7fgu15-32 7fdu15-32 7fgcu20-32 repair manual cu027-2 (2)

This manual covers the service procedures of the TOYOTA FORKLIFT

7FGU/7FDU15 - 32 series and 7FGCU20 - 32 series. Please use this manual

for providing quick, correct servicing of the corresponding forklift mode;&.

This manual deals with the above models as of October 1999. Please under-

stand 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 EQUlPMENT4Y ENGINE REPAIR MANUAL (NO. CE602-1)

TOYOTA INDUSTRIAL EQUIPMENT 1 DZ-I1 ENGINE REPAIR MANUAL (NO. CE618-1)

TOYOTA Material Handling Company A Division of TOYOTA INWSRIES CORPORATION

SECTION INDEX I W E 1 SECTION

I

GENERAL ENGINE TORQUE CONVERTER & TRANSMISSION PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY y I MAST CYLINDER OIL PUMP OIL CONTROL VALVE $3

GENERAL Page

EXTERIOR VIEWS ........................................................ 0-2

VEHICLE MODEL ......................................................... 0-3

FRAME NUMBER ........................................................... 0-4

HOW TO USE THIS MANUAL .................................... 0-5

EXPLANATION METHOD ................................................ 0-5

TERMINOLOGY .............................................................. 0-6

ABBREVIATIONS ............................................................ 0-6

OPERATIONAL TIPS .................................................... 0-7

HOISTING THE VEHICLE ........................................... 0-8

ATTENTIVE POINTS ON SAS .................................... 0-8

CIRCUIT TESTER ............................................ 0-9

STANDARD BOLT & NUT TIGHTENING TORQUE ............................................................ 0-11

BOLT STRENGTH TYPE IDENTIFICATION METHOD ...... 0-11

TIGHTENING TORQUE TABLE ........................................ 0-12

PRECOAT BOLTS ........................................................ 0-13

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ............................................ 0-13

WIRE ROPE SUSPENSION ANGLE LIST ............... 0-14

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ............................................... 0-14

COMPONENTS WEIGHT ............................................. 0-15

RECOMMENDED LUBRICANT QUANTITY & TYPES ................................................. 0-16

LUBRICATION CHART ................................................. 0-18

.......................................... PERIODIC MAINTENANCE 0-19

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ............................................................... 0-25

EXTERIOR VIEWS

Pneumatic tire model

Cushion tire model

0-3

VEHICLE MODEL Pneumatic Tire Models (Pn)

Cushion Tire Models (Cu)

Classificatron

*: USA and CANADA Only

Load Capaclty

3000 Ibs

3500 Ibs

4000 Ibs

5000 Ibs

6000 Ibs

6500 Ibs

Series

Pnl ton series

Pn2 ton series

Pn3 ton series

Model

Pn15

Pn18

Pn20

-

Pn25

Pn30

Pn32

Classification

Vehicle Model

7FGU15

7FDU 15

7FGU18

7FDU18

7FGU20

7FDU20

7FGU25

7FDU25

7FGU30

7FDU30

* 7FGU32

* 7FDU32

Load Capacity

4000 Ibs

5000 Ibs

6000 Ibs

Series

Cu2 ton series

Cu3 ton series

Model

Cu20

Cu25

Cu30

Transmission Type

TC

TIC

T/C

TIC

TIC

TK;

TK;

TK;

TIC

T/C

T/C

T/C

Cu32 1 6500 lbs / *7FGCU32 TIC

Vehicle Model

7FGCU20

7FGCU25

7FGCU30 I

4Y

Engine

Transmission Type

TIC

TIC

TIC

Gasoline

Engine

4Y

1 DZ-ll

4Y

1 DZ-ll

4Y

1 DZ-ll

4Y

1 DZ-11

4Y

1 DZ-ll

4Y

1 DZ-ll

4Y

4Y

4Y

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Gasoline

Gasoline

FRAME NUMBER Frame No. Punching Position

Pneumatic tire

Cushion tire

Series

1 ton series

Engine

2 ton series

3 ton series

4Y

1 DZ-ll

4Y

Vehicle model

7FGU15

4Y

*: EEC spec.

Punching format

.

7FGU18

7FDU20

7FDU25

7FGU30

2 ton series

3 ton series

7FGU18 - 6001 1

7FGU25

7FDU25 - 60011

7FGU32 - 60011

7FGU25 - 60011

1 DZ-ll

4Y

4Y

7FDU30

7FDU32

7FGCU20

7FGCU25

7FGCU30 I

7FDU32 - 6001 1

7FGCU25 - 60011

I 7FGCU25@60011

7FGCU32 - 6001 1

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, fol-

lowed by explanation of cautions and notes summarized as point operations.

Example of description in pattern B

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) r34.0 - 35.5)

8

DISASSEMBLY-INSPECTION-REASSEMBLY Tghtening torque unit T = N.m (kgf-cm) [ft-lbfl

Disassembly Procedure

1 Remove the cover. [Point 11

2 Remove the bushing [Point 21 C Operation explained later

3 Remove the gear.

Point Operations Explanation of key point for operation with an illustration

[Point 11 LL

Disassembly: Put a match mark when removing the pump cover.

[Point 21 Inspection: Measure the bush inside diameter.

Limit: 19.12 mm (0.7528 in)

2. How to read components figures (Example) (1) The components figure uses the illustration

in the 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 the parts catalog.

FIG number in parts catalog I 3. Matters omitted in this manual

(1) This manual omits description of the following jobs, but perform them in actual operation: @ Cleaning and washing of removed parts as required @ Visual inspection (partially described)

TERMINOLOGY Caution: lmportant matters negligence of which may cause physical damage. Be sure to observe them.

Note: lmportant items negligence of which may cause breakage or breakdown. And operation procedure requiring special attention.

Standard: Values showing allowable range in inspection and adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment.

Abbreviation (code)

ASSY

Meaning Abbreviation (code) Meaning

Assembly

Cu Cushion tire models -- LH Left hand

S AE

S AS

SST

5-m

T =

TK;

O O T

U/S

W/

U

UC

M/T

Society of Automotive Engineers (USA)

System of active stability

Special service tool

Standard

Tightening torque

Torque converter & transmission

Number of teeth (0 0)

Undersize

With

Less

Long life coolant --

Manual transmission -- No-load maximum

speed

OPT

01s

Pn

PS

QFV

Option

Oversize

Pneumatic tire models

Power steering

4-stage mast (Quadruple)

OPERATIONAL TIPS 1. Safe operation

(1) After jacking up, always support with wooden blocks or rigid stands. (2) When hoisting the vehicle 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, packing's and O-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. Jack up points

Front side: Jack up at the bottom surface of the frame.

Rear side: Jack up at the under the counteweight or the bottom surface of the frame.

HOISTING THE VEHICLE

When hoisting the vehicle, use the mast hook on the front of the vehicle and a wire net on the rear wheel.

Caution: Use wire ropes having sufficient strength. Never hoist the forklift by the weight hook holes or head guard.

ATTENTIVE POINTS ON SAS

1. Reference should be made to seperate manual "New Model Feature 7FGUnFDUl5-32 Pub. No.PU015" for the explanations of SAS functions and operations.

2. Read Section 15 SAS "Precautions for Repairn on Page 15-7 in this repair manual in advance.

3. Whenever the repair or replacement is performed to the place where relative to SAS function, re- setting procedure by which the SAS regain proper function must be performed. (See Page 15-1 9)

4. The warning on the SAS caution label must be confirmed when the modification c, change is such as to change the original specification. If improper, change the label. (See Page 15-10)

5. Care should always be exercised for safety operation whenever you operate the truck. Make distinction between the SAS featured trucks and those of none, because the control features are different.

6. The SAS oil control valves comprise many precision valves. Since dirty or contaminated hydraulic oil will adversely affect the functions of these valves, always wash the parts clean at the time of installation after disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic replacement of the hydraulic oil is very important.

7. Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause faults. Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary equipment, optional parts, etc.).

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.

(1) Analog circuit tester -

Forward direction Reverse direction

(2) Digital circuit tester i

Forward direction Reverse direction

Measurement result example Tester range: kC? range

Measurement result example Tester range: MS2 range

-

Forward

Reverse

Analog type

Continuity exists

I 1 kc2

No continuity

00

-

Fo~mrd

Reverse

i

Digital type

No continuity

1

Continuity exists

2 MR

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.

4

(mA) 6

- 5 c

4 3 0

g 3 2 9 2

1

O 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Forward voltage (v)

The resistance values of the same semiconductor measured with two types of circuit testers having different power supply voltages are different.

This manual describes the results of measurement with a circuit tester whose power supply voltage is 3.0 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 diodeis measured, the measurement result varies with the measurement range.

Always use the range described in the repair manual for measurement.

z = - c

I f

T Eer source: 1.5 v

@O Red 6," Black

Variable resistor

,- , ,, Resistor

Range: x 10 (sw1)

Resistor

h 1

Range: x 1 (sw2)

I

0-1 1

STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and tightening torques are not indicated. Judge the standard tightening torque as shown below.

1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the table. 2. The nut tightening torque can be judged from the mating bolt type.

BOLT STRENGTH TYPE IDENTIFICATION METHOD

IDENTIFICATION BY BOLT SHAPE IDENTIFICATION BY PART NO.

Hexagon head bolt

Parts No. 9161 1 -40625

Length (mm)

Diameter (mm) Es iameter

Stud bolt

Part No. 9 2 1 3 2 - 4 0 6 1 4

Length (mm)

Diameter (mm)

Class

4=4T 5=5T 6 = 6T 7=7T 8=8T

4T

4T

Shape and class

Hexagon Two protruding head bolt lines 5T

Hexagon head bolt

Hexagon flange bolt

@ Bolt head No.

0 No mark

No mark

0-1 2

TIGHTENING TORQUE TABLE

A

Pitch mm

1 .O

1.25

1.25

1.25

1.5

1.5

1 .O

1.25

1.25

1.25

1.5

1.5

1 .O

1.25

1.25

1.25

1.5

1.5

1 .O

1.25

1.25

1.25

1.5

1.5

1 .O

1.25

1.25

1.25

1.5

1.5

Class

a

5T

6T

7-r

ST

Specified

Hexagon head bolt

N-m ! kgfcm ! ft-lbf 5.4 I 55 48in-lbf

13 I I 9 130

25 1 260 1 19

47 1 480 1 35

75 1 760 1 55

113 1 1150 1 83

6.4 1 65 1 56in-lbf

16 I 160 I 12 I

32 1 I 24 330 1 59 1 600 1 43 91 1 930 1 67

137 1 1400 I101

7.8 1 80 1 69 in-lbf

19 195 I 14

38 I 400 I

I 29 I

72 I 730 1 53

I10 1 1100 1 80

170 1 1750 1127

11 1 110 1 8

25 1 260 1 19

52 I 530 I 38 ' 970 I 70 95 I

147 1 1500 1 108

226 1 2300 ( 166

12 1 125 1 9 29 1 300 1 22

61 1 620 1 45

108 I 1100 I

I 80 I

172 1 1750 1 127

265 1 2700 1 195

Diameter mm

6

8

10

12

14

16

6

8

10

12

14

16

6

8 10

12

14

16

6

8

10

12

14

16

6

8

10

12

14

16

toque

Hexagon flange bolt

N-m ! k- ! ft-lbf 5.9 I 60 52 in4bf

I l4 I I 10

28 1

145 1 290 1 21

53 1 540 1 39 83 1 850 ( 61 - I - I -

7.5 1 75 1 65 in-lbf

18 ' 175 I

I 13

36 1 26

65 1 670 1 4 8

100 1 1050 1 7 6

157 1 1600 1 116

8.8 1 90 1 78 in-lbf

21 215 16

43 440 I

32

79 1 I

810 1 59

123 1 1250 1 9 0 191 1 1950 1141

12 1 120 1 9

28 1 290 I 2 1

58 I 590 43

103 1050 76

167 1 1700 1123 - I - - 14 1 145 1 9 32 1 330 1 24

68 1 690 1 5 0

123 I 1250 90 I I 2000 1 145

299 1 3050 1 221 1

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:

(a) After it is removed. (b) When the precoat bolt is moved (loosened or tight-

ened) 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 por-

tion 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 of screw

711 6 - 20UNF

9116- 18UNF

314 - 16UNF

718- 14UNF

1-1116-12UNF

1-5116- 12UNF

PF114

PF318

PF112

P F 314

PFI

Hose inside diameter mm (in)

6 (0.24)

9 (0.35)

12 (0.47)

12 (0.47), 15 (0.59)

19 (0.75)

25 (0.98)

6 (0.24)

9 (0.35)

12 (0.47)

19 (0.75)

25 (0.98)

Standard tightening torque N-m (kgf-cm) [ft-lbfl

Standard

25( 250) [ 18.11

49 ( 500) [ 36.21

59 ( 600) [ 43.41

59 ( 600) [ 43.41

118 (1200) [ 86.81

137(1400) [101.3]

25 ( 250) [ 18. I ]

49 ( 500) [ 36.21

59 ( 600) [ 43.41

118 (1200) [ 86.81

137(1400) [101.3]

Tightening range

24 - 26 ( 240 - 270) I17.4 - 19.51

47 - 52 ( 480 - 530) [34.7 - 38.31

56 - 62 ( 570 - 630) [41.2 - 45.61 56 - 62 ( 570 - 630) [41.2 - 45.61

112-123(1140-1250)[82.5- 90.41

130 - 144 (1 330 - 1470) [96.2 - 106.41

24 - 26 ( 240 - 270) [17.4 - 19.51

47 - 52 ( 480 - 530) [34.7 - 38.31

56 - 62 ( 570 - 630) [41.2 - 45.61

112-123(1140-1250)[82.5- 90.41

130 - 144 (1 330 - 1470) [96.2 - 106.41

WlRE ROPE SUSPENSION ANGLE LIST

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: N (tf) [~bfl

Suspension method

6 ,d A

Tension

1.41 time

2.00 time

Wng angle

x0

120"

Comipres- sion

1 .OO time

1.73 time

Lifting angle

o0

30"

60"

Single-rope suspension

o0 3040 (0.31) (683.61

4410 (0.45) [992.3]

6960 (0.71)

[1565.6]

10980 (1.12)

12469.51

13730

(1.4) (30871

Rope diameter

6mm (0.24 in)

8 rnrn (O." in)

10 mm

(0'4 in)

12.5 mm (0.5 in)

14 rnrn

(0.56 in)

Compes- sion

Otime

0.27 time

0.58 time

Tension

1 .OO time

1.04 time

1.16 time

Cutting load

21380 (2.18)

[4807

31480 (3.21) 170781

49230 (5.02) [11.69]

76880 (7.84) [ I7387

96400 (9.83)

(216751

Two-rope suspension

Suspension method

6 b

h '

o0 6080 (0.62)

[ I367

8830

(0.9) [I9851

14020 (1.43) 131 531

21570

(2.2) [4851]

27460

(2.8) [6174]

Four-rope suspension

30"

5880 (0.6)

[I3231

8530 (0.87) [ I 9181

13440 (1.37) [3021]

21280

(2.1) [4631]

26480

(2.7) (59541

o0 12160 (1.24) I27341

17650 (1.8)

I39691

27460

(2.8) [6174]

43150

(4.4) 197021

54920

(5.6) 1123481

60"

10400 (1.06) 12337

15300 (1.561

[ N O ]

23540

(2.4) [5292]

37270

(3.8) [8379]

47070

(4.8) [I05841

30°

11770

(1.2) [2646]

17060 (1.74) [3937]

26480

(2.7) [5954]

41190

(4.2) 192611

52960

(5.4) (119071

90°

8630 (0.88) (19401

12550 (1.28) [2322]

19610

(2.0) [4410]

29420

(3.0) [6615]

37270 .

(3.8) [8379]

60°

5200 (0.53) (11691

7650 (0.78) [1720]

11770

(1.2) [2646]

18630

(1.9) [4190]

23540

(2.4) [5292]

90"

4310 (0.44)

[970]

6280 (0.64) [I4111

9810

(1.0) [2205]

14710

(1.5) [3308]

18630

(1.9) (41901

COMPONENTS WEIGHT Weight kg (Ib)

134 ( 295)

176 ( 388)

124 ( 273)

153 ( 337) 1

Approx. 750 (1655)

Approx. 885 (1 955)

Approx. 121 5 (2680)

Approx. 1505 (3320)

Approx. 1830 (4035)

Approx. 1935 (4270)

Approx. 11 30 (2495)

Approx. 151 5 (3340)

Approx. 1925 (4245)

Approx. 21 05 (4645)

Approx. 440 ( 970)

Approx. 550 (121 0)

Approx. 630 (1 390)

Approx. 51 0 (1 120)

Approx. 630 (1390)

Component

Engine

Transmission

Counter weight

V mast ASSY Ubackrest and fork (with lift cylinder, max. lifting he~ght: 3300 mm (131 in))

4Y

1 DZ-II

TIC ( I speed)

TIC (2 speeds)

Pn 15 model

Pn18 model

Pn20 model

Pn25 model

Pn30 model

Pn32 model

Cu20 model

Cu25 model

Cu30 model

Cu32 model

Pnl ton series

Pn2 ton serles

Pn3 ton series

Cu2 ton series

Cu3 ton series

RECOMMENDED LUBRICANT QUANTITY & TYPES

Type

Motor oil SAE30 (SAE20 in cold area)

SAE2OW-40 (SAE1 OW-30 in cold area)

Diesel engine oil SAE30 (SAE20 in cold area)

SAEl OW-30

GM Dexron" II

Hypoid gear oil SAE85W-90

Hydraulic oil

SAE J-1703 DOT-3

MP grease Molybdenum disulfide grease

LLC 30-50% mixture (for winter or all- season) Coolant with rust- inhibitor (for spring, summer and autumn)

f

Classification

API SH, SJ

API CE, CF

ATF

API GL-4, GL-5

IS0 VG32

-

-

-

LLC

Description Application

4Y

1 DZ-ll

TIC (1 speed)

TIC (2 speed)

Pnl ton series

Pn2 ton series Cu2-3 ton series

Pn3 ton series

Engine

Quantity e (US gal)

4.0 (1.06)

7.9 (2.09)

9.0 (2.38) - -

10.5 (2.77)

6.3 (1.66)

7.1 (, .87)

7.7 (2.03)

Gasoline

Diesel

Transmission

Dierential

Hydraulic oil

Fuel tank

Brake line

Chassis parts

Coolant (excluding reservoir tank)

Coolant (Reservoir Tank)

Attached Table 1 Hydraulic oil volume

Pnl ton series Cu2.3 ton series

Other series

All models

All models

45 .g)

65 (1 7.2)

Proper quantity Reservoir Tank 0.2 (0.05)

Proper quantity

Attached Table 2 Coolant volume

All models 0.6 (0.16) (at Full level)

Attached Table 1 Hydraulic oil volume [V mast, max. lifting height 3300 mm (1 31 in)] Unit: t! (US gal)

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

Model

4Y engine models

1 DZ-II engine models

Attached Table 2 Coolant volume Unit: t! (US gal)

Pnl ton series

29 (7.7)

29 (7.7)

Engine

4Y

1 DZ-ll

Cu2-3 ton series

30 (7.9)

Pn2 ton series

36 (9.5)

36 (9.5)

Pnl ton series

8.5 (2.24)

8.5 (2.24)

Pn3 ton series

38 (1 0.0)

38 (1 0.0)

Pn2 ton series

9.6 (2.53)

9.6 (2.53)

Pn3 ton series

9.6 (2.53)

9.6 (2.53)

Cu2.3 ton series

8.5 (2.24)

LUBRICATION CHART I 1

Inspection Replacement MP grease Engine oil Hypoid gear oil Hydraulic oil Automatic transmission fluid Brake fluid Molybdenum disulfide grease

Chain Differential Front wheel bearing Brake master cylinder Torque converter case Rear wheel bearing Steering knuckle king pin Oil tank Engine crank case

L Inspect every 8 hours (daily) II. lnspect every 40 hours (weekly) Ill. lnspect every 170 hours (monthly) IV. Inspect every 1000 hours (6 monthly) V. lnspect every 2000 hours (annual)

Rear axle beam front pin Rear axle beam rear pin Tilt steering locking mechanism Mast support bushing Tilt cylinder front pin Propeller shaft Swing lock cylinder lower pin Tie rod end pin Rear axle cylinder end pin

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

Inspection Period

Item

Every 1 month

Every 170 hours

Every 3 months

Every 500 hours

ENGINE

Main body

PCV system

Governor

Lubrication system

Fuel system

Cooling system

t

c

t

t

t

c

t

c

C

t

t

c

c

c

t

c

t

I

Every 6 months

Every 1000 hours

Proper starting and abnormal noise

Rotating condition at idling

Rotating condition during acceleration

Exhaust gas condition

Air cleaner element

Valve clearance

Compression

Cylinder head bolt loosening

Muffler rubber mount

Clogging and damage in PCV valve and piping

No-load maximum rpm

Oil leak

Oil level

Clogging and dirt of oil filter

Fuel leak

Operation of carburetor link mechanism

Dirt and clogging of fuel filter and element

Injection timing

Injection nozzle injection pressure and spray status

Draining of sedimenter

Coolant level in radiator and leak

Rubber hose degradation

Radiator cap condition

Fan belt tension, looseness and damage

Radiator rubber mount

Every 12 months

Every 2000 hours

I

M

M

I

C

M '

I

M

I

I

I

I

I

I

I

I

I

I

t

t

c

t

c

c

c

c

C

t

c

t

t

M

I

c

c

c

c

I

t

t

t

t

t

M

M

T

I

C-

t

t

t

t

t

t

t

t

M

t

t

t

t-

t

I

Every 12 months

Every 2000 hours

Inspection Period Every 1 month

Every Item 170 hours

E*v 3 months

Every 500 hours

POWER TRANSMISSION SYSTEM

EWV 6 months

Every 1000 hours

4-

4-

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t

t

t

t

T

t

t

t

t

t

t

t

M

t

c

t

T

t

t

t

t

t

c

t

I

I

I

I

I

I

I

I

I

I

Differential

Toque converter & transmission

.

Propeller shaft and axle shaft

DRIVE SYSTEM

Leak

Oil level

Bolt loosening

Leak

Fluid level - -

Operating mechanism function and looseness

Control valve and clutch functions

Inching valve function

Stall and hydraulic pressure measurement

Loose joint

Looseness at spline connections

Looseness of universal joint

Twisting and cracks of axle shaft

Wheels

Tire inflation pressure

Tire cuts, damage and uneven wearing

Loose rim and hub nuts

Tire groove depth

Metal chips, pebbles and other foreign matter trapped in tire grooves

Rim, side bearing and disc wheel damage

Abnormal sound and looseness of front wheel bearing

Abnormal sound and looseness of rear wheel bearing

M

I

T

M

I

I

I

I

t

t

t

t

t

t

t

t

t

t

t

t

4-

t

C

c

t

t

t

t

t

4-

t

4-



Even' 3 months

Every 500 hours

Front axle

Rear axle

STEERING SYSTEM

Every 6 months

Every 1000 hours

Cracks, damage and deformation of housing

Cracks, damage and deformation of beam

Looseness of axle beam in vehicle longitudinal direction

Every 12 months

Every 2000 hours

I

I

M M*

Steering wheel

Steering valve

Power Steering

Knuckle

c

c

t

c

t

t

c

I

I

I

T

I

I

I

Play and looseness

Function

Oil leak

Looseness of mounting

Oil leak

Mounting and linkage looseness

Damage of power steering hose

King pin looseness

Cranks and deformation

c

4-

4-

c

t

t

I

4-

I

BRAKING SYSTEM

c

t

c

c

t

t

t

Brake pedal

Parking brake

Brake pipe

Reservoir tank

Master cylinder and wheel cylinder

Play and reserve

Braking effect

Operating force

Braking effect

Rod and cable looseness and damage

Leak, damage and mounting condition

Leak and fluid level

Function, wear, damage, leak and mounting looseness

M

I

I

I

I

I

I

t

t

t

t

t

t

t

t

t

c

c

c

t

c

t

t

t

t

c

t

t

1

Every 6 months

Every 1000 hours

t

EW 3 months

Every 500 hours

t

Inspectmn Period Every 1 month

Every l tem 170 hours

Every 12 months

Every 2000 hours

4-

I

I

I

I

M

I

I

T

Brake drum and brake shoe

Backing plate

MATERIAL

Forks

Mast and lift bracket

Chain and chain wheel

Various attachments

HYDRAULIC

Clearance between drum and lining

Wear of shoe sliding portion and lining

Drum wear and damage

Shoe operating condition

Anchor pin rusting

Retum spring fatigue

Automatic adjuster function

Defomation, cracks and damage

Loose mounting

M

HANDLING SYSTEM

Abnormalrty of fork and stopper'pin

Misalignment between left and right fork fingers

Cracks at fork root and welded part

Deformation and damage of each part and crack at welded part

Mast and lift bracket looseness

Wear and damage of mast Support bushing

Wear, damage and rotating condition of rollers

Wear and damage of roller pins

Wear and damage of mast trip

Tension, deformation and damage of chain

Chain lubrication

Abnormality of chain anchor bolt

Wear, damage and rotating condition of chain wheel

Abnormality and mounting condition of each part

SYSTEM

Cylinder

t

t

+

t

t

t

t

t

t

t

t

I

I

I

I

I

I

I

I

I

I

I

Loosening and damage of cylinder mounting

Deformation and damage of rod, rod screw and rod end

Cylinder operation

Natural drop and natural forward tilt (hydraulic drift)

4-

4-

t

t

t

t

t

t

t

t

t

t

t

I-'

t

4-

I

t

I

t

t

t

t

t

C

T

I

I

M

t

t

t

t

t

t

t

t

t

t

t

t

Ewly I 12 months

Every 2000 hours

t

t

t

t

t

t

t

t

t

t

t

M

t

c

t

t

Every 6 months

Every 1000 hours

t

t

t

t

t

t

C

c

t

+ t

t

t

t

t

Every 3 months

Every 500 hours

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t

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t

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t

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t

t

t



Cylinder

Oil pump

Hydraulic Oil tank

Control lever

Oil control valve

Hydraulic piping

ELECTRICAL

Ignition timing

Starting motor

Charger

Battery

Electrical wiring

t

t

t

t

M

t

t

t

M

t

t

Oil leak and damage

Wear and damage of pin and cylinder bearing

Lifting speed

Uneven movement

Oil Leak and abnormal sound

Oil level and contamination

Tank and oil strainer

Oil leak

Loose linkage

Operation

Oil leak

Relief pressure measurement

Relief valve and tilt lock valve functions

Oil leak

Deformation and damage

Loose joint

SYSTEM

t

t

t

t

I

t

t

t

t

t

t

t

Cracks on distributor cap

Spark plug burning and gap

Distributor side terminal burning

Distributor cap center piece wear and damage

Plug cord internal discontinuity

Ignition timing

Pinion gear meshing status

Charging function

Battery fluid level

Battery fluid specific gravity

Damage of wiring harness

Fuses

I

I

M

I

I

I

I

I

I

I

I

I

I

T

I

I

I

I

I

I

I

I

I

t

t

t

t

t

t

t

t

t

Every 6 months

Every 1000 hours

I

c

Inspection Period

Item

Every 12 months

Every 2000 hours

c

t

Every 1 month

Every 170 hours

I

Pre heater

Engine stopping system

EW 3 months

Every 500 hours

t

Opencircuit in glow plug

Diesel engine key stop device function

t

4-

t

c

c

c

t

t

t

C

c

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I

T

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4-

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4-

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4-

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L

SAFETY DEVICES,

Head guard

Back-rest

Lighting system

Hom

Direction indicator

Instruments

Backup buzzer

Rear-view mirror

Seat

Body

SAS

Others

c

c

c

c

t

t

c

t

c

t

c

t

t

t

t

t

t

c

ETC.

Cracks at welded portion

Deformation and damage

Loosening of mounting

Deformation, crack and damage

Function and mounting condition



Functions


Dirt, damage

Rear reflection status

Loosening and damage of mounting

Seatbelt damage and function

Damage and cracks of frame, cross members, etc.

Bolt looseness

Functions

Loosening and damage at sensor mounting portion

Damage, deformation, oil leakage and loosening of the mounting of functional parts

Loosening and damage of wire harnesses

Lock cylinder accumulator performance

Rusting and corrosion of load sensor

Grease up

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS : Replacement

*I : for new vehicle *2: Every 2 years "3: Every 3 years '5: Every 10000 hours

Replacement shall be made upon arrival of the operation hours or months, whichever isearlier.

Interval Every 1 month

Every

Every 3 months

Every 500 hours

t

• •

Item

Engine oil

Engine oil filter

Engine coolant (every 2 years for LLC)

Fuel filter

Torque converter oil

Torque converter oil filter

Differential oil

Hydraulic oil

Hydraulic oil filter

Wheel bearing grease

Spark plugs

Air cleaner element

Cups and seals for brake master and wheel cylinders

Brake fluid

Power steering hoses

Power steering rubbers parts

Hydraulic hoses

Brake fluid reservoir tank hose

Fuel hoses

Torque converter rubber hoses

Chains

SAS Swing lock cylinder

170 hours

• • '1

• *1

Every 6 months

Every 1000 hours

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t

t

• • •

• •

•

•

Every 12 months

Every 2000 hours

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• t

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• t

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0-2

02

• *2

0 2

• '2

• *2

• *3

• '5

ENGINE Page Page

............. ENGINE SECTIONAL VIEWS 1-2 V-BELT TENSION INSPECTION- MAJOR SPECIFICATIONS ................... 1-3 ADJUSTMENT .................................... 1-21

ENGINE PERFORMANCE ACCELERATOR PEDAL ; 1-22

m ................. ....

.............................................. CURVES 1-4 COMPONENTS .................................... 1-22

ENGINE ASSY ........................................ 1-6 1NSPECTION.ADJUSTMENT .............. 1-23

.................. REMOVAL.INSTALLATION 1-6 ACCELERATOR PEDAL SWITCH

AIR BLEEDING FROM FUEL .......... SYSTEM (DIESEL VEHICLE) 1-9

ENGINE SPEED INSPECTION AND ADJUSTMENT .................................... I -9

........................................... 4Y ENGINE 1-9

...................................... ADZ-ll ENGINE 1-12

........................................ AIR CLEANER 1-1 3

................................. SPECIFICATIONS 1-13

.................................... COMPONENTS 1-13

AIR CLEANER CLEANING .................................... INSPECTION 1-14

INSPECTION AND ADJUSTMENT (Cu2-3 ton series: EEC spec.) ......... 1-23

EZ PEDAL (OPT) ................................... 1-25 .................................... COMPONENTS 1-25

DISASSEMBLY.INSPECTION- REASSEMBLY .................................. 1-26

ADJUSTMENT ................................... 1-28

VEHICLE SPEED CONTROL SYSTEM (OPT) .................................. 1-29 COMPONENTS .................................... 1-29

CONNECTING DIAGRAM .................... 1-30

...... CLOGGING WARNING SYSTEM

ELECTRICAL CIRCUIT DIAGRAM 1-31

INSPECTION .................................... 1-15 DIAGNOSIS .......................................... 1-32 .................. RADIATOR .............................................. 1-1 5 REMOVAL.lNSTALLATl0N 1-34

.................................... COMPONENTS 1-15 ACCELERATION AND THROTTLE ........................ SPECIFICATIONS 1-16

WIRE ADJUSTMENT 1-37 ................................. .........................

COOLANT CAPACITY AND TROUBLESHOOTING 1-38

ANTIFREEZE TABLE ........................ 1-16

............. MUFFLER & EXHAUST PIPE 1-17 .................................... COMPONENTS 1-17

REMOVAL.INSTALLATION .................. 1-18

CATALYTIC MUFFLER MAINTENANCE ................................ 1-1 8

................................................ BAITERY i -1 9 .................................... COMPONENTS 1-19

SPECIFICATIONS ................................. 1-19

INSPECTION ........................................ 1-20

1 -2

ENGINE SECTIONAL VIEWS 4Y Engine

1 DZ-ll Engine

1-3

MAJOR SPECIFICATIONS Gasoline Engines

Diesel Engines

4Y (Pn3 ton series)

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t

t

t

t

t

c

Gasoline :43 (58)/2600 GasolinelLPG :38 (52)/2600 LPG :40 (54)/2600

t

t

t

I 2800

Item

Engine type

Number of cylinders and a@gpr~tent- - . -

Combustion chamber type

Valve mechanism

Bore x stroke mm (in)

Total displacement cm3 (in3)

Compression ratio

Maximum power kW (PS)lrpm

Maximum torque N.m (kgf-m)lrpm

Minimum specific fuel consumption g/kW-h (g/PS-h)/rpm

Service weight kg (Ib)

No-load maximum rpm Tm

Note: For 2.3 ton series 1DZ-I1 models equipped wi th vehicle speed control system (OPT), the spec. figures and performance curve are same wi th those o f 1 ton series 1DZ-II models.

Pnl.2 ton series Cu2-3 ton series

Gasoline k y c l e

lnline 4 cylinders longitudinal

Wedge type

OHV- chaindriven

91.0 x 86.0 (3.583 x 3.386)

2237 (1 36.51)

8.8

Gasoline :40 (54)/2400 GasolinelLPG :35 (48)/2400 LPG :37 (50)/2400

Gasoline :I62 (16.5)11800 GasolinelLPG :I47 (15.0)11600 LPG :I 57 (16.0)11800

Gasoline :272 (200)/2300 GasolinelLPG :258 (190)/2400 LPG :252 (1 85)/2400

1 34 (295)

2600

Engine type

Number of cylinders and arrangement

Combustion chamber type

Valve mechanism

Bore x stroke mm (in)

Total displacement cm3 (in3)

Compression ratio

Maximum power kW (PS)lrpm

Maximum torque N.m (kgf-m)lrpm

Minimum specific fuel consumption glkW-h (g/PS-h)/rpm

Service weight kg (Ib) No-load maximum rpm rpm

1 DZ-11 (Pnl ton series)

Diesel 4-cycle

lnline 4 cylinders longitudinal

Whirl chamber type

OHV-geardriven

86.0 x 107.0 (3.386 x 4.21 3)

2486 (151.71)

21.5

40 (55)/2400

167 (17.0)/1600

252 (1 85)/1400

162 (357)

2600

1 DZ-I1 (Pn2-3 ton series)

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44 (60)/2600

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2800

1 -4

ENGINE PERFORMANCE CURVES 4Y Engine (Pnl-2 ton Series, Cu2-3 ton Series)

147N.m (1 5.0kgf-rn)/1600rpm

Gasoline vehicle - LPG only vehicle ---

Gasoline and LPG vehicle -----

0

6 10 14 18 22 16 2 LL

Engine speed (rprn) XI (P

4Y Engine (Pn3 ton Series)

162N-m (16.5kgf-m)11800rprn

0 .-

PI 6 10 14 18 22 a5 3b 3

LL

Engine speed (rprn) Xlc?

1-5

1DZ-ll Engine (Pnl ton Series)

167N.m (17.0kgf-m)/16Wrpm

w s-

ul c w P-

O .- - E

10-

U)

8 I I 6 14 18 Z? 26 l?

Engine speed (rpm) Xl Of

1DZ-II Engine (Pn2.3 ton Series)

167N-m (1 7.0kgf-m)/1600rpm

kgf-m N.m l7 165

kw 135 2 9)r

V) 125

44kW (60PS)/2600rpm m -

41 - Zj

g a - n. 8 e O =- 43- r 8 c .- m C J) -

m-

0 .- E

250 c 2529/kW.h(1859rpS-hYl4mpm

P) I I 3

10 14 18 22 9 LL

X1 (Y Engine speed (rpm)

1 -6

ENGINE ASSY REMOVAL*INSTALLATION T = N-rn (kgf-crn) [ft-Ibfj

Eng~ne mounting nut

End plate set bolt

Drive plate set bolt (for connecting engine crankshaft)

Drive plate set bolt (for connecting torque converter)

Torque converter housing set bolt

T = 53.9 - 99.0 (550 - 101 0) [39.8 - 73.11

T = 49.0 - 78.5 (500 - 800) [36.2 - 57.91

4Y: T = 56.9 - 64.7 (580 - 660) [42.0 - 47.71 1 DZ-ll: T = 76.5 - 93.2 (780 - 950) [56.4 - 68.71

T = 14.7 - 21.6 (1 50 - 220) [I 0.9 - 15.91

T = 29.4 - 44.1 (300 - 450) [21.7 - 32.61

Removal Procedure

1 Remove the engine hood. (See p. 9-6.)

2 Remove the toe board.

3 Drain coolant.

4 Remove the battery and battery tray.

5 Remove the relay block and electrical parts plate set bolts to free them.

6 Disconnect the accelerator wire and fuel hose. [Point 11

7 Diesel Vehicle: Remove the sedimenter bracket set bolt to free the bracket.

8 Disconnect connectors and wiring harness clamps around the engine.

9 Disconnect the torque converter cooler hose. [Point 21

10 Remove the radiator.

11 Disconnect the air cleaner hose.

12 Remove the oil pump set bolts to free the pump.

13 Disconnect the exhaust pipe.

14 Disconnect the wiring from the starting motor.

15 Remove the under cover.

16 Remove the cover plate.

17 Remove 6 drive plate set bolts.

18 Remove the engine ASSY mounting nuts.

19 Slightly hoist the engine. [Point 31

20 Support the torque converter housing with wooden blocks.

21 Separate the torque converter housing and engine. [Point 41

22 Remove the engine ASSY with drive plate and torque converter end plate.

23 Remove the drive plate.

24 Remove the torque converter end plate.

25 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 crankshaft). Bleed air from the fuel system after installation of the engine ASSY. (For diesel vehicle) (See p. 1-9.)

Point Operations

[Point 11 Removal:

Put a match marks on the fuel hose and the coupler.

[Point 21 Removal:

Put a match mark on the radiator and torque converter cooler hose.

[Point 31 Removal-Installation:

SST 0901 0-201 11 -71 -- GI 0901 0-23320-7 1 -4

Removal: Tentatively hoist up until the mounting bolt completely comes out from the hole in the frame.

[Point 41 Removal:

Use a straight-edge screwdriver for separation. If the fitting is too tight, change the SST hook position and adjust the engine angle for easier separation.

AIR BLEEDING FROM FUEL SYSTEM (DIESEL VEHICLE) 1. Operate the hand pump of the fuel filter until the pump

operating force becomes heavy.

ENGINE SPEED INSPECTION AND ADJUSTMENT Note: Warm up the engine, set the vehicle to the following conditions, and conduct inspection and adjustment. Coolant temperature: 80°C (176OF) or more, engine oil: 70°C (158'F) or more, operating oil temperature: 50°C (122OF) or more, auto choke in release state (4Y engine)

B

tor

4Y ENGINE Idling speed and idle up speed inspection and adjustment <Gasoline Vehicle> 1. Install the engine speedometer.

2. Disconnect the idle up actuator and inspect the idle up speed.

Standard: 1000 a 30 rpm

3. If the measured value is out of the specified range, adjust by turning adjusting screw B.

4. Connect the idle up actuator.

5. Check the idling speed.

Standard: 800 + 5 rpm

6. If the measured value is out of the specified range, adjust by adjusting screw A.

7. If the speed is still higher after adjustment in 3 above, adjust using the following procedure:

A

Regulator

(1) If the auto choke cam is contacting although the coolant temperature is as specified above, replace the auto choke.

(2) If the idle up actuator rod and adjusting screw B are in contact with each other, turn adjusting screw 6 counterclockwise.

<LPG/Gasoline or LPG> 1. Install the engine speedometer. 2. Disconnect the idle up actuator and inspect the idle up

speed. Standard:

LPGIGasoline: 1000 2 30 rpm

3. Check the idling speed.

Standard: LPGIGasoline: 800 :,sarpm LPG: 800 :,50 rpm

4. If the measured value is out of the specified range, make adjustment according to the following procedure:

(1) Make adjustment by turning adjusting screw B (LPG vehicle) or C (LPGIgasoline vehicle). (If less than the standard, turn adjusting screw A counterclockwise beforehand.)

(2) Slowly turn adjusting screw A clockwise or counterclockwise until the maximum speed is obtained.

(3) Determine the positions of adjusting screws B and C by repeating steps (1) and (2) until the value obtained in step (2) satisfies the standard.

(4) Slowly turn adjusting screw A clockwise until the CO concentration becomes 2 to 3%, and then turn it 45 degrees counterclockwise from the position where the speed begins to drop.

No-load Maximum Speed Inspection-Adjustment <Gasoline, LPG or LPGlGasoline Vehicle> 1. Install the engine speedometer. 2. Inspect and adjust the no-load static maximum speed.

(1) Measure the speed when the accelerator pedal is fully depressed.

Standard: 4Y engine:

Pnl-2 ton series: .......... 2600 f 50 rpm Cu2-3 ton series: .......... 2600 f 50 rpm Pn3 ton series: ............. 2800 f 50 rpm

(2) If the measured value does not satisfy the standard,make adjustment as follows:

Remove the seal and loosen the lock bolt. @ Fully depress the accelerator pedal. @ Turn the bushing for adjustment, while holding the

adjusting screw of the air governor immovable with a straight-edge screwdriver.

3. Check and adjust relief down. (1) Operate the tilt lever fully backward with the engine

running at the maximum speed, and measure the decrease in speed (relief down) upon full relief.

Standard: Within 300 rpm

(2) If the measured value is out of the standard range, make adjustment according to the following procedure:

@ Turn the adjusting screw counterclockwise to decrease relief down.

@ Return the screw by 111 0 of a turn to eliminate twisting of the spring in the air governor.

@ Adjust the no-load maximum speed. @ Repeat steps @, @ and @ until the measured value

satisfies the standard.

4. Check and adjust hunting. (1) Check for hunting upon tilt relief at the no-load maxi-

mum speed. (2) If hunting occurs a few times or more, make adjust-

ment according to the following procedure: @ Turn the adjusting screw clockwise by 112 of a turn

or more. @ Return the screw counterclockwise by 114 of a turn. @ Finally,.tum it by 111 0 of a turn to eliminate twisting

of the spring in the air governor. @ Adjust the no-load maximum speed. @ Repeat steps @through @ until hunting occurs no

more.

5. Repeat adjustments in steps 2 to 4 until respective standards are satisfied.

6. Seal the lock bolt.

1 DZ-ll ENGINE

Idle Speed Inspection.Adjustrnent 1. Install the engine speedometer.

2. Check the idle speed.

Standard: 750 f 25 rpm

3. If the measured value is out of the standard, loosen the lock nut and make adjustment by turning adjusting screw A.

No-load Maximum Speed Inspection.Adjustment 1. Install the engine speedometer. 2. Inspect and adjust the no-load maximum speed.

(1) Measure the speed when the accelerator pedal is fully depressed.

Standard: 1 DZ-ll engine:

.................... 1 ton series: 2600 f 50 rpm Vehicle speed control

.............. system spec.: 2600 f 50 rpm 2.3 ton series: ................. 2800 f 50 rpm

(2) If the measured value does not satisfy the standard , make adjustment as follows:

@ Remove the seal and loosen the lock nut. @ Make adjustment by turning adjusting screw B.

3. Check and adjust relief down. (1) Operate the tilt lever fully backward with the engine

running at the maximum speed and measure the decrease in speed (relief down) upon full relief.

Standard: Within 200 rpm

4. Seal the adjusting screws after the end of adjustment.

1-1 3

AIR CLEANER SPECIFICATIONS

COMPONENTS

- Type

Size

Intake type

Filtering area cm2 (in2)

Others

Single (STD)

Cyclone type

7inch

Fresh air introduction type

1 8600 (2883)

With evacuator valve

Double (OPT)

t

t

J t

Outer: 18600 (2883)

Inner. 510 (79.1)

t

Vehicle without

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 (7kgflcm2) [I00 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 kgflcm2) [40 psi] or less] After washing, naturally dry the element or dry the element with a dryer (cold air).

Note: Do not damage the element during washing. Never use compressed air or hot air for drying.

4. Clean the evacuator valve (dust discharge valve). ( 7 ) Hold the tip end of the evacuator valve and discharge

dust and dirt from the inside of the valve.

5. Inspect the element. (1) 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 witti a new element.

6. Element replacement Replace the element after it is washed six times or gen- erally at intervals of 12 months.

7. Install the element. (1) Install the evacuator valve in the illustrated direction.

CLOGGING WARNING SYSTEM INSPECTION

1. Warning lamp inspection (1) See that the air cleaner warning lamp comes on when

the ignition 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 conduction.

Standard Gasoline models:

2942 2 294 Pa (300 2 30 mm H20) (22.1 f 2.2 mmHg) [11.81 f 1.18 in H,O] [0.870 2 0.087 in Hg]: Conduction

Diesel models: 7473 f 569 Pa (762 2 58 mm H,O) (56.0 2 4.3 mmHg) r30.00 + 2.28 in H20] [2.205 f 0.169 in Hg]: Conduction

RADIATOR COMPONENTS

SPECIFICATIONS

COOLANT CAPACIN AND ANTIFREEZE TABLE Unit: e (US gal)

Type

Fin type

Coolant capacity (in radiator)

Cap opening pressure kPa (kgflcm2) [psi]

Others

Crossflow

Cormgated fin

See the table below

88 i 14.7 (0.9 i 0.15) [13 f 2.11

Built in torque converter cooler

Note: The total amount of coolant does not include the capacity of the reservoir tank. Reservoir tank capacity: 0.6t (0.16 US gal) (at FULL mark position)

Radiator capacity

Total amount of coolant

8.5 (2.24)

8.5 (2.24)

9.6 (2.53)

9.6 (2.53)

8.5 (2.24)

Pnl ton series

Pn2.3 ton series

Cu2.3 ton series

LLC mixing ratio at 30% (to - 1 5OC

(5OF))

2.6 (0.69)

2.6 (0.69)

2.9 (0.77)

2.9 (0.77)

2.6 (0.69)

4Y

lDZ-Il

4Y

1 DZ-II

4Y

2.7 (0.71)

2.7 (0.71)

3.7 (0.98)

3.7 (0.98)

2.7 (0.71)

LLC mixing ratio at 50% (to - 35OC (- 31°F))

4.3 (1.14)

4.3 (1.14)

4.8 (1.27)

4.8 (1.27)

4.3 (1.14)

Antirust mixing at

5%

0.4 (0.11)

0.4 (0.11)

0.5 (0.13)

0.5 (0.13)

0.4 (0.11)

MUFFLER & EXHAUST PIPE COMPONENTS

Gasoline model 1702

1702-362A

Diesel model

(UL-DS)

1702-361A

Note: The muffler can be removed by either of the two methods shown below. @ Remove the muffler after removing the counterweight. @ Remove the muffler after removing the radiator Wlcounterweight. Here, method @ is explained.

Removal Procedure

1 Remove the counterweight. (See p. 9-7.)

2 Disconnect the exhaust pipe.

3 Remove the muffler Witail pipe.

4 Disconnect the tail pipe from the muffler.



CATALYTIC MUFFLER MAINTENANCE

Replace the muffler ASSY every year (2000 hours) on either the gasoline or diesel engine vehicle.

BATTERY COMPONENTS

SPECIFICATIONS

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

1 DZ-ll

STD GR35 GR24R

(JIS 55D23L) (JIS 80D26L)

GR24R (JIS 80D26L)

c

55

c

19.0 (41.9)

GR35 (JIS 55D23L)

Voltage V

5-hour rate capacity Ah

Specific gravity of battery fluid in use (at 20°C (68°F))

Battery weight kg (Ib)

12

48

1.280

16.2 (35.7)

INSPECTION

1. Inspect the battery fluid level. (1) Inspect the battery fluid level and fill a distilled water if

insufficient. Do not overfill above the upper fluid limit.

2. Inspect the specific gravity of the battery fluid. (1) Use a hydrometer and measure the specific gravity

of the battery fluid.

Standard: 1.280 (at 20°C (68°F)) Calculating equation S2O = St + 0.0007 (t-20) S2O: Specific gravity converted to 20°C (68OF) St: Measured specific gravity at tOC t: Fluid temperature at the time of measurement

3. lnspect the battery terminals. (1) If battery terminals are contaminated to white, clean

then and apply a thin coat of MP grease on terminals.

4. Install the battery terminals and the harness connecting portion for loosening.

(1) Retighten the battery terminals and the harness connecting portion.

Battery Removal

1. Disconnect battery terminals.

Note: Disconnect the negative terminal first.

2. Remove the battery stopper.

3. Remove the battery.

Battery Installation

Reverse the removal procedure.

V-BELT TENSION INSPECTION. ADJUSTMENT 1. Inspect the V belt tension.

Standard [Deflection when pushed with a force of 98N (1 0 kgf) [22 Ibfl] 8-1 3 mm (0.31 -0.51 in)

Standard [When the tension gauge (SST) is used]

SST 0921 6-76002-71 (SST 0921 6-00021)

4Y 294-490 N (30-50 kg9 [66-110 lbfl 1 DZ-II 324-559 N (33-57-kg9 [73-126 Ibfl

2. Adjust the V belt tension.

1 DZ-ll: Use a lever rod and move the alternator for adjustment.

4Y: Make adjustment by turning the adjusting bolt.

1-22

ACCELERATOR PEDAL COMPONENTS

RG.5301-AS 2601

6- ES

C20.C25,UO,CH30(EEC SPEC)

941 2041 000

GY DO

HA - -

2601-205

4 Y

2601-203A

1 DZ-l l

EU

91611-40616

2601-206

Play

Diesel engine vehicle

Gasoline engine vehicle Stopper

p--------

Note: Adjust the accelerator pedal switch after inspecting and adjusting the accelerator pedal height. (EEC spec.)

1. Check the accelerator pedal height A (from the accelerator bracket to the top face of roller).

Standard: Gasoline engine vehicle: A = 68 mm (2.68 in) Diesel engine vehicle: A = 73 mm (2.87 in)

2. If the measured value does not satisfy the standard, make adjustment by turning the accelerator link stopper bolt a.

3. lnspect and adjust the accelerator wire play.

Standard: 5 - 7 mm (0.20 - 0.28 in)

If the standard is not satisfied, make adjustment at accelerator wire bracket @.

4. Adjust the stopper bolt @ so that the accelerator pedal comes into contact with stopper bolt @ at the following position: Position where clearance 5 between the injection pump lever (or carburetor throttle link) and maximum speed adjusting screw (or stopper) is as shown below:

Diesel engine vehicle: B = 0 - 0.5 mm (0 - 0.020 in)

Gasoline engine vehicle: B = 0 - 2.0 mm (0 - 0.079 in)

0 mm (0 in) clearance here means that the accelerator pedal comes into contact with the stopper bolt at the same time with establishment of the contact between the lever (or carburetor throttle link) and adjusting screw (or stopper).

Gasoline Diesel

ACCELERATOR PEDAL SWITCH INSPECTION AND ADJUSTMENT (Cu2-3 ton series: EEC spec.) Note: Adjust the accelerator pedal switch after inspecting and adjusting the accelerator pedal height.

1. lnspect and adjust the accelerator pedal height.

2. Adjust the accelerator pedal switch mounting position. Gasoline engine vehicle: Install the switch on the bracket so that the nut is flush with the end of the threaded portion of the switch case. Diesel engine vehicle: Install the switch on the bracket so that the switch case end face is flush with the nut end face as illustrated.

(0.20 - 0.28 in)

3. Adjust by turning accelerator link stopper bolt @) to make the clearance (A) between the accelerator pedal link and switch case end face satisfies the standard.

Standard: A = I f 0.5 mm (0.04 f 0.020 in)

Note: The accelerator pedal height may be changed as the result of this adjustment

4. Check to see that the accelerator link departs from the switch shaft end face within the range of the accelerator wire play.

Standard: 5 - 7 mm (0.20 - 0.28 in)

If the standard is not satisfied, make adjustment at accelerator wire bracket @.

Accelerator pedal switch inspection

1. inspect the ONIOFF state of the accelerator pedal switch.

