Hydraulic oil 55
(Mast 3 -- 4 m)
SAE 10W-CD
3.25 -- 3.5 ton

80
Compact truck
Fuel tank Gasoline
3.5 -- 5 ton
100
Standard truck
Brake reservoir tank Brake fluid SAE 70R-1, SAE 70R-3, DOT3 0.15
Lithium
Greasing points NLGI No.2
grease
Cooling system Coolant Add antifreeze 17
a Use CD or upper grade oil.

a Be sure to use genuine oil for Komatsu Forklifts
(Komatsu Forklift dealers provide oil, grease, and antifreeze).
20-34 CX-Series
TESTING AND ADJUSTING SPECIFIED FUEL, LUBRICATING OIL, AND FLUID
DIESEL ENGINE TRUCK
Engine : S6D102E
Ambient temperature ( C)
Lubrication point Type of fluid Capacity (l)
-30 -20 -10 0 10 20 30 40
SAE 10W-CD
Engine oil pan 11.5
SAE 30-CD
Engine oil
TORQFLOW transmission case 16

SAE 10W-CD
(Including torque converter 3.5 l)
Torque
Differential case converter SAE 80 13
truck
(Including transmission Gear oil
case 10 l) Clutch truck SAE 90 25
SAE
5W-CD
Hydraulic oil tank Hydraulic oil 55
SAE 10W-CD
3.25 -- 3.5 ton 90

ASTM D975 No. 2
Compact truck Diesel fuel
Fuel tank
3.5 -- 5 ton (*1) ASTM
D975 No. 1 100
Standard truck
Brake reservoir tank Brake fluid SAE 70R-1, SAE 70R-3, DOT3 0.15
Greasing points Lithium

NLG1 No.2
grease
Cooling system Coolant Add antifreeze 16
*1. Do not use fuel containing kerosene.
a Use CD or upper grade oil.

a Be sure to use genuine oil for Komatsu Forklifts
(Komatsu Forklift dealers provide oil, grease, and antifreeze).
CX-Series 20-35
TESTING AND ADJUSTING LUBRICATING TABLE
LUBRICATING TABLE
LUBRICATING PARTS AND INSPECTION AND MAINTENANCE CYCLES
Notes Symbol. Type of fluid

E : Check, then add if necessary.
Q : Replace or add oil/grease. Gasoline engine oil
T : Number of lubrication parts. EO
Diesel engine oil
MO Engine oil
GO Gear oil
HO Hydraulic oil
BF Brake fluid
G Grease
20-36 CX-Series
30. REMOVAL AND INSTALLATION
Unit installation positions.................................. 30- 3

Overall disassembly and assembly flowchart .. 30- 4
Weight table ..................................................... 30- 5
Overall disassembly and assembly drawing .... 30- 6
Mast ................................................................. 30- 8
Lift cylinder ....................................................... 30- 9
Engine .............................................................. 30-10
Clutch or torque converter + transmission
+ drive axle.................................................. 30-17
Steering axle and power steering cylinder ....... 30-23
Wheel brake ..................................................... 30-26
Standard tightening torque............................... 30-28
How to use loctite............................................. 30-30
CX-Series 30-1
REMOVAL AND INSTALLATION UNIT INSTALLATION POSITIONS
UNIT INSTALLATION POSITIONS
1. Mast 12. Rear wheel

2. Lift cylinder 13. Rear axle
3. Tilt cylinder 14. PS cylinder
4. Control valve 15. Hydraulic pump
5. Fork 16. Muffler
6. Front wheel 17. Weight
7. Front axle 18. Radiator
8. Transmission 19. Operator seat
9. Clutch or torque converter 20. Head guard
10. Starting motor 21. Steering wheel
11. Engine 22. Clutch/brake booster and master cylinder
CX-Series 30-3
REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY FLOWCHART
OVERALL DISASSEMBLY AND ASSEMBLY FLOWCHART
Overall disassembly flow Overall assembly flow
Parking brake Parking brake

lever wire
Front wheel Torque shaft Wheel brake
Wiring
Front axle
Tilt cylinder Mast +
torque
converter
Hydraulic (clutch)
Lift cylinder +
piping
transmission
Hydraulic
Floor plate Pedal plate
valve
Pedal bracket
assembly
Completed F/R and H/L

truck (lever)
Steering wheel,
meter panel and Steering gear
control lever box
Flexible and
pressure
plates
Engine
accessory
Engine hood Shroud Radiator Engine
Muffler
Hydraulic Hydraulic
Weight
piping pump
Rear wheel Power steering Rear axle

cylinder
Head guard Frame
30-4 CX-Series
REMOVAL AND INSTALLATION WEIGHT TABLE
WEIGHT TABLE
Unit: kg
Model FG(D) FG(D) FG(D) FG(D)
35ZT 40ZT 40T 45T FD50AT Remarks
Assembly
Gasoline 315 315 315 315

Engine assembly
Diesel 490 490 490 490 490
Clutch assembly 55 55 55 55 Including the clutch case
Toque converter assembly 80 80 80 80 80
Clutch type 240 240 240 240 240

Transmission
assembly Including the differential
Torque con- 295 295 295 300 300
verter type
(255)
Front (255) 265 265 265 265
Axle
Rear 160 160 160 160 160
(55)
Front (55) 60 75 75 75 Including the rim
Wheel
Rear 40 40 40 40 40 Including the rim and the
PS cylinder
Head guard 135 135 135 135 135
Gasoline 1,800 2,120 2,470 2,780 -

Counterweight
Diesel 1,755 2,075 2,470 2,780 2,780
For one piece

Lift cylinder assembly 40 40 40 45 45 (lifting height = 3.0 m)
Tilt cylinder assembly 20 20 20 20 20 For one piece
PS cylinder assembly 20 20 20 20 20
Gasoline 9 8 8 8 8
Hydraulic pump
Diesel 14 9 9 9 9
Hydraulic control valve 20 20 20 20 20 2CV
Steering gear box 10 10 10 10 10
(675) (675) Lifting height = 3.0 m

Mast assembly (675) 685 685 900 900 Excluding the fork car-
riage and the fork
Including the backrest and
Fork carriage assembly 220 220 220 245 330 excluding the fork
FG, D33T – 45T :
Fork assembly (For one piece) 90 90 100 100 115 L = 1,070
FD50AT : L = 1,220
a Values in parentheses refer to the Z specifications.
CX-Series 30-5
REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY DRAWING
OVERALL DISASSEMBLY AND ASSEMBLY DRAWING
30-6 CX-Series
REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY DRAWING
CX-Series 30-7
REMOVAL AND INSTALLATION MAST
MAST
REMOVAL
1. Put blocks under front and rear tires.
2. Lift the fork carriage with crane so that hydraulic

piping can be removed.
3. Remove forks.
4. Put block under the fork carriage.
5. Operate work equipment control levers several

times to release remaining pressure in hydraulic
piping, then remove piping.
a After removing the piping, fit a blind plug immedi-
ately to prevent the hydraulic oil from flowing out
and to prevent dirt or dust from getting in.
6. Raise the fork carriage slightly with crane, and re-

move block.
7. Lower the fork carriage.
8. Fit crane to mast.
9. Remove tilt pin.
10. Remove the cap bolt from the front axle with the
mast tilted slightly forward from the vertical posi-
tion.
Note: If the mast cap is removed with the mast
tilted back, there is danger that the mast
may fall over.
11. Lift the mast (to the extent that the mast support
comes off from the axle) and move the mast to-
ward the truck front to remove it.
Note: When carrying the removed mast hori-
zontally, fix the lower stay and the fork
carriage by the annealing wire with
k Put blocks under the bottom of the mast and

twisted.
lay the mast assembly horizontal so that the

fork carriage is at the top.
a Carry out installation in the reverse order to re-

moval.
30-8 CX-Series
REMOVAL AND INSTALLATION LIFT CYLINDER
LIFT CYLINDER
REMOVAL
1. Perpendicularly put the mast.
2. Remove the stopper bolt.
3. Lift the mast using a crane.
4. Engage a block under the inner mast.
5. Remove the cylinder clamp.
6. Move the operation lever of the work equipment

several times to remove the pressure remaining
in the piping and remove it.
a After removing the piping, immediately put the
blind plug to prevent hydraulic oil from flowing out
or dirt from entering.
7. Lift and remove the cylinder using a sling belt.
INSTALLATION
Synchronizing of the mast
1. Raise the mast to the maximum lifting height.
2. Check for the play on both sides.
3. Adjust with shims so that the right and left cylin-

ders are synchronized with each other at the
highest position.
Angled to left Insert shims into left cylinder

Angled to right Insert shims into right cylinder
CX-Series 30-9
REMOVAL AND INSTALLATION ENGINE
ENGINE
REMOVAL
1. Head guard (ceiling), hood (remove the steer-
ing wheel lift interlocking cable first), sub-
hood, counter weight, floor plate, step and
stay
k Be sure to put the fork and attachment on
the ground or remove them, or a hazard will
occur
the truck falls if the counter weight is removed
while the mast and attachment are lifted.
2. Wiring and battery (remove the battery first)

1) Truck having TB42
30-10 CX-Series
Steering wheel and attachment (for reference: Do not remove them)
2) Truck having S6D102E
CX-Series 30-11
3. Axle wire
Remove the axle wire.
4. Pipings (hydraulic and torque converter) and hoses (radiator, air cleaner and fuel)
• Gasoline engine truck (clutch having TB42)
• Diesel engine truck (clutch having S6D102E)
30-12 CX-Series
5. Muffler, exhaust pipe and hydraulic pipe joint S6D102E
6. Pedal assembly
Various hoses and pipes for the flow divider, the
brake valve, the clutch valve and the release cyl-
inder.
7. (Torque converter truck)

Remove the flexible plate mounting bolt.
(Clutch truck)
Mount and tighten the pressure plate set bolt to
release the clutch.
a Conduct operation written above after drain-
ing oil from the clutch case.
TB42
8. Engine
1) Engage a wooden block under the transmis-
sion case.
2) Lift the engine using a crane and keep it at
that position.
3) Remove the clutch case mounting bolt (clutch
truck) or the torque converter case mounting
bolt (Torque converter truck).
Flexible plate (Torque converter truck)
TORQFLOW transmission Clutch truck
CX-Series 30-13
INSTALLATION
Install parts in the opposite procedure from removal
by paying attention to the following points.
1. Tightening the engine mounting bolt

For the shim in the figure on the right, adjust the
clearance of the mount on the frame side by using
either left or right side.
20 Nm {2 kgf•m}
2. Tightening the clutch case mounting bolt

(clutch truck) or the torque converter case
mounting bolt (TORQFLOW truck)
59 – 74 Nm {6 – 7.5 kgf•m}
Note: The figure on the right shows the torque
converter truck specifications.
Flexible plate (torque converter truck)

3. Tightening the pressure plate mounting bolt
(clutch truck) or the flexible plate mounting
bolt (torque converter truck)
59 – 74 Nm {6 – 7.5 kgf•m}
a Refer to the section on CLUTCH REPLACE-
MENT for the pressure plate mounting bolt.
30-14 CX-Series
4. Pedal assembly and flow divider S6D102E

Install each hose and pipe for the clutch valve and
the release cylinder.
5. Hydraulic pump joint

Install the muffler, the exhaust pipe, etc.
6. Piping (hydraulic and torque converter)

Install the hoses (radiator, air cleaner and fuel),
etc.
7. Install the axle wire.
S6D102E
TB42
S6D102E S6D102E
CX-Series 30-15
8. Install the wiring and the battery.

k Properly clamp and install the wiring so that
no short-circuiting will occur at a corner of
equipment or parts due to vibration. Other-
wise, burning may occur due to short-cir-
cuiting.
9. Install the floor stay, the floor plate, the hood and
the steering wheel lift interlocking cable.
10. Install the counter weight and head guard.

Tightening counter weight mounting bolt
490 Nm {50 kgf•m}
30-16 CX-Series
REMOVAL AND INSTALLATION CLUTCH OR TORQUE CONVERTER + TRANSMISSION + DRIVE AXLE
CLUTCH OR TORQUE CONVERTER + TRANSMISSION + DRIVE

AXLE
REMOVAL
1. Head guard (ceiling), hood (steering wheel
lift) and counter weight
a Lift the front of the frame when removing the

clutch or torque converter, the transmission and
the drive axle. At this time, remove the counter
weight to prevent the truck from falling.
k Be sure to put the fork and attachment on

the ground, or a hazard will occur
the truck falls if the counter weight is removed
while the mast and attachment are lifted
2. Mast
a Refer to the section on the MAST.
S6D102E
3. Floor plate, step and stay
Remove the axle cable (1).
CX-Series 30-17
4. Torque converter cooler piping Torque converter cooler piping

Clutch/brake booster piping
Clutch cooling hose
Clutch truck
5. Forward/reverse lever, high/low speed lever
(clutch truck)
Electromagnetic valve (2) wiring (torque con-
verter truck)
6. Brake master cylinder

Brake piping, clutch master cylinder
Clutch piping
Parking brake lever
0.15 l (brake fluid)
7. Pedal assembly
30-18 CX-Series
8. Wiring
9. Torque converter truck

Remove the flexible plate mounting bolt. Flexible plate (Torque converter truck)
Clutch truck
Install and tighten the pressure plate mounting
bolt to release the clutch (the pressure plate re-
mains attached to the engine if the power train is
cut off with this state).
a When removing the pressure plate, refer to

the section on CLUTCH REPLACEMENT.
a Drain oil from the clutch case before opera-
tion.
CX-Series 30-19
10. Clutch or torque converter + transmission +

drive axle
1) Lift the frame approximately by 150 to 200
mm to engage a block under it.
2) Lift the engine using a crane and keep it at
that position.
3) Place a cart as shown in the figure on the
right to support the three components.
4) Remove the clutch case mounting bolt (clutch
truck) or the torque converter case mounting
bolt (Torque converter truck).
5) Remove the support mounting bolt from the
front shaft and pull the three components on
the cart forward.
30-20 CX-Series
INSTALLATION
1. Tightening the clutch case mounting bolt

(Clutch truck)
Tightening the torque converter case mount-
ing bolt
(Torque converter truck)
59 – 74 Nm {6 – 7.5 kgf•m}
Flexible plate (Torque converter truck)

2. Tightening the pressure plate mounting bolt
(Clutch truck)
Tightening the flexible plate mounting bolt
59 – 74 Nm {6 – 7.5 kgf•m}
a For the clutch truck, it is recommended to install

the clutch disk and the pressure plate on the en-
gine before combining the engine and the power
train.
When installing the clutch disk and the pressure
plate, however, use a disk centering jig (guide
bar). Pressure plate (clutch truck)
CX-Series 30-21
3. Drive axle support Drive axle support

Support mounting bolts and nuts
662 – 829 Nm {67.5 – 84.5 kgf•m}
a For the upper three pairs, bolts are to be in-
serted from the inside of the frame and the
nuts come outside.
For the lowest pair, the nut comes inside the
frame and the bolt outside.
4. Pedal assembly
Brake piping
a Bleeding air from the brake

Refer to the section on BLEEDING AIR.
a Adjusting pedal
Refer to the section on ADJUSTING PEDAL.
5. Counter weight
Counter weight mounting bolt
490 Nm {50 kgf•m}
6. Mast
Mast cap mounting bolt
342 – 427 Nm {35 – 43.5 kgf•m}
30-22 CX-Series
REMOVAL AND INSTALLATION STEERING AXLE AND POWER STEERING CYLINDER
STEERING AXLE AND POWER STEERING CYLINDER

REMOVAL
1. Counter weight
1) Lift the rear side of the frame using a crane
and engage a wooden block under the left
and right frames.
2) Slightly lift the counter weight using a crane to
remove the mounting bolt and the counter
weight.
2. PS cylinder and hydraulic hose

Remove the hydraulic hose.
a Put the blind plugs on the hydraulic hose and
the cylinder oil ports to prevent oil from flow-
ing out or dirt from entering.
3. Bell crank ball joint

Remove the ball joint.
4. Steering axle
1) Support the steering axle by a cart.
2) Remove the two axle support bolts on the
rear side to pull the steering axle toward the
truck tail. Lower the cart when the center
shaft is released from the front support and
completely pull the axle toward the truck tail in
a manner to prevent it from coming in contact
with the frame.
5. Power steering cylinder

1) Remove the knuckle arm and the PS cylinder
and piston rod link.
2) Remove the PS cylinder mounting bolt.
3) Pull the PS cylinder out toward either left or
right of the steering axle.
CX-Series 30-23
INSTALLATION
1. Tightening the steering axle support bolt (1)

490 – 608 Nm {50 – 62 kgf•m}
a Adjust clearance a within 0.5 mm using shims.
a Install the bushing so that the holes face up-
ward.
2. Steering linkage
a Set the three positions marked (*1) at the
specified dimensions (see the figure below).
1) Set the rear tires and pitman arm in the
straight-travel state.
2) Adjust the amount that ball joint (2) is to be
screwed so that the bell crank steering angle
becomes equal to the specified dimensions.
a Completely tighten the locknut (3).
a Completely bend the cotter pin.
30-24 CX-Series
3. Tightening the power steering cylinder mount- Steering axle (view from the right)
ing bolt
490 – 607 Nm {50 – 62 kgf•m}
1. PS cylinder
2. Oil port
3. 4 cylinder mounting bolts
4. Bell crank
5. Link
4. Tightening the counter weight mounting bolt

490 Nm {50 kgf•m}
Apply molybdenum
a Apply molybdenum disulfide before tighten-
ing the bolt.
CX-Series 30-25
REMOVAL AND INSTALLATION WHEEL BRAKE
WHEEL BRAKE
REMOVAL
1. Front wheel, torque shaft
1) Place blocks to the rear wheel.
2) Insert blocks under the frame to lift the front
wheel.
3) Apply parking brake.
4) Remove hub nut (1) and then the front wheel.

5) Remove bolt (2), nut (3) and torque shaft (4).
6) Release parking brake.
2. Hub
1) Remove bolt (5).
2) Remove locknut (6) using a box having width
across flats of 80 mm to remove plate (7).
3) Remove the hub not to be twisted upside
down.
30-26 CX-Series
REMOVAL AND INSTALLATION WHEEL BRAKE
INSTALLATION
Installing the back plate (after removed)
Before installing the brake, the shaft tube and the
back plate (2) are placed at inside-low.
Install the support (3) on the shaft tube and the back
plate (2) in this order and tighten them.
1. Standard truck and FD50AT Back plate

Apply Loctite to mounting bolt (1) and tighten it. (standard truck and FD50AT, left side)
245 – 309 Nm {25 – 31.5 kgf•m}
Loctite #271
2. Compact truck Back plate

Apply Loctite to mounting bolt (1) and tighten it. (compact truck and FD50AT, right side)
157 – 196 Nm {16 – 20 kgf•m}
Loctite #271
CX-Series 30-27
REMOVAL AND INSTALLATION STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

BOLT
For unspecified bolts and nuts, use the torques spec-
ified in this list.
Select a proper torque corresponding to the width
across flats (b) of bolts and nuts.
When replacing bolts and nuts, always use genuine
Komatsu Forklift parts the same size as the previous
ones.
Thread diameter Width across Tightening torque (Nm {kgf•m})

of bolt (a) flat (b)
(mm) (mm) Target value Range
6 10 13 {1.35} 12 – 15 {1.2 – 1.5}
8 13 31 {3.2} 27 – 34 {2.8 – 3.5}
10 17 66 {6.7} 59 – 74 {6.0 – 7.5}
12 19 113 {11.5} 98 – 123 {10.0 – 12.5}
14 22 177 {18.0} 157 – 196 {16.0 – 20.0}
16 24 279 {28.5} 245 – 309 {25.0 – 31.5}
18 27 382 {39.0} 343 – 427 {35.0 – 43.5}
20 30 549 {56.0} 490 – 608 {50.0 – 62.0}
22 32 745 {76.0} 662 – 829 {67.0 – 84.5}
24 36 927 {94.5} 824 – 1,030 {84.0 – 105.0}
27 41 1,324 {135.0} 1,177 – 1,471 {120.0 – 150.0}
30 46 1,716 {175.0} 1,520 – 1,912 {155.0 – 195.0}
33 50 2,206 {225.0} 1,961 – 2,452 {200.0 – 250.0}
36 55 2,746 {280.0} 2,452 – 3,040 {250.0 – 310.0}
39 60 3,285 {335.0} 2,893 – 3,628 {295.0 – 370.0}
30-28 CX-Series
REMOVAL AND INSTALLATION STANDARD TIGHTENING TORQUE
ELBOWS, NIPPLES AND UNIONS
Width across flats B mm 22 30 36
Width D mm 19 22 30
Tightening torque Nm {kgf•m} 29.4 – 39.2 {3 – 4} 78.5 – 103 {8 – 10.5} 117.7 – 161.8 {12 – 16.5}
Port size inch 3/4-16UNF 7/8-14UNF —
Tightening torque Nm {kgf•m} 68.6 – 73.6 {7 – 7.5} 78.5 – 83.3 {8 – 8.5} —
Union Elbow
HIGH-PRESSURE RUBBER HOSES, PIPES AND SLEEVE NUTS
Width across flats B mm 19 24 27 32 36
Bore A mm 14 18 22 24 30
19.6 – 29.4 23.5 – 68.6 58.8 – 98.1 107.9 – 166.7 147– 206
Tightening torque Nm {kgf•m} {2 – 3} {3 – 7} {6 – 10} {11 – 17} {15–21}
CX-Series 30-29
REMOVAL AND INSTALLATION HOW TO USE LOCTITE
HOW TO USE LOCTITE 4. Assembly

After applying LOCTITE, tighten the screw or fit
the shaft to the hole as usual. (When using LOC-
1. PROCEDURE FOR USING LOCTITE
TITE for structures or LOCTITE of instant glue
type, press the mating parts lightly (about 49 kPa
Male side {0.5 kgf/cm2}).
Degreasing Air drying
2. REMOVAL OF PARTS
Female
side
When screws and shafts are secured with LOC-
TITE, they usually can be removed with common
tools such as spanners, wrenches, pulley pull-
Applying
Leaving Assembly ers, etc. If LOCTITE is so strong that a part may
LOCTITE
be broken when it is removed, heat it (to 200 –
250°C) with a soldering iron, gas torch, etc., and
1. Degreasing and cleaning you can remove it easily. It is generally difficult
(a) Clean the parts in trichloroethylene, ace- to dissolve LOCTITE in chemical solutions.
tone, ether, alkaline solution, etc. which are
highly volatile. 3. WHEN ASSEMBLING AGAIN
(b) Degrease the parts as perfectly as possible. (a) If a LOCTITE film on threads is broken, it is
(c) Since gasoline, light oil, kerosene, etc. are left as white powder on the threads. In this
not highly volatile, they are not recommend- case, you can apply LOCTITE again to the
ed. If it is obliged to use them, dry them threads without removing the white powder.
completely. (b) If shafts or flanges secured with LOCTITE
(d) If the mating parts are made of thermoset- are disconnected, LOCTITE remaining on
ting resin, treat them with LOQUICK PRIM- them may need to be removed to maintain
ER after degreasing them. dimensional accuracy. You can remove the
remaining LOCTITE easily, however, with a
2. Air drying wire brush, etc.
(a) Wait until the cleaning fluid dries out. (c) If plates secured with LOCTITE need to be
(b) If the parts are treated with LOQUICK PRIM- assembled again after they are separated,
ER, do not wipe them but dry them in air for be sure to remove all the hardened LOC-
5 – 10 minutes. (If LOCTITE is used before TITE and roughen the mating surfaces with
LOQUICK PRIMER dries out, its effect is sandpaper.
lowered.)
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads
or the shaft and hole to be fitted by amount to fill
the clearance between them by one of the fol-
lowing methods.
• Applying directly from LOCTITE container
nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving
pan.)
• Sponge
• Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
30-30 CX-Series
40. DISASSEMBLY AND ASSEMBLY
Main clutch ....................................................... 40- 2

Clutch booster and master cylinder.................. 40- 7
Clutch release cylinder..................................... 40- 9
Transmission.................................................... 40-14
Torque coverter................................................ 40-34
TORQFLOW transmission ............................... 40-44
Transmission control valve............................... 40-70
Differential ........................................................ 40-74
Drive axle ......................................................... 40-82
Wheel brake ..................................................... 40-84
Brake and clutch boosters................................ 40-87
Rear axle........................................................ 40-114
Steering gear box........................................... 40-119
Conbination switch ......................................... 40-130
Hydraulic pump .............................................. 40-137
Flow divider .................................................... 40-141
Control valve .................................................. 40-144
Lift cylinder ..................................................... 40-146
Tilt cylinder (6°/12°)........................................ 40-150
Power steering cylinder.................................. 40-153
Mast ............................................................... 40-155
Fork carriage .................................................. 40-158
Special tool list ............................................... 40-161
CX-Series 40-1
DISASSEMBLY AND ASSEMBLY MAIN CLUTCH
MAIN CLUTCH
DISASSEMBLY AND ASSEMBLY
40-2 CX-Series
CX-Series 40-3
TESTING AND INSPECTION
FG, D35ZT – 45T-7
40-4 CX-Series
Unit: mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
A Thickness of clutch disc (both faces) 8.1 7.3 Replace
B Diameter of drive shaft tip 19.967 – 19.98 19.85 Correct hard chrome plating
Play of spline in rotating direction — 0.5

C Replace
Face runout of outside circumference — 0.7
Height of release lever 63 Variation between Replace release bearing (1) if

(when released) levers: Max. 0.7 there is any seizure, damage or
wear.
Distance of movement of release lever 13 —
Wear-in amount of release lever 6.5 5.5
E Pressure plate Damage, stepped wear of friction Replace

surface
Replace pressure plate assem-

F Coil spring Deformation, deterioration bly
Lever plate thickness a
G 6 4.9 Replace
Method of measuring remaining thickness of clutch disc

• Measure with calipers at both the engine end and pressure plate end.
(See diagram on right.)
Cluch disc thickness b: Min 0.3 mm
a Take the smallest depth to the head of the rivet as the standard when judging.
a Stopper bolt (for removing and installing clutch): Be sure to remove it after as-
sembling the clutch.
CX-Series 40-5
DRAWING FOR ASSEMBLY
40-6 CX-Series
DISASSEMBLY AND ASSEMBLY CLUTCH BOOSTER AND MASTER CYLINDER
CLUTCH BOOSTER AND MASTER CYLINDER
CX-Series 40-7
DISASSEMBLY AND ASSEMBLY CLUTCH BOOSTER AND MASTER CYLINDER
Unit: mm
No. Check item Standard value Repair limit Remedy
Basic Standard
dimensions Shaft Hole clearance Limit clearance
1 Clearance between cylin-
der and piston
– 0.020 + 0.052 0.020 –
25.4 – 0.053 0 0.105 0.150
2 Clearance between cylin- 22.2 – 0.020 + 0.052 0.020 – 0.150

der and piston – 0.053 0 0.105
Installed load Replace

Free length Installed length N{kgf} Free length
3 Deterioration of spring
37.5 33.5 69.6{7.1} 36.0
4 Deterioration of spring 24.1 19.5 39.2{4.0} 23.0
5 Deterioration of spring 12.2 10.5 30.4{3.1} 11.5
6 Deterioration of spring 88.6 56 71.6{7.3} 80
7 Tightening torque 21 – 30Nm{2.1 – 3.1kgf•m} —
8 Tightening torque 7.8 – 11.7Nm{0.8 – 1.2kgf•m} —

Retighten
9 Tightening torque 2.5 – 3.4Nm{25 – 35kgf•m} —
20 Tightening torque 27.4 – 34.3Nm{2.8 – 3.5kgf•m} —
40-8 CX-Series
DISASSEMBLY AND ASSEMBLY CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER

COMPONENT PARTS
No. Name Q'ty

1 Cylinder 1
2 Piston 1
3 S cup 1
4 R cup 1
5 Spring 1
6 Boot 1
7 Push rod 1
8 Nut 2
9 Yoke 1
10 Bleeder valve 1
11 Bleeder cap 1
12 Cap 1
20 Piston assembly 1
CX-Series 40-9
DISASSEMBLY
1. Remove boot from cylinder.
2. Take out piston assembly from cylinder.
Precautions
• Be careful not to damage the cylinder, piston, or cup.
• When carrying out disassembly, make sure that you understand the structure of the cylinder and lay
the disassembled parts out in order.
• Do not disassemble the piston assembly.
• Do not push the outside wall of the cylinder with a vice.
• If it is difficult to take out the piston, put a block against the end face of the cylinder, then pump in
low pressure air gradually from the discharge port.
COMPONENT PARTS
No. Name Q'ty
1 Cylinder 1
2 Piston 1
3 S cup 1
4 R cup 1
5 Spring 1
6 Boot 1
7 Push rod 1
8 Nut 2
9 Yoke 1
10 Bleeder valve 1
11 Bleeder cap 1
20 Piston assembly 1
40-10 CX-Series
Part name Check item Remedy
Scratches, uneven wear, corrosion of • For small scratches, remove with sandpaper
Cylinder inside surface • If the scratch will have an adverse effect on the cup,
replace the whole cylinder assembly.
• Small scratches, remove with oilstone

