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SHOP MANUAL
FD100/115-8
FD100/115/135/150E/160E-8
FD135/150E/160E-8
Printed in Japan
FD100/115-8
FD135/150E/160E-8
00. FOREWORD
70. TROUBLESHOOTING
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.
Tightening torque Fastening parts that require specified tightening force when assembling.
Specifications ..........................................................10- 2
Periodic replacement of consumable parts .............10- 6
Safety items for maintenance .................................10- 7
Standard tightening torque......................................10-16
How to use LOCTITE..............................................10-18
SPECIFICATIONS
1.2 Model Manufacturer's Designation FD100-8 FD115-8 FD135-8
1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel Diesel
Characteristics
Loaded
2.2.1 Rear kg(lb) 2120(4,670) 2370(5,220) 2530(5,580)
Axle Loading
2.3 Front kg(lb) 6230(13,730) 6590(14,530) 7110(15,670)
Unloaded
2.3.1 Rear kg(lb) 6750(14,880) 7770(17,130) 8370(18,450)
3.1 Tyre Type Pneumatic Pneumatic Pneumatic
3.2 Front 9.00-20-14PR(I) 10.00-20-14PR(I) 11.00-20-14PR(I)
Tyre Size
3.3 Rear 9.00-20-14PR(I) 10.00-20-14PR(I) 11.00-20-14PR(I)
Tyres
Loaded
2.2.1 Rear kg(lb) 2830(6,240) 3060(6,750)
Axle Loading
2.3 Front kg(lb) 7210(15,900) 7170(15,810)
Unloaded
2.3.1 Rear kg(lb) 9360(20,640) 10030(22,110)
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 11.00-20-16PR(I) 12.00-20-16PR(I)
Tyre Size
3.3 Rear 11.00-20-16PR(I) 12.00-20-16PR(I)
Tyres
• Only persons authorized by the owner or operator of the equipment and having proper certification
(local or national) may carry out inspection, maintenance and repairs of the lift truck.
If inspection, maintenance or repair work is carried out incorrectly, it is very dangerous.
MAINTENANCE LOCATION
• When carrying out inspection and maintenance, use a level, dry, dust–free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.
• To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know
how to use it.
• Before carrying out inspection, lower the forks to the ground and stop the machine.
• Do not run the engine unless it is necessary.
• Place the directional lever, speed lever, and work equipment control levers in neutral.
• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean
the lift truck before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.
• Wear suitable clothes for the job.
• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the
job.
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body
caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the
forks and mast from dropping.
• When carrying out job with another worker, decide who is the leader and carry out the job in accor-
dance with instructions from that person.
• After repairing, make sure that the trouble has been corrected by performing a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not
been fully corrected or that defective parts have not been removed.
• Immediately after using the lift truck, the engine coolant is at high temperature and high pressure. Do
not remove the radiator cap under these conditions.
Hot water may spurt out and cause burns.
• When removing the radiator cap, turn it slowly to
release the internal pressure.
• When checking the coolant level, stop the engine and
wait for the engine and radiator to cool down before
checking. For lift trucks equipped with a subtank or
reservoir, check the level in the subtank.
• When adding water on lift trucks equipped with a sub-
tank, add the water to the subtank.
• Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the
filter when the oil is hot. Hot oil may spurt out and cause burns.
• When carrying out inspection and maintenance,
wait for the oil temperature to go down, and carry
out the operation in the order given in this manual.
• Do not forget that the work equipment circuits are
always under pressure. Do not add oil, drain oil, or
carry out maintenance or inspection before com-
pletely releasing the internal pressure.
• If oil is leaking under high pressure from small
holes, it is dangerous if the jet of high–pressure oil
hits your skin or eyes. Always wear safety glasses
and thick gloves, and use a piece of cardboard or
a sheet of plywood to check for oil leakage.
• Release the internal pressure before checking the
accumulator piping.
• If you are hit by a jet of high pressure oil, consult a
doctor immediately.
• When removing a mast or a lift cylinder, always
depressurize the hydraulic piping.
1) Stop the forklift truck. Lower the fork to the ground.
2) Stop the engine.
3) Turn the starting switch to the ACC position.
4) Sit on the seat. Operate the lift lever and tilt lever forward and backward 4 to 5 times each to
depressurize the hydraulic piping.
No depressurization can be effected by lever operation without sitting on the seat.
• If the tyre inflation pressure is low, it will affect truck stability. However, do not inflate the tyres immedi-
ately. The inflation pressure may have gone down because of damage to the rim. If the rim is dam-
aged or cracked and the tyres are inflated, there is danger that the rim will break when the tyre is
under high pressure, and this may cause personal injury or death.
• For safety, when checking tyre pressure, place your body in front of the tread face of the tyre. Do not
check from the side face of the tyre.
• Suitable qualifications are needed for tyre inflation work.
Always have the work carried out by properly qualified
personnel.
• The tyre inflation pressure on a forklift truck is several
times higher than the pressure on an automobile.
• When the tyres are being inflated, there is danger that
dirt or dust may be thrown up by the compressed air and
enter your eyes, so always wear safety glasses.
HANDLING TYRES
• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you
spill electrolyte on yourself, immediately flush the area with a large quantity of water.
• Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes,
flush them immediately with large quantities of water and consult a doctor at once.
• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite
or vegetable oil. Call a doctor or poison prevention center immediately.
• When working with batteries, ALWAYS wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a
small spark or flame. Do not smoke or create any spark near the battery.
• Before working with batteries, stop the engine and turn the starting switch to the OFF position.
• When removing the battery, remove the cable from
the negative terminal first. When installing the
battery, install the cable to the positive terminal
first.
• Avoid short–circuiting the battery terminals through
accidental contact with tools or other metal objects
across the terminals.Tighten the battery terminals
securely. Loose terminals can generate sparks and
lead to an explosion.
• When removing or installing the battery, confirm
which is the positive terminal and negative ter-
minal. Be careful not to connect the cables to the
opposite terminals.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps
tightened.
• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit
and start a fire.
When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical
change. To prevent the danger of gas explosion, always do as follows.
• Carry out the charging operation in a well–ventilated place.
• Do not smoke or allow any flame.
• Start the charging operation when the temperature of the battery electrolyte is below 35°C (95 ). (If
the temperature goes above 50°C (122°F) during the charging operation, wait for it to go down below
35°C (95°F) before starting charging operation again.)
• When using a battery charger to charge the battery, take the battery caps off.
• ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.
• When starting using the battery of another lift truck, do not allow the two lift trucks to touch. For details
of the order of operations when using a booster cable.
• Stop the engine before connecting the cables.
• e extremely careful not to let the cables get caught in the fan or fan belt.
• Connect the batteries in parallel: positive to positive and negative to negative. Never connect positive
to negative.
• Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and
operate unexpectedly.
HANDLING ANTIFREEZE
WASTE MATERIALS
Width D (mm) 19 22 30
Bore A (mm) 14 18 22 24 30
19.6–29.4 23.5–68.6 58.8–98.1 108–167 147–206
Tightening torque Nm {kgm} {2–3} {3–7} {6–10} {11–17} {15–21}
4. Assembly
Male side After applying LOCTITE, tighten the screw or fit the
shaft to the hole as usual. (When using LOCTITE for
Degreasing Air drying
structures or LOCTITE of instant glue type, press the
Female
side mating parts lightly (about 49 kPa {0.5 kgf/cm2}).
SERVICE DATA
MPa
Compression Min. 24 {Min. 246} / 250–280
{kgf/cm²}/ rpm
Engine
MPa
Torque converter Inlet oil pressure {kgf/cm²} 1.2–1.5 {12–15}
MPa
Outlet oil pressure {kgf/cm²} 0.6–0.73 {6–7.4}
Power train
MPa
Relief pressure {kgf/cm²} 1.96 {20}
Tyre
pressure
Rear wheel kPa 735 690 660 760 690
{kgf/cm²} {7.5} {7.0} {6.75} {7.75} {7.0}
Stroke mm 83
Inching pedal
Interlocking stroke mm 50
Steering and braking device
Play mm 1–4
Brake pedal
Stroke mm 76
Opening at tip mm 50
MPa 21.6
Relief pressure
Hydraulic {kgf/cm2} {220}
system
Quantity of oil 170 200
HOW TO DEPRESSURIZE
1. Stop the forklift truck. Lower the fork to the ground.
2. Stop the engine.
3. Turn the starting switch to the ON (2) position.
4. Sit on the seat. Operate the lift lever and tilt lever for-
ward and backward 4 to 5 times each to depressur-
ize the hydraulic system.
CAUTION
Service the engine always after it is stopped completely and the temperature fully lowered.
Oil gauge
Filters
Drain plug
CAUTION
• Engine parts are in high temperature immediately after the engine is stopped. Do not replace filters
immediately. Replace only after the engine is cooled.
• When replacing filters, wait till the inner pressure lowers. Replace the filters 30 seconds or more after
the engine stopped.
• Keep fire away when replacing filters.
NOTICE
• Special filter of high-efficiency filtration property is adopted for the genuine Komatsu Utility fuel filter car-
tridges.
Always use genuine Komatsu Utility parts for replacement.
• The common rail fuel injection system adopted for the engine is configured with components of higher accu-
racy compared with conventional injection pumps and nozzles. Using other fuel filter cartridges than genuine
Komatsu Utility parts may cause mixing of foreign matters, leading to a failure of injection system. Never use
substitute part.
• For inspection and maintenance of the fuel system, more care should be given for the mixing of foreign mat-
ters than before. Attached dirt, if any, must be fully washed off using engine oil.
* REF (Reliable-Extra-Filtration)
: This specification provides an additional main
filter and a filter with the water separation func-
tion for the inferior fuel.
NOTICE
NOTICE
AIR CLEANER
CAUTION
• Do not clean or replace the air cleaner while the
engine is running.
• When cleaning the elements with compressed air,
dirt may be scattered to get into the eye. Put on the
protective glasses for evading the danger.
NOTICE
CLEANING
1. Remove element (3). Blow the element from inside
to outside with dry, compressed air of 0.68 MPa {7
kgf/cm²} all around the element.
2. Install cleaned element (3).
CHECKING
Visually check the element for any damage.
DIFFERENTIAL CASE
CAUTION
Oil is in high temperature immediately after the engine
operation.
Start working on it after the temperature is lowered.
OIL REPLACEMENT
1. Remove the oil filler port plug first. Then remove the
drain plug to drain oil.
2. After draining, tighten the drain plug and fill oil to the
specified level through the oil filler port.
3. Check the oil level after filling oil.
Oil capacity for replacement:
20 l (5.28 US gal, 4.40 UK gal)
NOTICE
NOTICE
Correct
Drain plug range
Strainer
HYDRAULIC TANK
REPLACEMENT OF OIL IN THE HYDRAULIC TANK
CAUTION
Oil is in high temperature immediately after the opera-
tion.
Do not replace oil immediately after operation.
Replace after the oil is cooled.