Switch position Standard

Closed

Pressed

1-25

EZ PEDAL (OPT) COMPONENTS

DISASSEMBLY-INSPECTION-REASSEMBLY T = Nom (kgf-cm) [ft-lbfl


1 Remove the pin and separate the pad Wlswitch from the pedal. [Point 11

2 Remove the switch ASSY. [Point 21

3 Remove the holder Wlmagnet. [Point 31

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 1-27.)

Point Operations

[Point I] Disassembly:

Extract the pin by lightly tapping the pin edge (the flange- less side).

Reassembly: Push the pin in with its notched flange portion in the illustrated direction until it goes beyond the pad side hook.

Reverse

[Point 21 Inspection:

Check continuity of direction switches.

Forward side: Continuity between @ and @when the switch is pressed. Reverse side: Continuity between @ and @ when the switch is pressed.

Reassembly: Reassemble in the following order: 1. Pass the switch through the -pedal side hole.

2. 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.

3. Fix the switch harness by means of the plate. 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 31 Reassembly:

Since the holder W/magnet needs height adjustment, set it temporarily in a low position. See page 1-28 for adjustment.

ADJUSTMENT

Note: Adjust the pedal roller height and pedal stopper bolt height in the same way as for the standard pedal. (See page 1-23.) Direction switch adjustment is explained here.

0

0

@

8. Lock nut Magnet holder

Direction Switch Adjustment Procedure

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

@ Screw in the magnet holder at the tilted side.

@ Where the pad starts moving slightly is the position that the magnet come to contact with the accelerator pedal pad plate. Then thread in by a half (112) turn from that point.

@ Tighten the lock nut. Secure the magnet holder so as not to turn.

@ Adjust the other side in the same manner as in @ to @.

@ After adjustment, confirm that the switches are actuated before magnets contact to the pedal pad plate by tilting the pad slowly.

1-29

VEHICLE SPEED CONTROL SYSTEM (OPT) COMPONENTS

CONNECTING DIAGRAM

0 VEHICE~W~C~.JHFA~UER @ V E H I C L E S P E E D ~ R Q S A S CONTROLLER @ I G N I T I O N s r l T c n

@ @ A C T U A T O R @ L I M I T SWITCH @ SPEEDSENSOR @BODY EARTH-

@ 0

@ NMRVOLUME @ CHECKER @COMB 1 N A T ION HETER

@ @ @ DIESEL ENGINE GASOLINE ENGINE

@MEMORY CLEAR @ F R O N T W I R E @RELAY BOX

@ @ TX8#aH@a

CHECKER

0

0 0

ACTUATOR rn VEHICLE SPEED L-h3z- CONTOROLLER @

LIMIT SWITCH NMR VARIABLE

I FUSE 0

I 1 0 SAS CONTOROLLER SPEED SENSOR

KEY SWITCH BATTERY

I I ,...-. 1-

-

ELECTRICAL CIRCUIT DIAGRAM

DIAGNOSIS

The diagnosis function, upon detection of a problem by the controller of the vehicle speed control system, informs the operator of the problem and its location by blinking the check lamp on the combination meter. The problem location is indicated by the check lamp blinking count. -

320msec 1280msec Example 1

Lamp ON 0. Repetition of the same cycle hereafter

For No.2 indication

Lamp OFF

320msec 0

1280msec Example 2

Lamp ON Repetition of the same

For No.1 and No.2 cycle hereafter

indication Lamp -TthuL OFF

0

Note: The check lamp may blink upon turning the ignition switch ON or while the vehicle is traveling (operating). If the lamp blinks during traveling (operating), promptly stop the vehicle and check the blinking count with the ignition switch ON (engine stops). Turn the ignition switch OFF and ON again to repeat diagnosis. If any abnormality is detected, the check lamp blinks again.

Method for Checking Error Codes Indicated in the Past To display error codes indicated in the past, disconnect diagnosis connector @ while keeping the key switch at ON. Once the error memory of the controller is reset, however, previous error codes cannot be displayed.

Method for Resetting Error Memory To reset the error memory, turn the ignition switch OFF and ON with the connector @ shorted to the ground.

Note: Reset the error memory as shown above to clear the error memory after the end of repair according to the diagnosis.

Diagnosis Code List

NMR: No-load maximum speed

Reference page for troubleshooting

1 -38

1-38

141

1-42

1 43

1 -44

1-44

146

146

Error code (check lamp

blinking count)

1

2

3

4

5

6

7

8

9

Meaning

Limit switch ON signal is not input although the stepping motor is started as specified.

Limit switch OFF signal is not input although the stepping motor is driven for the specified steps.

Although the SAS controller is not detecting a vehicle speed sensor failure, no vehicle speed signal is input.

Although the SAS controller is detecting a stop or vehicle speed sensor failure, the vehicle speed signal is input.

The SAS controller judges a vehicle speed sensor failure.

An abnormal value is input from the NMR variable resistor. (Open or short circuit)

The input value from the NMR variable resistor is abnormal.

The speed exceeds the set NMR value.

Access to the EEP RoM

Check item

Open circuit Of limit switch

Short circuit of limit switch

speed sensor signal abnormality

Vehicle speed fail signal abnormality

NMR resistor failure

A GND opencircuit

over-speed

EEP ROM abnormality

Symptom on vehicle

The stepping motor dflve is turned OFF. (Engine idling speed)

The stepping motor drive is turned OFF. (Engine idling speed)

The stepping motor is fixed at the specified position. (Vehicle speed restriction: 9 kmlh (5.6 mph))

The stepping motor is fixed at the specified position. (Vehicle speed restriction: 9 kmlh (5.6 rnph))


Fix step motor to the specified position. (Vehicle speed restriction: kmm (5.6 mph))



The stepping motor is fixed at the specified position. (Vehicle speed 9 kmlh (5.6 mph))

Note: Do not reset the error memory until the end of repair and replacement.

13

To injection pump

To carburetor

11

5

Removal Procedure

1 Open the engine hood and disconnect the battery negative (-) terminal 2 Remove the toe board. 3 Remove the step RH. 4 Disconnect the harness clamp from the controller bracket. 5 Remove the vehicle speed controller mounting bolt. 6 Disconnect the connector from the controller, and remove the controller. 7 Remove the cover for the NMR (no-load maximum speed) variable resistor. 8 Disconnect the connector from the NMR variable resistor, and remove the variable resistor. [Point I] 9 Disconnect connectors from the actuator and limit switch. 10 Disconnect the harness clamp from the actuator bracket. 11 Disconnect two accelerator wires. 12 Remove the accelerator wire bracket. (Only for diesel engine vehicle) 13 Remove the support bolt and the actuator Wflink ASSY. 14 Remove the wire link on the injection pump (carburetor) side. 15 Remove the limit switch. [Point 21 16 Remove the wire link on the pedal side. 17 Remove the actuator from the actuator bracket. [Point 31



Note: After installation, adjust the accelerator wire and throttle wire. (See p. 1-37.) After installation, operate the accelerator pedal t o see that links are functioning normally.

Set to 9 kml Hexagon h (5.6 mph)

head bolt

Point Operations

[Point 11 Removal:

Remove the hexagon socket head bolt from the knob using a 2-mm hexagon wrench.

Installation: Install the variable resistor as instructed below: 1. Turn the NMR variable resistor fully counterclockwise

and install it through the hole in the bracket by tightening the nut.

2. Install the knob through the washer and nut. Align the while line in the knob to 9 kmlh (5.6 mph) and tighten the hexagon socket head bolt.

Inspection: Check resistance of the maximum vehicle speed setting variable resistor. 1. Turn the knob of the variable resistor fully counterclock-

wise and measure the resistance.

Tester range: SZ x 1 k range Standard: Between @ and 0: 0 !2

Between @ and a: 10 f 1 k R Between @) and @: 10 f 1 kR

2. Turn the knob of the variable resistor all the way clockwise and measure the resistance.

Tester range: 52 x 1 k range Standard: Between @ and 0: 10 f 1 k R

Between @ and 0: 10 f 1 k R Between @) and @: 0 52


Check continuity of the limit switch.

Standard: Free position: ca i2 When pressed in by 2.3 (0.091 in) mm or more: 0 SZ


Check the actuator. 1. Check that the actuator shaft can be manually turned

smoothly without sticking. 2. Check the resistance of the actuator.

Tester range: R x 1 range Standard: Between @) and 0: 3.3 R

Between @ and 0: 3.3 R Between @) and @: 6.6 R Between @ and 0: 6.6 S2

Inspection: Measure the insulation resistance between each actuator terminal and body.

Tester range: R x 1 M range Standard: 100 MR or more

ACCELERATION AND THROTTLE WIRE ADJUSTMENT

Injection pump Carburetor

To injection pump

1. Adjust accelerator link height A.

2. Adjust @and @so that deflection of the accelerator wire is 5 mm (0.20 in) when @-I portion is pressed. Measure the deflection after setting the actuator bracket horizontally.

Gasoline engine vehicle (4Y): After warming up the engine, set the ignition key to ON. See that the limit switch @ is in contact with the link @ and pressed to ON. Next, while pushing the @-2 portion with the lever @is in contact with bolt a, adjust @until the deflection of the throttle wire becomes 5 mm (0.20 in). Diesel engine vehicle (1 DZ-11): See that the limit switch @ is in contact with the link @ when the ignition switch is turned ON. Next, while pushing the @-2 portion with the throttle lever in contact with the idle adjusting screw @, adjust a until the throttle wire deflection becomes 5 mm (0.20 in).

4. Gasoline engine vehicle (4Y): Turn the ignition switch ON and fully depress the accelerator pedal. Adjust the accelerator pedal stopper bolt @until the clearance between lever Oand body @becomes 2 mrn (0.079 in). Diesel engine vehicle (1 DZ-11): Turn the ignition switch ON and fully depress the accelerator pedal. Adjust the accelerator stopper bolt @until the clearance between throttle lever a and maximum adjusting screw comes 2 mm (0.079 in).

5. Operate the accelerator pedal 2 or 3 times after the above adjustment to check if links operate smoothly.

Note: A are the same as on the standard vehicle. (See p. 1-23.)

TROUBLESHOOTING

Troubleshooting of Problems with Error Code Display

1. Error codes 1 and 2 (Limit switch openlshort circuit)

I Do links operate normally when the accelerator pedal is depressed? Repair respective links.

1 I

YES I

Inspection 1 Is there any disconnected or loosened limit switch connector?

lnspection 3 Is the limit switch voltage normal?

NO , Repair connection of faulty connector.

lnspection 2 Is circuit continuous between limit switch and vehicle speed controller?

P+ Repair or replace the wiring.

YES I

NG 5 Repair or replace the wiring.

lnspection 4 Inspect the limit switch independently. (See p. 1-35.) Replace the limit switch.

OK I

lnspection 6 lnspect the actuator voltage.

lnspection 5 Is the circuit continuous between the vehicle speed controller and actuator?

P- Repair or replace the wiring.

NG 5 Repair or replace the wiring.

lnspection 7 Inspect the actuator independently. (See p. 1-36.) Replace the actuator.

Replace the vehicle speed controller.

lnspection 1 : Limit switch connector inspection Check for any disconnected or loose connector.

YES -+ Go to lnspection 2. NG + Repair connection of the connector.

lnspection 2: Limit switch harness continuity inspection Disconnect the limit switch connector and vehicle speed controller connector.

@VEHICLE SPEED @VEHICLE SPEED CONTROLLER CONTROLLER

@ LIMIT SWITCH

Tester range: Q x 1

OK -+ Go to lnspection 3. NG + Repair or replace the wiring between limit switch and vehicle speed controller.

Measurement terminals

Standard

lnspection 3: Limit switch harness voltage inspection Disconnect the limit switch connector and turn the ignition switch to ON.

Between vehicle speed controller A-7 and limit switch connector D-1 Between vehicle speed controller 8-13 and limit switch connector D-2

OR

@ LIMIT SWITCH

0 0

A

- Tester range: 50 V DC

OK -+ Go to lnspection 4. NG + Repair or replace the wiring between battery and limit switch.


Standard

Between limit switch D-1 @ and limit switch D-2 a 4.5 - 5.2 V

lnspection 4: Independent limit switch inspection (See p. 1-35.)

OK + Go to inspection 5. NG + Replace the limit switch.

lnspection 5: Actuator harness continuity inspection Disconnect the actuator connector and the vehicle speed controller connector.

0 ACTUATOR @VEHICLE SPEED CONTROLLER

Tester range: R x 1

OK + Go to lnspection 6. NG + Repair or replace the wiring between battery and actuator.


Standard

lnspection 6: Actuator voltage inspection Turn the ignition switch to ON.

Between vehicle speed controller B-6 and actuator C-4 Between vehicle speed controller B-5 and actuator C-5 Between vehicle speed controller 8-12 and actuator C-1 Between vehicle speed controller B-11 and actuator C-2

OR

@ACTUATOR @VEHICLE SPEED CONTROLLER

Tester range: 50 V DC

OK + Go to lnspection 7. NG -+ Repair or replace the wiring between battery and actuator.


Standard

lnspection 7: lndependent actuator inspection (See p. 1-36.)

Between actuator C-3 @ and vehicle speed controller A-2 @

12V (battery voltage)

OK -+ Replace the vehicle speed controller. NG -+ Replace the actuator

2. Error code 3 (Vehicle speed sensor failure)

lnspection 2 Is circuit continuous between vehicle speed Repair or replace the wiring. controller and SAS controller?

lnspection 1 Are there disconnected or loose SAS, vehicle speed controller connectors and front harness connectors?

v

Display the SAS controller diagnosis. Is there any Go to SAS Troubleshooting.

vehicle sensor error display (51-1 or 51-2)? (See vehicle speed sensor

YES I

No , Repair connection of connectors.

C Replace the vehicle speed controller.

lnspection 1 : SAS controller, vehicle speed controller and front harness connector inspection Check for any disconnected or loose connectors.

SAS controller @

YES -+ Go to lnspection 2. NO -+ Repair connection of connectors.

lnspection 2: SAS controller harness continuity inspection Disconnect the SAS controller connector and the vehicle speed controller connector 6.

O SAS CONTROLLER @VEHICLE SPEED CONTROLLER

Tester range: R x 1

OK + SAS controller diagnosis (vehicle speed sensor error 51-1 or 51-2) check. NG -+ Repair or replace the wiring between SAS controller and vehicle speed controller.


Standard

Between vehicle speed controller 8-4 and SAS controller J-13

OR

3. Error code 4 (Vehicle speed sensor failure)

lnspection 1 Is there any disconnected or loosened SASIvehicle speed controller or front harness connector? b- Repair connection of connectors.

I (See Inspection 1 for Error Code 3.) I I I

YES I lnspection 2 Is the circuit continuous between vehicle speed controller and SAS controller?

YES I - NG

)Repair or replace the wiring.

4 . Replace the vehicle speed controller. 1

Go to SAS Troubleshooting. (See vehicle speed sensor failure on section 15.)

7

lnspection 1 : SAS controller, vehicle speed controller and front harness connector inspection (See lnspection 1 of Error Code 3.)

Display the SAS controller diagnosis. Is there any vehicle sensor error (51-1 or 51 -2) display?

YES + Go to lnspection 2. NO + Repair connection of connectors.

NO

lnspection 2: SAS controller harness continuity inspection Disconnect the SAS controller connector and the vehicle speed controller connector A.

@ SAS CONTROLLER @VEHICLE SPEED CONTROLLER

2

Tester range: !2 x 1

OK -+ SAS controller diagnosis (vehicle speed sensor error 51-1 or 51-2) check. NG + Repair or replace the wiring between SAS controller and vehicle speed controller.


Standard

Between vehicle speed controller A-23 and SAS controller J-10

O n

4. Error code 5 (SAS controller failure)

I inspection 1 I I 1s there any disconnected or loosened SASIvehicle

speed controller or front harness connector? P- Repair or replace the wiring.

1 (See Inspection 1 for Error Code 3.) I -

YES I

(See lnspection 2 for Error Code 4.)

OK I I

J.

J.

[ Go to SAS Troubleshooting. (See vehicle speed I

lnspection 2 Is circuit continuous between vehicle speed controller and SAS controller?

I sensor failure on section 15.) I YES


NG )Repair or replace the wiring.

Inspection 1 : SAS controller, vehicle speed controller and front harness connector inspection (See lnspection 1 for Error Code 3.)

YES + Go to lnspection 2. NO -+ Repair connection of connectors.

lnspection 2: SAS controller harness continuity inspection (See lnspection 2 for Error Code 4.)

OK + Go to SAS Controller Troubleshooting. (See vehicle speed sensor failure on section 15.) NG -+ Repair or replace the wiring between SAS controller and vehicle speed controller.

5. Error code 6, 7 (Maximum vehicle speed set variable resistor failure)

Inspection 1 Is there any disconnected or loosened NMR variable resistor connector?

I lnspection 3 Check the NMR variable resistor voltage.

NO )Repair connection of connectors.

YES

P- Repair or replace the wiring.

lnspection 2 Is the circuit continuous between vehicle speed controller and NMR variable resistor?

NG )Repair or replace the wiring.


OK

Inspection 4 Independent NMR variable resistor inspection (See p. 1-35.)

lnspection 1 : NMR variable resistor connector inspection Check for any disconnected or loosened connector.

NG ,Replace the NMR variable resistor.

YES -+ Go to lnspection 2. NO -+ Repair connection of connectors.

Inspection 2: NMR variable resistor harness continuity inspection Disconnect the NMR variable resistor connector E and vehicle speed controller connector A.

@VARIABLE @VEHICLE SPEED RESISTOR CONTROLLER

Tester range: R x 1

OK + Go to lnspection 3. NG + Repair or replace the wiring between the NMR variable resistor and vehicle speed controller.


Standard

lnspection 3: NMR variable resistor voltage inspection Disconnect the NMR variable resistor connector and turn the ignition switch to ON.

Between vehicle speed controller A-20 and NMR variable resistor E-3 Between vehicle speed controller A-4 and NMR variable resistor E-1 Between vehicle speed controller A-21 and NMR variable resistor E-2

OR

@VARIABLE RESISTOR Po 0

-

Tester range: 50 V DC

OK -+ Go to lnspection 4. NG -+ Repair or replace the wiring between the battery and NMR variable resistor


Standard

lnspection 4: Independent NMR variable resistor inspection (See p. 1-35.)

NMR variable resistor E-3 @ and Between NMR variable resistor E-2

5 5 0.25 V

OK -+ Replace the vehicle speed controller. NG + Replace the NMR variable resistor.

6. Error code 8 (Over-speed)

Check the no-load maximum speed. Adjust. (For adjustment value, see page 1-11.1-1 2. Adjust Replace the air governor or injection to 2600 rpm for all models rided 1 DZ-ll engine.) Pump.


Error code 9 (EEP ROM failure)


Troubleshooting for No Error Code Display

1. Mismatching of maximum vehicle speed with set maximum speed * d

Do links operate normally when the accelerator pedal is depressed?

P- Repair respective links. I I

YES

I Check adjustment of throttle and accelerator wires. (See pl-37.) Adjust.

Check the no-load maximum speed. (For adjustment value, see p. 1-11, 1-12. Adjust to Adjust. 2600 rpm for all models rided 1 DZ-ll engine.)

lnspection 4 OK 1

Check the actuator voltage. (See Inspection 6 for NG

>Repair or replace the wiring. Error Code 1 .)

I I

OK

I lnspection 5 Independent actuator inspection (See p. 1-36.) P- Replace the actuator.

lnspection 1 Check the NMR variable resistor voltage. (See lnspection 3 for Error Code 6.)


NG +Repair or replace the wiring.

OK

lnspection 2 lndependent NMR variable resistor ~nspection (See p. 1-35.)

NG &Replace the NMR variable resistor.

OK

lnspection 3 Check continuity between the vehicle speed controller and actuator. (See lnspection 5 for Error Code 1 .)

. NG )Repair or replace the wiring.

lnspection 1 : NMR variable resistor voltage inspection (See lnspection 3 for Error Code 6.)

OK + Go to lnspection 2. NG + Repair or replace the wiring between the battery and NMR variable resistor.

lnspection 2: lndependent NMR variable resistor inspection (See p. 1-35.)

OK -+ Go to SAS Controller Troubleshooting. (See the vehicle speed sensor failure on section 15.) NG -+ Replace the NMR variable resistor.

lnspection 3: Actuator harness continuity inspection (See lnspection 5 for Error Code 1.)

OK -+ Go to lnspection 4. NG + Repair or replace the wiring'between actuator and vehicle speed controller.

lnspection 4: Actuator voltage inspection (See lnspection 6 for Error Code 1 .)

OK -+ Go to lnspection 2. NG -+ Repair or replace the wiring between battery and actuator.

lnspection 5: lndependent actuator inspection (See p. 1-36.)

OK + Replace the vehicle speed controller. NG -+ Replace the actuator.

TORQUE CONVERTER & TRANSMISSION Page

GENERAL .......................................................................... 2-2

................................. HYDRAULIC CIRCUIT DIAGRAM 2-8

SPECIFICATIONS .......................................................... 2-10

COMPONENTS .............................................................. 2-11

TROUBLESHOOTING ................................................... 2-20

TRANSMISSION & CONTROL VALVE ASSY ........... 2-21

REMOVAL*INSTALLATION ................................................ 2-21

.................... DISASSEMBLY*INSPECTION*REASSEMBLY 2-22

............................ TORQUE CONVERTERaOIL PUMP 2-26 REMOVAL • INSTALLATION ................................................ 2-26

TORQUE CONVERTER & TRANSMISSION ................................................................................ ASSY 2-29


............................. TRANSMISSION ASSY (1 SPEED) 2-32

DISASSEMBLY*INSPECTION-REASSEMBLY .................... 2 3 2

TRANSMISSION ASSY (2 SPEEDS) ........................... 2-39

DISASSEMBLY*INSPECTION*REASSEMBLY .................... 2-39

CLUTCH DRUM ASSY ................................................ 2-50

DISASSEMBLY*INSPECTION-REASSEMBLY .................... 2-50

DIRECTION SWITCH ASSY .......................................... 2-53


OIL PRESSURE MEASUREMENT AND STALL TEST ............................................................ 2-54

GENERAL 1 Speed Torque Converter (Standard) -

F: Forward R: Reverse

-- - - -

2 Speeds Torque Converter (Pn2-3 Ton Series: Option)

--

Control Valve (1 Speed, Upper) I

I I

A-A: Accumulator

B-B: Change valve

C-C: lnch~ng valve

D-D: Regulator valve

L

Control Valve (2 Speeds, Upper)

A-A: Accumulator

B-B: Inching valve

C-C: Regulator valve

2-6

Control Valve (1 Speed, Lower)

C-C: Safety valve

A-A: Shift change valve

B-B: Shift change valve (F)

Control Valve (2 Speeds, Lower)

0 0 r n ~

-f+ -I9

E E

0 0 W D

A-A: 1-2 shift valve

I

B-B: Safety valve

C-C: F shift valve

D-D: R shift valve

E-E: F-R change valve

HYDRAULIC CIRCUIT DIAGRAM 1 Speed

2 Speeds

SPECIFICATIONS

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

l tem

Maker

Torque converter type

Torque converter model

Stall torque ratio

Stall speed rpm

Control system

Clutch operating pressure (main pressure) kPa(kgf/cm2)[psi]

Torque converter outlet pressure kPa(kgflcm2)[psi]

Torque converter oil capacity & (USgal)

Torque converter oil

Torque Converter Ratio

1 speed torque converter (STD)

Aisin

3 elements. 1 stage, 2 phases type

AlSlN

4Y-ADZ-II : 2.68

4Y-1DZ-ll:2100

Solenoid type selector valve

1108 (11.3) [161]

392 (4.0) [57]

9.0 (2.38)

ATF GM Dexrona I I

2 speeds toque converter (Pn2.3 ton series: OPT)

t

t

t

t

t

t

t

t

10.5 (2.77)

t

Forward 1 st speed

Forward 2nd speed

Reverse

2 speeds torque converter

Pn2-3 ton series

4Y. 1 DZ-I I

1.255

0.905

1.060

1 speed torque converter

Pnl ton series

4Y.1 DZ-II

1.531

-

1.540 ,

Pn2.3 ton series

4Y.1 DZ-II

1.583

-

1.594

Cu2-3 ton series

4Y

1.531

-

1.540

2-1 1

COMPONENTS Torque Converter Housing

2-1 2

Torque Converter

Torque Converter Clutch (1 speed)

Torque Converter Clutch (2 speeds)

Forward 3203

Reverse

3205101C

Torque Converter Gear (1 speed)

Torque Converter Gear (2 speeds)

Control Valve (1 speed)

2-1 8

Control Valve (2 speeds)

Torque Converter Piping

Direction Switch

TROUBLESHOOTING

TRANSMISSION & CONTROL VALVE ASSY REMOVAL*INSTALLATION T = N-m (kgf-cm) [ft-lbfl

7 = 9.6 - 14.4 (98 - 145)

T = 9.81 - 15.7

': Note that only this bolt is M6 in the 1 speed torque converter and that all other bolts are different in size (Ma bolts).

Removal Procedure


2 Disconnect the inching wire.

3 Disconnect the electrical wiring.

4 Disconnect the torque converter cooler hose.

5 Remove the transmission cover & control valve ASSY.


The installation procedure is reverse of the removal procedure.

DISASSEMBLY*lNSPECllON.REASSEMBLY T = N-m (kgf-cm) [ft-lbfj


1 Disconnect the solenoid valve connector.

2 Remove the solenoid valve. [Point 11

3 Remove the sleeve lock plate and solenoid wire ASSY.

4 Remove the inching lever.

5 Remove the inching level oil seal. [Point 21

6 Remove the accumulator valve, inching valve and regulator valve. [Point 31

7 1st Speed: Remove the change valve. [Point 41

8 2 Speeds: Remove the shift valve cover plate and gasket.

9 Remove the lower valve body ASSY, oil strainer, steel ball and spring. [Point 51

10 2 Speeds: Remove the change valve.

11 Remove the safety valve, F shift valve, R shift valve and 1-2 shift valve (2 speeds only). [Point 61


The reassembly procedure is reverse of the disassembly procedure.

Point Operations


2 Speeds Route the wiring harness for F2 (black connector) between the valve body and F2 solenoid valve, and then install the solenoid valve.


SST 09950-7601 8-71 --- @I (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

[Point 31 Disassembly:

Remove the valve plug using the service bolt.

Service bolt size: M8 x 1.25

Disassembly: 2 Speeds Remove the accumulator valve using the SST. SST 09950-76002-71 (SST 09950-5001 2)

Inspection: Measure free length of each valve spring.


I st Speed 1. Remove the pin. 2. Remove the valve plug using the service bolt.

Service bolt size: M6 x 1.0

Limit mm (in)

81.7 (3.217)

11 1.2 (4.378)

-1999.11: 66.8 (2.630) 1999.1 1 -: 61 .O (2.402)

47.4 (1 366)

84.4 (3.323)

1 Standard mm (in)

Accumulator valve (inner) ' 86.0 (3.386)


1nstall.the lower valve body. 1. Install the oil strainer, spring and steel ball (*) on the lower

valve body, and put the plate and gasket on top. *: Since June 2000, the relief valve piston has been used

in place of the steel ball. 2. Reverse the above while maintaining the assembled

state and install it on the transmission cover.

Accumulator valve (outer)

Inching valve (plug side)

lnching valve (valve side)

Regulator valve

11 7.0 (4.606)

-1999.11: 70.3 (2.768) 1999.11-: 64.2 (2.528)

49.9 (1.465)

88.8 (3.496)


Press in the valve plug with its opening facing downwards and remove the key.

Inspection: Measure free length of each valve spring.

FIR shift valve

Safety valve

1-2 shift valve

Standard mm (in)

53.5 (2.1 06)

59.8 (2.354)

44.0 (1.732)

Limit mm (in)

50.8 (2.000)

56.8 (2.236)

41.8 (1.646)

TORQUE CONVERTERmOIL PUMP

REMOVAL*INSTALLATION T = N-m (kgf-cm) [ft-lbfj

Removal Procedure

1 Drain the torque converter oil.

2 Remove the engine. (See page 1-6.)

3 Remove the torque converter ASSY. [Point I]

4 Remove the oil pump with stator shaft. [Point 21

5 Remove the stator shaft.

6 Remove the oil pump gear. [Point 31

7 Remove the oil seal. [Point 41



Point Operations

[Point 11 Removal:

Be careful as the torque converter ASSY contains oil. Installation:

Apply grease before installing the seal ring and oil seal lip. Installation:

Install while rotating the torque converter ASSY so that the extension nail enters into the groove in the oil pump drive gear.

[Point 21 Removal:

SST 09950-76002-7 1 (SST 09950-5001 2)


Measure clearance between the oil pump driven gear and pump body.

Limit: 0.3 mm (0.012 in)

Inspection: Measure clearance between the oil pump driven gear and crescent.

Limit: 0.4 mm (0.01 6 in)

Inspection: Measure clearance between the oil pump drive gear and crescent.

Limit: 0.4 mm (0.01 6 in)

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

Limit: 0.1 mm (0.004 in)

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

Limit: 0.1 5 mm (0.0059 in)

[Point 41 Installation:

SST 09950-7601 9-71 --- @ (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-7001 0)

TORQUE CONVERTER & TRANSMISSION ASSY

REMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Engine mounting nut

Torque converter mounting set bolt


Drive plate set bolt (for connecting to engine crankshaft)

Drive plate set bolt (for connecting to torque converter)

T = 53.9 - 99.0 (550 - 1010) [39.8 - 73.11

T = 49.0 - 78.5 (500 - 800) [36.2 - 57.91

T = 29.4 - 44.1 (300 - 450) [21.7 - 32.61

Gasoline model: T = 56.9 - 64.7 (580 - 660) [42.0 - 47.8) Diesel model: T = 76.5 - 93.2 (780 - 950) [56.4 - 68.71

T = 14.7 - 21.6 (150 - 220) [10.9 - 15.91

2-30

Removal Procedure

1 Remove the engine hood. (See page 9-6.)


3 Drain the coolant.

4 Remove the battery and battery tray.

5 Diesel Vehicle: Remove the sedimenter bracket set bolt to make the bracket free.

6 Disconnect the accelerator wire and fuel hose. [Point 11

7 Remove fuse box and electrical parts plate set bolts to set them free.

8 Disconnect connectors and wiring harnesses from the engine.

9 Remove the horn with bracket.

10 Disconnect the inching wire.

11 Disconnect the torque converter cooler hose. [Point 21

12 Remove the radiator.

Disconnect the air cleaner hose.

Remove the oil pump set bolts to set the pump free.

Disconnect the exhaust pipe.

Remove the under cover.

Remove the propeller shaft. (See page 3-3.)

Remove the transmission mounting bolts.

Remove the engine mounting nuts.

Remove the engine with torque converter. [Point 31

Remove the cover plate.

Remove the drive plate set bolts. [Point 41

23 Separate the engine from the torque converter housing.

24 Remove the transmission cover and control valve ASSY.



Point Operations

[Point 11 Removal:

Put match marks on the fuel hose and the mating joint.

[Point 21 Removal:

Put match marks on the radiator and torque converter cooler hose.

[Point 31 Removal-installation:

SST 0901 0-201 11 -71 --- @ 0901 0-23320-71 --- @

Move the SST hook position to adjust the balance.

[Point41 Rernoval.lnstallation:

Turn the flywheel using the crankshaft pulley set bolt.

TRANSMISSION ASSY (1 SPEED) T = Norn (kgf-cm) [ft-lbfl



2 Remove the torque converter.

3 Remove the oil pump with stator shaft and shim. [Point I]

4 Remove the output shaft with front bearing case and the shim. [Point 21

5 Disassemble the output shaft with front bearing case. [Point 31

6 Remove the counter gear shaft.

7 Remove the main shaft ASSY. [Point 41

8 Remove the spacer, rear bearing, reverse clutch gear, forward clutch gear and reverse & forward clutch drum ASSY. [Point 51 (For disassembly, inspection and reassembly of the clutch drum ASSY, see page 2-50.)

9 Remove the reverse and forward clutch gear bearings. [Point 63

10 Remove the bearing spacer from the output gear portion. [Point 7]

11 Remove the counter gear

12 Remove the counter gear bearing. [Point 81

13 Remove the output gear.

14 Remove the oil filter. [Point 91

15 Remove the oil pan and oil strainer. [Point 101

16 Remove the main shaft front bearing and output shaft rear bearing. [Point 111



Shim

Point Operations


SST 09956-76003-71 (SST 09950-5001 2)

Reassembly: Tentatively install the oil pump with stator shaft and check the main shaft thrust clearance. Standard: 0.20 to 0.62 mm (0.0079 to 0.0244 in) If the measured clearance fails to fall within the specified range, increase or decrease the shim thickness for adjustment.


Remove the output shaft with front bearing case using the service bolt. Service bolt size: MI 0 x 1.25

Mark

0

1

2

3

Reassembly: Check the output shaft thrust clearance. Standard: 0.03 to 0.51 mm (0.001 2 to 0.0200 in) If the measured clearance fails to fall within the specified range, increase or decrease the shim thickness for adjustment.

Thickness mm (in)

0.67 - 0.75 (0.026 - 0.030) 0.855 - 0.945 (0.034 - 0.037) 1.065 - 1 .I75 (0.042 - 0.046) 1.335 - 1.465 (0.053 - 0.058)


Disassemble the output shaft front bearing case. 1. Remove the snap ring using the SST.

SST 09905-76002-71 (SST 09905-0001 2)

2. Remove the output shaft using a plastic hammer. 3. Remove the oil seal using a straight-edge screwdriver.

Mark

0

1

Thickness mm (in)

0.855 - 0.945 (0.034 - 0.037) 1.1 90 - 1.31 0 (0.047 - 0.052)

. 2 I 1.530 - 1.670 (0.060 - 0.066)

4. Remove the front bearing using the SST. SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-700 1 0)

5. Remove the dust deflector using a screwdriver.

Reassembly: lnstall the output shaft front bearing case. 1. lnstall the dust deflector using the SST.

SST 0931 6-76008-71 (SST 0931 6-6001 1)

2. lnstall the front bearing using the SST. SST 09950-7601 8-71 --- 0 (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-7001 0)

3. lnstall the oil seal using the SST. SST 091 50-1 01 70-71

4. lnstall the output shaft using a plastic hammer.

5. lnstall the snap ring using the SST. SST 09905-76002-71 (SST 09905-0001 2)

[Point 41 Disassembly.Reassembly:

Remove or install components while supporting them from disconnection or falling down.

Reassembly: Apply grease to the seal ring at the tip of main shaft before reassembly.


Measure side clearance of the seal ring.

Limit: 0.2 mm (0.008 in)

Reassembly: Trrce up the clutch disc serrations with a screwdriver and then install the clutch gear.


SST 09950-7601 9-71 --- @ (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-7001 0)

Reassembly: SST 09950-7601 9-71 --- @ (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-700 1 0)


Install the baring spacer. 1. Tentatively secure the bearing spacer by bringing the out-

put gear towards the output shaft. 2. Secure it from the outside by a screwdriver to protect it

from falling down.

[Point 8) Disassembly:

SST 09320-23000-71

Reassembly: SST 09950-7601 9-71 --- 0 (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-7001 0)

[Point 91 Disassembly-Reassembly:

SST 09228-76004-71 (SST 09228-07501)


Remove iron chips adhering on the magnet and locate the magnet as shown.


SST 09320-23000-71

Reassembly: SST 09950-7601 9-71 --- (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-7001 0)

Clutch operation check after reassembly Blow air through the oil hole on top of the transmission case and see that each clutch piston is operated.

TRANSMISSION ASSY (2 SPEEDS)

DISASSEMBLY-INSPECTION -REASSEMBLY T = N-m (kgf-cm) [ft-lbfl

2-40



2 Remove the torque converter.

3 Remove the oil pump with stator shaft and shim. [Point I]

4 Remove the reverse counter gear shaft. [Point 21

5 Remove the main shaft ASSY. [Point 31

6 Remove the rear bearing, drive gears, reverse clutch gear and reverse clutch drum ASSY. [Point 41 (See page 2-50 for the disassembly, inspection and reassembly procedures of the clutch drum ASSY.)

7 Remove the reverse clutch gear bearing. [Point 51

8 Remove the reverse counter gear. [Point 61

9 Remove the reverse counter gear bearing. [Point 7]

10 Remove the forward shaft front bearing case. [Point 81

11 Remove the forward shaft front bearing. [Point 91

Remove the bearing spacer and shim. [Point 101

Remove the F2 clutch gear snap ring. [Point 111

Remove the forward shaft with F2 clutch gear bearing. [Point 121

Remove the F1lF2 clutch drum ASSY. [Point 131 (See page 2-50 for disassembly, inspection and reassembly procedures for the clutch drum ASSY.)

Remove F1 and F2 clutch gears. [Point 141

Remove the F1 clutch gear bearing. [Point 51

Remove the forward output gear with bearing. [Point 151

Remove the forward idle gear shaft. [Point 161

Remove the forward idle gear and bearing. [Point 17]

Remove the oil pan and oil strainer.

22 Remove the output shaft with front bearing case. [Point 181

23 Disassemble the output shaft with front bearing case. [Point 191

24 Remove the shim and bearing spacer. [Point 201

25 Remove the output gear.

26 Remove the main shaft front bearing and output shaft rear bearing. [Point 211



Point Operations

[Point 11 Disassembly: SST 09950-76003-71 (SST 09950-5001 2)

Reassembly: Tentatively install the oil pump with stator shaft and check the main shaft thrust clearance.

Standard: 0.20 to 0.62 mm (0.0079 to 0.0244 in)

If the measured clearance fails to fall within the specified range, increase or decrease the shim thickness to adjust.


Remove the reverse counter gear shaft. 1. Remove the plate set bolt (on the case side). 2. Pinch the plate set bolt (on the shaft side) through a shop

cloth using pliers and extract the shaft.

Mark

0

1

2

3

Reassembly: lnstall the reverse counter gear shaft. 1. Check the plate position. 2. Install the shaft while guiding the reverse counter gear in

position using the wire being hooked beforehand in [Point 61.

3. Install the plate set bolt (on the case side). 4. Pull off the wire.

Thickness mm (in)

0.670 - 0.750 (0.0264 - 0.0295) 0.855 - 0.945 (0.0337 - 0.0372) 1.065 - 1 .I75 (0.0419 - 0.0463) 1.335 - 1.465 (0.0526 - 0.0577)

[Point 31 Disassembly~Reassembly:

Remove or install while supporting components to protect them from disconnection.

SST

SST

[Point 4) Inspection:

Measure side clearance of the seal ring.

Limit: 0.2 mm (0.008 in)

Reassembly: Arrange serration of the clutch disc using a screwdriver, and install the clutch gear.


SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

Reassembly: SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)


Hook a wire to the gear, which will be used for securing the gear at reassembly of the reverse counter gear shaft.

SST @

SST @


SST 09320-23000-71

Reassembly: SST 09950-7601 8-71 --- @I (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)


Remove the forward shaft front bearing case using the service bolt.

Service bolt size: MI 0 x 1.25


SST 09320-23000-71


-

SST


Tentatively install the forward shaft front bearing case and check the forward shaft thrust clearance.

Standard: 0.20 to 0.62 mm (0.0079 to 0.0244 in)



Install the snap ring while lifting up the F2 gear.

Mark

0

1

2

3


Remove the F2 gear bearing. SST 09950-7601 4-71 (SST 09950-4001 1 )

Thickness mm (in)

0.670 - 0.750 (0.0264 - 0.0295) 0.855 - 0.945 (0.0337 - 0.0372) 1.065 - 1.175 (0.0419 - 0.0463) 1.335 - 1.465 (0.0526 - 0.0577)

Inspection: Measure side clearance of the seal ring.

Limit: 0.2 mm (0.008 in)

Reassembly: Install the F2 clutch bearing. SST 09608-76003-71 (SST 09608-04031 )

[Point 131 Disassern bly-Reassern bly:

Remove or install components while supporting to protect them from disconnection.


True up the clutch disc serrations with a screwdriver and then install the clutch gear.


SST 09950-7601 4-71 (SST 09950-4001 1 )



Remove the forward idle gear shaft. 1. Release the caulking of stopper plate. 2. Loosen the shaft using the SST and then pull it out.

SST 09320-23320-71 3. Remove the lock washer set bolt and plate.

Reassem bty: Install the forward idle gear shaft. 1. lnstall the stopper plate and set bolt. 2. Tighten the shaft to the specified torque using the SST.

SST 09320-23320-71 3. Caulk the stopper plate at the positions shown.

If the position is the same as that of before disassembly, replace the stopper plate to a new one.

[Point 171 Disassembly Reassembly:

When the bearing is reused, secure the inner bearing by wire so that the same bearing will be used at reassembly.

Disassembly: Remove the forward idle gear bearing outer race. 1. Remove the bearing outer race (rear) using the SST.

SST 09320-23000-71 2. Remove the snap ring and bearing spacer.

3. Remove the bearing outer race (front) using the SST. SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

Reassembly: Install the forward idle gear bearing outer race. 1. lnstall the snap ring and bearing spacer. 2. lnstall the front and then the rear bearing outer races, in

this order, using the SST. SST 09950-760 1 8-7 1 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

SST


Remove the output shaft with front bearing case using the service bolt.

Service bolt size: MI 0 x 1.25


Disassemble the output shaft front bearing case. 1. Remove the snap ring using the SST.

SST 09905-76002-7 1 (SST 09905-0001 2)

2. Remove the output shaft using a plastic hammer. 3. Remove the oil seal using a straight-edge screwdriver.

4. Remove the front bearing using the SST. SST 09950-7601 8-71 --- (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

5. Remove the dust deflector using a screwdriver

Reassembly: Install the output shaft front bearing case. 1. Install the dust deflector using the SST.

SST 093 1 6-76008-71 (SST 0931 6-6001 1 )

2. Install the front bearing using the SST SST 09950-7601 9-71 --- @ (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-700 1 0)

SST

-

SST SST 3

3. Install the oil seal using the SST. SST 09150-1 01 70-71 After installation, apply MP grease to the lip.

4. Install the output shaft using a plastic hammer.

5. Install the snap ring using the SST. SST 09905-76002-71 (SST 09905-0001 2)


Tentatively install the output shaft with front bearing case and check the output shaft thrust clearance.

Standard: 0.03 to 0.51 mm (0.001 2 to 0.0201 in)



SST 09320-23000-71

Mark

0

1

2

Reassembly: SST 09950-7601 9-71 --- @ (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-7001 0)

Thickness mm (in)

0.855 - 0.945 (0.0337 - 0.0372)

1 . I9 - 1.31 (0.047 - 0.052)

1.53 - 1.67 (0.060 - 0.066)

Disassembly: SST 09320-23000-71

Reassembly: SST 09950-7601 9-71 --- @ (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-700 1 0)

Clutch operation check after reassembly Blow air through the oil hole on top of the transmission case and see that each clutch piston is operated.

2-50

CLUTCH DRUM ASSY DlSASSEMBLY*INSPECllON*REASSEMBLY


1 Remove the snap ring.

2 Remove the backing plate, clutch disc, clutch plate and camber plate. [Point I]

3 Remove the snap ring and clutch piston return spring. [Point 21

4 Remove the clutch piston. [Point 31



Clutch gear side

v a u n Piston side

Camber plate


Measure the clutch disc thickness.

Standard: 2.6 mm (0.102 in) Limit: 2.3 mm (0.091 in)

Inspection: Measure thickness of the clutch plate.


Inspection: Measure height of the camber plate curving.


Reassembly: Install the camber plate to the clutch drum, with punched mark A facing up.

Reassembly: Install the clutch plate and clutch disc alternately on the clutch drum, while applying torque converter oil.

Number of clutch discs

Pnl ton series

Pn2.3 ton series

Cu2-3 ton series

4Y and 1 DZ-II models

4Y and 1 DZ-II models

4Y model

4

5

4

Reassembly : Adjust the clearance between the backing plate and clutch disc. 1. Install the camber plate, clutch plate, clutch disc, back-

ing plate and snap ring on the clutch drum. 2. Measure clearance between the backing plate and clutch

. disc using thickness gauges. Standard: 4disc specification: 0.8 to 1.3 mm (0.031 to 0.051 in) 5disc specification: 1.0 to 1.6 mm (0.039 to 0.063 in)

1 3. If the measured value is out of the specified range, se-

lect a suitable backing plate. Backing plate thickness: A = 3.0, 3.5 and 4.0 mm (0.118,0.138 and 0.157 in)

[Point 21 Disassembly~Reassem bly:

Compress the return spring using the SST and remove or install the snap ring. Tie two hooks of the SST by a wire or string as shown and secure the hooks so that they will not disconnected from the clutch drum. SST 09220-22001 -71

Caution: If the hooks are disconnected from the clutch drum while the SST is in use, spring will jump out, which is dangerous.

Inspection: Measure free length of the clutch piston return spring.



Pinch the rib of clutch piston by pliers with cloth in-between and remove the piston.

DIRECTION SWITCH ASSY REMOVAL-INSTALLATION

Removal Procedure

1 Remove the turn signal switch cover.

2 Disconnect the wiring.

3 Remove the direction switch ASSY. [Point 11


The instatlation procedure is reverse of the removal procedure.

I I Point Operations

[Point I] Inspection:

Check electrical continuity between switch connector ter- I I minals.

LH spec. 1 :VR 2 : Ra 3 : ST 4 : VF2 5 : VF 6 : IG1 7 : N 8 : 1G2

VF : Forward solenoid VF2 : Forward (F2) solenoid VR : Reverse solenoid ST : Starting motor relay Ra : Backup lamp & buzzer

1st Speed (P: Position, T Terminal No., 0-0: Continuous)

2nd Speed Main pressure Outlet

pressure pressure

Standard

OIL PRESSURE MEASUREMENT AND STALL TEST 1. Maintain the vehicle horizontally and warm up the engine

with the direction switch at the N position. 2. Measure the oil level.

(1) Measure the oil level during idling using the level gauge. (2) If the oil level is not between F (upper limit) and L (lower

limit), adjust to an appropriate level.

3. Measure the oil pressure. (1) Check and adjust the engine speed. (See page 1-9.) (2) Stop the engine and jack up at the front axle to float

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) at each of the main pressure and clutch pressure detection port. SST 09350-23320-71 (SST thread size: Valve side 511 6 UNF, Oil pressure gauge side PT1/8)

(4) Start the engine, set the direction switch to the N position, and measure the main pressures at idling and 2000 rprn, and the torque converter outlet pressure at 2000 rprn.

(5) Operate the direction switch to each shift position and measure clutch operating pressures at idling and 2000 rprn.

Note: Do not step on the inching pedal during measurements of oil pressures.

kPa (kgf/cm2) [psi]

Detecting pressure Plug size Idling I

Main pressure I PT 118 (SST)

/ 49-441 (0.5-4.5)[7-641 !

2000 rpm

735 - 1324 (7.5 - 13.5) [l 07 - 1921 t Clutch pressure

Torque converter outlet pressure

834 - 1373 (8.5 - 14.0) [l 21 - 1991 834 - 1324 (8.5 - 13.5) [l 21 - 1921 ?

PT 118 -

4. Cany out the stall test. (1) Load a cargo having near the permissible maximum

load, firmly locate stoppers to the front and rear wheels, and activate the parking brake.

Caution: Prevent the vehicle from movement by pulling at the rear by a wire as shown, for safety during test.

(2) Warm up the engine and measure the idling speed, no-load static maximum revolution and relief down. (See page 1-14.)

(3) Set the direction switch to the forward position, press on the acceleration pedal all the way and measure the stall revolution after the revolution is stabilized.

Standard: 4Y: Approx. 21 00 rpm 1 DZ-II: Approx. 21 00 rpm

PROPELLER SHAFT Page

........................................................................ GENERAL 3-2

SPECIFICATIONS .......................................................... 3-2

COMPONENTS .............................................................. 3-2

.................................................... PROPELLER SHAFT 3-3

............................................... REMOVAL-INSTALLATION 3-3

................... DISASSEMBLY-INSPECTION-REASSEMBLY 3 4

3-2

GENERAL

SPECIFICATIONS

COMPONENTS

Cross type

77.5 (3.051)

108.5 (4.272)

Joint type

Length mm (in) A

B

PROPELLER SHAFT

Removal Procedure

1 Remove the propeller shaft cover.

2 Remove the propeller shaft set bolt.

3 Remove the propeller shaft.

Installation procedure


Note: Add MP grease through the grease fitting.

--

DISASSEMBLY-INSPECTION-REASSEMBLY


1 Fix the propeller shaft in a vise.

2 Remove the snap rings.

3 Remove the universal spider sets. [Point 11



Point Operations


Remove the universal spider sets. 1. Use a brass bar and extract the bearing cup.

2. Use the brass bar to extract the bearing cup on the other side and remove the spider.

3. Remove the spider set on the opposite side in the same way.

Reassembly: Install the universal spider sets. 1. Coat MP grease on the needle roller in the bearing cup. 2. Use a brass bar and drive in the bearing cup a little. 3. Install the spider. 4. Use the brass bar and drive in the bearing cup until the

snap ring groove appears.

5. Use the brass bar and drive in the bearing cup on the opposite side until the snap ring groove appears.

6. Install the spider set on the opposite side in the same way.

DIFFERENTIAL Page

GENERAL ........................................................................ 4-2

.......................................................... SPECIFICATIONS 4s

COMPONENTS .............................................................. 4-6 DIFFERENTIAL ASSY ................................................... 4-8

REMOVAL*INSTALLATION .............................................. 4-8

................... DISASSEMBLY*INSPECTION*REASSEMBLY 4-11

....................................... DIFFERENTIAL CASE ASSY 4-14

.................. DISASSEMBLY*INSPECTION*REASSEMBLY 4-14

............................................ DIFFERENTIAL CARRIER 4-17 DISASSEMBLY*INSPECnON*REASSEMBLY .................. 4-17

GENERAL Differential (Pnl Ton Series)

Differential (Pn2 Ton Series and Cu2-3 Ton Series)

Differential (Pn3 Ton Series)

Reduction Gear (Pnl Ton Series)

Reduction Gear (Pn2 Ton Series and Cu2-3 Ton Series)

Reduction Gear (Pn3 Ton Series)

SPECIFICATIONS

All models

Banjo type

5.833

6

35

10x4

14 x 2 -

Pnl ton series: 6.3 (1.66)

Pn2 ton series: 7.1 (1.87)

Pn3 ton series: 7.7 (2.03)

Cu2-3 ton series: 7.1 (1.87)

Vehicle model

Differential

Differential oil quantity l (US gal)

Differential case type

Reduction ratio (ring geartdrive pinion)

Number of teeth

Number of teeth x quantity

Drive p~nion ,

Ring gear

Pin~on gear

side gear

COMPONENTS

Pnl ton series

4101-141A

Pn2.3 ton series 41 01 Cu2.3 ton series

60A

91611-60816

4101-142A

DIFFERENTIAL ASSY

Note: Never apply impact to the frame at the time of removal or installation to protect the SAS controller from damage.

T = N-m (kgf-cm) [ft-lbfj 1

* I Axle shaft set bolt

7 Front axle ASSY set bolts

Pn3 ton series, Cu2-3 ton series

Other

T = 98.07 - 127.5 (1000 - 1300) [ 72.35 - 94.061

T = 68.6 - 88.3 (700 - 900) [50.6 - 65.11

Pnl.2 ton series, Cu2.3 ton series

Pn3 ton series

T = 107.9 - 137.3 (1100 - 1400) i79.59 - 101.31

T = 127.5 - 166.7 (1300 - 1700) [94.06 - 123.01

Removal Procedure

1 Remove the mast. (See page 11-9.)

2 Drain differential oil. [Point I]

3 Jack up the vehicle and remove the front wheels.

4 Drain brake fluid, and disconnect the brake pipe (from the wheel cylinder).

5 Disconnect the parking brake cable (from the lever).

6 Remove the parking brake cable clamp.

7 Remove the propeller shaft. (See page 3-3.)

8 Remove the transmission mount bolts.

9 Support the lower side of the transmission with a pantograph jack or wooden block.

10 Support the front axle & differential ASSY with a hoist and garage jack. [Point 21

11 Remove the speed sensor cover and disconnect the connector.

12 Remove the front axle bracket through bolt.

13 Remove the front axle bracket reamer bolt. [Point 31

14 Remove the front axle & differential ASSY.

15 Remove the front axle shaft.

16 Remove the front axle Wlbracket.

17 Remove the speed sensor.



Note: Bleed air from the brake system after installation. (See page 8-23.)