Scratches, uneven wear, corrosion of slid- • If the scratch will have an adverse effect on the inside
ing portion surface of the cylinder and cup, replace the whole piston
Piston assembly
Clearance between and cylinder piston • Replace if the clearance is greater than the limit
Clearance limit: 0.15 mm
Scratches on lip • Even if the scratches are small, replace the whole piston
A assembly
Wear of base B • If worn harmfully, replace piston assembly.
Cup
• If there is any abnormal deterioration, wear, or swelling,

Wear, swelling replace the whole piston assembly
• If the value is below the service limit, replace the whole

piston assembly
Interference Wear limit: 0.4 mm
Note: The cup is a specified periodic replacement part
Generally speaking, it is safer to replace each
time disassembly is carried out.
Scratches, wear, inclination • Replace if there is marked damage

Spring
Free length • Replace if it is less than the service limit
Service limit: 38 mm
Bleeder valve Scratches, deformation of seat surface • Replace if there is marked damage or deformation
Bleeder cap Cracks, deterioration • Replace if there are cracks or marked deterioration
Push rod Curvature, deformation • Replace if there is curvature or deformation
Cracks, damage • Replace if there are cracks or damage

Boot
• Replace if there is no interference or extremely little
Interference for cylinder, rod interference
Yoke Deformation, wear • Replace if there is marked deformation or wear
CX-Series 40-11
MAINTENANCE STANDARD
Unit: mm
Check item Standard value Limit Remedy
1 Clearance between cylinder and piston 0.020 – 0.105 0.15 Replace

(cylinder assembly)
Pressure side: Approx. 2 Replace

2 Interference of cup Secondary side: Approx. 0.6 mm 0.4 (piston assembly)
3 Free length of spring 43 38 Replace
4 Tightening torque for yoke and locknut 7.8 – 11.8 Nm — —

{80 – 120 kgf•cm}
5 Tightening torque for bleeder valve 6.8 – 8.8 Nm — —

{70 – 90 kgf•cm}
ASSEMBLY
1. Use alcohol or brake fluid to wash all parts that are to be reused.
a When cleaning the rubber parts such as the cup in alcohol, do not soak them in alcohol for more than 30
seconds.
2. Coat inside surface of cylinder and outside circumference of piston evenly with rubber grease or brake fluid.
3. Assemble spring to piston assembly, then insert in cylinder.
4. Insert push rod, then assemble boot, nut, and yoke in turn to push rod.
7.8 – 11.7 Nm {80 – 120 kgf•cm}
Precautions
• Do not use any fluid apart from alcohol or brake fluid to wash the parts.
In particular, never use mineral oil (petroleum, gasoline, etc.)
(If mineral oil gets on rubber parts, they will swell and become unusable.)
• After washing the parts, keep them in a clean place to prevent dust or dirt from sticking to them.
• Be careful not to let dirt or dust get in, and be careful not to damage the damage the cylinder, piston,
or cup.
40-12 CX-Series
ASSEMBLY DRAWING
SPECIFICATIONS
Part Name 22.2 C/0 cylinder assembly
Fluid used — Brake fluid
Cylinder diameter A mm 22.2
Max. stroke B mm 35
Max. pressure MPa {kgf/cm2} 98 {100}
CX-Series 40-13
DISASSEMBLY AND ASSEMBLY TRANSMISSION
TRANSMISSION
DISASSEMBLY DRAWING
Synchronous joint gear assembly components

No. Component No. Component
1 Gear 5 Balk ring
2 Gear (shift gear) 6 Synchronizer cone
3 Insert 7 Inner ring
4 Spring
40-14 CX-Series
DISASSEMBLY
1. Clutch case
1) Remove clutch release cylinder (1).
2) Remove neutral switch and back lamp switch
(2).
3) Remove the intermediate shaft bearing cover
and the bearing.
4) Remove connecting bolts (5) of clutch case
(3) and transmission case (4), and separate
clutch case.
2. Differential
1) Remove bolt (6), then remove cap (7).
2) Remove screw (8), then remove differential
(9).
3. Drive shaft
1) Remove snap ring (10) and pin (11) holding
drive shaft to input shaft.
2) Pull out drive shaft (12).
CX-Series 40-15
4. Shift lever
1) Remove bolt (13) to remove cover (14).
2) Pull out snap pin (15) to remove pin (16).
3) Pull shaft (17) to the outside of the case (in
the arrow direction) to remove shift lever (18).
5. Input shaft sub-assembly

Remove input shaft (22).
6. Intermediate shaft and shifter yoke sub-

assemblies
1) Remove stopper bolt (26) from yoke shaft
(21).
a When removing the shifter yoke only, the

transmission need not be disassembled. In
this case, simply remove roll pin (20) and
stopper bolt (26) from the yoke shaft to pull
shaft (21) toward the deferential.
40-16 CX-Series
2) Remove intermediate shaft sub-assembly

(23) and shifter yoke sub assemblies (19),
(20) and (21).
7. Output shaft sub-assembly

1) Remove bolt (24).
2) Remove output shaft sub-assembly (25) in-
cluding the bearing cage from the transmis-
sion case.
a Store adjustment shims a and b after binding

them so as to prevent the combination from
changing.
CX-Series 40-17
40-18 CX-Series
Unit: mm
Criteria
A1 49.93 – 49.975 49.8

Outside diameter of bushing Replace
(2nd speed and R gears)
A4 49.93 – 49.975 49.8
A
A2 54.93 – 54.975 54.8
Outside diameter of bushing
(1st speed and F gears) Replace
A3 54.93 – 54.975 54.8
B Clearance between balk ring and H, L gear (*1) 1.3 – 1.7 0.3 Replace as assembly (*1)
C Clearance between shifter yoke and sleeve 0.04 – 0.39 1.0 Replace (*2)
gear (*2)
D Clearance between balk ring and F, R gear 1.3 – 1.7 0.3 Replace as assembly (*1)
E Deterioration of spring (free length) 21 18
F Outside diameter of tip of shift lever 12.94 – 12.99 12.5
G Inside diameter of shifter yoke mount 22.0 – 22.033 22.1
Deterioration of key spring

H (abutment joint clearance) 110 95
Replace
Backlash 0.14 – 0.38 —
— Gears
Clearance in thrust direction 0.15 – 0.30 —
• Damage
— Tooth surface • Excessive wear, defective tooth
contact
• Seizure, wear
— Bearing • Abnormal noise, defective rota-
tion
Gasket Replace with new parts

— O-ring — during disassembly and
Seals assembly
*1: Dimension when balk ring is moved to outside

*2: Dimension when shifter yoke is pushed fully in either direction
CX-Series 40-19
ASSEMBLY DRAWING
1) Input shaft sub-assembly
Gear type (# of teeth) Z1 Z2
FG, D35ZT/40ZT 28 21
FG, D35T/40T/45T 28 19
2) Intermediate shaft sub-assembly
Gear type (# of teeth) Z3
FG, D35ZT/40ZT 21
FG, D35T/40T/45T 19
40-20 CX-Series
3) Output shaft sub-assembly
Classification of gear (Number of teeth) Z4
FG, D35ZT/40ZT 53
FG, D35T/40T/45T 54
Caulking and adjustment of shim

1. Caulking method of pinion shaft (*1)
• Caulk the pinion shaft with punch A so that it
will reach the round part of the bearing inner
race (at 3 places on the circumference).
2. Adjustment of shims (*2)

• Install shims (1) in the following arrangement;
Install the pieces 0.5 and 0.4 mm thick on the
B side, the piece 0.3 mm thick on the C side,
and the piece 0.25 mm thick among them.
• Tighten nut (2) to the specified torque, and
then adjust shims (1) so that the starting
torque of the pinion shaft will be 4 – 8 Nm {40
– 80 kgf•cm}.
3. Caulking method of locknut (*3)

• Caulk the locknut after setting the preload on
the pinion shaft (Adjustment of shim *2)
• Caulk at places where part D is flat for at least
2 mm.
• Caulk at 3 places like part E.
4. Adjustment of shims (*4)

Adjust the shims when installing the pinion shaft
to the transmission case.
CX-Series 40-21
ASSEMBLY
Carry out installation in the reverse order to removal
and observe the following points.
1. Assembly of pinion shaft assembly of output

shaft
1) Set the shim thickness of the bearing cage to
1.3 mm and tighten locknut (1) to 313.8 –
441.3 Nm {32 – 45 kgf•m}.
a Use the thickness of the removed shims
as standard.
• Shim thickness: 0.25, 0.3, 0.4, 0.5 mm

(1) Install shims (2) 0.4 and 0.5 mm thick on
the bearing side.
(2) Install shim (3) 0.25 mm thick between
shims (2) and (4).
(3) Install shim (4) 0.3 mm thick on the spac-
er side.
2) When locknut (1) is tightened, if the preload

on the pinion shaft is 3.9 – 7.8 Nm {40 – 80
kgf•cm}, the pinion shaft assembly is set cor-
rectly.
3) Jig to measure preload

Use special tools 3EC-97-99930 (for the
clutch model) and 3EC-99940 (for the torque
converter model) and a torque wrench.
4) Locknut
Use a new locknut.
• Caulk at places where part D is flat for at
least 2 mm.
• Caulk at 3 places like part E.
40-22 CX-Series
5) When the pinion shaft bearing (at the end) is

replaced, caulk the pinion shaft with punch A
so that it will be over the bearing inner race (at
3 places on the circumference).
2. Adjusting the pinion shaft shim

1) Calculate the shim first.
2) Check the tooth contact after inserting the
shim obtained from the above calculation.
3) If the contact is wrong, adjust the shim.
4) Adjust the shim so that the tooth contact as
shown in the figure on the right can be ob-
tained.
5) Refer to the following pages for how to adjust
the shim and check the tooth contact.
Procedure for adjusting the shim
Calculate the shim.
Assemble parts using the

shim obtained above.
Adjust the ring gear backlash

and pre-load.
Correct
Check the tooth contact. O.K.
Wrong
Adjust the shim.
a Be sure to replace the bevel gear and the pinion shaft at the same time.
CX-Series 40-23

Installing the pinion shaft assembly
1) Calculate the thickness of the shim (1) be-
tween the bearing cage and the transmission
using the expression below to determine the
pinion shaft protrusion (standard shim = 15
mm (operating range 0.6 – 2.4 mm)).
a+b+c+d
Shim (1) thickness T = 0.30 + —————
100
a and b: Numbers on the pinion shaft end.
c: Calculated using the expression be-

low after measuring length L.
c = (L – 115.28) × 100
d: Number stamped on the pinion shaft

installing face of the transmission
case.
Example:
a = 20
b = 10
L = 115.63 (measurement)
d = 30
c = (115.63 – 115.28) × 100 = 35
20+10+35+30
Shim thickness T = 0.30 + ———————
100
95
= 0.30 + ——
100
= 1.25 (mm)
40-24 CX-Series
2) Install the pinion shaft assembly (3) on the

case.
Apply Loctite #271 to the screw on the hole
side of the mounting bolt.
98 – 123 Nm {10 – 12.5 kgf•m}
4. Intermediate shaft sub-assembly

• Assemble the intermediate shaft sub-assem-
bly (4) having the H-L gear assemblies with
the transmission case.
• Install intermediate shaft sub-assembly (5) to

which the F-R gear assembly is installed.
CX-Series 40-25

Assemble the input shaft sub-assembly (6) with
the transmission case.
6. Shifter yoke
1) Insert an O-ring to shifter yoke shaft (21) from
the differential side to the transmission case
and keep it at the position where the end
comes out inside the case.
2) Insert yoke (19) to the slide gear on the RF
side of the intermediate shaft and spring
(19-1) and ball (19-2) to the yoke to insert
shaft (21).
3) Insert yoke (19) to the 1st and 2nd side and
the spring and the ball to the yoke to insert
shaft (21).
4) After the shaft has completely been inserted
(both R/F and [1]/[2] sides), mount stopper
bolt (26) and firmly tighten it.
5) Install roll pin (20).
7. Shift lever
1) Insert the end of shift lever (18) to yoke (19).
2) Put a seal on shaft (17), apply grease to it, in-
stall it from the outside of the case and insert
it to the hole of lever (18).
3) Insert pin (16) to the lever and the shaft, put
the washer on the pin and set it using spring
pin (15).
40-26 CX-Series
8. Clutch case
1) Clutch case
Set the gasket on the transmission case to
mount clutch case (3).
2) Intermediate shaft bearing
Assemble the bearing with the intermediate
shaft, put the plate and tighten it using a bolt.
Loctite #271 (screw)
27.5 – 34.3 Nm {2.8 – 3.5 kgf•m}
3) Intermediate shaft cover

Set an O-ring and mount cover (3-1).
58.8 – 73.5 Nm {6 – 7.5 kgf•m}
4) Flange
Put an oil seal in flange (3-2) (apply grease to
the lip), set an O-ring and assemble it with the
clutch case.
58.8 – 73.5 Nm {6 – 7.5 kgf•m}
5) Clutch shaft
Insert clutch shaft (12) from the flange to the
transmission input shaft, mount pin (11) and
set it using snap ring (10).
a Before mounting cover (14) (after mounting

intermediate shaft cover (3-1)), make sure
that one of the sleep gears (shift gears)
marked (*1) smoothly rotates when the other
is fixed and vice versa with the gear in the
neutral state.
Check again if any protrusion or drag turning
is detected to resolve the cause.
CX-Series 40-27
SECTIONAL VIEW OF CLUTCH AND TRANSMISSION
40-28 CX-Series
DIFFERENTIAL ASSEMBLY
1. Mount the differential assembly and tighten the
cap mounting bolt.
Loctite #271 (screw hole side)
490 – 608 Nm {50 – 62 kgf•m}
a Bevel and pinion gear backlash:

0.15 to 0.23 mm
2. Adjusting the backlash

Adjust the backlash by repeatedly releasing one
of the adjusting screw by one notch and tighten-
ing the other also by one notch. At this time,
check the dial gauge A indicator and gradually
move the differential case.
3. Differential side bearing pre-load

Adjust the pre-load to 21.56 to 33.32 Nm {220 to
340 kgf•cm} when setting the pinion shaft and the
ring gear by tightening the adjusting screw.
Special tool B 34C-97-99150
a The pre-load refers to those combining the

bevel gear and the pinion shaft and other
gears are excluded.
CX-Series 40-29
4. Adjustment of runout of back side of bevel

gear
1) Install dial gauge A, and then rotate bevel
gear (2) and stop it at a place where the
runout is large.
2) Tighten bolt (3) until it reaches bevel gear (2).

3) Return bolt (3) by 60° and fix it with locknut
(4). (Clearance: 0.2 – 0.3 mm)
Apply Loctite #271 all over the threads of
locknut (4).
a The runout indicated by dial gauge A
must be 0.1 mm or less.
40-30 CX-Series
CHECKING THE TOOTH CONTACT Foward side

1) Coat the bevel gear tooth surface with small
amount of red lead.
2) Turn the bevel gear forward and reverse several
times.
3) Check appropriateness of the tooth contact refer-
encing the pattern left on the tooth surface.
4) If correct tooth contact is not present, check and
adjust the following points:
• Shims used for the pinion shaft.
• Backlash of the bevel gear.
• Bearing pre-load on the bevel gear side.
Reverse side
• Appropriate tooth contact (no-load)
You can be sure that an appropriate tooth contact
is obtained if the pattern is situated at center of
the tooth surface, shares 40 to 70% of the overall
tooth length and contact becomes weaker at both
ends of the pattern.
a Tooth contact for both the forward and reverse

move must be correctly adjusted. If, however,
that is not practicable, the forward side alone
should be adjusted as specified.
Radial runout of the bevel gear: Max. 0.1 mm
CX-Series 40-31
CORRECTING THE TOOTH CONTACT

• Increase shims used for the pinion shaft to in-
crease protrusion of the pinion (in direction A).
Then, move the bevel gear away from the pinion
(in direction B) to adjust the backlash.
• Reduce shims used for the pinion shaft to de-

crease projection of the pinion (in direction A).
Then, move the bevel gear toward the pinion (in
direction B) to adjust the backlash.

crease projection of the pinion (in direction A).
Then, move the bevel gear toward the pinion (in
direction B) to adjust the backlash.

crease protrusion of the pinion (in direction A).
Then, move the bevel gear away from the pinion
40-32 CX-Series
SECTIONAL VIEW OF DIFFERENTIAL (CLUTCH TYPE)
CX-Series 40-33
DISASSEMBLY AND ASSEMBLY TORQUE COVERTER
TORQUE COVERTER
CONPONENT PARTS
No. Name Q’ty No. Name Q’ty

1 Torque converter circuit 1 4 Turbine shaft 1
1-2 Input plate assembly 1 5 Seal ring 1
1-3 Small hexagon bolt 6 6 Ball bearing 1
1-4 Washer 6 7 Snap ring 1
2 Gear pump assembly 1 8 Snap ring 1
2-1 Case assembly 1 9 Piston valve 2
2-2 Drive gear 1 10 Pressure spring 1
2-3 Driven gear 1 11 Plug 2
2-4 Oil seal 1 12 Gasket 2
2-5 Countersunk head screw 1 13 Hexagon bolt 5
2-6 Stator support 1 14 Gasket 5
2-7 O-ring 1 15 Hexagon socket head plug PT 1/4 4
3 Housing 1 16 Hexagon socket head plug PT 3/4 2
40-34 CX-Series

Unit : mm
Criteria
No. Check item Remedy Sym-
bol
Torque converter inlet valve

Piston and housing hole
A: Inside diameter of housing A: 14.000 – 14.018 — 3
B: Outside diameter of piston B: 13.960 – 13.970 — 9
Clearance:
Replace
1 0.030 – 0.058 0.080
piston
Torque converter inlet valve spring
C: Free length C: 103.4 —

D: Installed length D: 62.7 —
2 E: Installed load E: 75.6 N {7.71 kgf} ± 5% 68.0 N {6.93 kgf} Replace 10
Gear pump
Oil seal and torque converter impeller hub
F : Inside diameter of oil seal F: 61.3 2–4
G: Outside diameter of impeller hub G: 61.915 – 61.965 61.815 1–1
Replace
3
Bushing and torque converter impeller hub
J : Inside diameter of bushing H: 61.915 – 61.965 — 1–1
H : Outside diameter of impeller hub J : 62 – 62.030 — 2–1
Clearance:
0.035 – 0.115 0.17
Replace
a The symbols in the column at the right end of the table show the places of COMPONENT PARTS.
CX-Series 40-35
Unit : mm
Criteria
Sym-
No. Check item Remedy bol
Turbine shaft
Housing hole and seal ring groove
L : Inside diameter of housing K: 2.4 – 2.5 2.6 4
K : Width of groove L : 60.00 –60.03 60.15 3
Replace
Seal ring
M: 2.5 – 2.7 2.3 5

Replace
N: 2.35 – 2.40 2.15
40-36 CX-Series
ASSEMBLY
Carry out installation in the reverse order to removal
and observe the following points.
1. Assembly of control valve

Insert the piston, spring, etc. as they have been
installed and assemble all the parts in the reverse
order to disassembly, and then install the control
valve assembly to the transmission housing.
2. Assembly of gear pump

• Put gears (3) and (4) in case (2) and install
stator support (5) upside down in the reverse
order to disassembly.
• After tightening the flat head screws, check
that the gear rotates lightly. If the gear does
not rotate, disassemble and assemble again.
(Flat head screw) 0.98 Nm {0.1 kgf•m}
3. Installation of inlet relief valve

Insert the piston and spring and tighten the plug.
(Plug) 49 Nm {5.0 kgf•m}
4. Installation of turbine shaft

Check that the seal ring is installed securely, and
then insert the turbine shaft in the housing and in-
stall the snap ring.
5. Installation of gear pump

• Install the O-ring to the housing, taking care
not to slacken it.
a Thinly apply lithium grease to the O-ring so
that the O-ring will not be broken or cracked
when the pump is inserted.
• After checking that the O-ring is installed
without slack, insert the gear pump in the
housing slowly and vertically and tighten the
bolts.
(O-ring) Lithium grease
(Bolt) 38.2 Nm {3.9 kgf•m}
• Install the O-ring to the housing as shown in

the figure.
CX-Series 40-37
6. Installation of torque converter circuit

• Insert the torque converter circuit in the pump
in the housing.
• At this time, fill 1/3 – 1/2 of the space between
the oil seal lips with lithium grease or apply
clean hydraulic oil to the oil seal lips so that
the oil seal and bushings will not be broken or
scratched.
7. Assembly of input section

When installing the O-ring, apply lithium grease
to it.
(O-ring) Lithium grease
(Bolt) 58 – 74 Nm {5.9 – 7.5 kgf•m}
8. Assembly of torque converter assembly

Install the torque converter assembly to the trans-
mission and engine.
a Replace the removed O-rings and oil seals
with new ones.
a When installing, see the inspection items of
the MAINTENANCE STANDARD and take
care not to make an assembly trouble.
a When installing a new oil seal, apply semi-dry
gasket sealant (e.g. Three Bond No. 1211,
1104) to its periphery. Do not apply the gas-
ket sealant to the lips and sliding parts
against the shaft, however.
40-38 CX-Series
1. Check of oil pressure
Compo-
nent No. Inspection item Pressure (MPa {kgf/cm2}) Port
1 Torque converter inlet pressure 0.5 – 0.7 {5 – 7} E
Torque
converter 2 Pump discharge pressure 1.01 – 1.25 {10.3 – 12.7} B
3 Torque converter outlet pressure 0.20 – 0.66 {2.0 – 6.7} F
2. Tightening torque of bolts and plugs
Tightening torque (Nm {kgf•m})

Compo- Sym-
nent No. Tightening part Specification of screw bol
Target Max.
1 Input plate mounting part Hexagon head M10 × 1.5 × 16 57.8 {5.9} 74.5 {7.6} 1-3
bolt
2 Gear pump assembly Flat head screw M5 × 0.8 × 16 0.98 {0.1} 2.94 {0.3} 2-5
3 Inlet valve mounting part Plug M16 × 1.5 × 10 49.0 {5.0} 63.7 {6.5} 11
Torque
converter
Gear pump mounting Small hexagon
4 part head bolt M10 × 1.5 × 45 38.2 {3.9} 49.0 {5.0} 13
5 Each pressure pickup Hexagon socket PT 1/4 7.35 {0.75} 9.8 {1.0} 15
port head bolt
6 Blind plug Hexagon socket PT 3/4 56.8 {5.8} 70.6 {7.2} 16

head bolt
a The symbols in the column at the right end of the table refer to those of COMPONENT PART NAMES.
CX-Series 40-39
ASSEMBLY DRAWING
40-40 CX-Series
CX-Series 40-41
CAUSES AND REMEDIES FOR FAILURES
No. Problem Cause Remedy
A No hydraulic pressure
1) Lack of oil Add oil
2) Damaged gear pump or drive portion Disassemble and check, replace
with new parts or replace whole
assembly
3) Damaged piping or joint Disassemble and replace
1 Power is not transmitted 4) Broken piston in inlet port relief valve or Disassemble and replace
broken spring
B Mechanical breakage
1) Broken input plate Disassemble and replace
2) Broken shaft, gear Disassemble and replace
3) Broken spline Disassemble and replace
A Hydraulic pressure is too low

1) Lack of oil Add oil
2) Leakage of air from suction piping Check joint, gasket, replace parts if
necessary
3) Drop in efficiency of gear pump Disassemble and replace, replace
parts if necessary
4) Deteriorated spring in inlet port relief Disassemble and replace, replace
valve or defective operation of piston parts if necessary
2 Output drops
5) Worn or broken seal ring Disassemble and replace
B Mechanical breakage
1) Broken or deformed impeller Disassemble and replace
2) Deformed input plate Disassemble and replace
C Other
1) Non-specified oil is being used Change to specified oil
1) Incorrect oil level Add or drain oil

2) Contact of impeller Disassemble and replace, replace
parts if necessary
Oil pressure rises
3 3) Wear or seizure of bearing Disassemble and replace, replace
abnormally high
parts if necessary
4) Wear or damage of gear pump Disassemble and replace, replace
parts if necessary
1) Cavitation caused by leakage of air from Add oil or check and replace parts if
suction piping or lack of oil necessary
2) Failure of gear pump Disassemble and replace parts or
whole assembly
3) Contact caused by deformed impeller Disassemble and replace, replace
Abnormal noise is
4 parts if necessary
generated
4) Breakage of input plate Disassemble and replace
5) Breakage of gear Disassemble and replace
6) Wear or breakage of bearing Disassemble and replace
7) Wear of spline Disassemble and replace
8) Loose bolts Tighten, replace if necessary
40-42 CX-Series
No. Problem Cause Remedy
A Oil seal
1) Worn or damaged lip Disassemble and replace
2) Dirt caught Disassemble and replace, replace
parts if necessary
3) Worn or scratched shaft Correct or replace
4) Hardening or deterioration of rubber Disassemble and replace
because of abnormal rise in oil tempera-
ture
B O-ring
5 Oil oozes out or leaks 1) Broken O-ring Disassemble and replace
2) Scratched mating surface Correct or replace
3) Hardening or deterioration of rubber Disassemble and replace
because of abnormal rise in oil temper-
ature
4) Sudden use in extremely cold tempera- Carry out warming-up
tures (below -15°C) operation
C. Plug, screw
1) Loose screw Tighten
2) Broken screw Replace
3) Cracked hole Replace
CX-Series 40-43
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
DISASSEMBLY
1. Draining oil
Remove drain plug and drain oil from case.
2. Transmission valve, differential

Remove transmission valve mounting bolts (1)
and differential cap bolts (2), and separate into
transmission valve and differential.
3. Torque converter
1) Use wooden blocks as support and set facing
in direction shown in diagram on right.
2) Remove bolts (3) connecting torque convert-

er and transmission case, and separate
torque converter.
40-44 CX-Series
4. Strainer and plate

1) Remove bolt (12) and plate (13) to pull out
strainer (14).
2) Remove bolt (16) to pull out plate (17).
a For the F2/R1 truck, also remove bolt (18)
and plate (19).
5. Sensor
1) Remove thermo sensor (20).
2) Remove plug (15).
a For the truck having a speed meter (optional),
also remove it.
6. Accumulator
1) Remove plug (8).
2) Remove collar (9), spring (10) and piston
valve (11).
7. Plug, breather and cap

1) Remove drain plug (21), breather (22) and
cap (23).
2) Remove blind plugs (24).
a Number of blind plugs
• F1/R1 truck: 8
• F2/R1 truck: 13
CX-Series 40-45
8. Removing the gear (large) from the intermediate

shaft
1) Remove the bearing from the intermediate
shaft using a bearing puller.
2) Remove the gear.
a For the F2/R1 truck, remove it as an interme-
diate shaft sub-assembly (including a clutch
pack).

1) Remove the input shaft sub-assembly (in-
cluding a clutch pack assembly).
a The intermediate shaft can be removed as an

intermediate shaft sub-assembly without re-
moving the gear by removing the output shaft
sub-assembly mounting bolt first to raise the
output shaft sub-assembly. When combined-
ly disassembling parts, however, disassem-
ble them in a proper order, or parts may break
or your hand/finger may get injured.
40-46 CX-Series

1) Remove bearing cage support bolts (8) and
(9) from the output shaft to pull out the output
shaft sub-assembly.
a Store shims (5) between the transmission

case and the cage all together (by binding
them using a nylon tape, etc.).
11. Intermediate shaft

1) Remove the intermediate shaft (including the
small gear and the bearing).
CX-Series 40-47
12. Input shaft

Disassembly of clutch pack assembly
a The numbers show the order for disassembly.
k When removing snap rings (14), (29) there is

danger because it is under tension from the
spring.
Always use a special tool A to remove it.
Special tool A 3EC-97-99000
a When ordering parts, note that gears (6) and (21)

differ depending on truck types.
40-48 CX-Series
13. Intermediate shaft (FG,D45T/50AT: F2)

Disassembly of clutch pack assembly
a The numbers show the order for disassembly.
k When removing snap ring (16), there is dan-

ger because it is under tension from the
spring. Always use a special tool A to re-
move it.
CX-Series 40-49

(F1/R1 truck)
40-50 CX-Series
Unit: mm
Criteria
Sym-
bol Check item Remedy
A1 Thickness of drive plate 2.5 – 2.7 2.3

A Plate Replace
A2 Thickness of driven plate 1.93 – 2.07 1.7
Clearance at end gap when —

B2 inserting piston (Bias cut) —
Depth of oil groove in side Replace each

B Seal ring B3 face — — time disassembly
is carried out
B1 Thickness 2.45 – 2.55 2.25
D1
Inside diameter of seal ring

C1 contact surface (piston 45 – 45.025 45.175
boss)
C Piston
Seal ring insertion groove
C2 width 4.55 – 4.65 4.85
D1 Seal ring insertion groove 2.6 – 2.65 2.8

width
D Drive shaft
width
H2 Clearance at end gap when — —

inserting cap (Bias cut)
H Seal ring H1 Thickness 2.47 – 2.49 2.25
Diameter of transmission
— case 1st shaft hole 35 – 35.025 — (No stepped-type wear
should be detected)
E2 Clearance at end gap when 0.3 – 0.5 1.2 Replace

inserting clutch case
E Seal ring E1 Width 4.47 – 4.49 4.23
(C2) Insertion groove width 4.55 – 4.65 4.85

F Clutch case F1 contact surface (drum and 135 – 135.063 135.3
cylinder)
G Thrust washer G1 Thickness 2.9 – 3.1 2.5
Outside diameter of seal

I Retainer I1 ring contact surface (Out- 61.924 – 60 — (No stepped-type wear
put shaft retainer) should be detected)
— Backlash 0.14 – 0.41 —

— Gears
— Thrust clearance 0.15 – 0.6 —
Replace with new parts

— Gasket, O-ring, seals — — during disassembly and
assembly
CX-Series 40-51

(F2/R1 truck)
40-52 CX-Series
Unit: mm
Criteria
Sym-
K1 Thickness of drive plate 2.5 – 2.7 2.3

K Plate Replace
K2 Thickness of driven plate 1.93 – 2.07 1.7

L2 inserting piston (Bias cut) —

L Seal ring L3 face — — time disassembly
is carried out
(L1) Thickness 2.45 – 2.55 2.25

M1 contact surface (piston 40 – 40.025 40.3
boss)
M Piston
M2 width 4.55 – 4.65 4.85
N1 Seal ring insertion groove 2.6 – 2.65 2.8

width
N Idle shaft
width
O2 Clearance at end gap when 0.3 – 0.5 1.2

inserting cap
O Seal ring O1 Thickness 4.47 – 4.49 4.23
(M2) Insertion groove width 4.55 – 4.65 4.85

P Clutch case P1 contact surface (drum and 110 – Replace
cylinder)
T Thrust washer — Thickness

Q2 inserting clutch case (Bias cut) —
Q Seal ring Q1 Thickness
— Diameter of transmission 35 – 35.025

case 2nd shaft hole
S Retainer S1 Outside diameter of oil seal

contact surface
— Backlash 0.14 – 0.41 —

— Gears

assembly
CX-Series 40-53
PRECAUTIONS ON ASSEMBLY
1. Cleaning each part
1) Before assembly, completely clean the case
bolt screw holes and oil path corners.
2) In particular, completely clean the case verti-
cal hole bolt screws since a wrong tightening
torque may be used or the screws may break
when tightening the bolts if any Loctite or for-
eign matter remains.
2. Clutch pack assembly

Blow air to the oil hole to check entrainment drive
plate and driven plate operation.
Air pressure 0.49 MPa {5 kgf/cm2}
Stroke F1/R1 2 mm
Stroke F2 1.7 mm
3. Control valve
1) Tighten the mounting bolt in the order shown
in the figure on the right.
27 – 34 Nm {2.8 – 3.5 kgf•m}
2) After assembly, check spool operation.

