FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT 8FGFI
8FDF15-30 series. Please use this manual for providing quick, correct servicing of
the corresponding forklift models.

This manual deals with the above models as of August 2007. Please understand that
disagreement can take place between the descriptions in the manual and actual
vehicles due to change in design and specifications. Any change or modifications
thereafter will be informed by Toyota Industrial Equipment Parts & Service News.

For the service procedures of the mounted engine, read the repair manuals listed
below as reference together with thi.s manual.

(Reference)
Repair manuals related to this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 8FGF/8FDF15-30

VOL.2 REPAIR MANUAL (No. CE057)
TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE
REPAIR MANUAL (No. CE663)
TOYOTA INDUSTRIAL EQUIPMENT 1DZ-1I1 ENGINE
REPAIR MANUAL (No. CE670)
TOYOTA INDUSTRIAL EQUIPMENT 3Z ENGINE
REPAIR MANUAL (No. CE671)
TOYOTA INDUSTRIAL EQUIPMENT LPG DEVICE
REPAIR MANUAL (No. CE669)

TOYOTA Material Handling Company

A Division of TOYOTA INDUSTRIES CORPORATION
 SECTI N INDEX
NAME

~ENERAL _ _
l}NGINE
[TORQUE CONVERTER & TRANSMISS-'ON
IPROPELLER SHAFT
=-
-~
L-

LPIFFERENTIAL
LFRONT A X L E -
I ~EAR AXLE
~_~-
=-
~~~

=-
I
L_.
STEERING ~

[BRAKE IIm
lSODY lIE
lMATERIAL HANDLING SYSTEM III
l_ MAST III
!CYLINDER III
! OIL PUMP _ .-
lOlL CONTROL VALVE •
i MINI LEVER·JOYSTICK •
[ SAS/OPS
I SST LIST·SERVICE STANDARDS LIST
[ MULTIFUNCTIO-N DISPLAY (OPT)
I

I ELECTRICAL SYSTEM TROUBLESHOOTING

i WIRING DIAGRAM I
I
I
 0-1

GENERAL
Page Page
EXTERIOR VIEWS 0-2 WIRE ROPE SUSPENSION
ANGLE LIST 0-15
VEHICLE MODEL 0-3
SAFE LOAD FOR
FRAME NUM BER 0-4
EACH WIRE ROPE
HOW TO USE SUSPENSION ANGLE 0-15
'""'11""' • • • .,....... ... A. ...... ! n. ....
I MI~ IVIANUAL U-O
COMPONENTS WEIGHT 0-16
EXPLANATION METHOD 0-5
RECOMMENDED
TERMINOLOGY 0-6 LUBRICANT
ABBREVIATIONS 0-6 QUANTITY & TYPES 0-17
OPERATIONAL TIPS 0-7 LUBRICATION CHART 0-18
HOISTING THE VEHICLE 0-8 PERIODIC
MAINTENANCE 0..20
HOW TO START
THE HOUR METER 0..8 INSPECTION METHOD 0-20
CIRCUIT TESTER O..g PERIODIC REPLACEMENT
OF PARTS AND
STANDARD BOLT & NUT
LUBRICANTS 0-25
TIGHTENING TORQUE 0..11
BOLT STRENGTH CLASS
IDENTIFICATION METHOD 0..11
PRECOAT BOLTS 0-14
HIGH PRESSURE
HOSE FITTING
TIGHTENING TORQUE 0-14
0-2

EXTERIOR VIEWS
 0-3

VEHICLE MODEL

Classification
Vehicle Model Transmission Type Engine
Series Model

02-8FGF15 TIC 4Y Gasoline

1.5 ton model
02-8FDF15 TIC 1DZ-111 Diesel
1 ton series
02-8FGF18 TIC 4Y Gasoline
1.75ton mode)
02-8FDF18 TIC 1DZ-1I1 Diesel

02-8FGF20 TIC 4Y Gasoline

2.0 ton model 02-8FDF20 TIC 1DZ-III Diesel

52-8FDF20 TIC 3Z Diesel

2 ton series
02-8FGF25 TIC 4Y Gasoline I

2.5 ton model 02-8FDF25 TIC 1DZ-11I Diesel

52-8FDF25 TIC 3Z Diesel

02-8FGF30 TIC 4Y Gasoline

3 ton series 3.0 ton model 02-8FDF30 TIC 1DZ-11I Diesel

52-8FDF30 TIC 3Z Diesel

02-8FGKF20 TIC 4Y Gasoline

K2 ton series K2.0 ton model
02-8FDKF20 TIC 1DZ-11I Diesel

02-8FGJF35 TIC 4Y Gasoline

J3.5 ton series J3.5 ton model
52-8FDJF35 TIC 3Z Diesel
0-4

FRAME NUMBER
Frame No. Punching Position

/~
~//
Punching position
~

Series Engine Vehicle model Punching format Series Engine Vehicle model Punching format

02-8FGF15 02-8FGF30
4Y 8FGF18©1OO11 4Y 8FGJF35©1OO11
02-8FGF18 02-8FGJF35
1 ton series 3 ton,
02-8FDF15 J3.5 ton 1DZ-111 02-8FDF30 8FDF30©10011
1DZ-lIi 8FDF18©10011 series
02-8FDF18 52-8FDF30
3Z 508FDJF35© 10011
02-8FGF20 52-8FDJF35
4Y 8FGF25 © 10011
02-8FGF25 4Y 02-8FGKF20 8FGKF20 © 10011
K2ton
series
02-8FDF20 1DZ-1I1 02-8FDKF20 8FDKF20©10011
2 ton series 1DZ-1I1 8FDF25©10011
02-8FDF25

52-8FDF20
3Z 508FDF25 © 10011
52-8FDF25
 0-5

HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Operation procedure

(1) The operation procedure is described in either pattern A or pattern B below.

Pattern A: Explanation of each operation step with illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by
explanation of cautions and notes summarized as point operations.

Example of description in pattern B

Tightening torque unit T = N·m (kgf·cm) [ft·lbf]

Step Nos. are partially sometimes omitted in

illustrations.
When a part requIrIng tightening torque
instruction is not indicated in the illustration, the
part name is described in the illustration frame.

T = 46.1 - 48.1
(470 - 490)
[34.0 - 35.5]

Disassembly Procedure
1 Remove the cover. [Point 1]
2 Remove the bushing. [Point 2] +- Operation explained later
3 Remove the gear.

Point Operations
[Point 1] Explanation of key point for operation with an illustration
Disassembly: lit
Put a match mark when removing the pump cover.

[Point 2]
Inspection:
Measure the bush inside diameter.
Limit: 19.12 mm (0.7528 in)
0-6

2. How to read components figures

(1) The components figure uses the illustration in the

(Example)
parts catalog for the vehicle model. Please refer
to the catalog for checking the part name.
The number at the right shoulder of each
components figure indicates the Fig. number in FIG number in parts catalog----'
the parts catalog.

3. Matters omitted in this manual

(1) This manual omits description of the following jobs, but perform them in actual operation:

(a) Cleaning and washing of removed parts as required

(b) Visual inspection (partially described)

TERMINOLOGY
Caution:
Important matters of which negligence may cause hazards on human body. Be sure to observe them.
Note:
Important items of which negligence may cause breakage or breakdown, or matters in operation procedure
requiring special attention.

Standard: Values showing ailowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.

ABBREVIATIONS

Abbreviation (code) Meaning Abbreviation (code) Meaning

ASC Auto Speed Control RR Rear
ATT Attachment Society of Automotive
SAE
FR Front Engineers (USA)

JIB Junction block SAS System of active stability

ASSY Assembly SOL Solenoid
LH Left hand SST Special service tool i

LLC Long life coolant STD Standard

M/T Manual transmission T= Tightening torque
NMR No-load maximum speed Torque converter &
TIC
OPS Operator Presence Sensing transmission

OPT Option OOT Number of teeth (0 0)

OIS Oversize U/S Undersize
PS Power steering W/ With
RIB Relay block LI Less
RH Right hand
 0-7

OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vE::hicle or its heavy component, use wire rope(s) with a suffIcient reserve in load
capacity.
(3) Always disconnect the battery terminal before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge,
etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to
prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate
in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and a-rings with new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of the specified tightening torque range.)
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table.
3. Grasping the trouble state
When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble
requires disassembly or replacement for remedying.
4. Disposal of waste fluid, etc.
When draining waste fluid from the vehicle, receive it in a container.
If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or scrapped without
permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids, etc.
and treat them properly by requesting disposal by specialized companies.
5. Greasing up each part
In addition to periodic grease-up according to the lubrication chart, apply MP grease (or molybdenum disulfide
grease) to each sliding contact face when repairing a portion (like pedal link) involving sliding contact.

6. Jack up points
Jack up points are provided in the front and rear portions of the
vehicle. Always apply jacks at the jack up points.

Front side:
A circular groove to accept a screw jack is provided under the
front side of the frame.
When a garage jack is used, jack up at the bottom surface of
the frame.
~Forscrew
c~~~_'--'JI jack
0-8

Rear side:
A circular groove to accept a screw or garage jack is provided
For screw at the bottom surface of the counterweight.

~J For garage
jack

7. Hydraulic oil level inspection procedure

Checking the oil amount inside tank, as shown below, contact
top of cap on retainer. (Do not push it into retainer.)

HOISTING THE VEHICLE

When hoisting the vehicle, sling with wire rope(s) at the mast hook
holes and the rear side of the head guard.

When hoisting by the head guard, remove the head guard she'
and attach wire ropes to the positions as shown in the illustration.

HOW TO START THE HOUR METER

Be sure to start the hour meter when delivering a new vehicle to a
customer.
Remove the fuse (7.5 A) in position A inside the relay block and
install it to position B (HOUR MET).
Make sure that the engine is stopped when installing the fuse.

IGN [1C'illJ
~
 0-9

CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively according to the
purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the measured value should only
be used for reference or rough jUdgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.

1. Difference in measurement results with the digital type and analog type
* The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual.
Cautions when the polarities are different between the analog type and digital type are described below.

FOivvard direction Reverse direction I (1) Analog circuit tester

Measurement result example
Tester range: kQ range

Analog type
Continuity exists
Forward
11 kD.
No continuity
Reverse
"l)

(2) Digital circuit tester

Forward direction Reverse direction Measurement result example
Tester range: MQ range
Digital type
c==J
No continuity
Forward
1
7\ ~ Continuity exists
I Reverse
J 2Mn
0-10

2. Difference in result of measurement with circuit tester

The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage. The diode
characteristics are shown in the figure below.

(mA) 6 The resistance values of the same semiconductor measured with

I I I I i I I --rTTT-
i I two types of circuit testers having different power supply voltages
5i I I I I I I
I t I I I I are different.
C H'_Uli'V- ~U-:-
4 _.L_!~~_ i
Germanium
.-
This manual describes the results of measurement with a circuit
~ 3
I If
diode : I I I
::J
0 i • / I I I (_ I - - tester whose power supply voltage is 3.0 V.
1"' 2 I Ii SI"condlo
l i d ! ~-
e-l
(\)
I /
2:
0 I I 'I tf11' "---c-
I
u.
, I J-l-~ I"+)__L
01 ' I cVl I I I ILLk:::L..LJ LJ
0.1 0.2 0.3 0.4 0.5 0.6 O.T 0.8
Forward vollage (V)

3. Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the
circuit resistance. Even when the same diode is measured, the measurement result varies with
measurement range.

Always use the range described in the repair manual for

measurement.

OD
Variable resistor

~ 1 Resistor

Range: x 10 (SW1)

Resistor

Range: x1 (SW2)

(BIop~",""", 1.5 V

o
8
Red Black
 0-11

STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. For tightening torque of hexagon head bolt, welded bolt and stud bolt with the standard bearing surface, identify
bolt class based on the below chart and then determine using the tightening torque table.

2. For tightening torque of hexagon flange bolts, identify bolt class based on the below chart and then determine
using the tightening torque table.
3. For tightening torque of nuts, check the mating bolt and use the method 1.

BOLT STRENGTH CLASS IDENTIFICATION METHOD

Identification by Bolt Shape

~ Shape and class Class

4 = 4T
I @- Boil head No.
5
6
= 5T
= 6T
7 = 7T
8 = 8T

Hexagon head bolt

0 No mark 4T

CD Two protruding lines 5T

~ Three protruding lines 7T

~ Four protruding lines 8T

.: ::, elded bolt

0 4T

~Nommk 4T

Stud bolt

~Gcooved 6T
I
0-12

Identification by Part No.

Part No. Shape

---------------
Hexagon head bolt 1
91611-40625
[C Length (mm)
Diameter (mm)
~
~

'----
I\\~\\~I\\ II\\\~VWI\I 11\

Length
Diameter

Class

Stud bolt iT
92132-40614
T
Length (mm)
Diameter (mm)
~\\\\\\\\I\\I\\\\\\\I ~\\\\\\\\\\\\\\\\\\\~
.. I
Diameter

I. Lengm .1
'------Class

Tightening Torque Table

Diameter Pitch Specified torque i

Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.4 55 4
8 1.25 13 130 9
10 1.25 25 260 19
4T
12 1.25 47 480 35
14 1.5 75 760 55
16 1.5 113 1150 83
6 10 6.5 65 5
8 1.25 16 160 12
10 1.25 32 330 24
5T
12 1.25 59 600 43
14 1.5 91 930 67
16 1.5 137 1400 101
6 1.0 7.8 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6T
12 1.25 72 730 53
14 1.5 108 1100 80
16 1.5 172 1750 127
6 1.0 11 110 8
8 1.25 25 260 19
10 1.25 52 530 38
7T
12 1.25 95 970 70
14 1.5 147 1500 108
16 1.5 226 2300 166
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8T
12 1.25 108 1100 80
14 1.5 172 1750 127
16 15 265 2700 195
 0-13

Identification by Bolt Shape (Hexagon flange bolt)

Class 4.8T 6.8T 8.8T 10.9T 11.9T

£2 CD 0 C) e
Hexagon flange bolt

~
0 0 ~

2:: 0 V - -

I 0
Tightening Torque Table (Hexagon flange bolt)

Diameter Pitch Specified torque

Class
mm mm N·m kgf-cm ft-lbf
6 1.0 5.5 56 4
8 1.25 13 130 9
10 1.25 27 280 20
4.8T
12 1.25 50 510 37
14 1.5 78 800 58
16 1.5 120 1220 88
6 1.0 7.5 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6.8T
12 1.25 71 720 52
14 1.5 110 1120 81
16 1.5 170 1730 125
6 1.0 12 120 9
8 1.25 29 300 22
10 125 61 620 45
8.8T
12 125 110 1120 81
14 1.5 175 1780 129
16 1.5 270 2750 199
6 10 15.5 160 12
8 1.25 38 390 28
10 125 80 820 59
10.9T
12 125 145 1480 107
14 1.5 230 2350 170
16 1.5 360 3670 266
6 1.0 17.5 180 13
8 1.25 42 430 31
10 1.25 89 910 66
11.9T
12 125 160 1630 118
14 1.5 260 2650 192
16 1.5 400 4080 295
0-14

PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)

1. Do not use the precoat bolt as it is in either of the following

cases:

(1) After it is removed.

(2) When the precoat bolt is moved (loosened or tightened)

Seal lock agent
by tightness check, etc.

Note:
For torque check, use the lower limit of the allowable
tightening torque range. If the bolt moves, retighten it
according to the steps below.

2. Method for reuse of precoat bolts

(1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt)

(2) Perfectly dry the washed parts by air blowing.

(3) Coat the specified seal lock agent to the threaded portion
of the bolt

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth
to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before
installation.

2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.

3. The maximum tightening torque must not exceed twice the standard tightening torque.

Nominal diameter Standard tightening torque N'm (kgf-cm) [ft'lb!] Hose inside
of screw Standard Tightening range diameter mm (in)
7/16 - 20UNF 25 (250) [18.1] 24 - 26 (240 - 270) [17.4 - 19.5J 6 (0.24)
9/16 -18UNF 34 (350) [25.3] 32 - 36 (330 - 370) [29.3 - 26.8] 9 (0.35)
3/4- 16UNF 59 (600) [43.4J 56 - 62 (570 - 630) [41.2 - 45.6] 12 (0.47)
7/8 -14UNF 59 (600) [43.4] 56 - 62 (570 - 630) [41.2 - 45.6] 12 (0.47)
7/8-14UNF 78 (800) [57.9] 74 - 82 (740 - 840) [53.5 - 60.8] 15 (0.59)
1-1/16 - 12UNF 118 (1200) [86.8] 112 - 123 (1140 - 1250) [82.5 - 90.4] 19 (0.75)
1·5/16 -12UNF 137 (1400) [101.3J 130 - 144 (1330 - 1470) [96.2 -106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 - 26 (240 - 270) [17.4 - 19.5J 6 (0.24)
PF3/8 34 (350) [25.3J 32 - 36 (330 - 370) [23.9 - 268] 9 (0.35)
PF1/2 59 (600) [43.4J 56 - 62 (570 - 630) [41.2 - 456] 12 (0.47)
PF3/4 118 (1200) [86.8J 112 - 123 (1140 -1250) [82.5 - 90A] 19 (0.75)
PF1 137 (1400) [101.3] 130 - 144 (1330 - 1470) [96.2 - 106.4] 25 (0.98)
 0-15

WIRE ROPE SUSPENSION ANGLE LIST

Suspension Suspension
Lifting angle Tension Compression Lifting angle Tension Compression
method method

00 0
100 time o time 90 1.41 time 1.00 time
0
90
t
~~~~
SI 2t ~·1 2t I

I
30
0
1.04 time 0.27 time

~l
;l\"'2t I
120
0
2.00 time

I
1.73 time

~~M
r 2t
120°

0
60 1.16time 0.58 time
60°

",."~~/\ 2t

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit· N (tf) [Ibf]
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load 0 0 0 0 0
00 00 30 60 90 00 30 60 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6mm
(2.18) (031 ) (0.62) (06) (053) (0.44) (1.24) . (1.2) (1.06) (0.88)
(0.24 in)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8mm
(3.21 ) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0.32 in)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71 ) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0.4 in)
[11.69] [15656] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (15) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]
0-16

COMPONENTS WEIGHT
Component Weight kg (lb)
4Y 135 (298)
Engine 1DZ-111 163 (359)
3Z 212 (467)
TIC (1 speed) 62 (137)
Transmission
TIC (2 stator TIC) 130 (287)
1.5 ton model Approx. 770 (1698)
1.75 ton model Approx. 900 (1985)
2.0 ton model Approx. 1165 (2569)
Counter weight 2.5 ton model Approx. 1520 (3352)
3.0 ton model Approx. 1915 (4223)
K2.0 ton model Approx. 1260 (2778)
J3.5 ton model Approx. 2215 (4890)
1 ton series Approx. 330 (728)

V mast ASSY Llbackrest and fork 2 ton series Approx. 470 (1036)
(with lift cylinder, max. lifting height: 3 ton series Approx. 520 (1147)
3000 mm (118 in») K2 ton series A nrox. 430 1948\
J3.5 ton series Approx. 610 (1345)
 0-17

RECOMMENDED LUBRICANT QUANTITY & TYPES

Description Application Quantity e (US gal) Classification Type
Motor oil
API
Gasoline 4Y 4.0 (1.06) SAE30
SH, SJ, SL, SM
SAE10W-30
Engine
1DZ-111 7.9 (2.09) Diesel engine oil
API
Diesel SAE30
3Z 9.0 (2.38) CE, CF, CF-4
SAE10W-30
TIC (1 speed) 6.0 (1.58)
Transmission ATF GM Dexronfu 11
TIC (2 stator TIC) 10.0 (2.64)
1 ton series 5.8 (1.53)
2 ton series 6.1 (1.61),6.4 (1.69)*
API Hypoid gear oil
Differential K2 ton series 5.8 (1.53) GL-4 SAE85W-90
3 ton series,
8.2 (2.16), 8.4 (2.22)*
J3.5 ton series
1 ton series 30 (7.9)
Hydraulic oil 2 ton series 33 (8.7)
ISO
(V mast, max lifting height K2 ton series 33 (8.7) Hydraulic oil
VG32
3000 mm (118 in))
3 ton series,
34 (9.0)
J3.5 ton series
1 ton series 45 (11.9)
K2 ton series 55 (14.5)
Fuel tank --
2·3 ton series
60 (15.8)
J3.5 ton series
Proper quantity
SAE J-1703
Brake line All models Resef\(oir Tank --
DOT-3
0.2 (0.05)
Brake cooling oil' 2·3·J3.5 ton series 8.0 (2.11) -- Shell DONAX TD
• MP grease
Chassis parts All models Proper quantity -- • Molybdenum
disulfide grease
• LLC 30-50% mixture
(for winter or
allseason)
Coolant
Attached Table 1 Coolant volume LLC • Coolant with
(excluding reservoir tank)
rustinhibitor
(for spring, summer
and autumn)
0.47 (0124)
Coolant (Reservoir Tank) All models t t
(at Full level)

*: Only wet brake models

Note:
Since the hydraulic oil volume varies with the mast specification, be sure to check finally with the level
gauge.

Attached Table 1 Coolant volume Unit: e (US gal)

Engine 1 ton series K2 ton series 2·3 ton series J3.5 ton series
4Y 8.13 (2.15) 8.13 (2.15) 9.28 (2.45) 9.28 (2.45)
1DZ-111
3Z
6.77 (1.79)

---------- -------
6.77 (1.79) 7.91 (2.09)
8.83 (2.33)
---------
8.83 (2.33)
0-18

LUBRICATION CHART
STD Model

(14 ) G G (14 )
(1 ) (1 )
(13) (13)
(3) (3)
(4) (2)
(12) (15)

(10) (5)
(16) (8)
~,
(7) (9)
(6) ~N (7)
'---=+~~--d..---h---~
(17) ~/(~ "t--+----+--+---I (6)
(18) (17)
(11 ) G (18 )
-r--~
L_

11

III

IV
'---------;:::======V=====~-------)
*. For the engine oil grades listed below, change oil every 500 hours,
Gasoline vehicle: APt SL, SM and above
Diesel vehicle: API CF-4 and above

o Inspection
• Replacement
I Inspect every 8 hours (daily)
A MP grease
11 Inspect every 40 hours (weekly)
B Engine oil
III Inspect every 250 hours (6 weeks)
C Hypoid gear oil
IV Inspect every 1000 hours (6 monthly)
D Hydraulic oil
V Inspect every 2000 hours (annual)
E Automatic transmission fluid
F Brake fluid
G Molybdenum disulfide grease

1 Chain 10 Rear axle beam front pin

2 Differential 11 Rear axle beam rear pin
3 Front wheel bearing 12 Tilt steering locking mechanism
4 Brake master cylinder 13 Mast support bushing
5 Torque converter case 14 Tilt cylinder front pin
6 Rear wheel bearing 15 Propeller shaft
7 Steering knuckle king pin 16 Swing lock cylinder lower pin
8 Oil tank 17 Tie rod end pin
9 Engine crank case 18 Rear axle cylinder end pin
 0-19

Wet Brake Model

(14) G (14)
(1 ) (1 )
(13 ) (13)
(3) (3)
(2)
(12) (15)
~
(4)
(10) (5)
(16) (8)
(7) (9)
(6) (7)
(17) (6)
(18) - (17)
(11 ) (18)

11

[ III

l~ IV

*. For the engine oil grades lisled below, change oil every 500 hours.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above

o Inspection
• Replacement
I Inspect every 8 hours (daily)
A MP grease
11 Inspect every 40 hours (weekly)
B Engine oil
III Inspect every 250 hours (6 weeks)
C Hypoid gear oil
IV Inspect every 1000 hours (6 monthly)
o Hydraulic oil V Inspect every 2000 hours (annual)
E Automatic transmission fluid
F Shell DONAX TO
G Molybdenum disulfide grease

1 Chain 10 Rear axle beam fronl pin

2 Differential 11 Rear axle beam rear pin
3 Front wheel bearing 12 Tilt steering locking mechanism
4 Brake cooling oil lank 13 Mast support bushing
5 Torque converter case 14 Tilt cylinder front pin
6 Rear wheel bearing 15 Propeller shaft
7 Steering knuckle king pin 16 Swing lock cylinder lower pin
8 Oil tank 17 Tie rod end pin
9 Engine crank case 18 Rear axle cylinder end pin
0-20

PERIODIC MAINTENANCE

INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M: Measurement. Repair or adjustment if required.
T: Retightening C: Cleaning L: Lubrication
*: For new vehicle *1: Flaw detector

e,~---_======,~e:o~e"Od
Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ENG!NE
Proper starting and abnormal noise 1* I f- ,-
Rotating condition at idling M* M +-- f-

Rotating condition during acceleration M* M f- +--

Exhaust gas condition 1* I f- f-

Main body Air cleaner element C* C f- f-

Valve clearance (1 DZ-III·3Z) M* M

Compression M
Cylinder head bolt loosening T
Muffler rubber mount I
PCV system Clogging and damage in PCV valve and piping 1* I +-- f-

Governor No-load maximum rpm M* M f- f-

Oil leak 1* I f- f-
Lubrication
Oil level 1* I +-- +--
system
Clogging and dirt of oil filter I +-- f-

Fuel leak 1* I +-- f-

Dirt and clogging of fuel filter and element I +-- f-

Fuel system Injection timing M +--

Injection nozzle injection pressure and spray status M
Draining of sedimenter I f-

Coolant level in radiator and leak 1* I +-- +--

Rubber hose degradation 1* I f- +--
Cooling system Radiator cap condition 1* I +-- +--
Fan belt tension, looseness and damage 1* I +-- +--
Radiator rubber mount I
Filter I f-

DPF muffler Inline filter (for back pressure sensor) I ,- f-

DPF valve C
Pipe and joint gas leak 1* I +-- f-

Pipe and joint damage I f- f-

LPG fuel system Regulator tar removal I f- f-

LPG container installation section looseness and

I f- +--
damage.
I'

0-21

~
--_~ ~_________~~nssppee~c~tio~nPeen<riod , ~_E~V~e~ry_--I
6 weeks _3_E_V_e_ry_--+_~E_V~e_ry
r- months _ _+-_E_V_e_ry
6 months __
12 months -j

Every Every Every Every

Item 250 hours 500 hours 1000 hours 2000 hours
Exhaust gas concentration measurement
(carbon monoxide (CO:0.2% or less) and M
hydrocarbon (HC:100 ppm or less))
Exhaust system piping looseness and damage
3-Way catalytic Vacuum piping damage
converter system
Vacuum sensor damage
Coolant temperature sensor damage
Injector damage and cleaning (LPG vehicle)
Register damage (LPG vehicle)
Actuator damage +--
Travel and load
Axle pedal sensor and switch damage
handling control
Traveling speed sensor damage
.JWER TRANSMISSION SYSTEM

IomeC""".'
Leak

IOJllevel
Bolt loosening
I: T
Leak
Fluid level
Torque Operating mechanism function and looseness
converter &
transmission Control valve and clutch functions
Inching valve function
Stall and hydraulic pressure measurement M
Loose joint T
Propeller shaft Looseness at spline connections
and axle shaft Looseness of universal joint
Twisting and cracks of axle shaft
DRIVE SYSTEM
Tire inflation pressure M
Tire cuts, damage and uneven wearing I
Loose rim and hub nuts T (---

Tire groove depth M* M

Metal chips, pebbles and other foreign matter
Wheels 1*
trapped in tire grooves
Rim, side bearing and disc wheel damage 1*
Abnormal sound and looseness of front wheel
1*
bearing
Abnormal sound and looseness of rear wheel
1* (---
bearing
Front axle Cracks, damage and deformation of housing
Cracks, damage and deformation of beam
Rear axle Looseness of axle beam in vehicle longitudinal
M
direction
STEERING SYSTEM
Play and looseness 1*
Steering wheel
Function 1*
0-22

:-~___________ ,n,:eGt,on~rjOd Every Every Every Every

6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Oil leak 1* I +- «-
Steering valve
Looseness of mounting T* T +- +-
Oil leak 1 +- «-
Power steering Mounting and linkage looseness 1 +- «-
Damage of power steering hose I
King pin looseness 1 +- +-
Knuckle
Cracks and deformation I
BRAKING SYSTEM
Play and reserve M +- «-
Brake pedal
Braking effect 1 +-~ «-
Operating force I +- «-
Braking effect I f-- +-
Parking brake
Linkage and cable looseness and damage 1* 1 f-- «-
Grease applied to parking brake pedal release pin L
Brake pipe Leak, damage and mounting condition I f-- «-
Reservoir tank Leak and fluid level I +- «-
Master cylinder
Function, wear, damage, leak and mounting
and wheel I
looseness
cylinder
Clearance between drum and lining M t"" +-
Wear of shoe sliding portion and lining I
Drum wear and damage I
Brake drum and
Shoe operating condition I
brake shoe
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Deformation, cracks and damage I
Backing plate .
Loose mounting T
Oil leak I +- «-
Cooling oil level in tank I f-- (-

Accumulator operation 1
Wet brake
Brake valve function, damage, or looseness in the
I
installed parts
Brake disc clearance adjustment (disc wear) 1
 0-23

~ _______~__ :pect~p~Od Every

6 weeks
Every
Every
3 months
Every
Every
6 months
Every
Every
12 months
Every
Item 250 hours 500 hours 1000 hours 2000 hours
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I (- (-

Forks Misalignment between left and right fork fingers I (- (-

Cracks at fork root and welded part (1

Deformation and damage of each part and crack at
I (- (-
welded part
Mast and lift bracket looseness I (- (-

~,,1ast and lift Wear and damage of mast support bushing i

bracket
Wear, damage and rotating condition of rollers I (- (-

Wear and damage of roller pins I

Wear and damage of mast trip I (- (-

Tension, deformation and damage of chain 1* I (- (-

Chain lubrication I (- (-

Chain and chain

Elongation of chain I
wheel
Abnormality of chain anchor bolt I (- (-

Wear, damage and rotating condition of chain wheel I (- (-

Various
Abnormality and mounting condition of each part I (- (-
attachments
HYDRAULIC SYSTEM
Loosening and damage of cylinder mounting T (- (-

Deformation and damage of rod, rod screw and rod

I (- (-
end
Cylinder operation I (- (-

Cylinder Natural drop and natural forward tilt (hydraulic drift) M (- (-

Oil leak and damage I (- (-

Wear and damage of pin and pin support I (- (-

Lifting speed M (- (-

Uneven movement I (- (-

Oil pump Oil leak and abnormal sound I (- (-

Oil level and contamination I (- <-

Hydraulic oil tank Tank and oil strainer C (-

Oil leak I (-- (--

Loose linkage I (-- (-

Control lever
Operation I (- (-

Oil leak I I (-- (-

Oil control valve Relief pressure measurement M

Relief valve and tilt lock valve functions I (-- (-

Oil leak I (-- (-

Hydraulic piping Deformation and damage I (-- (-

Loose joint T +- (--

0-24

":-~_~~_____'"S~e:,o~penOd
Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Cracks on distributor cap 1* I +---- +----
Spark plug burning and gap 1* I (- +----
Distributor side terminal burning 1* I +---- +----
Ignition timing
Distributor cap center piece wear and damage 1* I +---- +----
Plug cord internal discontinuity I
Ignition timing M +----
Starting motor Pinion gear meshing status I' I +---- +----
Charger Charging function I' I +---- +----
f------
Battery fluid level I +---- +----
Battery
Battery fluid specific gravity M +----
Damage of wiring harness I +---- +---- (
Electrical wiring
Fuses I +---- +----
Open-circuit in glow plug I +----
Preheater
Open-circuit in intake heater I +----
Engine stopping
Diesel engine key stop device function I +---- +----
system
SAFETY DEVICES, ETC
Cracks at welded portion I +---- +----
Head guard
Deformation and damage I +---- +----
Loosening of mounting T +---- +----
Back-rest
Deformation, crack and damage I +---- +----
Lighting system Function and mounting condition I +---- +----
Horn Function and mounting condition I +---- +----
Direction indicator Function and mounting condition I +---- +----
Instruments Functions I +---- +----
Backup buzzer Function and mounting condition I +----. +---- (
Dirt, damage I +---- +----
Rear-view mirror
Rear reflection status I +---- +----
Loosening and damage of mounting I +---- +----
Seat Seatbelt damage and function I +---- +----
Seat switch function I +---- +----
OPS Functions I (-- +----
Damage and cracks of frame, cross members, etc. I
Body
Bolt looseness T
Functions I +---- +----
Loosening and damage at sensor mounting portion I +---- +----
Damage, deformation, oil leakage and loosening of
SAS I +---- +----
the mounting of functional parts
Loosening and damage of wire harnesses I +---- +----
Lock cylinder accumulator performance I
Others Grease up L +---- +----
 0-25

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

0: Replacement

~~~ _ _ _ ~____ _____ lnte"al

Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Engine oil 0'2 <- +- +-
Engine oil filter 0'1
• +- +-
Engine coolant (every 2 years for LLC)
Fuel filter
• +-
0
+-
+-
Torque converter oil
Torque converter oil filter
•
0
<-
+-
Differential oil 0
Hydraulic oil 0 +-
Hydraulic oil filter 0'1
• +-
,v'heel bearing grease
Spark plugs 0
•
+-
Air cleaner element
•
Cups and seals for brake master and wheel cylinders
•
Brake fluid
Power steering hoses
• +-
.'3

Power steering rubbers parts .'3

Hydraulic hoses .*3

Brake fluid reservoir tank hose 0'3

Fuel hoses .*3

Torque converter rubber hoses .'3

Chains .'4

Oil pump seal for material handling .'4

"~PF Mafler filter (OPT) .'4

DPF Mafler back pressure sensor inline filter (OPT)

DPF Air cleaner (OPT)
• +-
.'3

SAS Swing lock cylinder .'5

Catalytic mafler (OPT)

3-way catalytic muffler (OPT)
•
.'6

Wet brake cooling oil (OPT) .'1

• <-
Wet brake valve seal (OPT)
Wet brake cooling hose (OPT)
•
.'3

Wet brake piston seal (OPT) .'7

Wet brake disc and plate (OPT) .'7

Wet brake accumulator (OPT) 0'8

0-26

*1: For new vehicle

*2: For the engine oil grades listed below, change oil every 500 hours.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above
*3: Every 2 years
*4: Every 3 years
*5: Every 10000 hours
*6: Every 5 years or every 3500 hours
*7: Every 12000 hours
*8: Every 10 years

Replacement shall be made upon arrival of tt1e operation hours or months, wllichever is earlier.
 1-1

ENGINE
Page Page
ENGINE EXTERIOR ViEW 1-2 02 PEDAL (OPT) 1-38
ENGINE MAIN PARAMETERS 1-5 COMPONENTS 1-38
ENGINE PERFORMANCE DISASSEMBLY·INSPECTION·
REASSEMBLY 1-39
CURVES 1-7
ADJUSTMENT 1-41
ENGINE ASSY 1-10 TRAVEL AND LOAD HANDLING
REMOVAL·INSTALLATION 1-10 f""("\1II.1.0("'\1 nC\lIf""t:{(",\DT\
'-'''-'I''iI 1 1'''-'1- LJI- 11 1"-' \ ,,-,r 1 J
1_..1 'l
1--r..JI

AIR BLEEDING OF THE FUEL COMPONENTS 1-43

SYSTEM 1-13 REMOVAL·INSTALLATION 1-44
ENGINE THROTTLE OPENING DEGREE
. INSPECTION·ADJUSTMENT 1-14 ADJUSTMENT 1-46
4Y ENGINE 1-14 TROUBLESHOOTING 1-47
1DZ-I\I·3Z ENGINE 1-15 DPF-II SYSTEM (OPT) 1-49
AIR CLEANER 1-17 COMPONENTS 1-49
SPECIFICATIONS 1-17 CONNECTOR DIAGRAM 1-53
COMPONENTS 1-17 DPF MUFFLER
AIR CLEANER
REMOVAL·INSTALLATlON 1-55
CLEANING·INSPECTION 1-18 DPF MUFFLER DISASSEMBLY·
CLOGGING WARNING SYSTEM
INSPECTION·REASSEMBLY 1-56
INSPECTION (OPT) 1-19 CONTROLLER
REMOVAL·INSTALLATION 1-58
RADIATOR 1-20
BLOWER
COMPONENTS 1-20 REMOVAL·INSTALLATION 1-59
SPECIFICATIONS 1-24 DPF VALVE
COOLANT CAPACITY AND REMOVAL·INSTALLATION 1-60
ANTIFREEZE TABLE 1-24 DPF VALVE DISASSEMBLY·
COOLANT INSPECTION 1-24 INSPECTION·REASSEMBLY 1-61
MUFFLER & EXHAUST PIPE 1-26 INDIVIDUAL INSPECTION OF
FUNCTIONAL PARTS 1-62
COMPONENTS 1-26
CONTROLLER ERROR CODE
REMOVAL·INSTALLATION 1-29 CLEARING METHOD 1-66
MAINTENANCE OF CATALYTIC DPF FILTER MEMORY
MUFFLERS 1-29 CLEARING METHOD 1-66
BATTERY 1-30 REGENERATION METHOD 1-66
COMPONENTS 1-30 DISPLAY OF PAST
SPECIFICATIONS 1-31 ERROR CODES 1-67
INSPECTION 1-32 CLEARING OF PAST
ERROR CODES 1-68
FAN BELT TENSION
TROUBLESHOOTING 1-69
ADJUSTMENT 1-33
ENGINE CONTROLLER ASSY 1-94
ACCELERATOR PEDAL 1-35
ENGINE ECU (4Y) OR ASC
COMPONENTS 1-35 CONTROLLOER (1 DZ-III·3Z:0PT)
INSPECTION·ADJUSTMENT 1-36 REMOVAL·INSTALLATION 1-94
1-2

ENGINE EXTERIOR VIEW

4Y Engine
 DZ-II~I=En-·--------~ --------~ 1-3
gme .
1
1-4

3Z Engine
 1-5

ENGINE MAIN PARAMETERS

Gasoline Engine
Vehicle model
1·2·K2 ton series 3·J3.5 ton series
Item
Engine model 4Y r
Engine type GasolineA cycle r
In-line 4 cylinder, longitudinally
Number and arrangement of cylinders r
mounted
Combustion chamber type Wedge (-

Valve mechanism OHV·chain drive ,~

91.0 x 86.0
Bore x stroke mm (in) r
(3.583 x 3.386)
Total displacement cm 3 (in 3 ) 2237 (136.51) r
, Compression ratio 8.8 r
3ximum power Gasoline exclusive 38 (51)/2570 44 (59)/2570
kW (PS)/rpm LPG convertible/Gasoline 38 (51)/2570 43 (58)/2570
LPG convertible/LPG 38 (51 )/2570 42 (57)/2570
LPG exclusive 38 (51)/2570 42 (57)/2570
Maximum torque Gasoline exclusive 160 (16.3)/2100 165 (16.8)/2570
N-m (kgf·m)/rpm LPG convertible/Gasoline 160 (163)/2100 162 (16.5) 2570
LPG convertible/LPG 160 (16.3)/2100 160 (16.3) 2200
LPG exclusive 160 (16.3)/2100 160 (16.3) 2200
BSFC' Gasoline exclusive 298 (219)/2000 310(228)/1600
g/kW-h (g/PS-h)/rpm LPG convertible/Gasoline 298 (219)/2000 310 (228)/1600
LPG convertible/LPG 233 (171 )/2000 (-

LPG exclusive 233 (171 )/2000 (-

Service weight kg (Ib) 135 (298) (-

No-load maximum speed rpm 2570 r

.*. BSFC:Brake Specific Fuel Consumption·

1-6

Diesel Engine
odel
1·K2 ton series 2·3 ton series 2·3·J3.5 ton series
Item
Engine model 1DZ-1I1 +-- 3Z
Engine type Diesel' 4 cycle +-- +--
In-line 4 cylinder,
Number and arrangement of cylinders +-- +--
longitudinally mounted
Combustion chamber type Swirl chamber +-- +--
Valve mechanism OHV'gear drive +-- +--
86.0 x 107.0 98.0 x 115.0
Bore x stroke mm (in) <-
(3.386 x 4.213) (3.858 x 4.528)

Total displacement cm 3 (in 3 ) 2486 (151.71) +-- 3469 (211.69)

Compression ratio 21.5 +-- <-
Maximum power kW (PS)/rpm 38 (52)2400 41 (55) 2500 42(57)2200
Maximum torque N'm (kgf-m)/rpm 157 (160) 2300 157 (160) 2500 200 (20.4) 1600
BSFC* g/kW-h (g/PS-h)/rpm 250 (184) 1400 +-- 245 (180) 1000
Service weight kg (Ib) 163 (359) +-- 212 (467)
--_.
No-load maximum speed rpm 2600 2800 2400

*: BSFC:Brake Specific Fuel Consumption

 1-7

ENGINE PERFORMANCE CURVES

4Y Engine 1·2·K2 Ton Series

Gasoline (Exclusive-Converlible)
lBO
160N m(16. 3k [. m) 12100r m
LPG (Exclusive-Convertible)
170 160N- 00(16. 3k [- m) /2100r m

160

150 /
,- --
Torque /

140

130

120
(N· m)
3BkW (SIPS) 12570rpm
50
38kW (SIPS) 12570, m

40

30
Power
20

10

o
(kW)

BSFC

-------- ---
200
(g/kW'h)~~~~~~~
_ _~~~~~~~
10 15 20 25

4Y Engine 3·J3.5 Ton Series

190
Gasoline (Exclusive)
165N· m06. Bkgf- m) /2570T m Gasoline (Convertible with LPG)
lBO 162N- mOG. Sk r-m)/2510r rn LPG (Exclusive-Convertible)
170 160N· m(16. 3k [-m)/2200, m

160

150
Torque
140 Gasoline (Exclusive)
130
Gasoline (Convertible with LPG)
44k' (59PS) 12570r
(N- m) ID
LPG (Exclusive-Convertible)
43kW (5BPS) 12S70r ID
50
42kW(57PS)/2570r m

40

30

Power 20

10

o Gasoline (Exclusive-Convertible)
(kW)
LPG (Exclusive-Convertible)
500

3[Og/kW h (2lBg/PS- h) 11600rpm

400 233g/kW- h(l71g/PS· hi /2000rpm

BSFC 300

200
---
(g/k'l' h),~~~~~~~~~~~~~~~~
10 15 20 25 30
x 10'"
(rpm}
1-8

1DZ-III Engine 1·K2 Ton Series

180

170

160

Torque 150

140

130

120
(N- .)

50

40

30
Power
20

10
(kW)
250g/kW- h (l84g/PS- h) /1400rpm
280

270

260
BSFC
250

240
(g/kW h)

10 15 20 25 30
X 10 2
(rpm)

1DZ-III Engine 2·3 Ton Series

180

170

160

Torque 150

140

130

120
(N-m)

50 41kW (S5PS) /2500rpm

40

Power 30

20

10
(kW)

280

270

BSFC 260

250

240
(g/kW- h)

10 15 20 25 30
XlO"
(rpm)
 1-9

3Z Engine

210 20ON· m(20. 4kgf· m) /1600rprn

200

190

180

Torque 170

160

150

140
(N. m)

50

40

Power 30

20

la
(kW)

300

290

280

BSFC 270

260

250

240
(g/kW· h)

la 15 20 25 30
:--: 102-
(rpm)
1-10

ENGINE ASSY

REMOVAL -INSTALLATION
T = N·m (kgfcm) [ft·lbf]

\\ \

26
/ 12
28

Engine mount nut T = 532-980 (542-1000) [392-72.4]

End plate set bolt T = 49.0-78.4 (500-800) [36.2-57.9]
1DZ-II'·3Z: T = 76.4-93.1 (779-949) [56.4-68.7]
Drive plate set bolt (For connecting the engine crank shaft)
4Y: T = 56.8-64.7 (579-660) [41.9-47.7]
Drive plate set bolt (For connecting the torque converter) T = 14.7-21.6 (150-220) [10.9-15.9]
Torque converter housing set bolt T = 29.4-44.1 (300-450) [21.7-32.6]
 1-11

Removal Procedure
Remove the engine hood. (See page 9-10.)
2 Remove the lower panel and toe board.
3 Drain coolant.
4 Remove the battery.

5 Remove the sedimenter bracket set bolt to free the bracket. (1DZ-III'3Z engine vehicle)
6 Disconnect the accelerator wire
7 Disconnect the fuel hose.

8 Remove tile relay block bracket set bolt and free the relay block.
9 Remove the battery set plate.
10 Remove the air cleaner and air inlet.
11 Remove the exhaust cover plate.
1') Disconnect the exhaust pipe.

13 Disconnect the water hose.

14 Disconnect the TIC cooler hose [Point 1]

15 Remove the radiator and fan shroud
16 Remove the under cover.
17 Remove the wiring and wire harness clamps around the engine.
18 Remove the oil pump set bolt and free it
19 Remove the cover plate. [Point 2]
20 Remove the 6 drive plate set bolts [Point 3]
21 Remove the engine mount nuts

22 Slightly hoist the engine. [Point 4]

23 Support the torque converter housing with wooden blocks.
~4 Separate the torque converter housing and engine. [Point 5]
J Remove the engine ASSY.
26 Remove the drive plate.

27 Remove the torque converter end plate.

28 Remove the starting motor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply sealant (08833-76002-71 (08833-00080» before tightening the drive plate set bolt (for connecting
engine and crankshaft).
• Bleed air from the fuel system after installation of the engine ASSY. (1 DZ-III'3Z engine vehicle)
(See page 1-13.)
1-12

Point Operations
[Point 1]
Removal:
Put match marks on the radiator a~nd torque converter cooler
hose.

Cover plate [Point 2]

Removal:
Remove the cover plate~

[Point 3]
Removal·lnstallation:
Rotate the drive plate using the crank shaft pulley set bolt, and
remove the drive plate set bolt.

[Point 4]
Removal·lnstallation:
SST(2)
SST 09010-20111-71 ~ (1)
\
\ 09010-23320-71 ~ ~ (2)

Removal:
Temporarily hoist up until the mount bolt completely comes out
of the hole in the frame.
 1-13

[Point 5]
Removal:
Use a flat-head screwdriver for separation.
If the fitting is too tight, change the SST hook position and
adjust the engine angle for easier separation.

J\. AIR BLEEDING OF THE FUEL SYSTEM

1DZ-III·3Z Engine Vehicles Only
1. Perform air bleeding by moving the priming pump knob up and
down.
2. Once the pump operation becomes heavy, air bleeding is
completed.
1-14

ENGINE INSPECTION-ADJUSTMENT
Note:
• Warm up the engine beforehand, and proceed with inspection and adjustment when the vehicle is in the
following state:
• Coolant temperature: 75°C (167°F) or above, engine oil temperature: 60°C (140°F) or above, hydraulic oil
temperature: 50°C (122°F) or above

4Y ENGINE
Note:
Adjustment is not necessary. The engine speed is
electronically controlled.
If the engine speed is not within the specified range, there
may be malfunctioning components. In this case,
troubleshoot for the malfunctioning components. (See
section 19.)

Idle Speed Inspection

1. Attach a rev counter to the terminal for measuring engil)··
speed (Rev terminal).
2. Inspect the idle speed.
Standard: 750 ± 30 rpm (For both gasoline and LPG)

No-load Maximum Speed Inpsection

1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator is fully pressed down.
Standard: 2570 ± 35rpm (For both gasoline and LPG)
 1-15

Ignition Timing Inspection'Adjustment

1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Inspect the idle speed.
Standard: 750 ± 30 rpm
3. Install the timing light.
4. Use the SST to short circuit terminals TC and El of the
diagnostic connector.
Diagnostic connector
SST 09238-13130-71

Caution:
If the short circuit positions are incorrect, this will cause a
fault. Make sure to short circuit the correct terminals.

5. Inspect the ignition timing.

If the standard is not met, loosen the distributor set bolt and
rotate the distributor to adjust the ignition timing to the
standard value.
Standard: r (BTDC) (For both gasoline and LP G)

1DZ-III·3Z ENGINE
Idle Speed Inspection'Adjustment
1. Install the rev counter.

2. Check the return of the accelerator wire, and also check that
the injection pump idle adjusting screw is in contact with the
accelerator lever.
3. Inspect the idle speed.
Standard
1DZ-III: 750 ± 25 rpm
3Z: 775 ± 25 rpm
4. If the standard is not met, loosen the lock nut and adjust with
the idle adjusting screw.

5. Tighten the lock nut, and inspect the idle speed again.
1-16

Maximum adjusting screw

No-load Maximum Speed Inspection-Adjustment
1. Install the rev counter.
2. Inspect the no-load maximum speed.
(1) While the engine is at standstill, press down the
accelerator fully, and check that the adjusting lever is
touching the maximum adjusting screw.
(2) Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator pedal is fully
pressed down.
Standard
3Z: 2400 ± 50 rpm
1DZ-11I:
1·K2 ton series: 2600 ± 50 rpm
2-3 ton series: 2800 ± 50 rpm
In the case of vehicles equipped with travel and load handlin~
control, the rpm tolerance is ~~8.
3. Adjust the no-load maximum speed.
Remove the sealing of the maximum adjusting screw,
adjust by turning it.

4. Inspect the relief down amount.

(1) Operate the tilt lever to fully backward at the maximum
engine speed, and measure the engine speed upon full
relief. Measure the decrease (relief down) in the engine
rpm.
Standard: Within 200 rpm
5. Seal the set screw.
 1-17

AIR CLEANER
SPECIFICATIONS
Single (STD) Double (OPT)
Type Cyclone type ~

Size 7-inch ~

Intake type Fresh air introduction type ~

Outer 18600 (2883)

Filtering area cm 2 (in 2 ) 18600 (2883)
Inner 510 (79.1)

. Others With evacuator valve ~

COMPONENTS

1703
02
1" ...... - - - - - - - - - - ' - 1 - - - - - - - - -...... "1
•• •••
•I

20B

: 23 :
•IL. ...... - - - - - - - - - - - - - - - - - - - ...... ..I•

1703-501
1-18

AIR CLEANER CLEANING·INSPECTION

1. Open the engine hood.
2. Remove the element.
Note:
In case of the double element type (OPT), do not remove the
inner element for other than replacement.

3. Clean the element.

(1) For ordinary cleaning, blow with compressed air [690 kPa
(7 kgflcm 2 ) [100 psi] or less] vertically along the pleats
from the inside of the element.
If heavily contaminated, washing is possible.

(2) Element washing method

Dissolve neutral detergent in tepid water (approx. 40°C
(104°F)) and immerse the element in it for about 30
minutes. Then, rinse the element well with clear water.
[Water pressure: 275 kPa (2.8 kgf/cm 2 ) [40 psi] or less]
After washing, naturally dry the element or dry the
element with a dryer (cold air).
Note:
• Do not damage the paper filter during washing.
• Never use compressed air or hot air for drying.

4. Clean the evacuator valve (dust discharge valve).

Hold the tip end of the evacuator valve and discharge dust anlJ
dirt from the inside of the valve.
5. Inspect the element.
After cleaning, place an electric bulb in the element to inspect
any damage in the element. If any pinhole, tear or damage is
found, replace it with a new element.
6. Element replacement
Replace the element after it is waslled six times or generally at
intervals of 12 months.
 1-19

7. Install the element.

Install the evacuator valve in the illustrated direction.

CLOGGING WARNING SYSTEM

INSPECTION (OPT)
1. Warning lamp inspection
(1) Check that the air cleaner warning lamp comes on when
the ignition key switch is turned ON and goes out when
the engine starts.

2. Individual inspection
(1) Use a mity vac to apply a negative pressure to the
vacuum switch, and inspect for continuity.
Standard
4Y engine vehicle
2630-3218 Pa (270-330 mmAq) (19.9-24.3 mmHg):
continuity exists
1DZ-III·3Z engine vehicles
6904-8042 Pa(704-820 mmAq) (51.7-60.3 mmHg):
continuity exists
1-20

RADIATOR

COMPONENTS
4Y (1-K2 ton series)

1603

54

1603-531

4Y (2 ton series)

1603

1603·532
 1-21

4Y(3·J3.5 ton series)

1603
(PREMIUM CABIN), --,

i~ B:U i
i ~

L" _
10

BD

~-BX

I .

1603-533

1DZ-III (1·K2 ton series)

1603

I.

BO
~

Ef
54

~
54

1603-524
1-22

1DZ-III (2 ton series) 1603

(PREMIUM CABIN)

~ BU

Ba

~BX 47

54

1603-525

1DZ-III (3 ton series)

1603
(PREMIUM C~~A_B~IN)__ ~
BU- - - I
1 !
10 I
KJ---.)il

I I
I
" -

1603-526
 1-23

3Z

1603

I
I

64
Ba
~
47
,p'"--BX

1603·530
1-24

SPECIFICATIONS
Type Crossflow
Fin type Corrugated fin
Coolant capacity (in radiator) See the table below
Cap opening pressure 2 88 ± 14.7 (09 ± 015) [13 ± 2.1]
kPa (kgf/cm ) [psi]
Others Built in torque converter cooler

COOLANT CAPACITY AND ANTIFREEZE TABLE

Unit: I' (US gal)
30% Antifreeze 50% Antifreeze
Tota! coolant Antirust mixture
Radiator capacity mixture mixture
capacity 5%
(down to-15°C) (down to -35°C)

1 ton 4Y 26 (0.69) 8.1 (2.15) 2.4 (0.63) 4.1 (108) 0.4 (0.11)
series 1DZ-111 2.6 (0.69) 6.8 (1.79) 2.0 (0.53) 3.4 (0.90) 03 (0.08)

K2ton 4Y 2.6 (0.69) 8.1 (2.13) 2.4 (0.63) 4.1 (108) 0.4 (0.11)
I
series 1DZ-111 2.6 (0.69) 6.8 (1.79) 2.0 (0.53) 3.4 (0.90) 03 (0.08)

2·3·J3.5 4Y 37 (0.98) 9.3 (2.45) 2.8 (0.74) 4.6 (1.21) 05 (0.13)

ton 1DZ-111 3.7 (0.98) 7.9 (2.09) 2.4 (0.63) 4.0 (106) 0.4 (0.11)
series
I
3Z 3.7 (0.98) 8.8 (2.33) 2.6 (0.69) 4.4 (1.16) 0.4 (0.11)

Note:
• The total coolant capacity does not include the capacity of the reservoir tank.
• Reservoir tank capacity: 0.47 f. (0.124 US gal) (at FULL mark position)

COOLANT INSPECTION
1. Inspect the coolant level.
Check that the coolant level is between FULL and LOW in the
radiator reservoir tank.

2. Measure the coolant concentration. (LLC)

(1) Measure the temperature and specific gravity of the
coolant.
Note:
The coolant concentration must be 30% (STD:50%) or above.
 1-25

(2) Find the concentration of the coolant from the table on the
50% (approximately -38°C) left,
40% (approximately -26°C)
Note:
30% (approximately -16°C
This graph shows the relationship between coolant
1,090 ~
~----.
f temperature and specific gravity at concentrations of 30, 40

1,080
i'--- and 50%.
j' ~! For example when the coolant temperature is 55°C and the
specific gravity is 1.035, the coolant concentration at this ti me
1,070
I-- ~ I
"" ~ can be found as follows:

~
'3
1,060

1,050
r-...
-..........
7' ~
~
~
The intersection point of 55°C and 1.035 is between the 30%
line and 40% line, so this point is approximately 35%. In other

ljA '"
~
0) 1,040
fl---- ...... ~ i'.. words, the concentration is approximately 35%.
u f--- - - -
~ "- 3. Check that there is no oil etc. mixed in 'vvith the coolant.
~
Z0 1,030 1'-.
[''''
Cl
U)
1,020

1,010
I
I
J

I
~
~'"
1,000
I
-
o 10 20 30 40 55 I 60 70 80
55
Measured temperature (QC)
1-26

MUFFLER & EXHAUST PIPE

COMPONENTS

4Y (1·K2 ton series)

1702

jJ'--HZ
<g>-AG
~-42

40

Q(;P-- .
"'-~~
~'
FR

1702-492

4Y (2 ton series)

1702

01
':j'-HZ
:;;~AG
i
@-42

1702496
4Y (3·J3.5 ton series)

r 1702

1702-499

1 DZ-1I1 (1·K2 ton series)

1702
(CATALTIle, 3-WA~~!-A~'0~~L
-------- I

01
i,
---I

~~~-----"

20

40
J---a:::) _
/_,~~_\
I /"
()~/
""'(
FR
1702461
1-28

1DZ-III-3Z (2 ton series)

1702

----- ---,
(CATALYTIC, 3-WAY CATALYTIC)
r~-

1([········7
I :'---.... .
II ,\;.
"_". (l~.~
~~~
I ~_~__ .--.J

O-HZ
u
01
, ~>-AG
@l -42

1702-485

1DZ-III (3 ton series) . 3Z(3·J3.5 ton series)

1702

(e
I(CATALYTIC, 3-WAY-_._\
CATALYTIC)

I 0,1 ~
I <';I~-... (.i..-_~!~
I_~ .J

1702-487
 1-29

REMOVAL-INSTALLATION
Note:
The muffler can be removed by either of the two methods shown below.
(1)Remove the muffler after removing the counterweight.
(2) Remove the muffler after removing the radiator W! counterweight.
Here, method (1) is explained.

2
/

Removal Procedure
1 Remove the counterweight (See page 9-11.)
2 Separate the union between the exhaust pipe and muffler.
3 Remove the exhaust pipe fixation bolts.
4 Remove the muffler.
5 Disconnect the tail pipe from the muffler.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Use a new gasket.

MAINTENANCE OF CATALYTIC MUFFLERS

For diesel vehicles, replace the muffler ASSY every year or every 2000 hours.
For gasoline vehicles, replace the 3-way catalytic muffler ASSY every 5 years or every 3500 hours.
1-30

BATTERY

COMPONENTS

4Y

1901

1901-336

1DZ-III

1901

1901-334
 1-31

3Z

1901
li>--DY

1901-335

SPECIFICATIONS

Battery type list (The battery is selected according to the equipped engine).

,,p~:~:::e----~ ___~_~Eng,":
•.-:Opeciffication
Engine
STD
4Y
High capacity
battery
1DZ-111

STD STD
3Z

Cold weather

VARTA VARTA VARTA VARTA VARTA

Battery Type
540200036 562019048 574012068 600131 080 610200085
JIS 34B19L(S) 55D23L 95D31L 115D31L 130E41L
Voltage V 12 +- +- <c- <c-

20-hour rated capaxity Ah 36 60 75 100 110

Specific gravity of battery fluid in use
1.280 +- +--- +- <c-
(at 20°C (68°F))
Battery weight kg (Ib) 10.6 (23.4) 15.3 (33.7) 193 (42.6) 23.2 (51.2) 25.8 (56.9)
1-32

INSPECTION
1. Inspect the battery fluid level.
Inspect that the battery fluid level is between the UPPER and
LOWER lines. Add distilled water if insufficient. Do not overfill
above the upper fluid limit.

2. Inspect the specific gravity of the battery fluid.

Use a hydrometer to measure the specific gravity of the baitery
fluid.

Standard: 1.280 (at 20°C (68°F))

Calculating equation
=
S20 St + 0.0007 (t-20)
S20: Specific gravity converted to 20°C (68°F)
St: Measured specific gravity at ec
t: Fluid temperature at the time of measurement

3. Inspect the battery terminals.

If battery terminals are contaminated to white, clean then and
apply a thin coat of MP grease on terminals.

4. Inspect the battery terminals and the harness connecting

portions for loosening.
Retighten the battery terminals and the harness connecting
portions.

Battery Removal
1. Disconnect battery terminals.
Note:
Disconnect the negative terminal first.

2. Remove the battery stopper.

3. Remove the battery.

Battery Installation
The installation procedure is the reverse of the removal procedure.
 1-33

FAN BELT TENSION ADJUSTMENT

Fan Pulley
1. Inspect the fan belt tension.
Standard
[amount of deflection when pressed with force of 98 N (10
kgf)]
4Y: 8-13 mm (0.31-0.51 in)
1 DZ-III: 8-13 mm (0.31-0.51 in)
3Z: 8-9 mm (0.31-0.35 in) (Reference)*
*: For 3Z engine vehicles (without cooler), follow the
adjustment procedure (step 2) to meet this standard.
4Y·1 DZ-1I1 3Z

Vehicles with cooler (OPT)

Standard
[amount of deflection when pressed with force of 98 N (10
kgf)]
4Y
A: 8-13 mm (0.31-0.51 in)
B: 6-10 mm (0.24-0.39 in)

1 DZ-llI
A: 8-13 mm (0.31-0.51 in)
B: 11-18 mm (0.43-0.71 in)

3Z
A: 8-13 mm (0.31-0.51 in)
B: 17-26 mm (0.67-1.02 in)

2. Fan belt deflection adjustment

4Y engine vehicle
(1) Loosen the fixing bolt.
(2) Loosen the set bolt and turn the adjustment bolt to adjust
the tension.
(3) Tighten the fixing bolt and recheck the belt tension.
Note:
Be careful not to apply excessive tension to the belt.
1-34

1DZ-1I1 engine vehicles

(1) Loosen the fixing bolt and adjusting bolt.
(2) Stretch the fan belt using a pry bar with the length of 300
to 400 mm (11.8 to 15.7 in), and tighten the alternator
adjustment bolt.
(3) Tighten the fixing bolt then recheck the belt tension.

Adjustment bolt I 3Z engine vehicles

Note:
Perform this adjustment while the engine is cold.

(1) Loosen the fixing bolt and the adjustment bolt.

(2) Temporarily secure the adjustment bolt after tensionir
the belt by tilting the alternator away from the engine bj
hand. Do not use a pry bar when performing this step.
(3) Place a matchmark on the alternator and adjustment bar
Fixing bolt as shown in the illustration.

(4) Loosen the adjustment bolt.

(5) Using a pry bar, tilt the alternator in the direction shown by
the arrow in the illustration by the amount indicated below.

Used belt: A=6 - 7 mm (0.24 - 0.28 in)

New belt: A=9.5 - 10.5 mm (0.37 - 0.41 in)
Note:
A new belt means an unused belt. If this adjustment is
performed after the vehicle is driven for 5 minutes or more,
use the value for a used belt.
(6) Tighten the fixing bolt.
 1-35

ACCELERATOR PEDAL
COMPONENTS
4Y
2601

AN EG

\~1
~ .:;;

ox

2601-273

10Z-I11-3Z
I 2601

2601-271
1-36

INSPECTION·ADJUSTMENT
1. Inspect the angle of the accelerator pedal.
1DZ-III
Vehicle Type 1·K2 ton 2·3 ton 3Z
series series
A: When the accelerator is OFF 45° 45° 45°
//' B: At full throttle (reference) 19° 17" 14°

Stoppj~olt Adjust by adjusting the length of the rod or stopper bolt.

1DZ-III·3Z 2. 1DZ-III·3Z engine vehicles

engine vehicles Adjust the height of the stopper bolt on the floor side so that
the link contacts the stopper bolt on the engine side when the
pedal is depressed.

3. Adjust the accelerator wire so that there is about 0.5°-2° of

play in the pedal.

4Y·Diesel Vehicle with Travel and Load Handling Control (Op T \

1. Inspect the angle of the accelerator pedal.

A: When the accelerator is OFF 45°
I
B: At full throttle (Reference) 16°
I
Adjust by adjusting the length of the rod.

2. Temporarily set the pedal stopper bolt height to 52 mm

(2.05 in).

3. Adjust the accelerator sensor.

(1) Connect the plug-in analyzer.

SST 09240-26600-71

For diesel vehicles with travel and load handling control

(OPT) use the multifunction display.

Note:
For an explanation on using the display, refer to the
multifunction display section.
 1-37

(2) Adjust the sensor voltage when the accelerator is OFF.

Display the I/O ENGINE CTRL 4/10 screen on the display.
I/O ENGINE GTRL a/to Adjust the installation position of the accelerator sensor

VPAl :0.85(0.85) so that the VPA 1 output (V) comes to the value below,
and fix it with a the set screw.
VPA2 ·1.45(1.45) VPA1: 0.85 ± 0.1 V

PA 0.0
(NE}::T)

(3) Adjust the height of the stopper bolt so that the difference
between the VPA1 output (V) in the full throttle position
I/O ENGINE GTRL a/to and the initial VPA1 output (V) is 2.4 V or greater, and the

VPAl ·3.25(0.85) VPA2 output (V) in the full throttle position is less than 4.6
V.
VPA2 ·3.85(1.45) (Note: the change in output per single turn of the stopper
bolt is 0.06 V)
Pti ·100.0 (4) After adjustment, apply thread tightener (08833-76002-71
INEXT) (08833-00080)) to the threaded section of the stopper bolt
lock nut and reassemble it.
(5) Clear the learned values.
For the 4Y:
Remove the battery plug for more than 10 seconds, then
reconnect it.
For diesel vehicles with travel and load handling control:
Turn the key ON with the accelerator sensor connector
disconnected. (An accelerator sensor error will be
detected.)
Then, turn the key OFF and reconnect the accelerator
sensor connector.

(6) Check that the VPA1 and VPA2 values displayed with the
accelerator OFF are within a range specified below of the
values displayed inside the brackets.
Standard: Within ± 0.1 V
1-38

D2 PEDAL (OPT)
COMPONENTS

2601
4Y I

2601-274

1DZ-III'3Z

2601-272
 1-39

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N'm (kgfcm) [ft-lbf]

Disassembly Procedure
1 Remove the pin and separate the pad W/switch from the pedal. [Point 1]
Remove the switch ASSY. [Point 2]
Remove the holder W/magnet. [Point 3]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Apply grease on the inner surface of each bushing .
• After reassembly, adjust the direction switch. (See page 1-41)

Point Operations

1EfHOOk
Pin
[Point 1]
Disassembly:
Extract the pin by lightly tapping the pin edge (the flange-less
Pad Notched portion side).
~~~
Reassembly:
Push the pin in with its notched flange portion in the illustrated
direction until it goes beyond the pad side hook.
1-40

[Point 2]
Inspection:
Check continuity of direction switches.
Forward side:
Continuity between CD and CI> when the forward switch is
pressed.
Reverse side:
Continuity between CD and Q) when the reverse switch is
pressed.
Reverse

Reassembly:
Reassernbie in the foiiowing order:
1. Install the switch on the pedaL
Set the switch while fully pressing it onto the pad.
Apply locking agent (08833-76002-71 (08833-00080)) at the
tip end of the screw before tightening the nut.

2. Fix the switch harness by means of the plate.

A Avoid overlaying of three wire harnesses in the harness tube
as illustrated.
Also push portion A of the harness so as not to be raised (to
prevent interference at the time of pin insertion).

[Point 3]
Reassernbly:
Since the holder W/magnet needs height adjustment, set
temporarily in a low position. See page 1-41 for adjustment.
 1-41

ADJUSTMENT
Note:
• Refer to page 1-36 for accelerator sensor adjustment.
• Direction switch adjustment is explained here.

Direction Switch Adjustment Procedure

1. 1. Fully tilt the accelerator pedal pad to either of one side.
It shall not contact to the magnet at the time.

2. 2. Screw in the magnet holder at the tilted side.

3. 3. Where the pad starts moving slightly is the position that the
magnet come to contact with the accelerator pedal pad plate.
Tl181l thread in by a half (1/2) turn from that point.

4. 4. Tighten the lock nut.

LOCk~~
Secure the magnet holder so as not to turn.

5. Adjust the other side in the same manner as in 1. to 4.

Magnet holder

6. After adjustment, confirm that the switches are actuated before

magnets contact to the pedal pad plate by tilting the pad
slowly.
1-42

Adjusting Accelerator Link

1. Install the accelerator link stopper bolt.
2. After installing the stopper, adjust the bolt so that the clearance
is as specified in the illustration.

3. After installing the accelerator sensor, loosen the stopper bolt

and tighten the lock nut at the position where the link stops.

Adjusting Limit Switch (for Diesel Vehicles Except

Travel and Load Handling Control Model)
1. Install the limit switch to the accelerator switch bracket.
2. Temporarily install the accelerator switch bracket to the
accelerator link bracket.
3. Adjust the clearance as specified in the table below while
turning the accelerator switch bracket.
Clearance (T) mm (in) Switch Condition
0.15 (0.0059) ON
0.65 (0.0256) OFF

Adjusting Pedal Height (for Diesel Vehicles Except

Travel and Load Handling Control Model)
1. Adjust the stopper bolt height so that the link contacts
stopper bolt on the engine side when the pedal is depressed.
At this time, the pedal play should be adjusted to within 0.4 to
1.7 0

Reference:
1DZ-111
Vehicle Type 3Z
1·K2 ton series 2·3 ton series
A mm (in) 22 (0.87) 27 (1.06) 34 (1.34)
B 14° 13° 11°
C 32°
 1-43

TRAVEL AND LOAD HANDLING CONTROL DEVICE{OPT)

COMPONENTS

1DZ-III

2607

2607·016

3Z

2607

2607.jj15
1-44

REMOVAL-INSTALLATION

~
I c
6

Removal Procedure
Open the engine hood and disconnect the negative terminal of the battery.
2 Remove the battery.
3 Remove the relay block bracket set bolt and free the relay block.
4 Remove the sedimenter.
5 Remove the battery set plate.
6 Disconnect the injection pump side link.
7 Remove the actuator. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• After installation, adjust the throttle opening degree. (Refer to 1-46)
• After installation, operate the accelerator pedal and check that the links are working normally.
 1-45

[Point 1]
Inspection:
Inspect the actuator.
1. Check that the actuator shaft can be manually turned smoothly
without sticking.
2. Check the resistance of the actuator.
Tester range: .Q x 1 range

Standard
Between (1) and (3): Approx. 2.5-3.7.Q
Between (2) and (3): Approx. 2.5-3.7 .Q
Between (1) and (4): Approx. 5.0-7.4 D
Between (2) and (5): Approx. 5.0-7.4.Q

Inspection:
Measure the insulation resistance between each actuator
terminal and body.
Tester range: .Q x 1 M range
Standard: 100 Mfl. or more

[Point 2]
Inspection:
Inspect the continuity of the limit switch.
Standard
Free position: CfJ n
When pushed 2.3 mm (0.091 in) or more: O.Q

I --======~
1-46

Idle set THROTTLE OPENING DEGREE

screw
Thickness ADJUSTMENT
\
\ gauge
Idle Switch (Injection Pump Lever Completely Closed)

~
Adjustment
1. Fix the injection pump lever in completely closed state with a
thickness gauge (1.3 mm (0.051 in) thickness) placed between
the lever and the idle set screw.

2. Tighten the adjustment bolt on the idle switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
(OFF-.+ON). (It is possible to tighten up to 1/4 turn from the
Idle switch switching point)
3. Fix the adjustment bolt with the lock nut.
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.

NMR Switch (Injection Pump Lever Completely Open)

Thickness gauge Adjustment
NMR set 1. Fix the injection pump lever in completely open state with a
thickness gauge (0.3 mm (0.051 in) thickness) placed between
the lever and the NMR set screw.

2. Tighten the adjustment bolt on the NMR switch side from tt--
state where the switch and bolt are not in contact (switch OFt:
and adjust the bolt to the point where the switch switch .
(OFF--+ON). (It is possible to tighten up to 1/4 turn from the
NMR switch switching point)
3. Fix the adjustment bolt with the lock nut.
4. Unlock the injection pump lever from fully open state.
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.
 1-47

TROUBLESHOOTING
This page contains troubleshooting advice for the mechanical system of the travel and load handling control device.
In the case of an error code being recieved, or trouble with the electrical system, refer to the troubleshooting section .

• Idle switch open error

ICheck the injection pump

Check that the injection pump return spring is Not broken A defect in the mechanical system of the travel and
b

not broken. 1---------!PllilO- load handling control device.

Broken + Check the components of the travel and load

handling control device.

Replace the return spring

Checking the components

of the travel and load
handling control device.

There is
\lvlOVe the link by hand, and check that there is interference
no interference with surrounding parts. ~ Remove the interference.

There is no interference ~
There is
looseness or
Check that there is no looseness or rattling in the rattling
motor bracket. ... Retighten the installation bolts.

There is no looseness ~
or rattling
There is
Check that there is no bending in the connecting bending
rod or bracket. ... b
Replace defective components.

There is no bending ~

There is
Check that there is no catching on the sliding catching
b
..- Clean and grease the joint section.

t
portion of the ball joint.

There is no catching

90°C (194°F)
Check that the temperature around the motor in or more
Outside the range of the motor operation warranty.

t
use is 90°C (194 OF) or less po

90°C (194 OF) or less

Mechanically no cause can be found, therefore

refer to the travel and load handling control device
electrical system troubleshooting.
1-48

• The idle speed deviates from the specified value

I
Check the injection pump I
~------------------ specified A defect in the mechanical system of the travel and load
Hold pump lever completely closed with your speed _ handling control device.
hand, then start the engine and check whether f---:-----J!,.. Check the components of the travel and load handling
the engine idles at the specified speed. control device (refer to 1-47).
Not-specified speed +
Adjust the idle set screw

• The idle up speed does not rise

I
Check the injection pump I
~------------------, There is no A defect in the mechanical system of the travel and load
Move the pump lever with your hand to check catching
_ handling control device.
that there is no catching in the sliding
I.-------~!I\I> Check the components of the travel and load handling
movement.
control device (refer to 1-47).
There is catching +
Service the injection pump (apply grease, etc.)

• No NMR
I Check the injection pump

Check that there is NMR when starting the A defect in the mechanical system of the travel and load
There is NMR... handling control device.
engine and turning the pump lever to the fully-
open position with your hand. Check the components of the travel and load handling
control device (refer to 1-47).
There is no NM1"

Adjust the maximum set screw

• The engine does not respond to operation of the accelerator pedal

ICheck the injection pump I

A defect in the mechanical system of the travel and load
With the engine running, move the pump lever Engine revs u~
handling control device.
with your hand and check the rev-up response. "" Check the components of the travel and load handling
Engine doesn't rev up~ control device (refer to 1-47).

Service or replace the injection pump

 1-49

DPF-II SYSTEM (OPT)

COMPONENTS

5701

5701
1 50

1DZ-III (i-K2 ton series)

1702

AJ HZ

-
I BZ
i.l ~
?' -AG
r~,~:z,l;; ~L-42 FK
\ \ 'u
'C,,\ CF
,
, BB

,I

1702-483

1DZ-1I1 (2 ton series)

1702

GL

1702-486
 1-51

1DZ-III (3 ton series)

1702

1702-488

3Z (2 ton series)

I 1702

1702-490
1-52

3Z (3·J3.5 ton series)

1702

1702-491
 ("')
oz
z
m
n
-f
o
:::0
o
-»
G)
;0
ALTERNATOR L SIGNAL ):>
s:
ENGINE STARTING SIGNAL
{]] © I DISPLAY I
IGNITION SIGNAL

DPF CONTOROLLER
{]] ® I BLOWER I
I STARTER RELAY ~
I E/G REVOLUTION ~
@ --{]] ® I CHECKER I
SENSOR
@

HEATER RELAY

->.
1
U1
(.0
1-54

o Contoroller ® Controller ® Display

TAB TAB TAB

REC REC REC

@valve ® Heater o Blower

TAB REC TAB REC TAB REC

® Checker o Buzzer CD Temperature sensor

TAB REC TAB REC

cv Back pressure sensor ® Blower sensor CD Main relay

TAB REC TAB REC REC

I~I m
.1

® E/G Revolution sensor ® Starter relay

TAB REC REC

0FRwire

TAB REC
,..--,
,= P-- r-= P--
2 1 1 2
'd c- p
7 6 5 4 3 3 4 5 6 7
12 11 10 9 8 8 9 10 11 12
I----
15 14 13 13 14 15
~ L- t:= != ~ ~
DPF MUFFLER REMOVAL-INSTALLATION

Removal Procedure
1 Remove the radiator cover.
2 Remove the weight.
3 Open the engine hood, and disconnect the heater and temperature sensor connector.
4 Cut the tie-wrap and pull the heater and temperature sensor harness out toward the rear of the vehicle.
5 Disconnect the back pressure sensor connecting hose.
6 Disconnect the exhaust pipe from the muffler.
7 Remove the DPF muffler ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Replace the gasket between the muffler and exhaust pipe with a new one.
• When the muffler ASSY is replaced, clear the memory. (See page 1-66.)
1-56

DPF MUFFLER DISASSEMBLY·INSPECTION·REASSEMBLY

T = N'm (kgf-cm) [ft'lbf]

l~

T = 120-15.0
(122-153)
[8.85-1107J

Disassembly Procedure
1 Remove the outlet pipe.
2 Remove the 16 bolts. [Point 1]
3 Remove the DPF heater ASSY.
4 Remove the DPF jacket ASSY. [Point 2]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Replace the DPF jacket ASSY gasket with a new one.
• When the DPF jacket ASSY is replaced, clear the memory. (See page 1-66.)

Point Operations
o
[Point 1]
Reassembly:
Install the bolts, nuts and washers in the illustrated order.
Note:
Use the specified bolts, nuts and washers. Use of general
items may cause malfunctions.
o
o 6
2
 1-57

[Point 2]
Inspection:
Replace the DPF jacket ASSY if its center or inside wall is
blackened with soot when seen from the outlet side.
1-58

CONTROLLER REMOVAL-INSTALLATION
Note:
Since the two wires from the controller to the outlet are both black, put tags showing the connecting
positions.
T = N'm (kgf-cm) [ft·lbf]

Removal Procedure
Open the engine hood, and disconnect the battery negative terminal.
2 Remove the step.
3 Remove the bracket set bolts.
4 Disconnect the wiring from the controller to the outlet.
5 Disconnect the controller connector.
6 Remove the controller ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the controller is replaced, turn the ignition key switch ON and check no error is present.
 1-59

BLOWER REMOVAL·INSTALLATION
Note:
Since the blower is to be removed from under the frame, operate in a pit.

View A

qemoval Procedure
1 Open the engine hood, and disconnect the battery negative terminal.
Remove the toe board.
3 Remove under cover from the vehicle.
4 Disconnect the connector.
5 Disconnect the blower hose from the blower.
6 Remove the blower set bolts, and remove the blower W/ bracket from under the vehicle.
7 Remove the blower ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the blower wiring clamp is removed, replace it with a new one.
1-60

DPF VALVE REMOVAL"INSTALLATION

Removal Procedure
Disconnect the battery negative terminal.
2 Disconnect the DPF air cleaner hose (air cleaner side) and blower hose (flow rate sensor side).
3 Disconnect the back pressure sensor connector and back pressure sensor hose, and remove the back pressure
sensor.
4 Disconnect the DPF valve hose.
5 Disconnect the DPF valve connector and blower sensor connector.
6 Remove the base & bracket W/ DPF parts ASSY from the vehicle. Disconnect the wire harness clamps from the
base & bracket.
7 Remove the DPF valve W/ fitting. [point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operations
[Point 1]
Installation:
Install the DPF valve in the correct direction.
The arrow marked on the valve body must be pointing the front
of the vehicle.
The connector of the core must be facing the front of the
vehicle as well. (The core can be turned by hand.)
Front -411III11III----
(Blower side)
 1-61

DPF VALVE DISASSEMBLY·INSPECTION·REASSEMBLY

T = N·m (kgf-cm) [ft·lbf]

T= 20.6-30.4 (210-310) [15.2-22.4]

Disassembly Procedure
1 Fix the valve body in a vise, and loosen the lock nuL
2 Separate the valve body and core, and remove the plunger and spring. [Point 1]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
I Inspection:

~~I
Clean off soot accumulated in the valve body, plunger, and
core with compressed air.
Replace the valve ASSY if any damage or wear is seen on the
plunger seat.

Plunger seat

Reassembly:
Install the spring in the correct direction.
Face the minor diameter side of the spring to the valve body
side.
1-62

INDIVIDUAL INSPECTION OF FUNCTIONAL PARTS

Starter relay

l
,,~-------~---

For the heater

Heater
Inspect the heater coil resistance.
Inspection method: Measure the resistance between both
terminals of wiring from the heater
Tester range: Q x 1 range
Standard: Approx. 17 Q
 1-63

Temperature Sensor
Connector for temperature sensor Inspect the temperature sensor continuity.
Inspection method: Measure the resistance between both
terminals of the temperature sensor
connector.
Tester range: D. x 1 range
Standard: Approx. 1 D.

Note:
Do not scratch gold plating on the connector pins at the time
of inspection.

DPF Blower
Inspect the DPF b!ovver for continuity.
Inspection method: Measure the resistance between both
terminals of the DPF blower.
Tester range: .0. x 1 range
Standard: Approx. 2.2 D.
Note:
Do not scratch gold plating on the connector pins at the time
of inspection.

Inline Filter
Muffler side
Inspect the outlet on the back pressure sensor side for soot
accumulation. If soot is seen, replace the sensor.

t .
Back pressure sensor side

Note:
Back pressure Regarding the direction of the inline filter. Do not install in the
sensor side reverse direction after inspection. Check the direction by the
"DENSO" mark direction. Although no direction is specified
for installation of a new filter, it is recommended to install with
the "DEN SO" mark facing the back pressure sensor side.

View A

DPF Valve
Measure the resistance between both terminals of the DPF valve
hJ c~ wiring.

0 [Jp Inspection method: Between both terminals of the valve

connector
[Jp Tester range: D. x 1 range
Standard: Approx. 18 D.
"-
[[] Note:
'-- 1-0 The part has a direction, so take care not to reassemble it in
the opposite direction.
1-64

Main Relay
Remove the main relay and inspect the function.
Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Tester range: Ox 1 range
Standard: 00

Starting Motor Relay

Starting motor relay

id' Rernove the starting motor relay and inspect the function.
Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Tester range: Ox 1 range
Standard: 00

Heater Relay
c A Inspect the function.
Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Tester range: n x 1 range
Standard: on

o B
+

Buzzer
Inspect the buzzer for continuity.

Display

1. Disconnect the controller connector, and measure the applied

battery voltage on the wiring side.

Inspection method: Between BATT terminal EB of the

controller connector (wiring side)
and body ground 8
Tester range: DC 50 V range
Standard: 10-14 V
 1-65

2. Inspect the controller connector for continuity (on the controller

side).
Inspection method: E01-E1
E02-E1
E01
E1-E2
JrrJ"'Il\~\==:1j!!/11 ~ Tester range: D. x 1 range
E02 E2 E1 Standard: There is continuity.

3. Inspect if any LED is burnt out.

/' Turn the ignition key switch Ol\j and check if aii LEOs are lit for
1 second.
o =======:=J- The buzzer sounds for 0.5 seconds.
~BJ~ ~[fI~1 ~lII~ ~. ~lIJ~ ~lIJ~
.~ 1180 :f)g
? c
(FIfT}R) [ tj~ (R@T)
]

Note:
Regarding cleaning of the DPF filter
When the amount of soot reaches the limit, a buzzer sounds and 6 LEDs on the display flash. In this state, it
is necessary to pertorm regeneration process immediately. If the machine continues to be used in this
condition, a warning LED will light up and an error code "5-1" is generated. When the vehicle has reached
this condition, it is necessary to replace or to clean the filter.
If you feel that "We are carrying out regeneration process periodically, but the movement time is getting
shorter", it is recommended that you clean the filter.
Cleaning the filter
• Clean the filter when it is cold (when you feel no heat on touching it with your hand).
• Face the IN side of the filter downwards and apply high pressure water from above the OUT side. (The
filter is designed to withstand high pressure water to 5 MPa.)
• When no more white residual ash comes out under high pressure water, cleaning is finished.
After cleaning, always perform a "DPF filter memory clear".
1-66

CONTROLLER ERROR CODE CLEARING

METHOD
'0 -========:=le
IJlJmlJlJ ~m~m [J]llJrn ~~mm ~lJlJm~ mm 1. Turn the ignition key switch ON.

::J
°A °0 ,B. 1I

<
2.
3.
Press the RESET switch until the buzzer sounds.
Turn the ignition key switch OFF after the warning LED goes

~~
[ F\0 R] [ H§f ] R@)T
out.
~

==: Note:
o Do not turn the ignition key switch ON until all LEDs on
Press
the display go out.
o Do not perform this operation before reading the error
code.
o If the buzzer does not sound when the RESET switch is
pressed, an internal switch defect may be the cause.
4. After LEDs go out, turn the ignition key switch ON and check
that the warning LED is not blinking.

DPF FILTER MEMORY CLEARING METHOD

1. Turn the ignition key switch ON.
2. Press the FILTER switch until the buzzer sounds.
3. Turn the ignition key switch OFF.
Note:
• Do not turn the ignition key switch ON until all LEDs on
the display go out.
o Perform this operation only when the filter is replaced.
o If the buzzer does not sound when the FILTER switch is
pressed, an internal switch defect may be the cause.

REGENERATION METHOD
1. Connect the external power cord (AC 200 V).
2. Press the regeneration switch until the buzzer sounds.
Note:
• The regeneration process ends in about 50 minut(
(about 70 minutes in case of high collection). One soot
soot amount indicating LED goes out every ten minutes,
and the process ends when all LEDs go out.
o If the buzzer does not sound when the regeneration
switch is pressed, an internal switch defect may be the
cause.
3. Disconnect the external power cord (AC 200 V).
Note:
o During the regeneration process, the engine does not start even though the ignition key switch is turned
to the START position. In this case the buzzer sounds to warn the operator.
• If the external power supply (AC 200 V power) is cut off for more than one minute during the
regeneration process, the buzzer will sound and the regenerating LED will blinks to warn the operator.
• While the power cord is kept connected after the end of regeneration, the engine does not start even
though the ignition key switch is turned to the START position. In this case, the buzzer sounds and the
warning LED blinks to warn the operator.
 1-67

DISPLAY OF PAST ERROR CODES

Note:
• If any switch is operated incorrectly, turn the ignition key switch OFF once before retrying switch
operation.
• Check that no error code is displayed.

Operation Procedure
1. Turn the ignition key switch ON (engine in stopped state).
2. Press the FILTER, MODE and RESET switches at a time until
the buzzer sounds.

Press

I 3. Press the MODE switch until the buzzer sounds.

"\
o~.
mmm mmm ~mm~ mmm mmm m~m~

::J
f\
\Jl[1
D

Iloo;B. [
I

['@'I ~§ G,,~

Press within 10 seconds

Soot amount indicationg LED 4. Press the FILTER and MODE switches at a time until the

~
buzzer sounds.
-/_. -~
-/---~- ~
-\3-
O/~.c=,-=
'I, 5. The display becomes as follows:
ommn [ffiJ00 ~mlW m~~1J(] ~m[l]~ 000000 I When there is no past error code:

°A °O,'f)@J' 11

[
All LEOs are kept off for 5 seconds.
When there are any past error codes:
After the soot quantity display LEDs are kept off for one
[c~\}"l ~::tul'] second, the error codes are displayed one by one for five
'---I, - - seconds each from the oldest one. The buzzer sounds each
--=f==J time the error code is switched over. The display is repeated
Press within 10 seconds after all codes ale displayed.
6. After checking the display, turn the ignition key switch OFF.
1-68

CLEARING OF PAST ERROR CODES

Note:
• Operate with a past error code being displayed.
• If any switch is operated incorrectly, turn the ignition key switch OFF once and display the past error
code again before retrying switch operation.

Operation Procedure
1. Turn the ignition key switch ON (engine in stopped state).
2. Press the FILTER, MODE, and RESET switches at a time until

°A 1100:f>. the buzzer sounds.

f, r F (GFR 1r t@lrR@T1Cj

~~=rs2f~d Press

3. Press the MODE switch until the buzzer sounds.

o~.
~m~m ~~~~~~ mum lIDlIDlID moooo (]l]lID~~
0/9\ 1 °0 ,B.
,ll~~ ~~ G,ETj
Press within 10 seconds

4. Press the MODE and RESET switches at a time until the

buzzer sounds
'0 ~ .
5. Past error codes are cleared.
~oooo~ oo~m~ mmm ~OO~OO ~W ~~

°A °0 ,B. 11
6. Turn the ignition key switch OFF.

le@"I~r/j~
:::J

Press within 10 seconds

 1-69

TROUBLESHOOTING

How to Approach Diagnosis

On detecting an abnormal area the controller lights a warning LED on the display and sounds a buzzer. The detected
abnormal area is then displayed as an error code using the soot amount indicating LEDs. When the warning LED
lights, pressing and holding the MODE switch for about one second will display the error code using the soot amount
indicating LEDs.
When the regenerating LED flashes with the ignition key switch ON, this indicates that the previous regeneration was
aborted partway due to a drop in voltage of the external power supply (AC 200 V), and the error code is 7-2. In this
case performing regeneration again will reset the error code without clearing the error code.
The connector numbers (A to M) specified in troubleshooting are the same as those shown on lIle connector diagram
on page 1-49.

Error Code Indicating Method

Turn the ignition key switch ON, and remove the communication switch cover. The error code is displayed by the
lighting LED positions while the buzzer sounds.
No Error code Abnormal portion
I
During regeneration, the heater temperature does not rise to the specified level within the
1 1-1
specified time.
I
2 1-2 The heater temperature drops abnormally during regeneration.
I 3 1-3 The exhaust temperature rises abnormally vv'hile the engine is running.
4 1-4 The temperature sensor outputs an abnormally high temperature.
S 2-1 The back pressure sensor output is above or below the upper or lower limit.
The back pressure sensor output remains unchanged when the engine speed varies beyond
6 2-2
the given level.
7 3-1 The alternator L signal becomes abnormal upon starting the engine.
S 3-2 The rpm sensor output becomes abnormal after starting the engine.
9 3-3 The alternator L signal becomes abnormal after starting the engine.
10 4-1 The flow rate sensor output value is abnormal.
11 4-2 The blower flow rate is apart from the target level.
12 4-3 The flow rate sensor output deviates though the blower is not operated.
13 5-1 The amount of soot accumulated in theDPF filter is above the level that can be regenerated.
I 14 6-1 The controller memory is abnormal.
15 7-1 The vehicle battery voltage dropped abnormally.
I
16 7-2* The external power voltage (AC 200 V) dropped for 1 minute or more during regeneration.

*: For error code 7 -2, the regenerating LED flashes instead of the warning LED.
1-70

Explanation on Error Code

The abnormal system portion is indicated by the soot amount indicating LEDs. When multiple system abnormalities
are detected at a time, they are indicated alternately at intervals of 5 seconds.
0: On . : Off
Example: Error code 3-1
Code Soot amount indicating LE Os
No1
Green 1 Green 2 Green 3
display No.1 display No.2 display

11~1~~m
rnit
No.2
Green 4 Green 5 Yellow
display -----

r~1 O~:B-~l
-----
1
• • 0 ~~======= ,,~
2
• 0
•
J
• 0 0
4 0
• •
5 0
• 0 DPF-II

6
7
0
0
0
0
•
0

Before Troubleshooting
1. Check that there was no interruption during regeneration such as the plug being accidentally pulled from the
power socket or some other circumstance.
If there has been an interruption during regeneration, the regenerating LED will flash when the ignition key
switch is turned ON. Carry out regeneration again. In this case it is not necessary to perform an error code clear
operation. If a regeneration interruption reoccurs, carry out the troubleshooting for error code 7-2.
2. Check that the battery voltage is the specified voltage (10-14 V).
If it deviates from the specified voltage, charge or replace the battery.
3. Check that the bulbs for the display are not blown. (Refer to 1-65)
If the LEDs on the display do not light when the ignition key switch is turned ON, replace the display.
4. Check that the display does not always light.
Repair or replace the display wiring.
 ('

1-71

Troubleshooting

Error Code 1-1 or 1-2

Inspection 1: NG
Inspect the heater resistance.
....
..- Defective heater ASSY.

OK
,r
Inspection 2:
NG
-... Defective temperature sensor.

,
Inspect the temperature sensor for continuity.

OK J
Inspection 3: NG
Inspect continuity between the temperature sensor and I---~::'IIII>- Repair or replace the wiring.
controller.

OK

IInspectlon
...
4:
ING
...
Inspect continuity between the heater relay and controller. 1----1l1li>- Repair or replace the wiring.

OK

IDPF system in normal state.

Inspection 1:
Heater resistance inspection
Disconnect the heater connector.
I Tester range: D. x 1
I Measurement terminals Both terminals of heater connector: E-1 - E-2
Standard Approx. 17 D.

Heater connector
(E) Heater connector

OK --+ To inspection 2
NG --+ Defective heater ASSY
1-72

Inspection 2:
Temperature sensor continuity inspection
Disconnect the temperature sensor connector.
Tester range: Q x 1
Measurement terminals Both terminals of temperature sensor connector: 1-1 - 1-2
Standard Approx. 1 Q

(I) Temperature sensor connector

~\ \
\
Temperature sensor connector

OK ~ To inspection 3
NG -* Defective temperature sensor
Inspection 3:
Temperature sensor wiring continuity inspection
Disconnect the temperature sensor and controller connector.
Tester range: Q x 1
Controller connector B-8 - Temperature sensor connector 1-1
Measurement terminals
Controller connector B-21 - Temperature sensor connector 1-2
Standard OQ

(B) Controller connector (I) Temperature sensor

connector

Temperature sensor
connector

OK --f To inspection 4
NG ~ Repair or replace the wiring
 1-73

Inspection 4:
Heater relay wiring continuity check
Disconnect the heater relay and controller connectors.
Tester range: Q x 1
Measurement terminals Controller connector B-1 0 - Heater relay 3
Standard on

(8) Controller connector

r r
n
~n n
7 8
-<r.
1 2 3 4 5 11 12 13
I"'
0 :::J IU

14 15 16 17 18 19 20 21 22 23 24 25 26 I
-l u

Heater relay 3 1--~----_---!

OK -+ DPF system in normal state

NG -+ Repair or replace the wiring
1-74

Error Code 1-3

NG
Inspection 1:
Inspect the temperature sensor for continuity. -... Temperature sensor defect.

OK
'1
Inspection 2: NG
Inspect continuity of the wiring between the temperature ...
0-
Repair or replace the wiring.
sensor and controller.

OK
1
IController defect.

Inspection 1:
Temperature sensor continuity inspection
See inspection 2 of error code 1-1.
OK -~ To inspection 2
NG ---+ Temperature sensor defect
Inspection 2:
Temperature sensor wiring continuity inspection
See inspection 3 of error code 1-1.
OK ---+ Controller defect
NG -~ Repair or replace the wiring
 1-75

Error Code 1-4

NG
Inspection 1: ........ Temperature sensor defect.
Inspect the temperature sensor for continuity.

l'
OK

Inspection 2: NG
Inspect continuity of the wiring between the temperature
sensor and controller. -... Repair or replace the wiring.

OK
,
1
NG
Inspection 3: ........ Repair or replace the power cord .
Measure the power supply voltage (AC 190-220 V).

OK

Inspection 4: NG
Inspect continuity of the wiring between the heater relay ...
~
Repair or replace the wiring.
and controller.

OK
111'

NG
Inspection 5:
Inspect the heater resistance. ....
""- Heater ASSY defect.

OK

I Controller defect.

1spection 1:
Temperature sensor continuity inspection
See inspection 2 of error code 1-1.
OK ~ To inspection 2
NG ~ Temperature sensor defect
Inspection 2:
Temperature sensor wiring continuity inspection
See inspection 3 of error code 1-1.
OK ~ To inspection 3
NG ~ Repair or replace the wiring
1-76

Inspection 3:
Power supply voltage inspection
Connect the power cord to the power outlet.
Tester range: AC 500 V
Measurement terminals Power cord terminals
Standard AC 190-220 V

OK ---+ To inspection 4
NG -+ Repair or replace the power cord
Inspection 4:
Heater relay wiring continuity inspection
See inspection 4 of error code 1-1.
OK -+ To inspection 5
NG -+ Repair or replace the wiring
Inspection 5:
Heater resistance inspection
See inspection 1 of error code 1-1.
OK -+ Controller defect
NG -+ Heater ASSY defect
 1-77

Error Code 2-1

Inspection 1:
Inspect the back pressure sensor input.
OK
-... Controller defect

NG

Inspection 2:
l'
OK
Inspect continuity of the wiring between the back pressure
sensor and the controller.
...
"-
Back pressure sensor defect

NG
u

IRepair or replace the wiring.

Inspection 1:
Back pressure sensor input check
Voltage measurement between terminals
Controller connector: Back pressure sensor connector in connected state
Stop the engine and turn the ignition key switch ON.
B3 - B16
Measurement terminals Controller connector Controller connector
B4 - B16
Standard B3 - B 16 : 5 ± 025 V, B4 - B 16 : 1.5 ± 0.5 V

OK ~ Controller defect
NG ~ To inspection 2
Inspection 2:
Back pressure sensor wiring continuity inspection
Disconnect the back pressure sensor and controller connector.
Tester range: f2 x 1
B4 - J1
Measurement terminals Controller connector B16 - Back pressure sensor connector J2
B3 - J3
Standard OD.

(J) Back pressure

(B) Controller connector sensor connector

• I

OK ~ Back pressure sensor defect

NG ~ Repair or replace the wiring
1-78

Error Code 2-2

Check the exhaust pipe and DPF muffler for exhaust gas leakage from each part or joint.

Inspection 1: NG
Check the pipes and hoses connecting functional parts of ......... Repair or replacement
the DPF-II system for leakage or clogging.

OK
1ft

Inspection 2:
Check the pipes connecting functional parts of the DPF-II
NG
..... After leaving in idle state for about 30
minutes, conduct inspection 3.
system for freezing.

OK

NG
Inspection 3:
Check the in-line filter for clogging. ....... Replace the in-line filter.

OK
1J

II.
inspection 4:
Check the valve outlet for soot leakage.
ING
I ...
-
Replace the valve, flow rate sensor,
blower, controller and DPF air cleaner,
and clean or replace the piping.
OK
l' OK
Inspection 5: ...... Controller defect
Check the back pressure sensor input.

NG
u

Inspection 6: OK
Inspect continuity of the wiring between the back pressure .....
"-
Back pressure sensor defect
sensor and the controller.

NG

1Repair or replace the wiring.

Inspection 1:
DPF-II system gas leakage inspection
Check the pipes and hoses that connect parts for leakage or clogging.
OK ~ To inspection 2
NG ~ Repair or replacement
Inspection 2:
Pipe freezing check
Check the pipes and hoses that connect parts for freezing.
OK ~ To inspection 3
NG ~ To inspection 3 after defrosting.
Inspection 3:
In-line filter clogging check
OK ~ To inspection 4
NG ~ Replacement
 1-79

Inspection 4:
Valve outlet soot leakage check

Back pressure sensor Air cleaner

<E--

\
Valve outlet
Flow rate sensor
t Blower

To exhaust manifold
j

OK -? To inspection 5
NG -? Replace the valve, flow rate sensor, blower and DPF air cleaner, and clean or replace the piping.
Illspection 5:
Back pressure sensor input check
Voltage measurement between terminals
Controller connector: Back pressure sensor connector in connected state
) Stop the engine and turn the ignition key switch ON.
83 - B16
Measurement terminals Controller connector Controller connector
B4 - B16
Standard B3 - 816: 5 ± 0.25 V. B4 - B16: 1.5 ± 0.5 V
(2) Start the engine and keep the NMR running. (*)
Measurement terminals Controller connector B4 - Controller connector B16
Standard 84 - 816: Value measured between 84 and 816 in (1) above + 0.2 V or more

(*) Perform this inspection only when three or more soot amount indicating LEDs are lit.

OK -? Controller defect
NG -? To inspection 6
Inspection 6:
Back pressure sensor wiring continuity check
See inspection 2 of error code 2-1 .
OK -? Back pressure sensor defect
NG -? Repair or replace the wiring.
1-80

Error Code 3-1 or 3-3

Inspection 1:
Check that the charge lamp on the combination meter NG .........
Inspect the alternator by referring to the
comes on upon turning the ignition key switch ON and alternator section in the engine repair
goes out upon turning it to the START position. manual.

OK

"
Inspection 2:
Inspect continuity of the L signal wiring between the
alternator and controller.
NG
-... Repair or replace the wiring .

OK
'U

IController defect.

Inspection 1:
Charge lamp lighting inspection

-1=-:1 cllUlnnlJ]Hoilililililil
lliJl m:UIIlIIl
E F UO 0 0 0 0.0 h
g
~
~§~§~rn~
'----1-----------" Charge lamp

OK -+ To inspection 2
NG -+ To alternator inspection in the engine repair manual
Inspection 2:
Alternator L signal wiring continuity inspection
Disconnect the alternator and controller connectors.
Tester range: n x 1
Measurement terminals Controller connector 819 - Alternator terminal 1
Standard on

Alternator connector
(8) Controller connector Alternator

------~~~~ is c\~\~~)/d~s
Controller connector
F i

OK -+ Controller defect
NG -+ Repair or replace the wiring
 1-81

Error Code 3-2 (For Vehicles without Travel and Load Handling Control)

Inspection 1:
Inspect the engine rpm sensor installed on the injection NG
pump. .... Replace the injection pump ASSY.

OK
u

Inspection 2:
Inspect continuity of the wiring between the engine rpm
sensor and controller.
NG
-.... Repair or replace the wiring.

OK

IController defect.

i'-'spection 1:
Engine rpm sensor individual inspection
Disconnect the engine rpm sensor connector.
Tester range: .0. x 1k
Measurement terminals Between both terminals M-1 and M-2 of rpm sensor
Standard Approx. 1 kD

(M) Rpm sensor connector

OK -+ To inspection 2
NG -+ Replace the injection pump ASSY.
1-82

Inspection 2:
Engine rpm sensor wiring continuity inspection
Disconnect the engine rpm sensor and controller connectors.
Tester range: 0. x 1
87 - M2
Measurement terminals Controller connector 820- Engine rpm sensor connector
M1
Standard on

Engine rpm sensor connector

(M) Engine rpm
(8) Controller connector
sensor connector

OK ---c> Controller defect

f'JG ---c> Repair or replace the wiring
 1-83

Error Code3-2 (For Vehicles with Travel and Load Handling Control)

Inspection 1:
Check the error display of the meter.
NG
-
.... Carry out the relevant troubleshooting.

OK
'Ir

--
Inspection 2: NG
Inspect for continuity between the ASC controller and the Wiring repair or replacement.
DPF controller.

OK

--
Inspection 3:
NG
Remove the ASC controller, directly connect the engine
DPF controller defective.
rpm sensor and the DPF controller and check for any
errors.

OK

ASC controller defective.

Inspection 1:
Check for errors in the vehicle

I~
,-I t. ,
Lt I Ihl
~
~~8§8g~~~
I.

. 0K --+ To inspection 2
NG -7 To relevant troubleshooting
1-84

Inspection 2:
Continuity check of harness between ASC controller and DPF controller
Disconnect the ASC controller connector and DPF controller connector.
Tester range: D x 1
25 - 87
Measurement terminals ASC controller connector 38- DPF controller connector
820
Standard OD

11 (8) DPF controller connector ASC controller connector

ASC controller connector

OK .~ To inspection 3
NG ~ Repair or replace the wiring
Inspection 3:
Engine rpm sensor operation check when directly connected to the DPF controller
After clearing the error code disconnect the ASC controller connector, short circuit 25 to 36, and 24 to 38 of the
connector and start the engine. Check that an error reoccurs by the lighting of the warning LED (this time the
meter displays error 18-2).

ASC controller connector

I
I
i

I
'----~
ASC controller connector

No light ~ ASC control/er defective

Light ~ DPF controller defective
 1-85

Error Code 4-1

Inspection 1:
Inspect the blower air cleaner for gas leakage during NG
engine running. -.... Replace the valve, flow rate sensor,
blower and/or DPF air cleaner, and
clean or replace the piping.
OK
t
Inspection 2:
Inspect the flow rate sensor input.
OK
- Controller defect

NG
,
l
Inspection 3: OK
Inspect continuity of the wiring between the flow rate 1-----IIiIIII:;..- Flow rate sensor defect
sensor and controller.

NG

IController defect

Inspection 1:
Air cleaner gas leakage inspection
Check that there is no exhaust gas leakage from the blower air cleaner outlet.

Air cleaner

I-
Outlet of air cleaner

f---- ----, J
for blower

0))

OK -'.> To inspection 2
NG -'.> Replace the valve, flow rate sensor, blower and/or DPF air cleaner, and clean or replace the piping.
1-86

Inspection 2:
Flow rate sensor input check
Voltage measurement between terminals
Controller connector: Flow rate sensor connector in connected state
Stop the engine and turn the ignition key switch ON.
B1 - B15
Measurement terminals Controller connector B5- Controller connector B15

Standard B1 - B15 : Battery voltage, B5 - B15: 2.0 V or less

OK ----t Controller defect

NG ----t To inspection 3

Inspection 3:
Flow rate sensor wiring cointinuity inspection
Disconnect the flow rate sensor and controller connector.
Tester range: Qx 1
I
B1 - K3 I
Measurement terminals Controller connector B15- Forw rate sensor connector K2
B5 - K1
Standard OQ .

Flow rate sensor

11
connector (K) Flow rate
(B) Controller connector sensor connector

OK ----t Back pressure sensor defect

NG ----t Repair or replace the wiring
 1-87

Error Code 4-2

NG
Inspection 1:
Inspect the air cleaner for clogging.
... Clean or replace the air cleaner.
""
OK
,r
Inspection 2: NG
Inspect the piping between the air cleaner and blower ...... Clean or replace the piping .
sensor for clogging or leakage.

OK
,
1
Inspection 3: NG
Inspect continuity of the wiring between the blower and 1----1::
..... Repair or replace the piping.
controller.

OK

!Inspection 4: If-N_G_-1I!>"!!!!J!oo.- Blower defect.

ILI_n_s_pe_c_t_t_h_e_b_l_ow_e_r. .-- ....c1

~
OK

NG
Inspection 5:
Inspect the DPF valve.
.
~
DPF valve defect.

OK
~Ir

Inspection 6:
Inspect the wiring between the DPF valve and controller.
NG
-... Repair or replace the wiring .

OK
11J
., To the next page.
1-88

IFrom the previous page.

OK

Inspection 7:
Inspect the flow rate sensor input
OK
-
..- Controller defect

NG
1"

I
Inspection 8:
Inspect continuity between the flow rate sensor and
controller.
NG
-
" .. Reapair or replace the wiring.

OK

DisassembJe and inspect the DPF muffler.

Repair or replace if defective.

Inspection 9: OK
Inspect the piping between the blower sensor and muffler f----J::::
___ Flow rate sensor defect
for clogging.

NG t
IClean or replace the piping.

Inspection 1:
Air cleaner clogging inspection
Check that the blower air cleaner is not clogged.
Air cleaner

1------..

OK - f To inspaection 2
NG - f Clean or replace the air cleaner
 1-89

Inspection 2:
Gas leakage inspection
Check that no exhaust gas is leaking from the piping that connects the blower air cleaner and flow rate sensor.

Air cleaner

Blower

OK ---7 To inspection 3
NG ---7 Clean or replace the piping
Inspection 3:
Blower wiring continuity inspection
Disconnect the blower and controller connectors.
Tester range: D. x 1
B1 - F2
Measurement terminals Controller connector Blower connector
B12 - F1
Standard OD.

(F) Blower

~er
~ ~~~~:ctor
(B) Controller connector connector

~
OK ---7 To inspection 4
NG ---7 Repair or replace the wiring
Inspection 4:
Blower individual inspection
See page 1-62.
OK ---7 To inspection 5
NG ---7 Blower defect
1-90

Inspection 5:
DPF valve individual inspection
See page 1-62.
OK ~ To inspection 6
NG ~ DPF valve defect
Inspection 6:
DPF valve wiring continuity inspection
Disconnect the DPF valve and controller connectors.
Tester range: .0 x 1
B1 - D2
Measurement terminals Controller connector B 11 _ DPF valve connector
D1
Standard OD
I

DPF valve
connector
(D) DPF valve
(B) Controller connector connector
.I

OK -+ To inspection 7
NG ~ Repair or replace the wiring
Inspection 7:
Flow rate sensor input check
See inspection 2 of error code 4-1 .
OK ~ Controller defect
NG -+ To inspection 8
Inspection 8:
Flow rate sensor wiring continuity inspection
See inspection 3 of error code 4-1.
OK ~ To inspection 9 after DPF muffler individual inspection
NG -+ Repair or replace the wiring
Inspection 9:
Clogged piping inspection
Check that the piping between the blower sensor and muffler is not clogged.

Valve 1
Flow rate sensor
To muffler

OK -+ Flow rate sensor defect

NG -+ Clean or replace the piping
 1-91

Error Code 4-3

Inspection 1:
Inspect the flow rate sensor input.
OK
-.... Controller defect

NG
"
Inspection 2: OK
Inspect continuity of the wiring between the flow rate
sensor and controller.
-. Flow rate sensor defect

NG
i
IRepair or replace the wiring .

.1spection 1:
Flow rate sensor input check
See inspection 2 of error code 4-1.
OK -+ Controller defect
NG -+ To inspectinon 2
Inspection 2:
Flow rate sensor wiring continuity check
See inspection 3 of error code 4-1.
OK -+ Flow rate sensor defect
NG -+ Repair or replace the wiring

Error Code 5-1

Replace the DPF filter.

Error Code 6-1

Replace the controller.
1-92

Error Code 7-1

NG
Inspection 1:
Inspect the battery voltage (10-14 V).
...... Charge or replace the battery.

OK
'If

-..
Inspection 2: NG
Inspect the wiring defect between the battery and controller. Repair or replace the wiring .

OK

I
I Controller defect.
Inspection 1:
Battery voltage inspection
Check that the battery voltage is between 10 and 14 V.
OK -7 Controller defect
NG -7 Charge or replace the battery
Inspection 2:
Wiring inspection
Inspect the wiring between the battery and controller for continuity.
OK -7 Controller defect
NG -7 Repair or replace the wiring

Error Code 7-2

Check that the buzzer and display LED

Inspection 1: NG
... are functioning normally when the
Check that the power breaker is not open and that the
cord is securely connected to the outlet. - ignition key switch is tuned ON with the
power cord connected.
OK
'f
NG
Inspection 2:
Inspect continuity of the power cord.
....... Power code defect.

OK
111

Inspection 3:
Check that the AC wiring for the controller is correctly
connected. to the external power receptacle.
NG
-... Correct wiring connection .

OK
t
Inspection 4:
Connect the power cord and check that the voltage at NG
cord terminals is AC 200 V. Connect the cord to the ...... Controller defect.
vehicle and check for correct functioning when the
regeneration switch on the display is pressed.

OK

IDPF system in normal state.

 1-93

Inspection 1:
Power supply inspection
Check that the power breaker is not opened and the power cord is securely connected.
OK -+ To inspection 2
NG -+ Check for correct functioning of LEOs after the correction
Inspection 2:
Power cord continuity inspection
Inspect continuity between the terminals at both ends of the power cord.
OK -+ To inspection 3
NG -+ Power cord defect

Inspection 3: ]
Controller AC wiring inspection
Check that the wiring between the controller and outlet is securely connected.
OK -+ To inspection 4
NG -> Correct wiring connection

Inspection 4:
Power supply voltage inspection
Connect the power cord.
Tester range: AC 500 V
Measurement terminals I Power cord terminals
::itandard AC 190-220 V

OK -+ OPF system in normal state

NG -+ Controller defect
1-94

ENGINE CONTROLLER ASSY

ENGINE ECU (4Y) OR ASC CONTROLLOER (1 DZ-III-3Z:0PT)
REMOVAL-INSTALLATION
T == Nm (kgfcm) [ftlbf]

/~91Ij
~

Before Troubleshooting
1 Open the engine hood
2 Remove the toe board and lower panel.
3 Remove the side cover W/stop.
4 Remove the side cover bracket.
5 Remove the ECU box cover.
6 Disconnect the controller connector.

7 Remove the controller.

Installation Procedure
The installation procedure is the reverse of the removal procedure
 2-1

TORQUE CONVERTER & TRANSMISSION

Page
1 SPEED TORQUE 2 STATORS TORQUE
CONVERTER (STD) 2-2 CONVERTER (OPT) 2..41
GENERAL 2-2 GEN ERAL ..........................•... 2..41
HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT
DIAGRAM 2-5 DIAGRAM 2..43
~--~.-.~ . . . . . . . . . A.AI
SPECIFICATIONS 2-6
- . .. I",""", ...,.

~...,I::~It-IL;AIIUN~••••••••••••••••••• £ .. "1-"+

COMPONENTS 2-7 COMPONENTS 2..45

TROUBLESHOOTING 2-18 TROUBLESHOOTING 2 ..49
TRANSMISSION COVER & TORQUE CONVERTER 2..50
CONTROL VALVE ASSY 2..19 TORQUE CONVERTER &
"TRAt.c'SII.J1ICCIf"\I\' 1\ SCV ,,)_l:;~
TORl.lUE CONVERTER· I ." IVllvvl'V"I't 1"'"\ U . . . . . . DIII • • IIIIII &,;..-...",.,v

OIL PUMP 2..23 TRANSMISSION ASSY 2 ..60

TORQUE CONVERTER & STATOR SHAFT NO.2 &
TRANSMISSION ASSY 2..26 OIL PUMP ASSY 2..71
TRANSMISSION ASSY 2..30 CLUTCH DRUM ASSY 2 ..73
CLUTCH DRUM ASSY 2..37

DIRECTION SWITCH
ASSY 2..76
REMOVAL-INSTALLATION 2..76
OiL PRESSURE
MEASUREMENT AND
STALL TEST
(1 SPEED TORQUE
CONVERTER (STD» 2..77
OIL PRESSURE
MEASUREMENT AND
STALL TEST
(2 STATORS TORQUE
CONVERTER (OPT» 2..79
2-2

1 SPEED TORQUE CONVERTER (STD)

GENERAL

Torque Converter

F: Forward
R: Reverse
 2-3

Control Valve (Upper)

A ~'_h-lt-J~
-~- ----- - -------

B B

A-A: Regulator valve

B-B: Inching valve

c-c: Accumulator
2-4

Control Valve (Lower)

~'=I AASa!e'yva've

CC4~B'ShiftChangeVO'Ve(RJ

~ 3c-c, Shift change va'velF)

 - :I:
o-<
;;0
):>
Inching valve c:
Solenoid valve (R) --
r
(')
(')
-;;:c
(')

Shift change valve (R)

II~"-l! -
C
-I
---------+I;:I-1---:r:::;:;;1.1L,.
-)o:>
'---
--fr _+~r~
-----'
~ -L-_-----,"_~~
Accumulator~'
_ G)
;;:c
):>
:s:

Regulator valve

Relief
'---=-.:;;::::=.J
V valve

--
~
~'~"-- ~
-------- - -
-.- rl ,..-, ~

~,

Shift change valve (F)

NI
U'1
2-6

SPECIFICATIONS
Item 1 speed torque converter
Maker Aisin
Torque converter type 3 elements, 1 stage, 2 phases type
4Y·1DZ-1I1 2.68
Stall torque ratio
3Z 2.61
4Y·1DZ-1I1 2200
Stall speed rpm
3Z 2050
Control system Solenoid type selector valve
Clutch operating pressure (main pressure) kPa (kgf/cm 2 ) [psi] 1108 (11.3) [161J
Torque converter outlet pressure kPa (kgf/cm 2 ) [psi] 392 (4.0) [57]
Torque converter oil capacity ( (USgal) 6.0 (1.58)
Torque converter oil ATF GM Dexron® 11

Note: The indicated oil pressure is at an engine speed of 2000 rpm.

