toyota forklift 7fgu35 service

FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT

7FGU17FDU35 - 80 series and 7FGCU35 - 70 series. Please use this manual

for providing quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of December 2000. 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 Equip-

ment 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 G4 (GM6-262) ENGINE REPAIR MANUAL (No. C4630)

TOYOTA 11Z,12Z,13Z,14Z ENGINE REPAIR MANUAL (No. C4615)

TOYOTA MOTOR CORPORATION

Service Information Bulletins affecting Models 7FG(D)U35-80 and 7FGCU35-70 REV: 2/29/08Title File File Size Modified On

1 SIB MA04-001 Revision of Repair Manual for 7FG/DU35-80 & 7FGCU35-70 ma04-001.pdf 2739 KB 4/26/20062 SIB MA02-001 GM 6-262 Timing & Idle Adjustment Procedure Change ma02-001.pdf 237 KB 5/3/20063 SIB FS06-001 13Z Updated Fuel System Components fs06-001.pdf 278 KB 5/8/20064 SIB FS06-002 LPG Pre-Filter Service Parts fs06-002.pdf 62 KB 5/8/20065 SIB CE05-004 Starter Motor Engagement Delay (All I.C. Units) ce05-004.pdf 1018 KB 5/25/20066 SIB BR06-001 Stiffer Inching Pedal Spring br06-001.pdf 77 KB 6/1/20067 SIB EN04-004 13Z Injection Pump Changes en04-004.pdf 505 KB 6/7/20068 SIB MA05-003 Change to Periodic Replacement Parts (4Y & GM6-262) ma05-003.pdf 45 KB 6/7/20069 SIB EN04-001 EPA Compliant Three Way Catalyst System Identification & New SST en04-001.pdf 210 KB 6/7/200610 SIB EN03-004 Exhaust Y-Pipe Cracking en03-004.pdf 323 KB 6/7/200611 SIB CE01-005 Combination Meter Membrane Grease ce01-005.pdf 385 KB 6/8/200612 SIB FA06-001 Changes to Reamer Bolt Torque Specification fa06-001.pdf 82 KB 10/18/200613 SIB MA07-001 Caution During Oil Filling ma07-001.pdf 126 KB 1/31/200714 SIB FS07-001 New Fuel System for GM6-262 fs07-001.pdf 175 KB 1/31/200715 SIB MA07-001R Caution During Oil Filling ma07-001r.pdf 190 KB 6/27/200716 SIB FS07-002 MIL Strategy Change fs07-002.pdf 75 KB 6/27/200717 SIB FS07-003 ECM calibration revisions and DTC updates fs07-003.pdf 163 KB 7/12/200718 SIB CE07-002 Wiring Diagrams for Spectrum Fuel System ce07-002.pdf 3247 KB 9/25/200719 SIB ST07-002 Recommended Service Tools for a Field Service Technician st07-002.pdf 84 KB 9/25/200720 SIB FS07-004 New Spectrum DTC 652 and 653 fs07-004.pdf 87 KB 10/26/200721 SIB FS07-008 New Spectrum DTC 9999 and 1151 fs07-008.pdf 53 KB 10/26/200722 SIB FS07-005 New Spectrum DTC 627, 628, and 629 fs07-005.pdf 141 KB 10/26/200723 SIB CE07-006 Introduction of VSCS Vehicle Speed Control System ce07-006.pdf 741 KB 10/26/200724 SIB FS07-006 Spectrum Fuel System Relay Change fs07-006.pdf 77 KB 11/16/200725 SIB BF08-002 Product Improvement for 7FGU/7FDU35-80, 7FGCU35-70 bf08-002.pdf 2504 KB 2/12/2008

Technical New Briefs affecting Models 7FG(D)U35-80 and 7FGCU35-701 TNB-2007-08 Troubleshooting 13Z Diesel Exhaust Smoke tnb-2007-08.pdf 71 KB 10/26/20072 TNB-2005-04R2 Guidelines for Cleaning a Contaminated Hydraulic System tnb-2005-04-r2.pdf 77 KB 10/26/20073 TNB-2007-02 Chassis Lubrication Clarification tnb-2007-02.pdf 71 KB 4/9/20074 TNB-2007-01 Use of Torque Adapter for SSC FL06-007 tnb-2007-01.pdf 88 KB 4/9/20075 TNB-2003-03 7FGU35 – 80, 7FGCU35 – 70 Poor Engine Performance When Cold tnb-2003-03.pdf 156 KB 11/29/20056 TNB-2005-03 Quick Reference Sheet for 13Z Diesel Pump Timing tnb-2005-03.pdf 294 KB 11/29/2005

Hotline Tech Tip Articles affecting Models 7FG(D)U35-80 and 7FGCU35-70 REV: 2/29/081 HTT-11-2004 - V-6 hard start; Hydraulic valve sticking: Excessive brake wear & noise; Axle plate mounting bolts loose hotline tech tips-2004-11.pdf 114 KB 2/6/20062 HTT-12-2004 - GMV6 Timing; Strobe Light Failures; V6 hard start; Drive Train Noise; Hydraulic pump failures hotline tech tips-2004-12.pdf 130 KB 2/6/20063 HTT-1-2005 - Rotten Egg Smell, Retrieving TWC Error Codes, Flame Retardant Hydraulic Oil, GM V-6 Crank Pulley hotline tech tips-2005-01.pdf 119 KB 7/5/20064 HTT-2-2005 - LP Pre-filter Parts, Retrieving TWC Error Codes, Hydraulic Pump Change hotline tech tips-2005-02.pdf 153 KB 2/20/20065 HTT-3-2005 - “Rotten Egg” Smell; Driveline Vibration; Aisin LPG Regulator Rich/Lean Air/fuel Ratio; Abnormal Brake Noise; Diesel Engine Smoke;

Overheatinghotline tech tips-2005-03.pdf 121 KB 2/6/2006

6 HTT-4-2005 - Lean LPG Main Path, Engine Compression Check; Key Switch Change hotline tech tips-2005-04.pdf 94 KB 2/6/20067 HTT-5-2005 - Seat Switch Testing, Premium GM V-6 Engine; GM V-6 Crankshaft Bolt hotline tech tips-2005-05.pdf 168 KB 7/5/20068 HTT-6-2005 - Injector Harness Test Light; Cascade House Valves hotline tech tips-2005-06.pdf 326 KB 2/6/20069 HTT-7-2005 - TWC Initial Setting for Injector Period, Improvements to the new key switches, Operator Prescence System hotline tech tips-2005-07.pdf 118 KB 3/13/200610 HTT-8-2005 - TWC Initial Setting for Injector Period, Improvements To The New Key Switches, Operator Presence System hotline tech tips-2005-08.pdf 112 KB 3/13/200611 HTT-9-2005 - 13Z Diesel Injection Timing hotline tech tips-2005-09.pdf 323 KB 2/6/200612 HTT-10-2005 - 13Z Diesel Injection Timing hotline tech tips-2005-10.pdf 97 KB 2/2/200613 HTT-11-2005 - TWC Analyzer Tips, GM V6 Hot Soak Engine Shut Down hotline tech tips-2005-11.pdf 74 KB 2/6/200614 HTT-12-2005 - OPSS Component Information hotline tech tips-2005-12.pdf 278 KB 4/9/200715 HTT-1-2006 - TWC Trouble Shooting Tips, Metal Clad Wiper Seals on Rear Lift Cylinders hotline tech tips-2006-01.pdf 71 KB 2/2/200616 HTT-2-2006 - O.P.S.S. Error Code 1, TWC Light Strobing & Adjustments, Hood Vents, Replacement Radiators, GM V-6 Y Pipe Update hotline tech tips-2006-02.pdf 185 KB 3/2/200617 HTT-3-2006 - 7Series Starter Delay Circuit hotline tech tips-2006-03.pdf 249 KB 4/3/200618 HTT-4-2006 - LPG Regulator Air Testing, Home Depot Options, LPG Pre-Filter Service Parts hotline tech tips-2006-04.pdf 84 KB 4/27/200619 HTT-5-2006 -7FDU Oil Filing, Cotton Core Radiator, LPG Oil Contamination hotline tech tips-2006-05.pdf 279 KB 6/20/200620 HTT-6-2006 - V-Mast Rear Cylinders, Wire Harness Repair, SAS Code 63, Axle Mount Bolts hotline tech tips-2006-06.pdf 344 KB 7/11/200621 HTT-7-2006 - GM6-262 Exhaust Y-Pipe Breaking hotline tech tips-2006-07.pdf 131 KB 4/9/200722 HTT-8-2006 -Engine Shutdown Option, Extreme Environment Radiator hotline tech tips-2006-08.pdf 268 KB 9/6/200623 HTT-9-2006 - V-Mast Cylinder Spacer, GM6-262 Timing Chain Tensioner, TWC Tamper Resistant Plug hotline tech tips-2006-09.pdf 134 KB 10/3/200624 HTT-10-2006 - GM6-262 Hard/Impossible to Start, SAS L-Off hotline tech tips-2006-10.pdf 257 KB 4/9/200725 HTT-11-2006 - Ultra-Low Sulfur Diesel, 7FGCU35-45 Brake Noise, TWC Emission Warranty hotline tech tips-2006-11.pdf 99 KB 11/27/200626 HTT-12-2006 - Travel Speed Measurement, Clogged LP injector, New Fuel System SST hotline tech tips-2006-12.pdf 308 KB 4/9/200727 HTT-1-2007 - GM6-262 Spectrum Fuel System hotline tech tips-2007-01.pdf 136 KB 4/9/200728 HTT-2-2007 - Spectrum MIL Strategy change, Chassis Lubrication, USB adapter for Spectrum hotline tech tips-2007-02.pdf 519 KB 4/9/200729 HTT-3-2007 - IC Radiator Offerings hotline tech tips-2007-03.pdf 154 KB 4/9/200730 HTT-4-2007 - Spectrum Adapter hardware change hotline tech tips-2007-04.pdf 381 KB 5/10/200731 HTT-5-2007 - Spectrum Fuel System Terminology hotline tech tips-2007-05.pdf 216 KB 9/24/200732 HTT-6-2007 - New Active Radiator, Troubleshooting Smoke hotline tech tips-2007-06.pdf 162 KB 9/24/200733 HTT-7-2007 - New Hydraulic Oil, Troubleshooting Overheating, Spectrum III LP and/or Gasoline hotline tech tips-2007-07.pdf 600 KB 9/24/200734 HTT-9-2007 - Spectrum Fuel System Calibration hotline tech tips-2007-09.pdf 502 KB 9/24/200735 HTT-10-2007 - LP Lockoff Solenoid Orientation hotline tech tips-2007-10.pdf 303 KB 10/30/200736 HTT-11-2007 - Spectrum Calibration changes, Spectrum DTC 1152 hotline tech tips-2007-11.pdf 155 KB 11/19/200737 HTT-12-2007 - Spectrum hard start, Engine Block Heaters hotline tech tips-2007-12.pdf 490 KB 12/12/200738 HTT-1-2008 - Threshold Voltages hotline tech tips-2008-01.pdf 363 KB 1/28/200839 HTT-2-2008 - Proper Wheel Torque hotline tech tips-2008-02.pdf 204 KB 2/28/2008

SECTION INDEX NAME SECTION

I GENERAL ENGINE TORQUE CONVERTER & TRANSMISSION PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE SAS APPENDIX

GENERAL Page

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

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

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

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

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

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

............................................................. A6 BR EVl ATIONS 0-6

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

HOISTING THE VEHICLE ........................................ 0-7

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

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

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

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

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

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

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

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

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

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

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

................................................. LUBRICATION CHART 0-17

.......................................... PERIODIC MAINTENANCE 0-20

PERIODIC REPLACEMENT OF PARTS AND ............................................................... LUBRICANTS 0-26

EXTERIOR VIEWS

Pneumatic tire model

Cushion tire model

VEHICLE MODEL Pneumatic Tire Models (Pn)

Cushion Tire Models (Cu)

Note: The G4 engine is the same as the GM6-262 engine except for the nomenclature.

Vehicle Model

7FGU35

7FDU35

7FGKU40

7FDKU40

7FGU45

7FDU45

7FGAU50

7FDAU50

7FGU60

7FDU60

7FGU70

7FDU70

7FGU80

7FDU80

Load Capacity

8000 Ibs

9000 lbs

10000 lbs

11 000 Ibs

13500 Ibs

1 5500 Ibs

17500 Ibs

Classification

Series

Pn3.5 ton series

Pn4.5 ton series

Pn6.0 ton series

Model

Pn35

Pn40

Pn45

Pn50

Pn60

Pn70

Pn80

Transmission Type

TIC

TIC

TIC

TIC

TIC

TIC

TIC

TIC

TIC

TIC

TIC

TIC

TIC

TIC

Transmission Type

TIC

TIC

TIC

TIC

TIC

Engine Classification

G4 (GM6-262)

G4 (GM6-262)

G4 (GM6-262)

G4 (GM6-262)

G4 (GM6-262)

Engine

Load Capacity

8000 Ibs

10000 lbs

12000 Ibs

13500 Ibs

15500 Ibs

Series

Cu3.5 ton series

Cu5.5 ton series

Gasoline

Gasoline

Gasoline

Gasoline

Gasoline

G4 (GM6-262)

132

G4 (GM6-262)

1 32

G4 (GM6-262)

132

G4 (GM6-262)

132

G4 (GM6-262)

132

G4 (GM6-262)

132

G4 (GM6-262)

132

Vehicle Model

7FGCU35

7FGCU45

7FGCU55

7FGCU60

7FGCU70

Model

Cu35

Cu45

Cu55

Cu60

Cu70

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

FRAME NUMBER Frame No. Punching Position

Punching position

*: EEC spec.

Pneumatic tire

Cushion tire

Series

3.5 ton series

4.5 ton series

6.0 ton series

3.5 ton series

5.5 ton series

Engine

G4 (GM6-262)

1 32

G4 (GM6-262)

132

G4 (GM6-262)

132

G4 (GM6-262)

G4 (GM6-262)

Vehicle model

7FGU35

7FGKU40

7FDU35

7FDKU40

7FGU45

7FGAU50

7FDU45

7FDAU50

7FGU60

7FGU70

7FGU80

7FDU60

7FDU70

7FDU80

- 7FGCU35

7FGCU45

7FGCU55

7FGCU60

7FGCU70

Punching format

7FGKU40 - 6001 1

7FDKU40 - 6001 1

7FGAU50 - 6001 1

7FDAU50 - 6001 1

7FGU80 - 6001 1

7FDU80 - 6001 1

7FGCU45 - 6001 1

* 7FGCU45 O 6001 1

7FGCU70 - 6001 1

-

HOW TO USE THIS MANUAL EXPLANATION METHOD

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

Pattern A: Explanation of each operation step with illustration. Pattern 6 : Explanation of operation procedure by indicating step numbers in one illustration, fol-

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

Example of description in pattern B

DISASSEMBLY-INSPECTION-REASSEMBLY Tightening torque unit T = N-m (kgf-cm) [ft-lbf]

Step Nos. are partially sometimes omitted in illustrations.

1

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 51

8

Disassembly Procedure

1 Remove the cover. [Point 11

2 Remove the bushing [Point 21 C Operation explained later

3 Remove the gear.

Point Operations Explanation of key point for operation with an illustration

[Point 11 LL

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

[Point 21 Inspection: Measure the bushing inside diameter.

Limit: 19.12 mm (0.7528 in)

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

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

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

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

TERMINOLOGY Caution: lmportant matters of which negligence may cause hazards on human body. Be sure to observe them.

Note: lmportant 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

Meaning

Society of Automotive Engineers (USA)

System of active stability

Special service tool

Standard

Tightening torque

Torque converter & transmission

Number of teeth ( 0 0)

Undersize

With

Less

RH Right hand

Abbreviation (code)

SAE

Abbreviation (code)

ASSY

Cu

Meaning

Assembly --

Cushion tire models S AS

SST

STD

T = -

TIC

O O T

UIS

WI

U

U-l Left hand

LLC

M/T

Long life coolant --

Manual transmission

NMR

OPT

01s

Pn

PS

No-load maximum speed

Option

Oversize

Pneumatic tire models

Power steering

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

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

Rear side: Jack up at the under the counterweight.

HOISTING THE VEHICLE When hoisting the vehicle, sling with wire rope(s) at the mast hook holes and the counterweight hook holes.

ATTENTIVE POINTS ON SAS

1. Reference should be made to seperate manual "New Model Feature 7FG(C)U/7FDU35-80 Pub. No.PUO17" for the explanations of SAS functions and operations.

2. Read Section 15 SAS "Precautions for Repair" on Page 15-8 in this repair manual in advance.

3. Whenever the repair or replacement is performed to the place where relative to SAS function, re- setting procedure by which the SAS regain proper function must be performed. (See Page 15-23)

4. The warning on the SAS caution label must be confirmed when the modification or change is such as to change the original specification. If improper, change the label. (See Page 15-1 1)

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

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

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

L

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: kR range

(2) Digital circuit tester

Forward

Reverse

Forward direction Reverse direction - . - .

I I

Analog type

Continuity exists

11 kQ

No continuity

00

Measurement result example Tester range: Ma range

Forward

Reverse

Digital type

No continuity

1

Continuity exists

2 MQ

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

- 5 C

4 3 0

3

E 2 LL

1

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Forward voltage ( v )

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

This manual describes the results of measurement with a circuit tester whose power supply voltage is 3.0 V.

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

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

: - - - s

t

. .

Power source: 1.5 V

0 0 P Red 6' Black

Variable resistor

$1 , - Resistor \ Range: x 10 ( s w l )

I 4

Range: x 1 (sw2)

,,

1

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

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

BOLT STRENGTH TYPE IDENTIFICATION METHOD

IDENTIFICATION BY BOLT SHAPE IDENTIFICATION BY PART NO.

Hexagon head bolt k Parts No. 91 61 1 -4 0 6 2 5

Length (mm)

Diameter (mm)

L a s s

iameter

Length 4

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

-L Length (mm)

Diameter (mm)

I Class

iameter

TIGHTENING TORQUE TABLE

47 1 480 1 35 53 1 540 1 39

5T

6T

TT

8T

16

6

8

10

12

14

16

6

8

10

12

14

16

6

8

10

12

14

16

6

8

10

12

14

16

1.5

1 .O

1.25

1.25

1.25

1.5

1.5

1 .O

1.25

1.25

1.25

1.5

1.5

1 .O

1.25

1.25

1.25

1.5

1.5

1 .O

1.25

1.25

1.25

1.5

1.5

75 1 760 1 55

113 1 1150 1 83 6.4 65 56 in-lbf I

16 1 160 1 1 2 32 1 330 1 24 59 1 600 1 43

91 1 930 1 67

137 / 1400 1 101

7.8 80 / 69 in-lbf

19 1 195 1 14 38 1 400 1 29

72 1 730 1 53

110 I 1100 I 80

1 70 1 1750 (127

11 i 110 i 8 25 1 260 1 19 52 1 530 1 38

95 1 970 1 7 0

147 I 1500 ' 108 I

226 / 2300 1 166

12 1 125 1 9 29 1 300 1 22

61 1 620 1 45

108 I 1100 I 80 I

172 I 1750 1127 I 265 2700 1 195

83 1 850 1 6 1 - I - I _

I

7.5 I 75 ; 65 in-lbf

l8 1 175 1 13

36 1 360 1 26

65 1 670 1 48

100 1 1050 1 76

157 1 1600 1 116

8.8 i 90 i 78 in-lbf

21 1 215 [ 16 43 1 440 1 32

79 1 810 1 59

1 23 I 1250 I 90

191 ( 1950 1141 I I

12 1 120 1 9

28 1 290 1 2 1

58 1 590 1 43

103 1 1050 1 76

167 I 1700 '123 - I - I

14 1 1 4 5 1 9

32 1 330 1 24

68 1 690 1 50

123 I 1250 I 90

I 2000 1 145 196 1 299 3050 1 221

Seal lock agent

PRESSURE HOSE

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

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

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

ened) by tightness check, etc.

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

2. Method for reuse of precoat bolts (1) Wash the bolt and threaded hole. (The threaded hole

must be washed even for replacement of the bolt.) (2) Perfectly dry the washed parts by air blowing. (3) Coat the specified seal lock agent to the threaded por-

tion of the bolt.

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.

Hose inside diameter mm (in)

6 (0.24)

9 (0.35)

12 (0.47)

12 (0.47), 15 (0.59)

19 (0.75)

25 (0.98)

6 (0.24)

9 (0.35)

1 2 (0.47)

19 (0.75)

25 (0.98)

Nominal diameter of screw

711 6- 20UNF

911 6- 18UNF

314- 16UNF

718 - 14UNF

1.1116- 12UNF

1*5/16-12UNF

PF114

PF318

PF112

PF314

PFl

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

Standard

25( 250)[ 18.11

49 ( 500) [ 36.21

59 ( 600) [ 43.41

59 ( 600) [ 43.41

11 8 (1200) [ 86.81

137(1400)[101.3]

25( 250) [ 18.11

49 ( 500) [ 36.21

59 ( 600) [ 43.41

11 8 (1 200) [ 86.81

137 (1 400) [ I 01.31

Tightening range

24 - 26 ( 240 - 270) [ I 7.4 - 19.51

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

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

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

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

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

24 - 26 ( 240 - 270) [I 7.4 - 19.51

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

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

11 2 - 123 (1 140 - 1250) [82.5 - 90.41

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

WIRE ROPE SUSPENSION ANGLE LIST

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE unit: N (tf) [Ibf]

Lifting angle

o0

30°

60'

Rope diameter

6rnm (0.24 in)

mm

(0'32 in)

10 mm (0.4 in)

12.5 mm (0.5 in)

14 mm

(0.56 in)

Tension

1 .OO time

1.04 time

1.1 6 time

Compres- sion

0 time

0.27 time

0.58 time

Suspension method

1 f l r-

b * \'

Cutting load

21 380 (2.1 8) 148071

31 480 (3.21) [7078]

49230 (5.02) [ I 1.691

76880 (7.84)

[ I 73871

96400 (9.83)

[21675]

Lifting angle

90'

120°

Single-rope suspension

-

o0 3040 (0.31) [683.6]

441 0 (0.45) 1992.31

6960 (0.71)

[ I 565.61

10980 (1.12)

[2469.5]

13730

(1.4) 130871

Tension

1.41 time

2.00 time

Two-rope suspension

Compres- sion

1 .OO time

1.73 time

o0 6080 (0.62) [ I 3671

8830

(0.9) 119851

14020 (1.43) 131 531

21570

(2.2) [4851]

27460

(2.8) [6174]

Four-rope suspension

Suspension method

* C

\' A

o0 12160 (1.24) [2734]

17650

(1.8) (39691

27460

(2.8) [6174]

43150

(4.4) [9702]

54920

(5.6) [ I 23481

30'

5880

(0.6) [ I 3231

8530 (0.87) [I91 81

13440 (1.37) [3021]

21280

(2.1) [4631]

26480

(2.7) [5954]

30°

11770

(1.2) [2646]

17060 (1.74) [3937]

26480

(2.7) [5954]

41190

(4.2) [9261]

52960

(5.4) [ I 1 9071

60'

5200 (0.53) [ I 1691

7650 (0.78) [I7201

11770

(1.2) [2646]

18630

(1.9) [4190]

23540

(2.4) [5292]

90'

4310 (0.44)

[970]

6280 (0.64) 1141 11

9810

(1.0) [2205]

14710

(1.5) [3308]

18630

(1.9) [4190]

60'

10400 (1.06) 123371

15300 (1.561 134401

23540

(2.4) 152921

37270

(3.8) 183791

47070

(4.8) [ I 05841

90'

8630 (0.88) [ I 9401

12550 (1.28) [2322]

19610

(2.0) [4410]

29420

(3.0) [6615]

37270

(3.8) [8379]

COMPONENTS WEIGHT

Weight kg (Ib)

185 ( 408)

325( 717)

150 ( 331)

1 70 ( 375)

Approx. 2230 ( 4920)

Approx. 2630 ( 5800)

Approx. 2880 ( 6350)

Approx. 31 30 ( 6950)

Approx. 3430 ( 7565)

Approx. 41 1 0 ( 9065)

Approx. 4790 (1 0565)

Approx. 2370 ( 5225)

Approx. 31 20 ( 6880)

Approx. 3500 ( 7720)

Approx. 3920 ( 8645)

Approx. 4570 (1 0080)

Approx. 890 ( 1960)

Approx. 11 40 ( 251 0)

Approx. 1270 ( 2800)

Approx. 1340 ( 2950)

Approx. 1340 ( 2950)

Approx. 890 ( 1960)

Approx. 950 ( 2090)

Approx. 1270 ( 2800)

Approx. 1340 ( 2950)

Component

Engine


Counter weight

V mast ASSY Ubackrest and fork (with lift cylinder, max. lifting height: 3000 mm (1 18 in))

G4 (GM6-262)

132

Pn35 - 50, Cu35 - 70 model

Pn60 - 80 model

Pn35 model

Pn40 model

Pn45 model

Pn50 model

Pn60 model

Pn70 model

Pn80 model

Cu35 model

Cu45 model

Cu55 model

Cu60 model

Cu70 model

Pn35.40 model

Pn45 model

Pn50 model

Pn60.70 model

Pn80 model

Cu35 model

Cu45 model

Cu55 model

Cu60.70 model

Type

Motor oil SAE30 (SAE20 in cold area)

SAE20W-40 (SAE1 OW-30 in cold area)

Diesel engine oil SAE30 (SAE20 in cold area)

SAE1 OW-30

GM Dexronm) II

Hypoid gear oil SAE85W-90

Hydraulic oil

MP grease Molybdenum disulfide grease

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

t

TYPES

Classification

API SH, SJ

API CE, CF

ATF

API GL-4, GL-5

IS0 VG32

-

-

LLC

t

QUANTITY &

Quantity (US gal)

4.2 (1.11)

12.5 (3.30)

12.0 (3.1 7)

9.0 (2.38)

7.0 (1.85)

69 (1 8.2)

38 (1 0.0)

1 05 (27.7)

120 (31.7)

48 (1 2.7)

Proper quantity

13.0 (3.46)

13.0 (3.46)

0.6 (0.1 6) (at Full level)

LUBRICANT

Application

G4 (GM6-262)

132

TIC

Pn35-50 models

Pn60-80 models

Cu35-70 models

Pn35-80, Cu55-70 models

Cu35.45 models

Pn35-40, Cu55-70 models

Pn45-80 models

Cu35-45 models

All models

G4 (GM6-262)

1 32

All models

RECOMMENDED

Description

Engine

Gasoline

Diesel

Transmission

Differential

Hydraulic oil (V mast, max. lifting height 30Oomm (I1 8in))

Fuel tank

Chassis parts

Coolant (excluding reservoir tank)

Coolant (Reservoir Tank)

0-1 7

LUBRICATION CHART Pneumatic Tire Model (Pn35-50)

1 1

14 2

13 14

3 13

3

5 12

9 15

10 8

16 4

7 19

6 7

17 6

18 17

11 18

0 Inspection Replacement

8 MP grease I. Inspect every 8 hours (daily) @ Engine oil II. Inspect every 40 hours (weekly) @ Hypoid gear oil Ill. Inspect every 170 hours (monthly) @ Hydraulic oil IV. Inspect every 1000 hours (6 monthly) @ Automatic transmission fluid V. Inspect every 2000 hours (annual) @ Molybdenum disulfide grease

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

10 Rear axle beam front pin 19 Oil pump spline shaft

Pneumatic Tire Model (Pn60-80)


@ MPgrease @ Engine oil I. lnspect every 8 hours (daily) @ Hypoid gear oil II. Inspect every 40 hours (weekly) @ Hydraulic oil Ill. lnspect every 170 hours (monthly) @ Automatic transmission fluid IV. lnspect every 1000 hours (6 monthly) @ Molybdenum disulfide grease V. lnspect every 2000 hours (annual)

1 Chain 2 Differential 11 Rear axle beam rear pin 3 Planetary gear 12 Tilt steering locking mechanism 4 Oil pump drive shaft 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 Tie rod end pin 8 Oil tank 17 Rear axle cylinder end pin 9 Engine crank case 18 Oil pump spline shaft

10 Rear axle beam front pin

Cushion Tire Model


@ MPgrease I. Inspect every 8 hours (daily) @ Engine oil II. Inspect every 40 hours (weekly) @ Hypoid gear oil Ill. Inspect every 170 hours (monthly) @ Hydraulic oil IV. Inspect every 1000 hours (6 monthly) @ Automatic transmission fluid V. Inspect every 2000 hours (annual) @ Molybdenum disulfide grease