NOTICE
NOTICE
METHOD OF MEASURING
1. Stop the lift truck 500 mm in front of the platform.
2. Operate the lift and tilt repeatedly to set the hydraulic Set must
oil temperature to 50° (122 ). perpendicular
BRAKE PEDAL
1. Pedal height (from floor plate)
Adjust with stopper bolt (1). Pedal play 1- 4 mm
2. Pedal play
After adjusting the brake pedal height, adjust the
cable length so that the play of the brake pedal 2
becomes 1 to 4mm. (The play at the end of cable is 0
to 0.5mm.)
But, do not pull the linkage. (The connection pins at
both ends of cable should be smoothly moved by
hand.)
Cable 0 - 0.5 mm
Pedal play 1–4 mm (0.04–0.16 in) end
INCHING PEDAL
1. Pedal height (from floor plate)
Adjust with stopper bolt (3).
3. Interconnected stroke
Adjust with bolt (5) so that the inching pedal and
brake pedal are interconnected for the travel shown
below when the inching pedal is depressed.
Detail (a)
50 mm
The depressed inching
pedal travels at a distance
as shown until the brake
pedal starts to move.
INCHING PEDAL
1. Pedal height (from floor plate)
Adjust with stopper bolt (3)
Brake valve
2. Charging accumulator with nitrogen gas How to connect accumulator and nitrogen gas cylinder
1) Since the thread of gas valve (25) of the accu-
mulator is TV8, install the joint assembly to the
charging assembly.
2) Turn handle (23) of charging assembly (00) to
the left until it stops.
3) Turn handle (24) of the bleed plug to the left to
open the plug.
4) Remove the cap of the accumulator and install
charging assembly (21) to the gas valve of the
accumulator.
5) Connect nitrogen gas cylinder (2) and charging
assembly (21) by hose assembly (29).
a There are 2 types of threads of gas cylinders, 1. Accumulator
W22-14 thread (mail screw, type A) and W23-
2. Nitrogen gas cylinder
14 thread (female screw, type B). When using
3. Charging assembly
type-B gas cylinder, use the attached reducer
4. Hose assembly
(30).
6) Open the valve of nitrogen gas cylinder (2) a lit-
tle so that the gas will be discharged at pressure
of 0.2 – 0.3 MPa {2 – 3 kg/cm²}, taking care not
to discharge the gas quickly.
Then, the gas comes out of handle (24). At this
time, turn the handle to the right to prevent the
gas from escaping.
7) Turn handle (23) of charging assembly to the
right to lead the nitrogen gas to the accumulator.
At this time, stop handle (23) when you feel a
light reaction so that the gas valve piston will not
be damaged.
a If the handle is turned too strongly, the core
will be broken. Take care.
8) Open the gas cylinder valve gradually further to
charge the accumulator with the nitrogen gas.
While doing so, close the gas cylinder valve
sometimes and read pressure gauge (28) of the
charging assembly when it is stabilized.
Charge gas pressure: 4.9 MPa ± 0.2 {50 ± 2 kg/
cm²}
9) After the accumulator is charged to the specified
pressure, close the valve of nitrogen gas cylin-
der securely.
If the pressure in the accumulator is too high,
turn handle (24) to the left and release the nitro-
gen gas gradually.
10) Turn handle (23) to the left until it stops, and
then turn handle (24) to the left to open it and
discharge the gas remaining in the charging
assembly and hose.
11) Remove charging assembly (21) from the accu-
mulator.
12) Apply water or soap water to the gas valve of the
accumulator to check that the gas is not leaking,
and then install the cap.
Charging Ass'y
Joint Ass'y
2. Charging accumulator with nitrogen gas How to connect accumulator and nitrogen gas cylinder
1) Since the thread of gas valve (25) of the accu-
mulator is TV8, install the joint assembly to the
charging assembly.
2) Turn handle (23) of charging assembly (00) to
the left until it stops.
3) Turn handle (24) of the bleed plug to the left to
open the plug.
4) Remove the cap of the accumulator and install
charging assembly (21) to the gas valve of the
accumulator.
5) Connect nitrogen gas cylinder (2) and charging
assembly (21) by hose assembly (29).
a There are 2 types of threads of gas cylinders, 1. Accumulator
W22-14 thread (mail screw, type A) and W23- 2. Nitrogen gas cylinder
14 thread (female screw, type B). When using 3. Charging assembly
type-B gas cylinder, use the attached reducer 4. Hose assembly
(30).
Charging Ass'y
Joint Ass'y
MEASUREMENT
k With the engine stopped, step on the brake pedal
for 100 times or more to depressurize the accu-
mulator circuit.
1. Remove the floor cover.
2. Remove plug (1) from the accumulator charge valve.
3. Install the measuring nipple (PT1/8). Install the oil
pressure gauge (39.2 MPa {400 kgf/cm²})
4. Measure the accumulator charge cut-in pressure.
a Start the engine and run it at low idling speed.
Measure the oil pressure when the sound of
brake oil pressure-warning buzzer ends.
Cut-in +0.49 +5
5.88 0 MPa {60 0 kgf/cm²}
pressure
ADJUSTING CLEARANCE
1. Turn the adjust wheel (1) in the shoe expanding
direction to have the lining made contact with the
brake drum. 157 – 196 Nm
2. Turn the adjust wheel (1) so that the clearance {16 – 20 kgm}
between the drum and lining (points X and Y in the 2 Loctite #271
diagram to the right) reads 0.1 to 0.25 mm.
(Returning the adjust wheel by 11 notches adjusts
the clearance by 0.25 mm)
BLEEDING AIR
BRAKE PIPING
(HYDRAULIC DRUM BRAKE TYPE)
1. Remove the cap from the air bleed plug, fit one end
of a vinyl hose, and put the other end of the vinyl
hose in a container of brake fluid.
LIFT CYLINDER
1. Start the engine and run at low idling.
CAUTION
Carry out the work by two (2) persons. One person
steps on the brake pedal and other bleeds the air from
the bleeder screw.
CAUTION
Since high-pressure oil is stored inside the piping con-
necting the accumulator and brake valve after the
engine stopped, remove the piping according to the fol-
lowing method:
HOW TO REMOVE
1. Stop the engine.
2. Step on the brake pedal 100 times and over to drain
the high-pressure oil inside the piping to the hydrau-
lic tank.
3. Remove the piping.
STEERING AXLE
Adjusting alignment
Toe–in mm
Camber deg
0
Castor deg
1,900 (10 t)
Tread mm 1,890 (11.5 t–15 t)
1,870 (16 t)
Toe–in L1 = L2
CAUTION
• Never touch refrigerant. Never loosen the parts on the refrigerant circuit as well. Eyesight may be lost or hand may be
frostbitten if contacting with refrigerant gas.
• Keep fire away from the leaking point of refrigerant gas if any.
A : Refrigerant capacity
B : State of the sight glass
a : Correct...................... After the air conditioner is
turned ON, some bubbles are
noticed in the flow of refriger-
ant, then it turns light opaque
white.
b : Refrigerant volume ... In short. Bubbles are continu-
ally noticed after the air condi-
tioner is turned ON.
X : Flow state of refrigerant
Y : State of the sight glass
x : Bubbles are present. Refrigerant in liquid and gas-
eous state is mixed.
y : Bubbles are gone and all the refrigerant is in trans-
parent liquid state.
z : White turbid oil and refrigerant are in separated con-
dition in light opaque white.
BATTERY
CAUTION
Cautions for handling batteries
• First-aid treatment for exposure to battery electrolyte
If your eyes, skin or clothes is attached with battery electrolyte, wash it off with large amount of water. If it gets into
your eyes, immediately see an eye doctor.
• Keep fire away
Avoid short circuit and/or sparks to be generated near the battery. Keep a lit cigarette or other fire away from the bat-
tery.
4. Charge, if necessary.
TORQFLOW
Mast support
transmission
Power steering
Center pin, King pin
cylinder pin
Daily inspection
Once every 2 week (100 hours)
Monthly (200 hours)
Every 2 months (400 hours)
Every 3 months (600 hours)
Every 6 months (1200 hours)
Caution
Symbol Type of fluid
1. Check and add fluid if necessary
EO Diesel engine oil 2. Change or add oil
MO Engine oil 3. The figure in indicates the number of oil or greas-
GO Gear oil ing locations.
4. The intervals for checking the oil level, adding oil,
HO Hydraulic oil
and greasing are every day, every two weeks, every
G Lithium grease one month, every three months, and every six
months, or according to the hourmeter reading.
* Always use Komatsu Utility-designated oil for the
diesel engine.
LUBRICANT LIST
NOTICE:
• Never use fuel mixed with kerosene.
Ambient temperature
Lubrication
point Type of fluid -22 -4 14 32 50 68 86 140 °F
-30 -20 -10 0 10 20 30 40 °C
Diesel
Engine oil pan engine oil SAE J300 10W30 (*1)
TORQFLOW
transmission Engine oil SAE 10W (*2)
case
SAE 80
Differential
case Gear oil
SAE 90
SAE 5W (*2)
Hydraulic Hydraulic oil
system
SAE 10W (*2)
Greasing Lithium
G2-LI
points grease
GENERAL LOCATIONS
7 Fork – 80-17
21 Muffler – 30-7
22 Radiator – 30-7
23 Counterweight – 30-6
26 Battery (on the R.H. side of the lift truck) 20-34, 80-6
29 Aftercooler – –
WEIGHT TABLE
Unit: kg
Fork carriage assembly 785 870 1,010 1,135 1,135 Excluding fork
Radiator hose
Torque converter Torque converter Shroud
cooler hose cooler Radiator Aftercooler
Aftercooler hose Brake cooler
Brake cooler hose
Muffler
REMOVAL AND INSTALLATION
Engine hood
Pedal link
Air cleaner
Joint
Rear axle
Disassembly Counterweight Assembly
EX50 Series
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION MAST
MAST
2 54–118 Nm
{5.5–12 kgm} Method for bleeding air from lift cylinder
(1) Start the engine and run at low idling.
(2) Raise and lower the mast.
Inner mast Stop the mast approx. 100 mm before reaching
the max. lifting height and max. lowering posi-
tion.
Shims
(3) Repeat Step (2) 4–5 times.
(4) Raise and lower the mast to the maximum lifting
height and maximum lowering position.
Cylinder
rod (5) Repeat Step (4) 4–5 times.
POWER TRAIN
2. Centering of drive shaft
4. Installation of wheel
Tightening torque
CAUTION
• Park the lift truck on a level and safe place before starting the work.
• Jack can be dangerous if it is disengaged. Person may be caught by it and seriously injured. Always check that the
jack is safely engaged during the tightening work. Also remember never get under the machine.
Adjusting runout
1) Locate the gauge at a right angle to the side face
of the tyre and apart 10 mm from it.
2) Rotate the tyre with no load in the forward 1st
gear and find out a point that the gauge tip con-
tacted, and then loosen the hub nut opposite to
that point.
