Toyota Forklift 8FG, D, GK, DK Shop Manual
Uploaded by
Danilo .TheodoroToyota Forklift 8FG, D, GK, DK Shop Manual
Uploaded by
Danilo .TheodoroFOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT 8FG/
8FD10~30 series. Please use this manual for providing quick, correct servicing of the
corresponding forklift models.
This manual deals with the above models as of August 2006. Please understand that
disagreement can take place between the descriptions in the manual and actual
vehicles due to change in design and specifications. Any change or modifications
thereafter will be informed by Toyota Industrial Equipment Parts & Service News.
For the service procedures of the mounted engine, read the repair manuals listed
below as reference together with this manual.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT 8FG/8FD10~30
VOL.2 REPAIR MANUAL (No. CE049)
TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE
REPAIR MANUAL (No. CE663)
TOYOTA INDUSTRIAL EQUIPMENT 1DZ-II ENGINE
REPAIR MANUAL (No. CE664)
TOYOTA INDUSTRIAL EQUIPMENT 2Z ENGINE
REPAIR MANUAL (No. CE665)
SEC INDEX_vol1.fm 1 ページ ２００６年８月３１日 木曜日 午後９時１２分
SECTION INDEX
NAME SECTION
GENERAL 0
ENGINE 1
CLUTCH 2
TORQUE CONVERTER & TRANSMISSION 3
MANUAL TRANSMISSION 4
PROPELLER SHAFT 5
DIFFERENTIAL 6
FRONT AXLE 7
REAR AXLE 8
STEERING 9
BRAKE 10
BODY 11
MATERIAL HANDLING SYSTEM 12
MAST 13
CYLINDER 14
OIL PUMP 15
OIL CONTROL VALVE 16
MINI LEVER·JOYSTICK 17
SAS/OPS 18
SST LIST·SERVICE STANDARDS LIST 19
MULTIFUNCTION DISPLAY (OPT) 20
ELECTRICAL SYSTEM TROUBLESHOOTING 21
WIRING DIAGRAM E
0-1
GENERAL
Page Page
EXTERIOR VIEWS ..................0-2 WIRE ROPE SUSPENSION 0
ANGLE LIST........................ 0-17
VEHICLE MODEL....................0-3 1
FRAME NUMBER....................0-5 SAFE LOAD FOR
EACH WIRE ROPE 2
HOW TO USE SUSPENSION ANGLE ........ 0-17 3
THIS MANUAL.......................0-7
COMPONENTS WEIGHT ...... 0-18 4
EXPLANATION METHOD ...........0-7
RECOMMENDED
TERMINOLOGY ........................0-8 LUBRICANT 5
ABBREVIATIONS ......................0-8 QUANTITY & TYPES .......... 0-19 6
OPERATIONAL TIPS ..............0-9 LUBRICATION CHART ......... 0-21 7
HOISTING THE VEHICLE .....0-10 PERIODIC 8
MAINTENANCE................... 0-23
CIRCUIT TESTER..................0-11
INSPECTION METHOD ........... 0-23 9
STANDARD BOLT & NUT
TIGHTENING TORQUE .......0-13 PERIODIC REPLACEMENT 10
OF PARTS AND 11
BOLT STRENGTH CLASS
IDENTIFICATION METHOD ....0-13 LUBRICANTS...................... 0-28
12
PRECOAT BOLTS .................0-16
13
HIGH PRESSURE
HOSE FITTING 14
TIGHTENING TORQUE .......0-16
15
16
17
18
19
20
21
E
0-2
EXTERIOR VIEWS
0-3
VEHICLE MODEL
Classification
Vehicle Model Transmission Type Engine
Series Model 0
30-8FG10 M/T 1
4Y Gasoline
1.0 ton model
32-8FG10 T/C
2
60-8FD10 M/T
1DZ-II Diesel
3
62-8FD10 T/C
4
30-8FG15 M/T
1 ton series 4Y Gasoline 5
32-8FG15 T/C
1.5 ton model 6
60-8FD15 M/T
62-8FD15 T/C
1DZ-II Diesel
7
32-8FG18 T/C 4Y Gasoline
8
1.75 ton model
62-8FD18 T/C 1DZ-II Diesel 9
30-8FG20 M/T 10
4Y Gasoline
32-8FG20 T/C 11
60-8FD20 M/T 12
2.0 ton model 1DZ-II Diesel
62-8FD20 T/C
13
70-8FD20 M/T
2Z Diesel
14
72-8FD20 T/C
2 ton series 15
30-8FG25 M/T
4Y Gasoline 16
32-8FG25 T/C
17
60-8FD25 M/T
2.5 ton model
62-8FD25 T/C
1DZ-II Diesel
18
70-8FD25 M/T
19
2Z Diesel
72-8FD25 T/C 20
21
E
0-4
Classification
Vehicle Model Transmission Type Engine
Series Model
30-8FG30 M/T
4Y Gasoline
32-8FG30 T/C
60-8FD30 M/T
3 ton series 3.0 ton model 1DZ-II Diesel
62-8FD30 T/C
70-8FD30 M/T
2Z Diesel
72-8FD30 T/C
32-8FGK20 T/C 4Y Gasoline
K2.0 ton model
62-8FDK20 T/C 1DZ-II Diesel
K2 ton series
32-8FGK25 T/C 4Y Gasoline
K2.5 ton model
62-8FDK25 T/C 1DZ-II Diesel
32-8FGK30 T/C 4Y Gasoline
K3 ton series K3.0 ton model
62-8FDK30 T/C 1DZ-II Diesel
30-8FGJ35 M/T
4Y Gasoline
32-8FGJ35 T/C
J3.5 ton series J3.5 ton model
70-8FDJ35 M/T
2Z Diesel
72-8FDJ35 T/C
Note:
Control specification of 4Y engine is as follows.
STD: 4Y-M (carburetor specification)
OPT: 4Y-E (electronically controlled specification)
0-5
FRAME NUMBER
Frame No. Punching Position
0
1
2
3
4
5
6
7
8
9
10
11
Punching position
12
Series Engine Vehicle model Punching format Series Engine Vehicle model Punching format
13
30-8FG10 30-8FG20
32-8FG10 32-8FG20 14
4Y 308FG25-10011
4Y 30-8FG15 308FG18-10011 30-8FG25 15
32-8FG15 32-8FG25
16
32-8FG18 60-8FD20
1 ton series
60-8FD10 62-8FD20 17
2 ton series 1DZ-II 608FD25-10011
62-8FD10 60-8FD25
18
1DZ-II 60-8FD15 608FD18-10011 62-8FD25
62-8FD15 70-8FD20
19
62-8FD18 72-8FD20 20
2Z 708FD25-10011
70-8FD25
21
72-8FD25
E
0-6
Series Engine Vehicle model Punching format
30-8FG30
32-8FG30
4Y 308FGJ35-10011
30-8FGJ35
32-8FGJ35
3 ton, 60-8FD30
J3.5 ton 1DZ-II 608FD30-10011
series 62-8FD30
70-8FD30
72-8FD30
2Z 708FDJ35-10011
70-8FDJ35
72-8FDJ35
32-8FGK20
4Y 32-8FGK25 308FGK30-10011
32-8FGK30
K2·K3 ton
series
62-8FDK20
1DZ-II 62-8FDK25 608FDK30-10011
62-8FDK30
0-7
HOW TO USE THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by
explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLY·INSPECTION·REASSEMBLY
Tightening torque unit T = N·m (kgf·cm) [ft·lbf]
• Step Nos. are partially sometimes omitted in
illustrations.
• When a part requiring tightening torque
instruction is not indicated in the illustration, the
part name is described in the illustration frame.
T = 46.1 ~ 48.1
(470 ~ 490)
[34.0 ~ 35.5]
Disassembly Procedure
1 Remove the cover. [Point 1]
2 Remove the bushing. [Point 2] Ã Operation explained later
3 Remove the gear.
Point Operations
[Point 1] Explanation of key point for operation with an illustration
Disassembly:
Ã
Put a match mark when removing the pump cover.
[Point 2]
Inspection:
Measure the bush inside diameter.
Limit: 19.12 mm (0.7528 in)
0-8
2. How to read components figures
(1) The components figure uses the illustration in the
(Example)
parts catalog for the vehicle model. Please refer
to the catalog for checking the part name. 3201
The number at the right shoulder of each
components figure indicates the Fig. number in FIG number in parts catalog
the parts catalog.
3. Matters omitted in this manual
(1) This manual omits description of the following jobs, but perform them in actual operation:
(a) Cleaning and washing of removed parts as required
(b) Visual inspection (partially described)
TERMINOLOGY
Caution:
Important matters of which negligence may cause hazards on human body. Be sure to observe them.
Note:
Important items of which negligence may cause breakage or breakdown, or matters in operation procedure
requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASC Auto Speed Control RR Rear
ATT Attachment Society of Automotive
SAE
FR Front Engineers (USA)
J/B Junction block SAS System of active stability
ASSY Assembly SOL Solenoid
LH Left hand SST Special service tool
LLC Long life coolant STD Standard
M/T Manual transmission T= Tightening torque
NMR No-load maximum speed Torque converter &
T/C
OPS Operator Presence Sensing transmission
OPT Option ccT Number of teeth (c c)
O/S Oversize U/S Undersize
PS Power steering W/ With
R/B Relay block L/ Less
RH Right hand
0-9
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, packings 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
Jack up points are provided in the front and rear portions of the
vehicle. Always apply jacks at the jack up points.
Front side:
A circular groove to accept a screw jack is provided under the
front side of the frame.
When a garage jack is used, jack up at the bottom surface of
the frame.
For screw
jack Rear side:
A circular groove to accept a screw or garage jack is provided
at the bottom surface of the counterweight.
For screw
jack
For garage
jack
0-10
6. Hydraulic oil level inspection procedure
Checking the oil amount inside tank, as shown below, contact
top of cap on retainer. (Do not push it into retainer.)
HOISTING THE VEHICLE
When hoisting the vehicle, sling with wire rope(s) at the mast hook
holes and the rear side of the head guard.
When hoisting by the head guard, remove the roof cap and attach
wire ropes to the positions as shown in the illustration.
0-11
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.
Forward direction Reverse direction (1) Analog circuit tester
Measurement result example
Tester range: kΩ range
Analog type
Continuity exists
Forward
11 kΩ
No continuity
Reverse
∞
(2) Digital circuit tester
Forward direction Reverse direction Measurement result example
Tester range: MΩ range
Digital type
No continuity
Forward
1
Continuity exists
Reverse
2 MΩ
0-12
2. Difference in result of measurement with circuit tester
The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage. The diode
characteristics are shown in the figure below.
(mA) 6 The resistance values of the same semiconductor measured with
two types of circuit testers having different power supply voltages
5
are different.
4
Germanium This manual describes the results of measurement with a circuit
Forward current
diode
3 tester whose power supply voltage is 3.0 V.
2 Silicon diode
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (V)
3. Difference in measurement result by measurement range (analog type)
In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the
circuit resistance. Even when the same diode is measured, the measurement result varies with the
measurement range.
Always use the range described in the repair manual for
measurement.
Resistor Meter
0Ω
Current flow
Variable resistor
Resistor
Range: x 10 (SW1)
Resistor
Range: x 1 (SW2)
Power source: 1.5 V
Red Black
0-13
STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. For tightening torque of hexagon head bolt, welded bolt and stud bolt with the standard bearing surface, identify
bolt class based on the below chart and then determine using the tightening torque table.
2. For tightening torque of hexagon flange bolts, identify bolt class based on the below chart and then determine
using the tightening torque table.
3. For tightening torque of nuts, check the mating bolt and use the method 1.
BOLT STRENGTH CLASS IDENTIFICATION METHOD
Identification by Bolt Shape
Shape and class Class
4 = 4T
5 = 5T
Bolt head No. 6 = 6T
7 = 7T
8 = 8T
No mark 4T
Hexagon head bolt
Two protruding lines 5T
Three protruding lines 7T
Four protruding lines 8T
Welded bolt 4T
No mark 4T
Stud bolt
Grooved 6T
0-14
Identification by Part No.
Part No. Shape
Length (mm) Diameter
Hexagon head bolt
Diameter (mm)
Length
Class
Diameter
Length (mm)
Stud bolt
Diameter (mm)
Length
Class
Tightening Torque Table
Diameter Pitch Specified torque
Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.4 55 4
8 1.25 13 130 9
10 1.25 25 260 19
4T
12 1.25 47 480 35
14 1.5 75 760 55
16 1.5 113 1150 83
6 1.0 6.5 65 5
8 1.25 16 160 12
10 1.25 32 330 24
5T
12 1.25 59 600 43
14 1.5 91 930 67
16 1.5 137 1400 101
6 1.0 7.8 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6T
12 1.25 72 730 53
14 1.5 108 1100 80
16 1.5 172 1750 127
6 1.0 11 110 8
8 1.25 25 260 19
10 1.25 52 530 38
7T
12 1.25 95 970 70
14 1.5 147 1500 108
16 1.5 226 2300 166
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8T
12 1.25 108 1100 80
14 1.5 172 1750 127
16 1.5 265 2700 195
0-15
Identification by Bolt Shape (Hexagon flange bolt)
Class 4.8T 6.8T 8.8T 10.9T 11.9T
No mark
Hexagon flange bolt
— —
No mark
Tightening Torque Table (Hexagon flange bolt)
Diameter Pitch Specified torque
Class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.5 56 4
8 1.25 13 130 9
10 1.25 27 280 20
4.8T
12 1.25 50 510 37
14 1.5 78 800 58
16 1.5 120 1220 88
6 1.0 7.5 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6.8T
12 1.25 71 720 52
14 1.5 110 1120 81
16 1.5 170 1730 125
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8.8T
12 1.25 110 1120 81
14 1.5 175 1780 129
16 1.5 270 2750 199
6 1.0 15.5 160 12
8 1.25 38 390 28
10 1.25 80 820 59
10.9T
12 1.25 145 1480 107
14 1.5 230 2350 170
16 1.5 360 3670 266
6 1.0 17.5 180 13
8 1.25 42 430 31
10 1.25 89 910 66
11.9T
12 1.25 160 1630 118
14 1.5 260 2650 192
16 1.5 400 4080 295
0-16
PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the following
cases:
(1) After it is removed.
(2) When the precoat bolt is moved (loosened or tightened)
Seal lock agent
by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable
tightening torque range. If the bolt moves, retighten it
according to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded portion
of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth
to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before
installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Standard tightening torque N·m (kgf·cm) [ft·lbf] Hose inside
of screw Standard Tightening range diameter mm (in)
7/16 — 20UNF 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
9/16 — 18UNF 34 (350) [25.3] 32 ~ 36 (330 ~ 370) [29.3 ~ 26.8] 9 (0.35)
3/4 — 16UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 — 14UNF 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
7/8 — 14UNF 78 (800) [57.9] 74 ~ 82 (740 ~ 840) [53.5 ~ 60.8] 15 (0.59)
1·1/16 — 12UNF 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
1·5/16 — 12UNF 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
PF1/4 25 (250) [18.1] 24 ~ 26 (240 ~ 270) [17.4 ~ 19.5] 6 (0.24)
PF3/8 34 (350) [25.3] 32 ~ 36 (330 ~ 370) [23.9 ~ 26.8] 9 (0.35)
PF1/2 59 (600) [43.4] 56 ~ 62 (570 ~ 630) [41.2 ~ 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 ~ 123 (1140 ~ 1250) [82.5 ~ 90.4] 19 (0.75)
PF1 137 (1400) [101.3] 130 ~ 144 (1330 ~ 1470) [96.2 ~ 106.4] 25 (0.98)
0-17
WIRE ROPE SUSPENSION ANGLE LIST
Suspension Suspension
Lifting angle Tension Compression Lifting angle Tension Compression
method method
0° 1.00 time 0 time 90° 1.41 time 1.00 time
90°
1.0 tf
tf
41
1.
2t 2t
30°
30° 1.04 time 0.27 time 120° 2.00 time 1.73 time
tf
120°
1.04
f
2t
2t 2t
60° 1.16 time 0.58 time
60°
f
6t
1.1
2t
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
Unit: N (tf) [lbf]
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
0° 0° 30° 60° 90° 0° 30° 60° 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0.32 in)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 mm
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0.4 in)
[11.69] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379] [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0.56 in)
[21675] [3087] [6174] [5954] [5292] [4190] [12348] [11907] [10584] [8379]
0-18
COMPONENTS WEIGHT
Component Weight kgf (lb)
4Y 134 (295)
Engine 1DZ-II 162 (357)
2Z 212 (467)
M/T (Dry clutch) 34 (75)
M/T (Oil clutch) 43 (95)
Transmission
T/C (1 speed) 62 (137)
T/C (2 stator T/C) 130 (287)
1.0 ton model Approx. 465 (1025)
1.5 ton model Approx. 770 (1698)
1.75 ton model Approx. 900 (1985)
2.0 ton model Approx. 1165 (2569)
2.5 ton model Approx. 1520 (3352)
Counter weight
3.0 ton model Approx. 1915 (4223)
K2.0 ton model Approx. 1260 (2778)
K2.5 ton model Approx. 1650 (3638)
K3.0 ton model Approx. 1995 (4400)
J3.5 ton model Approx. 2215 (4890)
1 ton series Approx. 310 (684)
V mast ASSY L/backrest and fork 2 ton series Approx. 410 (904)
(with lift cylinder, max. lifting height: 3 ton, K3 ton series Approx. 500 (1103)
3000 mm (118 in)) K2 ton series Approx. 400 (882)
J3.5 ton series Approx. 600 (1323)
0-19
RECOMMENDED LUBRICANT QUANTITY & TYPES
Description Application Quantity l (US gal) Classification Type
Motor oil
API
Gasoline 4Y 4.0 (1.06) SAE30
SH, SJ, SL, SM
SAE10W-30
Engine
1DZ-II 7.9 (2.09) Diesel engine oil
API
Diesel SAE30
2Z 9.0 (2.38) CE, CF, CF-4
SAE10W-30
API Hypoid gear oil
GL-4 SAE85W-90
M/T 3.6 (0.95) Cold area spec:
API
Transmission Gear oil
GL-3
SAE75W-90
T/C (1 speed) 8.0 (2.11)
ATF GM Dexron® II
T/C (2 stator T/C) 9.0 (2.38)
1 ton series 5.8 (1.53)
2 ton series 6.1 (1.61)
K2 ton series 5.8 (1.53) API Hypoid gear oil
Differential
K3 ton series 6.1 (1.61) GL-4 SAE85W-90
3 ton series,
8.2 (2.16)
J3.5 ton series
1 ton series 30 (7.9)
2 ton series 33 (8.7)
Hydraulic oil
K2 ton series, ISO
(V mast, max. lifting height 33 (8.7) Hydraulic oil
K3 ton series VG32
3000 mm (118 in))
3 ton series,
34 (9.0)
J3.5 ton series
1 ton series 45 (11.9)
K2 ton series,
55 (14.5)
Fuel tank K3 ton series —— ————
2·3 ton series
60 (15.8)
J3.5 ton series
Proper quantity
SAE J-1703
Brake and clutch line All models Reservoir Tank ——
DOT-3
0.2 (0.05)
• MP grease
Chassis parts All models Proper quantity —— • Molybdenum
disulfide grease
• LLC 30-50% mixture
(for winter or
allseason)
Coolant
Attached Table 1 Coolant volume LLC • Coolant with
(excluding reservoir tank)
rustinhibitor
(for spring, summer
and autumn)
0.47 (0.124)
Coolant (Reservoir Tank) All models ↑ ↑
(at Full level)
0-20
Note:
Since the hydraulic oil volume varies with the mast specification, be sure to check finally with the level
gauge.
Attached Table 1 Coolant volume Unit: l (US gal)
Engine Transmission 1 ton series K2·K3 ton series 2 ton series 3·J3.5 ton series
M/T 8.2 (2.16) 8.2 (2.16) 8.3 (2.19) 8.3 (2.19)
4Y
T/C 8.4 (2.22) 8.4 (2.22) 8.5 (2.24) 9.7 (2.56)
M/T 6.8 (1.80) 6.8 (1.80) 7.0 (1.85) 7.0 (1.85)
1DZ-II
T/C 7.0 (1.85) 7.0 (1.85) 8.4 (2.22) 8.4 (2.22)
M/T 7.9 (2.09) 7.9 (2.09)
2Z
T/C 8.1 (2.14) 9.3 (2.46)
0-21
LUBRICATION CHART
Manual Transmission Model
(14) F F (14)
(1) B B (1)
(13) F F (13)
(3) A A (3)
(4) E E C C (2)
(12) A A (15)
C C (5)
(10) F F (19)
(16) F D D (8)
(7) A B B* (9)
(6) A A (7)
(17) A A (6)
(18) A A (17)
(11) F A (18)
I
II
III
IV
*: For the engine oil grades listed below, change oil every 500 hours.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above
{ Inspection
z Replacement
I Inspect every 8 hours (daily)
A MP grease
II Inspect every 40 hours (weekly)
B Engine oil
III Inspect every 250 hours (6 weeks)
C Hypoid gear oil
IV Inspect every 1000 hours (6 monthly)
D Hydraulic oil
V Inspect every 2000 hours (annual)
E Brake fluid
F Molybdenum disulfide grease
1 Chain 11 Rear axle beam rear pin
2 Differential 12 Tilt steering locking mechanism
3 Front wheel bearing 13 Mast support bushing
4 Brake and clutch master cylinder 14 Tilt cylinder front pin
5 Transmission case 15 Propeller shaft
6 Rear wheel bearing 16 Swing lock cylinder lower pin (SAS spec.)
7 Steering knuckle king pin 17 Tie rod end pin
8 Oil tank 18 Rear axle cylinder end pin
9 Engine crank case 19 Gear shift lever
10 Rear axle beam front pin
0-22
Torque Converter & Transmission Model
(14) G G (14)
(1) B B (1)
(13) G G (13)
(3) A A (3)
(4) F F C C (2)
(12) A A (15)
(10) G E E (5)
(16) G D D (8)
(7) A B B* (9)
(6) A A (7)
(17) A A (6)
(18) A A (17)
(11) G A (18)
I
II
III
IV
*: For the engine oil grades listed below, change oil every 500 hours.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above
{ Inspection
z Replacement
I Inspect every 8 hours (daily)
A MP grease
II Inspect every 40 hours (weekly)
B Engine oil
III Inspect every 250 hours (6 weeks)
C Hypoid gear oil
IV Inspect every 1000 hours (6 monthly)
D Hydraulic oil
V Inspect every 2000 hours (annual)
E Automatic transmission fluid
F Brake fluid
G Molybdenum disulfide grease
1 Chain 10 Rear axle beam front pin
2 Differential 11 Rear axle beam rear pin
3 Front wheel bearing 12 Tilt steering locking mechanism
4 Brake master cylinder 13 Mast support bushing
5 Torque converter case 14 Tilt cylinder front pin
6 Rear wheel bearing 15 Propeller shaft
7 Steering knuckle king pin 16 Swing lock cylinder lower pin (SAS spec.)
8 Oil tank 17 Tie rod end pin
9 Engine crank case 18 Rear axle cylinder end pin
0-23
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 Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ENGINE
Proper starting and abnormal noise I ← ← ←
Rotating condition at idling M ← ← ←
Rotating condition during acceleration M ← ← ←
Exhaust gas condition I ← ← ←
Main body Air cleaner element C ← ← ←
Valve clearance (IDZ-II·2Z) M* M
Compression M
Cylinder head bolt loosening T
Muffler rubber mount I
PCV system Clogging and damage in PCV valve and piping I ← ← ←
Governor No-load maximum rpm M ← ← ←
Oil leak I ← ← ←
Lubrication
Oil level I ← ← ←
system
Clogging and dirt of oil filter I ← ← ←
Fuel leak I ← ← ←
Operation of carburetor link mechanism I ← ← ←
Dirt and clogging of fuel filter and element I ← ← ←
Fuel system
Injection timing M ←
Injection nozzle injection pressure and spray status M
Draining of sedimenter I ←
Coolant level in radiator and leak I ← ← ←
Rubber hose degradation I ← ← ←
Cooling system Radiator cap condition I ← ← ←
Fan belt tension, looseness and damage I ← ← ←
Radiator rubber mount I
Filter I ←
DPF muffler Inline filter (for back pressure sensor) I ← ←
DPF valve C
Pipe and joint gas leak I ← ← ←
Pipe and joint damage I ← ← ←
LPG fuel system Regulator tar removal I ← ← ←
LPG container installation section looseness and
I ← ← ←
damage
0-24
Inspection Period Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Exhaust gas concentration measurement
M ← ← ←
(carbon monoxide and hydrocarbon)
Exhaust system piping looseness and damage I
3-Way catalytic Vacuum piping damage I ← ← ←
converter system Vacuum sensor damage I
Coolant temperature sensor damage I
Injector damage and cleaning (LPG vehicle) I
Register damage (LPG vehicle) I
Actuator damage I ← ←
Travel and load
Axle pedal sensor and switch damage I ← ←
handling control
Traveling speed sensor damage I
POWER TRANSMISSION SYSTEM
Clutch pedal play M ← ← ←
Abnormal sound and functioning (connection) I ← ← ←
Clutch Clutch master cylinder function and leak I ← ← ←
Fluid level I ← ← ←
Oil clutch mechanism function and leak (OPT) I ←
Leak I ← ← ←
Manual Fluid level I ← ← ←
transmission Gear function and abnormal noise I ← ← ←
Damage of shift lever cable I
Leak I ← ← ←
Differential Oil level I ← ← ←
Bolt loosening T
Leak I ← ← ←
Fluid level I ← ← ←
Torque Operating mechanism function and looseness I ← ← ←
converter &
transmission Control valve and clutch functions I ← ← ←
Inching valve function I ← ← ←
Stall and hydraulic pressure measurement M ←
Loose joint T ← ←
Propeller shaft Looseness at spline connections I
and axle shaft Looseness of universal joint I
Twisting and cracks of axle shaft I
DRIVE SYSTEM
Tire inflation pressure M ← ← ←
Tire cuts, damage and uneven wearing l ← ← ←
Loose rim and hub nuts T ← ← ←
Wheels
Tire groove depth M ← ← ←
Metal chips, pebbles and other foreign matter
l ← ← ←
trapped in tire grooves
0-25
Inspection Period Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Rim, side bearing and disc wheel damage I ← ← ←
Abnormal sound and looseness of front wheel
I ← ← ←
Wheels bearing
Abnormal sound and looseness of rear wheel
I ← ← ←
bearing
Front axle Cracks, damage and deformation of housing I
Cracks, damage and deformation of beam I
Rear axle Looseness of axle beam in vehicle longitudinal
M
direction
STEERING SYSTEM
Play and looseness I ← ← ←
Steering wheel
Function I ← ← ←
Oil leak I ← ← ←
Steering valve
Looseness of mounting T ← ← ←
Oil leak I ← ← ←
Power steering Mounting and linkage looseness I ← ← ←
Damage of power steering hose I
King pin looseness I ← ← ←
Knuckle
Cracks and deformation I
BRAKING SYSTEM
Play and reserve M ← ← ←
Brake pedal
Braking effect I ← ← ←
Operating force I ← ← ←
Parking brake Braking effect I ← ← ←
Linkage and cable looseness and damage I ← ← ←
Brake pipe Leak, damage and mounting condition I ← ← ←
Reservoir tank Leak and fluid level I ← ← ←
Master cylinder
Function, wear, damage, leak and mounting
and wheel I
looseness
cylinder
Clearance between drum and lining M ← ← ←
Wear of shoe sliding portion and lining I
Drum wear and damage I
Brake drum and
Shoe operating condition I
brake shoe
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Deformation, cracks and damage I
Backing plate
Loose mounting T
0-26
Inspection Period Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I ← ← ←
Forks Misalignment between left and right fork fingers I ← ← ←
Cracks at fork root and welded part I*1
Deformation and damage of each part and crack at
I ← ← ←
welded part
Mast and lift bracket looseness I ← ← ←
Mast and lift Wear and damage of mast support bushing I
bracket
Wear, damage and rotating condition of rollers I ← ← ←
Wear and damage of roller pins I
Wear and damage of mast trip I ← ← ←
Tension, deformation and damage of chain I ← ← ←
Chain lubrication I ← ← ←
Chain and chain
Elongation of chain I
wheel
Abnormality of chain anchor bolt I ← ← ←
Wear, damage and rotating condition of chain wheel I ← ← ←
Various
Abnormality and mounting condition of each part I ← ← ←
attachments
HYDRAULIC SYSTEM
Loosening and damage of cylinder mounting T ← ← ←
Deformation and damage of rod, rod screw and rod
I ← ← ←
end
Cylinder operation I ← ← ←
Cylinder Natural drop and natural forward tilt (hydraulic drift) M ← ← ←
Oil leak and damage I ← ← ←
Wear and damage of pin and pin support I ← ← ←
Lifting speed M ← ← ←
Uneven movement I ← ← ←
Oil pump Oil leak and abnormal sound I ← ← ←
Oil level and contamination I ← ← ←
Hydraulic oil tank Tank and oil strainer C ←
Oil leak I ← ← ←
Loose linkage I ← ← ←
Control lever
Operation I ← ← ←
Oil leak I ← ← ←
Oil control valve Relief pressure measurement M
Relief valve and tilt lock valve functions I ← ← ←
Oil leak I ← ← ←
Hydraulic piping Deformation and damage I ← ← ←
Loose joint T ← ← ←
0-27
Inspection Period Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
ELECTRICAL SYSTEM
Cracks on distributor cap I ← ← ←
Spark plug burning and gap I ← ← ←
Distributor side terminal burning I ← ← ←
Ignition timing
Distributor cap center piece wear and damage I ← ← ←
Plug cord internal discontinuity I
Ignition timing M ←
Starting motor Pinion gear meshing status I ← ← ←
Charger Charging function I ← ← ←
Battery fluid level I ← ← ←
Battery
Battery fluid specific gravity M ←
Damage of wiring harness I ← ← ←
Electrical wiring
Fuses I ← ← ←
Open-circuit in glow plug I ←
Preheater
Open-circuit in intake heater I ←
Engine stopping
Diesel engine key stop device function I ← ← ←
system
SAFETY DEVICES, ETC.
Cracks at welded portion I ← ← ←
Head guard
Deformation and damage I ← ← ←
Loosening of mounting T ← ← ←
Back-rest
Deformation, crack and damage I ← ← ←
Lighting system Function and mounting condition I ← ← ←
Horn Function and mounting condition I ← ← ←
Direction indicator Function and mounting condition I ← ← ←
Instruments Functions I ← ← ←
Backup buzzer Function and mounting condition I ← ← ←
Dirt, damage I ← ← ←
Rear-view mirror
Rear reflection status I ← ← ←
Loosening and damage of mounting I ← ← ←
Seat Seatbelt damage and function I ← ← ←
Seat switch function I ← ← ←
OPS Functions I ← ← ←
Damage and cracks of frame, cross members, etc. I
Body
Bolt looseness T
Functions I ← ← ←
Loosening and damage at sensor mounting portion I ← ← ←
Damage, deformation, oil leakage and loosening of
SAS I ← ← ←
the mounting of functional parts
Loosening and damage of wire harnesses I ← ← ←
Lock cylinder accumulator performance I
Others Grease up L ← ← ←
0-28
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
z: Replacement
Interval Every Every Every Every
6 weeks 3 months 6 months 12 months
Every Every Every Every
Item 250 hours 500 hours 1000 hours 2000 hours
Engine oil z*2 ← ← ←
Engine oil filter z*1 z ← ←
Engine coolant (every 2 years for LLC) z ← ←
Fuel filter z ←
Torque converter oil z ←
Torque converter oil filter z ←
Manual transmission oil z
Differential oil z
Hydraulic oil z ←
Hydraulic oil filter z*1 z ←
Wheel bearing grease z
Spark plugs z ←
Air cleaner element z
Cups and seals for brake master and wheel cylinders z
Brake fluid z ←
Power steering hoses z*3
Power steering rubbers parts z*3
Hydraulic hoses z*3
Brake fluid reservoir tank hose z*3
Fuel hoses z*3
Torque converter rubber hoses z*3
Chains z*4
Oil pump seal for material handling z*4
DPF Mafler filter (OPT) z*4
DPF Mafler back pressure sensor inline filter (OPT) z ←
DPF Air cleaner (OPT) z*3
SAS Swing lock cylinder (SAS spec.) z*5
Catalytic mafler (OPT) z
3-way catalytic muffler (OPT) z*6
*1: For new vehicle
*2: For the engine oil grades listed below, change oil every 500 hours.
Gasoline vehicle: API SL, SM and above
Diesel vehicle: API CF-4 and above
*3: Every 2 years
*4: Every 3 years
*5: Every 10000 hours
*6: Every 5 years or every 3500 hours
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
1-1
ENGINE
Page Page
ENGINE EXTERIOR VIEW ............. 1-2 V-BELT TENSION 0
ENGINE MAIN PARAMETERS ....... 1-6 ADJUSTMENT ............................ 1-39
ACCELERATOR PEDAL............... 1-40 1
ENGINE PERFORMANCE
CURVES........................................ 1-8 COMPONENTS ...............................1-40 2
ENGINE ASSY .............................. 1-12 INSPECTION·ADJUSTMENT ............1-41
REMOVAL·INSTALLATION DRIVE CONTROL DEVICE 3
(M/T VEHICLES) ........................... 1-12 (OPT) ...........................................1-43
REMOVAL·INSTALLATION COMPONENTS ...............................1-43
4
(T/C VEHICLES) ........................... 1-15 REMOVAL·INSTALLATION............... 1-44 5
AIR BLEEDING OF THE FUEL THROTTLE OPENING DEGREE
SYSTEM...................................... 1-18 ADJUSTMENT..............................1-46 6
ENGINE TROUBLESHOOTING ..................... 1-47
INSPECTION·ADJUSTMENT ..... 1-18 DPF-II SYSTEM (OPT) ..................1-49 7
4Y-M ENGINE (STD) ........................ 1-18 COMPONENTS ...............................1-49
8
4Y-E ENGINE (OPT) ........................ 1-22 CONNECTOR DIAGRAM .................1-52
1DZ-II·2Z ENGINE VEHICLE ............. 1-23 DPF MUFFLER 9
AIR CLEANER .............................. 1-25 REMOVAL·INSTALLATION ............1-54
SPECIFICATIONS ........................... 1-25
DPF MUFFLER DISASSEMBLY· 10
INSPECTION·REASSEMBLY .......... 1-55
COMPONENTS .............................. 1-25 CONTROLLER 11
AIR CLEANER REMOVAL·INSTALLATION ............1-57
CLEANING·INSPECTION............... 1-26 BLOWER 12
CLOGGING WARNING SYSTEM REMOVAL·INSTALLATION ............1-58
INSPECTION (OPT) ...................... 1-27 DPF VALVE 13
RADIATOR .................................... 1-28 REMOVAL·INSTALLATION ............1-59
COMPONENTS .............................. 1-28 DPF VALVE DISASSEMBLY· 14
INSPECTION·REASSEMBLY .......... 1-60
SPECIFICATIONS ........................... 1-31 15
INDIVIDUAL INSPECTION OF
COOLANT CAPACITY AND FUNCTIONAL PARTS ...................1-61
ANTIFREEZE TABLE .................... 1-31 16
CONTROLLER ERROR CODE
COOLANT INSPECTION .................. 1-31 CLEARING METHOD ....................1-65
MUFFLER & EXHAUST PIPE....... 1-33 DPF FILTER MEMORY 17
COMPONENTS .............................. 1-33 CLEARING METHOD ....................1-65
REGENERATION METHOD ..............1-65 18
REMOVAL·INSTALLATION .............. 1-35
DISPLAY OF PAST
MAINTENANCE OF CATALYTIC
ERROR CODES ............................ 1-66 19
MUFFLERS.................................. 1-35
BATTERY ...................................... 1-36 CLEARING OF PAST 20
ERROR CODES ............................ 1-67
COMPONENTS .............................. 1-36 TROUBLESHOOTING ..................... 1-68
SPECIFICATIONS ........................... 1-37
21
INSPECTION .................................. 1-38 E
1-2
ENGINE EXTERIOR VIEW
4Y-M Engine (STD)
1-3
4Y-E Engine (With Electronic Control: OPT)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
1-4
1DZ-II Engine
1-5
2Z Engine
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
1-6
ENGINE MAIN PARAMETERS
Gasoline Engine
Vehicle model 1·2·K2·K3 ton 1·2·K2·K3 ton
3·J3.5 ton series 3·J3.5 ton series
Item series series
Engine model 4Y-M ← 4Y-E (OPT) ←
Engine type Gasoline · 4 cycle ← ← ←
In-line 4 cylinder,
Number and arrangement of cylinders longitudinally ← ← ←
mounted
Combustion chamber type Wedge ← ← ←
Valve mechanism OHV·chain drive ← ← ←
91.0 × 86.0
Bore x stroke mm (in) ← ← ←
(3.583 × 3.386)
Total displacement cm3 (in3) 2237 (136.51) ← ← ←
Compression ratio 8.8 ← ← ←
Maximum output Gasoline exclusive 40 (54)/2400 43 (58)/2600 38 (51)/2570 44 (59)/2570
LPG convertible/
kW (PS)/rpm 35 (48)/2400 38 (52)/2600 38 (51)/2570 43 (58)/2570
Gasoline
LPG convertible/
35 (48)/2400 38 (52)/2600 38 (51)/2570 42 (57)/2570
LPG
LPG exclusive 37 (50)/2400 40 (54)/2600 38 (51)/2570 42 (57)/2570
Maximum torque Gasoline exclusive 162 (16.5)/1800 ← 160 (16.3)/2100 165 (16.8)/2570
LPG convertible/
N·m (kgf·m)/rpm 147 (15.0)/1600 ← 160 (16.3)/2100 ←
Gasoline
LPG convertible/
147 (15.0)/1600 ← 160 (16.3)/2100 ←
LPG
LPG exclusive 157 (16.0)/1800 ← 160 (16.3)/2100 ←
Minimum fuel
Gasoline exclusive 272 (200)/2300 ← 298 (219)/2000 310 (228)/1600
consumption
g/kW·h (g/PS·h)/ LPG convertible/
258 (190)/2400 ← 298 (219)/2000 310 (228)/1600
rpm Gasoline
LPG convertible/
258 (190)/2400 ← 233 (171)/2000 ←
LPG
LPG exclusive 252 (185)/2400 ← 233 (171)/2000 ←
Service weight kg (lb) 134 (295) ← ← ←
No-load maximum speedrpm 2600 2800 2570 ←
1-7
Diesel Engine
Vehicle model
1·K2·K3 ton series 2·3 ton series 2·3·J3.5 ton series
Item
Engine model 1DZ-II ← 2Z
Engine type Diesel · 4 cycle ← ←
In-line 4 cylinder,
Number and arrangement of cylinders ← ←
longitudinally mounted
Combustion chamber type Whirl chamber ← Direct injection
Valve mechanism OHV·gear drive ← ←
86.0 × 107.0 98.0 × 115.0
Bore x stroke mm (in) ←
(3.386 × 4.213) (3.858 × 4.528)
Total displacement cm3 (in3) 2486 (151.71) ← 3469 (211.69)
Compression ratio 21.5 ← 18.6
Maximum output kW (PS)/rpm 39 (53)/2400 42 (57)/2500 42 (57)/2200
Maximum torque N·m (kgf·m)/rpm 160 (16.3)/2300 160 (16.3)/2500 200 (20.3)/1600
Minimum fuel
g/kW·h (g/PS·h)/rpm 247 (181)/1400 ← 209 (153)/1000
conspumption
Service weight kg (lb) 162 (357) ← 212 (467)
No-load maximum speed rpm 2600 2800 2400
1-8
ENGINE PERFORMANCE CURVES
4Y-M Engine (STD) 1·2·K2·K3 Ton Series
Gasoline
LPG (Exclusive)
Torque LPG (Convertible)
Shaft torque
Fuel consumption ratio
4Y-M Engine (STD) 3·J3.5 Ton Series
Gasoline
Torque
LPG (Exclusive)
LPG (Convertible)
Shaft torque
Fuel consumption ratio
1-9
4Y-E Engine (OPT) 1·2·K2·K3 Ton Series
Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)
Torque
Shaft torque
Fuel consumption ratio
4Y-E Engine (OPT) 3·J3.5 Ton Series
Gasoline (Exclusive)
Gasoline (Convertible with LPG)
LPG (Exclusive·Convertible)
Torque
Gasoline (Exclusive)
Gasoline (Convertible with LPG)
LPG (Exclusive·Convertible)
Shaft torque
Fuel consumption ratio Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)
1-10
1DZ-II Engine 1·K2·K3 Ton Series
Torque
Shaft torque
Fuel consumption ratio
1DZ-II Engine 2·3 Ton Series
Torque
Shaft torque
Fuel consumption ratio
1-11
2Z Engine
Torque
Shaft torque
Fuel consumption ratio
1-12
ENGINE ASSY
REMOVAL·INSTALLATION (M/T VEHICLES)
T = N·m (kgf·cm) [ft·lbf]
21
24
17 8
12
18
Engine mount set T = 53.2~98.0 (542~1000) [39.2~72.4]
Clutch housing set bolt T = 49.0~78.4 (500~800) [36.2~57.9]
1-13
Removal Procedure
1 Remove the engine hood. (See page 11-10.)
2 Remove the lower panel and toe board.
3 Drain coolant.
4 Remove the battery.
5 Remove the sedimenter bracket set bolt to free the bracket. (1DZ-II·2Z engine vehicle)
6 Disconnect the accelerator wire.
7 Disconnect the fuel hose.
8 Remove the relay block bracket set bolts to free the relay block.
9 Remove the battery set plate.
10 Remove the air cleaner and air inlet.
11 Remove the exhaust cover plate.
12 Disconnect the exhaust pipe.
13 Disconnect the water hose.
14 Remove the radiator and fan shroud.
15 Remove the under cover.
16 Remove the wiring and wire harness clamps around the engine.
17 Remove the oil pump set bolt and free it.
18 Remove the clutch housing cover, then remove the clutch cover, clutch disc, and flywheel. (See page 2-8.)
19 Remove the starter motor.
20 Remove the engine mount nuts.
21 Slightly hoist the engine. [Point 1]
22 Support the clutch housing with wooden blocks.
23 Separate the engine and clutch housing. [Point 2]
24 Remove the engine ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the fuel system after installing the engine ASSY. (1DZ-II·2Z engine vehicle) (See page 1-18.)
1-14
SST(1) Point Operations
[Point 1]
SST(2)
Removal•Installation:
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)
Removal:
Temporarily hoist up until the mount bolt completely comes out
of the hole in the frame.
[Point 2]
Removal:
Use a flat-head screwdriver for separation. If the fitting is too
tight, move the SST hook position to adjust the engine ASSY
angle for easier separation.
Removal•Installation:
For the oil clutch vehicle, pay special attention so as not to
damage the crankshaft oil seal. If the oil seal is damaged,
replace it.
1-15
REMOVAL·INSTALLATION (T/C VEHICLES)
T = N·m (kgf·cm) [ft·lbf]
22
27
25
8
28
18 12
26
Engine mount nut T = 53.2~98.0 (542~1000) [39.2~72.4]
End plate set bolt T = 49.0~78.4 (500~800) [36.2~57.9]
1DZ-II·2Z: T = 125~186 (1275~1897) [92.2~137.2]
Drive plate set bolt (For connecting the engine crank shaft)
4Y: T = 78~98 (795~1000) [57.5~72.4]
Drive plate set bolt (For connecting the torque converter) T = 14.7~21.6 (150~220) [10.9~15.9]
Torque converter housing set bolt T = 29.4~44.1 (300~450) [21.7~32.6]
1-16
Removal Procedure
1 Remove the engine hood. (See page 11-10.)
2 Remove the lower panel and toe board.
3 Drain coolant.
4 Remove the battery.
5 Remove the sedimenter bracket set bolt to free the bracket. (1DZ-II·2Z engine vehicle)
6 Disconnect the accelerator wire.
7 Disconnect the fuel hose.
8 Remove the relay block bracket set bolt and free the relay block.
9 Remove the battery set plate.
10 Remove the air cleaner and air inlet.
11 Remove the exhaust cover plate.
12 Disconnect the exhaust pipe.
13 Disconnect the water hose.
14 Disconnect the T/C cooler hose. [Point 1]
15 Remove the radiator and fan shroud.
16 Remove the under cover.
17 Remove the wiring and wire harness clamps around the engine.
18 Remove the oil pump set bolt and free it.
19 Remove the cover plate. [Point 2]
20 Remove the 6 drive plate set bolts. [Point 3]
21 Remove the engine mount nuts.
22 Slightly hoist the engine. [Point 4]
23 Support the torque converter housing with wooden blocks.
24 Separate the torque converter housing and engine. [Point 5]
25 Remove the engine ASSY.
26 Remove the drive plate.
27 Remove the torque converter end plate.
28 Remove the starting motor.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply sealant (08833-76002-71 (08833-00080)) before tightening the drive plate set bolt (for connecting
engine and crankshaft).
• Bleed air from the fuel system after installation of the engine ASSY. (1DZ-II·2Z engine vehicle)
(See page 1-18.)
1-17
Point Operations
[Point 1]
Removal:
Put match marks on the radiator and torque converter cooler
hose.
Cover plate [Point 2]
Removal:
Remove the cover plate.
[Point 3]
Removal•Installation:
Rotate the drive plate using the crank shaft pulley set bolt, and
remove the drive plate set bolt.
SST(1) [Point 4]
Removal•Installation:
SST(2)
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)
Removal:
Temporarily hoist up until the mount bolt completely comes out
of the hole in the frame.
1-18
[Point 5]
Removal:
Use a flat-head screwdriver for separation.
If the fitting is too tight, change the SST hook position and
adjust the engine angle for easier separation.
AIR BLEEDING OF THE FUEL SYSTEM
1DZ-II·2Z Engine Vehicles Only
1. Perform air bleeding by moving the priming pump knob up and
down.
2. Once the pump operation becomes heavy, air bleeding is
completed.
ENGINE INSPECTION·ADJUSTMENT
Note:
• Warm up the engine beforehand, and proceed with inspection and adjustment when the vehicle is in the
following state:
• Coolant temperature: 75°C (167°F) or above, engine oil temperature: 60°C (140°F) or above, hydraulic oil
temperature: 50°C (122°F) or above
4Y-M ENGINE (STD)
Ignition Timing Inspection·Adjustment
1. Install the rev counter and timing light.
2. Inspect the idle speed.
Standard: 750 rpm
3. Inspect and adjust the ignition timing.
(1) Disconnect the distributor vacuum hose.
(2) Use the timing light to inspect the ignition timing.
Standard: BTDC 7°/750 rpm
(3) If the standard is not met, loosen the distributor set bolt
and rotate the distributor to adjust to standard value.
(4) Tighten the set bolt and inspect the ignition timing again.
(5) If the ignition timing has been adjusted, seal the
distributor set bolt with sealing tape.
1-19
Idle-up Speed Inspection·Adjustment
Idle up actuator
<Gasoline exclusive vehicles>
1. Install the rev counter. (Refer to 1-18)
2. Start the engine, and measure the engine speed with the
Vaccuum
vacuum hose removed from the idle-up actuator.
hose
Standard
M/T vehicle: 1100 ± 30 rpm
T/C vehicle: 1000 ± 30 rpm
If the standard is not met, adjust by turning the adjusting
screw.
Note:
Adjusting When the adjusting screw is turned clockwise, the engine
screw speed increases.
3. After adjustment, connect the vacuum hose.
<LPG or LPG/Gasoline Vehicle>
B
1. Install the rev counter. (Refer to 1-18)
2. Start the engine, and measure the engine speed with the
vacuum hose removed from the idle-up actuator.
(The idle up actuator is not provided for the LPG vehicle.)
Actuator Standard
hose M/T vehicle: 1100 ± 30 rpm
T/C vehicle: 1000 ± 30 rpm
LPG/Gasoline vehicle
Actuator 3. If the standard is not met, adjust by turning adjusting screw B.
hose 4. Connect the idle up actuator.
LAA11-047
B
LPG vehicle
Idle Speed Inspection·Adjustment
<Gasoline exclusive vehicles>
1. Install the rev counter and vacuum gauge.
(1) Install the rev counter. (Refer to 1-18)
(2) Disconnect the vacuum hose from the vacuum advancer,
and connect the vacuum gauge.
Vacuum hose
1-20
2. Inspect and adjust the idle speed.
(1) Start the engine and alternately adjust the throttle
adjusting screw “1” and the idle adjusting screw “2”, so
that the vacuum is at a stable maximum at the specified
idle speed.
(2) If the idle speed does not decrease because the idle up
adjusting screw is in contact with the idle up actuator rod,
loosen the idle up adjusting screw.
1 Standard
2
Idle speed: 750 rpm
Vacuum: 400 mmHg or more
<LPG exclusive vehicles, Gasoline/LPG convertible vehicles>
A B
1. Install the rev counter. (Refer to 1-18)
2. Inspect the idle speed.
Standard: 750 rpm
3. If the standard is not met, make adjustment according to the
following procedure:
(1) Make adjustment by turning the adjusting screw B (LPG
Regulator LPG carburetor
vehicle) or C (LPG/gasoline vehicle).
(If less than the standard, turn the adjusting screw A
counterclockwise beforehand.)
(2) Slowly turn the 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 the adjusting screw A clockwise to the
position where the speed begins to drop, and then turn it
45 degrees counterclockwise.
Lock bolt No-load Maximum Speed Inspection·Adjustment
1. Install the rev counter.
2. Inspect and adjust the no-load maximum speed.
(1) Measure the speed when the accelerator pedal is fully
depressed.
Standard
1·2·K2·K3 ton series: 2600 ± 50 rpm
3·J3.5 ton series: 2800 ± 50 rpm
1-21
Bushing Adjusting screw (2) If the standard is not met, make adjustment as follows:
(a) Remove the seal and loosen the lock bolt.
(b) Fully depress the accelerator pedal.
(c) Turn the bushing while holding the adjusting screw of
the air governor with a flat-head screwdriver in order
to adjust the speed.
Hold
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 standard is not met, make adjustment according to
the following procedure:
(a) (a) Turn the adjusting screw counterclockwise to
decrease relief down.
(b) (b) Return the screw by 1/10 of a turn to eliminate
twisting of the spring in the air governor.
(c) Adjust the no-load maximum speed.
(d) Repeat steps (a), (b) and (c) until the measured
value satisfies the standard.
4. Check and adjust hunting.
(c) (1) Check for hunting upon tilt relief at the no-load maximum
(b)
speed.
(a) (2) If hunting occurs a few times or more, make adjustment
according to the following procedure:
(a) Turn the adjusting screw clockwise by 1/2 of a turn or
more.
(b) Return the screw counterclockwise by 1/4 of a turn.
(c) Finally, turn it clockwise by 1/10 of a turn to eliminate
twisting of the spring in the air governor.
(d) Adjust the no-load maximum speed.
(e) Repeat steps (a) through (d) until hunting close not
occur.
5. Repeat adjustments in steps 2 to 4 until respective standards
are satisfied.
6. Seal the lock bolt.
1-22
4Y-E ENGINE (OPT)
Idle Speed Inspection·Adjustment
1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Inspect the idle speed.
Standard: 750 ± 30 rpm (For both gasoline and LPG)
Rev terminal
3. If the standard is not met, adjust by the following procedure.
(1) Connect the plug-in analyzer.
SST 09240-26600-71
Note:
• Vehicles equipped with the multifunction display (OPT)
have the same functions as the analyzer, so the plug-in
analyzer is not necessary.
• For an explanation on using the multifunction display and
plug-in analyzer, refer to the multifunction display section.
(2) Set the idle speed to within standard values on the idle
adjustment screen.
No-load Maximum Speed Inpsection
1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator is fully pressed down.
Standard: 2570 ± 30 rpm (For both gasoline and LPG)
Rev terminal
1-23
3. Inspect the relief down amount.
Operate the tilt lever fully backward at the maximum engine
speed, and measure the engine speed upon full relief.
Measure the decrease (relief down) in the engine rpm.
Standard: Within 200 rpm
Ignition Timing Inspection·Adjustment
1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Inspect the idle speed.
Standard: 750 ± 30 rpm
3. Install the timing light.
Diagnostic connector
4. Use the SST to short circuit terminals 10 and 16 of the
diagnostic connector.
SST 09843-76001-71
(09843-18040)
Caution:
If the short circuit positions are incorrect, this will cause a
fault. Make sure to short circuit the correct terminals.
Diagnostic connector
5. Inspect the ignition timing.
If the standard is not met, loosen the distributor set bolt and
rotate the distributor to adjust the ignition timing to the
standard value.
Standard: 7° (BTDC) (For both gasoline and LPG)
1DZ-II·2Z ENGINE VEHICLE
Idle Speed Inspection·Adjustment
1. Install the rev counter.
Rev counter
1-24
Idle adjusting screw 2. Check the return of the accelerator wire, and also check that
the injection pump idle adjusting screw is in contact with the
accelerator lever.
3. Inspect the idle speed.
Standard
1DZ-II: 750 ± 25 rpm
2Z: 775 ± 25 rpm
4. If the standard is not met, loosen the lock nut and adjust with
Accelerator lever the idle adjusting screw.
5. Tighten the lock nut, and inspect the idle speed again.
Maximum adjusting screw No-load Maximum Speed Inspection·Adjustment
1. Install the rev counter.
2. Inspect the no-load maximum speed.
(1) While the engine is at standstill, press down the
accelerator fully, and check that the adjusting lever is
touching the maximum adjusting screw.
(2) Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator pedal is fully
Accelerator lever pressed down.
Standard
2Z: 2400 ± 50 rpm
1DZ-II:
1·K2·K3 ton series: 2600 ± 50 rpm
2·3 ton series: 2800 ± 50 rpm
In the case of vehicles equipped with drive control, the rpm
tolerance is .
3. Adjust the no-load maximum speed.
Remove the sealing of the maximum adjusting screw, and
adjust by turning it.
4. Inspect the relief down amount.
(1) Operate the tilt lever to fully backward at the maximum
engine speed, and measure the engine speed upon full
relief. Measure the decrease (relief down) in the engine
rpm.
Standard: Within 200 rpm
5. Seal the set screw.
1-25
AIR CLEANER
SPECIFICATIONS
Single (STD) Double (OPT)
Type Cyclone type ←
Size 7-inch ←
Intake type Fresh air introduction type ←
Outer 18600 (2883)
Filtering area cm2 (in2) 18600 (2883)
Inner 510 (79.1)
Others With evacuator valve ←
COMPONENTS
1703
1-26
AIR CLEANER CLEANING·INSPECTION
1. Open the engine hood.
2. Remove the element.
Note:
In case of the double element type (OPT), do not remove the
inner element for other than replacement.
3. Clean the element.
(1) For ordinary cleaning, blow with compressed air [690 kPa
(7 kgf/cm2) [100 psi] or less] vertically along the pleats
from the inside of the element.
If heavily contaminated, washing is possible.
(2) Element washing method
Dissolve neutral detergent in tepid water (approx. 40°C
(104°F)) and immerse the element in it for about 30
minutes. Then, rinse the element well with clear water.
[Water pressure: 275 kPa (2.8 kgf/cm2) [40 psi] or less]
After washing, naturally dry the element or dry the
element with a dryer (cold air).
Note:
• Do not damage the paper filter during washing.
• Never use compressed air or hot air for drying.
4. Clean the evacuator valve (dust discharge valve).
Hold the tip end of the evacuator valve and discharge dust and
dirt from the inside of the valve.
5. Inspect the element.
After cleaning, place an electric bulb in the element to inspect
any damage in the element. If any pinhole, tear or damage is
found, replace it with a new element.
6. Element replacement
Replace the element after it is washed six times or generally at
intervals of 12 months.
1-27
7. Install the element.
Install the evacuator valve in the illustrated direction.
25°
CLOGGING WARNING SYSTEM
INSPECTION (OPT)
1. Warning lamp inspection
(1) Check that the air cleaner warning lamp comes on when
the ignition key switch is turned ON and goes out when
the engine starts.
2. Individual inspection
(1) Use a mity vac to apply a negative pressure to the
vacuum switch, and inspect for continuity.
Standard
4Y engine vehicle
2630~3218 Pa (270~330 mmAq) (19.9~24.3 mmHg):
continuity exists
1DZ-II·2Z engine vehicles
6904~8042 Pa (704~820 mmAq) (51.7~60.3 mmHg):
continuity exists
1-28
RADIATOR
COMPONENTS
4Y (M/T Vehicle)
1603
4Y (T/C Vehicle)
1603
1-29
1DZ-II (M/T Vehicle)
1603
1DZ-II (T/C Vehicle)
1603
1-30
2Z (M/T Vehicle)
1603
2Z (T/C Vehicle)
1603
1-31
SPECIFICATIONS
Type Crossflow
Fin type Corrugated fin
Coolant capacity (in radiator) See the table below
Cap opening pressure kPa (kgf/cm2) [psi] 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1]
Others Built in torque converter cooler (torque converter vehicle)
COOLANT CAPACITY AND ANTIFREEZE TABLE
Unit: l (US gal)
30% Antifreeze 50% Antifreeze
Total coolant Antirust mixture
Radiator capacity mixture mixture
capacity 5%
(down to -15°C) (down to -35°C)
M/T 2.2 (0.58) 7.0 (1.85) 2.1 (0.55) 3.5 (0.92) 0.4 (0.11)
4Y
1 ton T/C 2.0 (0.53) 7.8 (2.06) 2.3 (0.61) 3.9 (1.03) 0.4 (0.11)
series M/T 2.2 (0.58) 6.7 (1.77) 2.0 (0.53) 3.4 (0.90) 0.3 (0.08)
1DZ-II
T/C 2.0 (0.53) 6.5 (1.72) 2.0 (0.53) 3.3 (0.69) 0.3 (0.08)
M/T 2.2 (0.58) 8.0 (2.11) 2.4 (0.63) 4.0 (1.07) 0.4 (0.11)
K2·K3 4Y
T/C 2.0 (0.53) 7.8 (2.06) 2.3 (0.61) 3.9 (1.03) 0.4 (0.11)
ton
series M/T 2.2 (0.58) 6.7 (1.77) 2.0 (0.53) 3.4 (0.90) 0.3 (0.08)
1DZ-II
T/C 2.0 (0.53) 6.5 (1.72) 2.0 (0.53) 3.3 (0.69) 0.3 (0.08)
M/T 2.3 (0.61) 8.1 (2.14) 2.4 (0.63) 4.1 (1.08) 0.4 (0.11)
2·3 ton series:
T/C 8.1 (2.14) 2.4 (0.63) 4.1 (1.08) 0.4 (0.11)
4Y 2.25 (0.59)
J3.5 ton series:
T/C 9.5 (2.51) 2.9 (0.77) 4.8 (1.27) 0.5 (0.13)
3.7 (0.98)
2·3·J3.5 M/T 2.3 (0.61) 6.8 (1.80) 2.0 (0.53) 3.4 (0.90) 0.3 (0.08)
ton 1DZ-II
series T/C 3.7 (0.98) 8.2 (2.16) 2.5 (0.66) 4.1 (1.08) 0.4 (0.11)
M/T 2.3 (0.61) 7.8 (2.06) 2.3 (0.61) 3.9 (1.03) 0.4 (0.11)
2 ton series:
T/C 7.8 (2.06) 2.3 (0.61) 3.9 (1.03) 0.4 (0.11)
2Z 2.25 (0.59)
3·J3.5 ton series:
T/C 9.2 (2.43) 2.8 (0.74) 4.6 (1.21) 0.5 (0.13)
3.7 (0.98)
Note:
• The total coolant capacity does not include the capacity of the reservoir tank.
• Reservoir tank capacity: 0.47 l (0.124 US gal) (at FULL mark position)
COOLANT INSPECTION
1. Inspect the coolant level.
Check that the coolant level is between FULL and LOW in the
radiator reservoir tank.
1-32
2. Measure the coolant concentration. (LLC)
(1) Measure the temperature and specific gravity of the
coolant.
Note:
The coolant concentration must be 30% (50% in cold regions)
or above.
(2) Find the concentration of the coolant from the table on the
50% (approximately -38°C) left.
40% (approximately -26°C)
Note:
30% (approximately -16°C)
This graph shows the relationship between coolant
temperature and specific gravity at concentrations of 30, 40
and 50%.
For example when the coolant temperature is 55°C and the
specific gravity is 1.035, the coolant concentration at this time
can be found as follows:
The intersection point of 55°C and 1.035 is between the 30%
line and 40% line, so this point is approximately 35%. In other
Specific gravity
words, the concentration is approximately 35%.
3. Check that there is no oil etc. mixed in with the coolant.
Measured temperature (°C)
1-33
MUFFLER & EXHAUST PIPE
COMPONENTS
4Y
1702
1DZ-II (1·K2·K3 Ton Series)
1702
1-34
1DZ-II (2·3 Ton Series)·2Z
1702
1-35
REMOVAL·INSTALLATION
Note:
The muffler can be removed by either of the two methods shown below.
(1)Remove the muffler after removing the counterweight.
(2)Remove the muffler after removing the radiator W/ counterweight.
Here, method (1) is explained.
3
4
2
Removal Procedure
1 Remove the counterweight. (See page 11-11.)
2 Separate the union between the exhaust pipe and muffler.
3 Remove the exhaust pipe fixation bolts.
4 Remove the muffler.
5 Disconnect the tail pipe from the muffler.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Use a new gasket.
MAINTENANCE OF CATALYTIC MUFFLERS
For diesel vehicles, replace the muffler ASSY every year or every 2000 hours.
For gasoline vehicles, replace the 3-way catalytic muffler ASSY every 5 years or every 3500 hours.
1-36
BATTERY
COMPONENTS
4Y
1901
1DZ-II
1901
1-37
2Z
1901
SPECIFICATIONS
List of battery types (different batteries are used depending on which engine they are mounted).
Engine 2Z
4Y 1DZ-II 2Z (Specifications for cold
Specifications areas)
STD 34B 19L(S) 80D 26L 95D 31L 75D 23L × 2
OPT
55D 23L 95D 31L 55D 23L × 2 —
(High capacity battery)
Battery model
34B 19L 55D 23L 75D 23L 80D 26L 95D 31L
Item
Voltage V 12 ← ← ← ←
5 hour rated capacity Ah 27 48 52 55 64
Specific gravity of electrolyte in use
1.280 ← ← ← ←
(at 20°C (68°F))
Cold cranking current A 272 356 550 582 622
Cell weight kg (lb) 9.1 (20.1) 14.7 (32.4) 16.3 (35.9) 17.2 (37.9) 21.5 (47.4)
1-38
INSPECTION
1. Inspect the battery fluid level.
Inspect that the battery fluid level is between the UPPER and
LOWER lines. Add distilled water if insufficient. Do not overfill
UPPER
above the upper fluid limit.
LOWER
2. Inspect the specific gravity of the battery fluid.
Use a hydrometer to measure the specific gravity of the battery
fluid.
Standard: 1.280 (at 20°C (68°F))
Calculating equation
S20 = St + 0.0007 (t-20)
S20: Specific gravity converted to 20°C (68°F)
St: Measured specific gravity at t°C
t: Fluid temperature at the time of measurement
3. Inspect the battery terminals.
If battery terminals are contaminated to white, clean then and
apply a thin coat of MP grease on terminals.
4. Inspect the battery terminals and the harness connecting
portions for loosening.
Retighten the battery terminals and the harness connecting
portions.
Battery Removal
1. Disconnect battery terminals.
Note:
Disconnect the negative terminal first.
2. Remove the battery stopper.
3. Remove the battery.
Battery Installation
The installation procedure is the reverse of the removal procedure.
1-39
V-BELT TENSION ADJUSTMENT
1. Inspect the V-belt tension.
Standard
[amount of delfection when pressed with 98 N (10 kgf)]
4Y: 8~13 mm (0.31~0.51 in)
1DZ-II·2Z: 8~13 mm (0.31~0.51 in)
Standard
[When using a tension gauge (SST)]
SST 09216-76002-71 (09216-00021)
4Y: 294~490 N (30~50 kgf) [66~110 lbf]
1DZ-II·2Z: 324~559 N (33~57 kgf) [73~126 lbf]
Set bolt 2. V-belt deflection adjustment
4Y engine vehicle
Adjustment bolt (1) Loosen the fixing bolt.
(2) Loosen the set bolt and turn the adjustment bolt to adjust
the tension.
(3) Tighten the fixing bolt and recheck the belt tension.
Note:
Fixing bolt Be careful not to apply excessive tension to the belt.
1DZ-II·2Z engine vehicles
Adjustment bolt
(1) Loosen the fixing bolt and adjusting bolt.
(2) Stretch the V-belt using a pry bar with the length of 300 to
400 mm (11.8 to 15.7 in), and tighten the alternator
adjustment bolt.
(3) Tighten the fixing bolt then recheck the belt tension.
Note:
Adjustment of the tension using a pry bar gives rise to
Fixing bolt considerable individual differences, and tends to result in
excessive or insufficent tension. Therefore, be sure to inspect
the deflection amount.
1-40
ACCELERATOR PEDAL
COMPONENTS
2601
4Y-M (STD) 4Y-E (OPT)
1DZ-II·2Z
2601
1-41
INSPECTION·ADJUSTMENT
B 1. Inspect the angle of the accelerator pedal.
4Y 1DZ-II 2Z
A
A: When the accelerator is OFF 45° 45° 45°
Rod B: At full throttle (reference) 17° 20° 15°
Adjust by adjusting the length of the rod.
Stopper bolt
2. 4Y-M (STD) engine vehicle
1DZ-II·2Z Stopper bolt
Adjust the height of the stopper bolt on the floor side so that
engine vehicles
the throttle lever of the carburetor comes to a position just
Link
before full open when the pedal is depressed.
3. 1DZ-II·2Z engine vehicles
Adjust the height of the stopper bolt on the floor side so that
the link contacts the stopper bolt on the engine side when the
pedal is depressed.
4. Adjust the accelerator wire so that there is about 2° of play in
the pedal.
4Y-E (OPT)·Diesel Vehicle with Drive Control (OPT)
1. Inspect the angle of the accelerator pedal.
B
A: When the accelerator is OFF 45°
A
m)
B: At full throttle (Reference) 16°
2m
Rod Adjust by adjusting the length of the rod.
(5
2. Temporarily set the pedal stopper bolt height to 52 mm
(2.05 in).
Stopper bolt Accelerator
sensor
3. Adjust the accelerator sensor.
(1) Connect the plug-in analyzer.
SST 09240-26600-71
For diesel vehicles with drive control (OPT) use the
multifunction display.
Note:
For an explanation on using the display, refer to the
multifunction display section.
1-42
(2) Adjust the sensor voltage when the accelerator is OFF.
Display the I/O ENGINE CTRL 4/10 screen on the display.
Adjust the installation position of the accelerator sensor
so that the VPA1 output (V) comes to the value below,
and fix it with a the set screw.
VPA1: 0.85 ± 0.1 V
(3) Adjust the height of the stopper bolt so that the difference
between the VPA1 output (V) in the full throttle position
and the initial VPA1 output (V) is 2.4 V or greater, and the
VPA2 output (V) in the full throttle position is less than 4.6
V.
(Note: the change in output per single turn of the stopper
bolt is 0.06 V)
(4) After adjustment, apply thread tightener (08833-76002-71
(08833-00080)) to the threaded section of the stopper bolt
lock nut and reassemble it.
(5) Clear the learned values.
For the 4Y-E:
Remove the battery plug for more than 10 seconds, then
reconnect it.
For diesel vehicles with drive control:
Turn the key ON with the accelerator sensor connector
disconnected. (An accelerator sensor error will be
detected.)
Then, turn the key OFF and reconnect the accelerator
sensor connector.
(6) Check that the VPA1 and VPA2 values displayed with the
accelerator OFF are within a range specified below of the
values displayed inside the brackets.
Standard: Within ± 0.1 V
1-43
DRIVE CONTROL DEVICE (OPT)
1DZ-II·2Z Engine Vehicle
COMPONENTS
2607
1-44
REMOVAL·INSTALLATION
LBA26-006
Removal Procedure
1 Open the engine hood and disconnect the negative terminal of the battery.
2 Remove the battery.
3 Remove the relay block bracket set bolt and free the relay block.
4 Remove the sedimenter.
5 Remove the battery set plate.
6 Disconnect the injection pump side link.
7 Remove the actuator. [Point 1]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, adjust the throttle opening degree. (Refer to 1-46)
• After installation, operate the accelerator pedal and check that the links are working normally.
1-45
[Point 1]
Inspection:
Inspect the actuator.
1. Check that the actuator shaft can be manually turned smoothly
without sticking.
2. Check the resistance of the actuator.
Tester range: Ω × 1 range
Standard
Between (1) and (3): Approx. 2.5~3.7 Ω
Between (2) and (3): Approx. 2.5~3.7 Ω
Between (1) and (4): Approx. 5.0~7.4 Ω
Between (2) and (5): Approx. 5.0~7.4 Ω
Inspection:
Measure the insulation resistance between each actuator
terminal and body.
Tester range: Ω × 1 M range
Standard: 100 MΩ or more
[Point 2]
Inspection:
Inspect the continuity of the limit switch.
Standard
Free position: ∞ Ω
When pushed 2.3 mm (0.091 in) or more: 0 Ω
1-46
Idle set THROTTLE OPENING DEGREE
screw Thickness ADJUSTMENT
gauge
Idle Switch (Injection Pump Lever Completely Closed)
Adjustment
LBA26-010 1. Fix the injection pump lever in completely closed state with a
thickness gauge (1.3 mm (0.051 in) thickness) placed between
the lever and the idle set screw.
2. Tighten the adjustment bolt on the idle switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
(OFF→ON). (It is possible to tighten up to 1/4 turn from the
Idle switch switching point)
3. Fix the adjustment bolt with the lock nut.
Lock nut
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.
Adjustment bolt
NMR Switch (Injection Pump Lever Completely Open)
Thickness gauge Adjustment
NMR set 1. Fix the injection pump lever in completely open state with a
screw thickness gauge (0.3 mm (0.051 in) thickness) placed between
the lever and the NMR set screw.
2. Tighten the adjustment bolt on the NMR switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
Adjustment (OFF→ON). (It is possible to tighten up to 1/4 turn from the
NMR switch bolt switching point)
3. Fix the adjustment bolt with the lock nut.
Lock nut 4. Unlock the injection pump lever from fully open state.
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.
1-47
TROUBLESHOOTING
This page contains troubleshooting advice for the mechanical system of the drive control device. In the case of an
error code being recieved, or trouble with the electrical system, refer to the troubleshooting section.
● Idle switch open error
Check the injection pump
Check that the injection pump return spring is Not broken A defect in the mechanical system of the drive control
not broken. device.
Check the components of the drive control device.
Broken
Replace the return spring
Checking the components
of the drive control device
There is
Move the link by hand, and check that there is interference
no interference with surrounding parts. Remove the interference.
There is no interference
There is
looseness or
Check that there is no looseness or rattling in the rattling
motor bracket. Retighten the installation bolts.
There is no looseness
or rattling
There is
Check that there is no bending in the connecting bending
rod or bracket. Replace defective components.
There is no bending
There is
Check that there is no catching on the sliding catching
portion of the ball joint. Clean and grease the joint section.
There is no catching
90°C (194°F )
Check that the temperature around the motor in or more
use is 90°C (194°F) or less. Outside the range of the motor operation warranty.
90°C (194°F) or less
Mechanically no cause can be found, therefore
refer to the drive control device electrical system
troubleshooting.
1-48
● The idle speed deviates from the specified value
Check the injection pump
specified A defect in the mechanical system of the drive control
Hold pump lever completely closed with your speed device.
hand, then start the engine and check whether Check the components of the drive control device (refer
the engine idles at the specified speed. to 1-47).
Not-specified speed
Adjust the idle set screw
● The idle up speed does not rise
Check the injection pump
There is no A defect in the mechanical system of the drive control
Move the pump lever with your hand to check catching device.
that there is no catching in the sliding
Check the components of the drive control device (refer
movement.
to 1-47).
There is catching
Service the injection pump (apply grease, etc.)
● No NMR
Check the injection pump
Check that there is NMR when starting the A defect in the mechanical system of the drive control
There is NMR device.
engine and turning the pump lever to the fully-
open position with your hand. Check the components of the drive control device (refer
to 1-47).
There is no NMR
Adjust the maximum set screw
● The engine does not respond to operation of the accelerator pedal
Check the injection pump
A defect in the mechanical system of the drive control
With the engine running, move the pump lever Engine revs up
device.
with your hand and check the rev-up response.
Check the components of the drive control device (refer
Engine doesn't rev up to 1-47).
Service or replace the injection pump
1-49
DPF-II SYSTEM (OPT)
COMPONENTS
5701
5701
1-50
1DZ-II
1702
1702
1-51
2Z
1702
1-52
CONNECTOR DIAGRAM
1-53
1-54
DPF MUFFLER REMOVAL·INSTALLATION
3
1
Removal Procedure
1 Remove the radiator cover.
2 Remove the weight.
3 Open the engine hood, and disconnect the heater and temperature sensor connector.
4 Cut the tie-wrap and pull the heater and temperature sensor harness out toward the rear of the vehicle.
5 Disconnect the back pressure sensor connecting hose.
6 Disconnect the exhaust pipe from the muffler.
7 Remove the DPF muffler ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Replace the gasket between the muffler and exhaust pipe with a new one.
• When the muffler ASSY is replaced, clear the memory. (See page 1-65.)
1-55
DPF MUFFLER DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 11.76~14.70 3
(120~150)
[8.68~10.9] 2
Disassembly Procedure
1 Remove the outlet pipe.
2 Remove the 16 bolts. [Point 1]
3 Remove the DPF heater ASSY.
4 Remove the DPF jacket ASSY. [Point 2]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Replace the DPF jacket ASSY gasket with a new one.
• When the DPF jacket ASSY is replaced, clear the memory. (See page 1-65.)
1 Point Operations
5 8 [Point 1]
Reassembly:
Install the bolts, nuts and washers in the illustrated order.
3 4 Note:
Use the specified bolts, nuts and washers. Use of general
items may cause malfunctions.
7 6
2
1-56
[Point 2]
Inspection:
Replace the DPF jacket ASSY if its center or inside wall is
blackened with soot when seen from the outlet side.
1-57
CONTROLLER REMOVAL·INSTALLATION
Note:
Since the two wires from the controller to the outlet are both black, put tags showing the connecting
positions.
T = N·m (kgf·cm) [ft·lbf]
6 3
T = 1.18~1.76
(12~18)
[0.87~1.30]
Removal Procedure
1 Open the engine hood, and disconnect the battery negative terminal.
2 Remove the step.
3 Remove the bracket set bolts.
4 Disconnect the wiring from the controller to the outlet.
5 Disconnect the controller connector.
6 Remove the controller ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the controller is replaced, turn the ignition key switch ON and check no error is present.
1-58
BLOWER REMOVAL·INSTALLATION
Note:
Since the blower is to be removed from under the frame, operate in a pit.
View A
5
3
7
Removal Procedure
1 Open the engine hood, and disconnect the battery negative terminal.
2 Remove the toe board.
3 Remove under cover from the vehicle.
4 Disconnect the connector.
5 Disconnect the blower hose from the blower.
6 Remove the blower set bolts, and remove the blower W/ bracket from under the vehicle.
7 Remove the blower ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the blower wiring clamp is removed, replace it with a new one.
1-59
DPF VALVE REMOVAL·INSTALLATION
6
2
2 5
3 5
4
7
Removal Procedure
1 Disconnect the battery negative terminal.
2 Disconnect the DPF air cleaner hose (air cleaner side) and blower hose (flow rate sensor side).
3 Disconnect the back pressure sensor connector and back pressure sensor hose, and remove the back pressure
sensor.
4 Disconnect the DPF valve hose.
5 Disconnect the DPF valve connector and blower sensor connector.
6 Remove the base & bracket W/ DPF parts ASSY from the vehicle. Disconnect the wire harness clamps from the
base & bracket.
7 Remove the DPF valve W/ fitting. [Point 1]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1]
Installation:
Install the DPF valve in the correct direction.
The arrow marked on the valve body must be pointing the front
of the vehicle.
The connector of the core must be facing the front of the
vehicle as well. (The core can be turned by hand.)
Front
(Blower side)
1-60
DPF VALVE DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
1
T = 20.6~30.4 (210~310) [15.2~22.4]
Disassembly Procedure
1 Fix the valve body in a vise, and loosen the lock nut.
2 Separate the valve body and core, and remove the plunger and spring. [Point 1]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Inspection:
Clean off soot accumulated in the valve body, plunger, and
core with compressed air.
Replace the valve ASSY if any damage or wear is seen on the
plunger seat.
Plunger seat
Reassembly:
Core Install the spring in the correct direction.
Face the minor diameter side of the spring to the valve body
side.
Spring
Body
1-61
INDIVIDUAL INSPECTION OF FUNCTIONAL PARTS
Starter relay
Display
Main relay
Back pressure sensor
For the flow sensor
For the valve
For the heater Heater relay
Blower
Buzzer
For the temperature sensor Controller
Heater
Connector for heater
Inspect the heater coil resistance.
Inspection method: Measure the resistance between both
terminals of wiring from the heater
Tester range: Ω × 1 range
Standard: Approx. 17 Ω
Temperature Sensor
Connector for temperature sensor Inspect the temperature sensor continuity.
Inspection method: Measure the resistance between both
terminals of the temperature sensor
connector.
Tester range: Ω × 1 range
Standard: Approx. 1 Ω
Note:
Do not scratch gold plating on the connector pins at the time
of inspection.
1-62
DPF Blower
Inspect the DPF blower for continuity.
Inspection method: Measure the resistance between both
terminals of the DPF blower.
Tester range: Ω × 1 range
Standard: Approx. 2.2 Ω
Note:
Do not scratch gold plating on the connector pins at the time
of inspection.
Inline Filter
Muffler side
Inspect the outlet on the back pressure sensor side for soot
accumulation. If soot is seen, replace the sensor.
Back pressure sensor side
Note:
Back pressure Muffler Regarding the direction of the inline filter. Do not install in the
sensor side side reverse direction after inspection. Check the direction by the
Soot "DENSO" mark direction. Although no direction is specified
for installation of a new filter, it is recommended to install with
the "DENSO" mark facing the back pressure sensor side.
A
View A Mark
DPF Valve
Measure the resistance between both terminals of the DPF valve
wiring.
Inspection method: Between both terminals of the valve
connector
Tester range: Ω × 1 range
Standard: Approx. 18 Ω
Note:
The part has a direction, so take care not to reassemble it in
the opposite direction.
Main Relay
Remove the main relay and inspect the function.
Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Tester range: Ω × 1 range
Standard: 0Ω
Main relay
1-63
Starting Motor Relay
Remove the starting motor relay and inspect the function.
Starting motor relay Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Tester range: Ω × 1 range
Standard: 0Ω
Heater Relay
C A Inspect the function.
Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Tester range: Ω × 1 range
Standard: 0Ω
D B
Buzzer
Inspect the buzzer for continuity.
Display
1. Disconnect the controller connector, and measure the applied
battery voltage on the wiring side.
BATT Inspection method: Between BATT terminal ⊕ of the
controller connector (wiring side)
and body ground
Tester range: DC 50 V range
Standard: 10~14 V
2. Inspect the controller connector for continuity (on the controller
side).
Inspection method: E01-E1
E02-E1
E01
E1-E2
Tester range: Ω × 1 range
E02 E2 E1 Standard: There is continuity.
1-64
3. Inspect if any LED is burnt out.
Turn the ignition key switch ON and check if all LEDs are lit for
1 second.
The buzzer sounds for 0.5 seconds.
Note:
Regarding cleaning of the DPF filter
When the amount of soot reaches the limit, a buzzer sounds and 6 LEDs on the display flash. In this state, it
is necessary to perform regeneration process immediately. If the machine continues to be used in this
condition, a warning LED will light up and an error code "5-1" is generated. When the vehicle has reached
this condition, it is necessary to replace or to clean the filter.
If you feel that "We are carrying out regeneration process periodically, but the movement time is getting
shorter", it is recommended that you clean the filter.
Cleaning the filter
• Clean the filter when it is cold (when you feel no heat on touching it with your hand).
• Face the IN side of the filter downwards and apply high pressure water from above the OUT side. (The
filter is designed to withstand high pressure water to 5 MPa.)
• When no more white residual ash comes out under high pressure water, cleaning is finished.
After cleaning, always perform a "DPF filter memory clear".
1-65
CONTROLLER ERROR CODE CLEARING
METHOD
1. Turn the ignition key switch ON.
2. Press the RESET switch until the buzzer sounds.
3. Turn the ignition key switch OFF after the warning LED goes
out.
Note:
• Do not turn the ignition key switch ON until all LEDs on
Press
the display go out.
• Do not perform this operation before reading the error
code.
• If the buzzer does not sound when the RESET switch is
pressed, an internal switch defect may be the cause.
4. After LEDs go out, turn the ignition key switch ON and check
that the warning LED is not blinking.
DPF FILTER MEMORY CLEARING METHOD
1. Turn the ignition key switch ON.
2. Press the FILTER switch until the buzzer sounds.
3. Turn the ignition key switch OFF.
Note:
• Do not turn the ignition key switch ON until all LEDs on
the display go out.
• Perform this operation only when the filter is replaced.
Press • If the buzzer does not sound when the FILTER switch is
pressed, an internal switch defect may be the cause.
REGENERATION METHOD
1. Connect the external power cord (AC 200 V).
2. Press the regeneration switch until the buzzer sounds.
Note:
• The regeneration process ends in about 50 minutes
(about 70 minutes in case of high collection). One soot
soot amount indicating LED goes out every ten minutes,
and the process ends when all LEDs go out.
Press • If the buzzer does not sound when the regeneration
switch is pressed, an internal switch defect may be the
cause.
3. Disconnect the external power cord (AC 200 V).
Note:
• During the regeneration process, the engine does not start even though the ignition key switch is turned
to the START position. In this case the buzzer sounds to warn the operator.
• If the external power supply (AC 200 V power) is cut off for more than one minute during the
regeneration process, the buzzer will sound and the regenerating LED will blinks to warn the operator.
• While the power cord is kept connected after the end of regeneration, the engine does not start even
though the ignition key switch is turned to the START position. In this case, the buzzer sounds and the
warning LED blinks to warn the operator.
1-66
DISPLAY OF PAST ERROR CODES
Note:
• If any switch is operated incorrectly, turn the ignition key switch OFF once before retrying switch
operation.
• Check that no error code is displayed.
Operation Procedure
1. Turn the ignition key switch ON (engine in stopped state).
2. Press the FILTER, MODE and RESET switches at a time until
the buzzer sounds.
Press
3. Press the MODE switch until the buzzer sounds.
Press within 10 seconds
âüDz
Soot amount indicationg LED 4. Press the FILTER and MODE switches at a time until the
buzzer sounds.
5. The display becomes as follows:
When there is no past error code:
All LEDs are kept off for 5 seconds.
When there are any past error codes:
After the soot quantity display LEDs are kept off for one
second, the error codes are displayed one by one for five
seconds each from the oldest one. The buzzer sounds each
time the error code is switched over. The display is repeated
Press within 10 âüDz
seconds after all codes are displayed.
10ïbà»ì‡Ç
6. After checking the display, turn the ignition key switch OFF.
1-67
CLEARING OF PAST ERROR CODES
Note:
• Operate with a past error code being displayed.
• If any switch is operated incorrectly, turn the ignition key switch OFF once and display the past error
code again before retrying switch operation.
Operation Procedure
1. Turn the ignition key switch ON (engine in stopped state).
2. Press the FILTER, MODE, and RESET switches at a time until
the buzzer sounds.
Press
3. Press the MODE switch until the buzzer sounds.
Press within 10 seconds
4. Press the MODE and RESET switches at a time until the
buzzer sounds.
5. Past error codes are cleared.
6. Turn the ignition key switch OFF.
Press within 10 seconds
1-68
TROUBLESHOOTING
How to Approach Diagnosis
On detecting an abnormal area the controller lights a warning LED on the display and sounds a buzzer. The detected
abnormal area is then displayed as an error code using the soot amount indicating LEDs. When the warning LED
lights, pressing and holding the MODE switch for about one second will display the error code using the soot amount
indicating LEDs.
When the regenerating LED flashes with the ignition key switch ON, this indicates that the previous regeneration was
aborted partway due to a drop in voltage of the external power supply (AC 200 V), and the error code is 7-2. In this
case performing regeneration again will reset the error code without clearing the error code.
The connector numbers (A to M) specified in troubleshooting are the same as those shown on the connector diagram
on page 1-52.
Error Code Indicating Method
Turn the ignition key switch ON, and remove the communication switch cover. The error code is displayed by the
lighting LED positions while the buzzer sounds.
No. Error code Abnormal portion
During regeneration, the heater temperature does not rise to the specified level within the
1 1-1
specified time.
2 1-2 The heater temperature drops abnormally during regeneration.
3 1-3 The exhaust temperature rises abnormally while the engine is running.
4 1-4 The temperature sensor outputs an abnormally high temperature.
5 2-1 The back pressure sensor output is above or below the upper or lower limit.
The back pressure sensor output remains unchanged when the engine speed varies beyond
6 2-2
the given level.
7 3-1 The alternator L signal becomes abnormal upon starting the engine.
8 3-2 The rpm sensor output becomes abnormal after starting the engine.
9 3-3 The alternator L signal becomes abnormal after starting the engine.
10 4-1 The flow rate sensor output value is abnormal.
11 4-2 The blower flow rate is apart from the target level.
12 4-3 The flow rate sensor output deviates though the blower is not operated.
13 5-1 The amount of soot accumulated in the DPF filter is above the level that can be regenerated.
14 6-1 The controller memory is abnormal.
15 7-1 The vehicle battery voltage dropped abnormally.
16 7-2* The external power voltage (AC 200 V) dropped for 1 minute or more during regeneration.
*: For error code 7-2, the regenerating LED flashes instead of the warning LED.
1-69
Explanation on Error Code
The abnormal system portion is indicated by the soot amount indicating LEDs. When multiple system abnormalities
are detected at a time, they are indicated alternately at intervals of 5 seconds.
c : On ● : Off
Example : Error code 3-1
Code Soot amount indicating LEDs
No.1
Green 1 Green 2 Green 3 No.2 display
display No.1 display
No.2
Green 4 Green 5 Yellow
display
1 ● ● c
2 ● c ●
3 ● c c
4 c ● ●
5 c ● c
6 c c ●
7 c c c
Before Troubleshooting
1. Check that there was no interruption during regeneration such as the plug being accidentally pulled from the
power socket or some other circumstance.
If there has been an interruption during regeneration, the regenerating LED will flash when the ignition key
switch is turned ON. Carry out regeneration again. In this case it is not necessary to perform an error code clear
operation. If a regeneration interruption reoccurs, carry out the troubleshooting for error code 7-2.
2. Check that the battery voltage is the specified voltage (10~14 V).
If it deviates from the specified voltage, charge or replace the battery.
3. Check that the bulbs for the display are not blown. (Refer to 1-64)
If the LEDs on the display do not light when the ignition key switch is turned ON, replace the display.
4. Check that the display does not always light.
Repair or replace the display wiring.
1-70
Troubleshooting
Error Code 1-1 or 1-2
Inspection 1: NG
Inspect the heater resistance. Defective heater ASSY.
OK
NG
Inspection 2:
Defective temperature sensor.
Inspect the temperature sensor for continuity.
OK
Inspection 3: NG
Inspect continuity between the temperature sensor and Repair or replace the wiring.
controller.
OK
Inspection 4: NG
Inspect continuity between the heater relay and controller. Repair or replace the wiring.
OK
DPF system in normal state.
Inspection 1:
Heater resistance inspection
Disconnect the heater connector.
Tester range: Ω × 1
Measurement terminals Both terminals of heater connector: E-1 - E-2
Standard Approx. 17 Ω
Heater connector
(E) Heater connector
ÉCÉâÉXÉgë“Çø 2 1
OK → To inspection 2
NG → Defective heater ASSY
1-71
Inspection 2:
Temperature sensor continuity inspection
Disconnect the temperature sensor connector.
Tester range: Ω × 1
Measurement terminals Both terminals of temperature sensor connector: I-1 - I-2
Standard Approx. 1 Ω
(I) Temperature sensor connector
2 1
Temperature sensor connector
OK → To inspection 3
NG → Defective temperature sensor
Inspection 3:
Temperature sensor wiring continuity inspection
Disconnect the temperature sensor and controller connector.
Tester range: Ω × 1
Controller connector B-8 - Temperature sensor connector I-1
Measurement terminals
Controller connector B-21 - Temperature sensor connector I-2
Standard 0Ω
(B) Controller connector (I) Temperature sensor
connector
2 1
1 2
Temperature sensor
Controller connector connector
OK → To inspection 4
NG → Repair or replace the wiring
1-72
Inspection 4:
Heater relay wiring continuity check
Disconnect the heater relay and controller connectors.
Tester range: Ω × 1
Measurement terminals Controller connector B-10 ~ Heater relay 3
Standard 0Ω
Heater relay 3
(B) Controller connector
Heater relay 3
Controller connector
OK → DPF system in normal state
NG → Repair or replace the wiring
1-73
Error Code 1-3
NG
Inspection 1:
Temperature sensor defect.
Inspect the temperature sensor for continuity.
OK
Inspection 2: NG
Inspect continuity of the wiring between the temperature Repair or replace the wiring.
sensor and controller.
OK
Controller defect.
Inspection 1:
Temperature sensor continuity inspection
See inspection 2 of error code 1-1.
OK → To inspection 2
NG → Temperature sensor defect
Inspection 2:
Temperature sensor wiring continuity inspection
See inspection 3 of error code 1-1.
OK → Controller defect
NG → Repair or replace the wiring
1-74
Error Code 1-4
NG
Inspection 1:
Temperature sensor defect.
Inspect the temperature sensor for continuity.
OK
Inspection 2: NG
Inspect continuity of the wiring between the temperature Repair or replace the wiring.
sensor and controller.
OK
NG
Inspection 3:
Repair or replace the power cord.
Measure the power supply voltage (AC 190~220 V).
OK
Inspection 4: NG
Inspect continuity of the wiring between the heater relay Repair or replace the wiring.
and controller.
OK
NG
Inspection 5:
Heater ASSY defect.
Inspect the heater resistance.
OK
Controller defect.
Inspection 1:
Temperature sensor continuity inspection
See inspection 2 of error code 1-1.
OK → To inspection 2
NG → Temperature sensor defect
Inspection 2:
Temperature sensor wiring continuity inspection
See inspection 3 of error code 1-1.
OK → To inspection 3
NG → Repair or replace the wiring
1-75
Inspection 3:
Power supply voltage inspection
Connect the power cord to the power outlet.
Tester range: AC 500 V
Measurement terminals Power cord terminals
Standard AC 190~220 V
OK → To inspection 4
NG → Repair or replace the power cord
Inspection 4:
Heater relay wiring continuity inspection
See inspection 4 of error code 1-1.
OK → To inspection 5
NG → Repair or replace the wiring
Inspection 5:
Heater resistance inspection
See inspection 1 of error code 1-1.
OK → Controller defect
NG → Heater ASSY defect
1-76
Error Code 2-1
OK
Inspection 1:
Controller defect
Inspect the back pressure sensor input.
NG
Inspection 2: OK
Inspect continuity of the wiring between the back pressure Back pressure sensor defect
sensor and the controller.
NG
Repair or replace the wiring.
Inspection 1:
Back pressure sensor input check
Voltage measurement between terminals
Controller connector: Back pressure sensor connector in connected state
Stop the engine and turn the ignition key switch ON.
B3 ~ B16
Measurement terminals Controller connector Controller connector
B4 ~ B16
Standard B3 ~ B16 : 5 ± 0.25 V, B4 ~ B16 : 1.5 ± 0.5 V
OK → Controller defect
NG → To inspection 2
Inspection 2:
Back pressure sensor wiring continuity inspection
Disconnect the back pressure sensor and controller connector.
Tester range: Ω × 1
B4 ~ J1
Measurement terminals Controller connector B16 ~ Back pressure sensor connector J2
B3 ~ J3
Standard 0Ω
Back pressure sensor connector
(J) Back pressure
(B) Controller connector sensor connector
1 2 3
Controller connector
OK → Back pressure sensor defect
NG → Repair or replace the wiring
1-77
Error Code 2-2
Check the exhaust pipe and DPF muffler for exhaust gas leakage from each part or joint.
Inspection 1: NG
Check the pipes and hoses connecting functional parts of Repair or replacement
the DPF-II system for leakage or clogging.
OK
Inspection 2: NG
After leaving in idle state for about 30
Check the pipes connecting functional parts of the DPF-II
minutes, conduct inspection 3.
system for freezing.
OK
Inspection 3: NG
Check the in-line filter for clogging. Replace the in-line filter.
OK
NG Replace the valve, flow rate sensor,
Inspection 4:
blower, controller and DPF air cleaner,
Check the valve outlet for soot leakage.
and clean or replace the piping.
OK
OK
Inspection 5:
Controller defect
Check the back pressure sensor input.
NG
Inspection 6: OK
Inspect continuity of the wiring between the back pressure Back pressure sensor defect
sensor and the controller.
NG
Repair or replace the wiring.
Inspection 1:
DPF-II system gas leakage inspection
Check the pipes and hoses that connect parts for leakage or clogging.
OK → To inspection 2
NG → Repair or replacement
Inspection 2:
Pipe freezing check
Check the pipes and hoses that connect parts for freezing.
OK → To inspection 3
NG → To inspection 3 after defrosting.
Inspection 3:
In-line filter clogging check
OK → To inspection 4
NG → Replacement
1-78
Inspection 4:
Valve outlet soot leakage check
Back pressure sensor Air cleaner
Valve
Valve outlet Blower
Flow rate sensor
To exhaust manifold
OK → To inspection 5
NG → Replace the valve, flow rate sensor, blower and DPF air cleaner, and clean or replace the piping.
Inspection 5:
Back pressure sensor input check
Voltage measurement between terminals
Controller connector: Back pressure sensor connector in connected state
(1) Stop the engine and turn the ignition key switch ON.
B3 ~ B16
Measurement terminals Controller connector Controller connector
B4 ~ B16
Standard B3 ~ B16 : 5 ± 0.25 V, B4 ~ B16 : 1.5 ± 0.5 V
(2) Start the engine and keep the NMR running. (*)
Measurement terminals Controller connector B4 ~ Controller connector B16
Standard B4 ~ B16 : Value measured between B4 and B16 in (1) above + 0.2 V or more
(*) Perform this inspection only when three or more soot amount indicating LEDs are lit.
OK → Controller defect
NG → To inspection 6
Inspection 6:
Back pressure sensor wiring continuity check
See inspection 2 of error code 2-1.
OK → Back pressure sensor defect
NG → Repair or replace the wiring.
1-79
Error Code 3-1 or 3-3
Inspection 1:
Check that the charge lamp on the combination meter NG Inspect the alternator by referring to the
comes on upon turning the ignition key switch ON and alternator section in the engine repair
goes out upon turning it to the START position. manual.
OK
Inspection 2: NG
Inspect continuity of the L signal wiring between the Repair or replace the wiring.
alternator and controller.
OK
Controller defect.
Inspection 1:
Charge lamp lighting inspection
Charge lamp
OK → To inspection 2
NG → To alternator inspection in the engine repair manual
Inspection 2:
Alternator L signal wiring continuity inspection
Disconnect the alternator and controller connectors.
Tester range: Ω × 1
Measurement terminals Controller connector B19 ~ Alternator terminal 1
Standard 0Ω
Alternator connector
(B) Controller connector Alternator
1 2 3
Controller connector
OK → Controller defect
NG → Repair or replace the wiring
1-80
Error Code 3-2 (For Vehicles without Drive Control)
Inspection 1:
Inspect the engine rpm sensor installed on the injection NG
pump. Replace the injection pump ASSY.
OK
Inspection 2: NG
Inspect continuity of the wiring between the engine rpm Repair or replace the wiring.
sensor and controller.
OK
Controller defect.
Inspection 1:
Engine rpm sensor individual inspection
Disconnect the engine rpm sensor connector.
Tester range: Ω × 1 k
Measurement terminals Between both terminals M-1 and M-2 of rpm sensor
Standard Approx. 1 kΩ
Rpm sensor (M) Rpm sensor connector
connector
2 1
3
OK → To inspection 2
NG → Replace the injection pump ASSY.
1-81
Inspection 2:
Engine rpm sensor wiring continuity inspection
Disconnect the engine rpm sensor and controller connectors.
Tester range: Ω × 1
B7 ~ M2
Measurement terminals Controller connector Engine rpm sensor connector
B20 ~ M1
Standard 0Ω
Engine rpm sensor connector
(M) Engine rpm
(B) Controller connector
sensor connector
1 2
3
Controller connector
OK → Controller defect
NG → Repair or replace the wiring
1-82
Error Code3-2 (For Vehicles with Drive Control)
Inspection 1: NG
Carry out the relevant troubleshooting.
Check the error display of the meter.
OK
Inspection 2: NG
Inspect for continuity between the ASC controller and the Wiring repair or replacement.
DPF controller.
OK
Inspection 3:
NG
Remove the ASC controller, directly connect the engine
rpm sensor and the DPF controller and check for any DPF controller defective.
errors.
OK
ASC controller defective.
Inspection 1:
Check for errors in the vehicle
OK → To inspection 2
NG → To relevant troubleshooting
1-83
Inspection 2:
Continuity check of harness between ASC controller and DPF controller
Disconnect the ASC controller connector and DPF controller connector.
Tester range: Ω × 1
25 ~ B7
Measurement terminals ASC controller connector DPF controller connector
38 ~ B20
Standard 0Ω
(B) DPF controller connector ASC controller connector
17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42
DPF controller connector ASC controller connector
OK → To inspection 3
NG → Repair or replace the wiring
Inspection 3:
Engine rpm sensor operation check when directly connected to the DPF controller
After clearing the error code disconnect the ASC controller connector, short circuit 25 to 36, and 24 to 38 of the
connector and start the engine. Check that an error reoccurs by the lighting of the warning LED (this time the
meter displays error 18-2).
ASC controller connector
17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42
ASC controller connector
No light → ASC controller defective
Light → DPF controller defective
1-84
Error Code 4-1
Inspection 1:
Inspect the blower air cleaner for gas leakage during NG Replace the valve, flow rate sensor,
engine running. blower and/or DPF air cleaner, and
clean or replace the piping.
OK
Inspection 2: OK
Controller defect
Inspect the flow rate sensor input.
NG
Inspection 3: OK
Inspect continuity of the wiring between the flow rate Flow rate sensor defect
sensor and controller.
NG
Controller defect
Inspection 1:
Air cleaner gas leakage inspection
Check that there is no exhaust gas leakage from the blower air cleaner outlet.
Air cleaner
Outlet of air cleaner
for blower
OK → To inspection 2
NG → Replace the valve, flow rate sensor, blower and/or DPF air cleaner, and clean or replace the piping.
1-85
Inspection 2:
Flow rate sensor input check
Voltage measurement between terminals
Controller connector: Flow rate sensor connector in connected state
Stop the engine and turn the ignition key switch ON.
B1 ~ B15
Measurement terminals Controller connector Controller connector
B5 ~ B15
Standard B1 ~ B15 : Battery voltage, B5 ~ B15 : 2.0 V or less
OK → Controller defect
NG → To inspection 3
Inspection 3:
Flow rate sensor wiring cointinuity inspection
Disconnect the flow rate sensor and controller connector.
Tester range: Ω×1
B1 ~ K3
Measurement terminals Controller connector B15 ~ Forw rate sensor connector K2
B5 ~ K1
Standard 0Ω
Flow rate sensor
connector (K) Flow rate
(B) Controller connector sensor connector
1 2 3
Controller connector
OK → Back pressure sensor defect
NG → Repair or replace the wiring
1-86
Error Code 4-2
Inspection 1: NG
Inspect the air cleaner for clogging. Clean or replace the air cleaner.
OK
Inspection 2: NG
Inspect the piping between the air cleaner and blower Clean or replace the piping.
sensor for clogging or leakage.
OK
Inspection 3: NG
Inspect continuity of the wiring between the blower and Repair or replace the piping.
controller.
OK
Inspection 4: NG
Inspect the blower. Blower defect.
OK
NG
Inspection 5:
DPF valve defect.
Inspect the DPF valve.
OK
NG
Inspection 6:
Inspect the wiring between the DPF valve and controller. Repair or replace the wiring.
OK
To the next page.
1-87
From the previous page.
OK
Inspection 7: OK
Inspect the flow rate sensor input. Controller defect
NG
Inspection 8: NG
Inspect continuity between the flow rate sensor and Reapair or replace the wiring.
controller.
OK
Disassemble and inspect the DPF muffler.
Repair or replace if defective.
Inspection 9: OK
Inspect the piping between the blower sensor and muffler Flow rate sensor defect
for clogging.
NG
Clean or replace the piping.
Inspection 1:
Air cleaner clogging inspection
Check that the blower air cleaner is not clogged.
Air cleaner
OK → To inspaection 2
NG → Clean or replace the air cleaner
1-88
Inspection 2:
Gas leakage inspection
Check that no exhaust gas is leaking from the piping that connects the blower air cleaner and flow rate sensor.
Air cleaner
Flow rate sensor Blower
OK → To inspection 3
NG → Clean or replace the piping
Inspection 3:
Blower wiring continuity inspection
Disconnect the blower and controller connectors.
Tester range: Ω × 1
B1 ~ F2
Measurement terminals Controller connector Blower connector
B12 ~ F1
Standard 0Ω
(F) Blower
(B) Controller connector connector
Blower
connector
1 2
Controller connector
OK → To inspection 4
NG → Repair or replace the wiring
Inspection 4:
Blower individual inspection
See page 1-61.
OK → To inspection 5
NG → Blower defect
1-89
Inspection 5:
DPF valve individual inspection
See page 1-61.
OK → To inspection 6
NG → DPF valve defect
Inspection 6:
DPF valve wiring continuity inspection
Disconnect the DPF valve and controller connectors.
Tester range: Ω × 1
B1 ~ D2
Measurement terminals Controller connector DPF valve connector
B11 ~ D1
Standard 0Ω
DPF valve
connector
(D) DPF valve
(B) Controller connector connector
Controller connector
OK → To inspection 7
NG → Repair or replace the wiring
Inspection 7:
Flow rate sensor input check
See inspection 2 of error code 4-1.
OK → Controller defect
NG → To inspection 8
Inspection 8:
Flow rate sensor wiring continuity inspection
See inspection 3 of error code 4-1.
OK → To inspection 9 after DPF muffler individual inspection
NG → Repair or replace the wiring
Inspection 9:
Clogged piping inspection
Check that the piping between the blower sensor and muffler is not clogged.
Valve
Flow rate sensor
To muffler
OK → Flow rate sensor defect
NG → Clean or replace the piping
1-90
Error Code 4-3
OK
Inspection 1:
Controller defect
Inspect the flow rate sensor input.
NG
Inspection 2: OK
Inspect continuity of the wiring between the flow rate Flow rate sensor defect
sensor and controller.
NG
Repair or replace the wiring.
Inspection 1:
Flow rate sensor input check
See inspection 2 of error code 4-1.
OK → Controller defect
NG → To inspectinon 2
Inspection 2:
Flow rate sensor wiring continuity check
See inspection 3 of error code 4-1.
OK → Flow rate sensor defect
NG → Repair or replace the wiring
Error Code 5-1
Replace the DPF filter.
Error Code 6-1
Replace the controller.
1-91
Error Code 7-1
Inspection 1: NG
Charge or replace the battery.
Inspect the battery voltage (10~14 V).
OK
Inspection 2: NG
Inspect the wiring defect between the battery and controller. Repair or replace the wiring.
OK
Controller defect.
Inspection 1:
Battery voltage inspection
Check that the battery voltage is between 10 and 14 V.
OK → Controller defect
NG → Charge or replace the battery
Inspection 2:
Wiring inspection
Inspect the wiring between the battery and controller for continuity.
OK → Controller defect
NG → Repair or replace the wiring
Error Code 7-2
Check that the buzzer and display LED
Inspection 1: NG
are functioning normally when the
Check that the power breaker is not open and that the
ignition key switch is tuned ON with the
cord is securely connected to the outlet.
power cord connected.
OK
NG
Inspection 2:
Power code defect.
Inspect continuity of the power cord.
OK
Inspection 3: NG
Check that the AC wiring for the controller is correctly Correct wiring connection.
connected to the external power receptacle.
OK
Inspection 4:
Connect the power cord and check that the voltage at NG
cord terminals is AC 200 V. Connect the cord to the Controller defect.
vehicle and check for correct functioning when the
regeneration switch on the display is pressed.
OK
DPF system in normal state.
1-92
Inspection 1:
Power supply inspection
Check that the power breaker is not opened and the power cord is securely connected.
OK → To inspection 2
NG → Check for correct functioning of LEDs after the correction
Inspection 2:
Power cord continuity inspection
Inspect continuity between the terminals at both ends of the power cord.
OK → To inspection 3
NG → Power cord defect
Inspection 3: ]
Controller AC wiring inspection
Check that the wiring between the controller and outlet is securely connected.
OK → To inspection 4
NG → Correct wiring connection
Inspection 4:
Power supply voltage inspection
Connect the power cord.
Tester range: AC 500 V
Measurement terminals Power cord terminals
Standard AC 190~220 V
OK → DPF system in normal state
NG → Controller defect
2-1
CLUTCH
Page Page
GENERAL................................2-2 OIL CLUTCH COVER· 0
OIL CLUTCH DEVICE
SPECIFICATIONS ...................2-4 1
(OPT) ................................... 2-27
COMPONENTS........................2-5 2
REMOVAL·INSTALLATION ...... 2-27
CLUTCH COVER.....................2-8 DISASSEMBLY·INSPECTION· 3
REMOVAL·INSTALLATION ........2-8 REASEMBLY ........................ 2-31
4
DISASSEMBLY·INSPECTION· OIL CLUTCH
REASSEMBLY ......................2-12 BOOSTER (OPT)................. 2-34 5
CLUTCH MASTER TROUBLESHOOTING ............. 2-34 6
CYLINDER ...........................2-16 REMOVAL·INSTALLATION ...... 2-35
7
REMOVAL·INSTALLATION ......2-16 DISASSEMBLY·INSPECTION·
DISASSEMBLY·INSPECTION· REASSEMBLY ...................... 2-36 8
REASSEMBLY ......................2-17
OIL CLUTCH RELEASE 9
CLUTCH RELEASE CYLINDER (OPT) ................ 2-39
CYLINDER ...........................2-19 10
REMOVAL·INSTALLATION ...... 2-39
REMOVAL·INSTALLATION ......2-19 11
DISASSEMBLY·INSPECTION·
DISASSEMBLY·INSPECTION· REASSEMBLY ...................... 2-40 12
REASSEMBLY ......................2-20
CLUTCH AIR BLEEDING ..... 2-42 13
OIL CLUTCH (OPT)...............2-21
CLUTCH ADJUSTMENT....... 2-43
GENERAL ..............................2-21
14
CLUTCH PEDAL
SPECIFICATIONS ...................2-23 ADJUSTMENT ...................... 2-43 15
COMPONENTS .......................2-24 OIL CLUTCH RELEASE 16
CYLINDER ADJUSTMENT
(OPT) ................................... 2-44 17
18
19
20
21
E
2-2
GENERAL
Clutch Cover
2-3
Clutch Master Cylinder
0
1
2
3
4
5
6
7
8
9
10
Clutch Release Cylinder
11
12
13
14
15
16
17
18
19
20
21
E
2-4
SPECIFICATIONS
Installed engine
4Y·1DZ-II 4Y (TWC*spec.) ·2Z
Item
Clutch Operation method Hydraulic
Size in 11
Clutch cover
Installation load N (kgf) [lbf] 3236 (330) [728] 3923 (400) [882]
Type Dry type single plate with coil spring
Outside diameter mm (in) 275 (10.83)
Inside diameter mm (in) 175 (6.89)
Clutch disc Thickness mm (in) 3.5 (0.138)
Surface area of
frictional surface cm2 (in2) 276.4 (44.22)
(One side)
Material Woven
Type Conventional
Master cylinder
Bore mm (in) 15.87 (0.6248)
Type Adjustment-free type
Release cylinder
Bore mm (in) 22.2 (0.874)
Applicable fluid SAE J-1703 DOT-3
*: TWC: Three Way Catalytic System (OPT)
2-5
COMPONENTS
Clutch Cover·Clutch Housing (4Y engine vehicle)
3101
0
1
2
3
4
5
6
7
8
9
10
Clutch Cover·Clutch Housing (1DZ-II·2Z engine vehicle) 11
3101 12
13
14
15
16
17
18
19
20
21
E
2-6
Clutch Master Cylinder
3103
Clutch Release Cylinder
3104
2-7
Clutch Pedal
3102
2-8
CLUTCH COVER
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
7 3
8
T = 14.7 ~ 21.6 Fly wheel set bolt
6 (150 ~ 220) 4Y engine vehicle
[10.8 ~ 15.9] T = 78.0 ~ 98.0
(800 ~ 1000) [57.9 ~ 72.4]
1DZ-II·2Z engine vehicle
T = 125.0 ~ 186.0
(1280 ~ 1900) [92.6 ~ 137.5]
5 10
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Remove the clutch housing cover.
4 Remove the release fork and boot. [Point 1]
5 Remove the lock ring. [Point 2]
6 Install (three) service bolts to the clutch cover. [Point 3]
7 Remove the clutch cover set bolts.
8 Remove the clutch disc. [Point 4]
9 Remove the clutch cover.
10 Remove the release hub W/ bearing. [Point 5]
11 Remove the flywheel.
12 Remove the pilot bearing. [Point 6]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply a small amount of clutch spline grease (08887-76003-71 (08887-01706)) on the input shaft spline
portion.
• Be sure to remove the service bolts (3 bolts) from the clutch cover after installing.
2-9
Point Operations
[Point 1]
Removal:
Remove the release fork and boot.
1. Push the release cylinder push rod in.
2. Rotate the release hub and disconnect it from the release fork.
3. Remove the release fork and boot.
Installation:
Install the boot.
1. Push the boot in until the reverse side of it contacts with the
protruding section of the release fork.
2. Fit the flange section of the boot around the whole
circumference of the rear case.
Protruding section
[Point 2]
Removal:
Remove the lock ring.
1. Rotate the flywheel until the lock ring knob comes to the top.
2. Use pliers to remove the lock ring.
3. Use a straight-edge screwdriver to slide the input shaft fully to
the transmission side.
Installation:
Slide the input shaft towards the engine side until the checking
Checking line
line on the shaft is visible.
Installation:
After installing the lock ring, check that the input shaft is
securely locked and doesn't slide.
Engine side
[Point 3]
Removal•Installation:
Rotate the flywheel to a position where the service bolts can
easily be removed.
Service bolt size: M8 × 1.25, L = 40 mm
2-10
[Point 4]
Inspection:
Measure the wear (rivet sinking depth) of the clutch disc.
Limit: 0.3 mm (0.012 in)
Installation:
Pay attention to the clutch disc installing direction.
Transmission side Engine side
Grease fitting [Point 5]
Installation:
Attach the release hub W/ bearing as shown in the illustration
so that the grease fitting is at the top.
[Point 6]
Vehicle with 4Y engine
Removal:
SST 09330-23320-71
SST
Vehicle with 4Y engine
Installation:
SST 09340-23320-71
SST
2-11
Vehicle with 1DZ-II·2Z engine
SST(2) Removal•Installation:
SST 09950-76018-71................................. (1)
SST(1) (09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Greasing the release fork and release hub
When the inside of the clutch housing has been serviced, fill and
apply grease to the release fork and release hub.
A: Clutch release hub grease (08887-76004-71 (08887-01806))
B: MP grease
A B
2-12
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 14.7 ~ 21.6
(150 ~ 220) 7
6 3 [10.8 ~ 15.9]
Disassembly Procedure
1 Remove the adjusting nut. [Point 1]
2 Remove the strap set bolt and strap seat.
3 Remove the clutch cover. [Point 2]
4 Remove the compression spring. [Point 3]
5 Remove the release bearing plate.
6 Remove the nut lock plate, lock spring, eye bolt and release lever. [Point 4]
7 Remove the release bearing. [Point 5]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Reassembly:
Perform reassembly and adjustment as follows:
1. Adjust the height from the pressure plate surface to the cover
mounting surface to the following standard by using three
service bolts.
Standard: 8.8 mm (0.346 in)
2-13
2. Apply a thin coat of molybdenum disulfide grease on the
spherical portion of the adjusting nut before installation.
3. Adjust the height from the cover mounting surface to the
release bearing plate surface to satisfy the following standard
by turning the adjusting nut.
Standard
Height: 58.5 ~ 59.5 mm (2.30 ~ 2.34 in)
Parallelism (inclination): 0.4 mm (0.016 in) or less
[Point 2]
Disassembly:
Put a match mark on the clutch cover and pressure plate.
Reassembly:
Align the match marks when reassembling.
Disassembly:
Remove (three) service bolts while holding the clutch cover
with a press, release the press hydraulic pressure gradually
and remove the clutch cover.
Reassembly:
Install (three) service bolts while holding the clutch cover with
the press.
[Point 3]
Inspection:
Measure the free length of each compression spring.
Vehicle model Standard mm (in)
Vehicle with 4Y·1DZ-II engine 58.3 (2.295)
Vehicle with 4Y (TWC spec.) ·
62.0 (2.440)
2Z engine
Inspection:
Measure the squareness of the compression spring.
Standard: A = 2.5 mm (0.098 in) or less
A
2-14
Reassembly:
Do not mistake the position of each compression spring.
Springs
[Point 4]
Grease application
Reassembly:
Apply molybdenum disulfide grease on the sliding contact
surfaces of the eye bolt and release lever.
[Point 5]
Disassembly:
Use a press and the SST to remove the release bearing.
SST(1) SST(2) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Reassembly:
Protruding parts Reassemble so that the protruding parts of the release bearing
are hid behind the tab parts of the release hub.
Reassembly:
Use a press and the SST to reassemble the release bearing.
SST
SST SST 09950-76018-71
(09950-60010)
2-15
Reassembly:
A A Apply grease to the points indicated in the illustration.
A: Clutch release hub grease (08887-76004-71 (08887-01806))
B: MP grease
B
2-16
CLUTCH MASTER CYLINDER
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 25.6 ~ 38.4
(270 ~ 400)
[19.5 ~ 28.9]
6
4
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Disconnect the clutch reservoir hose from the reservoir tank and drain brake fluid.
4 Disconnect the piping.
5 Remove the push rod clevis pin.
6 Remove the clutch master cylinder.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After the end of installation, perform clutch air bleeding (on page 2-42) and clutch adjustment (on page 2-43).
2-17
DISASSEMBLY·INSPECTION·REASSEMBLY
Disassembly Procedure
1 Remove the push rod.
2 Remove the boot.
3 Remove the master cylinder piston and cylinder cup. [Point 1]
4 Remove the compression spring and retainer. [Point 2]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-18
Grease application Point Operations
[Point 1]
Reassembly:
Apply rubber grease on the whole periphery of the cylinder cup
in the illustration and the push rod coupling portion.
Grease application
[Point 2]
Inspection:
Measure the free length of the compression spring.
Standard: 79.8 mm (3.142 in)
Limit: 70.5 mm (2.776 in)
2-19
CLUTCH RELEASE CYLINDER
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
4
5 T = 14.7 ~ 21.6
(150 ~ 220)
[10.9 ~ 15.9]
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Disconnect the clutch side hose from the reservoir tank and drain brake fluid.
4 Disconnect the pipe.
5 Remove the clutch release cylinder.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After the end of installation, perform clutch air bleeding (on page 2-42) and clutch adjustment (on page 2-43).
2-20
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
5
T = 8.8 ~ 12.8
(90 ~ 130)
[6.5 ~ 9.4]
Disassembly Procedure
1 Remove the push rod.
2 Remove the boot.
3 Remove the release cylinder piston and cylinder cup. [Point 1]
4 Remove the conical spring.
5 Remove the bleeder plug.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Disassembly:
Cover the output side with cloth and blow air gradually from the
oil inlet to remove the piston.
Reassembly:
Apply rubber grease on the cylinder cup before reassembly.
2-21
OIL CLUTCH (OPT)
GENERAL
Oil Clutch Cover
2-22
Oil Clutch Booster
Flow divider
Master cylinder piston Reaction piston
Control valve
Power piston
Oil Clutch Release Cylinder
2-23
SPECIFICATIONS
Installed engine 4Y
4Y 1DZ-II 2Z
Item (TWC spec.)
Oil clutch Operation method Hydraulic
Size in 11
Oil clutch cover 5070 (517) 6865 (700) 5070 (517) 6865 (700)
Installation load N (kgf) [lbf]
[1140] [1543] [1140] [1543]
Wet single-plate type
Type Wet type single plate solid type
with coil spring
Outside diameter mm (in) 275 (10.83)
Inside diameter mm (in) 175 (6.89)
Oil clutch disc
Surface area of
frictional surface cm2 (in2) 185 (29.6)
(One side)
Material Special cork
Type Portless type with hydraulic booster
Oil clutch booster
Bore mm (in) 25.4 (1.00)
Type Adjustable type
Oil clutch release cylinder
Bore mm (in) 20.64 (0.813)
Cooling oil Type Hydraulic oil ISO VG32
2-24
COMPONENTS
Oil Clutch Cover·Oil Clutch Housing (4Y engine vehicle)
3101
Oil Clutch Cover·Oil Clutch Housing (1DZ-II·2Z engine vehicle)
3101
2-25
Oil Clutch Booster
3105
Oil Clutch Release Cylinder
3104
2-26
Oil Clutch Pedal
3102
2-27
OIL CLUTCH COVER·OIL CLUTCH DEVICE (OPT)
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
Fly wheel set bolt
4Y engine vehicle 10
9 T = 78.0 ~ 98.0
(800 ~ 1000) [57.9 ~ 72.4]
1DZ-II·2Z engine vehicle
T = 125.0 ~ 186.0
(1280 ~ 1900) [92.6 ~ 137.5]
8 T = 14.7 ~ 21.6
(150 ~ 220)
[10.9 ~ 15.9]
T = 16.0 ~ 24.0
(170 ~ 250) [12.3 ~ 18.1]
5 7
13 4 11 6
12
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Remove the clutch housing cover.
4 Remove the oil clutch pipe. [Point 1]
5 Remove the lock ring. [Point 2]
6 Disconnect the release fork shaft return spring.
7 Disconnect the clutch release cylinder push rod.
8 Install (three) service bolts on the clutch cover. [Point 3]
9 Remove the clutch cover set bolts.
10 Remove the clutch disc. [Point 4]
11 Remove the clutch cover.
12 Remove the release hub W/ bearing return spring.
13 Remove the release hub W/ bearing.
14 Remove the flywheel. [Point 5]
15 Remove the pilot bearing. [Point 6]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
2-28
Note:
• If the oil accumulated in the clutch housing or the inside of the housing is dirty, drain oil through the
drain plug and clean the inside of the housing.
• Use sandpaper and eliminate fouling (rust or adhesion of antirust or impurity) on the friction surface of
the pressure plate.
• Always remove the service bolts (3 pcs.) after installing the clutch cover.
• Inspect the hydraulic oil level.
• When the oil accumulated in the clutch housing is drained, add the same amount of new hydraulic oil in
the housing.
Point Operations
[Point 1]
Inspection:
Check for clogging of the oil clutch pipe injection hole.
Installation:
When reusing the oil clutch pipe set bolts (precoated bolts),
apply a sealant (08826-76002-71 (08826-00090)) to the
threaded part before fastening.
[Point 2]
Removal:
Remove the lock ring.
1. Rotate the flywheel to make the lock ring knob face upward.
2. Use pliers to remove the lock ring.
3. Use a straight-edge screwdriver to slide the input shaft fully to
the transmission side.
Installation:
Slide the input shaft towards the engine side until the checking
Checking line
line on the shaft is visible.
Installation:
After installing the lock ring, check that the input shaft is
securely locked and doesn't slide.
Engine side
[Point 3]
Removal•Installation:
Rotate the flywheel to the position for easy removal or
installation of each of three service bolts.
Service bolt size: M8 x 1.25, L = 40 mm
2-29
[Point 4]
Inspection:
Measure the clutch disc wear.
Standard: 1.3 mm (0.051 in)
(effective wear margin on one side)
Also check such defect as surface carbonization of the facing
material due to the influence of heat. If any defect is found,
always replace with a new clutch disc.
Installation:
Pay attention to the clutch disc installing direction.
Transmission side Engine side
[Point 5]
Installation:
Apply the sealing agent (08826-76002-71 (08826-00090)) on
Approx. 5 mm
the mating surfaces of the flywheel and crankshaft before
(0.20 in)
installation. (4Y engine vehicle)
SST [Point 6]
4Y engine vehicle
Removal:
SST 09330-23320-71
4Y engine vehicle
Removal:
SST 09340-23320-71
SST
2-30
1DZ-II·2Z engine vehicle
SST(2) Removal•Installation:
SST 09950-76018-71................................. (1)
SST(1) (09950-60010)
09950-76020-71................................. (2)
(09950-70010)
2-31
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 14.7 ~ 21.6
(150 ~ 220)
[10.8 ~ 15.9] 6
5 3
Disassembly Procedure
1 Remove the adjusting nut. [Point 1]
2 Remove the strap set bolt and strap seat.
3 Remove the clutch cover. [Point 2]
4 Remove the compression spring. [Point 3]
5 Remove the nut lock plate, lock spring, eye bolt and release lever. [Point 4]
6 Remove the release bearing. [Point 5]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Reassembly:
Perform reassembly and adjustment as follows:
1. Adjust the height from the pressure plate surface to the cover
mounting surface to the following standard by using three
service bolts.
Standard: 6.1 mm (0.240 in)
2-32
2. Apply a thin coat of molybdenum disulfide grease on the
spherical portion of the adjusting nut before installation.
3. Adjust the height from the cover attachment surface to the tip
end of the release lever using the adjusting nut.
Standard: 55.5 ~ 56.5 mm (2.19 ~ 2.22 in)
(All three release levers)
[Point 2]
Disassembly:
Put a match mark on the clutch cover and pressure plate.
Reassembly:
Align the match marks for reassembly.
Disassembly:
Remove (three) service bolts while holding the clutch cover
with a press, release the press hydraulic pressure gradually
and remove the clutch cover.
Reassembly:
Install (three) service bolts while holding the clutch cover with
the press.
[Point 3]
Inspection:
Measure the free length of each compression spring.
Vehicle series Standard mm (in)
Vehicle with 4Y·1DZ-II engine 62.0 (2.44)
Vehicle with 4Y (TWC spec.) ·
63.5 (2.5)
2Z engine
Inspection:
Measure the squareness of the compression spring.
Standard: A = 2.5 mm (0.098 in) or less
A
2-33
[Point 4]
Grease application
Reassembly:
Apply molybdenum disulfied grease on the sliding contact
surfaces of the eye bolt and release lever.
[Point 5]
SST(2) Disassembly:
Use a press and the SST to remove the release bearing.
SST(1) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Reassembly:
SST(1) Use a press and the SST to reassemble the release bearing.
SST(2) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
SST(1) (09950-70010)
2-34
OIL CLUTCH BOOSTER (OPT)
TROUBLESHOOTING
Phenomenon Estimated cause Corrective action
Push rod twisting due to defective installation
Adjustment of installed position
of clutch master cylinder
The pedal is heavy (or sometimes Clean or replace the reaction piston and
Valve seat defect or foreign matter trapping
heavy) power piston
Defective seals Replacement
Clogged oil hole of flow divider Cleaning
Defective check valve seat or foreign matter
Cleaning or replacement
trapping
Sudden pedal return upon engine stall Defective valve seat or foreign matter Clean or replace the reaction piston and
trapping power piston
Defective seals Replacement
Clutch disconnection failure (light Defective air bleeding from release cylinder Air bleeding
pedal stroke and clutch reconnection
during pedal depression) Defective seals Replacement
2-35
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
4
T = 25.6 ~ 38.4
(270 ~ 400)
[19.5 ~ 28.9]
3
3
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Disconnect the piping.
4 Remove the push rod clevis pin.
5 Remove the clutch booster.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After the end of installation, perform clutch air bleeding (on page 2-42) and clutch adjustment (on page 2-43).
2-36
DISASSEMBLY·INSPECTION·REASSEMBLY
Note:
When fixing the clutch booster on a vise, carefully operate so as not to damage the oil path to the brake
booster and piping connecting portion.
T = N·m (kgf·cm) [ft·lbf]
T = 7.8 ~ 11.8
(80 ~ 120)
[5.75 ~ 8.70]
7·9
T = 7.8 ~ 11.8 7·8
4
(80 ~ 120)
[5.75 ~ 8.70]
1
T = 39.2 ~ 68.6
(400 ~ 700)
[28.9 ~ 50.6] 3
2
Disassembly Procedure
1 Remove the push rod.
2 Remove the boot.
3 Remove the reaction piston and power piston. [Point 1]
4 Remove the master cylinder piston. [Point 2]
5 Remove the flow divider spool.
6 Remove the check ball.
7 Disconnect the reaction piston and power piston. [Point 3]
8 Disassemble the reaction piston. [Point 4]
9 Disassemble the power piston. [Point 5]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-37
Point Operations
[Point 1]
Reassembly:
After reassembly, see that the reaction piston and power
piston move smoothly.
[Point 2]
Disassembly:
Remove the master cylinder piston.
1. Fix the clutch booster in a vise with its pin hole facing the
ground vertically.
2. Remove the plug and gasket.
3. Using a round bar with cloth at the end to hold the master
cylinder piston, let the pin fall.
Carefully operate so as not to damage the inside of the
cylinder.
4. Remove the master cylinder piston and return spring.
Inspection:
Inspect the master cylinder bore in sliding contact with the
piston for wear.
Limit: 0.032 mm (0.00126 in) (diametric clearance)
Reassembly:
Install the master cylinder piston.
1. Fix the clutch booster in a vise with the pin hole vertical to the
ground but facing upward.
2. Use a round bar with cloth at the end to insert the master
cylinder piston and return spring slowly into the cylinder.
Before insertion, align the piston slit with the pin hole.
Carefully operate so as not to damage the cylinder bore.
3. Check the piston slit through the pin hole, and install the pin
securely.
4. Install the gasket and plug.
2-38
[Point 3]
Reassembly:
Apply silicone grease on both cylinder cups.
Reassembly:
Check the reaction piston guide installation direction.
[Point 4]
Disassembly:
While pushing the control valve seat, use a wire to remove the
pin.
Reassembly:
Install the reaction piston.
1. Align the pin holes in the piston and valve seat before
insertion.
2. Use a round bar to insert the control valve seat slowly.
3. Check the pin hole in the valve seat through the pin hole in the
piston, and install the pin so as not to leave any protrusion
from the outer periphery.
[Point 5]
Inspection:
Inspect the power piston sliding surface for any excessive
wear.
