SM Forklift Komatsu PDF
SM Forklift Komatsu PDF
SM Forklift Komatsu PDF
DX-Series 00-1
SECTION INDEX
00. FOREWORD
70. TROUBLESHOOTING
90. —
00-2 DX-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.
DX-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.
a Note
Special technical precautions are needed to perform the
work.
00-4 DX-Series
10. GENERAL AND SPECIFICATIONS
DX-Series 10-1
GENERAL AND SPECIFICATIONS SPECIFICATIONS
Loaded
Rear kg 1,235 1,420
Axle loading
Front kg 3,560 3,685
Unloaded
Rear kg 3,780 3,960
Tyre type Cushion, elastic cushion, pneumatic, polyurethane Pneumatic
Front 300-15-18PR(I)
Tyre size
Rear 8.25-15-12PR(I)
Tyre
Tank capacity l 70
Clutch Torque converter
Transmission TORQFLOW
10-2 DX-Series
GENERAL AND SPECIFICATIONS SPECIFICATIONS
DX-Series 10-3
GENERAL AND SPECIFICATIONS SPECIFICATIONS
Loaded
Rear kg 1,495 1,650
Axle loading
Front kg 3,640 3,730
Unloaded
Rear kg 4,560 4,715
Tyre type Cushion, elastic cushion, pneumatic, polyurethane Pneumatic
Front 8.25-15-12PR(I)
Tyre size
Rear 8.25-15-12PR(I)
Tyre
Tank capacity l 70
Clutch Torque converter
Transmission TORQFLOW
10-4 DX-Series
GENERAL AND SPECIFICATIONS SPECIFICATIONS
DX-Series 10-5
GENERAL AND SPECIFICATIONS SPECIFICATIONS
Loaded
Rear kg 1,775 1,915
Axle loading
Front kg 3,620 3,725
Unloaded
Rear kg 5,380 5,520
Tyre type Cushion, elastic cushion, pneumatic, polyurethane Pneumatic
Front 8.25-15-14PR(I)
Tyre size
Rear 8.25-15-14PR(I)
Tyre
Tank capacity l 70
Clutch Torque converter
Transmission TORQFLOW
10-6 DX-Series
GENERAL AND SPECIFICATIONS SPECIFICATIONS
DX-Series 10-7
GENERAL AND SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS (FD80-8)
• SPECIFICATION TABLE
Model Manufacturer's designation FD80-8
Characteristics
Loaded
Rear kg 2,050
Axle loading
Front kg 4,740
Unloaded
Rear kg 6,130
Tyre type Cushion, elastic cushion, pneumatic, polyurethane Pneumatic
Front 9.00-20-12PR(I)
Tyre size
Rear 9.00-20-12PR(I)
Tyre
Tank capacity l 70
Clutch Torque converter
Transmission TORQFLOW
10-8 DX-Series
GENERAL AND SPECIFICATIONS SPECIFICATIONS
DX-Series 10-9
GENERAL AND SPECIFICATIONS PERIODIC REPLACEMENT OF CONSUMABLE PARTS
1 Master cylinder and wheel cylinder caps, dust seals Every 1 year
10-10 DX-Series
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
DX-Series 10-11
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
10-12 DX-Series
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
DX-Series 10-13
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
10-14 DX-Series
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
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].
DX-Series 10-15
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
10-16 DX-Series
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
DX-Series 10-17
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
10-18 DX-Series
GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
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.
DX-Series 10-19
GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE
10-20 DX-Series
GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE
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}
Union Elbow
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}
DX-Series 10-21
GENERAL AND SPECIFICATIONS HOW TO USE LOCTITE
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.
10-22 DX-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
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
0.1 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
DX-Series 10-23
GENERAL AND SPECIFICATIONS CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
10-24 DX-Series
GENERAL AND SPECIFICATIONS CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
DX-Series 10-25
GENERAL AND SPECIFICATIONS CONVERSION TABLE
KILOGRAM TO POUND
1 kg = 2.2046 Ib
0 1 2 3 4 5 6 7 8 9
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
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
10-26 DX-Series
GENERAL AND SPECIFICATIONS CONVERSION TABLE
KGF/CM² TO LB/IN²
1 kgf/cm² = 14.2233 lb/in²
0 1 2 3 4 5 6 7 8 9
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
DX-Series 10-27
GENERAL AND SPECIFICATIONS CONVERSION TABLE
KGF • M TO FT. LB
1 kgf.m = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
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
10-28 DX-Series
GENERAL AND SPECIFICATIONS CONVERSION TABLE
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
DX-Series 10-29
20. TESTING AND ADJUSTING
DX-Series 20-1
TESTING AND ADJUSTING SERVICE DATA
SERVICE DATA
Torque MPa
converter Inlet port oil pressure {kgf/cm²} 0.6 – 0.8 {6 – 8}
MPa
Outlet port oil pressure {kgf/cm²} 0.1 – 0.67 {1 – 6.7}
Power train
MPa
Relief pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 16.7}
MPa
Clutch actuation pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 16.7}
TORQFLOW
transmission MPa
Lubricating oil pressure {kgf/cm²} 0.42 – 0.66 {5.3 – 5.7}
Oil capacity l 20
Front MPa
wheel {kgf/cm²} 0.78 {8.0} 0.69 {7.0} 0.78 {8.0}
Travel system
Front Nm
wheel {kgf•m} 294 – 490 {30 – 50}
Hub nut Tightening torque
Rear Nm
wheel {kgf•m} 294 – 490 {30 – 50}
20-2 DX-Series
TESTING AND ADJUSTING SERVICE DATA
Play mm 2–3
Steering, braking system
Inching pedal
Interconnected travel mm 23 – 28
Play mm 2–6
Brake pedal
Pedal height when depressed mm 103 – 113
Brake Parking brake operating effort Nm {kgf} Min. 98 {10} (Center grip)
Tightening torque for back plate Nm {kgf•m} 157 – 196 {16 – 20}
mounting bolt
3m
Chain Length of 17 links Max. 550
Lifting hight
Min 3m mm Max. 550
DX-Series 20-3
TESTING AND ADJUSTING SERVICE DATA
MPa
Injection pressure {kgf/cm²} 21.6 {220} 22 {224}
Torque MPa
converter Inlet port oil pressure {kgf/cm²} 0.6 – 0.8 {6 – 8}
MPa
Outlet port oil pressure {kgf/cm²} 0.1 – 0.67 {1 – 6.7}
Power train
MPa
Relief pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 16.7}
MPa
Clutch actuation pressure {kgf/cm²} 1.01 – 1.25 {10.3 – 16.7}
TORQFLOW
transmission MPa
Lubricating oil pressure {kgf/cm²} 0.42 – 0.66 {5.3 – 5.7}
Oil capacity l 20
Front MPa
wheel {kgf/cm²} 0.78 {8.0} 0.69 {7.0} 0.78 {8.0} 0.66 {6.5}
Travel system
20-4 DX-Series
TESTING AND ADJUSTING SERVICE DATA
Steering Play mm 30 – 60
wheel
Rear axle Min. turning radius mm 3,088 – 3,412 3,183 – 3,517 3,420 – 3,780
Play mm 2–3
Steering, braking system
Inching
pedal
Interconnected travel mm 23 – 28
Play mm 2–6
Brake pedal
Pedal height when depressed mm 103 – 113 115 – 125
3m
Chain Length of 17 links Max. 550 Max. 660
Lifting hight
Min 3m mm Max. 550
MPa
Relief pressure {kgf/cm²} 18 {185}
Hydraulic
system
Oil capacity l 70 77
DX-Series 20-5
TESTING AND ADJUSTING GASOLINE ENGINE
GASOLINE ENGINE
TB42
k Maintain the engine when the engine stops and after the temperature has completely dropped.
20-6 DX-Series
TESTING AND ADJUSTING GASOLINE ENGINE
Brand plug
DX-Series 20-7
TESTING AND ADJUSTING DIESEL ENGINE
DIESEL ENGINE
S6D102E/SA6D102E
k Maintain the engine when the engine stops and after the temperature has completely dropped.
20-8 DX-Series
TESTING AND ADJUSTING DIESEL ENGINE
DX-Series 20-9
TESTING AND ADJUSTING AIR CLEANER
AIR CLEANER
CLEANING OF ELEMENT
1. Remove and clean (inside to outside) the element
over by dry compressed air (0.69 MPa {7 kg/
cm²}).
2. Put the cleaned element back to the air cleaner.
k When compressed air is used for cleaning, a
pair of safety glasses must be put on.
a In case of severer working conditions and envi-
ronments, clean or replace the element as early
as possible.
a When any grease or carbon is found on the ele-
ment, clean it with a special cleaner prescribed in
the instruction for the air cleaner.
1. Element
2. Nut
3. Internal tube element
4. Dust evacuater
20-10 DX-Series
TESTING AND ADJUSTING METHOD OF ADJUSTING IGNITION TIMING
DX-Series 20-11
TESTING AND ADJUSTING METHOD OF ADJUSTING INJECTION TIMING
20-12 DX-Series
TESTING AND ADJUSTING METHOD OF ADJUSTING INJECTION TIMING
A 10°
B 8°
C 6°
D 0°
DX-Series 20-13
TESTING AND ADJUSTING MEASURING METHOD FOR COMPRESSION
Diesel engine
Causes for insufficient compression
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
20-14 DX-Series
TESTING AND ADJUSTING ADJUSTMENT METHOD FOR VALVE CLEARANCE
DX-Series 20-15
TESTING AND ADJUSTING TIGHTENING TORQUE FOR CYLINDER HEAD MOUNTING BOLTS
[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)
20-16 DX-Series
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
Unit : mm
Stopper bolt
Model Pedal height (B) height (A)
FD80 130 15
2. Pedal stroke D
Use stopper bolt (2) to adjust the height.
Unit : mm
Model Stopper bolt height (C)
FG50/60/70 62
FD50/60/70 51
FD80 71
TB42 SA6D102E
DX-Series 20-17
TESTING AND ADJUSTING ADJUSTING BRAKE/INCHING PEDAL
5, 6, 7 ton 333 80
8 ton 311 67
8 ton
INCHING PEDAL
1. Pedal height (from the upper end of the pedal
bracket)
Use stopper bolt (2) to adjust the height.
Unit : mm
Engine type Pedal height (A2) Pedal stroke (C)
5 – 7 ton
2. Inching spool protrusion amount
Use cable (3) to adjust the protrusion amount af-
ter adjusting the pedal height.