Point Operations

[Point 11 lnstallation:

After reassembly, fill hypoid gear oil to the specified level.

[Point 21 Removal~lnstallation:

Install hub nuts on hub bolts on the left and right side, and sling wire at the tapered portion.

[Point 31 Removal: SST 0931 0-23320-7 1


Operate carefully so as not to bring the axle shaft into contact with the oil seal lip to damage it.


1 Remove the differential cover. [Point 11

2 Measure the ring gear backlash. [Point 21

3 Remove the bearing cap and adjusting nut. [Point 31

4 Remove the differential case ASSY. (See page 4-1 4 for the disassembly, inspection and reassembly procedure.)

5 Remove the differential carrier. [Point 41 (See page 4-17 for the disassembly, inspection and reassembly procedure.)



-

" 0 - 1 0

Match m p

Point Operations


Apply sealing agent (Three Bond's No.1217C or the equiva- lent) on the mating surfaces of the differential cover and housing before reassembly.


Measure the ring gear backlash.

Standard: Pnl-2 ton series: 0.2 - 0.3 mm (0.008 - 0.012 in) Pn3 ton series: 0.3 - 0.4 mm (0.012 - 0.016 in) Cu2.3 ton series: 0.2 - 0.3 mm (0.008 - 0.012 in)


Put match marks on the bearing cap and differential hous- Ing.

Reassern bly: lnstall the adjusting nuts and bearing cap. 1. Install the adjusting nuts. 2. lnstall the bearing cap by aligning the match marks and

temporarily tighten the set bolt. T = 19.6 N.m (200 kgf-cm) [14.5 ft-lbfl

3. Set the dial gauge in the thrust direction of the differential case.

4. Use the SST and tighten until the thrust clearance is elirni- nated. SST 09630-1 011 0-71

5. Tighten adjusting nuts on both sides by one notch each. 6. Set the dial gauge vertical to the ring gear tooth surface,

and measure the backlash.

Standard: Pnl.2 ton series: 0.2 - 0.3 mm (0.008 - 0.012 in) Pn3 ton series: 0.3 - 0.4 mm (0.01 2 - 0.01 6 in) Cu2-3 ton series: 0.2 - 0.3 mm (0.008 - 0.012 in)

If the standard is not satisfied, adjust by turning the adjusting nut to move the differential case ASSY in the thrust direction. (1) When the backlash is excessive:

Loosen the adjusting nut on the ring gear teeth side and tighten the adjusting nut on the rear side as much to bring the ring gear closer to the drive pinion.

(2) When the backlash is insufficient: Loosen the adjusting nut of the rear side of the ring gear and tighten the adjusting nut on the teeth side as much to bring the ring gear away from the drive pinion.

7. Tighten the adjusting nut on the rear side of the ring gear further by 1.5 to 2 notches.

8. Install the adjusting nut lock plate. 9. Finally tighten the bearing cap set bolts.

T = 11 7.7 - 137.3 N-m (1 200 - 1400 kgf-cm) i86.82 - 101.3 ft-lbfl


Apply sealing agent (08826-76002-71 (08826-00090)) on the mating surfaces of the differential carrier and housing before reassembly.

Reassembly: Coat thread tightener (08833-76002-71 (08833-00080)) on the differential carrier set bolts before tightening it.

4-1 4

DIFFERENTIAL CASE ASSY DISASSEMBLY-INSPECTION*REASSEMBLY T = N-m (kgf-crn) [ft-lbfl

T = 127.4 - 176.5 (1300 - 1800) [94.0 - 130.21

(440 - 550) [31.8 - 39.81

Pn3 ton series: T = 86.3 - 103.0

(880 - 1050) [63.7 - 76.01

1


1 Remove the differential case bearings. [Point I]

2 Remove the differential upper case. [Point 21

3 Remove the side gear and pinion gear. [Point 31

4 Remove the ring gear. [Point 41



SST @

r

, SST @

-

Match marks

Point Operations


SST 09950-7601 4-71 --- 6) (SST 09950-4001 1) SST 09950-7601 8-71 --- @ (SST 09950-6001 0)

Reassembly: Install the side bearing. 1. Use the SST and drive in the side bearing to the end

surface. SST 09950-7601 9-71 --- 0 (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-7001 0)

2. Use a striking driver and fully drive in the bearing.


Check the match marks.

Reassembly: Apply locking agent (08833-76001 -71 (08833-00070)) on the set bolt threaded portion before reassembly.


Measure the inside diameter of the differential pinion. Pnl-2 ton series and Cu2.3 ton series Standard: 22.12 mm (0.8709 in) Limit: 22.22 mrn (0.8748 in) Pn3 ton series Standard: 24.67 mm (0.971 3 in) Limit: 24.77 mm (0.9752 in)

Inspection: Measure the spider outside diameter. Pnl.2 ton series and Cu2-3 ton series Standard: 22.00 mm (0.8661 in) Limit: 21.75 rnm (0.8563 in) Pn3 ton series Standard: 24.50 mm (0.9646 in) Limit: 24.25 mm (0.9547 in)

Inspection: Measure the side gear thrust washer thickness.


Inspection: Measure the pinion gear thrust washer thickness.


Reassembly: Install the side gear thrust washer with its oil groove facing the gear.

Reassembly: Apply chassis grease (molybdenum disulfide grease) on both sides of the spider pinion thrust washer before 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.

DIFFERENTIAL CARRIER DISASSEMBLY*INSPECTlON*REASSEMBLY T = N-m (kgf-cm) [ft-lbfl

Pnl ton series

T = 29 - 44 (300 - 450) 121.7 - 32.61

T = 16 - 20 (160 - 200) [11.6 - 14.51


1 Fix the differential carrier ASSY in a vise. [Point 11

Remove the drive pinion rear cover and gasket.

Remove the lock nut, washer, rear bearing roller and shim. [Point 21

Remove the differential carrier ASSY from the vise. [Point 31

Remove the bearing spacer (Pnl ton series), front bearing roller, spacer (Pnl ton series) and pilot bearing (excluding Pnl ton series) from the drive pinion. [Point 41

Remove the differential carrier cover, output gear and reduction gear Wlbearing. [Point 51

Remove the reduction gear bearing. [Point 61

Remove the drive pinion bearing outer race.

Remove the input shaft oil seal. [Point 71

Remove the input shaft dust deflector. [Point 81



Good examples

Bad examples

Point Operations


Fix the differential carrier ASSY in a vise. 1. Fix the SST in the vise.

SST 0941 0-23320-7 1 2. Use the service bolt and install the differential carrier

ASSY on the SST.


Remove the lock nut, washer, rear bearing roller and shim(s). 1. Unlock the lock nut. 2. Use the input shaft to stop the gear from rotation. 3. Remove the lock nut and washer.

4. Apply a wooden block under the drive pinion to prevent it from damage.

5. Use a plastic hammer and remove the rear bearing roller. 6. Remove the shirn(s).

Reassembly: Install the shim(s), rear bearing roller, washer and lock nut. 1. While supporting the drive pinion, install the shim(s), rear

bearing, washer and lock nut. Place the washer with its claw on the deep groove side.

2. Use the input shaft to stop the gear from rotation. 3. Tighten the lock nut to the specified torque. 4. Remove the input shaft. 5. Measure the drive pinion starting torque.

Standard: 8.82 - 13.23 N-m (90 - 135 kgf-cm) If the standard is not satisfied, make adjustment by in- creasing or decreasing the shim thickness.

Shim thickness: 0.13,0.10,0.15,0.35and 0.40 mm (0.0051,0.0039,0.0059,0.018 and 0.01 6 in)

6. Securely swage the lock nut.

SST

L


Fix the differential carrier ASSY in a vise. 1. Fix the SST in the vise.

SST 0941 0-23320-71 2. Place the drive pinion in the center of the service hole. 3. Use the service bolts and install the differential carrier

ASSY on the SST


SST 09420-23000-71

Reassembly: Install the drive pinion front bearing. 1. Check correctness of spacer direction at the time of in-

stallation. (Pnl ton series) 2. Use the SST and install the front bearing.

SST 0931 6-76008-71 (SST 0931 6-6001 1 )

Excluding 1 ton series Disassembly:

SST 09950-7601 4-71 (SST 09950-4001 1 )

Excluding Pnl ton series Reassembly:

Use the SST and install the pilot bearing. SST 09608-76003-71 (SST 09608-04031 ) Check the installed direction.


Check the installing directions of the output gear and reduction gear.

Reassembly: Apply sealing agent (08826-00090) on the bearing retainer surface to come into contact with the differential carrier cover.


SST 09950-7601 8-71 --- 0 (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0) SST 09420-23000-71 --- @

Reassembly: SST 09950-7601 8-71 --- 0 (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)


Use the SST to drive in the new oil seal to be flush with the inside end face of the differential carrier cover. SST 09950-7601 9-71 --- 0 (SST 09950-60020) SST 091 50-1 01 70-71 --- @ After installation, apply grease on the oil seal lip portion.

[Point 83 Reassem biy: SST 09370-20270-71

FRONT AXLE Page

GENERAL ........................................................................ 5-2

SPECIFICATIONS .......................................................... 5-4

COMPONENTS .............................................................. 5-5

TIRESeWHEELS (PNEUMATIC TIRE) ...................... 5-7

FRONT AXLE SHAFTeAXLE HUB ............................. 5-8

REMOVAL-INSTALLATION ............................................... 5-8

FRONT AXLE BRACKETeAXLE HOUSING ............ 5-12 REMOVAL*INSTALLATION ............................................... 5-12

52

GENERAL Pn1 ton series

Pn2 ton series

Pn3 ton series

Cu2 ton series

54

Cu3 ton series

SPECIFICATIONS

Vehicle model Pnl ton series

Item

Pn2 ton series Cu2-3 ton series

t

t

t

Front axle type

Suspension type

Axle shaft diameter mm (in)

Axle shaft diameter (spline portion) mm (in)

Pn3 ton series

t

t

42 (1.65)

Full-floating

Fixed to frame

40 (1.57)

40 (1.57) t / 49.5 (1 949) -

COMPONENTS Pnl ton series

Pn2 ton series

Pn3 ton series

Cu2-3 ton series

TIRES*WHEELS (PNEUMATIC TIRE) 1 Adjusting the lnflating 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 lnflating Pressure

2 Wheel Disassemly~Reassembly

Classification

Pnl ton series

Pn2 ton series

Pn3 ton series

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.

Specification Tire size

6.50-10-10PR

7.00-1 2-12PR

t

28x9-15-12PR

28XR1512PR 7.00L-15-12PR

ST0 OPT STD OPT

OPT

STD OPT

OPT

Single Single (Wide) Single Single (Wide)

Special double

Single

Single (Wide)

Special double

Rim type

Side ring

?

f

t

t

Inflating pressure kPa (kgf/cm2) [psi]

800 (8.0) [I141

850 (8.5) [I211

f

t

t

FRONT AXLE SHAFToAXLE HUB REMOVAL- INSTUTION T = N-m (kgf-cm) [ft-lbfJ

*l : Pn1.2 ton series and Cu2.3 ton series: - 2000. 8, Pn3 ton series T = 14.7 - 21.6 (1 50 - 220) [10.9 - 15.91 Pnl.2 ton series and Cu2.3 ton series: 2000. 8 - T = 2.0 - 3.9 (20 - 40) [ I .49 - 2.891

*: The front axle shaft gasket has been disused since June, 2000.

T = 107.9 - 196.1 (1 100 - 2000) [79.59 - 144.71

T = 176.5 - 392.3 (1 800 - 4000) [130.2 - 289.41

T = 294.2 - 588.4 (3000 - 6000) 2217.1 - 434.11

T = 176.5 - 392.3 (1 800 - 4000) [130.2 - 289.41

Hub nut (single tire)

Pnl ton series

Pn2 ton series

Pn3 ton series, Cu2.3 ton series

Pnl.2 ton series Hub nut (double tire)

Axle shaft set bolt

Hub bolt set nut

Pn3 ton series / T = 294.2 - 588.4 (3000 - 6000) [217.1 - 434.11

Pnl-2 ton series ! T = 68.6 - 88.3 (700 - 900) [50.6 - 65.11

Pn3 ton series, Cu2.3 ton series

Pnl ton series

Pn2 ton series

T = 98.07 - 127.5 (1 000 - 1300) p'2.35 - 94.061

T = 68.6 - 88.3 (700 - 900) 150.6 - 65.11

T = 147.1 - 186.3 (1 500 - 1900) [I 08.5 - 137.51

, Pn3 ton series, Cu2.3 ton series , T = 166.7 - 205.9 (1 700 - 21 00) [I 23.0 - 151.91

Removal Procedure

1 Drain differential oil. [Point 11

2 Jack up the vehicle and remove front wheel.

3 Remove the front axle shaft. [Point 21

4 Remove the axle shaft oil seal. [Point 31

5 Remove the bearing lock nut and plate. [Point 41

6 Remove the outer bearing roller and front axle hub. [Point 51

7 Remove the oil seal and inner bearing roller. [Point 61

8 Remove the bearing outer race. [Point 71

9 Remove the hub bolt.



Note: Apply thread tightener (08833-76001-71 (08833-00070)) on the hub bolt set nut before tightening.

5 mm (0.59 in) or less

Point Operations


Fill Hypoid gear oil to the specified level after installation.

[Point 21 Removal.lnstallation:

Carefully operate so as not to damage the oil seal by contact with the axle shaft.

SST

[Point 31 Removal:

SST 09320-23000-71

Installation: SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)


Pnl.2 ton series and Cu2.3 ton series SST 09509-76002-7 1 (SST 09509-55020) Pn3 ton series SST 09509-76003-71 (SST 09509-55030)

Installation: Adjust the front axle hub starting force. 1. Install the plate. 2. Fully tighten the bearing lock nut, and rotate the hub by 4

to 5 turns to run in the bearing. 3. Return the bearing lock nut by 111 2 to 116 turn (30 to

60°), and rotate the hub by 4 to 5 turns again. 4. Set a spring scale on a hub bolt, and measure the start-

ing force.

Standard: 25.5 - 72.6 N (2.6 - 7.4 kg9 [5.7 - 16.3 Ibfl

5. If the standard is not satisfied, adjust the degree of bearing lock nut tightening for adjustment.

6. Install the nut lock bolt. Coat thread tightener (08833-76001 -71 (08833-00070)) on the nut lock bolt before tightening. (Pnl.2 ton series and Cu2.3 ton series: - 2000. 8, Pn3 ton series)

6. Install the lock nut stopper screw. Coat thread tightener (08833-76002-71 (08833-00080)) on the lock nut stopper screw before tightening. (Pnl-2 ton series and Cu2-3 ton series: 2000. 8 -)


Fill MP grease in the hub before installing the front axle hub.

Installation: Pnl-2 ton series and Cu2.3 ton series: SST 09370-1 041 0-71 Pn3 ton series SST 09421 -33020-71

[Point 61 Removal:

Use a screwdriver or the like to remove the oil seal.

Installation: SST 09950-7601 9-71 --- @ (SST 09950-60020) SST 09950-76020-71 --- @ (SST 09950-7001 0)

[Point 71 Removal:

Use a brass bar to remove the bearing outer race.


FRONT AXLE BRACKEFAXLE HOUSING REMOVAt.INSTALLAnON T = N-m (kgf-cm) [ft-lbfj

T = 265 - 343 (2700 - 3500) [ I 95.3 - 253.21

Pnl.2 ton series and Cu2.3 ton series : T = 108 - 137 (1100 - 1400) [79.6 - 101.31 Pn3 ton series: T = 127 - 167 (1 300 - 1700) [94.0 - 123.01

T = 137 - 196 (1400 - 2000) [101.3 - 144.1

*-1: Only for Pnl ton series, nuts and washers have been disused since October 2000 as the tapped holes have been made in the front axle bracket.

'-2: For Pnl ton series since Oct. 2000 T = 294 - 343 (3000 - 3500) (21 7.1 - 253.21 Apply locking agent (08833-00080)

Removal Procedure

1 Remove the front axle & differential ASSY. (See page 4-8)

2 Remove the front axle shaft and axle hub. (See page 5-8)

3 Remove the backing plate Wlbrake ASSY. [Point 11

4 Remove the front axle bracket and O-ring.

5 Remove the axle hosing and O-ring.



Note: Apply grease on the O-ring before installation.

Pnl ton series:

.-.-- 8fTJ; @

Pn2 ton series:

8a @ a @

Pn3 ton series:

Point Operations


Apply sealing agent (08826-76001 -71 (08826-00080)) on the mating surfaces of the brake backing plate and front axle bracket before installation.

Installation: Apply locking agent (08833-76001 -71 (08833-00070)) on the set bolts before tightening.

Installation: Be careful as the brake backing plate set bolts are different in length. (Pnl -3 ton series) Bolt length A: l=36mm(1.42in) B: ! = 40 mm (1.57 in) C: !=45mm(l.?7in)

REAR AXLE Page

GENERAL ....................................................................... 6-2 .......................................................... SPECIFICATIONS 6 4

COMPONENTS ............................................................. 6-5

...................... TIRESaWHEELS (PNEUMATIC TIRE) 6-7

.............. REAR AXLE ASSY (Pnl-3 TON SERIES) 6-8

REMOVAL-INSTALLATION ............................................... 6-8

REAR AXLE ASSY (Cu2.3 TON SERIES) ............... 6-10 REMOVAL- INSTALLATION .............................................. 6-10

REAR AXLE HUB-STEERING KNUCKLE

(Pnl-3 TON SERIES) ................................................ 6-12 REMOVAL-INSTALLATION .............................................. 6-12

STEERING KNUCKLE (Cu2.3 TON SERIES) ........ 6-16 REMOVAL*lNSTALLATlON ............................................... 6-16

REAR AXLE CYLINDER ............................................... 6-20 REMOVAL* INSTALLATION ............................................... 6-20 DISASSEMBLYgINSPECTION*REASSEMBLY .................. 6-22

REAR WHEEL ALIGNMENT ( ~ 2 0 0 0 . 8) .................. 6-24

6-2

GENERAL

Pnl ton series and Cu2-3 ton series

2000.8 -

Pn2-3 ton series

I I

2000.8 -

I

Rear Axle Cylinder

SPECIFICATIONS

Elliot type

Center-supported right-left rocking type

0 (0)

1.5"

0"

0"

Pn15 : 1930 (76.0), Pn18 : 1980 (78.0)

Pn20 : 21 50 (84.5), Pn25 : 2220 (87.5)

Pn30 : 2350 (92.5), Pn32 : 2370 (93.3)

Cu20 : 1920 (75.5), Cu25 : 1970 (77.5)

Cu30 : 2030 (80.0), Cu32 : 2060 (81 . I )

Double acting

50.0 (1.969)

Pnl ton series : 76.0 (2.992)

Pn2 ton series : 80.0 (3.150) .

Pn3 ton series : 84.0 (3.307)

Cu2.3 ton series : 76.0 (2.992)

Rear axle type

Rear axle suspension type

Wheel alignment

Toe-in mm (in)

Camber degree

Caster degree

King pin angle

Minimum turning radius (outermost) mm (in)

Rear axle cylinder

Cylinder type

Piston rod outside diameter mm (in)

Cylinder bore mm (in)

COMPONENTS

Pnl-3 ton series

Cu2.3 ton series 01

4301-129A

TIRESaWHEELS (PNEUMATIC TIRE) 1. Adjusting the lnflating 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

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.

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.

Rim type

Divided

Side ring

Divided

Side ring

Divided

Side ring

Tire size

5.7015.00-8-8PR

6.9016.00-9-10PR

6.50-1 0-1 OPR

Classification

Pnl ton series

Pn2 ton series

Pn3 ton series

T = N-m (kgf-cm) [ft-lbfl I Pnl ton series 1 T = 29.4 - 44.1 (300 - 450) (21.7 - 32.61 I

lnflating pressure kPa (kgf/cmz) [psi]

800 (8.0) [I141

700 (7.0) [I 001

775 (7.75) [110.2]

Specnication

STD

OPT

STD

OPT

STD

OPT

1 Pn2-3 ton series 1 T = 49.0 - 68.6 (500 - 700) 136.2 - 50.71 I

6-8

REAR AXLE ASSY (Pnl-3 TON SERIES) REMOVAL.INSTALLATION T = N*m (kgf-cm) [ft-lbfj

Removal Procedure

1 Chock the front wheels.

2 Jack up the vehicle and remove rear wheels.

3 Remove the swing lock cylinder lower pin. (See section 15.)

4 Disconnect the rear axle cylinder hose.

5 Support the rear axle ASSY with a garage jack.

6 Remove the rear axle ASSY. [Point 11

7 Remove the center pin bushing. [Point 21

8 Remove the rear axle damper. (Pnl.2 ton series)



Note: After installation, add grease through each grease fitting. Add genuine molybdenum disulfide grease at the rear axle beam center pins (two places) and swing lock cylinder lower pin. Use MP grease to other grease fittings.

1

1 I I ' 1 First

1 t i l Second

\ J

Point Operations


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: 0.7 mm (0.028 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: 1.2.2.3-3.0.3.5.4.0.4.5 and 5.0 mm (0.047~0.091~0.118~0.138~0.157~0.177 and 0.1 97 in)

3. Install the spacer at the rear side center pin. The first spacer shall be installed with its chamfered at the inside diameter in contact with the center pin boss.


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 before installation.

Installation: Apply molybdenum disulfide grease on the bushing and install the bushing by aligning the grease groove in the bushing with the grease fitting position.

REAR AXLE ASSY (Cu2-3 TON SERIES) REMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure

1 Chock the front wheels.

2 Jack up the vehicle and remove rear wheels. (See removal procedure steps 2 to 4 in steering knuckle removal-installation section on page 6-1 6.)

3 Remove the swing lock cylinder lower pin. (See section 15.)

4 Disconnect the rear axle cylinder hose.

5 Support the rear axle ASSY with a garage jack.

6 Remove the rear axle ASSY. [Point 11

7 Remove the center pin bushing. [Point 21

8 Remove the rear axle damper. (FSV lifting height 5500 mm (21 6.5 in) or above)



Note: After installation, add grease through each grease fitting. Add genuine molybdenum disulfide grease at the rear axle beam center pins (two places) and swing lock cylinder lower pin. Use MP grease to other grease fittings.

C : J First I

3 Second

\ 7

- - Grease fitting

Grease fitting

Point Operations


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: 0.7 mm (0.028 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: 1.2.2.3.3.0.3.5-4.0-4.5 and 5.0 mm (0.047~0.091~0.118~0.138-0.157.0.177 and 0.197 in)

3. Install the spacer at the rear side center pin. The first spacer shall be installed with its chamfered at the inside diameter in contact with the center pin boss.


Inspect the inside diameter of the rear axle center pin bushing.

Limit: 52.0 rnm (2.047 in)

Installation: Apply molybdenum disulfide grease to the bushing before installation.

Installation: Apply molybdenum disulfide grease on the bushing and install the bushing by aligning the grease groove in the bushing with the grease fitting position.

6-1 2

REAR AXLE HUB-STEERING KNUCKLE (Pnl-3 TON SERIES) REMOVAL* INSTALLATION T = N.m (kgf-cm) [ft-lbfl

Removal Procedure

Jack up the vehicle and remove rear wheel.

Remove the hub cap. [Point I]

Remove the castle nut and claw washer. [Point 21

Remove the outer bearing and axle hub. [Point 31

Remove the bearing outer race from the axle hub. [Point 41

Remove the inner bearing roller and oil seal. [Point 51

Disconnect the tie rod (on the knuckle side). [Point 81

Remove the king pin cover.

Remove the king pin lock bolt and king pin. [Point 61

Remove the thrust bearing, spacer and steering knuckle.

Remove the king pin oil seal and needle roller bearing. [Point 71

Remove the bushing from the steering knuckle. [Point 91

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

Note: After installation, add MP grease through grease fittings.

Point Operations


Fill MP grease in the hub cap, and install by tapping the flange portion.


Adjust the rear axle hub starting force. 1. lnstall the claw washer in the correct direction. 2. lnstall the castle nut and temporarily tighten it to a torque

of 15 to 32 N-m (1 50 to 330 kgf-cm) [I 0.9 to 23.9 ft-lbfj. 3. Rotate the hub by 3 to 5 turns to run in the bearing.

4. Set a spring scale on a hub bolt, and measure the starting force.

Standards: Pnl ton series: 15 - 39 N (1.5 - 4.0 kgf) [3.3 - 8.5 lbf] Pn2-3 ton series: 15 - 44 N (1.5 - 4.5 kgf)

[3.3 - 9.9 Ibf]

5. If the standard is not satisfied, adjust the degree of castle nut tightening for adjustment.

6. Install a new cotter pin.

[Point 31 Removal:

SST 09950-7601 4-71 (SST 09950-4001 1)

Installation: lnstall the axle hub and outer bearing. 1. Fill MP grease in the axle hub and knuckle spindle. 2. Install the axle hub. 3. Use the SST and install the outer bearing roller.

SST 09370-20270-71

SST

%?&J--

[Point 4) Removal:

Use a brass bar and remove the bearing outer race.


[Point 51 Removal:

SST 09950-7601 4-71 (SST 09950-4001 1 )

Installation: Install the oil seal and inner bearing roller. 1. Use the SST and install the oil seal.

SST 09370-1 041 0-71

2. Use the SST and install the inner bearing roller. SST 09370-20270-71


Measure the king pin outside diameter.

Limit: 27.8 mm (1.094 in)

0 mm (0

4 mm (0.1 6 in)

Press-fitting direction

Installation: Measure the steering knuckle starting force. 1. Temporarily install the king pin and king pin lock bolt.

Select the spacer so as to minimize vertical looseness of the knuckle, and install it on top of the thrust bearing.

2. Set a spring scale at the tip end of the knuckle spindle, and measure the starting force.

Standard: 19.3 N (2.0 kgf) [4.4 Ibfl or less

3. If the standard is exceeded, check the king pin for bend, the needle bearing for damage and axle beam for deformation.

Spacer thickness: Pnl ton series: 0.5 and 1 .O rnm

(0.020 and 0.039 in) Pn2.3 ton series: 3.0,3.5,4.0 and 4.5 mm

(0.1 18,0.138,0.157 and 0.1 77 in)

4. Tighten the lock nut for the king pin lock bolt.

[Point 71 Removal:

Remove the king pin oil seal and needle roller bearing. 1. Use a straight-edge screwdriver to remove the dust seal

and oil seal. 2. Use the SST and remove the needle roller bearing.

SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

Installation: Install the needle roller bearing and king pin oil seal. 1. Use the SST and install the needle bearing.

Check the needle roller bearing press-fitting surface, pressing direction and installation depth. SST 09950-7601 8-71 --- O (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

2. Install the dust seal. 3. Use the SST and install the oil seal.

SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

7 Flush

[Point 81 (2000.8 -) Removal:

Mark the end pin punch mark position to the plate side.

Installation: Install by matching the end pin punch mark position to the marking on the plate side.

Installation: To install the end pin lock nut, install the cone washer in the illustrated direction and tighten to a specified toque.

T = 49.0 - 78.5 N-m (500 - 800 kgf-cm) 136.2 - 57.9 ft-lbfl

[Point 91 (2000. 8 -) Installation:

Press-in the bushing flush to the lower surface of the knuckle. (Clearance on the upper side will be used for the grease well)

Removal Procedure

Jack up the vehicle.

Remove the hub cap. [Point 11

Remove the castle nut and claw washer. [Point 21

Remove the outer bearing and rear wheel. [Point 31

Remove the bearing outer race from the rear wheel. [Point 41

Remove the inner bearing roller and oil seal. [Point 51

Disconnect the tie rod (on the knuckle side). [Point 81

Remove the king pin cover.

Remove the king pin lock bolt and king pin. [Point 61

Remove the thrust bearing, spacer and steering knuckle.

Remove the king pin oil seal and needle roller bearing. [Point 71

Remove the bushing from the steering knuckle. [Point 91



Note: After installation, add MP grease through grease fittings.

Point Operations


Fill MP grease in the hub cap, and install by tapping the flange portion.


Adjust the rear wheel starting force. 1. lnstall the claw washer in the correct direction. 2. Install the castle nut and temporarily tighten it to a torque

of 15 to 32 Narn (150 to 330 kgf-crn) [ I 0.9 to 23.9 ft-lbfl. 3. Rotate the hub by 3 to 5 turns to run in the bearing.

4. Set a spring scale at the outer periphery of the wheel, and measure the starting force.

Standards: 9.8 - 29 N (1.0 - 3.0 kg9 12.2 - 6.6 Ibf]

5. If the standard is not satisfied, adjust the degree of castle nut tightening for adjustment.

6. Install a new cotter pin.

[Point 31 Ins?allation:

Fill MP grease in the hub and knuckle spindle.

Installation: Install the rear wheel and outer bearing.

SST 09370-20270-71

SST

[Point 41 Removal:

Use a brass bar and remove the bearing outer race.

Installation: SST 09950-7601 9-71 --- (SST 09950-60020) SST 09950-76020-7 1 --- @ (SST 09950-7001 0)

[Point 51 Removal:

SST 09950-7601 4-71 (SST 09950-4001 1 )

Installation: Install the oil seal and inner bearing roller. 1. Use the SST and install the oil seal.

SST 09370-1 041 0-71

2. Use the SST and install the inner bearing roller. SST 09370-20270-7 1


Measure the king pin outside diameter.

Limit: 27.8 mm (1.094 in)

(0 in) Om"" t

(0.16 in)

Press-fitting direction

Installation: Measure the steering knuckle starting force. 1. Temporarily install the king pin and king pin lock bolt.

Select the spacer so as to minimize vertical looseness of the knuckle, and install it on top of the thrust bearing.

2. Set a spring scale at the tip end of the knuckle spindle, and measure the starting force.

Standard: 19.3 N (2.0 kgf) [4.4 Ibfl or less

3. If the standard is exceeded, check the king pin for bend, the needle bearing for damage and axle beam for deformation.

Spacer thickness:3.0,3.5,4.0 and 4.5 mm (0.118,0.138,0.157 and 0.177 in)

4. Tighten the lock nut for the king pin lock bolt.

[Point 71 Removal:

Remove the king pin oil seal and needle roller bearing. 1. Use a straight-edge screwdriver to remove the dust seal

and oil seal. 2. Use the SST and remove the needle roller bearing.

SST 09950-7601 8-71 --- 8 (SST 09950-6001 0) + SST 09950-76020-71 --- @ (SST 09950-7001 0)

Installation: Install the needle roller bearing and king pin oil seal. 1. Use the SST and install the needle bearing.

Check the needle roller bearing press-fitting surface, pressing direction and installation depth. SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)

2. Install the dust seal. 3. Use the SST and install the oil seal.

SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- O (SST 09950-7001 0)



Bush~ng

!


1 n


I

T = 49.0 - 78.5 N-m (500 - 800 kgf-cm) L36.2 - 57.9 ft-lbfl

Flush

[Point 91 (2000.8 -) Installation:

Press-in the bushing flush to the lower surface of the knuckle. (Clearance on the upper side will be used for the grease well)

6-20

REAR AXLE CYLINDER REMOVAL* INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure

1 Jack up the vehicle.

2 Disconnect the tie rod (on the piston rod side). [Point I]

3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 21

4 Remove the rear axle cylinder.

5 Remove the bushing from the piston rod. [Point 31



Match mark

Bushing

Flush

Point Operations

[Point 11 (- 2000.8) Removal:

Mark the punch mark position on each of cylinder end pins LH and RH.

Installation: Install each cylinder end pin by aligning the punch mark with the mark.





T = 49.0 - 78.5 N-m (500 - 800 kgf-cm) 136.2 - 57.9 ft-lbf]


lnstall the fitting in the illustrated direction.

[Point 31 (2000.8 -) Installation:

Press-in the bushing flush to the lower surface of the rod on both ends. (Clearance on the upper side will be used for the grease well.) Check the vertical direction of the rod when installing the cylinder.

DlSASSEMBLY*INSPECTION*REASSEMBLY T = N-rn (kgf-cm) [ft-lbfl


1 Remove the through bolt.

2 Remove the piston rod guide

3 Remove the piston rod. [Point 11

4 Inspect the cylinder. [Point 21



Note: Coat hydraulic oil before reassembly.

Point Operations


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 or water before installation. Do not stretch it excessively.

Caution: Operate carefully to avoid scalding.


Measure the rear axle cylinder bore.

Limit: Pnl ton series and Cu2.3 ton series:

76.35 mm (3.0059 in) Pn2 ton series: 80.35 mm (3.1634 in) Pn3 ton series: 84.40 mm (3.3228 in)

REAR WHEEL ALIGNMENT (- 2000.8)

Toein Inspection

1. Check to see that dimensions Ar and At of the rear axle cylinder are equal.

2. Measure the toe-in (Bf - Br). Standard: 0 i: 4 mm (0 2 0.16 in)

Toe-in Adjustment

Punch mark on plate side

Punch mark on cylinder end pin side

1. Check to see that Ar and Ae of the rear axle cylinder are equal.

2. Align the punch mark on the cylinder end pin (eccentric pin) with the punch mark on the plate on the front side for both the LH and RH sides.

3. Measure and adjust the toe-in (Bf - Br). Standard: 0 .c 4 mm (0 +. 0.16 in) If the standard is not satisfied, make adjustment by the cylinder end pin in the range where the difference between Re and Rr is within 0 + 3 mm (0.12 in). (1) When measued value > 4 mm (0.1 6 in):

Measure R! and Rr, and adjust the cylinder end pin on the smaller side toward IN.

(2) When measured value < 4 mm (0.1 6 in): Measure R! and Rr, and adjust the cylinder end pin on the greater side toward OUT.

Note: If R! equals to Rr, adjust the same amount on the LH and RH sides. If the standard i s not attained by adjustment on one side, make adjustment also on the other side.

4. Install the plate. The plate can be installed with either face UP.

5. After adjustment, fully steer the tires and check to see that they do not come into contact with the vehicle body.

STEERING Page

GENERAL .................................. .,., 7-2

SPECIFICATIONS .......................................................... 7-4

.............................................................. COMPONENTS 7-4

STEERING WHEELmMAST JACKET ........................ 7-7

REMOVAL* INSTALLATION ............................................... 7-7

HYDROSTATIC STEERING VALVE ASSY ............... 7-10

TROUBLESHOOTING .................................................... 7-10

REMOVAL*INSTALLATlON ............................................... 7-11

RELIEF PRESSURE INSPECTION* ADJUSTMENT ......................................................... 7-16

GENERAL

Neutral position (against levelling)

Meter box

Tilt adjusting lever

Power steering valve

For only Cu2 ton series, the following change has been put into effect:

Vehicle series Pnl-2 ton series Cu2-3 ton series

item

Pn3 ton series

COMPONENTS

Relief set pressure for Cu2 ton series since June 2000 kPa (kgf/crn2) [psi]

, 6 4501

m r" '-7

: a' ma &" AK

AC R 1 L... ...a

450144a

6370 (65) [920]

Steering wheel diameter rnm (in)

Steering wheel play (at idling) mm (in)

Power steering type

Hydrostatic steering valve

360 (14.2)

20 - 50 (0.79 - 1.97)

Hydrostatic steering

ospc (Danfoss) Type (manufacturer)

Delivery crn3 (in3)lrw

Rated flow rate !(US gal)/min

Relief set pressure kPa (kgf/cm2) [psi]

100 (6.10)

13 (3.43)

8040 (82) [I 1 70]*

115 (7.02)

c

c

7-7

STEERING WHEEL-MAST JACKET REMOVAL-INSTALL4TION T = N*m (kgf-cm) [ft-lbfj

Removal Procedure

Remove the steering wheel. [Point 11

Remove the combination meter ASSY cover.

Remove the lever switch ASSY cover. [Point 21

Remove the combination meter ASSY set bolts.

Disconnect the combination meter wiring.

Remove the combination meter ASSY.

Disconnect the lever switch ASSY wiring.

Remove the lever switch ASSY.

Remove the tilt lock mechanism. [Point 31

10 Disconnect the engine hood opening device.

11 Remove the steering valve set bolt and keep the valve free.

12 Remove the return spring.

13 Remove the mast jacket ASSY.



Note: Apply MP grease on each sliding portion of the tilt lock mechanism and engine hood opening device. Fill MP grease at the coupling between the tilt steering shaft and steering valve.

Parallel

\

Point Operations

[Point 11 Removal:

SST 09950-76003-71 (SST 09950-500 1 2)

Installation: install the steering wheel after applying rubber grease on the sliding portion (A) of the lever switch. After installation, rotate the steering wheel. when the steering wheel is ro- tated, pins (3 pcs.) on the cam side are automatically set in the holes on the steering wheel side.)

[Point 21 Removal:

Remove the set screw, and disengage the front cover and rear cover by pushing the A portion of the rear cover for removal.


Install so that the tilt lever line and meter box line are in parallel, and see that the tilt lock operation is normal.



1 Remove the snap ring.

2 Remove the tilt steering shaft.

3 Remove the bearing.

4 Remove the lever switch ASSY bracket.



Note: Apply rubber grease on each sliding portion of the lever switch ASSY.

7-1 0

HYDROSTATIC STEERING VALVE ASSY TROUBLESHOOTING

4

Fault

1. Steering wheel is heavy to tum

2. Regular adjustments of the steering wheel are necessary. ("meandering")

3. The steering wheel can turn on its own.

4. Backlash

5. Steering wheel can be turned wholly without moving the steered wheels.

6. Steering is too slow and heavy when operated quick-ly.

7. Heavy kick-back in steering wheel in both directions

8. Turning the steering wheel moves the steered wheels in opposite direction.

9. Leakage at either input shaft, end cover, gear-wheel set, housing or top part.

Possible cause

1.1 No or insufficient oil pressure

1.2 Pressure relief valve is stuck in open position or setting pressure is too low.

1.3 Too much friction at mechanical parts of the vehicle

2.1 Leaf spring without sufficient spring force or broken

2.2 Worn gear wheel set

2.3 Seized cylinder or worn piston seal.

3.1 Leaf springs are stuck or broken and have therefore reduced spring force.

3.2 Inner and outer spools are stuck, possibly due to dirt.

4.1 Cardan shaftworn or broken

4.2 Leaf springs without spring force or broken

4.3 Worn splines on the steering column

5.1 Gear wheel set worn

6.1 Insufficient oil supply to steering unit

6.2 Relief valve setting too low

6.3 Relief valve stuck due to dirt

7.1 Wrong setting of Cardan shaftand gear-wheel set

8.1 Hydraulic hoses for the steering

Remedy

Repair or replace oil pump. Repair or replace flow divider valve.

Repair or clean pressure relief valve. Adjust the valve to the correct pressure.

Lubricate joints of steering link or repair if necessary. Check steering column installation.

Replace leaf springs.

Replace gear wheel set.

Replace defects parts.


Clean steering unit.

Replace Cardan shaft.


Replace steering column.

Replace gear wheel set.

Repair or replace oil pump. Repair or replace flow divider valve.

-

Adjust valve to correct setting.

Clean the valve.

Correct setting as shown in Repair Manual.

1 Reverse the hoses. cylinders have been connected reversely.

9.1 Shaft seal defective

9.2 Screws loose

Replace shaft seal.

Tighten screws.

9.3 O-rings defective / Replace O-ring.

REMOVAL*INSTALLATION T = N-rn (kgf-crn) [ft-Ibfl

p~ ~-

Removal Procedure


2 Remove the lower panel.

3 Remove the combination meter cover.

4 Remove the instrument panel.

5 Disconnect the piping.

6 Remove the steering valve ASSY.

7 Remove the steering valve spacer.



T = Nom (kgf-cm) [ft-lbfl


1 Remove the end cover. [Point 11

2 Remove the gear wheel set, cardan shaft and distributor plate. [Point 21

3 Remove the check valve.

4 Remove the sleeve Wlspool and bearing. [Point 31

5 Remove the O-ring, kin-ring and dust seal ring. [Point 41

6 Remove the rerief valve. [Point 51


The reassembly procedure is the reverse of the disassembly procedure

Note: Wash each part with clean hydraulic oil before assembly.

&7 Parallel

Point Operations


Put a match mark.

Reassembly: 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 each set bolts.

Reassembly: As one out of seven set bolts is a bolt with pin, install it in the correct position.


Pay attention to the following points at the time of reassembly.

1. Fit the gearwheel (rotor) and cardan shaft so that a tooth base 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 carden shaft down into the bore so that 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.

O-ring \

Kin-ring


Extract the spool Wlsleeve upward. Othetwise, the spool cross pin may move during extraction to cause sticking.

Reassembly: Set and install the neutral position spring correctly.

Reassembly: Pay attention to the bearing direction for installation. (See the figure.)

Reassembly: Place the housing with its flanged side facing down, and insert the spool Wlsleeve into the housing. Set the cross pin of the spool in horizontal state during insertion.


Install the kin-ring and O-ring correctly.

Note: For SST No. SJ150-9000-11, please inquire at the near- est Danfoss service shop. (Refer to Parts & Service News Ref. No. GE-7022 of July 1,1997 for detail.)

1. Turn the steering unit until the bore is horizontal. Guide the outer part of the assembly tool into the bore for the spooUsleeve.

2. Apply O-ring and kin-ring with hydraulic oil and place them on the tool.

3. Hold the outer part of the assembly tool 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 0-ringlkin-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.


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.

RELIEF PRESSURE

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: PT118

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/cm2) [psi]

4. If the standard is not satisfied, remove the steering valve and make adjustment by turning the relief valve adjusting screw.

All models*

* Relief set pressure for the products of Cu2 ton series (June 2000 and thereafter) should be adjusted to the following value:

8040 (82';) [I 170+F]

Standard: Unit : kPa (kgf/cm2) [psi]

cf. Parts & Service News Ref. No. GE0013 of Nov. 1,2000

Cu2 ton series since June 2000

6370 +? (65';) [920+F]

BRAKE

........................................................................ GENERAL 8-2

.......................................................... SPECIFICATIONS 8-7

.............................................................. COMPONENTS 8-8

FRONT BRAKE .............................................................. 8-12 DISASSEMBLY-INSPECllON*REASSEMBLY

(Pnl . Cu2-3 TON SERIES) ........................................... 8-12

DlSASSEMBLY=lNSPECTlON*REASSEMBLY (Pn2-3 TON SERIES) ................................................... 8-17

BRAKE AIR BLEEDING ................................................ 8-23

BRAKING FORCE lNSPECTlON*ADJUSTMENT .. 8-23

BRAKE MASTER CY LINDER ...................................... 8-24 REMOVAL* INSTALLATION .............................................. 8-24

DISASSEMBLWINSPECTION-REASSEMBLY .................. 8-25

PARKING BRAKE INSPECTION-ADJUSTMENT .. 8-27

BRAKE PEDAL INSPECTlONmADJUSTMENT ....... 8-28

INCHING PEDAL INSPECTION-ADJUSTMENT .... 8-29

SINGLE BRAKE (INCHING) PEDAL INSPECTION*ADJUSTMENT (1 -PEDAL: OPT) .......................................................................... 8-31

8-2

GENERAL Hydraulic Circuit Diagram

(1) lnch~ng pedal (8) Flow divider (2) Brake pedal (9) Oil control valve (3) Reservoir tank (10) Lift cylinder (4) Brake master cylinder (11) Tilt cylinder (5) Brake wheel cyl~nder (12) Steenng valve (6) Oil tank (1 3) Power steertng cylinder (7) Oil pump

8-3

Front Brake

Pnl ton Series

Wheel Cylinder

8-4

Pn2.3 ton Series

Wheel Cylinder

Cu2-3 ton Series

Wheel Cylinder

8-6

Parking Brake

Master Cylinder

SPECIFICATIONS

Foot brake type

Parking brake

Brake drum inside diameter mrn (in)

Pnl ton series

Hydraulic internal expanding duo servo brake

lntemal expanding mechanical brake

254 (10.0)

Resin mold (asbestos-free)

279 x 48.5 x 5 (11.0 x 1.91 x 0.20)

22.2 (0.87)

19.05 (0.75)

30 (1.18)

SAE J-1703- DOT-3

Brake lining

Material

Dimensions Length x width x thickness mm (in)

Cu2-3 ton series

t

t

t

t

343 x 60 x 5.7 (13.5 x 2.36 x 0.22)

t

t

t

t

Pn2 ton series

c

t

310 (12.2)

t

323 x 60 x 7 (12.7 x 2.36 x 0.28)

28.5 (1.12)

c

t

t

Wheel cylinder bore mm (in)

Pn3 ton series

t

t

t

t

343 x 60 x 7 (13.5 x 2.36 x 0.28)

t

t

t

t

Brake master

cylinder

Bore mm (in)

Stroke mm (in)

Applicable oil

8 8

COMPONENTS Front Brake

Pnl ton Series

Pn2-3 ton Series

Cu2.3 ton Series

Brake Pipe

8-1 0

Brake Master Cylinder

Parking Brake

Brake Pedal (STD)

Brake Pedal (Single Brake Pedal (I-Pedal): OPT)

FRONT BRAKE DISASSEMBLY-lNSPECTlON0REASSEMBLY (Pnl , Cu2-3 TON SERIES)

T = N-m (kgf-cm) [ft-lbfj


1 Drain brake fluid.

2 Remove the front axle hub. (See page 5-8.)

3 Remove the shoe hold down spring and cup. [Point 11

4 Remove the anchor to shoe spring and shoe guide plate. [Point 21

5 Remove the cable and cable guide.

6 Remove the lever strut. [Point31

7 Remove the adjuster spring and adjusting screw. [Point 41

8 Disconnect the parking brake cable. [Point 51

9 Remove the brake shoe. [Point 61

10 Disconnect the brake pipe.

11 Remove the wheel cylinder ASSY. [Point 71

12 Remove the backing plate. [Point 81

13 Inspect the front axle hub (brake drum). [Point 91

Pnl ton series: T=7.8- 11.8 (80- 120)

(5.8 - 8.681 Cu2-3 ton series: T = 17.7 - 26.5 (180 - 27

[I 3.0 - 19.51

5

12

7

Brake backing plate set bolt T = 137 - 196 (1400 - 2000) [101.3 - 144.7



Note: See 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 for installation 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 8-23) and braking force inspection (see page 8-23).

Point Operations

[Point I] Disassembly-Reassembly: SST 0951 0-31 960-71

Inspection: Measure the free length of the hold down spring.

Standard: 25.5 mm (1.004 in)

Reassembly: Apply liquid packing (08826-76001 -71 (08826-00080)) on the shoe hold down pin and the contact surface on the back side of the backing plate to eliminate any clearance.


SST 0971 7-76001 -71 (SST 0971 7-2001 0)

Inspection: Measure the free length of the anchor to shoe spring.

Standard: Pnl ton series: 102.2 mm (4.024 in) Cu2-3 ton series: On the side of lining Wipin

139.3 mm (5.484 in) On the side of lining Vpin 121.8 mm (4.795 in)

Limit: No clearance between coil turns

Reassembly: SST 0971 8-76001 -71 (SST 0971 8-2001 0)


Measure the free length of the strut to shoe spring.

Standard: Pnl ton series: 19.7 mm (0.776 in) Cu2-3 ton series: 29.8 mm (1 .I73 in)


Measure the free length of the adjuster spring.

Standard: Pnl ton series: 99.4 mm (3.913 in) Cu2-3 ton series: 126.0 mm (4.961 in) Limit: No clearance between coil turns

Reassembly: Apply grease on 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 by pulling with a screwdriver.


Apply liquid packing (08826-76001 -71 (08826-00080)) on the parking brake cable outlet in the backing plate to eliminate any clearance.


Measure the brake lining thickness.

Standard: Pnl ton series: 4.9 mm (0.193 in) Cu2-3 ton series: 5.7 mm (0.224 in) Limit: Pnl ton series: 1.0 mm (0.039 in) Cu2-3 ton series: 1.0 mm (0.039 in)

Reassembly: Before brake shoe installation, apply grease on illustrated portions of the backing plate (6 places in contact with the shoe rim and the anchor pin).


Measure the clearance between the wheel cylinder and piston.

Limit: Pnl ton series: 0.125 mm (0.00492 in) Cu2-3 ton series: 0.15 mm (0.0059 in)

Pnl ton series Cu2.3 ton series

Reassembly: Apply liquid packing (08826-76001 -71 (08826-00080)) to backing plate fitting portion of the wheel cylinder and on whole periphery of the set bolts to eliminate any clearance.


Carefully install the backing plate set bolts because they are different in length. Apply thread tightener (08833-76001 -71 (08833-00070)) on the set bolts before reassembly.

Bolt length B: C = 40 mm (1.57 in)

Reassembly: Apply liquid packing (08826-76001 -71 (08826-00080)) on the backing plate surface in contact with the front axle bracket to eliminate any clearance.


Measure the brake drum inside diameter.

Standard: Pnl ton series: 254 mm (10.0 in) Cu2-3 ton series: 31 0 mm (1 2.20 in)

Limit: Pnl ton series: 256 mm (10.1 in) Cu2-3 ton series: 312 mm (12.28 in)

Reassembly: Apply thread tightener (08833-76001 -71 (08833-00070)) on the hub bolt set nut before reassembly.

DISASSEMBLY-INSPECTION*REASSEMBLY (Pn2-3 TON SERIES)


1 Drain brake fluid.

2 Remove front wheel.

3 Remove the front axle hub. (See page 5-8.)

4 Remove the hold down spring. [Point I ]

5 Remove the pawl lever stopper. [Point 21

6 Remove the pawl lever.

7 Remove the anchor to shoe spring. [Point 31

8 Remove the strut lever. [Point 41

9 Remove the adjuster spring and adjusting screw. [Point 51

10 Disconnect the parking brake cable. [Point 61

11 Remove the brake shoe. [Point 71

12 Disconnect the brake piping.

13 Remove the wheel cylinder ASSY. [Point 81

14 Remove the backing plate. [Point 91

15 Inspect the front axle hub (brake drum). [Point 101

4

Wheel cylinder set bolt T = 14.7 - 19.6 (1 50 - 200) [I 0.9 - 14.51 Brake backing plate set bolt T = 137- 196 (1400-2000) [101.3- 144.71


The reassembly procedure is the reverse of the disassembly procedure. (With regard to steps 4 and 5, however, install the pawl lever stopper after installing the hold down spring.)

Note: See 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 for installation to approx. 1 mm (0.04 in) less than the brake drum inside diameter by tightening the adjusting screw. After reassembly, perform brake air bleeding (page 8-23) and braking force inspection and adjustment (page 8-23).

Point Operations


SST 0951 0-31 960-71

Inspection: Measure the free length of hold down spring.

Standard: 32.3 mm (1 -272 in) Limit: 29.1 mm (1 .I46 in)

Reassern bly: Apply liquid packing (08826-76001 -71 (08826-00080)) on the back side of the backing plate in contact with the shoe hold down spring to eliminate any clearance.


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 and install the pawl lever stopper and actuator spring.


SST 0971 7-7600 1 -71 (SST 0971 7-2001 0)

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 0971 8-76001 -71 (SST 0971 8-200 1 0)


Measure the free length of the strut to shoe spring.

Standard: 23 mm (0.91 in) Limit: 20 mm (0.79 in)


Measure the free length of the adjuster spring.

Standard: 86 mm (3.39 in) Limit: No clearance between coil turns

Reassembly: Apply grease on the adjusting screw threaded portion and fill grease in the cap.


Apply liquid packing (08826-76001 -71 (08826-00080)) on the parking brake outlet on the backing plate to eliminate any clearance.


Measure the brake lining thickness.

Standard: 7.0 mm (0.276 in) Limit: 2.0 rnm (0.079 in)

Reassembly: Apply grease on the illustrated portions of the backing plate (6 places in contact with the shoe rim and the anchor pin) before brake shoe installation.