Torque Converter Gear Ratio

lorque Converter I-<atio

Vehicle model Engine
Forward Reverse
1 ton series 4Y·1DZ-1I1 1.633 1.641
K2 ton series 4Y·1DZ-1I1 t t
4Y·1DZ-11I l' t
2 ton series
3Z 1.323 1.341
1DZ-111 1.633 1.641
3 ton series
4Y·3Z 1.323 1.341
4Y t t
J3.5 ton series
3Z 1-I
t
 2-7

COMPONENTS

Torque Converter Housing (4Y Engine Vehicle, Dry Brake Model (STD»

3201

3201-246

Torque Converter Housing (4Y Engine Vehicle, Wet Brake Model (OPT»

3201

42

1
AR
3201-247
2-8

Torque Converter Housing (1 DZ-1I1 Engine Vehicle, Dry Brake Model (STD»

3201

AS 3201-242

Torque Converter Housing (1DZ-1II Engine Vehicle, Wet Brake Model (OPT»

3201
 2-9

Torque Converter Housing (3Z Engine Vehicle, Dry Brake Model (STD))

3201

36

42
I

r
AR

AS 3201-244

Torque Converter Housing (3Z Engine Vehicle, Wet Brake Model (OPT»

3201

GT

42

DJ
r
AR
3201·245
2-10

4Y Engine Vehicle

3202

3202-103

1DZ-III, 3Z Engine Vehicle

3202

3202-104
 _ _ _ _ _ _ _ _ 22--11

Torque C onverter Clutch

--
3203

3204

3204-1185
2-12

Control Valve

3206

L ..... __ - . _
3206-1278

3206
10
...,.
.
r........ i -------

~g=~ _fl---
.
'7JJ AF

®--AK /1
®--- AD / ' /@--A8

~ /../ Q ~ AL
, ~
 2-13

3206

16

~~e_~~~~~_~~~---~-.-1

LH - AY
AG

.
L ...... .~-_._---_._ . _. -- -- -- --- -- -- -~- • ..... ..1

3206-129A

Torque Converter Piping (1 DZ-III Engine Vehicle, Dry Brake Model (STD))

3213

8'--BA

42

Refer to
FIG.1603

BA~

BP~

3213-162
2-14

Torque Converter Piping (1 DZ-III Engine Vehicle, Wet Brake Model (OPT»

3213

HQ
BA-{;l\
BP~

3213-163

Torque Converter Piping (3Z Engine Vehicle)

3213

Refer to
FIG.1603

BA---9l
BP-4'J

3213-164
 2-15

Torque Converter Piping (4Y Engine Vehicle)

3213

,
$l---CT

42 ~~-41
Refer to
FIG.1603

FN-----i!

3213-165

Torque Converter Piping (4Y Engine Vehicle, 2·K2·3·J3.5 ton series, Cooler)

3213

Refer to
FIG.1603

3213-168
2-16

Torque Converter Piping (4Y Engine Vehicle, Wet Brake Model (OPT»

3213

Refer to
FIG.1603

HQ

BA~

BP--{j

3213-166

Torque Converter Piping (4Y Engine Vehicle, Wet Brake Model (OPT), Cooler)

3213

l~_BA
~~A
BA
BE-"· ". AQ

Refer to
FIG.1603 BA
BA
42

~,

BA---@
BP~

3213-167
 2-17

Direction Switch

5701

~Q8

~
A2
--L-I
\-+-_.....

,I

··
- ..... ..1

5701-510A
TROUBLESHOOTING

c
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r.n
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(J)
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c
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 2-19

TRANSMISSION COVER & CONTROL VALVE ASSY

REMOVAL-INSTALLATION
T = Nm (kgf·cm) [ft·lbf]

lemoval Procedl,lre
Remove the lower panel.
2 Remove the toe board.
3 Disconnect the inching wire.
4 Disconnect the connector.
5 Remove the transmission cover & control valve ASSY.

Installation Procedure
The installation procedure is reverse of the removal procedure.
2-20

DISASSEMBLY·INSPECTlON·REASSEMBLY
T = N'm (kgf-cm) [ft-lbf]

T = 12.5 (127) [9.2]

T = 21.0 (214) [15.5]~

Disassembly Procedure
1 Disconnect the solenoid valve connector.
2 Remove the solenoid valve.
3 Remove the sleeve lock plate and solenoid wire ASSy'
4 Remove the inching lever.
5 Remove the inching level oil seal. [Point 1]
6 Remove the accumulator valve, inching valve and regulator valve. [Point 2]
7 Remove the lower valve body ASSY, oil strainer, relief valve piston and spring. [Point 3]
8 Remove the safety valve, F shift valve and R shift valve. [Point 4]

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
 2-21

Point Operations
[Point 1]
Reassembly:
SST(2)
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

[Point 2]
Service bolt Disassembly:
Remove the accumulator valve plug using the service bolt.
Service bolt size: M8x 1.25

,-

Inspection:
Measure free length of each valve spring.

Standard mm (in) Limit mm (in)

Inner 67.4 (3.390) 64.0 (3.220)
'oScumulator valve
Outer 127.8 (5.031) 121.4 (4.780)
Plug side 64.2 (2.528) 61_0 (2.402)
Inching valve
Valve side 49.9 (1.965) 47.4 (1.866)
Regulator valve 132.4 (5.213) 125.8 (4.953)

[Point 3]
Reassembly:
Install the lower valve body.
1. Install the oil strainer, spring and relief valve piston on the
lower valve body, and put the gasket on top.
2. Reverse the above while maintaining the assembled state and
install it on the transmission cover.
2-22

[Point 4]
Disassembly:
Press in the valve plug with its opening facing downwards and
remove the key.

Inspection:
\ \ Measure free length of each valve spring.

Standard mm (in) Limit mm (in)

FIR shift valve 59.8 (2.354) 56.8 (2.236)
--
Safety valve 59.8 (2.354) 56.8 (2.236
~
 2-23

TORQUE CONVERTER-OIL PUMP

REMOVAL-INSTALLATION
T = N·m (kgf-cm) [ft·lbf]

Removal Procedure
1 Drain torque converter oil.
2 Remove the engine ASSY. (See page 1-10)
Remove the torque converter ASSY. [Point 1]
4 Remove the oil pump W/ stator shaft. [Point 2]
5 Remove the stator shaft. [Point 3]
6 Remove the oil pump drive gear and the oil pump driven gear. [Point 4]
7 Remove the oil seal. [Point 5]

Installation Procedure
The installation procedure is reverse of the removal procedure.

Point Operations
[Point 1]
Removal:
Be careful as the torque converter ASSY contains oil.
Installation:
Apply MP grease to the seal ring and oil seal lip before
installation.
Installation:
Install while rotating the torque converter ASSY so that the
extension claw engages with the groove in the oil pump drive gear.
2-24

[Point 2]
Service tap
Removal:
SST 09950-76014-71
(09950-40011 )

Service tap

Installation:
8e careful not to install the p,e-coated boits in incorrect
positions.
Installation:
When reusing precoated bolts, apply thread tighten er (0883?
76002-71 (08833-00080)) to the threaded part.

[Point 3]
Removal:
Put match marks on the oil pump and stator shaft ASSY.
Installation:
Align match marks when installing.

[Point 4]
Inspection:
Measure the clearance between the oil pump driven gear and
pump body.
Limit: 0.3 mm (0.012 in)

Inspection:
Measure the clearance between the pump body and each
gear.
Standard: 0.042 - 0.080 mm (0.002 - 0.003 in)
 2-25

Inspection:
The marks have no meaning for reassembly.

[Point 5]
Installation:
SST 09370-10410-71
2-26

TORQUE CONVERTER & TRANSMISSION ASSY

REMOVAL-INSTALLATION
T := N·m (kgf-cm) [ft·lbn

\ \

26 9

Engine mounting nut T == 53.2 - 98.0 (550 - 1000) [39.8 - 72.3]

Front insulator set bolt T:= 68.0 -102.0 (700 - 1050) [50.6 - 76.0]
Torque converter housing set bolt T:= 29.4 - 44.1 (300 - 450) [21.7 - 32.6]
4Y engine vehicle
T:= 56.8 - 64.7 (580 - 660) [42.0 - 47.8J
Drive plate set bolt (for connecting to engine crankshaft)
1DZ-III, 3Z engine vehicle
T:= 76.4 - 93.1 (780 - 950) [56.4 - 68.7J
Drive plate set bolt (for connecting to torque converter) T:= 14.7 - 21.6 (150 - 220) [10.9 -15.9J
 2-27

Removal Procedure
1 Remove the engine hood. (Refer to page 9-10)
2 Remove the lower panel.
3 Remove the toe board.
4 Drain coolant.
5 Remove the battery.
6 Remove the sedimenter bracket set bolt and leave it free. (1 DZ-III, 3Z engine vehicle)
7 Disconnect the accelerator wire. (1DZ-III, 3Z engine vehicle)
8 Disconnect the fuel hose.
9 Remove the relay block and leave it free.
10 Remove the battery set plate.
11 Remove the air cleaner and air inlet.
'L. Remove the exhaust pipe cover plate.
13 Disconnect the exhaust pipe.
14 Remove the RH side step and side cover.
15 Disconnect the main harness connector inside the RH side cover.
16 Disconnect the oil pump-to-oil control valve hose.
17 Disconnect the inching wire.
18 Disconnect the torque converter cooler hose (on the transmission side)and drain oil from the torque converter.
[Point 1]
19 Disconnect the torque converter cooler hose (on the radiator side). [Point 2]
20 Disconnect the water hose.
21 Remove the radiator and fan shroud.
22 Remove the under cover.
"1 Drain the brake cooling oil. (Wet Brake model) (Refer to page 8-64)
24 Remove the brake cooling oil tank. (Wet Brake model) (Refer to page 8-63)
25 Disconnect the wiring and wire harness clamps around the engine and transmission.
26 Remove the oil pump set bolt, and leave it free.
27 Remove the propeller shaft under cover and propeller shaft.
(Dry Brake model: Refer to page 3-5, Wet Brake model: Refer to page 3-6)
28 Remove the engine mount nut.
29 Attach the SST to the engine WI torque converter and transmission ASSY. [Point 3]
30 Remove the front insulator set bolt.
31 Remove the engine WI torque converter & transmission ASSY. [Point 4]
32 Remove the cover plate.
33 Remove the drive plate set bolts (6 bolts). [Point 5]
34 Disconnect the engine ASSY from the torque converter housing.
2-28

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the engine ASSY, perform air bleeding ofthe fuel system. (1 DZ-III, 3Z engine vehicle) (Refer to
page 1-13)

Point Operations
[Point 1J
Removal:
Put match marks on the transmission case and torque
converter cooler hose.

[Point 2J
Removal:
Put match marks on the radiator and torque converter cooler
hose.

[Point 3J
Removal-Installation:
SST 09010-20111-71........ . (1)
09010-23320-71 (2)

[Point 4J
Removal-Installation:
Move the SST hook position to adjust the balance.
 2-29 .

[Point 5]

Removal-I nstallation:
Turn the flywheel using the crankshaft pulley set bolt.

I.

Crankshaft
pulley set bolt
2-30

ON ASSY
TRANSMISSI REASSEMBLY
DlSASSEMBLY-INSPECTION-
T=N'm (kgf-cm) [ft·lbfJ
 2-31

Disassembly Procedure
1 Drain torque converter oil.
2 Remove the transmission cover & control valve ASSY.
3 Remove the torque converter.
4 Remove the oil pump W/ stator shaft ASSY and shim. [Point 1]
5 Remove the rear case. [Point 2]
6 Remove the output gear cover, output gear and shim. [Point 3]
7 Remove the counter gear and shim. [Point 4]
8 Remove the counter gear shaft and main shaft ASSY. [Point 5]
9 Remove the spacer, main shaft rear bearing, reverse clutch gear, forward clutch gear, and reverse & forward
clutch drum ASSY. [Point 6]
(Refer to page 2-37 for disassembly, inspection and reassembly of the clutch drum ASSY)
J Remove the forward clutch gear bearing. [Point 7]
Remove the reverse clutch gear bearing. [Point 8]
12 Remove the output shaft. [Point 9]
13 Remove the output shaft dust deflector. [Point 10]
14 Remove the main shaft front bearing, the counter gear bearing and output gear bearing. [Point 11]
15 Remove the output shaft oil seal. [Point 12]
16 Remove the oil strainer. [Point 13]
17 Remove the oil filter. [Point 14]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure

Point Operations
Service tap
[Point 1]
Disassembly:
SST 09950-76014-71
(09950-40011 )

Reassembly:
Be careful not to install the pre-coated bolts in incorrect
positions.
Reassembly:
When reusing precoated bolts, apply thread tightener (08833-
76002-71 (08833-00080)) to the threaded part.
2-32

Reassembly:
Adjust the thrust clearance of the main shaft system.
1. Temporarily assemble the oil pump W/ stator shaft ASSY,
shim, and rear case, and measure the thrust clearance of the
main shaft gear system.
Standard: A = 0.10 - 0.24 mm (0.004 - 0.009 in)

2. If the standard is not satisfied, increase or decrease the shim

thickness for adjustment.
Mark Thickness mm (in)
I
I
A 1.08 - 1.12 (0.043 - 0.044)
B 1.18 - 1.22 (0.046 - 0.048)
C 1.28 - 1.32 (0.050 - 0.052) i

E 1.38 - 1.42 (0.054 - 0.056)

.
F 1.48 - 1.52 (0.058 - 0.060)
G 1.58 - 1.62 (0.062 - 0.064)
H 1.68 - 1.72 (0.066 - 0.068)
J 1.78 - 1.82 (0.070 - 0.072)
K 1.88 - 1.92 (0.074 - 0.076)
L 1.98 - 2.02 (0.078 - 0.080)
M 2.08 - 2.12 (0.082 - 0.083)
N 2.18 - 2.22 (0.086 - 0.087)
P 2.28 - 2.32 (0.090 - 0.091 )
R 2.38 - 2.42 (0.094 - 0.095)
S 2.48 - 2.52 (0.098 - 0.099)

[Point 2]
Disassembly: .. .
Insert a flat head screwdriver in the cut portion of the rear ca"B
and remove the case.

Reassembly:
Assemble after removing iron powder staying on the magnet.
 2-33

[Point 3]
Reassembly:
Adjust the output gear thrust clearance.
1. Temporarily install the output gear, shim and rear case, and
measure the output gear thrust clearance.
Standard: A = 0.10 - 0.49 mm (0.004 - 0.019 in)

2. If the standard is not satisfied, increase or decrease the shim

thickness for adjustment.

Mark Thickness mm (in)

0 0.375 - 0.425 (0.015 - 0.017)
2 0.67 - 0.75 (0.026 - 0.030)
4 0.855 - 0.945(0.034 - 0.037)
6 1.065 - 1.175 (0.042 - 0.046)
7 1.12 - 1.24 (0.044 - 0.049)

[Point 4]
Reassembly:
Adjust the counter gear thrust clearance.
1. Temoporarily assemble the counter gear, shim and rear case,
and measure the thrust clearance of the counter gear.
Standard: 0.10 - 0.54 mm (0.004 - 0.021 in)

2. If the standard is not satisfied, increase or decrease the shim

thickness for adjustment.

Mark Thickness mm (in)

0 0.375 - 0.425 (0.015 - 0.017)
2 0.67 - 0.75 (0.026 - 0.030)
3 0.855 - 0.945 (0.034 - 0.037)
4 1.01 -1.11 (0.040 - 0.044)
5 1.12 - 1.24 (0.044 - 0.049)
6 1.24 -1.36 (0.049 - 0.054)

[Point 5J
Disassembly·Reassembly:
Disassemble or reassemble the counter gear shaft together
with the main shaft ASSY.
2-34

[Point 6]
Inspection:
Measure the seal ring side clearance.
Limit: 0.2 mm (0.008 in)

Reassembly:
After aligning the clutch disc serration using a screwdriver or
the like, reassemble the clutch gear.

[Point 7]
Disassembly:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

Reassembly:
SST 09950-76019-71 (1)
(09950-60020)
09950-76020-71 (2)
(09950-70010)

[Point 8]
Disassembly:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)
 2-35

Reassembly:
SST 09950-76019-71 (1)
(09950-60020)
09950-76020-71 (2)
(09950-70010)

[Point 9]
Disassembly-Reassembly:
SST 09905-76002-71
(09905-00012)

[Point 10]
Reassembly:
SST 09370-20270-71

[Point 11]
Disassembly:
SST 09320-23000-71

Reassembly:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)
2-36

[Point 12]
Disassembly· Reassembly:
Use a flat head screwdriver or the like to disassemble or
reassemble the output shaft oil seal.
Reassembly:
Reassemble the output shaft oil seal to the position A in the
illustration.
A = 6.7 - 7.7 mm (0.264 - 0.303 in)

[Point 13]
Disassembly:
Pinch the rib part of the oil strainer with long-nosed pliers, and
remove the oil strainer.

[Point 14]

Disassembly·Reassembly:
SST 09228-76004-71
(09228-07501 )

Clutch operation check after reassembly

Blow air through the oil hole on top of the transmission case a~
check that each clutch piston operates normally.
 2-37

CLUTCH DRUM ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY

---isassembly Procedure
Remove the snap ring.
L. Remove the backing plate, clutch discs, clutch plates and camber plate. [Point 1]
3 Remove the snap ring and clutch piston return spring. [Point 2]

4 Remove the clutch piston, piston ring and seal ring. [Point 3]

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.

Point Operations
[Point 1]
Inspection:
Measure thickness of the clutch disc.
Standard: 2.6 mm (0.102 in)
Limit: 2.3 mm (0.091 in)
2-38

Inspection:
Measure thickness of the clutch plate.
Standard: 2.0 mm (0.079 in)
Limit: 1.8 mm (0.071 in)

Inspection:
Measure height of the camber plate curving.
Standard: 3.4 mm (0.134 in)
Limit: 3.1 mm (0.122 in)

Reassembly:
Clutch gear side
Reassemble with the punched side facing upwards (the clutch
~ gear side).

C)
~
Punching
Piston side
 2-39

Reassembly:
Install the clutch plates and clutch discs alternately on the
clutch drum while applying torque converter oil.
Number of clutch discs
1 ton series 4Y·1 DZ-III models 4
K2 ton series 4Y·1DZ-1I1 models 5
4Y·1DZ-11I models 5
2·3 ton series
3Z model 5
4Y model 5
J3.5 ton series
3Z model 5

Reassembly:
Adjust the clearance between the backing plate and clutch
disc.
1. Install the camber plate, clutch plates, clutch discs, backing
plate and snap ring on the clutch drum.
2. Measure clearance between the backing plate and snap ring
using thickness gauges.

Standard:
4-disc specification: 0.8 - 1.4 mm (0.031 - 0.055 in)
5-disc specification: 1.0 - 1.6 mm (0.039 - 0.063 in)

3. If the measured value is out of the specified range, select a

Identifying grooves
suitable backing plate.
Backing plate thickness
A Identifying grooves

A 57 mm (0.224 in) 0
6.2 mm (0.244 in) One groove
6.7 mm (0.264 in) Two grooves

Identifying grooves Reassembly:

Install the backing plate with its stepped side (with groove)
facing upward (on the clutch gear side).
2-40

[Point 2]
Disassembly· Reassembly:
Compress the return spring using the SST and remove or
install the snap ring.
Tie two hooks of the SST using a wire or string as shown in the
illustration to fix it in the clutch drum.
SST 09220-22001-71 , (1)
09905-76002-71 (2)
(09905-00012)
Wire

\ \ Caution:
The hooks may come off the clutch drum and spring may jump
out when using the SST. Be careful not to allow the hooks to
come off the drum when removing or installing the snap ring.

Inspection:
Measure free length of the clutch piston return spring.
Standard: 63.4 mm (2.496 in)
Limit: 58.5 mm (2.303 in)

[Point 3]
Disassembly:
Pinch the rib of clutch piston using pliers with cloth in-between
and remove the piston.
Reassembly:
Apply torque converter oil on the piston ring and seal ring, and
assemble the clutch piston.
 2-41

2 STATORS TORQUE CONVERTER (OPT)

GENERAL

F: Forward
R: Reverse
2-42

Control Valve

Inching valve

~' 11
~U
[ fJilJJ
I

Regulator valve

Accumulator
 J:
Main pressure port
-<
o
PT1/8" ;;0
»
c
Main pressure
-
I
n
Regulator valve )I( Accumulator orifice n
/1'-,
,
-
::0
;, n
r --- ---
,
'! c
~
-1._ - , -
-'-
-
I ,
Regul.a.tor )I(
L!.J L!.J
:
I
,
I
:
I onflce
Accumulator a
i Oil cooler i »
G)
)I( Orifice I
: ,
:
1

::0
,;
; »
s
I '
r------------1:Xt-J \
Forward clutch Oil filter
Lubrication

1EJI Reversl3
pressure port
Forward PT1/8"
pressure port Sol (2) Sol (1)
~
f
PT1/8"
I
R
F

Reverse clutch Sol (1) Sol (2)

~I
Torque converter
F I ON OFF
Suction filter
R OFF ON
I AI
N OFF OFF I
I IN
I
~
W
2-44

SPECIFICATIONS
Item 2-Stators torque converter
Maker OKAMURA
Torque converter type 4-elements 2-step 3-phases type
Stall torque ratio 3.49
Stall speed rpm 1950
Forward 1.041
Torque converter gear ratio
Reverse 1.041
Control system Solenoid type selector valve
Clutch operating pressure (main pressure) kPa (kgf/cm 2 ) [psi] 1000 - 1400 (10.2 - 14.2) [145 - 203]

Torque converter outlet pressure kPa (kgf/cm 2 ) [psi] 100 - 400 (1.02 - 4.1) [14.5 - 58]
Torque converter oil capacity I' (USgal) 10.0 (2.64)
Torque converter oil ATF GM Dexron® I1

Note:
The indicated oil pressure is at an engine speed of 1500 rpm.
 2-45

COMPONENTS

Torque Converter Housing

3201

25

Torque Converter

3202
2-46

Torque Converter Clutch

3203

3204
Refer to
3203-10

3204-086
 2-47

Control Valve

I 3206

Torque Converter Piping

3213

3213-161
2-48

Direction Switch

5701

Q---~ aB
\

\
A2 \
r....· _1'-----_____ ' - 1

........... ___.
.
..... J
- -

5701-S10A
 ~
Inspection after disassembly· ;0
Control valves
Other then control valves Inspection on the vehicle oc
(torque converter & transmission)
to
r-
Q) m
0:: "0
e
::0
C1l
en
"0
e 0:: C1l
l)
:I:
C1l "0
e r. € 0»
l-
o
LL
I-

.2 l-
C1l
LL
(J)
CJ)
e
.;::
.2
.~ 0
0)
a. .~

"0
en
o~
-z
I-
0) 0) I-
(J)
a. e
> 0) l- t:: .2 C1l C1l 0)

Cii 0) > 0) 0) 0) wr. "0 ~

I-
e .a > e I-

e>
l)
> > 0 Cii E 0) 0)

a Cii
>
m > .~ L-
0)
e 0
a.
::J "0
e -e
Q) :::
:;:
C1l
a:;
>
.!!:2
I-
::J G)
Cil CJ)
:s "0
'0 en .(ij
l)
0) E
I-
"0 C1l 0_
(/)
> CJ)
(/)
(J) en
:3 e E e0) Q) I-
:J :J r. (J) :;:; C1l
l) L- -LL :.ce
0) Q)
I-
Q)
~

..c ::J e ~
(J) 0- D. .2 L-
C1l O)~ a.
CJ) u :J ::J Cii
Q)
0::
l)
..:::
l)
<J::
(5
(J) c (5
I-

~ (5 U
0)
0
I-
.-
o
0)
e t: l)
..::: (5 i75
The vehicle does not move when F is selected. 0 0 0 0 0
The vehicle does not move when R is selected. 0 0 0 0 0
Starting defect
The vehicle does not move for any range selection. 0 0 0 0 0 0 0 0 0 0 0
The vehicle moves regardless of N selection. 0 0 0 0

Starting N-7F 0 0 0 0
Excessive shock (shifting) N-7R 0 0 0 0
upon starting
(shifting). Starting At F 0 0 0 0 0 0
(inching) AtR 0 0 0 0 0 0
N-7F 0 0 0 0 0 0 0 0
Excessive time lag
upon starting N-7R 0 0 0 0 0 0 0 0
(shifting)
Upon switch-back F H R 0 0 0 0 0 0 0 0
AtF 0 0 0 0 0 0 0
Slipping
AtR 0 0 0 0 0 0 0
The starting motor does not run at N. 0
The starting motor runs at other than N. 0
Inching operation fails. 0 0 0 0
Others
Transmission overheating or oil spouting from
0 0 0 0 0 0 0
breather.

Abnormal noise. 0 0 0 0
NI
~
(0
2-50

TORQUE CONVERTER

REMOVAL-INSTALLATION
T = N·m (kgf-cm) [ft·lbf]

Removal Procedure
1 Drain torque converter oil.
2 Remove the engine ASSY. (See page 1-10)
3 Remove the torque converter.

Installation Procedure
The installation procedure is reverse of the removal procedure.
 2-51

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N'm (kgf-cm) [ft'lb~

/~----

Disassembly Procedure
1 Remove the pump impeller. [Point 1]
2 Remove the pump boss ASSY. [Point 2]
3 Remove the stator NO.2 parts. [Point 3]
4 Remove the stator NO.1 parts. [Point 4]
5 Remove the turbine runner.
6 Remove the pilot bearing. [Point 5]

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
2-52

Point Operations
[Point 1]
Disassembly:
Put match marks on the pump impeller and drive cover.
Reassembly:
Align the match marks on the pump impeller and drive cover.

[Point 2]
Disassembly:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

Reassembly:
SST 09950-76019-71 (1)
(09950-60020)
09950-76020-71 (2)
(09950-70010)

Inspection:
Measure the outside diameter at the oil seal sliding surface.
Standard: 70.00 mm (2.7559 in)
Limit: 69.85 mm (2.7450 in)

Inspection:
Measure the seal ring side clearance.
Limit: 0.3 mm (0.012 in)
 2-53

Inspection:
Measure the seal ring side clearance.
Limit: 0.3 mm (0.012 in)

[Point 3]
Disassembly:
Slowly remove the stator hub because rollers, springs and
spring caps come off at a time.
Inspection:
Measure the roller outside diameter.

000000000 Standard: 8.2 mm (0.323 in)

DDD0 D000 0 0 Limit: 8.17 mm (0.322 in)

B• I I I I BI I I

Inspection:
Measure the clearance between the stator hub and stator cam.
Standard: 0.08 - 0.12 mm (0.0031 - 0.0047 in)
Limit: 0.2 mm (0.0079 in)

Reassembly:
Stator installation
1. Apply grease on the springs and spring caps, and install them
with tweezers or a similar tool.

2. Install rollers while pushing each spring cap with a screwdriver.

2-54

3. Install the stator hub on the stator by turning it in the unlocking

direction.

4. Check the one-way clutch function after reassembly.

\ . \ Hold

[Point 4]
Reassembly:
Never install the one-way clutch, thrust bearing and stator hub
in wrong directions. (See the illustration)

Calor: Black

Reassembly:
Check the one-way clutch function after reassembly.

direction

[Point 5]
Disassembly:
SST 09320-23000-71
 2-55

Reassembly:
SST 09950-76018-71
(09950-60010) (1)
SST(2)
09950-76020-71
(09950-70010) (2)
2-56

TORQUE CONVERTER & TRANSMISSION ASSY

REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

/
29
\\ \

26 9

Engine mounting nut T = 53.2 - 98.0 (550 - 1000) [39.8 - 72.3]

Front insulator set bolt T = 68.0 - 102.0 (700 - 1050) [50.6 - 76.0]
Torque converter housing set bolt T = 29.4 - 44.1 (300 - 450) [21.7 - 32.6]
4Y engine vehicle
T = 56.8 - 64.7 (580 - 660) [42.0 - 47.8]
Drive plate set bolt (for connecting to engine crankshaft)
1DZ-III, 3Z engine vehicle
T = 76.4 - 93.1 (780 - 950) [56.4 - 68.7]
Drive plate set bolt (for connecting to torque converter) T = 14.7 - 21.6 (150 - 220) [10.9 - 15.9]
 2-57

Removal Procedure
Remove the engine hood. (Refer to page 9-10)
2 Remove the lower panel.
3 Remove the toe board.
4 Drain coolant.
5 Remove the battery.
6 Remove the sedimenter bracket set bolt and leave it free. (1 DZ-III, 3Z engine vehicle)
7 Disconnect the accelerator wire. (1 DZ-III, 3Z engine vehicle)
8 Disconnect the fuel hose.
9 Remove the relay block and leave it free.
10 Remove the battery set plate.
Remove the air cleaner and air inlet.
~ '2 Remove the exhaust pipe cover plate.
13 Disconnect the exhaust pipe.
14 Remove the RH side step and side cover.
i5 Disconnect the main harness connector inside the RH side cover.
16 Disconnect the oil pump-to-oil control valve hose.
17 Disconnect the inching wire.
18 Disconnect the torque converter cooler hose (on the transmission side) and drain oil from the torque converter.
[Point 1]
19 Disconnect the torque converter cooler hose (on the radiator side). [Point 2]
20 Disconnect the water hose.
21 Remove the radiator and fan shroud.
22 Remove the under cover.
3 Drain the brake cooling oil. (Wet Brake model) (Refer to page 8-64)
.. 1- Remove the brake cooling oil tank. (Wet Brake model) (Refer to page 8-63)
25 Disconnect the wiring and wire harness clamps around the engine and transmission.
26 Remove the oil pump set bolt, and leave it free.
27 Remove the propeller shaft under cover and propeller shaft.
(Dry Brake model: Refer to page 3-5, Wet Brake model: Refer to page 3-6)
28 Remove the engine mount nut.
29 Attach the SST to the engine W/ torque converter and transmission ASSY. [Point 3]
30 Remove the front insulator set bolt.
31 Remove the engine WI torque converter & transmission ASSY. [Point 4]
32 Remove the cover plate.
33 Remove the drive plate set bolts (6 bolts). [Point 5]
34 Disconnect the engine ASSY from the torque converter housing.
2-58

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the engine ASSY, perform air bleeding ofthe fuel system. (1DZ-III, 3Z engine vehicle) (Refer to
page 1-13)

Point Operations
[Point 1]
Removal:
Put match marks on the transmission case and torque
converter cooler hose.

[Point 2]
Removal:
Put match marks on the radiator and torque converter cooler
hose.

[Point 3]
Removal·lnstallation:
SST 09010-20111-71 (1)
09010-23320-71 (2)

[Point 4]
Removal·lnstallation:
Move the SST hook position to adjust the balance.
 2-59

[Point 5]
Removal·lnstallation:
Turn the flywheel using the crankshaft pulley set bolt.

Crankshaft
pulley set bolt
2-60

TRANSMISSION ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N'm (kgfcm) [ft·lbn
Disassembly Procedure
1 Drain the torque converter oil.
2 Remove the torque converter.
(For disassembly, inspection and reassembly of torque converter ASSY, see page 2-51)
3 Remove the solenoid valve. [Point 1]
4 Remove the inching valve ASSY.
5 Remove the inching spool and spring. [Point 2]
6 Remove the coin filter from the inching valve body. [Point 3]
7 Remove the oil seal from the inching valve body. [Point 4]
8 Remove the accumulator valve. [Point 5]
9 Remove the regulator valve. [Point 6]
10 Remove the oil filter. [Point 7]
11 Remove the oil strainer.
Separate the torque converter case and transmission case. [Point 8]
13 Remove the idle gear W/ bearing. [Point 9]
14 Remove the bearing from the idle gear. [Point 10]
15 Remove the stator shaft NO.1 W/ bearing. [Point 11]
16 Remove the bearing from the stator shaft NO.1. [Point 12]
17 Remove the output shaft bearing from torque converter case. [Point 13]
18 Remove the stator shaft NO.2 & oil pump ASSY.
(For disassembly, inspection and reassembly of stator shaft NO.2 & oil pump ASSY, see page 2-71) [Point 14]
19 Remove the reverse shaft bearing from torque converter case. [point 15]
20 Remove the reverse shaft counter gear. [Point 16]
21 Remove the main shaft counter gear W/ bearing. [Point 17]
'>2 Remove the main shaft counter gear bearing. [Point 18]
23 Remove the output shaft ASSY. [Point 19]
+ Remove the main shaft ASSY (clutch drum ASSY NO.1 W/ clutch gear).
(For disassembly, inspection and reassembly of clutch drum ASSY, see page 2-73)
25 Remove the reverse shaft ASSY (clutch drum ASSY NO.2 W/ clutch gear).
(For disassembly, inspection and reassembly of clutch drum ASSY, see page 2-73)
26 Remove the shaft seal ring and bearing. [Point 20]
27 Remove the clutch gear and clutch gear bearing. [Point 21]
28 Remove the output shaft oil seal. [Point 22]
29 Remove the output shaft bearing from transmission case. [Point 23}
2-62

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply sealing agent (08826-76001-71 (08826-00080)) on the oil strainer surface to be mounted on the torque
converter case.

u
Point Operations
[Point 1]
Inspection:
Inspect the solenoid valve for continuity.
Between 1 and 2: Continuity
Between 3 and 4: Continuity

[Point 2]
Inspection:
Measure the free length of the inching valve spring.
mm (in)
Standard Limit
Inner spring 27 (1.06) 24 (0.94)
Outer spring 63.3 (2.49) 58 (2.28)

Reassembly:
Never install the spring retainer in a wrong direction.

[Point 3]
Inspection:
Inspect and wash the coin filter to eliminate clogging.
 2-63

[Point 4]
Disassembly:
SST 09950-76018-71 (1)
SST (2)
(09950-60010)
SST (1) 09950-76020-71 (2)
(09950-70010)

[Point 5]
Inspection:
Measure the free length of the accumulator spring.
mm (in)

Standard Limit
Inner spring 70 (2.756) 62 (2.441)
Outer spring 122 (4.803) 108 (4.252)

[Point 6]
DisassemblyoReassembly:
Use the service bolt for disassembly and reassembly of the
regulator valve spool.
Service bolt size: M6 x 1.0

Inspection:
Measure the free length of the regulator valve spring.
Standard: 110 mm (4.331 in)
Limit: 98 mm (3.858 in)

[Point 7]
DisassemblyoReassembly:
SST 09228-76004-71
(09228-07501 )
2-64

[Point 8]
Disassembly·Reassembly:
SST 09010-13200-71

Reassembly:
Set the O-ring in the specified position on the case mating
surface.

Reassembly:
When joining the case, use a screwdriver and adjust so that
the No.1 stator gear meshes with the counter shaft gear.

[Point 9]
Disassembly:
SST 09950-76014-71
(09950-40011 )

Reassembly:
Use a round bar and install the idle gear W/ bearing.
 2-65

[Point 10]
Disassembly:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

Reassembly:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

[Point 11]
Inspection:
Measure the seal ring side clearance.
Limit: 0.3 mm (0.012 in)

[Point 12]
Disassembly:
SST 09950-76014-71 (1)
(09950-40011 )
09950-76018-71 (2)
(09950-60010)

Reassembly:
Use a round bar and install the bearing.
2-66

[Point 13]
Disassembly:
SST 09320-23000-71

Reassembly:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

[Point 14]
Disassembly:
Use a round bar and remove the stator shaft NO.2 & oil pump
ASSY.

[Point 15]
Disassembly:
SST 09950-76014-71
(09950-40011 )

Reassembly:

SST 09950-76019-71 (1)

(09950-60020)
09950-76020-71 (2)
(09950-70010)
 2-67

[Point 16]
Disassembly:
Use a bar and remove reverse shaft counter gear NO.1.

Disassembly:
Use a bar and remove reverse shaft counter gear ~~o.2.

[Point 17]
Disassembly:
Use a bar and remove the main shaft counter gear w/ bearing.

[Point 18]
Reassembly:
Install the bearing in the correct direction (See the illustration.)

[Point 19]
Disassembly:
Remove the output shaft ASSY by tapping its tip end with a
plastic hammer.
2-68

Reassembly:
Install the output shaft ASSY by tapping the joint using a
plastic hammer.

[Point 20]
Inspection:
Measure the side clearance of each shaft seal ring.
mm (in)
Limit
Main shaft 0.3 (0.012)
"

Reverse shaft 0.3 (0.012)

I

Inspection:
Measure the seal ring side clearance. (Main shaft only)
Limit: 0.3 mm (0.012 in)

Disassembly:
Remove the bearing using the SST and a press.
SST 09420-23002-71

Reassembly:
Use a round bar and install the bearing.
 2-69

[Point 21]
Disassembly:
Remove the clutch gear W/ bearing using the SST and a
press.
SST 09420-23002-71

Disassembly:
SST 09950-76019-71 (1)
(09950-60020)
09950-76020-71 (2)
(09950-70010)

Reassembly:
After aligning the clutch disc serration using a screwdriver or
the like, reassemble the clutch gear.

Reassembly:
1. Insert a plate between the clutch gear and clutch drum as
illustrated, and temporarily install the gear first.
2. Use a round bar and install the clutch gear bearing to the
clutch gear.
3. Remove the plate.

[Point 22]
Reassembly:
SST 09150-10170-71
2-70

[Point 23]
Disassembly:
SST (09950-60010)
09950-76018-71 (1)

09950-76020-71
(09950-70010) (2)

Reassembly:
SST (09950-60020)
09950-76019-71 (1)

09950-76020-71
(09950-70010) (2)
 2-71

STAlOR SHAFT NO.2 & OIL PUMP ASSY

D1SASSEMBLY·INSPECTION·REASSEMBLY
T = N'm (kgf-cm) [ft-lbf]

.... Isassembly Procedure

Remove the stator shaft NO.2. [Point 1]
2 Remove the oil pump gear. [Point 2]
3 Remove the oil seal. [Point 3]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Insert flathead screwdrivers between the stator shaft No. 2 and oil
pump ASSY to separate them.
2-72

Inspection:
Measure the outside diameter of the stator shaft NO.2 in sliding
contact with the pump drive gear.
Standard: 48 mm (1.889 in)
Limit: 47.9 mm (1.886 in)

[Point 2]
Inspection:
Measure the clearance between the oil pump driven gear and
pump body.

Standard: 0.14 - 0.20 mm (0.0055 - 0.0079 in)

Limit: 0.3 mm (0.012 in)

Inspection:
Measure the clearance between the pump body mounting
surface and each gear.

Standard: 0.06 - 0.10 mm (0.0024 - 0.0039 in)

Limit: 0.13 mm (0.0051 in)

Inspection:
Measure the clearance between the oil pump drive ge
bushing and stator shaft.

Standard: 0.025 - 0.066 mm (0.00098 - 0.00260 in)

Limit: 0.15 mm (0.0059 in)

[Point 3]
Reassembly:

SST 09370-20270-71
 2-73

CLUTCH DRUM ASSY

DISASSEMBLY·INSPECTION·REASS
__ EMBLY

r'\'
I
-=~~------~
Isassembl y p rocedure
..r
Remove the snap ring
L Remove th e pressure ' I
3 Remo ve the sna . p ate, camber plate, clutch
4 Rem p nng and clutch . plate and clutch .
DVC the clutch . piston return Wi diSC. [Point 1]
R piston. [Point 3] , ng. [Point 2]

Theassembl Y P rocedure
e reassembl y procedure'I S reverse of the d'Isassembl y procedure
2-74

Point Operations
[Point 1J
Inspection:
Measure the camber plate warp height.
Standard: 3.8 mm (0.150 in)
~) c::=:::::::::: Limit: 3.3 mm (0.130 in)

Inspection:
Measure tIle thicknesses of the pressure plate, clutch disc and
clutch plate.
Standard:
mm (in)

Standard Limit
Clutch plate 1.6 (0.063) 1.4 (0.055)',

Clutch plate Clutch disc

Clutch disc 2.6 (0.102) 2.3 (0.091)
I

Reassembly:
Install the camber plate with the "H" mark facing upward.
"H" mark

Reassembly:
Upward Install the camber plate with the chamfered face
upward.

D
Downward

Reassembly:
A Y Carefully install each plate in the correct order.

+ Clearance between snap ring and pressure plate.

Standard: A = 3.1 mm (0.122 in) (Reference)
 2-75

[Point 2]
DisassemblyoReassembly:
Use the SST to compress the return spring for snap ring
installation or removal. Bind two hooks of the SST with a wire
or cord as illustrated to prevent departure from the clutch
drum.
SST 09220-33901-71
Caution:
Carefully operate with sufficient check since the hook may
come off from the clutch drum to cause the spring to fly out
while the SST is in use.

Inspection:
Measure the free length of the clutch piston return spring.
Standard: 100 mm (3.94 in)
Limit: 90 mm (3.54 in)

[Point 3]
Inspection:
Measure the side clearance of the seal ring.
Limit: 0.30 mm (0.012 in)

Inspection:
Measure the side clearance of the piston ring.
Limit: 0.4 mm (0.0157 in)
2-76

DIRECTION SWITCH ASSY

REMOVAL·INSTALLATION

Disassembly Procedure
1 Remove the steering column cover.

2 Disconnect the connector.

3 Remove the direction switch ASSY. [Point 1]

Installation Procedure
The installation procedure is reverse of the removal procedure.

co .-. ,. Point Operations

~8 7 6 5 4 3 2rL [Point 1]
- r------t
'18 17 16 15 14 13 12 11 r.ro Inspection:
~ '---/L

RH spec. LH spec. Inspect for continuity between the pins of the switch connector.
1:- 1: VR
2: IG2 2:Ra (P:Position, T:Terminal No., OD:Continuous)
3: N 3: ST
4: IG1 4: VF2 ~ N IG1 IG2 VF ST VR Ra
5: VF 5: VF
F1
6: VF2 6: IG1
7: ST 7: N I
8: Ra
9: VR
8: IG2
9:-
N D
VF : Forward solenoid
VF2 : Forward (F2) solenoid R
VR : Reverse solenoid Rr
ST : Starting motor relay Ra 0 0
Ra : Backup lamp & buzzer
 2-77

OIL PRESSURE MEASUREMENT AND

STALL TEST (1 SPEED TORQUE
CONVERTER (STD))
1. Maintain the vehicle horizontally and warm up the engine with
the direction switch at the N position.
2. Measure the oil level.
(1) Stop the engine, and after 30 seconds has passed,
inspect the oil level using the level guage.
(2) If the oil level is not between F (upper limit) and L (lower
limit), adjust it to an appropriate level.

3. Measure the oil pressure.

(1) Check and adjust the engine speed.
(2) Stop the engine and jack up at the front axle to raise
[ wheels (both tires).
(3) Set the oil pressure gauge. (If three oil pressure gauges
are available, measure the main, clutch and torque
converter outlet pressures at a time.)
Use the adapter (SST) for the main pressure and clutch
pressure detection port.
SST 09350-23320-71
(SST thread size: Valve side 5/16 UNF, Oil pressure
gauge side PT1/8)

Use the adapter (SST) for the outlet pressure detection

port. (Wet brake model only)
SST 09321-26600-71
(4) Start the engine, set the direction switch to the N position.
Measure the main pressures at idle and 2000 rpm, and
the torque converter outlet pressure at 2000 rpm.
(5) Operate the direction switch to the F and R positions, and
measure the respective clutch working pressures at idle
and at 2000 rpm.
Note:
Do not step on the inching pedal while measuring oil pressure.
Standard:
kPa (kgf/cm 2 ) [psi]

Detecting pressure Plug size Idle 2000 rpm

735 - 1324 (7.5 -13.5)
Main pressure PT1/8 (88T) 890 -1270 (9.1 - 13.0) [129 -185]
[106.6 - 192.0]
Clutch pressure t t 890 - 1270 (9.1 - 13.0) [129 - 185]
Torque converter outlet
PT1/8 - 80 - 540 (0.8 - 5.5) [11.3 -78.2]
pressure
2-78

4. Carry out the stall test.

(1) Load cargo having near the permissible maximum load,
firmly set stoppers at the front and rear wheels, and
activate the parking brake.
Caution:
Prevent the vehicle from moving by pulling at the rear by a
wire as shown, to perform the stall test safely.

(2) Warm up the engine and measure the idle speed, no-load
static maximum revolution and reiief down.

~=~~~~
( . I ""

(3) Set the direction switch to the forward position, depress

Accelerator pedal the accelerator pedal all the way and measure the stall
speed after the engine speed is stabilized.
Standard:
4Y: Approx. 2200 rpm
1DZ-III: Approx. 2200 rpm
3Z: Approx. 2050 rpm
 2-79

OIL PRESSURE MEASUREMENT AND

STALL TEST (2 STATORS TORQUE
CONVERTER (OPT))
1. Maintain the vehicle horizontally and warm up the engine with
the direction switch at the N position.
2. Measure the oil level.
(1) Stop the engine, and after 30 seconds has passed,
inspect the oil level using the level guage.
(2) If the oil level is not between F (upper limit) and L (lower
limit), adjust it to an appropriate !evel.

3. Measure the oil pressure.

(1) Check and adjust the engine speed.
(2) Stop the engine and jack up at the front axle to raise
wheels (both tires).
(3) Set the oil pressure gauge. (If three oil pressure gauges
are available, measure the main, clutch and torque
converter outlet pressures at a time.)
Use the adapter (SST) for the outlet pressure detection
port. (Wet brake model only)
SST 09321-26600-71

(4) Start the engine, set the direction switch to the N position.
Wet brake
Measure the main pressures at idle and 1500 rpm, and
model
the torque converter outlet pressure at 1500 rpm.

ij (5) Operate the direction switch to the F and R positions, and

measure the respective clutch working pressures at idle
and at 1500 rpm.
Note:
Do not step on the inching pedal while measuring oil pressure.

,-,~andard:
kPa (kgf/cm 2 ) [psi]

Detecting pressure Plug size Idle 1:>00 rpm

600 or more (6 or more)
Main pressure PT1/8 1000 -1400 (10.2 - 14.2) [145 - 203]
[85 or more]
Clutch pressure t t t
Torque converter outlet
pressure
t - 100 - 400 (1.02 - 4.1) [14.5 - 58]
2-80

4. Carry out the stall test.

(1) Load cargo having near the permissible maximum load,
firmly set stoppers at the front and rear wheels, and
activate the parking brake.
Caution:
Prevent the vehicle from moving by pulling at the rear by a
wire as shown, to perform the stall test safely.

(2) Warm up the engine and measure the idle speed, no-load

:~ ,/ / ~" static maximum revolution and relief down.

~~(~~ (3) Set the direction switch to the forward position, depress
Accelerator pedal the accelerator pedal all the way and measure the stall
speed after the engine speed is stabilized.
Standard:
4Y: Approx. 1950 rpm
1DZ-III: Approx. 1950 rpm
3Z: Approx. 1950rpm
 3-1

PROPELLER SHAFT
Page
GEN ERAL 3..2
SPECIFICATIONS 3..2
COM PON ENTS 3-3
PROPELLER SHAFT 3-5
I:ll=lInr"fJ\ I .1t..ICTJ\ I I J\T10t..1
~ .... i"'I'-' VI"'\L -11'IIu II'"'\LLI'"'\.. • ..

(DRY BRAKE MODEL (STD» 3..5

REMOVAL-INSTALLATION
(WET BRAKE MODEL (OPT» 3..6
DISASSEMBLY·INSPECTION·REASSEMBLY 3..7
3-2

GENERAL
DRY BRAKE MODEL (STD)
A

B
I~ ~I

WET BRAKE MODEL (OPT)

A

SPECI FICATIONS

Item
~el Dry brake (STD) Wet brake (OPT)

Joint type Cross type

A 150.0 (5.906) 100.0 (3.937)
Length mm (in)
B 119.0 (4.685) 69.0 (2.717)
COMPONENTS
DRY BRAKE MODEL (STD) 3701

3701·109

WET BRAKE MODEL (OPT)

01

/?\
~;~ ~BZ
AZ

3701·110
3-4

3701

~1
.....
··
••• "\1

·••

··
I . •••
••
·
..... 01

3701-107
 3-5

PROPELLER SHAFT

REMOVAL·INSTALLATION (DRY BRAKE MODEL (STD))

T::: N'm (kgf'cm) [ft'lbf)

T::: 28.0 - 36.0

(290 - 370) [21.0 - 26.8)

T::: 11.4 - 26.6

(116 - 271) [8.4 - 19.6)

I .emoval Procedure
Remove the propeller shaft under cover.
2 Remove the propeller shaft set bolt.
3 Remove the propeller shaft.

Installation procedure
The installation procedure is the reverse of the removal procedure.
Note:
Add MP grease through the grease fitting.
3-6

REMOVAL-INSTALLATION (WET BRAKE MODEL (OPT»

T = N-m(kgf-cm) [ft-Ibf]

Removal Procedure
1 Remove the front under cover and rear under cover.
2 Disconnect the parking brake cable. (unit side)
3 Remove the parking cable bracket.
4 Remove the parking limit switch.
5 Remove the propeller shaft under cover.
6 Remove the propeller shaft set bolt.
7 Remove the propeller shaft.

Installation procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Add MP grease through the grease fitting.
• Apply thread tightener (08833-76002-71 (08833-00080)) to the set screw of the parking brake limit switch
before reassembly.
• After reassembling the parking brake cable, inspect and adjust the parking brake. (Refer to page 8-61,
62).
 3-7

DISASSEMBLY·INSPECTION·REASSEMBLY

Disa~sembly Procedure

1 Fix the propeller shaft in a vise.

Remove the snap rings.
Remove the universal spider sets. [Point 1]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
3-8

Point Operations
[Point 1]
Disassembly:
Remove the universal spider sets.
1. Use a brass bar to extract the bearing cup.

2. Use the brass bar to extract the bearing cup on the other side
and remove the spider set.
3. Remove the spider set on the opposite side in the same way.

Reassembly:
Install the universal spider sets.
1. Apply MP grease to the needle roller in the bearing cup.
2. Use a brass bar to slightly drive in the bearing cup.
,
3. Install the spider set.
4. Use the brass bar to drive in the bearing cup until the snap ring
groove appears.'

5. Use the brass bar to drive in the bearing cup on the oppos;
side until the snap ring groove appears.
6. Install the spider set on the opposite side in the same way.
 4-1

DIFFERENTIAL
Page

GENERAL 4..2
SPECIFICATIONS 4..5
COMPON ENTS ...........................................•..........4..6
DIFFERENTIAL ASSY 4..9

REMOVAL·INSTALLATION
(WET BRAKE MODEL) 4..12
DISASSEM BLY·INSPECTION ·REASSEMBLY
(1·2·K2 TON SERIES) 4 ..15
oISASSEM BLY·IN SPECTION· REASSEMBLY
(-3- .J-3- .5- -0'·
T N ~.... E-·E'""')
Kt ~ .AI .... AI
.q. .."" I

DIFFERENTIAL CASE ASSY 4..28

o ISASSEM BLY·IN SPECTIO N·REASSEM BLY
(1·2·K2 TON SERIES) 4..28
DISASSEMBLY·INSPECTION· REASSEMBLY
(3·J3.5 TON SERIES) 4..32
4-2

GENERAL
Differential (1·K2 Ton Series)

Differential (2 Ton Series)

 4-3

Differential (3·J3.5 Ton Series)

Reduction Gear (1·K2 Ton Series)

4-4

Reduction Gear (2 Ton Series)

Reduction Gear (3·J3.5 Ton Series)

 4-5

SPECIFICATIONS
del
1·K2 ton series 2 ton series 3·J3.5 ton series
Item
Differential case type Banjo type f-- f--

-ro Reduction ratio (ring gear/drive pinion) 5.833 f-- f--

~ Drive pinion 6 f-- f--

~ Number of teeth
ill Ring gear 35 f-- f--
~
0 11 2 10 2 10 x 4
Number of teeth x Pinion gear x x

quantity Side gear 16 x 2 f-- 14 x 2

Differential oil quantity Dry brake model 5.5-6.1 (1.45-1.61) 5.8 - 6.4 (1.53 - 1.69) 7.8 - 8.6 (2.06 - 2.27)
f (US gal) Wet brake model (OPT) ~-
6.1-67(1.61-1.77) 8.0 - 8.8 (2.11 - 2.32)
4-6

COMPONENTS
1·K2 ton se nes
.

4101

2 ton series

4101
 4-7

3·J3.5 ton se nes

.

4101

..
L ......

55

r~, 59 AH 59A GU
60A(NO.1]

4101-240
4-8

2 ton series (Wet brake· mo d el)

4101

02

: ... ~~L-I ~_ ... _.,

.. IBD
1
40 • •

AB G

~ t1fl' .
n

~~--~/I
AF

y-~ ..
EW

4101-235

3·J3.5 ton series (Wet brake model)

4101

02

r-.. ~~~I ~- --···1

AF
20

...... ~~~~ "

4101·236
 4-9

DIFFERENTIAL ASSY
REMOVAL-INSTALLATION (DRY BRAKE MODEL)
Note:
Never apply impact to the frame at the time of removal or installation to protect the controller from damage.
T =: N-m (kgf-cm) [ft·lbf]

17

18

*1

1·2 ton series, K2 ton series T =: 68.6 - 98.0 (700 - 1000) [50.6 - 72.3]
*1 Axle shaft set bolt
3 ton series, J3.5 ton series T =: 107 - 140 (1100 - 1400) [78.9 - 103.3]
1·2 ton series, K2 ton series T =: 108 -159 (1100 -1600) [79.7 -117.3]
*2 Front axle ASSY set bolts
3 ton series, J3.5 ton series T =: 127 -190 (1300 -1900) [93.4 - 140.2]
*3 Bolt T =: 294 - 343 (3000 - 3500) [216.9 - 253.1]
*4 Front axle bracket set nut T =: 235 - 294 (2400 - 3000) [173.4 - 216.9]
4-10

Removal Procedure
1 Remove the mast. (Refer to page 11-5)
2 Remove the lower panel and toe board.
3 Remove the instrument panel.
4 Drain differential oil. [Point 1]
5 Jack up the vehicle and remove the front wheel.
6 Remove the speed sensor cover, and disconnect the connector.
7 Drain brake fluid, and disconnect the brake pipe (wheel cylinder side).
8 Disconnect the parking brake cable (lever side).
9 Remove the parking brake cable clamp.
10 Disconnect the mount insulator link.
11 Remove the under cover and propeller shaft cover.
12 Disconnect the propeller shaft. (Refer to page 3-5)
13 Support the bottom of the transmission with a pantograph jack or wooden block.
14 Support the front axle & differential ASSY with a hoist or garage jack. [Point 2]
15 Remove the connector bracket.
16 Remove the front axle bracket through bolts.
17 Remove the front axle bracket reamer bolt. [Point 3]
18 Remove the front axle & differential ASSY.
19 Remove the front axle shaft. (Refer to page 5-9) [Point 4]
20 Remove the front axle W/ bracket. (Refer to page 5-13)
21 Remove the speed sensor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After reassembly, bleed air from the brake. (Refer to 8-22)
• After reassembling the parking brake cable, inspect and adjust the parking brake. (Refer to page 8-26)

Point Operations
[Point 1]
Installation:
After installation, add hypoid gear oil to the specified level.
Vehicle model A
1·K2 ton series 1.7 - 12.0 mm (0.07 - 0.47 in)
2 ton series 1.4 - 11.8 mm (0.06 - 0.46 in)
3·J3.5 ton series .1.2 - 13.8 mm (0.05 - 0.54 in)
 4-11

[Point 2]
Removal·lnstallation:
Install hub nuts on hub bolts on the left and right sides, and
sling wire at the tapered portion.

[Point 3]
Removal:
SST 09310-23320-71

[Point 4]
Removal-Installation:
Operate carefully so as not to bring the axle shaft into contact
with the oil seal lip to damage it.
4-12

REMOVAL-INSTALLATION (WET BRAKE MODEL)

Note:
• Never apply impact to the frame at the time of removal or installation to protect the controller from
damage.
• Release the pressure from the accumulator before starting operation. (Refer to page 8-48)
T:= N·m (kgf·cm) [ft·lbf]

2 ton series T:= 68.6 - 98.0 (700 - 1000) [50.6 - 72.3]

*1 Axle shaft set bolt
3·J3.5 ton series T:= 107 -140 (1100 - 1400) [78.9 - 103.3]
2 ton series T:= 108 -159 (1100 - 1600) [79.7 - 117.3]
*2 Front axle ASSY set bolts
3·J3.5 ton series T:= 127 - 190 (1300 - 1900) [93.4 - 140.2]
*3 Bolt T:= 294 - 343 (3000 - 3500) [216.9 - 253.1]
*4 Front axle bracket set nut T:= 235 - 294 (2400 - 3000) [173.4 - 216.9]
 4-13

Removal Procedure
1 Remove the mast. (Refer to page 11-5)
2 Drain brake cooling oil in ASSY. (Refer to page 8-64)
3 Remove the lower panel and toe board.
4 Remove the instrument panel.
5 Drain differential oil. [Point 1]
6 Jack up the vehicle and remove the front wheel.
7 Remove the speed sensor cover, and disconnect the connector.
8 Disconnect the parking brake cable (unit side).
9 Support the bottom of the transmission with a pantograph jack or wooden block.
10 Disconnect the mount insulator link.
~1 Disconnect the propeller shaft. (Refer to page 3-6)
"'? Remove the 3-way and disconnect each pipe.
·,3 Remove the accumulator ASSY. (Refer to page 8-55)
14 Support the front axle & differential ASSY with a hoist or garage jack. [Point 2]
i5 Remove the connector bracket.
16 Remove the front axle bracket through bolts.
17 Remove the front axle bracket reamer bolt. [Point 3]
18 Remove the front axle & differential ASSY.
19 Remove the parking brake ASSY. (Refer to page 8-58)
20 Remove the front axle shaft. (Refer to page 5-20) [Point 4]
21 Remove the front axle W/ bracket. (Refer to page 5-25)
22 Remove the speed sensor.

Installation Procedure
,e installation procedure is the reverse of the removal procedure.
,'<<:>te:
• After reassembly, bleed air from the brake. (Refer to page 8-48)
• After reassembly, check the operation of the accumulator. (Refer to page 8-57)
• After reassembling the parking brake cable, inspect and adjust the parking brake. (Refer to page 8-61, 62)

Point Operations
[Point 1]
Installation:
After installation, add hypoid gear oil to the specified level.
Vehicle model A
2 ton series 1.4 - 9.5 mm (0.06 - 0.37 in)
3·J3.5 ton series 1.2 - 11.8 mm (0.05 - 0.46 in)
4-14

[Point 2]
Removal-Installation:
Install hub nuts on hub bolts on the left and right sides, and
sling wire at the tapered portion.

1 [Point 3]
Removal:
SST 09310-23320-71

[Point 4]
Removal-Installation:
Operate carefully so as not to bring the axle shaft into contact
with the oil seal lip to damage it.
 4-15

DISASSEMBLY·INSPECTION·REASSEMBLY (1·2·K2 TON SERIES)

T = N·m (kgf-cm) [ft·lbf]

12

T=6.9-16.1
~~ >~~
~
~
~~~.
0
T=17.3-21.7 (70.4 -164.2) ~.
(176 - 221) [5.0 - 11.9] I '-{{)
[12.8 - 16.0] T = 343 - 392 T = 117.7 - 137.3
4 (3500 - 4000)
[253.1 - 289.2]
,
~
(1200 - 1400)
[86.8 - 101.31 ., r ","
~
T=13.5-24.5
(138 - 250)
[10.0 - 18.1]

8
Removal Procedure
1 Remove the differential cover. [Point 1]
2 Remove the bearing cap and adjusting nut. [Point 2]
3 Remove the differential case ASSY.
4 Remove the drive pinion rear cover.
5 Remove the lock nut. [Point 3]
6 Remove the input shaft.
7 Remove the drive pinion W/ bearing. [Point 4]
8 Remove the output gear and reduction gear W/ carrier cover. [Point 5]
9 Remove the reduction gear W/ bearing. [Point 6]
10 Remove the reduction gear bearing.
11 Remove the output gear.
12 Remove the drive pinion outer race. [Point 7]
13 Remove the oil seal. [Point 8]
14 Remove the input shaft dust deflector. [Point 9]

Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Reassembly:
Apply sealing agent (Three Bond's 1217C or equivalent
products) to the surfaces to be contact with the differential
cover and differential housing, and reassemble.

[Point 2]
Disassembly:
Make match marks on the bearing cap and differential housin\:i..
Reassembly:
Reassemble the adjusting nut and bearing cap in the following procedure.
1. Install the adjusting nut.
2. Align the match marks to install the bearing cap, and
temporarily tighten the set bolt.

Match marks
T =19.6 N'm (200 kgf'cm) [14.5 ft·lbf]
3. Set a dial gauge at the back of the ring gear, and tighten the
adjusting nut.
4. Using the SST, tighten until the thrust clearance becomes O.
SST 09630-10110-71
5. Tighten the adjusting nuts on both sides by one notch.
6. Set a dial gauge perpendicular to the tooth face of the ring
gear, and measure the backlash.
 4-17

Standard: 0.2 - 0.3 mm (0.008 - 0.012 in)

If the standard is not met, adjust by moving the differential
case ASSY to the thrust direction with the adjusting nut.
(1) When the backlash is excessive.
Loosen the adjusting nut on the ring gear tooth face side,
and tighten the adjusting nut on the back side by the
same amount in order to move the ring gear closer to the
drive pinion.
(2) When the backlash is insufficient.
Loosen the adjusting nut on the back side of the ring gear,
and tighten the adjusting nut on the tooth face side by the
same amount in order to move the ring gear away from
the drive pinion.
7. Further tighten the adjusting nut on the ring gear tooth face
side by 1.5 to 2 notches.
8. Install the adjusting nut lock plate.
9. Fully tighten the bearing cap set bolt.
T = 117.7 - 137.3 N'm (1200 -1400 kgf'cm)
[86.82 - 101.3 ft'lbf]

[Point 3]
Disassembly:
Remove the lock nut, washer and shim.
1. Unstake the lock nut.
2. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
3. Remove the lock nut and washer.

Reassembly:
Reassemble the shim, rear bearing roller, washer and lock nut
in the following procedure.
1. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
2. While supporting the drive pinion, reassemble the shim, rear
bearing and washer with its claw (pawl) lining up with the deep
groove.
Also, in order to avoid shock contact between the rear bearing
roller and rear bearing outer race, reassmble the rear bearing
by tightening the lock nut.
3. Tighten the lock nut to the temporarily specified torque.
T =157 - 235 N'm (1600 - 2400 kgf'cm) [115.8 -173.4 ft'lbf]
4. Remove the input shaft.
5. Using a wrench, turn the gear five times.
6. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
4-18

7. Tighten the lock nut again to the specified torque.

T =343 - 392 N'm (3500 - 4000 kgf'cm) [253.1 - 289.2 ft·lbf]
8. Remove the input shaft.
9. Using a wrench, turn the gear ten times.
10. Measure the drive pinion starting torque.
Standard
1·K2 ton series: 8.5 -13.0 N'm (90 -135 kgf-cm)
[6.3 - 9.6 ft-lbf]
2 ton series: 8.5 - 15.0 N'm (90 - 155 kgf'cm)
[6.3 -11.1 ft'lbf]
If the standard is not met, adjust by changing the thickness of
the shim.
Thickness of the shim:
0.1,0.13,0.15,0.32,0.35,0.4,0.5,0.59 mm
[0.0039'0.0051'0.0059·0.013'0.014'0.016·0.020·0.023 in]

11. Firmly stake the lock nut.

[Point 4]
Disassembly:
Remove the drive pinion W/ bearing.
1. Insert a wooden block inside the differential housing in order t
prevent damage to the drive pinion.
2. Using a plastic hammer, remove the drive pinion W/ bearing~

Disassembly:
Remove the bearing inner race using the SST and a press.
SST 09420-23002-71
 4-19

Reassembly:
Install the bearing inner race using the SST and a press.

1 ton series'K2 ton series:

SST 09316-76008-71
(09316-60011)

2 ton series:
SST 09410-26600-71

[Point 5]
Reassembly:
Check the reassembly direction of the output gear and
reduction gear.

Reassembly:
Apply sealing agent (08826-76002-71 (08826-00090)) to the
surface to be in contact with the differential carrier cover, and
reassemble.

[Point 6]
Disassembly:
Remove the reduction gear bearing using the SST and a
press.
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)
09420-23002-71 (3)

Reassembly:
Reassemble the reduction gear bearing using the SST and a
SST(2) press.

SST(1) SST 09950-76018-71 (1)

(09950-60010)
09150-76020-71 (2)
(09950-70010)
4-20

[Point 7]
Disassembly:

SST 09950-76018-71 (1)

(09950~6001 0)
09150-76020-71 (2)
(09950-70010)

Reassembly:

SST 09950-76018-71 (1)

(09950-60010)
09150-76020-71 (2)
(09950-70010)

[Point 8]
Reassembly:
Using a pin, tap new oil seal in from the edge of the differential
carrier cover to the depth shown by A.
A = 5.0 - 5.5 mm [0.20 - 0.22 in]
After reassembly, apply MP grease to the lip section of the oil
seal.

[Point 9]
Reassembly:
Using the SST, reassemble the input shaft dust deflector.
SST 09370-20270-71
 4-21

DISASSEMBlY·INSPECTION·REASSEMBLY (3·J3.5 TON SERIES)

T = N'm (kgf'cm) [ft'lbf]

13

1 3 2
14

T = 13.5 - 24.5
(138 - 250)
[10.0 - 18.1]

T=69-16.1 ~
~'" (70.4 - 164.2) ~
'--" [5.0 - 11.9] ~ •
-.~~ T = 117.7 - 137.3
~ (1200 - 1400)

~:'013]
5
T = 32.4 - 48.6
(330 - 496)
[23.9 - 35.9]

~"
T=54.2-;>
I (553 _ 768) ).3
~ ~

I 16
7

11

8
9
4-22

Disassembly Procedure
1 Remove the differential cover. [Point 1]
2 Remove the bearing cap and adjusting nut. [Point 2]
3 Remove the differential case ASSY.
4 Remove the drive pinion rear cover.
5 Remove the lock nut. [Point 3]
6 Remove the drive pinion outer bearing roller.
7 Remove the input shaft.
8 Remove the output gear and reduction gear W/ carrier cover. [Point 4]
9 Remove the reduction gear W/ bearing. [Point 5]
10 Remove the reduction gear bearing.
11 Remove the output gear.
12 Remove the drive pinion bearing retainer.
13 Remove the drive pinion W/ pilot bearing. [Point 6]
14 Remove the pilot bearing. [Point 7]
15 Remove the drive pinion bearing outer race. [Point 8]
16 Remove the oil seal. [Point 9]
17 Remove the input shaft dust deflector. [Point 10]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Reassembly:
Apply sealing agent (Three Bond's 1217C or equivalent
products) to the surfaces to be contact with the differenti
cover and differential housing, and reassemble.

[Point 2]
Disassembly:
Make match marks on the bearing cap and differential
housing.
Reassembly:
Reassemble the adjusting nut and bearing cap in the following
procedure.
1. Install the adjusting nut.

Match marks 2. Align the match marks to install the bearing cap, and
temporarily tighten the set bolt.
T = 19.6 N'm (200 kgf-cm) [14.5 ft'lbf]
 4-23

3. Set a dial gauge at the back of the ring gear, and tighten the
adjusting nut.
4. Using the SST, tighten until the thrust clearance becomes O.
SST 09630-10110-71

5. Tighten the adjusting nuts on both sides by one notch.

6. Set a dial gauge perpendicular to the tooth face of the ring
gear, and measure the backlash.

Standard
0.3 - 0.4 mm [0.012 - 0.016 in]
If the standard is not met, adjust by moving the differential
case ASSY to the thrust direction with the adjusting nut.
(1) When the backlash is excessive.
L Loosen the adjusting nut on the ring gear tooth face side,
and tighten the adjusting nut on the back side by the
same amount in order to move the ring gear closer to the
drive pinion.

(2) When the backlash is insufficient.

Loosen the adjusting nut on the back side of the ring gear,
and tighten the adjusting nut on the tooth face side by the
same amount in order to move the ring gear away from
the drive pinion.
7. Further tighten the adjusting nut on the ring gear tooth face
side by 1.5 to 2 notches.
8. Install the adjusting nut lock plate.

9. Fully tighten the bearing cap set bolt.

=
T 117.7 - 137.3 N"m (1200 - 1400 kgf-cm)
[86.82 - 101.3 ft'lbf]

[Point 3]
Disassembly:
Remove the lock nut, washer and shim.
1. Unstake the lock nut.
2. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
3. Remove the lock nut and washer.
4-24

Reassembly:
Reassemble the shim, rear bearing roller, washer and lock nut
in the following procedure.
1. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
2. While supporting the drive pinion, reassemble the shim, rear
bearing and washer with its claw (pawl) lining up with the deep
groove.
Also, in order to avoid shock contact between the rear bearing
roller and rear bearing outer race, reassemble the rear bearing
by tightening the lock nut.
3. Tighten the lock nut to the temporarily specified torque.
T =157 - 235 N'm (1600 - 2400 kgf'cm) [115.8 -173.4fHbf]
4. Remove the input shaft.
5. Using a wrench, turn the gear five times.
6. Reassemble the input shaft, and stop the gear from turning
using a pipe wrench.

7. Tighten the lock nut again to the specified torque.

T =343 - 392 N-m (3500 - 4000 kgf'cm) [253.1 - 289.2 ft·lbf]
8. Remove the input shaft.
9. Using a wrench, turn the gear ten times.
10. Measure the drive pinion starting torque.
Standard: 8.5 - 13.0 N'm (90 - 135 kgf'cm) [6.3 - 9.6 ft'lbf]
If the standard is not met, adjust by changing the thickness of
the shim.
Thickness of the shim:
0.1-0.13'0.15'0.32'0.35'0.4'0.5-0.59 mm
[0.0039,0_0051,0.0059'0.013,0.014'0.016-0.02-0.023 in]

11. Firmly stake the lock nut.

 4-25

[Point 4]
ReClssembly:
Apply sealing agent (08826-76002-71 (08826-00090» to the
surface to be in contact with the differential carrier cover,and
reassemble.

[Point 5]
Reassembly:
Check the reassembly direction of the output gear and
reduction gear.

Disassembly:
Remove the reduction gear bearing using the SST and a
press.
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)
09420-23002-71 (3)

Reassembly:
Reassemble the reduction gear bearing using the SST and a
SST(2) press.

SST(1) SST 09950-76018-71 (1)

(09950-60010)
09150-76020-71 (2)
(09950-70010)

[Point 6]
Disassembly:
SST 09950-76018-71 (1)
(09950-60010)
09150-76020-71 (2)
(09950-70010)

./
4-26

Disassembly:
SST 09950-76018-71 (1)
(09950-60010)
09150-76020-71 (2)
(09950-70010)

[Point 7]
Disassembly:
SST 09950-76014-71
TRI'~'--SST (09950-40011 )

Reassembly:
Reassemble the pilot bearing using the SST and a press.
SST 09608-76003-71
(09608-04031 )
After reassembling the pilot bearing, stake three places at the
end of the drive pinion.
Check the reassembly direction.

Disassembly:
Remove the bearing inner race using the SST and a press.
SST 09420-23002-71

Reassembly:
Reassemble the bearing inner race using the SST and a
press.
SST 09316-76008-71
(09316-60011 )
 4-27

[Point 8]
Disassembly:
SST 09950-76018-71 (1)
(09950-60010)
09150-76020-71 (2)
(09950-70010)

Disassembly:
SST 09950-76018-71 (1)
(09950-60010)
09150-76020-71 (2)
(09950-70010)

[Point 9]
Reassembly:
Using a pin, tap new oil seal in from the edge of the differential
carrier cover to the depth shown by A.
A = 5.0 - 5.5 mm [0.20 - 0.22 in]
After reassembly, apply MP grease to the lip section of the oil
seal.

[Point 10]
Reassembly:
Using the SST, reassemble the input shaft dust deflector.
SST 09370-20270-71
4-28

DIFFERENTIAL CASE ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY (1·2·K2 TON SERIES)

T == N·m (kgf·cm) [ftlbn

2
-4

T == 127.4 - 176.4
(1300 - 1800)
[94.0 -130.1]

Disassembly Procedure
1 Remove the side bearing. [Point 1]
2 Remove the ring gear. [Point 2]
3 Remove the pinion shaft pin. [Point 3]
4 Remove the side gear and pinion gear. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 4-29

Point Operations
[Point 1]
Disassembly:
SST 09950-76014-71 (1)
(09950-40011 )
09950-76018-71 (2)
(09950-60010)

Reassembly:
Install the side bearing.
1. Reassemble the side bearing to the edge of the case using the
SST and a press.
SST 09950-76019-71 (1)
(09950-60020)
09950-76020-71 (2)
(09950-70010)
2. Fully tap the side bearing in by using a striking driveL

[Point 2]
Reassembly:
Apply thread tightener (08833-76001-71 (08833-00070)) to the
threaded portion of the set bolts. Gradually tighten them in the
diagonal order, and finally tighten to the specified torque in the
circular order.

[Point 3]
Disassembly:
Unstake the differential case pin hole, and punch out the pin
using the SST.
SST 09411-13330-71

Reassembly:
Tap the pin in the differential case pin hole using SST until it
contacts the stepped section.
Reference value: A = 5 mm (0.20 in)
SST
Tap the pin in with the chamfer side facing down.
SST 09411-13330-71
~

Chamfer
4-30

CView After tapping, stake the differential case pin hole with a chisel.
Check that the staking allowance is B in the illustration = 1 mm
(0.039 in) or more, and there should be no cracks.

After staking, check that the gear rotates smoothly.

[Point 4]
Inspection:
Measure the differential pinion inside diameter.
Standard
1·K2 ton series: 26.12 mm (1.028 in)
2 ton series: 28.12 mm (1.107 in)
Limit
1·K2 ton series: 26.22 mm (1.032 in)
2 ton series: 28.22 mm (1.111 in)

Inspection:
Measure the outside diameter of the pinion shaft.
Standard
1·K2 ton series: 26.00 mm (1.024 in)
2 ton series: 28.00 mm (1.102 in)
Limit
1·K2 ton series: 25.75 mm (1.014 in)
2 ton series: . 27.75 mm (1.093 in)

Inspection:
Measure the thickness of the side gear thrust washer.

?\ \
Standard: 1.6 mm (0.063 in)
Limit:
Inspection:
1.3 mm (0.051 in)

Measure the thickness of the pinion thrust washer.

Standard
1·K2 ton series: 1.0 mm (0.039 in)
2 ton series: 1.6 mm (0.063 in)
Limit
1·K2 ton series: 0.7 mm (0.028 in)
2 ton series: 1.3 mm (0.051 in)
Reassembly: 4-31
Reassemble . .
chas . grease
SIS thespecial
pinion b~~~
onthr S~da::.er after evenly applying

Reassembly:
Reassemblin,g procedures are
1. Reassemble th . as follows.
e side gea .
2. Turn th e pinion
.. to the p., .r and pinion t 0 th e differential
. ca
nlon shaft hole. se.

3. Reassemble the pinion

.. shaft.
4-32

DISASSEMBLY·INSPECTION·REASSEMBLY (3·J3.5 TON SERIES)

T = N'm (kgf'cm) [ft·lbf]
4

T = 86.2 - 102.9
(879 - 1049)
[63.6 - 75.9]

p& C
g
~ ~~~~~/
~ ~
~ .~T=127.4-176.4
~ (1300-1800)
[94.0 - 130.1]

Disassembly Procedure
1 Remove the differential case bearings. [Point 1]
2 Remove the differential upper case. [Point 2]
3 Remove the side gear and pinion gear. [Point 3]
4 Remove the ring gear. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 4-33

Point Operations
[Point 1]
Disassembly:
SST 09950-76014-71 (1)
(09950-40011 )
09950-76018-71 (2)
(09950-60010)

Reassembly:
Install the side bearing.
1. Use the SST to drive in the side bearing to the end surface.
SST 09950-76019-71 (1)
(09950-60020 )
09950-76020-71 (2)
(09950-70010)
2. Use a striking driver to fully drive in the bearing.

[Point 2]
Disassembly·Reassembly:
Check the match marks.
Reassembly:
Apply locking agent (08833-76001-71 (08833-00070)) on the
set bolt threaded portion before reassembly.

Match marks

[Point 3]
Inspection:
Measure the inside diameter of the differential pinion.
Standard: 24.67 mm (0.971 in)
Limit: 24.77 mm (0.975 in)

Inspection: .
Measure the spider outside diameter.
Standard: 24.50 mm (0.965 in)
Limit: 24.25 mm (0.955 in)
4-34

Inspection:
Measure the side gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.3 mm (0.051 in)
Inspection:
Measure the pinion gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.0 mm (0.039 in)

Reassembly:
Install the side gear thrust washer with its oil groove facing the
gear.

Reassembly:
Gmase apPIi,atim,-~~ Apply chassis grease (molybdenum disulfide grease) on both
sides of the spider pinion thrust washer before reassembly.

[Point 4]
Reassembly:
Apply locking agent (08833-76001-71 (08833-00070)) on the
set bolt threaded portion before reassembly. Tighten the set
bolts gradually in the diagonal order, and finally tighten in the
circular order to the specified torque.
 5-1

FRONT AXLE
Page
DRY BRAKE MODEL (STD) 5-2
GENERAL 5-2
SPECIFICATIONS 5-4
COMPONENTS 5-5
TIRES·WHEELS 5-8
FRONT AXLE SHAFT·AXLE HUB 5-9
FRONT AXLE BRACKET·AXLE HOUSING 5-13

WET BRAKE MODEL (OPT) 5-15

GENERAL 5-15
SPECIFICATIONS (WET BRAKE MODEL} 5..16
COMPONENTS (WET BRAKE MODEL) 5-17
TIRES·WHEELS (WET BRAKE MODEL) 5..19
FRONT AXLE SHAFT·AXLE HUB
(WET BRAKE MODEL) 5..20
FRONT AXLE BRACKET·AXLE HOUSING
(WET BRAKE MODEL) 5-25
5-2

DRY BRAKE MODEL (STD)

GENERAL
1 ton series

K2 ton series
 5-3

2 ton series

3·J3.5 ton series

5-4

SPECIFICATIONS
odel J3.5 ton series
1-2-K2 ton series
Item 3 ton series
Front axle type Full-floating (-

Suspension type Fixed to frame (-

Axle shaft diameter mm (in) 40 (1.57) 42 (165)

Axle shaft diameter (spline portion) mm (in) 40 (1.57) 49.5 (1.949)
 5-5

COMPONENTS
1 ton series

4201
41

DP

AE 53

4201-308

2 ton series _

1_ __ _1
42 01

42

4201.311
5-6

K2 ton series

4201
41

!~~~B
I ~HV~
~~
41C BP
9410 1
:1:. 40G 41
. , ,

l f", .
FD ~o
41E
(j

'-'" f

rf~"'li
'------ 41G

r) ifI(j}/li,'
43'S'" C
R,

ffi_~
FS 0

FR---'l)~ ~~1
~ J 41B ,

FS ~ 1" EY

AA A~o "'.

4201-315

. (4Y En g ine Vehicle)

3·J3.5 tonl ~s~e~r~le:s~~ _
4201
41

4201-313
 5-7

.
. (IDZ-III·3Z
3·J3.5 ton series Eng ine Vehicle)
-

4201

DP
[, Gb
I
jJ?I'llt)J1JJ.to I 438

"'~

4201-309

. Chain Spec.
Front Tire

4201

41 ~-- --I 2025

30 J35

4201-316
5-8

TIRES-WHEELS
1. Adjusting the Inflating Pressure
Caution:
• Do not inflate tires beyond the specified pressure because
it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it in
a safety fence.

Specified Inflating Pressure

Inflating pressure
Classification Specification Tire size Rim type Maker
kPa (kgf/cm 2 ) [psi]
STD Single 6.50-10-10PR Side ring BRIGESTONE 700 (7.0) [102)

1.5 ton model

Single 6.50-10-14PR Side ring CONTINENTAL 800 (8.0) [116) .
OPT 6.00-9-10PR Side ring BRIGESTONE 700 (7.0) [102)
Special double --.
6.00-9-10PR Side ring CONTINENTAL 800 (8.0) (116)
STD Single 6.50-10-10PR Side ring BRIGESTONE 700 (7.0) (102)
Single 6.50-10-14PR Side ring CONTINENTAL 900 (9.0) [131)
1.75 ton model
OPT 6.00-9-10PR Side ring BRIGESTONE 700 (7.0) [102)
Special double
6.00-9-10PR Side ring CONTINENTAL 800 (8.0) [116)
STD Single 21X8-9-14PR Side ring BRIGESTONE 900 (9.0) (131)
K2.0 ton model
OPT Single 21X8-9-14PR Side ring CONTINENTAL 900 (9.0) [131]
STD Single 7.00-12-12PR Side ring BRIGESTONE 700 (7.0) (102)
Single 7.00-12-14PR Side ring CONTINENTAL 900 (9.0) [131]
2.0 to 2.5 ton model
OPT 7.00-12-12PR Side ring BRIGESTONE 700 (7.0) [102]
Special double
7.00-12-14PR Side ring CONTINENTAL 900 (9.0) [131]
STD Single 28X9-15-12PR Side ring BRIGESTONE 700 (7.0) [102]
3.0 ton model Single 28X9-15-14PR Side ring CONTIN.ENTAL 800 (8.0) [116)
OPT
Special double 29X8-15-12PR Side ring BRIGESTONE 700 (7.0) [102]
STD Single 250-15-16PR Side ring BRIGESTONE 850 (8.5) (123)
)
J3.5 ton model Single 250-15-16PR Side ring CONTINENTAL 950 (9.5) [138]
OPT
Special double 28X8-15-12PR Side rinrJ BRIGESTONE 700 (7.0) [102]

2. Wheel Disassemly'Reassembly
Caution:
Always discharge air fully before disassembling the wheel. Otherwise, it is very dangerous since the rim
may come off suddenly due to the internal pressure.
 5-9

FRONT AXLE SHAFT·AXLE HUB

REMOVAL·INSTALLATION
T = N'm (kgf-cm) [ft'lbf]

I K2 ton series

I
L

1 ton series T = 118.0 - 196.0 (1200 - 2000) [87.1 - 144.6J

Hub nut (single tire) 2·K2 ton series T = 177.0 - 392.0 (1800 - 4000) [130.6 - 289.2J
3·J3.5 ton seriess T = 294.0 - 588.0 (3000 - 6000) [216.9 - 433.8J
1·2 ton series T = 177.0 - 392.0 (1800 - 4000) [130.6 - 289.2J
Hub nut (double tire)
3·J3.5 ton series T = 294.0 - 588.0 (3000 - 6000) [216.9 - 433.8]
1·2·K2 ton series T = 68.6 - 98.0 (700 - 1000) [50.6 - 72.3J
Axle shaft set bolt
3·J3.5 ton series T = 107.0 - 140.0 (1100 - 1400) [78.9 - 103.3]
1·K2 ton series T = 49.0 - 68.0 (500 - 700) [36.2 - 50.2]
2 ton series T = 147.0 -186.0 (1500 -1900) [108.2 - 137.2]
Hub bolt set nut =
T 167.0 - 206.0 (1700 - 2100) [123.2 - 152.0J
3·J3.5 ton series W/tire chain spacer:
T = 216.0 - 275.0 (2200 - 2800) [159.4 - 202.9]
5-10

Removal Procedure
1 Drain differential oil. [Point 1]
2 Jack up the vehicle and remove front wheels.
3 Remove the front axle shaft. [Point 2]
4 Remove the axle shaft oil seal. [Point 3]
5 Remove the bearing lock nut and plate. [Point 4]
6 Remove the outer bearing roller and front axle hub. (1·K2·3·J3.5 ton series) [Point 5]
Remove the outer bearing roller and front axle hub W/brake drum. (2 ton series)
7 Remove the oil seal and inner bearing roller. [Point 6]
8 Remove the bearing outer race. [Point 7]
9 Remove the brake drum. (2 ton series)

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply thread tightener (08833-76001-71 (08833-00070)) on the hub bolt set nut before tightening.
(only tire chain spec. of 3·J3.5 ton series: tire side)

Point Operations
[Point 1]
Installation:
Add Hypoid gear oil to the specified level after installation.
Vehicle model A
1·K2 ton series 1-7 - 12.0 mm (0.067 - 0.472 in)
2 ton series 1.4 - 11.8 mm (0.055 - 0.465 in)
3·J3.5 ton series 1.2 - 13.8 mm (0.047- 0.543 in)

[Point 2]
Removal'lnstallation:
Carefully operate so as not to damage the oil seal lip
contact with the axle shaft.

[Point 3]
Removal:
SST 09320-23000-71
Installation:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

[Point 4]
Removal·lnstallation:
1·2·K2 ton series
SST 09509-76002-71
(09509-55020)

3-J3.5 ton series

SST 09509-76003-71
(09509-55030)

Installation:
Adjust the front axle hub starting force.
1. Install the plate.
2. Tighten the bearing lock nut to the specified torque and rotate
the hub by 4 or 5 turns to fit the bearing.
Standard
1·2·K2 ton series:
196 - 343 N'm (2000 - 3500 kgf'cm) [145 - 253 fHbf]
3·J3.5 ton series:
100 - 270 N'm (1020 - 2750 kgf.cm) [74 - 199 ft·lbf]
3. Rotate the bearing lock nut back by 1/12 to 1/6 turn (30 to 60°)
to align the stopper hole of the bearing with the thread hole of
the lock nut. Rotate the hub 4 or 5 turns again.
4. Set the spring scale to the hub bolt to measure the starting
force.
Standard
1·K2 ton series:
T == 24.5 - 99.0 N (2.5 - 10.1 kgf) [5.5 - 22.3 Ibf]
2·3·J3.5 ton series:
19.6 - 78.4 N (2.0 - 8.0 kgf) [4.4 -17.6 Ibf]
5. If the measured value is not within the standard range, adjust it
by tightening or loosening the bearing lock nut.
6. Install the nut lock screw or nut lock bolt to the specified
torque.
When reusing the nut' lock screw (precoated screw), apply
thread tightener (08833-76002-71 (08833-00080)) to the
threaded portion.
Tightening torque
1·2·K2 ton series:
T == 2 - 5.2 N'm (20 - 53 kgf'cm) [1.4 - 3.5 ft-lbf]
 Apply thread tightener (08833-76001-71 (08833-00070)) to the
nut lock bolt threaded portion and tighten it.
Tightening torque
3·J3.5 ton series:
T = 15 - 22 N'm (153 - 224 kgf-cm) [11 -16 ft·lbf]

Nut lock bolt

[Point 5]
Installation:
Fill the part of the hub shown in the illustration with MP grease.

Installation:
1·2·K2 ton series
SST 09370-10410-71

3·J3.5 ton series

SST 09421-33020-71

[Point 6]
Removal:
Use a screwdriver or the like to remove the oil seal.
Installation:
SST 09950-76019-71 (1)
(09950-60020)
09950-76020-71 (2)
(09950-70010)

[Point 7]
SST(2)~/f
SST(1~~
Removal:
Use a brass bar to remove the bearing outer race.

~ Installation:
SST 09950-76019-71
(09950-60020)
(1)

09950-76020-71 (2)
(09950-70010)
 5-17

COMPONENTS (WETS RAKE MODEL)

2 ton series

4201

4201-312

3"J3.5 ton se(:le:s~~_~

(4Y E n g "lne Vehicle)
_

- 4201 I

4201-314
5-18

3 ton series (IDZ-III Engine Vehicle), 3·J3.5 ton series (3Z Engine Vehicle)

4201

(: 408
'[,,I.
40A I
41J

4201-310
 5-19

TIRES-WHEELS (WET BRAKE MODEL)

1. Adjusting the Inflating Pressure
Caution:
- Do not inflate tires beyond the specified pressure because
it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it in
a safety fence.

Specified Inflating Pressure

Inflating pressure
Classification Specification Tire size Rim type Maker
kPa (kgf/cm 2 ) [psi]
STD Single 700-12-12PR Side ring BRIGESTONE 700 (7.0) [102]
Single f.00-12-14PR Side ring CONTINENTAL 900 (9.0) [131]
120 to 2.5 ton model
OPT Special double 7.00-12-12PR Side ring BRIGESTONE 700 (7.0) [102]
Special double 7.00-12-14PR Side ring CONTINENTAL 900 (9.0) [131]
STD Single 28X9-15-12PR Side ring BRIGESTONE 700 (7.0) [102]
3.0 ton model Single 28X9-15-14PR Side ring CONTINENTAL 800 (8.0) [116]
OPT
Special double 29X8-15-12PR Side ring BRIGESTONE 700 (7.0) [102]
STD Single 250-15-16PR Side ring BRIGESTONE 850 (8.5) [123]
J3.5 ton model Single 250-15-16PR Side ring CONTINENTAL 950 (9.5) [138]
OPT
Special double 28X8-15-12PR Side ring BRIGESTONE 700 (7.0) [102]

2. Wheel Disassemly·Reassembly
Caution:
Always discharge air fully before disassembling the wheel. Otherwise, it is very dangerous since the rim
may come off suddenly due to the internal pressure.
5-20

FRONT AXLE SHAFT-AXLE HUB (WET BRAKE MODEL)

REMOVAL-INSTALLATION
Note:
Release the pressure from the accumulator before starting operation. (Refer to page 8-48)
T = N'm (kgf'cm) [ft'lbf]

f~ ~ ''',10

1'2 " ~/', ',' ,'0(

~CQ,
,
12
9 '.. ' CQ, CQ,
2 ton series CQ,CQ,
T = 44 - 69 (449 - 704) [325 - 50.9]
3·J3.5 ton series
T = 137 - 210 (1397 - 2141) [101.1 -154.9]

2 ton series T = 177.0 - 392.0 (1800 - 4000) [130.6 - 289.2]

Hub nut (single tire)
3·J3.5 ton series T = 294.0 - 5880 (3000 - 6000) [216.9 - 433.8]
2 ton series T = 177.0 - 3920 (1800 - 4000) [130.6 - 289.2]
Hub nut (double tire)
3·J3.5 ton series T = 294.0 - 5880 (3000 - 6000) [2169 - 433.8]
2 ton series T = 68.6 - 98.0 (700 - 1000) [50.6 - 72.3]
Axle shaft set bolt
3·J3.5 ton series T = 107.0 - 140.0 (1100 - 1400) [78.9 - 103.3]
 5-21

Removal Procedure
1 Drain differential oil. [Point 1]
2 Jack up the vehicle and remove front wheels.
3 Drain the brake cooling oil in ASSY. (Refer to page 8-64)
4 Remove the front axle shaft. [Point 2]
5 Remove the axle shaft oil seal. [Point 3]
6 Remove the bearing lock nut and plate. [Point 4]
7 Lock the brake disk, plate No.1 and plate No.2. (Refer to page 8-49)
8 Remove the front axle hub W/spline ring. [Point 5]

9 Remove the disk brake cover.

10 Remove the front axle hub. [Point 6]
Remove the oil seal, inner bearing roller and o-ring. [Point 7]
I Remove the bearing outer race. [Point 8]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After reassembly, bleed air from the brake. (Refer to page 8-48)

Point Operations
[Point 1]
Installation:
Add Hypoid gear oil to the specified level after installation.
Vehicle model A
2 ton series 1.4 - 9.5 mm (0.055 - 0.374 in)
3·J3.5 ton series 12 - 11.8 mm (0.047 - 0.465 in)

[Point 2]
Removal-Installation:
Carefully operate so as not to damage the oil seal lip by
contact with the axle shaft.
5-22

[Point 3]
Removal:
SST 09320-23000-71

Installation:
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

[Point 4]
Removal:
2 ton series
SST 09509-76002-71
(09509-55020)

3·J3.5 ton series

SST 09509-76003-71
(09509-55030)

Installation:
Adjust the front axle hub bearing preload.
1. Install the plate.
2. Tighten the bearing lock nut to the specified torque.
2 ton series:
SST 09509-76002-71 (1)
(09509-55020 )
09471-26600-71 (2)

3·J3.5 ton series:

SST 09509-76003-71 (1)
(09509-55030)
9471-26600-71 (2)
Standard:
100 - 160 N'm (1020 - 1630 kgf'cm) [73.8 - 118.0 ft·lbf]
3. Tighten the lock nut plate and bearing lock nut.
To align them, use the first stopper hole of the lock nut plate
when rotating the bearing lock nut in the tightening direction.
 5-23

4. Tighten the nut lock screw or nut lock bolt to the specified
torque.
When reusing the nut lock screw (precoated screw), apply
thread tightener (08833-76001-71 (08833-00070)) to the
threaded portion and tighten it.
Tightening torque
2 ton series:
T = 2 - 5.2 N'm (20 - 53 kgf-cm) [1.4 - 3.8 ft·lbf]

Apply thread tightener (08833-76001-71 (08833-00070)) to the

nut lock bolt thread and tighten it.
Tightening torque
3·J3.5 ton series:
T = 15 - 22 N'm (153 - 224 kgf'cm) [11.1 - 16.2 ft·lbf]

[Point 5]
Installation:
2 ton series:
SST 09370-10410-71

3·J3.5 ton series:

SST 09421-33020-71

SST

[Point 6]
Fill up with grease Installation:
Fill the part of the hub shown in the illustration with MP grease.

Installation:
Apply sealing agent (08826-76002-71 (08826-00090)) to the
position shown in the illustration.
5-24

[Point 7]
Press-fitting direction
Removal:
Use a screwdriver or the like to remove the oil seal.

Installation:
Use a pin to reassemble the oil seal into the position A in the
drawing.
A = 1.5 ± 0.5 mm (0.059 ± O.02mm)
After reassembly, apply MP grease to the lip section of the oil
Oil seal seal.

[Point 8]
SST(1)
SST(2)R--r- Removal:

~
tt1.~~ ~
Use a brass bar to remove the bearing outer race.
Installation:

SST 09950-76019-71 (1)

(09950-60020)
09950-76020-71 (2)
(09950-70010)
 5-25

t-RONT AXLE BRACKET-AXLE HOUSING (WET BRAKE MODEL)

REMOVAL-INSTALLATION
T = N'm (kgf-cm) [ftlbf]

T = 137.0 - 210.0
(1400 - 2100)
[1011 - 154.9]

3 1~
~ct~'~
6

Removal Procedure
1 Remove the front axle & differential ASSY. (Refer to page 4-12)
2 Remove the front axle shaft and axle hub. (Refer to page 5-20)
3 Remove the bush. [Point 1]
4 Remove the brake ASSY. [Point 2]
5 Remove the front axle bracket.
6 Remove the axle housing.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
5-26

Point Operations
[Point 1]
Removal:
SST 09950-76018-71 (1)
(09950-60010)
09950-76014-71 (2)
(09950-40011 )

Installation:
Using a brass bar, install the bushing to the position shown by
A in the illustration.
A =0 - 1 mm (0 - 0.039 in)

[Point 2]
Installation:
Apply sealing agent (08826-76002-71 (08826-00090)) to the
mating surfaces of the brake ASSY and front axle bracket
before installation.

Installation:
Check the brake cooling oil opening and install the O-ring< • "
the position between the brake ASSY and front axle bracket~ ,"
 6-1

REAR AXLE
Page

GENERAL 6..2
SPECIFICATIONS 6..3
COMPONENTS 6..4
TIRES·WHEELS 6..8
REAR AXLE ASSY c •••••••• ,. 6..9
REMOVAL-INSTALLATION 6..9
REAR AXLE HUB·STEERING KNUCKLE 6..11
REMOVAL-INSTALLATION 6..11
REAR AXLE CYLINDER 6..17
REMOVAL-INSTALLATION 6..17
DISASSEMBLy·INSPECTION·REASSEMBLY 6..19
6-2

GENERAL

. ..
. ' .
• ~}'~,;: .
. ~ . ~~~ ~~~;~~..;~- --::
 6-3

Rear Axle Cylinder

SPECIFICATIONS
ear axle type Elliot type
1 <ear axle suspension type Center-supported right-left rocking type
Toe-in mm (in) 0(0)
Camber degree is
Wheel alignment
Caster degree 0°
IKing pin angle 0°
1.5 ton 1990 (78.3)
1.75 ton 2010(79.1)
2.0 ton 2200 (86.6)
Minimum turning radius (outermost) mm (in) 2.5 ton 2280 (89.8)
3.0 ton 2430 (95.7)
K2.0 ton 2040 (80.3)
J3.5 ton 2490 (98.0)
64

CuMPONENTS
1·K2 ton series

4301

4301-245

2·3·J3.5 ton series

4301

4301-246
 6-5

1 ton series

4301
01
I
···1
I01 K=(INCL. .. ) I ·

(STR-PIN BO~ I (RR SIDE RING)

44

'
I
J-Le" 1
1:7'1
iLf.'
: I Q
~Rito
. FIG. 4302
I
I 44D
f
L ..... ...........
4301-240

2 ton series

4301
01
I .... ,

CO:1K=(INC;~ ·I

CL~ ~CL
DG1 't- DG

~47[UPPER]

g~ -'\~ OG~ --C~

CK-@ @---CK CL --i

g~~~.~" '~~', C'~t:"",,,",

I';""~J
(RR SIDE RING)

JS-<§)
IK ---9 @--JS
_,K @-CK
4: 0
47[LOWER] Refer toI
FIG. 4302
CP -B
---@ e-----CP
CK ~@-CK
47[LOWER] ~ ~
Refer la
I
44C
~o (fJ
o ~44D
··
JS-@)

I . •••
IK -j;! @--JS
e=IK
FIG_ 4302

..... ··
4301-241
6-6

K2 ton series
----
4301
01

.r....·
[
-"-1
.

Refer to
FIG. 4302

CL~ """"CL
OG\!1 'J--OG
47[UPPERJ~~

CK~ @-CK

g~~~\~'-..
'-'9"
CP------@
CL- ..
OG-i <'-CL
CK-@
47[LOWERJ~ CK~~f-D4:IUPPERJ
:g~~r ,@
~@-CK
JS---@ @-JS
IK ---@ /ir"iK ,

CP~61
Refer to 2 CK-@ Q------.CP
FIG. 430 . '"l @-- CK
47[LOWERJ-S~
JS-l£)
IK -61 @-JS
_'K

3 ton seri~e~s~ _
4301
01
,. .... - I - .....
·· I01K=(INCL O)! ··

CL-.
DG~ {'-CL
CK:\~I t-0G
~ ~47[UPPERl
11'~~'~
"

@-CK

Relerla C~~ a.-CP

FIG, 4302 C ©--CK
47[LOWERJ~~

.
i.•••
JS---@
LK ----et @}----JS
B-IK
Refer to
FIG. 4302

••• 01
I·
----- 4301-243
 6-7

J3.5 ton series

4301
01
I
---1
·

I
I
.. Refer to iI
.....
FIG. 43~-----,
111 • •
··
..11

4301-244
1_ _-

Rear A xle CY'IiII:n~d:e~r ~

4302

BB

BC:
,=6'

.:.. ...... - -

1~~-'pIN BO()TS] -i

I ~ ~~~!
4302~-(0~4:,3 _
6-8

TIRES-WHEELS
1. Adjusting the Inflating Pressure

Caution:
- Do not inflate tires beyond the specified pressure because
it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it in
a safety fence.

Specified Inflating Pressure

Inflating pressure
Vehicle model Specification Tire size Rim type
kPa (kgf/cm 2 ) [psi]
STD 5.00-8-8PR Divided rim 800 (8.0) [116]
1 ton series DIVIDED 5.00-8-8PR Divided rim 800 (8.0) [116]
S-RING 5.00-8-8PR Side ring 800 (8.0) [116]
STD 18X7-8-10PR Divided rim 750 (7.5) [109]
K2 ton series S-RING 18X7-8-1 OPR Side ring 750 (7.5) [109]
S-RING 18X7-8-16PR Side ring 1000 (10.0) [145]
STD 6.00-9-10PR Divided rim 700 (70) [102]
2 ton series DIVIDED 6.00-9-10PR Divided rim 800 (8.0) [116]
S-RING 6.00-9-10PR Side ring 850 (85) [123]
STD 6.50-10-10PR Side ring 775 (7.75) [112]
3 ton series
S-RING 6.50-10-14PR Side ring 800 (8.0) [116]
STD 6.50-10-12PR Side ring 900 (9.0) [131]
J3.5 ton series
S-RING 6.50-10-14PR Side ring 900 (9.0) [131]

Abbreviations used in the specification column:

STD = Standard, S-RING = Side ring

2. Wheel DisassemlY'Reassembly
Caution:
Always discharge air fully before disassembling the whee;.
Otherwise, it is very dangerous since the rim may come off
suddenly due to the internal pressure.
Note:
Install each divided rim set bolt with its head on the outer rim
side and the chamfered portion facing the center of the wheel.

Outer rim
T = N·m (kgf·cm) [ft-Ibf]
1 ton series T = 29.5 - 44.0 (300 - 450) [218 - 32.5]
K2 ton series T = 78.5 - 1175 (800 - 1200) [579 - 86.7]
2 ton series T = 49.0 - 68.5 (500 - 700) [36.2 - 50.5]
 6-9

REAR AXLE ASSY

REMOVAL·INSTALLATION
T == N·m (kgf·cm) [ft·lbf]

T == 117.7 - 166.7
(1200 - 1700)
[86.83 - 123.0]

Hub Nut Tightening Torque

1 ton series 2 ton series K2 ton series 3 ton series J3.5 ton series
89.0 - 157.0 118.0 - 196
Divided rim (900 - 1600) (1200 - 2000)
[65.66 - 115.8] [87.06 - 144.60]
89.0 - 157.0 177.0-392 118.0-196
Side ring rim (900 - 1600) (1800 - 4000) (1200 - 2000)
[65.66 - 115.8] [130.6 - 289.2] [87.06 - 144.60]

Removal Procedure
Jack up the vehicle and remove the rear wheels.
2 Remove the swing lock cylinder lower pin. (See section 16.)
3 Disconnect the rear axle cylinder hose.
4 Disconnect the tire angle sensor connector.
5 Support the rear axle ASSY with a garage jack.
6 Remove the rear axle ASSY. [Point 1]
7 Remove the center pin bushing. [Point 2]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, add grease through each grease fitting. Use genuine molybdenum disulfide grease for the rear
axle beam center pins (two places) and swing lock cylinder lower pin. Use MP grease for other grease fittings.
6-10

Point Operations
[Point 1]
Inspection:
Measure the rear axle front to rear clearance.
1. Before removing the rear axle ASSY, measure the front to rear
clearance on the rear side.
Standard clearance: 1.0 mm (0.039 in) or less
2. If the measured value does not satisfy the standard, remove
the rear axle ASSY and make adjustment by selecting the
spacer.
Spacer thickness:
0.3,0.5,1.2,2.3,3.0,3.5,4.0,4.5,5.0 mm
(0.012'0.020-0.047'0.091-0.118'0.138-0.157'0.177'0.197 in)

[Point 2]
Inspection:
Inspect the inside diameter of the rear axle center pin bushing.
Limit: 52.0 mm (2.047 in)

Installation:
Apply molybdenum disulfide grease to the bushing and install
the bushing by aligning the grease groove in the bushing with
the grease fitting position.

r
anh-
I
I

~~---~
Grease groove
 6-11

REAR AXLE HUB-STEERING KNUCKLE

REMOVAL·I NSTALLATION
T = N'm (kgf'cm) [ft'lbf]

rh~~rl'
~ 6 . 10-
~_~~e
~r)~~f-11 flU
..................

~/ -~I~L7
v/ ~~---t~~
:~~ ) 12 T=441-53.9
(450 - 550)
[32.6 - 39.8]
0

T = 49.0 - 73.5
@@ (500 -750)
[36.2 - 54.2}

Removal Procedure
1 Jack up the vehicle and remove the rear wheels.

2 Remove the hub cap. [Point 1]

Remove the castle nut and claw washer. [Point 2]
Remove the outer bearing and axle hub. [Point 3]
5 Remove the bearing outer race from the axle hub. [Point 4]
6 Remove the inner bearing roller and oil seal. [Point 5]
7 Disconnect the tie rod (on the knuckle side). [Point 6]
8 Remove the king pin cover (on the LH side) or the tire angle sensor (on the RH side).

9 Remove the king pin lock bolt and king pin. [Point 7]
10 Remove the thrust bearing, spacer and steering knuckle.
11 Remove the king pin oil seals and needle bearings. [Point 8]
12 Remove the bushing from the steering knuckle. [Point 9]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, add MP grease through grease fittings.
6-12

Point Operations
[Point 1]
Installation:
Apply MP grease to the hub cap and install it by tapping the
flange portion.
(Instead of MP grease filling, spraying grease over the castle
nut is also available.)

[Point 2]
Installation:
Adjust the rear axle hub starting force.
1. Install the claw washer in the correct direction.
2. Temporally tighten the castle nut.
Tightening torque
1 ton series:
12 - 32 N·m (122 - 330 kgf-cm) [8.9 - 23.9 ft·lbf]
Claw washer Others:
15 - 44 N'm (153 - 449 kgf'cm) [11.1 - 32.5 ft-lbf]
3. Rotate the hub by 3 to 5 turns to fit in the bearing.

4. Set a spring scale to a hub bolt, and measure the starting force.
Standard:
1 ton series 15 - 39 N (1.5 - 4.0 kg f) [3.3 - 8.5 Ibf]
K2 ton series 20 - 58 N (2.0 - 5.9 kg f) [4.4 - 13.0 Ibf]
2·3·J3.5 ton series 15 - 44 N (1.5 - 4.5 kgf) [3.3 - 9.9 Ibf]

5. If the measured value does not satisfy the standard, adjust the
castle nut tightening.

6. Install a new cotter pin.

[Point 3]
Removal:
SST 09950-76014-71
(09950-40011 )
 6-13

Fill grease Installation:

Install the axle hub and outer bearing.
1. Apply MP grease to the axle hub and knuckle spindle.
2. Install the axle hub.
3. Use the SST to install the outer bearing roller.
SST 09370-20270-71

[Point 4]
Removal:
Use a brass bar to remove the bearing outer race.
Installation:
SST 09950-76019-71 (1)
(09950-60020)
09950-76020-71 (2)
(09950-70010)

[Point 5]
Removal:
SST 09950-76014-71
(09950-40011 )

Installation:
Install the oil seal and inner bearing.
1. Use the SST to install the oil seal.
SST 09370-10410-71

2. Use the SST to install the inner bearing.

SST 09370-20270-71
6-14

[Point 6]
Installation:
To install the end pin lock nut, install each cone washer with
seal in the direction shown in the illustration and tighten the nut
to the specified torque.
with seal
Tightening torque:
49.0 - 73.5 N'm (500 - 750 kgf'cm) [36.2 - 54.2 ft·lbf]

[Point 7]
Inspection:
Measure the king pin outside diameter.
Limit: 27.8 mm (1.094 in)

Installation:
Measure the steering knuckle starting force according to the
procedure below.
1. Temporarily reassemble the king pin and king pin lock bolt.
Select a spacer to adjust the vertical clearance of the steering
knuckle to 0.5 mm (0.020 in) or less, and install it on the upper
surface of the thrust bearing.
Spacer thickness:
3.0'3.5,4.0,4.5 mm (0.118'0.138-0.157'0.177 in)

2. Set a spring scale to the tip end of the knuckle spindle, ar

measure the starting force.
Standard: 19.3 N (2.0 kgf) [4.4lbf] or less
3. If the measured value exceeds the standard, check the king
pin for bend, the needle bearing for damage.and axle beam for
deformation.
4. Tighten the lock nut for the king pin lock bolt.

Installation:
When measuring the steering knuckle starting force with the
tire angle sensor installed, measure it within the movable
Front range of the tire angle sensor. If the range is exceeded, the
sensor will be damaged.
t --==!r:orl

Tire angle
sensor
-h'~;Dj~
~
90'

Steering knuckle
 6-15

[Point 8]
Removal:
Remove the king pin oil seals and needle bearings.
1. Use a straight-edge screwdriver to remove the dust seal and
oil seal.
2. Use the SST to remove the needle roller bearings in the
directions shown in the illustration.
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

Installation:
Install the needle roller bearings and king pin oil seals.
1. Use the SST to install the needle bearing.
Check the needle roller bearing press-fitting surface, pressing
direction and installation depth.
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
3.5 - 4.5 mm
( (0.138 - 0.177 in) (09950-70010)
'---~~~f= 2. Install the dust seal.
3. Use the SST to install the oil seal.
SST 09950-76018-71 (1)
(09950-60010)
09950-76020-71 (2)
(09950-70010)

4. Install the RH upper oil seal as shown in the illustration.

c
E~
Eco
co-r-:
·0
-q/
lLf)
NCO
-.i~
o
6-16

[Point 9]
Bushing
Installation:
1.3 mm Press fit the bushing as shown in the illustration.
t (0.051 in)

•
h1.3 mm)
((0.051 in))
 6-17

Rt:AR AXLE CYLINDER

REMOVAL-INSTALLATION
T = N'm (kgf.cm) [ft-lbf]

T = 166.7 - 215.8

b
/ (1700 - 2200)
[123.0 - 159.2]

~~

T = 49.0 - 735
(500 - 750)
4 [36.2 - 54.2]

Removal Procedure
1 Jack up the vehicle.
2 Disconnect the tie rod (on the piston rod side). [Point 1]
3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 2]
4 Remove the rear axle cylinder.
S Remove the bushing from the piston rod. [Point 3]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
6-18

Point Operations
[Point 1]
Installation:
To install the end pin lock nut, install each cone washer with
Cone washer seal in the direction shown in the illustration and tighten the nut
with seal
to the specified torque.

Tightening torque:
49.0 - 73.5 N'm (500 - 750 kgf'cm) [36.2 - 54.2 ft'lbf]

[Point 2]

Installation:
Install the fittings as shown in the illustration.
Vehicle model A I
1·K2 ton series 20°
23·J35 ton series 40°
'1

[Point 3]
Bushing
Installation:
1.3 mm
Press fit the bushing as shown in the illustration.
(0.051 in)

(1.3 mm)
((0.051 in))
 6-19

DISASSEMBLY·INSPECTiON·REASSEMBLY
T::: N·m (kgf-cm) (ftlbf]

[
Disassembly Procedure
1 Remove the through bolt.
2 Remove the piston rod guide.
3 Remove the piston rod. [Point 1]
4 Inspect the cylinder. [Point 2]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply hydraulic oil before reassembly.
6-20

Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
Limit: 49.92 mm (1.9654 in)

Inspection:
Measure the bend of the piston rod.
Limit: 0.5 mm (0.020 in)

Reassembly:
Warm the seal ring to a little below 80°C (176°F) in hot oil. ~.
water before installation.
Caution:
Operate carefully to avoid burn injury.
Note:
Do not stretch it excessively.

[Point 2]
Inspection:
Measure the rear axle cylinder bore.

Limit
1 ton series: 76.35 mm (3.0059 in)
2·K2 ton series: 80.35 mm (3.1634 in)
3 ton series: 84.40 mm (3.3228 in)
J3.5 ton series: 87.40 mm (3.4409 in)
 7-1

STEERING
Page

GEN ERAL 7-2

SPECIFICATIONS 7..5
COM PON ENTS 7-5
STEERING WHEEL·MAST JACKET 7..10
REMOVAL·INSTALLATION 7..10
DISASSEMBLY·INSPECTION·REASSEMBLY 7..12
HYDROSTATIC STEERING VALVE ASSY 7..15
TROUBLESHOOTING 7 ..15
REMOVAL·INSTALLATION 7 .. 16
DiSASSEMBLY·iNSPECTION·REASSEMBLY 7..17
RELIEF PRESSURE INSPECTION·ADJUSTMENT 7 21
0
7-2~.- - - - . : _ _ _ _ _ _ .

GENERAL
Tilt Steering

II
------- - - ________ _

~'-­
I
(
>-
I
/
"/
C,
--I /!
, /

I,

, IV /

/'
/'1'
/
I
/
I

/
,_

I
I

I
/
 7-3

Telescopic Steering (OPT)

Fully extended

Models with
~-- telescopic steering
- \
_--,,---- ~ 57 mm
~ (2.24 in)
Fulley
retracted
~. ,
20 mm , Steering position
(0.79 in) " for standard
models

o
7-4

Hydrostatic Steering Valve

9 2 5 4 6 7

1. Neutral position spring

2. Housing
3. Check valve
4. Spool
5. Sleeve
6. Cardan shaft
7. Gear rim
8. Gear wheel (rotor)
9. Relief valve

L I
-----1 R

\ I

\
I

I I

I I

I I

\
I

p T
-~
 7-5

SPECIFICATIONS
eries
1·2·K2 ton series 3 ton series J3.5 ton series
Item
Steering wheel diameter mm (in) 300 (11.81)
Steering wheel play (at idling) mm (in) 20 - 50 (079 - 1.97)
Power steering type Hydrostatic steering
Type (manufacturer) os pc (Danfoss)

Delivery cm 3 (in 3 )/rev 100 (6.10) 115 (7.02) 125 (7.63)

Hydrostatic steering valve Rated flow rate 13 (3.43) 15.8 (4.17) f--
i' (US gal)/min
Relief set pressure
8000 (82) [1170] f-- 8300 (85) [1210]
kPa (kgf/cm 2 ) [psi]

:OMPONENTS
4501

01
I

. ~---~

••, ••,
lbama----------------~-----a •• .11

4501-0678
7-6

1 ton series

I 4502

4502-260

2-3·K2·J3·5 ton series

I 4502

!
Refer to
4503-1l1

4502-261
 7-7

Telescopic Steering (OPT)

I 4502

16
r .... ---···-

0dL
@ OY

\6-;-FR

4502-262

4Y Engine Vehicle (1 ton), 1DZ-1Il Engine Vehicle (1-2-K2 ton)

4507

i.~ ..

4507-286
7-8

4Y Engine Vehicle (2·K2·3·J3.5ton), 1DZ-III Engine Vehicle (3 ton), 3Z Engine Vehicle (2·3·J3.5 ton)
4507

------ .....

4507-287

Wet Brake (OPT)

4507

01
I

Refer-la
6705·01
I

(:
BJ 4~ /
~.~,,;,
<9

4507-288
 7-9

PS Vaive

4503

-
.
~""·1

.i........
4503-036

4503

4503-063
7-10

STEERING WHEEL-MAST JACKET

REMOVAL-INSTALLATION
T = Nm (kgf-cm) [ftlbf]

1-----5

Removal Procedure
1 Remove the steering wheel. [Point 1]
2 Remove the parking brake release lever.
3 Remove the lower panel.
4 Remove the toe board.
5 Remove the instrument panel.
6 Remove the column cover.
7 Remove the parking brake release lever ASSY.
8 Disconnect the lever switch ASSY wiring.
9 Remove the lever switch ASSY.
10 Remove the steering valve set bolt and keep the valve free.
11 Remove the tilt lock mechanism. [Point 2]
12 Remove the mast jacket ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply MP grease to each sliding portion of the tilt lock mechanism.
• Apply MP grease to the coupling between the tilt steering shaft and steering valve.
 7-11

Point Operations
[Point 1]
Removal:
SST 09950-76003-71
(09950-50012)

Installation:
Apply rubber grease to the steering angle sensor sliding
Pins
portion A of the lever switch, and install the steering wheel.
After installation, turn the steering wheel. When the steering
wheel is turned, the three pins on the sensor will automatically
engage in the pin holes on the steering wheel.

[Point 2]
Install the tilt lever within +/- 20° of a line extending between the
upper part of the tilt lever and the notch in the column cover.
7-12

DISASSEMBLY·INSPECTION·REASSEMBLY
STD

Disassembly Procedure
1 Remove the snap ring.
2 Remove the tilt steering shaft.
3 Remove the bearing.
4 Remove the lever switch ASSY bracket.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply rubber grease to each sliding portion of the lever switch ASSY.
 7-13

TELESCOPiC STEERING (OPT)

N'm (kgf-cm) [fHbf]

Disassembly Procedure
Remove the snap ring.
Remove the extension gear.
j Remove the tilt steering shaft.
4 Remove the bearing.
5 Remove the stopper screw.
6 Remove the lever switch ASSY bracket W/mast upper jacket.
7 Remove the mast upper jacket.
S Remove the lever. [Point 1]
9 Remove the telescopic shaft.
10 Remove the telescopic lock nut.
11 Remove the bushing and shaft.
12 Remove the sleeve W/cap.
13 Remove the cap.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply rubber grease to each sliding portion of the lever switch ASSY.
7-14

50 0
±r Point Operations
[Point 1]
Installation:
Install the telescopic lever at a position 50° ± r from the
steering shaft.
 7-15

HYDROSTATiC STEERiNG VALVE ASSY

TROUBLESHOOTING
Phenomenon Estimated cause Corrective action
• The steering valve drive shaft is installed incorrectly or Inspect and correct or replace.
The steering wheel cannot
damaged.
be rotated.
• The piping is damaged. Replace.
• The tire inflating pressure is low. Adjust the inflating pressure.
• The oil pressure does not rise. Inspect and adjust the relief pressure.
The steering wheel is • The high and low pressure pipes are connected Inspect and correct.
heavy. reversely.
• The power steering cylinder rod is bent or the piston is Inspect and correct or replace.
sticking.
• The high and low pressure pipes are connected Inspect and correct.
reversely.
'he oil pressure does not • The relief valve is faulty or not closed. Inspect and correct.
"e. • The oil pump function is degraded or the oil volume is Inspect and correct or replace.
insufficient.
• The power steering cylinder piston packing is damaged. Replace.
• The tire inflating pressure is low. Adjust the inflating pressure.
The steering wheel does • The steering valve spool does not move smoothly. Correct or replace the steering valve
not return properly. ASSY.
I • The steering knuckle sliding motion is improper. Add the lubricant or correct.
• The steering valve spool does not move smoothly. Correct or replace the steering valve
The steering wheel does ASSY.
not return to the neutral • The steering valve drive shaft is damaged. Replace the steering valve ASSY.
position when released. • The centering spring is damaged. Replace.
• The piping is blocked (crushed or clogged). Inspect and correct or replace.
• Oil moves in the steering valve. Replace the steering valve ASSY
• The steering valve spool is not moving correctly. Correct or replace the steering valve
The play is excessive and
ASSY
the vehicle wobbles.
• Air is sucked from the piping. Inspect and correct or replace.
• The steering shaft is defective Inspect and correct or replace.
• Oil moves in the steering valve. Replace the steering valve ASSY.
• The relief valve is not functioning correctly. Inspect and correct.
-'le steering wheel in the • Air is sucked from the piping Inspect and correct or replace.
, _ling state is heavy. • The piping is blocked (crushed or clogged). Inspect and correct or replace.
• The end cap set screw is tightened to an excessive Tighten uniformly to the specified
torque. torque.
The steering wheel
• The steering valve drive shaft is installed incorrectly. Inspect and correct.
shimmies.
The tires are steered
opposite to the steering • The cylinder piping is connected reversely. Inspect and correct.
wheel operated direction.
• The relief valve is defective. Correct, inspect the pressure, and
Abnormal noise is adjust.
generated. • Air is sucked from the piping. Inspect and correct or replace.
• The piping is blocked (crushed or clogged). Inspect and correct or replace.
7-16

REMOVAL-INSTALLATION
T = N·m (kgf-cm) [ft·lbf]

Removal Procedure
1 Remove the lower panel.
2 Remove the teo board.
3 Remove the instrument panel.
4 Remove the parking brake release lever.
5 Remove the column cover.
6 Remove the parking brake release lever ASSY.
7 Disconnect the lever switch wiring.
8 Disconnect the piping.
9 Remove the steering valve set bolt and keep the valve free.
10 Remove the tilt lock mechanism.
11 Remove the mast jacket ASSY W/steering wheel.
12 Remove the steering valve ASSY and spacer.
13 Remove the fitting.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 7-17

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N'm (kgf'cm) [ft'lbf]

5-----l.

T = 24 - 36 (2.45 - 367) [177 - 26.6]

Disassembly Procedure
Remove the end cover. [Point 1]
Remove the gear wheel set, cardan shaft (drive shaft) and distributor plate. [Point 2]
3 Remove the check valve.
4 Remove the sleeve W/spool and bearing. (Point 3]
5 Remove the O-ring, kin-ring and dust seal ring. [Point 4]

6 Remove the rerief valve. [Point 5]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Wash each part with clean hydraulic oil before assembly.
7-18

Point Operations
[Point 1]
\ Disassembly:

) Put a match mark.

Disassembly:
Align the match marks.

Disassembly:
When removing each set bolts, carefully operate so as not to
lose the steel ball.
Reassembly:
Put a steel ball in the illustrated position before installing eac'
set bolts.
Reassembly:
As one out of seven set bolts is a bolt with pin, install it in the
correct position.

[Point 2]
Reassembly:
Pay attention to the following points at the time of reassembly.
1. Fit the gearwheel (rotor) and cardan shaft so that a tooth base
Parallel in the rotor is positioned in relation to the shaft slot as shown.
Turn the gear rim so that the seven through holes match the
holes in the housing.

2. Guide the cardan shaft (drive shaft) down into the bore so th
the slot is parallel with the connection flange.

3. Align the match marks on the distributor plate and gear wheel
made at the time of disassembly.
When these parts are replaced, match the holes in the housing
and plate at the time of reassembly.

I
 7-19

(
[Point 3)
/ Disassembly:
Extract the spool W/sleeve upward. Otherwise, the spool cross
pin may move during extraction to cause sticking.

Reassembty:
Set and install the neutral position spring correctly.

00

Reassembty:

::t:
Pay attention to the bearing direction for installation. (See the
figure.)

Chamfering

Reassembly:
Place the housing with its flanged side facing down, and insert
the spool W/sleeve into the housing. Set the cross pin of the
spool in horizontal state during insertion.

[Point 4]
O-ring Reassembly:
Install the kin-ring and O-ring correctly.
Note:
For SST No. SJ150-9000-11, please inquire at the nearest
Danfoss service shop.
(Refer to Parts & Service News Ref. No. GE-7022 of July 1,
Kin-ring 1997 for detail.)
7-20

1. I urn the steering unit until the bore is horizontal. Guide the
outer part of the assembly tool into the bore for the spool!
sleeve.
2. Apply O-ring and kin-ring with hydraulic oil and place them on
the tool.

3. Hold the puter part of the assembly too! in the bottom of the
steering unit housing and guide the inner part of the tool right
to the bottom.

4. Press and turn the O-ring/kin-ring into position in the housing.

5. Draw the inner and outer parts of the assembly tool out of the
steering unit bore, leaving the guide from the inner part in the
bore.

[Point 5]
Disassembly:
Do not remove the relief valve unless it is judged defective.
The valve seat cannot be removed.
Disassembly:
Measure the screwed-in depth of the relief valve adjusting
screw before starting disassembly.

Reassembly:
Reassemble by adjusting to the screwed-in depth of the valve
spring retainer measured before disassembly. After installing
the steering valve ASSY on the vehicle, measure the relief
pressure. If it is not within the standard range, adjust it by
changing the screwed-in depth of the retainer.
 7-21

RELIEF PRESSURE
INSPECTION-ADJUSTMENT
1. Install an oil pressure gauge.
(1) Disconnect the hose from the steering valve P port, and
connect the adapter (SST).
SST 09450-23320-71
(2) Install the pressure gauge.
Plug size: PT1/8

2. Start the engine and turn the steering wheel slowly clockwise
/ and counterclockwise.
3. Start the engine, rotate the steering wheel and measure the
relief pressure when the relief occurs
Standard: Unit: kPa (kgf/cm 2 ) [psi]
1·2·K2·3 ton series 8000 .~"O (82'~) [1170 .;u)
J3.5 ton series

4. If the standard is not satisfied, remove the steering valve and

make adjustment by turning the relief valve adjusting screw.
 8-1

BRAKE
Page Page
DRY BRAKE (STD) 82n
BRAKE VALVE 8..51
GENERAL 8 2
n BRAKE VALVE OPERATION
SPECIFICATIONS 8-6 INSPECTION 8-54
COMPONENTS 8 7
n
ACCUMULATOR ASSY 8..55
ACCUMULATOR
FRONT BRAKE 8-12 INSPECTION 8..57
BRAKE AIR BLEEDING 8-22 PARKING BRAKE ASSY 8..58
BRAKING FORCE PARKING BRAKE FUNCTION
INSPECTION· INSPECTION 8..61
ADJUSTMENT 8-22
ADJUSTING THE PARKING
.3RAKE MASTER LEVER & SWITCH 8..61
... CYLINDER 8-23
PARKING BRAKE INSPECTION
PARKiNG BRAKE AND ADJUSTMENT 8..62
INSPECTION·
ADJUSTMENT 8-26 BRAKE COOLING OIL TANK 8..63
BRAKE PEDAL INSPECTION· PROCEDURE FOR POURING
ADJUSTMENT 8-27 iN BRAKE COOLING OIL 8..64
INCHING PEDAL INSPECTION· BRAKE COOLING
ADJUSTMENT 8-28 OIL COOLER 8..65
SINGLE BRAKE (INCHING) BRAKE PEDAL INSPECTION
PEDAL INSPECTION· AND ADJUSTMENT 8..66
ADJUSTMENT INCHING PEDAL INSPECTION
(02 PEDAL: OPT) 8-29 AND ADJUSTMENT 8..67
INSPECTION AND ADJUSTMENT
OF THE SINGLE BRAKE
\/VET BRAKE (OPT) 8-30 (INCHING) PEDAL ...........•.... 8..68
GENERAL 8-30
SPECIFICATIONS 8-33
GREASING TO
HYDRAULIC CIRCUIT
DIAGRAM 8-34 PARKING BRAKE
COMPONENTS 8-35 PEDAL RELEASE PIN
FRONT BRAKE ASSY 8..42
(COMMON TO DRY BRAKE
AND WET BRAKE) 8..69
DEPRESSURIZING
THE ACCUMULATOR 8-48
BRAKE AIR BLEEDING 8..48
BRAKING FORCE
INSPECTION 8..48
POINTS FOR LOCKING
THE BRAKE DISK
Ob PLATE NO. 1
.. PLATE NO. 2 8-49
ADJUSTING THE BRAKE
DISK CLEARANCE 8-50
8-2

DRY BRAKE (STD)

GENERAL
FRONT BRAKE

1 ton series

Wheel Cylinder
 8-3

2·3·K2 ton series

Wheel Cylinder
8-4

J3.5 ton series

Wheel Cylinder
 8-5

Parking Brake
8-6

Master Cylinder

SPECIFICATIONS
I
1 ton series 2·K2 ton series 3 ton series J3.5 ton series ..
Item
Hydraulic internal
Foot brake expanding duo +--- +--- ~.

servo brake
Internal expanding
Parking brake +--- +--- +---
mechanical brake
Brake drum inside diameter mm (in) 254 (10.0) 310 (12.2) +--- 317.5 (12.5)
Resin maid
Material +--- +--- +---
(asbestos-free)
Brake lining Dimensions
279 x 48.5 x 5 323 x 60 x 7 343 x 60 x 7 352 x 60 x 56
Length x width x
(110 x 1.91 x 020) (12.7 x 2.36 x 0.28) (13.5 x 2.36 x 0.28) (13.9 x 2.36 x 0.22)
thickness mm (in)
Wheel cylinder bore mm (in) 22.2 (0.87) 28.5 (1.12) +--- +---

Brake master Bore mm (in) 19.05 (0.75) +--- +--- +---

cylinder Stroke mm (in) 30 (1.18) +--- +--- +---
Applicable oil SAE J-1703-DOT-3 +--- +--- +---
 8-7

COMPONENTS
FRONT BRAKE

1 ton series

4715

02[LHI
01{RH]
I

r ... - - - - -
:~I_~L~ AK
• :~L
-..
.
~·1

II
i
I
I
b ••• ~

4715--096

2·3·K2 ton series

4715

01[RH]
02lLHJ

4715-095
8-8

J3.5 ton series

4715

02(LH]
~0i'1[.:..:.RH~l,---_~ ••• ,
r., ....
.,

AF

10
,. ...... ---- ! --- --- ... ,,
: ~~~~_~I~

I
I
..I
L...... -- _ . - - .........

t ...... __ .....J
4715~097B

Brake pipe

4714

4714·285
 8-9

BRAKE MASTER CYLINDER

4702

L •••
..... - - - -
AD-~

AL~~-AE
cx--g·· ~AK

.
___ .. ", .. .J
4702-119
PARKING BRAKE

4601

4601
15
:r .. • .. - -
-,' ..... ,

··I .
L ...... ...... J
4601-196
 8-11

BRAKE PEDAL

I 4701

4701-239

SINGLE BRAKE PEDAL (02 PEDAL SPEC. (OPT))

I 4701

HX
AW~id' Refer to
o---AD 4702-01

4701-240
8-12

FRONT BRAKE

DISASSEMBLY·INSPECTION·REASSEMBlY (1·J3.5 TON SERIES)

11 4
__1 -, I
l

I
'f

I
I
I
/ :::----.- I

6 lTh'D~1
7

Disassembly Procedure
1 Drain brake fluid.
2 Remove the front axle hub. (See page 5-9) [Point 1]
3 Remove the shoe hold down spring and cup. [point 2]
4 Remove the anchor to shoe spring and shoe guide plate. [Point 3]
5 Remove the cable and cable guide.
6 Remove the lever strut. [Point 4]
7 Remove the adjuster spring and adjusting screw. [Point 5]
8 Disconnect the parking brake cable. [Point 6]
9 Remove the brake shoe. [Point 7]
10 Disconnect the brake pipe.
11 Remove the wheel cylinder ASSY. [Point 8]
12 Remove the backing plate. [Point 9]
 8-13

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Check that the brake lining and brake drum interior surface are free from grease or oil before
installation.
• Before reassembly, decrease the brake drum outside diameter to approx. 1 mm (0.04 in) less than the
drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (see page 8-22) and braking force inspection
(see page 8-22).
• Apply thread tightener (08833-76001-71 (08833-00070)) to the backing plate set bolt before reassembly.

Point Operations
[Point 1]
Inspection:
Measure tl,e brake drum inside diameter.

Standard
1 ton series: 254 mm (10.0 in)
J3.5 ton series: 317.5 mm (12.50 in)
Limit
1 ton series: 256 mm (10.1 in)
J3.5 ton series: 319.5 mm (12.579 in)
Reassembly:
Apply thread tightener (08833-76001-71 (08833-00070)) on
the brake drum set nut before reassembly.

[Point 2]
Disassembly·Reassembly:
SST 09510-31960-71

Inspection:
Measure the free length of the hold down spring.
Standard
1 ton series: 25.5 mm (1.004 in)
J3.5 ton series: 44.0 mm (1.732 in)
8-14

Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
shoe hold down pin and the contact surface on the back side
of the backing plate to eliminate any clearance.

[Point 3]
Disassembly:
SST 09717-76001-71
(09717-20010)

Inspection:
Measure the free length of the anchor to shoe spring.
Standard
1 ton series: 102.2 mm (4.024 in)
J3.5 ton series: On the side of lining WI pin
138.2 mm (5.441 in)
On the side of lining WIO pin
.121.2 mm (4.772 in)
Limit: No clearance between coil turns

Reassembly:
SST 09718-76001-71
(09718-20010)

[Point 4]
Inspection:
Measure the free length of the strut to shoe spring.
Standard
1 ton series: 19.7 mm (0.776 in)
J3.5 ton series: 31.4 mm (1.236 in)
 8-15

[Point 5]
Inspection:
Measure the free length of the adjuster spring.
Standard
1 ton series: 99.4 mm (3.913 in)
J3.5 ton series: 125.4 mm (4.937 in)
Limit: No clearance between coil turns

Reassembly:
Apply grease to the adjusting SCre\N threaded portion and
fill grease in the cap.

Reassembly:
Apply grease to the adjusting screw threaded portion and fill
grease in the cap.
Reassembly:
Tie a wire to the free end of the adjuster spring and set it by
pulling the wire with a screwdriver.

[Point 6]
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
parking brake cable outlet of the backing plate to eliminate any
clearance.

[point 7]
Inspection:
Measure the brake lining thickness.
Standard
1 ton series: 4.9 mm (0.193 in)
J3.5 ton series: 5.6 mm (0.220 in)
Limit
1 ton series: 1.0 mm (0.039 in)
J3.5 ton series: 1.0 mm (0.039 in)
8-16

Reassembly:
Before brake shoe installation, apply grease to the portions of
the backing plate shown in the illustration (6 places in contact
with the shoe rim and the anchor pin).

[Point 8]
Inspection:
Measure the clearance between the wheel cylinder and piston.
Limit
1 ton series: 0.125 mm (0.00492 in)
J3.5 ton series: 0.15 mm (0.0059 in)

Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
backing plate fitting portion of the wheel cylinder and on the
whole periphery of the set bolts to eliminate any clearance.

[Point 9]
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
contact surface between the backing plate and front axle
bracket shown in the illustration to eliminate any clearance.
 8:-17

DISASSEMBLY·INSPECTION·REASSEMBLY (Z·3·KZ TON SERIES)

Disassembly Procedure
1 Drain brake fluid_

Remove the front axle hub_ (See page 5-9) [Point 1)

Remove the hold down spring_ [Point 2)
4 Remove the pawl lever stopper. [Point 3]
5 Remove the pawl lever_
6 Remove the anchor to shoe spring_ [Point 4]
7 Remove the strut lever. [Point 5]
8 Remove the adjuster spring and adjusting screw_ [Point 6]
9 Disconnect the parking brake cable_ [Point 7]
10 Remove the brake shoe_ [Point 8]
11 Disconnect the brake piping_
12 Remove the wheel cylinder ASSY [Point 9]
13 Remove the backing plate_ [Point 10]
8-18

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
(With regard to steps 3 and 4, however, install the pawl lever stopper after installing the hold down spring.)
Note:
• Check that the brake lining and brake drum interior surface are free from grease or oil before
reassembly.
• Before reassembly, decrease the brake shoe outside diameter to approx. 1 mm (0.04 in) less thap the
brake drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (see page 8-22) and braking force inspection and
adjustment (see page 8-22).

Point Operations
[Point 1]
Inspection:
Measure the brake drum inside diameter.
Standard: 310 mm (12.20 in)
Limit: 312 mm (12.28 in)

Reassembly:
Apply thread tightener (08833-76001-71 (08833-00070)) to the
brake drum set nut before reassembly.

[Point 2]
Disassembly-Reassembly:
SST 09510-31960-71

Inspection:
Measure the free length of the hold down spring.
Standard: 34.5 mm (1.358 in)
Limit: 31.3 mm (1.232 in)

Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
back side of the backing plate in contact with the shoe hold
down spring to eliminate any clearance.
 8-19

[Point 3]
Inspection:
Measure the free length of the actuator spring.
Standard: 124.5 mm (4.902 in)
Limit: No clearance between coil turns

Reassembly:
Use snap ring pliers to install the pawl lever stopper and
actuator spring.

[Point 4]

Disassembly:
SST 09717-76001-71
(09717-20010)

Inspection:
Measure the free length of the anchor to shoe spring.
Standard: 106 mm (4.17 in)
Limit: No clearance between coil turns

Reassembly:
SST 09718-76001-71
(09718-20010)
8-20

[Point 5J
Inspection:
Measure the free length of the strut to shoe spring.

Standard: 23 mm (0.91 in)

Limit: 20 mm (0.79 in)

[Point 6]

Inspection:
Measure the free length of the adjuster spring.

Standard: 86 mm (3.39 in)

Limit: No clearance between coil turns

Reassembly:
Apply grease to the adjusting screw threaded portion and
fill grease in the cap.

[Point 7J
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
parking brake outlet of the backing plate to eliminate any
clearance.

[Point 8]

Inspection:
Measure the brake lining thickness.
Standard: 7.0 mm (0.276 in)
Limit: 2.0 mm (0.079 in)
 8-21

Reassembly:
Apply grease to the portions of the backing plate shown in the
illustration (6 places in contact with the shoe rim and the
anchor pin) before brake shoe installation.

[Point 9]

Inspection:
Measure the clearance between the wheel cylinder and piston.
Limit: 0.145 mm (0.00571 in)

Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
wheel cylinder backing plate fitting portion and the whole
periphery of set bolts to eliminate any clearance.

[point 10]
Reassembly:
Carefully install the backing plate set bolts in the correct
positions since they are different in length
Apply thread tightener (08833-76001-71 (08833-00070)) to the
set bolts before reassembly.
80lt length
A: f. = 36 mm (1.42 in)
2'f<2 ton series 3 ton series B: f. = 40 mm (1.57 in)
c: f. = 45 mm (1.77 in)
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
contact surface between the backing plate and front axle
bracket shown in the illustration to eliminate any clearance.
8-22

BRAKE AIR BLEEDING

Note:
Add brake fluid to the reservoir tank during air bleeding to
prevent it from becoming insufficient.
1. Bleed air from the brake master cylinder.
(1) Depress the brake pedal several times to compress the
air in the piping, and hold that state.
(2) Loosen the bleeder plug to discharge air in the piping with
the brake fluid, and tighten the plug immediately before
the fluid stops coming out.
(3) Repeat steps (1) and (2) above until no air bubbies are
seen in the discharged brake fluid.

2. Bleed air from wheel cylinders RH and LH.

(1) Operate as described in step 1 above for the RH anq'
side at a time.
3. Add brake fluid to the specified level.
(1) Add brake fluid through the filter provided in the reservoir
tank.
(2) Add brake fluid up to the specified level in the reservoir
tank.

BRAKING FORCE INSPECTION-ADJUSTMENT

1. Inspect the braking force using a brake tester or by traveling test
Braking distance (without load)
Initial speed of braking km/h (mph) Max. speed
Braking distance m (ft) 5.0 (16.4) or less

2. Adjust the braking force.

(1) Repeat traveling in the forward and reverse directions to adjust the brake shoe clearance.
The adjusting screw adjusts the ciearance automatically when the brake pedal is depressed in reverse
traveling.
(2) If the braking force is insufficient. adjuster malfunction, lining contact defect, foreign matter adhesion on the
lining or brake fluid leakage is assumed. Remove and inspect the brake drum.
(3) When the brake shoe is replaced with a new one, repeat traveling in the forward and reverse directions for
running in.
 8-23

BRAKE MASTER CYLINDER

REMOVAL-INSTALLATION
T = N·m (kgf·cm) [ft·lbq

.emovai Procedure
Remove the lower paneL
2 Remove the toe board.
3 Remove the instrument paneL
4 Remove the column cover.
5 Disconnect the brake side hose from the reservoir tank and drain brake fluid.
6 Disconnect the piping.
7 Remove the push rod clevis pin.
8 Remove the brake master cylinder.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, perform brake pedal adjustment (see page 8-27) and air bleeding (see page 8-22).
8-24

DISASSEMBLY·INSPECTION·REASSEMBLY

Disassembly Procedure
Turn the boot up and remove the snap ring.
2 Remove the push rod. [Point 1]
3 Remove the piston. [Point 2]
4 Remove the pin and the fluid inlet elbow.
5 Remove the outlet plug and valve.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 8-25

Point Operations
[Point 1]
Reassembly:
Temporarily set the push rod length to the illustrated
dimension, and make readjustment after installation.

130 mm (5.118 in)

[Point 2]
Reassembly:
Apply rubber grease to the piston cup and whole periphery of
the cup before reassembly.
8-26

PARKING BRAKE
INSPECTION-ADJUSTMENT
1. Check the parking brake cable set position.
Standard: A =0 - 2 mm (0 - 0.08 in)
2. Apply chassis grease to the portions indicated by arrows.

.
When using the SST 3. Inspect and adjust the parking brake pedal operating force.

(1) Set the SST to the parking brake pedal.

SST 09460-26600-71
(A)
(2) Set a spring scale to the SST and pull it backward
measure the operating force.

When not using the SST Standard:

(A) When using the (B) When not using
SST the SST
112 - 136 N 186 - 226 N
Except J35 ton
(11.4-13.9 kgf) (19 - 23 kgf)
series
[25.1 - 30.6 Ibf] [42 - 51 Ibf]
142 - 166 N 235 - 275 N
J3.5 ton series (14.5 - 16.9 kgf) (24 - 28 kgf)
[32.0 - 37.3 Ibf] [53 - 62 Ibf]

'--_-'--__________-.J I
(3) If the operating force is out of the standard range, rele;=
the parking brake and make adjustment at the adjust J

portion.

Clockwise turn: Increases the operating force.

Counterc!ockwise turn: Decreases the operating force.

RELEASE LEVER CABLE ADJUSTMENT

1. Adjust the play of the release lever to 0 to 5 mm (0 to 0.2 in) at
the tip of the lever using the release cable adjusting nut.

Adjusting nut---v,.,ty
 8-27

BRAKE PEDAL INSPECTION-ADJUSTMENT

Brake master cylinder

Push rod

1. Inspect brake pedal height A. (From toe board to top of pedal)

Standard: A:: 145 - 150 mm (5.91 - 6.10 in) (with pedal pad)

if the standard is not satisfied, make adjustment by changing the stop lamp switch position.

2. Inspect brake pedal play B.

Standard: B:: 1-5 mm (0.039 - 0.197 in)

If the standard is not satisfied, make adjustment by changing the master cylinder push rod length.

3. Check master cylinder push rod play C with the brake pedal in the above state.

Standard: C = 1 mm (0.04 in)

4. After the adjustment, fully depress the brake pedal and inspect pedal height D.

Standard: D =90 mm (3.54 in) or more

8-28

INCHING PEDAL INSPECTION-ADJUSTMENT

Adjusting nut

Adjusting nut

1. Inspect and adjust the brake pedal height and play (See page 8-27).
2. Inspect stroke A of the inching pedal until interlocking with the brake (pedal stroke until the inching pedal plate
comes into contact with the brake link)

Standard: A = 35 - 41 mm (1.38 -1.61 in)

If the standard is not satisfied, adjust the stopper bolt protrusion.

Adjust the brake pedal height within + 15 mm (0.59 in).
3. Inspect and adjust the inching cable
(1) Inspect inching cable length B on the 'pedal side.

Standard: B =17.5 mm (0.689 in)

If the standard is not satisfied, adjust it by turning the adjusting nuts on the pedal side.
(2) Inspect inching pedal play C before the inching lever starts to move.

Standard: C =1 - 3 mm (0.04 - 0.12 in)

If the standard is not satisfied, adjust it by turning the adjusting nuts on the inching lever side.
 8-29

SINGLE BRAKE (INCHING) PEDAL INSPECTiON-ADJUSTMENT

(D2 PEDAL: OPT)

Inching pedal Brake pedallj

i;) plate ~
Brake '"

Ii"k(~~
Adjusting bolt

\~
\

Adjusting ~--------

nut

E.s
E ~
E
E
.,1
~
\\ OLD oml
\ \ -q-LD LOID!
\/1 ~ I ~ I I
Floor mat I N I ~ I· Toe board
0"'- OLO

\~ ~ ~~!
," '==dm-d= t
Adjusting
nut
/// Inching lever

1 Tighten the adjusting bolt until there is no gap between the adjusting bolt and surface (a) of the inching pedal,
and tighten the lock nut.
Adjust the height and play of the pedal. The values specified in the above illustration should be used as the
standard for the pedal height. Refer to page 8-27 for adjustment method.
3. Inspect stroke A of the pedal until interlocking with the brake (pedal stroke until the pedal plate and bolt head
comes into contact with the brake link).

Standard
1 ton series: A =41.7 - 48.7 mm (1.64 -1.92 in)
Others: A =29.7 - 36.7 mm (1.17 - 1.44 in)

If the standard is not satisfied, adjust the stop lamp switch or stopper bolt protrusion.

4. Inspect and adjust the inching cable.

(1) Inspect the inching cable length 8 on the pedal side.

Standard: B = 17.5 mm (0.689 in)

If the standard is not satisfied, make adjustment by turning the adjusting nuts on the pedal side.
(2) Inspect inching pedal play C until the torque converter inching lever starts to move.

Standard: C =1 - 3 mm (0.04 - 0.12 in)

If the standard is not satisfied, make adjustment by turning the adjusting nuts on the torque converter side.
8-30

WET BRAKE (OPT)

GENERAL
Front Brake

A-A
 8-31

Parking Brake

2 ton series

3J3_5 ton series

Accumulator

WARNING:
o It contains nitrogen under high pressure.

• Don't allow fire or heat near it. Don't try to disassemble it. Wear eye protection and
carefully drill a hole at the point marked <0 to release GAS pressure before disposal.
8-32

Flow Divider Valve (for Brake Cooling System)

(p
I

~ 1--'':1
f.J

I
1
I
I te:..-=---::...--: I
I
, I'" 1\
It--
, "
~ Lb- -=--=- ~ 1/ Ct::::= ;--1
H
-+-
H
I-IC....--=---=-- ,=--=
tt 1

,, "
, ;,
I
I
"

,t--

Lb- -=-.:_
~f-

'===
I
1/1', j
~
-$-
-

