SERVICE MANUAL
Contents
1. ssssessesel e e 7 57 TILT CYLINDER REASSEMBLY ssssssssse 7 57 DRIVE AXLE DRIVE AXLE DISASSEMBLY ASSEMBLY EXPLODED VIEW PNEUMATIC 7 59 DRIVE AXLE ASSEMBLY TORQUE CHART PNEUMATIC 7 60 DRIVE AXLE DISASSEMBLY ASSEMBLY EXPLODED VIEW CUSHION 7 61 DRIVE AXLE ASSEMBLY TORQUE CHART CUSHION 7 62 DIFFERENTIAL DIFFERENTIAL TORQFLOW TRANSMISSION DISASSEMBLY ASSEMBLY EXPLODED VIEW i e kali died de RES atl e dado altho 7 63 DIFFERENTIAL TORQFLOW TRANSMISSION SPECIFICATIONS 7 64 DIFFERENTIAL ADJUSTING eee ERR Ode redes Em aede 7 65 DIFFERENTIAL ASSEMBLY n 7 68 HYDRAULIC CONTROL VALVE CONTROL VALVE ASSEMBLY eee 7 69 CONTROL VALVE WORK PORT RELIEF 00 00 0000 cee ee 7 70 SETTING PRESSURE ON WORK PORT RELIEF 0 000000 res 7 70 TROUBLE SHOOTING THE ANTI VOID FEATURE 0 000000 00 00000200000 7 70 SERVICING AND REPAIR INFORMATION 0 0 000000 RI I 7 70 SHUT OFF VALVE ier edet E ete deri o P tape t ae tec 7 71 SERVICE INFORMATION ssssesel e rer 7 71 HYDRAULIC PUMP GASOLINE ENGINES HYDRAULIC PUMP GASOLINE ENGINE PNEUMATIC 7 73 HYDRAULIC PUMP REAR PUMP2. INTERMEDIATE SHAFT DISASSEMBLY OF CLUTCH PACK EXPLODED VIEW F1 R1 TRANSMISSION SINGLE SPEED TESTING F1 R1 TRANSMISSION SPECIFICATION TABLE F2 R1 TRANSMISSION TWO SPEED TESTING F2 R1 TRANSMISSION SPECIFICATION TABLE PRECAUTIONS ON ASSEMBLY ssseseseeee ren F1 R1 TRANSMISSION INPUT SHAFT SUB ASSEMBLY F1 R1 AND F2 R1 TRANSMISSIONS INPUT SHAFT ASSEMBLY FLOWCHART F2 R1 TRANSMISSION INTERMEDIATE SHAFT SUB ASSEMBLY F2 R1 TRANSMISSION INTERMEDIATE SHAFT ASSEMBLY FLOWCHART OUTPUT SHAFT SUB ASSEMBLY e OUTPUT SHAFT SUB ASSEMBLY ADJUSTING PINION SHAFT THRUST PROTRUSION TRANSMISSION CASE ASSEMBLY 0 0 0 0 0 F1 R1 TRANSMISSION TORQFLOW TRANSMISSION ASSEMBLY DRAWING TRANSMISSION CONTROL VALVE EXPLODED VIEW TRANSMISSION CONTROL VALVE SPECIFICATIONS TRANSMISSION CONTROL VALVE REMOVAL TRANSMISSION CONTROL VALVE ASSEMBLY DRAWINGS TRANSMISSION CONTROL VALVE TROUBLESHOOTING TORQFLOW TRANSMISSION TORQUE CONVERTER CUSHION TRUCKS TORQUE CON
3. STRUCTURE ssssssseseee e a 7 25 WHEEL BRAKE INSTALLATION ssssssesle I ee 7 26 POWER STEERING VALVE ORBITAL POWER STEERING VALVE EXPLODED VIEW 0 00 00 ee 7 27 POWER STEERING VALVE TROUBLESHOOTING CHART 7 28 POWER STEERING VALVE DISASSEMBLY 7 30 POWER STEERING VALVE CLEANING 0 0000 nes 7 34 POWER STEERING VALVE ASSEMBLY 00 20 0000 cece eee 7 34 POWER STEERING VALVE INSTALLATION sssssssse eR II 7 43 BRAKE BOOSTER AND MASTER CYLINDER BRAKE MASTER CYLINDER EXPLODED VIEW 0 00 00 II 7 44 BRAKE MASTER CYLINDER BRAKE BOOSTER DIAGRAM 7 46 BRAKE MASTER CYLINDER DISASSEMBLY 7 47 BRAKE BOOSTER UNIT DISASSEMBLY 7 48 BRAKE BOOSTER AND MASTER CYLINDER SPECIFICATIONS 7 49 BRAKE BOOSTER AND MASTER CYLINDER INSPECTION AND TESTING 7 49 BRAKE MASTER CYLINDER ASSEMBLY ssssesseeee ees 7 51 BRAKE BOOSTER ASSEMBLY ssssselsellll s 7 51 POWER STEERING CYLINDER POWER STEERING CYLINDER DISASSEMBLY ASSEMBLY EXPLODED VIEW 7 55 TILT CYLINDER TILT CYLINDER EXPLODED VIEW sssesesel I I 7 56 TILT CYLINDER DISASSEMBLY sssssssseeel lae 7 56 TILT CYLINDER PARTS INSPECTION
4. and varranty 15 voided C 1 fuel rate PH or aititudes exceed VALVE LASH INCH INT EXH TIMING TDC air values for this mael and application COLD Date of Mfg FIRING ORDER FR LOWIDLERPM Made in JAPAN C I Z 66088 RATED HP KW AT RPM 560102 EPA DECALS 2 WARRANTY The following statement is hereby provided as required by regulations of the United States Environmental Protec tion Agency EPA YOUR WARRANTY RIGHTS AND OBLIGATIONS The Federal EPA and Tusk Lift Trucks hereinafter referred to as TUSK are pleased to explain the emission con trol system warranty on your 2004 or later Diesel heavy duty off road engine All new heavy duty off road engines must be designed built and equipped to meet the EPA s stringent anti smog standards TUSK must warrant the emission control system on your engine for the period of time listed below provided there has been no abuse damage neglect or improper maintenance of your engine Your emission control system may include parts such as fuel injection pump Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists an authorized TUSK dealer will repair the heavy duty off road engine at no cost to the owner including diagnosis parts and labor Now TUSK hereby certifies that diesel engines for lift trucks produced in 2004 model year and after shall be regu