Limit: 0.032 mm (0.00126 in) (diametric clearance)
2-39
OIL CLUTCH RELEASE CYLINDER (OPT)
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
5
3
2
4 T = 16.0 ~ 24.0
(170 ~ 250)
[12.3 ~ 18.1]
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Disconnect the release fork shaft return spring.
4 Remove the push rod clevis pin.
5 Disconnect the piping.
6 Remove the clutch release cylinder.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After the end of installation, perform clutch air bleeding (on page 2-42) and clutch adjustment (on page 2-43).
2-40
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 8.8 ~ 12.8
(90 ~ 130)
[6.5 ~ 9.4]
Disassembly Procedure
1 Remove the push rod. [Point 1]
2 Remove the boot.
3 Remove the release cylinder piston and cylinder cup. [Point 2]
4 Remove the breather plug.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-41
Point Operations
[Point 1]
Reassembly:
Assemble the push rod so that its length is as shown in the
illustration, and adjust it when installing the push rod on the
vehicle.
140 mm (5.118 in)
[Point 2]
Disassembly:
Cover the output side with cloth, and gradually blow air
through the oil inlet to remove the piston.
Reassembly:
Apply rubber grease on the cylinder cup before reassembly.
2-42
CLUTCH AIR BLEEDING
Vehicle with Dry Clutch
Note:
Add brake fluid to the reservoir tank during air bleeding to
maintain an appropriate level.
1. Bleed air from the clutch release cylinder.
(1) Depress the clutch pedal several times to compress the
air in the piping and hold the state.
(2) Loosen the breather plug to discharge air in the piping
and brake fluid, and tighten the plug just before the fluid
stops running out.
(3) Repeat steps (1) and (2) above until no air bubble is seen
in the discharged brake fluid.
2. Add brake fluid to the specified level.
Vehicle with Oil Clutch
Step on the clutch pedal with the engine idling to bleed air.
2-43
CLUTCH ADJUSTMENT
CLUTCH PEDAL ADJUSTMENT
Dry clutch vehicle Oil clutch vehicle
Pedal height adjustment bolt
233 mm (9.17 in))
233 mm (9.17 in))
(Reference:
(Reference:
C
B A
Floor mat Toe board
D D
1. Adjust clutch pedal height.
Standard: A = 145 ~ 150 mm (5.71 ~ 5.91 in) (From the toe board to the upper surface of the pedal)
Standard: B = 142 ~ 147 mm (5.59 ~ 5.79 in) (From the floor mat to the upper surface of the pedal)
2. Adjust the play in the clutch pedal.
Adjust by the length of the push rod in the clutch master cylinder or clutch booster.
Standard: C = 1 ~ 5 mm (0.039 ~ 0.197 in)
3. With the clutch pedal in the state described above, check the play D in the push rod of the clutch master cylinder
or clutch booster.
Vehicle with dry clutch: D = 1.0 mm (0.039 in) (Reference value)
Vehicle with oil clutch: D = 2.2 mm (0.087 in) (Reference value)
2-44
OIL CLUTCH RELEASE CYLINDER ADJUSTMENT (OPT)
Contact
1. Make certain that the release cylinder piston is in secure contact with the cylinder bottom, and that the release
cylinder push rod is in secure contact with the release cylinder piston.
2. In the above state, adjust the length of the release cylinder push rod so that the distance A between the release
bearing and release lever conforms with the value below.
Standard: A = 1 ~ 2 mm (0.039 ~ 0.079 in)
(When A is 1 ~ 2 mm (0.039 ~ 0.079 in), the stroke B of the push rod is 2 ~ 4 mm (0.079 ~ 0.157 in), so the
adjustment may be made by B also.)
3. Start the engine and bleed air from the release cylinder. (Refer to page 2-42)
4. After bleeding air, check that the measurement B above is within the standard values.
3-1
TORQUE CONVERTER & TRANSMISSION
Page
GENERAL...............................................................3-2
0
HYDRAULIC CIRCUIT DIAGRAM .........................3-5
1
SPECIFICATIONS ..................................................3-6
2
COMPONENTS ......................................................3-7
TROUBLESHOOTING..........................................3-13
3
TRANSMISSION COVER & 4
CONTROL VALVE ASSY ...................................3-14 5
REMOVAL·INSTALLATION .....................................3-14
6
DISASSEMBLY·INSPECTION·REASSEMBLY ...........3-15
7
TORQUE CONVERTER·OIL PUMP .....................3-18
8
REMOVAL·INSTALLATION .....................................3-18
TORQUE CONVERTER & 9
TRANSMISSION ASSY ......................................3-21 10
REMOVAL·INSTALLATION .....................................3-21
11
TRANSMISSION ASSY........................................3-25
12
DISASSEMBLY·INSPECTION·REASSEMBLY ...........3-25
13
CLUTCH DRUM ASSY.........................................3-32
DISASSEMBLY·INSPECTION·REASSEMBLY ...........3-32
14
DIRECTION SWITCH ASSY ................................3-36 15
REMOVAL·INSTALLATION .....................................3-36 16
OIL PRESSURE MEASUREMENT AND 17
STALL TEST.......................................................3-37
18
19
20
21
E
3-2
GENERAL
Torque Converter
R F
F: Forward
R: Reverse
3-3
Control Valve (Upper)
0
1
2
A A
3
B B
4
5
6
C C
7
8
9
10
11
12
A-A: Regulator valve
13
14
15
16
B-B: Inching valve
17
18
19
C-C: Accumulator
20
21
E
3-4
Control Valve (Lower)
A A
B B
C C
A-A: Safety valve
B-B: Shift change valve (R)
C-C: Shift change valve (F)
Inching valve
Solenoid valve (R)
Shift change valve (R)
Accumulator
Solenoid
Safety valve valve (F)
HYDRAULIC CIRCUIT DIAGRAM
Regulator valve
Relief
valve
In-line strainer
Oil pump
R clutch Cooler
Shift change valve (F)
F clutch Oil
filter
3-5
9
8
7
6
5
4
3
2
1
0
E
11
21
20
19
18
17
16
15
14
13
12
10
3-6
SPECIFICATIONS
Item 1 speed torque converter
Maker Aisin
Torque converter type 3 elements, 1 stage, 2 phases type
Torque converter model AISIN
4Y·1DZ-II 2.68
Stall torque ratio
2Z 2.61
4Y·1DZ-II 2100
Stall speed rpm
2Z 2050
Control system Solenoid type selector valve
Clutch operating pressure (main pressure) 2 1108 (11.3) [161]
kPa (kgf/cm ) [psi]
Torque converter outlet pressure kPa (kgf/cm2) [psi] 392 (4.0) [57]
Torque converter oil capacity l (USgal) 8.0 (2.11)
Torque converter oil ATF GM Dexron® II
Note: The indicated oil pressure is at an engine speed of 2000 rpm.
Torque Converter Ratio
Torque Converter Ratio
Vehicle model Engine
Forward Reverse
1 ton series 4Y·1DZ-II 1.633 1.641
K2 ton series 4Y·1DZ-II ↑ ↑
4Y·1DZ-II ↑ ↑
2 ton series
2Z 1.323 1.341
K3 ton series 4Y·1DZ-II 1.633 1.641
1DZ-II ↑ ↑
3 ton series
4Y·2Z 1.323 1.341
4Y ↑ ↑
J3.5 ton series
2Z ↑ ↑
3-7
COMPONENTS
Torque Converter Housing (4Y Engine Vehicle)
3201
Torque Converter Housing (1DZ-II·2Z Engine Vehicle)
3201
3-8
3201
Torque Converter
3202
3-9
Torque Converter Clutch
3203
Torque Converter Gear
3204
3-10
Control Valve
3206
3206
3-11
3206
Torque Converter Piping
3213
3-12
3213
Direction Switch
5701
Disassembly and inspection
Components other than control valves On-board inspection
Control valve (torque converter & transmission)
Regulator valve
Inching valve
Shift change valve for F
Shift change valve for R
Safety valve
Accumulator for F, R
Solenoid valve for F
Solenoid valve for R
In-line strainer
Relief valve
Wire to solenoid
Oil strainer
Torque converter
Oil pump
Clutch drum for F
Clutch drum for R
Gear, bearing
Shift lever switch and
neutral start switch
ATF level and quality
Inching lever, and
wire cable
Oil pressure test
Stall test
Faulty starting No starting at F
No starting at R
TROUBLESHOOTING
No starting at any ranges
No starting at N
Large shock at At N F
starting (shifting)
At N R
after shifting
At N
start
Inching At starting
At R
Large time lag at At N F
starting (shifting)
At N R
At switch back F R
Slippage At F
At R
Others Starter fails to revolve at N.
Starter revolve at ranges other than N.
No inching operation
Overheating of transmission,
no air flow from breather
Abnormal noise
3-13
3-14
TRANSMISSION COVER & CONTROL VALVE ASSY
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 21.0 (214) [15.5]
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Disconnect the inching wire.
4 Disconnect the connector.
5 Remove the transmission cover & control valve ASSY.
Installation Procedure
The installation procedure is reverse of the removal procedure.
3-15
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 12.5 (127) [9.2]
3
T = 21.0 (214) [15.5] 5
4
T = 7.9 (81)
[5.8]
3
2
7
T = 20.2 (206) [14.9]
T = 7.9 (81) [5.8]
Disassembly Procedure
1 Disconnect the solenoid valve connector.
2 Remove the solenoid valve.
3 Remove the sleeve lock plate and solenoid wire ASSY.
4 Remove the inching lever.
5 Remove the inching level oil seal. [Point 1]
6 Remove the accumulator valve, inching valve and regulator valve. [Point 2]
7 Remove the lower valve body ASSY, oil strainer, relief valve piston and spring. [Point 3]
8 Remove the safety valve, F shift valve and R shift valve. [Point 4]
Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
3-16
Point Operations
[Point 1]
Reassembly:
SST(2)
SST 09950-76018-71................................. (1)
SST(1) (09950-60010)
09950-76020-71................................. (2)
(09950-70010)
[Point 2]
Service bolt Disassembly:
Remove the accumulator valve plug using the service bolt.
Service bolt size: M8×1.25
Inspection:
Measure free length of each valve spring.
Standard mm (in) Limit mm (in)
Inner 67.4 (3.390) 64.0 (3.220)
Accumulator valve
Outer 127.8 (5.031) 121.4 (4.780)
Plug side 64.2 (2.528) 61.0 (2.402)
Inching valve
Valve side 49.9 (1.965) 47.4 (1.866)
Regulator valve 132.4 (5.213) 125.8 (4.953)
[Point 3]
Reassembly:
Install the lower valve body.
1. Install the oil strainer, spring and relief valve piston on the
lower valve body, and put the gasket on top.
2. Reverse the above while maintaining the assembled state and
install it on the transmission cover.
3-17
[Point 4]
Disassembly:
Press in the valve plug with its opening facing downwards and
remove the key.
Inspection:
Measure free length of each valve spring.
Standard mm (in) Limit mm (in)
F/R shift valve 59.8 (2.354) 56.8 (2.236)
Safety valve 59.8 (2.354) 56.8 (2.236)
3-18
TORQUE CONVERTER·OIL PUMP
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 21.0 (220) [15.9]
Removal Procedure
1 Drain torque converter oil.
2 Remove the engine ASSY. (See page 1-12.)
3 Remove the torque converter ASSY. [Point 1]
4 Remove the oil pump W/ stator shaft. [Point 2]
5 Remove the stator shaft. [Point 3]
6 Remove the oil pump drive gear and the oil pump driven gear. [Point 4]
7 Remove the oil seal. [Point 5]
Installation Procedure
The installation procedure is reverse of the removal procedure.
Point Operations
[Point 1]
Removal:
Be careful as the torque converter ASSY contains oil.
Oil
seals Installation:
Apply MP grease to the seal ring and oil seal lip before
installation.
Installation:
Install while rotating the torque converter ASSY so that the
extension claw engages with the groove in the oil pump drive gear.
3-19
[Point 2]
Service tap
Removal:
SST 09950-76014-71
(09950-40011)
Service tap
SST
Installation:
Be careful not to install the pre-coated bolts in incorrect
positions.
Installation:
When reusing precoated bolts, apply thread tightener (08833-
76002-71 (08833-00080)) to the threaded part.
[Point 3]
Removal:
Put match marks on the oil pump and stator shaft ASSY.
Installation:
Align match marks when installing.
[Point 4]
Inspection:
Measure the clearance between the oil pump driven gear and
pump body.
Limit: 0.3 mm (0.012 in)
Inspection:
Measure the clearance between the pump body and each
gear.
Standard: 0.042 ~ 0.080 mm (0.002 ~ 0.003 in)
3-20
Inspection:
The marks have no meaning for reassembly.
Marks
[Point 5]
Installation:
SST 09370-10410-71
SST
3-21
TORQUE CONVERTER & TRANSMISSION ASSY
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
29 27
24 9
Engine mounting nut T = 53.2 ~ 98.0 (550 ~ 1000) [39.8 ~ 72.3]
Front insulator set bolt T = 68.0 ~ 102.0 (700 ~ 1050) [50.6 ~ 76.0]
Torque converter housing set bolt T = 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
4Y engine vehicle
T = 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]
Drive plate set bolt (for connecting to engine crankshaft)
1DZ-II·2Z engine vehicle
T = 76.4 ~ 93.1 (780 ~ 950) [56.4 ~ 68.7]
Drive plate set bolt (for connecting to torque converter) T = 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
3-22
Removal Procedure
1 Remove the engine hood. (Refer to page 11-10)
2 Remove the lower panel.
3 Remove the toe board.
4 Drain coolant.
5 Remove the battery.
6 Remove the sedimenter bracket set bolt and leave it free. (1DZ-II·2Z engine vehicle)
7 Disconnect the accelerator wire. (1DZ-II·2Z engine vehicle)
8 Disconnect the fuel hose.
9 Remove the relay block and leave it free.
10 Remove the battery set plate.
11 Remove the air cleaner and air inlet.
12 Remove the exhaust pipe cover plate.
13 Disconnect the exhaust pipe.
14 Remove the RH side step and side cover.
15 Disconnect the main harness connector inside the RH side cover.
16 Disconnect the oil pump-to-oil control valve hose.
17 Disconnect the inching wire.
18 Disconnect the torque converter cooler hose (on the transmission side) and drain oil from the torque converter.
[Point 1]
19 Disconnect the torque converter cooler hose (on the radiator side). [Point 2]
20 Disconnect the water hose.
21 Remove the radiator and fan shroud.
22 Remove the under cover.
23 Disconnect the wiring and wire harness clamps around the engine and transmission.
24 Remove the oil pump set bolt, and leave it free.
25 Remove the propeller shaft under cover and propeller shaft. (Refer to page 5-3)
26 Remove the engine mount nut.
27 Attach the SST to the engine W/ torque converter and transmission ASSY. [Point 3]
28 Remove the front insulator set bolt.
29 Remove the engine W/ torque converter & transmission ASSY. [Point 4]
30 Remove the cover plate.
31 Remove the drive plate set bolts (6 bolts). [Point 5]
32 Disconnect the engine ASSY from the torque converter housing.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the engine ASSY, perform air bleeding of the fuel system. (1DZ-II·2Z engine vehicle) (refer to
page 1-18)
3-23
Point Operations
[Point 1]
Removal:
Put match marks on the transmission case and torque
converter cooler hose.
[Point 2]
Removal:
Put match marks on the radiator and torque converter cooler
hose.
SST(1) [Point 3]
SST(2) Removal•Installation:
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)
[Point 4]
Removal•Installation:
SST Move the SST hook position to adjust the balance.
3-24
[Point 5]
Removal•Installation:
Turn the flywheel using the crankshaft pulley set bolt.
Crankshaft
pulley set bolt
3-25
TRANSMISSION ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 56.0 (571) 16
[41.3]
17
T = 12.7 (129.5)
[9.4]
14 10
14
14
9
8
11
7
T = 69.0 ~ 96.0
T = 19.0 (193.7) [14.0] (703.6 ~ 978.9) 13
[50.9 ~ 70.8] 15
14
12
4
14 6
T = 21.0 (214.1) [15.5]
3
T = 49.0 (499.7)
[36.2]
T = 32 ~ 48 T = 56.0
(326.3 ~ 489.5) (571.0)
[23.6 ~ 35.4] [41.3]
3-26
Disassembly Procedure
1 Drain torque converter oil.
2 Remove the transmission cover & control valve ASSY.
3 Remove the torque converter.
4 Remove the oil pump W/ stator shaft ASSY and shim. [Point 1]
5 Remove the rear case. [Point 2]
6 Remove the output gear cover, output gear and shim. [Point 3]
7 Remove the counter gear and shim. [Point 4]
8 Remove the counter gear shaft and main shaft ASSY. [Point 5]
9 Remove the spacer, main shaft rear bearing, reverse clutch gear, forward clutch gear, and reverse & forward
clutch drum ASSY. [Point 6]
(Refer to page 3-51 for disassembly, inspection and reassembly of the clutch drum ASSY)
10 Remove the forward clutch gear bearing. [Point 7]
11 Remove the reverse clutch gear bearing. [Point 8]
12 Remove the output shaft. [Point 9]
13 Remove the output shaft dust deflector. [Point 10]
14 Remove the main shaft front bearing, the counter gear bearing and output gear bearing. [Point 11]
15 Remove the output shaft oil seal. [Point 12]
16 Remove the oil strainer. [Point 13]
17 Remove the oil filter. [Point 14]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
Service tap
[Point 1]
Disassembly:
SST 09950-76014-71
(09950-40011)
Service tap
SST
Reassembly:
Be careful not to install the pre-coated bolts in incorrect
positions.
Reassembly:
When reusing precoated bolts, apply thread tightener (08833-
76002-71 (08833-00080)) to the threaded part.
3-27
Reassembly:
Adjust the thrust clearance of the main shaft system.
1. Temporarily assemble the oil pump W/ stator shaft ASSY,
shim, and rear case, and measure the thrust clearance of the
main shaft gear system.
A
Standard: A = 0.10 ~ 0.24 mm (0.004 ~ 0.009 in)
2. If the standard is not satisfied, increase or decrease the shim
Shim thickness for adjustment.
Mark Thickness mm (in)
A 1.08 ~ 1.12 (0.043 ~ 0.044)
B 1.18 ~ 1.22 (0.046 ~ 0.048)
C 1.28 ~ 1.32 (0.050 ~ 0.052)
E 1.38 ~ 1.42 (0.054 ~ 0.056)
F 1.48 ~ 1.52 (0.058 ~ 0.060)
G 1.58 ~ 1.62 (0.062 ~ 0.064)
H 1.68 ~ 1.72 (0.066 ~ 0.068)
J 1.78 ~ 1.82 (0.070 ~ 0.072)
K 1.88 ~ 1.92 (0.074 ~ 0.076)
L 1.98 ~ 2.02 (0.078 ~ 0.080)
M 2.08 ~ 2.12 (0.082 ~ 0.083)
N 2.18 ~ 2.22 (0.086 ~ 0.087)
P 2.28 ~ 2.32 (0.090 ~ 0.091)
R 2.38 ~ 2.42 (0.094 ~ 0.095)
S 2.48 ~ 2.52 (0.098 ~ 0.099)
[Point 2]
Disassembly:
Insert a flat head screwdriver in the cut portion of the rear case
and remove the case.
Magnet Reassembly:
Assemble after removing iron powder staying on the magnet.
3-28
[Point 3]
Reassembly:
Adjust the output gear thrust clearance.
1. Temporarily install the output gear, shim and rear case, and
measure the output gear thrust clearance.
Standard: A = 0.10 ~ 0.49 mm (0.004 ~ 0.019 in)
A
Shim 2. If the standard is not satisfied, increase or decrease the shim
thickness for adjustment.
Mark Thickness mm (in)
0 0.375 ~ 0.425 (0.015 ~ 0.017)
2 0.67 ~ 0.75 (0.026 ~ 0.030)
4 0.855 ~ 0.945 (0.034 ~ 0.037)
6 1.065 ~ 1.175 (0.042 ~ 0.046)
7 1.12 ~ 1.24 (0.044 ~ 0.049)
[Point 4]
Reassembly:
Adjust the counter gear thrust clearance.
1. Temoporarily assemble the counter gear, shim and rear case,
and measure the thrust clearance of the counter gear.
Standard: 0.10 ~ 0.54 mm (0.004 ~ 0.021 in)
Shim
2. If the standard is not satisfied, increase or decrease the shim
thickness for adjustment.
Mark Thickness mm (in)
0 0.375 ~ 0.425 (0.015 ~ 0.017)
2 0.67 ~ 0.75 (0.026 ~ 0.030)
3 0.855 ~ 0.945 (0.034 ~ 0.037)
4 1.01 ~ 1.11 (0.040 ~ 0.044)
5 1.12 ~ 1.24 (0.044 ~ 0.049)
6 1.24 ~ 1.36 (0.049 ~ 0.054)
[Point 5]
Disassembly•Reassembly:
Disassemble or reassemble the counter gear shaft together
with the main shaft ASSY.
3-29
[Point 6]
Inspection:
Measure the seal ring side clearance.
Limit: 0.2 mm (0.008 in)
Reassembly:
After aligning the clutch disc serration using a screwdriver or
the like, reassemble the clutch gear.
[Point 7]
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(2) 09950-76020-71................................. (2)
(09950-70010)
SST(1)
Reassembly:
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
SST(2)
SST(1)
[Point 8]
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(2)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
3-30
Reassembly:
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
SST(2) (09950-70010)
SST(1)
[Point 9]
Disassembly•Reassembly:
SST 09905-76002-71
(09905-00012)
SST
[Point 10]
Reassembly:
SST 09370-20270-71
SST
[Point 11]
Disassembly:
SST
SST 09320-23000-71
Reassembly:
SST(2) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
3-31
[Point 12]
Disassembly•Reassembly:
Use a flat head screwdriver or the like to disassemble or
reassemble the output shaft oil seal.
Reassembly:
A Reassemble the output shaft oil seal to the position A in the
illustration.
A = 6.7 ~ 7.7 mm (0.264 ~ 0.303 in)
[Point 13]
Disassembly:
Pinch the rib part of the oil strainer with long-nosed pliers, and
remove the oil strainer.
[Point 14]
Disassembly•Reassembly:
SST 09228-76004-71
(09228-07501)
SST
Clutch operation check after reassembly
F
R Blow air through the oil hole on top of the transmission case and
check that each clutch piston operates normally.
F R
3-32
CLUTCH DRUM ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY
Disassembly Procedure
1 Remove the snap ring.
2 Remove the backing plate, clutch discs, clutch plates and camber plate. [Point 1]
3 Remove the snap ring and clutch piston return spring. [Point 2]
4 Remove the clutch piston, piston ring and seal ring. [Point 3]
Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
Point Operations
[Point 1]
Inspection:
Measure thickness of the clutch disc.
Standard: 2.6 mm (0.102 in)
Limit: 2.3 mm (0.091 in)
3-33
Inspection:
Measure thickness of the clutch plate.
Standard: 2.0 mm (0.079 in)
Limit: 1.8 mm (0.071 in)
Inspection:
Measure height of the camber plate curving.
Standard: 3.4 mm (0.134 in)
Limit: 3.1 mm (0.122 in)
Reassembly:
Clutch gear side
Reassemble with the punched side facing upwards (the clutch
gear side).
Piston side
Punching
3-34
Reassembly:
Install the clutch plates and clutch discs alternately on the
clutch drum while applying torque converter oil.
Number of clutch discs
1 ton series 4Y·1DZ-II models 4
K2·K3 ton series 4Y·1DZ-II models 5
4Y·1DZ-II models 5
Camber plate 2·3 ton series
2Z model 5
4Y model 5
J3.5 ton series
2Z model 5
Reassembly:
Adjust the clearance between the backing plate and clutch
disc.
1. Install the camber plate, clutch plates, clutch discs, backing
plate and snap ring on the clutch drum.
2. Measure clearance between the backing plate and snap ring
using thickness gauges.
Standard:
4-disc specification: 0.8 ~ 1.4 mm (0.031 ~ 0.055 in)
5-disc specification: 1.0 ~ 1.6 mm (0.039 ~ 0.063 in)
3. If the measured value is out of the specified range, select a
Identifying grooves suitable backing plate.
Backing plate thickness
A Identifying grooves
A 5.7 mm (0.224 in) 0
6.2 mm (0.244 in) One groove
6.7 mm (0.264 in) Two grooves
Identifying grooves Reassembly:
Install the backing plate with its stepped side (with groove)
facing upward (on the clutch gear side).
3-35
[Point 2]
Disassembly•Reassembly:
SST(1) Compress the return spring using the SST and remove or
install the snap ring.
SST(2) Tie two hooks of the SST using a wire or string as shown in the
illustration to fix it in the clutch drum.
SST 09220-22001-71................................. (1)
09905-76002-71................................. (2)
(09905-00012)
Wire
Caution:
The hooks may come off the clutch drum and spring may jump
out when using the SST. Be careful not to allow the hooks to
come off the drum when removing or installing the snap ring.
Inspection:
Measure free length of the clutch piston return spring.
Standard: 63.4 mm (2.496 in)
Limit: 58.5 mm (2.303 in)
[Point 3]
Disassembly:
Pinch the rib of clutch piston using pliers with cloth in-between
and remove the piston.
Reassembly:
Apply torque converter oil on the piston ring and seal ring, and
assemble the clutch piston.
3-36
DIRECTION SWITCH ASSY
REMOVAL·INSTALLATION
1
3
Disassembly Procedure
1 Remove the steering column cover.
2 Disconnect the connector.
3 Remove the direction switch ASSY. [Point 1]
Installation Procedure
The installation procedure is reverse of the removal procedure.
Point Operations
23 22 21 20 19 18 17 16 15
[Point 1]
32 31 30 29 28 27 26 25 24
Inspection:
LH spec. RH spec. Inspect for continuity between the pins of the switch connector.
15: — 15: VR
16: IG2 16: Ra (P:Position, T:Terminal No., :Continuous)
17: N 17: ST
18: IG1 18: VF2 P T N IG1 IG2 VF ST VR Ra
19: VF 19: VF
F1
20: VF2 20: IG1
21: ST 21: N
22: Ra 22: IG2 N
23: VR 23: —
VF : Forward solenoid
VF2 : Forward (F2) solenoid R
VR : Reverse solenoid Rr
ST : Starting motor relay Ra
Ra : Backup lamp & buzzer
3-37
OIL PRESSURE MEASUREMENT AND
STALL TEST
Front 1. Maintain the vehicle horizontally and warm up the engine with
the direction switch at the N position.
2. Measure the oil level.
(1) Stop the engine, and after 30 seconds has passed,
inspect the oil level using the level guage.
Back
(2) If the oil level is not between F (upper limit) and L (lower
limit), adjust it to an appropriate level.
Clutch pressure (F) Clutch pressure (R) 3. Measure the oil pressure.
Main
pressure (1) Check and adjust the engine speed.
(2) Stop the engine and jack up at the front axle to raise
wheels (both tires).
(3) Set the oil pressure gauge. (If three oil pressure gauges
are available, measure the main, clutch and torque
converter outlet pressures at a time.)
Use the adapter (SST) for the main pressure and clutch
pressure detection port.
Outlet pressure
SST 09350-23320-71
(SST thread size: Valve side 5/16 UNF, Oil pressure
gauge side PT1/8)
(4) Start the engine, set the direction switch to the N position.
Measure the main pressures at idle and 2000 rpm, and
the torque converter outlet pressure at 2000 rpm.
(5) Operate the direction switch to the F and R positions, and
measure the respective clutch working pressures at idle
and at 2000 rpm.
Note:
Do not step on the inching pedal while measuring oil pressure.
Standard:
kPa (kgf/cm2) [psi]
Detecting pressure Plug size Idle 2000 rpm
735 ~ 1324 (7.5 ~ 13.5)
Main pressure PT1/8 (SST) 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]
[106.6 ~ 192.0]
Clutch pressure ↑ ↑ 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]
Torque converter outlet
PT1/8 — 80 ~ 540 (0.8 ~ 5.5) [11.3 ~ 78.2]
pressure
3-38
4. Carry out the stall test.
(1) Load cargo having near the permissible maximum load,
firmly set stoppers at the front and rear wheels, and
activate the parking brake.
Caution:
Prevent the vehicle from moving by pulling at the rear by a
wire as shown, to perform the stall test safely.
(2) Warm up the engine and measure the idle speed, no-load
static maximum revolution and relief down.
(3) Set the direction switch to the forward position, depress
Accelerator pedal the accelerator pedal all the way and measure the stall
speed after the engine speed is stabilized.
Standard:
4Y: Approx. 2050 rpm
1DZ-II: Approx. 2100 rpm
2Z: Approx. 2050 rpm
4-1
MANUAL TRANSMISSION
Page
GENERAL...............................................................4-2
0
SPECIFICATIONS ..................................................4-3
1
COMPONENTS ......................................................4-4
2
MANUAL TRANSMISSION ASSY .........................4-7
REMOVAL·INSTALLATION .......................................4-7
3
DISASSEMBLY·INSPECTION·REASSEMBLY ...........4-10 4
SPEED SHAFT ASSY ..........................................4-15 5
DISASSEMBLY·INSPECTION·REASSEMBLY ...........4-15 6
COUNTERSHAFT ASSY......................................4-19 7
DISASSEMBLY·INSPECTION·REASSEMBLY ...........4-19
8
SHIFT LINK BRACKET ASSY .............................4-25
9
DISASSEMBLY·INSPECTION·REASSEMBLY ...........4-25
SHIFT LEVER, SHIFT WIRE CABLE...................4-26 10
REMOVAL·INSTALLATION .....................................4-26 11
12
13
14
15
16
17
18
19
20
21
E
4-2
GENERAL
4-3
SPECIFICATIONS
Transmission type Full synchromesh type
Operating method Instrument panel wire method
Transmission case oil capacity l (US gal) 3.6 (0.95) 0
Hypoid gear oil SAE 85W-90
Transmission oil
Cold area: gear oil API GL-3, SAE 75W-90
1
Gear Ratio
2
Gear ratio
Engine Forward Reverse 3
1st speed 2nd speed 1st speed 2nd speed
4Y·1DZ-II 3.628 1.582 3.643 1.588 4
2Z 3.339 1.348 3.353 1.354
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
4-4
COMPONENTS
Dry Clutch
3301
Oil Clutch (OPT)
3301
4-5
3302
0
1
2
3
4
5
6
7
8
9
10
3303
11
12
13
14
15
16
17
18
19
20
21
E
4-6
Dry Clutch
3303
Oil Clutch (OPT)
3303
4-7
MANUAL TRANSMISSION ASSY
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
29
27
22 9
Engine mount nut T = 53.2 ~ 98.0 (550 ~ 1000) [39.2 ~ 72.3]
Front insulator set bolt T = 68.0 ~ 102.0 (700 ~ 1050) [50.2 ~ 75.3]
Dry clutch vehicle:
T = 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.5]
Clutch housing set bolt
Oil clutch vehicle:
T = 32.3 ~ 48.5 (330 ~ 500) [23.8 ~ 35.8]
4-8
Removal Procedure
1 Remove the engine hood. (Refer to page 11-10)
2 Remove the lower panel.
3 Remove the toe board.
4 Drain the coolant.
5 Remove the battery.
6 Remove the sedimenter bracket set bolt, and leave it free. (1DZ-II/2Z engine vehicle)
7 Disconnect the accelerator wire. (1DZ-II/2Z engine vehicle)
8 Disconnect the fuel hose.
9 Remove the relay block and leave it free.
10 Remove the battery set plate.
11 Remove the air cleaner and air inlet.
12 Remove the exhaust pipe cover plate.
13 Disconnect the exhaust pipe.
14 Disconnect the oil clutch hose. (Oil clutch vehicle)
15 Disconnect the release fork shaft return spring. (Oil clutch vehicle)
16 Disconnect the clutch release cylinder push rod. (Oil clutch vehicle)
17 Remove the clutch release cylinder set bolt and hydraulic piping clamp set bolt, and leave them free.
18 Disconnect the water hose.
19 Remove the radiator and fan shroud.
20 Remove the under cover.
21 Disconnect the wiring and wire harness clamps around the engine and transmission.
22 Remove the oil pump set bolt, and leave it free.
23 Disconnect the wire cable on the shift link side. [Point 1]
24 Remove the shift wire cable bracket.
25 Remove the propeller shaft under cover and propeller shaft. (Refer to page 5-3)
26 Remove the engine mount nut.
27 Install SST to the engine W/ transmission ASSY. [Point 2]
28 Remove the front insulator set bolt.
29 Remove the engine W/ transmission ASSY. [Point 3]
30 Remove the clutch cover and release hub W/ bearing.
(Dry clutch vehicle: refer to page 2-8; oil clutch vehicle: refer to page 2-27)
31 Disconnect the engine ASSY from the clutch housing.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the engine ASSY, bleed air from the fuel system. (1DZ-II/2Z engine vehicle) (Refer to page 1-
18)
4-9
Point Operations
[Point 1]
Installation:
Identification
Check the identification mark on the wire cables (white tape for
mark
1st/2nd) and connect.
SST(1) [Point 2]
SST(2) Removal•Installation:
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)
[Point 3]
Removal•Installation:
SST Adjust the balance by moving the SST hook position.
4-10
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 34.3 ~ 51.5 1
(350 ~ 525)
[25.3 ~ 38.0]
T = 29.4 ~ 39.2
(300 ~ 400)
15 12 [21.7 ~ 28.9]
13 5
13
13
13
5
3
12
7
6
12
10
14
11
9
4-11
Disassembly Procedure
1 Pull out the oil level gauge, and drain the transmission oil.
2 Remove the shift link bracket ASSY. [Point 1]
3 Remove the clutch release bearing retainer.
4 Remove the neutral switch.
5 Remove the detent plug, spring and steel ball.
6 Remove the rear case.
7 Remove the input shaft oil seal. [Point 2]
8 Remove the fork shaft oil seal and spacer (dry clutch vehicle only). [Point 3]
9 Remove the output shaft rear bearing and output gear.
10 Remove the output shaft. [Point 4]
11 Remove the output shaft dust deflector. [Point5]
12 Remove the counter shaft ASSY, shim, speed shaft ASSY and fork shaft ASSY. [Point 6]
13 Remove the shift fork.
14 Remove the output shaft front bearing.
15 Remove the output shaft oil seal. [Point 7]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Make sure to remove the sealing agent applied to the
surface to be in contact with the transmission case and
each cover, and apply new sealing agent by referring to
illustration on the left.
Seal packing: 08826-76002-71 (08826-00090)
• If reusing the clutch release bearing set bolt (pre-coat
bolt), apply sealing agent (08833-76002-71 (08833-00080))
on the thread of the bolt.
Application of
the sealing agent
4-12
Point Operations
Shift link [Point 1]
Dust boot Reassembly:
Fork shaft Reassemble by aligning the tip end of the F/R and 1st/2nd shift
link with the groove on each shift fork shaft.
Reassemble the dust boot on the fork shaft beforehand.
[Point 2]
Inspection:
SST(2)
Inspect the input shaft oil seal lip for wear or damage.
Replace if there is excessive wear or damage.
Disassembly:
Using a flat-blade screwdriver or brass bar, remove the input
shaft oil seal.
Reassembly:
SST(1) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Apply MP grease to the outer periphery and lip of the input
shaft oil seal before reassembly.
Reassembly:
Oil seal Reassemble the input shaft oil seal to the dimension position A
in the illustration.
A A = 1.2 ~ 1.8 mm (0.0472 ~ 0.0708 in)
Direction of oil seal
press-fitting
[Point 3]
Disassembly•Reassembly:
A
Using a round bar, remove and install the fork shaft oil seal.
Dry clutch vehicle
Reassembly:
Reassemble the fork shaft oil seal to the dimension position A
in the illustration.
Direction of oil seal A = 0.2 ~ 0.8 mm (0.0079 ~ 0.0315 in)
press-fitting Oil seal
4-13
Direction of Oil clutch vehicle
oil seal
press-fitting Reassembly:
Reassemble the fork shaft oil seal to the dimension position A
A in the illustration.
A = 4.2 ~ 4.8 mm (0.165 in ~ 0.189 in)
Oil seal
[Point 4]
Disassembly•Reassembly:
SST 09950-76002-71
(09950-00012)
Reassembly:
Apply MP grease to the contact surface of the output shaft oil
seal lip.
SST
[Point 5]
Reassembly:
SST 09370-20270-71
SST
Input shaft [Point 6]
Disassembly•Reassembly:
Remove and install the counter shaft ASSY, speed shaft ASSY
and fork shaft ASSY together.
During disassembly, the input shaft may be pulled out if you lift
it, so lift the gear side instead.
4-14
Reassembly:
Adjust the thrust clearance of the counter shaft ASSY.
1. Measure the height A from the rear case shim reassembly
surface to the surface to be in contact with the front case.
Make sure to remove the sealing agent applied to the surface
to be in contact with the front case.
2. Tentatively assemble the counter shaft ASSY and shim to the
A front case, and measure the height B from the end surface of
the shim to the surface to be in contact with the rear case.
Make sure to remove the sealing agent applied to the contact
surface of the rear case.
Shim(s)
3. The value of height A – height B is the thrust clearance of the
B counter shaft ASSY.
Standard: 0.03 ~ 0.43 mm (0.0012 ~ 0.0169 in)
4. If the standard is not met, adjust by changing the thickness of
the shim.
Marks Thickness mm (in)
A 0.64 ~ 0.76 (0.025 ~ 0.030)
B 0.84 ~ 0.96 (0.033 ~ 0.038)
C 0.93 ~ 1.07 (0.037 ~ 0.042)
D 1.12 ~ 1.28 (0.044 ~ 0.050)
E 1.31 ~ 1.49 (0.051 ~ 0.059)
F 1.49 ~ 1.71 (0.059 ~ 0.067)
[Point 7]
Inspection:
Inspect the output shaft oil seal lip for wear or damage. If any
excessive wear or damage is found, replace the oil seal.
SST Disassembly:
Using a flat-blade screwdriver or brass bar, remove the output
shaft oil seal.
Reassembly:
SST 09150-10170-71
Apply MP grease to the outer periphery and lip of the output
shaft oil seal before reassembly.
Reassembly:
Reassemble the output shaft oil seal to the dimension position
A in the illustration.
A = 3.7 ~ 4.3 mm (0.146 ~ 0.169 in)
Oil seal
Direction of oil
seal press-fitting
A
4-15
SPEED SHAFT ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY
Disassembly Procedure
1 Inspect each clearance of the reverse idle gears. [Point 1]
2 Remove the input shaft. [Point 2]
3 Remove the rear bearing and thrust washer. [Point 3]
4 Remove the reverse idle gear and needle roller bearing. [Point 4]
5 Remove the front bearing. [Point 5]
6 Inspect the speed shaft. [Point 6]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply gear oil to each sliding contact surface.
4-16
Point Operations
[Point 1]
Inspection:
Measure the reverse idle gear thrust clearance.
Standard: 0.15 ~ 0.40 mm (0.0059 ~ 0.0157 in)
Inspection:
Measure the reverse idle gear radial clearance.
Standard: 0.010 ~ 0.052 mm (0.00039 ~ 0.00205 in)
[Point 2]
Disassembly:
Fix the speed shaft ASSY in a vise, and firmly pull out the input
shaft.
Vise
Reassembly:
Reassemble the stop ring in the groove of the input shaft, and
then insert the shaft by hammering the head of the shaft using
a plastic hammer.
Reassembly:
After reassembly, check that the shaft can not be pulled out by
gently pulling the input shaft with your hand.
If the shaft can be pulled out by gently pulling it, replace the
stop ring with new one.
Vise
Stop ring
4-17
SST(1) [Point 3]
Disassembly:
SST 09950-76014-71................................. (1)
SST(2)
(09950-40011)
09950-76018-71................................. (2)
(09950-60010)
Inspection:
Measure the thrust washer thickness.
Limit: 2.7 mm (0.106 in)
Reassembly:
SST 09370-20270-71
SST
[Point 4]
Inspection:
Measure the inside diameter of the reverse idle gear.
Limit: 49.1 mm (1.933 in)
SST(1) [Point 5]
Disassembly:
SST 09950-76014-71................................. (1)
(09950-40011)
09950-76018-71................................. (2)
(09950-60010)
SST(2)
4-18
Reassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(1) 09950-76020-71................................. (2)
SST(2) (09950-70010)
[Point 6]
Inspection:
Measure the outside diameter of the speed shaft journal.
Limit: 41.9 mm (1.650 in)
4-19
COUNTERSHAFT ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY
10
13
5 3
13
Disassembly Procedure
1 Inspect the thrust clearance of the forward gear and 2nd gear. [Point 1]
2 Inspect radial clearance of each gear. [Point 2]
3 Remove the front bearing, thrust washer and pin. [Point 3]
4 Remove the 2nd gear, synchronizer ring and needle roller bearing.
5 Remove the rear bearing, thrust washer and pin. [Point 4]
6 Remove the forward gear, synchronizer ring and needle roller bearing.
7 Remove the clutch hub snap ring. [Point 5]
8 Remove the clutch hub No.1 ASSY, synchronizer ring, 1st gear and needle roller bearing. [Point 6]
9 Inspect the reverse gear thrust clearance. [Point 7]
10 Remove the clutch hub No.2 ASSY, synchronizer ring, reverse gear and needle roller bearing. [Point 8]
11 Inspect the thrust clearance of the 1st gear. [Point 9]
12 Inspect the countershaft and each gear. [Point 10]
13 Disassemble the clutch hub No.1 ASSY and No.2 ASSY. [Point 11]
14 Inspect the shift fork and hub sleeve clearance. [Point 12]
15 Inspect the synchronizer ring. [Point 13]
4-20
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply gear oil to each sliding section.
2nd gear Forward gear Point Operations
[Point 1]
Inspection:
Measure the thrust clearances of the 2nd gear and forward
gear.
2nd gear
Standard: 0.15 ~ 0.40 mm (0.0059 ~ 0.0157 in)
Forward gear
Standard: 0.10 ~ 0.45 mm (0.0039 ~ 0.0177 in)
[Point 2]
Inspection:
Measure the radial clearance of each gear.
1st gear · reverse gear
Standard: 0.016 ~ 0.057 mm (0.00063 ~ 0.00224 in)
2nd gear · forward gear
Standard: 0.018 ~ 0.062 mm (0.00071 ~ 0.00244 in)
[Point 3]
Disassembly:
SST 09950-76014-71
SST (09950-40011)
Inspection:
Measure the thrust washer thickness.
Limit: 5.9 mm (0.232 in)
4-21
Reassembly:
Install the front bearing by checking the directions.
SST 09608-76003-71
(SST 09608-04031)
SST
[Point 4]
Disassembly:
SST 09950-76014-71
SST (09950-40011)
Inspection:
Measure the thrust washer thickness.
Limit: 5.9 mm (0.232 in)
Reassembly:
Install the rear bearing by checking the directions.
SST 09608-76003-71
(09608-04031)
SST
[Point 5]
Reassembly:
Select and install the thickest snap ring that can be installed to
make the clutch hub clearance of 0.1 mm (0.0039 in) or less.
Mark Thickness mm (in)
A 1.8 ~ 1.9 (0.0709 ~ 0.0748)
B 1.9 ~ 2.0 (0.0748 ~ 0.0787)
C 2.0 ~ 2.1 (0.0787 ~ 0.0827)
D 2.1 ~ 2.2 (0.0827 ~ 0.0866)
4-22
[Point 6]
SST
Disassembly:
Using SST and pressing device, remove the clutch hub No.1
ASSY, synchronizer ring, 1st gear and needle roller bearing.
SST 09420-23002-71
Reassembly:
Chamfering Press in after matching the chamfered side of the hub spline
with the shaft spline inlet.
Reassembly:
Using SST and pressing device, reassemble the clutch hub
No.1 ASSY, synchronizer ring, 1st gear and needle roller
bearing.
SST SST 09608-76003-71
(09608-04031)
[Point 7]
Inspection:
Measure the reverse gear thrust clearance.
Standard: A = 0.1 ~ 0.45 mm (0.0039 ~ 0.0177 in)
A
[Point 8]
SST
Disassembly:
Using SST and pressing device, remove the clutch hub No.2
ASSY, synchronizer ring, reverse gear and needle roller
bearing.
SST 09420-23002-71
Reassembly:
Chamfering
Press in after matching the chamfered side of the hub spline
with the shaft spline inlet.
Reassembly:
Using SST and pressing device, reassemble the clutch hub
No.2 ASSY, synchronizer ring, reverse gear and needle roller
bearing.
SST SST 09608-76003-71
(09608-04031)
4-23
[Point 9]
Inspection:
Measure the 1st gear thrust clearance.
Standard: A = 0.1 ~ 0.45 mm (0.0039 ~ 0.0177 in)
A
[Point 10]
Inspection:
Measure the countershaft journal outside diameter.
1st gear · reverse gear
Limit: 37.9 mm (1.492 in)
2nd gear · forward gear
Limit: 29.9 mm (1.177 in)
Inspection:
Measure the inside diameter of each gear.
1st gear · reverse gear
Limit: 46.1 mm (1.815 in)
2nd gear · forward gear
Limit: 38.1 mm (1.500 in)
[Point 11]
Reassembly:
When reassembling the clutch hub ASSY, be careful not to
align the opening of the key spring to the same position.
[Point 12]
Inspection:
Measure the clearance between the shift fork and hub sleeve.
Limit: 1.0 mm (0.039 in)
4-24
[Point 13]
Inspection:
Apply gear oil to the tapered portion of each gear. When the
synchronizer ring is brought into close contact and rotated, it
shall not slip.
Inspection:
Measure the clearance between the synchronizer ring and
each gear.
1st gear · 2nd gear
Standard: 0.95 ~ 1.75 mm (0.0374 ~ 0.0689 in)
Limit: 0.6 mm (0.024 in)
Forward gear · reverse gear
Standard: 1.12 ~ 1.88 mm (0.044 ~ 0.074 in)
Limit: 0.6 mm (0.024 in)
4-25
SHIFT LINK BRACKET ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 10.5 ~ 15.8
3
(110 ~ 170)
[7.75 ~ 11.66]
4
5
T = 19.0 ~ 28.5
(200 ~ 290) 1
[14.0 ~ 21.0]
5
6
1
4
Disassembly Procedure
1 Disconnect the shift wire cable on the transmission side.
2 Remove the backup lamp switch W/ bracket. [Point 1]
3 Remove the shift link shaft.
4 Remove the F/R shift link, 1st/2nd shift link and shift link spacer.
5 Remove the dust boot.
6 Remove the shift link bracket.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply molybdenum disulfide grease to each sliding section.
Point Operations
[Point 1]
Inspection:
Inspect the backup lamp switch for continuity.
Switch position Standard
Free No continuity
Pressed Continuity exists
4-26
SHIFT LEVER, SHIFT WIRE CABLE
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
3 1
T = 36.0 (370) [26.6]
4
7
8 2
9
T = 17.0 (180) [12.5]
Removal Procedure
1 Remove the shift lever knob.
2 Remove the shift lever boot.
3 Remove the shift lever cover. [Point 1]
4 Disconnect the shift wire cable from the shift lever side. [Point 2]
5 Remove the shift lever ASSY.
6 Loosen the lock nut of the shift wire cable.
7 Remove the clamp on the lower side of the vehicle.
8 Disconnect the shift wire cable from the transmission side. [Point 3]
9 Remove the shift wire cable bracket set bolt.
10 Remove the shift wire cable W/ bracket.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
4-27
Grease fittings Note:
After reassembly, add molybdenum disulfide grease through
the grease fittings as specified below.
1. Remove the boot from the slit.
2. Move the F/R shift lever to the reverse position and the 1st/2nd
shift lever to the 2nd position.
3. Add molybdenum disulfide grease through each grease fitting.
Point Operations
[Point 1]
Disassembly:
Remove the shift lever cover as follows.
1. Remove the upper cover set screw.
2. Remove the upper cover.
The upper cover is installed with 4 clips.
Clips
3. Remove the lower cover set screws, clip, and lower cover.
Lower cover
set screw
Clip
4-28
The lower cover is installed with a clip.
Clip
[Point 2]
Identification
mark Installation:
Check the identification mark on the shift wire cable (white
tape for 1st/2nd) and install.
Installation:
Neutral position mark Adjust the shift levers for F/R and 1st/2nd so that they align
with the neutral position mark by the wire adjusting nut on the
shift lever side.
Adjusting nut
[Point 3]
Installation:
Check the identification mark on the shift wire cable (white
Identification tape for 1st/2nd) and install.
mark
5-1
PROPELLER SHAFT
Page
GENERAL...............................................................5-2
0
SPECIFICATIONS ..................................................5-2
1
COMPONENTS ......................................................5-2
2
PROPELLER SHAFT .............................................5-3
REMOVAL·INSTALLATION .......................................5-3
3
DISASSEMBLY·INSPECTION·REASSEMBLY .............5-4 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
5-2
GENERAL
A
SPECIFICATIONS
Joint type Cross type
A 150.0 (5.906)
Length mm (in)
B 119.0 (4.685)
COMPONENTS
3701
5-3
PROPELLER SHAFT
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
0
1
T = 28.0 ~ 36.0
3
(290 ~ 370) [21.0 ~ 26.8] 2
2 3
4
5
6
7
2
8
9
10
1 11
12
13
Removal Procedure
1 Remove the propeller shaft under cover. 14
2 Remove the propeller shaft set bolt.
3 Remove the propeller shaft.
15
Installation procedure 16
The installation procedure is the reverse of the removal procedure.
17
Note:
Add MP grease through the grease fitting.
18
19
20
21
E
5-4
DISASSEMBLY·INSPECTION·REASSEMBLY
3
2
Disassembly Procedure
1 Fix the propeller shaft in a vise.
2 Remove the snap rings.
3 Remove the universal spider sets. [Point 1]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
5-5
Point Operations
[Point 1]
Disassembly:
Remove the universal spider sets.
1. Use a brass bar to extract the bearing cup. 0
1
2
2. Use the brass bar to extract the bearing cup on the other side
and remove the spider set.
3
3. Remove the spider set on the opposite side in the same way. 4
5
6
7
Reassembly:
Install the universal spider sets.
8
1. Apply MP grease to the needle roller in the bearing cup. 9
2. Use a brass bar to slightly drive in the bearing cup.
3. Install the spider set.
10
4. Use the brass bar to drive in the bearing cup until the snap ring
groove appears.
11
12
5. Use the brass bar to drive in the bearing cup on the opposite 13
side until the snap ring groove appears.
6. Install the spider set on the opposite side in the same way. 14
15
16
17
18
19
20
21
E
6-1
DIFFERENTIAL
Page
GENERAL...............................................................6-2
0
SPECIFICATIONS ..................................................6-5
1
COMPONENTS ......................................................6-6
2
DIFFERENTIAL ASSY ...........................................6-8
REMOVAL·INSTALLATION .......................................6-8
3
DISASSEMBLY·INSPECTION·REASSEMBLY 4
(1·2·K2·K3 TON SERIES) ...................................... 6-11
5
DISASSEMBLY·INSPECTION·REASSEMBLY
(3·J3.5 TON SERIES) ............................................6-17 6
DIFFERENTIAL CASE ASSY ..............................6-24 7
DISASSEMBLY·INSPECTION·REASSEMBLY 8
(1·2·K2·K3 TON SERIES) ......................................6-24
DISASSEMBLY·INSPECTION·REASSEMBLY 9
(3·J3.5 TON SERIES) ............................................6-28
10
DISASSEMBLY·INSPECTION·REASSEMBLY
(LSD) ..................................................................6-31 11
INSPECTION OF LSD OPERATING TORQUE ...........6-37 12
13
14
15
16
17
18
19
20
21
E
6-2
GENERAL
Differential (1·K2 Ton Series)
Differential (2·K3 Ton Series)
6-3
Differential (3·J3.5 Ton Series)
0
1
2
3
4
5
6
7
8
9
10
Reduction Gear (1·K2 Ton Series)
11
12
13
14
15
16
17
18
19
20
21
E
6-4
Reduction Gear (2·K3 Ton Series)
Reduction Gear (3·J3.5 Ton Series)
6-5
Differential Case Assy (LSD:OPT)
0
Pinion gear
Plate
1
Side gear
Friction plate
2
3
4
5
6
7
Cone spring washer
8
Differential Case
9
10
11
SPECIFICATIONS 12
Vehicle model
1·K2 ton series 2·K3 ton series 3·J3.5 ton series
13
Item
Differential case type Banjo type ← ← 14
Reduction ratio (ring gear/drive pinion) 5.833 ← ←
15
Differential
Drive pinion 6 ← ←
Number of teeth
Ring gear 35 ← ←
Number of teeth × Pinion gear 11 × 2 10 × 2 10 × 4 16
quantity Side gear 16 × 2 ← 14 × 2
Differential oil quantity l (US gal) 5.8 (1.53) 6.1 (1.61) 8.2 (2.16)
17
18
19
20
21
E
6-6
COMPONENTS
1·K2 ton series
4101
AG
02
40 BD
AF
FV 40C AB
48A
CT
AF
48
47
AB
EW
46A 40
20
46 20A
20B
48 CN
48A 46
46A
10A CN
61 49A
49
10D
AS 10E 12
CL 02
10C 20B
20A
55
DY
60A[NO.2]
60
60A[NO.1]
59 AH 59A GU
4101-231
2·K3 ton series
4101
6-7
3·J3.5 ton series
4101
LSD (OPT)
4101
6-8
DIFFERENTIAL ASSY
REMOVAL·INSTALLATION
Note:
Never apply impact to the frame at the time of removal or installation to protect the controller from damage.
(SAS specification)
T = N·m (kgf·cm) [ft·lbf]
17
17 16
16
12 17
8
8
17 13 6
21
*3
*2
20
*4 *4
18 19
*2
20
5
19 *1
*1
1·2 ton series, K2·K3 ton series T = 68.6 ~ 98.0 (700 ~ 1000) [50.6 ~ 72.3]
*1 Axle shaft set bolt
3 ton series, J3.5 ton series T = 107 ~ 140 (1100 ~ 1400) [78.9 ~ 103.3]
1·2 ton series, K2·K3 ton series T = 108 ~ 159 (1100 ~ 1600) [79.7 ~ 117.3]
*2 Front axle ASSY set bolts
3 ton series, J3.5 ton series T = 127 ~ 190 (1300 ~ 1900) [93.4 ~ 140.2]
*3 Bolt T = 294 ~ 343 (3000 ~ 3500) [216.9 ~ 253.1]
*4 Front axle bracket set nut T = 235 ~ 294 (2400 ~ 3000) [173.4 ~ 216.9]
6-9
Removal Procedure
1 Remove the mast. (Refer to page 13-8)
2 Remove the lower panel and toe board.
3 Remove the instrument panel.
4 Drain differential oil. [Point 1]
5 Jack up the vehicle and remove the front wheel.
6 Remove the speed sensor cover, and disconnect the connector (SAS spec.).
7 Drain brake fluid, and disconnect the brake pipe (wheel cylinder side).
8 Disconnect the parking brake cable (lever side).
9 Remove the parking brake cable clamp.
10 Disconnect the mount insulator link.
11 Remove the under cover and propeller shaft cover.
12 Disconnect the propeller shaft. (Refer to page 5-3)
13 Support the bottom of the transmission with a pantograph jack or wooden block.
14 Support the front axle & differential ASSY with a hoist or garage jack. [Point 2]
15 Remove the connector bracket.
16 Remove the front axle bracket through bolts.
17 Remove the front axle bracket reamer bolt. [Point 3]
18 Remove the front axle & differential ASSY.
19 Remove the front axle shaft.
20 Remove the front axle W/ bracket.
21 Remove the speed sensor (SAS spec.).
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After reassembly, bleed air from the brake. (Refer to 10-24)
Point Operations
[Point 1]
Installation:
After installation, add hypoid gear oil to the specified level.
Vehicle model A
A 1·K2 ton series 1.7 ~ 12.0 mm (0.07 ~ 0.47 in)
2·K3 ton series 1.4 ~ 11.8 mm (0.06 ~ 0.46 in)
3·J3.5 ton series 1.2 ~ 13.8 mm (0.05 ~ 0.54 in)
6-10
[Point 2]
Removal•Installation:
Install hub nuts on hub bolts on the left and right sides, and
sling wire at the tapered portion.
[Point 3]
SST Removal:
SST 09310-23320-71
[Point 4]
Removal•Installation:
Operate carefully so as not to bring the axle shaft into contact
with the oil seal lip to damage it.
6-11
DISASSEMBLY·INSPECTION·REASSEMBLY (1·2·K2·K3 TON SERIES)
T = N·m (kgf·cm) [ft·lbf]
12
3 2
T = 6.9 ~ 16.1
T = 17.3 ~ 21.7 (70.4 ~ 164.2)
(176 ~ 221) [5.0 ~ 11.9]
[12.8 ~ 16.0] T = 343 ~ 392 T = 117.7 ~ 137.3
(3500 ~ 4000) (1200 ~ 1400)
4
[253.1 ~ 289.2] [86.8 ~ 101.3]
5
T = 32.4 ~ 48.6
T = 13.5 ~ 24.5
7 (330 ~ 496)
(138 ~ 250)
[23.9 ~ 35.9]
[10.0 ~ 18.1]
14
13
6
10
10
8 9
11
6-12
Removal Procedure
1 Remove the differential cover. [Point 1]
2 Remove the bearing cap and adjusting nut. [Point 2]
3 Remove the differential case ASSY.
4 Remove the drive pinion rear cover.
5 Remove the lock nut. [Point 3]
6 Remove the input shaft.
7 Remove the drive pinion W/ bearing. [Point 4]
8 Remove the output gear and reduction gear W/ carrier cover. [Point 5]
9 Remove the reduction gear W/ bearing. [Point 6]
10 Remove the reduction gear bearing.
11 Remove the output gear.
12 Remove the drive pinion outer race. [Point 7]
13 Remove the oil seal. [Point 8]
14 Remove the input shaft dust deflector. [Point 9]
Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Reassembly:
Apply sealing agent (Three Bond’s 1217C or equivalent
products) to the surfaces to be contact with the differential
cover and differential housing, and reassemble.
[Point 2]
Disassembly:
Make match marks on the bearing cap and differential housing.
Reassembly:
Reassemble the adjusting nut and bearing cap in the following procedure.
1. Install the adjusting nut.
2. Align the match marks to install the bearing cap, and
temporarily tighten the set bolt.
T = 19.6 N·m (200 kgf·cm) [14.5 ft·lbf]
Match marks
3. Set a dial gauge at the back of the ring gear, and tighten the
adjusting nut.
4. Using the SST, tighten until the thrust clearance becomes 0.
SST 09630-10110-71
5. Tighten the adjusting nuts on both sides by one notch.
6. Set a dial gauge perpendicular to the tooth face of the ring
gear, and measure the backlash.
6-13
Standard: 0.2 ~ 0.3 mm (0.008 ~ 0.012 in)
SST If the standard is not met, adjust by moving the differential
case ASSY to the thrust direction with the adjusting nut.
(1) When the backlash is excessive.
Loosen the adjusting nut on the ring gear tooth face side,
and tighten the adjusting nut on the back side by the
same amount in order to move the ring gear closer to the
drive pinion.
(2) When the backlash is insufficient.
Loosen the adjusting nut on the back side of the ring gear,
and tighten the adjusting nut on the tooth face side by the
same amount in order to move the ring gear away from
the drive pinion.
7. Further tighten the adjusting nut on the ring gear tooth face
side by 1.5 to 2 notches.
8. Install the adjusting nut lock plate.
9. Fully tighten the bearing cap set bolt.
T = 117.7 ~ 137.3 N·m (1200 ~ 1400 kgf·cm)
[86.82 ~ 101.3 ft·lbf]
[Point 3]
Disassembly:
Remove the lock nut, washer and shim.
1. Unstake the lock nut.
2. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
3. Remove the lock nut and washer.
Reassembly:
Reassemble the shim, rear bearing roller, washer and lock nut
Deep groove
in the following procedure.
1. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
Claw (pawl)
2. While supporting the drive pinion, reassemble the shim, rear
bearing and washer with its claw (pawl) lining up with the deep
groove.
Shim Also, in order to avoid shock contact between the rear bearing
roller and rear bearing outer race, reassmble the rear bearing
by tightening the lock nut.
3. Tighten the lock nut to the temporarily specified torque.
T = 157 ~ 235 N·m (1600 ~ 2400 kgf·cm) [115.8 ~ 173.4 ft·lbf]
4. Remove the input shaft.
5. Using a wrench, turn the gear five times.
6. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
6-14
7. Tighten the lock nut again to the specified torque.
T = 343 ~ 392 N·m (3500 ~ 4000 kgf·cm) [253.1 ~ 289.2 ft·lbf]
8. Remove the input shaft.
9. Using a wrench, turn the gear ten times.
10. Measure the drive pinion starting torque.
Standard
1·K2 ton series: 8.5 ~ 13.0 N·m (90 ~ 135 kgf·cm)
[6.3 ~ 9.6 ft·lbf]
2·K3 ton series: 8.5 ~ 15.0 N·m (90 ~ 155 kgf·cm)
[6.3 ~ 11.1 ft·lbf]
If the standard is not met, adjust by changing the thickness of
the shim.
Thickness of the shim:
0.1·0.13·0.15·0.32·0.35·0.4·0.5·0.59 mm
[0.0039·0.0051·0.0059·0.013·0.014·0.016·0.020·0.023 in]
11. Firmly stake the lock nut.
Good
example
1 mm or less
Bad example
[Point 4]
Disassembly:
Remove the drive pinion W/ bearing.
1. Insert a wooden block inside the differential housing in order to
prevent damage to the drive pinion.
2. Using a plastic hammer, remove the drive pinion W/ bearing.
Disassembly:
Remove the bearing inner race using the SST and a press.
SST 09420-23002-71
SST
6-15
Reassembly:
Install the bearing inner race using the SST and a press.
SST 1 ton series·K2 ton series:
SST 09316-76008-71
(09316-60011)
2·K3 ton series:
SST 09410-26600-71
[Point 5]
Reassembly:
Check the reassembly direction of the output gear and
reduction gear.
Reassembly:
Apply sealing agent (08826-76002-71 (08826-00090)) to the
surface to be in contact with the differential carrier cover, and
reassemble.
[Point 6]
SST(2)
Disassembly:
SST(1) Remove the reduction gear bearing using the SST and a
press.
SST 09950-76018-71................................. (1)
(09950-60010)
SST(3) 09950-76020-71................................. (2)
(09950-70010)
09420-23002-71................................. (3)
Reassembly:
Reassemble the reduction gear bearing using the SST and a
SST(2) press.
SST(1) SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
6-16
[Point 7]
SST(2)
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
SST(1)
Reassembly:
SST(2) SST 09950-76018-71................................. (1)
SST(1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
[Point 8]
A
Reassembly:
Using a pin, tap new oil seal in from the edge of the differential
carrier cover to the depth shown by A.
A = 5.0 ~ 5.5 mm [0.20 ~ 0.22 in]
After reassembly, apply MP grease to the lip section of the oil
seal.
[Point 9]
Reassembly:
Using the SST, reassemble the input shaft dust deflector.
SST 09370-20270-71
SST
6-17
DISASSEMBLY·INSPECTION·REASSEMBLY (3·J3.5 TON SERIES)
T = N·m (kgf·cm) [ft·lbf]
13
15
3 2
14
T = 13.5 ~ 24.5
(138 ~ 250)
[10.0 ~ 18.1]
T = 343 ~ 392 T = 6.9 ~ 16.1
(3500 ~ 4000) (70.4 ~ 164.2)
4 [253.1 ~ 289.2] [5.0 ~ 11.9]
T = 117.7 ~ 137.3
(1200 ~ 1400)
5 [86.8 ~ 101.3]
6
T = 32.4 ~ 48.6
15 (330 ~ 496)
[23.9 ~ 35.9]
T = 17.3 ~ 21.7 T = 101.0 ~ 134.6
(176 ~ 221) (1029.9 ~ 1372.5)
[12.8 ~ 16.0] [74.5 ~ 99.3] 12
13
17
16
7
10
11
10
8
9
6-18
Disassembly Procedure
1 Remove the differential cover. [Point 1]
2 Remove the bearing cap and adjusting nut. [Point 2]
3 Remove the differential case ASSY.
4 Remove the drive pinion rear cover.
5 Remove the lock nut. [Point 3]
6 Remove the drive pinion outer bearing roller.
7 Remove the input shaft.
8 Remove the output gear and reduction gear W/ carrier cover. [Point 4]
9 Remove the reduction gear W/ bearing. [Point 5]
10 Remove the reduction gear bearing.
11 Remove the output gear.
12 Remove the drive pinion bearing retainer.
13 Remove the drive pinion W/ pilot bearing. [Point 6]
14 Remove the pilot bearing. [Point 7]
15 Remove the drive pinion bearing outer race. [Point 8]
16 Remove the oil seal. [Point 9]
17 Remove the input shaft dust deflector. [Point 10]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Reassembly:
Apply sealing agent (Three Bond’s 1217C or equivalent
products) to the surfaces to be contact with the differential
cover and differential housing, and reassemble.
[Point 2]
Disassembly:
Make match marks on the bearing cap and differential
housing.
Reassembly:
Reassemble the adjusting nut and bearing cap in the following
procedure.
1. Install the adjusting nut.
Match marks 2. Align the match marks to install the bearing cap, and
temporarily tighten the set bolt.
T = 19.6 N·m (200 kgf·cm) [14.5 ft·lbf]
6-19
3. Set a dial gauge at the back of the ring gear, and tighten the
adjusting nut.
4. Using the SST, tighten until the thrust clearance becomes 0.
SST 09630-10110-71
5. Tighten the adjusting nuts on both sides by one notch.
6. Set a dial gauge perpendicular to the tooth face of the ring
gear, and measure the backlash.
Standard
SST 3 ton series: 0.3 ~ 0.4 mm [0.012 ~ 0.016 in]
If the standard is not met, adjust by moving the differential
case ASSY to the thrust direction with the adjusting nut.
(1) When the backlash is excessive.
Loosen the adjusting nut on the ring gear tooth face side,
and tighten the adjusting nut on the back side by the
same amount in order to move the ring gear closer to the
drive pinion.
(2) When the backlash is insufficient.
Loosen the adjusting nut on the back side of the ring gear,
and tighten the adjusting nut on the tooth face side by the
same amount in order to move the ring gear away from
the drive pinion.
7. Further tighten the adjusting nut on the ring gear tooth face
side by 1.5 to 2 notches.
8. Install the adjusting nut lock plate.
9. Fully tighten the bearing cap set bolt.
T = 117.7 ~ 137.3 N·m (1200 ~ 1400 kgf·cm)
[86.82 ~ 101.3 ft·lbf]
[Point 3]
Disassembly:
Remove the lock nut, washer and shim.
1. Unstake the lock nut.
2. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
3. Remove the lock nut and washer.
6-20
Reassembly:
Reassemble the shim, rear bearing roller, washer and lock nut
Deep groove
in the following procedure.
1. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
Claw (pawl)
2. While supporting the drive pinion, reassemble the shim, rear
bearing and washer with its claw (pawl) lining up with the deep
groove.
Shim Also, in order to avoid shock contact between the rear bearing
roller and rear bearing outer race, reassemble the rear bearing
by tightening the lock nut.
3. Tighten the lock nut to the temporarily specified torque.
T = 157 ~ 235 N·m (1600 ~ 2400 kgf·cm) [115.8 ~ 173.4 ft·lbf]
4. Remove the input shaft.
5. Using a wrench, turn the gear five times.
6. Reassemble the input shaft, and stop the gear from turning by
using a pipe wrench.
7. Tighten the lock nut again to the specified torque.
T = 343 ~ 392 N·m (3500 ~ 4000 kgf·cm) [253.1 ~ 289.2 ft·lbf]
8. Remove the input shaft.
9. Using a wrench, turn the gear ten times.
10. Measure the drive pinion starting torque.
Standard: 8.5 ~ 13.0 N·m (90 ~ 135 kgf·cm) [6.3 ~ 9.6 ft·lbf]
If the standard is not met, adjust by changing the thickness of
the shim.
Thickness of the shim:
0.1·0.13·0.15·0.32·0.35·0.4·0.5·0.59 mm
[0.0039·0.0051·0.0059·0.013·0.014·0.016·0.02·0.023 in]
Good
11. Firmly stake the lock nut.
example
1 mm (0.039 in)
or less
Bad example
6-21
[Point 4]
Reassembly:
Apply sealing agent (08826-76002-71 (08826-00090)) to the
surface to be in contact with the differential carrier cover, and
reassemble.
[Point 5]
Reassembly:
Check the reassembly direction of the output gear and
reduction gear.
Disassembly:
SST(2)
Remove the reduction gear bearing using the SST and a
SST(1) press.
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(3) 09420-23002-71................................. (3)
Reassembly:
Reassemble the reduction gear bearing using the SST and a
SST(2) press.
SST(1) SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
[Point 6]
SST(2)
Disassembly:
SST 09950-76018-71................................. (1)
SST(1) (09950-60010)
09150-76020-71................................. (2)
(09950-70010)
6-22
SST(2) Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
SST(1)
[Point 7]
Disassembly:
SST 09950-76014-71
SST (09950-40011)
Reassembly:
Reassemble the pilot bearing using the SST and a press.
SST 09608-76003-71
SST (09608-04031)
After reassembling the pilot bearing, stake three places at the
end of the drive pinion.
Check the reassembly direction.
Disassembly:
Remove the bearing inner race using the SST and a press.
SST SST 09420-23002-71
Reassembly:
Reassemble the bearing inner race using the SST and a
press.
SST
SST 09316-76008-71
(09316-60011)
6-23
[Point 8]
Disassembly:
SST(2)
SST 09950-76018-71................................. (1)
(09950-60010)
09150-76020-71................................. (2)
(09950-70010)
SST(1)
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(2) 09150-76020-71................................. (2)
(09950-70010)
SST(1)
[Point 9]
A
Reassembly:
Using a pin, tap new oil seal in from the edge of the differential
carrier cover to the depth shown by A.
A = 5.0 ~ 5.5 mm [0.20 ~ 0.22 in]
After reassembly, apply MP grease to the lip section of the oil
seal.
[Point 10]
Reassembly:
Using the SST, reassemble the input shaft dust deflector.
SST 09370-20270-71
SST
6-24
DIFFERENTIAL CASE ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY (1·2·K2·K3 TON SERIES)
T = N·m (kgf·cm) [ft·lbf]
4 3
2
4
T = 127.4 ~ 176.4
(1300 ~ 1800) 1
[94.0 ~ 130.1]
Disassembly Procedure
1 Remove the side bearing. [Point 1]
2 Remove the ring gear. [Point 2]
3 Remove the pinion shaft pin. [Point 3]
4 Remove the side gear and pinion gear. [Point 4]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
6-25
Point Operations
[Point 1]
SST(1) Disassembly:
SST 09950-76014-71................................. (1)
SST(2) (09950-40011)
09950-76018-71................................. (2)
(09950-60010)
Reassembly:
Install the side bearing.
SST(2) 1. Reassemble the side bearing to the edge of the case using the
SST and a press.
SST(1)
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
2. Fully tap the side bearing in by using a striking driver.
[Point 2]
Reassembly:
Apply thread tightener (08833-76001-71 (08833-00070)) to the
threaded portion of the set bolts. Gradually tighten them in the
diagonal order, and finally tighten to the specified torque in the
circular order.
[Point 3]
Disassembly:
Unstake the differential case pin hole, and punch out the pin
using the SST.
SST SST 09411-13330-71
Reassembly:
Tap the pin in the differential case pin hole using SST until it
contacts the stepped section.
Reference value: A = 5 mm (0.20 in)
SST A
Tap the pin in with the chamfer side facing down.
SST 09411-13330-71
Chamfer
6-26
C C View After tapping, stake the differential case pin hole with a chisel.
Check that the staking allowance is B in the illustration = 1 mm
(0.039 in) or more, and there should be no cracks.
Pin
After staking, check that the gear rotates smoothly.
[Point 4]
Inspection:
Measure the differential pinion inside diameter.
Standard
1·K2 ton series: 26.12 mm (1.028 in)
2·K3 ton series: 28.12 mm (1.107 in)
Limit
1·K2 ton series: 26.22 mm (1.032 in)
2·K3 ton series: 28.22 mm (1.111 in)
Inspection:
Measure the outside diameter of the pinion shaft.
Standard
1·K2 ton series: 26.00 mm (1.024 in)
2·K3 ton series: 28.00 mm (1.102 in)
Limit
1·K2 ton series: 25.75 mm (1.014 in)
2·K3 ton series: 27.75 mm (1.093 in)
Inspection:
Measure the thickness of the side gear thrust washer.
Standard: 1.6 mm (0.063 in)
Limit: 1.3 mm (0.051 in)
Inspection:
Measure the thickness of the pinion thrust washer.
Standard
1·K2 ton series: 1.0 mm (0.039 in)
2·K3 ton series: 1.6 mm (0.063 in)
Limit
1·K2 ton series: 0.7 mm (0.028 in)
2·K3 ton series: 1.3 mm (0.051 in)
6-27
Reassembly:
Grease application Reassemble the pinion thrust washer after evenly applying
chassis grease special on both sides.
Reassembly:
Reassembling procedures are as follows.
1. Reassemble the side gear and pinion to the differential case.
2. Turn the pinion to the pinion shaft hole.
3. Reassemble the pinion shaft.
6-28
DISASSEMBLY·INSPECTION·REASSEMBLY (3·J3.5 TON SERIES)
T = N·m (kgf·cm) [ft·lbf]
4
1
T = 86.2 ~ 102.9
(879 ~ 1049)
[63.6 ~ 75.9]
T = 127.4 ~ 176.4
(1300 ~ 1800)
[94.0 ~ 130.1]
Disassembly Procedure
1 Remove the differential case bearings. [Point 1]
2 Remove the differential upper case. [Point 2]
3 Remove the side gear and pinion gear. [Point 3]
4 Remove the ring gear. [Point 4]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
6-29
Point Operations
[Point 1]
SST(1) Disassembly:
SST 09950-76014-71................................. (1)
SST(2)
(09950-40011)
09950-76018-71................................. (2)
(09950-60010)
Reassembly:
Install the side bearing.
SST(2) 1. Use the SST to drive in the side bearing to the end surface.
SST(1) SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
2. Use a striking driver to fully drive in the bearing.
[Point 2]
Disassembly•Reassembly:
Check the match marks.
Reassembly:
Apply locking agent (08833-76001-71 (08833-00070)) on the
set bolt threaded portion before reassembly.
Match marks
[Point 3]
Inspection:
Measure the inside diameter of the differential pinion.
Standard
3 ton series: 22.12 mm (0.871 in)
J3.5 ton series: 24.67 mm (0.971 in)
Limit
3 ton series: 22.22 mm (0.875 in)
J3.5 ton series: 24.77 mm (0.975 in)
Inspection:
Measure the spider outside diameter.
Standard
3 ton series: 22.00 mm (0.866 in)
J3.5 ton series: 24.50 mm (0.965 in)
Limit
3 ton series: 21.75 mm (0.856 in)
J3.5 ton series: 24.25 mm (0.955 in)
6-30
Inspection:
Measure the side gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.3 mm (0.051 in)
Inspection:
Measure the pinion gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.0 mm (0.039 in)
Reassembly:
Install the side gear thrust washer with its oil groove facing the
gear.
Reassembly:
Grease application Apply chassis grease (molybdenum disulfide grease) on both
sides of the spider pinion thrust washer before reassembly.
[Point 4]
Reassembly:
Apply locking agent (08833-76001-71 (08833-00070)) on the
set bolt threaded portion before reassembly. Tighten the set
bolts gradually in the diagonal order, and finally tighten in the
circular order to the specified torque.
6-31
DISASSEMBLY·INSPECTION·REASSEMBLY (LSD)
Note:
Disassembly of the clutch in the differential case shall be done in the same way for both the upper and lower
cases. Keep disassembled parts in an organized manner and mark them to indicate the order in which they
were removed to prevent confusion.
T = N·m (kgf·cm) [ft·lbf]
T = 26 ~ 32 (270 ~ 330) [19.5 ~ 23.9]
4
3
5 2
T = 127.4 ~ 176.5 (1300 ~ 1800) [94.0 ~ 130.2]
1
6
Disassembly Procedure
1 Remove the differential case bearings. [Point 1]
2 Remove the differential upper case. [Point 2]
3 Remove the pinion gears, pinion gear thrust washers, spider and side gears. [Point 3]
4 Remove the snap rings, plates, friction plates and cone spring washers. [Point 4]
5 Remove the side gear thrust washers. [Point 5]
6 Remove the ring gear. [Point 6]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
6-32
Point Operations
[Point 1]
SST(1) Disassembly:
SST 09950-76014-71................................. (1)
SST(2)
(09950-40011)
09950-76018-71................................. (2)
(09950-60010)
Reassembly:
Install the side bearing.
SST(2) 1. Use the SST and drive in the side bearing to the end surface.
SST(1)
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
2. Use a striking driver and fully drive in the bearing.
[Point 2]
Disassembly•Reassembly:
Match marks Check the match marks.
Reassembly:
Apply locking agent (08833-76003-71 (08833-00090)) on the
set bolt threaded portion before reassembly.
[Point 3]
Inspection:
Measure the inside diameter of the diffrential pinion.
Standard: 22.31 mm (0.8783 in)
Limit: 22.41 mm (0.8823 in)
Inspection:
Measure the spider outside diameter.
Standard: 22.20 mm (0.8740 in)
Limit: 21.95 mm (0.8642 in)
6-33
Inspection:
Measure the pinion gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.3 mm (0.051 in)
Replace it when any damage or discoloration is found, even if
the thickness is more than the specified standard.
Reassembly:
SST Before side gear installation, turn the friction plates with the
SST to achieve the state shown below.
SST 09410-23420-71
(1) Match the notch in one case with the side gear tooth root.
Side gear
(2) Match the notch in the other case with the side gear tooth
Side gear crest.
Reassembly:
Grease application Apply chassis grease (molybdenum disulfide grease) on both
sides of the pinion gear thrust washer before reassembly.
6-34
[Point 4]
Disassembly:
Follow the procedure below for disassembly:
Lock
1. Before removing the snap ring, measure the amount of friction
torque using the SST and torque wrench.
Use the differential case oil hole for locking undesirable
rotation.
For frictional torque, read the value not at the start of SST
rotation but while the SST is rotating.
Measure the value on each of the upper case and lower case
SST sides, and calculate the sum.
SST 09410-23420-71
Frictional torque:
Upper case side + lower case side
= 210 N·m (2140 kgf·cm) [155 ft·lbf] or more
If the amount of frictional torque is not as specified, replace the
clutch parts as a set (snap ring, plates, friction plates, and
cone spring washer).
Snap ring SST(1) 2. Use the SST to keep pushing the plates, and remove the snap
ring.
SST 09410-23420-71................................. (1)
09950-76018-71................................. (2)
(09950-60010)
SST(2)
3. Remove the plates, friction plates and cone spring washer.
Mark the plates and friction plates to indicate the order in
which they were removed.
Reassembly:
Cone spring washer
Reassemble the parts as follows:
1. Apply differential oil to each part.
2. Install the cone spring washer. Pay attention to the installation
direction.
6-35
3. Install the plates and friction plates in the correct order.
When reusing parts:
Assemble them by referring to the mark made at the time of
Friction plate
disassembly.
When using new parts:
Plates are selected from three types of thickness. First install
three 1.75 mm (0.069 in) plates (thinnest type) and make
Plate adjustments by measuring the initial frictional torque after
installing the snap ring (see step 4 below).
Cone spring washer
Snap ring SST(1) 4. Install the snap ring while pushing in the plate with the SST.
SST 09410-23420-71................................. (1)
09950-76018-71................................. (2)
(09950-60010)
Make sure that the snap ring fits securely in the snap ring
groove.
SST(2)
5. Adjust the initial frictional torque.
Use the differential case oil hole to lock undesirable rotation.
SST Measure the initial frictional torque after using the SST to
rotate the friction plates a few turns.
For the frictional torque, read the value not at the start of SST
rotation, but while the SST is rotating.
Measure the value on each of the upper case and lower case
sides, and calculate the sum.
SST 09410-23420-71
Initial frictional torque:
Upper case side + lower case side
= 350 ~ 400 N·m (3570 ~ 4080 kgf·cm) [258 ~ 295 ft·lbf] or
more
If the amount of frictional torque is not as specified, make
adjustment by changing the plate thickness.
Plate thickness: 1.75·1.85·1.95 mm (0.069·0.073·0.077 in)
Reference:
When the total plate thickness is changed by 0.1 mm
(0.004 in), the frictional torque varies by approximately 10 to
20 N·m (102 to 204 kgf·cm) [7.4 to 15 ft·lbf].
6-36
[Point 5]
Inspection:
Measure the side gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.3 mm (0.051 in)
Replace it when any damage or discoloration is found, even if
the thickness is more than the specified standard.
[Point 6]
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.
6-37
INSPECTION OF LSD OPERATING TORQUE
Note:
• LSD operating torque can be measured on the vehicle without having to disassemble the differential,
enabling wear of the LSD clutch to be checked as required. Always check the LSD clutch for wear when
performing an annual inspection.
• If a defective is determined as the result of inspection, disassemble the differential and replace the
clutch parts as a set (friction plates, plates, cone spring washer, and snap ring).
Procedure
1. Remove the propeller shaft.
2. Jack up the front axle to raise both wheels off the ground, and
support the bottom of the frame with a wooden block.
3. Release the parking brake.
4. Remove two opposing hub nuts from the front wheel.
If the vehicle is equipped with double-tires, first remove the
outer tire.
Hub bolts
5. Lock the universal joint flange yoke (on the differential side).
6. Set the SST on the hub bolt after hub nut removal.
SST 09420-23420-71
SST
7. Apply a wrench to the SST and measure the operating torque
(frictional torque).
Operating torque (fictional torque):
210 N·m (2140 kgf·cm) [155 ft·lbf] or more
If the tire rotates before the specified torque is achieved, the
clutch is worn. Disassemble the differential and replace the
clutch parts.
7-1
FRONT AXLE
Page
GENERAL...............................................................7-2
0
SPECIFICATIONS ..................................................7-4
1
COMPONENTS ......................................................7-5
2
TIRES·WHEELS .....................................................7-7
FRONT AXLE SHAFT·AXLE HUB.........................7-8
3
REMOVAL·INSTALLATION .......................................7-8 4
FRONT AXLE BRACKET·AXLE HOUSING ........7-12 5
REMOVAL·INSTALLATION .....................................7-12 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
7-2
GENERAL
1 ton series
K2 ton series
7-3
2 ton series
0
1
2
3
4
5
6
7
8
9
10
K3 ton series
11
12
13
14
15
16
17
18
19
20
21
E
7-4
3·J3.5 ton series
SPECIFICATIONS
Vehicle model 2·3·K2·K3 J3.5 ton series
1 ton series
Item ton series 3 ton series*
Front axle type Full-floating ← ←
Suspension type Fixed to frame ← ←
Axle shaft diameter mm (in) 40 (1.57) ← 42 (1.65)
Axle shaft diameter (spline portion) mm (in) 40 (1.57) ← 49.5 (1.949)
*: Vehicles with attachment
7-5
COMPONENTS
1 ton series
4201
0
1
2
3
4
5
6
7
8
9
10
2 ton series 11
4201 12
13
14
15
16
17
18
19
20
21
E
7-6
K2·K3·3·J3.5 ton series
4201
7-7
TIRES·WHEELS
1. Adjusting the Inflating Pressure
Caution:
• Do not inflate tires beyond the specified pressure because
it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it in
a safety fence.
Specified Inflating Pressure
Inflating pressure
Classification Specification Tire size Rim type
kPa (kgf/cm2) [psi]
STD 6.00-9-10PR Divided rim 700 (7.00) [101.5]
1.0 ton model
OS-S 6.50-10-10PR Divided rim 700 (7.00) [101.5]
STD 6.50-10-10PR Divided rim 700 (7.00) [101.5]
1.5·1.75 ton model
SPL-S 21X8-9-10PR Side ring 625 (6.25) [90.6]
1.0 to 1.75 ton model STD-D 4.50-12-8PR Drop center 700 (7.00) [101.5]
K2.0·K2.5 ton model STD 21X8-9-14PR Side ring 900 (9.00) [130.5]
K3.0 ton model STD 23X9-10-16PR Side ring 900 (9.00) [130.5]
STD 7.00-12-12PR Divided rim 700 (7.00) [101.5]
2.0 to 2.5 ton model STD-D 5.50-15-8PR Side ring 700 (7.00) [101.5]
SPL-D 7.00-12-12PR Side ring 700 (7.00) [101.5]
3.0 ton model STD 28X9-15-12PR Side ring 700 (7.00) [101.5]
J3.5 ton model STD 250-15-16PR Side ring 850 (8.50) [123.3]
STD-D 6.00-15-10PR Side ring 700 (7.00) [101.5]
3.0 ton model·J3.5 ton model
SPL-D 28X8-15-12PR Side ring 700 (7.00) [101.5]
Abbreviations used in the specification column:
STD = Standard, S-RING = Side ring, OS-S = Oversize single, SPL-S = Special single,
STD-D = Standard double, SPL-D = Special double
2. Wheel Disassemly·Reassembly
Chamfering 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.
Outer rim
N·m (kgf·cm) [ft·lbf]
1 ton series T = 49.0 ~ 68.6 (500 ~ 700) [36.2 ~ 50.6]
2 ton series T = 118.0 ~ 176.0 (1200 ~ 1800) [87.1 ~ 129.8]
7-8
FRONT AXLE SHAFT·AXLE HUB
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
8 5
8
4
1 ton series (divided rim), K3 ton series T = 118.0 ~ 196.0 (1200 ~ 2000) [87.1 ~ 144.6]
Hub nut (single tire) 3·J3.5 ton series T = 294.0 ~ 588.0 (3000 ~ 6000) [216.9 ~ 433.8]
Others T = 177.0 ~ 392.0 (1800 ~ 4000) [130.6 ~ 289.2]
3·J3.5 ton series T = 294.0 ~ 588.0 (3000 ~ 6000) [216.9 ~ 433.8]
Hub nut (double tire)
Others T = 177.0 ~ 392.0 (1800 ~ 4000) [130.6 ~ 289.2]
3·J3.5 ton series T = 107.0 ~ 140.0 (1100 ~ 1400) [78.9 ~ 103.3]
Axle shaft set bolt
Others T = 68.6 ~ 98.0 (700 ~ 1000) [50.6 ~ 72.3]
7-9
Removal Procedure
1 Drain differential oil. [Point 1]
2 Jack up the vehicle and remove front wheels.
3 Remove the front axle shaft. [Point 2]
4 Remove the axle shaft oil seal. [Point 3]
5 Remove the bearing lock nut and plate. [Point 4]
6 Remove the outer bearing roller and front axle hub. [Point 5]
7 Remove the oil seal and inner bearing roller. [Point 6]
8 Remove the bearing outer race. [Point 7]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1]
Installation:
Add Hypoid gear oil to the specified level after installation.
Vehicle model A
A
1·K2 ton series 1.7 ~ 12.0 mm (0.067 ~ 0.472 in)
2·K3 ton series 1.4 ~ 11.8 mm (0.055 ~ 0.465 in)
3·J3.5 ton series 1.2 ~ 13.8 mm (0.047 ~ 0.543 in)
[Point 2]
Removal•Installation:
Carefully operate so as not to damage the oil seal lip by
contact with the axle shaft.
[Point 3]
Removal:
SST 09320-23000-71
SST
7-10
Installation:
SST(1)
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(2)
[Point 4]
Removal•Installation:
1·2·K2·K3 ton series
SST 09509-76002-71
(09509-55020)
3·J3.5 ton series
SST 09509-76003-71
(09509-55030)
SST
Installation:
Adjust the front axle hub starting force.
1. Install the plate.
2. Tighten the bearing lock nut to the specified torque and rotate
the hub by 4 or 5 turns to fit the bearing.
Standard:
196 ~ 343 N·m (2000 ~ 3500 kgf·cm) [145 ~ 253 ft·lbf]
3. Rotate the bearing lock nut back by 1/12 to 1/6 turn (30 to 60°)
to align the stopper hole of the bearing with the thread hole of
the lock nut. Rotate the hub 4 or 5 turns again.
4. Set the spring scale to the hub bolt to measure the starting
force.
Standard
1 ton series (side ring rim type), K2 ton series:
T = 24.5 ~ 99.0 N (2.5 ~ 10.1 kgf) [5.5 ~ 22.3 lbf]
Others:
19.6 ~ 78.4 N (2.0 ~ 8.0 kgf) [4.4 ~ 17.6 lbf]
5. If the measured value is not within the standard range, adjust it
by tightening or loosening the bearing lock nut.
6. Install the nut lock screw or nut lock bolt to the specified
torque.
When reusing the nut lock screw (precoated screw), apply
thread tightener (08833-76002-71 (08833-00080)) to the
threaded portion.
Tightening torque
1·2·K2·K3 ton series:
T = 2 ~ 5.2 N·m (20 ~ 53 kgf·cm) [1.4 ~ 3.5 ft·lbf]
7-11
Apply thread tightener (08833-76001-71 (08833-00070)) to the
nut lock bolt threaded portion and tighten it.
Tightening torque
3·J3.5 ton series:
T = 15 ~ 22 N·m (153 ~ 224 kgf·cm) [11 ~ 16 ft·lbf]
Nut lock bolt
[Point 5]
Fill up with grease Installation:
Fill the part of the hub shown in the illustration with MP grease.
Installation:
1·2·K2·K3 ton series
SST 09370-10410-71
3·J3.5 ton series
SST 09421-33020-71
SST
[Point 6]
SST(2)
Removal:
SST(1)
Use a screwdriver or the like to remove the oil seal.
Installation:
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
SST(2) [Point 7]
Removal:
SST(1)
Use a brass bar to remove the bearing outer race.
Installation:
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
7-12
FRONT AXLE BRACKET·AXLE HOUSING
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
4
T = 294 ~ 343
(3000 ~ 3500)
[217 ~ 253]
T = 137 ~ 210
(1400 ~ 2100)
[101 ~ 155] 4
5 3
1·2·K2·K3 ton series
T = 108 ~ 159 (1100 ~ 1600) [80 ~ 117]
3 ton series, J3.5 ton series
T = 127 ~ 190 (1300 ~ 1900) [94 ~ 140]
Removal Procedure
1 Remove the front axle & differential ASSY. (See page 6-8)
2 Remove the front axle shaft and axle hub. (See page 7-8)
3 Remove the backing plate W/ brake ASSY. [Point 1]
4 Remove the front axle bracket.
5 Remove the axle housing.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
7-13
Point Operations
[Point 1]
Installation:
Apply sealing agent (08826-76002-71 (08826-00090)) to the
mating surfaces of the brake backing plate and front axle
bracket before installation.
Installation:
1 ton series: Be careful as the brake backing plate set bolts are different in
length.
Apply locking agent (08833-76001-71 (08833-00070)) on the
set bolts before tightening.
Bolt length
A: L = 36 mm (1.42 in)
B: L = 40 mm (1.57 in)
2·K2·K3 ton series: C: L = 45 mm (1.77 in)
3 ton series:
J3.5 ton series:
8-1
REAR AXLE
Page
GENERAL...............................................................8-2
0
SPECIFICATIONS ..................................................8-3
1
COMPONENTS ......................................................8-4
2
TIRES·WHEELS .....................................................8-7
REAR AXLE ASSY.................................................8-8
3
REMOVAL·INSTALLATION .......................................8-8 4
REAR AXLE HUB·STEERING KNUCKLE...........8-10 5
REMOVAL·INSTALLATION .....................................8-10 6
REAR AXLE CYLINDER ......................................8-16 7
REMOVAL·INSTALLATION .....................................8-16
8
DISASSEMBLY·INSPECTION·REASSEMBLY ...........8-18
9
10
11
12
13
14
15
16
17
18
19
20
21
E
8-2
GENERAL
Tire angle sensor
(Vehicle W/SAS)
Tie rod
8-3
Rear Axle Cylinder
0
1
2
3
SPECIFICATIONS 4
Rear axle type Elliot type 5
Rear axle suspension type Center-supported right-left rocking type
Toe-in mm (in) 0 (0) 6
Camber degree 1.5°
Wheel alignment
Caster degree 0°
7
King pin angle
1.0 ton
0°
1910 (75.2)
8
1.5 ton
1.75 ton
1990 (78.3)
2010 (79.1)
9
2.0 ton 2200 (86.6) 10
2.5 ton 2280 (89.8)
Minimum turning radius (outermost) mm (in)
3.0 ton 2430 (95.7) 11
K2.0 ton 2040 (80.3)
K2.5 ton 2090 (82.3) 12
K3.0 ton 2130 (83.9)
J3.5 ton 2490 (98.0) 13
14
15
16
17
18
19
20
21
E
8-4
COMPONENTS
1 ton series (VEHICLE L/SAS)
4301
2·3·J3.5 ton series (VEHICLE L/SAS)
4301
8-5
VEHICLE W/SAS
4301
0
1
2
3
4
5
6
7
8
9
10
1·2 ton series (VEHICLE W/SAS)·K2 ton series
4301
11
12
13
14
15
16
17
18
19
20
21
E
8-6
3·J3.5 ton series (VEHICLE W/SAS)·K3 ton series
4301
Rear Axle Cylinder
4302
8-7
TIRES·WHEELS
1. Adjusting the Inflating Pressure
Caution:
• Do not inflate tires beyond the specified pressure because
it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it in
a safety fence.
Specified Inflating Pressure
Inflating pressure
Vehicle model Specification Tire size Rim type
kPa (kgf/cm2) [psi]
STD 5.00-8-8PR Divided rim 800 (8.0) [116]
1 ton series
S-RING 5.00-8-8PR Side ring 800 (8.0) [116]
STD 18X7-8-10PR Divided rim 750 (7.5) [109]
K2 ton series
S-RING 18X7-8-16PR Side ring 1000 (10.0) [145]
K3 ton series STD 18X7-8-16PR Side ring 1000 (10.0) [145]
STD 6.00-9-10PR Divided rim 700 (7.0) [102]
2.0 ton model
S-RING 6.00-9-10PR Side ring 700 (7.0) [102]
STD 6.00-9-10PR Divided rim 700 (7.0) [102]
2.5 ton model S-RING 6.00-9-10PR Side ring 850 (8.5) [123]
OS 6.50-10-10PR Divided rim 700 (7.0) [102]
STD 6.50-10-10PR Divided rim 775 (7.75) [112]
3 ton series S-RING 6.50-10-10PR Side ring 775 (7.75) [112]
S-RING 6.50-10-12PR Side ring 900 (9.0) [131]
J3.5 ton series STD 6.50-10-12PR Side ring 900 (9.0) [131]
Abbreviations used in the specification column:
STD = Standard, S-RING = Side ring, OS = Oversize
2. Wheel Disassemly•Reassembly
Chamfering 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.
T = N·m (kgf·cm) [ft·lbf]
Outer rim
1 ton series T = 29.5 ~ 44.0 (300 ~ 450) [21.8 ~ 32.5]
K2 ton series T = 78.5 ~ 117.5 (800 ~ 1200) [57.9 ~ 86.7]
2·3 ton series
T = 49.0 ~ 68.5 (500 ~ 700) [36.2 ~ 50.5]
J3.5 ton series
8-8
REAR AXLE ASSY
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
1
2
T = 117.7 ~ 166.7
(1200 ~ 1700)
[86.83 ~ 123.0]
Hub Nut Tightening Torque
1 ton series 2 ton series K2 ton series 3 ton series K3·J3.5 ton series
89.0 ~ 157.0 118.0 ~ 196
Divided rim (900 ~ 1600) (1200 ~ 2000) ← ← —
[65.66 ~ 115.8] [87.06 ~ 144.60]
89.0 ~ 157.0 177.0 ~ 392 118.0 ~ 196
Side ring rim (900 ~ 1600) (1800 ~ 4000) (1200 ~ 2000) ← ←
[65.66 ~ 115.8] [130.6 ~ 289.2] [87.06 ~ 144.60]
Removal Procedure
1 Jack up the vehicle and remove the rear wheels.
2 Remove the swing lock cylinder lower pin. (Vehicle W/SAS) (See section 18.)
3 Disconnect the rear axle cylinder hose.
4 Disconnect the tire angle sensor connector. (Vehicle W/SAS)
5 Support the rear axle ASSY with a garage jack.
6 Remove the rear axle ASSY. [Point 1]
7 Remove the center pin bushing. [Point 2]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, add grease through each grease fitting. Use genuine molybdenum disulfide grease for the rear
axle beam center pins (two places) and swing lock cylinder lower pin. Use MP grease for other grease fittings.
8-9
Point Operations
[Point 1]
Inspection:
Measure the rear axle front to rear clearance.
1. Before removing the rear axle ASSY, measure the front to rear
clearance on the rear side.
Standard clearance: 1.0 mm (0.039 in) or less
2. If the measured value does not satisfy the standard, remove
the rear axle ASSY and make adjustment by selecting the
spacer.
Spacer thickness:
0.3·0.5·1.2·2.3·3.0·3.5·4.0·4.5·5.0 mm
(0.012·0.020·0.047·0.091·0.118·0.138·0.157·0.177·0.197 in)
[Point 2]
Inspection:
Inspect the inside diameter of the rear axle center pin bushing.
Limit: 52.0 mm (2.047 in)
Installation:
Apply molybdenum disulfide grease to the bushing and install
the bushing by aligning the grease groove in the bushing with
the grease fitting position.
Grease groove
8-10
REAR AXLE HUB·STEERING KNUCKLE
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
4
11
1
2
6
10 11
7
3 9
12
T = 44.1 ~ 53.9
(450 ~ 550)
[32.6 ~ 39.8] T = 49.0 ~ 73.5
(500 ~ 750)
[36.2 ~ 54.2]
Removal Procedure
1 Jack up the vehicle and remove the rear wheels.
2 Remove the hub cap. [Point 1]
3 Remove the castle nut and claw washer. [Point 2]
4 Remove the outer bearing and axle hub. [Point 3]
5 Remove the bearing outer race from the axle hub. [Point 4]
6 Remove the inner bearing roller and oil seal. [Point 5]
7 Disconnect the tie rod (on the knuckle side). [Point 6]
8 Remove the king pin cover (on the LH side) or the tire angle sensor (on the RH side) (Vehicle W/SAS).
9 Remove the king pin lock bolt and king pin. [Point 7]
10 Remove the thrust bearing, spacer and steering knuckle.
11 Remove the king pin oil seals and needle bearings. [Point 8]
12 Remove the bushing from the steering knuckle. [Point 9]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, add MP grease through grease fittings.
8-11
Point Operations
[Point 1]
Installation:
Apply MP grease to the hub cap and install it by tapping the
flange portion.
(Instead of MP grease filling, spraying grease over the castle
nut is also available.)
[Point 2]
Installation:
Adjust the rear axle hub starting force.
1. Install the claw washer in the correct direction.
2. Temporally tighten the castle nut.
Tightening torque
1 ton series:
12 ~ 32 N·m (122 ~ 330 kgf·cm) [8.9 ~ 23.9 ft·lbf]
Claw washer Others:
15 ~ 44 N·m (153 ~ 449 kgf·cm) [11.1 ~ 32.5 ft·lbf]
3. Rotate the hub by 3 to 5 turns to fit in the bearing.
4. Set a spring scale to a hub bolt, and measure the starting force.
Standard:
1 ton series 15 ~ 39 N (1.5 ~ 4.0 kgf) [3.3 ~ 8.5 lbf]
K2·K3 ton series 20 ~ 58 N (2.0 ~ 5.9 kgf) [4.4 ~ 13.0 lbf]
2·3·J3.5 ton series 15 ~ 44 N (1.5 ~ 4.5 kgf) [3.3 ~ 9.9 lbf]
5. If the measured value does not satisfy the standard, adjust the
castle nut tightening.
6. Install a new cotter pin.
[Point 3]
Removal:
SST 09950-76014-71
(09950-40011)
SST
8-12
Fill grease Installation:
Install the axle hub and outer bearing.
1. Apply MP grease to the axle hub and knuckle spindle.
2. Install the axle hub.
3. Use the SST to install the outer bearing roller.
SST 09370-20270-71
SST
[Point 4]
Removal:
Use a brass bar to remove the bearing outer race.
Installation:
SST 09950-76019-71................................. (1)
SST(2)
(09950-60020)
SST(1) 09950-76020-71................................. (2)
(09950-70010)
[Point 5]
Removal:
SST 09950-76014-71
(09950-40011)
SST
Installation:
Install the oil seal and inner bearing.
1. Use the SST to install the oil seal.
SST 09370-10410-71
SST
2. Use the SST to install the inner bearing.
SST 09370-20270-71
SST
8-13
[Point 6]
Installation:
To install the end pin lock nut, install each cone washer with
seal in the direction shown in the illustration and tighten the nut
Cone washer to the specified torque.
with seal
Tightening torque:
49.0 ~ 73.5 N·m (500 ~ 750 kgf·cm) [36.2 ~ 54.2 ft·lbf]
[Point 7]
Inspection:
Measure the king pin outside diameter.
Limit: 27.8 mm (1.094 in)
Installation:
Measure the steering knuckle starting force according to the
procedure below.
1. Temporarily reassemble the king pin and king pin lock bolt.
Select a spacer to adjust the vertical clearance of the steering
knuckle to 0.5 mm (0.020 in) or less, and install it on the upper
surface of the thrust bearing.
Spacer thickness:
3.0·3.5·4.0·4.5 mm (0.118·0.138·0.157·0.177 in)
2. Set a spring scale to the tip end of the knuckle spindle, and
measure the starting force.
Standard: 19.3 N (2.0 kgf) [4.4 lbf] or less
3. If the measured value exceeds the standard, check the king
pin for bend, the needle bearing for damage and axle beam for
deformation.
4. Tighten the lock nut for the king pin lock bolt.
Movable range of the tire angle sensor Installation:
When measuring the steering knuckle starting force with the
tire angle sensor installed, measure it within the movable
120°
Front range of the tire angle sensor. If the range is exceeded, the
sensor will be damaged. (Vehicle W/SAS)
90°
Tire angle
Steering knuckle
sensor
8-14
[Point 8]
Removal:
Remove the king pin oil seals and needle bearings.
1. Use a straight-edge screwdriver to remove the dust seal and
oil seal.
2. Use the SST to remove the needle roller bearings in the
directions shown in the illustration.
SST(1) SST(2) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Installation:
Install the needle roller bearings and king pin oil seals.
1. Use the SST to install the needle bearing.
0 mm Check the needle roller bearing press-fitting surface, pressing
(0 in) direction and installation depth.
SST 09950-76018-71................................. (1)
(09950-60010)
3.5 ~ 4.5 mm
09950-76020-71................................. (2)
(0.138 ~ 0.177 in) (09950-70010)
2. Install the dust seal.
3. Use the SST to install the oil seal.
Punched SST 09950-76018-71................................. (1)
surface (09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Press-fitting direction
4. Install the RH upper oil seal as shown in the illustration.
(0.165 ~ 0.189 in)
4.2 ~ 4.8 mm
8-15
[Point 9]
Bushing Installation:
1.3 mm Press fit the bushing as shown in the illustration.
(0.051 in)
(1.3 mm)
((0.051 in))
8-16
REAR AXLE CYLINDER
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 166.7 ~ 215.8
(1700 ~ 2200)
[123.0 ~ 159.2]
5 T = 49.0 ~ 73.5
(500 ~ 750)
4 [36.2 ~ 54.2]
Removal Procedure
1 Jack up the vehicle.
2 Disconnect the tie rod (on the piston rod side). [Point 1]
3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 2]
4 Remove the rear axle cylinder.
5 Remove the bushing from the piston rod. [Point 3]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
8-17
Point Operations
[Point 1]
Installation:
To install the end pin lock nut, install each cone washer with
Cone washer seal in the direction shown in the illustration and tighten the nut
with seal
to the specified torque.
Tightening torque:
49.0 ~ 73.5 N·m (500 ~ 750 kgf·cm) [36.2 ~ 54.2 ft·lbf]
[Point 2]
Installation:
Install the fittings as shown in the illustration.
Vehicle model A
1·K2·K3 ton series 20°
A A 2·3·J3.5 ton series 40°
[Point 3]
Bushing
Installation:
1.3 mm
Press fit the bushing as shown in the illustration.
(0.051 in)
(1.3 mm)
((0.051 in))
8-18
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 88 ~ 118 (900 ~ 1200) [65.1 ~ 86.8]
Disassembly Procedure
1 Remove the through bolt.
2 Remove the piston rod guide.
3 Remove the piston rod. [Point 1]
4 Inspect the cylinder. [Point 2]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply hydraulic oil before reassembly.
8-19
Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
Limit
1 ton series: 39.92 mm (1.5717 in)
Others: 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.
Caution:
Operate carefully to avoid burn injury.
Note:
Do not stretch it excessively.
[Point 2]
Inspection:
Measure the rear axle cylinder bore.
Limit
1 ton series: 70.35 mm (2.7697 in)
2·K2·K3 ton series: 80.35 mm (3.1634 in)
3 ton series: 84.40 mm (3.3228 in)
J3.5 ton series: 87.40 mm (3.4409 in)
9-1
STEERING
Page
GENERAL...............................................................9-2
0
SPECIFICATIONS ..................................................9-5
1
COMPONENTS ......................................................9-5
2
STEERING WHEEL·MAST JACKET ...................9-10
REMOVAL·INSTALLATION .....................................9-10
3
DISASSEMBLY·INSPECTION·REASSEMBLY ...........9-12 4
HYDROSTATIC STEERING VALVE ASSY ..........9-13 5
TROUBLESHOOTING ............................................9-13 6
REMOVAL·INSTALLATION .....................................9-14
7
DISASSEMBLY·INSPECTION·REASSEMBLY
(VEHICLE L/SAS) ................................................9-15 8
RELIEF PRESSURE INSPECTION·ADJUSTMENT 9
(VIEHICLE L/SAS)................................................9-17
DISASSEMBLY·INSPECTION·REASSEMBLY
10
(VEHICLE W/SAS) ...............................................9-18 11
RELIEF PRESSURE INSPECTION
(VEHICLE W/SAS) ...............................................9-21 12
13
14
15
16
17
18
19
20
21
E
9-2
GENERAL
Forw
a rd in
c linat
ion l
i mit
5.3°
12.1
°
Ne
u
tra
l
Ba
inc ckw
lin ar
ati d
55 on
lim
.7°
it
9-3
Hydrostatic Steering Valve (VEHICLE L/SAS)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Relief valve 15
16
17
18
19
20
21
E
9-4
Hydrostatic Steering Valve (VEHICLE W/SAS)
C C
C-C
A-A
B
A
B
B-B
9-5
SPECIFICATIONS
Vehicle series 2·K2·K3 ton
1 ton series 3 ton series J3.5 ton series
Item series
Steering wheel diameter mm (in) 300 (11.81)
Steering wheel play (at idling) mm (in) 20 ~ 50 (0.79 ~ 1.97)
0
Power steering type Hydrostatic steering
1
Delivery cm3 (in3)/rev 96 (5.86) 105 (6.41) 115 (7.02) 130 (7.93)
Rated flow rate
l (US gal)/min
13.6 (3.59) ← 15.8(4.17) ← 2
Hydrostatic steering Relief set pressure 7400 ~ 7900
2 ton series:
8000 ~ 8500
8300 ~ 8800 3
valve (75 ~ 80) ← (85 ~ 90)
kPa (kgf/cm2) [psi] (82 ~ 87)
[1073 ~ 1146]
[1160 ~ 1233]
[1204 ~ 1276]
4
Relief set pressure 7500 ~ 8000 8100 ~ 8600 8400 ~ 8900
(VEHICLE W/SAS)
kPa (kgf/cm2) [psi] (76 ~ 82)
[1088 ~ 1160]
(83 ~ 88)
[1175 ~ 1247]
← (86 ~ 91)
[1218 ~ 1291]
5
6
COMPONENTS 7
4501
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
9-6
4502
1 ton series (M/T)
4507
9-7
2·K2·K3·3·J3.5 ton series (M/T)
4507
1 ton series (T/C)
4507
9-8
2·K2·K3·3·J3.5 ton series (T/C)
4507
VEHICLE L/SAS
4503
9-9
VEHICLE W/SAS
4503
9-10
STEERING WHEEL·MAST JACKET
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 24.5 ~ 44.1
(250 ~ 450)
[18.1 ~ 32.6]
3
1
9 6
T = 29.4 ~ 39.2
(300 ~ 400)
7 [21.7 ~ 28.9]
3
4
2
Removal Procedure
1 Remove the steering wheel. [Point 1]
2 Remove the parking brake release lever. (for T/C only)
3 Remove the column cover.
4 Remove the parking brake release lever ASSY. (for T/C only)
5 Disconnect the lever switch ASSY wiring.
6 Remove the lever switch ASSY.
7 Remove the tilt lock mechanism. [Point 2]
8 Remove the steering valve set bolt and keep the valve free.
9 Remove the mast jacket ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply MP grease to each sliding portion of the tilt lock mechanism.
• Apply MP grease to the coupling between the tilt steering shaft and steering valve.
9-11
Point Operations
SST [Point 1]
Removal:
SST 09950-76003-71
(09950-50012)
Installation:
Apply rubber grease to the steering angle sensor sliding
Pins
portion A of the lever switch, and install the steering wheel.
After installation, turn the steering wheel. When the steering
wheel is turned, the three pins on the sensor will automatically
engage in the pin holes on the steering wheel.
[Point 2]
Install the tilt lever within +/- 20° of a line extending between the
upper part of the tilt lever and the notch in the column cover.
20°
20°
9-12
DISASSEMBLY·INSPECTION·REASSEMBLY
1
3
Disassembly Procedure
1 Remove the snap ring.
2 Remove the tilt steering shaft.
3 Remove the bearing.
4 Remove the lever switch ASSY bracket.
Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Apply rubber grease to each sliding portion of the lever switch ASSY.
9-13
HYDROSTATIC STEERING VALVE ASSY
TROUBLESHOOTING
Phenomenon Estimated cause Corrective action
• The steering valve drive shaft is installed incorrectly or Inspect and correct or replace.
The steering wheel cannot
damaged.
be rotated.
• The piping is damaged. Replace.
• The tire inflating pressure is low. Adjust the inflating pressure.
• The oil pressure does not rise. Inspect and adjust the relief pressure.
The steering wheel is • The high and low pressure pipes are connected Inspect and correct.
heavy. reversely.
• The power steering cylinder rod is bent or the piston is Inspect and correct or replace.
sticking.
• The high and low pressure pipes are connected Inspect and correct.
reversely.
The oil pressure does not • The relief valve is faulty or not closed. Inspect and correct.
rise. • The oil pump function is degraded or the oil volume is Inspect and correct or replace.
insufficient.
• The power steering cylinder piston packing is damaged. Replace.
• The tire inflating pressure is low. Adjust the inflating pressure.
The steering wheel does • The steering valve spool does not move smoothly. Correct or replace the steering valve
not return properly. ASSY.
• The steering knuckle sliding motion is improper. Add the lubricant or correct.
• The steering valve spool does not move smoothly. Correct or replace the steering valve
The steering wheel does ASSY.
not return to the neutral • The steering valve drive shaft is damaged. Replace the steering valve ASSY.
position when released. • The centering spring is damaged. Replace.
• The piping is blocked (crushed or clogged). Inspect and correct or replace.
• Oil moves in the steering valve. Replace the steering valve ASSY.
• The steering valve spool is not moving correctly. Correct or replace the steering valve
The play is excessive and
ASSY.
the vehicle wobbles.
• Air is sucked from the piping. Inspect and correct or replace.
• The steering shaft is defective. Inspect and correct or replace.
• Oil moves in the steering valve. Replace the steering valve ASSY.
• The relief valve is not functioning correctly. Inspect and correct.
The steering wheel in the • Air is sucked from the piping. Inspect and correct or replace.
idling state is heavy. • The piping is blocked (crushed or clogged). Inspect and correct or replace.
• The end cap set screw is tightened to an excessive Tighten uniformly to the specified
torque. torque.
The steering wheel
• The steering valve drive shaft is installed incorrectly. Inspect and correct.
shimmies.
The tires are steered
opposite to the steering • The cylinder piping is connected reversely. Inspect and correct.
wheel operated direction.
• The relief valve is defective. Correct, inspect the pressure, and
Abnormal noise is adjust.
generated. • Air is sucked from the piping. Inspect and correct or replace.
• The piping is blocked (crushed or clogged). Inspect and correct or replace.
9-14
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
2
3
T = 29.4 ~ 39.2
4 (300 ~ 400)
[21.7 ~ 28.9]
7
1
1
6
Removal Procedure
1 Remove the lower panel.
2 Remove the parking brake release lever. (for T/C only)
3 Remove the column cover.
4 Remove the instrument panel.
5 Disconnect the knob position correcting solenoid wiring. (Vehicle W/SAS)
6 Disconnect the piping.
7 Remove the steering valve ASSY.
8 Remove the fitting.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
9-15
DISASSEMBLY·INSPECTION·REASSEMBLY (VEHICLE L/SAS)
Note:
Clean dirt off from ports and joints before disassembly and operate in a clean place.
T = N·m (kgf·cm) [ft·lbf]
8
4
1
2
3
9
2
T = 22.6 (230) [16.6]
Disassembly Procedure
1 Remove the screw and retainer screw. [Point 1]
2 Remove the end cap and O-ring.
3 Remove the spacer, star, O-ring and rotor.
4 Remove the drive, spacer plate and O-ring. [Point 2]
5 Remove the retaining ring. [Point 3]
6 Remove the seal gland bushing and oil seal.
7 Remove the dust seal from the seal gland bushing.
8 Remove the bearing race and thrust needle.
9 Remove the spool and sleeve ASSY.
10 Remove the pin from the spool and sleeve ASSY. [Point 4]
11 Remove the centering spring. [Point 5]
12 Remove the sleeve from the spool.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
9-16
Point Operations
[Point 1]
Disassembly:
Fix the valve ASSY in a vise with the rotor facing upward.
Operate carefully since strong holding may cause distortion.
Disassembly:
Put a match mark to prevent an error in each retainer screw
tightening position.
Disassembly:
When removing each retainer screw, carefully operate so as
not to lose the steel ball.
Reassembly:
Put the steel ball in the illustrated position before installing
each retainer screw.
Reassembly:
Tighten the screws and retainer screws in the illustrated order.
[Point 2]
Reassembly:
Reassemble the drive and star as follows:
1. Rotate the spool and sleeve ASSY to bring the pin parallel with
the housing port surface.
2. Install the O-ring in the housing and place the spacer plate by
aligning the bolt holes.
3. Insert the drive and fit the pin.
4. Use a pen to put a line on the drive end in parallel with the pin.
5. Install the rotor and O-ring.
Roots in star D
6. Install the star by matching the roots of the gear teeth in the
A star with the line put in step 4.
Line B 7. Rotate the rotor without disengaging the drive and star until the
C bolt holes are aligned.
8. Check that lines A, B, C and D are parallel as illustrated.
Pin Port
surface
9-17
[Point 3]
Disassembly:
Use a straight-edge screwdriver and remove the retaining ring.
[Point 4]
Reassembly:
Put a match mark on the spool and sleeve.
Pin
Match marks
[Point 5]
Reassembly:
Install the centering springs with their notched portions in the
illustrated directions.
RELIEF PRESSURE
INSPECTION·ADJUSTMENT (VEHICLE L/SAS)
1. Install an oil pressure gauge.
SST (1) Disconnect the hose from the steering valve P port, and
connect the SST (adapter).
SST 09450-23320-71
(2) Install the oil pressure gauge.
Plug size: PT1/8
2. Start the engine and turn the steering wheel slowly clockwise
and counterclockwise.
3. Start the engine, rotate the steering wheel, and measure the
relief pressure when the relief occurs.
Standard: kPa (kgf/cm2) [psi]
1 ton series 7400 ~ 7900 (75 ~ 80) [1073 ~ 1146]
2·3 ton series 8000 ~ 8500 (82 ~ 87) [1160 ~ 1233]
J3.5 ton series 8300 ~ 8800 (85 ~ 90) [1204 ~ 1276]
4. If the standard is not satisfied, make adjustment by turning the
steering valve adjusting screw.
9-18
DISASSEMBLY·INSPECTION·REASSEMBLY (VEHICLE W/SAS)
Note:
Clean dirt off from ports and joints before disassembly and operate in a clean place.
T = N·m (kgf·cm) [ft·lbf]
T = 23 ~ 27
(235 ~ 275)
[17.0 ~ 19.9]
2
7 2
4
8 5
2
1 9
3
6
T = 17.6 ~ 21.5
(179 ~ 219)
[13.0 ~ 15.8]
10 T = 60 ~ 80 (612 ~ 816) [44.3 ~ 59.0]
Disassembly Procedure
1 Remove the knob position correcting solenoid valve ASSY.
2 Remove the set bolt and end cover. [Point 1]
3 Remove the gear wheel set, drive shaft, and distributor plate. [Point 2]
4 Remove the steel ball. [Point 3]
5 Remove the sleeve W/ spool and bearing. [Point 4]
6 Remove the relief valve. [Point 5]
7 Remove the pin from the sleeve W/ spool.
8 Remove the center spring. [Point 6]
9 Remove the packing and ring. [Point 7]
10 Remove the dust seal. [Point 8]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
9-19
Match mark Point Operations
[Point 1]
Disassembly:
Make a match mark across the end cover, outer gear, and
valve body.
Reassembly:
Follow the steps below for reassembly.
1. Align the match marks made at the time of disassembly.
2. Two types of set bolts are used.
• Set bolt with '10' mark on the head
• Set bolt without any mark on the head
Use a rod-tip bolt with no mark on its head at position A in the
illustration at left.
A
Driveshaft match mark [Point 2]
Pin Reassembly:
Install the driveshaft and inner gear in the illustrated relative
positions.
The spool pin shall pass the slit in the driveshaft.
Inner gear
match mark
Reassembly:
Install the outer gear with its side having the ∇ mark facing the
end cover side.
Mark
[Point 3]
Steel ball A
Disassembly:
A steel ball is placed in portion A of the valve body. Keep it so
as not to be lost.
Reassembly:
Make sure to put the steel ball in portion A.
9-20
[Point 4]
Reassembly:
Install the retaining bearing as illustrated at left.
Install one plate, the thrust bearing, and two plates in this order
from the depth.
Reassembly:
When inserting the sleeve W/ spool into the valve body, apply
MP grease to the packing, ring inner surface (portion in sliding
contact with the spool), and dust seal lip.
[Point 5]
Caulk Disassembly:
Measure the screwed-in depth of the adjust plug (depth to the
plug end face), and record it on a memo.
Reassembly:
Refer to the memo for the adjust plug screwed-in depth.
Reassembly:
Caulk two places on the circumference of the adjust plug after
hydraulic pressure adjustment.
[Point 6]
Reassembly:
Install the center spring as illustrated at left.
Reassembly:
Center spring
After spool insertion into the sleeve, the notched portion of the
spring shall securely set in the groove on the sleeve.
Notch
[Point 7]
Apply grease Reassembly:
The packing and ring shall be installed in the illustrated
directions.
Reassembly:
Apply MP grease to the ring before assembling with the
Bearing side
packing. Apply MP grease to the outer periphery of the packing.
Reassembly:
Dust seal side Guide the packing W/ ring to the assembling portion in the
valve body with a finger, and set them for insertion.
9-21
Reassembly:
SST(1) SST(2)
SST 09950-76018-71................................. (1)
(09950-60010) Plate with punch mark 37
09950-76018-71................................. (1)A
(09950-60010) Plate with punch mark 34
09950-76020-71................................. (2)
SST(1)A (09950-70010)
SST(2)
[Point 8]
Reassembly:
SST(2) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
RELIEF PRESSURE INSPECTION
(VEHICLE W/SAS)
1. Install an oil pressure gauge.
(1) Disconnect the hose from the P port of the steering valve,
and connect the SST (adapter).
SST 09450-23320-71
P port
(2) Install the oil pressure gauge.
Plug size: PT1/8
2. Start the engine, rotate the steering wheel slowly clockwise
and counterclockwise, and inspect the relief pressure at each
SST stroke end.
Standard: kPa (kgf/cm2) [psi]
1 ton series 7500 ~ 8000 (76 ~ 82) [1088 ~ 1160]
2·3·K2·K3 ton series 8100 ~ 8600 (83 ~ 88) [1175 ~ 1247]
J3.5 ton series 8400 ~ 8900 (86 ~ 91) [1218 ~ 1291]
10-1
BRAKE
Page
GENERAL.............................................................10-2
0
SPECIFICATIONS ................................................10-7
1
COMPONENTS ....................................................10-8
2
FRONT BRAKE ..................................................10-14
DISASSEMBLY·INSPECTION·REASSEMBLY
3
(1·J3.5 TON SERIES) ..........................................10-14 4
DISASSEMBLY·INSPECTION·REASSEMBLY
(2·3·K2·K3 TON SERIES) ....................................10-19 5
BRAKE AIR BLEEDING.....................................10-24 6
BRAKING FORCE 7
INSPECTION·ADJUSTMENT...........................10-24
8
BRAKE MASTER CYLINDER............................10-25
9
REMOVAL·INSTALLATION ...................................10-25
DISASSEMBLY·INSPECTION·REASSEMBLY .........10-26 10
PARKING BRAKE 11
INSPECTION·ADJUSTMENT...........................10-28 12
LEVER TYPE PARKING BRAKE (M/T MODEL) .......10-28
13
PEDAL TYPE PARKING BRAKE (T/C MODEL) .......10-29
RELEASE LEVER CABLE ADJUSTMENT ..............10-29
14
BRAKE PEDAL 15
INSPECTION·ADJUSTMENT...........................10-30 16
INCHING PEDAL 17
INSPECTION·ADJUSTMENT (T/C MODEL) ...10-31
18
19
20
21
E
10-2
GENERAL
FRONT BRAKE
1 ton series
Wheel Cylinder
10-3
2·3·K2·K3 ton series
0
1
2
3
4
5
6
7
8
9
10
11
Wheel Cylinder
12
13
14
15
16
17
18
19
20
21
E
10-4
J3.5 ton series
Wheel Cylinder
10-5
PARKING BRAKE
M/T model
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
10-6
T/C model
10-7
Master Cylinder
SPECIFICATIONS
Vehicle model
1 ton series 2·K2·K3 ton series 3 ton series J3.5 ton series
Item
Hydraulic internal
Foot brake expanding duo ← ← ←
servo brake
Internal expanding
Parking brake ← ← ←
mechanical brake
Brake drum inside diameter mm (in) 254 (10.0) 310 (12.2) ← 317.5 (12.5)
Resin mold
Material ← ← ←
(asbestos-free)
Brake lining Dimensions
279 x 48.5 x 5 323 x 60 x 7 343 x 60 x 7 352 x 60 x 5.6
Length x width x
(11.0 x 1.91 x 0.20) (12.7 x 2.36 x 0.28) (13.5 x 2.36 x 0.28) (13.9 x 2.36 x 0.22)
thickness mm (in)
Wheel cylinder bore mm (in) 22.2 (0.87) 28.5 (1.12) ← ←
Brake master Bore mm (in) 19.05 (0.75) ← ← ←
cylinder Stroke mm (in) 30 (1.18) ← ← ←
Applicable oil SAE J-1703-DOT-3 ← ← ←
10-8
COMPONENTS
FRONT BRAKE
1 ton series
4715
2·3·K2·K3 ton series
4715
10-9
J3.5 ton series
4715
Brake pipe
4714
10-10
BRAKE MASTER CYLINDER
M/T model
4702
T/C model
4702
10-11
PARKING BRAKE
M/T model
4601
4601
10-12
T/C model
4601
4601
10-13
BRAKE PEDAL
M/T model
4701
T/C model
4701
10-14
FRONT BRAKE
DISASSEMBLY·INSPECTION·REASSEMBLY (1·J3.5 TON SERIES)
11 4
12
6
7
Disassembly Procedure
1 Drain brake fluid.
2 Remove the front axle hub. (See page 7-8) [Point 1]
3 Remove the shoe hold down spring and cup. [Point 2]
4 Remove the anchor to shoe spring and shoe guide plate. [Point 3]
5 Remove the cable and cable guide.
6 Remove the lever strut. [Point 4]
7 Remove the adjuster spring and adjusting screw. [Point 5]
8 Disconnect the parking brake cable. [Point 6]
9 Remove the brake shoe. [Point 7]
10 Disconnect the brake pipe.
11 Remove the wheel cylinder ASSY. [Point 8]
12 Remove the backing plate. [Point 9]
10-15
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Check that the brake lining and brake drum interior surface are free from grease or oil before
installation.
• Before reassembly, decrease the brake drum outside diameter to approx. 1 mm (0.04 in) less than the
drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (see page 10-24) and braking force inspection
(see page 10-24).
• Apply thread tightener (08833-76001-71 (08833-00070)) to the backing plate set bolt before reassembly.
Point Operations
[Point 1]
Inspection:
Measure the brake drum inside diameter.
Standard
1 ton series: 254 mm (10.0 in)
J3.5 ton series: 317.5 mm (12.50 in)
Limit
1 ton series: 256 mm (10.1 in)
J3.5 ton series: 319.5 mm (12.579 in)
Reassembly:
Apply thread tightener (08833-76001-71 (08833-00070)) on
the brake drum set nut before reassembly.
[Point 2]
Disassembly•Reassembly:
SST 09510-31960-71
SST
Inspection:
Measure the free length of the hold down spring.
Standard
1 ton series: 25.5 mm (1.004 in)
J3.5 ton series: 44.0 mm (1.732 in)
10-16
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
shoe hold down pin and the contact surface on the back side
of the backing plate to eliminate any clearance.
[Point 3]
Disassembly:
SST 09717-76001-71
(09717-20010)
SST
Inspection:
Measure the free length of the anchor to shoe spring.
Standard
1 ton series: 102.2 mm (4.024 in)
J3.5 ton series: On the side of lining W/ pin
138.2 mm (5.441 in)
On the side of lining W/O pin
121.2 mm (4.772 in)
Limit: No clearance between coil turns
Reassembly:
SST
SST 09718-76001-71
(09718-20010)
[Point 4]
Inspection:
Measure the free length of the strut to shoe spring.
Standard
1 ton series: 19.7 mm (0.776 in)
J3.5 ton series: 31.4 mm (1.236 in)
10-17
[Point 5]
Inspection:
Measure the free length of the adjuster spring.
Standard
1 ton series: 99.4 mm (3.913 in)
J3.5 ton series: 125.4 mm (4.937 in)
Limit: No clearance between coil turns
Reassembly:
Apply grease to the adjusting screw threaded portion and fill
grease in the cap.
Reassembly:
Tie a wire to the free end of the adjuster spring and set it by
pulling the wire with a screwdriver.
[Point 6]
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
parking brake cable outlet of the backing plate to eliminate any
clearance.
[Point 7]
Inspection:
Measure the brake lining thickness.
Standard
1 ton series: 4.9 mm (0.193 in)
J3.5 ton series: 5.6 mm (0.220 in)
Limit
1 ton series: 1.0 mm (0.039 in)
J3.5 ton series: 1.0 mm (0.039 in)
Reassembly:
Before brake shoe installation, apply grease to the portions of
the backing plate shown in the illustration (6 places in contact
with the shoe rim and the anchor pin).