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

10 Rear axle beam front pin 19 Oil pump spline shafl

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 *I : Flaw detector

Inspection Period Every 1 month

Every Item 170 hours

Every 3 months

Every 500 hours

Every 6 months

Every 1000 hours

ENGINE

Main body

PCV system

Governor

Lubrication system

system

Cooling system

Every 12 months

Every 2000 hours

c

c

t

c

c

c

t

c

C

c

c

c

c

c

t

c

c

I

Proper starting and abnormal noise

Rotating condition at idling

Rotating condition during acceleration

Exhaust gas condition

Air cleaner element

Valve clearance

Compression

Cylinder head bolt loosening

Muffler rubber mount

Clogging and damage in PCV valve and piping

No-load maximum rpm

Oil leak

Oil level

Clogging and dirt of oil filter

Fuel leak

Operation of carburetor link mechanism

Dirt and clogging of fuel filter and element

Injection timing

Injection nozzle injection pressure and spray status

Draining of sedimenter

Coolant level in radiator and leak

Rubber hose degradation

Radiator cap condition

Fan belt tension, looseness and damage

Radiator rubber mount

c

t

t

t

c

t

t

t

t

t

t

t

t

M

I

t

t

c

c

I

M

M

I

C

M*

I

M

I

I

I

I

I

I

I

I

I

I

t

t

t

t

t

M

M

T

I

t

t

t

t

t

t

t

t

t

M

t

t

t

t

t

I

0-21



Every 6 months

Every 1000 hours

Every 3 months

Every 500 hours

Every 12 months

Every 2000 hours

t

t

T

t

t

T

t

t

t

t

t

t

t

I

I

I

c

c

t

c

t

c

t

t

t

M

t

t

t

t

t

t

t

t

t

t

T

DRIVE SYSTEM

I

I

I

I

I

I

I

I

I

POWER

Differential

Planetary gear


Propeller shaft and axle shaft

TRANSMISSION SYSTEM

Leak

Oil level

Bolt loosening

Leak

Oil level

Bolt loosening

Leak

Fluid level

Operating mechanism function and looseness

Control valve and clutch functions

Inching valve function

Stall and hydraulic pressure measurement

Loose joint

Looseness at spline connections

Looseness of universal joint

Twisting and cracks of axle shaft

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

M

I

T

M

I

I

I

I

Wheels

Tire inflation pressure

Tire cuts, damage and uneven wearing

Loose rim and hub nuts

Tire groove depth

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

Rim, side bearing and disc wheel damage

Abnormal sound and looseness of front wheel bearing

Abnormal sound and looseness of rear wheel bearing

Every 3 months

Every 500 hours

Every 6 months

Every 1000 hours

1 month

Item 170 hours

Every 12 months

Every 2000 hours

I

I

M

Front axle

Rear axle

STEERING SYSTEM

Steering wheel

Steering valve

Power Steering

Knuckle

Cracks, damage and deformation of housing

Cracks, damage and deformation of beam

Looseness of axle beam in vehicle longitudinal direction M*

Play and looseness

Function

Oil leak

Looseness of mounting

Oil leak

Mounting and linkage looseness

Damage of power steering hose

King pin looseness

Cracks and deformation

BRAKING SYSTEM

Brake pedal

Parking brake

Brake pipe

Brake and cylinder

I

I

I

T

I

I

I

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

I

t

I

Play and reserve

Braking effect

Operating force

Braking effect

Rod and cable looseness and damage

Leak, damage and mounting condition

Function, wear, damage, leak and mounting looseness

t

t

t

t

t

t

t

t

t

t

t

t

I

M

I

I

I

I

I

t

t

t

t

t

t

h

Item 170 hours

Every 3 months

Every 500 hours

t

Brake drum and brake shoe

Backing plate

Every 6 months

Every 1000 hours

t Clearance between drum and lining

Wear of shoe sliding portion and lining

Drum wear and damage

Shoe operating condition

Anchor pin rusting

Return spring fatigue

Automatic adjuster function

Deformation, cracks and damage

Loose mounting

MATERIAL

Forks

Mast and lift bracket

Chain and chain wheel

Various attachments

HYDRAULIC

Every 12 months

Every 2000 hours

t

I

I

I

I

M

I

I

T

M

t

t

t

t

t

t

t

t

t

t

C

HANDLING SYSTEM

Abnormality of fork and stopper pin

Misalignment between left and right fork fingers

Cracks at fork root and welded part

Deformation and damage of each part and crack at welded part

Mast and lift bracket looseness

Wear and damage of mast support bushing

Wear, damage and rotating condition of rollers

Wear and damage of roller pins

Wear and damage of mast trip

Tension, deformation and damage of chain

Chain lubrication

Abnormality of chain anchor bolt

Wear, damage and rotating condition of chain wheel

Abnormality and mounting condition of each part

SYSTEM

t

t

t

t

t

t

t

t

t

t

t

I

I

I

I

I

I

I

I

I

I

I

Cylinder

t

t

1''

t

t

I

C

I

t

t

c

c

t

t

t

t

t

t

Loosening and damage of cylinder mounting

Deformation and damage of rod, rod screw and rod end

Cylinder operation

Natural drop and natural forward tilt (hydraulic drift)

t

t

t

t

T

I

I

M

t

t

t

t



Every 3 months

Every 500 hours

t

t

t

t

t

t

t

t

t

t

t

t

t

t

Cylinder

Oil pump

Hydraulic Oil tank

Control lever

Oil valve

Hydraulic piping

ELECTRICAL

Every 6 months

Every 1000 hours

t

t

t

t

t

t

C

t

t

t

t

t

t

t

t

Oil leak and damage

Wear and damage of pin and cylinder bearing

Lifting speed

Uneven movement

Oil leak and abnormal sound

Oil level and contamination

Tank and oil strainer

Oil leak

Loose linkage

Operation

Oil leak

Relief pressure measurement

Relief valve and tilt lock valve functions

Oil leak

Deformation and damage

Loose joint

SYSTEM

t

t

t

I

I

t

t

t

t

t

t

t

Every 12 months

Every 2000 hours

t

t

t

t

t

t

t

t

t

t

t

M

t

t

t

t

I

I

M

I

I

I

I

I

I

I

I

I

I

T

t

t

t

t

t

t

t

t

I

I

I

I

I

I

I

I

Ignition timing

Starting motor

Charger

Battery

Electrical wiring

t

t

t

M

t

t

t

M

t

t

Cracks on distributor cap

Distributor side terminal burning

Distributor cap center piece wear and damage

State of spark plug (carbon, soot)

Plug cord internal discontinuity

Ignition timing

Pinion gear meshing status

Charging function

Battery fluid level

Battery fluid specific gravity

Damage of wiring harness

Fuses



Every 3 months

Every 500 hours

t

Preheater

Engine stopping system

SAFETY DEVICES,

Head guard

Back-rest

Lighting system

Hom

Direction indicator

Instruments

Backup buzzer

Rear-view mirror

Seat

Body

SAS

Others

Every 6 months

Every 1000 hours

I

t

Open-circuit in intake heater

Diesel engine key stop device function

Every 12 months

Every 2000 hours

t

t I

ETC.

Cracks at welded portion

Deformation and damage

Loosening of mounting

Deformation, crack and damage

Function and mounting condition



Functions


Dirt, damage

Rear reflection status

Loosening and damage of mounting

Seatbelt damage and function

Damage and cracks of frame, cross members, etc.

Bolt looseness

Functions

Loosening and damage at sensor mounting portion

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

Loosening and damage of wire harnesses

Lock cylinder accumulator performance

Rusting and corrosion of load sensor

Grease up

I

I

T

I

I

I

I

I

I

I

I

I

I

I

I

I

I

L

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

t

I

T

t

t

t

t

I

I

t

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS : Replacement

*l : for new vehicle *2: Every 2 years *3: Every 3 years *5: Every 10000 hours

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

1 month Every

3 months

Every 500 hours

t

• •

Item

Engine oil

Eng~ne oil filter

Engine coolant (every 2 years for LLC)

Fuel filter

Torque converter oil

Torque converter oil filter

Differential oil

Planetary gear oil

Hydraulic oil

Hydraulic oil filter

Wheel bearing grease

Spark plugs

Air cleaner element

Cups and seals for brake booster and wheel cylinders

Power steering hoses

Power steering rubbers parts

Hydraulic hoses

Fuel hoses

Torque converter rubber hoses

Chains

SAS Swing lock cylinder

rs

• • *1

• *1

Every 6 months

Every 1000 hours

t

t

t

• • •

• •

Every 12 months

Every 2000 hours

t

t

t

t

t

t

• • t

t

• -

• *2

• • • *2

• *2

• *2

• *2

• *2

*3

• *5

ENG INE Page

ENGINE EXTERIOR VIEWS ................ 1-2

MAJOR SPECIFICATIONS ................... 1-3

ENGINE PERFORMANCE CURVES ............................................... 1-5

ENGINE ASSY ......................................... 1-6 REMOVAL*INSTALLATION ................... 1-6

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

ENGINE SPEED INSPECTION AND ADJUSTMENT ..................................... 1-9 G4 (GM6-262) ENGINE ......................... 1-9 132 ENGINE ........................................... 1-13

AIR CLEANER ......................................... 1-1 4 SPECIFICATIONS .................................. 1-1 4 COMPONENTS ..................................... 1-14 AIR CLEANER CLEANING-

INSPECTION ..................................... 1-15 CLOGGING WARNING SYSTEM

INSPECTION ..................................... 1-1 6 RADIATOR ................................................ 1-1 6

COMPONENTS ..................................... 1-16 SPECIFICATIONS .................................. 1-17 COOLANT CAPACITY AND

ANTIFREEZE TABLE ......................... 1-1 7

FAN DRIVE ....................................... 1-18 REMOVAL-INSTALLATION ................... 1-1 8 DlSASSEMBLY.INSPECTION .

REASSEMBLY ................................... 1-20 MUFFLER & EXHAUST PIPE .............. 1-23

COMPONENTS ..................................... 1-23 REMOVAL-INSTALLATION ................... 1-24 CATALYTIC MUFFLER

MAINTENANCE ................................. 1-24

BATERY- SPARK PLUG (G4 (GM6-262)) .......

..................................... COMPONENTS SPECIFICATIONS .................................. BAlTERY ............................................... SPARK PLUG (G4 (GM6-262)) ..............

V BELT TENSION ADJUSTMENT ...... ACCELERATOR PEDAL .......................

COMPONENTS ..................................... INSPECTION*ADJUSTMENT ............... ACCELERATOR PEDAL SWITCH

INSPECTION AND ADJUSTMENT (EEC SPEC.) ......................................

ELECTRONIC GOVERNOR .............. COMPONENTS ..................................... PRECAUTIONS FOR REPAIR .............. OUTLINE OF REPAIR PROCEDURE ... BASIC INSPECTION ............................. FINAL INSPECTION .............................. SELF-DIAGNOSIS ................................. DIAGNOSTIC CODE LIST .................... SYSTEM CIRCUIT ................................. FUNCTIONAL PARTS INSPECTION ... SENSOR AND SWITCH

ADJUSTMENT .................................... TROUBLESHOOTING ..........................

EZ PEDAL (OPT) .................................... COMPONENTS , .................................... DISASSEMBLY-INSPECTION*

REASSEMBLY .................................... ADJUSTMENT .......................................

Page

ENGINE EXTERIOR VIEWS G4 (GM6-262) Engine

132 Engine

1-3

MAJOR SPECIFICATIONS GM (GM6-262) Engine

Note: *I : LPG exclusive is NMR 2400 rpm. *2: Governor system for LPG exclusive Pn50 - 80, Cu70 models is used electronic governor.

(Maximum power spec. is same as LPG convertible.)

LPG GasolineILPG -

Gasoline

Engine type

Number of cylinders and arrangement

Combustion chamber type

Valve mechanism

Bore x stroke mm (in)

Total displacement cm3 (in3)

Compression ratio

Gasoline 4-cycle

V-type 6 cylinders, vertical

Wedge type

OHV, chain-driven

101.60 X 88.39 (4.0 X 3.480)

4300 (262)

9.2

Maximum power kW (PS)/rpm

NMR 2350 rpm *I (Pn35 - 50, Cu35-45 model)

NMR 2600 rpm (Pn60 - 80, Cu55 - 70 model)

6112150 (83121 50)

6412400 (8712400)

28411 200 (2911 200)

25011 400 (1 8411 400)

Air governor (Electronic governor *2)

6712350 (91 12350)

71 I2600 (9612600)

29411 200 (3011 200)

25811 800 (1 9011 800)

Electronic govemor

N-m (kgf-m)/rpm Maximum torque

Minimum specific fuel consumption gJkW-h (glPS-h)lr~m

Governor system

Service weight kg (Ib)

No-load maximum rpm r Pm

1 85 (408)

See page 1-9.

6112350 (8312350)

6412600 (8712600)

28411 200 (2911 200)

24911 400 (1 8311 400)

Electronic govemor

- -

132 Engine

Diesel 4-cycle

In-line 6 cylinders, vertical

Direct injection type

OHV, gear-driven

98.0 x 102.0 (3.858 x 4.01 6)

461 6 (281)

18.5

62 (85) I2200

66 (90) I2400

284 (29) 11 600

224 (1 65) I1 200

325 (71 7)

Pn35 - 50 model: 2400 Pn60 - 80 model: 2600

1 Engine type

Number of cylinders and arrangement

Combustion chamber type

Valve mechanism

Bore x stroke mm (in)

Total displacement cm3 (in3)

Compression ratio

Maximum power kW (PS)lrpm

NMR 2400 rpm (Pn35 - 50 model)

NMR 2600 rpm (Pn60 - 80 model)

Maximum torque N-m (kgf-m)lrpm

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

Service weight kg (Ib)

No-load maximum rpm rPm

ENGINE PERFORMANCE CURVES G4 (GM6-262) Engine

- Gasoline

Engine torque

N.m

Shaftougxlt 67kW (91 PS)!2350rpm

kW 61 k w (83PS)!2350rpm

"- (PS) 61kW(83PS)l2150rpm

71 k w (96PS)!2600rpm

93- 64kW (87PS)l2600rpm

m-

I I I l l ' I I I 10 12 14 16 18 23 Z! 24 26

Engine speed (rprn) XI02 I

ENGINE ASSY REMOVAL-INSTALLATION T = N*m (kgf-cm) [ft-lbf]

Engine mounting nut

End plate set bolt

Flywheel set bolt

Flexible plate set bolt

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

T = 49.0 - 78.0 (500 - 800) [36.2 - 57.91

G4 (GM6-262) : T = 98.07 - 156.9 (1 000 - 1600) [72.35 - 11 5.81 13.2 : T = 98.07 - 156.9 (1 000 - 1600) 172.35 - 11 5.81

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

Removal Procedure

1 Remove the radiator cover.

2 Remove the engine hood.

3 Remove the toe board.

4 Drain coolant.

5 Remove the battery and battery tray.

6 132 engine vehicle: Disconnect the accelerator wire and fuel hose. Free the sedimenter bracket by removing the set bolts.

7 G4 (GM6-262) engine vehicle: Disconnect the fuel hose.

8 Remove the relay block and electrical parts plate set bolt to free them.

9 Disconnect the connectors and wiring harness clamps around the engine.

10 132 engine vehicle: Disconnect the torque converter cooler hose and hydraulic oil cooler hose. Remove the radiator and fan shroud.

I 1 G4 (GM6-262) engine vehicle: Disconnect the radiator hose.

12 Remove the air cleaner.

13 Disconnect the exhaust pipe.

14 Disconnect the starting motor wiring.

15 Remove the oil pump drive shaft ASSY. (see page 13-1 2)

16 Remove the flexible plate set bolts. [Point 11

17 Remove the engine mounting nuts.

18 Slightly hoist the engine ASSY. [Point 21

19 Support the torque converter housing with wooden blocks.

20 Separate the torque converter housing and engine ASSY. [Point 31

21 Remove the engine ASSY Wlflywheel and torque converter end plate.

22 Remove the flywheel.

23 Remove the torque converter end plate and starting motor.

Installation Procedure

The installation procedure is the reverse of the removal procedure.

Note: Bleed air from the fuel system after installation of the engine ASSY. (for diesel vehicle) (see page 1-9.) Apply thread tightener (08833-00080) on the flywheel set bolt, and tighten it.

Point Operations

[Point 11 Removal-Installation:

Remove the flexible plate set bolts while trrning the flywheel with a screwdriver.

[Point 21 Removal.lnstallation:

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

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

[Point 31 Removal:

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

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

operating force becomes heavy.

ENGINE SPEED INSPECTION AND ADJUSTMENT Note: Warm up the engine, set the vehicle to the following conditions, and conduct inspection and adjustment. Coolant temperature: 80°C (176°F) or more, engine oil temperature: 70°C (158°F) or more

G4 (GM6-262) ENGINE

F.1. cam 8 Lever --%

After full warming up

Standard

IDLE SPEED 1NSPECTION.ADJUSTMENT <Electronic Governor System>

Note: The idling speed is electronically controlled.

Model

Idle speed rpm

Idle-up speed rpm

No-load maximum speed rpm

1. Check the lever is not on the F.I. (First Idle) cam. If the lever is on the cam, depress the accelerator pedal for racing engine, and check the lever position again. If the lever still stays on the F.I. cam, the engine warm up is insufficient.

LPG engine model

Loaded maximum speed (speed down at tilt relief) rpm

Gasoline engine or GasolineILPG engine model

Pn60 - 80 Cu70 cu70 ("SCS')

Electronic

system

850 ??

No idle-up speed

2600 k 30

*: Vehicle Speed Control system spec.

Cu55 - 6o

Air governor System

850 + 25

1000 + 25

2600 k 50

Pn35 - 45 Cu35 - 45

Air governor 'ystem

850 k 25

1000 r 25

2400 + 50

Pn60 - 80 Cu55 - 70

Pn35 - 45 Cu35 - 45

/

Pn50 Ct.135 - 60 (VSCS')

Electronic

system

850fr

idle-u~ speed

2350 r 30

250 or less

Pn50

350 or less

/

Electronic governor system

850 :'? 750 'zO 850 :'zO No idle-up speed

2600 + 30 2350 + 30 2350 r 30

A

Regulator

2. Install a tachometer. (1) Disconnect the inspection connector and connect the

tachometer measurement cord to the male side. (2) Disconnect the vacuum hose.

3. Idle speed inspection and adjustment (1) Measure the idle speed.

Standard: See page 1-9.

Adjust the mixture adjusting screw so that the negative pressure then is stabilized at the highest level.

Note: When the idling speed is high, check if the idle adjusting screw is pushing the lever. If so, loosen the screw.

(2) Check and adjust the clearance between the idle adjusting screw and lever.

Standard: 0 mm (0 in)

<Air Governor System> 1. Install a tachometer. 2. Check the idling speed.


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

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

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

(3) Determine the positions of adjusting screw B by re- peating steps (1) and (2) until the value obtained in step (2) satisfies the standard.

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

Actuator hose

Adjusting screw

IDLE UP INSPECTION-ADJUSTMENT

<Air Governor System,

1. Install a tachometer. 2. Check the idle-up speed.

(1) Start the engine. Disconnect the vacuum hose from the idle-up actuator and measure the speed.


(2) If the standard is not satisfied, make adjustment by turning the adjusting screw.

Note: Turn the adjusting screw clockwise to increase speed.

(3) After adjustment, connect the vacuum hose.

NO-LOAD MAXIMUM SPEED 1NSPECTION.ADJUST- MENT

<Electronic Governor System>

Note: The maximum speed is controlled electronically.

1. lnstall a tachometer

2. Inspect the no-load maximum speed when the accelerator pedal is fully depressed.


Since adjustment is impossible, refer to the troubleshooting section when the standard is not satisfied.

<Air Governor System> 1. Install a tachometer. 2. lnspect and adjust the no-load maximum speed.

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


(2) If the standard is not satisfied, adjust the speed. Remove the air governor bushing lock bolt. Turn the air governor bushing while fixing the adjusting screw to adjust the speed.

(3) Install the air governor bushing lock bolt.

LOADED MAXIMUM SPEED MEASUREMENT

Note: In the electronic governor system, the maximum speed is controlled electronically.

<Air Governor System>

1. Operate the tilt lever fully backward with the engine run-

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


2. If the standard is not satisfied, turn the adjusting screw for adjustment.

132 ENGINE

Idling Speed Inspection.Adjustment

1. Install the engine tachometer.

2. lnspect the idling speed.

Standard: 750 + 25 rpm

3. Adjust the idling speed. (1) Loosen the lock nut and make adjustment by means

of the idle adjusting screw.

No-load Maximum Speed Inspection-Adjustment

1. Install the engine tachometer

2. lnspect the no-load maximum speed. (1) Fully depress the accelerator pedal and inspect the

no-load maximum speed.

Standard: Pn35 - 50 model 2400 + 50 rpm Pn60 - 80 model 2600 + 50 rpm

3. Adjust the no-load maximum speed. (1 ) Remove the seal. (2) Make adjustment by means of the maximum speed

adjusting screw.

4. lnspect the relief speed. (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: Pn35 - 50 model 250 rpm or less Pn60 - 80 model 350 rpm or less

5. Seal the engine with wire after adjustment.

AIR CLEANER SPECIFICATIONS

Single (STD)

Type

Size

Intake type

Filtering area cm2 (in2)

Others

COMPONENTS

1 703 02

r--- "11

Cyclone type

8-inch

Fresh air introduction type

32400 (5022)

With evacuator valve

I I

I I

AB 4

I a 23 I

L-11 111 4

1703-436A

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 (7kgf/cm2) [ I00 psi] or less] vertically along the pleats from the inside of the element. If heavily contaminated, washing is possible.

(2) Element washing method Dissolve neutral detergent in tepid water (approx. 40°C (104OF)) 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 element during washing. Never use compressed air or hot air for drying.

4. Clean the evacuator valve (dust discharge valve). (1) Hold the tip end of the evacuator valve and discharge

dust and dirt from the inside of the valve.

5. Inspect the element. (1) After cleaning, place an electric bulb in the element to

inspect any damage in the element. If any pinhole, tear or damage is found, replace it with a new element.

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

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

1-16

CLOGGING WARNING SYSTEM INSPECTION

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

the ignition switch is turned ON and goes out when the engine starts.

2. Individual inspection (1) Use a mity vac to apply a negative pressure to the

vacuum switch, and inspect conduction.

Standard 7473 + 569 Pa (762 + 58 mm H,O) (56.0 + 4.3 mmHg) [30.00 + 2.28 in H,O] [2.205 + 0.169 in Hg]: Conduction

RADIATOR

SPECIFICATIONS

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

Type

Fin type

Coolant capacity (in radiator)

Cap opening pressure kPa (kgf/cm2) [psi]

Others

Crossflow

Corrugated fin

See the table below

88 5 14.7 (0.9 k 0.15) [13 5 2.11

Built in torque converter cooler Built in hydraulic oil cooler (Pn35 - 50 (1 32) model: OPT, Others: STD)

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

Radiator capacity

132: Pn35 - 50 model 2.9 (0.77)

Others 2.6 (0.69)

LLC mixing ratio at 50 O/O

(to - 35OC (- 31 OF))

6.5 (1.72)

?

~d ta l amount of coolant

13.0 (3.43)

'I'

Antirust mixing at

5%

0.7 (0.1 8)

T

LLC mixing ratio at 30 %

(to - 15OC @OF))

3.9 (1.03)

7'

1-1 8

FAN DRIVE REMOVAL-INSTALLATION

Note: For the removal and installation of the pulley on the oil pump side, see the Oil Pump Removal~lnstallation section (on page 13-6).

I 1

I I

Removal Procedure


2 Remove the counterweight. (See page 0-1 5 for the weight of the counterweight.)

3 Remove the fan belt. [Point 11

4 Remove the fan support ASSY. [Point 21



Pushing force 6 - 8 m m 29 N (3 kgf) (0.24 - 0.31 i [6.6 Ibfl

Point Operations

[Point 11 Installation:

Fan belt tension adjustment

1. Adjust the fan belt tension to the standard level by turning the adjusting bolt.

Standard: 6 - 8 mm (0.24 - 0.31 in) [Flexure upon pushing with a force of 29 N (3 kgf) (6.6 Ibf)]

2. Tighten the pulley set bolt.

3. After running the engine for several seconds, inspect the fan belt tension again.


Set the fan belt on the pulley, and tighten the set bolt while pulling the plate upward.


Fan side

I Remove the fan and bearing housing from the fan support.

2 Remove the bearing housing. [Point 11

3 Remove the bearing. [Point 21

4 Remove the fan and pulley.

Oil pump side

5 Remove the pulley. [Point 31

6 Remove the bearing. [Point 41

Reassembly Procedure

The reassembly procedure is the reverse of the disassembly procedure.

Point Operations

[Point 11 Disassembly:

Bearing housing removal

1. Remove the snap ring.

2. Use the SST and remove the bearing housing. SST 09950-4001 1

Reassembly: Bearing housing installation

1. Use the SST and install the bearing housing. SST 09623-3001 1

2. Install the snap ring.


Use the SST and remove the bearing on the fan side. SST 09950-4001 1

Reassembly: Use the SST and install the bearing on the fan side. SST 09623-3001 1

Disassembly: Use the SST and remove the bearing on the housing side. SST 09623-3001 1

Reassembly: Use the SST and install the bearing on the fan side. SST 09623-3001 1


Pulley removal

1. Remove the snapring.

2. Use the SSTs to remove the pulley. SST 09950-6001 0...@

09950-7001 O...@


Bearing removal 1. Remove the snap ring.

2. Use the SST and remove the bearing. SST 09950-6001 0...@

09950-7001 O...@

Reassembly: Bearing installation I . Use the SST and install the bearing.

SST 09950-6001 Om..@ 09950-7001 O...@

2. Install the snap ring.

1 -24

REMOVAL-INSTALLATION

Removal Procedure


2 Remove the counterweight. (See page 0-1 5 for the weight of the counterweight.)

3 Remove the muffler set bolts.

4 Remove the muffler by disconnection from the exhaust pipe.



CATALYTIC MUFFLER MAINTENANCE

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

BATTERY-SPARK PLUG (G4 (GM6-262))

COMPONENTS

SPECIFICATIONS 132 (Cold area specification)

GROUP35 (JIS: 55D23L)

12 x 2 (parallel)

5-hour capacity Ah

Specific gravity of electrolyte (electrolyte at 20°C)

132

GROUP27 (JIS: 95D31 L)

t

Type

Voltage x quantity used V

G4 (GM6-262)

GROUP35 (JIS: 55D23L)

1 2 x 1

48

1.280

t

t

t

t

BATTERY

Inspection

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

insufficient. Do not overfill above the upper fluid limit.

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

the battery fluid.

Standard: 1.280 (at 20°C (68°F)) Calculating equation 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. lnspect the battery terminals. (1) If battery terminals are contaminated to white, clean

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

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

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

Removal

1. Disconnect battery terminals.

Note: Disconnect the negative terminal first.

2. Remove the battery stopper

3. Remove the battery.

Installation

Reverse the removal procedure.

SST

\

Ei+k 1.4 mm (0.055 in)

SPARK PLUG (G4 (GM6-262))

Removal

1. Disconnect No. 1 to No. 6 plug cords.

Note: Disconnect by holding the socket portion.

2. Remove No. 1 and No. 6 exhaust manifold shields.

3. Use the SST to remove each spark plug. SST 091 90-3051 0-71

Installation

The installation procedure is the reverse of the removal procedure.

1. Visually check the electrodes, threading and insulator of the spark plug.

2. Clean with a spark plug cleaner as required.

Note: -The air pressure of the spark plug cleaner shall be 588 kPa (6 kgf/cm2) [85 psi] or less, and cleaning shall be completed within 20 seconds. Never clean with a wire brush.

3. Inspect the gap between electrodes.

Standard: 1.4 mm (0.055 in) (in new state) Limit: 1.6 mm (0.063 in) If the limit is exceeded, replace the spark plug.

Note: Do not try to adjust the electrode gap. Never touch the platinum tip.

Measurement

-- -

V BELT TENSION ADJUSTMENT

1. Inspect the V belt tension.

[Deflection when pushed with a force of 98 N (1 0 kgf) [22 Ibf]]

Standard: G4 (GM6-262)

New belt 7 - 9 mm (0.28 - 0.35 in) Reused belt 8 - 16 mm (0.31 - 0.63 in)

132 New belt 7 - 9 mm (0.28 - 0.35 in) Reused belt 8 - 13 mm (0.31 - 0.51 in)

[When the tension gauge (SST) is used]

SST 0921 6-00021

Standard: G4 (GM6-262)

New belt 392 - 588 N (40 - 60 kgf) [88 - 132 Ibf]

Reused belt 294 - 392 N (30 - 40 kgf) [66 - 88 Ibf]

132 New belt

373 - 608 N (38 - 62 kgf) [84 - 137 Ibf]

Reused belt 196 - 392 N (20 - 40 kgf) [44 - 88 Ibf]

2. Adjust the V belt tension.

(1) Use a lever rod and move the alternator for adjustment.

ACCELERATOR PEDAL

G4 (GM6-262) (EEC spec.) G4 (GM6-262) (EEC spec.) Electronic governor Air governor

20

0

Play

132 engine vehicle

B

G4 (GM6-262) <Electronic Governor System> Engine Note: See page 1-40 LLAcceleration sensor"

G4 (GM6-262) <Air Governor System>, 132 Engine 1. Check the accelerator pedal height A (from the accel-

erator bracket to the top face of roller).

Standard: A = 80'2, mm (3.1S4"8, in)

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

3. lnspect and adjust the accelerator wire play.

Standard EEC spec.: 6 - 8 mm (0.24 - 0.31 in) Others: 4 - 8 mm (0.16 - 0.31 in)

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

4. Adjust the stopper bolt @ so that the accelerator pedal comes into contact with stopper bolt @ at the following position: G4 (GM6-262) engine vehicle: Position where the carburetor throttle lever is about to be fully opened 132 engine vehicle: Position where clearance B between the injection pump lever and maximum speed adjusting screw is as shown below:

B = 0 - 0.5 mm (0 - 0.020 in)

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

ACCELERATOR PEDAL SWITCH INSPECTION AND ADJUSTMENT (EEC SPEC.)