Insufficient tightening: Oil leakage
Excessive tightening : Malfunction
4. Seal ring
During assembly, apply grease to the seal ring.
40-54 CX-Series
5. Solenoid valve (forward/reverse travel switch)
CX-Series 40-55
ASSEMBLY OF FORWARD/REVERSE TRAVEL (INPUT SHAFT) SHAFT SUB-ASSEMBLY

(assemble parts generally in the opposite procedure from disassembly)
a Dip the clutch plate and disk in oil before assembly.
a Apply grease to the seal ring.

move it.
Gear (14)
Compact truck: Z = 21
Standard truck: Z = 19
40-56 CX-Series
FLOWCHART FOR ASSEMBLING INPUT SHAFT (FOR F1/R1 AND F2/R1) SUB-ASSEMBLY
Assembling
Input shaft
order
(Reverse travel side) (Forward travel side)
1 Put the seal on the shaft. Put the seal on the shaft.
2 Put the seal ring on the piston and Put the seal ring on the piston and
3 insert the piston to the drum. insert the piston to the drum.
4 Insert the spring. Insert the spring.
5 Insert the spacer. Insert the spacer.

Clutch pack
6 Fix it using a snap ring. Fix it using a snap ring.
7 Insert the plate (t = 4.5 ± 0.1 mm). Insert the plate (t = 4.5 ± 0.1 mm).
8 Insert the clutch disk and the plate (alternatively). Insert the clutch disk and the plate (alternatively).
9 Disk (6) and plate (5). Disk (6) and plate (5).
10 Insert the plate (t = 4.5 ± 0.1 mm). Insert the plate (t = 4.5 ± 0.1 mm).
11 Fix it using a ring. Fix it using a ring.
12 Insert the spacer. Assemble the gear and the bearing.
13 Assemble the gear and the bearing and Assemble the gear and the bearing (*) and
14 insert the gear (Z = 19). insert the gear (Z = 38).
15 Insert the washer. Fix it using a snap ring.
16 Fix it using a snap ring.
17 Insert the bearing.
19 Insert the seal ring.
CX-Series 40-57
ASSEMBLY OF FORWARD TRAVEL 2ND SPEED (INTERMEDIATE SHAFT) SHAFT

SUB-ASSEMBLY
(assemble parts generally in the opposite procedure from disassembly)
a Dip the clutch plate and disk in oil before assembly.
a Apply grease to the seal ring.

move it.
40-58 CX-Series
FLOWCHART FOR ASSEMBLING INTERMEDIATE SHAFT (FOR F2/R1) SUB-ASSEMBLY

Assembling
Intermediate shaft (for F2/R1)

order
1 Put the seal on the shaft.
2 Put the seal ring on the piston and
3 insert the piston to the drum.
4 Insert the spring.
5 Insert the spacer.

Clutch pack
7 Insert the plate (t = 5 ± 0.07).
8 Insert the clutch disk and the plate (alternatively).
9 Disk (8) and plate (7).
10 Insert the plate (t = 5 ± 0.07).
11 Fix it using a ring.
12 Insert the spacer.
13 Assemble the gear and the bearing and
14 insert the gear (Z = 34).
15 Insert the washer.
17 Mount the snap ring.
18 Assemble the gear.
19 Insert the bearing.
21 Insert the seal ring. Insert the bearing.
Intermediate shaft (for F2/R1) sub-assembly
CX-Series 40-59
ASSEMBLY OF OUTPUT SHAFT

SUB-ASSEMBLY
(Assemble parts generally in the opposite procedure
from disassembly)
1. Install the inner race of bearing (2) to pinion shaft

(1).
2. Install O-ring (3) to the inner race of bearing (2) by

pressing the ring to the race to install race (4).
a Assemble race (4) in such a manner that the
tapered side faces the spline.
3. Install oil seal (5) to cage (6) and put the outer
races of bearings (2) and (7) to both sides.
a Assemble the seal in such a manner that the
rounded side on the back faces the pinion.
a After assembling the seal, apply lithium
grease to the lip.
40-60 CX-Series
Detail of part P
4. Install shims (8).
a Use the thickness of the removed shims as
standard.
See ADJUSTMENT OF SHIM (See part P).
• Install shims (8) in the following arrange-
ment; Install the pieces 0.5 and 0.4 mm
thick on the B side, the piece 0.3 mm
thick on the C side, and the piece 0.25
mm thick among them.
5. Install the rollers of bearing (2) to the inner race

installed to pinion shaft (1).
6. nstall cage (6) [to which oil seal (5) and the outer
races of bearings (2) and (7) are installed] to the
pinion shaft.
7. Engage the roller (7-1) of bearing (7) with the out-

er race in cage (6).
8. Assemble the inner race of bearing (7).

a Make sure that the adjustment shim (8) has
been installed before assembling the inner
race.
9. Assemble gear (9) (Z = 54).

Compact truck: Z = 53
Standard truck: Z = 54
10. Mount and tighten nut (10).
Tightening torque 314 – 441 Nm {32 – 45 kgf•m}
a After tightening nut (10) by the specified

torque, make sure that the starting torque of
pinion shaft (1) is within the following range.
Starting torque 4 – 8 Nm {40 – 80 kgf•cm}
a If not, adjust shim (8) again to obtain a proper

torque.
CX-Series 40-61
11. Caulk part E of nut (10) after adjusting the starting

torque of the pinion shaft.
• Caulk at places where part E is flat for at least
2 mm.
• Caulk at 3 places like part F.
12. Install bearing (11) and caulk it.

• Caulk the pinion shaft with punch G so that it
will reach the round part of the bearing inner
race (at 3 places on the circumference).
13. Install O-ring (12) to the O-ring groove of cage

(6).
40-62 CX-Series
ADJUSTING OUTPUT SHAFT

SUB-ASSEMBLY
(PINION SHAFT THRUST PROTRUSION)
1. Shim between the bearing cage and the trans-
mission
Calculate the thickness using the following ex-
pression to obtain the pinion shaft protrusion
(standard shim = 1.5 mm (operating range 0.6 –
2.4)).
a+b+c+d
Shim thickness T = 0.30 +
100
• a and b: Numbers on the pinion shaft end.
Adjust the protrusion using the shim after
adjusting the starting torque of the output
shaft sub-assembly.
• c: Value expressing the difference against
the standard length of 120.82 mm in 1/100
units after measuring length L.
• d: Read the value stamped on the transmis-
sion case (for housing the bearing on the
pinion shaft end).
[Example: 25]
2. Example of shim calculation

a = 20 (stamped value on the pinion)
b = 10 (stamped value on the pinion)
(the following shows measurement calcula-
tion)
c = (L – 120.82) × 100
= (121.39 – 120.82 × 100)
= 57 (e.g.: L = 121.39)
d = 25 (stamped value on the transmission
case)
20 + 10 + 57 + 25
Shim thickness T = 0.3 +
100
= 1.42 mm
CX-Series 40-63
ASSEMBLY
1. Cleaning the transmission case and blowing
with air
1) Remove the cap before cleaning the trans-
mission case (since Loctite is used on the cap
mounting bolt).
2) Blow the machined hole of the transmission

case with air.
F1/R1 truck
2. Installing blind plugs on the transmission
case
Install blind plugs (2) and plug (3) on transmission
case (1).
a For the truck having a speed meter (optional),
which has a speed sensor, mount the sensor
after assembling the output, intermediate and
input shafts.
a Number of blind plugs (2)
• F1/R1 truck: 8
• F2/R1 truck: 13
F2/R1 truck
40-64 CX-Series
3. Intermediate shaft
1) Assemble intermediate shaft (8).
• Install the gear (large) and the bearing on the
torque converter case side after assembling
the input shaft sub-assembly.

• Make sure that nut (4) has completely been
caulked.
• Make sure that the bearing on the pinion end
has completely been caulked D portion after
installed.
1) Install shim (5) and O-ring (7) on cage (6) of

the output shaft sub-assembly and install
them on the transmission case.
• Standard shim thickness: 1.5 mm (Range:

0.6 to 2.4 mm)
• Shim mounting position

Mount the shim in such a manner that it
comes in contact with the notch E on the case
boss.
CX-Series 40-65
2) After assembling the output shaft sub-assem-

bly, tighten bolts (9) and (10) from the differ-
ential side.
Loctite #271 (hole-side screw)
1st time 49 – 74 Nm {5 – 7.5 kgf•m}
2nd time 98 – 123 Nm {10 – 12.5 kgf•m}
• Tightening order
Tighten them diagonally.
• If pinion shaft (1) rotation is less smooth than be-

fore assembly after tightening the bolts, remove
the output shaft sub-assembly and readjust them.

(assembling the input shaft sub-assembly)
Refer to the section on ASSEMBLING THE IN-
PUT SHAFT (FORWARD/REVERSE TRAVEL)
SUB-ASSEMBLY.
1) Slowly engage the input shaft sub-assembly

with the intermediate shaft gear in such a
manner to avoid damaging the seal ring and
insert the shaft end to the transmission case
shaft hole.
• Apply grease (G2-LI) to the seal ring.
40-66 CX-Series
6. Intermediate shaft gear (large) and bearing

1) Engage intermediate shaft gear (11) with the
input shaft sub-assembly gear and install
them on the intermediate shaft.
2) Assemble bearing (12) and press-fit it.
• Be sure to use a copper bar or a jig when
press-fitting the bearing.
7. Assembling the F2/R1 truck and the transmis-

sion
1) Assemble output shaft sub-assembly (1).
2) Assemble input shaft sub-assembly (2).
3) Assemble intermediate shaft sub-assembly
(3).
a Follow the opposite procedure for disassem-

bling them.
8. Installing the plate

Install plates A and B using bolts (13).
59 – 73 Nm {6 – 7.5 kgf•m}
FG, D35ZT to 40T: Plate A (F1/R1 truck)

FG, D45T/50AT: Plates A and B (F2/R1 truck)
CX-Series 40-67
9. Installing the torque converter assembly

1) Set gasket (14) on the transmission case.
2) Align the torque converter assembly with the
transmission case dowel pin and slowly join
them.
3) Tighten bolts (15).
59 – 73 Nm {6 – 7.5 kgf•m}
k If the transmission case and the torque con-

verter housing cannot be easily joined due
to slight dislocation of the input shaft spring
or the intermediate shaft bearing, do not
forcefully tighten the bolts but completely
F2/R1 truck
join them by slightly punching the housing
using a wooden hammer or the like and then
tighten bolts (15).
F1/R1 truck
40-68 CX-Series
10. Installing the transmission valve

Install it using bolts (16) and gaskets (tighten the
two of the eight bolts together with inching
change brackets).
Bolt tightening torque
27 – 34 Nm {2.8 – 3.5 kgf•m}
TORQFLOW TRANSMISSION ASSEMBLY

DRAWING (F1/R1 TRUCK)
CX-Series 40-69
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

DISASSEMBLY OF CONTROL VALVE
1. Remove bolt (1) to remove the control valve (3)
from the transmission and remove bolt (2) which
fixes the solenoid valve (4) to remove the valve
from the valve body.
(Hexagonal wrench: 4 mm)
a The F2 solenoid valve (5) on the F2/R1 truck is

mounted on the right side of the transmission
case.
Remove the bolt which fixes the cover to remove
the cover and the gasket.
2. Pull out the inching spool, valves and pistons

from the valve body. At this time, put them in or-
der so that the original positions can be remem-
bered and such inner parts as the valve springs
cannot be mixed.
40-70 CX-Series
COMPONENT PARTS
No. Name No. Name No. Name

1 Valve body 15 Bolt 29 Spring (l = 83)
2 Plug 16 Spring washer 30 Spring (l = 107)
3 Screw 17 Inching valve 31 Plug
4 Regulator valve (relief) 18 Inching spool 32 O-ring
5 Piston 19 Spring (l = 27) 33 Plug
6 Stopper 20 Stopper 34 Gasket
7 Spring (l = 55.5) 21 Nut 35 Bracket
8 Spring (l = 73.8) 22 Seal 36 Bolt
9 Lubrication relief valve 23 Snap ring 37 Inching lever
10 Spring (l = 33.8) 24 Plate 38 Pin
11 Plug 25 Spring (l = 74) 39 Solenoid valve
12 O-ring 26 Plug 40 Bolt
13 Plate 27 O-ring
14 O-ring 28 Piston (accumulator)
CX-Series 40-71
ASSEMBLY DRAWING
40-72 CX-Series
TROUBLESHOOTING
No. Failure Cause Remedy
No oil pressure.
1) Broken piston or spring of the inlet relief or Replace after disassembling.
1 Power is not transmitted.
regulator valve.
2) Stuck solenoid valve. Replace after disassembling.
Oil pressure is low.

1) Deformed spring or piston malfunction of Check it after disassembling. Replace
2 The output is low. the inlet relief or regulator valve. parts as necessary.
2) Stuck solenoid valve. Replace after disassembling.
3) Inching valve operation. Adjust it.
Gasket joint surface.

1) Slacken bolt. Retighten it.
3 Oil leaks.
2) Broken gasket. Replace after disassembling.
3) Flaw on the opposite surface. Repair or replace it.
No voltage.
1) Failed forward/reverse travel lever switch. Repair or replace it after checking.
2) Wrong connector contact. Repair it after checking.
3) Fused or disconnected fuse or wiring cir- Repair or replace it after checking.
cuit.
The solenoid valve does not
4 Voltage available.
function.
1) Disconnected grounding circuit. Repair it after checking.
2) Wrong connector contact. Repair it after checking.
3) Wrong frame grounding wire contact. Repair it after checking.
4) Stuck solenoid valve. Repair or replace it after checking.
5) Disconnected solenoid or wiring circuit. Repair or replace it after checking.
CX-Series 40-73
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DIFFERENTIAL
40-74 CX-Series
*1. Apply Loctite #271 to the threads (on the hole side).
40-76 CX-Series
Unit : mm
Criteria
Sym-
Set starting torque 21.56 – 33.32 Nm —

{2.2 – 3.4 kgf•m}
A Differential
pinion
Backlash 0.20 – 0.28 —
B Outside diameter of spider and pin 27.959 – 27.980 27.75
C Inside diameter of pinion gear 28.0 – 28.052 28.152
Bushing thickness 1.52 – 1.68 1.3

D Pinion gear
Oil groove (W × D) — —

E Side gear
Inside diameter of 68 – 68.03 68.13

mating hole
F Differential case
side gear boss
Oil groove (W × D) 4 × 1.5 4 × 1.4
G Outside diameter of differential case boss 90.013 – 90.035 —
H Bevel pinion gear backlash 0.15 – 0.23 —
J Runout on back of bevel gear Max. 0.1 —
K Differential case tightening bolt 78.4 – 122.5 Nm — Apply Loctite to screw

{8 – 12.5 kgf•m}
156.8 – 196 Nm
L Bevel gear mounting bolt {16 – 20 kgf•m} — Apply Loctite to screw
Differential carrier and support cap tight- 490 – 608 Nm

— ening bolt {50 – 62 kgf•m} — Apply Loctite to screw
Damage of tooth
— Differential gear tooth surface — surface such as Replace
pitching and spalling
Replace with new

— Gasket, O-ring and seals — — parts during disas-
sembly and assembly
CX-Series 40-77
ADJUSTING DIFFERENTIAL
1. Assembly of differential assembly
1) Assemble differential assembly, then install
adjustment screw (1).
2) Coat hole of cap (2) with Loctite #271, then
tighten temporarily with bolts (3).
2. Adjusting backlash
a When tightening adjustment screw (1), use
special tool A.
Special tool A 34C-97-99150
1) When adjusting, turn either left or right adjust-

ment screw (1) back one notch, then tighten
other adjustment screw one notch and read
dial gauge A indicator.
Backlash between ring 0.15 – 0.23 mm

gear and pinion gear
2) Rotate bevel gear and carry out adjustment

procedure in Step 1) at four places.
3. Adjusting preload of side bearing

1) Using tool B, tighten left and right adjustment
screws (1) uniformly to adjust preload.
Preload 21.56 – 33.32Nm {2.2 – 3.4kgf•m}
Special tool B 3EC-97-99960
2) Check again that backlash is within specified

value.
40-78 CX-Series
4. Checking the tooth contact Foward side

1) Coat the bevel gear tooth surface with small
amount of red lead.
2) Turn the bevel gear forward and reverse sev-
eral times.
3) Check appropriateness of the tooth contact
referencing the pattern left on the tooth sur-
face.
4) If correct tooth contact is not present, check
and adjust the following points:
• Shims used for the pinion shaft.
• Backlash of the bevel gear.
• Bearing pre-load on the bevel gear side.
• Appropriate tooth contact (no-load) Reverse side

You can be sure that an appropriate tooth
contact is obtained if the pattern is situated at
center of the tooth surface, shares 40 to 70%
of the overall tooth length and contact be-
comes weaker at both ends of the pattern.
a Tooth contact for both the forward and re-

verse move must be correctly adjusted. If,
however, that is not practicable, the forward
side alone should be adjusted as specified.
Radial runout of the bevel gear:

Max. 0.1 mm
CX-Series 40-79
5. Correcting the tooth contact

crease protrusion of the pinion (in direction
A).
Then, move the bevel gear away from the pin-
ion (in direction B) to adjust the backlash.

crease projection of the pinion (in direction
A).
Then, move the bevel gear toward the pinion

crease projection of the pinion (in direction
A).
Then, move the bevel gear toward the pinion

crease protrusion of the pinion (in direction
A).
Then, move the bevel gear away from the pin-
ion (in direction B) to adjust the backlash.
40-80 CX-Series
DIFFERENTIAL ASSEMBLY DRAWING
a Completely bend cotter pin A.
CX-Series 40-81
DISASSEMBLY AND ASSEMBLY DRIVE AXLE
DRIVE AXLE
Precautions on installing the front axle on the frame
1. Degrease the mounting bolts, nuts and tapped holes before installation.
2. Tighten them without using an impact wrench first and then retighten them using the wrench to check the
tightening torque.
*1. Adjust the starting torque with nut A.
40-82 CX-Series
DISASSEMBLY AND ASSEMBLY DRIVE AXLE
DRIVE AXLE ASSEMBLY DRAWING
*2. Apply gasket sealant to the joint faces of the housing and race B.
*3. Do not stick gasket sealant to the seal sliding surface of race B.
*4. Do not apply gasket sealant to mating face C of the hub and torque shaft.
CX-Series 40-83
DISASSEMBLY AND ASSEMBLY WHEEL BRAKE
WHEEL BRAKE
Item Unit Wheel brake
Type — Front wheel, internal expanding, hydraulic
Structure — Duo servo
Inner diameter of brake drum mm 317.5 – 317.6
Lining material — Resin mold (Adhesive type)
Width mm 60.0
Thickness mm 5.62
Inner diameter of wheel cylinder mm 31.75
40-84 CX-Series
DISASSEMBLY AND ASSEMBLY (FG, D35ZT/40ZT)
*1. 2 bolts (4) on the wheel cylinder side are reamer bolts. Do not use other bolts instead of them.

Unit: mm
Criteria
Check item Remedy
Inside diameter of drum 317.5 – 317.7 319.5
Thickness of lining 5.62 2
Springs (1) and (2) Free length: 120 Free length: 132
Deterioration of return spring Replace
Spring (3) Free length: 139 Free length: 153
Thickness of return spring hook portion 2.9 2.0
Clearance between piston and cylinder 0 – 0.05 0.2
a Check for scratches on the wheel cylinder sliding surface and for damage or deterioration of the cap.
CX-Series 40-85
DISASSEMBLY AND ASSEMBLY (FG, D35T-45T/FD50AT)

Unit: mm
Criteria
Check item Remedy
Thickness of lining 10.0 2.0

(from the rivet head)
220.6 – 269.7 N
Spring (1) Free length: 93 {22.5 – 27.5 kgf}
(when length = 101.2 mm)
70.6 – 86.3 N
Spring (2) Free length: 123.2 {7.2 – 8.8 kgf}
(when length = 152 mm)
40-86 CX-Series
DISASSEMBLY AND ASSEMBLY BRAKE AND CLUTCH BOOSTERS
BRAKE AND CLUTCH BOOSTERS

a For the brake of the torque converter truck, refer to the section on the brake booster and the master cylinder.
1. Brake booster and master cylinder

2. Clutch booster and master cylinder
SPECIFICATIONS
Item Specifications (values)
Fluid used — Mineral hydraulic oil
Cylinder diameter mm 25.4
Booster Maximum stroke mm 28
k
Maximum operating pressure MPa {kgf/cm2} 14.7 {150}
Maximum flow l/min 25 Never allow

hydraulic oil on the
Fluid used — Brake fluid booster side and
brake oil on the
mm Brake 25.4 master cylinder
Cylinder diameter
side to mix.
mm Clutch 22.22
Master Maximum stroke mm 28
cylinder
Brake 0.1 {1.0}

Residual pressure MPa {kgf/cm2}
Clutch 0 {0}
CX-Series 40-87
BRAKE AND CLUTCH BOOSTERS

(1) General disassembly drawing of brake booster and master cylinder
1. Booster (hydraulic oil) 2. Master cylinder (brake fluid)

1. Body 9. Body
2. Reaction piston sub-assembly 10. Piston assembly
3. Control valve sub-assembly 11. Spring
4. Piston guide sub-assembly 12. Stopper pin
5. Push rod 13. Check valve
6. Boot 14. Reservoir
7. Rod 15. Filter
8. Flow divider 16. Indicator
40-88 CX-Series
(2) Component parts of brake booster and master cylinder
No. Parts Qty No. Parts Qty No. Parts Qty

1 Body 1 18 O-ring 1 35 Snap ring 1
2 Piston 1 19 Ring 1 50 Master cylinder assembly 1
3 Link 1 20 Steel ball 1 51 Cylinder 1
4 Pin 1 21 Spool 1 52 Piston assembly 1
5 Rod 1 22 Cap 1 53 Spring 1
6 Snap rings 2 23 Spring 1 54 Snap ring 1
7 Piston assembly 1 24 O-ring 1 55 Stop pin 1
8 Valve assembly 1 25 Penta seal 1 56 Gasket 1
9 Valve assembly 1 26 Spring 1 57 Bolt 1
10 O-ring 1 27 O-ring 1 58 Gasket 1
11 Cap 1 28 Stud bolts 2 59 Check valve assembly 1
12 Snap ring 1 29 Boot 1 60 Valve spring 1
13 Spring 1 30 Push rod 1 61 Reservoir 1
14 Piston guide 1 31 Nuts 4 62 Filter 1
15 Snap ring 1 32 Yoke 1 63 Indicator assembly 1
16 O-rings 2 33 Washers 2 64 Clamp 1
17 Cup 1 34 Filter 1
CX-Series 40-89
(3) General disassembly drawing of clutch booster and master cylinder
1. Booster (hydraulic oil) 2. Master cylinder (brake fluid)

1. Body 9. Body
2. Reaction piston sub-assembly 10. Piston assembly
3. Control valve sub-assembly 11. Spring
4. Piston guide sub-assembly 12. Stopper pin
5. Push rod 13. Reservoir
6. Boot 14. Filter
7. Rod 15. Cap assembly
8. Flow divider
40-90 CX-Series
(4) Component parts of clutch booster and master cylinder
No. Parts Qty No. Parts Qty No. Parts Qty

1 Body 1 17 Cup 1 33 Washers 2
2 Piston 1 18 O-ring 1 34 Filter 1
3 Link 1 19 Ring 1 35 Snap ring 1
4 Pin 1 20 Steel ball 1 50 Master cylinder assembly 1
5 Rod 1 21 Spool 1 51 Cylinder 1
6 Snap rings 2 22 Cap 1 52 Piston assembly 1
7 Piston assembly 1 23 Spring 1 53 Spring 1
8 Valve assembly 1 24 O-ring 1 54 Snap ring 1
9 Valve assembly 1 25 Penta seal 1 55 Stop pin 1
10 O-ring 1 26 Spring 1 56 Gasket 1
11 Cap 1 27 O-ring 1 57 O-ring 1
12 Snap ring 1 28 Stud bolts 2 58 Reservoir 1
13 Spring 1 29 Boot 1 59 Filter 1
14 Piston guide 1 30 Push rod 1 60 Cap assembly 1
15 Snap ring 1 31 Nuts 4 61 Clamp 1
16 O-rings 2 32 Yoke 1
CX-Series 40-91
Clutch truck
DISASSEMBLY OF BRAKE/CLUTCH
BOOSTER AND MASTER CYLINDER
1. Separating the brake/clutch booster
1) Remove bolt (3) to separate the brake boost-
er (1) and clutch booster (2) assemblies.
2. Disassembling the clutch booster and the Clutch master cylinder

master cylinder
1) Remove nut (31) to separate the booster and
the master cylinder.
2) Disassembling the master cylinder
• Remove snap ring (54).
• Loosen stop pin (55) to remove it by
slightly pushing piston assembly (52).
• Remove piston assembly (52) and spring
(53).
Reservoir
• Remove cap (60) and filter (59).
• Loosen band (61) to remove the reservoir
tank.
40-92 CX-Series
Booster disassembly drawing

3. Disassembling the booster
1) Remove push rod (30) and boot (29).
2) Remove snap ring (15)
3) Press rod (5) from the master cylinder side to
remove piston guide (A), power piston as-
sembly (D) and the rod.
A: Piston guide sub-assembly

B: Reaction piston sub-assembly
C: Control valve sub-assembly
D: Power piston assembly (B + C)
E: Flow divider
4) Disassembling the sub-assembly

• Reaction piston sub-assembly
Disassemble it by pressing valve (9) and
pulling out pin (4).
• Control valve sub-assembly
Remove snap ring (12) to pull out cap
(11), spring (13) and valve (8).
• Flow divider
Remove snap ring (6), cap (22), spring
(23) and valve (21).
k • Do not damage the cylinder, piston, cups,

etc.
• During disassembling, properly under-
stand the booster configuration and put
parts in the disassembling order after dis-
assembling.
• When pinching using a vice, be sure to
pinch the mounting flange and do not ap-
ply excessive force.
• Do not remove the piston and valve set
seals (replace as the assembly).
CX-Series 40-93

Note: When cleaning the parts before testing, ob-
serve the following.
• Never use anything other than alcohol and brake
oil to clean the parts. In particular, never use min-
eral oil (kerosene, gasoline, etc.) If mineral oil
sticks to a rubber part, the latter will swell and
cannot be used.)
• When cleaning the rubber parts such as the cup
in alcohol, do not soak them in alcohol for more
than 30 seconds.
• Keep the cleaned parts in a clean place so that
dirt will not stick to them.
• Take care that foreign matter will not enter the cir-
cuit and the cylinder, piston, cup, etc. will not be
scratched.
Clutch booster and master cylinder
1. Spring 9. Reaction piston

2. Reservoir 10. Cup
3. Flow divider spool 11. Relief valve
4. Body 12. Control valve
5. Power piston 13. Rod
6. Bellows 14. Y-packing
7. Push rod 15 Piston assembly
8. Yoke 16. Cylinder
40-94 CX-Series
Sym-
No. Part name Inspection item Inspection method Remedy bol
Flaw and wear of slid- Remove minute flaws with sandpaper. If there is a
ing surface flow which may have bad effects on seal, replace
assembly.
1 Cylinder Replace 16
assembly
Clearance between
cylinder and piston If below limit, replace.
Flaw and wear of slid-

ing surface Remove minute flaws with sandpaper.
2 Power piston Replace 5

assembly assembly
Damage of seal If seal is damaged or worn excessively, replace.