~~~~

Check Valve

ll~_

~/
)!J- 1 (~~'
-
'i/- ~- -IJI -FJrd
'--vV
-T-------
I
k

Relief Valve

IN
 8-33

Brake Valve

From To From To
accumulator front brake oil pump oil tank

/
Pressure testing opening To
PS valve

SPECIFICATIONS
. odel
2 series 3'J3.5 series
Item
Type Wet disc brake
Q)
x Brake lining dimensions
~ 20x260x198
..0 (Thickness x Outside diameter x Inside mm (in) I (0.08 x 10.24 x 7.80)
-0 diameter)
0
LL
Number of discs 5 discs 6 discs
Q) Type Mechanical disc brake
x
~ Brake lining dimensions
..0 1.6 x 84 x 62 1.6 x 112 x 84
CD (Thickness x Outside diameter x inside mm (in)
c (0.06 x 3.31 x 244) (0.06 x 441 x 3.31)
~ diameter)
tU
CL Number of discs 7 disc
Type Full power CHPS
Q)
> Input piston outside diameter mm (in) 254 (1.0)
m
>
Q)
Input piston stroke mm (in) 12.9 (051) 12.7 (0.5)
..Y:
~ Maximum hydraulic pressure MPa (kgf/cm 2 ) [psi] 7.5 (76.5) [1088] 7.8 (79.5) [1131]
lJ)

Oil used Hydraulic oil ISO VG32

Cooling oil SHELL OONAX TO
Cooling oil capacity e(USgal) 7.8 - 8.2 (2.1 - 2.2)
8-34

HYDRAULIC CIRCUIT DIAGRAM

Brake operation system

PS valve
Brake
valve

Oil control
valve

Orifice
"'-, Check valve
I
~~I ~~
0 ~\ II
I I ///'-----------' , ( \ I

\ Oil tank ) Relief valve Accumulator -----.,.\JWarning buzzer & lamp

Brake cooling system

Wet brake LH

Brake cooling
oil tank

Oil
cooler
Engine
Torque Front axle
converter & ,
) transmission:

Oil pump

Relief valve
Wet brake RH
 8-35

COMPONENTS
Parking Brake

2 ton series 4601

"'l_GU 4601-198C

3·J3.5 ton series 4601

8-36

Brake Pedal

I 4701

HX
AW V C
/
.. '

AD

4701-241

SINGLE BRAKE PEDAL (02 PEDAL SPEC. (OPT»

4701

4701-242
 8-37

Brake Valve

4704

4704-024A

4704
01

.,
F .... ., _._~-~-~-

I [01~~-~L.~)1
8-38

Accumulator

4706

CH

01
co
~-- BD

01-

____ I
Relief Valve

23
4706l
I
.
,,0.0- ~-

··
~---oo ...!I

4706-025
 8-39

Brake PI" pmg

"

DA
RN ___ J
4714-2798

Brake Piping ( 2 ton series)

4714

4714-2696
8-40

Brake Piping (3·J3.5 ton series)

4714

4714-277A

Cheak Valve

4714
14
0._. L ~ . . .... .....__ ...... .,

14C
14F
14A

14A

- - - - - - - - - - - - - - - - ......

4714-i72
 . 8-41

Brake ASSY

02[LHJ
01[RHJ _

r ...... ~ ~ ~~ ...... ,
·,
I

d '-
J8 JE
~ 28 JA
I 28
/ JA

I '
/

(~, T 28
I JA 28
JO

I ;; T cl, JA

-/'1"
_/ OH

'r"
OH

·
i.••• = _
8-42

FRONT BRAKE ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY
Note:
• Depressurize the accumulator before starting the operation (Refer to 8-48)
• Do not wear gloves when disassembling or reassembling the brake ASSY.
• Do not allow water to come in or contact the brake ASSY.
T = N'm (kgfcm) [ftlbf]

4
@ I
iI

I
I
I
I

I I:".:,

I
I
I

Disassembly Procedure
1 Remove the front axle hub. (see page 5-20)
2 Remove the bushing. [Point 1]
3 Remove the brake ASSY. [Point 2]
4 Remove the inner housing. [Point 3]
5 Remove the plate No.2 and the spring. [Point 4]
6 Remove the plate NO.1 and the brake disk [point 5]
7 Remove the snap ring and oil seal.
S Remove the piston and piston seal. [Point 6]
9 Remove the pressure plate and steel balls. [Point 7]
10 Remove the cam, lever, adjusting bolt and O-ring.
 8-43

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
Note:
• After reassembly, perform adjust the brake disk clearance. (see page 8-50)
• After reassembly, perform brake air bleeding. (see page 8-48)
• After reassembling, check the operation of the accumulator. (see page 8-57)
• During reassembling, check that no foreign matter is attached to the parts.

Point Operations
[Point 1)

Removal:
SST 09950-760·18-7·1 (1)
(09950-60010)
09950-76014-71 (2)
(09950-40011 )

Installation:
Use a copper bar to reassemble the bushing into the position
A in the drawing.

A =0 - 1 mm (0 - 0.039 in)

[Point 2]
Reassembly:
Apply a sealant (08826-76002-71 (08826-00090)) to the
contact surface of the brake assembly and front axle bracket,
and reassemble them.

Reassembly:
Check the brake cooling oil hole, and assemble the 0 ring
between the brake assembly and front axle bracket.
8-44

[Point 3]

Reassembly:
Reassemble the brake assembly in the following procedure.

1. Raise the housing by placing wooden blocks under the outer

housing, taking care not to press on the oil seal.

2. Place the brake discs and plates NO.1 alternately in the

housing.

3. Reassemble the springs (6 pieces).

4. Align the plate No. 2 with the groove in the outer housing.

5. Hand tighten the housing set bolt and nut, and set the inner
housing so that it floats up by the power of the springs.

6. Press the inner housing by hand to check that it seals.

If it cannot be pressed to seal by hand, then plate No. 2 is not
in the correct position. Carry out step 4 again.

7. Reassemble the housing set bolt and nut to the stanoe.tl d

tightening torque.

Reassembly:
Use the SST to arrange the engagement of the spline of the
brake disc, plate No. 1, and plate No. 2.
SST 09472-26600-71

After engaging the spline, tighten the adjusting bolt to fix the
disc. (see page 8-49)

[Point 4]
Inspection:
Measure the thickness of plate No. 2.
Standard: 3.6 mm (0.142 in)
Limit: 3.3 mm (0.130 in)
 8-45

Inspection:
Measure the free length of the spring.
Standard: 25.7 mm (1.012 in)
Limit: 23.7 mm (0.933 in)

[Point 5]

Inspection:
Measure the thickness of plate No. 1.
Standard: 2.0 mm (0.079 in)
Limit: 1.7 mm (0.067 in)

Inspection:
Measure the thickness of the brake disc.
Standard: 3.5 mm (0.138 in)
Limit: 3.2 mm (0.126 in)
8,..46

[Point 6]
Disassembly:
When removing the brake piston, remove it using the 2 service
tabs (M6 x 1.0).

Reassembly:
Piston seal
Reassernble the brake piston in the foilowing procedure.
1. After applying hydraulic oil to the piston seal, reassemble it to
the housing by hand.
Do not wear gloves at this time.

u
, --
,~-
U U u

'f
u~.;::.u /
L.--.... u
~----~
Piston seal

2. Prepare 3 box wrenches of equal height as a holder on which

to place the housing.

3. Set the 3 box wrenches in contact with the fiat face in

center of the housing, and set on a hand press.

4. Apply hydraulic oil to the contact surface of the piston seal by

hand.
Do not wear gloves at this time.
 8-47

5. Place the piston on the insertion face,and place a round plate

or strong metal plate such as is shown in the drawing on top of
the piston.
Use a hand press to slowly insert the piston.
When the operation of the hand press becomes heavy, stop
the operation.

[Point 7]
Reassembly:
When reassembling the pressure plate, check that the steel
Pressure plate balls (3 balls) are assembled in the grooves of the inner

e:br
~--/~~
housing and pressure plate before inserting the pressure plate.

Steel ball
8-48

DEPRESSURIZING THE
ACCUMULATOR
1. With the engine stopped. Depress the brake pedal fully to its
stroke end.
Depress it 100 times or more.

BRAKE AIR BLEEDING

Bleed air from the brake assembly in the following procedure.
1. Loosen the air purging breather plug on the brake assembly on
one side.
2. Connect an air purging hose to the loosened breather plug~
3. Start the engine, and depress the brake pedal.
(Until air stops coming out from the air purging hose)
4. Tighten the breather plug, and remove the air purging hose.

Tightening torque:
7.0 - 12.0 N'm (71.4 - 122.4 kgf'cm) [5.2 - 8.9 ft-lbf]
5. Carry out the operations 1-4 above for the brake assembly on
the other side.

BRAKING FORCE INSPECTION

1. Inspect the braking power using a brake tester or by a driving test.
Braking stop distance (in unloaded condition)
Braking initial speed Maximum speed
Stopping distance 1.5.0 m (16.4 ft) or less I

2. When the braking power is insufficient, carry out the following inspections.
(1) Brake piping oi/leakage inspection.
(2) Brake valve operation inspection.
(3) If the brake disk is replace with a new part, drive forward and backward repeatedly to break the new disk in.
 8-49

POINTS FOR LOCKING THE BRAKE

DISK = PLATE NO. 1 - PLATE NO. 2
Note:
When detaching the front axei hub, the brake disk can be
temporarily locked so that the brake disk serrations do not
slip out of alignment.

The brake disk - plate NO.1 - and plate NO.2 are locked in the
following procedure.

1. Loosen bolt A.

2. Loosen the lock nut.

3. Tighten bolt B until the adjusting lever comes into contact with
the disk plate.
At this point, make a note of the number of turns taken to
tighten the bolt B.
4. Temporarily tighten bolt A.
5. To unlock the brake disc, reverse this procedure.

Note:
When the tightening dimension of the bolt B in point 3, is not
clear, or when bolt A is close to the end of the long hole in the
lever when bolt B is tightened, the disk may be worn. Adjust
the brake disk clearance. (Refer to page 8-50)
8-50

ADJUSTING THE BRAKE DISK CLEARANCE

Note:
Wear of the brake disk causes an increase in the brake piston stroke that affects the life of the brake.
Therefore, the brake disk clearance should be adjusted every year {once a year (once every 2000H)).

1. Remove the lower panel and toe board.

2. Remove the plug in the pressure testing opening of the brake
valve, attach the union there, then attach an oil pressure meter
via the SST.
Union 47711-21320-71

SST 09472-22000-71
3. With the engine stopped, depress the brake pedal and hold it
in the position at which the oil pressure reaches the value
below. Hold it in position either by having somebody step on it,
or by fixing it in place with rope etc.

Pedal holding standard pressure:

1.0 MPa (10 kgffcm 2 ) [140 psi]

4. Loosen the adjusting lever set bolt A, tighten the bolt B until
the adjusting lever comes into contact with the disk plate, then
tighten the bolt A temporarily.
5. In the status described in 3., adjust the bolt B until the
clearance X between the tip of bolt B and the adjusting lever
equals the value below, then fix bolt B with the lock nut.
Clearance
2 ton series: x =1.51 - 1.67 mm (O.0594 - 0.0657 in)
3·J3.5 ton series X = 1.34 - 1.48 mm (O.0528 - 0.0583 in)
6. Loosen the temporarily tightened bolt A, check that the
adjusting lever makes contact with the bolt B, then tighten the
bolt A to the correct torque.
Tightening torque for bolt A
T:: 13.7 - 22.6 N'm (139.7 - 230.5 kgf'cm) [10.1 -16.7 ft·!' .
 8-51

BRAKE VALVE
REMOVAL-INSTALLATION
Note:
Depressurize the accumulator before starting the operation (Refer to page 8-48)
T = N'm (kgf-cm) [ft·lbl]

Removal Procedure
1 Remove the lower panel.

2 Remove the toe board.

3 Remove the instrument panel.
4 Remove the column cover.

5 Disconnect the piping.

6 Remove the clevis pin of the push rod.

7 Remove the brake valve W/bracket
8 Remove the bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installing, adjust the brake pedal (Refer to page 8-66) and purge the air. (Refer to page 8-48)
• After installing check the operation of the accumulator. (Refer to page 8-57)
8-52

DISASSEM BLY ·INS PECTION· REASSEM BLY

Note:
o All components are machined to a high-precision finish. Be careful not to damage them while working.
o Conduct the work in a clean location.

T = N'm (kgfcm) [ftlbf]

'., ~-

4~ i
.- Q~cq J
~I!/
~.G)~J 10)! J~/
1

~
6 ~1918
~
I (\~ .1) l/
11 ../
:
T=67.7-107.9~~ . ~/
(690 -1100) ~ [/ 7
[499 -79.6]

Disassembly Procedure
1 Remove the push rod.
2 Remove the boots.

3 Remove the lock nut, snap ring, and plate washer. [Point 1]
4 Remove the input piston and compression spring. [Point 2]
5 Remove the cylinder cup from the input piston. [Point 3]
6 Remove the hole plug.
7 Remove the closed valve, valve return spring, and spring retainer. [Point 4]
8 Remove the reaction piston guide W/reaction piston and the brake valve spool.

9 Remove the reaction piston guide.

10 Remove the reaction piston.

Reasssembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
e Carefully clean all components, blow them off with compressed air to remove dirt, coat them with
hydraulic oil, and then reassembly them.
e Apply silicon grease to the cylinder cup and then reinstall the cup.
• Apply MP grease to the end of the push rod.
 8-53

Point Operations
[Point 1]
Reassembly:
Adjust the input piston stroke.
1. Install the plate washer.
2. Place the snap ring onto the input piston.
3. Screw on the lock nut and adjust the input piston stroke.
Standard
2 ton series:
=
A 12.9 ± 1.0 mm (0.51 ± 0.039 in)
3~J3.5 ton series:
=
A 12.7 ± 1.0 mm (0.5 ± 0.039 in)
4. Tighten the lock nuts.
5. Reinstall the snap ring.
Inspection:
After reassembly, check the brake hydraulic pressure.
(See page 8-54)
When lower than the standard value: Enlarge dimension A.
When higher than the standard value: Decrease dimension A.

[Point 2]
Inspection:
Measure the free length of the compression spring.
Standard: 21mm (0.83 in)

Limit: 18.9mm (0.744 in)

[point 3]
Reassembly:
Make sure the cylinder cup IS reinstalled in the correct
orientation.
SST 09471-22000-71

[Point 4]
Inspection:
Measure the free length of the valve return spring.
Standard: 21.9mm (0.862 in)
Limit: 19.7mm (0.776 in)
8-54

BRAKE VALVE OPERATION INSPECTION

1. Remove the lower panel and toe board.

2. Depressurize the accumulator.

(Refer to page 8-48)
3. Remove the plug in the pressure testing opening of the brake
valve, attach the union there, then attach an oil pressure meter
via the SST
Union 47711-21320-71
SST 09472-22000-71

4. With the engine idling, measure the oil pressure when the
brake pedal is fully depressed to the stroke end.

MPa (kgflcm 2 ) [psiJ

Vehicle model Standard
2 ton series 6.4 - 7.4 (65.3 - 75.5) [929 - 1074J. I
3·J35 ton series 6.9 -7.9 (70.4 - 80.6) [1001 - 1146]

5. Raise the engine idle speed to 1000 rpm, turn the steering left
and right until full lock 4 -5 times to build maximum pressure in
the accumulator, then cut the engine.
6. With the engine stopped, measure the oil pressure when the
brake pedal is fully depressed to the stroke end.

MPa (kgf/cm 2 ) [psiJ

Vehicle model Standard
2 ton series 5.0 (51.0) [725] or more
3·J3.5 ton series 5.5 (56.1) [798J or more
 8-55

ACCUMULATOR ASSY
REMOVAL·INSTALLATION
Note:
Depressurize the accumulator before starting the operation. (Refer to page 8-48)
T = N'm (kgf-cm) [ftlbf]

.. ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Removal Procedure
Remove the front under cover and rear under cover.
2 Remove the lower panel and toe board.

3 Disconnect the wiring.

4 Remove the propeller shaft cover set bolt.
S Disconnect the piping.
6 Remove the accumulator ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, bleed air from the brake. (Refer to page 8-48)
• After installing check the operation of the accumulator. (Refer to page 8-57)
DISASSEMBLY·INSPECTION·REASSEMBLY
T::: N'm (kgf-cm) [ft'lbf]

T::: 100 - 136

(1000 - 1400)
[73.8 - 100.3] T ::: 22.5 - 27.5
(229 - 280)
[16.6 - 20.3]

T::: 39 - 45
(400 - 460)
[28.8 - 32.2]

Disassembly Procedure
1 Remove the fitting, pressure switch, and check valve.

2 Remove the relief valve.

3 Remove the accumulator.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 8-57

ACCUMULATOR INSPECTION
Function inspection

1. Remove the lower panel and toe board.

2. Depressurize the accumulator.
(Refer to page 8-48)
3. Remove the plug in the pressure testing opening of the brake
valve, attach the union there, then attach an oil pressure meter
via the SST.
Union 47711-21320-71
SST 09472-22000-71
4. Raise the engine idle speed to 1000 rpm, turn the steering left
and right until full lock 4 -5 times to build maximum pressure in
the accumulator, then cut the engine.
5. With the engine stopped. Depress the brake pedal fully to its
stroke end, then release it. Wait 30 seconds, then depress and
release the pedal again.
6. After repeating item 5 ten times, inspect the oil pressure when
the pedal is depressed for the 11 th time.
Standard: 3.3 MPa (33.7 kgffcm 2 ) [479 psi] or more

Note:
If it is outside the standard, replace the accumulator.

7. With the engine stopped; depress the brake pedal fully to the
stroke end, and hold it like this for 5 minutes. Check that the
difference in the pressure values at the time when the pedal is
first depressed, and at 5 minutes afterwards is zero.
Note:
If there is a difference in the pressures, clean the check valve
and relief valve, check for damage to the seat part, and if there
are no abnormalities, replace the accumulator.

. ;umulator warning buzzer inspection

1. Raise the engine idle speed to 1000 rpm, turn the steering left and right until full lock 4 - 5 times to build
maximum pressure in the accumulator, then cut Ule engine.
2. With the engine stopped, turn the key to the ACC position, depress the brake pedal fully to its stroke end, then
release it.
3. Repeat 2., and inspect the pressure at which the buzzer sounds.
2
Buzzer sounds starts: 3.7 - 4.1 MPa (37.7 - 41.8 kgffcm ) [537 - 595 psi]

4. Once the buzzer has sounded, start the engine, and with the engine idling, depress the brake pedal and inspect
the pressure at which the buzzer stops.
Buzzer sounds stops: 4.7 - 5.5 MPa (47.9 - 56.1 kgffcm 2 ) [682 - 798 psi]
8-58

PARKING BRAKE ASSY

DISASSEM BLY·INSPECTION·REASSEMBLY
T = N·m (kgf-cm) [ft·lb~

T = 324 - 48.6
(330 - 500)

Disassembly Procedure
1 Remove the front axle & differential ASSY. (See page 4-12)
2 Remove the rear cover.
3 Remove the brake disc, plate No.2 and plate No.1. [Point 1]
4 Remove the retainer.
5 Remove the stopper bolt bracket, fork, and shaft. [Point 2]
6 Remove the oil seal. [Point 3]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
During reassembling, check that no foreign matter is attached to the parts.
 8-59

Point Operations
[Point 1]
Inspection:
Measure the thickness of plate NO.1.
2 ton series
Standard: 1.2 mm (0.047 in)
Limit: 1.0 mm (0.039 in)
3·J3.5 ton series
Standard: 1.5 mm (0.059 in)
Limit: 1.3 mm (0.051 in)

Inspection:
Measure the thickness of plate No2.
2 ton series
Standard: 9.0 mm (0.354 in)
Limit: 8.8 mm (0.35 in)
3·J3.5 ton series
Standard: 9.5 mm (0.374 in)
Limit: 9.3 mm (0.366 in)

I ,.

Inspection:
Measure the thickness of the brake disc.
Standard: 1.6 mm (0.063 in)
Limit: 1.2 mm (0.047 in)

Reassembly:
Align the notches in the brake disks and the reduction gear
and reassemble them. (2 ton series)

Reassembly:
Align the positions of the holes in the brake discs and
reassemble them. (3·J3.5 ton series)
8-60

[Point 2]
Reassembly:
Align the punch marks in the fork and shaft to reassemble
them.

[Point 3]
Reassembly:
Using a pin, tap the new oil seal in from the edge of the rear
cover to the position A.
Standard: A = 5.0 - 5.5 mm (0.20 - 0.22 in)
After reassembly, apply MP grease to the lip section of the u!1
seal.
 8-61

PARKING BRAKE FUNCTION INSPECTION

Checking the operation of the parking brake warning buzzer and warning lamp
If the parking brake warning buzzer and warning lamp do not operate as below, adjust the parking switch.
1. Check that the light turns on when the parking pedal is depressed.
2. Check that the light turns off when the parking pedal is released.

3. When travelling at 2 km/h (1.2 mph) without releasing the parking pedal, the buzzer sounds.
4. When leaving the dirving seat without locking the parking pedal, the buzzer sounds.

ADJUSTING THE PARKING

~
parking brake lever

. \ Stopper Bolt LEVER & SWITCH

~ ~ i
50 - 100 N . @ L. [i i 1. After reassembling the disk, pull the end of the parking brake
lever and adjust the clearance A between the tip of the stopper
[11 -22ft] @ pt 1::-' bolt and the parking brake lever. Lock the stopper bolt with the
o ',' nut.
A = 3.0 - 3.6 mm (0.12 - 0.14 in)
°O)C\ .
-~r;=J+-i--l+'-+'----'>.~~rtn
I

2. The parking brake limit switch can be adjusted by the following

Parking brake lever procedure.

\ Stopper Bolt
I
(1) Insert a 0.5 mm (0.02 in) thickness gauge between the
stopper bolt and parking brake lever.

ID

(2) Bring the bolt for the switch into contact with the switch
end, and lock the bolt for the switch with a lock nut, in the
position where the s'vvitch is ON.

(3) Insert a 1.5 mm (0.059 in) thickness gauge between the

stopper bolt and the lever, and check that the switch turns
OFF.
8-62

PARKING BRAKE INSPECTION AND

ADJUSTMENT
1. Check the set position of the parking brake cable.
Standard: A =0 - 2 mm (0 - 0.079 in)
2. Apply chassis grease to the points indicated by arrows in the
illustration.

ForLH
A
" For RH

.
When using SST 3. Inspect and adjust the operating force of the parking brake
pedal.
(1) Attach the SST to the pedal.

(A) SST 09460-26600-71

(2) Attach a spring balance to the SST, and pull the reve...
end to measure the operation force. '
SST

When not using SST Standard:

(A) When using the SST (8) When not using the SST
138 - 162 N 230 - 270 N
(14.1 - 16.5 kgf) (23.5 - 27.5 kgf)
[31,1 - 364 Ibf] [51.8 - 60.6 Ibf]

(3) If the operating force is outside of the standard, re!ea~

the parking brake and adjust with the adjusting part. '
Clockwise: Strong operation force
Counter clockwise: Weak operation force
Note:
If the warning lamp does not operate correctly after the
operating force has been properly adjusted, the parking
switch may be improperly adjusted. (See page 8-61)

ADJUSTING THE RELEASE LEVER CABLE

1. Use the release cable adjust nut to adjust so that the play at
the tip of the release lever is about 0 - 5 mm (0 - 0.197 in).
 8-63

BRAKE COOLING OIL TANK

REMOVAL·INSTALLATION
T = N·m (kgf-cm) [fHbD

.~
I:~
I

5-- :
I
I
I
I

T=17A-40.6 ~--
(177-414) ~
[12.8 - 30.0)

Removal Procedure
1 Remove the lower panel and toe board.

Remove the under cover.

3 Drain the brake cooling oil. (Refer to page 8-64)
4 Disconnect the piping.
5 Remove the brake cooling oil tank.

6 Remove the oil filter and fitting. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operations
[Point 1]
Inspection:
Inspect and clean the oil filter.
8-64

PROCEDURE FOR POURING IN BRAKE COOLING OIL

1. Pour 4.8 .e (1.27 US gal) into the tank.
2. Start the engine and allow the brake cooling oil to fill inside the
brakes.
3. Pour brake cooling oil into the tank again, checking the amount
on the level gauge.
Inspect the oil amount by putting the level gauge cap part on
the top end of the lubrication hole. (Do not push the cap part
into the lubrication hole).

Brake cooling oil amount for each part (guide)

Oil amount e(US gal)

Inside tank 3.9 (1.03)
Piping 1.0 (0.26)
Inside the brake 2.3 (0.61)
Inside the cool er 0.8 (0211)
Total 8.0(2112)

Oil to be used: Shell Donax TD

 8-65

BRAKE COOLING OIL COOLER

REMOVAL·INSTALLATION
T = N'm (kgf-cm) [ftlbf]

,m oval Procedure
l' Remove the radiator cover.
2 Remove the counter weight.
3 Drain the oil inside the brake cooling oil cooler. (Refer to page 8-64)

4 Disconnect the piping.

5 Remove the brake cooling oil cooler.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
8-66.

BRAKE PEDAL INSPECTION AND ADJUSTMENT

Stop lamp switch

'\

~~

c
~

lD
lD
I

«
o
r ,
i'"

,
, '
, '
I
I

I
I
I"
(,1'
I ' ....

"
) /
.-
/---

Toe board Floor· mat

1. Inspect the brake pedal height A. (From the toeboard to the upper surface of the pedal)

Standard: A =145 - 150 mm (5.71 - 5.91 in) (with pedal pad)

If outside of the standard, adjust with the projection amount of the stopper lamp switch.

2. Inspect the brake pedal play B.

Standard: B =14 -19 mm (0.55 - 0.75 in) (Push rod play: 3 - 4 mm (0.12 - 0.16 in))

If outside of the standard, adjust with the brake valve push rod length.
3. After adjusting, depress the brake pedal fully, and check the remaining depression margin O.

Standard: D =30 mm (1.18 in) or more

 8-67

INCHING PEDAL INSPECTION AND ADJUSTMENT

Stopper
bolt
Inching pedal
plate

E c E c
E ~ E ~
OlD 0 m
~t.D ~LD
I I I I

~~"
lI)~ lI)~

Floor mat ~
r0 r')
lI) =- ~
"'T t--:
Toe board

~ ="~",:~,j=",,~L~,, ~t/
="'="
Adjusting nut
~
~

1. Inspect and adjust the height and play of the brake pedal. (Refer to page 8-66)
2. Inspect the stroke A until the inching pedal links with the brake (the pedal stroke amount until the inching pedal
plate contacts with the brake link).

Standard: A = 35 - 41 mm (1.38 - 1.61 in)

If outside of the standard, adjust with the projection amount of the stopper bolt.
Here, adjust so that the shift in the height of the brake pedal is within 15 mm (O.59in).

3. Inspect and adjust the inching cable.

(1) Inspect the set dimension B of the inching cable on the pedal side.

Standard: 17.5 mm (0.689 in)

If outside of the standard, adjust with adjusting nut on the pedal side.
(2) Inspect the play C of the inching pedal until the inching lever starts to move.

Standard: C = 1 - 3 mm (0.04 - 0.12 in)

If outside of the standard, adjust with adjusting nut on the inching lever side.
8-68

INSPECTION AND ADJUSTMENT OF THE SINGLE BRAKE

(INCHING) PEDAL

Adjusting bolt I h'

y) d I
nc Ing pe a No clearance

Adjusting nut ~

E .-
C C
E .-
E ~
E 0
lD t'- lD

l.
LD
;! LD ~
co
I I I I

Adjusting nul

1. Tighten the adjusting bolt until the clearance between the side (a) of the inching pedal and the tip of the
adjustment bolt is gone, then lock it with the lock nut.
2. Adjust the pedal height and play. Use the standard value on this page for the pedal height, and refer to page 8-
67 for the adjustment method.
3. Inspect the stroke A until the inching pedal links with the brake (the pedal stroke amount until the inching pedal
plate contacts with the brake link).
Standard: A =61.7 - 68.6 mm (2.43 - 2.70 in)
If outside of the standard, adjust with the push rod length.
4. Inspect and adjust the inching cable.
(1) Inspect the set dimension B of the inching cable on the pedal side.
Standard: B = 17.5 mm (0.69 in)
If outside of the standard, adjust with adjusting nut on the pedal side.
(2) Inspect the play C of the inching pedal until the inching lever starts to move.
Standard: C = 1 - 3 mm (0.039 - 0.118 in)
If outside of the standard, adjust with adjusting nut on the inching lever side.
 8-69

GREASING TO PARKING BRAKE

PEDAL RELEASE PIN (COMMON TO
DRY BRAKE AND WET BRAKE)
After servicing the parking brake pedal, and every year or every
2000 hours, apply grease (molybdenum disulfide grease) to
parking brake pedal release pin.
 9-1

BODY
Page

COMPONENTS 9-2
ENGINE HOOD ASSY 9-10
REMOVAL·INSTALLATION 9-10
COUNTERWEIGHT 9-11
REMOVAL·INSTALLATION 9-11
DRIVER'S SEAT 9..12
REMOVAL·INSTALLATION 9..12
SEATBELT 9..13
SEATBELT RETRACTOR INSPECTION 9..13
HEADLAMPS 9-14
REMOVAL·INSTALLATION 9..14
B ULB REP LACEMENT 9 ..15
COMBINATION METER 9..16
REMOVAL·INSTALLATION 9-16
COMBINATION SWITCH 9..17
INSPECTION 9..17
FUEL SENDER GAUGE 9..18
INSPECTION 9..18
9-2

COMPONENTS
Radiator Cover (IDZ-III·3Z Engine Vehicle)

5101

K20
-----,--~.". __._-

5101-534

Radiator Cover (4Y Engine Vehicle)

5101

15.18 K20
(EXCLUSrVE[Z4J) (EXClUSIVE[Z4Jl
(CONVERTlBlEIZ3H (CONVERTl8lEID]l

~ ~~lNCE)
, FD- l' ~BR
R:g ~~NCE'
l 'IF-===----
! "'"~~ ,

," ~
~. \
~~~i:~I;"""
J1A[LH] - \
11
. )
, /y~ )~~ '15,18.20,15.30,J3S--------- J!
.V/-_:, ~~~>. ~ ~
-
6 _
f~-
/_,;i/>~
/.// ~~g~~~~~~:~t~igi'~~l"rB~t~~~?OR)
{CONVERTIBLE[ZJJ.. S.CABIN UHEATl
i~~g~~~~I_~~Ffl~~L~~Eci'~lCABJN)
L__.
15,18
(UPSWEPT..EXClUSrVE[Z4j. CONVERTrBlE[Z3])
J

%. ' , ,-1 (lPG UK.. HALF CABIN) :'UPSWEPFrD"~UK, LPG FRAN~_~

"~ ft~g ~~::~T'i~~I~~~~tT)
-FiJ;:.:,t '~-B~-----I
I r
f"';0~BR
I
!
'~
'="'~,,;::J
I r,1~"" :I
BI-
AW-_
, , ' . ' "-,,__ 3,1A lRH}
..........,;;;
t
I II ':,,;,~JI '~;:-"~l\
31A[LH]:
3~AIRH]
I '",--"~' I I

31AILH] ~I" i \
~ -- -~-~-- -~~--~-~- .:=:\~- ------! ~ 31AlCENTERJ '
199~~~~~:~t~~gl.:~~l~Bt1~:~~ORI 20,25,30,J35
(CONVERTIBlE[ZJ).. S-eABtN UHEAT) (UPSWEPLEXCLUSrvEjZ4j, CONVERTIBLE[Z3J)
lCONVERTIBLE[Z3J ,STEEL CABIN)
(lPG UK.H-CABIN UDDOR)
{lPG UK ..HALF CABIN;
(UPSWEPT.. LPG UK, LPG FRANCE)
I
I' FD..--.---y
I
(lPG UK. S-CABIN LlHEAT) , ~BR

!LPG ~~ST:EL~A:'~I _ I' ~~ 3,' I

I
!
~ 3
B~"'-=:~""~. 31 ; I 8f~I~~~.~-:~~~1A[RH~.J
~~~I\
I
,~1AIRH] '-- 31A[lH] \

'--- -'
''',!CH] ~ ~ 31A[CENTER]
- A
 9-3

5101

15,18
I--
I

VA

Step (RH) (1 ton series)

5101

EK~ ~

[STD!

I
9-4

Step (LH) (1 ton series)

5101

5101-544

Step (RH) (2·K2-3·J3.5 ton series)

5101
 9-5

Step (LH) (2·K2·3·J3.5 ton series)

5101

--------------
(STEEL CABIN, S-CAB 20QW HEAT)
I------~-----

Under Cover (1 ton series)

5101

iREAR MUDGUARD) _

i
I f.":';' ~\\
! iJ?"\\I- DK
\(~L BC AA(RHJ I
~[LHJ ~
'n
OK BC
5101-477A
9-6

Under Cover (2·K2·3·J3.5 ton series)

5101

(REAR MUOGUARot

I/1J,q) 0'
IIJt BC AA[RH]

I ~(LHJ
I

Hood & Hinge

5201
(MINI LEVER, JOY STICK, DOCUMENT BOX)

i~ ~A I
i ~~I ~ 65
I

FT

k
I

5201-310
 9-7

Instrument Panel

5301

5301-416

Toe-Board

5301
77

5301-419
9-8

Driver Seat

5308

EA-J;

5308-351

Lamp

5611

01

r o
,. -------'--01~B--
I Q··1
: 01ID~01,:, c1 ~01H :

~\ 'I
M;';r
~01C
1
01M -
CSYf,
'2,

:
01E 01J ~-'tr ~01G
01~----4 ~
I
..
•Loo. 01L••• .1•
17J[LWR]

I b. Qo - - _ ~
··
••• .1
04[RH] 04[LHJ
I I
··
..... '.'"'1 ..... ~~ - - - - ' - - - - '.'"'1

i ~~::jQ<)A("," i I
II~~A
I
V1 U
'rvl
AL I
I
'j

(-
e.
04A
04A [2115W] ,
[12WJ

··
04A 04E
: (21W) 04G : :
I.... • •• .1 I. ••• - - - - - ••• .1

5611-413
 9-9

Meter & Switch

5701

XA

:.. ...... -
9-10

ENGINE HOOD ASSY

REMOVAL·INSTALLATION

Removal Procedure
1 Remove the radiator cover.
2 Open the engine hood.
3 Disconnect the seat switch connector. Disconnect the seat switch sub harness from the harness clamp in the
engine hood.

4 Disconnecting the engine hood damper (on the engine hood side).
5 Close the engine hood.
6 Remove the engine hood bracket set bolts.
7 Remove the engine hood.

Installation procedure
The installation procedure is the reverse of the removal procedure.
 9-11

COUNTERWEIGHT

REMOVAL'INSTALLATION
T = N·m (kgf·cm) [ft-lbfj

Removal Procedure
1 Remove the radiator cover.
2 Remove the weight cap and temporarily hoist the counterweight using a wire rope.
3 Remove the drawbar and the counterweight set bolt.
4 Remove the counterweight.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
See page 0-16 for the weight of the counterweight.
9-12

DRIVER'S SEAT

REMOVAL·INSTALLATION

Removal Procedure
Disconnect the seat switch connector.
2 Open the engine hood.

3 Remove the driver's seat set nuts.

4 Remove the driver's seaL [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operations
[Point 1]
Inspection:
Push down on the seat cushion and inspect the seat switch for
continuity.
Measurement location: Between terminals 1 and 2
Standard
When not pressed: D
CIJ

When pressed: 0D
 9-13·

SEATBELT
SEATBELT RETRACTOR INSPECTION
1. The installed seatbelt should be pulled out and retracted
smoothly. Also check that it is locked when pulled out
suddenly.
2. Fasten the seatbelt. Travel straight at a high speed, and apply
the brake suddenly. Check that the belt is locked to hold your
body.
Caution:
Test this function in a place where safety can be ensured.
9-14

HEADLAMPS
REMOVAL-INSTALLATION

Removal Procedure
1 Pull the connector out from the piilar hole and disconnect it.
2 Remove each headlamp.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 9-15

BULB REPLACEMENT
Note:
• Since the halogen bulb (of the headlamp) becomes hot
when it is on, its life will be shortened if oil or grease
adheres to the glass surface. When handling the bulb,
therefore, hold the flange portion to avoid direct contact
between the glass surface and a hand or finger.
• Since the internal pressure of the halogen bulb (of the
headlamp) is high, it may be broken, causing scattering of
glass fragments when it is dropped, struck or when the
glass surface is scratched.
• Always use a bulb showing the same (specified) wattage
for replacement.
Headlamp: 12 V, 55 W, H3

Headlamp:
1. Remove the headlamp lens.

2. Remove the bulb Wf reflector.

3. Remove the connector.
4. Release the lock of the set spring and remove the bulb.
5. The installation procedure is the reverse of the removal
procedure.
9-16

COMBINATION METER

REMOVAL·INSTALLATION

Removal Procedure
1 Remove the lower panel.
2 Disconnect the combination meter wire harness.
3 Remove the instrument panel RH.
4 Remove the combination meter set screws.
5 Remove the combination meter ASSy'

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 9-17

COMBINATION SWITCH
Note:
See page 2-76 for the direction switch inspection.

INSPECTION

Turn signal switch Light switch

OFF T

\ I / H

1. Individual switch continuity inspection

Switch position Measurement terminals Standard
Light switch
--
OFF BT-T No continuity
T BT-T Continuity
,H. BT-T, BH-HL Continuity
---
Turn signal switch

Light & turn signal switch R TB-TR Continuity

OFF TB-TR-TL No continuity
I
L TB-TL Continuity
9-18

FUEL SENDER GAUGE

INSPECTION
T = N·m (kgfcm) [ftlbf]

w
o T=9.6-14.4

_ T--jLJ;=~~-i~I~~;II~~~~/ [7.1
( 98 -- 147)
10.6]

~;f{
--'--------E-~/ I
I
1. Remove the fuel tank cover ASSY.
2. Measure the resistance.

(1) Check if the float moves smoothly.

(2) Measure the resistance between the positive and negative (body ground) terminals of the sender gauge
while the float position is varied between F and E.
Also check if the resistance varies continuously.

Standard

Float position mm (in) Resistance n

F 125.2 (4.929) 15 ± 1.5
E 389.6 (15.339) 410±4.5
 9-19

Note:
Measure in the direction of float movement from F to E.
The resistance at each of F and E points shall be measured when the arm is in contact with the
respective stopper.

• When installing the fuel tank cover ASSY, tighten the bolts
in the order shown in the illustration.
 10-1

MATERIAL HANDLING SYSTEM

Page

HYDRAULIC CIRCUIT DIAGRAM 10-2

COMPO NENTS 10-4
RETURN FILTER 10-9
REMOVAL·INSTALLATION 10-9
SUCTION FILTER 10=1 0
REMOVAL·INSTALLATION 10-10
NATURAL DROP TEST 10..11
NATURAL FORWARD TILT TEST 10..11
OIL LEAK TEST 10-12
LIFT CyLINDER 1 0.. 12
TILT CYLINDER 1 0-12
10-2

HYDRAULIC CIRCUIT DIAGRAM

1-Z (1 DZ-lIl)-KZ (IDZ-lIl)-Z (3Z) Ton Series

(6) =:P (8)

(1) Oil pump (5) Solenoid valve

(2) Flow divider (6) Power steering cylinder
(3) Oil control valve (7) Lift, tilt and ATT cylinder
(4) Steering valve (8) Oil tank
 10-3

2 (4Y)·K2{4Y)·3·J3.5 Ton Series

-~
C··L

(1) Oil pump (6) Power steering cylinder

(2) Flow divider (7) Lift, tilt and ATT cylinder
(3) Oil control valve (8) Oil tank
(4) Steering valve (9) Oil cooler
(5) Solenoid valve (10) Relief valve
10-4

COMPONENTS
STD
6801

Xl

01

1H
FA
~--' l'
XJ

Uf

I
V,FSV,FS~~?~l ~~~l)i

AM
I I

10
o
\ - I
fO

I :
'---'

6801...{}71

Wet Brake

6801

/ ~/ ''!V'' /

_ r
'T~/
0"'-'

~'
~~J{I ...
.
_}
,-?';i~' (

..•
O· -:: I \ i

'. : f { ! J _. . XL
• . <;!j OF

@-1H--:28

52 f.r-T--FA~~

52A '-'TI--~'----
;: t,. --~::"

6801-672
 _ _~ 1110-5

STD

"W~: ,,~

32
f~'
/ !.J9A

\J: /;._ 51A

AD, -,
'i
. ".-....,
.I
/
ME ,,:\'..."
AG

30
,
59
51

AK

AX---- (J.
59A--'~

.:..'
! -<",:,;"..'~

,C'P'~'
" I
55A
1-
AR
R8fer 10
6701-{11

6801-669
---

Wet Brake

6801

30
30 ,'I
) AD--
ME ~,+"t
32
/AG--'tV
'AK ;/
/'

AT-b:!
__' 'j)~~~)/-• /' _ '-<,'
_",If;"
_?
~ ~
Id ,,'---I,
'-AC ';.', t:,i l /~ ···AB

_ " __ 59A-~". 'II"·u1r~VI JM"

;}~ C"--::t':
. 'V, !".~··Cr
i' " ....

55 \.{ U·
55A I I j ,,»'.'1\,""

55A~"
,:;:t:'
r-"_-'.~: ' ~i~ .- ,-i / l\~~""
,,""'.'f..
52A
52

"r
.~y4
U-..-J
_____________-====;,68~01-<;70
10-6

2 (1 DZ-III·3Z)·3·J3.5 ton series Wet Brake

6801

EK

KS

IT

6801-659

2 (4Y) ton series Wet Brake

6801

6801-660
 10-7

I 6801

i AU
IJ;:',
o

6801-665C

V·FV

6802
v .
~-----------------~ .- ----I
10-8

FSV

6802
-------~ --,
~"{/ ~~ EP i
DF I
GS
I~
i

CR '"

BX ~ \i

41 - 40

AN
CO,

x::-) , \,;
-- GS
5[}- -"I

I1
GT

50
GT ET 8E
co ."Yr - Cl

GS

76
7Qi./ 'l;fJ f~~>::~ GS 20 28 4B
CK l EY~ ,~-, ''', f,
Refer to ~:~BB-- ~;: tJ
6801 ~Z ~ ~ . ,_;....;~

ReleT to
6801-32
"t~ 0
AC "-'
_OL_ __ ~ _~_~_~ ~ ~ 6802-639A

FSW (2-3 ton series)

6802

""
t~ 73
$
1"',
R
I
I
jc -r,~ GB
i
8 40
CO
\' t11
~

~
I
8
41
co- e
" I,

~~ SO

\i
\\:i
'I

,!!~
CO
/1
if

6802-663
 10-9

RETURN FILTER

REMOVAL-INSTALLATION
T = Nm (kgfcm) [ftlb8
4

T=69-161
(70 - 164)
[51 - 119]

k __ m oval Procedure
Open the engine hood.

2 Remove the toe board.

3 Disconnect the hose from the return filter. [Point 1]

4 Remove the return filter.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operations
[Point 1]

Removal:
Cover the area around the filter to prevent oil from splashing
onto the wire harness or connectors because oil may spill out
from the hose when disconnecting it
10-10

SUCTION FILTER

REMOVAL-INSTALLATION
T = N·m (kgfcm) [ft·lb8

Removal Procedure
1 Open the engine hood.
2 Remove the toe board.
3 Remove the side cover W/ step.
4 Remove the side cover bracket-
5 Disconnect the hose from the return filter. [Point 1J
6 Remove the return filter.
7 Remove all hoses from the tank cover.
8 Remove the tank cover WI suction filter.
9 Remove the suction filler.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operations
[Point 1J
Removal:
Cover the area around the filter to prevent oil from splashing
onto the wire harness or connectors because oil may spill out
from the hose when disconnecting it.
 10-11

NATURAL DROP TEST

1. Set the mast vertical with the standard load on the fork. Lift the
fork by 1 to 1.5 m (40 to 59 in), and stop the engine.

2 Draw datum lines on the inner and outer masts, and measure
the drop in 15 minutes

Limit: 45 mm (1.77 in)

NATURAL FORWARD TILT TEST

Set the mast vertical with standard load on the fork Lift the
fork by about 50 cm (19.7 in) and stop the engine.

2 Measure the tilt cylinder rod extension in 15 minutes.

Vehicle model Natural forward tilt amount mm (in) I

1 ton series 15 (0.59) or less
I
2·K2 ton senes 20 (0.79) or less
3·J35 ton series 25 (098) or less
10-12

OIL LEAK TEST

LIFT CYLINDER
1. Set the mast vertical with the standard load on the fork. Lift the
fork by 1 to 15 m (40 to 59 in).

2 Slowly till the mast fully forward, and stop the engine

3 After 5 minutes. disconnect the oil control valve to oil tank

hose. Place a measuring cylinder under the elbow and
measure the amount of oil leaking in one minute.

Standard (at lift port): 8 cm 3 (0.49 in 3 ) or less

Note:
If the natural drop is big 'even though the oil leak amount is
within the standard, the lift cylinder packing is defective.

TILT CYLINDER
1. Set the mast vertical with standard load on the fork. Lift the
fork by about 50 cm (19.7 in) and stop the engine.

2. After 5 minutes, disconnect the oil control valve to oil te.

hose. Place a measuring cylinder under the elbow and
measure the amount of oil leaking in one minute.

Standard (total for lift and tilt): 16 cm 3 (0.98 in 3 ) or less

3. The leak amount at the tilt port is equal to the remainder when
you subtract the leak amount at the lift port from the total leak
amount of the lift and tilt cylinder.

Note:
If the natural forward tilt is great even though the oil leak
amount is within the standard, either the tilt lock valve or the
tilt cylinder packing is defective.
 11-1

MAST
Page

V MAST ASSY 11-2

COMPONENTS 11-2
REMOVAL·INSTALLATION 11-5
REMOVAL·INSTALLATION (W/LlFT BRACKET) 11-8
MAST DISASSEMBLY-INSPECTION·
REASSEMBLY 11 ..11
LIFT BRACKET DISASSEMBLY-REASSEMBLY 11-13
MAST ADJUSTMENT (V MAST) 11 ..15
MAST ROLLER REMOVAL·INSTALLATION 11-21
CHAIN 11 ..22
INSPECTION 11-22
REASSEMBLY 11-22
ADJUSTMENT 11-23
FORK 11 ..24
REMOVAL '.' 11-24
INSTALLATION 11-24
INSPECTION 11 ..24
FV· FSV· FSW MAST ASSY 11-25
COMPONENTS 11 ..25
MAST DISASSEMBLY·INSPECTION-
REASSEMBLY (FSW) 11-33
MAST ADJUSTMENT (FV·FSV·FSW) 11-35
STANDARD FOR SELECTING
AN OVERSIZE ROLLER 11-39
LIFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) 11-40
V·FSV·FSW MAST 11-40
FV MAST ~ 11-41
11-2

V MAST ASSY

COMPONENTS
6101

"

6 10 '~~93

1·2·3 ton series

I 6301

5301-704
K2 ton series

6301

Br 02

/:fjjL 58
'li~1 0 588
I>-¥ ~,
:> 42
i) ~"-
/) ~

43A DE i
Q
: ;:. , -',(\)'
59A ,"y,t Bf
4;8 i(ifj)
.J1,G '~i
41
59

J3.5 ton series

6301

02

'yjjl - 58
1(5#1 0-- 5BS

:i~ 0
! I
41 41A

59

6301-706
11-4

20K

• . ~.
:"', ,-;,....
~II •

I .;-

·· .
L .. __ ._ ~ .. ~,j

20M

6J02--440A
 11-5

REMOVAL-INSTALLATION
T = N·m (kgf·cm) [ft·lb~

~~-)

- lloval Procedure
Set the mast vertical and fully lower the fork.

2 Disconnect the chain. [Point 1]

3 Remove the chain wheeL [Point 2]

4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until the lift bracket comes off from the
inner mast, and slowly run the vehicle backward to move away from the lift bracket.)

5 Disconnect the fork height switch connector.

6 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast
and operate the lift lever several times to release the residuat pressure in the lift cylinder.)

7 Incline the mast forwards and suspend it temporarily. (Be careful never to operate the lift lever at this time.)

8 Remove the mast support set bolts.

9 Remove the tilt cylinder front pin. [Point 3]

10 Remove the mast ASSY.

11 Remove the tilt bracket bushing from the mast. [Point 4]

12 Remove the mast support pin and mast support bushing from the front axle bracket. [Point 5]
11-6

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
- After installation, add molybdenum disulfide grease through the grease nipple of the tilt cylinder front
pin.
- Adjust lift cylinder uneven movement using shims when any of the mast ASSY, outer mast, inner mast or
lift cylinder is replaced. (See page 11-40.)
- Adjust the chain tension after installation. (See page 11-22.)
- When the mast is replaced, perform SAS matching after installation. (See section 16.)

Point Operations
55T ..
,':\;, : [Point 1]
I I
, L' i Removal-Installation
SST 09630-23600-71

[Point 2]

Removal:
If the fitting is hard, use the SST for removaL

SST 09950-76014-71
(09950-40011 )

[Point 3]

Removal:
SST 09810-20172-71
 11-7

[Point 4]
Installation:
Use the SST to drive In the tilt bracket bushing from the mast
outer side_

SST 09950-76018-71___ _ _ (1)

(09950-60010)
09950-76020-71 _ __ (2)
(09950-70010)

Vehicle outer side V"hicle outer side

surface suriace
'.

Bushing

Flush
Bushing surfaces'~
I
1 ton series Other than 1 ton series

[Point 5]
Installation:
Use the SST to drive In the mast support bushing_

SST 09950-76018-71
(09950-60010)
09950-76020-71________________ ____ __ (2)
(09950-70010)

Installation:
While marking Position the joint of the mast support bushing (positon of the

\~
0
white marking) within the 180 range shown in the illustration_

'X(V
Mast support
bushing

' ~~, 85-95°

Installation:
Attach the grease nipple so that it faces towards the top of the

S
l'
-i--I-
II ,

'-;-/
"\
J_
vehicle_
After attaching the mast, add molybdenum disulfide grease
through the nipple until it comes out from both sides of the
front axle bracket.

Installation:
Before installing the mast, face the flat surface of the mast
support pin upward.
11-8

REMOVAL-INSTALLATION (W/LIFT BRACKET)

T:::: N·m (kgf-cm) [ft·lbf]

,
I
I

I ".

~~~~~~~~/
I I

1
2-

Removal Procedure
Set the mast vertical.

2 Remove the fork. (See page 11-24.)

3 Disconnect the wiring of the fork height switch.

4 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast
and operate the lift lever several times to release the residual pressure from the lift cylinder.)

5 Incline the mast forwards and suspend it temporarily. (Be careful never to operate the lift lever at this time).

6 Remove the mast support set bolts.

7 Remove the tilt cylinder front pin. [Point 1]

8 Remove the mast ASSY W/lift bracket.

9 Remove the tilt bracket bushing from the mast. [Point 2]

10 Remove the mast support pin and mast support bushing from the front axle bracket. [Point 3]
 11-9

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• After installation, add molybdenum disulfide grease through the grease nipple of the tilt cylinder front
pin.
• Adjust lift cylinder uneven movement using shims when any of the mast ASSY, outer mast, inner mast or
lift cylinder is replaced. (See page 11-40.)
• Adjust the chain tension after installation. (See page 11-22.)
• When the mast is replaced, perform SAS matching after installation. (See section 16.)

Point Operations
[Point 1]

Removal

SST 09810·20172·71

[Point 2]
SST(1) Installation:
Use the SST to drive in the tilt bracket bushing from the mast
outer side.

SST 09950-76018-71 .... (1 )

(09950-60010)
09950·76020-71 ............ (2)
(09950-70010)

Vehicle outer side Vehicle outer side

rface. surface

/'

Bushing

Flush
Bushing surfaces·'
I
1ton class Other than 1 ton class
11-10

Front axle bracket [Point 3]

Installation:
Use the SST to drive in the mast support bushing.

SST 09950-76018-71 (1)

(09950-60010)
09950-76020-71 (2)
(09950-70010)

Installation:
Position the joint of the mast support bushing (positon of the
0
white marking) within the 180 range shown in the illustration.
0
180

Installation:
Attach the grease nipple so that it faces towards the top of the
vehicle.
After attaching the mast, add molybdenum disulfide grease
through the nipple until it comes out from both sides of the
front axle bracket.

Installation:
Before installing the mast, face the flat surface of the mast
support pin upward.
 11-11

MAST DISASSEMBLY·INSPECTION·REASSEMBLY

Di..::>assembly Procedure
1 Remove the fork height switch.

2 Remove the hose cover.

3 Disconnect the high pressure hose.

4 Remove each cylinder rod end set bolt.

5 Remove each cylinder support.

6 Slide the inner mast upward and remove the lift cylinders. [Point 1]

7 Slide the inner mast downward and remove the lift rollers.

8 Remove the mast strip. [Point 2]

9 Remove the outer mast.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
11-12

Shim Point Operations

[Point 1]

Disassembly:

/ Shim adjustment is made at the lift cylinder rod end to prevent

uneven lifting by lift cylinders LH and RH.
Note the cylinder that was adjusted and the number of shims
used.

[Point 2]
Inspection:
Except J35 ton series
Measure the mast strip thickness
Limit: 1.5 mm (0.059 in)

Inspection:
Oil dimples
J3.5 ton series
Inspect the mast strip wear.

Wear limit: Until the oil dimples worn away

 11-13

LIFT BRACKET DISASSEMBLY·REASSEMBLY

T = N-m (kgf-cm) [ft-Ibf]

.. assembly Procedure
Remove lift rollers_ [Point 1]

2 Remove side rollers_ [Point 2)

3 Remove the backrest.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure_
11-14

Point Operations
[Point 1]
Disassembly:

SST 09950-76014-71
(09950-40011 )

[Point 2]

Reassembly:
The side chamfered with larger radius of the roller shall face
the front of the vehicle.
 11-15

MAST ADJUSTMENT (V MAST)

Lift Roller Adjustment at Mast

1. Inner mast roller clearance adjustment

Outer mast Inner mast

Brlllg into contact

Bring into contact

Inner mast roller

A

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Inspect and adjust the inner mast rollers.

Shift the inner mast to one side to bring the roller into
contact with the outer mast. Measure the clearance
between the roller side face on the opposite side and
outer mast at the point where they are the closest.

Standard: A =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by

changing the shim thickness. Distribute shims equally to
the rollers on the left and right side. (See page 11-21 for
the mast roller removal and installation.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check that the inner mast moves
smoothly in the outer mast.
11-16

2. Outer mast roller clearance adjustment

Outer mast roller

Bring Into contact

Bring into
contact
Outer mast Inner mast

(1) Adjust the mast overlap to approx. 450 mm (1772 in)

(2) Inspect and adjust the outer mast rollers.

Shift the outer mast to one side to bring the roller into
contact with the inner mast. Measure the clearance
between the roller side face on the opposite side and
inner mast at the point where they are the closest.

Standard: B =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment . ..

changing the shim thickness. Distribute shims equally:;!
the rollers on the left and right side. (See page 11-21 for
the mast roller removal and installation.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check that the inner mast moves
\ smoothly in the outer mast.
 11-17

Roller Adjustment at Lift Bracket

1. 1·2·3·J3.5 ton series

Bring into contact Upper side roller

----,ec:-----l.,1 _L-- Lower 11ft roller

100 mm (394 in)

Bring into I
1Ir
contact

Outer mast

~
Inner mast ~

Lift bracket

(1) Hoist the lift bracket to the specified position

Bring the center of the side roller in the lift bracket to 100
mm (394 in) below the top of the inner mast.

(2) Inspect and adjust the lower lift rollers.

Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.

Standard: C = 0 - 0.6 mm (0 - 0.024 in)

 If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
equally to the rollers on the right and left side.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

Shim(s)
(3) Inspect and adjust the middle lift rollers.
Hoist the 11ft bracket to the specified position.
Bring the center of the middle lift roller in the lift bracket to
100 mm (394 in) below the top of the inner mast.

Shift the 11ft bracket to one side to bring the roller intr
contact with the inner mast. Measure the lift roll~
clearance at the position on the opposite side where L
roller side IS closest to the mast.

Standard: C =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by

changing the lift roller shim thickness. Distribu te shims
equally to the rollers on the right and left side.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(4) Inspect and adjust the side rollers.

Hoist the lift bracket to the specified position.
Bring the center of the side roller in the lift bracket to 100
mm (394 in) below the top of the inner mast.

Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where tt">"
roller side is closest to the mast.

Standard: D = 0 - 0.6 mm (0- 0.024 in)

If the standard is not satisfied, make adjustment by

changing the lift roller shim thickness. Distribute shims
\ equally to the rollers on the right and left side.

! Refer to ("Lift bracket dissassembly and reassembly",

page 11-13. Also, shim replacement is possible on the
vehicle)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(5) Align the outer width of the lower side roller with that of
Shims
the upper side roller.

(6) After the adjustment, check that the lift bracket moves
smoothy along the overall length of the mast.
 11-19

2. K2 ton series

Bring into
contact Lower lift roiler 100 mm (394 in)
Lift bracket
-----rc:':=--4-J-- S id e rolie r

Bring 11110
contact

... ·.1) Hoist the lift bracket to the specified position.

Bring the center of the upper lift roller to approx.100 mm (394 in) below ihe top of the inner mast

(2) Inspect and adjust the lower lift rollers

Shift the lift bracket 10 one side to bring the roller into contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.

Standard: C =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Inspect and adjust the middle lift rollers.

Hoist the lift bracket to the specified position.
Bring the center of the middle 11ft roller in the lift bracket to 100 mm (3.94 In) below the top of the inner mast.

Shift the lift bracket to one side to bring the roller into contact with the inner mast Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.

Standard: C =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by changing the lift roller shim thickness Distribute shims
equally to the rollers on the right and left side.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(4) Inspect and adjust the side rollers.

Hoist the lift bracket to the specified position.
Bring the center of the side roller in the lift bracket to 100 mm (3.94 in) below the top of the inner mast.

Shift the lift bracket to one side to bring the roller into contact with tile inner mast. Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.

Standard: 0 =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(5) After the adjustment, check that the lift bracket moves smoothly over the entire length of the mast.
11-20

Mast Strip Adjustment

1. Mast strip clearance adjustment

Outer mast roller

Inner mast

Bring into contact

Outer mast

(1) Lower the inner mast fully

(2) Inspect and adjust the clearance between the mast strip
and the inner mast.
With the inner mast in contact with the outer mast roller,
measure the clearance between the mast strip and inner
mast.

Standard: E = 0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment

changing the shim thickness

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check the mast for smooth
movement.
 11-21

MAST ROLLER REMOVAL·INSTALLATION

1. Remove the lift bracket
(Refer to page 11-5, procedures 1 - 4)
2. Jack up the vehicle and support tires with wooden blocks.
Ctlock the front and rear tires

3 Remove the lift cylinders (See page 12-14)

4. Remove mast rollers

(1) Remove the wooden blocks under the inner mast and
lower the hoisted inner mast slowly until the mast rollers
appear.
(2) Support the bottom of the inner mast wittl wooden blocks.

(3) Remove the inner mast rollers and shims

(4) Remove the inner mast rollers and shims.

5 The installation procedure is the reverse of the removal

procedure.

\
\ \
11-22

CHAIN

INSPECTION
1. 1nspect the cham elongation according to the following
procedure:

SST 09631-22000-71

(1) Since the SST measurement line varies with the chain
type, set the corresponding line on the chain as
illustrated.

(2) Check the number of the chain to be inspected, and

check the pin center position.
If the pin center is at the arrow mark on the chain gauge,
change the cham.

Chain Link Pitch Standard

i No of links
Vehicle model Pitch mm (in) I Type
I Chain No
measured N
.. .~
-- --1-
I
15
1 ton serIes 1588 (0.6252) I BL534 I 50
f-----
2·K2 ton series
- ----

1905 (0 7500)
I BL634 ····i
I
60 13
.-

1-.
11

-=r
3 ton series 254 (1.0) BL823 80
J3.5 ton series 25.4 (1.0) BL834 80 11
. .- . ~ ~

FSW 2 ton series, front chain 254 (1.0) BL823 80 11

I
Note:
• Perform measurement without removing the chain from the vehicle.
• Inspect elongation over the entire chain length since it varies with positions.

REASSEMBLY
1. Installing direction
Applicable mast V: Lift bracket FSW: Inner mast FV Lift bracket
and portion FSV: Inner mast Lift bracket FSV Lift bracket

Center of vehicle 0 Center of V

vehicle
[

(
(

/~
D
Rough sketch ~~
Cotter pin 0 .----- ~
Caller pin

'-----
Install the chain with the cotter pin
facing the center of the vehicle. Install the chain with the cotter pin
facing the outside of the vehicle.
 11-23

2. Chain adjusting nut tightening order

(1) Tighten nuts (1) and (2). T= 64.0 Nm (653kgfcm) [47.2ftlbf]

(2) Tighten the nut (3) of the V and FSV outer mast.
Tighten the bolt (4) of the FV front cylinder part (1 IK2) or the FSV front cylinder part (1-2-K2), and fasten
with a clamp.
V: Outer mast FV: Front cylinder portion FV Front cylinder portion
Applicable mast FSV Outer mast (3J3.5 ton series) (12K2 ton series)
and portion FSWOuter masl FSV: Front cylinder portion FSV Frollt cylinder portion
Fronl cylinder portion (3J35 ton series) (1·2K2 ton series)
--- - - - -----_._-- _._---._--- -
... .._---

"J1J
..

r
(4)

131 E1[

(~~12) (4~12)
Rough sketch

lb~~··~ I?)

l-·
(1) L (1) ~ (1)

ADJUSTMENT
1 Incline the mast backwards and fully lower the forks.

2 Set the forks vertically and adjust the chain with the adjusting nut to remove slack in it.

3. Check that the chain tension is equal on the left and right side

4 Check the chain for twist.

5 Check that the fork height is the standard.

6 With the fork raised fully, check that the lift bracket stopper at the innermast upper beam is not in contact with the
lift bracket.

After adjusting the chain, check that the distance from the
center of the roller at the lower part of the lift bracket to the
Inner mast bottom end of the inner mast is within the range below.

A = 15 - 20 mm (0.59 - 0.79 in)

11-24

FORK

REMOVAL
1. Set the fork at approx 20 cm (7.9 in) above the ground

2. Place a wooden block under the cutout portion of the fork rail.

3 Unlock the fork by lifting the fork stopper pin and shift the fork
blades, one at a time, to the center.

4 Slowly lower the forks and remove them.

INSTALLATION
The installation procedure IS the reverse of the removal procedure.

INSPECTION
1. Inspect misalignment of the fork tip ends

Limit: 10 mm (0.39 in)

If the limit IS exceeded, inspect individual fork for bend,

looseness of the fork installation part and lift bracket finger bar
distortion.
 11-25

FV·FSV·FSW MAST ASSY

COMPONENTS

FV

6101

10

",
10 I
CJ JOA .

lOB

FSV

6101
11-26

FSW

6101
31
21
31A i
22 f,
30 42A -J J
i "
30A
",A 1

I
.'\]-1t O;'{i - 42

.. " __ ~.:, .1

. .\- :.

4JA 43

6101-596

F~V~(~1.~2~.3~~to~n~s~e~ri~e~s)~ [~6~3~O~1~1

6301-707
FV (K2 ton series)

6301

20

BF 02

(»58
-cc: o~ 588
43 ( 0) 0
~,~.

~ ;,--J-' 42
! 0
59A
/.. hl
',5::f' 41
41A
43A DE
AG 59

6301-708

~F=S~V~(J~3~.5~to~n,,-,s~e~ri~e~S)~~ ~ ~_~ -[~6~3~O~1~1

20

02

(/lJ)-- 58
J!2?' 0- 588

43
-·f
I
r.}i5
•
8F
(~ 9
41
41A

6301,709
11 28

FSV (1-2-3 ton series)

6301

20

Bf
07
",.
(C~,
'2e

4JC
m 5911
AG

6301-710

FSV (K2 ton series)

6301

20

02

6301-711
 11-29

FSV (J3.5 ton series)

6301

BF

':r. 02

.
43
(J ~",'
rJ):'I
. 0-
, -
1 'G
42C 42
,Jl '"
59{\ 8F
43A O'E A'G

6301-712

FSW (2 ton series)

I 6301

02 .'

- -0) 58
!iJ!l} 0 -- 58B

6301-713
11 30

FSW (3 ton series)

6301

10

01

,..§.
.Ziv 0-- -
58
588

. --/" " 43

'. Y f.eti) 42
I- ~ '_~ O~7tJJ) 59 ," .,
43A DE AG ''''- 8F "A
59A

6301· 714

FV (1·2·K2 ton series)

6302
 11-31

FV (3·J3.5 ton series)

6302

41A

~ ';r'':,\f\1\i~}Cl'
ill ' ~::v
l:b
41

\ : ,i;:1, 'if! I
i,!~\,i.·_\i
"'I~"1,, ,l" I" 1"
\
",ir."J@A
i I ill -
I ',11 :,'I
\l - I' --'i -,1_,\
v

6J02-439A

FSV (1·2·K2 ton series)

6302

6302-435A
11-32

FSV (3-J3,5 ton series)

6302

FSW

6302

6302-449
 11-33

MAST DISASSEMBLY·INSPECTION·REASSEMBLY (FSW)

,- .. _ - - ~ ~ - - - - ,-'-~ - '_._~._._-.

10
9

I
i

I
l__.. ._~ ~__
Disassembly Procedure
1 Remove the fork height switch.
2 Disconnect the hose and piping.
3 Remove the hose pulley.
4 Disconnect the front lift chain.
5 Remove each front cylinder support. [Point 1]
6 Remove the front cylinder.
7 Slide the inner mast downward and remove the lift rollers.
8 Remove the mast strip (middle). [Point 2]
9 Remove the middle mast ASSY W/outer mast ASSY
10 Remove each cylinder rod end set boiL
11 Remove each cylinder support.
12 Slide the middle mast upward and remove the rear lift cylinder. [Point 3]
13 Slide the middle mast downward and remove the lift rollers.
14 Remove the mast strip (oute). [Point 2]
15 Remove the outer mast-
11-34

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Installation:
Place the front lift cylinder support on the cylinder rod guide
with the larger gap A facing upward and perform the followlflg:

If there is a clearance C:

~
:~I
Flip the front 11ft cyllflder support and secure it (Wiltl gap A
1,- facing downward)

41
------=-~~~-=~
I'
=' J
,If
If there is a cleararlce D:
Secure the front 11ft cylinder support as is (with gap B faclflg
1 __ JI Clearance C
downward)

[Point 2]
Inspection:
Measure the mast strip thickness.

Limit: 1.5 mm (0.059 in)

[Point 3]
Disassembly:
Shim adjustment is made at the lift cylinder rod end to prevent
uneven lifting by lift cylinders LH and RH.
Note the cylinder that was adjusted and the number of shims
used.
 11-35

MAST ADJUSTMENT (FV-FSV-FSW)

Lift Roller Adjustment at Mast

1. Inner mast roller (FV·FSVFSW) and middle mast lower roller (FSV·FSW) clearance adjustment

Bring into contact

Position where the

roller IS the closest
FSVFSW Illast
FV mast
Inner IllClSt
Inner mast Outer mast /

Outer mast Middle mast

These rollers These rollers

(1) Adjust the mast overlap to approx. 450 mm (17J2 in).

(2) Adjust the inner mast rollers (FV·FSV·FSW) and the middle mast lower rollers (FSV·FSW). Shift the inner
mast (or middle mast) to one side to bring the roller into contact with the middle mast (or outer mast)
Measure the clearance between the roller side face on the opposite side and middle mast (or outer mast) at
the point where they are the closest.

Standard: A = 0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check that mutual mast movement is smooth.
11-36

2. Outer mast roller (FV·FSV·FSW) and middle mast upper roller (FSV·FSW) c1earanceadjustment

Bring into Bring into

contact contact

Bring mto
contact
B

Position where the

roller IS the closest
FV FSVFSW
These rollers

These rollers

Mldole mast

Outer mast Outer mast

Inner mast
Inner mast

(1) Adjust the mast overlap to approx. 450 mm (17.72 in)..

(2) Adjust the outer mast rollers (FV·FSV·FSW) and the middle mast upper rollers (FSV·FSW). Shift the outer
mast (or middle mast) to one side to bring the roller into contact with the middle mast (or inner mast).
Measure the clearance between the roller side face on the opposite side and middle mast (or inner mast) 8t
the point where they are the closest.

Standard: B =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check that mutual mast movement is smooth.
 11-37

Lift/Side Roller Adjustment at Lift Bracket

Bring into
contact Lower lift roller

Side roller

Bring into
contact

Lift bracket

~1'I'i
1

1'1'11

~ I

FV
~ I
FV (K2 ton series) FSV (except K2 ton series)
(except K2 ton series) FSV (K2 ton senes) FSW (2 ton series)
FSW (3 ton series)

(1) Raise the lift bracket to the uppermost posillon for the FSV'FSW·FV (only K2 ton series) mast, and bring the
center of the upper lift roller to approx 100 mm (3.94 in) below the top of the inner mast for the FV (except
K2 ton series) mast.

(2) Inspect and adjust the lower lift rollers.

Shift the lift bracket to one side to bring the roller into contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.

Standard: C =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Inspect and adjust the side rollers.

Shift the lift bracket to one side to bring the roller into contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.

Standard: 0 =0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(4) After the adjustment, check that the lift bracket moves smoothly over the entire length of the mast.
11-38

Mast Strip Adjustment

1. Mast strip clearance adjustment

Outer mast roller

FV mast Inner mast

Outer mast

Middle mast

FSVFSW mast Middle mast upper roller

Bring into contact

Inner mast

Outer mast

(1) Lower the inner (or middle) mast fully.

(2) Inspect and adjust the clearance between the mast strip and the mast.
FV Mast: With the inner mast in contact with the outer mast rollers, measure the clearance between
mast strip and the mast.
FSV Mast: With the inner (or middle) mast in contact with the middle mast upper rollers (or outer mf
rollers), measure the clearance between the mast strip and the mast.

Standard: E = 0 - 0.6 mm (0 - 0.024 in)

If the standard is not satisfied, make adjustment by changing the shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check the mast for smooth movement.
 11-39

STANDARD FOR SELECTING AN OVERSIZE ROLLER

The clearance is on 1 Select the mast lower lift rollers and lift bracket upper and
one side lower lift rollers.
Select the appropriate rollers from the table below so that the
minimum clearance between the mast or the lift bracket and
the roller is from 0 to 0.7 mm (0 to 0.028 in).
mm (in)
No Outside diameter of the roller
clearance >--~-- ... _-_.
957 (3768) 962 (3787) 967 (3.807)
-"- . ------.,----_. . ..
1077 (4 240) 1082 (4260) 1087 (4.280)
Minimum Minimum 1----------
clear,mce =A : clearance =A + B 1197 (4 713) 1202(4732) 1207 (4.752)
f--..-----
1245(4902) 1252 (4.919) 1257 (4949)

2. Select the middle lift rollers of the lift bracket.

Select middle lift rollers to correspond to the lift rollers selected
in 1. from the table below. (Use rollers of outer diameters 1 to
1.2 mm (0.04 to 0.047 in) smaller than those of the upper
roller)
mm (in)
OutSide diameter of the roller
---- - _... - - - - ------_.- --- - -.~, .. _--._ .. ~.-

Upper lift rollers Middle lift rollers

957 (3768) 94.5 (3.720)
1 - - - - - _._._ ..- ._._---~--._-

Middle lift rollers 962 (3 787) 950 (3.740)

1------
967 (3.807) 957 (3.768)
-- -
1077 (4240) 106.5 (4_193)
. __.
1082 (4260) 1070 (4.213)
- - - - ~

1087 (4280) 107.7 (4240)

_.
1197 (4.713) 118.5 (4.665)
C----.
1202 (4.732) 1190 (4.685)
1---------- -- - .
1205 (4744) 119.7 (4713)

Note:
• There is no selection for the upper lift rollers of the outer
mast and middle mast, and for the side roller of the lift
bracket.
• The outer diameter of the selected rollers may be different
between right and left.
11-40

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF

UNEVEN LIFTING)

V·FSV·FSW MAST
Note:
• For left and right lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• The inspection and adjustment must be made when any of the following parts is replaced: Lift cylinder
ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner
mast SUB-ASSY
• Perform SAS matching after adjustment. (See section 16)

1. Inspection method
Slowly raise the inner mast, and observe the stopping states of
the left and right cylinder rods at the moment when the inner
mast readies tlie maximum heighL

(1) Normal case

Both the left and right rods stop almost simultaneous.:
With almost no shaking of the inner mast.

I (2) Abnormal case

~I
1he rods stop WIth slight difference and the top of the
I Inner mast shakes at the time of stopping. To correct this,
add shims la the cylinder that stops first.

2. AdJustmerit method

(1) Remove the left and right cylinder rod end set bolts

(2) Suspend the inner mast with a hoist, attach the SST to
the outer mast tie beam, and lower the inner mast until it
makes contact with the SST.

SST 09610-22000-71

(3) Place shim(s) on top of the cylinder rod end on the side
be adjusted, then slowly raise it and insert into the inner
masL
Shim(s)
Shim thickness: 0.5·1.0·2.0·3.2 mm
(0.020·0.039·0.079·0.126 in)

(4) Reattach the left and right cylinder rod end set boils.

(5) Remove the SST.

(6) Raise the inner mast for reinspection.

(7) Repeat the inspection and adjustment until the number of

shims is determined.
 11-41

FV MAST
Note:
• For left and right lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• The inspection and adjustment must be made when any of the following parts is replaced: Lift cylinder
ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner
mast SUB-ASSY
• Perform SAS matching after adjustment. (See section 16)

1. Inspection method
Slowly raIse the IIlner mast, and observe the stopping states of
the left and right cylinder rods at the moment when the inner
mast reaches the maximum height.

(1) Normal case

Both the left and right rods stop almost simultaneously
with almost no shaking of the inner mast.

(2) Abnormal case

The rods stop with slight difference and the top of the

L inner mast shakes at the time of stopping In this case, it

is necessary to make a shim adjustment.

2. }\dJustment method

(1) Remove the left and right cylinder rod end set bolts.

(2) Suspend the inner mast with a hoist, attach the SST to
the outer mast tie beam, and lower the inner mast until it
makes contact with the SST

SST 09610-22000-71

(3) Place shim(s) on LH of the cylinder rod end, then slowly

\. raise the cylmder rod end into the inner mast.

Shim thickness: 0.5'1.0'2.0'3.2 mm

Shim(s)
(0.020'0.039,0.079'0.126 in)
(4) Reattach the left and right cylinder rod end set bolts.

(5) Remove the SST.

(6) Raise the inner mast for reinspection.

(7) Repeat the inspection and adjustment until the number of

shims is determined.

Shim(s)

Cylinder rod end LH Cylinder rod end RH

 12-1

CYLINDER
Page

LIFT CYLINDER (V)'REAR LIFT CYLINDER

(FV·FSV·FSW) 12-2
GENERAL 12-2
SPECIFICATIONS 12-5
COMPON ENTS 12-6
REMOVAL·INSTALLATION 12..14
DISASSEMBLY·INSPECTION·REASSEMBLY 12-16
SAFETY D0 W N VA LVE 12..19
REMOVAL·INSTALLATION 12-20
FRONT L!FT CYL!NDER (FV·FSV·FSVV) 12=21
G EN ERA L 12..21
SPECIFICATIONS 12-22
COMPON ENTS 12-23
REMOVAL·INSTALLATION 12..24
DISASSEMBLY·INSPECTION·REASSEMBLY 12-27
TILT CYLINDER 12..31
GENERAL 12.. 31
SPECIFICATIONS ~ 12.. 31
COMPONENTS 12.. 32
REMOVAL·INSTALLATION 12.. 33
DISASSEMBLY·INSPECTION·REASSEMBLY 12..35
MAST FORWARD BACKWARD
TILT ANGLE ADJUSTMENT·
(ADJUSTMENT OF UNEVEN TILTING) 12-38
12-2

LIFT CYLINDER (V)·REAR LIFT CYLINDER (FV·FSV·FSW)

GENERAL

Lift Cylinder (V/1·2·K2 ton series)-Rear Lift Cylinder (FSV/1-2·K2 ton series)

Lift Cylinder (V/3·J3.5 ton series)·Rear Lift Cylinder (FSV/3·J3.5 ton series)

~~~========~I~====~~~~~=n
11
-~-~- -~- - - - - r.--~-------

~~~~~~II~~~~~~~
 12-3

Rear Lift Cylinder (FV)

LH

··rFTI·.-_

Rear Lift Cylinder (FSW/2 ton series)

J1r -----------+t-r~
I
12-4

Rear Lift Cylinder (FSW/3 ton series)

 12-5

SPECIFICATIONS

Lift Cylinder (V)

-----------------
Item
Vehicle model
-------_______ 1 ton series I 2K2 ton series I 3 ton series J3.5 ton series
t-------------~------~-==_I----------L------

-=r
Cylinder type Single-acting type
~d~r bore ~nm (In) 45 (177) 50 (197) f=--- 55 (21i) - Q0(236)-----
Piston rod outside diameter
~--~---------
mm (In) 35 (1 38)
- - - - - f - - - - - - -- - - - - -
- J 40 (1 57)
~-----------
1
- ------ ~~
45 (1 77)
--- -- --- - - - -------1
Piston seal type U packing
r----~-- -- -- - - - f - - - - - - - - - - --- -------- - - - - - - - - - - - - - - - - - - - - - . - - - - - - - -- - . - - - - - - - - - - . - -
Rod seal type U packing
- ~ - - -------~~--- - --- - - - - - - - - - - - - -----------------------------~
- -.- . _ - - - - - - - - - - - -

Others Built-m salety down valve (LH)

Rear Lift Cylinder (FV)

_
- Vehicle model
----~------________________ 1 ton series 2-K2 ton series _
I
J__ ~n se~_:s
I
L J3~~0~_series __
~.. '1dcr t . y _ p e . . Single acting type

11-.-72-76·-~)1'--53-05-((-11---.-9378-~))- ~---~-7)-40 ·(:~1! -5-7---)~-6()-(2~6T- _____

I~~~~~~t~id~di;~~---~~~~~-:;~;
. .

Rod seal type

-- ----+----4-5-((
32 ~1 I
U packing
f----- --------------- -----t----------~----------- ---------------
Others Built-in safety down valve (LH)

Rear Lift Cylinder (FSV)

----~ Vehicle model . s I i
Item --------=~_-_--_==_I--1-t-o-n-s-e-r--I-e~ 2- K2 ton s._e_ri_e_s_ _"---_3_to_n_se_r_ie_s i'--_J_3_5_to_n_se_r_ie_s_ __I

Cylinder type Single acting type

t-----~---------------_+-------_.,-------_,-------_.,-------__I

Cylinder bore

------
mm (in)
----~--____+---~---+---~----"-+--~---~---------1
Piston rod outside diameter mm (in)
45(1.77)
35 (1.26)
50(197)
40 (157)
55(217)

-----'--------------------------1
I
45 (177)
60(236)
E
Piston seal type U packing
------------------------1-----------------------------------1
j sea! type U packing
Jhers Built-in safety down valve (LH)
L_

Rear Lift Cylinder (FSW)

Item
~el 2 ton series 3 ton series

Cylinder type Single acting type

Cylinder bore mm (in) 50 (1_97) 55 (217)
Piston rod outside diameter mm (in) 40 (1.57) 45 (1-77)
Piston seal type U packing
Rod seal type U packing
Others Built-in safety down valve (LH)
12-6

COMPONENTS
Lift Cylinder (V/1 ton series)

I 6503

011HH
02 LH l
r-.- ~_. . ._~ l ___ a_a'
9
AG-+
~------~
LO~~K~I~-~-~~_~1 :
i0 7K ;;O\INCL-E
30[RHJ; 0--.- AE
31(LHJ i 0------ AD
: 42 13
f~'
I

[ ,

I i l- _ 20[RHj ;
21[RHJ_--, 11{LH) :
23[LHJ I

i
i;
, i

I'
~ !

~
AA'~@
AB------O

Lift Cylinder (V/2-K2 ton series)

I 6503

11
'!

I:

::
ir i

:
~._~ 20(RHJ
11(LJ-lj
!I
it I,
!i i
I 1

,i
i i

AA-.-@l
U
L_. A~B_~ • __ '; 6503-236
 12-7

Lift Cylinder (V/3·J3.51on series)

l 6503

01[RH!
02[LH
- - - - - _... _- ..... ,
AG-a-
r01K~iINCL~~j: :
[OiK=IIi<CL.~j!
JO[RH]
31ILH1 -

-- 42

lOIRH]
21{LHI
22[RHJ
2J[lH]

,!

I;]
AA.q
AC- • -<2-
~_ .. ~f3 • -9 ____ ..i 6503-237

Rear Lift Cylinder (FV/1 ton series)

6503

F?
cz --~
. I !4'r ~- ,
00- -e g--- cz
~-OQ

I'

21 20
23 22

I
"

.! ,-

I1
' <id

.... _~------- ~------_ .. _.

6503·243
12-8

Rear Lift Cylinder (FV/2'K2 ton series)

6503

r·- ..
02(LH]
------~------ - ---, r---- -----
01[RHJ
-------_ .... ,
0 : : Q -. AG
AG - • --
.~ .. ~.
~~_l~~E':'I~~. _~~ :
31 ~ ~~ --:---~, : 8~ :_~ ~~ 30
AD
42
• 9.-' I
q-
-"
·-AO
- 42
AJ
AF
.-
•
g-- o
0
.. AJ
AF

Cl ~
00--.
Cl
DO

21--- 20

~ f::2 .. f::::
..
~
AA - . {~~.::~.--~ • - AA
L ..... ___ .J L_-=-. .. __ ..I
6503-244

Rear Lift Cylinder (FV/3·J3.5 ton series)

6503
02[LH) 01[RHJ
r·-"--~ ---, r---
AG -----.------0 : : o~ ...-- AG
~:~~-
~'!~

31---i ~~ -:.--.g ! j g- -.: _:~ 30

'AD~-O' .O-'.--AD
:..... 42 ----? ' ; 10.__ 42 ~
,~ AJ - '-'-0 i : 0---·- AJ ,~
~ 1 AF' o' I 0--.- AF
cz--~
;! it "
00--9
~ - Cl
• DO

,I
i:
21 20
23--~ '-~22

! :1
1I
:1 i ii
;.:1: '!:
j I
:d
'ti
i ;! ! I1 li j
ll( ill!! 11 i

. .~ W!!ill
L••• ~~~~~_AA~------©_••• Jt~~·~AA~~~~~_ .._.. ~
6503-245
 12-9

Rear Lift Cylinder (FSV/1 ton series)

6503

~OlK:::..(INCl .)
~~2K::(INCL __ 1

10(fHfJ
21(lHJ
l1[RHJ
23[LHJ

I::

t:J
AA-·A
AB--&---O
L_. _ _ __ -, 6503·236

Rear Lift Cylinder (FSV/2-K2 ton series)

6503
01[RH]
02[LHJ
r"'--~--··-
I ---,
AG .-0 j01K=(INCL_fO);
-~ ~°3~~Q~~_~:·);
30[RH] 0 - . - AE
31[LHJ . 0-.- AD
~- 42- ..S
r~),

: I

l! lO[RH)
. --- 21(LHJ

! .
,
ill

! ,
I II!
I I ! 1I

U lJ)
• AA--<>---§
i.••• _-.:...A=B~.--=O=-~~~~~~~ ..: 6503.239
12-10

Rear Lift Cylinder (FSV/3·J3.5ton series)

I 6503
01[RH]
___ ~_~2[LH]
r ...... ---
AG • ---0 O_l_K=(I.NCl.e)
~ l~~={-I'NCL:.~.
t=J;i
30{RH] j o 6 AE
31[LHJ o . AD
- 42 ~3
',';

2l[RH] 20[RH]
23[LHJ 21[LHJ

(0

BK

~
AA • --0
AC • .Q
L . AB 0 Q

Rear Lift Cylinder (FSW/2 ton series)

I 6503
02[LHJ 01[RH]
r- .... --·- ---, r---- - --~ .... _,
: [02K=(I,"-Cl··t AG--. -Q:: Q---- AG
LOlK=( INCL6>1 :
-~"@---- -
~ .~

31---f AE-.---Q I i 0- --.- AE . 30

, AD --. ---0 .. 0 --. AD
~41---B 'e~-41--

if· H

; i
. 'I

~I',
: I
.
. ;

21
23--~n1!· 22

,!
',I
: i
: i! i
'\'
;i I::
I I ~
I i;'"
: ii
I i! ! I]!) i j

I11 I iI i I i 1

~ ~IIU
AA~ •• @----AA :
L. ~_ _~_A_B_------e.j t~ A_B~_ _~_ ...... ..i __
6503-241
 12-11

Rear Lift Cylinder (FSWJ3 ton series)

6503
02(LH] 011RHj
r- .... -~ ..._-,.- - - ---., r .... ---------.:.--------- - .... ,
AG-~' 0:: 9
: (~~~J'~~,~~~)l +- AG [OiK=(INCL 01' :
r-~-g: 'e---l -~.
J1~ AE-·-..(3:: 0- ·-AE 1--30
; AD --. () 0 • - AD i
~__ 42 ,C.l. Cj. 41
~_J :, '~-:.'
l_.~ '>'-

21 20
23 - 22 ; I
I

P:
i ' _ BK
BK-
i, iI
:,
ii
·--AA
• AC ~
0-- AB
L _ ___ .I
6503-242
12-12

Lift Cylinder (V)

6503

tr - ~J;
"""I.' i I
AI

i
I
BP
I
I
I

r20 ,25,K20

6503-231

Rear Lift Cylinder (FV)

6503
30,J35
G- CJ
r- j)'--CJ
i
CJ CJ

i
AM AJ---{=-_--=~ - t)
BO i qC:P
CP I. ! ~... ,1-· BQ
AW : . J"'1"'1 '; AY BP ~
i~it) ;- i ,~~l)
'l." :' A,M
BP S,Oi~i "'I
C: P ;!: ."". ~ ~': Ba
AW' i ~. I
tJ~· , i AY
~.~ , I

~CJ

CJ

u'j
Al-C'"
AM ~ 1J
! I 6jJ I
sol ~'I
cp l I ~':rh"- ,I BO
AW I ~~"')~ i lAY
l,~~ I!
~' BP !

6503-234
 12-13

Rear Lift Cylinder (FSV)

6503
15,18.

CJ
CJ

20, 25,-K20
Cl

-- .:;:
AI·
A,
r~: i
BPq :>:t1
..·.-. 1'£1
AM I ';"t ~
BQ~i'"
CP; ",'
•
AW ,'j

.,L] \:J I;
§,
6503-232

Rear Lift Cylinder (FSW)

6503

6503,233
12-14

REMOVAL·INSTALLATION

a 0 5
6

Removal Procedure
Set the mast vertical and lower the fork fully.

2 Remove the lift cylinder rod end set boiL

3 Hoist the inner mast by slinging with a wire and disconnect the end of each lift cylinder rod. [Point 1]

4 Hoist the inner mast further so that the lift cylinder ASSY can be removed toward the front of the vehicle.

S Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer mast.
6 Remove the hose cover.

7 Disconnect the low pressure hose and high pressure hose.

S Remove the lift cylinder support.

9 Remove the lift cylinder ASSY.

 12-15

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the lift cylinder, follow the steps below.
1. Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
2. Check the hydraulic oil level and add if insufficient.
3. Ins pect lift cylinders for uneven lifting, and make necessary adjustment. (See page 11-40.)

Point Operations
[Point 1]

Removal:
Shim adjustment is made at the lift cylinder rod end to prevent
uneven lifting by lift cylinders LH and RH. Note the cylinder
that was adjusted and the number of shims used.
12-16

DISASSEM BLY-INSPECTION -REASSEMBLY

T = Nm (kgf-cm) [ftlbf]

1 ton series-
T = 225 (2290) [166_0]
2-K2 ton series:
T = 250 (2550) [1844]
3 ton series
r)
T = 275 (2800) [2029]
J35 ton series:
T = 305 (3110) [225]
I

I 4
I
I
I
i I

I i
I
1--3 I
I
I
I
! I
i
,I
J
Note: This illustralion IS for the V mast on the 1·2 or K2 ton series.

Disassembly Procedure
1 Remove the safety down valve (LH).

2 Remove the cylinder coveL [Point 1]

3 Remove the piston rod [Point 2]

4 Remove seals on the piston side. [Point 3]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure_

Note:
• Apply MP grease or hydraulic oil to the packing, O-ring, and dust seal lip portion .

1/3 to 1/2 of circumference • Apply sealant (08833-76002-71 (08833-00080)) to the

cylinder cover on the part shown in the illustration and
reassemble it.
2 ridges

! 2 to 3 ridges
 12-17

Point Operations
[Point 1]

Disassembly· Reassembly

SST 09620-10100-71

[Point 2]

Inspection:
Measure the piston rod outside diameter.
Unit: mm (In)

Vehicle model Standard Limit

1 ton series 35 (138) 3492 (13748)
'-' ~~---+----~~----

2K2 ton series 40 (1.575) 3992 (1 5717)

V
3
~I~n'r~:~~:!:~ ~ ~,55 «(1 7 7 ))
---
\
---13

~1-t-o~~les
- :' , ' "'='
----t-
'='::0"
1 77
32 (1-26)' I
4492 (17685)
v
4 4 ,09 2 « 11.:
31 2 25
j
,_6-86~7~)

FV 2 K2 ton senes 35 (1 38) 3492 (13748)

--,-_._--+----~+--~~----_.- .
3J35 ton series 40 (1575) 39.92 (1.5717)
1-------1-----
1 ton series 35 (1.38) 34.92 (1.3748)
FSV 2K2 ton series 40 (1575) 39.92 (1.5717) I
f--'-3-J35t()~ series 45 (1.77) 44.92 (176~

FSW
2 ton senes 40 (1.575) 3992 (15717) I
f - - - -3
- ton series 45 (177) 44.92 (1.7685) j
Inspection:
Measure the bend of the piston rod.

Limit: 2.0 mm (0.079 in)

Reassembly:
SST
Use a cylinder rod insertion guide (SST) to reassemble.
Cylinder rod 1 ton series: SST 09651-26600-71
2·K2 ton series: SST 09652-26600-71
3 ton series: SST 09653-26600-71
J3.5 ton series: SST 09654-26600-71

Cylinder
12-18

[Point 3J
Inspection:
Measure the lift cylinder bore.
Unit mm (In)
Vehicle model Standard Limit
e-.. . -...• --
1 ton series 45 (1.77) 4520 (1.7795)
2K2 ton series 50 (197) 5020 (19764)
-~

3 ton series 55 (217) 55.35 (2.1791)

._- --
J35 tOfl series 60 (236) 6035 (2.3760)
 12-19

SAFETY DOWN VALVE

Safety Down Valve Sectional View (for V) (for FV·FSV·FSW Rear Lift Cylinder)

for VFV for FSVFSW

I
" L,
,

"
I

I
ii
!
"I
11
1 I
1

~~
I

Safety Down Valve Sectional View (for FV·FSV·FSW Front Lift Cylinder)

I:
:I -l~~=P
I: :i
I
I
I
I

C) :i
\

I
I

I
I
12-20

REM OVAL-INSTALLATION

Removal Procedure
1 Hold the inner mast at an appropriate height [Poi nt 1]

2 Remove the lift cylinder rod end set boiL

3 . Fully lower the lift cylinder rod

4 Remove the hose cover.

5 Disconnect the high pressure hose

6 Remove the safety down valve.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operation
{point 1]

Removal:
Raise the inner mast, attach the SST to the outer mast tie
beam, and lower the inner mast until it makes contact with the
SST.

SST 09610-22000-71
 12-21

FRONT LIFT CYLINDER (FV·FSV·FSW)

GENERAL

Front Lift Cylinder (FV'FSV)

fr.lt Lift Cylinder (FSW)

=-==J)--------
12-22

SPECIFICATIONS

Front Lift Cylinder (FV·FSV)

_______________ Vehicle model
1 ton series 2K2 Ion series 3 ton series J3.5 ton series
Item ~ \ 1
~ .

Cylinder type Single acting type

.. -
Cylinder bore mm (in) 70 (276)
I 75 (295) 85 (325)
.- ..- - I 90 (354)
Piston rod outside diameter mm (in) 50(1.97) 60 (2.36)
c-. ~_

e"'otoo ' c " l y p e _ - - - = I~ U packing

--_ - . -
..•

Rod seal type

t-~-~._---~--~-------

Others
1- ------- --.----------._--
U packmg
Built-in safety down valve

Front Lift Cylinder (FSW)

Item
~el 2 ton series 3 ton series
1
Cylinder type Single acting lype
c---~------_. --
Cylinder bore
.-._-
mm (in) 55 (217) [ 60(736)~
Piston rod outside diameter mm (in) 45 (1.77)
- .------- - - _----
•...

Piston seal type U packing

Rod seal type U packing
---
Others Built-in safety down valve (LH)
 12-23

COMPONENTS

Front Lift Cylinder (FV)

6502
01
r .... _· - __.__ ~~_--.l ~_ .----_.- .. _-,
AF -0 [OlK=P NCl O} :

-~ \ ..-~c=;;'"
]0 !

I~
Al
i I
,, '
I
I

2'

20

11

CA --~
AB .-
BM -t
AB
Aa ·E~)
BE ,r--\

:~ :8 __ ~-AK
AU

6502-131

Front Lift Cylinder (FSV)

I 6502

-
01
,
---""------.-~- ---'-

~l
i: AL
I

l~·l
I

:
! I , i
20

21---- i ! !!
I
\ ,
r-"","~,.-:

, \..----i.}{i-__ l1

b n
CA -~
AB --.---<;>
BM -- -:J
AB-~ <0>

AO---e
BE~:H
:~=cs ~AJ{

L ...... ~A:::.U_-_~~~~~~~ ~ ..I

6502-129
12-24

Front Lift Cylinder (FSW)

6502

AL

BB
..... ,
.
r--" -
f?~1_~.~E~~L~_~}j :

o . AF

~
30

1\1
i :i
21- j \
I I I
21 ---- 20
20-

I ,
,I" "

i
I,j

ill

BM-
~
--{J
AB ··---.--CJ
Ao-~---B
BE .-~
BO·----.---Q
®-----AK
BM
AU ---0 0- -. AB
0-. AO
,~. . . BE
~-. BD •
AK--- -"'-
L __ .. __. __ o AU •
-----_.1
6502-130

REMOVAL-INSTALLATION

Front Lift Cylinder (FV-FSV)

Removal Procedure
Remove the lift bracket WI fork.

2 Disconnect the piping_

3 Remove the front lift cylinder.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installing the lift cylinder, follow the steps below.
(1) Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
(2) Check the hydraulic oil level, and add if insufficient.
(3) Adjust the lift chain tension equally on the left and right sides.
 12-25

Front Lift Cylinder (FSW)

Removal Procedure
Raise the lift bracket and place wooden blocks under the forks_

2 Fully lower the lift bracket to relax the chain_

3 Separate the front chain from the inner mast and remove the chain from the inside of the chain wheeL
4 Disconnect the low pressure hose and high pressure hose_
5 Remove the front lift cylinder support boiL [Point 1]

6 Remove the front lift cylinder [Point 2]

Installation Procedure
The installation procedure is the reverse of the removal procedure
Note:
After installing the lift cylinder, follow the steps below.
(1) Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
(2) Check the hydraulic oil level, and add if insufficient.
(3) Adjust the lift chain tension equally on the left and right sides.
12-26

Point Operations
{ Gap A (large)
[Point 1]

Installation:
Place the front lift cylinder support on the cylinder rod guide
with the larger gap A facing upward and perform the following:

If there is a clearance C:
Flip the front lift cylinder support and secure It (with gap A
L---=:t facing downward).

l~=-JH If there is a clearance 0:

Secure the front lift cylinder support as is (with gap B facing

I ID
I I Clearance C
downward).

Clearance D
I r------

lJ2·~---'
T -
T I r---
I I

[Point 2]

Positioning Installation:
pin Align the positioning pin with the inner mast hole and install it.
 12-27

DISASSEMBLY·INSPECTION·REASSEMBLY

Front Lift Cylinder (FV·FSV)

T = Nm (kgfcm) [ftlbi]

a j

,-r
, ,
i

G
i i

I j
! i
!;

C. dssembly Procedure
Remove the chain wheel support

2 Remove the cylinder cover

3 Remove the piston rod. [Point 1]

4 Remove the wear ring and U packing

5 Remove the check valve.

6 Remove the safety down valve from the cylinder. [Point 2]

12-28

Front Kift Cylinder (FSW)

T == N·m (kgf·cm) [ft·lb!]

~-_2
~-

~J~3
2 ton series
T = 275 (2800) [2029]
3 ton series
g. .
T=305(3110)[225] J

7
-i

i
~-4
I
I
I I
lJ~ 7

Disassembly Procedure
1 Remove the chain wheel support.

2 Remove the front lift cylinder support.

3 Remove the cylinder cover.

4 Remove the piston rod. [Point 1]

5 Remove the wear ring and U packing.

6 Remove the check valve.

7 Remove the safety down valve from the cylinder. [Point 2]

 12-29

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
o Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.

1/3 to 1/2 of circumference • Apply sealant (08833-76002-71 (08833-00080») to the

,~-----~
i I
r-~~ I
j) i 2 ridges
. o
cylinder cover on the part shown in the illustration to
reassemble it.
Fill the cylinder with the specified amount of hydraulic oil

~.~~.
-·--~.~~~c~ r.
1 through the cylinder top opening before installing the
cylinder cover.
to 3 ,iogcc
Vehicle model i Filling amount cm] (in])
f~~~~ ~~:~C=___

~~~SJ
i. -
I
~-'------,---~----'-'----
--'i~------"--

t-r
1 ton series i 30 -- liO (183 -- 3.66)

FV FSV
~2 ton series i
I------·-------~---··--------~I
40 ~ 70 (244 - 427)
I 3 ton series I 45 -- 75 (275 - 458)
l------. .~-.----.----------. - - - - - -
I J35 ton series I 55 -- 85 (336 -- 5.19)

--;SW TI 2 ton series

3tonseries [
~ __.15 --.:3~~92_=_2~~~)_ _
15~30(092--1.83)

Point Operations
[Point 1]

Inspection:
Measure the piston rod outside diameter
Unit mm (in)

Vehicle model Standard Limit

j-'
1 ton series (FVFSV) 50 (197) 4992 (1.9654)
f------- --_ ..• _"-
2·K2 ton series FVFSV 50 (197) 49.92 (1.9654)
2 ton series FSW 45 (177) 44.92 (1.7685)
---- I
FVFSV 60 (236) 5991 (23587)
3 ton series
FSW 45 (177) 4492 (17685)
I
J35 ton series (FV FSV) 60 (236) 5991 (23587)
I
Inspection:
Measure the bend of the piston rod.