10-18
[Point 8]
Inspection:
Measure the clearance between the wheel cylinder and piston.
Limit
1 ton series: 0.125 mm (0.00492 in)
J3.5 ton series: 0.15 mm (0.0059 in)
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
backing plate fitting portion of the wheel cylinder and on the
whole periphery of the set bolts to eliminate any clearance.
[Point 9]
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
contact surface between the backing plate and front axle
bracket shown in the illustration to eliminate any clearance.
10-19
DISASSEMBLY·INSPECTION·REASSEMBLY (2·3·K2·K3 TON SERIES)
12
3 13
6
10
3
5
8
3
Disassembly Procedure
1 Drain brake fluid.
2 Remove the front axle hub. (See page 7-8.) [Point 1]
3 Remove the hold down spring. [Point 2]
4 Remove the pawl lever stopper. [Point 3]
5 Remove the pawl lever.
6 Remove the anchor to shoe spring. [Point 4]
7 Remove the strut lever. [Point 5]
8 Remove the adjuster spring and adjusting screw. [Point 6]
9 Disconnect the parking brake cable. [Point 7]
10 Remove the brake shoe. [Point 8]
11 Disconnect the brake piping.
12 Remove the wheel cylinder ASSY. [Point 9]
13 Remove the backing plate. [Point 10]
10-20
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
(With regard to steps 3 and 4, however, install the pawl lever stopper after installing the hold down spring.)
Note:
• Check that the brake lining and brake drum interior surface are free from grease or oil before
reassembly.
• Before reassembly, decrease the brake shoe outside diameter to approx. 1 mm (0.04 in) less than the
brake drum inside diameter by tightening the adjusting screw.
• After reassembly, perform brake air bleeding (see page 10-24) and braking force inspection and
adjustment (see page 10-24).
Point Operations
[Point 1]
Inspection:
Measure the brake drum inside diameter.
Standard: 310 mm (12.20 in)
Limit: 312 mm (12.28 in)
Reassembly:
Apply thread tightener (08833-76001-71 (08833-00070)) to the
brake drum set nut before reassembly.
[Point 2]
Disassembly•Reassembly:
SST
SST 09510-31960-71
Inspection:
Measure the free length of the hold down spring.
Standard: 34.5 mm (1.358 in)
Limit: 31.3 mm (1.232 in)
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
back side of the backing plate in contact with the shoe hold
down spring to eliminate any clearance.
10-21
[Point 3]
Inspection:
Measure the free length of the actuator spring.
Standard: 124.5 mm (4.902 in)
Limit: No clearance between coil turns
Reassembly:
Use snap ring pliers to install the pawl lever stopper and
actuator spring.
[Point 4]
Disassembly:
SST 09717-76001-71
(09717-20010)
SST
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
SST 09718-76001-71
(09718-20010)
10-22
[Point 5]
Inspection:
Measure the free length of the strut to shoe spring.
Standard: 23 mm (0.91 in)
Limit: 20 mm (0.79 in)
[Point 6]
Inspection:
Measure the free length of the adjuster spring.
Standard: 86 mm (3.39 in)
Limit: No clearance between coil turns
Reassembly:
Apply grease to the adjusting screw threaded portion and
fill grease in the cap.
[Point 7]
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
parking brake outlet of the backing plate to eliminate any
clearance.
[Point 8]
Inspection:
Measure the brake lining thickness.
Standard: 7.0 mm (0.276 in)
Limit: 2.0 mm (0.079 in)
10-23
Reassembly:
Apply grease to the portions of the backing plate shown in the
illustration (6 places in contact with the shoe rim and the
anchor pin) before brake shoe installation.
[Point 9]
Inspection:
Measure the clearance between the wheel cylinder and piston.
Limit: 0.145 mm (0.00571 in)
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
wheel cylinder backing plate fitting portion and the whole
periphery of set bolts to eliminate any clearance.
[Point 10]
Reassembly:
Carefully install the backing plate set bolts in the correct
positions since they are different in length.
Apply thread tightener (08833-76001-71 (08833-00070)) to the
set bolts before reassembly.
Bolt length
A: l = 36 mm (1.42 in)
2·K2·K3 ton series 3 ton series B: l = 40 mm (1.57 in)
C: l = 45 mm (1.77 in)
Reassembly:
Apply liquid packing (08826-76002-71 (08826-00090)) to the
contact surface between the backing plate and front axle
bracket shown in the illustration to eliminate any clearance.
10-24
BRAKE AIR BLEEDING
Note:
Add brake fluid to the reservoir tank during air bleeding to
prevent it from becoming insufficient.
1. Bleed air from the brake master cylinder.
(1) Depress the brake pedal several times to compress the
air in the piping, and hold that state.
(2) Loosen the bleeder plug to discharge air in the piping with
the brake fluid, and tighten the plug immediately before
the fluid stops coming out.
(3) Repeat steps (1) and (2) above until no air 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 the RH and LH
side at a time.
3. Add brake fluid to the specified level.
(1) Add brake fluid through the filter provided in the reservoir
tank.
(2) Add brake fluid up to the specified level in the reservoir
tank.
BRAKING FORCE INSPECTION·ADJUSTMENT
1. Inspect the braking force using a brake tester or by traveling test.
Braking distance (without load)
Initial speed of braking km/h (mph) Max. speed
Braking distance m (ft) 5.0 (16.4) or less
2. Adjust the braking force.
(1) Repeat traveling in the forward and reverse directions to adjust the brake shoe clearance.
The adjusting screw adjusts the 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 adhesion on the
lining or brake fluid leakage is assumed. Remove and inspect the brake drum.
(3) When the brake shoe is replaced with a new one, repeat traveling in the forward and reverse directions for
running in.
10-25
BRAKE MASTER CYLINDER
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 6.8 ~ 15.8
(69 ~ 161)
[5.0 ~ 11.7]
6
8
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Remove the instrument panel.
4 Remove the column cover.
5 Disconnect the brake side hose from the reservoir tank and drain brake fluid.
6 Disconnect the piping.
7 Remove the push rod clevis pin.
8 Remove the brake master cylinder.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, perform brake pedal adjustment (see page 10-30) and air bleeding (see page 10-24).
10-26
DISASSEMBLY·INSPECTION·REASSEMBLY
1
4
4
3
5
Disassembly Procedure
1 Turn the boot up and remove the snap ring.
2 Remove the push rod. [Point 1]
3 Remove the piston. [Point 2]
4 Remove the pin and the fluid inlet elbow.
5 Remove the outlet plug and valve.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
10-27
Point Operations
[Point 1]
Reassembly:
Temporarily set the push rod length to the illustrated
dimension, and make readjustment after installation.
130 mm (5.118 in)
[Point 2]
Reassembly:
Apply rubber grease to the piston cup and whole periphery of
the cup before reassembly.
10-28
PARKING BRAKE
INSPECTION·ADJUSTMENT
LEVER TYPE PARKING BRAKE (M/T MODEL)
A
1. Check the parking brake cable set position.
Standard: A = 0 ~ 2 mm (0 ~ 0.08 in)
2. Apply chassis grease to the portions indicated by arrows.
56 mm (2.2 in) 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
Except J3.5 ton series:
175 ~ 215 N (18 ~ 22 kgf) [39 ~ 48 lbf]
J3.5 ton series:
225 ~ 265 N (23 ~ 27 kgf) [51 ~ 60 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.
10-29
PEDAL TYPE PARKING BRAKE (T/C MODEL)
1. Check the parking brake cable set position.
Standard: A = 0 ~ 2 mm (0 ~ 0.08 in)
2. Apply chassis grease to the portions indicated by arrows.
A
LH RH
When using the SST 3. Inspect and adjust the parking brake pedal operating force.
(1) Set the SST to the parking brake pedal.
SST 09460-26600-71
(A)
(2) Set a spring scale to the SST and pull it backward to
measure the operating force.
SST
When not using the SST Standard:
(A) When using the (B) When not using
SST the SST
112 ~ 136 N 186 ~ 226 N
Except J3.5 ton
(11.4 ~ 13.9 kgf) (19 ~ 23 kgf)
series
[25.1 ~ 30.6 lbf] [42 ~ 51 lbf]
(B) 142 ~ 166 N 235 ~ 275 N
J3.5 ton series (14.5 ~ 16.9 kgf) (24 ~ 28 kgf)
[32.0 ~ 37.3 lbf] [53 ~ 62 lbf]
(3) 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.
RELEASE LEVER CABLE ADJUSTMENT
1. Adjust the play of the release lever to 0 to 5 mm (0 to 0.2 in) at
the tip of the lever using the release cable adjusting nut.
Adjusting nut
Release
lever
10-30
BRAKE PEDAL INSPECTION·ADJUSTMENT
Stop lamp switch
Brake master cylinder
(0.642 in)
16.3 mm
Push rod
142 ~ 147 mm (5.591 ~ 5.787 in)
B
A
Reference value
C
Toe board Floor mat
1. Inspect brake pedal height A. (From toe board to top of pedal)
Standard: A = 145 ~ 150 mm (5.91 ~ 6.10 in) (with pedal pad)
If the standard is not satisfied, make adjustment by changing the stop lamp switch position.
2. Inspect brake pedal play B.
Standard: B = 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 and inspect pedal height D.
Standard: D = 90 mm (3.54 in) or more
10-31
INCHING PEDAL INSPECTION·ADJUSTMENT (T/C MODEL)
Brake pedal link
Stopper bolt
Inching pedal
plate
Adjusting nut B
A C
(5.591 ~ 5.787 in))
(5.709 ~ 5.906 in))
(142 ~ 147 mm
(145 ~ 150 mm
Floor mat Toe board
Adjusting nut
Inching lever
1. Inspect and adjust the brake pedal height and play (See page 10-29).
2. Inspect stroke A of the inching pedal until interlocking with the brake (pedal stroke until the inching pedal plate
comes into contact with the brake link).
Standard
1 ton series: A = 35 ~ 41 mm (1.38 ~ 1.61 in)
Others: A = 25 ~ 32 mm (0.98 ~ 1.26 in)
If the standard is not satisfied, adjust the stopper bolt protrusion.
Adjust the brake pedal height within + 15 mm (0.59 in).
3. Inspect and adjust the inching cable.
(1) Inspect inching cable length B on the pedal side.
Standard: B = 17.5 mm (0.689 in)
If the standard is not satisfied, adjust it by turning the adjusting nuts on the pedal side.
(2) Inspect inching pedal play C before the inching lever starts to move.
Standard: C = 1 ~ 3 mm (0.04 ~ 0.12 in)
If the standard is not satisfied, adjust it by turning the adjusting nuts on the inching lever side.
11-1
BODY
Page
COMPONENTS .................................................... 11-2
0
ENGINE HOOD ASSY........................................ 11-10
1
REMOVAL·INSTALLATION ................................... 11-10
2
COUNTERWEIGHT ............................................ 11-11
REMOVAL·INSTALLATION ................................... 11-11 3
DRIVER’S SEAT................................................. 11-12 4
REMOVAL·INSTALLATION ................................... 11-12 5
SEATBELT.......................................................... 11-13 6
REMOVAL·INSTALLATION ................................... 11-13
7
SEATBELT RETRACTOR INSPECTION ................. 11-13
8
HEADLAMPS ..................................................... 11-14
REMOVAL·INSTALLATION ................................... 11-14
9
BULB REPLACEMENT ......................................... 11-15 10
COMBINATION METER ..................................... 11-16 11
REMOVAL·INSTALLATION ................................... 11-16 12
COMBINATION SWITCH ................................... 11-17 13
INSPECTION ....................................................... 11-17
14
FUEL SENDER GAUGE..................................... 11-18
15
INSPECTION ....................................................... 11-18
16
17
18
19
20
21
E
11-2
COMPONENTS
Radiator Cover (1 ton series)
5101
Radiator Cover (2·3·J3.5 ton series)
5101
11-3
Radiator Cover (K2·K3 ton series)
5101
0
1
2
3
4
5
6
7
8
9
10
Step (RH) (1 ton series)
5101
11
12
13
14
15
16
17
18
19
20
21
E
11-4
Step (LH) (1 ton series)
5101
Step (RH) (2·K2·K3·3·J3.5 ton series)
5101
11-5
Step (LH) (2·K2·K3·3·J3.5 ton series)
5101
0
1
2
3
4
5
6
7
8
9
10
Under Cover (1 ton series)
5101
11
12
13
14
15
16
17
18
19
20
21
E
11-6
Under Cover (2·K2·K3·3·J3.5 ton series)
5101
Hood & Hinge
5201
11-7
Instrument Panel (T/C Model)
5301
Instrument Panel (M/T Model)
5301
11-8
Driver Seat
5308
Lamp
5611
11-9
Meter & Switch
5701
11-10
ENGINE HOOD ASSY
REMOVAL·INSTALLATION
2
4
Removal Procedure
1 Remove the radiator cover.
2 Open the engine hood.
3 Disconnect the seat switch connector. Disconnect the seat switch sub harness from the harness clamp in the
engine hood.
4 Disconnecting the engine hood damper (on the engine hood side).
5 Close the engine hood.
6 Remove the engine hood bracket set bolts.
7 Remove the engine hood.
Installation procedure
The installation procedure is the reverse of the removal procedure.
11-11
COUNTERWEIGHT
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 830 ~
(8500 ~)
[612 ~]
Removal Procedure
1 Remove the radiator cover.
2 Remove the weight cap and temporarily hoist the counterweight using a wire rope.
3 Remove the drawbar and the counterweight set bolt.
4 Remove the counterweight.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
See page 0-18 for the weight of the counterweight.
11-12
DRIVER’S SEAT
REMOVAL·INSTALLATION
Removal Procedure
1 Disconnect the seat switch connector.
2 Open the engine hood.
3 Remove the driver’s seat set nuts.
4 Remove the driver’s seat. [Point 1]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1]
Inspection:
Push down on the seat cushion and inspect the seat switch for
continuity.
Measurement location: Between terminals X1-1 and X1-2
Standard
2 1 When not pressed: ∞ Ω
When pressed: 0Ω
11-13
SEATBELT
REMOVAL·INSTALLATION
Note:
Never try to disassemble the seatbelt retractor.
T = N·m (kgf·cm) [ft·lbf]
T = 41.2 (420) [30.4]
1
T = 41.2 (420)
[30.4]
Removal Procedure
1 Remove the seatbelt buckle.
2 Remove the seatbelt retractor.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
SEATBELT RETRACTOR INSPECTION
1. The installed seatbelt should be pulled out and retracted
smoothly. Also check that it is locked when pulled out
suddenly.
2. Fasten the seatbelt. Travel straight at a high speed, and apply
the brake suddenly. Check that the belt is locked to hold your
body.
Caution:
Test this function in a place where safety can be ensured.
11-14
HEADLAMPS
REMOVAL·INSTALLATION
Removal Procedure
1 Pull the connector out from the pillar hole and disconnect it.
2 Remove each headlamp.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
11-15
BULB REPLACEMENT
Note:
• Since the halogen bulb (of the headlamp) becomes hot
when it is on, its life will be shortened if oil or grease
adheres to the glass surface. When handling the bulb,
therefore, hold the flange portion to avoid direct contact
between the glass surface and a hand or finger.
• Since the internal pressure of the halogen bulb (of the
headlamp) is high, it may be broken, causing scattering of
glass fragments when it is dropped, struck or when the
glass surface is scratched.
• Always use a bulb showing the same (specified) wattage
for replacement.
Headlamp: 12 V, 55 W, H3
Headlamp:
1. Remove the headlamp lens.
2. Remove the bulb W/ reflector.
3. Remove the connector.
4. Release the lock of the set spring and remove the bulb.
5. The installation procedure is the reverse of the removal
procedure.
11-16
COMBINATION METER
REMOVAL·INSTALLATION
Removal Procedure
1 Remove the lower panel.
2 Disconnect the combination meter wire harness.
3 Remove the instrument panel RH.
4 Remove the combination meter set screws.
5 Remove the combination meter ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
11-17
COMBINATION SWITCH
Note:
See page 3-36 for the direction switch inspection.
INSPECTION
Turn signal switch Light switch
OFF T
H
1. Individual switch continuity inspection
Switch position Measurement terminals Standard
Light switch
OFF BT-T No continuity
T BT-T Continuity
H BT-T Continuity
TR TB TL T BH BT
Turn signal switch
R TB-TR Continuity
Light & turn signal switch
OFF TB-TR-TL No continuity
L TB-TL Continuity
TR TL
TB T BH BT
Vehicle with RH direction lever
11-18
FUEL SENDER GAUGE
INSPECTION
T = N·m (kgf·cm) [ft·lbf]
T = 9.6 ~ 14.4
(98 ~ 147)
[7.1 ~ 10.6]
F
E
1. Remove the fuel tank cover ASSY.
2. Measure the resistance.
(1) Check if the float moves smoothly.
(2) Measure the resistance between the positive and negative (body ground) terminals of the sender gauge
while the float position is varied between F and E.
Also check if the resistance varies continuously.
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
Float position mm (in) Resistance Ω
F 130 (5.118) 15 ± 1.5
E 391.1 (15.398) 410 ± 4.5
12-1
MATERIAL HANDLING SYSTEM
Page
HYDRAULIC CIRCUIT DIAGRAM .......................12-2
0
COMPONENTS ....................................................12-5
1
RETURN FILTER ..................................................12-8
2
REMOVAL·INSTALLATION .....................................12-8
SUCTION FILTER.................................................12-9 3
REMOVAL·INSTALLATION .....................................12-9 4
NATURAL DROP TEST .....................................12-10 5
NATURAL FORWARD TILT TEST .....................12-10 6
OIL LEAK TEST ................................................. 12-11 7
LIFT CYLINDER ................................................... 12-11
8
TILT CYLINDER ................................................... 12-11
9
10
11
12
13
14
15
16
17
18
19
20
21
E
12-2
HYDRAULIC CIRCUIT DIAGRAM
STD (Oil Control Valve with 2-Way)
(7)
(3)
(4)
(5)
(2)
(1)
(6) (8)
(1) Oil pump (5) Solenoid valve (SAS spec.)
(2) Flow divider (6) Power steering cylinder
(3) Oil control valve (7) Left and tilt cylinder
(4) Steering valve (8) Oil tank
12-3
STD (Oil Control Valve with 3-Way or More)
0
1
2
3
4
(9)
5
(7)
6
(3)
7
(10)
(4)
8
(5)
(2)
9
(1)
10
11
12
(6) (8)
13
14
15
16
17
18
(1) Oil pump (6) Power steering cylinder 19
(2) Flow divider (7) Lift·tilt·ATT cylinder
(3) Oil control valve (8) Oil tank 20
(4) Steering valve (9) Oil cooler
(5) Solenoid valve (SAS spec.) (10) Relief valve (Not available for the oil cooler built into 21
the radiator)
E
12-4
Vehicle with Oil Clutch
(7)
(3)
(9)
(4)
(5)
(10)
(2)
(1)
(8)
(6)
(11)
(12)
(13)
(1) Oil pump (8) Oil tank
(2) Flow divider (9) Clutch pedal
(3) Oil control valve (10) Clutch master cylinder
(4) Steering valve (11) Clutch release cylinder
(5) Solenoid valve (SAS spec.) (12) Oil clutch
(6) Power steering cylinder (13) Oil cooler
(7) Lift·tilt·ATT cylinder
12-5
COMPONENTS
6801
0
1
2
3
4
5
6
7
8
9
10
6801 11
12
13
14
15
16
17
18
19
20
21
E
12-6
6801
6801
12-7
V·FV
6802
FSV
6802
12-8
RETURN FILTER
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 6.9 ~ 16.1
(70 ~ 164)
[5.1 ~ 11.9]
Removal Procedure
1 Open the engine hood.
2 Remove the toe board.
3 Disconnect the hose from the return filter. [Point 1]
4 Remove the return filter.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1]
Removal:
Cover the area around the filter to prevent oil from splashing
onto the wire harness or connectors because oil may spill out
from the hose when disconnecting it.
12-9
SUCTION FILTER
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 9.8 ~ 14.7
5
(100 ~ 150) [7.2 ~ 10.9]
Removal Procedure
1 Open the engine hood.
2 Remove the toe board.
3 Remove the side cover W/ step.
4 Remove the side cover bracket.
5 Disconnect the hose from the return filter. [Point 1]
6 Remove the return filter.
7 Remove all hoses from the tank cover.
8 Remove the tank cover W/ suction filter.
9 Remove the suction filter.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1]
Removal:
Cover the area around the filter to prevent oil from splashing
onto the wire harness or connectors because oil may spill out
from the hose when disconnecting it.
12-10
NATURAL DROP TEST
1. Set the mast vertical with the standard load on the fork. Lift the
fork by 1 to 1.5 m (40 to 59 in), and stop the engine.
2. Draw datum lines on the inner and outer masts, and measure
the drop in 15 minutes.
Limit: W/SAS, L/SAS 45 mm (1.77 in)
NATURAL FORWARD TILT TEST
1. Set the mast vertical with standard load on the fork. Lift the
fork by about 50 cm (19.7 in) and stop the engine.
2. Measure the tilt cylinder rod extension in 15 minutes.
Natural forward tilt amount mm (in)
Vehicle model
W/SAS, L/SAS
1 ton series 15 (0.59) or less
2·K2 ton series 20 (0.79) or less
3·K3·J3.5 ton series 25 (0.98) or less
12-11
OIL LEAK TEST
LIFT CYLINDER
1. Set the mast vertical with the standard load on the fork. Lift the
fork by 1 to 1.5 m (40 to 59 in).
2. Slowly tilt the mast fully forward, and stop the engine.
3. After 5 minutes, disconnect the oil control valve to oil tank
hose. Place a measuring cylinder under the elbow and
measure the amount of oil leaking in one minute.
Standard (at lift port):
W/SAS, L/SAS 8 cm3 (0.49 in3) or less
Note:
If the natural drop is big even though the oil leak amount is
within the standard, the lift cylinder packing is defective.
TILT CYLINDER
1. Set the mast vertical with standard load on the fork. Lift the
fork by about 50 cm (19.7 in) and stop the engine.
2. After 5 minutes, disconnect the oil control valve to oil 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):
W/SAS, L/SAS 16 cm3 (0.98 in3) or less
3. The leak amount at the tilt port is equal to the remainder when
you subtract the leak amount at the lift port from the total leak
amount of the lift and tilt cylinder.
Note:
If the natural forward tilt is great even though the oil leak
amount is within the standard, either the tilt lock valve or the
tilt cylinder packing is defective.
13-1
MAST
Page
V MAST ASSY......................................................13-2
0
COMPONENTS ......................................................13-2
1
REMOVAL·INSTALLATION .....................................13-5
REMOVAL·INSTALLATION (W/LIFT BRACKET)........13-8 2
MAST DISASSEMBLY·INSPECTION· 3
REASSEMBLY ................................................... 13-11
4
LIFT BRACKET DISASSEMBLY·REASSEMBLY ......13-13
MAST ADJUSTMENT (V MAST) ............................13-15
5
MAST ROLLER REMOVAL·INSTALLATION ............13-22 6
CHAIN.................................................................13-23 7
INSPECTION .......................................................13-23 8
REASSEMBLY .....................................................13-23
9
ADJUSTMENT .....................................................13-24
10
FORK ..................................................................13-25
11
REMOVAL ...........................................................13-25
INSTALLATION ....................................................13-25 12
INSPECTION .......................................................13-25 13
FV·FSV MAST ASSY..........................................13-26 14
COMPONENTS ....................................................13-26 15
MAST ADJUSTMENT (FV·FSV) .............................13-34
16
STANDARD FOR SELECTING
AN OVERSIZE ROLLER ..................................13-42 17
LIFT CYLINDER ROD SHIM ADJUSTMENT 18
(PREVENTION OF UNEVEN LIFTING) ...........13-43
19
V·FSV MAST .......................................................13-43
20
FV MAST ............................................................13-44
21
E
13-2
V MAST ASSY
COMPONENTS
6101
1 ton series
6301
13-3
2·K2 ton series
6301
0
1
2
3
4
5
6
7
8
9
10
3·K3·J3.5 ton series
6301
11
12
13
14
15
16
17
18
19
20
21
E
13-4
6302
13-5
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
0
5 1
6
6
2
9
3
4
3
8 T = 138.0 ~ 322.0 10 T = 66.0 ~ 154.0 5
(1407 ~ 3282) (673 ~ 1570)
[48.7 ~ 113.6]
[101.8 ~ 237.5]
6
2
7
6
8
4 9
10
11
8
T = 138.0 ~ 322.0
(1407 ~ 3282)
12
[101.8 ~ 237.5]
13
Removal Procedure
14
1 Set the mast vertical and fully lower the fork.
2 Disconnect the chain. [Point 1] 15
3 Remove the chain wheel. [Point 2]
4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until the lift bracket comes off from the
16
inner mast, and slowly run the vehicle backward to move away from the lift bracket.)
5 Disconnect the fork height switch connector. (SAS spec.)
17
6 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast 18
and operate the lift lever several times to release the residual pressure in the lift cylinder.)
7 Incline the mast forwards and suspend it temporarily. (Be careful never to operate the lift lever at this time.) 19
8 Remove the mast support set bolts.
9 Remove the tilt cylinder front pin. [Point 3]
20
10 Remove the mast ASSY. 21
11 Remove the tilt bracket bushing from the mast. [Point 4]
12 Remove the mast support pin and mast support bushing from the front axle bracket. [Point 5] E
13-6
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, add molybdenum disulfide grease through the grease nipple of the tilt cylinder front
pin.
• Adjust lift cylinder uneven movement using shims when any of the mast ASSY, outer mast, inner mast or
lift cylinder is replaced. (See page 13-43.)
• Adjust the chain tension after installation. (See page 13-23.)
• When the mast is replaced, perform SAS matching after installation. (SAS spec.) (See section 18.)
Point Operations
SST
[Point 1]
Removal•Installation:
SST 09630-23600-71
SST [Point 2]
Removal:
If the fitting is hard, use the SST for removal.
SST 09950-76014-71
(09950-40011)
[Point 3]
SST
Removal:
SST 09810-20172-71
13-7
[Point 4]
SST(1) Installation:
SST(2) Use the SST to drive in the tilt bracket bushing from the mast
outer side.
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Vehicle outer side Vehicle outer side
surface surface
Bushing
Flush
Bushing surfaces
1 ton series Other than 1 ton series
[Point 5]
Front axle bracket
Installation:
SST(2) Use the SST to drive in the mast support bushing.
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
SST(1) (09950-70010)
Installation:
White marking Position the joint of the mast support bushing (positon of the
white marking) within the 180° range shown in the illustration.
180°
45°
Mast support
bushing
Installation:
90° Attach the grease nipple so that it faces towards the top of the
vehicle.
After attaching the mast, add molybdenum disulfide grease
through the nipple until it comes out from both sides of the
front axle bracket.
Nipple Installation:
Before installing the mast, face the flat surface of the mast
support pin upward.
Mast support pin
13-8
REMOVAL·INSTALLATION (W/LIFT BRACKET)
T = N·m (kgf·cm) [ft·lbf]
3
4
6 T = 138.0 ~ 322.0 8 T = 66.0 ~ 154.0
(1407 ~ 3282) (673 ~ 1570)
[101.8 ~ 237.5] [48.7 ~ 113.6]
6
T = 138.0 ~ 322.0
(1407 ~ 3282)
[101.8 ~ 237.5]
Removal Procedure
1 Set the mast vertical.
2 Remove the fork. (See page 13-25.)
3 Disconnect the wiring of the fork height switch. (SAS spec.)
4 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast
and operate the lift lever several times to release the residual pressure from the lift cylinder.)
5 Incline the mast forwards and suspend it temporarily. (Be careful never to operate the lift lever at this time).
6 Remove the mast support set bolts.
7 Remove the tilt cylinder front pin. [Point 1]
8 Remove the mast ASSY W/ lift bracket.
9 Remove the tilt bracket bushing from the mast. [Point 2]
10 Remove the mast support pin and mast support bushing from the front axle bracket. [Point 3]
13-9
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, add molybdenum disulfide grease through the grease nipple of the tilt cylinder front
pin.
• Adjust lift cylinder uneven movement using shims when any of the mast ASSY, outer mast, inner mast or
lift cylinder is replaced. (See page 13-43.)
• Adjust the chain tension after installation. (See page 13-23.)
• When the mast is replaced, perform SAS matching after installation. (SAS spec.) (See section 18.)
Point Operations
[Point 1]
SST
Removal:
SST 09810-20172-71
[Point 2]
SST(1) Installation:
SST(2) Use the SST to drive in the tilt bracket bushing from the mast
outer side.
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Vehicle outer side Vehicle outer side
surface surface
Bushing
Flush
Bushing surfaces
1ton class Other than 1 ton class
13-10
Front axle bracket [Point 3]
Installation:
SST(2) Use the SST to drive in the mast support bushing.
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
SST(1) (09950-70010)
Installation:
White marking
Position the joint of the mast support bushing (positon of the
white marking) within the 180° range shown in the illustration.
180°
45°
Mast support
bushing
Installation:
Attach the grease nipple so that it faces towards the top of the
90°
vehicle.
After attaching the mast, add molybdenum disulfide grease
through the nipple until it comes out from both sides of the
front axle bracket.
Nipple Installation:
Before installing the mast, face the flat surface of the mast
support pin upward.
Mast support pin
13-11
MAST DISASSEMBLY·INSPECTION·REASSEMBLY
1
2
7
8
Disassembly Procedure
1 Remove the fork height switch. (SAS spec.)
2 Remove the hose cover.
3 Disconnect the high pressure hose.
4 Remove each cylinder rod end set bolt.
5 Remove each cylinder support.
6 Slide the inner mast upward and remove the lift cylinders. [Point 1]
7 Slide the inner mast downward and remove the lift rollers.
8 Remove the mast strip. [Point 2]
9 Remove the outer mast.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
13-12
NJljǧ
Shim Point Operations
[Point 1]
Disassembly:
Shim adjustment is made at the lift cylinder rod end to prevent
uneven lifting by lift cylinders LH and RH.
Note the cylinder that was adjusted and the number of shims
used.
[Point 2]
Inspection:
Except J3.5 ton series
Measure the mast strip thickness.
Limit: 1.5 mm (0.059 in)
Inspection:
Oil dimples
J3.5 ton series
Inspect the mast strip wear.
Wear limit: Until the oil dimples worn away
13-13
LIFT BRACKET DISASSEMBLY·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
L/ side roller
3 1
T = 240 (2447) [177.04]
1
W/ side roller
3 2
T = 240 (2447) [177.04]
1
13-14
Disassembly Procedure
1 Remove lift rollers. [Point 1]
2 Remove side rollers. [Point 2]
3 Remove the back rest.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Disassembly:
SST 09950-76014-71
(09950-40011)
SST
1·2·3·K2·K3 ton series, L/ side roller:
Round
Round chamfering chamfering Disassembly:
small large Remove the rollers after removing the roller stopper plate.
Shims Reassembly:
Bring Install each roller with the side chamfered with larger radius
into
facing outward.
contact
Reassembly:
Plate
Bring the stopper plate into contact with the roller inner ring.
Minimize the clearance between the plate and pin by shim
insertion.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
1 mm 9 mm (0.35 in) [Point 2]
(0.04 in) Front
Reassembly:
The side chamfered with larger radius of the roller shall face
the front of the vehicle.
Round
chamfering
13-15
MAST ADJUSTMENT (V MAST)
Lift Roller Adjustment at Mast
1. Inner mast roller clearance adjustment
Outer mast Inner mast
Bring into contact
Bring into contact
A Inner mast roller
(1) Adjust the mast overlap to approx. 450 mm (17.72 in).
(2) Inspect and adjust the inner mast rollers.
Shift the inner mast to one side to bring the roller into
contact with the outer mast. Measure the clearance
between the roller side face on the opposite side and
outer mast at the point where they are the closest.
Standard: A = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
Shims
changing the shim thickness. Distribute shims equally to
the rollers on the left and right side. (See page 13-22 for
the mast roller removal and installation.)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check that the inner mast moves
smoothly in the outer mast.
13-16
2. Outer mast roller clearance adjustment
Outer mast roller
Bring into contact
Bring into
contact
Outer mast Inner mast
B
(1) Adjust the mast overlap to approx. 450 mm (17.72 in).
(2) Inspect and adjust the outer mast rollers.
Shift the outer mast to one side to bring the roller into
contact with the inner mast. Measure the clearance
between the roller side face on the opposite side and
inner mast at the point where they are the closest.
Standard: B = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the shim thickness. Distribute shims equally to
Shims the rollers on the left and right side. (See page 13-22 for
the mast roller removal and installation.)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check that the inner mast moves
smoothly in the outer mast.
13-17
Roller Adjustment at Lift Bracket
1. 1·2·3·K2·K3 ton series
100 mm (3.94 in)
Outer mast
Bring into
D contact
Inner mast
Lift bracket
Upper/middle lift roller Position of lift bracket during upper
and lower lift roller inspection
100 mm (3.94 in)
Bring into contact
Outer mast
Bring into
contact Lift bracket
Inner mast
C
Position of lift bracket during middle
Lower lift roller lift rollers inspection
(1) Hoist the lift bracket to the specified position.
Bring the center of the middle lift rollers in the lift bracket
to 100 mm (3.94 in) below the top of the inner mast.
(2) Inspect and adjust the middle lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: E = 0.6 ~ 0.8 mm (0.024 ~ 0.031 in)
If the standard is not satisfied, make adjustment by
Shims changing the lift roller shim thickness. Distribute shims
equally to the rollers on the right and left side.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Lower the lift bracket to the specified position.
Bring the center of the upper lift rollers in the lift bracket to
100 mm (3.94 in) below the top of the inner mast.
Middle lift roller
13-18
(4) Inspect and adjust the lower lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: C = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
equally to the rollers on the right and left side.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
Shims
(5) Inspect and adjust the upper lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: D = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
Shims
equally to the rollers on the right and left side.
Refer to ("Lift bracket dissassembly and reassembly",
page 13-13)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(6) After the adjustment, check that the lift bracket moves
smoothly along the overall length of the mast.
Upper lift roller
13-19
2. J3.5 ton series
Bring into contact Upper side roller
D
Lower lift roller
100 mm (3.94 in)
Bring into
contact
Outer mast
Inner mast
Lift bracket
(1) Hoist the lift bracket to the specified position.
Bring the center of the upper side roller in the lift bracket
to 100 mm (3.94 in) below the top of the inner mast.
(2) Inspect and adjust the lower lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: C = 0 ~ 0.6 mm (0 ~ 0.024 in)
13-20
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
equally to the rollers on the right and left side.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
Shim(s)
(3) Inspect and adjust the upper side rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: D = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
equally to the rollers on the right and left side.
Refer to ("Lift bracket dissassembly and reassembly",
page 13-13. Also, shim replacement is possible on the
vehicle)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(4) Align the outer width of the lower side roller with that of
Shims
the upper side roller.
(5) After the adjustment, check that the lift bracket moves
smoothy along the overall length of the mast.
13-21
Mast Strip Adjustment
1. Mast strip clearance adjustment
Outer mast roller
Inner mast
Bring into contact
E
Outer mast
(1) Lower the inner mast fully.
(2) Inspect and adjust the clearance between the mast strip
and the inner mast.
With the inner mast in contact with the outer mast roller,
measure the clearance between the mast strip and inner
mast.
Standard: E = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the shim thickness.
Shims
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check the mast for smooth
movement.
13-22
MAST ROLLER REMOVAL·INSTALLATION
1. Remove the lift bracket.
(Refer to page 13-5, procedures 1 ~ 4)
2. Jack up the vehicle and support tires with wooden blocks.
Chock the front and rear tires.
3. Remove the lift cylinders. (See page 14-11.)
4. Remove mast rollers.
Shims (1) Remove the wooden blocks under the inner mast and
lower the hoisted inner mast slowly until the mast rollers
appear.
(2) Support the bottom of the inner mast with wooden blocks.
(3) Remove the inner mast rollers and shims.
(4) Remove the inner mast rollers and shims.
5. The installation procedure is the reverse of the removal
Shims procedure.
13-23
CHAIN
SST
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,
change the chain.
N
N
Chain Link Pitch Standard
No. of links
Vehicle model Pitch mm (in) Type Chain No.
measured N
1 ton series 15.88 (0.6252) BL534 50 15
2·K2 ton series 19.05 (0.7500) BL634 60 13
3·K3 ton series 25.4 (1.0) BL823 80 11
J3.5 ton series 25.4 (1.0) BL834 80 11
Note:
• Perform measurement without removing the chain from the vehicle.
• Inspect elongation over the entire chain length since it varies with positions.
REASSEMBLY
1. Installing direction
Applicable mast V: Lift bracket FV: Lift bracket
and portion FSV: Inner mast FSV: Lift bracket
Center of vehicle Center of
vehicle
Rough sketch
Cotter pin
Cotter pin
Install the chain with the cotter pin
facing the center of the vehicle. Install the chain with the cotter pin
facing the outside of the vehicle.
13-24
2. Chain adjusting nut tightening order
(1) Tighten nuts (1) and (2). T = 64.0 N·m (653 kgf·cm) [47.2 ft·lbf]
(2) Tighten the nut (3) of the V and FSV outer mast.
Tighten the bolt (4) of the FV front cylinder part (1·2·K2) or the FSV front cylinder part (1·2·K2), and fasten
with a clamp.
FV: Front cylinder portion FV: Front cylinder portion
Applicable mast V: Outer mast (3·K3·J3.5 ton series) (1·2·K2 ton series)
and portion FSV: Outer mast FSV: Front cylinder portion FSV: Front cylinder portion
(3·K3·J3.5 ton series) (1·2·K2 ton series)
(4)
(3)
Rough sketch
(2)
(2) (2)
(1) (1) (1)
ADJUSTMENT
1. Incline the mast backwards and fully lower the forks.
2. Set the forks vertically and adjust the chain with the adjusting nut to remove slack in it.
3. Check that the chain tension is equal on the left and right side.
4. Check the chain for twist.
5. Check that the fork height is the standard.
6. With the fork raised fully, check that the lift bracket stopper at the innermast upper beam is not in contact with the
lift bracket.
7. After adjusting the chain, check that the distance from the
center of the roller at the lower part of the lift bracket to the
Inner mast bottom end of the inner mast is within the range below.
A = 15 ~ 20 mm (0.59 ~ 0.79 in)
A
13-25
FORK
REMOVAL
1. Set the fork at approx. 20 cm (7.9 in) above the ground.
2. Place a wooden block under the cutout portion of the fork rail.
3. Unlock the fork by lifting the fork stopper pin and shift the fork
blades, one at a time, to the center.
4. Slowly lower the forks and remove them.
INSTALLATION
The installation procedure is the reverse of the removal procedure.
INSPECTION
1. Inspect misalignment of the fork tip ends.
Limit: 10 mm (0.39 in)
If the limit is exceeded, inspect individual fork for bend,
looseness of the fork installation part and lift bracket finger bar
distortion.
13-26
FV·FSV MAST ASSY
COMPONENTS
FV
6101
FSV
6101
13-27
FV (1·2 ton series)
6301
FV (K2 ton series)
6301
13-28
FV (3·K3·J3.5 ton series)
6301
FSV (1 ton series)
6301
13-29
FSV (2 ton series)
6301
FSV (K2 ton series)
6301
13-30
FSV (3·K3 ton series)
6301
FSV (J3.5 ton series)
6301
13-31
FV (1·2·K2 ton series)
6302
FV (3·K3·J3.5 ton series)
6302
13-32
FSV (1·2·K2 ton series)
6302
FSV (3·K3 ton series)
6302
13-33
FSV (J3.5 ton series)
6302
13-34
MAST ADJUSTMENT (FV·FSV)
Lift Roller Adjustment at Mast
1. Inner mast roller (FV·FSV) and middle mast lower roller (FSV) clearance adjustment
Bring into contact
Position where the
roller is the closest
FSV mast
FV mast
Inner mast
Inner mast Outer mast
Outer mast Middle mast
These rollers These rollers
(1) Adjust the mast overlap to approx. 450 mm (17.72 in).
(2) Adjust the inner mast rollers (FV·FSV) and the middle mast lower rollers (FSV). Shift the inner mast (or
middle mast) to one side to bring the roller into contact with the middle mast (or outer mast). Measure the
clearance between the roller side face on the opposite side and middle mast (or outer mast) at the point
where they are the closest.
Standard: A = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check that mutual mast movement is smooth.
13-35
2. Outer mast roller (FV·FSV) and middle mast upper roller (FSV) clearance adjustment
Bring into Bring into
contact contact
Bring into
contact
B
Position where the
roller is the closest
FV FSV
These rollers
These rollers
Middle mast
Outer mast Outer mast
Inner mast
Inner mast
(1) Adjust the mast overlap to approx. 450 mm (17.72 in).
(2) Adjust the outer mast rollers (FV·FSV) and the middle mast upper rollers (FSV). Shift the outer mast (or
middle mast) to one side to bring the roller into contact with the middle mast (or inner mast). Measure the
clearance between the roller side face on the opposite side and middle mast (or inner mast) at the point
where they are the closest.
Standard: B = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check that mutual mast movement is smooth.
13-36
Lift/Side Roller Adjustment at Lift Bracket
1. FV mast·FSV mast (J3.5 ton series)
Bring into
contact Lower lift roller
D
Side roller
Bring into
contact
100 mm (3.94 in)
Lift bracket Lift bracket
FV FSV
(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) below the top of the inner mast for the FV mast.
(2) Inspect and adjust the lower lift rollers.
Shift the lift bracket to one side to bring the roller into contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.
Standard: C = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Inspect and adjust the side rollers.
Shift the lift bracket to one side to bring the roller into contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the roller side is closest to the mast.
Standard: D = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. Distribute shims equally to
the rollers on the left and right sides.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(4) After the adjustment, check that the lift bracket moves smoothly over the entire length of the mast.
13-37
2. FSV mast (1·2·3·K3 ton series)
Bring into
D contact
Outer mast
Upper lift roller
Middle mast
Bring into Inner mast
contact
Lift bracket
Bring into
contact
Lower lift roller
(1) Raise the lift bracket to the uppermost position.
(2) Inspect and adjust the lower lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: C = 0 ~ 0.6 mm (0 ~ 0.024 in)
13-38
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
equally to the left and right rollers.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
Shim(s)
(3) Inspect and adjust the upper lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: D = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
Shims equally to the left and right rollers.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(4) After the adjustment, check that the lift bracket moves
smoothly along the overall length of the mast.
Upper lift roller
13-39
3. FSV mast (K2 ton series)
100 mm (3.94 in)
Bring into Outer mast
D contact
Middle mast
Inner mast
Lift bracket
Upper/middle lift roller Position of lift bracket during upper and lower lift
rollers inspection
100 mm (3.94 in)
Bring into contact
Outer mast
Bring into
contact
Middle mast
Inner mast
C Lift bracket
Position of lift bracket during middle lift rollers
Lower lift roller inspection
(1) Hoist the lift bracket to the specified position. Bring the
center of the middle lift rollers in the lift bracket to 100 mm
(3.94 in) below the top of the inner mast.
(2) Inspect and adjust the middle lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: D = 0.6 ~ 0.8 mm (0.024 ~ 0.031 in)
If the standard is not satisfied, make adjustment by
Shims changing the lift roller shim thickness. Distribute shims
equally to the left and right rollers.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) Lower the lift bracket to the specified position.
Bring the center of the upper lift rollers in the lift bracket to
100 mm (3.94 in) below the top of the inner mast.
Middle lift roller
13-40
(4) Inspect and adjust the lower lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: C = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
equally to the left and right rollers.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
Shim(s)
(5) Inspect and adjust the upper lift rollers.
Shift the lift bracket to one side to bring the roller into
contact with the inner mast. Measure the lift roller
clearance at the position on the opposite side where the
roller side is closest to the mast.
Standard: D = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by
changing the lift roller shim thickness. Distribute shims
Shims equally to the left and right rollers.
Refer to ("Lift bracket dissassembly and reassembly",
page 13-13)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(6) After the adjustment, check that the lift bracket moves
smoothly along the overall length of the mast.
Upper lift roller
13-41
Mast Strip Adjustment
1. Mast strip clearance adjustment
Outer mast roller
FV mast Inner mast
Bring into contact
E
Outer mast
Middle mast
FSV mast Middle mast upper roller
Outer mast roller Bring into contact
Inner mast
Outer mast
(1) Lower the inner (or middle) mast fully.
(2) Inspect and adjust the clearance between the mast strip and the mast.
FV Mast: With the inner mast in contact with the outer mast rollers, measure the clearance between the
mast strip and the mast.
FSV Mast: With the inner (or middle) mast in contact with the middle mast upper rollers (or outer mast
rollers), measure the clearance between the mast strip and the mast.
Standard: E = 0 ~ 0.6 mm (0 ~ 0.024 in)
If the standard is not satisfied, make adjustment by changing the shim thickness.
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)
(3) After the adjustment, check the mast for smooth movement.
13-42
STANDARD FOR SELECTING AN OVERSIZE ROLLER
The clearance is on The clearance is on 1. Select the mast lower lift rollers and lift bracket upper and
one side both sides lower lift rollers.
A A Select the appropriate rollers from the table below so that the
minimum clearance between the mast or the lift bracket and
the roller is from 0 to 0.7 mm (0 to 0.028 in).
mm (in)
No Outside diameter of the roller
clearance B
95.7 (3.768) 96.2 (3.787) 96.7 (3.807)
107.7 (4.240) 108.2 (4.260) 108.7 (4.280)
Minimum Minimum
clearance = A clearance = A + B 119.7 (4.713) 120.2 (4.732) 120.7 (4.752)
124.5 (4.902) 125.2 (4.919) 125.7 (4.949)
Upper lift rollers 2. Select the middle lift rollers of the lift bracket.
Select middle lift rollers to correspond to the lift rollers selected
in 1. from the table below. (Use rollers of outer diameters 1 to
1.2 mm (0.04 to 0.047 in) smaller than those of the upper
roller).
mm (in)
Outside diameter of the roller
Upper lift rollers Middle lift rollers
95.7 (3.768) 94.5 (3.720)
Middle lift rollers 96.2 (3.787) 95.0 (3.740)
96.7 (3.807) 95.7 (3.768)
107.7 (4.240) 106.5 (4.193)
108.2 (4.260) 107.0 (4.213)
108.7 (4.280) 107.7 (4.240)
119.7 (4.713) 118.5 (4.665)
120.2 (4.732) 119.0 (4.685)
120.7 (4.752) 119.7 (4.713)
Note:
• There is no selection for the upper lift rollers of the outer
mast and middle mast, and for the side roller of the lift
bracket.
• The outer diameter of the selected rollers may be different
between right and left.
13-43
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF
UNEVEN LIFTING)
V·FSV MAST
Note:
• For left and right lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• The inspection and adjustment must be made when any of the following parts is replaced: Lift cylinder
ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner
mast SUB-ASSY
• Perform SAS matching after adjustment. (SAS spec.) (See section 18)
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
SST (1) Remove the left and right cylinder rod end set bolts.
(2) Suspend the inner mast with a hoist, attach the SST to
the outer mast tie beam, and lower the inner mast until it
makes contact with the SST.
SST 09610-22000-71
(3) Place shim(s) on top of the cylinder rod end on the side to
be adjusted, then slowly raise it and insert into the inner
mast.
Shim(s)
Shim thickness: 0.5·1.0·2.0·3.2 mm
(0.020·0.039·0.079·0.126 in)
(4) Reattach the left and right cylinder rod end set bolts.
(5) Remove the SST.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the number of
shims is determined.
13-44
FV MAST
Note:
• For left and right lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• The inspection and adjustment must be made when any of the following parts is replaced: Lift cylinder
ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner
mast SUB-ASSY
• Perform SAS matching after adjustment. (SAS spec.) (See section 18)
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. In this case, it
is necessary to make a shim adjustment.
2. Adjustment method
SST (1) Remove the left and right cylinder rod end set bolts.
(2) Suspend the inner mast with a hoist, attach the SST to
the outer mast tie beam, and lower the inner mast until it
makes contact with the SST.
SST 09610-22000-71
(3) Place shim(s) on LH of the cylinder rod end, then slowly
raise the cylinder rod end into the inner mast.
Shim thickness: 0.5·1.0·2.0·3.2 mm
Shim(s)
(0.020·0.039·0.079·0.126 in)
(4) Reattach the left and right cylinder rod end set bolts.
(5) Remove the SST.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the number of
shims is determined.
Çñ
Set bolts
Shim(s)
Inner mast
Cylinder rod end LH Cylinder rod end RH
14-1
CYLINDER
Page
LIFT CYLINDER (V)·REAR LIFT CYLINDER
(FV·FSV) .............................................................14-2 0
GENERAL .............................................................14-2 1
SPECIFICATIONS ..................................................14-4 2
COMPONENTS ......................................................14-5 3
REMOVAL·INSTALLATION ................................... 14-11
4
DISASSEMBLY·INSPECTION·REASSEMBLY .........14-13
5
SAFETY DOWN VALVE .....................................14-16
REMOVAL·INSTALLATION ...................................14-17
6
FRONT LIFT CYLINDER (FV·FSV)....................14-18 7
GENERAL ...........................................................14-18 8
SPECIFICATIONS ................................................14-18 9
COMPONENTS ....................................................14-19
10
REMOVAL·INSTALLATION ...................................14-19
11
DISASSEMBLY·INSPECTION·REASSEMBLY .........14-20
12
TILT CYLINDER .................................................14-23
GENERAL ...........................................................14-23 13
SPECIFICATIONS ................................................14-23 14
COMPONENTS ....................................................14-24 15
REMOVAL·INSTALLATION ...................................14-25
16
DISASSEMBLY·INSPECTION·REASSEMBLY .........14-27
17
MAST FORWARD BACKWARD
TILT ANGLE ADJUSTMENT 18
(ADJUSTMENT OF UNEVEN TILTING) .................14-30
19
20
21
E
14-2
LIFT CYLINDER (V)·REAR LIFT CYLINDER (FV·FSV)
GENERAL
Lift Cylinder (V/1·2·K2 ton series)·Rear Lift Cylinder (FSV/1·2·K2 ton series)
Lift Cylinder (V/3·K3 ton series)
14-3
Lift Cylinder (V/J3.5 ton series)·Rear Lift Cylinder (FSV/3·K3·J3.5 ton series)
0
1
2
3
4
5
6
7
8
9
10
Rear Lift Cylinder (FV)
11
12
RH
13
14
15
16
17
LH
18
19
20
21
E
14-4
SPECIFICATIONS
Lift Cylinder (V)
Vehicle model
1 ton series 2·K2 ton series 3·K3 ton series J3.5 ton series
Item
Cylinder type Single-acting type
Cylinder bore mm (in) 45 (1.77) 50 (1.97) 55 (2.17) 60 (2.36)
32 (1.26) (∼H3000) 35 (1.38) (∼H3000) 40 (1.57) (∼H3000)
Piston rod outside diameter mm (in) 45 (1.77)
35 (1.38) (H3300∼) 40 (1.57) (H3300∼) 45 (1.77) (H3300∼)
Piston seal type U packing
Rod seal type U packing
Others Built-in safety down valve (LH)
Rear Lift Cylinder (FV)
Vehicle model
1 ton series 2·K2 ton series 3·K3 ton series J3.5 ton series
Item
Cylinder type Single acting type
Cylinder bore mm (in) 45 (1.77) 50 (1.97) 55 (2.17) 60 (2.36)
Piston rod outside diameter mm (in) 32 (1.26) 35 (1.38) 40 (1.57)
Rod seal type U packing
Others Built-in safety down valve (LH)
Rear Lift Cylinder (FSV)
Vehicle model
1 ton series 2·K2 ton series 3·K3 ton series J3.5 ton series
Item
Cylinder type Single acting type
Cylinder bore mm (in) 45 (1.77) 50 (1.97) 55 (2.17) 60 (2.36)
Piston rod outside diameter mm (in) 35 (1.26) 40 (1.57) 45 (1.77)
Piston seal type U packing
Rod seal type U packing
Others Built-in safety down valve (LH)
14-5
COMPONENTS
Lift Cylinder (V/1·2·K2 ton series)
6503
0
1
2
3
4
5
6
7
8
9
10
Lift Cylinder (V/3·K3 ton series) 11
6503
12
13
14
15
16
17
18
19
20
21
E
14-6
Lift Cylinder (V/J3.5 ton series)
6503
Rear Lift Cylinder (FV/1·2·K2·3·K3 ton series)
6503
14-7
Rear Lift Cylinder (FV/J3.5 ton series)
6503
Rear Lift Cylinder (FSV/1·2·K2 ton series)
6503
14-8
Rear Lift Cylinder (FSV/3·K3 ton series)
6503
Rear Lift Cylinder (FSV/J3.5 ton series)
6503
14-9
Lift Cylinder (V)
6503
Rear Lift Cylinder (FV)
6503
14-10
Rear Lift Cylinder (FSV)
6503
14-11
REMOVAL·INSTALLATION
2
6
7
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 end of each lift cylinder rod. [Point 1]
4 Hoist the inner mast further so that the lift cylinder ASSY can be removed toward the front of the vehicle.
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 low pressure hose and high pressure hose.
8 Remove the lift cylinder support.
9 Remove the lift cylinder ASSY.
14-12
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the lift cylinder, follow the steps below.
1. Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
2. Check the hydraulic oil level and add if insufficient.
3. Inspect lift cylinders for uneven lifting, and make necessary adjustment. (See page 13-43.)
Point Operations
[Point 1]
Shim Removal:
Shim adjustment is made at the lift cylinder rod end to prevent
uneven lifting by lift cylinders LH and RH. Note the cylinder
that was adjusted and the number of shims used.
14-13
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
1 ton series:
T = 225 (2290) [166.0]
2•K2 ton series:
T = 250 (2550) [184.4]
3•K3
T = 275 (2800) [202.9]
J3.5 ton series:
T = 353 (3600) [260.4]
4
Note: This illustration is for the V mast on the 1·2 or K2 ton series.
Disassembly Procedure
1 Remove the safety down valve (LH).
2 Remove the cylinder cover. [Point 1]
3 Remove the piston rod. [Point 2]
4 Remove seals on the piston side. [Point 3]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Apply MP grease or hydraulic oil to the packing, O-ring, and dust seal lip portion.
1/3 to 1/2 of circumference • Apply sealant (08833-76002-71 (08833-00080)) to the
cylinder cover on the part shown in the illustration and
reassemble it.
2 ridges
2 to 3 ridges
14-14
Point Operations
[Point 1]
SST Disassembly•Reassembly:
If the cylinder cover is a U-groove type, use the SST.
SST 09620-10100-71
[Point 2]
Inspection:
Measure the piston rod outside diameter.
Unit: mm (in)
Vehicle model Standard Limit
~H3000 32 (1.26) 31.92 (1.2567)
1 ton series
H3300~ 35 (1.38) 34.92 (1.3748)
~H3000 35 (1.38) 34.92 (1.3748)
2·K2 ton series
V H3300~ 40 (1.575) 39.92 (1.5717)
~H3000 40 (1.575) 39.92 (1.5717)
3·K3 ton series
H3300~ 45 (1.77) 44.92 (1.7685)
J3.5 ton series 45 (1.77) 44.92 (1.7685)
1 ton series 32 (1.26) 31.92 (1.2567)
FV 2·K2 ton series 35 (1.38) 34.92 (1.3748)
3·K3·J3.5 ton series 40 (1.575) 39.92 (1.5717)
1 ton series 35 (1.38) 34.92 (1.3748)
FSV 2·K2 ton series 40 (1.575) 39.92 (1.5717)
3·K3·J3.5 ton series 45 (1.77) 44.92 (1.7685)
Inspection:
Measure the bend of the piston rod.
Limit: 2.0 mm (0.079 in)
Reassembly:
SST
Use a cylinder rod insertion guide (SST) to reassemble.
Cylinder rod 1 ton series: SST 09651-26600-71
2·K2 ton series: SST 09652-26600-71
3·K3 ton series: SST 09653-26600-71
J3.5 ton series: SST 09654-26600-71
Cylinder
14-15
[Point 3]
Inspection:
Measure the lift cylinder bore.
Unit: mm (in)
Vehicle model Standard Limit
1 ton series 45 (1.77) 45.20 (1.7795)
2·K2 ton series 50 (1.97) 50.20 (1.9764)
3·K3 ton series 55 (2.17) 55.35 (2.1791)
J3.5 ton series 60 (2.36) 60.35 (2.3760)
14-16
SAFETY DOWN VALVE
Safety Down Valve Sectional View (for V) (for FV·FSV Rear Lift Cylinder)
for V·FV for FSV
Safety Down Valve Sectional View (for FV·FSV Front Lift Cylinder)
14-17
REMOVAL·INSTALLATION
Removal Procedure
1 Hold the inner mast at an appropriate height. [Point 1]
2 Remove the lift cylinder rod end set bolt.
3 Fully lower the lift cylinder rod.
4 Remove the hose cover.
5 Disconnect the high pressure hose.
6 Remove the safety down valve.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operation
SST [Point 1]
Removal:
Raise the inner mast, attach the SST to the outer mast tie
beam, and lower the inner mast until it makes contact with the
SST.
SST 09610-22000-71
14-18
FRONT LIFT CYLINDER (FV·FSV)
GENERAL
Front Lift Cylinder (FV·FSV)
SPECIFICATIONS
Vehicle model
1 ton series 2·K2 ton series 3·K3 ton series J3.5 ton series
Item
Cylinder type Single acting type
Cylinder bore mm (in) 70 (2.76) 75 (2.95) 85 (3.25) 90 (3.54)
Piston rod outside diameter mm (in) 50 (1.97) 60 (2.36)
Piston seal type U packing
Rod seal type U packing
Others Built-in safety down valve
14-19
COMPONENTS
6502
REMOVAL·INSTALLATION
Removal Procedure
1 Remove the lift bracket W/ fork.
2 Disconnect the piping.
3 Remove the front lift cylinder.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the lift cylinder, follow the steps below.
(1) Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
(2) Check the hydraulic oil level, and add if insufficient.
(3) Adjust the lift chain tension equally on the left and right sides.
14-20
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
2
T = 392 (3997)
[289.2]
3 6
Disassembly Procedure
1 Remove the chain wheel support.
2 Remove the cylinder cover.
3 Remove the piston rod. [Point 1]
4 Remove the wear ring and U packing.
5 Remove the check valve.
6 Remove the safety down valve from the cylinder. [Point 2]
14-21
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
1/3 to 1/2 of circumference • Apply sealant (08833-76002-71 (08833-00080)) to the
cylinder cover on the part shown in the illustration to
reassemble it.
2 ridges • Fill the cylinder with the specified amount of hydraulic oil
through the cylinder top opening before installing the
2 to 3 ridges cylinder cover.
Vehicle model Filling amount cm3 (in3)
1 ton series 30 ~ 60 (1.83 ~ 3.66)
2·K2 ton series 40 ~ 70 (2.44 ~ 4.27)
3·K3 ton series 45 ~ 75 (2.75 ~ 4.58)
J3.5 ton series 55 ~ 85 (3.36 ~ 5.19)
Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
Unit: mm (in)
Vehicle model Standard Limit
1 ton series 50 (1.97) 49.92 (1.9654)
2·K2 ton series 50 (1.97) 49.92 (1.9654)
3·K3 ton series 60 (2.36) 59.91 (2.3587)
J3.5 ton series 60 (2.36) 59.91 (2.3587)
Inspection:
Measure the bend of the piston rod.
Limit: 2.0 mm (0.079 in)
Reassembly:
SST
Use a cylinder rod insertion guide (SST) to reassemble.
Cylinder rod 1 ton series: SST 09655-26600-71
2·K2 ton series: SST 09656-26600-71
3·K3 ton series: SST 09657-26600-71
J3.5 ton series: SST 09658-26600-71
Cylinder
14-22
[Point 2]
Inspection:
Measure the lift cylinder bore.
Unit: mm (in)
Vehicle model Standard Limit
1 ton series 70 (2.76) 70.35 (2.7697)
2·K2 ton series 75 (2.95) 75.35 (2.9665)
3·K3 ton series 85 (3.35) 85.40 (3.3622)
J3.5 ton series 90 (3.54) 90.40 (3.5591)
14-23
TILT CYLINDER
GENERAL
SPECIFICATIONS
Cylinder type Double acting type
Cylinder bore mm (in) 70 (2.76)
Piston rod outside diameter mm (in) 30 (1.18)
Piston seal type U packing
Rod seal type U packing
14-24
COMPONENTS
6511
14-25
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
6 5
T = 66.0 ~ 154.0
(673 ~ 1570)
[48.9 ~ 113.6]
5
8
T = 36.6 ~ 85.4
(373 ~ 871)
[27.0 ~ 63.0]
Removal Procedure
1 Open the engine hood.
2 Remove the toe board and lower panel.
3 Remove the side cover W/ step.
4 Hoist the mast temporarily.
5 Disconnect the hoses.
6 Disconnect the tilt angle sensor link (RH) (SAS spec.).
7 Remove the tilt cylinder front pin. [Point 1]
8 Remove the tilt cylinder rear pin.
9 Remove the tilt cylinder ASSY.
10 Remove the tilt cylinder rear bushing. [Point 2]
14-26
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, add molybdenum disulfide grease through the grease nipple to the tilt cylinder front
pin and rear pin.
• After installation, slowly tilt the mast forward and backward a few times to check normal functioning.
• Check the hydraulic oil level, and add if insufficient.
• After installation, perform SAS matching. (SAS spec.) (See section 18.)
Point Operations
SST [Point 1]
Removal:
SST 09810-20172-71
[Point 2]
SST(2) Removal•Installation:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(1) 09950-76020-71................................. (2)
(09950-70010)
14-27
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
4
8
8
4
4
2•7
6
3
T = 88.0 ~ 132.0
(897 ~ 1346)
[64.9 ~ 97.4]
T = 353 (3600) [260.5]
Disassembly Procedure
1 Before disassembling, measure the total length of the tilt cylinder when fully contracted, and make a note. [Point 1]
2 Disconnect the boot fitting on the cylinder side, and move it toward the joint side. [Point 2]
3 Loosen the rod guide. [Point 3]
4 Remove the piston rod W/ piston. [Point 4]
5 Remove the piston.
6 Remove the rod guide.
7 Remove the boot.
8 Remove the joint. [Point 5]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Apply MP grease or hydraulic oil to the packing, O-ring,and dust seal lip portion.
• Apply sealant (08833-76002-71 (08833-00080)) to the threaded portion of the rod guide before
reassembly.
14-28
Point Operations
[Point 1]
Disassembly•Reassembly:
Check the total length L of the tilt cylinder when fully
contracted.
[Point 2]
Air bleeding hole Reassembly:
Assemble the boot to the vehicle with its air bleeding holes
vertical.
[Point 3]
SST Disassembly•Reassembly:
SST 09620-10100-71
[Point 4]
Inspection:
Measure the cylinder bore.
Standard: 70.0 mm (2.756 in)
Limit: 70.35 mm (2.7697 in)
Reassembly:
SST
Use a cylinder rod insertion guide (SST) to reassemble.
SST 09659-26600-71
Cylinder
Cylinder rod
14-29
[Point 5]
Inspection:
Measure the piston rod outside diameter.
Standard: 30.0 mm (1.181 in)
Limit: 29.92 mm (1.1780 in)
Inspection:
Measure the bend of the piston rod.
Limit: 0.5 mm (0.020 in)
14-30
MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (ADJUSTMENT OF
UNEVEN TILTING)
Note:
Adjust the mast forward and backward tilt angles (uneven tilting) when the tilt cylinder and mast ASSY are
replaced or overhauled.
After adjustment, perform SAS matching. (SAS spec.) (See section 18.)
1. Inspect the forward and backward tilt angle and uneven lifting amount.
Standard
Mast forward tilt angle: Standard set angle 0° ~ +0.4°
Mast backward tilt angle: Standard set angle -0.6° ~ 0°
Uneven lifting amount: 1 mm (0.04 in) or less
2. If the standard is not satisfied, adjust it.
Tilt the mast forwards, loosen the nut that holds the rod, then adjust the mast tilt angle and uneven lifting by
adjusting the screw engagement margin between the rod and the joint. (To adjust the screw engagement
margin, position a wrench to the 2-faced section on the rod and turn the rod.)
Caution:
Do not turn the rod when it is in the forward most tilt position (or the backward most tilt position) (Turn it
with the mast slightly before forward most tilt position).
T = N·m (kgf·cm) [ft·lbf]
2-faced section of
Nut
T = 88.0 ~ 132.0 the rod
(897 ~ 1346)
[64.9 ~ 97.4]
3. After adjusting, tighten the nut to fix the rod.
15-1
OIL PUMP
Page
GENERAL.............................................................15-2
0
SPECIFICATIONS ................................................15-3
1
COMPONENTS ....................................................15-4
2
OIL PUMP ASSY ..................................................15-6
REMOVAL·INSTALLATION .....................................15-6
3
DISASSEMBLY·INSPECTION·REASSEMBLY 4
(4Y·1DZ-II engine vehicle) ....................................15-7
5
DISASSEMBLY·INSPECTION·REASSEMBLY
(4Y engine vehicle (low noise specification)) ...... 15-11 6
DISASSEMBLY·INSPECTION·REASSEMBLY 7
(2Z engine vehicle) ............................................15-15
PERFORMANCE TEST......................................15-18 8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
15-2
GENERAL
4Y·1DZ-II Engine Vehicle
4Y Engine Vehicle (low noise specification)
15-3
2Z Engine Vehicle
0
1
2
3
4
5
6
7
8
9
SPECIFICATIONS
Theoretical
10
Vehicle model Engine Specification Maker (Model) Pump type discharge
cm3 (in3)/rev 11
Standard KYB (KFS23) Gear pump/single gear 25.7 (1.568)
1 ton series
4Y
Low noise specification KYB (DGP23) Gear pump/double gear 25.0 (1.526) 12
1DZ-II KYB (KFS23) Gear pump/single gear 25.7 (1.568)
Standard KYB (KFS23) Gear pump/single gear 27.8 (1.696)
13
2 ton series 4Y
Low noise specification KYB (DGP23) Gear pump/double gear 26.5 (1.617)
K2 ton series
1DZ-II KYB (KFS23) Gear pump/single gear 27.8 (1.696)
14
K3 ton series
2Z
Standard
Shimadzu (SMG1)
KYB (KFS23)
Gear pump/single gear
Gear pump/single gear
31.8 (1.941)
27.8 (1.696)
15
4Y-M
Low noise specification KYB (DGP23) Gear pump/double gear 26.5 (1.617)
16
Standard KYB (KFS23) Gear pump/single gear 29.4 (1.794)
3 ton series 4Y-E
Low noise specification KYB (DGP23) Gear pump/double gear 28.6 (1.745) 17
1DZ-II KYB (KFS23) Gear pump/single gear 27.8 (1.696)
2Z Shimadzu (SMG1) Gear pump/single gear 31.8 (1.941) 18
Standard KYB (KFS23) Gear pump/single gear 27.8 (1.696)
4Y-M
Low noise specification KYB (DGP23) Gear pump/double gear 26.5 (1.617) 19
J3.5 ton series Standard KYB (KFS23) Gear pump/single gear 29.4 (1.794)
4Y-E
Low noise specification KYB (DGP23) Gear pump/double gear 28.6 (1.745) 20
2Z Shimadzu (SMG1) Gear pump/single gear 31.8 (1.941)
21
E
15-4
COMPONENTS
4Y·1DZ-II Engine Vehicle
6701
4Y Engine Vehicle (low noise specification)
6701
15-5
2Z Engine Vehicle
6701
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
15-6
OIL PUMP ASSY
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 24.0 ~ 33.0
(245 ~ 337)
[17.73 ~ 24.38]
7
10
10
9
Removal Procedure
1 Open the engine hood.
2 Remove the toe board.
3 Remove the RH rear tire cover.
4 Remove the air cleaner.
5 Disconnect the outlet hose.
6 Disconnect the inlet hose at the tank side.
7 Remove the oil pump ASSY W/ inlet hose.
8 Remove the oil pump gasket.
9 Remove the inlet hose from the oil pump ASSY.
10 Remove the fitting from the oil pump ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease (molybdenum disulfide grease) on the pump shaft spline section before installation.
15-7
DISASSEMBLY·INSPECTION·REASSEMBLY (4Y·1DZ-II engine vehicle)
T = N·m (kgf·cm) [ft·lbf]
4
4
6
1·8
4 7
T = 88 ~ 98
(900 ~ 1000)
[64.92 ~ 72.30]
1·2·8
3
3
4
1·5
Disassembly Procedure
1 Put match marks on the cover, gear plate and mounting flange.
2 Remove the cover. [Point 1]
3 Remove the plate seal, back up, and dowel pin. [Point 2]
4 Remove the side plate, drive gear and driven gear. [Point 3]
5 Remove the gear plate. [Point 4]
6 Remove the plate seal, back up, and dowel pin. [Point 2]
7 Remove the oil seal. [Point 5]
8 Inspect the cover and mounting flange. [Point 6]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Use new seals for reassembly.
• Apply the hydraulic oil before reassembly.
15-8
Point Operations
[Point 1]
Reassembly:
Intake side The reassembly procedure is as follows.
1. Temporarily tighten the through bolt to the specified torque
below.
Discharge side T = 2.0 ~ 4.9 N·m (20 ~ 50 kgf·cm) [1.45 ~ 3.62 ft·lbf]
2. As shown in the illustration, place the oil pump ASSY with the
intake side facing upward and keep the pump horizontal with
wooden blocks placed under the mounting flange and cover.
Tap the gear plate using a plastic hammer to slide the gear
plate.
3. Secure the pump in a vise and tighten the through bolt to the
proper torque.
Bushing [Point 2]
Back up
Reassembly:
The plate seal and back up are not to protrude from the cover
Not to protrude
or the bushing of the mounting flange.
Plate seal
[Point 3]
Inspection:
Measure the side plate thickness.
Limit: 2.927 mm (0.1152 in)
Inspection:
Inspect traces of contact with the side plate.
Intake side Standard:
There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.
Contact area
15-9
Reassembly:
Intake side Install with the copper alloy side facing towards the inside of
the pump. Also, be careful not to mistake the direction of the
intake side and discharge side when assembling.
Discharge side
Disassembly:
Put match marks on the teeth of the drive and driven gears.
Reassembly:
Align match marks at the time of reassembly.
Match marks
Inspection:
Measure the outside diameter of each gear shaft.
Limit: 20.99 mm (0.8264 in)
[Point 4]
Inspection:
A Inspect the gear plate inside surface (intake chamber side) for
Intake chamber traces of contact with the gears.
Standard:
Trace of The traces of contact should not exceed half of the
contact circumference.
Inspection:
Trace of contact Measure the depth of the flaw at the gear plate inside surface.
Limit: 0.20 mm (0.0079 in)
Reassembly:
Do not get the direction confused.
15-10
[Point 5]
Flat head screwdriver Disassembly:
Oil seal Use a flat head screwdriver to prise it off.
Reassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
Apply MP grease on the oil seal lip section after reassembly.
SST(2)
[Point 6]
Bearing
section Inspection:
150° Inspect for wear on the inside surface of the bearing section of
the cover and mounting flange.
Intake Standard:
chamber The area of bare metal exposed (color = reddy copper
color) should not exceed 150 °.
150°
Bearing
section
15-11
DISASSEMBLY·INSPECTION·REASSEMBLY (4Y engine vehicle (low noise
specification))
T = N·m (kgf·cm) [ft·lbf]
1·7
1 · 10
4
4
8
3
6
6
1 · 2 · 10
T = 88 ~ 98 3
(900 ~ 1000)
[65.1 ~ 72.4]
Disassembly Procedure
1 Put match marks on the cover, body and mounting flange.
2 Remove the cover. [Point 1]
3 Remove the plate seal, back up, and dowel pin. [Point 2]
4 Remove the side plate, rear drive gear and rear driven gear. [Point 3]
5 Remove the center bushing. [Point 4]
6 Remove the side plate, front drive gear and front driven gear. [Point 3]
7 Remove the body. [Point 5]
8 Remove the plate seal, back up, and dowel pin. [Point 2]
9 Remove the oil seal. [Point 6]
10 Inspect the cover and mounting flange. [Point 7]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Use new seals for reassembly.
• Apply the hydraulic oil before reassembly.
15-12
Point Operations
[Point 1]
Reassembly:
Intake side The reassembly procedure is as follows.
1. Temporarily tighten the through bolt to the specified torque
below.
Discharge side T = 2.0 ~ 4.9 N·m (20 ~ 50 kgf·cm) [1.45 ~ 3.62 ft·lbf]
2. As shown in the illustration, place the oil pump ASSY with the
intake side facing upward and keep the pump horizontal with
wooden blocks placed under the mounting flange and cover.
Tap the body using a plastic hammer to slide the body.
3. Secure the pump in a vise and tighten the through bolt to the
proper torque.
Bushing [Point 2]
Back up
Reassembly:
The plate seal and back up are not to protrude from the cover
Not to protrude or the bushing of the mounting flange.
Plate seal
[Point 3]
Inspection:
Measure the side plate thickness.
Limit: 2.927 mm (0.1152 in)
Inspection:
Inspect traces of contact with the side plate.
Intake side Standard:
There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.
Contact area
15-13
Reassembly:
Intake side Install with the copper alloy side facing towards the inside of
the pump. Also, be careful not to mistake the direction of the
intake side and discharge side when assembling.
Discharge side
Disassembly:
Put match marks on the teeth of the drive and driven gears.
Reassembly:
Align match marks at the time of reassembly.
Match marks
Inspection:
Measure the outside diameter of each gear shaft.
Limit: 20.961 mm (0.8252 in)
Thickness
[Point 4]
Inspection:
Inspect traces of contact with the center bushing.
Standard:
Intake side There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.
Inspection:
Inspect the thickness of the center bushing.
Contact area Limit: 41.38 mm (1.6291 in)
Inspection:
Inspect for wear on the inside surface of the bearing section of
the center bushing.
150°
Intake Standard:
side The area of bare metal exposed (color = reddy copper
color) should not exceed 150 °.
150°
15-14
Reassembly:
Intake side Reassemble 2 center bushings simultaneously, paying
attention to their direction.
Discharge side
[Point 5]
Inspection:
A Inspect the body inside surface (intake side) for traces of
Intake side contact with the gears.
Standard:
Trace of The traces of contact should not exceed half of the
contact circumference
Inspection:
Trace of contact Measure the depth of the flaw at the body inside surface.
Limit: 0.2 mm (0.0079 in)
Reassembly:
Flat head screwdriver Do not get the direction confused.
Oil seal
[Point 6]
Disassembly:
Use a flat head screwdriver to prise it off.
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
Apply MP grease on the oil seal lip section after reassembly.
SST(1)
SST(2)
[Point 7]
Bearing
section Inspection:
150° Inspect for wear on the inside surface of the bearing section of
the cover and the mounting flange.
Standard:
Intake
The area of bare metal exposed (color = reddy copper
chamber
150° color) should not exceed 150 °.
Bearing
section
15-15
DISASSEMBLY·INSPECTION·REASSEMBLY (2Z engine vehicle)
T = N·m (kgf·cm) [ft·lbf]
6
5
1•4
6 7
T = 88.3 ~ 93.2
(900 ~ 950)
[65.12 ~ 68.73]
1•2
3 1•6
Disassembly Procedure
1 Put match marks on the rear cover, body and front cover.
2 Remove the rear cover. [Point 1]
3 Remove the side plate and gasket. [Point 2]
4 Remove the front cover. [Point 1]
5 Remove the side plate and gasket. [Point 2]
6 Remove the drive gear, driven gear, and body. [Point 3]
7 Remove the oil seal. [Point 4]
15-16
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Use new seals for reassembly.
• Apply hydraulic oil before reassembly.
Point Operations
[Point 1]
Inspection:
Measure the inside diameter of the bushing.
Limit: 22.23 mm (0.8752 in)
[Point 2]
Inspection:
Measure the side plate thickness.
Limit: 2.70 mm (0.1063 in)
Inspection:
Inspect traces of contact with the side plate.
Standard:
Relatively stronger traces of contact on the intake side,
and slight traces of contact on the discharge side.
[Point 3]
Disassembly:
Put match marks on the teeth of the drive and driven gears.
Reassembly:
Align match marks at the time of reassembly.
Match marks
Inspection:
Measure the outside diameter of each gear shaft.
Limit: 21.95 mm (0.8642 in)
15-17
Inspection:
Inspect the inner surface of the body (intake side) for traces of
contact with the gears.
Standard:
Traces of contact on about 1/3 of the body inside
circumference.
Traces of Inspection:
contact Measure the depth of the flaw at the body inside surface.
with gear Limit: 0.15 mm (0.0059 in)
teeth
[Point 4]
Disassembly:
SST 09319-76001-71
(09319-60020)
SST
Reassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(2)
Apply MP grease on the oil seal lip portion after reassembly.
SST(1)
15-18
PERFORMANCE TEST
As the performance test in servicing of the oil pump, judge the quality by the lifting speed of the fork by installing the
oil pump on the vehicle. Bench test measurements shall be made for strict testing of the performance.
Note:
The engine rpm and relief pressure shall be adjusted to satisfy respective standards.
(See the engine rpm adjustment procedure on page 1-16, and the relief pressure adjustment procedure on
page 16-44.)
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 lift cylinder, and calculate the lifting speed for performance judgment.
Lifting Speed
Lifting speed (loaded/no-load) mm/sec (fpm)
V mast FSV mast FV mast
Engine model
When When not When When not When When not
loaded loaded loaded loaded loaded loaded
4Y 610 (120) 660 (130) 570 (112) 615 (121) 565 (111) 610 (120)
1 ton series
1DZ-II 650 (128) 675 (133) 620 (122) 650 (128) 600 (118) 640 (126)
4Y 600 (118) 640 (126) 560 (110) 600 (118) 560 (110) 600 (118)
2 ton series 1DZ-II 615 (121) 655 (129) 590 (116) 630 (124) 600 (118) 640 (126)
2Z 650 (128) 675 (133) 620 (122) 645 (127) 625 (123) 655 (129)
4Y 510 (100) 550 (108) 480 (94) 520 (102) 450 (89) 490 (96)
3 ton series 1DZ-II 500 (98) 530 (104) 470 (93) 500 (98) 445 (88) 480 (94)
2Z 550 (108) 570 (112) 510 (100) 530 (104) 480 (94) 500 (98)
4Y 600 (118) 640 (126) 560 (110) 600 (118) 560 (110) 600 (118)
K2 ton series
1DZ-II 580 (114) 600 (118) 550 (108) 575 (113) 550 (108) 585 (115)
4Y 490 (96) 530 (104) 460 (91) 480 (94) 445 (88) 460 (91)
K3 ton series
1DZ-II 480 (94) 510 (100) 430 (85) 465 (92) 420 (83) 460 (91)
4Y 410 (81) 450 (89) 400 (79) 440 (87) 420 (83) 460 (91)
J3.5 ton series
2Z 440 (87) 460 (91) 430 (85) 460 (91) 450 (89) 480 (94)
16-1
OIL CONTROL VALVE
Page
OIL CONTROL VALVE ASSY ..............................16-2
0
GENERAL .............................................................16-2
1
SPECIFICATIONS ..................................................16-7
COMPONENTS ......................................................16-7 2
TROUBLESHOOTING ............................................16-8 3
REMOVAL·INSTALLATION ...................................16-22 4
DISASSEMBLY·INSPECTION·REASSEMBLY .........16-24
5
OIL CONTROL VALVE ASSY
(MINI LEVER·JOYSTICK SPECIFICATION)....16-29 6
GENERAL ...........................................................16-29 7
SPECIFICATIONS ................................................16-34 8
COMPONENTS ....................................................16-34 9
TROUBLESHOOTING ..........................................16-35
10
REMOVAL·INSTALLATION ...................................16-37
11
DISASSEMBLY·INSPECTION·REASSEMBLY .........16-39
CONTROL VALVE LEVER ASSY ......................16-44 12
REMOVAL·INSTALLATION ...................................16-44 13
RELIEF PRESSURE ADJUSTMENT .................16-45 14
MANUAL DOWN VALVE....................................16-47 15
16
17
18
19
20
21
E
16-2
OIL CONTROL VALVE ASSY
GENERAL
X1
X2 X3
C2 C4
S
S X4
OUT
T2
X1 T1
X4 C5
C3
C1
X2 X3
16-3
X1-X1
Flow divider 0
1
Relief valve 2
3
4
5
6
7
Unloading valve 8
(Unloading SOL)
9
10
X2-X2
11
Flow regulator valve
12
Lift lock valve
(Lift lock SOL) 13
Manual down valve 14
15
16
17
18
19
Lift spool 20
21
Lift limit switch (lifting side) Lift limit switch (lowering side)
E
16-4
X3-X3
Tilt control valve
(Tilt control SOL) Backward tilt lock valve
(Backward tilt lock SOL)
Tilt spool
Backward tilt limit switch Forward tilt limit switch
X4-X4
Attachment spool
16-5
Solenoid Connector Diagram
0
1
2
3
4
Unloading solenoid connector
5
Lift lock solenoid connector 6
7
Tilt control solenoid connector
8
Backward tilt lock solenoid connector 9
Lift limit switch connector
10
11
Tilt limit switch connector
12
13
14
15
16
17
18
19
20
21
E
16-6
Hydraulic Circuit Diagram
Flow divider valve
Unloading valve Gauge port
(Unloading SOL)
Lift lock valve
(Lift lock SOL) Load check valve
Flow regulator valve
Load check valve
Manual down valve
Tilt control valve
(Tilt control SOL)
Load check valve
Backward tilt lock valve
(Backward tilt lock SOL)
16-7
SPECIFICATIONS
Vehicle model
1 ton series K2·2 ton series K3 ton series 3 ton series J3.5 ton series
Item
Type Add-on type
Relief set pressure Lift 17.8 (182) [2590] 18.7 (191) [2720]
2
MPa (kgf/cm ) [psi] Tilt 11.8 (120) [1710] 14.7 (150) [2130]
Flow divider flow rate Standard vehicle 13.6 (3.59) 15.8 (4.17)
l/min (US gal/min) Oil clutch vehicle 13.6 (3.59) 15.8 (4.17)
Flow regulator flow volume
50 (13.2) 65 (17.2) 75 (19.8) 85 (22.4)
l/min (US gal/min)
No-load 550 (108) 500 (98) 450 (89)
V
Loaded 500 (98)
Lowering speed No-load 450 (88) 420 (83) 390 (77)
specification FSV
mm/sec (fpm) Loaded 480 (94) 460 (91)
No-load 420 (83) 390 (77)
FV
Loaded 480 (94) 460 (91)
COMPONENTS
6705
TROUBLESHOOTING
16-8
Note:
For the positions of (1) ~ (16) in the table, refer to page 16-20 ~ 21.
Operation Phenomenon Probable cause Inspection item
During steering Cannot turn the Flow divider valve piston seizure • Whether the flow divider can be removed
operation steering • Whether there are any scratches on the flow divider
• Whether foreign matter is stuck in the flow divider
Steering is heavy Flow divider valve piston malfunction • Whether there are any scratches on the flow divider
• Whether foreign matter is stuck in the flow divider
Insufficient spring force of the flow divider return spring • Whether the return spring is not broken
• Whether the return spring base surface is worn
• Whether the stopper (plug) base surface at the return spring
side is worn
During lift operation Cannot lift Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Manual down valve is loose • Whether the manual down valve is tightened
Load pressure detection circuit check valve (2) stuck closed • Not possible to inspect
Lift by-pass check valve (1) stuck closed • Whether the lift by-pass check valve and lift lock plunger can
and the lift lock plunger stuck closed be removed
• Whether there are any scratches on the lift by-pass check
valve and lift lock plunger
• Whether foreign matter is stuck in the lift by-pass check
valve or lift lock plunger
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Operation Phenomenon Probable cause Inspection item
During lift operation Lift speed is slow Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Unload SOL seat defect • Not possible to inspect
Manual down valve is loose • Whether the manual down valve is tightened
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve (2) malfunction • Not possible to inspect
Lift by-pass check valve (1) malfunction • Whether there are any scratches on the lift by-pass check
valve
• Whether foreign matter is stuck in the lift by-pass check
valve
Lift lock plunger malfunction • Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Lift spool malfunction • Whether the lift spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Cannot lower Lift lock plunger stuck closed • Whether the lift lock plunger can be removed
• Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
Foreign matter is stuck in the lift lock plunger orifice (5) • Whether foreign matter is stuck in the lift lock plunger orifice
Lift lock SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
16-9
Operation Phenomenon Probable cause Inspection item
During lift operation Cannot lower Lift spool stuck closed • Whether the lift spool can be operated
16-10
(Whether the lift lever can be operated)
Lowering operation detection limit switch stuck open, or • Limit switch continuity inspection
damaged
Foreign matter is stuck in the lift lock valve pilot circuit (4) • Whether foreign matter is stuck in the lift lock valve pilot
circuit
Lowering speed is slow Lift lock plunger malfunction • Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
Foreign matter is stuck in the lift lock plunger orifice (5) • Whether foreign matter is stuck in the lift lock plunger orifice
Lift lock SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Lift spool malfunction • Whether the lift spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Foreign matter is stuck in the lift lock valve pilot circuit (4) • Not possible to inspect
Flow regulator valve piston malfunction • Whether there are any scratches on the flow regulator valve
piston
• Whether foreign matter is stuck in the flow regulator valve
piston
Insufficient spring force of the flow regulator valve piston • Whether the return spring is broken
spring • Whether the return spring base surface (6) is worn
During tilt operation Cannot tilt forward Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Operation Phenomenon Probable cause Inspection item
During tilt operation Cannot tilt forward Tilt control valve plunger stuck closed • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Foreign matter is stuck in the tilt control valve plunger orifice • Whether foreign matter is stuck in the tilt control valve
(7) plunger orifice
Tilt control valve SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Tilt spool stuck closed • Whether the tilt spool can be operated
(Whether the tilt lever can be operated)
Forward tilt detection limit switch stuck open, or damaged • Limit switch continuity inspection
Foreign matter is stuck in the tilt control valve pilot circuit (8) • Whether foreign matter is stuck in the tilt control valve pilot
circuit
Tilt lock plunger stuck closed • Whether the tilt lock plunger can be removed
• Whether there are any scratches on the tilt lock plunger
• Whether foreign matter is stuck in the tilt lock plunger
Load pressure detection circuit check valve (9) stuck closed • Not possible to inspect
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Foreign matter is stuck in the orifice (10) of the tilt spool tilt • Whether foreign matter is stuck in the orifice of the tilt spool
lock plunger spring chamber tilt lock plunger spring chamber
Foreign matter is stuck in the tilt spool pilot orifice (11) • Whether foreign matter is stuck in the tilt spool pilot orifice
Foreign matter is stuck in the tilt lock plunger pilot orifice (three • Whether foreign matter is stuck in the tilt lock plunger pilot
places) orifice
Forward tilt speed is Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
slow plunger
• Whether foreign matter is stuck in the relief valve main
plunger
16-11
Operation Phenomenon Probable cause Inspection item
During tilt operation Forward tilt speed is Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
16-12
slow spring • Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL operated • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Unload SOL seat defect • Not possible to inspect
Tilt control valve malfunction • Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Foreign matter is stuck in the tilt control valve plunger orifice • Whether foreign matter is stuck in the tilt control valve
(7) plunger orifice
Tilt control valve SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Tilt spool malfunction • Whether the tilt spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Foreign matter is stuck in the tilt control valve pilot circuit (8) • Whether foreign matter is stuck in the tilt control valve pilot
circuit
Tilt lock plunger malfunction • Whether there are any scratches on the tilt lock plunger
• Whether foreign matter is stuck in the tilt lock plunger
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve (9) malfunction • Not possible to inspect
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Foreign matter is stuck in the orifice (10) of the tilt spool tilt • Whether foreign matter is stuck in the orifice of the tilt spool
lock plunger spring chamber tilt lock plunger spring chamber
Foreign matter is stuck in the tilt spool pilot orifice (11) • Whether foreign matter is stuck in the tilt spool pilot orifice
Operation Phenomenon Probable cause Inspection item
During tilt operation Forward tilt speed is Foreign matter is stuck in the tilt lock plunger pilot orifice (three • Whether foreign matter is stuck in the tilt lock plunger pilot
slow places) orifice
Cannot tilt backward Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Backward tilt lock valve plunger stuck closed • Whether the backward tilt lock valve plunger can be
removed
• Whether there are any scratches on the backward tilt lock
valve plunger
• Whether foreign matter is stuck in the backward tilt lock
valve plunger
Foreign matter is stuck in the backward tilt lock valve plunger • Whether foreign matter is stuck in the backward tilt lock
orifice (12) valve plunger orifice
Backward tilt lock valve SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Tilt spool stuck closed • Whether the tilt spool can be operated
(Whether the tilt lever can be operated)
Backward tilt detection limit switch stuck open, or damaged • Limit switch continuity inspection
Foreign matter is stuck in the backward tilt lock valve pilot • Whether foreign matter is stuck in the backward tilt lock
circuit (13) valve pilot circuit
Load pressure detection circuit check valve stuck closed • Not possible to inspect
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Backward tilt speed is Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
slow plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
16-13
Operation Phenomenon Probable cause Inspection item
During tilt operation Backward tilt speed is Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
16-14
slow main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Unload SOL seat defect • Not possible to inspect
Backward tilt lock valve malfunction • Whether there are any scratches on the backward tilt lock
valve plunger
• Whether foreign matter is stuck in the backward tilt lock
valve plunger
Foreign matter is stuck in the backward lift lock valve plunger • Whether foreign matter is stuck in the backward tilt lock
orifice (12) valve plunger orifice
Backward tilt lock valve SOL malfunction • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Tilt spool malfunction • Whether the tilt spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Foreign matter is stuck in the backward tilt lock valve pilot • Whether foreign matter is stuck in the backward tilt lock
circuit (13) valve pilot circuit
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve malfunction • Not possible to inspect
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
Key switch OFF Natural drop is big Lift lock plunger seat malfunction • Whether there are any scratches on the seat surface
• Whether foreign matter is stuck on the seat surface
Lift lock plunger stuck open • Whether the lift lock main plunger can be removed
• Whether there are any scratches on the lift lock main
plunger
• Whether foreign matter is stuck in the lift lock main plunger
Insufficient spring force of the lift lock plunger return spring • Whether the return spring is broken
• Whether the return spring base surface is worn
Operation Phenomenon Probable cause Inspection item
Key switch OFF Natural drop is big Lift by-pass check valve seat defect • Whether there are any scratches on the seat surface
• Whether foreign matter is stuck on the seat surface
Lift by-pass check valve plunger stuck open • Whether the lift by-pass check valve plunger can be
removed
• Whether there are any scratches on the lift by-pass check
valve plunger
• Whether foreign matter is stuck in the lift by-pass check
valve plunger
Insufficient spring force of the lift by-pass check valve return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Manual down valve is loose • Whether the manual down valve is tightened
Lift lock SOL seat defect • Not possible to inspect
Lift lock SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Lowering operation detection limit switch stuck closed, or • Limit switch continuity inspection
damaged
Wear or damage of the flow regulator valve sleeve (14) or • Whether the sleeve or O-ring is worn or damaged
O-ring No.2 (16)
Natural forward tilt is Tilt control valve plunger seat defect • Whether there are any scratches on the seat surface
big • Whether foreign matter is present on the seat surface
Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
16-15
Operation Phenomenon Probable cause Inspection item
Key switch OFF Natural forward tilt is Insufficient spring force of the tilt control valve plunger return • Whether the return spring is broken
16-16
big spring • Whether the return spring base surface is worn
Tilt control valve check ball seat defect • Not possible to inspect
Tilt control valve check ball stuck open • Whether the check ball moves when pressed
Insufficient spring force of the tilt control valve check ball • Whether there is a spring reactive force when the check ball
return spring is pressed
Tilt control valve SOL seat defect • Not possible to inspect
Tilt control valve SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Forward tilt detection limit switch stuck closed, or damaged • Limit switch continuity inspection
Forward tilt automatic Does not stop Tilt control valve plunger seat defect • Whether there are any scratches on the seat surface
leveling stop automatically • Whether foreign matter is present on the seat surface
Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
• Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Insufficient spring force of the tilt control valve plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Tilt control valve check ball seat defect • Not possible to inspect
Tilt control valve check ball stuck open • Whether the check ball moves when pressed
Insufficient spring force of the tilt control valve check ball • Whether there is a spring reactive force when the check ball
return spring is pressed
Tilt control valve SOL seat defect • Not possible to inspect
Tilt control valve SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Backward tilting speed Speed is fast Tilt control valve malfunction • Whether there are any scratches on the tilt control valve
regulation plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Operation Phenomenon Probable cause Inspection item
Backward tilting speed Speed is fast Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
regulation • Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Tilt control valve SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Foreign matter is stuck in the tilt control valve pilot circuit • Whether foreign matter is stuck in the tilt control valve pilot
circuit
During ATT operation ATT does not move Relief valve main plunger stuck open • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient setting pressure of the relief valve • Check the relief setting pressure
Unload SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
ATT spool stuck closed • Whether ATT spool can be operated
(Whether ATT lever can be operated)
Load pressure detection circuit check valve stuck closed • Not possible to inspect
Load check valve stuck closed • Whether the load check valve can be removed
• Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
ATT movement is slow Relief valve main plunger malfunction • Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Insufficient spring force of the relief valve main plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Relief valve main plunger seat defect • Whether there are any scratches or chipping at the tip of the
main plunger
• Whether there are any scratches or chipping on the seat (3)
Insufficient setting pressure of the relief valve • Check the relief setting pressure
16-17
Operation Phenomenon Probable cause Inspection item
During ATT operation ATT movement is slow Unload SOL malfunction • Whether you can hear the operating sound of the solenoid
16-18
when operating the lever with the key switch ON
• Whether foreign matter is attached to the filter section
Unload SOL seat defect • Not possible to inspect
ATT spool malfunction • Whether ATT spool strokes as required
Standard: 8 ± 0.4 mm (0.31 ± 0.016 in)
Foreign matter is stuck in the load pressure detection circuit • Whether foreign matter is stuck in the load pressure
detection circuit
Load pressure detection circuit check valve malfunction • Not possible to inspect
Load check valve malfunction • Whether there are any scratches on the load check valve
• Whether foreign matter is stuck in the load check valve
During OPS operation Does not lift and stop Relief valve main plunger stuck closed • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Unload SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Does not lower and Lift lock plunger stuck open • Whether the lift lock plunger can be removed
stop • Whether there are any scratches on the lift lock plunger
• Whether foreign matter is stuck in the lift lock plunger
Foreign matter is stuck in the lift lock plunger orifice • Whether foreign matter is stuck in the lift lock plunger orifice
Lift lock SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Foreign matter is stuck in the lift lock valve pilot circuit • Whether foreign matter is stuck in the lift lock valve pilot
circuit
Wear or damage of the flow regulator valve sleeve (14) or • Whether the sleeve or O-ring is worn or damaged
O-ring No.2 (16)
Does not tilt forward Tilt control valve plunger seat defect • Whether there are any scratches on the seat surface
and stop • Whether foreign matter is present on the seat surface
Operation Phenomenon Probable cause Inspection item
During OPS operation Does not tilt forward Tilt control valve plunger stuck open • Whether the tilt control valve plunger can be removed
and stop • Whether there are any scratches on the tilt control valve
plunger
• Whether foreign matter is stuck in the tilt control valve
plunger
Insufficient spring force of the tilt control valve plunger return • Whether the return spring is broken
spring • Whether the return spring base surface is worn
Tilt control valve check ball seat defect • Not possible to inspect
Tilt control valve check ball stuck open • Whether the check ball moves when pressed
Insufficient spring force of the tilt control valve check ball • Whether there is a spring reactive force when the check ball
return spring is pressed
Tilt control valve SOL seat defect • Not possible to inspect
Tilt control valve SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
Does not tilt backward Backward tilt lock valve plunger seat defect • Whether there are any scratches on the seat surface
and stop • Whether foreign matter is present on the seat surface
Backward tilt lock valve plunger stuck open • Whether the backward tilt lock valve plunger can be
removed
• Whether there are any scratches on the backward tilt lock
valve plunger
• Whether foreign matter is stuck in the backward tilt lock
valve plunger
Insufficient spring force of the backward tilt lock valve plunger • Whether the return spring is broken
return spring • Whether the return spring base surface is worn
Backward tilt lock valve SOL stuck open • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
ATT does not stop Relief valve main plunger stuck closed • Whether the relief valve main plunger can be removed
• Whether there are any scratches on the relief valve main
plunger
• Whether foreign matter is stuck in the relief valve main
plunger
Unload SOL stuck closed • Whether you can hear the operating sound of the solenoid
when operating the lever with the key switch ON
16-19
16-20
(3)
(5) (14)
(6) (1)
(15) (6) (16)
(2)
16-21
(7)
(8) (12)
(13)
(9)
(10) (11)
(4)
16-22
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
9 5
T = 22 ~ 26
(230 ~ 270)
[16.23 ~ 19.18]
T = 21.6 ~ 50.4
(220 ~ 514)
[15.92 ~ 37.19]
8
8
Removal Procedure
1 Remove the lower panel and toe board.
2 Remove the shift lever box cover. (M/T vehicle)
3 Remove the instrument panel RH.
4 Disconnect the connector.
5 Disconnect the lever rod.
6 Remove the control valve lever. (Oil control valve ASSY of over fourth-way. See page 16-44, “Control Valve
Lever ASSY”.)
7 Remove the harness bracket.
8 Disconnect all the piping and the load sensor connectors.
9 Remove the oil control valve ASSY W/ bracket. [Point 1]
10 Remove the oil control valve.
11 Remove the fitting and load sensor.
16-23
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply chassis grease special to the oil control valve lever linkage.
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced. (See section 18)
Point Operations
[Point 1]
Removal•Installation:
For the removal of the oil control valve ASSY W/ bracket for
over fourth-way, use a hoist.
16-24
DISASSEMBLY·INSPECTION·REASSEMBLY
Note:
• Work in a clean location.
• Since individual parts are finished with high precision, carefully operate so as not to damage them.
T = N·m (kgf·cm) [ft·lbf]
8 10
9
5
10 1
3
11
4
4 7
3
4 12
7
6 2 12
2 6 11
T = 39.2 (400) [28.94]
6
Disassembly Procedure
1 Remove the lift lock SOL and flow regulator valve. [Point 1]
2 Remove the lift limit switch and spring cover. [Point 2]
3 Remove the lift spool. [Point 3]
4 Remove the tilt control SOL. [Point 4]
5 Remove the backward tilt lock SOL. [Point 5]
6 Remove the tilt limit switch and spring cover. [Point 6]
7 Remove the tilt spool. [Point 7]
8 Remove the unload SOL. [Point 8]
9 Remove the flow divider valve. [Point 9]
10 Remove the relief valve. [Point 10]
11 Remove the attachment valve.
12 Remove the rod bolt, and then remove the housing.
16-25
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.
Point Operations
[Point 1]
Disassembly:
Put match marks to prevent solenoid installation in an incorrect
position.
Reassembly:
Align match marks for reassembly.
Inspection:
Check the lift lock solenoid for continuity.
Inspection:
Check and clean any clogged filter.
Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool, etc.
[Point 2]
2 1 Inspection:
Check the lift limit switch for continuity.
Lowering side (measurement terminal 1 ⇔ 2):
No continuity when the switch is pressed.
4 3
Lifting side (measurement terminal 3 ⇔ 4):
No continuity when the switch is pressed
Reassembly:
Be careful not to mistake the lowering side and lifting side.
16-26
Washer [Point 3]
Disassembly•Reassembly:
Remove the compression spring from the lift spool.
SST 09610-10161-71
Use the SST after attaching a washer.
SST
[Point 4]
Inspection:
Check the tilt solenoid for continuity.
Inspection:
Check and clean any clogged filter.
Inspection:
Check and clean any clogged orifice.
Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool.
[Point 5]
Inspection:
Check the backward tilt lock SOL for continuity.
16-27
Inspection:
Check and clean any clogged filter.
Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool.
[Point 6]
1 2 Inspection:
Check the tilt limit switch for continuity.
Forward tilting side (measurement terminals 1 ⇔ 2):
No continuity when the switch is pressed.
3 4 Backward tilting side (measurement terminals 3 ⇔ 4):
No continuity when the switch is pressed.
Be careful not to mistake the forward and backward tilt limit
switches.
Washer
[Point 7]
Disassembly•Reassembly:
Remove the compression spring from the tilt spool.
SST 09610-10161-71
Use the SST after attaching a washer.
SST
[Point 8]
Inspection:
Check the unload solenoid for continuity.
Inspection:
Check and clean any clogged filter.
16-28
[Point 9]
Inspection:
Check and clean any clogged orifice.
[Point 10]
Inspection:
Check and clean any clogged filter.
Reassembly:
When the relief valve is disassembled, temporarily install it
after fitting the nuts as illustrated.
a = 27.0 mm (1.06 in)
a
16-29
OIL CONTROL VALVE ASSY (MINI LEVER·JOYSTICK
SPECIFICATION)
GENERAL
X4
X1 X2 X3
C2
S C4
S
OUT X5
T2
R1
X5 T1
X1
C5
C3
C1
X2 X3 X4
16-30
X1-X1
Flow divider
Relief valve
Unloading valve
(Unloading SOL)
X2-X2
Flow regulator valve
Lift lock valve
(Lift lock SOL)
Manual down valve
Proportional SOL (b) Proportional SOL (a)
16-31
X3-X3
Tilt control valve (Tilt control SOL)
Proportional SOL (b) Proportional SOL (a)
X4-X4
Proportional SOL (b) Proportional SOL (a)
16-32
X5-X5
Decompression valve
Solenoid Connector Diagram
Proportional solenoid (b) connector
Proportional solenoid (a) connector
Lift lock solenoid connector
Tilt control solenoid connector
Unloading solenoid connector
16-33
Hydraulic Circuit Diagram
Flow divider valve
Unloading valve Gauge port
(Unloading SOL)
Lift lock valve
(Lift lock SOL)
Flow regulator valve
Manual down valve
Tilt control valve
(Tilt control SOL)
Decompression
valve
16-34
SPECIFICATIONS
Vehicle model
1 ton series K2·2 ton series K3 ton series 3 ton series J3.5 ton series
Item
Type Add-on type
Relief set pressure Lift 17.8 (182) [2590] 18.7 (191) [2720]
2
MPa (kgf/cm ) [psi] Tilt 11.8 (120) [1710] 14.7 (150) [2130]
Flow divider flow rate Standard vehicle 13.6 (3.59) 15.8 (4.17)
l/min (US gal/min) Oil clutch vehicle 13.6 (3.59) 15.8 (4.17)
Flow regulator flow rate
50 (13.2) 65 (17.2) 75 (19.8) 85 (22.4)
l/min (US gal/min)
No-load 550 (108) 500 (98) 450 (89)
V
Loaded 500 (98)
Lowering speed No-load 450 (88) 420 (83) 390 (77)
specification FSV
mm/sec (fpm) Loaded 480 (94) 460 (91)
No-load 420 (83) 390 (77)
FV
Loaded 480 (94) 460 (91)
COMPONENTS
6705
TROUBLESHOOTING
Note:
Only the defective phenomena caused by the parts specific to the mini lever specification are listed.
Others not listed here are the same as those for the STD specification.
Operation Phenomenon Probable cause Inspection item
General material Cannot operate Decompression valve piston stuck closed • Whether the decompression valve piston can be removed
handling operation material handling • Whether there are any scratches on the decompression
valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston stuck closed • Whether the proportional solenoid valve piston can be
removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional solenoid
valve piston
Proportional solenoid SOL malfunction • Remove the proportional solenoid SOL (while harness is
connected), and check whether the pin at the tip is operating
when the lever is operated
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool stuck closed • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
Material handling is Decompression valve piston malfunction • Whether there are any scratches on the decompression
slow valve piston
• Whether foreign matter is stuck in the decompression valve
piston
Proportional solenoid valve piston malfunction • Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional solenoid
valve piston
Proportional solenoid SOL malfunction • Remove the proportional solenoid SOL (while harness is
connected), and check whether the pin at the tip is operating
when the lever is operated
Foreign matter is stuck in the proportional solenoid valve pilot • Whether foreign matter is stuck in the proportional solenoid
circuit valve pilot circuit
Main spool malfunction • Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
16-35
Operation Phenomenon Probable cause Inspection item
Backward tilt automatic Does not stop Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
16-36
leveling stop automatically removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional solenoid
valve piston
Proportional solenoid SOL malfunction • Remove the proportional solenoid SOL (while harness is
connected), and check whether the pin at the tip is operating
when the lever is operated
Tilt spool stuck open • Whether the tilt spool can be removed
• Whether there are any scratches on the tilt spool
• Whether foreign matter is stuck in the tilt spool
During OPS operation Material handling does Proportional solenoid valve piston stuck open • Whether the proportional solenoid valve piston can be
not stop removed
• Whether there are any scratches on the proportional
solenoid valve piston
• Whether foreign matter is stuck in the proportional solenoid
valve piston
Proportional solenoid SOL malfunction • Remove the proportional solenoid SOL (while harness is
connected), and check whether the pin at the tip is operating
when the lever is operated
Main spool stuck open • Whether the main spool can be removed
• Whether there are any scratches on the main spool
• Whether foreign matter is stuck in the main spool
16-37
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 22 ~ 26
(230 ~ 270)
[16.23 ~ 19.18]
T = 21.6 ~ 50.4
(220 ~ 514)
[15.92 ~ 37.19]
4
5 5
Removal Procedure
1 Remove the lower panel and toe board.
2 Remove the instrument panel RH.
3 Disconnect the connector.
4 Remove the harness bracket.
5 Disconnect all the piping and the load sensor connectors.
6 Remove the oil control valve ASSY W/ bracket. [Point 1]
7 Remove the oil control valve.
8 Remove the fitting and load sensor.
16-38
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced. (See section 18)
Point Operations
[Point 1]
Removal•Installation:
For the removal of the oil control valve ASSY W/ bracket for
over fourth-way, use a hoist.
16-39
DISASSEMBLY·INSPECTION·REASSEMBLY
Note:
• Work in a clean location.
• Since individual parts are finished with high precision, carefully operate so as not to damage them.
T = N·m (kgf·cm) [ft·lbf]
6 3 8
7
3
1
8 3
5
2
4
2 5
2
4
5
4
9
T = 39.2 (400) [28.94]
Disassembly Procedure
1 Remove the lift lock SOL and flow regulator valve. [Point 1]
2 Remove the tilt control SOL. [Point 2]
3 Remove the proportional solenoid (a). [Point 3]
4 Remove the proportional solenoid (b). [Point 4]
5 Remove the lift spool, tilt spool and attachment spool.
6 Remove the unload SOL. [Point 5]
7 Remove the flow divider valve. [Point 6]
8 Remove the relief valve. [Point 7]
9 Remove the rod bolt, and then remove the housing.
16-40
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.
Point Operations
[Point 1]
Disassembly:
Put match marks to prevent solenoid installation in an incorrect
position.
Reassembly:
Align match marks for reassembly.
Inspection:
Check the lift lock solenoid for continuity.
Inspection:
Check and clean any clogged filter.
Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool, etc.
[Point 2]
Inspection:
Check the tilt solenoid for continuity.
16-41
Inspection:
Check and clean any clogged filter.
Inspection:
Check and clean any clogged orifice.
Reassembly:
Carefully reassemble to prevent incorrect installation of each
solenoid spool.
[Point 3]
1 2 3
Inspection:
Check the proportional solenoid (a) for continuity.
5 6 7 Measurement terminal 1 ⇔ 5: Continuity exists.
Measurement terminal 2 ⇔ 6: Continuity exists.
Measurement terminal 3 ⇔ 7: Continuity exists.
Disassembly:
A Before disassembly, measure the installation position
Adjusting screw
(dimension A) of the material handling start timing adjusting
screw.
Reassembly:
Reassemble according to the dimension A measured before
disassembly.
Adjustment:
After installing the control valve to the vehicle, check whether
there are any abnormalities in material handling start timing by
slowly operating the lever. If you feel any abnormalities,
perform tuning with the display. (See section 20)
16-42
[Point 4]
1 2 3
Inspection:
Check the proportional solenoid (b) for continuity.
5 6 7 Measurement terminal 1 ⇔ 5: Continuity exists.
Measurement terminal 2 ⇔ 6: Continuity exists.
Measurement terminal 3 ⇔ 7: Continuity exists.
Disassembly:
A Before disassembly, measure the installation position
Adjusting screw
(dimension A) for the material handling start timing adjusting
screw.
Reassembly:
Reassemble according to the dimension A measured before
disassembly.
Adjustment:
After installing the control valve to the vehicle, check whether
there are any abnormalities in material handling start timing by
slowly operating the lever. If you feel any abnormalities,
perform tuning with the display.(See section 20)
[Point 5]
Inspection:
Check the unload solenoid for continuity.
Inspection:
Check and clean any clogged filter.
16-43
[Point 6]
Inspection:
Check and clean any clogged orifice.
[Point 7]
Inspection:
Check and clean any clogged filter.
Reassembly:
When the relief valve is disassembled, temporarily install it
after fitting the nuts as illustrated.
a = 27.0 mm (1.06 in)
a
16-44
CONTROL VALVE LEVER ASSY
REMOVAL·INSTALLATION
5
3
Removal Procedure
1 Remove the lower panel.
2 Remove the instrument panel RH.
3 Disconnect the knob switch connector.
4 Disconnect the connection between the control valve lever and the lever rod.
5 Remove the set bolt.
6 Remove the control valve lever. [Point 1]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply chassis grease special on the control valve lever links.
Point Operations
[Point 1]
Inspection:
Check the knob switch for continuity.
16-45
RELIEF PRESSURE ADJUSTMENT
Note:
• Since the relief valve is structured in two stages, be sure to adjust the lift (high pressure) side first and
adjust the tilt (low pressure) side then. (If the lift side is normal and tilt side is abnormal as the result of
relief pressure inspection, only the tilt side adjustment can be performed.)
• Always adjust the relief pressure as described below. Avoid hasty adjustment since it may cause high-
pressure generation that may result in damage to the oil pump and other hydraulic devices.
• Before starting adjustment, check if the no-load maximum rpm is as specified.
1. Open the engine hood.
2. Remove the lower panel and toe board.
3. Install an oil pressure gauge.
Remove the oil-pressure detecting plug installed on the left
9/16-18 side of the oil control valve, and install the oil pressure gauge
UNF
there.
Plug size: 9/16-18UNF
Fitting
Fitting size: 9/16-18UNF × PF1/4
Fitting: 90407-13469-71
Lock nut 1 4. Set the adjusting screw A and adjusting sleeve B of the relief
Adjusting screw A valve as described below.
(1) Loosen lock nut 1. After fully tightening·adjusting screw A
once, loosen it by 1 to 2 turns.
Adjusting
sleeve B (2) Loosen lock nut 2, and position adjusting sleeve B to the
following dimension.
a
a = 27.0 mm (1.06 in)
Lock nut 2
5. Start the engine, and check for oil leaks and abnormal noise.
6. Install the toe board.
7. Close the engine hood.
8. Adjust the lift side relief pressure.
(1) Set the seat switch to ON. (Operate by two workers with
one sitting on the seat.)
(2) Operate the lift lever to lift the fork fully.
(3) While running the engine at the maximum speed, operate
the lift lever to the lifting side. Gradually tighten adjusting
sleeve B to make the oil pressure in the relief state satisfy
the standard in the table on the next page, and fix the
sleeve position by tightening lock nut 2.
16-46
9. Adjust the tilt side relief pressure.
(1) Set the seat switch to ON. (Operate by two workers with
one sitting on the seat.)
(2) Operate the tilt lever to tilt the mast fully backward.
(3) While running the engine at the maximum speed, operate
the tilt lever to the backward side. Gradually tighten
adjusting screw A to make the oil pressure in the relief
state satisfy the standard in the table below, and fix the
sleeve position by tightening lock nut 1.
10. Turn the key switch OFF.
11. Remove the oil pressure gauge, and install and tighten the
removed plug.
Standards MPa (kgf/cm2) [psi]
Vehicle model 1 ton series Other than 1 ton series
+1.7 +240 +1.7 +240
Lift side relief pressure 17.8 0 (182 +17
0 ) [2590 0 ] 18.7 0 (191 +17
0 ) [2720 0 ]
+1.7 +240 +1.7 +240
Tilt side relief pressure 11.8 0 (120 +17
0 ) [1710 0 ] 14.7 0 (150 +17
0 ) [2132 0 ]
16-47
MANUAL DOWN VALVE
T = N·m (kgf·cm) [ft·lbf]
Manual down valve
T = 32.0 (326) [23.59]
If the forks do not descend due to a malfunction or other cause, loosen the manual down valve to lower the forks in
emergencies.
When loosening the manual down valve, do not rotate it more than one full turn.
After making repairs, tighten it securely.
17-1
MINI LEVER·JOYSTICK
Page
GENERAL.............................................................17-2
0
JOYSTICK.............................................................17-4
1
COMPONENTS ....................................................17-6
2
MINI LEVER·JOYSTICK.......................................17-8
REMOVAL·INSTALLATION .....................................17-8 3
DISASSEMBLY·INSPECTION·REASSEMBLY .........17-10 4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
17-2
GENERAL
Mini Lever
Armrest
Lift lever
Tilt lever
Direction switch
Lever for fixing rotation
of lever box
Automatic fork leveling switch
Lift Lever-Attachment Lever
22.5 ~ 26° 22.5 ~ 26°
5 V (1)
PS1 (2)
GND (3)
PS2 (4)
17-3
Tilt Lever
22.5 ~ 26° 22.5 ~ 26°
0
1
2
5 V (1) 3
PS1 (2) 4
GND (3) 5
PS2 (4) 6
7
Connector pin arrangement 8
(1) Power line: Red
(2) GND line: Black
(3) Signal line: Green
9
10
Direction Switch
11
12
T
P
13
N IG1 IG2 VF ST VR Ra
F1
N
14
R
Rr
Ra
15
8 7 6 5 4 3 2 1
16
17
MARK TERMINAL
1 VR
18
2 Ra
3
4
ST
-
19
20
5 VF
6 IG1
7 N
8 IG2
21
E
17-4
JOYSTICK
Armrest
Automatic fork
leveling switch
Direction switch
Joystick for lift and tilt
operation
Lever for fixing rotation
of lever box
Joystick for Lift and Tilt Operation
22.5 ~ 26° 22.5 ~ 26° 22.5 ~ 26° 22.5 ~ 26°
5 V (1)
PS1 (2)
GND (3)
PS2 (4)
1 2 4 3
3 4 2 1
2
1 3
Connector pin arrangement
(1) Power line: Red
(2) GND line: Black
(3) Signal line: Green
17-5
Joystick for Attachment Operation
22.5 ~ 26° 22.5 ~ 26° 22.5 ~ 26° 22.5 ~ 26°
0
1
2
3
5 V (1)
4
PS1 (2)
5
GND (3) 6
1 2 4 3
PS2 (4) 7
8
3 4 2 1
9
10
11
Direction Switch
12
P T N IG1 IG2 VF ST VR Ra
13
F1
N
14
Rr
R
Ra
15
16
8 7 6 5 4 3 2 1
17
18
MARK TERMINAL
19
1 VR
2 Ra
3 ST
4
5 VF
-
20
6 IG1
7
8 IG2
N
21
E
17-6
COMPONENTS
6712
17-7
Mini Lever
6712
Joystick
6712
17-8
MINI LEVER·JOYSTICK
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
4 T = 14 (143)
[10.3]
3 10 8
T = 35 ~ 40 7
5 (357 ~ 408) 9
[26 ~ 30]
8
6
T = 2.0 ~ 4.0
7 (20.4 ~ 40.8)
7 T = 2.0 ~ 4.0 [1.5 ~ 3.0]
(20.4 ~ 40.8) [1.5 ~ 3.0]
Removal Procedure
1 Open the engine hood and disconnect the connector.
2 Close the engine hood.
3 Remove the lever cover for setting rotation.
4 Remove the mini lever box W/ armrest and the armrest bracket.
5 Remove the lever for setting rotation. [Point 1]
6 Remove the rotary damper ASSY.
7 Remove the knob for fixing height and the lower bracket.
8 Remove the lever for setting forward and backward. [Point 2]
9 Remove the upper bracket.
10 Remove the armrest ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
17-9
Point Operations
[Point 1]
Installation:
Install the lever for setting rotation so that the dimension B
shown in the illustration on the left becomes 3 to 6 mm (0.118
to 0.236 in).
B The B part moves 3.6 mm (0.142 in) with 1 notch of the
serration.
[Point 2]
Installation:
Align the hole in the clamp bracket with the lever shaft
protrusion to install, then turn as shown in the illustration on
the left.
Installation:
Follow the procedure below to install the forward-backward
adjustment lever.
(1) Move the armrest to the rearmost part.
(2) Tighten the flange nut until the operating force at the top of
the lever becomes 65 to 100 N (6.6 ~ 10.2 kgf) [14.6 ~ 22.5
lbf].
(3) Press the armrest forward with the force of 100 N (10.2
kgf) [22.5 lbf], and check that it doesn't move. If it moves,
100 N (10.2 kgf) [22.5 lbf] tighten the flange nut further.
(4) Tighten nut A to the specified torque.
T = 14 N·m (142.8 kgf·cm) [10.3 ft·lbf]
Nut A
17-10
DISASSEMBLY·INSPECTION·REASSEMBLY
Mini lever 3 Joystick
4
1
3
1
3 4
Disassembly Procedure
1 Remove the lever cover.
2 Disconnect the connector. [Point 1]
3 Remove each lever ASSY and guide. [Point 2]
4 Remove the direction switch ASSY.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Disassembly:
Always mark connectors with a tag etc. so that the connection
points can be found during reassembly.
18-1
SAS/OPS
Page Page
GENERAL..............................18-2 OPS FUNCTIONS ............... 18-25 0
SAS FUNCTION ....................18-4 GENERAL ............................ 18-25 1
COMPONENTS .......................18-4 CONTROL SPECIFICATION ... 18-25
2
PRECAUTIONS FOR REPAIR 18-11 MATCHING .......................... 18-26
3
SAS/OPS CONTROLLER GENERAL ............................ 18-26
REMOVAL·INSTALLATION...18-14
BEFORE STARTING
4
YAW RATE SENSOR MATCHING ........................ 18-28 5
REMOVAL·INSTALLATION...18-15
OPTION SET ....................... 18-32 6
TIRE ANGLE SENSOR
REMOVAL·INSTALLATION...18-16 DIAGNOSIS MEMORY........ 18-34
7
SWING LOCK CYLINDER REAR WHEEL SWING
REMOVAL·INSTALLATION...18-18 CONTROL CHECK............ 18-35 8
TILT ANGLE SENSOR PLUG-IN ANALYZER .......... 18-36 9
REMOVAL·INSTALLATION...18-20
OPS PLUG-IN ANALYZER ..... 18-36 10
LOAD SENSOR
REMOVAL·INSTALLATION...18-21 SCREEN CONFIGURATION ... 18-36 11
SPEED SENSOR BASIC OPERATION .............. 18-37
REMOVAL·INSTALLATION...18-22 12
ANALYZER .......................... 18-41
FORK HEIGHT SWITCH 13
REMOVAL·INSTALLATION...18-23 SAS/OPS PLUG-IN
ANALYZER ........................ 18-45 14
FUNCTIONAL PARTS ............18-24
15
16
17
18
19
20
21
E
18-2
GENERAL
SAS (System of Active Stability) /OPS (Operator Presence Sensing) system configuration
Sensors are installed at each point of the vehicle to detect the vehicle movement and send signals to the controllers.
These signals are controlled by the controllers, and sent to each actuator to be operated.
Control Con
Sensor Actuator
S T K O -trol
Swing lock cylinder
(1) Fork height switch S
(Single tire only㧕
Tilt control valve
(2) Tilt angle sensor T
Lift lock valve
Knob position correcting
(3) Forward tilt switch K
valve
Output Forward interrupt relay
(4) Backward tilt switch
(toque converter vehicle only㧕
Backward interrupt relay
(5) Lower switch (toque converter vehicle only㧕
Unload valve
O Lift lock valve
(6) Load sensor Backward tilt lock valve
(Standard lever vehicle only)
(7) Fork automatic OPS lamp
leveling switch Buzzer
Input
Controller
Tilt control valve
(8) Speed sensor
S,T Error lamp
K,O Error code display
Steering wheel
(9)
angle sensor
(10) Tire angle sensor MULTI-FUNCTION display
S,T
Output (OPT)
Yaw rate sensor K,O
(11) (Bilt-in analyzer)
(Single tire only㧕
S,T
(12) Seat switch Plug-in anallyzer(SST)
K,O
Forward switch
(13) (toque converter S :Rear wheel swing control
vehicle only㧕
T :Mast tilting control
Backward switch K :Steering knob position control
(14) (toque converter
vehicle only㧕 O:OPS control
18-3
(7)
0
(1)
1
(26)
(9)(13)(14)
2
(24)(25) 3
(18)
(12) 4
(28)
5
(23)
6
7
(3)(4)(5)(6)
(16)(17)(21)(22)
8
9
(8)
10
(2)
11
(10)
(27) (19)(20) (11)
(15) 12
13
No. Name No. Name 14
(1) Fork height switch (15) Swing lock cylinder
(2) Tilt angle sensor (16) Tilt control valve
15
(3)
(4)
Forward tilt switch *1
Backward tilt switch *1
(17)
(18)
Lift lock valve
Knob position correction valve
16
(5)
(6)
Lower lift switch *1
Load sensor
(19)
(20)
Forward interrupt relay
Reverse interrupt relay
17
(7) Fork automatic leveling switch (21) Unload valve 18
(8) Speed sensor (22) Backward tilt lock valve
(9) Steering wheel angle sensor (23) Buzzer 19
(10) Tire angle sensor (24) OPS lamp
(11) Yaw rate sensor (25) Error lamp, Error code display 20
(12) Seat switch (26) Multi-function display
(13) Forward switch (27) Plug-in analyzer 21
(14) Reverse switch (28) SAS/OPS controller
*1 For the mini lever/joystick vehicles, (3) (4) and (5) switches are the lever angle sensors.
E
18-4
SAS FUNCTION
COMPONENTS
Controller
1910
Yaw Rate Sensor
5803
18-5
Tire Angle Sensor
4301
Tire angle sensor
0
1
2
3
4
5
6
7
8
9
10
Swing Lock Cylinder
11
4301
12
13
Swing lock cylinder
14
15
16
17
18
19
20
21
E
18-6
Steering Knob Position Correcting Valve
4503
Steering knob position
correcting valve
Fork Height Switch (V Mast) (1·K2·K3·2·3 ton series)
5803
18-7
Fork Height Switch (V Mast) (J3.5 ton series)
5803
Fork Height Switch (FV Mast)
5803
18-8
Fork Height Switch (FSV Mast) (1·K2·K3·2·3 ton series)
5803
Fork Height Switch (FSV Mast) (J3.5 ton series)
5803
18-9
Tilt Angle Sensor
5803
Load Sensor
5803
18-10
Speed Sensor
5803
18-11
PRECAUTIONS FOR REPAIR
Fully understand the functions of SAS/OPS 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.
Do not perform high pressure washing for the controller,
tilt angle sensor, fork height switch, horn button, meters,
switches on the instrument panel and electrical
components and parts in the engine compartment.
(2) Remove contamination and/or water from respective
sections.
(3) Transport the controllers in a packed state with cushions, and keep it packed until installation. Never
transport it in an exposed state. Also, do not apply mechanical shock on the controllers by dropping or
crashing them.
(4) Part number for a controller varies by the vehicle specifications. Check the correct part number in advance.
(5) If a repair work requires matching, always park the vehicle on a flat place.
(6) Arrange for necessary tools and measuring instrument (such as a plug-in analyzer (SST 09240-26600-71)
and TOYOTA electrical tester (SST 09082-76002-71 (SST 09082-00050)), etc.).
2. During repair
(1) Never use an impact wrench for removing and installing controllers and sensors.
(2) Do not turn the ignition key switch ON or OFF more than necessary when the sensor wiring is
disconnected. Turning the ignition key switch ON in this state causes an error and an error code will be
stored in the controller. The error code is not erasable and a maximum of ten errors will be stored. If 11 or
more error codes are stored, the oldest error code will be sequentially erased.
(3) When turning the solenoid (for lock cylinder, knob position correction valve) ON during an “Active Test” of
the analyzer, do not keep it ON for more than one (1) minute. Since SAS/OPS functions are forcibly
suspended during an active test, use caution when performing the running test carefully at a low speed.
(4) SAS/OPS functions are suspended during matching. Do not operate the vehicle in this state.
(5) Do not turn the ignition key switch ON with one side (RH or LH) of a vehicle jacked up. It is very dangerous
to turn the ignition 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 other reasons, keep the ignition
key switch turned ON throughout from the start of jacking up, tire replacement and lowering to the ground.
(7) When the hydraulic piping is disconnected, apply cover to the fitting and hose to prevent the dirt from
entering.
(8) If the oil control valve for manual lowering is loosened, tighten it to a prescribed torque.
(9) Tighten respective set bolts to a prescribed toque.
(10) Respective sensors require no adjustment during installation. Make initialization during matching.
(11) To disconnect a connector, do not pull it by the harness.
(12) When inspecting the harness, carefully operate so as not to damage connector terminals.
(13) The swing lock cylinder must not be disassembled. If disassembled, air enters to make it not reusable.
(14) Do not apply strong impacts to the frame and head guard to prevent the yaw rate sensor from being
damaged.
(15) The meanings of high and low fork heights in the troubleshooting section are as follows:
Low fork height: From the lowermost position to immediately before actuation of the fork height switch
High fork height: Height above the position where the fork height switch is actuated
18-12
3. Temporary measures
If the mast should fail to lower because of some trouble, it can
be lowered manually.
Loosening the illustrated valve on the top of the oil control
valve lowers the mast. Operate the lift lever for lowering with
the manual lowering valve loosened.
After the repair, tighten it appropriately.
T = 32.0 N·m (326 kgf·cm) [23.6 ft·lbf]
18-13
4. Precautions for vehicle modification
H (fork height): mm (in)
No. Content of modification Condition Content of work
Change the controller. (for vehicle without swing
1 Single tire → Double tire — control)
Remove the lock cylinder.
Change the controller. (for vehicle with swing control)
2 Double tire → Single tire — Change the rear axle beem.
Install the lock cylinder.
3 Installation/Removal of attachment — Install or remove attachments.
When temporarily replace/use SAS/OPS
controllers between different vehicles
4 (However, this should be done only — Perform SET-5 of the matching
between the ones with the identical part
number.)
Note:
• Proceed with the alignment (matching) procedure after the above-mentioned modification.
(See page 18-26.)
• When placing a supply order for a mast ASSY, place order for sensors (for lifting height switch, mast
harness and other SAS related parts) simultaneously if such parts are required.
18-14
SAS/OPS CONTROLLER REMOVAL·INSTALLATION
Note:
Do not use an impact wrench for removing/installing the set bolts from/to the connector boot bracket and
SAS/OPS controller.