Control valve
3 assembly and Replace 11, 12
relief valve assem- assembly
bly
Flaw and wear of slid- Remove minute flaws with sandpaper.

ing surface
Reaction piston Replace
4 assembly assembly 9
Flaw, wear, leaning If spring is damaged or worn excessively, replace.
5 Spring Replace 1
Free length If below limit, replace.
Remove minute flaws with sandpaper. If there is a

6 Rod Flaw and wear of slid- flow which may have bad effects on seal, replace Replace 13
ing surface assembly.

7 Flow divider spool Flaw and wear of slid- flow which may have bad effects on seal, replace Replace 3
8 Y-packing, cup, Damage of sealing If seal is damaged or worn excessively, replace. Replace 10, 14
and O-ring surface
9 Push rod Deformation and wear If push rod is deformed or worn excessively, Replace 7
replace.
10 Yoke Deformation and wear If yoke is deformed or worn excessively, replace. Replace 8
Crack If bellows is cracked, replace.
11 Bellows Replace 6
Tightening allowance
on cylinder If tightening allowance is little, replace.
CX-Series 40-95
Unit: mm
Basic Standard
A Clearance between cylin-
der and piston
– 0.020 + 0.052 0.020 –
25.4 – 0.053 0 0.105 0.150
B Clearance between cylin- 22.2 – 0.020 + 0.052 0.020 – 0.150


Free length Installed length (N {kgf}) Free length
C Deterioration of spring
37.5 33.5 69.3 {7.1} 36.0
D Deterioration of spring 24.1 19.5 39.2 {4.0} 23.0
E Deterioration of spring 12.2 10.5 30.4 {3.1} 11.5
F Deterioration of spring 88.6 56 71.6 {7.3} 80
G Tightening torque 21 – 30 Nm {2.1 – 3.1 kgf•m} —
H Tightening torque 7.8 – 11.7 Nm {0.8 – 1.2 kgf•m} —

Retighten
J Tightening torque 2.5 – 3.4 Nm {25 – 35 kgf•cm} —
K Tightening torque 27.4 – 34.3 Nm {2.8 – 3.5 kgf•m} —
40-96 CX-Series
Clutch master cylinder

ASSEMBLY
• Clean recycled parts with alcohol or brake fluid.
• When cleaning rubber parts such as cups with al-
cohol, do not dip them in alcohol for more than 30
seconds.
• Assemble it after completely applying brake fluid
or rubber grease to the outer piston circumfer-
ence and the inside of the cylinder.
1. Assembling the clutch master cylinder

1) Assemble piston assembly (52) with spring
(53) and insert them in the cylinder.
2) Adjust the directions A of the piston groove
and the hole of cylinder stop pin (55).
3) Assemble the gasket and O-ring with the stop
pin and insert them with the piston inserted to
assemble the cylinder.
Stop pin tightening torque
2.45 – 3.4 Nm {0.25 – 0.35 kgf•m}
4) Slightly press the piston and fix it using snap

ring (54).
k • Be sure to use brake fluid or alcohol to

clean parts.
• Never use mineral oil (e.g. petroleum and
gasoline).
• If mineral oil adheres to rubber parts, they
will swell, causing clutch malfunction and
an accident.
• Do not allow foreign matters to enter and
work at a clean place.
CX-Series 40-97
2. Assembling the booster (refer to the disas-

sembly drawing)
1) Clean recycled parts with detergent or miner-
al hydraulic oil.
a Use mineral hydraulic oil to clean rubber
parts and do not clean them with deter-
gent oil, petroleum or gasoline.
2) Assembling the reaction piston sub-assembly

• Assemble the O-ring with the reaction pis-
ton.
• Insert the spring in the hole of the reaction
piston.
• Insert the relief valve by matching the re-
lief valve and reaction piston holes and in-
sert the pin after making sure that the
holes have overlapped.
3) Assembling the control valve

• Apply hydraulic oil to the control valve
and insert it together with the spring to the
power piston.
• Assemble the O-ring with the cap, insert
them to the power piston and assemble
them using a snap ring.
4) Assembling the power piston sub-assembly

• Apply hydraulic oil to the reaction piston
and insert it to the power piston.
• Insert the ring from the side and assem-
ble them using a snap ring.
40-98 CX-Series
5) Assembly of piston guide

• Apply grease to the O-ring, Y-packing,
and cup, and then install them to the pis-
ton guide in the correct direction.
6) Installation of Y-packing to body

• Apply grease to the Y-packing, and then
install it to the body in the correct direc-
tion.
7) Assembling the power piston assembly

• Apply grease to the rod and assemble it
with the body.
a Clutch booster only.
• Apply hydraulic oil to the inside of the cyl-
inder and the outer circumference of the
power piston and insert the power piston
assembly to the cylinder.
• Assemble the piston guide with the reac-
tion piston, completely pressing them and
assemble them using a snap ring.
CX-Series 40-99
8) Assembling the flow divider

• Apply hydraulic oil to the spool and insert
it to the body in the proper direction.
• After checking that the spool smoothly
operates, insert the spring.
• Assemble the O-ring with the cap, apply
grease and assemble the spring by
pressing it using a snap ring.
9) Assembling the boot

• Assemble the boot after pressing reaction
piston by hand to make sure that it
smoothly operates.
10) Insert the push rod and install the bellows,

nut, and yoke to the push rod in order.
8 – 12 Nm {0.8 – 1.2 kgf•m}

clean parts.
Never use mineral oil (e.g. petroleum and
gasoline).
If mineral oil adheres to rubber parts, they
will swell and become unavailable.
• Keep parts at a clean place away from dirt
after cleaning.
avoid damaging the cylinder, piston,
cups, etc.
40-100 CX-Series
Clutch booster
3. Joining the clutch booster and the master cyl-
inder
Assemble the booster and clutch master cylinder
assemblies and tighten them using nut (1).
20.6 – 30.3 Nm {2.1 – 3.1 kgf•m}
Clutch truck
4. Joining the clutch and brake boosters
1) Apply grease to the O-rings and install them
to the 2 mating faces A of the booster.
2) Join the clutch booster (3) and brake boost-
ers (2) and tighten them using bolt (4).
27.5 – 34.3 Nm {2.8 – 3.5 kgf•m}
• Bolt size: M8 × 1.25 × 50

• Hexagonal wrench used: 6-mm type
• O-rings on the mating face
(inside diameter × thickness):
a 20.8 mm × 2.4 mm
b 10.8 mm × 2.4 mm
a For disassembling and assembling the brake

booster and the master cylinder, refer to the
next section.
CX-Series 40-101
BRAKE BOOSTER AND MASTER CYLINDER

(Torque converter truck) (Clutch truck)
• Side view of brake booster and master cylinder
Specifications
Item Specifications (values)
k
Fluid used — Mineral hydraulic oil
Cylinder diameter mm 25.4 • Never allow

hydraulic oil and
Brake Maximum stroke mm 28 brake oil to mix.
booster
• Never allow min-
Maximum operating pressure MPa {kgf/cm2} 14.7 {150} eral oil (e.g. gas-
oline and
Maximum flow l/min 25 petroleum) to
adhere to rubber
Fluid used — Brake fluid parts. Otherwise,
the parts will
Cylinder diameter mm 25.4 swell, causing
Brake brake malfunc-
master Maximum stroke mm 28 tion and an acci-
cylinder dent.
Residual pressure MPa {kgf/cm2} Brake 0.1 {1.0}
40-102 CX-Series
BRAKE BOOSTER AND MASTER CYLINDER DISASSEMBLY DRAWING
CX-Series 40-103
DISASSEMBLING AND ASSEMBLING

BRAKE BOOSTER AND MASTER CYLIN-
DER
• On the clutch truck, the brake and clutch boosters
are assembled on each assembly.
When disassembling them, be careful not to lose
the O-ring on the mating face since it is not sepa-
rately supplied.
• The torque converter truck is a single unit consist-
ing of the brake booster and master cylinder as-
semblies.
1. Separating the booster and the master cylin-

der
Remove nut (31) to separate the booster (1) from
the master cylinder (2).
2. Disassembling the master cylinder

1) Remove snap ring (54).
2) Remove stop pin (55).
a Remove the stop pin (55) by pressing the
piston assembly after loosening the stop
pin.
3) Remove piston assembly (52) and spring
(53).
a If piston assembly (52) does not come
out, push it in lightly, and it will be pushed
out by the spring.
4) Remove bolt (57) to pull out check valve (59)
and spring (60) from the cylinder.
40-104 CX-Series
Booster disassembly drawing

3. Disassembling the booster
1) Remove push rod (30) and boot (29).
2) Remove snap ring (15).
3) Press rod (5) from the master cylinder side to
remove piston guide (A), power piston as-
sembly (D) and the rod.
A: Piston guide sub-assembly

B: Reaction piston sub-assembly
C: Control valve sub-assembly
D: Power piston assembly
E: Flow divider
(Disassembling the sub-assembly)

• Reaction piston sub-assembly
Disassemble it by pressing valve (9) and pull-
ing pin (4).
• Control valve sub-assembly
Remove snap ring (12) to pull out cap (11),
spring (13) and valve (8).
• Flow divider
Remove snap ring (6), cap (22), spring (23)
and valve (21).
k • Do not damage the cylinder, piston, cups,

etc.
• During disassembling, properly under-
stand the booster configuration and put
parts in the disassembling order after dis-
assembling.
• When pinching using a vice, be sure to
pinch the mounting flange and do not ap-
ply excessive force.
• Do not remove the piston and valve set
seals (replace as the assembly).
CX-Series 40-105

Note: When cleaning the parts before testing, ob-
serve the following.
• Never use anything other than alcohol and brake
oil to clean the parts. In particular, never use min-
eral oil (kerosene, gasoline, etc.) If mineral oil
sticks to a rubber part, the latter will swell and
cannot be used.)
• When cleaning the rubber parts such as the cup
in alcohol, do not soak them in alcohol for more
than 30 seconds.
• Keep the cleaned parts in a clean place so that
dirt will not stick to them.
• Take care that foreign matter will not enter the cir-
cuit and the cylinder, piston, cup, etc. will not be
scratched.
Brake booster and master cylinder
1. Spring 9. Reaction piston

2. Reservoir 10. Cup
3. Flow divider spool 11. Relief valve
4. Body 12. Control valve
5. Power piston 13. Rod
6. Bellows 14. Y-packing
7. Push rod 15 Piston assembly
8. Yoke 16. Cylinder
40-106 CX-Series
Sym-
No. Part name Inspection item Inspection method Remedy bol
Flaw and wear of slid- Remove minute flaws with sandpaper. If there is a
ing surface flow which may have bad effects on seal, replace
assembly.
1 Cylinder Replace 16
assembly
Clearance between
cylinder and piston If below limit, replace.

2 Power piston Replace 5

assembly assembly

Control valve
3 assembly and Replace 11, 12
relief valve assem- assembly
bly
Flaw and wear of slid- Remove minute flaws with sandpaper.

ing surface
Reaction piston Replace
4 assembly assembly 9
Flaw, wear, leaning If spring is damaged or worn excessively, replace.
5 Spring Replace 1
Free length If below limit, replace.

6 Rod Flaw and wear of slid- flow which may have bad effects on seal, replace Replace 13

7 Flow divider spool Flaw and wear of slid- flow which may have bad effects on seal, replace Replace 3
8 Y-packing, cup, Damage of sealing If seal is damaged or worn excessively, replace. Replace 10, 14
and O-ring surface
9 Push rod Deformation and wear If push rod is deformed or worn excessively, Replace 7
replace.
10 Yoke Deformation and wear If yoke is deformed or worn excessively, replace. Replace 8
Crack If bellows is cracked, replace.
11 Bellows Replace 6
Tightening allowance
on cylinder If tightening allowance is little, replace.
CX-Series 40-107
Unit: mm
Basic Standard
A Clearance between cylin-
der and piston
– 0.020 + 0.052 0.020 –
25.4 – 0.053 0 0.105 0.150
B Clearance between cylin- 25.4 – 0.020 + 0.052 0.020 – 0.150


Free length Installed length (N {kgf}) Free length
37.5 33.5 69.3 {7.1} 36.0
F Deterioration of spring 106 68.5 101.0 {10.3} 96

Retighten
J Tightening torque 17.6 – 21.6 Nm {1.8 – 2.2 kgf•m} —
40-108 CX-Series
ASSEMBLY
• Clean recycled parts with alcohol or brake fluid.
When cleaning rubber parts such as cups with al-
cohol, do not dip them in alcohol for more than 30
seconds.
• Completely apply rubber grease or brake fluid to
the inside of the cylinder and the outer piston cir-
cumference.
1. Assembling the brake master cylinder

1) Assemble valve spring (60) and check valve
(59) with the cylinder and tighten bolt (57) and
gasket to the cylinder.
39.2 – 44.1 Nm {4 – 4.5 kgf•m}
2) Assemble piston assembly (52) with the

spring and insert them to the cylinder. At this
time, adjust the directions of the piston
groove and the stop pin hole.
3) Assemble the gasket with the stop pin and in-
sert them with the piston inserted to assem-
ble the cylinder.
17.6 – 21.6 Nm {1.8 – 2.2 kgf•m}
4) Slightly press the piston and fix it using the

snap ring.

clean parts.
Never use mineral oil (e.g. petroleum and
gasoline).
If mineral oil adheres to rubber parts, they
will swell and become unavailable.
• Keep parts at a clean place away from dirt
after cleaning.
avoid damaging the cylinder, piston,
cups, etc.
CX-Series 40-109
2. Assembling the booster (refer to the disas-

sembly drawing)
1) Clean recycled parts with detergent or miner-
al hydraulic oil.
a Use mineral hydraulic oil to clean rubber
parts and do not clean them with deter-
gent oil, petroleum or gasoline.
2) Assembling the reaction piston sub-assembly

• Assemble the O-ring with the reaction pis-
ton.
• Insert the spring in the hole of the reaction
piston.
• Insert the relief valve by matching the re-
lief valve and reaction piston holes and in-
sert the pin after making sure that the
holes have overlapped.
3) Assembling the control valve

• Apply hydraulic oil to the control valve
and insert it together with the spring to the
power piston.
• Assemble the O-ring with the cap, insert
them to the power piston and assemble
them using a snap ring.
4) Assembling the power piston sub-assembly

• Apply hydraulic oil to the reaction piston
and insert it to the power piston.
• Insert the ring from the side and assem-
ble them using a snap ring.
40-110 CX-Series
5) Assembly of piston guide

• Apply grease to the O-ring, Y-packing,
and cup, and then install them to the pis-
ton guide in the correct direction.
6) Installation of Y-packing to body

• Apply grease to the Y-packing, and then
install it to the body in the correct direc-
tion.
7) Assembling the power piston assembly

• Apply grease to the rod and assemble it
with the body.
CX-Series 40-111
8) Assembling the flow divider

• Apply hydraulic oil to the spool and insert
it to the body in the proper direction.
• After checking that the spool smoothly
operates, insert the spring.
• Assemble the O-ring with the cap, apply
grease and assemble the spring by
pressing it using a snap ring.
9) Assembling the boot

• Assemble the boot after pressing reaction
piston by hand to make sure that it
smoothly operates.
10) Insert the push rod and install the bellows,

nut, and yoke to the push rod in order.
8 – 12 Nm {0.8 – 1.2 kgf•m}
k • Never use anything other than alcohol and

brake oil to clean the parts.
Never use anything (kerosene, gasoline,
etc.) other than mineral oil-based hydrau-
lic oil to clean the rubber parts.
a If mineral oil-based hydraulic oil sticks
to a rubber part, the latter will swell
and cannot be used.)
• Keep the cleaned parts in a clean place so
that dirt will not stick to them.
• Take care that foreign matter will not enter
the circuit and the cylinder, piston, cup,
etc. will not be scratched.
40-112 CX-Series
3. Joining the brake booster and the master cyl-

inder
Assemble the booster and brake master cylinder
assemblies and tighten them using nut (31).
20.6 – 30.3 Nm {2.1 – 3.1 kgf•m}
Clutch truck
Clutch truck
4. Joining the clutch and brake boosters
1) Apply grease to the O-rings and install them
to the 2 mating faces A of the booster.
2) Join the clutch booster (3) and brake boost-
ers (2) and tighten them using bolt (4).
27.5 – 34.3 Nm {2.8 – 3.5 kgf•m}
• Bolt size: M8 × 1.25 × 50

• Hexagonal wrench used: 6-mm type
• O-rings on the mating face
(inside diameter × thickness):
a 20.8 mm × 2.4 mm
b 10.8 mm × 2.4 mm Torque converter truck (only brake booster)
CX-Series 40-113
DISASSEMBLY AND ASSEMBLY REAR AXLE
REAR AXLE
DISASSEMBLY DRAWING
a Use the jig to press fit bolt (1).
40-114 CX-Series
ASSEMBLY DRAWING
1. Adjusting the stopper bolt

Adjust it so that the left and right stoppers apply at the same time when the tire steering angle is set at the
maximum.
2. Assembling the ball socket

• Make sure that no grease or paint adheres to each tapered part when assembling the ball socket to the
bell crank.
• Bend the cotter pin at part A securely (3 places).
3. Greasing
Apply lithium grease (G2-LI) to grease nipples ({G} x 9) and hubs.
CX-Series 40-115
DETAILS ON REAR AXLE

1. Bell crank
1) Lock bolt (2) of bell crank (1)
Tightening torque 27.5 – 34 Nm {2.8 – 3.5 kgf•m}
2) Snap ring (3)

Make sure that the snap ring has completely
been engage with the ring groove.
2. King pin
1) Adjust the needle bearing (7) end surface to
the boss (4) end surface (within the range of
0 to -1 mm).
2) Adjust the plays above and under the knuckle
(5) to the minimum using the shim (6).
Standard 0.05 to 0.2 mm
3. Link
1) Completely bend cotter pin (8).
2) Make sure that snap ring (9) has completely
been engage with the ring groove.
4. Hub
1) Apply sufficient grease (G2-LI) to the hub
bearing and also fill 1/2 to 2/3 (shaded por-
tion) of the hub capacity with grease (on both
sides).
2) When assembling the hub, apply grease (G2-
LI) to the lip of seal (10).
3) After adjusting the starting torque with nut
(12), bend cotter pin (11) securely.
40-116 CX-Series
5. Adjusting the rotation starting torque of the

hub
1) Tighten the locknut until it becomes difficult to
turn the hub by single hand and turn the hub
by 1/4 rotation from that position in the oppo-
site direction. Adjust the rotation starting
torque to 39 – 78 N {4 – 8 kgf} using nut (12)
by applying a spring scale to the hub bolt and
apply pre-load to the tapered roller bearing.
Starting torque 431 – 862 Ncm {44 – 88 kgf•cm}
a Distance between knuckle and hub bolt

centers: 110 mm
2) After adjustment, insert a cotter pin (rotation

stopper) to a place where the nut and shaft
holes match and completely bend it.
6. Adjusting the tire steering angles Standard height of stopper bolt

Set the tire steering angles to the maximum and
adjust angle A to 77°20' and B to 54° for both
sides using stopper bolts (1) to (4).
After adjustment, completely tighten the locknut.
A 77°20'
B 54°
CX-Series 40-117
REAR WHEEL (ADJUSTING RIM)

k • Before disassembling the wheel, be sure
to completely release the air. If the rim ad-
justing bolt (4) is loosened without com-
pletely releasing the air, personnel injury
may occur.
• Before removing the wheel from the body,
check that the rim adjusting bolt (4), nut
(5) is not broken or dropped. If any break-
age or dropping is detected, remove the
wheel after jacking it and releasing the air.
k • Assemble the rim adjusting bolt (4) in
such a manner that the bolt head (semi- Rear wheel (adjusting rim)
circle) comes outside the body.
• Be sure to use a specified genuine rim ad-
justing bolt (4).
• Be sure to use a special tool for disassem-
bling and assembling the adjusting rim.
Disassembly
1) Completely release the air.
2) Remove the rim adjusting bolt (4), nut (5) using a
special tool A (adapter: 3BA-97-13310) and a
general socket wrench.
3) Remove the rim (2), (3) from the tire (1).
4 Remove the tube (6) from the tire (1).
Assembly
1) Assemble the tube (6) with the tire (1).
2) Fill a small amount of air to the tube (6) to remove
the tube twist (do not swell it).
3) Adjust the rim (2), (3) in such a manner to adjust
the tube and rim mouthpieces from both sides of
the tire (1).
4) Install the rim adjusting bolts (4) and diagonally
tighten them by the same torque.
• Rim adjusting bolt
245 – 308 Nm {25 – 31.5 kgf•m}
• Rim size: 5.00S × 12

• Tire size: 7.00 – 12 – 12PR(1)
• Tire air pressure: 0.83 MPa {8.5 kg/cm2}
40-118 CX-Series
DISASSEMBLY AND ASSEMBLY STEERING GEAR BOX
STEERING GEAR BOX

DISASSEMBLY DRAWING
1. Worm shaft a Bend 2 parts of the flange of nut (4).

2. Worm shaft gear a Set the match mark (slit) of sector shaft (5) at right
3. Closed valve (CV) spool angles to worm shaft (2).
4. Nut a Fill end cover at part B of worm shaft (1) with
5. Sector shaft (End face) grease. (20 – 25 mm)
CX-Series 40-119
DISASSEMBLY
Precautions when disassembling
1) Cleaning function parts
Clean function parts with volatile metal deter-
gent (TRICLEN, CROROSEN, METACLEN),
and dry with compressed air.
2) Handling oil seals, O-rings and rubber
parts
Remove foreign materials with compressed
air.
In order to clean oil seals, O-ring and rubber
part, never use some metal detergents which
are dipped before using.
Replace all abnormal parts by new parts.
3) Oil seal
When it is removed from the steering body
and the end cover, replace by new oil seal.
4) Needle radial bearing and bushing
The needle radial bearing, which are press-
fitted to the steering body, and the bushing,
which are press-fitted to the steering body,
and the bushing, which are press-fitted to the
side cover, are not disassembled. If there are
any abnormal it, replace the steering body as-
sembly and the side cover assembly.
1. Rear cover
Loosen bolts, then remove rear cover (1).
a When removing the rear cover, oil will flow
out, so prepare a container to catch it.
2. Control valve assembly

1) Loosen locknut (2).
2) Remove needle thrust bearing and centering
plate.
40-120 CX-Series
3) Remove control valve assembly (3).

a Be careful not to let the valve spool and
reaction plunger fall out.
4) Remove centering plate and neutral thrust
bearing.
3. Disassembly of control valve assembly

Remove reaction spring (4).
a If the valve spool will not come out easily,
slide it two or three times and then remove it.
Never hit it in with a hammer.
4. Side cover assembly

1) Loosen bolt (5).
2) Loosen seal washer (6).
a Remove seal washer non recycred.
3) Turn adjustment screw (7) to right with a
screwdriver, then pull out side cover assem-
bly.
5. Sector shaft assembly

Lightly hitting the serrated side of sector shaft as-
sembly (8) with a plastic hammer, pull out the
sector shaft.
a When removing the sector shaft, take care
not to damage the oil seal and friction seal in-
stalled to the gear case.
CX-Series 40-121
6. Disassembly of sector shaft assembly

Disassemble the sector shaft assembly into shim
(11), adjustment screw (10), and sector shaft (9).
7. End cover assembly

1) Remove dust cover (14).
2) Loosen bolts (12) and remove end cover (13).
8. Disassembly of end cover assembly

Disassemble the end cover assembly into dust
cover (14), end cover (15), O-ring (16), oil seal
(17), and bearing (18).
a When removing the oil seal, take care not to
damage the bearing inserting part in the end
cover with the screwdriver.
9. Ball screw assembly

Remove ball screw assembly (19).
40-122 CX-Series
10. Disassembly of steering body assembly

1) Insert pin A body hole, and remove snap ring
(20).
2) Remove oil seal.
a When removing the oil seal, be careful
not to damage the needle radial bearing
of the steering body bushing (21) with the
screwdriver.
Location Check item Remedy
Valve spool, valve housing

Abnormal wear, rust, scratches
sliding surface
Sector shaft Scratches, abnormal wear, cracks Replace
Propulsion force when rotating: Max. 98.1 N {10 kgf}

Ball screw assembly Secure ball nut in horizontal position, apply propul- Replace assembly
sion force to steering shaft, and measure propulsion
force when rotating
Abnormality in bearing roller and steering shaft, sector Replace (replace radial bearing as
Needle bearing
shaft roller tread surface assembly)
Bushing Abnormal wear and flaw of bushing Replace (bushing assembly)
Oil seal and friction seal Abnormal wear, flaw, and tear Replace
CX-Series 40-123
ASSEMBLY
Precautions when assembly
1) Wash all parts and check that they are clean
when assembling.
2) Replace all O-rings, oil seals, and rubber
parts. (Replace all the rubber parts once ev-
ery year.)
3) Apply grease to rubber parts and bearings.
4) After making the sub-assembly, carry out the
overall assembly.
Assembly of sub-assembly
1) Insert valve spool into valve housing.
2) Insert reaction plunger and reaction spring
(4).

1) Insert adjustment screw (10) and shim (11) to
sector shaft (9).
a If there is any play between the sector
shaft and adjustment screw, replace with
a thicker shim and adjust so that there is
no play in the adjustment screw when ro-
tating.

1) Fill grease around the shaft in 20 to 25 mm
width from the seal to the spline side in the
end cover tube (min. 3 g).
2) Coat outside circumference of oil seal (17)
thinly with grease (G2-LI), then press fit to
end cover (15).
a When press fitting, be careful not to dam-
age the lip on the inside diameter of the
oil seal.
3) Insert bearing (18).
40-124 CX-Series
4. Steering gear box, body assembly

1) Coat outside circumference of oil seal (23)
thinly with grease (G2-LI), press fit to steering
body (22), then secure with snap ring (24).
a When press fitting, be careful not to dam-
age the lip o the inside diameter of the oil
seal.
Overall assembly
1. Ball screw assembly
1) Fix steering body assembly in a vice.
2) Insert ball screw assembly (19), then insert
portion of steering shaft with largest diameter
into needle radial bearing portion of steering
body assembly.
a When carrying out the rest of the opera-
tion, be careful not to let the outside diam-
eter portion of the steering shaft come out
from the needle radial bearing.

1) Fit O-ring to end cover.
2) Coat end cover O-ring and oil seal lip with
grease (G2-LI) and assemble to steering
body.
a Be extremely careful that the O-ring is not
cut or pushed out, and that the oil seal is
not damaged.
3) Tighten bolts to specified torque.
CX-Series 40-125

1) Set ball not of ball screw assembly (assem-
bled to steering body) at approximately cen-
ter of stroke.
2) Coat oil seal lip of steering body with grease

(G2-LI).
3) Assemble sector shaft so that teeth of ball nut

and teeth of sector shaft are meshed when
facing straight forward.
a Be careful not to damage the oil seal lip
when assembling the sector shaft.