3) Tighten the hub nut at the point that the gauge
tip contacted to adjust.
BRAKE SYSTEM
(HYDRAULIC DRUM BRAKE TYPE)
Method of removing
2. Align both the lift and tilt levers with bracket (B),
insert support pin (C), then tighten bolt (D).
3. Connect the lever yoke and the end of link (A) with a
pin. Insert a cotter pin into the pin and bend it to hold
in position.
5. Lever travel
mm
S1 S2
Lift lever 126 126
Tilt lever 130 130
TORQUE CONVERTER
The numbers show the order for disassembly
ASSEMBLY
35.3–44.1 Nm {3.6–4.5kgm}
2. Stator shaft
1) Install pump boss gear (1) to stator shaft (2).
4. Pump
1) Assemble the pump.
Align the pump boss spline and pump gear
spline and assemble the pump.
5. Stator
1) Assemble the collar, trust washers (1) and (2),
stator, and thrust washers (3) and (4) in turn.
2) Set the tab of lock washer (5) facing the outside,
and insert.
3) Secure the stator with ring nut (6). (Check that
the stator rotates lightly when doing this.)
4) Secure the ring nut with the tab of the lock
washer.
9. Oil strainer
TORQFLOW TRANSMISSION
Gasket
Transmission
Torque converter
59–73.5 Nm
{6–7.5 kgm}
(Solenoid valve)
Standard 24 V
Range 22–26 V
(Inching spool)
Torque converter
Mounting bolts
Insufficient tightening: Oil leakage
Over tightening: Defective operation of spool
EX50 Series
Main pressure regulator valve
1.5 MPa {15.3 kg/cm²}
F/R
Line filter pressure
pick-up port
Oil tempera- Oil
ture gauge T/C cooler Accumulator for F/R
take-out slot pressure
DISASSEMBLY AND ASSEMBLY
Inching
valve
Solenoid valve
for F/R Accumulator
for speed
40-11
TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY
Torque converter
pump
Torque converter
Flexible plate
Oil level
DISASSEMABLY
1. TORQFLOW transmission
After completion of the operation for removing the Lifting equipment
TORQFLOW transmission assembly from the chas-
sis, wash the case and the area surrounding the
accessory parts, then remove the following parts.
• Sending unit
• Oil
Stand
Lifting up together
of a work stand.
Special tool-1
The operation is easier to carry out if the 1st/2nd
and 3rd clutch shaft sub assemblies are pulled Special tool-2
up at the same time.
If they are removed separately, there will be
twisting and gouging, or damage to the case.
3rd
1/2nd
Torque converter
3rd 1st/2nd
Torque converter
k CAUTION
If the snap rings (15 and 27 in diagram above) used
to hold the piston and return spring are removed, the
force of the spring will be brought to bear and this will
cause a dangerous condition. Always use the special
tool to remove them.
Snap ring
Snap ring Plate
Plate Plate
Spring
Spring
Disc
NOTICE
A. k Caution
When removing the snap ring for holding the piston
return spring, the spring tension may cause injuries.
Always apply a special tool for removing snap ring.
(3EC-97-99000)
Piston
Plate
Camber plate
Camber plate
Snap
ring Plate
2. Solenoid valve
1 4
Tighten the mounting bolts in the order shown in
the diagram on the right.
3 2
When assembling, check the operation of the
spool.
Insufficient tightening: Oil leakage
Overtightening: Defective operation
3. Seal ring
After assembling, coat the seal ring with grease.
CONNECTING DWG.
F: 3(+), 4(-)
FR VALVE 4 1
R: 1(+), 2(-)
3 2
1st/2nd
1(+), 2(-)
VALVE 1 2
F/R
1, 2 speed
3rd, output
14
16
17
18 15
19
20
21
22
23
26
25
6
5
4
3
2
1
A
1
2
8
9
10
11
38
37
36
35
34
33
32
31 39
30
29
Torque converter
27
28 (Forward end)
6 5 4 1 2 2 1 9 10 11
(Forward end) (Reverse end)
23
39 38 37 36 35 34 31 32 33 30 29 28 27 26 25 3 8 12 13 14 16 17 15 18 19 20 21 22
(1st end)
Transmission case
Torque converter
(2nd end)
6 5 4 1 3 2 2 8 1 9 10 11
(2nd end) (1st end)
38 37 36 34 35 33 32 31 30 29 28 27 26 25 12 13 141516 1718 19 20 21 22 23
13
14
15
16
17
Transmission case 18
19
1
2
3
4
5
6
7
9
10
11
12
8
(3rd end)
21
20
C Torque converter
21 20 2 3 1 7 9 10 4 5 6 11 1213 14 15 16 17 18 19
5 Assemble spacer
6 Fix with snap ring
7 Assemble clutch discs and plates alternately
8 Discs (4), plates (4)
9 Assemble plate (t=4)
10 Fix with ring
11 Assemble washer
12 Assemble gear (Z=21)
13 Assemble bearing
14 Assemble washer
15 Fix with ring
16 Assemble gear (Z=29)
17 Assemble spacer
18 Assemble gear (Z=43)
19 Assemble bearing
20 Assemble bearing
21 Install seal ring
Torque converter
HYDRAULIC PUMP
Item Unit
Name of pump — FAL3–045
Relief pressure MPa {kgf/cm2} 1.5 {14.7 }
Discharge cc/rev 43.7
Rated speed rpm 2,200
HYDRAULIC PUMP
1. Hydraulic pump
(Wet disc brake type)
Pumps for work equipment, power steering, brake
and brake cooling are combined into a unit, which is
driven by PTO system of torque converter.
Name of pump — Pump No. 1 Pump No. 2 Pump No. 3 Pump No. 4
Torque converter
DRIVE AXLE
(HYDRAULIC DRUM BRAKE TYPE)
Coat sliding portion of
490.5 -- 605 Nm oil seal with grease.
{50 -- 62 kgm}
490.5 -- 605 Nm
{50 -- 62 kgm}
Reduction gear
type Planetary gear
DRIVE AXLE
(WET DISC BRAKE TYPE)
Coat sliding portion of
oil seal with grease.
490.5 -- 605 Nm
{50 -- 62 kgm}
10.8 -- 14.7 Nm
{1.1 -- 1.5 kgm}
245 -- 309 Nm 343 -- 427 Nm
Loctite #572 {25 -- 31.5 kgm} {35 -- 43.5 kgm}
441 -- 539 Nm
{45 -- 55 kgm}
490.5 -- 605 Nm
{50 -- 62 kgm}
Reduction gear
type Planetary gear
FRONT HUB
(HYDRAULIC DRUM BRAKE TYPE)
Hub starting friction torque: 20–39 Nm {200–400 kgcm}
FRONT HUB
(WET DISC BRAKE TYPE)
G2-LI
Gear
Hub
Shaft nut
Gear Clamp
Bearing
343 -- 427 Nm
{35 -- 43.5 kgm}
Loctite #271
FRONT AXLE
(HYDRAULIC DRUM BRAKE TYPE)
FRONT AXLE
(WET DISC BRAKE TYPE)
Hub
1,961 -- 2,452 Nm
{200 -- 250 kgm}
Loctite #271
Differential case
Frame connecting
bolt
Cap
G2-LI
490.5 -- 605 Nm
Stud {50 -- 62 kgm}
Tube
490.5 -- 605 Nm
{50 -- 62 kgm}
Hub
DIFFERENTIAL
245 -- 309 Nm
{25 -- 31.5 kgm}
Loctite #271
* Be extremely careful
not to get grease or oil
on the inside surface of
the brake drum.
343 -- 427 Nm
{35 -- 43.5 kgm}
Loctite #271
9JL01914
157 -- 196 Nm
{16 -- 20 kgm}
Special tool 34B–97–99110
a+b+c+d
(s) = Round the 2nd place of
100
decimal.
0.20–0.28 mm
Backlash (0.008–0.011 in)
3040–5590 Ncm
Starting torque {310–570 kgcm}
Differential carrier
245 -- 309 Nm
{25 -- 31.5 kgm}
49 -- 73.5 Nm Loctite #271
{5 -- 7.5 kgm}
Pinion shaft
Loctite #271
Shim
Coat with
grease
(G2-LI)
After adjusting backlash, tighten so that starting torque of ring gear 9JL01915
and pinion shaft is 3,040 -- 5,590 Ncm {310 -- 570 kgcm}
Oil capacity 20
STEERING AXLE
PARKING BRAKE
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
WHEEL BRAKE
(HYDRAULIC DRUM BRAKE TYPE)
FD100/115
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
FD135/150E/160E
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
50 ± 5 kgf 42 ± 4 kgf
[ =178 (7.013)] [ =159 (6.265)]
B Shoe return spring Strength
169.5 (6.678)
Free length: (Reference)
148 (5.831)
0.025–0.126 0.025–0.126 Replace
Clearance
C Wheel cylinder between piston (0.001–0.005) (0.001–0.005)
and cylinder
Clacks, chips, rust
WHEEL BRAKE
(WET DISC BRAKE TYPE)
10.8 -- 14.7 Nm
{1.1 -- 1.5 kgm}
Loctite #572
245 -- 309 Nm
{25 -- 31.5 kgm}
373 -- 426 Nm
{38 -- 43.5 kgm}
Loctite #271
157 -- 196 Nm
{16 -- 20 kgm}
9JL01916
Brake pedal
Torque converter
Brake valve
Inching pedal
Inching pedal
Brake valve
BRAKE VALVE
(HYDRAULIC DRUM BRAKE TYPE)
Warning
The accumulator circuit is under high hydraulic
pressure. It is therefore very dangerous to loosen
any connections before releasing this pressure.
When removing the accumulator, first stop the
engine, then repeatedly (at least 10 times)
depress the brake pedal fully. After completely
releasing the pressure in the accumulator, discon-
nect the pipes.
2. Remove bolt (2) from body (1) and then remove snap
ring (3).
Pull out washer (4) and input piston assembly (5)
carefully.
FD100/115 only
• Turn hole on disassembled side of body to face
down and spring (8) will come out.
When disassembling cup (6), be careful not to
scratch piston.
Nut (7)
If it is loosened, the stroke of piston or hydraulic
pressure must be adjusted.
ASSEMBLY
FD100/115 only
• Install spring (8) in hole in spool (5).
• Install sub–assembly with spool (5).
Coat spool (5) with engine oil.
SAE10W
mm (in)
Standard depth of guide 40 (1.6)
500–800 kgcm
500–800 kgcm
BRAKE VALVE
(WET DISC BRAKE TYPE)
6 — 21 Snap ring
8 Drive 23 O-ring
11 Sleeve 26 Ball
12 Spool 27 O-ring
13 Pin 28 Seat
DISASSEMBLY PROCEDURES
1. Removing the column assembly
Hold the flange of a column assembly with a vise,
loosen the bolts to remove the column assembly.