Measure the clearance between the wheel cylinder and piston.

Limit: 0.145 mm (0.00571 in)

Pn2 ton series Pn3 ton series

Reassembly: Apply liquid packing (08826-76001 -71 (08826-00080)) on the wheel cylinder backing plate fitting portion and whole periphery of set bolts to eliminate any clearance.


Carefully install the backing plate set bolts in correct positions since they are different in length. Apply thread tightener (08833-76001 -71 (08833-00070)) on the set bolts before reassembly.

Bolt length A: I = 36 mm (1.42 in) B: e = 40 mm (1.57 in) C: ! = 45 mm (1.77 in)

Reassembly: Apply liquid packing (08826-76001 -71 (08826-00080)) on the backing plate surface in contact with the front axle bracket to eliminate any clearance.


Measure the brake drum inside diameter.

Standard: 31 0 mm (1 2.20 in) Limit: 31 2 mm (1 2.28 in)

Reassembly: 'Apply thread tightener (08833-76001 -71 (08833-00070)) on the brake drum set nut before reassembly.

Single brake pedal spec

BRAKE AIR BLEEDING Note:

Add brake fluid to the reservoir tank during air bleeding to prevent it from becoming insufficient. When the pedal needs to be pushed all the way for air bleeding, torque converter inching cable shall be disconnect from torque converter at inching lever. (single brake pedal spec.)

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 breather plug to discharge air in the piping

with the brake fluid, and tighten the plug immediately before the fluid stops to run out.

(3) Repeat steps (1) and (2) above until no air bubbles 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 each of the

RH and LH side at a time. 3. Add brake fluid to the specified level.

(1) Add brake fluid through the filter provided at the reservoir tank.

(2) Add brake fluid up to the staged portion in the reservoir tank.

BRAKING FORCE INSPECTION*ADJUSTMENT 1. Inspect the braking force by means of a brake tester or traveling test.

Braking distance (without load)

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 clearance automatically when the brake pedal is depressed in reverse traveling.

(2) If the braking force is insufficient, adjuster malfunction, lining contact defect, foreign matter adhe- sion 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.

Initial speed of braking krnlh (rnph)

Braking distance (ft)

Max. speed

5.0 (16.4) or less

BRAKE MASTER CYLINDER REMOVAL*INSTALLATION

--

T = N-rn (kgf-crn) [ft-lbfl

Removal Procedure



3 Remove the instrument panel.


5 Disconnect the brake side hose from the reservoir tank and drain brake fluid.


7 Remove the push rod clevis pin.

8 Remove the brake master cylinder.



Note: After installation, perform brake pedal adjustment (page 8-28) and air bleeding (page 8-23).


1 Turn the boot up and remove the snap ring.

2 Remove the push rod. [Point 11

3 Remove the piston. [Point 21

4 Remove the pin and the fluid inlet elbow.

5 Remove the outlet plug and valve.


The reassembly procedure is the reverse of the disassembly procedure

Point Operations


Temporarily set the push rod length to the illustrated dimension, and make readjustment after installation.


Apply rubber grease on the piston cup and whole periphery of the cup before reassembly.

PARKING BRAKE INSPECTION*ADJUST- MENT 1. Check the parking brake cable set position.

Standard: A = 0 - 2 mm (0 - 0.08 in)

2. Apply chassis grease on the portions indicated by ar- rows.

3. Inspect and adjust the parking brake lever operating force.

(1) Set a spring scale at the center of the lever knob, and measure the operating force by pulling it backward.

Standard: 147 - 196 N (15 - 20 kgf) 133 - 44 lbf]

(2) If the operating force is out of the standard range, release the parking brake and make adjustment at the adjusting portion.

Clockwise turn: Increases the operating force. Counterclockwise turn: Decreases the operating force.

BRAKE PEDAL lNSPECTlON*ADJUSTMENT

Stop lamp switch

Brake master cylinder

Toe board

1. lnspect brake pedal height A. (From toe board to top of pedal)

Standard: A = 150 - 155 mrn (5.91 - 6.1 0 in) (with pedal pad)

If the standard is not satisfied, make adjustment by changing the stop lamp switch position or the stopper bolt protrusion.

2. lnspect brake pedal play B.

Standard: B = 3 - 7 mm (0.12 - 0.28 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 D and inspect the pedal height in that state.

Standard: D = 90 mrn (3.54 in) or more

INCHING PEDAL INSPECTION-ADJUSTMENT (- Mar. 2000)

Stop lamp switch

Adjusting nut

ching lever

Adjusting nuts

1. lnspect and adjust the brake pedal height and play (See page 8-28).

2. lnspect 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: Pnl ton series A = 35 - 46 mm (1.38 - 1.81 in) Others A = 25 - 36 mm (0.98 - 1.42 in)

If the standard is not satisfied, adjust the stop lamp switch or stopper bolt protrusion. Make adjustment to make the deviation from the brake pedal height within t 15 mm (0.59 in).

3. lnspect and adjust the inching cable.

(1) lnspect the inching cable length B 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) lnspect 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.

INCHING PEDAL INSPECTION-ADJUSTMENT (Mar. 2000 -)

Adjusting nut

Adjusting nut

1. lnspect and adjust the brake pedal height and play (See page 8-28).

2. lnspect 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: Pnl ton series A = 35 - 41 mm (1.38 - 1.61 in) Others A=26-32mm(1.02-1.26in)

If the standard is not satisfied, adjust the stopper bolt protrusion. Make adjustment to make the deviation from the brake pedal height within 15 mm (0.59 in).

3. lnspect and adjust the inching cable.





Standard: C = 1 - 3 mm (0.04 - 0.20 in)


SINGLE BRAKE (INCHING) PEDAL INSPECTION-ADJUSTMENT (1 -PEDAL: OPT)

opper bolt protrusion

1. Align the adjusting bolt head surface @with the pedal plate surface @.

2. lnspect and adjust the brake pedal height. (See page 8-28)

3. lnspect 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: Pnl ton series A = 35 - 46 mm (1.38 - 1.81 in) Others A= 25 - 36 mm (0.98 - 1.42 in)

If the standard is not satisfied, adjust the stop lamp switch or stopper bolt protrusion, 4. lnspect and adjust the inching cable.





Standard: C = 1 - 3 mm (0.04 - 0.12 in)


BODY Page

..................................................... COMPONENTS 9-2

................................................... ENGINE HOOD ASSY 9-6

............................................... REMOVAL*INSTALLATION 9-6

....................................................... COUNTERWEIGHT 9-7

REMOVAL*INSTALLATION ............................................... 9-7

DRIVER'S SEAT (ORS WIFULL SUSPENSION SEAT: OPT) ................................................................ 9-8

DISASSEMBLY-INSPECTION-REASSEMBLY ................... 9-8

....................................................................... SEATBELT 9-12

l NSTALLATION (STD SEAT) ............................................. 9-12

REMOVAL*INSTALLATlON (ORS WIFULL SUSPENSION SEAT) .......................................................................... 9-12

SEATBELT RETRACTOR INSPECTION ........................... 9-13

............................................... COMBINATION METER 9-14

REMOVAL*INSTALLATION ............................................... 9-14

.............................................. COMBINATION SWITCH 9-15

INSPECTION .................................................................... 9-15

............................................... FUEL SENDER GAUGE 9-16

INSPECTION .................................................................... 9-16

RELAY BLOCK .......................................................... 9-17

RELAY INSPECTION ........................................................ 9-17

PORTIONS PROTECTED BY FUSES ............................... 9-1 8

COMPONENTS

51 01 @ (SKID PLATE )

@ 15,18.C20.CZS.C3O,CH30

5101-277A

cc &-,BG 5308

26

=-e# 01

FO.0 .ooq 1

1

1

1

s

b... .

...a

EA 5308-213

87 r-.- . "'7

5701 . *

79

I . I I I

b... ... a 5701-212

(YELLOW FREIGHT) 5401

5401-2156.

Caution: Renew all the warning and caution indicators or labels when replacing the overhead guard. Overhead guard set bolts tightening torque T = 58.8 - 88.3 N-m (600 - 900 kgf-cm) [43.4 - 65.1 ft-lbfl

COUNTERWEIGHT REMOVAL*INSTALLATlON

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 remove the counterweight set bolts.

4 Remove the counterweight.



Note: See page 0-15 for the weight of the counterweight.

DRIVER'S SEAT (ORS WlFULL SUSPENSION SEAT OPT) DISASSEMBLY*INSPECTIONaREASSEMBLY T = N*m (kgf-cm) [ft-lbfl


1 Turn the suspension adjuster knob counterclockwise until the suspension control cable is loosened.

2 Remove the reclining control lever and suspension adjuster knob. [Point 11

3 Remove the magazine pocket. [Point 21

4 Remove the pocket.

5 Remove the backboard.

6 Remove the seat back.

7 Remove the reclining adjuster. [Point 31

8 Remove the seat track handle. [Point 41

9 Remove the suspension indicator. [Point 51

10 Remove the shield.

11 Remove the suspension control shaft.

12 Remove the plate, spring, trim and cushion ASSY.

13 Remove the seatbelt buckle, retractor and bezel. (See steps 3,4 and 5 on page 9-12)

14 Remove the frame.

15 Remove the torsion bar

16 Remove the torsion bar stopper.

17 Remove the shock absorber ASSY.

18 Remove the suspension frame.

19 Remove the suspension control cable. [Point 61



Note: Apply a small amount of chassis grease on the suspension link portion, torsion bar stopper movable portion, torsion bar clamp portion, and suspension adjuster gear and shaft portion before installation. Apply thread tightener (08833-76002-71 (08833-00080)) on the threaded portion of the reclining adjuster set bolt before tightening.

Suspension Reclining control lever

1

Free

Point Operations


Install a clip on each of the reclining control lever and suspension adjuster knob and press them in after matching with the shaft spline. After installation, check to see that they will not come off.

Reassembly: lnstall the reclining control lever almost in parallel with the seatbelt buckle end face.


Remove the magazine pocket. 1. Force the center pin in to free the clip for removal.

2. Unhook the lower part of the magazine pocket for removal.

Reassembly: Install the magazine pocket. 1. Fit the hook in the lower part of the magazine pocket to

be locked in position.

Lock qo'=~ 8

2. Pull the center pin out to the free position and insert it to the locked position after installation.


Install the reclining adjuster in the illustrated direction.


Remove the seat track handle by pulling it forward while unhooking it.

Reassembly: See that the hook to lock the handle securely catches the spring.


Remove the suspension indicator. 1. Use a screwdriver to remove the shaft. 2. Remove the indicator while paying attention to the shape

of the hook portion.


Install the stopper screw while holding it so as not to damage the wire.

SEATBELT INSTALLATION (STD SEAT)

1. Install the seat belt with its angle as illustrated. T = 17.6 - 20.6 N-m (180 - 210 kgf-cm) [I 3.0 - 15.2 ft-lbfl

REMOVAL-INSTALLATION (ORS WIFULL SUSPENSION SEAT)

Note: Never try to disassemble the seatbelt retractor. T = N-m (kgf-cm) [ft-lbfl

Removal Procedure

1 Remove the driver's seat. 2 Remove the shield set screws. 3 Remove the seatbelt buckle. [Point I] 4 Remove the seatbelt retractor. [Point 21 5 Remove the seatbelt bezel [Point 31



Point Operations

[Point 11 Removal:

After tightening the seatbelt buckle set bolt, check to see that the buckle moves in the bolt circumferential direction.


See that the seatbelt retractor positioning pin fits in the stop per.

[Point 31 Removal:

Unhook from the inside of the seat.

Installation: After setting the outer hook, push the inner hook in.

SEATBELT RETRACTOR INSPECTION 1. The installed seatbelt should be able to be pulled out

smoothly, and be retracted smoothly. Also check to see it is locked when pulled out suddenly.

2. Apply the seatbelt. Travel straight at a high speed, and apply the brake suddenly. See that the belt is locked to retain the body.

Caution: Test this function in a place where safety can be ensured.

9-1 4

COMBINATION METER REMOVAL-INSTALLATION

Removal Procedure


2 Remove the combination meter set bolts.

3 Disconnect the combination meter wiring.

4 Remove the combination meter ASSY.



COMBINATION SWITCH Note: See page 2-53 for the direction switch inspection.

INSPECTION

Turn signal switch Light swlch

Light B turn signal switch

1. Individual switch continuity inspection

9-1 6

FUEL SENDER GAUGE INSPECTION

1. Measure the resistance. (1) Check to see if the float moves smoothly. (2) Measure the resistance between the sender positive terminal and sender negative (body ground)

terminal while the float position is varied between F and E. Also check if the resistance varies continuously

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.

Standard

Resistance R

3 & 2

32.5

110 ?s 7

Float position mm (in)

F

112 (Reference value)

141.3 ?s 8 (5.563 0.31)

291.8 (1 1.488)

E I 423.5 + 8 (16.673 k 0.31)

RELAY BLOCK

Layout Front

8

Front

8

RELAY INSPECTION

Individual Relay Continuity Inspection Headltail relay

5 - 0 1 3

1 5 ? n m P 2

GlowIST relay

1

When the battery voltage is applied to terminals 1 and 2:

SAS-Lamp relay 4

3

1-2

d o - 2

3- 4

34 No continuity

PORTIONS PROTECTED BY FUSES

Including options

Fusible links

Screw-fastened type

Main protected portions

-

TWC (Sway catalytic) system (4Y-ECS)

Starting motor relay (IG) and glow plug timer (IG)

Electric shift TIC

SAS controller and SAS error lamp relay

Alternator, glow plug timer, ignition coil, LPG main solenoid, LPG slow solenoid, fuel cut and vehicle speed control system

Turn signal lamp and flasher relay

Hour meter, water temperature gauge, fuel gauge, warning lamps (charge, engine oil pressure, air cleaner, lock indicator, sedimenter, glow indicator, fuel, brake, cooling water and battery), back-up buzzer, TIC oil thermometer, strobo, back-up lamp and SAS buzzer

EFI injector, EFI fuel pump

Governor ECU, EFI ECU, Electronic throttle body

Hom

Alternator sending

Headlamp

Charge lamp, choke and glow plug t~mer

Tail lamp, clearance lamp and meter ~llum~natlon

TWC (3-way catalyt~c) system

Stop lamp

Capacity

-

7.5A

7.5A

7.5A

7.5A

7.5A

7.5A

1 0A

15A

15A

7.5A

5A

15A

7.5A

7.5A

7.5A

7.5A

NO

0 @

@

@

0

@

@

03

@

@

@

@

@

@

0

@

@

Name

-

W C

ST (Starting motor)

SFT(Shift)

SAS-ECU

IGN (Ignition)

TURN(Tum)

GAUGE (Meter)

EFI

GOV

HORN(Hom)

ALT-S (Alternator sending)

HEAD (Headlamp)

CHARGE (Charge)

TAIL Fail)

JWC

STOP (Stop lamp)

MATERIAL HANDLING SYSTEM Page

............................... HYDRAULIC CIRCUIT DIAGRAM 10-2

.............................................................. COMPONENTS 10-3

........................ RETURN FILTER.SUCTION FILTER 10-10 REMOVAL*INSTALLATION ............................................... 1 0-1 0

NATURAL DROP TEST .............................................. 10-11

NATURAL FORWARD TILT TEST ............................. 10-11

OIL LEAK TEST ............................................................ 10-12 LIFTCYLINDER .............................................................. 10-12

TILT CYLINDER ............................................................. 10-1 2

HYDRAULIC CIRCUIT DIAGRAM

(9) Oil control valve (1 0) Lift cylinder (1 1) Tilt cylinder (1 2) Steering valve (1 3) Power steering cylinder

,

I-- 7

(1) Inching pedal (2) Brake pedal (3) Reservoir tank (4) Brake master cylinder (5) Brake wheel cylinder (6) Oil tank (7) Oil pump (8) Flow divider

COMPONENTS

10-4

V Mast

Pn 6801 1 ton series

6801427A

Pn-Cu 2 ton series 3 ton series

6801428A

FV Mast

FSV Mast

Pn 6802 1 ton series

6802-485A

FSV Mast

PnCu 6802 2 ton series

6802-486A

-

FSV Mast

Pn-Cu 6802 3 ton series

91 61 1-40825 91 651 -41 020

6802-487A

QFV Mast

Cu2 ton series 6802 F 0

(D 0 X

0 0

w w cm

U) CY OD

\ 0 P .- ln (D 7 QI

7

@Y

I m

y- a ---? Q P a

W -3

L L U

L--- ---a

10-10

RETURN FILTER*SUCTION FILTER REMOVAL*INSTALLATlON T = N*m (kgf-cm) [ft-Ibfl

Removal Procedure

1 Open the engine hood.

2 Disconnect the return hose, suction hose and overflow hose.

3 Remove the tank cover Wlreturn filter and suction filter.

4 Remove the return filter.

5 Remove the suction filter.



NATURAL DROP TEST 1. Set the mast in the vertical position 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:

WISAS 45 mm (1.77 in) USAS 90 mm (3.54 in)

NATURAL FORWARD TILT TEST 1. Set the mast in the vertical position with standard load on

the fork. Lift the fork by about 50 cm (1 9.7 in) and stop the engine.

2. Measure the tilt cylinder rod extension in 15 minutes.

Vehicle model

Pn 1 ton series

Pn.Cu2 ton series

Pn.Cu3 ton series

Natural forward tilt amount mm (in)

WISAS: 15 (0.59) or less USAS: 30 (1.18) or less



OIL LEAK TEST LIFT CYLINDER

1. Set the mast in the vertical position with the standard load on the fork. Lift the fork by 1 to 1.5 m (40 to 59 in).

2. Slowly tilt the mast fully forward, and stop the engine. 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): WlSAS 8 cm3 (0.49 in3) or less USAS 16 cm3 (0.98 in3) or 'less

Note: If the natural drop is great even though the oil leak amount is within the standard, the lift cylinder packing is defective.

TILT CYLINDER

1. Set the mast in the vertical position with standard load on the fork. Lift the fork by about 50 cm (19.7 in) and stop the engine.

2. After waiting for 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 (total for lift and tilt): WlSAS 16 cm3 (0.98 in3) or less USAS 32 cm3 (1.95 in3) or less

3. The leak amount at the tilt port is the total leak amount less the leak amount from the lift port.

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.

MAST Page

................................................................. V MAST ASSY 11-2

COMPONENTS ................................................................ 11-2

............................................... REMOVAL-INSTALLATION 11-6

REMOVAL* INSTALLATION (WILIFT BRACKET) .............. 11-9

MAST DlSASSEMBLY*lNSPECTION- REASSEMBLY ............................................................... 11-11

LlFT BRACKET DISASSEMBLY-INSPECTION- REASSEMBLY ......................................................... 11 -1 3

MAST ADJUSTMENT (V MAST) ....................................... 11 -1 5

MAST ROLLER REMOVAL* INSTALLATION ..................... 11 -20

CHAIN ................................................................................ I 1 -21

INSPECTION .................................................................. 11-21

REASSEMBLY (V-FV-FSV) ............................................ I I -21

REASSEMBLY (QFV) ..................................................... I 1 -22

ADJUSTMENT ............................................................... 11-23

FORK ............................................................................... I 1 -23

....................................................................... REMOVAL 11-23

INSPECTION .................................................................. 11-23

FV* FSV MAST ASSY .................................................... I I -24

COMPONENTS ............................................................. 11 -24

MAST ADJUSTMENT (FVoFSV) .................................... 11 -27

QFV MAST ASSY ....................................................... 11-31

COMPONENTS .............................................................. 11 -31

MAST ADJUSTMENT (QFV) ......................................... 11 -33

LlFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING) ................ 11-35

V MAST ASSY COMPONENTS

Pn v N 6301

1 ton series

02

FSV

40

6301-465

series

FSV

41 1-

Pn3 ton series 6302 Cu3 ton series

6502-298

REMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbfj

Removal Procedure

1 Set the mast vertical and fully lower the fork.

2 Disconnect the chain. [Point 11

3 Remove the chain wheel. [Point 21

4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift bracket, and slowly run the vehicle backward to depart from the lift bracket.)


6 Disconnect the fork height switch and load sensor wiring.

7 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast, operate the lift lever several times to release the residual pressure in the lift cylinder.)

8 Slightly hoist the mast.

9 Remove the mast support cap.

10 Remove the tilt cylinder front pin. [Point 31

11 Remove the mast ASSY.



Note: Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior surfaces. Apply MP grease to the tilt cylinder front pin. Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced. (See page 11-35.) Adjust the chain tension after installation. (See page 11-23.) When the mast is replaced, perform SAS re-setting after installation. (See section 15.) Necessity of the damper to be installed on top of the rear axle beam depends on the model and mast specification. (Refer to the Parts Catalog.)

Point Operations

[Point 1] Removal-Installation:

SST 09630-23600-7 1

[Point 21 Removal:

If the fitting is hard, use the SST for removal. SST 09950-7601 4-71 (SST 09950-4001 1 )

[Point 31 Removal:

Put match marks to clarify relative positions of the front pin, stopper plate and lock bolt. Match marks, however, are unnecessary when the mast or mast ASSY is replaced since mast tilt angle adjustment is to be done after the replacement.

Removal: SST 0981 0-201 72-71

11-9

REMOVAL-INSTALLATION (WILIFT BRACKET) T = N-m (kgf-cm) [ft-Ibfl

Removal Procedure

1 Set the mast vertical.

2 Remove the fork. (See page 11 -23.)


4 Disconnect the wiring of the fork height switch and load sensor.

5 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.)

6 Slightly hoist the mast.

7 Remove the mast support cap.

8 Remove the tilt cylinder front pin. [Point 11

9 Remove the mast ASSY Wllift bracket.



Note: Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior surfaces. Apply MP grease to the tilt cylinder front pin. Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced. (See page 11-35.) When the mast is replaced, perform SAS re-setting after installation. (See section 15.)

Point Operation

[Point 11 Removal:

Put match marks to clarify relative positions of the front pin, stopper plate and lock bolt. Match marks, however, are unnecessary when the mast or mast ASSY is replaced since mast tilt angle adjustment is to be done after the replacement.

Removal: SST 0981 0-201 72-71

MAST DISASSEMBLY*INSPECTION*REASSEMBLY


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, and take each rod end off. [Point I]

5 Remove each cylinder support. [Point 21

6 Remove each cylinder bottom set bolt, and remove each lift cylinder.

7 Slide the inner mast in the lowering direction, and remove the lift rollers.

8 Remove the mast strip. [Point 31

9 Remove the outer mast.



Point Operations


Shim adjustment is made at the lift cylinder rod end for preventing uneven lifting by lift cylinders LH and RH. Take a note on the cylinder where the adjustment is made and the number of shims in use.

[Point 21 Disassmbly:

Take a note on the number of cylinder support shims in use.

Reassembly: Make cylinder support shim adjustment if the mast or either cylinder is replaced. With the cylinder rod end inserted to the inner mast, insert shim@) between the cylinder support and outer mast to eliminate the clearance. The shim thickness should be slightly greater than the clearance.


Measure the mast strip thickness.

Thickness limit: A = 2.7 mm (0.106 in) B = 1.3 mm (0.051 in)

LIFT BRACKET DlSASSEMBLY.INSPECTlON-REASSEMBLY T = N-m (kgf-cm) [ft-lbfl


1 Remove lift rollers. [Point 11

2 Remove side rollers. [Point 21

3 Remove the back rest.



Point Operations


SST 09950-7601 4-7 1 (SST 09950-4001 1)

[Point 2J Reassembly: '

Install the side roller in the correct direction. The side chamfered with a greater radius of the roller shaH be on the front side of the vehicle.

MAST ADJUSTMENT (V MAST)

Lift Roller Adjustment at Mast

1. Clearance between inner mast roller and outer mast

into

I Shims;

Inner mast Oute mast

These rollers

Adjust the mast overlap to approx. 450 mm (17.72 in). Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the clearance between the roller side face and mast where they are the closest.

Standard: A = 0 - 0.8 rnm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness. (See page 11 -20 for the mast roller removal and installation.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right side.

(4) After the adjustment, see that the inner mast moves smoothly in the outer mast.

2. Clearance between outer mast roller and inner mast

These rollers

Outer mast Inner

mast

(1) Adjust the mast overlap to approx. 450 mm (17.72 in). (2) Shift the inner mast to one side to bring the roller into

contact with the outer mast, and inspect the clearance between the roller side face and mast where they are the closest.

Standard: B = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness. (See page 11 -20 for the mast roller removal and installation.)


(3) Distribute shims equally to the rollers on the left and right side.

(4) After the adjustment, see that the inner mast moves smoothly in the outer mast.

Roller Adjustment at Lift Bracket

1. Middlellower lift roller and side roller clearance adjustment

I I 100 mm (3.94 in)

Bring into contact

Bring into contact

Bring into contact

lnner mast bracket '

V Mast Pnl.2 ton series

100 mm (3.94 in)

Outer

lnner mast bracket

,, Mast Pn3 ton series Cu2.3 ton series

(1) Bring the center of the side roller in the upper part of the lift bracket to approx. 100 mm (3.94 in) from the top of the inner mast.

(2) Remove side rollers. (3) Shift the lift bracket to one side to bring the roller into

contact with the inner mast, and inspect on the opposite side the clearance between the roller side face and the mast where they are the closest. (No adjustment is necessary for the upper lift rollers since they are fastened by snap rings.)

Standard Pnl ton-2 ton series: C = 0 - 0.8 mm (0 - 0.031 in) Pn3 ton series and Cu2 tom3 ton series: C = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the lift roller shim thickness.


(4) Distribute shims equally to the left and right side. (5) Install side rollers.

(6) After adjusting the middle and lower lift rollers, bring the side roller on one side into contact with the outer mast and measure on the opposite side the clearance between the side roller and inner mast surface.

Standard Pnl ton-2 ton series: D = 0 - 0.6 mm (0 - 0.024 in) Pn3 ton series and Cu2 ton3 ton series: D = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the side roller shim thickness.


(7) Distribute shims equally to the left and right side. (See Lift Bracket Disassembly-Inspection-Reassembly section for the side roller installation method. Shim replacement is possible on the vehicle.)

(8) After the adjustment, see that the lift bracket moves smoothly over the entire length of the mast.

Mast Strip Adjustment

1. Mast strip clearance adjustment -

Bring into contact

Out ward

Note: The strip is of tapered shape, thicker side of the width must be placed outward.

(1) Lower the inner mast fully. (2) With the inner mast in contact with the outer mast roller,

measure the clearance between the mast strip and inner mast.

Standard: E = 0.5 - 1.0 mm (0.020 - 0.039 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness. (See page 11 -20 for the mast roller removal/installation method.)


(3) After the adjustment, check the mast for smooth movement.

MAST ROLLER REMOVAL*INSTALLATlON

1. Remove the l i f t bracket. (See steps 1 to 4 of the mast ASSY removal procedure on page 11 -6.)

2. Jack up the vehicle, and support tires with wooden blocks. Also lock the front and rear tires from rotation.

3. Remove the lift cylinders. (See page 12-1 1 .)

4. Remove mast rollers. (1) Remove wooden blocks under the inner mast, and

lower the hoisted inner mast slowly until mast rollers appear.

(2) Support the bottom of the inner mast with wooden blocks.

(3) Remove the inner mast rollers and shims.

(4) Remove the outer mast rollers and shims. 5. The installation procedure is the reverse of the removal

procedure.

CHAIN INSPECTION 1. Inspect the chain 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, it is the limit.

Chain Link Pitch Standard (V-WFSV-QFV)

Note: Perform measurement without removing the chain from the vehicle.

Vehicle model

Pnl ton series

PnSCu2 ton series QFV inner and middle chain

PnaCu3 ton series

QFV outer chain

lnspect elongation over the entire chain length since it may be localized.

REASSEMBLY (V-FV-FSV)

Pitch mm (in)

15.88 (0.6252)

19.05 (0.7500)

25.4 (1 .O)

25.4 (1 .O)

1. Installing direction

Type

BL534

BL634

BL823

BL834

2. Chain adjusting nut tightening order (1) Tighten nuts @ and 0. T = 49.0 - 78.0 Nem (500 - 800 kgf-cm) [36.1 - 57.5 ft-lbfl (2) Tighten nut 8.

Chain No.

50

60

80

80

and portion

Sketch

V: Lift bracket

Install with the split pin on the vehicle center side.

Applicable mast and portion

Sketch

I

FV: Lift bracket FSV: Lift bracket

Outside of 0 vehicle

Split pin

Install with the split pin on the vehicle outside.

V: Outer mast m: Front ton series, FSV: ~~~~t cylinder (1.2 ton series)

0

0

FSV: Inner mast

Rearof 0 vehide

Split pin

Install with the split pin on the vehicle rear side.

N: Front cylinder (3 ton series) FSV: Front cylinder (3 ton series)

0

0

FSV: Outer mast

0

0

REASSEMBLY (QFV)

1. Installing direction As shown in the table below.

2. Chain adjusting nut tightening order (1) Tighten nuts and 0. T = 49.0 - 78.0 N-m (500 - 800 kgf-cm) [36.1 - 57.5 ft-lbfj (2) Tighten nut @.

Outer chain

c'mp $ Etz

P' T = 98.0 - 147.0 N-rn (1 000 - 1500 kgf-crn)

(72.35 - 108.5 R-lbfl

Upper middle

a

T = 98.0 - 147.0 N-m (1000 - 1500 kgf-cm) (72.35 - 108.5 ft-lbfl

Middle chain

ckrnp 5

0

Split pin % Inner mast

Installation side of split pin is at center side of the truck.

Inner chain

abc %::er

0

Installation side of split pin is outward of the truck center.

Chain connection Middle chain Outer chain

ADJUSTMENT

1. Park the vehicle on a flat ground and set the mast vertical.

2. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting nut.

3. Check to see that the chain tension is equal on the left and right side.

4. Check to see no chain twist.

5. See that the fork height is the standard.

6. With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast is not in contact with the lift bracket.

FORK REMOVAL

1. Set the fork at approx. 20 cm (7.9 in) above the ground. 2. Place a wooden block under the knotched 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 fork for removal.

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 bend, looseness of fork installation and lift bracket finger bar distor- tion.

FV-FSV MAST ASSY COMPONENTS

FSV 31 61 O I -

434 6101-491A

FV 6302 Pnl-2 ton series Cu2 ton series

nu

FV Pn3 ton series Cu3 ton series

-21K

6302-297

FSV 6302 Pnl.2 ton series Cu2 ton series

FSV Pn3 ton series Cu3 ton series

MAST ADJUSTMENT (FV*FSV)

Lift Roller Adjustment at Mast

1. Clearance between: lnner mast roller and outer mast (FV). lnner mast lower roller and middle mast (FSV). Middle mast lower roller and outer mast (FSV).

- - -

Bring into contact

Position where the roller is the closest

FSV mast

lnner mast

r / I- Outer mast -

These rollers These rollers

FV mast

(1) Adjust the mast overlap to approx. 450 mm (17.72 in). (2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the

clearance between the roller side face and mast where they are the closest.

Standard: A = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness.


(3) Distribute shims equally to the rollers on the left and right sides. (4) After the adjustment, see that mutual mast movement is smooth.

2. Clearance between: Outer mast roller and inner mast (FV). Middle mast upper roller and inner mast (FSV). Outer mast upper roller and middle mast (FSV).

FV mast These rollers

fi Outer mast

Inner mast

(1) Adjust the mast overlap to approx. 450 mm (1 7.72 in). (2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on

the opposite side the clearance between the roller side face and mast where they are the closest.

Standard: B = 0 - 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness.


(3) Distribute shims equally to the rollers on the left and right sides. (4) After the adjustment, see that mutual mast movement is smooth.

1 1-29

LifUSide Roller Adjustment at Lift Bracket

N-FSV mast r

Lower lift roller

Pnl5- 30 FSV Mast Pn32 RI Mast

Cu20 - 30 Cu32

(1) Raise the lift bracket to the uppermost position for the FSV mast, and bring the center of the upper lift roller to approx. 100 mm (3.94 in) from the top of the inner mast for N mast.

(2) No adjustment is necessary for the upper lift rollers and intermediate rollers ( N and FSV on PnCu 32 only) since they are fastened by snap rings.

(3) Shift the lift bracket to one side to bring the lower lift roller, and measure on the opposite side the clearance between the roller side face and the mast where they are the closest.

Standard: C = 0 - 0.5 mm (0 - 0.020 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.)


(4) After the inspection and adjustment in step (3) above, inspect and adjust the side rollers. Bring the side roller on one side into contact with mast side surface, measure on the opposite side the clearance between the side roller and the inner mast side surface where they are the closest.

Standard: D = 0 - 0.5 mm (0 - 0.020 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.)


(51 After the adiustment. check to see that the lift bracket moves smoothly over the entire length of the

Mast Strip Adjustment

Mast strip clearance adjustment

FV mast

Bring into contact

FSV mast .Middle mast

w

(1) Lower the inner (or middle) mast fully. (2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),

measure the clearance between the mast strip and mast.

Standard: E = 0.5 - 1.0 mm (0.020 - 0.039 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness.

Shim thickness: 0.5 and 1.0 rnm (0.020 and 0.039 in)

(3) After the adjustment, check the mast for smooth movement.

QFV MAST ASSY COMPONENTS

6301 v FV

FSV QW

02

40

40 6301467A

MAST ADJUSTMENT (QFV)

Lift Roller Adjustment The lift roller adjustments, for most part, are same with FSV mast. Where to be adjusted are as shown:

Channel s e e n from the top Channel s e e n from the bottom

Note: The mast strip & shim adjustment between the mast channels can also be performed in the same sequence with those of V-FV-FSV.

Lift Roller Position on Each Upright:

Upper Middle

C

d

Lower Middle

e

f

Outer

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)

Note: For double 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 whenever 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

Shim

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 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 inner mast shakes at the time of stopping. To correct this, add shims to the cylinder that stops first.

2. Adjustment method (1) Raise the inner mast, set the SST to the outer mast

tie beam, and lower the inner mast until it reaches the SST. SST 0961 0-22000-71

(2) Remove the set bolt of the cylinder rod end on the side requiring shim adjustment.

(3) Slowly lower the lift cylinder rod and disconnect the cylinder rod end.

(4) Place shims on the cylinder rod end. Slowly raise the cylinder rod end into the inner mast.

(5) Fix the set bolt of the cylinder rod end. (6) Raise the inner mast for reinspection. (7) Repeat the inspection and adjustment until the num-

ber of shims is determined.


CYLINDER Page

LlFT CYLINDER (V) REAR LIFT CYLINDER (FV*FSV*QFV) ................ 12-2

GENERAL ..................................................................... 12-2

SPECIFICATIONS ........................................................... 12-5

.............................................................. COMPONENTS 12-7

REMOVAL-I NSTALLATION ............................................ 12-1 1

FLOW REGULATOR VALVE (V*FV*FSV*QFV) ...... 1235

GENERAL ....................................................................... 12-25

SPECIFICATIONS ........................................................... 12-25

SAFETY DOWN VALVE (V*FV*FSV*QFV) .............. I 2-26

GENERAL ...................................................................... 12-26

FRONT-LIFT CYLINDER (FV*FSV*QFV) ................. 12-27

GENERAL ....................................................................... 12-27

SPECIFICATIONS ............................................................. 12-28

COMPONENTS ................................................................ 12-29

REMOVAL-INSTALLATION ............................................... 1230

TILT CYLINDER ............................................................ 1235

GENERAL ........................................................................ 1235

SPECIFICATIONS ............................................................. 1235

COMPONENTS ................................................................ 1236

REMOVAL-INSTALLATION ............................................... 1237

MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF UNEVEN TILTING) ...................... 12-41

LlFT CYLINDER (V) REAR LlFT CYLINDER (FV*FSV*QFV) GENERAL

Lift Cylinder (VIPnl Ton Series and Pn.Cu3 on Series)

Lift Cylinder (VIPn.Cu2 Ton Series)

12-3

Rear Lift Cylinder (FV)

Rear Lift Cylinder (FSVIPnl Ton Series (Except Fork Height 4800 mm (189 in)) and Pn-Cu3 Ton Series)

--

Rear Lift Cylinder (FSVIPnl Ton Series (Fork Height 4800 mm (189 in))

Rear Lift Cylinder (FSVIPn.Cu2 Ton Series)

Rear Lift Cylinder (QFV)

- Dec. 1999

RH

Dee. 1 999 -

H n

LH

SPECIFICATIONS

Lift Cylinder (V)

Pn.Cu3 ton series

Single-acting

55.0 (2.17)

45.0 (1 .n) U packing

U packing

Pn.Cu2 ton series

Single-acting

50.0 (1.97)

42.0 (1.65)

U packing

U packing


Item

Cylinder type



Piston seal type

Rod seal type

Others

Single-acting

44.45 (1.75)

34.93 (1.38)

U packing

U packing

Built-in safety down valve (RH, LH)

1 2-6

Rear Lift Cylinder (FV)

Rear Lift Cylinder (FSV)

Pn.Cu3 ton series

Single acting

55.0 (2.1 7)

40.0 (1.57)

U packing

Rear Lift Cylinder (FSV)

Pn.Cu2 ton series

Single acting

50.0 (1.97)

34.9 (1.37)

U packing


Item


Cylinder type



Rod seal type

Others

Rear Lift Cylinder (QFV)

Single acting

45.0 (1 .TI)

32.0 (1.26)

U packing

Built-in safety down valve (LH)

H4800 mrn (1 89 in) only

Single acting

45.0 (1.77)

35.0 (1.38)

U packing

U packing

Item All except H4800 mrn (1 89 in)

Cylinder type

Cylinder bore mrn (in)

Piston rod outside diameter rnrn (in)

Piston seal type

Rod seal type

Pn.Cu3 ton series

Single acting

55.0 (2.1 7)

45.0 (1.77)

U packing

U packing

Vehicle model Pn-Cu2 ton series

Itern

Single acting

44.45 (1.75)

34.93 (1.38)

U packing

U packing

Others

Cylinder type

Cylinder bore rnrn (in)

Piston rod outside diameter mrn (in)

Piston seal type

Rod seal type

Vehicle model Cu2 ton series

ltem


Single acting

50.2 (1.98)

42.0 (1.65)

U packing

U packing

Others

Cylinder type

Cylinder bore rnm (in)

Piston rod outside diameter rnm (in)

Rod seal type

Others

Built-in safety down valve (RH)

Single acting type

- Dec. 1999: 63.5 (2.50)

- Dec. 1999: 50.8 (2.00)

Dec. 1999 - : 63 (2.48)

Dec. 1999 - : 50 (1.97)

U packing


COMPONENTS

Lift Cylinder for V Mast

Rear Lift Cylinder for FV Mast on Pnl ton Series

Rear Lift Cylinder for FV Mast on Pn-Cu2 Ton & 3 Ton Series

Rear Lift Cylinder for FSV Mast on Pnl Ton Series (Except FSV 4800 rnm (189 in))

Rear Lift Cylinder for FSV Mast on Pn-Cu2 Ton & 3 Ton Series

6503 941 25-412-

BR

An m&"1 01 [RH] .... r---

6M3-1 l Z A

Rear Lift Cylinder for FSV 4800 mm (189 in) on Pnl Ton Series

Rear Lift Cylinder for QFV Mast

- Dec. 1999

02 [LHI 01 PHI AW

r . - .I ...-

L...

65030938

Dec. 1999 -

@3iJk ppE AM ?@BP 7

02 [LHI AW

01 [RH] . / ..., r... e m I...- I

I . I I m .

I I L... / - ... 4 L.-. --.A

6503.1271

Removal Procedure

1 Set the mast vertical and lower the fork fully.

2 Remove the lift cylinder rod .end set bolt.

3 Hoist the inner mast by slinging with a wire and disconnect the lift cylinder rod end. [Point 11

4 Hoist the inner mast further so that the lift cylinder ASSY can be removed from the front space.

5 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 hose.

8 Disconnect the load sensor wiring. (SAS spec.)

9 Remove the lift cylinder bottom end set bolt.

10 Remove the lift cylinder support. [Point 21

11 Remove the lift cylinder ASSY.



Note: After installing the lift cylinder, follow the steps below. 1. Repeat full-stroke raising and lowering of the cylinder to bleed air and check normal function-

ing. 2. Check the hydraulic oil level and add if insufficient. 3. Inspect lift cylinders for uneven lifting, and make necessary adjustment. (See page 11-35.)

Point Operations

[Point 11 Removal:

Shim adjustment is made at the lift cylinder rod end to prevent uneven lifting by lift cylinders LH and RH. Take notes on the cylinder where adjustment is made and the number of shims used.


Temporarily fasten the cylinder support here, and eliminate any clearance between the cylinder support and outer mast by shim insertion after connecting the rod end. (Use shim@) slightly thicker than the clearance.)

12-13


Lift Cylinder for V Mast T = N-m (kgf-cm) [ft-ibfl

2 3 2

4 4 5

6

* Cylinder cover 1 ton series: 3 ton series:

T = 170 - 237 (1730 - 2419) [I25 - 1751 T = 264 - 305 (2695 - 3110) [I75 - 2251 2 ton series:

T = 230 - 265 (2345 - 2703) [I 70 - 1951 A


1 Remove the safety down valve.

2 Remove the cylinder cover. [Point 11

3 Remove the seals from the cylinder cover.


5 Remove the seals on the piston rod.

6 Remove the check valve from the piston rod. [Point 31

7 Remove the cylinder. [Point 41



Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the cylinder cover before tightening.

Point Operations

[Point 11

Disassembly~Reassembly: SST 09620-1 01 00-71

[Point 21

Inspection: Measure the piston rod outside diameter.

Pnl ton series Standard: 34.93 mm (1.375 in) Limit: 34.85 mm (1.3720 in)

Pn.Cu2 ton series Standard: 42.0 mm (1.654 in) Limit: 41.92 mm (1.6504 in)

PnoCu3 ton series Standard: 45.0 mm (1.772 in) Limit: 44.92 mm (1.7685 in)

Inspection: Measure the piston rod bend.

Limit: 2.0 mm (0.079 in)

[Point 31

Reassembly: Install the check valve arrow pointing to the lower side of the cylinder.

Inspection: Measure the cylinder bore.

Pnl ton series Standard: 44.45 mm (1.750 in) Limit: 44.65 rnm (1.7579 in)



Rear Lift Cylinder for FV Mast T = N-m (kgf-cm) [fl-lbfj

LH FW '-2 '-2

2 3

4

Pnl ton series LH W-1

2 3

4

Pn.Cu2 ton series and 3 ton series

'-1 Cylinder cover Pnl ton series:

T = 169 -237 (1728 - 2419) [A25 - 1751 Pn.Cu2 ton series:

T = 203 - 271 (2073 - 2764) [ I 50 - 2001 Pn-Cu3 ton series:

T = 237 - 305 (241 9 - 3110) [175 - 2251

'-2 Air bleed screw: T = 4.5 - 5.0 (46 - 51) I3.33 - 3.691

Disassembly Procedure (1) LH Rear Lift Cylinder.





5 Remove the wear ring.

6 Remove the bleed screw.


(2) RH Lift Cylinder.

1 Loosen the cylinder cover. [Point 11


3 Remove the piston. [Point 31

4 Remove the piston seals.

5 Remove the cover and the seals.

6 Remove the bleed screw.




Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the cylinder cover before tightening. Upon completing the installation of the FV rear lift cylinder, perform air bleeding in the following sequence: (1) Extend the FV rear lift cylinder. (2) Stop the engine. (3) Loosen the bleed screw by the time oil will come out and tighten the bleed screw again.

Point Operations

[Point 11

Disassembly- Reassembly: SST 09620-1 01 00-71

[Point 21



Pn-Cu2 ton series Standard: 34.9 mm (1.374 in) Limit: 34.82 mm (1.3709 in)

Pn-Cu3 ton series Standard: 40.0 mm (1 575 in) Limit: 39.92 mm (1.5717 in)


Limit: 2.0 mm (0.079 in)

[Point 31

Disassembly Reaseembly: Follow the procedure view. 1. Fix the boss portion at the tip end of the piston rod in a

vise.

2. Use a screwdriver and rotate the piston to remove the wire.

3. The installation is the reverse.

[Point 41

Inspection: Measure thslift cylinder bore.




Rear Lift Cylinder for FSV Mast (Except Fork Height 4800 mm (189 in) on Pnl ton series)

T = Nem (kgf-cm) [ft-lbfl

LH Pnl ton series FW I

PnaCu2 ton series and 3 ton series

Cylinder cover: Pnl ton series T = 169-237 (1728-2419) 1125- 1751 PnaCu2 ton series T = 230 - 265 (2345 - 2702) [ I 70 - 1951 Pn.Cu3 ton series T=237-305(2419-3110)[175-2251






5 Remove the piston seals, and the check valve. [Point 31


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


Point Operations

[Point 11

Disassem bly. Reassem bly: SST 09620-1 01 00-71

[Point 21






Limit: 2.0 mm (0.079 in)

[Point 31

Reassembly: Install the check valve so that the arrow directs to downward of the lift cylinder.

[Point 41

Inspection: Measure the lift cylinder bore.




Rear Lift Cylinder for FSV Mast (Fork Height 4800 mm (189 in) on Pnl ton series)



2 Remove the cylinder cover.



5 Remove the piston seals, and the check valve. [Point 21





[Point 11




Limit: 2.0 mm (0.079 in)

[Point 21

Reassembly: Install the check valve so that the arrow directs to downward of the lift cylinder.

[Point 31



12-23

Rear Lift Cylinder for QFV Mast

- Dec. 1999 Dec. 1999 -

4 3 4 3

7 7

5

6 6 2


1 Remove the safety down valve. (LH only)

2 Remove the plug. (for Cylinder "- Dec. 1999")

3 Remove the cylinder cover








Point Operations

[Point 1)


- Dec. 1999 Standard: 50.8 mm (2.00 in) Limit: 50.72 mm (1.9969 in)

Dec. 1999 - Standard: 50.0 mm (1.97 in) Limit: 49.92 mm (1.9654 in)


Limit: 2.0 mm (0.079 in)

[Point 21


- Dec. 1999 Standard: 63.5 mm (2.50 in) Limit: 63.85 mm (2.51 38 in)

Dec. 1999 - Standard: 63.0 mm (2.48 in) Limit: 63.35 mm (2.4941 in)

--

FLOW REGULATOR VALVE (V*FV*FSV*QFV) GENERAL T = N-m (kgf-cm) [ft-lbfl

Piston

T = 58.8 - 68.6 (600 - 700) [43.4 - 50.61

SPECIFICATIONS

Fork Lowering Speed Unit: rnmlsec (fpm)

Note: The flow regulator valve is installed in the hydraulic piping system, respectively for each model, please see Page 10-4 - 10-9.

QFV

- - - - - -

400 (79)

510(100)

Veh~cle model V W

420 (87)

480 (94)

420 (87)

480 (94)

390 (77)

460 (91 )

420 (83)

480 (94)

390 (77)

460 (91)

Pnl ton series

Pn2 ton serles

Pn3 ton series

Cu2 ton series

Cu3 ton series

FSV

450 (89)

480 (94)

450 (89)

480 (94)

420 (83)

460 (91)

450 (89)

480 (94)

420 (83)

460 (9 1 )

No-load

Loaded

No-load .

Loaded

No-load

Loaded

No-load

Loaded

No-load

Loaded

550 (1 08)

500 (98)

500 (98)

500 (98)

500 (98)

500 (98)

500 (98)

500 (98)

500 (98)

500 (98)

SAFETY DOWN VALVE (V*FV*FSV*QFV) GENERAL

I I

j I I

Cartridge type L - - --I Ex. FSV Rear Cyl.

on 2.3 ton series internal type

12-27

FRONT LIFT CYLINDER (FV-FSV-QFV) GENERAL

FV: Pnl ton series, Pn-Cu2 ton series FSV: Pnl ton series (except H 4800 mm (189 in)), PrCuZ ton series QFV: Cu2 ton series 0

I I

0 N: PneCu3 ton series FSV: Pn'Cu3 ton series

- 0

1 a I I

, I I

I

0

FSV: Pnl ton series (H 4800 mm (1 89 in))

0 4

i 1.

0

12-28

SPECIFICATIONS

Front Lift Cylinder (FV)

Front Lift Cylinder (FSV-QFV)

Pn.Cu3 ton series

Single acting

85.0 (3.35)

50.8 (2.00)

U packing

U packing

Pn.Cu2 ton series

Single acting

75.0 (2.95)

50.8 (2.00)

U packing

U packing


kern

Vehicle model

Item

Cylinder type



Piston seal type

Rod seal type

Others

Cylinder type



Rod seal type

Piston seal type

Others

Single acting

70 (2 1 .76)

50.8 (2.00)

U packing

U packing --

Built in safety down valve

Pnl ton series

Built-in safety down valve

All except H 4800 mm

(1 89 in)

Single acting

70.0 (2.76)

50.8 (2.00)

U packing

U packing

Cu2 ton series QFV

Single acting

75.0 (2.95)

50.8 (2.00)

U packing

U packing

PmCu 2 ton series

Single acting

75.0 (2.95)

50.8 (2.00)

U packing

U packing

H 4800 mm (1 89 in)

Single acting

70.0 (2.76)

50.0 (1.969)

U packing

U packing

PnCu ton

Series

Single acting

85.0 (3.35)

50.8 (1 369)

U packing

U packing

COMPONENTS

Front Lift Cylinder for FV Mast

Front Lift Cylinder for FSV and QFV Mast (Except FSV H 4800 mm (189 in) on Pnl Ton Series)

12-30

Front Lift Cylinder for FSV H 4800 mm (189 in) on Pnl Ton Series

REMOVAL01 NSTALLATION

01

Removal Procedure

6502

1 Remove the lift bracket Wlfork.

L... .--A 6502-087


3 Remove the front lift cylinder.



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 function-

ing. (2) Check the hydraulic oil level, and add if insufficient. (3) Adjust the lift chain tension equally on the left and right sides.

Front Lift Cylinder for FV-FSV (Except FSV H 4800 mm (189 in) on Pnl Ton Series).QFV

T = N-m (kgf-cm) [ft-lbfl I

* Cylinder cover FVIFSV on 1 ton series T = 305 - 373 (31 10 - 3801) [225 - 2751 FVIFSVIQFV on 2 ton series T = 339 - 407 (3455 - 4147) [250 - 3001 FVIFSV on 3 ton series T = 420 - 454 (4283 - 4630) [310 - 3351

Disassern bly Procedure



3 Remove the cover seals.



6 Remove the check valve. [Point 31


Reassern bly Procedure


Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the cylinder cover before tightening. Fill the amount of hydraulic oil specified below into the cylinder from its top before installing the cylinder cover.

Filling amount cm3 (in3): WIFSV 1 ton series 80 (4.88) FVIFSV 2 ton series 100 (6.1 0) FVIFSV 3 ton series 75 - 80 (4.57 - 4.88)

Point Operations

[Point 11

Disassembly-Reassembly: SST 09620-1 01 00-7 1

[Point 21


Pn 1 ton series, PmCu 2 ton series and PmCu 3 ton series: Standard: 50.8 mm (2.0 in) Limit: 50.72 mm (1.9969 in)


Limit: 2.0 mm (0.079 in)

[Point 31

Assembly: Install the check valve so that the arrow will direct downward of the front lift cylinder.

[Point 41





Front Lift Cylinder for FSV H 4800 mm (189 in) on Pnl Ton Series T = N-m (kgf-cm) [ft-lbfl



2 Remove the rod guide.

3 Remove the rod guide seals.



6 Remove the check valve. [Point 21




Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the rod guide before tightening. Fill the amount of hydraulic oil specified below into the cylinder from its top before installing the rod guide.

Filling amount cm3 (in3): 30 (1.83) - 60 (3.66)

Point Operations

[Point 11




Limit: 2.0 mm (0.079 in)

[Point 21

Reassembly: Install the check valve so that O-ring side of the check valve will locate downward in the cylinder.