1) Fit O-ring (1) to steering body.
2) Install needle thrust bearing (2) and centering

plate (3).
3) Install control valve assembly (4).

cut or pushed out.
4) Install centering plate (5) and needle thrust

bearing (6).
5) Tighten locknut (7), then caulk flange at 2

points.
40-126 CX-Series
5. Rear cover
1) Fit O-ring to control valve assembly, then
tighten bolts to install.
2) Tighten bolts.
37 – 57 Nm {3.8 – 5.8 kgf•m}

cut or pushed out.
6. Side cover
1) Fit O-ring to side cover.
2) Align threaded portion of side cover with
threaded portion of adjustment screw of sec-
tor shaft assembly, then use a flat-headed
screwdriver to turn adjustment screw to left
while assembling side cover.
cut or pushed out.
3) Tighten bolts.
34 – 53 Nm {3.5 – 5.4 kgf•m}
7. Dust cover
Assemble dust cover.
8. Measuring reverse rotation torque

Set steering shaft in free condition, and measure
rotating torque of sector shaft in both left and right
directions.
Reverse rotation
24.5 Nm {2.5 kgf•m}
torque
CX-Series 40-127
ADJUSTMENT AND CHECK

1. Adjustment of backlash
1) Set the sector shaft and ball nut in the straight
travel position.
2) Install the pitman arm, apply dial gauge to its

end, and adjust the backlash below.
0.1 – 0.3 mm
Backlash (In straight travel position)
3) After adjusting the backlash, tighten the seal

washer while fixing the adjustment screw.
20 – 29 Nm {2 – 3 kgf•m}
4) After adjusting the backlash to 0.1 – 0.3 mm,

return the sector shaft by 2 – 3 turns with the
pitman arm, then measure the backlash
again.
a Repeat adjustment until the backlash is
set to 0.1 – 0.3 mm.
5) Tighten the seal washer and fix the adjust-

ment screw.
20 – 29 Nm {2 – 3 kgf•m}
2. Measurement of forward starting torque

Set the sector shaft free and measure the starting
torque of the steering shaft in each direction.
Starting torque 1.5 Nm {0.15 kgf•m}
40-128 CX-Series
DISASSEMBLY AND ASSEMBLY CONBINATION SWITCH
CONBINATION SWITCH
CLUTCH TRUCK
COMPONENT PARTS
1. Body 6. Screw
2. Turn signal switch 7. Wire
3. Boot 8. Dush boad wiring harness
4. Cover 9. Connector
5. Screw 10. Engine wiring harness
40-130 CX-Series
TORQUE CONVERTER TRUCK

COMPONENT PARTS
1. Lighting/turn signal light switch 5. Screw

2. Forward/reverse switch 6. Screw
3. Cover 7. Dash board wiring harness
4. Boots 8. Engine wiring harness
CX-Series 40-131
CHECKING LIGHTING/TURN SIGNAL

SWITCH
Without dimmer switch
1. Remove connection of 8-pin coupler (1) between
combination switch cord and main wiring harness
2. Check continuity between terminals at each posi-
tion, and check that there is continuity between
Q–Q.
3. Insulating resistance: Min. 10 Mz at each termi-
nal with 500 V megger
Connection positions for lighting switch Circuit diagram

Circuit 1 2 3 4
Position
OFF
Lighting SMALL Q Q
switch
HEAD
Q Q
Q Q
• On the clutch specification truck, terminal [5]
(dimmer circuit) is a dummy circuit.
Connection positions of turn signal switch Circuit diagram

Circuit 6 7 8
Position
R Q Q
Intermediate
L Q Q
40-132 CX-Series
With dimmer switch

1. Remove connection of 8-pin coupler (1) between
combination switch cord and main wiring harness
Q–Q.
3. Insulating resistance: Min. 10 Mz at each termi-
nal with 500 V megger
Connection positions for lighting switch Circuit diagram
Circuit 1 2 3 4
Position
OFF
Lighting
SMALL Q Q
switch
LO Q Q
HEAD
HI Q Q Q
Connection positions of turn signal switch Circuit diagram
Circuit 5 6 7
Position
R Q Q
Intermediate
L Q Q
CX-Series 40-133
TESTING OF F/R SWITCH

1. Disconnect 6P coupler (1) and 2P coupler (2) be-
tween the combination switch cable and main wir-
ing harness.
Q–Q only.
F/R switch Circuit diagram
Circuit 1 2 3 4 5 6
Position
Starting Q Q
motor and N
F/R
F1 Q Q
switch
R1 Q Q
F2 Q Q
40-134 CX-Series
REPLACING THE COMBINATION SWITCH

1. Remove 4 screws (5), steering column upper cover (1), and lower cover (4).
2. Disconnect 8P coupler (3), 6P coupler (6) between the switch cable of combination switch (2) and the main
wiring harness. (for the F2/R1 truck, also remove connection of 2-pin coupler)
3. Remove 2 screws (8) of band (9) which is fixing steering shaft (7) and combination switch, and then remove
the switch.
4. Assembly is done in the reverse order of disassembly.
CX-Series 40-135
REPLACING THE LIGHTING AND F/R SWITCH

1. Remove 4 screws (5), steering column upper cover (1), and lower cover (4).
2. Disconnect 8P coupler (3), 6P coupler (6), and 2P coupler between the switch cable of combination switch
(2) and the main wiring harness.
3. Remove 2 screws (8) of band (11) which is fixing steering shaft (7) and combination switch, and then remove
the switch.
4. Remove 2 mounting screws (9) of lighting switch (10) and cable fixing plastic band, and then remove the
switch.
5. Assembly is done in the reverse order of disassembly.
40-136 CX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
HYDRAULIC PUMP
Notes
• Avoid disassembling them as much as possible.
• Do not remove the cover and the plate from the bushing.
• Do not change the combinations of gears and side plates (3), (4) and (5), and (8), (9) and (10).
Avoid disassembling them as much as possible.
• During assembly, do not allow oil to remain on the mating faces of the cover, the body, etc.
No. Parts Qty No. Parts Qty
1 Front cover 1 12 Bushings 4
2 Body 1 13 Gaskets 2
3 Drive gear 1 14 Gaskets 2
4 Driven gear 1 15 Backup strips 2
5 Side plates 2 16 Gaskets 2
6 Adapter plate 1 17 Gaskets 2
7 Body 1 18 Oil seal 1
8 Drive gear 1 19 Snap ring 1
9 Driven gear 1 20 Hexagon hole bolt 4
10 Side plates 2 21 Washers 4
11 Bushings 4
CX-Series 40-137
DIESEL ENGINE TRUCK
No. Parts Qty No. Parts Qty
Pump assembly 1 12 • Coupling 1

1 • Gear plate 1 13 • Dowel pin 1
• Gear set 1 14 • Bolts 4
2 • • Drive gear 1 15 • Washers 4
3 • • Drive gear 1 16 • O-ring (K18) 1
4 • Frange assembly 1 17 • Bolts 2
5 • Cover plate assembly 1 18 • Washers 2
6 • Pressure plates 2 19 • O-ring (K18) 1
7 • Seal (K18) 2 20 • Cover 1
8 • Backup rings (K18) 2 21 • Bolts 2
9 • Oil seal (K18) 1 22 • O-ring (K18) 1
10 • Snap ring (K18) 1 23 • Pump 1
11 • Adapter plate 1
40-138 CX-Series
FAILURES AND CAUSES
Condition of failure Probable causes Remedy
1) Reverse rotation 1) Remove cause of reverse rotation or

2) Abnormally high pressure at suction side abnormally high pressure at suction side
1) Oil leakage from oil seal
3) Seal lip damaged by dirt 2) Replace oil seal
4) Wear or damage to shaft seal portion 3) Replace shaft
1) Damage or looseness of bolt 1) Remove abnormally high pressure or

2) Leakage of oil from join 2) Damage or drop in sealing performance vibration causing damage or loosening of
of cover and body caused by heat hardening of gasket bolts
2) Replace bolts, gasket
1) Damage or looseness at port joint 1) Remove abnormally high pressure or

2) Damage to joint seal material vibration causing damage or loosening of
3) Leakage of oil from port 3) Damage to port joint
2) Replace joint seal material
3) Replace cover
1) Lack of oil in tank 1) Correct tank oil level, change to correct

2) Abnormally high temperature of hydraulic type of hydraulic oil, replace cooling
oil caused by lack of capacity of cooling device
device or increase in internal leakage 2) Change dirty hydraulic oil
4) Reduction in discharge
caused by unsuitable viscosity of hydrau- 3) Check length and thickness of suction
amount or lack of pres-
lic oil piping, clean filter, and remove other
sure
3) Drop in pump performance caused by dirt causes of abnormal negative pressure
in hydraulic oil 4) Replace pump
4) Cavitation
5) Pump failure
1) Abnormal generation of heat by frequent 1) Change to suitable negative pressure

5) Abnormal rise in temper-
actuation of relief valve 2) Replace cooling device
ature of pump or hydrau-
2) Lack of capacity in cooling device 3) Replace pump
lic oil
3) Pump failure
1) Cavitation 1) Remove cause of abnormal negative

2) Entry air pressure
3) Defective centering during installation 2) Remove cause of low oil level or entry of
6) Abnormal noise or vibra-
4) Resonance of piping or mounting flange air into suction piping
tion
3) Collect installation and centering
4) Strengthen piping or mounting flange to
remove cause of resonance
CX-Series 40-139

1. Replacing the oil seal
(Disassembly)
1) Loosen bolt (20) to remove front cover (1).
2) Remove snap ring (19) and oil seal (18).
(Assembly)
1) Assemble the oil seal with front cover (1) and
fix them using snap ring (19).
2) Apply grease (G2-LI) to the oil seal lip and
mount the front cover in such a manner to
avoid damaging the lip.
3) Tighten bolt (20).
98 – 107 Nm {10 – 11 kgf•m}
2. Replacing the gasket and the back-up ring

(Disassembly)
1) Loosen bolt (20) to disassemble the assem-
bly into A, B, C and D (refer to the procedure
for replacing the oil seal).
2) Remove gaskets (13) to (17) and back-up
ring (15).
(Assembly)
1) Assemble gaskets (13) to (17) and backup
ring (15) with the front cover, the adapter
plate and the body.
2) Assemble the four A, B, C and D blocks and
tighten them using bolt (20).
98 – 107 Nm {10 – 11 kgf•m}
40-140 CX-Series
DISASSEMBLY AND ASSEMBLY FLOW DIVIDER
FLOW DIVIDER
Parts Flow divider assembly
Fluid used Mineral hydraulic oil (ISO VG32)

Specifications
Flow control 5.0 l/ min
Maximum operating pressure 18.1 MPa {185 kgf/cm2}
Maximum flow 25 l/min
1. Body A. OUT port

2. Spring B. IN port
3. Spool C. Flow control port
4. O-ring
5. Bolt
CX-Series 40-141
DISASSEMBLY
1. Remove bolt (3).
2. Remove spring (4).
3. Remove spool (2).
a Be careful not to damage the outside of the spool

and the inside of the body.
• During disassembling, properly understand the

configuration and put parts in the disassembling
order after disassembling.
ASSEMBLY
a Clean recycled parts with detergent or mineral
hydraulic oil.
• Make sure that the spool smoothly operates after

assembling it.
1. Assemble spool (2) with the body.
2. Assemble spring (4).
3. Assemble the O-ring with bolt (3) and install them

on the body.
98 – 107.8 Nm {10 – 11 kgf•m}
40-142 CX-Series
No. Parts Check item Check procedure Remedy
Remove small flaws using sand paper.

1 Cylinder (Body) Flaw or wear on sliding Replace the assembly if any flaw which may affect Replace the flow
surface sealing is detected. divider assembly.
Flaw, wear or fall Replace if any significant flaw or wear is detected.

2 Spring
Free length Replace if the length is less than the limit.
Replace
3 Flow divider spool Flaw or wear on sliding Remove small flaws using sand paper.
surface Replace if any significant flaw or wear is detected.
Flaw or wear on sliding Replace if any damage or significant wear is

4 O-ring surface detected on the seal.
Maintenance standard
Unit: mm
Free length Installed length Installed load Free length

(N{kgf})
2 Deterioration of spring
37.5 33.5 69.6 {7.1} 36.0 Replace
5 Tightening torque 98 – 107.8 Nm {10 – 11 kgf•m} —
CX-Series 40-143
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
DISASSEMBLY
• Loosen the bottom cap mounting bolt and remove 1. Attachment spool assembly
only the cap. (with 2 relief valves)
• Remove the screws on the head side first, and 2. Tilt spool assembly
then remove the dust seals. 3. Lift spool assembly
• Arrange the removed spools so that they can be
distinguished. When removing the tilt spool, pro-
tect it with soft material and grip its head side in a
vice.
40-144 CX-Series
DISASSEMBLY AND ASSEMBLY CONTROL VALVE

• Smooth the sliding surfaces of each part using
lapping agent if they are as rough as catching fin-
gers.
• Replace deteriorated or bent springs.
Unit: mm
Basic length
Item (Free length) Repair limit
Check valve spring 38.5 35
Tilt lock spring 35.8 32
Spool return spring 74.5 67
ASSEMBLY
1. Assembly of tilt spool (6)
Install the tilt lock spring in the spool and install
the O-ring to the cap screw.
a At this time, take care of the direction of tilt
lock spool (5).
Tightening torque for cap screw:
11.8 – 13.7 Nm {1.2 – 1.4 kgf•m}
(Apply Loctite)
2. Apply clean hydraulic oil to tilt spool (3) and install

it to control valve housing (4).
a At this time, take care not to install the spool
in the wrong direction.
3. Apply lithium grease No. 2 to the return spring

and install the cap, and then install the seal plate
on the head side.
Return spring: Lithium grease No. 2
Tightening torque for mounting bolts
Bolt (2) on head side:
11.8 – 14.7 Nm {1.2 – 1.5 kgf•m}
Bolt (1) on bottom side:
11.8 – 14.7 Nm {1.2 – 1.5 kgf•m}
4. Tighten the long bolts (7) and (8) to couple the

blocks with specified torque.
CX-Series 40-145
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
LIFT CYLINDER
COMPONENT PARTS (FG, D45T/50AT)
Down control valve
Safety valve
1. Cylinder rod Lift cylinder (height: 3 m)

2. Dust seal • Inside diameter × outside diameter x stroke
3. Cylinder head 3.25 to 4.0 ton truck: 65 × 73 × 1,505 (mm)
4. Bushing 4.5 to 5.0 ton truck: 70 × 79 × 1,505 (mm)
5. Cylinder tube • Rod diameter: 50 mm
6. (Collar) a Collar (6) is added to increase overlap for those
7. Piston ring having a height of 3.8 m or higher.
8. U packing
9. Retainer
10. Stopper
40-146 CX-Series
DISASSEMBLY DRAWING
FG, D35ZT/40ZT/35T/40T
1. Cylinder 7. O-ring
2. Piston rod 8. U packing
3. Cylinder head 9. Backup ring
4. Bushing 10. Bushing
5. U packing 11. Spacer (lifting height: min. 4 m)
6. Dust seal 12. O-ring
CX-Series 40-147
DISASSEMBLY
1) Grip the cylinder tube in a vice and loosen and re-
move the cylinder head.
2) Pull the spacer out of the cylinder tube and drive
out the bushing.
3) Apply wrench A to the hole of retainer (2) on the
piston side and turn it to pry stopper (1) open, and
then turn it in the fixing direction of the stopper
again, and the stopper comes off.
Unit: mm
Criteria
Sym-
A Clearance between cylinder rod and bushing 0.072 – 0.288 0.5 Replace bushing
B Clearance between piston ring and tube 0.05 – 0.30 0.5 Replace piston
ring
ASSEMBLY
1) Soak the piston ring in hydraulic oil at 40 – 50°C
to increase its inside diameter and install it to the
piston.
2) Install the U-packing and fix the spacer with stop-
per (1).
3) Bend the stopper end and turn retainer (2) with
wrench A to roll in the stopper perfectly.
40-148 CX-Series
DISASSEMBLY AND ASSEMBLY TILT CYLINDER (6°/12°)
TILT CYLINDER (6°/12°)

DISASSEMBLY DRAWING
40-150 CX-Series
ASSEMBLY DRAWING
a After tightening piston nut (13), caulk 3 points of part A.
1. Cylinder 12. Rod Tilt cylinder

2. Bushing 13. Nut • Inside diameter × outside diameter × stroke:
3. Head 14. Piston 90 × 105 × 185 mm
4. Dust seal 15. Seal • Rod diameter: 40 mm
5. Bushing 16. Rod head • Collar width (6°/6°): 127 mm
6. Packing 17. Seal
7. Ring 18. Nipple
8. Washer 19. Bolt
9. Ring 20. Spring washer
10. O-ring 21. Nut
11. O-ring
CX-Series 40-151
DISASSEMBLY
1) Grip the bottom parallel part of the cylinder tube
in a vice and make a mark at the rod head to
check the tightening depth, and then remove the
rod head.
2) Apply a wrench to the cut of the cylinder head and
turn it to pull the cylinder head out of the cylinder
tube. (At this time, wind a tape onto threaded part
A of the rod to protect the dust seal and U-pack-
ing in the cylinder head.)
3) Pull out the piston rod, remove the nut, and disas-
semble the piston.
a Line up the removed parts in order.
a After tightening the piston nut, caulk 3 points at part P.

Unit: mm
Criteria
Sym-
A Clearance between piston rod and cylinder 0.072 – 0.288 0.5

head bushing
Replace bushing
B Clearance between cylinder mounting pin 0.10 – 0.35 0.6
and bushing (bottom)
Clearance between rod head pin and head Replace pin or rod
C pin hole 1.96 – 2.0 2.5 head
D Inside diameter of rod head pin hole 34.989 – 35.014 35.5 Replace rod head
E Tightening torque for piston mounting nut 1,088 – 1,577 Nm {111 – 161 kgf•m} —
ASSEMBLY
Carry out installation roughly in the reverse order to
removal.
40-152 CX-Series
DISASSEMBLY AND ASSEMBLY POWER STEERING CYLINDER
POWER STEERING CYLINDER

DISASSEMBLY DRAWING
1. Cylinder 9. Head
2. Boss 10. Bushing
3. Bracket 11. Packing
4. Piston rod 12. Wiper
5. Piston 13. O-ring
6. Bushing 14. O-ring
7. O-ring 15. Nipple
8. Seal 16. Plug
CX-Series 40-153
DISASSEMBLY AND ASSEMBLY POWER STEERING CYLINDER
Item Unit Specifications
Cylinder (inside × outside diameters) mm 75 × 85
Stroke mm 215
Outside diameter of rod mm 50
a After tightening the cylinder head, caulk 1 point at part P on the circumference.
Unit: mm
Criteria
Sym-
A Clearance between cylinder and piston 0.05 – 0.25 0.4
B Clearance between piston rod and bushing 0.03 – 0.18 0.3

Replace
C Piston rod Flaw, dent, streak or concave on claw
D Cylinder Flaw, dent, streak or concave on claw
E Head tightening torque 294 – 343 Nm {30 – 35 kgf•m} —
40-154 CX-Series
DISASSEMBLY AND ASSEMBLY MAST
MAST
COMPONENT PARTS
1. OUTER MAST
1. Outer mast Outer mast (3 m)

2. Shims • Weight: 344 kg (FG, D35ZT/40ZT)
3. Roller 349 kg (FG, D35T/40T)
4. Lift cylinder clamp 504 kg (FG, D45T/50AT)
5. Tilt cylinder pin
6. Grease fitting
7. Mast cap
8. Bushing
CX-Series 40-155
2. INNER MAST
1. Inner mast Inner mast (3 m)

2. Lift cylinder bracket • Weight: 331 kg (FG, D35ZT/40ZT)
3. Lift chain 335 kg (FG, D35T/40T)
4. Chain stopper 396 kg (FG, D45T/50AT)
5. Roller
6. Chain wheel
40-156 CX-Series
ADJUSTMENTS
1. Outer main roller
1) Selection of roller size
Select such rollers (S, M, L, O) as no differ-
ence can be made at the a between the left
and right masts.
2) Adjustment of shims
Adjust shims (1) so that b will be as 0.1 b
0.4. Then, adjust shims (2) so that c will be as
0 c 0.5 (at the maximum lifting height).
a Insert shims of the same thickness to
both sides.
2. Inner main roller

1) Selecting roller size
Select roller (S, M, L, O) so that 0.2 a
0.9.
2) Adjusting shim
Adjust with shim (1) so that 0 b 0.5 (at
max. lifting height).
a Insert same thickness of shim on left and
right.
CX-Series 40-157
DISASSEMBLY AND ASSEMBLY FORK CARRIAGE
FORK CARRIAGE
a Press the back rest at part A against the board
and tighten the bolt.
1. Section AA
1) Adjust the shims so that a will be as 0 a
0.5 mm (at the top of the finger board).
40-158 CX-Series
2. Section BB
1) Select the roller so that b = 0.4 – 1.6 mm.
2) Insert shims of the same thickness to both
sides so that c will be as 0.5 c 1.0 mm
at the top of the finger board.
3. Section CC
1) Select the roller so that d = 0.4 – 1.6 mm.
2) nsert shims of the same thickness to both
sides so that c will be as 0.5 e 1.0 mm
4. Projection B of roller
(when lowered to bottom)
1) Measure distance B between the lower end
of finger board (1) and the lower end of roller
(2) on the lower side of the finger board.
Projection B of roller
Unit: mm
FG, D35ZT/40ZT 7.5
FG, D35T/40T 46.5
FG, D45T/50AT 39.5
CX-Series 40-159

Unit: mm
Criteria
Check item Remedy
Adjustment of
To side 0.5 – 1.0 Max. 2.5 shims
Clearance between inner mast and
outer mast To front/ 0.4 – 1.6 Max. 2.0 Replacement
rear
To side 0.5 – 1.0 Max. 2.5 Adjustment of

shims
fork carriage
To front/
rear 0.4 – 1.6 Max. 2.0
Depth of oil groove in mast support bushing Oil groove noted No oil groove
3.25 ton 50 Min. 48

truck
3.5 ton 50 Min. 48 Replacement

truck
4.0 ton
Thickness of forks A (at the basis) truck 55 Min. 50
4.5 ton
truck 55 Min. 50
5 ton 55 Min. 50
truck
40-160 CX-Series
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Item Tool No. Drawing
For driving the differential pinion shaft oil 3ED-97-99590

seal
• 3EC-97-99930
For measuring the differential pinion (clutch truck)
pre-load • 3EC-97-99940
For measuring the front hub starting 3ED-97-99570

torque
For measuring the differential pinion shaft 3EC-97-99600

starting torque
CX-Series 40-161
For tightening the differential adjusting

screw nut 34C-97-99110
For turning the differential ring gear 3EC-97-99960
For tightening the front axle locknut 308-968-9110
For compressing the clutch pack return 3EC-97-99000

spring
40-162 CX-Series
For inserting the clutch pack piston 3EC-97-99030
For driving the transmission output shaft 3ED-97-99110

bearing and oil seal
For driving the bearing 3EC-97-99210
For stopping and tightening the differential A 3EC-97-99151

pinion shaft B 3EC-97-99180
CX-Series 40-163
For removing and installing the rear wheel

and adjusting rim bolt 3BA-97-13310
For driving the transmission F and R shaft 3EC-97-99190

bearings
40-164 CX-Series
CAULKING JIG A
CAULKING JIG B
Notes
1. For the part marked , harden and temper 5 mm from the end (normalizing is also acceptable).
2. Chamfer C0.5 to 1.0 mm at the corner.
3. Material: S45C
CX-Series 40-165
50. MAINTENANCE STANDARD
Main clutch ....................................................... 50- 2

Transmission.................................................... 50- 4
Torque coverter................................................ 50- 6
TORQFLOW transmission (F1/R1) .................. 50-10
TORQFLOW transmission (F2/R1) .................. 50-12
Transmission control valve............................... 50-14
Differential ........................................................ 50-16
Wheel brake ..................................................... 50-18
Clutch booster and master cylinder.................. 50-20
Brake booster and master cylinder .................. 50-21
Clutch release cylinder .................................... 50-22
Steering gear box............................................. 50-24
Flow divider ...................................................... 50-26
Lift cylinder ....................................................... 50-27
Tilt cylinder ....................................................... 50-28
Power steering cylinder.................................... 50-29
Mast and fork ................................................... 50-30
Fork carriage .................................................... 50-32
Steering axle (Rear axle) ................................. 50-34
CX-Series 50-1
MAINTENANCE STANDARD MAIN CLUTCH
MAIN CLUTCH
FG, D35ZT – 45T-7
50-2 CX-Series
MAINTENANCE STANDARD MAIN CLUTCH
Unit: mm
Criteria
A Thickness of clutch disc (both faces) 8.1 7.3 Replace
B Diameter of drive shaft tip 19.967 – 19.98 19.85 Correct hard chrome plating
Play of spline in rotating direction — 0.5

C Replace
Face runout of outside circumference — 0.7
Height of release lever 63 Variation between Replace release bearing (1) if

(when released) levers: Max. 0.7 there is any seizure, damage or
wear.
Distance of movement of release lever 13 —
Wear-in amount of release lever 6.5 5.5
E Pressure plate Damage, stepped wear of friction Replace

surface
Replace pressure plate assem-

F Coil spring Deformation, deterioration bly
Lever plate thickness a
G 6 4.9 Replace
Method of measuring remaining thickness of clutch disc

• Measure with calipers at both the engine end and pressure plate end.
(See diagram on right.)
Cluch disc thickness b: Min 0.3 mm
a Take the smallest depth to the head of the rivet as the standard when judging.
a Stopper bolt (for removing and installing clutch): Be sure to remove it after as-
sembling the clutch.
CX-Series 50-3
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
50-4 CX-Series
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
Criteria
A1 49.93 – 49.975 49.8

Outside diameter of bushing Replace
(2nd speed and R gears)
A4 49.93 – 49.975 49.8
A
A2 54.93 – 54.975 54.8
Outside diameter of bushing
(1st speed and F gears) Replace
A3 54.93 – 54.975 54.8
B Clearance between balk ring and H, L gear (*1) 1.3 – 1.7 0.3 Replace as assembly (*1)
C Clearance between shifter yoke and sleeve 0.04 – 0.39 1.0 Replace (*2)
gear (*2)
D Clearance between balk ring and F, R gear 1.3 – 1.7 0.3 Replace as assembly (*1)
E Deterioration of spring (free length) 21 18
F Outside diameter of tip of shift lever 12.94 – 12.99 12.5
G Inside diameter of shifter yoke mount 22.0 – 22.033 22.1
Deterioration of key spring

H (abutment joint clearance) 110 95
Replace
Backlash 0.14 – 0.38 —
— Gears
Clearance in thrust direction 0.15 – 0.30 —
• Damage
— Tooth surface • Excessive wear, defective tooth
contact
• Seizure, wear
— Bearing • Abnormal noise, defective rota-
tion
Gasket Replace with new parts

— O-ring — during disassembly and
Seals assembly
*1: Dimension when balk ring is moved to outside

*2: Dimension when shifter yoke is pushed fully in either direction
CX-Series 50-5
MAINTENANCE STANDARD TORQUE COVERTER
TORQUE COVERTER
No. Name Q’ty No. Name Q’ty

1 Torque converter circuit 1 4 Turbine shaft 1
1-2 Input plate assembly 1 5 Seal ring 1
1-3 Small hexagon bolt 6 6 Ball bearing 1
1-4 Washer 6 7 Snap ring 1
2 Gear pump assembly 1 8 Snap ring 1
2-1 Case assembly 1 9 Piston valve 2
2-2 Drive gear 1 10 Pressure spring 1
2-3 Driven gear 1 11 Plug 2
2-4 Oil seal 1 12 Gasket 2
2-5 Countersunk head screw 1 13 Hexagon bolt 5
2-6 Stator support 1 14 Gasket 5
2-7 O-ring 1 15 Hexagon socket head plug PT 1/4 4
3 Housing 1 16 Hexagon socket head plug PT 3/4 2
50-6 CX-Series
Unit : mm
Criteria
No. Check item Remedy Sym-
bol
Torque converter inlet valve

Piston and housing hole
A: Inside diameter of housing A: 14.000 – 14.018 — 3
B: Outside diameter of piston B: 13.960 – 13.970 — 9
Clearance:
Replace
1 0.030 – 0.058 0.080
piston
Torque converter inlet valve spring
C: Free length C: 103.4 —

D: Installed length D: 62.7 —
2 E: Installed load E: 75.6 N {7.71 kgf} ± 5% 68.0 N {6.93 kgf} Replace 10
Gear pump
Oil seal and torque converter impeller hub
F : Inside diameter of oil seal F: 61.3 2–4
G: Outside diameter of impeller hub G: 61.915 – 61.965 61.815 1–1
Replace
3
Bushing and torque converter impeller hub
J : Inside diameter of bushing H: 61.915 – 61.965 — 1–1
H : Outside diameter of impeller hub J : 62 – 62.030 — 2–1
Clearance:
0.035 – 0.115 0.17
Replace
CX-Series 50-7
Unit : mm
Criteria
Sym-
No. Check item Remedy bol
Turbine shaft
Housing hole and seal ring groove
L : Inside diameter of housing K: 2.4 – 2.5 2.6 4
K : Width of groove L : 60.00 –60.03 60.15 3
Replace
Seal ring
M: 2.5 – 2.7 2.3 5

Replace
N: 2.35 – 2.40 2.15
50-8 CX-Series
MAINTENANCE STANDARD TORQFLOW TRANSMISSION (F1/R1)
TORQFLOW TRANSMISSION (F1/R1)
50-10 CX-Series
Unit: mm
Criteria
Sym-
A1 Thickness of drive plate 2.5 – 2.7 2.3

A Plate Replace
A2 Thickness of driven plate 1.93 – 2.07 1.7

B2 inserting piston (Bias cut) —

B Seal ring B3 face — — time disassembly
is carried out
B1 Thickness 2.45 – 2.55 2.25
D1

C1 contact surface (piston 45 – 45.025 45.175
boss)
C Piston
C2 width 4.55 – 4.65 4.85

width
D Drive shaft
width
H2 Clearance at end gap when — —

inserting cap (Bias cut)
H Seal ring H1 Thickness 2.47 – 2.49 2.25
Diameter of transmission
— case 1st shaft hole 35 – 35.025 — (No stepped-type wear
should be detected)
E2 Clearance at end gap when 0.3 – 0.5 1.2 Replace

inserting clutch case
E Seal ring E1 Width 4.47 – 4.49 4.23
(C2) Insertion groove width 4.55 – 4.65 4.85

F Clutch case F1 contact surface (drum and 135 – 135.063 135.3
cylinder)
G Thrust washer G1 Thickness 2.9 – 3.1 2.5
Outside diameter of seal

I Retainer I1 ring contact surface (Out- 61.924 – 60 — (No stepped-type wear
put shaft retainer) should be detected)
— Backlash 0.14 – 0.41 —