Note: An accelerator pedal switch is adopted to the EEC spec. Adjust the accelerator pedal switch after inspecting and adjusting the accelerator pedal height.

G4 (GM6-262) <Air Governor System> engine vehicle: See page 1-30. G4 (GM6-262) <Electronic Governor System> engine vehicle: See page 1-40.

G4 (GM6-262) <Air Governor System* engine vehicle

1. lnspect and adjust the accelerator pedal height.

2. Adjust the accelerator pedal switch position until the switch case end face is flush with the set nut end face.

Clearance

-

(0.24 - 0.31 in)

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

Standard: I:& mm (0.04';: in)

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

Standard: 6 - 8 mm (0.24 - 0.31 in)

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

G4 (GM6-262) <Electronic Governor System> engine

1. lnspect and adjust the accelerator pedal height.

2. Adjust the accelerator pedal switch mounting position. Install the switch on the bracket so that the nut is flush with the end of the threaded portion of the switch case.

3. Adjust the clearance between the accelerator pedal link and switch case end face to the standard, and fix the stopper bolt @.

Standard: mm (0.04'E in)

Accelerator pedal switch inspection

1. lnspect the ONJOFF state of the accelerator pedal switch.

Switch position Standard

Closed

Pressed Opend

ELECTRONIC GOVERNOR

PRECAUTIONS FOR REPAIR

Repair operation 1. Carefully protect electrical parts from direct water pressure (1 00 kPa (1 kgf/cm2) [ I 4 psi]) application

during vehicle washing. 2. After any repair, always conduct the final inspection according to the specified procedure. 3. Never attempt at electrical wiring modification. (Never install any electrical parts other than OPT.)

Parts handling 1 . Handle each part with care. Especially avoid any impact on controller sensor parts as it will bring about

adverse influence. 2. Sensor adjustment is necessary after repairing a part related to each sensor. 3. When installing the throttle switch, avoid incorrect connection of the max. (full) side and min. (idle)

side. (The shorter wiring is for the min. side.) 4. Three types of controllers are used selectively according to the vehicle model.

Items to be provided Prepare the following tools:

OUTLINE OF REPAIR PROCEDURE

Purpose

Sensor and switch inspection and measurement

Sensor and switch inspection and measurement

Upon sensor adjustment

Part No.

SST 09082-00050

-

08833-00080

SSTImeasuring instrument

Bond, etc.

Name

Toyota electrical tester

Thickness gauge

Thread tightener

Reference page

Page 1-33 (Items to be prepared)

Page 1-34 (basic inspection)

Page 1-34 (final inspection)

Page 1-35 (inspection by diagnosis)

Page 1-52 (inspection of defect no indicated by diagnosis)

-

Page 140 (sensor and switch adjustment)

Page 1-34 (final inspection)

-

Job description

1. Prepare necessary tools.

1. Inspect basic characteristics before starting troubleshooting.

2. Perform functional inspection (function check of each part) to clarify the defect status.

1. Inspect according to the self-diagnosis code.

2. For a defect for which no self-diagnosis code is displayed, determine the inspection method according to the phenomenon.

1. Perform removal, installation, inspection and replacement.

1. Sensor adjustment is necessary if any part related to the system is repaired (removed, installed or replaced). Parts requiring adjustment are as follows: Acceleration sensor, idle switch and throttle switch.

1. After the end of repair job, inspect according to the final inspection procedure.

1. Summarize the defects and repair details. (Keep them for reference in the future.)

*-

Repair

Final inspection

Procedure

Preparation

Troubleshooting 1. Basic inspection 2. Functional

inspection

3. Diagnostic inspection

4. Other inspection

Removal, installation or replacement

Adjustment

Stopped state Traveling state

End

BASIC INSPECTION

lnspect basic items shown below before starting troubleshooting:

FINAL INSPECTION

After the end of repair, perform inspection according to the following procedure:

Remarks

Specific gravity: 1.280 Voltage: 10 to 14 V Erroneous diagnosis will result if the battery voltage is low.

Defective grounding will cause erroneous diagnosis.

Defective contact of the wiring or harness connector will cause erroneous diagnosis.

There shall be no looseness in the carburetor link.

Manually rotate the throttle lever and stepping motor.

Shall be rotated smoothly.

Item

Electrical system inspection

lnspection around carburetor

Content

1. lnspect the battery voltage and specific gravity of electrolyte.

2. lnspect any blown fuse and grounding state.

3. Inspect the wiring and harness connector conditions.

1. Inspect the carburetor function.

(1) Carburetor link operation state

(2) Stepping motor operation state

Inspection standard

Shall not be disconnected, loosened or wetted.

Shall move smoothly.

The movement shall follow the accelerator pedal depression state.

Shall normally be off.

The CHECK lamp shall be kept off.

No self-diagnostic code shall be displayed.

Inspection method

1. lnspect each connector for the connection state.

2. Mechanical operation of acceleration sensor and idle switch.

1. Depress the accelerator pedal and check the throttle movement.

1. Inspect the CHECK lamp for lighting state.

1. Inspect the CHECK lamp during traveling.

2. Disconnect the diagnosis connector for self-diagnostic code display, and check if any code is displayed.

Inspection order

Vehicle stopping state

Vehicle traveling state

1. lnspection with engine switch OFF

2. Inspection before engine starting with engine switch ON

3. Inspection after engine starting

4. Self-diagnostic inspection

SELF-DIAGNOSIS

The self-diagnostic function inform the driver of trouble occurrence and trouble position by flashing the CHECK lamp in the combination meter if any trouble occurs in electronic governor control. The trouble position is indicated by the CHECK lamp flashing count.

Display of diagnostic code 5

ON

------ OFF

Display of diagnostic codes 5 and 7 0.3 S

Repetition of above cycle operation

Note: The CHECK lamp may come on when the engine switch is turned to ON or may flash during traveling (during operation). If it flashes during operation, immediately stop the vehicle and check the flashing count with the engine switch at the ON position (engine not running). The flashing count becomes the self- diagnostic code. The diagnosis is repeated when the engine switch is set to OFF once and to ON again. If any abnormality exists, the CHECK lamp flashes. After the end of repair according to the diagnostic result, turn the ignition switch to ON with the memory clear terminal being grounded to reset the ECU memory. (See the illustration below.)

Checker connector

Memory clear terminal

Rechecking the diagnostic result displayed before To check the diagnostic result displayed in the past (after ECU memory resetting), disconnect the diagnosis connector (checker connector) for re-display. Once the ECU memory is reset, preceding results are not displayed.

DIAGNOSTIC CODE LIST 0 : Normal traveling A: Low-speed traveling X: Traveling failure

Code No

1

2

3

9

10

Diagnosed state

Abnormal engine speed rise

When the signal from the sensor is abnormal or the line is shorted or opened.

ON signal though the potentiometer opening signal is 112 or more (short circuit).

The signal is OFF though the stepping motor is rotated toward the throttle closing side by a specified angle or more.

The signal is OFF though the throttle is opened beyond the specified opening.

The signal is ON though the throttle opening is beyond the specified level.

The signal is ON when the throttle opening is below the specified level.

The engine speed does not drop though the controller issues the throttle closing instruction.

No engine ignition signal

The alternator signal is OFF

Diagnostic item

Overrun

Accelerator opening signal line

Acceleration1 idle signal line (short circuit)

Throttle full close switch signal (open circuit)

Throttle full open switch signal (short circuit)

Throttle full close switch signal (short circuit)

Throttle full open switch signal (short circuit)

Stepping motor

Engine pulse

Alternator

Engine

A

0

O

0

0

0

X

A

Backup

Controller action upon defect detection.

The engine is stopped by setting engine ignition to off.

Idle traveling possible.

Ordinary traveling possible though the maximum speed may decrease.

Normal traveling possible though the maximum speed may decrease because the throttle opening is limited.

t

'T

1'

The engine is stopped by setting the engine ignition to OFF.

Idle traveling possible.

t

SYSTEM CIRCUIT

-------

Vc VTA IDL E2

(V) - m C In .- V)

c 0 - .- 0 X T 0

9 - - - OFFclose Open -+ Pedal depression Potentiometer turning angle (accelerator pedal opening)

FUNCTIONAL PARTS INSPECTION

Acceleration Sensor

Note: Carefully handle pins VTA and E2 since they are gold- plated. Do not pinch a terminal directly with an alligator clip.

1. Measure the resistance between Vc and E2 (between 4 and 1).

Standard: 2.6 + 0.8 kQ (at 25 + 10°C)

2. Turn the potentiometer and measure the resistance between VTA and E2.

Standard: The resistance shall increase in propor tion to the degree of opening.

3. Turn the potentiometer and measure the continuity between IDL and E2 (between 2 and 1).

Standard: Shall be turned from ON to OFF by about 15" when turned from the free state.

Harness side

Throttle Switch

1. lnspect the throttle switch. (1) Disconnect the connector and inspect continuity of full

open (between 3 and 4) and full close (between 1 and 2) switches for ON and OFF.

Standard: ON Continuity OFF No continuity

2. lnspect the vehicle side harness. (1) Disconnect the connector and inspect the wire har-

ness side connector.

Standard: 1-Body ground 4.5 - 5.25 V 2-Body ground Continuity 3-Body ground 4.5 - 5.25 V 4-Body ground Continuity

Stepping Motor

1. lnspect the signal voltage on the vehicle. (1 ) Measure the stepping motor operating voltage with the

engine switch in the ON position.

Standard: Between 3 and Body ground: Battery voltage

lnspect continuity individually. (1) Manually rotate the stepping motor shaft and check

that it is rotated smoothly. (2) Measure the resistance.

Standard: Terminal 1 and 3: 3.3 SZ

2 and 3: 3.3 SZ 1 and 4: 6.6 SZ 2 and 5: 6.6 SZ

(3) Measure the insulation resistance between the stepping motor and each of terminals 1,2,3, 4 and 5.

Standard: 100 MSZ or more (with a 500 V DC megger)

(4) After installing the stepping motor, manually turn the throttle lever in the full opening direction (full open, 112 open and 114 open) and release it. Check to see that the lever shall be returned smoothly by the spring force.

Ignition Relay-Fuel Pump Relay

1. Inspect continuity of the relay coil.

Standard

Continuity

No continuity

Continuity

Measurement state

Normal state

When the battery voltage is applied across terminals 1 and 3.

Measured terminals

1 - 3

2 - 4

2 - 4

SENSOR AND SWITCH ADJUSTMENT

Acceleration Sensor

Note: The acceleration sensor requires adjustment after the following jobs: Acceleration sensor part replacement (removal/installation)-Accelerator pedal height adjustment. The acceleration sensor shall be adjusted after adjusting the accelerator pedal height.

Accelerator Pedal Height Adjustment

w Accelerator link roller

Accelerator pedal stopper bolt

Accelerator link stoDDer bolt

Accelerator pedal stopper bolt

Accelerator link stopper bolt

Return side pedal height adjustment Make adjustment by turning the accelerator pedal stopper bolt to make the height (A) from top of the accelerator link roller to the link bracket mounting surface satisfy the following value:

Standard EEC specification models:

A = 108 2 1 mm (4.25 2 0.04 in) Other models:

A = 99 2 1 mm (3.90 2 0.04 in)

2. Depression side pedal height adjustment Make adjustment to make the accelerator link stopper bolt height (B) satisfy the following standard:

Standard B = 55 1; mm (2.17$,, in)

-------

sw~tch

2 (IDL) 1 (E2)

Insert a thickness gauge here g.. , . 1. - ---- -\, :,

Acceleration sensor

Acceleration Sensor Adjustment

1. See that the accelerator pedal heights (on the return and depression sides) are standard. (See the accelerator pedal height section.)

2. Remove the accelerator link bracket Wlsensor. (1) Accelerator link bracket set bolts (2) Disconnect the acceleration sensor wiring. (3) Accelerator link bracket W/sensor

3. Adjust the acceleration sensor mounting position. (Adjustment of ON-OFF transition point of IDL switch in sensor)

(1) Loosen the sensor set screw. (2) Use a circuit tester and check ON-OFF of the accel-

eration sensor switch. Between connector terminals E2 and IDL

Note: Carefully operate so as not to damage the sensor terminals.

(3) Insert each of the following thickness gage between the accelerator link stopper bolt and accelerator link. EEC specification models: 2.5 mm (0.098 in) Other models: 0.8 mm (0.031 in)

(4) In the state of (3), manually turn the acceleration sensor gradually. Tighten the acceleration sensor set screw for fixing at the position where the signal is set from ON to OFF.

4. Check the IDL ONIOFF state after fixing the acceleration sensor (between terminals 1 and 2 in the same way as in step 3).

(1) lnsert each of the following thickness gages between the accelerator link stopper bolt and accelerator link for confirmation:

Standard

EEC specification models

(2) If the standard above is not satisfied as a result of confirmation, recheck it after fine adjustment by turning the accelerator link stopper bolt. The accelerator link roller height may vary in the following range as a result of this adjustment. It shall be checked by temporary installation on the vehicle. (Dimension A on page 1-41)

Standard EEC specification models: A = 108 + 2 mm (4.25 f 0.08 in) Other models: A = 99 f 2 mm (3.90 f 0.08 in)

If the standard is exceeded, adjust the accelerator pedal height and readjust the acceleration sensor from the beginning.

(3) Tighten the accelerator link stopper bolt lock nut after applying thread tightener (08833-00080) on the threaded portion.

(4) After tightening the above lock nut, re-check if the acceleration sensor position standard in 4-(1) is satisfied. (Check it after operating the pedal for a few strokes.)

5. Check the acceleration sensor signal voltage on the vehicle.

(1) Disconnect the connector from the accelerator link bracket Wlsensor.

(2) Set the engine switch at the On position (without starting the engine), measure the signal voltage between the connector terminals at the connector on the main harness side. Use SST 09082-00050 (Toyota electrical tester).

Measure and record the input voltage (Vc) to the acceleration sensor.

Measurement terminals Standard input voltage value Between Vc and E2 : Vc = 5 + 0.25 V (4 and 1) (voltage to ground)

(3) Measure the acceleration sensor output voltage (VTA) when the accelerator pedal is fully depressed and when it is fully released. Check if the output to input voltage ratio given by the following equation is within the standard (%):

Output voltage (VTA) Input voltage (Vc) x 100 = Standard (%)

Standard Upon full pedal depression: 13.5% or above Upon full pedal release: 64.5% or less

(4) Measure the output voltage when the acceleration IDL switch is set from ON to OFF (measurement between terminals 3 and 1). Use another circuit tester for the IDL switch ON and OFF operation check (measurement between terminals 2 and 1).

Standard: 4.5 to 5.25 V when the pedal is fully depressed and 0.8 V when a 0.8 mm (0.031 in) thickness gage is inserted between the accelerator link stopper bolt and accel erator link.

(5) If the measurement result is not within the standard, readjust the accelerator link stopper bolt and pedal stopper bolt.

(6) Coat yellow paint on the accelerator link stopper bolt lock nut and sensor screw for sealing.

6. Install the accelerator link bracket Wlsensor in the correct position.

--

Throttle Switches

Note: Throttle switch adjustment is necessary whenever any of the following parts is repaired (removed, installed, disassembled or replaced). The min. side switch adjustment, however, is unnecessary.

Throttle switch Part (adjusting link part, stepping motor, carburetor, etc.) around throttle switch

When installing the throttle switches, carefully install the max. (full open) side and min. (full close) side. (The one with a shorter harness is for the max. side.)

Throttle Switch Adjustment

1. See that the engine switch is at the OFF position.

2. Disconnect the throttle switch wiring.

3. Check and adjust the throttle switch output state. (1) Set so that switch ONIOFF can be checked at the

throttle switch connector. Measurement terminals: 3-4

(2) Manually turn the throttle lever and hold it in the full open position. The switch is normal if it is ON in this state. For read- justment, turn the adjusting screw once in the direction of B to set the switch to OFF. Then, slowly turn the adjusting screw in the direction of A and stop it when the switch is set from OFF to ON. Furthermore, turn the adjusting screw in the direction of A (ON direction) by one or two turns.

TROUBLESHOOTING

For Troubles Displayed by Self-diagnosis

Diagnostic Code 1 (Overrun)

Check the operation as follows for operation check 1 or 2 in the flowchart:

Operation check

1. The throttle valve shall open in response to accelerator pedal depression with the engine switch set to ON (without starting the engine). The CHECK lamp shall be off.

2. When the engine is running with the engine switch at the START position, the engine speed shall be able to be controlled in the full throttle state.

Replace the controller.

lnspection 1. Check the carburetor link operation.

NG + Carburetor linkcorrection

OK 1

Inspection 2. Check if the stepping motor connector is disconnected.

NG ) Correct the connector connection state.

OK 7

Inspection 3. Check the stepping motor wiring (power and signal lines). (See page 1-38.)

NG Correct the connector connection state or replace the wiring

OK NG

Conduct operation check 1. Inspection 4. Inspect the stepping motor. (See page 1-38.)

OK NG

7 Replace the stepping motor.

OK NG 1

Correct the connector connection state , Inspection 5. Inspect the distributor connector (2P) or replace the wiring.

NG OK 7

Normal 4 Conduct operation check 2.

NG 1

Diagnostic Code 2 (Accelerator Opening Signal Line Open or Short Circuit)

If NG as a result of each inspection, always make correction according to the given instruction. Then be sure to conduct the operation check below to confirm if the repair has been appropriate or not.

Operation check

1. The throttle valve shall open in response to accelerator pedal depression with the engine switch set to ON (without starting the engine). The CHECK lamp shall be off.

Correct the connector connection state. Inspection 1. See that the acceleration

sensor connector is not disconnected.

Correct by adjustment.

NG F

Correct the connector connection state or replace the wiring.

Replace the acceleration sensor.

OK 7


lnspection 2. Check the acceleration sensor adjustment state.(See page 1-38.)


NG

F

OK 7 NG

lnspection 3. lnspect the acceleration sensor wiring (power and grounding lines).

F

OK 1

Inspection 4. Acceleration sensor individual inspection. (See page 1-37.)

NG F

OK 7

lnspection 5. lnspect the acceleration sensor wiring (signal line).(See page 1-42.)

NG

+

OK 7

Diagnostic Code 3 (Acceleration IDL Signal Line Abnormality)


Operation check

1. The CHECK lamp shall be off (shall not be lit) when the engine switch is set to ON (without starting the engine).

2. The throttle valve shall open in response to accelerator pedal depression in the state of operation check 1. The CHECK lamp shall be off (shall not be lit).


Inspection 1. lnspect the acceleration sensor connector for wetting or any other abnormality.

NG = Clean, correct or replace the connector.

OK

NG Conduct operation check 1. Inspection2. lnspect the acceleration sensor

individually. (See page 1-37.)

OK NG


NG Conduct operation check 2.

Inspection 3. Inspect the acceleration IDL switch wiring (signal line). (See page 1-42.)

7

Normal

OK NG


7


7

Diagnostic Code 4 (Open Circuit in Throttle Full Close Switch Signal Line)

If NG as a result of each inspection, always make correction according to the given instruction. Then, be sure to conduct the operation check below to confirm if the repair has been appropriate or not.

Operation check

1. The CHECK lamp shall be off (not be lit) when the engine switch is set to the ON position (without starting the engine). The stepping motor shall be operated with the carburetor throttle valve in fully closes state.

Correct each link. lnspection 1. lnspect the carburetor and

stepping motor link operations.

Correct the connector connection state.

NG w

Correct or replace the wiring.

Replace the throttle full close switch.

Replace the stepping motor.

OK 1


lnspection 2. lnspect the throttle full close switch connector to see that it is not disconnected.

NG

w

OK 7 NG

lnspection 3. lnspect the throttle full close switch wiring. (See page 1-38.)

w

OK 1 NG

lnspection 4. lnspect the throttle full close switch individually. (See page 1-38.)

w

lo. Inspection 5. lnspect the stepping motor

individually. (See page 1-38.)

OK 1

Diagnostic Code 5 (Open Circuit in Throttle Full Open Switch Signal Line)

If NG as a result of inspection, always make correction according to the given instruction. Then, be sure to conduct the operation check below to confirm if the repair has been appropriate or not.

Operation check

1. Disconnect the throttle full open switch connector.

2. Set the engine switch to the ON position (without starting the engine) and depress the accelerator pedal.

3. Check the carburetor full throttle open switch ONIOFF by measurement at the disconnected connector.

Correct the carburetor link. lnspection 1. lnspect the carburetor link for

normal operation.

Correct the connector connection state.

NG *

Adjust the throttle full open switch.

Replace the stepping motor.

OK 1


Inspection 2. Inspect the throttle full open switch connector to see that it is not disconnected.

Replace the throttle full open switch.

NG w


OK 1

lnspection 3. Check to see that the carburetor full throttle valve is fully opened and the throttle valve link portion is in contact with the throttle full open switch when the accelerator pedal is deprassed to the full open position.

NG - 7

OK 7 NG

Inspection4. lnspect the stepping motor individually. (See page 1-38.)

*

OK 1 NG

lnspection 5. lnspect the throttle full open switch wiring. (See page 1-38.)

*

OK 1

lnspection 6. lnspect continuity of the throttle full open switch (with the throttle switch in full open state).

NG +

OK 7

Diagnostic Code 6 (Short Circuit in Throttle Full Close Switch Signal Line)


Operation check

1. The CHECK lamp shall not flash when the engine switch is turned to ON (without starting the engine). Do not depress the accelerator pedal then.

2. The CHECK lamp shall not flash when the accelerator pedal is depressed fully with the engine switch turned to the ON position (without starting the engine).

lnspection 1. lnspect the carburetor link for normal operation. Correct the carburetor link.

OK

lnspection 2. lnspect the throttle full close switch connector for wetting Correct the connector connection state. or any other abnormality.

NG lnspection 3. lnspect the acceleration sensor individually. (See page 1-37.)

I " Adjust or replace the acceleration sensor.

NG Inspection 4. Check if the stepping motor is

operated in operation check 2.

Normal Adjust or replace the acceleration sensor.

I lnspect and replace the stepping motor.

lnspection 5. lnspect the throttle full close switch wiring. (See page F- Correct or replace

1-38.) the wiring.

Inspection 6. lnspect the stepping motor Replace the stepping individually. (See page 1-38.) motor.

IoK Replace the controller

Diagnostic Code 7 (Short Circuit in Throttle Full Open Switch Signal Line)

If NG as a result of inspection, always make correction according to the given instruction. Then, be sure to conduct the operation check below to confirm if the repair has been appropriate or not. Operation check 1 . The CHECK lamp shall be off (and not flashing) when the engine switch is tuned to ON (without

starting the engine).

lnspection 2. lnspect the throttle full open switch for wetting or P- Clean, correct or replace the any other abnormality. connector.

Inspection 1. See that the throttle full open switch is not pushed when the engine is in stopped state.

NG Inspect the carburetor link, = acceleration sensor and

stepping motor. i OK

v - NG Correct the connector

t OK Replace the controller.

Inspection 3. Inspect the throttle full open switch wiring. (See page 1-38.)

I I - OK

Diagnostic Code 8 (Stepping Motor Operation Defect)

connection state or replace the wirina.

Inspection 4. Inspect the throttle full open switch for continuity (throttle switch full open state). (See page 1-38.)

If NG as a result of inspection, always make correction according to the given instruction. Then, be sure to conduct the operation check below to confirm if the repair has been appropriate or not. Operation check 1. The throttle valve shall open in response to accelerator pedal depression after turning the engine

switch to the ON position (without starting the engine). The CHECK lamp then shall be off (and not flashing).

NG Replace the throttle full open switch.

lnspection 1. See that the stepping motor connector is not disconnected.

Inspection 3. Inspect the stepping motor individually. (See page 1-38.) Replace the stepping motor.

NG b Correct the connector

connection state.

+ OK

lnspection 2. lnspect the stepping motor wiring (power and signal lines). (See page 1-38.)


NG Correct or replace the wiring.

I

Inspection 4. Inspect the throttle full close switch harness and inspect the throttle full close switch individually. (See page 1-38.)

NG b - Correct or replace.

Diagnostic Code 9 (Engine Pulse)

Parform the following check for "operation check 1" in the flowchart:

Operation check

1. The ignition timing shall be normal.

lnspect the distributor for any internal open circuit. Replace the distributor.

Inspection 1. See that the distributor connector is not disconnected.

- -

Conduct operation check 1.

OK

NG Correct the connector ) connection state.


Diagnostic Code 10 (Alternator Abnormality)

Conduct the following operation check after the end of the job:

Operation check

1. Turn the engine switch to ON, to ST (engine starting) and to ON again. Fully depress the accelerator pedal and see that the maximum engine speed is controlled.

NG Inspection 1. Inspect t], b Adjust the V-belt tension.

OK

NG Inspection 4. Inspect the alt e Replace the alternator.

Inspection2. See that the alternator connector is not disconnected.

I I

OK


NG Correct the connector rn

connection state.

Inspection 3. Inspect the alternator harness (defective connector contact or harness open circuit).

NG - Replace the connector and/ - or harness.

Troubleshooting for Defects Not Displayed by Self-diagnosis

The engine is cranked but does not start. I V U

Inspection 1. Inspect t +

OK 'I

h I- Correct the connector connection state or replace the wiring.

Inspection 2. Inspect the carburetor solenoid individually. Check the acceleration sensor adjustment state.

Replace the carburetor solenoid.

NG w

Replace the fuse.


OK

NG +

OK

NG Inspection 4. Inspect the ig +

OK 1

Replace the ignition relay. Inspection 5. Inspect the ignition relay individually. (See page

1-39.)


Knocking occurs.

NG *

lnspection 1. lnspect the ignition timing. NG

t

OK

Replace the MAP sensor with a new one.

NG 7

OK v

Adjust the ignition timing.


EZ PEDAL (OPT)

COMPONENTS

G4 (GM6-262) Electronic governor

G4 (GM6-262) Air governor 2601 132

AV

1-54

DISASSEMBLY*INSPECTION*REASSEMBLY T = N*m (kgf-cm) [ft-lbf]


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

2 Remove the switch ASSY. [Point 21

3 Remove the holder Wlmagnet. [Point 31



Note: Apply grease on the inner surface of each bushing. After reassembly, adjust the direction switch. (See page 1-56.)

Notched portion

Point Operations


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

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

Reverse

[Point 21 Inspection:

Check continuity of direction switches.

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

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

2. Install the switch on the pedal. Set the switch while fully pressing it onto the pad. Apply locking agent (08833-00080) at the tip end of the screw before tightening the nut.

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

[Point 31 Reassembly:

Since the holder W/magnet needs height adjustment, set it temporarily in a low position. See page 1-56 for adjustment.

ADJUSTMENT

Note: See the following pages for adjustment of the pedal roller height and pedal stopper bolt height. G4 (GM6-262) <Air Governor System>, 132 Engine : See pagel-30. G4 (GM6-262) <Electronic Governor System> : See pagel-40. Direction switch adjustment is explained here.

0

0

@

Lock 8 nut Magnet holder

Direction Switch Adjustment Procedure

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

@ Screw in the magnet holder at the tilted side.

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

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

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

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

TORQUE CONVERTER & TRANSMISSION Page

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

HYDRAULIC CIRCUIT DIAGRAM ................................. 2-5

SPECIFICATIONS ............................................................ 2-6

................................................................ COMPONENTS 2-7

.................................................... TROUBLESHOOTING 2-12

................................................. TORQUE CONVERTER 2-13

................................................. REMOVAL-INSTALLATION 2-13

DISASSEMBLY-INSPECTION-REASSEMBLY .................... 2-14

TORQUE CONVERTER & TRANSMISSION ................................................................................ ASSY 2-18

................................................. REMOVAL-INSTALLATION 2-18

................................................... TRANSMISSION ASSY 2-21 DISASSEMBLY-INSPECTION-REASSEMBLY .................... 2-21

STATOR SHAFT N0.2 & OIL PUMP ASSY .............. 2-31 DISASSEMBLY-INSPECTION-REASSEMBLY .................... 2-31

CLUTCH DRUM ASSY ................................................... 2-33 .................... DISASSEMBLY-INSPECTION-REASSEMBLY 2-33

DIRECTION SWITCH ASSY .......................................... 2-36 REMOVAL-INSTALLATION ................................................ 2-36

OIL PRESSURE MEASUREMENT AND .................................................................. STALL TEST 2-37

GENERAL Pn35 - 50, Cu35 - 70 model

Pn60 - 80 model

Control Valve

I

A - A

HYDRAULIC CIRCUIT DIAGRAM

SPECIFICATIONS Model

Pn35 - 50 Item

Pn60 - 80 Cu35 - 70

Manufacturer

TYW

Stall/torque ratio

Stall/rotational frequency rPm

Transmission gear ratio

Okamura

4-members 2-stages 3-phases

5.1

G4 (GM6-262): 1950 132: 1950

Forward (F)

Reverse (R)

0.875

0.875

Solenoid type selector valve

981 - 1373 (10 - 14) [I42 - 1991

588 (6) [85] or more

167 - 441 (1.7 - 4.5) [24 - 641

12.0 (3.1 7)

ATF GM ~exron@ II

0.85

0.85

Control system

0.85

0.85

Clutch operation pressure (main pressure)

kPa(kgf/cm2)[psi]

Torque converter hydraulic pressure (outlet pressure)

kPa(kgf/cm2)[psi]

Engine: at 1500 rpm

Eninge: at idling

Engine: at 1500 rpm

Oil level l (USgal)

Hydraulic fluid

COMPONENTS Torque Converter Housing

Torque Converter

Torque Converter Clutch

Pn35 - 50, Cu35 - 70 model 3203

58A

Pn60 - 80 model

Torque Converter Gear

2-1 0

Control Valve

Torque Converter Piping

2-1 3

TORQUE CONVERTER REMOVAL*INSTALLATION T = N-m (kgf-cm) [ft-lbf]

Removal Procedure

1 Remove the engine. (See page 1-5.)

2 Drain torque converter oil.

3 Remove the pilot boss.

4 Remove the snap ring.

5 Remove the torque converter.


The installation procedure is reverse of the removal procedure.