2) Lift the end cap (3), gerotor (4) and plate (7) as a
unit. Remove the gerotor assembly.
a When lifting them in the unit, hold the plate
with fingertips.
ASSEMBLING PROCEDURES
1. Assembling control valve assembly
1) Place the housing on a flat wooden block with
the front side (steering column side) facing
upward. Install O-ring (18) to the check valve
assembly and screw it in to the housing.
60 – 80 kgcm
k Warnings
Align positions correctly. Wrong combination may
cause malfunction, leading to a serious accident.
Tightening torque
k Warnings
If spring pin (2) is not installed, malfunction may
occur, causing a serious accident.
DISASSEMBLY PROCEDURES
1. Removing the column assembly
Hold the flange of a column assembly with a vise,
loosen the bolts to remove the column assembly.
2) Lift the end cap (3), gerotor (4) and plate (7) as a
unit. Remove the gerotor assembly.
a When lifting them in the unit, hold the plate
with fingertips.
ASSEMBLING PROCEDURES
1. Assembling control valve assembly
1) Place the housing on a flat wooden block with
the front side (steering column side) facing
upward. Install O-ring (18) to the check valve
assembly and screw it in to the housing.
60 – 80 kgcm
k Warnings
Align positions correctly. Wrong combination may
cause malfunction, leading to a serious accident.
Tightening torque
k Warnings
If spring pin (2) is not installed, malfunction may
occur, causing a serious accident.
LIFT CYLINDER
1. Cylinder
2. Piston rod
3. Piston ring
4. Wear ring
5. Cylinder head
6. O-ring
7. Dust seal
8. Rod packing
9. Wear ring
10. Collar
11. O-ring
(Lifting height: 3 m)
Cylinder (inside diameter × outside diameter) mm 95 × 110 100 × 113 110 × 124 120 × 136
Stroke mm 1510
INSPECTION
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
0.097–0.366 0.666
Clearance between FD100 (0.004–0.014) (0.026)
A piston rod and Replace bushing
bushing 0.107–0.395 0.695
FD115/135/150E/160E (0.004–0.016) (0.027)
TILT CYLINDER
(lifting height: 3 m)
Item Unit FD100–160E
Stroke mm 240
INSPECTION
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
3) Insert one end of the piston ring into the groove first,
then push the other side along the taper surface by
hand to expand and install it.
883–1,080 {90–110}
(FD135/160E)
838–1,020 {85.5–104.5}
(FD100/115)
For tilt
cylinder 932–1,130 {95–115}
(FD135/160E)
(lifting height: 3 m)
INSPECTION
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
CONTROL VALVE
DISASSEMBLY AND ASSEMBLY
This section describes disassembling and assembling 2. Spool assembly
procedures of the representative 3-port relief model. 1) Detach button bolt (41) from lift spool (27) using
When disassembling or assembling work varies accord- a 6 mm hexagon key wrench.
ing to the number of port reliefs or their presence/ 2) Remove spring (26) and spring holder (28).
absence, additional instructions are given in [ ]. 3) Detach button bolt (41) from tilt spool (31) using
Disassembling and assembling units should be con- a 6 mm hexagon key wrench.
ducted at the manufacturer's factory in principle. If this is 4) Remove spring (26) and spring holder (28).
impossible, ask a service shop with in-depth knowledge 5) Remove head spool (20) using a 10 mm span-
of hydraulic machines for the disassembling/assembling ner.
work. Since precision-made hydraulic machines form 6) Remove O-ring (53) using a scriber.
many small gaps inside, conduct disassembly and 7) Pull out spring (22) and plunger (21).
assembly in the following procedures, while paying atten- 8) Since orifice (24) is caulked, it cannot be disas-
tion to the handling of the machine in a clean, dust-free sembled.
place. Do not hit any part even if it does not work 9) Detach button bolt (41) from spool (29) using a 6
smoothly. mm hexagon key wrench.
[Dual-port relief model: not necessary, 4/5-port
NECESSARY TOOLS relief model: in the same way]
• Hexagon key wrench 10) Remove spring (26) and spring holder (28).
(width across flats: 4, 5, 6, 8, 12 mm)
• Spanner (width across flats: 10, 24, 27, 32 mm) 3. Main relief assembly
• Torque wrench 1) Remove sleeve (33) as an assembly using a 24
• Scriber mm spanner, while holding cap nut (5) and lock-
• Vice nut (7) to prevent the set pressure from varying.
Do not disassemble the main relief. It has
DISASSEMBLY been set to the specified pressure.
1. Spool
1) Remove two hexagonal socket head bolts (40) 4. Port relief assembly
using an 8 mm hexagon key wrench. [This work 1) Remove pilot sleeve (16) as an assembly using
is required for all port reliefs.] a 27 mm spanner, while holding cover (17) to
2) Remove cap (3) and O-ring (51). [This work is prevent the set pressure from varying.
required for all port reliefs.] Do not disassemble the port relief. It has
3) Pull out lift spool (27) from body (37) with parts been set to the specified pressure.
(26), (28) and (41) united.
4) Pull out tilt spool (31) in the same way.
5) Pull out spool (29) in the same way.
[Dual-port relief model: not necessary, 4/5-port
relief model: in the same way]
Since clearance is controlled for body (37) and
spool (29), check the combination of spool when
disassembling, and reassemble it at its original
position.
6. Plunger 2. Sleeve
1) Remove two plugs (1) using a 12 mm hexagon 1) Tighten two sleeves (23) together with O-rings
key wrench. (54) to body (37) using a 32 mm spanner.
2) Remove O-ring (57) using a scriber. 78.3–95.7 Nm {8.0–10.1 kgm}
3) Pull out two sets of spring (2) and plunger (4).
Check the combination of these parts when
disassembling, and reassemble them at 3. Plug, oil seal
their original positions. 1) Install oil seal (46) to body (37). [This work is
4) Since steel balls (44) are press-fit into body (37), required for all port reliefs.]
it cannot be disassembled. 2) Tighten seal holder (36) with two hexagonal
5) Since plate name (35) is riveted with rivet screws socket head bolts (39) using a 4 mm hexagon
(43), it cannot be disassembled. key wrench.
[This work is required for all port reliefs.]
7. Spool assembly
1) Hold the width across flats (10 mm) of lift spool
(27) in a vice.
2) Install spring holder (28), spring (26), and spring
holder (28) in this order to the held lift spool, and
then tighten button bolt (41) using a 6 mm hexa-
gon key wrench.
1 Plug
2 Spring
3 Cap
4 Plunger
5 Cap nut
6 Adjusting screw
7 Locknut
8 Needle valve
9 Circlip
10 Wire
11 Spring 31 Tilt spool
12 Spring 32 Seat
13 Spring holder 33 Sleeve
14 Spring 34 Seat
15 Plunger 35 Plate name
16 Pilot sleeve 36 Seal holder
17 Cover 37 Body
18 Adjusting screw 38
19 Plug 39 Hexagonal socket head bolt
20 Head spool 40 Hexagonal socket head bolt
21 Plunger 41 Button bolt
22 Spring 42 Nut 51 O-ring
23 Sleeve 43 Rivet screw 52 O-ring
24 Orifice 44 Steel ball 53 O-ring
25 Wire 45 Steel ball 54 O-ring
26 Spring 46 Oil seal 55 O-ring
27 Lift spool 47 O-ring 56 O-ring
28 Spring holder 48 O-ring 57 O-ring
29 Spool 49 O-ring 58 O-ring
30 Gasket 50 O-ring 59 Socket head plug
40-91
CONTROL VALVE
MAST DISASSEMBLY AND ASSEMBLY
MAST
Set wooden blocks under the mast and lay the mast
assembly horizontally with the fork carriage at the
top.
SHIM ADJUSTMENT
a 0–0.5 mm c 0.5–1.0 mm
b 0.5–1.0 mm
FORK CARRIAGE
Shim adjustment
d 0.5–1.0 mm
e 0.5–1.0 mm
f 0.5–1.0 mm
ADJUSTING CHAIN
1. Chain length
Adjust with the chain stopper so that the bottom face
of the fork is 15 mm below the ground level when the
forks are lowered fully.
INSPECTION
mm (in)
Judgement standard
Inspection item Remedy
Standard size Repair limit
Depth of busing oil groove at mast support portion 5.0 (0.197) There must be oil
groove
Driving in differential pinion shaft oil seal Tightening differential adjusting screw nut
3ED-97-99590 34B-97-99110
3EE-97-99110 3EB-97-99960
Measuring starting torque of front hub Tightening front axle lock nut
3ED-97-99570 308-968-9110
Measuring starting torque of differential pinion shaft Compressing clutch pack return spring
3ED-97-99600 3EC-97-99000
a 3ED-97-99151
3EC-97-99030 b 3ED-97-99180
Driving in transmission output shaft bearing, oil seal Inserting steering valve leaf spring
3EE-97-99110 3BA-97-99220
3EB-97-99210 3BA-97-99210
φ30
Lifting tool 2
15
3EE-97-99190 f11
1. Removing and installing bottom assembly screw 2. Press fitting dust wiper
3. Piston inserting guide (for FD100) 4. Piston insertion guide (for FD115/135/150E)
ACCELERATOR PEDAL
Neutral (a1) 45 ± 2 ° —
— Pedal angle
Maximum (a2) 17 ± 2 ° —
Speedometer sensor
Bracket
Front
axle
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
Clearance between sensor and
drum
a Screw in sensor and check that 1.5 (0.059)
it contacts drum lightly, then
turn back three turns and lock in
position. Replace
(Tightening torque)
1 Sensor locknut 49 Nm {5.0 kgm}
2 Sensor bracket mounting bolt 98–123 Nm {10.0–12.5 kgm}
Gearshift lever
Coolant level SW
Stop lamp SW Fuel level sensor
Coolant temperature
sensor
Parking brake SW
F/R SW Combination SW
H/L SW
Starting SW
Parking
brake SW
Parking brake SW
Dashboard
Automatic transmission SW
(Option)
Low pressure SW
T/C oil
temperature
sensor
To air cleaner
and sheet SW
Coolant level SW
Automatic transmission
Coolant
temperature
sensor
Top of engine
TORQUE CONVERTER
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
A Wear of pilot tip 25 (0.985) 24.85 (0.979)
TORQFLOW TRANSMISSION
F / R / 1st / 2nd 1.35 – 1.65 MPa {13.8 – 16.8 kgf/cm²}
Clutch actuating pressure
3rd 12.0 – 15.0 MPa {12.2 – 15.3 kgf/cm²}
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
J Clutch piston inner diameter (piston ring contact surface) 50 (1.970) 50.15 (1.976)
Width 2.5 (0.099) 1.93 (0.076)
K Piston ring (5 points)
Thickness 2.0 (0.079) 1.52 (0.060)
Inching spool
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
DRIVE SHAFT
Differential Mission
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
DIFFERENTIAL
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
* Replace damaged gear, if any (replace the bevel gear and pinion gear in set).