5. pneumatic tire truck long wheelbase 2 spd trans S6D102bE 1000PD 8 10 000 Ib capacity pneumatic tire truck long wheelbase 1 spd trans S6D102bE 1000PD2 8 10 000 Ib capacity pneumatic tire truck long wheelbase 2 spd trans S6D102bE 1100PDA2 8 11 000 Ib capacity pneumatic tire truck long wheelbase 2 spd trans S6D102bE FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF ROAD LSI NON DIESEL ENGINES TB45E ENGINES This section presents information concerning the correct labeling warranty parts and maintenance of TB45E engines in order to comply with the EPA off road large spark ignition LSI engine regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All engines will display the required identification label as follows Note that decal content will vary between gaso line LP and Dual Fuel engines Location on TB45E Series engines Includes TB45D TB45G and TB45L Series EPA LABEL LOCATION TBASE EPA Emission compliance label DUAL FUEL D SAMPLE shown below EMISSION CONTROL INFORMATION ENGINE FAMILY 4NSXBO04 546C ENGINE DISPLACEMENT 4 5 LITER ENGINE MAXIMUM POWER 106 1 HP THIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE AND LPG ENGINE S USEFUL LIFE IS 5000 HOURS OF OPERATION OR SEVEN YEARS EXHAUST EMISSION CONTROL TYPE MPI TBI TWC 25 TEST MODE VARIABLE SPEED ONLY IDLE SPEED NO OTHERADJUSTMENTS NEEDED 9 NO OTHER ADJUSTMENTS NEEDED THE ENGINE MEETS CALIFORNIA AND U S EPA REGU
6. 1 SERVICE DATA GASOLINE ENGINE TRUCKS sess n 3 2 SERVICE DATA DIESEL ENGINE TRUCKS ssssseseee e n 3 5 CH 04 TESTING ADJUSTING AND MEASURING 4 1 CHECKING ENGINE OIL TB45E RR I 4 2 ADJUSTING ENGINE OIL LEVEL sak cette 4 2 ADJUSTING IGNITION TIMING TB45E 0 0 00 cee 4 2 ADJUSTING SPARK PLUG GAP TB45E 2 0 0 0 tees 4 3 ADJUSTING VALVE CLEARANCE TB45E 2 2 eee ee 4 4 ADJUSTING VALVE CLEARANCE S6D102E 4 5 ADJUSTMENT OF ENGINE DRIVE BELTS TB45E 4 7 MEASURING ENGINE CYLINDER COMPRESSION TB45E 4 8 MEASURING HYDRAULIC DRIFT ON LIFT amp TILT CYLINDERS 4 9 MAST ee deed O44 ebb Pde Meares bias ie t 4 10 ADJUSTING CLEARANCE THRUST PAD AND RAIL 0 0 0 0 0000 ee 4 12 ADJUSTING THE PARKING BRAKE LEVER 0 0 e cece eee eet eens 4 15 ADJUSTING THE ACCELERATOR PEDAL TB45E ENGINE 4 15 ACCELERATOR PEDAL POSITION SENSOR TB45 ENGINE 4 17 ADJUSTING ACCELERATOR PEDAL S6D102E ENGINE 4 18 MEASURING BRAKE STOPPING DISTANCE BRAKING EFFECT 4 19 ADJUSTING THE INCHING BRAKE PEDAL TORQFLOW TRUCKS
7. 4 19 ADJUSTING THE STOP LAMP SWITCH 2 0 0 0 ccc tees 4 20 WHEEL BRAKE ADJUSTING Eniri mh rms 4 22 CHECKING TORQFLOW CLUTCH ACTUATION PRESSURE PNEUMATIC 4 23 CHECKING TORQUE CONVERTER STALL SPEED 4 23 CHECKING TORQFLOW CLUTCH ACTUATION PRESSURE CUSHION TIRE 4 24 CHECKING TORQUE CONVERTER STALL SPEED 4 24 INCHING VALVE SPOOL ADJUSTMENT 0 0 e hh 4 25 TESTING SPECIFIC GRAVITY OF BATTERY ELECTROLYTE 4 26 CHECKING TIRES AND ADJUSTING PNEUMATIC TIRE PRESSURE 4 27 MEASURING MINIMUM LEFT AND RIGHT TURNING RADIUS 4 27 REAR AXLE THRUST CLEARANCE ADJUSTMENT 4 29 CH CH 05 1 5 5 bU RUPEE EE GI RE ERU UR ROUEGRCR OK isto Bisa ow Gora ata 5 1 INSPECT ENGINE STARTING OPERATION sssesss ee Is 5 2 INSPECT ENGINE RUNNING CONDITION ssssssses IRI 5 2 INSPECT AIR CLEANER ASSEMBLY ssesssseseee es 5 2 INSPECT RETORQUE LOOSE CYLINDER HEAD MOUNTING BOLTS TB45E 5 3 INSPECT ENGINE MOUNTS 2 rs 5 4 INSPECT THE ENGINE LUBRICATING SYSTEM 5 4 INSPECT ENGINE FUEL SYSTEM vxo nx m ace el ea neko an ea ibe bua eus d 5 5 INSPECT DIESEL FUEL INJECTION NOZZ