DISASSEMBLY*INSPECTION*REASSEMBLY T = N-m (kgf-cm) [ft-lbf]


1 Remove the flexible plate.

2 Remove the drive cover. [Point 11

3 Remove the turbine runner. [Point 21

4 Remove the stator No.1 parts. [Point 31

5 Remove the stator No.2 parts. [Point 41

6 Remove the pump boss. [Point 51


The reassembly procedure is the reverse of the removal procedure.

SST 0

Point Operations

[Point 1] Disassembly:

Punch a match mark on the drive cover and pump impeller.

Reassembly: Align the match marks on the drive cover and pump impeller.

Disassembly: Remove the drive cover. SST 09950-5001 2...@

09950-6001 0.. .@

Disassembly: Remove the bearing. SST 09950-6001 0...@

09950-7001 O...@

Reassembly: Bearing installation 1. Temporarily install the pilot boss on the drive cover. 2. lnstall the bearing.

SST 09950-6001 0.. .@ SST 09950-7001 0...@

3. Remove the pilot boss. Install the pilot boss and flexible plate after the torque converter is installed in the housing.


Select the turbine runner spacer before installing the turbine runner as follows.

1. Measure dimension A after temporarily installing the turbine runner (without spacer) on the drive cover. Remove the O-ring of the pump impeller beforehand.

2. Measure pilot boss dimension B and bearing thickness C.

3. Select the turbine runner spacer so as to satisfy the following equation: A - (B + C + spacer thickness)

= 0.2 - 0.8 mm (0.008 - 0.031 in) Types of spacer thickness:

2.5, 2.7 and 3.0 mm (0.098, 0.106 and 0.118 in)

4. Remove the drive cover, and install the pump impeller O-ring and the spacer selected above.


Never install the one-way clutch, thrust bearing and stator hub in wring directions. (See the illustration.)

Check the one-way clutch function after reassembly.


Slowly remove the stator hub because rollers, springs and spring caps come off at a time.

Inspection: Measure the roller outside diameter.

Standard: 8.30 mm (0.327 in) Limit: 8.17 mm (0.322 in)

Inspection: Measure the clearance between the stator hub and stator cam.

Standard: 0.03 - 0.07 mm (0.0012 - 0.0028 in)

Limit: 0.15 mm (0.0059 in)

Reassembly: Stator installation

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

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

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

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


Measure the outside diameter at the oil seal sliding surface.


TORQUE CONVERTER & TRANSMISSION ASSY

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

Propeller shafi set bolt

Engine mounting nut

Torque converter mounting set bolt


T=70-105(710- 1070) [51.4-77.41

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

T = 39.2 - 75.5 (400 - 770) 128.9 - 55.71

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

Removal Procedure


2 Remove the engine hood.

3 Remove the toe board and lower panel.

4 Drain the coolant.

5 Remove the battery and battery tray.

6 132 engine vehicle: Disconnect the fuel hose. Remove the sedimenter bracket set bolt to set the bracket free. Disconnect the accelerator wire.

7 G4 (GM6-262) engine vehicle: Disconnect the fuel hose.

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

9 Disconnect connectors and wiring harness clamps around the engine.

10 Disconnect the inching wire.

11 Disconnect the torque converter cooler hose and hydraulic oil cooler hose.

12 132 engine vehicle: Remove the radiator and fan shroud.

13 G4 (GM6-262) engine vehicle: Disconnect the radiator hose.

14 Disconnect the oil control valve inlet pipe.

15 Remove the air cleaner.

16 Disconnect the exhaust pipe.

17 Remove the oil pump drive shaft ASSY. (See page 13-1 2.)

18 Remove the propeller shaft. (See page 3-4.)

19 Remove the transmission mounting bolts.

20 Remove the engine mounting nuts.

21 Remove the torque converter & transmission ASSY Wlengine. [Point 11

22 Remove the flexible plate set bolts. [Point 21

23 Separate the engine from the torque converter housing.



Point Operations

[Point 11 Rernoval*lnstallation:

SST09010-20111-71 ..... @ 0901 0-23320-71 ..... @

Move the SST hook position to adjust the balance.

[Point 21 Rernoval*lnstallation:

Turn the flywheel using the crankshaft pulley set bolt.

TRANSMISSION ASSY DISASSEMBLY*INSPECTION*REASSEMBLY T = N-m (kgf-cm) [ft-

I

. I bf]


Drain the torque converter oil.

Remove the torque converter. (For disassembly, inspection and reassembly of torque converter ASSY, see page 2-1 4.)

Remove the solenoid valve. [Point 11

Remove the inching valve ASSY.

Remove the inching spool and spring. [Point 21

Remove the coin filter from the inching valve body. [Point 31

Remove the oil seal from the inching valve body. [Point 41

Remove the accumulator valve. [Point 51

Remove the regulator valve. [Point 51

Remove the oil filter. [Point 61

Remove the oil strainer

Separate the torque converter case and transmission case. [Point 71

Remove the idle shaft ASSY. [Point 81

Remove the O-ring and bearing. (When replacing the bearing, replace two taper roller bearings, spacer and snap ring as a set. These parts are selected to set each bearing at the optimum pre-load.)

Remove the stator shaft No.1 Wlbearing [Point 91

Remove the bearing from the stator shaft No.1. [Point 101

Remove the stator shaft No.2 & oil pump ASSY. (For disassembly, inspection and reassembly of stator shaft No.2 & oil pump ASSY, see page 2-31 .) [Point 111

Remove the reverse shaft bearing from torque converter case. [Point 121

Remove the counter gear shaft ASSY. [Point 131

Remove the bearing from the counter gear shaft. [Point 141

Remove the main shaft counter gear Wlbearing. [Point 151

Remove the main shaft counter gear bearing. [Point 161

Remove the reverse shaft counter gear. [Point 171

Remove the main shaft ASSY (clutch drum ASSY No.1 Wlclutch gear). [Point 181 (For disassembly, inspection and reassembly of clutch drum ASSY, see page 2-33.)

Remove the reverse shaft ASSY (clutch drum ASSY No.2 W/clutch gear). [Point 191 (For disassembly, inspection and reassembly of clutch drum ASSY, see page 2-33.)

Remove the shaft seal ring and bearing. [Point 201

Remove the clutch gear and clutch gear bearing. [Point 211

Remove the output shaft parts. [Point 221



Note: Apply sealing agent (08826-00080) on the oil strainer surface to be mounted on the torque converter case.

Point Operations

[Point I] Inspection:

lnspect the solenoid valve for continuity. Between 1 and 2: Continuity Between 3 and 4: Continuity


Measure the free length of the inching valve spring. mm (in)

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


lnspect and wash the coin filter to eliminate clogging.

Limit

24 (0.94)

58 (2.28)

Inner spring

Outer spring

Standard

27 (1.06)

63.3 (2.49)

- -

O-ring

I I


SST 09950-6001 0 ..... @ 09950-7001 0 ..... @

After installation, apply grease on the oil seal lip portion.


Measure the free length of the accumulator spring.

mm (in)

Inspection: Measure the free length of the regulator valve spring.

mm (in)

Limit

135.0 (5.31 5)

138.5 (5.453)

Inner spring

Outer spring

[Point 61 Disassembly*Reassembly:

SST 09228-07501

Standard

150.0 (5.906)

153.5 (6.043)


After set bolt removal, slightly hoist by slinging to torque converter case side with wire ropes. Then use a service bolt for separation. Service bolt size: M I 0 x 1.5

Limit

135.5 (5.31 5)

131.0(5.157)

Inner spring

Outer spring

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

Standard

153.5 (6.043)

148.0(5.827)

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


Tighten the lock nut to the specified torque. T = 147.1 - 176.5 N-m (1 500 - 1800 kgf-cm)

[I 08.5 - 130.2 ft-lbf]

Swage the lock nut securely at one point.


Remove the stator shaft No. 1 Wlbearing by tapping its tip end with a plastic hammer.


SST 09950-4001 1 ..... @ 09950-6001 0 ..... @


Use a round bar and remove the stator shaft No.2 & oil pump ASSY.


SST 09320-23000-71


Use a bar and remove the counter gear shaft ASSY.


SST 09950-4001 1

Reassembly: SST 09950-6001 0 ..... @

09950-7001 0 ..... @


Use a bar and remove the main shaft counter gear.


Since this bearing may be damaged when removed from the gear, do not use it again.

Reassembly: Install the bearing in the correct direction (see the illustration).


Use a bar and remove the reverse shaft counter gear.


Remove the main shaft ASSY by hoisting it.


Use a bar and remove the reverse shaft ASSY.


Remove the bearing from each of the main shaft and reverse shaft. SST 09950-4001 1

Reassembly: SST 09370-20270-71

Inspection: Measure the side clearance of each shaft seal ring.


Use a hand press or a large puller and remove the clutch gear Wlbearing.

Main shaft Reverse shaft

Disassembly: Remove the clutch gear bearing. SST 09950-60020 .....

09950-7001 0 . .. . . @

Limit mm (in)

0.29 (0.01 14)

0.29 (0.01 14)

Reassembly: 1. Insert a plate

as illustrated, between the clutch gear and clutch drum and temporarily install the gear first.

2. lnstall the clutch gear bearing on the clutch gear.

3. Remove the plate, and install the clutch gear Wlclutch gear bearing.

[Point 221 Disassembly: 1. Use the service bolt (MI 0 x 1.25) and a round bar to lock

the coupling from rotation, and remove the set bolt.

2. Remove the shaft Wlbearing, output gear and coupling.

3. Use a copper bar and remove the bearing from the case.

4. Remove the oil seal.

Reassembly: 1. Install the oil seal.

Apply sealing agent (08826-00080) on the oil seal surface to be in contact with the case. After installation, apply grease on the oil seal lip portion.

2. Install the coupling and bearing on the case. While supporting the coupling with a wooden block under it, insert the bearing from above using a copper bar.

3. Install the output gear and shaft Wlbearing.

4. Install the O-ring and lock plate. Pay attention to the direction of the lock plate. (See the illustration.)

5. Lock the coupling from rotation, and tighten the set bolt to the specified torque.

STATOR SHAFT N0.2 & OIL PUMP ASSY DISASSEMBLY*INSPECTION-REASSEMBLY T = N-m (kgf-cm) [ft-lbf]


1 Remove the stator shaft No.2. [Point 11

2 Remove the oil pump gear. [Point 21

3 Remove the oil seal. [Point 31



Point Operations

[Point 1] Inspection:

Measure the outside diameter of the stator shaft in sliding contact with the pump drive gear.



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

Standard: 0.12 - 0.20 mm (0.0047 - 0.0079 in) Limit: 0.3 mm (0.01 2 in)

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

Standard: 0.05 - 0.10 mm (0.0020 - 0.0039 in) Limit: 0.1 3 mm (0.0051 in)

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

Standard: 0.03 - 0.079 mm (0.0012 - 0.00311 in) Limit: 0.1 5 mm (0.0059 in)


SST 09950-60020 ..... @ 09950-7001 0 ..... @

CLUTCH DRUM ASSY DISASSEMBLY-INSPECTION-REASSEMBLY

I I



2 Remove the pressure plate, camber plate, clutch plate and clutch disc. [Point 11

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

4 Remove the clutch piston. [Point 31


The reassembly procedure is reverse of the disassembly procedure.

Point Operations


Measure the camber plate warp height.


Inspection: Measure the thicknesses of the pressure plate, clutch disc and clutch plate. Standard:

mm (in) - --

Reassembly: Install the camber plate with the UP mark facing upward.

Reassembly: Carefully install each plate in the correct order.

Limit 2.1 (0.083)

2.3 (0.091 )

Clutch plate Clutch disc

Clearance between snap ring and pressure plate

Standard 2.3 (0.091 )

2.6 (0.1 02)

Standard: Pn35 - 50, Cu35 - 70 model: A = 3.0 mm (0.118 in)

(Reference) Pn60 - 80 model: A = 4.2 mm (0.165 in)(Reference)

[Point 21 Disassembly Reassembly:

Use the SST to compress the return spring for snap ring installation or removal. Bind two hooks of the SST with a wire or cord as illustrated to prevent departure from the clutch drum. SST 09220-33901 -71

Caution: Carefully operate with sufficient check since the hook may come off from the clutch drum to cause the spring to fly out while the SST is in use.

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

Standard: 56 mm (2.20 in) Limit: 50 mm (1.97 in)


Measure the side clearance of the seal ring.

Limit: 0.30 mm (0.012 in)

Inspection: Measure the side clearance of the piston ring.

Limit: 0.15 mm (0.0059 in)

DIRECTION SWITCH ASSY

1 Remove the turn signal switch cover.

2 Disconnect the wiring.

3 Remove the direction switch ASSY. [Point I]


The installation procedure is reverse of the removal procedure.

LH spec. 1 :VR 2 : Ra 3 : ST 5:VF 6 : IG1 7 : N 8 : IG2

VF : Forward solenoid VR : Reverse solenoid ST : Starting motor relay Ra : Backup lamp & buzzer

Point Operations

[Point I] Inspection:

Check electrical continuity between switch connector terminals.

(P: Position, T: Terminal No., C-0: Continuous)

A

A: Main pressure (PT 118) B: Forward clutch pressure (PT 118) C: Reverse clutch pressure (PT 118)

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

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

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

limit), adjust to an appropriate level.

3. Measure the oil pressure. (1) Check and adjust the engine speed. (See page 1-8.) (2) Stop the engine and jack up at the front axle to float

wheels (both tires). (3) Set the oil pressure gauge. (If three oil pressure

gauges are available, measure the main, clutch and torque converter outlet pressures at a time.)

(4) Start the engine, set the direction switch to the N position, and measure the main pressures at idling and 1500 rpm, and the torque converter outlet pressure at 1500 rpm.

(5) Operate the direction switch to each shift position and measure clutch operating pressures at idling and 1500 rpm.

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

Standard kPa (kgf/cm2) [psi]

Detecting pressure

Main pressure

Clutch pressure

Torque converter outlet pressure

Idling

588 or more (6 or more)

[85 or more]

588 or more (6 or more)

[85 or more]

-

1500 rpm

981 - 1373 (10 - 14)

[I42 - 1991

981 - 1373 (10 - 14)

[I 42 - 1991

167 - 441 (1.7 - 4.5) [24 - 641

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

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

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

(2) Warm up the engine and measure the idling speed, no-load static maximum revolution and relief down. (See page 1-8.)

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

Standard: 132: 1950 rpm G4 (GM6-262): 1950 rpm

PROPELLER SHAFT Page

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

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

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

PROPELLER SHAFT .................................................... 3-4

REMOVAL-INSTALLATION .............................................. 3-4

DISASSEMBLY-INSPECTION-REASSEMBLY ...................................... (Pn35 . 50. Cu35-45 MODEL) 3-5

GENERAL

Pn35 - 50, Cu35.45 model

Cu55 - 70, Pn60 - 80 model

I

SPECIFICATIONS

Pn60 - 80 Pn35 - 50 Cu35.45 Cu55 - 70

Joint type Cross type

Length rnrn (in) A

B

125 (4.92)

160 (6.30)

70 (2.76)

105 (4.13)

100 (3.94)

135 (5.31)

COMPONENTS

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

Removal Procedure

1 Remove the propeller shaft cover. (Except Pn60 - 80 model)

2 Remove the propeller shaft set bolt.

3 Remove the propeller shaft.

Installation procedure


Note: Add MP grease through the grease fitting.

DISASSEMBLY-INSPECTION-REASSEMBLY (Pn35 - 50, Cu35-45 MODEL)

I


1 Fix the propeller shaft in a vise.

2 Remove the snap rings.

3 Remove the universal spider sets. [Point 11



Point Operations


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

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

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

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

snap ring groove appears.

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

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

DIFFERENTIAL Page

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

SPECIFICATIONS ....................................................... 4-3

.............................................................. COMPONENTS 4-4

DIFFERENTIAL ASSY ................................................... 4-6

REMOVAL*INSTALLATION (Pn35 . 50 MODEL) .............. 4-6

REMOVAL*INSTALLATlON (Pn60 . 80. Cu35 . 70 MODEL) ................................... 4-9

DISASSEMBLY-INSPECTION*REASSEMBLY ................... 4-12

DIFFERENTIAL CASE ASSY ....................................... 4-15

DISASSEMBLY*INSPECTION* REASSEMBLY .................. 4-15

DIFFERENTIAL CARRIER COVER ASSY ................ 4-18

DISASSEMBLY*INSPECTION-REASSEMBLY .................. 4-1 8

GENERAL

SPECIFICATIONS

All models

Banjo type

5.833

6

35

1 0 x 4

14 x 2

Pn35 - 50 model: 9.0 (2.38)

Pn60 - 80, Cu35 - 70 model: 7.0 (1.85)

Vehicle model

Item

Differential

Differential oil quantity e (US gal)

Differential case type

Reduction ratio (ring gearldrive pinion)

Number of teeth

Number of teeth x quantity

Drive pinion .

Ring gear

Pinion gear

Side gear

COMPONENTS

Pn 35 - 80 model 41 01 BD

-9451 2-01 000

49~-

4 9 4

4101-171

Cu 35 - 70 model 41 01

4 9 - 4 3

41 01 -1 72

DIFFERENTIAL ASSY REMOVAL-INSTALLATION (Pn35 - 50 MODEL) Note: Never apply impact to the frame at the time of removal or installation to protect the SAS controller from damage. T = N-m (kgf-cm) [ft-lbf]

Removal Procedure

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

2 Drain differential oil. [Point 11

3 Jack up the vehicle and remove the front wheels.

4 Remove the speed sensor cover and disconnect the connector.

5 Disconnect the brake pipe (from the wheel cylinder).

6 Disconnect the parking brake cable (from the actuator lever).


8 Remove the transmission mount bolts.

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

10 Remove the front axle & differential ASSY. [Point 21

11 Remove the front axle housing ASSY and front axle shaft (inner). [Point 31

12 Remove the speed sensor.

13 Remove the differential housing.



Note: Bleed air from the brake system after installation. (See page 8-26.)

Point Operations


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

A = Within 10 mm (0.39 in)

[Point 21 Removal: Remove the front axle and differential ASSY.

1. Use the SST and temporarily hoist the front axle and differential ASSY. SST 09090-04020

2. In the temporarily hoisted state, loosen the set bolts by 10 to 15 mm. Then lower the front axle and differential ASSY.

3. Support the front axle and differential ASSY with a garage jack, and remove the set bolts.

4. Remove the front axle and differential ASSY.


SST 09090-04020

REMOVAL-INSTALLATION (Pn60 - 80, Cu35 - 70 MODEL) Note: Never apply impact to the frame at the time of removal or installation to protect the SAS controller from damage. T = N-m (kgf-cm) [ft-lbf]

T = 49 - 78 (500 - 800) i36.2 - 57.91

Removal Procedure

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

2 Drain differential oil and planetary gear oil. [Point 11

3 Jack up the vehicle and remove the front wheels.

4 Remove the planet gear carrier ASSY Wlcarrier cover.

5 Remove the front axle shaft. [Point 21

6 Remove the speed sensor cover and disconnect the connector.

7 Disconnect the brake pipe (from the wheel cylinder).

8 Cu35-45 model: Disconnect the parking brake cable (from the actuator lever). Pn60 - 80, Cu55 - 70 model: Disconnect the parking brake cable (from the parking brake lever).

9 Remove the parking brake cable clamp. (Pn60 - 80, Cu55 - 70 model)


11 Remove the transmission mount bolts.

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

13 Remove the front axle & differential ASSY. [Point 31

14 Remove the speed sensor.

15 Remove the differential ASSY.



Note: Bleed air from the brake system after installation. (See page 8-26.)

Point Operations


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

A = Within 10 mm (0.39 in)

@ Oil supply hole

Mark

Installation: After reassembly, set the "-" mark on the carrier cover in horizontal state and fill planetary gear oil full to the brim of the oil supply hole.

[Point 21 Removal~lnstallation:

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

[Point 31 Removal:

1. Sling the front axle with a wire rope and slightly hoist it. Support the differential with a garage jack under it.

2. Remove the front axle bracket set bolts. Use the SST to remove the reamer bolts in the illustrated positions.

Cu35-45 model: SST 0931 0-23320-71

Cu55 - 70, Pn60 - 80 model: Use a bar and remove the reamer bolts.

3. Operate the hoist and garage jack, to remove the front axle & differential ASSY.

DISASSEMBLY*INSPECTION.REASSEMBLY N-m (kgf-cm) [ft-Ibf]


1 Measure the ring gear backlash. [Point 11

2 Remove the bearing cap and adjusting nut. [Point 21

3 Remove the differential case ASSY. (See page 4-1 5 for the disassembly, inspection and reassembly procedure.)

4 Remove the differential carrier cover ASSY. [Point 31 (See page 4-1 8 for the disassembly, inspection and reassembly procedure.)



SST

SST

Point Operations


Measure the ring gear backlash.

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


Put match marks on the bearing cap and differential housing.

Reassembly: Install the adjusting nuts and bearing cap. 1. Install the adjusting nuts. 2. Install the bearing cap by aligning the match marks and

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

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

4. Use the SST and tighten until the thrust clearance is elimi- nated. SST 09630-1 01 10-71

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

and measure the backlash.

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

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

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

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

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

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

T = 11 7.7 - 137.3 N-m (1 200 - 1400 kgf-cm) [86.82 - 101.3 ft-lbf]


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

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

DIFFERENTIAL CASE ASSY DISASSEMBLY-INSPECTION-REASSEMBLY T = N-m (kgf-cm) [ft-lbf]


1 Remove the differential case bearings. [Point 11

2 Remove the differential upper case. [Point 21

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

4 Remove the ring gear. [Point 41



SST @

, SST @

Match marks

Point Operations


SST 09950-4001 1 --- O 09950-6001 0 --- 0

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

surface. SST 09950-60020 --- @I

09950-7001 0 --- @ 2. Use a striking driver and fully drive in the bearing.

[Point 21 Disassembly-Reassembly:

Check the match marks.

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


Measure the inside diameter of the differential pinion. Standard: 22.12 mm (0.8709 in) Limit: 22.22 mm (0.8748 in)

Inspection: Measure the spider outside diameter. Standard: 22.00 mm (0.8661 in) Limit: 21.75 mm (0.8563 in)

Inspection: Measure the side gear thrust washer thickness.


Inspection: Measure the pinion gear thrust washer thickness.


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

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


Apply locking agent (08833-00070) on the set bolt threaded portion before reassembly. Tighten the set bolts gradually in the diagonal order, and finally tighten in the circular order to the specified torque.

DIFFERENTIAL CARRIER COVER ASSY DISASSEMBLY*INSPECTION*REASSEMBLY T = N-m (kgf-cm) [ft-Ibf]

T = 343.2 - 392.3

T = 15.7 - 19.6 (160 - 200) [11.6 - 14.51


1 Fix the differential carrier cover ASSY in a vise. [Point I]

2 Remove the drive pinion rear cover and gasket.

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

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

5 Remove the front bearing roller and pilot bearing from the drive pinion. [Point 41

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

7 Remove the reduction gear bearing. [Point 61

8 Remove the drive pinion bearing outer race.

9 Remove the input shaft oil seal. [Point 71

10 Remove the input shaft dust deflector. [Point 81



Good examples

Bad examples

Point Operations

[Point 11 Disassembly :

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

SST 0941 0-23320-71 2. Use the service bolt and install the differential carrier

cover ASSY on the SST.


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

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

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

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

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

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

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

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

6. Securely swage the lock nut.

SST


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

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

cover ASSY on the SST.


Install the drive pinion front bearing. SST 0931 6-6001 1

Disassembly: SST 09950-4001 1

Reassembly: Use the SST and install the pilot bearing. SST 09608-04031 Check the installed direction

After installing the drive pinion pilot bearing, caulk the tip end of the drive pinion at 3 places.


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

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


SST 09950-6001 0 --- O 09950-7001 0 --- @


Use the SST to drive in the new oil seal to be flush with the inside end face of the differential carrier cover. SST 09950-60020 ---

0921 4-7601 1 --- @ After installation, apply grease on the oil seal lip portion.


SST 0931 6-6001 1

FRONT AXLE Page

GENERAL ........................................................................ 5-2 SPECIFICATIONS ...................................................... 5-6 COMPONENTS .............................................................. 5-6 TIRES.WHEELS (PNEUMATIC TIRE) ...................... 5-10 FRONT AXLE ASSY (Pn35 - 50 MODEL) .............. 5-11

............................................... REMOVAL-INSTALLATION 5-11

................... DISASSEMBLY-INSPECTION-REASSEMBLY 5-13

FRONT AXLE ASSY (Pn60 - 80. Cu35 - 70 MODEL) ............................ 5-17


FRONT AXLE BRACKET (Pn35 - 50 MODEL) ..... 5-25 ............................................... REMOVAL-INSTALLATION 5-25

FRONT AXLE HOUSING-DIFFERENTIAL HOUSING ............................ (Pn60 - 80. Cu35 - 70 MODEL) 5-27

REMOVAL-INSTALLATION (Pn60 . 80 MODEL) .............. 5-27 REMOVAL-INSTALLATION (Cu35 N 70 MODEL) ............. 5-28

Cu35-45 Model

Cu55 - 70 Model

SPECIFICATIONS

Reduction gear type

Reduction ratio

Cu55 - 70 Cu35.45 Model

Pn35 - 50 Item

Planetaty gear reduction

Pn60 - 80

Full-floating Front axle type

4.25

Half-floating

3.0 3.0

Suspension type

4.25

Fixed to frame

4201 -21 9A

Cu35 - 70 model

TIRES*WHEELS (PNEUMATIC TIRE) 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

Abbreviations used in the specification column: ml = Standard, SPL-S = Special single, STD-D = Standard double, SPL-D = Special double

2. Wheel Disassemly-Reassembly

Inflating pressure kPa (kgf/cm2) [psi]

843 (8.50) [ I 211

760 (7.75) [ I 101

686 (7.00) [ I 001

785 (8.00) [ I 141

834 (8.50) [ I 211

686 (7.00) [ I 001

686 (7.00) [ I 001

785 (8.00) [ I 141

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.

Classification

Pn35-40 model

Pn45.50 model

Pn60-70 model

Pn80 model

Tire size

250-1 5-1 6PR

28x12-1520PR

29x8-15-12PR

300-1 5-1 8PR

32X12.1-1520PR

8.25-1 5-1 2PR

8.25-1 5-1 2PR

8.25-1 5-14PR

Specification

SPL-S

STD-D

ISTD( SPL-S

SPL-D

Rim type

Side ring

Side ring

Side ring

Side ring

Side ring

Side ring

Side ring

Side ring

FRONT AXLE ASSY (Pn35 - 50 MODEL) REMOVAL-INSTALLATION Note: Never apply impact to the frame at the time of removal or installation to protect the SAS controller from damage. T = N-m (kgf-cm) [ft-lbf]

I

T = 180.4 - 323.6 (1 840 - 3300) [133.1 - 238.81

Hub nut: T = 294.2 - 588.4 (3000 - 6000) [217.1 - 434.11

Removal Procedure

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

2 Jack up the frame and remove the front wheels.

3 Drain differential oil thoroughly.

4 Disconnect the brake piping.

5 Disconnect the parking brake cable.

6 Support the bottom of the differential with a pantograph jack or a wooden block.

7 Remove the differential housing set nuts.

8 Support the bottom of the front axle ASSY with a garage jack.

9 Remove the front axle bracket set bolts. [Point 11

10 Remove the front axle ASSY and front axle shaft (inner).



Note: Apply thread tightener (08833-00070) onto the threaded portion of each diffrential housing set bolt before tightening it. Perform brake system air bleeding and adjustment after the end of installation. (See page 8-26.)

Point Operations

[Point 11 Removal:

Front axle bracket set bolt removal 1. Remove ordinary bolts (3 pcs. in the center). 2. Use the SST and remove reamer bolts (2 pcs. at the

top and bottom). SST 0931 0-23320-71

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

T = 294.2 - 343.2

Pn50 model

T = 294.2 - 588.4 (3000 - 6000) [217.1 - 434.11

Brake ASSY set nut: T = 88.3 - 117.7 (900 - 1200) [65.1 - 86.821 (M12, 7pcs.) T = 11 7.7 - 137.3 (1 200 - 1400) [86.82 - 101.31 (MI 4, 2 ~ ~ s . )


1 Remove the brake drum.

2 Remove the lock nut. [Point 11

3 Remove the planet carrier ASSY.

4 Disassembly the planet carrier ASSY. [Point 21

5 Remove the internal gear. [Point 31

6 Remove the front axle shaft (outer). [Point 41

7 Remove the brake ASSY.

8 Disassemble the front axle housing. [Point 51

Reassemble Procedure


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

Point Operations

[Point 11 Reassembly :

Adjust the front axle shaft starting force.