Projection of spool 31 mm
Clearance e: 0 – 0.5 mm
(Spool must not be pushed, however.)
3. Interlocking stroke
Adjust using bolt (4) so that the inching pedal will
interlock with the brake pedal in the following
stroke. 8 ton
Interlocking stroke 25 mm
20-18 DX-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:
a Manually adjust the clearance of the 8 ton truck
on two places (top and bottom).
5 – 7 ton 5 – 7 ton
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).
DX-Series 20-19
TESTING AND ADJUSTING WHEEL BRAKE
8 ton
4. Adjustment method for clearance
1) Turn adjustment screw (1) in shoe expanding
direction A to fit the shoe to the drum.
2) Return adjustment screw (1) by 4 – 5 notch-
es.
After the above work, clearance a is set to
0.24 – 0.30 mm.
20-20 DX-Series
TESTING AND ADJUSTING ACCUMULATOR FOR BRAKE
Buzzer sounds when brake Buzzer sounds when brake pedal Buzzer does not sound even if brake
pedal is pressed 9 times or less. is pressed 10 times or more. pedal is pressed 40 times or more.
Gas pressure in
accumulator 3.4 MPa {35 kgf/cm²}
• Inspection of accumulator
• Inspection of gas pressure Q Q 2,400
and charging with gas
DX-Series 20-21
TESTING AND ADJUSTING ACCUMULATOR FOR BRAKE
20-22 DX-Series
TESTING AND ADJUSTING ACCUMULATOR FOR BRAKE
DX-Series 20-23
TESTING AND ADJUSTING ACCUMULATOR FOR BRAKE
Charging Ass’y
20-24 DX-Series
TESTING AND ADJUSTING ADJUSTING PARKING BRAKE
DX-Series 20-25
TESTING AND ADJUSTING TORQFLOW TRANSMISSION CASE
20-26 DX-Series
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.
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:
5, 6, 7 ton 12.5 l
8 ton 15 l
Supplementary explanation
The differential case and TORQFLOW transmission
case of the torque converter type truck use exclusive
types of oil. When the differential case oil is checked
and changed, the TORQFLOW transmission case oil
also need to be checked and changed.
DX-Series 20-27
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 (4) on the
bottom of the tank, remove the cover (3) to take
out the strainer and clean the strainer (5) with the
flushing oil.
2. After cleaning inside of the tank, mount the drain
plug (4).
3. After cleaning strainer (5), blow air from its inside
to dry well, and then install it and cover (3).
4. Remove the line filter (1) and mount a new one.
5. Pour specified amount of oil through breather
hole. Check the oil level from the inspection win-
dow.
5, 6, 7 ton 70 l
8 ton 77 l
20-28 DX-Series
TESTING AND ADJUSTING MEASURING HYDRAULIC DRIFT OF LIFT CYLINDER, TILT CYLINDER
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.
5, 6, 7 ton 33 mm / 15 min
8 ton 39 mm / 15 min
DX-Series 20-29
TESTING AND ADJUSTING ADJUSTING MAST
ADJUSTING MAST
SYNCHRONOUS ADJUSTMENT
(SHIM ADJUSTMENT)
1. Mast stay
2. Shim
3. Lift cylinder
20-30 DX-Series
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
Put shims of the same thickness to the left
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
DX-Series 20-31
TESTING AND ADJUSTING ADJUSTING FINGER BAR
20-32 DX-Series
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.
Protrusion g
5 ton 60 mm
6 ton 50 mm
7 ton 49 mm
8 ton 62.5 mm
DX-Series 20-33
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:
5 – 7 ton : 15 l
8 ton : 21 l
20-34 DX-Series
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
FUEL PIPING (DIESEL ENGINE MODEL)
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.
BRAKE PIPING
1. Brake drum cover 4. Brake fluid
2. Air bleed plug 5. Brake drum
3. Vinyl hose 6. Lining
1. Remove the cap from the air bleeding 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. Step on the brake pedal and loosen the air bleed-
ing plug (2) for about 3/4 turns to drain the brake
fluid containing air.
3. Tighten the air bleeding plug (2), then release the
brake pedal.
4. Repeat Steps 2 and 3 until no more bubbles
come out of the hose. (3)
5. When all the bubbles of air have been completely
removed, tighten the plug (2) and install the cap.
6. After bleeding all air, remove cap (7) and the in-
ner cap from brake reservoir tank (8) and check
the oil level. Add oil by the quantity reduced by
the air bleeding work and check that the oil level
is in the proper range (25 – 45 mm).
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.
DX-Series 20-35
TESTING AND ADJUSTING SPECIFIED FUEL, LUBRICATING OIL, AND FLUID
Ambient temperature ( C)
Lubrication point Type of fluid Capacity (l)
-30 -20 -10 0 10 20 30 40
Engine oil
SAE 80
Differential case Gear oil 12.5
SAE 90
SAE
5W-CD
Hydraulic oil tank Hydraulic oil 65
SAE 10W-CD
Brake reservoir tank Brake fluid SAE 70R-1, SAE 70R-3, DOT3 0.05
Lithium
Greasing points grease NLGI No.2
20-36 DX-Series
TESTING AND ADJUSTING SPECIFIED FUEL, LUBRICATING OIL, AND FLUID
Ambient temperature ( C)
Lubrication point Type of fluid Capacity (l)
-30 -20 -10 0 10 20 30 40
SAE 10W-CD
Engine oil pan 16.5
SAE 30-CD
Engine oil
TORQFLOW
SAE 10W-CD 20
transmission case
SAE
5W-CD FD50 -- 70 : 65
Hydraulic oil tank Hydraulic oil
SAE 10W-CD FD80 : 72
Brake reservoir tank (*2) Brake fluid SAE 70R-1, SAE 70R-3, DOT3 0.05
Lithium
Greasing points NLG1 No.2
grease
FD50 -- 70 : 15
Cooling system Coolant Add antifreeze
FD80 : 20
DX-Series 20-37
TESTING AND ADJUSTING LUBRICATING TABLE
LUBRICATING TABLE
LUBRICATING PARTS AND INSPECTION AND MAINTENANCE CYCLES
MO Engine oil
GO Gear oil
HO Hydraulic oil
BF Brake fluid
G Grease
20-38 DX-Series
30. REMOVAL AND INSTALLATION
DX-Series 30-1
REMOVAL AND INSTALLATION UNIT ASSEMBLY POSITION
30-2 DX-Series
REMOVAL AND INSTALLATION WEIGHT TABLE
WEIGHT TABLE
Unit: kg
Radiator assembly 17 17 17
Front 100 135 135 Including the rim (on one side
alone).
Wheel (a single wheel)
Rear 50 70 70
Hydraulic pump 17 17 17
Control valve 27 27 27
Steering valve 6 6 6
PS cylinder assembly 40 40 40
Note: The single-tire specification is employed for the front wheels of the FG50.
DX-Series 30-3
REMOVAL AND INSTALLATION WEIGHT TABLE
Unit: kg
Radiator assembly 22 22 22 31
Hydraulic pump 17 17 17 17
Control valve 27 27 27 27
Steering valve 6 6 6 6
PS cylinder assembly 40 40 40 40
Finger bar assembly 325 325 325 500 Excluding the fork.
Note: The single-tire specification is employed for the front wheels of the FD50.
30-4 DX-Series
Front wheel Torque shaft Differential Brake
DX-Series
Tilt cylinder Mast Brake piping Front axle
Engine hood
Pedal link
Completed
machine Head guard
Forward-reverse
lever link
Engine
Hydraulic
accessories
control valve Engine
+
Floor plate Wire harness Torque
converter
+
Parking Transmission
Master back Torque converter
brake lever
piping
Hydraulic
REMOVAL AND INSTALLATION FLOWCHART
Handle
piping
Hydraulic pump
Steering link
Rear axle
Counter-
Removal weight Installation
REMOVAL AND INSTALLATION FLOWCHART
30-5
REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY DRAWING
30-6 DX-Series
REMOVAL AND INSTALLATION OVERALL DISASSEMBLY AND ASSEMBLY DRAWING
DX-Series 30-7
REMOVAL AND INSTALLATION LIFT CYLINDER
LIFT CYLINDER
REMOVAL
1) Erect the mast straight up.
2) Remove the stopper bolt.
3) Lift the mast using the crane.
4) Apply the block under the inner mast.
5) Remove the cylinder clamp.
6) Operate the work equipment control lever several
times to bleed pressure remaining in the piping.
Then, remove the piping.
a After removing the piping, attach the blind plug
immediately so that flow out of hydraulic oil or en-
try of dusts may be prevented.
7) Lift up and then remove the cylinder using the
spring belt.
• Place a piece of square timber under the
mast assembly (1), then place the assembly
horizontally so that the finger bar comes up-
per side.
• Secure part A with wires.
30-8 DX-Series
REMOVAL AND INSTALLATION LIFT CYLINDER
INSTALLATION
Installation operation is essentially performed in the
reverse order of removal. Then, the synchronous ad-
justment of the mast and cylinder is done along with
air bleeding of the lift cylinder air.
1. Synchronization of masts
1. Inner mast
2. Cylinder rod
3. Outer mast
4. Shim (Right side)
5. Shim (Left side)
(1) Raise the masts to the maximum lifting
height.
(2) Check the lateral play of the masts.
(3) Adjust the shims so that the masts will be syn-
chronized with the right and left cylinders
when they are at the maximum lifting height.
DX-Series 30-9
REMOVAL AND INSTALLATION LIFT CYLINDER
30-10 DX-Series
REMOVAL AND INSTALLATION MAST
MAST
REMOVAL
1. Apply blocks to the front and rear wheels.
6. Lift the finger bar slightly using the crane, then re-
move the block.
DX-Series 30-11
REMOVAL AND INSTALLATION ENGINE
ENGINE
REMOVAL
1. Head guard (at the ceiling)
Bonnet (first, remove the interlocking cable for
the steering wheel spring-up mechanism).
Counter weight
k Before starting the disassembly, the fork
and attachment must be placed on the
ground or removed.
The truck falls if the counter weight is re-
moved while the mast attachment are lifted.
1) FG50/60/70
30-12 DX-Series
REMOVAL AND INSTALLATION ENGINE
2) FD50/60/70
3) FD80
DX-Series 30-13
REMOVAL AND INSTALLATION ENGINE
3. Axle wire
Remove the axle wire.
4. Piping (for hydraulic system and torque converter) and hose (for radiator, air cleaner and fuel)
Remove the piping and hoses.