8. Bldg 2 Covington GA 30014 4908 Voice phone 770 385 4815 Fax phone 770 385 4838 15
9. HYDRAULIC PUMP REASSEMBLY OF REAR PUMP UNIT DIESEL HYDRAULIC PUMP TESTING ssssssseesl s HYDRAULIC PUMP TROUBLESHOOTING essssees eee TORQFLOW TRANSMISSION TORQUE CONVERTER PNEUMATIC TRUCKS TORQUE CONVERTER ASSEMBLY DRAWING 0 0ccc sls TORQFLOW GEAR PUMP ASSEMBLY EXPLODED VIEW PNEUMATIC TORQUE CONVERTER PART SPECIFICATIONS PNEUMATIC TORQUE CONVERTER ASSEMBLY PNEUMATIC TORQUE CONVERTER PRESSURE AND TORQUE SPECIFICATIONS PNEUMATIC acad ee htc etu ot rel iat Lie Le TORQUE CONVERTER TRANSMISSION CONTROL VALVE PNEUMATIC TRUCKS OVERVIEW ins pt ances a Seats fold ede LIAE teal at UG Att gu tad HANDLING PRECAUTIONS cee TORQUE CONVERTER ASSEMBLY edors nii tia iia phe ORAE o ea e E Eea i ig CONTROL VALVE ASSEMBLY apa oiai iaa a neme i a ee TORQUE CONVERTER ASSEMBLY SECTIONAL VIEW PNEUMATIC TORQUE CONVERTER ASSEMBLY ASSEMBLY DRAWING PNEUMATIC TORQUE CONVERTER ASSEMBLY FLUID DIAGRAM PNEUMATIC TORQUE CONVERTER TROUBLESHOOTING CHART PNEUMATIC TORQFLOW TRANSMISSION PNEUMATIC TRUCKS DISASSEMBLY asyr r A Gh Aves e Pat M EX act INPUT SHAFT CLUTCH PACK DISASSEMBLY EXPLODED VIEW
10. hh 1 FORKLIFT TRUCKS COVERED IN THIS PUBLICATION S N 130001A MODEL DESIGNATION DESCRIPTION ENGINE GASOLINE AND LPG TRUCKS 800CG 8 8 000 Ib capacity cushion tire truck 1 speed transmission TB45 800CGB 8 8 000 Ib capacity cushion tire truck Box Car Special BCS 1 spd trans TB45 800PG 8 8 000 Ib capacity pneumatic tire truck compact wheelbase 1 spd trans TB45 800PG2 8 8 000 Ib capacity pneumatic tire truck compact wheelbase 2 spd trans TB45 900PG 8 9 000 Ib capacity pneumatic tire truck long wheelbase 1 spd trans TB45 900PG2 8 9 000 Ib capacity pneumatic tire truck long wheelbase 2 spd trans TB45 1000PG 8 10 000 Ib capacity pneumatic tire truck long wheelbase 1 spd trans TB45 1000PG2 8 10 000 Ib capacity pneumatic tire truck long wheelbase 2 spd trans TB45 1000CG 8 10 000 Ib capacity cushion tire truck long wheelbase 1 spd trans TB45 1000CGB 8 10 000 Ib capacity cushion tire truck Box Car Special BCS 1 spd trans TB45 1100PGA2 8 11 000 Ib capacity pneumatic tire truck long wheelbase 2 spd trans TB45 DIESEL TRUCKS 800PD 8 8 000 Ib capacity pneumatic tire truck compact wheelbase 1 spd trans S6D102bE 800PD2 8 8 000 Ib capacity pneumatic tire truck compact wheelbase 2 spd trans S6D102bE 900PD 8 9 000 Ib capacity pneumatic tire truck long wheelbase 1 spd trans S6D102bE 900PD2 8 9 000 Ib capacity
11. it often and learn the repair testing and adjustment procedures to the best of your ability Please note that some illustrations are generic and may not look exactly like your unit in every detail Ensure that when you are working on or around industrial trucks Safety is priority Number One Read understand and obey all WARNINGS and CAUTIONS Follow the instructions and procedures presented in this manual when working on these lift trucks and their systems Damage to the equipment and possible injury to yourself or others may result if these procedures are not adhered to carefully Keep this manual nearby and accessible for use when necessary If this book becomes dirty worn or illegible contact TUSK for a replacement The procedures outlined in this manual will be updated periodically Be sure that you have the latest revision in order to learn the newest information available Revision dates will be clearly displayed on the lower left hand corner of the cover page This will aid in maintaining your equipment in excellent condition and in ensuring that these lift trucks will operate safely at maximum efficiency ENGINE SERIAL NUMBER LOCATION The TB45E series engine serial number is stamped on a flat machined painted pad on the right side of the engine block just behind the dis tributor The right side is determined by the opera tor s right side when seated on the lift truck The serial number faces upwards for ease of iden t