— Gears

assembly
CX-Series 50-11
TORQFLOW TRANSMISSION (F2/R1)
50-12 CX-Series
Unit: mm
Criteria
Sym-
K1 Thickness of drive plate 2.5 – 2.7 2.3

K Plate Replace
K2 Thickness of driven plate 1.93 – 2.07 1.7

L2 inserting piston (Bias cut) —

L Seal ring L3 face — — time disassembly
is carried out
(L1) Thickness 2.45 – 2.55 2.25

M1 contact surface (piston 40 – 40.025 40.3
boss)
M Piston
M2 width 4.55 – 4.65 4.85

width
N Idle shaft
width
O2 Clearance at end gap when 0.3 – 0.5 1.2

inserting cap
O Seal ring O1 Thickness 4.47 – 4.49 4.23
(M2) Insertion groove width 4.55 – 4.65 4.85

P Clutch case P1 contact surface (drum and 110 – Replace
cylinder)
T Thrust washer — Thickness

Q2 inserting clutch case (Bias cut) —
Q Seal ring Q1 Thickness
— Diameter of transmission 35 – 35.025

case 2nd shaft hole
S Retainer S1 Outside diameter of oil seal

contact surface
— Backlash 0.14 – 0.41 —

— Gears

assembly
CX-Series 50-13
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
No. Name No. Name No. Name

1 Valve body 15 Bolt 29 Spring (l = 83)
2 Plug 16 Spring washer 30 Spring (l = 107)
3 Screw 17 Inching valve 31 Plug
4 Regulator valve (relief) 18 Inching spool 32 O-ring
5 Piston 19 Spring (l = 27) 33 Plug
6 Stopper 20 Stopper 34 Gasket
7 Spring (l = 55.5) 21 Nut 35 Bracket
8 Spring (l = 73.8) 22 Seal 36 Bolt
9 Lubrication relief valve 23 Snap ring 37 Inching lever
10 Spring (l = 33.8) 24 Plate 38 Pin
11 Plug 25 Spring (l = 74) 39 Solenoid valve
12 O-ring 26 Plug 40 Bolt
13 Plate 27 O-ring
14 O-ring 28 Piston (accumulator)
50-14 CX-Series
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit : mm
Criteria
Sym-
No. Check item bol Remedy
Piston or spool and body hole
A: Inside diameter of valve body
B: Outside diameter of piston and spool
— — — —
Outside diameter of piston 27.97 – 27.98

1 Accumulator Inside diameter of body 28 – 28.021 28
Clearance 0.020 – 0.051 0.080 Replace
2 Regulator Inside diameter of body 20 – 20.021 4
Clearance 0.020 – 0.061 0.080
3 Lubrication relief Inside diameter of body 20 – 20.021 9
Clearance 0.020 – 0.061 0.080
Outside diameter of spool 19.97 – 19.98
Inching spool Inside diameter of body 20 – 20.021 18
4 Clearance 0.020 – 0.051 0.070
Piston Clearance 0.020 – 0.051 0.070 17
Spring
— — — —
C: Free length
D: Installed length
E: Installed load
Free length 66.51

Accumulator Installed length 58.7 29
spring (large) Installed load 53.9 N {5.5 kgf} ± 5% 49.0 N {5.0 kgf}
5
Free length 88.83
Spring (small) Installed length 83.7 30
Installed load 36.3 N {3.7 kgf} ± 5% 32.4 N {3.3 kgf}
Free length 111.07 Replace
Regulator spring Installed length 74.7 8
(large) Installed load 163.8 N {16.7 kgf} ± 5% 147.1 N {15.0 kgf}
6
Free length 123.43
Spring (small) Installed length 96.7 7
Installed load 206 N {21.0 kgf} ± 5% 185.4 N {18.9 kgf}
Free length 64.65
7 Lubrication relief Installed length 47.9 10
spring Installed load 138 N {14.1 kgf} ± 5% 124.5 N {12.7 kgf}
Free length 73.97
Inching spool Installed length 48.0 25
8
Free length 28.88
Small spring Installed length 22.0 19
The numbers used in the No. column of the table refer to the numbers in the component part drawing.
CX-Series 50-15
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
*1. Apply Loctite #271 to the screw (hole side).
50-16 CX-Series
MAINTENANCE STANDARD DIFFERENTIAL
Unit : mm
Criteria
Sym-
Set starting torque 21.56 – 33.32 Nm —

{2.2 – 3.4 kgf•m}
A Differential
pinion
Backlash 0.20 – 0.28 —
B Outside diameter of spider and pin 27.959 – 27.980 27.75
C Inside diameter of pinion gear 28.0 – 28.052 28.152

D Pinion gear

E Side gear
Inside diameter of 68 – 68.03 68.13

mating hole
F Differential case
side gear boss
Oil groove (W × D) 4 × 1.5 4 × 1.4
G Outside diameter of differential case boss 90.013 – 90.035 —
H Bevel pinion gear backlash 0.15 – 0.23 —
J Runout on back of bevel gear Max. 0.1 —
K Differential case tightening bolt 78.4 – 122.5 Nm — Apply Loctite to screw

{8 – 12.5 kgf•m}
156.8 – 196 Nm
L Bevel gear mounting bolt {16 – 20 kgf•m} — Apply Loctite to screw
Differential carrier and support cap tight- 490 – 608 Nm

— ening bolt {50 – 62 kgf•m} — Apply Loctite to screw
Damage of tooth
— Differential gear tooth surface — surface such as
pitching and spalling
Replace with new

— Gasket, O-ring and seals — — parts during disas-
sembly and assembly
CX-Series 50-17
MAINTENANCE STANDARD WHEEL BRAKE
WHEEL BRAKE
FG, D35ZT/40ZT
Unit: mm
Criteria
Check item Remedy
Thickness of lining 5.62 2
Springs (1) and (2) Free length: 120 Free length: 132
Spring (1) Free length: 139 Free length: 153
50-18 CX-Series
MAINTENANCE STANDARD WHEEL BRAKE
FG, D35T – 45T/FD50AT
Unit: mm
Criteria
Check item Remedy
2.0
Thickness of lining 10.0 (from the rivet head)
220.6 – 269.7 N
Spring (1) Free length: 93 {22.5 – 27.5 kgf}
(when length = 101.2 mm)
70.6 – 86.3 N
Spring (2) Free length: 123.2 {7.2 – 8.8 kgf}
(when length = 152 mm)
CX-Series 50-19
MAINTENANCE STANDARD CLUTCH BOOSTER AND MASTER CYLINDER
CLUTCH BOOSTER AND MASTER CYLINDER
Unit: mm
Basic Shaft Hole Standard Limit clearance

dimensions clearance
Clearance between cylin-
A der and piston
– 0.020 + 0.052 0.020 –
25.4 – 0.053 0 0.105 0.150
Clearance between cylin- – 0.020 + 0.052 0.020 –

B der and piston 22.2 – 0.053 0 0.105 0.150
Free length Installed length Installed load Free length Replace

(N {kgf})
37.5 33.5 69.3 {7.1} 36.0
F Deterioration of spring 88.6 56 71.6 {7.3} 80

Retighten
J Tightening torque 2.5 – 3.4 Nm {25 – 35 kgf•cm} —
50-20 CX-Series
MAINTENANCE STANDARD BRAKE BOOSTER AND MASTER CYLINDER
BRAKE BOOSTER AND MASTER CYLINDER
Unit: mm
Basic Shaft Hole Standard Limit clearance

dimensions clearance
Clearance between cylin-
A der and piston
– 0.020 + 0.052 0.020 –
25.4 – 0.053 0 0.105 0.150
Clearance between cylin- – 0.020 + 0.052 0.020 –

B der and piston 25.4 – 0.053 0 0.105 0.150
Free length Installed length Installed load Free length Replace

(N {kgf})
37.5 33.5 69.3 {7.1} 36.0
F Deterioration of spring 106 68.5 101.0 {10.3} 96

Retighten
J Tightening torque 17.6 – 21.6 Nm {1.8 – 2.2 kgf•m} —
CX-Series 50-21
MAINTENANCE STANDARD CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER
Unit: mm
Sym- Check item Standard value Limit Remedy
bol
A Clearance between cylinder and piston 0.020 – 0.105 0.15 Replace

(cylinder assembly)
B1 Pressure side Approx. 2 0.4

Replace
B Interference of cup (piston assembly)
B2 Secondary side Approx. 0.6 0.4
C Free length of spring 43 38 Replace
D Tightening torque of yoke and locknut 7.8 – 11.8 Nm — —

{80 – 120 kgf•cm}
E Tightening torque for bleeder valve 6.8 – 8.8 Nm — —

{70 – 90 kgf•cm}
F Maximum stroke 35 — —
50-22 CX-Series
MAINTENANCE STANDARD STEERING GEAR BOX
STEERING GEAR BOX
1. Caulk the nut flange (at two points).
Gear ratio — 18.9
Sector shaft operating angle Degree 42 × 2
Handle rotation (left/right) Rotation 2.0/2.0

14.7/1.4.7
Handle steering torque (left/right) N{kgf}
{1.5/1.5}
50-24 CX-Series
MAINTENANCE STANDARD STEERING GEAR BOX
Unit : mm
Criteria
Sym-
• No screw groove peeling off or no abnor-

mal wear
A Ball nut assembly • Smooth rotation Replace assembly
If not, rotate it while cleaning it in deter-
gent oil
B Sector shaft (shaft and gear) No abnormal wear or streak
C1 Bearing
Gear box and side
C cover No abnormal wear
C2 Bushing Remedy
D1 Bearing
D Cover No abnormal wear
D2 Oil seal
E1 Thrust race
E2 Thrust bearing
E3 Thrust race
E4 Thrust race
No damage or concave
E Control valve E5 Spool valve Smooth operation —
E6 Spring
E7 Sleep body
E8 Orifice
E9 Nut
Tightening torque
Bolt size Tightening torque (Nm {kgf•cm})
M8 × 1.25 20 – 29 {200 – 300}
M10 × 1.25 20 – 29 {200 – 300}
CX-Series 50-25
MAINTENANCE STANDARD FLOW DIVIDER
FLOW DIVIDER
Unit: mm
Free length Installed length Installed load Free length

(N{kgf})
1 Deterioration of spring Replace
37.5 33.5 69.6 {7.1} 36.0
2 Tightening torque 98 – 107.8 Nm {10 – 11 kgf•m} — Retighten
50-26 CX-Series
MAINTENANCE STANDARD LIFT CYLINDER
LIFT CYLINDER
Unit: mm
Criteria
Sym- Check item Remedy
bol
Replace of bush-
A Clearance between piston rod and bushing 0.072 – 0.288 0.5 ing
Replace of piston
B Clearance between piston ring and tube 0.05 – 0.30 0.5 ring
CX-Series 50-27
MAINTENANCE STANDARD TILT CYLINDER
TILT CYLINDER
a After tightening the piston nut, caulk 3 points at part P.
Unit: mm
Criteria
bol
Clearance between piston rod and cylinder

A head bushing 0.072 – 0.288 0.5
Replace of bush-
ing
Clearance between cylinder mount pin and
B bushing (bottom) 0.10 – 0.35 0.6
Clearance between rod head pin and head Replace pin or rod
C pin hole 1.96 – 2.0 2.5 head
D Inside diameter of rod head pin hole 34.989 – 35.014 35.5 Replace rod head
E Piston mounting nut tightening torque 1,088 – 1,577 Nm {111 – 161 kgf•m} —
50-28 CX-Series
MAINTENANCE STANDARD POWER STEERING CYLINDER
POWER STEERING CYLINDER
Cylinder (inside × outside diameters) mm 75 × 85
Stroke mm 215
Outside diameter of rod mm 50
a After tightening the cylinder head, caulk 1 point at part P on the circumference.
Unit: mm
Criteria
bol
A Clearance between cylinder and piston 0.05 – 0.25 0.4
B Clearance between piston rod and bushing 0.03 – 0.18 0.3

Replace
C Piston rod Flaw, dent, streak or concave on claw
D Cylinder Flaw, dent, streak or concave on claw
E Head tightening torque 294 – 343 Nm {30 – 35 kgf•m} —
CX-Series 50-29
MAINTENANCE STANDARD MAST AND FORK
MAST AND FORK

Unit: mm
Criteria
Check item Remedy
Adjustment of
To side 0.5 – 1.0 Max. 2.5 shims
outer mast To front/
rear 0.4 – 1.6 Max. 2.0 Replacement
To side 0.5 – 1.0 Max. 2.5 Adjustment of

shims
fork carriage
To front/ 0.4 – 1.6 Max. 2.0
rear
Depth of oil groove in mast support bushing Oil groove noted No oil groove
3.25 ton
truck 50 Min. 48
3.5 ton
truck 50 Min. 48 Replacement
Thickness of forks A (at the basis) 4.0 ton 55 Min. 50

truck
4.5 ton 55 Min. 50

truck
5 ton
truck 55 Min. 50
50-30 CX-Series
MAINTENANCE STANDARD FORK CARRIAGE
FORK CARRIAGE
a Press the back rest at part A against the board
and tighten the bolt.
1. Section AA
1) Adjust the shims so that a will be as 0 a
0.5 mm (at the top of the finger board).
50-32 CX-Series
MAINTENANCE STANDARD FORK CARRIAGE
2. Section BB
1) Select the roller so that b = 0.4 – 1.6 mm.
2) Insert shims of the same thickness to both
sides so that c will be as 0.5 c 1.0 mm
3. Section CC
1) Select the roller so that d = 0.4 – 1.6 mm.
2) nsert shims of the same thickness to both
sides so that c will be as 0.5 e 1.0 mm
4. Projection B of roller
(when lowered to bottom)
1) Measure distance B between the lower end
of finger board (1) and the lower end of roller
(2) on the lower side of the finger board.
Projection B of roller
Unit: mm
FG, D35ZT/40ZT 7.5
FG, D35T/40T 46.5
FG, D45T/50AT 39.5
CX-Series 50-33
MAINTENANCE STANDARD STEERING AXLE (REAR AXLE)
STEERING AXLE (REAR AXLE)
Unit: mm
Criteria
bol
A Diameter of king pin 35 34.8 Replace
B Vertical play of knuckle — 0.2 Adjust shim
C Diameter of bell crank pin 22 21.8
D Diameter of center pin 55 54.5 Replace
• Cracks
— Steering axle, hub, knuckle, bearing • Damage, peeling
• Seizure, defective rotation, abnormal noise
50-34 CX-Series
60. STRUCTURE AND FUNCTION
Torque converter/transmission control valve................................................................... 60- 2

Hydraulic pump ............................................................................................................... 60-12
Hydraulic circuit diagram ................................................................................................. 60-13
Flow divider ..................................................................................................................... 60-17
Control valve ................................................................................................................... 60-18
Brake and clutch booster................................................................................................. 60-21
Power steering ................................................................................................................ 60-23
Assembly drawings
Electrical circuit diagram (Gasoline engine truck) ........................................................ 60-25
Electrical circuit diagram (For EU spec.) (Gasoline engine truck) ................................ 60-27
Electrical circuit diagram (Diesel engine truck) ............................................................ 60-29
Electrical circuit diagram (For EU spec.) (Diesel engine truck) .................................... 60-31
TORQFLOW transmission (For F1/R1) ........................................................................ 60-33
TORQFLOW transmission (For F2/R1) ........................................................................ 60-34
General view of TORQFLOW transmission (For F2/R1) .............................................. 60-35
Clutch and transmission ............................................................................................... 60-36
Transmission, shifter yoke, and outer appearance (Clutch truck) ................................ 60-37
Pinion shaft (TORQFLOW type)................................................................................... 60-38
Drive axle (Standard) ................................................................................................... 60-39
Wheel brake (FG, D35T – 45T, 50AT) ......................................................................... 60-40
Wheel brake (FG, D35ZT/40ZT) .................................................................................. 60-41
Steering axle ................................................................................................................ 60-42
Frame ........................................................................................................................... 60-43
Piping (1) (Clutch truck (Gasoline engine)) .................................................................. 60-44
Piping (1) (Clutch truck (Diesel engine)) ...................................................................... 60-45
Piping (1) (Torque converter truck (Gasoline engine)) ................................................. 60-46
Piping (1) (Torque converter truck (Diesel engine)) ..................................................... 60-47
Piping (2) (GASOLINE ENGINE) ................................................................................. 60-48
Piping (2) (DIESEL ENGINE) ....................................................................................... 60-49
Piping (3) (GASOLINE ENGINE) ................................................................................. 60-50
Piping (3) (DIESEL ENGINE) ....................................................................................... 60-51
Control valve ................................................................................................................ 60-52
Mast (FG, D35T/40T) ................................................................................................... 60-53
Fork carriage (3.3N – 4.0 ton (W mast STD dimension)) ............................................. 60-54
CX-Series 60-1
STRUCTURE AND FUNCTION TORQUE CONVERTER/TRANSMISSION CONTROL VALVE
TORQUE CONVERTER/TRANSMISSION CONTROL VALVE

1. Overview
1) Torque converter
Size: 292 mm
Type: 3-component, 1-step, 2-phase type (with one-way clutch)
2) Gear pump
Capacity: Theoretical discharge amount = 25.8 cc/rev
Actual discharge amount
Actual discharge
Revolution (rpm) amount (l/min) Condition
600 Min. 10
Discharge pressure: 1.5 MPa (15 kgf/cm2)
Oil temperature: 65 ± 5°C
2,000 Min. 40
Type: Inscribed-type gear pump
3) Control valve
Speed step: 1 Forward 1-step, reverse 1-step solenoid valve switch type (FG, D35Z/40Z/35/40)
2 Forward 2-step, reverse 1-step solenoid valve switch type (FG, D45/FD50A)
Inching: Mechanical inching
2. Precautions on handling
• Be careful not to allow dirt to enter the hydraulic circuit on the transmission mounting side.
• Make sure that each bolt or plug has securely been installed before assembling.
• Properly assemble parts to the transmission or engine side.
• When assembling parts to the engine side, adjust the torque converter end boss to the flywheel center
and slowly insert them.
• At the first greasing after assembly, check the oil level using the oil gauge on the transmission side after
rotating the torque converter for approximately one minute.
60-2 CX-Series
SECTIONAL VIEW OF TORQUE CONVERTER ASSEMBLY
1. Torque converter housing 6. Pilot

2. Gear pump (*1) 7. Turbine shaft
3. Pump (impeller) (*1) 8. Free wheel (one-way clutch) (*1)
4. Turbine (*1) 9. Flexible plate
5. Stator (*1)
*1 The torque converter circuit cannot disassem-
bled.
CX-Series 60-3
3. Torque converter assembly

1) Configuration
It is configured as shown in the sectional view and
the components are roughly classified as follows:
(1) Torque converter
(2) Gear pump
(3) Housing
(4) Power combining portion (input plate and
turbine shaft)
(1) Torque converter

The torque converter is the 3-component, 1-
step, 2-phase type and consists of as follows:
a. Pump • impeller
Combined with the input plate
b. Stator
Fit with the stator support via the one-way
clutch using the spline
c. Turbine
Combined with the turbine shaft
60-4 CX-Series
(2) Gear pump

This inscribed-type gear pump is designed to
supply oil to the transmission and the torque
converter and be driven by the width across
flats on the impeller hub end.
(3) Housing
A torque converter inlet relief valve is built in
the housing in order to restrain internal torque
converter pressure from rising.
(4) Power combining portion

a. Input plate
The outer circumference is combined
with the flywheel on the engine side and
the inner circumference is combined with
the torque converter impeller to transmit
the engine torque to the torque converter.
b. Turbine shaft
The one side is combined with the torque
converter turbine and the other is com-
bined with the transmission input portion
in order to transmit the torque converter
output torque to the transmission side.
CX-Series 60-5
2) Function
1. Input plate
2. Turbine
3. Pump
4. Stator
5. Turbine shaft
A. Input
B. Output
C. Oil inlet
D. Oil output
1) The power of the engine is transmitted through input plate (1) to pump (3). The oil in the pump is pushed
out along the pump vanes by the centrifugal force .
2) The oil pushed out of the pump flows against the vanes of turbine (2). The force generated at this time
is output through turbine shaft (5).
3) After the oil flows out of the turbine, its direction is so changed by stator (4) that it will flow in again at a
proper angle to the pump vanes.
The engine power is transmitted to the transmission by repeating 1) - 3) above. The gear pump is driven
constantly with the pump hub end at the speed of the engine.
60-6 CX-Series

The speed steps are one for forward and reverse travel respectively (FG, D45/50A-7: Forward 2-step and
reverse 1-step) and switched by the solenoid valve.
It is equipped with the inching function for releasing the hydraulic clutch when the truck stops and the mod-
ulation function for reducing shock generated when the truck starts moving or changes the speed.
Sectional View of Control Valve Assembly
1. Accumulator (modulate valve)

2. Inching valve
3. Regulator valve
4. Lubrication relief valve
CX-Series 60-7
5. Hydraulic circulation route

1) After starting the engine, the gear pump is driven by the PTO gear of the torque converter and the oil in the
transmission enters the gear pump via the strainer to be forcefully fed.
2) The pressure of the oil drained from the gear pump is adjusted to the relief pressure (1.01 – 1.25 MPa (10.3
– 12.7 kgf/cm²)) by the regulator valve in the control valve and the adjusted oil is supplied to the solenoid
valve in the hydraulic clutch circuit.
3) The accumulator is released when the circuit is switched to the forward or reverse travel by the solenoid valve
and the oil in the accumulator is supplied to the circuit to the hydraulic clutch.
4) Power is smoothly transmitted since the pressure in the clutch gradually rises after clutch starts operation
since the oil on the hydraulic circuit side flows into the clutch side while filling the accumulator.
5) The oil drained from the regulator valve, on the other hand, is supplied to the torque converter.
6) There is a relief valve at the torque converter inlet for retaining the pressure in the torque converter at 0.59
to 0.78 MPa {6 to 8 kgf/cm²}.
7) Part of the oil drained from the torque converter is used to set the coolant and lubrication flow loads so that
the pressure in the lubrication circuit will be retained at 0.42 to 0.66 MPa {4.3 to 6.7 kgf/cm²} by the lubrication
relief valve in the control valve and the rest is fed to the oil cooler.
8) The oil cooled in the oil cooler is returned to the transmission case alter lubricating or cooling each part of the
transmission via the filter.
The following pages show the hydraulic circuit diagrams and the positions of each port.
6. Hydraulic characteristics of inching valve

Measuring condition: P1 port pressure : 1.25 MPa {12.7 kgf/cm²}
Point Lower limit value Upper limit value
MPa {kgf/cm²} 0.18 {1.8} 0.69 {7.0}

A
Stroke (mm) 3.4 4.1
MPa {kgf/cm²} 0.05 {0.5} 0.23 {2.3}

B
Stroke (mm) 7.6 5.5
MPa {kgf/cm²} — 0.1 {1.0}

C
Stroke (mm) — 10.2
60-8 CX-Series
7. Position of control valve assembly hydraulic port
C1. Forward travel-side clutch pressure measuring port A. To forward travel-side clutch
C2. Reverse travel-side clutch pressure measuring port B. To reverse travel-side clutch
P1. Main relief pressure measuring port C. To forward travel 2nd speed-side clutch
P2. Inching valve oil pressure measuring port (FG, D45T/50AT)
P3. Solenoid valve inlet pressure measuring port D. To torque converter inlet
P4. Lubrication oil pressure measuring port E. From torque converter pump
F. To torque converter outlet
CX-Series 60-9
8. Position of control valve assembly hydraulic port
1. Torque converter inlet relief valve E. Torque converter inlet

A. Torque converter inlet pressure measuring port F. Pump discharge port
B. Pump pressure measuring port G. Torque converter outlet
C. Torque converter outlet pressure measuring port H. Drain
D. Drain J. Pump intake port
60-10 CX-Series
TORQUE CONVERTER/TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
CX-Series 60-11
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
WORK EQUIPMENT AND STEERING/CLUTCH/BRAKE BOOSTERS
This is a tandem pump with the first pump (for work equipment) and the second pump (for brake/clutch boosters
and work equipment) directly combined.
• Pump inlet port: Commonly used for 1st and 2nd pumps
• Pump discharge port: Separately used for 1st and 2nd pumps
Discharge amount per rotation

Truck type Pump type Direction of rotation
1st pump 2nd pump
Gasoline truck SDYB487F1H9-L327 48.7 cc/rev 7.0 cc/rev Counterclockwise
Diesel truck KFP3260-KP1005AK 60 cc/rev 5.45 cc/rev Counterclockwise
60-12 CX-Series
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

CLUTCH TRUCK (GASOLINE ENGINE)
CX-Series 60-13
CLUTCH TRUCK (DIESEL ENGINE)
60-14 CX-Series
TORQUE CONVERTER TRUCK (GASOLINE ENGINE)
CX-Series 60-15
TORQUE CONVERTER TRUCK (DIESEL ENGINE)
60-16 CX-Series
STRUCTURE AND FUNCTION FLOW DIVIDER
FLOW DIVIDER
Parts Flow divider assembly
Fluid used Mineral hydraulic oil (ISO VG32)

Specifications
Flow control 5.0 l/ min
Maximum operating pressure 18.1 MPa {185 kgf/cm2}
Maximum flow 25 l/min
1. Body A. OUT port

2. Spring B. IN port
3. Spool C. Flow control port
4. O-ring
5. Bolt
CX-Series 60-17
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
1. Attachment spool assembly

(with 2 relief valves)
2. Tilt spool assembly
3. Lift spool assembly
60-18 CX-Series
COMPOUND VALVE UNIT

The control valve consists of lift valve (4), tilt valve
(3), main relief valve (1), and attachment valve (2). In
addition, PS relief valve (5), flow divider with PS load
sensing valve (6), and engine stall prevention valve
(7).
LOAD SENSING VALVE

With the PS load sensing valve, while the steering
wheel is in neutral, most of the oil for the PS is sup-
plied for the work equipment. Accordingly, the work
equipment speed is increased and the operator can
work efficiently.
Principle of operation of load sensing valve

• While the steering wheel is in neutral
As shown in the figure at right, flow divider (8) is
balanced by the differential pressure between the
front and rear sides of hole a. Accordingly, a little
amount of the hydraulic oil flows through hole a to
PS valve (10) and most hydraulic oil flows in con-
trol valve (11) to move the work equipment.
• When the steering wheel is turned

If the steering wheel is turned, load sensing valve
(9) is pushed up by the pressure from PS valve
(10) and hole b opens. Since flow divider (8) is
balanced by the differential pressure between the
front and rear sides of holes a and b, the flow di-
vider lowers less. Accordingly, the oil flowing in
control valve (11) is reduced and the oil neces-
sary to the PS flows in PS valve (10).
CX-Series 60-19
ENGINE STALL PREVENTION VALVE

The engine stall prevention valve is installed in the
control valve inlet to improve operability when an at-
tachment is installed.
1. Structure of engine stall prevention valve
2. Function Pressure wave form when engine stall preven-

When pressure is applied to the work equipment, tion valve is installed
the flow divider increases the open area on the
work equipment. Since the valve responds slow-
ly at this time, the oil flow does not follow up the
pressure for a moment. Accordingly, generation
of the peak pressure is delayed and the engine
does not stall.
60-20 CX-Series
STRUCTURE AND FUNCTION BRAKE AND CLUTCH BOOSTER
BRAKE AND CLUTCH BOOSTER
1. Wheel cylinder 9. Orifice 17. Master cylinder piston

2. Reservoir 10. Flow divider spring 18. Piston return spring
3. Body 11. Ball
4. Flow divider spool 12. Reaction piston A. Power chamber
5. Damper orifice hole 13. Relief valve spring B. 1st chamber
6. Pump 14. Seat control valve C. 2nd chamber
7. Downstream meter 15. Control valve
8. Hydraulic tank 16. Booster piston
OPERATION OF FLOW DIVIDER