FINAL DRIVE
(HYDRAULIC DRUM BRAKE TYPE)
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
1 Inside diameter of housing, dowel pin hole 18 (0.709) 18 (0.709)
2 Outside diameter of housing, dowel pin 18 (0.709) 18 (0.709)
3 Outside diameter of mast support mount 170 (6.698) 170 (6.698)
FINAL DRIVE
(WET DISC BRAKE TYPE)
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
1 Housing, dowel pin inside diameter 18 (0.709) 18 (0.709)
2 Housing, dowel pin outside diameter 18 (0.709) 18 (0.709)
Outside diameter, mast support mounting
3 170 (6.698) 169.5 (6.678)
base
Housing, outside diameter, seal retainer
4 130 (5.122) —
engaging portion
Outside diameter, inner bearing
5 200 (7.880) —
engaging portion
Hub
Outside diameter, outer bearing
6 210 (8.274) —
engaging portion
Inside diameter 130 (5.122) No flaw allowed
7 Seal retainer Outside diameter (seal
170 (6.698) No flaw allowed
contact face)
Inside diameter, inner bearing
8 130 (5.122) —
engaging portion
Hub
Inside diameter, outer bearing
9 140 (5.516) —
engaging portion
10 Front hub starting torque 20 – 39 Nm {200 – 400 kgcm}
(Tightening torque)
See the part for disas- Lock the bolt securely
11 Lock bolt (for hub nut)
sembly and assembly (Use a cotter pin)
12 Shaft tube joint bolt 490.5 – 605 Nm {50 – 62 kgm}
13 Gear case mount bolts 343 – 427 Nm {35 – 43.5 kgm}
14 Wheel clip nut 441.5 – 539.5 Nm {45 – 55 kgm}
15 Disc wear sensor mounting plug 10.8 – 14.7 Nm {1.1 – 1.5 kgm}
REAR AXLE
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
Hole inside diameter (bear- +0.018
1 Axle king pin ing engaging section) 72 –0.012 —
boss
2 Inner height 212 ± 0.2 211.5
3 Height of knuckle king pin boss 175 ± 0.5 174
Clearance for assembling axle king pin
4 0.1 – 0.3 0.5
boss and knuckle
PS cylinder, rod end, pin hole inside diam-
5 25 +0.25 —
eter +0.05
Upper 30 +0.1
0
6 PS cylinder link, pin hole inside diameter —
Lower 25 +0.1
0
–0.025
7 PS cylinder link, pin hole outside diameter 25 –0.048 —
–0.008
8 Knuckle arm, pin hole inside diameter 50 –0.003 —
–0.060
9 Axle center pin outside diameter 80 –0.106 79.5
Tyre operating angle (adjusted using the
* 76 ° ± 30’
stopper bolt)
10 Rear hub starting torque 7 – 10 Nm {0.7 – 1.0 kgm}
(Tightening torque)
* Center pin, support mounting bolts 490 – 608 Nm {50 – 62 kgm}
Steering cylinder mounting bolt
11 735.5 – 828.5 Nm {75 – 84.5 kgm}
(Loctite application)
12 Wheel clip nut 441.5 – 539.5 Nm {45 – 55 kgm}
STEERING
2°
2°
65°
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
Steering wheel play (when idling) 30–60 (1.182–2.364) 30–60 (1.182–2.364)
Steering wheel tilt angle 2° 2°
Steering wheel lock lever, lock angle 65° 65°
Operating effort of steering wheel 9.8 N {1.0 kgf}
(at knob)
FRAME
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
Inside dimension between rear axle
A and center support 360 (14.18) 365 (14.38)
BRAKE PEDAL
(HYDRAULIC DRUM BRAKE TYPE)
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
(Brake)
A Brake pedal height (when free) 231 (9.1) —
B Brake stroke 76 (3.0) —
D Inching stroke 83 (3.3) —
Interlocking point with the inching
E brake pedal 50 (1.97) —
BRAKE PEDAL
(WET DISC BRAKE TYPE)
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
(BRAKE)
A Brake pedal height (when free) 231 (9.1) —
B Brake stroke 47 (1.85) —
C Height of pedal when depressed Approx. 65 (2.56) —
D Inching stroke 75 (2.96) —
Interlocking point with the inching 28.5 – 33.5
E —
brake pedal (1.12 – 1.32)
Each joint shall have no oil smear or leakage
Leakage from joints
upon applying brake.
(Brake inching pedal)
Pedal anchor bushing (outside diam-
26 × 20 × 20 (1.02 × 0.79 × 0.79) 3EE-36-11520
eter × inside diameter × width)
Inching rod link lever bushing (out-
side diameter × inside diameter × 16 × 14 × 20 (0.63 × 0.55 × 0.79) 3EE-36-31250
width)
(Brake piping)
Joints of elbows, nipples, etc. Apply gasket sealant
8 mm 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
Tightening torque of
respective sleeve nuts for 10 mm 19.6 – 44.1 Nm {2.0 – 4.5 kgm}
brake pipe
12 mm 48 – 68.6 Nm {5.0 – 7.0 kgm}
BRAKE VALVE
(HYDRAULIC DRUM BRAKE TYPE)
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Standard size
BRAKE VALVE
(WET DISC BRAKE TYPE)
mm (in)
Criterion
No. Inspection item Reference dimmensions Tolerance limit Action
Free length Mounting length Mounting load Free length
1 (*) Control spring 340 (1.340) 33.5 (1.320) 3.82 N {0.39 kgf} —
2 Control spring 46.3 (1.824) 46 (1.812) 12.8 N {1.3 kgf} —
Replacement
3 Return spring 86.2 (3.396) 58 (2.285) 60.8 N {6.2 kgf} —
4 Return spring 31.5 (1.241) 19.5 (0.768) 16.7 N {1.70 kgf} —
* FD100 to 135 are not installed with the control spring (1).
FRONT BRAKE
(HYDRAULIC DRUM BRAKE TYPE)
FD 100, 115
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
A Inside diameter of drum 438 (17.24) 440 (17.32)
B Thickness of lining 12.7 (0.5) 5.5 (0.22)
C Inside diameter of wheel cylinder 47.62 (1.875) There must be no
scratches on sliding
D Outside diameter of piston surface
There must be no
E Outside diameter of piston cup scratches or deteriora-
tion
F Clearance between piston and cylinder 0.025–0.126 0.025–0.126
17.65–26.46 Nm
L Wheel cylinder tightening bolt {1.8–2.7 kgm} —
FRONT BRAKE
(WET DISC BRAKE TYPE)
mm (in)
Criterion
Symbol Inspection item Remedy
Reference dimensions Tolerance Tolerance limit
2.3 – 2.5
A Plate 2.4 (0.095) 2.2 (0.087)
(0.091 – 0.099)
5.0 – 5.2
Disc thickness 5.1 (0.201) 4.6 (0.181)
(0.197 – 0.205)
B
Depth of lining groove 0.5 (min) (0.020) — 0.25 (0.010)
Replacement
Lining thickness 1 (0.039) 0.6 (min) (0.024) —
Reference dimensions Tolerance limit
C Spring load Mounting height Mounting load (N {kgf}) Mounting load (N {kgf})
60.7 (2.39) 456.7 {46.6} 411.0 {41.9}
PARKING BRAKE
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
Lining thickness 5.45 (0.215) 3.3 (0.130)
152 N {15.5 kg} 137 N {14 kg}
Shoe return Strength ( = 50) ( = 50)
spring
Free length 54.7 (2.15)
Clearance between drum and lining
After bringing lining into tight
contact with drum, turn adjuster 0.1–0.25
back 11 notches to adjust clear- (0.0039–0.0098)
ance to 0.25
Max. operating effort of parking
lever (at center of grip) 196 N {20 kgf}
CONTROL VALVE
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
Free length 57 (2.25) 55 (2.16)
A
(20) Return spring Installed length 35.8 (1.41) –
Install load 165 N {16.9 kgf} 147–186 N {15–19 kgf}
Free length 70 (2.76) 67 (2.64)
B
(13) Tilt lock spring Installed length 64 (2.52) – Replace
Install load 49 N {5 kgf} 44–53 N {4.5–5.5 kgf}
Free length 48 (1.89) 44 (1.73)
C Check valve
(2) spring Installed length 40.8 (1.60) –
Install load 9.8 N {1 kgf} 8.8–10.7 N {0.9–1.1 kgf}
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
(tightening torque)
Coat thread of spool return set bolt 25–34.3 Nm
31 with Locite #242. {2.5–3.5 kgm} —
53.0–64.7 Nm
45 Tightening of relief valve assembly {5.4–6.6 kgm} —
34.3–44.1 Nm
Nipple (return pipe) mounting bolt {3.5–4.5 kgm} —
(hexagonal 13.0–16.7 Nm
socket 5 mm) {1.3–1.7 kgm} —
PRIORITY VALVE
1 12
7
7
11
10
9
8
6
5
4
3
2
16 : Standard
16
15 16
14
13
or
18
16
Set pressure
LIFT CYLINDER
INSPECTION
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
TILT CYLINDER
(Lifting height: 3 m)
INSPECTION
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
Clearance between piston rod and 0.036–0.267 0.567
A bushing (0.001–0.011) (0.022)
B Piston rod Scratches that catch finger nail, dents, hollows Replace
C Piston ring Scratches that catch finger nail
D Cylinder Scratches that catch finger nail, hollows
(Tightening torque)
E Rod head locknut 98–123 Nm {10.0–12.5 kgm}
F Set bolt for rod head mounting pin 98–123 Nm {10.0–12.5 kgm}
Set bolt for cylinder bottom mount- 01010-81230
G ing pin 98–123 Nm {10.0–12.5 kgm}
(Lifting height: 3 m)
INSPECTION
mm (in)
Judgement standard
Symbol Inspection item Remedy
Standard size Repair limit
Clearance between cylinder and 0.05–0.25 0.4
A piston (0.002–0.010) (0.016)
WORK EQUIPMENT
ADJUSTING CHAIN
1. Chain length
Adjust with the chain stopper so that the bottom face
of the fork is 15 mm below the ground level when the
forks are lowered fully.
INSPECTION
mm (in)
Judgement standard
Inspection item Remedy
Standard size Repair limit
0.5–1.0
Left–right (0.020–0.039) Within 2.0 (0.079) Adjust with shim
Clearance between inner mast
and fork carriage 0.5–1.0
Front–rear Within 5.0 (0.197) Replace roller
(0.020–0.039)
0.5–1.0
Clearance between side roller and rail (0.020–0.039) Within 3.0 (0.118) Adjust with shim
Engine
Torque converter
Transmission
Parking brake
Reduction gear
(No. 2)
TORQUE CONVERTER
PTO drive
A PTO drive is installed to the torque converter to drive the torque converter charging pump, power steering pump, and
hydraulic pump.
PTO gear
No. 1 shaft
No. 2 shaft
No. 3 shaft
Idller gear
R F
Input shaft
1st-2nd shaft
1ST 2ND
Output shaft
3RD
6. Oil cooled with the oil cooler is fed to inside the trans-
mission to lubricate and cool individual components.