12. lated by Federal EPA exhaust gaseous regulations The difference between current and EPA certified engines is only the labels attached on the engine See available drawing and or illustration of emission label and its location 13 MANUFACTURER S WARRANTY COVERAGE Beginning January 1 2004 heavy duty off road EPA engines are warranted for a period of five 5 years or three thousand 3 000 hours of operation whichever occurs first If any emission related part on your engine is defec tive the part will be repaired or replaced by at an authorized Tusk Lift Trucks dealer EMISSION RELATED PARTS Fuel injection pump Fuel injection nozzles Turbocharger OWNER S WARRANTY RESPONSIBILITIES As the heavy duty off road engine owner you are responsible for the performance of the required maintenance listed in owner s manual Instruction Manual TUSK recommends that you retain all receipts and records covering the maintenance on your engine but TUSK cannot deny warranty solely for the lack of receipts and records or for your failure to ensure the performance of all scheduled maintenance For your reference the following is an emis sion control maintenance schedule for certified Diesel engines Check oil level and coolant level Everyday Change of lubricating Every 200 hours e Change lubricating oil filter Every 200 hours Initial adjustment of valve clearance Every 200 hours Change fuel filter Every 50
13. maintenance of S6D102E diesel engines in order to comply with current EPA regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All certified S6D102E diesel engines will display the required identification labels 4 as follows S6D102E diesel engines Labels will be affixed to all appropriate engines on TUSK production trucks Locations on S6D102E Series diesel engines TOP VIEW 6D102E ee MW iw 560102 1 1 CERTIFICATION DECAL 2 LOCATIONS SEE ITEM 1 IN PRECEEDING ILLUSTRATION 1 2 EPA EC CERTIFICATION ASSISTANCE PLATE SEE ITEM 2 IN PRECEEDING ILLUSTRATION 1 3 EPA EC CERTIFICATION DATA PLATE SEE ITEM 3 IN PRECEEDING ILLUSTRATION 12 1 EPA EU CERTIFICATION DECAL IMPORTANT ENGINE INFORMATION This engine conforms to 2004 U S EPA and California and EU Stage regulations for heavy duty non road compression ignited diesel cycle engines as applicable THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL FUEL 2 EPA EU CERTIFICATION ASSISTANCE PLATE 0070 EPA Cort XXXXXXXXXXXX EU Approval HO XXXsXX XXXN XX ANN SAXXK ERX Gross Rated XX XX at XXXXron FRXXXXX Low ldel RPM XXX rom CPL XXXX CID L XXXX X X Timing BTDC XXdes Firing Order XXXXXX Valve Lash Cold ln X XXXen Ex X XXXnm Fuel Rate at Rated HP TY XXXmm3 st Date of Manufacture XXXXXXXX 6732 81 5870 3 EPA EU CERTIFICATION DATA PLATE CIDIL ENGINE SERIAL NO FAMILY KOMATSU PN
14. 0 hours e Check turbocharger rebuild or replace if necessary Every 2 000 hours Adjust valve clearance Every 2 000 hours Check fuel injection nozzles replace if necessary Every 2 000 hours Keep records to show proof of compliance with the required maintenance practices and intervals Asthe heavy duty off road engine owner you should however be aware that TUSK may deny your war ranty coverage if your heavy duty off road engine or part has failed due to abuse damage neglect improper maintenance or disapproved modifications Your engine is designed to operate on commercial diesel fuel only Use of any other fuel in our engine will result in the engine operating in non compliance with the Federal EPA regulations You are responsible for initiating the warranty process It is suggested that you present your heavy duty off road engine to an authorized TUSK dealer as soon as you become aware that problem exists The warranty repair should be completed by the dealer as expeditiously as possible f you have any questions regarding your warranty rights and responsibilities you should contact the authorized TUSK dealer LIMITATIONS TUSK is not responsible for resultant damages to an emission related part or component resulting from Any application or installation TUSK deems improper as explained in the Instruction Manual Attachments accessory items or parts not authorized for use by TUSK mproper off road engine main