Limit: 2.0 mm (0.079 in)

Reassembly:
SST
Use a cylinder rod insertion guide (SST) to reassemble.
Cylinder rod FV·FSV:
1 ton series: SST 09655-26600-71
2·K2 ton series: SST 09656-26600-71
3 ton series: SST 09657-26600-71
J3.5 ton series: SST 09658-26600-71

FSW:
Cylinder
2 ton series: SST 09653-26600-71
3 ton series: SST 09654-26600-71
12-30

[Point 2]
Inspection:
Measure the lift cylinder bore.
Unit: mm (in)
Vehicle model Standard Limit
.-
1 ton series (FVFSV) 70 (276) 70.35 (2 7697)
2·K2 ton series FVFSV 75 (295) 75.35 (29665)
2 ton series FSW 55 (217) 5535 (21791)
-----
FVFSV 85 (335) 8540 (33622)
3 ton series . . - ..-.-
FSW 60 (236) 6035 (2.3760)
e - - . ~ - . ~ ~ _L...._~_

J35 ton series (FVFSV) 90 (354) 9040 (3.5591)

 12-31

TILT CYLINDER

GENERAL

ECIFICATIONS
-
L der type Double acting type
~
Cylinder bore mm (in) 70 (2.76)
Piston rod outside diameter mm (in) 30 (1.18)
Piston seal type U packing
Rod seal type U packing
12-32

COMPONENTS

6511

.----
I
I
I

- - - am m ,
I
/ I
•

.'. \

'. \ \.

;'
;'
 12-33

REMOVAL~INSTALLATION
T:= N·m (kgf-cm) [ft·lbf]

Removal Procedure
1 Open the engine hood.

2 Remove the toe board and lower panel.

3 Remove the side cover W/ step.

4 Hoist the mast temporarily

5 Disconnect the hoses.

6 Disconnect the tilt angle sensor link (RH).

7 Remove the tilt cylinder front pin. [Point 1]

8 Remove the tilt cylinder rear pin.

g Remove the tilt cylinder ASSY.

10 Remove the tilt cylinder rear bushing. [Point 2]

11 Remove the fitting.

12-34

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, add molybdenum disulfide grease through the grease nipple to the tilt cylinder front
pin and rear pin.
• After installation, slowly tilt the mast forward and backward a few times to check normal functioning.
• Check the hydraulic oil level, and add if insufficient.
• After installation, perform SAS matching. (See section 16.)

Point Operations
[Point 1]

Removal:

SST 09810-20172-71

[Point 2]

Removal-Installation:

SST 09950-76018-71 ................... (1)

(09950-60010)
09950-76020-71 .... . (2)
(09950-70010)
 12-35

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N-m (kgf-cm) [ftlbf]

4
8
/"1

<....::>'\ . i

iJ/

8
4
4

Disassembly Procedure
Before disassembling, measure the tota/length of the tilt cylinder when fully contracted, and make a note. [Point 1]

Disconnect the boot fitting on the cylinder side, and move it toward the joint side_ [Point 2]

Loosen the rod guide. [Point 3]

4 Remove the piston rod W/ piston. [Point 4]
5 Remove the piston.
6 Remove the rod guide.
7 Remove the boot.
8 Remove the joint [Point 5]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Apply MP grease or hydraulic oil to the packing, O-ring,and dust seal lip portion.
• Apply sealant (08833-76002-71 (08833-00080)) to the threaded portion of the rod guide before
reassembly.
12-36

p.
omt Operat"Ions
[Point 1]
~II Disassembl
i 1
1
Check y• Reassembly:
the total
contracied length L of the tilt cylinder when fUlly

, L
r-- -- .....
I

[ \

[Point 2]

Reassembly
Assemble lh boot to th e vehicle wl"th its air
" bleeding holes
vertical e

[Point 3]
Oisassembl y • Reassembl .
SST y.
09620-10100-71

[Point 4]

Inspection:
Measure th e cylmder
.' bore .
Standard: 70 .0 mm (2 7 .
Limit- - 56 in)
. 70.35 mm (2 .7697 in)

Reassembly:
Use a cy IInder rod msertlo
ST 09659-2'6600-71 n gUide (SST) t 0 reassemble
S

.~ }J J'de,
_ _ _ " Cylinder rod "
 12-37

[Point 5]
Inspection:
Measure the piston rod outside diameter.

Standard: 30.0 mm (1.181 in)

Limit: 29.92 mm (1.1780 in)

Inspection:
Measure the bend of the piston rod.

Limit: 0.5 mm (0.020 in)

12-38

MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (ADJUSTMENT OF

UNEVEN TILTING)
Note:
Adjust the mast forward and backward tilt angles (uneven tilting) when the tilt cylinder and mast ASSY are
replaced or overhauled.
After adjustment, perform SAS matching. (See section 16.)

Inspect the forward and backward tilt angle and uneven lifting amount.
Standard
Mast forward tilt angle: Standard set angle 0° - +0.4°
Mast backward tilt angle: Standard set angle -0.6° - 0°
Uneven lifting amount: 1 mm (0.04 in) or less

2 If the standard is not satisfied, adjust it

Tilt the mast forwards, loosen the nut that holds the rod, then adjust the mast till angle and uneven lifting by
adjusting the screw engagement margin between the rod and the joint. (To adjust the screw engagement
margin, position a wrench to the 2-faced section on the rod and turn the rod.)

Caution:
Do not turn the rod when it is in the forward most tilt position (or the backward most tilt position) (Tun.
with the mast slightly before forward most tilt position).
T = Nm (kgf'cm) [ftlb!l

11 I
2-faced section of
Nut
the rod
T = 880 - 132.0
(897 - 1346)

3. After adjusting, tighten the nut to fix the rod.

 13-1

OIL PUMP
Page
GENERAL _.............. 13..2
SPEel FieATION S 13..4
CO M PO NENTS _ '" 13..5
OIL PUMP ASSY 13..7
REMOVAL·INSTALLATION
(Dry Brake Spec.) 13.. 7
REMOVAL·INSTALLATION
(Wet Brake Spec.) 13..8
DISASSEMBLY·INSPECTION·REASSEMBLY
(4Y (STD), 1DZ-III, 3Z) 13.. 9
DISASSEMBLY·iNSPECTiON·REASSEiviBLY
(4Y (Cabin Spec., Low Noise Spec.)) 13..13
D ISASSEM BLY·INS PECTION ·REASS EM BLY
(Wet Brake Spec.) 13..17
PERFORMANCE TEST 13..23
13-2

GENERAL
4Y (STD), 1DZ-III, 3Z

4Y (Cabin Spec., Low Noise Spec.)

 13-3

Wet Brake S pec.

L
r
('j----=~L11d9iL _ ir:=--=<::=I --- -C--
--=:h -~

~ttD:[:~t~e-c- .
\

____l__ ~_r=----l------~-I
I

E
13-4

SPECIFICATIONS
Dry Brake Spec.
Theoretical
Vehicle model Engine Specifica tion Maker (Model) Pump type discharge
cm 3 (in 3 ) /rev
-- -------------+----------+-------------t---=---==--c---::-~____j
STD KYB (KFS23) Gear pump/single gear 257 (1.568)
4Y r--;------- .---
1 ton series _____ LCabln spec-Low nOise spec. I- KYB (DGP23) Gear pump/double gear 250 (1.526)

---------+·----t----
K2 ton series
lOZ-1I1

4Y -
STD
, Cabin spec-Low noise spec
-r--KYB(KFS23)-
--
KYB (DGP23)
KYB (KFS23) Gear pump/single gear
Gear pump/single gear
Gear pumpfdoubie gear
257 (1568)
278 (1696)
--
26.5 (1 617)
_---L _ .__.. _
lOZ-111 KYB (KFS23) Gear pump/single gear 278 (1.696)
--------~~/-l STD. KYB (KFS23) Gearpumpi~,~-gear 278 (1_~
;; ton series __ L~abin spec-Low nOise spec KYB (DGP2_3) Gear pump/double gear 26.5 (1617)
lOZ-111 KYB (KFS23) Gear pump/single gear 278 (1696)
--- -._--------
3Z KYB (KFS23) Gear pump/single gear 32_8 (2002'
---------+---
1~4Y STD KYB (KFS23) Gear pump/single gear 29.4 (1~

3 ton series
Cabin spec-Low lIoise spec KYB (DGP23)
- - - - - ' - - - - - - - - - - - - - - - + - - - - - ---_.
Gear pump/double gear
.-.-
I 286 (1745)
- - - - - - - - - - - ... - - - -
I
i lDZ-111 KYB (KFS23) Gear pump/single gear 278 (1.696)
r------------- ------1-------.--.--- - - - - - - - - - - -
3Z KYB (KFS23) Gear pump/single gear 32_8 (2.002)
I 4Y t STD -----_-_-_t-f---_-_K=Y=B==(K==F=S_23) Gear pump/single gear 294 (17_~
J3 5 ton series I~ _ _ LCabin spec-Low noise spec KYB (DGP23) Gear pump/d~ubl~ge~~__
2 _8_.6_(_1~
I 3Z KYB (KFS23) Gear pump/single gear 328 (2002)

Wet Brake Spec.

Vehicle model Engine Maker (Model) Pump type Theoretical discharge cm 3 (in 3 ) /rev

~ .. _- -- .
4Y KYB (KFS23-9C) Gear pump/tandem gear Main 27.8 (1696) /Sub 94 (0574)
2 ton series lOZ-111 KYB (KFS23-9C) Gear pump/tandem gear Main 27_8 (1696) /Sub 94 (0.574)
3Z KYB (KFS23-9C) Gear pump/tandem gear Main 312 (1904) /Sub 94 (0_574)
4Y KYB (KFS23-9C) Gear pump/tandem gear Main 294 (1794) /Sub 94 (0_574)
3 ton series lOZ-111 KYB (KFS23-9C) Gear pump/tandem gear Main 278 (1696) /Sub 94 (0574)
3Z KYB (KFS23-9C) Gear pump/tandem gear Main 312 (1904) /Sub 94 (0_574)
4Y KYB (KFS23-9C) Gear pump/tandem gear Main 294 (1794) /Sub 94 (0574)
J3.5 ton series
3Z KYB (KFS23-9C) Gear pump/tandem gear Main 312 (1904) /Sub 94 (0574)
COMPONENTS
4Y (STD), 1DZ-III, 3Z

6701
01

10
~ I BG

(~~
01K

~,' 'I
"<:dr---Lj

10
i

1.. ...... _ - .. --~

6701-220

4Y (Cabin Spec., Low Noise Spec.)

6701
01

III
136

Wet Brake Spec.

6701

01

L.. __ _ _._.J:
6701-222A
 13-7

OIL PUMP ASSY

REMOVAL·INSTALLATION (Dry Brake Spec.)

T " Nm (kgf·cm) [ftlbf]

"..t::moval Procedure
Open the engine hood.

2 Remove the toe board.

3 Remove the RH rear tire cover.

4 Remove the air cleaner.

5 Disconnect the outlet hose.

6 Disconnect the inlet hose at the tank side.

7 Remove the oil pump ASSY W/ inlet hose.

8 Remove the oil pump gasket.

9 Remove the inlet hose from the oil pump ASSY.

10 Remove the fitting from the oil pump ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease (molybdenum disulfide grease) on the pump shaft spline section before installation.
13-8

REMOVAL-INSTALLATION (Wet Brake Spec.)

T = N·m (kgf-cm) [ftlbf]

Removal Procedure
1 Open the engine hood

2 Remove the toe board.

3 Remove the RH rear tire cover.

4 Remove the air cleaner.

5 Disconnect the outlet hose.

6 Disconnect the inlet hose at the tank side

7 Remove the oil pump ASSY W/ inlet hose

8 Remove the oil pump gasket.

9 Remove the inlet hose from the oil pump ASSY

10 Disconnect the brake cooling hose.

11 Remove the fitting from the oil pump ASSY

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply grease (molybdenum disulfide grease) on the pump shaft spline section before installation.
 13-9

DISASSEMBLY·INSPECTION·REASSEMBLY (4Y (STD), 1DZ-III, 3Z)

T = N·m (kgf·cm)[ft·lb~

4
4

T = 88 - 98
(900 - 1000)
[6492 - 7230]

Disassembly Procedure
1 Out match marks on the cover, gear plate and mounting flange

Remove the cover. [Point 1]

3·,~emove the plate seal, back up, and dowel pin [Point 2]

4 Remove the side plate, drive gear and driven gear. [Point 3}

5 Remove the gear plate. [Point 4]

6 Remove the plate seal, back up, and dowel pin. [Point 2]

7 Remove the oil seal. [Point 5]

8 Inspect the cover and mounting flange. [Point 6]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Use new seals for reassembly.
• Apply the hydraulic oil before reassembly.
13-10

Point Operations
[Point 1]

Reassembly:
Intake side The reassembly procedure is as follows.

1. Temporarily tighten the through bolt to the specified torque

below.
T =2_0 - 4.9 N-m (20 - 50 kgf'cm) [1.45 - 3_62 ft-Ibf]

2 As shown in the illustration, place the oil pump ASSY with the
intake side facing upward and keep the pump horizontal with
wooden blocks placed under the mounting flange and cover
Tap the gear plate using a plastic hammer to slide the gear
plate
3. Secure the pump in a vise and tighten the through bolt to the
proper torque.

Bushing [Point 2]
Back up
Reassembly:
\ /
/ The plate seal and back up are not to protrude from the cover

¥' __
\ / or the bushing of the mounting flange.
\ I Not to protrude

I---·~I ~', ~
I '

"

Plate seal

[Point 3]

Inspection:
Measure the side plate thickness.

Limit: 2.927 mm (0.1152 in)

Inspection:
Inspect traces of contact with the side plate.
Intake side Standard:
There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.
 13-11

Reassembly:
Intake side Install with the copper alloy side facing towards the inside of
the pump. Also, be careful not to mistake the direction of the
intake side and discharge side when assembling.

Disassembly:
Put match marks on the teeth of the drive and driven gears

Reassembly:
Align match marks at the time of reassembly

Inspection:
Measure the outside diameter of each gear shafL

Limit: 20.99 mm (0.8264 in)

\
[Point 4]

Inspection:
Inspect the gear plate inside surface (intake chamber side) for
traces of contact with the gears.

Standard:
The traces of contact should not exceed half of the
circumference.

Inspection:
Trace of contact Measure the depth of the flaw at the gear plate inside surface

Limit: 0.20 mm (0.0079 in)

Reassembly:
Do not get the direction confused.
13-12

[Point 5]
Flat head screwdriver Disassembly:
Use a flat head screwdriver to prise it off

Reassembly:
SST 09950-76018-71 .. .... (1 )
(09950-60010)
09950-76020-71 .. (2)
(09950-70010)

Apply MP grease on the oil seal lip section after reassernbly

[Point 6]
Inspection:
Inspect for wear on the inside surface ot the bearing section of
the cover and mounting flange.

Standard:
The area of bare metal exposed (calor = reddy copper
calor) should not exceed 150°.
 13-13

DISASSEMBLY·INSPECTION·REASSEMBLY (4Y (Cabin Spec., Low Noise Spec.»

T = N m (kgf·cm) [ftlbt]

1 ·7

T = 88 - 98
(900 - 1000)
[65.1 - 724]

Disassembly Procedure
1 Put match marks on the cover, body and mounting flange.

Remove the cover [Point 1]

:5 Remove the plate seal, back up, and dowel pin. [Point 2]

4 Remove the side plate, rear drive gear and rear driven gear. [Point 3]

5 Remove the center bushing. [Point 4]

6 Remove the side plate, front drive gear and front driven gear. [Point 3]

7 Remove the body [Point 5]

8 Remove the plate seal, back up, and dowel pin. [Point 2]

9 Remove the oil seaL [Point 6]

10 Inspect the cover and mounting flange. [Point 7]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Use new seals for reassembly.
• Apply the hydraulic oil before reassembly.
13-14

Point Operations
[Point 1]

Reassembly:
Intake side The reassembly procedure is as follows.

Temporarily tighten the through bolt to the specified torque

below.

r---------'------'r-,-~Discharge side T =2.0 - 4.9 N'm (20 - 50 kgf'cm) [1.45 - 3.62 ft'lbf]

2 As shown in the illustration, place the oil pump ASSY with the
intake side facing upward and keep the pump horizontal with
wooden blocks placed under the mountlflg flange and cover.
Tap ttJe body using a plastic hammer to slide the body.

3 Secure the pump in a vise and tighten the through bolt to the
proper torque.

Bushing [Point 2]
Back up
I Reassembly:
I
The plate seal and back up are not to protrude from the cove.
/
~-~r~-'l ( "'\ 1--- Nollo protrude
or the bushing of the mounting flange

! r,~~···-
Plate seal

[Point 3]

Inspection:
Measure the side plate thickness.

Limit: 2.927 mm (0.1152 in)

Inspection:
Inspect traces of contact with the side plate.
Inlake side Standard:
There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.

Contact area
 13-15

Reassembly:
Install with the copper alloy side facing towards the inside of
the pump. Also, be careful not to mistake the direction of the
intake side and discharge side when assembling.

Disassembly:
Put match marks on the teeth of the drive and driven gears

Reassembly:
Align ITlatch marks at the time of reassembly.

Match marks

Inspection:
Measure the outside diameter of each gear shaft.

Limit: 20.961 mm (0.8252 in)

Intake side
u
lhiCkno
[Point 4]

Inspection:
Inspect traces of contact with the center bushing.
Standard:
There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.

Inspection:
Inspect the thickness of the center bushing.

Limit: 41.38 mm (1.6291 in)

Inspection:
Inspect for wear on the inside surface of the bearing section of
the center bushing.

Intake Standard:
side The area of bare metal exposed (color = reddy copper
color) should not exceed 150°.
13-16

Reassembly:
Intake side Reassemble 2 center bushings simultaneously, paying
attention to their direction.

[Point 5J

Inspection:
A Inspect the body inside surface (intake side) for traces of
Intake side contact with the gears

Standard:
The traces of contact should not exceed half of f
circumference

Inspection:
Measure the depth of the flaw at the body inside surface.

Limit: 0.2 mm (0.0079 in)

Reassembly:
Flat head screwdriver Do not get the direction confused

[Point 6]

Disassembly:
Use a flat head screwdriver to prise it off.

SST 09950-76018-71 (1)

(09950-60010)
09950-76020-71... (2)
(09950-70010)

Apply MP grease on the oil seal lip section after reassembly.

~ SST(2)
~/

[Point 7J

~
~ Bearing
\1 ~~/ section Inspection:
1500~~/ Inspect for wear on the inside surface of the bearing section of

~~~i)Y~;
the cover and the mounting flange.

Standard:

(~(~(
Intake // ,
chamber
The area of bare metal exposed (calor = reddy copper
calor) should not exceed 150 0.
150o_~

~
 13-17

DISASSEMBLY·INSPECTION·REASSEMBLY{Wet Brake Spec.)

r = N'm (kgf-cm) [ft'lbf]

T = 88 - 98
(900 - 1000)
[651 - 72.4J

12

" ,
I
4 ~",
. J

Disassembly Procedure
1 Secure the mounting flange in a vise and put match marks. [Point 1J
2 Remove the cover and dowel pin. [Pont 2J
Remove the plate seal and backup. [Point 3J
,., ',Remove the side plates, rear drive gear and driven gear. [Point 4J
5 Remove the rear body, snap ring and oil seals [Point 5J
6 Remove the spline cup ring, bushing and O-ring
7 Remove the cover plate and dowel pin.
8 Remove the plate seal and backup. [Point 6J
9 Remove the side plates, front drive gear and driven gear. [Point 7J
10 Remove the gear plate and dowel pin. [Point 8]
11 Remove the plate seal, backup and dowel pin. [Point 9J
12 Remove the snap ring and oil seal. [Point 10]
13 Inspect the cover, cover plate and mounting flange. [Point 11J

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Be sure to use new seals.
• Be sure to apply hydraulic oil before reassembly.
13-18

Point Operations
[Point 1]

Disassembly:
Put match marks on the cover, rear body, cover plate, gear
plate and mounting flange.

[Point 2]

Reassembly:
The reassembly procedure is as follows
Intake side
1. Temporarily tighten the through bolt to the specified torque
below

T = 2.0 - 4.9 N'm (20 - 50 kgf'cm) [1.45 - 3.62 ft'lbf]

Discharge side 2 As shown in [t,e illustration, place the oil pump ASSY with the
IIltake side facing upward and keep the pump horizontal with
wooden blocks placed under the mounting flange and cover.
Tap the body using a plastic hammer to slide the gear plate.

3 Secure the pump in a vise and tighten the through bolt to the
proper torque

[point 3]
Bushing
Back up Reassemb!y

--+FLl,-
\ /
'X
~-,----
No protrusion
00 not allow the plate seal and backup to protrude from the
cover or seal groove.

"
,
"\.".,
Plate seal

[Point 4]

Inspection:
Measure the Side plate thickness.

Limit: 2.927 mm (0.1152 in)

 13-19

Inspection:
Inspect traces of contact with the side plate.
Intake side Standard:
There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.

Contact area

Reassembly:
Intake side
Install witr-, trle copper alloy side facing towards the inside of
the pump Also, be careful not to mistake the direction of the
intake side and discharge side when assembling

Reassembly:
Intake side Intake side Be sure to install the front side plate and rear side plate to the
correct positions

Discharge side Discharge side

For front pump For rear pump

Inspection:
Inspect the outside diameter of the front drive gear shaft and
driven gear shaft.

Limit: 20.99 mm (0.8264 in)

Disassembly:
Put match marks on the tooth faces of the rear drive gear and
driven gear.

Reassembly:
Align match marks at the time of reassembly.
13-20

[Point 5J

Inspection:
Inspect the body inside surface (intake side) for traces of
contact with the gears.
Standard:
The traces of contact should not exceed half of the
circumference

Inspection.
Measure the depth of the flaw at the body inside surface.

Limit: 0.2 mm (0.0079 in)

Reassembly:
Do not get the direction confused

SST 09950-76018-71. .. (1 )
(09950-60010)
09950-76020-71 .... ...... (2)
(09950-70010)

Apply MP grease on the oil seal lip section after reassembl;·

Reassembly

-
Oil seal
....•. ~
Install the oil seals and snap ring as shown in the illustration.

Bushing [Point 6J
Back up
Reassembly:
Do not allow the plate seal and backup to protrude from
No protrusion cover or seal groove.

""
Plate seal

[Point 7J

Inspection:
Measure the side plate thickness.

Limit: 2.927 mm (0.1152 in)

 13-21

Inspection:
Inspect traces of contact with the side plate.
Intake side Standard:
There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.

Contact area

Reassembly:
Intake side install with the copper aiioy side facing towards the inside of
the pump Also, be careful not to mistake the direction of the
Intake side and discharge side when assembling.

Discharge side

Reassembly:
Intake side Intake side Be sure to install the front side plate and rear side plate to the
correct positions.

OBO
Discharge side Discharge side

For front pump For rear pump

Disassembly:
Put match marks on the tooth faces of the rear drive gear and
driven gear

Reassembly:
Align match marks at the time of reassembly.

Inspection:
Inspect the outside diameter of the front drive gear shaft and
dnven gear shaft.

Limit: 20.99 mm (0.8264 in)

13-22

[Point 8J
Inspection:
Inspect the body inside surface (intake side) for traces of
contact W,Ul the gears.

Standard:
The traces of contact should not exceed half of the
circumference

Inspection:
Measure the depth of the flaw at the body inside surface

Limit: 0.2 mm (0.0079 in)

Reassembly:
Bushing
Back up Do not get the direction confused.

/ [Point 9]

10:
Do not allow the plate seal and backup to protrude from tr-
( No protruSion
cover or mounting flange bushing.

I ",

PI;)le s8al

[Point 10J
Flat head screwdriver
Oil seal Disassembly:
Use a flat head screwdriver to prise it oH.

SST 09950-76018-71 (1 )
(09950-60010)
09950-76020-7'1 . . (2)

c;~!
(09950-70010)

Apply MP grease on the oil seal lip section after reassembly

__ SST(I)

SST(2) '-' ~

[Point 11J
Bearing
section Inspection:
Inspect the bearing contact surfaces of the cover, cover plate
and mounting flange for wear.
Standard:
The area of bare metal exposed (calor = reddy copper
calor) should not exceed 150°.
 13-23

PERFORMANCE TEST
As the performance test in servicing of the oil pump, judge the quality by the lifting speed of the fork by installing the
oil pump on the vehicle Bench test measurements shall be made for strict testing of the performance.

Note:
The engine rpm and relief pressure shall be adjusted to satisfy respective standards.
(See the engine rpm adjustment procedure on page 1-14, and the relief pressure adjustment procedure on
page 14-47.)

1. Set the engine tachometer

2 Operate the oil pump for running tn

Note:
• Do not operate material handling levers.
• Immediately stop the engine if any abnormality is observed.

(1) Start the engine and operate at the idling speed to 1,000 rpm for 10 minutes

(2) If no abnormality is found in the oil pump, operate for another 10 minutes by raising the engine speed to
1,500 to 2,000 rpm_

Measure the full-stroke lifting time of the lift cylinder, and calculate the lifting speed for performance judgment

Lifting Speed
I , l i l t Ill) ,l 1_( I J- Ud ) III III ~t;L,. ~ I Ill)

I
"'::'
1
Vehicle model
,,,,,me Iype ~,,~,:~~;~o~~l,,:,::: to"~~:i';:~ 7'~~ '0'" I
Foil , : : : m~:lload
c----- 4Y__ ~~_~3~~~~~ 620 (122) 635 (125) 615 (121) 630 (124) ~ ~

1 ton series
lOZ-111 \ 650 (128) 675 (133) 620 (122) 650 (128) 600 (118) 640 (126) - ~

~---i----- -
4Y I 600 (118) 640 (126) 560 (110) 600 (118) 560 (110) 600 (118) - ~

K2 ton series
10Z-111 +580 (114) 600 (118) 550 (108) 575 (113) 550 (108) 585(115) - -

I 4Y 1600 (118) !40~~) r-~65 (111) 600 (118) 575 (113) 600 (118) 555 (109) 565 (111)
2 ton series ~OZ-III
j----
1615(121),655(129) 590(116) 630 (124) 600 (118) 640 (126) 575 (113) 615(121)
3Z 1665 ( \ 31) 1700(138) , 640 (126) 670 (132) 650 (128) \680 (134) 625 (123) 655(129)
-- 4y-----rsio (100) 1550 (108) 480(94) 520 (102) 460 (91) 490 (96) 480 (94) 520 (102)
--
, .on series I lOZ-111 I 500 (98) '530 (104) 470 (93) I 500 (98) 445 (88) 480(94) 470 (93) 500 (98)
3Z \ 550 (108) 570 (112) 510 (100) 530 (104) 485 (95) ,510 (100) 510 (100) 530(104)
4Y i 425 (84) 450 (89) 410(81) 440 (87) 440 (87) 460 (91) - -
J35 ton series -~

3Z ., 450 (89) 475 (94) 430 (85) 460 (91) 465 (92) 490 (96) - -
 14-1

OIL CONTROL VALVE

Page

OIL CONTROL VALVE ASSY 14-2

GEN ERAL 14 -2
SPECIFICATIONS 14-7
COMPONENTS 14-8
TROUBLESHOOTING 14-9
REMOVAL-INSTALLATION 14-23
DISASSEMBLY·INSPECTION·REASSEMBLY 14-25
OIL CONTROL VALVE ASSY
(MINI LEVER·JOYSTICK SPECIFICATION) .... 14-30
,...r-NE"""'
\.:JCI
". ~u-
t<AL .•.•••.•.•.•••••••••.•••••.•••••••••.•••••..••.•••••.•••..• 14-j
A •

SPECIFICATIONS 14-35
COMPON ENTS '" 14-36
TROUBLESHOOTING 14-37
REMOVAL·INSTALLATION 14-39
DISASSEMBLY·INSPECTION·REASSEMBLY 14-41
CONTROL VALVE LEVER ASSY 14-46
REMOVAL·INSTALLATION 14-46
RELIEF PRESSURE ADJUSTMENT 14-47 •
MAN UAL DOWN VALVE 14-49
14-2

OIL CONTROL VALVE ASSY

GENERAL

X2 X3

C3

I I
X2 X3
 14-3

Xi-Xi

Flow divider

Relief valve

X2-X2

Flow regulator valve

Lift lock valve
(Lift lock SOL)

, Manual down valve

Lift spool
I
I
Lift limit switch (lifting side) Lift limit switch (lowering side)
14-4

X3-X3

Tilt control valve

(Tilt control SOL)

Tilt spool

Backwa rd tilt limit sWitch Forward tilt limit switch

X4-X4

o
 14-5

Solenoid Connector Diagram

1
B
Unloading solenoid connector

Lift limit switch connector

Till limit switch connector

III
00
14-6

Hydraulic Circuit Diagram

Flow divider valve

Unloading valve
(Unloading SOL) T2 R Gauge port

Lift lock valve

(Lift lock SOL)

Tilt control valve

(Tilt control SOL)

Backward tilt lock valve

(Backward tilt lock SOL)
 14-7

SPECIFICATIONS
----------- Vehicle model 1 .!
Item ~ II 1 ton series 2K2 ton series I 3 Ion sefles J3.5 ton series
---- . ==t--------l-~~,~--~-.--~----.-L~~-__1
Type I Add-on type
--., I ~~--~--~~~~~~~~---j

Relief pressure Lift I 17.8 (182) (2S90Tl 187 (191) (2720]

MP a (kg flc",? ) [psi] "lilt --=_~j 118 (170) [1 j Hifl ST" 13 6 (3 '9 )-1"':'(,,0 1I'-130]_--'-~~~~~~~'~~~~~:-l
Flow divider flow rate .' .. 1 136 (359) 2 Ion series I 15.8 (417)
!lmm (US gal/mm) (Wet brake spec) I 158 (417)
1 158(417) I

FIO~-r-;;~g~JI~l-t-;r flow volume i-- !-------~~-~+--~~~~~---j

. 1/ . (US
. mm
1/ "
ga mln)!
~)O
(132) 65 (172)
."
I 7b 119 8) 85 (22.4)

V
Full load
r-----~----~,
1,'-' 500 (98)-
-------~~-----~,--.-----
500 (98~)---1_-50-0'-(-9--8-)~-+-- 500 (98)
-----.. ----~---I~--~~~~~l
No load i 550 (108) 500 (98) 500 (98) 450 (89)
I Full load f--- 480 ~ 480-(94)- ----1"- -460-(-91)-- ~460(91)-

-~~c~;:~,;,,;~,eo ~~II'~:'~rl ----~~(:~)) ~t --~:~~ ((~:J)=-~~:~~ ((~~,)-- - ~:~ ( :~)

SV
I L I
I-_
'1I

mm/sec (fpm) 1, F..V

_
... _.._..
__ No load I 420 (83) --~I ~- -.:39.0(77)
__-- 42083) (7i~ 390
1
I FSVV
Full load I
+--~~~~-T~~'~~~~-+-'--~--~---'-
-- 2 tall series 480 (94) I 460 (91)
~---~---~~t---~--~
I -
I No load I - 2 ton series 4~)0 (89) i 420 (83) i -
14-8

COMPONENTS

6705

6705-878
TROUBLESHOOTING
Note:
For the positions of (1) - (16) in the table, refer to page 14-21 - 22.
Operation Phenomenon Probable cause Inspection item

During steering Cannot turn the Flow divider valve piston seizure • Whether the flow divider can be removed
operation steering • Whether there are allY scratches on the flow divider
• Whether foreign matter is stuck in the flow divider

Steering is heavy Flow divider valve piston malfunction • Whether there are any scratches on the flow divider
• Whether foreign matter is stuck in the flow divider
Insufficient spring force of the flow divider return spring • Whether the return spring is not broken
• Whether the return spring base surface is worn
• Whether the stopper (plug) base surface at the return spring
side is worn
During lift operation Cannot lift Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure

Uo[oed SOL 'tcok opeo =t~Whethe' yac 0" he" the apeeet"9 wc od of the wleoolC
when operating the lever with the key sWitch ON
Manual down valve IS loose • Whether the manual down valve IS tlghtenea
Load pressure detection CIrCUit check valve (2) stuck closed • Not pOSSible to Inspect
ILift by-pass check valve (1) stuck closed 1· Whether the 11ft by-pass check valve and lift lock plunger can
I and the lift lock plunger stuck closed I be removed
I • Whether there are any scratches on the 11ft by-pass check
I valve and lift lock plunger
I
• Whether foreign matter is stuck in the lift by-pass check
valve or lift lock plunger
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve

....>.
..j:>.
I
to
 ---"
Operation Phenomenon Probable cause Inspection item ~
I
---"
During lift operation Lift speed is slow Relief valve main plunger malfunction • Whether there are anv scratches on the relief valve main o
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter Is attached to the filter section
Unload SOL seat defect • Not possible to inspect
Manual down valve is loose • Whether the manual down valve is tightened
-
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
--
Load pressure detection circuit check valve (2) malfunction • Not possible to inspect
Lift by-pass check valve (1) malfunction • Whether there are any scratches on the lift by-pass check
valve
1 • Whether foreign matter is stUck in the 11ft by-pass check
valve
I
Lift lock plunger malfunction 1· Whether there are any scratches on the lift lock plunger
Load check valve malfunction
------

-
J. I • Whether foreign matter is stuck in the lift lock plunger
I

Whether there are any scratches on the load check valve

• Whether foreign matter is stuck in the load check valve
Lift spool malfunction • Whether the lift spool strokes as required
Standard: 8 :t 0.4 mm (0,31 :t 0.016 in)
Cannot lower Lift lock plunger stuck closed • Whether the lift lock plunger can be removed
• Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
Foreign matter is stuck in the lift lock plunger orifice (5) • Whether foreign matter is stuck in the lift lock plunger orifice
Lift lock SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
 4i
Operation Phenomenon Probable cause Inspection item

During lift operation Cannot lower Lift spool <,luck closed • Vvnether the lift spool can be operated
(Whether the lift lever can be operated)
I Low"icg 0o",lioo d,lodioD limit ,witoh ,leo' opec oc --. Umil ,witch oocI'ooily ,,,peelioc .--
damaged
Foreign matter is stuck in the lift lock valve pilot circuit (4) • Whether foreign matter is stuck in the lift lock valve pUot
circuit
Lowering speed is slow I Lift lock plunger malfunction • Whether there are any scratches on the lift lock plunger
Whether foreign matter is stuck in the lift lock plunger
Foreign matter is stuck in the lift lock plunger orifice (5) • Whether foreign matter is stuck in the 11ft lock plunger orifice
Lift lock SOL malfunction 1• Whether you can hear the operating sound of the solenoid
I I when operating the lever with the key sWitch ON
i • Whether foreign matter is attached to the filter section

Lift spool malfunction twhether the lift spool strokes as require' -------j
1
I Standard: 8 ± 0.4 mm (0.31 ± 0,016 in)
Foreign matter is stuck in the lift lock valve pilot Circuit (4) I • Not possible to Inspect
Flow r'egulator valve piston malfunction I • Whether there are any scratches on the flow regulator valve
piston
\Vhether foceign matte c is stllck in the flow regUlator valve
, piston
I - - - - - - - - - - .- - :------------- -----~--.- . - - - - - - - - - - - - . - - - -
Insufficient spring force of the flow regulator valve piston • Whether the return spring IS broken
spring i • Whether the return spring base surface (6) is worn
I During tilt operation ---rcannot tilt forward I Relief valve main plunger stuck open --------i--:-w ----
I • Whether there are any scratches on the relief valve main
I plunger
, • Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve Check the relief setting pressure
Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON

->.
~
I
->.
->.
 Operation Phenomenon Probable cause Inspection item .....
,l::.
I
Cannot tilt forward Tilt control valve plunger stuck closed • Whether the tilt control valve plunger can be removed -"
During tilt operation
N
• Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Foreign matter is stuck in the tilt control valve plunger orifice • Whether foreign matter is stuck in the tilt control valve
(7) plunger orifice
Tilt control valve SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Tilt spool stuck closed • Whether the tilt spool can be operated
(Whether the tilt lever can be operated)
Forward tilt detection limit switch stuck open, or damaged • Limit switch continuity inspection
----
,
Foreign matter is stuck in the tilt control valve pilot circuit (8) • Whether foreign matter IS stuck in the tilt control valve pilot
CIrcuit
Tilt lock plunger stuck closed • Whether the tilt lock plunger can be removed
• Whether there are any scratches on the tilt lock plunger
I • Whether foreign matter is stuck in the till lock plunger
-+-
Load pressure detection circuit check valve (9) stuck Close_~-t. Not possible to inspect
----
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Foreign matter is stuck in the orifice (10) of the tilt spool tilt • Whether foreign matter is stuck in the orifice of the tilt spool
lock plunger spring chamber tilt lock plunger spring chamber
Foreign matter is stuck in the tilt spool pilot orifice (11 ) • Whether foreign matter is stuck in the tilt spool pilot orifice
Foreign matter is stuck in the tilt lock plunger pilot orifice (three • Whether foreign matter is stuck in the tilt lock plunger pilot
I places) orifice
Forward tilt speed is Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
slow plunger
• Whether foreign matter is stuck in the relief valve main
plunger
 Operation

During tilt operation

slow
Phenomenon

Forvvard tilt speed is - Probable cause

Insufficient spring force of the relief valve main plunger return
spring
Relief valve main plunger seat defect
-
11- -
_. Inspection item
~ "nether the return spring is broken
• Whether the return spring base surface is worn
• Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL-operated--------------------~------I·Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
I . Whether foreign matter IS attached to the filter section
----------- ------------ --1------------------------ -
Unload SOL seat defect I • Not possible to inspect
Tilt control valve malfunction
------------------+--
I' Whether there are any scratches on the tilt control valve

I' plunger
Whether foreign matter is stuck in the tilt control valve
plunger
Foreign matter is stuck in the tilt control valve plunger orifice I' Whether foreign matter is stuck in the tilt control valve
(7) I plunger orifice
Tilt control valve SOL malfunction
._--
-----1------------- --------
, • Whether you can hear the operating sound of the solenoid
I when operating the lever with the key switch ON
I • Whether foreign matter is attached to the filter section
Tilt spool malfunction !. Whether the tilt spool strokes as ~equired
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Foreign matter is stuck in the tilt control valve pilot circuit (8) • Whether foreign matter is stuck in the tilt control valve pilot
circuit
--------
Tilt lock plunger malfunction • Whether there are any scratches on the tilt lock plunger
· Whether foreign matter is stuck in the tilt lock plunger
Foreign matter is stuck In the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve (9) malfunction • Not possible to inspect
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Foreign matter is stuck in the orifice (10) of the tilt spool tilt • Whether foreign matter is stuck in the orifice of the tilt spool
lock plunger spring chamber tilt lock plunger spring chamber
1

Foreign matter is stuck In the tilt spool pilot orifice (11) • Whether foreign matter is stuck in the tilt spool pilot orifice

.p..
1
~

W
 Probable cause Inspection item -'
Operation Phenomenon +:>
I
During tilt operation Forward tilt speed is Foreign matter is stuck in the tilt lock plunger pilot orifice (three • Whether foreign matter is stuck in the tilt lock plunger pilot -'
+:>
slow places) orifice
Cannot tilt backward Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
I, ,,,mcieol selti'9 pcessuce uf Ihe cellef " , " • Check the relief setting pressure
I Unload SOL stuck open -- • Whether you can hear the operating sound of the solenoid
I when operating the lever with the key switch ON
I - I --
IBackward tilt lock valve pIIJngtYstUckc:lo-se-cf : • Whether the backwar'd tilt lock valve plunger can be
I removed
I
I I • VVhethe r there are anv scratches on the backward lilllock
I I
I valve plunger
i . Whether foreign matter is stuck In the backward lilllock
valve plunger
Foreign matter is stuck in Ihe backward tilt lock valve Plun:j • Whether foreign matter is stuck In the backward tilt lock
orifice (12) valve plunger orifice
Backward tilt lock valve SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Tilt spool stuck closed • Whether the tilt spool can be operated
(Whether the tilt lever can be operated)
Backward tilt detection limit switch stuck open or damaged • Limit switch continuity inspection
Foreign matter is stuck in the backward tilt lock valve pilot • Whether foreign matter is stuck in the backward tilt lock
circuit (13) valve pilot cirCUit
Load pressure detection circuit check valve stuck closed • Not possible to inspect
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the ioad check valve
Backward tilt speed is Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
slow plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
 Operation
- I -
Phenomenon probable cause I Inspection item
During jilt operation Backward tilt speed is
slow
Reiief valve main plunger· seat defect
----1'
j. VVhe'hec thecc ecc eoy "cakhoo oc ,hippleg at the lip pf the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve .. _._. --··1 ~-Ch;;~k-the-r~ii~f settl~gpress~re
Unload SOL malfunction T Whether you can hear the operating sound of the solenoid
I I when oper;]tlng the lever with the key SWitch ON
i, • Whether matter is attached to the filter section
--'---~------~~-"'~----~-'-~---'---'-'-- - - .~ --+------ --_._- -_._-_._------~-----_._------------

Unload SOL seat defect I . Not [lOssl"le to Inspr;ct

Backward tilt lock valve malfunction
----_·1-------------_··_-
, • Whether there are any scratches on the backward tilt lock
valve piu nger
• Whether foreign matter is stuck in the backward tilt lock
valve plunger
Foreign matter is stuck in the backward lift lock valve plunger • Whether foreign matter is stuck in the backward tilt lock
orifice (12) valve plunger orifice
Backward tilt lock valve SOL malfunction [ • Whether you can hear the operating sound of the solenoid
I when operating the lever with the key switch ON
I • Whether foreign matter is attached to the filter section
Tilt spool malfunction • Whether the tilt spool strokes as required
Standard: 8 ± 0.4 mm (0,31 ± 0.016 in)
Foreign matter is stuck in the backward tilt lock valve pilot • Whether foreign matter is stuck in the backward tilt lock
circuit (13) valve pilot circuit
Foreign matter is stuck in the load pressure detection circuit I • Whether foreign matter is stuck in the load pressure
I detection CirCUit
I Load pressure detection circuit check valve malfunction i . Not pOSSible to inspect
- !
Load check valve malfunction I • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Key switch OFF Natural drop is big Lift lock plunger seat malfunction • Whether there are any scratches on the seat surface
• Whether foreign matter is stuck on the seat surface
Lift lock plunger stuck open • Whether the lift lock main plunger can be removed
! . Whether there are any scratches on the lift lock main
I plunger
I
i • Whether foreign matter is stuck In the lift lock main plunger
Insufficient spring force of the lift lock plunger return Spri~g-r Whether the return spring is broken
I • Whether the return spring base surface is worn

.....
.p..
.....
I

(Jl
 -.l.
Operation Phenomenon Probable cause i Inspection item .j:;:.

Key switch OFF Natural drop is big Lift by-pass check valve seat defect i . Whether there are any scratches on the seat surface I
-.l.
Ol
I . Whether foreign matter IS stuck on the seat surface
Lift by-pass check valve plunger stuck open • Whether the lift by-pass check valve plunger can be
removed
• Whether there are any scratches on the lift by-pass check
I valve plunger
• Whether foreign matter is stuck in the lift by-pass check
valve plunger
-
Insufficient spring force of the lift by-pass check valve retUrll • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Manual down valve is loose • Whether the manual down valve is tightened
Lift lock SOL seat defect I • Not possible to inspect
-----------_._-. I
Lift lock SOL stuck open I • Whether you can hear the operating sound of the solenoid
I
when operating the lever with the key switch ON
I
Lowering operation detection limit sWitch stuck closed. ~~---r Lim·lt switch continUity inspection
damaged I

Wear or damage of the flow regUlator valve sleeve (14) or • Whether the sleeve or a-ring is worn or damaged
O-ring No.2 (16)
Natural forward tilt is Tilt control valve plunger seat defect • Whether there are any scratches on the seat surface
big • Whether foreign matter is present on the seat surface
Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
I plunger
• Whether foreign matter IS stuck in the tilt control valve
plunger
I
 Operation Phenomenon Probable cause 1 - Inspection item
Key switch OFF Natural forvvard tilt is Insufficient sprin\:j force of the tilt control valve plunger return 1 ';vhether the return spnng IS broken
big spring I ' Whether the return spring base surface IS worn
Tilt control valve check ball seat defecl-I~N~posslble(; inspect I
Tilt control valve check ball stuck open---r.vih;ill;e-~th8-c~allm;ve~when pressed
Insufficient spring force of the tilt control valve check bal; , Whether there is a spring reactive force when the check ball
return spring is pressed
Tilt control valve SOL seat defect I • Not possible to inspect
Tilt control valve SOL stuck open ------1. Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
I

Forward tilt detection limit switch stuck closed, or damaged I • Limit switch continuity inspection
Forvvard tilt automatic Does not stop Tilt control valve plunger seat defect I . Whether there are any scratches on the seat surface
leveling stop automatically • Whether foreign matter is present on the seat surface
Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
plunger
, Whether foreign matter is stuck in the tilt control valve
I plunger
I Insufficient spring force of the tilt control valve plunger retu~ • Whether the return spring IS broken
spring I ' Whether the return spring base surface worn
Tilt control valve check ba~1 seat defec: =-=-_~~: ~ ~_~t poss~eto-:~sPec.t--------~---~---- -
IS

--=1
Tilt control valve check ball stuck open ' • Whether the check ba'l moves when pressed
Insufficient spring force of the tilt control valve ~heck bal;- -----~-Whetheru:-;e;~TS8springreactive force when the cheCk ball
return spring , IS pressed
I Tilt control valve SOL seat defect • Not possible to Inspect
ITilt control valve SOL st~ck open I' Whether you can hea-r-th-e-o-p-e-ra-t-In-g-s-o-u-n-d-o-f-th-e-s-o-l-e-n-o-Id---J1
when operating the lever with the key switch ON
Backward tilting speed Speed is fast Tilt control valve malfunction -VWhether there are any scratches on the tilt control valve
regUlation plunger
, Whether foreign matter is stuck in the tilt control valve
plunger

.....
.,f::.
.....I
'"'-l
 ->.
Operation Phenomenon Probable cause - I Inspection item
~
--t~whether the
I
.---- till control valve plunger can be removed ->.
Backward tilting speed Speed is fast Tilt control valve plunger stuck open
co
regulation I ' Whelher there are any scratches on the tilt conlrol valve
! plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Tilt control valve SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Foreign matter is stuck in the tilt control valve pilot circuit ' Whether foreign matter is stuck in the tilt control valve pilot
i cirCUit
.---!
During ATT operation ATT does not move I Relief valve main plunqer stuck open
I ~
I' Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
I
, plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
, ATT spool stuck closed ' Whether ATT spool can be operated
(Whether ATT lever can be operated)
-~
Load pressure detection circuit check valve stuck closed ' Not possible to inspect
Load check valve stuck closed ' Whether the load check valve can be removed
i' VVhether there are any scratches on the load check valve
I • VVhether foreign malt er is stuck in the load check valve
~._._-_._-----~----- -_._....._.. _--_._-_ ..._. . . . --_. . . _ . - ---"-"- ... - ...... -~--_._-_._._-~------_.- -------------

ATT movement is slow ,Relief valve main plunger malfunctioll I • \Nhether there are any scralches on the relief valve main
I I plunger
i. Whether foreign matter is stuck in the relief valve main
I plunger

'"offi,i,,! ,pcl,g locoe of the 'etief " , " mei, p'"ger "~ Whether the '''om ,pli'g i' brokec
spring , Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
I
main plunger
, Whether there are any scratches or chipping on the seat (3)
Insufficient- settilig pressure of the relief valve ' Check the relief setting pressure
 Operation Phenomenon
--
- Probable cause =T. - Inspection item
During ATT operation ATT movement is slow Unload SOL malfunction : • Whether you can hear the operating sound of the solenoid
- + E n operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
f---
Unload SOL seat defect I • Not possible to inspect
ATT spool malfunction • Whether ATT spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve malfunction • Not possible to inspect
Load check valve malfunction • Whether there are any scratches on the load check valve
1 • Whether foreign matter is stuck in the load check valve
During OPS operation Does not lift and stop Relief valve main plunger stuck closed -l . Whether the l'el18f valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Unload SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
I
Does not lower and Lift lock plunger stuck open I • Whether the lift lock plunger can be removed
stop • VVhether there are any scratches on the lift lock plunger
I
• Whether foreign matter is stuck in the lift lock plunger
Foreign matter is stuck in the lift lock plunger orifice • Whether foreign matter IS stuck in the lift lock plunger orifice
Lift lock SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
---~

Foreigll matter is stuck in the lif1 lock valve pilot Circuit • Whether foreign matter is stuck in the lift lock valve pilot
circuit
--- _._------_._-- --_.. - -----
Wear or damage of the flow regUlator valve sleeve (14) or • Whether the sleeve or O-ring IS worn or damaged
O-ring No2 (16)
----
Does not tilt forward Tilt control valve plunger seat defect • Whether there are any scratches on the seat surface
and stop • Whether foreign matter is present on the seat surface

.I::-
I
......\,

<.0
 Operation Phenomenon Probable cause Inspection item -'"
.j::>.
1
During OPS operation Does not tilt forward Tilt control valve plunger stuck open I . Whether the tilt control valve plunger can be removed N
o
and stop I • Whether there are any scratches on the till control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Insufficient spring force of the tilt control valve plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Tilt control valve check ball seat defect • Not possible to inspect
Tilt control valve check ball stuck open • Whether the check ball moves when pressed
Insufficient spring force of the tilt control valve check ball
• Whether there is a spring reactive force when the check ball
return spring I is pressed
I-c-c-:------,----,---,------~----~-.----!
Tilt control valve SOL seat defect
Tilt control valve SOL stuck open ------~i .
- - - - - - - - - - - - - - - - - - - . - - - -------1
I • Not possible to inspect
Whether you can hea-r-t-h-e-o-pe-r-a-ti-ng sound of the solenoid
when operating the lever with the key switch ON
Does not tilt backward Backward tilt lock valve plunger seat defect • Whether there are any scratches on the seal surface
and stop • Whether foreign matter is present on the seat surface
Backward tilt lock valve plunger stuck open I • Whether the backward tilt lock valve plunger can be
1 removed
1
• Whether there are any scratches on the backward tilt lock
! valve plunger
• Whether foreign matter is stuck in the backward tilt lock
valve plunger
Insufficient spring force of the backward tilt lock valve plunger • Whether the return spring is broken
return spring • Whether the return spring base surface is wom
Backward tilt lock valve SOL sluck open • Whether you can hear the operating sound of the solenoid
when operating the lever With the key switch ON
ATT does not stop Relief valve main plunger stuck closed • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Unload SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
 ( 1)
/

o
14-22

[
oJ

fuu~
I L_
(4)

H-- _.~uuuu~
L
-----t- - uu:::-<:>
"W)
- u :~:; --j~I---

:
_~~ ~lj~:
I , ,
1

_~/\J\/..~,
I : '
', , ,
--~T' u_u r~V
I
'I _ _ _ _ _ _ _ _ _ _ _-
I L_ _ :
:11

i,
I

1 1

I 1
I
1
1

11i><J ~u. .-:. ~~---~------=------~----l__1_- _

1 1
I 1
1 I
1 1
 14-23

REMOVAL-I NSTALLATION
T = Nm (kgfcm) [ft·lbf]

Jr
I
I

R. . ~noval Procedure
1 Remove the lower panel and toe board.

2 Remove the instrument panel RH.

3 Disconnect the connector.

4 Disconnect the lever rod.

5 Remove the control valve lever. (Oil control valve ASSY of over fourth-way. See page 14-46, "Control Valve
Lever ASSY"-)

6 Remove the harness bracket.

7 Disconnect all the piping and the load sensor connectors.

8 Remove the oil control valve ASSY WI bracket. [Point 1)

9 Remove the oil control valve.

10 Remove the fitting and load sensor.

14-24

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply chassis grease special to the oil control valve lever linkage.
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced. (See section 16)

Point Operations
[Point 1]

Removal'lnstallation:
For the removal of the oil control valve ASSY W/ bracket for
over fourth-way, use a hoist.
 14-25

DISASSEMBLY·INSPECTION·REASSEMBLY
Note:
• Work in a clean location.
• Since individual parts are finished with high precision, carefully operate so as not to damage them.
T = Nm (kgfcm) [ftlbf]

nisassembly Procedure
I Remove the lift lock SOL and flow regulator valve. [Point 1]

2 Remove the lift limit switch and spring cover. [Point 2]

3 Remove the lift spool. [Point 3]

4 Remove the tilt control SOL [Point 4]

5 Remove the backward tilt lock SOL. [Point 5]

6 Remove the tilt limit switch and spring cover. [Point 6]

7 Remove the tilt spool. [Point 7]

8 Remove the unload SOL [Point 8]

9 Remove the flow divider valve. [Point 9]

10 Remove the relief valve. [Point 10]

11 Remove the attachment valve.

12 Remove the rod bolt, and then remove the housing.
14-26

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.

Point Operations
[Point 1]

Disassembly:
Put match marks to prevent solenoid installation in an Incorrect
position

Reassembly:
Align match marks for reassembly.

Inspection:
Check the lift lock solenoid for continuity

Inspection:
Check and clean any clogged filter.

Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool, etc.

[Point 2]

Inspection:
Check the lift limit switch for continuity.
Lowering side (measurement terminal 1 <=> 2):
No continuity when the switch is pressed.

Lifting side (measurement terminal 3 <=> 4):

No continuity when the switch is pressed

Reassembly:
Be careful not to mistake the lowering side and lifting side.
 14-27

Washer [Point 3]

~- Oisassembly-Reassembly:
Remove the compression spring from the lift spool.

SST 09610-10161-71
Use the SST after attaching a washer.

SST'

[Point 4]

Inspection:
Check the tilt solenoid for continuity

Inspection:
Check and clean any clogged filler

r Inspection:
Check and clean any clogged orifice.

ReassembIy:
Carefully reassemble to prevent incorrect installation of each
solenoid spool.

[Point 5]

Inspection:
Check the backward tilt lock SOL for continuity.
14-28

Inspection:
Check and clean any clogged filter.
Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool.

[Point 6]

Inspection:
Check the tilt limit switch for continuity
Forward tilting side (measurement terminals 1 c:> 2):
No continuity when the switch is pressed.

Backward tilting side (measurement terminals 3 CC> 4):

No continuity when the switch is pressed.
Be careful not to mistake the forward and backward tilt lil·
switches.

[Point 7]

Disassembly-Reassembly:
Remove the compression spring from the tilt spool.
SST 09610-10161-71
Use the SST after attaching a washer.

[Point 8]

Inspection:
Check the unload solenoid for continuity.

Inspection:
Check and clean any clogged filter.
 14-29

[Point 9]
Inspection:
Check and clean any clogged orifice

[Point 10]

Inspection:
Check and clean any clogged filter

Reassembly:
c:_-:-~-- . -=~-=-:J
When the relief valve is disassembled, temporarily install it
. ~~;;.:=--::-~~ after fitting the nuts as illustrated~

a = 27.0 mm (1.06 in)

14-30

OIL CONTROL VALVE ASSY (MINI LEVER-JOYSTICK

SPECIFICATION)

GENERAL

X1 X2 X3
!

OUT

C1
I I
X3 X4
 14-29

[Point 9]

Inspection:
Check and clean any clogged orifice.

[Point 10]

Inspection:
Check and clean any clogged filter

Reassembly:
When the relief valve is disassembled, temporarily install it
after fitting the nuts as illustrated.

a = 27.0 mm (1.06 in)

14-30

OIL CONTROL VALVE ASSY (MINI LEVER-JOYSTICK

SPECIFICATION)

GENERAL

X1 X2 X3

I
X1

C1
 14-31

X1-X1

Flow divider

Unloading valve
(Unloading SOL)

X2-X2

Flow regulator valve

\\

Manual down valve

\
/
Proportional SOL (b)
\
\
Proportional SOL (a)
14-32

X3-X3

Tilt control valve (Tilt

' control SOL)

,
/
/
/
/

Prop o rt'lonal/ SOL (b) Proportional SOL (a)

X4-X4

/
Prop o rt'lonal/ SOL (b) Proportional SOL (a)
C5-X5

Solenoid Connector Diagram

Proportional solenoid (b) connector

o o Proportional solenoid (a) connector

(D
Tilt control solenoid connector

~
Unloading solenoid connector

00
14-34

Hydraulic Circuit Diagram

Flow divider valve

Gauge port

c 1

Flow regulalor valve

T1
 14-35

SPECIFICATIONS
~ Vehicle model
1 Ion series 2·K2 ton series 3 tOn series J3.5 ton series
118
rTl _ ~~
Type Add-on Iype
Relief pressure ~ft-- ---------'-1~8 (182) [2590J 187 (191) [2720]
L
MPa (kgflcm ) [pSI] ! Tilt 118 (120) [1710] 147 (150) [2130]
~_.
Flow divider flow rate
IImin (US gal/m In)
I
~_._---!-.~~-~~---+--~-~--

120 (317) 136 (359) 136 (359) 136 (359)

~---------~.------ ~~·~-~~t----~~--~~-----t_·-~~~~--1---·--~-··----
Flow regulator flow volume
I/rnln (US gal/mln) I 50 (13 2) 65 (17 2) 75 (19.8) 85 (22.4)

-I ~":~d=t~ C,;~)\~O,~) :~~::; ---+--~-~-~-~9-9~-~-~1------~._--

---------r----1F-;:;ii-load---i- -- 500 (98) 500(98) --~--50~0-(-9-8-)-----1~-----'-
500 (98)

~:~ 450 (89)

460 (91)
-

ic FSV
~C=;I~;d--r--~ 450 (89)
.. -
-~._

---f.~lloa_d -=t~_~_ 480(94)~-C_

Lowering speed 450 (89) 420 (83) 390 (77)

)eCll~C~~~oenc (fpm) ~
-----

I
FV

FSW
I 1 No load
F~lloacJ...._~ ~
420 (83)
--
480 (94T
4-2-0-~(8-3-)--+----_~-3_9_0_(_7_7)
2tonsenes 480(94)
~
460(91)
) _---+
4_60_(9.1__
l--
460 (91) _
390(77) _
--
~

------
-

I Ii i No load -- 2 Ion series: 480 (89) 420(83) -

--
14-36

COMPONENTS
6705

!,NLET]

j --- ---'

~1~~~_INCl:~)j

01

670S-877A

1-:--
67_o5

10[ATI,3-WAY]

6705-B84A
TROUBLESHOOTING
Note:
Only the defective phenomena caused by the parts specific to the mini lever specification are listed.
Others not listed here are the same as those for the STD specification,
Operation Phenomenon Probable cause Inspection item
General material Cannot operate Decompression valve piston stuck closed r . Whether the decompression valve piston can be removed
handling operation material handling I • Whether there are any scratches on the decompression
I valve piston
I • Whether foreign matter is stuck in the decompression valve
" piston
I . L __. . I
Proportional ",olenoid valve piston stuck closed I • Whethu the proportional solenOid valve piston can be
renlovcd
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional solenoid
valve piston
Proportional solenoid SOL malfunction • Remove the proportional solenoid SOL (while harness is
connected), and check whether the pin at the tip is operating
when the lever is operated
Foreign matter is stuck in the proportional solenOid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed Whether the main spool can be removed
Whether there are any scratches on the main spool
Whether foreign matter is stuck in the main spool
Material handling is Decompression valve piston malfunction • Whether there are any scratches on the decompression
slow valve piston
Whether foreign matter is stuck In the decompression valve
piston
Proportional solenoid valve piston malfunction Whether there are any scratches on the proportional
solenoid valve piston
Whether foreign matter is stuck in the proportional solenoid
valve piston
Proportional solenoid SOL malfunction Remove the proportional solenoid SOL (while harness is
I connected), and check whether the pin at the tip is operating
I when the lever is operated
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool malfunction Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
->,
~
I
W
--.J
 Operation Phenomenon Probable cause Inspection item .......
..I:>.
I
Backward tilt automatic Does not stop Proportional solenoid valve piston stuck open ' Whether the proportional solenoid valve piston can be W
co
leveling stop automatically removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter IS stuck in the proportional solenoid
valve piston
Proportional solenoid SOL malfunction
--JI • Remove the proportional solenoid SOL (while harness is
I
I connected) and check whether the pin at the tip is operating
I
when the lever IS operated
I
Tilt spool stuck open I' Whether the tilt spool can be removed
, Whether there are any scratches on the tilt spool
• Whether foreign matter is stuck in the tilt spool
During OPS operation Material handling does Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
not stop removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional solenoid
valve piston
Proportional solenoid SOL malfunction I ' Remove the proportional solenoid SOL (while harness is
connected), and check whether the pin at the tip is operating
when the lever is operated
Main spool stuck open ' Whether the main spool can be removed
• Whether there are any scratches on the main spool
I ' Whether foreign matter is stuck In the main spool
 14-39

REMOVAL-INSTALLATION
T = N'm (kgf-cm) [ft:lbf]

r~-~---------
I

I
i
I
i
I
I

i
i

~.

f\.,noval Procedure
1 Remove the lower panel and toe board

2 Remove the instrument panel RH

3 Disconnect the connector.

4 Remove the harness bracket.

5 Disconnect all the piping and the load sensor connectors.

6 Remove the oil control valve ASSY W/ bracket. [point 1]

7 Remove the oil control valve.

8 Remove the fitting and load sensor.

14AO

Installation Procedure
The installation procedure is the reverse of the removal procedure.
"Note:
• After installation, check the hydraulic oil/evel, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced. (See section 16)

Point Operations
[Point 1]
Removal-Installation:
For the removal of the oil control valve ASSY W/ bracket for
over fourttl~way, use a hoist.
 14-41

DISASSEM BLY·INSPECTION·REASSEMBLY
Note: .
• Work in a clean location.
• Since individual parts are finished with high precision, carefully operate so as not to damage them.
T = Nm (kgfcm) lft·lbf]

Disassembly Procedure
1 Remove the lift lock SOL and flow regulator valve [Point 1]

2 Remove the tilt control SOL. [Point 2]

3 Remove the proportional solenoid (a). [Point 3]

4 Remove the proportional solenoid (b). [Point 4]

5 Remove the lift spool, tilt spool and attachment spooL

6 Remove the unload SOL. [Point 5]

7 Remove the flow divider valve. [Point 6]

8 Remove the relief valve. [Point 7]

9 Remove the rod bolt, and then remove the housing.
14-42

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.

Point Operations
[Point 1]

Disassembly
Put match marks to prevent solenoid installation in an incorrect
position

Reassembly:
Align match marks for reassembly.

Inspection
Check the Iltt lock solenoid for continuity.

Inspection
Check and clean any clogged filter.

Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool, etc

1/
[Point 2]

Inspection
Check the tilt solenoid for continuity.
 14-43

Inspection:
Check and clean any clogged filter.

Inspection:
Check and clean any clogged orifice.

Reassernbly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool.

[Point 3]

Inspection:
Check the proportional solenoid (a) for continuity

Measurement terminal 1 <=> 5: Continuity exists.

Measurement terminal 2 <=> 6: Continuity exists.

Measurement terminal 3 <=> 7: Continuity exists.

r Ad;u,"ng ,,,ew
A
Disassembly:
Before disassembly, measure the installation position
(dimension A) of the material handling start timing adjusting
screw.

Reassembly:
Reassemble according to the dimension A measured before
disassembly.

Adjustment:
After installing the control valve to the vehicle, check whether
there are any abnormalities in material handling start timing by
slowly operating the lever. If you feel any abnormalities,
perform tuning with the display. (See section 18)
14-44

[Point 4]
1 2 3

~)
Inspection:
Check the proportional solenoid (b) for continuity.
, .-,

6 7 Measurement terminal 1 cc> 5: Continuity exists.

Measurement terminal 2 cc> 6: Continuity exists.

Measurement terminal 3 cc> 7: Continuity exists.

Disassembly:
Before disassembly, measure the installation position
(dimension A) for the material handling start timing adjusting
screw.
l _ Reassembly:
Reassemble according to the dimension A measured beforL.
disassembly

Adjustment:
After installing the control valve to the vehicle, check whec.
there are any abnormalities in material handling start timing by
slowly operating the lever. If you feel any abnormalities,
perform tuning with the display. (See section 18)

[Point 5]

Inspection:
Check the unload solenoid for continuity.

Inspection:
Check and clean any clogged filter.
 14-45

[Point 6]

Inspection:
Check and clean any clogged orifice.

[Point 7]

Inspection:
Check and clean any clogged filter

Reassembly:
When the relief valve is disassembled. temporarily install It
after fitting the nuts as illustrated.

a =27.0 mm (1.06 in)

14-46

CONTROL VALVE LEVER ASSY

REMOVAL-INSTALLATION

Removal Procedure
Remove the lower panel.

2 Remove the instrument panel RH.

3 Disconnect the knob switch connectoL

4 Disconnect the connection between the control valve lever and the lever rod.

5 Remove the set boiL

6 Remove the control valve leveL [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply chassis grease special on the control valve lever links.

Point Operations
[Point 1]

Inspection:
Check the knob switch for continuity.
 14-'47

~ELIEF PRESSURE ADJUSTMENT

-.lote:
• Since the relief valve is structured in two stages, be sure to adjust the lift (high pressure) side first and
adjust the tilt (Iow pressure) side then. (If the lift side is normal and tilt side is abnormal as the result of
relief pressure inspection, only the tilt side adjustment can be performed.)
• Always adjust the relief pressure as described below. Avoid hasty adjustment since it may cause high-
pressure generation that may result in damage to the oil pump and other hydraulic devices.
Before starting adjustment, check if the no-load maximum rpm is as specified.

1. Open the englrle hood.

2. Remove the lower panel and toe board

3. Install an oil pressure gauge

Remove the Oil-pressure detecting plug installed on the left
side of the oil control valve, and Install the oil pressure gauge
there.

Plug size: 9f16-18UNF

Fitting size: 9f16-18UNF i PF1f4

Fitting: 90407-13469-71

4. Set the adjusting screw A and adjusting sleeve B of the relief

valve as described below

(1) Loosen lock nut 1. After fully tightening' adjusting screw A

once, loosen it by 1 to 2 turns

(2) Loosen lock nut 2, and position adjusting sleeve B to the

following dimension

a::: 27.0 mm (1.06 in)

5. Start the engine, and check for oil leaks and abnormal noise.

6. Install the toe board

7. Close the engine hood

8. Adjust the lift side relief pressure.

(1) Set the seat switch to ON. (Operate by two workers with
one sitting on the seat)

(2) Operate the lift lever to lift the fork fully.

(3) While running the engine at the maximum speed, operate

the lift lever to the lifting side. Gradually tighten adjusting
sleeve B to make the oil pressure in the relief state satisfy
the standard in the table on the next page, and fix the
sleeve position by tightening lock nut 2.
14-48

9. Adjust the tilt side reliefpressure.

(1) Set the seat switch to ON. (Operate by two workers with
one sitting on the seat.)

(2) Operate the tilt lever to tilt the mast fully backward.

(3) While running the engine at the maximum speed, operate

the till lever to the backward side. Gradually tighten
adjusting screw A to make the oil pressure in the relief
slale satisfy the standard in the table below, and fix the
sleeve position by tightening lock nut 1.

10. Turn the key switch OFF.

11. Remove the oil pressure gauge, and install and tighten the
removed plug
Standards MPa (kgf/cm 2 ) [psi]

Vehicle model 1 ton series Other than 1 ton series I

1--------- -------~I--- ----~----~-

Lift side relief pressure 178+~.7 (182 +6 7 ) l2590+~40] 187+~7 (191 +6 7 ) [2720+~40]
f----------- I
7 4
Till side relief pressure 11.8 +~7 (120 +6 7 ) [1710+~40] 14 7+6 (150+f) [2132+6 °]
 14-49

rJlANUAL DOWN VALVE

T = N·m (kgf-cm) [ft·lbf]

Manual down valve

T = 32.0 (326) [23.59]

If the forks do not descend due to a malfunction or other cause, loosen the manual down valve to lower the forks in
emergencies.
When loosening the manual down valve, do not rotate it more than one full turn.

After making repairs, tighten it securely.

 15-1

MINI LEVER-JOYSTiCK
Page

GEN ERAL 15-2

MINI LEVER 15-2
JOySTiCK............................................................• 15-4
COMPONENTS 15-7
MIN I LEVER·JOYSTICK 15-9
REMOVAL·INSTALLATION 15-9
DISASSEMBLy·INSPECTION·REASSEMBLY 15..13
15-2

GENERAL

MINI lEVER

Direction shift lever Attachment lever

(3rd)
(5way valves specification, 3rd and 4th)
. 1 - - - - - . - - - Attachment lever
(4th)
. ~ ~ (5way valves specification, 5th)
Load display switch ---c-'-"-'~~
\ ~ ~3rd - 4th changing-over switch
~ (Only 5way valves specification)

~"
Tilt lever
Lever for fixing height

Lever for fixing rotation of lever box

Lift Lever-Attachment Lever

0
\ 22.5 - 26 ~60;'
\~l -E:...,/

\ /
~' r~
I \ / I

\ ' , J -----~- _._-------------,

I
I

5 v: (1)
r-~I- .------~

3: ~ -.;f~-~ _~l, (2)

~ ~-
I ('
I i GND~ (3)
C)

I
I
I _
 15-3

Tilt Lever

i
\ 22.5 - 26° 22.5 - 26°/
\~~,
\ /
~'
I \

\'

[] []

Connector pin arrangement

(1) Power line: Red
(2) GND line: Black
(3) Signal line: Green

Direction Switch

~T N IG, IG, 'JF 3i '·m R,

F1 0 - kJ
1
N 10 -0
1

•
1R rG- )
RrrRa !C )

MARK TERMINAL
1 VR
2 Ra
3 ST
4 .
5 VF
6 IG1
7 N
8 IG2
15-4

JOYSTICK

Armrest
Joystick lever for Attachment

Direction shift lever

''''~
"

Lever for fixing rotation of lever box

Joystick lever for Lift, Tilt operation

Joystick for Lift and Tilt Operation

22.5 - 26° I 22.5 - 26°

\~~/' ~--------------------------l

('~\~ ,-£/)
M , '\
( \ / ;'
5 V :('1)
~+--co<.o.. /
,/' ----0
c'F--~~ j
PSi: (2)
-----<0
I
I

GNO:(3)
----10

Connector pin arrangement

(1) Power line: Red
(2) GNO line: Black
(3) Signal line: Green
 15-5

Joystick for Attachment Operation

22.5 - 26° . 22_5 - 26°

'-~-~,
\----- , ~ 1 \ /
/\ \ / ' '
I \ I / )

\ ' \ I !J I I

, \ \\' / /
\' I
'r\ '-
',{
,-.-----T-~~---·C)
5 v: (1)
! , )

{~!? PSi: (2)

!~
~::> ~ ~,-----(~.1
<> '> I

II '-r> <r GND 1 (3)

- - - - '- - .. _----{,)

I
I -.
L ~
PS2~i ) (4)
,
, ,
I_~ __ ~ ~ __ ~ t

Direction Switch

lP'= TIN I ISl I lGI I 'IF I ST I '/R I Ra

F1

Rr

MARK TERMINAL
1 VR
2 Ra
3 5T
4
5 VF
6 IG1
7 N
8 IG2
15-6

Co mrort seat (MSG85) spec.

p

Lever for setting forward and backward

Lever for f-IXlhg

- height

Knob f or adjusting
- tilt angle
 15-7

COMPONENTS
6712

BK

OF
1
./ 0
o CU --
~~
DE~Th1l
00 CA

('
CR
AT CN CV

BL

CP

_ _ 6712-034
Mini L~e~v~e~r~ _
6712
20

AP

6712-032 _

Joystick

6712

(EZPE~~l

II CH i,
:

SI

45
CG

AM

AP

6712-033
 15-9

MINI LEVER-JOYSTICK
REMOVAL-INSTALLATION
T = Nm (kgf-cm) [ft'lbD

Removal Procedure
Open the engine hood and disconnect the connector.
2 Close the engine hood.
3 Remove the lever cover for setting rotation.
4 Remove the mini lever box WI armrest and the armrest bracket.
5 Remove the lever for setting rotation. [Point 1]
6 Remove the rotary damper ASSY.
7 Remove the knob for fixing height and the lower bracket.
S Remove the lever for setting forward and backward. [Point 2]
9 Remove the upper bracket.
10 Remove the armrest ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
· 15-10

Point Operations
[Point 1]
Installation:
Install the lever for setting rotation so that the dimension B
shown in the illustration on the left becomes 3 to 6 mm (0.118
to 0.236 in).
The B part moves 3.6 mm (0.142 in) with 1 notch of the
serration.

[Point 2]
Installation:
Align the hole in the clamp bracket with the lever shaft
protrusion to install, then turn as shown in the illustration on
the left.

Installation:
Follow the procedure below to install the forward-backward
adjustment lever.

(1) Move the armrest to the rearmost part.

(2) Tighten the flange nut until the operating force at the top of
the lever becomes 65 to 100 N (6.6 - 10.2 kgf) [14.6 - 22.5
Ibf].

(3) Press the armrest forward with the force of 100 N (

kgf) [22.5 Ibf], and check that it doesn't move. If it moves,
100 N (10.2 kgf) [22.5 Ibf] tighten the flange nut further.
~
(4) Tighten nut A to the specified torque.

T = 14 N'm (142.8 kgf'cm) [10.3 ft·lbf]

 15-11

COMFORT SEAT (MSG85) SPEC.

T=14 (143) [103]

6

-~ )
T=20 - 4.0
6 (20.4 - 40.8)
" 4 [1.5 - 30]

! ___. ... ..
I
-.-J
L_

Removal Procedure
Open the engine hood and disconnect the connector.
2 Close the engine hood.
3 Remove the mini lever box W/armrest and the rail.
4 Remove the knob for adjusting tilt angle.
5 Remove the lever for fixing swing.
6 Remove the lever for fixing height and rail.
7 Remove the lever for setting forward and backward. [Point 1]
8 Remove the upper bracket.
9 Remove the armrest ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
15~12

Point Operations
[Point 1]
Install ation:
Align the hole in the clamp bracket with the lever shaft
protrusion to install, then turn as shown in the illustration on
the left

Installation:
Follow the procedure below to install the forward-backward
adjustment lever.

(1) Move the armrest to the rearmost part

(2) Tighten the flange nut until the operating force at the te 1/

the lever becomes 65 to 100 N (6.6 - 10.2 kgf) [14.6

Ibf].

(3) Press the armrest forward with the force of 100 N (102
kgf) [22.5 Ibf], and check that it doesn't move. If it moves,
100 N (102 kgf) [22.5 Ibf] tighten the flange nut further.
(4) Tighten nut A to the specified torque.

T = 14 N'm (142.8 kgf'cm) [10.3 ft·lbf]

Nut A
 15-13

DISASSEMBLY·INSPECTION·REASSEMBLY

1
1---11

I
~

\ ....::>assembly Procedure
Remove the lever cover.

2 Disconnect the connector. [Point 1]

3 Remove each lever ASSY and guide.

4 Remove the direction switch ASSY

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Disassembly:
Always mark connectors with a tag etc. so that the connection
points can be found during reassembly.
 16-1

SAS/OPS
Page Page
GE NERAL 16-2 OPS FUNCTIONS 16..25
SAS FUNCTION 16.. 4 GENERAL 16..25
CaM PO N ENTS 16-4 CONTROL SPECIFICATION 16..25
PRECAUTIONS FOR MATCHING 16..26
REPAIR 16-1 0
GENERAL 16..26
SAS/OPS CONTROLLER
REMOVAL"INSTALLATION ... 16..13 BEFORE STARTING
MATCHING 16..28
YAW RATE SENSOR
REMOVAL-INSTALLATION ... 16.. 14 OPTION SET 16..32
TIRE ANGLE SENSOR DIAGNOSIS MEMORY 16..34
REMOVAL·INSTALLATION ... 16..15
REAR WHEEL SWiNG
SWING LOCK CYLINDER CONTROL CHECK 16-35
REMOVAL·INSTALLATION ... 16..17
SAS/OPS PLUG ..IN
STEERING KNOB POSITION
ANALYZER 16..36
CORRECTING VALVE
REMOVAL·INSTALLATION ... 16-19
TILT ANGLE SENSOR
REMOVAL"INSTALLATION ... 16..20
I DAD SENSOR
RE "Vl,","J\'
11 U V.M.L" I""C'TJ\' , J\T'OI\'
1'1>:> 11-\1...1...1-\ C. I');fI
1 1'1 ••• ;fI U"L

SPEED SENSOR
REMOVAL·INSTALLATION ... 16.. 22
FORK HEIGHT SWITCH
REMOVAL·INSTALLATION 16..23
FUNCTIONAL PARTS 16..24
16-2

GENERAL
SAS (System of Active Stability) lOPS (Operator Presence Sensing) system configuration
Sensors are installed at each point of the vehicle to detect the vehicle movement and send signals to the controllers_
These signals are controlled by the controllers, and sent to each actuator to be operated_

Control
Sensor Control Actuator
S T K 0
Swing lock cylinder
(1 ) Fork height switch 0 0 S
(Single tire only)

Tilt control valve

(2) Tilt angle sensor 0 T
Lift lock valve

Knob position correcting

(3) Forward tilt switch 0 K

..
valve
output Forward interrupt relay
(4 ) Backward tilt switch 0 Backward interrupt relay -- ,
I
Unload valve
(5) Lower switch
1 0 0 Lift lock valve
Backward tilt lock valve
I I 0 (':::tandard IOllor \lOhif'IO nnly\I VI

0 0'
'-' I ' - ' V ' - ' I V ....... III'-.J .......

(6) I Load sensor OPS lamp

l-
Input Q) Buzzer
Fork automatic o Tilt control valve
(7)
leveling switch
0 I-
-<-'
C
o
o S, T IError lamp
K,O Error code display
(8) Speed sensor (J 0 i

Steering wheel
(9)
angle sensor
0

(10) Tire angle sensor 0 S,T Multifunction display (OPT)

.
Output
K,O (Bilt-in analyzer)
(11 ) Yaw rate sensor 0 I
j S, T Plug-in anallyzer (SST)!
I K,O I I
(12) Seat switch 0
(13 ) Forward switch 0 S :Rear wheel swing control
T :Mast tilting control
(14 ) Backward switch 0 K :Steering knob position control
O:OPS control
 16-3

.- ~o. Name No. Name

(1 ) Fork height switch (15) SWing lock cylinder
(2) Tilt angle sensor (16) Tilt control valve
(3) Forward tilt switch * i (17) Lift lock valve
(4) Backward tilt switch * 1 (18) Knob position correction valve
--
(5) Lower lift switch *1 (19) Forward interrupt relay
(6) Load sensor (20) Reverse interrupt relay
(7) Automatic fork leveling switch (21 ) Unload valve
I
(8) Speed sensor (22) Backward tilt lock valve *3 I
(9) Steering wheel angle sensor (23) Buzzer
(10) Tire angle sensor (24) OPS lamp
(11 ) Yaw rate sensor *2 (25) Error lamp, Error code display
(12) Seat switch (26) Multi-function display I
(13) Forward switch (27) Plug-in analyzer
(14 ) Reverse switch (28) SAS/OPS controller

*1 Forthe mini lever/joystick vehicles, (3) (4) and (5) switches are the lever angle sensors.
*2 Single tire models only.
*3 Except the minilever/joystick vehicles.
16-4

SAS FUNCTION
COMPONENTS

Controller

1910

1910-036

Yaw Rate Sensor

5803

5803-158A
 16-5

Tire Ang Ie Sensor

I
01Ko(INCL G) I •
.
..... .,

CL ~-.
DG---<g <>- CL
CK~\ ,1 ~-OG c\S1R~PIN BOOTS) __ \
\';~L
j

'" ,£~} 47[UPPER]

Refer to
(~~, (O'~CK
'''''-'JL:::~)-
CP '--~ CP q~
FIG~ 4302 CK~ ~CK
471 LDWERj ~.""
~~
JS..------..:§:l
Lf-J
Refer to

··........ ~
IK ---<il @)-JS
~-
FIG. 4302
··
.........

Swing Loc k Cylinder

4301

ft\-BU

4301-2:46~ _
 ~----------
16-6

Steering Knob Po T mg Valve --------......;---

I SI Ion Correct"
4507

1
07
.L

. ..
La ... __ .. - .. .I

4507-287

I -- g
Fork Hei h t Switch (V M
ast)
I 5803
10
r.... . - ...... ,
··
a ---. -

I ·

64

·
L ••• __ __~ ........i

5803-172
 16-7

Fork Height Switch (FV Mast)

5803

.
F .. "' .. ----- -'-~ ...... .,.
I
'ft-BC

BE

AR

AS

.,
I

L ..... _

5803-209

Fork Height Switch (FSV Mast)

5803
10

.r··-------~- - - - - - ......·
·

5803-207
16-8

Fork Height Switch (FSW Mast)

5803
10

··r···
~------'-~--- ••• "li

··

I
I
I

I
I
i
···
1 . ••• _
··,
"""""",J{

5803-205

Tilt Angle Sensor

5803
Load Sensor

5803

5803-206

Speed Sensor

5803

5803-204
16-10

PRECAUTIONS FOR REPAIR

Fully understand the functions of SAS/OPS before repairing it.

1. Preparation for repair

II 1\\1 / / ;I'\~ I,
1'\\1 / it I '
/;' '\ '\
/<1 lir~~l O/!I '1(~~fS'
(1) When washing the vehicle, care should be taken not to
1, _-
splash water directly to the electrical components.
Do not perform high pressure washing for the controller,

I~
I Ill/ d'~ :LJ-~~j
c;- 4' ,1' 'IT 'r,?J[_I;, ,¥r:51
I\ ~ ~,L,
tilt angle sensor, yaw rate sensor, fork height switch, horn
button, meters, switches on the instrument panel and
\11.1L; .l:j("2~~~'+5x~1 ~~~ electrical components and parts in the engine

~J:>--',~ '" {~r~' ~'''::I! compartment.

~ , '\c;?i:J'- Gf, ~--,
-, 0' ~ "-.," \ ~-'/ t~
/ (2) Remove contamination and/or water from respective
'[ '~;,\ \ \ / / \\{j
I (, r-:=::::::f?~,~ "" _ sections,

(3) Transport the controllers or sensors in a packed state with cushions, and keep it packed until installation,
Never transport it in an exposed state. Also, do not apply mechanical shock on the controllers or sensors by
dropping or crashing them.
(4) Part number for a controller varies by the vehicle specifications. Check the correct part number in adv<;:s.
(5) If a repair work requires matching, always park the vehicle on a flat place,
(6) Arrange for necessary tools and measuring instrument (such as a plug-in analyzer (SST 09240-26600-71)
and circuit tester, etc.),
2. During repair
(1) Never use an impact wrench for removing and installing controllers and sensors.
(2) Do not turn the ignition key switch ON or OFF more than necessary when the sensor wIring is
disconnected. Turning the ignition key switch ON in this state causes an error and an error code will be
stored in the controller. The error code is not erasable and a maximum of ten errors will be stored. If 11 or
more error codes are stored, the oldest error code will be sequentially erased.
(3) When turning the solenoid (for lock cylinder, knob position correction valve) ON during an "Active Test" of
the analyzer, do not keep it ON for more than one (1) minute. Since SAS/OPS functions are forcibly
suspended during an active test, use caution when performing the running test carefully at a jow speed.
(4) SAS/OPS functions are suspended during matching. Do not operate the vehicle in this state,
(5) Do not turn the ignition key switch ON with one side (RH or LH) of a vehicle jacked up. It is very danger
to turn the ignition key switch ON in this state as it releases the swing lock and the vehicle bec?
suddenly tilted.
(6) If a vehicle is in tilted condition because of the repair of a flattened tire or other reasons, keep the ignition
key switch turned ON throughout from the start of jacking up, tire replacement and lowering to the ground.
(7) When the hydraulic piping is disconnected, apply cover to the fitting and hose to prevent the dirt from
entering.
(8) If the oil control valve for manual lowering is loosened, tighten it to a prescribed torque.
(9) Tighten respective set bolts to a prescribed toque.
(10) Respective sensors require no adjustment during installation, Make initialization during matching.
(11) To disconnect a connector, do not pull it by the harness.
(12) When inspecting the harness, carefully operate so as not to damage connector terminals.
(13) The swing lock cylinder must not be disassembled. If disassembled, air enters to make it not reusable.
(14) Do not apply strong impacts to the frame and head guard to prevent the yaw rate sensor from being
damaged.
(15) The meanings of high and low fork heights in the troubleshooting section are as follows:
Low fork height: From the lowermost position to immediately before actuation of the fork height switch
High fork height: Height above the position where the fork height switch is actuated
 16-11

3. Temporary measures
If the mast should fail to lower because of some trouble, it can
be lowered manually.
Loosening the illustrated valve on the top of the oil control
valve lowers the mast. Operate the lift lever for lowering with
the manual lowering valve loosened.
After the repair, tighten it appropriately.
T =32.0 N'm (326 kgf-cm) [23.6 ft·lbf]
16-12

4. Precautions for vehicle modification

No. Content of modification Condition Content of work
Change the controller. (for vehicle without swing
1 Single tire ~ Double tire - control)
Remove the lock cylinder.
Change the controller. (for vehicle with swing control)
2 Double tire ~ Single tire - Change the rear axle beem.
Install the lock cylinder and SAS related parts.
3 Installation/Removal of attachment - Install or remove attachments.
When temporarily replace/use SAS/OPS
controllers between different vehicles
4 (However, this should be done only - Perform SET-5 of the matching
between the ones with the identical part
number.)

Note:
• Proceed with the alignment (matching) procedure after the above-mentioned modification.
(See page 16-26.)
• When placing a supply order for a mast ASSY, place order for sensors (for lifting height switch, m
harness and other SAS related parts) simultaneously if such parts are required.
 16-13

SAS/OPS CONTROLLER REMOVAL-INSTALLATION

Note:
Do not use an impact wrench for removinglinstalling the set bolts from/to the connector boot bracket and
SAS/OPS controller.
T:= N'm (kgfcm) [ftlbf]

,....~moval Procedure
Remove the lower paneL
2 Remove the toe board.
3 Disconnect the attachment lever rod.

4 Disconnect the tilt lever rod.

5 Remove the connector boot bracket.
6 Disconnect the connector.
7 Remove the SAS/OPS controller.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the SAS/OPS controller is replaced, perform the matching (See page 16-26).
16-14

YAW RATE SENSOR REMOVAL·INSTALLATION

Note:
• Extremely be careful not to apply mechanical shock in order to protect the yaw rate sensor. Do not use
an impact wrench.
• Do not use the yaw rate sensor which you accidentally dropped.
T = Nm (kgf-cm) [ft·lbf]

Removal Procedure
Remove the battery.
2 Remove tile relay block from the battery set plate.
3 Remove the battery set plate.
4 Disconnect the yaw rate sensor connector.
5 Remove the yaw rate sensor W/ bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 16-15

TIRE ANGLE SENSOR REMOVAL· INSTALLATION

T:= N'm (kgfcm) [ft'lbf]

Removal Procedure
1 Remove the harness protector.
2 Remove the sensor cover.
Disconnect the tire angle sensor connector.
Remove the tire angle sensor and joint [Point 1]
5 Remove the sensor plate.

Installation Procedure
The installation procedure is the reverse of the removal porcedure.
Note:
When the tire angle sensor is removedlinstalled or replaced, proceed with the matching procedure.
(See page 16-26)

Joint Point Operations

r@ [Point 1]

V Installation:

1. Turn the steering wheel fully clockwise and hold it there.

2. Insert the joint into the kingpin groove. Apply a small amount of
MP grease on the joint surface in contact with the king pin and
sensor plate.
16-16

3. Install the tire angle sensor by aligning it with the joint center

~
Tireangle
sensor axis.

«>" (~

4. Turn the tire angle sensor until the tire angle sensor mounting
hole is aligned with the sensor plate screw hole.
(Approx. 180°)

5. J-IX by tightening the tapping screw after mounting hole

alignment.
 16-17

SWING LOCK CYLINDER REMOVAL-INSTALLATION

T = N·m (kgf·cm) [ft·lbf]

f«tfrC1J
T = 29.0 (296) [21.4]
4
-I_I~III

Removal Procedure
This is not applicable to i-ton series vehicles.
Remove the radiator.
Jack up the vehicle.
3 Remove the lower pin and swing lock cylinder.
4 Disconnect the swing lock solenoid connector.
5 Remove the upper pin and swing lock cylinder. [Point 1]
6 Remove the swing lock cylinder. [Point 2]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply chassis grease to the spherical portion of the upper pin and its mounting hole before installation.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the threaded portions of the upper and lower
pin set bolts before tightening them.
• After installation, apply chassis grease from the grease fitting.
16-18

Point Operations
[Point 1]
Removal:
SST 09810-20172-71

[Point 2]

Inspection:
Measure accumulator piston depth L.

1_ Remove the plug, with a coin (or a screw driver) from thp
center at the end of the accumulator.

2 Using a caliper, measure depth L of the accumulator piston.

Standard
46 mm (1.81 in) {20°C (68°F»,
42 mm (i.65 in) (40°C (104°F»
Limit
52 mm (2.05 in) {20°C (68°F»,
48 mm (1.89 in) (40°C (104°F»

Temperature QC (OF) Standard cannot be judged correctly in a low temperature, ?

60
fluctuates gr0atly by the oil temperature inside the ,<.
(140) ,---,---.,----.,--. ··:c---- -.------,-----c--··,-----;-· ---;- - .;- .. '"..-----'".:
cylinder. (Refer to the graph)
(10~~ , , ~----~-----:'---,c----,-----j-----j'./--.. ,~/.;---: - .-- ----. If temperature is low, raise the oil temperature (approx. 40°C
~ . i './~ ._.~ (104°F): a level of human body temperature for the cylinder body)
(68): > t ......r_I
,:_:.;po:""· ' __ ,. ' .. __ .i' .. _, .. __ ._;
by forward and reverse traveling on an irregular road surface
o ~;: before measuring. (Or, warm up from outside using a heater)
(~:~ ~n:-::~:r-:::::::1-----,----,-----'----.,---- .,-----,----:,.----, If the limit value is exceeded, replace the swing lock cylinder
(4 )52--~----50---~---48----·---46 44 42 40 38 ASSY
(2_05) (1.97) (1891 (1.81) (173) (1651 (157) (1.50)
3_ After inspection, push a plug in with a finger.
L dimension mm (in)

Installation:
Install with the mark (protruded portion) at the rod end facing
outward.
 16-19

STEERING KNOB POSITION CORRECTING VALVE REMOVAL·INSTALLATION

Removal Procedure
Remove the under cover.
2 Disconnect the piping .
.., ,Jisconnect the connector.
. Remove the steering knob position correcting valve.

Installation Procedure
Reverse the removal procedure.
16-20

TILT ANGLE SENSOR REMOVAL·INSTALLATION

T = N·m (kgf-cm) [ft·lbf)

Removal Procedure
Remove the lower panel.
2 Remove the toe board.
3 Disconnect the tilt angle sensor link rod.
4 Disconnect the connector.
5 Remove the tilt angle sensor W/ bracket.
6 Remove the tilt angle sensor.
7 Remove the link shaft and link lever.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply MP grease on the spherical portion of the link arm, inside the oil seal and inside the bushing, and
then install.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the threaded portion of the tilt angle sensor
installation screws and the link lever installation nuts, and tighten them.
e Perform matching if the tilt angle sensor is removed or installed, or the tilt angle sensor link is replaced.
(Refer to page 16-26)
 16-21

LOAD SENSOR REMOVAL-INSTALLATION

T = N·m (kgf-cm) [ft-Ibf]

Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
Disconnect the connector.
't Remove the load sensor.

Installation Procedure
The installation procedure is tlle reverse of the removal procedure.

Note:
When the load sensor is removed/installed or replaced, proceed with the matching procedure.
(See page 16-26.)
16-22

SPEED SENSOR REMOVAL-INSTALLATION

T = Nm (kgfcm) [ft'lbf)

T = 3.0 -7.0 (31 - 71) [2.2 - 5.2J

~ o
o

Removal Procedure
Remove the speed sensor cover.

2 Disconnect the connector.

3 Remove the speed sensor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 16-23

FORK HEIGHT SWITCH REMOVAL·INSTALLATION

T = Nm (kgf'cm) [fHbn

Y mast

3
I

. Cf&;- T = 16.2 - 378 (165.2 - 385.5) [12.0 - 27.9]

·0

FY·FSY·FSW mast

igj!r-~ T = 78 - 182 (795 - 185.6) [58 -13.4].

II
T = 16.2 - 37.8 (1652 - 385.5) [120 - 279]

Removal Procedure
1 Remove the lower cover.
2 Disconnect the connector.
3 Remove the fork height switch.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
16-24

FUNCTIONAL PARTS
Note:
• Refer to section 7 (STEERING) for the steering angle sensor. Refer to section 14 (OIL CONTROL VALVE)
for the solenoids installed at the oil control valve and the tilt lever knob switch.
• Refer to section 19 (TROUBLESHOOTING) for inspection of functional components.
 16-25

OPS FUNCTIONS

GENERAL
OPS system detects the operator with the seat switch, and if the operator is not in the proper driving position, it cuts
off the driving force while limiting the material handling operation.

CONTROL SPECIFICATION
1. Traveling OPS functions
If the controller detects that the seat switch is OFF for 2 seconds, it will cut off the driving force by interrupting the
voltage supply line to the forward/reverse drive valve of the torque converter through the control of forward
traveling and reverse traveling interruption relays.
While the seat switch is ON, traveling OPS state is cancelled by shifting the forward-reverse travel lever back to
neutral.
Note:
.,.. ::ancel traveling OPS for the 02 pedal (optional), apply and release the parking brake or depress and
c,ease the accelerator pedal.

Material handling OPS system

( 1) STD lever vehicle
If the controller detects that the seat switch is OFF for 2 seconds, it will stop the operations of lift lowering
and forward/backward tilting by controlling the lift lock valve, tilt control valve and backward tilt lock valve.
For lifting and attachment, the material handling operation will be stopped by cutting off the hydraulic oil
supply through the control of the unload valve.
In addition, the material handling OPS state is cancelled in the following conditions according to material
handling operations.
(a) Lowering: when the seat switch is ON, and the lift lever is set to the condition other than lowering.
(b) Other than lowering: when the seat switch is ON for more than 1 second.
If you operate the attachment lever while OPS is operated, it may move by the attachment's own weight, or
by the back pressure of the unload valve.
(2) Mini lever/joystick vehicle (OPT)
If the controller detects that the seat switch is OFF for more than 2 seconds, lifting, tilting and attachment
operations will be stopped by controlling the solenoid valves.
Material handling OPS state is cancelled when the seat switch is ON, and all the levers are shifted back to
neutral.
3. OPS operation notification functions
If the controller detects that the seat switch is OFF, the buzzer will sound for approx. 1 second and the OPS lamp
will turn on to notify the operator that OPS is going to be activated. In addition, the OPS light stays on while the
seat switch is OFF to notify that it is in the OPS state.
4 Return-to-neutral warning
After the traveling OPS is activated, if the seat switch turns ON without shifting the forward-reverse travel lever
back to neutral, the buzzer will sound (repeated beeps) to notify the operator that traveling OPS is not cancelled.
(1) STD lever vehicle
After material handling OPS is activated, if the seat switch turns ON while leaving the lift lever at the
lowering operation, buzzer will sound (repeated beeps) to notify the operator that the lowering operation
stop is not cancelled.
(2) Mini lever/joystick vehicle (OPT)
After material handling OPS is activated, if the seat switch turns ON without shifting all the material handling
levers to neutral, buzzer sounds (repeated beeps) to notify the operator that the material handling OPS is
not cancelled.
16-26

MATCHING

GENERAL
• For the tilt angle, load and tire angle sensors among sensors used for SAS functions, the signal voltage values
under the mast vertical, no load and tire straight are stored in the controller for control based on these values.
When servicing these sensors or replacing related parts, matching (updating the sensor signal voltage under the
standard vehicle condition) is necessary. In addition, matching is required for the tilt angle sensor if the vehicle
posture changes considerably, and for the material handling sensor, when the loading in no-load state changes
as a result of adding/removing the attachment, replacing the mast, change in the fork length or removing/
installing the fork. Matching is also necessary for the load sensor when forks are installed to a forkless vehicle.
There are three methods of matching: using the hour meter and tilt knob switch; using the multifunction display
and using the plug-in analyzer (S3T part number 09240-26600-71) (refer to 18-58).
• Each lever angle sensor for mini lever or joystick function is controll8d based on the signal voltage value stored
in the controller with each lever neutral at the time of shipment. When servicing these sensors or replacing
related parts, matching (updating the sensor signal voltage under the standard vehicle condition) is necessary.
• Live load gauge stores mast specification information and signal voltage values of the load sensor during nr
load to the multi-function display, and indicates based on these information. When servicing the mast or '
sensor or replacing related parts, matching (updating the sensor signal voltage with the mast specifiC'
information or under the standard vehicle condition) is necessary.

Matching Items and Prerequisite for Implementation

1. SAS
Prerequisite for
No. Indication Description
implementation
Tilt angle sensor output with fork in the horizontal position is stored in
1 TILTL *1,*2,*3,*6,*7,*8
the controller.
Tilt angle sensor output with the forward tilt control the mast vertical
2 TILTF LOAD standard condition, and the load sensor output in the no-load *1,*2,*3,*4,*6,*7,*8
condition are stored in the controller.
Tire angle sensor output in the condition of the vehicle traveling
3 TIRE *1,*5
straight ahead is stored in the controller
4 SWING - -

2. MINI LEVER (OPT: mini lever or joystick vehicle only)

Prerequisite fe.:
No. Indication Description
implementatic :: .
Lift lever angle sensor output with the lift lever in the neutral position
6 LEVER1 *1,*9
is stored in the controller.
Tilt lever angle sensor output with the tilt lever in the neutral position
7 LEVER2 *1,*10
is stored in the controller.
Attachment (1) lever angle sensor output with the attachment (1)
8 LEVER3 *1,*11
lever in the neutral position is stored in the controller.
Attachment (2) lever angle sensor output with the attachment (2)
9 LEVER4 *1,*12
lever in the neutral position is stored in the controller.
 16-27

3. LOAD METER (OPT: vehicle with multi-function display OX model only)

Prerequisite for
No. Indication Description
implementation
Number of the mast lift cylinders is stored.
10 LIFT CYL. NUMBERS *7:13
(Total number including front and rear)
11 LIFT CYL. BORE Bore of the lift cylinder is stored. *7:13
12 LOADMETER 0 SET o point of the load gauge is stored. *4,*6:7,*13
When you want to
13 COMPENSATION Accuracy of the load meter is adjusted.
adjust the accuracy

Prerequisite for implementation

*1 When replacing the SAS/OPS controller
*2 When removing/installing or replacing the tilt angle sensor
*3 When changing the tilt angle sensor rod length or replacing the rod
*4 When removing/installing or replacing the load sensor
*5 When removing/installing or replacing the tire angle sensor/sensor cover
+~ When removing/installing or changing the attachment and fork
_ When replacing the mast
-When replacing the tilt cylinder
'::1 When replacing the lift lever angle sensor

*10 When replacing the tilt lever angle sensor

*11 When replacing the attachment (1) lever angle sensor
*12 When replacing the attachment (2) lever angle sensor
*13 When replacing the multi-function display
16-28

BEFORE STARTING MATCHING

Set the vehicle to "Standard vehicle condition" before starting matching.
"Standard vehicle condition" means that the vehicle satisfies the conditions described below.

Vmast FV·FSV·FSW mast Standard Vehicle Condition

Note:
• Items 1 - 4 below show the standard vehicle condition for
SAS matching.
• Before carrying out matching for mini lever/joystick
vehicles, move the armrest to the driving position and
check the neutral state of the levers.
• In case of a detachable attachment, keep the attachment

I500 mm
(197 in)
1 100 mm
(3.93 in) 1.
installed on the vehicle.
Tire pressure check
Adjust the tire pressure to the specified level. Matching will be
inaccurate if the pressure is low, or if there are air pressure
fluctuations between front and rear as well as left and right.
2. Surface levelness check
If matching is conducted on an inclined or rough floor
errors in standard vehicle condition will occur, so perform
0
matching on a flat. level surface (inclination: within 0.5 ).

3. No-load vertical condition check

Store the output voltage of the load sensor in no-load state in
the controller. At this time, the following conditions must be
satisfied:
(1) For the V mast, set the lifting height to about 500 mm
(19.7 in) and use a goniometer to check that the mast is
vertical.
(2) For the FV/FSV/FSW mast, set the rear cylinder rod
projection to about 100 mm (3.93 in) and use a
x~': goniometer to check that the mast is vertical.
(3) In the case of a special vehicle with a heavy attachment
(exceeding the additional weight shown in the table
below), adjust the perpendicularity of the mast with the
attachment height at 500 mm (19.7 in), and perform reli
at the topmost position.
(4) Set the mast in the vertical position from the backw
tilted position by operating the tilt lever in the forward
tilting direction.

Additional Weight Table kg (Ibs)

Lift height mm (in) 1.5 ton 1.75 ton K2.0 ton 2.0 ton 2.5 ton 3.0 ton J3.5 ton
700 800 950 950 950 1200 1400
3000 (118)
(1544) (1764) (2095) (2095) (2095) (2646) (3087)
3300 (130) 700 700 950 950 950 1200 1400
- 4000 (1575) (1544) (1544) (2095) (2095) (2095) (2646) (3087)
4300 (169) 600 650 800 900 900 1000 1000
-5000(197) (1323) (1433) (1764) (1985) (1985) (2205) (2205)
5500 (216.5) 450 550 650 650 800 800 1000
- 6000 (236) (992) (1213) (1433) (1433) (1764) (1764) (2205)
6500 (256) 500 500
- - - - -
- 7000 (275.5) (1103) (1103 )
 16-29

4. Tire straight traveling position check

Store the tire angle sensor output voltage in the controller in
the condition of the vehicle traveling straight ahead.
Condition of the vehicle traveling straigHt atw'~O means that
the deviance to left or right is withJn5,(2r;P i)'! (2.1) in) when the
vehtde travels for 5 meters (1gft.\:,;)q~nhe steering being fixed.
L,oadmct8r 0 set (0 set oUh~"'Y§d gauge) check '. I~

ror ;;111 the V/FV/FSV/c.$)p,t'r:nast, the mast is to be vertico: "nd

the fork height is t(jJ;;) 500 mm (19.7 in).

1VI::itching Procedure
WhOrl there is a matching connector (STD lever vehicle)
Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching conn~ctor causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
".
controller, for which care must be'taken.,
1. Turn the ignition key switch ON (or start the engine).
2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench larnp turns on,
and then password display is indicated.

Tilt knob switch...... 3. While shifting the tilt lever to backward tilt for rnore than 5
seconds, returning the lever and tilt knob switch after pressing
the switch for more than 2 seconds will indicate "1-dIAG" on
the hour meter.
Menu No Menu description
1-dIAG Diagnosis memory menu
,-,-,;::,;::,-
I III I ,
2-0PT Option set menu

+ 3-SET
4-SAS
Matching menu
Rear wheel swing control check menu

e-, - U,-,
nn,

I 1 1'-
':1 - ':::1 C '

11
-(
+,-,.:::,
- .:::'
1 ," "
.
 16-30

\-". 4. Operate the tilt lever to indicate "3-SET" and press the tilt knob
switch to display "SET1-". Set number display changes as
indicated in the table below each time the tilt knob switch is

J
--- '<.
pressed for less than 2 seconds.
Set No. Description of matching
~ SET1 Fork stop position with automatic leveling
3- ::tEf] Forward tilting limit position and

, , ,
..- SET2

SET3 ./~
no-load standard load
Tires in straight traveling position
.:' C J
..- -' SET4*1 ~-

, , ,

.
.:' C J !..

, , , _I _
-
SET5*2':_~ Deletingengine and display ECU information

*1: Indication may be made but actually.it is not used .

*2: Indicates only when CAN communication abnormalities (AD-1
or AD-7) occur.
.:' C J
.- -' *3: Perform SET5 when temporarily replacing SAS/OPS controller

.
between the different vehicles .
, , ,- ,_I -
.:tc I , Note:
When SWitching the matching menu, do not press the tilt knob
, , , switch for more than 2 seconds. Pressing the switch for more
':IC J
-''- - than 2 seconds will carry out the displayed matching.

o display 5. Press the knob switch to indicate "SET1-" and press the tilt
knob switch for more than 2 seconds to carry out matching.
,-- ,-,-- ,-- 1 o indication: Matching is completed. (Wrench lamp starts to
.."

""""I""""
t 1 Cl blink)
H indication: Check for the sensor abnormality,
disconnection of the harness and the short-
H display circuit since the signal voltage value is outside

,-- ,,-- ,... 1 , f

the matching rang. (Refer to the troubleshooting
section.)
.... ....
.....f"""" t I n Note:
• For re-matching, repeat step 5.
o To make a separate matching, repeat steps 4 to 5.

6. Connect the matching connector and turn the ignition

switch OFF.
 16-31

When There is No Matching Connector

(Mini Lever/Joystick Vehicle)
Note:
Even when there is nq matching connector, engine and

2. TUNING display ECU information can be deleted.

• Refer to the multifunction display for SAS matching.
3. UPT I ONSET (Section 18)
( .. J 1. Turn the ignition key switch ON (engine stop).
2. Display the mask menu on the multifunction display. (refer to
page 18-13)

3. Keep pressing the fork automatic leveling switch for more than
Fork automatic leveling switch
2 seconds to display the matching menu.
Note:
• Only SETS will be indicated.
• Indicated only when CAN communication abnormalities
(AD-1 or AD-7) occur.

4. Keep pressing the fork automatic leveling sWitch for more than
2 seconds to delete the information.
o indication: deleting the information is completed. (Wrench
o indication (Deleting information) lamp will be flashing)
5. Turn the ignition key switch OFF.

I
l
16-32

OPTION SET
The option set function is to invalidate the mast forward tilting angle control. There are three methods to do this: one
is to use the hour meter and tilt knob switch and the other method is to use the multifunction display or the plug-in
analyzer (SST). (See section 18.)
Caution:
When the option set is changed, perform maintenance of the caution label of "CAUTION FOR OPERATION."

Option Set Procedure

Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching connector causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
controller, for which care must be taken.

i. Turn the ignition key switch ON (or start the engine).

2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench lamp turn~
and then password display is indicated.

3. While shifting the tilt lever to backward tilt for more than 5
_Jr-''-_/-~\ seconds, returning the lever and tilt knob switch after pressing
the switch for more than 2 seconds wiii indicate "i-diAG" on
/~:=-~-=~=-\ the hour meter.
/ /
/ /
/ /

/
/
/
/ 4. Operate the tilt lever to indicate "2-0PT" and press the tilt knob
/
/
/
/ switch to display "OPT1-y".
/ /

,/ , / /

5. The displayed set number changes each time the knob switch
is pressed for less than 2 seconds.
Option No Control name !
I
OPT1 Mast forward tilt angle control .:

cl-o pr OPT2*
OPT3
-
(Unused: always n)
'i

-+, *: Displayed but not in use.

'lit,
Uj-j I -'-'
-' 1#1 itlt,
U,-, - (", 6. Keep the knob switch pressed until the wrench lamp starts
blinking (for 2 seconds or over) to change y to n, and n to ¥.

,1,1,
+-, ,-, ,-,,- -,
y: Control valid
n: Control invalid
Uj- j
1#\ C - ::'
" U,- I C - 1/ I 7. Connect the matching connector and turn the ignition key

+- 1
switch OFF

Lt:-' r .:f -::: 1#1 '/1/'-'

u ,-, ::'1 - n 1
 16-33

8. Perform the maintenance of the caution label.

If the control is invalidated:
Remove the pertinent validation indication to replace with
invalid indication.
If the control is validated:
Replace the caution label to indicate valid control.

Note:
When mast front tilt angle control is invalidated, and T-OFF
When mast forward tilt angle control
display will be indicated for 10 seconds when the ignition key
is invalidated:
switch is turned ON.

,, ,,-
n" ,-
•....t
16-34

DIAGNOSIS MEMORY
There are t)llree methods of diagnosis memory for STD lever vehicles: using the hour meter and tilt lever; using the
multifunction display and using the plug-in analyzer (SST) (refer to page 18-22).
Refer to troubleshooting (refer to section 19) for the diagnosis code list.

Diagnosis Memory Procedure

Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching connector causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
controller, for which care must be taken.
1. Turn the ignition key switch ON (or start the engine).
2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench lamp turns on,
and then password display is indicated.

3. While shifting the tilt lever to backward tilt for more thqJ
r - .... , , _ / seconds, returning the lever and tilt knob switch after press.. '9
~-----~ ~
J~
the switch for more than 2 seconds will indicate "1-dIAG" on
/'
/
//
--,
------- the hour meter.
/ /

/" /" ~l.J

/
/
/

/
/
/ -
, ,/
/ /

4. As you press the tilt knob switch for less than 2 seconds, the
diagnosis No. and the error code will be indicated, and each
error code and the time when it occurred will be indicated

,.., 1 __I 11 I'

1 Lt InU
Note:
alternately every 2 seconds.

• The maximum number of error codes that can be stored ;c-

III
i 0, and as the diagnosis number gets smaller, the el
T will be newer.
,1 1
Lt !..
,._1
IL.
1*1 • The error detected when turning the ignition key switch
ON may be stored with the memory time as 0.0.
+ 5. Connect the matching connector and turn the ignition key

I ue Sa-
'11
1*1 switch OFF.

III
III

+,
~I 11 I
ILt Cl I
r. I
I
1*1
:I
J
11 lit
1:::'1 ID
 16-35

REAR WHEEL SWING CONTROL CHECK

There are three methods of the rear wheel swing control check: using the hour meter and the tilt lever; using the
multifunction display and using the plug-in analyzer (SST) (refer to page 18-41)

Rear Wheel Swing Control Check Procedure

Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching connector causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
controller, for which care must be taken.

1. Turn the ignition key switch ON (or start the engine).

2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench lamp turns on,
and then password display is indicated.

3. While shifting the tilt lever to backward tilt for more than 5
seconds, returning the lever and tilt knob switch after pressing
the switch for more than 2 seconds will indicate "1-dIAG" on
the hour meter.

4. Operate the tilt lever until "4-SAS" is indicated.

5. When you press the tilt knob switch, two segments rotate, and
indication that the rear wheel swing lock control is being
checked is displayed. (Wrench lamp is ON)
6. Check the rear wheel swing lock control by driving the vehicle.
While the rear wheel swing lock control is operated (during
locking), the OPS lamp turns on.

7 Connect the matching connector and turn the ignition key

switch OFF.

L-_::_'_:-_:_~_'_::-_C ~U
16-36

SAS/OPS PLUG-IN ANALYZER

SST 09240-26600-71 For the maintenance and servicing of SAS/OPS controller, a
separate-placement type plug-in analyzer is added as SST
(dJ (servicing special tool).
PLUG·IN ANALYZER
The plug-in analyzer can read the operation states of the sensors
and actuators used for each controller, and error information
detected by the controllers, which is useful in checking the
operation state of each function and in saving repair time when a
defect occurs.

Mask Function List

Application I
Function Description When replacing
Others
controller
Displays the vehicle's electrical system
Upon vehicle
Analyzer operating status and reads the error ~

abnormality
information detected by controllers.
Makes fine adjustment of traveling and 0 Requests from
Tuning
material handling functions. *2 users
.
Sets each vehicle option and other 0
Specification setting ~

specifications. *1 *2
Option Setting
Each control function 0
Enables or disables each control function ~

enable/disable *2
Updates voltage values of sensor signals 0
Matching ~

under the standard vehicle condition. *2

Engine idle adjustment 0 Requests from
Adjusts engine idle speed
(4Y engine vehicle only) *2 users
Adjusts the contrast of the plug-in analyzer
Contrast ~ ~

display screen.
J

*1: This matches the controller and screen control according to the installed options and control functions equir; ..
on the vehicle; note that this function does not enable or disable the option or control function itself. I.·
*2: SAS/OPS controller

Note:
Refer to the multifunction display (Section 18) for the functions of the plug-in analyzer.
 17-1

SST LIST·SERVICE STANDARDS LIST

Page
SST LIST 17..2
SERVICE STAN DARDS LIST 17..9
17-2

SST LIST
* : Newly adopted SST
Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 16

~ 09010-13200-71 Motor hook 0

n 09010-20111-71

--
Engine unit hanger 0 0

~~
~~~;
09010-23320-71
Engine with
transmission hanger
0 0
1

Transmission bearing
09150-10170-7'1 0
replacer

~ I

Torque converter
~ 09220-22001-71 clutch drum spring 0
( remover & replacer

I I
;-

.<,l,>
09228-76004-71
Oil filter wrench
(tm (09228-07501 )
0

/ 09238-13130-71 CN25 sub-harness

I
I 0

g
p\..uo-m~Y2Ell

tn [1 *
0 9240-26600-71 Plug-in analyzer 0 0
[0 CID ell
-
~ ~-
~O~)
 17-3

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 16
/
/.