It then returns to the transmission case. (See the
hydraulic circuit diagram in the next page onward.)
EX50 Series
Main pressure regulator valve
1.5 MPa {15.3 kg/cm²}
F/R
pressure
Line filter pick-up port
Oil tempera- Oil
ture gauge cooler Accumulator for F/R
STRUCTURE AND FUNCTION
T/C
take-out slot pressure
M16 = 1.5 pick-up port
Torque converter oil PT1/8
outlet-cum-lubricant
regulator valve
0.45 ± 0.15 MPa
HYDRAULIC CIRCUIT DIAGRAM
Inching
valve
Solenoid valve Accumulator
for F/R for speed
60-9
TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION STRUCTURE AND FUNCTION
INCHING VALVE
This is interconnected with the pedal, and controls the oil pressure to the multiple disc clutch according to the amount that
the pedal is depressed.
Full stroke
F/R clutch pressure port
Inching spool
Protrusion
F/R lever
H/L lever
1st F clutch
3rd
Auto/Manual Inching R clutch
Controller SW valve
1st clutch
3rd clutch
Power
Adjustment cut relay
volume 3rd 2nd clutch
Vehicle speed
Input pulse
Truble
Speed detecter
sensor F/R
ACC fuse cut relay
Speed can be shifted using the volume switch. Troubleshooting function provides ease of servicing.
Volume switch
Controller
CAUTIONS
1. Select forward-reverse travel after the machine
comes to complete stop.
TROUBLESHOOTING TABLE
Trouble indicator
(LED) Truck body
No. Content of trouble Repair method Resetting method
Number of behavior
Color
LED flashing
1st speed solenoid in Check the 1st speed sole- Reset by turning
1 Red One time 1 Disabled to travel 1
short circuit noid and replace it. key switch
3rd speed solenoid Check the 3rd speed sole- Reset by turning
2 Red Two times 1 Disabled to travel 1
in short circuit noid and replace it. key switch
1st speed solenoid
Check the controller and
1 drive of the controller Disabled to travel 1
replace it.
in short circuit Reset by turning
3 Red Three times
1st speed solenoid key switch
Check the controller and
1 drive of the controller Holding 2nd speed 1
replace it.
is open.
3rd speed solenoid
Check the controller and
1 drive of the controller Disabled to travel 1
replace it.
in short circuit Reset by turning
4 Red Four times
3rd speed solenoid key switch
Check the controller and
1 drive of the controller Holding 2nd speed 1
replace it.
is open.
Power supply cut Check the short circuit and
1 relay contact in short 1 replace the power supply
circuit cut relay contact.
Check the short circuit and
F/R cut relay contact
2 2 replace the F/R cut relay
in short circuit
contact.
Power supply cut Check the grounding and Reset by turning
5 Red Five times Holding 2nd speed
3 relay solenoid 3 replace the power supply key switch
grounded cut relay solenoid.
Check the grounding and
F/R cut relay sole-
4 4 replace the F/R cut relay
noid grounded
solenoid.
Relay drive transistor Check the controller and
5 5
in short circuit replace it.
Shift lever (H-L Check the short circuit and
Reset by turning
6 Red Six times 1 switch) contacts turn Gear shift holding 1 replace the shift lever (H-L
key switch
ON simultaneously. switch) contact.
Trouble indicator
(LED) Truck body
No. Content of trouble Repair method Resetting method
Number of behavior
Color
LED flashing
Check the opening and
1st speed solenoid
1 1 replace the 1st speed
harness is open.
solenoid harness.
Check the opening and
1st speed solenoid is
2 2 replace the 1st speed
open.
solenoid.
Check the grounding and
1st speed solenoid is
3 3 replace the 1st speed
grounded.
solenoid.
Power supply cut Check the opening and
4 relay is grounded 4 replace the power supply
Reset by turning
7 Red Seven times and open. Disabled to travel cut relay contact.
key switch
Check the opening and
F/R cut relay contact
5 5 replace the F/R cut relay
is open.
contact.
Power supply cut Check the opening and
6 relay solenoid is 6 replace the power supply
open. cut relay solenoid.
Check the opening and
F/R cut relay sole-
7 7 replace the F/R cut relay
noid is open.
solenoid.
Relay drive transistor Check the controller and
8 8
is open. replace it.
Check the opening and
3rd speed solenoid
1 1 replace the 3rd speed
harness is open.
solenoid harness.
Check the opening and
3rd speed solenoid is
2 2 replace the 3rd speed
open.
solenoid.
Check the grounding and
3rd speed solenoid is
3 3 replace the 3rd speed
grounded.
solenoid.
Check the opening and
Power supply cut
4 4 replace the power supply
relay contact is open. Reset by turning
8 Red Eight times Disabled to travel cut relay contact.
key switch
Check the opening and
F/R cut relay contact
5 5 replace the F/R cut relay
is open.
contact.
Power supply cut Check the opening and
6 relay solenoid is 6 replace the power supply
open. cut relay solenoid.
Check the opening and
F/R cut relay sole-
7 7 replace the F/R cut relay
noid is open.
solenoid.
Relay drive transistor Check the controller and
8 8
is open. replace it.
Trouble indicator
(LED) Truck body
No. Content of trouble Repair method Resetting method
Number of behavior
Color
LED flashing
Check the opening and
Travel speed sensor
1 1 replace the travel speed
is open.
sensor.
Check the short circuit and
Travel speed sensor
2 2 replace the travel speed
in short circuit
sensor.
9 Red Nine times Gear shift holding
Check the opening and
Travel speed sensor
3 3 replace the travel speed
harness is open.
sensor harness.
Travel speed sensor Check the short circuit and
4 harness in short cir- 4 replace the travel speed
cuit sensor harness.
Check the controller and
10 Green ON 1 Defective controller Disabled to travel 1
replace it.
Trouble indicator lamp (red LED) flashes as follows: For repair method, implement measures in the
1 CYCLE 3.0 SEC
order of the descriptions.
Remarks
0.5 0.5
DRIVE AXLE
(HYDRAULIC DRUM BRAKE TYPE)
1. Differential
Item Unit FD100/115 FD135–160E
Reduction gear type – Hypoid bevel gear
Reduction ratio – 4,375
Outside diameter of torque shaft mm 42 42
Oil capacity (including final drive) 20 20
2. Final drive
Item Unit FD100/115 FD135–160E
Type – Fixed single shaft full–floating type
Reduction gear type – Planetary gear type
Reduction ratio – 5.4 5.4
Tread mm 1700 1770
STEERING AXLE
This has a thick steel plate welded integrated structure with a built–in 2–rod type power steering cylinder.
Specifications
Item FD100 FD115–150E FD160E
Type Center pin support, Center pin support, Center pin support,
single–shaft type single–shaft type single–shaft type
Structure of knuckle Elliot type Elliot type Elliot type
Alignment None None None
Swing angle 5° 5° 5°
Tyre turning angle (inside) 76° ± 30’ 76° ± 30’ 76° ± 30’
Tyre turning angle (outside) 53° 53° 53°
Tread 1900 mm 1890 mm 1870 mm
STEERING SYSTEM
Full hydraulic power steering (FHPS)
Compared with semi–integral power steering, full hydraulic power steering is superior in straight travel stability, there is no
kick back, and it is also easier to carry out inspection and maintenance.
1. STEERING VALVE
Structure
Power steering system using full hydraulic power steering
basically consist of a hydraulic pump, full hydraulic power Model FD100-160E
steering body, and power steering cylinder.
Discharge 230 cc/rev
The internal structure of the full hydraulic power steering
body can be divided into the control valve and metering Relief pressure 12.7 MPa {130 kg/cm2}
device. The control valve consists of the No. 1 rotating Inlet flow 22.7 /min
valve (called the spool), and the No. 2 rotating valve
Valve charac- Open center non–reaction type
(called the sleeve). The metering device consists of a teristic
special gear set called a Gerotor.
In addition, a feedback link is installed to provide feed-
back of the metering flow in the metering device to the
control valve.
Principle of operation
(At neutral)
• The pressure oil entering pump port (P) of the power
steering from the hydraulic pump passes through
passage (11), goes through spool groove (15) and
passage (14), then returns to the oil tank from tank
port (T).
When this happens, cylinder port (R) is blocked
inside the sleeve, so the power steering cylinder is
kept in the same condition and the machine travels in
a straight line or at the set turning angle.
(Turning right)
• When the steering wheel is turned to the right, the
spool also rotates to the right and an oil passage is
formed between the spool and sleeve. The passage
to (11)–(15) is throttled and a passage is formed to
(11)–(16) and (17). At the same time, a passage is
formed from Gertor chambers (D), (E), and (F)
through passages (18), (19), and (12) to cylinder port
*R*. The hydraulic oil sent from the pump to the cylin-
der all passes through the metering mechanism and
is sent to the cylinder.
The oil discharged from the cylinder goes from cylin-
der port (L) through passage (13), (15), and (14) and
returns from tank port (T) to the oil tank.
When the hydraulic oil discharged from the hydraulic
pump passes through the metering mechanism, it
rotates external tooth trochoid gear (23) to the right.
This rotation is transmitted to the sleeve by the feed-
back link, so the sleeve also rotates in the same
direction as the spool. When the relative position of
the sleeve and spool returns to the neutral condition,
the flow of oil to the metering mechanism is shut off,
and the oil from the pump all passes through pas-
sages (15) and (14) and returns from port (T) to the
tank.
Precautions
1. The full hydraulic power steering (FHPS) is a type of hydraulic direction selector valve. There is no drag link or other
mechanical connection with the rear axle, so if the steering is turned fully to the lock position, there is leakage of
hydraulic oil inside the valve. This means that the position of the steering wheel knob when traveling in a straight line
may become different.
It is possible to correct the position of the steering wheel knob as follows, but it is difficult to prevent this change in
position from occurring.
Method of correction
(1) Set the rear wheels facing straight.
(2) Turn the starting switch OFF.
(3) Check that the engine has stopped.
(4) Turn the steering wheel and set the steering wheel knob to the specified position.
2. Bleed all the air from the piping between the FHPS valve and power steering cylinder. (This causes abnormal noise
and play in the steering wheel.)
3. For safety reasons, always replace the hose between the FHPS valve and power steering cylinder once every two
year.
BRAKE
(HYDRAULIC DRUM BRAKE TYPE)
Wheel brake
Brake valve
When the brake pedal is operated, the hydraulic oil in the power steering hydraulic circuit is adjusted to a pressure that
matches the amount that the pedal is depressed, and this actuates the wheel cylinder. If the engine stalls and the flow of
oil from the hydraulic pump stops, the pressure stored in the accumulator makes it possible to carry out braking operations
several times.