1) FG50/60/70
2) FD50/60/70
30-14 DX-Series
REMOVAL AND INSTALLATION ENGINE
3) FD80
DX-Series 30-15
REMOVAL AND INSTALLATION ENGINE
S6D102E
5. Radiator, shroud and exhaust pipe
SA6D102E
7. Engine
1) Place a wooden block under the transmission
case.
2) Using the crane, lift the engine and hold it in
that position.
3) Remove the clutch case mounting bolt (for
the machine employing the clutch).
Remove the torque converter mounting bolt
(for the machine employing the torque con-
verter).
30-16 DX-Series
REMOVAL AND INSTALLATION ENGINE
INSTALLATION
Installation is done in the reverse order of removal.
Care must be paid to the following points.
DX-Series 30-17
REMOVAL AND INSTALLATION ENGINE
Inside diame- mm 14 18 22 24 30
ter A
Tightening Nm 20 – 30 30 – 69 56 – 98 108 – 167 147 – 206
torque {kgf•m} {2 – 3} {3 – 7} {6 – 10} {11 – 17} {15 – 21}
30-18 DX-Series
REMOVAL AND INSTALLATION TORQUE CONVERTER + TRANSMISSION
2. Floor plate
Reservoir tank
Floor stay and accelerator pedal
Wiring
Meter panel
Steering wheel (including the column, valve)
Hydraulic piping
k • After removing the hydraulic piping, make
sure to attach the blind plug immediately so
that flow our of hydraulic oil and entry of
dusts may be prevented.
• When assembling the steering valve pip-
ing, attach numbered tags to the four pipes
(hoses) so that the assembly may not devi-
ate from specified procedure.
• Whenever attaching or detaching the con-
nector for the meterpenal wiring, do it hold-
ing the connector body. Don’t try to
disconnect the connector holding the cord.
DX-Series 30-19
REMOVAL AND INSTALLATION TORQUE CONVERTER + TRANSMISSION
4. Pedal
Inching cable
Master back link rod
Solenoid valve wiring
30-20 DX-Series
REMOVAL AND INSTALLATION TORQUE CONVERTER + TRANSMISSION
DX-Series 30-21
REMOVAL AND INSTALLATION TORQUE CONVERTER + TRANSMISSION
INSTALLATION
Installation is done in the reverse order of removal.
Care must be paid to the following points.
3. Pedal assembly
Brake piping
a Pedal adjustment
Refer to the section describing the "PEDAL AD-
JUSTMENT PROCEDURE".
FD80 is equipped with a fully hydraulic brake sys-
tem.
30-22 DX-Series
REMOVAL AND INSTALLATION DRIVE AXLE
DRIVE AXLE
REMOVAL
1. Mast
(Refer to the section describing the "MAST".)
3. Brake pipe
Disconnect the brake pipe from the master cylin-
der at the T block (disconnection of the brake
5. Propeller shaft
Remove the propeller shaft mounting bolts (6)
(one each on the transmission side and parking
brake side) to dismount the propeller shaft.
6. Front axle
• Place the carriage under the front axle, then re-
move the frame mounting bolt (5).
• Lower the carriage slowly, then after making sure
that the front axle has been detached from the
frame, take out the front axle through the front
side of the vehicle.
DX-Series 30-23
REMOVAL AND INSTALLATION DRIVE AXLE
INSTALLATION
Installation is done essentially in the reverse order of
removal. Care must be paid to the following points.
30-24 DX-Series
REMOVAL AND INSTALLATION STEERING AXLE AND POWER STEERING
3. Steering axle
1) Support the steering axle using the carriage.
2) Remove the 4 rear side axle support bolts,
then drive the steering axle approximately 85
mm backward.
3) After making sure that the center pin is driven
out of the front side support (welded), lower
the carriage slowly to move the steering axle
(with the PS cylinder) out of the vehicle.
DX-Series 30-25
REMOVAL AND INSTALLATION STEERING AXLE AND POWER STEERING
INSTALLATION
Installation is done essentially in the reverse order of
removal. Care must be paid to the following points.
3. Steering linkage
• The cotter pin must be positively bent.
30-26 DX-Series
REMOVAL AND INSTALLATION STEERING AXLE AND POWER STEERING
DX-Series 30-27
REMOVAL AND INSTALLATION WHEEL BRAKE
WHEEL BRAKE
REMOVAL
1. Front wheels and torque shaft
1) Apply chocks to the rear wheels.
2) Place a block under the frame to lift the front
wheels.
3) Apply the parking brake.
2. Hub
1) Remove the bolt (7).
2) Remove the lock nut (8).
3) Remove the hub while paying attention so
that it may not be twisted.
4) Remove the inch lace (10) on the hub inner
bearing.
5) Remove the retainer (11).
30-28 DX-Series
REMOVAL AND INSTALLATION WHEEL BRAKE
5 – 7 ton
3. Brake drum
1) 5 – 7 ton
(1) Remove the bolt (1).
(2) Remove the brake drum (2).
8 ton
2) 8 ton
(1) Remove the nut (3).
(2) Remove the brake drum (4).
a The bolt assembled to the brake drum
and that on the nut are united hub and
bolt type.
5 – 7 ton
4. Back plate and brake shoe assembly
1) 5 – 7 ton
(1) Remove the sleeve nut on the brake pipe.
a Receive the brake fluid using a pan.
Don’t forget to clean the spilt fluid.
(2) Remove the bolts (1) and (2).
Bolt (1): Four bolts are provided on the
wheel cylinder side.
Bolt (2): Three bolts are provided on the
adjuster side.
a Care must be used to avoid
confusion between them.
(3) Remove the back plate and shoe assem-
bly. 8 ton
2) 8 ton
(1) Remove the sleeve nut on the brake pipe.
a Receive the brake fluid using a pan.
Don’t forget to clean the spilt fluid.
(2) Remove the nut (1) and bolt (2).
(3) Remove the back plate and shoe assem-
bly.
DX-Series 30-29
REMOVAL AND INSTALLATION WHEEL BRAKE
5 – 7 ton
INSTALLATION
Installation is done essentially in the reverse order of
removal. Care must be paid to the following points.
2) 8 ton
245 – 309 Nm {25 – 31.5 kgf•m}
Coat the threaded portion with Loctite
#271.
8 ton
2) 8 ton (Nut is tightened to hub bolt)
319 – 490 Nm {32.5 – 50 kgf•m}
a After tightening the nut to the hub bolt,
cross caulk them.
30-30 DX-Series
REMOVAL AND INSTALLATION WHEEL BRAKE
5 – 7 ton
3. Adjusting the front hub and brake
1) Front hub starting torque
14.7 – 29.4 Nm {1.5 – 3 kgf•m}
a Tighten the lock nut (1), then adjust the start-
ing torque to the specified level.
a After the starting torque adjustment is com-
plete, tighten the lock bolt (2) and then attach
the cotter pin. The cotter pin must be posi-
tively bent.
a When assembly and adjustment of the hub
are over, double check the starting torque
value. If it is not conforming to the specified
value, the adjustment must be repeated.
8 ton
DX-Series 30-31
REMOVAL AND INSTALLATION STANDARD TIGHTENING TORQUE
30-32 DX-Series
REMOVAL AND INSTALLATION STANDARD TIGHTENING TORQUE
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}
Union Elbow
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}
DX-Series 30-33
REMOVAL AND INSTALLATION HOW TO USE LOCTITE
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.
30-34 DX-Series
40. DISASSEMBLY AND ASSEMBLY
DX-Series 40-1
DISASSEMBLY AND ASSEMBLY DISASSEMBLY DRAWING
DISASSEMBLY DRAWING
40-2 DX-Series
DISASSEMBLY AND ASSEMBLY DISASSEMBLY DRAWING
4 Bearing 34 Retainer
16 O-ring 46 Bearing
22 Stator 52 Bearing
24 Hub 54 Bolt
25 Spacer 55 Seal
26 Pump 56 Spring
29 O-ring 59 Adapter
• The number allocated to each part roughly indicates the order in which they are disassembled.
• Parts of No. 27, 28 and 29 are normally not disassembled.
DX-Series 40-3
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
TORQUE CONVERTER
40-4 DX-Series
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
35.2 – 44.1 Nm
2 Idle shaft A {3.6 – 4.5 kgf•m} —
67.6 – 78.4 Nm Assembled with the seal ring, then coated with
3 Stator shaft B {6.9 – 8.0 kgf•m} small amount of grease.
4 PTO driven shaft — — Bearing: One each is provided on the case side
and gear side.
7 Seal retainer D 18.6 – 24.5 Nm The seal is first assembled to the retainer. The
{1.9 – 2.5 kgf•m} lip is coated with small amount of grease.
10 Thrust washer — — —
11 Thrust washer — — —
12 Lock plate — — * Assemble the ring nut (13), then bend the
washer claw at 2 points to lock.
14 Turbine —
98 – 118 Nm * The turbine and drive cover are normally not
{10 – 12 kgf•m} separated.
35.2 – 44.1 Nm
17 Flexible plate F {3.6 – 4.5 kgf•m} —
35.2 – 44.1 Nm
18 Charging pump G {3.6 – 4.5 kgf•m} Coat the pump drive spline axis with grease.
20 Snap ring — — —
DX-Series 40-5
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
Unit : mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
40-6 DX-Series
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
ASSEMBLY
a Assembly is done essentially in the reverse order
of disassembly.
a Before starting the assembly, clean inside and
outside of the case as well as the components.
Make sure that they are free from foreign sub-
stance.
DX-Series 40-7
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
40-8 DX-Series
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
7. Piping
Attach the piping (hose and nipple).
DX-Series 40-9
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
40-10 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DX-Series 40-11
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
40-12 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DX-Series 40-13
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
40-14 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
40-16 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DX-Series 40-17
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
40-18 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DISASSEMBLY
1. TORQFLOW transmission
After the TORQFLOW transmission assembly
has been dismounted from the machine body,
clean the case and accessories. Then, remove
the following parts:
• Oil and oil temperature sensor.
• Torque converter oil gauge, pipe and hose.
• Torque converter pump, hose and pipe.
• Work equipment hydraulic pump.
• Solenoid valve and plate.
• Control valve.
• Output shaft flange, and retainer pipe on in-
put and shafts.