1. Tighten a new lock nut to the specifying torque.

T = 294.2 - 343.2 N-m (3000 - 3500 kgf-cm) [217.1 - 253.2 ft-lbf]

2. Rotate the axle housing several turns to break in the bearing.

3. Set a spring scale on an axle housing set bolt and measure the starting force.

Standard: 68.6 - 127.5 N (7 - 13 kgf) [15 - 29 Ibf]

If the standard is not satisfied, increase or decrease the shim thickness for adjustment. Increase the shim thickness if the starting force is excessive, and decrease it if insufficient.

Shim thickness: 0.1 -0.4.1.0 mm (0.004 0.016.0.039 in)

4. Lock the lock nut securely for contact at portions A. No crack shall arise in portions B at the time of locking.


Measure the planet gear shaft outside diameter.


Inspection: Measure the planet gear bushing inside diameter.


Disassembly-Reassembly: SST 09222-3001 0 Install to make the dimension from the bushing end face to the gear end face equal.

Reassembly: Apply a thin coat of molybdenum disulfide grease on the planet gear bushing inside surface and shaft outside surface.

Disassembly: Use SSTs to remove the bearing.

........ SST 09950-60020 (1 )

........ 09950-7001 0 (2) 09420-23000-71 ... (3)

Reassembly: Use a steel pipe matching the bearing diameter to install the bearing.

Reference: Bearing inside diameter:

80 mm (3.1 5 in)


Punch match marks and remove the reamer bolts.

Reassembly: Align the match marks before reassembly.

Reassembly: Apply grease on the O-ring before reassembly.


SST 09420-23000-71

Reassembly: After filling MP grease in the bearing, use a steel pipe matching the diameter and install the bearing.

Reference: Bearing inside diameter:

70 mm (2.76 in)


Install the oil seal (inner) to satisfy the following dimension:

A = 12 mm (0.47 in)

Reassembly: Fill MP grease in the illustrated B portion. (Grease amount: 68 - 170 g (0.1 5 - 0.37 Ib))

Reassembly: Apply MP grease on the oil seal (innerlouter) seal lips.

FRONT AXLE ASSY (Pn60 - 80, Cu35 - 70 MODEL)

Removal Procedure

1 Jack up the frame and support it with stand or wooden blocks.

2 Remove front wheel.

3 Drain the planetary gear oil. [Point I ]

4 Remove the planet gear carrier cover. [Point 21

5 Remove the planet gear carrier assembly. [Point 31

6 Remove the front axle shaft. [Point 41

7 Remove the planet gear. [Point 51

8 Remove the internal gear hub. [Point 61

9 Remove the outer bearing. [Point 71

10 Remove the front axle hub wlbrake drum. [Point 81

11 Remove the inner bearing and oil seal. [Point 91

12 Remove the front axle shaft oil seal. [Point 101



Note: The tightening torque for each portion is as follows:

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

Pn60 - 80 model

Apply locking agent (08833-00070) T = 294.2 - 588.4 (3000 - 6000) [217.1 - 434.11 T = 294.2 - 588.4 (3000 - 6000) [217.1 - 434.11 T = 294.2 - 588.4 (3000 - 6000) i217.1 - 434.11 Apply locking agent (08833-00080) T = 20.4 - 30.6 (208 - 31 2) [ I 5.0 - 22.61 T = 98.1 - 127.5 (1 000 - 1300) [72.4 - 94.11 Apply sealing agent (08826-00080) Apply locking agent (08833-00070) T = 300.0 - 400.0 (3060 - 4080) [221.4 - 295.21 T = 137.3 - 205.9 (1 400 - 21 00) [ I 01.3 - 151.91

Cu35.45 model

@ Apply locking agent (08833-00070) T = 264.8 - 294.2 (2700 - 3000) [I 95.3 - 21 7.11

@ T = 294.2 - 323.6 (3000 - 3300) [217.1 - 238.81 @ Apply locking agent (08833-00080)

T = 20.4 - 30.6 (208 - 31 2) 11 5.0 - 22.61

@ T = 98.1 - 127.5 (1 000 - 1300) [72.4 - 94.11

@ T = 88.3 - 137.3 (900 - 1400) [65.1 - 101.3]

@ T = 88.3 - 11 7.7 (900 - 1200) [65.1 - 86.81 @ Apply sealing agent (08826-00080) @ Apply locking agent (08833-00070) @ T = 88.3 - 137.3 (900 - 1400) 165.1 - 1 01.31

@ T = 88.3 - 11 7.7 (900 - 1200) [65.1 - 86.81

, Cu55 - 70 model

@ Apply locking agent (08833-00070) T = 264.8 - 294.2 (2700 - 3000) [I 95.3 - 217.1]

@ T = 294.2 - 323.6 (3000 - 3300) [217.1 - 238.81 @ Apply locking agent (08833-00080)

T = 20.4 - 30.6 (208 - 31 2) [I 5.0 - 22.61

@ T = 98.1 - 127.5 (1000 - 1300) [72.4 - 94.11 @ Apply sealing agent (08826-00080) @ Apply locking agent (08833-00070)

T = 300.0 - 400.0 (3060 - 4080) 1221.4 - 295.21 @ Apply sealing agent (08826-00080)

Q Oil supply hole

Mark

@:_I; 0

Pn60 - 80 model Cu55 - 70 model Cu35-45 model

Service bolt

Point Operations


After installation, set the "" mark on the carrier cover in horizontal state and fill planetary gear oil full to the brim of the oil supply hole.

[Point 21 Removal:

Using a service bolt, remove the planet gear carrier cover. Service bolt size: M8 x 1.25

Installation: Apply sealing agent (08826-00090) on the mating surfaces of the planet gear carrier and carrier cover before installation.

[Point 31 Removal:

Use 2 service bolts and remove the planet gear carrier ASSY. Service bolt size: MI0 x 1.25


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


Measure the planet gear shaft outside diameter.

Standard: 26.0 (1.024 in) Limit: 25.85 (1.018 in)

Inspection: Measure the planet gear bushing inside diameter.

Standard: 26.0 (1.024 in) Limit: 26.18 (1.031 in)

Disassembly.Reassembly: SST 09950-6001 0 ....... @

09950-7001 0 ........ @ Install to make the dimension from the bush end face to the gear end face equal.

Reassembly: Apply a thin coat of molybdenum disulfide grease on the planet gear bush inside surface and shaft outside surface.


Pn60 - 80, Cu55 - 70 model Use the SST and remove/install the bearing lock nut. SST 09509-55030

Cu35.45 model Use a brass bar and remove/install the bearing lock nut.

Installation: Adjust the front axle hub starting force. 1. Pn60 - 80, Cu55 - 70 model

Install the bearing lock nut (inner) Wlsecew. Cu35.45 model Install the bearing lock nut.

2. Fully tighten the bearing lock nut, and rotate the hub by 4 to 5 turns to run in the bearing.

3. Return the bearing lock nut by 1/12 to 116 turn (30 to 60°), and rotate the hub by 4 to 5 turns again.

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

Standard: Pn60 - 80 model

88.2 - 156 N (9 - 16 kgf) [20 - 35 Ibf] Cu35 - 70 model

49- 118N (5 - 12 kgf) [I1 - 26Ibfl

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

[Point 71 Removal:

Pn60 - 80, Cu35-45 model Use 2 service bolts and remove the outer bearing. Service bolt size: M12 x 1.25

Cu55 - 70 model Use a brass bar and remove the outer bearing.


Pn60 - 80 model Use the SST and removelinstall the front axle hub Wlbrake drum. SST 0901 0-201 11 -71

Cu35 - 70 model Sling the hub bolts with a wire rope. Operate the hoist and garage jack to remove or install the front axle hub Wlbrake drum.


SST 09700-30020-71 Drive in equally around the oil seal outer circumference. After installation, apply MP grease to the oil seal lip.


SST 09950-6001 0 ....... @ 09950-7001 0 ....... @

After installation, apply MP grease to the oil seal lip.

FRONT AXLE BRACKET (Pn35 - 50 MODEL) REMOVAL-INSTALLATION T = N*m (kgf-cm) [ft-lbf]

Removal Procedure

1 Remove the front axle & differential ASSY. (See page 4-6)

2 Remove the parking brake cable bracket and clamp.

3 Remove the front axle bracket. [Point 11

4 Remove the brake pipe protector bolt. [Point 21



Point Operations

[Point 11 Removal:

SST 0931 0-23320-71


Install the brake pipe protector bolt after adjustment to the illustrated length.

FRONT AXLE HOUSING-DIFFERENTIAL HOUSING (Pn60 - 80, Cu35 - 70 MODEL)

REMOVAL-INSTALLATION (Pn60 - 80 MODEL) T = N-m (kgf-cm) [ft-lbf]

T=180-323 (1840 - 3290) [133.1 - 238.01

Brake ASSY set bolt: T = 300 - 400 (3060 - 4080) [221.4 - 295.21

Removal Procedure

1 Remove the differential ASSY. (See page 4-9.)

2 Remove the front axle hub Wlbrake drum. (See page 5-1 7.)


4 Remove the front axle housing and O-ring.



Note: Apply grease on the O-ring before installation. Apply thread tightener (08833-00070) on the front axle housing set bolt and brake ASSY set bolt betor tightening.

REMOVAL-INSTALLATION (Cu35 - 70 MODEL) T = N-m (kgf-cm) [ft-lbf]

Cu35.45 model: Brake ASSY set nut: Cu35-45 model T=88 - 118(900- 1200) [65.1 -86.81

Cn55 - 70 model: Brake ASSY set bolt: T = 300 - 400 (3060 - 4080) [221.4 - 295.21

Removal Procedure

1 Remove the differential ASSY. (See page 4-9.)

2 Cu 35.45 model: Remove the front axle hub Wlbrake drum. (See page 5-1 7.) Cu 55 - 70 model: Remove the front axle hub. (See page 5-1 7.)


4 Remove the differential housing.



Note: Apply thread tightener (08833-00070) on the brake ASSY set bolt befor tightening. (Cu55 - 70 model)

REAR AXLE Page

GENERAL .................................................................... 6-2

SPECIFICATIONS ......................................................... 6-7

COMPONENTS .............................................................. 6-8

TIRESOWHEELS (PNEUMATIC TIRE) ...................... 6-11

REAR AXLE ASSY (Pn35 . 80 MODEL) ................. 6-12

REMOVAL-INSTALLATION ............................................... 6-12

REAR AXLE ASSY (Cu35 . 70 MODEL) ................. 6-14


REAR AXLE HUBoSTEERING KNUCKLE

(Pn35 - 80 MODEL) ................................................... 6-16

REMOVAL-INSTALLATION (Pn35 . 50 MODEL) .............. 6-16


STEERING KNUCKLE (Cu35 . 70 MODEL) .......... 6-24


REAR AXLE CYLINDER ............................................... 6-28


REMOVAL*INSTALLATION (Cu35 N 70 MODEL) ............. 6-30

DISASSEMBLY-INSPECTION *REASSEMBLY .................. 6-32

6-2

GENERAL

Pn35 - 50 model

~ -

Cu35-45 model

Rear Axle Cylinder

Pn35 - 50 model

Pn60 - 80 model

Pn35 - 70 model

SPECIFICATIONS

Elliot type

Center-supported right-left rocking type

0 (0)

0"

0"

0"

Pn35 : 2585 (1 01.8), Pn40 : 2650 (1 04.3)

Pn45 : 2750 (1 08.3), Pn50 : 2800 (1 10.2)

Pn60 : 3080 (1 21.2), Pn70 : 31 30 (1 23.2), Pn80 : 3200 (1 25.9)

Cu35 : 2280 (89.8), Cu45 : 2390 (94.1 )

Cu55 : 2550 (1 00.4), Cu60 : 2585 (1 01.8), Cu70 : 2585 (1 01.8)

Double acting

Pn35 - 50, Cu35 - 70 : 55.0 (2.165)

Pn60 - 80 : 70.0 (2.756)

Pn35 - 50 : 95.0 (3.740)

Pn60 - 80 : 1 05.0 (4.134)

Cu35 - 45 : 87.0 (3.425)

Cu55 - 70 : 90.0 (3.543)

Rear axle type

Rear axle suspension type

Wheel alignment

Toe-in mm (in)

Camber degree

Caster degree

King pin angle

Minimum turning radius (outermost) mm (in)

Rear axle cylinder

Cylinder type -

Piston rod outside diameter (in)

Cylinder bore mrn (in)

6-8

COMPONENTS

Pn35 - 50 model 4301 01

4301-138

Pn60 - 80 model 01 ,.... ....I

EJ -@

GB%

1-14

4301 -1 39A

Cu35 - 70 model 01 4301 ....I .

142K=(INCL..j :

. L... ...A

4301-140A

Pn35 - 50 model 01 4302 p.. "'7 I I I

I

m

L...

4302-030

Pn35 - 70 model

TIRESaWHEELS (PNEUMATIC TIRE) 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

2. Wheel Disassernly-Reassembly

Caution: Always discharge air fully before disassembling the wheel. Otherwise, it is very dangerous since the rim may come off suddenly due to the internal pressure.

Inflating pressure kPa (kgf/cm2) [psi]

686 (7.00) [ I 001

686 (7.00) [ I 001

834 (8.50) [ I 211

686 (7.00) [ I 001

980 (1 0.0) [ I 421

686 (7.00) [ I 001

785 (8.00) [ I 141

Note: Install each divided rim set bolt with its head on the outer rim side and the chamfered portion facing the center of the wheel.


Rim type

Divided

Side ring

Side ring

Divided

Side ring

Side ring

Side ring

Side ring

Classification

Pn35 model

Pn40 model

Pn45 model

Pn50 model

Pn60-70 model

Pn80 model

Specification

STD

OPT

STD

STD

OPT

STD

STD

STD

Pn35 - 45 model

Tire size

7.00-12-1 2PR

7.00-1 2-1 2PR

7.00-1 2-1 2PR

7.00-1 2-14PR

8.25-1 5-1 2PR

8.25-1 5-14PR

T = 11 7.7 - 176.5 (1 200 - 1800) [86.82 - 130.231

6-1 2

REAR AXLE ASSY (Pn35 - 80 MODEL) REMOVAL*INSTALLATlON T = N-m (kgf-cm) [ft-Ibf]

Removal Procedure

1 Chock the front wheels.

2 Jack up the vehicle and remove rear wheels.

3 Remove the swing lock cylinder lower pin. (Pn35 - 50 model) (See section 15.)

4 Disconnect the rear axle cylinder hose.

5 Support the rear axle ASSY with a garage jack.

6 Remove the rear axle ASSY. [Point 11

7 Remove the center pin bushing. [Point 21



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

Point Operations


Measure the rear axle front to rear clearance. 1. Before removing the rear axle ASSY, measure the front

to rear clearance on the rear side.

Standard clearance: 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: 0.6.1 -2-2.3-3.2 and 4.5 mm (0.024.0.047-0.091-0.1 25 and 0.1 77 in)

3. Install the spacer at the rear side center pin.

Removal: Draw a match mark on the rear axle bracket cap and frame.

Installation: Install after aligning the match mark.


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

Limit: Pn35 - 50 model: 67.0 mm (2.638 in) Pn60 - 80 model

Front pin bushing: 82.0 mm (3.228 in) Rear pin bushing: 67.0 mm (2.638 in)

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

6-1 4

REAR AXLE ASSY (Cu35 - 70 MODEL) REMOVAL.INSTALLATION T = N-m (kgf-cm) Eft-lbf]

Removal Procedure

1 Chock the front wheels.

2 Jack up the vehicle and remove rear wheels. (See removal procedure steps 2 to 4 in steering knuckle removal-installation section on page 6-24.)

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

4 Disconnect the rear axle cylinder hose.

5 Support the rear axle ASSY with a garage jack.

6 Remove the rear axle ASSY. [Point 11

7 Remove the center pin bushing. [Point 21



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

Point Operations


Measure the rear axle front to rear clearance. 1. Before removing the rear axle ASSY, measure the front

to rear clearance on the rear side.

Standard clearance: 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: 0.6-1.2.2.3-3.2 and 4.5 mm (0.024.0.047.0.091-0.1 25 and 0.1 77 in)

3. Install the spacer at the rear side center pin.

Removal: Draw a match mark on the rear axle bracket cap and frame.

Installation: Install after aligning the match mark.


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

Limit: Front pin bushing 82.0 mm (3.228 in) Rear pin bushing 67.0 mm (2.638 in)

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

6-1 6

REAR AXLE HUBmSTEERING KNUCKLE (Pn35 - 80 MODEL) REMOVAL*INSTALLATION (Pn35 - 50 MODEL) T = N-m (kgf-cm) [ft-Ibf]

Removal Procedure

Jack up the vehicle and remove rear wheels.

Remove the hub cap. [Point 11

Remove the castle nut and claw washer. [Point 21

Remove the outer bearing and axle hub. [Point 31

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

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

Disconnect the tie rod (on the knuckle side).

Remove the king pin cover.

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

Remove the thrust bearing, spacer and steering knuckle.

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



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

Point Operations


Fill MP grease in the hub cap, and install by tapping the flange portion. (Instead of MP grease filling, spraying grease over the castle nut is also usable.)


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

of 12 to 32 N-m (1 20 to 330 kgf-cm) [8.7 to 23.9 ft-lbfl. 3. Rotate the hub by 3 to 5 turns to run in the bearing.


Standard: 43 - 72 N (4.4 - 7.3 kgf) [9.7 - 16.1 Ibf]

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

6. lnstall a new cotter pin.

[Point 31 Removal:

SST 091 20-23600-71

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

SST 09370-20270-71

SST

[Point 41 Removal:

Use a brass bar and remove the bearing outer race.

Installation: SST 09950-60020 --- @I

09950-7001 0 --- @

[Point 51 Removal:

SST 09950-4001 1

Installation: Install the oil seal and inner bearing roller. 1. Install the oil seal. 2. Use the SST and install the inner bearing roller.

SST 0931 6-6001 1


Measure the king pin outside diameter.

Limit: 34.8 mm (1.370 in)

0 rnrn (0 in)

4 rnrn (0.16 in)

Press-fitting direction

Installation: Measure the steering knuckle starting force. 1. Temporarily install the king pin and king pin lock bolt.

Select the spacer so as to minimize vertical looseness of the knuckle, and install it to lower side of the steering knuckle.

2. Set a spring scale at the tip end of the knuckle spindle, and measure the starting force.

Standard: 19.3 N (2.0 kgf) [4.4 Ibf] or less

3. If the standard is exceeded, check the king pin for bend, the needle bearing for damage and axle beam for deformation.

Spacer thickness: 0.15,0.25 and 0.35 mm (0.006,0.010 and 0.01 4 in)

4. Tighten the lock nut for the king pin lock bolt.

[Point 71 Removal:

Remove the king pin oil seal and needle roller bearing. 1. Use a straight-edge screwdriver to remove the dust seal

and oil seal. 2. Use the SST and remove the needle roller bearing.

SST 09950-6001 0 --- @I 09950-7001 0 --- @

Installation: Install the needle roller bearing and king pin oil seal. 1. Use the SST and install the needle bearing.

Check the needle roller bearing press-fitting surface, pressing direction and installation depth. SST 09950-6001 0 --- @I

09950-700 1 0 --- 0 2. Install the dust seal. 3. Use the SST and install the oil seal.

SST 09950-6001 0 --- @I 09950-7001 0 --- @

6-20

REMOVAL-INSTALLATION (Pn60 - 80 MODEL) T = N*m (kgf-cm) [ft-Ibf]

Removal Procedure

Jack up the vehicle and remove rear wheels.



Remove the outer bearing and axle hub. [Point 31

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


Disconnect the tie rod (on the knuckle side). [Point 61

Remove the king pin lock bolt and king pin. [Point 7] Remove the thrust bearing, spacer and steering knuckle.


Remove the bushing from the steering knuckle. [Point 91

Remove the hub bolt.



Note: Apply thread tightener (08833-00070) on the hub bolt set nut before tightening. After installation, add MP grease through grease fittings.

Point Operations




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

of 12 to 32 N-m (1 20 to 330 kgf-cm) [8.7 to 23.9 ft-lbfl. 3. Rotate the hub by 3 to 5 turns to run in the bearing.


Standard: 78 - 157 N (8.0 - 16.0 kgf) [17.6 - 35.3 Ibf]


6. lnstall a new cotter pin.


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

SST 09370-20270-71

[Point 41 Removal:


Installation: SST 09950-60020 --- O

09950-7001 0 --- O

Punch mark

Lock bolt

[Point 51 Removal:

SST 09950-4001 1


Align the punch marks on the tie rod pin and tie rod.

[Point 7] Inspection:


Limit: 39.8 mm (1 -567 in)

Installation: Before installation, check the positional relationships between the punch mark on top of the king pin and the king pin lock bolt.


Select the spacer so as to minimize vertical looseness of the knuckle, and install it on top of the thrust bearing.

34 mm (1.34 ln)

34 mm (1.34 in)

@$-@. w

t

r

1

A

Flush

2. Set a spring scale at the tip end of the knuckle spring, and measure the starting force.



Spacer thickness: 0.15,0.25,0.35,0.5 and 1.0 mm (0.006,0.010,0.014,0.020 and 0.039 in)

4. Tighten the lock nut for the king pin lock bolt. [Point 81 Removal:



SST 09950-6001 0 --- @ 09950-7001 0 --- @


Check the needle roller bearing press-fitting surface, pressing direction and installation depth. SST 09950-6001 0 --- @

09950-7001 0 --- 0 2. lnstall the dust seal. 3. Use the SST and install the oil seal.

SST 09950-6001 0 --- @ 09950-7001 0 --- 0


Press-in the bushing flush to the lower surface of the knuckle. (Clearance on the upper side will be used for the grease well.).

6-24

STEERING KNUCKLE (Cu35 - 70 MODEL) REMOVAL*INSTALLATION T = N-m (kgf-cm) [ft-lbf]

Removal Procedure

Jack up the vehicle.



Remove the outer bearing and rear wheel. [Point 31

Remove the bearing outer race from the rear wheel. [Point 41


Disconnect the tie rod (on the knuckle side).

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

Remove the thrust bearing, spacer and steering knuckle.




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

Point Operations

[Point I ] Installation:



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

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

4. Set a spring scale at the outer periphery of the wheel, and measure the starting force.

Standards: Cu35.45 model

29 - 44 N (3.0 - 4.5 kgf) [6.6 - 9.9 Ibf] Cu55 - 70 model

31 - 63 N (3.2 - 6.4 kgf) [7.1 - 14.1 Ibfl


6. Install a new cotter pin. [Point 31 Installation:

Fill MP grease in the hub and knuckle spindle.

Installation: Install the rear wheel and outer bearing.

SST 09370-20270-71

Punch mark

Lock bolt

[Point 41 Removal:


Installation: SST 09950-60020 --- @I

09950-7001 0 --- O

[Point 51 Removal:

SST 09950-4001 1



Limit: 39.8 mm (1 -567 in)

Installation: Before installation, check the positional relationships between the punch mark on top of the king pin and the king pin lock bolt.


Select the spacer so as to minimize vertical looseness of the knuckle, and install it on top of the thrust bearing.

2. Set a spring scale at the tip end of the knuckle spindle, and measure the starting force.



Spacer thickness: 0.15,0.25,0.35,0.5 and 1.0 mm (0.006,0.010,0.014,0.020 and 0.039 in)

4. Tighten the lock nut for the king pin lock bolt.

[Point 71 Removal:



SST 09950-6001 0 --- 0 09950-7001 0 --- @


Check the needle roller bearing press-fitting surface, pressing direction and installation depth. SST 09950-6001 0 ---

09950-7001 0 --- @ 2. Install the dust seal. 3. Use the SST and install the oil seal.

SST 09950-6001 0 --- @ 09950-7001 0 --- @

34 rnrn (1.34 in)

34 rnrn (1.34 in)

@=-f$ u

+

REAR AXLE CYLINDER REMOVAL.INSTALLATION (Pn35 - 80 MODEL) T = N-m (kgf-cm) [ft-Ibf]

1 Jack up the vehicle.

2 Disconnect the tie rod (on the piston rod side). [Point I]

3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 21

4 Remove the rear axle cylinder

5 Remove the bushing from the piston rod. (Pn60 - 80 model) [Point 31



Front Punch mark - 1'-

Stopper plate

Bushing

Upper

1' /

I 1

v \

Flush

Point Operations


Pn35 - 50 model Align the punch marks on the cylinder end pin and the stopper plate.

Pn60 - 80 model Align the punch marks on the tie rod pin and tie rod.


Install the fitting in the illustrated direction. Pn35 - 50 model: A = 20" Pn60 - 80 model: A = 45"


Press-in the bushing flush to the lower surface of the rod on both ends. (Clearance on the upper side will be used for the grease well.)

6-30

REMOVALaINSTALLATION (Cu35 - 70 MODEL) T = N-m (kgf-cm) [ft-Ibf]

Removal Procedure


2 Disconnect the tie rod (on the piston rod side).

3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 11

4 Remove the rear axle cylinder.



Point Operations


Install the fitting in the illustrated direction.

6-32

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


1 Remove the through bolt.

2 Remove the piston rod guide.

3 Remove the piston rod. [Point 11

4 Inspect the cylinder. [Point 21



Note: Coat hydraulic oil before reassembly.

Point Operations


Measure the piston rod outside diameter. Limit: Pn35 - 50, Cu35 - 70 model: 54.91 mm (2.1618 in) Pn60 - 80 model: 69.91 mm (2.7524 in)

Inspection: Measure the bend of the piston rod. Limit: 0.5 mm (0.020 in)

Reassembly: Warm the seal ring to a little below 80°C (176°F) in hot oil or water before installation. Do not stretch it excessively.

Caution: Operate carefully to avoid scalding.


Measure the rear axle cylinder bore.

Limit: Pn35 - 50 model: 95.40 mm (3.7559 in) Pn60 - 80 model: 105.40 mm (4.1496 in) Cu35.45 model: 87.40 mm (3.4409 in) Cu55 - 70 model: 90.40 mm (3.5591 in)

STEERING Page

GENERAL ....................................................................... 7-2

SPECIFICATIONS ......................................................... 7-4

.............................................................. COMPONENTS 7-4

STEERING WHEEL*MAST JACKET ........................ 7-7 REMOVAL*INSTALLATION ............................................... 7-7

.................. DISASSEMBLY-INSPECTION-REASSEMBLY 7-9

............... HYDROSTATIC STEERING VALVE ASSY 7-10 TROUBLESHOOTING ...................................................... 7-10

DISASSEMBLY*INSPECTION*REASSEMBLY .................. 7-12

RELIEF PRESSURE INSPECTION* ADJUSTMENT ............................................................ 7-16

GENERAL

Neutral position (against levelling)

Tilt adjusting lever

Power steering valve

Neutral position spring Housing Check valve Spool Sleeve Cardan shaft Gear rim Gear wheel (rotor) -Relief valve

7-3

Hydrostatic Steering Valve

3

- - -

I 1 ,a ;-1

' L - J

1 I - - - -

P T - J

SPECIFICATIONS

COMPONENTS

, 6 4501

01

y--

QLAc AK

AC --d L... ...A

4501M2A

Model

Item Pn60 - 80 Pn35 - 45 Cu35-60 Pn50

Steering wheel diameter mm (in)

Steering wheel play (at idling) mm (in)

Power steering type

Cu70

Hydrostatic steering valve

360 (1 4.2)

20 - 50 (0.79 - 1.97)

Hydrostatic steering

ospc (Danfoss) Type (manufacturer)

Delivery cm3 (in3)/rev

Rated flow rate C(US gal)/min

Relief set pressure kPa (kgf/cm2) [psi]

150 (9.15)

17 (4.5)

9610(98) [I 3901

t

t

lllOO(113) [ I 61 01

t

t

lllOO(113) [ I 61 01

200 (1 2.20)

22 (5.8)

+

185 (1 1.29)

c

9120(93) [ I 3201

STEERING WHEELaMAST JACKET R EMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbf]

Mast jacket set nut: T = 34.3 - 53.9 (350 - 550) [25.3 - 39.81 I Removal Procedure

1 Remove the steering wheel. [Point 11

2 Remove the combination meter ASSY cover.

3 Remove the lever switch ASSY cover. [Point 21

4 Remove the combination meter ASSY set bolts.

5 Disconnect the combination meter wiring.

6 Remove the combination meter ASSY.

7 Disconnect the lever switch ASSY wiring.

8 Remove the lever switch ASSY.

9 Remove the tilt lock mechanism. [Point 31

10 Disconnect the engine hood opening device.

11 Remove the steering valve set bolt and keep the valve free.

12 Remove the return spring.

13 Remove the mast jacket ASSY.



Note: Apply MP grease on each sliding portion of the tilt lock mechanism and engine hood opening device. Fill MP grease at the coupling between the tilt steering shaft and steering valve.