T = N·m (kgf·cm) [ft·lbf]
T = 5.5 (56.1) [4.1]
4
7
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Remove the shift lever box upper cover and lower cover. (M/T vehicle)
4 Disconnect the tilt lever rod.
5 Remove the connector boot bracket.
6 Disconnect the connector.
7 Remove the SAS/OPS controller.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the SAS/OPS controller is replaced, perform the matching (See page 18-26).
18-15
YAW RATE SENSOR REMOVAL·INSTALLATION
Note:
• Extremely be careful not to apply mechanical shock in order to protect the yaw rate sensor. Do not use
an impact wrench.
• Do not use the yaw rate sensor which you accidentally dropped.
T = N·m (kgf·cm) [ft·lbf]
5
T = 5.5 (56.1) [4.1]
Removal Procedure
1 Remove the battery.
2 Remove the relay block from the battery set plate.
3 Remove the battery set plate.
4 Disconnect the yaw rate sensor connector.
5 Remove the yaw rate sensor W/ bracket.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
18-16
TIRE ANGLE SENSOR REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
1
3
4
T = 10 ~ 16 (100 ~ 160) [7.2 ~ 12]
Removal Procedure
1 Remove the harness protector.
2 Remove the sensor cover.
3 Disconnect the tire angle sensor connector.
4 Remove the tire angle sensor and joint. [Point 1]
5 Remove the sensor plate.
Installation Procedure
The installation procedure is the reverse of the removal porcedure.
Note:
When the tire angle sensor is removed/installed or replaced, proceed with the matching procedure.
Joint Point Operations
[Point 1]
Installation:
Apply grease
1. Turn the steering wheel fully clockwise and hold it there.
2. Insert the joint into the kingpin groove. Apply a small amount of
MP grease on the joint surface in contact with the king pin and
sensor plate.
18-17
Tire angle 3. Install the tire angle sensor by aligning it with the joint center
sensor axis.
Joint
4. Turn the tire angle sensor until the tire angle sensor mounting
hole is aligned with the sensor plate screw hole.
(Approx. 180°)
5. Fix by tightening the tapping screw after mounting hole
alignment.
18-18
SWING LOCK CYLINDER REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
5
4 6
T = 29.0 (296) [21.4]
T = 29.0
(296) [21.4]
Removal Procedure
1 This is not applicable to 1-ton series vehicles.
Remove the radiator.
2 Jack up the vehicle.
3 Remove the lower pin and swing lock cylinder.
4 Disconnect the swing lock solenoid connector.
5 Remove the upper pin and swing lock cylinder. [Point 1]
6 Remove the swing lock cylinder. [Point 2]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply chassis grease to the spherical portion of the upper pin and its mounting hole before installation.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the threaded portions of the upper and lower
pin set bolts before tightening them.
• After installation, apply chassis grease from the grease fitting.
18-19
SST
Point Operations
[Point 1]
Removal:
SST 09810-20172-71
[Point 2]
Inspection:
Measure accumulator piston depth L.
1. Remove the plug, with a coin (or a screw driver) from the
center at the end of the accumulator.
2. Using a caliper, measure depth L of the accumulator piston.
Standard
46 mm (1.81 in) (20°C (68°F)),
42 mm (1.65 in) (40°C (104°F))
L Limit
52 mm (2.05 in) (20°C (68°F)),
48 mm (1.89 in) (40°C (104°F))
Temperature °C (°F) Standard cannot be judged correctly in a low temperature, as it
60
fluctuates greatly by the oil temperature inside the lock
(140) cylinder. (Refer to the graph)
40
(104)
If temperature is low, raise the oil temperature (approx. 40°C
(104°F): a level of human body temperature for the cylinder body)
20
(68) by forward and reverse traveling on an irregular road surface
0 before measuring. (Or, warm up from outside using a heater)
(32)
If the limit value is exceeded, replace the swing lock cylinder
-20
(4)
52 50 48 46 44 42 40 38
ASSY.
(2.05) (1.97) (1.89) (1.81) (1.73) (1.65) (1.57) (1.50)
3. After inspection, push a plug in with a finger.
L dimension mm (in)
Installation:
Install with the mark (protruded portion) at the rod end facing
outward.
18-20
TILT ANGLE SENSOR REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
3 4
T = 17.0
(173)
[12.5]
T = 17.0
(173)
[12.5] 5
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Disconnect the tilt angle sensor link rod.
4 Disconnect the connector.
5 Remove the tilt angle sensor W/ bracket.
6 Remove the tilt angle sensor.
7 Remove the link shaft and link lever.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply MP grease on the spherical portion of the link arm, inside the oil seal and inside the bushing, and
then install.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the threaded portion of the tilt angle sensor
installation screws and the link lever installation nuts, and tighten them.
• Perform matching if the tilt angle sensor is removed or installed, or the tilt angle sensor link is replaced.
(Refer to page 18-26)
18-21
LOAD SENSOR REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 22.0 ~ 26.0
(224 ~ 265)
[16.2 ~ 19.2]
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Disconnect the connector.
4 Remove the load sensor.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the load sensor is removed/installed or replaced, proceed with the matching procedure.
(See page 18-26.)
18-22
SPEED SENSOR REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
T = 3.0 ~ 7.0
1
(31 ~ 71)
[2.2 ~ 5.2] 3
Removal Procedure
1 Remove the speed sensor cover.
2 Disconnect the connector.
3 Remove the speed sensor.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
18-23
FORK HEIGHT SWITCH REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
V mast
1·K2·K3·2·3 ton
T = 15 ~ 25 (153.0 ~ 254.9) [11.1 ~ 18.4]
2 J3.5 ton
T = 27 (275.3) [19.9]
1
(J3.5 Vehicle only)
T = 13
(132.6)
[9.6]
FV·FSV mast
T = 13 (132.6) [9.6]
T = 27 (275.3) [19.9]
Removal Procedure
1 Remove the lower cover.
2 Disconnect the connector.
3 Remove the fork height switch.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
18-24
FUNCTIONAL PARTS
Note:
• Refer to section 9 (STEERING) for the steering angle sensor. Refer to section 16 (OIL CONTROL VALVE)
for the solenoids installed at the oil control valve and the tilt lever knob switch.
• Refer to section 20 (TROUBLESHOOTING) for inspection of functional components.
18-25
OPS FUNCTIONS
GENERAL
OPS system detects the operator with the seat switch, and if the operator is not in the proper driving position, it cuts
off the driving force while limiting the material handling operation.
However, M/T vehicles do not have traveling OPS functions.
CONTROL SPECIFICATION
1. Traveling OPS functions (T/C vehicle only)
If the controller detects that the seat switch is OFF for 2 seconds, it will cut off the driving force by interrupting the
voltage supply line to the forward/reverse drive valve of the torque converter through the control of forward
traveling and reverse traveling interruption relays.
While the seat switch is ON, traveling OPS state is cancelled by shifting the forward-reverse travel lever back to
neutral.
2. Material handling OPS system
(1) STD lever vehicle
If the controller detects that the seat switch is OFF for 2 seconds, it will stop the operations of lift lowering
and forward/backward tilting by controlling the lift lock valve, tilt control valve and backward tilt lock valve.
For lifting and attachment, the material handling operation will be stopped by cutting off the hydraulic oil
supply through the control of the unload valve.
In addition, the material handling OPS state is cancelled in the following conditions according to material
handling operations.
(a) Lowering: when the seat switch is ON, and the lift lever is set to the condition other than lowering.
(b) Other than lowering: when the seat switch is ON for more than 1 second.
If you operate the attachment lever while OPS is operated, it may move by the attachment's own weight, or
by the back pressure of the unload valve.
(2) Mini lever/joystick vehicle (OPT)
If the controller detects that the seat switch is OFF for more than 2 seconds, lifting, tilting and attachment
operations will be stopped by controlling the solenoid valves.
Material handling OPS state is cancelled when the seat switch is ON, and all the levers are shifted back to
neutral.
3. OPS operation notification functions
If the controller detects that the seat switch is OFF, the buzzer will sound for approx. 1 second and the OPS light
will turn on to notify the operator that OPS is going to be activated. In addition, the OPS light stays on while the
seat switch is OFF to notify that it is in the OPS state.
4. Return-to-neutral warning
After the traveling OPS is activated, if the seat switch turns ON without shifting the forward-reverse travel lever
back to neutral, the buzzer will sound (repeated beeps) to notify the operator that traveling OPS is not cancelled.
(1) STD lever vehicle
After material handling OPS is activated, if the seat switch turns ON while leaving the lift lever at the
lowering operation, buzzer will sound (repeated beeps) to notify the operator that the lowering operation
stop is not cancelled.
(2) Mini lever/joystick vehicle (OPT)
After material handling OPS is activated, if the seat switch turns ON without shifting all the material handling
levers to neutral, buzzer sounds (repeated beeps) to notify the operator that the material handling OPS is
not cancelled.
18-26
MATCHING
GENERAL
• For the tilt angle, load and tire angle sensors among sensors used for SAS functions, the signal voltage values
under the mast vertical, no load, tire straight and rear axle beam horizontal conditions are stored in the
controller for control based on these values. When servicing these sensors or replacing related parts, matching
(updating the sensor signal voltage under the standard vehicle condition) is necessary. In addition, matching is
required for the tilt angle sensor if the vehicle posture changes considerably, and for the material handling
sensor, when the loading in no-load state changes as a result of adding/removing the attachment, replacing the
mast, change in the fork length or removing/installing the fork.
There are two methods of matching: using the hour meter and tilt knob switch; and using the plug-in analyzer
(SST part number 09240-26600-71) (refer to 20-58).
• Each lever angle sensor for mini lever or joystick function is controlled based on the signal voltage value stored
in the controller with each lever neutral at the time of shipment. When servicing these sensors or replacing
related parts, matching (updating the sensor signal voltage under the standard vehicle condition) is necessary.
• Live load gauge stores mast specification information and signal voltage values of the load sensor during no-
load to the multi-function display, and indicates based on these information. When servicing the mast or load
sensor or replacing related parts, matching (updating the sensor signal voltage with the mast specification
information or under the standard vehicle condition) is necessary.
Matching Items and Prerequisite for Implementation
1. SAS
Prerequisite for
No. Indication Description
implementation
Tilt angle sensor output with fork in the horizontal position is stored in
1 TILTL *1,*2,*3,*6,*7,*8
the controller.
Tilt angle sensor output with the forward tilt control the mast vertical
2 TILTF LOAD standard condition, and the load sensor output in the no-load *1,*2,*3,*4,*6,*7,*8
condition are stored in the controller.
Tire angle sensor output in the condition of the vehicle traveling
3 TIRE *1,*5
straight ahead is stored in the controller.
4 SWING — —
2. MINI LEVER (OPT: mini lever or joystick vehicle only)
Prerequisite for
No. Indication Description
implementation
Lift lever angle sensor output with the lift lever in the neutral position
6 LEVER1 *1,*9
is stored in the controller.
Tilt lever angle sensor output with the tilt lever in the neutral position
7 LEVER2 *1,*10
is stored in the controller.
Attachment (1) lever angle sensor output with the attachment (1)
8 LEVER3 *1,*11
lever in the neutral position is stored in the controller.
Attachment (2) lever angle sensor output with the attachment (2)
9 LEVER4 *1,*12
lever in the neutral position is stored in the controller.
18-27
3. LOAD METER (OPT: vehicle with multi-function display DX model only)
Prerequisite for
No. Indication Description
implementation
Number of the mast lift cylinders is stored.
10 LIFT CYL. NUMBERS *7,*13
(Total number including front and rear)
11 LIFT CYL. BORE Bore of the lift cylinder is stored. *7,*13
12 LOADMETER 0 SET 0 point of the load gauge is stored. *4,*6,*7,*13
When you want to
13 COMPENSATION Accuracy of the load meter is adjusted.
adjust the accuracy
Prerequisite for implementation
*1 When replacing the SAS/OPS controller
*2 When removing/installing or replacing the tilt angle sensor
*3 When changing the tilt angle sensor rod length or replacing the rod
*4 When removing/installing or replacing the load sensor
*5 When removing/installing or replacing the tire angle sensor/sensor cover
*6 When removing/installing or changing the attachment and fork
*7 When replacing the mast
*8 When replacing the tilt cylinder
*9 When replacing the lift lever angle sensor
*10 When replacing the tilt lever angle sensor
*11 When replacing the attachment (1) lever angle sensor
*12 When replacing the attachment (2) lever angle sensor
*13 When replacing the multi-function display
18-28
BEFORE STARTING MATCHING
Set the vehicle to "Standard vehicle condition" before starting matching.
"Standard vehicle condition" means that the vehicle satisfies the conditions described below.
Standard Vehicle Condition
Note:
• Items 1 ~ 4 below show the standard vehicle condition for
SAS matching.
• Before carrying out matching for mini lever/joystick
vehicles, move the armrest to the driving position and
check the neutral state of the levers.
1. Tire pressure check
Adjust the tire pressure to the specified level. Matching will be
Level surface inaccurate if the pressure is low, or if there are air pressure
fluctuations between front and rear as well as left and right.
V mast FV·FSV mast 2. Surface levelness check
If matching is conducted on an inclined or rough floor surface,
errors in standard vehicle condition will occur, so perform
matching on a flat, level surface (inclination: within 0.5°).
3. No-load vertical condition check
Store the output voltage of the load sensor in no-load state in
the controller. At this time, the following conditions must be
satisfied:
500 mm 100 mm (1) For the V mast, set the lifting height to about 500 mm
(19.7 in) (3.93 in) (19.7 in) and use a goniometer to check that the mast is
vertical.
(2) For the FV/FSV mast, set the rear cylinder rod projection
to about 100 mm (3.93 in) and use a goniometer to check
that the mast is vertical.
(3) Set the mast in the vertical position from the backward
tilted position by operating the tilt lever in the forward
tilting direction.
4. Tire straight traveling position check
Store the tire angle sensor output voltage in the controller in
the condition of the vehicle traveling straight ahead.
50 mm Condition of the vehicle traveling straight ahead means that
(2.0 in) the deviance to left or right is within 50 mm (2.0 in) when the
50 mm vehicle travels for 5 meters (16 ft) with the steering being fixed.
(2.0 in)
5. Loadmeter 0 set (0 set of the load gauge) check
For all the V/FV/FSV mast, the mast is to be vertical and the
5 m (16 ft) fork height is to be 500 mm (19.7 in).
18-29
Matching connector Matching Procedure
When there is a matching connector (STD lever vehicle)
Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching connector causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
controller, for which care must be taken.
1. Turn the ignition key switch ON (or start the engine).
2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench lamp turns on,
and then password display is indicated.
Tilt knob switch 3. While shifting the tilt lever to backward tilt for more than 5
seconds, returning the lever and tilt knob switch after pressing
the switch for more than 2 seconds will indicate "1-dIAG" on
the hour meter.
Menu No. Menu description
1-dIAG Diagnosis memory menu
2-OPT Option set menu
3-SET Matching menu
4-SAS Rear wheel swing control check menu
18-30
Tilt knob switch 4. Operate the tilt lever to indicate "3-SET" and press the tilt knob
switch to display "SET1-". Set number display changes as
indicated in the table below each time the tilt knob switch is
pressed for less than 2 seconds.
Set No. Description of matching
SET1 Fork stop position with automatic leveling
Forward tilting limit position and
SET2
no-load standard load
SET3 Tires in straight traveling position
SET4*1 —
SET5*2,*3 Deleting engine and display ECU information
*1: Indication may be made but actually it is not used.
*2: Indicates only when CAN communication abnormalities (AD-1
or AD-7) occur.
*3: Perform SET5 when temporarily replacing SAS/OPS controller
between the different vehicles.
Note:
When switching the matching menu, do not press the tilt knob
switch for more than 2 seconds. Pressing the switch for more
than 2 seconds will carry out the displayed matching.
O display
5. Operate the tilt lever to indicate "3-SET" and press the tilt knob
switch for more than 2 seconds to carry out matching.
O indication: Matching is completed. (Wrench lamp starts to
blink)
H indication: Check for the sensor abnormality,
disconnection of the harness and the short-
H display circuit since the signal voltage value is outside
the matching rang. (Refer to the troubleshooting
section.)
Note:
• For re-matching, repeat step 5.
• To make a separate matching, repeat steps 4 to 5.
6. Connect the matching connector and turn the ignition key
switch OFF.
18-31
When There is No Matching Connector
(Mini Lever/Joystick Vehicle)
Note:
• Even when there is no matching connector, engine and
display ECU information can be deleted.
• Refer to the multi-function display for SAS matching.
(Section 20)
1. Turn the ignition key switch ON (engine stop).
2. Display the mask menu on the multi-function display or multi-
function display DX. (refer to page 20-14)
3. Keep pressing the fork automatic leveling switch for more than
Fork automatic leveling switch
2 seconds to display the matching menu.
Note:
• Only SET5 when there is a matching connector, will be
indicated.
• Indicated only when CAN communication abnormalities
(AD-1 or AD-7) occur.
4. Keep pressing the fork automatic leveling switch for more than
2 seconds to delete the information.
0 indication: deleting the information is completed. (Wrench
O indication (Deleting information) light will be flashing)
5. Turn the ignition key switch OFF.
18-32
OPTION SET
The option set 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 section
20.)
Caution:
When the option set is changed, perform maintenance of the caution label of “CAUTION FOR OPERATION.”
Matching connector Option Set Procedure
Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching connector causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
controller, for which care must be taken.
1. Turn the ignition key switch ON (or start the engine).
2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench lamp turns on,
and then password display is indicated.
3. While shifting the tilt lever to backward tilt for more than 5
seconds, returning the lever and tilt knob switch after pressing
the switch for more than 2 seconds will indicate "1-dIAG" on
the hour meter.
4. Operate the tilt lever to indicate "2-OPT" and press the tilt knob
switch to display "1-dIAG".
5. The displayed set number changes each time the knob switch
is pressed for less than 2 seconds.
Option No. Control name
OPT1 Mast forward tilt angle control
OPT2* —
OPT3 (Unused: always n)
*: Displayed but not in use.
6. Keep the knob switch pressed until the wrench lamp starts
blinking (for 2 seconds or over) to change y to n, and n to y.
y: Control valid
n: Control invalid
7. Connect the matching connector and turn the ignition key
switch OFF.
18-33
8. Perform the maintenance of the caution label.
Material handling swing lock control If the control is invalidated:
Remove the pertinent validation indication to replace with
invalid indication.
If the control is validated:
Replace the caution label to indicate valid control.
Mast forward tilt angle control
Note:
When mast front tilt angle control is invalidated, and T-OFF
When mast forward tilt angle control display will be indicated for 10 seconds when the ignition key
is invalidated:
switch is turned ON.
18-34
DIAGNOSIS MEMORY
There are two methods of diagnosis memory for STD lever vehicles: using the hour meter and tilt lever; and using the
plug-in analyzer (SST) (refer to page 20-22).
Refer to troubleshooting (refer to section 21) for the diagnosis code list.
Matching connector Diagnosis Memory Procedure
Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching connector causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
controller, for which care must be taken.
1. Turn the ignition key switch ON (or start the engine).
2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench lamp turns on,
and then password display is indicated.
3. While shifting the tilt lever to backward tilt for more than 5
seconds, returning the lever and tilt knob switch after pressing
the switch for more than 2 seconds will indicate "1-dIAG" on
the hour meter.
4. As you press the tilt knob switch for less than 2 seconds, the
diagnosis No. and the error code will be indicated, and each
error code and the time when it occurred will be indicated
alternately every 2 seconds.
Note:
• The maximum number of error codes that can be stored is
10, and as the diagnosis number gets smaller, the error
will be newer.
• The error detected when turning the ignition key switch
ON may be stored with the memory time as 0.0.
5. Connect the matching connector and turn the ignition key
switch OFF.
18-35
REAR WHEEL SWING CONTROL CHECK
There are two methods of the rear wheel swing control check: using the hour meter and the tilt lever; and using the
plug-in analyzer (SST) (refer to page 20-32).
Matching connector Rear Wheel Swing Control Check Procedure
Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching connector causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
controller, for which care must be taken.
1. Turn the ignition key switch ON (or start the engine).
2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench lamp turns on,
and then password display is indicated.
3. While shifting the tilt lever to backward tilt for more than 5
seconds, returning the lever and tilt knob switch after pressing
the switch for more than 2 seconds will indicate "1-dIAG" on
the hour meter.
4. Operate the tilt lever until "4-SAS" is indicated.
5. When you press the tilt knob switch, two segments rotate, and
indication that the rear wheel swing lock control is being
checked is displayed. (Wrench lamp is ON)
6. Check the rear wheel swing lock control by driving the vehicle.
While the rear wheel swing lock control is operated (during
locking), the wrench lamp turns on.
7. Connect the matching connector and turn the ignition key
switch OFF.
18-36
PLUG-IN ANALYZER
OPS PLUG-IN ANALYZER
For the maintenance and service of OPS 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 OPS functions and
the error information detected by the controller. It serves to check on the operating state of OPS functions and
shortens the repair time for a problem. Moreover, it is equipped with a save function to file data displayed on the
screen in the SST.
SST 09240-23323-71
Menu name Content of function Reference page
with the OPS controller on
DIAG MEMORY Indication of ten error codes and sub-codes in past. 18-41
Communication function
the vehicle side
Monitoring input voltage value from the sensors and the output
IN/OUT MONITOR 18-42
signal, etc. to the solenoid, etc.
OPS
ACTIVE TEST Forced operation of solenoids and warning lamps. 18-43
CONTROLLER DATA Indication of OPS controller abbreviation number and version 18-44
SCREEN CONFIGURATION
MAIN MENU
1.SAS NO USED
2.OPS ANALYZER MENU
1.DIAGޓMEMORY DAIG MEMORY(1/1)
2.IN/OUT MONITOR IN/OUT MONITOR(1/3)
IN/OUT MONITOR(2/3)
IN/OUT MONITOR(3/3)
3.ACTIVE TEST ACTIVE TEST(1/1)
4.CONTROLLER DATE CONTOLLER DATE(1/1)
7.END
7.TESTER SET TESTER SET MENU
1.CONTRAST SET CONTRAST SET
2.LANGUAGE SET LANGUAGE SET
3.FILE INITIALIZER FILE INITIALIZE
7.END
18-37
BASIC OPERATION
Name of sections and the switch functions
Position of
Name of section Mark Function Switch
indication
Main unit • Moves the cursor to the above item.
• Moves to the preceding page.
Selector
A • Moves the cursor to right or left. switch c
<Blank> <No function>
Connector
• Selects the item below.
Switch • Moves to the following page.
Screen title A Selector
B
switch d
<Blank> <No function>
• Determines an item for selection.
Menu
C
switch e
B C Switch mark indicator
<Blank> • Moves to MENU screen.
Caution on using:
• Operate the switch with finger tip.
• Do not apply strong impact from dropping or collision.
• Do not leave it under the direct rays of the sun for long time.
Connection and Operation of SST
1. Turn the ignition key switch OFF.
2. Open the diagnosis connector cover of the vehicle and
properly connect the connector on the SST side.
SST 09240-23323-71
Note:
Since the connector has no locking device, securely connect
Diagnosis it to prevent contact defect upon closing the engine hood with
connector the connector in connected state.
3. Turn the ignition key switch ON or start the engine.
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 e.
18-38
5. "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 c
or d.
• Japanese
• English
(2) Press MENU switch e to determine the language setting.
Note:
Once the display language is defined, "LANGUAGE SET"
screen will not be displayed from the next time onward. To
change the language, go to "TESTER SET".
6. "MAIN MENU" screen
(1) Select the menu using selector switch c and d and
determine by pressing MENU switch e.
• SAS: Not used.
• OPS: Moves to OPS ANALYZER MENU screen.
• TESTER SET: Moves to "TESTER SET" screen.
18-39
7. "TESTER SET" screen
(1) Select the menu using selector switch c and d and
determine by pressing MENU switch e.
(a) CONTRAST SET: Moves to "CONSTAST SET"
screen to adjust the contrast. (Refer to step 8)
(b) LANGUAGE SET: Moves to "LANGUAGE SET"
screen to select the language. (Refer to step 9)
(c) FILE INITIALIZE: Moves to "FILE INITIALIZE"
screen to initialize data in the main unit. (This is not
used for OPS)
(d) END: Returns to MAIN MENU screen.
8. "CONTRAST SET" screen
(1) Select a contrast level using selector switch c and d
Contrast level: 1 (Light) to 8 (Dark)
(2) Press MENU switch e to store the contrast level and
return to "TESTER SET" screen.
18-40
9. "LANGUAGE SET" screen
(1) Select the language using selector switch c or d.
(a) Japanese
(b) English
(2) Press MENU switch e to determine the language and
display SAVING → COMPLETE in the message column.
(3) Select "ENG" using selector switch c or d and press
MENU switch e to return to "TESTER SET" screen.
10. "FILE INITIALIZE" screen
This is not used for OPS.
Removal of SST
1. Check that the screen title is for one of the MENU screens.
2. Turn the ignition key switch OFF.
3. Disconnect the connector.
Note:
To disconnect, hold the body of the connector.
4. Close the diagnosis connector cover.
18-41
ANALYZER
ANALYZER MENU Display contents and function Page
1. DIAG MEMORY Indication of error codes for 10 most recent errors 18-41
2. IN/OUT MONITOR Indication of operating conditions of vehicle electrical system 18-42
3. ACTIVE TEST Forced operation signal output to the selected item 18-43
4. CONTROLLER DATA Indication of the OPS controller abbreviation number and version 18-44
Operation Procedure
1. Select and enter "2OPS" on the main menu screen to display
the OPS ANALYZER MENU screen.
2. "ANALYZER MENU" screen
(1) Move the cursor to the desired menu by operating
selector switch c or d, and enter by operating MENU
switch e.
(2) Select and enter "END" to return to the "MAIN MENU"
screen.
"1 DIAG MEMORY"
This screen displays ten error codes from the most recent one.
[Explanation on display contents]
(1) Order of error occurrence
(2) Error codes
[Clear memory]
Press selector switch c continuously for 2 seconds.
(1) (2)
[End]
Press MENU switch e to return to the "ANALYZER MENU" screen.
Note:
• Only "-" appears at the end of the item involving no error
occurrence.
• If reception has not been completed, only the number
appears without "-" indication.
18-42
"2 IN/OUT MONITOR" (Excluding the mini-lever
vehicle)
[Explanation on display contents]
(1)
(2) (1) SEAT: Seat switch input signal
(3) (2) DIR: Direction switch input signal (T/C vehicle only)
FWD: Forward direction switch input signal
(4) REV: Reverse direction switch input signal
(3) RLY: Output signal from the forward/reverse travel
interruption relay and backward tilt lock solenoid
FWD: Output signal to the forward/reverse travel
(1) interruption relay (T/C vehicle only)
(5) REV: Output signal to the backward tilt lock
(6)
(7)
solenoid
(8)
(4) VOLTAGE: OPS controller power supply voltage
(4)
(5) LIFT LOWER: Lift lowering switch input signal
(6) UNLOAD SOL: Output signal to the unload solenoid
(7) LWR SOL: Output signal to the lowering lock solenoid
(8) TILS SOL: Output signal to the tilt solenoid
(9) TILT: Tilt lever switch input signal
FWD: Forward tilt switch input signal
(1)
(9)
BWD: Backward tilt switch input signal
CONT: No used
(8) (10) LSOPT: Backup.
(10)
(4) [End]
Press MENU switch e to return to the "ANALYZER MENU" screen.
18-43
"3 ACTIVE TEST" (Excluding the mini-lever vehicle)
Note:
ON indication on the screen shows the controller output state.
(1)
(2) The operation, therefore, should be checked visually, by
(3) operating sound, etc.
(4)
(5) 1. Select the item by selector switch d, and set OFF/ON by
(6) selector switch c.
(7)
[Explanation on display contents]
(1) RLY FWD*
Set to ON for forced output of forward/reverse travel
interruption relay activation signal. (Forward/reverse
travel disabled state)
(2) RLY REV
Set to ON for forced output of backward tilt lock solenoid
activation signal. (Backward tilt disabled state)
(3) UNLOAD SOL
Set to ON for forced output of unload solenoid activating
signal. (Material handling disabled state)
(4) LWR SOL
Set to ON for forced output of lowering lock solenoid
activating signal. (Lowering enabled state)
(5) TILT SOL
Set to ON for forced output of tilt solenoid activating
signal. (Forward tilting enabled state with backward tilting
speed restriction)
(6) LAMP
Set to ON for forced output of OPS lamp lighting signal.
(OPS lamp lighting state)
(7) BUZZER
Set to ON for forced output of OPS buzzer sounding
signal. (Continuous OPS buzzer sounding)
* The drive power interrupting function is not provided on the
manual transmission vehicle.
2. After resetting all items to OFF, press MENU switch e to return
to the "ANALYZER MENU" screen.
18-44
M/T "4 CONTROLLER DATA"
The OPS controller abbreviation No. and version No. can be
displayed on this screen.
[Explanation on display contents]
(1) DATA
Controller abbreviation No.
(2) VER
Version No.
T/C [End]
Press MENU switch e to return to the "ANALYZER MENU"
screen.
18-45
SAS/OPS PLUG-IN ANALYZER
SST 09240-26600-71 For the maintenance and servicing of SAS/OPS controller, a
separate-placement type plug-in analyzer is added as SST
(servicing special tool).
The plug-in analyzer can read the operation states of the sensors
and actuators used for each controller, and error information
detected by the controllers, which is useful in checking the
operation state of each function and in saving repair time when a
defect occurs.
Mask Function List
Application
Function Description When replacing
Others
board
Displays the vehicle's electrical system
Upon vehicle
Analyzer operating status and reads the error —
abnormality
information detected by controllers.
Makes fine adjustment of traveling and c Requests from
Tuning
material handling functions. *2 users
Sets each vehicle option and other c
Specification setting —
specifications. *1 *2
Option Setting
Each control function c
Enables or disables each control function —
enable/disable *2
Updates voltage values of sensor signals c
Matching —
under the standard vehicle condition. *2
Engine idle adjustment c Requests from
Adjusts engine idle speed.
(4Y-E engine vehicle only) *2 users
Adjusts the contrast of the plug-in analyzer
Contrast — —
display screen.
*1: This matches the controller and screen control according to the installed options and control functions equipped
on the vehicle; note that this function does not enable or disable the option or control function itself.
*2: SAS/OPS controller board
Note:
Refer to the multi-function display (Section 20) for the functions of the plug-in analyzer.
19-1
SST LIST·SERVICE STANDARDS LIST
Page
SST LIST ..............................................................19-2
0
SERVICE STANDARDS LIST ..............................19-9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
19-2
SST LIST
Section
Illustration Part No. Part Name
1 2 3 4 6 7 8 9 10 13 14 15 16 18
09082-76002-71 TOYOTA
c
(09082-00050) electrical tester
09010-20111-71 Engine unit hanger c c c
Engine with
09010-23320-71 c c c
transmission hanger
Transmission
09150-10170-71 c
bearing replacer
09216-76002-71
Belt tension gage c
(09216-00021)
Torque converter
09220-22001-71 clutch drum spring c
remover & replacer
09228-76004-71
Oil filter wrench c
(09228-07501)
09240-26600-71 Plug-in analyzer c c
19-3
Section
Illustration Part No. Part Name
1 2 3 4 6 7 8 9 10 13 14 15 16 18
09310-23320-71 Reamer bolt remover c 0
1
2
09316-76008-71
Bearing replacer c
(09316-60011)
3
4
09319-76001-71
Output shaft needle
roller bearing c
5
(09319-60011)
remover
6
7
09320-23000-71 Bearing remover c c 8
9
10
09330-23320-71 Pilot bearing puller c
11
12
13
09340-23320-71 Pilot bearing replacer c
14
15
09350-23320-71 Adapter c 16
17
18
Front axle bearing
09370-10410-71
replacer
c c c
19
20
21
E
19-4
Section
Illustration Part No. Part Name
1 2 3 4 6 7 8 9 10 13 14 15 16 18
Drive pinion bearing
09370-20270-71 c c c c
replacer
09410-23420-71 LSD tool set c
Drive pinion bearing
09410-26600-71 c
replacer
09411-13330-71 Spring pin remover c
09420-23002-71 Bearing remover c c
LSD measuring tool
09420-23420-71 c
set
Front axle hub
09421-33020-71 c
replacer
09450-23320-71 Adapter c
19-5
Section
Illustration Part No. Part Name
1 2 3 4 6 7 8 9 10 13 14 15 16 18
09460-26600-71
Parking brake
measuring tool
c 0
1
2
09509-76002-71 Rear wheel bearing
c
(09509-55020) nut wrench
3
4
09509-76003-71 Rear wheel bearing
c
5
(09509-55030) nut wrench
6
7
Brake hold down
09510-31960-71 spring remover and c 8
replacer
9
Front hub inner
10
09608-76003-71
bearing cone c c
(09608-04031)
replacer 11
12
Oil control valve 13
09610-10161-71 spring remover and c
replacer
14
15
09610-22000-71 Inner mast stopper c c 16
17
18
Cylinder cap remover
09620-10100-71
and replacer
c
19
20
21
E
19-6
Section
Illustration Part No. Part Name
1 2 3 4 6 7 8 9 10 13 14 15 16 18
Tilt cylinder cap
09630-10110-71 c
remover and replacer
09630-23600-71 Deep socket A c
09631-22000-71 Wear scale chain c
Piston rod insert
09651-26600-71 c
guide
Piston rod insert
09652-26600-71 c
guide
Piston rod insert
09653-26600-71 c
guide
Piston rod insert
09654-26600-71 c
guide
Piston rod insert
09655-26600-71 c
guide
19-7
Section
Illustration Part No. Part Name
1 2 3 4 6 7 8 9 10 13 14 15 16 18
Piston rod insert
09656-26600-71 c
guide
Piston rod insert
09657-26600-71 c
guide
Piston rod insert
09658-26600-71 c
guide
09659-26600-71 Piston rod guide c
09717-76001-71 Brake shoe return
c
(09717-20010) spring remover
09718-76001-71 Brake shoe return
c
(09718-20010) spring replacer
09810-20172-71 Joint pin remover c c c
09843-76001-71
Sub-harness c
(09843-18040)
19-8
Section
Illustration Part No. Part Name
1 2 3 4 6 7 8 9 10 13 14 15 16 18
09905-76002-71 Snap ring No.1
c c
(09905-00012) expander
09950-76003-71
Puller C set c
(09950-50012)
09950-76014-71
Puller B set c c c c c
(09950-40011)
09950-76018-71
Replacer set c c c c c c c c c
(09950-60010)
09950-76019-71
Replacer set No.2 c c c c
(09950-60020)
09950-76020-71
Handle set c c c c c c c c c
(09950-70010)
19-9
SERVICE STANDARDS LIST
ENGINE
Engine
4Y-M Standard 750 ± 30
+50
4Y-E Standard 750 0
Idle speed rpm
1DZ-II Standard 750 ± 25
2Z Standard 775 ± 25
1·2·K2·K3 ton
Standard 2600 ± 50
4Y-M series
3·J3.5 ton series Standard 2800 ± 50
No-load static maximum speed rpm 1·K2·K3 ton
Standard 2600 ± 50
1DZ-II series
2·3 ton series Standard 2800 ± 50
2Z Standard 2400 ± 50
4Y-M Standard 300 or less
Engine speed down at full relief rpm
4Y-E·1DZ-II·2Z Standard 200 or less
Air cleaner
Vacuum switch continuity test Pa (mmH2O) Gasoline engine Standard 2630 ~ 3218 (270 ~ 330) [19.9 ~ 24.3]
(There is continuity) [mm Hg] Diesel engine Standard 6904 ~ 8042 (704 ~ 820) [51.7 ~ 60.3]
Radiator
Radiator cap opening pressure kPa (kgf/cm2) [psi] Standard 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1]
Battery
Electrolyte specific gravity (at 20°C [68°F]) Standard 1.280
Alternator
Fan belt tension (when pushed with 98 N (10 kgf) [22 lbf]) mm (in) Standard 8 ~ 13 (0.315 ~ 0.512)
4Y Standard 294 ~ 490 (30 ~ 50) [66 ~ 110]
Fan belt tension (when measured with a
mm (in) 1DZ-II Standard 324 ~ 559 (33 ~ 57) [73 ~ 126]
tension gage (SST))
2Z Standard 324 ~ 559 (33 ~ 57) [73 ~ 126]
Accelerator pedal
Gasoline engine Standard
Pedal angle (at the accelerator OFF) 45°
Diesel engine Standard
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Torque converter end plate set bolt Standard 49.0 ~ 78.4 (500 ~ 800) [36.2 ~ 57.9]
Drive plate set bolt (for torque converter connection) Standard 141.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
Torque converter housing set bolt Standard 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
19-10
CLUTCH (Dry clutch models)
Clutch disc
Rivet installation depth mm (in) Limit 0.3 (0.012)
Clutch cover
Pressure plate height mm (in) Standard 8.8 (0.346)
Release bearing plate height mm (in) Standard 58.5 ~ 59.5 (2.30 ~ 2.34)
Release bearing plate parallelism (inclination) mm (in) Standard 0.4 (0.016) or less
4Y (TWC spec.)·2Z Standard 62.0 (2.440)
Compression spring free length mm (in)
4Y·1DZ-II Standard 58.3 (2.295)
Compression spring squareness mm (in) Standard 2.5 (0.098) or less
Clutch master cylinder
Standard 79.8 (3.142)
Compression spring free length mm (in)
Limit 70.5 (2.776)
Clutch pedal
Height (from toe board: with pad) mm (in) Standard 145 ~ 150 (5.709 ~ 5.906)
Clutch pedal play mm (in) Standard 1 ~ 5 (0.039 ~ 0.197)
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Clutch cover set bolt Standard 14.7 ~ 21.6 (150 ~ 220) [10.8 ~ 15.9]
4Y Standard 78.0 ~ 98.0 (800 ~ 1000) [57.9 ~ 72.4]
125.0 ~ 186.0 (1280 ~ 1900)
1DZ-II Standard
Flywheel set bolt [92.6 ~ 137.5]
125.0 ~ 186.0 (1280 ~ 1900)
2Z Standard
[92.6 ~ 137.5]
Clutch master cylinder set bolt Standard 25.6 ~ 38.4 (270 ~ 400) [19.5 ~ 28.9]
Clutch release cylinder set bolt Standard 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
Release cylinder breather plug Standard 8.8 ~ 12.8 (90 ~ 130) [6.5 ~ 9.4]
CLUTCH (Oil clutch models)
Clutch disc
Effective wear margin of facing (one side) mm (in) Standard 1.3 (0.051)
Clutch cover
Pressure plate height mm (in) Standard 6.1 (0.240)
Release lever tip height mm (in) Standard 55.5 ~ 56.5 (2.19 ~ 2.22)
4Y·1DZ-II Standard 62.0 (2.44)
Compression spring free length mm (in)
4Y (TWC spec.)·2Z Standard 63.5 (2.5)
Compression spring squareness mm (in) Standard 2.5 (0.098) or less
Oil clutch booster
Master cylinder (Wear at the surface in sliding contact with the
mm (in) Limit 0.032 (0.00126)
piston)
Clutch pedal
Height (from toe board: with pad) mm (in) Standard 145 ~ 150 (5.71 ~ 5.91)
Clutch pedal play mm (in) Standard 1 ~ 5 (0.039 ~ 0.197)
19-11
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Clutch cover set bolt Standard 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
Clutch housing cover set bolt Standard 16.0 ~ 24.0 (170 ~ 250) [12.3 ~ 18.1]
78.0 ~ 98.0 (800 ~ 1000)
4Y Standard
[57.9 ~ 72.4]
125.0 ~ 186.0 (1280 ~ 1900)
Flywheel set bolt 1DZ-II Standard
[92.6 ~ 137.5]
125.0 ~ 186.0 (1280 ~ 1900)
2Z Standard
[92.6 ~ 137.5]
Release cylinder bleeder plug Standard 8.8 ~ 12.8 (90 ~ 130) [6.5 ~ 9.4]
Clutch booster set bolt Standard 25.6 ~ 38.4 (270 ~ 400) [19.5 ~ 28.9]
Clutch release cylinder set bolt Standard 16.0 ~ 24.0 (170 ~ 250) [12.3 ~ 18.1]
TORQUE CONVERTER
Transmission cover & control valve ASSY
Standard 132.4 (5.213)
Regulator valve spring free length mm (in)
Limit 125.8 (4.953)
Standard 64.2 (2.528)
Inching valve spring free length (plug side) mm (in)
Limit 61.0 (2.402)
Standard 49.9 (1.965)
Inching valve spring free length (valve side) mm (in)
Limit 47.4 (1.866)
Standard 67.4 (3.390)
Accumulator valve (inner side) mm (in)
Limit 64.0 (3.220)
Standard 127.8 (5.031)
Accumulator valve (outer side) mm (in)
Limit 121.4 (4.780)
Standard 59.8 (2.354)
F/R shift valve mm (in)
Limit 56.8 (2.236)
Standard 59.8 (2.354)
Safety valve mm (in)
Limit 56.8 (2.236)
Torque converter and oil pump
Oil pump driven gear to pump body clearance mm (in) Limit 0.3 (0.012)
Pump body to each gear clearance mm (in) Limit 0.042 ~ 0.080 (0.002 ~ 0.003)
Transmission
Main shaft thrust clearance mm (in) Standard 0.10 ~ 0.24 (0.004 ~ 0.009)
Output shaft thrust clearance mm (in) Standard 0.10 ~ 0.49 (0.004 ~ 0.019)
Counter gear thrust clearance mm (in) Standard 0.10 ~ 0.54 (0.004 ~ 0.021)
Each clutch shaft to seal ring clearance mm (in) Limit 0.2 (0.008)
Standard 2.6 (0.102)
Clutch disc thickness mm (in)
Limit 2.3 (0.091)
Standard 2.0 (0.079)
Clutch plate thickness mm (in)
Limit 1.8 (0.071)
Standard 3.4 (0.134)
Camber plate curve height mm (in)
Limit 3.1 (0.122)
4-disc type Standard 0.8 ~ 1.4 (0.031 ~ 0.055)
Clutch disc to backing plate clearance mm (in)
5-disc type Standard 1.0 ~ 1.6 (0.039 ~ 0.063)
Standard 63.4 (2.496)
Clutch piston return spring free length mm (in)
Limit 58.5 (2.303)
19-12
Measurement and tests
4Y Standard 2050
Stall speed rpm 1DZ-II Standard 2100
2Z Standard 2050
At idle Standard 735 ~ 1324 (7.5 ~ 13.5) [106.6 ~ 192.0]
Main pressure kPa (kgf/cm2) [psi]
2000 rpm Standard 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]
At idle Standard 735 ~ 1324 (7.5 ~ 13.5) [106.6 ~ 192.0]
Clutch pressure kPa (kgf/cm2) [psi]
2000 rpm Standard 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]
Torque converter pressure
(outlet pressure) kPa (kgf/cm2) [psi] 2000 rpm Standard 50 ~ 540 (0.5 ~ 5.5) [7.3 ~ 78.3]
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Stator shaft set bolt Standard 21.0 (214) [15.5]
Transmission cover (upper cover) set bolt Standard 21.0 (214) [15.5]
Engine mounting nut Standard 53.2 ~ 98.0 (550 ~ 1000) [39.8 ~ 72.3]
Front insulator set bolt Standard 68.0 ~ 102.0 (700 ~ 1050) [50.6 ~ 76.0]
Torque converter housing set bolt Standard 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
Drive plate set bolt 4Y Standard 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]
(for connecting to engine crank shaft) 1DZ-II, 2Z Standard 76.4 ~ 93.1 (780 ~ 950) [56.4 ~ 68.7]
Drive plate set bolt (for connecting to torque carver) Standard 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
TRANSMISSION ASSY
Transmission ASSY
Countershaft ASSY thrust clearance mm (in) Standard 0.03 ~ 0.43 (0.001 ~ 0.017)
Speed shaft ASSY
Reverse idle gear thrust clearance mm (in) Standard 0.15 ~ 0.40 (0.0059 ~ 0.0157)
Reverse idle gear radial clearance mm (in) Standard 0.010 ~ 0.052 (0.00039 ~ 0.00205)
Reverse idle gear thrust washer thickness mm (in) Limit 2.7 (0.106)
Reverse idle gear inside diameter mm (in) Limit 49.1 (1.933)
Speed shaft journal outside diameter mm (in) Limit 41.9 (1.886)
19-13
Counter shaft ASSY
2nd gear thrust clearance mm (in) Standard 0.15 ~ 0.40 (0.0059 ~ 0.0157)
Forward gear thrust clearance mm (in) Standard 0.15 ~ 0.40 (0.0059 ~ 0.0157)
1st gear·reverse gear radial clearance mm (in) Standard 0.016 ~ 0.057 (0.0006 ~ 0.0022)
2nd gear·forward gear radial clearance mm (in) Standard 0.018 ~ 0.062 (0.0007 ~ 0.0024)
2nd gear thrust washer thickness mm (in) Limit 5.9 (0.232)
Forward gear thrust washer thickness mm (in) Limit 5.9 (0.232)
Reverse gear thrust clearance mm (in) Standard 0.10 ~ 0.45 (0.0039 ~ 0.0177)
1st gear thrust clearance mm (in) Standard 0.10 ~ 0.45 (0.0039 ~ 0.0177)
1st gear·reverse
Limit 37.9 (1.492)
gear
Countershaft journal outside diameter mm (in)
2nd gear·forward
Limit 29.9 (1.177)
gear
1st gear·reverse gear inside diameter mm (in) Limit 46.1 (1.815)
2nd gear·forward gear inside diameter mm (in) Limit 38.1 (1.500)
Shift fork to hub grease clearance mm (in) Limit 1.0 (0.039)
Standard 0.95 ~ 1.75 (0.0374 ~ 0.0689)
1st gear·2nd gear
Synchronizer ring to gear clearance Limit 0.6 (0.024)
mm (in) Forward gear· Standard 1.12 ~ 1.88 (0.044 ~ 0.074)
reverse gear Limit 0.6 (0.024)
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Engine mounting nut Standard 53.2 ~ 98.0 (550 ~ 1000) [39.2 ~ 72.3]
68.0 ~ 102.0 (700 ~ 1050)
Front insulator set bolt Standard
[50.2 ~ 75.3]
Dry clutch Standard 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.5]
Clutch housing set bolt
Oil clutch Standard 32.3 ~ 48.5 (330 ~ 500) [23.8 ~ 35.8]
19-14
DIFFERENTIAL
Differential
1·2·K2·K3 ton
Standard 0.2 ~ 0.3 (0.008 ~ 0.012)
Ring gear backlash mm (in) series
3·J3.5 ton series Standard 0.3 ~ 0.4 (0.012 ~ 0.016)
Standard 26.12 (1.028)
1·K2 ton series
Limit 26.22 (1.032)
Standard 28.12 (1.107)
2·K3 ton series
Limit 28.22 (1.111)
Standard 22.12 (0.871)
Differential pinion bore mm (in) 3 ton series
Limit 22.22 (0.875)
Standard 24.67 (0.971)
J3.5 ton series
Limit 24.77 (0.975)
Standard 22.31 (0.878)
LSD
Limit 22.41 (0.882)
Standard 26.00 (1.024)
1·K2 ton series
Limit 25.75 (1.014)
Pinion shaft outside diameter mm (in)
Standard 28.00 (1.102)
2·K3 ton series
Limit 27.75 (1.093)
Standard 22.20 (0.874)
LSD
Limit 21.95 (0.864)
Standard 22.00 (0.866)
Spider outside diameter mm (in) 3 ton series
Limit 21.75 (0.856)
Standard 24.50 (0.965)
J3.5 ton series
Limit 24.25 (0.955)
Standard 1.6 (0.063)
Side gear thrust washer thickness mm (in)
Limit 1.3 (0.051)
Standard 1.0 (0.039)
1·K2 ton series
Limit 0.7 (0.063)
Pinion thrust washer thickness mm (in)
2·3·K3·J35 ton Standard 1.6 (0.028)
series Limit 1.3 (0.051)
1·K2·3·J3.5 ton
Drive pinion bearing starting torque Standard 8.5 ~ 13.0 (90 ~ 135) [6.3 ~ 9.6]
series
N·m (kgf·cm) [ft·lbf]
2·K3 ton series Standard 8.5 ~ 15.0 (90 ~ 155) [6.3 ~ 11.1]
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Drive pinion lock nut Standard 343 ~ 392 (3500 ~ 4000) [253.1 ~ 289.2]
Drive pinion rear cover set bolt Standard 17.3 ~ 21.7 (176 ~ 221) [12.8 ~ 16.0]
Differential carrier set bolt Standard 32.4 ~ 48.6 (330 ~ 496) [23.9 ~ 35.9]
Ring gear set bolt Standard 127.4 ~ 176.4 (1300 ~ 1800) [94.0 ~ 130.1]
3·J3.5 ton series Standard 86.2 ~ 102.9 (879 ~ 1049) [63.6 ~ 75.9]
Differential carrier upper case set bolt
LSD Standard 26 ~ 32 (270 ~ 330) [19.5 ~ 23.9]
117.7 ~ 137.3 (1200.0 ~ 1400.0)
Differential case bearing cap set bolt Standard
[86.8 ~ 101.3]
Differential front cover set bolt Standard 13.5 ~ 24.5 (138 ~ 250) [10.0 ~ 18.1]
Front axle reactive force bolt Standard 294 ~ 343 (3000 ~ 3500) [216.9 ~ 253.1]
19-15
1·2·K2·K3 ton
Standard 68.6 ~ 98.0 (700 ~ 1000) [50.6 ~ 72.3]
Axle shaft set bolt series
3·J3.5 ton series Standard 107 ~ 140 (1100 ~ 1400) [78.9 ~ 103.3]
1·2·K2·K3 ton
Standard 108 ~ 159 (1100 ~ 1600) [79.7 ~ 117.3]
Front axle ASSY set bolt series
3·J3.5 ton series Standard 127 ~ 190 (1300 ~ 1900) [93.4 ~ 140.2]
Front axle bracket set nut Standard 235 ~ 294 (2400 ~ 3000) [173.4 ~ 216.9]
FRONT AXLE
Front axle hub
1·K2 ton series Standard 24.5 ~ 99.0 (2.5 ~ 10.1) [5.5 ~ 22.3]
Front axle bearing starting force N (kgf) [lbf]
Other Standard 19.6 ~ 78.4 (2.0 ~ 8.0) [4.4 ~ 17.6]
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Nut lock bolt 3·J3.5 ton series Standard 15.0 ~ 22.0 (153 ~ 224) [11 ~ 16]
Nut lock screw 1·2·K2·K3 ton series Standard 2.0 ~ 5.2 (20 ~ 53) [1.4 ~ 3.8]
107.0 ~ 140.0 (1100 ~ 1400)
3·J3.5 ton series Standard
Axle shaft set bolt [78.9 ~ 103.3]
Other Standard 68.6 ~ 98.0 (700 ~ 1000) [50.6 ~ 72.3]
1 ton series Standard 49.0 ~ 68.6 (500 ~ 700) [36.2 ~ 50.6]
Divided rim set nut (1·2 ton series only) 118.0 ~ 176.0 (1200 ~ 1800)
2 ton series Standard
[87.1 ~ 130.1]
1·K3 ton series· 118.0 ~ 196.0 (1200 ~ 2000)
Standard
Divided rim specification [87.1 ~ 144.6]
Front wheel hub nut 294.0 ~ 588.0 (3000 ~ 6000)
3·J3.5 ton series Standard
(single tire) [216.9 ~ 433.9]
177.0 ~ 392.0 (1800 ~ 4000)
Other Standard
[130.6 ~ 289.2]
294.0 ~ 588.0 (3000 ~ 6000)
3·J3.5 ton series Standard
Front wheel hub nut [216.9 ~ 433.9]
(double tire) 177.0 ~ 392.0 (1800 ~ 4000)
Other Standard
[130.6 ~ 289.2]
REAR AXLE
Rear axle ASSY
Rear axle ASSY front to rear clearance mm (in) Standard 1.0 (0.039) or less
Rear axle center pin bushing inside diameter mm (in) Limit 52.0 (2.047)
Rear axle hub and steering knuckle
1 ton series Standard 15 ~ 39 (1.5 ~ 4.0) [3.3 ~ 8.5]
Rear axle hub starting force N (kgf) [lbf] K2·K3 ton series Standard 20 ~ 58 (2.0 ~ 5.9) [4.4 ~ 13.0]
2·3·J3.5 ton series Standard 15 ~ 44 (1.5 ~ 4.5) [3.3 ~ 9.9]
King pin outside diameter mm (in) Limit 27.8 (1.094)
Steering knuckle starting force N (kgf) [lbf] Standard 19.3 (2.0) [4.4] or less
Rear axle cylinder
Rear axle cylinder piston rod 1 ton series Limit 39.92 (1.5717)
mm (in)
outside diameter Other Limit 49.92 (1.9654)
Rear axle cylinder piston rod bend mm (in) Limit 0.5 (0.020)
19-16
1 ton series Limit 70.35 (2.7697)
2·K2·K3 ton series Limit 80.35 (3.1634)
Rear axle cylinder inside diameter mm (in)
3 ton series Limit 84.40 (3.3228)
J3.5 ton series Limit 87.40 (3.4409)
Rear wheel alignment
1.0 ton Standard 1910 (75.2)
1.5 ton Standard 1990 (78.3)
1.75 ton Standard 2010 (79.1)
2.0 ton Standard 2200 (86.6)
2.5 ton Standard 2280 (89.8)
Minimum turning radius mm (in)
3.0 ton Standard 2430 (95.7)
K2.0 ton Standard 2040 (80.3)
K2.5 ton Standard 2090 (82.3)
K3.0 ton Standard 2130 (83.9)
J3.5 ton Standard 2490 (98.0)
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Axle bracket cap set bolt Standard 117.7 ~ 166.7 (1200 ~ 1700) [86.8 ~ 123.0]
King pin lock bolt and lock nut Standard 44.1 ~ 53.9 (450 ~ 550) [32.6 ~ 39.8]
1 ton series Standard 29.5 ~ 44.0 (300 ~ 450) [21.8 ~ 32.5]
Divided rim bolt set nut K2 ton series Standard 78.5 ~ 117.5 (800 ~ 1200) [57.9 ~ 86.7]
2·3·J3.5 ton series Standard 49.0 ~ 68.5 (500 ~ 700) [36.2 ~ 50.5]
Rear axle cylinder rod guide set nut Standard 88 ~ 118 (900 ~ 1200) [65.1 ~ 86.8]
Rear axle cylinder set bolt Standard 166.7 ~ 215.8 (1700 ~ 2200) [123.0 ~ 159.1]
1 ton Divided rim Standard 89.0 ~ 157.0 (900 ~ 1600) [65.7 ~ 115.8]
series Side ring rim Standard 89.0 ~ 157.0 (900 ~ 1600) [65.7 ~ 115.8]
2 ton Divided rim Standard 118.0 ~ 196 (1200 ~ 2000) [87.1 ~ 144.6]
series Side ring rim Standard 177.0 ~ 392 (1800 ~ 4000) [130.6 ~ 289.2]
Hub nut
3·K2 ton Divided rim Standard 118.0 ~ 196 (1200 ~ 2000) [87.1 ~ 144.6]
series Side ring rim Standard 118.0 ~ 196 (1200 ~ 2000) [87.1 ~ 144.6]
K3·J3.5
Side ring rim Standard 118.0 ~ 196 (1200 ~ 2000) [87.1 ~ 144.6]
ton series
Tie rod end pin lock nut Standard 49.0 ~ 73.5 (503 ~ 750) [36.2 ~ 54.2]
STEERING
Hydrostatic steering valve ASSY
1 ton series Standard 7400 ~ 7900 (75 ~ 80) [1073 ~ 1146]
Relief pressure
(Vehicle L/SAS) kPa (kgf/cm2) [psi] 2·3 ton series Standard 8000 ~ 8500 (82 ~ 87) [1160 ~ 1233]
J3.5 ton series Standard 8300 ~ 8800 (85 ~ 90) [1204 ~ 1276]
1 ton series Standard 7500 ~ 8000 (76 ~ 82) [1088 ~ 1160]
Relief pressure
(Vehicle W/SAS) kPa (kgf/cm2) [psi] 2·3·K2·K3 ton series Standard 8100 ~ 8600 (83 ~ 88) [1175 ~ 1247]
J3.5 ton series Standard 8400 ~ 8900 (86 ~ 91) [1218 ~ 1291]
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Steering wheel set nut Standard 24.5 ~ 44.1 (250 ~ 450) [18.1 ~ 32.6]
Steering valve ASSY set bolt Standard 29.4 ~ 39.2 (300 ~ 400) [21.7 ~ 28.9]
Steering valve end cap set screw Standard 23 ~ 27 (235 ~ 275) [17.0 ~ 19.9]
19-17
BRAKE
Front brake (1 ton series)
Hold down spring free length mm (in) Standard 25.5 (1.004)
Standard 102.2 (4.024)
Anchor to shoe spring free length mm (in)
Limit No clearance between coil turns
Strut to shoe spring free length mm (in) Standard 19.7 (0.776)
Standard 99.4 (3.913)
Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 4.9 (0.193)
Brake lining length mm (in)
Limit 1.0 (0.039)
Wheel cylinder to piston clearance mm (in) Limit 0.125 (0.00492)
Standard 254.0 (10.00)
Brake drum inside diameter mm (in)
Limit 256.0 (10.08)
Front brake (2·3·K2·K3 ton series)
Standard 34.5 (1.358)
Hold down spring free length mm (in)
Limit 31.3 (1.232)
Standard 124.5 (4.902)
Actuator spring free length mm (in)
Limit No clearance between coil turns
Standard 106 (4.17)
Anchor to shoe spring free length mm (in)
Limit No clearance between coil turns
Standard 23 (0.91)
Strut to shoe spring free length mm (in)
Limit 20 (0.79)
Standard 86 (3.39)
Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 7.0 (0.276)
Brake lining thickness mm (in)
Limit 2.0 (0.079)
Wheel cylinder to piston clearance mm (in) Limit 0.145 (0.00571)
Standard 310.0 (12.20)
Brake drum inside diameter mm (in)
Limit 312.0 (12.28)
Front brake (J3.5 ton series)
Hold down spring free length mm (in) Standard 44.0 (1.732)
Anchor to shoe spring free length Standard 138.2 (5.441)
mm (in)
(On the side of lining W/ pin) Limit No clearance between coil turns
Anchor to shoe spring free length Standard 121.2 (4.772)
mm (in)
(On the side of lining W/O pin) Limit No clearance between coil turns
Strut to shoe spring free length mm (in) Standard 31.4 (1.236)
Standard 125.4 (4.937)
Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 5.6 (0.220)
Brake lining thickness mm (in)
Limit 1.0 (0.039)
Wheel cylinder to piston clearance mm (in) Limit 0.15 (0.00492)
Standard 317.5 (12.50)
Brake drum inside diameter mm (in)
Limit 319.5 (12.58)
19-18
Parking brake
J3.5 ton series Standard 225 ~ 265 (23 ~ 27) [51 ~ 60]
Parking brake lever operating force N (kgf) [lbf]
Others Standard 175 ~ 215 (18 ~ 22) [39 ~ 48]
Foot parking brake operating force J3.5 ton series Standard 142 ~ 166 (14.5 ~ 17.0) [32 ~ 37]
N (kgf) [lbf]
(when SST is used) Others Standard 112 ~ 136 (11.4 ~ 14.0) [25 ~ 31]
Foot parking brake operating force J3.5 ton series Standard 235 ~ 275 (23.0 ~ 27.0) [53 ~ 62]
N (kgf) [lbf]
(when SST is not used) Others Standard 186 ~ 226 (19.0 ~ 23.0) [42 ~ 51]
Brake pedal
Brake pedal height (from toe board: with pad) mm (in) Standard 145 ~ 150 (5.709 ~ 5.906)
Brake pedal play mm (in) Standard 1 ~ 5 (0.039 ~ 0.197)
Brake pedal depressed height (with pad) mm (in) Standard 90 (3.54) or more
Brake master cylinder push rod play mm (in) Standard 1 (0.039)
Inching pedal play mm (in) Standard 1 ~ 3 (0.039 ~ 0.118)
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Backing plate set bolt Standard 137 ~ 210 (1400 ~ 2140) [101 ~ 155]
1 ton series Standard 7.85 ~ 11.8 (80 ~ 120) [5.8 ~ 8.7]
Wheel cylinder set bolt 2·3·K2·K3 ton series Standard 14.7 ~ 19.6 (150 ~ 200) [10.8 ~ 14.5]
J3.5 ton series Standard 17.7 ~ 26.5 (180 ~ 270) [13.1 ~ 19.6]
Brake master cylinder set nut Standard 6.8 ~ 15.8 (69 ~ 161) [5.0 ~ 11.7]
MATERIAL HANDLING SYSTEM
Natural drop test
Natural drop mm (in) Limit 45 (1.77)
Natural forward tilt test
1 ton series Standard 15 (0.59) or less
Natural forward tilt mm (in) 2·K2 ton series Standard 20 (0.79) or less
3·K3·J3.5 ton series Standard 25 (0.98) or less
Oil leak test
Lift cylinder oil leak amount cm3 (in3) Standard 8 (0.49) or less
Tilt cylinder oil leak amount
(total for lift and tilt) cm3 (in3) Standard 16 (0.98) or less
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Tank cover Standard 9.81 ~ 14.7 (100 ~ 150) [7.24 ~ 10.85]
Return filter Standard 6.9 ~ 16.1 (70 ~ 160) [5.09 ~ 11.88]
19-19
MAST
Mast adjustment (V mast)
Inner mast roller clearance mm (in) Standard 0 ~ 0.6 (0 ~ 0.024)
Mast rollers
Outer mast roller clearance mm (in) Standard 0 ~ 0.6 (0 ~ 0.024)
Upper and lower lift roller clearance mm (in) Standard 0 ~ 0.6 (0 ~ 0.024)
Lift bracket
Middle lift roller clearance mm (in) Standard 0.6 ~ 0.8 (0.024 ~ 0.031)
rollers
Side roller clearance mm (in) Standard 0 ~ 0.6 (0 ~ 0.024)
Mast strip to inner mast clearance mm (in) Standard 0 ~ 0.6 (0 ~ 0.024)
Other Limit 1.5 (0.059)
Mast strip thickness mm (in)
J3.5 ton series Limit Until the oil dimples are worn away
Fork
Fork front end misalignment mm (in) Limit 10 (0.39)
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Chain adjusting nut Standard 64.0 (653) [47.2]
Tilt cylinder front pin set bolt Standard 66.0 ~ 154.0 (673 ~ 1570) [48.7 ~ 113.6]
138.0 ~ 322.0 (1407 ~ 3282)
Mast support set bolt Standard
[101.8 ~ 237.4]
CYLINDER
Lift cylinder (V)
1 ton series Standard 32 (1.26)
~ H3000 Limit 31.92 (1.2567)
1 ton series Standard 35 (1.38)
H3300 ~ Limit 34.92 (1.3748)
2·K2 ton series Standard 35 (1.38)
~ H3000 Limit 34.92 (1.3748)
2·K2 ton series Standard 40 (1.57)
Piston rod outside diameter mm (in)
H3300 ~ Limit 39.92 (1.5717)
3·K3 ton series Standard 40 (1.57)
~ H3000 Limit 39.92 (1.5717)
3·K3 ton series Standard 45 (1.77)
H3300 ~ Limit 44.92 (1.7685)
Standard 45 (1.77)
J3.5 ton series
Limit 44.92 (1.7685)
19-20
Standard 45 (1.77)
1 ton series
Limit 45.20 (1.7795)
Standard 50 (1.97)
2·K2 ton series
Limit 50.20 (1.9764)
Cylinder bore mm (in)
Standard 55 (2.17)
3·K3 ton series
Limit 55.35 (2.1791)
Standard 60 (2.36)
J3.5 ton series
Limit 60.35 (2.3760)
Piston rod bend mm (in) Limit 2.0 (0.079)
Rear lift cylinder (FV·FSV)
Standard 32 (1.26)
FV
Limit 31.92 (1.2567)
1 ton series
Standard 35 (1.38)
FSV
Limit 34.92 (1.3748)
Standard 35 (1.38)
FV
Piston rod outside diameter 2·K2 ton Limit 34.92 (1.3748)
mm (in) series Standard 40 (1.57)
FSV
Limit 39.92 (1.5717)
Standard 40 (1.57)
FV
3·K3·J3.5 ton Limit 39.92 (1.5717)
series Standard 45 (1.77)
FSV
Limit 44.92 (1.7685)
Standard 45 (1.77)
1 ton series
Limit 45.20 (1.7685)
Standard 50 (1.97)
2·K2 ton series
Limit 50.20 (1.9764)
Cylinder bore mm (in)
Standard 55 (2.17)
3·K3 ton series
Limit 55.35 (2.1791)
Standard 60 (2.36)
J3.5 ton series
Limit 60.35 (2.3760)
Piston rod bend mm (in) Limit 2.0 (0.079)
Front lift cylinder (FV·FSV)
Standard 50 (1.97)
1 ton series
Limit 49.92 (1.9654)
Standard 50 (1.97)
2·K2 ton series
Limit 49.92 (1.9654)
Piston rod outside diameter mm (in)
Standard 60 (2.36)
3·K3 ton series
Limit 59.91 (2.3587)
Standard 60 (2.36)
J3.5 ton series
Limit 59.91 (2.3587)
19-21
Standard 70 (2.76)
1 ton series
Limit 70.35 (2.7697)
Standard 75 (2.95)
2·K2 ton series
Limit 75.35 (2.9665)
Cylinder bore mm (in)
Standard 85 (3.35)
3·K3 ton series
Limit 85.40 (3.3622)
Standard 90 (3.54)
J3.5 ton series
Limit 90.40 (3.5591)
Piston rod bend mm (in) Standard 2.0 (0.0079)
Tilt cylinder
Standard 70 (2.756)
Cylinder bore mm (in)
Limit 70.35 (2.7697)
Standard 30 (1.181)
Piston rod outside diameter mm (in)
Limit 29.92 (1.1780)
Piston rod bend mm (in) Limit 0.5 (0.079)
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
1 ton series Standard 225 (2290) [166.0]
2·K2 ton series Standard 250 (2550) [184.4]
V
3·K3 ton series Standard 275 (2800) [202.9]
J3.5 ton series Standard 353 (3600) [260.4]
1 ton series Standard 225 (2290) [166.0]
2·K2 ton series Standard 250 (2550) [184.4]
Lift cylinder cover FV
3·K3 ton series Standard 275 (2800) [202.9]
J3.5 ton series Standard 353 (3600) [260.4]
1 ton series Standard 225 (2290) [166.0]
2·K2 ton series Standard 250 (2550) [184.4]
FSV
3·K3 ton series Standard 275 (2800) [202]
J3.5 ton series Standard 353 (3600) [260.4]
Front lift cylinder cover Standard 392 (4000) [289.2]
88.0 ~ 132.0 (897 ~ 1346)
Tilt cylinder joint set nut Standard
[64.9 ~ 97.4]
Tilt cylinder cover Standard 353 (3600) [260.5]
66.0 ~ 154.0 (673 ~ 1570)
Tilt cylinder front pin set bolt Standard
[48.7 ~ 113.6]
36.0 ~ 85.4 (373 ~ 871)
Tilt cylinder rear pin set bolt Standard
[27.0 ~ 63.0]
19-22
OIL PUMP
Oil pump ASSY (4Y·1DZ-II)
Side plate thickness mm (in) Limit 2.927 (0.1152)
Gear shaft outside diameter mm (in) Limit 20.99 (0.8264)
Gear plate inside surface flaw depth mm (in) Limit 0.2 (0.0079)
Oil pump ASSY (4Y (low-noise specification))
Side plate thickness mm (in) Limit 2.927 (0.1152)
Gear shaft outside diameter mm (in) Limit 20.961 (0.8252)
Gear plate inside surface flaw depth mm (in) Limit 0.2 (0.0079)
Center bushing thickness mm (in) Limit 41.38 (1.6291)
Oil pump ASSY (2Z)
Bushing inside diameter mm (in) Limit 22.23 (0.8752)
Side plate thickness mm (in) Limit 2.70 (0.1063)
Gear shaft outside diameter mm (in) Limit 21.95 (0.8642)
Gear plate inside surface flaw depth mm (in) Limit 0.15 (0.0059)
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
24.0 ~ 33.0 (245 ~ 337)
Oil pump ASSY set bolt Standard
[17.73 ~ 24.38]
OIL CONTROL VALVE
Oil control valve
1 ton +1.7 +17 +247
Standard 17.8 (182 0) [2581 0]
series 0
Lift
+1.7 +17 +247
Other Standard 18.7 (191 0) [2712 0]
Relief pressure 0
MPa (kgf/cm2) [psi] 1 ton +1.7 +17 +247
Standard 11.8 (120 0) [1711 0]
series 0
Tilt
+1.7 +17 +247
Other Standard 14.7 0 (150 0) [2132 0]
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Oil control valve ASSY set bolt Standard 21.6 ~ 50.4 (220 ~ 514) [15.92 ~ 37.19]
SAS / OPS
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
SAS/OPS controller set bolt Standard 5.5 (56.1) [4.1]
Tire angle sensor set bolt Standard 10 ~ 16 (100 ~ 160) [7.2 ~ 12.0]
Swing lock cylinder pin set bolt Standard 29 (296) [21.4]
Tilt angle sensor set bolt Standard 17 (173) [12.5]
Load sensor Standard 22 ~ 26 (224 ~ 265) [16.2 ~ 19.2]
Speed sensor set bolt Standard 3 ~ 7 (31 ~ 71) [2.2 ~ 5.2]
Other Standard 15 ~ 25 (153.0 ~ 254.9) [11.1 ~ 18.4]
V
Fork height switch ASSY set bolt J3.5 ton series Standard 27 (275.3) [19.9]
FV·FSV Standard 27 (275.3) [19.9]
Published by
1st Printing: Aug. 2006
Pub. No. CE048
Printed in Japan
C
FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT 8FG/
8FD10~30 series. Please use this manual for providing quick, correct servicing of the
corresponding forklift models.
This manual deals with the above models as of August 2006. Please understand that
disagreement can take place between the descriptions in the manual and actual
vehicles due to change in design and specifications. Any change or modifications
thereafter will be informed by Toyota Industrial Equipment Parts & Service News.
For the service procedures of the mounted engine, read the repair manuals listed
below as reference together with this manual.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT 8FG/8FD10~30
VOL.1 REPAIR MANUAL (No. CE048)
TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE
REPAIR MANUAL (No. CE663)
TOYOTA INDUSTRIAL EQUIPMENT 1DZ-II ENGINE
REPAIR MANUAL (No. CE664)
TOYOTA INDUSTRIAL EQUIPMENT 2Z ENGINE
REPAIR MANUAL (No. CE665)
SEC INDEX_vol2.fm 1 ページ ２００６年８月３１日 木曜日 午後９時１６分
SECTION INDEX
NAME SECTION
GENERAL 0
ENGINE 1
CLUTCH 2
TORQUE CONVERTER & TRANSMISSION 3
MANUAL TRANSMISSION 4
PROPELLER SHAFT 5
DIFFERENTIAL 6
FRONT AXLE 7
REAR AXLE 8
STEERING 9
BRAKE 10
BODY 11
MATERIAL HANDLING SYSTEM 12
MAST 13
CYLINDER 14
OIL PUMP 15
OIL CONTROL VALVE 16
MINI LEVER·JOYSTICK 17
SAS/OPS 18
SST LIST·SERVICE STANDARDS LIST 19
MULTIFUNCTION DISPLAY (OPT) 20
ELECTRICAL SYSTEM TROUBLESHOOTING 21
WIRING DIAGRAM E
20-1
MULTIFUNCTION DISPLAY (OPT)
Page
GENERAL.............................................................20-2
0
GENERAL FUNCTIONS.......................................20-3
1
GENERAL .............................................................20-3
DISPLAY SCREEN AND OPERATION
2
PROCEDURE ......................................................20-4 3
ADMINISTRATOR FUNCTIONS ...............................20-9
4
MASK FUNCTIONS............................................20-13
5
GENERAL ...........................................................20-13
PASSWORD ........................................................20-14
6
ANALYZER .........................................................20-17 7
TUNING ..............................................................20-45 8
OPTION SET .......................................................20-56 9
MATCHING..........................................................20-58
10
TIRE CONSTANT SET ..........................................20-66
11
ENGINE IDLE SPEED ADJUSTMENT
(4Y-E ENGINE VEHICLE) ....................................20-68 12
LCD CONTRAST ADJUSTMENT ...........................20-69
13
METER START ....................................................20-70
14
MULTIFUNCTION DISPLAY ASSY....................20-72
DISASSEMBLY·REASSEMBLY .............................20-72
15
16
17
18
19
20
21
E
20-2
GENERAL
The multifunction display is capable of indicating various types of vehicle information by switching the screen
according to the displayed contents.
Name of Each Part
(5)
(1) (2) (3) (4) (1) (2) (3) (4)
STD model/DX model DX model with travel and load handling control
Display specification
No.
STD model DX model DX model (with travel and load handling control)
(1) Lower switch Lower switch Low-speed setting switch/lower switch
(2) Left switch
(3) Right switch
(4) Meter display changeover switch
(5) Multiplex screen display area
20-3
GENERAL FUNCTIONS
GENERAL
General functions are the functions normally used by an operator or an administrator.
Also, there are three models for the multifunction display, and each has different functions available. 0
General Function List 1
c: Operator can use
✩: Administrator can use (Protected by password)
2
—: No setting
Model Display specification
3
STD model
DX model
Without travel and With travel and
4
Functions load handling control load handling control
Digital speedometer c c c
5
Torque converter oil temperature indicator *1
Planned maintenance hour warning indicator
c
c
c
c
c
c
6
Status display
Load meter
Low speed setting indicator
—
—
c
—
c
c
7
Traveling control indicator *1 — — c
8
Odometer c c c
Integrating meters Trip meter c c c 9
Planned maintenance hour meter c c c
Diagnostic code display c c c 10
Parking brake ON warning c c c
Warning Parking brake OFF warning c c c 11
Torque converter oil temperature warning *1 c c c
Over speed alarm — c c 12
Low speed level setting — — c
Traveling speed limiter level setting — — ✩ 13
Over speed alarm setting — c c
Level setting
Load meter zero point adjustment — ✩ ✩
14
Planned maintenance hour meter setting ✩ ✩ ✩
Menu lock setting — ✩ ✩
15
Output limit during overheating *2 c c c
16
*1: T/C vehicle only
*2: 4Y-E engine vehicle only 17
18
19
20
21
E
20-4
DISPLAY SCREEN AND OPERATION PROCEDURE
Key ON Initial Screen
Displayed for about 1 second when turning the ignition key switch
on.
General Screen (Meter Start not Performed)
If the indicator shown in the left illustration is displayed in the
general screen, perform the meter start. (Refer to page 20-70)
Unless the meter start is performed, adding to the odometer, trip
meter, and maintenance hour meter will not start.
General Screen (T/C Vehicle)
• Digital speedometer
Traveling speed is displayed in digital for every 1 km/h.
• Torque converter oil gauge
Oil temperature of the torque converter is displayed in 10
levels.
General Screen (M/T Vehicle)
• Digital speedometer
Traveling speed is displayed in digital for every 1 km/h.
20-5
Meter Display Screen
(1) With travel and As you press switch (4) on the general screen, the display changes
load handling control over in sequence of odometer → trip meter → maintenance hour
meter → general screen.
0
1
(1) (2) (3) (4) 2
• Odometer
Displays cumulative traveling distance.
3
• Trip meter
Displays cumulative distance of a trip traveling. 4
Pressing switch (1) for more than 2 seconds will reset the
meter. 5
6
7
• Maintenance hour meter
Displays set value and current value of the maintenance hour
8
meter.
9
10
11
12
Load Meter (DX Model/DX Model with Travel and Load
Handling Control Only) 13
• Pressing the load display switch on the lift lever will display
current live load on the screen. 14
In the joystick specification (OPT) vehicle, the fork automatic
leveling stop switch is used. 15
16
17
• The arrow is displayed at a high lift, and flashing the value will
indicate that the display is not correct. 18
• Less than 100 kg will be displayed as 0.00 t.
• If it is displayed as -0.00 t, it indicates that zero point is slightly 19
misaligned to minus side.
• Since it detects the lift cylinder pressure and performs only
simple measurement, do not use it for judging overloading
20
when it is around permissible load.
21
E
20-6
• When there is an abnormality in the load sensor, the screen
flashes as shown in the illustration.
Indicator Display
• Low-speed setting set indicator (DX model with travel and load
handling control only)
As you press switch (1), the indicator is turned on/off, and the
low-speed setting control is activated when the indicator is on.
Level setting is carry out in the low-speed setting screen.
• Travel and load handling control indicator (only for DX model
T/C vehicle with travel and load handling control)
Displayed when the travel and load handling control is
activated, indicating that the travel and load handling control is
operating.
When lifting height/load sensing traveling speed limit function
is off.
(Lifting height/load sensing sudden acceleration prevention
function can be operated.)
• Maintenance indicator
When the time set in the maintenance hour meter comes, it will
notify with the indicator display and alarm.
20-7
Warning Display
• Diagnosis display
When the diagnosis is performed, it displays the indicator and
detected error code and sounds an alarm. (Only the errors that
the multifunction display can recognize will be indicated.)
• Parking brake ON warning
If you try to drive with the parking brake on, the indicator is
displayed and an alarm sounds.
• Parking brake reminder warning
If you turn the ignition key switch off or leave the driving seat
without applying the parking brake, an alarm sounds. (There
will be no indication on the display.)
• Torque converter oil temperature warning (T/C vehicle only)
When the torque converter oil temperature reaches the level 9
(approx. 120°C (248°F)), it warns by flashing the indicators all
the way to the level 9. If the oil temperature becomes approx.
140°C (284°F) or above, all the indicators will flash.
• Over speed alarm (only for DX model/DX model with travel
and load handling control)
If the set traveling speed is exceeded, the traveling speed
display will invert and start flashing, and an alarm sounds.
20-8
Setting Screen (DX Model/DX Model with Travel and Load
(1) With travel and Handling Control Only)
load handling control In DX model, pressing switch (1) on the general screen for more
than 2 seconds will display the setting menu screen.
(If the menu lock is set to "enable" in the administrator function, the
setting menu screen will not be displayed.)
(1) (2) (3) (4)
• Setting menu screen (DX model)
Select an item with switch (1), and press switch (4) to display
each setting screen.
• Setting menu screen (DX model with travel and load handling
control)
Select an item with switch (1), and press switch (4) to display
each setting screen.
• Low speed setting screen (only for DX model with travel and
load handling control)
Sets the level of the low speed setting.
If you set it to the level 8, low speed setting function will be
disabled.
Switch (2): Setting level down
Switch (3): Setting level up
Switch (4): Returning to menu screen
• Over speed alarm setting screen (DX model/DX model with
travel and load handling control only)
Sets the traveling speed for the over speed alarm.
Switch (2): Setting traveling speed down
Switch (3): Setting traveling speed up
Switch (4): Returning to menu screen
20-9
ADMINISTRATOR FUNCTIONS
Administrators can set the vehicle's performance and each function.
Administrator functions are protected with password so that the general operators cannot change those functions.
Administrator Password
Note:
• Always operate switches displayed on the display with a finger tip. If a sharp pointed tool is used, the
switch may be damaged.
• If an operation error occurs during entry operation, turn the ignition key switch OFF and reenter from the
beginning.
Password Entry Procedure
Step Display Operation Vehicle response
When pressing the
switches, a short beep
Press switch (2) and switch (4) at the
1 sounds, and after 2
same time for more than 2 seconds.
seconds another short beep
sounds.
(2) (4)
2 Press switch (3) within 10 seconds. A short beep sounds.
(3)
3 Press switch (3) within 10 seconds. A short beep sounds.
(3)
When pressing the
Within 10 seconds, press switch (2) switches, a short beep
4 and switch (4) at the same time for sounds, and after 2
more than 2 seconds. seconds repeated short
beeps sound.
(2) (4)
5 Administrator menu screen is displayed automatically.
20-10
Administrator Menu Screen
(1) With travel and
load handling control Switch (1): Switching selection to next item
Switch (4): Moving to each setting screen
(1) (4)
• STD model
• DX model
20-11
• DX model with travel and load handling control
Administrator Function Setting Screen
• Low speed setting screen (DX model with travel and load
handling control only)
This is the same as the one in the general functions.
• Top speed limit screen (DX model with travel and load
handling control only)
Sets the top speed limit when traveling.
If you set it to the level 8, top speed limit function will be
disabled.
Switch (2): Setting level down
Switch (3): Setting level up
Switch (4): Returning to menu screen
• Over speed alarm setting screen (DX model/DX model with
travel and load handling control only)
This is the same as the one in the general functions.
20-12
• Load meter zero point adjustment screen (only for DX model/
DX model with travel and load handling control)
Zero point of the load meter is adjusted.
Pressing switch (1) for more than 2 seconds will reset the
indicated value to 0.
Switch (4): Returning to menu screen
• Maintenance hour meter setting screen
Time for maintenance hour meter is set.
It can be set from 10 to 2000 hours, but you can set it by 10-
hour increments between 10 and 200 hours,
while 50-hour increments between 200 and 2000 hours.
Switch (2): Reducing set time
Switch (3): Increasing set time
Switch (4): Returning to menu screen
Pressing switch (1) for more than 2 seconds will reset the
current value to 0.
• Menu lock screen (DX model/DX model with travel and load
handling control only)
Change in the setting values by an operator can be limited.
Setting to "Yes" will cancel displaying the setting menu screen
for an operator.
Switch (2): Selecting "Yes"
Switch (3): Selecting "No"
Switch (4): Returning to menu screen
20-13
MASK FUNCTIONS
GENERAL
In the multifunction display, aside from the general functions that an operator or an administrator normally use, the
following mask functions for use by the service staff for vehicle maintenance and specification setting are also
provided.
The service functions are protected by the password so that the important internal data will not be damaged by wrong
use of service functions by users by mistake.
Mask Function List
When used
Function Description Vehicle Board
Others
delivery replacement
Displays the electrical system status
Upon vehicle
Analyzer and reads the error information — —
abnormality
detected by controllers.
Makes fine adjustment of traveling c As requested
Tuning —
and material handling functions. *2 by customer
Sets each vehicle option and other c
Specification setting — —
specifications. *1 *2·*3
Option Setting
Each control function Enables or disables each control c
— —
enable/disable function. *2·*3
Updates voltage values of sensor
c c
Matching signals under the standard vehicle —
*2·*3 *5
condition.
Makes the speedometer reading c c
Wheel radius —
appropriate. *2 *4
Engine idle adjustment c As requested
Adjusts engine idle speed. —
(4Y engine vehicle only) *2 by customer
Adjusts the contrast of the display c As requested
Contrast —
screen. *3 by customer
Starts counting the odometer, trip c
Meter start c —
meter and maintenance hour meter. *3
*1: This is to match the controller and display control according to the installed option and control functions equipped
in the vehicle. Note that this function does not enable or disable the option or control function itself.
*2: Board: SAS/OPS controller control board
*3: Board: Control board for the multifunction display
*4: When tire size is changed or tire is replaced
*5: During the condition that is listed in matching, page 20-58
20-14
PASSWORD
Note:
• Always operate switches displayed on the display with a finger tip. If a sharp pointed tool is used, the
switch may be damaged.
• If an operation error occurs during entry operation, turn the ignition key switch OFF and reenter from the
beginning. If the MASK MENU cannot be displayed after several attempts, the system may be faulty.
Password Entry Procedure
Step Display Operation Vehicle response
When pressing the
Press switch (2), switch (3) and switches, a short beep
1 switch (4) at the same time for more sounds, and after 2
than 2 seconds. seconds another short beep
sounds.
(2) (3) (4)
2 Press switch (4) within 10 seconds. A short beep sounds.
(4)
3 Press switch (1) within 10 seconds. A short beep sounds.
(1)
When pressing the
Within 10 seconds, press switch (2) switches, a short beep
4 and switch (3) at the same time for sounds, and after 2
more than 2 seconds. seconds repeated short
beeps sound.
(2) (3)
5 Mask function initial screen is displayed for 5 seconds.
6 MASK MENU screen is automatically displayed.
20-15
MASK MENU Screen
Caution:
During all the test screen display, the vehicle can be operated normally.
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
2. Select a desired function using switch (1). Then, press switch
(1) With travel and (4) (set) to display the function screen or setting screen of the
load handling control selected function.
3. Press (enter) switch (4) while selecting "9. END" menu to
return to the general screen.
Also, in each screen, once the ignition key switch is turned
OFF, you can move to the general screen.
(1) (4)
"1. ANALYZER"
This function indicates the electrical system status and reads
the error information detected by the controller.
Switch (1): Switching selection to next item
Switch (4): To ANALYZER MENU screen
"2. TUNING"
Use this function for fine adjustment of control of the traveling
and material handling.
Switch (1): Switching selection to next item
Switch (4): To TUNING MENU screen
"3. OPTIONSET"
Use this function to match control of the controller or display
according to the set options or control.
Switch (1): Switching selection to next item
Switch (4): To OPTION SET setting screen
20-16
"4. MATCHING"
This function updates the signal voltage values stored in the
controller (signal voltage values from the SAS, Mini Lever or
Load Meter functions sensors under the standard vehicle
condition).
Switch (1): Switching selection to next item
Switch (4): To MATCHING MENU screen
"5. WHEEL RADIUS"
This function rewrites the tire information in the controller for
correcting the speed indication, odometer and trip meter.
Switch (1): Switching selection to next item
Switch (4): To TIRE CONSTANT setting screen
"6. IDLE ADJUSTMENT" (4Y-E engine vehicle only)
Adjusts engine idle speed of the 4Y-E engine vehicle.
Switch (1): Switching selection to next item
Switch (4): To IDLE SPEED ADJUSTMENT setting screen
"7. CONTRAST"
Adjusts the contrast of the display LCD screen.
Switch (1): Switching selection to next item
Switch (4): To CONTRAST ADJUSTMENT setting screen
"8. METER START"
Starts counting the odometer, trip meter and maintenance hour
meter.
Switch (1): Switching selection to next item
Switch (4): To METER START setting screen
Note:
After start counting the meters, "METER START" will not be
displayed on the MASK MENU screen.
"9. END"
Switch (1): Switching selection to next item
Switch (4): To general screen
20-17
ANALYZER
GENERAL
Analyzer function supports operations for inspecting/investigating faulty section by displaying the condition of the
control system, using communication between each controller and the multifunction display.
By switching the multifunction display to analyzer mode, operative conditions of the sensor actuator that is used for
traveling, material handling and SAS/OPS functions, or the error information detected by the controller can be read.
This is very useful for checking operative condition of each function and saving time for repairing when there is a
defect.
Full utilization of the analyzer functions helps quick, easy servicing.
The analyzer has the following functions:
1. Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes (diagnosis codes) detected in the electrical system in the past. The
diagnosis function reads these error codes and indicates them on the display.
Each error code is displayed with its detection time as the key ON hour meter reading.
2. In/out monitor function (I/O MONITOR)
This function displays the analog input values from individual sensors in the traveling, material handling, FHPS,
SAS and OPS systems. Monitoring the displayed values enables the quality of each circuit/sensor to be judged.
(1) I/O ENGINE CTRL
Displays ON/OFF states of the 4Y-E engine controller/ASC controller switch, various input values including
analog input voltage from the sensor, correction value of the control and output condition to the relay.
(2) I/O TRAVELING
Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
(3) I/O MATERIAL HANDLING
Displays the material handling and mast switch ON/OFF states and analog input voltages from material
handling and mast sensors.
(4) I/O STEERING
Displays the ON/OFF states of knob position correction control and the analog input voltages from
respective sensors.
(5) I/O OTHER
Displays the ON/OFF states of hour meter time and other switches and the analog input voltages from
respective sensors.
3. Active test (ACTIVE TEST)
In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected
item in order to permit operation check of that function.
4. Program version display (VERSION)
Displays program version of each controller.
20-18
ANALYZER SCREEN MENU LIST
Analyzer menu screen Display item Description
1. DIAG MEMORY 1. ~ 10. Indications of errors occurred
2. I/O ENGINE CTRL IGSW Key switch (IG)
(4Y-E engine controller) STA Key switch (ST)
BATT Battery voltage
G/LP Fuel changeover switch
SEL Fuel specification discrimination signal
ADJ Engine specification discrimination signal
MREL EFI main relay drive signal
FC Circuit opening relay drive signal
LPR LP gas main relay drive signal
LFC LP gas slow solenoid drive signal
OXHT O2 sensor heater drive signal
THA Intake temperature sensor voltage
THW Coolant temperature sensor voltage
PIM Intake pipe negative pressure sensor voltage
VPA1 Accelerator sensor (1) voltage
VPA2 Accelerator sensor (2) voltage
PA Accelerator opening angle
VTA1 Throttle position sensor (1) voltage
VTA2 Throttle position sensor (2) voltage
TA Throttle opening angle
IM Electronic throttle motor current
PA Accelerator opening angle
NE Engine speed
TA Throttle opening angle
NE Engine speed
PIM Intake pipe pressure
IGT Ignition timing (spark advance amount)
NE Engine speed
PIM Intake pipe pressure
INJ Injector correction value (gasoline)
OX O2 sensor voltage
NE Engine speed
PIM Intake pipe pressure
VF VF voltage (LPG)
OX O2 sensor voltage
NE Engine speed
PIM Intake pipe pressure
LINJ Injector correction value (LPG)
FCM Air-fuel ratio motor correction value (LPG)
20-19
Analyzer menu screen Display item Description
2. I/O ENGINE CTRL VPA1 Accelerator sensor (1) voltage
(ASC controller) VPA2 Accelerator sensor (2) voltage
IDLE Idle switch condition
NMR NMR switch condition
BATT Battery voltage
MEN+ Motor relay output
SRLY Motor relay output condition
STA Key switch (ST)
NE Engine speed
SOP1 Spare switch input (1) condition
SOP2 Spare switch input (2) condition
OOP1 Spare output (1) condition
3. I/O TRAVELING SPD Traveling speed sensor voltage
(Traveling/swing system) ACCSW Spare
BRKSW Brake switch
PKBSW Parking brake switch
SPARE Spare
SEAT Seat switch
DRF Forward traveling switch
DRR Reverse traveling switch
RYF Forward/reverse traveling interrupt relay
YRS Yaw rate sensor voltage
MH Lifting height switch
SA (Unused)
SWN Swing lock solenoid
PRES Load sensor voltage
SPEED Traveling speed
4. I/O M.HANDLING MD/MU Lift lowering switch/Lift raising switch
(Material handling/mast control system) MF/MR Forward tilt switch/Backward tilt switch
USOL Unload solenoid
LSOL Lift lowering lock solenoid
TSOL Tilt solenoid
BTSL Backward tilt lock solenoid
SEAT Seat switch
MA Tilt angle sensor voltage
MH Lifting height switch
PRES Load sensor
SWLK Load display switch
SWTK Automatic fork leveling stop switch
SWATS 3/4 way changeover switch
20-20
Analyzer menu screen Display item Description
4. I/O M.HANDLING Lift lever angle sensor (1) voltage
(Material handling/mast control system) POTL
Lift lever angle sensor (2) voltage
LPSOL Lift proportional valve solenoid current
LSOL Lift lowering lock solenoid
Tilt lever angle sensor (1) voltage
POTT
Tilt lever angle sensor (2) voltage
TPSOL Tilt proportional valve solenoid current
TSOL Tilt solenoid
Attachment (1) lever angle sensor (1) voltage
POTA1
Attachment (1) lever angle sensor (2) voltage
A1SOL Attachment (1) proportional valve solenoid current
Attachment (2) lever angle sensor (1) voltage
POTA2
Attachment (2) lever angle sensor (2) voltage
A2SOL Attachment (2) proportional valve solenoid current
5. I/O STEERING TIRE Tire angle sensor voltage
(Steering control system) SPEED Traveling speed
K-POS Steering angle knob position actual value (target value)
STS Steering angle sensor
6. I/O OTHERS HR Hour meter
(Others) BATT Battery voltage
THO Torque converter oil temperature sensor voltage
IGSW Key switch (IG)
MAT Matching connector
MTC M/T, T/C identification
7. ACTIVE TEST SWING SOL Swing lock solenoid forced operation
(Operation test) STEERING SOL Knob position compensation solenoid forced operation
T/C RLY Forward/reverse traveling cut-off relay forced operation
ASC RLY ASC motor relay forced operation
LIFT LWR SOL Lift lowering lock solenoid forced operation
TILT SOL Tilt solenoid forced operation
TILT BWD SOL Backward tilt lock solenoid forced operation
UNLOAD SOL Unload solenoid forced operation
OPTION RLY Control valve switching forced operation
BUZZER Warning buzzer forced operation
SWG TEST LMP Swing lock operation check
8. VERSION DISPLAY Display control program version
(Program version) SAS/OPS ECU SAS/OPS controller program version
ENGINE ECU 4Y-E engine controller (or ACS controller) program version
20-21
ANALYZER MENU Screen
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
2. Check that "1. ANALYZER" is selected (highlighted) on the
(1) With travel and screen and press switch (4) (enter) to call the ANALYZER
load handling control MENU screen.
3. Select the menu with switch (1), and press (enter) switch (4) to
move to the screen of the selected item.
4. If you select "9. END" on the ANALYZER MENU screen and
press switch (4) (enter), the MASK MENU screen appears
again.
(1) (4)
"1. DIAG MEMORY"
Switch (1): Switching selection to next item
Switch (4): To "DIAG MEMORY" screen
"2. I/O ENGINE CTRL"
Switch (1): Switching selection to next item
Switch (4): To "I/O ENGINE CTRL" screen
"3. I/O TRAVELING"
Switch (1): Switching selection to next item
Switch (4): To "I/O TRAVELING" screen
"4. I/O M.HANDLING"
Switch (1): Switching selection to next item
Switch (4): To "I/O M.HANDLING" screen
"5. I/O STEERING"
Switch (1): Switching selection to next item
Switch (4): To "I/O STEERING" screen
"6. I/O OTHERS"
Switch (1): Switching selection to next item
Switch (4): To "I/O OTHERS" screen
20-22
"7. ACTIVE TEST"
Switch (1): Switching selection to next item
Switch (4): To "ACTIVE TEST" screen
"8. VERSION"
Switch (1): Switching selection to next item
Switch (4): To "VERSION" screen
"9. END"
Switch (1): Returning to "1. DIAG MEMORY" selection
Switch (4): Returning to MASK MENU screen
Diagnosis Memory Function (DIAG MEMORY)
The controller stores up to 10 most recent errors. The DIAG MEMORY screen displays these diagnosis codes with
their detection time information (in key ON hour meter reading).
The most recent diagnosis code is displayed as 1, followed by 2, 3 and so on to 10.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Check that "1. DIAG MEMORY" is selected on the screen, and
press (enter) switch (4) to display "DIAG MEMORY 1/2"
screen.
3. Press switch (4) on "DIAG MEMORY 2/2" screen to return to
the ANALYZER MENU screen.
Note:
• When no error codes are displayed on the screen and the
(4) hour meter time is 0.0h, it indicates that no errors
occurred in the past after that row.
• It is impossible to directly jump from the DIAG MEMORY
screen to other function screen. Return to the ANALYZER
MENU screen once and then go to the desired function
screen.
• For details of diagnosis code, refer to section 21,
Diagnosis Code List.
20-23
"DIAG MEMORY 1/2"
Displays diagnosis 1 to 5.
Switch (4): To "DIAGMEMORY 2/2" screen
"DIAG MEMORY 2/2"
Displays diagnosis 6 to 10.
Switch (4): Returning to the ANALYZER MENU screen
20-24
In/Out Monitor Function (I/O MONITOR)
This function displays the analog input voltage from each of traveling, material handling, FHPS, SAS and OPS
sensors. The circuit or sensor quality can be judged by monitoring the displayed value.
In/Out Monitor (1) (I/O ENGINE CTRL)
4Y-E Engine Vehicle
Displays ON/OFF states of the 4Y-E engine controller switch, various input values including analog input voltage
from the sensor, correction value of the control and output condition to the relay.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (1) once to check that "2. I/O ENGINE CTRL" is
(1) With travel and selected, and press (enter) switch (4) to display "I/O ENGINE
load handling control CTRL 1/10" screen.
Note:
You cannot move directly from I/O ENGINE CTRL screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.
(1) (4)
20-25
"I/O ENGINE CTRL 1/10"
IGSW: Key switch (IG)
IGSW: 0 = OFF
IGSW: 1 = ON
STA: Key switch (ST)
STA: 0 = OFF
STA: 1 = ON
BATT: Battery voltage (V)
Displays battery voltage.
Standard: 8.0 ~ 16.0 V
G/LP: Fuel changeover switch
Displays states of the fuel changeover switch selection.
G/LP: 10 When gasoline is selected
G/LP: 01 When LP gas is selected
SEL: Fuel specification discrimination signal
Displays states of fuel specification discrimination signal.
SEL: 1100 Exclusive for gasoline
SEL: 1010 Exclusive for LP gas
SEL: 0110 Gasoline/LP gas convertible type
SEL: 0101 Gasoline/CNG (no used) convertible type
ADJ: Engine specification discrimination signal
Displays states of engine specification discrimination
signal.
Switch (4): To "I/O ENGINE CTRL 2/10" screen
"I/O ENGINE CTRL 2/10"
MREL: EFI main relay drive signal
Displays states of drive signal output to EFI main relay.
MREL: 1 Drive
MREL: 0 Halted
FC: Circuit opening relay drive signal
Displays states of drive signal output to the circuit
opening relay.
FC: 1 Drive
FC: 0 Halted
LPR: LP gas main relay drive signal
Displays states of drive signal output to LP gas main
relay.
LPR: 1 Drive
LPR: 0 Halted
LFC: LP gas slow solenoid drive signal
Displays states of drive signal output to LP gas slow
solenoid.
LFC: 1 Drive
LFC: 0 Halted
20-26
OXHT: O2 sensor heater drive signal
Displays states of drive signal output to the O2 sensor
heater.
OXHT: 1 Drive
OXHT: 0 Halted
Switch (4): To "I/O ENGINE CTRL 3/10" screen
"I/O ENGINE CTRL 3/10"
THA: Intake temperature sensor
Displays input voltage (V) from the intake temperature
sensor to the controller, and the intake temperature (°C).
THW: Coolant temperature sensor
Displays input voltage (V) from the coolant temperature
sensor to the controller, and the engine coolant
temperature (°C).
PIM: Intake pipe pressure
Displays input voltage (V) from the intake pipe negative
pressure sensor to the controller, and intake pipe
pressure (kPa).
Standard:
3.6 ± 0.3 V (100 ± 10 kPa) (when engine is halted)
Switch (4): To "I/O ENGINE CTRL 4/10" screen
"I/O ENGINE CTRL 4/10"
VPA1: Accelerator sensor 1
Displays input voltage (V) from the accelerator sensor (1)
to the controller, and the fully closed accelerator position
stored value (V).
Accelerator sensor (1) voltage standard:
0.2 ~ 1.3 V (when accelerator is not operated)
1.4 ~ 4.1 V (during maximum pressing of accelerator)
Accelerator fully closed position stored value standard:
0.2 ~ 1.3 V
VPA2: Accelerator sensor (2)
Displays input voltage (V) from the accelerator sensor (2)
to the controller, and the fully closed accelerator position
stored value (V).
Accelerator sensor (2) voltage standard:
0.7 ~ 2.0 V (when accelerator is not operated)
2.1 ~ 4.7 V (during maximum pressing of accelerator)
Accelerator fully closed position stored value standard:
0.7 ~ 2.0 V
PA: Accelerator opening angle
Displays operation amount of the accelerator pedal (%).
Accelerator opening angle standard:
0% (when accelerator is not operated)
100% (during maximum pressing of accelerator)
Switch (4): To "I/O ENGINE CTRL 5/10" screen
20-27
"I/O ENGINE CTRL 5/10"
VTA1: Throttle position sensor (1)
Displays input voltage (V) from the throttle position sensor
(1) to the controller, and the fully closed throttle position
stored value (V).
Throttle position sensor (1) voltage standard:
0.3 ~ 1.5 V (during engine idle (after warm-up))
Throttle fully closed position stored value standard:
0.3 ~ 1.5 V
VTA2: Throttle position sensor (2) voltage
Displays input voltage (V) from the throttle position sensor
(2) to the controller, and the fully closed throttle position
stored value (V).
Throttle position sensor (2) voltage standard:
1.7 ~ 3.3 V (during engine idle (after warm-up))
Throttle fully closed position stored value standard:
1.7 ~ 3.3 V
TA: Throttle opening angle
Displays throttle position (° ).
Standard:
1.0 ~ 8.0° (during engine idle (after warm-up))
IM: Electronic throttle motor current
Displays current flowing to the electronic throttle motor.
Standard: 0.2 ~ 10.0 A
Switch (4): To "I/O ENGINE CTRL 6/10" screen
"I/O ENGINE CTRL 6/10"
PA: Accelerator opening angle (refer to page 20-26)
NE: Engine speed
Displays engine speed (rpm) and traveling speed (km/h).
Engine speed standard: 0 ~ 3500 rpm
TA: Throttle opening angle (refer to page 20-27)
Switch (4): To "I/O ENGINE CTRL 7/10" screen
"I/O ENGINE CTRL 7/10"
NE: Engine speed (refer to page 20-27)
PIM: Intake pipe pressure (refer to page 20-26)
IGT: Ignition timing (spark advance amount)
Displays ignition timing (spark advance amount: ° ).
Standard:
5.0 ~ 25.0 ° (during engine idle (after warm-up))
Switch (4): To "I/O ENGINE CTRL 8/10" screen
20-28
"I/O ENGINE CTRL 8/10"
NE: Engine speed (refer to page 20-27)
PIM: Intake pipe pressure (refer to page 20-26)
INJ: Injector correction value (gasoline)
Displays correction value of the fuel injection amount.
OX: O2 sensor voltage
Displays input voltage (V) from the O2 sensor to the
controller, and the O2 sensor monitor.
O2 sensor voltage standard: 0 ~ 1.0 V
O2 sensor monitor
1: rich
0: lean
Switch (4): To "I/O ENGINE CTRL 9/10" screen
"I/O ENGINE CTRL 9/10"
NE: Engine speed (refer to page 20-27)
PIM: Intake pipe pressure (refer to page 20-26)
VF: VF voltage (LPG)
Displays the voltage (V) output from VF terminal.
Standard: 0 ~ 5.0 V
OX: O2 sensor voltage (refer to page 20-28)
Switch (4): To "I/O ENGINE CTRL 10/10" screen
"I/O ENGINE CTRL 10/10"
NE: Engine speed (refer to page 20-27)
PIM: Intake pipe pressure (refer to page 20-26)
LINJ: Injector correction value (LPG)
Displays correction value of the fuel injection amount.
FCM: Air-fuel ratio motor correction value (LPG)
Displays correction value of the air-fuel ratio motor
opening angle.
Switch (4): To ANALYZER MENU screen
In/Out Monitor (1) (I/O ENGINE CTRL)
1DZ-II/2Z Engine Travel and Load Handling Control Specification Vehicle
Displays ON/OFF states of the ASC controller switch, and analog input voltage of the sensor and its output condition
to the relay.
Operating Procedure
1. Display the ANALYZER MENU screen.
20-29
2. Press switch (1) once to check that "2. I/O ENGINE CTRL" is
selected, and press (enter) switch (4) to display "I/O ENGINE
CTRL 1/3" screen.
Note:
You cannot move directly from I/O ENGINE CTRL screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.
(1) (4)
"I/O ENGINE CTRL 1/3"
VPA1:
Displays accelerator sensor (1) voltage and accelerator sensor
(1) fully closed position stored value.
Accelerator sensor (1) voltage standard:
0.2 ~ 1.3 V (when accelerator is not operated)
1.4 ~ 4.1 V (during maximum pressing of accelerator)
Accelerator fully closed position stored value standard:
0.2 ~ 1.3 V
VPA2:
Displays accelerator sensor (2) voltage and accelerator sensor
(2) fully closed position stored value.
Accelerator sensor (2) voltage standard:
0.7 ~ 2.0 V (when accelerator is not operated)
2.1 ~ 4.7 V (during maximum pressing of accelerator)
Accelerator fully closed position stored value standard:
0.7 ~ 2.0 V (fully closed position stored value)
IDLE: Idle switch condition
IDLE: 0 = OFF
IDLE: 1 = ON
NMR: NMR switch condition
NMR: 0 = OFF
NMR: 1 = ON
Switch (4): To "I/O ENGINE CTRL 2/3" screen
"I/O ENGINE CTRL 2/3"
BATT: Battery voltage
Displays battery voltage (V).
Standard: 8.0 ~ 16.0 V
MEN+: Motor relay output voltage
Standard: 8.0 ~ 16.0 V
20-30
SRLY: Motor relay output state
SRLY: 0 = OFF
SRLY: 1 = ON
STA: Key switch (ST)
STA: 0 = OFF
STA: 1 = ON
Switch (4): To "I/O ENGINE CTRL 3/3" screen
"I/O ENGINE CTRL 3/3"
NE:
Displays engine speed (rpm), and engine speed sensor
voltage (V).
Engine speed standard: 0 ~ 3000 rpm
SOP1: state of spare switch input 1
Unused
SOP2: state of spare switch input 2
Unused
OOP: State of spare switch input 1
Unused
Switch (4): To ANALYZER MENU screen
In/Out Monitor (1) (I/O ENGINE CTRL)
1DZ-II/2Z Engine Vehicle (Vehicle without Engine Control Controller)
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (1) once to check that "2. I/O ENGINE CTRL" is
selected, and press (enter) switch (4) to display "I/O ENGINE
CTRL 1/1" screen.
Note:
You cannot move directly from I/O ENGINE CTRL screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.
(1) (4)
20-31
"I/O ENGINE CTRL 1/1"
Switch (4): To ANALYZER MENU screen
In/Out Monitor (2) (I/O TRAVELING)
This function displays the ON/OFF status of traveling and swing switches, and analog input voltages of sensors.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (1) twice to check that "3. I/O TRAVELING" is
(1) With travel and selected, and press (enter) switch (4) to display "I/O
load handling control TRAVELING 1/3" screen.
Note:
You cannot move directly from I/O TRAVELING screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.
(1) (4)
"I/O TRAVELING 1/3"
SPD: Traveling speed sensor voltage (V), and traveling speed
(km/h)
Checks traveling speed sensor voltage when the vehicle
is halted.
ACCSW: Spare
20-32
BRKSW: Brake switch check
BRKSW: 1 = ON when brake pedal is depressed
BRKSW: 0 = OFF when brake pedal is not operated
Switch ON/OFF quality judgment by operating the brake
pedal
PKBSW: Parking switch check
PKBSW: 1 = ON in a state of parking brake being
operated
PKBSW: 0 = OFF in a state of parking brake being
released
Judges the quality of the switch ON/OFF by operating the
parking brake lever (or pedal).
SPARE: Spare
Unused
Switch (4): To "I/O TRAVELING 2/3" screen
"I/O TRAVELING 2/3"
SEAT: Seat switch check
SEAT: 1 = ON when taking the seat
SEAT: 0 = OFF when leaving the seat
Switch ON/OFF quality judgment by sitting on and leaving
the operator’s seat
DRF: Forward direction switch check
DRR: Reverse direction switch check
Displayed code
Direction lever
DRF: DRR:
Forward traveling position 1 (= ON) 0 (= OFF)
Neutral position 0 (= OFF) 0 (= OFF)
Reverse travel position 0 (= OFF) 1 (= ON)
Switch ON/OFF quality judgment by operating the
direction lever
RYF: Forward/reverse traveling cut-off relay
Displays output signal to forward/reverse traveling cut-off
relay.
RYF: 1 = ON Relay energized (forward/reverse traveling
not possible) state
RYF: 0 = OFF Relay non-energized (forward/reverse
traveling possible) state
Switch (4): To "I/O TRAVELING 3/3" screen
"I/O TRAVELING 3/3"
YRS: Yaw rate sensor voltage (V)
Checks the input voltage from the yaw rate sensor to the
controller.
Standard when vehicle is stationary: 2.2 ~ 2.8 V
20-33
MH: Lifting height switch check
MH2-2
MH1 MH2-1
1 = ON
0 = OFF
Judges the quality of the switch ON/OFF by raising and
lowering the material handling. (Refer to Lifting Height
Switch ON/OFF Combination List)
SA: Unused
SWN: Swing lock solenoid
Displays output signal to the swing lock solenoid.
SWN: 1 = ON Energized (swing lock released) state
SWN: 0 = OFF Non-energized (swing lock) state
PRES: Load sensor
Displays input voltage (V) from the load sensor to the
controller, and detected pressure (MPa).
Standard at no load: 0.5 ~ 4.5 V
Voltage increases as load increases.
SPEED: Traveling speed (km/h)
Checks traveling speed.
Switch (4): To ANALYZER MENU screen
Lifting Height Switch (MH) ON/OFF Combination Table
(MH1)
E3
Lifting height switch circuit diagram (MH2-1)
(MH2-2)
MH1 1 (= ON)
At a low lift
MH2-1 0 (= OFF)
(less than 2200 mm (87 in)*)
MH2-2 0 (= OFF)
MH1 0 (= OFF)
At a medium lift
MH2-1 1 (= ON)
(2200 mm (87 in) or more)
MH2-2 0 (= OFF)
*: The height at which the lifting height switch changes will vary according to the lifting height set for the mast.
20-34
In/Out Monitor (3) (I/O MATERIAL HANDLING)
This function displays the ON/OFF status of material handling and mast control switches and analog input voltages
from sensors.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (1) 3 times to check that "4. I/O M.HANDLING" is
(1) With travel and selected, and press (enter) switch (4) to display "I/O
load handling control M.HANDLING 1/6" screen.
Note:
You cannot move directly from I/O MATERIAL HANDLING
screen to the screen of the other items. Return to ANALYZER
MENU screen once, then move to screen of each item.
(1) (4)
"I/O M.HANDLING 1/6"
MD: Lift lowering switch check (STD lever vehicle only)
MU: Lift raising switch check (vehicle with travel and load
handling control (OPT) only)
Displayed code
Lift lever
MD: MU:
Lowering position 1 (= ON) 0 (= OFF)
Neutral position 0 (= OFF) 0 (= OFF)
Raising position 0 (= OFF) 1 (= ON)
Switch ON/OFF quality judgment by operating the lift
lever
MF: Forward tilt switch check (STD lever vehicle only)
MR: Backward tilt switch check (STD lever vehicle only)
Displayed code
Tilt lever
MF: MR:
Forward tilt position 1 (= ON) 0 (= OFF)
Neutral position 0 (= OFF) 0 (= OFF)
Backward tilt position 0 (= OFF) 1 (= ON)
Switch ON/OFF quality judgment by operating the tilt
lever
20-35
USOL: Unload solenoid
Displays output signal to the unload solenoid.
LSOL: Lift lowering lock solenoid
Displays output signal to the lift lowering lock solenoid.
TSOL: Tilt lock solenoid
Displays output signal to the tilt lock solenoid.
BTSL: Backward tilt lock solenoid (STD lever vehicle only)
Displays output signal to the backward tilt lock solenoid.
SEAT: Seat switch check
Judge the quality of the switch ON/OFF by sitting on and
leaving the operator ’s seat.
Switch (4): To "I/O M.HANDLING 2/6" screen
Condition of the seat/lever and detected values (USOL/LSOL/TSOL/BTSL/SEAT)
Seat condition Sitting on seat Leaving seat
Lift lever Tilt lever
Not Backward tilt
Lever condition —
operated Raising Lowering Forward tilt Low lifting High lifting
height height
USOL 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF) 1 (= ON)
LSOL 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF)
STD lever vehicle TSOL 0 (= OFF) 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 1 (= ON) 0 (= OFF)
BTSL 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF) 1 (= ON) 1 (= ON) 0 (= OFF)
SEAT 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 0 (= OFF)
USOL 0 (= OFF) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 0 (= OFF)
LSOL 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 0 (= OFF) 0 (= OFF) 0 (= OFF)
Mini lever vehicle TSOL 0 (= OFF) 0 (= OFF) 0 (= OFF) 1 (= ON) 0 (= OFF) 1 (= ON) 0 (= OFF)
BTSL — — — — — — —
SEAT 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 1 (= ON) 0 (= OFF)
"I/O M.HANDLING 2/6"
MA: Tilt angle sensor voltage (V)
Checks the input voltage from the tilt angle sensor to the
controller.
Standard with mast in the vertical position:
1.1 ~ 4.2 V
Mast vertical → forward tilt: Input voltage decreases
Mast vertical → backward tilt: Input voltage increases
MH: Lifting height switch check (refer to page 20-33)
PRES: Load sensor (refer to page 20-33)
SWLK: Load display switch check
SWLK: 0 = OFF
SWLK: 1 = ON
Judge the quality of the switch ON/OFF by operating the
lift knob switch.
20-36
SWTK: Automatic fork leveling stop switch
SWTK: 0 = OFF
SWTK: 1 = ON
Judge the quality of the switch ON/OFF by operating the
tilt knob switch.
SWATS: 3/4 way changeover switch check
SWATS: 1 = ON
When tilting the switch to right (4 way side is activated)
SWATS: 0 = OFF
When tilting the switch to left (3 way side is activated)
Judge the quality of the switch ON/OFF by operating the
changeover switch.
Switch (4): To "I/O M.HANDLING 3/6" screen
"I/O M.HANDLING 3/6"
POTL: Lift lever angle sensor (1) voltage (V)/lift lever angle
sensor (2) voltage (V)
Standard
Lift lever angle sensor Lift lever angle sensor
Lift lever
(1) voltage (2) voltage
Raising 1.8 ~ 4.1 V 0.3 ~ 2.9 V
Lowering 0.4 ~ 2.8 V 1.6 ~ 4.3 V
Judge the raise and lower input quality by lift lever
operation.
LPSOL: Lift proportional valve solenoid current (A)
Judge the output quality to lift proportional valve solenoid
by lift lever operation.
Standard when lever is operated: 0.3 ~ 0.85 A
LSOL: Lift lowering lock solenoid (refer to page 20-35)
Switch (4): To "I/O M.HANDLING 4/6" screen
"I/O M.HANDLING 4/6"
POTT: Tilt lever angle sensor (1) voltage (V)/tilt lever angle
sensor (2) voltage (V)
Standard
Tilt lever angle sensor Tilt lever angle sensor
Tilt lever
(1) voltage (2) voltage
Forward tilt 1.8 ~ 4.1 V 0.3 ~ 2.9 V
Backward tilt 0.4 ~ 2.8 V 1.6 ~ 4.3 V
Judge the input quality during forward tilt/backward tilt by
tilt lever operation.
20-37
TPSOL: Tilt proportional valve solenoid current (A)
Judge the output quality to tilt proportional valve solenoid
by tilt lever operation.
Standard when lever is operated: 0.3 ~ 0.85 A
TSOL: Tilt lock solenoid (refer to page 20-35)
Switch (4): To "I/O M.HANDLING 5/6" screen
"I/O M.HANDLING 5/6"
POTA1: Attachment (1) lever angle sensor (1) voltage (V)
/attachment (1) lever angle sensor (2) voltage (V)
Standard
Attachment (1) lever Attachment (1) lever
Attachment (1)
angle sensor (1) angle sensor (2)
lever
voltage voltage
Backward tilt
1.8 ~ 4.1 V 0.3 ~ 2.9 V
side
Forward tilt
0.4 ~ 2.8 V 1.6 ~ 4.3 V
side
Judge the input quality by attachment (1) lever operation.
A1SOL: Attachment (1) proportional valve solenoid current (A)
Judge the output quality to attachment (1) proportional
valve solenoid by attachment (1) lever operation.
Standard when lever is operated: 0.3 ~ 0.85 A
Switch (4): To "I/O M.HANDLING 6/6" screen
"I/O M.HANDLING 6/6"
POTA2: Attachment (2) lever angle sensor (1) voltage (V)
/attachment (2) lever angle sensor (2) voltage (V)
Standard
Attachment (2) lever Attachment (2) lever
Attachment (2)
angle sensor (1) angle sensor (2)
lever
voltage voltage
Backward tilt
1.8 ~ 4.1 V 0.3 ~ 2.9 V
side
Forward tilt
0.4 ~ 2.8 V 1.6 ~ 4.3 V
side
Judge the input quality by attachment (2) lever operation.
A2SOL: Attachment (2) proportional valve solenoid current (A)
Judge the output quality to attachment (2) proportional
valve solenoid by attachment (2) lever operation.
Standard when lever is operated: 0.3 ~ 0.85 A
Switch (4): Returning to ANALYZER MENU screen
20-38
In/out monitor (4) (I/O STEERING)
This function displays ON/OFF status of the knob position correction and other switches, and analog input voltages
from sensors.
Operation Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (1) 4 times to check that "5. I/O STEERING" is
(1) With travel and selected, and press (enter) switch (4) to display "I/O
load handling control STEERING 1/1" screen.
Note:
You cannot move directly from I/O STEERING screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.
(1) (4)
"I/O STEERING 1/1"
TIRE: Tire angle sensor voltage (V)
Operates the steering wheel to check the variation in
voltage.
Standard when tires are in straight ahead position:
1.9 ~ 2.4 V
SPEED: Traveling speed (refer to page 20-33)
K-POS: Steering knob position actual value (target value) and
steering synchronizer solenoid
Actual value:
The knob position calculated and recognized by the
controller from the steering angle sensor signal
Target value:
The knob position calculated and recognized by the
controller from the tire angle sensor signal
Steering synchronizer solenoid:
0 = OFF (non-energized) state
1 = ON (energized) state
20-39
One rotation (360°) of the steering wheel is divided by
160, and the value is set to "80" when the knob is in the
position as indicated in the illustration.
159 Clockwise turn of the steering wheel: Increase in value
0 Counterclockwise turn of the steering wheel: Decrease in
1
value
STS: Steering angle sensor check
80
Standard position STSC
STS1 STS2
1 = ON
0 = OFF
When the steering wheel is rotated once, STS1 and STS2
repeat ON and OFF.
STSC only turns on when the knob is in the standard
position.
Switch (4): To ANALYZER MENU screen
In/Out Monitor (5) (I/O OTHERS)
Displays the ON/OFF states of hour meter time and other switches, and the analog input voltages from respective
sensors.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (1) 5 times to check that "6. I/O OTHERS" is
(1) With travel and selected, and press (enter) switch (4) to display "I/O OTHERS
load handling control 1/2" screen.
Note:
You cannot move directly from I/O OTHERS screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.
(1) (4)
20-40
"I/O OTHERS 1/2"
HR: Hour meter
Displays hour meter value.
BATT: Battery voltage (V)
Displays battery voltage.
Standard: 8.0 ~ 16.0 V
THO: Torque converter oil temperature
Displays torque converter oil temperature sensor voltage
(V), and oil temperature (°C).
This will not be displayed for M/T vehicle.
Switch (4): To "I/O OTHERS 2/2" screen
"I/O OTHERS 2/2"
IGSW: Key switch
Displays key switch ON/OFF.
IGSW: 1 = ON
IGSW: 0 = OFF
MAT: Matching connector
Displays states of matching connector.
MAT: 0 = OFF
State of matching connector separation
MAT: 1 = ON
State of matching connector connection
This will not be displayed for mini lever or joystick vehicle.
MTC: Transmission identification
Displays input state of the M/T and T/C identification
numbers.
MTC: 0 T/C
MTC: 1 M/T
Switch (4): Returning to ANALYZER MENU screen
20-41
Active Test (ACTIVE TEST)
This function outputs ON/OFF signals to switches in the electrical system and compare controller input signals with
those signals.
Active Test Menu List
Selection item
Item Description
Signal Content of operation Signal Content of operation
SWING SOL Swing lock solenoid forced operation ON Unlock OFF Lock
Steering synchronizer solenoid forced
STEERING SOL ON By-pass open OFF By-pass close
operation
Forward/reverse traveling interrupt relay Traveling not
T/C RLY ON OFF Traveling possible
forced operation possible
ASC RLY ASC motor relay forced operation ON Engine control OFF Engine idle state
Lowering not
LIFT LWR SOL Lift lowering lock solenoid forced operation ON Lowering possible OFF
possible
Forward tilt possible Forward tilt not
TILT SOL Tilt solenoid forced operation ON Backward tilting OFF possible
speed limited Backward tilt possible
Backward tilt not
TILT BWD SOL Backward tilt lock solenoid forced operation ON Backward tilt possible OFF
possible
STD lever vehicle:
STD lever vehicle:
Material handling
Material handling
other than lowering
possible
not possible
UNLOAD SOL Unload solenoid forced operation ON OFF Mini lever or joystick
Mini lever or joystick
lever vehicle:
vehicle:
Material handling not
Material handling
possible *1
possible
4th way material 3rd way material
OPTION RLY 3/4 way changeover switch ON OFF
handling operation*2 handling operation
BUZZER Warning buzzer forced operation ON Buzzer ON OFF Buzzer OFF
SWG TEST LMP Swing lock solenoid operation display ON Indication OFF No indication
*1: It may be lowered according to load condition.
*2: Number of ways may differ according to material handling piping.
Operating Procedure
1. Display the ANALYZER MENU screen.
20-42
2. Press switch (1) 6 times to check that "7. ACTIVE TEST" is
(1) With travel and selected, and press (enter) switch (4) to display "ACTIVE
load handling control
TEST 1/3" screen.
Switch (1): Move to next item
Switch (2): Forced OFF
Switch (3): Forced ON
Switch (4): Returning to ANALYZER MENU screen
Note:
(1) (2) (3) (4) You cannot move directly from ACTIVE TEST screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each item.
"ACTIVE TEST 1/3"
SWING SOL: Swing lock solenoid
Jack up the rear axle, and check that the rear axle
swings.
ON (solenoid ON): Unlock
OFF (solenoid OFF): Lock
STEERING SOL: Steering synchronizer solenoid
Slowly turn the steering wheel, and check the difference
of the rear tire movement.
ON (By-pass open): Tires do not move much
OFF (By-pass close): Tires move (normal operation)
T/C RLY: Forward/reverse interrupt relay
Check the operation of the torque converter forward/
reverse interrupt relay.
ON (relay ON): Traveling not possible
OFF (relay OFF): Traveling possible (normal operation)
ASC RLY: ASC motor relay
Check the operation of the motor power supply relay.
ON (relay ON): Traveling possible (normal operation)
OFF (relay OFF): Engine idle state
"ACTIVE TEST 2/3"
Note:
When performing ACTIVE TEST 2/3 item, make sure to sit on
the seat correctly. If not, OPS is activated and material
handling operation may be limited.
LIFT LWR SOL: Lift lowering lock solenoid
Check the quality of lowering action by lift lowering
operation.
ON (solenoid ON): Lowering possible
(normal operation)
OFF (solenoid OFF): Lowering not possible
20-43
TILT SOL: Tilt solenoid
Check the quality of mast forward tilt operation by forward
tilt operation.
ON (solenoid ON):
Forward tilt possible, backward tilting speed limited
OFF (solenoid OFF):
Forward tilt not possible, backward tilt operated normally
TILT BWD SOL: Backward tilt lock solenoid
Check the quality of mast backward tilt operation by
backward tilt operation.
ON (solenoid ON): Backward tilt possible
(normal operation)
OFF (solenoid OFF): Backward tilt not possible
UNLOAD SOL: Unload valve solenoid
Check the quality of material handling operation by
material handling operation.
STD lever vehicle
ON (solenoid ON):
Material handling other than lowering operation not
possible (Depending on the attachment, 3rd to 5th
way operation may be possible)
OFF (solenoid OFF):
Material handling operation possible
Mini lever or joystick vehicle
ON (solenoid ON):
Material handling operation possible
OFF (solenoid OFF):
Material handling operation not possible (It may
slowly lower according to load condition, but this is
not a fault.)
"ACTIVE TEST 3/3"
OPTION RLY: 3/4 way changeover
Using a dual lever, check that the allocated material
handling operation is switched over.
ON (relay ON):
4th way operation is possible. (Number of ways may differ
according to material handling piping.)
OFF (relay OFF):
3rd way operation is possible.
BUZZER: Warning buzzer forced operation
Check the warning buzzer operation.
ON: Buzzer sounds
OFF: Buzzer stops
SWG TEST LAMP:
Check the swing lock operation states according to traveling
and material handling states by OPS light.
ON (Indicated):
Operation situation is indicated with OPS light.
OPS light ON: Swing lock operated
OPS light OFF: Swing lock released
OFF (not indicated):
OPS light operates as OPS light (normal operation).
20-44
Program Version (VERSION)
Displays program version of each controller.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (1) 7 times to check that "8. VERSION" is
(1) With travel and selected, and press (enter) switch (4) to display "VERSION"
load handling control screen.
Switch (4): Returning to ANALYZER MENU screen
(1) (4)
"VERSION"
DISPLAY: Displaying program version
Program version of the multifunction display
SAS/OPS: SAS/OPS program version
Program version of SAS/OPS controller
ENGINE: 4Y-E (or ASC) program version
4Y-E engine controller (or ASC controller) program
version
20-45
TUNING
GENERAL
Performs fine adjustment of traveling and material handling control.
When receiving a request from a user such as "I want you to adjust the lift idle up", a setting level can be altered from
the tuning screen.
55 tuning items are provided including spares.
Tuning Item List
• No.6 ~ No.19 are not used (not indicated).
• No.20 ~ No.69 are for mini lever or joystick specification (OPT) vehicle only.
Level (z: initial setting value)
No. Item
1 2 3 4 5 6 7 8
1 Lift idle up * z
2 Spare 1 z
3 Spare 2 z
4 Spare 3 z
5 Spare 4 z
Lift lowering adjustment (1):
20 Adjusts solenoid output current at the beginning of lift lowering Small z Large
operation.
Lift lowering adjustment (2):
21 Slow z Fast
Adjusts inching speed during lift lowering operation.
Lift lowering adjustment (3):
22 Adjusts solenoid maximum output current during the lift Small z Large
lowering operation.
Lift lowering adjustment (4):
23 Weak z Strong
Adjusts acceleration speed during lift lowering operation.
Lift lowering adjustment (5):
24 Weak z Strong
Adjusts deceleration speed during lift lowering operation.
Lift raising adjustment (1):
25 Adjusts solenoid output current at the beginning of lift raising Small z Large
operation.
Lift raising adjustment (2):
26 Slow z Fast
Adjusts inching speed during lift raising operation.
Lift raising adjustment (3):
27 Adjusts solenoid maximum output current during the lift raising Small z Large
operation.
Lift raising adjustment (4):
28 Weak z Strong
Adjusts acceleration speed during lift raising operation.
Lift raising adjustment (5):
29 Weak z Strong
Adjusts deceleration speed during lift raising operation.
Forward tilt adjustment (1):
30 Adjusts solenoid output current at the beginning of forward tilt Small z Large
operation.