[Point 31



TILT CYLINDER GENERAL

SPECIFICATIONS

Cylinder type



Piston seal type

Rod seal type

Double acting type

70 (2.76)

30 (1.1 8)

U packing

U packing

12-36

COMPONENTS

(TILT BOOTS)

0 1

r=== -==l : p G i k q m m

m AC

m

21 30

I I I L m m m

3 1

BT 651 1-21 6

T = N-m (kgf-cm) [ft-lbfl

Removal Procedure

Remove the toe board and lower panel.

Remove the instrument panel.

Remove the step.

Remove the side cover.

Remove the fender cover.

Hoist the mast slightly.

Disconnect the hose.

Disconnect the tilt angle sensor link (RH). (SAS spec.)

Remove the tilt cylinder front pin. [Point 11

Remove the tilt cylinder rear pin.

Remove the tilt cylinder ASSY.


The installation procedure is the reverse of the removal procedure

Note: Apply MP grease on the portions for inserting tilt cylinder front and rear pins before installation. 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 re-setting. (See section 15.)

Point Operation

[Point 11 Removal:

Put a match mark to indicate relative positions of the stopper plate and tilt cylinder front pin.

Removal: SST 0981 0-201 72-71

DISASSEMBLY-INSPECTION-REASSEMBLY T = N-m (kgf-cm) [ft-lbfl


1 Loosen the rod guide. [Point 11

2 Extract the piston rod Wlpiston.

3 Remove the tilt cylinder. [Point 21

4 Remove the bushing. (- 2000.8) [Point 31

5 Remove the piston.

6 Remove the rod guide.




Note: Apply MP grease or hydraulic oil on the packing, 0-ring,and dust seal lip portion. Apply sealant (08833-76002-71 (08833-00080)) on the threaded portion of the rod guide before reassembly.

-

SST @

Point Operations

[Point I] Disassembly-Reassembly:

SST 09620- 1 0 1 00-7 1


Measure the cylinder bore.


[Point 31 Removal-Installation:

SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0)


Measure the piston rod outside diameter.

Standard: 30.0 mm (1 .I 81 in) Limit: 29.92 mm (1 .I 780 in)

Inspection: Measure the bend of the piston rod.

Limit: 1.0 mm (0.039 in)

MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF UNEVEN TILTING)

Note: Adjust the mast forward and backward tilting angles (to prevent uneven tilting) when the tilt cylinder and mast ASSY are replaced or overhauled. After adjustment, perform SAS re-setting. (See section 15.)

1. With the mast in the neutral position, install the stopper with the tilt cylinder pin eccentric direction on the lower side.

. , Eccentr~c

The front pin eccentric direction is not in fixed relative position to the flat sides of the hex-

2. Inspect the forward and backward tilting angles and unevenness in tilting at the pin position above.

Standard: Mast forward tilting angle: Standard set angle -0.6" - +1.6" Mast backward tilting angle: Standard set angle -0.8" - +0.6" Unevenness: 1 mm (0.04 in) or less

3. If the standard is not satisfied, make adjustment by turning the fixation angle of the eccentric pin in alliance with the stopper bolt hole matching in the stopper plate. To align the hole with the tapped hole in the tilt bracket, either of two holes in the plate is selective and the plate reversible on side to find desirous position.

4. After the adjustment, tighten the stopper set bolt to lock the front pin.

OIL PUMP Page

GENERAL ........................................................................ 13-2

........................................................... SPECIFICATIONS 13-2

COMPONENTS ................. ; ............................................ 133

............................................................ OIL PUMP ASSY 134 REMOVAL-INSTALLATION .............................................. 134

DISASSEMBLY*INSPECTlON-REASSEMBLY ................... 13-5

PERFORMANCE TEST ............................................... 13-8

1 3-2

GENERAL

SPECIFICATIONS

Vehicle models

7FGU 15.1 8 7FDU 15.1 8

7FDU 20.25.30-32

7FGU 20.25 7FGCU 20.25 7FGCU 30.32

7FGU 30.32

Manufacturer (Model)

KAYABA (KZP4-25C)

KAYABA (KZP4-27C)

KAYABA (KZP4-283C)

KAYABA (KZP4-28C)

Engine

4Y 1 DZ-ll

1 DZ-l l

4Y

4Y

Pump Type

Single gear pump

f

I'

f

Displacement cm3 (in3)/rev

24.5 (1.495)

26.5 (1.61 7)

28.3 (1.727)

27.5 (1 517)

COMPONENTS

1 3-4

OIL PUMP ASSY REMOVAL-INSTALLATION

Removal Procedure

1 Disconnect the inlet hose. (Tank side)

2 Disconnect the outlet hose.

3 Remove the oil pump ASSY.

4 Remove the inlet hose and fitting.

5 Remove the gasket.



Note: Apply grease (molybdenum disulfide grease) on the pump shaft spline portion before installation. Clean the fitting mounting portion thoroughly to prevent damage to the O-ring.

DISASSEMBLY*INSPECllON*REASSEMBLY T = N-m (kgf-cm) [ft-Ibfl


1 Put match marks on the cover, body and mounting flange.

2 Remove the cover.

3 Remove the mounting flange

4 Remove the bushing set and pump gear set. [Point 11

5 Remove the oil seal. [Point 21

6 Inspect the body. [Point 31



Note: Use new seals for reassembly. Apply the hydraulic oil before reassembly.

\ Suction side

Inside diameter

Point Operations


Put match marks on the teeth of the drive and driven gears.

Reassembly: Align match marks at the time of reassembly.

Inspection: lnspect the bushing set contact trace.

Standard: Relatively stronger contact trace on the suction side, with slight trace on the discharge side.

Inspection: Measure the bushing set length.

Limit: 26.41 1 mm (1.03980 in)

Inspection: lnspect the bushing set for wear at the interior surface. Limit: Replace if the teflon coating layer is worn out even locally.

Inspection: Measure the outside diameter of each gear shaft.

Limit: 18.935 mm (0.74547 in)


SST 0931 9-76001 -71 (SST 0931 9-60020)

SST

Contact of gear t crests

Reassembly: SST 09950-7601 8-71 --- @ (SST 09950-6001 0) SST 09950-76020-71 --- @ (SST 09950-7001 0) After installation, apply MP grease on the oil seal lip portion.


Inspect the contact trace on the inner surface of the body (suction side).

Limit: Contact trace covers more than half of the cir- cumference.

Inspection: Measure the depth of flaw on the inner surface of the body.

Limit: 0.1 mm (0.004 in)

PERFORMANCE TEST As the performance test in servicing of the oil pump, judge the quality by the lifting speed of the forks 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 1-9, and the relief pressure adjustment procedure on page 14-14, 14-22.)

1. Set the engine tachometer. 2. Operate the oil pump for running in.

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. 3. Measure the full-stroke lifting time of the forks, and calculate the lifting speed for performance judg-

ment.

Lifting Speed

Pnl ton series

Pn2 ton serles

Pn3 ton serles

Cu2 ton series

Cu3 ton series

Cu2 ton series

Engine model

4Y

1 DZ-II

4Y

1 DZ-II

4Y

1 DZ-I 1

4Y

4Y

Lifting speed (loadedlno-load) mmlsec (fpm)

4Y

V mast

QFV mast

560(110) 1 580(113)

600 (1 18)

650 (1 28)

600 (1 1 8)

610 (120)

51 0 (1 00)

500 (98)

600 (1 18)

51 0 (1 00)

640 (1 26)

670 (1 32)

640 (1 26)

640 (126)

550 (1 08)

530 (1 04)

640 (1 26)

550 (1 08)

FSV mast

550 (1 08)

620 (1 22)

560 (1 10)

600 (118)

470 (93) -

480 (94)

560 (1 10)

470 (93)

FV mast

61 0 (1 20)

650 (1 28)

600 (1 18)

610 (120)

51 0 (1 00) - -

500 (98)

600 (1 18)

51 0 (1 00)

540 (1 06)

560 (1 10)

560 (1 10)

570 (112)

450 (89)

440 (87)

560 (1 10)

450 (89)

600 (1 18)

600 (1 18)

600 (1 18)

610 (120)

490 (97) - 470 (92)

600 (1 18)

490 (97)

OIL CONTROL VALVE Page

VEHICLE W/SAS ....................................................... 14-2

GENERAL ................................................................. 14-2

SPECIFICATIONS ..................................................... 14-7

COMPONENTS ........................................................... 14-7

O IL CONTROL VALVE ASSY .................................. 14-8

DISASSEMBLY-INSPECTION-REASSEMBLY ............... 14-9

CONTROL VALVE LEVER ASSY ........................... 14-13

........................................... REMOVAL-INSTALLATION 14-1 3

RELIEF PRESSURE ADJUSTMENT (- 2000 . I 0) .............................................................. 14-14

RELIEF PRESSURE ADJUSTMENT . (2000 I0 -) ........................................................... 14-15A

..................................... VEHICLE WITHOUT SAS 14-16

GENERAL ................................................................... 14-16

SPECIFICATIONS ...................................................... 14-18

COMPONENTS ........................................................... 14-18

OIL CONTROL VALVE ASSY .................................. 14-19 REMOVAL-INSTALLATION ........................................... 14-19

DISASSEMBLY-INSPECTION-REASSEMBLY ............... 14-20

RELIEF PRESSURE ADJUSTMENT ...................... 14-22

VEHICLE W/SAS GENERAL

T2

TI

Our C1

C3

*1: A solenoid at @ has been dispensed with since Oct., 2000.

Note: For symbols @ to @, respective sectional views are shown on succeeding pages.

Oil Control Valve (- 2000. 10)

@@solenoid Valve

"1: A solenoid at @ (SOL2) has been dispensed with since Oct., 2000.

@Filter and Lift Load Check Valve

@ Flow Divider Valve

@ @ Relief Valve

-

@I Needle Valve (Manual Down Valve)

@$ Flow Control Valve (- 2000.1 O)

@ Lift Select Valve

@ Tilt Select Valve

@ Limit Switch @ Lift Lock Checkvalve @ ~ i l t Lock Check Valve

Forward kward switch switch

Hydraulic Circuit Diagram (- 2000.10)

Oil Control Valve (2000.10 -)

@ Relief Valve (2000. 10 -)

@ Flow Control Valve (2000.1 0 -)

SPECIFICATIONS

COMPONENTS

Pn3 ton series

t

c

c

15.2 (4.02)

c -

Vehicle model Pnl.2 ton series

Cu2.3 ton series

Add-on type (1 -, 2-spool monoblock)

181 40 (1 85) I26301

15690 (1 60) [2280]

13.0 (3.43)

Built-in flow divider valve

Oil control valve type

Relief set pressure

kPa (kgf/cm2) [psi]

Lift

Tilt

Flow divider flow rate tlrnin (USgalImin)

--

Others

OIL CONTROL VALVE ASSY REMOVAL-INSTALLATION

Note: Before disconnecting the lever rod, operate the control levers to bring the mast to the neutral position and fully lower the fork to release the residual pressure in the material handling system piping.

T = N-rn (kgf-cm) [ft-lbfl

Removal Procedure



3 Disconnect the lever rod.

4 Disconnect the wiring.


6 Remove the oil control valve ASSY.


The installation procedure is the reverse of the removal procedure. Note:

Apply grease (chassis grease) on the oil control valve lever links. lnsoect the hydraulic oil level, and add if insufficient.


Note: Select a clean location for operation. Since individual parts are finished with high precision, carefully disassemble so as not to damage them.

T = N-m (kgf-cm) [ft-lbfl


Remove the limit switch and spring cover. [Point 11 Remove the tilt spool. Remove the solenoid valve. [Point 21 Remove the lift spool. [Point 31 Remove relief valve No. 1. [Point 41 Remove relief valve No.2. [Point 51 Remove the flow divider valve. [Point 61 Remove the filter. [Point 71 Remove the lift select valve. [Point 81 Remove the tilt select valve. [Point 91 Remove the flow control valve. [Point 101 Remove the tilt lock check valve. Remove the lift lock check valve. Remove the additional spool. Remove the outlet housing.



Note: Wash each part thoroughly, remove dirt by blowing compressed air and apply hydraulic oil before reassembly.

Backward Backward

Front side (SOL1)

=::,I

Rear side (SOL2) (- 2000. 10)

(+I

(-)

Point Operations


Check continuity of limit switches.

Forward tilt side: No continuity when the switch is pressed.

Backward tilt side: No continuity when the switch is pressed.

Reassembly: Carefully connect the limit switches on the forward and backward tilt sides in correct positions. Install the one for the forward tilt on the upper side. (It is regular that the both switches must be in pressed state when installed.)


Put a match mark to ensure installation of each solenoid in the correct position.

Inspection: Check continuity of each solenoid.

Inspection: Inspect and wash each orifice to eliminate clogging.

Reassembly: Carefully install SOL1 and SOL2 spools in correct positions.

[Point 31 Disassem bly-Reassembly:

Remove the compression spring from the lift spool. SST 09610-10161-71 Use the SST with a washer.


lnspect and wash the orifice to eliminate clogging.

Reassembly: When the relief valve is disassembled, ternporalily reassemble after positioning the nuts as illustrated.

a = 27.0 mm (0.62 in)






lnspect and wash the filter to eliminate clogging.

Service nut

Service bolt




Use the service bolt and nut to remove the sleeve. Service bolt size: MI0 x 1.25

Inspection: lnspect and wash the filter to eliminate clogging.



14-13

CONTROL VALVE LEVER ASSY REMOVAL-INSTALLATION

Removal Procedure

I Remove the instrument panel.

2 Disconnect the lever rod.

3 Disconnect the knob switch wiring at the tilt lever.

4 Remove the set bolt.

5 Remove control valve levers. [Point 11



Note: Apply chassis grease on the control valve lever links.

Point Operations


Check the knob switch for continuity.

RELIEF PRESSURE ADJUSTMENT (- 2000.10) Note: Always adjust the relief pressure in due order, the lift (high pressure) side first and then the tilt (low pressure) side since the relief valve is structured in two stages. (If the lift side is normal and the tilt side is abnormal as a result of relief pressure inspection, it is allowed to adjust only the tilt side pressure.)

Adjusting screw A

Adjusting sleeve B

1. Install an oil pressure gauge. (1) Remove the oil pressure detection port plug (illustrated)

from the front side of the oil control valve, and install the oil pressure gauge.

Plug size: 911 6-1 8UNF-2B

2. Set adjusting screw A and adjusting sleeve B of the relief valve as follows:

(1) Loosen lock nut @ and fully tighten adjusting screw A. Then loosen it by one to two turns.

(2) Loosen lock nut @ and position adjusting sleeve B to satisfy the following dimension:

a = 27.0 mm (0.62 in)

3. Start the engine and check for any oil leak or abnormal noise.

4. Adjust the lift side relief pressure. (1) Operate the lift lever to raise the forks to the upper-

most position. (2) Operate the tilt lever slightly to the backward side with-

out causing backward tilt of the mast, and hold the lever with the backward tilt limit switch in actuated state.

(3) In the state of (2) above, operate the lift lever in the upward direction while the engine is running at the maximum speed. Gradually tighten adjusting sleeve B until the oil pressure in the relief state satisfies the standard below. Then fix the position by turning lock nut 0.

Standard Unit: kPa (kgf/cm2) [psi]

Vehicle model

Lift relief set pressure

All models

181402~ (1 85';) [2630+iq

5. Adjust the tilt side relief pressure. (1) Operate the tilt lever to tilt the mast fully backward. (2) Operate the tilt lever the backward tilt direction while

the engine is running at the maximum speed. Gradu- ally tighten adjusting screw A until the oil pressure in the relief state satisfies the standard below. Then fix the position by turning lock nut 0.

Standard Unit: kPa (kgflcm2) [psi]

6. Remove the oil pressure gauge and tighten the plug.

Vehicle model

Tilt relief set pressure

All models

1 5690"090 (1 605) [2280*$7

RELIEF PRESSURE ADJUSTMENT (2000.10 -) Note:

Always adjust the relief pressure in due order, the lift (high pressure) side first and then the tilt (low pressure) side since the relief valve is structured in two stages. (If the lift side is normal and the tilt side is abnormal as a result of relief pressure inspection, it is allowed to adjust only the tilt side pressure.) There are two cases: Case A: The method in which the plug in-analyzer (SST 09240-23320-71 or SST 09240-23321-71)

is utilized. Case B: The method in which the plug in-analyzer is unused.

Adjusting screw A

Adjusting sleeve B

Diagnosis connector

ACTIVE TEST (112)

SWING SOL

TlLT SOL2 - - - I - - KNOB SOL - - - I "

1. Install an oil pressure gauge. (1) Remove the oil pressure detection port plug (illustrated)

from the front side of the oil control valve, and install the oil pressure gauge.

Plug size: 911 6-1 8UNF-2B

2. Set adjusting screw A and adjusting sleeve B of the relief valve as follows:

(1) Loosen lock nut @ and fully tighten adjusting screw A. Then loosen it by one to two turns.

(2) Loosen lock nut @ and position adjusting sleeve B to satisfy the following dimension:

a = 27.0 mm (0.62 in)

Case A: 3. Connect the plug in-analyzer. 4. Turn the ignition switch ON (stop the engine). 5. Manipulate the analyzer so that ACTIVE TEST (1 12) will

be displayed. Analyzer manipulation steps: MAIN MENU -. SAS MENU +ANALYZER MENU+. ACTIVE TEST (1 12)

6. Choose TlLT SOL1, as it is shown in the illustration and check to confirm that TlLT SOL1 is in OFF state. (If the fork height is at low, around 2 m (79 in) or less, it is in OFF state.) On this displayed condition, proceed to next step.

wi3=

Solenoid connector

Standard

7. Start the engine and check for any oil leak or abnormal noise.

8. Adjust the lift side relief pressure. (1) Operate the lift lever to raise the forks to the upper-

most position. (2) Operate the lift lever in the upward direction while the

engine is running at the maximum speed. Gradually tighten adjusting sleeve B until the oil pressure in the relief state satisfies the standard below. Then fix the position by turning lock nut 0.

9. Adjust the tilt side relief pressure. (1) Operate the tilt lever to tilt the mast fully backward. (2) Operate the tilt lever the backward tilt direction while

the engine is running at the maximum speed. Gradu- ally tighten adjusting screw A until the oil pressure in the.relief state satisfies the standard below. Then fix the position by turning lock nut 0.

10. Return the plug in-analyzer to MAIN MENU. 11. Turn the ignition switch OFF. 12. Remove the oil pressure gauge and tighten the plug.

Case B: 3. Disconnect the solenoid connector. 4. Do the same operations as in Case A, step 7 to 9. 5. Turn the ignition switch OFF. 6. Connect the solenoid connector. 7. Remove the pressure gauge and tighten the plug.

Note: In the event of Case B relief pressure measurement, there remains error code "64-1" in memory since the solenoid connector has been removed once.

Unit: kPa (kgf/cm2) [psi]

Vehicle model

Lift relief set pressure

Tilt relief set pressure

All models

1 81 4O'4o9O (1 85';) [2630+60]

15690+4oW (1 60+3 [2280+67

VEHICLE WITHOUT SAS GENERAL Oil Control Valve

Relief Valve

Relief valve for lift cylinder Relief valve for tilt cylinder

Flow Divider

Hydraulic Circuit

r---- .- .- .- -

C 4 C 5

C2 C3

C 1

P: Pump port T Tank port TI : To tank T2: From power steering

T1 T2 P OUT

SPECIFICATIONS

COMPONENTS

Vehicle model

Oil control valve type

Pn 1.2 ton series Cu2.3 ton series

Add-on type (1 -, 2-spool rnonoblock)

181 40 (1 85) [2630]

15690 (160) [2280]

13.0 (3.43)

Built-in flow divider valve

Relief set pressure kPa (kgf/crn2) [psi]

Pn3 ton series

t

t

c

15.2 (4.02)

c

Lift

Tilt

Flow divider flow rate elrnin (USgalImin)

Others

OIL CONTROL VALVE ASSY

Note: Before disconnecting the control lever link, release the residual pressure in the material handling system piping by operating the control lever, set the mast in the neutral state and lowering the fork to the bottom position.

Removal Procedure


2 Disconnect the control valve lever link.


4 Remove the oil control valve set bolt.

5 Remove the oil control valve ASSY.



Note: Apply grease to the oil control valve lever link parts. Check the hydraulic oil level, and add if insufficient.

Note: Operate in a clean place. As each part is finished with high precision, carefully disassemble them to prevent any damage.


1 Remove the seal holder.

2 Remove the spring cover.

3 Remove the tilt spool and lift spool. [Point 11

4 Remove the relief valve. [Point 21

5 Remove the flow divider valve.

6 Remove the check plunger.

7 Remove the additional spool.

8 Remove the outlet housing and additional spool body.



Note: Wash each part thoroughly, blow with compressed air and apply hydraulic oil before assembly.

Point Operations

[Point 11 Disassembly.Reassembly:

SST 09610-10161-71


When the relief valve is disassembled, always loosen the adjust screw fully.

RELIEF PRESSURE ADJUSTMENT Note:

Always make adjustment according to the procedure described below. Careless adjustment may generate a high pressure to cause damage to the oil pump or other hydraulic devices. Always check that the no-load maximum speed is as specified.

1. Install an oil pressure gage. (1) Remove the oil pressure detection plug (9116-1 8UNF-

28) installed on top of the oil control valve, and install the oil pressure gage.

2. Check loosening of the adjust screw. (1) Remove the cap nuts and packings on top of the relief

valves LH and RH. Loosen the lock nut and loosen the adjust screw to a degree not to come off from the body.

3. Start the engine and check for no oil leak or abnormal noise.

4. Adjust the lift side relief pressure. (1) Set the control lever to the lift position and gradually

tighten the adjust screw on the left side until the fork starts to rise.

(2) Run the engine at the maximum speed, and read the pressure gage when the fork is raised to the maximum height. Adjust the oil pressure then to the specified level by turning the adjust screw and lock with the lock nut.

5. Adjust the tilt side relief pressure. Relief Set Pressure (1) Set the control lever at the backward tilt position, and

Unit: kPa (kgf/cm2) [psi] gradually tighten the adjust screw on the right side until the mast starts to be tilted backward.

(2) Run the engine at the maximum speed, and read the oil pressure gage when the mast is tilted fully backward. Adjust the oil pressure then to the specified level by turning the adjust screw and lock by the lock nut.

Ail models

181 4 0 7 (1 85+2)[2630':0]

Tilt 15690';PO (1 60+~)[2280'~~]

6. After the adjustment, insert the packing and tighten the cap nut. Inspect the relief pressure again.

7 . Remove the oil pressure gage, and tighten the plug.

SAS Page

........................................................................ GENERAL 15-2

.............................................................. COMPONENTS 15-3

..................................... PRECAUTIONS FOR REPAIR 15-7

RENEWAL OF SAS CAUTION LABEL ..................... 15-10 ................................................... FUNCTIONAL PARTS 15-11

.............. SAS CONTROLLER REMOVAL-INSTALLATION 15-12

YAW RATE SENSOR REMOVALINSTALLATION .......... 15-1 2A

SWING LOCK CYLINDER REMOVAL*INSTALLATION ..... 15-13 TILT ANGLE SENSOR REMOVAL-INSTALLATION .......... 15-15 LOAD SENSOR REMOVAL-INSTALLATION .................... 15-1 6

SPEED SENSOR REMOVALINSTALLATION .................. 15-1 7 ....... FORK HEIGHT SWITCH REMOVALINSTALLATION 15-18

RE-SEITING ................................................................ 15-19 CUSTOMIZE .................................................................... 15-22 PLUG-IN ANALYZER ..................................................... 15-23

BASIC OPERATION ........................................................ 15-25 ....................................................................... ANALYZER 1 5-28

RE-SElTlNG ................................................................. 15-38 OPTION SET (CUSTOMIZE) ........................................ 15-40

...................................................... TROUBLESHOOTING 15-41

DIAGNOSIS .................................................................... 15-43 TROUBLESHOOTING .................................................. 15-46

TROUBLESHOOTING BY ERROR CODE ........................ 15.46 TROUBLESHOOTING BY PHENOMENON ...................... 15-90

CONNECTOR LAYOUT ............................................. 15-132 CONNECTOR DIAGRAMS ....................................... 15-133

GENERAL Composition of SAS (System of Active Stability) This system performs rear wheel swing control (S) and mast tilting control (T) by driving various actuators according to the vehicle movement signals sent to the SAS controller from the sensors and switches installed on necessary portions on the vehicle.

Output d

- 8 -, v,

d

Fork height switch

Swing lock lamp Diagnosis (hour meter)

Functional part

Swing lock cylinder Oil control valve SOLl.SOl.2

[ Diagnosis connector ( 0 1 0 1 .1

I Plug-in analyzer 1

Control

%l'Fiv Tilt knob switch

S 0

Combination meter SAS warning lamp Tilt angle sensor Swing lock lamp Fault diagnosis dis

SAS controller Yaw rate sensor

Oil control valve

T

0

Speed sensor Forward tilt switch Backward tilt switch

I Solenoid 1

m Solenoid 2 L I - / -

I Load sensor

Plug-in analyzer ::=: Diagnosis connector

Swing lock cylinder

COMPONENTS

Controller 191 0

1910-012A

Swing lock cylinder

*

Fork height switch (V) 5803 10

r... I ..., I .

I 1

I I

Fork height switch (FV-FSV-QFV)

I

5803

1.. 4 5803-026

10

T"' ..., n BA

5803-002A

Tilt angle sensor 5803

I

Load sensor (Pnl ton series: V) (FV)

I i I

I LH LIFT CYLINDER

Load sensor (Pn2-3 ton series: V) (Cu2.3 ton series: V)

Load sensor (FSV) Load sensor (QFV) 5803

9161140814

5803-030 5803-040

Speed sensor 5803

V

5803-022

PRECAUTIONS FOR REPAIR Fully understand the functions of SAS (System of Active Stability) before repairing it.

1. Preparation for repair ,,

(1) When washing the vehicle, care should be taken not to splash water directly to the electrical components. Don't apply high pressure washing to the controller, tilt angle sensor, lifting height switch, horn button, meters, switches on the instrument panel and electrical components and parts in the engine room.

(2) Remove contamination and/or water from respective sections.

(3) Transport a controller in cushioned packing and open it only before installation. Never transport it unpacked. Care should be taken not to drop the controller or give it impact by allowing contact with other objects.

(4) Part number for a controller varies by the vehicle specifications. Check correct part number in advance.

(5) Should a repair work require matching (re-setting), always park the vehicle on a flat place. (6) Arrange for necessary tools and measuring instrument (such as a plug-in analyzer (SST 09240-

23321 -71) and TOYOTA electrical tester (SST 09082-76002-71 (SST 09082-00050)), etc.).

2. During repair (1) Never apply an impact wrench for removing the controller. Lay waste beneath the controller in

precaution for an accidental dropping. (2) Don't turn the key switch ON-OFF for no specific reason when the sensor wiring is disconnected.

Turning the 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. Beyond 10th error code, the older error will be sequentially erased.

(3) When turning the solenoid (for lock cylinder) ON during an "Active Test" of the analyzer, don't keep it ON for more than one (1) minute. Since SAS functions are forcibly suspended during an operation check, perform the running test carefully at low speed.

(4) SAS functions are suspended during matching (re-setting). Don't operate the vehicle in this state. (5) Don't turn the key switch ON with one side (RH or LH) of avehicle jacked up. It is very dangerous to

turn the key switch ON in this state as it releases the swing lock and the vehicle becomes suddenly tilted.

(6) If a vehicle is in tilted condition because of the repair of a flattened tire or otherwise, keep the 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 dirts from entering.

(8) If the oil control valve for manual lowering is loosened, tighten it up to a prescribed torque level. (9) Tighten respective set bolts with prescribed toque. (10) Respective sensors require no adjustment during installation. Make initialization during matching

(re-setting) . (11) To extract a connector, do not pull it by the harness. (1 2) 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 re-

usable. (14) Do not apply strong impacts to the frame and head guard to prevent the controller from damage. (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

SAS-ECU

-

3. Temporary measures (1) If swing lock fails to unlock for some trouble when the

key switch is turned ON, it may be unlocked manually for temporary action. Loosen the illustrated plug of the swing lock cylinder by 1 to 2 turns for unlocking. Care should be taken not to over-loosen it. After the repair, tighten it properly. T = 8 - 10 N-m (80 - 100 kgf-cm)

[5.8 - 7.24 ft-lbfl

(2) If the mast should fail to tilt forward or backward because of the failure of the forward or backward tilt limit switch, tilting operation may be made by extracting SAS-ECU fuse in the relay box for temporary measure. Care should be taken in this case that SAS functions are suspended. The swing control enters the lock state.

(3) 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 = 26.5 - 32.4 N-m (270 - 330 kgf-cm) [ I 9.5 - 23.9 ft-lbfl

4. Precautions for vehicle modification

H (fork height): mm (in)

Note: Proceed with the alignment (re-setting) procedure after the above-mentioned modification. (See page 15-1 9.) After modification, replace the caution label affixed on the vehicle with the one matching the new SAS function. When placing a supply order for a mast ASSY, place order for sensors (for lifting height switch, load sensor, mast harness and other SAS related parts) simultaneously if such parts are required.

Content of work

Change controller. (for vehicle without swing control) Remove the lock cylinder.

Change controller. (for vehicle with swing control) Change the rear axle beam. lnstall the lock cyiinder. Change the mast.

Change the mast. Install the lifting height switch. Install the mast harness.

Chenge the mast. Remove the lifting height switch. Remove the mast harness.

Install or remove attachment.

Install the mast. Install the lifting height switch. lnstall the mast harness.

Condition -

-

Between two H2000 (79) s

H2000 (79) -. H2500 (98.5) or above

H2500 (98.5) or above -, H2000 (79)

- -

No.

1

2

3

4

5

Content of modification

Single tire -. Double tire

Double tire -. Single tire

Mast replacement

Installation/Removal of attachment

Mast installation (Mast less spec. model)

RENEWAL OF SAS CAUTION LABEL The warning instructions on the SAS caution label affixed to each truck must always agree with the SAS features that particular model owns. You must be strictly careful because the SAS caution label must be changed to the one with different warning in case that the modification on your side may vary the SAS features. Notice that the caution label must be changed in the following cases:

(1) The modification was such as to change the original specification features, tire spec. modification done by the dealar premises for example. Depending on single or double, the SAS caution label must be changed.

(2) The selective function of the mast forward tilt angle control was switched to either of Validation and Invalidation.* (*: See Page 15-22 Customize for the switching method.)

1. Case of Original Specification Feature Change. *

Label @ Label @

Single tire Dual tire

0 0

0 - 0 Single tire Dual tire

2. Case of Switching "Mast forward tilt control Validllnvalid."

Label @ Label @

0 + 0

Label @ for use on the SINGLE TlRE models Label @ for use on the SINGLE TIRE models having the following SAS features: having the following SAS features:

Equipped with swing lock control Equipped with swing lock control Mast forward tilt angle control "VALID". Mast forward tilt angle control "INVALID".

Label @ Label @

Valid l nvalid

@ @ MIS FORKLIFT TRUCK HAS

@ @ ACTIVE STABILITY FEATUFZES.

Valid Invalid

Label @for use on the DUAL TIRE models Label @ for use on the DUALTIRE models having the following SAS feature: having "NO ACTIVE STABILITY FEA- Mast forward tilt angle control "VALID". TURES". (No swing lock control) Mast forward tilt angle control "INVALID.

(No swing lock control)

3. Case of Mast Installation for Mast-Less Spec. models. When you install the mast to the mastless models, make sure the specification features with the mast assem bled. Take note that the proper caution label must be chosen to be affixed to the truck. The proper label can be found among four types of the label numbering @ - @ in the illustration.

FUNCTIONAL PARTS Note:

Read Section 14 for the oil control valve solenoids 1 and 2, forward tilt switch, backward tilt switch and the tilt lever knob switch. Checking of functional parts is described in the troubleshooting.

SAS CONTROLLER REMOVAL*INSTALLATION

Note: SAS controller has a built-in yaw rate sensor. Care should be taken in handling it by preventing tl dropping, contact with other objects and so forth. If dropped, replace with a new one. Don't app the impact wrench in removinglinstalling the set bolts fromlto the oil control lever valve conne tor bracket, connector boot bracket, and SAS controller.

T = N-m (kgf-cm) [ft-It

Removal Procedure



3 Disconnect the tilt lever rod.

4 Remove the oil control valve connector bracket.

5 Remove the connector boot set plate.

6 Disconnect the connector.

7 Remove the controller



Note: Apply locking agent (08833-76002-71 (08833-00080)) on the threaded portion of the controller set bolts and the boot set plate set bolts before tightening them. Always use genuine controller set bolts. Correct tightening will fail if non-genuine bolts are used. When the SAS controller is replaced, perform the re-setting (read 15-19).

YAW RATE SENSOR REMOVAL*lNSTALLATlON

Note: Take the utmost care so as not to give a shock or impact on the yaw rate sensor. Don't use an air impact wrench on controller parts wholly.

T = N*m (kgf-cm) [ft-lbfl

Removal Procedure

1 Remove SAS controller. (See page 15-1 2.)

2 Remove the cover. [Point 11

3 Disconnect the jumper on the base print board connector. [Point 21

4 Loosen the lower set plate mount screw, and remove the yaw rate sensor together with the lower set plate. [Point 31

5 Remove the yaw rate sensor mount screw, and separate the yaw rate sensor from the set plate. [Point 41



Don't loosen th~s screw

Point Operations

[Point 11 Removal .Installation:

Use "Tom (size: Tom Tamper Proof T-20)" wrench.

[Point 21 Removal.l nstallation:

When removing or installing the jumper, take care so as not to harm the base plate connector. Insert firmly when installing. And avoid adverse contact such as to element.

[Point 31 Removal:

Never separate the upper set plate from the lower set plate, in other words, don't loosen three pieces M3 screws. If this screw is loosened, apply thread tightener (08833- 76002-71 (08833-00080)) and tighten it to the specified torque. T = 0.49 - 0.88 N.m (5 - 9 kgf-cm)

10.36 - 0.65 ft-lbf]


Don't change the direction (or orientation) of the yaw rate sensor when re-installing.

Removal Procedure

1 This is not applicable to Pnl ton series and Cu2.3 ton series vehicles. Remove the radiator.

2 Jack up the vehicle.

3 Remove the lower pin, swing lock cylinder.

4 Disconnect the swing lock solenoid connector.

5 Remove the upper pin, swing lock cylinder. [Pointl]

6 Remove the swing lock cylinder. [Point 21



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.

Point Operations

[Point 11 Removal:

SST 0981 0-201 72-71

[Point 21 Inspection: - 2000.4 :

Remove the plug from the center at the end of the accumulator, and measure accumulator piston depth L. Standard : 46 mm (1.81 in) (20°C (68°F)) Limit : 52 mm (2.05 in) (20°C (68°F)) If the limit value is exceeded, replace the swing lock cylinder ASSY. After inspection, tighten the plug to be flush with the end face of the accumulator (do not tighten it excessively).

2000.4 - : Remove the plug, with a coin (or a screw driver) from the center at the end of the accumulator. Measure accumulator piston depth L. Standard : 46 mm (1.81 in) (20°C (68°F)) Limit : 52 mm (2.05 in) (20°C (68°F)) If the limit value is exceeded, replace the swing lock cylinder ASSY. After inspection, push a plug in with a finger.

Installation: Install with the mark (protruded portion) at the rod end facing outward.

Removal Procedure



3 Remove the instrument panel (RH).

4 Remove the step.

5 Remove the side cover.

6 Remove the fender cover.

7 Disconnect the tilt angle sensor link.


9 Remove the tilt angle sensor.



Note: When the tilt angle sensor is remove/installed or replaced, or when the length of the tilt angle sensor link is adjusted or replaced, proceed with the re-setting procedure. (Read 15-1 9.)

LOAD SENSOR REMOVAL*INSTALLATION


Pn l ton series: V Pnl-3 ton series: R/

Pn2-3 ton series: V Cu: v PmCu: FSV

Cu2 ton series: QFV

Removal Procedure

1 Hoist the inner mast. (Pnl ton series: V, Pnl - 3 ton series: FV, Cu: FV) [Point I]

2 Remove the front hose cover. (Pnl ton series: V, Pnl - 3 ton series: FV, Cu: FV)

3 Remove the sensor cover.


5 Remove the load sensor



Note: When the load sensor is replaced, proceed with the re-setting procedure. (Read 15-19.)

Point Operations

Removal~lnstallation: Raise the inner mast, set SST to the outer mast tie beam and lower the inner mast until it makes contact with SST. SST 0961 0-22000-71

-~

SPEED SENSOR REMOVAL-INSTALLATION


Removal Procedure

1 Remove the speed sensor cover.


3 Remove the speed sensor



Removal Procedure

1 Remove the lower cover.


3 Remove the mast lifting height switch.



RE-SETTING Of the sensors used for SAS, the signal voltage values of the tilt angle sensor and load sensor are stored respectively to the SAS controller for control accordingly when the mast is in vertical state and in no-load state. Therefore, when making service for these sensors or replacing their parts, re-setting (updating of sensor signal voltage values in the standard vehicle condition) is required. Re-setting is also required for the tilt angle sensor when the vehicle attitude is sharply changed and for the load sensor when the weight changes sharply because of the addition/removal of the attachment. Re-setting may be performed by using the hour meter and the tilt knob switch or plug-in analyzer (SST 09240-23321 -7 1 ) (read 1 5-38).

": Perform re-setting with the mast in the vertical position since the controller calculated the limit position for forward tilting.

Object of re-setting

Re-setting condition

Vehicle indication (hour meter)

Analyzer (SST) indication

Object sensor

Note: The tilt angle sensor re-setting value of SETl determines the mast stop position under the automatic fork stop control at horizontal level. Accordingly, if the fork fails to stop at the horizontal level due to the service condition by the user (inclination of the floor, etc.), bring the mast vertical on the site and perform re-setting. (In such a case, the mast stop angle drifts on the level floor.)

Re-setting

Fork stopping position with automatic leveling

Mast in vertical position

SET1

TILT LNEL

required

Forward tilting limit position

No-load standard load

Mast in vertical position"

No load

SET2

CONT-LOAD

Tilt angle sensor and load sensor

0 0 0 0 0 0 0 0

Tilt angle sensor Work example

Replacement of SAS controller

Removal/lnstallation or replacement of tilt angle sensor

Change of the length of tilt angle sensor rod or replacement

Replacement of load sensor

Change to other attachment

Replacement of mast

Replacement of tilt cylinder

Adjustment of tilt cylinder uneven tilting

0 0 0 0 0 0 0 0

STANDARD STATE OF VEHICLE If the surface on which re-setting is to be performed is slanted, error occurs to the standard state. Select a level floor without irregularity for re-setting.

Note: The finishing accuracy of the floors for factories, warehouses and buildings in general calls for the floor inclination to be 0.5" or under. Therefore, re-setting on these floors is not affected. Don't perform re-setting on a floor that is inclined for over 0.5" for draining purpose.

V FWFSV-QFV

- c .- o! 5 E E 0 z

500 mm (1 9.7 in)

Additional Weight Table

Fork stop position with automatic leveling and forward tilting limit position

Set the vehicle in the following condition so as to have the tilt angle sensor signal voltage value stored with the mast held vertical to the floor surface:Load sensor

No-load standard load Set the vehicle in the following condition so as to have the load sensor signal voltage value stored under no-load condition:

Standard: Raise the fork to a height of 500 mm (1 9.7 in) for the V mast or raise the rear lift cylinder to a height of I00 mm (3.9 in) for the FV, FSV or QFV mast. Place a level (goniometer) at a height of 1200 to 1500 mm (47.2 to 59.1 in) on the front or rear side of the outer mast and set the mast in the vertical position. 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 relief at the topmost position.

Note: Keep the fork or attachment installed on the vehicle. Set the mast vertical from a backward tilted position (not from the forward tilted position). In case of a detachable attachment, keep the attachment installed on the vehicle.

kg (Ibs)

Lift height mm (in)

3000 (1 18) or less

Pn15

700 (1544)

Cu30 Cu32

1200 (2646)

Pn32 Pn30

1200 (2646)

Pn18

800 (1764)

3300 (1 30) 700 700 - 4000 (1 57.5) 1 (1544) ' (1544)

1200 (2646) 1000 (2205)

800 (1 764)

500 (1 103)

1200 (2646)

1000 (2205)

800 (1764)

500 (1 103)

950 (2095)

900

Cu20

950 (2095)

950 (2095)

900

Pn20 I Pn25

650 (1433)

4300 (169) - 5000 (1 97)

Cu25

950 (2095)

950 (2095)

700 (1544)

450 (992) 300 (662)

950 (2095)

600 (1323)

950 (2095)

900 (1985)

650 (1 433)

500 (1 103)

950 (2095)

5500 (216.5) - 6000 (236)

6500 (256) - 7000 (275.5)

(1985) ( (1985)

(992) 450 (:::3)

- 1 - 650

(1433)

450 (992)

800 (1764)

500 (1 103)

Re-settng connector

Knob switch

& [ T I

0 indication

[X] H indication

RE-SETTING PROCEDURE

Note: Turning the key switch ON (or starting engine) after disconnecting the re-setting connector causes an error (error code 41) to be displayed and stored to the contro.ller, 'for which care must be taken.

1. Turn the key switch ON (or start the engine). 2. Disconnect the re-setting connector (orange color).

(1 ) The hour meter display reads "SET" and the SAS lamp turns ON. (The buzzer sounds.)

3. Press the knob switch until the re-setting mode (SET1 is displayed) is displayed (2 seconds or over).

4. Display the set number subject to the re-setting. (1) Set number display changes sequentially each time

the knob switch is pressed for less than 2 seconds.

Note: Pressing the knob switch 2 seconds and over will run the re-setting, for which care should be taken.

": Indication may be made but actually it is not used.

Set No. SET1 SET2

S ET3 " S ET4 "

5. Set the sensor of the display set number to the standard state (or check if it is in the standard state). Read 15-20 page.

6. Press the knob for 2 seconds or more and execute re- setting.

Object of re-setting Fork stop position with automatic leveling Forward tilting limit position and no-load standard load

-

0 indication: Re-setting is completed. (SAS lamp starts to blink)

H indication: Check for the sensor abnormality, disconnection of the harness and the short-circuit since the signal voltage value is outside the re-setting rang. (Read the troubleshooting section.)

Note: For re-re-setting, repeat Step 6. To make a separate re-setting, repeat Steps 4 to 6.

7 . Connect the re-setting connector and turn the key switch OFF.

CUSTOMIZE The customize function is to invalidate the mast forward tilting angle control. There are two methods to do this; one is to use the hour meter and tilt knob switch and the other method is to use the plug-in analyzer (SST). (See page 15-23.)

Caution: When the customize is changed, maintain the caution label of "WARNING." (See page 15-10.)

Re-setting connector CUSTOMIZE PROCEDURE

Note: Turning the key switch ON (or starting engine) after disconnecting the re-setting connector causes an error (error code 41) to be displayed and stored to the controller, for which care must be taken.

1. Turn the key switch ON (or start the engine). 2. Disconnect the re-setting connector.

(1) The hour meter display reads "SET" and the SAS lamp turns ON. (The buzzer sounds.)

3. Set the tilt lever to backward tilt for 5 seconds and over. Then press the knob switch until the option set mode (OPT1 is displayed) is displayed (2 seconds and over), then return the lever.

4. Display the option number to change the option set. (1) Set number display changes sequentially each time

the knob switch is pressed for less than 2 seconds.

1 I I

*:Displayed but not in use.

Option No. OPT1

5. Keep the knob switch pressed until the SAS lamp starts blinking (for 2 seconds or over) to change y to n, and n to Y.

Control name Mast forward tilt anale control

y: Control valid n: Control invalid

6. Connect the re-setting connector and turn the key switch OFF.

7. Replace the caution label. (See page 15-1 0.)

PLUG-IN ANALYZER For the maintenance and service of SAS functions, a separate type plug-in analyzer is introduced as an SST (Special Tool for Service). The plug-in analyzer is designed to read the operating state of sensors and actuators used for the SAS functions and the error information detected by the controller. It serves to check on the operating state of SAS functions and shortens the repair time for a trouble. Moreover, it is installed with save function to file data displayed on the screen in the SST.

SST 09240-23321 -71

Reference Page -

1528

1538

1540

15-25

Content of function

Indication of ten error codes and sub-codes in past.

Monitoring input voltage value from the sensors and the output signal. etc. to the solenoid, etc.

name

DlAG MEMORY

lNioUT

ACT'VE TEST

DATA MANAGE

CONTROLLER NO

save function

0

0

Menu

ANALYZER

aa' t, TI

(I)

5 2 3 .O s = .G 9 E a r n r g 3 - - C ? c o r n .P L m S 0 0 .- s k 3 K

E E cn

Forced operation of solenoids and warning lamps.

Display and erasure of save screen

Reading controller part number, ROM part number and controller manufacturing number.

Implementation of re-setting (updating the sensor signal voltage value in the vehicle standard state).

Setting validtinvalid of forward tilt restriction control

Adjustment of the screen contrast

Change to the display language.

Main unit data initialization

Q:

a rn

' RE-SETING

CUSTOMIZE

CONTRASTSET

LANGUAGE SET : FILE INITIALIZE

S $

- O - '0 .z C 3

.- 2 .G U

+-

$ 5 + "

BASIC OPERATION

Name of Sections and the Switch Functions

Caution on using: Keep the main unit, wire harness, connector, etc. away from the exhaust and other heated sections. Operate the switch with finger tip. Don't give it strong impact from dropping or collision. Don't leave it under the direct rays of the sun for long time.

Connection and Operation of SST 1. Turn the key switch OFF. 2. Open the diagnosis connector cover of the vehicle and

properly connect the connector on the SST side. SST 09240-23321 -71

Note: Since the connector has no locking device, securely connect it to prevent contact defect upon closing the engine hood with the connector in connected state. 3. Turn the key switch ON or start engine.

Switch

Selector

switch @

Selector

switch @

Menu

switch @

4. Display of the initialization screen After about 15 seconds of display, "LANGUAGE SET" or "MAIN MENU" screen appears. The screen may be changed during this period by pressing the menu switch

Function

Move the cursor to the above item.

Move to the preceding page.

Move the cursor to right or left.

Save the screen.

Re-set the display screen.

Initialize the file.

<No function>

Select the item below.

Move to the following page.

<No function>

Determine an item for selection.

Move to MENU screen.

Mark

t

SAVE

SET

START

<Blank>

4 <Blank>

<Blank>

Name of section

Main un~t

Connector

A Swltch Screen title

Position of indication

A

B

C

Sw~tch mark lnd~cator

LANGUAGE SET l 3 > 3 t

,

4 4,

I MAlN MENU t

,7TESTER SET

S. "LANGUAGE SET" screen Since this screen appears only when the language is undefined, determine a language to use for display.

(1) Select a display language by pressing selector switch @) and @.

Japanese English

(2) Press MENU switch @ to determine the language setting.

4 ,

TESTER SET MENU 0 " P

3FILE INITIALIZE

,7END

Note: Once the display language is defined, "LANGUAGE SET" screen will not be displayed from the next time onward. To change language, go to Step 8 "TESTER SET."

r c

6. "MAIN MENU" screen (1) Select the menu using selector switch @ and @ and

determine by pressing menu switch @. SAS: Moves to SAS MENU screen. (Step 7) TESTER SET Moves to TESTER SET screen. (Step 8)

--

7. "SAS MENU" screen (1) Select the menu using selector switch @ and @ and

determine by pressing menu switch @. ANALYZER: Moves to ANALYZER MENU screen. RE-SETTING: Moves to RE-SETTING screen. CUSTOMIZE: Moves to CUSTOMIZE (111) screen. END: Returns to MAlN MENU screen.

8. "TESTER SET" screen (1) Select the menu using selector switch @ and @ and

press MENU switch @to determine the setting. CONTRAST SET: Moves to CONTRAST SET screen for contrast adjustment. (Read Step 9.) LANGUAGE SET Moves to LANGUAGE SET screen for changing language. (Read Step 10.) FlLE INITIALIZE: Moves to FlLE INITIALIZE screen for a total erasure of the main unit data. (Read Step 11 .) END: Returns to MAlN MENU screen.

' CONTRAST SET

CONTRAST LEVEL 4

-, FlLE INITIALIZE

CHECK OIY C)

L

r c

FlLE INITIALIZE

i

. FILE INITIALIZE

INITIALIZING

J

4,@

LANGUAGE SET

ZENGLISH

7END

., START

9. "CONTRAST SET" screen (1) Select the level of contrast using selector switch

and 0. Contrast level: (Light) 1 2 3 4 5 6 7 8 (Dark)

(2) Press the menu switch @ to determine the setting. Then "SAVING+COMPLETEw appears to the message column and the screen returns to INITIAL SET MENU.

10. "LANGUAGE SET" screen (1) Select other language using selector switch @ and

0. Japanese English

(2) Press MENU switch @to determine the setting. Then "SAVING+COMPLETE" appears in the message column.

(3) Select END by selector switches @ and @ and press MENU switch @. The INITIAL SET MENU screen re- appears.

11. "FILE INITIALIZEn screen

Note: Check the databeforehand because the main unit data is initialized.

(1) Have the message displayed on the screen by pressing selector switch @.

(2) Select an item using selector switch @) and determine by pressing MENU switch a. N: File initialization can be cancelled.

Y Starts file initialization. Initialization ends when INITIALIZING-+COMPLETE appears to the message column.

(3) Press MENU switch @to return to the TESTER SET MENU screen.

Screen tlle

2INIOUT MONITOR 3ACTlVE TEST 4DATA MANAGE SCONTROLLER NO

7END

Removal of SST 1. Check that the screen title is for one of the MENU screens. 2. Turn the key switch OFF. 3. Disconnect the connector.

Note: To disconnect, hold the body of the connector.

4. Close the diagnosis connector cover.

ANALYZER

Message column

1 11223.3h 42-1 2 1223.3h 41 -1 3 223.3h 42-1 4 23.3h 41-1 5 O.Oh

,

Save function In the screen *I and *2 in the table, pressing selector switch @saves the content to respective menu of "4 DATA MANGE." Upon running the SAVE function, "SAVING

n appears to the

message column and "FILE*ICOMPLETE FILE*"(* represent- ing the number in the file) appears when the saving normally ends. After checking the file number, press MENU switch @ to return to "ANALYZER MENU" screen.

Page

1529

1531

1532

-

1533

1534

1535

1535

1537

ANALYZER MENU

1 DlAG MEMORY

Content of display and function

lndicates ten error codes and the time of error generation in the past.

lndicates the swing control-related controller data.

lndicates the TILT control-related controller data.

-(Displayed but not in use.)

Indicates other controller data.

2 INIOUT MONITOR

- Save function

Yes''

Yese2

Yese2

- Yess2

Forcibly outputs operating s~gnal to a selected item.

Indicates and erases DlAG MEMORY saved data. (Display screen of '1)

lndicates and erases INlOUT MONITOR saved data. (Dsplay screen of *2)

lndicates SAS controller part number, ROM part number and manufacturing number.

3 z W

3

z

DATA

2MAST DATA

' 3 ST. KNOB DATA

4 OTHER

3 ACTIVE TEST

DlAG

lNloUT

4 DATA MANAGE

5 CONTROLLER NO --

2

* DlAG MEMORY (112) SAVE

FILE ERR 1 11 223.3h 42-1 2 1223.3h 41-1 3 223.3h 42-1 4 23.3h 41-1 5 O.Oh

2

DlAG MEMORY (112) FlLE FULL 1 11 223.3h 42-1 2 1223.3h 41-1 3 223.3h 42-1 4 23.3h 41-1 5 O.Oh

Other messages FlLE FULL: Since no free number is available in "FILE MAN-

AGE", press MENU switch @to return to "ANA- LYZER MENUn screen and erase unnecessary files.

1

SAVE

, 4 , J

FILE ERR: Saving disabled for an error.

[Action] (1) Press selector switch @ to re-run the saving. (2) If FlLE ERR is displayed again, some abnormality ex-

ists in the file. To recover from the abnormal state, initialize the main unit data on the FlLE INITIALIZE screen. (See the step 11 on page 15-27.)