DX-Series 40-19
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
40-20 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DX-Series 40-21
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
Disc 3EC-15-31270 7 7 7
Disc 3FD-15-21470 7
Plate 3EC-15-31280 6 6 6 6
40-22 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
1 Seal 1
2 Piston ring 2
3 Piston 3
4 Plate [1] 4
5 Disk 5 7 9 11 13 15 17
6 Plate 6 8 10 12 14 16
7 Plate [2] 18
8 Plate [3] 19
9 Ring 20
10 Spring 21
11 Spacer 22
12 Snap ring 23
13 Boss gear 24
DX-Series 40-23
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
40-24 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
Assembling
sequence
R1/R2 shaft
(R1 side) (R2 side)
1 Assemble the seal to the shaft. Assemble the seal to the shaft.
2 Assemble the seal ring to the piston. Assemble the seal ring to the piston.
3 Assemble the piston to the drum. Assemble the piston to the drum.
6 Secure it with the snap ring. Secure it with the snap ring.
7 Assemble the plate (t = 4.5 ± 0.1 mm). Assemble the plate (t = 4.5 ± 0.1 mm).
8 Assemble the clutch disk and plate (6). Assemble the clutch disk and plate (6).
9 Disc (7) and plate (6). Disc (7) and plate (6).
10 Assemble the plate (t = 4.5 ± 0.1 mm). Assemble the plate (t = 4.5 ± 0.1 mm).
Assemble the plate (t = 2 ± 0.07 mm) Assemble the plate (t = 2 ± 0.07 mm)
11
(with the warped surface facing outside). (with the warped surface facing outside).
12 Fix them using the ring. Fix them using the ring.
14 Assemble the bearing to the boss gear, then Assemble the bearing to the boss gear, then
15 assemble the boss gear to the drum (Z3 = 25). assemble the boss gear to the drum (Z2 = 43).
17 Fix the washer using the snap ring. Assemble the gear (Z1 = 45).
Fix it using the snap ring. Fix it using the snap ring.
DX-Series 40-25
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
40-26 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
Assembling
sequence
F1/F2 shaft
(F1 side) (F2 side)
1 Assemble the seal to the shaft. Assemble the seal to the shaft.
2 Assemble the seal ring to the piston. Assemble the seal ring to the piston.
3 Assemble the piston to the drum. Assemble the piston to the drum.
6 Fix them with the snap ring. Fix them with the snap ring.
7 Assemble the plate (t = 4.5 ± 0.1 mm). Assemble the plate (t = 4.5 ± 0.1 mm).
8 Assemble the clutch disk and plate alternately. Assemble the clutch disk and plate alternately.
9 Disc (7) and plate (6). Disc (7) and plate (6).
10 Assemble the plate (t = 4.5 ± 0.1 mm). Assemble the plate (t = 4.5 ± 0.1 mm).
11 Assemble the plate (t = 2±0.07 mm). Assemble the plate (t = 2 ± 0.07 mm).
12 Fix them using the ring. Fix them using the ring.
14 Assemble the bearing to the boss gear, then Assemble the bearing to the boss gear, then
15 assemble the boss gear to the drum (Z3 = 25). assemble the boss gear to the drum (Z2 = 43).
17 Fix the washer using the snap ring. Assemble the gear (Z1 = 45).
19 Fix it using the snap ring. Fix it using the snap ring.
DX-Series 40-27
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
Stroke 2.2 mm
2. Solenoid valve
Solenoid valve (1) : For F1, F2
Solenoid valve (2) : For R1
a Tighten the mounting bolts in the order of [1]
– [4] shown in the figure at right.
3. Seal ring
a It must be coated with grease prior to the as-
sembly.
40-28 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DX-Series 40-29
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
ASSEMBLY
a Before starting the assembly, inside and outside
of the transmission, oil route and bolt holes must
be sufficiently cleaned to prevent contamination
by foreign substances.
1. Filter
1) Attach the O-ring (2) to the filter (1), then as-
semble them.
2) Assemble the gasket (3) and plate (4), then
tighten them with the bolt.
2. Dumper
1) Assemble the piston (6), spring (7) and collar
(8), then assemble the plate (9). Tighten
them using the bolt.
40-30 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DX-Series 40-31
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
40-32 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
8. Pipe
1) Using the bolt (6), assemble the pipe (5) to
the input shaft and intermediate shaft side re-
tainer.
a If alignment between the retainer (3) bolt
hole and pipe (5) mounting hole is lost
and thus you can’t tighten the bolt (6),
loosen the retainer mounting bolt (4), then
tighten the pipe amounting bolt first.
Then, tighten the retainer mounting bolt.
9. Cage
1) Assemble the cage (7) between the transmis-
sion case and intermediate shaft.
DX-Series 40-33
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
11. Plate
1) Mate the gasket (10) with the transmission
while facing the gasket seal toward the plate,
then fix it using the bolt (12).
40-34 DX-Series
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DX-Series 40-35
DISASSEMBLY AND ASSEMBLY PROPELLER SHAFT
PROPELLER SHAFT
DISASSEMBLY DRAWING
ASSEMBLY DRAWING
Misalignment of shafts A and B: Max. 2.5 mm
40-36 DX-Series
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DIFFERENTIAL
40-38 DX-Series
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
Unit : mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
*1. Replace when damages recognized the tooth flank (bevel gears or pinion gears must be replaced as a set).
DX-Series 40-39
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
40-40 DX-Series
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DX-Series 40-41
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
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.
40-42 DX-Series
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DX-Series 40-43
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
5 – 7 ton 12.5 l
Amount of oil
8 ton 15 l
40-44 DX-Series
DISASSEMBLY AND ASSEMBLY DRIVE AXLE (FRONT AXLE)
DX-Series 40-45
DISASSEMBLY AND ASSEMBLY DRIVE AXLE (FRONT AXLE)
5 – 7 ton
40-46 DX-Series
DISASSEMBLY AND ASSEMBLY DRIVE AXLE (FRONT AXLE)
8 ton
DX-Series 40-47
DISASSEMBLY AND ASSEMBLY DRIVE AXLE (FRONT AXLE)
8 ton
40-48 DX-Series
DISASSEMBLY AND ASSEMBLY WHEEL BRAKE
WHEEL BRAKE
5 – 7 ton
40-50 DX-Series
DISASSEMBLY AND ASSEMBLY WHEEL BRAKE
Unit : mm
Criteria
Sym- Check item Remedy
bol
Standard size Repair limit
Free length: 90 mm
Return
B spring Strength
245N {25kgf} (l = 101.2mm) 221N {22.5kgf} (l = 101.2mm)
Free length: 93 mm
Crush or wear.
— Clearance between lining and drum 0.4 – 0.6 0.4 – 0.6 Testing and
adjusting
DX-Series 40-51
DISASSEMBLY AND ASSEMBLY WHEEL BRAKE
8 ton
40-52 DX-Series
DISASSEMBLY AND ASSEMBLY WHEEL BRAKE
Unit : mm
Criteria
Sym- Check item Remedy
bol
Standard size Repair limit
Testing and
— Clearance between lining and drum 0.3 – 0.5 0.3 – 0.5 adjusting
DX-Series 40-53
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
PARKING BRAKE
Unit : mm
Criteria
Sym- Check item Remedy
bol
Standard size Repair limit
Operator of brake lever Min. 196 N {20 kgf} Min. 196 N {20 kgf}
40-54 DX-Series
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
Adjusting clearance
1. Turn the adjustment wheel to the shoe expansion
direction so that the lining can completely come
into contact with the drum.
2. Turn the adjustment wheel so that the clearance
between the drum and lining (points X and Y in
the right figure) can be set to 0.1 to 0.25 mm
(when the adjustment wheel is turned for 11
notches, the clearance is adjusted for 0.25 mm).
DX-Series 40-55
DISASSEMBLY AND ASSEMBLY STEERING AXLE (REAR AXLE)
40-56 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING AXLE (REAR AXLE)
DX-Series 40-57
DISASSEMBLY AND ASSEMBLY STEERING AXLE (REAR AXLE)
8 ton
Unit : mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
40-58 DX-Series
DISASSEMBLY AND ASSEMBLY BRAKE PEDAL
BRAKE PEDAL
5 – 7 ton
DX-Series 40-59
DISASSEMBLY AND ASSEMBLY BRAKE PEDAL
8 ton
40-60 DX-Series
DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH
COMBINATION SWITCH
COMPONENTS
DX-Series 40-61
DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH
Circuit 1 2 3 4 5
Position
OFF Q
1st stage Q Q Q
2nd stage Q Q Q
DIMMER Q Q Q
Circuit diagram
Turn signal light switch connection position
Circuit 6 7 8
Position
R Q Q
Intermediate
L Q Q
40-62 DX-Series
DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH
DX-Series 40-63
DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH
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 (9) which is fixing steering shaft (7) and combination switch, and then remove
the switch.
40-64 DX-Series
DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH
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.
DX-Series 40-65
DISASSEMBLY AND ASSEMBLY MASTER BACK AND MASTER CYLINDER ASSEMBLY
40-66 DX-Series
DISASSEMBLY AND ASSEMBLY MASTER BACK AND MASTER CYLINDER ASSEMBLY
MASTER CYLINDER
5 – 7 ton
DX-Series 40-67
DISASSEMBLY AND ASSEMBLY MASTER BACK AND MASTER CYLINDER ASSEMBLY
Scratches on the lip • When scratches are minor, replace the piston assembly.
Exposed base substrate • When the base is bared seriously, replace the piston
assembly.
Cup Wear and swelling • If excessive fatigue, wear or swelling is present, replace
the piston assembly.
Scratches, wear or collapse • Replace the spring suffered from excessive scratches or
wear.
Spring
Free length • Replace the spring if its free length exceeds the tolerable
limit.
Alarm action • Move the float up and down. If the alarm lamp is not
Indicator assembly activated, replace the indicator assembly.
40-68 DX-Series
DISASSEMBLY AND ASSEMBLY MASTER BACK AND MASTER CYLINDER ASSEMBLY
DISASSEMBLY PROCEDURE
DX-Series 40-69
DISASSEMBLY AND ASSEMBLY MASTER BACK AND MASTER CYLINDER ASSEMBLY
Unit: mm
1.47 – 2.45 Nm
4 Clamp tightening torque {0.15 – 0.25 kgf•m} — —
40-70 DX-Series
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
BRAKE VALVE
8 ton
DX-Series 40-71
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
DISASSEMBLY
k When removing the brake valve from the ve-
hicle, stop the engine and press the brake
pedal repeatedly more than 10 times to re-
lease the pressure, and then disconnect the
piping.