15. ATES sssssseseeseeee nes 5 12 INSPECT LOAD FORKS rr 5 12 INSPECT MASI redes tg n er And are Joe ern bed ald qi cath 5 12 INSPECT FORK CARRIAGE hake a xa SM ete RE rx ERE ERU AE Lea 5 13 INSPECT EFA CHAINS attri e me enemies edi us aud Pire ect ag 5 13 INSPECT ATTACHMENTS s sssssesessl eee 5 13 INSPECT HYDRAULIC TANK rs 5 14 INSPECT CHASSIS AND ATTACHMENT PIPING sssse RII 5 14 INSPECT HYDRAULIC PUMP ee 5 14 INSPECT LIFT CYLINDER vairaa a I I ret 5 14 INSPECT TILT CYLINDERS ias eI gale aw aed eae 5 14 INSPECT ATTACHMENT CYLINDERS IF EQUIPPED 5 14 INSPECT LIFT TRUCK CHASSIS AND FRAME 5 14 INSPECT CAB IF EQUIPPED sssseeeee RI AA Itt 5 14 INSPECT THE OPERATOR S SEAT ssssslselell ls 5 14 INSPECT EQUIPMENT USED FOR ACCESSING THE LIFT TRUCK 5 14 INSPECT DISPLAY PANEL z ieiet erena re et d en Athy deena a PUR rien 5 15 INSPECT OVERHEAD GUARD ssssselslsl lm 5 15 INSPECT LIGHTS GAUGES AND WARNING DEVICES 5 15 INSPECT REAR VIEW MIRROR AND REFLECTORS 5 15 06 MAINTENANCE OPERATIONS seeeeesee ee n hh 6 1 LUBRICANT LIST GASOLINE ENGI
16. LATIONS FOR 2004 LARGE NONROAD SI ENGINES NISSAN MOTOR CO LTD TB45 D TB45E EPA LABEL 2 WARRANTY The following statement is hereby provided as required by regulations of the United States Environmental Protec tion Agency EPA YOUR WARRANTY RIGHTS AND OBLIGATIONS All off road large spark ignition LSI engines must be designed built and equipped to meet the Federal EPA s stringent anti smog standards Tusk Lift Trucks TUSK must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse damage neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor regulator or fuel injection system ignition system engine computer unit ECM catalytic converter and air induction system Also included may be sensors hoses belts connectors and other emission related assemblies Where a warrantable condition exists an Authorized Tusk Lift Trucks Dealer will repair your LSI engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Beginning January 1 2004 off road large spark ignition EPA engines are warranted for the time periods listed below If any emission related part on your engine is defective the part will be repaired or replaced by an Autho rized Tusk Lift Trucks Dealer OWNER S WARRANTY RESPONSIBILITIES As the off road LSI engine owner you
17. LES 0 0000000000000 cece eee eee eee 5 5 INSPECT LPG VAPORIZER FOR TAR BUILDUP EVERY MONTH TB45E 5 6 INSPECT THE BLOW BY GAS RECIRCULATION SYSTEM 45 5 7 INSPECT COOLING SYSTEM AND RADIATOR 5 7 INSPECT COOLING WATER LEVEL n 5 8 INSPECT FAN ASSEMBLY rn 5 8 INSPECT CHARGING SYSTEM WIRING 00 0000000002 5 8 INSPECT FRONT AXLE AND RETORQUE MOUNTING BOLTS 5 8 INSPECT REAR AXLE AND RETORQUE MOUNTING BOLTS 5 9 INSPECT WHEELS mee EM RENS agate Aisa kd 5 9 INSPECT RIM SIDE RING 2 eee 5 9 INSPECT WHEEL BEARINGS ces 5 9 INSPECT STEERING KNUCKLES es 5 9 INSPECT STEERING WHEEL ee 5 10 INSPECT THE POWER STEERING SYSTEM 0 0 0 5 10 INSPECT BRAKE SYSTEM RODS CABLES AND LINKS 5 10 INSPECT BRAKE PIPING AND CONNECTIONS 0 000000000 les 5 10 INSPECT BRAKE MASTER AND WHEEL CYLINDERS 5 11 INSPECT BRAKE SHOES AND ASSOCIATED PARTS 5 11 INSPECT BRAKE DRUMS eem ata dea eae CERE eae aah dn aa Tite ia 5 11 INSPECT BRAKE BACKING PL