Note: Since all main unit data is initialized upon FlLE INITIAL- IZE, check the data beforehand.

ANALYZER MENU * ' I - 2INIOUT MONITOR 3ACTIVE TEST IJ t

4DATA MANAGE SCONTROLLER NO

C ,7END 4,

DIAG MEMORY (212) SAVE 6 O.Oh 7 O.Oh 8 O.Oh 9 O.Oh

10 O.Oh

OPERATING PROCEDURE 1. Select and enter "1 SAS" in MAlN MENU screen to have

"SAS MENUn displayed on the screen.

2. Select and enter "1 ANALYZERn in SAS MENU screen to have "ANALYZER MENUn displayed on the screen.

3. "ANALYZER MENU" screen (1) Using selector switch @ and @ move the cursor to a

desired menu in "ANALYZER MENU" screen and enter by pressing MENU switch @.

(2) Select and enter "END" to return to "SAS MENUn

screen.

"1 DIAG MEMORY This screen displays the hour meter time for generated errors and ten latest error codes and sub-codes sequentially in two separate screens.

[Descriptions on the contents of display] (1) Sequence of error generation (2) Hour meter time for error generation (3) Error code

[Transfer of page] Selector switch @

[Endl Press MENU switch @ and return to "ANALYZER MENU" screen.

[SAVE] Press selector switch @) from any screen to save the two screens as one file.

"2 INIOUT MONITOR" This menu has the following menus in addition: swing control, TILT control, ST. KNOB control and other. It can display the following data on the screen:

INlOUT MENU

2MAST CONTROL 3ST.KNOB CONTROL

t ' 40THER , $ ?END

Menu name

1 SWING CONTROL

2 MAST CONTROL

3 ST. KNOB CONTROL

4 OTHER

Content of display

lndicates the swing control-related sensor analog input voltage, switch input state, controller internal calculation value and the signal state to the solenoid.

lndicates the TILT control-related sensor analog input voltage, switch input state and the signal state to the solenoid.

-(Displayed but not in use.)

lndicates the controller input voltage, hour meter value, RE ADJUST CONNECTOR state and DlAG PIN state.

SWING DATA (112)

YAW SENSOR 2.50V SPEED O.Okmih

SWlNG SOL ON

i

1. Select and enter "2 INIOUT MONITOR" in "ANALYZER MENUn screen to have "INJOUT MENUn displayed on the screen.

2. Move the cursor to the desired menu by using selector switches (iJ and 0, and determine by pressing MENU switch @.

END: Return to "ANALYZER MENU."

SAVE

, 4 J

SWING DATA (212)

SWlNG - - LOAD 0:90(0 .90)~

HEIGHT SW1 ON SW21 OFF SW22 OFF

1. SWlNG DATA

SAVE

' 4

[Descriptions on the content of display] (1) YAW SENSOR: Yaw rate sensor input voltage (2) SPEED: A speed calculated and recognized by the

controller from the speed sensor signals. (NG is indicated for abnormality.)

(3) SWING SOL: Output signal to the swing solenoid. ON for energization: Swing lock resetting OFF for de-energization: Swing lock application

(4) SWING: - (Unused)

(5) LOAD: Load sensor input voltage. (Parentheses) represent the re-setting voltage.

(6) HEIGHT SW 1 : Lifting height switch 1 input signal SW21: Lifting height switch 21 input signal SW22: Not set

See page 15-33 for the relationship between the fork height and the fork height switch (ONIOFF).

(1) (2) (3) (4) (5)

2. MAST DATA

MAST DATA (112)

I L T 2.20V [CONT 2.207 4 LEVEL 2.20V

LOAD 0.90(0.90 V TILT SOLl ON

SOL2 OFF \

MASTDATA (112)

TlLT FWD OFF BWD OFF KNOB OFF

HEIGHT SW1 ON SW21 OFF SW22 OFF

[Descriptions on the content of display] (1) TILT Tilt angle sensor input voltage. (2) C O W Re-setting voltage (CONT-LOAD) (3) LEVEL: Re-setting voltage (TILT LNEL) (4) LOAD: Pressure sensor input voltage. (Parenthe-

ses) represent the re-setting voltage. (5) TlLT SOL1 : Output signal to tilt solenoid 1.

SOL2 Output signal to tilt solenoid 2.

(6)

(7)

SAVE

. 4 J

The tilt solenoid output signal ON indicates energization, and OFF de-energization. The combinations are shown in the table below.

*: Rear tilting operation with the tilt lever knob depressed. Example: If SOL1 is ON and SOL2 is OFF, the tilt hydraulic circuit is considered to be in the state of tilt stop circuit.

(6) TlLT FWD: Tilt forward switch input signal. BWD: Tilt backward switch input signal. KNOB: Tilt knob switch input signal.

(7) HEIGHT SW 1 : Lifting height switch 1 input signal. SW21: Lifting height switch 21 input signal. SW22: Not set.

SOL2


SOLl

OFF

[Endl Press MENU switch @to return to "INIOUT MENU" screen.

OFF

Semi-open circuit High lift height Rear tilt speed control Low lift height Rear tilt speed contror Front tilt

Full open circuit ON Low lift height Rear tilt

[SAVE] Pressing selector switch @ from any screen saves the contents of two screens as one file.

ON

Tilt stop circuit *Tilt lever neutral

Front tilt angle restrain & stop Fork leveling & automatic stop

Not applicable

3. ST. KNOB DATA

Displayed but not in use.

Low fork height

High fork height

4. OTHER

With lifting height SW p r o w

SAS controller

r

OTHER DATA (1/1)

VOLTAGE 12.4V HOURS 11 223.3h RE-SET CN ON DlAG PIN 0 N

[Descriptions of display content] (1) VOLTAGE: Controller supply voltage. (2) HOURS: Hour meter values. (3) RE ADJUST CN: State of re-setting connector (4) DlAG PIN: State of diagnosis pin.

Without lifting height SW p r o w

SAS controller

1

SAVE

a [Endl Press MENU switch @to return to "INIOUT MENU."

[SAVE] Press selector switch @ from any screen to save the contents of a screen as one file.

L i n g he~ght SW1

swn - €02

SW1

21

22

SW1

21

22

ON

OFF

OFF

OFF

ON

OFF

SW1

21

22

SW1

21

22

ON

OFF

OFF

ON

OFF

OFF

(7) SPEED FAIL ~IEEEIWOFFION

I SOL 1 I

I I

The relationsh~ps between ON and OFF of SOL1 and SOL2 are as follows: (- 2000. 10)

SOL 1

"3. ACTIVE TEST" This menu enables to check a selected item through a forcible output of operating signal to it.

ON

Tilt hydraulic circuit closed

-

1 OFF

OFF

Tilt hydraulic circuit full

Caution: When the swing lock cylinder solenoid is turned ON, drive vehicle at low speed (for test drive, etc.).

The relatic-sh~p between ON and OFF of SOL1 IS as ~OIIOWS: 12330 10 -)

SOL 2

ON

Tilt hydraulic / hydraulic

Note: "ON" on the screen indicates that the controller is in an output state. Therefore, check operation visually or with the operating sound, etc. Don't allow the solenoid to operate over one minute as it causes a failure.

1. Select an item using selector switch @and set ON-OFF using selector switch @.

OFF

ON

[Descriptions of display content] (1) SWING SOL: When set to ON, outputs forcible opera-

tion signal to swing lock cylinder solenoid. (Constantly unlock)

(2) TlLT SOL1: When set to ON, outputs forcible operation signal to tilt solenoid 1 .*

(3) TlLT SOL2: When set to ON, outputs forcible operation signal to tilt solenoid 2.* (- 2000. 10)

(4) KNOB SOL: - (Unused) (5) WARNING: When set to ON, outputs forcible opera-

tion signal to SAS warning lamp (buzzer interlocked). (SAS lamp on and continuous buzzer sounding)

(6) LOCK LMP: When set to ON, outputs forcible operation signal to swing lock lamp. (Swing lock lamp on)

(7) SPEED FAIL: When set to OFF or ON, outputs vehicle speed controller signal.

OFF: Outputs LOW signal irrespective of vehicle speed.

ON: Outputs Hi signal irrespective of vehicle speed.

If the vehicle is driven with this menu turned OFF or ON, an error will be stored to the vehicle speed controller.

Tilt hydraulic circuit half open

Tilt hydraulic circuit full open

2. After turning all items OFF or returning to NORMAL setting, press MENU switch @ to return to "ANALYZER MENU" screen.

I open I circuit half / circuit I / open / closed

"4. DATA MANAGE" This menu has DATA MENU for DIAG MEMORY and INIOUT MONITOR. It can display saved data of DIAG MEMORY and INIOUT MONITOR or erase them. File numbers on "OPENn and "DELETEn screens indicate the number displayed when the saving ends normally, and the file number is displayed after processing it according to the following rules:

> DlAG DATA FILE

,7END

I

INlOUT DATA FILE

PDELETE

,7END

Saved to:

1 DIAG MEMORY

1. Select and enter "4. DATA MANAGE" on "ANALYZER MENUn screen and have "FILE MENUIDATA MENUn displayed on the screen.

2. "DATA MENUn screen Move the cursor to a desired menu on "DATA MENU" using selector switch (ij and 0, enter it by pressing MENU switch @ and move to "DIAG DATA FILEn or "IN1 OUT DATA FILE."

3. "DIAG DATA FILE" screen "INIOUT DATA FILE" screen

(1) Select the menu using selector switch @) and @ and press MENU switch @to determine the setting.

OPEN: Moves to "FILE OPEN" screen. (Step 4) DELETE: Moves to "FILE DELETE" screen. (Step 5) END: Returns to "FILE MENU" screen.

Max. number of file

10

Total: 20

File name

1 SWING CONTROL

2 MAST CONTROL

3 ST. KNOB CONTROL

OTHER

2 INlOUT MONITOR

Manufacturing number of the opposite SAS controller

Add "S" to the end of the manufacturing number of the SAS controller.

Add "T" to the end of the manufacturing number of the SAS controller.

-(Unused)

Add "On to the end of the manufacturing number of the SAS controller.

2 +

8 - z

Example: 800001

Example: 800001 S

Example: 800001 T

-

Example: 80000 1 0

11 END

19 800025T 20 8000698 21 END

FILE OPEN (112)

- 2 800025 3 800011 4 800044 5 800003 6 800107

t 4 4 ,

I \

FlLE DELETE (112)

1 800001 2 800025

t , 3 800011 4 800044 5 800003

+ , 6 800107

FlLE NO3 (1 12) 80001 1

1 11223.3h 42-1 2 1223.3h 41-1 3 223.3h 42-1 4 23.3h 41-1 5 O.Oh

10 800009 f ALL DELETE

L 4 ,

21 END ALL DELETE

.

4. "FILE OPEN" screen (1) Select an item using selector switch @) and 0.

END: Returns to "DIAG DATA FILE" or "INIOUT DATA END FILE."

Note: The file name is displayed only when it is saved. If not saved, only END is displayed.

(2) When entry is made using MENU switch 0, the screen returns to "FILE."

(3) "FILE" screen Saved data is displayed along with the file number and name.


[Endl Press MENU switch @to return to "FILE OPEN" screen.

5. "FILE DELETE" screen (1) Select an item using selector switch @ and 0.

ALL DELETE: Select this for totally erasing files displayed on all the pages of FlLE DE- LETE screen.

END: Returns to "DIAG DATA FILE" or "IN/OUT DATA FILE."

(2) Press MENU switch @to have a message displayed.

FlLE DELETE -

2 800025 3 800011 4 800044 5 800003

,6 800107

\

CONTROLLER NO (1 H )

CONTROLLER NO 2421 0-23320-71 -A

ROM NO 24295-23320-71 -A

SERIAL NO 800001

\ J

Select N or Y using selector switch and make entry by pressing MENU switch a. N: File delete can be cancelled.

Y Starts deletion. Operation ends when COMPLETE is displayed in the message column.

(4) Press MENU switch (@to return to the FlLE DELETE screen.

"5. DATA" This menu is used to display the part number of the SAS controller, ROM part number and manufacturing number.

[Descriptions of display content] (1) CONTROLLER NO.: Controller part number. (2) ROM NO.: ROM part number. (3) SERIAL NO.: Controller manufacturing number.

[Endl Press MENU switch @to return to "ANALYZER MENU."

RESElTNG Re-setting can be also performed by using the hour meter and tilt knob switch on the vehicle. Using this menu, re-setting can be made by monitoring the signal voltage of respective sensors on the screen.

"RE-SETTING" screen is also displayed for a specification that requires no re-setting on the part of the vehicle. If re-setting is run on such a vehicle NG will be displayed on the screen.

RE-SETTING MENU

1 TILT LEVEL

2 CONTsLOAD

3 TIRE

4 SWING

I SAS MENU

1 ANALYZER

3CUSTOMIZE

7END 4 ,

RE-SETTING MENU

2CONT.LOAD 3TlRE 4SWING

7END

Re-setting name

RE-SETTING TILT LEVEL

RE-SETTING CONT-LOAD

-

-

TlLT LEVEL

2.1 ov

2.10v

Object sensor

Tilt angle sensor

Tilt angle sensor and load sensor

-

- a

Operating Procedure

1. Select and enter "2. RE-SETTING" on "SAS MENUn

screen to have RE-SETTING MENU displayed on the screen.

2. RE-SETTING MENU SCREEN (1) Move the cursor to a desired menu using selector

switch @ and @ and make entry using MENU switch 0.

(2) Selecting and entering "END" returns to "SAS MENU" screen.

3. "RE-SETTING" screen TlLT LEVEL

[Descriptions of display content] (1) TILT Tilt angle sensor input voltage. (2) MEMORY: Tilt angle sensor re-setting value prior to

the re-setting. (Standard voltage for fork automatic leveling control)

(3) MEMORY: Re-setting value after running re-setting.

RE-SETTING CONT-LOAD

(1) TILT 2.30V

6 (2) MEMORY 2.20V

(3) LOAD 0.80V (4) MEMORY 0.90V

2.30V (5) MEMORY 2.30V OK 1 zD 0.80V H (5 MEMORY 0.80V OK

CONTOLOAD (1) TILT Tilt angle sensor input voltage. (2) MEMORY Tilt angle sensor resetting voltage before

resetting (standard voltage for fonvard tilt restriction control).

(3) LOAD: Load sensor input voltage. ' (4) MEMORY Load sensor re-setting value prior to the

re-setting . (5) MEMORY Re-setting value after running re-setting .

TIRE, SWING Displayed but not in use.

Set the sensor to be re-set to the standard state. (Or check that it is in the standard state.) (Read 15-20.) Press SELECTOR switch @ and excute re-setting. OK: Re-setting complete under the indicated voltage. NG: The signal voltage value is outside the re-setting

range. Check for sensor abnormality, harness disconnection andlor short-circuit. (Read Trouble- shooting.)

Press MENU switch @ in respective screens to return to "RE-SETTING MENU" screen.

I 7

I MAIN MENU t

, + -

,7TESTERSET

OPTION SET (CUSTOMIZE) This menu is used for setting VALIDATION/INVALIDATlON of the mast forward tilt angle control.

SAS MENU 1 ANALYZER 2RE-SETTING

Caution: If CUSTOMIZE is changed, perform the maintenance of the label for "WARNING." (See page 15-10.)

* . """"4- , TEND

Operating Procedure 1. Select and enterul SAS" in "MAIN MENU" screen to have

"SAS MENU" displayed on the screen.

4 ,

2. Select and enter "3 CUSTOMIZEn to have "CUSTOM- IZE" displayed on the screen.

3. "CUSTOMIZE" screen (1) Move the cursor to a desired item using selector switch

@ and set WIL using selector switch a. TILT CONT Mast forward tilt angle control. SWING W LOCK: (Display only, not for actual application) W: Valid control L: Invalid control

(2) Press MENU switch @ to return to the SAS MENU screen.

4. Replace the caution label. (See page 15-1 0.)

1541

TROUBLESHOOTING

Nothing appears on the screen.

Related Portion

Estimated causes: @ Incomplete contact of connector @ Defective analyzer harness (power supply) @) Defective plug-in analyzer

L 0

2 - m 2

Check 1: Measure voltage between CN44-12 and CN44. Turn the key switch ON (with engine stopped) Standard: CN44-12 O - CN44-3 0 : 8 - 16 V

CNI c ~ 4 4 Analyzer CN

1

Check 2: Measure voltage between analyzer CN-1 and analyzer CN-13. Turn the key switch ON (with engine stopped) Standard: Analyzer CN-1 O - Analyzer CN-13 8 : 8 - 16 V

6 U m .&!

z - - 0 0

Check the screen after making correction. Check for disconnection of CN44 and analyzer connectors.

CN44 (REC)

-

2-

-

NG %

Analyzer CN (REC)

m

--

OK 1 NG

o 2 2 -

Defective harness on the vehicle. Check 1: Measure voltage between CN44-12 and CN44-3. NG ,

CN1-2 CN44-1

CN44-3

OK

Check 2: Measure voltage between analyzers CN-1 and CN-13.

--L

0 &!

OK

1

Defective plug-in analyzer.

NG 9

m 2

i

Defective analyzer harness.

13

15-42

Screen for data (DIAG MONITOR, voltage values and speed, etc.) does not display data.

Related Portion

Estimated causes @ Incomplete contact of connectors @ Defective analyzer harness (communications) @ Defective SAS controller

I Check for the disconnection of CN44 and analyzer connector.

% N % - m 2

Check the data indication after making correction.

1

Check continuity between CN44-1 and CN1. NG , Defective harness on the vehicle side.

OK

CN1 CN44 Analvzer CN

6 o m L

- ! 2 .4

c

5

-

2

- + a

L-

L

Defective SAS controller.

Check 2: Check continuity between analyzer CN-6 and CN44-1.

J.

Check 1: Check continuity between CN44-1 and CN1-2. Turn the key switch OFF and disconnect CN44 and CNI. Standard: CN44-1 and CB1-2: Continuity shall exist ~ ~ 4 4 (REC)

(IG)

2:-CN1-2 CN44-1

CN44-3

Connect the analyzer to other vehicle and check if the data is displayed.

,

Check 2: Check continuity between analyzer CN-6 and CN44-1. n 1(2)314)516171819(10

Turn the key switch OFF and disconnect analyzer CN and CN44. I ~ ~ ~ ~ 2 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ l ~ ~ ~ ~ ~ l 9 ~ 2 d

Standard: Analyzer CN-6 to CN44-1: Continuity shall exist Analyzer CN (REC)

CN44 (TAB)

NG ,

-

0 .E

Defective analyzer harness.

OK

NG 9 Defective plug-in analyzer

m 2

13

SAS is provided with the following diagnosis function:

P=% I - ] [:o]

0 0

Display example of diagnosis memory

0

0

0

Displays E04 to E09.

] State with no memory

0 T'X-II -1 } Separation

When abnormality is detected with SAS sensors and switches, SAS warning lamp starts blinking or is turned ON with the sounding of the buzzer. At the same time, error codes (maximum 5 error codes for multiple errors) are displayed to the hour meter. The SAS controller stores these error codes and their time of generation (in maximum ten memories). Displaying those errors on the hour meter enables to check abnormality that has occurred temporarily. When these error memory contents are displayed on the analyzer (SST), further classified error codes can be checked. (See page 15-46.) Perform repair promptly by referring to a pertinent troubleshooting to the error code concerned.

How to display diagnosis memory

Note: Turning the key switch ON (or starting engine) after removing the DlAG MEMORY short pin causes an error (code 42) displayed and stored to the controller, for which care should be taken.

1. Turn the key switch ON (or start engine). 2. Open the diag connector cover and remove the diag

memory short pin. -

(1) Ten error codes and the corresponding hour meter times are displayed sequentially from the latest one.

(2) If no error code memory exists, the error number is followed with a blank space and the hour meter time with a period only.

(3) Upon indicating tenth error code and generation time, the dotted line appears to make separation and the display starts again with the latest error code in memory.

3. Install the diag memory short pin and close the diag connector cover.

Note: lnstall position error may cause a controller failure, for which care should be taken.

a Don't substitute a short pin with other object.

4. Turn the key switch OFF.

List of Diagnosis Error Codes

Error code

4 1

4 2

51

52

54

6 1

62

63

64

65 (- 2000. 10)

"

Content

Re-setting switch abnormality

Diag switch abnormality

Speed sensor abnormality

Yaw rate sensor abnormality

Swing solenoid abnormality

Load sensor abnormality

Tilt angle sensor abnormality

Tilt lever switch abnormality

Tilt solenoid No. 1 abnormality

Tilt solenoid No. 2 abnormality

Tilt angle resetting abnormality

Rear wheel

Lateral lock

Normal control

Normal control

Locking .3 disabled

Locking .3 disabled

Phenomenon differs by the state of a

- failure

Normal control

Normal control

Normal control

Normal control

Normal control

Normal control

Phenomenon generated to the machine

swing control -.

Yaw rate lock

e

C

Locking disabled

Locking disabled

+-

Control as no load

C

+

---

+-

+

+

Manual forward tilting

operation

+

C

t

C

t

Normal control

Normal control

Mast tilt control

Mast backward tilt

speed control

C

t

+

+-

+

+-

t

Mast forward tilt angle control

Normal control

Normal control

Normal control

Normal control

Normal control

Operates to a maximum forward tilt position


Operates to a

Manual backward

tilting operation

C

C

c

+

+

C

+

Automatic horizontal stop

control

C

C

+-

+

+

Stops when knob switch is turned ON

Stops when knob switch is turned ON

C

C

+

C

Stops when maximum knob switch is Normal forward tilt control position

Phenomenon differs by the state of a failure

Phenomenon differs by the state of a failure


+

+-

Stops when know switch is turned ON

+

+-

C

-- -

+

Normal control

*I: Stores sub-error codes only to the SAS control without display on the hour meter.

*2: Because of an error code output by the hour meter, no storage is made on the SAS controller.

'3: If an error is detected in the locked state, locking is maintained until the ignition switch is turned OFF.

Error code

67

(AF)''

EF

F,.2

Content

Lifting height switch abnormality

Controller abnormality


Communication abnormality between the controller and the hour meter

Rear wheel

Lateral G lock

Controlled as the lower lifting height

Constant locking

Constant locking

Normal control

Phenomenon generated to the machine

swing control

Yaw rate lock

t

t

t

t

Manual backward

tilting operation

Backward tilting speed is faster for a high lifting height

Slower backward tilting speed for a lower lifting height

Slower backward

. tilting speed for a lower lifting height

t

Manual forward tilting

operation

Normal control

Normal control

Normal control

t

Mast tilt control

Mast backward tilt

speed control

t



t

Mast forward angle control

Operates maximum to a

forward tilt position

Operable to a maximum forward tilt position

Operable to a maximum forward tilt position

Normal control

horizontal stop control

stops when knob switch is turned ON

stop horizontal

horizontal

t

TROUBLESHOOTING Perform troubleshooting according to the troubleshooting by error code when an error code is displayed, and according to the troubleshooting by phenomenon when no error code is displayed.

TROUBLESHOOTING BY ERROR CODE Troubleshooting by error code is described below in the order of the error code. Perform troubleshooting according to the procedure corresponding to each error code. When the plug in analyzer (SST) is available, use the DlAG MEMORY and check the error code and perform troubleshooting accordingly.

List of Reference Pages for Error Codes and Sub Error Codes

Page

15-48

15-49

1550

15-52

1553

15-57

15-63

15-67

Without analyzer (SST)

Page

1W

15-49

1550

1550

15-52

1552

1552

1553

15-57

1557

15-63

15-63

15-67

15-67

15-67

Error code

41-1

42-1

51-1

51-2

52-1

52-2

52-3

54-1

61-1

61-2

62-1

62-2

63-1

, 632

63-3

Error code

41

42

51

52

With analyzer (SST)

Error description

Resetting switch abnormality

DlAG switch abnormality

Speed sensor open circuit

Speed sensor short circuit

Yaw rate sensor open circuit

Yaw rate sensor short circuit

Yaw rate sensor neutral voltage abnomlality

Swing solenoid abnormality

Load sensor open circuit

Load sensor short circuit

Tilt angle sensor open circuit

Tilt angle sensor short circuit

Tilt lever switch simultaneous ON

Forward tilt switch short circuit for 2 minutes

Backward tilt switch short circuit for 2 minutes

Error description

Resetting switch abnormality

DlAG switch abnormality

Speed sensor abnormality

Yaw rate sensor abnormality

54 / Swing solenoid abnormality

61

62

63

Load sensor abnormality

Tilt angle sensor abnormality

Tilt lever switch abnormality

' I : The error code is stored in the SAS controller, and display by the hour meter is not made.

*2: Because of the error code output from the hour meter, it is not stored in the SAS controller and checking by the analyzer fails.

Page

15-74

1 5-78

15-79

15-83

-

-

1589

Error code

64-1

651 (- 2000.10)

67- 1

AF-1

AF-2

AF-3

AF-4

EF-1

EF-2

-

Error code

64

65 (- 2000.10)

66

67

(AF)"

EF

FIT

Without analyzer (SST)

Error description

Tilt solenoid No.1 abnormality


Tilt angle resetting value abnormality

Fork height switch abnormality (When there is no fork height switch)

Fork height switch abnormality (When fork height switch is used)



Abnormal communlcatlon between controller and hour meter

With analyzer (SST)

Error description



Tilt angle resetting value abnormalw

Fork height switch abnormality (When there is no fork height switch)

Fork height switch abnormality (When fork height switch is used)

CPU abnormality

ROM abnormality

RAM abnormality

AD conversion abnormality

EEPROM abnormality

EEPROM abnormality

-

Page

15-74

1576

15-78

1 5-79

15-83

-

-

-

-

-

-

1548

Error Code 41 or 41-1 (Re-setting switch abnormality)

Related Portion

Estimated Causes: @) Connector contact defect @ Resetting connector harness defect @ Controller defect

Inspection 1 : Continuity inspection between CN1 and CN35 Turn the ignition switch OFF, and disconnect CN1 and CN35.

lnspect connectors CN1 and CN35 for disconnection. NG

Error display cneck after correction.

NG

Standard: CNI-7 - CN35-1: Continuity shall exist. CNI-23 - CN35-1: Continuity shall exist.

Inspection 1 Inspect continuity between CNI-7 and CN35-1 and between CNI-23 and CN35-1.

CN1 (REC)

CN35 (REC)

OK 1 Controller defect.

NG * Harness defect.

Error Code 42 or 42-1 (Diag. switch abnormality)

Related Portion

Estimated Causes: @) Disconnected shorting pin @ Connector contact defect @ DlAG connector harness defect @ Controller defect

- P 2 5 u

-- 9 % + a

-d

Error display check after correction. lnspect the shorting pin at CN44 for disconnection.

lnspect the CN1 connector for disconnection.

I between CN1-23 and CN44-22. I I I

CN1 C W

C N l d (SW2. DIAGSW) UU4-!23

CN1-23 (E02 SW. GND) CTW-22

NG +

4

I Controller defect.

OK i, 1 NG

NG

lnspection 1 : lnspect continuity between CN1 and CN44. Turn the ignition switch OFF and disconnect CN? and CN44 shorting pin.

Standard: CNI (REC) CN1-6 - CN44-23: Continuity shall exist.

-

Error display check after correction.

Harness defect. Inspection 1 lnspect continuity between CN1-6 and CN44-23 and

CN1-23 - CN44-22: Continuity shall exist.

- Shorting pn

-

NG

CN44 (REC)

a Error Code 51 (Speed sensor abnormality) a Error Code 51-1 (Speed sensor open circuit) a Error Code 51-2 (Speed sensor short circuit)

Related Portion

Estimated Causes: @) Connector contact defect @ Speed sensor harness defect @ Speed sensor defect @ Controller defect

I Error code 51 (

lnspect CN2 and CN22 connectors for disconnection or internal wetting.

lnspection 2 Inspect resistance between sensor CN22-1 and CN22-2 and Speed sensor defect. continuity between CN22-1 or CN22-2 and frame.

*

J.

I Controller defect. 1

NG *

lnspection 1 Inspect continuity between harness CN2 and CN22 and between the SPD+/SPD- line and frame.

I J

lnspection 1 : lnspect continuity between harness CN2 and CN22 and between the SPD+/SPD- line and frame.

f

Check SAS lamp off after correction.

Turn the ignition switch OFF and disconnect CN2 and CN22.

NG *

Standard: CN2-4 - CN22-1: Continuity shall exist. CN2-5 - CN22-2: Continuity shall exist. CN22-1 - CN22-2: No continuity. CN22-1 - Frame: No continuity. CN22-2 - Frame: No continuity.

Harnessdefect. -

CN2 (REC) CN22 (REC)

lnspection 2: lnspect resistance between sensor CN22-1 and CN22-2 and continuity between CN22-1 or CN22-2 and frame.

Turn the ignition switch OFF and disconnect CN22.

Standard: Resistance between CN22-1 and CN22-2: 620 c 60 C2 (standard) CN22-1 - Frame: No continuitv

CN22 (TAB)

CN22-2 - Frame: No continuiti.

Inspect for disconnection and internal wetting of the After correction, make sure the SAS lamp CN2 and CN22 connectors. goes out.

OK (

Inspection 1 Inspect continuity between harness CN2 and CN22.

I Controller defect. I

lnspection 2 Make sure that speed indication corresponding to the actual speed is made during traveling.

lnspection 1 : lnspect continuity between CN2 and CN22.

OK

NG

7

Speed sensor defect.


Harness defect.

Standard: CN2-4 - CN22-1: Continuity shall exist. CN2-5 - CN22-2: Continuity shall exist. CN22-1 - CN22-2: No continuity. CN2 (REC) CN22 (REC)

lnspection 2: Make sure that speed indication corresponding to the actual speed is made during traveling.

Connect all connectors, turn the ignoition switch ON (start the engine) and travel.

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU + SWING DATA

Standard: Speed indication shall change depending on the traveling speed.

YAW SPEED SENSOR 2.50V o . o k m / h ~

SWING SOL ON

lnspection 1 : lnspect continuity between the harness SPD+/SPD- line and frame.


After correction, make sure the SAS lamp goes out.

Inspect for disconnection and internal wetting of the CN2 and CN22 connectors.

Standard: CN22-1 - Frame: No continuity. CN22-2 - Frame: No continuity.

NG

CN22 (REC)

OK

lnspection 2: Make sure that speed indication corresponding to the actual speed is made during traveling.

NG

I

Connect all connectors, turn the ignoition switch ON (start the engine) and travel.

Analyzer: MAIN MENU -. SAS MENU +ANALYZER MENU -. IN OUT MENU + SWING DATA

v

Standard: Speed indication shall change depending on the traveling speed.

Inspection 1 lnspect continuity between harness SPD+/SPD- line and frame.

a Error code 52 (Yaw rate sensor abnormality) Error code 52-1 (Yaw rate sensor open circuit)

a Error code 52-2 (Yaw rate sensor short circuit) a Error code 52-3 (Yaw rate sensor neutral voltage abnormality)

YAW SENSOR 2.50V

SWING SOL ON

NG

Estimated Cause: @ Yaw rate sensor defect

Harness defect.

OK

lnspection 2 Make sure that speed indication corresponding to the Speed sensor defect.

actual speed is made during traveling.

Controller defect.

Error code 54 (Swing solenoid abnormality) Error code 54-1 (Swing solenoid abnormality)

Related Portion

Estimated Causes: @ Connector contact defect @ Swing solenoid harness defect @ Swing solenoid defect @ Diode defect @ Controller defect

- - - 0

I Inspect for disconnection and internal wetting of the Inspection 1 CNl , CN4, CN7, and C N l l connectors. After correction, make sure that the I

SAS lamp goes out. I NG 1

J lnspection 2 Inspect continuity with the diode (between CNI-25 and frame). Diode defect.

OK

4 P 2

(rn.

--GI '77.5

-Srng- CN1-25

A

- A

J.

I Controller defect.

CNll u ~ o d y goundlng ( ~ 1 grasrdfog)

-

lnspection 3 Inspect continuity between harness CNI-25 and CN11-1, between the SWN line and frame, and between CNll-2 and frame.

OK 1 .

lnspection 4 Resistance between solenoid CN 11 -1 and CN 11 -2, and inspect continuity between CN11-1 and frame.

- m4-5

m4-2(UL-S)

m O 2 %

:: a

Solenoid defect.

- CN4

- $ +

CNI-1 - m 2

CKI-2

O k!

- o g

CN11-1

m 3 rnija

lnspection 1 : After correction, make sure that the SAS lamp goes out.

Connect all connectors then turn the ignoition switch on (start the engine). Standard: The SAS lamp shall not blink upon swing or slalom traveling (traveling that lights the lock lamp normally). Caution: Perform the traveling test carefully at a low speed.

lnspection 2: lnspect continuity with the diode (between CN1-25 and frame).

Turn the ignition switch OFF and disconnect CN1 and CN4. CNI (REC)

Standard: CN1-25 (Digital circuit tester O) - Frame (Digital circuit tester 0): No continuity. CN1-25 (Digital circuit tester 8 ) - Frame (Digital circuit tester O): Continuity shall exist. CN1-25 (Analog circuit tester 8 ) - Frame (Analog circuit tester @): No continuity. CN1-25 (Analog circuit tester 63) - Frame (Analog circuit tester €3): Continuity shall exist.

lnspection 3: lnspect continuity between harness CN1-25 and CN11-1, between the SWN line and frame, and between CNll-2 and frame.

Turn the ignition switch OFF and disconnect CN1 and CN11

Standard: CN1-25 - CN11-1: Continuity shall exist. CN11-1 (Digital circuit tester O) - Frame (Digital circuit tester 8 ) : No continuity. CN11-1 (Analog circuit tester 8 ) - Frame (Analog circuit tester 8 ) : No continuity. CN 1 (REC)

CN11-2 - Frame: Continuity shall exist. CN11-1 (Digital circuit tester O) - CN11-2 (Digital circuit tester 8 ) : No continuity. CN11-1 (Analog circuit tester 8) - CN11-2 (Analog circuit tester 8 ) : No continuity.

&' CN11 (REC)

lnspection 4: Resistance between solenoid CN11-1 and CN11-2 and inspect continuity between CN11-1 and frame.

Turn the ignition switch OFF and disconnect CN l l

Standard: CN11-1 - Frame: No continuity. Resistance between CN 11 -1 and CNl l-2: Approx. 6 R (20°C).

C N l l (TAB)

lnspection 1 : After correction, make sure that the SAS lamp goes out.

Connect all connectors then turn the ignition switch ON (stop the engine).

Inspection 1 After correction, make sure that the SAS lamp goes out.

Inspect for disconnection and internal wetting of the CN1, CN4, CN7, and CN l l connectors.

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU +ACTIVE TEST

NO / <

V

lnspection 2 Inspect continuity with the diode (between CN1-25 and frame). Diode defect.

OK - lnspection 3 Inspect continuity between harness CN1-25 and CN11-1, between the SWN line and frame, and between CNll-2 and frame.

OK

lnspection 4 Resistance between solenoid CN11-1 and CNll-2 and Solenoid defect.

inspect continuity between CN11-1 and frame. - OK

Controller defect.

NG

Standard: The SAS lamp shall not blinkupon returning to the ANALYZER MENU by setting the SWING SOL to ONH (for 1 second or more) and OFF (for 1 second or more).

OK

ACTIVE TEST (112)

KNOB SOL

Return to the ANALYZER MENU.

lnspection 2: lnspect continuity with the diode (between CN1-25 and frame).

Turn the ignition switch OFF and disconnect CN1 and CN4. CNl (REC)

Standard: CN1-25 (Digital circuit tester @) - Frame (Digital circuit tester 8): No continuity. CN1-25 (Digital circuit tester 8) - Frame (Digital circuit tester @): Continuity shall exist. CN1-25 (Analog circuit tester 8) - Frame (Analog circuit tester $): No continuity. CN1-25 (Analog circuit tester @) - Frame (Analog circuit tester 8): Continuity shall exist.

lnspection 3: lnspect continuity between harness CN1-25 and CN11-1, between the SWN line and frame, and between CNll-2 and frame.


Standard: CN1-25 - CN11-1: Continuity shall exist. CN11-1 (Digital circuit tester @) - Frame (Digital circuit tester 8): No continuity. CN11-1 (Analog circuit tester 8 ) - Frame (Analog circuit tester @): No continuity. CNll-2 - Frame: Continuity shall exist. CNI (REC)

CN11-1 (Digital circuit tester @) - CNll-2 (Digital circuit tester 8): No continuity. CN11-1 (Analog circuit tester 8) - CN11-2 (Analog circuit tester @): No continuity. ,&

CN11 (REC)

Inspection 4: Resistance between solenoid CN11-1 and CN11-2 and inspect continuity between CN11-1 and frame.


Standard: CN11-1 - Frame: No continuity. Resistance between CN11-1 and CN11-2: Approx. 6 Q (20°C).

CNl1 (TAB)

Error code 61 (Load sensor abnormality) Error code 61-1 (Load sensor open circuit) Error code 61-2 (Load sensor short circuit)

Related Portion

Estimated Causes: @) Connector contact defect @ Load sensor harness defect @ Load sensor defect @) Controller defect

h - g - 8

Inspect for disconnection of the CN1 , CN3, and CN26 connectors.

--

+ a

--

--

m P Z

--

NG '

CN1 CN3 W28

CNl-l(5PRS. Load-pcmer)

CN1-18(PRES.Load-)

CN1-22 (EOI. Sensor GND) - E 8 2

After correction, check SAS lamp indication.

OK NG <

m ;i

V

lnspect for internal wetting of the CN1, CN3, and CN26 connectors.

o

- o P

A

cN3-1 cN26-3

CN52 C W

CN3-5 C M g l

NG , After correction, check SAS lamp indication.

OK NG <

V

Inspection 1 Inspect continuity between CN1 and CN26.


NG ' Harness defect.

OK OK

"".1 Replace the load sensor then check SAS lamp indication.


Harness defect.

NG OK

. NG 'I Controller defect. CN3 connector defect.

Inspection 1 : lnspect continuity between CN1 and CN26.

Turn the ignition switch OFF and disconnect CNI and CN26.

Standard: CN1-1 - CN26-3: Continuity shall exist. CN1-18 - CN26-2: Continuity shall exist. CNI-22 - CN26-1: Continuity shall exist. CN1-1 - CN1-18: No continuity. CN1-1 - CN1-22: No continuity. CN1-18 - CN1-22: No continuity.

lnspection 2: lnspect continuity between CN1 and CN3.


Standard: CN1-1 - CN3-1: Continuity shall exist. CN1-18 - CN3-2: Continuity shall exist. CN1-22 - CN3-5: Continuity shall exist. CN1-1 - CN1-18: No continuity. CN1-1 - CN1-22: No continuity. CN1-18 - CN1-22: No continuity.




CNl (REC) CN26 (REC)

CN3 (TAB)


Inspect for disconnection of the CNl , CN3, and CN26 connectors.

lnspection 1 lnspect continuity between CN1 and CN26.

Inspect for water entry into the CN1, CN3, and CN26 connectors.

OK I NO I

NG ' I


NG '

L -

After correction, check SAS lamp indication. -

+

Controller defect.

Harnessdefect. lnspection 2 Inspect continuity between CN1 and CN3.

- CN3 connector defect.

Inspection 4 lnspect the voltage of the load sensor when the mast is in each status.

NG ,

OK

NG ,

lnspection 3 Inspect continuity between CN3 and CN26.

Load sensor defect.

OK

NG , Harnessdefect.

lnspection 1 : Inspect continuity between CN 1 and CN26.


Standard: CN1-1 - CN26-3: Continuity shall exist. CN1-18 - CN26-2: Continuity shall exist. CN1-22 - CN26-1: Continuity shall exist. CN1-1 - CN1-22: No continuity. CN1-18 - CN1-22: No continuity. CNl (REC) CN26 (REC)

inspection 2: lnspect continuity between CN1 and CN3.


Standard: CN1-1 - CN3-1: Continuity shall exist. CN 1-1 8 - CN3-2: Continuity shall exist. CN 1-22 - CN3-5: Continuity shall exist. CN1-1 - CN1-22: No continuity. CN1-18 - CN1-22: No continuity.



Standard: CN3-1 - CN26-3: Continuity shall exist. CN3-2 - CN26-2: Continuity shall exist. CN3-5 - CN26-1: Continuity shall exist. CN3-1 - CN3-5: No continuity. CN3-2 - CN3-5: No continuity.

. ,

CN3 (TAB)


lnspection 4: lnspect the voltage of the load sensor when the mast is in each status.

Turn the ignition switch ON (start the engine).

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Standard: Load value Fully lowered state (with the lift cylinder pressure released):

0.10to l .00V Relief state at the uppermost end:

3.5 to 4.8 V

MAST DATA (112)


lnspect for water entry to the inside of the CN1, CN3, and CN26 connectors.

NG '

1 CN3 connector defect.


Harnessdefect lnspection 2 Inspect continuity between CN1 and CN3.

4

NG ,



lnspection 4 Inspect the voltage of the load sensor when the mast is in each status.

OK

NG Harness defect.

OK /

NG Load sensor defect.



Standard: CN1-1 - CN1-18: No continuity.

CN1 (REC)




CN1 (REC)




CN3 (REC)

lnspection 4: lnspect the voltage of the load sensor when the mast is in each status.


Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU -+ IN OUT MENU + MAST DATA

Standard: Load value Fully lowered state (with the lift cylinder pressure released):

0.lOto l .00V Relief state at the uppermost end:

3.5 to 4.8 V

TlLT 2.20v CONT 2.20V LEVEL 2.20V

SOL2 OFF

Error code 62 (Tilt angle sensor abnormality) Error code 62-1 (Tilt angle sensor open circuit) Error code 62-2 (Tilt angle sensor short circuit)

Related Portion

- -- CN1-14 (5MA. Tilt angle sensor power) CN27-1

z - - m CN1-17 (MA, Tilt angle sensor) 2 - z $ c 0 0

4341-22 (E01, Sensor GND)

CN1 CN27

Estimated Causes: @) Connector contact defect @ Tilt angle sensor harness defect @ Tilt angle sensor defect @ Controller defect

Inspect for connector disconnection between After correction, check SAS lamp indication. CN1 and CN27.

Inspect for water entry into the connector NG After correction, check SAS lamp indication. between CN1 and CN27.

OK I NG

, After correction, check SAS lamp indication. Inspect the tilt angle sensor for disconnection

from the link and damages.

OK / NG

NG


6

Harness defect. Inspection 1 Inspect continuity between CN1 and CN27.

NG

OK

Tilt angle sensor defect. Inspection 2 lnspect the tilt angle sensor.

OK I 1

NG



Standard: CN1-14 - CN27-1: Continuity shall exist. CN1-17 - CN27-2: Continuity shall exist. CN1-22 - CN27-3: Continuity shall exist. CN1-14 - CN1-17: No continuity. CN1-14 - CN1-22: No continuity. CNI-17 - CN1-22: No continuity. CN1 (REC) CN27 (REC)

lnspection 2: lnspect the potential change upon tilt operation.

Remove the tilt angle sensor and perform re-setting after installing the tilt angle sensor.

Standard: Measure resistance between tilt angle sensor terminals. CN27-1 - CN27-3: 1.5 kR f 0.3 kR CN27-2 - CN27-3: 0 kR when the sensor lever is free:

1.5 kR f 0.3kR when the sensor lever is in full stroke: CN27 (TAB)

I Inspect the tilt angle sensor for disconnection After correction, check SAS lamp from the link and damages. indication.

&

&


Inspect for connector disconnection between CN1 and CN27.

&


OK 1 NG

NG '


Inspect for water entry into the CN1 and CN27 connectors.

4

OK 1 NG

NG '

Harness defect. Inspection 1 lnspect continuity between CN1 and CN27.

- OK I

NG >

Tilt angle sensor defect. lnspection 2 lnspect the potential change upon tilt operation.

OK I

NG >

Inspection 1 : Inspect continuity between CN1 and CN27


Standard: CN1-14 - CN27-1: Continuity shall exist. CN1-17 - CN27-2: Continuity shall exist. CN1-14 - CNI-22: No continuity. CN1-17 - CNI-22: No continuity.

CNI (REC) CN27 (REC)

lnspection 2: Inspect the potential change upon tilt operation.


Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU + MAST DATA

Standard: The tilt value shall be 0.1 - 4.8 V when the mast is tilted fully backward from the full forward position. The value shall rise as the mast is tilted backward.

MAST DATA (112) SAVE

TILT 2.ZOV CON1 2 20V

[LEVEL 2:20Vl 4 LOAD O.SO(0.90 V TILT SOL1 ON

SOL2 OFF

Inspect the tilt angle sensor for disconnection After correction, check SAS lamp from the link and damages. I p- indication.

O K L (NG J.



Inspect for connector disconnection between CN1 and CN27.


1 Controller defect. I

NG

NG

3.

lnspection 1 : Inspect continuity between CN1 and CN27


NG ,


Hamessdefect.

Tilt angle sensor defect. Inspection 2 Inspect the potential change upon tilt operation.

Standard: CNI-22 - CN27-3: Continuity shall exist. CNI-14 - CN1-17: No continuity.

OK I

NG


lnspection 2: lnspect the potential change upon tilt operation.


Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU +MAST DATA

Standard: The tilt value shall be 0.1 - 4.8 V when the mast is tilted fully backward from the full forward tilt position. The value shall rise as the mast is tilted backward.

Error code 63 (Tilt lever switch abnormality) Error code 63-1 (Both tilt lever switches ON at the same time) Error code 63-2 (Forward tilt switch 2-minute short circuit) Error code 63-3 (Backward tilt switch 2-minute short circuit)

Related Portion

Estimated Causes: @) Connector contact defect @ Tilt switch harness defect @ Forward tilt switch defect

@ Backward tilt switch defect @ Tilt switch mounting defect @ Controller defect

Zi - - 2 - c 0 0

CN34

m <

--

u W

lnspection 2 lnspect continuity through the tilt lever switch only (mounted on the vehicle).

CN1-10 (MF, Tilt lever SW1 (forward)) CN34-1 .

After correction, check SAS lamp indication.*

Inspect forwater entry into the CN1 and CN34 connectors.

Inspection 1 lnspect continuity through the tilt lever switch wiring.

lnspection 3 lnspect continuity between CN1 and CN34. I

OK I I NG

NG

lnspection 4 1

NG lnspect continuity through the tilt lever switch only 1

Harness defect.

(removed from the vehicle).

CN1-9 (MR, Tilt lever SW2 (backward))

CN1-23 (E02, SW - GND)

NG >

Tilt lever switch mounting defect. I

I

Controller defect.

LI CN34 connector defect. 1

0 ill a

m < '

CN34-2

* After the ignition switch is turned ON, make sure that the SAS lamp is lit upon tilting forward and backward. Make sure that the 2-minute waiting SAS lamp blinks when the tilt lever is on the neutral position.

Forward tilt switch

- Tilt lever switch abnormality.

CN34-3

~ ~ 3 4 - 4 Backward tilt switch

Inspection 1 : lnspect continuity through the tilt lever switch wiring.


Standard: CN1 (REC)

Inspection 2: lnspect continuity through the tilt lever switch only (mounted on the vehicle).


CN1-10-CN1-23

CNI-9-CN1-23

CN34 (TAB) Standard:

Lever at neutral position

No continuity.

No continuity.

Inspection 3:

CN34-1 - CN34-2

CN34-3 - CN34-4

lnspect continuity between CN1 and CN34.


Lever at forward tilt position

Continuity shall exist.

No continuity.

CN1 (REC)

Standard: CN1-10 - CN1-9: No continuity. CN1-10 - CN1-23: No continuity. CNI-9 - CNl-23: No continuity. @

lnspection 4: CN34 (TAB)

lnspect continuity through the tilt lever switch only (removed from the vehicle).

Lever at backward tilt position

No continuity.



No continuity.

No continuity.


Standard: Upper side switch (switch on the top when mounted on the vehicle)



No continuity.


No continuity.


Lower side switch (switch on the bottom when mounted on the vehicle)

CN34-1- CN34-2

Switch free


Switch depressed

No continuity.

Switch depressed

No continuity. CN34-3 - CN34-4

Switch free


I Error code 63-1 1

Harness defect.

CN34 connector defect.

Inspect for water entry into the CN1 and CN34 connectors..

Inspection 1 Inspect continuity through the tilt lever switch wiring.

lnspection 4 lnspect continuity through the tilt lever switch only (removed from the Tilt lever switch abnormality.

vehicle).

rTiliver switch mounting defect. I

OK I NG

NG

OK r

* After the ignition switch is turned ON, make sure that the SAS lamp is lit upon tilting forward and backward.

After correction, check SAS lamp indication.'

lnspection 1 :

Inspection 5 Inspect the switch output upon tilt lever operation.

CNl connector defect. NG

lnspect continuity through the tilt lever switch wiring.


Standard:

NG r

CN1 (REC)

OK Controller defect

lnspection 2: lnspect continuity through the tilt lever switch only (mounted on the vehicle).

CNI-10-CNI-23

CN1-9- CNI-23

Turn the ignition switch OFF and disconnect CN34

Standard:


No continuity.

No continuity.

@ CN34 (TAB)



No continuity.


No continuity.


CN34-1 - CN34-2

CN34-3 - CN34-4 L


No continuity.



No continuity.

No continuity.



No continuity.

Inspection 3: lnspect continuity between CN1 and CN34.


Standard: CNI-10 - CN1-9: No continuity. CNI-10 - CN 1-23: No continuity. CN1-9 - CN1-23: No continuity.

Inspection 4: CNI (REC) lnspect continuity through the tilt lever switch only (removed from the vehicle).

Turn the ignition switch OFF and disconnect CN34. @ CN34 (TAB)

Standard: Upper side switch (switch on the top when mounted on the vehicle)

Lower side switch (switch on the bottom when mounted on the vehicle)

CN34-1 -CN34-2

lnspection 5: lnspect the switch output upon tilt lever operation.

Turn the ignition switch ON (stop the engine).

Analyzer: MAIN MENU -+ SAS MENU +ANALYZER MENU + IN OUT -'NU + MAST DATA

Standard:

Switch free


CN34-3 - CN34-4

-- Switch depressed

No cont~nuity.

MAST DATA (212)

KNOB OFF HEIGHT SW1 SW21 OFF ON

SW22 OFF

Switch free


. -

Switch depressed

No continuity.

Lever tilted backward

OFF

ON

Forward tilt

Backward tilt

OFF

OFF

ON

OFF

Inspection 1 Inspection 5 Inspect continuity between CN1-10 Controller defect. and CN1-23. tilt lever is at the neutral position.

NG CN1 connector defect.


OK lnspection 3 Inspect continuity between CN34-1 Inspect continuity between CN1-10 Harness defect. and CN34-2. and CN1-23 (harness only). -

1 I i -1 CN34 connector defect. I

OK I NG

. NG ,

I inspection 4 I U

After correction, check SAS lamp indication."

I lnspect continuity through the tilt lever switch only (removed from the Tilt lever switch abnormality. I

Tilt lever switch mounting defect.'* * *I: Make sure that the 2-minute waiting SAS lamp blinks when the tilt lever is at the neutral position. *2: This tilt lever switch is the upper switch among two switches mounted on the second spool of the

control valve.

lnspection 1 : lnspect continuity between CN1-10 and CN1-23



CN1 (REC)

lnspection 2: lnspect continuity between CN34-1 and CN34-2. (Inspect on the connector at the tilt switch side.)



lnspection 3: lnspect continuity between CN1-10 and CN1-23 (harness only).

Turn the ignition switch OFF and disconnect CN1 and CN34. CN1 (REC)

Standard: CN 1-1 0 - CN1-23: No continuity.

lnspection 4: lnspect continuity through the tilt lever switch only (removed from the vehicle).


Standard: Upper side switch (switch on the top when mounted on the vehicle) CN34 (TAB)

lnspection 5: lnspect the switch output when the tilt lever is at the neutral position.