When spool (4) is at the position in the diagram above and the downstream equipment (power steering, etc.) is operated,
the oil pressure at pump port (P) rises. However, pump ports (P) and (11) are blocked by normally–closed valve (b), so the
pressure oil does not flow to the control pressure chamber. Therefore, even if the downstream equipment is operated, the
brake is naturally not applied.
When the brake pedal is depressed, push rod (10) and input piston (2) move to the left, spool (4) and reaction piston (5)
are pushed by springs (3), (3’), and (3Åh), push return spring (9) and move to the left. When spool (4) moves to the left,
the circuit between (11) and reservoir port (R) is blocked by valve (a), and the control pressure chamber is shut off from
reservoir port (R). Next, normally–closed valve (b) opens, forms a circuit between (P) and (11), and pump port (P) and the
control pressure chamber are connected.
From this condition, if spool (4) is moved further to the left, valve (C) is throttled, and the oil pressure at pump port (P)
rises. For this reason, the oil pressure in control pressure chamber connected to pump port (P) also rises, so the oil pres-
sure in the wheel cylinder also rises.
The pressure in the control pressure chamber pushes reaction piston (5) to the right (it is returned by the hydraulic reac-
tion force), so the condition is balanced with the amount that the pedal is depressed by the operator.
If the brake pedal is depressed fully, nut (8) contacts stopper (14), so the input piston cannot move further to the left from
this position, and the oil pressure in the control pressure chamber becomes the maximum in this condition.
When disassembling, do not loosen nut (8) unless the input piston is to be replaced.
Spool (4)
Valve (b) of spool (4) must control the flow of a small
amount of oil, so it has a ring orifice as shown in the
diagram on the right.
If the pump stops (if the engine stalls, etc.), it is possible to use the oil pressure stored in the accumulator to operate the
emergency brake.
When the brake is depressed, push rod (10), input piston (2), and spool (4) move to the left. When spool (4) moves to the
left, valve (a) closes, normally–closed valve (b) opens, and valve (c) is throttled, but no oil pressure is generated in the
control pressure chamber while the pump is stopped.
If the brake pedal is further depressed, spool (4) and reaction piston (5) move to the left, the tip of reaction piston (5) con-
tacts valve rod (6), valve (d) closes, and the circuit between (13) and the control pressure chamber is blocked. If the brake
pedal is depressed even further, spool (4), reaction piston (5), and valve rod (6) move as one unit to the left, push open
ball valve (7), and a circuit is formed between accumulator port (A) and the control pressure chamber.
As a result, the pressure oil stored inside the accumulator goes to the control pressure chamber, and raises the pressure
inside the wheel cylinder. At the same time, the oil pressure in the control pressure chamber applies a reaction force to
reaction piston (5), so the system is balanced with the amount that the operator depresses the brake pedal.
When the brake pedal is released, spool (4), reaction piston (5), and valve rod (6) move to the right, ball valve (7) returns
to the valve seat, and blocks the passage between the accumulator (A) and the control pressure chamber. Valve rod (6)
then moves partially, and reaction piston (5) moves further to the right, so valve (d) opens, and forms a passage between
(13) and the control pressure chamber. Pressure oil flows, so the oil pressure in the wheel cylinder goes down. If spool (4)
moves further to the right, valve (a) opens, and a circuit is formed between (11) and reservoir port (R), so the oil pressure
in the wheel cylinder goes down completely.
BRAKE
(WET DISC BRAKE TYPE)
BRAKE VALVE
to the tank
1. Control spring(*)
2. Control spring
3. Return spring
4. Return spring
* FD100 to 135 are not installed with the control spring (1).
WHEN OPERATING
Stepping on the pedal transfers the operating efforts to
spool (3) via rod (2) and spring (4). When the spool (3) is From the pump
lowered, the drain port (a) closes, and the oil from the
pump and accumulator flows from the port (A) to port (C)
Accumulator
to operate the brake cylinder.
To brake cylinder
WHEN RELEASING
When the pressure to the pedal is reduced and the pedal
operating efforts are removed from the top of the spool,
the back pressure from the brake cylinder and the spool
return spring move the spool (3) upward to release the
Accumulator
drain port (a). Oil from the brake cylinder then returns to
the hydraulic tank and flows to the circuit to release the
brake
A : To the tank
ACC : To the brake valve
P : From the brake pump
PP : To the brake valve
T : To the tank
FUNCTION
• The accumulator charge valve operates to maintain oil
pressure from the pump at specified pressure level
and stores the pressure in the accumulator.
• When the pressure exceeds the specified level, the oil
from the pump is led to the drain circuit to reduce the
pump load.
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. Relief valve (R2)
5. Relief valve (H1)
6. Filter
OPERATIONS
1. When no oil is supplied to the accumulator (cut 2. When oil is supplied to the accumulator
out state) 1) Cut in state
• Because the pressure of port (B) is higher than the • When the pressure of port (B) reaches the set pres-
set pressure of relief valve (R1), piston (8) is forcibly sure for relief valve (R1) or lower, spring (5) returns
pushed upward by the oil pressure from port (B) to piston (8) downward. The valve seat (7) and poppet
open poppet (6), thus short-circuiting ports (C) and (6) are in contact and cut port (C) from port (T).
(T). • Right hand spring chamber of spool (15) is also cut
• Since the spring chamber at the right end of spool off from port (T). Likewise the pressure of port (P)
(15) is connected with port (C) of relief valve (R1), rises.
the pressure level of spring chamber is equal to that • When the pressure of port (P) reaches a level higher
of the brake oil tank. than that of port (B) (accumulator), oil supply to the
• Oil from the pump enters port (P) and pushes spool accumulator starts at this point. In this case, fixed
(15) to the right with low pressure equivalent to the quantity determined by the size (area) of orifice (17)
load of spring (14), flowing to the tank from port (A). and the pressure difference generated before and
At the same time, the oil also flows to the tank via ori- after the oil supply to the accumulator (equivalent to
fices (17), (18) and (16). the load of spring (14)) is supplied to the accumulator
irrespective of engine speed, and the remaining oil
flows to port (A).
Tank
Tank
Pilot
pressure of
accumulator
Pilot
pressure of
accumulator
To
accumu-
lator
To
accumu-
lator
Tank
Pilot
pressure of
accumulator
To
accu-
mulator
To
accu-
mulator
BRAKE
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc
FUNCTION
• The brake has wet type multiple disc structure.
• Stepping on the brake pedal causes the pressured
oil from the brake valve to move brake piston (4) to
the right direction and bring the disc (8) and plate (7)
to close contact. As the result, frictional force is gen-
erated between the disc and plate. As the wheel
turns with the disc, this friction causes the machine
to decelerate and stop.
HYDRAULIC PUMPS
The pump for the work equipment and the pump for the power steering (brake) are a parent–child type and are driven by
the torque converter PTO.
Name of pump — Pump No. 1 Pump No. 2 Pump No. 3 Pump No. 4
LIFT CYLINDER
TILT CYLINDER
Stroke mm 24
Weight kg–each 50
METER PANEL
Integrated meter panel with safety checkers
The integrated meter panel with safety checkers informs
the operator of vehicle status that is monitored by many
sensors installed in the units of the vehicle and then
immediately processed for display.
Cate-
No. Symbol Indicated item Indication (range) Indication method
gory
Parking brake in
6 During operation When parking brake is applied: Lights up
operation
Operation indicator
8 During operation Flashes during operation
Hour meter operation
Safety checker
Air cleaner element When the clogging of air cleaner is near the
12 When clogged:
clogging limit: Lights up
Cate-
No. Symbol Indicated item Indication (range) Indication method
gory
• Indicated when the starter switch is ON
while the engine has stopped.
When normal : Turns OUT
Radiator cooling
13 Below proper quantity When abnormal: Lights up
Safety checker
water level
• Indicated during engine revolution
When normal: Turns OUT
When abnormal: Lights up
15 Travel speed
The electronically controlled engine controller of this machine indicates a failure code when a trouble occurs. The failure
code can be checked by the following 2 methods.
• Check of failure code with troubleshooting tool
• Check of failure code by blinking lamp of meter panel
Failure code of
Trouble Place of description
troubleshooting tool
Failure code of
Trouble Place of description
troubleshooting tool
TORQUE CONVERTER
1. Causes and remedies for failures
4 Abnormal noise is 1) Cavitation caused by leakage of air Add oil or check and replace parts if
generated
from suction piping or lack of oil necessary
2) Failure of gear pump Disassemble and replace parts or
whole assembly
3) Contact caused by deformed impel- Disassemble and replace, replace
ler parts if necessary
4) Breakage of input plate Disassemble and replace
5) Breakage of gear Disassemble and replace
6) Wear or breakage of bearing Disassemble and replace
7) Wear of spline Disassemble and replace
8) Loose bolts Tighten, replace if necessary
70-12
Main pressure regulator valve
1.5 MPa {15.3 kg/cm²}
F/R
TORQUE CONVERTER
pressure
Line filter pick-up port
Oil tempera- Oil
ture gauge T/C cooler Accumulator for F/R
take-out slot pressure
M16 = 1.5 pick-up port
Torque converter oil PT1/8
outlet-cum-lubricant
regulator valve
0.45 ± 0.15 MPa
Inching
valve
Solenoid valve
for F/R Accumulator
for speed
EX50 Series
TROUBLESHOOTING
TROUBLESHOOTING CONTROL VALVE
CONTROL VALVE
Troubleshooting
Problem Cause Remedy
External oil leakage • Damage/deformation/disengagement of • Replace with a new O-ring.
O-ring
• Flaws on O-ring seal • Correct flaws with oilstone.
• Damage of oil seal • Replace with a new oil seal.
• Loosened bolt or plug due to excessive • Check machine pressure.
pressure
Pressure fluctuation or • Damage of needle valve or oil seat • Replace relief assembly.
low pressure of relief valve • Stuck foreign matter
Lift elevation speed or • Relief set pressure drop and cracking • Replace relief assembly.
tilting speed down pressure drop
Speed down (only when • Malfunction of plunger (21) • Replace valve assembly.
forward tilting)
Large natural drop • Excessive wear of lift spool (27) • Replace valve assembly.
Large natural tilting • Excessive wear of plunger (21) coupling • Replace valve assembly.
portion
• Excessive wear of tilt spool (31)
Mast descends when lever • Malfunction of plunger (4) • Disassemble, wash and
is returned after elevation (due to stuck foreign matter) reinstall the plunger.
• Defect of spring (2) • Disassemble and correct the spring or
replace it with a new one.
Spool does not • Foreign matter remaining in the spool • Remove the foreign matter or replace
move smoothly. sliding area. valve assembly.