18. N 7 168 TORQFLOW SYSTEM TROUBLESHOOTING CHART PNEUMATIC AND CUSHION 7 169 COMBINATION SWITCH COMPONENT PARTS DIAGRAM 1 172 CHECKING LIGHTING TURN SIGNAL SWITCH W O DIMMER SWITCH 7 173 CHECKING LIGHTING TURN SIGNAL SWITCH WITH DIMMER SWITCH 7 174 CHECKING LIGHTING TURN SIGNAL SWITCH 2 0 0 0 0 202 ee 7 175 CHECKING FIR SWITCH uos aom pas UP SOLES E EE 7 176 COMBINATION SWITCH ASSEMBLY REPLACING 7 177 LIGHTING AND F R SWITCH REPLACING se ese RR eee 7 178 08 TROUBLESHOOTING 1 cece eee hn hn nnn 8 1 ENGINE TROUBLESHOOTING CHART 0 0 000 0000 eee eee 8 2 TORQFLOW TROUBLESHOOTING CHART 2 0 00 0 0 ee eee 8 3 TORQUE CONVERTER TROUBLESHOOTING CHART CUSHION TRUCKS 8 7 TORQUE CONVERTER TROUBLESHOOTING CHART PNEUMATIC TRUCKS 8 9 TORQFLOW CONTROL VALVE TROUBLESHOOTING CHART CUSHION 8 11 TORQFLOW CONTROL VALVE TROUBLESHOOTING CHART PNEUMATIC 8 12 ELECTRICAL SYSTEM TROUBLESHOOTING CHART 0 0 000 0000 cc eee eee eee 8 13 STEERING SYSTEM TROUBLESHOOTING CHART oaaao aoaaa 00000 eee eee 8 14 BRAKE SYSTEM TROUBLESHOOTING CHART cee 8 16 HYDRAULIC SYSTEM TROUBLESHOOTING CHART 0 0000 ees 8 18 APPENDIX SERVICE DIAGRAMS sseseeseee ee hn
19. NE LIFT TRUCKS 6 2 LUBRICANT LIST DIESEL ENGINE LIFT TRUCKS ssseee nes 6 3 OIL AND GREASING CHART m 6 8 CHANGING OIL AND FILTER IN GASOLINE ENGINES 6 9 CHANGING OIL AND FILTER IN DIESEL ENGINES 0 6 11 CH CHANGING GEAR OIL IN DIFFERENTIAL CASE 0 00 00 00 nee 6 12 CHANGING TRANSMISSION FLUID IN TORQFLOW TRANSMISSION CASE 6 13 CHANGING OIL IN HYDRAULIC TANK 2 0 2 2 ee 6 14 REPLACING THE FUEL FILTER GASOLINE ENGINES 6 15 REPLACING THE FUEL FILTER DIESEL ENGINES 6 15 REPLACING AIR CLEANER ELEMENT TB45E 6 16 REPLACING AIR CLEANER ELEMENT S6D102bE 6 17 CLEANING THE RADIATOR sssssesee s rs 6 17 CLEANING RADIATOR FINS aniei suana re 6 18 BLEEDING AIR FROM BRAKE SYSTEM ssssssessesl rs 6 18 07 REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION 7 1 UNIT INSTALLATION POSITIONS DIAGRAM 0 000000 s Ih 7 2 OVERALL DISASSEMBLY ASSEMBLY FLOW CHART 7 3 WEIGHT TABLE COMPONENT ASSEMBLIES AND 5 7 4 MAST REMOVAL TYPICAL s n 7 5 ENGINE ENGINE REMOVAL FROM CHA
20. S For the first 2 500 operating hours or for a period of thirty six months from the date of the first use by the original purchaser from an Authorized Tusk Lift Trucks Dealer whichever occurs first TUSK warrants the following emis sion related parts Oxygen sensor e PCV valve Gasoline injector sensor LPG injector LPG pressure sensor LPG solenoid LPG switching module Mass air flow sensor Throttle chamber Ignition coil e Crankshaft position sensor Camshaft position sensor Distributor e Spark plugs EMISSION CONTROL WARRANTY 36 MONTHS OR 4 000 HOURS FOR POWER TRAIN PARTS ntake manifold Exhaust manifold EMISSION CONTROL WARRANTY 60 MONTHS OR 3 500 HOURS FOR GENERAL PARTS ECM Catalytic converter e Vaporizer NOTICE Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance For questions and additional information concerning EPA Gasoline Engine Exhaust Regulations contact Tusk Lift Trucks 14481 Lochridge Blvd Bldg 2 Covington GA 30014 4908 Voice phone 770 385 4815 Fax phone 770 385 4838 11 FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF ROAD DIESEL ENGINES S6D102E ENGINES Exhaust emissions produced by diesel engines are regulated by the United States Environmental Protection Agency EPA This section presents information concerning the correct labeling warranty parts and
21. SECTION DISASSEMBLY GASOLINE PNEUMATIC 7 74 HYDRAULIC PUMP FRONT PUMP SECTION DISASSEMBLY GASOLINE PNEUMATIC 7 74 HYDRAULIC PUMP REAR PUMP SECTION REASSEMBLY GASOLINE PNEUMATIC 7 74 HYDRAULIC PUMP FRONT PUMP SECTION REASSEMBLY GASOLINE PNEUMATIC 7 75 HYDRAULIC PUMP GASOLINE ENGINE CUSHION 7 76 HYDRAULIC PUMP REAR PUMP SECTION DISASSEMBLY GASOLINE CUSHION 7 77 HYDRAULIC PUMP FRONT PUMP SECTION DISASSEMBLY GASOLINE CUSHION 7 77 HYDRAULIC PUMP REAR PUMP SECTION REASSEMBLY GASOLINE CUSHION 7 77 HYDRAULIC PUMP FRONT PUMP SECTION REASSEMBLY GASOLINE CUSHION 7 78 HYDRAULIC PUMP INSPECTION AND REPAIR GASOLINE CUSHION 7 78 HYDRAULIC PUMP DIESEL ENGINES HYDRAULIC PUMP FRONT UNIT DIESEL 00 0 0 00 0000 00 000000 7 80 HYDRAULIC PUMP FRONT PUMP UNIT DISASSEMBLY DIESEL 7 80 HYDRAULIC PUMP INSPECTION AND REPAIR PROCEDURES DIESEL 7 82 HYDRAULIC PUMP REASSEMBLY OF FRONT PUMP UNIT DIESEL 7 83 HYDRAULIC PUMP OIL SEAL INSTALLATION JIG DIAGRAM 7 85 HYDRAULIC PUMP REAR UNIT DIESEL EXPLODED VIEW 7 86 HYDRAULIC PUMP REAR PUMP UNIT DISASSEMBLY 7 87 4 HYDRAULIC PUMP INSPECTION AND REPAIR PROCEDURES DIESEL