40-72 DX-Series
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
DX-Series 40-73
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
ASSEMBLY
a When installing the O-rings and cup, apply suffi-
cient amount of silicone grease (SHINETSU KA-
GAKU G40M) prepared in the kit to them.
a Take care of installing direction of cup (2).
40-74 DX-Series
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
49 – 78 Nm
Locknut (2) {500 – 800 kgf•cm}
DX-Series 40-75
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
Dimension (e + f) 11 ± 0.3 mm
Locknut (2) 49 – 78 Nm
{500 – 800 kgf•cm}
40-76 DX-Series
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
Unit : mm
Criteria
Sym- Inspection item Remedy
bol
Standard size Repair limit
DX-Series 40-77
DISASSEMBLY AND ASSEMBLY STEERING VALVE
STEERING VALVE
40-78 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DX-Series 40-79
DISASSEMBLY AND ASSEMBLY STEERING VALVE
1. Hydraulic system
a. Insufficient hydraulic pressure on the PS Checking, adjustment and repair.
circuit.
b. Insufficient hydraulic pump delivery. Checking and repair.
c. Oil leakage in the PS cylinder. Checking and repair.
2. PS valve
a. Foreign substance is entrapped Checking, repair and part replace-
between the spool and sleeve or sleeve ment.
and housing.
b. An excessive torque is used for tighten- Tighten the ball uniformly according to
1 Smooth steering wheel ing the end cap tightening bolt. the specified torque.
operation is not available c. The ball on the emergency steering Assemble the ball.
check valve have not been assembled.
3. Hydraulic pump
a. Wear or damages on the gear body. Checking, repair and replacement.
b. Wear or damages on the drive shaft Checking, repair and replacement.
spline.
4. Machine body
a. Scuffing or seize on the steering link or Checking, repair and part replace-
bushing. ment.
1. PS valve
a. Foreign substance is entrapped Checking, repair and part replace-
Leaving my hands off the between the spool and sleeve valve, or ment.
2 steering wheel does not seize on that part.
return it to the neutral. b. Damages or cracks on the centering Checking, repair and part replace-
spring. ment.
c. Scuffing between the column shaft and Checking, repair and part replace-
bushing. ment.
1. Hydraulic system
a. Air is mixed into the system. Check and repair the piping and tank.
b. Cavitation has occurred. Check and repair the filter and tank.
c. Insufficient pump delivery. Check, repair and replace (if neces-
sary) the pump.
3. PS cylinder
a. Damages, wear or scuffing on the piston Checking, repair and part replace-
cylinder seal. ment.
40-80 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING VALVE
1. Hydraulic system
a. Improper piping is done for the 4th port. Checking and repair.
Steering wheel turns in
4 the direction opposite to
my intention. Or, wheel 2. PS valve
kick occurs. a. Improper valve timing is set (after re- Checking and repair.
assembly)
1. Hydraulic system
a. Air is mixed into the system. Check and repair (as necessary) the
piping and tank.
5 Vibrations occur
2. Machine body
a. Wear or backlash on the steering link. Checking and part replacement.
b. Backlash on the wheel bearing or hub. Checking and adjustment.
1. Hydraulic system
a. Sounds are generated from the control Checking, adjustment and repair.
valve.
b. Sounds are generated from the hydrau- Checking, adjustment and repair.
lic pump.
c. Sounds are generated from the piping or Checking, adjustment and repair.
Abnormal sounds (includ- tank.
6 ing abnormal relief
sounds) occurs.
2. PS valve
a. Sounds are generated from the spool or Checking and repair.
sleeve assembly.
b. Sounds are generated from the gerotor Checking and repair.
or drive.
1. PS valve
[Wear or damages on the shaft (spool)
oil seal]
a. Hydraulic oil is contaminated. Replace hydraulic oil or filter.
b. Rusts on the spool surface. Replace the assembly.
c. Damages due to disassembly or assem- Replace the part.
bly.
7 Oil leak [Damages on the O-ring used on the
mating surface (gerotor)]
a. The O-ring was pinched during disas- Replace the part.
sembly or assembly work.
b. Damages on the O-ring groove. Replace the part.
c. Insufficient tightening torque is Tighten the bolt uniformly according to
employed for the end cap fastening bolt. the specified torque.
DX-Series 40-81
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DISASSEMBLY
1. Disassembling the steering valve assembly
1) Remove the bolt (1) by holding the flange of
the column assembly with the vise, then re-
move the steering valve assembly (now you
can separate the column from the valve).
40-82 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DX-Series 40-83
DISASSEMBLY AND ASSEMBLY STEERING VALVE
40-84 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DX-Series 40-85
DISASSEMBLY AND ASSEMBLY STEERING VALVE
40-86 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING VALVE
ASSEMBLY
a Joints of every part must be checked. Parts with scratches or burrs resulting from disassembly operation
must be replaced with new one. Otherwise, oil leakage can occur.
a Parts are cleaned with commercially available detergents and then dried with air blow. Don’t try to wipe
cleaned parts with a piece of cloth or paper, otherwise they can be contaminated by foreign substance.
a It is prohibited to file or sand the parts.
a When assembling, consumable parts such as O-rings and seals must be replaced with new ones and, after
assembly, they must be coated with the grease (G2-LI).
a O-rings (5), (9) and (12) are very similar in their size, so reasonable care must be exercised to prevent con-
fusion between them.
k Care must be used in the assembly operation so that you may not be injured by machined edges
and such of the sleeve/spool assembly or housing.
DX-Series 40-87
DISASSEMBLY AND ASSEMBLY STEERING VALVE
40-88 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DX-Series 40-89
DISASSEMBLY AND ASSEMBLY STEERING VALVE
• End of housing
G. Bolt hole ( 5/16-24UNF)
H. Oil hole ( 6.4)
J. Ball insertion hole ( 11 × P1.0)
40-90 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DX-Series 40-91
DISASSEMBLY AND ASSEMBLY STEERING VALVE
12) Assemble the end cap (4) using six bolts (2)
and a retainer bolt (3).
a Coat threaded portion on each bolt with
oil.
a For the tightening sequence, refer to the
numbers provided in the figure to the
right.
a Make sure that the hole [7] contains the
ball (14) and adapter bolt (13). Assemble
the adapter bolt (3) to this hole.
40-92 DX-Series
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DX-Series 40-93
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
HYDRAULIC PUMP
FG50/60/70
40-94 DX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
FG50/60/70 SAL56 56.5/rev Counterclockwise 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
Unit: mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
D Contact between gear and side plate/ Contact face shall be free from
body scratches or streaks on claw.
E Seal ring and backup ring Shall be free from scuffing or tears.
DX-Series 40-95
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
FD50/60/70
FD80
40-96 DX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
FD50/60/70 SAL40+28 40.2 cc/rev 28.0 cc/rev 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
FD80 SAL40+36 40.2 cc/rev 36.1 cc/rev 18.1 MPa {185 kgf/cm²} 10.3 MPa {105 kgf/cm²}
Contact between gear and side plate/ Contact face shall be free from
D body scratches or streaks on claw.
E Seal ring and backup ring Shall be free from scuffing or tears.
DX-Series 40-97
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
40-98 DX-Series
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
A1 Return spring 78 66 – 90
A4 Inlet 46.4 39
DX-Series 40-99
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
LIFT CYLINDER
40-100 DX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
Cylinder
(inner diam. × outer diam.) mm 80 × 90 85 × 90 90 × 102 —
Rod outer-dimeter
0.097 – 0.366 0.666
60
A Clearance between pis- Replace the
ton rod and bushing Rod outer-dimeter bushing
0.107 – 0.395 0.695
65
DX-Series 40-101
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
TILT CYLINDER
40-102 DX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
Cylinder
(inner diam. × outer diam.) mm 100 × 116 110 × 129
DX-Series 40-103
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
40-104 DX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DX-Series 40-105
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
40-106 DX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DX-Series 40-107
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
40-108 DX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
573.5 – 700.5 Nm
For lift cylinder 7 ton {58.5 – 71.5 kgf•m}
661.5 – 808.5 Nm
8 ton {67.5 – 82.5kgf•m}
DX-Series 40-109
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
40-110 DX-Series
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
a After installing the piston head, caulk along the periphery (on both right and left sides).
INSPECTION
Unit : mm
Criteria
Symbol Inspection item Remedy
Standard size Repair limit
A Clearance between cylinder and 0.03 – 0.18 0.30 Replace piston ring
piston ring
J Stroke 282
DX-Series 40-111
DISASSEMBLY AND ASSEMBLY MAST
MAST
1. Strip shim
2. Outer main roller
3. Inner roller
*1. Used for mast having lifting height of 4 m or higher
40-112 DX-Series
DISASSEMBLY AND ASSEMBLY MAST
ADJUSTING SHIM
Dimension a 0 – 0.5 mm
Dimension b 0 – 0.5 mm
DX-Series 40-113
DISASSEMBLY AND ASSEMBLY MAST
Dimension c 0 – 0.5 mm
40-114 DX-Series
DISASSEMBLY AND ASSEMBLY MAST
FINGER BAR
1. Roller on F side
2. Side roller
Dimension b 0 – 0.5 mm
40-116 DX-Series
DISASSEMBLY AND ASSEMBLY MAST
ADJUSTING CHAIN
1. Length of chain
1) Lower the mast to the lowest position.
2) Adjust the length of the chain so that projec-
tion A of the bottom of inner rail (1) from lower
roller (2) of finger bar (3) will be as follows.