Forward tilt adjustment (2):
31 Slow z Fast
Adjusts inching speed during forward tilt operation.
20-46
Level (z: initial setting value)
No. Item
1 2 3 4 5 6 7 8
Forward tilt adjustment (3):
32 Adjusts solenoid maximum output current during forward tilt Small z Large
operation.
Forward tilt adjustment (4):
33 Weak z Strong
Adjusts acceleration speed during forward tilt operation.
Forward tilt adjustment (5):
34 Weak z Strong
Adjusts deceleration speed during forward tilt operation.
Backward tilt adjustment (1):
35 Adjusts solenoid output current at the beginning of backward Small z Large
tilt operation.
Backward tilt adjustment (2):
36 Slow z Fast
Adjusts inching speed during backward tilt operation.
Backward tilt adjustment (3):
37 Adjusts solenoid maximum output current during backward tilt Small z Large
operation.
Backward tilt adjustment (4):
38 Weak z Strong
Adjusts acceleration speed during backward tilt operation.
Backward tilt adjustment (5):
39 Weak z Strong
Adjusts deceleration speed during backward tilt operation.
Attachment (1) lever forward tilt side adjustment (1):
40 Adjusts solenoid output current at the beginning of attachment Small z Large
(1) lever forward tilt side operation.
Attachment (1) lever forward tilt side adjustment (2):
41 Adjusts inching speed during the attachment (1) lever forward Slow z Fast
tilt side operation.
Attachment (1) lever forward tilt side adjustment (3):
42 Adjusts solenoid maximum output current during the Small z Large
attachment (1) lever forward tilt side operation.
Attachment (1) lever forward tilt side adjustment (4):
43 Adjusts acceleration speed during the attachment (1) lever Weak z Strong
forward tilt side operation.
Attachment (1) lever forward tilt side adjustment (5):
44 Adjusts deceleration speed during the attachment (1) lever Weak z Strong
forward tilt side operation.
Attachment (1) lever backward tilt side adjustment (1):
45 Adjusts solenoid output current at the beginning of attachment Small z Large
(1) lever backward tilt side operation.
Attachment (1) lever backward tilt side adjustment (2):
46 Adjusts inching speed during the attachment (1) lever Slow z Fast
backward tilt side operation.
Attachment (1) lever backward tilt side adjustment (3):
47 Adjusts solenoid maximum output current during the Small z Large
attachment (1) lever backward tilt side operation.
Attachment (1) lever backward tilt side adjustment (4):
48 Adjusts acceleration speed during the attachment (1) lever Weak z Strong
backward tilt side operation.
Attachment (1) lever backward tilt side adjustment (5):
49 Adjusts deceleration speed during the attachment (1) lever Weak z Strong
backward tilt side operation.
20-47
Level (z: initial setting value)
No. Item
1 2 3 4 5 6 7 8
Attachment (2) lever forward tilt side adjustment (1):
50 Adjusts solenoid output current at the beginning of attachment Small z Large
(2) lever forward tilt side operation.
Attachment (2) lever forward tilt side adjustment (2):
51 Adjusts inching speed during the attachment (2) lever forward Slow z Fast
tilt side operation.
Attachment (2) lever forward tilt side adjustment (3):
52 Adjusts solenoid maximum output current during the Small z Large
attachment (2) lever forward tilt side operation.
Attachment (2) lever forward tilt side adjustment (4):
53 Adjusts acceleration speed during the attachment (2) lever Weak z Strong
forward tilt side operation.
Attachment (2) lever forward tilt side adjustment (5):
54 Adjusts deceleration speed during the attachment (2) lever Weak z Strong
forward tilt side operation.
Attachment (2) lever backward tilt side adjustment (1):
55 Adjusts solenoid output current at the beginning of attachment Small z Large
(2) lever backward tilt side operation.
Attachment (2) lever backward tilt side adjustment (2):
56 Adjusts inching speed during the attachment (2) lever Slow z Fast
backward tilt side operation.
Attachment (2) lever backward tilt side adjustment (3):
57 Adjusts solenoid maximum output current during the Small z Large
attachment (2) lever backward tilt side operation.
Attachment (2) lever backward tilt side adjustment (4):
58 Adjusts acceleration speed during the attachment (2) lever Weak z Strong
backward tilt side operation.
Attachment (2) lever backward tilt side adjustment (5):
59 Adjusts deceleration speed during the attachment (2) lever Weak z Strong
backward tilt side operation.
Attachment (3) lever forward tilt side adjustment (1):
60 Adjusts solenoid output current at the beginning of attachment Small z Large
(3) lever forward tilt side operation.
Attachment (3) lever forward tilt side adjustment (2):
61 Adjusts inching speed during the attachment (3) lever forward Slow z Fast
tilt side operation.
Attachment (3) lever forward tilt side adjustment (3):
62 Adjusts solenoid maximum output current during the Small z Large
attachment (3) lever forward tilt side operation.
Attachment (3) lever forward tilt side adjustment (4):
63 Adjusts acceleration speed during the attachment (3) lever Weak z Strong
forward tilt side operation.
Attachment (3) lever forward tilt side adjustment (5):
64 Adjusts deceleration speed during the attachment (3) lever Weak z Strong
forward tilt side operation.
Attachment (3) lever backward tilt side adjustment (1):
65 Adjusts solenoid output current at the beginning of attachment Small z Large
(3) lever backward tilt side operation.
20-48
Level (z: initial setting value)
No. Item
1 2 3 4 5 6 7 8
Attachment (3) lever backward tilt side adjustment (2):
66 Adjusts inching speed during the attachment (3) lever Slow z Fast
backward tilt side operation.
Attachment (3) lever backward tilt side adjustment (3):
67 Adjusts solenoid maximum output current during the Small z Large
attachment (3) lever backward tilt side operation.
Attachment (3) lever backward tilt side adjustment (4):
68 Adjusts acceleration speed during the attachment (3) lever Weak z Strong
backward tilt side operation.
Attachment (3) lever backward tilt side adjustment (5):
69 Adjusts deceleration speed during the attachment (3) lever Weak z Strong
backward tilt side operation.
*: Vehicle with travel and load handling control (OPT)
20-49
TUNING MENU Screen
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
2. Press switch (1) to check that "2. TUNING" is selected, and
press (enter) switch (4) to display TUNING MENU screen.
(1) With travel and
load handling control 3. Select the menu with switch (1), and press (enter) switch (4) to
move to the tuning screen of the selected item.
4. Press (enter) switch (4) while selecting "7. END" menu to
return to MASK MENU screen.
(1) (4)
"1. COMMON"
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen
"2. LIFT LEVER"
(mini lever/joystick vehicle)
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen
"3. TILT LEVER"
(mini lever/joystick vehicle)
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen
"4. ATT1 LEVER"
(mini lever/joystick vehicle)
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen
"5. ATT2 LEVER"
(mini lever/joystick vehicle)
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen
"6. ATT3 LEVER" (mini lever vehicle)
Switch (1): Switching selection to next item
Switch (4): To TUNING LEVEL setting screen
20-50
"7. END"
Switch (1): Returning to "1. COMMON" selection
Switch (4): Returning to MASK MENU screen
COMMON (TUNING COMMON)
Sets tuning levels for standard functions.
Operating Procedure
1. Display the TUNING MENU screen.
2. Check that "1. COMMON" is selected, and press (enter) switch
(1) With travel and (4) to display TUNING LEVEL setting screen.
load handling control
Note:
You cannot move directly from level setting screen of
COMMON to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.
(1) (2) (3) (4)
"TUNE COM."
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
20-51
LIFT LEVER (TUNING LIFT LEVER)
Sets tuning levels for the lift lever of mini lever and joystick vehicles.
Operating Procedure
1. Display the TUNING MENU screen.
2. Press switch (1) once to check that "2. LIFT LEVER" is
selected, and press (enter) switch (4) to display the TUNING
(1) With travel and LEVEL setting screen.
load handling control
Note:
You cannot move directly from level setting screen of LIFT
LEVER to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.
(1) (2) (3) (4)
"TUNE LIFT"
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
20-52
TILT LEVER (TUNING TILT LEVER)
Sets tuning levels for the tilt lever of mini lever and joystick vehicles.
Operating Procedure
1. Display the TUNING MENU screen.
2. Press switch (1) twice to check that "3. TILT LEVER" is
(1) With travel and selected, and press (enter) switch (4) to display the TUNING
load handling control LEVEL setting screen.
Note:
You cannot move directly from level setting screen of TILT
LEVER to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.
(1) (2) (3) (4)
"TUNE TILT"
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
20-53
ATT1 LEVER (TUNING ATT1 LEVER)
Sets tuning levels for the ATT1 lever of mini lever and joystick vehicles.
Operating Procedure
1. Display the TUNING MENU screen.
2. Press switch (1) 3 times to check that "4. ATT1 LEVER" is
(1) With travel and selected, and press (enter) switch (4) to display the TUNING
load handling control LEVEL setting screen.
Note:
You cannot move directly from level setting screen of ATT1
LEVER to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.
(1) (2) (3) (4)
"TUNE ATT1"
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
20-54
ATT2 LEVER (TUNING ATT2 LEVER)
Sets tuning levels for the ATT2 lever of mini lever and joystick vehicles.
Operating Procedure
1. Display the TUNING MENU screen.
2. Press switch (1) 4 times to check that "5. ATT2 LEVER" is
(1) With travel and selected, and press (enter) switch (4) to display the TUNING
load handling control LEVEL setting screen.
Note:
You cannot move directly from level setting screen of ATT2
LEVER to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.
(1) (2) (3) (4)
"TUNE ATT2"
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
20-55
ATT3 LEVER (TUNING ATT3 LEVER)
Sets tuning levels for ATT3 of mini lever vehicles.
Operating Procedure
1. Display the TUNING MENU screen.
2. Press switch (1) 5 times to check that "6. ATT3 LEVER" is
selected, and press (enter) switch (4) to display the TUNING
(1) With travel and LEVEL setting screen.
load handling control
Note:
You cannot move directly from level setting screen of ATT3
LEVER to the screen of the other items. Return to TUNING
MENU screen once, then move to level setting screen of each
item.
(1) (2) (3) (4)
"TUNE ATT3"
Switch (1): Switching selection to next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Returning to TUNING MENU screen
20-56
OPTION SET
Note:
• The option set function is used to set control of the controller and display control according to the
options equipped on the vehicle. It does not enable or disable the function itself.
• If OPS/SAS controller or multifunction display is replaced, it is necessary to reset it according to the
vehicle specification.
Option Set Menu List
Switching settings
Indication Description Indi- Indi-
Setting content Setting content
cation cation
DISP. MODE* Setting display language J Japanese I English
MPH* Setting traveling speed display unit YES mph NO km/h
USA* Setting buzzer specification YES USA NO Other than USA
Setting to enable/disable buzzer sound when seat
SEAT BUZZER YES Enabled NO Disabled
switch is off
Setting to enable/disable warning when forgetting to
PKB BUZZER YES Enabled NO Disabled
apply the parking brake.
TEMPGAUGE Setting to enable/disable oil temperature indication YES Enabled NO Disabled
CONV. TEMP Unused (fixed to YES) YES — NO —
ASC W/LOAD Setting to enable/disable driving control YES Enabled NO Disabled
Setting to enable/disable traveling speed limit of
MODE S Enabled A Disabled
driving control
T/C INTLOCK Unused (fixed to NO) YES — NO —
Setting to enable/disable engine output down when
H.TEMP P-LIM YES Enabled NO Disabled
detecting coolant overheat
LIFT IDLEUP Setting to enable/disable lift idle up YES Enabled NO Disabled
T FWD LIMIT Setting to enable/disable forward tilt regulating control YES Enabled NO Disabled
Setting to enable/disable backward tilt automatic
T BWD LEVEL YES Enabled NO Disabled
leveling control
SWG W-LOCK Unused (fixed to YES) YES — NO —
OCV WAY* Setting number of ways for oil control valve 2/3/4/5
Switching output destination during C/V 5th way Switching 3rd Switching 2nd
WAY SELECT* 3→ 2→
specification way and 4th way way and 3rd way
*: These are set according to the vehicle specification at the time of shipment.
OPTION SET Screen
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
20-57
2. Press switch (1) twice to check that "3. OPTION SET" is
(1) With travel and selected, and press (enter) switch (4) to display the OPTION
load handling control SET setting screen.
(1) (2) (3) (4)
"OPTION SET" Screen 1
Switch (1): Switching selection to next item
Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Switch (4): Returning to MASK MENU screen
While "PKB BUZZER" is selected, press switch (1) to switch to
next screen.
"OPTION SET" Screen 2
Switch (1): Switching selection to next item
Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Switch (4): Returning to MASK MENU screen
While "T/C INTLOCK" is selected, press switch (1) to switch to
next screen.
"OPTION SET" Screen 3
Switch (1): Switching selection to next item
Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO
Switch (4): Returning to MASK MENU screen
While "SWG W-LOCK" is selected, press switch (1) to switch
to next screen.
"OPTION SET" Screen 4
Switch (1): Switching selection to next item
Switch (2):
Setting 5 → 4 → 3 → 2, or 2 −> → 3 −>
Switch (3):
Setting 2 → 3 → 4 → 5 or 3 −> → 2 −>
Switch (4): Returning to MASK MENU screen
While "WAY SELECT" is selected, pressing switch (1) to
switch to next screen (returning to screen 1).
20-58
MATCHING
GENERAL
• For the tilt angle, load and tire angle sensors among sensors used for SAS functions, the signal voltage values
under the mast vertical, no load, tire straight and rear axle horizontal conditions are stored, respectively, in the
controller for the control based on these values. When servicing or replacing these sensors, matching (updating
the sensor signal voltage value in the standard vehicle condition) is necessary. Also, matching is needed for the
tilt angle sensor when the vehicle posture has changed excessively, and for the load sensor when the load under
no load condition (no load on fork) is changed because of addition or removal of any attachment, replacement of
mast or change of fork length.
• Each lever angle sensor for mini lever or joystick function is controlled based on the memory of signal voltage
values in the neutral position stored in the controller at the time of shipment. When servicing these sensors or
replacing related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condition)
is necessary.
• Load meter stores mast specification information and signal voltage values during no-load of the load sensor to
the multifunction display, and indicates based on these. When servicing the mast or load sensor, or replacing
related parts, matching (updating the sensor signal voltage value and mast specification information in the
standard vehicle condition) is necessary.
Matching Items and Prerequisite for Implementation
1. SAS
Prerequisite for
No. Indication Description
implementation
Stores the tilt angle sensor output value with fork in the horizontal position to
1 TILTL *1, *2, *3, *6, *7, *8
the controller.
Stores the tilt angle sensor output value at the forward tilt limit position and *1, *2, *3, *4, *6, *7,
2 TILTF LOAD
the load sensor output value with no load to the controller. *8
Stores the tire angle sensor output value while the vehicle is traveling straight
3 TIRE *1, *5
to the controller.
4 SWING Unused —
2. MINI LEVER (mini lever or joystick vehicle only)
Prerequisite for
No. Indication Description
implementation
Lift lever angle sensor output value in the lift lever neutral position is stored in
6 LEVER1 *1, *9
the controller.
Tilt lever angle sensor output value in the tilt lever neutral condition is stored
7 LEVER2 *1, *10
in the controller.
Attachment (1) lever angle sensor output value in the attachment (1) lever
8 LEVER3 *1, *11
neutral position is stored in the controller.
Attachment (2) lever angle sensor output value in the attachment (2) lever
9 LEVER4 *1, *12
neutral position is stored in the controller.
20-59
3. LOAD METER (Vehicle with multifunction display DX model only)
Prerequisite for
No. Indication Description
implementation
Number of the mast lift cylinder is stored.
10 LIFT CYL. NUMBERS *7, *13
(Number combining front and rear)
11 LIFT CYL. BORE Bore of the lift cylinder is stored. *7, *13
12 LOADMETER 0 SET Zero point of the load gauge is stored. *4, *6, *7, *13
When you want to
13 COMPENSATION Accuracy of the load meter is adjusted.
adjust the accuracy
Prerequisite content for implementation
*1: SAS/OPS controller replacement
*2: Tilt angle sensor removing/installing or replacement
*3: Length change or replacement of tilt angle sensor rod
*4: When removing/installing or replacing load sensor
*5: When removing/installing or replacing tire angle sensor or sensor cover
*6: When installing or changing attachment or fork
*7: When removing/installing or replacing mast
*8: When removing/installing or replacing tilt cylinder
*9: When replacing lift lever angle sensor
*10: When replacing tilt lever angle sensor
*11: When replacing attachment (1) lever angle sensor
*12: When replacing attachment (2) lever angle sensor
*13: When replacing multifunction display
Before Starting Matching
Before performing matching, you must set the vehicle to "standard condition". For "standard vehicle condition", refer
to Section 18, "SAS/OPS".
20-60
MATCHING MENU Screen
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
2. Press switch (1) 3 times to check that "4. MATCHING" is
(1) With travel and selected, and press (enter) switch (4) to display the
load handling control MATCHING MENU screen.
3. Select the menu with switch (1), and press (enter) switch (4) to
move to the MATCHING setting screen of the selected item.
4. Press (enter) switch (4) while selecting "4. END" menu to
return to MASK MENU screen.
(1) (4)
"1. SAS"
Switch (1): Switching selection to next item
Switch (4): To MATCHING SET screen
"2. MINI LEVER"
Switch (1): Switching selection to next item
Switch (4): To MATCHING SET screen
"3. LOAD METER"
Switch (1): Switching selection to next item
Switch (4): To MATCHING SET screen
"4. END"
Switch (1): Returning to "1. SAS" selection
Switch (4): Returning to MASK MENU screen
Note:
• "2. MINI LEVER" will not be displayed other than on mini
lever or joystick vehicle.
• "3. LOAD METER" will not be displayed on vehicles other
than DX model.
20-61
SAS (MATCHING SAS)
Matching is performed for standard functions.
Operating Procedure
1. Display the MATCHING MENU screen.
2. Check that "1. SAS" is selected, and press (enter) switch (4) to
(1) With travel and display MATCHING SET screen.
load handling control On MATCHING SET screen:
Values in bracket ( ) are currently stored value.
Values outside bracket ( ) are current vehicle condition value.
Note:
• You cannot move directly from each matching set screen
of SAS to the matching set screen of the other items.
Return to MATCHING MENU screen once, then move to
(1) (4) matching set screen of each item.
• In standard vehicle condition, if the value in the bracket ( )
and the value outside the bracket ( ) are different,
matching is required.
"TILTL" Screen
If matching is performed (press switch (1)), "OK" is indicated
on the display.
Switch (1): Pressing this for more than 2 seconds will perform
matching
Switch (4): To "TILTF LOAD" screen
"TILTF LOAD" Screen
If matching is performed (press switch (1)), "OK" is indicated
on the display.
Switch (1): Pressing this for more than 2 seconds will perform
matching
Switch (4): To "TIRE" screen
20-62
"TIRE" Screen
If matching is performed (press switch (1)), "OK" is indicated
on the display.
Switch (1): Pressing this for more than 2 seconds will perform
matching.
Switch (4): To "SWING" screen
"SWING" Screen
Unused.
Switch (4): Returning to MATCHING MENU screen
MINI LEVER (MATCHING MINI LEVER or JOYSTICK)
Matching is performed for mini lever or joystick functions.
Operating Procedure
1. Display the MATCHING MENU screen.
2. Press switch (1) to check that "2. MINI LEVER" is selected,
(1) With travel and and press (enter) switch (4) to display the MATCHING SET
load handling control screen.
On MATCHING SET screen:
Values in bracket ( ) are currently stored value.
Values outside bracket ( ) are current vehicle condition value.
Note:
• You cannot move directly from each matching set screen
of MINI LEVER to the matching set screen of the other
(1) (4) items. Return to MATCHING MENU screen once, then
move to matching set screen of each item.
• In standard vehicle condition, if the value in the bracket ( )
and the value outside the bracket ( ) are different,
matching is required.
20-63
"LEVER1" Screen
If matching is performed (press switch (1)), "OK" is indicated
on the display.
Switch (1): Pressing this for more than 2 seconds will perform
matching
Switch (4): To "LEVER2" screen
"LEVER2" Screen
If matching is performed (press switch (1)), "OK" is indicated
on the display.
Switch (1): Pressing this for more than 2 seconds will perform
matching.
Switch (4): To "LEVER3" screen
"LEVER3" Screen
If matching is performed (press switch (1)), "OK" is indicated
on the display.
Switch (1): Pressing this for more than 2 seconds will perform
matching.
Switch (4): To "LEVER4" screen
Note:
"LEVER3" screen will be displayed according to the number of
ways being set.
"LEVER4" Screen
If matching is performed (press switch (1)), "OK" is indicated
on the display.
Switch (1): Pressing this for more than 2 seconds will perform
matching.
Switch (4): Returning to MATCHING MENU screen
Note:
"LEVER4" screen will be displayed according to the number of
ways being set.
20-64
LOAD METER (MATCHING LOAD METER)
In order to optimize the load meter, it is necessary to input each value of the "number of lift cylinders", "lift cylinder
bore", "0 point adjustment" and "accuracy adjustment" according to the mast attached, on the display.
These values are already set at the time of shipment, but when replacing the mast or readjustment is required for the
accuracy of the load meter, set these values again.
Operating Procedure
1. Display the MATCHING MENU screen.
2. Press switch (1) twice to check that "3. LOAD METER" is
(1) With travel and selected, and press (enter) switch (4) to display "LIFT CYL.
load handling control NUMBERS" screen.
Note:
You cannot move directly from each setting screen of LOAD
METER to the matching set screen of the other items. Return
to MATCHING MENU screen once, then move to matching set
screen of each item.
(1) (2) (3) (4)
"LIFT CYL. NUMBERS" Screen
Switch (2): Reducing the number of cylinders
Switch (3): Increasing the number of cylinders
Switch (4): To "LIFT CYL. BORE" screen
Number of lift cylinders
Mast type Number of lift cylinders
V 2
FV, FSV 3
"LIFT CYL. BORE" Screen
Switch (2): Making cylinder bore smaller
Switch (3): Making cylinder bore larger
Switch (4): To "LOADMETER 0 SET" screen
Front lift cylinder bore
Cylinder bore (mm)
Vehicle model Front lift cylinder
Lift cylinder
(FV/FSV mast)
1 ton series 45 70
2/K2 ton series 50 75
3/K3 ton series 55 85
J35 ton series 60 90
20-65
"LOADMETER 0 SET" Screen
If matching is performed (press switch (1) for more than 2
seconds), "OK" (or "NG") is displayed on the display.
OK: Matching completed
NG: Signal voltage value is outside the matching range
When "NG" is indicated, check the vehicle condition,
abnormalities of load sensor, disconnection and short circuit of
the harness.
Note:
Make sure to perform matching with the vehicle set to
"standard vehicle condition".
Switch (1): Performing matching
Switch (4): To "COMPENSATION" screen
"COMPENSATION" Screen
This function corrects values indicated on the display
according to actual live load.
When performing correction, set the mast vertically and take
on loading object (object with its accurate weight is known),
then while raising the fork for approx. 1 m, adjust the value
indicated on the top right hand corner of the screen to the
laden weight by operating the switch.
Switch (2): Minus correction
Switch (3): Plus correction
Switch (4): Returning to MATCHING MENU screen
20-66
TIRE CONSTANT SET
GENERAL
It is necessary to input the tire constant to the controller according to the tire radius, for optimizing the speedometer
reading. Although the tire constant is set to the value of new tires at the time of shipment, adjust it whenever the tire
size or type is changed according to "Tire Constant List".
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
2. Press switch (1) 4 times to check that "5. WHEEL RADIUS" is
(1) With travel and selected, and press (enter) switch (4) to display the TIRE
load handling control CONSTANT setting screen.
3. Change the tire constant to desired value with switch (2) and
switch (3), and press (enter) switch (4) to set the value and
return to MASK MENU screen.
(1) (2) (3) (4)
"WHEEL RADIUS" Screen
Switch (2): Reducing tire constant
Switch (3): Increasing tire constant
Switch (4): Entering tire constant and returning to MASK
MENU screen.
20-67
Tire Constant List
Vehicle model Specification Tire size Tire type Tire constant
6.00-9 10PR J lag (STD)/long life 278
Single 6.00-9 Non-puncture (J lag white) 278
1.0 ton model 6.50-10 10PR J lag/long life 304
4.50-12 8PR J lag/long life 292
Double
4.50-12 Non-puncture (J lag) 293
6.50-10 10PR J lag (STD)/long life 301
6.50-10 Non-puncture (J lag white) 303
Single J lag 270
21X8-9 10PR
1.5 ton model Long life 278
21X8-9 Non-puncture (J lag) 278
4.50-12 8PR J lag/long life 293
Double
4.50-12 Non-puncture (J lag) 294
6.50-10 10PR J lag (STD)/long life 300
6.50-10 Non-puncture (J lag white) 303
Single J lag 269
21X8-9 10PR
1.75 ton model Long life 279
21X8-9 Non-puncture (J lag) 278
4.50-12 8PR J lag/long life 293
Double
4.50-12 Non-puncture (J lag) 292
J lag (STD) 344
7.00-12 12PR
Single Long life 348
7.00-12 Non-puncture (J lag white) 346
2.0 and 2.5 ton model 5.50-15 8PR J lag/long life 357
5.50-15 Non-puncture (J lag) 354
Double
7.00-12 12PR J lag/long life 358
7.00-12 Non-puncture (J lag) 350
K2.0 and K2.5 ton 21X8-9 14PR J lag (STD) 279
Single
model 21X8-9 Non-puncture (J lag white) 275
23X9-10 16PR J lag (STD) 298
K3.0 ton model Single
23X9-10 Non-puncture (J lag white) 306
28X9-15 12PR J lag (STD)/long life 375
Single
28X9-15 Non-puncture (J lag white) 376
6.00-15 10PR J lag/long life 373
3.0 ton model
6.00-15 Non-puncture (J lag) 369
Double
28X8-15 12PR J lag/long life 380
7.00-15 Non-puncture (J lag) 395
250-15 16PR J lag (STD)/long life 388
Single
250-15 Non-puncture (J lag white) 383
6.00-15 10PR J lag/long life 369
J3.5 ton model
6.00-15 Non-puncture (J lag) 369
Double
28X8-15 12PR J lag/long life 380
7.00-15 Non-puncture (J lag) 393
20-68
ENGINE IDLE SPEED ADJUSTMENT (4Y-E ENGINE VEHICLE)
GENERAL
Adjusts 4Y-E engine idle speed.
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
2. Press switch (1) 5 times to check that "6. IDLE
(1) With travel and ADJUSTMENT" is selected, and press (enter) switch (4) to
load handling control display the IDLE ADJUSTMENT setting screen.
3. Change the speed to desired value with switch (2) and switch
(3), and press (enter) switch (4) to set the value and return to
MASK MENU screen.
(1) (2) (3) (4)
"IDLE ADJUSTMENT" Screen
Switch (2): Reducing the speed
Switch (3): Increasing the speed
Switch (4): Entering idle speed and returning to MASK MENU
screen.
20-69
LCD CONTRAST ADJUSTMENT
GENERAL
Adjusts LCD contrast.
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
2. 4Y-E engine vehicle
Press switch (1) 6 times to check that "7. CONTRAST" is
selected, and press (enter) switch (4) to display the
CONTRAST ADJUSTMENT setting screen.
1DZ-II/2Z engine vehicle
Press switch (1) 5 times to check that "6. CONTRAST" is
selected, and press (enter) switch (4) to display the
CONTRAST ADJUSTMENT setting screen.
3. Change the contrast level with switch (2) and switch (3), and
press (enter) switch (4) to set the value and return to MASK
(1) With travel and MENU screen.
load handling control
(1) (2) (3) (4)
"CONTRAST" Screen
Switch (2): Reducing contrast
Switch (3): Increasing contrast
Switch (4): Entering idle speed and returning to MASK MENU
screen.
20-70
METER START
GENERAL
Starts counting the odometer, trip meter and maintenance hour meter.
Operating Procedure
1. Enter the password on the general screen (Refer to page 20-
14) to display the MASK MENU screen.
2. 4Y engine vehicle
Press switch (1) 7 times to check that "8. METER START" is
selected, and press (enter) switch (4) to display the METER
START setting screen.
1DZ-II/2Z engine vehicle
Press switch (1) 6 times to check that "7. METER START" is
selected, and press (enter) switch (4) to display the METER
START setting screen.
(1) With travel and
load handling control
(1) (2) (3) (4)
"METER START" Screen
3. Press switch (2) for more than 2 seconds to display the right
arrow on the screen.
20-71
4. While pressing switch (2), if you press switch (3), inverted NO
on the screen turns to inverted YES, and the setting is
completed.
5. Press switch (4) to return to MASK MENU screen.
Note:
After completing the meter start setting, "METER START" will
not be displayed on the MASK MENU screen.
Note:
If the meter start is not set yet, the symbol indicating that the
hour meter is not started will be displayed on the GENERAL
screen.
20-72
MULTIFUNCTION DISPLAY ASSY
DISASSEMBLY·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
T = 0.6 ~ 0.8 (6 ~ 8) [0.43 ~ 0.58]
3
2
Removal Procedure
1 Remove the case
2 Remove the board and LCD panel ASSY from the cover.
3 Disconnect the LCD panel ASSY flat cable from the board. [Point 1]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
20-73
LCD panel Point Operations
[Point 1]
(1) Reassembly:
Follow the procedure below to install the LCD panel to the
(2) (1)
housing.
1. Remove the protective sheet from the back face of the LCD
panel.
2. Install the LCD panel to the housing according to the following
Housing steps.
(1) Press the upper part of the LCD panel to the claws. When
pressing the panel, do not apply excessive force.
(2) Press the lower part of the LCD panel to engage the
claws.
Note:
Do not damage the LCD panel.
3. After installing the LCD panel, remove the protective sheet
from the front face of the LCD panel.
Note:
After removing the protective sheet, do not touch the surface
of the LCD panel.
21-1
ELECTRICAL SYSTEM TROUBLESHOOTING
Page Page
BEFORE TROUBLESHOOTING 0
TROUBLESHOOTING.........21-2 (OPT EQUIPPED
VEHICLE*) ......................... 21-65 1
CONNECTOR HANDLING ........21-2
BEFORE BEGINNING 2
WIRE HARNESS AND
CONNECTOR INSPECTION TROUBLESHOOTING
FOR THE 4Y-E ENGINE ....... 21-65 3
PROCEDURE .......................21-2
TROUBLESHOOTING DIAGNOSIS (SELF 4
DIAGNOSIS FUNCTION) ..... 21-66
(SAS-LESS MODEL) ...........21-4 5
DIAGNOSIS DISPLAY
OPS PLUG-IN ANALYZER....21-6 METHOD............................ 21-66 6
SCREEN CONFIGURATION .....21-6 LIST OF DIAGNOSIS
CODES .............................. 21-67
7
BASIC OPERATION ................21-7
WARNING LIST .................... 21-73 8
ANALYZER.............................21-9
TROUBLESHOOTING ...........21-13
VIEWING RELATED 9
PORTIONS ......................... 21-74
OPS 10
ERROR CONFIRMATION
TROUBLESHOOTING.......21-15 DRIVE MODE ..................... 21-74 11
DIAGNOSIS ..........................21-15 TROUBLESHOOTING
BY ERROR CODE ............... 21-75
12
DIAGNOSIS ERROR
CODE LIST .........................21-16 TROUBLESHOOTING 13
TROUBLESHOOTING WHEN THERE IS NO
ERROR CODE .................. 21-217 14
BY ERROR CODE ...............21-19
TROUBLESHOOTING 15
BY PHENOMENON .............21-34 16
17
*: An OPT equipped vehicle means vehicles that are equipped with the following options:
4Y engine with electronic control, mini lever, joystick, 3-way catalytic converter system,
travel and load handling control, multifunction display, and deluxe multifunction display.
18
19
20
21
E
21-2
BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull the wire harness
but hold the connector itself and pull it after unlocking it.
To connect, push the connector fully until it is locked in
position.
3. Bring a tester probe into contact with a connector terminal from
the rear side of the connector (harness side).
4. If insertion from the rear side is impossible, as in the case of a
waterproof connector, bring the tester probe carefully into
contact with the terminal so as not to cause deformation of the
connector terminal.
5. Do not touch connector terminals directly with your hand.
6. When bringing tester probes into contact with terminals that
voltage is applied to prevent two tester probes from coming
into contact with each other.
WIRE HARNESS AND CONNECTOR
INSPECTION PROCEDURE
When any trouble occurs, first inspect the connectors and wire
harness of the related circuit according to the following procedure:
Continuity Inspection
1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between corresponding terminals of
the connectors at both ends.
Standard: 10 Ω or less
Note:
• Measure while jiggling the wire harness up and down and
sideways.
• Open circuit at the wire harness occurs rarely partway
through a vehicle wiring but mostly at connectors. Inspect
especially the sensor connectors with sufficient care.
21-3
Short Circuit Check
1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between the corresponding connector
terminal and frame. Be sure to inspect the connectors at both 0
ends.
Standard: 1 MΩ or above 1
Note:
Measure while jiggling the wire harness up and down and 2
sideways.
3. Measure the resistance between terminals of the
3
corresponding connector. Be sure to inspect the connectors at
both ends. 4
Standard: 1 MΩ or above
5
Note:
The wiring may short-circuit due to pinching by the body or
defective clamping.
6
7
Visual and Contact Pressure Checks
8
1. Disconnect the connectors at both ends of the corresponding
harness.
9
2. Visually inspect that there is neither rust nor foreign matter 10
trapped at connector terminals.
3. Inspect that there is no looseness or damage at the crimped 11
portion. Also, lightly pull the wire harness from the connector to
check that it does not come off. 12
13
4. Insert a male terminal same as that of the connector terminal
to a female connector and check the drawing force.
Defective contact may exist at a terminal where the drawing 14
force is less than that of other terminals.
Note:
15
Even if there is rust or foreign matter trapped at the terminal,
or the contact pressure between male and female terminals is 16
low, abnormal contact condition may be changed to normal by
disconnecting and reconnecting the connector. In this case, 17
disconnect and reconnect the connector several times, and if
a fault occurs even once, then consider the terminal may have
a defective contact.
18
19
20
21
E
21-4
TROUBLESHOOTING (SAS-LESS MODEL)
NAME OF EACH PART
(3) (4)
(13)
(2)
(1)
(14)
(7) (8) (9) (10)
(11) (12) (16)
(5) (6)
(15)
(1) OPS controller (9) Backward tilt switch
(2) Seat switch (10) Unload valve
(3) Forward switch (11) Lift lock valve
(4) Reverse switch (12) Tilt control valve
(5) Forward interrupt relay (13) OPS lamp
(6) Reverse interrupt relay (14) OPS buzzer
(7) Lower switch (15) Plug-incanalyzer
(8) Forward tilt switch (16) Backward tilt lock valve
21-5
FUNCTION OF EACH PART
Input to controller
Name Function
(2) Seat switch Mounted underneath the seat and detects the operator sitting on the seat.
Forward switch
Inputs the voltage branched from the forward drive valve power supply 0
(3) line of the torque converter to the OPS controller for detecting forward
(torque converter vehicle only)
drive operation.
Inputs the voltage branched from the reverse drive valve power supply
1
Reverse switch
(4) line of the torque converter to the OPS controller for detecting reverse
(torque converter vehicle only)
drive operation. 2
Installed at the lift spool of the oil control valve and detects the lowering
(7) Lower switch
operation by the lift lever. 3
Installed at the tilt spool of the oil control valve and detects the forward
(8) Forward tilt switch
operation of the tilt lever. 4
Installed at the tilt spool of the oil control valve and detects the backward
(9) Backward tilt switch
operation of the tilt lever.
5
Output from controller
Name Function
6
(5) Forward interrupt relay
Interrupts the voltage supply to the forward drive valve in the torque
converter according to the instruction from the OPS controller.
7
(6) Reverse interrupt relay
Cuts off the voltage supply to the reverse drive valve in the transmission
according to the instruction from the OPS controller. 8
Provides a bypass to the tank circuit for the hydraulic oil supplied from the
(10) Unload valve
oil pump to the oil control valve. 9
Cuts off the oil flow from the lift cylinder to the oil tank according to the
(11) Lift lock valve
instruction from the OPS controller to disable fork lowering. 10
Changes the oil path to the tilt cylinder according to the instruction from
(12) Tilt control valve the OPS controller to disable forward tilting and to slow down the
backward tilting speed.
11
(13) OPS lamp
Lights while the seat switch is off to indicate the OPS operation.
Furthermore, it blinks when the OPS controller detects any abnormality. 12
Sounds in the predetermined pattern when the seat switch is turned off or
(14) OPS buzzer when the forward/reverse shift lever needs returning to the neutral 13
position (return to neutral warning).
Added with the OPS analyzer functions to the service functions of the 14
conventional SAS analyzer. It is connected to the same service connector.
OPS analyzer functions
• Diagnostic display (More detailed display than OPS lamp blinking 15
(15) Plug-in analyzer
frequency)
• I/O monitor display (Shortening the time required for troubleshooting)
• Output test (Shortening the troubleshooting time by setting each output
16
on and off according to the instruction from the OPS controller)
Cuts off the oil flow from the tilt cylinder bottom side to the oil tank
17
Backward tilt lock valve
(16) according to the instruction from the OPS controller to disable backward
(Standard lever vehicle)
tilt. 18
19
20
21
E
21-6
OPS PLUG-IN ANALYZER
For the maintenance and service of OPS 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 OPS functions and
the error information detected by the controller. It serves to check on the operating state of OPS functions and
shortens the repair time for a problem. Moreover, it is installed with save function to file data displayed on the screen
in the SST.
SST 09240-23323-71
Menu name Content of function Reference page
with the OPS controller on
DIAG MEMORY Indication of ten error codes and sub-codes in the past. 21-9
Communication function
the vehicle side
Monitoring input voltage values from the sensors and the output
IN/OUT MONITOR 21-10
signal, etc. to the solenoid, etc.
OPS
ACTIVE TEST Forced operation of solenoids and warning lamps. 21-11
CONTROLLER DATA Indication of OPS controller abbreviation number and version 21-12
SCREEN CONFIGURATION
Page
21-9
21-10
21-10
21-10
21-11
21-12
21-7
BASIC OPERATION
Name of Sections and the Switch Functions
Position of
Name of section Mark Function Switch
indication
Main unit
• Move the cursor to the above item.
• Move to the preceding page.
Selector
A • Move the cursor to right or left. switch c
<Blank> <No function>
Connector • Select the item below.
• Move to the following page.
Selector
Screen title A Switch B
switch e
<Blank> <No function>
• Determine an item for selection.
Menu
C
B switch e
C Switch mark
indicator <Blank> • Move to MENU screen.
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.
• Do not apply strong impact to the analyzer due to dropping or collision.
• Do not leave the analyzer under the direct rays of the sun for long time.
Connection and Operation of SST
1. Turn the ignition key switch OFF.
2. Open the diagnosis connector cover of the vehicle and
properly connect the connector on the SST side.
SST 09240-23323-71
SST Note:
Since the connector has no locking device, securely connect
Diagnosis it to prevent contact defect upon closing the engine hood with
connector the connector in connected state.
3. Turn the ignition key switch ON or start the engine.
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 MENU switch e.
21-8
5. "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 c
or d.
• Japanese
• English
(2) Press MENU switch e to determine the language setting.
Note:
Once the display language is defined, "LANGUAGE SET"
screen will not be displayed from the next time onward. To
change the language, go to "TESTER SET" of "MAIN MENU".
6. "MAIN MENU" screen
(1) Select the menu using selector switch c and d and
determine by pressing MENU switch e.
• SAS: Moves to SAS MENU screen.
• OPS: Moves to OPS ANALYZER MENU Screen.
• TESTER SET: Moves to TESTER SET screen.
Removal of SST
1. Check that the screen title is for one of the MENU screens.
2. Turn the ignition key switch OFF.
3. Disconnect the connector.
Note:
To disconnect, hold the body of the connector.
4. Close the diagnosis connector cover.
21-9
ANALYZER
ANALYZER MENU Display contents and function Page
1. DIAG MEMORY Indication of error codes for 10 most recent errors 21-9
2. IN/OUT MONITOR Indication of operating conditions of vehicle electrical system 21-10
3. ACTIVE TEST Forced operation signal output to the selected item 21-11
4. CONTROLLER DATA Indication of the OPS controller part number and version 21-12
Operation Procedure
1. Select and enter "2OPS" on the main menu screen to display
the OPS ANALYZER MENU screen.
2. ANALYZER MENU screen
(1) Move the cursor to the desired menu by operating
selector switch c or d, and enter by operating MENU
switch e.
(2) Select and enter "END" to return to the MAIN MENU
screen.
"1 DIAG MEMORY"
This screen displays ten error codes from the most recent one.
[Explanation on display contents]
(1) Order of error occurrence
(2) Error codes
[Clear memory]
Press selector switch c continuously for 2 seconds.
(1) (2)
[End]
Press MENU switch e to return to the ANALYZER MENU screen.
Note:
• Only "-" appears at the end of the item involving no error
occurrence.
• If reception has not been completed, only the number
appears without "-" indication.
21-10
"2 IN/OUT MONITOR"
[Explanation on display contents]
(1) (1) SEAT: Seat switch input signal
(2)
(2) DIR: Direction switch input signal (T/C vehicle only)
(3)
FWD: Forward direction switch input signal
(4) REV: Reverse direction switch input signal
(3) RLY: Output signal to forward/reverse interrupt relay and
backward tilt lock solenoid (T/C vehicle only)
FWD: Output signal to forward/reverse interrupt relay
(1)
(5) REV: Output signal to backward tilt lock solenoid
(6)
(7) (4) VOLTAGE: OPS controller power supply voltage
(8)
(5) LIFT LOWER: Lift lowering switch input signal
(4)
(6) UNLOAD SOL: Output signal to unload solenoid
(7) LWR SOL: Output signal to lowering lock solenoid
(8) TILS SOL: Output signal to tilt solenoid
(9) TILT: Tilt lever switch input signal
(1) FWD: Forward tilt switch input signal
(9)
BWD: Backward tilt switch input signal
*
(8) CONT: SAS tilt control command input signal
(10)
(4) (10) LSOPT: Reserved.
*: “CONT—” appears on the SAS-less spec. model. [End]
Press MENU switch e to return to the ANALYZER MENU screen.
21-11
"3 ACTIVE TEST"
Note:
ON indication on the screen shows the controller output state.
(1)
(2) The operation, therefore, should be checked visually, by
(3) operating sound, etc.
(4)
(5) 1. Select the item by selector switch d, and set OFF/ON by
(6)
selector switch c.
(7)
[Explanation on display contents]
(1) RLY FWD*
Set to ON for forced output of forward/reverse interrupt
relay activating signal. (Forward/reverse traveling
disabled state)
(2) RLY REV*
Set to ON for forced output of backward tilt lock solenoid
activating signal. (Backward tilt disabled state)
(3) UNLOAD SOL
Set to ON for forced output of unload solenoid activating
signal. (Material handling disabled state)
(4) LWR SOL
Set to ON for forced output of lowering lock solenoid
activating signal. (Lowering enabled state)
(5) TILT SOL
Set to ON for forced output of tilt solenoid activating
signal. (Forward tilting enabled state with backward tilting
speed restriction)
(6) LAMP
Set to ON for forced output of OPS lamp lighting signal.
(OPS lamp lighting state)
(7) BUZZER
Set to ON for forced output of OPS buzzer sounding
signal. (Continuous OPS buzzer sounding)
* The drive power interrupting function is not provided on the
manual transmission vehicle.
2. After resetting all items to OFF, press MENU switch e to return
to the ANALYZER MENU screen.
21-12
"4 CONTROLLER DATA"
The OPS controller abbreviation No. and version No. can be
displayed on this screen.
[Explanation on display contents]
(1)
(1) DATA
Controller abbreviation No.
(2)
(2) VER
Version No.
[End]
Press MENU switch e to return to the ANALYZER MENU screen.
21-13
TROUBLESHOOTING
z No display on the screen.
Related Portion
ECU-IG
1C-14
To IG SW
1C-6
A25-12
(IG, Power supply) 1
OPS controller
A22-1 A25-1 6
Analyzer
1E-14 A25-3 13
1C-22
Analyzer CN
(E2, Main GND)
Estimated Causes:
c Connector contact defect
d Analyzer harness (power supply) defect
e Plug-in analyzer defect
NG
Check A25 and analyzer connector for any disconnection. Screen check after correction.
OK NG
Inspection 1: NG
Harness defect on vehicle side
Measure the voltage between A25-12 and A25-3.
OK
Inspection 2: NG
Analyzer harness defect
Measure the voltage between analyzer CN-1 and analyzer CN-13.
OK
Plug-in analyzer defect
Inspection 1: 6 5 4 3 2 1
Measure the voltage between A25-12 and A25-3. 11 10 9 8 7
17 16 15 14 13 12
Ignition key switch ON (engine in stopped state)
A25 (REC)
Standard:
A25-12 (+) ~ A25-3 (-) 8 ~ 16 V
Inspection 2:
Measure the voltage between analyzer CN-1 and analyzer CN-13.
Ignition key switch ON (engine in stopped state) Analyzer CN (REC)
Standard:
Analyzer CN-1(+) ~ analyzer CN-13 (-) 8 ~ 16 V
21-14
z No data display on data (DIAG MEMORY, voltage value, etc) display screen
Related Portion
ECU-IG 1C-14
To IG SW
1C-6
A25-12
(IG, Power supply) 1
OPS controller
A22-1 A25-1 6
Analyzer
1E-14 A25-3 13
1C-22
Analyzer CN
(E2, Main GND)
Estimated Causes:
c Connector contact defective
d Analyzer harness (communication) defect
e Plug-in analyzer defect
f OPS controller defect
NG
Check A25 and analyzer connector for any disconnection. Data display check after correction.
OK NG
Inspection 1: NG
Harness defect on vehicle side
Check continuity between A25-1 and A22-1.
OK
Inspection 2: NG
Analyzer harness defect
Check continuity between analyzer CN-6 and A25-1.
OK
NG
Check data display by connecting the analyzer to another vehicle. Plug-in analyzer defect
OK
OPS controller defect
Inspection 1: 6 5 4 3 2 1
Check continuity between A25-1 and A22-1. 11 10 9 8 7
17 16 15 14 13 12
Ignition key switch OFF, disconnection between A25 and A22.
A25 (REC)
Standard:
A25-1 ~ A22-1 Continuity
Inspection 2:
Check continuity between analyzer CN-6 and A25-1.
Ignition key switch OFF, disconnection between analyzer CN and A25. A25 (TAB)
Analyzer CN (REC)
Standard:
Analyzer CN-6 ~ A25-1 Continuity
21-15
OPS TROUBLESHOOTING
DIAGNOSIS
The diagnosis function informs the operator of a trouble occurrence and the trouble position by blinking the OPS
lamp on the combination meter when the OPS controller detects an abnormality. The trouble position is indicated by
the number of blinks of the OPS lamp.
Note:
• The OPS lamp is lit for 1 second upon ignition key switch ON for broken lamp check.
• The OPS lamp comes on when the operator leaves the seat.
• If multiple errors occur at a time, only the lowest error code appears. Upon correction of that error, the
next lowest error code appears.
Example:
Display example of error code 3
Break point indication Code indication
ON
OFF
2 sec. 0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.
0.5 sec. 0.5 sec. 0.5 sec.
Abnormality detection
(Code 3)
21-16
DIAGNOSIS ERROR CODE LIST
Error Phenomenon on vehicle
Lamp Vehicle spec. Error description Major cause
code T/C vehicle M/T vehicle
Dead lamp
ON — — — —
check
Blinking
Seat switch Sticking GND
(one short 1-1 SAS-less The OPS does not function.
abnormality fault
ON pulse)
Lift lowering
2-1 SAS-less switch
Blinking abnormality
Sticking GND No special change from normal state
(two short 2-2 fault (excessive leak during lowering)
ON cycles) Tilting switch
2-3 SAS-less*
abnormality
2-4
Forward/reverse
traveling is possible
Discontinuity
Forward/reverse when the OPS is
Blinking operated
SAS-less interrupt relay
(three short 3-1 —
T/C (RYF) GND fault ↑
ON cycles)
abnormality Forward/reverse
+B shorting traveling is always
disabled.
When the OPS is operated, fork lowering
and backward tilting are disabled but all
Discontinuity
other material handling operations are
possible.
Unload solenoid
GND fault ↑
4-1 (USOL)
abnormality When the OPS is operated all material
handling operations are disabled. When the
+B shorting OPS is not operated, only fork lowering is
possible and all other material handling
operations are disabled.
When the OPS is operated, all material
handling operations are disabled. When the
Blinking Discontinuity OPS is not operated, fork lowering is
(four short SAS-less disabled but all other material handling
Lowering lock
ON cycles) operations are possible.
4-2 solenoid (LSOL)
abnormality GND fault ↑
When the OPS is operated, fork lowering is
+B shorting possible but all other material handling
operations are disabled.
When the OPS is operated, all material
handling operations are disabled. When the
Tilt solenoid Discontinuity OPS is not operated, only forward tilting is
4-3 (TSOL) disabled but all other material handling
abnormality operations are possible.
GND fault ↑
+B shorting —
21-17
Error Phenomenon on vehicle
Lamp Vehicle spec. Error description Major cause
code T/C vehicle M/T vehicle
When the OPS is operated, all material
handling operations are disabled. When the
Tilt backward Discontinuity OPS is not operated, backward tilting is
Blinking disabled but all other material handling
lock solenoid
(four short 4-4 SAS-less operations are possible.
(BSOL)
ON cycles)
abnormality GND fault ↑
It may tilt backward even when the OPS
+B shorting
system is in operation.
When the OPS is
Blinking operated, it cannot be
SAS-less Shift lever
(five short 5-1 +B shorting reset (locked state by —
T/C abnormality
ON cycles) the return to neutral
function).
7-1 The drive OPS does not function. Fork
ON 7-2 lowering is always disabled. The material
7-3 CPU handling OPS does not function.
abnormality
Blinking Controller
(seven short 7-4 SAS-less None in particular.
abnormality
ON cycles)
7-5 The drive OPS does not function. Fork
EEPROM
lowering is always disabled. The material
7-6 abnormality
handling OPS does not function.
The warning before OPS operation occurs,
ON Low voltage Low battery
SAS-less but the drive/material handling OPS does not
alarm voltage
— function.
Departure from
— OPS operation —
seat
*: SAS-less spec. model only because of detection by the SAS controller here on the SAS spec. models.
21-18
List of Reference Pages for Error Codes and Sub Error Codes
Without analyzer (SST) With analyzer (SST)
Error Error
Error description Page Error description Page
code code
1 Seat switch abnormality 21-19 1-1 Seat switch abnormality 21-19
2-1 Lowering switch abnormality 21-24
2-2 Tilt lever switch simultaneous ON abnormality 21-25
Lowering switch abnormality Forward tilt switch 2-minute shorting
2 21-22 2-3 21-25
Tilt switch abnormality (L/SAS spec.) abnormality
Backward tilt switch 2-minute shorting
2-4 21-25
abnormality
Forward/reverse interrupt relay (RYF) Forward/reverse interrupt relay (RYF)
3 21-27 3-1 21-27
abnormality abnormality
4-1 Unload solenoid (USOL) abnormality
4-2 Lowering lock solenoid (LSOL) abnormality
4 Solenoid (SOL) abnormality 21-29 21-29
4-3 Tilt solenoid (TSOL) abnormality
4-4 Backward tilt lock solenoid (BSOL) abnormality
5 T/C shift lever abnormality 21-31 5-1 T/C shift lever abnormality 21-32
7-1
7-2
CPU abnormality
7-3
7 OPS controller abnormality — —
7-4
7-5
EEPROM abnormality
7-6
List of Pages to be Referenced by Phenomenon
Pages to be referenced
Description Without With
analyzer analyzer
The OPS buzzer does not sound, or keeps sounding. 21-34 21-34
The OPS lamp does not come on. 21-38 21-38
The OPS lamp keeps lighting. (Including when traveling and material handling are both disabled) 21-40 21-43
Cannot lower the fork. 21-45 21-48
The material handling OPS does not function. (Including when OPS for lowering is functional) 21-50 21-50
Material handling fails. (Including when fork lowering is not fail) 21-51 21-51
The mast backward tilting speed is slow. 21-52 21-52
Mast does not tilt forward. 21-53 21-53
The drive OPS does not function. (Excluding the M/T vehicle) 21-55 21-55
Traveling fails. (Including forward traveling only, reverse traveling only, and occasional
21-58 21-58
abnormalities) (Excluding the M/T vehicle)
Mast does not tilt backward. 21-61 21-63
21-19
TROUBLESHOOTING BY ERROR CODE
z Error Code 1 · 1-1 (Seat switch abnormality)
Related Portion
OPS controller
A22-23 (DMI, Seat SW) AO1-1 XO4-1 X1-2
Seat switch
A22-17 (E03, Switch GND) 1B-24 1E-30 XO4-2 X1-1
Estimated Causes:
c Connector contact defect
d Seat switch defect
e Harness defect
f Controller defect
Error code 1
Check A22, 1B, 1E, XO4, AO1 and X1 connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG
Inspection 1: NG
Seat switch defect
Check the seat switch individually for continuity.
OK
Inspection 2: NG
Harness defect
Check continuity between A22-23 and A22-17
OK
Controller defect
*: After correction, check the OPS lamp indication.
After connecting all connectors, turn the ignition key switch OFF once, then ON (for 2 seconds or more), and OFF
again.
After waiting without seating for about 15 minutes and turn the ignition key switch ON. The OPS must not display
error code 1 by blinking.
21-20
Inspection 1:
Check the individual seat switch for continuity.
Ignition key switch OFF, X1 disconnected.
Standard:
Seated Unseated
X1-1 ~ X1-2 Continuity No continuity
Inspection 2:
Check for continuity between A22-23 and A22-17.
Ignition key switch OFF, A22 disconnected. (AO1, 1B, 1E, XO4 and X1 must be
kept connected.)
Standard:
Seated Unseated
A22-23 ~ A22-17 Continuity No continuity
Error code 1-1
Check A22, AO1, 1B, 1E, XO4 and X1 connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG
Inspection 1: OK
Seat switch defect
With X1 disconnected, check the input signal to the controller.
NG
Inspection 2: NG
Harness defect
Check for continuity between A22-23 and A22-17.
OK
Controller defect
*: After correction, check the OPS lamp indication.
After connecting all connectors, turn the ignition key switch OFF once, then ON (for 2 seconds or more), and OFF
again.
After waiting without seating for about 15 minutes and turn the ignition key switch ON. The OPS must not display
error code 1 by blinking.
21-21
Inspection 1:
With X04 disconnected, check the input signal to the controller.
X04 connector disconnected, ignition key switch OFF ⇒ ON
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Seated Unseated
SEAT OFF OFF
Inspection 2:
Check for continuity between A22-23 and A22-17.
Ignition key switch OFF, A22 disconnected. (AO1, 1B, 1E, XO4 and X1 must be kept
connected.)
Standard:
Seated Unseated
A22-23 ~ A22-17 Continuity No continuity
21-22
z Error Code 2
z Error Code 2-1 (Lowering switch abnormality)
z Error Code 2-2 (Tilt lever switch simultaneous ON abnormality)
z Error Code 2-3 (Forward tilt switch 2-minute shorting abnormality)
z Error Code 2-4 (Backward tilt switch 2-minute shorting abnormality)
Related Portion
A22-25 (TFI, Forward tilt switch) A13-1
Forward tilt
A13-2
switch
A22-24 (TRI, Backward tilt switch) A13-3
OPS controller
Backward tilt
A13-4 switch
A22-26 (DOWN, Lowering switch) A14-1
1C-19
Lowering switch
1C-20
A22-17 (E03, SW-GND) 1B-24 1C-23 A14-2
Estimated Causes:
c Connector contact defect g Forward tilt switch defect
d Lowering switch defect h Backward tilt switch defect
e Harness defect i Tilt switch installation defect
f Controller defect j Lowering switch installation defect
Error code 2
Check the A22, A13, A14, 1B, and 1C connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG
Inspection 1: OK
Controller defect
Check the lift lowering switch wiring and tilt lever switch wiring for
continuity.
NG
Inspection 2: OK
Harness defect
Check the lift lowering switch and tilt lever switch individually
(as installed on the vehicle) for continuity.
NG
Inspection 3: NG
Switch defect
Check the lift lowering lever switch and tilt lever switch individually
(as removed from the vehicle) for continuity.
OK
Lever switch installation defect
*: After correction, check the OPS lamp indication.
After the ignition key switch is turned ON, operate the tilt lever forward and backward to check if the OPS lamp
blinks.
Or keep the tilt lever in the neutral position for 2 minutes and check if the OPS lamp blinks.
Or keep the lift lever in the neutral position for 2 minutes and check if the OPS lamp blinks.
The OPS lamp must not indicate error code 2 by blinking.
21-23
Inspection 1:
Check the lift lower lever switch wiring and tilt lever switch wiring for continuity.
Ignition key switch OFF, A22 disconnected.
Standard:
• Lift lower switch
Lever at neutral position Lever at up position Lever at down position
A22-26 ~ A22-17 No continuity No continuity Continuity
• Tilt switch
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
A22-25 ~ A22-17 No continuity Continuity No continuity
A22-24 ~ A22-17 No continuity No continuity Continuity
Inspection 2:
Check the lift lower lever switch and tilt lever switch individually (as installed on the 1
3
2
4
vehicle) for continuity.
Ignition key switch OFF, A14 and A13 disconnected.
Standard:
• Lift lower switch
Lever at neutral position Lever at up position Lever at down position
A14-1 ~ A14-2 No continuity No continuity Continuity
• Tilt switch
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
A13-1 ~ A13-2 No continuity Continuity No continuity
A13-3 ~ A13-4 No continuity No continuity Continuity
Inspection 3:
Check the lift lower lever switch and tilt lever switch individually (as removed from the 1
3
2
4
vehicle) for continuity.
Ignition key switch OFF, A14 and A13 disconnected.
Standard:
• Lift lower switch (switch on the upper side when installed on the vehicle)
Switch free Switch pressed
A14-1 ~ A14-2 Continuity No continuity
• Forward tilt switch (switch on the upper side when installed on the vehicle)
Switch free Switch pressed
A13-1 ~ A13-2 Continuity No continuity
• Backward tilt switch (switch on the lower side when installed on the vehicle)
Switch free Switch pressed
A13-3 ~ A13-4 Continuity No continuity
21-24
Error code 2-1
Check A22 and A14 connectors for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*
OK NG
Inspection 1: Inspection 4:
Disconnect A14, and check the switch output upon lowering operation. NG Check for continuity between A22 and
A14.
OK NG OK
Inspection 2: OK Harness Controller defect (Error
Check lift lower lever switch individually (as installed on the vehicle) for defect occurrence upon
continuity. continuing lowering
operation for 2 minutes
NG
or more, however, is
normal.)
Inspection 3: NG Lower switch defect
Check the lift lower lever switch individually (as removed from the
vehicle) for continuity.
OK
Lever switch installation defect
*: After correction, check the OPS lamp indication.
After the ignition key switch is turned ON, keep the lift lever in the neutral position for 2 minutes and check if the
OPS lamp blinks.
The OPS lamp must not indicate error code 2 with blinking.
Inspection 1:
Disconnect A14 and check the switch output upon lowering
operation.
Ignition key switch ON (engine in stopped state)
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Lift lower switch
Lever at neutral position Lever at up position Lever at down position
LIFT LOWER OFF OFF OFF
Inspection 2:
Check the lift lower lever switch individually (as installed on the vehicle) for continuity.
Ignition key switch OFF, A14 disconnected.
Standard:
Lift lower switch
Lever at neutral position Lever at up position Lever at down position
A14-1 ~ A14-2 No continuity No continuity Continuity
21-25
Inspection 3:
Check the lift lower lever switch individually (as removed from the vehicle) for continuity.
Ignition key switch OFF, A14 disconnected.
Standard:
Lift lower switch (switch on the upper side when installed on the vehicle)
Switch free Switch pressed
A14-1 ~ A14-2 Continuity No continuity
Inspection 4:
Check for continuity between A22 and A14.
Ignition key switch OFF, A22 and A14 disconnection.
Standard:
A22-26 ~ A22-17 No continuity
Error codes: 2-2, 2-3, and 2-4
Check A22 and A13 connectors for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*
OK NG
Inspection 1: NG Inspection 4:
Disconnect A13, and check the switch output upon tilting operation. Check for continuity between A22 and
A13.
OK
NG OK
Inspection 2: OK Harness Controller defect
Check the tilt lever switch individually (as installed on the vehicle) for defect (Error occurrence upon
continuity. continuing lever
operation for 2 minutes
NG or more or upon
simultaneous ON during
installation adjustment,
however, is normal.)
Inspection 3: NG
Tilt switch defect
Check the tilt lever switch individually (as removed from the vehicle) for
continuity.
OK
Lever switch installation defect
*: After correction, check the OPS lamp indication.
After the ignition key switch is turned ON, keep the lift lever in the neutral position for 2 minutes and check if the
OPS lamp blinks.
The OPS lamp must not display error code 2 by blinking.
21-26
Inspection 5:
Check the switch output upon tilting operation after disconnecting
A13.
Ignition key switch ON (engine in stopped state)
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Tilt switch
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
TILT FWD OFF OFF OFF
TILT BWD OFF OFF OFF
Inspection 6:
Check the tilt lever switch individually (as installed on the vehicle) for continuity. 1
3
2
4
Ignition key switch OFF, A13 disconnected.
Standard:
Tilt switch
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
A13-1 ~ A13-2 No continuity Continuity No continuity
A13-3 ~ A13-4 No continuity No continuity Continuity
Inspection 7:
Check the tilt lever switch individually (as removed from the vehicle) for continuity. 1
3
2
4
Ignition key switch OFF, A13 disconnected.
Standard:
• Tilt forward switch (switch on the upper side when installed on the vehicle)
Switch free Switch pressed
A13-1 ~ A13-2 Continuity No continuity
• Tilt backward switch (switch on the lower side when installed on the vehicle)
Switch free Switch pressed
A13-3 ~ A13-4 Continuity No continuity
Inspection 8:
Check for continuity between A22 and A13.
Ignition key switch OFF, A22 and A13 disconnected.
Standard:
A22-25 ~ A22-17 No continuity
A22-24 ~ A22-17 No continuity
21-27
z Error Code 3
z Error Code 3-1 (Forward/reverse interrupt relay (RYF) abnormality)
Related Portion
A22-10 (RYF, J/B
Forward/reverse interrupt relay) 1B-8 2
Forward
interrupt
OPS controller
1 relay
2
Reverse
interrupt
A22-17 (E03, SW-GND) 1B-24 1 relay
1A-9 1A-7
Estimated Causes:
c Connector contact defect f Harness defect
d Forward interrupt relay defect g Controller defect
e Reverse interrupt relay defect
Error Codes 3, 3-1
Check the A22, 1A and 1B connectors for disconnection or internal NG After correction, check the OPS lamp
wetting and the relays for insertion. indication.*
OK NG
Inspection 1: NG
Interrupt relay defect
Check the forward/reverse interrupt relay individually (on the coil side)
for the resistance value.
OK
Inspection 2: NG
Check the wiring between A22 and the interrupt relays for continuity. Harness defect
OK
Controller defect
*: After correction, check the OPS lamp indication.
After the ignition key switch is turned ON, place the shift lever in the forward or reverse position and leave the seat
to check if the OPS lamp blinks.
The OPS lamp must not display error code 3 by blinking.
Note:
When the analyzer is provided, check the related portion after checking the error memory for the current
error code. See page 21-9 "1 DIAG MEMORY" for the error memory check method.
21-28
Inspection 1:
Check the forward/reverse interrupt relay (on coil side) individually.
Measure the resistance between terminals of each of the forward and reverse interrupt relays.
Ignition key switch OFF, relay disconnected from the J/B.
Standard:
Resistance
Forward interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)
Reverse interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)
Inspection 2:
Check for continuity of the wiring between A22 and interrupt relays.
Ignition key switch OFF, A22 disconnected, relay removed from the J/B.
Standard:
• Discontinuity check
A22-10 ~ Forward interrupt relay terminal 2 Continuity
A22-10 ~ Reverse interrupt relay terminal 2 Continuity
A22-17 ~ Forward interrupt relay terminal 1 Continuity
A22-17 ~ Reverse interrupt relay terminal 1 Continuity
• GND fault check
A22-10 ~ A22-17 No continuity
• +B shorting check
A22-10 ~ A22-32 No continuity
• IG line shorting check
A22-10 ~ A22-15,-16 No continuity
21-29
z Error Code 4
z Error Code 4-1 (Unload solenoid (USOL) abnormality)
z Error Code 4-2 (Lowering lock solenoid (LSOL) abnormality)
z Error Code 4-3 (Tilt solenoid (TSOL) abnormality)
z Error Code 4-4 (Backward tilt lock solenoid (BSOL) abnormality)
Related Portion
A22-14 (VSOL, Unload SOL) A12-1
A12-2 Unload SOL
A22-13 (LSOL, Lowering lock SOL) A11-1
A11-2 Lowering lock SOL
OPS controller
A22-12 (TSOL, Tilt SOL) A10-1
A10-2 Tilt SOL
A22-28 (BSOL,
Backward tilt lock SOL) A56-1
Backward tilting lock
A22-30 (E01, SOL-GND) A56-2 SOL
A22-29 (E02, SOL-GND)
22 26 23 25 1A-21 2 3
1B 1C
(A4, Body GND)
Estimated Causes:
c Connector contact defect f Tilt solenoid defect
d Unload solenoid defect g Controller defect
e Lowering lock solenoid defect h Harness defect
i Tilt backward lock solenoid defect
Error Codes 4, 4-1, 4-2, 4-3, 4-4
Check the A22, 1A, 1B, 1C, A10, A11, A12 and A56 connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG
Inspection 1: NG
Solenoid defect
Check the solenoids (USOL - BSOL) individually for the resistance
value.
OK
Inspection 2: NG
Harness defect
Check the wiring between A22 and each solenoid (USOL - BSOL) for
continuity.
OK
Controller defect
*: After correction, check the OPS lamp indication.
After starting the engine, operate lift up/down, forward/backward tilt in each of OPS activation and deactivation to
check if the OPS lamp blinks.
The OPS lamp must not display error code 4 by blinking.
Note:
When the analyzer is provided, check the related portion after checking the error memory for the current
error code. See page 21-9 "1 DIAG MEMORY" for the error memory check method.
21-30
Inspection 1:
Check the resistance of each solenoid (USOL to BSOL).
Ignition key switch OFF, A12, A11, A10 and A56 disconnected.
Standard:
Resistance
USOL A12-1 ~ A12-2 Approx. 9 Ω (20°C)
LSOL A11-1 ~ A11-2 Approx. 9 Ω (20°C)
TSOL A10-1 ~ A10-2 Approx. 9 Ω (20°C)
BSOL A56-1 ~ A56-2 Approx. 9 Ω (20°C)
Inspection 2:
Check for continuity of the wiring between A22 and each of solenoids USOL to BSOL.
Ignition key switch OFF, A22, A12, A11, A10 and A56 disconnected.
Standard:
• Discontinuity check
A22-14 ~ A12-1 Continuity
A22-29 ~ A12-2 Continuity
A22-30 ~ A12-2 Continuity
A12-2 ~ Frame Continuity
A22-13 ~ A11-1 Continuity
A22-29 ~ A11-2 Continuity
A22-30 ~ A11-2 Continuity
A11-2 ~ Frame Continuity
A22-12 ~ A10-1 Continuity A22-28 ~ A56-1 Continuity
A22-29 ~ A10-2 Continuity A22-29 ~ A56-2 Continuity
A22-30 ~ A10-2 Continuity A22-30 ~ A56-2 Continuity
A10-2 ~ Frame Continuity A56-2 ~ Frame Continuity
• GND fault check
A22-14 ~ A22-29,-30 No continuity
A22-13 ~ A22-29,-30 No continuity
A22-12 ~ A22-29,-30 No continuity A22-28 ~ A22-29,-30 No continuity
• +B shorting check
A22-14 ~ A22-32 No continuity
A22-13 ~ A22-32 No continuity
A22-12 ~ A22-32 No continuity A22-28 ~ A22-32 No continuity
• IG line shorting check
A22-14 ~ A22-15,-16 No continuity
A22-13 ~ A22-15,-16 No continuity
A22-12 ~ A22-15,-16 No continuity A22-28 ~ A22-15,-16 No continuity
21-31
z Error Code 5 · 5-1 (T/C shift lever abnormality)
Related Portion
SFT CN41-6
I-2
To IG1
J/B
Forward Reverse Shift
OPS controller
interrupt relay interrupt relay lever
4 4
A22-3 (DRF, Forward drive SW) 1B-3 1B-36 A41-5
A22-4 (DRR, Reverse drive SW) 1B-19 1B-17 A41-1
Estimated causes:
c Connector contact defect f Controller defect
d Shift lever switch defect g Fuse defect
e Harness defect
Error Code 5
NG After correction, check the OPS lamp
Check if the fuse (SFT) is blown.
indication.*
OK NG
Check connectors A22, 1B and A41 for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*
OK NG
Inspection 1: NG
Shift lever defect
Check the shift lever individually for continuity.
OK
Inspection 2: NG
Harness defect
Check for the continuity of wiring between A22 and IG SW.
OK
Controller defect
*: After correction, check the OPS lamp indication.
After the ignition key switch is turned ON, operate the shift lever to forward or reverse position and check if the
OPS lamp blinks.
The OPS lamp must not display error code 5 by blinking.
21-32
Inspection 1:
Check the shift lever individually for continuity.
Ignition key switch OFF, A41 disconnected.
Standard:
Lever at neutral Lever at forward Lever at reverse
position traveling position traveling position
Between pins 5 and 6 on lever side No continuity Continuity No continuity
Between pins 6 and 1 on lever side No continuity No continuity Continuity
Inspection 2:
Check the wiring between A22 and A2 (IG SW) for continuity.
Ignition key switch OFF, A22 and A2 (IG SW) connectors disconnected.
(1B and A41 must be connected.)
Standard:
• Lever at neutral
A22-3 ~ A2-4 No continuity
A22-4 ~ A2-4 No continuity
• +B shorting check
A22-3 ~ A22-32 No continuity
A22-4 ~ A22-32 No continuity
• IG line shorting check
A22-3 ~ A22-15,-16 No continuity
A22-4 ~ A22-15,-16 No continuity
Error code 5-1
NG After correction, check the OPS lamp
Check if the fuse (SFT) is blown.
indication.*
OK NG
Check A22, 1B and A41 connectors for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*
OK NG
Inspection 1: OK
Shift lever defect
Disconnect A41, and check the input signal to the controller.
NG
Inspection 2: NG
Harness defect
Check for wiring between A22 and IG SW for continuity.
OK
Controller defect
*: After correction, check the OPS lamp indication.
After the ignition key switch is turned ON, operate the shift lever to the forward or reverse position and check if the
OPS lamp blinks.
The OPS lamp must not indicate error code 5 by blinking.
21-33
Inspection 1:
Disconnect A41, and check the input signal to the controller.
A41 disconnected, ignition key switch ON (engine in stopped state)
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Lever at forward Lever at reverse
Lever at neutral position
traveling position traveling position
DIR FWD OFF OFF OFF
DIR REV OFF OFF OFF
Inspection 2:
Check the wiring between A22 and A2 (IG SW) for continuity.
Ignition key switch OFF, A22 and A2 (IG SW) connectors disconnected.
(1B and A41 must be connected.)
Standard:
• Lever at neutral
A22-3 ~ A2-4 No continuity
A22-4 ~ A2-4 No continuity
• +B shorting check
A22-3 ~ A22-32 No continuity
A22-4 ~ A22-32 No continuity
• IG line shorting check
A22-3 ~ A22-15,-16 No continuity
A22-4 ~ A22-15,-16 No continuity
21-34
TROUBLESHOOTING BY PHENOMENON
z The OPS buzzer does not sound.
z The OPS buzzer keeps sounding.
Related Portion
ECU-B
1C-12
To Batt
A22-32 (BATT) 1A-29
OPS controller
1B-5
A8-1
A22-9 (BZO, OPS buzzer) A8-2 OPS buzzer
Estimated Causes:
c Connector contact defect f Controller defect
d OPS buzzer defect g Fuse defect
e Harness defect
The OPS buzzer does not sound.
NG After correction, check if the OPS
Check for blown fuse (ECU-B).
buzzer sounds.*
OK NG
NG After correction, check if the OPS
Check the A22 and A8 for any disconnection or internal wetting.
buzzer sounds.*
OK NG
Inspection 1: NG Harness defect
Check for continuity between the A2 and A8, and between A22 and A8.
OK
Inspection 2: OK
Check for continuity between A8-2 and the frame. OPS buzzer defect
NG
Controller defect
*: After correction, check if the OPS buzzer sounds.
After connecting all connectors, turn the ignition key switch ON, and leave the seat to check if the buzzer sounds.
21-35
Inspection 1:
Check for continuity between the 1C and A8, and between A22 and A8.
Ignition key switch OFF, A22, A8, 1C connector disconnected.
Standard:
A2-2 ~ A8-1 Continuity
A22-9 ~ A8-2 Continuity
Inspection 2:
Check for continuity between A8-2 and the frame.
• Without analyzer
Disconnect A8 and turn the ignition key switch ON (engine in stopped state).
Standard:
Buzzer ON Buzzer OFF
Between A8-2 and frame Continuity No continuity
* Normally, the buzzer sounds for 1 second upon lapse of 0.5 seconds after the operator leaves the seat.
• With analyzer
Disconnect A8 and turn the ignition key switch ON (engine in
stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
Forcibly turn the OPS buzzer ON and OFF, and check the continuity
between A8-2 and the frame.
Buzzer ON Buzzer OFF
Between A8-2 and frame Continuity No continuity
21-36
The OPS buzzer keeps sounding.
NG After correction, check if the OPS
Check A22 and A8 for any disconnection or internal wetting.
buzzer sounds.*
OK NG
Inspection 1: NG
Harness defect
Check for continuity between A2 and A8, between A22 and A8, and
between A22 and the frame.
OK
Inspection 2: OK
OPS buzzer defect
Check for continuity between A8-2 and the frame.
NG
Controller defect
*: After correction, check if the OPS buzzer sounds.
After connecting all connectors, turn the ignition key switch ON and leave the seat to check if the buzzer sounds.
Inspection 1:
Check for continuity between the A2 and A8, and between A22 and A8.
Ignition key switch OFF, A22, A8, A2 connector disconnected.
Standard:
A2-2 ~ A8-1 Continuity
A2-9 ~ A8-2 Continuity
Between A2-9 and frame No continuity
21-37
Inspection 2:
Check for continuity between A8-2 and the frame.
• Without analyzer
Disconnect A8 and turn the ignition key switch ON (engine in stopped state).
Standard:
Buzzer ON Buzzer OFF
Between A8-2 and frame Continuity No continuity
* Normally, the buzzer sounds for 1 second upon lapse of 0.5 sec after the operator leaves the seat.
• With analyzer
Disconnect A8 and turn the ignition key switch ON (engine in
stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
Forcibly turn the OPS buzzer ON and OFF, and check for continuity
between A8-2 and the frame.
Buzzer ON Buzzer OFF
Between A8-2 and frame Continuity No continuity
21-38
z The OPS lamp does not come on.
Related Portion
GAUGE 1C-32
To IG SW
1C-27
OPS controller
QAI-12 Q1-1
A22-8 (RYLP, OPS lamp) QAI-7 Q1-4
Combination
1E-28 1C-8 QAI-4 Q1-8 meter
1C-25 QAI-13 Q1-9
Estimated Causes:
c Connector contact defect f Controller defect
d OPS lamp defect g Fuse defect
e Harness defect
NG After bulb replacement, check that the
Check if the OPS lamp is burnt out.
OPS lamp comes on.
OK NG
NG After correction, check that the OPS
Check for blown fuse (GAUGE).
lamp comes on.*
OK NG
NG After correction, check that the OPS
Check A22 and CN41 for any disconnection or internal wetting.
lamp comes on.*
OK NG
Inspection 1: NG
Harness defect
Check the A2, A22, Q1 and frame for continuity.
OK
Inspection 2: NG
OPS controller defect
Check the OPS controller.
OK
Meter defect
*: After correction, check that the OPS lamp comes on.
After connecting all connectors, turn the ignition key switch ON (engine in stopped state) and leave the seat to
check that the OPS lamp comes on.
21-39
Inspection 1:
Check the A2, A22, Q1 and frame for continuity.
Turn the ignition key switch OFF, disconnect A2, A22 and Q1.
Standard:
Between A2-4 and Q1-1 Continuity
Between Q1-8 and the frame Continuity
Between A22-8 and Q1-4 Continuity
Inspection 2:
Check the OPS controller.
• Without analyzer
Turn the ignitionkey switch OFF, disconnect Q1 and then turn the ignition key
switch ON (engine in stopped state). Check for continuity between Q1-4 and the
frame with no one on the seat.
Standard:
Lamp ON Lamp OFF
Between Q1-4 and the frame No continuity Continuity
• With analyzer
Turn the ignition key switch OFF, disconnect Q1 and then turn the
ignition key switch ON (engine in stopped state). Check for
continuity between Q1-4 and the frame with no one on the seat.
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
Forcibly turn the OPS lamp ON and OFF, and check for continuity.
Lamp ON signal Lamp OFF signal
Between Q1-4 and the frame No continuity Continuity
21-40
z The OPS lamp keeps lighting. (Including when traveling and material handling are both disabled)
Related Portion
ECU-IG
1C-14
IG
ECU-B
1C-12
BATT
1E-14
A22-32 1B-5
A22-15 1B-6
A22-16 1B-7
A22-31 1B-20
OPS controller
A22-8 QA1-7 Q1-4 Combination
meter
A22-23 (DMI, Seat SW) AO1-1 XO4-1 X1-2
Seat switch
A22-17 (E03, Switch GND) 1B-24 1E-30 XO4-2 X1-1
Estimated Causes:
c Contactor contact defect g Fuse defect
d OPS lamp defect h Low battery voltage
e Harness defect i Seat switch discontinuity
f Controller defect
21-41
Without Analyzer
NG After correction, check that the OPS
Check for blown fuse (ECU-B, ECU-IG).
lamp goes off.*
OK NG
Check A22, Q1, X1, XO4, AO1, 1B, 1E and 1C for any disconnection NG After correction, check that the OPS
or internal wetting. lamp goes off.*
OK NG
Inspection 1: NG
Harness defect
Check for continuity and measure the voltage between A2 and A22,
between A22 and the frame, between A22 and Q1, and between X1
and A22.
OK
Inspection 2: NG
Battery defect (low battery voltage)
Check the input voltage from the IG line to the controller.
OK
Inspection 3: NG
Seat switch defect
Check the seat switch.
OK
Inspection 4: NG
OPS controller defect
Check the OPS controller.
OK
Meter defect
*: After correction, check that the OPS lamp goes off.
After connecting all connectors, turn the ignition key switch ON while staying on the seat (engine in stopped state).
Check that the OPS lamp goes off after 1 second.
21-42
Inspection 1:
Check for continuity and measure the voltage between A2 and A22, between A22 and the frame, between Q1
and A22, and between X1 and A22.
Turn the ignition key switch OFF, disconnect A22, Q1, X1 and A2 connectors.
Standard:
A2-4 ~ A22-16 Continuity
A2-4 ~ A22-15 Continuity
A2-2 ~ A22-32 Continuity
A22-31 ~ frame Continuity
A22-23 ~ X1-2 Continuity
A22-17 ~ X1-1 Continuity
A22-8 ~ Q1-4 Continuity
A22-15 ~ A22-31 No continuity
A22-16 ~ A22-31 No continuity
A22-32 ~ A22-31 Approx. 12 V
Inspection 2:
Check the input voltage from the IG line to the controller.
Disconnect A22 and turn the ignition key switch ON. (Connectors other than A22 must
be connected).
Standard:
A22-15 ~ A22-31 11 V or more
A22-16 ~ A22-31 11 V or more
Inspection 3:
Check the individual seat switch for continuity.
Turn the ignition key switch OFF, and disconnect X1.
Standard:
Seated Unseated
X1-1 ~ X1-2 Continuity No continuity
Inspection 4:
Check the OPS controller.
Turn the ignition key switch OFF, disconnect Q1 and then turn the ignition key switch ON
(engine in stopped state). Check for continuity between Q1-4 and the frame with no one on
the seat.
Standard:
Lamp ON Lamp OFF
Between Q1-4 and frame No continuity Continuity
21-43
With Analyzer
NG After correction, check that the OPS
Check for blown fuse (ECU-B, ECU-IG).
lamp goes off.*
OK NG
Check A22, Q1, X1, XO4, AO1, 1B, 1C and 1E for any disconnection NG After correction, check that the OPS
or internal wetting. lamp goes off.*
OK NG
Inspection 1: NG
Harness defect
Check for continuity and measure the voltage between the A2 and
A22, between A22 and the frame, between A22 and Q1, and between
X1 and A22.
OK
Inspection 2: NG
Battery defect (low battery voltage)
Check the input voltage from the IG line to the controller.
OK
Inspection 3: NG
Seat switch defect
Check the seat switch.
OK
Inspection 4: OK
OPS controller defect
Check the OPS controller.
NG
Meter defect
*: After correction, check that the OPS lamp goes off.
After connecting all connectors, turn the ignition key switch ON while staying on the seat (engine in stopped state).
Check that the OPS lamp goes off after 1 second.
21-44
Inspection 1:
Check for continuity and measure the voltage between A2 and A22, between A22 and the frame, between Q1
and A22, and between X1 and A22.
Turn the ignition key switch OFF, disconnect A22, Q1, X1 and A2 connectors.
Standard:
A2-4 ~ A22-16 Continuity
A2-4 ~ A22-15 Continuity
A2-2 ~ A22-32 Continuity
A22-31 ~ frame Continuity
A22-23 ~ X1-2 Continuity
A22-17 ~ X1-1 Continuity
A22-8 ~ Q1-4 Continuity
A22-15 ~ A22-31 No continuity
A22-16 ~ A22-31 No continuity
A22-32 ~ A22-31 Approx. 12 V
Inspection 2:
Check the input voltage from the IG line to the controller.
After connecting all connectors, turn the ignition key switch ON
(engine in stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Ignition key ON
VOLTAGE 11 V or more
Inspection 3:
Check the seat switch individually.
Turn the ignition key switch OFF and disconnect X1.
Standard:
Seated Unseated
X1-1 ~ X1-2 Continuity No continuity
Inspection 4:
Check the OPS controller.
Turn the ignition key switch OFF, disconnect Q1, and then turn the
ignition key switch ON (engine in stopped state). Check for continuity
between Q1-4 and the frame with no one on the seat.
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
Forcibly turn the OPS lamp on and off, and check for continuity.
Lamp ON signal Lamp OFF signal
Between Q1-4 and frame No continuity Continuity
21-45
z Cannot lower the fork.
Related Portion
A22-26 (DOWN, Lowering switch) A14-1
Lowering switch
A22-17 (E03, SW-GND) 1B-24 1C-23 A14-2
OPS controller
A22-28 (BSOL, Backward tilt lock SOL) A11-1
Lowering lock
A22-30 (E01, SOL-GND) A11-2
SOL
A22-29 (E02, SOL-GND)
22 26 25
1B
Estimated Causes:
c Connector contact defect f Lowering lever switch installation defect
d Lowering switch defect g Controller defect
e Control valve lowering lock valve sticking defect h Harness defect
21-46
Without Analyzer
Is the OPS lamp blinking to indicate an Yes Perform troubleshooting
error? according to the error code.
No
No Perform troubleshooting for "The
Does the OPS lamp go off when seated?
OPS Lamp keeps lighting".
Yes
Check A22, 1B, 1C, A11 and A14 for any NG After correction, get on the seat
disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG
Inspection 1: NG Inspection 2: NG
Harness defect
Check the lift lowering lever switch wiring for Check for continuity between A22
continuity. and A14.
OK OK
Inspection 3: NG Lowering switch
Check the lift lowering lever defect
switch (as removed from the
vehicle) for continuity.
OK
Lowering lever switch installation
defect
Put a hand on the lowering lock solenoid (at NG
Controller defect
the rear lower left-hand portion of the control
valve) and operate for lowering the fork while
seating to check the solenoid open/close
sound (with the engine in stopped state and
the fork in the fully lowered position).*
OK
Lowering lock valve sticking
Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.
Inspection 1:
Check the lift lowering lever switch wiring for continuity.
Turn the ignition key switch OFF and disconnect A22.
Standard:
Lever at neutral position Lever at up position Lever at lowering position
A22-26 ~ A22-17 No continuity No continuity Continuity
21-47
Inspection 2:
Check for continuity between A22 and A14.
Turn the ignition key switch OFF, and disconnect A22 and A14.
Standard:
A22-26 ~ A14-1 Continuity
A22-17 ~ A14-2 Continuity
Inspection 3:
Check the lift lowering lever switch individually (as removed from the vehicle) for
continuity.
Turn the ignition key switch OFF, and disconnect A14.
Standard:
Free Pressed
A14-1 ~ A14-2 Continuity No continuity
21-48
With Analyzer
Is the OPS lamp blinking to indicate an Yes Perform troubleshooting
error? according to the error code.
No
Does the OPS lamp go off when seated? No Perform troubleshooting for "The
OPS Lamp keeps lighting."
Yes
Check A22, 1B, 1C, A11 and A14 for any NG After correction, get on the seat
disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG
Inspection 1: NG Inspection 2: NG
Harness defect
Check the switch output when operated for Check for continuity between A22
fork lowering. and A14.
OK OK
Inspection 3: NG Lowering switch
Check the lowering lever switch defect
individually (as removed from the
vehicle) for continuity.
OK
Lowering lever switch installation
defect
Put a hand on the lowering lock solenoid (at NG
Controller defect
lower rear left-hand portion of the control
valve) and operate for fork lowering on the
seat to check the solenoid open/close sound
(with the engine stopped and the fork in the
fully lowered position).*
OK
Lowering lock valve sticking
Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.
Inspection 1:
Check the switch output when operated for lowering.
Turn the ignition key switch ON (engine in stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU →
IN/OUT MONITOR
Standard:
Lever at neutral position Lever at up position Lever at lowering position
LIFT LOWER OFF OFF ON
21-49
Inspection 2:
Check for continuity between A22 and A14.
Turn the ignition key switch OFF, and disconnect A22 and A14.
Standard:
A22-26 ~ A14-1 Continuity
A22-17 ~ A14-2 Continuity
Inspection 3:
Check the lift lowering lever switch individually (as removed from the vehicle) for
continuity.
Turn the ignition key switch to OFF, and disconnect A14.
Standard:
Free Pressed
A14-1 ~ A14-2 Continuity No continuity
21-50
z The material handling OPS does not function. (Including when OPS for lowering is functional)
Related Portion
A22-14 (VSOL, Unload SOL) A12-1
A12-2 Unload SOL
OPS controller
A22-13 (LSOL, Lowering lock SOL) A11-1
Lowering lock
A22-30 (E01, SOL-GND) A11-2 SOL
A22-29 (E02, SOL-GND)
22 26 25 2 3
1B 1C
(A4, Body GND)
Estimated Causes:
c Controller defect
d Control valve unload valve or lowering lock valve defect
Yes Perform troubleshooting according to
Is the OPS lamp blinking?*1
the error code.
No
NG
Check the operating sound of the control valve solenoid.*2 Controller defect
OK
Sticking unload valve on control valve or lowering lock valve
*1: Check if the OPS lamp is blinking.
Turn the ignition key switch OFF → ON (2 seconds or more) → OFF with no one on the seat. Leave the vehicle
as it is for 15 minutes or more, and turn the ignition key switch ON again to confirm that the OPS lamp does not
blink.
*2: Check the control valve solenoid operating sound.
• Turn the ignition key switch ON (engine in stopped state) and put a hand on the unload solenoid of the control
valve to check that the solenoid open/close sound is heard 2 seconds after leaving the seat or upon getting on
the seat.
• Put a hand on the lowering lock solenoid of the control valve while seating to check if the solenoid open/close
sound is heard upon fork lowering operation.
Caution:
*2: Be careful so as not to get burnt because the solenoid may be hot.
21-51
z Material handling fails. (Including when fork lowering is not fail)
Related Portion
A22-14 (VSOL, Unload SOL) A12-1
OPS controller
A12-2 Unload SOL
A22-30 (E01, SOL-GND)
A22-29 (E02, SOL-GND)
22 26 2 3
1B 1C
(A4, Body GND)
Estimated Causes:
c Sticking unload valve on control valve
d Controller defect
Yes Perform troubleshooting according to
Is the OPS lamp blinking to indicate an error?
the error code.
No
No Perform troubleshooting for "The OPS
Check if the OPS lamp turns OFF while sitting on the seat.
lamp keeps lighting".
Yes
NG
Check the unload solenoid operating sound.* Controller defect
OK
Sticking unload valve on control valve
*: Check the control valve solenoid operating sound.
Turn the ignition key switch ON (engine in stopped state) and put a hand on the unload solenoid of the control
valve to check if the solenoid open/close sound is heard 2 seconds after leaving the seat or upon getting on the
seat.
Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.
21-52
z The mast backward tilting speed is slow.
Related Portion
OPS controller
A22-12 (TSOL, Tilt SOL) A10-1
A22-30 (E01, SOL-GND) A10-2 Tilt SOL
A22-29 (E02, SOL-GND)
22 26 23
1B
Estimated Causes:
c Controller defect
d Sticking tilt control valve
Yes Perform troubleshooting according to
Is the OPS lamp blinking?*1
the error code.
No
OK
Check the tilt solenoid operating sound.*2 Sticking tilt control valve
NG
OPS controller defect
*1: Check if the OPS lamp is blinking.
Turn the ignition key switch OFF → ON (2 seconds or more) → OFF with no one on the seat. Leave the vehicle
as it is for 15 minutes or more, and turn the ignition key switch ON again to confirm that the OPS lamp does not
blink.
Furthermore, operate the tilt lever to the forward position on the operator's seat, make sure that the OPS lamp
does not blink.
*2: Check the tilt solenoid operating sound.
Turn the ignition key switch ON (engine in stopped state) while staying on the seat and put a hand on the tilt
solenoid on the control valve to check if the solenoid open/close sound is heard when the tilt lever is operated to
the forward tilt position.
Caution:
*2: Be careful so as not to get burnt because the solenoid may be hot.
21-53
z Mast does not tilt forward.
Related Portion
A22-25 (TFI, Forward tilt switch) A13-1
controller
Forward tilt
OPS
A22-17 (E03, SW-GND) 1B-24 1C-29 A13-2 lever switch
Estimated Causes:
c Connector contact defect f Forward tilt lever switch defect
d Harness defect g Forward tilt lever switch installation defect
e OPS controller defect h Sticking tilt control valve
Yes Perform troubleshooting according to
Check if the OPS lamp blinks to indicate an error.
the error code.
No
No Perform troubleshooting for Disabled
Stay on the seat and check if the fork can be lifted.
Material Handling error.
Yes
Check A22, 1B, 1C and A13 for any disconnection or internal wetting. NG After correction, check forward tilting
operation while sitting on the seat.*1
OK NG
Inspection 1: Inspection 2: OK
NG Harness defect
Check the forward tilt lever switch signal to Check the forward tilt lever switch
the OPS controller. individually (as installed on the vehicle) for
continuity.
OK
NG
Inspection 3: NG Forward tilt lever
Check the forward tilt lever switch switch defect
individually (as removed from the vehicle)
for continuity.
OK
Forward tilt lever switch installation defect
NG
Check the tilt solenoid operating sound.*2 OPS controller defect
OK
Sticking tilt control valve
21-54
*1: Stay on the seat and check the forward tilting operation.
After turning the ignition key switch ON, operate the tilt lever to check if the mast can be tilted forward.
*2: Check the tilt solenoid operating sound.
Stay on the seat and turn the ignition key switch ON (with the engine in stopped state), put a hand on the tilt
solenoid to hear the solenoid operating sound generated when the tilt lever is operated forward.
Caution:
*2: Be careful so as not to get burnt because the solenoid may be hot.
Inspection 1:
Check the forward tilt lever switch signal to the OPS controller.
Ignition key switch OFF, A22 disconnected. (1B, 1C and A13 must be connected).
Standard:
Lever at backward tilt
Lever at neutral position Lever at forward tilt position
position
A22-25 ~ A22-17 No continuity Continuity No continuity
Inspection 2:
Check the forward tilt lever switch individually (as installed on the vehicle) for continuity. 1 2
3 4
Ignition key switch OFF, A13 disconnected.
Standard:
Lever at backward tilt
Lever at neutral position Lever at forward tilt position
position
A13-1 ~ A13-2 No continuity Continuity No continuity
Inspection 3:
Check the forward tilt lever switch individually (as removed from the vehicle) for continuity. 1 2
3 4
Ignition key switch OFF, A13 disconnected.
Standard:
Forward tilt switch (switch on the upper side as installed on the vehicle)
Free Pressed
A13-1 ~ A13-2 Continuity No continuity
21-55
z The drive OPS does not function. (Excluding the M/T vehicle)
Related portion
SFT
I-2 A41-6
To IG1
A41-5
Shift lever
A41-1
J/B
A22-10 (RYF, Forward/ 1B
Reverse interrupt relay) 1B 36 37
8 2 4
1 3
24 7
A22-17 (E03, SW-GND) 9
Forward interrupt relay
OPS controller
1A 1A 1 4
2 3
A22-3 Reverse interrupt relay
(DRF, Forward drive SW) 1B
3
19 1A
A22-4 4 2
(DRR, Reverse drive SW)
1 2
A55
Shift SOL
Estimated Causes:
c Connector interrupt defect f Harness defect
d Forward interrupt relay defect g Controller defect
e Reverse interrupt relay defect
21-56
Yes Perform troubleshooting according to
Check if the OPS lamp blinks to indicate an error.*1
the error code.
No
Check A22, A41, 1A, 1B and A55 (A47) for any disconnection or NG After correction, check if the OPS
internal wetting, and any relay disconnection. functions normally.*2
OK NG
Inspection 1: NG
Harness defect
Check for continuity of the wiring between A41 and J/B, and the wiring
between A55 (A47) and J/B.
OK
Inspection 2: NG
Interrupt relay defect
Check the forward/reverse interrupt relay.
OK
Controller defect
*1: Check if the OPS lamp blinks to indicate an error.
Without getting on the seat, turn the ignition key switch OFF → ON (2 seconds or more) → OFF. Leave the vehicle
as it is for at least 15 minutes. Then turn the ignition key switch ON again and make sure that the OPS lamp does
not blink.
*2: After correction, check if the drive OPS functions normally.
Turn the ignition key switch ON, set the shift lever to either forward or reverse and leave the seat. Check if the
drive OPS is activated.
Inspection 1:
Check for continuity of the wiring between A41 and J/B, and the wiring between A55 (A47) and
J/B.
Turn the ignition key switch OFF, disconnect A41 and A55 (A47), and remove the relays from the
J/B.
Standard:
Between A41-5 and pin 4 of forward interrupt relay Continuity
Between A41-1 and pin 4 of reverse interrupt relay Continuity
Between A55 (A47)-1 and pin 3 of forward interrupt relay Continuity
Between A55-2 (A47-3) and pin 3 of reverse interrupt relay Continuity
A41-6 ~ A2-4 Continuity
21-57
Inspection 2:
Check the forward/reverse interrupt relay individually.
(1) Turn the ignition key switch OFF and disconnect the relays from the J/B. Measure the
resistances between the specified pins of the forward/reverse interrupt relay.
Standard:
Resistance
Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
(2) Install the relay and disconnect A41 and A55 (A47). Leave the seat unseated, and turn the
ignition key switch ON (with the engine in stopped state).
• Without analyzer
Standard:
Unseated Seated
A41-5 ~ A55 (A47)-1 No continuity Continuity
A41-1 ~ A55-2 (A47-3) No continuity Continuity
• With analyzer
Forcibly turn the forward and reverse interrupt relays ON and OFF
and check for continuity in each state.
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
• Forward and reverse interrupt relay (RLY FWD)
Relay ON Relay OFF
A41-5 ~ A55 (A47)-1 No continuity Continuity
A41-1 ~ A55-2 (A47-3) No continuity Continuity
21-58
z Traveling fails. (Including forward traveling only, reverse traveling only, and occasional abnormalities)
(Excluding the M/T vehicle)
Related Portion
SFT
I-2 A41-6
To IG1
A41-5
Shift lever
A41-1
J/B
A22-10 (RYF, Forward/ 1B
Reverse interrupt relay) 1B 36 37
8 2 4
1 3
24 7
A22-17 (E03, SW-GND) 9
Forward interrupt relay
OPS controller
1A 1A 1 4
2 3
A22-3 Reverse interrupt relay
(DRF, Forward drive SW) 1B
3
19 1A
A22-4 4 2
(DRR, Reverse drive SW)
1 2
A55
Shift SOL
Estimated Causes:
c Connector contact defect g Controller defect
d Forward interrupt relay defect h Shift lever switch defect
e Reverse interrupt relay defect i Fuse defect
f Harness defect
Yes Perform troubleshooting according to
Check if the OPS lamp blinks to indicate an error.
the error code.
No
No Perform troubleshooting for "OPS lamp
Stay on the seat and check if the OPS lamp goes off.
keeps lighting".
Yes
NG After correction, check if the OPS
Check if the fuse (SFT) is blown.
functions normally.*
OK
Check A22, A41, 1A, 1B and A55 (A47) for any disconnection or NG After correction, check if the OPS
internal wetting. functions normally.*
OK NG
A
21-59
Inspection 1: NG
Shift lever defect
Check the shift lever unit individually for continuity.
OK
Inspection 2: NG
Harness defect
Check the wirings between A41/A55 (A47) and the J/B, and between
A22 and A41 for continuity.
OK
Inspection 3: NG
Interrupt relay defect
Check the forward/reverse interrupt relay.
OK
Controller defect
* After correction, check if the OPS functions normally.
Check that the buzzer sounds at short intervals (pip-pip) when the shift lever is set to the forward position with the
operator taking seat after leaving the seat to operate the OPS while the ignition key switch is in the ON position.
Next, check that forward traveling is enabled if the shift lever is set to neutral once and then to forward again.
Inspection 1:
Check the T/C shift lever unit individually for continuity.
Ignition key switch OFF, A41 disconnected.
Standard:
Lever at neutral Lever at forward Lever at reverse
Between pins 6 and 5 on lever side No continuity Continuity No continuity
Between pins 6 and 1 on lever side No continuity No continuity Continuity
Inspection 2:
Check the wiring between A41/A55 (A47) and J/B and between A22 and A41 for continuity.
Turn the ignition key switch OFF, disconnect A41, A55 (A47) and A22, and disconnect relays from the J/B.
Standard:
Between A41-5 and pin 4 of forward interrupt relay Continuity
Between A41-1 and pin 4 of reverse interrupt relay Continuity
Between A55 (A47)-1 and pin 3 of forward interrupt relay Continuity
Between A55-2 (A47-3) and pin 3 of reverse interrupt relay Continuity
A41-6 ~ A2-4 Continuity
A22-3 ~ A41-5 Continuity
A22-4 ~ A55 (A47)-1 Continuity
21-60
Inspection 3:
Check the forward/reverse interrupt relay individually.
(1) Turn the ignition key switch OFF and remove the relays from the J/B. Measure the resistance between pins
of the forward and reverse interrupt relays.
Standard:
Resistance
Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
(2) Install the relays and disconnect A41 and A55 (A47). Turn the ignition key switch ON (with the engine in
stopped state) after leaving the seat.
• Without analyzer
Standard:
Unseated Seated
A41-5 ~ A55 (A47)-1 No continuity Continuity
A41-1 ~ A55-2 (A47-3) No continuity Continuity
• With analyzer
Forcibly turn each of the forward and reverse interrupt relays ON
and OFF, and check for continuity in each state.
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
• Forward and reverse interrupt relay (RLY FWD)
Relay ON Relay OFF
A41-5 ~ A55 (A47)-1 No continuity Continuity
A41-1 ~ A55-2 (A47-3) No continuity Continuity
21-61
z Mast does not tilt backward.
Related Portion
A22-24 (TRI, Backward tilt switch) A13-3
Backward tilt
A22-17 (E03, SW-GND) 1B-24 1C-20 A13-4 switch
OPS controller
A22-28 (BSOL, Backward tilt lock Solenoid) A56-1
Backward tilt
A22-30 (E3, SOL-GND) A56-2 lock SOL
A22-29 (E3, SOL-GND)
22 26 1A-21
1B
Estimated Causes:
c Connector contact defect f Backward tilt switch installation defect
d Backward tilt switch defect g Controller defect
e Control valve backward tilt lock valve sticking defect h Harness defect
21-62
Without Analyzer
Is the OPS lamp blinking to indicate an Yes Perform troubleshooting
error? according to the error code.
No
No Perform troubleshooting for "The
Does the OPS lamp go off when seated?
OPS Lamp keeps lighting".
Yes
Check A22, A13, 1B, 1C and A56 for any NG After correction, get on the seat
disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG
Inspection 1: NG Inspection 2: NG
Harness defect
Check the backward tilt switch wiring for Check for continuity between A22
continuity. and A13.
OK OK
Inspection 3: NG Lowering switch
Check the backward tilt switch (as defect
removed from the vehicle) for
continuity.
OK
Backward tilt switch installation
defect
Put a hand on the tilt backward lock solenoid NG
Controller defect
(at the upper right-hand portion of the control
valve) and operate for tilting backward the
mast while seating to check the solenoid
open/close sound (with the engine in
stopped state, the fork in the fully lowered
position, and the mast in the fully backward
tilted position).*
OK
Tilt backward lock valve sticking
Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.
Inspection 1:
Check the backward tilt switch wiring for continuity.
Turn the ignition key switch OFF and disconnect A22.
Standard:
Lever at backward tilt Lever at forward tilt
Lever at neutral position
position position
A22-24 ~ A22-17 No continuity Continuity No continuity
21-63
With Analyzer
Is the OPS lamp blinking to indicate an Yes Perform troubleshooting
error? according to the error code.
No
Does the OPS lamp go off when seated. No Perform troubleshooting for "The
OPS Lamp keeps lighting."
Yes
Check A22, A13, 1B, 1C and A56 for any NG After correction, get on the seat
disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG
Inspection 1: NG Inspection 2: NG
Harness defect
Check the switch output when operated for Check for continuity between A22
tilting backward the mast. and A13.
OK OK
Inspection 3: NG Lowering switch
Check the backward tilt switch defect
individually (as removed from the
vehicle) for continuity.
OK
Backward tilt switch installation
defect
Put a hand on the tilt backward lock solenoid NG
Controller defect
(at the upper right-hand portion of the control
valve) and operate for tilting backward the
mast while seating to check the solenoid
open/close sound (with the engine in
stopped state, the fork in the fully lowered
position, and the mast in the fully backward
tilted position).*
OK
Tilt backward lock valve sticking
Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.
Inspection 1:
Check the switch output when operated for lowering.
Turn the ignition key switch ON (engine in stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Lever at backward tilt Lever at forward tilt
Lever at neutral position
position position
TILT BWD OFF ON OFF
21-64
Inspection 2:
Check for continuity between A22 and A13.
Turn the ignition key switch OFF, and disconnect A22 and A13.
Standard:
A22-24 ~ A13-3 Continuity
A22-17 ~ A13-4 Continuity
Inspection 3:
Check the backward tilt switch individually (as removed from the vehicle) for continuity. 1
3
2
4
Turn the ignition key switch OFF, and disconnect A13.
Standard:
Free Pressed
A13-3 ~ A13-4 Continuity No continuity
21-65
TROUBLESHOOTING (OPT EQUIPPED VEHICLE)
BEFORE BEGINNING TROUBLESHOOTING FOR THE 4Y-E ENGINE
It is extremely risky to begin troubleshooting for the 4Y engine on the basis of results only. It can lead to mistaken
corrective action, wasted time, and sometimes to an increase in abnormalities. Therefore, ask the customer about
detailed information on conditions around the time a problem occurred, based on the following.
Diagnostic Procedure
First, it is necessary to be informed of the "fault history and service history" for the vehicle, and then to gather definite
information about the fault occurence such as "when", "at what times", "in what places", "during what operations or
actions", "what happened afterwards", and “frequency of occurrence”.
Also, try to recreate the conditions for the fault occurence. (a. Recreation impossible b. Recreation possible: in what
condition?)
• General items
Customer name Date of delivery Date fault occurred / hour meter reading
Vehicle model Frame No. Engine No. (punched)
Fuel type
F Gasoline F LPG F Gasoline - LPG combination (Note LPG fuel company name: )
• Condition of the defect (Tick the items that apply)
Defect phenomena
1. Cannot start a. Does not crank b. Combustion does not start c. Incomplete combustion
2. Does not start well Poor cranking (when cold - when warm - at all times)
3. Poor idle a. Poor idle speed b. Unstable idle speed c. Hunting (regular fluctuation in speed)
a. Immediately after start-up (when cold - when warm) b. During deceleration c. After deceleration
4. Engine stalling d. Without sign e. After the engine has been running rough f. When steering
g. When handling materials h. Can be re-started immediately
a. Insufficient power output b. Hesitation
5. Defect operational
c. Surging (swaying forward and backward during acceleration) d. Knocking e. Backfiring f. After
status
firing
a. Excessive fuel consumption b. Excessive oil consumption c. Overheating d. Water or oil leaks
6. Other
e. Abnormal noise f. Other ( )
Environment at the time of the defect's occurrence
The time when the fault a. Since the vehicle was new b. Recently (from around the following date (month and year): )
began to occur c. After being serviced
Frequency of occurence a. Always b. Under certain conditions c. Sometimes
Sunny - cloudy - rain - snow - Approximately Approximately
Weather Temperature Humidity
thunderstorm °C %
Temperature conditions Coolant: a. When cool b. When warm Temperature inside engine room: °C
a. No relation b. When idling c. When revving d. When accelerating
e. When traveling at constant speed f. When decelerating g. When climbing a slope
Operation conditions h. During material handling operations When not loaded (when steering - when lifting - when tilting)
When loaded (load: appox. kg) (when steering - when lifting - when tilting)
i. Other (when using the inching brake - when steering - other)
Lamps a. Lights constantly b. Lights occaisonally c. Does not light
21-66
DIAGNOSIS (SELF DIAGNOSIS FUNCTION)
General
When the computer detects a problem in the system, the fault is indicated by lighting a warning lamp on the
combination meter and displaying an error code, and fail-safe functions operate to ensure safety by stopping the
engine or controlling the engine to a low speed.
DIAGNOSIS DISPLAY METHOD
Error code display
1. Diagnosis display method
The diagnosis is displayed by means of an error code as
shown in the illustration to the left, and by the lights turning on.
When the ignition key switch is turned ON, the lamp lights
once to allow checking for the bulb, and then turns off again if
the status is normal.
With the ignition key switch ON, if an abnormality is detected
An orange colored lamp lights Lamp blinks when the vehicle is stopped, travelling or performing meterials
(Engine ECU only) handling operations, an error code is displayed and the lamps
turn on as a warning.
When this happens, stop the vehicle immediately and check
the error code.
2. Diagnosis memory display method
To display the diagnosis memory display, there are a method using the hour meter and tilt lever, a method using
the optional display, and a method using a plug-in analyzer.
Here the display method using the hour meter and tilt lever is described.
(1) From the main menu, display the diagnosis memory menu. For how to display the main menu, refer to page
18-30.
(2) A diagnosis No. and error code are displayed each time the knob switch is pressed and released. Each
error code and the time at which it occurred are displayed alternately at 2 second intervals.
Note:
• The maximum number of error codes that can be stored is 10. The smaller the diagnosis No., the more
recent the error is.
• The stored time of an error code appearing just when the ignition key switch is turned ON may be stored
as 0.0.
(3) Connect the matching connector and turn the ignition key switch OFF.
Knob switch
Diagnosis memory menu
Press the knob switch to return it.
Switches automatically
every 2 seconds
LIST OF DIAGNOSIS CODES
Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
01-1 01-1 Blinking 4Y-ECS Fuel feedback control error (gasoline) rich
21-75
01-2 01-2 Blinking 4Y-ECS Fuel feedback control error (gasoline) lean
The engine speed is unstable and it may stop.
01-3 01-3 Blinking 4Y-ECS Fuel feedback control error (LPG) rich
21-79
01-4 01-4 Blinking 4Y-ECS Fuel feedback control error (LPG) lean
01-5 01-5 Blinking 4Y-ECS O2 sensor open abnormality The engine speed is unstable and it may stop. 21-84
01-6 01-6 Blinking 4Y-ECS O2 sensor heater open abnormality Display only 21-86
02-1 02-1 Blinking 4Y-ECS Intake temperature sensor open abnormality The engine may have a problem at low
21-88
02-2 02-2 Blinking 4Y-ECS Intake temperature sensor short abnormality temperatures.
03-1 03-1 Blinking 4Y-ECS Intake pipe pressure sensor open abnormality
The engine may have a problem 21-90
03-2 03-2 Blinking 4Y-ECS Intake pipe pressure sensor short abnormality
04-1 04-1 Blinking 4Y-ECS Coolant temperature sensor open abnormality The engine may have a problem at low
21-92
04-2 04-2 Blinking 4Y-ECS Coolant temperature sensor short abnormality temperatures.
05-1 05-1 Blinking 4Y-ECS Throttle position sensor 1 open abnormality
05-2 05-2 Blinking 4Y-ECS Throttle position sensor 1 short abnormality
05-3 05-3 Blinking 4Y-ECS Throttle position sensor 2 open abnormality Limting speed of traveling and materials
21-94
05-4 05-4 Blinking 4Y-ECS Throttle position sensor 2 short abnormality handling due to limited engine power output
05-5 05-5 Blinking 4Y-ECS Throttle position sensor offset abnormality
05-6 05-6 Blinking 4Y-ECS Throttle position sensor out of range error
06-1 06-1 Blinking 4Y-ECS Throttle motor drive circuit open abnormality
21-96
06-2 06-2 Blinking 4Y-ECS Throttle motor drive circuit short abnormality
06-3 06-3 Blinking 4Y-ECS Throttle motor power supply circuit open abnormality Limting speed of traveling and materials
21-98
06-4 06-4 Blinking 4Y-ECS Throttle motor power supply circuit short abnormality handling due to limited engine power output
06-5 06-5 Blinking 4Y-ECS Throttle motor seizing abnormality 21-99
06-6 06-6 Blinking 4Y-ECS Electronic throttle system error 21-101
07-1 07-1 Blinking 4Y-ECS Air-fuel ratio motor open abnormality The engine speed is unstable and it may stop. 21-102
08-1 08-1 Blinking 4Y-ECS Low voltage (battery line open) error Display only 21-104
09-1 09-1 Blinking 4Y-ECS Ignition signal error The engine speed is unstable and it may stop. 21-105
0A-1 0A-1 Blinking 4Y-ECS Fuel specification determination signal error Display only
0A-2 0A-2 Blinking 4Y-ECS Fuel specification changeover switch error Display only 21-108
0A-3 0A-3 Blinking 4Y-ECS Fuel specification type unmatch Engine may stop
21-67
Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
21-68
Limting speed of traveling and materials
0A-4 0A-4 Blinking 4Y-ECS Engine specification determination error 21-110
handling due to limited engine power output
13-1 13-1 Blinking ASC Motor relay contact point open abnormality Continuation of engine idling status
13-2 13-2 Blinking ASC Motor relay contact point short abnormality Display only 21-111
13-3 13-3 Blinking ASC Motor relay open circuit or load short abnormality Continuation of engine idling status
15-1 15-1 Blinking ASC NMR switch open abnormality The engine may idle during full acceleration.
21-113
15-2 15-2 Blinking ASC NMR switch short abnormality Continuation of engine idling status
Continuation of engine idling status after
15-3 15-3 Blinking ASC Idle / NMR switch simultaneously ON error 21-116
acceleration off.
16-1 16-1 Blinking ASC Idle switch open abnormality
Continuation of engine idling status 21-119
16-2 16-2 Blinking ASC Idle switch short abnormality
4Y-ECS Cam angle sensor open abnormality Engine stop 21-122
18-1 18-1 Blinking
ASC Engine speed sensor open abnormality Partial limitation of the drive control function. 21-126
4Y-ECS Cam angle sensor open abnormality (on start up) Engine will not start 21-122
18-2 18-2 Blinking
ASC Engine speed sensor GND short abnormality Partial limitation of the drive control function. 21-126
18-3 18-3 Blinking 4Y-ECS Crank angle sensor open abnormality Display only 21-124
Continuation of engine idling status
Maximum speed may be limited
1F-1 ~ 8 1F-1 ~ 8 Blinking ASC CPU error 21-128
Function of automatic idle speed increse during
lifting limited
41-1 41-1 Blinking SAS/OPS Matching connector open abnormality Display only 21-129
51-1 51-1 Blinking SAS/OPS Speed sensor open abnormality The vehicle speed indicator shows 0 km/h
Partial limitation of the rear wheel swing control
function. 21-130
51-2 51-2 Blinking SAS/OPS Speed sensor GND short abnormality Knob offest compensation stops
Partial limitation of the drive control function.
52-1 52-1 Blinking SAS/OPS Yaw rate sensor open abnormality
Partial limitation of the rear wheel swing control
52-2 52-2 Blinking SAS/OPS Yaw rate sensor VCC short abnormality 21-132
function
52-3 52-3 Blinking SAS/OPS Yaw rate sensor neutral voltage error
Partial limitation of the rear wheel swing control
54-1 54-1 Blinking SAS/OPS Swing lock solenoid open circuit or load short abnormality 21-134
function
61-1 61-1 Blinking SAS/OPS Load sensor open abnormality Partial limitation of the rear wheel swing control
function
Partial limitation of mast control function 21-136
61-2 61-2 Blinking SAS/OPS Load sensor VCC short abnormality Limitation of the drive control function
Load indicator cannot display
Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
62-1 62-1 Blinking SAS/OPS Tilt angle sensor open abnormality
Partial limitation of mast control function 21-139
62-2 62-2 Blinking SAS/OPS Tilt angle sensor VCC short abnormality
63-1 63-1 Blinking SAS/OPS Tilt switches simultaneously ON
63-2 63-2 Blinking SAS/OPS Tilt switch forward tilt SW short Partial limitation of mast control function 21-142
63-3 63-3 Blinking SAS/OPS Tilt switch backward tilt SW short
64-1 64-1 Blinking SAS/OPS Lift lower lock solenoid open circuit or load short abnormality Lift lower may stop 21-145
Forward tilt may stop, backward tilt may go fully
65-1 65-1 Blinking SAS/OPS Tilt control solenoid open circuit or load short abnormality 21-147
back
66-1 66-1 Blinking SAS/OPS Outside matching value range for tilt angle error Partial limitation of mast control function 21-149
Partial limitation of the rear wheel swing control
function
67-1 67-1 Blinking SAS/OPS Lifting height switch open abnormality Partial limitation of mast control function 21-150
Limitation of the drive control function
Load indicator display is unsteady
Lowering may stop
68-1 68-1 Blinking SAS/OPS Lift switch raise and lower simultaneously ON error Function of automatic idle speed increse during
lifting limited
21-153
Function of automatic idle speed increse during
68-2 68-2 Blinking SAS/OPS Lift switch raise SW short abnormality
lifting limited
68-3 68-3 Blinking SAS/OPS Lift switch lower SW short abnormality Lowering may stop
Backward tilt lock solenoid open circuit or load short
69-1 69-1 Blinking SAS/OPS Backward tilt may stop 21-156
abnormality
71-1 71-1 Blinking SAS/OPS Tire angle sensor open abnormality
Knob offest compensation stops 21-158
71-2 71-2 Blinking SAS/OPS Tire angle sensor VCC short abnormality
72-1 72-1 Blinking SAS/OPS Steering-wheel angle sensor SS1 open abnormality
72-2 72-2 Blinking SAS/OPS Steering-wheel angle sensor SS2 open abnormality
Knob offest compensation stops 21-161
72-3 72-3 Blinking SAS/OPS Steering-wheel angle sensor SSC open abnormality
72-4 72-4 Blinking SAS/OPS Steering-wheel angle sensors SS1 and SS2 open abnormality
21-69
Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
21-70
Knob position compensation solenoid open circuit or load short
73-1 73-1 Blinking SAS/OPS Knob offest compensation stops 21-169
abnormality
74-1 74-1 Blinking SAS/OPS Outside matching value range for tire angle error Knob offest compensation stops 21-171
Traveling and material handling possible even
after leaving the seat.
A5-1 A5-1 Blinking SAS/OPS Seat switch GND short abnormality 21-172
Parking brake reminder and release reminder
alarm partially disabled.
A7-1 A7-1 Blinking SAS/OPS Brake switch GND short abnormality Partial limitation of the drive control function 21-174
AD-1 AD-1 Blinking SAS/OPS CAN communication 4Y-ECS or ASC data reception error Partial limitation of the drive control function
AD-2 AD-2 Blinking 4Y-ECS CAN communication SAS/OPS data reception error Partial limitation of the drive control function
Limitation of the drive control function
Function of automatic idle speed increse during 21-176
AD-7 AD-7 Blinking SAS/OPS CAN communication display data reception error
lifting limited
Display warning function operation failure
AD-8 AD-8 – Display CAN communication SAS/OPS data reception error Display not stable
AF-1 ~ 3 AF-1 ~ 3 On SAS/OPS
CPU error Various control operations not stable 21-180
AF-4 ~ 8 AF-4 ~ 8 Blinking SAS/OPS
4Y-ECS
C4-1 C4-1 Blinking Accelerator sensor 1 open
ASC
4Y-ECS
C4-2 C4-2 Blinking Accelerator sensor 1 short
ASC
4Y-ECS
C4-3 C4-3 Blinking Accelerator sensor 2 open Limting speed of traveling and materials
ASC 21-184
handling due to limited engine power output
4Y-ECS
C4-4 C4-4 Blinking Accelerator sensor 2 short
ASC
4Y-ECS
C4-5 C4-5 Blinking Accelerator sensor offset abnormality
ASC
C4-6 C4-6 Blinking 4Y-ECS Accelerator sensor out of range error
Travel return to neutral operation disabled
C7-1 C7-1 Blinking SAS/OPS Shift lever forward and reverse travel switch open abnormality
Partial limitation of the drive control function.
21-187
Shift lever forward and reverse travel switches simultaneously Travelling may stop
C7-2 C7-2 Blinking SAS/OPS
ON error Partial limitation of the drive control function.
Forward and reverse travel T/C relay open circuit or load short Travelling and material handling enabled even
CA-1 CA-1 Blinking SAS/OPS 21-190
abnormality after leaving the seat.
Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
Travelling and material handling enabled even
EC-1 EC-1 Blinking SAS/OPS Unload solenoid open circuit or load short abnormality 21-192
after leaving the seat.
F1-1 – Blinking
Meter SAS/OPS data reception error Display only 21-194
F1-2 – Blinking
F4-1 ~ 8 F4-1 ~ 8 Blinking Display CPU error Display not stable 21-195
H1-1 H1-1 Blinking SAS/OPS Lift lever potentiometer open abnormality
H1-2 H1-2 Blinking SAS/OPS Lift lever potentiometer VCC short abnormality Lift stop
H1-3 H1-3 Blinking SAS/OPS Lift lever potentiometer assembly error 21-196
H1-4 H1-4 Blinking SAS/OPS Lift lever potentiometer neutral abnormality Material handling disabled
H1-5 H1-5 Blinking SAS/OPS Lift lever potentiometer matching value abnormality Lift stop
H2-1 H2-1 Blinking SAS/OPS Tilt lever potentiometer open abnormality
H2-2 H2-2 Blinking SAS/OPS Tilt lever potentiometer VCC short abnormality Tilt stop
H2-3 H2-3 Blinking SAS/OPS Tilt lever potentiometer assembly error 21-199
H2-4 H2-4 Blinking SAS/OPS Tilt lever potentiometer neutral error abnormality Material handling disabled
H2-5 H2-5 Blinking SAS/OPS Tilt lever potentiometer matching error Tilt stop
H3-1 H3-1 Blinking SAS/OPS Attachment 1 lever potentiometer open abnormality
H3-2 H3-2 Blinking SAS/OPS Attachment 1 lever potentiometer VCC short abnormality Attachment 1 stop
H3-3 H3-3 Blinking SAS/OPS Attachment 1 lever potentiometer combination error 21-202
H3-4 H3-4 Blinking SAS/OPS Attachment 1 lever potentiometer neutral abnormality Material handling disabled
H3-5 H3-5 Blinking SAS/OPS Attachment 1 lever potentiometer matching value abnormality Attachment 1 stop
H4-1 H4-1 Blinking SAS/OPS Attachment 2 lever potentiometer open abnormality
H4-2 H4-2 Blinking SAS/OPS Attachment 2 lever potentiometer VCC short abnormality Lever 2 stop
H4-3 H4-3 Blinking SAS/OPS Attachment 2 lever potentiometer combination error 21-205
H4-4 H4-4 Blinking SAS/OPS Attachment 2 lever potentiometer neutral abnormality Material handling disabled
H4-5 H4-5 Blinking SAS/OPS Attachment 2 lever potentiometer matching value abnormality Lever 2 stop
H5-1 H5-1 Blinking SAS/OPS Lift PUSH solenoid open abnormality
Lift may stop 21-208
H5-2 H5-2 Blinking SAS/OPS Lift PULL solenoid open abnormality
H6-1 H6-1 Blinking SAS/OPS Tilt PUSH solenoid open abnormality
Tilt may stop 21-210
H6-2 H6-2 Blinking SAS/OPS Tilt PULL solenoid open abnormality
H7-1 H7-1 Blinking SAS/OPS Attachment 1 PUSH solenoid open abnormality
Attachment 1 may stop 21-212
H7-2 H7-2 Blinking SAS/OPS Attachment 1 PULL solenoid open abnormality
21-71
Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
21-72
H8-1 H8-1 Blinking SAS/OPS Attachment 2 PUSH solenoid open abnormality
Attachment 2 may stop 21-214
H8-2 H8-2 Blinking SAS/OPS Attachment 2 PULL solenoid open abnormality
HA-1 HA-1 Blinking SAS/OPS 3/4 way change relay GND short abnormality Attachment switching disabled 21-216
WARNING LIST
Caution:
If the wrench lamp illuminates and the following phenomena occur on the vehicle without an error being displayed, it is not a fault. Take the
appropriate corrective action.
Wrench Detection
Indication Memory Phenomenon on vehicle Content of warning Appropriate corrective action
lamp ECU
Water
temperatur Top speed and load lifting speed are limited.
OB-1 – 4Y-ECS Overheat Leave the vehicle at idle for a while
e gauge (Only when OPT equipped)
flashing
Swing lock control is always locked
Knob offset occurrence Use a battery of the specified
– – On SAS/OPS High battery voltage
Material handling disabled (mini lever) voltage
Material handling except lifting disabled
– – On SAS/OPS Swing lock control is always locked Low battery voltage Charge or replace the battery
– – On SAS/OPS Tilt operates to forward most tilt position Forward tilt restriction angle not matching
Tilt disabled with the knob switch in the ON
– – On SAS/OPS Auto leveling angle not matching
position
Tilt operates to forward most tilt position
SAS/OPS NL load not matching
– – On SAS/OPS Tilt disabled with the knob switch in the ON
(NL: No-load)
position
– – On SAS/OPS Knob offset occurrence Tire angle not matching Carry out matching for each item
– – On SAS/OPS Swing lock control disabled Swing leveling not matching
– – On SAS/OPS Lift stop Lift lever not matching
– – On SAS/OPS Tilt stop Tilt lever not matching
– – On SAS/OPS Attachment 1 stop Attachment 1 not matching
– – On SAS/OPS Attachment 2 stop Attachment 2 not matching
21-73
21-74
VIEWING RELATED PORTIONS
In the wiring diagrams for related portions, there are cases in which the parts are connected directly, and cases
where they are connected via a junction block or similar.
Refer below for how to identify wiring configuartions.
Example of a Related Portion
: Direct connection
: Connection via a junction
A21
ECU-B
8 (BATT)
1 (IG1) ECU-IG Q2
SAS/OPS 2 (IG2) 2 (IG)
controller A20
12 (CANH) 5 (CANH) Multifunction
13 (CANL) 6 (CANL) display
3 (E1)
A36
28 (CAN+)
29 (CAN-)
Engine
EFI 3 (BATT)
controller
IGN 9 (IGSW)
ERROR CONFIRMATION DRIVE MODE
c Turn the ignition key switch ON, start and completely warm up the engine.
d Fully depress the accelerator pedal for 3 to 5 minutes with the direction neutral.
e Release and leave the accelerator pedal (run the engine at idle) for 2 minutes.
f Repeat steps d and e 3 times.
g Turn the ignition key switch OFF (for 1 minute).
h Repeat steps c to g 3 times.
Engine speed 3 ~ 5 minutes 3 ~ 5 minutes 3 ~ 5 minutes
NMR
Warmed up
Idle
time
IG IG
OFF OFF
2 minutes 2 minutes 2 minutes
21-75
TROUBLESHOOTING BY ERROR CODE
z Error codes 01-1, 01-2 (Fuel feedback control abnormality)
Related portion
A35 C1
20 (OX) 3 (OX)
Engine
controller 21 (E11) 4 (E11) O2 sensor
Probable cause
c Intake system defect g Fuel system defect
d Exhaust system defect h Harness defect
e Sensor defect i Engine controller defect
f Ignition defect
Caution:
When another error code is present repair the related parts first before carrying out the following.
Error codes 01-1 and 01-2
Disconnect the battery negative terminal (for
more than 10 seconds). Check the connection
status of C1, disconnect C1 and perform a visual
and contact pressure inspection of the
connector. Short circuit the service connector TC
terminal with the E1 terminal, and after
connecting C1 and the battery negative terminal
(on a combination vehicle, switch the fuel
changeover switch to gasoline), turn the ignition
key switch ON (engine stopped), depress the
accelerator pedal 5 times within 30 seconds
(fully open to fully closed), then start the engine
and check that the error has been cleared.
Service connector
Disconnect the battery negative terminal,
disconnect TC terminal - E1 terminal, connect
the battery negative terminal, start the engine, No error
Connector contact defect
and check whether the error occurs after
performing error confirmation drive mode (see
21-74).
Error
Inspection 1: NG Intake system defect
Inspect the air intake Intake system connection defect
OK
A
21-76
Inspection 2: NG Exhaust system defect
Exhaust gas leakage inspection Exhaust system
OK
Inspection 3: NG Fuel system defect
Fuel leakage inspection Fuel system connection defect
OK
Pressure regulator defect
Inspection 4: NG
Fuel filter defect
Fuel pressure inspection
Fuel pump defect
OK
Inspection 5: NG
Spark plug individual inspection Spark plug defect
OK
Inspection 6: NG
Injector individual inspection Injector defect
OK
Inspection 7:
NG
Intake pipe pressure sensor voltage inspection Intake pipe pressure sensor defect
ANL.: I/O ENGINE CTRL 3/10
OK
Inspection 8:
NG
Intake temperature sensor voltage inspection Intake temperature sensor defect
ANL.: I/O ENGINE CTRL 3/10
OK
Inspection 9:
NG
Coolant temperature sensor voltage inspection Coolant temperature sensor defect
ANL.: I/O ENGINE CTRL 3/10
OK
Inspection 10: NG
Harness continuity and short circuit inspection Harness defect
OK
B
21-77
Inspection 11:
OK
O2 sensor voltage inspection Connector contact defect
ANL.:I/O ENGINE CTRL 8/10
NG
Inspection 12:
NG
O2 sensor voltage inspection Engine controller defect
ANL.:I/O ENGINE CTRL 8/10
OK
O2 sensor defect
Inspection 1:
Inspect for air suction.