22. SM202T SERVICE MANUAL CX Forklift Truck Federal Environmental Protection Agency EPA Emission Control Compliant SINASOUUTAT Gasoline and LP 800 1000CGL 8 800 1000CGB 8 800 1000PG S L 2 8 900PG 2 8 1100PGA2 8 Diesel 800 900PD 2 8 1000PD S 2 8 1100PD S A2 8 a WARNING Read and observe all warnings on this unit before operating it DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place ISSUED MARCH 2006 INTRODUCTION This Service Manual has been developed as an information resource to help the reader learn about understand repair and maintain the CX20 Series forklift trucks and the var ious equipment systems inspections sensors diagnostic procedures and diagnostic equipment utilized to maintain adjust and troubleshoot these systems Although refer ence is made to maintenance procedures necessary to perform servicing of this vehicle you should refer to the applicable Operation and Maintenance Manual for these lift trucks for more complete maintenance information TUSK is involved in a concentrated and highly technical program of designing and devel oping cleaner burning more efficient and more powerful engines for use in the industrial truck market As a result new computerized sensors systems and diagnostic monitors have been created to make the job of maintaining and repairing these systems simple and easy Read this manual carefully refer to
23. SSIS sssssesesslee es 7 6 ENGINE DISASSEMBLY ASSEMBLY ssssessssesll res 7 8 ENGINE INSTALLATION tara etes ma e eme n Lo ee RE ED NS 7 8 TRANSMISSION AND DRIVE AXLE TORQUE CONVERTER TRANSMISSION DRIVE AXLE REMOVAL FROM CHASSIS 7 10 TORQUE CONVERTER INSTALLATION seeese ee 7 12 TRANSMISSION AND DRIVE AXLE INSTALLATION 0 000000 RR 7 12 PEDAL ASSEMBLY BRAKE PIPING INSTALLATION 7 12 BRAKE SYSTEM BLEEDING AIR FROM LINES sese es 7 12 INSTALLING THE COUNTERWEIGHT sssssesse eee 7 13 MAST INSTALLATION TYPICAL 2 0 2 RR I I Ir 7 13 STEERING AXLE STEERING AXLE AND POWER STEERING CYLINDER REMOVAL FROM CHASSIS 7 14 POWER STEERING CYLINDER STRUCTURE 0 0 0 0 2 cece eee eee 7 15 STEERING AXLE DISASSEMBLY 0 000000 7 16 STEERING AXLE LUBRICATION AND TORQUE VALUES 7 17 STEERING AXLE CHECKING SPECIFICATIONS 7 18 STEERING AXLE AND POWER STEERING CYLINDER INSTALLATION 7 19 STEERING AXLE TORQUE VALUES 0 000000 0c 7 20 WHEEL BRAKE WHEEL BRAKE REMOVAL seb Ret c tied te rer C RA at ede a eg 7 22 WHEEL BRAKE DISASSEMBLY ASSEMBLY DRAWING CUSHION 7 23 WHEEL BRAKE DISASSEMBLY ASSEMBLY DRAWING PNEUMATIC 7 24 WHEEL BRAKE
24. VERTER ASSEMBLY DRAWING TORQUE CONVERTER PART SPECIFICATIONS CUSHION HYDRAULIC CIRCUIT DIAGRAM 0 0 0 0 TORQUE CONVERTER PRESSURE TESTING PORTS CUSHION TORQUE CONVERTER TROUBLESHOOTING CHART CUSHION TORQFLOW TRANSMISSION CUSHION TRUCKS DISASSEMBLY gas Ae Gan tee alga bart alien Matra Ebo Ed drop dating SERVICING AND INSPECTION 000000022 eee TORQFLOW TRANSMISSION CUSHION TRUCKS TORQFLOW TRANSMISSION ASSEMBLY 00 00 00 0 0000 eee 7 154 MAIN SHAFT A ASSEMBLY REVERSE 0 0 0000s 7 155 MAIN SHAFT ASSEMBLY REVERSE FLOWCHART 0 0 0000 00000 ee eee ee 7 156 MAIN SHAFT B ASSEMBLY FORWARD e 7 157 MAIN SHAFT ASSEMBLY FORWARD FLOWCHART 0 0 0000 eee 7 158 OUTPUT SHAFT SUB ASSEMBLY ASSEMBLY 7 159 OUTPUT SHAFT SUB ASSEMBLY ADJUSTING PINION SHAFT PROTRUSION 7 161 TRANSMISSION ASSEMBLY 0 0 0 0 000 cee eee 7 162 TRANSMISSION CONTROL VALVE CUSHION TRUCKS TRANSMISSION CONTROL VALVE DISASSEMBLY 7 165 TRANSMISSION CONTROL VALVE DIAGRAM CUSHION 7 166 TRANSMISSION CONTROL VALVE SPECIFICATIONS CUSHION 1 167 TRANSMISSION CONTROL VALVE TROUBLESHOOTING CHART CUSHIO