7/11 09310-23320-71 Reamer bolt remover 0

~
1, ~ 8f)
$)

09316-76008-71
Bearing replacer 0
(09316-60011 )

~~ C\.~~
09320-23000-71 Bearing remover 0 0
\

I I

~
*
09321-26600-71 Adapter 0

Front axle bearing

09370-10410-71 0 0 0
replacer

CJ
I
Drive pinion bearing
09370-20270-71 0 0 0
replacer

CJ I

~
*
09410-26600-71
Drive pinion bearing
0
replacer

/ 09411-13330-71 Spring pin remover 0

17-4

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 16

~••. ~~ u~. 09420-23002-71 Bearing remover 0 0

(Lp 09421-33020-71 Front axle hub replacer 0

0 09450-23320-71 Adapter 0

r *
09460-26600-71
Parking brake
measuring tool
0

a:=P 09471-22000-71
Cylinder cup
installation tool 0

~
*
09471-26600-71 Adapter 0 . !

) 09472-22000-71 Adapter 0

---

~~
*
09472-26600-71
Wet brake disc
0
setting tool
 17-5

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 16

~~ ( ...
\:
- ".
1,'
\
09509-76002-71
(09509-55020)
Rear wheel bearing
nut wrench 0

". . .."

~
09509-76003-71 Rear wheel bearing
(09509-55030 ) nut wrench
0

. _ ~ - -

r~o{€
Brake hold down
09510-31960-71 spring remover and 0
replacer

T-
09608-76003-71 Front hub inner
~ (09608-04031 ) bearing cone replacer
0

~) ~ ""-"
::::.---:::J'I ~
09610-10161-71
Oil control valve spring
remover and replacer 0 0
\01

I 1- I
C::~~ 09610-22000-71 Inner mast stopper 0

~:>
Cylinder cap remover
/ .~~.
09620-10100-71 0
~. .......~'- ,~./".......---
..•
and replacer

if 09630-10110-71
Tilt cylinder cap
remover and replacer
0
17-6

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 16

~ 09630-23600-71 Deep socket A 0

~:,
:3
101
..... @1. ,::3
09631-22000-71 Wear scale chain 0
G; ·-·rf1W'J:

())) *
0 9651-26600-71 Piston rod insert guide 0 ,

Q)) *
09652-26600-71 I Piston rod insert guide 0

~
*
0 9653-26600-71 Piston rod insert guide 0

I
I

I I I I
QS) *
09654-26600-71 Piston rod insert guide
I I
0 I
I. )

QS)
I
*
09655-26600-71 Piston rod insert guide
I
0

QS) *
0 9656-26600-71 Piston rod insert guide 0
 17-7

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 16

~
*
0 9657-26600-71 Piston rod insert guide 0

~
*09658-26600-71 Piston rod insert guide 0

~
*9659-26600-71
0 Piston rod guide 0

~
09717-76001-71 Brake shoe return
(09717-20010) spring remover
0

~
09718-76001-71 Brake shoe return
(09718-20010) spring replacer 0

I
~ 09810-20172-71 Joint pin remover 0 0 0

09905-76002-71
~
Snap ring NO.1
0
(09905-00012) expander

......~~ 1(( 09950-76003-71

@~~.~ .Don ~~ ~ Puller C set 0
""',0 or.'c:O ~ (09950-50012)
17-8

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 16

~<&P p8
09950-76014-71
~~
c;:> <8> C'"
<Y
(09950-40011 )
Puller B set 0 0 0 0 0 0
~~~~
=

09950-76018-71
~ (09950-60010)
Replacer set 0 0 0 0 0 0 0

@OOOO 09950-76019-71
r- f----

6 0000
(09950-60020)
Replacer set NO.2 0 0 0 0 0
000o"
• j

---

a0 09950-76020-71
(09950-70010)
Handle set 0 0 0 0 0 0 0 0

I
 17-9

SERVICE STANDARDS LIST

ENGINE

Engine
~-

4Y Standard 750 ± 30
Idle speed rpm 1DZ-111 Standard 750 ± 25
3Z Standard 775 ± 25
~ ,

4Y Standard 2570 ± 35
No-load static maximum speed rpm
1K2 ton series Standard 2600 ± 50*
* : In the case of vehicles equipped 1DZ-III
2·3 ton series Standard 2800 ± 50*
with travel and load handling
control, the rpm tolerance is'lG. 3Z Standard 2400 ± 50'
Engine speed down at full relief rpm 1DZ-1113Z Standard 200 or less
Air cleaner
Pa (mmH 2 O) Gasoline engine Standard 2630 - 3218 (270 - 330) [19.9 - 243]
, ,cuum switch continuity test
'here is continuity) [mm Hg] Diesel engine Standard 6904 - 8042 (704 - 820) [51.7 - 60.3]
Radiator
.,.

Radiator cap opening pressure kPa (kgflcm 2 ) [psi] Standard 88 ± 14.7 (09 ± 015) [13 ± 2.1]

Battery
Electrolyte specific gravity (at 20°C [68°F]) Standard 1.280

Alternator
4Y Standard 8-13(0.31-0.51)
Fan belt tension (when pushed with 98 N
mm (in) 1DZ-1I1 Standard 8-13(0.31-0.51)
(10 kgf) [22 IbD)
3Z Standard 8 - 9 (0.31 - 0.35)

Accelerator pedal
Gasoline engine Standard
Pedal angle (at the accelerator OFF) 45"
Diesel engine Standard

Tightening torque Unit: N'm (kgf-cm) [ftolbf]

,

we converter end plate set bolt Standard 49.0 - 78.4 (500 - 800) [36.2 - 57,9]
~

-ive plate set bolt (for torque converter connection) Standard 141.7 - 21.6 (150 - 220) [10.9 -15.9]
ITorque converter housing set bolt Standard 29.4 - 44.1 (300 - 450) [21.7 - 32.6]
17-10

TORQUE CONVERTER (1 SPEED TIC (STD))

Transmission cover & control valve ASSY
Standard 1324 (5213)
Regulator valve spring free length mm (in)
Limit 125.8 (4.953)
Standard 642 (2528)
Inching valve spring free length (plug side) mm (in)
Limit 61.0 (2402)
Standard 499 (1.965)
Inching valve spring free length (valve side) mm (in)
Limit 474 (1.866)
Standard 674 (3390)
Accumulator valve (inner side) mm (in)
Limit 640 (3.220)
Standard 1278 (5.031)
Accumulator valve (outer side) mm (in)
Limit 1214 (4.780)
..
Standard 59.8 (2354)
FIR shift valve mm (in)
Limit 568 (2236)
[
Standard 598 (2.354)
Safely valve mm (in) . ...e...-
Limit 56.8 (2236)

Torque converter and oil pump

I· 't
Oil pump driven gear to pump body clearance mm (in) L...lmll 0.3 (0.012)
Pump body to each gear clearance mm (in) Limit 0.042 - 0.080 (0002 - 0.003)

Transmission
Main shaft thrust clearance mm (in) Standard 0.10 - 0.24 (0.004 - 0.009)
Output shaft thrust clearance mm (in) Standard 0.10 - 049 (0.004 - 0.019)
Counter gear thrust clearance mm (in) Standard 010 - 0.54 (0.004 - 0.021)
Each clutch shaft to seal ring clearance mm (in) Limit 0.2 (0.008)
Standard 2.6 (0.102)
Clutch disc thickness mm (in)
Limit 2.3 (0091)
Standard 20 (0.079)
Clutch plate thickness mm (in)
Limit 1.8 (0.071)
Standard 34 (0.134)
Camber plate curve height mm (in) ;~

Limit 3.1 (0.122) "

4-disc type Standard 0.8 - 14 (0031 - 0.055)

Clutch disc to backing plate clearance mm (in)
5-disc type Standard 1.0 - 1.6 (0.039 - 0.063)
Standard 634 (2496)
Clutch piston return spring free length mm (in)
Limit 585 (2.303)
 17-11

Measurement and tests

4Y Standard 2200
Stall speed rpm 1DZ-III Standard 2200
3Z Standard 2050
At idle Standard 735 - 1324 (7.5 - 135) [1066 - 1920]
Main pressure kPa (kgf/cm 2 ) [psi]
2000 rpm Standard 890 - 1270 (9.1 - 130) [129 - 185]
At idle Standard 735 - 1324 (7.5 - 135) [1066 - 192.0]
Clutch pressure kPa (kgf/cm 2 ) [psi]
2000 rpm Standard 890 - 1270 (91 - 130) [129 - 185]
Torque converter pressure
kPa (kgf/cm 2 ) [psi] 2000 rpm Standard 50 - 540 (0.5 - 5.5) [73 - 783]
(outlet pressure)
Tightening torque Unit: N'm (kgf'cm) [ft'lbf]
Stator shaft set bolt Standard 21.0 (214) [15.5]
Transmission cover (upper cover) set bolt Standard 210 (214) [155]
ccngine mounting nut Standard 53.2 - 980 (550 - 1000) [398 - 723]
.ront insulator set bolt Standard 68.0 - 102.0 (700 - 1050) [50.6 - 76.0]
- .orque converter housing set bolt Standard 294 - 44.1 (300 - 450) [21.7 - 326]

Drive plate set bolt 4Y Standard 568 - 647 (580 - 660) [42.0 - 47.8]
(for connecting to engine crank shaft) 1DZ-III,3Z Standard 764 - 93.1 (780 - 950) [564 - 68.7]
.-
Drive plate set bolt (for connecting to torque carver) Standard 14.7 - 21.6 (150 - 220) [10.9 - 15.9]

TORQUE CONVERTER (2 STATOR TIC (OPT))

Control valve
Standard 110 (4.331)
Regulator valve spring free length mm (in)
Limit 98 (3858)
Standard 70 (2.756)
Inner
Limit 62 (2441)
Accumulator spring free length mm (in)
Standard 122 (4.803)
Outer
Limit 108 (4.252)

I Inner
Standard 27.0 (106)
I
Limit 24.0 (0.94)
... Ielling valve spring free length mm (in)
Standard 63.3 (249)
Outer
Limit 58.0 (2.28)
Torque converter
Standard 70.00 (2.7559)
Pump boss outside diameter mm (in)
Limit 69.85 (2.7450)
Standard 82 (0.323)
Stator (N02) roller outside diameter mm (in)
Limit 8.17 (0322)
I

Standard 0.08 - 0.12 (0.0031 - Cl.0047)

Stator (No.2) hub to cam clearance mm (in)
Limit 0.2 (0.0079)
17-12

Statorshaft NO.2 & oil pump

Stator shaft No.2 outside diameter Standard 48 (1.889)
mm (in)
(at portion in sliding contact with oil pump) Limit 47.9 (1.886)
Standard 0.14 - 0.20 (0.005 - 0.0079)
Pump driven gear to pump body clearance mm (in)
Limit 0.3 (0.012)
Standard 0.025 - 0066 (0.00098 - 000260)
Pump drive gear bushing to stator shaft clearance mm (in)
Limit 0.15 (0.0059)

Pump body mounting surface and drive/driven Standard 0.06 - 010 (0.0024 - 0.0039)
mm (in)
gear clearance Limit 0.13 (0.0051)

Transmission
Main shaft and reverse shaft seal ring side clearance mm (in) Limit 0.30 (0012)
Clutch piston ring side clearance mm (in) Limit 04 (0.0157)
Standard 3.8 (0.150)
Clutch camber plate warp mm (in)
Limit 3.3 (0.130)
Standard 2.6 (0.102)
Clutch disc plate thickness mm (in)
Limit 2.3 (0.091)
Standard 1.6 (0063)
Clutch plate thickness mm (in)
Limit 14 (0.055)
Snap ring to pressure plate clearance mm (in) Standard 31 (0122) (Reference)
Standard 100 (3.94)
Clutch piston return spring free length mm (in)
Limit 90 (3.54)

Measurement and tests

Stall speed rpm Standard 1950
At idle 600 or more (6.0 or more) [85 or more]
Main pressure kPa (kgf/cm 2 ) [psi]
1500 rpm 1000 - 1400 (10.2 - 142) [145 - 203]
At idle 600 or more (6.0 or more) [85 or more]
Clutch pressure kPa (kgf/cm 2 ) [psi]
1500 rpm I 1000 -1400 (10.2 - 142) [145 - 203]
2
Torque converter outlet pressure kPa (kgf/cm ) [psi] 1500 rpm 100 - 400 (1.02 - 4.1) [14.5 - 58]

Tightening torque Unit: N'm (kgf-cm) [ft-Ibf]

. ,
Engine mounting nut Standard 53.2 - 98.0 (550 - 1000) [39.8 -72 .
Front insulator set bolt Standard 680 - 102.0 (700 - 1050) [50.6 -76.0]
Torque converter housing set bolt Standard I 294 - 44.1 (300 - 450) [21.7 - 32.6]

Drive plate set bolt 4Y 568 - 647 (580 - 660) [42.0 - 47.8]
Standard
(for connecting to engine crank shaft) 1DZ-III'3Z 764 - 93.1 (780 - 950) [564 - 687]
Drive plate set bolt (for connecting to torque converter) Standard 14.7 - 21.6 (150 - 220) [10.9 - 15.9]

DIFFERENTIAL

Differential
1·2·K2 ton series Standard 0.2 - 0.3 (0.008 - 0012)
Ring gear backlash mm (in)
3·J3.5 ton series Standard 03 - 04 (0.012 - 0016)
 17-13

Standard 2612 (1028)

1K2 ton series
Limit 26.22 (1032)
Standard 2812 (1107)
2 ton series
Limit 2822 (1111)
Differential pinion bore mm (in)
Standard 2212 (0871)
3 ton series
Limit 22.22 (0875)
~~---- ---_.--- ._----_._-
Standard 2467 (0.971)
J35 ton series
Limit 2477 (0975)
I-----~~. ._--
Standard 2600 (1024)
1·K2 ton series
Limit 2575 (1.014)
Pinion shaft outside diameter mm (in) -- ----- - - ~-

Standard 2800(1.102)
2 ton series
Limit 2775 (1.093)
f------ -- _ ....- ------ --_ ... - _.. _-- - - ---- . - - - - - - - _ .. _- -
Standard 2200 (0866)
3 ton series
Limit 2175 (0856)
id er outside diameter mm (in)
, Standard 24.50 (0.965)
J3.5 ton series
Limit 2425 (0955)

I S;dc ge" theu,t wo'he, thicku%, mm (in)

Standard
Limit
16(0063)
13(0.051)
Standard 10 (0039)
1K2 ton series
Limit 07 (0063)
Pinion thrust washer thickness mm (in)
2·3·J35 ton Standard 1.6 (0028)
series Limit 13 (0051)
1K2·3J3.5 ton
Drive pinion bearing starting torque Standard 8.5 - 130 (90 - 135) [6.3 - 9.6]
series
N·m (kgf.cm) [ftlbf]
2 ton series Standard 85 -150 (90 -155) [6.3 -11.1]

Tightening torque Unit: N-m (kgf-cm) [ftolbf]

Drive pinion lock nut Standard 343 - 392 (3500 - 4000) [253.1 - 2892]
Drive pinion rear cover set bolt Standard 17.3 - 21.7 (176 - 221) [128 - 16.0]
['ifferential carrier set bolt Standard 32.4 - 48.6 (330 - 496) [23.9 - 35.9]
. I .. ,g gear set bolt Standard 127.4 -176.4 (1300 - 1800) [94.0 - 130.1]
.. .Jifferential carrier upper case set bolt 3·J3.5 ton series Standard 86.2 - 102.9 (879 - 1049) [63.6 -75.9]
117.7 -137.3 (12000 - 1400.0)
Differential case bearing cap set bolt Standard
[86.8 - 101.3]
Differential front cover set bolt Standard 13.5 - 24.5 (138 - 250) [10.0 - 18.1]
Front axle reactive force bolt Standard 294 - 343 (3000 - 3500) [216.9 - 2531]
1-2-K2 ton series Standard 686 - 980 (700 - 1000) [50.6 - 72.3]
Axle shaft set ball
3·J3.5 ton series Standard 107 - 140 (1100 - 1400) [789 - 103.3]
12K2 ton series Standard 108 -159 (1100 - 1600) [79.7 - 117.3]
Front axle ASSY set bolt
3J3.5 ton series Standard 127 -190 (1300 -1900) [93.4- 140.2]
Front axle bracket set nut Standard 235 - 294 (2400 - 3000) [173.4 - 216.9]
17-14

FRONT AXLE
Front axle hub (Dry brake)
1·K2 ton series Standard 24.5 - 99.0 (2.5 - 10.1) [5.5 - 22.3]
Front axle bearing starting force N (kgf) [Ibf)
2·3·J3.5 ton series Standard 196 - 78.4 (2.0 -8.0) [4.4 - 17.6]

Front axle hub (Wet brake)

100 - 160 (1020 - 1630)
Front axle bearing starting torque N'm (kgfcm) [ftlbf) Standard
[738 - 118.0]

Tightening torque Unit: N'm (kgf-cm) [ft-Ibf]

Nut lock bolt 3·J3.5 ton series Standard 15.0 - 22.0 (153 - 224) [11 - 16]
Nul lock screw 12K2 Ion series Standard 20 - 5.2 (20 - 53) [1.4 - 3.8]
1IK2 ton series Standard 686 - 98.0 (700 - 1000) [50.6 - 72.3]
Axle shaft set ball 107.0 - 140.0 (1100 - 1400)
3J35 ton series Standard
[789 - 103.3]
1 ton series' 1180 - 196.0 (1200 - 2000)
Standard
Divided rim specification [87.1 - 144.6]

~
Front wheel hub nut 1770 - 392.0 (1800 - 4000)
2·K2 ton series Standard
(single tire) [130.6 - 289.2]
294.0 - 588.0 (3000 - 6000)
3·J3.5 ton series I Standard r')11O; a _ -''''''''''''''00J
/1C!':l Ol
lL...' v - v

177.0 - 392.0 (1800 - 4000)

1IK2 ton series Standard
Front wheel hub nut [130.6 - 289.2]
(double tire) 2940 - 588.0 (3000 - 6000)
3·J3.5 ton series Standard
[216.9 - 433.9]

REAR AXLE
Rear axle ASSY
Rear axle ASSY front to rear clearance mm (in) Standard 10 (0039) or less
Rear axle center pin bushing inside diameter mm (in) Limit 52.0 (2.047)
Rear axle hub and steering knuckle
1 ton series Standard 15 - 39 (1.5 - 4.0) [3.3 - 8.5]
Rear axle hub starting force N (kgf) [Ibf) K2 ton series Standard 20 - 58 (2.0 - 5.9) [4.4 - 13.0] , I

2·3·J3.5 ton series Standard 15 - 44 (1.5 -4.5) [3.3 - 9.9]

f<ing pin outside diameter mm (in) Limit 278 (1.094)
Steering knuckle starting force N (kgf) [Ibf) Standard 193 (2.0) [4.4] or less
Rear axle cylinder
Rear axle cylinder piston rod outside diameler mm (in) Limit 49.92 (1.9654)
Rear axle cylinder piston rod bend mm (in) Limit 05 (0.020)
1 ton series Limit 76.35 (3.0059)
2·K2 ton series Limit 8035 (3.1634)
Rear axle cylinder inside diameter mm (in)
3 ton series Limit 84.40 (3.3228)
J3.5 ton series Limit 87.40 (3.4409)
 17-15

Rear wheel alignment

1.5 ton Standard 1990 (783)
1.75 ton Standard 2010 (79.1)
2.0 ton Standard 2200 (86.6)
Minimum turning radius mm (in) 2.5 ton Standard 2280 (89.8)
3.0 ton Standard 2430 (95.7)
K2.0 ton Standard 2040 (80.3)
J35 ton Standard 2490(98.0)
Tightening torque Unit: N-m (kgf-cm) [ft-Ibf]
Axle bracket cap set bolt Standard 117.7 - 1667 (1200 - 1700) [868 - 123.0]
King pin lock bolt and lock nut Standard 44.1 - 53.9 (450 - 550) [326 - 39.8]
1 ton series Standard 29.5 - 440 (300 - 450) [218 - 32.5]
Divided rim bolt set nut K2 ton series Standard 785 - 1175 (800 - 1200) [57.9 - 86.7]
2 ton series Standard 49.0 - 68.5 (500 - 700) [362 - 50.5]
'ear axle cylinder rod guide set nut ~ard 88 - 118 (900 - 1200) [651 - 868]
Rear axle cylinder set bolt . Standard 1667 - 215.8 (1700 - 2200) [1230 - 159.1]

1 ton Divided rim Standard 890 -1570 (900 -1600) [65.7 - 1158]
series Side ring rim Standard 890 - 1570 (900 - 1600) [65.7 - 115.8]

2 ton Divided rim Standard 1180 - 196 (1200 - 2000) [87.1 - 1446]
series Side ring rim Standard 1770 - 392 (1800 - 4000) [1306 - 289.2]
Hub nut
3K2 ton Divided rim Standard 118.0 - 196 (1200 - 2000) [871 -144.6]
series Side ring rim Standard 1180 - 196 (1200 - 2000) [87.1 - 1446]
J3.5 ton
Side ring rim Standard 1180 - 196 (1200 - 2000) [87.1 - 144.6]
series
Tie rod end pin lock nut Standard 490 - 73.5 (503 - 750) [36.2 - 542]

STEERiNG

Hydrostatic steering valve ASSY

, 123K2 ton series Standard 8000 - 8500 (82 - 87) [1170 - 1233]
l .ief pressure kPa (kgf/cm 2 ) [psi]
J35 ton series Standard 8300 - 8800 (85 - 90) [1210 - 1276]

Tightening torque Unit: N-m (kgf-cm) [ft-Ibf]

Steering wheel set nut Standard 245 - 44.1 (250 - 450) [18.1 - 326]
Steering valve ASSY set bolt Standard 29.4 - 39.2 (300 - 400) [217 - 28.9]
Steering valve end cover set screw Standard 24 - 36 (245 - 367) [17.7 - 26.6]
17-16

BRAKE
Front brake (1 ton series)
Hold down spring free length mm (in) Standard 25.5 (1.004)
Standard 102.2 (4.024)
Anchor to shoe spring free length mm (in)
Limit No clearance between coil turns
Strut to shoe spring free length mm (in) Standard 19.7 (0.776)
Standard 994 (3913)
Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 4.9 (0.193)
Brake lining thickness mm (in)
Limit 10 (0.039)
Wheel cylinder to piston clearance mm (in) Limit 0.125 (0.00492)
Standard 254.0 (10.00)
Brake drum inside diameter mm (in)
Limit 256.0 (10.08)

Front brake (2'3'K2 ton series)

,
Standard 34.5 (1.358)
Hold down spring free length mm (in)
Limit 31.3 (1.232)
Standard 124.5 (4.902)
Actuator spring free length mm (in)
Limit No clearance between coil turns
Standard 106 (4.17)
Anchor to shoe spring free length mm (in)
Limit No clearance between coil turns
Standard 23 (0.91)
Strut to shoe spring free length mm (in)
Limit 20 (0.79)
Standard 86 (3.39)
Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 7.0 (0.276)
Brake lining thickness mm (in)
Limit 2.0 (0079)
Wheel cylinder to piston clearance mm (in) Limit 0.145 (0.00571)
Standard 310.0 (12.20)
Brake drum inside diameter mm (in)
Limit 312.0 (12.28)
Front brake (J3.5 ton series) .',"
Hold down spring free length mm (in) Standard 44.0 (1.732)

Anchor to shoe spring free length Standard 138.2 (5441)

mm (in)
(On the side of lining WI pin) Limit No clearance between coil turns

Anchor to shoe spring free length Standard 121.2 (4.772)

mm (in)
(On the side of lining WIO pin) Limit No clearance between coil turns
Strut to shoe spring free length mm (in) Standard 314 (1.236)
Standard 1254 (4.937)
Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 56 (0.220)
Brake lining thickness mm (in)
Limit 1.0 (0.039)
Wheel cylinder to piston clearance mm (in) Limit 0.15 (0.00492)
Standard 3175 (12.50)
Brake drum inside diameter mm (in)
Limit 319.5 (12.58)
 17-17

Wet brake
Piston return spring
Limit 237 (0.933)
free length

Front brake ASSY mm (in) Plate NO.1 thickness Limit 1.7 (0.067)
Plate NO.2 thickness Limit 3.3 (0.130)
Brake disc thickness Limit 3.2 (0.126)

Plate NO.1 2 ton series Limit 1.0 (0039)

thickness 3·J35 ton series Limit 13 (0.051)

Plate NO.2 2 ton series Limit 8.8 (0.35)

Parking brake ASSY mm (in)
thickness 3J35 ton series Limit 9.3 (0.366)

Brake disc 2 ton series Limit 1.2 (0047)

thickness 3J35 ton series Limit 12 (0.047)
Brake valve (Wet brake)
..
'llve return spring free length mm (in) Limit 197 (0.776)
,.pmpression spring free length mm (in) Limit 18.9 (0.744)

IParking brake
Release lever play mm (in) Standard 0-5 (0 - 0.2)

Foot parking brake operating force I Dry brake Standard 112 -136 (114 -13.9) [25.1 - 30.6]
N (kgf) [Ibf]
(when SST is used) Wet brake Standard 138-162(14.1-16.5)[31.1-36.4)

Foot parking brake operating force Dry brake Standard 186 - 226 (19.0 - 23.0) [42 - 51]
N (kgf) [Ibf]
(when SST is not used) Wet brake Standard 230 - 270 (23.5 - 27.5) [51.8 - 60.6)
Brake pedal
Brake pedal height (from toe board: with pad) mm (in) Standard 145 - 150 (5.91 - 6.10)
Dry brake Standard 1 - 5 (0.039 - 0.197)
Brake pedal play mm (in)
Wet brake Standard 14 - 19 (0.55 - 075)
Dry brake Standard 90 (3.54) or more
Brake pedal depressed height (with pad) mm (in)
Wet brake Standard 30 (1.18) or more
Brake master cylinder push rod play mm(in) Dry brake Standard 1 (0039)
ingpedal play mm (in) Standard 1 - 3 (0.039 - 0.118)
~

'ightening torque Unit: N-m (kgf-cm) [ft-Ibf]

137 - 210 (1400 - 2100)
Backing plate set bolt Standard
[101.3 - 154.9)
1 ton series Standard 7.8 - 11.8 (80 - 120) [5.8 - 8.68)
Wheel cylinder set bolt 2·3K2 ton series Standard 14.7 - 19.6 (150 - 200) [10.9 - 145)
J3.5 ton series Standard 17.7 - 26.5 (180 - 270) [13.0 - 19.5)
Brake master cylinder set nut Standard 6.8 -15.8 (69 -161) [5.0 -11.7)
Wet brake ASSY set bolt Standard 137 - 210 (1400 - 2100) [101 - 155)
Inner housing set bolt (Wet brake) Standard 44.1 - 59.8 (450 - 610) [32.5 - 44.1]
Brake valve lock nut (Wet brake) Standard 49.0 - 78.5 (500 - 800) [36.2 - 57.9)
Accumulator ASSY set bolt (Wet brake) Standard 32.1 - 48.6 (330 - 500) [23.9 - 359)
100 - 136 (1000 - 1400)
Accumulator tank (Wet brake) Standard
[73.8 - 100.3)
Parking brake rear cover (Wet brake) Standard 32.4 - 48.6 (330 - 500) [23.9 - 35.9)
MATERIAL HANDLING SYSTEM
Natural drop test
Natural drop mm (in) Limit 45 (1.77)

Natural forward tilt test

1 ton series Standard 15 (0.59) or less
Natural forward tilt mm (in) 2·K2 ton series Standard 20 (0.79) or less
3J35 ton series Standard 25 (0.98) or less

Oil leak test

Lift cylinder oil leak amount cm 3 (in 3 ) Standard 8 (0.49) or less
Tilt cylinder oil leak amount
cm 3 (in 3 ) Standard 16 (0.98) or less
(total for lift and tilt)
Tightening torque Unit: N'm (kgf-cm) [ft-Ibf]
Tank cover Standard 9.8 - 14.7 (100 - 150) [7.24 -1085)
Return filter Standard 6.9 - 16.1 (70 -160) [5.09 - 11
.....1

MAST
Mast adjustment (V mast)
Inner mast roller clearance mm (in) Standard 0- 0.6 (0 - 0.024)
Mast rollers
Outer mast roller clearance mm (in) Standard 0- 0.6 (0 - 0.024)
Upper and lower lift roller clearance mm (in) Standard 0- 0.6 (0 - 0.024)
Lift bracket
Middle lift roller clearance mm (in) Standard 0- 0.6 (0 - 0.024)
rollers
Side roller clearance mm (in) Standard 0- 0.6 (0 - 0.024)
Mast strip to inner mast clearance mm (in) Standard 0- 06 (0 - 0.024)
Other Limit 1.5 (0.059)
Mast strip thickness mm (in)
J3.5 ton series Limit Until the oil dimples are worn away
Fork
Fork front end misalignment mm (in) Limit 10 (0.39)
Tightening torque Unit: N'm (kgf-cm) [ft-Ibf]
Chain adjusting nut Standard 64.0 (653) [47.2]
.... ~

Tilt cylinder front pin set bolt Standard 66.0 - 154.0 (673 - 1570) [48.7 - 1136]
138.0 - 322.0 (1407 - 3282)
Mast support set bolt Standard
[101.8 - 237.4]
 17-19

CYLINDER
Lift cylinder (V)
Standard 35 (1.38)
1 ton series
Limit 3492 (13748)
Standard 40(1.575)
Piston rod outside diameter mm (in) 2·K2 ton series
Limit 3992 (15717)
Standard 45 (177)
3·J3.5 ton series
Limit 4492 (17685)
Standard 45 (1.77)
1 ton series
Limit 45.20 (17795)
Standard 50 (1.97)
2·K2 ton series
Limit 5020 (19764)
Cylinder bore mm (in) ~-

Standard 55 (217)
3 ton series --
Limit 5535 (2.1791)
Standard 60 (2.36)
J35 ton series
Limit 60.35 (2.3760)
Piston rod bend mm (In) Limit 20 (0.079)
Rear lift cylinder (FV·FSV-FSW)
Standard 32 (1.26)
FV ..-
Limit 31.92 (1.2567)
1 ton series
Standard 35 (1.38)
FSV
Limit 34.92 (1.3748)
Standard 35(1.38)
FV
Limit 34.92 (1.3748)
K2 ton series
Standard 40 (1.575)
FSV
. Limit 3992 (1.5717)
Standard 35 (1.38)
I FV
Limit 34.92 (1.3748)
Ir
I
'on rod outside diameter mm (in) 2 ton series
Standard 40 (1.575)
FSVFSW
Limit 3992 (1.5717)
Standard 40 (1575)
FV
Limit 3992 (15717)
3 ton series
Standard 45 (1.77)
FSVFSW
Limit 4492 (1.7685)
Standard 40 (1.575)
FV
J3.5 ton Limit 3992 (1.5717)
series Standard 45 (1.77)
FSV
Limit 4492 (1.7685)
17-20

Standard 45 (1.77)
1 ton series
Limit 45.20 (1.7795)
Standard 50 (1.97)
2·K2 ton series
Limit 5020 (19764)
Cylinder bore mm(in)
Standard 55 (2.17)
3 ton series
Limit 55.35 (2.1791)
Standard 60 (2.36)
J35 ton series
Limit 6035 (2.3760)
Piston rod bend mm (in) Limit 2.0 (0.079)

Front lift cylinder (FV-FSV-FSW)

Standard 50 (1.97)
1 ton series FVFSV
Limit 49.92 (1.9654)
~ .. _ . _ . _ - - -

Standard 50 (1.97)
K2 ton series FV·FSV
Limit 49.92 (1.9654)
Standard 50 (1.97)
FVFSV ~

Limit 49.92 (1.9654)

2 ton series
Piston rod outside diameter mm (in) Standard 45(1.77)
FSW
Limit 44.92 (1.7685)
---------- 1 - - - - -.. - - -
Standard 60 (2.36)
FVFSV
Limit 59.91 (2.3587)
3 ton series
Standard 45 (1.77)
FSW
Limit 44.92 (1.7685)
- - - - - - . - _.
J3.5 ton Standard 60 (2.36)
FV·FSV
series Limit 59.91 (2.3587)
Standard 70 (276)
1 ton series FV·FSV
Limit 70.35 (2.7697)
. __ .",.-._.. ,---
Standard 75 (2.959)
I K2 ton series FVFSV
I Limit 75.35 (2.9665)
-' - - - - - - - - - - f----
I
Standard 75 (2.959)
FVFSV
Limit 75.35 (2.9665)
2 ton series l .1..
Standard 55(2.17)
Cylinder bore mm (in) FSW
Limit 55.35 (2.1791)
Standard 85 (3.35)
FVFSV
Limit 85.40 (33622)
3 ton series
Standard 60 (2.36)
,I FSW
Limit 60.35 (2.3760)
•
J35 ton Standard 90 (3.54)
FVFSV
I
series Limit 90.40 (3.5591)
Piston rod bend mm (in) Limit 2.0 (0.079)
 17-21

Tilt cylinder
Standard 70 (2756)
Cylinder bore mm (in)
Limit 70.35 (2.7697)
Standard 30 (1.181)
Piston rod outside diameter mm (in)
Limit 29.92 (1.1780)
Piston rod bend mm (in) Limit 05 (0.020)
Tightening torque Unit: N'm (kgf-cm) [ft-Ibf]
1 ton series Standard 225 (2290) [1660]
2·K2 ton series Standard 250 (2550) [1844]
Lift cylinder cover
3 ton series Standard 275 (2800) [2029]
J3.5 ton series Standard 305 (3110) [225.0]
FV·FSV Standard 392 (4000) [2892]
Front lift cylinder cover 2 ton series Standard 275 (2800) [202.9]
FSW
3 ton series Standard 305 (3110) [225.0]
880 - 1320
it cylinder Joint set nut Standard
(897 - 1346) [649 - 974]
Tilt cylinder cover Standard 353 (3600) [2605]
66.0 - 1540
Tilt cylinder front pin set bolt Standard
(673 - i 570) [487 - 1i 3.6]
I
360 - 854
Tilt cylinder rear pill set bolt Standard
(373 - 871) [27.0 - 63.0]
17-22

OIL PUMP
Oil pump ASSY (4Y'1 DZ-III·3Z)
Side plate thickness mm (in) Limit 2.927 (0.1152)
Gear shaft outside diameter mm (in) Limit 20.99 (0.8264)
Gear plate inside surface flaw depth mm (in) Limit 0.2 (0.0079)

Oil pump ASSY (4Y (Cabin Spec., Low Noise Spec.))

Side plate thickness mm (in) Limit 2.927 (01152)
Gear shaft outside diameter mm (in) Limit 20.961 (0.8252)
Gear plate inside surface flaw depth mm (in) Limit 0.2 (00079)
Center bushing thickness mm(in) Limit 41.38 (16291)

Oil pump ASSY (Wet brake)

Main Limit 2.927 (0.1152)
Side plate thickness mm (in)
Sub Limit 2.927 (0.1152)
Main Limit 2099 (0.8264)
Drive/driven gear shaft outside diameter mm (in) .. '~
Sub Limit 2099 (0.8264)
Main Limit 0.2 (0.0079)
Gear plate inside surface flaw depth mm (in)
Sub Limit 0.2 (00079)

I ightening torque Unit: N'm (kgf'cm) [fHbf]

24.0 - 33.0 (245 - 337)
Oil pump ASSY set bolt Standard
[17.73 - 24.38]

OIL CONTROL VALVE

Oil control valve
1 ton +1.7 +17 +240
Standard 178 0 (182 0) [2590 0]
series
Lift
+1.7 +17 +240
Other Standard 18.7 0 (191 0) [2720 0]
Relief pressure
MPa (kgf/cm 2 ) [psi] 1 ton +1.7 +17 +240
Standard 11.8 0(120 0)[1710 0]
series
Tilt
+1.7 +17 +240
Other Standard 147 0 (150 0) [2132 0]
.c-
Tightening torque Unit: N'm (kgf-cm) [ft·lbf]
. Oil control valve ASSY set bolt Standard 216 - 50.4 (220 - 514) [1592 - 37.19]
 17-23

SAS lOPS
Tightening torque Unit: Nom (kgfocm) [ftolbf]
SAS/OPS controller set bolt Standard 5 5 (561) [4.1]
Tire angle sensor set bolt Standard 10 - 16 (100 - 160) [7.2 - 12.0]
Swing lock cylinder pin set bolt Standard 29 (296) [21 A]
Tilt angle sensor set bolt Standard 17 (173) [125]
Load sensor Standard 22 - 26 (224 - 265) [16.2 - 19.2]
Speed sensor set bolt Standard 3 - 7 (31 -71)[2.2 - 52]
162 - 378
Fork height switch ASSY set bolt Standard
(1652 - 385.5) [12.0 - 279J
 Published by

TOYOTA Material Handling Company

A Division of TOYOTA INDUSTRIES CORPORATION

1st Printing: July 2007

Pub. No. CE056

Printed in Japan
 FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT 8FGF/
8FDF15-30 series. Please use this manual for providing quick, correct servicing of
the corresponding forklift models.

This manual deals with the above models as of August 2007. Please understand that
disagreement can take place between the descriptions in the manual and actual
vehicles due to change in design and specifications. Any change or modifications
thereafter will be informed by Toyota Industrial Equipment Parts & Service News.

For the service procedures of the mounted engine, read the repair manuals listed
below as reference together with this manual.

(Reference)
Repair manuals related to this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 8FGF/8FDF15-30

VOL.1 REPAIR MANUAL (No. CE056)
TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE
REPAIR MANUAL (No. CE663)
TOYOTA INDUSTRIAL EQUIPMENT 1DZ-III ENGINE
REPAIR MANUAL (No. CE670)
TOYOTA INDUSTRIAL EQUIPMENT 3Z ENGINE
REPAIR MANUAL (No. CE671)
TOYOTA INDUSTRIAL EQUIPMENT LPG DEVICE
REPAIR MANUAL (No. CE669)

TOYOTA Material Handling Company

A DIvIsion of 10YOTA INDUSTRIES CORPORATION
 SECTI N INDEX
l~-==~==_=-=:____ ---~~~~_=~-~-_~_~ ~~===~-=_=_==-L_SECTI
--------------------------- -- ---------------------- ------,--~

I-EGE
l ~~~~~______ __
N GIN E ------- - - -- ------ - - -- ----------- --~I-
L - I_

---
,~_____________________________ _ 1'----------_

lTORQUEC-ONVERTER-&-TRANSMlsSIO-N--T-
I _ _
\PRO-PELLE-R-S,..fAFT------ d - - - - - - - I
'--________________________ L _

~~RE~!1~1~- _-~_-~~_~--- _- -- ~I_

l FRON_T-~~_~~ __ ~~ ~-_-~-~~~-~~-~~~ _~_- - -----~I~
iREAR -AXLE-=_~~_~-_~_~~~_-~~~____ -
r--------~------- -- ------- -
~~~~~~_
---------- - - ====:=,====
I

L~!..~ERI~_~________________ _ _ ~_
\ BRAKE
[!30DY---
--------~_~~-=~=~-~
_--=~~_~~~~~-
__-_ -----------T-
~_~_-~~~==~.._J~

I MATERIAL HANDLING-SYS-fEM~-------~~
I _ _ _ __ _ I

i, MAST _ JI _
\ CYLINDER - ----------------- I
, - - -- - -- =----=---=-------------~-==:- _~I===
lOll PUMP
[ - - - - -----------------------------------

! OIL CONTROLVAL\fE--------- ~
, --------------- --- ~I ====
:--NIINI-
L
LEVE-R-JOvs=fitSK---- - -
~
I
~
ISAS/OPS ------------------------ I
==;===
lssTCiS~ERVICE-_~_!~~~~!\~DS LIST
- - -- --.----,..- - ' - - - - - - - .. _--.----
L
i
L_
MULTIFUNCTION
_
DiSPLAY (OPT) ~ _

~-Ei_ECTRICAL SYSTEM
I
TROUBLESHOOTING
: WIRING DIAGRAM
 18-1

MULTIFUNCTION DISPLAY (OPT)

Page
GENERAL 18..2
GENERAL FUNCTIONS 18..3
GENERAL 18.. 3
DISPLAY SCREEN AND OPERATION
PROCEDURE 18..4
ADMINISTRATOR FUNCTIONS 18..9
MASK FUNCTIONS 18..13
GENERAL 18..13
PASSWORD 18..14
ANALYZER 18..17
TU NIN G 18..45
OPTION SET 18.. 56
MATCHING 18..58
WHEEL RADIUS SET 18.. 66
ENGINE IDLE SPEED ADJUSTMENT
(4Y ENGINE VEHICLE) 18..68
LCD CONTRAST ADJUS1MENT 18..69
METER START 18.. 70
MULTIFUNCTION DISPLAY ASSY 18..72
DISASSEMBLY·REASSEMBLY 18..72
18-2

GENERAL
The multifunction display is capable of indicating various types of vehicle information by switching the screen
according to the displayed contents.

Name of Each Part

(5)

( '\

I \
I hrn/h

t~I~~:cDII "'"OH

(1 ) (2) (3) .(4)

STD model/OX model OX model with travel and load handling control

Display specificalion
No
STD model OX model OX model (with travel and load handling control)
(1 ) Lower switch Lower switch Low-speed setting switch/lower switch
(2) Left switch
(3) Right switch
(4) Meter display changeover switch
(5) Multiplex screen display area
 18-3

GENERAL FUNCTIONS

GENERAL
General functions are the functions normally used by an operator or an administrator.
Also, there are three models for the multifunction display, and each has different functions available

General Function List

0: Operator can use
-;:,: Administrator can use (Protected by password)
- : No setting

UOC"OUS------______~Odel
Display specification
OX model
STD model Without travel and With travel and
Functions load handling control load handling control
,
Digital speedometer 0 0 0
Torque converter oil temperature indicator 0 0 0

~
Planned maintenance hour warning indicator 0 0 0
Status display
Load meter - 0 0
Low speed setting indicator - -1 - I 0 I
Travel and load handling control indicator - - 0
-
Odometer 0 0 0
Integrating meters Trip meter
_. 0 0 0
Planned maintenance hour meter 0 0 0
Diagnostic code display 0 0 0
Parking brake ON warning 0 0 0
Warning Parking brake OFF warning 0 0 0
Torque converter oil temperature warning 0 0 0
Over speed alarm - 0 0
Low speed level setting - - 0

I Traveling speed limiter level setting - - "c-

l-!

Over speed alarm setting - 0 0

Level setting
Load meter zero point adjustment - ~-
W
-'~
I-!

Planned maintenance hour meter setting ,. -{\+ ·t:T

I
Menu lock setting - .J~

I .,~( 1-.\

Output limit during overheating' 0 0 0

*: 4Y engine vehicle only

18-4

DISPLAYSCREEN AND OPERATION PROCEDURE

Key ON Initial Screen
Displayed for about 1 second when turning the ignition key switch
on.

General Screen (Meter Start not Performed)

If the indiCator shown in the left illustration is displayed in the
general screen, perform the meter start (Refer to page 18-70)
Unless the meter start is performed, adding to the odometer, trip
km/h meter, and maintenance hour meter will not start

COHV
TEMP C H
,I

General Screen
, Digital speedometer
Traveling speed is displayed in digital for every 1 km/h or 1
mph
km/h , Torque converter oil gauge
Oil temperature of the torque converter is displayed in 10
levels.

CONY-cUD
TEMP
 18-5

Meter Display Screen

(1) With travel and As you press switch (4) on the general screen, the display changes
load handling control over in sequence of odometer~-t trip meter ~--t maintenance hour
meter --t general screen

(1 ) (2) (3) (4)

Odometer
Displays cumulative traveling dIstance.

ODD o 0 km
a
• Trip meter
Displays cumulative distance of a tnp traveling
TRIP oaOkm Pressing switch (1) for more than 2 seconds will reset the
meter.

2SEC
(BESET) (NEXT)

• Maintenance hour meter

Displays set value and current value of the maintenance hour

e1; MAI NTENANCE HR meter

CURRENT El 0h
ISETT I NC 2000 h
I ( t:' )
Load Meter (DX ModellDX Model with Travel and Load
Handling Control Only)
Pressing the load display sWitch on the lift lever will display
current live load on the screen.
In the joystick specification (OPT) vehicle, the fork automatic
1
leveling stop switch is used

t
• The arrow is displayed at a high lift, and flashing the value will
Indicate that the display is not correct
• Less than 100 kg will be displayed as 000 t
• If it is displayed as -0.00 t, it indicates that zero point is slightly
misaligned to minus side.
Since it detects the lift cylinder pressure and performs only
simple measurement, do not use it for judging overloading
when it is around permissible load.
.18-6

• When there is an abnormality in the load sensor, the screen

flashes as shown in the illustration .

• ~",\I///
--- ---
---
---/ / / I \ ",~t
,.."." 4 liW'tid

'---------,----------'

Indicator Display
Low-speed setting set Indicator (DX model with travel and load
handling control only)
As you press switch (1), the indicator is turned on/off, and the
low-speed setting control is activated when the indicator is on.
Level setting is carry out in the low-speed setting screen.

CONVc
TEMP H

• Travel and load handling control indicator (DX model with

travel and load handling control only)
Displayed when the travel and load handling control is
activated, indicating that the travel and load handling control is

km/h operating

When lifting height/load sensing traveling speed limit function

IS off.
(Lifting height/load sensing sudden acceleration preventior
function can be operated)
km/h

cot~VcBB
TEMP

Maintenance indicator
When the time set in the maintenance hour meter comes, it will
notify with the indicator display and alarm

km/h

CONvcBB
TEMP
 18-7

Warning Display
Diagnosis display
When the diagnosis is performed, it displays the indicator and
f detected error code and sounds an alarm (Only the errors that
I the multifunction display can recognize will be indicated)
-,

I
Parking brake ON warning
If you drive with the parking brake on, the indicator ,s displayed
and an alarm sounds.

hrn/h

• Parking brake reminder warning

If you turn the ignition key switch off or leave the dnving seat
without applying the parking brake, an alarm sounds (There
will be no indication on the display)

• Torque converter oil temperature warning

When the torque converter oil temperature reaches the level 9
(approx 120°C (248°F)), it warns by flashing the indicators all
the way to the level 9 If the oil temperature becomes approx.
140°C (284°F) or above, all the Indicators will flash

• Over speed alarm (only for OX modellDX model with travel

and load handling control)
If the set traveling speed is exceeded, the traveling speed
display will invert and start flashing, and an alarm sounds.
18-8

Setting Screen (OX Model/OX Model with Travel and Load

(1) With travel and Handling Control Only)
load handling control In OX model, pressing switch (1) on the general screen for more
than 2 seconds will display the setting menu screen.
(If the menu lock is set to "enable" in the administrator function, the
setting menu screen will not be displayed)

(1 ) (2) (3) (4)

Setting menu screen (DX model)

Select an item \vith s\vitch (1), and press svvitch (4) to display
each setting screen

!::a END

( .. ) ( t:B )

• Setting menu screen (OX model with travel and load handling
control)
Select an item with sWitch (1), and press switch (4) to display
each setting screen
11 SPEED ALARM SET
!:) END

( .. ) ( t:B )

Low speed setting screen (only for OX model with travel and
load handling control)
~LOW SPEED SET Sets the level of the low speed setting
If you set it to the level 8, low speed setting function will be
disabled.
Switch (2): Setting level down
Switch (3): Setting level up
Switch (4): Returning to menu screen
(+ m+) (tJ)

Over speed alarm setting screen (DX modellDX model with

travel and load handling control only)
£i SPEED ALARM SET Sets the traveling speed for the over speed alarm.
Switch (2): Setting traveling speed down
hrn/h
1
Switch (3): Setting traveling speed up
Switch (4): Returning to menu screen

(+ m+) (tJ)
 18-9

ADMINISTRATOR FUNCTIONS
Administrators can set the vehicle's performance and each function.
Administrator functions are protected with password so that the general operators cannot change those functions

Administrator Password
Note:
Always operate switches displayed on the display with a finger tip. If a sharp pointed tool is used, the
switch may be damaged.
If an operation error occurs during entry operation, turn the ignition key switch OFF and reenter from the
beginning.

Password Entry Procedure

Step Display Operation Vehicle response
---------------_._--~~-+---------

3 Press switch (3) within 10 seconds. A short beep sounds

(3)

Wifhin 10 seconds, press switch (2)

4 and switch (4) at the same time for
more than 2 seconds.

(2) (4)

!:) END
5 Administrator menu screen is displayed automatically

(+ ( ;.J )
18-10

Administrator Menu Screen

(1) With travel and
load handling control Switch (1) Switching selection to next item
SWitch (4) Moving to each setting screen

(1 ) (4)

. STD model

!J END

( .. ) ( t>J )

• OX model

~ LOADMETER 0 SET
~ MAINTENANCE HR
a MENU LOCK
(+) (+J)

( .. ) ( tJ )
 18-11

. ox model with travel and load handling control

W SPEED LIMIT SET

n SPEED ALARM SET
~ LOADMETER 0 SET
(+) (+J)

a ME~lU LOCt\ I
!:) END
( t-' 11

Administrator Function Setting Screen

Low speed setting screen (OX model with travel and load
~LOW SPEED SET handling control only)
This IS the same as the one in the general functions

( • I -+ ) (+J)

• Top speed limit screen (OX model with travel and load
handling control only)

~SPEED LIMIT SET Sets the top speed limit when traveling.
If you set it to the level 8, top speed limit function will be
disabled
Switch (2) Setting level down
"
ti Switch (3) Setting level up
Switch (4) Returning to menu screen
c•• -+) (tJ)

• Over speed alarm setting screen (DX model/DX model with

travel and load handling control only)
SPEED ALARM SET
1
This is the same as the one in the general functions
l}
km/h

( • • -+) (t-J)
18~12

• Load meter zero point adjustment screen (only for OX model!

OX model with travel and load handling control)
Zero point of the load meter is adjusted.
~ LOADMETER 0 SET

2SEC
t
(OSET) ~J

Pressing switch (1) for more than 2 seconds will reset the
indicated value to 0
SWitch (4) Returning to menu screen
~ LOAD METER 0 SET

2SEC
t
( OSET) ( ~ )

• Maintenance hour meter setting screen

Time for maintenance hour meter IS set

e.x MA I NTENANCE
HR
It can be set from 10 to 2000 hours, but you can set it by 10-
hour increments between 10 and 200 hours,

CURRENT 8 0h while 50-hour increments between 200 and 2000 hours

Switch (2) Reducing set time
SETTING 2000 h I' Switch (3) increasing set time

1L: :(R2=ES=S~=%~( =.==--__ =tJ==:::-lj I

Switch (4) Returning to menu screen
Pressing switch (!) for more than 2 seconds will reset the
--:=::( current value to 0

• Menu lock screen (OX model/OX model with travel and load
handling control only)

a MENU LOCK
Change in the setting values by an operator can be limited
Setting to "Yes" will cancel displaying the setting menu screen
for an operator
Switch (2) Selecting "Yes"
/ NO Switch (3) Selecting "No"
Switch (4) Returning to menu screen

I ... ) ( ~ )
 18-13

MASK FUNCTIONS
GENERAL
In the multifunction display, aside from the general functions that an operator or an administrator normally use, the
following mask functions for use by the service staff for vehicle maintenance and specification setting are also
provided
The service functions are protected by the password so that the important Internal data will not be damaged by wrong
use of service functions by users by mistake

Mask Function List

Function Description
L Vehicle
)
When lIsed
Board
)

Others
delivery replacement

I Analyzer
~-~-~-

Displays the electncal system status

and reads the error information
,----

- -
Upon vehicle
abnormality
detected by controllers
\
Makes fine adjustment of traveling 0 As requested
-
IILlnin 9 _ and material handling functions '2 by customer

ISpecification setting Sets each vehicle option and other

specifications *1
-
0
*2~*3
-

Option Setting IEach contcol function Enables or disables each control 0

- -
enable/disable function *2*3
Updates voltage values of sensor
0 0
Matching signals under the standard vehicle -
*2~*3 *5
condition
Makes the speedometer reading 0 0
Wheel radiUS -
appropriate~ *2 *4
--
Engine idle adjustment 0 As requested
Adjusts engine idle speed -
(4Y engine vehicle only) *2 by customer
Adjusts the contrast of the display 0 As requested
Contrast -
screen. *3 by customer

rMet~~-start Starts counting the odometer, triP

meter and maintenance hour meter.
0
*3
0
-

This is to match the controller and display control according to the installed option and control functions equipped
in the vehicle. Note that this function does not enable or disable the option or control function itself
*2 Board SAS/OPS controller
*3 Board Control board for the multifunction display
* 4 When tire size is changed or tire is replaced
*5 During the condition that is listed in matcllmg. page 18-58
18-14

PASSWORD
Note:
• Always operate switches displayed on the display with a finger tip. If a sharp pointed tool is used, the
switch may be damaged.
o If an operation error occurs during entry operation, turn the ignition key switch OFF and reenter from the
beginning.

Password Entry Procedure

Step Display Operation Vehicle response

When pressing the

Press sWitch (2), switch (3) and sWitches, a short beep
switch (4) at the same time for more sounds, and after 2
than 2 seconds seconds another short beep
sounds.
(2) (3) (4)

2 Press sWitch (4) within 10 seconds A short beep sounds.

A short beep sounds.

(1 )

I When pressing the

Within 10 seconds, press switch (2) Iswitches, a short beep
4 and sWitch (3) at the same time for i sounds, and after 2
more than 2 seconds. 'I seconds repeated short
beeps sound.
(2) (3)

5 \fER 1.00 Mask function initial screen is displayed for 5 seconds.

6
2.TUNING MASK MENU screen is automatically displayed

3.0PTIONSET
(+) (+J)
 18-.15

MASK MENU Screen

Caution:
During all the test screen display, the vehicle can be operated normally.

Operating Procedure

1 Enter the password on the general screen (Refer to page 18-

14) to display the r\flASK MENU screen

2aTUNING
3 OPT I Ot~SET
( ,.
a

) ( tJ )
I\
2 Select a deSired function uSing switch (1) Then, press SWitch
(1) With travel and (4) (set) to display the function screen or setting screen of the
------ load handling control selected function
3 Press (enter) switch (4) while selecting "9. END" menu to
return to the general screen
Also, in each screen, once the ignition key switch is turned
OFF, you can move to the general screen

(1) (4)

"i. ANALYZER"
This function indicates the electrical system status and reads
the error information detected by the controller

Switch (1) Switching selection to next item

I Switch (4) To ANALYZER MENU screen
I 2. TUN I NG "2. TUNING"
1
1
3 OPT I ONSET
a Use this function for fine adjustment of control of the traveling

. k'" ) ( ;:J ) and material handling

Switch (1) SWitch Ing selection to next item

SWitch (4) To TUNING MENU screen

"3. OPTIONSET"
Use this function to match control of the controller or display
according to the set options or controls

Switch (1) Switching selection to next item

Switch (4) To OPTION SET setting screen
18-16

"4. MATCHING"
This function updates the signal voltage values stored in the
controller (signal voltage values from the SAS, Mini Lever or
Load Meter functions sensors under the standard vehicle
condition)

5.WHEEL RADIUS Switch (1) Switching selection to next item

B.IDLE ADJUSTMENT Switch (4) To MATCHING MENU screen

(.) (t:J) "5. WHEEL RADIUS"

This function rewrites the tire information in the controller for
correcting the speed indication, odometer and trip meter

Switch (1) Switching selection to next item

Switch (4) To WHEEL RADIUS setting screen

"6. IDLE ADJUSTMENT" (4Y engine vehicle only)

Adjusts engine Idle speed of the 4Y engine vehicle

SWitch (1) Switching selection to next item

SWitch (4) To IDLE SPEED ADJUSTMENT setting screen

"7. CONTRAST"
Adjusts the contrast of the display LCD screen.

SWitch (1) Switching selection to next item

Switch (4) To CONTRAST ADJUSTMENT setting screen

8.METER START "8. METER START"

Starts counting the odometer, trip meter and maintenance hour
9.END meter
(+) (+J) Switch (1) SWitch ing selection to next item
Switch (4) To METER START setting screen

Note:
After start counting the meters, "METER START" will not be
displayed on the MASK MENU screen.
"9. END"
Switch (1) Switching selection to next item
Switch (4) To general screen
 18-17

ANALYZER
GENERAL
Analyzer function supports operations for inspecting/investigating faulty section by displaying the condition of the
control system, using communication between each controller and the multifunction display.
By switching the multifunction display to analyzer mode, operative conditions of the sensor actuator that is used for
traveling, material handling and SAS/OPS functions, or the error information detected by the controller can be read.
This is very useful for checking operative condition of each function and saving time for repairing when there is a
defect.
Full utilization of the analyzer functions helps quick, easy servicing

The analyzer has the following functions:

1. Diagnosis memory function (DIAG MEMORY)

The controller stores up to 10 error codes (diagnosis codes) detected in the electrical system in the past· The
diagnosis function reads these error codes and indicates them on the display.
Each error code is displayed with its detection time as the key ON 110ur meter reading.
In/out monitor function (I/O MONITOR)
This function displays the analog input values from individual sensors in the traveling, material handling, SAS
and OPS systems. Monitoring the displayed values enables the quality of each circuit/sensor to be judged ..
(1) ]/0 ENGINE CTRL
Displays ON/OFF states of the 4Y engine controller/ASC controller sWltcll, various input values including
analog input voltage from the sensor, correction value of tr,e control and output condition to the relay.

(2) I/O TRAVELlNG

Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
(3) I/O MATERIAL HANDLING
Displays the material handling and mast control switch ON/OFF states and analog input voltages from
material handling and mast control sensors.
(4) I/O STEERING
Displays the ON/OFF states of knob position correction control and the analog input voltages from
respective sensors.
(5) I/O OTHER
Displays the ON/OFF states of hour meter time and other switches and the analog input voltages from
respective sensors.
Active test (ACTIVE TEST)
In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected
item in order to permit operation check of that function
4 Program version display (VERSION)
Displays program version of each controller.
18-18

ANALYZER SCREEN MENU LIST

Analyzer menu screen Display item Description

Screen No
1_DIAG MEMORY 1_ - 10 Indications of errol s occurred
2_ 110 ENGINE CTRL IGSW Key switch (IG)
(4Y engine controller) -------~---.- - - - - - - .. - - - -- --'-------',-. __ .. - .. _---.--

STA Key switch (ST)

--
BATT Battery voltage
1110
1- G/L~ Fuel changeover switch

I~~~
Fuel specification discrimination signal
Engllle specification discrimination signal
f--~~-~EL EFl main relay drive signal
-------------..-j

-"--- - -------

FC Circuit opening relay drive signal

2/10 LPR LP gas main relay drive signal
----._--- ---------,-_.-
I LFC LP gas slow solenoid drive signal

- I-_~ °T::--- -~~,::n~::~:c:~:c~::~:~~~:""Je

3/10 I THW Coolant temp~~~t~r~_sensorvoltage
PIM Intake pipe negative pressure sensor voltage

l_-4/10 J,
I
~_~:21 ---t-e:~:~::;:j~~~:E~~::n:~~:~: - - - - - - -' - -' - - '- -~ I
VTA 1 I hrotUe position sensor (1) voltage

5/10 I VTA2- -- - -~~;~:::: :::I~i~~~~~~:; (2) vollage------ - ---I

6110
: :~ ::c~;:;~:~~h~~:I;,;:O,:~~:;" " n ' m l
I NE Engine speed I
I I
1
TA Throttle opening angle
--- -l----N-E----+E-n-g-'n-e-s-pee-d-----------------------l_ i
7/10 I PIM Intake pipe pressure
- -- . . '-' ----._~-_ ...-. __.- -_._--_ .. ~- -"-.

IGT Ignition timing (spark advance amount)