1 Plug
2 Spring
3 Cap
4 Plunger
5 Cap nut
6 Adjusting screw
7 Locknut
8 Needle valve
9 Circlip
10 Wire
11 Spring 31 Tilt spool
12 Spring 32 Seat
13 Spring holder 33 Sleeve
14 Spring 34 Seat
15 Plunger 35 Plate name
16 Pilot sleeve 36 Seal holder
17 Cover 37 Body
18 Adjusting screw 38
19 Plug 39 Hexagonal socket head bolt
20 Head spool 40 Hexagonal socket head bolt
21 Plunger 41 Button bolt
22 Spring 42 Nut 51 O-ring
23 Sleeve 43 Rivet screw 52 O-ring
24 Orifice 44 Steel ball 53 O-ring
25 Wire 45 Steel ball 54 O-ring
26 Spring 46 Oil seal 55 O-ring
27 Lift spool 47 O-ring 56 O-ring
28 Spring holder 48 O-ring 57 O-ring
29 Spool 49 O-ring 58 O-ring
30 Gasket 50 O-ring 59 Socket head plug
EX50 Series
TROUBLESHOOTING
80. CHECK ITEMS FOR EACH EQUIPMENT
Engine......................................................................80- 2
Power train...............................................................80- 7
Travel system...........................................................80-11
Steering system .......................................................80-13
Braking system ........................................................80-15
Loading system........................................................80-18
Hydraulic system......................................................80-20
Chassis, safety system ............................................80-23
Overrall test..............................................................80-23
1. Startup condition • Pull back the parking lever. Set the F/R travel lever to neutral, then start
and abnormal sound engine and check the following:
1. Does engine start smoothly?
2. Is there any abnormal noise?
3. Does glow plug operate normally?
4. Do the accelerator pedal and lever operate smoothly?
2. Rotating condition, • Step on the accelerator pedal and inspect the following:
exhaust color, etc. 1. Does engine rotation increase smoothly?
2. Is exhaust gas color normal?
FD100/115
FD135/150E 700–750 rpm
FD160E
2. Max. speed
FD100/115
FD135/150E 2,375–2,475 rpm
FD160E
Com-
ponent Inspection item Nature of inspection
7. Compression Compression
Engine
Com-
ponent Inspection item Nature of inspection
11. Engine mount Check the engine mount for the following points:
1) Cracks and deformation of bracket
2) Loosening and falling of mount bolts and nuts
3) Damage and degradation of vibration absorbing rubber
ADJUSTING.
13. Fuel system Check the fuel system for the following points:
1) Fuel leakage
2) Damage and degradation of hoses and pipes
3) Fuel filters
Periodically replace filters since their condition is not determined by
visual inspection.
a For the fuel filter replacement method, see the section of TESTING
AND ADJUSTING.
Com-
ponent Inspection item Nature of inspection
Com-
ponent Inspection item Nature of inspection
amounts of water.
If the electrolyte gets in your
eyes, wash your eyes with
water, then get medical atten-
tion.
2. Check battery electrolyte level for
batteries other than maintenance–
free batteries.
If the battery electrolyte is not within
the specified range, add distilled
water to upper limit line (A).
Clean the terminals and battery cap
breather.
3. Loose, corroded battery terminals
4. Loose wiring connections
5. Damaged wiring
Com-
ponent Inspection item Nature of inspection
2. Speed lever
1) Check for ease of shifting to
each speed position.
2) Check for play at each speed
position.
3. Transmission
1) Check for any abnormal noise
2) Check for oil leakage
If the oil forms drops, replace the
packing.
3) Check oil level
Stop the truck in a level place
and check with the oil level gauge.
Correct
Drain plug range
Strainer
Com-
ponent Inspection item Nature of inspection
2) Interconnected travel
Adjust with adjustmentbolt so that
the inching pedal and brake pedal
Adjustment bolt
are interconnected for the travel
shown below when the inching
pedal is depressed.
3) Pedal height
Power train
Com-
ponent Inspection item Nature of inspection
23. Torque converter For the following inspection, block the wheels of the lift truck and apply
the parking securely.
1. Clutch actuation pressure
Place the directional lever at FORWARD or REVERSE, depress the
accelerator pedal, and measure the pressure.
F/R
Clutch actuation 1st and 2nd 1.35–1.65 MPa {13.8–16.8 kgf/cm2}
pressure
3rd 1.20–1.50 MPa {12.2–15.3 kgf/cm2}
From line filter Main pressure T/C oil oressure To cooler F/R clutch
1 1/16-12 UNF measurement port measurement port 7/8-14 UNF pressure port
1, 2, 3 speed
clutch pressure
port
Oil level
gauge
2. Stall speed
Place the directional lever at FORWARD and REVERSE, run the engine
at maximum speed, and measure the engine speed at this point.
SAA6D107E-1-A
(Komatsu) 2,000 rpm
The torque converter oil temperature will rise, so do not continue this
operation for a long time.
Com-
ponent Inspection item Nature of inspection
24. Drive shaft 1. Oil leakage from seal of connecting part (case)
3. Dirty oil
For details of the method of check-
ing the oil level and changing the
oil, see TESTING AND ADJUST-
ING.
2. Oil level
Check that there is ample oil inside the planetary gear.
3. Dirty oil
Com-
ponent Inspection item Nature of inspection
1,961–2,452 Nm
{200–250 kgm}
4. Abnormal wear
Check for uneven or stepped wear.
Com-
ponent Inspection item Nature of inspection
30. Wheel
1. Loose hub nut
Hub nut tightening torque
Unit: Nm {kgm}
Front wheel Rear wheel
441.5–539.5 {45–55} 441.5–539.5 {45–55}
Com-
ponent Inspection item Nature of inspection
2. Operating effort
Play
3. Looseness, play
2. King pin
1) Play
2) Cracks, damage
3. Knuckle
Damage
Check visually or check with the crack detection method.
Com-
ponent Inspection item Nature of inspection
FD100
FD115 Within 4,000 mm (157.6 in) ± 5 %
37. Power steering 1. Oil leakage from power steering cylinder and hose
system 2. Damaged, deteriorated hose
3. Loose, missing mounting bolt
4. Interference with chassis
5. Oil pressure
Remove plug (1) in the diagram
on the right, install an oil pressure
gauge, and measure the oil pres-
sure when the steering wheel is
turned fully.
Com-
ponent Inspection item Nature of inspection
2) Pedal play
1–4 mm
Pedal play (0.04–0.16 in)
2. Braking performance
Drive the lift truck on a flat, dry, paved road surface at full speed, then
apply the brake suddenly and check for the following.
1) Pulling of steering wheel to one side
2) Braking on one side only
3) Abnormal noise
4) Stopping distance (braking performance)
42. Brake piping Check the pipes, hoses, and joints visually for the following.
1. Oil leakage, air leakage 2. Damage
3. Deteriorated hoses 4. Loose mounting bolts
5. Interference with chassis
Com-
ponent Inspection item Nature of inspection
3. Wheel cylinder
45. Brake booster Check operation of valve and other equipment, check for leakage of hydraulic oil
Braking system
FD100/115
Lining thickness Within 5.5 mm (0.22 in)
FD135/150E/160E
Com-
ponent Inspection item Nature of inspection
Strength (when =50 mm) (2.0 in) Min. 137 N {14 kgf}
Item FD100–FD160E
Inside diameter of Within 216 mm
Parking drum (Within 8.5 in)
brake Clearance between 0.1–0.2 mm
drum and lining (0.004–0.008 in)
Com-
ponent Inspection item Nature of inspection
54. Fork (2) 1. Cracks, wear at upper hook, lower hook portion
2. Cracks, wear at fork root
Check that the thickness of the fork
root is within the specified value.
From time to time, use the crack detection method to check the fork
Loading system
Com-
ponent Inspection item Nature of inspection
2. Elongation
Measure the length between 17 links and check that it is within the speci-
fied value.
Com-
ponent Inspection item Nature of inspection
2. Oil level
Check the oil level with the
oil level gauge and add oil
if necessary. (Check the
dirtiness of the oil also.)
3. Clean strainer
2. Oil leakage
Hydraulic system
2. Oil leakage
2. Abnormal vibration
3. Abnormal noise
Com-
ponent Inspection item Nature of inspection
71. Hydraulic drift of lift Load the forks with the maximum pay-
cylinder, tilt cylinder load, set the mast perpendicular, raise
the forks approx. 1 m from the ground,
then check that the hydraulic drift is
within the specified value given below.
Adjustment:
Replace the control valve, cylinder
packing
Com-
ponent Inspection item Nature of inspection
3. Oil leakage
Hydraulic system
Com-
ponent Check item Details of check
85. Function of all sys- Carry out travel, operation test to check
tem
Overrall test
CONVERSION TABLE
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 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.881 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 2.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Inches to Millimeters
0.1 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
0 1 2 3 4 5 6 7 8 9
10 13.08 14.39 15.70 17.00 18.31 19.62 20.93 22.24 36.62 24.85
20 26.16 27.47 28.78 30.08 31.39 32.70 34.01 35.32 36.62 27.93
30 39.24 40.55 41.86 43.16 44.47 45.78 47.09 48.40 49.70 51.01
40 52.32 53.63 54.94 56.24 57.55 58.86 60.17 61.48 62.78 64.09
50 65.40 66.71 68.02 69.32 70.63 71.94 73.24 74.56 75.86 77.17
60 78.48 79.79 81.10 82.40 83.71 85.02 86.33 87.64 88.94 90.25
70 91.56 92.87 94.18 95.48 96.79 98.10 99.41 100.72 102.02 103.33
80 104.64 105.95 107.26 108.56 109.87 111.18 112.49 113.80 115.10 116.41
90 117.72 119.03 120.34 121.64 122.95 124.26 125.57 126.88 128.18 129.49
0 1 2 3 4 5 6 7 8 9
10 7.65 8.41 9.18 9.94 10.70 11.47 12.23 13.00 13.76 14.53
20 15.29 16.06 16.82 17.59 18.35 19.12 19.88 20.64 21.41 22.17
30 22.94 23.70 24.47 25.23 26.00 26.76 27.53 28.29 29.05 29.82
40 30.58 31.35 32.11 32.88 33.64 34.41 35.17 35.94 36.70 37.47
50 38.23 38.99 39.76 40.52 41.29 42.05 42.82 43.58 44.35 45.11
60 45.88 46.64 47.41 48.17 48.93 49.70 50.46 51.23 51.99 52.76
70 53.52 54.29 55.05 55.82 56.58 57.35 58.11 58.57 59.64 60.40
80 61.17 61.93 62.70 63.46 64.23 64.99 65.76 66.52 67.28 68.05
90 68.81 69.58 70.34 71.11 71.87 72.64 73.40 74.17 74.93 75.70
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
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 353.62 257.41 261.19
70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05
80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90
90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76
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
30 136.38 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76
50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22
60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68
70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14
80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60
90 409.15 413.69 418.24 422.79 427.33 431.88 436.42 440.97 445.52 450.06
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
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 27.669 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298
70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843
80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906
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
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1644 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1946 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 223 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2360 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3124 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
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
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1220.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
Temperature
Fahrenheit–Centigrade Conversion. –A simple way to convert a Fahrenheit temperture reading into a Centigraqde
temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired it convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures abd read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
velues, and read the corresponding Fahrenheit temperature on the right.
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