Start the engine and check whether air is being sucked in from the engine oil level gauge, oil filler cap, or PCV
hose etc.
Standard: There is no air being sucked in.
Check if there is air being sucked in from the intake system parts and connections between the air cleaner and
the cylinder head.
Standard: There is no air being sucked in.
Inspection 2:
Inspect for exhaust gas leakage.
Start the engine and check if there is any exhaust gas leakage from the exhaust system parts and connections
between the cylinder head and the catalytic muffler.
Standard: There is no exhaust gas leakage.
Inspection 3:
Inspect for fuel leakage.
Start the engine and check if there is any fuel leakage from the fuel system parts and connections between the
fuel pump and the injectors.
Standard: There is no fuel leakage.
Inspection 4:
Inspect the fuel pressure.
For the fuel pressure inspection, refer to the repair manual for the 4Y engine.
Inspection 5:
Carry out a spark plug individual inspection.
For the spark plug individual inspection, refer to the repair manual for the 4Y engine.
Inspection 6:
Carry out an injector individual inspection.
For the individual injector inspection, refer to the repair manual for the 4Y engine.
21-78
Inspection 7:
Inspect the intake pipe pressure sensor voltage.
Ignition key switch ON, engine stopped
Intake pipe pressure sensor voltage (I/O monitor: PIM)
Standard:
PIM 3.6 ± 0.3 V (100 ± 10 kPa (1 ± 0.1 kgf/cm2) [14 ± 1.4 psi])
Inspection 8:
Inspect the intake temperature sensor voltage.
Ignition key switch ON, engine stopped
Intake temperature sensor voltage (I/O monitor: THA)
Standard:
2.4 ± 0.6 V (20 ± 10°C)
THA
0.55 ± 0.15 V (80 ± 10°C) (reference value)
Inspection 9:
Inspect the coolant temperature sensor voltage.
Start the engine, warm up completely (coolant temperature gauge: at 5-6 bars)
Coolant temperature sensor voltage (I/O monitor: THW)
Standard:
0.55 ± 0.15 V (80 ± 10°C)
THW
2.4 ± 0.6 V (20 ± 10°C) (reference value)
Inspection 10:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect battery negative terminal, disconnect A35 and C1.
Standard:
A35-20 ~ C1-3 Continuity
A35-21 ~ C1-4 Continuity
A35-20 ~ Frame No continuity
A35-21 ~ Frame No continuity
Inspection 11:
Inspect the O2 sensor output.
Connect A35 and C1, start the engine, warm up completely, set direction in neutral, fully open the accelerator
pedal
O2 sensor voltage (I/O monitor: OX)
Standard:
OX 0.4 V or less and 0.5 V or more alternately output
Inspection 12:
Inspect the O2 sensor output.
Disconnect C1, connect A35, start the engine, warm up completely, set direction in neutral, fully open the
accelerator pedal
O2 sensor voltage (I/O monitor: OX)
Standard:
OX 0.2 V or less
21-79
z Error codes 01-3, 01-4 (Fuel feedback control abnormality) (LPG)
Related portion
A35 C1
20 (OX) 3 (OX)
Engine
controller 21 (E11) 4 (E11) O2 sensor
Probable cause
c Intake system defect g Fuel system defect
d Exhaust system defect h Harness defect
e Sensor defect i Engine controller defect
f Ignition defect
Caution:
When another error code is occuring, repair the related parts first before carrying out the following.
Error codes 01-3 and 01-4
Disconnect the battery negative terminal (for
more than 10 seconds). Check the connection
status of C1, disconnect C1 and perform a visual
and contact pressure inspection of the
connector. Short circuit the service connector TC
terminal with the E1 terminal, and after
connecting C1 and the battery negative terminal
(on a combination vehicle, switch the fuel
changeover switch to gasoline), turn the ignition
key switch ON (engine stopped), depress the
accelerator pedal 5 times within 30 seconds
(fully open to fully closed), then start the engine
and check that the error has been cleared. Service connector
Disconnect the battery negative terminal,
disconnect TC terminal - E1 terminal, connect
the battery negative terminal, start the engine, No error
and check whether the error occurs after Connector contact defect
performing error confirmation drive mode (see
21-74).
Error
Inspection 1: NG Intake system defect
Inspect the air intake Intake system connection defect
OK
A
21-80
Inspection 2: NG Exhaust system defect
Exhaust gas leakage inspection Exhaust system connection defect
OK
Inspection 3: NG Fuel system defect
Fuel leakage inspection Fuel system connection defect
OK
Inspection 4: NG
Regulator primary pressure inspection Regulator defect
OK
Inspection 5: NG
Spark plug individual inspection Spark plug defect
OK
Inspection 6: NG
Injector individual inspection Injector defect
OK
Inspection 7: NG
Air-fuel ratio motor individual inspection Air-fuel ratio motor defect
OK
Inspection 8:
NG
Intake pipe pressure sensor voltage inspection Intake pipe pressure sensor defect
ANL.: I/O ENGINE CTRL 3/10
OK
Inspection 9:
NG
Intake temperature sensor voltage inspection Intake temperature sensor defect
ANL.: I/O ENGINE CTRL 3/10
OK
Inspection 10:
NG
Water temperature sensor voltage inspection Water temperature sensor defect
ANL.: I/O ENGINE CTRL 3/10
OK
Inspection 11: NG
Harness continuity and short circuit inspection Harness defect
OK
B
21-81
Inspection 12:
OK
O2 sensor voltage inspection Connector contact defect
ANL.:I/O ENGINE CTRL 8/10
NG
Inspection 13:
NG
O2 sensor voltage inspection Engine controller defect
ANL.:I/O ENGINE CTRL 8/10
OK
O2 sensor defect
Inspection 1:
Inspect for air suction.
Start the engine and check whether air is being sucked in from the engine oil level gauge, oil filler cap, or PCV
hose etc.
Standard: There is no air being sucked in.
Check if there is air being sucked in from the intake system parts and connections between the air cleaner and
the cylinder head.
Standard: There is no air being sucked in.
Check if there is air being sucked in from the intake system parts and connections among the air cleaner hose,
the resonator, and the cylinder head.
Standard: There is no air being sucked in.
Inspection 2:
Inspect for exhaust gas leakage.
Start the engine and check if there is any exhaust gas leakage from the exhaust system parts and connections
between the cylinder head and the catalytic muffler.
Standard: There is no exhaust gas leakage.
Inspection 3:
Inspect for fuel leakage.
Start the engine and check if there is any fuel leakage from the fuel system parts and connections between the
fuel tank and the regulator.
Standard: There is no fuel leakage.
Check if there is fuel leakage from the fuel system parts and connections between the regulator and the LPG
adapter.
Standard: There is no fuel leakage.
Check if there is fuel leakage from the fuel system parts and connections between the regulator and the injector.
Standard: There is no fuel leakage.
Inspection 4:
Inspect the regulator primary pressure.
For the regulator primary pressure inspection, refer to the LPG repair manual.
21-82
Inspection 5:
Carry out a spark plug individual inspection.
For the spark plug individual inspection, refer to the repair manual for the 4Y engine.
Inspection 6:
Carry out an injector individual inspection.
For the individual injector inspection, refer to the repair manual for the 4Y engine.
Inspection 7:
Carry out an individual inspection of the air-fuel ratio motor.
For the individual air-fuel ratio motor inspection, refer to the LPG repair manual.
Inspection 8:
Inspect the intake pipe pressure sensor voltage.
Ignition key switch ON, engine stopped
Intake pipe pressure sensor voltage (I/O monitor: PIM)
Standard:
PIM 3.6 ± 0.3 V (100 ± 10 kPa (1 ± 0.1 kgf/cm2) [14 ± 1.4 psi])
Inspection 9:
Inspect the intake temperature sensor voltage.
Ignition key switch ON, engine stopped
Intake temperature sensor voltage (I/O monitor: THA)
Standard:
2.4 ± 0.6 V (20 ± 10°C)
THA
0.55 ± 0.15 V (80 ± 10°C) (reference value)
Inspection 10:
Inspect the coolant temperature sensor voltage.
Start the engine, warm up completely (coolant temperature gauge: 5-6 bars)
Coolant temperature sensor voltage (I/O monitor: THW)
Standard:
0.55 ± 0.15 V (80 ± 10°C)
THW
2.4 ± 0.6 V (20 ± 10°C) (reference value)
Inspection 11:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C1
Standard:
A35-20 ~ C1-3 Continuity
A35-21 ~ C1-4 Continuity
A35-20 ~ Frame No continuity
A35-21 ~ Frame No continuity
21-83
Inspection 12:
Inspect the O2 sensor output.
Start the engine, warm up completely, put the direction in neutral, fully open the accelerator pedal
O2 sensor voltage (I/O monitor: OX)
Standard:
OX 0.4 V or less and 0.5 V or more alternately output
Inspection 13:
Inspect the O2 sensor output.
Start the engine, warm up completely, put the direction in neutral, fully open the accelerator pedal
O2 sensor voltage (I/O monitor: OX)
Standard:
OX 0.2 V or less
21-84
z Error code 01-5 (O2 sensor open abnormality)
Related portion
A35 C1
20 (OX) 3 (OX)
Engine
controller 21 (E11) 4 (E11) O2 sensor
Probable cause
c O2 Sensor defect
d Harness defect
e Engine controller defect
Caution:
When another error code is present, repair the related parts first before carrying out the following.
Error code 01-5
Disconnect the battery negative terminal (for
more than 10 seconds). Check the connection
status of C1, disconnect C1 and perform a visual
and contact pressure inspection of the
connector. Short circuit the service connector TC
terminal with the E1 terminal, and after
connecting C1 and the battery negative terminal
(on a combination vehicle, switch the fuel
changeover switch to gasoline), turn the ignition
key switch ON (engine stopped), depress the
accelerator pedal 5 times within 30 seconds
(fully open to fully closed), then start the engine
and check that the error has been cleared. Service connector
Disconnect the battery negative terminal,
disconnect TC terminal - E1 terminal, connect
No error
the battery negative terminal, start the engine, Connector contact defect
and check whether the error occurs after
performing error confirmation drive mode (see
21-74).
Error
Inspection 1: NG
Harness defect
Harness continuity and short circuit inspection
OK
O2 sensor defect
If the error occurs even
after replacing the O2
sensor
Engine controller defect
21-85
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C1
Standard:
A35-20 ~ C1-3 Continuity
A35-21 ~ C1-4 Continuity
A35-21 ~ Frame No continuity
21-86
z Error code 01-6 (O2 sensor heater open abnormality)
Related portion
A35
R/B EFI Main relay
C1 C1
Engine 6 (HTR) 1 (HTR) O2 2 (+) 3 (L) EFI
controller sensor main relay
Probable cause
c O2 Sensor defect
d Harness defect
e Engine controller defect
Error code 01-6
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
correcting disconnection of CN1 and internal
wetting, reconnect all connectors and battery
negative terminal, turn the ignition key switch ON
(start the engine), and check whether or not there
is an error. No error
c Turn the ignition key switch ON. Connector contact defect
(Start and run the engine for more than 10
seconds.)
d Turn the ignition key switch OFF for more
than10 seconds.
e Turn the ignition key switch ON.
(Start and run the engine for more than 10
seconds.)
f Check for errors.
Error
Inspection 1: NG
O2 sensor individual inspection O2 sensor defect
OK
Inspection 2: NG
O2 sensor heater power voltage inspection Harness defect
OK
Inspection 3: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect
21-87
Inspection 1:
Carry out O2 sensor individual inspection.
2 1
Ignition key switch OFF, disconnect C1, connect A35 4 3
Standard: (Sensor side)
C1
C1-2 ~ C1-1 13 ~ 16 Ω (20°C)
Inspection 2:
Carry out O2 sensor heater power voltage inspection.
Ignition key switch OFF, diconnect C1, connect A35, start engine
Standard:
C1-2 ~ Frame 8 ~ 16 V
Inspection 3:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C1
Standard:
A35-6 ~ C1-1 Continuity
A35-6 ~ Frame No continuity
21-88
z Error codes 02-1, 02-2 (Intake temperature sensor abnormality)
Related portion
A35 C3
29 (THA) 2 (THA) Intake
Engine
controller 28 (E2) 1 (E2) temperature
sensor
Probable cause
c Intake temperature sensor defect
d Harness defect
e Engine controller defect
Caution:
When another error code is present, repair the related parts first before carrying out the following.
Error codes 02-1 and 02-2
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of C3 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error
Inspection 1: NG
Intake temperature sensor individual inspection Intake temperature sensor defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect
Inspection 1:
Carry out intake temperature sensor individual inspection.. 2 1
Ignition key switch OFF, disconnect C3, connect A35 C3
Standard: (Sensor side)
2.45 ± 0.24 kΩ (20°C)
C3-1 ~ C3-2
0.32 ± 0.03 kΩ (80°C)
21-89
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C3
Standard:
A35-29 ~ C3-2 Continuity
A35-28 ~ C3-1 Continuity
A35-29 ~ Frame No continuity
21-90
z Error codes 03-1, 03-2 (Intake pipe negative pressure sensor abnormality)
Related portion
A35
G12
17 (VC) 3 (VC)
Engine Intake pipe
18 (PIM) 2 (PIM)
controller pressure
28 (E2) 1 (E2) sensor
Probable cause
c Intake pipe negative pressure sensor defect
d Harness defect
e Engine controller defect
Error codes 03-1 and 03-2
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of G12 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 2:
NG
Intake pipe pressure sensor voltage inspection Engine controller defect
ANL.: I/O ENGINE CTRL 3/10
OK
Intake pipe pressure sensor defect
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and G12
Standard:
A35-18 ~ G12-2 Continuity
A35-28 ~ G12-1 Continuity
A35-18 ~ A35-17 No continuity
A35-17 ~ G12-3 Continuity
A35-18 ~ Frame No continuity
21-91
Inspection 2:
Inspect the intake pipe pressure sensor voltage.
Ignition key switch OFF, disconnect G12, connect A35, ignition key switch ON, engine stopped
Intake pipe pressure sensor voltage (I/O monitor: PIM)
Standard:
PIM 4.80 V or more
21-92
z Error codes 04-1, 04-2 (Coolant temperature sensor abnormality)
Related portion
A35 G16
19 (THW) 2 (THW) Coolant
Engine
controller 28 (E2) 1 (E2) temperature
sensor
Probable cause
c Coolant temperature sensor defect
d Harness defect
e Engine controller defect
Error codes 04-1 and 04-2
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of G16 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error
Inspection 1: NG
Water temperature sensor individual inspection Water temperature sensor defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect
Inspection 1:
Carry out coolant temperature sensor individual inspection.
Ignition key switch OFF, disconnect A35 and G16
Standard: (Sensor side)
2.45 ± 0.24 kΩ (20°C)
G16-1 ~ G16-2
0.32 ± 0.03 kΩ (80°C)
21-93
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and G16
Standard:
A35-19 ~ G16-2 Continuity
A35-28 ~ G16-1 Continuity
A35-19 ~ Frame No continuity
21-94
z Error codes 05-1, 05-2, 05-3, 05-4, 05-5, 05-6 (Throttle position sensor abnormality)
Related portion
G27 G6
20 (VC2) 5 (VC)
Engine 21 (VTA) 6 (VTA) Throttle
controller 29 (VTA2) 4 (VTA2) position sensor
28 (E21) 3 (E21)
Probable cause
c Throttle position sensor defect
d Harness defect
e Engine controller defect
Error codes 05-1, 05-2, 05-3, 05-4, 05-5, 05-6
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of G6 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 2:
Throttle position sensor voltage inspection NG
ANL.: I/O ENGINE CTRL 5/10 Engine controller defect
OK
Throttle position sensor defect
21-95
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G6
Standard:
G27-21 ~ G6-6 Continuity
G27-28 ~ G6-3 Continuity
G27-21 ~ G27-20 No continuity
G27-20 ~ G6-5 Continuity
G27-21 ~ Frame No continuity
G27-29 ~ G6-4 Continuity
G27-29 ~ G27-20 No continuity
G27-29 ~ Frame No continuity
G27-21 ~ G27-29 No continuity
Inspection 2:
Inspect the throttle position sensor voltage.
Ignition key switch OFF, disconnect G6, connect G27, ignition key switch ON
Throttle position sensor voltage (I/O monitor: VTA1, VTA2)
Standard:
VTA1, VTA2 4.80 V or more
21-96
z Error codes 06-1, 06-2 (Throttle motor drive circuit open/short abnormality)
Related portion
E-THRO
G27 G6
7 (+BM)
6 (M+) 2 (M+)
Throttle
Engine 5 (M-) 1 (M-) motor
controller 4 (ME01)
Probable cause
c Throttle motor defect
d Harness defect
e Engine controller defect
Error codes 06-1 and 06-2
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of G6 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error
Inspection 1: NG
Throttle motor individual inspection Throttle motor defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect
21-97
Inspection 1:
Carry out throttle motor individual inspection. 6 5 4 3 2 1
Ignition key switch OFF, disconnect G6, connect G27
G6
(1) Throttle motor resistance inspection
Standard: (Motor side)
G6-2 ~ G6-1 0.3 ~ 100 Ω (20°C)
(2) Throttle valve drive condition
Standard:
Throttle valve operates smoothly when fully opened.
Throttle valve operates smoothly when fully closed.
When you remove your hand from the throttle valve, it returns to the opener angle.
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G6
Standard:
G27-6 ~ G6-2 Continuity
G27-5 ~ G6-1 Continuity
G27-6 ~ Frame No continuity
G27-5 ~ Frame No continuity
G27-6 ~ G27-5 No continuity
G27-6 ~ G27-7 No continuity
G27-5 ~ G27-7 No continuity
21-98
z Error codes 06-3, 06-4 (Throttle motor power circuit open/short abnormality)
Related portion
G27
Engine E-THRO
7 (+BM)
controller
Probable cause
c Harness defect
d Engine controller defect
Error codes 06-3 and 06-4
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of G27 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error
Inspection 1: NG
Throttle motor power voltage inspection Harness defect
OK
Engine controller defect
Inspection 1:
Inspect the throttle motor power voltage.
Ignition key switch OFF, disconnect G27
Standard:
G27-7 ~ Frame 8 ~ 16 V
21-99
z Error code 06-5 (Throttle motor seized abnormality)
Related portion
E-THRO
G27
G6
7 (+BM)
6 (M+) 2 (M+)
Throttle
Engine 5 (M-) 1 (M-) motor
controller 4 (ME01)
Probable cause
c Throttle motor defect
d Harness defect
e Engine controller defect
Error code 06-5
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of G6 and internal Connector contact defect
wetting, reconnect all connectors and the battery
negative terminal, turn the ignition key switch ON
(start the engine) and check whether or not there
is an error.
Error
Inspection 1: NG
Throttle motor individual inspection Throttle motor defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect
Inspection 1:
Carry out throttle motor individual inspection. 6 5 4 3 2 1
Ignition key switch OFF, disconnect G6, connect G27
G6
(1) Throttle motor resistance inspection
Standard: (Motor side)
G6-2 ~ G6-1 0.3 ~ 100 Ω (20°C)
(2) Throttle valve drive condition
Standard:
Throttle valve operates smoothly when fully opened.
Throttle valve operates smoothly when fully closed.
When you remove your hand from the throttle valve, it returns to the opener angle
21-100
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G6 and G27
Standard:
G27-6 ~ G27-5 No continuity
G27-6 ~ G27-7 No continuity
G27-5 ~ G27-7 No continuity
21-101
z Error code 06-6 (Electronic throttle abnormality)
Related portion
Engine
controller
Probable cause
c Engine controller defect
Error code 06-6
Disconnect the negative terminal of the battery for
10 seconds or more. Reconnect the battery No error
negative terminal, turn the ignition key switch ON Connector contact defect
(start the engine) and check whether or not there is
an error.
Error
Engine controller defect
21-102
z Error code 07-1 (Air-fuel ratio motor open abnormality)
Related portion
R/B Main relay
G28 G13 G13
21 (FCM1) 3 (FCM1) 2 (B1) 3 (L) EFI
31 (FCM2) 6 (FCM2) Air-fuel 5 (B2) main relay
Engine
controller 20 (FCM3) 1 (FCM3) ratio
motor
30 (FCM4) 4 (FCM4)
Probable cause
c Air-fuel ratio motor defect
d Harness defect
e Engine controller defect
Error code 07-1
Disconnect the battery negative terminal (for more
than 10 seconds), after inspecting and correcting
No error
disconnection of G13 and internal wetting, Connector contact defect
reconnect all connectors and the battery negative
terminal, turn the ignition key switch ON (start the
engine) and check whether or not there is an error.
Error
Inspection 1: NG
Air-fuel ratio motor individual inspection Air-fuel ratio motor defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect
21-103
Inspection 1:
Carry out an individual inspection of the air-fuel ratio motor. 3 2 1
(1) Air-fuel ratio motor resistance inspection 6 5 4
Ignition key switch OFF, disconnect G13, connect G28
G13
Standard: (Air-fuel ratio motor side)
G13-2 ~ G13-1
G13-2 ~ G13-3 20 ± 5 Ω (-10 ~ 50°C)
G13-5 ~ G13-4 25 ± 5 Ω (50 ~ 100°C)
G13-5 ~ G13-6
(2) Valve operation check
Connect the battery positive terminal to G13-2 and G13-5 and ground in the following terminal order.
Standard: (Air-fuel ratio motor side)
G13-3→G13-6→G13-1→G13-4: Moves to the close side
G13-4→G13-1→G13-6→G13-3: Moves to the open side
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G28, G13 and R/B main relay
Standard:
G28-21 ~ G13-3 Continuity
G28-31 ~ G13-6 Continuity
G28-20 ~ G13-1 Continuity
G28-30 ~ G13-4 Continuity
G13-2 ~ R/B main relay terminal 3 Continuity
G13-5 ~ R/B main relay terminal 3 Continuity
G28-21 ~ Frame No continuity
G28-31 ~ Frame No continuity
G28-20 ~ Frame No continuity
G28-30 ~ Frame No continuity
21-104
z Error code 08-1 (Low voltage abnormality)
Related portion
A36
EFI
Engine 3 (BATT)
controller
Probable cause
c Harness defect
d Engine controller defect
Error code 08-1
Disconnect the battery negative terminal (for more
than 10 seconds), after inspecting and correcting
No error
disconnection of A36 and internal wetting, Connector contact defect
reconnect all connectors and the battery negative
terminal, turn the ignition key switch ON (start the
engine) and check whether or not there is an error.
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A36
Standard:
A36-3 ~ EFI Continuity
A36-3 ~ Frame No continuity
21-105
zError code 09-1 (Ignition signal abnormality)
Related portion
IGN
G27 G25 G25
33 (IGT) 2 (IGT) 3 (IG2)
Engine
32 (IGF) 1 (IGF) Igniter 5 (IG1)
controller
G21
2 (IG-)
Ignition coil 1 (IG+)
Probable cause
c Ignition coil
d Igniter defect
e Harness defect
f Engine controller defect
21-106
Error code 09-1
Disconnect the battery negative
terminal (for more than 10
seconds), after inspecting and
correcting disconnection of G21 Engine will not start
and G25 and internal leakage,
reconnect all connectors and the
battery negative terminal, turn the
ignition key switch ON to start the
engine.
Engine
starts
Operate the accelerator pedal and No error
check whether there is an error. Connector contact defect
Error
Inspection 2:
Inspection 1: NG NG
Harness continuity and short circuit Harness defect
Ignition abnormality signal (IGF) inspection
inspection
OK
OK
Engine controller defect
Igniter defect
Inspection 3: NG
Ignition coil individual inspection Ignition coil defect
OK
Inspection 4:
NG
Harness continuity and short circuit Harness defect
inspection
OK
Inspection 5: NG
Igniter IGT signal inspection Engine controller defect
OK
Igniter defect
Inspection 1:
Carry out an ignition signal (IGF) inspection. 5 4 3 2 1
Ignition key switch OFF, disconnect G25, connect G27, ignition key switch ON, engine G25
stopped
Standard:
G25-1 ~ Frame 4.0 ~ 5.5 V
21-107
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G25
Standard:
G27-32 ~ G25-1 Continuity
G27-32 ~ Frame No continuity
Inspection 3:
Carry out distributor individual inspection. 2 1
Ignition key switch OFF, disconnect G21 and G25, connect G27
G21
Standard:
Primary side (G21-1 ~ G21-2) 1.2 ~ 1.5 Ω
Secondary side (IIA inner terminal) 7.7 ~ 10.4 Ω
Inspection 4:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27, G21 and G25
Standard:
G27-33 ~ G25-2 Continuity
G27-32 ~ G25-1 Continuity
G27-33 ~ G27-32 No continuity
G27-33 ~ Frame No continuity
G27-32 ~ Frame No continuity
G25-5 ~ G21-2 Continuity
G25-3 ~ G21-1 Continuity
G25-5 ~ G25-3 No continuity
G25-5 ~ frame No continuity
G25-3 ~ frame No continuity
Inspection 5:
Carry out an igniter (IGT) signal inspection. 5 4 3 2 1
Ignition key switch OFF, disconnect G21 and G25, connect G27, ignition key switch G25
ON, (cranking)
Standard:
G25-2 ~ Frame Not 0 V
21-108
z Error code 0A-1, 0A-2, 0A-3 (Fuel specification determination abnormality)
Related portion
G28 T6 T6 R/B EFI Main relay
14 (GAS) 6 (GAS) Fuel
4 (IG) 3 (L) EFI
13 (LPG) 3 (LPG) changeover
main relay
switch
G27
15 (SEL1)
Engine
controller 14 (SEL2)
13 (SEL3) Connection status of SEL1 to 4
differs depending on vehicle specification (refer to inspection 3).
12 (SEL4)
10 (ESEL)
Probable cause
c Fuel changeover switch defect
d Harness defect
e Engine controller defect
Error codes 0A-1, 0A-2, 0A-3
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
correcting disconnection of T6 and internal No error
wetting, reconnect all connectors and the battery Connector contact defect
negative terminal, turn the ignition key switch
ON (start the engine) and check whether or not
there is an error.
Error
Inspection 1:
Switch input signal inspection
ANL.: I/O ENGINE CTRL 1/10
OK
Inspection 2: NG
Fuel changeover switch defect
Fuel changeover switch individual inspection
OK
Inspection 3: NG
Harness defect
Harness continuity and short circuit inspection
OK
Engine controller defect
21-109
Inspection 1:
Carry out switch input signal inspection.
Ignition key switch ON
Switch input signal (I/O monitor: G/LP, SEL1-4)
Standard:
Vehicle specification Fuel changeover switch G/LP SEL
Gasoline specification – 10 1100
LPG exclusive – 01 0101
Gasoline selection 10
LPG/Gasoline convertible LPG selection 01 0110
Neutral 00
Gasoline selection 10
Gasoline/CNG convertible LPG selection 01 0011
Neutral 00
Inspection 2:
Carry out fuel changeover switch individual inspection.
(Carry out only for convertible vehicles, and only when the G/LP input in inspection 1 is outside 6 43
the standard value)
T6
Ignition key switch OFF, disconnect T6, connect G28 and G27
Standard: (Switch side)
Fuel changeover switch
Gasoline LPG/CNG Neutral
T6-4 ~ T6-6 Continuity No continuity No continuity
T6-4 ~ T6-3 No continuity Continuity No continuity
Inspection 3:
Inspect for continuity and short circuiting of the harness. (Begin with the place that was outside the standard
value in inspection 1)
Ignition key switch OFF, disconnect G28, G27 and T6
Harness
Vehicle specification
SEL1 SEL2 SEL3 SEL4
Short circuit to Short circuit to
Gasoline specification – –
ESEL ESEL
Short circuit to Short circuit to Short circuit to
LPG exclusive –
ESEL ESEL ESEL
Short circuit to Short circuit to
LPG/Gasoline convertible – –
ESEL ESEL
Short circuit to Short circuit to
Gasoline/CNG convertible – –
ESEL ESEL
21-110
z Error code 0A-4 (Engine specification determination abnormality)
Related portion
Engine
controller
Probable cause
c Engine controller defect
Error code 0A-4
Disconnect the battery negative terminal (for 10
seconds or more), reconnect the battery No error
Normal
negative terminal, then turn the ignition key
switch ON (start the engine) and check whether
or not there is an error.
Error
Engine controller defect
21-111
z Error codes 13-1, 13-2, 13-3 (Relay abnormality)
Related portion
IGN
To IGN SW
G39 R/B ASC relay
5 (SRLY) 1
13 (E01) 2
ASC controller ASC relay
3
2 (MEN+) 5
G37
Step motor
Probable cause
c Connector contact defect
d ASC relay defect
e Harness defect
f ASC controller defect
Error codes 13-1, 13-2, 13-3
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of G39
No error Connector contact defect
and the ASC relay and internal wetting, reconnect
ASC relay not plugged in properly
all connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error.
Error
Inspection 1: NG
ASC relay individual inspection ASC relay defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
ASC controller defect
21-112
Inspection 1:
Carry out ASC relay individual inspection.
Ignition key switch OFF, remove ASC relay
Standard: (Relay side)
ASC relay
1 ~ 2 terminals Continuity
At all times
3 ~ 5 terminals No continuity
When battery voltage is applied
3 ~ 5 terminals Continuity
between terminals 1 ~ 2
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G39, remove ASC relay
Standard:
G39-2 ~ ASC relay terminal 3 Continuity
ASC relay terminal 5 ~ IGN Continuity
G39-2 ~ BATT No continuity
G39-5 ~ ASC relay terminal 1 Continuity
G39-5 ~ G39-13 No continuity
G39-5 ~ Frame No continuity
G39-5 ~ BATT No continuity
ASC relay terminal 2 ~ Frame Continuity
21-113
z Error codes 15-1 and 15-2 (NMR switch abnormality)
Related portion
IGN
To IGN SW
G36
G39
2
12 (NMR) 1 NMR switch
ASC controller
R/B Starting motor relay
2 (STA) 1 Starting motor relay
Probable cause
c Connector contact defect
d NMR switch defect
e Harness defect
f ASC controller defect
g Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)
21-114
Error codes 15-1, 15-2
Disconnect the battery negative terminal, then
inspect and repair disconnection of G36, G39 and
starting motor relay and any internal leakage.
Reconnect the connectors and the battery negative
terminal, then repeat the operations c to f below
several times and check whether an error occurs.
c Turn the ignition key switch ON (engine stopped)
d Operate the accelerator pedal ON/OFF (several No error
times) Connector contact defect
e Start the engine with the accelerator fully
depressed
f Release the accelerator pedal and turn the
ignition key switch OFF
Error
Inspection 1: NG
NMR switch individual inspection NMR switch defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 3:
Inspection of the status of the NMR switch in the NG
ASC controller ASC controller defect
ANL.: I/O ENGINE CTRL 1/3
OK
Refer to and carry out mechanical system inspection
items such as link catching or switch position
adjustment.
Inspection 1:
Carry out an NMR switch individual inspection.
Ignition key switch OFF, disconnect G36, connect G39
Standard: (Switch side) G36
Switch OFF Switch ON
G36-1 ~ G36-2 No continuity Continuity
21-115
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G36, G39 and starting motor relay
Standard:
G39-12 ~ G36-1 Continuity
IGN ~ G36-2 Continuity
G39-2 ~ Starting motor relay terminal 1 Continuity
G39-12 ~ IGN No continuity
Inspection 3:
Carry out inspection of the status of the NMR switch in the controller.
Ignition key switch OFF, remove NMR switch so that it can be turned ON and OFF manually,
connect G39 and G36, ignition key switch ON
NMR switch (I/O monitor: NMR)
Standard:
Analyzer display Switch OFF Switch ON
NMR 0 1
21-116
z Error code 15-3 (NMR switch abnormality)
Related portion
IGN
To IGN SW
G39 G36
2
12 (NMR) 1 NMR switch
ASC controller
G36
4
15 (ZERO) 3 Idle switch
Probable cause
c Connector contact defect
d NMR switch defect
e Idle switch defect
f Harness defect
g ASC controller defect
h Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)
21-117
Error code 15-3
Disconnect the battery negative terminal, then
inspect and repair disconnection of G39 and G36
and any internal leakage.
Reconnect the connectors and the battery negative
terminal, then repeat the operations c to e below
several times and check whether an error occurs.
c Turn the ignition key switch ON (engine stopped) No error
Connector contact defect
d Operate the accelerator pedal ON/OFF (several
times)
e Turn the ignition key switch OFF
Error
Inspection 1: NG NMR switch defect
NMR and idle switch individual inspection Idle switch defect
OK
Inspection 2: NG
Carry out harness continuity and short circuit Harness defect
inspection
OK
Inspection 3:
Inspection of the status of the NMR and idle NG
switches in the controller ASC controller defect
ANL.: I/O ENGINE CTRL 1/3
OK
Refer to and carry out mechanical system inspection
items such as link catching or switch position
adjustment.
Inspection 1:
Carry out an NMR and idle switch individual inspection.
Ignition key switch OFF, disconnect G36, connect G39
Standard: (Switch side) G36
Switch OFF Switch ON
G36-1 ~ G36-2 No continuity Continuity
G36-3 ~ G36-4 No continuity Continuity
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G36 and G39
Standard:
G39-12 ~ IG No continuity
G39-15 ~ IG No continuity
21-118
Inspection 3:
Carry out inspection of the status of the NMR and idle switches in the controller.
Ignition key switch OFF, remove NMR and idle switches so that they can be turned ON and OFF manually,
connect G36 and G39, ignition key switch ON
NMR and idle switches (I/O monitor: NMR, IDLE)
Standard:
Analyzer display Switch OFF Switch ON
NMR 0 1
IDLE 0 1
21-119
z Error codes 16-1 and 16-2 (Idle switch abnormality)
Related portion
IGN
To IGN SW
G36
G39
4
15 (ZERO) 3 Idle switch
G38 G37
ASC controller 11 (NINA) 2
12 (NINB) 1
3 (INA) 5 Step motor
4 (INB) 4
Probable cause
c Connector contact defect
d Idle switch defect
e Harness defect
f ASC controller defect
g Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)
Note:
In the case where a 13-1 error is present, service that error first before dealing with this one.
21-120
Error codes 16-1, 16-2
Disconnect the battery negative terminal, then
inspect and repair disconnection of G39, G36 and
G37 and any internal wetting.
Reconnect the connectors and the battery negative
terminal, then repeat the operations c to e below
several times and check whether an error occurs.
No error
c Turn the ignition key switch ON (engine stopped) Connector contact defect
d Operate the accelerator pedal ON/OFF (several
times)
e Turn the ignition key switch OFF
Error
Inspection 1: NG
Idle switch individual inspection Idle switch defect
OK
Inspection 2: NG
Carry out harness continuity and short circuit Harness defect
inspection
OK
Inspection 3:
Inspection of the status of the idle switch in the NG
controller ASC controller defect
ANL.: I/O ENGINE CTRL 1/3
OK
Refer to and carry out mechanical system inspection
items such as link catching or switch position
adjustment.
Inspection 1:
Carry out idle switch individual inspection.
Ignition key switch OFF, disconnect G36, connect G39
Standard: (Switch side) G36
Switch OFF Switch ON
G36-3 ~ G36-4 No continuity Continuity
21-121
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G36, G37, G38 and G39
Standard:
G39-15 ~ G36-3 Continuity
IGN ~ G36-4 Continuity
G39-15 ~ IGN No continuity
G38-11 ~ G37-2 Continuity
G38-12 ~ G37-1 Continuity
G38-3 ~ G37-5 Continuity
G38-4 ~ G37-4 Continuity
G38-11 ~G38-12 No continuity
G38-11 ~ G38-3 No continuity
G38-11 ~ G38-4 No continuity
G38-12 ~ G38-3 No continuity
G38-12 ~ G38-4 No continuity
G38-3 ~ G38-4 No continuity
G38-11 ~ IGN No continuity
G38-12 ~ IGN No continuity
G38-3 ~ IGN No continuity
G38-4 ~ IGN No continuity
Inspection 3:
Carry out inspection of the status of the idle switch in the controller.
Ignition key switch OFF, remove idle switch so that it can be turned ON and OFF manually, connect G36 and
G39, ignition key switch ON
Idle switch (I/O monitor: IDLE)
Standard:
Analyzer display Switch OFF Switch ON
IDLE 0 1
21-122
z Error codes 18-1, 18-2 (4Y engine: Cam angle sensor abnormality)
Related portion
IGN
G25
3 (IG2)
Igniter 5 (IG1)
G27 G19 G21
31 (NE+) 1 (NE+) 2 (IG-)
Engine controller 30 (NE-) 2 (NE-) Distributor 1 (IG+)
Probable cause
c Distributor (cam angle sensor) defect
d Starter defect
e Defect in the part connecting the starter and engine
f Harness defect
g Engine controller defect
Caution:
If the engine does not crank, troubleshoot "Does not crank (see 21-217)" first.
Error codes 18-1, 18-2
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
correcting disconnection of G19 and internal No error
wetting, reconnect all connectors and the battery Connector contact defect
negative terminal, turn the ignition key switch
ON (start the engine) and check whether or not
there is an error.
Error
Inspection 1: NG
Distributor individual inspection Distributor (cam angle sensor) defect
OK
Inspection 2: NG Starter defect
Timing rotor operation inspection Defect in the part connecting the starter and engine
OK
Inspection 3: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect
21-123
Inspection 1:
Carry out distributor individual inspection. 2 1
Ignition key switch OFF, disconnect G19 and G21, connect G27
G19
(1) Pickup coil (2 in series) resistance measurement
Standard: (Distributor side)
G19-1 ~ G19-2 460 ± 50 Ω
(2) Inspection of the air gap between the pickup coils and the timing rotor
Standard: 0.2 ~ 0.4 mm (0.008 ~ 0.016 in)
Inspection 2:
Inspect the timing rotor operation.
Disconnect G19 and G21, connect G27, ignition key switch ON
Standard: Timing rotor rotates during cranking
Inspection 3:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G19, G21 and G27
Standard:
G27-31 ~ G19-1 Continuity
G27-30 ~ G19-2 Continuity
G27-31 ~ G27-30 No continuity
21-124
z Error code 18-3 (4Y engine: Crank angle sensor abnormality)
Related portion
G27 G18
11 (G2) 1 (G2)
Crank angle
Engine controller 22 (G-) 2 (G-) sensor
Probable cause
c Crank angle sensor defect
d Harness defect
e Engine controller defect
Error code 18-3
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
correcting disconnection of G18 and internal No error
wetting, reconnect all connectors and the battery Connector contact defect
negative terminal, turn the ignition key switch
ON (start the engine) and check whether or not
there is an error.
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 2: NG
Crank angle sensor individual inspection Crank angle sensor defect
OK
Inspection 3:
Crank angle sensor installation inspection
Install the crank angle sensor, connect G27, G18
and battery negative terminal, start the engine. No error Normal
Check whether an error occurs. (Entry of foreign matter etc.)
Error
Engine controller defect
21-125
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G18
Standard:
G27-11 ~ G18-1 Continuity
G27-22 ~ G18-2 Continuity
G27-11 ~ G27-22 No continuity
Inspection 2:
Carry out crank angle sensor individual inspection.
Ignition key switch OFF, disconnect G27 and G18 2 1
Standard: (Sensor side)
G18-1 ~ G18-2 1100 ± 150 Ω G18
Inspection 3:
Carry out crank angle sensor installation inspection.
Ignition key switch OFF, disconnect G27 and G18
Standard:
Remove the crank angle sensor, ensure that there is no foreign matter etc. adhereing to the sensor part.
If there is remove it.
21-126
z Error codes 18-1, 18-2 (1DZ-II, 2Z engines: NE sensor abnormality)
Related portion
G39 G31
9 (NE+) 2
Engine speed
ASC controller 22 (NE-) 1 sensor (NE sensor)
Probable cause
c Connector contact defect
d Engine speed sensor defect
e Harness defect
f ASC controller defect
Caution:
In the event that the engine stops while traveling, when the ignition key switch is turned from OFF to ON, an
18-2 error may be detected, however this is not a fault.
Stop the vehicle, turn the ignition key switch OFF and restart the engine.
Error codes 18-1, 18-2
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of G31
and G39 and internal wetting, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON and check
whether or not there is an error.
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 2: NG
Engine speed sensor individual inspection Engine speed sensor defect
OK
ASC controller defect
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G31 and G39
Standard:
G39-9 ~ G31-2 Continuity
G39-22 ~ G31-1 Continuity
G39-9 ~ G39-22 No continuity
21-127
Inspection 2:
Carry out engine speed sensor individual inspection.
2 1
Ignition key switch OFF, disconnect G31 and G39 3
Standard: (Sensor side)
G31
G31-1 ~ G31-2 Approx. 1 kΩ
21-128
z Error codes 1F-1, 1F-2, 1F-3, 1F-4, 1F-5, 1F-6, 1F-7, 1F-8 (CPU abnormality)
Related portion
ASC controller
Probable cause
c ASC controller defect
21-129
z Error code 41-1 (Matching connector abnormality)
Related portion
A20 A45
24 (MAT) 1
SAS/OPS Matching
controller 1 (E3) 2 connector
Probable cause
c Connector contact defect
d Matching connector harness defect
e SAS/OPS controller defect
Error code 41-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A20
and A45 internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Inspection 1: NG
Matching connector defect
Matching connector individual inspection
OK
Inspection 2: NG
Harness defect
Harness continuity check
OK
SAS/OPS controller defect
Inspection 1:
Inspect for continuity of the matching connector. 1 2 3
Ignition key switch OFF, disconnect A45 and A46 4 5 6
Standard: (Matching connector side) A45
A45-1 ~ A46-1 Continuity
Inspection 2:
Inspect for continuity of the harness.
Ignition key switch OFF, disconnect A20, A45 and A46
Standard:
A20-24 ~ A45-1 Continuity
A20-1 ~ A46-1 Continuity
21-130
z Error codes 51-1, 51-2 (Speed sensor abnormality)
Related portion
A20 A19
22 (SPD+) 1
SAS/OPS Speed
controller 23 (SPD-) 2 sensor
Probable cause
c Connector contact defect
d Harness defect
e Speed sensor defect
f SAS/OPS controller defect
Error code 51-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A19
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Inspection 1: No error
Speed sensor inspection Speed sensor defect
Error
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS controller defect
Inspection 1:
Carry out speed sensor individual inspection.
Ignition key switch OFF, disconnect A19, use SST 09236-13900-71 to short circuit A19, ignition key switch ON,
engine stopped
51-1, 51-2 displayed → to inspection 2
No error displayed → Speed sensor error
21-131
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A19 and A20
Standard:
A20-22 ~ A19-1 Continuity
A20-23 ~ A19-2 Continuity
A20-22 ~ Frame No continuity
A20-23 ~ Frame No continuity
Error code 51-2
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A19
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Inspection 1: No error
Speed sensor inspection Sensor defect
Error
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS controller defect
Inspection 1:
Carry out speed sensor individual inspection.
Ignition key switch OFF, disconnect A19, use SST 09236-13900-71 to short circuit A19, ignition key switch ON,
engine stopped
51-2 displayed → to next inspection
No error code → Speed sensor defect
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A19 and A20
Standard:
A20-22 ~ A19-1 Continuity
A20-23 ~ A19-2 Continuity
A20-22 ~ Frame No continuity
A20-23 ~ Frame No continuity
21-132
z Error codes 52-1, 52-2, 52-3 (Yaw rate sensor abnormality)
Related portion
A21
O1
24 (YRS+) 1
SAS/OPS 25 (YRS) 2 Yaw-rate
controller sensor
26 (YRS-) 3
Probable cause
c Connector contact defect
d Yaw rate sensor harness defect
e Yaw rate sensor defect
f SAS/OPS controller defect
Error code 52-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of O1
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Inspection 1: 52-2 is displayed
Yaw rate sensor defect
Yaw rate sensor inspection
52-1 is displayed
Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
Inspection 1:
Carry out a yaw and rate sensor individual inspection.
Ignition key switch OFF, disconnect O1, use SST 09232-13130-71 to short circuit O1-1 and O1-2, ignition key
switch ON, engine stopped
52-1 displayed → to inspection 2
52-2 displayed → Yaw rate sensor defect
21-133
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect O1 and A21
Standard:
A21-25 ~ O1-3 Continuity
A21-26 ~ O1-2 Continuity
A21-25 ~ Frame No continuity
A21-26 ~ Frame No continuity
Error codes 52-2, 52-3
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of O1
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Turn the ignition key switch OFF, disconnect the
battery negative terminal, disconnect O1,
connect the battery negative terminal, turn the 52-1
Yaw-rate sensor defect
ignition key switch ON (engine stopped), check
whether the error changes.
52-2 or 52-3
Inspection 1: NG
Harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect O1 and A21
Standard:
A21-25 ~ O1-3 Continuity
A21-26 ~ O1-2 Continuity
A21-25 ~ Frame No continuity
A21-26 ~ Frame No continuity
21-134
z Error code 54-1 (Swing lock solenoid abnormality)
Related portion
A20 Z1
3 (SWN+) 1
Swing lock
2 (SWN-) 1 solenoid
SAS/OPS
controller 8 (E01)
9 (E02)
Probable cause
c Connector contact defect
d Harness defect
e Swing lock solenoid defect
f SAS/OPS controller defect
Error code 54-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A20
and Z1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.
Error
Inspection 1: NG
Swing lock solenoid individual inspection Swing lock solenoid defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS controller defect
*: Make sure that no error is displayed when driving in a circle or during repeated left and right turns.
Inspection 1:
Carry out swing lock solenoid individual inspection.
2 1
Ignition key switch OFF, disconnect Z1
Standard: (Solenoid side) Z1
Z1-1 ~ Z1-2 Approx. 6 Ω (20°C)
21-135
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect Z1 and A20
Standard:
A20-3 ~ Z1-1 Continuity
A20-2 ~ Z1-2 Continuity
A20-3 ~ Frame No continuity
A20-2 ~ Frame No continuity
21-136
z Error codes 61-1, 61-2 (Load sensor abnormality)
Related portion
A21
A18
19 (5PRS) 1
SAS/OPS 27 (PRES) 2 Load sensor
controller 5 (E2) 3
Probable cause
c Connector contact defect
d Load sensor defect
e Harness defect
f SAS/OPS controller defect
Error code 61-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A18
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Inspection 1: 61-2 is displayed
Load sensor individual inspection Load sensor defect
61-1 is displayed
Inspection 2: No continuity
Main harness defect
Harness continuity and short circuit inspection
Continuity
Inspection 3: No continuity
SAS/OPS controller defect
Harness continuity and short circuit inspection
Continuity
Main harness defect
Inspection 1:
Carry out load sensor individual inspection.
Ignition key switch OFF, disconnect A18, use SST 09230-13700-
71 to short circuit A18-1 and A18-2 (main harness side), ignition
key switch ON, engine stopped
61-1 displayed → to inspection 2
61-2 not displayed → load sensor defect
SST
21-137
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21 (with the SST used in inspection 1 still connected)
Standard:
A21-19 ~ A21-27 Continuity
Inspection 3:
Inspect for continuity and short circuiting of the harness.
In the same state as for inspection 2
Standard:
A21-27 ~ A21-5 No continuity
Error code 61-2
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A18
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Disconnect A18, ignition key switch ON (engine 61-1
stopped), inspect the diplayed error code.
61-2
Inspection 1: No continuity SAS/OPS
Harness continuity and short circuit inspection controller defect
Continuity
No continuity Inspection 2:
Main harness defect
Load sensor individual inspection
Continuity
· Sub harness defect
· Load sensor defect
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-19 ~ A21-27 No continuity
21-138
Inspection 2:
Carry out load sensor individual inspection.
Ignition key switch OFF, disconnect the battery negative terminal, disconnect A18 and A21, use SST 09230-
13700-71 to short circuit A18-2 to A18-3 (main harness side)
Standard:
A21-27 ~ A21-5 Continuity
21-139
z Error codes 62-1, 62-2 (Tilt angle sensor abnormality)
Related portion
A21
A42
28 (5MA) 1
SAS/OPS 32 (MA) 2 Tilt angle
controller sensor
5 (E2) 3
Probable cause
c Connector contact defect
d Tilt angle sensor harness defect
e Tilt angle sensor defect
f SAS/OPS controller defect
Error code 62-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A21
and A42 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
62-2 is
Inspection 1: displayed
Tilt angle sensor individual inspection Tilt angle sensor defect
62-1 is displayed
Inspection 2: No continuity
Harness continuity and short circuit inspection Main harness defect
Continuity
Inspection 3: No continuity
Harness continuity and short circuit inspection SAS/OPS controller defect
Continuity
Main harness defect
Inspection 1:
Carry out tilt angle sensor individual inspection.
Ignition key switch OFF, disconnect A42, use SST 09232-13130-71 to short circuit A42-1 and A42-2 (main
harness side), ignition key switch ON (engine stopped)
62-1 displayed → to inspection 2
62-2 not displayed → tilt angle sensor defect
21-140
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21 (with the SST used in inspection 1 still connected)
Standard:
A21-28 ~ A21-32 Continuity
Inspection 3:
Inspect for continuity and short circuiting of the harness.
In the same state as for inspection 2
Standard:
A21-32 ~ A21-5 No continuity
Error code 62-2
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A21
and A42 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Inspection 1: 62-1 is displayed
Tilt angle sensor individual inspection
62-2 is displayed
Inspection 2: No continuity SAS/OPS
Harness continuity and short circuit inspection controller defect
Continuity
No continuity Inspection 3:
Main harness defect
Tilt angle sensor individual inspection
Continuity
Tilt angle sensor defect
Inspection 1:
Carry out tilt angle sensor individual inspection.
Ignition key switch OFF, disconnect A42, ignition key switch ON, engine stopped
62-1 displayed → to inspection 3
62-2 displayed → to inspection 2
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-28 ~ A21-32 No continuity
21-141
Inspection 3:
Carry out tilt angle sensor individual inspection.
Ignition key switch OFF, disconnect A21 and A42, use SST 09232-13130-71 to short circuit A21-2 and A42-3
(main harness side)
Standard:
A42-32 ~ A21-5 Continuity
21-142
z Error codes 63-1, 63-2, 63-3 (Tilt lever switch abnormality)
Related portion
A20 A13
20 (MF) 1
Forward tilt
1 (E3) 2 switch
SAS/OPS
controller
21 (MR) 3
Backward tilt
4 switch
Probable cause
c Connector contact defect f Harness defect
d Forward tilt switch defect g Tilt switch installation defect
e Backward tilt switch defect h SAS/OPS controller defect
21-143
Error codes 63-1, 63-2, 63-3
Disconnect the battery negative
terminal, after inspecting and
correcting disconnection of A13
and A20 and internal moisture No error
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON and check
whether or not there is an error.*
Error
Inspection 1:
Check the condition of the switch
ANL.: I/O M.HANDLING 1/6
Inspection 2:
Inspection 4:
Individual continuity inspection of OK NG
Harness continuity and short circuit
the tilt lever switch(es) that was
inspection
abnormal in inspection 1 (while still
installed on the vehicle). OK
NG
SAS/OPS controller defect
Inspection 3:
Individual continuity inspection of NG
the tilt lever switch (removed from Tilt switch defect
the vehicle).
OK
Inspection 4:
OK
Harness continuity and short circuit Tilt switch installation defect
inspection
NG
Harness defect
*: Make sure there is no error displayed after turning the ignition key switch ON, and moving the tilt lever forward and
backward. Also, make sure that no error is displayed when the tilt lever is left standing in neutral position for 2
minutes.
Inspection 1:
Check the condition of the switch.
Ignition key switch ON, engine stopped
Tilt switch (I/O monitor: MF·MR)
Standard:
Lever in neutral Lever in forward tilt Lever in backward
position position tilt position
MF (Forward tilt switch) 0 1 0
MR (Backward tilt switch) 0 0 1
21-144
Inspection 2:
Individual continuity inspection of the tilt lever switch (still installed on the vehicle).
Ignition key switch OFF, disconnect A13
Standard: (Switch side)
Lever in neutral Lever in forward tilt Lever in backward
position position tilt position
A13-1 ~ A13-2 No continuity Continuity No continuity
A13-3 ~ A13-4 No continuity No continuity Continuity
Inspection 3:
Carry out individual continuity inspection of the tilt lever switch (removed from the vehicle).
Ignition key switch OFF, disconnect A13
Standard: (Sensor side) 1 2
Switch OFF Switch ON 3 4
A13-1 ~ A13-2 No continuity Continuity A13
A13-3 ~ A13-4 No continuity No continuity
Inspection 4:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A13 and A20
Standard:
A20-20 ~ A20-1 No continuity
A20-21 ~ A20-1 No continuity
A20-20 ~ A20-21 No continuity
A20-20 ~ Frame No continuity
A20-21 ~ Frame No continuity
21-145
z Error code 64-1 (Lift lock solenoid abnormality)
Related portion
A20 A11
7 (LSOL) 1
Lift lock
SAS/OPS 9 (E02) 2 solenoid
controller 8 (E01)
Probable cause
c Connector contact defect
d Harness defect
e Lift lock solenoid defect
f SAS/OPS controller defect
Error code 64-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A11
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.*
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 2: NG
Lift lock solenoid individual inspection Solenoid defect
OK
SAS/OPS controller defect
*: Make sure that no error is displayed when the material handling lever is lowered.
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A11 and A20
Standard:
A20-7 ~ A11-1 Continuity
A11-2 ~ Frame Continuity
A20-9 ~ Frame Continuity
A20-8 ~ Frame Continuity
A20-7 ~ Frame No continuity
21-146
Inspection 2:
Carry out lift lock solenoid individual inspection. 1 2
Ignition key switch OFF, disconnect A11
A11
Standard: (Solenoid side)
A11-1 ~ A11-2 9.9 ± 0.5 Ω (20°C)
21-147
z Error code 65-1 (Tilt control solenoid abnormality)
Related portion
A20 A10
4 (TSOL) 1
Tilt control
SAS/OPS 9 (E02) 2 solenoid
controller 8 (E01)
Probable cause
c Connector contact defect
d Harness defect
e Tilt control solenoid defect
f SAS/OPS controller defect
Error code 65-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A10
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.*
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 2: NG
Tilt control solenoid individual inspection Solenoid defect
OK
SAS/OPS controller defect
*: Make sure that no error is displayed when the material handling lever is operated to tilt forward.
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A10 and A20
Standard:
A20-4 ~ A10-1 Continuity
A10-2 ~ Frame Continuity
A20-9 ~ Frame Continuity
A20-8 ~ Frame Continuity
A20-4 ~ Frame No continuity
21-148
Inspection 2:
Carry out tilt control solenoid individual inspection.
1 2
Ignition key switch OFF, disconnect A10
A10
Standard: (Solenoid side)
A10-1 ~ A10-2 9.9 ± 0.5 Ω (20°C)
21-149
z Error code 66-1 (Outside matching value range abnormality)
Related portion
SAS/OPS
controller
Probable cause
c Tilt horizontal angle matching value is outside the specified range for matching.
d Tilt forward tilt angle matching value is outside the specified range for matching.
e Load sensor matching value is outside the specified range for matching.
Error code 66-1
Carry out tilt horizontal angle matching, tilt
forward tilt angle matching, and load sensor
matching. (Refer to section 18)
Error
Controller defect
21-150
z Error code 67-1 (Lifting height switch abnormality)
Related portion
Single tire, V mast, mast lifting height: ~ H2500
A20 b1
1 (E3) 1
31 (MH1) 2 Lifting height
SAS/OPS 32 (MH21) 3 switch
controller
33 (MH22)
N.C.
Probable cause
c Connector contact defect
d Harness defect
e Lifting height switch defect
f SAS/OPS controller defect
g IG fuse defect
21-151
Error code 67-1
Disconnect the battery negative
terminal, after inspecting and
correcting disconnection of A20
and b1 and internal moisture, Error
reconnect all connectors and the None
Connector contact defect
battery negative terminal, turn the
ignition key switch ON (engine
stopped) and check whether or not *: Raise the lift lever from the fully lowered
there is an error.* position until an error is detected.
Error
Except Inspection 2:
Inspection 1: MH000 Harness continuity and short circuit MH:000 Lifting height switch
Lifting height switch input value inspection
inspection defect
ANL.: I/O M.HANDLING 2/6
ANL.: I/O M.HANDLING 2/6
Except MH:000
MH:000
Inspection 3:
OK SAS/OPS
Harness continuity and short circuit
controller defect
inspection
NG
Main harness defect
Inspection 4: NG
Lifting height switch individual Lifting height switch defect
inspection
OK
Inspection 5:
OK SAS/OPS
Harness continuity and short circuit
controller defect
inspection
NG
Main harness defect
21-152
Inspection 1:
Check the condition of the switch.
Maintain the error status and check the display.
Lifting height switch (I/O monitor: MH)
MH: 000 displayed → to checking the mast height at the time of error detection
MH: Except 000 → to inspection 2
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 and b1, ignition key switch ON, stop the
engine, check the display
MH: 000 displayed → sub harness defect or lifting height switch defect
MH: Except 000 → to inspection 3
Inspection 3:
Inspect for continuity and short circuiting of the harness.
Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 and b1
Standard:
A20-1 ~ A20-31 No continuity
A20-1 ~ A20-32 No continuity
A20-1 ~ A20-33 No continuity
A20-31 ~ A20-32 No continuity
A20-32 ~ A20-33 No continuity
A20-33 ~ A20-31 No continuity
Inspection 4:
Carry out lifting height switch individual inspection. 1 3 2
Maintain the error status, ignition key switch OFF, disconnect b1 b1
Standard: (Switch side)
b1-1 ~ b1-2 No continuity
Inspection 5:
Inspect for continuity and short circuiting of the harness.
Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 adn b1, use SST 09236-13900-71 to
short circuit the terminals
Standard:
Inspection terminal Short circuit terminals Continuity
A20-1 ~ A20-31 b1-1 ~ b1-2 Continuity
A20-1 ~ A20-32 b1-1 ~ b1-3 Continuity
21-153
z Error codes 68-1, 68-2, 68-3 (Lift switch abnormality)
Related portion
A20 A14
22 (MU) 3
Raising lift
1 (E3) 4 switch
SAS/OPS
controller
23 (MD) 1
Lowering lift
2 switch
Probable cause
c Connector contact defect f Harness defect
d Raising lift switch defect g Lift switch installation defect
e Lowering lift switch defect h SAS/OPS controller defect
21-154
Error codes 68-1, 68-2, 68-3
Disconnect the battery negative
terminal, after inspecting and
correcting disconnection of A14
and A20 and internal moisture, Error
reconnect all connectors and the None
battery negative terminal, turn the Connector contact defect
ignition key switch ON (engine
stopped) and check whether or not
there is an error.*
Error
Inspection 1:
Lift switch condition check
ANL.: I/O M.HANDLING 1/6
Inspection 2:
Inspection 4:
Individual continuity inspection of OK NG
Harness continuity and short circuit
the lift lever switch(es) that was
inspection
abnormal in inspection 1 (while still
installed on the vehicle). OK
NG
SAS/OPS controller defect
Inspection 3:
Individual continuity inspection of NG
the lift lever switch (removed from Lift switch defect
the vehicle).
OK
Inspection 4:
OK
Harness continuity and short circuit Lift switch installation defect
inspection
NG
Harness defect
*: Make sure there is no error displayed after turning the ignition key switch ON, and moving the lift lever upward and
downward. Also, make sure that no error is displayed when the lift lever is left standing in neutral position for 2
minutes.
21-155
Inspection 1:
Check the condition of the switch.
Ignition key switch ON (engine stopped)
Lift switch (I/O monitor: MU·MD)
Standard:
Lever in neutral Lever in forward tilt Lever in backward
position position tilt position
MU (Raising switch) 0 1 0
MD (Lowering switch) 0 0 1
Inspection 2:
Carry out individual continuity inspection of the lift lever switch (still installed on the vehicle).
Ignition key switch OFF, disconnect A14
Standard: (Switch side)
Lever in neutral Lever in raised Lever in lowered
position position position
A14-3 ~ A14-4 No continuity No continuity Continuity
A14-1 ~ A14-2 No continuity Continuity No continuity
Inspection 3:
Carry out individual continuity inspection of the lift lever switch (removed from the vehicle).
Ignition key switch OFF, disconnect A14
Standard: (Switch side) 2 1
Switch ON Switch OFF 4 3
A14-3 ~ A14-4 Continuity No continuity
A14
A14-1 ~ A14-2 Continuity No continuity
Inspection 4:
Harness continuity and short circuit inspection
Ignition key switch OFF, disconnect A14 and A20
Standard:
A20-22 ~ Frame No continuity
A20-23 ~ Frame No continuity
A20-22 ~ A20-1 No continuity
A20-23 ~ A20-1 No continuity
A20-22 ~ A20-33 No continuity
21-156
z Error code 69-1 (Backward tilt lock solenoid abnormality)
Related portion
A20 A56
10 (BTSL) 1
Backward tilt
SAS/OPS 9 (E02) 2 lock solenoid
controller 8 (E01)
Probable cause
c Connector contact defect
d Harness defect
e Backward tilt lock solenoid defect
f SAS/OPS controller defect
Error code 69-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A20
and A56 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.*
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 2: NG
Backward tilt lock solenoid individual inspection Solenoid defect
OK
SAS/OPS controller defect
*: Make sure that no error is displayed when the material handling lever is operated to tilt backward.
Inspection 1:
Carry out harness continuity and short circuit inspection.
Ignition key switch OFF, disconnect A20 and A56
Standard:
A56-2 ~ Frame Continuity
A20-8 ~ A20-9 Continuity
A20-10 ~ Frame Continuity
21-157
Inspection 2:
Carry out tilt backward tilt lock solenoid individual inspection. 1 2
Ignition key switch OFF, disconnect A56
A56
Standard: (Solenoid side)
A56-1 ~ A56-2 9.9 ± 0.5 Ω (20°C)
21-158
z Error codes 71-1 and 71-2 (Tire angle sensor abnormality)
Related portion
A21
Z3
30 (5T) 3
SAS/OPS 34 (T) 2 Tire angle
controller 5 (E2) sensor
1
Probable cause
c Connector contact defect
d Tire angle sensor harness defect
e Tire angle sensor defect
f Tire angle sensor joint, rear axle link system defect
g SAS/OPS controller defect
Error code 71-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of Z3
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Inspection 1: 71-2 is displayed
Tire angle sensor individual inspection Tire angle sensor defect
71-1 is displayed
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 3: OK
Harness continuity and short circuit inspection SAS/OPS controller defect
NG
Harness defect
Inspection 1:
Carry out tire angle sensor individual inspection.
Ignition key switch OFF, disconnect Z3, use SST 09232-13130-71 to short circuit Z3-2 and Z3-3, ignition key
switch ON, engine stopped
71-1 displayed → to inspection 2
71-2 displayed → Tire angle sensor defect
21-159
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
(With the SST used in inspection 1 still connected)
Standard:
A21-30 ~ A21-34 Continuity
Inspection 3:
Inspect for continuity and short circuiting of the harness.
In the same state as for inspection 2
Standard:
A21-34 ~ A21-5 No continuity
Error code 71-2
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of Z3
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error
Inspection 1: 71-1 is displayed
Tire angle sensor individual inspection
71-2 is displayed
Inspection 2: OK SAS/OPS
Harness continuity and short circuit inspection controller defect
NG
No continuity Inspection 3:
Main harness defect
Tire angle sensor individual inspection
Continuity
Tire angle sensor defect
Inspection 1:
Carry out tire angle sensor individual inspection.
Ignition key switch OFF, disconnect Z3, ignition key switch ON, engine stopped
71-1 displayed → to inspection 3
71-2 displayed → to inspection 2
21-160
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-30 ~ A21-34 No continuity
Inspection 3:
Carry out tire angle sensor individual inspection.
Ignition key switch OFF, disconnect Z3 and A21, use SST 09232-13130-71 to short circuit Z3-1 to Z3-2 (main
harness side)
Standard:
A21-34~ A21-5 Continuity
21-161
z Error codes 72-1, 72-2, 72-3, 72-4 (Steering angle sensor abnormality)
Related portion
A21
1 (IG1) A3
2 (IG2) 1
SAS/OPS 14 (SS1) 3
Steering angle
controller 15 (SS2) 4 sensor
16 (SSC) 5
2
5 (E2)
Probable cause
c Connector contact defect f SAS/OPS controller defect
d Steering angle sensor harness defect
e Steering angle sensor defect
21-162
Error code 72-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, turn Connector contact defect
the ignition key switch ON, operate (rotate) the
steering and check whether or not there is an
error.
Error
Check the STS value with an analyzer while
1**
operating the steering.
ANL.: I/O STEERING 1/1
0**
(* is 0 or 1)
Disconnect the battery negative terminal and A3,
short circuit A3-2 to A3-3 (main harness side)
using SST 09232-13130-71, reconnect the
battery negative terminal, and turn the ignition
key switch ON.
Check the STS value with an analyzer while
1**
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1
0**
Inspection 1: NG
Main harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
Disconnect the battery negative terminal and A3,
reconnect the battery negative terminal, and turn
the ignition key switch ON.
Check the STS value with an analyzer while
0**
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1
1**
Inspection 2: NG
Main harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
21-163
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-14 ~ A21-5 Continuity
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-14 ~ A21-5 No continuity
21-164
Error code 72-2
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, turn Connector contact defect
the ignition key switch ON, operate (rotate) the
steering and check whether or not there is an
error.
Error
Check the STS value with an analyzer while
*1*
operating the steering.
ANL.: I/O STEERING 1/1
*0*
(* is 0 or 1)
Disconnect the battery negative terminal and A3,
short circuit A3-2 to A3-4 (main harness side)
using SST 09232-13130-71, reconnect the
battery negative terminal, and turn the ignition
key switch ON.
Check the STS value with an analyzer while
*1*
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1
*0*
Inspection 1: NG
Harness continuity and short circuit inspection Main harness defect
OK
SAS/OPS controller defect
Disconnect the battery negative terminal and A3,
reconnect the battery negative terminal, and turn
the ignition key switch ON.
Check the STS value with an analyzer while
*0*
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1
*1*
Inspection 2: NG
Main harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
21-165
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-15 ~ A21-5 Continuity
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-15 ~ A21-5 No continuity
21-166
Error code 72-3
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all
No error
connectors and the battery negative terminal, turn Connector contact defect
the ignition key switch ON, operate the steering
(one or more rotations) and check whether or not
there is an error.
Error
Check the STS value with an analyzer while
**1
operating the steering.
ANL.: I/O STEERING 1/1
**0
(* is 0 or 1)
Disconnect the battery negative terminal and A3,
short circuit A3-2 to A3-5 (main harness side)
using SST 09232-13130-71, reconnect the
battery negative terminal, and turn the ignition
key switch ON.
Check the STS value with an analyzer while
**1
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1
**0
Inspection 1: NG
Main harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
Disconnect the battery negative terminal and A3,
reconnect the battery negative terminal, and turn
the ignition key switch ON.
Check the STS value with an analyzer while
**0
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1
**1
Inspection 1: NG
Main harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
21-167
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-16 ~ A21-5 Continuity
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-15 ~ A21-5 No continuity
Error code 72-4
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A3
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate (rotate)
the steering and check whether or not there is an
error.
Error
Battery voltage
Inspection 1: (approx. 12 V) Disconnect the battery negative terminal and A3,
Steering angle sensor supply voltage inspection reconnect the battery negative terminal, and turn
the ignition key switch ON.
Approx. 0 V
To troubleshooting for 72-1 and 72-2
Inspection 2: NG
Harness continuity and short circuit inspection Main harness defect
OK
SAS/OPS controller defect
Inspection 1:
Carry out steering angle sensor supply voltage inspection.
Standard:
A3-1 ~ A3-2 Battery voltage (approx. 12 V)
21-168
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A3 and A21
Standard:
A21-1 ~ A3-1 Continuity
A21-2 ~ A3-1 Continuity
A21-5 ~ Frame Continuity
A3-2 ~ Frame Continuity
21-169
z Error code 73-1 (Knob position compensation solenoid abnormality)
Related portion
A20 A5
6 (STRG) 1
Knob position
SAS/OPS 9 (E02) 2 compensation
controller
8 (E01)
Probable cause
c Connector contact defect
d Harness defect
e Knob position compensation solenoid defect
f SAS/OPS controller defect
Error code 73-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A5
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*
Error
Inspection 1: NG
Harness defect
Harness continuity and short circuit inspection
OK
Inspection 2: NG
Knob position compensation solenoid defect
Knob position compensation solenoid individual
inspection
OK
SAS/OPS controller defect
*: Make sure that no error is displayed when turning the knob position compensation solenoid ON/OFF using the
active test function.
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A5 and A20
Standard:
A20-6 ~ A5-1 Continuity
A5-2 ~ Frame Continuity
A20-8 ~ Frame Continuity
A20-9 ~ Frame Continuity
A20-6 ~ Frame No continuity
21-170
Inspection 2:
Carry out knob position compensation solenoid individual inspection. 2 1
Ignition key switch OFF, disconnect A5
Standard: (Solenoid side) A5
A5-1 ~ A5-2 Approx.10 Ω (20°C)
21-171
z Error code 74-1 (Outside matching value range abnormality)
Related portion
SAS/OPS controller
Probable cause
c Tire alignment value is outside the specified range for matching.
Error code 74-1
Perform tire alignment.
(Refer to section 18)
Error
Controller defect
21-172
z Error code A5-1 (Seat switch abnormality)
Related portion
A20 X1
35 (DMS) 1
SAS/OPS
1 (E3) 2 Seat switch
controller
Probable cause
c Connector contact defect
d Seat switch defect
e Harness defect
f SAS/OPS controller defect
Error code A5-1
Disconnect the battery negative terminal, then
No error
inspect and repair disconnection of A20 and X1 Connector contact defect
and any internal moisture.*
Error
Inspection 1:
NG
Check the condition of the switch Seat switch defect
ANL.: I/O M.HANDLING 1/6
OK
Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
*: After correcting, connect the connector and turn the ignition key switch OFF → ON (at least 2 seconds) → OFF.
Make sure that no error is displayed when the ignition key is turned ON after leaving the vehicle with the seat
empty for 15 minutes.
Inspection 1:
Check the condition of the switch.
Disconnect X1, ignition key switch ON, engine stopped
Seat switch (I/O monitor: SEAT)
Standard:
Analyzer display When seat is empty When seat is occupied
SEAT 0 1
21-173
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and X1
Standard:
A20-35 ~ A20-1 No continuity
A20-35 ~ Frame No continuity
21-174
z Error code A7-1 (Brake switch abnormality)
Related portion
BATT
A20 A6
1
Brake
SAS/OPS 17 (BSW) 2 switch
controller
Probable cause
c Connector contact defect
d Brake switch defect
e Harness defect
f SAS/OPS controller defect
Error code A7-1
Disconnect the battery negative
terminal, then inspect and repair No error
disconnection of A20 and A6 and Connector contact defect
any internal moisture.*
Error
Inspection 1: Inspection 2:
NG NG
Check the condition of the switch Harness continuity and short circuit Harness defect
ANL.: I/O TRAVELING 1/3 inspection
OK OK
SAS/OPS controller defect
Inspection 3:
Individual continuity inspection of NG
the brake switch (removed from Brake switch installation defect
the vehicle)
OK
Brake switch defect
*: After correcting, connect the connector and turn the ignition key switch OFF → ON (at least 2 seconds) → OFF.
Make sure that no error is displayed when the ignition key is turned ON after leaving the vehicle with the seat
empty for 15 minutes.
Inspection 1:
Check the condition of the switch.
Disconnect A6, ignition key switch ON, engine stopped
Brake switch (I/O monitor: BRKSW)
Standard:
Analyzer display Pedal not depressed Pedal depressed
BRKSW 0 1
21-175
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A6 and A20
Standard:
A20-17 ~ BATT No continuity
Inspection 3:
Carry out individual continuity inspection of the brake switch (removed from the vehicle).
Ignition key switch OFF, disconnect A6
Standard: (Switch side) 1 2
Switch OFF Switch ON
A6
A6-1 ~ A6-2 No continuity Continuity
21-176
z Error codes AD-1, AD-2, AD-7, AD-8 (4Y-E spec.) (CAN communication abnormality)
Related portion
A21
ECU-B
8 (BATT)
1 (IG1) ECU-IG Q2
2 (IG2) 2 (IG)
SAS/OPS
controller A20
12 (CANH) 5 (CANH) Multi-function
13 (CANL) 6 (CANL) display
3 (E1)
A36
28 (CAN+)
29 (CAN-)
EFI 3 (BATT) Engine
controller
IGN
9 (IGSW)
Probable cause
c Connector contact defect g Engine controller defect
d Engine controller harness defect h Option display defect
e Optional display harness defect i SAS/OPS controller defect
f Fuse defect
Caution:
When the controller or optional display is replaced into another vehicle with different specifications, AD-1
and AD-7 may occur. In such cases, perform "Engine and display ECU information clear".
Error codes AD-1, AD-2, AD-7, AD-8
Disconnect the negative terminal of the battery NG
and inspect the fuses. Fuse defect
OK
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of A20, A21, A36 and
Connector contact defect
Q2 and internal moisture, reconnect all
connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error.*
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect (AD-1)
Optional display defect (AD-7)
SAS/OPS controller defect (AD-8)
SAS/OPS controller or
engine controller defect (AD-2)
21-177
*: It is not necessary to inspect A36 when AD-1 and AD-2 have not occurred, and Q2 when AD-7 and AD-8 have not
occurred.
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect Q2 (unnecessary if AD-7 and AD-8 have not occurred), A20, A21 and A36
(unnecessary if AD-1 and AD-2 have not occured)
Standard:
A21-8 ~ ECU-B Continuity
A21-1 ~ ECU-IG Continuity
A21-2 ~ ECU-IG Continuity
Q2-2 ~ ECU-IG Continuity
21-178
z Error codes AD-1, AD-2, AD-7, AD-8 (ASC spec.) (CAN communication abnormality)
Related portion
A21
8 (BATT) ECU-B
1 (IG1) ECU-IG Q2
SAS/OPS 2 (IG2) 2 (IG)
controller A20
12 (CANH) 5 (CANH) Multi-function
13 (CANL) 6 (CANL) display
3 (E1)
G38
28 (CANH)
29 (CANL)
ECU-B2 3 (BATT) Engine
controller
IGN
9 (IGSW)
Probable cause
c Connector contact defect g Engine controller defect
d Engine controller harness defect h Option display defect
e Optional display harness defect i SAS/OPS controller defect
f Fuse defect
Caution:
When the controller or optional display is replaced into another vehicle with different specifications, AD-1
and AD-7 may occur. In such cases, perform "Engine and display ECU information clear".
Error codes AD-1, AD-2, AD-7, AD-8
Disconnect the negative terminal of the battery NG
and inspect the fuses. Fuse defect
OK
Disconnect the battery negative terminal (for
more than 10 seconds), after inspecting and
No error
correcting disconnection of A20, A21, G38 and
Connector contact defect
Q2 and internal moisture, reconnect all
connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error.*
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Engine controller defect (AD-1)
Optional display defect (AD-7)
SAS/OPS controller defect (AD-8)
SAS/OPS controller or
engine controller defect (AD-2)
21-179
*: It is not necessary to inspect G38 when AD-1 and AD-2 have not occurred, and Q2 when AD-7 and AD-8 have not
occurred.
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect Q2 (unnecessary if AD-7 and AD-8 have not occurred), A20, A21 and G38
(unnecessary if AD-1 and AD-2 have not occured)
Standard:
A20-12 ~ Q2-5 Continuity
A20-13 ~ Q2-6 Continuity
A20-12 ~ G38-28 Continuity
A20-13 ~ G38-29 Continuity
A20-12 ~ Frame No continuity
A20-13 ~ Frame No continuity
21-180
z Error codes AF-1, AF-2, AF-3, AF-4, AF-5, AF-6, AF-7, AF-8 (CPU abnormality)
Related portion
SAS/OPS controller
Probable cause
c SAS/OPS controller defect
Caution:
When AF is displayed, the SAS/OPS controller is defective and must be replaced.
21-181
z Error codes C4-1, C4-2, C4-3, C4-4, C4-5, C4-6 (4Y-E spec.) (Accelerator sensor abnormality)
Related portion
A35 a1
25 (VCPA) 5
26 (VPA) 4
27 (EPA) 6
ASC controller Accelerator
33 (VCP2) 1 sensor
34 (VPA2) 3
35 (EPA2) 2
Probable cause
c Connector contact defect
d Accelerator sensor defect
e Harness defect
f 4Y-E controller defect
Error codes C4-1, C4-2, C4-3, C4-4, C4-5
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A35
and a1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine),
and check whether or not there is an error.*
Error
Inspection 1: NG
Accelerator sensor individual inspection Accelerator sensor defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
ASC controller defect
*: Make sure that no error code is displayed when the accelerator pedal is operated.
21-182
Error code C4-5
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A35
and a1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*
Error
Inspection 1: NG
Accelerator sensor defect
Accelerator sensor individual inspection
OK
Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection
OK
Inspection 3:
NG
Accelerator sensor voltage inspection Accelerator sensor defect
ANL.: I/O ENGINE CTRL 4/10
OK
ASC controller defect
*: Make sure that no error code is displayed when the accelerator pedal is operated.
Inspection 1:
Carry out accelerator sensor individual inspection.
Ignition key switch OFF, disconnect a1, conenct A35
(1) Accelerator sensor resistance measurement
6 5 4 3 2 1
Standard: (Sensor side)
a1
a1-5 ~ a1-6 Approx. 1.8 ~ 3.5 kΩ
a1-1 ~ a1-2 (released)
(2) Accelerator sensor output circuit resistance measurement
Standard: (Sensor side)
a1-4 ~ a1-6 Make sure that the resistance value increases proportionally to the
a1-3 ~ a1-2 rotation of the potentiometer when the potentiometer section is rotated.
21-183
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and a1
Standard:
A35-26 ~ a1-4 Continuity
A35-25 ~ a1-5 Continuity
A35-26 ~ Frame No continuity
A35-27 ~ a1-6 Continuity
A35-25 ~ A35-26 No continuity
A35-26 ~ A35-33 No continuity
A35-34 ~ a1-3 Continuity
A35-33 ~ a1-1 Continuity
A35-34 ~ Frame No continuity
A35-34 ~ A35-25 No continuity
A35-34 ~ A35-33 No continuity
A35-26 ~ A35-34 No continuity
Inspection 3:
Inspect the accelerator sensor voltage.
Ignition key switch OFF, disconnect a1, connect A35, ignition key switch ON
Accelerator sensor (I/O monitor: VPA1, VPA2)
Standard:
VPA1 0.20 V or less
VPA2 0.20 V or less
21-184
z Error codes C4-1, C4-2, C4-3, C4-4, C4-5 (ASC spec.) (Accelerator sensor abnormality)
Related portion
G39 a1
19 (VCPA) 5
6 (VPA) 4
7 (EPA) 6
ASC controller Accelerator
18 (VCP2) 1 sensor
5 (VPA2) 3
17 (EPA2) 2
Probable cause
c Connector contact defect
d Accelerator sensor defect
e Harness defect
f ASC controller defect
Error codes C4-1, C4-2, C4-3, C4-4, C4-5
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of G39
and a1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine),
and check whether or not there is an error.*
Error
Inspection 1: NG
Accelerator sensor individual inspection Accelerator sensor defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 3: NG
Accelerator sensor voltage inspection Accelerator sensor defect
ANL: I/O ENGINE CTRL 1/3
OK
ASC controller defect
*: Make sure that no error code is displayed when the accelerator pedal is operated.
21-185
Inspection 1:
Carry out accelerator sensor individual inspection.
Ignition key switch OFF, disconnect a1, conenct G39
(1) Accelerator sensor resistance measurement
6 5 4 3 2 1
Standard: (Sensor side)
a1
a1-5 ~ a1-6 Approx. 1.8 ~ 3.5 kΩ
a1-1 ~ a1-2 (released)
(2) Accelerator sensor output circuit resistance measurement
Standard: (Sensor side)
a1-4 ~ a1-6 Make sure that the resistance value increases proportionally to the
a1-3 ~ a1-2 rotation of the potentiometer when the potentiometer section is rotated.
21-186
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G39 and a1
Standard:
G39-6 ~ a1-4 Continuity
G39-19 ~ a1-5 Continuity
G39-6 ~ Frame No continuity
G39-7 ~ a1-6 Continuity
G39-19 ~ G39-6 No continuity
G39-6 ~ G39-18 No continuity
G39-5 ~ a1-3 Continuity
G39-18 ~ a1-1 Continuity
G39-5 ~ Frame No continuity
G39-5 ~ G39-19 No continuity
G39-5 ~ G39-18 No continuity
G39-6 ~ G39-5 No continuity
Inspection 3:
Inspect the accelerator sensor voltage.
Ignition key switch OFF, disconnect a1, connect G39, ignition key switch ON
Accelerator sensor (I/O monitor: VPA1, VPA2)
Standard:
VPA1 0.20 V or less
VPA2 0.20 V or less
21-187
z Error codes C7-1 and C7-2 (Shift lever switch abnormality)
Related portion
SFT
A41
6
A20
18 (DRF) 5 Shift switch
SAS/OPS
controller 19 (DRR) 1
The above chart is for vehicles of the left shift lever column specification.
For vehicles of the right shift lever column specification, A43-4, A43-5 and A43-9 should be used.
For vehicles of the armrest specification, Y4-7, Y4-6 and Y4-1 should be used.
Probable cause
c Connector contact defect f Harness defect
d Forward travel shift switch defect g Shift switch installation defect
e Reverse travel shift switch defect h SAS/OPS controller defect
Caution:
In the event that the engine stops while travelling, when the ignition key switch is turned from OFF to ON, an
C7-1 error may be detected, however this is not a fault.
Stop the vehicle, turn the ignition key switch OFF and restart the engine.
21-188
Error code C7-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A20
and A41 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*
Error
Inspection 1:
Check the condition of the switch
ANL.: I/O TRAVELING 2/3
OK
Inspection 2:
Individual continuity inspection of the direction NG
lever switch that was abnormal in inspection 1 Shift switch defect
(while still installed on the vehicle).
OK
Inspection 3: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS controller defect
*: Check if an error occurs after turning the ignition key switch ON, moving the shift lever and traveling from stopped
state to more than 10 km/h within 3 seconds.
Error code C7-2
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A20
and A41 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*
Error
Inspection 4:
OK
Check the condition of the switch Shift switch defect
ANL.: I/O TRAVELING 2/3
NG
Inspection 3: OK
Harness continuity and short circuit inspection Harness defect
NG
SAS/OPS controller defect
*: Make sure there is no error after turning the ignition key switch ON, and move the shift lever to forward and reverse
travel.
21-189
Inspection 1:
Check the condition of the switch.
Ignition key switch ON
Direction switch (I/O monitor: DRF - DRR)
Standard:
Lever in neutral Lever in forward Lever in reverse
position travel position travel position
DRF (for forward travel) 0 1 0
DRR (for reverse travel) 0 0 1
Inspection 2:
9 8 7 6 5 4 3 2 1
Individual continuity inspection of the direction lever switch(es) (still installed on the
vehicle). 1817161514131211 10
Ignition key switch OFF, disconnect A41 A41
Standard: (Switch side)
Lever in neutral Lever in forward Lever in reverse
position travel position travel position
A41-6 ~ A41-5 No continuity Continuity No continuity
A41-6 ~ A41-1 No continuity No continuity Continuity
Inspection 3:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and A41
Standard:
A20-18 ~ A41-5 Continuity
A20-18 ~ Frame No continuity
A20-19 ~ A41-1 Continuity
A20-19 ~ Frame No continuity
A20-18 ~ A41-6 No continuity
A20-19 ~ A41-6 No continuity
A20-18 ~ A20-19 No continuity
Inspection 4:
Check the condition of the switch.
Disconnect A41, ignition key switch ON (engine stopped), direction switch (I/O monitor: DRF·DRR)
Standard:
Analyzer display
DRF (for forward travel) 0
DRR (for reverse travel) 0
21-190
z Error code CA-1 (Forward-reverse travel lever abnormality)
Related portion
A20
17 (RYF) 1
Forward travel
43 (E01) 2
relay
44 (E02)
SAS/OPS
controller
1
Reverse travel
2 relay
Probable cause
c Connector contact defect f Reverse travel relay harness defect
d Forward travel relay harness defect g Reverse travel relay defect
e Forward travel relay defect h SAS/OPS controller defect
Error code CA-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A20
and internal moisture, reconnect all connectors No error
and the battery negative terminal, turn the Connector contact defect
ignition key switch ON and check whether or not
there is an error.
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
Inspection 2: NG
Relay individual inspection Relay defect
OK
SAS/OPS controller defect
Inspection 1:
Carry out relay individual inspection.
Ignition key switch OFF, disconnect forward/reverse relay, connect A20
Standard: (Relay side)
R/B forward relay terminal 1 ~
Forward/reverse relay
R/B forward relay terminal 2
91 ± 15 Ω (20°C)
R/B reverse relay terminal 1 ~
R/B reverse relay terminal 2
21-191
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and forward/reverse relay
Standard:
A20-17 ~ R/B forward relay terminal 1 Continuity
R/B reverse relay terminal 2 ~ Frame Continuity
A20-44 ~ Frame Continuity
A20-43 ~ Frame Continuity
A20-17 ~ Frame No continuity
21-192
z Error code EC-1 (Unload solenoid abnormality)
Related portion
A20 A12
5 (USOL) 1
Unload
SAS/OPS 9 (E02) 2 solenoid
controller 8 (E01)
Probable cause
c Connector contact defect
d Harness defect
e Unload solenoid defect
f SAS/OPS controller defect
Error code EC-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A12
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*
Error
Inspection 1: NG
Unload solenoid defect
Unload solenoid individual inspection
OK
Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection
OK
SAS/OPS controller defect
*: Check whether an error occurs after turning the ignition key switch ON and leaving the seat (for at least 2
seconds).
Inspection 1:
Carry out unload solenoid individual inspection.
1 2
Ignition key switch OFF, disconnect A12
A12
Standard: (Solenoid side)
A12-1 ~ A12-2 9.9 ± 0.5 Ω (20°C)
21-193
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and A12
Standard:
A20-5 ~ A12-1 Continuity
A12-2 ~ Frame Continuity
A20-8 ~ Frame Continuity
A20-9 ~ Frame Continuity
A20-5 ~ Frame No continuity
21-194
z Error codes F1-1, F1-2 (Controller to combination meter communication abnormality)
Related portion
A20 Q1
SAS/OPS 14 (SIL) 3 (SIL)
Combination
controller 9 (WITHOUT SAS)
N.C. meter
Probable cause
c Connector contact defect
d Hour meter harness defect
e Hour meter defect
f SAS/OPS controller defect
Error codes F-1, F-2
Disconnect the battery negative terminal, after
inspecting and correcting disconnection of A20
and Q1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON and check
whether or not there is an error.
F1-1 F1-2
Combination meter defect
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS controller or
combination meter defect
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and Q1
Standard:
Q1-9 ~ Frame No continuity
Q1-3 ~ Frame No continuity
A20-14 ~ Q1-3 Continuity
21-195
z Error codes F4-1, F4-2, F4-3, F4-4, F4-5, F4-7, F4-8 (CPU abnormality)
Related portion
Multi-function display
Probable cause
c Multi-function display board defect
21-196
z Error codes H1-1, H1-2, H1-3, H1-4, H1-5 (Lift lever potentiometer abnormality)
Related portion
A23
7 (IG1)
8 (IG2) Y6
29 (LIF+) 4
27 (LIF1) 3
SAS/OPS/ Lift lever
28 (LIF2) 2 potentiometer
mini lever
controller 26 (E2) 1
9 (E43)
10 (E44)
A21
10 (E42)
9 (E41)
3 (E11)
4 (E12)
Probable cause
c Connector contact defect
d Lift lever potentiometer harness defect
e Lift lever potentiometer defect
f SAS/OPS controller defect
g Fuse defect
21-197
Error codes H1-1, H1-2, H1-3, H1-4
Disconnect the battery negative
terminal, after inspecting and
correcting disconnection of A21,
A23 and Y6 and internal moisture, No error
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error.
Error
Turn the ignition key switch OFF,
disconnect the battery negative
terminal, replace the lift lever H2-4 Inspection 1: OK
potentiometer with the tilt lever Lift lever potentiometer inspection Installation defect
potentiometer, and check if there is
any change in the error. NG
H1-*
H2-1·H2-2·H2-3
Lift lever potentiometer abnormality
Inspection 2:
NG
Harness continuity and short circuit Harness defect
inspection
OK
NG
Fuse inspection Replace fuse
OK
SAS/OPS/mini lever
controller defect
Note:
If the lever has been removed, be sure to perform matching after the lever is reinstalled.
Inspection 1:
Carry out lift lever potentiometer inspection.
Ignition key switch OFF, return the lift lever potentiometer and tilt lever potentiometer to their original positions,
check lift lever potentiometer installation (refer to section 20), ignition key switch ON, match lift lever
potentiometer
21-198
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y6
Standard:
A23-29 ~ Y6-4 Continuity
A23-27 ~ Y6-3 Continuity
A23-28 ~ Y6-2 Continuity
A23-26 ~ Y6-1 Continuity
Error code H1-5
OK
Match lift lever potentiometer Matching value misalignment
NG
SAS/OPS/mini lever
controller defect
21-199
z Error codes H2-1, H2-2, H2-3, H2-4, H2-5 (Tilt lever potentiometer abnormality)
Related portion
A23
7 (IG1)
8 (IG2) Y5
30 (TIL+) 4
11 (TIL1) 3
SAS/OPS/ Tilt lever
12 (TIL2) 2 potentiometer
mini lever
controller 26 (E2) 1
9 (E43)
10 (E44)
A21
10 (E42)
9 (E41)
3 (E11)
4 (E12)
Probable cause
c Connector contact defect
d Tilt lever potentiometer harness defect
e Tilt lever potentiometer defect
f SAS/OPS controller defect
g Fuse defect
21-200
Error codes H2-1, H2-2, H2-3, H2-4
Disconnect the battery negative
terminal, after inspecting and
correcting disconnect of A21, A23
and Y5 and internal moisture, No error
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error.
Error
Turn the ignition key switch OFF,
disconnect the battery negative
terminal, replace the lift lever H1-4 Inspection 1: OK
potentiometer with the tilt lever Installation defect
Tilt lever potentiometer inspection
potentiometer, and check if there is
any change in the error. NG
H2-*
H1-1·H1-2·H1-3
Tilt lever potentiometer abnormality
Inspection 2:
NG
Harness continuity and short circuit Harness defect
inspection
OK
NG
Fuse inspection Replace fuse
OK
SAS/OPS/mini lever
controller defect
Note:
If the lever has been removed, be sure to perform matching after the lever is reinstalled.
Inspection 1:
Carry out tilt lever potentiometer inspection.
Ignition key switch OFF, return the tilt lever potentiometer and lift lever potentiometer to their original positions,
check tilt lever potentiometer installation (refer to section 20), ignition key switch ON, match tilt lever
potentiometer
21-201
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y5
Standard:
A23-30 ~ Y5-4 Continuity
A23-11 ~ Y5-3 Continuity
A23-12 ~ Y5-2 Continuity
A23-26 ~ Y5-1 Continuity
Error code H2-5
OK
Match tilt lever potentiometer Matching value misalignment
NG
SAS/OPS/mini lever
controller defect
21-202
z Error codes H3-1, H3-2, H3-3, H3-4, H3-5 (Attachment 1 lever potentiometer abnormality)
Related portion
A23
7 (IG1)
8 (IG2) Y2
31 (AT1+) 4
13 (AT11) 3
Attachment 1 lever
14 (AT12) 2
potentiometer
SAS/OPS/ 26 (E2) 1
mini lever 9 (E43)
controller 10 (E44)
A21
10 (E42)
9 (E41)
3 (E11)
4 (E12)
Probable cause
c Connector contact defect
d Attachment 1 lever potentiometer harness defect
e Attachment 1 lever potentiometer defect
f SAS/OPS controller defect
g Fuse defect
21-203
Error codes H3-1, H3-2, H3-3, H3-4
Disconnect the battery negative
terminal, after inspecting and
correcting disconnect of A21, A23 Error
and Y2 and internal moisture, None
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error.
Error
Turn the ignition key switch OFF,
disconnect the battery negative
terminal, replace the attachment 1 Inspection 1:
H2-4 NG
lever potentiometer with the tilt Attachment 1 lever potentiometer Installation defect
lever potentiometer, and check if inspection
there is any change in the error. OK
H3-*
H2-1·H2-2·H2-3 Attachment 1
lever potentiometer abnormality
Inspection 2:
NG
Harness continuity and short circuit Harness defect
inspection
OK
NG
Fuse inspection Replace fuse
OK
SAS/OPS/mini lever
controller defect
Note:
If the lever has been removed, be sure to perform matching after the lever is reinstalled.
Inspection 1:
Carry out attachment 1 lever potentiometer inspection.
Ignition key switch OFF, return the attachment 1 lever potentiometer and tilt lever potentiometer to their original
positions
Check attachment 1 lever potentiometer installation (refer to section 20), ignition key switch ON, match
attachment 1 lever potentiometer
21-204
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y2
Standard:
A23-31 ~ Y2-4 Continuity
A23-13 ~ Y2-3 Continuity
A23-14 ~ Y2-2 Continuity
A23-26 ~ Y2-1 Continuity
Error code H3-5
OK
Match attachment 1 lever potentiometer Matching value misalignment
NG
SAS/OPS/mini lever
controller defect
21-205
z Error codes H4-1, H4-2, H4-3, H4-4, H4-5 (Attachment 2 lever potentiometer abnormality)
Related portion
A23
7 (IG1)
8 (IG2) Y3
32 (AT2+) 4
15 (AT21) 3
16 (AT22) 2 Attachment 2 lever
SAS/OPS/ potentiometer
mini lever 26 (E2) 1
controller 9 (E43)
10 (E44)
A21
10 (E42)
9 (E41)
3 (E11)
4 (E12)
Probable cause
c Connector contact defect
d Attachment 2 lever potentiometer harness defect
e Attachment 2 lever potentiometer defect
f SAS/OPS controller defect
g Fuse defect
21-206
Error codes H4-1, H4-2, H4-3, H4-4
Disconnect the battery negative
terminal, after inspecting and
correcting disconnect of A21, A23
and Y3 and internal moisture, No error
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error.
Error
Turn the ignition key switch OFF,
disconnect the battery negative
terminal, replace the attachment 1 Inspection 1:
H3-4 NG
lever potentiometer with the Attachment 2 lever potentiometer Installation defect
attachment 2 lever potentiometer, inspection
and check if there is any change in
OK
the error.
H4-*
H3-1·H3-2·H3-3 Attachment 2
lever potentiometer abnormality
Inspection 2:
NG
Harness continuity and short circuit Harness defect
inspection
OK
NG
Fuse inspection Replace fuse
OK
SAS/OPS/mini lever
controller defect
Note:
If the lever has been removed, be sure to perform matching after the lever is reinstalled.
Inspection 1:
Carry out attachment 2 lever potentiometer inspection.
Ignition key switch OFF, return the attachment 2 lever potentiometer and tilt lever potentiometer to their original
positions
Check attachment 2 lever potentiometer installation (refer to section 20), ignition key switch ON, match
attachment 2 lever potentiometer
21-207
Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y3
Standard:
A23-32 ~ Y3-4 Continuity
A23-15 ~ Y3-3 Continuity
A23-16 ~ Y3-2 Continuity
A23-26 ~ Y3-1 Continuity
Error code H4-5
OK
Attachment 2 lever potentiometer matching Matching value misalignment
NG
SAS/OPS/mini lever
controller defect
21-208
z Error codes H5-1 and H5-2 (Lift solenoid abnormality)
Related portion
A23 A51
17 (LSO+) 5
Lift PUSH
18 (LPSH) 1 solenoid
SAS/OPS/
mini lever
controller A52
5
Lift PULL
19 (LPLL) 1 solenoid
Probable cause
c Connector contact defect f Lift PULL solenoid harness defect
d Lift PUSH solenoid harness defect g Lift PULL solenoid defect
e Lift PUSH solenoid defect h SAS/OPS/mini lever controller defect
Error codes H5-1, H5-2
H5-1 is now described. For H5-2, substitute A52 for A51 and PULL for PUSH in the following.
Disconnect the battery negative terminal, after
inspecting and correcting disconnect of A23 and
A51 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate the lift
lever and check whether or not there is an error.
Error
Inspection 1: NG
Lift solenoid individual inspection Lift PUSH solenoid defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS mini lever controller defect
Inspection 1:
Carry out lift solenoid individual inspection.
1 2 3 4
Ignition key switch OFF, disconnect battery negative terminal, disconnect A51 5 6 7 8
Standard: (Solenoid side) A51
A51-5 ~ A51-1 7.2 ± 0.36 Ω (20°C)
21-209
Inspection 2:
Inspect for continuity and short circuiting of the harness.
1 2 3 4
Ignition key switch OFF, disconnect battery negative terminal, disconnect A23 and A51 5 6 7 8
Standard: A52
A23-17 ~ A51-5 Continuity
A23-18 ~ A51-1 Continuity
A23-17 ~ A23-18 No continuity
A23-17 ~ A23-19 No continuity
21-210
z Error codes H6-1 and H6-2 (Tilt solenoid abnormality)
Related portion
A23 A51
1 (TSO+) 6
Tilt PUSH
2 (TPSH) 2 solenoid
SAS/OPS/
mini lever
A52
controller
6
Tilt PULL
3 (TPLL) 2 solenoid
Probable cause
c Connector contact defect f Tilt PULL solenoid harness defect
d Tilt PUSH solenoid harness defect g Tilt PULL solenoid defect
e Tilt PUSH solenoid defect h SAS/OPS/mini lever controller defect
Error codes H6-1 and H6-2
H6-1 is now described. For H6-2, substitute A52 for A51 and PULL for PUSH in the following
Disconnect the battery negative terminal, after
inspecting and correcting disconnect A23 and
A51 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate the tilt
lever and check whether or not there is an error.
Error
Inspection 1: NG
Tilt solenoid individual inspection Tilt PUSH solenoid defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS mini lever controller defect
Inspection 1:
Carry out tilt solenoid individual inspection.
1 2 3 4
Ignition key switch OFF, disconnect A51 5 6 7 8
Standard: (Solenoid side) A51
A51-6 ~ A51-2 7.2 ± 0.36 Ω (20°C)
21-211
Inspection 2:
Inspect for continuity and short circuiting of the harness.
1 2 3 4
Ignition key switch OFF, disconnect A23 and A51 5 6 7 8
Standard: A52
A23-1 ~ A51-6 Continuity
A23-2 ~ A51-2 Continuity
A23-1 ~ A23-2 No continuity
A23-1 ~ A23-3 No continuity
21-212
z Error codes H7-1, H7-2 (Attachment 1 solenoid abnormality)
Related portion
A23 A51
20 (3SO+) 7
Attachment 1
21 (3PSH) 3 PUSH solenoid
SAS/OPS/
mini lever
A52
controller
7
Attachment 1
22 (3PLL) 3 PULL solenoid
Probable cause
c Connector contact defect
d Attachment 1 PUSH solenoid harness defect
e Attachment 1 PUSH solenoid defect
f Attachment 1 PULL solenoid harness defect
g Attachment 1 PULL solenoid defect
h SAS/OPS/ mini lever controller defect
Error codes H7-1, H7-2
H7-1 is now described. For H7-2, substitute A52 for A51 and PULL for PUSH in the following
Disconnect the battery negative terminal, after
inspecting and correcting disconnect of A23 and
A51 and internal moisture, reconnect all
No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate
attachment lever 1 and check whether or not
there is an error.
Error
Inspection 1: NG Attachment 1 PUSH
Attachment 1 solenoid individual inspection solenoid defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS mini lever controller defect
21-213
Inspection 1:
Carry out attachment 1 solenoid individual inspection.
1 2 3 4
Ignition key switch OFF, disconnect A51 5 6 7 8
Standard: (Solenoid side) A51
A51-7 ~ A51-3 7.2 ± 0.36 Ω (20°C)
Inspection 2:
Inspect for continuity and short circuiting of the harness.
1 2 3 4
Ignition key switch OFF, disconnect A23 and A51 5 6 7 8
Standard: A52
A23-4 ~ A51-8 Continuity
A23-5 ~ A51-4 Continuity
A23-4 ~ A23-5 No continuity
A23-4 ~ A23-6 No continuity
21-214
z Error codes H8-1, H8-2 (Attachment 2 solenoid abnormality)
Related portion
A23 A51
4 (4SO+) 8
Attachment 2
5 (4PSH) 4 PUSH solenoid
SAS/OPS/
mini lever
A52
controller
8
Attachment 2
6 (4PLL) 4 PULL solenoid
Probable cause
c Connector contact defect
d Attachment 2 PUSH solenoid harness defect
e Attachment 2 PUSH solenoid defect
f Attachment 2 PULL solenoid harness defect
g Attachment 2 PULL solenoid defect
h SAS/OPS/ mini lever controller defect
Error codes H8-1, H8-2
H8-1 is now described. For H8-2, substitute A52 for A51 and PULL for PUSH in the following.
Disconnect the battery negative terminal, after
inspecting and correcting disconnect of A23 and
A51 and internal moisture, reconnect all
No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate
attachment lever 2 and check whether or not
there is an error.
Error
Inspection 1: NG Attachment 2 PUSH
Attachment 2 solenoid individual inspection solenoid defect
OK
Inspection 2: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS mini lever controller defect
21-215
Inspection 1:
Carry out attachment 2 solenoid individual inspection.
Ignition key switch OFF, disconnect battery negative terminal and A51
Standard: (Solenoid side) 1 2 3 4
A51-8 ~ A51-4 7.2 ± 0.36 Ω (20°C) 5 6 7 8
A51
Inspection 2:
Inspect for continuity and short circuiting of the harness.
1 2 3 4
Ignition key switch OFF, disconnect A23 and A51 5 6 7 8
Standard: A52
A23-4 ~ A51-8 Continuity
A23-5 ~ A51-4 Continuity
A23-4 ~ A23-5 No continuity
A23-4 ~ A23-6 No continuity
21-216
z Error code HA-1 (3/4-way change relay abnormality)
Related portion
IG
A21
1
3/4-way change
12 (ATSO) 2 relay 1
SAS/OPS/
Mini lever
controller 3
3/4-way change
4 relay 2
Probable cause
c Connector contact defect
d 3/4-way change relay 1 harness defect
e 3/4-way change relay 1 defect
f 3/4-way change relay 2 harness defect
g 3/4-way change relay 2 defect
h SAS/OPS controller defect
Error code HA-1
Disconnect the battery negative terminal, after
inspecting and correcting disconnect of A21 and
internal moisture, reconnect A21 and the battery
No error
negative terminal (leave relay disconnected), 3/4-way change relay defect
turn the changeover switch to the 3-way side,
turn the ignition key switch ON, and check
whether or not there is an error.
Error
Inspection 1: NG
Harness continuity and short circuit inspection Harness defect
OK
SAS/OPS/mini lever controller defect
Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21 and change relay
Standard:
A21-12 ~ Relay terminal 2 Continuity
A21-12 ~ Relay terminal 4 Continuity
A21-12 ~ Frame No continuity
21-217
TROUBLESHOOTING WHEN THERE IS NO ERROR CODE
4Y-E Engine List by Symptom
Symptom Portion to be inspected Page for reference
1. Starter relay and starter 21-218
Does not crank
2. Neutral start switch –
1. ECU power supply system 21-220
Cannot start 2. Igniter system 21-105
(no starting combustion) 3. Fuel pump circuit 21-222
4. Fuel injector Refer to engine repair manual
1. Fuel pump circuit 21-222
Cannot start
2. Igniter system 21-105
(no complete combustion)
3. Fuel injector Refer to engine repair manual
1. Electronic throttle Refer to engine repair manual
2. Fuel pump circuit 21-222
3. Igniter system 21-105
Does not start well
4. Spark plugs Refer to engine repair manual
5. Fuel injector Refer to engine repair manual
6. Compression Refer to engine repair manual
Fast idling rough 1. Electronic throttle Refer to engine repair manual
1. Electronic throttle Refer to engine repair manual
Idle speed high 2. ECU power supply system 21-220
3. Neutral start switch –
1. Electronic throttle Refer to engine repair manual
2. Fuel injector Refer to engine repair manual
Idle speed low 3. Igniter system 21-105
4. Compression Refer to engine repair manual
5. Fuel pump circuit 21-222
1. Electronic throttle Refer to engine repair manual
Idle unstable 2. ECU power supply system 21-220
3. Fuel pump circuit 21-222
1. Fuel injector Refer to engine repair manual
Hunting 2. Fuel pump circuit 21-222
3. Igniter system 21-105
1. Igniter system 21-105
Hesitation, poor acceleration 2. Spark plugs Refer to engine repair manual
3. Fuel injector Refer to engine repair manual
1. Fuel pump circuit 21-222
After fire 2. Spark plugs Refer to engine repair manual
3. Fuel injector Refer to engine repair manual
Engine stalling 1. Fuel pump circuit 21-222
(immediately after start up)
Engine stalling 1. Fuel injector Refer to engine repair manual
(immediately after deceleration) 2. Engine control computer –
21-218
z Starter relay and starter
Related portion
STA
5 3
Starter
1 2
to meter-related circuit Starter relay
Ignition switch Neutral switch
G27-24 (STA)
Engine controller
Probable cause
c Neutral switch defect
d Starter relay defect
e Starter defect
f Wire harness, connector defect
Inspection 1:
OK Neutral switch defect
Starter signal inspection
ANL.: I/O ENGINE CTRL 1/10 Starter relay defect
NG
Inspection 2: OK
Wire harness and connector inspection Starter defect
NG
Wire harness, connector defect
Inspection 1:
Carry out starter signal inspection.
Ignition key switch ON
Starter signal (I/O motor: STA)
Standard:
Starter stopped Starter in operation
STA 0 1
21-219
Inspection 2:
Carry out wire harness inspection.
Ignition key switch OFF, remove the starter relay, crank the engine and check voltage
Standard:
Relay terminal 1 ~ frame 9 ~ 14 V
Relay terminal 2 ~ frame 0V
Relay terminal 3 ~ frame 0V
Relay terminal 5 ~ frame 9 ~ 14 V
21-220
z ECU power supply system
Related portion
A36 G28
IGN
3 (BATT)
BATT 3 (E1)
EFI Engine
5 3 1 (+B) controller 2 (E01)
2 (+B1)
1 2 19 (MREL) 1 (E02)
EFI main relay
Probable cause
c Blown fuse
d EFI main relay defect
e Wire harness, connector defect
Inspection 1: NG
EFI and IGN fuse inspection Replace fuse
OK
Inspection 2: NG
EFI main relay operation and continuity EFI main relay defect
inspection
OK
Inspection 3: NG
Harness continuity inspection Wire harness, connector defect
OK
Engine controller defect
Inspection 1:
Carry out a fuse continuity inspection.
Remove the EFI fuse and IGN fuse.
Standard: Continuity exists.
21-221
Inspection 2:
Inspect the EFI main relay.
(1) Inspect the EFI main relay operation.
Ignition key switch ON, operate the EFI main relay
Standard:
The EFI main relay makes an operating sound in coordination with the ignition key switch.
(2) Inspect for continuity between each of the terminals of the relay.
Ignition key switch OFF, remove the EFI main relay
Standard:
Relay terminals 1 ~ 2 Continuity EFI relay
Relay terminals 3 ~ 5 No continuity
(3) Inspect for continuity between relay terminals 3 and 5 when the battery voltage is applied
accross terminals 1 to 2.
Standard: Continuity exists.
Inspection 3:
Inspect for continuity of the wire harness.
Ignition key switch OFF
Standard:
IGN ~ IG switch Continuity
MREL ~ EFI main relay (N18) Continuity
EFI main relay (Z23) ~ frame Continuity
EFI ~ +B Continuity
EFI ~ +B1 Continuity
EFI ~ BATT Continuity
E01 ~ frame Continuity
E02 ~ frame Continuity
E1 ~ frame Continuity
21-222
z Fuel pump control system
Related portion
Fuel changeover switch
6 (GAS) T6
4 (IG) 3 5
3 (LPG)
Engine 1 2
controller
5 3 EFI relay
FC 1 2 4 O2
Fuel pump
Circuit
opening 5
relay
Probable cause
c Blown fuse
d EFI main relay defect
e Wire harness, connector defect
f Fuel pump defect
Inspection 1: NG
Fuse inspection Replace fuse
OK
Inspection 2: NG
EFI main relay operation and continuity inspection EFI main relay defect
OK
Inspection 3: NG
Harness continuity inspection Wire harness, connector defect
OK
Fuel pump defect
Inspection 1:
Carry out a fuse continuity inspection.
Remove the EFI fuse and IGN fuse.
Standard: Continuity exists.
21-223
Inspection 2:
Inspect the EFI main relay.
(1) Inspect the EFI main relay operation.
Ignition key switch ON, inspect the operation of the EFI main relay
Standard: The EFI main relay makes an operating sound in coordination with the ignition key switch
(2) Inspect for continuity between each of the terminals of the relay
Ignition key switch OFF, remove EFI main relay
Standard:
Relay terminals 1 ~ 2 Continuity EFI relay
Relay terminals 3 ~ 5 No continuity
(3) Inspect for continuity between relay terminals 3 and 5 when the battery voltage is applied
accross terminals 1 to 2.
Standard: Continuity exists
Inspection 3:
Inspect for continuity of the wire harness.
Ignition key switch OFF
Standard:
Main relay ~ fuel changeover switch Continuity
Fuel changeover switch ~ GAS Continuity
FC ~ Circuit opening relay Continuity
Circuit opening relay ~ GND Continuity
Fuel changeover switch ~ Circuit opening relay Continuity
Circuit opening relay ~ Fuel pump Continuity
Fuel pump ~ GND Continuity
Defect Causes When There is No SAS/OPS Error Display
Caution:
21-224
If an error code or wrench lamp is flashing, repair it first.
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Brake switch unit:
Open fault
(Stuck in depressed state, or
internal damage) ON/OFF check with analyzer Harness check or replace switch
Brake switch line:
For T/C vehicles with drive control: Disconnection fault
Engine is always slow to rev up. (Harness, connector, fuse)
(Even with the direction lever left in F
Accelerator sensor unit:
or R position and the brake applied,
Internal damage Accelerator pedal position check:
the engine is still slow to rev up) If not close to 0%, installation check or
Accelerator sensor installation: Check the opening degree of the
replace sensor.
Link, installation part destroyed, accelerator pedal when not operated.
damaged
SAS/OPS controller:
– Replace
Controller defect
Drive control Lift raise switch unit:
Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Lift raise switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
For vehicles with drive control: (Harness, connector)
Even if the lift is raised, the idle Switch ground line:
speed does not rise. Disconnection fault
(Harness, connector)
Display setting:
Check settings with option set and
Lift idle up disabled, Idle up speed Change
tuning
tuning value low
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check:
(Power supply, signal, ground): If there is no change, perform a
Mount a load, ground the forks and
Disconnection fault harness check or replace the sensor.
check the change in voltage.
(Harness, connector)
For T/C vehicles with drive control: Short or link fault
Speed limit applies at high lifting (Harness, connector)
height despite not being loaded
Check the setting content of the
Display setting:
maximum speed limiter, check the
Maximum speed limiter, Change
setting content of the speed limit
Speed limit setting enabled
setting.
SAS/OPS controller:
– Replace
Controller defect
Load sensor unit:
Drive control
Sensor defect
Load sensor line
Load sensor voltage check:
(Power supply, signal, ground): If there is no change, perform a
Mount a load, ground the forks and
Disconnection fault harness check or replace the sensor.
check the change in voltage.
(Harness, connector)
Short or link fault
For T/C vehicles with drive control:
(Harness, connector)
Despite being loaded
at high lifting height the speed limit Lifting height switch unit:
does not operate. Disconnection fault (internal damage, ON/OFF check with analyzer Harness check or replace sensor
stuck)
Display setting:
Traveling limit setting disabled Check setting values with option set Change
Load sensing speed limit disabled
SAS/OPS controller:
– Replace
Controller defect
21-225
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Lifting height switch unit:
21-226
Disconnection fault ON/OFF check with analyzer Harness check or replace switch
(Internal damage, stuck)
For T/C vehicles with drive control: Check the setting content of the
Display setting:
Speed limit applies when loaded maximum speed limiter, check the
Maximum speed limiter, speed limiter Change
despite being at a low lifting height setting content of the speed limit
setting enabled
setting.
Drive control SAS/OPS/mini lever controller:
– Replace
Controller defect
Check the setting content of the
Display setting:
maximum speed limiter, check the
For T/C vehicles with drive control: Maximum speed limiter, speed limiter Change
setting content of the speed limit
Speed limit applies at all times setting enabled
setting.
regardless of lifting height or load
SAS/OPS controller:
– Replace
Controller defect
Buzzer unit:
Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Lead-in side):
Buzzer sounds constantly Ground short or link fault
(Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Buzzer unit:
Buzzer related Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
OPS leaving seat warning does not (Harness, connector)
sound.
Display setting:
OPS leaving seat notification buzzer Check setting values with option set Change
setting disabled
SAS/OPS controller, OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Buzzer unit:
Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
(Harness, connector)
T/C vehicles: Direction lever unit:
Traveling OPS return to neutral alarm Lever defect
Refer to "Traveling OPS does not Refer to "Traveling OPS does not
does not sound. Direction lever signal:
operate, cannot travel". operate, cannot travel".
Disconnection fault
(Harness, connector)
Display setting:
Check setting values with option set. Change
USA specification enabled
SAS/OPS controller:
– Replace
Controller defect
Buzzer related
Buzzer unit:
Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
(Harness, connector)
For cowl lever vehicles: Lowering lever switch: Refer to “Cowl lever vehicles: cannot
Material handling OPS return to Lever defect lower lift”.
Refer to “Cowl lever vehicles: cannot
neutral alarm does not sound. Lowering lever signal: *: The material handling OPS return to
lower lift”.
Disconnection fault neutral is only a function for the
(Harness, connector) lowering lever on cowl lever vehicles.
Display setting:
Check setting values with option set. Change
USA specification enabled
SAS/OPS controller:
– Replace
Controller defect
21-227
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Buzzer unit:
21-228
Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
(Harness, connector)
Material handling lever potentiometer
unit: If there is no change, perform a
For mini lever vehicles: Lever defect Material handling lever potentiometer harness check or replace the
Material handling OPS return to Material handling lever line voltage check: potentiometer
neutral alarm does not sound. (Power supply, signal, ground): Move the lever into forward and If none of the material handling levers
Disconnection fault reverse tilt positions and check the move, refer to “Cowl lever vehicles,
(Harness, connector) voltage change. mini lever vehicles: cannot perform
Short or link fault any material handling”.
(Harness, connector)
Display setting:
Check setting values with option set Change
USA specification enabled
SAS/OPS controller:
– Replace
Controller defect
Buzzer unit:
Buzzer related Buzzer defect
Buzzer harness line – Harness check or replace buzzer
(Power supply side, lead-in side):
Fault (Harness, connector)
Parking brake switch unit:
Open fault
(stuck in released state, internal
damage) If there is no change, perform an
Vehicles with multi display, multi Parking brake detection mechanism: ON/OFF check with analyzer. installation check, harness check, or
display DX: Always released replace the switch.
Parking brake reminder alarm does Parking brake line:
not sound. Disconnection fault
(Harness, connector)
Display setting:
Parking brake reminder alarm setting
Check setting values with option set Change
disabled.
USA specification enabled
SAS/OPS controller setting:
– Follow matching procedure to match.
Not matched
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Parking brake switch unit:
Ground short fault
(Stuck in released state, internal
Vehicles with multi display, multi damage) If there is no change, perform an
display DX: Parking brake detection mechanism: ON/OFF check with analyzer installation check, harness check, or
Parking brake reminder alarm Always released replace the switch.
continues to sound even after the Parking brake line:
parking brake has been depressed Ground short fault
(or pulled). (Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Buzzer unit:
Buzzer defect
Buzzer harness line – Harness check or replace buzzer
Buzzer related (Power supply side, lead-in side):
Vehicles with multi display, multi Fault (Harness, connector)
display DX:
Vehicle speed sensor unit:
Parking brake return reminder alarm Check sensor voltage and vehicle
Cannot detect low speed
does not sound. speed with the analyzer
(Internal damage) If there is no change, perform an
* First perform a “Parking brake * With the parking brake not returned,
Vehicle speed sensor line installation check or replace the
reminder alarm does not sound” even when the accelerator pedal is
(SPD+ side, SPD- side): sensor.
check. depressed, the alarm only sounds at
Link fault
speeds above 2 km/h.
(Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Vehicles with multi display, multi Meter unit (with OK monitor):
– Replace
display DX: Meter defect
Parking brake return reminder alarm SAS/OPS controller:
sounds on traveling. – Replace
Controller defect
21-229
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Load indicator switch unit:
21-230
Open fault (Internal damage)
Load indicator switch detection
mechanism (Mini lever, joystick):
Vehicles with multi display DX: If there is no change, perform an
Detection part gap adjustment defect
When the load indicator switch is ON/OFF check with analyzer installation check, harness check, or
Load indicator switch line
pressed, the load is not displayed. replace the switch (lever).
(Power supply, signal, ground):
Open fault
(Power supply, harness,
connector)
Load indicator switch unit:
Short fault (Internal damage)
Vehicles with multi display DX: Load indicator switch detection
Display If there is no change, perform an
When the vehicle is stopped, the mechanism (Mini lever, joystick):
function ON/OFF check with analyzer installation check, harness check, or
display continually shows load Detection part gap adjustment defect
replace the switch (lever).
indicator. Load indicator switch line (Signal):
Short fault
(Harness, connector)
Follow the procedure for matching,
Carry out rematching and check
and rematch (cylinder bore, number of
operation
cylinders, 0 point correction)
Load sensor voltage check:
Display setting: In cases where precision is required,
Vehicles with multi display DX: Mount a load, ground the forks and
Cylinder bore, number of cylinders, 0 adjust on the load indicator matching
The correct load is not displayed. check the change in voltage
point correction, calibration LOAD CALIBRATION screen.
* At high lifting height, correct load
If there is no change during the voltage
cannot be calculated and the display
check, perform a harness check or
flashes.
replace the sensor.
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Torque converter oil temperature
sensor unit:
Open fault (Internal damage)
Torque converter oil temperature
T/C vehicles with multi display, multi
sensor line (Signal, ground): Start the engine and after leaving the
display DX: Harness check or replace sensor, or
Disconnection fault vehicle running for a while, check the
Torque converter oil temperature replace SAS/OPS controller
(Harness, connector) indicator.
indicator stays at level 1.
+B short fault
(Harness, connector)
SAS/OPS controller:
Controller defect
Torque converter oil temperature
Display sensor unit:
function T/C vehicles with multi display, multi Short fault (Internal damage)
display DX: Torque converter oil temperature Stop the engine and after leaving the
Harness check or replace sensor, or
Torque converter oil temperature sensor line (Signal): vehicle stopped for a while, check the
replace SAS/OPS controller
indicator continually displays Ground short fault indicatior.
overheat warning indication. (Harness, connector)
SAS/OPS controller:
Controller defect
There is no display on MT vehicles. If the TEMPGAUGE is set to NO on
T/C vehicles with multi display, multi Display setting: Check that the TEMPGAUGE on the the option set screen, change it to
display DX: Torque converter oil temperature option set screen is set to YES, and YES, and if MTC on the analyzer I/O
Torque converter oil temperature emergency setting enabled that the MTC on the analyzer I/O OTHERS screen is set to 1, perform a
indicator does not display. SAS/OPS controller: OTHERS screen is set to 0. harness check or replace the SAS/
Controller defect (MTC line short) OPS controller.
21-231
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tire unit:
21-232
Burst, tire pressure adjustment – Adjust or replace
defect
Lock cylinder unit:
Leak, cannot lock
(Internal damage) Check the locked status with an active
Replace
Lock cylinder locked status: test.
Installation part damaged or
destroyed
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Peform lift relief and check the installation check or replace the
Disconnection fault
change in voltage. sensor.
(Harness, connector)
Short or leak fault
Feels unstable when traveling. (Harness, connector)
Swing lock (Traveling lock has become difficult or Lifting height switch unit:
no longer possible) Disconnection fault ON/OFF check with analyzer Harness check or replace switch
(Internal damage, stuck)
Yaw rate sensor unit:
Reduced sensitivity, voltage stuck Yaw rate sensor voltage check:
(Internal damage) Check that the voltage is
Installation check or replace sensor
Yaw rate sensor line (Signal): approximately 2.5 V when the vehicle
Leak is stopped.
(Harness, connector)
Vehicle speed sensor unit:
Cannot detect low speeds
(Internal damage) If there is no change, perform an
Check sensor voltage and vehicle
Vehicle speed sensor line installation check or replace the
speed with the analyzer
(SPD+ side, SPD- side): sensor.
Leak fault
(Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Lock cylinder unit: Check the locked status with an active
Replace
Lock stuck (internal damage) test.
Swing lock solenoid line (SWN+,
SWN-):
Disconnection fault
Check the locked status with an active
(Harness, connector) Harness check or replace solenoid
test.
Solenoid ground line (E01, E02):
Disconnection fault
(Harness, connector)
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Swing lock continually activates while Peform lift relief and check that the installation check or replace the
Disconnection fault
traveling and material handling voltage rises. sensor.
Swing lock (Harness, connector)
operations, or swing lock activates Short or leak fault
frequently. (Harness, connector)
Lifting height switch unit (2200H):
Disconnection fault (internal damage,
stuck)
ON/OFF check with analyzer Harness check or replace switch
Lifting height switch unit (4000H):
Disconnection fault (internal damage,
stuck)
Yaw rate sensor voltage check:
Yaw rate sensor unit:
Check that the voltage is
Reduced sensitivity, voltage stuck Installation check or replace sensor
approximately 2.5 V when the vehicle
(Internal damage)
is stopped.
SAS/OPS controller:
– Replace
Controller defect
21-233
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tilt angle sensor unit:
Tilt angle sensor voltage check:
21-234
Sensor defect If there is no change, perform an
Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
–
Does not match actual status rematch.
(rematch)
Automatic fork leveling switch unit:
Open fault (internal damage)
Forward tilt automatic fork leveling Automatic fork leveling switch
does not stop. detection mechanism (mini lever,
Tilt control (Continues to tilt to the forward most joystick):
tilt position without stopping at the ON/OFF check with analyzer. Harness check or replace switch
Detection part gap adjustment defect
level position) Automatic fork leveling switch line
(Power supply, signal, ground):
Disconnection fault
(Harness, connector)
C/V tilt control valve: Turn the tilt solenoid OFF and operate If forward tilt can be performed,
Stuck (internal damage) to forward tilt using an active test. replace the C/V tilt control valve.
Display setting (mini lever, joy stick):
3/4 way change over specification is Check the option set content. Change
set to 2/3 way change over setting
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Peform lift relief and check that the installation check or replace the
Disconnection fault
voltage rises. sensor.
(Harness, connector)
Short or leak fault
(Harness, connector)
Load sensor no-load matching value:
Follow matching procedure to
Forward tilt automatic fork leveling Does not match actual status –
rematch.
does not stop. (rematch)
Tilt control
(Stops at a position slightly off the level Tilt angle sensor unit:
Tilt angle sensor voltage check:
position) Sensor defect If there is no change, perform an
Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
–
Does not match actual status rematch.
(rematch)
SAS/OPS controller:
– Replace
Controller defect
21-235
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Load sensor unit:
21-236
Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Check that the voltage rises on lift installation check or replace the
Disconnection fault
relief. sensor.
(Harness, connector)
Short or leak fault
(Harness, connector)
Load sensor no-load matching value:
Follow matching procedure to
Does not match actual status –
rematch.
(rematch)
Forward tilt automatic fork leveling
does not stop. Tilt angle sensor unit:
Tilt angle sensor voltage check:
Tilt control (Stops at the position where the Sensor defect If there is no change, perform an
Tilt to forward and backward tilt
automatic fork leveling switch is Tilt angle sensor installation: installation check or replace the
positions and check the voltage
pressed) Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
–
Does not match actual status rematch.
(rematch)
Lifting height switch unit (2200H):
Disconnection fault (internal damage, ON/OFF check with analyzer. Harness check or replace switch
stuck)
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Automatic fork leveling switch unit:
Open fault (internal damage)
Automatic fork leveling switch
detection mechanism (mini lever,
joystick):
ON/OFF check with analyzer Harness check or replace switch
Detection part gap adjustment defect
Automatic fork leveling switch line
(Power supply, signal, ground):
Disconnection fault
(Harness, connector)
Mast backward tilting speed is not
limited. Turn the tilt solenoid ON/OFF and If there is no change in the backward
Tilt control C/V tilt control valve:
Or, backward tilting speed is always operate to backward tilt using an active tilting speed when ON/OFF operated,
Stuck (internal damage)
slow. test. replace the C/V tilt control valve.
Lifting height switch unit (2200H):
Disconnection fault (internal damage, ON/OFF check with analyzer Harness check or replace switch
stuck)
Display setting
(mini lever, joystick):
Check the option set content. Change
3/4-way change over specification is
set to 2/3-way change over setting
SAS/OPS controller:
– Replace
Controller defect
21-237
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tilt angle sensor unit:
Tilt angle sensor voltage check:
21-238
Sensor defect If there is no change, perform an
Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
–
Does not match actual status rematch.
(rematch)
Automatic fork leveling switch unit:
Mini lever, joystick vehicles:
Open fault (internal damage)
Backward tilt automatic fork leveling
Automatic fork leveling switch
does not stop. (Continues to tilt to
detection mechanism (mini lever,
backward most tilt position without
Mini lever joystick):
stopping at the level position) ON/OFF check with analyzer Harness check or replace switch
function Detection part gap adjustment defect
Automatic fork leveling switch line
(Power supply, signal, ground):
Disconnection fault
(Harness, connector)
Display setting (mini lever, joy stick):
3/4-way change over specification Check the option set content Change
set to 2/3-way change over setting
SAS/OPS controller:
– Replace
Controller defect
Mini lever, joystick vehicles: Refer to forward tilt automatic fork
Backward tilt automatic fork leveling leveling does not stop (stops at the
– –
does not stop. (Stops at a position position where the automatic leveling
slightly off the level position) switch is pressed).
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tilt angle sensor unit:
Tilt angle sensor voltage check:
Sensor defect If there is no change, perform an
Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Mini lever, joystick vehicles: Link, installation part destroyed, sensor.
change.