NE Engine speed
I
! PIM Intake pipe pressure
co~recti~n-value (gasoline)
8/10

I,
INJ Injector
I
~~~~~---I
OX 02 sensor voltage
- - , -t--~N-E-----+-E-n~ginespe--e-d~----

I PIM - In_t~ke p~= pressure I

9/10
I
I
VF
OX
VF voltage (LPG)
02 sensor voltage
I
-1- NE Engine speed
PIM Intake pipe pressure
10/10 I L1NJ
-

Injector correction value (LPG)

- - ----
- - -- -I
FCM Air-fuel ratio motor correction value (LPG)
 18-19

Analyzer menu screen Display item Description

Screen No.
2. I/O ENGINE CTRL VPA1 Accelerator sensor (1) voltage
(ASC controller)
-_._ .. _----~._-- -- ~ .. _ - - - _ . _ ~ _ . _ .. - - - - - . _ ' - . _ - - - - , - - - ' - - - ' , - - - - ' . ' - - - " -. -"'.- ' - ' - - -~---_.~-- -.--.--
VPA2 Accelerator sensor (2) voltage
1/3
IDLE Idle switch condition
. -.- ,--- ._~ -.--

NMR. NMR switch condition

BATT Battery voltage
MEN+ Motor relay output
2/3 1-- -- --.--.---_.---,._--- --"'---,--- - --- ---,------ -_._--'-'------- .. '- -

SRLY Motor relay output condition

STA
NE
1·- - "-- .. ---
Ci\01
vu. I Spare svvitch input (1) condition
3/3
SOP2 Spare switch input (2) condition
------'-,_._'.'-- ~--_ .. ,--_.-

00P1 Spare output (1) condition

3. I/O TRAVELlNG SPD Traveling speed sensor voltage
1·- -_._----_ ..
'Traveling/swing control
_--~~_._---

ACCSW Accelerator switch (02 pedal')

system) ---- - ' - - ' . - .. - .... _--.-- .. -_.-
1/3 BRKSW Brake switch

I I :::~;-- -~~~~:g~~~~e switch

1- -:-
_ u

s::;~ --+-:-:·-:-t-~--;-lt-t~-~-v-e-li~-9---s--:N-il·-C--h-------------------------
1
2/3 - I-
I DRR Reverse traveling switch
I '- RYF- - Fo;;';,Cd""ecse l,a,,'1"9 ",le"upl eelay
YRS Yaw rate sensor voltage
- -- ···1
~:
Lifting height switch
._- .. ._---- -.--
I
~ .---.'- --~_ ~-----~--

3/3
(Unused)
--.--.----- ----.- --------. ----- ------1
SWN
PRES
ILoad sensor
Swing lock solenoid
-- _._"-- --"------_._. -- ----'--- -~._-_ .... _,_._--- -- I

I SPEED Traveling speed

4. I/O M HANDLING MD/MU Lift lowering switch/Lift raising switch
-- .----- .. _-- ..----"----------_. -
-- -- _._- .. -._- ---". ---. -
(Material handlingimast control
----~-~----

system)
MF/MR
_._,---_ .•. _-

USOL
Forward tilt switch/Backward tilt switch
Unload solenoid
I
----_ ..- - - . . ._-----

I
--~

1/6 LSOL Lift lowering lock solenoid

TSOL Tilt control solenoid
-

BTSL Backward tilt lock solenoid

SEAT Seat switch
MA Tilt angle sensor voltage
MH Lifting height switch

2/6
PRES
SWLK
Load sensor
Load display switch
I
SWTK Automatic fork leveling stop switch -I
SWATS 3i4 way changeover switch
*: 1DZ-III-3Z (Except travel and load handling control model)
18-20

Analyzer menu screen Screen No. Display item Description

4. I/O M.HANDLlNG Lift lever angle sensor (1) voltage

(Material handling/mast control POTL - -.•. ~ ~ - ~ - - - - - - - " ~ - - . - . - - - . - - - - - - - - - - - - - . ~ - - - - - - _ . ~-"----
_ .•.

Lift lever angle sensor (2) voltage

system) 3/6 __ .. _ _ • __ _ _ .• .__ • __ - .. __ , .__ _, _ •. ' _ _ .. 0_.- ----_.---.-

---I

~
_
.
LPSOL Lift proportional valve solenoid current
Lift lowering lock solenoid
LSOL
-----+------.+:::-::-~- .--------------------1
Tilt lever angle sensor (1) vol tage
POTT .. ------ _-.---- -._'-,---'--" - .. - - ..

Tilt lever angle sensor (2) voltage

4/6 . .. - ----_.,--._._~ '-

TPSOL Tilt proportional valve solenoid current

TSOL Tilt solenoid
Attachment (1) lever angle sensor (1) voltage
POTA1
I Atta~~;;'nellt (1) lever ~ngie~e~~~~(2) voitage
--- - --'--

A1S0L Attachment (1) proportional valve solenoid current

~---------1--------+------.---
Attachment (2) lever angle sensor (1) voltage
POTA2 '-- ----",._---_.. ---- - ~_. _ _.
.. __ ._~ ----,-, --.--.-----_ .. _-----'- ... ' - -------_.-._--.. _" ...
6/6 Attachment (2) lever angle sensor (2) voltage
.- --.---
A2S0L Attachment (2) proportional valve solenoid current
I
5 I/O STEERING -----\------T-IR-E---.+-I_-~-i~e-._
..-~-_~-g-~e-_-_se-_n~sor voltage . _ , . ..1
(Steering control system)

%~:~~I ~~~~~~~~ga~~::-nOb positionaclual value (targ-et VaIUe)-j

T
6. I/O OTHERS
(Others)
-1/~-+t B:~ I::~::::~;:~C'~;O; m u . u u un~1
_ _ _ _ _-+_lI_o~rq_u_e_converteroil temperature sensor voltage ·····1,
---~ ~ I~:~
.. ... ....
' Key switch (IG)
- - _ _. _ . _ . 0_ _ • • _. •• ~. ,_._

2/2 MAT Matching connector

MTC (Unused)
._-------+
7 ACTIVE TEST SWING SOL Swing lock solenoid forced operation
---_ ....• _.- ----- ----_ .. ,----_ .. _------_ _----,_.,- ----_._._-._,'-------------
..
(Operation lest)
--------~_.

STEERING SOL Knob position compensation solenoid forced operation

1/3 --_.-,-"-,------'. - - - _ .. __ .. _-.- -- -'--------_. __ .. _----,---'-. - - -~--

TIC RLY Forward/reverse lfavel1ll8 cut-off relay forced operation

- --,-------_._---_._- - .--.,'--- -. - .. _-----_.. -_._---_.' ... _--
ASC RLY ASC motor relay forced operation
LIFT LWR SOL Lift lowering lock solenoid forced opera lion
TILT SOL Tilt solenoid forced operation
2/3 - .. --' .,'- -_._- -

TILT BWD SOL Backward tilt lock solenoid forced operation

-

UNLOAD SOL Unload solenoid forced operation

--------f-.-----
• Control valve switching forced operation
OPTION RLY
• T/C interlock relay forced operalion

f--.---.--.--.--~

8. VERSION
(Program version)
I . -
3/3
I BUZZER
SWG TEST LMP Swing lock operation check

SAS/OPS ECU
DISPLAY
Warning buzzer forced operation
_ _ _ _ _ _ _ _,." -

Display control program version

SAS/OPS controller program version
.-'0'·'_'_".-,._'. __ .'_

._------~----------j

ENGINE ECU 4Y engine controller (or ACS controller) program version

 18-21

ANALYZER MENU Screen

Operating Procedure

1. Enter the password on the general screen (Refer to page 18-

14) to display the MASK MENU screen

2uTUNING
( .
3.0PTIONSET
) ( +J )

2 Check that "1 ANALYZER" is selected (highlighted) on the

(1) With travel and screen and press switch (4) (enter) to call the ANALYZER
load handling control MENU screen

3 Select the menu with switch (1), and press (enter) switch (4) to
move to the screen of the selected item

4 if you select "9 END" on the ANALYZER MENU screen and

press sWitch (4) (enter), the MASK MENU screen appears
again.
I ,
(1 ) (4)

"1. DIAG MEMORY"

Switch (1) Switching selection to next item
Switch (4) To "DIAG MEMORY" screen

"2. 110 ENGINE CTRL"

Switch (1): Switching selection to next item
2.1/0 ENGINE CTRL Switch (4) To "I/O ENGINE CTRL" screen

3.1/0 TRAVELING "3. 1/0 TRAVELlNG"

I \( .. ) ('--;.J-J!I Switch (1) Switching selection to next item
Switch (4) To "I/O TRAVELlNG" screen

"4. 110 M.HANDLlNG"

Switch (1) Switching selection to next item
Switch (4) To "If 0 M HANDLING" screen

"5. 1/0 STEERING"

Switch (1) Switching selection to next item
5.1/0 STEERING Switch (4) To "i/O STEERiNG" screen

8.110 OTHERS "6. lfO OTHERS"

( .. ) ( tJ )\ Switch (1): Switching selection to next item

I' SWitch (4) To "I/O OTHERS" screen

18-22

"7. ACTIVE TEST"

Switch (1) SWItching selection to next item
Switch (4): To "ACTIVE TEST" screen

"8. VERSION"
Switch (1) Switching selection to next item
8uVERSION Switch (4) To "VERSION" screen

9&END "9. END"

=+::=::.....)
tL::::( --.:.(=~~)J Switch (1) Returning to "1 DIAG MEMORY" selection
Switch (4) Returning to MASK MENU screen

Diagnosis Memory Function (D!AG MEMORY)

The controller stores up to 10 most recent errors The DIAG MEMORY screen displays these diagnosis codes with
their detection time information (In key ON hour meter reading)
The most recent diagnosis code is displayed as 1, followed by 2, 3 and so on to 10

Operating Procedure
Display the ANALYZER MENU screen.

2&1/0 ENGINE CTRLI

I 3 110 TRAVELING I
&

l( • ) ( +JJJ

2 Check that "1. DIAG MEMORY" IS selected on the screen, and

press (enter) switch (4) to display "DIAG MEMORY 1/2"
screen.

3 Press switch (4) on "DIAG MEMORY 2/2" screen to return to

the ANALYZER MENU screen
Note:
• When no error codes are displayed on the screen and thr
(4) hour meter time is O.Oh, it indicates that no error:.·
occurred in the past after that row.
s It is impossible to directly jump from the DIAG MEMORY
screen to other function screen. Return to the ANALYZER
MENU screen once and then go to the desired function
screen.
• For details of diagnosis code, refer to section 19,
Diagnosis Code List.
 "DIAG MEMORY 112"
Displays diagnosis 1 to 5.
DI~G MEMORY 1/2 Switch (4) To "DIAGMEMORY 2/2" screen
1. 18-1 i(j9q99. 9h
2. C7-1 19909. Oh
3. RD-1 11000. Oh
.:1. Hl~L1 10000. Oh
5. [4-5 1000.0h~~E~X=n

"DIAG MEMORY 2/2"

Displays diagnosis 6 to 1O.
DIAG MEMORY 2/2 Switch (4) Returning to the ANALYZER MENU screen
6. R~-t 100. Oh
1" 51-1 100. Oh
:8. 6.:1- i i. Oh
.: g.. 72-.::1 0 .. Oh
i 0" o. Oh (,,-05"----")
18-24

In/Out Monitor Function (110 MONITOR)

This function displays the analog input voltage from each oftraveling, material handling, SAS and OPS sensors. The
circuit or sensor quality can be jUdged by monitoring the displayed value

In/Out Monitor (1) (110 ENGINE GTRL)

4Y Engine Vehicle
Displays ONIOFF states of the 4Y engine controller switch, vanous Input values including analog input voltage from
the sensor, correction value of the control and output condition to the relay

Operating Procedure
1. Display the ANALYZER MENU screen
<i-\Ni-\LYZER MENU>
.. r ..... T.l.-r. llr-II~""""'!

I I. Ul Ab MtMUK"Y

3.1/0 TRi-\VELING
( • ) (r--;J-=--)

2. Press sWitch (1) once to check that "2. I/O ENGINE CTRL" is
(i) \fliith travel and selected, and press (enter) sWitch (4) to display "1/0 ENGiNE
load handling control CTR L 1/10" screen
Note:
You cannot move directly from 1/0 ENGINE CTRL screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.

(1 ) (4)
 18-25

"1/0 ENGINE CTRL 1/10"

IGSW: Key switch (IG)
CTRL 1/10 IGSW: 0 = OFF

I Go 1.1\1 m 1 ::;TA :0 IGSW: 1 = ON

STA: Key switch (ST)
BATT ·13.6 Ij/LP:10 STA: 0 = OFF
STA: 1 = ON
:3EL . 1100 BATT: Battery voltage (V)

AD.J : 0101 INEXT) Displays battery voltage.

Standard: 8.0 - 16.0 V

G/LP: Fu~changeoverswikh
Displays states of the fuel changeover switch selection.
GiLP: 10 When gasoline is selected
G/LP: 01 When LP gas is selected
SEL: Fuel speCification discrimination signal
Displays states of fuel specification discrimination signal.
SEL: 1100 Exclusive for gasoline
SEL: 1010 Exclusive for LP gas
SEL: 0110 Gasoline/LP gas convertible type
SEL: 0101 Gasoline/CNG convertible type (no used)
ADJ: Engine specification discrimination signal
Displays states of engine specification discrimination
signal.

Switch (4): To "I/O ENGINE CTRL 2/10" screen

"I/O ENGINE CTRL 2/10"

MREL: EFl main relay drive signal
I/O ENGINE CTRL 2/10 Displays states of drive signal output to EFl main relay.
MREL: 1 Drive
MREL : 1 Fe :1 MREL: 0 Halted
LPR :0 LFC :0 FC: Circuit opening relay drive signal
Displays states of drive signal output to the circuit
O){HT : 1 opening relay.
FC: 1 Drive
It (NEX:T)j FC: 0 Halted
LPR: LP gas main relay drive signal
Displays states of drive signal output to LP gas main
relay.
LPR: 1 Drive
LPR: 0 Halted
LFC: LP gas slow solenoid drive signal
Displays states of drive signal output to LP gas slow
solenoid.
LFC: 1 Drive
LFC: 0 Halted
18-26

OXHT: 02 sensor heater drive signal

Displays states of drive signal output to the 02 sensor
heater.
OXHT: 1 Drive
OXHT: 0 Halted

Switch (4): To "I/O ENGINE CTRL 3/10" screen

"I/O ENGINE CTRL 3/10"

THA: Intake temperature sensor
I/O ENGINE CTRL 3/10 Displays Input voltage (V) from the intake temperature

THA :2a35< 20nO) sensor to the controller, and the intake temperature (DC).
THW: Coolant temperature sensor
TH'.'.1 :0.53( 80.0) Displays input voltage (V) from the coolant temperature
sensor to the controller, and the engine coolant
PIM :3.60(100.0) temperature (DC)
PIM: Intake pipe pressure
(NEXT] Displays input voltage (V) from the intake pipe negative
pressure sensor to the control!er, and intake pipr
pressure (kPa).

Standard:
3.6 ± 0.3 V (100 ± 10 kPa) (when engine is halted)

Switch (4): To "!/O ENGINE CTRL 4/10" screen

"1/0 ENGINE CTRL 4/10"

Ir~-I~/~O~E~t-·~I.:i--·I-t-~E-C-:T-F-:L-4-/-1~O1 VPA1: Accelerator sensor 1

Displays input voltage (V) from the accelerator sensor Cl)

IVPAl :0.85(0.85) to the controller, and the fully closed accelerator position
stored value (V).
\VPA2 "1.45(1.45) Accelerator sensor (1) voltage standard:

IIPA 0.0 0.2 - 1.3 V (when accelerator is not operated)

1.4 - 4.1 V (during maximum pressing of accelerator)
IL: . : :IN: :E: :}': :,:T: =.J) Accelerator fully closed position stored value standard:
0.2-1.3V

VPA2: Accelerator sensor (2)

Displays input voltage (V) from the accelerator sensor (> •
to the controller, and the fully closed accelerator positiofl •
stored value (V).

Accelerator sensor (2) voltage standard:

0.7 - 2.0 V (when accelerator is not operated)
2.1 - 4.7 V (during maximum pressing of accelerator)

Accelerator fully closed position stored value standard:

0.7 - 2.0 V

PA: Accelerator opening angle

Displays operation amount of the accelerator pedal (%)

Accelerator opening angle standard:

0% (when accelerator is not operated)
100% (during maximum pressing of accelerator)

Switch (4): To "I/O ENGINE CTRL 5/10" screen

 18-27

"I/O ENGINE CTRL 5/10"

VTA1: Throttle position sensor (1)
I/O ENGINE CTRL 5/10 Displays input voltage (V) from the throttle position sensor
(1) to the controller, and the fully closed throttle position
:0.91(0.71) stored value (V).
:2.50(2.25) Throttle position sensor (1) voltage standard:
TH
I~
5.0 0.3 - 1.5 V (during engine idle (after warm-up))

IM 0.85 INE::{T) Throttle fully closed position stored value standard:

0.3 - 1.5 V

VTA2: Throttle position sensor (2) voltage

Displays input voltage (V) from the throttle position sensor
(2) to the controller, and the fully closed throttle position
stored value (V).

Throttle position sensor (2) voltage standard:

1.7 - 3.3 V (during engine idle (after warm-up))

Throttle fully closed position stored value standard:

1.7 - 3.3 V

TA: Throttle opening angle

Displays throttle position (D )

Standard:
0
1.0 - 8.0 (during engine idle (after warm-up))

IM: Electronic throttle motor current

Displays current flowing to the electronic throttle motor.
Standard: 0.2 - 10.0 A

Switch (4): To "I/O ENGINE CTRL 6/10" screen

"I/O ENGINE CTRL 6/10"

PA: Accelerator opening angle (refer to page 18-26)
Et~G I t'~E CTRL 6/10 NE: Engine speed

PA 0.0 Displays engine speed (rpm) and traveling speed (km/h).

Engine speed standard: 0 - 3500 rpm
. INE
, 750( 0.0) TA: Throttle opening angle (refer to page 18-27)
I IT A 5.0 Switch (4): To "I/O ENGINE CTRL 7/10" screen
II~ -=(N=E=}::T=.:...,))

"I/O ENGINE CTRL 7/10"

NE: Engine speed (refer la page 18-27)
I/O PIM: Intake pipe pressure (refer to page 18-26)

NE 750( 0.0) IGT: Ignition timing (spark advance amount)

Displays ignition timing (spark advance amount: 0 ).

PIM 35.0 Standard:

18T 15.0 5.0 - 25.0
0
(during engine idle (after warm-up))

INEXT) Switch (4): To "I/O ENGINE CTRL 8/10" screen

18-28

"I/O ENGINE CTRL 8/10"

NE: Engine speed (refer to page 18-27)
ENGINE CTRL 8/10 PI M: Intake pipe pressure (refer to page 18-26)

NE 750( 0.0) INJ Injector correction value (gasoline)

Displays correction value of the fuel injection amount
PIM 35.0 OX 02 sensor voltage
Displays input voltage (V) from the 02 sensor to the
I tlJJ :100.0 controller, and the 02 sensor monitor.

OX : O. 15(0) (NEXT) 02 sensor voltage standard: 0 - 1.0 V

02 sensor monitor
1: rich
0: lean

Switch (4) To "I/O ENGINE CTRL 9/10" screen

"I/O ENGINE CTRL 9/10"

NE Engine speed (refer to page 18-27)
ENGINE CTRL 9/10 PIM Intake pipe pressure (refer to page 18-26)

750( 0.0) VF VF voltage (LPG)

Displays the voltage (V) output from VF terminal
35.0 Standard: 2.0 - 3.0 V
: 2.50 OX 02 sensor voltage (refer to page 18-28)
: 0.23(0) [NEXT)] I Switch (4) To "I/O ENGINE CTRL 10/10" screen

"lID ENGINE CTRL 10/10"

NE Engine speed (refer to page 18-27)
I/O ENGINE CTRL10/10, PIM Intake pipe pressure (refer to page 18-26)
I NE 750 ( O. 0) !
L1NJ Injector correction value (LPG)
Displays correction value of the fuel injection amount
I PI M • 35.0 FCM Air-fuel ratio motor correction value (LPG)
Displays correction value of the air-fuel ratio motor
I LI NJ . 100. 0 I 100. 0 opening angle

I FCM 0 ( 5 )) I Switch (4) To ANALYZER MENU screen

1 .

InlOut Monitor (1) (1/0 ENGINE CTRL)

1 DZ-1I1/3Z Engine Travel and Load Handling Control Specification Vehicie
Displays ON/OFF states of the ASC controller switch, and analog input voltage of the sensor and its output condition
to the relay

Operating Procedure
1 Display the ANALYZER MENU screen
f<ANALVZER MENU>
1• DI AG MEMORV
 18-29

2. Press switch (1) once to check that "2. I/O ENGINE CTRL" is
selected, and press (enter) switch (4) to display "I/O ENGINE
CTRL 1/3" screen.

Note:
You cannot move directly from I/O ENGINE GTRL screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.

(1 ) (4)

"I/O ENGINE GTRL 1/3"

VPA1:
I/O ENGINE CTRL 1/3 Displays accelerator sensor (1) voltage and accelerator sensor
(1) fUlly closed position stored value.
VPAl :0.85(0.85)
Accelerator sensor (1) voltage standard:
'}PA2 ·1 45( 1. 45) <
0.2 - 1.3 V (when accelerator is not operated)
IDLE . 1 1.4 - 4.1 V (during maximum pressing of accelerator)

NMR :0 (NEXT) Acceleratorfully closed position stored value standard:

O.2-1.3V
VPA2:
Displays accelerator sensor (2) voltage and accelerator sensor
(2) fully closed position stored value.
Accelerator sensor (2) voltage standard:
0.7 - 2.0 V (when accelerator is not operated)
2.1 - 4.7 V (during maximum pressing of accelerator)
Accelerator fully closed position stored value standard:
0.7 - 2.0 V (fully closed position stored value)

IDLE: Idle switch coridition

IDLE: 0 = OFF
iDLE: 1 = ON
NMR: NMR switch condition
NMR: 0 = OFF
NMR: 1 = ON

Switch (4): To "I/O ENGINE CTRl 2/3" screen

,--------------------,
"I/O ENGINE GTRL 2/3"
BATT: Battery voltage
Displays battery voltage (V).

BATT . 12.00 Standard: 8.0 - 16.0 V

MEN+ . 12.00 MEN+: Motor relay output voltage

1-'
':1
FILlY
I
I • 1 Standard: 8.0 - 16.0 V

c· TH
.J I" ". 0 (NE::{T)
18-30

SRLY: Motor relay output state

SRLY: 0 = OFF
SRLY 1 = ON
STA Key switch (ST)
STA 0 = OFF
STA 1 = ON

Switch (4) To "1/0 ENGINE CTRL 3/3" screen

"Iro ENGINE GTRL 3/3"

NE
I/O ENGINE CTRL 3/3 Displays engine speed (rpm), and engine speed sensor
voltage (V)
NE 0(0.20)
QnD 1 • n Engine speed standard: 0 - 3000 rpm

SOP2 ~O I SOP1' state of spare switch input 1

Unused

,-O_OP_l_:O l5 I I SOP2 state of spare switch Input 2

Unused
OOP State of spare output 1
Unused

Switch (4) To ANALYZER MENU screen

iniOut Monitor (1) (iiG ENGiNE CTRL)

1 DZ-1Il/3Z Engine Vehicle (Vehicle without Engine Control Controller)

Operating Procedure
1. Display the ANALYZER MENU screen
<ANALYZER MENU>
1• DI AG MEMORV

If ~ 1/ 0 TRAVELI~G~ J) I
2. Press switch (1) once to check that "2. 1/0 ENGINE CTRL" is
selected, and press (enter) switch (4) to display "!fQ ENGINE
CTRL 111" screen

Note:
You cannot move directly from 110 ENGINE CTRL screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.

(1 ) (4)
 18-31

"I/O ENGINE CTRL1/1"

Switch (4): To ANALYZER MENU screen

1./1

f 5 )

In/Out Monitor (2) (I/O TRAVELlNG)

This function displays the ON/OFF status of traveling and swing switches, and analog input voltages of sensors.

Operating Procedure
1. Display the ANALYZER MENU screen
<ANAL\IZEF: MENU>
( 1. DI AG MEMIJF:V
2.1/0 ENGINE CTRL

2. Press switch (1) twice to check that "3. I/O TRAVELlNG" is

(1) With travel and selected, and press (enter) switch (4) to display "I/O
load handling control TRAVELlNG 1/3" screen.

Note:
You cannot move directly from I/O TRAVELlNG screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.

(1 ) (4)

"1/0 TRAVELlNG 1/3"

SPO: Trave!ing speed sensor voltage (V), and travel!rlg speed
I/O TRRUELING 1/3 (km/h)
Checks traveling speed sensor voltage when the vehicie
SPD :2.54< 0.0) is halted.
v ,_I III " 0
f'r'c' 8F 1':·C'IIID 0
1
1'1
H ..J 11 • I rI I '-' 11 •
ACCSW: Accelerator switch check (02 pedal)
ACCSW: 1 = ON when D2 pedal is depressed
P~':; El ::; 11 1
I 11\ : ACCSW: 0 = OFF when 02 pedal is not operated

ISPARE:O ~Exn Switch ON/OFF quality judgment by operating the D2

pedal
18-32

BRKSW: Brake switch check

BRKSW: 1 = ON when brake pedal is depressed
BRKSW: 0 = OFF when brake pedal is not operated
Switch ON/OFF quality judgment by operating the brake
pedal
PKBSW: Parking switch check
PKBSW: 1 = ON in a state of parking brake being
operated
PKBSW: 0 = OFF in a state of parking brake being
released
Judges the quality of the switch ON/OFF by operating the
parking brake pedal
SPARE: Spare
Unused

Switch (4): To "I/O TRAVELlNG 2/3" screen

"'/0 TRAVELlNG 2/3"

SEAT: Seat switch check
1.····0 TRRUEL I t'~G SEAT: 1 = ON when taking the seat

SE~T :0 SEAT: 0 = OFF when leaving the seat

Switch ON/OFF quality judgment by sitting on and leaving
DRF :0 DRF: the operator's seat
.. ""I DRF: Forward direction switch check
DRR: Reverse direction switch check
Displayed code
Direction lever
DRF: DRR:
Forward traveling position 1 (= ON) 0(= OFF)
Neutral position 0(= OFF) 0(= OFF)
Reverse travel posilion 0(= OFF) 1 (= ON)

Switch ON/OFF quality judgment by operating the

direction lever
RYF: Forward/reverse traveling cut-off relay
DIsplays output signal to forward/reverse traveling cut-off
relay.
RYF: 1 = ON Relay energized (forward/reverse travelinr
not possible) state
RYF: 0 = OFF Relay non-energized (forward/reverse ....
traveling possible) state

Switch (4): To "I/O TRAVELlNG 3/3" screen

"'/0 TRAVELlNG 3/3"

YRS: Yaw rate sensor voltage (V)
TRRI..JEL I t¥3 Checks the input voltage from the yaw rate sensor to the
controller.
'.IDC'
I I'"J : 2 . 45 MH . 100
S~ . 0 00 c, III tlJ· 1
• lB ._1 11 g
Standard when vehicle is stationary: 2.2 - 2.8 V

F' F: E:3 : 0 . 57 ( O. 3)
::;PEED: 0.0 ( '5)
 18-33

MH: Lifting height switch check

'IRI-'
~. .)
TF:RUEL I t~G
:2.45 MH "100
MH :100
TTT MH2-2
MH1~
('l~
OH . 0 00 c' III t1j· 1
D I!I I_I 11 •
= ON
MH2-1

PF:E::; : o. 57( 0.3)

1
0= OFF
Judges the quality of the switch ON/OFF by raising and
SPEED: 0.0 f '5 ) lowering the material handling. (Refer to Lifting Height
Switch ON/OFF Combination List)
SA Unused
SWN: Swing lock solenoid
Displays output signal to the swing lock solenoid.
SWN: 1 = ON Energized (swing lock released) state
SWN: 0 = OFF Non-energized (swing lock) state
PRES: Load sensor
Displays input voltage (V) from the load sensor to the
controller, and detected pressure (MPa).
Standard: 0.5 - 4.5 V

Voltage increases as load increases.

SPEED: Traveling speed (km/h)
Checks traveling speed.

Switch (4): To ANALYZER MENU screen

Lifting Height Switch (MH) ON/OFF Combination Table

E"'"~~L(MH1)
Lifting height SWitch circuit diagram (MH2-1)

I o(MH2-2)
MH1 1 (= ON)
At a low lift
MH2-1 0(= OFF)
,ess than 2200 mm (87 in)')
MH2-2 0(= OFF)
MH1 0(= OFF)
At a medium lift
MH2-1 1 (= ON)
(2200 mm (87 in) or more) -;- MH2-2 0(= OFF)
I
*: The height at which the lifting height switch changes will vary according to the lifting height set for the mast
18-34

In/Out Monitor (3) (I/O MATERIAL HANDLING)

This function displays the ONIOFF status of material handling and mast control switches and analog input voltages
from sensors.

Operating Procedure
1. Display the ANALYZER MENU screen.

5.1/0 STEERING
6.1/0 OTHERS
(+) (t!),
__ J

2 Press switch (1) 3 times to check that "4 1/0 M HANDLING" is

(1) With travel and selected, and press (enter) switch (4) to display "110
load handling control M HANDLING 1/6" screen

Note:
You cannot move directly from 1/0 MATERIAL HANDLING
screen to the screen of the other items. Return to ANALYZER
MENU screen once, then move to screen of each item .

(1 ) (4)

"lfO M.HANDLlNG 1/6"

MD Lift lowering switch check (STD lever vehicle only)
I, VO M. HRNDLING {/I») I MU Lift raising switch check (STD lever vehicle with travel and

MD/MU:OO MF/MR:OO I load handling control (OPT) only)

Oisplayed code
USOL :0 LSOL :0 Lift lever
I
---1-----------1
MO: MU: I
TSOL :0 BTSL:O -----

Lowering position 1 (= ON) o (= OFF) I

I SEA T :0 (NEXT) Neutral position 0(= OFF) .0 (= OFF)
Raising position 0(= OFF) 1 (= ON) ,
;

Switch ONIOFF quality judgment by operating the lift

lever
MF Forward tilt switch check (STD lever vehicle only)
MR Backward tilt sWitch check (STD lever vehicle only)
Displayed code
Tilt lever
MF MR:
Forward tilt position 1 (= ON) 0(= OFF) i
------- _._ ... ~

i-----
Neutral position 0(= Ot--F) 0(= OFF)
-
Backward tilt position 0(= 01-£-) 1 (= ON)
I
Switch ON/OFF quality Judgment by operating the tilt
lever
 18-35

USOL: Unload solenoid

Displays output signal to the unload solenoid.
I/O M.HRNDLING 1/6 LSOL: Lift lowering lock solenoid

MD/MU:OO MF/MR:OO Displays output signal to the lift lowering lock solenoid.
TSOL: Tilt control solenoid
U::iOL : 0 L::iOL: 0 Displays output signal to the tilt control solenoid.
BTSL: Backward tilt lock solenoid (STD lever vehicle only)
T::iOL : 0 BT::;L: 0 Displays output signal to the backward tilt lock solenoid.
SEAT :0 ~EXn SEAT: Seat switch check
Judge the quality of the switch ON/OFF by silting on and
leaving the operator's seat.

Switch (4): To "I/O M.HANDLlNG 2/6" screen

Condition of the seat/lever and detected values (USOL/LSOL/TSOL/BTSL/SE.A,T)

Seat condition Sitting on seat Leaving seat
Tilt lever
Backward tilt
Lever condition
Low lifting High lifting
height height
0(= OFF) 0(= OFF)
0(= OFF) 0(= OFF)
I I
0(= OFF) 1 (= O~~)

1 (= ON) 1 (= ON)
1 (= ON) 1 (= ON)
1 (= ON) 1 (= ON)
0(= Or-F) 0(= OFF)
Mini lever vehicle 0(= Or-F) 1 (= ON)
- - I
1 (= ON)
I 1 (= ON)
I 0(= OFF)

"I/O M,HANDLlNG 2/6"

MA,: Tilt angle sensor voltage (V)
I/O M.H~NDLING 2/6 Checks the input voltage from the tilt angle sensor to the

MA :2.45 MH ·100 controller.

Standard with mast in the vertical position:

PRES :O.57( 0.3) I 1.1 - 4,2 V
C'IIlL 1,:' •
d 11 r I "
0 C'IIIT
..J
11
1{ •
rI· 0 I11' Mast vertical -} forward tilt: Input voltage decreases
C'IIII'I TC, 0 !'NE"/T'J'
l,:.j~I,:"",1H~~._::.-I _=
Mast vertical -} backward tilt: Input voltage increases
-.-:::'==,':::':',==-J
B
-=-.B
MH: Lifting height switch check (refer to page 18-33)
PRES: Load sensor (refer to page 18-33)
SVVLK: Load display switch check (OX model only)
SVVLK: 0 = OFF
SVVLK: 1 = ON
Judge the quality of the switch ON/OFF by operating the
lift knob switch.
18-36

SWTK: Automatic fork leveling stop switch

SWTK: 0 = OFF
SWTK: 1 = ON
Judge the quality of the switch ON/OFF by operating the
tilt knob switch.
SWATS: 3/4 way changeover switch check
SWATS: 1 = ON
When tilting the switch to right (4 way side is activated)
SWATS: 0 = OFF
When tilting the switch to left (3 way side is activated)
Judge the quality of the switch ON/OFF by operating the
changeover switCh.

Switch (4): To "I/O M.HANDLlNG 3/6" screen

"'/0 M.HANDLlNG 3/6"

POTL: Lift lever angle sensor (1) voltage (V)/lift lever angle
I/O M.HRNDLING 3/6 sensor (2) voltage (V)

POTl :2.31/2.20 Standard

LP:3IJL: 0.00 liFt lever

Lifllever angle sensor
(1) voltage
Liff I"ec ",gle ,e"COi~
(2) voltage
LSOL : 1 Raising 1.8-4.1V 0.3 - 2.9 V
Lowerin 9 -1 c:. _- A '") \1
!
0.4 - 2.8 V I.V ~ • ...., v

Judge the raise and lower input quality by lift lever

operation.
LPSOL: Lift proportional valve solenoid current (A)
Judge the output quality to lift proportional valve solenoid
by lift lever operation.

Standard when lever is operated: 0.3 - 0.85 A

LSOL: Lift lowering lock solenoid (refer to page 18-35)

Switch (4): To "I/O M.HANDLlNG 4/6" screen

"I/O M.HANDLlNG 4/6"

POTT: Tilt lever angle sensor (1) voltage (V)/tilt lever angle
I/O M.HRNDLING ~/61 sensor (2) voltage (V)

PO TT :2.25/2.26 Standard

TPSOL:O.OO I
" TOlt I
I ever
I Tilt lever angle sensor
I
I
(1) voltage
Tilt lever angle sensor
(2) voltage
T:30L : 1 IForward tilt I 1.8-4.1V 0.3-2.9V ~
(NEXT) IBackward tilt I 0.4 - 2.8 V 1.6 - 4.3 V i
Judge the input quality during forward tilUbackward tilt by
tilt lever operation.
 18-37

TPSOL: Tilt proportional valve solenoid current (A)

Judge the output quality to tilt proportional valve solenoid
by tilt lever operation.

Standard when lever is operated: 0.3 - 0.85 A

TSOL: Tilt lock solenoid (refer to page 18-35)

Switch (4): To "1/0 M.HANDLlNG 5/6" screen

""0 M.HANDLlNG 5/6"

POTA1: Attacllment (1) lever angle sensor (1) voltage (V)
I/O M.H~NDLING 5/6 lattachment (1) lever angle sensor (2) voltage (V)

P[I TI~ 1: 2 . 38./2. 14 Standard

IH I ;:IIJ L • U • UU
.1. of .-. 1-' I R lA ft. f t
Attachment (1)
lever
MllaCllrnerll \ I ) lever
angle sensor (1 )
I
MllaCllrnerll \ I} lever
!\U l-

angle sensor (2)

voltage voltage
Backward tilt
1L..- --.:::1N=E=:J{=.T:::J) side
1.8 - 4.1 V 0.3 - 2.9 V

Forward tilt
0.4 - 2.8 V 1.6 - 4.3 V
side

Judge the input quality by attachment (1) lever operation.

A 1SOL: Attachment (1) proportional valve solenoid current (A)
Judge the output quality to attachment (1) proportional
valve solenoid by attachment (1) lever operation.

Standard when lever is operated: 0.3 - 0.85 A

Switch (4): To "J/O M.HANDLlNG 6/6" screen

""0 M.HANDLlNG 6/6"

I POTA2: Attachment (2) lever angle sensor (1) voltage (V)
I I/O M.H~NDLING 6/6 lattachment (2) lever angle sensor (2) voltage (V)

POTA2:2.29/2.21 Standard

A2~iDL: 0.00 I
!
Attachment (2)
Attachment (2) lever
angle sensor (1)
Attachment (2) lever
angle sensor (2)
I
lever
voltage voltage i
1Backward tilt
side
I 1.8 - 4.1 V 0.3 - 2.9 V
I
Forward lilt
side
0.4 - 2.8 V

Judge the input quality by attachment (2) lever operation.

1.6-4.3V
I
A2S0L: Attachment (2) proportional valve solenOid current (A)
Judge the output quality to attachment (2) proportional
valve solenoid by attachment (2) lever operation.

Standard when lever is operated: 0.3 - 0.85 A

Switch (4) Returning to ANALYZER MENU screen

18-38

In/out monitor (4) (I/O STEERING)

This function displays ONIOFF status of the knob position correction and other switches, and analog input voltages
from sensors.

Operation Procedure

1. Display the ANALYZER MENU screen.

<~N~LVZEF: MENU>
4. I/O M. HANDLINI3
6. I/O OTHEF::3
+J
\. -_.---

J I
2. Press switch (1) 4 times to check that "5. I/O STEERING" is
(1) With travel and selected, and press (enter) switch (4) to display "I/O
load handling control STEERING 11'1" screen.

Note:
You cannot move directly from lIO STEERING screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.

IL_ (1)
_ (4)

"1/0 STEERING '1/1 n

I TIRE: Tire angle sensor voltage (V)
r\ I./O ~3TEER I r·H3 1/11 Operates the steering wheel to check the variation in

TIRE :2.07 I voltage

Standard when tires are in straight ahead position:

\SPEED: 0.0 11 1.9 - 2.4 V
.I~I, -P0S: aD ( 83 )_O~ . II SPEED: Traveling speed (refer to page 18-33)

lISTS · 100 (-5 )11 K-POS: Steenng knob position actual value (target value) an
steering synchronizer solenoid
Actual value:
The knob position calculated and recognized by the
controller from the steering angle sensor signa!
Target value:
The knob position calculated and recognized by the
control!er from the tire angle sensor signal
Steering synchronizer solenoid:
0= OFF (non-energized) state
1 = ON (energized) state
 18-39

One rotation (360°) of the steering wheel is divided by

160, and the value IS set to "80" when the knob is in the
position as indicated in the illustration.
Clockwise turn of the steering wheel Increase in value
Counterclockwise turn of the steering wheel: Decrease in
value
STS: Steering angle sensor check
80

/'\" STS :·000

Standard position "'"
STS1 -
T ~j L--STSC
STS2

1 = ON
0= OFF
When the steering wheel is rotated once, STS1 and STS2
repeat ON and OFF
STSC only turns on when the knob is in the standard
position

Switch (4) To ANALYZER MENU screen

In/Out Monitor (5) (I/O OTHERS)

Displays the ONIOFF states of hour meter time and other switches. and the analog input voltages from respective
sensors

I Operating Procedure
1. Display the ANALYZER MENU screen
I r <ANALYZER MENU>
11 4.110 M.HANDLING
11 5. I/O STEERING
I,
\ t(..-;;;.....--;;;;;)
I- - - - - - - - - - - - - - - -
2 Press switch (1) 5 times to check that "6. 1/0 OTHERS" is
(1) With travel and selected, and press (enter) switch (4) to display "1/0 OTHERS
load handling control 1/2" screen
Note:
You cannot move directly from 110 OTHERS screen to the
screen of the other Items. Return to ANALYZER MENU screen
once, then move to screen of each item.

(1 ) (4)
18-40

"lID OTHERS 1/2"

HR: Hour meter
I/O OTHERS 1/2 Displays hour meter value.
BATT: Battery voltage (V)
HF: 78.3h Displays battery voltage.
BATT ·13.5 Standard: 8.0 - 16.0 V
THO :4.34( 35) THO: Torque converter oil temperature
IN E}::T) Displays torque converter oil temperature sensor voltage
(V), and oil temperature (QC).

Switch (4): To "I/O OTHERS 2/2" screen

"lID OTHERS 2/2"

IGSW: Key switch
I/n OTHEF:S Displays key switch ON/OFF

I 11 III • 1
I .JJII
I IGSW 1 = ON
IGSW 0 = OFF
MAT ·1 MAT: Matching connector
Displays states of matching connector.
MTC ·0 MAT: 0 = OFF

1:5 State of matching connector separation

MAT: 1 = ON
State of matching connector connection

This will not be displayed for mini lever or joystick vehicle.

MTC: Unused

Switch (4): Returning to ANALYZER MENU screen

 18-41

Active Test (ACTIVE TEST)

This function outputs ON/OFF signals to switches in the electncal system and compare controller input signals with
those signals.

Active Test Menu List

Selection item
Item Description
Signal Content of operation Signal Content of operation
SWING SOL Swing lock solenoid forced operation ON Unlock OFF Lock
Steering synchronizer solenoid forced
STEERING SOL ON By-pass open OFF By-pass close
operation
Forward/reverse traveling interrupt relay Traveling not
T/C RLY ON OFF Traveling possible
forced operation possible
--f----------
A0C KLY ASC motor relay forced operation ON Engine control OFF Engine idle state
Lowering not
LIFT LWR SOL Lift lowering lock solenoid forced operation ON Lowering possible OFF
possible
Forward tilt not
Forward tilt possible
possible
, TILT SOL Tilt control solenoid forced operation ON Backward tilting OFF
Backward tilting
speed limited
speed not limited
Backward tilt not
TILT BWD SOL IBackward tilt lock solenoid forced operation I
I ON Backward tilt possible OFF
possible
L STD lever vehicle:
STD lever vehicle:
\ Material handling
Material handling
other than lowering
possible
not possible
UNLOAD SOL Unload solenoid forced operation ON OFF Mini lever or joystick
Mini lever or joystick
lever vehicle:
vehicle:
Material handling not
Material handling
I possible *1
possible
-I • 4th way material

OPTION RLY
I·
I•
3/4 way changeover switch
T/C interlock relay forced operation
ON
handling
operation*2 OFF
• 3rd way material
handling operation
• T/C interlock
• T/C interlock
I activated
I
released
BUZZER Warning buzzer forced operation ON Buzzer ON OFF Buzzer OFF

, ;:'WG TEST LMP Swing lock solenoid operation display ON Indication OFF No indication

I. It may be lowered according to load condition.

*2: Number of ways may differ according to material handling piping

Operating Procedure
1. Display the ANALYZER MENU screen

8aVERSION
9.END
( ,. J ( ;J J
18-42

2. Press switch (1) 6 times to check that "7. ACTIVE TEST" is

(1) With travel and selected, and press (enter) switch (4) to display "ACTIVE
load handling control
TEST 1/3" screen.

Switch (1): Move to next item

Switch (2): Forced OFF
Switch (3): Forced ON
Switch (4): Returning to ANALYZER MENU screen

Note:
(1 ) (2) (3) (4) You cannot move directly from ACTIVE TEST screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.

"ACTIVE TEST 1/3"

SWING SOL: Swing lock solenoid
ACTIVE TEST 1/] Jack up the rear axle, and check that the rear axle
swings.
~OFF/[ijD ON (solenoid ON): Unlock
:3TEEF: I t'~G SOL Ot·~ 00iGI./ OFF (solenoid OFF): Lock
T/C F:LIy' OFF./[ijU STEERING SOL: Steering synchronizer solenoid
RSC F:L V ooaij./ OH Slowly turn the steering wheel, and check the difference
( + ) (-+a u+) ( 5 ) of the rear tire movement.
O~~ (By-pass open)~ Tires de not move much
OFF (By-pass close): Tires move (normal operation)
T/C RLY: Forward/reverse interrupt relay
Checl< the operation of the torque converter forward/
reverse interrupt relay.
ON (relay ON): Traveling not possible
OFF (relay OFF): Traveling possible (normal operation)
ASC RLY: ASC motor relay
Check the operation of the motor power supply relay.
ON (relay ON): Traveling possible (normal operation)
OFF (relay OFF): Engine idle state

"ACTiVE TEST 2/3"

ACTIVE TEST 2/] Note:

When performing ACTIVE TEST 2/3 item, make sure to sit
~I./Ot.~
TllT SOL 1 . / Ot·4
the seat correctly. If not, OPS is activated and material
handling operation may be limited.
i TILT Bl.dD SOL I ./ Ot·~
I
I
Ut'~LORD :=;Ol 1 1 . / Ot·4 LIFT LWR SOL: Lift lowering lock solenoid
Check the quality of lowering action by lift lowering
(+) ( ... *) (5) operation
ON (solenoid ON): Lowering possible
(normal operation)
OFF (solenoid OFF): Lowering not possible
 18-43

TILT SOL: Tilt control solenoid

Check the quality of mast forward tilt operation by forward
~CTIVE TEST 2/3 tilt operation.
Of\J (solenoid ON):
~I·/Ot'~
T I l T SOL 1 , / m·~
Forward tilt possible. backward tilting speed limited
OFF (solenoid OFF):
T I l T E:l.dD ~:;Ol III ,/ ot·~ Forward tilt not possible, backward tilt operated normally
Ut'~lORD sell I / OH TILT BWD SOL: Backward tilt lock solenoid (STD lever
f+] f+u • • ) (5) vehicle)
Check the quality of mast backward tilt operation by
backward tilt operation.
ON (solenoid ON): Backward tilt possible
(normal operation)
OFF (solenoid OFF): Backvvard tilt not possible
UNLOAD SOL: Unload valve solenoid
Check the quality of material handling operation by
material handling operation.
STD lever vehicle
ON (solenoid ON):
Material handling other than lowering operation not
possible (Depending on the attachment, 3rd to 5th
way operation may be possible)
OFF (solenoid OFF):
Material handling operation possible
Mini lever or Joystick vehicle
ON (solenoid ON):
Material handling operation possible
OFF (solenoid OFF):
Material handling operation not possible (It may
slowly lower according to load condition, but ttlis is
not a fault.)

"ACTIVE TEST 3/3"

OPTION RLY:

Ilf ACTIVE TEST 3/31 3/4 way changeover:

Using a dual lever, check that the allocated material
~I ~~.~
ot·~
1. 1 BUZZER ,, Ot,~ I handling operation is switched over.
ON (relay ON):
. ~=;I..JG TEST lRt'1P ... ,"
Ot,~ 4th way operation is possible. (Number of ways may differ
according to materia! handling piping.)
If . . . " I
.I 5 ) OFF (relay OFF):
l" " 3rd way operation is possible.
TIC interlock relay:
ON (relay ON): Travel is possible
OFF (relay OFF): Travel is not possible
BUZZER: Warning buzzer forced operation
Check the warning buzzer operation.
ON: Buzzer sounds
OFF: Buzzer stops
SWG TEST LAMP:
Check the swing lock operation states according to tr'aveling
and material handling states by OPS light.
ON (Indicated):
Operation situation is indicated with OPS light.
OPS light ON: Swing lock operated
OPS light OFF: Swing lock released
OFF (not indicated):
OPS light operates as OPS light (normal operation).
18-44

Program Version (VERSION)

Displays program version of each controller

Operating Procedure
Display the ANALYZER MENU screen
<ANALVZER MENU>
7.ACTIVE TEST

( ..
9.END
) ( i=" )

2 Press switch (1) 7 times to check that "8 VERSION" IS

(1) With travel and selected, and press (enter) switch (4) to display "VERSION"
load handling control screen

Switch (4): Returning to ANALYZER MENU screen

"VERSION"
DISPLAY Displaying program version
Program version of the multifunctlon display
SAS/OPS: SAS/OPS program version
Program version of SAS/OPS controller
ENGINE: 4Y (or ASC) program version
4Y engine controller (or ASC controller) program version
 18-45

TUNING

GENERAL
Performs fine adjustment of traveling and material handling control.
When receiving a request from a user such as "I want to adjust the lift idle up", a setting level can be altered from the
tuning screen.

Tuning Item List

No.6 - NO.19 are not used (not indicated).
NO.20 - NO.69 are for mini lever or joystick specification (OPT) vehicle only.

Level (. initial setting value)

No. Item
2 I 3 I 4 I 5 I 6 I 7 8

Lift idle up * Slow ! Fast

2 TIC Interlock threshold Slow EIl - - - - ' - .----.,..fl~~.

-<iiIIl---- - - : Fast

, ':',~.__+-s_p_a-re-1---------..- . - - . - - - - - - _ . - - + - - _ + _ _ - - - - - - - _ - ,,_l!I
- I -1
4 Spare 2
t------t-------------- --.-.--------- -.-+----'--------------T----~--.,___-__+

5 Spare 3 I
Lift lowering adjustment (1) c~-+--J--.L....--~---------'-:-·-
20 Adjusts solenoid output current at the beginning of lift lowering Small ~ •
operation. ,
1-----+--~-------........c------_;__-___1

Lift lowering adjustment (2): _ . , Slow

21
Adjusts inching speed dUring 11ft lowering operation.
Lift lowering adjustment (3):
22 Adjusts solenoid maximum output current during the lift Small Large
lowering operation
t-------+---------------.-.----------.---+---+-------~----____+_--....L..-------j

23 Lift lowering adjustment (4): Weak i Strong

Adjusts acceleration speed during lift lowering operation. :
Lift lowering adjustment (5):
24 Weak
Adjusts deceleration speed during lift lowering operation.
_._-----------+----------------'----'--~-------j
Lift raising adjustment (1):
'5 Adjusts solenoid output current at the beginning of lift raising Small
\. operation.
Lift raising adjustment (2):
26 Slow! . I-ast
Adjusts inching speed during lift raising operation.
Lift raising adjustment (3):
27 Adjusts solenoid maximum output current during the lift raising Small Large
operation.
Lift raising adjustment (4):
28 Weak Strong
Adjusts acceleration speed during lift raising operation.

29
Lift raising adjustment (5):
Adjusts deceleration speed during lift raising operation.
Weak Strong I
Forward tilt adjustment (1): , . :
30 Adjusts solenoid output current at the beginning of forward tilt Small ....~4-------,-4il~-+---'_I~~ Large
operation. ,
!
31 Forward tilt adjustment (2):
Slow ....<OI'IfIl'f--------4il.--;-----'_I~~ Fast
. Adjusts inching speed during forward tilt operation.

*: Vehicle with travel and load handling control (OPT)

18-46

Level (CD: initial setting value)

No. Item
1 2 3 4 5 6 7 8
I I I I l
Forward lilt adjustment (3): 1
32 Adjusts solenoid maximum output current during forward tilt Small ....... li ~ ! Large

.
i
operation. . ;

Forward tilt adjustment (4) ;

33 Weak -<l!1( lilt ; Strong
Adjusts acceleration speed during forward tilt operation. . ; \
Forward tilt adjustment (5)'
34
Adjusts deceleration speed during forward tilt operation.
Weak: ~ e ;
~. IStrong
•

Backward tilt adjustment (1) , ,

•
!

35 Adjusts solenoid output current at the beginning of backward

tilt operation.
Small -<l!1(
• Large
!

i Fo,! I
Backward tilt adjustment (2)
36 Slow <lI'!il @ ~
Adjusts inching speed during backward tilt operation. i

Backward tilt adjustment (3): I

37 Adjusts solenoid maximum output current during backward tilt Small <lI'!il Ell P, i Larg
i
operation. ;
'I. (..
' .....

38
Backward tilt adjustment (4)'
Adjusts acceleration speed during backward tilt operation
Weak· ~. • ... iStron~1
I
...
!

Backward tilt adjustment (5):

39 Weak' ~ IIll iStrongl
,
.
,il,djusts deceleration speed during backv\/ard tilt operation. : , :
;
Attachment (1) lever forward tilt side adjustment (1): : !

!~~:J
40 Adjusts solenoid output current at the beginning of attachment Small 0!lI @l

(1) lever forward tilt side operation ; ,

Attachment (1) lever forward tilt side adjustment (2): . ;

41 Adjusts inching speed during the attachment (1) lever forward Slow --<lI'!il' lI!l
I
.... : Fast!
,t

.
tilt side operation. I ,
, ; .~--

i
Attachment (1) lever forward lilt side adjustment (3): :
42 Adjusts solenoid maximum output current during the Small ~. liI
i
, i Large
attachment (1) lever forward tilt side operation. , ,
,
43
Attachment (1) lever forward tilt side adjustment (4):
Adjusts acceleration speed during the attachment (1) lever
forward tilt side operation.
Weak ~ 1&
i

,:
... Strong

;
Attachment (1) lever forward tilt side adjustment (5):
i
44 Adjusts deceleration speed during the attachment (1) lever Weak <li!ifi. ;
l!l , ~ I Strol
~ I
forward tilt side operation.
; I
Attachment (1) lever backward tilt side adjustment (1)
; ,
! ; !
45 Adjusts solenoid output current at the beginning of attachment Small ""li!l l\I iIiI" Large I
(1) lever backward tilt side operation i :
46
Attachment (1) lever backward tilt side adjustment (2)
Adjusts inching speed during [he attachment (1) lever
backward tilt side operation.
I

Slow
,
"llII. liD . !

!
Fast

Attachment (1) lever backward tilt side adjustment (3): :

47 Adjusts solenoid maximum output current during the Small --<lI'!il !ll ~ Large
attachment (1) lever backward tilt side operation
,
Attachment (1) lever backward tilt side adjustment (4): ;
I
48 Adjusts acceleration speed during the attachment (1) lever IWeak --<lI'!il 11 ~ Strong
backward tilt side operation ,

49
Attachment (1) lever backward tilt side adjustment (5):
Adjusts deceleration speed during the attachment (1) lever Weak
;

.......
; ;

lI1I
;

!
;
,.. Strongl
I
backward tilt side operation. j
.
 18-47

Level (e: initial setting value)

No. Item
2 8

50
Attachment (2) lever forward tilt side adjustment (1):
Adjusts solenoid output current at the beginning of attachment
(2) lever forward tilt side operation
Small CIlIl 11 , ... Large
!
--~t-~------------------------t------~-~--__:__---,------~__:__----"---~1

51
Attachment (2) lever forward tilt side adjustment (2):
Adjusts inching speed during the attachment (2) lever forward
tilt side operation.
Slow 41 Ill>
:
... Fast

Attachment (2) lever forward tilt side adjustment (3): i : I

52 Adjusts solenoid maximum output current during the
attachment (2) lever forward tilt side operation.
Small - ;
~

,P
Large

'------------lI\4 ......... r-h r-....--.! /r")\ 1""0"- f"n~f rrl tilt cifto ::::lrlillctmpnt fL!l>

~
h 3 I~~jUG~;~:~~~~r~~i~G~ ~~~~~ ~~'~;nV~~t~;~.t~;~;l'I~~~'n\ '(2) lever Weak ~ IStrong
forward tilt side operation.

54
Attachment (2) lever forward tilt side adjustment (5)
Adjusts deceleration speed during the attachment (2) lever
forward tilt side operation.
Weak ... Strong

~. r----------------.~-----------------__+--_;__--_o__--------__:__--~--_._-____1 ,:
I 55
I
. Attachment (2) lever backward tilt side adjustment (1)
Adjusts solenoid output current at the beginning of attachment
I (2) lever backward tilt side operation.
Small .... Large

r---I
l5: Attachment (2) lever backward tilt side adjustment (2): I '
lAdlIdo I ",hmn o·rced dl"i"9 'hc altachmcnt (2) I"el
~

backward tilt side operation.

~ I Slow Cast
I
I
Attachment (2) lever backward tilt side adjustment (3): :
I
i 57 Adjusts solenoid maximum output current during the Small! CIlIl III Ii!mo Large

..
attachment (2) lever backward tilt side operation.
,
Attachment (2) lever backward tilt side adjustment (4):
58 Adjusts acceleration speed during the attachment (2) lever
backward tilt side operation.
Weak • ;Ii!mo Strong

IAttachment (2) lever backward tilt side adjustment (5): •

59 Adjusts deceleration speed during the attachment (2) lever Weak' ~ 1Il .~ Strong

~
backward tilt side operation. ,
,
Attachment (3) lever forward tilt side adjustment (1):
60 Adjusts solenoid output current at the beginning of attachment Small: ~ liI .~ Large
(3) lever forward lilt side operation ..
Attachment (3) lever forward tilt side adjustment (2):
.
~ .~
61 Adjusts inching speed during the attachment (3) lever forward
tilt side operation.
i Slow
I
, liI Fast
I
I ,
Attachment (3) lever forward tilt side adjustme:lt (3):
62 Adjusts solenoid maximum output current during the \ Small ~ l!I ~ Large
attachment (3) lever forward tilt side operation

63
Attachment (3) lever forward tilt side adjustment (4):
Adjusts acceleration speed during the attachment (3) lever
forward tilt side operation. J:8k ,
<!Ill • ~ :Strong

I 64 Attachment (3) lever forward tilt side adjustment (5):

Adjusts deceleration speed during the attachment (3) lever
I
IWeak <!Ill ~ .~ Strong
I forward tilt side operation.

I
Attachment (3) lever backward tilt side adjustment (1)
65 Adjusts solenoid output current at the beginning of attachment Small 'OIi!l I!> ~ Large
(3) lever backward tilt side operation. : ,
I
18-48

Level (lit: initial setting value)

No Item
1 2 3 4 5 6 7 8
I I I I I
Attachment (3) lever backward tilt side adjustment (2): i

•
1 i

66 Adjusts inching speed during the attachment (3) lever

backward tilt side operation.
Slow
• f
• , Fast

Attachment (3) lever backward tilt side adjustment (3): 1

I
67 Adjusts solenoid maximum output current during the Small I ~. @ ~ Large
attachment (3) lever backward tilt side operation.

68
Attachment (3) lever backward tilt side adjustment (4):
Adjusts acceleration speed during the attachment (3) lever
backward tilt side operation.
Weak ~
,
• ...
i

!
Strong

Attachment (3) lever backward tilt sieJe adjustment (5)'

69 Adjusts deceleration speed during the attachment (3) lever
backward tilt side operation.
Weak ~
• ~
i
Strong
 18-49

TU NING MENU Screen

Operating Procedure
1. Enter Hie password on the general screen (Refer to page 18-
<MA:3P~ MENU> 14) to display the MASK MENU screen.

1. ANALVZEF:

( .
3.C1PTIClNSET
) ( t..J )

2. Press sWllch (1) 10 check that "2. TUNING" is selected, and

press (enter) switch (4) to display TUNING MENU screen.
(1) With travel and
load handling control 3. Select the menu with switch (1), and press (enter) switch (4) to
move to the tuning screen of the selected item.

4. Press (enter) switch (4) while selecting "7. END" menu to

return to MASK MENU screen.

\
(4)

"1. COMMON"
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen

"2. LIFT LEVER"

(mini lever/joystick vehicle)
LEVER Switch (1): Switching selection to next item

LEVEF: Switch (4): To TUNING LEVEL setting screen

"3. TILT LEVER"

(mini lever/joystick vehicle)
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen

"4. ATTi LEVER"

(mini lever/joystick vehicle)
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen

"5. ATT2 LEVER"

5. ATT2 LE"lER (mini lever/joystick vehicle)
Switch (1): Switching selection to next item
Ei. ATT3 LE"/EF: Switch (4): To TUNING LEVEL setting screen
(+) (;-J)
"6. ATT3 LEVER" (mini lever vehicle)
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen
18-50

"7. END"
Switch (1): Returning to "1. COMMON" selection
Switch (4): Returning to MASK MENU screen

COMMON (TUNING COMMON)

Sets tuning levels for standard functions.

Operating Procedure

1. Display the TUNING MENU screen

LEVEr: I
LEVER
...::=:::===-----....::=(:::::r'::::::J) 'I
2 Check that "1. COMMON" is selected, and press (enter) switch
(1) With travel and (4) to display TUNING LEVEL setting screen.
load handling control
Note:
You cannot move directly from level setting screen of
COMMON to the screen of the other items. Return to TUNING
MENU screen once, then move to leve! setting screen of each
item.

(1 ) (2) (3) (4)

"TUNE CaM."
,._-------------- Switch (1): SWitching selection to next item
TUr·1E ~ • • ~ODDDD Switch (2): Tuning level down
Switch (3): Tuning level up
COt'1. 02 • • • ElDDDD Switch (4): Retul1llng to TUNING MENU screen
03 • • ~OODDO
O.:1 • • • • ~DDD
I 05 • • • • ~DDO
I· . (._*J (5J
)
 18-51

LIFT LEVER (TU NING LIFT LEVER)

Sets tuning levels for the lift lever of mini lever and joystick vehicles.

Operating Procedure
1. Display the TUNING MENU screen.
<TUNING MENU>

cl. TILT LE'·lEF:

( .. ) [tJ)

2. Press switch (1) once to check that "2. LIFT LEVER" is

selected, and press (enter) switch (4) to display the TUNING
(1) With travel and LEVEL setting screen.
load handling control
Note:
You cannot move directly from level setting screen of LIFT
LEVER to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.

(1 ) (3) (4)

"TUNE LIFT"
Switch (1): Switching seiection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen

TUt'~E 25 • • • • ~DDD
LIFT 1tim • • • • ~DDD
21 • • • • ~DDD
28 • • • • ~DDD
29 • • • II~DDD
( .. I .. ) ( 5. )
18-52

TILT LEVER (TUNING TILT LEVER)

Sets tuning levels for the tilt lever of mini lever and joystick vehicles.

Operating Procedure

1. Display the TUNING MENU screen.

<TUNING MENU>
1.CDMMON
2. LI FT LE"/EF:

2. Press switch (1) twice to check that "3. TILT LEVER" is

(1) With travel and selected, and press (enter) switch (4) to display the TUNING
load handllllg control LEVEL setting screen.

Note:
You cannot move directly from level setting screen of TIU
LEVER to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.

(1 ) (4)

"TUNE TILT"

1,------------..
I TU~iE
ItlIJ •••• ~DDD
Switch (1 ):
Switch (2):
Switch (3):
Switching selection to next item
Tuning level down
Tuning level up
lTILT 31 • • • II~DDD
li 32 • • • • ~DDO
33 • • • • ~DDD
Switch (4): Returning to TUNING MENU screen

I 3L1 • • • • ~DDD; I
\l( .. ) ( .. I .. ) ( 5 ) I

I
r TUt·iE 35 • • • • ~DDDl
'TILT ~ • • • • ~DDO
31 • • • • ~DDD
38 • • • • ~DOD
3'9 • • • • ~DOD
( .... -.] (5)
 18-53

ATTi LEVER (TUNING ATTi LEVER)

Sets tuning levels for the ATT1 lever of mini lever and joystick vehicles.

Operating Procedure

1. Display the TUNING MENU screen.

h TTt) LE\,'ER
(,

.
.....1
Q
U.H
m H L
.'ITT'::'oJ LE"/ER
(.---::,....--')

2. Press switch (1) 3 times to check that "4. ATT1 LEVER" is

(1) With travel and selected, and press (enter) switch (4) to display the TUNING
load handling control LEVEL setting screen.
Note:
You cannot move directly from level setting screen of ATT1
LEVER to the screen of the other items . Return to TUNING
MENU screen once, then move to level setting screen of each
item.

(1 ) (2) (3)

"TUNE ATT1"
Switch (1): Switching selection to next item
arro •••• ~DDD Switch (2):
Switch (3):
Tuning level down
Tuning level up
41 • • • • ~DDD Switch (4): Returning to TUNING MENU screen
L12 • • • • ~DDD
a3 •••• ~DDD
<1<1 l1li111l1li111 \;'l ODD 1
r+t.u';-J (5)1
1

. I

TUHE LIS • • • • ~DDD

RTTt E:ill •••• ~DDD
a111• • • ~DDDI
43 • • • • ~DDD
49 • • • • I!jODD
( ..... ) (5)
18-54

ATT2 LEVER (TUNING ATT2 LEVER)

Sets tuning levels for the ATT2 lever of mini lever and joystick vehicles.

Operating Procedure

1. Display the TUNING MENU screen.

<TUN I tlJIJ MENU>
4.ATTl LEVER
6.ATT3 LE\.'EF:
(+ J ( t.J I

2. Press switch (1) 4 times to check that "5 ATT2 LEVER" is

(1) With travel and selected, and press (enter) switch (4) to display the TUNING
load handling control LEVEL setting screen.
Note:
You cannot move directly from level setting screen of AT1 "-
LEVER to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.

(1 ) (2) (3) (4)

"TUNE ATT2"
Switch (1): Switching selection to next item
I TUt'~E ~ • • • • ~DDDl Switch (2): Tuning level down
Switch (3): Tuning level up
RTT2 51 • • • II~DDDI Switch (4): Returning to TUNING MENU screen
52 • • • • ~DDDI
53 • • • • ~DDD
54 • • • • ~ODDI
(+ I: .. I .. J ( '5 )1.

55 • • • • ~DDD
~ • • • • ~DDD
57 • • • • ~DDD
S8 • • • • ~DDD
S9 • • • • ~DDDI
I: .. I .. ) I: '5 )J I
I
 18-55

ATT3 LEVER{TUNING ATT3 LEVER)

Sets tuning levels for ATT3 of mini lever vehicles

Operating Procedure

1. Display the TUNING MENU screen

\"<_ T:....:=.U...::-.:..N.;::...:..1 G.......:~..:...=I~E::..:..-:..N-=-II~_';' _ _
tl..:....=..J

4. ATT 1 LE\I'EF:
5.ATT2 LEVER

2. Press switch (1) 5 times to check that "6. ATT3 LEVER" is

selected. and press (enter) switch (4) to display the TUNING
(1) With travel and LEVEL setting screen.
load handling control
Note:

II You cannot move directly from level setting screen of ATT3

LEVER to the screen of the other items. Return to TUNING

I
I
MENU screen once, then move to level setting screen of each
item.
I
I
I
I (1 ) (2) (3) (4)

I ~Ut~E
"TUNE ATT3"
Switch (1): Switching selection to next item
Switch (2): Tuning level down
IRIIfJ •••• ~DDD Switch (3): Tuning level up
11 HTT3 61 • • • • ~DDD Switch (4): Returning to TUNiNG MENU screen
62 • • • • ~DDD
63 • • • • ~DDD '
1I
6.:1 .III• • ~DDD 1
[If .. ) ( • I ~. ) ( 5 )J 1
_ _ _ _ _ _ _ _ _1

I ,.- ~

I r TUt'1E 65 • • • • ~DDD 1
RTT3 IIfm •••• ~DDD
61 • • • • ~DDD
68 • • • • ~DDD

( . 69 • • • • ~DDD
) (+a .-+) ( 5 )
18-56

OPTION SET
Note:
• The option set function is used to set control of the controller and display control according to the
options equipped on the vehicle. It does not enable or disable the function itself.
If OPS/SAS controller or muitifunction display is replaced, it is necessary to reset it according to the
vehicle specification.

Option Set Menu List

Switching settings
Indication Descnption Indi- Indi-
Setting content Setting content
cation cation
Other than
DISP MODE* Setting display language J Japanese I
Japanese I
MPW Setting traveling speed display unit YES mph NO km/h
-~- - - -- - - - - - - - -
USA* Setting buzzer speCification YES USA NO Other than USA
Setting to enable/disable buzzer sound when seat
SEAT BUZZER YES Enabled NO Disabled
switch is off
Setting to enable/disable warning when forgetting to "
PKB BUZZER YES Enabled NO Disabled
apply the parking brake
TEMPGAUGE Setting to enable/disable oil temperature indication YES Enabled NO Disabled
CONY !EMP Unused (fixed to YES) YES - ""
I~V -
Setting to enable/disable travel and load handling
ASC W/LOAD YES Enabled NO Disabled
control
-
Setting to enable/disable traveling speed limit of travel
MODE S Enabled A Disabled
and load handling control
T/C INTLOCK Setting to enable/disable T /C Interlock control YES Enable NO Disable
Setting to enable/disable engine output down when
H_TEMP P-L1M YES Enabled NO Disabled
detecting coolant overheat (4Y engine model)
LIFT IDLEUP Setting to enable/disable lift idle up YES Enabled NO Disabled
I t-WD LIMIT Setting to enable/disable forward tilt regulatlllg control YES enabled NO Disabled
Setting to enable/disable backward tilt automatic
T BWD LEVEL YES Enabled NO Disabled
leveling control
SWG W-LOCK Unused (fixed to YES) YES - NO -
OCVWAY* Setting number of ways for oil control valve 2/3/4/5 i

WAY SELECr
Switching output destination during CIV 5th way
3 ->
Switching 3rd
2 ->
Switching 2nd I
specification way and 4th way way and 3rd way

* These are set according to the vehicle specification at the time of shipment

OPTION SET Screen

Operating Procedure

1 Enter the password on the general screen (Refer to page 18-

<MASK MENU> 14) to display the MASK MENU screen.

1.ANALYZER
2. TUNING
 18-57

2. Press switch (1) twice to check that "3. OPTION SET" is

(1) With travel and selected, and press (enter) switch (4) to display the OPTION
load handling control SET setting screen.

(1 ) (2) (3) (4)

"OPTION SET" Screen 1

SVvitch (1): S'vvitching selection to next Hem
[~mI;M11[@~ J .. Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
t'1 PH \1 Et; ,/ I."lliJ
Switch (4): Returning to MASK MENU screen
USR '/ES /1mJ
SERT BUZZEr: ~./ t·~O While "PKB BUZZER" is selected, press switch (1) to switch to
1. 'PKB E:\JZZEF: ~./ t·~O next screen.

==::.)~( :::::.===--I_ _.. ::::(~5~)

1Il::::(==...

"OPTION SET" Screen 2

Switch (1): Switching selection to next item
~~ ~/t·~O Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Cot·~I). TEt1P ~/ t·~O
Switch (4): Returning to MASK MENU screen
RSC v.!/LORD ~/ HO
NODE l1;li/ R I While "TIC INTLOCK" is selected, press switch (1) to switch to
T.····C It..jTLOCI< 'iJES /1mJ I next screen.

(+) I.,.) 1:5),

)I
"OPTION SET" Screen 3
Switch (1 ): Switching selection to next item
~~/·t·~o Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
L I FT I DLEUP w;@/ t·~O Switch (4): Returning to MASK MENU screen
T Fb.lD L !t'1I T ~/ t·Kt
T BI..JD LEI.)EL ~/ t·KI While "SWG W-LOCK" is selected, press switch (1) to switch
I Sb.H3 bJ-LOCK ~./ t·KI to next screen.

r.) 1"-) Cb)

"OPTION SET" Screen 4

Switch (1): Switching selection to next item
~ 2.····3/L1.···~ Switch (2):
Setting 5 ~ 4 --7 3 -t 2, or 2 ~> --7 3 ~>
J. U1 ':'ELE'-'T
IIH- '_' _. ~/2->
Switch (3):
Setting 2 --73 --7 4 --7 5 or 3 ~> --t 2 ~>
Switch (4): Returning to MASK MENU screen

While "WAY SELECT" is selected, pressing switch (1) to

( .. ) ( .. 1 ( '5 ) switch to next screen (returning to screen 1).
18-58

MATCHING

GENERAL
For the tilt angle, load and tire angle sensors among sensors used for SAS functions, the signal voltage values
under the mast vertical, no load and tire straight are stored, respectively, in the controller for the control based on
these values. When servicing or replacing these sensors, matching (updating the sensor signal voltage value in
the standard vehicle condition) is necessary. Also, matching is needed for the tilt angle sensor when the vehicle
posture has changed excessively, and for the load sensor when the load under no load condition (no load on
fork) is changed because of addition or removal of any attachment, replacement of mast or change of fork
length.
• Each lever angle sensor for mini lever or joystick function is controlled based on the memory of signal voltage
values in the neutral position stored in the controller at the time of shipment. When servicing these sensors or
replacing related parts, MATCHING (updatmg tile sensor signal voltage value in the standard vehicle condition)
is necessary.
• Load meter stores mast specification information and signal voltage values during no-load of the load sensor to
the multifunction display, and indicates based on these. When servicing the mast or load sensor, or replacing
related parts, matching (updating the sensor signal voltage value and mast specification information in the
standard vehicle condition) is necessary.

Matching Items and Prerequisite for Implementation

1. SAS
Prerequisite for
jl'lU. IllUIL.QlIUI ue 'UlfJ lio r1
~'s-'
implementation

I 1 TILTL
Stores the tilt angle sensor output value with fork
the controller.
In t'ne hOrizontal position to
'1, *2, *3, *6, '7, '8

I 2
3
TILTF LOAD

TIRE
Stores the tilt angle sensor output value at the forwar d tilt limit position and
the load sensor output value with no load to the contr oiler.
Stores the tire angle sensor output value while the vel licle is traveling straight
*1, *2, *3, *4, *6, *7,
*8

*1, *5
to the controller.
4 SWING Unused

2 MINI LEVER (mini lever or joystick vehicle only)

r--lo Indication Description d

Lift lever angle sensor output value in the lift lever neutral position is stored in
Prerequisite for
implementation
I
6 LEVER1 *1, *9
the controller.
Tilt lever angle sensor output value in the tilt lever neutral condition is stored
I 7 LEVER2 *1, * 10
in the controller.
I
8 LEVER3
Attachment (1) lever angle sensor output value in the attachment (1) lever
neutral position is stored in the controller.
*1, *11 -I
Attachment (2) lever angle sensor output value in the attachment (2) lever
9 LEVER4 *1, *12
neutral position is stored in the controller.
 18-59

3. LOAD METER (Vehicle with multifunction display OX model only)

Prerequisite for
No Indication Description
implementation

10 LIFT CYL. NUMBERS

Number of the mast lift cylinder is stored.
(Number combining front and rear)
*7, *13
I
11 LIFT CYL. BORE Bore of the lift cylinder is stored. *], *13
12 LOADMETER 0 SET Zero point of the load gauge is stored. *4, *6, *7, *13
When you want to
13 COMPENSATION Accuracy of the load meter is adjusted.
adjust the accul"acy

Prerequisite content for implementation

*1: SAS/OPS controller replacement
*2: Ti!t angle sensor removing/installing or replacement
*3: Length change or replacement of tilt angle sensor rod
*4: When removing/installing or replacing load sensor
*5: When removing/installing or replacing tire angle sensor or sensor cover
*6: When installing or changing attachment or fork
7: When removing/installing or replacing mast
When removing/installing or replacing tilt cylinder
*9: Wtlen replacing lift lever angle sensor
*10: When replacing tilt lever angle sensor
*11: When replacing attachment (1) lever angle sensor
*12: When replacing attachment (2) lever angie sensor
*13: When replacing multifunctlon display

Before Starting Matching

Before performing matching, you must set the vehicle to "standard condition". For "standard vehicle condition", refer
to Section 16, "SAS/OPS".
18-60

MATCHING MENU Screen

Operating Procedure

1. Enter the password on the general screen (Refer to page 18-

14) to display the MASK MENU screen.

5. lnHEEL r:AD IUS

6.IDLE ADJUSTMENT
r ..... J (;J)

2. Press switch (1) 3 times to check that "4. MATCHING" is

(1) With travel and selected, and press (enter) switch (4) to display the
load handling control MATCHING MENU screen.

3. Select the menu with switch (1), and press (enter) switch (4) tn

move to the MATCHING setting screen of the selected item.

4. Press (enter) switch (4) while selecting "4. END" menu to

return to MASK MENU screen.

(1 )

"1. SAS"
Switch (1): Switching selection to next item
Switch (4): To MATCHING SET screen

"2. MINI LEVER"

Switch (1): Switching selection to next item
2. MI rlJ I LE"lER Switch (4): To MATCHING SET screen

I 3.LIJAD METER "3. LOAD METER"

!l' ...... ."I
I r. ,.....)
• I J' Switch (1): Switelling selection to next item
Switch (4): To MATCHING SET screen

"4. END"
Switch (1): Returning to "1. SAS" selection
Switch (4): Returning to MASK MEf\JU screen

Note:
• "2. MINI LEVER" will not be displayed other than on mini

.
I
I
lever or joystick vehicle.
• "3. LOAD METER" will not be displayed on vehicles other
l( :1 ;J than DX model.

II
 18-61

SAS (MATCHING SAS)

Matching is performed for standard functions.

Operating Procedure

1. Display the MATCHING MENU screen

2.MINI LE1·lER
" L-JI AD METER
.). l

I: ... )

2 Check that "1. SAS" is selected, and press (enter) switch (4) to
(1) With travel and display MATCHING SET screen.
load handling conlrol On MATCHING SET screen:
Values in bracket ( ) are currently stored value.
r Values outside bracket ( ) are current vehicle condition value

Note:
• You cannot move directly from each matching set screen
of SAS to the matching set screen of the other items~
Return to MATCHING MENU screen once, then move to
(1) (4) matching set screen of each item.
• In standard vehicle condition, if the value in the bracket ( )
and the value outside the bracket ( ) are different,
matching is required.

I~TILTL
"TILTL" Screen
If matching is performed (press switch (1 )), "OK" is indicated
on the display.
1 Switch (1): Pressing this for more than 2 seconds will perform

I I 2.50 0 •.J::ri
(.L JJJ 'I j
matching
Switch (4): To "TILTF LOAD" screen

I)\lEn~
2t;EC
I. SET)

"T1LTF LOAD" Screen

If matching is performed (press switch (1)). "OK" is indicated
on the display.

Switch (1): Pressing this for more than 2 seconds will perform
matching
Switch (4): To "TIRE" screen
18-62

"TIRE" Screen
If matching is performed (press switch (1)), "OK" is indicated
·r
\
TI F:E
-'---'--------
on the dispiay.

Switch (1): Pressing this for more than 2 seconds will perform
i) ') Cl (')(~)CI) matching.
L.Ld .L.Ld. Switch (4): To "SWING" screen

2~:;EC
f SET :I (NEXT)

"SWING" Screen
I I~,. ,~_...J
Ullu;:,eu.

:3W I NG Switch (4): Returning to MATCHING MENU screen

0.00 (0.00)
2SEC
( SET) (5 )

MINI LEVER (MATCHING MINI LEVER or JOYSTICK)

Matching is performed for mini lever or joystick functions.

U->-~) I
Operating Procedure

---<-M-AT-C-H-r-NG-M-E-N 1 Dispiay the MATCHING MENU screen

1• C'Ac'
'-' ,_I

lr ~ ~OAD METER

Press switch (1) to check that "2. MINI LEVER" is selected,

(1) With travel and and press (enter) switch (4) to display the MATCHING SET
load handling control screen.
On MATCHING SET screen:
Values in bracket ( ) are currently stored value.
Values outside bracket ( ) are current vehicle condition value.

Note:
• You cannot move directly from each matching set screen
of MINI LEVER to the matching set screen of the other
(1 ) (4) items. Return to MATCHING MENU screen once, then
L move to matching set screen of each item.
• In standard vehicle condition, if the value in the bracket ( )
and the value outside the bracket ( ) are different,
matching is required.
 18-:63

lLEVER1" Screen
If matching is performed (press switch (1)), "OK" is indicated
LEVER1 on the display.

Switch (1): Pressing this for more than 2 seconds will perform
('7 'IF")
• _I
1-- re. '--
matching
(') ')S·'j Switch (4): To "LEVER2" screen
1" L III LL ..
2~=;EC .
r ~;ET :I INE::-::T)

"LEVER2" Screen
!f matching is performed (press switch (1)), "OK" is indicated
on the display.

(i)
I.L.L:.J.
Sq::") Switch (1): Pressing thiS for more than 2 seconds will perform
matching.
"L.LJ
'IR (') ')n") Switch (4): To "LEVER3" screen
'. L. LO.
2SEC
f ~3ET ) INEXTJ

"LEVER3" Screen
If matching is performed (press switch (1 )), "OK" is indicated

LEVER3 on the display.

Switch (1): Pressing this for more than 2 seconds will perform
2.25 (")
'. L. L·_I.
SII=:)
matching.
I.
L.LO
I},-.
(2.28) Switch (4): To "LEVER4" screen

2SEC
( SET ) [jJB (NEXT]
Note:
"LEVER3" screen will be displayed according to the number of
ways being set.
L- --'

lLEVER4" Screen
.. :.:. If matching is performed (press switch (1 )),"OK" is indicated
on the display.
II--=:L::..=.E-:-;:;VE::..:....:.R.....:.....4 _
Switch (1): Pressing this for more than 2 seconds will perform
III 2.25 (2.25) matching
')
L.
')0
LU
(? ~)O)
............. u.
Switch (4): Returning to MATCHING MENU screen

2SEC Note:
f SET J I: 5 ) lLEVER4" screen will be displayed according to the number of
ways being set.
18-64
,
LOAD METER (MATCHING LOAD METER)
In order to optimize the load meter, it is necessary to input each value of the "number of lift cylinders", "lift cylinder
bore", "0 point adjustment" and "accuracy adjustment" according to the mast attached, on the display.
These values are already set at the time of shipment, but when replacing the mast or readjustment is required for the
accuracy of the load meter, set these values again.

Operating Procedure
1. Display the MATCHING MENU screen.
<MATCHING MENU>
1 • C'A'
,_I
0.J
I•

2 Press switch (1) twice to check that "3. LOAD METER"

(1) With travel and selected, and press (enter) switch (4) to display "LIFT CY.
load handling control NUMBERS" screen.

Note:
You cannot move directly from each setting screen of LOAD
METER to the matching set screen of the other items. Return
to MATCHING MENU screen once, then move to matching set
screen of each item.
(1) (2) (3) (4)

"LIFT CYL. NUMBERS" Screen

Switch (2): Reducing the number of cylinders

LIFT CYL. NUMBERS Switch (3): Increasing the number of cylinders

Switch (4): To "LIFT CYL. BORE" screen

Number of lift cylinders

Mast type Number of lift cylinders
V 2
.. ) [NEXT) I--~~_~~F_V_,F_S_V~_~~ ~~ 3~ ~I'
FSW 4 .

"LIFT CYL. BORE" Screen

Switch (2): Making cylinder bore smaller

LIFT I-·'·JL BDF:E

_' I •
Switch (3): Making cylinder bore larger
Switch (4): To "LOADMETER 0 SET" screen

Lift cylinder bore

Cylinder bore (mm)
TflTH Vehicle model Front lift cylinder Front lift cylinder
Lift cylinder
f • I .. J [NEXT] (FV/FSV mast) (FSW mast)
1 ton series 45 70 ~

K2 ton series 50 75 -
2 ton series 50 75 55
3 ton series 55 85 60
J3.5 ton series 60 90 -
 18-65

"LOADMETER 0 SET" Screen

If matching is performed (press switch (1) for more than 2
seconds), "OK" (or "NG") is displayed on the display.
OK: Matching completed
NG: Signal voltage value is outside the matching range
When "NG" is indicated, check the vehicle condition,

2SEC
t abnormalities of load sensor, disconnection and short circuit of
the harness.

lr OSET ) INE::{T) Note:

Make sure to perform matching with the vehicle set to
"standard vehicle condition".
Standard vehicle condition:
For all the V/FV/FSV/FSW mast, the mast is to be vertical
and the fork height is to be 500 mm (19.7 in).

Switch (1): Performing matching

Switch (4): To "COMPENSATION" screen

"COMPENSATION" Screen
This function corrects values indicated on the display
C[lMPEN~;A TION according to actual live load.
When performing correction, set the mast vertically and take
1.09 on loading object (object with its accurate weight is known),

tl then while raising the fork for approx. 500 mm ("19.7 in), adjust
the value indicated on the top right hand corner of the screen
to the laden weight by operating the switch.
( ... I " ( 5 )J Switch (2): Minus correction
Switch (3): Plus correction
Switch (4): Returning to MATCHING MENU screen
18-66

WHEEL RADIUS SET

GENERAL
It is necessary to input the wheel radius to the controller according to the tire radius, for optimizing the speedometer
reading. Although the wheel radius is set to the value of new tires at the time of shipment, adjust it whenever the tire
size or type is changed according to "Wheel Radius List".

Operating Procedure
1. Enter the password on the general screen (Refer to page 18-
14) to display the MASK MENU screen.

4.MATCHING

( .
6.IDLE AD IU:3TMENT
)
L

(t.J

2 Press switch (1) 4 times to check that "5. WHEEL RADIUS" I~

(1) With travel and selected, and press (enter) switch (4) to display the TIRE
load handling control CONSTANT setting screen.

3. Change the wheel radius to desired value with switch (2) and
switch (3), and press (enter) switch (4) to set the value and
return to MASK MENU screen.

(1 ) (2) (3) (4)

"WHEEL RADIUS" Screen

Switch (2): Reducing wheel radius
~IIIHEEL F:AD IUS Switch (3): Increasing wheel radius
Switch (4) Entering wheel radius and returning to MASK
MENU screen.
 18-67

Wheel Radius
Vehicle model Specification Tire size Wheel radius
--
650-10-10PR (STD) 304
Single 650-10-14PR 314
1.5 ton model 650-10 302
6.00-9-10PR 289
Special Dual
6.00-9 281
-
650-10-10PR (STD) 304
Single 6.50-10-14 PR 313
1.75 ton model 650-10 302
-

Special Dual I 600-9-10PR

6.00-9
286
;;81
--

700-12-12PR (STD) 348

1- Single 7.00-12-14PR
-
352
I

700-12 344
I ) () ton model
700-12-12PR 353
--
Special Dual 700-12-14PR 356
700-12 346
700-12-12PR (STD) 343

I Single 700-12-14PR 352

2.5 ton model r---------- I 7.00-12

7.00-12-12PR
343
353
Special Dual 7.00-12-14PR 356
7.00-12 348
j
21 X8-9-14PR (STD) 275
K2.0 ton model Single
21X8-9 273
28X9-15-12PR (STD) 374 i
Single 28X9-15-14PR 3/3 !
I

3.0 ton model 28X9-15 367

1
I
.--------.J
I
28X8-15-12PR 380
Special Dual !
7.00-15 393 -1
I

Single
250-15-16PR (STD)
250-15
391
378
1I
I
J3.5 ton model r---- .-------1
28X8-15-12PR 3/9 I
Special Dual -----.J
700-15 393
i
18-68

ENGINE IDLE SPEED ADJUSTMENT (4Y ENGINE VEHICLE)

GENERAL
Adjusts 4Y engine idle speed

Operating Procedure

1. Enter the password on the general screen (Refer to page 18-

<MA::; ~'~ MEtrJ U:> 14) to display the MASK MENU screen

2. Press switch (1) 5 times to check that "6. IDL·

(1) With travel and ADJUSTMENT" is selected, and press (enter) switch (4)
------. load handling control display the IDLE ADJUSTMENT setting screen.
3. Change the speed to desired value with switch (2) and switch
(3), and press (enter) switch (4) to set the value and return to
MASK MENU screen.

(1 ) (2) (3) (4)

"IDLE ADJUSTMENT" Screen

Switch (2): Reducing the speed
IDLE A[LJU3TMENT Switch (3): Increasing the speed
Switch (4): Entering idle speed and returning to MASK MENU
850 screen.

1 rpm
 18-69

Leo CONTRAST ADJUSTMENT

GENERAL
Adjusts LCD contrast.

Operating Procedure

1. Enter the password on the general screen (Refer to page 18-

14) to display the MASK MENU screen.

2. 4Y engine vehicle

elT .'. [)T

d HI'I
Press switch (1) 6 times to check that "7. CONTRAST" is
selected, and press (enter) switch (4) to display the
CONTRAST ADJUSTMENT setting screen

( ~ Jj I
1DZ-! 1I/3Z engine vehicle
Press switch (1) 5 times to check that "6. CONTRAST" is

~=.....:....:--:-:.=....:....:~--l
selected, and press (enter) switch (4) to display the
CONTRAST ADJUSTMENT setting screen.

11
I

3 Change the contrast level with switch (2) and switch (3), and
press (enter) switch (4) to set the value and return to MASK
(1) With travel and M EN U screen.
load handling control

(1 ) (3) (4)

"CONTRAST" Screen
Switch (2): Reducing contrast
Switch (3): Increasing contrast
Switch (4): Entering idle speed and returning to MASK MENU
screen.
18-70

METER START

GENERAL
Starts counting the odometer, trip meter and maintenance hour meter.

Operating Procedure

1. Enter the password on the general screen (Refer to page 18-

MENU>
<MA:3~1~ 14) to display the MASK MENU screen.

7. CONTRA::iT 2. 4Y engine vehicle

Press switch (1) 7 times to check that "8. METER START" is
selected, and press (enter) switch (4) to display the METER
9.END START setting screen.

\l( .. ) ( +-J )11

1DZ-III/3Z engine vehicle

Press switch (1) 6 times to check that "7 METER START'"
selected, and press (enter) switch (4) to display the METE:.
START setting screen.

It r~.Ir-..
o. c.1'~ LJ

f .... J

(1) With travel and

load handling control

(1 ) (2) (3) (4)

"METER START" Screen

3 Press switch (2) for more than 2 seconds to display the right
METER STA~:T arrow on the screen.

I,

'I'
,IE(i0
f '5 :Ij
 18-71

4. While pressing switch (2), if you press switch (3), inverted NO

on the screen turns to inverted YES, and the setting is
METEr: :3T ART completed.

1"E0
'( .. /[mJ
)....

5. Press switch (4) to return to MASK MENU screen.

METEr: :3T ART

Note:
After completing the meter start setting, "METER START" will
not be displayed on the MASK MENU screen.
<MASK MENU>
7gCONTRAST

(+ ( ;..J )

+)

Note:
If the meter start is not set yet, the symbol indicating that the
hour meter is not started will be displayed on the GENERAL
screen.
hrn/h

cm~vcllD
1EMP
18-72

MULTIFUNCTION DISPLAY ASSY

DISASSEMBLY·REASSEMBLY
T = Nm (kgfcm) [ftlbf)

T = 0.6 -

,
0.8 (6 - 8) [0.43 - 0.58]

Removal Procedure
Remove the case

2 Remove the board and LCD panel ASSY from the cover.
3 Disconnect the LCO panel ASSY flat cable from the board [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 18-73

Leo panel Point Operations

[Point 1]
Reassembly:
Follow the procedure below to install the LCD panel to the
housing.

1. Remove the protective sheet from the back face of the LCo
panel.
2. Install the LCD panel to the housing according to the following
steps.

(1) Press the upper part of the LCD panel to the claws. When
pressing the panel, do not apply excessive force.
(2) Press the lower part of the LCo panel to engage the
claws.

Note:
Do not damage the LCD panel.
3. After installing the LCD panel, remove the protective sheet
from the front face of the LCD panel.

Note:
After removing the protective sheet, do not touch the surface
of the LCD panel.
 19-1

ELECTRICAL SYSTEM TROUBLESHOOTING

Page
BEFORE TROUBLESHOOTING 19-2
CONNECTOR HANDLING 19-2
WIRE HARNESS AND CONNECTOR INSPECTION
PROCEDURE 19-2
TROU B LESHOOTI NG 19-4
BEFORE BEGINNING TROUBLESHOOTING FOR
THE 4Y (4Y=E) ENGINE 19-4
DIAGNOSIS (SELF DIAGNOSIS FUNCTION) 19-5
DIAGNOSIS DISPLAY METHOD 19..5
LIST OF DIAGNOSIS CODES 19..6
WARNING LIST 19..12
VIEWING RELATED PORTIONS 19..13
ERROR CONFIRMATION DRIVE MODE 19..13
TROUBLESHOOTING BY ERROR CODE 19-14
TROUBLESHOOTING WHEN THERE IS NO
ERROR CODE 19..156
19-2

BEFORE TROUBLESHOOTING

CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull the wire harness
but hold the connector itself and pull it after unlocking it.
To connect, push the connector fully until it is locked in
position.

3. Bring a tester probe into contact with a connector terminal from

the fear side of the connector (harness side).

4. If insertion from the rear side is impossible, as in the case of a

waterproof connector, bring the tester probe carefully into
contact with the terminal so as not to cause deformation of the
connector terminal.
5. Do not touch connector terminals directly with your hand.
6. When bringing tester probes into contact with terminals that
voltage is applied to prevent two tester probes from coming
into contact with eacl-j other.

WIRE HARNESS AND CONNECTOR

INSPECTION PROCEDURE
When any trouble occurs, first inspect the connectors and wire
harness of the related circuit according to the following procedure:

Continuity Inspection

1. Disconnect the connectors at both ends of the corresponding

harness.
2. Measure the resistance between corresponding terminalS of
the connectors at both ends.
Standard: 10 D or less

Note:
• Measure while jiggling the wire harness up and down and
sideways.
• Open circuit at the wire harness occurs rarely partway
through a vehicle wiring but mostly at connectors. Inspect
especially the sensor connectors with sufficient care.
 19-3

Short Circuit Check

1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between the corresponding connector
terminal and frame. Be sure to inspect the connectors at both
ends.

Standard: 1 MO or above
Note:
Measure while jiggling the wire harness up and down and
sideways.

3. Measure the resistance between terminals of the

corresponding connector. Be sure to inspect the connectors at
both ends.

Standard: 1 MO or above
Note:
The wiring may short-circuit due to pinching by the body or
defective clamping.

Visual and Contact Pressure Checks

1. Disconnect the connectors at both ends of the corresponding
harness.

2. Visually inspect that there is neither rust nor foreign matter

trapped at connector terminals.
3. Inspect that there is no looseness or damage at the crimped
portion. Also, lightly pull the wire harness from the connector lo
check that it does not come off.

4. Insert a male terminal same as that of the connector terminal

to a female connector and check the drawing force.
Defective contact may exist at a terminal where the drawing
force is less than that of other terminals.
Note:
Even if there is rust or foreign matter trapped at the terminal,
or the contact pressure between male and female terminals is
low, abnormal contact condition may be changed to normal by
disconnecting and reconnecting the connector. In this case,
disconnect and reconnect the connector several times, and if
a fault occurs ever:' once, then consider the terminal may have
a defective contact.
19-4

TROUBLESHOOTING

BEFORE BEGINNING TROUBLESHOOTING FOR THE 4Y (4Y-E) ENGINE

It is extremely risky to begin troubleshooting for the 4Y engine on the basis of results only. It can lead to mistaken
corrective action, wasted time, and sometimes to an increase in abnormalities. Therefore, ask the customer about
detailed information on conditions around the time a problem occurred, based on the following.

Diagnostic Procedure
First, it is necessary to be informed of the "fault history and service history" for the vehicle, and then to gather definite
information about the fault occurence such as "when", "at what times", "in what places", "during what operations or
actions", "what happened afterwards", and "frequency of occurrence".
Also, try to recreate the conditions for the fault occurence. (a. Recreation impossible b. Recreation possible: in what
condition?)
• General items
Customer name Date of delivery Date fault occurred / hour meter reading I
Vehicle model Frame No. Engine No. (punched)

Fuel type
o Gasoline DLPG o Gasoline - LPG combination
--._-
(Note LPG fuel company name: )

• Condition of the defect (Tick the items that apply)

Defect phenomena
1. Cannot start a. Does not crank b. Combustion does not start c. Incomplete combustion
2. Does not start well Poor cranking (when cold - when warm - at all times)
3. Poor idle a Poor idle speed b. Unstable idle speed c Hunting (regular fluctuation in speed)
a. Immediately after start-up (when cold - when warm) b. During deceleration c. After deceleration
4. Engine stalling d. Without sign e. After the engine has been running rough f. When steering
g. When handling materials h. Can be re-started immediately
a. Insufficient power output b. Hesitation
5. Defect operational
c. Surging (swaying forward and backward during acceleration) d. Knocking e. Backfiring f. After
status
firing
a. Excessive fuel consumption b. Excessive oil consumption c. Overheating d. Water or oil leaks
6. Other
e. Abnormal noise f. Other ( ) .

Environment at the time of the defect's occurrence

The time when the fault a. Since the vehicle was new b. Recently (from around the following date (month and year): )
began to occur c. After being serviced
Frequency of occurence a. Always b. Under certain conditions c. Sometimes

Weather
Sunny - cloudy - rain - snow -
thunderstorm
ITemperature I I ..
Approximately QC Humidity IApproximately 0/0
Temperature conditions Coolant: a. When cool b. When warm Temperature inside engine room: DC
--
a. No relation b. When idling c. When revving d. When accelerating
e. When traveling at constant speed f. When decelerating g. When climbing a slope
Operation conditions h. During material handling operations When not loaded (when steering - when lifting - when tilting)
When loaded (load: appox. kg) (when steering - when lifting - when tilting)
i. Other (when using the inching brake - when steering - other)
Lamps a. Lights constantly b. Lights occaisonally c. Does not light
 19-5

DIAGNOSIS (SELF DIAGNOSIS FUNCTION)

General
When the computer detects a problem in the system, the fault is indicated by lighting a warning lamp on the
combination meter and displaying an error code, and fail-safe functions operate to ensure safety by stopping the
engine or controlling the engine to a low speed.

DIAGNOSiS DISPLAY METHOD

Error code display
1. Diagnosis display method

~I i~ 8
The diagnosis is displayed by means of an error code as

m
nu
ollllll!lII!!"OC
ElIImlllDF !.- !.../n
..
/
00 -1
/h
shown in the illustration to the left, and by the lights turning on.
When the ignition key switch is turned ON, the lamp lights
once to allow checking for the bulb, and then turns off again if

I D ~~ 0._0 0 ~ O~j the status is normal.

With the ignition key switch ON, if an abnormality is detected
An orange colored lamp lights Lamp blinks when the vehicle is stopped, travelling or performing meterials
(Engine ECU only) handling operations, an error code is displayed and the lamps
turn on as a warning.
When this happens, stop the vehicle immediately and check
the error code.
2. Diagnosis memory display method
To display the diagnosis memory display, there are a method using the hour meter and tilt lever, a method using
the optional display, and a method using a plug-in analyzer.
Here the display method using the hour meter and tilt lever is described.

(1) From the main menu, display the diagnosis memory menu. For how to display the main menu, refer to page
16-34.
(2) A diagnosis No. and error code are displayed each time the knob switch is pressed and released. Each
error code and the time at which it occurred are displayed alternately at 2 second intervals.
Note:
• The maximum number of error codes that can be stored is 10. The smaller the diagnosis No., the more
recent the error is.
• The stored time of an error code appearing just when the ignition key switch is turned ON may be stored
as 0.0.
(3) Connect the matching connector and turn the ignition key switch OFF

Knob switch _____

Diagnosis memory menu

f-cl fRC r
...J.press the knob switch to return it.

0: C7-21 ~ ~ --[-/-/-/.:-:-3-.'--: I
Switches automatically
every 2 seconds

I if
I Lt
C I. I I
Lt I I . ,_::i I J ID
' _, I.Lt.
I
LIST OF DIAGNOSIS CODES ....>.
<.0
I.
Q)

Wrench Detection Described

Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
01-1 01-1 Blinking 4Y-ECS Fuel feedback control error (gasoline) rich
19-14
01-2 01-2 Blinking 4Y-ECS Fuel feedback control error (gasoline) lean
The engine speed is unstable and it may stop.
01-3 01-3 Blinking 4Y-ECS Fuel feedback control error (LPG) rich
19-18
01-4 01-4 Blinking 4Y-ECS Fuel feedback control error (LPG) lean
01-5 01-5 Blinking 4Y-ECS 02 sensor open abnormality The engine speed is unstable and it may stop. 19-23
01-6 01-6 Blinking 4Y-ECS 02 sensor heater open abnormality Display only 19-25
02-1 02-1 Blinking 4Y-ECS Intake temperature sensor open abnormality The engine may have a problem at low
-- 19-27
02-2 02-2 Blinking 4Y-ECS Intake temperature sensor short abnormality temperatures.

03-1 03-1 Blinking 4Y-ECS Intake pipe pressure sensor open abnormality
The engine may have a problem 19-29
03-2 03-2 Blinking 4Y-ECS Intake pipe pressure sensor short abnormality
04-1 04-1 Blinking 4Y-ECS Coolant temperature sensor open abnormality The engine may have a problem at low
19-31
04-2 04-2 Blinking 4Y-ECS Coolant temperature sensor short abnormality temperatures.
-
05-1 05-1 Blinking 4Y-ECS Throttle position sensor 1 open abnormality
--
05-2 05-2 Blinking 4Y-ECS Throttle position sensor 1 short abnormality
05-3 05-3 Blinking 4Y-ECS Throttle position sensor 2 open abnormality Limting speed of traveling and materials
19-33
05-4 05-4 Blinking 4Y-ECS Throttle position sensor 2 short abnormality handling due to limited engine power output

05-5 05-5 Blinking 4Y-ECS Throttle position sensor offset abnormality

05-6 05-6 Blinking 4Y-ECS Throttle position sensor out of range error
06-1 06-1 Blinking 4Y-ECS Throttle motor drive circuit open abnormality
06-2 06-2 Blinking 4Y-ECS Throttle motor drive circuit short abnormality -l 19-35

06-3 06-3 Blinking 4Y-ECS Throttle motor power supply circuit open abnormality -I Limting speed of travellng and materials
handling due to limited engine power output
19-37
06-4 06-4 Blinking 4Y-ECS Throttle motor power supply circuit short abnormality
06-5 06-5 Blinking 4Y-ECS Throttle motor seizing abnormality 19-38
06-6 06-6 Blinking 4Y-ECS Electmnic throttle system error 19-40
07-1 07-1 Blinking 4Y-ECS Air-fuel ratio motor open abnormality The engine speed is unstable and it may stop. 19-41
08-1 08-1 Blinking 4Y-ECS Low voltage (battery line open) error Display only 19-43
09-1 09-1 Blinking 4Y-ECS Ignition signal error" The engine speed is unstable and it may stop. 19-44
OA-1 OA-1 Blinking 4Y-ECS Fuel specification determination signal error Display only
OA-2 OA-2 Blinking 4Y-ECS Fuel specification changeover switch error Display only 19-47
OA-3 OA-3 Blinking 4Y-ECS Fuel specification type unmatch Engine may stop
Indication
Wrench
lamp
S -TDeteCtiOn
panner ECU
1---'
,
Error' mode
-_.
1
."

Phenomenon on vehicle
Described
on page
Limting speed of traveling and materials
OA-4 OA-4 Blinking 4Y-ECS Engine specification determination error 19-49
handling due to limited engine power output
13-1 13-1 Blinking ASC Motor relay contact point open abnormality Continuation of engine idling status
13-2 13-2 Blinking ASC Motor relay contact point short abnormality Display only 19-50
13-3 13-3 Blinking ASC Motor relay open circu it or load short abnormality Continuation of engine idling status
15-1 15-1 Blinking ASC NMR switch open abnormality The engine may idle during full acceleration.
19-52
15-2 15-2 Blinking ASC NMR switch short abnormality Continuation of engine idling status
Continuation of engine idling status after
15-3 15-3 Blinking ASC Idle I NMR switch simUltaneously ON error 19-55
acceleration off.
16-1 16-1 Blinking ASC Idle switch open abnormality
Continuation of engine idling status 19-58
16-2 16-2 Blinking ASC Idle switch short abnormality
4Y-ECS Cam angle sensor open abnormality Engine stop 19-61
18-1 18-1 Blinking
ASC Engine speed sensor open abnormality Partial limitation of the drive control function. 19-65
4Y-ECS Cam angle sensor open abnormality (on start up) Engine will not start 19-61
18-2 18-2 Blinking
ASC Engine speed sensor GND short abnormality Partial limitation of thl3 drive control function. 19-65
18-3 18-3 Blinking 4Y-ECS Crank angle sensor open abnormality Display only 19-63
Continuation of engine idling status
Maximum speed may be limited
1F-1 - 8 1F-1 - 8 Blinking ASC CPU error 19-67
Function of automatic idle speed increse during
lifting limited
41-1 41-1 Blinking SAS/OPS Matching connector open abnormality Display only 19-68
51-1 51-1 Blinking SAS/OPS Speed sensor" open abnormality The vehicle speed indicator shows 0 km/h
Partial limitation of the rear wheel swing control
function 19-69
51-2 51-2 Blinking SAS/OPS Speed sensor GND short abnormality Knob offest compen~,ation stops
Partial limitation of the drive control function .
.
52-1 52-1 Blinking SAS/OPS Yaw rate sensor open abnormality
Partial limitation of the rear wheel swing control
52-2 52-2 Blinking SAS/OPS Yaw rate senSiJr VCC short abnormaiity 19-71
function
52-3 52-3 Blinking SAS/OPS Yaw rate sensor neutral voltage error
Partial limitation of the rear wheel swing control
54-1 54-1 Blinking SAS/OPS Swing lock solenoid open circuit or load short abnormality 19-73
function
61-1 61-1 Blinking SAS/OPS Load sensor open abnormality Partial limitation of the rear wheel swing control
function
Partial limitation of mast control function 19-75
61-2 61-2 Blinking SAS/OPS Load sensor VCC short abnormality Limitation of the drive control function
-'
Load indicator cannot display (0
I
:---J
 .....>.
Wrench Detection Described <.b
Indication Spanner Error mode Phenomenon on vehicle I
lamp ECU on page co
62-1 62-1 Blinking SAS/OPS Tilt angle sensor open abnormality
Partial limitation of mast control function 19-78
62-2 62-2 Blinking SASfOPS Tilt angle sensor VCC short abnormality
63-1 63-1 Blinking SASfOPS Tilt switches simultaneously ON
63-2 63-2 Blinking SASfOPS Tilt switch forward tilt SW short Partial limitation of mast control function 19-81
63-3 63-3 Blinking SAS/OPS Tiit switch backward tilt SW short
,64-1 64-1 Blinking SASfOPS Lift lower lock solenoid open circuit or load short abnormality Lift lower may stop 19-84
Forward tilt may stop, backward tilt may go fully
65-1 65-1 Blinking SASfOPS Tilt control solenoid open circuit or load short abnormality 19-86
back
66-1 66-1 Blinking SAS/OPS Outside matching value range for tilt angle error Partial limitation of mast control function 19-88
Partial limitation of the rear wheel swing control
function
67-1 67-1 Blinking SASfOPS Lifting height switch open abnormality Partial limitation of mast control function 19-89
Limitation of the drive control function
Load indicator display is unsteady
I
Lowering may stop
68-1 68-'1 Blinking SASfOPS Lift switch raise and lower simUltaneously ON error Function of automatic idle speed increse during
lifting limited
19-92
Function of automatic: idle speed increse during
68-2 68-2 Blinking SAS/OPS Lift switch raise SW short abnormality
lifting limited
68-3 68-3 Blinking SAS/OPS Lift switch lower SW short abnormality Lowering may stop
Backwar'd tilt lock solenoid open circuit or load short
69-1 69-1 Blinking SAS/OPS Backward tilt may stop 19-95
abnormality
71-1 71-1 Blinking SAS/OPS Tire angle sensor open abnormality
Knob offest compensation stops 19-97
71-2 71-2 Blinking SAS/OPS Tire angle sensor VCC short abnormality
72-1 72-1 Blinking SAS/OPS Steering-wheel angle sensor SS 1 open abnormality
72-2
72-3
72-2
72-3
Blinking
Blinking
SAS/OPS
SAS/OPS
Steer'lng-wheel angle sensor SS2 open abnormality
Steering-wheel angle sensor SSC open abnormality
;;=1 Knob offest compensation stops 19-100

72-4 72-4 Blinking SAS/OPS Steering-wheel angle sensors SS1 and, .SS2
__ open
___ abnormality
__ I
 _. -
Wrench Detection
'- Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
Knob position compensation solenoid open circuit or load, short
73-1 73-1 Blinking SAS/OPS Knob offest compensation stops 19-108
abnormality
----
74-1 74-1 Blinking SAS/OPS Outside matching value I'ange for tire angle error Knob offest compensation stops 19-110
Traveling and matericll handling possible even
after leaving the seat.
A5-1 A5-1 Blinking SAS/OPS Seat switch GND short abnormality 19-111
Parking brake reminder and release reminder
alarm partially disabliOld.
A7-1 A7 -1 Blinking SAS/OPS Brake switch GND short abnormality Paliial limitation of the drive control function 19-113
AD-1 AD-1 Blinking SASIOPS CAN communication 4Y-ECS or ASC data I'eception error Partial limitation of the drive control function
AD-2 AD-2 Blinking 4Y-ECS CAN communication SAS/OPS data reception error Partial limitation of the drive control function
Limitation of the drive control function
Function of automatic idle speed increse during 19-115
AD-7 AD-7 Blinking ,_ SASIDPS rAN oommcoicetioo di,pl'y d,w cocoptioo e,m, lifting limited
Display warning function operation failure
-- .---'-
AD-8 AD-8 - Display CAN communicatioll SASIOPS data reception error Display not stable
I -,
AF-1 - 3 P,F-1 - 3 On SASIOPS
CPU error Various control operations not stable '19-119
AF-4 - 8 AF-4 - 8 Blinking SASIOPS
_.
4Y-ECS
C4-1 C4-1 Blinking Accelerator sensor 1 open
ASC
4Y-ECS
C4-2 C4-2 Blinking Accelerator sensor 1 shol1
ASC
--
4Y-ECS
C4-3 C4-3 Blinking Accelerator sensor 2 open Limting speed of traveling and materials 19-120
ASC
handling due to limited engine power output 19-123
4Y-ECS
C4-4 C4-4 Blinking Accelerator sensor 2 short
ASC
4Y-ECS
C4-5 C4-5 Blinking Accelerator sensor offset abnormality
ASC
--
C4-6 C4-6 Blinking 4Y-ECS Accelerator sensor out of range error
Travel return to neutral operation disabled
C7-1 C7-1 Blinking SASIOPS Shift lever forward and reverse travel switch open abnormality
Partial limitation of the drive control function
19-126
Shift lever forward and reverse travel switches simultaneously Travelling may stop
C7-2 C7-2 Blinking SASIOPS
ON error Partial limitation of the drive control function.

CA-1 CA-1 ~g SAS/OPS Forward and reverse travel TIC relay open circuit
abnormality
01' load short Travelling and material handling enabled even
after leaving the seat.
19-129
--'--- . ->.
<.D
I
<.D
 ~
Wrench Detection Described <.0
Indication Spanner· Error mode Phenomenon on vehicle I
lamp ECU on page ~

o
Travelling and mater·ial handl'lng enabled even
EC-1 EC-1 Blinking SAS/OPS Unload solenoid open circuit or load short abnormality 19-131
after leaving the seat.
F1-1 - Blinking
Meter SAS/OPS data reception error Display only 19-133
F2-1 - Blinking
_._--.
F4-1 - 8 F4-1 - 8 Blinking Display CPU elTor Display not stable 19-134
-
H1-1 H1-·' Blinking SAS/OPS Lift lever potentiometer open abnormality
--
H1-2 H1-2 Blinking SAS/OPS Lift lever potentiometer VCC short abnormality Lift stop
H1-3 H 1-3 Blinking SAS/OPS Lift lever potentiometer assembly error 19-135
H1-4 H1-4 Blinking SAS/OPS Lift lever potentiometer neutral abnormality Material handling disabled
H1-5 H1-5 Blinking SAS/OPS Lift lever potentiometer matching value abnormality Lift stop
H2-1 H2-1 Blinking SAS/OPS Tilt lever potentiometer open abnormality
~
H2-2 H2-2 Blinking SAS/OPS Tilt lever potentiomete r VCC short abnormality . Tilt stop
--
H2-3 H2-3 Blinking SAS/OPS Tilt lever potent'lometer assembly ermr 19-138
H2-4 H2-4 Blinking SAS/OPS Tilt lever potentiometer neutral error abnormality Material handling disabled
H2-5 H2-5 Blinking SAS/OPS Tilt lever potentiometer matching error Tilt stop
H3-1 H3-1 Blinking SAS/OPS Attachment 1 lever potentiometer open abnormality
H3-2 H3-2 Blinking SAS/OPS Attachment 1 lever potentiometer VCC short abnormality Attachment 1 stop
H3-3 H3-3 Blinking SAS/OPS Attachment 1 lever potentiometer combination error 19-141
H3-4 H3-4 Blinking SAS/OPS Attachment 1 lever potentiometer neutral abnormality Material handling disabled
H3-5 H3-5 Blinking SAS/OPS Attachment 1 lever potentiometer matching value abnormality Attachment 1 stop
H4-1 H4-1 Blinking SAS/OPS Attachment 2 lever potentiometer open abnormality
H4-2 H4-2 Blinking SAS/OPS Attachment 2 lever potentiometer VCC short abnormality Lever 2 stop
H4-3 H4-3 Blinking SAS/OPS Attachment 2 lever potentiometer combination error 19-144
H4-4 H4-4 Blinking SAS/OPS Attachment 2 lever potentiometel· neutral abnormality Material handling disabled
H4-5 H4-5 Blinking SAS/OPS Attachment 2 lever potentiometer matching value abnormality Lever 2 stop
H5-1 H5-1 Blinking SAS/OPS Lift F'USH solenoid open abnormality
Lift may stop 19-147
H5-2 H5-2 Blinking SAS/OPS Lift PULL solenoid open abnormality
H6-1 H6-1 Blinking SAS/OPS Tilt PUSH solentlld open abnormality
Tilt may stop 19-149
H6-2 H6-2 Blinking SAS/OPS Tilt PULL solenoid open abnormality
H7-1 H7-1 Blinking SAS/OPS Attachment 1 PUSH solenoid open abnormality
-- Attachment 1 may stop 19-151
H7-2 H7-2 Blinking SAS/OPS Attachment 1 PULL solenoid open abnormality
 Wr"ench Detection Described
Indication Spanner Error mode Phenomellon on vehicle
lamp ECU on page
H8-1 1-18-1 Blinking SAS/OPS Attachment 2 PUSH solenoid open abnormality
-- Attac;hment 2 may stop 19-153
H8-2 H8-2 Blinking SAS/OPS Attachment 2 Pl LL solenoid open abnormality

HA-1 HA-1 Blinidng SAS/OPS 3/4 way changE; relay GND short abnormality Atta,~hment switching disabled 19-155
.. - .' -

-'-
(0
t
-'-
-'-
 ->.
WARNING LIST (0
I
->.
N
Note:
If the wrench lamp illuminates and the following phenomena occur on the vehicle without an error being displayed, it is not a fault. Take the
appropriate corrective action.
Wrench Detection Appropriate corrective action
Indication Memory Phenomenon on vehicle Content of warning
lamp ECU
Water
I
temperatur Top speed and load lifting speed are limited,
08-1 - 4Y-ECS Overheat Leave (he vehicle at idle for a while
e gauge (Only when OPT equipped)
flashing
Swing lock control is always locked
Knob offset occurrence Use a battery of the specified
- - On SAS/OPS
Material handling disabled (mini lever)
High battery voltage
voltage
Material handling except lifting disabled /.,1' \.

- - On SAS/OPS Swing lock contml is always locked Low battery voltage CharQe or replace the battery
- - On SAS/OPS Tilt operates to forward most tilt position Forward tilt restriction angle not matching
I:
i
Tilt disabled with the knob switch in the ON
- - On SAS/OPS Auto leveling cmgle not matching
position
,--
THt operates to forward most tilt position t ;, ,I
SAS/OPS NL load not matching
Tilt disabled with the knob switch in the or\l
I
- - On SAS/OPS
(NL', No-load) \
position
il
- - On SAS/OPS Knob offset occurrence Th-e angle not matching Carry out matching for each item
'\
- - On SAS/OPS Swing lock control disabled Swing leveling not match'Ing "
- - On SAS/OPS Lift stop I Lift lever not matching
- - On SAS/OPS Tilt stop Tilt lever not matching
- - On SAS/OPS Attachment 1 stop Attachment 1 not matching
- - On SAS/OPS Attachment 2 stop Attachment 2 not matching
 19-13

VIEWING RELATED PORTIONS

In the wiring diagrams for related portions, there are cases in which the parts are connected directly, and cases
where they are connected via a junction block or similar.
Refer below for how to identify wiring configuartions.

Example of a Related Portion

: Direct connection
: Connection via a junction
A21
.-------~ ECU-B
!SIRATI:
SAS/OPS
1 (IG1)
2 (IG2) T
~ 2 (IG/
Q2

controller A20
12 (CANH) 5 (CANH) Multifullction
~------~---
display
13 (CANL) 6 (CANL)

L~~
~-~-------

3 (E1)

*A36

'---

EFl
~2~_-_(CAN-)~
28 (CAN+)

3 (BATT)
Engine
I
controller

IGN 9 (IGSW)
---I~f--------~

ERROR CONFIRMATION DRIVE MODE

Q) Turn the ignition key switch ON, start and completely warm up the engine.
Il>Fully depress the accelerator pedal for 3 to 5 minutes with the direction neutral.
iJ) Release and leave the accelerator pedal (run the engine at idle) for 2 minutes
® Repeat steps <I! and Q) 3 times.
13) Turn the ignition key switch OFF (for 1 minute).
@ Repeat steps G) to (3) 3 times.
I . 3 - 5 minutes 3 - 5 millutes 3 - 5 minutes
Engine speed I
I
NMR - ------------------ I
I
I
Idle
Warmed up
-------- I
I \
time
IG IG
OFF OFF

2 minutes 2 minutes 2 millutes

19-14

TROUBLESHOOTING BY ERROR CODE

• Error codes 01-1, 01-2 (Fuel feedback control abnormality)
Related portion

A35 C1
~~~~~~~

20 (OX) 3 (OX)
Engine
controller 21 (E11) 4 (E1) 02 sensor
\--~~~~~-~- - - - - - - - - - -~~-~-~--i

Probable cause
CD Intake system defect (iJFuel system defect
ell Exhaust system defect ~) Harness defect
Q) Sensor defect CD Engine controller defect
® Ignition defect
Note:
When another error code is present repair the related parts first before carrying out the following.

I
Error codes 01-1 and 01-2

Disconnect the battery negative terminal (for

more than 10 seconds). Check the connection
status of C1, disconnect C1 and perform a visual
and contact pressure inspection of the
connector. Short circuit the service connector TC
terminal with the E1 terminal, and after
connecting C1 and the battery negative terminal
(on a combination vehicle, switch the fuel
changeover switch to gasoline), turn the ignition
key switch ON (engine stopped), depress the
accelerator pedal 5 times within 30 seconds
(fu'lIy open to fully closed), then start the engine
and check that the error has been cleared.

./
Service connector
Disconnect the battery negative terminal,
disconnect TC terminal - E1 terminal, connect
the battery negative terminal, start the engine, No error
r-----~~~~-7 Connector contact defect
and check whether the error occurs after
performing error confirmation drive mode (see
19-13).
Error

Inspection 1: NG Intake system defect

Inspect the air intake \---~----7lntake system connection defect
 19-15

Inspection 2: NG Exhaust system defect

Exhaust gas leakage inspection ~~~~--~7 Exhaust system

OK

Inspection 3: NG Fuel system defect

Fuel leakage inspection '--~--~~-"> Fuel system connection defect

OK

1
IInspection 4:
Fuel pressure inspection
NG
Pressure regulator defect
---7 Fuel filter defect
Fuel pump defect
OK

Inspection 5: NG
Spark plug individual inspection -----7 Spark plug defect

OK

Inspection 6: NG
Injector individual inspection -------0>- Injector defect

OK

Inspection 7:
NG
Intake pipe pressure sensor voltage inspection ) Intake pipe pressure sensor defect
ANL.: I/O ENGINE CTRL 3/10

OK

spection 8:
NG
':)take temperature sensor voltage inspection Intake temperature sensor defect
IIANL.: I/O ENGINE CTRL 3/10

OK

Inspection 9:
NG
Coolant temperature sensor voltage inspection Coolant temperature sensor defect
ANL. I/O ENGINE CTRL 3/10

OK
.

Inspection 10: NG
Harness continuity and short circuit inspection Harness defect

d)
19-16

IInspection 11: lOK

I02 sensor voltage inspection
-~
Connector contact defect
ANL_:I/O ENGINE CTRL 8/10

NG

Inspection 12:
02 sensor voltage inspection
1lt\11 -l/n f=t\If::It\If= TOI P/1n
l NG -----3> Engine controller defect

02 sensor defect

Inspection 1:
Inspect for air suction.
Start the engine and check vvhether air is being sucked in from the engine oil level gauge, oH filler cap, or pev
hose etc.

Standard: There is no air being sucked in.

Check jf there is air being sucked in from the intake system parts and connections between the air cleaner and
the cylinder head.

Standard: There is no air being sucked in.

Inspection 2:
Inspect for exhaust gas leakage.
Start the engine and check if there is any exhaust gas leakage from the exhaust system parts and connections
between the cylinder head and the catalytic muffler.

Standard: There is no exhaust gas leakage.

Inspection 3:
Inspect for fuel leakage.
Start the engine and check if there is any fuel leakage from the fuel system parts and connections between the
fuel pump and the injectors.

Standard: There is no fuel leakage.

Inspection 4:
Inspect the fuei pressure.
For the fuel pressure inspection, refer to the repair manual for the 4Y engine.

Inspection 5:
Carry out a spark plug individual inspection_
For the spark plug individual inspection, refer to the repair manual for the 4Y engine.

Inspection 6:
Carry out an injector individual inspection.
For the individual injector inspection, refer to the repair manual for the 4Y engine.
 19-17

Inspection 7:
Inspect the intake pipe pressure sensor voltage.
Ignition key switch ON, engine stopped
Intake pipe pressure sensor voltage (I/O monitor: PIM)

Standard:
PIM 3.6 ± 03 V (100 ± 10 kPa (1 ± 0.1 kgf/cm 2 ) [14 ± 1.4 psi])

Inspection 8:
Inspect the intake temperature sensor voltage
Ignition key switch ON, engine stopped

Intake temperature sensor voltage (I/O monitor: THA)

Standard:
2.4 ± 06 V (20 ± 10°C)
THA ,-.-----.---.---------------1
0.55 ± 015 V (80 ± 10°C) (reference value)

. pection 9:
Inspect the coolant temperature sensor voltage.
Start the engine, warm up completely (coolant temperature gauge: at 5-6 bars)

Coolant temperature sensor voltage (I/O monitor: THW)

Standard:

THW
0.55±015V(80±i0°C) I
2.4 ± 0.6 V (20 ± 10°C) (reference value) I
Inspection 10:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect battery negative terminal, disconnect A35 and C1.

Standard:
A35-20 - Ci-3 I Continuity
A35-21 .- Ci-4 -1--- Continuity
A35-20 - Frame I No continuity
A35-2i - Frame No continuity

Inspection 11:
Inspect the 02 sensor output

Connect A35 and C1, start the engine. warm up completely, set direction in neutral, fully open the accelerator
pedal
02 sensor voltage (I/O monitor: OX)
Standard:
OX 0.4 V or less and 0.5 V or more alternately output

Inspection 12:
Inspect the 02 sensor output

Disconnect C1, connect A35, start the engine, warm up completely, set direction in neutral, fully open the
accelerator pedal
02 sensor voltage (I/O monitor: OX)
Standard:
OX 0.2 V or less
19..,18

• Error codes 01-3, 01-4 (Fuel feedback control abnormality) (LPG)

Related portion

A35 C1
,--------,
20 (OX) 3 (OX)
Engine
controller 21 (E11) 4 (E1) 02 sensor
r-----~'--- - - - - - - - - - ------------j

Probable cause
CD Intake system defect (3) Fuel system defect
<2) Exhaust system defect @ Harness defect
Q) Sensor defect CV Engine controller defect
® Ignition defect
Note:
When another error code is occuring, repair the related parts first before carrying out the following.

IError codes 01-3 and 01-4

Disconnect the battery negative terminal (for
more than 10 seconds), Check the connection
status of C 1, disconnect C1 and perform a visual
and contact pressure inspection of the
connector, Short circuit the service connector TC
terminal with the E1 terminal, and after
connecting C1 and the battery negative terminal
(on a combination vehicle, switch the fuel
changeover switch to gasoline), turn the ignition
key switch ON (engine stopped), depress the
accelerator pedal 5 times within 30 seconds
(fully open to fully closed), then start the engine
and check that the error has been cleared,

Service connector
Disconnect the battery negative terminal,
disconnect TC terminal - E1 terminal, connect
the battery negative terminal, start the engine, No error
and check whethe, the error occurs after 1-----------'0> Connector contact defect
performing error confirmation drive mode (see
19-13),

Error

Inspection 1: NG Intake system defect

Inspect the air intake r - - - - - - - + Intake system connection defect
 19-19

Inspection 2: NG Exhaust system defect

Exhaust gas leakage inspection. - - - - - - - - 7 Exhaust system connection defect

OK

Inspeclion 3: NG Fuel system defect

Fuel leakage inspection ~-----'3» Fuel system connection defect

OK

Inspection 4: NG
Regulator primary pressure inspection RegUlator defect

OKl

IIlspection 5: NG
Spark plug individual inspection Spark plug defect
-

~
Inspection 6: NG
Injector individual inspection ) Injector defect

OK

inspection 7: NG
Air-fuel ratio motor individual inspection Air-fuel ratio motor defect

OK

11 Inspection 8:
Intake pipe pressure sensor voltage inspection ING ) Intake pipe pressure sensor defect
.NL.: 1/0 ENGINE CTRL 3/10
I
Inspection 9:
NG
Intake temperature sensor voltage inspection t ) Intake temperature sensor defect
ANL.: 1/0 ENGINE CTRL 3/10

OK

Inspection 10:
NG
Water temperature sensor voltage inspection Water temperature sensor defect
ANL.: 1/0 ENGINE CTRL 3/10

OK

Inspection 11: NG
Harness continuity and short circuit inspection Harness defect

0
19-20

Inspection 12:
OK
02 sensor voltage inspection ) Connector contact defect
ANL.:I/O ENGINE CTRL 9/10

NG
,

Ir
Inspection 13:
G
02 sensor voltage inspection ) Engine controller defect
ANL!!O ENGINE CTR.L 9/10
L======r=====~
OKI
02 sensor defect

Inspection 1:
Inspect for air suction.
Start the engine and check vvhether air is being sucked in from the engine off level gauge, oH fiiler cap, or PC\i
hose etc.

Standard: There is no air being sucked in.

Check if there is air being sucked in from the intake system parts and connections between the air cleaner and
the regulater.

Standard: There is no air being sucked in.

Check if there is air being sucked in from the intake system parts and connections among the air cleaner hose,
the resonator, and the regulater.

Standard: There is no air being sucked in.

Inspection 2:
Inspect for exhaust gas leakage.
Start the engine and check if there is any exhaust gas leakage from the exhaust system parts and connectio .
between the cylinder head and the catalytic muffler.

Standard: There is no exhaust gas leakage.

Inspection 3:
Inspect for fuel leakage.
Start the engine and check if there is any fuel leakage from the fuel system parts and connections between the
fuel tank and the regulator.

Standard: There is no fuel leakage.

Check if there is fuel leakage from the fuel system parts and connections between the regulator and the LPG
adapter.

Standard: There is no fuel leakage.

Check if there is fuel leakage from the fuel system parts and connections between the regulator and the injector.

Standard: There is no fuel leakage.

Inspection 4:
Inspect the regulator primary pressure.
For the regulator primary pressure inspection, refer to the LPG repair manual.
 19-21

Inspection 5:
Carry out a spark plug individual inspection.

For the spark plug individual inspection, refer to the repair manual for the 4Y engine.

Inspection 6:
Carry out an injector individual inspection.

For the individual injector inspection, refer to the repair manual for the 4Y engine.

Inspection 7:
Carry out an individual inspection of the air-fuel ratio motor.

For the individual air-fuel ratio motor inspection, refer to the LPG repair manual.

Inspection 8:
Inspect the intake pipe pressure sensor voltage.

Ignition key switch ON, engine stopped

Intake pipe pressure sensor voltage (I/O monitor: PIM)

Standard:
PIM 3.6 ± 03 V (100 ± 10 kPa (1 ± 0.1 kgf/cm 2 ) [14 ± 1.4 psi])

Inspection 9:
Inspect the intake temperature sensor voltage.

Ignition key switch ON, engine stopped

Intake temperature sensor voltage (I/O monitor: THA)

Standard:
2.4 ± 0.6 V (20 ± 10 e C)
THA
0.55 ± 0.15 V (80 ± 10 De) (reference value)

Inspection 10:
Inspect the coolant temperature sensor voltage.

Start the engine, warm up completely (coolant temperature gauge: 5-6 bars)
Coolant temperature sensor voltage (I/O monitor: THW)

Standard:
0.55 ± 0.15 V (80 ± 10 DC)
I THW
2.4 ± 06 V (20 ± 1ODC) (reference value)
I
Inspection 11:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect A35 and C1

Standard:
A35-20 - C1-3 ContinUity
A35-21 - C1-4 Continuity
A35-20 - Frame No continuity
A35-21 - Frame No continuity
19-22

Inspection 12:
Inspect the 02 sensor output
Start the engine, warm up completely, put the direction in neutral, fully open the accelerator pedal
02 sensor voltage (I/O monitor: OX)
Standard:
ox 0.4 V or less and 0.5 V or more alternately output

Inspection 13:
Inspect the 02 sensor output.

Start the engine, warm up completely, put the direction in neutral, fully open the accelerator pedal
02 sensor voltage (I/O monitor: OX)

Standard:
ox 02 V or less
 19-23

lit Error code 01-5 (02 sensor open abnormality)

Related portion

A35 C1
.--------~
20 (OX) 3 (OX)
Engine
controller 21 (E11) 4(E1) 02 sensor
~ - - - - - - - -~ - - - - - - - - --------~

Probable cause
CD 02 Sensor defect
G') Harness defect
GJ Engine controller defect
le:
When another error code is present, repair the related parts first before carrying out the following.

Ierror code 01-5

Disconnect the battery negative terminal (for
more than 10 seconds). Check the connection
status of C 1, disconnect C1 and perform a visual
and contact pressure inspection of the
connector. Short circuit the service connector TC
terminal with the E1 terminal, and after
connecting C1 and the battery negative terminal
(on a combination vehicle, switch the fuel
changeover switch to gasoline), turn the ignition
key switch ON (engine stopped), depress the
accelerator pedal 5 times within 30 seconds
(fully open to fully closed), then start the engine
and check thalthe error has been cleared
Service connector

lisconnect the battery negative terminal,

disconnect TC terminal - E1 terminal, connect
No error
the battery negative terminal, start the engine, f--------'7 Connector contact defect
and check whether the error occurs after
performing error confirmation drive mode (see
19-13)

Error

Inspection 1: NG
f--------3> Harness defect
Harness continuity and short circuit inspection

OK

02 sensor defect

If the error occurs even I

after replacing the 02
sensor 1
Engine controller defect
19-24

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C1

Standard:
A35-20 - C1-3 Continuity
A35-21 - C1-4 Continuity
A35-20 - Frame No continuity
 19-25

• Error code 01-6 (02 sensor heater open abnormality)

Related portion

A35
RIB EFl Main relay
C1 C1
Engine
controller
6 (HT) 1 (HTR) 02 l~ t)_
sensorJ - -
- - - -
3 (L)
------:-~
EFl
main relay

Probable cause
CD 02 Sensor defect
~ Harness defect
Q) Engine controller defect

for code 01-6

Disconnect the battery negative terminal (for I

more than 10 seconds), after inspecting and

I~:;t7~~i,n~~~Snc~;~~e~~i~~nO~~~~:~~~t~~~~ry
negative terminal, turn the ignition key switch ON
(start the engine), and check whether or not there
is an error. No error
CD Turn the ignition key switch ON. Connector contact defect
(Start and run the engine for more than 10
seconds.)
o Turn the ignition key switch OFF for more
thani0 seconds.
Cl) Turn the ignition key switch ON
(Start and run the engine for more than 10
seconds.)
I
I
@) Check for errors.
-------------;------_._------'
Error I
'Y
Inspection 1: ~---~I NG
02 sensor individual inspection ~i__---------C» 02 sensor defect

OKl
Inspection 2: I
NG
02 sensor heater power voltage inSpeCtion_~i-----------C»Harness defect

OKl
Inspection 3: NG
~------"> Harness defect
Harness continuity and short circuit inspection

Engine controller defect

19-26

Inspection 1:
Carry out 02 sensor individual inspection.
Ignition key switch OFF, disconnect C1, connect A35

Standard: (Sensor side)

I C1-2 - CH 13 - 16 n (20°C)
C1

Inspection 2:
Carry out 02 sensor heater power voltage inspection.
Ignition key switch OFF, diconnect C1, connect A35, start engine

Standard:
C1-2 - Frame 8 - 16 V

Inspection 3:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect A35 and C1

Standard:
A35-6 - C1-1 Continuity
A35-6 - Frame No continuity
 19-27

• Error codes 02-1, 02-2 (Intake temperature sensor abnormality)

Related portion

A35 C3
.---._-~~~~~,

29 (THA) 2 (THA) Intake

Engine r----~~~~~~~- - - - - - - - - - ~~~~~~---=-~--j

controller 28 (E2) 1 (E2) temperature

sensor

Probable cause
CD Intake temperature sensor defect
ell Harness defect
(J) Engine controller defect

'te:
when another error code is present, repair the related parts first before carrying out the following.

IError codes 02-1 and 02·2

Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of C3 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error

Errorl

Inspection 1: NG
Intake temperature sensor individual inspection Intake temperature sensor defect

OKl

Inspection 2: NG
larness continuity and short circuit inspection Harness defect
I
OKl

Engine control,ler defect

Inspection 1:
Carry out intake temperature sensor individual inspection ..
Ignition key switch OFF, disconnect C3, connect A35
C3
Standard: (Sensor side)
2.45 ± 024 kD (20°C)
C3-1 - C3-2
032 ± 0.03 kD (80°C)
19-28

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C3

Standard:
A35-29 - C3-2 Continuity
A35-28 - C3-1 Continuity
A35-29 - Frame No coniinuity
 19-29

• Error codes 03-1, 03-2 (Intake pipe negative pressure sensor abnormality)
Related portion

A35

17 (VC)
Intake pipe
Engine 18 (PIM)
controller pressure
28 (E2) sensor
f---------~ - - - - - - - - - -------.--1

Probable cause
CD Intake pipe negative pressure sensor defect
W Harness defect
CD Engine controller defect

L~
. 'or codes 03·1 and 03-2 _

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G12 and internal Connector contact defect
we!!ing. reconnect ail connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error

Inspection 1: NG
Harness continUity and short circuit inspection Harness defect

OK

11 Inspection 2:
NG
Intake pipe pressure sensor voltage inspection Engine controller defect
ANL: I/O ENGINE CTRL 3/10

OKI
\V
Intake pipe pressure sensor defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and G12

Standard:
A35-18 - G12-2 Continuity
A35-28 - G12-1 Continuity
A35-18 - A35-17 No continuity
A35-17 - G12-3 Continuity
A35-17 - Frame No continuity
A35-18 - Frame No continuity
19-30

Inspection 2:
Inspect the intake pipe pressure sensor voltage.
Ignition key switch OFF, disconnect G 12, connect A35, ignition key switch ON, engine stopped
Intake pipe pressure sensor voltage (I/O monitor: PIM)

Standard:
PIM 4.80 V or more
 19-31

• Error codes 04-1, 04-2 (Coolant temperature sensor abnormality)

Related portion

A35 G16
,.-----------, ~-------
19 (THW) 2 (THW) Coolant
Engine f---------- ~ - - - - - - ~ - ---------1
controller 28 (E2) 1 (E2) temperature
f---------- - - - ~ - - - - - ---------1
sensor

Probable cause
CD Coolant temperature sensor defect
o Harness defect
Q) Engine controller defect

L _o_r_c_o_d_e_s_O_4_-1_3_n_d_O_4_-Z_---J
"i,wooed the h,tte<Y 'Onative teemioal (:;~ ~-I
more than 10 seconds), after inspecting and N o error
...................,...... ...... J;r-o ...... ,-l; ................... ., ... " ..... t;"n ,-..f nrl .
\...UII t:;vllll~ UI'::>vUI11IGvlIV~I VI 1:21
0,6 811'-'1 Internal I 7 Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.

ErrorJ

Inspection 1: NG
Water temperature sensor individual inspection Water temperature sensor defect

OKl
!Inspection 2: NG
Harness continuity and short circuit inspection --7 Harness defect

Engine controller defect

Inspection 1:
Carry out coolant temperature sensor individual inspection.
Ignition key switch OFF, disconnect A35 and G16

Standard: (Sensor side)

2.45 ± 0.24 kO (20°C)
G16-1 - G16-2
0.32 ± 0.03 kn (80°C)
19-32

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and G16

Standard:
A35-19 - G16-2 Continuity
A35-28 - G16-1 Continuity
A35-19 - Frame No continuity
• Error codes 05-1, 05-2, 05-3, 05-4, 05-5, 05-6 (Throttle position sensor abnormality)
Related portion

G27 G6
20 (VC2) 5 (VC)

Engine 21 (VTA) 6 (VTA) Throttle

controller 29 (VTA2) 4 (VTA2) position sensor
28 (E21) 3 (E2)

Probable cause
CD Throttle position sensor defect
o Harness defect
Gl Engine controller defect

./or codes 05-1, 05-2, 05-3, 05-4, 05-5, 05-61

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
I
correcting disconnection of G6 and internal
INo error
Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

11 Inspection 2:
Throttle position sensor voltage inspection NG
ANL.:J/O ENGINE CTRL 5/10 Engine controller defect
I
I

Throttle position sensor defect

19-34

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G6

Standard:
G27-21 - G6-6 Continuity
G27-28 - G6-3 Continuity
G27-21 - G27-20 No continuity
G27-20 - G6-5 Continuity
G27-21 - Frame No continuity
G27-29 - G6-4 Continuity
G27-29 - G27-20 No continuity
G27-29 - Frame No continuity
G27-21 - G27-29 No continuity
G27-21 - G27-28 No continuity
G27-29 - G27-28 No continuity
G27-20 - Frame No continuity

Inspection 2:
Inspect the throttle position sensor voltage.

Ignition key switch OFF, disconnect G6, connect G27, ignition key switch ON
Throttle position sensor voltage (I/O monitor: VTA 1, VTA2)

Standard:
VTA1, VTA2 4.80 V or more
 19-35

et Error codes 06-1, 06-2 (Throttle motor drive circuit open/short abnormality)
Related portion
E-THRO

G27 G6
7 (+BM)
~ ~ --
6 (M+) 2 (M+)
- - - -- - - - - ~~~~~~~~'-j Throttle
Engine 5 (M-) 1 (M-) motor
controller - - - -- - - - - ~~~~~~~~'-j

4 (ME01)

&-
Probable cause
CD Throttle motor defect
<D Harness defect
<lJ Engine controller defect
I:. :. (or codes 06-1 and 06-2

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G6 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Errorl

Inspection 1: NG
Throttle motor individual inspection Throttle motor defect

OKl

/Inspection 2: NG
arness continuity and short circuit inspection Harness defect

OKj
\V
Engine controller defect
19-36

Inspection 1:
Carry out throttle motor individual inspection.
Ignition key switch OFF, disconnect G6, connect G27
G6
(1) Throttle motor resistance inspection

Standard: (Motor side)

I G6-2 - G6-1 0.3 - 100 n (20°C)
(2) Throttle valve drive condition

Standard:
Throttle valve operates smoothly when fully opened.
Throttle valve operates smoothly when fully closed.
\Nhen you remove your hand from the throttie valve, it returns to the opener angle.

Inspection 2:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect G27 and G6

Standard:
G27-6 - G6-2 Continuity
G27-5 - G6-1 Continuity
--
G27-6 - Frame No continuity
G27-5 - Frame No continuity
G27-6 - G27-5 No continuity
G27-6 - G27-7 No continuity
~I
G27-5 - G27-7 No continuity
 19-:37

• Error codes 06-3, 06-4 (Throttle motor power circuit open/short abnormality)
Related portion

G27

E-THRO
Engine 7 (+BM)
controller .~~~

Probable cause
Q! Harness defect
<1) Engine controller defect

, Error codes 06-3 and 06-4

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G27 and internal Connector contact defect
wetting, reconnect all connectors and the baHery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.

Errorl

Inspection 1: NG
Throttle motor power voltage inspection Harness defect

OKl

Engine controller defect

1spection 1:
Inspect the throttle motor power voltage.
Ignition key switch OFF, disconnect G27

Standard:
G27-7 - Frame 8 - 16 V
19-38

• Error code 06-5 (Throttle motor seized abnormality)

Related portion
E-THRO

G27
~------~7(+BM)
G6
---------- - - - -
6 (M+) 2 (M+)
f-----'---'-------- - - - - - - - - - ----------1 Throttle
Engine 5 (M-) 1 (M-) motor
f------------ - - - - - - - - - ----------1
controller
4 (ME01)

Probable cause
CD Throttle motor defect
o Harness defect
CD Engine controller defect

IError code 06-5

Disconnect the battery negative terminal (for

more than 10 seconds). after inspecting and
No error
correcting disconnection of G6 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.

Errorl

Inspection 1: NG
Throttle motor individual inspection Throttle motor defect

OKl

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OKl

Engine controller defect

Inspection 1:
Carry out throttle motor individual inspection.
Ignition key switch OFF, disconnect G6, connect G27
G6
(1) Throttle motor resistance inspection

Standard: (Motor side)

I G6-2 - G6-1 0.3 - 100 D (20°C)

(2) Throttle valve drive condition

Standard:
Throttle valve operates smoothly when fully opened.
Throttle valve operates smoothly when fully closed.
When you remove your hand from the throttle valve, it returns to the opener angle
 19-39

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G6 and G27

Standard:
G27-6 - G27-5 No contir1Uity
G27-6 - G27-7 No continuity
G27-5 - G27-7 No continuity
19-40

<I Error code 06-6 (Electronic throttle abnormality)

Related portion

Engine
controller

Probable cause
CD Engine controller defect

IError code 06-6

Disconnect the negative terminal of the battery for
10 seconds or more. Reconnect the battery No error
negative terminal, turn the ignition key switch ON ~ Connector contact defect
(start the engine) and check whether or not there is
an error.

Errorl

Engine controller defect

 19-41

CID Error code 07 -1 (Air-fuel ratio motor open abnormality)

Related portion

RIB Main relay

G28 G13 G13
21 (FCM1) 3 (FCM1) 2 (81) 3 (L) EFl
~ -I
31 (FCM2) 6 (FCM2) Air-fuel 5 (82) main relay
Engine
controller 20 (FCM3 1 (FCM3) ratio
motor
30 (FCM4 4 (FCM4)

Probable cause
CD Air-fuel ratio motor defect
Q) Harness defect
Q) Engine controller defect

ror code 07-1

Disconnect the battery negative terminal (for more

than 10 seconds), after inspecting and correcting
No error ,
disconnection of G13 and internal wetting, Connector contact defect
reconnect all connectors and the battery negative
terminal, turn the ignition key switch ON (start the
engine) and check whether or not there is an error.

Errorl

Inspection 1: NG
Air-fuel ratio motor individual inspection Air-fuel ratio motor defect

OKl

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OKl

Engine controller defect

19-42

Inspection 1:
Carry out an individual inspection of the air-fuel ratio motor.
~
~
(1) Air-fuel ratio motor resistance inspection
Ignition key switch OFF, disconnect G 13, connect G28
G13
Standard: (Air-fuel ratio motor side)
G13-2 - G13-1
G13-2 - G13-3 20 ± 5 [2 (-10 - 50°C)
G13-5 - G13-4 25 ± 5 n (50 - 100°C)
G13-5 - G13-6

(2) Valve operation check

Connect the battery positive terminal to G13-2 and G13-5 and ground in the following terminal order.

Standard: (Air-fuel ratio motor side)

G13-3~G13-6~G13-1~G13-4:Moves to the close side
G13-4~G13-1~G13-6~+G13-3:Moves to the open side

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G28, G 13 and RIB main relay

Standard:
G28-21 - G13-3 Continuity
G28-31 - G13-6 Continuity
G28-20 - G13-1 Continuity
G28-30 - G13-4 Continuity
G13-2 - RIB main relay terminal 3 Continuity
G13-5 - RIB main relay terminal 3 Continuity
G28-21 - Frame No continuity
G28-31 - Frame No continuity
G28-20 - Frame No continuity
"-
G28-30 - Frame No continuity
 19-43

• Error code 08-1 (Low voltage abnormality)

Related portion

A36

EFl
Engine 3 (BATT)
controller -------------------~~--~

Probable cause
CD Harness defect
o Engine controller defect
Frror code 08-1

Disconnect the battery negative terminal (for more

than 10 seconds), after inspecting and correcting
No error
disconnection of A36 and internal wetting, ? Connector contact defect
reconnect all connectors and the battery negative
terminal, turn the ignition key switch ON
(start the
engine) and check whether or not there is an error.

Errorl

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OKl
Engine controller defect

spection 1:
Inspect for continuity and short circuitihg of the harness.
Ignition key switch OFF, disconnect A36

Standard:

11 ._A_3_6_-3_-~E-F-1 -4_~_c_on-t__:in_:_u-ity~-_1
A36-3 - Frame No continuity
19-44

eError code 09-1 (Ignition signal abnormality)

Related portion

IGN

r----E-n-g-i-n~e_-_-_-~-~-~7-(I-G-T)-i[~I-G-2-5--~-----~G-2-5----_-_-_-,-_----;]
2 (IGT) 3 (IG2)
1 (IGF) Igniter 5 (IG1)
controller 32 (IGF)
- - - --I
I
I
G21 I
1 1
2 (IG-) I I

Ignition coil 1(IG+)-----o :

1---'----------

Probable cause
Q) Ignition coil
(£I igniter defect
Q) Harness defect
@ Engine controller defect
 19-45

IError code 09-1

Disconnect the battery negative
terminal (for more than 10
seconds), after inspecting and
correcting disconnection of G21 Engine will not s_ta~rt ,
and G25 and internal leakage,
reconnect all connectors and the
battery negative terminal, turn the
ignition key switch ON to start the
engine.

Engine
starts
I
J,
Operate the accelerator pedal and No error
check whether there is an error. ---3>- Connector contact defect

Error

lr
Inspection 2:
Inspection 1: NG NG
Harness continuity and short circuit -+ Harness defect
Ignition abnormality signal (IGF) inspection
inspection
--
OKI

Engine controller defect

Igniter defect

Inspection 3: NG
r - - - - - - 7 Ignition coil defect
Ignition coil individual inspection

OK

I Inspection 4: NG
',arness continuity and short circuit ,
Harness defect
- 'lspection

OKl

Inspection 5: NG
Igniter IGT signal inspection Engine controller defect

OKl

Igniter defect

Inspection 1:
Carry out an ignition signal (IGF) inspection.

Ignition key switch OFF, disconnect G25, connect G27, ignition key switch ON, engine
stopped

Standard:
G25-1 - Frame 4.0 - 5.5 V
19-46

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G25

Standard:
G27-32 - G25-1 Continuity
G27-32 - Frame No continuity

Inspection 3:
Carry out distributor individual inspection.
Ignition key switch OFF, disconnect G21 and G25, connect G27
G21
Standard:
Primary side (G21-1 - G21-2) 12 - 1.50.
Secondary side (IIA inner terminal) 7.7-1040.

Inspection 4:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27, G21 and G25

Standard:
G27-33 - G25-2 Continuity
G27-32 - G25-1 Continuity
G27-33 - G27-32 No continuity
G27-33 - Frame No continuity
G27-32 - Frame No continuity
G25-5 - G21-2 Continuity
G25-3 - G21-1 Continuity
G25-5 - G25-3 No continuity
G25-5 - frame No continuity
G25-3 - frame No continuity

Inspection 5: . '\if
Carry out an igniter (IGT) signal inspection.
Ignition key switch OFF, disconnect G21 and G25, connect G27, ignition key switch
ON, (cranking)

Standard:
G25-2 - Frame Not OV
 19-47

• Error code OA-1, OA-2, OA-3 (Fuel specification determination abnormality)

Related portion

G28 T6 T6 R/B EFl Main relay

14 (GAS) 6 (GAS) Fuel
~

4(IG) 3 (L) EFl

13 (LPG) 3 (LPG) changeover
- main relay
switch
G27
15(SEL1)
Engine
14 (SEL2)
controller
13 (SEL3) Connection status of SEL1 to 3
differs depending on vehicle specification (refer to inspection 3).
110 (ESCL) I
--------

Probable cause
CD Fuel changeover switch defect
(f) Harness defect
G) Engine controller defect

IError codes OA-1, OA-2, OA-3

Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
correcting disconnection of T6 and internal No error
wetting, reconnect all connectors and the battery Connector contact defect
negative terminal, turn the ignition key switch
ON (start the engine) and check whether or not
there is an error.
Error

.1spection 1: I
<·witch input signal inspection
11 ANL: I/O ENGINE CTRL 1/10

OK

Inspection 2: NG
Fuel changeover switch defect
Fuel changeover switch individual inspection

OK

Inspection 3: NG
Harness defect
Harness continuity and short circuit inspection

OKl

Engine controller defect

19-48

Inspection 1:
Carry out switch input signal inspection.
Ignition key switch ON
Switch input signal (I/O monitor: G/LP, SEL 1-3)

Standard:
Vehicle specification Fuelchangeoverswi~h G/LP SEL
Gasoline specification ~

10 1100
LPG exclusive ~

01 0101
Gasoline selection 10
LPG/Gasoline convertible LPG selection 01 0110
Neutral 00

Inspection 2:
Carry out fuel changeover switch individual inspection.
(Carry out only for convertible vehicles, and only when the G/LP input in inspection 1 is outside
the standard value)
T6
Ignition key switch OFF, disconnect T6, connect G28 and G27

Standard: (Switch side)

I I ...... '-'......... ;:1 .................... '-' ..............

Gasoline LPG Neutral

T6-4 - T6-6 Continuity No continuity No continuity
T6-4 - T6-3 No continuity Continuity No continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness. (Begin with the place that was outside the standard
value in inspection 1)
Ignition key switch OFF. disconnect G28, G27 and T6
Harness
Vehicle specification
SEL1 SEL2 SEL3
Short circuit to Short circuit to
Gasoline specification -
ESEL ESEL
Short circuit to Short circuit to Short circuit to
LPG exclusive
ESEL ESEL ESEL
Short circuit to Short circuit to
LPG/Gasoline convertible ~

ESEL ESEL
 19-49

et Error code OA-4 (Engine specification determination abnormality)

Related portion

Engine
controller

Probable cause
CD Engine controller defect

::rror code OA-4

.3connect the battery negative terminal (for 10

seconds or more), reconnect the battery No error
f--~~~~~-o>- Normal
negative terminal, then turn the ignition key
switch ON (start the engine) and check whether
or not there is an errOL

Error

Engine controller defect

19-50

• Error codes 13-1, 13-2, 13-3 (Relay abnormality)

Related portion

IGN
To IGN SW
--~'---------
~ ----,

RiB ASC relay

G38
,-------~
5 (SRLY) 1
13 (E12)
-----------------(---- 2
ASC controller -----------------(---- 5 ASC relay

2 (MEN+) 3
-~--~-----~-----~----
I
1
1
I

~------------?}!-1 '----
Step motor
--J

Probable cause
Q) Connector contact defect
Gl /\SC relay defect
(J) Harness defect
@) ASC controller defect

I Error codes 13-1, 13-2, 13-3

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of G38
No error Connector contact defect
and the ASC relay and internal wetting, reconnect
ASC relay not plugged in properly
all connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error.

Error

Inspection 1: NG
ASC relay individual inspection ASC relay defect

OK
\I
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OKl
ASC controller defect
 19-51

Inspection 1:
Carry out ASC relay individual inspection.