The flow divider (4) controls flow to the brake booster power chamber A at almost the same level according to
the changes in flow at the inlet port, called the "constant flow control type" or "preferred dividing type".
1) Figure 1 shows the non-operating state where the 3) The oil pressure in the 1st chamber B works on
pump stops. In this state, spool (4) is moved to the left side of spool (4) to overcome spring (10),
the maximum left by spring (10). moving spool (4) to the right (state in Figure 2),
thereby generating valve clearances a and b be-
2) When oil starts being supplied to the inlet port by tween the groove of body (3) and spool (4).
the pump (6), the oil at the inlet port is supplied to
the 1st chamber B via damper orifice hole (5) of 4) At this time, the oil at the inlet port flows in the
spool (4), which flow in the power chamber A of clutch booster port via port a from the 1st cham-
the brake booster via orifice (9) and the 2nd ber B (the state is changed to that in Figure 2 im-
chamber C, increasing the oil pressure in the 1st mediately after the pump is started).
chamber B due to flow resistance of orifice (9).
CX-Series 60-21
STRUCTURE AND FUNCTION BRAKE AND CLUTCH BOOSTER
5) In the operating state shown in Figure 2, the pres- er, port c is not throttled any more, stopping oil
sure difference between the 1st B and 2nd C pressure rise in the power chamber A.
chambers is controlled at almost the same level
since the pressure difference between them for 8) If the operator pedals the brake early, seat control
pushing spool (4) to the right and the force of valve (14) directly presses control valve (15) to
spring (10) for pushing it to the left is balanced the left to forcefully open port d consisting of
(due to almost constant force of spring (10)). booster piston (16) and control valve (15) (since
the pump (6) is connected to the upstream of port
6) Since the pressure difference is equal to that be- d), allowing a large amount of oil to flow in the
fore and after orifice (9), the control flow to the power chamber A and thereby eliminating re-
brake booster power chamber A via orifice (9) is sponse delay.
also controlled at almost the same level (port a
and b are designed to control the pressure differ- 9) The check valve (ball (11), etc.) is designed to
ence before and after the spool mentioned above prevent the brake pedal from being suddenly re-
at the same level even if the oil pressure at each turned when the brake is pedaled by preventing
output port changes). the oil in the power chamber A from back-flowing
even if the pump discharge stops due to engine
stop or other reason.
OPERATION OF HYDRAULIC BOOSTER
10) When the pump fails or the engine stops, manual
1) The oil supplied from the flow divider (4) enters operation is available since reaction piston (12),
the power chamber A in the brake booster via booster piston (16) and master cylinder piston
check valve (ball (11)), passes port c (generated (17) are mechanically connected.
between control valve (15) and seat control valve
(14)) and the passage hole of booster piston (16)
and flows in the hydraulic tank (8).
2) When the brake booster does not operate, no in-

ternal oil pressure is generated since port c is
wide and there is little resistance of the oil pass-
ing in the booster.
3) When the brake is pedaled by the operator, reac-

tion piston (12) is pressed to the left by the input
rod, throttling port c.
4) With port c throttled, the oil passing it receives re-

sistance, increasing the oil pressure in the power
chamber A.
5) Due to the increased oil pressure in the power

chamber A, the oil pressure works on the right
side of booster piston (16), overcoming return
spring (18) to move master cylinder piston (17) to
the left.
6) Since the oil pressure in the power chamber A

pushes back reaction piston (12) to the right (gen-
erates hydraulic reaction force), it balances with
the operator's operating physical force.
7) Accordingly, the pressured area ratio between

booster piston (16) and reaction piston (12) cor-
responds to the servo ratio.
If the force to push back seat control valve (14) to
the right due to the increased oil pressure in the
power chamber A overcomes spring (13), howev-
60-22 CX-Series
STRUCTURE AND FUNCTION POWER STEERING
POWER STEERING
This new closed-type semi-integral power steering is
directly connected to the worm shaft of the steering
gear box and its close coupled-type spool valve has
the steering holding function for restraining kick back.
1. Overview of function
Power assisting operation is conducted by
mounting a close coupled-type spool valve on the
worm shaft end of the steering gear box connect-
ed to the steering wheel and switching the oil pas-
sages by moving the steering shaft direction
using the road surface load reaction force on the
tire side.
The close coupled-type spool valve of the CX-
type truck has an additional function for holding
steering (closed-type valve). This feature dis-
ables the steering wheel from being unintention-
ally steered even if a reverse input is input from
the tire side since both sides of the steering cylin-
der are closed by the valves to lock the oil flow,
although the hydraulic oil from the hydraulic
pump returns the oil tank.
Neutral and holding
2. Steering mechanism
1) Neutral and holding
While the vehicle is not steered, the oil from the
pump is returned from the valve to the oil tank.
On the other hand, the oil in the cylinder is locked
since both sides of the cylinder are closed by the
valves. Accordingly, the steering angle is held. In
addition, even if a pushing force is applied to the
piston rod from the tire side, the vehicle is not
steered.
Steering to right
2) Steering to right (Turning to right)
If the steering wheel is turned to the right, the right
steering circuit of the valve directly coupled with
the worm shaft is formed and the oil flows in the
left side of the piston in the cylinder, and then the
piston moves to the right and the vehicle turns to
the right.
If the steering wheel is held at a position, the
valve is set in neutral and held and the tire
(steering) angle is held at the current position.
CX-Series 60-23
STRUCTURE AND FUNCTION POWER STEERING
Steering to left
3) Steering to left (Turning to left)
If the steering wheel is turned to the left, the left
steering circuit of the valve directly coupled with
the worm shaft is formed and the oil flows in the
right side of the piston in the cylinder, and then
the piston moves to the left and the vehicle turns
to the left.
If the steering wheel is held at a position, the
valve is set in neutral and held and the tire
(steering) angle is held at the current position.
60-24 CX-Series
ELECTRICAL CIRCUIT DIAGRAM
CX-Series 60-25
ELECTRICAL CIRCUIT DIAGRAM (For EU spec.)
CX-Series 60-27
ELECTRICAL CIRCUIT DIAGRAM
DIESEL ENGINE TRUCK
CX-Series 60-29
ELECTRICAL CIRCUIT DIAGRAM (For EU spec.)
DIESEL ENGINE TRUCK
CX-Series 60-31
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
FOR F1/R1
CX-Series 60-33
FOR F2/R1
60-34 CX-Series
GENERAL VIEW OF TORQFLOW TRANSMISSION

FOR F2/R1
CX-Series 60-35
CLUTCH AND TRANSMISSION
60-36 CX-Series
TRANSMISSION, SHIFTER YOKE, AND OUTER APPEARANCE

CLUTCH TRUCK
CX-Series 60-37
PINION SHAFT
TORQFLOW TYPE
60-38 CX-Series
DRIVE AXLE
STANDARD
CX-Series 60-39
WHEEL BRAKE
FG, D35T – 45T, 50AT
60-40 CX-Series
WHEEL BRAKE
FG, D35ZT/40ZT
CX-Series 60-41
STEERING AXLE
60-42 CX-Series
FRAME
CX-Series 60-43
PIPING (1)
CLUTCH TRUCK (Gasoline engine)
60-44 CX-Series
PIPING (1)
CLUTCH TRUCK (Diesel engine)
CX-Series 60-45
PIPING (1)
TORQUE CONVERTER TRUCK (Gasoline engine)
60-46 CX-Series
PIPING (1)
TORQUE CONVERTER TRUCK (Diesel engine)
CX-Series 60-47
PIPING (2)
GASOLINE ENGINE
60-48 CX-Series
PIPING (2)
DIESEL ENGINE
CX-Series 60-49
PIPING (3)
GASOLINE ENGINE
60-50 CX-Series
PIPING (3)
DIESEL ENGINE
CX-Series 60-51
CONTROL VALVE
60-52 CX-Series
MAST
FG, D35T/40T
CX-Series 60-53
FORK CARRIAGE
3.3N – 4.0 TON (W MAST STD DIMENSION)
60-54 CX-Series
70. TROUBLESHOOTING
Engine .............................................................. 70- 2

Electrical system .............................................. 70- 3
Clutch and clutch transmission ........................ 70- 4
TORQFLOW system ........................................ 70- 5
Steering system ............................................... 70- 8
Brake system ................................................... 70-10
Hydraulic system.............................................. 70-12
CX-Series 70-1
TROUBLESHOOTING ENGINE
ENGINE
Problem Major cause Remedy
• Lowered oil level in the oil pan. • Fill oil.

The oil pressure warning light • Clogging of oil filter element. • Replace the element.
does not go out. • Oil leakage due to the loose or worn oil • Check and repair it.
pipe joint.
• Insufficient coolant or water leakage. • Fill coolant or repair it.

Steam is blown out of the radiator • Loose fan belt. • Adjust the belt tension.
pressure valve. • Dirt or scale in the cooling system. • Replace coolant or clean the cooling
system.
• Clogged or broken radiator fin. • Clean or repair it.

The water temperature gauge • Failed thermostat or water temperature • Replace it.
pointer indicates the black range gauge.
on the right. • Loose radiator filler cap. • Retighten the cap or replace the pack-
ing.
The water temperature gauge • Failed thermostat. • Replace it.

pointer indicates the black range • Failed water temperature gauge. • Replace it.
on the left.
• Insufficient fuel. • Fill fuel.

• Air entering in the fuel system. • Repair it.
The engine does not start even • Failed fuel injection pump or nozzle. • Replace it.
after turning the starting motor • Slow revolution of the starting motor. • Refer to "ELECTRICAL SYSTEM".
on. • Insufficient engine compression.
• Improper adjustment of the valve clear- • Adjust the clearance.
ance.
• Excessive oil in the oil pan. • Decrease oil.

White or blue exhaust gas.
• Wrong fuel. • Replace it with specified fuel.
Black exhaust gas. • Clogging of air cleaner element. • Clean or replace the element.
Irregular fuel noise. • Failed fuel pump. • Replace it.
• Wrong fuel used. • Replace it with specified fuel.

• Overheat. • Refer to the section "STEAM IS
Noise occurs (due to burning or BLOWN OUT OF THE RADIATOR
mechanism). PRESSURE VALVE" above.
• Broken muffler. • Replace it.
• Excessive valve clearance. • Adjust the clearance.
70-2 CX-Series
TROUBLESHOOTING ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
The light is dark even when the • Wrong wiring. • Check if there is any loose terminal or
engine revolves at the highest disconnection.
speed. • Wrong alternator. • Check and repair it.
• Improper belt tension. • Adjust the belt tension

The light flickers during engine (TB42).
operation. • Wrong auto tension. • Check and repair it
(S6D102E, SA6D102E).
The charge lamp does not come • Failed charge lamp. • Replace it.
on even after the engine starts • Wrong wiring. • Check and repair it.
normal operation.
The alternator generates abnor- • Failed alternator. • Replace it.

mal sound.
The starting motor does not • Wrong wiring. • Check and repair it.
revolve even after turning the • Low battery voltage. • Charge it.
starting switch on.
The starting motor pinion repeat- • Low battery voltage. • Charge it.
edly comes in and goes out. • Failed holding coil. • Check and repair it.
The revolution speed of the start- • Low battery voltage. • Charge it.
ing motor is too low. • Failed starting motor. • Replace it.
The starting motor stops before • Wrong wiring. • Check and repair it.
the engine starts operation. • Low battery voltage. • Charge it.
The heater signal is not turned • Wrong wiring. • Check and repair it.
red. • Broken glow plug. • Replace it.
The engine oil pressure warning • Failed warning lamp. • Replace it.
lamp does not come on even • Failed warning lamp switch. • Replace it.
after the engine stops (with the
starting switch turned on).
CX-Series 70-3
TROUBLESHOOTING CLUTCH AND CLUTCH TRANSMISSION
CLUTCH AND CLUTCH TRANSMISSION
The clutch slips • Excessively worn clutch disk. • Replace it.

The engine torque is not • Distorted flywheel or pressure plate. • Repair or replace it.
transmitted to the transmis- • Small play of the release bearing. • Adjust it.
sion. • Broken or deformed coil spring. • Replace it.
• Deteriorated clutch disk spline. • Replace it.

• Excessively dislocated or distorted • Replace it.
clutch disk.
• Loose clutch disk rivet. • Replace it.
Poor response
• Deformed coil spring. • Replace it.
Difficult to operate and noise
• Large play of the release bearing. • Adjust it.
occurs
• Insufficient grease on the pilot bearing. • Apply grease.
• Worn tapered part of the synchro gear • Replace it.
balk ring.
• Deformed synchro gear key spring. • Replace it.

Jitter occurs • Distorted clutch disk. • Repair or replace it.
Beat-vibration occurs when • Partially worn pressure plate or flywheel. • Replace it.
starting traveling with the • Deformed coil spring.
clutch partially applied. • Height difference between the release • Replace it.
levers. • Adjust it.

The truck does not start traveling • Partially worn pressure plate and fly- • Replace it.
smoothly. wheel.
• Deformed coil spring. • Replace it.
• Deformed detent spring. • Replace it.

• Deformed synchro key spring. • Replace it.
The lever (gear) is released dur-
• Worn tooth surface of the sleep gear or • Replace it.
ing traveling.
balk ring.
• Large play of the shift fork. • Replace it.
70-4 CX-Series
TROUBLESHOOTING TORQFLOW SYSTEM
TORQFLOW SYSTEM
• Improper oil amount. • Check the amount and fill or drain oil.
• Contact of the vane wheel. • Check oil by draining it from the oil
tank or transmission and replace it.
• Air is taken in. • Check the joint or piping on the inlet
1. Oil temperature rise side and retighten it or replace the
1) Torque converter gasket.
• Water entering the transmission case. • Drain oil and check or replace it.
• Worn or seized bearings. • Repair or replace it after disassem-
bling and checking.
• Failed meter. • Check and replace it.
• Clutch dragging. • Check if the truck operates by setting it

in the neutral state and replace the
2) Transmission clutch plate.
• Worn or seized bearings. • Replace it after disassembling and
checking.
• Cavitation. • Replace oil or parts where air leaks.

• Broken flexible plate. • Check the revolution sound at low
speed and replace the flexible plate.
• Broken or worn bearings. • Replace after disassembling and
checking.
• Broken gear. • Replace after disassembling and
checking.
2. Noise occurs. • Contact of the vane wheel. • Replace after checking it or draining oil
1) Torque converter to check whether foreign matter has
entered or not.
• Loose bolt. • Retighten or replace after disassem-
bling and checking.
• Worn spline. • Replace after disassembling and
checking.
• Gear pump noise. • Replace after disassembling and
checking.
• Dragging noise due to seized clutch. • Check if the truck operates by setting
the transmission in the neutral state
and replace the clutch plate.
• Worn or seized bearings. • Replace after disassembling and
checking.
2) Transmission • Broken gear. • Replace after disassembling and
checking.
• Loose bolt. • Retighten or replace after disassem-
bling and checking.
• Worn spline. • Replace after disassembling and
checking.
Low oil pressure

• (1) Insufficient oil • Check the amount and fill oil.
3. Lowered horsepower
• (2) Air is taken in from the intake side. • Check each joint and pipe and
1) Torque converter
retighten them or replace the packing.
• (3) Clogged oil filter. • Check and replace it.
CX-Series 70-5
• (4) Worn oil pump (decreased discharge • Check the oil pressure and replace the
amount) pump.
• (5) Deformed coil spring of the regulator • Check the spring tension and replace
valve. it.
• (6) Proper spool operation of the control • Repair or replace it after disassem-
1) Torque converter
valve. bling and checking.
• (7) Worn or broken seal ring. • Replace the seal ring.
• Deformed flexible plate. • Replace the flexible plate.
• Breakage or contact of the vane wheel. • Check if foreign matter has entered by
draining oil and replace it.
• Improper oil used or bubbling • Check and replace it.

• (1) Air is taken in from the intake side. • Check each joint and valve and
retighten or replace them.
• (2) Bubbling occurs due to excessively • Check the oil pressure.
low torque converter pressure.
• (3) Water mixes oil. • Drain oil to check and replace it.
• (4) Improper adjustment of the inching • Check and adjust it.
rod or slipped clutch.
2) Transmission
• (1) Decreased oil. • Check the oil pressure.
• (2) Worn piston ring or O-ring. • Replace it after disassembling, check-
ing and measuring.
• (3) Broken clutch or piston. • Replace it after disassembling and
checking.
• (4) Seized and dragged clutch plate. • Check if the truck operates by setting it
in the neutral state and replace the
clutch plate.
• Control valve malfunction. • (1) Replace the valve after checking

whether the spool operates or not.
• (2) Check if the small hole of the valve
4. Abnormal oil pressure
body is clogged or not and clean or
1) High pressure
repair it.
• When cold (high viscosity). • Replace it if the ambient temperature
is lower than 0°C (recheck after raising
the oil temperature to 60 to 80°C).
• Improper oil used. • Check and replace it.

• Failed (worn) gear pump. • Replace it after disassembling and
checking.
• Excessively leaked oil.
• (1) Failed coil spring of the control valve. • Check the spring tension (refer to the
spring standard) and replace it.
2) Low pressure
• (2) Failed control valve spool. • Repair or replace the valve after disas-
sembling and checking.
• Air is taken in. • Check each joint and pipe and
retighten them or replace the packing.
• Insufficient oil. • Check the oil level and fill oil.
• Clogged oil filter. • Check and replace it.
• Excessive leakage. • Replace it after disassembling and

3) Transmission checking (wear of the piston ring and
O-ring, etc.).
70-6 CX-Series
• Broken clutch plate. • Check the revolution sound at low

speed and replace it.
• Failed driving system of the oil pump. • Replace worn pump, gear, shaft or
5. Power is not transmitted. spline after disassembling and check-
1) Torque converter ing.
• Broken shaft. • Check and replace it.
• No oil pressure. • Check oil, pump and gear wear to see
whether the inlet side has inlet force
and replace them.

• Dislocated inching valve and link lever. • Adjust it after checking and measuring.
• Dislocated forward/reverse travel spool • Adjust it after checking.
and link lever.
The clutch works for both.
• (1) Failed piston ring of the clutch case. • Replace it after disassembling and
checking.
• (2) Pulled-out plug of the main shaft. • Repair or replace it after disassem-
bling and checking.
• Seized clutch. • Check if the truck operates (travels) by
setting the transmission in the neutral
2) Transmission
state and replace the clutch.
• Broken shaft. • Replace it after disassembling and
checking (main shaft, etc.).
• Broken clutch dram (snap ring groove). • Replace it after disassembling and
checking.
• Broken snap ring of the clutch drum. • Replace it after disassembling and
checking.
• Foreign matter entering the oil passage • Repair or replace it after disassem-
to the clutch. bling and checking.
• Worn shaft or spline. • Replace it after disassembling and
checking.
• From the oil seal. • Disassemble and check wear of the

seal lip and the sliding surface of its
counterpart (pump, boss, coupling,
etc.) and replace oil seal, pump boss,
coupling, etc.
• From the case mating surface. • Check and retighten them or replace
• From each joint or pipe. the packing. After checking, repair it
or replace the pipe gasket.
• From the drain plug. • Check and retighten it or replace the
6. Oil leakage (transmission/ gasket.
torque converter) • Crack. • Check and replace it.
• Oil is blown out of the transmission case. • (1) Check if water is contained in oil by
draining it (white if oil contained)
and replace it.
• (2) Check if air is taken in from the inlet
joint and retighten it or replace the
packing.
• (3) Check the air hole of the air
breather and repair it.
• Excessive oil. • Check the oil level and drain the oil.
CX-Series 70-7
TROUBLESHOOTING STEERING SYSTEM
STEERING SYSTEM
• Excessively low oil pressure. • Check the oil pressure and correct it.
• Failed bearing. • Clean or replace it.
• Failed spring spool. • Clean or replace it.
• Failed rear cushion plunger. • Replace it.
• Failed ball screw assembly. • Clean or replace it.
1. Heavy handle • Excessively tightened adjusting screw of • Adjust it.
the sector shaft.
• Wrong gear engagement. • Check and repair the mesh.
• Deformed coil spring of the flow divider. • Replace it.
• Clogged ACV orifice or spool malfunc- • Clean or replace it.
tion
• Failed bearing. • Clean or replace it.

2. The handle does not return • Stuck reaction spring. • Check and replace it.
smoothly. • Failed ball screw assembly. • Clean or replace it.
• Wrong gear engagement. • Check and correct the backlash.
• Loose locknut. • Retighten it.

3. Unstable handle rotation or the • Worn metal spring. • Replace it.
steering system generates • Wrong gear backlash. • Adjust it.
noise or vibration. • Loose bolt. • Retighten it.
• Air mixes the hydraulic circuit. • Remove air.
Valve
• Failed (not opened). • Adjust the valve set pressure and
4. Noise occurs when turning the check the specified oil pressure.
handle to the maximum. Piping
• Concaved or clogged pipe (power steer- • Repair or replace it.
ing cylinder pump).
• Oil pump.
• Insufficient oil. • Fill oil.
5. Piping generates noise.
• Air entering from the oil inlet pipe. • Repair it.
• Air has not been removed completely. • Completely remove air.
• Oil pump.
• Air entering from the oil inlet pipe. • Repair it.
Valve
6. The valve or valve unit gener- • Failed (unbalanced oil pressure). • Adjust the valve set pressure and
ates noise. Piping check the specified oil pressure.
a Concaved or clogged pipe (power steer- • Repair or replace it.
ing cylinder pump).
a Air has not been removed completely. • Completely remove air.
70-8 CX-Series
TROUBLESHOOTING STEERING SYSTEM
• Clogged flow control valve orifice. • Clean it.

Valve
• Failed (the valve remains closed and • Adjust the valve set pressure and
does not supply oil to the power steering check the specified oil pressure.
7. The drained oil amount is
cylinder).
small or changes.
• Failed (unbalanced oil pressure). • Adjust the valve set pressure and
check the specified oil pressure.
Piping
a Concaved or narrowed pipe (tank pipe). • Repair or replace it.
8. The discharging pressure is • Deformed flow control valve coil spring. • Replace it.
low or changes. Valve
• Failed (the valve remains open and does • Adjust the valve set pressure and
not supply oil to the power steering cylin- check the specified oil pressure.
der).
• Failed (unbalanced oil pressure). • Adjust the valve set pressure and
check the specified oil pressure.
CX-Series 70-9
TROUBLESHOOTING BRAKE SYSTEM
BRAKE SYSTEM
• Oil leakage in the hydraulic system. • Repair it and fill fluid.

• Air entering the hydraulic system. • Bleed air.
• Water or oil adhering to the lining sur- • Clean or replace it.
face.
• Hardened lining surface or wrong • Grind and repair or replace it.
engagement.
• Worn lining. • Replace it.
1. Insufficient braking force.
• Master back wheel • Check, correct or repair it.
• Clogged hydraulic system. • Clean it.
• Air intake from the vacuum hose joint • Check or repair it.
• Defective vacuum pump (5 – 7 ton) • Check or replace it.
• Clogging of master back filter (5 – 7 ton) • Check, repair or replace it.
• Improper adjustment of brake valve (8 ton) • Check, repair or replace it.
• Defective accumulator (8 ton) • Check, repair or replace it.
• Improper adjustment of the tire air pres- • Adjust the air pressure.
sure.
• Improper adjustment of the brake. • Adjust it.
• Water or oil adhering to the lining sur- • Clean or replace it.
face.
• Earth or sand entering the brake drum. • Clean it.
• Hardened lining surface. • Grind and repair or replace it.
• Wrong lining engagement. • Grind and repair it.
2. Brake pull
(the steering wheel becomes
• Partially worn or broken (distorted) brake • Repair or replace it.
uncontrollable when braking).
drum.
• Wheel or cylinder malfunction. • Repair or replace it.
• Wrong sliding of the shoe. • Adjust it.
• Loose back plate mounting bolt. • Retighten or replace it.
• Deformed back plate. • Replace it.
• Improper adjustment of the wheel bear- • Adjust or replace it.
ing.
• Clogged hydraulic system. • Clean it.
• No play of the pedal. • Adjust it.

• Wrong sliding of the shoe. • Adjust it.
• Wheel cylinder malfunction. • Repair or replace it.
• Failed piston cup. • Replace it.
• Deformed or broken return spring. • Replace it.
3. Brake dragging • Improper return or adjustment of the • Repair or replace it.
parking brake.
• Clogged brake valve or return port. • Check or repair it.
• Failed piston return of master cylinder. • Clean it.
• Improper adjustment of the wheel or • Adjust or replace it.
bearing.
70-10 CX-Series
TROUBLESHOOTING BRAKE SYSTEM
• Brake dragging. • Refer to the section on BRAKE DRAG-

GING above.
4. Brake noise
• Improper piston return. • Replace it.
(cheeping)
• Changed lining surface. • Grind and repair or replace it.
• Changed lining surface. • Grind and repair or replace it.

• Poor adhesion between the shoe and • Replace it.
the lining.
• Excessively worn shoe and back plate. • Clean the brake and apply grease.
• Foreign matter adhering to the drum slid- • Clean it.
ing surface.
• Broken or dislocated drum sliding sur- • Replace it.
5. Brake noise
face.
(screeching)
• Deformation or wrong mounting of the • Replace or repair it.
shoe.
• Loose back plate mounting bolt. • Retighten it.
• Worn contact of the anchor or other • Replace it.
assembly.
• Improper contact of the lining. • Repair or replace it.
• Improper mounting of the anti-rattle • Repair it.
equipment or spring.
• Rough drum sliding part. • Grind and repair or replace it.

6. Brake noise • Non-centered drum or excessive distor- • Replace it.
(tapping) tion.
• Rough lining surface. • Grind and repair or replace it.
• Improper adjustment of the brake. • Adjust it.

• Air entering the hydraulic system. • Bleed air.
• Fluid leakage from the hydraulic system • Check and repair it and fill fluid.
7. Large pedal stroke. or insufficient fluid.
• Falling or wrong return of the shoe. • Repair it.
• Improper contact of the lining. • Repair it.
• Prying of push rod due to incorrect mas- • Check or adjust it.

ter back mounting
8. The pedal is heavy. • Insufficient vacuum and failed hose joint • Check or repair it.
• Clogging of master back filter (5 – 7 ton) • Check, repair or replace it.
• Insufficient pressure in accumulator (8 ton) • Check, repair or replace it.
CX-Series 70-11
TROUBLESHOOTING HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
• Wrong sealing of the control valve. • Replace the spool or valve body.
1. Excessively slow descending
• Oil leakage from the joint or hose. • Replace it.
speed of the fork.
• Wrong sealing of the cylinder. • Replace the packing.
• Backward inclination: Failed check • Clean or replace it.

valve.
2. Excessive hydraulic inclina-
• Forward inclination: Failed tilt lock valve. • Clean or replace it.
tion of the mast.
• Oil leakage from the joint or hose. • Replace it.
• Wrong sealing of the cylinder. • Replace seals.
• Insufficient hydraulic oil. • Fill oil.

• Air entering the hydraulic circuit. • Bleed air.
• Oil leakage from the joint of hose. • Replace it.
• Large oil flow resistance on the suction • Clean the filter.
side of the pump.
• The specified pressure is not maintained • Adjust the relief valve.
by the relief valve.
3. Slow ascending of the fork or • Wrong sealing of the cylinder. • Replace the packing.
slow inclination of the mast. • Excessive viscosity of the hydraulic oil. • Replace it with CD-class SAE10W
engine oil.
• The mast does not move smoothly. • Adjust the clearance between the roll
and the rail.
• Oil leakage from the lift control valve • Replace the spool or the valve body.
spool.
• Oil leakage from the tilt control valve • Replace the spool or the valve body.
spool.
• Large flow resistance on the suction side • Clean the filter.

of the pump.
4. Noise occurs on the hydraulic
• Failed gear or bearing in the work equip- • Replace the gear or bearing.
system.
ment hydraulic pump.
• Worn hydraulic pump spline. • Replace the drive shaft.
• Foreign matter caught between the • Clean them.

5. The control valve lever does spool and the valve body.
not move. • Failed valve body. • Tighten the body mounting bolts in the
same way.
• Insufficient hydraulic oil. • Fill oil.

6. Excessively high oil tempera- • Excessive viscosity of the hydraulic oil. • Replace it with CD-class SAE10W
ture. engine oil.
• Clogged hydraulic oil filter. • Clean the filter.
70-12 CX-Series
80. CHECK ITEMS FOR EACH EQUIPMENT
Engine .............................................................. 80- 2

Power train ....................................................... 80- 9
Travel device.................................................... 80-13
Steering device ................................................ 80-16
Braking device.................................................. 80-18
Loading device ................................................. 80-21
CX-Series 80-1
CHECK ITEMS FOR EACH EQUIPMENT ENGINE
ENGINE
a The Nos. of the inspection items refer to those in the specific self-inspection record table.
Com- Inspection item Contents of inspection
ponent
1. Starting condition and • Set the directional lever in neutral, pull the parking brake, start the engine, and
abnormal sound inspect the following.
1. Does the engine start smoothly?
2. Is abnormal sound heard?
2. Revolution during • After warming up the engine, run it at idling and check the following.
idling 1. Hunting 2. Abnormal sound
3. Abnormal combustion 4. Irregular vibration of engine
5. Idling speed
TB42 850 – 900 rpm

S6D102E 675 – 725 rpm
a Adjustment method
Adjust with the adjustment bolt.
Engine unit
3. Revolution during • Press the accelerator pedal and check the following.
acceleration 1. Hunting 2. Abnormal sound
3. Abnormal combustion 4. Irregular vibration of engine
5. Hitch of pedal 6. Smooth rise of engine speed
4. Condition of exhaust 1. Exhaust gas color

gas
During idling Colorless
When pedal is pressed Pale black
5. Air cleaner 1. Dirtiness of element 2.Damage of element

3. Cleaning or replacement of element
a For cleaning and replacing method, see TESTING AND ADJUSTING.
80-2 CX-Series
Com-
ponent Inspection item Contents of inspection
7. Valve clearance Valve clearance

(mm)
Engine Intake valve Exhaust valve
TB42 0.38 (Warm) 0.38 (Warm)
S6D102E 0.25 (Cold) 0.51 (Cold)
a For adjustment method, see TESTING AND ADJUSTING.