Parallel

\

\

Point Operations

[Point 11 Removal:

SST 09950-5001 2

Installation: Install the steering wheel after applying rubber grease on the sliding portion (A) of the lever switch. After installation, rotate the steering wheel. (When the steering wheel is rotated, pins (3 pcs.) on the cam side are automatically set in the holes on the steering wheel side.)

[Point 21 Removal:

Remove the set screw, and disengage the front cover and rear cover by pushing the A portion of the rear cover for removal.


Install so that the tilt lever line and meter box line are in parallel, and see that the tilt lock operation is normal.



2 Remove the tilt steering shaft.

3 Remove the bearing.

4 Remove the lever switch ASSY bracket.



Note: Apply rubber grease on each sliding portion of the lever switch ASSY.

HYDROSTATIC STEERING VALVE ASSY TROUBLESHOOTING

Remedy

Repair or replace oil pump. Repair or replace flow divider valve.

Repair or clean pressure relief valve. Adjust the valve to the correct pressure.

Lubricate joints of steering link or repair if necessary. Check steering column installation.

Replace leaf springs.

Replace gear wheel set.

Replace defects parts.


Clean steering unit.

Replace Cardan shaft.


Replace steering column.

Replace gear wheel set.

Repair or replace oil pump. Repair or replace flow divider valve.

Adjust valve to correct setting.

Clean the valve.

Correct setting as shown in Repair Manual.

Reverse the hoses.

Replace shaft seal.

Tighten screws.

Replace O-ring.

Fault

1. Steering wheel is heavy to turn

2. Regular adjustments of the steering wheel are necessary. ("meandering")

3. The steering wheel can turn on its own.

4. Backlash

5. Steering wheel can be turned wholly without moving the steered wheels.

6. Steering is too slow and heavy when operated quick-ly.

7. Heavy kick-back in steering wheel in both directions

8. Turning the steering wheel moves the steered wheels in opposite direction.

9. Leakage at either input shaft, end cover, gear-wheel set, housing or top part.

Possible cause

1.1 No or insufficient oil pressure

1.2 Pressure relief valve is stuck in open position or setting pressure is too low.

1.3 Too much friction at mechanical parts of the vehicle

2.1 Leaf spring without sufficient spring force or broken

2.2 Worn gear wheel set

2.3 Seized cylinder or worn piston seal.

3.1 Leaf springs are stuck or broken and have therefore reduced spring force.

3.2 Inner and outer spools are stuck, possibly due to dirt.

4.1 Cardan shaft worn or broken

4.2 Leaf springs without spring force or broken

4.3 Worn splines on the steering column

5.1 Gear wheel set worn

6.1 Insufficient oil supply to steering unit

6.2 Relief valve setting too low

6.3 Relief valve stuck due to dirt

7.1 Wrong setting of Cardan shaft and gear-wheel set

8.1 Hydraulic hoses for the steering cylinders have been connected reversely.

9.1 Shaft seal defective

9.2 Screws loose

9.3 O-rings defective

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

Removal Procedure


2 Remove the lower panel.

3 Remove the combination meter cover.

4 Remove the instrument panel.

5 Disconnect the piping.

6 Remove the steering valve ASSY.

7 Remove the steering valve spacer.



7-1 2

DISASSEMBLY*INSPECTION*REASSEMBLY T = N-m (kgf-cm) [ft-Ibf]


1 Remove the end cover. [Point 11

2 Remove the gear wheel set, cardan shaft and distributor plate. [Point 21

3 Remove the check valve.

4 Remove the sleeve W/spool and bearing. [Point 31

5 Remove the O-ring, kin-ring and dust seal ring. [Point 41

6 Remove the rerief valve. [Point 51



Note: Wash each part with clean hydraulic oil before assembly.

b7 Parallel

Point Operations


Put a match mark.

Reassembly: Align the match marks.

Disassembly: When removing each set bolts, carefully operate so as not to lose the steel ball.

Reassembly: Put a steel ball in the illustrated position before installing each set bolts.

Reassembly: As one out of seven set bolts is a bolt with pin, install it in the correct position.


Pay attention to the following points at the time of reassembly.

1. Fit the gearwheel (rotor) and cardan shaft so that a tooth base in the rotor is positioned in relation to the shaft slot as shown. Turn the gear rim so that the seven through holes match the holes in the housing.

2. Guide the carden shaft down into the bore so that the slot is parallel with the connection flange.

3. Align the match marks on the distributor plate and gear wheel made at the time of disassembly. When these parts are replaced, match the holes in the housing and plate at the time of reassembly.

O-ring \

Kin-ring


Extract the spool Wlsleeve upward. Otherwise, the spool cross pin may move during extraction to cause sticking.

Reassembly: Set and install the neutral position spring correctly.

Reassembly: Pay attention to the bearing direction for installation. (See the figure.)

Reassembly: Place the housing with its flanged side facing down, and insert the spool Wlsleeve into the housing. Set the cross pin of the spool in horizontal state during insertion.


Install the kin-ring and O-ring correctly.

Note: For SST No. SJ150-9000-11, please inquire at the near- est Danfoss service shop. (Refer to Parts & Service News Ref. No. GE-7022 of July 1,1997 for detail.)

1. Turn the steering unit until the bore is horizontal. Guide the outer part of the assembly tool into the bore for the spool/sleeve.

2. Apply O-ring and kin-ring with hydraulic oil and place them on the tool.

3. Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.

4. Press and turn the 0-ringtkin-ring into position in the housing.

5. Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore.


Do not remove the relief valve unless it is judged defective. The valve seat cannot be removed.

Disassembly: Measure the screwed-in depth of the relief valve adjusting screw before starting disassembly.

Reassembly: Reassemble by adjusting to the screwed-in depth of the valve spring retainer measured before disassembly. After installing the steering valve ASSY on the vehicle, measure the relief pressure. If it is not within the standard range, adjust it by changing the screwed-in depth of the retainer.

r

SST

RELIEF PRESSURE INSPECTION*ADJUSTMENT 1. Install an oil pressure gauge.

(1) Disconnect the hose from the steering valve P port, and connect the adapter (SST). SST 09450-23320-71

(2) Install the pressure gauge. Plug size: PT118

2. Start the engine and turn the steering wheel slowly clockwise and counterclockwise.

3. Start the engine, rotate the steering wheel and measure the relief pressure when the relief occurs.

Standard: Unit : kPa (kgf/cm2) [psi]

4. If the standard is not satisfied, remove the steering valve and make adjustment by turning the relief valve adjusting screw.

Pn35 - 45 model

Pn50 - 80 model Cu70 model

Cu35 - 60 model

961 0 yo (98';) [I 390+~O]

11 1 00 (1 13';) [ I 61 0+7,0]

91 20 (93';) [ I 320°7,0]

BRAKE Page

GENERAL .................................................................... 8-2

SPECIFICATIONS .......................................................... 8-8

COMPONENTS ........................................................... 8-9

FRONT BRAKE .............................................................. 8-14

DISASSEMBLY-INSPECTION-REASSEMBLY (Pn35 . 50 MODEL) ...................................................... 8-14

DISASSEMBLY-INSPECTION-REASSEMBLY (Cu35.45 MODEL) ....................................................... 8-18

DISASSEMBLY-INSPECTION-REASSEMBLY . ................................... . (Pn60 80. Cu55 70 MODEL) 8-22

BRAKE AIR BLEEDING ................................................ 8-26

BRAKING FORCE INSPECTION* ............................................................. ADJUSTMENT 8-26

BRAKE BOOSTER ........................................................ 8-27

TROUBLE SHOOTING ..................................................... 8-27


DISASSEMBLY-INSPECTION-REASSEMBLY .................. 8-28

PARKING BRAKE INSPECTION* ............................................................. ADJUSTMENT 8-31

BRAKE PEDAL lNSPECTlON*ADJUSTMENT ....... 8-32

INCHING PEDAL INSPECTION*ADJUSTMENT .... 8-33

SINGLE BRAKE PEDAL INSPECTION* ADJUSTMENT (1 -PEDAL: OPT) ............................ 8-34

8-2

GENERAL Hydraulic Circuit Diagram

(1 ) Inching pedal (2) Brake pedal (3) Brake master cylinder (Brake booster) (4) Brake wheel cylinder (5) Oil tank (6) Oil pump (7) Flow divider (8) Oil control valve (9) Lift cylinder (1 0) Tilt cylinder (1 1 ) Steering valve (1 2) Power steering cylinder (1 3) Hydraulic oil cooler *

*: The oil cooler is specified as option for Pn35 - 50 with 132 engine.

Front Brake

Pn35.40, Cu35-45 model

Pn45 model

Pn50 model

Pn60 - 80 model

Cu55 - 70 model

I I

Wheel Cylinder

Pn35.40 model

Pn60 - 80 model

Pn45.50, Cu35.45 model

Cu55 - 70 model

Cu55 - 70 model A

8-8

Brake Boostor

Master cylinder piston

/ - I Control valve ' ' &action piston

Power piston

SPECIFICATIONS

Cu55 - 70 Cu35.45 Pn4.5-50 Pn60 - 80

Foot brake type

Parking brake type

Brake drum inside diameter mm (in)

Brake lining material

Brake lining dimensions Thickness x width x length mm (in)

Wheel cylinder bore mm (in)

Hydraulic internal expanding duo servo brake

Internal expanding mechanical brake

31 7.5 (1 2.50)