Ignition key switch OFF, remove ASC relay

Standard: (Relay side)

ASC relay
1 - 2 terminals Continuity (approx 90 Q)
At all times
3 - 5 terminals No continuity
When battery voltage is applied
3 - 5 terminals Continuity
between terminals 1 - 2

Inspection 2:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect G38, remove ASC relay

Standard:
G38-2 - ASC relay terminal 3 Continuity
ASC relay terminal 5 - IGN Continuity
G38-2 - BATT No continuity
G38-5 - ASC relay terminal 1 Continuity
--
G38-5 - G38-13 No continuity
G38-5 - Frame No continuity
G38-5 - BATT
ASC relay terminal 2 - Frame
No continuity
Continuity
l
19-52

• Error codes 15-1 and 15-2 (NMR switch abnormaiity)

Related portion

IGN
TolGNSW 171
- - - - - - ' L : : : : : : : - J r - - - - - - - - - - - - - - - - - --

G36
G39
2
12 (NMR) NMR switch
--~~~- - - - - - - - - - - ---~~-~~~----1

ASC controller
RIB Starting motor relay

f---2----'{_S_T_A'--) . ~ ~~~_1__1 Starting motor relay

Probable cause
CD Connector contact defect
@ NMR switch defect
CD Harness defect
@) ASC controller defect
13) Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)
IError codes 15-1, 15-2
Disconnect the battery negative terminal, then
inspect and repair disconnection of G36, G39 and
starting motor relay and any internal leakage.

Reconnect the connectors and the battery negative

terminal, then repeat the operations CD to @) below
several times and cheek whether an error occurs.
CD Turn the ignition key swilch ON (engine stopped)
CV Operate the accelerator pedal ON/OFF (several No error
times) ------7 Conneclor contact defect
:]) Start the engine with the accelerator fully
depressed
8) Release the accelerator pedal and turn the
ignition key switch OFF
Error

Inspection 1: NG
NMR switch individual Inspection f------------:?> NMR switch defect

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 3:
Inspeclion of the status of the NMR switch in the NG
ASC controller ASC controller defect
ANL: 110 ENGINE CTRL 1/3
-

OKI
\j;
,efer to and carry out mechanical system inspection
items such as link catching or switch position
adjustment.

Inspection 1:
Carry out an NMR switch individual inspection. ~
Ignition key switch OFF, disconnect G36, connect G39
~
Standard: (Switch side) G36
Switch OFF Switch ON
G36-1 - G36-2 No continuity Continuity
19-54

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G36, G39 and starting motor relay

Standard:
G39-12 - G36-1 Continuity
IGN - G36-2 Continuity
G39-2 - Starting motor relay terminal 1 Continuity
G39-12 - IGN No continuity

Inspection 3:
Carry out inspection of the status of the NMR switch in the controller.
Ignition key switch OFF, remove NMR switch so that it can be turned ON and OFF manually,
connect G39 and G36, ignition key switch ON
NMR switch (I/O monitor: NMR)

Standard:
Analyzer display Switch OFF Switch ON
NMR 0 1
 19-55

., Error code 15-3 (NMR switch abnormality)

Related portion

IGN
TOIG_N_S_VV ~~ l

A.se controller
G39

~1_2~(N__M_R~) ~t
G36
2
1_ NMR,wilch J
G36
4
15 (ZERO) 3 Idle switch
1------------- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Probable cause
CD Connector contact defect
(]) NMR switch defect
CD Idle switch defect
® Harness defect
13) ASC controller defect
© Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)
19-56

I Error code 15-3

Disconnect the battery negative terminal, then

inspect and repair disconnection of G39 and G36
and any internal leakage.

1
Reconnect the connectors and the battery negative
terminal, then repeat the operations Q) to Cl> below
several times and check whether an error occurs.
No error
CD Turn the ignition key switch ON (engine stopped)
Connector contact defect
CD Operate the accelerator pedal ON/OFF (several
times)
G) Turn the ignition key switch OFF

Erro1

Inspection 1: NG NMR switch defect

NMR and idle switch individual inspection Idle switch defect

~._---

Inspection 2: ING
Carry out harness continuity and short circuit Harness defect
inspection

OK

Inspection 3:
Inspection of the status of the NMR and idle NG
switches in the controller ASC controller defect
ANL. I/O ENGINE CTRL 1/3

OK

Refer to and carry out mechanical system inspection

items such as link catching or switch position
adjustment.

Inspection 1:
Carry out an NMR and idle switch individual inspection. ~
Ignition key switch OFF, disconnect G36, connect G39

Standard: (Switch side)

U
G36
Switch OFF Switch ON
G36-1 - G36-2 No continuity Continuity
G36-3 - G36-4 No continuity Continuity

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G36 and G39

Standard:
G39-12 - IG No continuity
G39-15 - IG No continuity
 19-57

Inspection 3:
Carry out inspection of the status of the NMR and idle switches in the controller.
Ignition key switch OFF, remove NMR and idle switches so that they can be turned ON and OFF manually,
connect G36 and G39, ignition key switch ON
NMR and idle switches (1/0 monitor: NMR, IDLE)

Standard:
Analyzer display Switch OFF Switch ON
NMR 0 1
IDLE 0 1

......
19..:58

411» Error codes 16-1 and 16-2 (Idle switch abnormality)

Related portion

IGN
To IGN SW
---~~----------------------------~
I
I
,
I G36
G39 I
I 4
15 (ZERO) 3 Idle switch
------------------------

G38 G37
ASC controller 11 (NINA) 2
12 (NINB) 1
3 (INA) 5 Step motor

4 (INB) 4
--------------------------1

Probable cause
CD Connector contact defect
CD Idle switch defect
(IJ Harness defect
® ASC controller defect
~ Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)

Note:
In the case where a 13-1 error is present, service that error first before dealing with this one.
 19-59

I Error codes 16-1, 16-2

Disconnect the battery negative terminal, then
inspect and repair disconnection of G39, G36 and
G37 and any internal wetting.

Reconnect the connectors and the battery negative

terminal, then repeat the operations CD to W below
several times and check whether an error occurs.
No error
CD Turn the ignition key switch ON (engine stopped) ------7 Connector contact defect
CV Operate the accelerator pedal ONIOFF (several
times)
W Turn the ignition key switch OFF

Error

Inspection 1: NG
. e switch individual inspection -----7 Idle switch defect
I
OK

Inspection 2~
NG
Carry out harness continuity and short circuit Harness defect
inspection

OK

Inspection 3:
Inspection of the status of the idle switch in the NG
;.. ASC controller defect
controller
ANL: 1/0 ENGINE CTRL 1/3

OK

Refer to and carry out mechanical system inspection

"qms such as link catching or switch position
Jjustment

Inspection 1:
Carry out idle switch individual inspection. ~
Ignition key switch OFF, disconnect G36, connect G39
~
G36
Standard: (Switch side)
Switch OFF Switch ON
G36-3 - G36-4 No continuity Continuity
19-60

Inspection 2:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect G36, G37, G38 and G39

Standard:
G39-15 - G36-3 Continuity
IGN - G36-4 Continuity
G39-15 - IGN No continuity
G38-11 - G37-2 Continuity
G38-12 - G37-1 Continuity
G38-3 - G37-5 Continuity
G38-4 - G37-4 Continuity
G38-11 -G38-12 No continuity
G38-11 - G38-3 No continuity
G38-11 - G38-4 No continuity
G38-12 - G38-3 No continuity
G38-12 - G38-4 No continuity
G38-3 - G38-4 No continuity
G38-11 - IGN No continuity
G38-12 - IGN No continuity
G38-3 - IGN No continuity
G38-4 - IGN No continuity
G38-3 - Frame No continuity
G38-4 - Frame No continuity
G38-11 - Frame No continuity
G38-12 - Frame No continuity

Inspection 3:
Carry out inspection of the status of the idle switch in the controller.

Ignition key switch OFF, remove idle switch so that it can be turned ON and OFF manually, connect G36 and
G39, ignition key switch ON
Idle switch (I/O monitor: IDLE)

Standard:
Analyzer display Switch OFF Switch ON
IDLE 0 1
 19-61

• Error codes 18-1, 18-2 (4Y engine: Cam angle sensor abnormality)
Related portion

IGN

-----.-J0---~11~~-~~-~-~-:f-~-~~~G-2_)~~~~-_-_-_-,-----,]
Igniter 5 (IG1) I
-----1 I
I I
I I
G27 Gig G21 1 I
I I
31 (NE+) 1 (NE) 2 (IG-) I 1
----- I
Engine controller 30 (NE-) 2 (NE-) Distributor 1 (IG+) I
'--------------_ _----.11 ---

I
Probable cause
CD Distributor (cam angle sensor) defect
CD Starter defect
Q) Defect in the part connecting the starter and engine
® Harness defect
~ Engine controller defect
Note:
If the engine does not crank, troubleshoot "Does not crank (see 19-156)" first.
IError codes 18-1, 18-2
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
correcting disconnection of Gig and internal No error
wetting, reconnect all connectors and the battery f-------'3» Connector contact defect
'legative terminal, turn the ignition key switch
IN (start the engine) and check whether or not I
'ere IS an error.

Error I
\jI

Inspection 1:
Distributor individual inspection
ING ) Distributor (cam angle sensor) defect

OKl
Inspection 2: NG Starter defect
Timing rotor operation inspection Defect in the part connecting the starter and engine

OKl
Inspection 3: NG ,
Harness continuity and short circuit inspection Harness defect

OKl
Engine controller defect
19-62

Inspection 1:
Carry out distributor individual inspection.
Ignition key switch OFF, disconnect G19 and G21, connect G27
G19
(1) Pickup coil (2 in series) resistance measurement

Standard: (Distributor side)

I G19-1 - G 19-2 460 ± 50 Cl

(2) Inspection of the air gap between the pickup coils and the timing rotor

Standard: 0.2 - 0.4 mm (0.008 - 0.016 in)

Inspection 2:
Inspect the timing rotor operation.
Disconnect G 19 and G21, connect G27, ignition key switch ON

Standard: Timing rotor rotates during cranking

Inspection 3:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G19, G21 and G27

Standard:
G27-31 - G19-1 Continuity
G27-30 - G19-2 Continuity
G27-31 - G27-30 No continuity
 19-63

Error code 18-3 (4Y engine: Crank angle sensor abnormality)

'«t
Related portion

G27 G18
,-------,
11 (G2) 1 (G2)
1--------'------ - - - - - - - - - ---------j Crank angle
Engine controller 22 (G-) 2 (G-) sensor
1----------- - - - - - - - - - ---------j

Probable cause
CD Crank angle sensor defect
CV Harness defect
0) Engine controller defect

')r code 18-3

L
Disconnect the battery negative terminal (for
more than 10 seconds). after inspecting and
correcting disconnection of G 18 and internal No error
wetting, reconnect all connectors and the battery Connector contact defect
negative terminal. turn the ignition key switch
ON (start the engine) and check whether or not
there is an error.

Error J
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OKl

I Inspection 2: NG
~ank angle sensor individual inspection Crank angle sensor defect
I

Inspection 3:
Crank angle sensor installation inspection

1
Install the crank angle sensor, connect G27, G18
and battery negative terminal, start the engine, No error Normal
Check whether 'an error occurs. (Entry of foreign matter etc.)

1
Error

Engine controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G18

Standard:
G27-11 - G18-1 Continuity
G27-22 - G18-2 Continuity
G27-11 - G27-22 No continuity

Inspection 2:
Carry out crank angle sensor individual inspection.

Ignition key switch OFF, disconnect G27 and G18

Standard: (Sensor side)

I G18-1 - G18-2 1100 ± 150 D G18

Inspection 3:
Carry out crank angle sensor installation inspection.
Ignition key switch OFF, disconnect G27 and G 18

Standard:
Remove the crank angie sensor, ensure that there is no foreign matter etc. adhereing to the sensor part.
If there is remove it.
 19-65

• Error codes 18-1, 18-2 (1DZ-III, 3Z engines: NE sensor abnormality)

Related portion

G39 G31
,----------,
9 (NE+) 2
Engine speed
ASC controller 22 (NE-) sensor (NE sensor)
f------'---'------ ~ - - - - - ~ - - -----------1

Probable cause
CD Connector contact defect
@ Engine speed sensor defect
W Harness defect
@) ASC controller defect

!\lote:
In the event that the engine stops while traveling, when the ignition key switch is turned from OFF to ON, an
18-2 error may be detected, however this is not a fault.
Stop the vehicle, turn the ignition key sVvitch OFF and restart the engine.

IError codes 18-1, 18-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of G31
and G39 and internal wetting, reconnect all No error
connectors and the battery negative terminal, f----------7 Connector contact defect
turn the ignition key switch ON and check
whether or not there is an error.

~~pection 1:
Harness continuity and short circuit inspection
I-NG- - - - - ' 7 > Harness defect

Inspection 2: NG
Engine speed sensor individual inspection ---------7 Engine speeu sensor defect

OK

ASC controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G31 and G39

Standard:
G39-9 - G31-2 Continuity
G39-22 - G31-1 Continuity
G39-9 - G39-22 No continuity
G39-9 - Frame No continuity
G39-22 - Frame No continuity

Inspection 2:
Carry out engine speed sensor individual inspection.
Ignition key switch OFF, disconnect G31 and G39

Standard: (Sensor side)

G31
I G31-1 - G31-2 Approx. 1 kQ
 19-67

• Error codes iF-i, iF-2, iF-3, iF-4, iF-5, 1F-6, iF-7, iF-8 (CPU abnormality)
Related portion

ASC controller

Probable cause
CD ASC controller defect
19-68

• Error code 41-1 (Matching connector abnormality)

Related portion

A20 A45
,----------, .---------~
24 (MAT) 1
SAS/OPS Matching
controller 1 (E3) connector
f------------ ~ ~ ~ ~ ~ - ~ ~ - ------------1

Probable cause
CD Connector contact defect
CD Matching connector harness defect
Q) SAS/OPS controller defect

I Error code 41-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and A45 internal moisture, reconnect all No error
connectors and the battery negative terminal, ~ Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error

Err01

Inspection 1. NG
Harness defect
Harness continuity check

OKl

SAS/OPS controller defect

Inspection 1:
Inspect for continuity of the harness.
Ignition key switch OFF, disconnect A20, A45 and A46

Standard:
A20-24 - A45-1 Continuity
A20-1 - A46-1 Continuity
 19-69

CD Error codes 51-1, 51-2 (Speed sensor abnormality)

Related portion

A21 A19
,---------,
22 (SP1+) 1
SAS/OPS ~ - - - - - - - -- - - - - - - - - -------- Speed
controller 23 (SP1-) 2 sensor
~-_.~----- - - - - - - - - - ---------

Probable cause
CD Connector contact defect
(]) Harness defect
Q) Speed sensor defect
® SAS/OPS controller defect
r-fror code 51-1

Disconnect the battery negative terminal, after I

inspecting and correcting disconnection of A 19 I
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: No error
Speed sensor inspection Speed sensor defect

Error

,J;

Inspection 2: NG
I. Harness continuity and short circuit inspection --7 Harness defect

OKI

SAS/OPS controller defect

Inspection 1:
Carry out speed sensor inspection.

Ignition key switch OFF, disconnect A19, use SST 09236-13900-71 to short circuit A19, ignition key switch ON,
engine stopped

51-1 displayed ----+ to inspection 2

No error displayed ----+ Speed sensor defect
19-70

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A 19 and A21

Standard:
A21-22 - A19-1 Continuity
A21-23 - A19-2 Continuity
A21-22 - Frame No continuity
A21-23 - Frame No continuity

IError code 51-2

--
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A 19
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error1

Inspection 1: 51-1
Speed sensor inspection -------7 Sensor defect

2
51- 1

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK1

SAS/OPS controller defect

Inspection 1:
Carry out speed sensor inspection.
Ignition key switch OFF, disconnect A 19, ignition key switch ON, engine stopped
51-2 displayed -+ to next inspection
No error code -+ Speed sensor defect

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A 19 and A21

Standard:
A21-22 -A19-1 Continuity
A21-23 - A19-2 Continuity
A21-22 - Frame No continuity
A21-23 - Frame No continuity
 19-71

• Error codes 52-1, 52-2, 52-3 (Yaw rate sensor abnormality)

Related portion

A21
01
24 (YRS+) 1
SAS/OPS 25 (YRS) 3 Yaw-rate
controller sensor
26 (YRS-) 2
I--.-------~- - - - - - - - - ---------1

Probable cause
CD Connector contact defect
Q) Yaw rate sensor harness defect
GJ Yaw rate sensor defect
® SAS/OPS controller defect
IError code 52-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of 01
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, f----------'7) Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: 52-2 is displayed

Yaw rate sensor defect
Yaw rate sensor inspection

52-1 is displayed 1
nspection 2: NG
Harness defect
.Harness continUity and short circuit inspection

OKI
w
SAS/OPS controller defect
,

Inspection 1:
Carry out a yaw and rate sensor inspection.

Ignition key switch OFF, disconnect 01, use SST 09232-13130-71 to short circuit 01-1 and 01-2, ignition key
switch ON, engine stopped
52-1 displayed --+ to inspection 2
52-2 displayed -, Yaw rate sensor defect
19-72

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect 01 and A21

Standard:
A21-25 - 01-3 Continuity
A21-26 - 01-2 Continuity
A21-24 - Frame No continuity
A21-25 - Frame No continuity
A21-26 - Frame No continuity

I Error codes 52-2, 52-3

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of 01
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Turn the ignition key sWitch OFF, disconnect the

battery negative terminal, disconnect 01,
52-1
connect the battery negative terminal, turn the /
Yaw-rate sensor defed
ignition key switch ON (engine stopped), check
whether the error changes.

52-2 or 52-3

Inspection 1: NG
Harness defect
Harness continuity and short circuit inspection

OKl

SAS/OPS controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect 01 and A21

Standard:
A21-25 - 01-3 Continuity
A21-26 - 01-2 Continuity
A21-24 - Frame No continuity
A21-25 - Frame No continuity
A21-26 - Frame No continuity
 19-73

• Error code 54-1 (Swing lock solenoid abnormality)

Related portion

A20 Z1
3 (SWN+) 1
Swing lock
2 (SWN-) 2
SAS/OPS -- - - - - - - -- - - - -------------1 solenoid
controller 8 (E01)
9 (E02)

J7
Probable cause
CD Connector contact defect
(1) Harness defect
0) Swing lock solenoid defect
@) SAS/OPS controller defect

ror code 54-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and Z1 and internal moisture, reconnect all
I
No error
connectors and the battery negative terminal, > Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.

Error 1
Inspection 1: NG
Swing lock solenoid individual inspection Swing lock solenoid defect

OKl

Inspection 2: NG
Harness continuit\l and short circuit ins p ection I Harness defect

OKJ

SAS/OPS controller defect

*: Make sure that no error is displayed when driving in a circle or during repeated left and right turns.

Inspection 1:
Carry out swing lock solenoid individual inspection.
Ignition key switch OFF, disconnect Z1

Standard: (Solenoid side) Z1

I Z1-1 - Z1-2 Approx. 6 n (20°C) I
1.9-74

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect Z1 and A20

Standard:
A20-3 - Z1-1 Continuity
A20-2 - Z1-2 Continuity
A20-3 - Frame No continuity
A20-2 - Frame No continuity
 19-75

• Error codes 61-1 61-2 (Load sensor abnormality)

J

Related portion

A21
A18
19 (5PRS) 1
r::-:::-:-::=--==------ - - - - - - - - -
SAS/OPS 27 (PRES) 2
I-=c-~=-------- - - - - - - - -- -- Load sensor
controller 5 (E2) 3
1
Probable cause
CD Connector contact defect
CD Load sensor defect
G> Harness defect
® SAS/OPS controller defect
It.rror code 61-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A 18
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, 7 Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error_

Errorl

Inspection 1: 61-2 is displayed

Load sensor inspection -7 Load sensor defect

61-1 is displayed 1
spection 2: No continuity
") Main harness defect
.. -1arness continuity and short circuit inspection

Continuity 1
Inspection 3: No corltinulty
Harness continuity and short circuit inspection -7 SAS/OPS controller defect

Continuity I
'If
Main harness defect

Inspection 1:
Carry out load sensor inspection_
Ignition key switch OFF, disconnect A 18, use SST 09230-13700-
71 to short circuit A 18-1 and A 18-2 (main harness side), ignition
key switch ON, engine stopped
61-1 displayed --7 to inspection 2
61-2 not displayed --7 load sensor defect
19-76

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21 (with the SST used in inspection 1 still connected)

Standard:
A21-19 - A21-27 Continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness
In the same state as for inspection 2

Standard:
A21-27 - A21-5 No continuity
A21-19 - Frame No continuity
A21-27 - Frame No continuity

IError code 61-2

I Disconnect the battery negative terminal, afterl
inspecting and correcting disconnection of A 18
and A21 and internal moisture, reconnect all INo error
I conne....tors and the hattery ne"a';"e torrr;nal -~ Connector contact defect
tu;~ th~ i~niti~n ~e~ ~v:ttch ~N8(~~Vgi~;'~;~P~~d) I
1
and check whether or not there is an error.

Error

Disconnect A 18, ignition key switch ON (engine 61-1

stopped), inspect the displayed error code

61-2

Inspection 1: No continuity
Harness continuity and short circuit inspection

Continuity1
f\!o continuity Inspection 2:
Main harness defect (
, Load sensor inspection

Continuity 1
. Sub harness defect
• Load sensor defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21

Standard:
A21-19 - A21-27 No continuity
A21-19 - Frame No continuity
A21-27 - Frame No continuity
 19-77

Inspection 2:
Carry out load sensor inspection.

Ignition key switch OFF, disconnect the battery negative terminal, disconnect A 18 and A21, use SST 09230-
13700-71 to short circuit A 18-2 to A 18-3 (main harness side)

Standard:
1'\21-27 - A21-5 Continuity
19-78

ClIP Error codes62~1, 62-2 (Tilt angle sensor abnormality)

Related portion

A21
A42
28 (5MA)
--- - - - - - - - - - ---------1
SAS/OPS 32 (MA) 2 Tilt angle
controller sensor
5 (E2) 3
1---------- - - - - - - - - - - - ----------1

Probable cause
CD Connector contact defect
CD Tilt angle sensor harness defect
Q) Tilt angle sensor defect
@) SAS/OPS controller defect

IError code 62-1

I Disconnect the battery negative terminal, afterl
I inspecting and correcting disconnection of A21
and A42 and internal moisture, reconnect all No error
connectors and the battery negative terminal, 1 - - - - - - - . 0 , . Connector contact defect
turn the ignition key switch ON (engine stopped)
I and check whether or not there is an error.

Error

Inspection 1: --J
_
62-2 is
displayed
) Till angle sensor defect
Tilt angle sensor inspection
'------------,--------
62-1 is displayed

!Inspection 2: I No continuity
I Harness continuity and short circuit inspection I ) Main harness defect

Continuity

Inspection 3: No continuity
Harness continuity and short circuit inspection 1-------7 SAS/Of.JS controller defect

Continuity 1
Main harness defect

Inspection 1:
Carry out tilt angle sensor inspection_

Ignition key switch OFF, disconnect A42, use SST 09232-13130-71 to short circuit A42-1 and A42-2 (main
harness side), ignition key switch ON (engine stopped)
62-1 displayed ----+ to inspection 2
62-2 not displayed ----+ tilt angle sensor defect
 19-79

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21 (with the SST used in inspection 1 still connected)

Standard:
A21-28 - A21-32 Continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness.
In the same state as for inspection 2

Standard:
1'.21-32 - Jl,21-5 No continuity
A21-28 - Frame No continuity
_.
A21-32 - Frame No continuity

'::rror code 62-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A21
and A42 and internal moisture, reconnect all No error
3' Connector contact defect
connectors and trle battery negative terminal,
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Errorl

Inspection 1: 62-1 is displayed

1
Displayed error code inspection

62-2 is displayed

Inspection 2: No continuity SASfOPS

Harness continuity and short circuit inspection controller defect

Continuity I
~ No continuity Inspection 3:
Main harness defect
Tilt angle sensor inspection

Continuity

Tilt angle sensor defect

Inspection 1:
Inspect the displayed error code.
Ignition key switch OFF, disconnect A42, ignition key switch ON, engine stopped
62-1 displayed --+ to inspection 3
62-2 displayed - j to inspection 2

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21

Standard:
A21-28- A21-32 No continuity
19-80

Inspection 3:
Carry out tilt angle sensor inspection.
Ignition key switch OFF, disconnect A21 and A42, use SST 09232-13130-71 to short circuit A21-2 and A42-3
(main harness side)

Standard:
A42-32 - A21-5 Continuity
 19-81

,. Error codes 63-1, 63-2, 63-3 (Tilt lever switch abnormality)

Related portion

A20 A13
,--~~~~~---.

20 (MF) 1
f---~~~~~~----- ------------ Forward tilt
1 (E3) 2 switch
f---~---------------------

SAS/OPS
controller
21 (MR) 3
f - - - - - - - - - - - - -- - - - - - - - -- --- Backward tilt
4 switch

Probable cause
CD Connector contact defect @ Harness defect
CV Forward tilt switch defect t3) Tilt switch installation defect
Q) Backward tilt switch defect ® SAS/OPS controller defect
IError codes 63-1, 63-2, 63-3
Disconnect the battery negative
terminal, after inspecting and
correcting disconnection of A 13
and A20 and internal moisture No error
Connector contact defect
reconnect all connectors and the
battery negative terminal, turn the
ignition key switch ON and check
whether or not there is an error:
Error

Inspection 1:
Check the condition of the switch
ANL.: I/O M.HANDLlNG 1/6

Inspection 2:
Inspection 4:
Individual continuity inspection of OK NG
Harness continuity and short circuit
the tilt lever switch(es) that was
inspection
abnormal in inspection 1 (while still
installed on the vehicle).
OKl
NG
SAS/OPS controller defect

Inspection 3:
Individual continuity inspection of NG
Tilt switch defect
the tilt lever switch (removed from
the vehicle).

OK

!:reclion4
Harness continuity and short circuit
OK
Tilt switch installation defect
inspection

NG

Harness defect

*: Make sure there is no error displayed after turning the ignition key switch ON, and moving the tilt lever forward and
backward. Also, make sure that no error is displayed when the tilt lever is left standing in neutral position for 2
minutes.

Inspection 1:
Check the condition of the switCh.
Ignition key switch ON, engine stopped
Tilt switch (1/0 monitor: MF'MR)

Standard:
Lever in neutral Lever in forward tilt Lever in backward
position position tilt position
MF (Forward tilt switch) 0 1 0
MR (Backward tilt switch) 0 0 1
 19-83

Inspection 2:
Individual continuity inspection of the tilt lever switch (still installed on the vehicle).

Ignition key switch OFF, disconnect A 13

Standard: (Switch side)

Lever in neutral Lever in forward tilt Lever in backward
position position tilt position
A13-1 - A13-2 No continuity Continuity No continuity
A13-3 - A13-4 No continuity No continuity Continuity

Inspection 3:
Carry out individual continuity inspection of the tilt lever switch (removed from the vehicle).

Ignition key switch OFF, disconnect A 13

Standard: (Sensor side)

Switch OFF Switch ON
A13-1 - A13-2 No continuity Continuity A13
A13-3 - A13-4 No continuity No continuity

Inspection 4:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect A 13 and A20

Standard:
A20-20 - A20-1 No continuity
A20-21-A20-1 No continuity
A20-20 - A20-21 No continuity
A20-20 - Frame No continuity
A20-21 - Frame No continuity
·19-84

et Error code 64-1 (Lift lock solenoid abnormality)

Related portion

A20 A 11

~, L~ift_IO_C~k
7 (LSOL)
SAS/OPS
controller
9 (E02)
8 (E01)
2
1 --L __solenoid
_ _--.--J

Probable cause
ill Connector contact defect
CV Harness defect
Q) Lift lock solenoid defect
@) SAS/OPS controller defect

IError code 64-1

Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A'I1
I
and A20 and internal moisture, reconnect all No error ,
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error*

Error1
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OKl

Inspection 2: NG
Lift lock solenoid individual inspection Solenoid defect

OK!
\jI

SAS/OPS controller defect

*: Make sure that no error is displayed when the material handling lever is lowered.

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A 11 and A20

Standard:
A20-7 - A11-1 Continuity
A11-2 - Frame Continuity
A20-9 - Frame Continuity
A20-8 - Frame Continuity
A20-7 - Frame No continuity
 19-85

Inspection 2:
Carry out lift lock solenoid individual inspection.
Ignition key switch OFF, disconnect A11
A11
Standard: (Solenoid side)
I A11-1 - A11-2 9.9 ± 05 n D
(20 C)
19-86

• Error code 65-1 (Tilt control solenoid abnormality)

Related portion

A20 AlO
4 (TSOL) 1
Tilt control
SAS/OPS 9 (E02) 2 solenoid
- - - - - - - - - - -----------1
controller
8 (E01)

Probable cause
CD Connector contact defect
I1J Harness defect
Q) Tilt control solenoid defect
® SAS/OPS controller defect
I Error code 65-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of Ai 0
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, -7 Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error:

Errorl

Inspection 1: NG
Harness continuity and short circuit inspection ----7 Harness defect

OKl

Inspection 2: NG
Tilt control solenoid individual inspection '" Solenoid defect

OKl

SAS/OPS controller defect

*: Make sure that no error is displayed when the material handling lever is operated to tilt forward.

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A10 and A20

Standard:
A20-4 - A10-1 Continuity
A10-2 - Frame Continuity
A20-9 - Frame Continuity
A20-8 - Frame Continuity
A20-4 - Frame No continuity
 19-87

Inspection 2:
Carry out tilt control solenoid individual inspection.
Ignition key switch OFF, disconnect A 10
Ai0
Standard: (Solenoid side)
I Ai0-i - A10-2 9.9 ± 05 D (20°C)
19-88

• Error code 66-1 (Outside matching value range abnormality)

Related portion

SAS/OPS
controller

Probable cause
CD Tilt horizontal angle matching value is outside the specified range for matching.
o Tilt forward tilt angle matching value is outside the specified range for matching.
Q) Load sensor matching value is outside the specified range for matching.

IError code 66-1

Carry out tilt horizontal angle matching, tilt
forward tilt angle matching, and load sensor
I matching. (Refer to section 16) ~

Error~

Controller defect
 19-89

• Error code 67 -1 (Lifting height switch abnormality)

Related portion

A20 b1
1 (E3) 1
--- - - - - - - - - - - - - - - - - - 1
31 (MH1) 2 Lifting height
- - - - - - - - - - --------:::-----1
SAS/OPS 32(MH21) 3 switch
controller ------ --- - - - - - - - - - - - 1

33 (MH22)
----- - - - - - - - - - - - - - N.C.

Probable cause
CD Connector contact defect
o Harness defect
Q) Lifting height switch defect
® SAS/OPS controller defect
G.l IG fuse defect
IError code 67-1
Disconnect the battery negative
terminal, after inspecting and
correcting disconnection of A20
and b1 and internal moisture, Error
reconnect all connectors and the None
f--~~~-7' Connector contact defect
battery negative terminal, turn the
ignition key switch ON (engine
stopped) and check whether or not >. Raise the lift lever from the fully lowered
there is an error: position until an error is detected.
Error

rr=======~======1J1Except Inspection 2:
Inspection 1: MHOOO Harness continuity and short circuit MH:OOO
, Lifting height switch
Lifting height switch input value n"-~~~--7i1 inspection
inspection defect
ANL I/O M.HANDLlNG 2/6
ANL.: I/O M HANDLING 2/6
Except MH:OOO
MH:OOO

Inspection 3:
OK SAS/OPS
Harness continuity and short circuit
~---;:. controller defect
inspection

Main harness defect

Inspection 4: NG
Lifting height switch individual I--~~-~ Lifting height switch defect
inspection

OK

\j/

Inspection 5:
OK SAS/OPS
Harness continuity and shori circuit
f--~~~"""';" controller defect
inspection

Main hamess defect

 19-:91

Inspection 1:
Check the condition of the switch.
Maintain the error status and check the display.
Lifting height switch (I/O monitor: MH)
MH: 000 displayed -----+ to checking the mast height at the time of error detection
MH:' Except 000 ---f to inspection 2

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 and b1, ignition key switch ON, stop the
engine, check the display
MH: 000 displayed -> sub harness defect or lifting height switch defect
MH: Except 000 -----+ to inspection 3

Inspection 3:
Inspect for continuity and short circuiting of the harness.

Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 and b1

Standard:
A20-1 - A20-31 No continuity
A20-1 - A20-32 No continuity

~
A20-1 - A20-33 No continuity
A20-31 - A20-32 No continuity
A20-32 - A20-33 No continuity

I A20-33 - A20-31 No continuity

A20-31 - Frame No continuity
A20-32 - Frame No continuity
A20-33 - Frame No continuity

inspection 4:
Carry out lifting height switch individual inspection.
Maintain the error status, ignition key switch OFF, disconnect"b1 b1

Standard: (Switch side)

i b1-1 - b1-2 No continuity

Inspection 5:
Inspect for continuity and short circuiting of the harness.

Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 adn b1, use SST 09236-13900-71 to
short circuitthe terminals

Standard:
Inspection terminal Short circuit terminals Continuity
A20-1-A20-31 b1-1 - b1-2 Continuity
A20-1 - A20-32 b1-1-b1-3 Continuity
19-92

et Error codes 68-1, 68-2, 68-3 (Lift switch abnormality)

Related portion

A20 A14
,-----------,
22 (MU) 3
f---------~- --------- Raising lift
1 (E3) 4 switch
f---------~----------

SAS/OPS
controller
23 (MO) 1
f---------~- - - - - - - - -- Lowering lift
2 switch

Probable cause
CD Connector contact defect @)Harness defect
Q) Raising lift switch defect m Lift switch
installation defect
Q) Lowering lift switch defect @ SAS/OPS controller defect
 19-93

I Error codes 68-1, 68-2, 68-3

Disconnect the battery negative
terminal, after inspecting and
correcting disconnection of A 14
and A20 and internal moisture, Error
reconnect all connectors and the None
battery negative terminal, turn the r-~~~-7' Connector contact defect
ignition key switch ON (engine
stopped) and check whether or not
there is an error.*

Error

Inspection 1:
Lift switch condition check
ANL.: I/O M.HANDLlNG 1/6

Inspection 2:
OK Inspection 4:
Individual continuity inspection of NG
r-~~~-7J Harness continuity and short circuit
the lift lever switch(es) that was
abnormal in inspection 1 (While still lL..i_n_s_p_e_ct_iO_f'_'~~-,-~~~~~~_I
installed on the vehicle)
OKI
NG
SAS/OPS controller defect

Inspection 3:
Individual continuity inspection of NG
the lift lever switch (removed from f---~~~-+ Lift switch defect
the vehicle).

OK

3pection4:
OK
(~ Jarness continuity and short circuit f------"-7 Lift switch installation defect
I inspection

NG

Harness defect
*: Make sure there is no error displayed after turning the ignition key switch ON, and moving the lift lever upward and
downward. Also, make sure that no error is displayed when the lift lever is left standing in neutral position for 2
minutes.
19-94

Inspection 1:
Check the condition of the switch.

Ignition key switch ON (engine stopped)

Lift switch (I/O monitor: MU·MD)
Standard:
Lever in neutral Lever in raised Lever in lowered
position position position
MU (Raising switch) 0 1 0
MD (Lowering switch) 0 0 1

Inspection 2:
Carry out individual continuity inspection of the lift lever switch (still installed on the vehicle).

Ignition key switch OFF, disconnect A 14

Standard: (Switch side)

Lever in neutral Lever in raised Lever in lowered
position position position
A 14-3 - A 14-4 No continuity No continuity Continuity
A14-1 - A14-2 No continuity Continuity No continuity

Inspection 3:
Carry out individual continuity inspection of the lift lever switch (removed from the vehicle).

Ignition key switch OFF, disconnect /1.14

Standard: (Switch side)

Switch ON Switch OFF
A14-3 - A14-4 Continuity No continuity
A14
A14-1 - A14-2 Continuity No continuity

Inspection 4:
Harness continuity and short circuit inspection

Ignition key switch OFF, disconnect A 14 and A20

Standard:
A20-22 - Frame No continuity
A20-23 - Frame No continuity
--
A20-22 - A20-1 I No continuity
A20-23- A20-1 No continuity
A20-22 - A20-33 No continuity
 19-95

• Error code 69-1 (Backward tilt lock solenoid abnormality)

Related portion

A20 A56
10 (BSO+) 1
----------~--~-~~-~-j Backward tilt
SAS/OPS 9 (E02) 2 lock solenoid
----------~~~~-~----j

controller 8 (E01)

Probable cause
CD Connector contact defect
CV Harness defect
Q) Backward tilt lock solenoid defect
@) SAS/OPS controller defect

I cor code 69-1

L.-,

I Disconnect the battery negative termi~-;fterl

inspecting and correcting disconnection of A20
and A56 and internal moisture, reconnect all No error
connectors and the battery negative terminal, > Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error. *

Error I
\jf

Inspection 1: NG
Harness continuity and short circuit inspection ----7 Harness defect

OK

,j;
~

3pection 2: NG
Solenoid defect
.. .oackward tilt lock solenoid individual inspection
,

OKJ

SAS/OPS controller defect

*: Make sure that no error is displayed when the material handling lever is operated to tilt backward.

Inspection 1:
Carry out harness continuity and short circuit inspection.
Ignition key switch OFF, disconnect A20 and A56

Standard:
A20-10 - A56-1 Continuity
A56-2 - Frame Continuity
A20-9 - Frame Continuity
A20-8 - Frame Continuity
A20-10 - Frame No continuity
19-96

Inspection 2:
Carry out tilt backward tilt lock solenoid individual inspection.
Ignition key switch OFF, disconnect A56
(Ci©)
A56
Standard: (Solenoid side)
I A56-1 - A56-2 9.9 ± 0.5 Q (20°C)
 19-97

• Error codes 71-1 and 71-2 (Tire angle sensor abnormality)

Related portion

A21
Z3
30 (5T) 3
r-::-c-c:::::;------~ - - ~ - - - ~ - ~ ---------j
SAS/OPS 34 (T) 2 Tire angle
controller r-::-c-=~------ - ~ - - - - - - - -----------i sensor
5 (E2) 1
f----------- - ~ - - - ~ - ~ - -----------i

Probable cause
CD Connector contact defect
Cl) Tire angle sensor harness defect
Q) Tire angle sensor defect
® Tire angle sensor Joint, rear axle link system defect
GJ SAS/OPS controller defect

I Error code 71-1

I ~

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of Z3
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, I--------C'> Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error I
.- --"v'----_. _

Inspection 1: 71-2 is displayed

Tire angle sensor inspection > Tire angle sensor defect
1
'-------------~------------'

71-1 is displayed 1
.,''lspection 2: NG
f--------~ Harness defect
/,arness continuity and short circuit inspection

OKI

Inspection 3:
1 OK
Harness continuity and short circuit inspection I--------C'>' SAS/OPS controller defect

NGJ
Harness defect

Inspection 1:
Carry out tire angle sensor inspection.
Ignition key switch OFF, disconnect Z3, use SST 09232-13130-71 to short circuit Z3-2 and Z3-3, ignition key
switch ON, engine stopped
71-1 displayed ~ to inspection 2
71-2 displayed ~ Tire angle sensor defect
19-98

Inspection 2:
inspect for continuity and short circuiting of the harness.
ignition key switch OFF, disconnect A21
(With the SST used in inspection 1 still connected)

Standard:
A21-30 - A21-34 Continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness.
in the same state as for inspection 2

Standard:
A21-34 - A21-5 No continuity

IError code 71-2

Disconnect the battery negative terminal, after
inspecting and correcting disconnection of Z3
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal f-------'7> Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

1
Error

Inspection 1:

rDisplayed error code inspection I

71-2 is disP,ayedl

Inspection 2: OK SAS/OPS
Harness continuity and short circuit inspection f-------'7 controller defect

I
.,I
No conllfluity Inspection 3:
Main harness defect
~------------ITire angle sensor inspection

Continuity

Tire angle sensor defect

Inspection 1:
inspect the displayed error code.
Ignition key switch OFF, disconnect Z3, ignition key switch ON, engine stopped
71-1 displayed -7 to inspection 3
71-2 displayed -7 to inspection 2
 19-99

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21

Standard:
A21-30 - A21-34 No continuity

Inspection 3:
Carry out tire angle sensor inspection.

Ignition key switch OFF, disconnect Z3 and A21, use SST 09232-13130-71 to short circuit Z3-1 to Z3-2 (main
harness side)

Standard:
A21-34- A21-5 Continuity
19-100

et Error codes 72-1, 72-2, 72-3, 72-4 (Steering angle sensor abnormality)
Related portion

I
A21
ECU-IG
1 (IG1) A3
1/1
I.
2 (IG2) I I
~--------
1

SAS/OPS 14 (SS1) 3
--------- Steering angle
controller 15 (SS2) 4 sensor
---------
16 (SSC) 5
---------
5 (E2)
---------
2
I
I II
•I
Probable cause
(1\ Connector contact defect ® SASJOPS controller defect
Cl) Steering angle sensor harness defect
(] Steering angle sensor defect

Note:
Turning the steering angle sensor without turning the steering wheel may cause error code 72-4 to be set.
 19-101

I Error code 72-1

Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, turn Connector contact defect
the ignition key switch ON, operate (rotate) the
steering and check whether or not there is an
error.
Error

Check the STS value with an analyzer while

o,.,."rrYlinr. the stooring
1'*
11 :NV~~';/~ ~~E~'R~NG1/1
I
0**
(* is 0 or 1)

Disconnect the battery negative terminal and A3,

I . Jrt circuit A3-2 to A3-3 (main harness side)

I using SST 09232-13130-71, reconnect the

I battery negative terminal, and turn the ignition
key switch ON.

Check the STS value with an analyzer while

1**
operating the steering. Steering angle sensor defect
ANL: I/O STEERING 1/1

0**

Inspection 1: NG
Main harness defect
Harness continuity and short circuit inspection

OKl

SAS/OPS controller defect

I
1
Disconnect the battery negative terminal and A3,
reconnect the battery negative terminal, and turn
the ignition key switch ON.

Check the STS value with an analyzer while

0**
operating the steering. Steering angle sensor defect
ANL: I/O STEERING 1/1

1**

Inspection 2: NG
Main harness defect
Harness continuity and short circuit inspection /

OKl

SAS/OPS controller defect

19-102

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21

Standard:
A21-14 - A21-5 Continuity

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21

Standard:
A21-14 - A21-5 No continuity
A21-14 - Frame No continuity
 19-103

IError code 72-2

Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all
connectors and the battery negative terminal, turn
No error
.....- Connector contact defect
the ignition key switch ON, operate (rotate) the
steering and check whether or not there is an
error.
Error

Check the STS value with an analyzer while

*1*
operating the steerinCj.
I
I
ANL.: I/O STEERING 1/1
I
*0*
(* is 0 or 1),ir

Disconnect the battery negative terminal and A3,

10rt circuit A3-2 to A3-4 (main harness side)
using SST 09232-13130-71, reconnect the
battery negative terminal, and turn the ignition
key switch ON.

1
1
Check the STS value with an analyzer while
*1*
operating the steering. ~
Steering angle sensor defect
ANL.: I/O STEERING 1/1

*0*
,Iv

Inspection 1: NG
Harness continuity and short circuit inspection ~ Main harness defect

OK

t
SAS/OPS controller defect

Disconnect the battery negative terminal and A3,

reconnect the battery negative terminal, and turn
the ignition key switch ON.

If
Check the STS value with an analyzer while
*0*
operating the steering. ... Steering angle sensor defect
ANL.: I/O STEERING 111

*1*
1

Inspection 2: NG
Harness continuity and short circuit inspection fil!l>- Main harness defect

t
OK

SAS/OPS controller defect

19-104

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21

Standard:
A21-15 - A21-5 Continuity

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21

Standard:
A21-15 - A21-5 No continuity
A21-15 - Frame No continuity
 19-105

IError code 72-3

Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all
No error
connectors and the battery negative terminal, turn f - - - - - - - - - o > Connector contact defect
the ignition key switch ON, operate the steering
(one or more rotations) and check whether or not
there is an error.
Error

Check the STS value with an analyzer while

**1
operating the steering.
ANL.: 1/0 STEERING 1/1

I
(* is 0 or*~~ I
flisconnect the battery negative terminal and A3,
jort circuit A3-2 to A3-5 (main harness side)
using SST 09232-13130-71, reconnect the
battery negative terminal, and turn the ignition
key switch ON.

Check the STS value with an analyzer while

**1
operating the steering. If--------o,> Steering angle sensor defect
ANL.: I/O STEERING 1/1

**0

Inspection 1: NG
f-------?> Main harness defect
Harness continuity and short circuit inspection

SAS/OPS controller defect

1
Disconnect the battery negative terminal and A3,
reconnect the battery negative terminal, and turn
the ignition key switch ON.

1
Check the STS value with an analyzer while
**0
operating the steering. Steering angle sensor defect
ANL: I/O STEERING 1/1

**1

Inspection 1: NG
Main harness defect
Harness continuity and short circuit inspection

OKl

SAS/OPS controller defect

19-106.

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21

Standard:
A21-16 - A21-5 Continuity

Inspection 2:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect A21

Standard:
A21-16 - A21-5 No continuity
f--------:-:~-c-----------.-+--------.:---
A21-16 - Frame No continuity

IError code 72-4

Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A3
l,u-"'""
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, --~) Connector contact defect
turn the ignition key switch ON, operate (rotate)'J
the steenng and check whether or not there is an
error.

Error

r - - - - - - - - - - - - - " : . - - - - - - - - - - Battery voltage

(approx 12 V) Disconnec[ the battery negative terminal and A3,
Inspection 1:
f--------~ reconnect the battery negative terminal, and turn
Steering angle sensor supply voltage inspection
the ignition key switch ON.
Approx. 0 V

1
To troubleshooting for 72-1 and 72-2

Inspection 2: NG
Harness continuity and short circuit inspection f---------'7 Main harness defect

OKl
SAS/OPS controller defect

Inspection 1:
Carry out steering angle sensor supply voltage inspection.
Standard:
A3-1 - A3-2 I Battery voltage (approx. 12 V) I
 19-107

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A3 and A21

Standard:
A21-1 - A3-1 Continuity
A21-2 - A3-1 Continuity
A21-5 - A3-2 Continuity
19-108

Et Error code 73-1 (Knob position compensation solenoid abnormality)

Related portion

A20 A5
6 (STRG) 1
Knob position
SAS/OPS 9 (E02) 2
- - -- - - - - - - - - - - - - - - - - - - - j compensation
controller
8 (E01)

Probable cause
CD Connector contact defect
(1) Harness defect
Q) Knob position compensation solenoid defect
@ SAS/OPS controller defect

IError code 73-1

Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A5
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error,'

Error

Inspection 1: NG
Harness defect
Harness continuity and short circuit inspection

OK

v
Inspection 2: ING
) . Knob position compensation solenoid defect
Knob position compensation solenoid individual
inspection
I
OKl

S/\S/OPS controller defect

., Make sure that no error is displayed when turning the knob position compensation solenoid ON/OFF using the
active testfunction,

Inspection 1:
inspect for continuity and short circuiting of the harness,

Ignition key switch OFF, disconnect A5 and A20

Standard:
A20-6 - A5-1 Continuity
A5-2 - Frame Continuity
A20-8 - Frame Continuity
A20-9 - Frame Continuity
A20-6 - Frame No continuity
 19-109

Inspection 2:
Carry out knob position compensation solenoid individual inspection.
Ignition key switch OFF, disconnect A5

Standard: (Solenoid side) A5

I A5-1 - A5-2 Approx.10 n (20°C)
19-110

et Error code 74-1 (Outside matching v'alue range abnormality)

Related portion

SAS/OPS controller

Probable cause
CD Tire alignment value is outside the specified range for matching.
IError code 74-1
Perform tire alignment.
(Refer to section 16)

Error

'",'

Controller defect
 19-111

• Error code A5-1 (Seat switch abnormality)

Related portion

A20 Y10

35 (DMS) 2
SAS/OPS f------~-~---~ - - - - - - - - - --------
1
Seat switch
controller 1 (E3)

Probable cause
(l) Connector contact defect
Q) Seat switch defect
G) Harness defect
@) SAS/OPS controller defect

l"Jte:
The controller is monitoring ON/OFF status of seat switch even after the key switch is turned off. While 15
minutes after turned the key switch off, if none of OFF condition on seat switch is detected, the error is
stored temporarily in some cases. Then it is shown at the timing when the key switch is turned on at the next
time as the seat switch abnormality error.
The detected error can be cancelled when OFF status of the seat switch is deteced for approx., 1 second or
more.

IError code A5-1

Disconnect the battery negative terminal, then

No error
inspect and repair disconnection of A20 and Y10 Connector contact defect
and any internal moisture.*

Error

11 Inspection 1:
NG
heck the condition of the switch Seat switch defect
ANL.: I/O M.HANDLlNG 1/6

OK

Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection

OKl

SAS/OPS controller defect

*: After correcting, connect the connector and turn the ignition key switch OFF -> ON (at least 2 seconds) -> OFF.
Make sure that no error is displayed when the ignition key is turned ON after leaving the vehicle with the seat
empty for 15 minutes.
19-112

Inspection 1:
Check the condition of the switch.
Disconnect Y1 0, ignition key switch ON, engine stopped
Seat switch (I/O monitor: SEAT)

Standard:
SEAT o

Inspection 2:
Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect A20 and Y10

Standard:
A20-35 - A20-1 No continuity
A20-35 - Frame No continuity
 19-113

~ Error code A7-1 (Brake switch abnormality)

Related portion

STOP
~~-jc::===Jt----------- - -- -- -- - ---

A20 A6
,--------,
1
Brake
SAS/OPS 17 (BSW) 2
f------------ - - - - - - - - - ----~-"----__i switch
controller

Probable cause
CD Connector contact defect
G') Brake switch defect
CD Harness defect
® SAS/OPS controller defect
IError code A7-1
I Disconnect the battery negative
I terminal, then inspect and repair No error
I disconnection of A20 and A6 and Connector contact defect
I any internal moisture.*
I
Error

[~PCCtiO" 1
Check the condition of the switch
NG
Inspection 2:
Harness continuity and short circuit
NG
-7 Harness defect
ANL: I/O TRAVELlNG 1/3 inspection

OK
OKl

SAS/OPS controller defect

"" >spection 3:
,ildividual continuity inspection of NG
the brake switch (removed from Brake switch installation defect
the vehicle)

OK!
'W
Brake switch defect

*: After correcting, connect the connector and turn the ignition key switch OFF --+ ON (at least 2 seconds) --+ OFF.
Make sure that no error is displayed when the ignition key is turned ON after ieaving the vehicle with the seat
empty for 15 minutes.

Inspection 1:
Check the condition of the switch.

Disconnect A6, ignition key switch ON, engine stopped

Brake switch (I/O monitor: BRKSW)

Standard:
BRKSW o
19-114

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A6 and A20

Standard:
A20-17 - BATT No continuity

Inspection 3:
Carry out individual continuity inspection of the brake switch (removed from the vehicle).
Ignition key switch OFF, disconnect A6

Standard: (Switch side)

Switch OFF Switch ON
A6
A6-1 - A6-2 No continuity Continuity
 19-115

" Error codes AD-1, AD-2, AD-7, AD-8 (4Y-E spec,) (CAN communication abnormality)
Related portion
A21
ECU-B
8 (BATT)

1 (IG) ECU-IG 02

SAS/OPS
2 (IG2)
I 2 (IG)
controller A20
12 (CANH) 5 (CANH) Multi-function
-~~-------

13 (CANL) 6 (CANL) display

-------~-

3 (E1)

~A36
28 (CAN+)
29 (CAN-)

EFl Engine
3 (BATT)
controller
-------
IGN
9 (IGSW)
~

Probable cause
CD Connector contact defect C9 Engine controller defect
CD Engine controller harness defect @ Multifunction display defect
Q) Multifunction display harness defect (j) SAS/OPS controller defect
® Fuse defect
Note:
When the controller or optional display is replaced into another vehicle with different specifications, AD-1
and AD-7 may occur. In such cases, perform "Engine and display ECU information clear",

IError codes AD-1, AD-2, AD-?, AD-8

I Disconnect the negative terminal of the battery NG
and inspect the fuses. Fuse defect

OKl

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of A20, A21, A36 and Connector contact defect
02 and internal moisture, reconnect all
connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error!

Error 1
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK!
'V
Engine controller defect (AD-1 )
Multifunction display defect (AD-7)
SAS/OPS controller defect (AD-8)
SAS/OPS controller or
engine controller defect (AD-2)
19-116

*: it is not necessary to inspect A36 when AD-1 and AD-2 have not occurred, and Q2 when AD-7 and AD-8 have not
occurred.

Inspection 1:
inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect Q2 (unnecessary if AD-7 and AD-8 have not occurred), A20, A21 and A36
(unnecessary if AD-1 and AD-2 have not occured)

Standard:
A21-8 - ECU-B Continuity
A21-1 - ECU-IG Continuity
A21-2 - ECU-IG Continuity
02-2 .-... ECU-IG Continuity
A20-12 - 02-5 Continuity
- -..
A20-13 - 02-6 Continuity
A20-12 - A36-28 Continuity
A20-13 - A36-29 Continuity
A20-12 - Frame No continuity
A20-13 - Frame No continuity
~ . - _ . ~

A36-3 - EFl Continuity

'-- A_3_6_-_9_-_I_G_N --.L.Qontmult y

 19-117

• Error codes AD-1, AD-2, AD-7, AD-8 (ASC spec.) (CAN communication abnormality)
Related portion
A21
ECU-B
8 (BATT)

1 (IG)
-----
ECU-IG
02
~
SAS/OPS
controller
2 (IG2) I 2 (IG)
A20
12 (CANH) 5 (CANH) Multi-function
~~-~-~--~~-

13 (CANL) 6 (CANL) display

~--~-~----

3 (E1)

~39
13 (CANH)
26 (CANL)
G38
ECU-B2 1 (B) ASC
controller
IGN G39
25 (IGSW)

Probable cause
CD Connector contact defect G) Engine controller defect
en Engine controller harness defect @ Multifunction display defect
Q) Multifunction display harness defect (j) SAS/OPS controller defect
® Fuse defect
Note:
When the controller or optional display is replaced into another vehicle with different specifications, AO·1
and AO-7 may occur. In such cases, perform "Engine and display ECU information clear".

IError codes AD-i, AD-2, AD-7, AD-8

Disconnect the negative terminal of the battery NG
and inspect the fuses. f-----------'? Fuse defect

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of A20, A21, G38, G39
f---------~ Connector contact defect
and 02 and internal moisture, reconnect all
connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error. *

Error I
\jI

Inspection 1: NG
Harness continuity and short circuit inspection f----------------7 Harness defeet

OKl
Engine controller defect (AD-1)
Multifunction display defect (AD-7)
SAS/OPS controller defect (AD-8)
SAS/OPS controller or
engine controller defect (AD-2)
19-118

*: It is not necessary to inspect G38 and G39 when AD-1 and AD-2 have not occurred, and Q2 when AD-7 and AD~8
have not occurred.

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect Q2 (unnecessary if AD-7 and AD-8 have not occurred), A20, A21, G38 and
G39 (unnecessary if AD-1 and AD-2 have not occured)

Standard:
A20-12 - 02-5 Continuity
A20-13 - 02-6 Continuity
A20-12 - G39-13 Continuity
--
A20-13 - G39-26 Continuity
A20-12 - Frame No continuity
A20-13 - Frame No continuity
A21-8 - ECU-B Continuity
A21-1 - ECU-IG Continuity
A21-2 - ECU-IG Continuity
02-2 - ECU-IG Continuity
--
G38-1 - ECU-B2 Continuity
--
G39-25 - IGN Continuity
 19-119

• Error codes AF-1, AF-2, AF-3,AF-4, AF-5, AF-6, AF~7, AF-8 (CPU abnormality)
Related portion

SAS/OPS controller

Probable cause
CD SAS/OPS controller defect

'ote:
IIhen AF is displayed, the SAS/OPS controller is defective and must be replaced.
19-120

• Error codes C4-1, C4-2, C4-3, C4-4,C4-5, C4-6 (STD:4Y-E) (Accelerator sensor abnormality)
Related portion

A35 a1
25 (VCPA) 5
26 (VPA) 4
27 (EPA) 6
ASC controller Accelerator
33 (VCP2) 1 sensor
1---
34 (VPA2) 3
35 (EPA2) 2

Probable cause
cD Connector contact defect
o Accelerator sensor defect
CD Harness defect
® 4Y-E controller defect
IError codes C4-1, C4-2, C4-3, C4-4, C4-5
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of ,1'1.35 I
and a1 and internal moisture. reconnect a/l No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine),
and check whether or not there is an error. *

Error1
Inspection 1: NG
Accelerator sensor individual inspection Accelerator sensor defect

OKl

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OKl

ASC controller defect

*: Make sure that no error code is displayed when the accelerator pedal is operated.
 19-121

IError code C4-5

Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A35
and a1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error:

Error

Inspection 1: NG
Accelerator sensor defect
Accelerator sensor individual inspection /

OK
r

-J,
I Inspection 2: NG
Harness defect
,-iarness continuity and short circuit inspection

OK

ilnspection 3:
NG
Accelerator sensor voltage inspection Accelerator sensor defect
lANL: 1/0 ENGINE CTRL 4/10
I
OKl

ASC controller defect

*: Make sure that no error code is displayed when the accelerator pedal is operated.

Inspection 1:
Carry out accelerator sensor individual inspection.
Ignition key switch OFF, disconnect ai, conenct A35
(1) Accelerator sensor resistance measurement

Standard: (Sensor side)

a1
a1-5 - a1-6 Approx. 1.8 - 3.5 kG
1--~~~~-a-1-.-1---a-1~--2~~~~--1 (released)

(2) Accelerator sensor output circuit resistance measurement

Standard: (Sensor side)

a1-4 - a1-6 Make sure that the resistance value increases proportionally to the
1-------a-1.-3---a-1-.2------1 rotation of the potentiometer when the potentiometer section is rotated.
19-122

Ihspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and a1

Standard:
A35-26 - a1-4 Continuity
A35-25 - a1-5 Continuity
A35-26 - Frame No continuity
A35-27 - a1-6 Continuity
A35-25 - A35-26 No continuity
A35-26 - A35-33 No continuity
A35-34 - a1-3 Continuity
J
A35-33 - a1-1 Continuity
-~

A35-34 - Frame No cont;,nuity

A35-34 - A35-25 No continuity
A35-34 - A35-33 No continuity
A35-26 - A35-34 No continuity

Inspection 3:
Inspect the accelerator Sensor voltage.
Ignition key switch OFF, disconnect a1, connect A35, ignition key switch ON
Accelerator sensor (I/O monitor: VPA 1, VPA2)

Standard:
VPA1 0.20 V or less
VPA2 020 V or less
 19-123

• Error codes C4-1, C4-2, C4-3, C4-4, C4-5 (ASC spec.) (Accelerator sensor abnormality)
Related portion

G39 a1
19 (VCPA) 5
6 (VPA) 4
7 (EPA) 6
ASC controller Accelerator
18 (VCP2) 1
sensor
5 (VPA2) 3
-~

17 (EPA2) 2

Probable cause
(D Connector contact defect
o Accelerator sensor defect
Q) Harness defect
® ASC controller defect
IError codes C4-1, C4-2, C4-3, C4-4, C4-5
Disconnect the battery negative terminal, after
Inspecting and correcting disconnection of G39
and a1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine),
and check whether or not there is an error.*

Error

Inspection 1: NG
Accelerator sensor individual inspection Accelerator sensor defect

OK

I I"spection 2: NG
Jrness continuity and short circuit inspection Harness defect

OK

It"CtiO"
Accelerator3sensor voltage inspection
ANL: I/O ENGINE CTRL 1/3
NG
Accelerator sensor defect

OKl

ASC controller defect

*: Make sure that no error code is displayed when the accelerator pedal is operated
19-124

Inspection 1:
Carry out accelerator sensor individual inspection.
Ignition key switch OFF, disconnect a 1, conenct G39
(1) Accelerator sensor resistance measurement

Standard: (Sensor side)

a1
a1-5-a1-6 Approx.1.8-35kD
r-----~a-1--1---a-1--2----------1 (released)

(2) Accelerator sensor output circuit resistance measurement

Standard: (Sensor side)

a1-4 - a1-6 Make sure that the resistance value increases proportionally to the
r-------a-1-~3---a-1--2-----------i1rotation of the potentiometer when the potentiometer section is rotated.
 19-125

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G39 and a1

Standard:
G39-6 - a1-4 Continuity
G39-19 - a1-5 Continuity
G39-6 - Frame No continuity
G39-7 - a1-6 Continuity
G39-19 - G39-6 No continuity
G39-6 - G39-18 No continuity
G39-5 - a1-3 Continuity
G39-18 - a1-1 Continuity
G39-5 - Frame No continuity
G39-5 - G39-19 No continuity
G39-5 - G39-18 No continuity
G39-6 - G39-5 No continuity

Inspection 3:
Inspect the accelerator sensor voltage.
Ignition key switch OFF, disconnect ai, connect G39, ignition key switch ON
Accelerator sensor (I/O monitor: VPA1, VPA2)

Standard:
VPA1 0.20 V or less
VPA2 0.20 V or less
19-126

• Error codes C7-1 and C7-2 (Shift lever switch abnormality)

Related portion

SFT

A41 ,--~~~~~~-.
6

A20
~~~~~~~~_F_)~~~~~~~~~~~~~_~_~~~_5--i Shift switch

SAS/OPS I
'----~c_o_n_tr_o_lle_r~~:1-9-('---D-R-R'---)~~~~~~-~--~-~~-~~~~~_~'---_~~~~~_

The above chart is for vehicles of trle left shift lever column specification.
For vehicles of the right shift lever column specification, A43-4, A43-5 and A43-9 should be used.
For vehicles of the armrest specification, Y4-7, Y4-6 and Y4-1 should be used.

Probable cause
Cl) Connector contact defect ® Harness defect
ill Forward travel shift switch defect Shift switch installation defect
(3)
Cl> Reverse travel shift switch defect @ SAS/OPS controller defect

Note:
In the event that the engine stops while travelling, when the ignition key switch is turned from OFF to ON, an
C7-1 error may be detected, however this is not a fault.
Stop the vehicle, turn the ignition key switch OFF and restart the engine.
 19-127

I Error code C7-1

"---
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A20
and A41 and internal moisture, reconnect all No error
connectors and the battery negative terminal, 7 Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.'
.~

Error

Inspection 1:
Check the condition of the switch I
ANL.: 1/0 TRAVELlNG 2/3

OK
J
. ~.spection 2:
" Jividual continuity inspection of the direction NG
lever switch that was abnormal in inspection 1 Shift switch defect
(while still installed on the vehicle)"

OK

Inspection 3: NG
Harness continuity and short circuit inspection Harness defect

OKl

SAS/OPS controller defect

*: Check ifan error occurs after turning the ignition key switch ON, moving the shift lever and traveling from stopped
state to more than 10 km/h within 3 seconds.

I Error code C7-2

I
. ;sconnect the battery negative terminal, after
lspecting and correcting disconnection of A20
. : Id A41 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error'

Error

Inspection 4:
OK
Check the condition of the switch Shift switch defect
ANL.: 1/0 TRAVELlNG 2/3

NG

Inspection 3: OK
Harness continuity and short circuit inspection Harness defect

NGl

SAS/OPS controller defect

*. Make sure there is no error after turning the ignition key switch ON, and move the shift lever to forward and reverse
travel.
19-128

Inspection 1:
Check the condition of the switch.

Ignition key switch ON

Direction switch (I/O monitor: DRF - DRR)

Standard:
Lever in neutral Lever in forward Lever in reverse
position travel position travel position
DRF (for forward travel) 0 1 0
DRR (for reverse travel) 0 0 1

Inspection 2:
Individual continuity inspection of the direction lever switch(es) (still installed on the
vehicle).

Ignition key switch OFF, disconnect A41

Standard: (Switch side)

Lever in neutral Lever in forward Lever in reverse
position travel position travel position
A4 1-6 - A41-5 No continuity Continuity No continuity
A41-6 - A41-1 No continuity No continuity Continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and A41

Standard:
A20-18 - A41-5 Continuity
A20-18 - Frame No continuity
A20-19 - A41-1 Continuity
A20-19 - Frame No continuity
A20-18 - A41-6 No coniinuity
A20-19 - A41-6 No continuity
A20-18 - A20-19 . No continuity

Inspection 4:
Check the condition of the switch.
Disconnect A41, ignition key switch ON (engine stopped), direction switch (I/O monitor: DRF'ORR)

Standard:
Analyzer display
DRF (for forward travel) 0
DRR (for reverse travel) 0
 19-129

• Error code CA-1 (Forward-reverse travel lever abnormality)

Related portion

A21
17 (RYF)
- - - - - _ . _ __
A20
.. . _ ~ ~ -- - - - - - - - - - - .-
A

- -I ~
_2_~lay
1
[-1
c::
Forward travel

SAS/OPS
controller
8 (EO_1-,)~__~~_.-
9 (E02)
-. eb

Reverse travel
relay

Probable cause
CD Connector contact defect (4) Reverse travel relay harness defect
<1) Forward travel relay harness defect G) Reverse travel relay defect
Q) Forward travel relay defect ® SAS/OPS controller defect
'or code CA-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
1
and A21 and internal moisture, reconnect aii No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON and check
whether or not there is an error.

Erro1

Inspection 1: NG
Harness continuity and short circuit inspection 0> Harness defect
~-~

OKl

!Inspeclion 2: NG
I Relay individual inspection Relay defect

OKl

SAS/OPS controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20, A21 and forward/reverse relay

Standard:
- i
A20-17 - RIB forward relay terminal 1
RIB reverse relay terminal 2 - Frame
Continuity
Continuity
I
A20-9 - Frame
A20-8 - Frame
Continuity
Continuity
I
A20-17 - Frame No continuity
19-130

Inspection 2:
Carry out relay individual inspection.

Standard: (Relay side)

Forward relay terminal 1 -
Forward relay terminal 2 Forward/reverse relay
Approx 90 n (20°C)
Reverse relay terminal 1 -
Reverse relay terminal 2
 19-131

et Error code EC-1 (Unload solenoid abnormality)

Related portion

A20 A12
~----------, ,---------,
5 (USOL) 1
f---------- - - - - - - - - - - ---------- Unload
SASfOPS 9 (E02) . 2 solenoid

~1).· .. ~~;r----------
controller
1-----

'-----------'

Probable cause
CD Connector contact defect
(1) Harness defect
Cl) Unload solenoid defect
® SAS/OPS controller defect
It:rror code EC-1

Disconnect the battery negative terminal, aft~

inspecting and correcting disconnection of A 12
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*

Err01

Inspeclion 1: NG
Unload solenoid individual inspection 0- Unload solenoid defect

OKI

spection 2:
'iarness continuity and short circuit inspection
IfNG
- - - - - - - - ' 7 ) Harness defect

I
OKl
SAS/OPS controller defect

*: Check whether an error occurs after turning the ignition key switch ON and leaving the seat (for at least 2
seconds).

Inspection 1:
Carry out unload solenoid individual inspection.
Ignition key switch OFF, disconnect A 12
Ai2
Standard: (Solenoid side)
I A12-1 - Ai2-2 Approx 10 D (20°C)
19-132

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and A 12

Standard:
A20-5 - A12-1 Continuity
A12-2 - Frame Continuity
A20-8 - Frame Continuity
--
A20-9 - Frame Continuity
--
A20-5 - Frame No continuity
 19-133

• Error codes F1-1, F2-1 (Controller to combination meter communication abnormality)

Related portion

A20 01
,----~~~~~~~

SAS/OPS
controller
14 (SIL)
--~------~

N.C
3 (SIL2)
- - - -- - - - - - - - - - - - - - - - - 1
~ _(\'V~~H()U_T_~~~~
Combination
meter
J

Probable cause
CD Connector contact defect
(£l Hour meter harness defect
Q) Hour meter defect
® SAS/OPS controller defect
ferror codes F1-1, F2-1

I Disconnect the battery negative terminal. after I

inspecting and correcting disconnection of A20 I
and 01 and internal moisture, reconnect all No error
connectors and the battery negative terminal, -------'7) Connector contact defect
turn the ignition key switch ON and check
'----w~h_e_th_e_r_o~r_n_o_t~t._h-e-re-is-a~n-e-rr-o-r.___,--,-_~
F1-1 F2-1 t

Ll- - - - - - - - - - - - - 7 > Combination meter defect

Inspection 1:
Harness continuity ~
and Sh~rt circuit inspection ---,I,_N_G~~~-~7
' ) Harness defect

OKi'
\Jf
SAS/OPS controller or
combination meter defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect ,,6,,20 and 01

Standard:
01-9 - Frame No continuity
01-3 - Frame No continuity
A20-14 - 01-3 Continuity
I
19-134

• Error codes F4-1, F4-2, F4-3, F4-4, F4-5, F4-7, F4-8 (CPU abnormality)
Related portion

Multi-function display

Probable cause
CD Multi-function display board defect
 19-135

• Error codes H1-1, H1-2, H1-3, H1-4, H1-5 (Lift lever potentiometer abnormality)
Related portion

ECU-IG
[:/I/

A23
7 (IG)
8 (IG2) Y6

~ -:=~=----=._-=._-.~ ~-j~-j, ~~~~:i~netec- -I

29 (L1F+)
27 (L1F1)
SASJOPSJ
28 (L1F2) :---: -: : -:-.=--:=-
mini lever 1-'
26 (E2)

'L
controller _._.- - - - - - - - - - - - - - - - - -
9 (E43) I
10(E44) ~
A21
9 (E41)
I I
I
10 (E42)
J
3 (E11)
--

I --
4 (E12)

'------ J

Probable cause
CD Connector contact defect
o Lift lever potentiometer harness defect
G) Lift lever potentiometer defect
('I) SAS/OPS controller defect
~ Fuse defect
19-136

IError codes Hi-i, Hi-2, Hi-3, Hi-4

Disconnect the battery negative
terminal, after inspecting and
correcting disconnection of A21 ,
A23 and Y6 and internal moisture, No error
reconnect all connectors and the ~ Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error

Turn the ignition key switch OFF,

disconnect the battery negative
terminal, replace the lift lever ~pectlon 1: ~l OK
H2-4
1 .

~
~otentiometer with the tilt lever Lift lever potentiometer inspecti~-----7Installation defect
po.tentiometer, and check ifthere is
any change in the error. - - NG1
H1-* I
IH2-1'H2-2H2-3
-7 Lift lever potentiometer abnormality

Inspection 2: NG
Harness continuity and short circuit f - - - - - ~ Harness defect
! inspection
Il......--. ~------.-J
OK

Luse
r
inspection 1.' NG ~-C7Replace fuse

OKI
SAS/OPS/mini lever
controller defect

Note:
If the lever has been removed, be sure to perform matching after the lever is reinstalled.

Inspection 1:
Carry out lift lever potentiometer inspection.
Ignition key switch OFF, return the lift lever potentiometer and tilt lever potentiometer to their original positions,
check lift lever potentiometer installation (refer to section 18), ignition key switch ON, match lift lever
potentiometer
 19-137

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y6
Standard:
A23-29 - Y6-4 Continuity
A23-27 - Y6-3 Continuity
f---
A23-28 - Y6-2 Continuity
f------.
A23-26 - Y6-1 Continuity
A23-27 - Frame No continuity
A23-28 - Frame No continuity
-----
A23-29 - Frame No continuity
I
~-

I Error code H 1-5

I

~LO.K _
,%tch lift lever potentiometer ~- -> Matching value misalignment

NGI
SAS/OPSfmini lever
controller defect
19-138

e Error codes H2-1, H2-2, H2-3, H2-4, H2-5 (TUt lever potentiometer abnormality)
Related portion

EUC-IG
---0i-------------~

A23
r-------------~
7 (IG)

II 8 (IG2) Y5
30 (IlL+) 41:

SAS/OPSI :1=1=(T=I=L=1=)==========
f-1_2_(_T_IL_2._) __ __ ___ __ _
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~_-======_========-_
3
- -1 Tilt lever
~ potentiometer
mini lever
controller
f-:-~_~E-4~-;---------- - - - - - - - - - - --------'l --'
10 (E44) I
i---------
A21 l I
~_t---9(_E4_1) j ,\1

10 (E42) ------'
~-+---------
3 (E11)

'--------+-4_(_E_1_2) - - - - -t
///

Probable cause
\D Connector contact defect
(~) Tilt lever potentiometer harness defect
I]) Tilt lever potentiometer defect
® SAS/OPS controller defect
W Fuse defect
 19-139

I Error codes H2-1, H2-2, H2-3, H2-4

Disconnect the battery negative
terminal, after inspecting and
correcting disconnect of A21, A23
and Y5 and internal moisture, No error
reconnect all connectors and the :; Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error

1
Error

Turn the ignition key switch OFF,

disconnect the battery negative
terminal, replace the lift lever H1-4 Inspection 1: LOK
' t 't' th e t'lt
1)0 t en t lome er WI ,) I
IeverL
,--~~~---'"
-7 Tilt lever potentiometer inspection I -~~~-7' Installation defect
.JOtentiometer, and check if there is
y
,'n change :~I:I e'_ro_r'_ 1 : : , H13-~--NG1~-----"-"~
lH
~ ) Tilt lever polentiometer abnormality
\jt

l
:nspection 2: NG
Harness continuity and short circuit f----------C7 Harness defect
Inspection

OK

NG
I1--~~~-----7 Replace fuse

SAS/OPS/mini lever
controller defect
te:
r the lever has been removed, be sure to perform matching after the lever is reinstalled.

Inspection 1:
Carry Qut Hit lever potentiometer inspection.

Ignition key switch OFF, return the tilt lever potentiometer and lift lever potentiometer to their original positions,
check tilt lever potentiometer installation (refer to section 18), ignition key switch ON, match tilt lever
potentiorneter
19-140

Inspection 2:
Inspect for continuity and short circuiting of the harness
Ignition key switch OFF, disconnect A21, A23 and Y5
Standard:
A23-30 - Y5-4 Continuity
f---~--~-~---~--- - ~ ~ ~ ~ - -

A23-11 - Y5-3 Continuity

A23-12 - Y5-2 Continuity
1------ --~-

A23-26 - Y5-1 Continuity

-~--

A23-11 - Frame No continuity

-~-

A23-12 - Frame No continuity

- -~-

A23-30 - Frame No continuity

I I

I Error code H2-5

Match tilt lever potentiomete_r -----'~-~--~--O> Matching value misalignment

NG1-
SAS/OPS/mini lever
controller defect
 19-141

• Error codes H3-1, H3-2, H3-3, H3-4, H3-5 (Attachment 1 lever potentiometer abnormality)
Related portion

ECU-IG

A23
7 (IG)
'-~

8 (IG2) Y2
,---------,
31 (AT1+) 4
13 (AT11) 3
- - - - - - - - - - ------------i Attachment 1 lever
14 (AT12) 2
SAS/OPS/
mini lever
26 (E2)
9 (E43)
__________
- - - - - - - - - ------------i
~ ~11
potentiometer

'--------
controller
10 (E44)

r--~
A21
9 (E41)
10 (E42)
3 (E11)
4 (E12)
f]
---

Probable cause
CD Connector contact defect
CV Attachment 1 lever potentiometer harness defect
C]) Attachment 1 iever potentiometer defect
® SAS/OPS controller defect
~ Fuse defect
19-142

IError codes H3-1, H3-2, H3-3, H3-4

Disconnect the battery negative

terminal, after inspecting and
correcting disconnect of A21, A23 Error
~ne
and Y2 and Internal moisture,
reconnect all connectors and the
battery negative terminal, turn the
1---7 Connector contact defect

ignition key switch ON, and check

whether or not there is an error.
I
I
- ErrorJ

~T-u-rn-th-e-ignitionkey switch OFF"l'

disconnect the battery negative
terminal, replace the attachment 1
lever potentiometer with the tilt
H2-4
-----
I
Inspection 1:
Attachment 1 lever potentiometer NG I ~
~ Installation defect

,-----ell'r--
lever poteniiometer, and check if inspection
there is any change in the error. I
H3'I lH2:1H7 2H2-:'
1 ---"7)
Atlachment 1
lever potentiorneter abnormality

Inspection 2:
NG
Harness continuity and short circuit 1------3> Harness defect
inspection
--.- ---.---J
OK!

,---

Fuse inspection
1l , NG
r-----~) Replace fuse

OK

SAS/OPS/mini lever
controller defect

Note:
If the lever has been removed, be sure to perform matching after the lever is reinstalled.

Inspection 1:
Carry out atiachment 1 lever potentiometer inspection

Ignition key switch OFF, return the attachment 1 lever potentiometer and tilt lever potentiometer to their original
positions
Check attachment 1 lever potentiometer installation (refer to section 18), ignition key switch ON, match
attachment 1 lever potentiometer
 19-143

Inspection 2:
Inspect for continuity and short circuiting of the harness
Ignition key switch OFF, disconnect A21, A23 and Y2
Standard:
A23-31 - Y2-4 Continuity
-----
A23-13 - Y2-3 Continuity
A23-14 - Y2-2
A23-26 - Y2-1
Cootiootly
Continuity
-J
A23-13 - Frame No Cool",oly ___
A23-14 - Frame No Continuity
- - - . __ .--_.. - .. ----
A23-31 - Frame No Continuity i
, ~

IError code H3-S

OK
latch attachment 1 lever potentiometer Matching value misalignment

SAS/OPS/mini lever
controller defect
19-144

• Error codes H4-1, H4-2, H4-3, H4-4, H4-5 (Attachment 2 lever potentiometer abnormality)
Related portion

ECU-IG
~-01------~-

A23
7 (IG)
8 (IG2) Y3
--

~~~~~~~~~~---------4~~,-A-tta-c-h~m-e-n-t~2-I-ev~e~c·1
32 (AT2+)
15 (AT21)
.---~

16 (AT22)
SAS/OPS/
mini lever
controller
26 (E2)
9 (E43)
"_._-~--

~~~~~~~~~~ -----.. _ 'I potept'ometec I

IJ
10 (E44)
A21
9 (E41)
10 (E42)
.-
3 (E11)
.-
4 (E12)

L ----'

Probable cause
CD Connector contact defect
o Attachment 2 lever potentiometer harness defect
UI Attachment 2 lever potentiometer defect
@) SAS/OPS controller defect
QI Fuse defect
 19-145

IError codes H4-1, H4-2, H4-3, H4-4

Disconnect the battery negative
terminal, after inspecting and
correcting disconnect of A21, A23
and Y3 and internal moisture, No error
reconnect all connectors and the ~-~~7 Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error. J
Error

I Turn the ignition key switch OFF!

disconnect the battery negative
lI~spection 1:
terminal, replace the attachment 1 H
-------1
r •

::lA 1

1 "
NG
lever potentiometer with the Attachment 2 lever polentiorneter r-~~~----7' Installation defect
ittachment 2 lever polentiometer, IlIspectlon
and check if there is any change in L~~~~__~,-----~~~~~----.1
OK
~ error.

e .~ ~471-131H32H3 3 \V
Attachment 2
lever potentiometer abnormalily
J
Itedi002
.
Harness continuity and short circuit
NG
-------3> Harness defect
inspection

OK

~.. - -__
iT--------'3>
-
NG
I use inspection Replace fuse
OK

1
SAS/OPS/mini lever
controller defect

'te:
," ..he lever has been removed, be sure to perform matching after the lever is reinstalled.

Inspection 1:
Carry out attachment 2 lever potentiometer inspection.
Ignition key switch OFF, return the attachment 2 lever potentiometer and tilt lever potentiometer to their original
positions
Check attachment 2 lever potentiometer installation (refer to section 18), ignition key switch ON, match
attachment 2 lever potentiometer
19-146

Inspection 2:
Inspect for continuity and short circuiting of the harness.
ignition key switch OFF, disconnect A21, A23 and Y3

Standard:
A23-32 - Y3-4 Continuity
c--. I
A23-15 - Y3-3 Continuity
i
A23-16 - Y3-2 I
Continuity
A23-26 - Y3-1 Continuity
A23-15 - Frame No continuity
A23-16 - Frame
-I
I=-
I No continuity
A23-32 - Frame i No continuity

IError code H4-5

N.
[AUachment 2 lever poten;iometer matching

SAS/OPS/mini lever
controller defect
c-.

----.J
OK
I - - - ~ Matching value misalignment
 19-147

• Error codes H5-1 and H5-2 (Lift solenoid abnormality)

Related portion

A23 A51

;~:'~
17 (LSO+) 5
--------------- Lift PUSH
18 (LPSH) 1 solenoid
---------------
SAS/OPS/ I
mini lever ~
I
-1
controller A52
I 5
~9(l!'LL~) _ 1
Lift PULL
solenoid
__~. J
Probable cause
Cl) Connector contact defect (4) Lift PULL solenoid harness defect
CIJ Lift PUSH solenoid harness defect ~,l Lift PULL solenoid defect
Cl) Lift PUSH solenoid defect (E) SJl.,S/OPS/minj lever controller defect

'or codes H5-1, H5-2

H5-1 is now described For H5-2 substitute A52 for A51 and PULL for PUSH in the following.

I Disconnect th~ b;ill;~y i1~gat;vet~fmi~~,-a~

InspectIng dno correcting disconnect or A23 and
A51 and internal moisture, reconnect a!! No error
connectors and the battery negative termmal, -----7 Connector contact defect
turn the ignition key switch or~, operate the lift
lever and check whether or not there is an error.
Error I --~-~

J,
Inspection 1:
Lift solenoid indivicJual iIlspectior: . -~ Lift PUSH solenoid defect

OKi-'-"
I
r------.-.-----~-- - - .,'~-,-~-
I Inspection 2: ~
arness continuity and short circuit inspection I ---)- Harness defect
:--·------oKi-·-'-' I

i
,1,
S/\S/OPS mini !cver cCJntfo!iet defect

Inspection 1:
Carry out lift solenoid Individual Inspection.

Ignition key switch OFF, disconnect battery negative terminal, disconnect A51

Standard: (Solenoid side)

I A51-S - A51-1 Approx. 7 n. (20°C)
19-148

Inspection 2:
Inspect for continuity and short circuiting of the harness.
ignition key switch OFF, disconnect battery negative terminal, disconnect A23 and A51

Standard:
A52
A23~17 - A51~5 Continuity
L
~--
A23~18 - A51~1 Continuity
--- A23~17 - A23~18 No continuity
A23-17 - A23~19
--+-----~--~
f\lo continuity
f-.- ----.-
A23~ 17 - Frame No continuity
-I----~----~-~--

A23~ 18 - Frame No continuity

1-
I
A23~19
--~----

- Frame
--1----- - - -
I No continuity
 19-149

• Error codes H6-1 and H6-2 (Tilt solenoid abnormality)

Related portion

A51
6
TiltPUS~
2 solenoid I
SAS/OPS/
mini lever
controller
Tilt PULL
solenoid

Probable cause
CD Connector contact defect @)Tilt PULL solenoid harness defect
W Tilt PUSH solenoid harness defect Tilt PULL solenoid defect
(3)
Cl) Tilt PUSH solenoid defect @ SAS/OPS/mini lever controller defect

Ir-:~ror codes H6-1 and H6-2

H6-1 is now described. For H6-2, SUbstitute /'\52 for /'\51 and PULL for PUSH in the following

~isconnect the battery negative terminal, after

I inspecting and correcting disconnect .A23 and
I A51 and internal moisture, reconnect all No error
connectors and the battery negative terminal, > Connector contact defect
turn the ignition key switch ON, operate the tilt
lever and check whether or not there is an error.
Error

, Inspection 1: -~-- ING

ICt solenoid individual inspection I~~~~~-C'» Tilt PUSH solenoid defect

OKI
-~~~~-

I Inspection 2: NG
lrness continuity and short circuit inspection f--~~~-~+> Harness detect

OKi
\jI
SAS/OPS mini lever controller defect

Inspection 1:
Carry out tilt solenoid individual inspection,

Ignition key switch OFF, disconnect A51

Standard: (Solenoid side)

'-- A_5_1-_6_-_A_5_1_-2 J__A_p_p_r_ox_._7_D_-_(_2_0_C_l_---l
0
19-150

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A23 and A51

Standard:
A52
A23-1 - A51-6 Continuity
A23-2 - A51-2 Continuity
A23-1-A23-2 No continuity
A23-1 - A23-3 No continuity
A23-1 - Frame No continuity
A23-2 - Frame No continuity
A23-3 - Frame No continuity
 19-151

• Error codes H7-1, H7-2 (Attachment 1 solenoid abnormality)

Related portion

A23 A51
r-------~

20 (3S0+) 7
Attachment 1
21 (3PLL) 3 PUSH solenoid
r----------- - - - - - - - - - -
SASJOPS/
mini lever
A52
controller
7
Attachment 1
22 (3PSH) 3 PULL solenoid
r - - - - - - - - - - - - - - - - - - --

Probable cause
CD Connector contact defect
CV Attachment 1 PUSH solenoid harness defect
Q) Attachment 1 PUSH solenoid defect
@) Attachment 1 PULL solenoid harness defect
W Attachment 1 PULL solenoid defect
@ SASJOPS/ mini lever controller defect

IError codes H7-1, H7-2

H7-1 is now described. For H7-2, substitute A52 for A51 and PULL for PUSH in the following

Disconnect the battery negative terminal, after

inspecting and correcting disconnect of A23 and
A51 and internal moisture, reconnect all
No error
connectors and the battery negative terminal, f---------':> Connector contact defect
turn the ignition key switch ON, operate
attachment lever 1 and check whether or not
there is an error.

Inspection 1: NG . Attachment 1 PUSH

!Attachment 1 solenoid individual inspection --7 solenoid defect
I

I Harness
Inspection 2:
continuity and short circuit inspection
lNG.. .
1~·------3>- Harness defect

. OKl
SAS/OPS mini lever controller defect
19-152

Inspection 1:
Carry out attachment 1 solenoid individual inspection.
Ignition key switch OFF, disconnect A51

Standard: (Solenoid side)

[ A51-7 - A51-3 Approx 7 n (20°C)

Inspection 2:
inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect A23 and A51

Standard:
A52
A23-20 - A51-7 Continuity
A23-21 - A51-3 Continuity
A23-20 - A23-21 No continuity
-_.

A23-20 - A23-22 No continuity

- .-
A23-20 - Frame No continuity
,-._--

A23-21 - Frame No continuity

- .... , - - - _... _'.

A23-22 - Frame No continuity

 19-153

• Error codes H8-1, H8-2 (Attachment 2 solenoid abnormality)

Related portion

A23 A51
.----------,
4 (4S0+) 8
1-----'------------------ - Attachment 2
5 (4PSH) 4 PUSH solenoid
1 - - - - - ' - - - - - - - - - - - - -- -- - --
SAS/OPS/
mini lever
A52
controller
8
Attachment 2
6 (4PLL) 4 PULL solenoid
1 - - - - - ' - - - - - - - - - - - - - - - - -- - -

Probable cause
CD Connector contact defect
CD Attachment 2 PUSH solenoid harness defect
(3) Attachment 2 PUSH solenoid defect
® Attachment 2 PULL solenoid harness defect
(i) Attachment 2 PULL solenoid defect
@ SAS/OPS/ mini lever controller defect

I Error codes H8-i, H8-2

H8-1 is now described_ For H8-2, substitute ,fl52 for /\51 and PULL for PUSH in the following.

Disconnect the batiery negative terminal, after

inspecting and correcting disconnect of A23 and
A5i and internal moisture, reconnect all
No error
connectors and the battery negative terminal, f----------'3>- Connector contact defect
turn the ignition key switch ON, operate
attachment lever 2 and check whether or not
there is an error
Error I

inspection 1:
1 NG
- - _ ..._-----,; Attachment 2 PUSH
Attachment 2 solenOid individual inspection solenoid defect

OKi
1
l
-'Inspection 2:
Harness continuity and short circuit inspection ------)- Harness defect

OKl
SAS/OPS mini lever controller defect
19-154

Inspection 1:
Carry out attachment 2 solenoid individual inspection.
Ignition key switch OFF, disconnect battery negative terminal and A5!

Standard: (Solenoid side)

I A5i-8 - A5iA

Inspection 2:
Inspect for continuity and short circuiting of the harness.
~
Ignition key switch OFF, disconnect A23 and A51

Standard:
~
A52
A23-4 - A5i-8 Continuitv

tI A23-5 - A5iA
.-.

-----1
-, .. --.'~"-
Continuity
A23-4 - A23-5 No continuity
I
A23-4 - A23-6 -----1- No continuity

C
I
A23-4 - Frame
A23-5 - Frame
! No continuity
No continuity
--

t-- A23-6 - Frame

-~."--"'-~-"'._--'-

No continuity
 19-155

• Error code HA-1 (3/4-way change relay abnormality)

Related portion

ECU-IG
~~0r---~~~~~~-~~~~--.

A21 A96
1
FIATSO) 4
3/4-way change
relay 1
SAS/OPSI
Mini lever
controller
3/4-way change
relay 2

L _

Probable cause
CD Connector contact defect
(0' 3/4-vV8Y change relay 1 harness defect
Q) 3/4-way change relay 1 defect
® 3/4-way change relay 2 harness defect
~) 3/4-way change relay 2 defect
(§.! SAS/OPS controller defect

I
Error code HA-1

I Disconnect the battery negative terminal, after

I, internal moisture, reconnect A21 and the battery Ii "
inspecting and correcting disconnect of A21 and

I negative terminal (leave relay disconnected), . ! 1''0 error - - > 3/4-way change relay defect
turn the changeover switch to the 3-way side,
1-
1 turn the ignition key switch ON, and check i
!
i
,ether or not there is an error.
i

llnsoection 1: ! N(; ~ Hamess defect

I Ha~ness continuity and short circuit inspection i

'_. OK1-
S.£I's/OPS/mini lever controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness,

Ignition key switch OFF, disconnect A21 am] change relay

Standard:
f--_ _ A_2_1-_1_2_-_R_e_la_y_t_e_rn~1_in_a_I_1_-4
_ _ I~~~y-
A21-12 _ Relay terminal 2-4 I Continuity
A21-12 - Frame I No continuity
19-156

TROUBLESHOOTiNG WHEN THERE IS NO ERROR CODE

4Y-E Engine List by Symptom
Symptom Portion to be inspected Page for reference
1. Starter relay and starter 19-157
Does not crank
2. Neutral start switch -
-
1 . 19-159
1 ECU power supply system
f-----.

Cannot start 2. Igniter system 19-44

- -
(no starting combustion) 3. Fuel pump circuit 19-161
4. Fuel injector Refer to engine repair manual

Ir~"Mt~h-t 1
--
Fuel pump circuit 19-161

10:'~';~~'I:t~
~
2. Igniter system 19-44
combustion)

r
3. Fuel injector Refer to engine repair manual
_.
~
1. Electronic throttle Refer to engine repair manual
2. Fuel pump circuit 19-161
,
3. Igniter system 19-44 ..
Does not start well 1------
4. Spark plugs Refer to engine repair manual 1
I

II
5. Fuel injector Refer to engme repair manual I
-1
16 . Compression IRefer to engme repair manual j
V~li~~9h ._~~1·
__E_ie_c_t_ro_l_li_c-t_h~r~o~tt~le~~~~~~~ ~~~~~:~R=e=f=e=r_t-o=e=n=g=i=n_e~-r_e-p=a=i=r=m=a=n=u=a=I===~-1
1. Electronic throttle Refer to engine repair manual l
II idle speed high 2. ECU power supply system 119-159
f - - - - - - - - - - - - - - - - - - - - - - - ..- - + - - - - - - - - - - - - - - - - - - -
1
L ~-~~-=tra,-I-s--ta-rt-s-w-i-tc-h-. .._. +I_- ~_J
1. Electronic throttle Refer [0 engine repair m a n u a l ]

2·~~!L'_~e__c_t_o_r ._ Refer to engine repair manual 1

3 1
Ildle speed low Igniter system
~~-~-
1-4_.__C_o_m_p_r_e__ ~_~_n .
19-44

+_R_e_fe_f_to_e.n_g_in_e_r_e_p_a_ir_m_an_,u_a-1-
---1-I
1
'1 5. Fue! pump circuit 19-161
1-.- - - - - - - - - - - - - - - - ' - - + - - - - - - . - - - - - - - - - - - - - - - - - + - - - - - - - - - - - - - - - -
1. Electronic throttle R.efer to engine repair manual

I
I
ldle unstable _2._ _ Ec: U power supply system__
3. Fuel pump circuit
11199--116591 ....ji
1--------------------T-F-u-e-l-i~Je->c-t-o-r------·--- IRefer to engine [epa'lr m~-i~--I
IHunting 2~-Fu~l-p·-u-rm-·p--c-ir-c-u-it--·--··-· ··----··T19.161 1
I -3-.--Ig-,-'i-te·r,,--}-/s-t-e;;----------- ------119A4---·-~----· ----l
- - - - - - - - - - - - - - - - 1"--lgnite;system 119-44 I
f----.- I ""1
1Hesitation, poor acceleration 2. Spark plugs 1Refer to engine repair manual I
~ ~ __ ~~~.(j.I_~nlector - =~=I Ref~~~i~~-~~~a~- . - - -I
~~~el f=l.ump cjr~~ . 119-161 . 1

After fire 2 Spark plugs I Refer to engine repair manual 1

f--- --t-3_.~ Fuel injector - Refer to engine repair manual 1
. Engine stalling 1. Fuel pump circuit i
1-
(immediately. after start up) --+ . ~--+,1_1_9_->_16_1!!.
. __

Engine stalling 1 Fuel injector Refer to engine repair manual

(immediately after deceleration) 2. Engine control computer
 19-157

11Starter relay and starter

Related portion
r-----------------------------------------------.....,

STA
5
1

Starter relay
to meter-related circuit
ST

0--
Ignition switch Neutral switch
G27-24 (STA)

T
7//
IEngme
I
_ controller

L--'-- ---.J

Probable cause
Q; Neutral switch defect
I]) Starter relay defect
Q) Starter defect
® Wire harness, connector defect
IInspection 1:
IStarter signal inspection
ANL: I/O ENGINE CTRL 1110

NG
J OK -------7 Neutral switch defect
Starter relay defect

Inspection 2:
Wire harness and connector inspection JOK ~) Starter defect

Wire harness, connector defect

Inspection 1:
Carry out starter signal inspection
Ignition key switch ON
Starter signal (I/O motor: STA)

Standard:
Starter stopped Starter in operation
L
STA 0 1
r
19-158

Inspection 2:
Carry out wire harness inspection.
Ignition key switch OFF, remove the starter relay, crank the engine and check voltage

Standard:
Relay terminal 1 - frame 9 -14 V
,----
Relay terminal 2 - frame OV
Relay terminal 3 - frame OV
-~

Relay terminal 5 - frame 9 - 14 V

 19-159

• ECU power supply system

Related portion

A36 G27
IGN
9 (IGSW)
3 (BATT) 3 (E1)

EFl Engine G28

5 3 1 (+8) controller 2 (E01)
12 (+81)
1 2 19 (MREL) 1 (E02)

EFl main relay

/7/

Probable cause
CD Blown fuse
(]) EFl main relay defect
Q) Wire harness, connector defect

Inspection 1: NG
EFl and IGN fuse inspection --7 Replace fuse

OK

Inspection 2: NG ,
EFl main relay operation and continuity EFl main relay defect
inspection

OK\

.spection 3: NG
.~--------") Wire harness, connector defect
Harness continuity inspection

Engine controller defect

Inspection 1:
Carry out a fuse continuity inspection.
Remove the EFl fuse and IGN fuse

Standard: Continuity exists.

19-160

Inspection 2:
Inspect the EFl main relay_
(1) Inspect the EFl main relay operation_
Ignition key switch ON, operate the EF! main relay

Standard:
The EFl main relay makes an operating sound in coordination with the ignition key switch.

(2) Inspect for continuity between each of the terminals of the relay_

Ignition key switch OFF. remove the EFl main relay

Standard:
Relay terminals 1 - 2 Continuity
I
I
EFl main
Relay terminals 3 ~- 5 No continuity
! relay

(3) Inspect for continuity between relay terminals 3 and 5 when the battery voltage is applied
accross terminals 1 to 2_

Standard: Continuity exists.

Inspection 3:
Inspect for continuity of the wire harness.

Ignition key switch OFF

Standard:
IGN - A36-9 Continuity .~

L A39-19 - EFl main relay (2) Continuity

-------
j
EFl main relay (1) - frame Continuity
-~
f--~·-·----1
EFl main relay (3) - A36-1 Continuity
f-------- ·--------1
EFl main relay (3) - A36-2 I Continuity I
' - ---------!
I EFl - A36-3 Continuity I
L
C;~tin-l~--l
L G28-2 - frame
_ _ _'_ _ 1
G28-1 - frame
- ..
Contllluity
- - - - - . -..- - - - ; I
L- G_2_7_-_3_-_f_ra_n_l_e -'--__'""'_r'_O_ht_lIl_l_1I1_y_ _J
 19-161

• Fuel pump control system

Related portion

Engine
controller

2 (FC) ~2
!
,--~__ ~J
Circuit
opening
relay

Probable cause
CD Blown fuse
CD EFi main relay defect
CIJ Wire harness, connector defect
@) Fuel pump defect

Inspection 1: ~NG --~ Replace fuse

Fuse inspection
___I
OK

I Inspection 2: I NG
EFl main relay operation and continuity inspection r------~ EFl main relay defect
I
OK

------------~-, NG
.spection 3:
'arness continuity inspection jc------------'3> Wire harness, connector defect

OKl

Fuel pump defect

Inspection 1:
Carry out a fuse continuity inspection,
Remove the EFl fuse and IGN fuse,

Standard: Continuity exists.

19-162

Inspection 2:
Inspect the EFl main relay.
(1) Inspect the EFl main relay operation.
Ignition key switch ON, inspect the operation of the EFl main relay

Standard: The EFl main relay makes an operating sound in coordination with the ignition key switch

(2) Inspect for continuity between each of the terminals of the relay

Ignition key switch OFF, remove EFl main relay

Standard:
Relay terminals 1 - 2 Continuity EFl main
-.--.~---~~---c-------~-- -~-- ..
Relay terminals 3 - 5 No continuity relay

(3) Inspect for continuity between relay terminals 3 and 5 when the battery voltage is applied
accross terminals 1 to 2.

Standard: Continuity exists

Inspection 3:
Inspect for continuity of the wire harness.
Ignition key switch OFF

Standard:
EFl main relay (3) - T6-4 COn~H1Ult~

_~~ T6~~G28-14~__ __~Ontll~Ul1y 1

_._~28-22__=_ Circu~penin_~lay~1) Contlnult~ ~
Circuit opening relay (2) - GND Continuity ----1
T6-6 - Circuit opening relay (5) I Continuity I
Circuit openina relav (3) - 02-4
f--.-~.- -------':'-~
+------ContinultY--=J
-----t
'
I 02-5 - GND
' - - - . - .--
i Continuity j
Defect Causes When There is No SAS/OPS Error Di 3:>
Note:
If an error code or wrench lamp is flashing, repair it first.
-,......-.

Control type Phenomenon on vehicle Malfunction area' mode Checking method Corrective action
Brake switch unit:
Open fault
(Stucl, in depressed state, or
internal damage) ON/OFF check with analyzer Harness check or replace switch
Brake switch line:
Engine is always slow to r-ev up. Disconnection fault
(Even with the direction lever left in F (Harness, connector, fuse)
or R position and the brake applied, Accelerator sensor unit:
the engine is still slow to rev up) Internal damage Accelerator pedal position check
If not close to 0%, installation check or
Accelerator sensor installation: Check the opening degr-ee of the
replace sensor.
Link, installation part destroyed, accelerator pedal when not operated.
I damaged
SAS/OPS controller:
Travel and load
handing control
-le Coolcollec defecl
Lift raise switch unit:
- I Replace
I
(ASC) Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Lift raise switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Har-ness, connector')
Even if the lift is raised, the idle speed Switch ~lroLlnd line:
does not rise, Disconnection fault
(Harness, connectol')
I
Display setting:
Check settings with option set and
Lift idle up disabled, Idle up speed Change

L
tuning
tuning value low
SAS/OPS controller:
Controller defect
- Replace
,-----'------ -, -

-'
(0
J
-'
0)
w
 · Corrective action -\.
Control type Phenomenon on vehicle Malfunction area' mode Checking method (0
I
-\.
Load sensor ullit: (J)
Sensor defect .j::>.

Load sensor line I

Load sensor voltage check:
(Power supply, signal, ground): Ilf there is no change, perform a
Mount a load, ground the forks and
Disconnection fault harness check or replace the sensor.
check the change in voltage.
(Harness, connector)
Speed limit applies at high lifting height Short 01' link fault
(Harness, connector)
despite not being loaded
Check the setting content of the
Display setting:
maximum speed limiter, check the
Maximum speed limiter, Change
setting content of the speed limit
Speed limit setting enabled
setting.
SAS/OPS contmller:
- Replace
Controller defect
Travel and load
Load sensor unit:
handing control
Sensor defect
(ASC)
II.oad sensor line
Load sensor voltage check:
I (Power supply. signal, ground): Ilf there is no change, perfor'm a
Mount a load, ground the forks and
Iharness check or replace the sensor.

-+
Disconnection fault
check the change in voltage
(Harness, connector)
Short or link fault
Despite being loaded (Harness, connector)
at high lifting height the speed limit I Lifting height switch unit: - .
IH,me"
i------------r,:
does not operate.
I Disconnection fault (inter'nal damage, ION/OFF check with analyzer check oc ccpl"e eeow

Display setting:
Traveling limit setting disabled Check setting values with option set Change
Load sensing speed limit disabled
SAS/OPS contmller:

.
Controller defect [ - Replace
 ,.- . - I
Control type Phenomenon on vehicle MCilllmction area' mode Checkin~ ,thod Corrective action
Lifting height switch unit
Disconnection fault ON/OFF clleck with analyzer Harness check or replace switch
(Internal damage, stuck)
_.
Check the setting content of the
Speed limit applies when loaded I Display setHng maximum speed limiter, check the
despite being at a low lifting height Maximum speed limiter, speed limiter Change
setting content of the speed limit
setting enabled
Travel and load
handing control
(ASC) ---jI SASiOPSlmini lever controller-
Coclmllec delecl
setting.

- I Replace -
-- - --------------_._------ --------~---------------~------------
Check the setting content of the i
Display setting
ma)(imum speed limiter, check the Ch
.... Maximum speed limiter, speed limiter
setting content of the speed limit ange
Speed limit applies at all times setting enabled
regardless of lifting height or load setting.
SAS/OPS controller:
- Replace
Controller defect
Buzzer unit
Buzzer defect
Buzzer har-ness line
- Harness check or replace buzzer
(Lead-in side):
Buzzer sounds constantly Grourid short or link fault
(Harness, connector)
SAS/OPS controller
- Replace
Controller defect
Buzzer unit:
Buzzer related Buzzer defect 1

Buzzer harness line

- Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
OPS leaving seat warning does not (Harness, connector)
sound.
Display setting:
OPS leaving seat notification buzzer Check setting values with option set Change
setting disabled
SAS/OPS controller
- : Replace
LController defect
._- -_._---_.., , - - - _ . _ - - . - - - - - .-_.._---". ..L -

r.o
I
->.
m
01
 Control type Phenomenon on vehicle Malfunction area· mode Corrective action -'-
Checking method (0
!
-'-
Buzzer unit: O'l
Buzzer defect O'l
Buzzer harness line
- Harness check or replace buzzer
(Power supply side, lead-in side)
Disconnection fault
(Harness, connector)
Direction lever unit:
Traveling OPS return to neutral alarm Lever defect
does not sound Refer to "Traveling OPS does not Refer to "Traveling OPS does not
Direction lever signal
Disconnection fault
operate, cannot travel". Ioperate, cannot travel"
(Harness. connector)
Vehicle spec. setting:
USA specification enabled
-I Check setting values with option set. Change

I
:1-1
SAS/OPS controller":
- Replace
Controller defect
Buzzer related -

Bcme
Buzzerc,l,
defect
Buzzer harness line
- Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
(Harness, connector)

For cowl lever vehicles: Lowering lever switch: Refer to "Cowl lever vehicles: cannot
Material handling OPS return to Lever defect lower lift".
Refer to "Cowl lever vehicles: cannot
neutral alarm does not sound. Lowering lever signal: *: The material handling OPS return to
I lower lift"
Disconnection fault neutral is only a function for the
I
(Harness, connector) lowering lever on cowl lever vehicles.
_.
Vehicle spec setting:
USA specification enabled
Check setting values with option set. IChange
SAS/OPS controller:
- .1 Replace
Controller defect
!
- -
 -,
Control type Phenomenon on vehicle Mc..Jnction area' mode Checkin~ , 2thou Corrective action
I
Buzzer unit:
Buzzer defect I
Buzzer harness line
(Power supply side. lead-in side):
- I Harness check or replace buzzer
Disconnection fault
(Harness. connector)
Material handling lever potentiometer
unit: If there is no change. perform a
For mini lever vehicles: Lever defect Material handling lever potentiometer harness check or replace the
Material handling OPS return to Material handling lever line voltage check potentiometer
neutral alarm does not sound, (Power supply. signal, ground): Move the lever into forward and If none of the material handling levers
Disconnection fault reverse tilt positions and cheCk the move, refer to "Cowl lever vehicles.
(Harness, connector) voltage change mini lever vehicles: cannot perform
Short or link fault any material handling",
(Harness, connector)
Vehicle spec, setting:
Check setting values with option set Change
USA specification enabled
SAS/OPS controller:
- Replace
Controller defect
Buzzer unit:
Buzzer related Buzzer defect
Buzzer harness line - Harness check or replace buzzer
(Power supply side, lead-in side):
Fault (Harness. connector)
Parking brake switch unit:
Short fault
(stuck, internal damage)
Ilf there is no change. perform an
Parking brake detection mechanism:
ON/OFF check with analyzer, I installation check, harness check, or
Always short
Vehicles with multi display. multi
Parkirlg brake line: I replace the switch,
display OX:
Short fault
Parking brake reminder alarm does
(Harness. connector)
not sound, I

rc~:~:--
Display setting:
Parking brake reminder alarm setting Check settirlg values with option set
disabled,
SAS/OPS controller setting:
Not matched
- I Follow matching procedure to match.

SAS/OPS controller:
- Replace
Controller defect
Brake fluid (with OK monitor): -'
- Add brake fluid co
I
Low brake fluid level -'
m
-.J
 -------------_. -'-
Control type Phenomenon on vehicle Malfunction area' mode Checking method Corrective action c.o
Parking brake switch unit:
-- I
-'-
OJ
Open fault co
(Stuck in released state. internal
Vehicles with multi display. multi damage) If there is no change. perform an
display OX Parking brake detection mechanism: ON/OFF check with analyzer installation check, harness check, or
Parking brake reminder alarm Always released , replace the switch,
continues to sound even after the Parking brake line:
parking brake has been depressed, Open fault
(Harness. connector)
SAS/OPS controller:
- Replace
Controller defect
Buzzer unit:
Buzzer defect
Buzzer harness line - Harness check or replace buzzer
(Power supply side, lead-in side)
Vehicles with multi display, multi Fault (Harness, connector)
Buzzer related display OX
Vehicle speed sensor unit:
Parking brake return reminder alarm
Cannot detect low speed
Check sensor voltage and vehicle I
does not sound speed with the analyzer
(Internal damage) If there is no change, perform an
* First perform a "Parking brake • With the parking brake not returned,
Vehicle speed sensor line installation check or replace the
reminder alarm does not sound" even when the accelerator pedal is
(SPO+ side, SPO- side): sensor,
check. depressed, the alarm only sounds at
Link fault
speeds above 2 km/h.
(Harness, connector)
SAS/OPS controller:
- Replace
Controller defect
Meter unit (w'lth OK monitor):
- Replace
Vehicles with multi display, multi Meter defect
display OX: Brake fluid (with OK monitor):
Parking brake return reminder alarm
- Add brake fluid
Low brake fluid level
sounds on traveling,
SAS/OPS controller:
- I Replace
--_._--,---_.._----_.__._-~._---------_.
Controller defect
. ,
-
I Control type I Phenomenon on vehicle--"i--- '·Mclllu;ctlon·al:e~-:-mod~--'--i--····-'Checkin.<
" ';thod -----r-- Co~~ective action
I :1= dicator switch unit f F
Open fault (Internal damage)
Load indicator switch detection
mechanism (Mini lever, joystick):
Vehicles with multi display OX: If there is no change, perform an
When the load indicator switch is Detection part gap adjustment defect ION/OFF h k 'th I installation check, harness check, or
Load indicator switch line c ec WI ana yzer
pressed, the load is not displayed replace the switch (lever),
(Power supply, signal, ground):
Open fault
(Power supply, harness,
connector)
Load indicator switch unit
Short fault (Internal damage)
Vehicles with muiti display OX: Load indicator switch detection
Display If there is no change, perform an
When the vehicle is stopped, the mechanism (Mini lever,joystick): ION/OFF check with analyzer
function installation check, harness check, or
display continually shows load Detection part gap adjustment defect
replace the switch (lever),
indicator, Load indicator switch line (Signal): I
Short fault
(Harness, connector)

Carry ~ut rematching and check I Follow the procedure for matching,
operation I and rematch (cylinder bore, number of
Vehicles with multi display OX: Display setting: Load sensor voltage check cylinders, 0 point correction)
The correct load is not displayed, Cylinder bore, number of cylinders, 0 Mount a load, ground the forks and in cases where precision is required,
POint cOITection, calibration • check the change in voltage adjust on the load indicator matching

I
II
~
1 I At high lifting height, correct load I LOAD COMPENSATION screen,
cannot he calculated and the display Ilf there is no change during the voltage
flashes Icheck, perform a hal'ness checi( or
._ _,, ' ,____ I replace the sensor,

-"
<.0
I
-"
(J)
<.0
 ->.
Control type Phenomenon on vehicle Malfunction area' mode Checking method Corrective action (,0
I
->.
Torque converter oil temperature
sensor unit: "o
Open fault (Internal damage)
Torque converter oil temperature
Vehicles with multi display, multi
sensor line (Signal, ground): Start the engine and after leaving the
display OX: Harness check or replace sensor, or
Disconnection fault vehicle running for a while, check the
Torque converter oil temperature I'eplace SAS/OPS controller
(Harness, connector) indicator,
indicator stays at level -I,
+8 short fault
(Harness, connector)
SAS/OPS controller:
Controller defect
Torque converter oil temperature
Display sensor unit:
function Vehicles with multi display, multi Short fault (Internal damage)
display DX Torque conver1er oil temperature I Stop the engine and after leaving the
Harness check or replace sensor, or
Torque converter' oil temperature sensor line (Signal)' 'vehicle stopped for a while, check the
replace SAS/OPS controller
indicator continually displays Ground short faUlt indicatior,
overheat warning indication, (Harness, connector)
SAS/OPS controller:
Controller defect
0' I ' 'T If the TEMPGAUGE is set to NO on
Vehicles with multi display, multi I ~p ay settln g :rt 'I t t Check that the TEMPGAUGE on the I the option set screen, change it to
' Iay DX :
d ISP lorque conve t er
' 01 empera
bl d u r - e ,
option set screen 'ISY
set E
to S , and , 'y-ES ,an d I'f MTC on th e ana Iyzer 1/0
, emergency se tlng ena e
Torque converter oil temperature I SAS/OPS ' I1 _
, i ,
that the MTC on the analyzer I/O I OTHERS screen IS set to 1, perform a
indicator' does not display, C t- II ~odnttro e(I , TC I' h rt) LOTHERS screen is set to 0 [harness cheek or replace the SASI
-1._______ on 10 el e ect M
__'________ _._.__ _ .
I',

. Ine s O l OPS t 11
I I
_.~ ..LI con ro er, ...J
 -
Phenomenon on vehicle
-r---; ._- -
Corrective action
Control type ;'", unction area' mode Checking' "loa
fuunit:
Burst, tire pressure adjustment - Adjust or replace
defect
Lock cylinder unit:
Leak, cannot lock
(Internal damage) Check the locked status with an active
Replace
Lock cylinder locked status: test.
Installation part damaged or
destroyed
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check: i If there is no change, perform an
(Power supply, signal, ground):
Peform lili relief and check the I illstallation check or replace the
Disconnection fault
(Harness, connector)
change in voltage Isensor,
Short or leak fault I

Feels unstable when traveling (Harness, connector)

I
Swing lock (Traveling lock has become difficult or Lifting height switch unit
no longer possible) Disconnection fault ON/OFF check with analyzer Harness check or replace switch
(Internal damage, stuck)
Yaw rate sensor unit:
Reduced sensitivity, voltage stuck Yaw rate sensor voltage check:
(Internal damage) Check that the voltage is
Installation check or replace sensor
Yaw rate sensor line (Signal): approximately 2,2 to 2,8 V when the
Leak vehicle is stopped,
(Hamess, connector)
I
1
r--
Vehicle speed sensor unit:
Cannot detect low speeds i
I
(Internal damage) Ilf there is no change, peliorm an
Check sensor voltage and vehicle
Vehicle speed sensor line installation check or replace the
speed with the analyzer
(SPD+ side, SPD- side) sensor,
Leak fault
(Harness, connector)
SAS/OPS controller:
- [ Replace
Controller defect

---'
<.0
I
---'
0--1
---'
 ->.
Control type Phenomenon on vehicle Malfunction area· mode Checking method Corrective action (D
I
->.
Lock cylinder unit: Check the locked status with an active -....J
Replace N
Lock stuck (internal damage) test.
-'------,.
Swing lock solenoid line (SWN+,
SWN-):
Disconnection fault
Check the locked status with an active
(Harness, connector) Harness check or replace solenoid
test
Solenoid ground line (E01, E02)'
Disconnection fault
(Harness, connector)
Load sensor unit:
Sensor defect
Swing lock continually activates while Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Swing lock
traveling and material handling
Disconnection fault
Peform lift relief and check that the Iinstallation check or replace the
operations, or swing lock activates voltage rises. sensor.
frequently. (Harness, connector)
Short or leak fault I

(Harness, connector) I
I
rLifting height switch unit: -
I t-
I
I
I Disconnection fault (internal damage, ION/OF F check with analyzer i Harness check or replace switch
I
stuck)
-'
Yaw rate sensor unit·
Yaw rate sensor voltage check' I
Check that the voltage is ., .
Reduced sensitivity . t I 22 t 2 8 V h th [Instaliatlon check or replace sensor
approxlma e y . o. w en e
(Internal damage)
vehicle is stopped
SAS/OPS controller:
- Replace
Controller defect
--,-, _.
 - ,-----
Control type Phenomenon on vehicle ~ vI Jnction area' mode Checkin!=: ' trlOU Corrective action
Tilt angle sensor unit:
Tilt angle sensor voltage check:
Sensor defect If there is no change, perform an
Tilt to fonNard and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor,
change,
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
-
Does not match actual status rematch
(rematch)
Automatic fork leveling switch unit:
Open fault (internal damage)
Forward tilt automatic fork leveling Automatic fork leveling switch
does not stop, detection mechanism (mini lever,
Tilt control (Continues to tilt to the forward most joystick)
tilt position without stopping at the ON/OFF check with analyzer, Harness check or replace switch
Detection part gap adjustment defect
level position) Automatic fork leveling switch line
(Power supply, signal, ground):
Disconnection fault
(Harness, connector)
CN tilt control valve: Turn the tilt solenoid OFF and operate If forward tilt can be performed,
Stuck (internal damage) to forward tilt using an active test. replace the CN tilt control valve,
Display setting (mini lever, JOY stick)
3/4 way change over specification is Check the option set content. , Change
I I
I set to 2/3 way change over setting
AS/OPS contmller-
Controller defect
- I Repla"

--'-
co
I
--'-
-.J
W
 Malfunction area' mode Checking method Corrective action -"
Control type Phenomenon on vehicle c.o
I
-"
Load sensor unit: I '!
Sensor defect I .j:>.