Engine unit
8. Compression Compression
(MPa {kgf/cm2}/rpm)
Engine Standard value Limit value
TB42 1.2 {12}/200 Min. 0.9 {9}/200 (*1)
S6D102E 3.5 {36}/280 – 320 Min. 2.5 {25.2}/280 – 320
*1: Check that the difference between the cylinders is 0.1 MPa {1.0 kgf/cm2} or less.
10. Governor • After warming up the engine, press the accelerator pedal fully to test the no-load
(No-load max. speed) maximum speed of the engine.
No-load max. speed
Governor
TB42 engine 2,300 – 2,400 rpm

S6D102E engine 2,300 – 2,400 rpm
11. 1. Oil level

Engine oil
12. Check the oil level with the oil level gauge. If it is low, add new oil.
Q'ty of replacement oil
TB42 engine 8l
S6D102E engine 11.5 l
Lubricating device
2. Discoloration and deterioration

If the oil is deteriorated, replace it.
13. Engine oil filter Since the engine oil filter cannot be judged visually, replace it periodically.
CX-Series 80-3
Com-
14. Fuel leakage Visually check the fuel tank, fuel pump, carburetor, piping, etc. for leakage.
15. Fuel filter Since the fuel filter cannot be judged visually, replace it periodically.
16. Link mechanism of 1. Wear and damage

carburetor (Only for Check visually and by feeling.
gasoline model)
17. Fuel injection nozzle 1. Fuel injection start pressure

(Only diesel model) Install the nozzle to the nozzle tester and test it.
Fuel injection 21.6 MPa

pressure {220 kgf/cm2}
Fuel device
Adjusting:
Adjust with adjustment shim.
2. Fuel injecting condition

If the injecting condition is bad (see
the figure at right), remove the nozzle
from the holder and remove carbon
from it and clean it in fuel oil.
Nozzle 30 Nm
nut {3.1 kgf•m}
Nozzle 60 Nm
holder {6.1 kgf•m}
18. Fuel injection timing

(Only diesel model) Fuel injection timing (ATDC deg.) 1° ± 1 (When plunger is lifted 1 mm)
19. Coolant level If antifreeze is used, add new antifreeze, too.
• If the coolant level is out of the proper

range L while the coolant in the radiator
sub tank is cold, add new coolant to FUL.
• If there is not coolant in the sub tank at all,

Cooling device
remove the radiator cap and add coolant

to radiator first, then add to the sub tank.
20. Water leakage Visually check the following for water leakage.
1. Radiator 2. Water pump 3. Hose
80-4 CX-Series
Com-
21. Deterioration of rub- 1. Visually check the outside of the hose.

ber hose 2. Press and bend the hose to check it for crack and thermal hardening.
22. Radiator cap k Do not remove the radiator cap

when the coolant temperature is
high. Otherwise, hot water may
k When removing the radiator cap

gush out.
after the coolant temperature

drops, slowly turn the cap to
release the pressure, then remove
it.
1. Pressure adjustment valve

Press the cap spring with your finger
and check that the spring has the
appropriate tension.
2. Negative pressure valve

Pull the valve, then release it, and
check that it is immediately closed.
Cooling device
a If the packing is damaged, replace the

radiator cap assembly.
23. Fan belt 1. Looseness (Deflection) of fan belt

Press the center between the fan pulley and
alternator with a finger to check.
15 – 17 mm
TB42 engine (98 N {10 kgf
finger pressure})
S6D102E engine (Auto-tensioner)
Adjusting: Loosen the alternator mounting

nuts and adjustment bar bolt
and move the alternator to
adjust the belt tension.
2. Damage of fan belt

• Check the belt from inside, too.
• If the bottom of the pulley is shiny, replace the belt since it slips easily.
3. Auto-tensioner
If the roller race has extremely stepped wear or uneven wear, replace the belt.
CX-Series 80-5
Com-
24. 1. Deformation, crack, and damage

Fan
25. Visually check the fan plate and holder.
Cooling device
2. Play and looseness of mounting part

Move the fan forward and backward to check it for play and looseness.
Tighten the mounting bolts with a spanner, etc.
143. 1. Crack of cap

144. Remove the cap and check it visually.
146. Distributor
147. (Only gasoline
148. engine model)
149. 2. Inserting condition of high-tension cable of cap
Remove the coil cable and plug cable and check them for rusting and test their
fitting condition.
3. Burn of segments of cap

Check visually.
4. Wear and burn of center piece

Electric device
Check the center piece for wear and burn.

Check the spring for fatigue by pressing it with your finger.
80-6 CX-Series
Com-
145. Ignition plug and 1. Ignition plug

150. ignition timing 1) Gap
(Gasoline engine truck) Remove the plug with the plug
wrench and measure the gape with
the gauge.
Plug gap A: 0.7 – 0.8 mm
[1] Normal
[2] Badly burnt
[3] Sooty
a If the plug is burnt or its gap is
out of the specified range,
replace it.
(Model name)
NGK: B4ES, BPR-4ES
(Noise prevention)
HITACHI: L47W
2) Disconnection of plug cable
Set the tester in the 100 kz range
and check the plug cable for discon-
nection.
3) Cleaning
Remove carbon from the tip of the
plug and around it.
Electric device
2. Ignition timing
1) Run the engine at low idling.
2) Check the ignition timing with the
timing light and timing marks on the
front cover and crank pulley.
Adjusting: Adjust the ignition timing by
turning the body of the dis-
tributor.
Ignition timing TB42 7/700 (BTDC/rpm)
151. Starting motor Start the engine with the starting switch and check the function of the switch and
meshing condition of the pinion gear.
152. Battery charger Test with the charge caution lamp.

a If the caution lamp lights up when the start-
ing switch is turned ON and goes off after
the engine is started, the battery charger is
normal.
CX-Series 80-7
Com-
153. Wiring of battery Check the following items.

charger, etc. 1. Electrolyte specific gravity
Electrolyte Necessity
specific Charge level of charge
gravity
1.280 Fully charged
1.240 Discharged by 1/4 No
1.210 Discharged by 1/2 Yes

1.130 Fully discharged
a If the battery is not charged suffi-

ciently, check the alternator.
2. Electrolyte level
3. Looseness and corrosion of battery
terminals
4. Looseness of wire connectors
5. Damage of wires
154. 1. Damage of wiring harness and looseness of clamp

Electric wiring
155. Check visually.
Electric device
2. Looseness of connectors
Check visually.
80-8 CX-Series
CHECK ITEMS FOR EACH EQUIPMENT POWER TRAIN
POWER TRAIN
Com-
30. Clutch pedal 1. Play
Play b 3 – 5 mm
2. Pedal height (above floor plate)

Pedal height a 175 – 185 mm
(when free)
a For adjustment of the play and height of the pedal, see TESTING AND ADJUST-
ING.
31. 1. Abnormal sound

32. Press the clutch pedal fully and check that no abnormal sound comes out.
33. Clutch
34. 2. Sound of gears
35. While pressing the clutch pedal, set the directional lever in neutral and increase
the engine speed a little. Then, set the lever in the FORWARD position and
check that the gears do not make a sound.
3. Disengagement of clutch
Power train
Press the clutch pedal fully and check that the clutch is disengaged completely.
4. Slip and engaging condition

On a flat ground, release the pedal slowly and check that the vehicle starts more
slowly and smoothly than usual.
5. Oil level
Remove cap (1) and inside cap of reser-
voir tank (2) and check that the oil level is
in proper range L (10 mm).
6. Pressing effort of pedal

Start the engine, press the clutch pedal, and measure the pressing effort of the
pedal.
Pressing effort of clutch pedal 98 – 118 N {10 – 12 kgf}
7. Oil leakage
Check visually. (If the power clutch is employed, in particular, check the piping
and clutch case for oil leakage.)
CX-Series 80-9
Com-
36. Clutch transmission 1. Oil leakage

Check visually. If oil is oozing to make a drop, replace the packings.
37. Shift lever 1. Play and moving condition

(F-R, H-L) • Check that the lever has no play in the neutral position.
• Check the moving condition of the lever to each gear speed position and check
for play at each gear speed position.
38. 1. Oil leakage

TORQFLOW
39. Check visually. If oil is oozing to make a drop, replace the packings.
transmission
41.
2. Oil level
Stop the vehicle on a flat place and check the oil level with the oil level gauge.
k When performing inspections No. 3 and No. 4, set chocks under the tires
and apply the parking brake securely.
3. Clutch operating pressure and torque converter pressure

Set an oil pressure gauge to the pressure pickup port, set the directional lever in
the FORWARD or REVERSE position, and press the accelerator pedal. When
Power train
the engine speed reaches 1,500 rpm, measure the pressure.
Item Pickup port Pressure

Torque converter inlet
pressure
h 0.5 – 0.7 MPa {5 – 7 kgf/cm2}
Clutch operating pressure F, R 1.01 – 1.25 MPa {10.3 – 12.7 kgf/cm2}
P : Pump outlet pressure pickup port (PT1/4)

h : Torque converter inlet pressure pickup port (PT1/4)
i : Torque converter outlet pressure pickup port (PT1/4)
C1: Forward clutch oil pressure pickup port
C2: Reverse clutch oil pressure pickup port
80-10 CX-Series
Com-
4. Stall speed
Set the directional lever in the FORWARD or REVERSE position, increase the
engine speed to the maximum, and measure the engine speed.
a Do not continue this operation for a long time since it raises the torque con-
verter oil temperature.
TB42 1,970 ± 150 rpm

S6D102E 2,090 ± 150 rpm
40. Directional lever • Operate the lever and check the following. [1st gear speed of torque
(Torque converter 1. Play (Neutral position and each converter model]
model) gear speed position)
2. Moving condition to each gear
speed position
3. Abnormal heaviness or hitch
4. Operating condition of forward
and reverse switches
[2nd gear speed of torque

converter model]
Power train
42. Inching valve 1. Function

While pressing the inching pedal fully, set the directional lever in the FORWARD
or REVERSE position. Then, increase the engine speed gradually and check
that the vehicle does not move.
2. Projection of inching spool
While the inching pedal is returned, check that projection a of the inching spool is
at the specified value.
Projection a 31 mm
Clearance b 0.01 – 0.5 mm
Adjustment: Adjust with the cable.
CX-Series 80-11
Com-
43. Inching pedal 1. Play
Play b 2 – 3 mm
2. Pedal height (above floor plate)

(when free)
3. Interlocking point
Interlocking 35 – 41 mm
stroke
48. Differential 1. Oil leakage

Check visually.
2. Oil level
Remove level plug (2) or (3) to check the
oil level. If the oil level is near the lower
line of the plug hole, it is normal. If it is
too low, remove oil filler plug (1) and add
Power train
oil.
1. Oil filler plug

2. Level plug (Clutch model)
3. Level plug (Torque converter model)
4. Drain plug
80-12 CX-Series
CHECK ITEMS FOR EACH EQUIPMENT TRAVEL DEVICE
TRAVEL DEVICE
Com-
50 – 54. Tires 1. Tire inflation pressure

Test the tire inflation pressure with a tire gauge.
Unit: kPa {kgf/cm2}
Front tire inflation pressure Rear tire inflation pressure
(tire size) (tire size)
830 {8.5}
(250 – 15 – 16PR)
690 {7.0}
Tire inflation pressure 830 {8.5}
(8.25 – 15 – 12PR)
780 {8.0}
(300 – 15 – 18PR)
2. Crack and damage of tread and side wall

If the tread or side wall is cracked or damaged excessively, replace the tire.
3. Wear (Depth of tire pattern)

If pneumatic tires are used, measure pat-
tern depth C at part B at 1/4 of the tread
width. Check that dimension C is 1.6 mm
Travel device
or larger.
4. Abnormal wear
Visually check the tires for abnormally
uneven wear and stepped wear.
Possible causes: Defective adjustment of toe-in, bend of tie-rod, bend of
knuckle spindle, play of king pin, bend of axle
5. Foreign matter sticking in tires

Visually check the tires for sticking metal chips, stones, etc.
CX-Series 80-13
Com-
55. Hub nut 1. Looseness

Check the hub nut for looseness. If it is loosened, tighten it to the specified
torque.
294 – 490 Nm {30 – 50 kgf•m} (Front)
Hub nut 294 – 490 Nm {30 – 50 kgf•m} (Rear)
55. Rim fitting nut 1. Looseness

Check the hub nut for looseness. If it is loosened, tighten it to the specified
torque.
Rim fitting nut
(Rear wheel) 196 – 294 Nm {20 – 30 kgf•m} (Only rear wheel)
56. Rim side ring 1. Deformation and crack

Check visually or by a crack detecting method.
57. Wheel bearing 1. Play

58. Jack up the vehicle and shake the top and bottom of each tire with the hands to
check for play.
Travel device
2. Abnormal sound
Rotate each wheel with the hands to check its heaviness and abnormal sound
during revolution.
57. Rear axle 1. Deformation, crack, and damage

Check the front axle visually or by a crack detecting method.
2. Thrust clearance
Press the axle to either side and mea-
sure the clearance or measure the
clearance at the front or rear.
Clearance a Max. 2.0 mm
Adjusting: If the clearance exceeds 2.0

mm, reduce it to below 0.7
mm by adjusting shims.
Bolt (1) 490 – 608 Nm {50 – 62 kgf•m}
3. Clearance between center pin and bushing
Clearance Max. 0.5 mm

Bushing Must have oil groove
80-14 CX-Series
Com-
59. Front axle 1. Deformation, crack, and damage

Check the front axle visually or by a crack detecting method.
Travel device
CX-Series 80-15
CHECK ITEMS FOR EACH EQUIPMENT STEERING DEVICE
STEERING DEVICE
Com-
60 – 63. Steering wheel 1. Play
Play L 30 – 60 mm
(While engine is idling)
a Adjusting:
Adjust with the gear box.
2. Play
Move the steering wheel in the axial direction and radial direction to check for
play.
3. Steering condition
Drive the vehicle and operate the steering wheel actually to check for abnormal-
ity.
64. 1. Oil leakage

Steering gear box
65. Visually check the bottom of the gear box for sticking oil.
2. Looseness of mounting parts

Let the assistant turn the steering wheel largely and check the bolts fixing the
Steering device
gear box to the frame for looseness.
98 – 123 Nm {10 – 12.5 kgf•m}
66 – 68. 1. Play and looseness of mounting parts

Steering linkage Let the assistant turn the steering wheel largely and check the moving parts for
[ Rod, arm,
and bell crank ] play, the mounting parts for looseness, and the connecting parts for play. (A little
play is normal. Visible play is abnormal.)
2. Bend, damage, and wear

Check visually.
3. Breakage and bending condition of cotter pin

Check visually.
a If the cotter pin is broken, tighten the bolt to the specified torque, and then lock
it with a new cotter pin.
69. Knuckle 1. Deformation and crack

Check the knuckle visually or by a crack detecting method.
2. Play of king pin

Jack up the vehicle and shake the top and bottom of each tire with the hands to
check for play.
80-16 CX-Series
CHECK ITEMS FOR EACH EQUIPMENT STEERING DEVICE
Com-
70. Rear axle 1. Camber

Apply the camber gauge to each hub to measure the inclination.
Camber angle 0 deg.
2. Minimum turning radius

1) Let the assistant drive the vehicle with the minimum turning radius.
2) Install a bar having a chalk at its end to the outside of the weight and draw a
circle on the ground.
3) Measure the circle drawn on the ground.
4) Measure the right turning radius and left turning radius.
FG, D35ZT 2,530 ± 150 mm FG, D40T 2,770 ± 150 mm

FG, D40ZT 2,580 ± 150 mm FG, D45T 2,820 ± 150 mm
FG, D35T 2,730 ± 150 mm FD50AT 3,050 ± 150 mm
Distance
between right Max. ± 150 mm
and left
Adjusting: Adjust with the stopper bolt.

Steering device
71 – 73. Power steering 1. Oil level

device Check the oil level in the hydraulic tank. (See LOADING DEVICE.)
2. Oil leakage
Let the assistant operate the steering wheel and check for oil leakage (through
each connecting part, in particular).
3. Looseness of mounting parts and connecting parts

Let the assistant operate the steering wheel and check for looseness.
4. Oil pressure
Specified pressure 9.8 – 10.3 MPa {100 – 105 kgf/cm2}
CX-Series 80-17
CHECK ITEMS FOR EACH EQUIPMENT BRAKING DEVICE
BRAKING DEVICE
Com-
74 – 78. Brake pedal 1. Play
Play b 3 – 7 mm
2. Height of pedal
(From cut of flexible plate)
(when free)
Pedal height a
(pressed pedal) 90 – 100 mm
a Test with parking brake released.
3. Stop lamp switch

1) After setting height H of the brake
pedal, set mounting position of the stop
lamp switch mounting to dimension a.
Dimension a 0.5 – 1.5 mm
2) Check that the switch operates when

the pedal is pressed.
4. Air in brake circuit

Braking device
Press the pedal strongly and judge from its condition if air is in the brake circuit.
5. Braking force
Drive the vehicle at the maximum speed on a dry and flat paved road, and then
stop suddenly and check the following.
1) Turning of steering wheel 2) Uneven operation of brake
3) Abnormal sound 4) Stopping distance
When empty Max. 5 m (When travel speed is 20 km/h)

When loaded Max. 2.5 m (When travel speed is 10 km/h)
79. 1. Operating effort of lever

Parking brake
80. 196 N {Min. 20 kgf}
2. Braking force
• Check that the vehicle is kept stopped on the
following slope.
When empty Slope of 20% (11.2°) or sharper

When loaded Slope of 15% (8.5°) or sharper
• If there is not a proper slope, drive the vehicle at low speed and check the
effect of the parking brake.
80-18 CX-Series
Com-
85. 1. Damage, oil leakage, and contact

Brake piping
86. Visually check the pipes, hoses, and joints for damage, oil leakage, and possibil-
ity of contact.
2. Looseness of connecting parts and clamps

Retighten.
3-way joint pipe 7.8 – 9.8 Nm {0.8 – 1.0 kgf•m}

Wheel cylinder pipe 9.8 – 12.7 Nm {1.0 – 1.3 kgf•m}
Brake valve pipe 9.8 – 12.7 Nm {1.0 – 1.3 kgf•m}
89 – 91. Wheel cylinder 1. Operating condition

Operate the brake pedal and check the following.
1) Pressing effort
2) Change of pressing effort
3) Change of position of pedal kept pressed
4) Returning condition of released pedal
a When the pedal is kept pressed, if its position changes but the oil does not
leak out, the brake valve is abnormal.
Braking device
2. Oil leakage and damage

Check visually.
3. Wear and damage of cylinder, piston, and cup

Disassemble and check the wheel cylinder.
Clearance between cylinder and piston Max. 0.2 mm
92 – 99. Brake drum and 1. Looseness of drum mounting parts

brake shoe Retighten each mounting bolt to 319 – 426 Nm {32.5 – 43.5 kgf•m}. If it is turned,
caulk it again.
2. Wear of lining
Measure the most worn part of the lining.
Thickness of lining Min. 2.0 mm
a If rivets are used, measure from the head of each rivet.
3. Operating condition of shoe

Hold the lining surface with a screwdriver, etc. to fix the piston, press the brake
pedal, and check the operating condition of the shoe.
CX-Series 80-19
Com-
92 – 99. Brake drum and 4. Rust of anchor pin

brake shoe Remove the shoe from the anchor pin and check the anchor pin for rust and
wear.
a When installing the shoe, thinly apply special grease for the brake to the slid-
ing parts.
5. Fatigue of return spring

FG35ZT/40ZT Short: Max. 132 mm (Free length)
FD35ZT/40ZT Long: Max. 153 mm (Free length)
FG35T – 45T
FD35T – 45T Short: 245.2 ± 24.5 N {25 ± 2.5 kgf} (When length is 101.2 mm)
FD50AT Long: 78.4 ± 7.8 N {8 ± 0.8 kgf} (When length is 52 mm)
6. Hook of return spring

Visually check that there is not a flaw.
7. Operation of automatic adjusting device

See TESTING AND ADJUSTING.
8. Wear and damage of drum

If the inside surface of the drum is worn unevenly, tapered, or scratched
extremely, repair it by grinding.
Repair limit of brake drum Max. 319.5 mm (Inside diameter of drum)

Braking device
100. 1. Deformation and crack

Back plate
101. Check visually. (In particular, check the outside of the back plate for deformation
and the mounting bolts for crack.)
2. Looseness of mounting bolts

When tightening the mounting bolts, apply Loctite to them.
FG, D35ZT/40ZT 156.9 – 196.1 Nm {16 – 20 kgf•m}

FG, D35T – 45T
FD50AT 245.2 – 304.0 Nm {25 – 31 kgf•m}
80-20 CX-Series
CHECK ITEMS FOR EACH EQUIPMENT LOADING DEVICE
LOADING DEVICE
Com-
112 – 114. Fork 1. Damage and wear of fork and fork lock pin
2. Deformation of fork
Set both forks at the center of the vehicle and
measure the height difference between them
and the distance between their tips. Check the
results are within the specified ranges.
Distance between tips a Max. 35 mm

Height difference b Max. 15 mm
3. Wear of fork
Measure thickness c at the base of each fork
and check that it is larger than the specified
value.
3.25 ton 3.5 ton 4.0 ton 4.5 ton 5.0 ton
Standard value
50 mm 50 mm 55 mm 55 mm 55 mm
(Reference)
Service limit Min. 48 mm Min. 48 mm Min. 50 mm Min. 50 mm Min. 50 mm
Loading device
4. Crack of fork
Check the following points by a crack detecting method, since forces are concen-
trated on them.
• Base of fork
• Hook of fork
115 – 123. Mast and 1. Crack

fork carriage Check for a crack visually or by a crack detecting method.
• Cross members of outer mast and inner mast
• Welded parts of tilt cylinder bracket and mast
• Welded parts of outer mast and cylinder support
• Outer mast and inner mast
2. Play of roller bearing

Set the mast vertically, raise the fork about 100 mm from the ground, and check
the change of the backward and forward clearance and lateral clearance
between the inner mast and finger bar and between the outer mast and inner
mast. Judge the play of the roller and rail from the result.
Backward and forward clearance Max. 2.0 mm

Lateral clearance Max. 2.5 mm
CX-Series 80-21
Com-
115 – 123. Mast and 3. Bushing of mast support

fork carriage Check that there is oil grooves on the bushing.
4. Crack and damage of roller and roller pin

1) Visually check the rolling contact surface of the rollers on the inside of the
mast for abnormality.
2) Insert a steel rod about 200 mm long between the outer mast and inner mast
and try to pry off those masts and check the roller and roller pin for a crack and
damage.
a If the welded parts of the roller pin seem to be cracked, disassemble the mast
and check the welded parts by a crack detecting method.
124 – 126. Chain 1. Tension

Set the mast vertically, raise the fork about 100 mm from the ground, and press
the middle point of the lift chain with your finger to check for difference in tension.
Adjustment: Adjust with chain stopper.
2. Elongation
Measure length L of 17 links and check that the
result is the specified value.
Loading device
Length L of 3.3 – 4.0 ton Max. 440 mm

17 links 4.5 – 5.0 ton Max. 440 mm
3. Deformation, damage, lubrication, and rust

Check visually.
4. Deformation and damage of threads of anchor bolt

Check visually.
127. 1. Deformation and damage

Chain wheel
128. Check visually.
2. Play of bearing
Turn the chain wheel with your hand to check the bearing for play.
129. Various attachments 1. Looseness, deformation, crack, damage, and wear

Operate the attachments and check visually.
2. Mounting condition
Operate the attachments and check visually.
80-22 CX-Series
Com-
130 – 133. Cylinder 1. Looseness, deformation, crack, and damage

Check the rod, rod threads, and rod end for looseness, deformation, crack, and
damage.
Important check points

1) Bend of rod: Damage and rust (Check visually or by feeling with fingers)
2) Crack in rod treads (Check visually or by dye penetrant test)
3) Looseness of lift cylinder mounting bolts
Piston rod side 58.8 – 73.5 Nm {6.0 – 7.5 kgf•m}

Bottom side 98.1 – 122.6 Nm {10 – 12.5 kgf•m}
4) Looseness of set bolt of tilt cylinder mounting pin
58.8 – 73.5 Nm {6.0 – 7.5 kgf•m}
2. Hydraulic drift of lowering and hydraulic drift of forward leaning
Max. 100 mm/15 min (Fork)

Hydraulic drift of lowering
Max. 50 mm/15 min (Cylinder)
Hydraulic drift of forward leaning Max. 40 mm/15 min (Cylinder)
Loading device
a For the measuring method, see TESTING AND ADJUSTING.

Adjustment: If the hydraulic drift exceeds the specified value, replace the pack-
ings of the control valve and cylinders.
3. Oil leakage and damage

Check visually.
4. Clearance between tilt cylinder bushing and mounting pin
Clearance Max. 0.6 mm
134. Hydraulic pump 1. Oil leakage and abnormal sound
2. Looseness, damage, and abnormal sound of pump drive unit
CX-Series 80-23
Com-
135. 1. Oil leakage

Hydraulic tank
136. Stop the engine and lower the fork.
Check that oil level is in proper range L
with hydraulic oil level gauge (2). If oil
level is too low, add oil through the oil
filler.
1. Cover
2. Breather (Level gauge)
3. Line filter
4. Strainer
5. Drain plug
2. Replacement of hydraulic oil, clean-

ing of strainer, and replacement of
line filter
See TESTING AND ADJUSTING.
137. 1. Play of joints and movement of lever

Control lever
Loading device
138. Operate the lever and check by feeling.
139 – 141. Control valve 1. Oil leakage

Check visually.
2. Operation of relief valve

After raising the fork to the maximum lifting height, check by the operating sound
of the relief valve.
3. Relief pressure
1) Install an oil pressure gauge (for mea-
surement of maximum oil pressure of
24.5 MPa {250 kgf/cm2}) to relief pres-
sure pickup port (1).
2) Raise the fork to the maximum lifting
height and relieve the oil. Measure the
oil pressure at this time and check that
the result is in the specified range.
Specified pressure 17.6 – 18.1 MPa {180 – 185 kgf/cm2}
a If the port valve is installed, lean the attachment lever forward when measuring
the relief pressure.
80-24 CX-Series
BEC08E1-01
SHOP MANUAL
FG,D35/50-7,8 MACHINE MODEL SERIAL NO.
FG35ZT/40ZT-7 100001 and up
FG35T/40T/45T-7 100001 and up
FG50AT-7 100001 and up
FD35ZT/40ZT-8 110001 and up
No. 3-4, 2-chome, Akasaka, Minato-ku, Tokyo, Japan
FD40ZW-8 110001 and up
FD35T/40T/45T-8 110001 and up
FD35W/40W/45W-8 110001 and up
FD50AT-8 110001 and up

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What are the main components covered in the manual?

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What maintenance tasks are described in the manual?

BEC08E1-01

MACHINE MODEL SERIAL NO.

10. GENERAL AND SPECIFICATIONS

20. TESTING AND ADJUSTING

30. REMOVAL AND INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

80. CHECK ITEMS FOR EACH EQUIPMENT

DESCRIPTION OF THE SYMBOLS

Symbol Item Description

Special safety precautions are needed to perform the

Fastening parts that require specified tightening force

Weight of parts or systems.

Places to be coated with adhesives, etc. When assem-

SPECIFICATIONS (FG35ZT-7, FD35ZT-8)

Operation type Pedestrian, driver standing, sitting, order picking Sitting

Number of wheel Front/rear (x=driven) 2x/2

Length, with Std. forks l1 mm 3,970

Lowering speed Loaded/unloaded mm/s 480/550

Output SAE gross kW{HP}rpm 64{84}2,100 70{94}2,150

• OUTSIDE VIEW DRAWINGS

SPECIFICATIONS (FG35T-7, FD35T-7, FD35W-7)

Operation type Pedestrian, driver standing, sitting, order picking Sitting

Number of wheel Front/rear (x=driven) 2x/2

Length, with Std. forks l1 mm 4,150

Lowering speed Loaded/unloaded mm/s 480/550

Output SAE gross kW{HP}rpm 63{84}2,100 70{94}2,150

• OUTSIDE VIEW DRAWINGS

SPECIFICATIONS (FG40ZT-7, FD40ZT-8, FD40ZW-8)

Operation type Pedestrian, driver standing, sitting, order picking Sitting

Number of wheel Front/rear (x=driven) 2x/2

Length, with Std. forks l1 mm 4,020

Lowering speed Loaded/unloaded mm/s 480/550

Output SAE gross kW{HP}rpm 63{84}2,100 70{94}2,150

• OUTSIDE VIEW DRAWINGS

SPECIFICATIONS (FG40T-7, FD40T-7, FD40W-7)

Operation type Pedestrian, driver standing, sitting, order picking Sitting

Number of wheel Front/rear (x=driven) 2x/2

Length, with Std. forks l1 mm 4,215

Lowering speed Loaded/unloaded mm/s 480/550

Output SAE gross kW{HP}rpm 63{84}2,100 70{94}2,150

• OUTSIDE VIEW DRAWINGS

SPECIFICATIONS (FG45T-7, FD45T-7, FD45W-7)

Operation type Pedestrian, driver standing, sitting, order picking Sitting

Number of wheel Front/rear (x=driven) 2x/2

Length, with Std. forks l1 mm 4,265

Lowering speed Loaded/unloaded mm/s 450/520

Output SAE gross kW{HP}rpm 63{84}2,100 70{94}2,150

• OUTSIDE VIEW DRAWINGS

SPECIFICATIONS (FG50AT-7, FD50AT-7)

Operation type Pedestrian, driver standing, sitting, order picking Sitting

Number of wheel Front/rear (x=driven) 2x/2

Length, with Std. forks l1 mm 4,435 4,605