- --

CN34-1- CN34-2



Switch free


Standard: FORWARD OFF when the tilt lever is at the neutral position

Switch depressed

No continuity.

MAST DATA (212)

KNOB OFF HEIGHT SW1 ON

SW21 OFF SW22 OFF

inspect for water entry into the CN1 and CN34 connectors.

OK lnspection 3 (,,,I Inspect continuity between CN34-3 Inspect continuity between CNI-9 NG,Iri Harness defect.

and CNI-23. (Individual harness . ,- inspection).

NG '

Inspection 1 1 Inspection 5 NG , 1

I Inspection 4 I

SAS lamp indication check after correction.*l

+

Inspect continuity between CNI-9 and CN1-23.

CN34 connector abnormality. 1

Inspect the switch output with the Ccntroller defect. tilt lever in the neutral position.

Inspect continuity of the tilt lever I

switch alone (after removal from NG ' Tilt lever switch abnormality. the

Tilt lever switch installation defe~t. '~ I

NG

* I : Wait for 2 minutes with the tilt lever in the neutral position, and check if the SAS lamp blinks. *2: This tilt lever switch is the lower one out of two switches in stalled on the second spool of the control

valve.

CN 1 connector'defect.

lnspection 1 : lnspect continuity between CN1-9 and CN1-23.



lnspection 2: lnspect continuity between CN34-3 and CN34-4. (Inspect on the connector at the tilt switch side.)



lnspection 3: lnspect continuity between CN1-9 and CN1-23 (harness only).


Standard: CNI-9 - CNI-23: No continuity.

lnspection 4: lnspect continuity of the tilt lever switch alone (after removal from the vehicle).


Standard: Lower switch (switch on the lower side when installed on the vehicle)

CNl (REC)

@ CN34 (TAB)

lnspection 5: lnspect the switch output when the tilt lever is at the neutral position.

CN34-3 - CN34-4

Turn the ignition switch ON (engine in stopped state)


Switch in free state


Standard: BACKWARD OFF state when the tilt lever is in the neutral position.

Switch in pressed state

No continuity.

MAST DATA (212)

KNOB OFF HEIGHT SW1 SW21 OFF

SW22 OFF

Error code 64 (Tilt solenoid No.1 abnormality) Error code 64-1

Related Portion

r .- Tilt Solenoid

CN1-13 (TLT1, Tilt solenoidl) CN12-1 No. 1 T

?i - m o 0 m - - - 2 a w A A - c

I- LL E s s CN1-24 (El, Main GND) CN12-2

U N W CN12 I Estimated Causes:

@ Connector contact defect @ Tilt solenoid No. 1 harness defect

@ Tilt solenoid No.1 defect @ Controller defect

Make sure that the SAS lamp blinks immediately after the key is turned on.

Make sure that the SAS lamp blinks when the tilt lever is operated after the key is turned on. I

I I lnspect forwater entry into the CN1 and CN12 After correction, check SAS lamp indication. connectors. I

Inspect for disconnection of the CN1 and CN12 connectors.

NG h

Inspection 1 lnspect resistance through the tilt solenoid No.1 wiring.

1 nspection 2 rNG + 14-1 Inspect resistance through the tilt CN 12 connector defect. solenoid No. 1 only. Solenoid defect.


"" I OK

I I T

lnspection 4 jG hl Harness defect,

OK h

lnspection 3 lnspect continuity between

el Harnessdefect. 1 CN1 and CN12.

Controller defect.

/ (12 V) line. 1 L Inspect continuity between the tilt I solenoid No. I + line and power Controller defect.

inspect resistance through the tilt solenoid No.1 wiring.

Turn the ignition switch OFF and disconnect CN1. CN1 (REC)

Standard: CN1-13 (Digital circuit tester @) - CN1-24 (Digital circuit tester 8): Resistance Approx. 10 R CN1-13 (Analog circuit tester €3) - CN1-24 (Analog circuit tester $): Resistance Approx. 10 R

lnspection 2: lnspect resistance through the tilt solenoid No.1 only.


@ CN12 (TAB)

Standard: CN12-1 (Digital circuit tester @) - CN12-2 (Digital circuit tester 0): Resistance Approx. 10 R CN12-1 (Analog circuit tester 8) - CN12-2 (Analog circuit tester 63): Resistance Approx. 10 R

lnspection 3: lnspect continuity between CN1 and CN 12.


Standard: CN1-13 - CN12-1: Continuity shall exist. CN1-24 - CN12-2: Continuity shall exist. CN1-13 - CN1-24: No continuity.

" " CN1 (REC) ~ ~ 1 2 (REC)

lnspection 4: lnspect continuity between the tilt solenoid No.1 + line and power (12 V) line.



CNl (REC)

Error code 65 (Tilt solenoid No.2 abnormality) (- 2000.10) Error code 65-1

Related Portion

r TR solenoid

CN1-12 (TLT2, Tilt solenoid 2) CN13-1 No.2

5 - - - - m o 2 a w A A - I- a

E z K

a t-

3 CN1-24 (El, Main GND) CN13-2 A

U_I CN13 l-l

Estimated Causes: @ Connector contact defect @ Tilt solenoid No.2 defect @ Tilt solenoid No.2 harness defect @ Controller defect

1 I 1 YES

Error code 65 65-1

YES Make sure that the SAS lamp blinks immediately after the key is turned on. at a low lifting height after the ignition switch is

+ -

Inspection 1 OK Controller defect. lnspect resistance through the tilt solenoid No.2 wiring.

NG Harness defect.

lnspect continuity between CN1 and CN13.

OK

lnspection 2 Inspect resistance through the tilt CN13 connector defect. solenoid No.2 only. Solenoid defect.

Inspection 4 Harness defect. lnspect continuity between the t~lt solenoid No.2 + line and power OK (1 2 V) line. Controller defect.

turned ON.

+

*: Make sure that the SAS lamp blinks when the tilt lever backward operation is performed with the mast at a low lifting height after the ignition switch is turned on.

After correction, check SAS lamp indication.* Inspect for disconnection of the CN1 and CN13 connectors.

NG *

After correction, check SAS lamp indication.* lnspect for water entry into the CNl and CN13 connectors.

NG .

lnspection 1 : Inspect resistance through the tilt solenoid No.2 wiring.

Turn the ignition switch OFF and disconnect CN1. CN1 (REC)

Standard: CN 1-1 2 (Digital circuit tester @) - CN 1-24 (Digital circuit tester 8): Resistance Approx. 10 R CN 1-1 2 (Analog circuit tester 0) - CN 1 -24 (Analog circuit tester @): Resistance Approx. 10 R

lnspection 2: lnspect resistance through the tilt solenoid No.2 only.

Turn the ignition switch OFF and disconnect CN13. Q CN 1 3 (TAB)

Standard: CN13-1 (Digital circuit tester 63) - CN13-2 (Digital circuit tester €3): Resistance Approx. 10 Q CN13-1 (Analog circuit tester 8) - CN13-2 (Analog circuit tester 63): Resistance Approx. 10 i2



Standard: CN1-12 - CN13-1: Continuity shall exist. CN1-24 - CN13-2: Continuity shall exist. CNI-12 - CN1-24: No continuity. CN1 (REC) CN13 (REC)

lnspection 4: lnspect continuity between the tilt solenoid No.2 + line and power (12 V) line.


Standard: CN1-11 - CN1-12: No continuity, CNI (REC)

Error code 66 66-1 (Tilt anglelNL load re-setting value abnormality)

Estimated Cause: @ Controller defect

Controller abnormality. Turn onloff the ignition switch to check error indication.

OK

Reset the controller to the normal status.

,

1 5-79

Error code 67 67-1 (Lifting height switch abnormality)

<When there is no fork height switch:>

Related Portion

Mast harness

Short circuit

Estimated Causes: @ Connector contact defect @ (Lifting height switch) Harness defect @ Controller defect

z - - 2 - c

S

m <

Inspect for water entry into the CN1 and CN3 After correction, check SAS lamp indication. connectors. I

CN3-3

CN3-7

CN3-4

CN 1 CN3

-7 CN1-23 (E02, SW - GND)

After correction, check SAS lamp indication. Inspect for disconnection of the CN1 and CN3 connectors.

r

: O IJJ a

NG

J'

OK K CN3 connector defect.

E a

CN1-3 (MH1, Lifting height sensor 1)

CN1-4 (MH21, Lifting height sensor 21)

lnspection 3 lnspect continuity between CN 1 and CN3.

Controller defect. Inspection 1 lnspect continuity through the mast harness wiring.

OK +

NG +

NG

Harness defect.

Mast harness defect. Inspection 2 lnspect continuity through the mast harness only.

NG

lnspection 1 : lnspect continuity through the mast harness wiring.


Standard: CN1-23 - CN1-3: Continuity shall exist. CN1-23 - CN1-4: No continuity.

CNl (REC)

lnspection 2: lnspect continuity through the mast harness only.


Standard: CN3-3 - CN3-7: Continuity shall exist. CN3-3 - CN3-4: No continuity. CN3-3 - CN3-8: No continuity. CN3-4 - CN3-8: No continuity.



Standard: CN1-23 - CN3-3: Continuity shall exist CN1-3 - CN3-7: Continuity shall exist. CN 1-23 - CN1-3: No continuity. CN1-23 - CN1-4: No continuity. CN1-3 - CN1-4: No continuity. CN1-3 - CN1-5: No continuity. CN1-4 - CN1-5: No continuity.

CN3 (REC)

CN1 (REC) CN3 (TAB)

lnspection 1 : lnspect continuity through the mast harness wiring.

Inspect for disconnection of the. CN1 and CN3 connectors.


Standard: CN1-23 - CN1-3: Continuity shall exist. CN1-23 - CN1-4: No continuity. CN1-4 - CN1-5: No continuity.

NG ,

lnspection 2: lnspect continuity through the mast harness only.


OK I NG

lnspect for water entry into the NG , After correction, check SAS lamp CN1 and CN3 connectors. indication.

OK


Inspection 1 Inspect continuity through the mast harness wiring.

CN1 (REC)

Standard: CN3-3 - CN3-7: Continuity shall exist CN3-3 - CN3-4: No continuity. CN3-3 - CN3-8: No continuity. CN3-4 - CN3-8: No continuity.

OK

CN3 (REC)

Inspection 4 Inspect the output of the lifting height switch.

CN1 connector defect. NG

lnspection 2 Inspect continuity through the Mast harness defect. mast harness only.

lnspection 3 Inspect continuity between CN1 Harness defect. and CN3.


NG b

OK b Controller defect.



Standard: CNI-23 - CN3-3: Continuity shall exist. CNI-3 - CN3-7: Continuity shall exist. CNI-23 - CNI-3: No continuity. CNI-23 - CN1-4: No continuity. CNI-3 - CN1-4: No continuity.

CN1 (REC) CN3 (TAB)

lnspection 4: lnspect the output of the lifting height switch.


Analyzer: MAIN MENU -+ SAS MENU -+ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Standard: SW1: ON SW21: OFF SW22: OFF KNOB OFF

HEIGW SWl ON SWZl OFF SW22 OFF

a Error code 67 67-1 (Lifting height switch abnormality)

<When fork height switch is used:>

Related Portion

Estimated Causes: @ Connector contact defect @ (Lifting height switch) Harness defect

@ Lifting height switch defect @ Controller defect

ki - .d

K o 0

7-

2 t-

2 cc

-2

CN 1 CN3

CN1-23 (E02, SW - GND) (MH1. Lifting

CN1-3 height sensor 1)

(MH21, Lift~ng CN1-4 he~ght sensor 21)

r


r

Inspect for disconnection of the CN1, CN3, and CN31 connectors.

J.

2 t-

OK I< NG

NG '

[f

-


Inspect for water entry into the CNI, CN3, and CN31 connectors.

Controller defect. Inspection 1 lnspect continuity through the lifting height switch wiring.

Inspection 2 lnspect continuity through the lifting switch only.

I

- c 0 .- 2 E 0) .- 01 .c 0)

.- c s: -I

-

CN3-3 CN31-1 - -

I

NG

OK

Inspection 3 lnspect continuity between CN1 and CN31.

NG

Inspection 4 lnspect continuity between CN1 and CN3.

OK 0 1 CN3 connector defect.

:- -

CN3-7 C~31-2

CN3-4 CN31-3

Lifting height switch defect.

OK


I 1 *: If the SAS lamp blinks at a particular lifting height, check SAS lamp indication at the height.

CN31


NG

m 2

Harness defect.

NG >

0

Harnessdefect.

Inspection 1 : lnspect continuity through the lifting height switch wiring.


Standard:

- CN1 (REC)

Large lifting height

No continuity.


CNI-23-CN1-3

CNI-23-CNI-4

CNI-3-CN1-4

Inspection 2: lnspect continuity through the lifting switch only.


Standard:

Small lifting height


No continuity.

No continuity. I

CN31-1- CN31-2

CN31-I - CN31-3

lnspection 3: lnspect continuity between CN1 and CN31

CN31-2 - CN31-3




No continuity.

No continuity.



No continuity.


I CN31 (REC)

CN1 (REC) -

CN31 (TAB)



(1) If continuity does not exist between connector terminals in which continuity should exist in inspection 3:

Standard: CN1-23 - CN3-3: Continuity shall exist. CNI-3 - CN3-7: Continuity shall exist. CN1-4 - CN3-4: Continuity shall exist.

(2) If continuity exist between connector terminals in which continuity should not exist in inspection 3:

Standard: CN1-23 - CNI-3: No continuity. CN1-23 - CN1-4: No continuity. CN 1-3 - CN 1-4: No continuity.

CNl (REC)




Standard: CN3-3 - CN31-1: Continuity shall exist. CN3-7 - CN31-2: Continuity shall exist. CN3-4 - CN31-3: Continuity shall exist.

CN3 (REC) CN31 (TAB)

(2) If continuity exists between connector terminals in which continuity should not exist in inspection 3:

Standard: CN3-3 - CN3-7: No continuity. CN3-3 - CN3-4: No continuity. CN3-7 - CN3-4: No continuity.

CN3 (REC)

Inspect for disconnection of the CN1, CN3, and CN31 connectors.

4 OK I NG

NG '

Inspect for water entry into the CN1, CN3, and CN31 connectors.

J.

lnspection 1 Inspect continuity through the Inspect the output of the lifting lifting height switch wiring. height switch in each mast status.

lifting switch only. 1


NG

4, I

lnspection 3 Inspect continuity between CN1 CN31 connector defect. and CN31.

OK 1 NG

NG *

CN 1 connector defect.

lnspection 2 Inspect continuity through the



C

NG ,I Lifting height switch defect.

lnspection 5 Inspect continuity between CN3

OK i o CN3 connector defect. I I

*: If the SAS lamp blinks at a particular lifting height, check SAS lamp indication at the height.

Inspection I : lnspect continuity through the lifting height switch wiring.


Standard:

lnspection 2: lnspect continuity through the lifting switch only.


No continuity.


CN1-23 -CNl-3

CNI-23-CN1-4

CNI-3-CN1-4




No continuity.

No continuity.

Standard:

I CNl (REC)



No continuity.


CN31-1 - CN31-2

CN31-1 -CN31-3

CN31-2 - CN31-3

Turn the ignition switch OFF and disconnect CNI and CN31



No continuity.

No continuity.

Standard: CNI-23 - CN31-1: Continuity shall exist. CNI-3 - CN31-2: Continuity shall exist. CNI-4 - CN31-3: Continuity shall exist. CNI-23 - CNI-3: No continuity. CNI-23 - CNI-4: No continuity. CNI-3 - CNI-4: No continuity.

CN31 (REC)

- CN1 (REC) CN31 (TAB)

lnspection 4: Inspect continuity between CN1 and CN3.




CN1 (REC) CN3 (TAB)

(2) If continuity does not exist between connector terminals in which continuity should not exist in inspection 3:

Standard: CN1-23 - CN1-3: No continuity. CN1-23 - CN1-4: No continuity. CN1-3 - CN1-4: No continuity. CNI (REC)





CN3 (REC) CN31 (TAB)

(2) If continuity exists between connector terminals in which continuity should not exist in inspection 3:

Standard: CN3-3 - CN3-7: No continuity. CN3-3 - CN3-4: No continuity. CN3-7 - CN3-4: No continuity.

CN3 (REC)

lnspection 6: lnspect the output of the lifting height switch in each mast status.


Analyzer: MAIN MENU -+ SAS MENU +ANALYZER MENU + IN OUT MENU + MAST DATA

Standard:

MAST DATA (2/2)

KNOB OFF HEIGHT S W I

SW21 SW22 OFF OFF

SW1

SW21

SW22


ON

OFF

OFF


OFF

ON

OFF

15-89

Error code F1 (Controller - hourmeter communication abnormality)

Related Portion

Estimated Causes: @ Connector contact defect ' @ Hourmeter harness defect @ Hourmeter defect @ Controller defect

ti - - g E S

t

lnspect for slip off of the CN2, CN41, and CN42 connectors.

$ a c

--

J.


2

$ 3 =

+ 8 g c .- 0 - m C

E U

m u 2 %

OK 1

NG *

lnspection 1 Inspect continuity between CN2 and CN41 and between CN2 and CN42.

J.

lnspection 1 : lnspect continuity between CN2 and CN41 and between CN2 and CN42. Turn the ignition switch OFF and disconnect CN2, CN41, and CN42.

CN2-3 (HRM1. Clock) CN41-4 CN2-12 (HRM2,Transrnission) CN41-3

CN41

CN2-11 (HRM3, Reception) CN42-12

CN2 CN42

After correction, check indication.

Standard:

OK I

NG *

Hourmeter defect. Inspection 2 lnspect the communication line.

CN2-3 - CN41-4: Continuity shall exist. CN2-12 - CN41-3: Continuity shall exist. CN2-11 - CN42-12: Continuity shall exist.

Harnessdefect.

OK I

NG *

CN2 (REC)

CN41 (REC)

Inspection 2: ~ ~ 4 2 (REC)

lnspect continuity between CN2 and CN41 and between CN2 and CN42. Turn the ignition switch ON (stop the engine).

Analyzer: MAIN MENU + SAS MENU -, ANALYZER MENU + IN OUT MENU + OTHER DATA

Standard: VOLTAGE 1 2 . 4 ~ HOURS 11223.lh

The correct time is indicated by the hourmeter (0.1 hour shortage permissible).

TROUBLESHOOTING BY PHENOMENON For SAS control related troubleshooting on failures with no error code indicated, procedures are described for without analyzer (SST) and with analyzer (SST). For combination meter (SAS) related troubles, a procedure contains the case without analyzer (SST) and the case with analyzer (SST). Perform troubleshooting according to each procedure.

List of pages to be referenced by symptom

8 9 - .- -z 9

0 cn v

C 0 .- C1 0 r L

2 g z 9 2 5 .- Y

2

- rn

5 CI

E .- Y

m . n

S

Description

Stability not provided during traveling. (Locking hardly or not provided during traveling.)

Swing lock always occurs during traveling or loading work. Or, swing lock frequently occurs

Active fork leveling is not provided. (Does not stop at a horizontal position but tilts at the forward-most position.)

Active fork leveling is not provided. (Stops at a non-horizontal position.)

Active fork leveling is not provided. (Stops at a position when the knob switch is pressed.)

The active mast rear tilt speed control is not regulatated, or the backward tilting speed is always slow.

The mast does not perform frontlrear tilt.

No error code is indicated although SAS warning lamp blinks.

" - " (underscore) is displayed on the hourmeter.

The SAS warning lamp is always lit.

When the ignition switch is turned on, the SAS warning lamp is not lit.

No hourmeter indication

The buzzer is not interlocked with the SAS warning lamp.

When the ignition switch is turned on, the swing lock lamp is not lit.

Page to be

Without analyzer

1591

1 5-96

1598

15104

15106

15110

15115

15-124

15-124

15125

15127

I 15129

151 30

15131

referenced

With analyzer

1593

15-97

15101

15-1 05

151 08

15113

15120

t

t

t

t

t

t

t

a Stability not provided during traveling. (Locking hardly or not provided during traveling.)

-1 Hasn't any tire burst or isn't tire air pressure low?

NG Tire burstlair pressure abnormality.

v

I J I I

NO 1 I NO 1 YES

(C

I I Go to that error code. I

Lock cylinder component failure. Visually inspect for damages N G on the lock cylinder and pin.

Inspection 1 Is the error code recorded? ) YES *

I Make sure that the lock lamp is not lit when the I

OK 1

- Is there any current error in the record?

I simply (Fork height: 500 mm (19.7 in) or lower). I

- parking lever is operated slightly strongly.

@ Make sure that the lock lamp is not lit when the fork is lowered and the speed is gradually increased

All OK I * 1 Does this trouble occurs during traveling with a large I

NG +

I lifting height only? I

Yaw rate sensor internal abnormality (Replace the yaw rate sensor).

I Does this trouble occur only when a load is provided? I

Inspection 2 NG lnspect operation of the lifting height switch.

L I

NO JYES I Can the mast be tilted to the forward-most 1

Lifting height switch abnormality.

I I position with a large lifting height and without I load (excluding relief)? Does the mast stop at an approximately 1 degree front tilted position when the fork is at the upper-most position with no-load relief?

OK *

NG

I - I

OK

lnspect to see if the speed sensor body and sensor mounted state are normal.

NG Speed sensor defect.

Load sensor abnormality.

lnspection 3 Make sure that the rear axle does not switch when the connector of the lock cylinder solenoid is removed and a front wheel aoes over a stem

I Yaw rate sensor defect or controller defect (Replace the controller).

NG Failure such as lock cylinder internal leak, leak of operation oil to the outside, or solenoid sticking.

lnspection 1 : Is the error code recorded?

Turn ignition switch ON then remove the diagnosis shorting pin and check error code indication on the hourmeter display.

Standard: Errors near the current time shall not exist.

lnspection 2: Inspect operation of each lifting height switch.

Standard: Tilt backward at heights of small lifting height (fast) and large lifting height (slow), respectively, without load. The speeds shall be different.

lnspection 3: Make sure that the rear axle does not switch when the connector of the lock cylinder solenoid is removed and a front wheel goes over a step. (Alternatively, lift the rear of the vehicle with a jack and make sure that the rear axle does not swing.)

Standard: Remove the lock cylinder solenoid connector on a flat road. A front wheel or rear wheel shall be lifted when swing lock is performed and a front wheel goes over a step.

Caution: Front tire Perform this operation without load and at a small lifting height. Check for rocking for a large lifting height mast. After check, return to a flat road then connect the connector.

Slope

Note: Since this inspection requires connector removal and ignition switch ON, an error occurs, the SAS lamp blinks, and the error code is indicated and stored.

1 With analper I Hasn't Tire bursvair pressure abnormality.

I

Visually inspect for damages N G on the lock cylinder and oin.

Lock cylinder component failure.

OK 1

I I Go to that error code. I

.

Failure such as lock cylinder internal leak, leak of operation oil to the outside, or solenoid sticking.

Inspection 1 Make sure that the rear axle does not swing when a front wheel goes over a step after swing SOL OFF.

lnspection 2 Is the error code recorded?

YES

lnspection 4 @ Is the yaw rate sensor voltage change normal upon accelerated swing

along a circle with an approximately 2-meter (6.6 ft) radius? (Inspect the right and left, respectively.)

@ Make sure that the lock lamp is not lit when the parking lever is operated slightly strongly.

@ Make sure that the lock lamp is not lit when the fork is lowered and the speed is gradually increased simply. (Fork height: 500 mm (19.7 in) or lower)

OK 1

NG

Is there any current error in the record?

Does the speed value change according to the traveling

All OK 1

NG 4 Speed sensor defect. I

Yaw rate sensor internal

(Replace the yaw rate sensor).

NO I NO

~ o e ~ t h i s trouble occur during traveling with a large lifting height only?

NO JYES

YES

Inspection 5 Lifting height switch Inspect operation of each lifting height switch (LIFTING HEIGHT SW1, SW21 ONIOFF).

defect.

I Does this trouble occur only when a load is provided? I Can the mast be tilted to the forward-most position with a large lifting height and without load (excluding relief)? Does the mast stop at an approximately 1 degree front tilted position when the fork is at the upper-most position with no-load relief? I NG

Load sensor defect. I

Controller defect.

Inspection 1 : see that the rear axle does not swing when one front wheel rides on a high place after swing solenoid OFF.

Analyzer: MAlN MENU + SAS MENU +ANALYZER MENU +ACTIVE TEST

Standard: When one front wheel rides on a high place after the swing solenoid is set to ON and OFF on a flat road, one front or rear wheel shall float above the ground. -

Caution: Perform this inspection with no load at a low fork height.

lnspection 2: Is any error code recorded?

ACTIVE TEST (In)

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU -, DIAG MEMORY

Standard: No error shall be displayed near the current time on the hour meter.

lnspection 3: Does the speed value change according to the traveling speed?

Analyzer: MAlN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU + SWING DATA

Standard: During traveling the speed value shall change according to the varying vehicle speed.

Note: The speed value is in a range of 95 to 130% of the actual vehicle speed.

SWING DATA (112)

YAW SENSOR 2.50V

SWING SOL ON

lnspection 4: @ Let the vehicle travel with acceleration on a circle whose radius is approx. 2 m (79 in), and check if the

yaw sensor voltage variation is appropriate (check for each of right and left turns).

Analyzer: MAlN MENU -. SAS MENU -.ANALYZER MENU -. IN OUT MENU -. SWING DATA

Standard: At a low fork height with no load, travel with gradual acceleration (at a speed of 5 to 6 kmlh (3.1 - 3.7 rnilelh)) on a circle whose radius is approx. 2 m (6.6 ft) (with respect to the center of the vehicle). The yaw sensor voltage shall vary smoothly.

SWNG DATA (ln)

YAW SENSOR 2.50V

SWNGSOL ON

In right turn

In left turn

lnspection 5: Check functioning of each fork height switch (ONJOFF of fork height SWI and SW21).

2.5 V (stationary state) -. approx. 3.0 V

2.5 V (stationary state) -. approx. 2.0 V

Analyzer: MAlN MENU -. SAS MENU -.ANALYZER MENU -. IN OUT MENU -. MAST DATA

Standard: (iJ Lift and lower the fork at around 2,200 mm (86.6 in) to actuate the fork height switch. Only fork height SW 1 is ON at a low fork height (below the fork height switch). Only SW21 is ON at a high fork height (above the fork height switch).


SW21 SW22 OFF OFF

Swing lock always occurs during traveling or loading work. Or, swing lock frequently occurs.

1 although the lock lamp is not lit (upon engine start). I I I I No

I Lock is always maintained (bracing kept) and the rear axle does not swing when the vehicle goes over a step

--

1 All OK

YES


@ Make sure that the lock lamp is not lit when the fork is lowered and the speed is gradually increased simply. (Fork height: 500 mm (1 9.7 in) or lower)

I lnspection 1 lnspect the operation of the lifting height switch.

Lock cyiinder solenoid valve sticking.

Pi Lifting height switch defect.

NG

Can the mast be tilted to the forward-most position with a large lifting height and without load (excluding relief)? Does the mast stop at an approximately 1 degree front tilted position when the fork is at the upper-most position with no-load relief?

Yaw rate sensor internal defect. (Replace the yaw rate sensor).

1 OK

Yaw rate sensor defect or controller defect. (Replace the controller.)

NG

lnspection 1 : lnspect operation of lifting height switch.

Load sensor defect.

Standard: Tilt backward at heights of small lifting height (fast) and large lifting height (slow), respectively, without load. The speeds shall be different.

Lock is always maintained (bracing kept) and the rear axle does not swing when the vehicle goes over a step although the lock lamp is not lit (upon engine start).

I @ Make sure that the lock lamp is not lit when the fork is I

lnspection 1 @) Is the yaw rate sensor voltage change normal upon

accelerated swing along a circle with an approximately 2-meter (6.6 ft) radius? (Inspect the right and left, respectively.)


I - lowered and the speed is gradually increased simply. (Fork height: 500 mm (19.7 in) or lower). I

YES Failure such as lock cylinder solenoid valve sticking or clogging.

NG

Load sensor abnormality.

fork is at the upper-most position with no-load relief?

Yaw rate sensor internal abnormality (Replace the yaw rate sensor).

I I All OK


lnspection 2 Inspect the operation of each the lifting height switch. (LIFTING HEIGHT SW1, SW21 ONIOFF)

lnspection 1 : @) Is the yaw rate sensor voltage change normal upon accelerated swing along a circle with an approxi-

mately 2-meter (6.6 ft) radius? (Inspect the right and left, respectively.)

Analyzer: MAIN MENU -. SAS MENU -. ANALYZER MENU -. IN OUT MENU -. SWING DATA

NG *

Standard: With a small lifting height and without load, perform accelerated swing along an approximately 2-meter radius circle (based on the vehicle center) gradually (up to 5 to 6 kmlh (3.1 - 3.7 milelh)). The yaw rate sensor voltage shall change.

Lifting height switch.

SWING DATA (112)

YAW SENSOR 2.50V

SWINGSOL ON

Swing to the right

Swing to the left

2.5 V (stop) to Approx.3.0 V

2.5 V (stop) to Approx. 2.0 V 4

Inspection 2: Inspect the operation of each the lifting height switch. (LIFTING HEIGHT SW1, SW21 ONJOFF)

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU MAST DATA

Standard: @) Lift and lower the fork at a height of approximately 2200 mrn (87 in) to activate the lifting height switch.

Note: LIFTING HEIGHT SW1 only is turned ON for a small lifting height (below the switch). LIFTING HEIGHT SW21 only is turned ON f.or a large lifting height (above the switch).

KNOB OFF HElGM SW1 ON

sw21 OFF s w 2 2 OFF

Stopping with automatic leveling fails. (Does not stop at a horizontal position but tilts at the forward-most position.)

Related Portion

Tilt angle sensor

Active fork leveling switch

-. - . -.

P

--

o W .

I-n:

--

L a = 0 5 c 0 0

- CN1-14 (5MA, Tilt angle sensor power) CN27-1

CN1-17 (MA, Tilt angle sensor)

CNI-22 (E01, Sensor GND)

--

m 4

r 0 - .- VJ S m C .- - al > al - + 2 ? .- - 9

t - - F - c

S

CN1 CN27 -

A

m

CN33-1

CN33-2

. CN1 CN33

o a u I - C C

i-

CN1-8 (MN Tilt knob SW)

CN~-23 (EO2 SW-GND)

-

n: E Z

I-

I

p o u t analyzer I I 1

Check if automatic stop occurs upon forward tilting by approx. 1 degree in tilting operation immediately after relief in the uppermost position in no-load lifting.*

*: Tilt the mast forward especially slowly on a vehicle with an attachment.

J.

-&

I I After re-setting again, check active fork leveling. Controller defect. I

After repair, check active fork leveling. lnspect for link bending and damages of the tilt angle sensor.

Make sure that natural forward tilt is obviously large. (Can the motion be checked visually?)

lnspect for slip off of the CN1 and CN33 connectors. After correction, check active fork leveling.

NG

Tilt angle sensor defect. lnspection 1 lnspect the tilt angle sensor.

Control valve solenoid No.1 sticking or tilt lock check valve sticking defect.

lnspection 2 Inspect continuity of the active fork leveling switch 1%~ Controller defect. I

OK I

NG ,

wiring. 1 I NG I

I

Inspection 3 Inspect continuity of the active fork leveling switch only.

I CN33 connector defect. I

4 OK I

NG b

lnspection 4 lnspect continuity between CN1 and CN33

Active fork leveling switch defect.

OK 1

NG + Harness defect.

lnspection 1 : lnspect the tilt angle sensor.

Turn the ignition switch OFF and remove the tilt angle sensor.

Standard:

lnspection 2: lnspect continuity of the active fork leveling switch wiring.


Standard:

CN27-2 - CN27-3

lnspection 3: lnspect continuity of the active fork leveling switch only.


Standard:

Sensor lever free

Om

CN1-8- CN1-23

Sensor lever with full stroke

1 .Ski2 f 0.3kR


Active fork leveling switch free

No continuity

CN33-1 - CN33-2


Active fork leveling switch with full stroke


Standard: CN1-8 - CN33-1: Continuity shall exist. CN1-23 - CN33-2: Continuity shall exist.


No continuity

CN27 (TAB)

Active fork leveling switch with full stroke


CN1 (REC)

CN33 (TAB)

CN1 (REC)

CN33 (REC)

Inspect the output of the active fork leveling switch. I

Tilt angle sensor defect.

active fork leveling.

NG I

I I

OK


OK - lnspection 2 lnspect the output of the tilt angle sensor.

lnspect for slip off of the CN1 and CN33 connectors.

lnspection 7 Harness defect. lnspect continuity between CN1 and CN33.

OK 1

NG

6

1 CN33 connector defect.

NG '

lnspection 5 lnspect continuity of the active fork leveling switch wiring.

After repair, check active fork leveling.

Inspect for link bending and damages of the tilt angle sensor.

After correction, check active fork leveling. I Controller defect.

OK I I NG

NG '

NG

lnspection 6

: I Active fork leveling switch defect.

lnspect continuity of the active fork leveling switch only.

OK

Inspection 1 : lnspect the output of the active fork leveling switch.


Analyzer: MAlN MENU +SAS MENU +ANALYZER MENU + IN OUT MENU + MAST DATA

Standard:


SW21 OFF SW22 OFF

lnspection 2: lnspect the output of the tilt angle sensor.

Active fork leveling switch depressed

ON KNOB


-


OFF

Analyzer: MAlN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU + MAST DATA

Standard: When the tilt operation is performed and the mast is moved from the forward-most tilt position to the backward-most tilt position, the potential shall rise between 0.1 V and 4.9 V along with backward tilting.

MAST DATA (112)

TILT 2.20v

LEVEL 2.20V

SOL2 OFF

lnspection 3: lnspect the tilt angle sensor

Turn the ignition switch OFF and remove the tilt angle sensor

Standard:

I CN27-2-CN27-3 / OkR / 15kQ t 0.3kQ I Sensor lever free

CN27 (TAB)

Sensor leverwith full stroke

lnspection 4: lnspect the leveling stored value of the tilt angle sensor.


Analyzer: MAIN MENU +'SAS MENU +ANALYZER MENU + IN OUT MENU + MAST DATA

Standard: The TILT value shall be smaller than the LEVEL value when the tilt is at the foward-most position.



Standard:



Standard:

CNI-8 - CNI-23

lnspection 7: lnspect continuity between CN1 and CN33


No continuity

CN33-1 - CN33-2






No continuity

- CN1 (REC)


Continuity shall exist. CN33 (TAB)

" CN1 (REC) "

CN33 (REC)

15-104

Active fork leveling is not provided. (Stops at a non-horizontal position.)

Related Portion:

Tilt angle sensor -

I lnspection 1 Inspect the tilt angle sensor.

o 2:

L-

L

P) = g S

lnspect for link bending and damages of the tilt angle sensor.

w Tilt angle sensor defect.

-- CN1-14 (5MA. Tilt angle sensor power) CN27-1


CNI-n (E01, Sensor GND)

--

--

m

CN 1 CN27

NG ,



Is there possibility of deviation of the stored leveling position due to worn-out tires or vehicle deterioration? -

Inspection 1: lnspect the tilt angle sensor.


NG ,

Standard:

After re-setting again, check active fork leveling.

OK I NG

I CN27-2 - CN27-3 / OkR 1 15kQf 0.3kR

Sensor lever free

CN27 (TAB)

Sensor lever with full stroke I I

I With analyzer I lnspect for link bending and damages of the tilt angle sensor.

Inspection 2 After re-setting again, check active fork Inspect the stored leveling value of the tilt angle sensor. leveling.

lnspection 1 lnspect the tilt angle sensor.

4

Controller defect.

NG ,



,


Tilt angle sensor defect.

Standard:

CN27 (TAB)

CN27-2 - CN27-3

lnspection 2: lnspect the stored leveling value of the tilt angle sensor.


Sensor lever free

OkR

Analyzer: MAIN MENU + SAS MENU -, ANALYZER MENU + IN OUT MENU -, MAST DATA

Sensor lever with full-stroke

1.5kR + 0.3kR

Standard: The TlLT value shall be the LEVEL value + 0.05 V when the mast is upright.

Note: Set the mast slowly forward from the backward-tilted position.

MAST DATA (112)

TlLT 2.20v

LEVEL 2:zoV r LOAD TILT 2:' 0.90(0.&0 V

15106

a Active fork leveling is not provided. (Stops at a position when the knob switch is pressed.)

Related Portion

Loadsensor --

- --

Tilt angle sensor P

E

5 C 0 0

--

0 4 W I - =

--

L

2 - 2 - c

S

Lifting height switch

m

-- CN1-14 (SMA, Tilt angle sensor power) CN27-1


CNI-z (EOl, Sensor GND)

-

i N 1 L L J

CN3

$

CN 1 CN27 -

--

,a

& - - 2 + c 0 0

--

rn re

u C N 3 1 L A - I CN3

--

m 2

L

0 V)

E

I V)

9 V)

o %.

CN1-1 (5V power, SPRS)

CN1-18 (Signal, PRES)

CN1-22 (GND. EO1)

CN1-23 (EO2, SW-GND)

(MH1. Lifting CN1-3 height sensor 1)

(MH21. Lifting CN1-4 height sensor 21)

CN3-1 CN26-3

CN3-2 CN262

CN3-5 CN261

-

m u i-

m - 3

0

o UJ c

-

0 2

- r 0 .- 2 E m .- a r

m C .- !G

CN3-3 CN31-1 -

CN3-7 CN31-2

C N M CN31-3

-

:- -

7

m 2

0

I ~ i h o u t analyzer I Make sure that active fork leveling is possible with a fork lifting height of approxrmately 500 mm (19.6 in) and approximately 500

I I mm (19.6 in) without load. I NG 1

4 Check if automatic leveling is possible at a high position OK without any load. Controller defect.

*

lnspect for link bending and damages of the tilt angle sensor. > After repair. check active fork leveling.

OK I NG

Make sure that active fork leveling is possible with a fork lifting height of approximately 500 mm (19.6 in) and approximately 500 mm (1 9.6 in) with a load on the fork.

4 Inspection 1 NG Inspect the tilt angle sensor. Tilt angle sensor detect. I

NG 1 OK

.. , . , . . = . a . I Re~lace the load sensor. and check if I +

Controller defect. r

OK

Check if automatic leveling occurs after resetting again.

NG I


v

lnspection 2 Inspect continuity of the lifting height switch only. Controller defect. I

J.

Controller defect. Lifting switch defect.

NG

lnspection 1 : lnspect the tilt angle sensor. Turn the ignition switch OFF and remove the tilt angle sensor.

Controller defect.

Standard:

CN27 (TAB)

lnspection 2: lnspect continuity of the lifting height switch only. Turn the ignition switch OFF and disconnect CN31.


1.5kQ 5 0.3kR CN27-2 - CN27-3

Standard:

Sensor lever free

OkR

CN31 (REC) CN31-1 - CN31-2

CN31-1 - CN31-3

Fork height: Approximately 500 mm (19.6 in)


No continuity

I I Make sure that active fork leveling is possible with a fork lifting OK height of approximately 500 mm (19.6 in) and approximately 500 Controller defect. mm (19.6 in) mth a load on the fork.

OK Make sure that active fork leveling is possible with a fork lifting height of approximately 500 mm (19.6 in) and approximately 500 mm (19.6 in) without load.

NG .I

NG $.

lnspect for link bending and damages of the tilt angle sensor.

Controller defect. Check if automatic leveling is possible at a high position without any load.

Inspection 1 NG Inspect the tilt angle sensor.

4,

Controller defect.

NG 1

OK

,

Tilt angle sensor detect.

*

After repair. check active fork leveling.

OK

OK I

Inspection 2 Inspect the stored leveling value of the tilt angle sensor.

J.

Inspect the road sensor output signal. automatic leveling occurs at a high fork

1 OK position without a load.

] NG

J.

-1 Controller defect.

OK I I NG

NG ,

NG


Make sure that active fork leveling is possible with a fork lifting height of approximately 500 mm (19.6 in) and approximately 500 rnrn (19.6 in) with a load on the fork.

* lnspection 5 Inspect continuity of the lifting height switch only. I NG ,I Lifting height switch defect. 1

OK I

-1

+ Controller defect.

Inspection 4 lnspect the output of the lifting height switch.

NG 1

OK + Controller defect.



Standard:

CN27 (TAB)

lnspection 2: lnspect the stored leveling value of the tilt angle sensor.


1.5kR i 0.3kR CN27-2 - CN27-3


Sensor lever free

OkQ

Analyzer: MAlN MENU -+ SAS MENU -+ANALYZER MENU -+ IN OUT MENU + MAST DATA

Standard: The TlLT value with the mast tilted fully backward is greater than the LEVEL value.

lnspection 3: lnspect the load sensor output signal. SOL2 OFF

Turn the ignition switch ON (Start the engine).

Analyzer: MAlN MENU -+ SAS MENU -+ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Standard: The LOAD value is the value in ( ) + 0.2 V or lower. (Fork lifting height of approximately 500 mm (1 9.6 in) without load.)

lnspection 4: lnspect the lifting height switch output signal

Turn the ignition switch ON (Start the engine).

Analyzer: MAlN MENU -+ SAS MENU +ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Standard: When the fork height is 500 mm (19.6 in). the LIFTING HEIGHT output shall be as follows: SWI: ON SW21: OFF C SW22: OFF c

lnspection 5: lnspect continuity of the lifting height switch only.


Standard:

KNOB OFF HEIGHT SW1 SW21 OFF ON

SW22 OFF

CN31-1 - CN31-2

CN31-1 - CN31-3 CN31 (REC)

Fork height: Approximately 500 rnrn (19.6 in)


No continuity

The active mast rear tilt speed is not regulated, or the backward tilting speed is always slow. Related Portion

Active fork leveling switch

.K 0 + .- E

!z .- - P

CNl CN33 -

1

Lifting height switch

Tilt solenoid No. 2 (- 2000. 10)

z - - 2 - c

6

& - - g - g 0

$ o w I - [r

--

--

5 - - c

S

-

o . u cf

CN1-8 (MN Tilt knob SW)

CNI-23 (EO2 SW-GND)

I l l -I

1 N l

CN31

CN3

--

m a

u CN13

u W.

I -u

Tilt solenoid No.2

-- AL

m u I-

-

CN1-23 (E02, SW-GND)

(MH1, Lifting CNI-3 height sensor 1)

(MH21, Lifting CN1-4 height sensor 21)

--

m o UU1 I-rr

CN33-1

CN33-2

I

m a I-

CN1-12 (TLT2, Tilt solenoid 2)

CN1-24 (El , Main GND)

3 K

u W (T

c 0 .- .- 2 E 0 .- a, r 0 .- ?E

CN3-3 CN31-1 T

2 I-

CN3-7 CN31-2

cN3-4 CN31-3

CN13-1

CN13-2

$ t- a

-

-

-

I Stopping with automatic leveling occurs when tilted forward I

I (without pressing the automtic I leveling switch) when the fork is raised to approx. 500 rnrn (1 9.6 in) without a load.

--

Stopping with automatic leveling occurs upon automatic leveling switch operation when the fork is raised to approx. 500 mrn (1 9.6 in) without a load. + lnspection 1

Check the automatic leveling Controller defect.

switch wiring for continuity.

NG -

lnspection 2 Check continuity of the Automatic leveling switch defect.

automatic leveling switch alone.

OK I NG

Check connectors CN1 and CN33 for disconnection or water invasion.

CN33 coneector defect.

+

lnspection 4 Check continuity of the fork heigh switch alone.

. NG ,

Fork height switch abnormality.

Check if the backward tilting speed is normal after the repair.

Harness defect. Inspection 3 Check continuity between CNl

Touch tilt solenoid*' and check the solenoid operating sound with the mast tilt to backward and with the fork raised to approx. 500 rnm (19.6 in) with no load. (Check with the engine stopped.)*

and CN33.

NG

*1 Solenoid to be checked: - 2000.10: No.2 solenoid

, 2000. 10 -: One unit of solenoic

1 - 2000.10. Control valve solenoid No.2 sticking defect. 2000.10 -: Control valve solenoid sticking defect.

*: Since the solenoid may be hot after lifting operation, carefully prevent the hand from getting scalded.

Inspection 1 : Inspect continuity of the active fork leveling switch wiring.

Turn the ignition switch OFF, and disconnect CN1.

Standard:


CN1-8 - CN1-23


Standard:


No continuity.




CN33-1- CN33-2




No continuity.

CNl (REC)


Continuity shall exist. CN33 (TAB)

- CN1 (REC)

CN33 (REC)



Standard:

CN31 (REC)

CN31-1 - CN31-2

CN31-1 - CN31-3



No continuity.


No continuity.


OK -

lnspection 3 Inspect continuity of the active Active fork leveling switch defect.

lnspection 1 lnspect the output signal of the active fork leveling switch.

lnspection 2

lnspection 4 lnspect continuity between CN1

NG Harness defect.

lnspect continuity of the active OK

I and CN33. 1 I OK I

NG

CN1 connector or controller


Inspect for slip off of the CN1 and NG , CN33 connectors.

fork levelinn switch wirinn. I- defect.

lnspection 5 lnspect the output signal of the lifting height switch.

After correction, check the backward tilting speed.

Touch tilt solenoid" and check the solenoid operating sound with the mast tilt to backward and with the fork raised to approx. 500 mm (19.6 in) with no load. (Check with the engine stopped.)*

OK I NG

Solenoid to be checked: - 2000. 10: No.2 solenoid 2000. 10 -: One unit of solenoid

- OK 1 Controller defect.

lnspection 6 Inspect continuity of the lifting Lifting height switch defect. height switch only.

.1 - 2000. 10: Control valve solenoid No.2 sticking defect. 2000.10 -: Control valve solenoid sticking defect.

lnspection 1 : lnspect the output signal of the active fork leveling switch.

Controller defect.


*: Since the solenoid may be hot after lifting operation, carefully

Analyzer: MAIN MENU + SAS MENU -ANALYZER MENU - IN OUT MENU - MAST DATA

prevent the hand from getting scalded.

Standard: MAST DATA (212)

KNOB OFF HEIGHT S W l ON

SW21 SW22 OFF OFF

KNOB


OFF


ON



Standard:



Standard:


Continuity shall exist. CN1-8 - CN1-23



No continuity

CN33-1 - CN33-2




No continuity

lnspection 5: lnspect the output signal of the lifting height switch.




CNl (REC)

CN33 (TAB)

- CN1 (REC)

CN33 (REC)


Standard: When the fork height is 500 mm (19.6 in). the LIFTING HEIGHT output shall be as follows: SW1: ON SW21: OFF SW22: OFF c


c @

KNOB OFF HEIGHT SW1 SWZ1 OFF ON

SW22 OFF


Standard:

CN31 (REC)

CN31-1 - CN31-2

CN31-1 - CN31-3



No continuity.


No continuity.


The mast does not perform fotwardlbackward tilt

Related Portion

I Without analyzer I

Tilt lever switch

Neither forward nor backward tilting fails.

disconnection. correction.

zi - - g 6

Inspection 1 OK Touch tilt solenoid No.1 Check the tilt lever switch (solenoid valve on the upper d

rear side (truck FWD) of the controlvalve for solenoid No. 1.

wiring for continuity. control valve) and check the

NG solenoid operating sound OK when the tilt lever is + Controller defect. operated.(Check with the engine in stopped state.)'

v I i

CN34

,, CNi-10 (MF, Tilt lever SW1 (forward))

m t-

Inspection 2 OK Inspection 3 Check continuity of the tilt Check continuity between Harness defect. lever switch alone (without CN1 and CN34. removal from the vehicle). vkK' CN34 connector defect. '

u < w a

lnspection 4 Check continuity of the tilt Tilt lever switch defect. lever switch alone (after removal from the vehicle).

* Since the solenoid may be hot after lifting operation, carefully prevent the hand from getting scalded.

defect.

+ Go to the next page.

CN 1

CNI-g (MR; Tilt lever SW2 (backward))

- CN34-1

~ ~ 3 4 - 2 -

CN1-23 (E02,S

L

Forward tilt switch

CN34-4 -

0 w

Backward tilt switch

m a CN34-3

Aqer correction, check the tilt CN34 connectors. operation.

OK ,

After repair, check backward CN34 connectors. tilting.

1 NG

lnspection 5 Inspect continuity of the forward Controller defect. tilt lever switch wiring.

Inspectton 6 lnspect continuity of the forward tilt lever switch only (mounted on Harness defect.

the vehicle). and CN34.


Inspect continuity of the Controller defect.

lnspection 8 lnspect continuity of the forward tilt lever switch only (removed from the vehicle).

lnspection 10 ,HI NG +

lnspect continuity of the backward tilt lever switch only

Inspect continuity between CN1 Harness defect.

(mounted on the vehicle). I i

CN34 connector defect. I Inspection 12 1

OK

Fotward tilt lever sw~tch mountlng defect.

NG

I lnspect continuity of the backward tilt lever switch only

(--%I Backward tilt lever switch defect. I

Forward tilt lever switch defect.

J. I Backward tilt lever switch 1

[ (removed from the vehicle).

1 mountina defect. I

I I

OK I

lnspection 1 : Check the tilt lever switch wiring for continuity. Turn the ignition switch OFF and disconnect CN1.

Standard:

lnspection 2: Check continuity of the tilt lever switch alone (without removal from the vehicle). Turn the ignition switch OFF and disconnect CN34.

CNl-10- CN1-23

CN1-9-CN1-23

Standard:

CNI (REC)

Tilt lever in neutral

No continuity

No continuity

CN34 (TAB)

Tilt lever in forward


No continuity

CN34-1- CN34-2

CN34-3 - CN34-4

lnspection 4: Check continuity of the tilt lever switch alone (after removal from the vehicle). Turn the ignition switch OFF and disconnect CN34.

Tilt lever in backward

No continuity


Tilt lever in forward


No continuity


No continuity

No continuity

lnspection 3: Check continuity between CN1 and CN34. Turn the ignition switch OFF and disconnect CN1 and CN34.

Standard:

Standard:

Tilt lever in backward

No continuity


CNI (REC)

@ CN34 (REC)

CN1-10 - CN34-1

CN 1-9 - CN34-3

CN1-23 - CN34-2

CN1-23 - CN344

lnspection 5: Inspect continuity of the foward tilt lever switch wiring. Turn the ignition switch OFF and disconnect CN1.





CN34-1 - CN34-2

CN34-3 - CN34-4

Standard:

CN34 (TAB)

When the backward tilt switch is pressed


No continuity

in free state



CNI-10-CNI-23

CN1 (REC)

When the forward tilt switch is pressed

No continuity

,Continuity shall exist.


No continuity

Tilt lever at forward


Inspection 6: lnspect continuity of the forward tilt lever switch only (mounted on the vehicle).


Standard:

CN34 (TAB)

CN34-1- CN34-2



Tilt lever neutral

No continuity




" CN1 (REC)

Inspection 8: ~ ~ 3 4 (REC) lnspect continuity of the forward tilt lever switch only (removed from the vehicle).

Turn the ignition switch OFF and disconnect CN34. Remove the forward tilt lever switch (upper-side switch on the control valve)

Standard:

CN34 (TAB)

CN34-1 - CN34-2

lnspection 9: lnspect continuity of the backward tilt lever switch wiring


Switch free


Standard:

Switch depressed

No continuity

CNl (REC) CNI-9 - CN1-23

Tilt lever neutral

No continuity



lnspection 10: lnspect continuity of the backward tilt lever switch only (mounted on the vehicle).


Standard:


CN34-3 - CN34-4



Tilt lever neutral

No continuity

CN34 (TAB)



- CNl (REC)

@ CN34 (REC)

lnspection 12: Inspect continuity of the backward tilt lever switch only (removed from the vehicle).

Turn the ignition switch OFF and disconnect CN34. Remove the backward tilt lever switch (lower-side switch on the control valve).

Standard:

CN34 (TAB)

CN34-3 - CN34-4

Switch free


Switch depressed

No continuity

n l * , lnspect the switch output signal when the tilt lever is operated.

Inspect slip off of the CN34 NG After correction, check the tilt operation.