Load sensor' line

Load sensor voltage check Ilf there is no change, perform an
(Power supply, signal, ground)
Disconnection fault
Pefol'm lift relief and check that the
voltage rises
["OII'bOO
sensor
check oc copleco tha
(Harness, connector)
Short or leak fault
(Harness, connector)
Load sensor no-load matching value'
I Follow matching procedure to
Forward tilt automatic fork leveling Does not match actual status -
rematch
does not stop. (rematch)
r
Tilt control '--
(Stops at a position slightly off the level Tilt angle sensor unit:
Tilt angle ::;ensor voltage check:
position) Sensor defect If there is no change. perform an
Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
Does not match actual status
- rematch.
(rematch)
AS/OPS controller:
- Replace
Controller defect
Control type Phenomenon on vehicle ,1\ Jnction area' mode Checkin~ .
- the.. __ Corrective action
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground)
Check that the voltage rises on lift installation check or replace the
Disconnection fault
relief. sensor,
(Harness, connector)
Short or leak fault
(Harness, connector)
Load sensor no-load matching value:
Follow matching procedure to
Does not match actual status - rematch.
(rematch)
Forward tilt automatic fork leveling
does not stop. Tilt angle sensor unit:
Tilt angle ,;ensor voltage check
Tilt control (Stops at the position where the Sensor defect If there is no change, perform an
Tilt to forNard and backward tilt
automatic fork leveling switch is Tilt angle sensor installation: installation check or replace the
positions and check the voltage
pressed) Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
-
Does not match actual status rematch
(rematch)
-
Lifting height switch unit
Disconnection fault (internal damage ON/OFF check with analyzer, Harness check or replace switch
stuck)
SAS/OPS controller:
- Replace
Controller defect

-'-
<.0
I
...>.
-,j
c.n
Control type Phenomenon on vehicle
.- -
I Malfunction area' mode
Automatic fork leveling switch unit:
Open fault (internal damage)
r-
'I
Checking method r== Corrective action -"
<0
-"
I

-.....j
0)

Automatic fork leveling switch i

detection mechanism (mini lever, I
joystick):
ON/OFF check with analyzer i Harness check or replace switch
Detection part gap adjustment defect
Automatic fork leveling switch line I
(Power supply, signal, ground)
Disconnection fault
(Harness, connector)
I I
Mast backward tilting speed is not
limited. Turn the tilt solenoid ON/OFF and If there is no change in the backward
Tilt control CN tilt control valve:
Or, backward tilting speed is always operate to backward tilt using an active tilting speed when ON/OFF operated,
Stuck (internal damage)
slow. test. replace the CN tilt control valve.
I

Lifting height switch unit: I

Disconnection fault (internal damage, ON/OFF check with analyzer i Harness check or replace switch
stuck)
,
Display setting
I
(mini lever, joystick):
Check the option set content. : Change
3/4-way change over specification is I

set to 2/3-way change over setting I

SAS/OPS controller:
Controller defect
- I Replace
Control type Phenomenon on vehicle
- -, rv, -
,ilctlon area' mode
,.

Checkin l•
--
o;thc,u Corrective action
-
Tilt angle sensor unit:
Tilt angle sensor voltage check:
Sensor defect r If there is no change. perform an
Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: . Follow matching procedure to
-
Does not match actual status rematch.
(rematch)
Automatic fork leveling switch unit:
Open fault (internal damage)
Mini lever, joystick vehicles:
Automatic fork levellng switch
Backward tilt automatic fork leveling I
detection mechanism (mini lever,
does not stop, (Continues to tilt to

Mini lever
backward most tilt position without
stopping at the level position)
joystick):
Detection part gap adjustment defect
ON/OFF check with analyzer IHom'" oheok " cep'"e ewitoh
function Automatic fork leveling switch line
(Power supply. signal, ground)
Disconnection fault
(Harness. connector) I
Display setting (mini lever, joy stick)
• 3/4-way change over specification
set to 2/3-way change over setting
• Backward tilt automatic fork leveling
Check the option set content I
I
Chepge

is deactivated
SAS/OPS controller:
- I Replace
Controller defect
--
Mini lever, joystick vehicles: Refer to forward tilt automatic fork I
I
'"olipg doO' pot ,top (,top, et th

L
Backward tilt automatic fork leveling
- -
does not stop. (Stops at a position position where the automatic leveling
slightly off the level position) switch is pressed).
- .

->.
I'.D
I
->.
:--I
-..j
 ->.
Control type Phenomenon on vehicle Malfunction area' mode Checking method Corrective action CD
I
->.
Tilt angle sensor unit: ---J
Tilt angle sensor voltage check:
Sensor defect If there is no change, perform an co
Tilt to forward and backward tilt
Tilt angle sensor' installation: installation check or replace the
positions and check the voltage
Mini lever, joystick vehicles: Link, installation part destroyed, sensor,
change,
Backward tilt automatic fork leveling damaged
does not stop, (Stops at the position Horizontal matching value for tilt angle
where the automatic fork leveling sensor: Follow matching procedure to
-
switch is pressed) Does not match actual status rematch,
(rematch)
SAS/OPS controller:
- Replace
Controller defect
Lever change over switch unit:
Open fault (internal damage)
Mini lever Lever change over switch detection
function mechanism (mini lever):
Detection part gap adjustment defect ON/OFF check with analyzer Harness check or replace switch
Lever change over switch line
(Power supply, signal, ground):
Mini lever 3/4-way (2/3-way) change Disconnection fault i
over specification: (Harness, connector)
3-way (2-way) operation even when
the lever change over switch is
Lever change over relay 1 or 2 unit' ·1
Stuck, welding fault (internal
pressed, (Does not change over-) I
damage) , I
L ever c h anqe over' re Iay 1 or 2 ' I Check the chanqeover
primary, ~
status With an
I Harness check or replace relay
I side line - , active test
I
I
Disconnection fault I
i
(wire, connector)
i
SAS/OPS/mini lever controller:
- -I Replace
Controller defect
i
 Control type .,.... Phenomenon on vehicle r, I\;,
----'--------,-------'
Jnction area' mode
I
--
Checkir 'elik~ "1 Corrective action
Lever change over switch unit: 1I
Ground short fault (Internal damage)
Lever change over switch detection
mechanism (mini lever):
Detection part gap adjustment defect ON/OFF check with analyzer Harness check or replace switch
Lever change over switch line
(signal)
I Ground short fault
Mini lever 3/4-way (2/3-way) change (Harness. connector)
over specification: Lever change over relay 1 or 2 unit:
4-way (3-way) continues to operate Stuck, welding fault (internal )
even though the lever change over damage)
switch has been operated. (Stays Lever change over relay 1 or 2 primary Check the changeover status with an 1 Harness check or replace relay
changed over) active tesl:.
side lower line:
Mini lever Ground short fault 1

function (wil'e, connector) I

I
I-----~-~---- --~--~i--
,: I
i Display setting
Number of attachment levers is not Check thE! option set COlltent. Change
set to 5 way
SAS/OPS controller:
Replace
Controller defect
Mini lever 2/3-way change over
speci fica tion: Display setting
During ATT1 operation and high Number of attachment levers is not I Check the option set content, 1 Change
lifting height, and when loaded. ATT1 set to 2/3-way

theek th~ OPIiO~:~t conte:---tCh,nge

stops and pUll-side operation is slow,
3-way (4-way) specifcation
Although ATT1 (ATT2) is operated, it
Display setting,
Number of attachment levers is not I
I -l-...
does not work, ..__........l.-
set to 3-way .(4-way)
_ , --------------~----

->.
C.D
I
->.
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" C.D
 ...>.
Control type Phenomenon on vehicle Malfunction area' mode Checking method Corrective actioll <D
I
...>.
Tire angle sensor unit: I co
Sensor defect Tire angle sensor voltage check: Ilf there is no change, perform an o
Tire angle sensor installation: Operate the steering and check the . installation checl, or replace the
Looseness of the attachment part, change in voltage sensor,
damage, bearing housing damage
Tire angle sensor matching value:
Follow matching procedure to
Does not match actual status -
rematch
(rematch)
Steering angle sensor unit:
Knob moves out of alignment into a Sensor defect
Knob ON/OFF check with anaiyzer Harness check or replace sensor
certain position, Steering angle sensor installation:
compensaiton
(More than 10' off the straight ahead Cam or steering wheel defect
control
posit'lon)
Using an active test, turn the knob
compensation SOL ON and OFF and
operate the steering at the tire end,
Knob compensation valve unit: SOL ON: check that the steering
. Replace
Leak, stuck, (internal damage) wheel can be turned freely.
I SOL OFF Check that the steering [

I wheel cannot be turned freely i

(steerrng is heavy)
I
I L
-~
SAS/OPS controller
- I Replace
Controller defect
Control type Phenomenon on vehicle 1- - lVI, unction area' mode Checking
-thvu Corrective action
Tire angle sensor unit:
Sensor defect Tire angle sensor voltage checl<: If there is no change, perform an
Tire angle sensor installation: Operate the steering and check the I installation check or replace the
Looseness of the attachment part, change in voltage Isensor.
damage, bearing housing damage
Tire angle sensor matching value:
I Follow matching procedure to
Does not match actual status -
rematch.
(rematch)
Steering angle sensor unit:
Sensor defect
ION/OFF check with analyzer I Harness check or replace sensor
Steering angle sensor installation
Cam 01" steering wheel defect I
Using an active test, turn the knob t
compensation SOL ON and OFF and
I
operate the steering at the tire end.
Knob compensation valve unit: SOL ON: Check that the steering
Replace
Knob Knob position is out of alignment. Leak, stuck, (internal damage) Wheel can be turned freely.
compensation (Knob position is not constant when SOL OFF: Check that the steering
control traveling straight ahead) wheel cannot be turned freely
(steering is heavy)
PS cylinder system link defect:
Eccentric pin, kingpin defect
- I Replace

Vehicle speed sensor unit:

Cannot detect low speed (internal
damage)
Vehicle speed sensor installation:
High speed not detected correctly Ilf there is no change, perform an
Check sellsor voltage and vehicle
I (sensor tip has metallic particle installation check or replace the
speed with the analyzer
adhered) sensor.
Vehicle speed sensor line
(SPD+ side, SPD- side): I
Leak fault I
(Harness, connector) I
SAS/OPS controller
Controller defect
- I Replace
- I I

->.
CD
I
->.
co
-l.
 F
.....i.
Control type Phenomenon on vehicle Malfunction area' mode Checking method Corrective action CD
I
~~- .....i.
Fuse. co
ECU+B fuse blown I - ICheck for blown fuse N
ECU-IG fuse blown I --
Meter communication line I I
Ground short I
(Harness, connector) I
Disconnection fault
(Harness, connector) - Harness check
SAS/OPS IG line, +B l'lne, ground
system:
Disconnection fault
Wrench lamp is lit continually.
(Harness, connector)
Battery unit:
Check battery voltage with the Keep the engine at high speed for a
Low voltage, intake heater, large
analyzer. while.
current auxiliary equipment operation
SAS/OPS controller setting: Follow matching procedure to
-
Not matched rematch.
Meter
Meter unit:
Meter defect I
- Replace

SAS/OPS controller I I
- I Replace
Controller defect
I
Meter power supply line:
The wrench lamp does not light even Disconnection fault - Harness check
when the ignition key switch is turned (Harness, connector)
ON. Meter unit:
- Replace
Meter defect
Hour meter start fuse:
Not connected
Hour meter start signal line: - Harness check or replace fuse
Hour meter is not displayed. Disconnection fault
(Harness, fuse)
Meter unit:
- Replace
Meter defect
.- - ---"------ -
I Control type -k '----.-,...-.-
Phenomenon on vehicle --J- _ "'----'-'-'----r--------'
,unction area' mode _I Checkin~ hou ~ Corrective action . _ . _ -

t Lift lower switch unit iI .---

l, Open fault
(Switch mounted incorrectly,
I
I internal damage, stuck)
Lift lower switch line
Disconnection fault
ON/OFF check with analyzer IHarness check or replace switch
(Harness, connector)
Switch ground line:
Disconnection fault
For cowl lever vehicles: (Harness, connector)
!
Cannot lower the lift,
CN lift lower lock valve Using an active test, turn the lift lower If the lift cannot lower by lower
Stuck (internal damage) lock solenoid ON and perform lower operation replace the C/V.
I operation
Seat switch unit:
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground)
Oiscormection faull
OPS (Harness, connector)
Forward tilt switch unit:
Open fault
(Switch mounted incorrectly, I
internal damage, stuck) I
Forward tilt switch line , .
' t' f It ON/OFF check With analyzer Harness check or replace SWitch
DIsconnec ion au
(Harness, connector) I
Switch ground line. I
For cowl lever vehicles: Disconnection fault
Cannot perform forward lill. (Harness, connector) I
I CN tilt control valve ·------rTllin the@ solenoid ON and operate 1-'- - - - - - - - - - - - -
Stuck (internal damage) I to forward lill using an active test [ replace the CN tilt control valve.
Seat switch unit
Open fault (internal damage)
Seat switch line
(Signal, ground):
IION/OFF check With analyzer Harness check or replace switch

Disconnection fault
IL-_---L ~(Harness, _connector) _ I

-"
<.0
I
-"
co
w
 ~
Control type Phenomenon on vehicle Malfunction area' mode Checking method Corrective action (CJ

I
I
~
Backward tilt switch unit co
.)::>.
Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Backward tilt switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
Switch ground line:
Disconnection fault
For cowl lever vehicles: (Harness, connector)
Cannot perform backward tilt.
Turn the backward tilt lock solenoid If backward tilt cannot be performed,
CN backward tilt lock valve
ON and operate to backward tilt using replace the CN backward tilt lock
Stuck (internal damage)
an active test. valve.
OPS Seat switch unit:
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
For cowl lever vehicles:
Turn the unload valve solenoid OFF
and perform raising operation using
Cannot perform material handling eN unload valve'. an active test. If raising cannot be performed, replace
except for lift lower. Stuck (internal damage) For mini lever vehicles: . I the CN unload valve.
Turn the uclo'd ,,',e wlec"d ON I
and perform raising operation using
an active test.
I I
Control type Phenomenon on vehicle
-rv, ,unction area' mode Checkin ethv-l Corrective action
CN tilt control valve: Turn the tilt solenoid OFF and operate If forvvard tilt can be performed,
Stuck (internal damage) to forward tilt using an active test. replace the eN tilt control valve,
f------',
Turn the backward tilt lock solenoid
CN backward tilt lock valve: If backward tilt can be performed,
OFF and operate to backward tilt using
Stuck (internal damage) replace the CN tilt control valve,
an active test.
Using an active test, turn the lift lower
CN lift lower lock valve: If lowering can be performed, replace

t-
lock solenoid OFF and perform lower
Stuck (internal damage) the CN lift lower lock valve,
operation,
For cowl lever vehicles:
Turn the un',oad valve solenoid ON
and perform lift raising operation
Material handling OPS does not CN unload valve: using an active test If raising can be performed, replace
OPS
operate, Stuck (internal damage) For mini lever vehicles: the CN unload valve,
Turn the unload valve solenoid OFF
and perform lift raising operation
using an active test.
Seat switch unit:
Short fault (internal damage) I
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground)
Disconnection fault
(Harness, connector)
SAS/OPS controller:
- I Replace
Controller defect
I ..

CD
I
~

co
U1
 --'
Control type Phenomenon on vehicle Malfunction area' mode Checking method I Corrective action ~
I
--'
Seat switch unit: co
(J)
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
For cowl lever vehicles:
COWl lever, mini lever vehicles:
Turn the unload valve solenoid OFF
No material handling can be
and perform lift raising operation
performed
CN unload valve using an active test. [If raising cannot be performed, replace
Stuck (internal damage) For mini lever vehicles: the C/V unload valve.
Turn the unload valve solenoid ON

OPS I
SAS/OPS controller:
Controller defect
Forward travel interrupt relay unit
,
and per"form lift raising operation
using an active test.

~
l----
I Replace
-tIlf forward travel can be performed,
Stuck (internal damage, welded)
Turn the forward and reverse Iravel
Ireplace the forward !I'avel interrupt
Reverse travel int8l'rupt relay unit I relay
interrupt relays ON and operate
Stuck (internal damage, welded) Ilf reverse travel can be performed,
forward and reverse travel using an
Relay secondary side line: replace the reverse travel interrupt
active test
Short fault relay.
(Harness, connector) Or perform a harness check.
Traveling OPS does not operate. Seat switch unit:
I
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
SAS/OPS controller:
- Replace
Controller defect
I
Control type Phenomenon on vehicle Jnction area' mode
.._----
Checking thl>,",
- Corrective action
Fuse:
- Check for blown fuse
Shift fuse blown
Forward travel interrupt relay unit:
Open fault
If forward travel cannot be performed,
(inter'nal damage. welded)
Turn the forward and reverse travel replace the forward travel interrupt
Reverse travel interrupt relay unit:
inter'rupt relays OFF and operate relay If reverse travel cannot be
Open fault
forward and reverse travel using an i performed. replace the reverse travel
I (internal damage. welded)
active test I interrupt relay. Or perform a harness
Relay secondary side line
I Open fault ! [CheCk
I- - - - - - -
(Harness. connector) I I
..-----------i-------.------------------.--- ------~
Seat switch unit I I
OPS Cannot travel.
. Open fault (Internal damage) I i
Seat switch line i - . .
(8 I d) ION/OFF check with analyze r I Harness check or replace sWitch
Igna. groun :
Disconnection fault I i
(Harness. connector) ,
Direction lever unit:
Open system fault (internal damage)
Direction lever signal line: ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
8A8/0P8 controller:
- Replace
Controller defect
-

-'
<.0
I
-'
OJ
-.J
Control type Phenomenon on vehicle Malfunction area' mode Checking method Corrective action --"
(!)
I
Torque converter interlock relay main -'-
co
unit for forward movement: Check the harnesses co
An open circuit (internal damage) If the vehicle cannot travel forward,
Torque converter interlock relay main replace the torque converter interlock
unit for backward movement: - relay for forward movement
The vehicle cannot travel An open circuit (internal damage) If the vehicle cannot travel backward,
Relay secondar"y line: replace the torque converter interlock
An open circuit I relay for backward movement,
I (harnesses, connectors)
SAS/OPS controller
-L -
I
I Replace the controller
Internal damage
Torque I
converter SAS/OPS contmller is set: I -
ISet the controller again according to
interlock Option set is not set the option set pwcedure,
I

Torque converter interlock relay ma~1

unit for forward movement: '
rCheck the harnesses,
If tile vehicle cannot travel forward,
An open circuit (Internal damage)
replace the torque converter interlock
The torque converter interlock does Torque converter interlock relay main
- relay for forward movement
not operate, unit for backward movement:
If the vehicle cannot travel backward,
An open circuit (internal damage)
replace the torque converter interlock
Relay secondary line:
relay for backward movement
Frame short (harnesses)
SAS/OPS controller:
Internal damage
- IReplace the controller
Defect Causes When There is No ASC Error Display<

Note:
If an error code or wrench lamp is flashing, repair it first.

Phenomenon on vehicle Malfunction area' mode Checking method Corrective action

NMR switch unit:
Switch defect
NMR switch line
I Harness check or
Disconnection fault
Occaisonally full speed is not reached ON/OFF check witl, analyzer replace switch. or adjust switch, adjust and
(Harness, connector)
even with the accelerator pedal fully r'epair mechanical parts.
NMR switch adjustment
depressed. (NMR speed not acheived) Adjustment defect, seal bolt position
defect or some other mechanical defect
1----

f~PI'CO
-----~-

ASC controller: ~

Controller defect
Idle switch adjustment:
- I Switch adjustment
Adjustment defect or mechanical defect
1--
Diesel engine model:
Accelerator sensor adjustment, or, if a fault
occurs after sensor replacement, turn the
Accelerator sensor:
ignition key ON with the accelerator sensor
Sensor catching, mistake in procedure
connectors removed, in order to create an
during sensor replacement (when the
Idle speed Is higher than specified speed error once.
sensor is beng replaced, if a C4 series Check accelerator sensor voltage with the
even when the accelerator pedal Is not Then turn the ignition key OFF, connect
error is not created by turning the ignition analyzer.
depressed, connectors and turn the ignition key ON
key ON while the sensor connector is
Gasoline engine model:
disconnected, the fully closed position
Accelerator sensor adjustment, or, if a fault
leaming value is not reset)
occurs after sensor replacement, remove
the battery plug for more than 10 seconds,
then reconnect it,
ASC controller:
- Replace
Controller defect
Drop in battery voltage:
Check battery voltage with the analyzer. Battery replacement
Battery life, intake heater, after'heat
Engine rev up is poor or slow.
ASC controller:
- Replace
Controller defect

<.0
I
~

co
<.0
 T
->.
Phenomenon on vehicle Malfunction area' mode I Checking method Corrective action (0
I
->.
IGN, +8 line (0
Disconnection fault o
(Harness, connector, fuse)
Check battery voltage with the analyzer Harness check or replace fuse
GNO line complete loss:
Does not rev up from idling Disconnection fault
(Harness, connector)
ASC controller:
- Replace
Controller defect
 E

WIRING DIAGRAM

~HAPTE_~1 INTRODU~_T_I~~
[C-HAPTER2illCrRICALWIRING RO-UT-IN-GS-A-N-OR-E-UX-YLOCATIONS

I CHAPTER 3 SYSTEM CIRCUITS------

I _. ' __.. . '.'.' ' _ _ .,_" '_. _._.",_._, .~ _

ICHAPTER 4 GROUND POINTS-

l ". ._~. __ . ~ _ _ . _
r-- --. -----."~-~- .~

LCHAPl'~~5_~~S~~~()R_~?yv~RSUPPLY __"_ _
@HAPTER 6 CON~~C!?~_LIST
 E1-1
INTRODUCTION

CHAPTER 1 INTRODUCTION

CHAPTERS OF THIS SECTION... E1-2

HOW TO READ CHAPTERS

Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS
ELECTRICAL WIRING ROUTINGS E1-3
RELA'( LOCATIO~~S
JUNCTION BLOCK (JIB) I RELAY BLOCK (RIB) E1-4

Chapter 3 SYSTEM CIRCUITS

POWER SUPPLY CIRCUIT E1-6
REFERENCE PAGE E1-10

Chapter 4 GROUND POINTS

GROUND POINTS E1-11

Chapter 5 FUSES FOR POWER SUPPLY

FUSES FOR POWER SUPPLy E1-11

Chapter 6 CONNECTOR LIST

CONNECTOR LIST E1-12
WIRE TO WiRE E1-13

ABBREVIATIONS : E1-14
GLOSSARY OF TERMS AND SYMBOLS E1-15
E1-2
INTRODUCTION
CHAPTERS OF THIS SECTION
This section consists of the following 6 chapters:

Chapter 1 INTRODUCTION Gives brief explanation of each chapter, provides instructions on how
to use this manual, and defines the abbreviations used in the electrical
c;ircuit diagrams.

Chapter 2 ELECTRICAL WIRING Electrical wiring routings show installation positions, ground points,
ROUTINGS and connector numbers, and part names related to wire harnesses,
RELAY LOCATIONS connectors, relay blocks and junction blocks used in the forklift, such as
in the engine room, instrument panel and mast area.
Relay locations show design drawings and internal circuit diagrams
related to relays, relay blocks (RIB), junction blocks (JIB), fusible links
(F/L) and junction connectors (J/C).

Chapter 3 SYSTEM CIRCUITS Show power supply circuit diagrams and wiring diagrams for each
system, such as the engine.
(Only wiring information for complete circuits is shown.)

Chapter 4 GROUND POINTS Show related systems for each ground point.

Chapter 5 FUSES FOR POWER Show power distribution from each power supply (fuse or fusible link) to
SUPPLY various systems.

Chapter 6 CONNECTOR LIST Shows shapes and part numbers of connectors used in electrical wiring
routings and electrical wiring diagrams.
 E1-3
INTRODUCTION
HOW TO READ CHAPTERS
Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS
ELECTRICAL WIRING ROUTINGS
Electrical wiring routings show installation positions, ground points, connector numbers, and part names related
to wire harnesses, connectors, relay blocks and junction blocks used in the forklift.

~~ ~--- - -- - -------- ---- -1'-- --

(Connector codes are the same as those used in the electrical wiring diagrams.)
-~-~ -~-'---- --------l
I E2 10 :;;/[A~c.':.1:".r'lw'R'"hROU1,,''.::'._______ I clt:CTHjC/\lWIRINI._;ROU1INc,:~ E2-11 1

I F- ROI..J1 BOO) :;~ ~ ~~< ~~f~ r>-.... e v::' AS'" '<:J 'o>(.·;HrJ- H l£I ' r. i

I, [B~] i ) \ [K]-~!; :,~:-~ ~':~ : : ~';~

:'~~' ':J"'I0"'''(O~''CTC«
~ ::'::::~::::~':".:::::'::- [H]
V
.0£1 """'~""O'''CC''_' v;;; .'.•.."".•"•• """
I _ . _ [':1~,.r';I':RH
i~) [~r!Jf'i'I1;::O'<"f(T("
.'_~~'.i c::-,."',,",~C~'J·.~,,c,~..,., r II
V

1 • .•
I '-.~~.~, L"','_\~:OC-·"";",!-,-,," I , ~

li LI j . .
" ,
,"
"..
", CC] I
'
:~~::c;·:;":::::';~:~,:
'~~, "';;"'.G'.'!;E/''''C.p
LUJ
l
:.::':::2' c·-'" :;·J.~·U,'i)(;,

_-===.\ "H1l"'-,,-E"0'0'"
1.5 0_1<1 ~:\UIU~'>;'1

.~.'·"'·'.'S""'.ll"-'ir,-o.,
_.>i':... \ ,.I>;'"~·.CL.t"''i~1C''' ,~,
-[L]
I( ~-0 I~ ~r ~ I I '¥~-:. ~'":'~:"~'F'~~~::,~~'~"'::."Of'''

'"~-~"~r
.' er- --- -

r~l

,l;',
~ €v~ ~~
I[ (~.' "_"~ \lO'. LPH"r~C,;'"i

., I! :3 "r"--"~"'";"2""cr-r-""

/ ';~~ leE,a '0'::- '~":; i

~~~
LGJ
rOl
- -
r~
~-
J

I1
- [ VJ

[,.1'\] Title [G] Ground point code

Indicates a location on the forklift. indicates a ground point code.
'Wire harness [H] Ground point name
Indicates a wire harness name. Indicates a ground point name.
[e] Reference page for electrical wiring routing [I] Harness to harness connector
Indicates a reference page showing a wire Indicates a connector code that joins two wire
harness iocation when the wire harness continues harnesses.
to the different electrical wiring routing. [J] Wire harness names
[D] Junction block Indicate two wire harness names for a wire
Indicates a junction block name and a connector harness and wire harness connection.
code to be connected. [K] Part connector
[E] Junction block connector Indicates a connector code connected to a part.
Indicates a connector code connected to a [l] Part name
junction block. Indicates a part name connected to a connector.
[F] Wire harness and junction block connection
Indicates a junction block name and a wire
harness flame to be connected.
E1-4
INTRODUCTION
RELAY LOCATIONS
Relay locations show connectors connected to junction blocks, relays, fuses and internal circuit diagrams.

E2:;-;-l
_ _ _ _ _ _ _R_E--'L_A'i..
' L--'O--'C_A_TI_O_r'ls -_-_-~----j !
INCTION BLOCK LEFT STEPIINNER CiRCUIT SEE PAGE E224)
[B] i
,~----- --- - ,--~-"'

[C] I
[A]
!I I
J
------_/
II
I I
I
I
I

I [F]

I
I

I
I

I -[E] II

L_~
-..
---~ . ------~-
~ ======-=------- ~~j L.....- ~ ~ .J

r
I E2-24
I
JUNCTION BLOCK IINNEf~ CIRCUIT) (113)

I
I
I
I [GJ- JJ@ -- ~-'-c.,"

::: ~==-:-.-~-'~-.-- .--~CJ==-~~----

n@
"(iD-
lJt§

1~,@) - -

'I (ill
1')@
1'31::;:ID
Tg@
 E1-5
INTRODUCTION

[A] Junction block /relay block

Indicates a junction block or relay block name, its location and a reference page for an internal circuit
diagram.
[8] Connector code and color
Indicates the code and color of a connector connected to a junction block.
[e] Connector part number
Indicates the part number of a connector.
[0] Connector shape and terminal number
indicates a connector shape on the junction block side.
Numbers indicate terminal numbers.
[E] Connector shape and terminal number
Indicates a connector shape on the wire harness side.
Numbers indicate terminal numbers.
<Fuse
Indicates a fuse name and capacity.
Terminal 1 is on the primary side and terminal 2 is on the secondary side.
[G] Internal cirCUit diagram
Indicates an internal circuit diagram of a junction block.
[H] Connector code and terminal number
Indicates a connector code and a terminal number connected to a junction block.
E1-6
INTRODUCTION
Chapter 3 SYSTEM CIRCUITS (1)
SYSTEM CIRCUITS
A system circuit consists of a power source circuit diagram and respective system circuit diagrams. A power
source circuit diagram shows the connections from the power source to fuses. A system diagram shows the
connections from fuses to ground points of each system.

[A]
I
\
E3-12

"
S
QC

e
"
u
o
z
w
Z

[C] Cl]
 E1-7
INTRODUCTION
[A] Section page [G] Page-to-page connection code
Indicates the page number for the section. Indicates a wire harness continues onto the
[B] System title following page from the matching code.
Indicates a system name.
[H] Harness to harness connector
[e] Part name and connector code
Indicates a part name and connector code to be Indicates a connector code that connects two wire
connected.For connector shapes, refer to chapter harnesses.
6 CONNECTOR LIST. For the connector shape, refer to chapter 6
CONNECTOR LIST.

;
I~----'~-- ------- ----------··--------l - ---------------------------------------l
C7 Part connector \' _ Harness to harness connector \
cj ~--. Terminal number

l I
lo~~t::ire harness in which the connector is I, 7)Ei}-

Example: "C" indicates a connector used in

v't
l'
q
\
~Wire harness to be connected
I

Example: "AK" means a connection of the

111

the C wire harness. I female connector*1 of the "A" wire and the I
For wire harness names, refer to Chapter 2 I male connector*2 of the "K" wire.
I ELECTRICAL WIRING ROUTINGS and I *1: A female connector has a female
L RELAY LOCATIONS. I terminal.
i
~____
Serial number allocated to the connector
_----.J
I *2: A male connector has a male
,------------- I terminal.
~
L_+
P1j (A), 042 (D) Serial number of a connector
L __ o
I
Connector number i
I
--<>
___________~
Male terminal side
.__. J
I

I
'----------e • _ •

Used to Indicate different connectors when

multiple connectors are connected to a part, I
or multiple types of connectors are used I

according to specifications.

[0] Fuse
Indicates a fuse name and capacity.
Terminal 1 is on the primary side and terminal 2 is
on the secondary side.
For fuse installation positions, refer to chapter 2
ELECTRICAL WIRING ROUTINGS and RELAY
LOCATIONS.
[E] Power supply information
indicates the Ignition key position when power is
supplied to a fuse.
[F] Specification information
Indicates that connectors or wire colors vary
depending on forklift models, engine types or
specifications
E1-8
INTRODUCTION
Chapter 3 SYSTEM CIRCUITS (2)

[A] [B]
I

_______________E_N_G_IN_E_C_O_NT_R_O
__
\
L(4_Y_-E_l
[G]
I ~

UJ~ ) OJ))~T~l
CL ~ ~I s
:-1
I
w
Z

-n-l
en
<
(J
I
[J] --1 , , I

I N
(3NI10S\f~))
8<1! ~~-- nil
1 I I

_-~{91~--'.~G}~--~~-- I I I I
I. . ~ -;- I 1, 1
1
1,/'d3 H:JlIMS 3~NVH:J ~dl :
0' 1
I. 9 1 .-J i I I
« 0:
1
! I
M~'d
I ,
CC] ~ v[L]

[DJ

I >-
m
 E1-9
INTRODUCTION
[I] Terminal number [L) Wire calor
Indicates a terminal number of a connector to be Indicates a wire harness calor.
connected. When two alphabetical codes are indicated, for
[J] Junction block connector example "W-B", the first letter indicates the basic
Indicates a connector code connected to a wire calor and the second letter indicates the color
junction block. of the stripe.
For a connector shape, refer to chapter 2 Code Wire Col or Code Wire Calor Code Wire Calor

-
ELECTRICAL WIRING ROUTINGS and RELAY
B Black L Blue SB Sky Blue
LOCATIONS.
BR Brown LG Light Green V
------1Violet

It
;~J---
...
Junction block connector
~Inside of a junction block
DG Dark Gray 0 Orange W White

4@ G Green P Pink Y Yellow

t Junction block type ! : GR, Gray IJ
R , Red u
AM , Amber ,
Serial number allocated to the connector.
•
Example: "1 B" indicates connector B in the
center junction block. I Example: W-B
I W B
1.------------<> Terminal number (White) (Black)
I
CJ:)---<. A number inside indicates a relay block or I [M] Switch
fuse block. I Circuit diagrams are shown with the switches in
For shapes, refer to chapter 2 ELECTRICAL i the OFF pOSition.
I

L WIRING ROUTINGS and RELAY LOCATIONS.!. J

_______..._ _.._.- .
For s\1vitch operation conditions: refer to the repair
manual.

[K] Ground point code

Indicates a ground point code.
For ground point positions, refer to chapter 2
ELECTRICAL WiRING ROUTINGS and RELAY
LOCATIONS.

'tr----------------------
lt
\01 Ground point code
Wire harness connected to the ground paint
_ --4 A ground pOint is Indicated by an alphabetical
.' code.
I Example: "MJ" indicates that the M wire
I harness
'-----_._-.----~
is grounded at point J.
.. _ - - - - - _ . -
- _ ... - --- - - -.. _ - - - - - - - - - _ . - - - - - - -
E1-10
INTRODUCTION
REFERENCE PAGE

-----,.- - - - - .

[A] PARTS
Code :::;ee PrtlJr: Codc' S'-~e p()~Jf:' Code Sf:e Pa~e Code See Page
A 20 E28 G 7 E2~2 G21 E2~2 K 6 E2·2
A 25 E 2~ 10 G 8 E2-? G 25 E2·2 0 2 E2-14
A 27 t?~1O G Ij fc2~2 G 26 E2~2 0 1 E2~B

A :15 E210 c; 1\1 E2·2 G 27 E2~ 10 S 12 E2 14

A :16 E2~ 111 G11 E2~2 G 28 F2-10 T 6 E2~ 16
A 6~ E210 G 12 E2~2 G 29 E210 a 1 E28
A 66 E2~10 G 1:1 E?~2 G73 E2~ 10

C 1 E2-16 G Hi E2~2 K 1 E2-2

C .3 E)·la G 18 E 22 K 2 r;J·2
G 6 E ?~2 G 19 E2~2 K 3 f<:·2

[B] RELAY BLOCK , JUNCTION BLOCK

Code Relay Blocks Name or .h)inmg Wire Harness and JIB

lC E2·1S BODY MAin WIRE to JiB

10 E2 18
lE' E2-18 t H SI OF \r\,Ilf~E le) J,'8

[C] WIRE TO WIRE

Code JOlning Wire Harnes::, dli(j'.f'Jile Harness
AC2 E 2~ 10 BODY MAIN WiI,E 10 SIDE RH WIRE
AC.3 E2·10 BODY MAI"J 'NII,E 10 SIDE RH WIRE
AG1 E2~ 10 BODY 1\1AiN '/'liRE 10 Ff'JGINE WIRE
AOl E2~ 10 BODY 1\i1.u.IN WIRE 10 LH SIDE WIRE
Aal E2 8 BODY M/\IN 'NIRE 10 SUB ACCEl WIRE
GKl E?~2 ENGINE WIH!' 10 ENGINE SUB WIRE
E2-2
OAl E2~8 II,STRUM!'nT PAnEL WIRE 10 BODY MAIN WIRE'
SOl E2 14 REAr, ur'PER '.I(-_In WIRE 10 lH SIDE WIRE
1C2 E2~ 16 .f'EAR I IPPE R Sl18 RH WIr,E to SIDE RH WIRE
TSl E2-16 "EAR UPPER SU8 RH WIRE 10 REAR UPPER MAII-, WIRE

[D] EARTH
Code See Page I Name 1
AB E7~ln IFRONI PI ATE I EFT OUTSIDE EARTH I
E2~ 14 IREAR PILlER LEFT UNDER EARTH I

[A.] Parts
Indicates pages showing electrical wiring routings for the parts
[B] Relay blocks and junction blocks
Indicates titles and pages showing electrical wiring roulings for the relay blocks or junction blocks.
[Cl Connections of wire harness and wire harness
Indicates titles and pages showing electrical wiring routings for the connections of two vvire harnesses.
[D] Ground points
Indicates titles and pages showing electrical wiring routings for the ground points.
 E1-11
INTRODUCTION

Chapter 4 GROUND POINTS

GROUND POINTS
These tables describe related systems for each ground point.

I
----~---~---

E4-2
GROUND POINTS

[DOE G;~UUHD f'UIHT LOCATION SYSTEM I-JAME PAGE

SASIOPS SYSTEM E3-35
CLEARAHCE LAMP E3-72
STOP LAMP E3-75
STROBE LIGHT E3-52
!V~ FI~ONT F'LATE I.EFT OUTSIDE
TU RH SIGHAL LAMP E3-70
BACK UP LAMP BUZZER E3-74
I HF'An I A.MP E3·58
POWER SHIFT TRANSlvIISSII-J E3-32
SASIOPS SYSTEM E3·35
EHGINE COHTROL (4Y-E) E3·l0
COOLER E3·80
AB FRONT PlATE LEFT OUTSIDE CLEARANCE LAMP E3-72
COMBIHATIOH METER E3·54
BACI, UP LAMP BUZZER E3·l4
WET BRAKE E3-34
DIAG E3·42
I
I COOLER E3-80
I STARTING E3-5

I ! STROBE LIGHT
TURN SIGHAL l f,MP
E3-52
E3·70
i
I AI', IFROIH PIJ,TE lEFT OUTSIDE
HEATER
FRONT V;l1PEr~ Ar~D Vv'ASHER I
E3·78
E3~60
I- II HEAD LAMP I E3-58
---
-. -.
..J
HORN .....---------- I E3-54
REAR WIPE Rp>-'"" ----....... E3-52
. -. ..f3:,Il.flY"'" ~-
- -- ------

Chapter 5 FUSES FOR POWER

FUSES FOR POWER
These tables describe power distribution from each power supply (fuse or fusible link) to various systems.
--- - - - - - - - - - --------_.~--_._----- - .------ ----- --

E:l·]

FUSE FOR POWER SUPPL Y

----

FUSIBLE liNK BLOCK ASSY

FUSE SYSTEM Page
GLOW E3-76
100A GLOW
INTAKE HEATER E3-84

I 1120 / 1 1 11 CHARGING E3-96

ENGINE ROOM RIB

I I
~-
FUSE I
lops SYSTEM
SYSTEM Page
E3-250
7_51'. IAcc-s
SASIOPS SYSTEM E3-258
751'. i\LT-S CHARGING E3-194

I 7 5A ECU-B SASIOPS SYSTEM

BACK UP LAMP BUZZER
E3-234
EJ-220
IOl' BilCK LP REAR WORKING LAMP I E3-204
E3-182
I I
STROBE LIGHT
GLOW E3-162

~
INTAKE HEATER E3-166
I
J .
----------------- - - -~-~ ..
ENGINE CONTROL (~'
FUEL
_--- =~
.----.......- ..... ....~ -.
E3-170
E1-12
INTRODUCTION

Chapter 6 CONNECTOR LIST

CONNECTOR LIST

,-----~~~~-~~- ~~~-~~_._--------

~~[A] CONNECTOR L1S~~,

DARK GRAY
T [B]
"6

DARK GRAy
r\ .... r
OAHK GRAY
E6~3

1 2

909f...o 11162
17 18 909f\O·1116B
'-!U'-llijilU!:iUI 90'J!lQ-10~·12

9U9fl,ll'5~

A4B A51 A 52
DARK GP,j\Y GRAY

~ ~
9mnO-l0,:/.Jl
~ ~
90980·10896 CjI)9t.\')·10B9D

A,., A;7 A 58 A 60
GRAY GRAY GRAY BLACK

909r.G-1129t:. 9U950-111G2
9IJ980-110S-1
SU,"80-10213

[A] Connector shape and terminal number

Indicates the connector shape on the wire harness side, which is connected to a part.
Numbers indicate terminal numbers that are used in the circuit diagrams.
[8] Connector calor
Indicates a connector calor.
[e] Part connector
Indicates a connector number connected to a part.
The code is the same as that used in the electrical wiring routing.
[0] Connector part number
Indicates the part number of a connector.
 E1-13
INTRODUCTION
HARNESS TO HARNESS CONNECTOR

I . WIR[[o WIR-E~-- E6-13

--~-O;,-C-A-J- - 0 - '- - - - 0 - 5' - - - - - 1s-V/,r------C

-C]
V

I el.'" I \ GR,-'Y- - - - - ,

~. [I ,"~,I
90980·10794
~ ~ .~ I~l S09flO-1UI9fl 90980-10919

,
G
,
\
I CD]
~
~
Q::J

909AO-l0906
':iG980 10f!~

[B]
0/
DARk. GHft.Y

[AJ Connector shape and terminal number

Indicates the connector shape that connects two wire harnesses.
On left Female connecto(1 shape (This example indicates a connector for the G wire)
On right: Male connector'2 shape (This example indicates a connector for the K wire)
*1: A female connector has a female terminal.
*2: A male connector has a male terminal.
Connector calor
indicates a connector color.
[C] Harness to harness connector
indicates a connector code that connects two wire harnesses
The code is the same as that used in the electrical wiring routing and wiring diagram.
[0] Connector part number
Indicates the part number of a connector
E1-14
INTRODUCTION

ABBREVIATIONS
The following abbreviations are used in this section.

Abbreviations Explanation
ASC Auto Speed Control
ASSY Assembly
CNG Compressed Nutural Gas
DPF Diesel Particulate Filter
ECU Electronic Control Unit
FR Front
JIB Junction Block
LH Left-Hand
LPG Liquefied Petroleum Gas
MIT Manual Transmission
OPS Operator Presence Sensing
PS Power Steering
RIB Relay Block
RH Right-Hand
RR Rear
SAS System of Active Stability
SOL Solenoid
SPEC. Specification
TIC Torque Converter & Transmission
WI With
WIO Without
 E1-15
INTRODUCTION

GLOSSARY OF TERMS AND SYMBOLS

BATTERY GROUND RELAY ITCH, MANUAL

rt-il1.
Lt-tJ NORMALLY
CLOSED
1. NORMALLY
OPEN

CAPACITOR HEADLIGHTS
(Condenser)
1. SINGLE
FILAMENT
~I
Lf--+J 2. NORMALLY'
OPEN
rhYJ 2. NORMALLY
CLOSED

- -~-"----_._----_ .. ~-_." --------- ..• _-

CiGARETTE LIGHTER RELAY, DOUBLE THROW SWITCH, DOUBLE THROW

rb
DIODE
W 2. DOUBLE
FILAMENT

HORN
n
RESISTOR. TAPPED SWITCH, IGNITION

I~
I R:+-
I
I
I

DIODE, ZEN ER LIGHT SENSOR (Termistor)

LED METER, ANALOG SENSOR SWITCH, WIPER PARK

(Light Emitting Diode)
II
I~ ~
r
PHOTODIODE METER, DIGITAL SHORT PIN WIRES

\\ FUEL - 1. NOT
'
~ CONNECTEU
f
MOTOR RESISTOR FUSE

---<>- 2. SPLlCUJ

SPEAKER RESISTOR,
SOLENOID HIGH-TENSION WIRE
VALlABLE or RHEOSTAT

~ TRANSISTOR

I~~
MEMO
 E2-1

CHAPTER 2 ELECTRICAL WIRING ROUTINGS AND

RELAY LOCATIONS

ELECTRICAL WIRING ROUTINGS

ENGiNE ROOM (4Y-E) . . E2-2
ENGINE ROOM (1 DZ) .. . E2-4
ENGINE ROOM (3Z) . . E2-6
INSTRUMENT PANEL . . E2-8
FRONT BODY . . E2-10
MAST AREA . . E2-12
REAR BODY (NO.1) . . E2-14
REAR BODY (N02) . . E2-16

RELAY LOCATIONS
JUNCTION BLOCK (JIB) I RELAY BLOCK (RIB) E2-18

SYMBOLS WIRE NAME SYMBOLS WIRE NAME

. --_._-- _.- - _ .. - ..... - ~~-

A BODY MAIN WIRE S RR UPR MAIN WIRE

------.-._._--_ __ . __ . __ . -_._- _. .._-_. .. ~~ .._ - - - - - - -

_ . _ - ~
B
- - - _ __
. ._ .. _----_.
BODY SUB NO 1 WIRE
_~------_._-~~_.- '.,--.
T RR- UPR SUB RH WIRE
-_ __ ._.__
.... . _ - _ . _ ~ ~ . _ - - - ~ _ . _ -

_ ...• _.. _
C -
SIDE _
. - _ . _ - _ .. _-
RH WIRE
._._ ...•. _ ----- _--_.
U HEAD GUARD SW WIRE ._-_ ..•. _--
o _
- - , - ' , - - - _ . _ .. .. - - - - - - - - - - - - -
TIC HEAT GAUGE WIRE
. .--- - - - - , . ' . _ - _ .. ' - _ . _ - - ' . ' - - - -------
V RR UPR SUB LH WIRE
E DPF AC WIRE W COOLER WIRE
-_ .. -'------------.--- ._ ... --.'--.------_... '.-_ .. _ - - - - - . _ . . --------- - - - - - - - - - _ .. _-_ ... -

F DPF HEATER WIRE X HOOD MAIN WIRE

---- . - - - - ' . - - - - _... --,' .. - - - - - - _... _ - - , , - - , - - - - -

G
--------_._--..,----- .. - - - _ ...
BATTERY STARTER _---.-_
WIRE_-
_-.,-.-. __ .,.' .. , - - - - . _ - - - - - - - _.. .. -------------
Y HOOD SUB__._._-_
NO ..1 WIRE
- - - - - _ . _ - - - - _.. _..... ----~_._-------.~-

__ ...t::J.__ .L_t:lJ\TTE~YSTA~TE:.R VV'I~E:.___ Z~_ _ ~_~ LWR WIRE ~~

I BATTERY
--_ . ..
EARTH WIRE
... __ -----_ " •... _---~----- ---_.- -
a SUB ACCEL WIRE
_._ _-_ .. ... _._._._---

J __ E_NGINE EA.~:!"i2 WIRE b "_MA_S.I SENSOR \J\/.1i=<J=___ _

K I ENGINE SUB WIRE ,d i FR STAY WIRE LH
M -- : LPG-PRES-SU-RE SWITCH-WIRE ,]' e- .. i MAP
LAMP WIRE---------
---0---1 CH_~IDE ~~_~_~ ~··----r-___=--h--·-~IPERS-U~BV,/I~--~------j
Q INSTRUMENT PANEL WIRE k EZ PEDAL LIMIT SW WIRE
~ - -

R FR STAY WIRE RH m INSTRUMENT PANEL WIRE

E2-2
ELECTRICAL WIRING ROUTINGS

ENGINE ROOM(4Y-E)
'1W/O COOLER
'2W/COOLER

[Cl ENGINE WIRE

I
i
to E2-10
I:

i
WENGINE EARTH WIRE ----'----'----~--,
i
I

\,~)'1
 E2-3
ELECTRICAL WIRING ROUTINGS

(G~) ALTERNATOR

CGD ALTERNATOR

( GD ALTERNATOR

CG 6 ) THROTTLE POSITION SENSOR (WITH MOT OF,)

U,;.sJ INJECTOR NO. 1

( G9 ) INJECTOR NO.2

@~ INJECTOR NO 3
(<:;i1) INJECTOR NO.4
(0) VACUUM SENSOR
(<:;i3) FCM STEP MOTOR
(G14 ') WATER TEMPERATURE SENDER

(G1SJ VVATER TEMPERli,TURE SENSOR

c® G2 SENSOR
(09) DISTRIBUTOR
(;:;B IGNITION COIL
.22) OIL PRESSURE SWITCH

'<'~ STARTER
_,\1
~.___J FUSIBLE LINK BLOCK ASSY
(G25)
-~'
IGNITER

( G25) TACHO CHECK

@)
~D LPG INJECTOR

CBI) STARTER

( H3 ) BATTERY

CID BATTERY

OD STARTER
(JIJ BATTERY

CB LPG SOLENOID(SLOW)
( K2 ) LPG RESISTOR
( K3 ) LPG SOLENOID(MAIt~)

( M1 ) LPG PRESSURE SW
( M2 ) LPG PRESSURE SW

ENGINE WIt~E 10 ENGINE SUB WIRE

ENGINE SUB WIRE 10 LPG PRESSURE SWITCH WIRE

ENGINE UPPER EARTH

ENGINE UPPER EARTH

REAR PILLAR LEFT UNDER EARTH

E2-4
ELECTRICAL WIRING ROUTINGS

ENGINE ROOM(1 DZ)

'1 WIO COOLER
'2WI COOLER

l6J BODY MAIN WIRE

\
19 ENGINE WIRE
I

I,G44)
~---

I
_..----------~.~ .'

-_._---------'"
 E2-5
ELECTRICAL WIRING ROUTINGS

C9D AL TERNATOR

0D AL TERNATOR
(G14) WATER TEMPERATURE SEI,DER

(]2D WATER TEMPERATURE SENSOR

( G22) OIL PRESSURE SWITCH
(G24 ) FUSIBLE LINK BLOCK A5SY
(G30 ) GLOW PLUG
'---~

CG3D INJECTOR PUMP

(G32) STARTER
(G33 'I GLOW PLUG RELAY
'--~

(G34 ) FUEL CUT SOLENOID

(~-~) OPEN CLOSE S\JVITCH

(G3~J STEP MOTOR

(G41 ) JUNCTION CONNECTOR(G)
... ';42) JUNCTION CONI,ECTOR(H)
J44 ) AlC RELAY

~ <,45 ) AlC RELAY

_~B DPF CHECKER

Cc;~J VLV
(GSO) AlP

(,--~51 ) DPF BUZZER

(G52) AIR FLOW SENSOR

(53) PRESS SENSOR
(GS4 ) TEMP SENSOR

~G64) AlC MAGNETIC CLUTCH

(G6? ) DPF ECU

(G69 ) DPF ECU

( Hf) STARTER

CH3 ) BATTERY

CID BAnERY
(J2) STARTER

fl JUNCTION BLOCK IN FRONT INSIDE EARTH

\)7 JUNCTION BLOCK IN mONT INSIDE EARTH

\(7 F~EAR PILLAR LEFT lmDER EARTH

~
FRONT PLATE LEFT INSIDE EARTH
E2-6
ELECTRICAL WIRING ROUTINGS

ENGINE ROOM(3Z)
'1:WIO COOLER
'2:WI COOLER

~ BODY MAIN WIRE

i,
 E2-7
ELECTRICAL WIRING ROUTINGS

C~~)"LTERr~ATOR
CG4,\ ALTEHNATOR
(G14) WATER TEMPERATURE SENDER
CG17) WATER TEMPERATURE SENSOR
@D OIL PRESSURE SWITCH
(G24) FUSIBLE LINK BLOCK ASSY

(C:;.3()) GLOW PL UG
INJECTOR PUMP
(G32i S1ARTER
(G33-) GLOW PLUG RELAY

( G34) FUEL CUT SOLENOID

CG3G> OPEN CLOSE SWITCH

STEP t·,10TOR

G41 JUNCTION CONNECTOR(G)

..- "=;42) JUI'iCTION CONNECTOR(H)

NC RELAY
f\)C RELAY

DPF CHECKER

'/LV

AlP
DPF BUZZER
AIR FLOW SENSOR
CG53) PRESS SENSOR

G64 NC MAGNETIC CLUTCH

C(;68~) DPF ECU
(Gyri) DPF ECU
TEMP SENSOR
STARTER
BATTERY
BATTERY
STARTER

JUNCTION BLOCK IN FRONT INSIDE EARTH

JUNCTION BLOCK IN FRONT INSIDE EARTH

REAR PILLAR LEFT UNDER EARTH

::RO~IT PLATE LEFT INSIDE EARTH

E2-8
ELECTRICAL WIRING ROUTINGS

INSTRUMENT PANEL
o BODY MAIN WIRE [ill FR STAY WIRE RH [t}] MAST SENSOR WIRE
[ill BODY SUB NO.1 WIRE []] HEAD GUARD SW WIRE @] FR STAY WIRE LH
@] INSTRUMENT PANEL WIRE @] SUB ACCEL WIRE [E] WIPER SUB WIRE
[E] EZ PEDAL LIMIT SW WIRE
~lINSTRUMENTPANEL WIRE

'1 PREMiUM CABIN

?EXCEfOT PREMIUM CABIN

to E2-10

[4Y-E 5WAY1 [W/ SAS/OPS SYSTEM]

" A15
~ -",-)
 E2-9
ELECTRICAL WIRING ROUTINGS

CA~ HORN SWITCH ~ BODY MAIN WIRE to INSTRUMENT PANEL WIRE

(N) IGNITION SWITCH ~ BODY MA!I, WIRE to SUB ACCEl WIRE
(1\3-) STEERING SENSOR ~ BODY MAIN WIRE to WIPER SUB WIRE
( M_) LIGHT CONTROL SWITCH ~ BODY MAIN WIRE to El PEDAL LIMIT SW WIRE

8~ STOP LAMP SWITCH ~ INSTRUMENT PANEL WIRE to BODY MAIN WIRE

(]0-) BRAKE WARNING SWITCH ~ WIPER SUB WIRE 10 BODY MAIN WIRE

~8_) OPS WARI~ING BUUER ~ INSTRUMENT PANEL WIRE 10 BODY MAIN WIRE

C~~__ ) PARKING BRAKE SWITCH

(A10J TILT SOLENOID

(2\:i1) LIFT SOLENOID

(!,12) UNLOAD SOLENOID
T!LT SWITCH

LIFT SWITCH
NEUTRAL TILT SWITCH

LOAD INDICATOR SWITCH

PRESSURE SENSOR
, (\ 19 SPEED SENSOR

SASIOPS ECU
SAS/OPS ECU
fc1INI LEVER ECU
LEFl TIC SH!FT S\.lijlTCH

TILT ANGLE SENSOR

CONTROL VALVE PUSH SOLENOID

CONTROL VALVE PULL SOLENOID

BACK TILT SOLENOID

I, A~7~) TO DPF DISPLAY

C!'(jS) WET BRAKE BUZZER
C:%9) WET BRAKE LAMP
PRESSURE SWITCH
El PEDAL DIRECTION SWITCH
r-"-.---..
,,-A88) mNT WIPER RELAY
@f) FRONT WIPER MOTOR RELAY
'\90 INTERMITTENT RELAY

,,-~) FRONT WIPER MOTOR

CIGARETTE LIGHTER
CIGARETTE LIGHTER
}\TTACHMENT 3 SOLENOID
CONTROL VALVE SELECT RL Y 1
CA97=1 CONTROL VALVE SELECT F~L Y 2
01 COMBINATION METER

Lq1~) DISPLAY
(_~) ACCELSENSOR
(h1~; FRONT WIPER RELAY
h2 FRONT WIPER MOTOR
k1 ACCEL SWITCH

GiJ 12\/ POWER SUPPLY

E2-10
ELECTRICAL WIRING ROUTINGS

FRONT BODY
'1~PREMIUMCABIN
?EXCEPT.,PREfV! I urv'! CABle!

/
/

JIB
-~

I ;-1A]
I '1EC)
I
I '~1~)
I ':- 10)
/'
/' I UE )
!

[4Y-EJ

[1DZ-ASC,3Z-ASCj
 E2-11
ELECTRICAL WIRING ROUTINGS

( A~ STEERING SOLENOID l1A)

(A24) FUSIBLE LINK BLOCK ASSY (iB~) BODY MAIN WIRE 10 JIB

~ DIAGNOSIS 1C

LAiD DIODE ClDJ LH SIDE WIRE 10 JIB

@J JUNCTION CONNECTOR C~F:-J ENGINE WIRE 10 JIB

(A29 ) CAN JOINT CONNECTOR

C~ CAN JOINT CONNECTOR

0D CAN JOINT COI~NECTOR I AB2 I BODY MAIN WIRE io BODY SUB NO.1 WIRE

(A33 ) CAN JOINT CONNECTOR I AC2 I

@D CAN JOINT Cot~NECTOR
~
(A35 ) ENGINE ECU ~ BODY MAIN WI"E lu SIDE RH WIRE
I~ ~
E~~GlNE ECU
\~~ ~

CED LPG WARr'lNG RELAY I ACo I

@D LPG WARNING BUZZER ~
( 1\45 ) MATCHING COI~NECTOR
~
,46) MATCHING CONNECTOR [§ BODY MAIt~ WIRE to HIGINE WIRE
,. '40 SHIFT SOLEI~OID2 I AG3 I
, ,4S) SHIFT SOLENOID2 ~
@D SHIFT SOLENOID1 ! Am , BODY MAIN WIRE tu LH SIDE WIRE

@D JUNCTION CONNECTOR(J) I A03 I

~
(A6S) JUNClI0i~ COi\iNcCTOR(A) BODY SUB NO.! \NiRE to BODY Mj:"l~~ Vv'iRE
~
(A66) JUNCTION cm,NECTOR(B) i CI\1 r SIDE RH WIRE to BODY IvlAIN WIRE

0\71) DIODE (WET BRAKE) ~ TIC HEAT GAUGE WIRE to BODY MAIN WIRE

(AiD TIC INTERLOCK(FR)

@jJ SHORT CONNECTOR(FR)

@J
@£J
TIC INTERLOCK(RR)

SHORT CONNECTOR(RR) V FRONT PLATE LeFT OUTSIDE EARTH

(A~
(AS3 )
FRONT SOLENOID RELAY
REAR SOLENOID RELAY \7 FRONT PLATE LEFT OUTSIDE EflRTH

~
(AS4 ) EZ PEDAL MAIN RELAY FRONT PLATE LEFT OUTSIDE EARTH

(AS5 ) NEUTRAL START RELAY

OD
~
BArleR\

FUSE CONDENSER FAN

'\j TRANSMISSION UPPER EARTH

-:'iD FUSE 200'/\/ HEATER

10 TIC OIL TEIliIPERf,TURE SENSOR

l G27) ENGINE ECU

( G2S-) ENGINiC E'_>.'
(G29] JUNCTIOI" CONNECTOR\B)

@D GLOW PLUG TIMER

(G3S) ASC Eeu

(G39 ) ASC ECU

~ JUNCTION CONNECTOR(E)

(G73) JUNCTION CONNECTOR(A)

E2-12
ELECTRICAL WIRING ROUTINGS

MAST AREA
'1:V MAST
'2:FSV MAST
'3:WI STAY

[PREMIUM CABIN]

--@ MAP .LAMP WIRE

 E2-13
ELECTRICAL WIRING ROUTINGS

Ci~ HORN
@) HEAD LAMP RIGHT

C§:) FRONT COMBINATION LArvlP RIGHT

em) HEATER SWITCH
GD FRONT WIPER SWITCH
(U3) REAR WIPER SWITCH

C~D MAST SWITCH

( d2 -) HEAD LAMP LEFT

~ FRONT COMBINATION LAMP LEFT

(jf) MAP LAMP

~ BODY MAIN WIRE 10 BODY SUB NO 1 WIRE

~ BODY MAIN WIRE to MAST SENSOR WIRE

~
-,Af] BODY SUB NO 1 WIRE to BODY MAIN WIRE

'. _~ FR STAY WIRE RH to BODY MAIN WIRE

~Ir HEAD GUARD SW WIRE

~ to XBOOY MAIN WIRE
~
~ HEAD GUARD SW WIRE 10 BODY SUB NO.1 WIRE
[dA1l FR STAY WIRE LH 10 BODY MAIN WIRE
~ MAP LAMP WIRE 10 BODY rvlAIN WIRE
E2-14
ELECTRICAL WIRING ROUTINGS

REAR BODY(NO,1)

[PREMIUM CABIN]

'1.W/O REAR WIPER

'2 REAR WIPER
'3.PREMIUM CABIN
[\.I] RR UPR SUB LH WIRE
/"

~SJL.) *2
 E2-15
ELECTRICAL WIRING ROUTINGS

(01 ) YAW RATE SENSOR LH SIDE WIRE \0 RR UPR MAIN WIRE

~ FUEL SENDER GAUGE & FUEL PU~JIP

(03) SEDIMENTARY SWITCH

RR UPR IAAIN WIRE to LH SIDE WIRE
( 04 ) REAR WASHER MOTOR

Cg_~U FRONT WASHER MOTOR

~-) RADIATOR WARNING SWITCH RR UPR MAIN WIRE 10 RR UPR SUB LH WIRE
( S1 ) WORK LAMP LEFT COOLER WIRE 10 RR UPR MAIN WIRE

CS2 ) REAR WIPER MOTOR

(S3~) REAR COMBINATION LAlvlP lEFT HOOD SUB NO.1 WIRE 10 LH SIDE WIRE

GD REAR COMBINATION LAMP RIGHT

( S8) REAR WIPER RELAY RR LWR WIRE \0 LH SIDE WIRE
~ .....
~~y~ WORK LJ\MP RIGHT

@B BEACON LAMP
(]ill REAR HORN SWITCH REAR PILLAR LEFT UNDER EARTH
r~ BEACON LAMP
25 ) REAR WIPER MOTOR RELf' Y

,, 52 0 DOME LAMP

C". ~) DOME LAMP

(S28 ) AlC SWITCH

~~) AIC SWITCH

(S3O) AlC SWITCH

(Sill BLOWER SWITCH

(S32) BLOWER SWITCH

~ BLOWER SWITCH
@D BLOWER SWITCH

@~J BLOWER SWITCH

( S36) BLOWER MOTOR RELAY

(VD DOME LAMP

( V4) DOME LAMP
(1;\/1-) PRESSURE SWITCH

( W2) CONDENSER FAN RELAY

( W3) MAGNET CLUTCH RELAY

"~~) THERMISTOR
045) DIODE
C'5~ CONDENSER FAN MOTOR
1';,7j BLOWER MOTOR

y 1 I~EUTRAL TILT SWITCH

( Y2 ') ATTACHMENT LEVER1

C'l'~J ATTACHMENT LEVER2

C2'D TIC SHIFT SWITCH
( Y5_) TILT LEVER
( Y6) LIFT LEVER
CV?} LOAD INDICATOR SWITCH
C-YD CONTROL VALVE LEVER 3ASELECT SWITCH

c=cD SHORT CONNECTOR

(Y_10J SEAT SWITCH
C~) SWING LOCK SOLENOID
(~ TIRE ANGLE SENSOR
E2-16
ELECTRICALWIRING ROUTINGS

REAR BODY(NO.2)
·1:200W HEATER

to E2-14
~
I! I i
[§J RR UPR MAIN WIRE---------'-"---<-

I
I
IT] RR UPR SUB RH WIRE ~~----c-j
 E2-17
ELECTRICAL WIRING ROUTINGS

CB3') HEATER BLOWER MOTOR

(B:D HEATER RELAY

~1) HEATER HI RELAY

CB8~) HEATER LO RELAY
C1 02 SENSOR

(C3 ) IN AIR SENSOR

C4 AIR CLEANER WARNING SWITCH(+)
CS AIR CLEANER WARNING SWITCH(-)

(C~_) RADIATOR WARNING SWITCH

0: 7 -) BACK UP BUZZER
('C8 ') LPG CHANGE SWITCH
C9 ) LPG VVARNING S\~\flTCH

WORK LAMP SWITH

C11 HEATER SWITCH
I (::12 ) REAR WIPER SWITCH
-':13 FRONT WIPER SWITCH
.1: 14 WIPER ON/OFF SWITCH
RADIO
FRONT WASHER MOTOR
AlC REI AY
A.iC PLUG

AlC PLUG
(C20) DPF HEATER

(C21) NC PLUG
RADIO

Cc::2_3J LPG CHENGE SWITCH

El AlC RELAY
NC PLUG
AlC PLUG
DPF HEATER
NC PLUG

I,-~~/ NC RELAY
LPG CHENGE SWITCH
WORK LAMP SWITH
LPG WARNING SWITCH

Fm UPR MAIN WIRE to SIDE RH WIRE

RR UPR MAIN WIRE 10 RR UF'R SUB RH WIRE
RR UPR SUB RH WIRE to SIDE RH WIRE

REAR PLATE RIGHT OUTSIDE EARTH

FRONT PLATE RIGHT OUTSIDE EARTH

E2-18
RELAY LOCATONS

FUSIBLE LINK BLOCK ASSY (INNER CIRCUIT: SEE PAGE E2-23)

[FRONT]
-

(~)

n~
-~

1== 1
--_
1
... ~-

GLOW
I MAIN I
60A
L t±j

[REAR]

r--~-_J

luJlgwl1
L--_I,
BLACK @) BLACK (~
1 _

90980-11881 90980-11996
 E2-19
RELAY LOCATONS

CD ENGINE ROOM RIB: ENGINE ROOM LEFT

* 1:15AE-THRO(4Y-E)
7.5A ECU-B2 (1 DZ, 3Z)
* 2:15A(4Y-E)
7.5A (1DZ,3Z)
* 3:EFI (4Y-E)
DPF (1 DZ, 3Z)
* 4:30A (PREMIUM CABIN)
20A (EXCEPT PREMIUM CABIN) SPARE I I 30A I I BLR('S) lj--1---l.-_-L-..J
* 5:PREMIUM CABIN
SPARE ~ STA lj--1---l.-_-L-..J

HOUR fviET !2 I i1I RR WiP 1

'j---'-~~

ST IT: I 7.5A 1 1 I FR WIP 1

'j--l_---L..----'

GAUGE

BACK LP
2

2
10A

10A
1G
40AAM1

~ S~.T ~ ~ ~ ~5A
I UKI" IL i I'JA
: :
I I~
f
IGNIT:j '2 !It\

SPARE []~) HOR, rt-r-------,---,

CIOPN RELAY

ASC RELAY SPARE

l~1
~J DPF RELAY

AM2 RELAY

l~l WORK LP 1
't-'--'--L-l

~~ l~{;~mJ
HEAD 1
lj---'---'------'------'

STRELAY 1 G
, 40AAM2 J
------------------
E2-20
RELAY LOCATONS

o JIB LEFT STEP (INNER CIRCUIT SEE PAGE E2-24)

@
90980-12506 @
90980-12383
,---{~
~ ~
• 1BACI, UP LAMP RELAY (W/ EZ PEDAL) 20 2
1~
,--
2 4 ~
I "+-''*=~ 110 3,i
4~
5 7
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7 0
n
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30 12 '1
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@
90980-12320

TIC RR RELAY

o WORK LP RELAY '1

[~[~1 @)
90980-12308

" r,~'
@
) I l H~RN RUAi

~I~~~ j l~l
90980-12311
C:;-;0lr:J
16132
15~1 '-----j
fj43ii
f--- FLASHER RELAY
S 9
"---------------

12 8
'11 7
~O 6
rg
f-c-
5
J7 4

o
3
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4 0
'319
f-cc -'-'-

~~
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 E2-21
RELAY LOCATONS

CAN JOINT CONNECTOR: INSIDE OF THE ECU BOX

(INNER CIRCUIT: SEE PAGE E2-27)

BLUE Q\~ BLACK (Z,-34) BROWN (~)

90980-12355 90980-12355 90980-12355

(~@

[I 90980-10871

Q)
I
I -l I--'~-
I

: I

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:-1 ~~] ~-~ ~~~II~
I~J L'J
F~
1~.I.L.<Jl . JT'=----~-- JUNCTION TERMINAL.

@
90980-12355
E2-22
RELAY LOCATONS

JUNCTION CONNECTOR

r:-:::'
BLACK I,~ - - -- - JUNCTION COr~NECTOR (A)- -- SLACI, 0E)

BlUE (~) - - -- - - - -- - - - -- -- - - - -- -JUNCTiON CONNECTOR (B) -- -- - - -- - -- -- - - - - - -- . BLUE C~"2)

I
~
~'---------')

GRAY @JUNCTION CONNECTOR (G) GRAY C§ Jur'JCTION CONNECTOR

GRAY @JUNCTION CONNECTOR (H) GRA Y (~JUNCTION CONNECTOR (E)

(i)1(3X4)
GXD1XD

~ JUNCTION CONNECTOR (J)

 E2-23
RELAY LOCATONS

[FUSIBLE LINK BLOCK ASSY INNER CIRCUIT]

1(R9) f I I
120AALT
I
20 2-4;)

G~W 1
1@ 1
~~,

1~~
120AMAIN
~
J
E2-24
RELAY LOCATONS

[JiB INNI:::R CIRCUIT (1/3)]

* 1:W/ EZ PEDAL

13@~~~~ 1 @)

31@ l----~~~ 14 @)

33@~~~~ BACK UP LAMP RELAY (* 1) 15 @)

:r:t~
15 @ I--~~~j>- 32 @

15 @ l-------~~________<o_____~~~-­
1 -- 16 @

23 @ ~~~----'
1 I 16 @

28 @
25 @ l----~~________<o_____~~ - - -
24 @
13 @ I--~~---l WORK LP RELAY
5 __________
3
15 @ I-------.-~- - 13 @

l
9 @ l-------~~---l 31 @
1 2
19@~~~--------. 29 @

36 @ L-~~____o 1O@

19 @ I---~~---<It--
41 4@
3
f-<>~~ 5@

1 2
8@ ~-------~~--'-~~-----l--' 1@

3 @ I---~~~ TiC FR RELAY 1 3@)

17@~~~~ 2@

22 @ ~~~-'b-----~~-+--------'41 3@

18 @ I---~-~
34 @ i----------------.
18 @) 1 - - - - - - -

11 @ 1-------------'
1

'-------+--'
~

TiC RR RELAY
-v- 3

2
I
J_ --+-1-

_ 11
2@

1
19 @
@
@
28@ l - ~__j1 2--- 1-----------J35@

26 @ I------~ 2 -------l--- 7 @)

22 @ l-------~-____o FLASHER RELAY 8 @)

24@ I-----~ &--_ _ ~ @ 21

25 @ I-----~ 6------------1 33 @

23 @ 1-----------4> &----------1 29 @

3@ 1------ &---------112@

4 ® I------~ '---~_ _____I 30 @

21@ I----~

2 ® 1----------'
 E2-25
RELAY LOCATONS

[JIB INNER CIRCUiT (2/3)]

r----
-
HORN RELAY 34@

:bt
16@ r 17@
4@ ~----
[ 8@
33@
32@
16@
'---, 6(29
14(29
14@
10@
25@
27@
7@
24@
6@
20@ [
1== -<
6@
15@
22 @ ,I __------lI +---------1 32@

27@
34@r-
28@
12@
26@
26@
26@
5@
19@ 30@

r------~
23@
6@ ----~

21@
20@
30@
9@
10@
r 19@
20@
4@
1@ - - 31@
18@ I 21@
I
23@
17@ '-------- ---
8@
1@
17@ 9@
1O@
3@
17@ , 24@
1 11@
1@
32@

-
E2-26
RELAY LOCATONS

[JIB iNNER CIRCUIT (3/3)]

18@ f---- 7@
9@ f---- 6@
27 @ f----~~__(l

30@ I -----.
7@ J
tL
'----i21@

,- 11@
23@

22@ 14@
20@
16@)
f---

I
t=-= 8@
2@

F-
-~-~

14@ -- 2S@
20@ 28@
s(jC) I 31@
13@ 12@
9(1])
10@
f---------

t I
S@)
29@
11@ 4@)
I
12@ 18@
12@ L--= 24@
 E2-27
RELAY LOCATONS

[CAN JOINT CONNECTOR INNER CIRCUIT]

II 2

,,~----
I

2( A341
I I
I I
-

2 i A31)

L 2

3
JUNCTIOr~ TERMlr~AL

AA

1 11 1
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MEMO
 E3-1

CHAPTER 3 SYSTEM CIRCUITS

POWER SOURCE
POWER SOURCE E3-2
CHARGING E3-4
STARTING E3-6
ENGINE
FUEL E3-8
ENGINE CONTROL (4Y-E) E3-10
GLOW E3-16
DPF-2 , E3-18
ASC . E3-22
LPG WARNING SYSTEM (PREMIUM CABIN) E3-26
LPG WARNING SYSTEM (EXCEPT PREMIUM CABIN) E3-28
CHASSIS
POWER SHIFT TRANSMISSION . E3-30
C7Dcnlll ,00A
LL I LL.Jr-\L _ _.. CJ-JLt

WET BRAKE . ........................................... E3-38

BODY
SAS/OPS SYSTEM E3-40
MINI LEVER (W/ 5WAY VALVES) E3-44
MINI LEVER (W/O 5WAY VALVES) E3-48
DIAG E3-50
REAR WORKING LAMP (PREMIUM CABIN) E3-52
REAR WORKING LAMP (EXCEPT PREMIUM CABIN) E3-54
STROBE LIGHT E3-56
INSTRUMENT PANEL
COMBINATION METER E3-58
MULTI DISPLAY E3-62
FRONT WIPER & WASHER (PREMIUM CABIN) E3-64
FRONT WIPER & WASHER (EXCEPT PREMIUM CABIN) E3-66
REAR WIPER & WASHER (PREMIUM CABIN) E3-68
REAR WiPER & WASHER (EXCEPT PREMIUM CABIN) E3-70
RADIO E3-72
HORN . E3-74
CIGARETTE LIGHTER E3-76
LIGHTING SYSTEM
HEAD LAMP E3-78
TURN SIGNAL LAMP E3-80
CLEARANCE LAMP E3-82
BACK UP LAMP BUZZER . E3-84
STOP LAMP . E3-86
HEATER SYSTEM
HEATER (200W HEATER) E3-88
HEATER (EXCEPT 200W HEATER) E3-90
COMMUNICATION SYSTEM
CAN E3-92
OTHER
MAP LAMP E3-94
DOME LAMP (PREMIUM CABIN) E3-96
DOME LAMP (EXCEPT PREMIUM CABIN) E3-98
COOLER E3-100
EARTH TO EARTH E3-104
 m
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I 2 1 2

15A EFl (* 1'1

WORK LP I
2
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-- ~-
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 E3-3
POWER SOU RCE

PARTS
Code See Page Code See Page Code See Page Code See Page
A 2 E2-8 I 1 E2-2 m 1 E2-8
A24 E2-1O,18 I 2 E2-4,6

RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block f\Jarne or Joining Wire Harness to JIB i
1 E2-10,19 ENGINE ROOM RIB !

1C E2-10,20 BODY MAIN WIRE TO JIB !

WIRE TO WIRE
See Page Jommg Wire Harness and Wire Harness
E2-8 INSTRur"lENT PANEL. WIRE TO BODY MAIN WIRE

EARTH
I Code See Page Name I
AC E2-10 FROI\jT PLATE LEFT OUTSIDE EARTH !
,
IH E2-2,4,6 REAR PILLAR LEFT UNDER EARTH
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m
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.
ALT
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BLOCK ASSY

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 E3-5
CHARGING

PARTS
Code See Page Code See Page Code See Page Code See Page
G 1 E2-2 G 3 E2-2 G 24 E2-2,4,6,18
G 2 E2-4,6 G 4 E2-2,4,6 Q 1 E2-8

RELAY BLOCK JUNCTION BLOCK

1

Code See Page Relay Block Name or Joining Wire Harness 10 JIB I
1 E2-10,19 ENGINE ROOM RIB !
I
1C E2-10,20 BODY MAIN WIRE TO JIB
10 E2-10,20 ENGINE WIRE TO JIB i
WIRE TO WIRE
L-ooe See Page ,JoirHng vvire n3iness anu vflvire I ,olne-S5 I
1

AG1 E2-10 BODY MAIN WIRE TO ENGINE \MIRE I

OA1 E2-8 INSTRUMENT PANEL WIRE TO BODY MAIN WIRE !
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 E3-7
STARTING

PARTS
I CodE!.-_ See Page Code See Page Code See Page Code See Page
A41 E2-8 G 35 E2-10 H 2 E2-4,6 J' '7
L E2-4,6
A8S E2-10 G 39 E2-10 H 3 E2-2,4,6 J 3 E2-2
G 23 E2-2 G 69 E2-4 I 1 E2-2 Y 4 E2-14
G 27 E2-10 G 70 E2-6 I 2 E2-4,6
G 32 E2-4,6 H 1 E2-2 I J 1 E22 iI

RELAY BLOCK JUNCTION BLOCK 1

Code See Page Relay Block Name or Joining Wire Harness to JIB I
1 E2-10,19 ENGINE ROOM RIB I
1
18 E2-10,20 BODY MAIN WIRE TO JIB i
I 1C E2-10,20 _JBODY MAIN WIRE TO JIB I
__1 D_---'_ _--=-E=-2--.:1=-0'-=,2=-0_ _ I~E~N_G_IN_E_-_W_IR_E_T_O_J_/B --'

WIRE TO WIRE
Code See Page JOining Wire Harness and Wire Harness
C,Gl E2-10 BODY MAIN WIRE TO ENGIfJE WIRE
AG2 E2-10 !BODY MAIN WIRE TO ENGII\jE WIRE
ACJ3 E2-10 BODY MAIN WIRE TO LH SIDE WIRE
Y02 E2-14 HOOD SUB NO,1 WIRE TO LH SIDE WJRE

EARTH
Code See Page I Nanv:-?
AC E2-10 FRONT PLATE LEFT OUTSIDE EARTH
IH E2-2,4,6 REAR PILLAR LEFT UNDER EAHTH
JL E2-4,6 FRONT PLATE LEFT INSIDE EARTH
E3-8
FUEL

<:'JiL

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o 101-4310S
lflJ I~(-I.:J

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 E3-9
FUEL

See Page See Page See Page See Page

E2-4.6

RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block f'Jame or JOtrling Wire Harness to JIB
1 E2-10.19 ENGINE ROOM RIB
1C E2-10.20 BODY MAIN WIRE TO JIB
10 E2-10,20 ENGINE WIRE TO JIB
E3-10
ENGINE CONTROL (4Y-E)

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EARTH
i Code I Name
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Code See Page Code See Page Code See Page I Code See Page
A41 E2-8 G 24 E2-4.6.18 G 35 E2-10 I Y 4 E2-14
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RELAY BLOCK JUNCTION BLOCK
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EARTH
Code See Page Name
GJ E2-4.6 JUNCTION BLOCK IN FRONT INSIDE EARTH
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A67 E2-8 G 31 E2-4,6 G 49 E2-4,5 G 69 E2-4
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RELAY BLOCK, JUNCTION BLOCK

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EARTH
Code See Page Name
I EM E2-16 FRONT PLATE RIGHT OUTSIDE EARTH
GJ E2-4.6 JUNCTION 8LOCK IN FRONT INSIDE EARTH
GL E2-4.6 JUNCTION BLOCK If\j FRONT INSIDE EARTH
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ASC

PARTS
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G 31 E2~4.6 G 37 E2~4.6 G 39 E2~ 10 a 1 E2~8

RELAY BLOCK, JUNCTION BLOCK

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EARTH ~
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 E3-27
LPG WARNING SYSTEM (PREMIUM CABIN)

PARTS
Code See Page Code See Page Code See Page Code See Page
A36 E2-10 A65 E2-10 C 9 E2-16 M 1 E2-2
A37 E2-10 A66 E2-10 G 29 E2-10 M 2 E2-2
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RELAY BLOCK, JUNCTION BLOCK

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EARTH
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E3-52
REAR WORKING LAMP (PREMIUM CABIN)

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REAR WORKING LAMP (EXCEPT PREMIUM CABIN)

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RELAY BLOCK, JUNCTION BLOCK
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RELAY BLOCK, JUNCTION BLOCK

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E3-68
REAR WIPER & WASHER (PREMIUM CABIN)

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REAR WIPER & WASHER (PREMIUM CABIN)

PARTS
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C 12 E2-16 o 4 E2-14 S 25 E2-14
C 22 E2-16 S 2 E2-14

RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block Nanle or J()lfllfi~J Wire Hill (less to JIB i
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,

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EARTH ,,~

Code See Page Namp i

AB E2-10 FROi'H PLATE LEFT OUTSIDE EARTH
AC E2-10 FRONT PLATE LEFT OUTSIDE EARTH I
E3-70
REAR WIPER & WASHER (EXCEPT PREMIUM CABIN)

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 E3-71
REAR WIPER & WASHER (EXCEPT PREMIUM CABIN)

PARTS
See Page See Page See Page See Page
E2-14 E2-14 E2-12

RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block N3me or Joining Wire Harness to JIB i
1 E2-10.19 ENGINE ROOM RIB I
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A02 E2-10 BODY MAIN WIRE TO LH SIDE WIRE I
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::'l\RTH
See Page Name
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RADIO

PARTS
Code See Page Code See Page Code See Page Code See Page
C 15 E2-16 C 18 E2-16 C 20 E2-16 C 2~.1 E2-1<>
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RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block 1\lame or JOlnlflg Wire Harness to J/8
1 E2-10.Hi ENGINE ROOM RIB !
,
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Code See Paue JOlnlll\cJ Wire Harness and Wire Harness
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, RTH
I \...-ode I See Page Name
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PARTS
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Code See Page Relay Block Name or Joining Wire Harness to JIB I
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ARTH
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E3-76
CIGARETTE LIGHTER

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CIGARETTE LIGHTER

PARTS
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RELAY BLOCK, JUNCTION BLOCK

Relay Block Name or Joining Wire Harlless to JIB
:
Code See Page
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EARTH
See Page Name
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E3-78
HEAD LAMP

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HEAD LAMP

PARTS
Code See Page Code See Page Code See P;;Jge Code See Page
A 4 E2-8 R 5 E2-12 d 5 E2-i2
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RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block Name or JOining Wire Harness to JIB
1 E2-10,19 ENGINE ROOM RIB
1B E2-10,20 BODY MAII'~ WIRE TO JIB

WIRETOWIRE
See Page Joining Wire Harness and Wire Harness
E2-12 FR STAY WIRE RH TO BODY MAli\) WIRE
E2-12 IFR STAY WIRE LH TO BODY MAIN WIRE
EARTH
-':ode See Page Name
AA E2-10 FRONT PLATE LEFT OUTSIDE EARTH
E3-80
TURN SIGNAL LAMP

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TURN SIGNAL LAMP

PARTS
Code See Page Code See Page Code See Page Code See Page
A 4 E2-8 S 3 E2-14 d 5 E2-12
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RELAY BLOCK JUNCTION BLOCK

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Code See Page Relay Block Name or Joining Wire Harness 10 JiB
I
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WIRETOWIRE
Code See P"ge JOining Wire Harness and Wire Harness i
OSI E2-14 LH SIDE WIRE TO RR UPR MAIr\l WIRE
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EARTH
See PClqe l\lame
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E2-10 IFROI\lT PLATE LEFT OUTSIDE EARTH
E3-82
CLEARANCE LAMP

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CLEARANCE LAMP

PARTS
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E2-14 E2-14

RELAY BLOCK JUNCTION BLOCK

Code See Page Relay Block Name or JOlllillg Wire Harness to JIB I
1 E2-10.19 ENGINE ROOM RIB I
1B E2-10.20 BODY MAIN WIRE TO JIB I
1E E2-10.20 LH SIDE WIRE TO JIB I

WIRE TO WIRE
Code See Page Joillillg Wire Harness alld Wire Harness I
OS1 E2-14 LH SIDE WIRE TO RR UPR MAIN WIRE I
S01 E2-14 RR UPR MAIN WIRE TO LH SIDE Wlf~E I

EARTH
Code See Page Nallle
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BACK UP LAMP BUZZER

PARTS
Code See Page Code See Page Code See Page Code See Page
A41 E2-8 C 7 E2-16 Y 4 E2-14
A 83 E2-10 S 4 E2-14

RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block Name or JUlrllng Wire Hamess to JIB i
I
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18 E2-10.20 BODY MAIN WIRE TO JIB i

1C E2-10.20 BODY MAIN WIRE TO JIB I

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WIRETOWIRE
I Code See Page Joining \[vir,,· H;-lll1ess anc! Wire Harness
I AC2 E2-10 BODY MAIN WIRE TO SIDE RH WIRE
AC4 E2-10 BODY MAIN WIRE TO SIDE RH WIRE i
AC5 E2-10 BODY MAIN WIRE TO SIDE RH WIRE

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EARTH
Coc!e See Page Name i
i
AA E2-10 FRONT PLATE LEFT OUTSIDE EARTH
AB E2-10 FRONT PLATE LEFT OUTSIDE EARTH i
AC E2-10 FRONT PLATE LEFT OUTSIDE EARTH
E3-86
STOP LAMP

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STOP LAMP

PARTS
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E2-8 E2-14 E2-14

RELAY BLOCK JUNCTION BLOCK

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1 E2-10.19 ENGINE ROOM RIB I

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WIRE TO W1RE
I Code I See Page JOining Wire Harness and Wire Harness
E2-14 LH SIDE WIRE TO RR UPR MAIN WIRE
E2-14 RR UPR MAIN WIRE TO LH SIDE WIRE

ARTH
See Page Name
E2-\O FRONT PLATE LEFT OUTSIDE EARTH
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HEATER SLONER
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 E3-89
HEATER (200W HEATER)

PARTS
Code See Page Code See Page Code See Page Code See Page
B 3 E2~ 16 8 8 E2~ 16 C 11 E2~16 U 1 E2~12

B 5 E2~ 16 B 9 E2~10 I 1 E2~2

B 7 E2~ 16 811 E2~10 I 2 E2-4,6

RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block Name or Joinil10 Wire Hall1Pss to JIB
1
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WIRETOWIRE - :
Code See Page Joining Wire Harness and Wlre Harness
AB1 E2~ 12 BODY f\1AIN WIRE TO BODY SUB 1'10.1 WIRE
AC7 E2~ 10 BODY fv1AII\j WIRE TO SIDE RH WIRE
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I
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EARTH
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E3-90
HEATER (EXCEPT 200W HEATER)

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 E3-91
HEATER (EXCEPT 200WHEATER)

PARTS
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E2~ 16 E2~ 16 E2~ 12

RELAY BLOCK JUNCTION BLOCK

Code See Page Relay Block Name or Joining Wire Harness to JIB
1 E2~10,19 ENGINE ROOM RIB
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J=:ARTH
CorJe See Page Name
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OK
 E3-93
CAN

PARTS
Code See Page Code See Page Code See Page Code See Page
A 20 E2~8 A29 E2-10,21 A33 E2-10,21 G 39 E2-10
A 25 E2-1O A 31 E2-10,21 A34 E2-10,21 o 2 E2-3
A 27 E2-10 A32 E2-10,21 A36 E2-10

RELAY BLOCK, JUNCTION BLOCK

!
Code See Page Relay Block Name or Joining Wire HiHness 10 JIB
I
1C E2-10,20 BODY MAIN WIRE TO JIB
1E E2-10.20 LH SIDE WIRE TO JIB

WIRE TO WIRE
I Code See Page JOlOlOg Wire Harness and Wire Harness
I AG2 E2-10 BODY MAIN WIRE TO ENGINE WIRE
I ,1\01 E28 BODY rv1AIN WIRE TO INSTRUMENT PANEL WIRE !

See Page Name

E2-14 REAR PILLAR LEFT UNDER EARTH
E3-94
MAP LAMP
 E3-95
MAP LAMP

PARTS
See Page See Page See Page See Page
E2~ 12

RELAY BLOCK JUNCTION BLOCK

1

See Page Relay Block Name or Joinlllg Wire Harness to JIB

E2~ 10.19 ENGINE ROOM RIB

WIRETO WIRE
See Page Joinlllg Wire Harness and Wire Hallless
E2-12 MAP LAMP WIRE TO BODY MAIN WIRE

EARTH
See Page
E2-10 FRONT F'U\TE LEFT OUTSIDE EART H
E3-96
DOME LAMP (PREMIUM CABIN)
 E3-97
DOME LAMP (PREMIUM CABIN)

PARTS
See Page See Pa~je See Page See Page
E2-14

RELAY BLOCK, JUNCTION BLOCK

._--------------------------,
See Page F~e!ay Block Name or Joining Wire Harness 10 JIB
E2-10,19 ENGINE ROOM RIB

WIRETOWIRE
Cocle See Page JOining Wire Harness and Wire Harness
,
A02 E2-10 BODY MAIN WIRE TO LH SIDE WIRE
OS1 E2-14 LH SIDE WIRE TO RR UF'R MAIN WIRE i

EARTH
See Page Name
E2-10 FRONT PLATE LEFT OUTSIDE EI\f~TH
E3-98
DOME LAMP (EXCEPT PREMIUM CABIN)

-
S
«ocr:
C'J a: >0
b
~ ~8f----lJ~--l~~««-lJ---l--'i7»~~««--u-
.. -,-{~~9---M-*»lliJf---9----If-\--{~(t-( --7»)~r---t.-"--rv-1-D>-i
-g---/,-1 ll '
 E3-99
DOME LAMP (EXCEPT PREMIUM CABIN)

PARTS
See Page See Page See Page See Page
E2-14

RELAY BLOCK, JUNCTION BLOCK

See Page Relay Block Name or Joining Wire Harness to JIB
E2-10.19 EI\)GINE ROOM RiB

WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness i
A02 E2-10 BODY MAIN WIRE TO LH SIDE WIRE ,

S02 E2-14 RR UPR MAIN WIRE TO LH SIDE WIRE

,
SV2 E2-14 RR UPR MAIN WIRE TO RR UPR SUB LH WIRE

EARTH
See Page Name
E2-10 FRONT PLATE LEFT OUTSIDE EARTH
E3-100
COOLER

m D

rn
>- :s
- --- - -------------- - - ~ -----------

. d'" 0 ,,", ': ' :,:: i . _:

M -- b lli}:<c- --,:-

,-
C)

-B(f----~0j~, ~b~J
2-

u' W L3 H' 8-')

Hll l'llS J,. ~\j

J 1 l...It S b n"" C; \;J J H7 S

; - '*
Ii ,-- "
1 CD si
1 I :> I
~
i .~--~
J~(:<-( _ <1 I 00-u ~ -------:»fcl-__
~ -----r:::J ~ _ 8~N' liS 8 If,
~
Y
\
I
00
" CD I
_______________--'1Y
j'JC>! .J

ti -Cj H-·N\

LJ..!
I
,\ 3 ./'v\

l+--+~~~~~~~~i,-~F'
er
o
u,
1-

~l.) 1 10\; 1 I
Sf-

8-M
i. 0' - er>- J. 'LI .J

~«
i./)..-J
z~
~a
('oJ 0
zz

-----9
I
.s 0uu..
«

/ 8 --(.",\

.\ 8 -N\

b··-).,

i::1010V~
j"JV::i d3SN.30r-JOJ
9 NI.

M-l

A83LL\lB
(J) (; I
'(8) L • (~) 6 B
 E3-101
COOLER

~'

w,
;,r~ 255
Lu.:
'fl run

;:::
<i
m
m
>- I
:;':
E3-102
COOLER

PARTS
Code See Page Code See Page Code See Page Code See Page
B 9 E2-10 S 29 E2-14 S 35 E2-14 W 5 E2-14
B 10 E2-10 S 30 E2-14 S 36 E2-14 W 6 E2-14
G64 E2-2,4,6 S 31 E2-14 W1 E2-14 W 7 E2-14
I 1 E2-2 S 32 E2-14 W2 E2-14
I 2 E2-4,6 S 33 E2-14 W 3 E2-14
S 28 E2-14 S 34 E2-14 W 4 E2-14

RELAY BLOCK, JUNCTION BLOCK

Code See Page Relay Block Name or JOining Wire Harness to JIB
1 E2-10,19 ENGINE ROOM RIB
1C E2-10,20 BODY MAIN WIRE TO JIB
10 E2-10,20 ENGINE WIRE TO JIB
•

1E E2-10,20 LH SIDE WIRE TO JIB ,

WIRE TO WIRE --
Code See Page JOining Wire Harness and Wire Harness
AB2 E2-10 BODY MAIN WIRE TO BODY SUB NO.1 WIRE
A02 E2-10 BODY MAIN WIRE TO LH SIDE WIRE
S04 E2-14 RR UPR MAIN WIRE TO LH SIDE WIRE
WS1 E2-14 COOLER WIRE TO RR UPR MAIN WIRE

EARTH
Code See Page Name ..

AB E2-10 FRONT PLATE LEFT OUTSIDE EARTH

IH E2-2,4,6 REAR PILLAR LEFT UNDER EARTH
 E3-103
MEMO
E3-104
EARTH TO EARTH

~u
ux
X u.)

""'
~
~
,
I~
~<C

<co
~o

;-" ~
:"s.s

11'
r----19!" I-i::-"{>I"
18>1" co
-

i
il
ml
(D en :T ,-.j
CD
i
"*

~1 __[V1"
3:
*
::J)
s *

[911 1, L[3>I" 8>1 11 ,

 E3-105
EARTH TO EARTH

WIRETO WIRE
See Page Joining Wire Harness and Wire Harness
E2-10 BODY MAIN WIRE TO LH SIDE WIRE

EARTH
Code See Page Name
AA E2-10 FROhlT PLATE LEFT OUTSIDE EARTH
AB E2-10 FRONT PLATE LEFT OUTSIDE EARTH
AC E2-10 FRONT PLATE LEFT OUTSIDE EARTH
AD E2-10 TRANSMISSION UPPER EARTH
EM E2-16 FRONT PLATE RIGHT OUTSIDE EARTH
GF E2-2 ENGINE UPPER EARTH
GG E2-2 ENGINE UPPER EARTH
GJ E2-4,6 JUNCTION BLOCK IN FRONT INSIDE EARTH
GL E2-4,6 JUNCTION BLOCI< IN FRONT INSIDE EARTH
I IH E2-2,4,6 REAR PILLAR LEFT UNDER EARTH
I JL E2-4,6 FRONT PLATE LEFT INSIDE EARTH
01< I E2-14 REAR PILLAR LEFT UI'lDER EARTH I
MEMO
 E4-1

CHAPTER 4 GROUND POINTS

E4-2
GROur\JD POINTS

CODE LOCATION SYSTEM NAME PAGE

BACK UP LAMP BUZZER E3-84
CLEARN1CE LAMP E3-82
EZ PEDAL E3-34
HEAD LAMP E3-78
Ai', FRom PU\TE LEFT OUTSIDE Efl,RTH POWER SHIFT TRANSMISSION E3-30
SAS/OPS SYSTEM E3-40
STOP LAMP E3-86
STROBE LIGHT E3-56
TURN SIGNAL LAMP E3-80
BACI< UP LAMP BUZZER E3-84
CIGARETIE LIGHTER E3-76
COMBINATION METER E3-58
COOLER E3-100
ENGINE CONTROL (4Y-E) E3-10
AB FROi\jT PLATE LEFT OUTSIDE EAI'<TH
EZ PEDAL E3-34
RADIO E3-72
REAR WIPER & WASHER (PREMIUM CABIN) E3-68
SAS/OPS SYSTEM E3-40
WET BRAKE E3-38
ASC
BACK UP LAMP BUZZER
DOME LAMP (EXCEPT PREMIUM CABIN)
E3-22
E3-84
E3-98
·l
I
DOME LAMP (PREMIUM CABIN) E3-96
FRON I WIPER & WASHER (PREMIUM CABIN) E3-64
I 1- I-< uN I WIPu,: & WASHeR (eXCel-' I I-'RUvlIUM CA8IN) E3-66
HEATER (EXCEPT 200W HEATER) E3-90
HEATER (200W HEATER) E3-88
HORI'! E3-74
AC FRONT PLATE LEFT OUTSIDE EARTH LPG WARNING SYSTEM (EXCEPT PREMlurvl CABIN) E3-28
LPG WARNING SYSTEM (PREMIUM CABIN) E3-26

I IMAP LAMP (PREMIUM CABIN)

POWER SOURCE
E3-94
E3-2
REAR WIPER & WASHER (EXCEPT PREMIUM Ci',BIN) E3-70
I REAR WIPER & WASHER (PREMIUlv1 CABIN) E3-68
REAR WORKING LAMP (EXCEPT PREMIUM CABIN) E3-54
1~t:AR WORKING LAMP (PREMIUM CA811') E3-52
ISTARTING E3-6
I URI'1 SIGNAL LAMP E3-80
AD TRANSMISSION UPPER EARTH POWER SHIFT TRANSMISSION I E3-30
CE FRONT PLATE RIGHT OUTSIDE EARTH RADIO E3-72
EM FRONT PLATE RIGHT OUTSIDE EARTH DPF-2 E3-18
ENGINE CONTROL (4Y-E) E3-10
GF ENGINE UPPER EARTH LPG WARNING SYSTEM (EXCEP I PREMIUM CABIN) E3-28
LPG WARNIf'1G SYS I EM (PREMIUM CABIN) E3-26
DI!\G e3-50
ENGINE CONTROL (4Y-E) E3-10
GG ENGINE UPPER EARTH
LPG WARNII'1G SYSTEM (EXCEP I PREMIUM CABIf\j) E3-28
ILPG WARNIf'1G SYSTEM (PREMIUM CA811'1) E3-26
JUNCTION BLOCK IN FRONT INSIDE ASC E3-22
GJ UPF-2 E3-18
EARTH
,GLOW E3-16

GL
JUNC I iON BLOCK IN FRONT INSIDE !UPF-2 I, E3-18
I
EARTH GLOW E3-16 I
 E4-3
GROUND POINTS

CODE LOCATION SYSTEM NAME PAGE

COOLER E3-100
HEATER (200W HEATER) E3-88
IH REAR PILLAR LEFT UNDER EARTH
POWER SOURCE E3-2
STARTli~G E3-6
JL FRONT PLATE LEFT INSIOE EARTH STARTING E3-6
CAN E3-92
COMBINATION METER E3-58
DIAG E3-50
DPF-2 E3-18
GLOW E3-16
01< REAR PILLAR LEFT Ui'-JDER EARTH
HORN E3-74
MULTI DISPLAY E3-62
REAR WORI<ING LAMP (EXCEPT PREMIUM CABIN) E3-54
REAR WORKING LAMP (PREMIUM CABIN) E3-52
ISASIOPS SYSTEM E3-40
MEMO
 E5-1

CHAPTER 5 FUSES FOR POWER SUPPLY

E5-2
FUSES FOR POWER SUPPLY

FUSIBLE LINK BLOCK ASSY

FUSE SYSTEM NAfl'IE PAGE
60A !GLOW GLOW E3-16
120A IALT CHARGING E3-4

ENGINE ROOM RIB

FUSE SYSTEfv1 NAME PAGE
75A /\CC·B RADIO [3-72
7.5A ALT·S CHARGII\lG E3-4
7.5A ECU-B SAS/OPS SYSTEM E3-40
ASC E3·22
7.5A ECU-B2 ,
DPF·2 E3-18
ASC E3-22
DPF-2 E3-18
7.5A ICjr-J
FUEL E3-8
GLOW E3-16
EZ PEDAL E3-3
7.5A SFT .'-
POWER SHIFT TRANSMISSION E3-30
DPF-2 E3-18
EZ PEDAL E3-34
7.5A SI
_ .
GLOW [3-16
STARTING E3-6
SAS/OPS SYSTEM l::::3-40
7.5A STOP
STOP LAMP [3-86
7'5A TAiL CLEARANCE LAMP [3·82
7.5A TURN TURN SIGNAL LAMP ---+------ E 3- 80
BACK UP LAMP BUZZER E3-84
CIGARETTE LIGHTER E3-76
10A BACK LP REAR WORI<ING LAMP (EXCEPT PREMIUM CABIN) t::3-54
REAR WORKING LAMP (PREMIUM CABIN) I E3-52
STROBE LIGHT E3-56
DIAG [3-50
MINI LEVER (lflf/ ATTACHMENT 3) [3-44
Mil\)l LEVER (W/O AITACHMENT 3) U-48
10A ECLI-IG
MULTI DISPLAY I E3-67
.~

POWER SHIFT TRANSMISSION E3-3L "-

SAS/OPS SYSTEM E3-40
CHARGING E3-4
COrvlBINATIOI\J METER i [3-58
COOLER t:3·100

I ENGINE COf\JTROL (4Y-E)

FRONT WIPER & WASHER (PREMIUM CABIN)
t::3-10
E3-64
FRONT WIPER & WASHER (EXCEPT PREMIUM CABIN) E3-66
GLOW E3-16
10A GAUGE
HEATER (EXCEP I 200W HEATER) E3-90
I
HEATER (200W HEATER) E3-88
RADIO E3-72
REAR WIPER & WASHER (EXCEPT PREMIUM Ci;BIN) E3-70
REAf\ WIPER & WASHER (PREMIU;vl CABIN) I E3-68
SAS/OPS SYSTEM [3-40
WET BRAKE I E3-38
15A DPF DPF-2 [3-18
ENGINE COl\) I ROL (4Y-E) E3-10
15A EFl LPG WARNING SYSTEM (EXCEPT PREMIUM CABIN) E3-28
LPG WARNING SYSTEM (PREMIUM CABIN) E3-26
 E5-3
FUSES FOR POWER SUPPLY

FUSE SYSTEM NAME PAGE

15A E-THRO ENGINE CONTROL (4Y-E) E3-10
15A HEAD HEAD LAMP E3-78
15A HEATER HEATER (EXCEPT 200W HEATER) E3-90
15A HORN HORN E3-74
15A HTR HEATER (EXCEPT 200W HEATER) E3-90
15A IGN ENGINE CONTROL (4Y-E) E3-10
MAP LAMP E3-94
15A WORf< LP REAR WORKING LAMP (EXCEPT PREMIUM CABIN) E3-54
REAR WORKING LAMP (PREMIUM CABIN) E3-52
20A FRWIP FRONT WIPER & WASHER (EXCEPT PREMIUM CABIN) E3-66
DOME LAMP (EXCEPT PREMIUM CABIN) E3-98
20A RRWIP
REAR WIPER & WASHl::R (EXCEPT PREMIUM CABIN) E3-70
._-~-----

25A BLR COOLER E3-100

30A FRWIP FRON I WIPER & WASHER (PREMIUM CABIN) E3-64
DOME LAMP (PREMIUM CABIN) E3-96
I:lOA RRWIP
REAR WIPER & WASHER (PREMIUM CABIN) E3-68
'." STA STAR liNG E3-6 I
(
MEMO
 E6-1

CHAPTER 6 CONNECTOR LIST

CONNECTOR LIST
PARTS CONNECTOR E6-2

WIRE TO WIRE
WIRE TO WIRE E6-9
E6-2
CONNECTOR LIST

A A 2 !\ 3 A 4 A 5 A 6
B lA C K

l±8J
o
L

cfJxhBJ 14

~
3 4
90980· 11070
90980· 10171 90980· 11155
90980· 10935 90980· 10807

A 7 A 8 !\ 9 f\ 1 0 A 1 1 (' 2 ) A 11 (' 1 ) !\ 1 2 (. 2)
DARK GRAY GRAY G RAY GRAY BlACI,

90980· 10899 90980· 11002 90980· 1',002

90980· 10214 90980· 10959

A 12 (' 1 ) A 13 (' 2) A 13 (' 1 ! A 14 (. 2 ) A 14 1'1 ) A 15

DARK GRAY B lA C K GRAY Df\RK GRAY GRAY DARK GRAY

~ r@
90980·10959 ~ ~ 90980· 10900

90980· 10941 90980· 11028

A 16 !\ 18 A 19 A 20
B LAC K GRAY B LAC K

~
~a;p~ ~
9098[1· 11168

90080 98200

90980- 12528

A 21 f\ 23 /" 2 4
BLACK

n
3JI4JXl 5 JI6
909811· 11881
10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27
90980· 12556
28 29 30 31 32 33 34 35

90980· 12529

A 25 f\ 2G .'\ c" ,7 A 29 A 31
GRAY G R J\ Y B LU E B RO W N

8
~ Q 8
1 2 3 1213
') 5 I
~~
1<,. I;)

G)r--
8 9

\
10

0
5leill· 26600· 7',
11 16 17

r- 90980·1125',

9095U- 11542 90980· 12355 90980- 12355

A 32 A 33 A 34 A J 5 A 36
B LAC K

90980· 10871

90980· 12355 90980· 12355

:7 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32 33 34 35
1 W/EZPEDAl
2 W 10 E Z PE 0 A L 90980· 12529 90980- 12525
 E6-3
CONNECTOR LIST

A 37 A 38 A 41 A 42 A 45
B LAC K DARK GRAY

~
0iliJ
90980·10173 10 11 i2 13 15 16 17 18
90980- 11162
90980- 10214 tdU9.3u· 108·+5

90980- I 'I ~) ~J-:

fl 46 [1, 47 A 48 A 49 A 51 A 52
D,I\RK GRAY DARK GR/IY D i\ R K G R i\ Y SLi\CK G R f\ Y

~
00~80· i 1158
90980· 10942
~
90080- 1Ug4 1
~
00930- 11235
~
~ 90980· 10896
~ 90980- 10890

A 54 f\ 56 J\ 6 ~ A 65 A 66
G RA Y B LAC K B LAC K B LUE

12 7 12
9U980· 10899 90980 11168
90980· 11561 00980- 11661

A 67 !\ 68 A 69 f" 7 0 A 71 A 73
BLACK G RAY

90~bO· 1: OU3 90980- 11162

~
90980- 11251

90980- 11 U88 90980- 109,\2

A 74 A 75 A 76 fI. 78 A 82 A 83

(~ ~
~ 0iliJ GTITIJ
~
90980-10941
90980· 10942
90980- 10173 90080-10173

A 84 A 85 !" 8 El .t\ B 9 A 90 A 91
G RAY G RAY G RAY

(1~T31 r~
ru~ D_vJIJ
0iliJ GTITIJ QEIIIIJ
~
90980- 10173 90980· 10173
90980- 10976

A 92 A 93 A 95 f\ 96 A 97 B 3 B
B LAC 1\

~I
0iliJ
m
7115· 2893· 02 711G-2893~02 9098U-l{)173 90980- 10173 9
90980- 11742

32G6U- 53\) i IJ

S 7 B 8 S 9 e· 1 Cl B 11 C 1 C 3
D f\ R K GRAY SLACI,

IJ 1111 Y B2 675- 30090

tffil
J

9U':!i3U- ;0171
~
8 $
'Jlj~80- 10214
9095U- 10869
[112)
90980- 10622

G~G60- 53010 32660- 53010

E6-4
CONNECTOR LIST

C 4 C 5 C C 7 C 8 C 9
BLU E B L!'. C K

0 0 QXp ~ ~ ~
~ ~
7316~ 2095 73iG- 2095
90980· 11 i4U 90980· IDe.iS
,10%:)· 10799

C 10 C 11 C 12 13 C 14 C 15
BLUE BLACK B LAC K B L f'. C K BLUE G RAY

~
~
m ~
~
~
~
90980·10799
~ 90980· 10199 HJ797
90980~ 11051
90080· 10795 91J980~ ;<)795

C 16 C 17 C 18 C 20 C 21 C 22
B LAC K
[1E[i14},
~
7187~
90980~ 10214 170037· 1 7116~ '0 '0 170037~ 1 7', 16~ 1010

82660· 20340

C 23 D 1 E E E F F 2 3
G RAY DARK G RAY

8
17171J6· 1
Q
I er ~ er c!J
171706~
1·17995a~ 2
90980· 11025 9~i ':J; 11004 99-,41~ 11004

82660· 37070

G G 2 G G 4 G 6 G 8
B LAC K B LA C K DARK GRAY

y o 9 0

I
90980~ 11858 90980~ 11153
91]980~ 09567 90980· 09212
90980· 09213 91J980~ 1134 \'

G 9 G 10 G 11 G 12 G 13 G 14
G RE E N DARK GRAY GREEN B LA C K

®
~
90980· 10786
90980· 11153 90980~ 11153 90930· 11153
90980~ 1" 144

G 16 G 17 G 18 (~ I G 21 G 22 G 23
GREEN G R E EN B LAC K GRAY DARK GRAY B LAC K BLACi<

o
90930· 10179
SlU98U- 11286 90980~ 11038 90980~ 10703
90980· 10947
90980~ 11062

G 24 G 25 G 26 G 27
B LA C K B LAC K

99144-12239

90980~ 11996 90980~ 11024

90980~ 12528
 E6-5
CONNECTOR LIST

G 28 G 29 G 30 G 31 G 32
BLUE 6 LA C K

n
1== Al 2 J
1

g 9
I
10 11

18 19 20 21
3 11 4 J
11

5 11 6

12 13 14 15 16 17

22 23 24 25 26 27
n
JI 7
909bl)· ~i '1561
"L

7010~
T ~
3025- Cl?
90980- 10690
[J
90~je[l- 10165

28 29 3D 31 32 33 34
~
90980~ 12527

G 33 G 34 G 35 G 36 G 37 G 38
GRAY GRAY DARK GRAY

~
(I[J980~ 10179 ~ ~3 4

90980- 10,176
~ 4 5 6

90980- 11194
7254- 1548,40 90980~ 11391

G 39 G 41 G 42 G 43
G RAY G RAY GRAY

G 44
9U980~

G
11390

45 G 46
DARK GRAY
G:XiXD2J
(SJJJJJJ)
90980~ 10897

G 49
• 5 6

90980~
7

10897
8

G 50 G 51
90980~ 11542

@
171728~ 1 i71728~1
1
5
8
2
6
9
3
7
10

o
8
G I
12 13
I-- I--
14 15
1--1--
16 17

T~
LITTI
174463- 1
90980- 10887 ffi
91J980~ 10214

I
90930- 10773

G 52 G 53 G 54 G 64 G 67
8 R 0 IN N 8 LA C K

~'X2X3X4~ ~Fx?x3~ @ m
90980~ 10 179
5098~ 0309 174357- 2 90980- 10899

90980~ 113":

G 68 G 69 G 70
DARK GRAY DARK GRAY

%'J30- 11391 90980- 11390 90980- 11390

G 72 G 73 G 74 H H 2 H
DARK GRAY 8 LAC K 8 LAC K

@
90980- 10899
90980- 11561
12

~ 90980~ 10108
er
99142~ 16080 7003~ 1191~
er 02
er
90980~ 09222
er
99142- 15080
E6-6
CONNECTOR LIST

I 2 2 3 K 1 K 2 K 3 M
o i\ R K GRAY 01, R K GRAY BLt,CK

g9142~
8
I
1[l'c'SO
er
700:i· ",172- 02
8
I
7UU3- i 182-02 ~0980-
er 09481
®
~lUS!('O· 11162
~ '

90980· 10S25
<

~
90980- 11235
T
7010-301"

M 2 o o 2 0 :, 0 4 0 5 o 6
GRAY G R /1, Y BLACK SLACK

@ [E rH 8J
90980-11016
\!11Jf/
90980- 11077
~O255
9000u· 98182 40080- 98182
9098U· 1021C

o o 2 R 2 R 5 S 1
GREEN B LAC K BLACK

~
I~!
'I I1 I \"
1 2 ] 4 5 6 7 8

9 10 11 IL 13 14 15 16 90980- 11 ~ 56 l:m9(1980- t 1001

90%0 12553 IL- AG5- 7S- S3C1

s S S 4 S 8 s 9 S 10 S 11
BL/,Cf< B LAC K GRAY DARK G RA Y

~
I~l
~ ~
F';-'I;l

I~I
~ ~
90~)80- 11 ',5C 90980- ",0825
90980- 11155
5 6
90980- 107":,

32bGU- 203-40
90980-11011

S 13 S 25 S 26 S 27 S 28 S 29 S :l 0 S 31
GRAY GRAY

8
90980- 10183
Cl i 90980- 1078b 90980- 10786 90980- 10786 90980- 10785
9U980- lU825 9(J 1J 1- 11UO.1

S 32 S 33 S 34 S 35 S 36 T 6 T 7
B LU E 8 LUE

~ ~
9U980- 10786 90980- 10785 9U980- 10786 90980- 10786
~ ~
82650- 20340

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 Published by

TOYOTA Material Handling Company

A DIvISion of TOYOTA INDUSTRIES CORPORATION

1st Printing: July 2007

Pub. No. CE057

Printed in Japan