Projection A
Unit : mm
5 ton 60
6 ton 55
7 ton 49
8 ton 62.5
DX-Series 40-117
DISASSEMBLY AND ASSEMBLY MAST
Unit : mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
Oil groove is
C Depth of bushing oil groove on mast support 1.5 provided
5 ton 55 50
Replace
6 ton 60 55
D Fork thickness (at root)
7 ton 65 60
8 ton 65 60
40-118 DX-Series
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
DX-Series 40-119
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
40-120 DX-Series
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
DX-Series 40-121
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
40-122 DX-Series
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
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
DX-Series 40-123
50. MAINTENANCE STANDARD
DX-Series 50-1
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Unit : mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
A Wear on tip of pilot 20 19.85
B Inside diameter of pump boss (seal ring engaging surface) 68 68.15
C1 Width 2.5 1.93
C Seal ring
C2 Thickness 2.0 1.52 Replace
D Inside diameter of converter case (seal ring engaging surface) 48 48.15
Width 2.5 1.93
E Seal ring
Thickness 2.7 2.22
1 Idling shaft mounting bolt tightening torque 67.6 – 78.4 Nm {6.9 – 8.0 kgf•m}
2 PTO bearing retainer mounting bolt tightening torque 67.6 – 78.4 Nm {6.9 – 8.0 kgf•m}
3 Seal retainer mounting bolt tightening torque 18.6 – 24.5 Nm {1.9 – 2.5 kgf•m}
Retighten
4 Pump case mounting bolt tightening torque 27.4 – 33.3 Nm {2.8 – 3.4 kgf•m}
5 Pilot boss and flexible plate mounting bolt tightening torque 35.2 – 44.1 Nm {3.6 – 4.5 kgf•m}
6 Charging pump mounting bolt tightening torque 35.2 – 44.1 Nm {3.6 – 4.5 kgf•m}
50-2 DX-Series
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
50-4 DX-Series
MAINTENANCE STANDARD TRANSMISSION
DX-Series 50-5
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
50-6 DX-Series
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit : mm
Criteria
Sym-
No. Check item bol Remedy
Standard size Repair limit
Piston or spool and body hole
A: Inside diameter of valve body
B: Outside diameter of piston and spool
— — —
Spring
— — — —
C: Free length
D: Installed length
E: Installed load
Free length 83
6 Accumulator Spring Installed length 80 11
(large) Installed load 34.3 – 38.2 N {3.5 – 3.9 kgf} 33 N {3.4 kgf}
Free length 107
7 Accumulator Spring Installed length 100 12
(small) Installed load 69.87 – 7.22 N {7.13 – 7.88kgf} 66 N {6.7 kgf}
Free length 73.8
8 Regulator Spring Installed length 37 3
(large) Installed load 34.3 – 38.2 N {3.5 – 3.9 kgf} 33 N {3.4 kgf}
Free length 55.5
9 Regulator Spring Installed length 36 2 —
(small) Installed load 41.2 – 45.1 N {4.2 – 4.6 kgf} 39 N {3.9 kgf}
Free length 34.5
10 Lubrication relief Valve Installed length 29 4
spring Installed load 29.4 – 32.3 N {3 – 3.3kgf} 28 N {2.8 kgf}
Free length 74
11 Inching Spring Installed length 54 9
(large) Installed load 35.3 – 38.7 N {3.6 – 3.95 kgf} 33 N {3.4 kgf}
Free length 28
12 Inching Spring Installed length 24.5 8
(small) Installed load 6.3 – 6.86 N {0.64 – 0.7 kgf} 5.9 N {0.6 kgf}
• The symbols at the right end of the table correspond to Nos. of NAME OF COMPONENT PARTS (1).
DX-Series 50-7
MAINTENANCE STANDARD PROPELLER SHAFT
PROPELLER SHAFT
Unit : mm
Sym- Criteria
Check item Remedy
bol Standard size Repair limit
50-8 DX-Series
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
50-10 DX-Series
MAINTENANCE STANDARD DIFFERENTIAL
Unit : mm
Sym- Criteria
Check item Remedy
bol Standard size Repair limit
J Outside diameter of seal engaging sur- 54.97 – 55.00 There must be no flaw. 3FD-21-21310
face of drum boss
P Bevel pinion shaft case tightening bolt 98 – 123 Nm {10.0 – 12.5 kgf•m} 01010-81245
R Parking brake drum tightening bolt 196 – 245 Nm {20 – 25 kgf•m} Loctite on thread
DX-Series 50-11
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
5 – 7 ton
50-12 DX-Series
MAINTENANCE STANDARD FINAL DRIVE
Unit : mm
Sym- Criteria
Check item Remedy
bol Standard size Repair limit
8 Inside diameter of hub seal mating hole 165 There must be no flaw. —
Hub
10 Inside diameter of external 180 –– 0.028 — —
bearing mating hole 0.068
Be sure to stop
13 Lock bolt (for ring nut) tightening torque 58.8 – 73.5 Nm {6 – 7.5 kgf•m} rotation (mount
the cotter pin).
14 Axis pipe connection bolt tightening torque 196 – 309 Nm {20 – 31.5 kgf•m} —
15 Gear case mounting bolt tightening torque 157 – 196 Nm {16 – 20 kgf•m} Apply Locktite
#271 on the
threaded portion.
16 Brake drum mounting bolt tightening torque 196 – 309 Nm {20 – 31.5 kgf•m}
Cross-caulk the
17 Hub bolt mounting nut tightening torque 441 – 588 Nm {45 – 60 kgf•m} bolt.
18 Wheel and clip (hub) nut tightening torque 294 – 490 Nm {30 – 50 kgf•m} —
DX-Series 50-13
MAINTENANCE STANDARD FINAL DRIVE
8 ton
50-14 DX-Series
MAINTENANCE STANDARD FINAL DRIVE
Unit : mm
Sym- Criteria
Check item Remedy
bol Standard size Repair limit
8 Inside diameter of hub seal mating hole 165 There must be no flaw. —
Hub
10 Inside diameter of external 180 –– 0.028 — —
bearing mating hole 0.068
Be sure to stop
13 Lock bolt (for hub nut) tightening torque 58.8 – 73.5 Nm {6 – 7.5 kgf•m} rotation (mount
the cotter pin).
14 Axis pipe connection bolt tightening torque 196 – 309 Nm {20 – 31.5 kgf•m} —
Apply Locktite
15 Gear case mounting bolt tightening torque 196 – 309 Nm {20 – 31.5 kgf•m} #271 on the
threaded portion.
16 Brake drum mounting nut (also used to 319 – 490 Nm {32.5 – 50 kgf•m} Cross-caulk the
mount hub bolt) tightening torque bolt.
DX-Series 50-15
MAINTENANCE STANDARD STEERING AXLE (REAR AXLE)
8 ton
Unit : mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
50-16 DX-Series
MAINTENANCE STANDARD MASTER BACK AND MASTER CYLINDER ASSEMBLY
DX-Series 50-17
MAINTENANCE STANDARD MASTER BACK AND MASTER CYLINDER ASSEMBLY
5 – 7 ton
(Master cylinder)
Unit : mm
50-18 DX-Series
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
8 ton
Unit : mm
Criteria
Sym-
bol Inspection item Remedy
Standard size Repair limit
DX-Series 50-19
MAINTENANCE STANDARD WHEEL BRAKE
WHEEL BRAKE
5 – 7 ton
50-20 DX-Series
MAINTENANCE STANDARD WHEEL BRAKE
Unit : mm
Criteria
Sym- Check item Remedy
bol
Standard size Repair limit
Free length: 90 mm
Return
B spring Strength
245N {25kgf} (l = 101.2mm) 221N {22.5kgf} (l = 101.2mm)
Free length: 93 mm
Crush or wear.
— Clearance between lining and drum 0.4 – 0.6 0.4 – 0.6 Testing and
adjusting
DX-Series 50-21
MAINTENANCE STANDARD WHEEL BRAKE
8 ton
50-22 DX-Series
MAINTENANCE STANDARD WHEEL BRAKE
Unit : mm
Criteria
Sym-
bol Check item Remedy
Standard size Repair limit
Testing and
— Clearance between lining and drum 0.3 – 0.5 0.3 – 0.5 adjusting
DX-Series 50-23
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
Unit : mm16
Criteria
Sym- Check item Remedy
bol
Standard size Repair limit
Operator of brake lever Min. 196 N {20 kgf} Min. 196 N {20 kgf}
50-24 DX-Series
MAINTENANCE STANDARD HYDRAULIC PUMP (SINGLE TYPE)
Unit: mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
Clearance between shaft hole inner
A diameter and gear shaft outer diameter 0.06 – 0.148 0.15
Contact between gear and side plate/ Contact face shall be free from
D body scratches or streaks on claw.
E Seal ring and backup ring Shall be free from scuffing or tears.
Tightening torque of pump body
F assembly bolt 98.1 – 122.6 Nm {10 – 12.5 kgf•m} Retighten
DX-Series 50-25
MAINTENANCE STANDARD HYDRAULIC PUMP (TANDEN TYPE)
Contact between gear and side plate/ Contact face shall be free from
D body scratches or streaks on claw.
E Seal ring and backup ring Shall be free from scuffing or tears.
50-26 DX-Series
MAINTENANCE STANDARD POWER STEERING CYLINDER
a After installing the piston head, caulk along the periphery (on both right and left sides).
INSPECTION
Unit : mm
Criteria
Symbol Inspection item Remedy
Standard size Repair limit
J Stroke 282
DX-Series 50-27
MAINTENANCE STANDARD LIFT CYLINDER
LIFT CYLINDER
Cylinder mm 80 × 90 85 × 90 90 × 102 —
(inner diam. × outer diam.)
Unit: mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
Rod outer-dimeter
0.097 – 0.366 0.666
60
Clearance between pis- Replace the
A ton rod and bushing bushing
Rod outer-dimeter
0.107 – 0.395 0.695
65
50-28 DX-Series
MAINTENANCE STANDARD TILT CYLINDER
TILT CYLINDER
Unit: mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
DX-Series 50-29
MAINTENANCE STANDARD MAST
MAST
Unit : mm
Criteria
Symbol Check item Remedy
Standard size Repair limit
Oil groove is
C Depth of bushing oil groove on mast support 1.5 provided
5 ton 55 50
Replace
6 ton 60 55
D Fork thickness (at root)
7 ton 65 60
8 ton 65 60
50-30 DX-Series
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Unit : mm
Sym- Criteria
bol Check item Remedy
Standard size Repair limit
A1 Return spring 78 66 – 90
A4 Inlet 46.4 39
DX-Series 50-31
60. STRUCTURE AND FUNCTION
DX-Series 60-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
60-2 DX-Series
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
DX-Series 60-3
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
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)
60-4 DX-Series
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
(3) Housing
A torque converter inlet relief valve is built in the housing in order to restrain internal torque converter
pressure from rising.
b. Turbine shaft
The one side is combined with the torque converter turbine and the other is combined with the trans-
mission input portion in order to transmit the torque converter output torque to the transmission side.
DX-Series 60-5
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
2) Function
(1) The rotation from the engine is transmitted to the impeller via the input plate.
The oil in the impeller is discharged along the impeller blades by centrifugal force.
(2) The oil drained from the impeller hits the turbine blade train. At this time, power is generated, which is
output via the turbine shaft.
(3) The direction of the oil drained from the turbine is changed by the stator so that it will re-enter in a desired
angle against the impeller blade train.
By repeating procedures (1) to (3) above, the engine torque is transmitted to the transmission side.