I NG

Solenoid No.1 control valve on the upper rear side (truck FWD) of sticking defect. control valve) and check the solenold operat~ng sound when the tilt lever IS operated. (Chetk with the englne In stopped state.) Controller defect.

*: Since the solenoid may be hot after lifting operation, carefully prevent the hand from getting scalded.

lnspection 2 lnspect the switch output signal when the tilt lever is operated for

Controller defect. I I forward tilting. I I 1

After correction, check the forward CN34 connectors. tilting operation.

I NG

lnspection 3 Inspect continuity of the forward tilt Controller defect. lever. switch wiring.

lnspection 4 lnspect continuity of the forward tilt lnspect continuity between CN1 lever switch only Harness defect.

(mounted on the vehicle). I ' I


lnspect continuity of the forward tilt lever switch only (removed from the

Forward tilt lever switch defect.

vehicle).

Forward tilt lever switch mounting defect.

4 Go to the next page.

Continued

lnspection 7 lnspect the switch output signal when the tilt lever is operated

1 for backward tilting.

NG 1

+ Controller defect. OK I

I lnspect for slip off of the CN1 and CN34 connectors.

NG After correction, check the -1 backward tilting operation. I lnspection 8 Inspect continuity of the Controller defect. backward tilt lever switch wiring.

lnspection 9 lnspect continuity of the backward tilt lever switch only Harness defect.

(mounted on the vehicle). and CN34.

NG c 1

lnspection 11 lnspect continuity of the backward tilt lever switch only (removed from the vehicle).

-1 CN34 connector defect. I Backward tilt lever switch defect.

lnspection 1 : lnspect the switch output signal when the tilt lever is operated for backward tilting. Turn the ignition switch ON (stop the engine). Analyzer: MAlN MENU + SAS MENU -+ ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Standard:

lnspection 2: lnspect the switch output signal when the tilt lever is operated for forward tilting. Turn the ignition switch ON (stop the engine). Analyzer: MAlN MENU + SAS MENU + ANALYZER MENU -+ IN OUT MENU + MAST DATA

TILT FWD

TILT BWD

Standard:

Tilt lever neutral OFF

OFF

KNOB OFF HEIGHT SW1

SW21 SW22 OFF OFF TILT FWD

TILT BWD

Tilt lever at forward ON

OFF

Tilt lever at backward OFF

ON

Tilt lever neutral OFF OFF

Tilt lever at forward ON OFF

Inspection 3: lnspect continuity of the foward tilt lever switch wiring.


Standard:

CN1 (REC)

lnspection 4: lnspect continuity of the forward tilt lever switch only (mounted on the machine).


Continuity shall exist. CNl-10-CN1-23


Tilt lever neutral

No continuity

Standard:

CN% (TAB)

CN34-1 - CN34-2



Tilt lever neutral

No continuity




CN1 (REC)

@ CN34 (REC)

lnspection 6: lnspect continuity of the forward tilt lever switch only (removed from the machine).

Turn the ignition switch OFF and disconnect CN34. Remove the forward tilt lever switch (upper-side switch on the control valve).

Standard:

CN34 (TAB) lnspection 7:

lnspect the switch output signal when the tilt lever is operated for backward tilting.

CN34-1 - CN34-2

Turn the ignition switch ON (stop the engine). Analyzer: MAIN MENU -+ SAS MENU +ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Standard:

Switch free


Switch depressed

No continuity


SW21 OFF SWZZ OFF

TILT FWD

TILT BWD

Tilt lever neutral

OFF

OFF

Tilt lever at backward

OFF

ON

lnspection 8: lnspect continuity of the backward tilt lever switch wiring.


Standard:



Continuity shall exist. CN1-9- CN1-23

CN34-3 - CN34-4


Tilt lever neutral

No continuity


Tilt lever neutral

No continuity

CNl (REC)



lnspection 9: lnspect continuity of the backward tilt lever switch only (mounted on the vehicle).


Standard:

CN34 (TAB)

CNl (REC)

CN34 (REC)

lnspection 11: lnspect continuity of the backward tilt lever switch only (removed from the vehicle).

Turn the ignition switch OFF and disconnect CN34. Remove the backward tilt lever switch (lower-side switch on the control valve).

Standard:

CN34 (TAB)

CN34-3 - CN34-4

Switch free


Switch depressed

No continuity

a No error code is indicated although SAS warning lamp blinks. a "-" (underscore) is displayed on the hourmeter.

Related Portion

Estimated Causes: @ Connector contact defect @I Hourmeter defect @ Hourmeter harness defect @ Controller defect

lnspection 1 lnspect continuity between CN2 and CN41 and between CN2 and CN42.

OK 1 Controller defect.

lnspection 1 : lnspect continuity between CN2 and CN41 and between CN2 and CN42. Turn the ignition switch OFF and disconnect CN2, CN41, and CN42.

After correction, check indication. Inspect for slip off of the CN2, CN41, and CN42 connectors.


OK L I NG

NG

NG ,

Hourmeter defect. lnspection 2 Inspect the communication line.

lnspection 2: lnspect continuity between CN2 and CN41 and between CN2 and CN42. Turn the ignition switch ON (stop the engine).

Harness defect.

NG )

Analyzer: MAIN MENU + SAS MENU -+ ANALYZER MENU -+ IN OUT MENU + OTHER DATA Display the hourmeter time on the analyzer.

Standard: Same time as the time displayed on the hourmeter (0.1 hour shortage permissible).

CNsl (REC)

CN42 (REC)

VOLTAGE 12.4V HOURS 11223.3h RE-SET DIAG PIN CN

15-1 25

The SAS warning lamp is always lit.

Related Portion

Estimated Causes: @) Re-setting not complete @ SAS-ECU fuse defect @ Connector contact defect @ Power system harness defect

@ SAS lamp relay defect @ Low battery voltage @ Controller defect

- 2 E Q

- g V) a

I Re-setting complete (when the controller is replaced).

- 2 - c 8

Pi After re-setting, SAS lamp indication.

-- CN1-11 (IG, Power) CN6-3 - 2 m a I-

m 3

(UL-S)

Inspect the SAS-ECU fuse. After correction, SAS lamp indication.

o u -- 0

CN2

lnspect for slip off of the CN1, CN2, CN5, CN6, and CN41 connectors. After correction, SAS larnp indication. I

CN5-16 CN5 3m

CN41-1 u c

J.

lnspection 1 lnspect continuity between CN1 and CN6, between CN2 and CN5, between CN1 and the frame, between CN6 and the relay block, between CN5 and the relay block, and between CN5 and CN41.

CN1-24 (El, Main GND)CN5-22

CN1 Frame&, ICN5-1f CN2-1 UL-S ~ R N SAS lamp refay) d~5-2:

-- 6

+ Harness defect.

CNT~

$

lnspection 2 lnspect the supply voltage of the controller.

!$ +

!$ I-

J

2 a & g %i

Defect of the power supply harness before the relay block. I

-

I SAS-ECU fuse defect. Batteryvoltage defect. I

$ '

C N ~ --k

$ u

1


Inspection 3 lnspect the SAS larnp relay.

NG + SAS lamp relay defect.

Inspection 1 : lnspect continuity between CN1 and CN6, between CN2 and CN5, between CN6 and the relay block, between CN5 and the relay block, and between CN5 and CN41.

Turn the ignition switch OFF and disconnect CN1, CN5, CN6, CN41, and the SAS lamp relay.

Standard: CN1-11 - CN6-3: Continuity shall exist. CN1-24 - Frame: Continuity shall exist. CN1 (REC)

CN2-1 - CN5-2UCN5-17 (UL-S): Continuity shall exist. CN6-3 - SAS lamp relay terminal 2: Continuity shall exist. 1 2 3 4 5 6 7 8

9 10 11 12 13 4 15 16 CN5-21lCN5-16 (UL-S) - SAS lamp relay terminal 3: BEE3 CNZ (REC) Continuity shall exist. CN5-22lCN5-17 (UL-S) - SAS lamp relay terminal 1 : Continuity shall exist. CN5-21lCN5-16 (UL-S) - CN41-1: Continuity shall exist.

lnspection 2: lnspect the supply voltage of the controller. Turn the ignition switch ON (stop the engine).

Standard: CN1-11 - CN1-24: 11 - 16V

lnspection 3: lnspect the SAS lamp relay.

With analyzer: Turn the ignition switch ON (stop the engine).

- CN5 (TAB)

CN5 (TAB) (UL-S)

A

CN41 (REC) @ SAS lamp relay

CN1 (REC)

Analyzer: MAIN MENU + SAS MENU -+ANALYZER MENU +ACTIVE TEST Operate the SAS lamp forcibly.

Standard: OFF - Turned off

C ON - Lit C

@ Without analyzer:

The controller is defective if the lamp is kept lit even after replacing the SAS lamp relay.

ACTIVE TEST (212)

SPEED FAIL -OFFION

When the ignition switch is turned on, the SAS warning lamp is not lit.

Related Portion

Estimated Causes: @ SAS lamp bulb blown @ GAUGE fuse defect @ Connector contact defect

@ Power system harness defect @ SAS lamp relay defect @ Controller defect

I Check to see if the SAS larnp bulb is blown.

b - - e 'S B m" - d

&

After the bulb is replaced, SAS lamp indication.

CN5-22 - c 8

zm

Check to see if the combination meter fuse is After the fuse is replaced, SAS lamp blown. indication.

0 a w m +

CN41-1 L -nz 5 z z

CN2-1 1

(RLY, SAS 3

-- 8.g .

Inspection 1 lnspect continuity between CN2 and CN5, between CN5 and the relay block, and between CN5 and CN41.

lamp relay) CN2

CN41

J.

After correction. SAS larnp indication. lnspect for slip off of the CN5 and CN41 connectors.

-

Controller defect. -

NG

OK I

NG

I

lnspection 2 Inspect the SAS lamp relay.

Harness defect.

OK 1

NG * SAS lamp relay defect.

inspection 1 : lnspect continuity between CN2 and CN5, between CN5 and the relay block, and between CN5 and CN41.

Turn the ignition switch OFF and disconnect CN2, CN5, CN41, and the SAS lamp relay.

Standard: CN2-1 - CN5-22/CN5-17 (UL-S): Continurty shall exist. CN5-211CN5-16 (UL-S) - SAS lamp relay terminal 3: Continuity shall exist. C N ~ (REC) CN5-22lCN5-17 (UL-S) - SAS lamp relay terminal 1 : Continuity shall exist. CN5-211CN5-16 (UL-S) - CN41-1: Continuity shall exist. CN5 (TAB)

lnspection 2: lnspect the SAS lamp relay.

With analvzer

CN41 (REC)

CN5 (TAB) (UL-S)


Analyzer: MAIN MENU -. SAS MENU -. ANALYZER MENU -.ACTIVE TEST

Operate the SAS lamp forcibly. - Standard: 4- OFF - Turned off ON - Lit

c @

Without analyzer: The controller is defective if the lamp is kept lit even after replacing the SAS lamp relay.

ACTIVE TEST (Z2 )

LOCKLUP m%

15-1 29

No hourmeter indication

Related Portion

- -- CN37-2 m 0 C N 4 1 - 6 0 ~ 0

x 0 ~2 E. 0 - CN41 E 2 f

c n Frame -- .- o Z

.- m CN37 0 - c

d CN42-6 8 2 a E, = + 0

Estimated Causes: @ Hourmeter not started @ Connector contact defect @ Hourrneter harness defect

Inspection 1 lnspect continuity between CN37 and CN41, between CN37 and the frame, and between CN42 and the relay block.

Connect CN37 and check hourmeter indication.

Hourmeter started?

Hourmeter defect. 1

NG ,

NG

Inspection 1 : lnspect continuity between CN37 and CN41, between CN37 and the frame, and between CN42 and the relay block.

Harness defect.

Turn the ignition switch OFF and disconnect CN37, CN41, and GAGE fuse.

Standard: CN37 - CN41: Continuity shall exist. @ &13141516f -11112113j

CN37 - Frame: Continuity shall exist. Y

CN37 (REC) CN42 - Controller-side terminal of the GAUGE fuse in the relay block: CN~I (REC)


@ I ' - ' ~ 1 1 2 1 3 ) 4 ( 5 ) 6 1 17[819110111)1211

CN37 (TAB) CN42 (REC)

1 5-1 30

The buzzer is not interlocked with the SAS warning lamp.

Related Portion

Estimated Causes: @ Hourmeter not started @ Connector contact defect @ Hourmeter harness defect @ Buuer defect

- (RLY, SAS lamp relay)

Hourmeter started? Connect CN37 then check hourmeter indication. I

k - - g - C

8

lnspect for slip off of the CN2, CN5, CN37, and CN43 connectors. After correction, check error indication.

- - 3 n A d Z

- CN2-1 CN5-22lCN5-17 (UL-S) - 1

7

Buuer defect.

CN2

CN43-2 -

lnspection 1 lnspect continuity between CN2 and CN5, between CN5 and the relay block, between CN43 and the relay block, between CN5 and CN37, and between CN37 and CN43.

lnspection 1 : lnspect continuity between CN2 and CN5, between CN5 and the relay block, between CN43 and the relay block, between CN5 and CN37, and between CN37 and CN43. Turn the ignition switch OFF and disconnect CN2, CN5, CN37, CN43, and the GAUGE fuse in the relay block.

m O

1 2 3 4 5 6 7 8

Standard: 9 lo IT 12 13 14 15 16

CN2-1 - CN5-22/CN5-17 (UL-S): Continuity shall exist. EEEm

CN2 (REC) CN5-21 ICN5-16 (UL-S) - SAS lamp relay terminal 3: Continuity shall exist. CN5-22lCN5-17 (UL-S) - SAS lamp relay terminal 1 : & CN5 (TAB)

m 2 CN5-211CN5-16 (UL-S)

OK

NG

Continuity shall exist. . ~ ~ 4 3 (REC)

CN43-2 - Controller-side terminal of the GAUGE fuse in the relay block: Continuity shall exist. CN5-21 /CN5-16 (UL-S) - CN37-1: Continuity shall exist. - . - . . . - , - . . - . . CN37 (TAB)

^ - 1 ' ? -

EB CN5 (TAB) (UL-S)

2 z

--

2 M a m

Harness defect.

o

CN5

CN37 CN43 - CN37-1

3

ZI; o: 2 c- -

m o 2 CN43-1 I

15-1 31

a When the ignition switch is turned on, the swing lock lamp is not lit.

Related Portion

I

- 7-

CN42-9 8

m CN2-Q (OUT1, Swing lock lamp output) - Q

Controller 2 E a- O m 5 g .-

CN2 CN42-6 f B

E -A 8

CN42

- Relay block

Estimated Causes: @) Swing lock lamp bulb blown @ GAUGE fuse defect @) Connector contact defect @ Swing lock lamp harness defect @ Controller defect

I Inspect for slip off of the CN2 and CN42 After correction, check swing lock lamp connectors. indication.

Replace the bulb then check swing lock lamp indication.

Check to see if the swing lock lamp bulb is blown.

*

NG


Replace the fuse then check swing lock lamp indication.

Check to see if the combination meter fuse is blown.

v

L I

Inspection 1 : lnspect continuity between CN2 and CN42 and between CN42 and the relay block. Turn the ignition switch OFF and disconnect CN2, CN42, and the GAGE fuse in the relay block.

OK ) ,

I NG

NG

Inspection 1 Inspect continuity between CN2 and CN42 and between CN42 and the relay block.

Standard: CN2-9 - CN42-9: Continuity shall exist. - cN2 (REC) CN42-6 - Controller-side terminal of the GAUGE fuse in the relay block: Continuity shall exist.

CN42 (REC)

OK I

NG +

Harness defect.

15-1 32

CONNECTOR LAYOUT

Note: WIH: Wire harness The SAS controller sequence is explained in section 16 (Page 16-25).

CONNECTOR DIAGRAMS

TAB E.2

TAB

J RLY I

YB1 16 I TRG 1

WISPLICE-A WISPLICE-A

CN3 one fork height switch CN4 (UL-S)

CN3 No fork height switch

TAB

TAB

Note: *:Terminal not related to SAS

I F - #

TAB

1181 B-Y I * I

CN5 (UL-S)

h o . 1 2 3 4 5

-6 7 8 9 10 11 12 13 14 1 5 16 17 18 19 20 ,21 22 23

TAB

C R-L R-B R-W

G B-Y - G-Y R-Y G W

W LG R-G LGR

R Y

B-0 V-G B-Y

B R

P G L-W W-B

J * * * * * I * * * * I * * * sic I * * * *

SAS LAMP RLY-3 (8) SAS LAMP RLY-1 (+S) SAS LAMP RLY-4 (L)

. .-

3 R-W A r, *

No. 1 2 3

,11 12 13 i d

C R-L R-B R-W

LG-R R Y

R-n

J * * * - 8 -

I I *

7 , w

* * * *

5 6 7

G-Y R-Y G-w

TAB

No. I

. 2 3 4 5 6 7 8 9

,10 11

E c

Phortin : + Phortin : -

fiEC

TAB rn

1 G-B CN2-4 -S 2 G R CN2-5

'40. 1

- 2

4 5

, 6 7

C BIB-W B-w B-R B-w P-6 6-Y G-B L-

6-L W-L G

TAB E C

J * * CNl-I1 * CN2-10 * CN2-13 * * * *

pjqziG 2 W-B BODY EARTH03

C B-

B-w

B-R

B-W P

6-Y L

CNl l

J * * F=ECU-IG (L)

SAS-LAMP RLY (-S: * * *

TAB F7K:

* * * * 8 9 10 11

TAB FGC

--WlL -

W-L L-w

REC TAB E C No. C J 1 BR CN3-5 5V or GND 1 P C CN1-8

Vout Out ut si nal 2 G-Y CN3-2 GND or 5V 2 BR WEPLICE-A CN3-1

TAB

In case of one fork height switch TAB

N o 1 2 3

J Power sup~lv Sensor output

GND

No. 1 2 3

Fork height switch

REC

C - - -

C G R Y-G BR 2 B Forward tilt side -

4 B Backward tilt side - WISPLICE-A

J CN1-14 CN1-17

WISPLICE-A A

TAB REC

No. 1 2 3

NO./ c I J J COM NC NO

C BR-W

L L-B

No. 1 2

NO.] c I J J CN3-3 CN3-7 CN3-4

C B R

3 W

1 I BR / WISPLICE-A 1 1 L G I CN1-7 I

I 9 1 L-Y 1 CN2-15

I I

12 1 B-R I FUSEECU-IG 13 1 * 141 L-B I CN2-16

I

SAS Lamp relay (Base side)

J CN5-22/17 (UL-S) F=ECU-IG (CN6-3) CN5-21/16 (UL-S) CN5-23/18 (UL-S) *

No. . 1 2 3 4 5

C L-W B-R F-G W-B

-

APPENDIX Page

SST LlST ..................................................................... 16-2

SERVICE STANDARDS LlST ...................................... 16-6

WIRING DIAGRAM ...................................................... 16-19

SST LIST

Illustration

-*'%& -+

/ ?'

Part No.

09082-7602-71 (09082-00050)

09216-76002-71 (0921 6-00021 )

09228-76004-71 (09228-0750 1 )

0931 6-76008-71 (0931 6-6001 1 )

09319-76001-71 (0931 9-60020)

09509-76002-71 (09509-55020)

09509-76003-71 (09509-55030)

09608-76003-71 (0~08-04031)

0971 7-76001-71 (0971 7-2001 0)

0971 8-76001 -71 (0971 8-2001 0)

Part Name

TOYOTA electrical tester

Belt tension gage

Oil filter wrench

Transm~sson & transfer bearing replacer

Output shaft needle roller bearing remover

Rear wheel nut

wrench

I

Rear wheel bearing nut wrench

I

Front hub inner bearing cone replacer

I

Brake shoe return spring remover

Brake shoe return spring replacer

0

1 2

0

0

I

I

0

I

I l l

4

0

0

5

0

I

0

I

I

6

I

I

7

I

I

Section

I

I

0

0

I

I

I

I

8 1 1 1 2 1 3 1 4 1 5

0

I

I

I

I

0

1

lllustrat~on

&-

e+Z*-J %+

OOaa

/ /

Part No.

0990576002-71 (099050001 2)

09950-76014-71 (0995040011)

09950-76003-71 (09950-5001 2)

09950-7601 8-71 (09950-6001 0)

09950-7601 471 (09950-60020)

09950-76020-71 (09950-7001 0)

0901 0-201 11 -71

09010-23320-71

09150-1 70-71

09220-22001-71

1

Part Name

Snap ring No. 1 expander

Puller B set

Puller set

Replacer set

Replacer set NO. 2

Handle set

Eng~ne unit hanger

Eng~ne with transmiss~on hanger

Transm~ss~on bear~ng replacer

Torque converter clutch drum sprlng remover & replacer

O

0

1 2

0

0

O

0

O

0

0

0

4

0

0 0 0 0

0

0 0 0 0

0

5

0

I

6

0

0

I

7

O

I

Section

8

I

I

0

I

0

0

I

1 1 1 2 1 3 1 4 1 5

0

0

I I

I

G I , , e 8 : I n

Differential carrier

09370-1 041 0-71

09370-20270-71

replacer Front axle bearing

Drive pinion bearing replacer 0

0

0

Illustration

P

d @ @

Part Name

Brake hold down sprlng remover and replacer

Oil control valve spring remover and replacer

Inner mast stopper

Cyl~nder cap remover and replacer

Tilt cyl~nder cap remover and

I rep'acer

Part No.

0951 0-31 960-71

0961 0-1 0161 -71

0961 0-22000-71

09620-1 01 00-71

09630-1 01 1 0-71

0

0

6 9 @-

6 7 -

1

0981 0-20172-71 Jo~nt pin remover

I

09630-23600-71

09631 -22000-71

2

Deep socket A

Wear scale cham

4

0

5

0 1

6

0 0

Section

7 8

0

11

O

12

O

0

1 3 1 4

0

15

O

SERVICE STANDARDS LIST ENGINE

Engine

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

4Y

1 DZ-ll

Pnl-2 ton series Cu2-3 ton series

Pn3 ton series

1 ton series

2-3 ton series

Gasoline engine

Diesel engine

Idling speed tpm 800 +:

750 + 25

2600 k 50

2800 + 50

2600 r 50

2800 + 50

300 or less

200 or less

No-load static maximum speed rpm

Air cleaner

4Y

1DZ-ll

Vacuum switch conduction test (conduction base) Pa (mm H20) [rnm Hg]

Full relief engine speed down rPm

Gasoline engine

Diesel engine

Radiator

Standard

Standard

Radiator cap opening pressure kPa (kgf/cm2) (psi)

2942 +. 294 (300 + 30) [22.1 + 2-21

7473 + 569 (762 + 58) [56.0 + 4.31

Standard 88 + 14.7 (0.9 + 0.15) [13 + 2.11

Battery

Electrolyte specific gravity (at 20°C [68"4) Standard 1 1.280

Alternator

Fan belt tension (when pushed with 98 N (1 0 kg9 [22 lbfj mrn (in)

Fan belt tension (when measured with a tension gage (SST)) N (kg9 [Ibfl

4Y

1 DZ-ll

4Y

1 DZ-ll

Accelerator pedal

Standard

Standard

Standard

Standard

Pedal roller height (from accelerator Gasoline engine bracket to top of roller)

m m (in) Diesel engine

8 - 13 (0.31 - 0.51)

t 294 - 490 (30 - 50) [66 - 11 01

324 - 559 (33 - 57) 173 - 1261

Standard

Standard

68 (2.68)

73 (2.87)

TORQUE CONVERTER

Tightening torque Unit: N-m (kgf-cm) [ft-lbfl

Engine mounting nut

Torque converter end plate set bolt

Transmission cover & control valve ASSY

Regulator valve spring free length mm (in)

lnching valve spring free length (plug side) mm (in)

lnching valve spring free length (valve side) mm (in)

Accumulator valve spring free length (inner side) mm (in)

Accumulator valve spring free length (outer side) mm (in)

FIR shift valve spring free length

Safetyvalve spring free length

1-2 shift valve

Torque converter and oil pump

Standard

Standard

Standard

Standard

Standard

Standard

Drive plate set plate (for engine crankshaft connection)

53.9 - 99.0 (550 - 101 0) [39.8 - 73.11

49.0 - 78.5 (500 - 800) I36.2 - 57.91

56.9 - 64.7 (580 - 660) f42.0 - 47.71

76.5 - 93.2 (780 - 950) [56.4 - 68.71

14.7 - 21.6 (150 - 220) [ I 0.9 - 15.91

29.4 - 44.1 (300 - 450) [21.7 - 32.61

4Y

1 DZ-ll

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Drive plate set bolt (for torque converter connection)


88.8 (3.496)

84.4 (3.323)

- 1999.11 : 70.3 (2.768) 1999. 11 - : 64.2 (2.528)

- 1999. 11 : 66.8 (2.630) 1999. 11 - : 61 .O (2.402)

49.9 (1.965)

47.4 (1.866)

86.0 (3.386)

81.7 (3.21 7)

11 7.0 (4.606)

11 1.2 (4.378)

53.5 (2.106)

50.8 (2.000)

59.8 (2.354)

56.8 (2.236)

44.0 (1.732)

41.8 (1.646)

Oil pump driven gear to pump body clearance mm (in)

Oil pump driven gear to crescent clearance mm (in)

Oil pump drive gear to crescent clearance mm (in)

Pump body to each gear clearance mm (in)

Oil pump drive gear bushing to stator shaft clearance mm (in)

Limit

Limit

Limit

Limit

Limit

0.3 (0.01 2)

0.4 (0.01 6)

t 0.1 (0.004)

0.15 (0.0059)

Transmission

Main shaft thrust clearance mm (in)

Output shaft thrust clearance mm (in)

Each clutch shaft to seal ring clearance mm (in)

Clutch disc thickness mm (in)

Clutch plate thickness mm (in)

Camber plate warpage height mm (in)

Clutch disc to backing plate clearance mm (in)

clutch piston return spring free length mm (in)

Standard

Standard

Limit

Standard

Limit

Standard

Limit

Standard .

Limit

Standard

Limit

0.20 - 0.62 (0.0079 - 0.0244)

0.03 - 0.51 (0.0012 - 0.0201)

0.2 (0.008)

2.6 (0.102)

2.3 (0.091)

2.0 (0.079)

1.8 (0.071)

3.4 (0.134)

3.1 (0.122)

4-disc type 0.8 - 1.3 (0.031 - 0.051) 5-disc type I .0 - 1.6 (0.039 - 0.063)

63.4 (2.496)

58.5 (2.303)

Measurement and tests

Stall speed rpm

Main pressure kPa (kgflcm2) [psi]

Clutch pressure kPa (kgflcm2) [psi]

Torque converter pressure (outlet pressure) kPa (kgf/cm2) [psi]

4Y

- 1DZ-11

At idling

At 2000 rpm

At idling

At 2000 rpm

At 2000 rpm

Tightening torque Unit: N-m (kgf-crn) [fi-lbfl

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Oil pump set bolt

Stator shaft set bolt

Oil strainer set bolt

Oil pan set bolt

Idle shaft (2-speed)

Idle shaft set bolt (2-speed)

Front cover set bolt (2-speed)

Side cover set bolt

Transmission cover (upper cover) set bolt

2100

21 00

735 - 1324 (7.5 - 13.5) [ lo7 - 1921

834 - 1373 (8.5 - 14.0) [I21 - 1991

735 - 1324 (7.5 - 13.5) [ I 07 - 1921

834 - 1324 (8.5 - 13.5) [I21 - 1921

49 - 441 (0.5 - 4.5) [7.1 - 641

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

9.81 - 18.6 (100 - 190) [7.24 - 13.81

9.81 - 15.7 (100 - 160) [7.24 - 11.61

9.81 - 15.7 (100 - 160) [7.24 - 11.61

5.9 - 7.8 (60 - 80) [4.34 - 5.791

4.90 - 9.81 (50 -100) [3.62 - 7.241

3.92 - 6.86 (40 - 70) [2.89 - 5.061

18.63 - 30.40 (1 90 - 31 0) [ I 3.75 - 22.431

3.92 - 6.86 (40 - 70) [2.89 - 5.061

M6: 9.6 - 14.4 (98 - 145) [7.09 - 10.51 M8: 9.81 - 15.7 (100 - 160) [7.24 - 11.61

DIFFERENTIAL .- Differential

Ring gear backlash mm (in)

Differential pinion bore mm (in)

Spider outside diameter mm (in)

Pnl -2 ton series Cu2'3 series

Pn3 ton series

Pnl-2 ton series Cu2.3 ton series

Pn3 ton series


Pn3 ton series

Side gear thrust washer thickness mm (in)

Pinion gear thrust washer thickness mm (in)

Drive pinion bearing starting torque

N-rn (kgf-cm) [ft-lbfl

Standard

Standard

L~~~~

Standard

Limit

&tndard

Limit

Standard

Limit

0.2 - 0.3 (0.008 - 0.012)

0.3 - 0.4 (0.012 - 0.016)

22.12 (0.8709)

22.22 (0.8748)

24.67 (0.971 3)

24.77 (0.9752)

22.00 (0.8661)

21.75 (0.8563)

24.50 (0.9646)

24.25 (0.9547)

Standard

Limit

Standard

Limit

Standard

1.6 (0.063)

1.3 (0.051)

1.6 (0.063)

1.0 (0.039)

8.82 - 13.23 (90 - 135) [6.51 - 9.771


Drive pinion lock nut

Drive pinion rear cover set bolt

Differential carrier cover set bolt

Ring gear set bolt

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Differential upper case set bolt

343.2 - 392.3 (3500 - 4000) [253.23 - 289.401

15.7 - 19.6 (160 - 200) [11.6 - 14.51

29.4 - 44.1 (300 - 450) [21.71 - 32.561

127.4 - 176.5 (1 300 - 1800) [94.06 - 130.231

43.2 - 53.9 (440 - 550) [31.83 - 39.791

86.3 - 103.0 (880 - 1050) [63.67 - 75.971

117.7 - 137.3 (1200 - 1400) 186.82 - 101.291

29.4 - 44.1 (300 - 450) [21.7 - 32.61

88.3 - 117.7 (900 - 1200) [65.1 - 86.821


Pn3 ton series

Differential case bearing cap set bolt

Differential front cover set bolt

Differential carrier set bolt

16-10

FRONT AXLE

Front axle shaft hub

Front axle bearing starting force N (kgf) [Ibfl

Standard 25.5 - 72.6 (2.6 - 7.4) [5.7 - 16.31

Tightening torque Unit:

Hub bolt set nut

Bearing lock nut Stopper bolt

Bearing lock nut stopper screw

Axle shaft set bolt

Front wheel hub nut (single tire)

Front wheel hub nut (double tire)

N.m (kgf-cm) [ft-lbfj

Pnl ton series

Pn2 ton series

Pn3 ton series Cu2.3 ton series

Pnl -2 ton series and Cu2.3 ton series: - 2000. Pn3 ton series

Pnl-2 ton series and Cu2.3 ton series: 2000. 8 - Pnl-2 ton series


Pnl ton series

Pn2 ton series


Pnl-2 ton series

Pn3 ton series

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

68.6 - 88.3 (700 - 900) [50.6 - 65.11

147.1 - 186.3 (1 500 - 1900) [ I 08.5 - 137.473

166.7 - 205.9 (1 700 - 21 00) [I 23.0 - 151.91

14.7 - 21.6 (1 50 - 220) [ I 0.9 - 15.91

2.0 - 3.9 (20 - 40) [ I .49 - 2.891

69.0 - 88.0 (700 - 900) [50.7 - 65.11

98.0 - 127 (1 000 - 1300) [72.35 - 94.061

108.5 - 196.1 (1 100 - 2000) [79.59 - 144.71

176.5 - 392.3 (1 800 - 4000) [ I 30.2 - 289.41

294.2 - 588.4 (3000 - 6000) [217.1 - 434.11

176.5 - 392.3 (1 800 - 4000) [ I 30.2 - 289.41

294.2 - 588.4 (3000 - 6000) [217.1 - 434.11

16-1 1

REAR AXLE

Rear axle ASSY

Rear axle ASSY front to rear clearance mm (in)

Rear axle center pin bushing inside diameter mm (in)

Standard

Limit

0.7 (0.028) or less

52.0 (2.047)

Rear axle hub and steering knuckle

Rear axle hub starting force (at hub bolt) (kg9 [Ibfl

Rear axle wheel starting force (at outer periphery of the wheel)

N (kg9 [Ibfl

series

Pn2.3 ton series

Cu2.3 ton series

King pin outside diameter mm (in)

Steering knuckle starting force (at front end of knuckle) N (kg9 [lbfl

Standard

Standard

15 - 39 (1.5 - 4.0) [3.3 - 8.81

15 - 44 (1.5 - 4.5) [3.3 - 9.91

9.8 - 29 (1 .O - 3.0) [2.2 - 6.61

Limit

Standard

27.8 (1.094)

19.3 (2.0) [4.4] or less

Rear axle cylinder

Rear axle cylinder piston rod outside diameter mm (in)

Rear axle cylinder piston rod bend mm (in)

Limit

Limit

Limit

Limit

Limit

Rear axle cylinder inside diameter mm (in)

49.92 (1.9654)

0.5 (0.01 7)

76.35 (3.0059)

80.35 (3.1634)

84.40 (3.3228)

Pnl ton series Cu2-3 ton series

Pn2 ton series

Pn3 ton series

STEERING

Rear wheel alignment

*cf. Parts & Service News Ref. No. GE0013 of Nov. 1,2000

0 + 4 (0+0.16) Toe-in mm (in)

Hydrostatic steering valve ASSY

Standard

Relief pressure kPa (kgf/cm2) [psi]

Relief pressure* (7FGCU20.25 series, June 2000-) kPa (kgf/cm2) [psi]


Standard

Sandard

Axle bracket cap set bolt

King pin lock bolt and lock nut

804017 (82;;) [I 1 70:

6370:4,90 (65:;) [920;;q


Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Divided rim bolt set nut

Mast jacket set nut

Steering wheel set nut

Steering valve ASSY set bolt

Steering valve end cap set screw

11 7.7 - 166.7 (1 200 - 1700) [86.82 - 123.01

44.1 - 53.9 (450 - 550) [32.6 - 39.81

29.4 - 44.1 (300 - 450) 121.7 - 32.61

49.0 - 68.4 (500 - 700) [36.2 - 50.71

88 - 11 8 (900 - 1200) [65.1 - 86.81

11 6.7 - 21 5.8 (1 700 - 2200) [I 23.00 - 159.171

88.3 - 157.0 (900 - 1600) [65.1 - 11 5.81

88.3 - 157.0 (900 - 1600) [65.1 - 11 5.81

11 7.6 - 196 (1 200 - 2000) [86.82 - 144.71

176.4 - 392 (1 800 - 4000) [I 30.2 - 289.41

11 7.6 - 196 (1 200 - 2000) [86.82 - 144.71

11 7.6 - 196 (1 200 - 2000) l86.82 - 144.73

Pnl ton series

Pn2.3 ton series

Standard

Standard

Standard

Standard

Rear axle cylinder rod guide set nut

Rear axle cylinder set bolt

34.3 - 53.9 (350 - 550) [25.3 - 39.81

24.5 - 58.8 (250 - 600) [18.1 - 43.41

29.4 - 39.2 (300 - 400) [21.7 - 28.91

24 - 36 (245 - 367) [I 7.7 - 26.63

Divided rim

Side ring rim

Divided rim

Side ring rim

Divided rim

Side ring rim

Hub nut

Pnl ton series

Pn2 ton series

Pn3 ton series

BRAKE

Front brake (Pnl ton series)

Hold down spring free length mm (in)

Anchor to shoe spring free length mm (in)

Strut to shoe spring free length mm (in)

Adjuster spring free length mm (in)

Brake lining length mm (in)

Wheel cylinder to piston clearance mm (in)

Brake drum inside diameter mm (in)

Standard

Standard

Limit

Standard

Standard

Limit

Standard

Limit

Limit

Standard

Limit

25.5 (1 .OW)

102.2 (4.024)

Replace if any clearance in coil exists.

19.7 (0.776)

99.4 (3.91 3)

Replace if any clearance in coil exists.

4.9 (0.193)

1 .O (0.039)

0.125 (0.00492)

254 (1 0.00)

256 (1 0.08)

Front brake (Pn2.3 ton series)


Actuator spring free length mm (in)

Anchor to shoe spring free length mm (in)



Brake lining thickness mm (in)



Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Limit

Standard

Limit

32.3 (1.272)

29.1 (1.146)

124.5 (4.902)

No clearance between coil turns

106 (4.17)


23 (0.91)

20 (0.79)

86 (3.39)


7.0 (0.276)

2.0 (0.079)

0.145 (0.00571)

31 0 (12.20)

312 (12.28)

Front brake (Cu2.3 ton series)


Anchor to shoe spring free length (On the side of lining Wlpin) mm(in)

Anchor to shoe spring free length (On the side of lining LI pin) mm(in)


Standard

Standard

Limit

Standard

Limit

Standard

25.5 (1.004)

139.3 (5.484)


121.8 (4.795)


31.4 (1.236)


Brake lining thickness mm (in)



Standard

Limit

Standard

Limit

Limit

Standard

. Limit

126.0 (4.961)


5.7 (0.224)

1 .O (0.039)

0.1 5 (0.0059)

31 0 (1 2.20)

31 2 (1 2.28)

Parking brake

Parking brake operating force (measured at center of lever knob) N (kgf) [Ibfl

Standard 147 - 196 (15 - 20) [33 - 441

Brake pedal

Brake pedal height (from toe board: with pad) mm (in)

Brake pedal play mm (in)

Brake pedal depressed height (with pad) mm (in)

Brake master cylinder push rod play mm (in)

lnching pedal stroke until interlocking with brake mm (in)

Inching cable set dimension mm (in)

lnching pedal play (until start mm (in) of inching lever movement)

Standard

Standard

Standard

Standard

Standard

Standard

Standard

150- 155. (5.91 -6.10)

3 - 7 (0.12 - 0.28)

90 (3.54) or more

1 (0.04)

Pnl ton series: 35 - 46 (1.38 - 1.81) Others: 25 - 36 (0.98 - 1.42)

17.5 (0.689)

1 - 3 (0.04 - 0.12)

Tightening torque Unit: N-m (kgf-cm) [ft-lbf]

Backing plate set bolt Standard

Standard

Standard

Standard

Standard

Wheel cylinder set bolt

137 - 196 (1 400 - 2000) [ I 01.3 - 144.71

7.85 - 11.77 (80 - 120) [5.79 - 8.681

14.7 - 19.6 (1 50 - 200) [ I 0.85 - 14.47

17.7 - 26.5 (1 80 - 270) [ I 3.0 - 19.51

6.8 - 15.8 (69 - 161) 15.0 - 11.61

Pnl ton series

Pn2-3 ton series

Cu2-3 ton series

Brake master cylinder set nut

--

MATERIAL HANDLING SYSTEM

MAST

Natural drop test

Natural drop mm (in)

Mast adjustment (V mast)

Limit

M~~~

Lift bracket rollers

WISAS: 45 (1.77) LISAS: 90 (3.54)

Natural forward tilt test -

Natural forward tilt mm (in)

Inner mast roller clearance mm (in)

Outer mast roller clearance mm (in)

Middle and lower lift roller clearance mm (in)

Side roller clearance mm (in)

Mast strip to inner mast clearance mm (in)

Pnl ton series

Pn.Cu2 ton series

Pn.Cu3 ton series

Standard

Standard

Standard

Standard

Oil leak test

0 - 0.8 (0 - 0.031)

0 - 0.5 (0 - 0.017)

Pnl.2 ton series: 0 - 0.8 (0 - 0.031)

Pn3 ton series and Cu2,3 ton series: 0 - 0.5 (0 - 0.020)

Pnl.2 ton series: 0 - 0.6 (0 - 0.024)

Pn3 ton series and Cu2.3 ton series: 0 - 0.5 (0 - 0.020)

Limit

Standard

Standard

Lift cylinder oil leak amount cm3

Tilt cylinder oil leak amount (total for lift and tilt) cm3

0.5 - 1 .O (0.020 - 0.039)

Fork

WISAS: 15 (0.59) or less USAS: 30 (1.1 8) or less


WISAS: 25 (0.98) or less USAS: 45 (1 .TI) or less

Fork front end misalignment mm (in)

Standard

WJSAS: 8 (0.49) or less USAS: 16 (0.98) or less


Limit I 0 (0.39)

Tightening torque Unit: N-m (kgf-cm) [ft-lb]

Mast support cap set bolt

Back rest set bolt

Chain adjusting nut

Standard

Standard

Standard

68.6 - 107.9 (700 - 1100) [50.7 - 79.571

99.54 - 184.9 (101 5 - 1885) [73.42 - 136.43

49.0 - 78.0 (500 - 800) [36.2 - 57.91

Lift cylinder 0

Piston rod outside mm (in) diameter


Pnl ton series

Pn.Cu2 ton series

Pn-Cu3 ton series

Pnl ton series

Pn.Cu2 ton series

Pn.Cu3 ton series

Piston rod bend mm (in)

Limit

Limit

Limit

Limit

Limit

Limit

34.85 (1.3720)

41.92 (1.6504)

44.92 (1.7685)

44.65 (1.7579)

50.20 (1.9764)

55.35 (2.1791)

Limit 2.0 (0.079)

Rear lift cylinder (FV-FSV-QRI)



Piston rod bend

Pnl ton series

Pn.Cu2 ton series

Pn-Cu3 ton series

Cu2 ton series

Pnl ton series

Pn.Cu2 ton series

Pn.Cu3 ton series

Cu2 ton series

FV

FSV

FV

FSV

FV

FSV

QFV

FV

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

31.92 (1.2567)

Except H 4800 mm (1 89 in): 34.85 (1.3720)

H 4800 mm (1 89 in): 34.92 (1.3784)

34.82 (1.3709)

41.92 (1.6504)

39.92 (1.571 7)

44.92 (1.7685)

- Dec. 1999: 50.72 (1.9969) Dec. 1999 -: 49.92 (1.9654)

45.20 (1.7795)

Except H 4800 mm (1 89 in): 44.65 (1.7579)

H 4800 mm (1 89 in): 45.20 (1.7795)

50.20 (1.9764)

50.40 (1.9843)

55.35 (2.1 791)

55.20 (2.1 732)

- Dec. 1999: 63.85 (2.51 38) Dec. 1999 -: 63.35 (2.4941)

2.0 (0.079)

FSV 1 Limit

FV

FSV

FV - FSV

QN

mm (in)

Limit

Limit

Limit

Limit

Limit

Limit

OIL PUMP

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

FV

FSV

FV

FSV

FV

FSV

QW

N

FSV

FV

FSV

FV

FSV

QN

mm (in)

Front lift cylinder (FV-FSV-QFV)

Piston rod outside diameter mm i n


Piston rod bend

Oil pump ASSY

50.72 (1.9969)

Except H 4800 mm (189 in): 50.72 (1 -9969)

H 4800 mm (1 89 in): 49.92 ( I .9654)

50.72 (1.9969)

? t ?- t

70.35 (2.7697)

Except H 4800 mm (1 89 in): 70.35 (2.7697)

H 4800 mm (1 89 in): 70.35 (2.7697)

75.35 (2.9665)

T 85.40 (3.3622)

t 75.35 (2.9665)

2.0 (0.079)

Tilt cylinder

Pnl ton series

Pn.Cu2 ton series

Pn.Cu3 ton series

Cu2 ton series

Pnl ton series

pn.cu2 ton series

Pn.Cu3 ton series

Cu2 ton series

Bushing axial length mm (in)

Gear shaft outside diameter mm (in)

70.35 (2.7697)

29.92 (1.1780)

1 .O (0.039)



Piston rod bend mm (in)

Limit

Limit

Limit

Limit

Limit


26.411 (1.03980)

18.935 (0.74547)

Body inside surface flaw depth mm (in) / Limit

Flow regulator valve

Tilt cylinder piston castle nut

Tilt cylinder cover

0.1 (0.004)

Standard

Standard

Standard

58.8 - 68.7 (600 - 700) [43.4 - 50.71

225.4 - 284.2 (2300 - 2900) [166.4 - 209.81

284.4 - 421.7 (2900 - 4300) [209.8 - 311. I ]

OIL CONTROL VALVE

Oil control valve

Tightening torque Unit: N-m (kgf-em) [ft-lbfl

181 42 ty (1 85%) 12631 ?q 1 5690ty (1 60:;) [2276?3

Relief set pressure kPa (kgf/cm2) [psi]

SAS controller set bolt

Swing lock cylinder pin set bolt

Tilt angle sensor set bolt

Load sensor

Speed sensor set bolt

Fork height switch ASSY set bolt

Lift

Tin

Standard

Standard

Standard

Standard

Standard

Standard

Standard

standard

10 - 15 (102 - 153) [7.3 - 11.11

Upper side: 10.5 - 24.5 (1 07 - 250) 17.74 - 18.11 Lower side : 1 6.2 - 37.8 (1 62 - 378) [I 1.7 - 27.31

7.0 - 16.0 (71 - 163) [5.1 - 11.81 35.3 - 43.1 (360 - 440) 126.0 - 31.81

3.0 - 7.0 (31 - 71) [2.2 - 5.11 14.4 - 33.6 (147 - 343) [10.6 - 24.81

WIRING DIAGRAM

NAME BATTERY, RELAY BOX ELECTRIC SHIFT TIC (1 SPEED) STARTl NG BACK UP LAMP BACK BUZZER SMART ALARM ELECTRIC SHIFT TIC (2SPEED) STARTl NG BACK UP LAMP BACK BUZZER SMART ALARM ELECTRIC SHIFT TIC (1 SPEED, EZ PEDAL) STARTl NG BACK UP LAMP BACK BUZZER SMART ALARM CHARGING SAS ECU FUEL SYSTEM (GASOLINE) IGNITION SYSTEM FUEL SYSTEM (LPG EXCLUSIVE) IGNITION SYSTEM FUEL SYSTEM (LPG CONVERTIBLE) IGNITION SYSTEM FUEL SYSTEM (DIESEL) HEAD L4MP TIC OILTEMPERATURE INDICATOR STROBE LIGHT COMBINATION METER

COMBINATION METER (EZ PEDAL) STOP LAMP TAIL LAMP CLEARANCE LAMP TURN SIGNAL LAMP

VEHICLE SPEED CONTROL SYSTEM COMPARTMENT LIGHT REAR WORKING LAMP ENGINE SHUT DOWN DEVICE LPG WARNING INDICATOR GLOW

GLOW (EZ PEDAL)

G

-

-

-

0 - -

1

D

0 - -

-

-

0

- -

-,01-

LP

O O O O -

-

O O O O -

O O O O -

0

0 1 -

GRP 0 0 0 0 0 0 0

0 0 0 0 0 0 0

O O O O O O O

0 0 0 0 0 0 0 O O O O O O O

-

0 - - -

- 0 - -

O O O O O O O

O O O O O O O

O O O O O O O 0 0 0 0 - - O O O O O O O

O O O O O O O

0 0 0 0 0 0 0

0 0 0 -

- -

LPS

-

-

0

-

-

-

-

- - - -

GS

0

-

-

-

Page

16-20

16-21

16-22

1 6-23

16-24 16-25

16-26

16-27

16-28

16-29 16-30

16-31

1 6-32 1 6-33 1 6-34

1 6-35

1 6-36 16-37

16-38

16-39 1 6-40 16-41 16-42

DS

-

-

-

- 0 -

-

-

- -

0 -

I 0 - y GAUGE I O A R -G HOUR M T E R WATER T B P I NO, F E L I M) BAC% EUZZER (OPT). BACK UP L W (OPT) b\

8 - Y A R-Y I DOUBLE T/C OIL TEMTRATURE INOICATOR (OPT) r TURN 7 . 5 A

0- Y - 0-v - n TLRN SIGNAL LA14 (0Pn \ -

0-Y I G N 7 . 5 ~ 8-0 ALTERNATOR aow PLUO TIMER

z N E L CUT SOL GASa lNE SCL L w SOL IGNITION COIL VSCS ECU (OPT)

F U S E A L T- S OoUBLE ECU- I G 7 . 5 A 0 - R

SAS ECU

FUSE I G N

ELECTRIC SHIFT T/C

STARTER RELAY (COIL) . aov PLUG T I WR

8 s I G L RELAY B O X

A L T I

t€AD LAW, E T E R ILLWINAT ION

TA l L L A W (OPT) . CREALANCE L A W

STOP LAM' (OPT)

aow PLUG r u-a DSI

STARTER

ALTERNATC#? SENSING

HORN .

F L HEAD HEAD AOA R - L

OC < m

[L In 4 3 m m V)

F L GLOW

R - 8

G R-W

7 . 5 A - v m 6 0 A B 0 - R

(U-n 08 aow PLUG RELAY

F L AM1 (u* DB) 4 0 A w- L w- L B

I

-I F L A L T I W-L STARTER RELAY A L T- S 5A

r W-L 8 0 A

G-Y

ELECTRIC SHIFT TIC (ISPEED), STARTING, BACK UP LAMP, BACK BUZZER, SMART ALARM

UdODMZUleX)vB

d l

,Y'

4 1 8 - A

111

3 -1 a

I 3 a f

2- >I- \v, v a

. A 85

x a m w 0 2 ai m 0

111

0 . . U) oz

% 0 0 W - a I I C J 2 2 K 5;: w -- a > a a I-

d > m I I V)

LL m m

(7 8-8

( s d i .so 'so- in )

( d v o 'dl *a -9-in A

ELECTRIC SHIFT TIC (2SPEED), STARTING, BACK UP LAMP, BACK BUZZER, SMART ALARM

o k l 3 z a s nve

m R-A e n e-n I ' I

ELECTRIC SHIFT TIC (1 SPEED, EZ PEDAL), STARTING, BACK UP LAMP, BACK BUZZER, SMART ALARM

V

/ (UL-G. D. LP. G A P ) I

Dl SCONKCT SV ( UL-GB. DS. LP8)

C O N N E C T O R FOR S A S E C U

FUEL

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM

FUEL SYSTEM (LPG CONVERTIBLE), IGNITION SYSTEM

FUEL SYSTEM (DIESEL)

I (a- in ) A

HEAD LAMP

TIC OILTEMPERATURE INDICATOR, STROBE LIGHT (LdO)

A S NYOH xnv

v (UL-G. D. LP. G A P )

B-Y 1 1 1 I - I

B A T T E R Y DISCONNECT SV ( UL-GS. DS. LPG)

T-@T SAS - WARNING

L M RELAY - OUT I

L - 0

ln > V-G LOCK IN0 ln HRMI

'? "RM, V-R

' - 8 ElnRm) P - L $ 1 1

V- B -,\ Y - 8 1 1 1 // &)

mXR MET , 1

F E L WARNING (OPT)

Y - G

v - e I 111 I WATER T W I

BODY SENDER E A R T H

I w L G == L G - B

v- B

BODY E A R T H

PARK I f f i BRAKE SW (OPT)

i G-V , I 1 I R " R *

(UL-D. DS) a w TIMR GLOW

BODY E A R T H 0

V-G , V- G A

( G. L P. G A P) WATER T E W SV (OPT) OVER S A T (OPT) (0. LP. G A P ) R " R

\ R- V ( D) M C K (VSCS) (OPT)

R- G "r

1

BRAKE (OPT)

s 1 m E L A Y a m IMI

PARKING BRAlQ sv

R R 111 % t

mi} BODY EARTH V- G , V-G

x

( O. LP. GAP) WATER T W SV WT) OVER l€AT (OPT)

16-34

STOP LAMP

TAIL LAMP, CLEARANCE LAMP

TURN SIGNAL LAMP

1 6-38

COMPARTMENT LIGHT, REAR WORKING LAMP

ENGINE SHUT DOWN DEVICE

16-40

LPG WARNING INDICATOR

1641

GLOW

CC+BINATION METER (cH4RG€ LAHI)

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7fgu15-32 7fdu15-32 7fgcu20-32 repair manual cu027-2 (2)