Backward tilt automatic fork leveling damaged
does not stop. (Stops at the position Horizontal matching value for tilt angle
where the automatic fork leveling sensor: Follow matching procedure to
–
switch is pressed) Does not match actual status rematch.
(rematch)
SAS/OPS controller:
– Replace
Controller defect
Lever change over switch unit:
Open fault (internal damage)
Mini lever Lever change over switch detection
function mechanism (mini lever):
Detection part gap adjustment defect ON/OFF check with analyzer Harness check or replace switch
Lever change over switch line
(Power supply, signal, ground):
Mini lever 3/4-way (2/3-way) change Disconnection fault
over specification: (Harness, connector)
3-way (2-way) operation even when
Lever change over relay 1 or 2 unit:
the lever change over switch is
Stuck, welding fault (internal
pressed. (Does not change over)
damage)
Check the changeover status with an
Lever change over relay 1 or 2 primary Harness check or replace relay
active test.
side line:
Disconnection fault
(wire, connector)
AS/OPS/mini lever controller:
– Replace
Controller defect
21-239
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Lever change over switch unit:
21-240
Ground short fault (Internal damage)
Lever change over switch detection
mechanism (mini lever):
Detection part gap adjustment defect ON/OFF check with analyzer Harness check or replace switch
Lever change over switch line
(signal):
Ground short fault
Mini lever 3/4-way (2/3-way) change (Harness, connector)
over specification: Lever change over relay 1 or 2 unit:
4-way (3-way) continues to operate Stuck, welding fault (internal
even though the lever change over damage)
switch has been operated. (Stays Check the changeover status with an
Lever change over relay 1 or 2 primary Harness check or replace relay
changed over) active test.
side lower line:
Mini lever Ground short fault
function (wire, connector)
Display setting:
Number of attachment levers is not Check the option set content. Change
set to 5 way
SAS/OPS controller:
– Replace
Controller defect
Mini lever 2/3-way change over
specification: Display setting:
During ATT1 operation and high Number of attachment levers is not Check the option set content. Change
lifting height, and when loaded, ATT1 set to 2/3-way
stops and pull-side operation is slow.
3-way (4-way) specifcation: Display setting:
Although ATT1 (ATT2) is operated, it Number of attachment levers is not Check the option set content. Change
does not work. set to 3-way (4-way)
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tire angle sensor unit:
Sensor defect Tire angle sensor voltage check: If there is no change, perform an
Tire angle sensor installation: Operate the steering and check the installation check or replace the
Looseness of the attachment part, change in voltage. sensor.
damage, bearing housing damage
Tire angle sensor matching value:
Follow matching procedure to
Does not match actual status –
rematch.
(rematch)
Steering angle sensor unit:
Knob moves out of alignment into a Sensor defect
Knob ON/OFF check with analyzer Harness check or replace sensor
certain position. Steering angle sensor installation:
compensaiton
(More than 10° off the straight ahead Cam or steering wheel defect
control
position) Using an active test, turn the knob
compensation SOL ON and OFF and
operate the steering at the tire end.
Knob compensation valve unit: SOL ON: check that the steering
Replace
Leak, stuck, (internal damage) wheel can be turned freely.
SOL OFF: Check that the steering
wheel cannot be turned freely
(steering is heavy).
SAS/OPS controller:
– Replace
Controller defect
21-241
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tire angle sensor unit:
21-242
Sensor defect Tire angle sensor voltage check: If there is no change, perform an
Tire angle sensor installation: Operate the steering and check the installation check or replace the
Looseness of the attachment part, change in voltage. sensor.
damage, bearing housing damage
Tire angle sensor matching value:
Follow matching procedure to
Does not match actual status –
rematch.
(rematch)
Steering angle sensor unit:
Sensor defect Check sensor voltage with the
Harness check or replace sensor
Steering angle sensor installation: analyzer.
Cam or steering wheel defect
Using an active test, turn the knob
compensation SOL ON and OFF and
operate the steering at the tire end.
Knob compensation valve unit: SOL ON: Check that the steering
Replace
Knob Knob position is out of alignment. Leak, stuck, (internal damage) wheel can be turned freely.
compensation (Knob position is not constant when SOL OFF: Check that the steering
control traveling straight ahead) wheel cannot be turned freely
(steering is heavy).
PS cylinder system link defect:
– Replace
Eccentric pin, kingpin defect
Vehicle speed sensor unit:
Cannot detect low speed (internal
damage)
Vehicle speed sensor installation:
High speed not detected correctly If there is no change, perform an
Check sensor voltage and vehicle
(sensor tip has metallic particle installation check or replace the
speed with the analyzer.
adhered) sensor.
Vehicle speed sensor line
(SPD+ side, SPD- side):
Leak fault
(Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Fuse:
ECU+B fuse blown – Check for blown fuse
ECU-IG fuse blown
Meter communication line:
Ground short
(Harness, connector)
Disconnection fault
(Harness, connector) – Harness check
SAS/OPS IG line, +B line, ground
system:
Disconnection fault
Wrench lamp is lit continually.
(Harness, connector)
Battery unit:
Check battery voltage with the Keep the engine at high speed for a
Low voltage, intake heater, large
analyzer. while.
current auxiliary equipment operation
SAS/OPS controller setting: Follow matching procedure to
–
Not matched rematch.
Meter Meter unit:
– Replace
Meter defect
SAS/OPS controller:
– Replace
Controller defect
Meter power supply line:
The wrench lamp does not light even Disconnection fault – Harness check
when the ignition key switch is turned (Harness, connector)
ON. Meter unit:
– Replace
Meter defect
Line to the meter
(OPS lamp output):
– Harness check
Ground short fault
ROW standard (except for compact (Harness, connector)
vehicles):
Meter unit:
OPS lamp does not light. – Replace
Meter defect
OPS controller:
– Replace
Controller defect
21-243
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Line to the meter
21-244
(OPS lamp output):
– Harness check
Disconnection fault
(Harness, connector)
Meter unit:
– Replace
Meter defect
Seat switch unit:
ROW standard (except for compact Open fault (internal damage)
vehicles): Seat switch line
ON/OFF check with plug-in analyzer Harness check or replace switch
OPS lamp is lit continually. (Signal, ground):
Disconnection fault
(Harness, connector)
Meter
Battery unit:
Check battery voltage with plug-in Keep the engine at high speed for a
Low voltage, intake heater, large
analyzer. while.
current auxiliary equipment operation
OPS controller:
– Replace
Controller defect
Hour meter start connector:
Not connected
Hour meter start signal line: – Harness check or replace connector
Hour meter is not displayed. Disconnection fault
(Harness, connector)
Meter unit:
– Replace
Meter defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Lift lower switch unit:
Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Lift lower switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
Switch ground line:
Disconnection fault
For cowl lever vehicles: (Harness, connector)
Cannot lower the lift.
Using an active test, turn the lift lower
C/V lift lower lock valve If the lift cannot lower by lower
lock solenoid ON and perform lower
Stuck (internal damage) operation, replace the C/V.
operation.
Seat switch unit:
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
OPS (Harness, connector)
Forward tilt switch unit:
Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Forward tilt switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
Switch ground line:
For cowl lever vehicles: Disconnection fault
Cannot perform forward tilt. (Harness, connector)
C/V tilt control valve Turn the tilt solenoid ON and operate If forward tilt cannot be performed,
Stuck (internal damage) to forward tilt using an active test. replace the C/V tilt control valve.
Seat switch unit:
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
21-245
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Backward tilt switch unit:
21-246
Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Backward tilt switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
Switch ground line:
Disconnection fault
For cowl lever vehicles: (Harness, connector)
Cannot perform backward tilt.
Turn the backward tilt lock solenoid If backward tilt cannot be performed,
C/V backward tilt lock valve
ON and operate to backward tilt using replace the C/V backward tilt lock
Stuck (internal damage)
an active test. valve.
OPS Seat switch unit:
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
For cowl lever vehicles:
Turn the unload valve solenoid OFF
and perform raising operation using
Cannot perform material handling C/V unload valve: an active test. If raising cannot be performed, replace
except for lift lower. Stuck (internal damage) For mini lever vehicles: the C/V unload valve.
Turn the unload valve solenoid ON
and perform raising operation using
an active test.
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
C/V tilt control valve: Turn the tilt solenoid OFF and operate If forward tilt can be performed,
Stuck (internal damage) to forward tilt using an active test. replace the C/V tilt control valve.
Turn the backward tilt lock solenoid
C/V backward tilt lock valve: If backward tilt can be performed,
OFF and operate to backward tilt using
Stuck (internal damage) replace the C/V tilt control valve.
an active test.
Using an active test, turn the lift lower
C/V lift lower lock valve: If lowering can be performed, replace
lock solenoid OFF and perform lower
Stuck (internal damage) the C/V lift lower lock valve.
operation.
For cowl lever vehicles:
Turn the unload valve solenoid ON
and perform lift raising operation
Material handling OPS does not C/V unload valve: using an active test. If raising can be performed, replace
OPS
operate. Stuck (internal damage) For mini lever vehicles: the C/V unload valve.
Turn the unload valve solenoid OFF
and perform lift raising operation
using an active test.
Seat switch unit:
Short fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
SAS/OPS controller, OPS controller:
– Replace
Controller defect
21-247
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Seat switch unit:
21-248
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
For cowl lever vehicles:
Cowl lever, mini lever vehicles:
Turn the unload valve solenoid OFF
No material handling can be
and perform lift raising operation
performed.
C/V unload valve: using an active test. If raising cannot be performed, replace
Stuck (internal damage) For mini lever vehicles: the C/V unload valve.
Turn the unload valve solenoid ON
and perform lift raising operation
using an active test.
SAS/OPS controller, OPS controller:
– Replace
OPS Controller defect
Forward travel interrupt relay unit: If forward travel can be performed,
Stuck (internal damage, welded) replace the forward travel interrupt
Turn the forward and reverse travel
Reverse travel interrupt relay unit: relay.
interrupt relays ON and operate
Stuck (internal damage, welded) If reverse travel can be performed,
forward and reverse travel using an
Relay secondary side line: replace the reverse travel interrupt
active test.
Short fault relay.
(Harness, connector) Or perform a harness check.
T/C vehicles:
Short switch unit:
Traveling OPS does not operate.
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
SAS/OPS controller, OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Fuse:
– Check for blown fuse
Shift fuse blown
Forward travel interrupt relay unit:
Open fault
If forward travel cannot be performed,
(internal damage, welded)
Turn the forward and reverse travel replace the forward travel interrupt
Reverse travel interrupt relay unit:
interrupt relays OFF and operate relay. If reverse travel cannot be
Open fault
forward and reverse travel using an performed, replace the reverse travel
(internal damage, welded)
active test. interrupt relay. Or perform a harness
Relay secondary side line:
check.
Open fault
(Harness, connector)
T/C vehicles: Seat switch unit:
OPS
Cannot travel. Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
Direction lever unit:
Open system fault (internal damage)
Direction lever signal line: ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
SAS/OPS controller, OPS controller:
– Replace
Controller defect
21-249
Defect Causes When There is No ASC Error Display
Caution:
21-250
If an error code or wrench lamp is flashing, repair it first.
Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
NMR switch unit:
Switch defect
NMR switch line:
Harness check or
Disconnection fault
Occaisonally full speed is not reached ON/OFF check with analyzer replace switch, or adjust switch, adjust and
(Harness, connector)
even with the accelerator pedal fully repair mechanical parts.
NMR switch adjustment:
depressed. (NMR speed not acheived) Adjustment defect, seal bolt position
defect or some other mechanical defect
ASC controller:
– Replace
Controller defect
Idle switch adjustment:
– Switch adjustment
Adjustment defect or mechanical defect
Accelerator sensor:
Accelerator sensor adjustment, or, if a fault
Sensor catching, mistake in procedure
occurs after sensor replacement, turn the
during sensor replacement (when the
Idle speed is higher than specified speed ignition key ON with the accelerator sensor
sensor is beng replaced, if a C4 series Check accelerator sensor voltage with the
even when the accelerator pedal is not connectors removed, in order to create an
error is not created by turning the ignition analyzer.
depressed. error once.
key ON while the sensor connector is
Then turn the ignition key OFF, connect
disconnected, the fully closed position
connectors and turn the ignition key ON
learning value is not reset)
ASC controller:
– Replace
Controller defect
Drop in battery voltage:
Check battery voltage with the analyzer. Battery replacement
Battery life, intake heater, afterheat
Engine rev up is poor or slow.
ASC controller:
– Replace
Controller defect
IGN, +B line:
Disconnection fault
(Harness, connector, fuse)
Check battery voltage with the analyzer. Harness check or replace fuse
GND line complete loss:
Does not rev up from idling Disconnection fault
(Harness, connector)
ASC controller:
– Replace
Controller defect
E
WIRING DIAGRAM
CHAPTER 1 INTRODUCTION E1
CHAPTER 2 ELECTRICAL WIRING ROUTINGS AND RELAY LOCATIONS E2
CHAPTER 3 SYSTEM CIRCUITS E3
CHAPTER 4 GROUND POINTS E4
CHAPTER 5 FUSES FOR POWER SUPPLY E5
CHAPTER 6 CONNECTOR LIST E6
E
E1-1
INTRODUCTION
CHAPTER 1 INTRODUCTION E1
CHAPTERS OF THIS SECTION .......................................................................... E1-2
HOW TO READ CHAPTERS
Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS
ELECTRICAL WIRING ROUTINGS .......................................................... E1-3
RELAY LOCATIONS
JUNCTION BLOCK (J/B) / RELAY BLOCK (R/B) ................................... E1-4
Chapter 3 SYSTEM CIRCUITS
POWER SUPPLY CIRCUIT ...................................................................... E1-6
REFERENCE PAGE ................................................................................. E1-10
Chapter 4 GROUND POINTS
GROUND POINTS ................................................................................... E1-11
Chapter 5 FUSES FOR POWER SUPPLY
FUSES FOR POWER SUPPLY ................................................................ E1-11
Chapter 6 CONNECTOR LIST
CONNECTOR LIST .................................................................................. E1-12
WIRE TO WIRE....................................................................................... E1-13
ABBREVIATIONS ............................................................................. E1-14
GLOSSARY OF TERMS AND SYMBOLS ........................................ E1-15
E
E1-2
INTRODUCTION
CHAPTERS OF THIS SECTION
This section consists of the following 6 chapters:
Chapter 1 INTRODUCTION Gives brief explanation of each chapter, provides instructions on how
to use this manual, and defines the abbreviations used in the electrical
circuit diagrams.
Chapter 2 ELECTRICAL WIRING Electrical wiring routings show installation positions, ground points,
ROUTINGS and connector numbers, and part names related to wire harnesses,
RELAY LOCATIONS connectors, relay blocks and junction blocks used in the forklift, such as
in the engine room, instrument panel and mast.
Relay locations show design drawings and internal circuit diagrams
related to relays, relay blocks (R/B), junction blocks (J/B), fusible links
(F/L) and junction connectors (J/C).
Chapter 3 SYSTEM CIRCUITS Show power supply circuit diagrams and wiring diagrams for each
system, such as the engine.
(Only wiring information for complete circuits is shown.)
Chapter 4 GROUND POINTS Show related systems for each ground point.
Chapter 5 FUSES FOR POWER Show power distribution from each power supply (fuse or fusible link) to
SUPPLY various systems.
Chapter 6 CONNECTOR LIST Shows shapes and part numbers of connectors used in electrical wiring
routings and electrical wiring diagrams.
E1-3
INTRODUCTION
HOW TO READ CHAPTERS
Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS
ELECTRICAL WIRING ROUTINGS
Electrical wiring routings show installation positions, ground points, connector numbers, and part names related
to wire harnesses, connectors, relay blocks and junction blocks used in the forklift.
(Connector codes are the same as those used in the electrical wiring diagrams.)
E2-10 E2-11
ELECTRICAL WIRING ROUTINGS ELECTRICAL WIRING ROUTINGS
FRONT BODY
A24 FUSIBLE LINK BLOCK ASSY AA FRONT PLATE LEFT OUTSIDE EARTH
A25 DIAGNOSIS
A27 JUNCTION CONNECTOR AB FRONT PLATE LEFT OUTSIDE EARTH
A29 CAN JOINT CONNECTOR
A30 CAN JOINT CONNECTOR AC FRONT PLATE LEFT OUTSIDE EARTH
A31 CAN JOINT CONNECTOR
A32 CAN JOINT CONNECTOR AD TRANSMISSION UPPER
A33 CAN JOINT CONNECTOR
C SIDE RH A34 CAN JOINT CONNECTOR
WIRE
A37 LPG WARNING RELAY
G ENGINE WIRE
A38 LPG WARNING BUZZER
A40 BACK UP LAMP SWITCH
1 ENGINE ROOM RELAY BLOCK A42 TILT ANGLE SENSOR
A45 MATCHING CONNECTOR
A46 MATCHING CONNECTOR
A24
to E2-2 A47 SHIFT SOLENOID(2)
AC1 to E2-16
A48 SHIFT SOLENOID(2)
AA1 A54 SHIFT SOLENOID(1)
to E2-4 A57
A55 SHIFT SOLENOID(1)
A48
AC3 A37 A57 TO PUSH PULL RELAY
A40 to E2-14
A38 A65 JUNCTION CONNECTOR (A)
AG3
A46 A66 JUNCTION CONNECTOR (B)
A47 A25
AC2 D1 T/C OIL TEMPERATURE SENSOR
G27 ENGINE ECU
A42
A45 G28 ENGINE ECU
A54 D1
G29 JUNCTION CONNECTOR (B)
AD G73 JUNCTION CONNECTOR (A)
A55
to E2-8
DA1
1A
AC 1B BODY MAIN WIRE to J/B
AB O LH SIDE WIRE
1C
AA
1D ENGINE WIRE to J/B
1E LH SIDE WIRE to J/B
J/B
D TC HEAT GAUGE WIRE
A BODY MAIN WIRE AA1 BODY MAIN WIRE to BODY MAIN WIRE
1A
G29
AC1
A65 AG1 1B
A55 AC2 BODY MAIN WIRE to SIDE RH WIRE
1C
AC3
DA1 1D AG1
A27
BODY MAIN WIRE to ENGINE WIRE
G27 1E AG3
G28 AO1
AO2 BODY MAIN WIRE to LH SIDE WIRE
AO2
AO3
A29 A34
AO1 DA1 T/C HEAT GAUGE WIRE to BODY MAIN WIRE
A30
G73
A31
A33 A32 A66
AO3
[A] Title [G] Ground point code
Indicates a location on the forklift. Indicates a ground point code.
[B] Wire harness [H] Ground point name
Indicates a wire harness name. Indicates a ground point name.
[C] Reference page for electrical wiring routing [I] Harness to harness connector
Indicates a reference page showing a wire Indicates a connector code that joins two wire
harness location when the wire harness continues harnesses.
to the different electrical wiring routing. [J] Wire harness names
[D] Junction block Indicate two wire harness names for a wire
Indicates a junction block name and a connector harness and wire harness connection.
code to be connected. [K] Part connector
[E] Junction block connector Indicates a connector code connected to a part.
Indicates a connector code connected to a [L] Part name
junction block. Indicates a part name connected to a connector.
[F] Wire harness and junction block connection
Indicates a junction block name and a wire
harness name to be connected.
E
E1-4
INTRODUCTION
RELAY LOCATIONS
Relay locations show connectors connected to junction blocks, relays, fuses and internal circuit diagrams.
E2-20 E2-21
RELAY LOCATIONS
JUNCTION BLOCK:LEFT STEP(INNER CIRCUIT SEE PAGE E2-24) 1 ENGINE ROOM R/B:ENGINE ROOM LEFT
1A
90980-12506 BLACK 1B
90980-12383 * 1:15A E-THRO (4Y-E)
18 1 7.5A ECU-B2 (1DZ, 2Z)
19 2 19 1 * 2:7.5A (1DZ, 2Z)
20 3 20 2 15A (4Y-E)
21 4 21 3 * 3:DPF RELAY (1DZ, 2Z)
22 4 SPARE 30A BLR 1 25A 2
22 5 15A (4Y-E)
23 6 23 5
7 24 6 * 3:DPF RELAY (1DZ, 2Z)
24 SPARE 7.5A STA 1 30A 2
25 8 25 7 EFI MAIN RELAY (4Y-E)
26 9 26 8 * 4:C/OPN RELAY (4Y-E)
27 10 27 9 ASC RELAY (1DZ, 2Z) HOUR MET 2 7.5A 1 RR WIP 1 20A 2
28 11 28 10 * 5:EFI (4Y-E)
29 12 29 11 DPF (1DZ, 2Z) 2 1
13 30 12 ST 7.5A FR WIP 1 20A 2
30
31 14 31 13
32 15 32 14 GAUGE 2
10A
33 16 T/C FR RELAY 33 15
1 1 2
34 17 34 16
3 1 19 35 17 *3 BACK LP 2 10A
1 18 1 18
2 20 36 18 40A AM1
5 2 19 2 19 1
3 21
3 20 3 20 SFT 2 7.5A 1
1 4 2 4 22 5 3
4 21 4 21 1C
5 23
5 22 5 22 2
6 24 90980-12320 TURN 2 7.5A 1
6 23 6 23
7 25
7 24 7 24
3 8 26 18 1
8 25 8 25 2
5 9 27 19 2 IGN 2 *2 1
9 26 9 26
10 28 20 3 3 5 HORN 1 15A 2
1 4 2 10 27 10 27
11 29 21 4
11 28 11 28 1 SPARE 15A
12 30 22 5
12 29 12 29
T/C RR RELAY 13 31 23 6 *4 CDS 1 15A 2
13 30 13 30
14 32 24 7
14 31 14 31
15 33 25 8
15 32 15 32 *5 1 15A 2
16 34 26 9
16 33 16 33 DOUBLE HORN RELAY SPARE
17 35 27 10 10A
17 34 17 34
18 36 28 11 ALT-S 1 7.5A 2
1
29 12 ECU-IG 2 10A 1
30 13 5 3
WORK LP RELAY BCON LP RELAY STOP 1 7.5A 2
31 14 2
32 16
32 15
31 15 3 3 33 16
30 14 5 5 ACC-B 1 7.5A 2
34 17
29 13 2
28 12 1 2 1 2 24 12 3 5 TAIL 1
1D 7.5A 2
27 11 23 11
26 10 22 10 90980-12308 1
25 9 1 21 9 ECU-B 1 7.5A 2
12 24 LPG MAIN RELAY
24 8 20 8
5 3 11 23
23 7 19 7
22 6 2 18 6 10 22 *1 1 2
21 5 17 5 9 21 AM2 RELAY
HORN RELAY 8 20
1E 20 4 16 4 1
19 3 2 15 3 7 19 HTR 1 15A 2
90980-12311 18 2 14 2 6 18 5 3
3 5 17
17 1 13 1 2 WORK LP 1 15A 2
16 32 4 16
1
15 31 3 15
14 30 FLASHER RELAY 2 14 HEAD 1 15A 2
13 29 1 13 2
12 28 3 5
11 27
10 26 1
1 2
9 25 ST RELAY
8 24
7 23 40A AM2
6 22
5 21
4 20
3 19
2 18
1 17
E2-24
JUNCTION BLOCK (INNER CIRCUIT) (1/3)
13 1C 1 1D
31 1A 14 1D
33 1B BCON LP RELAY 15 1D
5 3
15 1E 32 1A
1 2 16 1E
15 1B
16 1B
23 1E
28 1B
25 1E
24 1E
13 1A WORK LP RELAY
5 3
15 1C 13 1E
9 1E 31 1B
1 2
19 1B 29 1B
36 1B 10 1E
19 1E
4 4 1A
3
5 1A
1 2
8 1B 7 1A
3 1B T/C FR RELAY 13 1D
17 1B 2 1E
22 1E
4 3 1A
18 1E 3
2 1A
34 1B
1 2 1 1B
18 1D
19 1A
11 1C T/C RR RELAY
11 1E
1 3
28 1C 35 1B
26 1B 2
7 1D
22 1B
FLASHER RELAY 8 1D
24 1A
21 1E
25 1B
33 1C
23 1B
29 1C
3 1C
12 1A
4 1C
30 1C
21 1A
2 1C
E1-5
INTRODUCTION
[A] Junction block /relay block
Indicates a junction block or relay block name, its location and a reference page for an internal circuit
diagram.
[B] Connector code and color
Indicates the code and color of a connector connected to a junction block.
[C] Connector part number
Indicates the part number of a connector.
[D] Connector shape and terminal number
Indicates a connector shape on the junction block side.
Numbers indicate terminal numbers.
[E] Connector shape and terminal number
Indicates a connector shape on the wire harness side.
Numbers indicate terminal numbers.
[F] Fuse
Indicates a fuse name and capacity.
Terminal 1 is on the primary side and terminal 2 is on the secondary side.
[G] Internal circuit diagram
Indicates an internal circuit diagram of a junction block.
[H] Connector code and terminal number
Indicates a connector code and a terminal number connected to a junction block.
E1-6
(BAT)
E3-12
* 1: GASOLINE
* 2: LPG
15A * 3: WITH GASOLINE INDICATOR LAMP
EFI * 4: CNG
1
SYSTEM CIRCUITS
B-Y B-Y
a
LG
b
LG-R
c
O
d
R-W *1 R-W
Chapter 3 SYSTEM CIRCUITS (1)
e
*1 *2 R-L
f
R-L
g
*2
*1
*1
R-B
A 65(A),G 73(B) A 65(A),G 73(B)
R-W
R-W
JUNCTION CONNECTOR (A) 2 A JUNCTION CONNECTOR (A) 7 A 12 B 10 B
R-L
R-L
R-W
(LPG)
6 A 2 B 1 B 6 B 5 B 1 A 8 A
9 8 7
Y
Y
Y
*1
*2
*1
R-B
R-W
7 GK1 *2 4 AC3 3 AC3
R-B
R-B
1 2 3 4 5 6
8 GK1 7 GK2 *4
(GASOLINE)
JUNCTION CONNECTOR
A 66
*1
*1
connections from fuses to ground points of each system.
R-B
R-L
R-B
R-L
R-L
R-L
R-L
R-W
(GASOLINE)
12 1D
Y
Y
*2
*2
*4
1 TC2 2 TC2
Y-B
R-B
INTRODUCTION
1 A *2
ENGINE CONTROL (4Y-E)
1
4 1D 9 AC2
1 B *4
*3
R-B
R-B
R-W
6 3
1(A)
5(B)
LPG SOLENOID
(MAIN)
R-L
GAS LPG
K
OIL PRESSURE SWITCH (*1)
K
OIL PRESSURE SWITCH (*2)
2 2 A *2
R-L
2 B *4
6
IG
LPG CHANGE SWITCH
T
R-L
4 h
*2
*1
L-B
W-B
R-L *1 R-L
i
*1 R-L
2 GK1 6 GK1 *2 j
6 GK2 *4 *3
R-B
k
*2
*1
L-B
W-B
L-B
l
*1 R-L
m
W-B
n
GG
source circuit diagram shows the connections from the power source to fuses. A system diagram shows the
A system circuit consists of a power source circuit diagram and respective system circuit diagrams. A power
E1-7
INTRODUCTION
[A] Section page [G] Page-to-page connection code
Indicates the page number for the section. Indicates a wire harness continues onto the
[B] System title following page from the matching code.
Indicates a system name.
[H] Harness to harness connector
[C] Part name and connector code
Indicates a part name and connector code to be Indicates a connector code that connects two wire
connected.For connector shapes, refer to chapter harnesses.
6 CONNECTOR LIST. For the connector shape, refer to chapter 6
CONNECTOR LIST.
C7 Part connector Harness to harness connector
8 Terminal number
The wire harness in which the connector is AK1
located.
Wire harness to be connected
Example: "C" indicates a connector used in
Example: "AK" means a connection of the
the C wire harness.
female connector*1 of the "A" wire and the
For wire harness names, refer to Chapter 2
male connector*2 of the "K" wire.
ELECTRICAL WIRING ROUTINGS and
*1: A female connector has a female
RELAY LOCATIONS.
terminal.
Serial number allocated to the connector
*2: A male connector has a male
terminal.
D11 (A), D42 (D) Serial number of a connector
Connector number Male terminal side
Used to indicate different connectors when
multiple connectors are connected to a part,
or multiple types of connectors are used
according to specifications.
[D] Fuse
Indicates a fuse name and capacity.
Terminal 1 is on the primary side and terminal 2 is
on the secondary side.
For fuse installation positions, refer to chapter 2
ELECTRICAL WIRING ROUTINGS and RELAY
LOCATIONS.
[E] Power supply information
Indicates the ignition key position when power is
supplied to a fuse.
[F] Specification information
Indicates that connectors or wire colors vary
depending on forklift models, engine types or
specifications.
E1-8
(BAT)
E3-12
* 1: GASOLINE
* 2: LPG
15A * 3: WITH GASOLINE INDICATOR LAMP
EFI * 4: CNG
B-Y B-Y
a
LG
b
LG-R
c
O
d
R-W *1 R-W
Chapter 3 SYSTEM CIRCUITS (2)
e
*1 *2 R-L
f
R-L
g
*2
*1
*1
R-B
A 65(A),G 73(B) A 65(A),G 73(B)
R-W
R-W
JUNCTION CONNECTOR (A) 2 A JUNCTION CONNECTOR (A) 7 A 12 B 10 B
R-L
R-L
R-W
(LPG)
6 A 2 B 1 B 6 B 5 B 1 A 8 A
9 8 7
Y
Y
Y
*1
*2
*1
R-B
R-W
7 GK1 *2 4 AC3 3 AC3
R-B
R-B
1 2 3 4 5 6
8 GK1 7 GK2 *4
(GASOLINE)
JUNCTION CONNECTOR
A 66
*1
*1
R-B
R-L
R-B
R-L
R-L
R-L
R-L
R-W
(GASOLINE)
12 1D
Y
Y
*2
*2
*4
1 TC2 2 TC2
Y-B
R-B
INTRODUCTION
1 A *2
ENGINE CONTROL (4Y-E)
1
4 1D 9 AC2
1 B *4
*3
R-B
R-B
R-W
6 3
1(A)
5(B)
LPG SOLENOID
(MAIN)
R-L
GAS LPG
K
OIL PRESSURE SWITCH (*1)
K
OIL PRESSURE SWITCH (*2)
2 2 A *2
R-L
2 B *4
6
IG
LPG CHANGE SWITCH
T
R-L
4 h
*2
*1
L-B
W-B
R-L *1 R-L
i
*1 R-L
2 GK1 6 GK1 *2 j
6 GK2 *4 *3
R-B
k
*2
*1
L-B
W-B
L-B
l
*1 R-L
m
W-B
n
GG
E1-9
INTRODUCTION
[I] Terminal number [L] Wire color
Indicates a terminal number of a connector to be Indicates a wire harness color.
connected. When two alphabetical codes are indicated, for
[J] Junction block connector example "W-B", the first letter indicates the basic
Indicates a connector code connected to a wire color and the second letter indicates the color
junction block. of the stripe.
F o r a c o n n e c t o r s h a p e , r e f e r t o c h a p t e r 2 Code Wire Color Code Wire Color Code Wire Color
ELECTRICAL WIRING ROUTINGS and RELAY SB Sky Blue
B Black L Blue
LOCATIONS.
BR Brown LG Light Green V Violet
Junction block connector DG Dark Gray O Orange W White
Inside of a junction block Y Yellow
G Green P Pink
Junction block type GR Gray R Red AM Amber
Serial number allocated to the connector.
Example: "1B" indicates connector B in the
center junction block. Example : W-B W B
Terminal number (White) (Black)
A number inside indicates a relay block or [M] Switch
fuse block. Circuit diagrams are shown with the switches in
For shapes, refer to chapter 2 ELECTRICAL the OFF position.
WIRING ROUTINGS and RELAY LOCATIONS. For switch operation conditions, refer to the repair
manual.
[K] Ground point code
Indicates a ground point code.
For ground point positions, refer to chapter 2
ELECTRICAL WIRING ROUTINGS and RELAY
LOCATIONS.
Ground point code
Wire harness connected to the ground point
A ground point is indicated by an alphabetical
code.
Example: "MJ" indicates that the M wire
harness is grounded at point J.
E1-10
INTRODUCTION
REFERENCE PAGE
PARTS
Code See Page Code See Page Code See Page Code See Page
A 20 E2-8 G 7 E2-2 G 21 E2-2 K 6 E2-2
A 25 E2-10 G 8 E2-2 G 25 E2-2 O 2 E2-14
A 27 E2-10 G 9 E2-2 G 26 E2-2 Q 1 E2-8
A 35 E2-10 G 10 E2-2 G 27 E2-10 S 12 E2-14
A 36 E2-10 G 11 E2-2 G 28 E2-10 T 6 E2-16
A 65 E2-10 G 12 E2-2 G 29 E2-10 a 1 E2-8
A 66 E2-10 G 13 E2-2 G 73 E2-10
C 1 E2-16 G 16 E2-2 K 1 E2-2
C 3 E2-16 G 18 E2-2 K 2 E2-2
G 6 E2-2 G 19 E2-2 K 3 E2-2
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Blocks Name or Joining Wire Harness and J/B
1 E2-10 Engine Room R/B
1C E2-19 BODY MAIN WIRE to J/B
1D E2-18 ENGINE WIRE to J/B
1E E2-18 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AC2 E2-10 BODY MAIN WIRE to SIDE RH WIRE
AC3 E2-10 BODY MAIN WIRE to SIDE RH WIRE
AG1 E2-10 BODY MAIN WIRE to ENGINE WIRE
AO1 E2-10 BODY MAIN WIRE to LH SIDE WIRE
Aa1 E2-8 BODY MAIN WIRE to SUB ACCEL WIRE
GK1 E2-2 ENGINE WIRE to ENGINE SUB WIRE
GK2 E2-2 ENGINE WIRE to ENGINE SUB WIRE
QA1 E2-8 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
SO1 E2-14 REAR UPPER MAIN WIRE to LH SIDE WIRE
TC2 E2-16 REAR UPPER SUB RH WIRE to SIDE RH WIRE
TS1 E2-16 REAR UPPER SUB RH WIRE to REAR UPPER MAIN WIRE
EARTH
Code See Page Name
AB E2-10 FRONT PLATE LEFT OUTSIDE EARTH
GF E2-2 ENGINE UPPER EARTH
GG E2-2 ENGINE UPPER EARTH
OK E2-14 REAR PILLER LEFT UNDER EARTH
[A] Parts
Indicates pages showing electrical wiring routings for the parts.
[B] Relay blocks and junction blocks
Indicates titles and pages showing electrical wiring routings for the relay blocks or junction blocks.
[C] Connections of wire harness and wire harness
Indicates titles and pages showing electrical wiring routings for the connections of two wire harnesses.
[D] Ground points
Indicates titles and pages showing electrical wiring routings for the ground points.
E1-11
INTRODUCTION
Chapter 4 GROUND POINTS
GROUND POINTS
These tables describe related systems for each ground point.
E4-2
GROUND POINTS
CODE GROUND POINT LOCATION SYSTEM NAME PAGE
SAS/OPS SYSTEM E3-36
CLEARANCE LAMP E3-72
STOP LAMP E3-76
STROBE LIGHT E3-52
AA FRONT PLATE LEFT OUTSIDE
TURN SIGNAL LAMP E3-70
BACK UP LAMP BUZZER E3-74
HEAD LAMP E3-68
POWER SHIFT TRANSMISSIN E3-32
SAS/OPS SYSTEM E3-36
ENGINE CONTROL (4Y-E) E3-10
COOLER E3-80
AB FRONT PLATE LEFT OUTSIDE CLEARANCE LAMP E3-72
COMBINATION METER E3-54
BACK UP LAMP BUZZER E3-74
WET BRAKE E3-34
DIAG E3-42
COOLER E3-80
STARTING E3-6
STROBE LIGHT E3-52
TURN SIGNAL LAMP E3-70
HEATER E3-78
AC FRONT PLATE LEFT OUTSIDE
FRONT WIPER AND WASHER E3-60
HEAD LAMP E3-68
HORN E3-64
REAR WIPER AND WASHER E3-62
REAR WORK E3-28
Chapter 5 FUSES FOR POWER
FUSES FOR POWER
These tables describe power distribution from each power supply (fuse or fusible link) to various systems.
E5-3
FUSE FOR POWER SUPPLY
FUSIBLE LINK BLOCK ASSY
FUSE SYSTEM Page
GLOW E3-76
100A GLOW
INTAKE HEATER E3-84
120A ALT CHARGING E3-96
ENGINE ROOM R/B
FUSE SYSTEM Page
OPS SYSTEM E3-250
7.5A ACC-B
SAS/OPS SYSTEM E3-258
7.5A ALT-S CHARGING E3-194
7.5A ECU-B SAS/OPS SYSTEM E3-234
BACK UP LAMP BUZZER E3-220
10A BACK LP REAR WORKING LAMP E3-204
STROBE LIGHT E3-182
GLOW E3-162
INTAKE HEATER E3-166
ENGINE CONTROL (4Y-E) E3-170
FUEL E3-278
GAUGE REAR WIPER E3-76
E1-12
INTRODUCTION
Chapter 6 CONNECTOR LIST
CONNECTOR LIST
E6-3
CONNECTOR LIST
A 43 A 44 A 45 A 46 A 47
DARK GRAY DARK GRAY DARK GRAY
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 1 2 2 1 1 2
7 8 9 10 11 12 13 14
90980-11162 3 4
10 11 12 13 14 15 16 17 18 90980-11168
90980-10807 90980-10942
90980-11594
A 48 A 49 A 50 A 51 A 52 A 53
DARK GRAY BLACK BLACK GRAY BLACK
2 1 1 2 1 2 4 3 2 1 4 3 2 1 1 2
4 3 8 7 6 5 8 7 6 5
90980-11235 90980-11051 90980-11051
90980-10941 90980-10896 90980-10890
A 54 A 55 A 56 A 57 A 58 A 59 A 60
GRAY GRAY BLACK GRAY GRAY BLACK
2 1 1 2 3 1 1 2
1 2 1 2 1 2
2
90980-11051 90980-11296 9098 0-11162
90980-10899 90980-10899 90980-11168
9098 0-10213
A 64 A 65 A 66 A 67
BLACK BLUE
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 1 2 3 4 5 6 6 5 4 3 2 1
12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12 7 8 9 10 11 12 15 14 13 12 11 10 9 8 7
90980-11915 90980-11661 90980-11661 90980-11088
[A] Connector shape and terminal number
Indicates the connector shape on the wire harness side, which is connected to a part.
Numbers indicate terminal numbers that are used in the circuit diagrams.
[B] Connector color
Indicates a connector color.
[C] Part connector
Indicates a connector number connected to a part.
The code is the same as that used in the electrical wiring routing.
[D] Connector part number
Indicates the part number of a connector.
E1-13
INTRODUCTION
HARNESS TO HARNESS CONNECTOR
E6-13
WIRE to WIRE
SO3 ST1 SV1 SW1
BLACK GRAY
1 2 1
1 2 2 1 1
1 2 2 1 2 1 3 4 5 6
3 4 4 3 3 4 6 5 4 3 2 3
4 3 3 2
90980-10797 90980-109 80
90980-11036 90980-10795
90980-10796 90980-10979
90980-11035 90980-10794
SW2 Sx1
GRAY
1 2 3 1
3 2 1 1 2
4 5 6 7 8 99144 -12239
8 7 6 5 4
90980 -10906
90980-10799
90980-10798
TC1 TC2 TS1
DARK GRAY
1 2 3 4 5 6 6 5 4 3 2 1 1 1
1 2 3 3 2 1
7 8 9 10 11 12 13 14 15 15 14 13 12 11 10 9 8 7 4 5 6 6 5 4 90980-10871
90980-11089 90980-10870
90980-11088 90980-11194
90980-11193
[A] Connector shape and terminal number
Indicates the connector shape that connects two wire harnesses.
On left: Female connector*1 shape (This example indicates a connector for the G wire)
On right: Male connector*2 shape (This example indicates a connector for the K wire)
*1: A female connector has a female terminal.
*2: A male connector has a male terminal.
B] Connector color
Indicates a connector color.
[C] Harness to harness connector
Indicates a connector code that connects two wire harnesses
The code is the same as that used in the electrical wiring routing and wiring diagram.
[D] Connector part number
Indicates the part number of a connector
E1-14
INTRODUCTION
ABBREVIATIONS
The following abbreviations are used in this section.
Abbreviations Explanation
ASC Auto Speed Control
ASSY Assembly
CNG Compressed Nutural Gas
DPF Diesel Particulate Filter
ECU Electronic Control Unit
FR Front
J/B Junction Block
LH Left-Hand
LPG Liquefied Petroleum Gas
M/T Manual Transmission
OPS Operator Presence Sensing
PS Power Steering
R/B Relay Block
RH Right-Hand
RR Rear
SAS System of Active Stability
SOL Solenoid
T/C Torque Converter & Transmission
W/ With
W/O Without
E1-15
INTRODUCTION
GLOSSARY OF TERMS AND SYMBOLS
BATTERY GROUND RELAY SWITCH, MANUAL
1. NORMALLY 1. NORMALLY
CLOSED OPEN
CAPACITOR HEADLIGHTS
(Condenser)
2. NORMALLY 2. NORMALLY
1. SINGLE OPEN CLOSED
FILAMENT
CIGARETTE LIGHTER RELAY, DOUBLE THROW SWITCH, DOUBLE THROW
2. DOUBLE
FILAMENT
DIODE HORN RESISTOR, TAPPED SWITCH, IGNITION
DIODE, ZENER LIGHT SENSOR (Termistor)
LED METER, ANALOG SENSOR SWITCH, WIPER PARK
(Light Emitting Diode)
PHOTODIODE METER, DIGITAL SHORT PIN WIRES
1. NOT
CONNECTED
MOTOR RESISTOR FUSE
2. SPLICED
SPEAKER RESISTOR,
VALIABLE or RHEOSTAT SOLENOID HIGH-TENSION WIRE
TRANSISTOR
MEMO
E2-1
CHAPTER 2 ELECTRICAL WIRING ROUTINGS AND
RELAY LOCATIONS
E2
ELECTRICAL WIRING ROUTINGS
ENGINE ROOM (4Y-M) ..................................................................... E2-2
ENGINE ROOM (4Y-E) ..................................................................... E2-4
ENGINE ROOM (1DZ) ....................................................................... E2-6
ENGINE ROOM (2Z) .......................................................................... E2-8
INSTRUMENT PANEL .................................................................... E2-10
FRONT BODY ................................................................................. E2-12
MAST AREA .................................................................................... E2-14
REAR BODY (NO.1) ........................................................................ E2-16
REAR BODY (NO.2) ........................................................................ E2-18
RELAY LOCATIONS
JUNCTION BLOCK (J/B) / RELAY BLOCK (R/B) ........................... E2-20
SYMBOLS WIRE NAME SYMBOLS WIRE NAME
A BODY MAIN WIRE Q INSTRUMENT PANEL WIRE
B BODY SUB NO.1 WIRE R FR STAY WIRE RH
C SIDE RH WIRE S RR UPR MAIN WIRE
D T/C HEAT GAUGE WIRE T RR UPR SUB RH WIRE
E DPF AC WIRE U HEAD GUARD SW WIRE
F DPF HEATER WIRE V RR UPR SUB LH WIRE
G BATTERY STARTER WIRE X HOOD MAIN WIRE
H BATTERY STARTER WIRE Y HOOD SUB NO.1 WIRE
I BATTERY EARTH WIRE Z RR LWR WIRE
J ENGINE EARTH WIRE a SUB ACCEL WIRE
K ENGINE SUB WIRE b MAST SENSOR WIRE
L BATTERY WIRE c LICENCE LAMP WIRE
M LPG PRESSURE SWITCH WIRE d FR STAY WIRE LH
N BATTERY EARTH WIRE h WIPER SUB WIRE
O LH SIDE WIRE
E2-2
ELECTRICAL WIRING ROUTINGS
ENGINE ROOM(4Y-M)
エンジン_4YM
H BATTERY STARTER WIRE
H3
H1
G24
to E2-12
G26
G23
G22
G ENGINE WIRE
J ENGINE EARTH WIRE
G65 G34
J3
J1
I1 K1
G4
GK1
I BATTERY EARTH WIRE
K3
G1
K ENGINE SUB WIRE G20
G14
IH
M1
GG GF
KM1 M2
M LPG PRESSURE SWITCH WIRE
[RUSSIA]
K7
K8
GK1
E2-3
ELECTRICAL WIRING ROUTINGS
G1 ALTERNATOR
G4 ALTERNATOR
G14 WATER TEMP SENDER
G20 DISTRIBUTOR
G22 OIL PRESS SWITCH
G23 STARTER
G24 FUSIBLE LINK BLOCK ASSY
G26 TACHO CHECK
G34 FUEL CUT SOLENOID
G65 GAS SOLENOID
H1 STARTER
H3 BATTERY
I1 BATTERY
J1 STARTER
J3 BATTERY
K1 LPG SOLENOID(SLOW)
K3 LPG SOLENOID(MAIN)
K7 LPG SOLENOID(SLOW)
K8 LPG SOLENOID(MAIN)
M1 LPG PRESSURE SW
M2 LPG PRESSURE SW
GKI ENGINE WIRE to ENGINE SUB WIRE
KM1 ENGINE SUB WIRE to LPG PRESSURE SWITCH WIRE
GF ENGINE UPPER EARTH
GG ENGINE UPPER EARTH
IH REAR PILLER LEFT UNDER EARTH
E2-4
ELECTRICAL WIRING ROUTINGS
ENGINE ROOM(4Y-E)
G ENGINE WIRE
H BATTERY STARTER WIRE
G12
H1 G11
H3 G23
to E2-12
G24 G13
G10
G22
G26
J ENGINE EARTH WIRE
J3 J1
G7
I1 G14
G6
G25
GK1 G9
G8
I BATTERY EARTH WIRE
K ENGINE SUB WIRE G4
G2
K1
G21
G16
IH G19
GG GF
G18
K2 K3
M1
KM1 M2
M LPG PRESSURE SWITCH WIRE
E2-5
ELECTRICAL WIRING ROUTINGS
G2 ALTERNATOR GF ENGINE UPPER EARTH
G4 ALTERNATOR
G6 THROTTLE POSITION SENSOR (WITH MOTOR) GG ENGINE UPPER EARTH
G7 LPG INJCTOR
G8 INJECTOR NO.1 IH REAR PILLER LEFT UNDER EARTH
G9 INJECTOR NO.2
G10 INJECTOR NO.3
G11 INJECTOR NO.4
G12 VACUUM SENSOR
G13 FCM STEP MOTOR
G14 WATER TEMP SENDER
G16 WATER TEMPERATURE SENSOR
G18 G2 SENSOR
G19 DISTRIBUTOR
G21 IGNITION COIL
G22 OIL PRESS SWITCH
G23 STARTER
G24 FUSIBLE LINK BLOCK ASSY
G25 IGNITER
G26 TACHO CHECK
H1 STARTER
H3 BATTERY
I1 BATTERY
J1 STARTER
J3 BATTERY
K1 LPG SOLENOID(SLOW)
K2 LPG RESISTOR
K3 LPG SOLENOID(MAIN)
M1 LPG PRESSURE SW
M2 LPG PRESSURE SW
GK1 ENGINE WIRE to ENGINE SUB WIRE
KM1 ENGINE SUB WIRE to LPG PRESSURE SWITCH WIRE
E2-6
ELECTRICAL WIRING ROUTINGS
ENGINE ROOM(1DZ)
A BODY MAIN WIRE
G ENGINE WIRE to E2-12
J ENGINE EARTH WIRE G51
G42
H2 G50 G45
JL
G41 G44
G33 G49
H3 G37
G69
G67
to E2-12 G52
G36
G24 G46
J2
GJ
G53
H BATTERY STARTER WIRE G22
I2 G30
G54
G32 G4
I BATTERY EARTH WIRE
G34
GL G1
G31 G17
G14
IH
E2-7
ELECTRICAL WIRING ROUTINGS
G1 ALTERNATOR
G4 ALTERNATOR
G14 WATER TEMP SENDER
G17 WATER TEMPERATURE SENSOR
G22 OIL PRESS SWITCH
G24 FUSIBLE LINK BLOCK ASSY
G30 GLOW PLUG
G31 INJECTOR PUMP
G32 STARTER
G33 GLOW PLUG RELAY
G34 FUEL CUT SOLENOID
G36 OPEN CLOSE SWITCH
G37 STEP MOTOR
G41 JUNCTION CONNECTOR(G)
G42 JUNCTION CONNECTOR(H)
G44 AC RELAY
G45 AC RELAY
G46 DPF CHECKER
G49 DPF VALVE
G50 DPF BLOWER
G51 DPF BUZZER
G52 AIR FLOW SENSOR
G53 PRESS SENSOR
G54 TEMP SENSOR
G67 DPF ECU
G69 DPF ECU
H2 STARTER
H3 BATTERY
I2 BATTERY
J2 STARTER
GJ JUNCTION BLOCK IN FRONT INSIDE EARTH
GL JUNCTION BLOCK IN FRONT INSIDE EARTH
IH REAR PILLER LEFT UNDER EARTH
JL FRONT PLATE LEFT INSIDE EARTH
E2-8
ELECTRICAL WIRING ROUTINGS
ENGINE ROOM(2Z)
A BODY MAIN WIRE
G ENGINE WIRE to E2-12
G51
G57 G42
G61
JL G50 G45
G59
G41 G44
G60
G37 G49
L1 G69
GJ
G24 G70
G68
to E2-12 G52
G36
G58 G46
J2
J ENGINE EARTH WIRE
G53
G22
N1
G31
L2
G34 G72
L BATTERY WIRE
G4
GL
G32 G17 G1
I3 G56 G14
I BATTERY EARTH WIRE
N2
IH
N BATTERY EARTH WIRE
H3
H2
H BATTERY STARTER WIRE
I2
I BATTERY EARTH WIRE
IH
E2-9
ELECTRICAL WIRING ROUTINGS
G1 ALTERNATOR GJ JUNCTION BLOCK IN FRONT INSIDE EARTH
G4 ALTERNATOR
G14 WATER TEMP SENDER GL JUNCTION BLOCK IN FRONT INSIDE EARTH
G17 WATER TEMPERATURE SENSOR
G22 OIL PRESS SWITCH IH REAR PILLER LEFT UNDER EARTH
G24 FUSIBLE LINK BLOCK ASSY
G31 INJECTOR PUMP JL FRONT PLATE LEFT INSIDE EARTH
G32 STARTER
G34 FUEL CUT SOLENOID
G36 OPEN CLOSE SWITCH
G37 STEP MOTOR
G41 JUNCTION CONNECTOR(G)
G42 JUNCTION CONNECTOR(H)
G44 AC RELAY
G45 AC RELAY
G46 DPF CHECKER
G49 DPF VALVE
G50 DPF BLOWER
G51 DPF BUZZER
G52 AIR FLOW SENSOR
G53 PRESS SENSOR
G56 INTAKE HEATER
G57 INTAKE HEATER RELAY
G58 INTAKE HEATER RELAY
G59 INTAKE HEATER RELAY
G60 INTAKE HEATER RELAY
G61 INTAKE HEATER RELAY
G68 DPF ECU
G69 DPF ECU
G70 DPF ECU
G72 TEMP SENSOR
H2 STARTER
H3 BATTERY
I2 BATTERY
I3 BATTERY
J2 STARTER
L1 BATTERY
L2 BATTERY
N1 BATTERY
N2 BATTERY
E2-10
ELECTRICAL WIRING ROUTINGS
INSTRUMENT PANEL
A BODY MAIN WIRE R FR STAY WIRE RH b MAST SENSOR WIRE
B BODY SUB NO.1 WIRE U HEAD GUARD SW WIRE d FR STAY WIRE LH
Q INSTRUMENT PANEL WIRE a SUB ACCEL WIRE h WIPER SUB WIRE
*1:T/C
*2:M/T
Ah1 h2
to E2-14
h h1 QA1
to E2-14 hA1 *2
*1 A7 Q1
A7 A20 Q2 AQ1 U
A21
A8 A9 Q
A22
A49
d A23
A69 R
A12
A68 A10
to E2-14 A51
A52
B
A41
A A19 A11
A1
A2 A3
A4 A6 b
A5 to E2-18
A70
to E2-12
A18
a1 A42
Aa1 a
[W/O SAS/OPS SYSTEM] [W/ SAS/OPS SYSTEM]
A58 A59 A67 Q2 A67 A14
Q1 Q1
A15
A10
A16
A12
A56
AQ1 A13
A11
AQ1
QA1
E2-11
ELECTRICAL WIRING ROUTINGS
A1 HORN SWITCH AQ1 BODY MAIN WIRE to INSTRUMENT PANEL WIRE
A2 IGNITION SWITCH Aa1 BODY MAIN WIRE to SUB ACCEL WIRE
A3 STEERING SENSOR Ah1 BODY MAIN WIRE to WIPER SUB WIRE
A4 LIGHT CONTROL SW QA1 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
A5 STEERING SOLENOIDE hA1 WIPER SUB WIRE to BODY MAIN WIRE
A6 STOP LAMP SWITCH
A7 BRAKE WARNING SWITCH
A8 OPS WARNING BUZZER
A9 PARKING BRAKE SWITCH
A10 TILT SOLENOID
A11 LIFT SOLENOID
A12 UNLOAD SOLENOID
A13 TILT SWITCH
A14 LIFT SWITCH
A15 NEWTRAL TILT SWITCH
A16 LOAD INDICATOR
A18 PRESS SENSOR
A19 SPEED SENSOR
A20 SAS/OPS ECU
A21 SAS/OPS ECU
A22 OPS ELECTRONIC CONTROL UNIT
A23 MINI LEVER ECU
A41 LEFT T/C SHIFT SWITCH
A42 TILT ANGLE SENSOR
A49 HORN
A51 CONTROL VALVE PUSH SOLENOID
A52 CONTROL VALVE PULL SOLENOID
A56 BACK TILT SOLENOID
A58 SPEED METER
A59 SPEED METER
A67 TO DPF DISPLAY
A68 WET BRAKE BUZZER
A69 WET BRAKE LAMP
A70 PRESSURE SW
Q1 COMBINATION METER
Q2 DISPLAY
a1 ACCEL SENSOR
h1 FRONT WIPER RELAY
h2 FRONT WIPER MOTOR
E2-12
ELECTRICAL WIRING ROUTINGS
FRONT BODY
G ENGINE WIRE
C SIDE RH WIRE
to E2-2 1 ENGINE ROOM R/B
to E2-4
to E2-6
A24
to E2-8
to E2-18
to E2-6
to E2-8 A57
AA1
A48
A37
AC3 A40 to E2-16
A38
AG3
A47 A46
A25
AC2
AC4
A45
A39 D1
A54
AD A55 to E2-10
DA1
O LH SIDE WIRE
AC
AB
AA
D T/C HEAT GAUGE WIRE A BODY MAIN WIRE
[4Y-M]
G66
J/B
1A
AG1
1B
A26 AG1
1C
A66 G29
1D
[1DZ,2Z]
1E AG2
A71
AO2 G35
A64 G63
G73
AG1
A65 G43
AO1
A36
AO3 A35
A27 G27 [1DZ-ASC,2Z-ASC]
A32 G39
AG2
G28
G35
A31
A30 G63
AG1
A34
G43
A29
A33 G38
E2-13
ELECTRICAL WIRING ROUTINGS
A24 FUSIBLE LINK BLOCK ASSY AA1 BODY MAIN WIRE to BODY MAIN WIRE
A25 DIAGNOSIS AC2
A26 DIODE AC3 BODY MAIN WIRE to SIDE RH WIRE
A27 JUNCTION CONNECTOR AC4
A29 CAN JOINT CONNECTOR AG1
A30 CAN JOINT CONNECTOR AG2 BODY MAIN WIRE to ENGINE WIRE
A31 CAN JOINT CONNECTOR AG3
A32 CAN JOINT CONNECTOR AO1
A33 CAN JOINT CONNECTOR AO2 BODY MAIN WIRE to LH SIDE WIRE
A34 CAN JOINT CONNECTOR AO3
A35 ENGINE ECU DA1 T/C HEAT GAUGE WIRE to BODY MAIN WIRE
A36 ENGINE ECU
A37 LPG WARNING RELAY
A38 LPG WARNING BUZZER AA FRONT PLATE LEFT OUTSIDE EARTH
A39 NEWTRAL START SWITCH
A40 BACK UP LAMP SWITCH AB FRONT PLATE LEFT OUTSIDE EARTH
A45 MATCHING CONNECTOR
A46 MATCHING CONNECTOR AC FRONT PLATE LEFT OUTSIDE EARTH
A47 SHIFT SOLENOID(2
A48 SHIFT SOLENOID(2 AD TRANSMISSION UPPER EARTH
A54 SHIFT SOLENOID(1
A55 SHIFT SOLENOID(1
A57 TO PUSH/PULL RLY
A64 JUNCTION CONNECTOR(J)
A65 JUNCTION CONNECTOR(A)
A66 JUNCTION CONNECTOR(B)
A71 DIODE (WET BRAKE)
D1 T/C OIL TEMP SENSOR
G27 ENGINE ECU
G28 ENGINE ECU
G29 JUNCTION CONNECTOR(B)
G35 GLOW PLUG TIMER
G38 ASC ECU
G39 ASC ECU
G43 JUNCTION CONNECTOR(E)
G63 PRE HEATING TIMER
G66 ENGINE REVOLUTION SWITCH
G73 JUNCTION CONNECTOR(A)
1A
1B BODY MAIN WIRE to J/B
1C
1D ENGINE WIRE to J/B
1E LH SIDE WIRE to J/B
E2-14
ELECTRICAL WIRING ROUTINGS
MAST AREA
*1:V MAST
*2:FSV MAST
*3:W/ STAY [W/ STAY]
*4:W/ MAST
d2
d5
U2 U4
U1 U5 d FR STAY WIRE LH b
U3
R FR STAY WIRE RH [W/ MAST]
d2 d1
*2 b
b1
U HEAD GUARD SW WIRE *1
b2
a
dA1 *4
d
UA1
dA1 *3
UA2
BA1
d
UB1 c
A BODY MAIN WIRE
to E2-18
B BODY SUB NO.1 WIRE
*3 RA1 b1 *1
b3 *2
*4 RA1
b MAST SENSOR WIRE
[W/ STAY] Ab1
R2
R5
[W/ MAST]
R2 R1
c
E2-15
ELECTRICAL WIRING ROUTINGS
R1 FRONT COMBINATION LAMP RIGHT
R2 HEAD LAMP RIGHT
R5 FRONT COMBINATION LAMP RIGHT
U1 HEARTER SWITCH
U2 FRONT WIPER SWITCH
U3 REAR WIPER SWITCH
U4 BEACON LAMP SWITCH
U5 LPG WARNING SWITCH
b1 MAST SWITCH
b2 MAST SWITCH2
b3 ULTRA SONIC SSR
d1 FRONT COMBINATION LAMP LEFT
d2 HEAD LAMP LEFT
d5 FRONT COMBINATION LAMP LEFT
Ab1 BODY MAIN WIRE to MAST SENSOR WIRE
BA1 BODY SUB NO.1 WIRE to BODY MAIN WIRE
RA1 FR STAY WIRE RH to BODY MAIN WIRE
UA1
HEAD GUARD SW WIRE to BODY MAIN WIRE
UA2
UB1 HEAD GUARD SW WIRE to BODY SUB NO.1 WIRE
dA1 FR STAY WIRE LH to BODY MAIN WIRE
E2-16
ELECTRICAL WIRING ROUTINGS
REAR BODY(NO.1)
*1:W/O *2
*2:W/ REAR WIPER
Y4 Y8
Y2
Y3
Y1
V RR UPR SUB LH WIRE
Y9
S RR UPR MAIN WIRE
Y7
V4
Y6 Y5
V3
S4
to E2-18
S11
S10
S8
S9 *2
S9 *1
a
SV2
S3 c3
c4
S2
S1 *2 c LICENCE LAMP WIRE Y HOOD SUB NO.1 WIRE
S1 *1
Sc1
a
X1 YX2
X HOOD MAIN WIRE
YX1
OK XO4
XO2
SO3
to E2-12
XO1
XO3
O1
SO1
ZO1
O2 Z1 Z3
SO2
O3
O LH SIDE WIRE
Z RR LWR WIRE
E2-17
ELECTRICAL WIRING ROUTINGS
O1 YAW RATE SENSOR
O2 FUEL SENDER GAUGE & FUEL PUMP
O3 SEDIMENTARY SWITCH
S1 WORK LAMP LEFT
S2 REAR WIPER MOTOR
S3 REAR COMBINATION LAMP LEFT
S4 REAR COMBINATION LAMP RIGHT
S8 REAR WIPER RELAY
S9 WORK LAMP RIGHT
S10 BEACON LAMP
S11 REAR HORN SWITCH
V3 DOME LAMP
V4 DOME LAMP
X1 SEAT SWITCH
Y1 NEUTRAL TILT SWITCH
Y2 ATTACHMENT LEVER1
Y3 ATTACHMENT LEVER2
Y4 T/C SHIFT SWITCH
Y5 TILT LEVER
Y6 LIFT LEVER
Y7 LOAD INDICATOR SWITCH
Y8 CONTROL VALVE LEVER 3,4SELECT SWITCH
Y9 SHORT CONNECTOR
Z1 SWING LOCK SOLENOID
Z3 TIRE ANGLE SENSOR
c3 LICENSE LAMP
c4 LICENSE LAMP
SO1
SO2 RR UPR MAIN WIRE to LH SIDE WIRE
SO3
SV2 RR UPR MAIN WIRE to RR UPR SUB LH WIRE
Sc1 RR UPR MAIN WIRE to LICENCE LAMP WIRE
XO1
XO2
HOOD MAIN WIRE to LH SIDE WIRE
XO3
XO4
YX1
HOOD SUB NO.1 WIRE to HOOD MAIN WIRE
YX2
ZO1 RR LWR WIRE to LH SIDE WIRE
OK REAR PILLER LEFT UNDER EARTH
E2-18
ELECTRICAL WIRING ROUTINGS
REAR BODY(NO.2)
*1:W/O HEATER
*2:DX CABIN
*3:W/ HEATER W/O DX CABIN
S RR UPR MAIN WIRE
T6
T4 T7
ST1
to E2-16
to E2-14
T RR UPR SUB RH WIRE
F DPF HEATER WIRE
*2
B1 B2 *1
B6 B3 B1
E3
C5 C4 B BODY SUB NO.1 WIRE
EM B4
C3 B5
F2
C7
F1 E2
TC2 F3
E DPF AC WIRE
CC2 C1 to E2-12
E1 B1
*3
C6
C SIDE RH WIRE
E2-19
ELECTRICAL WIRING ROUTINGS
B1 FRONT WASHER MOTOR
B2 HEATER BLOWER MOTOR
B3 HEATER BLOWER MOTOR
B4 HEATER RELAY
B5 HEATER RELAY
B6 REAR WASHER MOTOR
C1 O2 SENSOR
C3 IN AIR SENSOR
C4 AIR CLEANER WARNING SWITCH
C5 AIR CLEANER WARNING SWITCH
C6 RADIATOR WARNING SWITCH
C7 BACK UP BUZZER
E1 AC RELAY
E2 AC PLUG
E3 AC PLUG
F1 DPF HEATER
F2 AC PLUG
F3 AC RELAY
T4 BACK UP BUZZER ON OFF SWITCH
T6 LPG CHANGE SWITCH
T7 WORK LAMP SWITCH
CC2 SIDE RH WIRE to SIDE RH WIRE
ST1 RR UPR MAIN WIRE to RR UPR SUB RH WIRE
TC2 RR UPR SUB RH WIRE to SIDE RH WIRE
EM FRONT PLATE RIGHT OUTSIDE EARTH
E2-20
RELAY LOCATONS
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E2-21
RELAY LOCATONS
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E2-22
RELAY LOCATONS
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E2-23
RELAY LOCATONS
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E2-24
RELAY LOCATONS
JUNCTION CONNECTOR
BLACK A65 JUNCTION CONNECTOR (A) BLACK G73
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12
BLUE A66 JUNCTION CONNECTOR (B) BLUE G29
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12
GRAY G41 JUNCTION CONNECTOR (G) GRAY A27 JUNCTION CONNECTOR
GRAY G42 JUNCTION CONNECTOR (H) GRAY G43 JUNCTION CONNECTOR (E)
1 2 3 4
1 2 3 4 5
5 6 7 8
6 7 8 9 10 11 12 13
A64 JUNCTION CONNECTOR (J)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
E2-25
RELAY LOCATONS
[FUSIBLE LINK BLOCK ASSY INNER CIRCUIT]
80A ALT (2Z)
100A ALT (4Y-M, 4Y-E, 1DZ)
2 G24
120A GLOW (2Z)
60A GLOW (1DZ)
1 G24
120A MAIN
1 A24
E2-26
RELAY LOCATONS
[J/B INNER CIRCUIT (1/3)]
13 1C 1 1D
31 1A 14 1D
33 1B BCON LP RELAY 15 1D
5 3
15 1E 32 1A
1 2 16 1E
15 1B
16 1B
23 1E
28 1B
25 1E
24 1E
13 1A WORK LP RELAY
5 3
15 1C 13 1E
9 1E 31 1B
1 2
19 1B 29 1B
36 1B 10 1E
19 1E
4 4 1A
3
5 1A
1 2
8 1B 7 1A
3 1B T/C FR RELAY 13 1D
17 1B 2 1E
22 1E
4 3 1A
18 1E 3
2 1A
34 1B
1 2 1 1B
18 1D
19 1A
11 1C T/C RR RELAY
11 1E
1 3
28 1C 35 1B
26 1B 2
7 1D
22 1B
FLASHER RELAY 8 1D
24 1A
21 1E
25 1B
33 1C
23 1B
29 1C
3 1C
12 1A
4 1C
30 1C
21 1A
2 1C
E2-27
RELAY LOCATONS
[J/B INNER CIRCUIT (2/3)]
HORN RELAY 34 1A
5 3
16 1C 17 1A
4 1E
1 2 8 1E
33 1A
6 1C
32 1C
14 1C
16 1A
14 1A
10 1C
25 1A
27 1C
7 1B
24 1D
6 1B
6 1E
15 1A
20 1E
32 1B
22 1A
27 1A
34 1C
28 1A
12 1D
26 1E
26 1C
26 1A
5 1D
30 1A
19 1D
23 1A
6 1D
21 1B
20 1D
30 1E
9 1D
19 1C
10 1D
20 1C
4 1D
31 1E
1 1A
21 1C
18 1A
23 1C
17 1C
8 1A
1 1E
9 1A
17 1E
10 1A
3 1E
24 1B
17 1D
11 1A
1 1C
32 1E
E2-28
RELAY LOCATONS
[J/B INNER CIRCUIT (3/3)]
18 1B 7 1C
9 1C 6 1A
27 1B 21 1D
30 1B 11 1D
7 1E 23 1D
22 1C 14 1B
20 1B 8 1C
16 1D 2 1B
14 1E 25 1C
20 1A 28 1E
5 1C 31 1C
13 1B 12 1C
9 1B 5 1B
10 1B 29 1A
11 1B 4 1B
12 1B 18 1C
12 1E 24 1C
E2-29
RELAY LOCATONS
[CAN JOINT CONNECTOR INNER CIRCUIT]
1 A33 1 A29
2 A33 2 A29
1 A34
2 A34
1 A30
2 A30
1 A31
2 A31
JUNCTION TERMINAL
3 1
1 A32
MEMO
E3-1
CHAPTER 3 SYSTEM CIRCUITS
POWER SOURCE
POWER SOURCE ...................................................................................................... E3-1 E3
CHARGING ................................................................................................................. E3-4
STARTING ................................................................................................................... E3-6
ENGINE
IGNITION .................................................................................................................... E3-8
FUEL ......................................................................................................................... E3-10
ENGINE CONTROL (4Y-E) ....................................................................................... E3-16
GLOW ....................................................................................................................... E3-20
INTAKE HEATER ...................................................................................................... E3-24
DPF-2 ........................................................................................................................ E3-28
ASC ........................................................................................................................... E3-30
LPG SYSTEM (4Y-M) ................................................................................................ E3-34
LPG WARNING SYSTEM (4Y-E) .............................................................................. E3-36
CHASSIS
POWER SHIFT TRANSMISSION ............................................................................. E3-38
WET BRAKE ............................................................................................................. E3-40
BODY
SAS/OPS SYSTEM ................................................................................................... E3-42
OPS SYSTEM ........................................................................................................... E3-46
MINI LEVER .............................................................................................................. E3-50
DIAG .......................................................................................................................... E3-52
REAR WORNING LAMP ........................................................................................... E3-54
STROBE LIGHT ........................................................................................................ E3-56
INSTRUMENT PANEL
COMBINATION METER ............................................................................................ E3-58
SPEED METER ......................................................................................................... E3-62
MULTI DISPLAY ........................................................................................................ E3-64
FRONT WIPER & WASHER ..................................................................................... E3-66
REAR WIPER & WASHER ........................................................................................ E3-68
HORN ........................................................................................................................ E3-70
LIGHTING SYSTEM
HEAD LAMP .............................................................................................................. E3-72
TURN SIGNAL LAMP ................................................................................................ E3-74
CLEARANCE LAMP .................................................................................................. E3-76
BACK UP LAMP BUZZER ......................................................................................... E3-78
STOP LAMP .............................................................................................................. E3-80
HEATER SYSTEM
HEATER .................................................................................................................... E3-82
COMMUNICATION SYSTEM
CAN ........................................................................................................................... E3-84
OTHER
DOME LAMP ............................................................................................................. E3-86
EARTH TO EARTH ................................................................................................... E3-88
E3-2
＊ １：２Ｚ
１５Ａ Ｅ−ＴＨＲＯ ＊ ２：１ＤＺ
１ ２ ＊ ３：４Ｙ−Ｅ，１ＤＺ
＊ ４：４Ｙ−Ｅ
＊ ５：１ＤＺ，２Ｚ ＳＴＡＮＤＡＲＤ
７．５Ａ ＥＣＵ−Ｂ ７．５Ａ ＥＣＵ−Ｂ２ ＊ ６：２Ｚ ＨＩＧＨ ＣＡＰＡＣＩＴＹ ＢＡＴＴＥＲＹ ＯＲ
１ ２ １ ２ ＣＯＬＤ ＷＥＡＴＨＥＲ
＊ ７：ＥＸＣＥＰＴ ４Ｙ−Ｅ
＊ ８：４Ｙ−Ｍ，２Ｚ
１５Ａ ＥＦＩ ＊ ９：４Ｙ−Ｍ，４Ｙ−Ｅ
１５Ａ ＷＯＲＫ ＬＰ １ ２
１ ２
１５Ａ ＤＰＦ
７．５Ａ ＳＴＯＰ １ ２
１ ２
１５Ａ ＣＤＳ
１５Ａ ＨＥＡＤ １ ２
１ ２
２５Ａ ＢＬＲ
７．５Ａ ＴＡＩＬ １ ２
Ｗ １ ２
１
１５Ａ ＨＴＲ
１５Ａ ＨＯＲＮ １ ２
１ ２
２０Ａ ＦＲ ＷＩＰ
７．５Ａ ＡＣＣ−Ｂ １ ２ １５Ａ ＩＧＮ ＊４
１ ２ ７．５Ａ ＩＧＮ ＊７
１ ２ Ｂ−Ｗ
Ｗ
２０Ａ ＲＲ ＷＩＰ １
７．５Ａ ＡＬＴ−Ｓ １ ２
１ ２ ７．５Ａ ＴＵＲＮ
１Ａ １ ２
３０Ａ ＳＴＡ
１ ２ ７．５Ａ ＳＦＴ
１ ２
ＡＣＣ
４０Ａ ＡＭ１ １０Ａ ＥＣＵ−ＩＧ
１ ２ Ｗ−Ｌ ２ ＡＭ１ ＩＧ１ ４ Ｂ−Ｙ １ ２
１ １
POWER SOURCE
ＳＴ１ ３
７．５Ａ ＳＴ
１２０Ａ ＭＡＩＮ
１２０Ａ ＧＬＯＷ ＊１
６０Ａ ＧＬＯＷ ＊２
１００Ａ ＡＬＴ ＊３
８０Ａ ＡＬＴ ＊８
Ａ ２ Ｂ−Ｗ １ ２
ＩＧＮＩＴＩＯＮ １
ＳＷＩＴＣＨ
ＦＵＳＩＢＬＥ ＬＩＮＫ
ＢＬＯＣＫ ＡＳＳＹ
Ａ ２４（Ａ）
Ｂ−Ｒ
＊６
１Ａ １Ｅ
Ｂ−Ｗ １ ２ Ｗ−Ｂ
１ １
Ｉ １（Ｂ），Ｉ ２（Ｃ），
Ｉ ３（Ｄ），Ｌ ２（Ｅ），
Ｎ ２（Ｆ） ４０Ａ ＡＭ２ １０Ａ ＢＡＣＫ ＬＰ
ＢＡＴＴＥＲＹ １ ２ Ｗ−Ｒ ５ ３ Ｂ−Ｙ １ ２ ３０ １Ｃ
１ １ １ １
ＢＡＴＴＥＲＹ
Ｌ １（Ａ），Ｎ １（Ｂ）
１Ｂ １ Ｆ １ Ｂ ＊９ ＡＭ２ ＲＥＬＡＹ １０Ａ ＧＡＵＧＥ
１ Ｃ ＊５ １ ２
Ｂ−Ｙ １ Ｄ ＊６ １ ３３ １Ｃ
＊６
１０ ３２
Ｗ−Ｂ
１ Ｒ Ｒ
Ｂ−Ｙ
＋Ｓ １Ｃ １Ｃ
ＡＣ
ＩＨ Ａ ５７
ＴＯ ＰＵＳＨ／ＰＵＬＬ
ＲＥＬＡＹ
E3-3
POWER SOURCE
PARTS
Code See Page Code See Page Code See Page Code See Page
A 2 E2-10 I 1 E2-2,4 L 1 E2-8 N 2 E2-8
A 24 E2-12 I 2 E2-6 L 2 E2-8
A 57 E2-12 I 3 E2-8 N 1 E2-8
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1C E2-12,22 BODY MAIN WIRE to J/B
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
IH E2-2,4,6,8 REAR PILLER LEFT UNDER EARTH
E3-4
（ＢＡＴ） （ＢＡＴ） （ＩＧ） ＊ １：４Ｙ−Ｅ，１ＤＺ
＊ ２：４Ｙ−Ｍ，２Ｚ
＊ ３：４Ｙ−Ｍ，１ＤＺ，２Ｚ
１００Ａ（＊１） ７．５Ａ １０Ａ ＊ ４：４Ｙ−Ｅ
８０Ａ（＊２） ＡＬＴ−Ｓ ＧＡＵＧＥ
ＡＬＴ
２ Ｇ ２４ ２ ２
ＦＵＳＩＢＬＥ ＬＩＮＫ
ＢＬＯＣＫ ＡＳＳＹ １ １
Ｗ
Ｗ−Ｌ
１
３２ １Ｃ
Ｑ １
ＣＨＡＲＧＥ
ＣＯＭＢＩＮＡＴＩＯＮ
ＭＥＴＥＲ
２４ １Ｄ ２７ １Ｃ
Ｒ
Ｒ
Ｙ
４ ＡＧ１
１２ ＱＡ１ ８ ＱＡ１
Ｙ
CHARGING
７ １Ｃ
Ｗ
Ｗ−Ｌ
２１ １Ｄ
Ｙ
１ Ａ ＊３
１ Ｂ ＊４ ３Ｃ ２Ｃ １Ｃ
Ｂ Ｓ ＩＧ Ｌ
Ｇ １（Ａ），Ｇ ２（Ｂ），Ｇ ４（Ｃ）
ＡＬＴＥＲＮＡＴＯＲ
E3-5
CHARGING
PARTS
Code See Page Code See Page Code See Page Code See Page
G 1 E2-2,6,8 G 4 E2-2,4,6,8 Q 1 E2-10
G 2 E2-4 G 24 E2-2,4,6,8,20
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
QA1 E2-10 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
E3-6
（ＢＡＴ） （ＳＴ）
Ｇ ３９ Ｇ ６９（Ｃ），Ｇ ７０（Ｄ）
３０Ａ ＡＳＣ ＥＣＵ ＤＰＦ ＥＣＵ ７．５Ａ
ＳＴＡ ＳＴ
２ ２
ＳＴＡ
１ ＳＴＡ ＳＴＬＹ １
２
１７ Ｃ ２５ Ｃ ＊１０
１７ Ｄ ２５ Ｄ ＊１１
Ｗ
＊５
Ｒ
＊９
＊９
Ｂ−Ｏ
３ ＡＧ２
＊ １：４Ｙ−Ｅ，４Ｙ−Ｍ
＊ ２：１ＤＺ，２Ｚ ＳＴＡＮＤＡＲＤ Ｂ
＊ ３：２Ｚ ＨＩＧＨ ＣＡＰＡＣＩＴＹ
＊１８
＊１７
Ｂ−Ｙ
Ｂ−Ｙ
ＢＡＴＴＥＲＹ ＯＲ ＣＯＬＤ ＷＥＡＴＨＥＲ ＊１２，＊１３
＊ ４：１ＤＺ，２Ｚ Ｂ−Ｏ
＊ ５：Ｗ／ ＡＳＣ
＊ ６：４Ｙ−Ｅ ＊８
＊ ７：ＥＸＣＥＰＴ ４Ｙ−Ｅ
＊５
Ｂ−Ｌ
Ｂ−Ｏ
＊ ８：Ｗ／Ｏ ＤＰＦ−２
＊ ９：Ｗ／ ＤＰＦ−２ Ｂ−Ｏ ３ ＡＧ１ １ ＡＧ１ ８ ＡＡ１ ７ ＡＡ１
＊１０：ＥＸＣＥＰＴ ２Ｚ Ｗ／ ＡＳＣ
＊１１：２Ｚ Ｗ／ ＡＳＣ
＊１２：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ Ｒ
Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊１３：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ １ １ ＊１２，＊１３
Ｂ
ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊７
＊６
＊１２
Ｂ−Ｏ
Ｂ−Ｏ
＊１４：Ｗ／Ｏ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ ５ １
＊１５：Ｍ／Ｔ
＊１６：Ｔ／Ｃ ＳＨＩＦＴ ＬＥＶＥＲ ＣＯＬＵＭＮ １９ ＡＯ３ １０ ＡＯ３
＊１７：Ｔ／Ｃ ＡＲＭ ＲＥＳＴ ＳＴ
＊１８：ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ ＲＥＬＡＹ
STARTING
Ｂ
＊１２
＊１７
１１ １Ｃ ３４ １Ｂ
Ｂ−Ｙ
３ ２ Ｂ
Ｂ
１ １ １ ＸＯ１ ７ ＸＯ１
＊１４
＊１３
Ｂ
＊１２
＊１７
Ｂ−Ｙ
１８ １Ｄ
Ｂ
１３ ＹＸ２ １１ ＹＸ２
５ ＡＧ１
Ｗ−Ｂ
Ｂ
＊１２
１Ａ
Ｂ−Ｒ
２ Ａ ＊１５
＊６
＊４
２９ １Ｃ ３ Ｂ ＊１６
Ｂ−Ｏ
Ｂ−Ｏ
１Ａ １ Ｃ ＊１
１Ｂ １ Ｄ ＊４ ３ Ｃ ＊１７
５ Ａ （１ＤＺ）
＊１８
＊１７
Ｂ−Ｙ
Ｂ−Ｙ
Ｇ ２３（Ｃ），Ｇ ３２（Ｄ）， ２４ １１ Ｂ （２Ｚ）
ＢＡＴＴＥＲＹ
Ｈ ３（Ａ），Ｉ １（Ｂ），
Ｉ ２（Ｃ），Ｉ ３（Ｄ），
Ｊ ３（Ｅ）
Ｈ １（Ａ），Ｈ ２（Ｂ），
１ Ｂ ＊１ １ Ｅ Ｊ １（Ｅ），Ｊ ２（Ｆ） ＳＴＡ ＳＴＡ
３３ １Ｃ
１ Ｃ ＊２ ＳＴＡＲＴＥＲ １ Ａ ＊１５
１ Ｅ ＊１
１ Ｄ ＊３ ７ Ｂ ＊１６
１ Ｆ ＊４
７ Ｃ ＊１７
Ｂ−Ｙ Ｇ ２７ Ｇ ３５（Ａ）
ＮＥＵＴＲＡＬ ＳＴＡＲＴ
ＳＷＩＴＣＨ
ＬＥＦＴ Ｔ／Ｃ ＳＨＩＦＴ
ＳＷＩＴＣＨ
Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ａ ３９（Ａ）
Ａ ４１（Ｂ）
Ｙ ４（Ｃ）
ＥＮＧＩＮＥ ＥＣＵ ＧＬＯＷ ＰＬＵＧ
＊１ ＴＩＭＥＲ
Ｂ−Ｙ
Ｗ−Ｂ
Ｇ ６３（Ｂ）
＊４
Ｂ−Ｙ
ＰＲＥ ＨＥＡＴＩＮＧ
ＴＩＭＥＲ
ＩＨ ＪＬ ＡＣ
E3-7
STARTING
PARTS
Code See Page Code See Page Code See Page Code See Page
A 39 E2-12 G 35 E2-12 H 1 E2-2,4 I 3 E2-8
A 41 E2-10 G 39 E2-12 H 2 E2-6,8 J 1 E2-2,4
G 23 E2-2,4 G 63 E2-12 H 3 E2-2,4,6,8 J 2 E2-6,8
G 27 E2-12 G 69 E2-6,8 I 1 E2-2,4 J 3 E2-2,4
G 32 E2-6,8 G 70 E2-8 I 2 E2-6,8 Y 4 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AA1 E2-12 BODY MAIN WIRE to BODY MAIN WIRE
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
AG2 E2-12 BODY MAIN WIRE to ENGINE WIRE
AO3 E2-12 BODY MAIN WIRE to LH SIDE WIRE
XO1 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
YX2 E2-16 HOOD SUB NO.1 WIRE to HOOD MAIN WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
IH E2-2,4,6,8 REAR PILLER LEFT UNDER EARTH
JL E2-6,8 FRONT PLATE LEFT INSIDE EARTH
E3-8
（ＩＧＮ）
７．５Ａ
ＩＧＮ
２ ＊ １：ＬＰＧ
＊ ２：ＥＸＣＥＰＴ ＬＰＧ
１
Ｂ−Ｗ
３４ １Ｃ
２０ １Ｄ
Ｂ−Ｗ
１
＋Ｂ
Ｇ ２０
IGNITION
ＤＩＳＴＲＩＢＵＴＯＲ
ＴＡＣＨ
２
Ｂ
＊１
１５ １Ｄ
Ｂ
＊２
１４ １Ｄ
Ｂ
＊１
１
ＴＣ
Ｇ ２６
ＴＡＣＨＯ ＣＨＥＣＫ
E3-9
IGNITION
PARTS
Code See Page Code See Page Code See Page Code See Page
G 20 E2-2 G 26 E2-2
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
E3-10
（ＩＧ）
＊ １：１ＤＺ，２Ｚ Ｗ／ ＡＳＣ ＯＲ ＤＰＦ−２
７．５Ａ ＊ ２：４Ｙ−Ｍ ＧＡＳＯＬＩＮＥ
ＩＧＮ ＊ ３：１ＤＺ，２Ｚ ＥＸＣＥＰＴ ＊１
Ｂ−Ｗ
３４ １Ｃ
１９ １Ｄ
＊１
FUEL
Ｂ−Ｗ
Ｂ−Ｗ
＊２，＊３
３ １
ＩＮＪＥＣＴＯＲ ＰＵＭＰ
ＦＵＥＬ ＣＵＴ
ＳＯＬＥＮＯＩＤ
Ｇ ３１
Ｇ ３４
E3-11
FUEL
PARTS
Code See Page Code See Page Code See Page Code See Page
G 31 E2-6,8 G 34 E2-2,6,8
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
ＥＦＩ ＭＡＩＮ
ＲＥＬＡＹ
３
５
２
Ｒ−Ｌ Ｂ−Ｙ
１
１
１
（ＢＡＴ）
１
２
Ｗ−Ｂ Ｗ−Ｂ ＬＧ
１５Ａ
ＥＦＩ
７Ｂ
１２ Ａ
１
１
ＧＦ
Ｂ−Ｙ
Ｗ−Ｂ
８Ｂ
Ｗ−Ｂ
１１ Ａ
１０ Ａ
＊１ Ｃ／ＯＰＮ
Ａ ６５（Ａ），Ｇ ７３（Ｂ） ＲＥＬＡＹ
２
１
ＪＵＮＣＴＩＯＮ Ｗ−Ｂ ＬＧ−Ｒ
１
１
ＣＯＮＮＥＣＴＯＲ（Ａ）
＊３ ＊３
５
４
３
５
Ｗ−Ｂ Ｗ−Ｂ Ｇ−Ｗ Ｇ−Ｗ Ｒ−Ｂ
Ｍ
１
１
１７ １Ｃ
１７ １Ｅ
ＡＢ
１６ ＡＯ１
＊３ ＊３ ＊３ ＊３ ＊３
Ｏ ２
ＦＵＥＬ ＳＥＮＤＥＲ ＧＡＵＧＥ
＆ ＦＵＥＬ ＰＵＭＰ
ＬＰＧ ＭＡＩＮ
ＲＥＬＡＹ
２
１
Ｗ−Ｂ Ｏ
１
１
＊１ ＊１
３
５
１
１
Ｙ
Ｋ ３
６Ａ
ＬＰＧ ＳＯＬＥＮＯＩＤ ＊１
（ＭＡＩＮ）
２
１
Ｗ−Ｂ Ｗ−Ｂ Ｙ Ｙ
２Ｂ
ＧＧ
＊１
２ ＧＫ１
８ ＧＫ１
Ｒ−Ｗ
＊１ ＊１ ＊１ ＊１
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ａ）
Ｋ １
ＬＰＧ ＳＯＬＥＮＯＩＤ
Ａ ６５（Ａ），Ｇ ７３（Ｂ）
（ＳＬＯＷ）
２
１
Ｌ−Ｂ Ｌ−Ｂ Ｙ Ｙ
１Ｂ
６ ＧＫ１
７ ＧＫ１
＊１ ＊１ ＊１ ＊１
Ｒ−Ｂ Ｒ−Ｂ
６Ｂ
２Ａ
＊３ ＊３
Ｒ−Ｂ
５Ｂ
＊４
ＪＵＮＣＴＩＯＮ
ＧＡＳ
６
Ｒ−Ｂ Ｒ−Ｂ Ｒ−Ｂ
ＣＯＮＮＥＣＴＯＲ（Ａ）
１Ａ
１ ＴＣ２
４ ＡＣ３
＊２ ＊２ ＊２
Ａ ６５（Ａ），Ｇ ７３（Ｂ）
ＩＧ
４
＊ １：ＬＰＧ
ＬＰＧ
３