60-6 DX-Series
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
DX-Series 60-7
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
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.
60-8 DX-Series
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
DX-Series 60-9
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
(2) TRANSMISSION
60-10 DX-Series
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION CONTROL VALVE
The speed steps are forward travel 2-step and reverse travel 2-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.
DX-Series 60-11
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL VALVE
60-12 DX-Series
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL VALVE
DX-Series 60-13
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL VALVE
60-14 DX-Series
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
Hydraulic setting
Engine type Classification Pump type
[1] Main relief pressure [2] Port relief pressure
FG50/60/70 P1 SAL56
18.88 MPa {185 kgf/cm²} 10.71 MPa {105 kgf/cm²}
FD50/60/70 P1 + P2 SAL40 + 28
60-16 DX-Series
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
8 ton
Hydraulic setting
Engine type Classification Pump type
[1] Main relief pressure [2] Port relief pressure
FD80 P1 + P2 SAL40 + 36 18.88 MPa {185 kgf/cm²} 10.71 MPa {105 kgf/cm²}
DX-Series 60-17
STRUCTURE AND FUNCTION BRAKE SYSTEM
BRAKE SYSTEM
5 – 7 ton
Vacuum tank
• Vacuum level : Max. 91 kPa {680 mmHg}
• Alarm level : 60 kPa {450 mmHg} (during vacuum switch operation)
60-18 DX-Series
STRUCTURE AND FUNCTION BRAKE SYSTEM
8 ton
Accumulator
• Volume for accumulation: 300 cc
• Alarm level: Operates at 6.3 – 6.9 MPa {64 – 70 kgf/cm²}
DX-Series 60-19
STRUCTURE AND FUNCTION MASTER BACK, MASTER CYLINDER
60-20 DX-Series
STRUCTURE AND FUNCTION MASTER BACK, MASTER CYLINDER
1. Non-operating state
When not stepping on the brake pedal
The negative pressure from the vacuum pump via
the vacuum tank is guided on both sides of the di-
aphragm with the vacuum valve set to ON
(opened) and the air valve set to OFF (closed).
The master back will not move because no pres-
sure difference is generated.
DX-Series 60-21
STRUCTURE AND FUNCTION MASTER BACK, MASTER CYLINDER
4. During return
Releasing the brake pedal
When releasing the brake pedal, the plunger
head drops until it touches the key. Then, be-
cause the air valve closes and the vacuum valve
opens, the air in the air chamber is discharged via
the vacuum valve. Consequently, the diaphragm
moves to the rear (right side) by the force of the
spring and the push rod returns to the original po-
sition, and then the brake is released.
60-22 DX-Series
STRUCTURE AND FUNCTION MASTER BACK, MASTER CYLINDER
DX-Series 60-23
STRUCTURE AND FUNCTION MASTER BACK, MASTER CYLINDER
60-24 DX-Series
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
8 ton
SPECIFICATIONS
• The brake valve regulates the oil pressure in the brake oil circuit according to the pressing distance of the
brake pedal and operates the wheel cylinder. Even if the oil from the hydraulic pump stops because of an
engine stall, etc., the brake can be operated several times with the oil pressure saved in the accumulator.
DX-Series 60-25
STRUCTURE AND FUNCTION BRAKE VALVE
• If a downstream device (power-assisted steering system, etc.) is operated while spool (5) is in the position
shown above, the oil pressure in pump port C rises. Since pump port C and port F are blocked by normally-
closed valve b, however, the hydraulic oil does not flow in control oil chamber G. Accordingly, the brake does
not work by itself, even if a downstream device is operated.
2. When the brake pedal is pressed
• If the brake pedal is pressed, push rod (10) and input piston (7) move to the left and spool (5) and reaction
piston (4) are pushed by spring (11) to push and move return spring (3) to the left. As spool (5) moves to the
left, the pass between port F and drain port D is blocked by valve a and control pressure chamber G is dis-
connected from drain port D. Then, normally-closed valve b opens and forms the pass between ports C and
F. As a result, pump port c is connected to control oil chamber G.
• If spool (5) is moved further to the left, valve c is closed and the oil pressure in pump port C rises. Accord-
ingly, the oil pressure in control pressure chamber G connected to port C rises and the oil pressure in the
wheel cylinder also rises.
• Since the oil pressure in control pressure chamber G presses reaction piston (4) to the right (which is returned
by the reaction force to the oil pressure), it is balanced with the pressing force of the operator.
60-26 DX-Series
STRUCTURE AND FUNCTION BRAKE VALVE
• If the brake pedal is pressed to the stroke end, nut (9) touches stopper (8) and input piston (7) cannot move
to the left any more. Accordingly, the oil pressure in control pressure chamber becomes highest at this time.
k Loosen nut (9) only when replacing input piston (7).
• Even if the pump stops (because of an engine stall, etc.), the emergency brake can be operated with the pres-
sure saved in the accumulator.
If the brake pedal is pressed, push rod, (10), input piston (7), and spool (5) move to the left. As spool (5)
moves to the left, valve a closes and normally-closed valve b open and valve c closes. While the pump is
stopped, however, no oil pressure is generated in control pressure chamber G.
• If the brake pedal is pressed further, spool (5) and reaction piston (4) move to the left. Accordingly, the end
of reaction piston (4) touches valve rod (2) and valve d is closed and the pass between port H and control
pressure chamber G is blocked. If the brake pedal is pressed further, spool (5), reaction piston (4), and valve
rod (2) move to the left as 1 unit. Accordingly, ball valve (1) is pushed open and the pass is formed between
accumulator port A and control pressure chamber G. As a result, the oil pressure saved in the accumulator
is led into control pressure chamber G to raise the pressure in the wheel cylinder.
• Since the oil pressure in control pressure chamber G gives a reaction force to reaction piston (4), it is bal-
anced with the pressing force of the operator.
DX-Series 60-27
STRUCTURE AND FUNCTION BRAKE VALVE
• If the brake pedal is released, spool (5), reaction piston (4), and valve rod (2) move to the right and ball valve
(1) returns to the valve seat to block the pass between accumulator A and control pressure chamber G.
• Valve rod (2) stops halfway but reaction piston (4) moves further to the right. Accordingly, valve d opens to
form the pass between port H and control pressure chamber G, then the hydraulic oil flows and the oil pres-
sure in the wheel cylinder lowers. If spool (5) moves further to the right, valve a opens and the pass is formed
between port F and drain port D, then the oil pressure in the wheel cylinder lowers completely.
60-28 DX-Series
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
ACCELERATOR PEDAL
FG50/60/70-7 (TB42 engine)
60-30 DX-Series
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
ACCELERATOR PEDAL
FD50/60/70-8 (S6D102E engine)
DX-Series 60-31
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
ACCELERATOR PEDAL
FD80-8 (SA6D102E engine)
60-32 DX-Series
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
a Coat each sliding portion with lithium grease (G2-LI) during assembly.
60-34 DX-Series
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
DX-Series 60-35
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
a Coat each sliding part with lithium grease (G2-LI) during assembly.
60-36 DX-Series
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
DX-Series 60-37
STRUCTURE AND FUNCTION ASSEMBLY DRAWINGS
PARKING BRAKE
60-38 DX-Series
70. TROUBLESHOOTING
DX-Series 70-1
TROUBLESHOOTING ENGINE
ENGINE
Black exhaust gas. • Clogging of air cleaner element. • Clean or replace the element.
70-2 DX-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.
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 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).
DX-Series 70-3
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.
• 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.
70-4 DX-Series
TROUBLESHOOTING TORQFLOW SYSTEM
• (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.
DX-Series 70-5
TROUBLESHOOTING TORQFLOW SYSTEM
70-6 DX-Series
TROUBLESHOOTING STEERING SYSTEM
STEERING SYSTEM
1. Hydraulic system
a. Insufficient oil pressure of PS circuit Check, adjust, or repair it.
b. Insufficient hydraulic pump delivery Check or repair it.
c. Oil leak in PS cylinder Check or repair it.
2. PS valve
a. Contaminant being caught between Check or repair it and replace the parts.
spool sleeves or between the sleeve
and housing
b. Large tightening torque of end cap Uniformly tighten it at a regular tighten-
1. The steering wheel operation tightening bolt ing torque.
is heavy. c. Failed ball incorporation of check Incorporate the ball.
valve for emergency steering
3. Hydraulic pump
a. Wear and damage of gear body Check, repair, or replace it.
b. Wear and damage of drive shaft Check, repair, or replace it.
spline
4. Truck body
a. Scuffing and baking of steering link Check or repair it or replace the parts.
and bushings
1. PS valve
a. Contaminant being caught between Check or repair it and replace the parts.
2. Even the steering wheel is spool sleeve valves, scuffing, or bak-
released, it does not return to ing
neutral. b. Damage of center ring spring Check or repair it or replace the parts.
c. Scuffing of column shaft and bush- Check or repair it or replace the parts.
ings
1. Hydraulic system
a. Mixing in of air Check or repair the piping and tank.
b. Generation of cavitation Check or repair the piping, filter, and
tank.
c. Insufficient pump delivery Check, repair, or replace the pump.
3. The follow-up performance of
the cylinder is bad or ineffec- 2. PS valve
tive for the steering wheel rota- a. Wear of internal parts Check or repair it or replace the parts.
tion. b. Small tightening torque of bolt for end Uniformly tighten it at a regular torque.
Otherwise, the wheel slip is cap tightening
abnormally large. c. Failed incorporation of drive or Assemble it regularly.
spacer
3. PS cylinder
a. Damage, wear, and scuffing of piston Check or repair it or replace the parts.
ring seal
DX-Series 70-7
TROUBLESHOOTING STEERING SYSTEM
1. Hydraulic system
4. The steering wheel is turned in a. Wrong piping mounting on four ports Check or repair it.
the reserve direction, or a
wheel kick symptom is gener- 2. PS valve
ated. a. Incorrect valve timing (after re- Check or repair it.
assembly)
1. Hydraulic system
a. Mixing in of air Check or repair the piping and tank.
5. Vibration is generated.
2. Truck body
a. Wear of steering link with backlash Check it or replace the parts.
b. Backlash of wheel bearing or hub Check or adjust it.
1. Hydraulic system
a. Noise from control valve Check, adjust, or repair it.
b. Noise from hydraulic pump Check, adjust, or repair it.
6. An abnormal noise (including a c. Noise from piping and tank Check, adjust, or repair it.
relief noise) is generated.
2. PS valve
a. Noise from spool sleeve assembly Check or repair it.
b. Noise from gerotor and drive Check or repair it.