Resin mold (asbestos-free)

~~~k~ booster

Applicable oil

Master cylinder piston

9 . 3 ~ 6 0 ~ 3 4 3 (0.37~2.36~13.50)

10.0~100~324 (0.39~3.94~12.75)

9 . 3 ~ 6 0 ~ 3 4 3 (0.37~2.36~13.50)

Diameter mm (in)

Full stroke mm (in)

10 .0~63~332 (0.39~2.48~13.07)

9 . 3 ~ 7 5 ~ 3 4 3 (0.37~2.95~13.50)

Maximum servo pressure (power relief pressure)

kPa (kgf/cm2) [psi]

31.75 (1.25)

25.4 (1 .OO)

28 (1 . lo)

0790 0) [ I 5641 12750 (1 30) [ I 8491

Hydraulic oil IS0 VG32

COMPONENTS Parking Brake

Pn35 - 50 model A AT

Cu35-45 model

model A AT

Brake Booster

Brake Pipe

Cu35.45 model

)rum Brake

Ol[RH] 471 5

Pn35 - 50 model 02[LHl I

Pn60 - 80, Cu55 - 70 model 471 5

01 (RH) 02(LH)

r m m m I m m m q 8 m r - 1 8 w w I lOK=(INCL.@) : 8

I

8 8 I

L l l l ' -1111)

9451 2-00800 /

I

471 5-1 03

FRONT BRAKE DISASSEMBLY*INSPECTION*REASSEMBLY (Pn35 - 50 MODEL) T = N-m (kgf-cm) [ft-lbf]


1 Remove the front wheel.

2 Remove the brake drum. [Point 11

3 Remove the shoe return spring. [Point 21

4 Remove the shoe hold down spring. [Point 31

5 Remove the brake shoe adjuster. [Point 41

6 Remove the brake shoe. [Point 51

7 Disassemble the brake shoe (secondary). [Point 61

8 Remove the wheel cylinder. [Point 71

9 Disassemble the wheel cylinder.


11 Remove the actuator lever. [Point 81

12 Remove the parking brake lever ASSY. [Point 91

13 Disassemble the parking brake lever ASSY.



Note: See that the brake lining and brake drum interior surface are free from grease or oil before installation. Before reassembly, decrease the brake drum outside diameter for installation to approx. 1 mm (0.04 in) less than the drum inside diameter by tightening the adjusting screw. After reassembly, perform brake air bleeding (see page 8-26) and braking force inspection (see page 8-26).

Point Operations

[Point I] Disassembly:

Use two service bolts for removal. Service bolt size: M I 4 x 1 -5

Inspection: Measure the brake drum inside diameter.

Standard: 31 7.5 mm (1 2.50 in) Limit: 319.5 mm (12.58 in)


Connect a wire at the spring hook portion and use a screwdriver for removal. (Reference) Use the SST (for shoe return spring) if the brake ASSY has been removed. SST 0971 7-2001 0

Inspection: Measure the free length of the spring.

Limit: No clearance between coil turns.

Reassembly: SST 0971 8-2001 0


SST 0951 0-31 960-71

Inspection: Measure the free length of the shoe hold down springs.

Standard: Upper spring 25.4 mm (1 .OO in) Center spring 43.7 mm (1.72 in) Lower spring 27.8 mm (1.09 in)


Apply grease on the illustrated portion of the brake shoe adjuster.


Measure the brake lining thickness.

Standard: 9.3 mm (0.36 in) Limit: 4.3 mm (0.17 in) (Each dimension does not include the rim thickness.)

Reassembly: Apply grease on the brake shoe rim and backing plate sliding contact portion before reassembly.


Apply grease on the illustrated portion of the adjuster lever link.


Apply locking agent (08833-00070) on the threaded portion of the set bolts before reassembly.


Install the actuator lever.

1. Apply grease to the spline and lever sliding contact portion.

2. Align the match marks for installation.


Apply grease on two parking brake lever shaft portions.

DISASSEMBLY-INSPECTION-REASSEMBLY (Cu35-45 MODEL) T = N-m (kgf-cm) [ft-Ibf]



2 Remove the front axle hub Wlbrake drum. (See page 5-17.) [Point 11





7 Disassemble the brake shoe (secondary). [Point 61

8 Remove the wheel cylinder. [Point 71



11 Remove the actuator lever. [Point 81

12 Remove the parking brake lever ASSY. [Point 91

13 Disassemble the parking brake lever ASSY.



Note: See that the brake lining and brake drum interior surface are free from grease or oil before installation. Before reassembly, decrease the brake drum outside diameter for installation to approx. 1 mm (0.04 in) less than-the drum inside diameter by tightening the adjusting screw. After reassembly, perform brake air bleeding (see page 8-26) and braking force inspection (see page 8-26).

Point Operations

[Point 11

Inspection: Measure the brake drum inside diameter.



SST 0971 7-2001 0





SST 0951 0-31 960-71


Standard: Upper spring 25.4 mm (1 .OO in) Center spring 43.7 mm (1 -72 in) Lower spring 27.8 mm (1 -09 in)


Apply grease on the illustrated portion of the brake shoe adjuster.



Standard: 9.3 mm (0.36 in) Limit: 4.3 mm (0.17 in) (Each dimension does not include the rim thickness.)



Apply grease on the illustrated portion of the adjuster lever link.


Apply locking agent (08833-00070) on the threaded portion of the set bolts before reassembly.


Install the actuator lever

1. Apply grease to the spline and lever sliding contact portion.

2. Align the match marks for installation.


Apply grease on two parking brake lever shaft portions.

DlSASSEMBLY*INSPECTION-REASSEMBLY (Pn60 - 80, Cu55 - 70 MODEL) T = N-m (kgf-cm) [ft-lbf]

9-

i

G 9 \

5

6



2 Remove the front axle hub Wlbrake drum. (See page 5-1 7.) [Point 11



5 Remove the adjuster lever, link and spring.




9 Remove the wheel cylinder.




Note: See that the brake lining and brake drum interior surface are free from grease or oil before installation. Before reassembly, decrease the brake drum outside diameter for installation to approx. 1 mm (0.04 in) less than the drum inside diameter by tightening the adjusting screw. After reassembly, perform brake air bleeding (see page 8-26) and braking force inspection (see page 8-26).

Front C

D > d

Point Operations


Measure the brake drum inside diameter.



SST 0971 7-2001 0

Reassembly : Pn60 - 80 model Pay attention to the mounting position of the shoe return spring. The end of the spring greater in diameter shall be on the front side.





SST 0951 0-31 960-71


Standard: 29.2 mm (1.15 in)


Inspect if the adjusting screw rotates smoothly.

Reassembly: Apply grease on the threaded portion of the brake shoe adjuster.



Standard: A = 10.0 mm (0.39 in) Limit: B = 1.0 mm (0.039 in)


Reassembly: Apply grease on the illustrated portion of the brake shoe.

BRAKE AIR BLEEDING

Note: Perform air bleeding by two operators.

1. Start the engine. 2. Loosen the wheel cylinder breather plug with the brake

pedal kept depressed. 3. Tighten the breather plug when no air bubble is seen in

the discharged hydraulic oil.

BRAKING FORCE INSPECTION-ADJUSTMENT

1. lnspect the braking force with a brake tester or by running test. Braking distance (at no load)

Initial speed of braking: Max. speed Stopping distance: 5.0 m (16.4 ft) or less

2. Adjust the braking force. (1) Repeat traveling in the forward and reverse direction to adjust the brake shoe clearance.

When the brake pedal is depressed in reverse traveling, the adjusting screw performs automatic adjustment.

(2) If the braking force is insufficient, adjuster malfunction, lining contact defect, foreign matter adhe- sion on brake lining or leaking brake fluid may be the reason. lnspect by removing 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.

BRAKE BOOSTER

TROUBLESHOOTING

I I . Damaged O-ring for reaction piston 1 Replacement I

Phenomenon

I I

I Continuous spool holding by loosening I Adjustment 1

Estimated cause

Oil leak from hydraulic piping or insufficient oil level in tank

Poor braking performance

I Brake dragging I of clevis lock nut I I

Corrective action

Repair or replacement

Foreign matter trapping by piston

Increases play by loosened clevis lock nut

Air entrance in wheel cylinder circuit

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

Cleaning or correction

Clevis adjustment

Air bleeding

Foreign matter trapping by spool

Removal Procedure



3 Disconnect the brake booster piping.

4 Remove the push rod clevis pin.

Cleaning or correction

5 Remove the brake booster.



Note: When setting the brake booster on a vise, carefully operate so as not to damage the piping joint.


1 Remove the push rod and boot.

2 Remove the reaction piston & power piston. [Point 11

3 Remove the master cylinder pistion. [Point 21

4 Remove the flow divider spool.

5 Remove the outlet check valve.

6 Remove the check ball.

7 Separate the reaction piston & power piston. [Point 31

8 Disassemble the reaction piston. [Point 41

9 Disassemble the power piston. [Point 51



Note: Wash each part in new hydraulic oil, dry it by blowing compressed air and apply hydraulic oil at the time of installation. Apply silicone grease on the cylinder cup at the time of installation.

Point Operations


Check smooth movement of the reaction pistion & power piston after reassembly.


Master cylinder piston removal

1. Remove the plug and gasket.

2. Drop the pin while holding the master cylinder piston with a screwdriver wrapped with waste cloth at the tip end. Carefully operate so as not to damage the inside.

3. Remove the master cylinder piston and return spring.

Inspection: Inspect the master cylinder piston for wear at the sliding contact surface.

Limit: 0.032 mm (0.0013 in) (Diametrical clearance)

Reassembly: Master cylinder piston installation

1. Insert the master cylinder piston and return spring slowly by pushing with a screwdriver wrapped with waste cloth at the tip end. Before installation align the piston slit and pin hole directions. Carefully operate so as not to damage the cylinder bore.

2. Check the piston slit through the pin hole and install the pin securely.

3. Install the gasket and plug.


Apply silicone grease to both cylinder cups.

Reassembly: Check the reaction piston guide mounting direction.

[Point 41

Disassembly: While pushing the control valve seat with a round bar, remove the pin by pushing with a wire.

Reassembly: Reaction piston installation

1. Align the piston pin hole and valve seat pin hole directions before insertion.

2. Insert the control valve seat slowly by pushing with a round bar.

3. Check the valve seat oil hole through the piston pin hole and install the pin so as not to protrude from the outer circumference.

[Point 51

Inspection: Inspect the power piston sliding surface for wear.

Limit: 0.032 mm (0.001 3 in) (Diametrical clearance)

PARKING BRAKE INSPECTION* ADJUSTMENT 1. Check the parking brake cable set position.

Standard: A = 3 - 5 mm (0.12 - 0.20 in)

2. Apply chassis grease on the portions indicated by ar- rows.

3. Inspect and adjust the parking brake lever operating force.

(1) Set a spring scale at the center of the lever knob, and measure the operating force by pulling it backward.

Standard: Pn35 - 45, Pn60.70, Cu35 - 70 model

196 - 245 N (20 - 25 kgf) [44 - 55 Ibf] Pn50, Pn80 model

245 - 294 N (25 - 30 kgf) [55 - 66 Ibf]

(2) If the operating force is out of the standard range, release the parking brake and make adjustment at the adjusting portion.

Clockwise turn: Increases the operating force. Counterclockwise turn: Decreases the operating force.

BRAKE PEDAL INSPECTION*ADJUSTMENT

Stop lamp switch

Stopper bolt protrusion

Brake booster

Toe board

1. lnspect brake pedal height A. (From toe board to top of pedal)

Standard: A = 150 - 155 mm (5.91 - 6.10 in) (with pedal pad)

If the standard is not satisfied, make adjustment by changing the stop lamp switch position or the stopper bolt protrusion.

2. lnspect brake pedal play B.

Standard: B = 3 - 7 mm (0.12 - 0.28 in)

If the standard is not satisfied, make adjustment by changing the brak booster push rod length.

3. Check brake booster push rod play C with the brake pedal in the above state.

Standard: C = 1 mm (0.04 in)

4. After the adjustment, fully depress the brake pedal D and inspect the pedal height in that state.

Standard: D = 90 mm (3.54 in) or more

INCHING PEDAL INSPECTION-ADJUSTMENT

Adjusting nuts

Adjusting nuts

1. lnspect and adjust the brake pedal height and play (See page 8-32).

2. lnspect stroke A of the inching pedal until interlocking with the brake (pedal stroke until the inching pedal plate comes into contact with the brake link).

Standard: A = 26 - 32 mm (1.02 - 1.26 in)

If the standard is not satisfied, adjust the stopper bolt protrusion. Make adjustment to make the deviation from the brake pedal height within + 15 mm (0.59 in).

3. lnspect and adjust the inching cable.

(1) lnspect the inching cable length B on the pedal side.

Standard: B = 17.5 mm (0.689 in)

If the standard is not satisfied, make adjustment by turning the adjusting nuts on the pedal side.

(2) lnspect inching pedal play C until the torque converter inching valve spool starts to move.

Standard: C = 1 - 3 mm (0.04 - 0.12 in)

If the standard is not satisfied, make adjustment by turning the adjusting nuts on the torque converter side.

SINGLE BRAKE PEDAL INSPECTION*ADJUSTMENT (1 -PEDAL: OPT)

Apply locking agent (08833-00070)

Adjusting nuts

Y Adjusting nuts

1. Make adjustment by turning the adjusting bolt so that @ comes into contact with @ , and @ into @ , at the same time when the pedal is depressed.

2. lnspect and adjust the brake pedal height. (See page 8-32)

3. lnspect stroke A of the pedal until interlocking with the brake (pedal stroke until the pedal plate and bolt head comes into contact with the brake link).

Standard: A = 26 - 32 mm (1 -02 - 1.26 in)

If the standard is not satisfied, adjust the stop lamp switch or stopper bolt protrusion. 4. lnspect and adjust the inching cable.

(1) lnspect the inching cable length B on the pedal side.

Standard: B = 17.5 mm (0.689 in)

If the standard is not satisfied, make adjustment by turning the adjusting nuts on the pedal side.

(2) lnspect inching pedal play C until the torque converter inching valve spool starts to move.

Standard: C = 1 - 3 mm (0.04 - 0.12 in)

If the standard is not satisfied, make adjustment by turning the adjusting nuts on the torque converter side.

BODY Page

..................................................... COMPONENTS 9-2

....................................................... COUNTERWEIGHT 9-6


DRIVER'S SEAT (ORS WIFULL SUSPENSION SEAT: OPT) .................................................................. 9-7

SEATBELT ..................................................................... 9-11

INSTALLATION (STD SEAT) ............................................. 9-11

REMOVAL-INSTALLATION (ORS WIFULL SUSPENSION ............................................................................ SEAT) 9-11

SEATBELT RETRACTOR INSPECTION ........................... 9-12

............................................... COMBINATION METER 9-13


COMBINATION SWITCH .............................................. 9-14

.................................................................... INSPECTION 9-14

FUEL SENDER GAUGE ............................................... 9-15

.................................................................... INSPECTION 9-15

RELAY BLOCK ............................................................... 9-16

RELAY INSPECTION .................................................... 9-16

PORTIONS PROTECTED BY FUSES ............................... 9-17

COMPONENTS

cc &-BG 5308

26

BG 4 01

1

I 8

L... ... J

E A 5308-213

87

f "' I ---I 5701

79

. ---J

5701-212

5401-248 Caution:

Renew all the warning and caution indicators or labels when replacing the overhead guard. Overhead guard set bolts tightening torque T = 58.8 - 88.3 N-m (600 - 900 kgf-cm) 143.4 - 65.1 ft-lbfl

COUNTERWEIGHT REMOVAL-INSTALLATION

Removal Procedure


2 Remove the weight cap and temporarily hoist the counterweight using a wire rope.

3 Remove the drawbar and remove the counterweight set bolts.

4 Remove the counterweight.



Note: See page 0-15 for the weight of the counterweight.

DRIVER'S SEAT (ORS WlFULL SUSPENSION SEAT: OPT)


1 Turn the suspension adjuster knob counterclockwise until the suspension control cable is loosened.

2 Remove the reclining control lever and suspension adjuster knob. [Point 11

3 Remove the magazine pocket. [Point 21

4 Remove the pocket.

5 Remove the backboard.

6 Remove the seat back.

7 Remove the reclining adjuster. [Point 31

8 Remove the seat track handle. [Point 41

9 Remove the suspension indicator. [Point 51

10 Remove the shield.

11 Remove the suspension control shaft.

12 Remove the plate, spring, trim and cushion ASSY.

13 Remove the seatbelt buckle, retractor and bezel. (See steps 3,4 and 5 on page 9-1 1)

14 Remove the frame.

15 Remove the torsion bar.

16 Remove the torsion bar stopper.

17 Remove the shock absorber ASSY.

18 Remove the suspension frame.

19 Remove the suspension control cable. [Point 61



Note: Apply a small amount of chassis grease on the suspension link portion, torsion bar stopper movable portion, torsion bar clamp portion, and suspension adjuster gear and shaft portion before installation. Apply thread tightener (08833-00080) on the threaded portion of the reclining adjuster set bolt before tightening.

Suspension Reclining control lever

Free

QF

Point Operations

[Point I ] Reassembly:

Install a clip on each of the reclining control lever and suspension adjuster knob and press them in after matching with the shaft spline. After installation, check to see that they will not come off.

Reassembly: Install the reclining control lever almost in parallel with the seatbelt buckle end face.


Remove the magazine pocket. 1. Force the center pin in to free the clip for removal.

2. Unhook the lower part of the magazine pocket for removal.

Reassembly: Install the magazine pocket. 1. Fit the hook in the lower part of the magazine pocket to

be locked in position.

Lock

2. Pull the center pin out to the free position and insert it to the locked position after installation.


Install the reclining adjuster in the illustrated direction.


Remove the seat track handle by pulling it forward while unhooking it.

Reassembly: See that the hook to lock the handle securely catches the spring.


Remove the suspension indicator. 1. Use a screwdriver to remove the shaft. 2. Remove the indicator while paying attention to the shape

of the hook portion.


Install the stopper screw while holding it so as not to damage the wire.

SEATBELT INSTALLATION (STD SEAT)

1. Install the seat belt with its angle as illustrated. T = 17.6 - 20.6 N-m (1 80 - 21 0 kgf-cm)

[ I 3.0 - 15.2 ft-lbf]

REMOVAL-INSTALLATION (ORS WIFULL SUSPENSION SEAT)

Note: Never try to disassemble the seatbelt retractor. T = Nom (kgf-cm) [ft-lbf]

Removal Procedure

1 Remove the driver's seat. 2 Remove the shield set screws. 3 Remove the seatbelt buckle. [Point 11 4 Remove the seatbelt retractor. [Point 21 5 Remove the seatbelt bezel [Point 31



Point Operations

[Point 11 Removal:

After tightening the seatbelt buckle set bolt, check to see that the buckle moves in the bolt circumferential direction.


See that the seatbelt retractor positioning pin fits in the stopper.

[Point 31 Removal:

Unhook from the inside of the seat.

Installation: After setting the outer hook, push the inner hook in.

SEATBELT RETRACTOR INSPECTION 1. The installed seatbelt should be able to be pulled out

smoothly, and be retracted smoothly. Also check to see it is locked when pulled out suddenly.

2. Apply the seatbelt. Travel straight at a high speed, and apply the brake suddenly. See that the belt is locked to retain the body.

Caution: Test this function in a place where safety can be ensured.

COMBINATION METER

1 Remove the combination meter cover.

2 Remove the combination meter set bolts.

3 Disconnect the combination meter wiring. [Point 11

4 Remove the combination meter ASSY.



Combination meter

F NG: Upward loop \:::,: OK: Down ward loop

Point Operations


The combination meter wiring must form downward loop. When the combination meter wiring is looped upward, moist on the harness, or water droplet may permeate into the connector.

COMBINATION SWITCH Note: See page 2-36 for the direction switch inspection.

INSPECTION

Turn signal switch Light switch

H

OFF,

Light & turn signal switch

1. Individual switch continuity inspection

-

FUEL SENDER GAUGE INSPECTION

1. Measure the resistance. (1) Check to see if the float moves smoothly. (2) Measure the resistance between the sender positive terminal and sender negative (body ground)

terminal while the float position is varied between F and E. Also check if the resistance varies continuously

Note: Measure in the direction of float movement from F to E. The resistance at each of F and E points shall be measured when the arm is in contact with the respective stopper.

Standard

--

E

Resistance R

3 + 2

32.5

Float position mm (in)

Pn35 - 80, Cu55 - 70 model

Cu35.45 model

11 8.9 + 8 (4.681 + 0.31)

141.3 + 8 (5.563 + 0.31)

299.2 (1 1.780)

291.8 (1 1.488)

F

112 (Reference value)

Pn35 - 80, Cu55 - 70 model

Cu35-45 model

Pn35 - 80, Cu55 - 70 model

Cu35.45 model

457.2 f 8 (1 8.000 + 0.31)

423.5 f 8 (1 6.673 + 0.31) 110+7

9-1 6

RELAY BLOCK

Layout Front

0

Front

RELAY INSPECTION

Individual Relay Continuity Inspection Headitail relay

5-0-3

1 m 2

ST relay

Measurement state

1 H C - 2

3-4

SAS-Lamp relay 4

3

1 m 2

-- - - -

PORTIONS PROTECTED BY FUSES

Including options

Fusible links

NO

@

0

@

@

@

@

@

@

@

@

@

@

@

63

@

@

@

Screw-fastened type

Name

FUEL

-

ST (Starting motor)

SFT(Shift)

SAS-ECU

IGN (Ignition)

TURN (Turn)

GAUGE (Meter)

-

-

HORN (Horn)

ALT-S (Alternator sending)

HEAD (Headlamp)

-

TAIL (Tail)

TWC

STOP (Stop lamp)

Capacity

7.5A

7.5A

7.5A

7.5A

7.5A

7.5A

10A

-

-

7.5A

5A

15A

-

7.5A

7.5A

7.5A

Main protected portions

Fuel solenoid

-

Starting motor relay (IG) and pre-heating timer (IG)

Electric shift TIC

SAS controller and SAS warning lamp relay

Alternator, pre-heating timer, ignition coil, LPG main solenoid, LPG slow solenoid and fuel cut

Turn signal lamp and flasher relay

Hour meter, water temperature gauge, fuel gauge, warning lamps (charge, engine oil pressure, air cleaner, lock indicator, sedimenter, glow indicator, fuel, brake, cooling water and battery), back-up buzzer, TIC oil thermometer, strobo, back-up lamp and SAS buzzer

-

Horn

Alternator sending

Headlamp and meter illumination

Tail lamp and clearance lamp

TWC (three way catalytic) controller

Stop lamp

MATERIAL HANDLING SYSTEM Page

HYDRAULIC CIRCUIT DIAGRAM ............................... 10-2

COMPONENTS .............................................................. 10-3

RETURN FILTER*SUCTION FILTER ........................ 10-12

............................................... REMOVAL.INSTALLATION 10-1 2

NATURAL DROP TEST ............................................... 10-1 3

NATURAL FORWARD TILT TEST ............................. 10-1 3

OIL LEAK TEST ............................................................. 10-14

............................................................... LIFT CY LINDER 10-1 4

TILT CYLINDER ............................................................... 10-14

HYDRAULIC CIRCUIT DIAGRAM

(1 ) Inching pedal (9) Lift cylinder (2) Brake pedal (1 0) Tilt cylinder (3) Brake master cylinder (Brake booster) (1 1 ) Steering valve (4) Brake wheel cylinder (1 2) Power steering cylinder (5) Oil tank (1 3) Hydraulic oil cooler * (6) Oil pump (7) Flow divider *: The oil cooler is specified as Option for Pn35 - 50 with 132 (8) Oil control valve

engine.

COMPONENTS 135 - 50 model

(OIL FULL) (OIL FULL)

Cu35 - 55 model 6801

EL 6801 -454A

Cu60 70 model (OIL FULL)

(OIL FULL)

6801-455A

Hydraulic oil cooler

91651-40825

Cu55 model 6801

6801-467

Cu60 70 model

6801-468

10-8

V Mast

Pn35 - 50 model Pn60 - 80, Cu55 - 70 model 6801

NW NW

6801-392 r 6801-456

Cu35 45 model

NW

6801-457

FV Mast

Pn35 - 45 model Cu35 45 model 6801

6801-395 6801-450

FSV Mast

Pn35 - 50 model Cu35 - 70 model 6801

NW NW

NW NW

EU 6801-458 6801 -459A

10-1 0

FV Mast

FSV Mast

All the models of FV 6802

3jfrr

91651-41020

bY@ m 4 8

6802-477

Pn35 40, Cu35 model Pn45 50 model 6802

6802-475 6802-476 -

10-1 2

RETURN FILTER-SUCTION FILTER REMOVAL.INSTALLATION T = N-m (kgf-cm) [ft-lbf]

Removal Procedure

1 Open the engine hood.

2 Drain hydraulic oil.

3 Disconnect the return hose and overflow hose.

4 Remove the tank cover Wlreturn filter.

5 Remove the return filter.

6 Disconnect the suction hose.

7 Remove the suction filter cover.

8 Remove the suction filter.



NATURAL DROP TEST 1. Set the mast in the vertical position with the standard

load on the fork. Lift the fork by 1 to 1.5 m (40 to 59 in), and stop the engine.

2. Draw datum lines on the inner and outer masts, and measure the drop in 15 minutes.

Limit 45 mm (1.77 in)

NATURAL FORWARD TILT TEST 1. Set the mast in the vertical position with standard load

on the fork. Lift the fork by about 50 cm (1 9.7 in) and stop the engine.

2. Measure the tilt cylinder rod extension in 15 minutes.

Limit 25 mm (0.98 in)

OIL LEAK TEST

LIFT CYLINDER

1. Set the mast in the vertical position with the standard load on the fork. Lift the fork by 1 to 1.5 m (40 to 59 in).

2. Slowly tilt the mast fully forward, and stop the engine. After 5 minutes, disconnect the oil control valve to oil tank hose. Place a measuring cylinder under the elbow and measure the amount of oil leaking in one minute.

Standard (at lift port) 8 cm3 (0.49 in3) or less

Note: If the natural drop is great even though the oil leak amount is within the standard, the lift cylinder packing is defective.

TILT CYLINDER

1. Set the mast in the vertical position with standard load on the fork. Lift the fork by about 50 cm (19.7 in) and stop the engine.

2. After waiting for 5 minutes, disconnect the oil control valve to oil tank hose. Place a measuring cylinder under the elbow and measure the amount of oil leaking in one minute.

Standard (total for lift and tilt) 16 cm3 (0.98 in3) or less

3. The leak amount at the tilt port is the total leak amount less the leak amount from the lift port.

Note: If the natural forward tilt is great even though the oil leak amount is within the standard, either the tilt lock valve or the tilt cylinder packing is defective.

MAST Page

V MAST ASSY ............................................................... 11-2 COMPONENTS ................................................................ 11-2

.............. REMOVAL*INSTALLATION (WILIFT BRACKET) 11-9

MAST DISASSEMBLY-INSPECTION*REASSEMBLY ........ 11 -11 LlFT BRACKET DISASSEMBLY*INSPECTION*

REASSEMBLY .............................................................. 11 -1 4 ....................................... MAST ADJUSTMENT (V MAST) 11 -1 5

..................... MAST ROLLER REMOVAL*INSTALLATION 11 -21

CHAIN .............................................................................. 11 -22 INSPECTION ................................................................... 11 -22 REASSEMBLY .............................................................. 11 -22 ADJUSTMENT ................................................................. 11 -25

................................................................................. FORK 11-25

REMOVAL .................................................................... 1 1 -25 INSTALLATION ................................................................. 11 -25 INSPECTION .................................................................... 11 -25

.................................................... FV. FSV MAST ASSY 11 -26

COMPONENTS ................................................................ 11 -26 MAST ADJUSTMENT (FV* FSV MAST) ............................. 11 -33

LlFT CYLINDER ROD SHIM ADJUSTMENT ................. (PREVENTION OF UNEVEN LIFTING) 11-44

V MAST ASSY

Pn50 model

Pn35-40, Cu35 model Pn45 model

+

Cu45 model

6301

Cu55 model Pn60 - 80, Cu60.70 model 6301

Pn35-40, Cu35 model Pn45.50, Cu45 model

02 02 + + 02K 02K

r..'-....I I r"'-"-' .

6301-51 8 8 6301-5198

6302

6302-357 6302-

11-6


All the models: T = 86.3 - 129.4

(880 - 1320) [63.7 - 95.481

T = 147.1 - 343.2 (1 500 - 3500) [I 08.5 - 253.21

+

Removal Procedure

1 Set the mast vertical and fully lower the fork.

2 Disconnect the chain. [Point 11

3 Remove the chain wheel. [Point 21

4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift bracket, and slowly run the vehicle backward to depart from the lift bracket.)


6 Disconnect the fork height switch and load sensor wiring.

7 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast, operate the lift lever several times to release the residual pressure in the lift cylinder.)

8 Slightly hoist the mast.

9 Remove the mast support cap. [Point 31

10 Remove the tilt cylinder front pin. [Point 41

11 Remove the mast ASSY



Note: Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior surfaces. Apply MP grease on the tilt cylinder front pin. Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced. (See page 11-44.) Adjust the chain tension after installation. (See page 11-25.) When the mast is replaced, perform SAS re-setting after installation. (SAS spec.) (See section 15.)

Point Operations


Pn35.40, Cu35 model SST 09630-31 720-71

Pn45 -70, Cu45 - 70 model SST 09630-33900-71

Pn80 model SST 09630-3391 0-71

[Point 21 Removal:

If the fitting is hard, use the SST for removal. SST 09950-4001 1

[Point 31 Removal:

Make a match mark. Installation:

Align the match mark.

11-8

[Point 41 Removal:

Put match marks to clarify relative positions of the front pin, stopper plate and lock bolt. Match marks, however, are unnecessary when the mast or mast ASSY is replaced since mast tilt angle adjustment is to be done after the replacement.

Removal: Pn35 - 50, Cu35-45 model SST 0981 0-201 72-71

Pn60 - 80, Cu55 - 70 model SST 0981 0-201 72-71 -----a

09820-31 040-71 -----@I

REMOVAL-INSTALLATION (W/LIFT BRACKET) T = N-m (kgf-cm) [ft-lbf]

8

All the models: T = 86.3 - 129.4

(880 - 1320) 163.7 - 95.481

All the models: T = 147.1 - 343.2

(1500 - 3500) [I 08.5 - 253.21

Removal Procedure

1 Set the mast vertical.

2 Remove the fork. (See page 11 -25.)


4 Disconnect the wiring of the fork height switch and load sensor.

5 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast and operate the lift lever several times to release the residual pressure from the lift cylinder.)

6 Slightly hoist the mast.

7 Remove the mast support cap. [Point I]

8 Remove the tilt cylinder front pin. [Point 21

9 Remove the mast ASSY Wllift bracket.



Note: Apply MP grease on the mast support bushing and mast support cap interior surfaces and on the tilt cylinder front pin. Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced. (See page 11-44.) When the mast is replaced, perform SAS re-setting after installation. (See section 15.)

Point Operation

[Point 11 Removal:

Make a match mark. Installation:

Align the match mark.

[Point 21 Removal:

Put match marks to clarify relative positions of the front pin, stopper plate and lock bolt. Match marks, however, are unnecessary when the mast or mast ASSY is replaced since mast tilt angle adjustment is to be done after the replacement.

Removal: Pn35 - 50, Cu35.45 model SST 0981 0-201 72-71

Pn60 - 80, Cu55 - 70 model SST 0981 0-201 72-71 -----a

09820-31 040-71 -----0

MAST DISASSEMBLY*INSPECTION-REASSEMBLY

Pn35.40, Cu35 model Pn60 - 80, Cu55 - 70 model Pn45-50, Cu45 model

\ 1 L


1 Remove the fork height switch.

2 Disconnect the overflow hose and high pressure hose.

3 Remove each cylinder rod end set bolt, and take each rod end off. [Point 11

4 Remove each cylinder support. [Point 21

5 Remove each cylinder bottom set bolt. (Pn60 - 80, Cu55 - 70 model)

6 Remove each lift cylinder.

7 Slide the inner mast in the lowering direction, and remove the lift rollers.

8 Remove the mast strip. [Point 31

9 Remove the outer mast.



Pn35-40, Cu35 model

Pn35-40, Cu35 model Support

a, 0 C 2 m a, - 0

Cylinder

Pn45-50, Cu45 model

Point Operations

[Point I ] Disassembly:

Shim adjustment has been made at the lift cylinder rod end for prevention of cylinder uneven motion between the left and right sides. Take a note on which side the shim adjustment is made and the number of shims in use.

[Point 21 Pn35.40, Cu35 model Disassembly:

Take a note on the number of cylinder support shims used.

Reassembly: When the mast or cylinder is replaced, make shim adjustment at the cylinder support. With the cylinder rod end inserted to the inner mast, eliminate the clearance between the cylinder support and outer mast by inserting shims. The shim thickness should be slightly thicker.

Reassembly: The supports can be used in either the upper or lower direction. Since a level difference of 5 mm (0.20 in) will arise depending on the direction, install in the direction for less clearance with the cylinder.

Pn60 - 80, Cu55 - 70 model Disassembly:

Take a note on the number of cylinder support shims in use.

Reassembly: Make cylinder support shim adjustment if the mast or either cylinder is replaced. With the cylinder rod end inserted to the inner mast, insert shim(s) between the cylinder support and outer mast to eliminate the clearance. The shim thickness should be slightly greater than the clearance.

Pn45.50, Cu45 model Disassembly:

Take a note on the number of cylinder support shims in use.

Reassembly: Make cylinder support shim adjustment if the mast or either cylinder is replaced. With the cylinder rod end inserted to the inner mast, insert shim(s) between the cylinder support and outer mast to eliminate the clearance. The shim thickness should be slightly greater than the clearance.


Inspect the mast strip for wear.

Limit: Worn to leave no oil sump

11-14

LIFT BRACKET DISASSEMBLY.INSPECTION*REASSEMBLY T = N-m (kgf-cm) [ft-Ibf]


1 Remove lift rollers. [Point 11

2 Remove side rollers.

3 Remove the back rest.



Point Operations


SST 09950-4001 1

MAST ADJUSTMENT (V MAST)

Lift Roller Adjustment at Mast

1. lnner mast roller clearance adjustment

into

I Shims,

Inner mast Oute mast

These rollers

(1) Adjust the mast overlap to approx. 500 mm (19.69 in). (2) Shift the inner mast to one side to bring the roller into

contact with the outer mast, and measure the clearance between the roller side face and mast on the opposite side where they are the closest.

Standard: A = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness. (See page 11- 21 for the mast roller removal and installation.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right side.

(4) After the adjustment, see that the inner mast moves smoothly in the outer mast.

11-16

2. Outer mast roller clearance adjustment

Rrinn into contact 7 I f l

Bring into, contact

Shims

Outer mast

These rollers

A

Inner mast

(1) Adjust the mast overlap to approx. 500 mm (1 9.69 in). (2) Shift the inner mast to one side to bring the roller into

contact with the outer mast, and measure the clearance between the roller side face and mast on the opposite side where they are the closest.

Standard: B = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness. (See page 11 -21 for the mast roller removal and installation.)




3. Roller selection (1) In Pn35, Cu35-45 models, use oversize No. 2 as a rule for the inner mast roller. Use No. 1 only

when the mast inside width (rolling contact surface) is narrow. The roller size may be different between the right and left sides.

Inner mast roller

Outer mast roller

Model

Pn35, Cu35-45

Pn45 - 80, Cu55 - 70

No.

No. 1

No. 2

No. 1

Model

Pn35, CU35-45

Pn45 - 80, Cu55 - 70

Outside diameter mrn (in)

124.5 (4.902)

164.5 (6.476)

Outside diameter

rnm (in)

124.5 (4.902)

125.2 (4.929)

1 64.5 (6.476)

Outer mast inside width

mm (in)

125.0 (4.921 )

165.0 (6.496)

Remarks

-

Oversize

-

Lift Bracket Roller Adjustment

1 . Lift roller and side roller clearance adjustment Pn35-40, Cu35-45 model

100 mm (39 In)

Outer mast

Brlng Into contact

Inner mast L~ft bracket

(1) Measure the clearance when the center of the lift bracket upper side roller is 100 mm (3.9 in) from the top of the inner mast.

(2) The upper lift rollers and the middle lift rollers need no adjustment because they are fixed by snap rings.

(3) Measure the clearances at the middle and lower lift rollers after removing the side rollers. Shift the lift bracket to one side to bring the roller into contact with the inner mast, and measure the clearance between the roller side face and the mast at the closest position on the opposite side to the following value by inserting the lift roller shim.

Standard clearance: C = 0 - 0.5 mm (0 - 0.020 in) Shim thickness:

0.5 and 1.0 mm (0.020 and 0.039 in)

(4) Distribute the shim thickness equally to the left and right sides. (For the shim replacement procedure, see the lift bracket disassembly section on page 11 -21 .)

(5) Install the side rollers.

(6) Adjust the upper side rollers after adjusting the lower lift rollers. Bring the side roller on one side into contact with the mast side surface and make adjustment by changing the side roller shims to make the clearance between the side roller and inner mast side surface on the opposite side satisfy the following standard:

Standard: D = 0 - 0.5 mm (0 - 0.039 in) Shim thickness: 0.5-1.0 mm (0.020-0.039 in)

(7) Distribute shims equally between the side rollers RH and LH.

(8) Adjust the lower side rollers after adjusting the lower lift rollers and upper side rollers. Shift the lift bracket to one side to bring the upper side roller into contact with the mast side surface on that side, and make side roller shim adjustment to make the clearance between the side roller and mast side surface on the opposite side satisfy the following standard:

Standard: D = 0.5 - 1.0 mm (0.020 - 0.039 in) Shim thickness: 0.5-1 -0 mm (0.020.0.039 in)