Ｒ−Ｗ Ｒ−Ｗ Ｒ−Ｗ ８Ａ Ｒ−Ｗ
７Ａ
２ ＴＣ２
３ ＡＣ３
＊２ ＊２ ＊２ ＊１
＊ ４：ＧＡＳＯＬＩＮＥ
＊２
Ｒ−Ｌ
Ｔ ６
ＬＰＧ ＣＨＡＮＧＥ Ｒ−Ｗ
１２ Ｂ
ＳＷＩＴＣＨ
＊１
＊ ２：ＬＰＧ ＣＯＮＶＥＲＴＩＢＬＥ
Ｒ−Ｌ Ｒ−Ｌ Ｒ−Ｌ
１Ａ
１０ Ｂ
３ ＴＣ２
２ ＡＣ３
＊２ ＊２ ＊２
＊ ３：ＥＸＣＥＰＴ ＬＰＧ ＥＸＣＬＵＳＩＶＥ
Ｒ−Ｂ
３Ｂ
＊４
Ｒ−Ｌ Ｒ−Ｗ
２Ａ
４Ｂ
＊１
Ｒ−Ｌ Ｒ−Ｌ
５Ａ
９ ＡＣ２
Ｒ−Ｌ Ｒ−Ｌ
２Ｂ
４Ａ
＊１
Ｒ−Ｌ Ｒ−Ｌ
１Ｂ
３Ａ
＊１
Ａ ６６（Ａ），Ｇ ２９（Ｂ）
＊１
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ｂ）
Ｏ
ＬＧ
＊３
＊１ Ｒ−Ｌ
＊３ Ｌ−Ｂ
Ｒ−Ｂ
＊１ Ｒ−Ｌ
Ｒ−Ｌ
Ｒ−Ｌ
＊１ Ｒ−Ｌ
Ｂ−Ｙ
＊１ Ｒ−Ｗ
Ｗ−Ｂ
ＬＧ−Ｒ
ｍ
ｌ
ｋ
ｊ
ｉ
ｈ
ｇ
ｆ
ｅ
ｄ
ｃ
ｂ
ａ
ENGINE CONTROL (4Y-E)
E3-12
＊ １：ＬＰＧ
＊ ３：ＥＸＣＥＰＴ ＬＰＧ ＥＸＣＬＵＳＩＶＥ
＊ ５：ＳＨＩＥＬＤＥＤ ＷＩＲＥ
ＢＲ
３Ａ ４Ａ
Ａ ６５（Ａ），Ｇ ７３（Ｂ）
ＪＵＮＣＴＩＯＮ
１０ ＡＣ２
４Ｂ ３Ｂ ＣＯＮＮＥＣＴＯＲ（Ａ）
ＢＲ
ＢＲ
ＢＲ
Ｂ−Ｙ
ａ １ １ １
ＬＧ
ｂ Ｅ２ Ｅ２ Ｅ２
ＬＧ−Ｒ
ｃ
＊３ ＴＨＡ ＴＨＷ ＶＣ ＰＩＭ
ＷＡＴＥＲ ＴＥＭＰＥＲＡＴＵＲＥ
ＳＥＮＳＯＲ
ＶＡＣＵＵＭ
ＳＥＮＳＯＲ
Ｇ １６
Ｇ １２
Ｏ ２ ２ ３ ２
ＩＮ ＡＩＲ ＳＥＮＳＯＲ
Ｃ ３
ｄ
Ｒ−Ｗ ＊１
Ｒ
ｅ
Ｒ−Ｌ
Ｙ−Ｇ
Ｌ−Ｒ
Ｒ−Ｌ ＊１
ｆ
１１ ＡＧ１ ７ ＡＧ１
Ｒ−Ｌ ６ ＡＣ２ １ ＡＧ１ １５ ＡＧ１ ８ ＡＧ１
ｇ
Ｏ
Ｒ
＊１
＊１
＊３
ＬＧ
ＢＲ
Ｒ−Ｌ
Ｒ−Ｌ
Ｂ−Ｙ
Ｒ−Ｌ
Ｙ−Ｇ
Ｌ−Ｒ
Ｒ−Ｗ
ＬＧ−Ｒ
１Ｂ ２Ｂ １３ Ｄ ３２ Ｄ ２２ Ｄ １９ Ｂ ３Ｂ ２９ Ａ １９ Ａ １７ Ａ １８ Ａ ２８ Ａ
＋Ｂ ＋Ｂ１ ＬＰＧ ＬＰＧＲ ＦＣ ＭＲＥＬ ＢＡＴＴ ＴＨＡ ＴＨＷ ＶＣ ＰＩＭ Ｅ２
Ａ ３５（Ａ），Ａ ３６（Ｂ），Ｇ ２７（Ｃ），Ｇ ２８（Ｄ）
ＥＮＧＩＮＥ ＥＣＵ
ＦＣＭ１ ＦＣＭ２ ＦＣＭ３ ＦＣＭ４ ＧＡＳ ＬＦＣ Ｅ０１ ＨＴ ＯＸ Ｅ１１ ＮＥ＋ ＮＥ− Ｇ２ Ｇ−
２１ Ｄ ３１ Ｄ ２０ Ｄ ３０ Ｄ １４ Ｄ ２５ Ｃ ２Ｄ ６Ａ ２０ Ａ ２１ Ａ ３１ Ｃ ３０ Ｃ １１ Ｃ ２２ Ｃ
Ｂ
Ｂ
Ｌ
Ｙ
Ｗ
Ｗ
＊１
＊１
＊１
＊１
＊３
＊１
＊５
＊５
＊５
Ｂ−Ｌ
Ｐ−Ｌ
Ｌ−Ｂ
Ｒ−Ｂ
Ｌ−Ｂ
Ｇ−Ｒ
Ｗ−Ｂ
ＬＧ−Ｂ
ENGINE CONTROL (4Y-E)
３ ６ １ ４
ＢＲ
ＢＲ
ＦＣＭ１ ＦＣＭ２ ＦＣＭ３ ＦＣＭ４
Ｂ１ Ｂ２ １ ＡＣ２ ４ ＡＣ２ ７ ＡＣ２ ３ ＡＣ２
２ ５ Ｇ １３
ＦＣＭ ＳＴＥＰ
ＢＲ
Ｂ
Ｗ
＊５
ＭＯＴＯＲ
Ｇ−Ｒ
１ ２ １ ２
＊１
Ｒ−Ｌ
Ｒ−Ｌ ３ ４ ＮＥ ＮＥ− Ｇ２ Ｇ−
ｈ
Ｒ−Ｌ ＊１ ＯＸ Ｅ１
ｉ
＊１ ＨＴＲ ＋ Ｇ １９ Ｇ １８
Ｏ２ ＳＥＮＳＯＲ
Ｃ １
ＤＩＳＴＲＩＢＵＴＯＲ Ｇ２ ＳＥＮＳＯＲ
１ ２
ＢＲ
ＢＲ
ＢＲ
Ｒ−Ｂ
ｊ
Ｒ−Ｌ
９Ａ ９Ｂ ８Ｂ
Ｌ−Ｂ ＊３
ｋ
Ｒ−Ｌ ＊１ １１ Ｂ
ｌ Ａ ６６（Ａ），Ｇ ２９（Ｂ）
Ｗ−Ｂ ＪＵＮＣＴＩＯＮ ＣＯＮＮＥＣＴＯＲ（Ｂ）
ｍ
ＢＲ
ＧＧ
E3-13
E3-14
（ＢＡＴ） （ＩＧ）
１５Ａ １５Ａ １２ １Ｄ
Ｂ−Ｗ
Ｅ−ＴＨＲＯ ＩＧＮ ５
１Ｄ １
２ ２
１ １ ３４ １Ｃ ６ １Ｄ ２０ １Ｄ ９ １Ｄ １０ １Ｄ ２６ １Ｃ ４ １Ｄ
ＩＧ−
ＩＧＮＩＴＩＯＮ
ＣＯＩＬ
ＴＡＣＨＯ ＣＨＥＣＫ
Ｇ ２１
Ｇ ２６
２ １
＊３
＊３
＊３
＊３
＊１
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ−Ｗ
２ ２ ２ ２ １ ２
Ｙ
Ｂ−Ｒ
Ｂ−Ｗ
Ｒ−Ｗ
ＩＮＪＥＣＴＯＲ
ＮＯ．１
ＩＮＪＥＣＴＯＲ
ＮＯ．２
ＩＮＪＥＣＴＯＲ
ＮＯ．３
ＩＮＪＥＣＴＯＲ
ＮＯ．４
ＬＰＧ
ＩＮＪＥＣＴＯＲ
Ｇ ８
Ｇ ９
Ｇ １０
Ｇ １１
Ｇ ７
３ ５ ４
＊ １：ＬＰＧ １ １ １ １ ２ １
ＩＧ２ ＩＧ１ ＴＡＣＨ
ＬＰＧ ＲＥＳＩＳＴＯＲ
Ｋ ２
＊ ３：ＥＸＣＥＰＴ ＬＰＧ
Ｂ
Ｒ
Ｂ
Ｒ
Ｌ
Ｌ
ＥＸＣＬＵＳＩＶＥ
＊３
＊３
＊３
＊３
＊１
＊１
＊１
Ｌ−Ｗ
＊ ５：ＳＨＩＥＬＤＥＤ ＷＩＲＥ
ＩＧＦ ＩＧＴ
ＩＧＮＩＴＥＲ
Ｇ ２５
１３ ＡＧ１ １ ２
５ ＧＫ１ １ ＧＫ１
Ｂ
Ｒ
Ｌ
Ｌ
＊３
＊３
＊１
＊１
＊１
Ｇ−Ｂ
Ｒ−Ｂ
Ｒ−Ｗ
Ｂ−Ｗ
Ｌ−Ｗ
Ａ ３５（Ａ），Ａ ３６（Ｂ），Ｇ ２７（Ｃ），Ｇ ２８（Ｄ）
７Ｃ ＥＮＧＩＮＥ ＥＣＵ ５Ｄ ６Ｄ ９Ｂ ４Ｄ ３Ｄ ３２ Ｃ ３３ Ｃ
＋ＢＭ ＃１０ ＃２０ ＩＧＳＷ ＬＩＮＪ ＲＥＳ ＩＧＦ ＩＧＴ
Ｅ１ ＶＦ ＯＸＳ ＴＣ Ｇ０１Ｌ Ｍ＋ Ｍ− ＶＣ２ ＶＴＡ ＶＴＡ２ Ｅ２１ ＶＣＰＡ ＶＰＡ ＥＰＡ ＶＣＰ２ ＶＰＡ２ ＥＰＡ２
３Ｃ １７ Ｂ ２５ Ｂ ２４ Ｂ ３５ Ｃ ６Ｃ ５Ｃ ２０ Ｃ ２１ Ｃ ２９ Ｃ ２８ Ｃ ２５ Ａ ２６ Ａ ２７ Ａ ３３ Ａ ３４ Ａ ３５ Ａ
Ｏ
＊５
ＢＲ
ＢＲ
Ｇ−Ｙ
Ｐ−Ｇ
Ｌ−Ｇ
Ｌ−Ｙ
Ｏ−Ｌ
Ｗ−Ｌ
ＬＧ−Ｒ
ENGINE CONTROL (4Y-E)
ＢＲ
ＢＲ
４ Ａａ１ ８ Ａａ１ ２ Ａａ１ ３ Ａａ１ ７ Ａａ１ １ Ａａ１ ５ Ａａ１
Ｂ
Ｂ
Ｇ
Ｒ
Ｗ
Ｗ
＊５
＊５
ＢＲ
１２ １３ １１
ＶＦ１ ＯＸ１ Ｔ２
Ｂ
Ｒ
Ｇ
Ｙ
Ｌ
＊５
Ｅ１ Ｅ１１
２ １ ５ ６ ４ ３
１４ １５ Ａ ２５
ＤＩＡＧＮＯＳＩＳ Ｍ＋ Ｍ− ＶＣ ＶＴＡ ＶＴＡ２ Ｅ２ ５ ４ ６ １ ３ ２
ＶＣＰ１ ＶＰＡ１ ＥＰ１ ＶＣＰ２ ＶＰＡ２ ＥＰＡ２
ＢＲ
ＢＲ
ＢＲ
７Ｂ ７Ａ ８Ａ Ｇ ６
Ａ ６６（Ａ），Ｇ ２９（Ｂ） ＴＨＲＯＴＴＬＥ ＰＯＳＩＴＩＯＮ ＳＥＮＳＯＲ
ＪＵＮＣＴＩＯＮ （ＷＩＴＨ ＭＯＴＯＲ）
ＣＯＮＮＥＣＴＯＲ（Ｂ） ａ １
ＢＲ
１０ Ａ １０ Ｂ ＡＣＣＥＬ ＳＥＮＳＯＲ
ＢＲ
ＢＲ
（ＩＧ） ＊ １：ＬＰＧ
＊ ４：ＧＡＳＯＬＩＮＥ
＊ ６：ＴＷＩＳＴＥＤ ＷＩＲＥ
１０Ａ
ＧＡＵＧＥ
２
＋Ｓ
１
ＳＴ ＲＥＬＡＹ
１
Ｒ
１５ １Ｄ １４ １Ｄ １ １Ｄ
１
３２ １Ｃ
Ｐ
１１ １Ｃ
２７ １Ｃ
＊１
＊４
＊４
＊１
Ｇ−Ｗ
Ｇ−Ｗ
Ｇ−Ｗ
Ｇ−Ｗ
Ｇ−Ｗ
１８ １Ｄ Ｒ
１２ ＱＡ１
Ｂ
Ｗ
＊６
Ｐ
Ｒ
１０ Ｃ １５ Ｃ １４ Ｃ １３ Ｃ ２４ Ｃ ２８ Ｂ ２９ Ｂ １
８ １１
ＥＳＥＬ ＳＥＬ１ ＳＥＬ２ ＳＥＬ３ ＳＴＡ ＣＡＮ＋ ＣＡＮ− ＩＧ＋
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ
Ａ ２７
ＥＣ ＭＥ０１ Ｅ０２ ＭＩ
１ ５
ＣＨＥＣＫ
Ｅ／Ｇ
２６ Ｂ ４Ｃ １Ｄ Ａ ３５（Ａ），Ａ ３６（Ｂ），Ｇ ２７（Ｃ），Ｇ ２８（Ｄ） １６ Ｂ
ＥＮＧＩＮＥ ＥＣＵ
＊６
Ｇ−Ｒ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｖ−Ｗ
ENGINE CONTROL (4Y-E)
ＥＦＩ
１４ ＡＧ１
ＣＯＭＢＩＮＡＴＩＯＮ ＭＥＴＥＲ
Ｑ １
１ ＱＡ１
１６
１３ １２
ＣＡＮＬ ＣＡＮＨ
Ｖ−Ｗ
Ｖ−Ｗ
Ａ ２０
ＳＡＳ／ＯＰＳ ＥＣＵ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
ＧＧ ＧＦ
E3-15
E3-16
ENGINE CONTROL (4Y-E)
PARTS
Code See Page Code See Page Code See Page Code See Page
A 20 E2-10 G 6 E2-4 G 18 E2-4 K 1 E2-4
A 25 E2-12 G 7 E2-4 G 19 E2-4 K 2 E2-4
A 27 E2-12 G 8 E2-4 G 21 E2-4 K 3 E2-4
A 35 E2-12 G 9 E2-4 G 25 E2-4 O 2 E2-16
A 36 E2-12 G 10 E2-4 G 26 E2-4 Q 1 E2-10
A 65 E2-12 G 11 E2-4 G 27 E2-12 T 6 E2-18
A 66 E2-12 G 12 E2-4 G 28 E2-12 a 1 E2-10
C 1 E2-18 G 13 E2-4 G 29 E2-12
C 3 E2-18 G 16 E2-4 G 73 E2-12
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AC2 E2-12 BODY MAIN WIRE to SIDE RH WIRE
AC3 E2-12 BODY MAIN WIRE to SIDE RH WIRE
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
AO1 E2-12 BODY MAIN WIRE to LH SIDE WIRE
Aa1 E2-10 BODY MAIN WIRE to SUB ACCEL WIRE
GK1 E2-4 ENGINE WIRE to ENGINE SUB WIRE
QA1 E2-10 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
TC2 E2-18 RR UPR SUB RH WIRE to SIDE RH WIRE
EARTH
Code See Page Name
AB E2-12 FRONT PLATE LEFT OUTSIDE EARTH
GF E2-4 ENGINE UPPER EARTH
GG E2-4 ENGINE UPPER EARTH
E3-17
MEMO
E3-18
（ＢＡＴ） （ＩＧ）
Ｇ ６９（Ｃ） （ＳＴ）
Ｇ ２４ ＤＰＦ ＥＣＵ
６０Ａ ＦＵＳＩＢＬＥ ＬＩＮＫ ７．５Ａ
ＧＬＯＷ ＢＬＯＣＫ ＡＳＳＹ ＩＧＮ ７．５Ａ
ＳＴ
１ ２
Ｌ ＳＴＡ ＳＴＬＹ ２
ＡＬＴＥＲＮＡＴＯＲ
Ｇ ４
１ １ １７ Ｃ ２５ Ｃ
１
Ｂ−Ｒ
Ｂ−Ｗ
２１ １Ｄ ３４ １Ｃ
＊１
＊１
Ｂ−Ｏ
１１ １Ｄ １２ １Ｄ
＊６
＊９
Ｂ
Ｂ−Ｙ
Ｂ−Ｙ
Ｂ−Ｏ
＊３，＊４
＊２
Ｂ−Ｒ
Ｇ−Ｒ
Ｂ−Ｗ
Ｇ ３５ ３ ＡＧ１ １ ＡＧ１ ８ ＡＡ１ ７ ＡＡ１
１ ３ １ ２ ＧＬＯＷ ＰＬＵＧ ＴＩＭＥＲ ３
Ｇ ３３
ＧＬＯＷ ＰＬＵＧ ＲＬＹ１ ＣＨＧ Ｂ Ｒ
ＲＥＬＡＹ
＊３，＊４
Ｂ
＊３
Ｂ−Ｏ
２ ４ ＴＭＰ＋ Ｅ ＷＲＮ ＳＴ
４ ６ ７ ５ １９ ＡＯ３ １０ ＡＯ３
GLOW
Ｂ
＊３
＊９
Ｂ−Ｙ
Ｂ
Ｇ
＊２
＊１
＊１
＊２
ＢＲ
ＢＲ
Ｂ−Ｏ
Ｗ−Ｂ
Ｗ−Ｂ
ＬＧ−Ｂ
Ｂ
Ｂ
＊５
＊４
１ ＸＯ１ ７ ＸＯ１
１８ １Ｄ
Ｂ
１
＊３
＊９
Ｂ−Ｙ
２
１２ ＡＧ１
１３ ＹＸ２ １１ ＹＸ２
３４ １Ｂ
Ｂ
＊３
ＧＬＯＷ ＰＬＵＧ
Ｇ ３０
ＷＡＴＥＲ ＴＥＭＰＥＲＡＴＵＲＥ
ＳＥＮＳＯＲ
Ｇ １７
Ｇ
Ｂ−Ｏ
２ Ａ ＊７
３ Ｂ ＊８
３ Ｃ ＊９
＊１
ＢＲ
＊６
＊９
Ｂ−Ｙ
Ｂ−Ｙ
１０
１１ ＊ １：Ｗ／ ＤＰＦ−２
＊２
＊２
ＢＲ
ＢＲ
＊ ２：Ｗ／Ｏ ＤＰＦ−２ １ Ａ ＊７
＊ ３：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
９ ７ Ｂ ＊８
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ｅ）
Ｇ ４３
＊ ４：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ ＥＸＣＥＰＴ
Ｔ／Ｃ ＡＲＭ ＲＥＳＴ ７ Ｃ ＊９
＊ ５：Ｗ／Ｏ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
＊ ６：ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊１
＊１
＊２
ＢＲ
Ｗ−Ｂ
Ｗ−Ｂ
ＮＥＵＴＲＡＬ ＳＴＡＲＴ
ＳＷＩＴＣＨ
ＬＥＦＴ Ｔ／Ｃ ＳＨＩＦＴ
ＳＷＩＴＣＨ
Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ａ ３９（Ａ）
Ａ ４１（Ｂ）
Ｙ ４（Ｃ）
＊ ７：Ｍ／Ｔ
＊ ８：Ｔ／Ｃ ＳＨＩＦＴ ＬＥＶＥＲ ＣＯＬＵＭＮ
＊ ９：Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
ＧＪ ＧＪ ＧＬ Ｇ
ａ
（ＩＧ）
１０Ａ
ＧＡＵＧＥ
Ｒ
３２ １Ｃ
２７ １Ｃ
Ｒ
１２ ＱＡ１
Ｒ
１
ＩＧ＋
GLOW
ＰＯＷＥＲ
ＧＬＯＷ
ＣＩＲＣＵＩＴ
ＣＯＮＴＲＯＬ
ＣＩＲＣＵＩＴ
ＥＦＩ Ｅ１
ＣＯＭＢＩＮＡＴＩＯＮ ＭＥＴＥＲ
Ｑ １
１６ ８
Ｗ−Ｂ
Ｖ−Ｗ
１ ＱＡ１ ４ ＱＡ１
Ｇ
Ｗ−Ｂ
８ １Ｃ
２８ １Ｅ
Ｗ−Ｂ
Ｇ ＯＫ
ａ
E3-19
E3-20
GLOW
PARTS
Code See Page Code See Page Code See Page Code See Page
A 39 E2-12 G 17 E2-6 G 33 E2-6 G 69 E2-6
A 41 E2-10 G 24 E2-6,20 G 35 E2-12 Q 1 E2-10
G 4 E2-6 G 30 E2-6 G 43 E2-12 Y 4 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AA1 E2-12 BODY MAIN WIRE to BODY MAIN WIRE
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
AO3 E2-12 BODY MAIN WIRE to LH SIDE WIRE
QA1 E2-10 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
XO1 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
YX2 E2-16 HOOD SUB NO.1 WIRE to HOOD MAIN WIRE
EARTH
Code See Page Name
GJ E2-6 JUNCTION BLOCK IN FRONT INSIDE EARTH
GL E2-6 JUNCTION BLOCK IN FRONT INSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-21
MEMO
E3-22
（ＢＡＴ） （ＩＧ）
Ｇ ６９（Ｃ），Ｇ ７０（Ｄ） （ＳＴ）
Ｇ ２４ ＤＰＦ ＥＣＵ
１２０Ａ ＦＵＳＩＢＬＥ ＬＩＮＫ ７．５Ａ
ＧＬＯＷ ＢＬＯＣＫ ＡＳＳＹ ＩＧＮ ７．５Ａ
ＳＴ
１ ２
Ｌ ＳＴＡ ＳＴＬＹ ２
ＡＬＴＥＲＮＡＴＯＲ
Ｇ ４
１ １ １７ Ｃ ２５ Ｃ ＊５
１
１７ Ｄ ２５ Ｄ ＊６
Ｂ−Ｌ
Ｂ−Ｗ
２１ １Ｄ ３４ １Ｃ
＊３
＊３
Ｂ−Ｏ
１１ １Ｄ １２ １Ｄ
Ｂ
＊１０
＊１３
Ｂ−Ｙ
Ｂ−Ｙ
Ｂ−Ｏ
＊７，＊８
＊４
Ｂ−Ｌ
Ｇ−Ｒ
Ｂ−Ｗ
Ｇ ６３ ３ ＡＧ１ １ ＡＧ１ ８ ＡＡ１ ７ ＡＡ１
１Ｃ １Ｄ ５ ９ ＰＲＥ ＨＥＡＴＩＮＧ ＴＩＭＥＲ ４
１ ＲＬＹ１ ＣＨＧ Ｂ Ｒ
Ｂ
＊７，＊８
Ｂ
＊７
１Ａ １Ｅ
Ｂ−Ｏ
ＳＰ ＴＭＰ＋ Ｅ ＷＲＮ ＳＴ
ＩＮＴＡＫＥ ＨＥＡＴＥＲ
ＲＥＬＡＹ
Ｇ ５７（Ａ），Ｇ ５８（Ｂ），Ｇ ５９（Ｃ），
Ｇ ６０（Ｄ），Ｇ ６１（Ｅ）
６ ７ １０ ３ １１ １９ ＡＯ３ １０ ＡＯ３
Ｂ
＊７
＊１３
Ｂ−Ｙ
Ｐ
Ｂ
Ｇ
＊２
＊１
＊３
＊４
ＢＲ
ＢＲ
Ｂ−Ｏ
Ｗ−Ｂ
Ｗ−Ｂ
ＬＧ−Ｂ
Ｂ
Ｂ
＊９
＊８
１ ＸＯ１ ７ ＸＯ１
INTAKE HEATER
１８ １Ｄ
Ｂ
＊７
＊１３
Ｂ−Ｙ
１ ２
１２ ＡＧ１
１３ ＹＸ２ １１ ＹＸ２
ＦＬ
１．２５Ｇ
３４ １Ｂ
ＩＮＴＡＫＥ ＨＥＡＴＥＲ
Ｇ ５６
Ｂ
＊７
ＷＡＴＥＲ ＴＥＭＰＥＲＡＴＵＲＥ
ＳＥＮＳＯＲ
Ｇ １７
Ｐ
Ｇ
Ｂ−Ｏ
２ Ａ ＊１１
３ Ｂ ＊１２
３ Ｃ ＊１３
＊ １：Ｗ／ ＡＳＣ ＯＲ ＤＰＦ−２
＊１
＊１
ＢＲ
ＢＲ
＊ ２：ＥＸＣＥＰＴ ＊１
＊１０
＊１３
Ｂ−Ｙ
Ｂ−Ｙ
１０ ＊ ３：Ｗ／ ＤＰＦ−２
１１ ＊ ４：Ｗ／Ｏ ＤＰＦ−２
＊２
ＢＲ
＊ ５：Ｗ／Ｏ ＡＳＣ １ Ａ ＊１１
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ｅ）
Ｇ ４３
＊ ６：Ｗ／ ＡＳＣ
９ ＊ ７：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ ７ Ｂ ＊１２
Ｔ／Ｃ ＡＲＭ ＲＥＳＴ ７ Ｃ ＊１３
＊ ８：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
ＮＥＵＴＲＡＬ ＳＴＡＲＴ
ＳＷＩＴＣＨ
ＬＥＦＴ Ｔ／Ｃ ＳＨＩＦＴ
ＳＷＩＴＣＨ
Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ａ ３９（Ａ）
Ａ ４１（Ｂ）
Ｙ ４（Ｃ）
ＥＸＣＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊２
＊１
＊３
＊４
ＢＲ
ＢＲ
Ｗ−Ｂ
Ｗ−Ｂ ＊ ９：Ｗ／Ｏ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
＊１０：ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊１１：Ｍ／Ｔ
＊１２：Ｔ／Ｃ ＳＨＩＦＴ ＬＥＶＥＲ ＣＯＬＵＭＮ
＊１３：Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
ＧＪ ＧＪ ＧＬ Ｇ
ａ
（ＩＧ）
１０Ａ
ＧＡＵＧＥ
Ｒ
３２ １Ｃ
２７ １Ｃ
Ｒ
１２ ＱＡ１
Ｒ
１
ＩＧ＋
ＰＯＷＥＲ
ＧＬＯＷ
ＣＩＲＣＵＩＴ
INTAKE HEATER
ＣＯＮＴＲＯＬ
ＣＩＲＣＵＩＴ
ＥＦＩ Ｅ１
ＣＯＭＢＩＮＡＴＩＯＮ ＭＥＴＥＲ
Ｑ １
１６ ８
Ｗ−Ｂ
Ｖ−Ｗ
１ ＱＡ１ ４ ＱＡ１
Ｇ
Ｗ−Ｂ
８ １Ｃ
２８ １Ｅ
Ｗ−Ｂ
Ｇ ＯＫ
ａ
E3-23
E3-24
INTAKE HEATER
PARTS
Code See Page Code See Page Code See Page Code See Page
A 39 E2-12 G 43 E2-12 G 60 E2-8 Q 1 E2-10
A 41 E2-10 G 56 E2-8 G 61 E2-8 Y 4 E2-16
G 4 E2-8 G 57 E2-8 G 63 E2-12
G 17 E2-8 G 58 E2-8 G 69 E2-8
G 24 E2-8,20 G 59 E2-8 G 70 E2-8
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AA1 E2-12 BODY MAIN WIRE to BODY MAIN WIRE
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
AO3 E2-12 BODY MAIN WIRE to LH SIDE WIRE
QA1 E2-10 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
XO1 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
YX2 E2-16 HOOD SUB NO.1 WIRE to HOOD MAIN WIRE
EARTH
Code See Page Name
GJ E2-8 JUNCTION BLOCK IN FRONT INSIDE EARTH
GL E2-8 JUNCTION BLOCK IN FRONT INSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-25
MEMO
E3-26
Ｇ ４
（ＳＴ） （ＢＡＴ） ＡＬＴＥＲＮＡＴＯＲ ＳＴ ＲＥＬＡＹ
７．５Ａ ７．５Ａ
ＳＴ ＥＣＵ−Ｂ２ Ｌ ＋Ｓ ＊ １：ＥＸＣＥＰＴ ２Ｚ Ｗ／ ＡＳＣ
＊ ２：２Ｚ Ｗ／ ＡＳＣ
１ １ ＊ ３：１ＤＺ
２ ２ ＊ ４：２Ｚ
１ ＊ ５：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
１ １ ＊ ６：Ｗ／Ｏ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
＊ ７：Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
Ｙ
＊ ８：ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
Ｂ−Ｏ
Ｂ−Ｙ ＊ ９：Ｍ／Ｔ
＊１０：Ｔ／Ｃ ＳＨＩＦＴ ＬＥＶＥＲ ＣＯＬＵＭＮ
Ｂ−Ｒ
＊７ ２１ １Ｄ １１ １Ｃ ＊１１：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊１２：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
１０ ＡＯ３
２３ １Ｄ ３４ １Ｂ
＊７
Ｂ−Ｙ
Ｂ−Ｒ
Ｂ−Ｒ
Ｂ−Ｏ
＊８
７ ＸＯ１
Ｂ−Ｙ
６ ＡＧ３ ３ ＡＧ１
＊７
Ｂ−Ｙ
Ｙ
１１ ＹＸ２
Ｂ−Ｒ
Ｂ−Ｏ
Ｂ−Ｙ ２Ｃ １９ Ｃ １７ Ｃ ＊１ Ｇ ６７（Ａ），Ｇ ６８（Ｂ），Ｇ ６９（Ｃ），Ｇ ７０（Ｄ）
２Ｄ １９ Ｄ １７ Ｄ ＊２ ＤＰＦ ＥＣＵ
＊７
ＢＡＴＴ ＣＨＧ ＳＴＡ
１ Ａ ＊９
７ Ｂ ＊１０
７ Ｃ ＊７ ＲＥＧ ＲＩＬ ＷＩＬ ＩＬ６ ＩＬ５ ＩＬ４ ＩＬ３ ＩＬ２ ＩＬ１ ＲＳＴ ＭＯＤＥ ＦＩＬ
８Ａ ９Ａ １Ａ １２ Ａ ４Ａ １１ Ａ ３Ａ １０ Ａ ２Ａ １６ Ａ １５ Ａ ７ Ａ ＊３
DPF-2
８Ｂ ９Ｂ １Ｂ １２ Ｂ ４Ｂ １１ Ｂ ３Ｂ １０ Ｂ ２Ｂ １６ Ｂ １５ Ｂ ７ Ｂ ＊４
２ Ａ ＊９ Ｒ
ａ
３ Ｂ ＊１０
３ Ｃ ＊７
Ｙ
Ｇ
Ｗ
Ｇ−Ｏ
Ｂ−Ｌ
Ｒ−Ｇ
Ｒ−Ｂ
Ｇ−Ｙ
Ｙ−Ｂ
Ｖ−Ｗ
Ｒ−Ｗ
ＢＲ−Ｙ
ＮＥＵＴＲＡＬ ＳＴＡＲＴ
ＳＷＩＴＣＨ
ＬＥＦＴ Ｔ／Ｃ ＳＨＩＦＴ
ＳＷＩＴＣＨ
Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ａ ３９（Ａ）
Ａ ４１（Ｂ）
Ｙ ４（Ｃ）
Ｂ
＊１１
１３ ＹＸ２ ４ ＡＧ３ １３ ＡＧ３ １４ ＡＧ３ １２ ＡＧ３ １１ ＡＧ３ １０ ＡＧ３ ９ ＡＧ３ ８ ＡＧ３ ７ ＡＧ３ ３ ＡＧ３ ２ ＡＧ３ １ ＡＧ３ ５ ＡＧ３
Ｂ
＊１１
Ｙ
Ｇ
Ｒ
Ｂ−Ｒ
Ｇ−Ｏ
Ｂ−Ｌ
Ｒ−Ｇ
Ｒ−Ｂ
Ｇ−Ｙ
Ｙ−Ｂ
Ｖ−Ｗ
Ｒ−Ｗ
ＢＲ−Ｙ
１ ＸＯ１
６ ４ １３ １４ １２ １１ １０ ９ ８ ７ ３ ２ １ ５
Ｂ
Ｂ
＊６
＊１２
ＢＡＴＴ ＲＥＧ ＲＩＬ ＷＩＬ ＩＬ６ ＩＬ５ ＩＬ４ ＩＬ３ ＩＬ２ ＩＬ１ ＲＳＴ ＭＯＤＥ ＦＩＬ ＋Ｂ１
Ｂ
＊１１
１９ ＡＯ３
Ｂ
＊１１
７ ＡＡ１
Ａ ６７
ＴＯ ＤＰＦ ＤＩＳＰＬＡＹ
Ｂ Ｂ
ｂ
＊５ ＊５
Ｂ
ｃ
＊６
Ｗ−Ｂ
ａ
（ＩＧ）
Ｂ−Ｗ
Ｇ ５３
７．５Ａ ＊１４ Ｇ ３１ ＰＲＥＳＳ ＳＥＮＳＯＲ
ＩＧＮ Ｇ ３９ ＩＮＪＥＣＴＯＲ
ＡＳＣ ＥＣＵ ３ ＰＵＭＰ
２ Ｂ
ＶＣ Ｅ２ ＰＥＭ
Ｗ−Ｂ
１ ３ ２ １
Ｅ３ ＴＡＣ＋ ＴＡＣ− ＮＥ＋ ＮＥ−
１４ １Ｅ ２１ ２０ ８ ２ １
＊１４
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ
Ｒ
Ｗ
＊１５
＊１３
＊１３
＊１３
３４ １Ｃ １９ １Ｄ
Ｂ
Ｂ
Ｒ
Ｗ
Ｗ
１６ １Ｄ
＊１５
＊１４
＊１４
＊１５
７ ６
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ｅ）
Ｇ ４３
１０ １Ｄ ＢＲ
Ｗ−Ｂ １ ２ ｂ
ＢＲ ＢＲ
＊１３ ｃ
＊１３
Ｗ−Ｂ
Ｗ−Ｂ
＊１４
Ｂ−Ｗ
１８ Ｃ １５ Ｃ ７Ｃ ２０ Ｃ ３Ｃ １６ Ｃ ４ Ｃ ＊１
１８ Ｄ １５ Ｄ ７Ｄ ２０ Ｄ ３Ｄ １６ Ｄ ４ Ｄ ＊２
ＩＧ Ｅ１ ＮＥ＋ ＮＥ− ＶＣ Ｅ２ ＰＥＭ
Ｇ ６７（Ａ），Ｇ ６８（Ｂ），Ｇ ６９（Ｃ），Ｇ ７０（Ｄ）
ＤＰＦ ＥＣＵ
ＳＴＬＹ ＡＰ ＢＵＺ ＶＬＶ ＋Ｂ１ ＥＧＷＴ Ａ０ Ａ１ ＷＲ ＣＬＫ ＤＩ ＳＴＲ ＫＯＮ
２５ Ｃ １２ Ｃ ２４ Ｃ ＊１ １１ Ｃ １Ｃ ６Ｃ ２３ Ｃ １４ Ｃ ＊１ ５Ａ １３ Ａ １４ Ａ ６ Ａ ＊３ ２２ Ｃ ＊１
DPF-2
２５ Ｄ １２ Ｄ ２４ Ｄ ＊２ １１ Ｄ １Ｄ ６Ｄ ２３ Ｄ １４ Ｄ ＊２ ５Ｂ １３ Ｂ １４ Ｂ ６ Ｂ ＊４ ２２ Ｄ ＊２
Ｒ
ａ
Ｒ
Ｒ
Ｂ
Ｌ
Ｙ
Ｇ
Ｐ
Ｏ
Ｗ
ＧＲ
Ｇ−Ｙ
Ｖ−Ｗ
Ｂ−Ｗ
１ ＡＧ１ １ １ １ ４ ７ １ ６ ２ ３ ８ ９
ＡＰ ＢＵＺ ＶＬＶ ＥＧＷＴ Ａ０ Ａ１ ＷＲ ＣＬＫ ＤＩ ＳＴＲ ＫＯＮ
Ｇ ４６
ＤＰＦ ＣＨＥＣＫＥＲ
＋Ｂ１ ＋Ｂ１ ＋Ｂ１ ＋Ｂ ＧＮＤ
ＤＰＦ ＢＬＯＷＥＲ
ＤＰＦ ＢＵＺＺＥＲ
ＤＰＦ ＶＡＬＶＥ
Ｇ ５０
Ｇ ５１
Ｇ ４９
２ ２ ２ ５ １０
＊ １：ＥＸＣＥＰＴ ２Ｚ Ｗ／ ＡＳＣ
Ｒ
＊ ２：２Ｚ Ｗ／ ＡＳＣ
＊５
＊６
Ｂ−Ｙ
＊ ５：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
Ｒ
Ｒ
Ｒ
Ｒ
Ｒ
＊ ６：Ｗ／Ｏ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
ＢＲ
＊１３：Ｗ／ ＡＳＣ
＊１４：Ｗ／Ｏ ＡＳＣ
８ ＡＡ１ ６ ８ ４ ３ ５ ７ ＊１５：ＳＨＩＥＬＤＥＤ ＷＩＲＥ
２ Ｒ Ｒ
ｄ
Ｇ ４２ １
ＪＵＮＣＴＩＯＮ ＣＯＮＮＥＣＴＯＲ（Ｈ） ＢＲ
ｅ
Ｒ Ｒ
Ｂ ｆ
ｂ
＊５
Ｂ
ｃ
＊６
E3-27
E3-28
Ｗ−Ｂ
ａ
（ＢＡＴ）
Ｇ ５４（Ａ），Ｇ ７２（Ｂ） ＊ １：ＥＸＣＥＰＴ ２Ｚ Ｗ／ ＡＳＣ
ＴＥＭＰ ＳＥＮＳＯＲ ＊ ２：２Ｚ Ｗ／ ＡＳＣ １５Ａ
＊ ３：１ＤＺ ＤＰＦ
＊ ４：２Ｚ
＊１５：ＳＨＩＥＬＤＥＤ ＷＩＲＥ
２
ＴＩＮ＋ ＴＩＮ−
１Ａ ２ Ａ ＊３ １
１Ｂ ２ Ｂ ＊４
ＢＲ
Ｂ−Ｙ
ＢＲ
ＢＲ
Ｒ
Ｗ
＊１５
ＢＲ
ＢＲ
ｂ
ＬＧ−Ｒ
ＢＲ
ｃ
ＬＧ−Ｒ
Ｇ−Ｏ
７ ＡＧ１
８Ｃ ２１ Ｃ ＊１ ９ Ｃ ＊１ １０ Ｃ ＊１
８Ｄ ２１ Ｄ ＊２ ９ Ｄ ＊２ １０ Ｄ ＊２
ＴＩＮ＋ ＴＩＮ− ＭＲＬＹ ＨＴ
Ｂ−Ｙ
ＬＧ−Ｒ
Ｇ ６７（Ａ），Ｇ ６８（Ｂ），Ｇ ６９（Ｃ），Ｇ ７０（Ｄ）
ＤＰＦ ＥＣＵ ＡＣ＋ ＡＣ− Ｅ １ １
ＡＣ ＰＬＵＧ
Ｅ ２（Ａ），Ｅ ３（Ｂ），
Ｆ ２（Ｃ）
ＶＡ Ｅ０１ Ｅ０２ １Ａ １Ｃ １Ｂ
５ Ｃ ＊１ １３ Ｃ ２６ Ｃ ＊１ １ ５
DPF-2
５ Ｄ ＊２ １３ Ｄ ２６ Ｄ ＊２
Ｂ
Ｂ
Ｇ
Ｇ−Ｏ
ＤＰＦ
ＲＥＬＡＹ
１Ａ １Ｃ ２ ３
１ １
Ｗ−Ｂ
Ｗ−Ｂ
Ｒ
Ｗ
Ｗ
＊１５
＊１５
ＡＣ ＲＥＬＡＹ
Ｇ ４４（Ａ），Ｇ ４５（Ｂ），
Ｅ １（Ｃ），Ｆ ３（Ｄ）
１Ｂ １Ｄ
Ｒ
Ｗ−Ｂ
３ １ ２
Ｂ
２ ＡＧ１ ８ ＡＧ１
Ｗ−Ｂ
＋Ｂ１ ＶＡ Ｅ１
１
Ｒ
Ｗ−Ｂ
Ｗ
Ｇ ５２ Ｗ−Ｂ
ＢＲ
ＡＩＲ ＦＬＯＷ ＳＥＮＳＯＲ
ＤＰＦ ＨＥＡＴＥＲ
Ｆ １
６ ５ ２
ＢＲ ４ Ｇ ４１
ＪＵＮＣＴＩＯＮ
Ｗ−Ｂ
ＣＯＮＮＥＣＴＯＲ（Ｇ）
１ ８ ７ ２ ３
Ｒ ＢＲ
ｄ
ＢＲ
ＢＲ
ＢＲ
ＢＲ
ＢＲ ＢＲ
Ｗ−Ｂ
Ｗ−Ｂ
ｅ
Ｒ Ｒ
ｆ
ＧＬ ＥＭ ＯＫ ＧＪ
E3-29
DPF-2
PARTS
Code See Page Code See Page Code See Page Code See Page
A 39 E2-12 F 3 E2-18 G 45 E2-6,8 G 67 E2-6
A 41 E2-10 G 4 E2-6,8 G 46 E2-6,8 G 68 E2-8
A 67 E2-10 G 31 E2-6,8 G 49 E2-6,8 G 69 E2-6,8
E 1 E2-18 G 39 E2-12 G 50 E2-6,8 G 70 E2-8
E 2 E2-18 G 41 E2-6,8 G 51 E2-6,8 G 72 E2-8
E 3 E2-18 G 42 E2-6,8 G 52 E2-6,8 Y 4 E2-16
F 1 E2-18 G 43 E2-12 G 53 E2-6,8
F 2 E2-18 G 44 E2-6,8 G 54 E2-6
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AA1 E2-12 BODY MAIN WIRE to BODY MAIN WIRE
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
AG3 E2-12 BODY MAIN WIRE to ENGINE WIRE
AO3 E2-12 BODY MAIN WIRE to LH SIDE WIRE
XO1 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
YX2 E2-16 HOOD SUB NO.1 WIRE to HOOD MAIN WIRE
EARTH
Code See Page Name
EM E2-18 FRONT PLATE RIGHT OUTSIDE EARTH
GJ E2-6,8 JUNCTION BLOCK IN FRONT INSIDE EARTH
GL E2-6,8 JUNCTION BLOCK IN FRONT INSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-30
（ＢＡＴ） （ＩＧ）
＊ １：１ＤＺ Ｗ
７．５Ａ ７．５Ａ ＊ ２：２Ｚ ａ
ＥＣＵ−Ｂ２ ＩＧＮ ＊ ３：ＳＨＩＥＬＤＥＤ ＷＩＲＥ Ｂ
ｂ
２ ２
１ １ Ｌ−Ｇ
Ｍ０５ ｃ
Ｗ
ＳＴ ＲＥＬＡＹ
１ ｄ
Ｏ
Ｂ−Ｒ
Ｂ−Ｗ
ｅ
３４ １Ｃ ９ １Ｄ ６ １Ｄ ２０ １Ｄ １ Ｌ−Ｙ
ｆ
１ ＡＧ２
Ｗ−Ｌ
ｇ
Ｏ−Ｌ
Ｂ−Ｏ
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ−Ｗ
Ｂ−Ｗ
ｈ
＊３
４ ２ ｉ
Ｌ−Ｇ
Ｌ−Ｙ
Ｏ−Ｌ
Ｗ−Ｌ
＋ ＋
３ ＡＧ２ ６ ＡＧ２ ７ ＡＧ２ ８ ＡＧ２ ９ ＡＧ２ １０ ＡＧ２ １１ ＡＧ２ １２ ＡＧ２
− −
ＯＰＥＮ ＣＬＯＳＥ
ＳＷＩＴＣＨ
Ｇ ３６
３ １
Ｂ
Ｏ
Ｗ
Ｗ
Ｗ
＊３
Ｂ−Ｒ
Ｇ−Ｂ
Ｒ−Ｂ
Ｌ−Ｇ
Ｌ−Ｙ
Ｏ−Ｌ
Ｗ−Ｌ
Ｂ−Ｗ
Ｇ ３８（Ａ），Ｇ ３９（Ｂ）
１Ａ ＡＳＣ ＥＣＵ ２５ Ｂ １５ Ｂ １２ Ｂ ２Ｂ ２６ Ｂ １３ Ｂ １９ Ｂ ６Ｂ ７Ｂ １８ Ｂ ５Ｂ １７ Ｂ
Ｂ ＩＧＳＷ ＺＥＲＯ ＮＭＲ ＳＴＡ ＣＡＮＬ ＣＡＮＨ ＶＣＰＡ ＶＰＡ ＥＰＡ ＶＣＰ２ ＶＰＡ２ ＥＰＡ２
ASC
Ｅ３ ＴＡＣ＋ ＴＡＣ− ＩＮＡ ＩＮＢ ＮＩＮＡ ＮＩＮＢ ＭＥＮ＋ Ｅ１２ ＳＲＬＹ ＮＥ＋ ＮＥ− Ｅ１１ Ｅ１２
２１ Ｂ ２０ Ｂ ８Ｂ ３Ａ ４Ａ １１ Ａ １２ Ａ ２Ａ １３ Ａ ５Ａ ９Ｂ ２２ Ｂ ９Ａ １０ Ａ
Ｇ
Ｙ
Ｒ
Ｇ
Ｒ
Ｗ
＊３
＊３
ＬＧ
ＢＲ
ＢＲ
Ｗ−Ｂ
Ｂ
Ｒ
Ｗ
＊３
Ｂ
Ｂ
７Ｃ ２０ Ｃ ＊１
７Ｄ ２０ Ｄ ＊２ ５ ４ ２ １ ３ ２ １ ４ ５ １２
ＮＥ＋ ＮＥ− ＩＡ ＩＢ ＮＩＡ ＮＩＢ Ｂ ＮＥ ＮＥ−
Ｅ１ １３ ９
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ｅ）
Ｇ ４３
１５ Ｃ ＊１
ＤＰＦ ＥＣＵ
Ｇ ６９（Ｃ），Ｇ ７０（Ｄ）
Ｇ ３１
１５ Ｄ ＊２ ＩＮＪＥＣＴＯＲ ＰＵＭＰ
ＢＲ
Ｇ ３７
Ｂ
ＳＴＥＰ ＭＯＴＯＲ
Ｗ−Ｂ
６ ２ ＬＧ
Ｇ ４３ ｊ
ＪＵＮＣＴＩＯＮ Ｗ−Ｂ
ＣＯＮＮＥＣＴＯＲ（Ｅ） ｋ
７ １ Ｂ
ｌ
１６ １４
Ｗ−Ｂ Ｗ−Ｂ
１Ｄ １Ｅ
ＯＫ ＧＪ
（ＩＧ）
Ｗ
ａ ＊ ３：ＳＨＩＥＬＤＥＤ ＷＩＲＥ ７．５Ａ
Ｂ ＊ ４：ＴＷＩＳＴＥＤ ＷＩＲＥ ＩＧＮ
ｂ
２
Ｌ−Ｇ １
ｃ
Ｗ
ｄ
Ｏ
ｅ
Ｌ−Ｙ
ｆ
Ｗ−Ｌ
Ｂ
Ｗ
ｇ
＊４
Ｏ−Ｌ
Ｂ−Ｗ
ｈ
＊３
ｉ
４ ＡＧ２ ５ ＡＧ２
Ｏ
Ｗ
＊３
Ｏ−Ｌ
Ｌ−Ｙ
Ｌ−Ｇ
Ｗ−Ｌ
１ １
Ｂ
Ｗ
＊４
１ ５
ＡＳＣ
ＲＥＬＡＹ
１ ２
Ｗ−Ｂ
２ ３
Ａ ３４
５ Ａａ１ １ Ａａ１ ７ Ａａ１ ３ Ａａ１ ２ Ａａ１ ８ Ａａ１ ４ Ａａ１ ＣＡＮ ＪＯＩＮＴ １ １
ASC
ＣＯＮＮＥＣＴＯＲ
ＢＲ
Ｂ
ＬＧ
Ｗ−Ｂ
２ ＡＧ２ １３ ＡＧ２
Ｏ
Ｗ
＊３
Ｏ−Ｌ
Ｌ−Ｙ
Ｌ−Ｇ
Ｗ−Ｌ
Ｂ
ＬＧ
２ ３ １ ６ ４ ５ １２ １Ａ
ＥＰＡ２ ＶＰＡ２ ＶＣＰ２ ＥＰ１ ＶＰＡ１ ＶＣＰ１
８ １Ｄ ３３ １Ｃ
ａ １
ＡＣＣＥＬ ＳＥＮＳＯＲ
Ｗ−Ｂ
Ｗ−Ｂ
ＬＧ
ｊ
Ｗ−Ｂ
ｋ
Ｂ
ｌ
ＡＣ
E3-31
E3-32
ASC
PARTS
Code See Page Code See Page Code See Page Code See Page
A 34 E2-12,23 G 37 E2-6,8 G 43 E2-12 a 1 E2-10
G 31 E2-6,8 G 38 E2-12 G 69 E2-6,8
G 36 E2-6,8 G 39 E2-12 G 70 E2-8
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AG2 E2-12 BODY MAIN WIRE to ENGINE WIRE
Aa1 E2-10 BODY MAIN WIRE to SUB ACCEL WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
GJ E2-6,8 JUNCTION BLOCK IN FRONT INSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-33
MEMO
ＧＡＳ
６
Ｒ−Ｂ Ｒ−Ｂ
４ ＡＣ３
１ ＴＣ２
ＩＧ
４
２
Ｒ−Ｌ Ｒ−Ｌ Ｂ−Ｗ Ｂ−Ｗ
１
２６ １Ｃ
３４ １Ｃ
＊ ３：ＲＵＳＳＩＡ
３ ＴＣ２
２ ＡＣ３
（ＩＧ）
ＳＯＬ
３
Ｒ−Ｗ
ＩＧＮ
７．５Ａ
２ ＴＣ２
＊ ２：ＥＸＣＥＰＴ ＲＵＳＳＩＡ
Ｔ ６
ＬＰＧ ＣＨＡＮＧＥ
Ｒ−Ｗ
ＳＷＩＴＣＨ
＊ ４：Ｗ／ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
Ｒ−Ｗ Ｒ−Ｗ
３ ＡＣ３
＊ １：Ｗ／ ＬＰＧ ＷＡＲＮＩＮＧ ＳＹＳＴＥＭ
Ｒ−Ｂ
Ｇ ３４
ＦＵＥＬ ＣＵＴ
ＳＯＬＥＮＯＩＤ
１
Ｒ−Ｂ
２
１
Ｗ−Ｂ Ｒ−Ｂ
１０ ＡＧ１
Ｇ ６５
ＧＡＳ ＳＯＬＥＮＯＩＤ
４
１
Ｗ−Ｂ Ｗ−Ｂ Ｒ−Ｗ Ｒ−Ｗ
Ｅ
Ｂ
ＧＦ
１１ ＡＧ１
１
３
２
Ｂ Ｂ Ｇ
１４ １Ｄ
１ １Ｄ
ＩＧ−
ＲＬＹ
１５ ＡＧ１
ＴＡＣＨ
Ｗ−Ｂ
Ｇ ２６ Ｇ ６６
１
２
ＴＡＣＨＯ ＥＮＧＩＮＥ ＲＥＶＯＬＵＴＩＯＮ Ｇ
１
１
ＣＨＥＣＫ Ｋ ３（Ａ），Ｋ ８（Ｂ） ＳＷＩＴＣＨ
ＬＰＧ ＳＯＬＥＮＯＩＤ
（ＭＡＩＮ）
Ｒ−Ｗ
Ｒ−Ｗ
３
５
Ｗ−Ｂ Ｗ−Ｂ Ｙ Ｙ Ｙ Ｙ
１
１
ＧＧ
２ ＧＫ１
８ ＧＫ１
１４ ＡＧ１
＊２
２ Ｂ ＊３
２ Ａ ＊２
１ Ｂ ＊３
１ Ａ ＊２ Ｙ−Ｂ
＊３
Ｙ
Ｋ １（Ａ），Ｋ ７（Ｂ）
ＲＥＬＡＹ
ＬＰＧ ＳＯＬＥＮＯＩＤ
（ＳＬＯＷ）
ＬＰＧ ＭＡＩＮ
Ｗ−Ｂ Ｌ−Ｂ Ｙ Ｙ
６ ＧＫ１
７ ＧＫ１
＊２
２ Ｂ ＊３
２ Ａ ＊２
１ Ｂ ＊３
１ Ａ ＊２
Ｙ−Ｂ
＊３
Ｒ−Ｗ Ｒ−Ｗ Ｙ
１Ｂ
１Ａ
３ ＧＫ１
１ ＫＭ１
＊１ ＊１ ＊１
Ｍ １（Ａ），Ｍ ２（Ｂ）
ＬＰＧ ＰＲＥＳＳＵＲＥ ＳＷ
Ｌ Ｌ Ｌ Ｌ Ａ ３７
ＬＰＧ ＷＡＲＮＩＮＧ
４ ＧＫ１
１３ ＡＧ１
２ ＫＭ１
＊１ ＊１ ＊１ ＊１ ＲＥＬＡＹ
１
５
Ｌ
＊１
Ｌ
＊１
Ｇ
Ｇ
＊１
＊１
６
３
Ｗ−Ｂ Ｗ−Ｂ Ｗ−Ｂ
３３ １Ｃ
１２ １Ａ
ＡＣ
＊４ ＊４ ＊４
４
Ｗ−Ｂ Ｗ−Ｂ Ｗ−Ｂ
＊１
７ ＵＡ２
Ｌ−Ｂ
＊１ ＊１ ＊１
Ｌ
＊１
１
４
２
１
Ｗ−Ｂ Ｌ Ｌ Ｌ
１ ＵＡ２
＊１ ＊１ ＊１ ＊１
Ａ ３８
ＬＰＧ ＷＡＲＮＩＮＧ
ＢＵＺＺＥＲ
５
７
Ｗ−Ｂ Ｇ Ｇ
４ ＵＡ２
＊１ ＊１ ＊１
Ｕ ５
ＬＰＧ ＷＡＲＮＩＮＧ
ＳＷＩＴＣＨ
LPG SYSTEM (4Y-M)
E3-34
E3-35
LPG SYSTEM (4Y-M)
PARTS
Code See Page Code See Page Code See Page Code See Page
A 37 E2-12 G 65 E2-2 K 7 E2-2 T 6 E2-18
A 38 E2-12 G 66 E2-12 K 8 E2-2 U 5 E2-14
G 26 E2-2 K 1 E2-2 M 1 E2-2
G 34 E2-2 K 3 E2-2 M 2 E2-2
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AC3 E2-12 BODY MAIN WIRE to SIDE RH WIRE
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
GK1 E2-2 ENGINE WIRE to ENGINE SUB WIRE
KM1 E2-2 ENGINE SUB WIRE to LPG PRESSURE SWITCH WIRE
TC2 E2-18 RR UPR SUB RH WIRE to SIDE RH WIRE
UA2 E2-14 HEAD GUARD SW WIRE to BODY MAIN WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
GF E2-2 ENGINE UPPER EARTH
GG E2-2 ENGINE UPPER EARTH
Ａ ３６
ＥＮＧＩＮＥ ＥＣＵ
ＥＦＩ ＭＡＩＮ
ＲＥＬＡＹ
１
２
３
１９
Ｗ−Ｂ Ｗ−Ｂ ＬＧ Ｂ−Ｙ
７Ｂ
１２ Ａ
１
１
ＧＦ
ＢＡＴＴ
ＭＲＥＬ
３
５
２
Ｒ−Ｌ Ｂ−Ｙ Ｂ−Ｙ
１
１
１
Ｗ−Ｂ
（ＢＡＴ）
ＪＵＮＣＴＩＯＮ
１５Ａ
ＥＦＩ
ＧＧ
ＣＯＮＮＥＣＴＯＲ（Ａ）
Ａ ６５（Ａ），Ｇ ７３（Ｂ）
ＧＡＳ
６
Ｒ−Ｂ
＊２
ＩＧ
４
Ｒ−Ｌ Ｒ−Ｌ Ｒ−Ｌ
１Ａ
２ ＡＣ３
３ ＴＣ２
＊２ ＊２ ＊２
ＬＰＧ
３
Ｒ−Ｗ
Ｒ−Ｌ ＊２
２Ａ
４Ｂ
Ｔ ６
ＬＰＧ ＣＨＡＮＧＥ
Ａ ６６（Ａ），Ｇ ２９（Ｂ） ＳＷＩＴＣＨ
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ｂ）
＊１
Ｒ−Ｗ
Ｒ−Ｗ Ｒ−Ｗ Ｒ−Ｗ
１Ｂ
１Ａ
１１ Ｂ
１０ Ｂ
３ ＧＫ１
１ ＫＭ１
Ｍ １（Ａ），Ｍ ２（Ｂ）
ＬＰＧ ＰＲＥＳＳＵＲＥ ＳＷ
Ｒ−Ｗ Ｒ−Ｗ Ｒ−Ｗ
８Ａ
３ ＡＣ３
２ ＴＣ２
＊２ ＊２ ＊２
Ａ ６５（Ａ），Ｇ ７３（Ｂ）
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ａ）
Ｌ Ｌ Ｌ Ｌ Ａ ３７
ＬＰＧ ＷＡＲＮＩＮＧ
４ ＧＫ１
１２ ＡＧ１
２ ＫＭ１
ＲＥＬＡＹ
１
５
Ｌ
Ｌ
Ｇ
Ｇ
６
３
Ｗ−Ｂ Ｗ−Ｂ Ｗ−Ｂ
３３ １Ｃ
１２ １Ａ
ＡＣ
４
Ｗ−Ｂ Ｗ−Ｂ Ｗ−Ｂ
７ ＵＡ２
Ｌ−Ｂ
１
４
２
１
Ｗ−Ｂ Ｌ Ｌ Ｌ
１ ＵＡ２
Ａ ３８
ＬＰＧ ＷＡＲＮＩＮＧ
ＢＵＺＺＥＲ
５
７
Ｗ−Ｂ Ｇ Ｇ
４ ＵＡ２
Ｕ ５
ＬＰＧ ＷＡＲＮＩＮＧ
ＳＷＩＴＣＨ
＊ １：ＬＰＧ
＊ ２：ＬＰＧ ＣＯＮＶＥＲＴＩＢＬＥ
LPG WARNING SYSTEM (4Y-E)
E3-36
E3-37
LPG WARNING SYSTEM (4Y-E)
PARTS
Code See Page Code See Page Code See Page Code See Page
A 36 E2-12 A 65 E2-12 G 73 E2-12 T 6 E2-18
A 37 E2-12 A 66 E2-12 M 1 E2-4 U 5 E2-14
A 38 E2-12 G 29 E2-12 M 2 E2-4
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AC3 E2-12 BODY MAIN WIRE to SIDE RH WIRE
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
GK1 E2-4 ENGINE WIRE to ENGINE SUB WIRE
KM1 E2-4 ENGINE SUB WIRE to LPG PRESSURE SWITCH WIRE
TC2 E2-18 RR UPR SUB RH WIRE to SIDE RH WIRE
UA2 E2-14 HEAD GUARD SW WIRE to BODY MAIN WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
GF E2-4 ENGINE UPPER EARTH
GG E2-4 ENGINE UPPER EARTH
E3-38
（ＩＧ） ＊ １：Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊ ２：ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊ ３：Ｔ／Ｃ ＳＨＩＦＴ ＬＥＶＥＲ ＣＯＬＵＭＮ
７．５Ａ ＊ ４：ＦＵＬＬ ＯＰＴＩＯＮ
ＳＦＴ ＊ ５：ＳＴＡＮＤＡＲＤ
＊ ６：２ＳＴＡＴＯＲ Ｔ／Ｃ
＊ ７：１ＳＰＥＥＤ Ｔ／Ｃ
Ｌ−Ｒ
２
Ｌ−Ｏ
１ １９ １Ｂ ３ １Ｂ ８ １Ｂ
Ｒ−Ｂ
Ｌ−Ｏ
Ｌ−Ｒ
＊１
Ｌ−Ｂ
４ １ ４ １ １７ Ｂ １９ Ａ １８ Ａ
１１ ＡＯ３
ＲＹＦ ＤＲＲ ＤＲＦ
Ｔ／Ｃ ＦＲ Ｔ／Ｃ ＲＲ
ＲＥＬＡＹ ＲＥＬＡＹ
＊１
Ｌ−Ｂ
３ ２ ３ ２
Ａ ２０（Ａ），Ａ ２１（Ｂ）
ＳＡＳ／ＯＰＳ ＥＣＵ
＊２
３ ＸＯ１
Ｌ−Ｂ
＊１
Ｌ−Ｂ
１７ １Ｂ ２２ １Ｅ ３６ １Ｂ １９ １Ｅ ４ １Ａ ２ １Ａ ５ １Ａ ３ １Ａ ７ １Ａ
１ ＹＸ２
＊１
Ｌ−Ｂ
Ｗ−Ｂ
＊２
＊１
＊２
＊１
＊４
＊４
＊５
＊５
６ Ａ ＊３
Ｌ−Ｏ
Ｌ−Ｒ
Ｌ−Ｒ
Ｐ−Ｌ
Ｐ−Ｌ
Ｐ−Ｌ
Ｌ−Ｗ
ＬＧ−Ｂ
ＬＧ−Ｂ
ＬＧ−Ｂ
６ Ｂ ＊１
３Ａ １Ａ ２ １ １ ３
６ ＸＯ１ ８ ＸＯ１
ＬＥＦＴ Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ａ ４１（Ａ）
Ｙ ４（Ｂ）
POWER SHIFT TRANSMISSION
＊６
＊６
ＤＩＯＤＥ
Ａ ２６
５Ａ １ Ａ ＊３ ２
ＳＨＩＦＴ ＳＯＬＥＮＯＩＤ１
Ａ ５５
５Ｂ １ Ｂ ＊１
＊１
＊１
Ｌ−Ｒ
Ｌ−Ｗ
＊７
＊７
２４ １Ａ
Ｌ−Ｏ ＊６
＊６
＊２ ３ ＹＸ２ １５ ＹＸ２
ＳＨＩＦＴ ＳＯＬＥＮＯＩＤ２
Ａ ４７（Ａ），Ａ ４８（Ｂ）
３Ｃ １Ｃ ４Ａ ２Ａ
Ｌ−Ｗ
２ １Ｃ
＊１
＊７
＊７
＊６
＊６
Ｐ−Ｌ
Ｗ−Ｂ
Ｗ−Ｂ
ＬＧ−Ｂ
Ｌ−Ｒ
＊２ ２ １
Ｌ−Ｒ
＊１
Ｗ−Ｂ
Ｗ−Ｂ
ＳＨＩＦＴ
ＳＯＬＥＮＯＩＤ１
Ａ ５４
ＡＤ ＡＤ ＡＡ
E3-39
POWER SHIFT TRANSMISSION
PARTS
Code See Page Code See Page Code See Page Code See Page
A 20 E2-10 A 41 E2-10 A 54 E2-12
A 21 E2-10 A 47 E2-12 A 55 E2-12
A 26 E2-12 A 48 E2-12 Y 4 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AO3 E2-12 BODY MAIN WIRE to LH SIDE WIRE
XO1 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
YX2 E2-16 HOOD SUB NO.1 WIRE to HOOD MAIN WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
AD E2-12 TRANSMISSION UPPER EARTH
E3-40
（ＩＧ）
１０Ａ
ＧＡＵＧＥ
Ｒ
３２ １Ｃ
２７ １Ｃ
Ｒ
Ｒ
Ｒ
２
１
Ａ ６９ Ｂ
ＷＥＴ ＢＲＡＫＥ
ＬＡＭＰ
２ Ｅ
ＷＥＴ ＢＲＡＫＥ
ＢＵＺＺＥＲ
Ａ ６８
１ ２
Ｇ
Ｌ
Ｌ
Ａ ７０
WET BRAKE
ＰＲＥＳＳＵＲＥ ＳＷ
２
１
ＤＩＯＤＥ
（ＷＥＴ ＢＲＡＫＥ）
Ａ ７１
３ １
Ｗ−Ｂ
Ｙ
Ｌ
Ｙ
Ｗ−Ｂ
７ １Ｃ
１ １Ａ
２１ １Ｄ
Ｙ
１７ １Ｃ
１
Ｇ ４
Ｗ−Ｂ
Ｌ ＡＬＴＥＲＮＡＴＯＲ
ＡＢ
E3-41
WET BRAKE
PARTS
Code See Page Code See Page Code See Page Code See Page
A 68 E2-10 A 70 E2-10 G 4 E2-2,4,6,8
A 69 E2-10 A 71 E2-12
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
EARTH
Code See Page Name
AB E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-42
Ｌ
ａ
（ＢＡＴ） （ＢＡＴ） ＊２
（ＩＧ）
＊ １：Ｔ／Ｃ Ｗ／ ＡＳＣ
７．５Ａ ７．５Ａ ＊ ２：ＭＩＮＩ ＬＥＶＥＲ
ＥＣＵ−Ｂ ＳＴＯＰ ＊ ３：ＳＴＡＮＤＡＲＤ ＴＹＰＥ ＣＯＮＴＲＯＬ １０Ａ
ＶＡＬＶＥ ＬＥＶＥＲ ＥＣＵ−ＩＧ
＊ ４：Ｗ／ ＵＬＴＲＡ ＳＯＮＩＣ ＳＥＮＳＯＲ
２ ２
２
１ １
１
Ｂ
Ｇ
＊１
Ｌ
Ｌ
Ｌ
＊２
１２ １Ｃ ２９ １Ａ １
１５ １Ａ ２６ １Ｅ １４ １Ｃ
ＳＴＯＰ ＬＡＭＰ
ＳＷＩＴＣＨ
Ａ ６
２
Ｂ
５ １Ｂ Ａ ２３
７ １Ｂ ６ １Ｂ ２６ １Ａ
ＭＩＮＩ ＬＥＶＥＲ
＊１
Ｂ−Ｌ
１ ＥＣＵ １
１９ １Ａ
Ｅ４３ Ｅ４４
ＯＰＳ ＷＡＲＮＩＮＧ
ＢＵＺＺＥＲ
ＳＰＥＥＤ
ＳＥＮＳＯＲ
Ａ ８
Ａ １９
２ １ １Ｂ ９ １０ ２ Ｌ
８ １Ｂ ｂ
＊４
Ｒ−Ｂ
Ｌ
Ｌ
＊１
（Ｔ／Ｃ）
Ｂ−Ｌ
Ｗ−Ｂ
Ｗ−Ｂ
ＬＧ−Ｂ
Ｇ−Ｂ
Ｇ−Ｒ
１ ４ １ ４
１７ Ｂ ８Ｂ １１ Ｂ １７ Ａ １０ Ｂ ９Ｂ ２２ Ｂ ２３ Ｂ １Ｂ ２Ｂ
ＲＹＦ ＢＡＴＴ ＢＵＺＺ ＢＳＷ Ｅ４２ Ｅ４１ ＳＰ１＋ ＳＰ１− ＩＧ ＩＧ２
Ａ ２０（Ａ），Ａ ２１（Ｂ）
Ｔ／Ｃ ＦＲ
ＲＥＬＡＹ
Ｔ／Ｃ ＲＲ
ＲＥＬＡＹ
ＳＡＳ／ＯＰＳ ＥＣＵ
２ ３ ２ ３
ＤＲＲ ＤＲＦ ＬＳＯＬ ＴＳＯＬ ＵＳＯＬ ＳＴＲＧ ＢＳＯ＋ Ｅ０１ Ｅ０２ Ｅ１１ Ｅ１２
１９ Ａ １８ Ａ ７Ａ ４Ａ ５Ａ ６Ａ １０ Ａ ８Ａ ９Ａ ３Ｂ ４Ｂ
SAS/OPS SYSTEM
１９ １Ｂ ３ １Ｂ
Ｒ
＊３
Ｒ−Ｂ
Ｒ−Ｙ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｒ−Ｗ
ＬＧ−Ｒ
Ｌ−Ｒ
Ｌ−Ｗ
（Ｔ／Ｃ）
（Ｔ／Ｃ）
１ １ １ １ １
ＬＩＦＴ
ＳＯＬＥＮＯＩＤ
ＴＩＬＴ
ＳＯＬＥＮＯＩＤ
ＵＮＬＯＡＤ
ＳＯＬＥＮＯＩＤ
ＳＴＥＥＲＩＮＧ
ＳＯＬＥＮＯＩＤ
ＢＡＣＫ ＴＩＬＴ
ＳＯＬＥＮＯＩＤ
Ａ １１
Ａ １０
Ａ １２
Ａ ５
Ａ ５６
２ ２ ２ ２ ２
＊３
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
２５ １Ｂ ２３ １Ｂ ３ １Ｃ ４ １Ｃ ２１ １Ａ ２６ １Ｂ ２２ １Ｂ ２０ １Ｂ ２ １Ｂ
２ １Ｃ １４ １Ｅ ２８ １Ｅ
Ｌ
ｃ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
ＡＡ ＯＫ
Ｌ Ｌ
ａ ａ
＊２ ＊２
ＢＲ
＊ ２：ＭＩＮＩ ＬＥＶＥＲ ＊ ７：ＳＴＡＮＤＡＲＤ ＴＹＰＥ ＣＯＮＴＲＯＬ ＶＡＬＶＥ
＊４ ＊ ３：ＳＴＡＮＤＡＲＤ ＴＹＰＥ ＣＯＮＴＲＯＬ ＬＥＶＥＲ Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ
ＶＡＬＶＥ ＬＥＶＥＲ ＊ ８：ＬＩＦＴ ＨＩＧＨＴ ＯＦ ３０００
＊ ４：Ｗ／ ＵＬＴＲＡ ＳＯＮＩＣ ＳＥＮＳＯＲ Ｗ／ ＳＩＮＧＬＥ ＴＩＲＥ
＊ ５：Ｗ／Ｏ ＵＬＴＲＡ ＳＯＮＩＣ ＳＥＮＳＯＲ ＊ ９：Ｔ／Ｃ Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ
＊ ６：Ｗ／ ＭＡＳＴ ＳＷＩＴＣＨ２ ＊１０：Ｗ／ ＳＩＮＧＬＥ ＴＩＲＥ
＊４
＊４
ＢＲ
ＢＲ
Ｌ−Ｒ
５ ４ １ １
ｂ
Ｅ Ｌ−ＳＷ
＊６
＊４
１１ １Ａ ２４ １Ｂ ２１ １Ｂ １０ １Ａ ２３ １Ａ ８ １Ａ １９ １Ｃ ２０ １Ｃ ２１ １Ｃ ２３ １Ｃ
Ｌ−Ｒ
Ｌ−Ｒ
ＭＡＳＴ
ＳＷＩＴＣＨ２
ＭＡＳＴ ＳＷＩＴＣＨ
ｂ ２
ｂ １
＋Ｂ ＯＵＴ２ ＯＵＴ１
３ ２ ３ ２
ＵＬＴＲＡ ＳＯＮＩＣ
ＳＥＮＳＯＲ
ｂ ３
１ ３ ２
＊６
＊６
＊３
＊７
＊３
＊３
＊８
＊８
ＢＲ
ＢＲ
ＢＲ
ＢＲ
ＢＲ
ＢＲ
ＢＲ
Ｌ−Ｂ
Ｌ−Ｗ
Ｌ
＊４
＊４
＊４
＊４
Ｌ−Ｂ
Ｌ−Ｗ
２ ４ ４ ２
Ｅ Ｅ Ｅ Ｅ
Ｌ
１ １
＊５ Ｌ−Ｙ
ＢＲ
ＢＲ
１Ｂ
Ｌ−Ｂ
２ Ａｂ１
Ｆ Ｒ Ｕ Ｄ
ＭＡＴＣＨＩＮＧ
ＣＯＮＮＥＣＴＯＲ
ＮＥＵＴＲＡＬ ＴＩＬＴ
ＳＷＩＴＣＨ
ＬＯＡＤ ＩＮＤＩＣＡＴＯＲ
ＴＩＬＴ ＳＷＩＴＣＨ
ＬＩＦＴ ＳＷＩＴＣＨ
Ａ ４５（Ａ），Ａ ４６（Ｂ）
Ａ １５
Ａ １６
Ａ １３
Ａ １４
１Ａ ２ ２ １ ３ ３ １
Ｌ
ｂ １ Ａｂ１ ５ Ａｂ１ ３ Ａｂ１ ４ Ａｂ１
＊４
Ｐ
Ｙ
＊３
＊７
＊３
＊３
＊８
＊８
ＢＲ
ＢＲ
Ｖ−Ｇ
Ｇ−Ｂ
Ｙ−Ｂ
Ｒ−Ｌ
Ｒ−Ｇ
Ｌ−Ｂ
Ｌ−Ｙ
Ｌ−Ｗ
３３ Ａ ３２ Ａ ３１ Ａ １Ａ ２６ Ａ ２４ Ａ ３０ Ａ ３４ Ａ ２０ Ａ ２１ Ａ ２２ Ａ ２３ Ａ
ＭＨ２２ ＭＨ２１ ＭＨ１ Ｅ３ ＭＴＣ ＭＡＴ ＭＮ ＰＩ ＭＦ ＭＲ ＭＵ ＭＤ
Ａ ２０（Ａ），Ａ ２１（Ｂ）
ＳＡＳ／ＯＰＳ ＥＣＵ
ＳＳ１ ＳＳ２ ＳＳＣ Ｅ２ ５ＰＲＳ ＰＲＥＳ ５ＭＡ ＭＡ ＴＨＯ ５Ｔ Ｔ ＳＷＮ＋ ＳＷＮ−
１４ Ｂ １５ Ｂ １６ Ｂ ５Ｂ １９ Ｂ ２７ Ｂ ２８ Ｂ ３２ Ｂ ３５ Ｂ ３０ Ｂ ３４ Ｂ ３Ａ ２Ａ
SAS/OPS SYSTEM
Ｖ
Ｒ
＊９
ＢＲ
＊１０
＊１０
Ｖ−Ｒ
Ｒ−Ｌ
Ｇ−Ｏ
Ｇ−Ｒ
Ｙ−Ｇ
Ｐ−Ｌ
Ｗ−Ｂ
Ｖ−Ｗ
Ｇ−Ｗ
ＬＧ−Ｂ
３ ４ ５ １ ２ １ ２ １ ＤＡ１ １１ ＡＯ１ ２ ＡＯ１ ８ ＡＯ１ １２ ＡＯ１ １３ ＡＯ１
ＳＳ１ ＳＳ２ ＳＳＣ Ｂ Ｐ
Ｖ
＊９
Ｒ
２
ＢＲ
＊１０
＊１０
Ｐ−Ｌ
Ｗ−Ｂ
３
Ｇ−Ｗ
ＩＧ ＥＳＳ Ｅ Ａ ４２
ＴＩＬＴ
１ ２ Ａ ３ ３ Ａ １８ ＡＮＧＬＥ
ＳＴＥＥＲＩＮＧ ＰＲＥＳＳＵＲＥ ＳＥＮＳＯＲ １ ＺＯ１ ４ ＺＯ１ ３ ＺＯ１ ７ ＺＯ１ ２ ＺＯ１
Ｔ／Ｃ ＯＩＬ ＴＥＭＰ
ＳＥＮＳＯＲ
Ｄ １
ＳＥＮＳＯＲ ＳＥＮＳＯＲ
１
Ｌ
ＢＲ
ＢＲ
ＢＲ
Ｒ
＊９
ＢＲ
ＢＲ
ＢＲ
＊１０
＊１０
Ｐ−Ｌ
Ｗ−Ｂ
Ｇ−Ｗ
３ ２ １
２ ＤＡ１
＊９
ＢＲ
ＴＩＲＥ ＡＮＧＬＥ
ＳＥＮＳＯＲ
Ｚ ３
ＳＷＩＮＧ ＬＯＣＫ
ＳＯＬＥＮＯＩＤ
Ｚ １
Ｌ
ｃ ＢＲ ＢＲ ＢＲ １ ２
E3-43
Ｙ １
E3-44
Ｌ
ａ ＮＥＵＴＲＡＬ ＴＩＬＴ
＊２ ＳＷＩＴＣＨ （ＩＧ）
Ｇ−Ｒ
＊２ １０Ａ
２７ １Ｃ
Ｒ
ＩＧ Ｅ ＋ ＧＡＵＧＥ
＊２
ＢＲ
３Ｂ
１ ２ ３ ２
２
Ｌ
Ｅ ＩＧ ＰＩ
＊２
＊２
＊２
ＢＲ
Ｇ−Ｂ
＊２
ＢＲ
２Ａ １Ａ ３Ａ １２ ＱＡ１ ３２ １Ｃ １
ｂ ＢＲ ＢＲ
１
ＬＯＡＤ ＩＮＤＩＣＡＴＯＲ
ＳＷＩＴＣＨ
ＳＨＯＲＴ
ＣＯＮＮＥＣＴＯＲ
Ｙ ７（Ａ）
Ｙ ９（Ｂ）
Ｌ
Ｐ
＊２
＊２
Ｒ
＊２ ＊２
ＣＯＮＴＲＯＬ ＶＡＬＶＥ
ＬＥＶＥＲ ３，４ＳＥＬＥＣＴ
ＳＷＩＴＣＨ
Ｙ ８
Ｒ
３０ １Ｅ ３１ １Ｅ
＊２
Ｇ−Ｗ
１
Ｌ
＊２
＊２
＊２
ＢＲ
Ｇ−Ｂ
＊２
ＢＲ
ＢＲ
ＩＧ＋
１０ ＹＸ２ ８ ＹＸ２ ７ ＹＸ２ １２ ＹＸ２ ５ ＹＸ２
１ ＸＯ３ ８ ＸＯ３ ＊２
１ ＸＯ４ ２ ＸＯ４ ＊３
Ｌ
Ｐ
＊２
＊２
＊２
＊２
＊２
ＢＲ
Ｇ−Ｂ
Ｇ−Ｗ
２ ＸＯ３ １３ ＸＯ３ ９ ＸＯ３ １５ ＸＯ３ １１ ＸＯ３
ＢＲ
ＢＲＡＫＥ
Ｙ−Ｇ
Ｙ−Ｇ
ＰＯＷＥＲ
１ ＣＩＲＣＵＩＴ
Ｌ
Ｐ
＊２
＊２
＊２
＊２
＊２
ＢＲ
１ ＡＯ１
Ｇ−Ｂ
Ｇ−Ｗ
２０ ＡＯ３ １７ ＡＯ３ １８ ＡＯ３ ＣＯＮＴＲＯＬ
ＳＥＡＴ
ＳＷＩＴＣＨ
Ｘ １
２ ＣＩＲＣＵＩＴ
Ｙ−Ｇ
Ｐ
＊２
＊２
＊２
Ｇ−Ｂ
Ｇ−Ｗ
３５ Ａ ３０ Ａ ３４ Ａ ２５ Ａ
ＳＩＬ２ Ｅ１ ＰＫＢＩ
ＤＭＳ ＭＮ ＰＩ ＡＴＳ
ＣＯＭＢＩＮＡＴＩＯＮ ＭＥＴＥＲ
Ｑ １
Ａ ２０（Ａ），Ａ ２１（Ｂ） ３ ８ １１
ＳＡＳ／ＯＰＳ ＥＣＵ
ＹＲＳ＋ ＹＲＳ ＹＲＳ− ＣＡＮＨ ＣＡＮＬ ＰＫＢ ＳＩＬ
＊１１
Ｒ−Ｇ
Ｗ−Ｂ
Ｒ−Ｗ
２４ Ｂ ２５ Ｂ ２６ Ｂ １２ Ａ １３ Ａ １５ Ａ １４ Ａ ２
SAS/OPS SYSTEM
１０ ＱＡ１ ４ ＱＡ１ １６ ＱＡ１
ＬＧ
＊１１
＊１１
＊１１
＊１１
Ｙ−Ｂ
Ｒ−Ｇ
ＰＡＲＫＩＮＧ ＢＲＡＫＥ
ＳＷＩＴＣＨ
Ａ ９
Ｒ−Ｗ
＊１４
Ｇ−Ｒ
３
＊１１
＊１１
Ｒ−Ｇ
Ｗ−Ｂ
Ｒ−Ｗ
Ｒ−Ｗ
４ ＡＯ１ ６ ＡＯ１ ５ ＡＯ１
＊１２
Ｗ−Ｂ
５Ａ １ Ａ ＊８
１Ｂ ２ Ｂ ＊９
８ １Ｃ ２４ １Ｃ １８ １Ｃ
Ｙ
Ａ ２７（Ａ）
ＬＧ
＊１１
＊１１
＊１１
Ｙ−Ｂ
ＪＵＮＣＴＩＯＮ ＣＯＮＮＥＣＴＯＲ
Ａ ２９（Ｂ）
＊１３
＊１２
Ｗ−Ｂ
Ｗ−Ｂ
１ ３ ２ ＣＡＮ ＪＯＩＮＴ ＣＯＮＮＥＣＴＯＲ
ＹＲＳ＋ ＹＲＳ ＹＲＳ−
１ １Ｃ １ １Ａ
２８ １Ｅ ４ １Ｂ
＊１１
Ｒ−Ｗ
Ｏ １
Ｗ−Ｂ
ＹＡＷ ＲＡＴＥ ＳＥＮＳＯＲ １７ １Ｃ
＊ ２：ＭＩＮＩ ＬＥＶＥＲ
＊５
Ｗ−Ｂ
＊ ３：ＳＴＡＮＤＡＲＤ ＴＹＰＥ ＣＯＮＴＲＯＬ ＶＡＬＶＥ ＬＥＶＥＲ
＊１０：Ｗ／ ＳＩＮＧＬＥ ＴＩＲＥ
＊１１：Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ ＯＲ ＯＫ ＭＯＮＩＴＯＲ
＊１２：Ｔ／Ｃ Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ ＯＲ ＯＫ ＭＯＮＩＴＯＲ ＯＫ ＡＢ
＊１３：Ｍ／Ｔ Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ ＯＲ ＯＫ ＭＯＮＩＴＯＲ
＊１４：ＴＷＩＳＴＥＤ ＷＩＲＥ
E3-45
SAS/OPS SYSTEM
PARTS
Code See Page Code See Page Code See Page Code See Page
A 3 E2-10 A 15 E2-10 A 45 E2-12 Y 9 E2-16
A 5 E2-10 A 16 E2-10 A 46 E2-12 Z 1 E2-16
A 6 E2-10 A 18 E2-10 A 56 E2-10 Z 2 E2-16
A 8 E2-10 A 19 E2-10 D 1 E2-12 Z 3 E2-16
A 9 E2-10 A 20 E2-10 O 1 E2-16 b 1 E2-14
A 10 E2-10 A 21 E2-10 Q 1 E2-10 b 2 E2-14
A 11 E2-10 A 23 E2-10 X 1 E2-16 b 3 E2-14
A 12 E2-10 A 27 E2-12 Y 1 E2-16
A 13 E2-10 A 29 E2-12,23 Y 7 E2-16
A 14 E2-10 A 42 E2-10 Y 8 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AO1 E2-12 BODY MAIN WIRE to LH SIDE WIRE
AO3 E2-12 BODY MAIN WIRE to LH SIDE WIRE
Ab1 E2-14 BODY MAIN WIRE to MAST SENSOR WIRE
DA1 E2-12 T/C HEAT GAUGE WIRE to BODY MAIN WIRE
QA1 E2-10 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
XO3 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
XO4 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
YX2 E2-16 HOOD SUB NO.1 WIRE to HOOD MAIN WIRE
ZO1 E2-16 RR LWR WIRE to LH SIDE WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
AB E2-12 FRONT PLATE LEFT OUTSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-46
（ＢＡＴ） （ＩＧ）
７．５Ａ １０Ａ
ＥＣＵ−Ｂ ＥＣＵ−ＩＧ
２ ２
１ １
Ｂ
Ｌ
１２ １Ｃ ２９ １Ａ １４ １Ｃ ２４ １Ｂ １９ １Ｃ ２０ １Ｃ ２３ １Ｃ ３０ １Ｅ ９ １Ａ
ＢＲ
ＢＲ
ＢＲ
ＢＲ
ＢＲ
Ｂ
５ １Ｂ ７ １Ｂ ６ １Ｂ
２ ４
１ Ｅ Ｅ ２
２ ＸＯ４
８ １Ｂ ＳＩＬ Ｆ Ｒ
ＯＰＳ ＷＡＲＮＩＮＧ
ＢＵＺＺＥＲ
ＤＩＡＧＮＯＳＩＳ
ＴＩＬＴ ＳＷＩＴＣＨ
ＬＩＦＴ ＳＷＩＴＣＨ
Ａ ８
Ａ ２５
Ａ １３
Ａ １４
２ １ １ ３ １
ＢＲ
Ｂ
Ｌ
Ｌ
Ｙ
ＢＲ
Ｒ−Ｂ
Ｒ−Ｇ
Ｙ−Ｂ
Ｒ−Ｇ
ＬＧ−Ｂ
（Ｔ／Ｃ）
１ ４ １ ４
１０ ３２ ９ １６ １５ １ １７ ２５ ２４ ２６ １
ＲＹＦ ＢＡＴＴ ＢＵＺＺ ＩＧ ＩＧ２ ＳＩＬ Ｅ３ ＭＦ ＭＲ ＭＤ
Ａ ２２
Ｔ／Ｃ ＦＲ
ＲＥＬＡＹ
Ｔ／Ｃ ＲＲ
ＲＥＬＡＹ
ＯＰＳ ＥＬＥＣＴＲＯＮＩＣ ＣＯＮＴＲＯＬ ＵＮＩＴ
２ ３ ２ ３
ＳＥＡＴ ＳＷＩＴＣＨ
Ｘ １
ＤＲＲ ＤＲＦ ＬＳＯＬ ＴＳＯＬ ＵＳＯＬ ＢＳＯ＋ Ｅ０１ Ｅ０２ Ｅ１１ ＲＹＬＰ ＤＭＳ ２
OPS SYSTEM
４ ３ １３ １２ １４ ２８ ２９ ３０ ３１ ８ ２３
７ １Ａ １９ １Ｂ ３ １Ｂ
Ｇ
Ｌ−Ｏ
Ｌ−Ｒ
Ｒ−Ｂ
Ｒ−Ｙ
Ｙ−Ｇ
Ｙ−Ｇ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｒ−Ｗ
ＬＧ−Ｒ
（Ｔ／Ｃ）
（Ｔ／Ｃ）
１ １ １ １
ＢＲ
Ｌ−Ｒ
（Ｔ／Ｃ）
１ ＡＯ１ １ ＸＯ４
７ ＱＡ１
ＬＩＦＴ
ＳＯＬＥＮＯＩＤ
ＴＩＬＴ
ＳＯＬＥＮＯＩＤ
ＵＮＬＯＡＤ
ＳＯＬＥＮＯＩＤ
ＢＡＣＫ ＴＩＬＴ
ＳＯＬＥＮＯＩＤ
Ａ １１
Ａ １０
Ａ １２
Ａ ５６
２ ２ ２ ２
Ｇ
Ｙ−Ｇ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
２５ １Ｂ ２３ １Ｂ ３ １Ｃ ２１ １Ａ ２６ １Ｂ ２２ １Ｂ ２０ １Ｂ
Ｇ
２ １Ｃ １４ １Ｅ ａ
Ｗ−Ｂ
Ｗ−Ｂ
ＡＡ ＯＫ
（ＩＧ）
１０Ａ
ＧＡＵＧＥ
Ｒ
３２ １Ｃ
１２ ＱＡ１
２７ １Ｃ
Ｒ
１
ＩＧ＋
ＰＯＷＥＲ
ＣＩＲＣＵＩＴ
ＣＯＮＴＲＯＬ
ＣＩＲＣＵＩＴ
OPS SYSTEM
ＲＹＬＰ Ｅ１ Ｅ２
ＣＯＭＢＩＮＡＴＩＯＮ ＭＥＴＥＲ
Ｑ １
４ ８ ９
Ｇ
Ｗ−Ｂ
Ｗ−Ｂ
４ ＱＡ１ １３ ＱＡ１
Ｗ−Ｂ
Ｗ−Ｂ
８ １Ｃ ２５ １Ｃ
Ｇ ２８ １Ｅ
ａ
Ｗ−Ｂ
ＯＫ
E3-47
E3-48
OPS SYSTEM
PARTS
Code See Page Code See Page Code See Page Code See Page
A 8 E2-10 A 12 E2-10 A 22 E2-10 Q 1 E2-10
A 10 E2-10 A 13 E2-10 A 25 E2-12 X 1 E2-16
A 11 E2-10 A 14 E2-10 A 56 E2-10
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AO1 E2-12 BODY MAIN WIRE to LH SIDE WIRE
QA1 E2-10 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
XO4 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-49
MEMO
E3-50
（ＩＧ） ＢＲ ＢＲ ＢＲ
＊ １：２ ＯＲ ３ＷＡＹ
１０Ａ ＊ ２：４ＷＡＹ
ＥＣＵ−ＩＧ
＊１
＊２
ＢＲ
ＢＲ
Ｙ ２ Ｙ ３
Ｗ−Ｂ
Ｗ−Ｂ
Ｙ ６ Ｙ ５ ＡＴＴＡＣＨＭＥＮＴ ＡＴＴＡＣＨＭＥＮＴ
２ ＬＩＦＴ ＬＥＶＥＲ １ ＴＩＬＴ ＬＥＶＥＲ １ ＬＥＶＥＲ１ １ ＬＥＶＥＲ２ １
１ ＬＩＦ− ＴＩＬ− ＡＴ１− ＡＴ２−
ＬＩＦ＋ ＬＩＦ１ ＬＩＦ２ ＴＩＬ＋ ＴＩＬ１ ＴＩＬ２ ＡＴ１＋ ＡＴ１１ ＡＴ１２ ＡＴ２＋ ＡＴ２１ ＡＴ２２
４ ３ ２ ４ ３ ２ ４ ３ ２ ４ ３ ２
Ｌ
Ｖ
Ｐ
Ｙ
Ｇ
Ｒ
＊１
＊１
＊１
＊２
＊２
＊２
ＢＲ
Ｂ−Ｙ
Ｌ−Ｒ
Ｌ−Ｂ
Ｇ−Ｙ
Ｂ−Ｗ
Ｇ−Ｗ
Ｌ−Ｗ
３ ＹＸ１ １２ ＹＸ１ １４ ＹＸ１ ６ ＹＸ１ １０ ＹＸ１ ８ ＹＸ１ １３ ＹＸ１ １５ ＹＸ１ １６ ＹＸ１ ２ ＹＸ１ ４ ＹＸ１ ５ ＹＸ１ ７ ＹＸ１
１４ １Ｃ
Ｖ
Ｐ
Ｙ
Ｇ
Ｒ
＊１
＊１
＊１
＊２
＊２
＊２
Ｂ−Ｙ
Ｌ−Ｒ
Ｌ−Ｂ
Ｙ−Ｇ
Ｇ−Ｙ
Ｗ−Ｂ
Ｂ−Ｗ
Ｌ−Ｗ
７ ＸＯ３ ６ ＸＯ３ ５ ＸＯ３ １ ＸＯ２ ２ ＸＯ２ ４ ＸＯ２ １０ ＸＯ２ ５ ＸＯ２ ６ ＸＯ２ ８ ＸＯ２ ７ ＸＯ２ ９ ＸＯ２ ４ ＸＯ３
２７ １Ａ ２８ １Ａ
Ｖ
Ｐ
Ｙ
Ｇ
Ｒ
Ｂ
＊１
＊１
＊１
＊２
＊２
＊２
Ｂ−Ｙ
Ｂ−Ｒ
Ｌ−Ｂ
Ｙ−Ｇ
Ｇ−Ｙ
Ｂ−Ｗ
Ｌ−Ｗ
Ｌ
Ｌ
１４ ＡＯ３ １２ ＡＯ３ １３ ＡＯ３ １５ ＡＯ３ ９ ＡＯ３ ８ ＡＯ３ ７ ＡＯ３ ６ ＡＯ３ ５ ＡＯ３ ４ ＡＯ３ ３ ＡＯ３ ２ ＡＯ３ １ ＡＯ３
Ｖ
Ｐ
Ｙ
Ｇ
Ｒ
Ｂ
＊１
＊１
＊１
＊２
＊２
＊２
Ｂ−Ｙ
Ｂ−Ｒ
Ｌ−Ｂ
Ｙ−Ｇ
Ｇ−Ｙ
Ｂ−Ｗ
Ｌ−Ｗ
７ ８ ２９ ２７ ２８ ３０ １１ １２ ３１ １３ １４ ３２ １５ １６ ２６
ＩＧ ＩＧ２ ＬＩＦ＋ ＬＩＦ１ ＬＩＦ２ ＴＩＬ＋ ＴＩＬ１ ＴＩＬ２ ＡＴ１＋ ＡＴ１１ ＡＴ１２ ＡＴ２＋ ＡＴ２１ ＡＴ２２ Ｅ１
MINI LEVER
Ａ ２３
ＭＩＮＩ ＬＥＶＥＲ ＥＣＵ
４ＳＯ＋ ＴＳＯ＋ ３ＳＯ＋ ＬＳＯ＋ ＬＰＳＨ ３ＰＬＬ ＴＰＳＨ ４ＰＳＨ ＬＰＬＬ ３ＰＳＨ ＴＰＬＬ ４ＰＬＬ Ｅ４４ Ｅ４３
４ １ ２０ １７ １８ ２１ ２ ５ １９ ２２ ３ ６ １０ ９
Ｇ−Ｏ
Ｇ−Ｒ
Ｇ−Ｂ
Ｒ−Ｌ
Ｒ−Ｂ
Ｒ−Ｙ
Ｒ−Ｇ
Ｗ−Ｌ
Ｗ−Ｇ
Ｗ−Ｒ
Ｇ−Ｗ
Ｒ−Ｗ
Ｗ−Ｂ
Ｗ−Ｂ
１ ３ ２ ４ １ ３ ２ ４
ＬＤＳ− ３ＦＳ− ＴＦＳ− Ｌ ＬＵＳ− ３ＲＳ− ＴＲＳ− Ｌ ９ １０
Ｅ４１ Ｅ４２ Ａ ２１
ＳＡＳ／ＯＰＳ ＥＣＵ
ＬＤＳ＋ ３ＦＳ＋ ＴＦＳ＋ Ｂ ＣＯＮＴＲＯＬ ＶＡＬＶＥ ＬＵＳ＋ ３ＲＳ＋ ＴＲＳ＋ Ｂ
ＰＵＳＨ ＳＯＬＥＮＯＩＤ
ＣＯＮＴＲＯＬ ＶＡＬＶＥ
ＰＵＬＬ ＳＯＬＥＮＯＩＤ
Ａ ５１
Ａ ５２
５ ７ ６ ８ ５ ７ ６ ８
Ｇ−Ｂ
Ｇ−Ｒ
Ｇ−Ｏ
Ｇ−Ｂ
Ｇ−Ｒ
Ｇ−Ｏ
Ｇ−Ｗ
Ｇ−Ｗ
１１ １ ２０ ４ ６ ２１ ３ １０ ５ ２２ ２ ７
Ａ ６４
ＪＵＮＣＴＩＯＮ ＣＯＮＮＥＣＴＯＲ（Ｊ）
E3-51
MINI LEVER
PARTS
Code See Page Code See Page Code See Page Code See Page
A 21 E2-10 A 52 E2-10 Y 3 E2-16
A 23 E2-10 A 64 E2-12 Y 5 E2-16
A 51 E2-10 Y 2 E2-16 Y 6 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AO3 E2-12 BODY MAIN WIRE to LH SIDE WIRE
XO2 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
XO3 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
YX1 E2-16 HOOD SUB NO.1 WIRE to HOOD MAIN WIRE
E3-52
（ＩＧ）
＊ １：４Ｙ−Ｅ
＊ ２：４Ｙ−Ｍ，１ＤＺ，２Ｚ
１０Ａ ＊ ３：ＴＷＩＳＴＥＤ ＷＩＲＥ
ＥＣＵ−ＩＧ
Ｌ
Ａ ３６
ＥＮＧＩＮＥ ＥＣＵ
１４ １Ｃ
ＶＦ ＯＸＳ ＴＣ
６ １Ｃ １７ ２５ ２４
Ｌ
Ｒ
＊１
＊１
＊１
＊３
ＬＧ
Ｇ−Ｙ
Ｐ−Ｇ
Ａ ２５ １３ Ａ ６ Ａ ＊１
８ ＤＩＡＧＮＯＳＩＳ １２ １３ １１ ７ ６ １Ｄ ２ Ｄ ＊２
ＩＧ ＶＦ１ ＯＸ１ Ｔ２ ＣＡＮＬ ＣＡＮＨ Ａ ２７（Ａ）
ＪＵＮＣＴＩＯＮ ＣＯＮＮＥＣＴＯＲ
Ａ ３１（Ｄ）
ＣＡＮ ＪＯＩＮＴ ＣＯＮＮＥＣＴＯＲ
Ｅ１ Ｅ１１ Ｅ
１４ １５ ３
DIAG
＊１
＊１
ＢＲ
ＢＲ
Ｗ−Ｂ
７Ａ ８Ａ
２２ １Ｃ
１１ Ｂ Ａ ６６（Ａ），Ｇ ２９（Ｂ）
ＪＵＮＣＴＩＯＮ
ＣＯＮＮＥＣＴＯＲ（Ｂ） １４ １Ｅ
＊１
ＢＲ
Ｗ−Ｂ
ＧＧ ＯＫ
E3-53
DIAG
PARTS
Code See Page Code See Page Code See Page Code See Page
A 25 E2-12 A 31 E2-12,23 A 66 E2-12
A 27 E2-12 A 36 E2-12 G 29 E2-12
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
EARTH
Code See Page Name
GG E2-4 ENGINE UPPER
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-54
（ＩＧ） （ＢＡＴ）
＊ １：Ｍ／Ｔ
＊ ２：Ｔ／Ｃ ＳＨＩＦＴ ＬＥＶＥＲ ＣＯＬＵＭＮ
１０Ａ １５Ａ ＊ ３：Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
ＢＡＣＫ ＬＰ ＷＯＲＫ ＬＰ ＊ ４：ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
２ ２
１ １
Ｒ−Ｇ
Ｙ−Ｂ
＊４
Ｒ−Ｗ
１３ １Ｃ １５ １Ｅ
４ ＸＯ１
１５ １Ｃ
＊４
Ｒ−Ｗ
３３ １Ｂ
１ ５ ２ ＳＴ１
４ ＹＸ２
Ｙ−Ｇ
Ｙ−Ｇ
ＷＯＲＫ ＬＰ
ＲＥＬＡＹ
２ ３
＊１
＊２
＊３
Ｒ−Ｇ
Ｒ−Ｗ
Ｒ−Ｗ
１５ １Ｂ ２３ １Ｅ ３３ １Ｃ １３ １Ｅ ９ １Ｅ
Ｒ
Ｒ
Ｂ
＊４
＊３
Ｙ−Ｂ
Ｙ−Ｇ
Ｙ−Ｇ
Ｙ−Ｇ
Ｙ−Ｇ
Ｙ−Ｇ
Ｗ−Ｂ
１ Ａ ＊１ １ ５ ３
８ Ｂ ＊２ Ｌ１ Ｌ２ ＋ １ １
２ ＸＯ１ １ ＳＯ２ ４ ＳＯ２
８ Ｃ ＊３
REAR WORKING LAMP
２ ２
Ｒ
Ｂ１ Ｂ２ −
＊３
ＷＯＲＫ ＬＡＭＰ
ＳＷＩＴＣＨ
ＷＯＲＫ ＬＡＭＰ
ＬＥＦＴ
ＷＯＲＫ ＬＡＭＰ
ＲＩＧＨＴ
Ｔ ７
Ｓ １
Ｓ ９
２ ４ ８
２ Ａ ＊１ ６ ＹＸ２
ＢＡＣＫ ＵＰ ＬＡＭＰ
ＳＷＩＴＣＨ
ＬＥＦＴ Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ａ ４０（Ａ）
Ａ ４１（Ｂ）
Ｙ ４（Ｃ）
Ｂ
Ｙ
Ｂ
２ Ｂ ＊２
Ｙ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
２ Ｃ ＊３
Ｒ
Ｙ
＊３
４ ＳＴ１ ３ ＳＴ１ １ ＳＴ１
＊４
Ｙ
＊３
Ｗ−Ｂ
Ｗ−Ｂ
１ ＳＯ１
Ｗ−Ｂ
Ｗ−Ｂ
ＡＣ ＯＫ
E3-55
REAR WORKING LAMP
PARTS
Code See Page Code See Page Code See Page Code See Page
A 40 E2-12 S 1 E2-16 T 7 E2-18
A 41 E2-10 S 9 E2-16 Y 4 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
SO1 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
SO2 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
ST1 E2-18 RR UPR MAIN WIRE to RR UPR SUB RH WIRE
XO1 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-56
＊ １：Ｍ／Ｔ
（ＩＧ） ＊ ２：Ｔ／Ｃ ＳＨＩＦＴ ＬＥＶＥＲ ＣＯＬＵＭＮ
＊ ３：Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊ ４：ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
１０Ａ
ＢＡＣＫ ＬＰ
１ ５
Ｒ−Ｇ
１３ １Ｃ
ＢＣＯＮ ＬＰ
ＲＥＬＡＹ
２ ３
３３ １Ｂ １５ １Ｅ １５ １Ｂ ２３ １Ｅ ３３ １Ｃ １６ １Ｅ ３２ １Ａ ３１ １Ａ
Ｒ
Ｒ
＊３
＊４
＊３
Ｒ−Ｗ
Ｒ−Ｌ
Ｒ−Ｌ
Ｒ−Ｇ
Ｗ−Ｂ
４ ＸＯ１
２ ＸＯ１
＊３
９ ＳＯ２ ５ ＵＡ２
Ｒ−Ｗ
Ｒ
＊１
＊２
＊３
Ｒ−Ｇ
Ｒ−Ｗ
４ ＹＸ２
Ｒ−Ｌ
Ｒ−Ｇ
６ ＹＸ２ ５
１
＊３
Ｒ−Ｗ
STROBE LIGHT
ＢＥＡＣＯＮ ＬＡＭＰ
ＢＥＡＣＯＮ ＬＡＭＰ
ＳＷＩＴＣＨ
Ｓ １０
４ Ｕ ４
１ Ａ ＊１
８ Ｂ ＊２
８ Ｃ ＊３
Ｒ−Ｌ
Ｗ−Ｂ
５ ＳＯ１ ８ ＵＡ２
２ Ａ ＊１
２ Ｂ ＊２
２ Ｃ ＊３
Ｒ
ＢＡＣＫ ＵＰ ＬＡＭＰ ＳＷＩＴＣＨ
ＬＥＦＴ Ｔ／Ｃ ＳＨＩＦＴ
ＳＷＩＴＣＨ
Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ａ ４０（Ａ）
Ａ ４１（Ｂ）
Ｙ ４（Ｃ）
Ｗ−Ｂ
＊４
Ｙ
＊３ １２ １Ｅ
１３ １Ｂ
Ｗ−Ｂ
ＡＣ ＡＡ
E3-57
STROBE LIGHT
PARTS
Code See Page Code See Page Code See Page Code See Page
A 40 E2-12 S 10 E2-16 Y 4 E2-16
A 41 E2-10 U 4 E2-14
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
SO1 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
SO2 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
UA2 E2-14 HEAD GUARD SW WIRE to BODY MAIN WIRE
XO1 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-58
＊ １：Ｗ／ ＯＫ ＭＯＮＩＴＯＲ
（ＩＧ） ＊ ２：１ＤＺ，２Ｚ
＊ ３：４Ｙ−Ｅ
＊ ４：Ｔ／Ｃ Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ ＯＲ ＯＫ ＭＯＮＩＴＯＲ
１０Ａ ＊ ５：Ｍ／Ｔ Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ ＯＲ ＯＫ ＭＯＮＩＴＯＲ
２７ １Ｃ
Ｒ
ＧＡＵＧＥ ＊ ６：Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ ＯＲ ＯＫ ＭＯＮＩＴＯＲ
＊ ７：Ｗ／Ｏ ＳＡＳ／ＯＰＳ ＳＹＳＴＥＭ
２
１ ３２ １Ｃ １２ ＱＡ１
Ｒ
Ｒ
Ｑ １
１ ＣＯＭＢＩＮＡＴＩＯＮ ＭＥＴＥＲ
ＩＧ＋
ＧＬＯＷ
ＣＨＥＣＫ Ｅ／Ｇ
ＢＲＡＫＥ
ＰＯＷＥＲ ＬＣＤ
ＯＰＳ
ＣＩＲＣＵＩＴ
ＳＥＤＩＭＥＮＴＥＲ
ＳＰＡＮＮＥＲ
＊２
＊３
ＣＯＮＴＲＯＬ ＣＩＲＣＵＩＴ
＊２
ＬＣＤ ＩＬＬＵＭＩＮＡＴＩＯＮ
＊２
＊３
＊２
＊２
Ｅ１ Ｅ２ − Ｓ ＳＩＬ２ ＰＫＢＩ ＳＷ Ｌ −Ｓ
８ ９ １０ ２ ３ １１ １２ ７ １３
＊７
＊１
＊２
Ｇ−Ｒ
Ｙ−Ｒ
Ｒ−Ｇ
Ｇ−Ｂ
Ｖ−Ｒ
Ｒ−Ｌ
Ｗ−Ｂ
Ｗ−Ｂ
Ｒ−Ｗ
COMBINATION METER
４ ＱＡ１ １３ ＱＡ１ １５ ＱＡ１ ３ ＱＡ１ １０ ＱＡ１ １６ ＱＡ１ ９ ＱＡ１ ２ ＱＡ１ １１ ＱＡ１
Ｒ−Ｗ
＊１
＊２
Ｙ−Ｒ
Ｇ−Ｂ
Ｖ−Ｒ
Ｒ−Ｌ
＊７
Ｇ−Ｒ
Ｒ−Ｇ
Ｗ−Ｂ
Ｗ−Ｂ
Ｒ−Ｗ １
９ ＡＧ１ ７ ＡＯ１ １４ ＡＯ１
＊６
１ １４ ２
Ｖ
＊２
２４ １Ｃ １８ １Ｃ
Ｒ−Ｌ
ＳＩＬ
ＢＲＡＫＥ ＷＡＲＮＩＮＧ
ＳＷＩＴＣＨ
Ａ ７
Ｙ−Ｒ
２ ２ １
１
８ １Ｃ ２５ １Ｃ ＰＫＢ
ＳＡＳ／ＯＰＳ ＥＣＵ
ＰＡＲＫＩＮＧ ＢＲＡＫＥ
ＳＷＩＴＣＨ
Ａ ２０
Ａ ９
＊１
Ｗ−Ｂ
１５ ３
ＦＵＥＬ ＳＥＮＤＥＲ ＧＡＵＧＥ
＆ ＦＵＥＬ ＰＵＭＰ
ＳＥＤＩＭＥＮＴＡＲＹ
ＳＷＩＴＣＨ
Ｏ ２
Ｏ ３
７．５Ａ
ＨＯＵＲ ＭＥＴ
４ １Ｂ Ｗ−Ｂ
２ ３ ２
＊４
ＷＡＴＥＲ ＴＥＭＰ．
ＳＥＮＤＥＲ
Ｇ １４
１
Ｒ−Ｗ
＊２
２８ １Ｅ ３１ １Ｃ Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
＊５
Ｗ−Ｂ
１ １Ｃ １ １Ａ ３ １Ｅ １ １Ｅ
１７ １８
Ｗ−Ｂ
Ｗ−Ｂ Ｗ−Ｂ
１Ｃ １Ａ ａ
＊１
ＯＫ ＡＢ
＊ １：Ｗ／ ＯＫ ＭＯＮＩＴＯＲ
＊ ２：１ＤＺ，２Ｚ
＊ ３：４Ｙ−Ｅ
＊ ８：ＥＸＣＥＰＴ ４Ｙ−Ｅ
＊ ９：１ＤＺ
＊１０：２Ｚ
Ｑ １
ＣＯＭＢＩＮＡＴＩＯＮ ＭＥＴＥＲ
ＯＩＬ
ＣＨＡＲＧＥ
ＲＡＤＩＡＴＯＲ
ＡＩＲ ＣＬＥＡＮＥＲ
Ｓ ＳＷ Ｓ ＥＦＩ ＣＨＧ−
１４ １５ ６ １６ ５
＊１
＊１
Ｙ−Ｇ
Ｙ−Ｂ
Ｇ−Ｗ
Ｖ−Ｗ
COMBINATION METER
６ ＱＡ１ ５ ＱＡ１ １４ ＱＡ１ １ ＱＡ１ ８ ＱＡ１
＊１
＊１
Ｇ
Ｙ−Ｇ
Ｇ−Ｗ
Ｙ−Ｂ
＊２
２ ＡＣ２ ５ ＡＣ２ ＊３
Ｙ
４ ＡＣ４ ３ ＡＣ４ ＊８ ６ ＡＧ１ １２ ＡＧ１
＊３
Ｙ
Ｖ−Ｗ
Ｇ
＊２
＊１
＊１
７ １Ｃ ２１ １Ｄ
Ｙ−Ｇ
Ｙ−Ｂ
Ｇ−Ｗ
７ Ａ ＊９
２ １Ｂ １ １６ ３ Ｂ ＊１０ １
ＭＩ ＷＲＮ Ｌ
ＯＩＬ ＰＲＥＳＳ ＳＷＩＴＣＨ
Ｇ ２２
１Ａ ＣＨＧ １１ １Ｄ
１
ＥＮＧＩＮＥ ＥＣＵ
ＧＬＯＷ ＰＬＵＧ ＴＩＭＥＲ
ＰＲＥ ＨＥＡＴＩＮＧ ＴＩＭＥＲ
ＡＬＴＥＲＮＡＴＯＲ
Ａ ３６
Ｇ ３５（Ａ）
Ｇ ６３（Ｂ）
Ｇ ４
２ Ａ ＊９
ＲＡＤＩＡＴＯＲ ＷＡＲＮＩＮＧ
ＳＷＩＴＣＨ
ＡＩＲ ＣＬＥＡＮＥＲ
ＷＡＲＮＩＮＧ ＳＷＩＴＣＨ
Ｃ ６
Ｃ ４（Ａ），Ｃ ５（Ｂ）
９ Ｂ ＊１０
＊１
＊１
Ｗ−Ｂ
Ｗ−Ｂ
Ｙ
＊２
８ １
Ｗ−Ｂ Ｗ−Ｂ
ａ ＡＣ２ ＡＣ４
＊１ ＊１
＊３ ＊８
E3-59
E3-60
COMBINATION METER
PARTS
Code See Page Code See Page Code See Page Code See Page
A 7 E2-10 C 4 E2-18 G 14 E2-2,4,6,8 O 2 E2-16
A 9 E2-10 C 5 E2-18 G 22 E2-2,4,6,8 O 3 E2-16
A 20 E2-10 C 6 E2-18 G 35 E2-12 Q 1 E2-10
A 36 E2-12 G 4 E2-2,4,6,8 G 63 E2-12
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1D E2-12,22 ENGINE WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AC2 E2-12 BODY MAIN WIRE to SIDE RH WIRE
AC4 E2-12 BODY MAIN WIRE to SIDE RH WIRE
AG1 E2-12 BODY MAIN WIRE to ENGINE WIRE
AO1 E2-12 BODY MAIN WIRE to LH SIDE WIRE
QA1 E2-10 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
EARTH
Code See Page Name
AB E2-12 FRONT PLATE LEFT OUTSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-61
MEMO
E3-62
（ＢＡＴ） （ＩＧ）
７．５Ａ １０Ａ
ＴＡＩＬ ＧＡＵＧＥ
２ ２
１ １
Ｇ−Ｂ
Ａ ４ ３２ １Ｃ
７ ＬＩＧＨＴ ＣＯＮＴＲＯＬ ＳＷ
ＢＴ Ｔ ＥＬ （Ｈ）
ＯＦＦ １０ １Ｃ
ＴＡＩＬ
Ｒ
ＨＥＡＤ
９
１Ａ
ＩＧ
Ｇ
１８ １Ｂ
SPEED METER
９ １Ｃ
Ｂ ＋Ｓ −Ｓ Ｅ
ＳＰＥＥＤ ＭＥＴＥＲ
Ａ ５８（Ａ），Ａ ５９（Ｂ）
２Ａ ２Ｂ １Ｂ ３Ａ
Ｇ
Ｇ
Ｐ
Ｗ−Ｂ
Ｗ−Ｂ
２
ＳＰＥＥＤ ＳＥＮＳＯＲ
Ａ １９
ＡＣ
E3-63
SPEED METER
PARTS
Code See Page Code See Page Code See Page Code See Page
A 4 E2-10 A 19 E2-10 A 58 E2-10 A 59 E2-10
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-64
（ＩＧ）
１０Ａ
ＥＣＵ−ＩＧ
＊ １：４Ｙ−Ｅ
＊ ２：４Ｙ−Ｍ，１ＤＺ，２Ｚ
２ ＊ ３：ＴＷＩＳＴＥＤ ＷＩＲＥ
Ｌ
１４ １Ｃ
３２ １Ｂ
Ｌ
２ ＡＱ１ ４ ＡＱ１ １ ＡＱ１
Ｌ
Ｇ
Ｇ
Ｗ
Ｗ
＊３
＊３
２ ６ ５ １２ Ａ ７ Ａ ＊１
ＩＧ ＣＡＮＬ ＣＡＮＨ １Ｆ ２ Ｆ ＊２
Ａ ２７（Ａ）
ＪＵＮＣＴＩＯＮ ＣＯＮＮＥＣＴＯＲ
Ａ ３３（Ｆ）
MULTI DISPLAY
ＣＡＮ ＪＯＩＮＴ ＣＯＮＮＥＣＴＯＲ
Ｅ１
３ Ｑ ２
ＤＩＳＰＬＡＹ
Ｗ−Ｂ
３ ＡＱ１
Ｗ−Ｂ
１４ １Ｂ
２８ １Ｅ
Ｗ−Ｂ
ＯＫ
E3-65
MULTI DISPLAY
PARTS
Code See Page Code See Page Code See Page Code See Page
A 27 E2-12 A 33 E2-12,23 Q 2 E2-10
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AQ1 E2-10 BODY MAIN WIRE to INSTRUMENT PANEL WIRE
EARTH
Code See Page Name
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-66
（ＩＧ） （ＢＡＴ）
１ ２ ３ ４
１０Ａ ２０Ａ ＷＩＰ
ＧＡＵＧＥ ＦＲ ＷＩＰ ＷＳＨ Ｕ ２
ＷＩＰ ＦＲＯＮＴ ＷＩＰＥＲ
２ ２ ＳＷＩＴＣＨ
ＯＦＦ
１ １
ＷＳＨ
２ １ ６ ４
Ｒ
Ｖ
Ｌ
Ｒ−Ｌ
Ｙ−Ｇ
Ｌ−Ｗ
３２ １Ｃ
１６ １Ａ ４ ＵＡ１ １ ＵＡ１ ２ ＵＡ１
Ｒ
Ｖ
Ｌ
Ｒ−Ｌ
Ｙ−Ｇ
Ｌ−Ｗ
２ ｈＡ１ ３ ｈＡ１ ２ Ａｈ１ １ Ａｈ１ ５ ＵＢ１
Ｒ
Ｖ
Ｙ
Ｒ−Ｌ
Ｙ−Ｇ
２ １
２ ５
１
ｈ １
ＦＲＯＮＴ ＷＩＰＥＲ Ｍ Ｍ
ＲＥＬＡＹ
ＦＲＯＮＴ ＷＡＳＨＥＲ
ＭＯＴＯＲ
Ｂ １
２
１ ３
FRONT WIPER & WASHER
ＦＲＯＮＴ ＷＩＰＥＲ
ＭＯＴＯＲ
ｈ ２
３ ４
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｌ−Ｗ
Ｌ−Ｗ
１ ｈＡ１ ４ ｈＡ１ ３ Ａｈ１ ４ Ａｈ１ ３ ＢＡ１
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｌ−Ｗ
Ｌ−Ｗ
Ｗ−Ｂ
ＡＣ
E3-67
FRONT WIPER & WASHER
PARTS
Code See Page Code See Page Code See Page Code See Page
B 1 E2-18 U 2 E2-14 h 1 E2-10 h 2 E2-10
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
Ah1 E2-10 BODY MAIN WIRE to WIPER SUB WIRE
BA1 E2-14 BODY SUB NO.1 WIRE to BODY MAIN WIRE
UA1 E2-14 HEAD GUARD SW WIRE to BODY MAIN WIRE
UB1 E2-14 HEAD GUARD SW WIRE to BODY SUB NO.1 WIRE
hA1 E2-10 WIPER SUB WIRE to BODY MAIN WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-68
（ＩＧ） （ＢＡＴ） ＊ １：ＤＸ ＣＡＢＩＮ
１ ２ ３ ４ ＊ ２：ＥＸＣＥＰＴ ＤＸ ＣＡＢＩＮ
１０Ａ ２０Ａ ＷＩＰ
ＧＡＵＧＥ ＲＲ ＷＩＰ ＷＳＨ Ｕ ３（Ａ），（Ｂ）
ＷＩＰ ＲＥＡＲ ＷＩＰＥＲ
ＳＷＩＴＣＨ
２ ２ ＯＦＦ
１ １ ＷＳＨ
３ Ａ ２ Ａ ８ Ａ ６ Ａ ＊１
２ Ｂ ５ Ｂ ＊２ １ Ｂ ＊２
Ｒ
Ｌ−Ｒ
Ｒ
＊１
Ｇ−Ｂ
３２ １Ｃ
Ｙ−Ｒ
Ｒ−Ｗ
６ ＵＡ２ ２ ＵＡ２ １０ ＵＡ２
４ １Ｅ
Ｙ−Ｒ
Ｇ−Ｂ
Ｒ−Ｗ
４ ＡＯ２ ８ ＡＯ２ ７ ＡＯ２ ６ ＵＢ１ ６ ＡＯ２
Ｒ
Ｒ
＊１
Ｌ−Ｒ
Ｙ−Ｒ
Ｇ−Ｂ
Ｒ−Ｗ
１１ ＳＯ２ ６ ＳＯ２ ４ ＳＯ３ ３ ＳＯ３
２ ＳＯ２
Ｒ
Ｌ−Ｒ
Ｙ−Ｒ
Ｒ−Ｗ
２ １
１ ４
１
Ｓ ８
ＲＥＡＲ ＷＩＰＥＲ Ｍ Ｍ
ＲＥＬＡＹ
ＲＥＡＲ ＷＡＳＨＥＲ
ＭＯＴＯＲ
Ｂ ６
２
REAR WIPER & WASHER
３ ２
ＲＥＡＲ ＷＩＰＥＲ
ＭＯＴＯＲ
Ｓ ２
３ ４
＊１
Ｇ−Ｂ
Ｇ−Ｂ
Ｇ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
１０ ＳＯ２
Ｗ−Ｂ
３ ＢＡ１
３ ＡＯ２
＊１
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
ＡＣ
E3-69
REAR WIPER & WASHER
PARTS
Code See Page Code See Page Code See Page Code See Page
B 6 E2-18 S 2 E2-16 S 8 E2-16 U 3 E2-14
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AO2 E2-12 BODY MAIN WIRE to LH SIDE WIRE
BA1 E2-14 BODY SUB NO.1 WIRE to BODY MAIN WIRE
SO2 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
SO3 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
UA2 E2-14 HEAD GUARD SW WIRE to BODY MAIN WIRE
UB1 E2-14 HEAD GUARD SW WIRE to BODY SUB NO.1 WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-70
（ＢＡＴ）
１５Ａ
ＨＯＲＮ
Ｇ−Ｙ
Ｇ−Ｙ
１６ １Ｃ
１ ５ １
ＨＯＲＮ
ＲＥＬＡＹ
ＨＯＲＮ
ＳＷＩＴＣＨ
Ａ １
２ ３ ２
１７ １Ａ ３４ １Ａ ８ １Ｅ
HORN
Ｇ
Ｇ
Ｇ−Ｒ
６ ＳＯ１
Ｇ−Ｒ
２
２
ＨＯＲＮ
Ａ ４９
１
ＲＥＡＲ ＨＯＲＮ
ＳＷＩＴＣＨ
Ｓ １１
１
Ｗ−Ｂ
１ ＳＯ１
Ｗ−Ｂ
Ｗ−Ｂ
ＡＣ ＯＫ
E3-71
HORN
PARTS
Code See Page Code See Page Code See Page Code See Page
A 1 E2-10 A 49 E2-10 S 11 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
SO1 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-72
（ＢＡＴ）
＊ １：ＳＴＡＮＤＡＲＤ ＯＲ ＭＡＳＴ ＴＹＰＥ ＨＥＡＤ ＬＡＭＰ
１５Ａ ＊ ２：ＳＴＡＹ ＴＹＰＥ ＷＩＴＨ ＦＲＯＮＴ ＣＯＮＢＩＮＡＴＩＯＮ ＬＡＭＰ
ＨＥＡＤ
１
Ｒ−Ｇ
Ｒ−Ｂ
Ｒ−Ｇ
Ｒ−Ｇ
８ １１ １ ｄＡ１ １ ＲＡ１
ＢＴ Ｔ ＢＨ （Ｈ）
ＯＦＦ
ＴＡＩＬ
＊１
＊２
＊１
＊２
Ｒ−Ｇ
Ｒ−Ｇ
Ｒ−Ｇ
Ｒ−Ｇ
ＨＥＡＤ
１ ３ １ ３
Ａ ４
ＬＩＧＨＴ ＣＯＮＴＲＯＬ ＳＷ
２ ５ ２ ５
ＨＥＡＤ ＬＡＭＰ ＬＥＦＴ
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＬＥＦＴ
ＨＥＡＤ ＬＡＭＰ ＲＩＧＨＴ
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＬＥＦＴ
ｄ ２
ｄ ５
Ｒ ２
Ｒ ５
HEAD LAMP
＊１
＊２
＊１
＊２
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
５ ｄＡ１ ５ ＲＡ１
Ｗ−Ｂ
Ｗ−Ｂ
９ １Ｂ １０ １Ｂ
１３ １Ｂ
Ｗ−Ｂ
ＡＡ
E3-73
HEAD LAMP
PARTS
Code See Page Code See Page Code See Page Code See Page
A 4 E2-10 R 5 E2-14 d 5 E2-14
R 2 E2-14 d 2 E2-14
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
RA1 E2-14 FR STAY WIRE RH to BODY MAIN WIRE
dA1 E2-14 FR STAY WIRE LH to BODY MAIN WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
２
１
２
Ｗ−Ｂ Ｇ−Ｗ
１
３３ １Ｃ
２８ １Ｃ
ＡＣ
（ＩＧ）
７．５Ａ
Ｎ
ＴＵＲＮ
ＬＨ
ＲＨ
１２
Ｇ−Ｌ
ＴＬ
ＲＥＬＡＹ
１３
Ｇ−Ｏ
ＦＬＡＳＨＥＲ
３５ １Ｂ
ＴＢ
１４
Ｇ−Ｙ
ＴＲ
Ａ ４
ＬＩＧＨＴ ＣＯＮＴＲＯＬ ＳＷ
＊ ２：ＳＴＡＹ ＴＹＰＥ
＊ １：ＭＡＳＴ ＴＹＰＥ
Ｇ−Ｙ
１６ １Ｂ
Ｇ−Ｌ
３１ １Ｂ
ｄ １
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＬＥＦＴ
ＴＵＲＮ
３
１
Ｗ−Ｂ Ｇ−Ｙ
＊１ ＊１
ｄ ５
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＬＥＦＴ
ＴＵＲＮ
１
４
Ｗ−Ｂ Ｗ−Ｂ Ｗ−Ｂ Ｇ−Ｙ Ｇ−Ｌ
１３ １Ｂ
１１ １Ｂ
２９ １Ｂ
ＡＡ
６ ｄＡ１
３ ｄＡ１
＊２ ＊２
Ｒ １
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
ＴＵＲＮ
３
１
Ｗ−Ｂ Ｇ−Ｙ
＊１ ＊１
Ｒ ５
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
ＴＵＲＮ
１
４
Ｗ−Ｂ Ｗ−Ｂ Ｇ−Ｙ Ｇ−Ｙ
１２ １Ｅ
１２ １Ｂ
２８ １Ｂ
６ ＲＡ１
３ ＲＡ１
＊２ ＊２
Ｓ ３
Ｗ−Ｂ
ＲＥＡＲ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＬＥＦＴ
ＴＵＲＮ
４
３
Ｗ−Ｂ Ｗ−Ｂ Ｇ−Ｌ Ｇ−Ｌ
１０ １Ｅ
５ ＳＯ１
２ ＳＯ１
Ｓ ４
ＲＥＡＲ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
ＴＵＲＮ
６
５
Ｗ−Ｂ Ｇ−Ｙ Ｇ−Ｙ ２４ １Ｅ
７ ＳＯ１
TURN SIGNAL LAMP
E3-74
E3-75
TURN SIGNAL LAMP
PARTS
Code See Page Code See Page Code See Page Code See Page
A 4 E2-10 R 5 E2-14 S 4 E2-16 d 5 E2-14
R 1 E2-14 S 3 E2-16 d 1 E2-14
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
RA1 E2-14 FR STAY WIRE RH to BODY MAIN WIRE
SO1 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
dA1 E2-14 FR STAY WIRE LH to BODY MAIN WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
Ａ ４
ＯＦＦ
ＨＥＡＤ
ＴＡＩＬ
７
２
Ｇ−Ｂ
１
ＢＴ
（ＢＡＴ）
＊ ２：ＳＴＡＹ ＴＹＰＥ
＊ １：ＭＡＳＴ ＴＹＰＥ
９
Ｔ
ＬＩＧＨＴ ＣＯＮＴＲＯＬ ＳＷ
７．５Ａ
ＴＡＩＬ
ＥＬ
（Ｈ）
ｄ １
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
ＣＬＥＡＲＡＮＣＥ
ＬＡＭＰ
３
２
Ｗ−Ｂ Ｇ
＊１ ＊１ Ｇ
１８ １Ｂ
ｄ ５
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
ＣＬＥＡＲＡＮＣＥ
ＬＡＭＰ
１
２
Ｗ−Ｂ Ｗ−Ｂ Ｗ−Ｂ Ｇ Ｇ
１３ １Ｂ
１１ １Ｂ
３０ １Ｂ
ＡＡ
６ ｄＡ１
４ ｄＡ１
＊２ ＊２
Ｒ １
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
ＣＬＥＡＲＡＮＣＥ
ＬＡＭＰ
３
２
Ｗ−Ｂ Ｗ−Ｂ Ｗ−Ｂ Ｇ Ｇ
１２ １Ｅ
１２ １Ｂ
２７ １Ｂ
６ ＲＡ１
４ ＲＡ１
＊１ ＊１
Ｒ ５
ＦＲＯＮＴ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
ＣＬＥＡＲＡＮＣＥ
ＬＡＭＰ Ｇ
１
２
７ １Ｅ
Ｗ−Ｂ Ｇ
＊２ ＊２
Ｓ ３
ＲＥＡＲ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＬＥＦＴ
ＴＡＩＬ ＬＡＭＰ
４
１
Ｗ−Ｂ Ｇ
Ｓ ４
ＲＥＡＲ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
ＴＡＩＬ ＬＡＭＰ
６
１
Ｗ−Ｂ Ｗ−Ｂ Ｗ−Ｂ Ｇ Ｇ Ｇ
５ ＳＯ１
４ ＳＯ１
Ｗ−Ｂ
Ｗ−Ｂ Ｇ
１Ｂ
１Ａ
２ Ｓｃ１
１ Ｓｃ１
ｃ ３（Ａ），ｃ ４（Ｂ）
ＬＩＣＥＮＳＥ ＬＡＭＰ
CLEARANCE LAMP
E3-76
E3-77
CLEARANCE LAMP
PARTS
Code See Page Code See Page Code See Page Code See Page
A 4 E2-10 S 3 E2-16 c 4 E2-16
R 1 E2-14 S 4 E2-16 d 1 E2-14
R 5 E2-14 c 3 E2-16 d 5 E2-14
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1B E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
RA1 E2-14 FR STAY WIRE RH to BODY MAIN WIRE
SO1 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
Sc1 E2-16 RR UPR MAIN WIRE to LICENCE LAMP WIRE
dA1 E2-14 FR STAY WIRE LH to BODY MAIN WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-78
（ＩＧ）
１０Ａ
ＢＡＣＫ ＬＰ
２
Ｒ
１ ＊６
Ｒ
Ｒ−Ｇ
＊５
１３ １Ｃ １３ １Ａ １１ ＡＣ２ ２ ＡＣ４
Ｔ ４
Ｒ
Ｒ
ＢＡＣＫ ＵＰ ＢＵＺＺＥＲ
＊５
＊６
ＯＮ ＯＦＦ ＳＷＩＴＣＨ
３３ １Ｂ １５ １Ｅ １５ １Ｂ ２３ １Ｅ ２５ １Ｅ
２ １
Ｒ
１
＊３
Ｒ−Ｇ
Ｂ Ｃ ７
４ ＸＯ１ ３ ＳＯ１ ＢＡＣＫ ＵＰ
＊１２
＊１２
Ｇ−Ｂ
Ｗ−Ｂ
ＢＵＺＺＥＲ
Ｅ
Ｗ−Ｂ
２
Ｒ
Ｒ
Ｒ
＊１
＊２
＊３
＊４
＊３
Ｒ−Ｇ
＊１３
Ｒ−Ｗ
Ｒ−Ｗ
５ ＴＣ２ ６ ＴＣ２ ＊１２
４ ＹＸ２
５ ＣＣ２ ６ ＣＣ２ ＊１３
＊８
＊９
２ ＸＯ１
Ｗ−Ｂ
Ｗ−Ｂ
Ｒ−Ｗ
３
＊３
Ｒ
＊３
Ｇ−Ｂ
＊７
１ Ａ ＊１
Ｗ−Ｂ
＊７
８ Ｂ ＊２
８ Ｃ ＊３ ６ ＹＸ２ Ｗ−Ｂ
ＢＡＣＫ ＵＰ
ＬＡＭＰ
＊１０
BACK UP LAMP BUZZER
ＲＥＡＲ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＲＩＧＨＴ
Ｓ ４
Ｗ−Ｂ
Ｙ
＊３
２ Ａ ＊１ ＊１１
２ Ｂ ＊２
２ Ｃ ＊３ ８ ＡＣ２ １ ＡＣ４
Ｗ−Ｂ
ＢＡＣＫ ＵＰ ＬＡＭＰ ＳＷＩＴＣＨ
ＬＥＦＴ Ｔ／Ｃ ＳＨＩＦＴ
ＳＷＩＴＣＨ
Ｔ／Ｃ ＳＨＩＦＴ ＳＷＩＴＣＨ
Ａ ４０（Ａ）
Ａ ４１（Ｂ）
Ｙ ４（Ｃ）
Ｒ
＊４ ＊ １：Ｍ／Ｔ
＊ ２：Ｔ／Ｃ ＳＨＩＦＴ ＬＥＶＥＲ ＣＯＬＵＭＮ
＊５
＊６
Ｙ
Ｗ−Ｂ
Ｗ−Ｂ
＊ ３：Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊３ ５ ＳＯ１ ＊ ４：ＥＸＣＥＰＴ Ｔ／Ｃ ＡＲＭ ＲＥＳＴ
＊ ５：４Ｙ−Ｅ
＊ ６：ＥＸＣＥＰＴ ４Ｙ−Ｅ
＊ ７：ＦＵＬＬ ＯＰＴＩＯＮ
Ｗ−Ｂ
＊ ８：ＳＴＡＮＤＡＲＤ ４Ｙ−Ｅ
＊ ９：ＳＴＡＮＤＡＲＤ ＥＸＣＥＰＴ ４Ｙ−Ｅ
１２ １Ｅ １８ １Ａ ＊１０：ＦＵＬＬ ＯＰＴＩＯＮ ４Ｙ−Ｅ
＊１１：ＦＵＬＬ ＯＰＴＩＯＮ ＥＸＣＥＰＴ ４Ｙ−Ｅ
＊１２：Ｗ／ ＯＮ−ＯＦＦ ＳＷＩＴＣＨ
＊１３：Ｗ／Ｏ ＯＮ−ＯＦＦ ＳＷＩＴＣＨ
１３ １Ｂ １７ １Ｃ
Ｗ−Ｂ
Ｗ−Ｂ
ＡＡ ＡＢ
E3-79
BACK UP LAMP BUZZER
PARTS
Code See Page Code See Page Code See Page Code See Page
A 40 E2-12 C 7 E2-18 T 4 E2-18
A 41 E2-10 S 4 E2-16 Y 4 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1B E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AC2 E2-12 BODY MAIN WIRE to SIDE RH WIRE
AC4 E2-12 BODY MAIN WIRE to SIDE RH WIRE
CC2 E2-18 SIDE RH WIRE to SIDE RH WIRE
SO1 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
TC2 E2-18 RR UPR SUB RH WIRE to SIDE RH WIRE
XO1 E2-16 HOOD MAIN WIRE to LH SIDE WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
AB E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-80
（ＢＡＴ）
７．５Ａ
ＳＴＯＰ
２
１９ １Ａ
１
１１ １Ｅ
Ｇ
１
Ｂ−Ｌ
Ｂ−Ｌ
８ ＳＯ１
ＳＴＯＰ ＬＡＭＰ
ＳＷＩＴＣＨ
Ａ ６
Ｂ−Ｌ
Ｂ−Ｌ
Ｂ−Ｌ
２ ２
Ｓ ３ Ｓ ４
ＳＴＯＰ ＳＴＯＰ
ＬＡＭＰ ＲＥＡＲ ＣＯＭＢＩＮＡＴＩＯＮ ＬＡＭＰ ＲＥＡＲ ＣＯＭＢＩＮＡＴＩＯＮ
ＬＡＭＰ ＬＥＦＴ ＬＡＭＰ ＲＩＧＨＴ
STOP LAMP
４ ６
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
５ ＳＯ１
Ｗ−Ｂ
１２ １Ｅ
１３ １Ｂ
Ｗ−Ｂ
ＡＡ
E3-81
STOP LAMP
PARTS
Code See Page Code See Page Code See Page Code See Page
A 6 E2-10 S 3 E2-16 S 4 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1B E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
SO1 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-82
（ＢＡＴ） （ＩＧ）
１５Ａ １０Ａ
ＨＴＲ ＧＡＵＧＥ
Ｌ−Ｒ
２ ２
１ Ｂ ＊１
１ １ １ Ａ ＊２
Ｐ
Ｒ
Ｍ
３２ １Ｃ
ＨＥＡＴＥＲ ＢＬＯＷＥＲ
ＭＯＴＯＲ
Ｂ ２（Ａ），Ｂ ３（Ｂ）
４Ｂ ３ Ｂ ＊１
３３ １Ａ ３Ａ ２ Ａ ＊２
Ｒ
Ｌ
Ｌ−Ｂ
１ ＢＡ１ ２ ＢＡ１ ３ ＵＢ１ ２ ＵＢ１
Ｐ
Ｒ
Ｌ
Ｌ−Ｂ
５Ｂ ２ Ｂ ＊１
４Ａ ６ Ａ ＊２ １ ４
Ｂ ４（Ａ），Ｂ ５（Ｂ）
ＨＥＡＴＥＲ
ＲＥＬＡＹ
HEATER
４Ｂ ３Ｂ １ Ｂ ＊１
ＨＥＡＴＥＲ
ＳＷＩＴＣＨ
Ｕ １
２Ａ １Ａ ３ Ａ ＊２
２
Ｌ−Ｒ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
Ｗ−Ｂ
１ ＵＢ１
Ｗ−Ｂ
３ ＢＡ１
＊ １：Ｗ／ ＲＥＡＲ ＷＩＰＥＲ ＆ ＷＡＳＨＥＲ
＊ ２：Ｗ／Ｏ ＲＥＡＲ ＷＩＰＥＲ ＆ ＷＡＳＨＥＲ
Ｗ−Ｂ
ＡＣ
E3-83
HEATER
PARTS
Code See Page Code See Page Code See Page Code See Page
B 2 E2-18 B 4 E2-18 U 1 E2-14
B 3 E2-18 B 5 E2-18
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
1A E2-12,22 BODY MAIN WIRE to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
BA1 E2-14 BODY SUB NO.1 WIRE to BODY MAIN WIRE
UB1 E2-14 HEAD GUARD SW WIRE to BODY SUB NO.1 WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-84
＊ １：Ｗ／ ＡＳＣ
＊ ２：Ｗ／ ＭＵＬＴＩ ＤＩＳＰＬＡＹ
＊ ３：４Ｙ−Ｅ
＊ ４：４Ｙ−Ｍ，１ＤＺ，２Ｚ
＊ ５：ＴＷＩＳＴＥＤ ＷＩＲＥ
Ａ ２７（Ａ）
ＪＵＮＣＴＩＯＮ ＣＯＮＮＥＣＴＯＲ
Ａ ２９（Ｂ），Ａ ３０（Ｃ），Ａ ３１（Ｄ），Ａ ３２（Ｅ），Ａ ３３（Ｆ），Ａ ３４（Ｇ）
ＣＡＮ ＪＯＩＮＴ ＣＯＮＮＥＣＴＯＲ
ＪＵＮＣＴＩＯＮ
ＴＥＲＭＩＮＡＬ
＊４
＊４
＊４
７Ａ １２ Ａ ６Ａ １３ Ａ ８Ａ １１ Ａ １Ａ ５ Ａ ＊３
１Ｅ ２Ｆ １Ｆ ２Ｄ １Ｄ ２Ｇ １Ｇ ２Ｂ １ Ｂ ＊４
＊４
Ｗ−Ｂ
CAN
Ｇ
Ｂ
Ｗ
Ｗ
＊５
＊２
＊２
＊５
＊１
＊１
５ １Ｃ
４ ＡＱ１ １ ＡＱ１ ５ ＡＧ２ ４ ＡＧ２
１４ １Ｅ
Ｇ
Ｒ
Ｂ
Ｂ
Ｇ
Ｗ
Ｗ
Ｗ
Ｗ
＊５
＊２
＊２
＊５
＊５
＊１
＊１
＊５
＊３
＊３
＊５
Ｇ−Ｒ
６ ５ ７ ６ ２６ １３ ２９ ２８ １３ １２
ＣＡＮＬ ＣＡＮＨ ＣＡＮＬ ＣＡＮＨ ＣＡＮＬ ＣＡＮＨ ＣＡＮ− ＣＡＮ＋ ＣＡＮＬ ＣＡＮＨ
Ｑ ２ Ａ ２５ Ｇ ３９ Ａ ３６ Ａ ２０
ＤＩＳＰＬＡＹ ＤＩＡＧＮＯＳＩＳ ＡＳＣ ＥＣＵ ＥＮＧＩＮＥ ＥＣＵ ＳＡＳ／ＯＰＳ ＥＣＵ
＊４
Ｗ−Ｂ
ＯＫ
E3-85
CAN
PARTS
Code See Page Code See Page Code See Page Code See Page
A 20 E2-10 A 29 E2-12,23 A 32 E2-12,23 A 36 E2-12
A 25 E2-12 A 30 E2-12,23 A 33 E2-12,23 G 39 E2-12
A 27 E2-12 A 31 E2-12,23 A 34 E2-12,23 Q 2 E2-10
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1C E2-12,22 BODY MAIN WIRE to J/B
1E E2-12,22 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AG2 E2-12 BODY MAIN WIRE to ENGINE WIRE
AQ1 E2-10 BODY MAIN WIRE to INSTRUMENT PANEL WIRE
EARTH
Code See Page Name
OK E2-16 REAR PILLER LEFT UNDER EARTH
E3-86
（ＢＡＴ）
２０Ａ
ＲＲ ＷＩＰ
Ｌ−Ｒ
４ ＡＯ２
Ｌ−Ｒ
６ ＳＯ２
Ｌ−Ｒ
１ ＳＶ２
Ｌ−Ｒ
１Ｂ Ｖ ３（Ａ），Ｖ ４（Ｂ）
DOME LAMP
ＤＯＭＥ ＬＡＭＰ
１Ａ
Ｗ−Ｂ
２ ＳＶ２
Ｗ−Ｂ
１０ ＳＯ２
Ｗ−Ｂ
３ ＡＯ２
Ｗ−Ｂ
ＡＣ
E3-87
DOME LAMP
PARTS
Code See Page Code See Page Code See Page Code See Page
V 3 E2-16 V 4 E2-16
RELAY BLOCK , JUNCTION BLOCK
Code See Page Relay Block Name or Joining Wire Harness to J/B
1 E2-12,21 ENGINE ROOM R/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AO2 E2-12 BODY MAIN WIRE to LH SIDE WIRE
SO2 E2-16 RR UPR MAIN WIRE to LH SIDE WIRE
SV2 E2-16 RR UPR MAIN WIRE to RR UPR SUB LH WIRE
EARTH
Code See Page Name
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
E3-88
Ｗ−Ｂ
＊ １：４Ｙ−Ｍ，４Ｙ−Ｅ
＊ ２：１ＤＺ，２Ｚ Ｗ／ ＤＰＦ−２
＊ ３：１ＤＺ，２Ｚ Ｗ／Ｏ ＤＰＦ−２
ＡＢ ＡＣ
Ｗ−Ｂ
１０ ＡＯ１
Ｗ−Ｂ
ＡＡ ＯＫ
Ｗ−Ｂ
EARTH TO EARTH
＊１
ＧＦ ＧＧ
ＢＲ
＊２
Ｗ−Ｂ
＊３
ＧＪ ＧＬ
E3-89
EARTH TO EARTH
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AO1 E2-12 BODY MAIN WIRE to LH SIDE WIRE
EARTH
Code See Page Name
AA E2-12 FRONT PLATE LEFT OUTSIDE EARTH
AB E2-12 FRONT PLATE LEFT OUTSIDE EARTH
AC E2-12 FRONT PLATE LEFT OUTSIDE EARTH
GF E2-2,4 ENGINE UPPER EARTH
GJ E2-6,8 JUNCTION BLOCK IN FRONT INSIDE EARTH
GL E2-6,8 JUNCTION BLOCK IN FRONT INSIDE EARTH
OK E2-16 REAR PILLER LEFT UNDER EARTH
MEMO
E4-1
CHAPTER 4 GROUND POINTS
E4
E4-2
GROUND POINTS
CODE LOCATION SYSTEM NAME PAGE
BACK UP LAMP BUZZER E3-78
CLEARANCE LAMP E3-76
HEAD LAMP E3-72
OPS SYSTEM E3-46
AA FRONT PLATE LEFT OUTSIDE EARTH POWER SHIFT TRANSMISSIN E3-38
SAS/OPS SYSTEM E3-42
STOP LAMP E3-80
STROBE LIGHT E3-56
TURN SIGNAL LAMP E3-74
BACK UP LAMP BUZZER E3-78
COMBINATION METER E3-58
AB FRONT PLATE LEFT OUTSIDE EARTH ENGINE CONTROL (4Y-E) E3-12
SAS/OPS SYSTEM E3-42
WET BRAKE E3-40
ASC E3-30
DOME LAMP E3-86
FRONT WIPER & WASHER E3-66
HEATER E3-82
HORN E3-70
LPG SYSTEM (4Y-M) E3-34
LPG WARNING SYSTEM (4Y-E) E3-36
AC FRONT PLATE LEFT OUTSIDE EARTH
POWER SOURCE E3-2
REAR WIPER & WASHER E3-68
REAR WORKING LAMP E3-54
SPEED METER E3-62
STARTING E3-6
STROBE LIGHT E3-56
TURN SIGNAL LAMP E3-74
AD TRANSMISSIN UPPER EARTH POWER SHIFT TRANSMISSIN E3-38
EM FRONT PLATE RIGHT OUTSIDE EARTH DPF-2 E3-26
ENGINE CONTROL (4Y-E) E3-12
GF ENGINE UPPER EARTH LPG SYSTEM (4Y-M) E3-34
LPG WARNING SYSTEM (4Y-E) E3-36
DIAG E3-52
ENGINE CONTROL (4Y-E) E3-12
GG ENGINE UPPER EARTH
LPG SYSTEM (4Y-M) E3-34
LPG WARNING SYSTEM (4Y-E) E3-36
ASC E3-30
JUNCTION BLOCK IN FRONT INSIDE DPF-2 E3-26
GJ
EARTH GLOW E3-18
INTAKE HEATER E3-22
JUNCTION BLOCK IN FRONT INSIDE DPF-2 E3-26
GL GLOW E3-18
EARTH INTAKE HEATER E3-22
POWER SOURCE E3-2
IH REAR PILLER LEFT UNDER EARTH
STARTING E3-6
JL FRONT PLATE LEFT INSIDE EARTH STARTING E3-6
E4-3
GROUND POINTS
CODE LOCATION SYSTEM NAME PAGE
ASC E3-30
CAN E3-84
COMBINATION METER E3-58
DIAG E3-52
DPF-2 E3-26
GLOW E3-18
OK REAR PILLER LEFT UNDER EARTH
HORN E3-70
INTAKE HEATER E3-22
MULTI DISPLAY E3-64
OPS SYSTEM E3-46
REAR WORKING LAMP E3-54
SAS/OPS SYSTEM E3-42
MEMO
E5-1
CHAPTER 5 FUSES FOR POWER SUPPLY
E5
E5-2
FUSES FOR POWER SUPPLY
FUSIBLE LINK BLOCK ASSY
FUSE SYSTEM NAME PAGE
60A GLOW GLOW E3-18
80A ALT CHARGING E3-4
100A ALT CHARGING E3-4
120A GLOW INTAKE HEATER E3-22
ENGINE ROOM R/B
FUSE SYSTEM NAME PAGE
7.5A ALT-S CHARGING E3-4
OPS SYSTEM E3-46
7.5A ECU-B
SAS/OPS SYSTEM E3-42
ASC E3-30
7.5A ECU-B2
DPF-2 E3-26
7.5A HOUR MET COMBINATION METER E3-58
ASC E3-30
DPF-2 E3-26
FUEL E3-10
7.5A IGN GLOW E3-18
IGNITION E3-8
INTAKE HEATER E3-22
LPG SYSTEM (4Y-M) E3-34
7.5A SFT POWER SHIFT TRANSMISSIN E3-38
DPF-2 E3-26
GLOW E3-18
7.5A ST
INTAKE HEATER E3-22
STARTING E3-6
SAS/OPS SYSTEM E3-42
7.5A STOP
STOP LAMP E3-80
CLEARANCE LAMP E3-76
7.5A TAIL
SPEED METER E3-62
7.5A TURN TURN SIGNAL LAMP E3-74
BACK UP LAMP BUZZER E3-78
10A BACK LP REAR WORKING LAMP E3-54
STROBE LIGHT E3-56
DIAG E3-52
MINI LEVER E3-50
10A ECU-IG MULTI DISPLAY E3-64
OPS SYSTEM E3-46
SAS/OPS SYSTEM E3-42
CHARGING E3-4
COMBINATION METER E3-58
ENGINE CONTROL (4Y-E) E3-12
FRONT WIPER AND WASHER E3-66
GLOW E3-18
HEATER E3-82
10A GAUGE
INTAKE HEATER E3-22
OPS SYSTEM E3-46
REAR WIPER AND WASHER E3-68
SAS/OPS SYSTEM E3-42
SPEED METER E3-62
WET BRAKE E3-40
15A DPF DPF-2 E3-26
E5-3
FUSES FOR POWER SUPPLY
ENGINE ROOM R/B
FUSE SYSTEM NAME PAGE
ENGINE CONTROL (4Y-E) E3-12
15A EFI
LPG WARNING SYSTEM (4Y-E) E3-36
15A E-THRO ENGINE CONTROL (4Y-E) E3-12
15A HEAD HEAD LAMP E3-72
15A HORN HORN E3-70
15A HTR HEATER E3-82
15A IGN ENGINE CONTROL (4Y-E) E3-12
15A WORK LP REAR WORKING LAMP E3-54
20A FR WIP FRONT WIPER AND WASHER E3-66
DOME LAMP E3-86
20A RR WIP
REAR WIPER AND WASHER E3-68
30A STA STARTING E3-6
MEMO
E6-1
CHAPTER 6 CONNECTOR LIST
CONNECTOR LIST
PARTS CONNECTOR ....................................................................... E6-2
WIRE TO WIRE
WIRE TO WIRE ................................................................................. E6-9
E6
E6-2
CONNECTOR LIST
A 1 A 2 A 3 A 4 A 5 A 6
BLACK
1 1 2 3 4 5 6
1 2 1 2 1 2 2 1
2 3 4 7 8 9 10 11 12 13 14
3 4 5 6 90980- 11070
90980- 10171 90980- 11155
90980- 10935 90980- 10807
90980- 10996
A 7 A 8 A 9 A 10 A 11 A 12 A 13
DARK GRAY GRAY GRAY GRAY DARK GRAY GRAY
1 2 1
1 2 2 1 2 1 2 1
2 1 2 3
4 3
90980- 10214 90980- 10899 90980- 11486 90980- 11002 90980- 10959
90980- 11349
90980- 10941
A 14 A 15 A 16 A 18 A 19 A 20
GRAY DARK GRAY BLACK GRAY BLACK
2 1 1 1 2
1 2 2 1
2 1 2 3 4 5 6 7
3 4
90980- 10900 90980- 11168 3 90980- 11156 8 9 10 11 12 13 14 15 16 17 18 19
90980- 11028 90080- 98200 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
90980- 12528
A 21 A 22
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
17 18 19 20 21 22 23 24 25 26 17 90980- 12556
28 29 30 31 32 33 34 35
90980- 12529
A 23 A 24 A 25 A 26
BLACK DARK GRAY
1 1 2 3 4 12 13 1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 5 6 7 14 15
90980- 11881 8 9 10 11 16 17 90980- 11251
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
18
90980- 12556
57671- 26600- 71
A 27 A 29 A 30 A 31 A 32 A 33 A 34
GRAY BLUE GRAY BROW N BLACK
1 2 3 4 5 1 1 1 1 1 1
6 7 8 9 10 11 12 13
2 2 2 90980- 10871 2 2
90980- 11542 90980- 12355 90980- 12355 90980- 12355 90980- 12355 90980- 12355
A 35 A 36 A 37 A 38 A 39
GRAY
1 2 3 1 1 2
1 2 3 4 5 6 1 2 3 4 5 6 7 4 5 6 2
90980- 10576
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 90980- 10214
90980- 10023
17 18 19 20 21 22 23 24 25 26 17 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 26 27 28 29 30 31
90980- 12529 90980- 12525
XXXXXXXXXXXXXXX
E6-3
CONNECTOR LIST
A 40 A 41 A 42 A 45 A 46 A 47
GRAY BLACK DARK GRAY DARK GRAY DARK GRAY
1 2 1 2 3 4 5 6 7 8 9 1 2 2 1
1 2 3 1 2
90980- 11070 90980- 11162 3 4
10 11 12 13 14 15 16 17 18 90980- 10845 90980- 11168
90980- 10942
90980- 11594
A 48 A 49 A 51 A 52 A 54 A 55
DARK GRAY BLACK GRAY GRAY GRAY
2 1 1 2 4 3 2 1 4 3 2 1 1 2 1 2
4 3 8 7 6 5 8 7 6 5
90980- 11235 90980- 10899 90980- 10899
90980- 10941 90980- 10896 90980- 10890
A 56 A 57 A 58 A 59 A 64 A 65
BLACK GRAY GRAY BLACK
2 1 1 2 3 1 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6
1 2
2 12 13 14 15 16 17 18 19 20 21 22 7 8 9 10 11 12
90980- 11051 90980- 11296
90980- 11168
90980- 10213 90980- 11915 90980- 11661
A 66 A 67 A 68 A 69 A 70 A 71
BLUE BLACK GRAY
1 2 3 4 5 6 6 5 4 3 2 1 1 2 1 2 1 2 1 2 3
7 8 9 10 11 12 15 14 13 12 11 10 9 8 7 90980- 11003 90980- 11162 90980- 11162 90980- 11251
90980- 11661 90980- 11088
B 1 B 2 B 3 B 4 B 5 B 6 C 1
GRAY DARK GRAY
1 1 1 2 3 1
1 2 3 1 2
2 2 3 4 5 6 5 2
3 4
90980- 10214 3 4 90980- 10173 1 4 2 90980- 10214
90980- 10216
90980- 10869
90980- 11742
6098- 1493
C 3 C 4 C 5 C 6 C 7 D 1 E 1 E 2
BLACK GRAY
1 1 1 1
1 2 1 2 1 2 1 2
7316- 2095 7316- 2095 171706- 1
90980- 10622
90980- 11156 90980- 10825 90980- 11025 99141- 11004
E 3 F 1 F 2 F 3 G 1 G 2 G 4
DARK GRAY BLACK
1 1 1 1
1 2 1
171706- 1 1 2 3
1- 179958- 2
99141- 11004 99141- 11004 90980- 09567 90980- 09213 90980- 11349
G 6 G 7 G 8 G 9 G 10 G 11
BLACK BLACK DARK GRAY GREEN DARK GRAY GREEN
1 2
1 2 3 4 5 6 1 2 1 2 1 2 1 2
90980- 11858 90980- 11153 90980- 11153 90980- 11153 90980- 11153
90980- 10108
XXXXXXXXXXXXXXX
E6-4
CONNECTOR LIST
G 12 G 13 G 14 G 16 G 17 G 18 G 19
BLACK GREEN GREEN BLACK GRAY
1 1 2
1 2 3 1 2 3 1 2 1 2
1 2
90980- 10786
4 5 6 90980- 11286
90980- 10845 90980- 10947
90980- 11062
90980- 11144 90980- 10109
G 20 G 21 G 22 G 23 G 24 G 25 G 26
DARK GRAY BLACK BLACK BLACK BLACK
1 1
1 1 2 1 1 2
1 2 3 4 5 99144- 12239
2 90980- 10179
90980- 11038 90980- 10703 90980- 11996 90980- 11024
90980- 10157
G 27 G 28 G 29 G 30
BLUE
1 2 3 4 5 6 1
1 2 3 4 5 6 7 1 2 3 4 5 6 7 7 8 9 10 11 12
8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
90980- 11661 7010- 3025- 02
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34
90980- 12528 90980- 12527
G 31 G 32 G 33 G 34 G 35 G 36 G 37
BLACK GRAY DARK GRAY
1 1 2 3
1 1 2 1 2 3
1 2 1 2 4 5 6 7
90980- 10179 3 4
3 90980- 10165 4 5 6
3 4 90980- 10043
90980- 10476
90980- 11194
90980- 10690
7254- 1548- 40
G 38 G 39 G 41 G 42
GRAY GRAY
1 2 3 4 1 2 3 4
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13
5 6 7 8 5 6 7 8
9 10 11 12 13 14 15 16 14 15 16 17 18 19 20 21 22 23 24 25 26
90980- 10897 90980- 10897
90980- 11391 90980- 11390
G 43 G 44 G 45 G 46 G 49 G 50
GRAY DARK GRAY
1 1
1 2 3 4 5 1 2 3 4 12 13 1 2 1 2
171728- 1 171728- 1 5 6 7 14 15
6 7 8 9 10 11 12 13 177463- 1
8 9 10 11 16 17 90980- 10887
90980- 11542 18
90980- 10778
G 51 G 52 G 53 G 54 G 56 G 57 G 58
BROW N BLACK
1 1 1 1
1 2 3 4 1 2 3 1 2
2
6098- 0309 174357- 2 90980- 10899 90980- 09567 90980- 09567 7009- 1323- 02
90980- 10214
G 59 G 60 G 61 G 63 G 66 G 67
1 1 1 1 2 3 4 5 6 1 2
7 8 9 10 11 12 13 3 4 5 1 2 3 4 5 6 7 8
90980- 10786 90980- 10786
90980- 09567 9 10 11 12 13 14 15 16
90980- 10062 90980- 10309
90980- 11391
XXXXXXXXXXXXXXX
E6-5
CONNECTOR LIST
G 68 G 69 G 70
DARK GRAY DARK GRAY
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13
9 10 11 12 13 14 15 16 14 15 16 17 18 19 20 21 22 23 24 25 26 14 15 16 17 18 19 20 21 22 23 24 25 26
90980- 11391 90980- 11390 90980- 11390
G 72 G 73 H 1 H 2 H 3 I 1 I 2
DARK GRAY BLACK
1 1 1 1 1
1 2 3 4 5 6
1 2
7 8 9 10 11 12
90980- 10899 99142- 16080 7003- 1191- 02 90980- 09222 99142- 15080 99142- 16080
90980- 11661
I 3 J 1 J 2 J 3 K 1 K 2 K 3
DARK GRAY DARK GRAY BLACK
1 1 1 1
1 2 1 2 1 2
90980- 11162 90980- 10626 90980- 11235
7003- 1520- 02 7003- 1172- 02 7003- 1182- 02 90980- 09481
K 7 K 8 L 1 L 2 M 1 M 2 N 1 N 2 O 1
1 1 1 1 1 1 1
1 2 1 2
2 3
90980- 11162
90980- 10214 7003- 2455- 02 8100- 0719 8100- 0719 8100- 0719
7010- 3015 7010- 3015 90980- 11016
O 2 O 3 Q 1 Q 2 R 1
GRAY GRAY GREEN
1 2 3 1 2 1 2 3 4 5 6 7 8 1 2 3
4 5 1 2 3 4 5 6 7
90980- 10256 9 10 11 12 13 14 15 16
90980- 11349
90980- 11077 90980- 12553 IL- AG5- 7S- S3C1
R 2 R 5 S 1 S 2 S 3 S 4 S 8
BLACK BLACK BLACK
1 2 1 2 3 1 2 1 2 1 2
1 2 3
4 5 6 3 4 3 4 5
90980- 11156 90980- 11156 3 4 1 4 2
90980- 11001 90980- 10795 5 6
90980- 11742
82660- 20340
90980- 11011
S 9 S 10 S 11 T 4 T 6 T 7 U 1
BLACK GRAY DARK GRAY BLUE BLUE BLUE BLACK
1 2 1 2 3
1 2 1 2 2 1 1 2 1 2
3 4 5 6 4 5 6 7 8
3 4 3 4
90980- 11156 90980- 10825
90980- 11155 90980- 10797 90980- 10799
90980- 10795 90980- 10795
U 2 U 3 U 4 U 5 V 3 V 4
BLACK BLACK BLACK BLACK
1 2 1 2 3 1 2 1 2 3 1 1
3 4 5 6 4 5 6 7 8 3 4 5 6 4 5 6 7 8
90980- 10183
99141- 11004
90980- 10797 90980- 10799 90980- 10797 90980- 10799
XXXXXXXXXXXXXXX
E6-6
CONNECTOR LIST
X 1 Y 1 Y 2 Y 3 Y 4
BLACK BLACK
1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9
3
90980- 11142 90980- 11885 90980- 11885 10 11 12 13 14 15 16 17 18
90980- 11245
90980- 11594
Y 5 Y 6 Y 7 Y 8 Y 9 Z 1
BLACK BLACK BLACK BLACK BLACK
1 2 3 4 1 2 3 4 1 2 1 2 2 1
1 2
3 3
90980- 11885 90980- 11885 90980- 10887
90980- 11245 90980- 11407 90980- 11255
Z 2 Z 3 a 1 b 1 b 2
GRAY BLACK BLACK GRAY GRAY
1 2 3 1 2 3 1 2 3 4 5 6 3 2 1 3 2 1
7123- 7730 90980- 11858
90980- 10845
90980- 11607 90980- 11607
b 3 c 3 c 4 d 1 d 2 d 5
BLACK
1 1
1 2 1 2 3
1 2 3 4 5 99144- 12239 1 2 3
4 5 6
90980- 11317 99141- 11005 90980- 11156
90980- 11349
90980- 11001
h 1 h 2
BLACK
3 1 2
5
1 4 2 3 4
90980- 11742
82660- 20340
XXXXXXXXXXXXXXX
E6-7
CONNECTOR LIST
1A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
90980- 12506
1B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
90980- 12383
1C 1D
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10 11 12
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 13 14 15 16 17 18 19 20 21 22 23 24
90980- 12320 90980- 12308
1E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
90980- 12311
XXXXXXXXXXXXXXX
E6-8
WIRE TO WIRE
AA1 AC2 AC3
GRAY DARK GRAY GRAY
1 2 3 4 4 3 2 1 1 3 3 1 1 2 3 4 4 3 2 1
2 2
5 6 7 8 8 7 6 5 4 5 5 4 5 6 7 8 8 7 6 5
6 6
7 8 8 7 90980- 10897
90980- 10897
90980- 10896 10 10 90980- 10896
9 11 11 9
90980- 11240
90980- 11239
AC4 AG1
GRAY BLACK
1 2
1 2 2 1
2 1
3 4 4 3 3 4 5 6 7
7 6 5 4 3
90980- 10942 8 9 10 11 12
90980- 10941 12 11 9 8
10
13 14 15
15 14 13
90980- 10815
90980- 10814
AG2 AG3
GRAY
1 2 3 4 5 1 2 3 4 5 6 6 5 4 3 2 1
5 4 3 2 1 7 8 9 10 11 12 13 14 15 15 14 13 12 11 10 9 8 7
6 7 8 9 10 11 12 13
13 12 11 10 9 8 7 6 90980- 11089
90980- 11542 90980- 11088
90980- 11541
AO1 AO2
BROW N
1 2 3 4 5 6
6 5 4 3 2 1
1 2 3 4
7 8 9 10 11 12 13 4 3 2 1
13 12 11 10 9 8 7
5 6 7 8
14 15 16 17 18 19 20 8 7 6 5
20 19 18 17 16 15 14
90980- 11615
90980- 10817 90980- 11551
90980- 10816
XXXXXXXXXXXXXXX
E6-9
WIRE TO WIRE
AO3 AQ1
BLUE DARK GRAY
1 2 3 4 5 6 7 8 9 10 1 2 2 1
10 9 8 7 6 5 4 3 2 1
3 4 4 3
11 12 13 14 15 16 17 18 19 20
20 19 18 17 16 15 14 13 12 11
90980- 11028 90980- 11027
90980- 12378
90980- 12377
Ah1
Aa1 Ab1
BLACK DARK GRAY GRAY
1 2
1 2 3 4 4 3 2 1 1 2 3 3 2 1 2 1
3 4
5 6 7 8 8 7 6 5 4 5 6 6 5 4 4 3
90980- 11136
90980- 10891 90980- 11034 90980- 11135
90980- 10890 90980- 11033
BA1 (* 1 ) BA1 (* 2 ) CC2
DARK GRAY DARK GRAY
1 2 2 1 1 2 2 1 1 2 3 3 2 1
3 3 3 3 4 5 6 6 5 4
90980- 11016 90980- 11016 90980- 11194
90980- 11015 90980- 11015
90980- 11193
DA1 GK1 KM1
GRAY BLACK DARK GRAY GRAY GRAY DARK GRAY
1 2 2 1 1 2 3 4 4 3 2 1 1 2 2 1
90980- 11162 5 6 7 8 8 7 6 5
90980- 11168 90980- 11051 90980- 11050
90980- 10891
90980- 10890
QA1 RA1
1 2 3 4 5 6 7 1 2 2 1
7 6 5 4 3 2 1
8 9 10 11 12 13 14 15 16
16 15 14 13 12 11 10 9 8 3 4 4 3
90980- 11463
5 6 6 5
90980- 11462
90980- 11011
90980- 11452
* 1 : W / S A S /O P S S Y S T E M E X C E P T 4 Y - E
* 2 : 4 Y - E , W /O S A S /O P S S Y S T E M
XXXXXXXXXXXXXXX
E6-10
WIRE TO WIRE
SO1 SO2 SO3
DARK GRAY BLACK DARK GRAY BLACK
1 2 3 4 4 3 2 1 1 3 3 1 1 2 2 1
2 2
5 6 7 8 8 7 6 5 4 5 5 4 3 4 4 3
6 6
90980- 10891 7 8 8 7 90980- 11036
90980- 10890 10 10 90980- 11035
9 11 11 9
90980- 11240
90980- 11239
ST1 SV2 S c1 TC2
BROW N BLUE GRAY DARK GRAY
1 2 1 2 1 2 2 1 1 2 3 3 2 1
2 1 2 1
3 4 4 5 6 6 5 4
4 3
90980- 10906 90980- 11051 90980- 11050
90980- 10795 90980- 10905 90980- 11194
90980- 10794 90980- 11193
UA1 UA2 UB1
BLACK GRAY GRAY
1 2 2 1 1 3 3 1 1 2 3 3 2 1
2 2
3 4 4 3 4 5 5 4 4 5 6 6 5 4
6 6
90980- 11036 7 8 8 7 90980- 11194
90980- 11035 10 10 90980- 11193
9 11 11 9
90980- 11240
90980- 11239
XO1 XO2
GRAY BLACK
1 2 3 4 4 3 2 1 1 2 3 4 5 5 4 3 2 1
5 6 7 8 8 7 6 5 6 7 8 9 10 10 9 8 7 6
90980- 10891
90980- 10890 90980- 12380
90980- 12379
XO3 XO4
GRAY BLACK
1 2 3 4 5 6 7
7 6 5 4 3 2 1 1 2 2 1
8 9 10 11 12 13 14 15 16
16 15 14 13 12 11 10 9 8
90980- 11162
90980- 11463 90980- 11168
90980- 11462
XXXXXXXXXXXXXXX
E6-11
WIRE TO WIRE
YX1
1 2 3 4 5 6 7
7 6 5 4 3 2 1
8 9 10 11 12 13 14 15 16
16 15 14 13 12 11 10 9 8
90980- 11463
90980- 11462
YX2 ZO 1
DARK GRAY
1 2 3 4 5 6 6 5 4 3 2 1 1 2 3 4 4 3 2 1
7 8 9 10 11 12 13 14 15 15 14 13 12 11 10 9 8 7 5 6 7 8 8 7 6 5
90980- 11089
90980- 11088 90980- 10897
90980- 10896
dA1 hA1
GRAY
1 2 2 1
1 2 2 1
3 4 4 3 3 4 4 3
5 6 6 5
90980- 10844 90980- 10749
90980- 11011
90980- 11452
XXXXXXXXXXXXXXX
MEMO
Published by
1st Printing: Aug. 2006
Pub. No. CE049
Printed in Japan
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