1. PS valve
[Damage of wear of spool part oil seal]
a. Stain of hydraulic oil Replace the hydraulic oil and filter.
b. Rust of spool seal surface Replace the assembly.
c. Damage during disassembly and Replace the parts.
assembly
7. Oil leakage [Damage of O-ring of mating face
(gerotor part)]
a. Being caught during disassembly Replace the parts.
and assembly
b. Damage of O-ring groove part Replace the parts.
c. Insufficient tightening torque of bolt Uniformly tighten the end cap at a regu-
for end cap tightening lar tightening torque.
70-8 DX-Series
TROUBLESHOOTING BRAKE SYSTEM
BRAKE SYSTEM
• 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
• Worn lining. • Replace it.
(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.
DX-Series 70-9
TROUBLESHOOTING BRAKE SYSTEM
70-10 DX-Series
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.
DX-Series 70-11
80. CHECK ITEMS FOR EACH EQUIPMENT
DX-Series 80-1
CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
ponent Check item Check contents
1. Starting, noise • Pull the parking brake lever and set the selector lever to neutral, then start the
engine and record the following items:
1. Whether the engine starts smoothly
2. Abnormal noise
3. Whether the glow plug operates normally
4. Whether the accelerator pedal and lever operate smoothly
2. Rotation, exhaust gas • Step on the accelerator pedal and check the following items:
color 1. Whether the engine speed rises smoothly
2. Whether the exhaust gas color is normal
Idling No color
When the pedal is stepped on Thin black
3. Engine speed • Check the following items after warming up the engine:
1. Idling speed
Engine
2. Maximum speed
4. Air cleaner • Check the following items for the air cleaner:
1. Crack and deformation on the air cleaner
2. Loosening of the air cleaner mounting
3. Stain and damage on the element
a For cleaning and replacing the element, see section "TESTING AND ADJUST-
ING".
80-2 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
ponent Check item Check contents
a For measuring the valve clearance, see section "TESTING AND ADJUSTING".
7. Compression Compression
(Compression pres- (MPa {kgf/cm2}/rpm)
sure)
Model Engine Compression
FG50/60/70 TB42 Min. 1.18 {12}/200
FD50/60/70 S6D102E
Min. 2.41 {24.6}/250 – 280
FD80 SA6D102E
Engine
Adjustment:
Using the adjustment shim
DX-Series 80-3
CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
ponent Check item Check contents
2. Injection timing
Check the fuel injection timing.
2) Discoloration
If the oil is discolored, change it.
a For changing the oil, see section "TESTING AND ADJUSTING".
3) Oil leakage
80-4 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
ponent Check item Check contents
ing by heat
4. Radiator cap
DX-Series 80-5
CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
ponent Check item Check contents
2) Deflection amount
Push the centers of fan pulley (1)
and alternator (2) belts with your fin-
ger for check.
Deflection amount a
TB42 15 – 7mm
[98N{10kgf}Finger pressure]
bolts
3) Crack and deformation on the
shroud
4) Loosening of the shroud mount-
ing bolts
80-6 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT ENGINE
Com-
ponent Check item Check contents
Ignition timing
(BTDC deg/rpm) TB42 7/700
DX-Series 80-7
CHECK ITEMS FOR EACH EQUIPMENT POWER TRAIN
Com-
ponent Check item Check contents
2. Transmission
1) Abnormal noise
2) Oil leakage
If leaked oil form drops, replace the
packing.
3) Oil level
Place the truck on a horizontal place
and check the oil level with the dip-
stick.
(Mast be in range of L)
1. Oil level gauge
2. Oil filler plug
3. Drain plug
Power train
4. Strainer
80-8 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT POWER TRAIN
Com-
ponent Check item Check contents
Both-way moving 31 mm
amount (a)
Interlocking stroke 23 – 28 mm
5 – 7 ton 83 – 93 mm
Power train
Height a
8 ton 85 – 95 mm
4) Play
Play b 2 – 3 mm
DX-Series 80-9
CHECK ITEMS FOR EACH EQUIPMENT POWER TRAIN
23. Torque converter k Check the following items after locking the wheels and operating the
parking brake.
1. Clutch actuation pressure
Switch the selector lever to forward or reverse, step on the accelerator pedal, and
measure the pressure.
C1 R1 clutch
C2 R2 clutch
P1 Main relief pressure
• Inching valve outlet side
P2 • Orifice (ø2 in diameter) inlet
side
P3 F1, F2 clutch
P4 lubrication relief pressure
2. Stall speed
Switch the selector lever to forward or reverse, run the engine at the maximum
speed, and measure the engine speed.
a Because this test raises the temperature of the torque converter oil, do not
execute it for a long time.
80-10 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT POWER TRAIN
Com-
ponent Check item Check contents
24. Propeller shaft 1. Oil leakage from the seal of the connection mating side (case)
3. Oil stain
a For checking the oil level and chang-
ing the oil, see section "TESTING
Power train
AND ADJUSTING."
2. Oil level
Check that the planetary gear case contains the sufficient amount of oil.
3. Oil stain
DX-Series 80-11
CHECK ITEMS FOR EACH EQUIPMENT TRAVEL SYSTEM
Com-
ponent Check item Check contents
157 – 225 Nm
Bolt (1) {16 – 23 kgf•m}
Travel system
4. Abnormal wear
Partial wear or uneven wear
80-12 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT TRAVEL SYSTEM
Com-
ponent Check item Check contents
DX-Series 80-13
CHECK ITEMS FOR EACH EQUIPMENT STEERING SYSTEM
Com-
ponent Check item Check contents
2. Steering effort
Play
30 – 60 mm
Play L
(when engine is idling)
1) Backlash
Hold the top and bottom of a tire and shake it to check backlash.
2) Abnormal noise
Turn a tire with your hand to check an abnormal noise.
2. Kingpin
1) Backlash
3. Knuckle
Crack and damage
Visually check or use the crack search method for checking.
80-14 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT STEERING SYSTEM
Com-
ponent Check item Check contents
Difference between
left and right turns Max. ±100 mm
36. Power steering 1. Oil leakage from the power steering cylinder and hose
system
2. Damage or deterioration of hose
5. Oil pressure
Remove each plug in the right fig-
ure, then mount the hydraulic
gauge and measure the oil pres-
sure when the steering is turned to
the either end.
Oil 10.3 – 10.8 MPa
pressure {105 – 110 kgf/cm2}
DX-Series 80-15
CHECK ITEMS FOR EACH EQUIPMENT BRAKING SYSTEM
Com-
ponent Check item Check contents
2) Play
Play b 2 – 6 mm
2. Brake effect
Select a dry and plane road, drive the truck at the maximum speed, then stop it
rapidly and check the following items:
1) Steering unstableness 2) One side braking 3) Abnormal noise
4) Stop range (braking ability)
40. Brake piping Visually check the following items for pipes, hoses, and joints:
80-16 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT BRAKING SYSTEM
Com-
ponent Check item Check contents
41. Oil brake 1. Master cylinder, wheel cylinder oper- FG50 – 70, FD50 – 70
ation
Operate the brake pedal and check the
following items:
1) Stepping on effort,
2) Change in the stepping on effort,
3) Change in the pedal position when
the pedal is kept stepping on
4) Return of the pedal when it is
released
3. Wheel cylinder
42-1. Brake booster Check the vacuum pump, tank and master back pump, and incomplete vacuum.
FG50/60/70 Max. 90 kPa 60 kPa
FD50/60/70 Vacuum Alarm device operating point
{680 mmHg} {450 mmHg}
Braking system
DX-Series 80-17
CHECK ITEMS FOR EACH EQUIPMENT BRAKING SYSTEM
Com-
ponent Check item Check contents
46. Parking brake lining, 1. Lining peeling off, damage, and wear
back plate
Lining thickness Min. 3.3 mm
Braking system
Item 5 – 8 ton
Inside diameter of drum Max. 218.2 mm
Parking
brake Clearance between
drum and lining 0.1 – 0.25 mm
80-18 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT LOAD SYSTEM
Com-
ponent Check item Check contents
5 ton Min. 55 mm
6 ton Min. 60 mm
7, 8 ton Min. 65 mm
a Apply the crack search method to check the fork root and hook on which stress is
concentrated at loading.
Load system
a Since the fork thickness varies with the fork length, etc., check the standard value
of the installed fork.
Tightening torque
DX-Series 80-19
CHECK ITEMS FOR EACH EQUIPMENT LOAD SYSTEM
Com-
ponent Check item Check contents
2. Extension
Measure lengths L between 17 links and check that they conform to the specifi-
cation.
56. Attachment unit (2) 1. Crack, deformation, damage, and wear on parts
80-20 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT HYDRAULIC SYSTEM
Com-
ponent Check item Check contents
2. Oil level
Check the oil level with the dipstick and
fill the oil if necessary (also check stain
in the oil).
a For checking the oil level and chang-
ing the oil, see section "INSPEC-
TION AND ADJUSTMENT."
3. Cleaning strainer
58. Power train piping 1. Crack, damage, deterioration, and bend on piping
2. Oil leakage
Hydraulic system
2. Oil leakage
2. Abnormal vibration
3. Abnormal noise
2. Abnormal vibration
3. Abnormal noise
DX-Series 80-21
CHECK ITEMS FOR EACH EQUIPMENT HYDRAULIC SYSTEM
Com-
ponent Check item Check contents
65. Lowering and forward 1) Apply the permissible load, set mast [1]
tilting by hydraulic vertically, and increase height H to
drift about 1,500 mm.
2) Set rule [1] to the piston rod of lift cylin-
der (2), make mark A, and measure the
hydraulic drift.
3) Set rule [2] to the piston rod of tilt cylin-
der (3), make mark B, and measure the
hydraulic drift.
When
Max. 100
Hydraulic system
measured
Lowering at fork mm/15 min
by hydrau-
lic drift When
measured Max. 50
at cylinder mm/15 min
Forward
tilting by When Max. 40
hydraulic measured mm/15 min
drift at cylinder
80-22 DX-Series
CHECK ITEMS FOR EACH EQUIPMENT HYDRAULIC SYSTEM
Com-
ponent Check item Check contents
3. Oil leakage
DX-Series 80-23
CHECK ITEMS FOR EACH EQUIPMENT BODY SAFETY SYSTEM, OVERALL TEST
Com-
ponent Check item Check contents
2. Mounting status
69. Component functions Check functions of components by executing the traveling and work tests.
80-24 DX-Series