25. are responsible for the performance of the required maintenance listed in your Operation and Maintenance Manual TUSK recommends that you retain receipts covering maintenance on your off road engine but TUSK cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the off road large spark ignition engine owner you should be aware however that TUSK may deny you war ranty coverage if your off road large spark ignition engine or a part thereof has failed due to abuse damage neglect improper maintenance or unapproved modifications Your engine is designed to operate on gasoline and or LPG fuel Use of any other fuel may result in your engine no longer operating in compliance with the Federal EPA s emissions requirements You are responsible for initiating the warranty process It is suggested that you present your off road large spark ignition engine to an Authorized TUSK Dealer as soon as you become aware that a problem exists The warranty repairs should be completed by the dealer as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities you should contact the TUSK Prod uct Support Dept at 1 770 385 4815 In addition to the standard warranty periods the components listed below are covered by the following specific warranty periods 10 EMISSION CONTROL WARRANTY 36 MONTHS OR 2 500 HOURS FOR GENERAL PART
26. ification The S6D102E series engine serial number is stamped on the left side of the engine to the left of the oil filter NOTICE For EPA TB45E D G L engine related troubleshooting refer to the following manual e TM100 EPA Engine Training Manual NOTICE For EPA S6D102E engine related troubleshooting refer to the following manual e SM140 S6D102E Service Manual CONTENTS Page No INTRODUCTION tate tb E 3 ENGINE SERIAL NUMBER LOCATION 0 000 cece eee eee n n nh hn eens 4 FORKLIFT TRUCKS COVERED IN THIS PUBLICATION 8 FEDERAL EPA EMISSION CONTROL STATEMENT 9 CH 01 SAFETY SECTION 4 emere es ee Se ee ee eee 1 1 SAFE FY MANAGEMENT oap terea phd Beaty Pee Pr lee UD Jor eee doa be adage pnd 1 2 SAFE TRAVEL ura da S s RAPERE EUG Run E i 1 7 LOADING OPERATIONS x eens Gaede ee e qure lr ques e ee abe tquue pri xi aig 1 15 STOPPING ANB PARKING nieve meae ISI BER C 1 22 INSPECTION AND MAINTENANCE 2 hh hs 1 24 STRUCTURE AND STABILITY OF THE LIFT TRUCK sssseee mh 1 32 SAFETY LABEL STICKING POSITIONS ssssseeeee e m 1 35 CH 02 GENERAL INFORMATION AND SPECIFICATIONS 2 1 CH 03 SERVICE DATA 2 5 atte echt aire Reece the lean adh ote te alee Ee ae ees 3
27. tenance repair or abuse Owner s unreasonable delay in making the product available after being notified of a potential product problem This warranty is in addition to the TUSK standard warranty applicable to the off road engine product involved Remedies under this warranty are limited to the provision of material and services as specified herein TUSK is not responsible for incidental or consequential damages such as downtime or lost use of the forklift truck 14 CUSTOMER ASSISTANCE EMISSION CONTROL SYSTEMS WARRANTY Tusk Lift Trucks aims to ensure that the Emission Control Systems Warranty is properly administered In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Sys tems Warranty call or write to your Tusk Lift Trucks Dealer Authorized dealers are recommended for major maintenance and repair work as they are staffed with trained per sonnel proper tools and are aware of the latest maintenance methods and procedures Owners and others who desire to perform their own work should purchase a service manual and obtain current service information from their TUSK engine dealer NOTICE Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance For questions and additional information concerning EPA Diesel Engine Exhaust Regulations contact Tusk Lift Trucks 14481 Lochridge Blvd
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