(9) At the time of adjustment, see that the lift bracket moves smoothly along the entire length of the mast. Check that the side roller does not rotate in contact with the mast side surface. If the side roller rotates in contact, repeat adjustment in step (8) to widen the clearance between the roller and mast side surface so that the lower side roller does not rotate over the entire mast length.

Pn45 - 80, Cu55 - 70 model

(1) Perform measurement where the center of lift bracket upper lift roller is 100 mm (3.94 in) from the top end of the inner mast.

(2) Lift rollers out of lift bracket rollers do not require adjustment because of fastening with snap rings. For side rollers, bring the side roller on one side into contact with the mast side surface, and make side roller shim adjustment to make the clearance between the side roller and mast surface.

Standard: 0 - 0.8 mm (0 - 0.031 in)

(3) After the adjustment, the lift bracket shall move smoothly along the entire length of the mast.

2. Roller selection (1) As a rule, use only middle roller No. 1. (Pn35.40, Cu35 model)

(2) As a rule, use upper and lower rollers No. 2 (oversize). Use No. 1 only when the mast inside width (at rolling contact surface) is narrow. The roller size may be different between the left and right or between the upper and lower sides. (Pn35-40, Cu35 model)

Lift bracket roller list

Vehicle model

Pn35-40, Cu35 model

Cu45 model

No.

No. 1

No. 2

No. 3

No. 4

No. 5

Outside diameter

mm (in)

124.5 (4.902)

125.2 (4.929)

93.3 (3.673)

124.5 (4.902)

93.3 (3.673)

Place used

Lift roller

Lift roller

Side roller

Lift roller

Side roller

Remarks

- Oversize - - -

Mast Strip Adjustment

1. Mast strip clearance adjustment

ihi- Roller

Inner mast

, Bring into contact I Ut--

(1) Lower the inner mast fully. (2) With the inner mast in contact with the outer mast roller,

measure the clearance between the mast strip and inner mast.

Standard: E = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness. (See page 11- 21 for the mast roller removal/installation method.)


(3) After the adjustment, check the mast for smooth movement.

Shims I

C-

MAST ROLLER REMOVAL-INSTALLATION

1. Remove the lift bracket. (See steps 1 to 4 of the mast ASSY removal procedure on page 11 -6.)

2. Jack up the vehicle, and support tires with wooden blocks. Also lock the front and rear tires from rotation.

3. Remove the lift cylinders. (See page 12-1 3.)

4. Remove mast rollers. (1) Remove wooden blocks under the inner mast, and

lower the hoisted inner mast slowly until mast rollers appear.

(2) Support the bottom of the inner mast with wooden blocks.

(3) Remove the inner mast rollers and shims.

(4) Remove the outer mast rollers and shims. 5. The installation procedure is the reverse of the removal

procedure.

CHAIN

INSPECTION 1. Inspect the chain elongation according to the following

procedure: SST 09631 -22000-71

(1) Since the SST measurement line varies with the chain type, set the corresponding line on the chain as illustrated.

(2) Check the number of the chain to be inspected, and check the pin center position. If the pin center is at the arrow mark on the chain gauge, it is the limit.

Chain Link Pitch Standard

Note: Perform measurement without removing the chain from the vehicle. lnspect elongation over the entire chain length since it may be localized.

REASSEMBLY

Note: Assemble in the order of the fixed side and adjusting side. Tighten (or install) in the order of illustrated numbers so as not to twist the chain.

Tightening order & Tightening torque. 1. The chain stud bolt nuts a, @ should be tightened to the specified torque, as shown:

N-m (kgf-cm) [ft-lbf]

Chain No.

80

100

120

TYP

BL834

BL1034

BL1234

Model

Pn35-40, Cu35 model

Pn45 - 70, Cu45 - 70 model

Pn80 model

Pitch mm (in)

25.4 .O)

31.75 (1.2500)

38.1 0 (1.50)

V FV

Outer mast Front cylinder Lift bracket Lift bracket

A

D

B

E

H

98 - 147 (1 000 - 1500) [72 - 1081

167 - 225 (1 700 - 2300) 1123 - 1661

294 - 323 (3000 - 3300) [217 - 2391

Pn35, Cu35

Pn45, Cu45

Pn50, Cu55 Cu55 Pn70, Cu70

Pn80

B

E

98 - 147 (1 000 - 1500) [72 - 1081

167 - 225 (1 700 - 2300) [ I 23 - 1661

98 - 147 (1 000 - 1500) [72 - 1081

167 - 225 (1 700 - 2300) [I23 - 1661

294 - 323 (3000 - 3300) [217 - 2391

A

D

A

98 - 147 (1 000 - 1500) [72 - 1081

167 - 225 (1 700 - 2300) [ I 23 - 1661

2. Tighten the nut @ , or @

Pn35, Cu35

Pn45, Cu45 Pn50 Cu55 Pn70, Cu70

FSV

Lift bracket

B

F

Front cylinder Outer mast

98 - 147 (1 000 - 1500) [72 - 1081

167 - 225 (1 700 - 2300) [217 - 2391

A

D

Inner mast

A

D

98 - 147 (1 000 - 1500) [72 - 1081

167 - 225 (1 700 - 2300) [217 - 2391

C

E

98 - 147 (1 000 - 1500) [72- 1081

167 - 225 (1 700 - 2300) [217 - 2391

-

167 - 225 (1 700 - 2300) [217 - 2391

3. Pn35, Cu35 FSV H3700 - H5500 mm (145 - 216.5 in)

*: Before assemble a piece to the chain, put it through the rod.

A- A

ADJUSTMENT

1. Park the vehicle on a flat ground and set the mast vertical.

2. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting nut.

3. Check to see that the chain tension is equal on the left and right side.

4. Check to see no chain twist.

5. See that the fork height is the standard.

6. With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast is not in contact with the lift bracket.

Inner mast

Note: The stopper shows the instance of the V mast. Depend- ing on the models, the type of- the stopper differs although the principal of the stopper means is the same.

FORK REMOVAL

1. Set the fork at approx. 20 cm (7.9 in) above the ground. 2. Place a wooden block under the knotched portion of the

fork rail. 3. Unlock the fork by lifting the fork stopper pin, and shift

the fork blades, one at a time, to the center. 4. Slowly lower the fork for removal.

INSTALLATION

The installation procedure is the reverse of the removal procedure.

INSPECTION

1. Inspect misalignment of the fork tip ends.

Limit: 10 mm (0.39 in)

If the limit is exceeded, inspect individual fork bend, looseness of fork installation and lift bracket finger bar distor- tion.

FV*FSV MAST ASSY

COMPONENTS

FV : Pn35 - 45, Cu35-45 model 61 01

6101-509A

-

FSV : Pn35.40, Cu35 model FSV : Pn45-50 model

6101-505A 6101-507C

FSV : Cu45 model FSV : Pn60-70, Cu55 - 70 model 61 01

FV : Pn35-40, Cu35 model FV : Pn45 model

6101-506A 61 01-5086

6301 02 02

& + 02K

r...- ..., r'..-'.'.I . . I ' I

[LIBACKRESTI

BG BG I L... - - - A

6301525A 6301-526A

FV : Cu45 model 6301 02 + 02K r...i...q I I I I

BG

6301-527A

FSV : Pn35-40, Cu35 model FSV : Pn45 model 02 02 + + 02K 02K

r...I-....I r...J-'."I I I I I 8 m I

6301-520A 6301 -521A

6301 -522A 6301 -5236

FSV : Cu45 model 02 + 02K

F...A....l I m I

FSV : Pn50 model FSV : Pn60-70, Cu55-70 model 6301 02 02 + + 02K 02K

r..._i ..., . . I I

BG

FV : Pn35-40, Cu35 model 6302

21

6302-379

FV : Pn45, Cu45 model

@AD

BS

6302-380

6302-354A

FSV : Pn35.40. Cu35 model H6000 -' H7000 mm (H236 - H275.5 in)

FSV : Pn45.50, Cu45 model 6302

6302-317A

FSV : Pn60-70, Cu55 - 70 model

b... -... 4 6302-378

1 1-33

MAST ADJUSTMENT (FV-FSV MAST)

Lift Roller Adjustment at Mast (FV)

1. Inner mast roller clearance adjustment

Adjust the mast overlap to approx. 500 mm (1 9.69 in). Shift the inner mast to one side to bring the roller into contact with the outer mast, and measure the clearance between the roller side face and mast where they are the closest.

Standard: A = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness.




- -

2. Outer mast roller clearance adjustment

These rollers

Outer dR mast Inner

mast

Adjust the mast overlap to approx. 500 mm (1 9.69 in). Shift the inner mast to one side to bring the roller into contact with the outer mast, and measure the clearance between the roller side face on the opposite side and mast where they are the closest.

Standard: B = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness.




3. Roller selection (1) In Pn35, Cu35-45 models, use oversize No. 2 as a rule for the inner mast roller. Use No. 1 only

when the mast inside width (rolling contact surface) is narrow. The roller size may be different between the right and left sides.

Inner mast roller

Outer mast roller

Remarks

-

Oversize -

Outer mast inside width

mm (in)

125.0 (4.921 )

165.0 (6.496)

Model

Pn35, Cu35.45

Pn45

Model

Pn35, Cu35-45 model

Pn45 model

Outside diameter mm (in)

124.5 (4.902)

164.5 (6.476)

No.

No. 1

No. 2

No. 1

Outside diameter

mm (in)

124.5 (4.902)

125.2 (4.929)

1 64.5 (6.476)

1 1 -36

Lift Roller Adjustment at Mast (FSV)

1. Pn35-40, Cu35-45 model

0

Bring into contact

ition where the roller is the closest

Bring into contact

sition where the

0

+Outer mast B Middle mast

Inner mast

0 0 0 0

Adjustment sequence The encircled Nos. @ - @ mean the rollers to be adjusted in due order in accordance with the following steps: (1) Adjust the mast overlap to approx. 500 mm (1 9.69 in). (2) Shift the mast to one side to bring the roller into contact with the mast, and measure the clearance

on opposite side between the roller and the mast where they are the closest.

Standard: A = 0 - 0.8 mm (0 - 0.031 in) B = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the mast roller shim thickness.


(3) Distribute shims equally to the rollers on the left and right side. (4) After the adjustment, see that mutual mast movement is smooth.

1 1-38

2. Pn45 - 70, Cu55 - 70 model

0 0 0 0

Bring into contact

ition where the roller is the closest

0

sition where the roller is the closest fl;

t-- Outer mast

Middle mast

0 0 Inner mast

0

*: No adjustment due to snap ring fitting

Adjustment sequence The encircled Nos. @ - @ mean the rollers to be adjusted in due order in accordance with the following steps: (1) Adjust the mast overlap to approx. 500 mm (1 9.69 in). (2) Shift the mast to one side to bring the roller into contact with the mast, and measure the clearance

on opposite side between the roller and the mast where they are the closest.

For lift rollers (@ - 0 ) Standard: A = 0 - 0.8 mm (0.- 0.031 in)

B = 0 - 0.8 mm (0 - 0.031 in)

For side rollers (@) Standard: C = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the mast roller shim thickness.

Shim thickness: For lift rollers (@ - 0 )

0.5 and 1.0 mm (0.020 and 0.039 in)

For side rollers (@) 0.5 and 1.0 mm (0.020 and 0.039 in)

Side roller

(3) Distribute shims equally to the rollers on the left and right sides. (4) After the adjustment, see that mutual mast movement is smooth.

3. Roller selection Inner mast rollers and middle mast lower rollers

In the case of Pn35.40, Cu35eCu45 models, use oversize No. 2 rollers as a rule, and use No. 1 only when the mast inside width (rolling contact surface) is narrow. The roller size may be different between the left and right sides.

Outer mast rollers and middle mast upper rollers

Remarks

-

Oversize

-

Model

Pn35-40, Cu35, Cu45 model

Pn45 - 70, Cu55 - 70 model

Model

Pn35.40, Cu35, Cu45 model

Pn45 - 70, Cu55 - 70 model

Outside diameter

mm (in)

124.5 (4.902)

125.2 (4.929)

1 64.5 (6.476)

No.

No. 1

No. 2

No. 1


124.5 (4.902)

164.5 (6.476)

Mast inside width

mm (in)

125.0 (4.921 )

1 65.0 (6.496)

Lift Bracket Portion LiftJSide Roller Adjustment

1. Pn35-40, Cu35, Cu45 model

FV mast

g z- Lower lift roller Outer mast

Inner mast 1"' 1 Lift bracket

FSV mast

Outer mast

(Position where the Middle mast roller is the closest)

lnner mast

I Lift bracket I (1) Perform adjustment where the lift bracket upper lift roller is 100 mm (3.9 in) from the top end of the

inner mast.

(2) No adjustment is needed for the upper and middle lift rollers since they are fastened by snap rings.

(3) For lower lift rollers, shift the lift bracket to one side to bring the roller on one side into contact with the mast and adjust the clearance between the lift roller and mast on the opposite side,

Standard: D = 0 - 0.5 mm (0 - 0.020 in)

(4) Adjust the upper side rollers after adjusting the lower lift rollers (in step 3 above). Bring the side roller on one side into contact with the mast side surface, and adjust the clearance between the side roller and mast on the opposite side.

Standard: E = 0 - 0.5 mm (0 - 0.020 in)

(5) Adjust lower side rollers after adjusting the lower lift rollers and upper side rollers (in steps 3 and 4). Shift the lift bracket to one side to bring the upper side roller and lower lift roller into contact with the mast, and adjust the clearance between the mast and lower side roller to 0.5 to 1.0 mm (0.02 to 0.04 in). Repeat the same on the opposite side.

(6) After adjustments in steps 3 to 5, the lift bracket shall move smoothly along the entire mast length. See that the lower side roller does not rotate in contact with the mast in this state. If the side roller rotates in contact, repeat step 5 to widen the clearance between the roller and mast to prevent the lower side roller from being rotated in contact along the entire mast length.

2. Pn45 - 80, Cu55 - 70 model

(1) Perform adjustment where the center of the lift bracket upper roller is 100 mm (3.94 in) from the inner mast top end.

(2) Out of lift bracket rollers, lift rollers need no adjustment since they are fastened by snap rings. For side rollers, bring the side roller on one side into contact with the mast, and adjust the clearance between the side roller and mast on the opposite side.

Standard: 0 - 0.8 mm (0 - 0.031 in)

(3) After the adjustment, the lift bracket shall move smoothly along the entire length of the mast.

3. Roller selection Use only No. 1 as middle rollers. (Pn35.40, Cu35 model) As a rule, use No. 2 (oversize) as upper and lower rollers. Use No. 1 only when the mast inside width (rolling contact surface) is narrow. The roller size may be different between the left and right or between the upper and lower sides. (Pn35-40, Cu35 model)

Lift bracket roller list

Remarks

-

Oversize -

-

-

Vehicle model

Pn35-40, Cu35

Cu45

No.

No. 1

No. 2

No. 3

No. 4

No. 5


124.5 (4.902)

125.2 (4.929)

93.3 (3.673)

124.5 (4.902)

93.3 (3.673)

Place used

Lift roller

Lift roller

Side roller

Lift roller

Side roller

Mast Strip Adjustment

1. Mast strip clearance adjustment

FV mast

Bring into contact

F

Bring into contact

FSV mast (Pn45 - 70, Cu55 - 70 model) F

Bring into contact

F

(1) Lower the inner (or middle) mast fully. (2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),

measure the clearance between the mast strip and mast.

Standard: F = 0 - 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness.


(3) After the adjustment, check the mast for smooth movement.

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)

Note: For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left and right side due to tolerances of parts, etc. The inspection and adjustment must be made whenever any of the following parts is replaced: Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner mast SUB-ASSY

Shim

1. Inspection method Slowly raise the inner mast, and observe the stopping states of the left and right cylinder rod at the moment when the inner mast reaches the maximum height.

(1) Normal case Both the left and right rod stop almost simultaneously with almost no shaking of the inner mast.

(2) Abnormal case The rods stop with slight difference and the top of the inner mast shakes at the time of stopping. To correct this, add shims to the cylinder that stops first.

2. Adjustment method (1) Raise the inner mast.

Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer mast.

(2) Remove the set bolt of the cylinder rod end on the side requiring shim adjustment.

(3) Slowly lower the lift cylinder rod and disconnect the cylinder rod end.

(4) Place shims on the cylinder rod end. Slowly raise the cylinder rod end into the inner mast.

(5) Fix the set bolt of the cylinder rod end. (6) Raise the inner mast for reinspection. (7) Repeat the inspection and adjustment until the num-

ber of shims is determined.


CYLINDER Page

LlFT CYLINDER (V) REAR LIFT CYLINDER (FVmFSV) ........................... 12-2

GENERAL ..................................................................... 12-2

............................................................. SPECIFICATIONS 12-8

COMPONENTS .............................................................. 12-9

DISASSEMBLY*INSPECTION*REASSEMBLY (V) ............. 12-1 5

DISASSEMBLY*INSPECTION*REASSEMBLY (FV) ........... 12-1 8

DISASSEMBLY*INSPECTION*REASSEMBLY (FSV) ........ 12-21

FLOW REGULATOR VALVE ....................................... 12-23

............................................... REMOVAL*INSTALLATION 12-24

SAFETY DOWN VALVE .............................................. 12-25

REMOVAL*INSTALLATION ............................................... 12-26

FRONT LIFT CY LINDER (FVoFSV) ........................... 12-27

........................................................................ GENERAL 1 2-27

............................................................. SPECIFICATIONS 1 2-27

................................................................ COMPONENTS 1 2-28

............................................... REMOVAL*INSTALLATION 1 2-30

DISASSEMBLY*INSPECTION*REASSEMBLY .................. 12-31 m TILT CYLINDER .............................................................. 12-33

GENERAL .................................................................... 12-33

............................................................. SPECIFICATIONS 12-33

................................................................ COMPONENTS 1 2-34

MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF UNEVEN TILTING) .......................... 12-39

LlFT CYLINDER (V) *REAR LlFT CYLINDER (FV-FSV) GENERAL

Lift Cylinder (VlPn35-40, Cu35 model)

RH Flow regulator valve

LH

Safety down valve

- -

Lift Cylinder (VICu55 model)

RH

Flow regulator valve

LH Safety down valve

Lift Cylinder (VIPnGO - 80, Cu60-70 model) ,

RH


LH

Safety down valve

Rear Lift Cylinder (FVlPn35-40, Cu35 model)


LH

Safety down valve

Rear Lift Cylinder (FSVlPn35-40, Cu35 model)


LH

Safety down valve

Rear Lift Cylinder (FSVIPn45, Cu45 model)

FIOW regulator valve

Rear Lift Cylinder (FSVlPn60-70, Cu60-70 model)

RH


LH

Rear Lift Cylinder (FSVIPn50 model)

RH


LH

I Safety down valve

Rear Lift Cylinder (FSVICu55 model) -

RH

/ < ' ' - Flow regulator valve

LH

12-8

SPECIFICATIONS

Lift Cylinder (V)

Rear Lift Cylinder (FV)

Rear Lift Cylinder (FSV)

Cu55

t

75 (2.95)

55 (2.1 7)

t

t

Cylinder type

Cylinder bore mm (in)

Piston rod outside diameter mm (in)

Piston seal type

Rod seal type

Pn60 - 80

t

80 (3.15)

55 (2.1 7)

t

t

Pn45 Cu45

t

70 (2.76)

50 (1.97)

t

t

Single- acting

65 (2.56)

50 (1.97)

U packing

U packing

Others

Pn50

t

70 (2.76)

50 (1.97)

c

c

Built-in flow regulator valve (RH) Built-in safety down valve (LH)

Pn50

t

70 (2.76)

50 (1.97)

t

c

model Pn35.40 Cu35

Pn60 Cu60.70

t

80 (3.1 5)

55 (2.1 7)

t

t

Pn45 Cu45

t

70 (2.76)

50 (1.97)

t

t

Cylinder type



Piston seal type

Rod seal type

Others

Cu55

C

75 (2.95)

55 (2.1 7)

c

t

Single- acting

65 (2.56)

50 (1.97)

U packing

U packing

Built-in flow regulator valve (RH) Built-in safety down valve (LH)

COMPONENTS

Lift Cylinder (V)

Pn35-40, Cu35 model 6501

Lm-. -.-A L... ---A

6501-150

Pn45, Cu45 model

...A I.... ..-4

6501-127

Pn50 model 650 1

. I I I L... -1.1 LI.. ...A

6501-1 28

Pn60 - 80, Cu55 - 70 model

9161 1-41045

Ol[RH] I ...q

-AG*

01 K

. . I . I .

L... ... A L...' 1.11

C%--CD &91611-41014 6501-151

12-1 2

Rear Lift Cylinder (FSV)

Pn35-40, Cu35 model Pn45-50, Cu45 model 6503

11 A" -9

02K :

L... -1.4

9451 2-01600

6503-136 6503-137

Pn60-70, Cu55 - 70 model 11

I

@--CE k g 1 6 1 1-41014 6503-138A

Removal Procedure

1 Remove the lift bracket. (See removal procedure steps 1 to 4 in mast removal-installation section on page 11 -6.)

2 Remove the cylinder rod end set bolt.

3 Disconnect the cylinder rod end. [Point 11

4 Remove the front hose cover. (V: Pn60.70, Cu55 - 70 model)

5 Disconnect the hose.

6 Disconnect the load sensor wiring.

7 Remove the lift cylinder support. [Point 21

8 Remove the cylinder bottom set bolt. (Pn60 - 80, Cu55 - 70 model)

9 Remove the lift cylinder ASSY.



Note: Perform the following operations after installing the lift cylinder:

Repeat lifting and lowering to stroke ends without load to bleed the air and to check normal operation. After the operation check, check the hydraulic oil level and add oil if insufficient. Inspect the lift cylinders for uneven movements and make adjustment if necessary. (See the lift cylinder rod shim adjustment section on page 11-44.)

Pn35-40, Cu35 model

\

Point Operations

[Point 11 Removal:

Hoist the inner mast. Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer mast.

Removal: Shim adjustment is made at the lift cylinder rod end to prevent uneven movements of the lift cylinders RH and LH. Take a note on which side the adjustment is made and the number of shims used.


The cylinder support shall be tightened temporarily here and make shim adjustment after rod end connection.

Adjustment: With the rod end connected, insert shims between the cylinder support and outer mast to eliminate the clearance. The shim thickness shall be slightly on the thicker side.

Pn45-50, Cu45 model

'6"

Pn60 - 80, Cu55 - 70 model T = 343.2 - 441.3

T = 343.2 - 441.3 (3500 - 4500)

6

T = 58.8 - 68.6 T = 88.3 - 98.1 (600 - 700) (900 - 1000) [43.4 - 50.71 [65.1 - 72.43


1 Remove the flow regulator valve or safety down valve.

2 Remove the cylinder cover. [Point 11

3 Remove the rod guide.


5 Remove seals on the piston side.

6 Remove the lift cylinder. [Point 31



Note: Apply MP grease -or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.

Point Operations


Pn35 - 50, Cu35 - 45 model SST 09620-1 01 00-71


Measure the piston rod outside diameter

Unit: mm (in)

Inspection: Measure the bend of the piston rod.

Limit: 2.0 mm (0.079 in)


Measure the lift cylinder bore.

Unit: mm (in)

Limit Standard Mast Model

DISASSEMBLY*INSPECTION*REASSEMBLY (FV) T = N-m (kgf-cm) [ft-Ibf] I


1 Remove the flow regulator value or safety down value.

2 Remove the cylinder cover. [Point 11



5 Remove the wear ring.


7 Remove the bleed screw.



Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening. Upon completing the installation of the FV rear lift cylinder, perform air bleeding in the following sequence: (1) Extend the FV rear lift cylinder. (2) Stop the engine. (3) Loosen the bleed screw by the time oil will come out and tighten the bleed screw again.

Point Operations

[Point 11 Disassembly~Reassembly:

SST 09620-1 01 00-71


Measure the piston rod outside diameter.

Unit: mm (in)

1 Mast I Model I Standard / Limit I


Limit: 2.0 mm (0.079 in)



Unit: mm (in)

Mast 1 Model I Standard I Limit

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

Pn35.40, Cu35 model = 284 - 421

(2900 - 4300)

Pn45-50, Cu45 model


1 Remove the flow regulator value or safety down value.

2 Remove the cylinder cover.



5 Remove seals on the piston side.

6 Remove the busing.




Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.

Point Operations


Measure the piston rod outside diameter


Unit: mm (in)

Limit: 2.0 mm (0.079 in)



Limit

49.92 (1.9654)

54.91 (2.1618)

Mast

Standard

50 (1.97)

55 (2.17)

Mast

FSV

FSV

Model

Pn35 - 50, Cu35.45

Pn60, Cu55 - 70

Unit: mm (in)

Model

Pn35.40, Cu35

Pn45.50, Cu45

Cu55

Standard

65 (2.56)

70 (2.76)

75 (2.95)

Limit

65.35 (2.5728)

70.35 (2.7697)

75.35 (2.9665)

FLOW REGULATOR VALVE

Lowering Speed Specifications Unit: mmlsec (fpm)

Model

Pn35-40

Pn45

Pn50

Pn60.70

Pn80

Cu35

Cu45

Cu55

Cu60-70

V mast FV mast

Full load

SOO(98)

SOO(98)

SOO(98)

SOO(98)

500(98)

SOO(98)

SOO(98)

500(98)

SOO(98)

FSV mast

Full load

450(89)

400(79)

- - -

450(89)

400(79)

-

-

No load

550(109)

SOO(98)

SOO(98)

470(93)

480(95)

550(109)

500(98)

550(109)

470(93)

Full load

450(89)

400(79)

400(79)

480(95)

-

450(89)

400(79)

500(98)

480(95)

No load

500(98)

400(79)

- -

-

SOO(98)

400(79)

-

-

No load

SOO(98)

400(79)

400(79)

41 O(81)

-

SOO(98)

400(79)

470(93)

41 O(81) I

12-24

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

Pn35 - 50, Cu35-45 model Pn60 - 80, Cu55 - 70 model

T = 88.3 - 98.1 (900 - 1000) 165.1 - 72.41 3

T = 88.3 - 98.1 (900 - 1000) [65.1 - 72.41

Removal Procedure

1 Hoist the inner mast. (Pn35 - 50, Cu35.45 model) [Point 11

2 Fully lower the fork. (Pn60 - 80, Cu55 - 70 model)

3 Remove the flow regulator valve.



Point Operation

[Point I ] Removal:


SAFETY DOWN VALVE

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

I

Removal Procedure

Remove the lift cylinder rod end set bolt. Hoist the inner mast. [Point 11 Remove the lift cylinder (LH) support. Remove the front hose cover. (V: Pn60-70, Cu55 - 70 model) Disconnect the hose. Remove the load sensor cover. Disconnect the load sensor connector and remove the load sensor. Remove the cylinder bottom set bolt. (Pn60 - 80, Cu55 - 70 model) With the lift cylinder (LH) hoisted slightly upward, remove the three-way. Remove the safety down valve.



Point Operation

[Point 11 Removal:


FRONT LIFT CYLINDER (FVoFSV) GENERAL

FV: Pn45-Cu45 model FSV: Pn45-50, Cu45 model

FSV: Pn60 - 70, Cu55 - 70 model

SPECIFICATIONS

Pn60-70 Cu55 - 70

FSV

t

120 (4.72)

t

t

Cu55

FV

t

11 0 (4.33)

t

t

Others

Model & Pn35-45 Cu35

Spec. FV-FSV

Pn45 Cu45

FV

Built-in safety down valve

Cylinder type



Piston rod seal type

Pn45.50 Cu45

FSV

Single-acting

95 (3.74)

70 (2.76)

U packing

t

105 (4.1 3)

t

t

COMPONENTS

Removal Procedure

1 Remove the lift bracket Wlfork.

2 Disconnect the pipng.

3 Remove the front lift cylinder.



Note: After installing the lift cylinder, follow the steps.below. (1) Repeat full-stroke raising and lowering without load to bleed air and check normal function-

ing. (2) Check the hydraulic oil level, and add if insufficient. (3) Adjust the lift chain tension equally on the left and right side.



1 Remove the chain wheel supporter.

2 Remove the cylinder rod guide.


4 Remove the wear ring and U packing.

5 Remove the check valve. [Point 21


7 Remove the safety down valve.

3

v7 T = 107.9 - 127.5 (1 100 - 1300) [79.59 - 94.061

*

FSV

Pn50 - 70, Cu55 - 70 model

FV-FSV

Pn35.40, Cu35 model Pn45-Cu45 model

343.2 - 441.3(3500 - 4500) [253.2-325.63

392 - 490(4000 - 5000)[289.4 - 361.81



Point Operations

Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. Apply sealant (08833-00080) on the threaded portion of the rod guide before tightening. Fill the amount of hydraulic oil specified below into the cylinder from its top before installing the rod guide.


Measure the piston rod outside diameter.

Model

Pn35.40, Cu35

Standard: 70 mm (2.76 in) Limit: 69.91 mm (2.7524 in)

Filling amount cm3 (in3)

140 - 170 (8.54 - 10.4)


Limit: 2.0 mm (0.079 in)

[Point 21 Assembly:

Install the check valve so that the arrow will direct downward of the front lift cylinder.



Unit: mm (in)

I Model I Standard I Limit I

I Cu55 (FSV) 1 11 0 (4.33) 1 110.40 (4.3465) 1 Pn60.70 Cu55 - 70 (FSV)

1 120(4.72) 1 120.40 (4.7402) 1

12-33

TILT CYLINDER GENERAL

SPECIFICATIONS

CU55 - 70, Pn60 - 80

c

100 (3.94)

45 (1.77)

c

c

Pn35 - 50, Cu35 - 45

Cylinder type

Cylinder bore rnrn (in)

Piston rod outside diameter rnrn (in)

Piston seal type

Rod seal type

Double acting type

90 (3.54)

40 (1.57)

U packing

U packing

COMPONENTS

Pn35 - 50, Cu35.45 model (T'LTBOOTS) 651 1

BT 651 1 -226A

I Pn60 - 80, Cu55 - 70 model 01


I

Removal Procedure

Remove the toe board and lower panel.

Remove the instrument panel.

Remove the step.

Remove the side cover.

Remove the fender cover.

Remove the tilt cylinder side cover.

Hoist the mast slightly.

Disconnect the hose.

Disconnect the tilt angle sensor link (RH).

Remove the tilt cylinder front pin. [Point 11

Remove the tilt cylinder rear pin.

Remove the tilt cylinder ASSY.



Note: Apply MP grease on the portions for inserting tilt cylinder front and rear pins before installation. After installation, slowly tilt the mast forward and backward a few times to check normal functioning. Check the hydraulic oil level, and add if insufficient. After installation, perform SAS re-setting. (See section 15.)

[Point 11 Removal:

Put match marks to clarify relative positions of the front pin, stopper plate and lock bolt. Match marks, however, are unnecessary when the mast or mast ASSY is replaced since mast tilt angle adjustment is to be done after the replacement.

Removal: Pn35 - 50, Cu35-45 model

SST 0981 0-201 72-71

Pn60 - 80, Cu55 - 70 model SST 0981 0-201 72-71 ----- @

09820-31 040-71 ----- 0

DISASSEMBLY-INSPECTION*REASSEMBLY T = N-m (kgf-cm) [ft-lbf]

Pn35 - 50, Cu35-45 model Pn60 - 80, Cu55 - 70 model

T = 343.2 - 441.3

- 245.2 - 343.2


1 Loosen the rod guide. [Point 11

2 Extract the piston rod Wlpiston.

3 Remove the tilt cylinder. [Point 21

4 Remove the bushing. [Point 31

5 Remove the piston.





Note: Apply MP grease or hydraulic oil on the packing, 0-ring,and dust seal lip portion. Apply sealant (08833-00080) on the threaded portion of the rod guide before reassembly.

Point Operations

[Point 11 Disassembly~Reassembly:

SST 09620-1 01 00-71


Measure the cylinder bore. Pn35 - 50, Cu35.45 model Standard: 90.0 mm (3.543 in) Limit: 90.40 mm (3.5591 in)

Pn60 - 80, Cu55 - 70 model Standard: 100.0 mm (3.937 in) Limit: 100.40 mm (3.9528 in)


SST 09950-6001 0 --- @ 09950-7001 0 --- @


Measure the piston rod outside diameter. Pn35 - 50, Cu35 - 45 model Standard: 40.0 mm (1.575 in) Limit: 39.92 mm (1.5717 in)

Pn60 - 80, Cu55 - 70 model Standard: 45.0 mm (1.772 in) Limit: 44.92 mm (1.7685 in)


Limit: 1.0 mm (0.039 in)

MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF UNEVEN TILTING)

Note: Adjust the mast forward and backward tilting angles (to prevent uneven tilting) when the tilt cylinder and mast ASSY are replaced or overhauled. After adjustment, perform SAS re-setting. (SAS spec.) (See section 15.)

1. With the mast in the neutral position, install the stopper with the tilt cylinder pin eccentric direction on the lower side.

2. Inspect the forward and backward tilting angles and unevenness in tilting at the pin position above.

Standard: Mast forward tilting angle: Standard set angle -0.6" - +1.6" Mast backward tilting angle: Standard set angle -0.8" - +0.6" Unevenness: 1 mm (0.04 in) or less

3. If the standard is not satisfied, make adjustment by changing the combination among eight types (two tapped holes in the mast side tilt bracket, two holes in pin fixing plate and front and rear sides of the plate). (The joint center axis is shifted by + 5 mm (0.20 in) when the eccentric pin is rotated.)

4. After the adjustment, tighten the stopper set bolt to lock the front pin.

OIL PUMP Page

........................................................................ GENERAL 13-2

.......................................................... SPECIFICATIONS 13-3

.............................................................. COMPONENTS 13-4

OIL PUMP ASSY ............................................................ 13-6

............................................... REMOVAL*INSTALLATION 13-6

................... DISASSEMBLY-INSPECTlON*REASSEMBLY 13-7

PERFORMANCE TEST ................................................ 13-11

............................................ OIL PUMP DRIVE SHAFT 13-12

............................................... REMOVAL-INSTALLATION 13-1 2

DISASSEMBLY-INSPECTION-REASSEMBLY ................... 13-1 2

GENERAL Oil Pump

Pn35 - 50, Cu35 - 55 model

Pn60 - 80, Cu60-70 model

13-3

Oil Pump Drive Shaft

GM6-262: Pn35 - 80, Cu55 - 70 model

132: Pn35 - 80 model GM6-262: Cu35-45 model

SPECIFICATIONS IB Pn35 40 Cu35 - 55

Pn45 50 (GM6-262)

Pump Type Dual gear

Manufacturer's model SDYA567

cm3 (in3) 1 rev 1 Sub pump 1 7.0 (0.43) t I t I

Rotational ratio to engine

Pn45.50 (1 3Z)

t

SDYA607

Pn60 - 80 Cu60 70

Triple gear

STYA32277

1 : 1

Theoretical discharge amount / Main pump 55.8 (3.41) 60.0 (3.66) 32.5 (1.98) + 27.4 (1.67)

t t

Pn60 - 80, Cu60-70 model

COMPONENTS

Pn35 - 50, Cu35 - 55 model 6701

13-6

OIL PUMP ASSY REMOVAL-INSTALLATION

Removal procedure

1 Remove the counterweight. (See page 9-6.)

2 Drain hydraulic oil.

3 Remove the oil pump drive shaft. [Point 11

4 Remove the muffler.

5 Remove the fan belt, fan and fan shroud.

6 Disconnect the pump piping.

7 Remove the oil pump Wlhousing.

8 Remove the housing and rear mount.



Note: Apply grease (molybdenum disulfide grease) to the oil pump spline shaft. After installation, adjust the fan belt tension. (see page 1-19.)

Point Operation


Tie the coupling yoke with a wire.

DISASSEMBLY-INSPECTION-REASSEMBLY

Note: Select a clean location for the operation. Wash the disassembled parts after inspecting the contact mark, etc.


Dual gear pump Triple gear pump


Remove the oil pump body. [Point 11

Remove the gear set. [Point 21

Remove the adapter plate. [Point 31

Remove the gear set. [Point 41

Remove the oil pump body. [Point 51

Remove the adapter plate. (triple gear pump only) [Point 31

Remove the gear set. (triple gear pump only) [Point 41

Remove the oil pump body. (triple gear pump only) [Point 51

Remove the oil seal. [Point 61



Note: Wash each part, blow with compressed air and apply hydraulic oil before reassembly. Use new seals.

Point Operations


Punch a match mark on the pump body and mounting flange.

Reassembly: Align the match marks for reassembly.

Inspection: lnspect the contact mark on the body inner surface on the suction side.

Standard Contact mark on approx. 113 of the body inner circumference

Inspection: Measure the depth of any flaw on the body inner surface.

Limit 0.1 mm (0.0039 in)

[point 21 Disassembly:

Put a match mark on the teeth surfaces of the drive and driven gears.

Reassembly: Align the match marks for reassembly.

Inspection: Measure the side plate thickness.

Limit 4.85 mm (0.1 909 in)

Inspection: lnspect the contact mark on the side plate.

Standard Somewhat apparent on the suction side and slight on the discharge side

Match mark

Inspection: Measure the gear shaft diameter.

Limit 33.05 mm (1.301 2 in)


Measure the bushing inside diameter.

Limit Front side (flange side): 24.1 mm (0.949 in) Rear side: 17.1 mm (0.673 in)

Inspection: lnspect the contact mark on the inner sliding contact face. Standard Glossy contact mark on about half on the

suction side


Put a match mark on the teeth of the drive and driven gears.

Reassembly: Align the match marks for reassemply.

Inspection: Measure the side plate thickness.

Limit 2.65 mm (0.1 043 in)

Inspection: lnspect the contact mark on the side plate.

Standard Somewhat apparent mark on the suction side and slight mark on the discharge side

Inspection: Measure the gear shaft diameter.

Limit 46.27 mm (1 -8217 in)

Gear tooth crest

Contact mark

SST


lnspect the contact mark on the body inner face on the suction side.

Standard Contact mark on about 113 of the body inside circumference

Inspection: lnspect the depth of flaw on the body inner face.

Limit 0.05 mm (0.0020 in) [Point 61 Reassembly:

SST 09950-6001 0 ------- @ 09950-7001 0 ------- @

After reassembly, apply a thin coat of MP grease on the oil seal lip portion.

PERFORMANCE TEST As the performance test in servicing of the oil pump, judge the quality by the lifting speed of the lift cylinder by installing the oil pump on the vehicle. Bench test measurements shall be made for strict testing of the performance.

Note: The engine rpm and relief pressure shall be adjusted to satisfy respective standards. (See the engine rpm adjustment procedure on page 1-9, and the relief pressure adjustment procedure on page 14-16, 14-17.)

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 rprn 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

Model

Pn35.40

Pn45

Pn50

Pn60 70

Pn80

Cu35

Cu45

CU55

Cu60 70

Engine

G4 (GM6-262)

132

G4 (GM6-262)

1 32

G4 (GM6-262)

1 32

G4 (GM6-262)

132

G4 (GM6-262)

1 32

G4 (GM6-262)

G4 (GM6-262)

G4 (GM6-262)

G4 (GM6-262)

V mast

Full load

51 0 (1 01)

51 0 (1 01)

440 (87)

480 (95)

440 (87)

480 (95)

41 0 (81)

410(81)

370 (73)

370 (73)

51 0 (1 01)

440 (87)

420 (83)

41 0 (81)

FV mast

No load

550 (1 09)

550 (1 09)

480 (95)

520 (1 02)

480 (95)

520 (1 02)

440 (87)

440(87)

430 (85)

430 (85)

550 (1 09)

480 (95)

440 (87)

440 (87)

Full load

480 (95)

480 (95)

420 (83)

440 (87)

- - - - -

480 (95)

420 (83) - -

FSV mast

No load

520 (1 02)

520 (1 02)

440 (87)

480 (95) - - - - - -

520 (1 02)

440 (87) - -

Full load

480 (95)

480 (95)

420 (83)

440 (87)

420 (83)

440 (87)

410(81)

4 1 0 (81 ) - -

480 (95)

420 (83)

400 (79)

400 (79)

No load

520 (1 02)

520 (1 02)

440 (87)

480 (95)

440 (87)

480 (95)

440(87)

440 (87) - -

520 (1 02)

440 (87)

420 (83)

420 (83)

OIL PUMP DRIVE SHAFT

Note: See the oil pump removal*installation section on page 13-6 for the removal and installation procedures. Fill grease (molybdenum disulfide grease) through the grease fitting.


1 Remove the grease nipple (from the universal joint yoke portion on the oil pump side).

2 Fix the propeller shaft (yoke portion) in a vise.


4 Remove the universal spider set. [Point 11



Point Operations


Remove the universal spider set.

1. Use a brass bar and take the bearing cup out.

2. Fix the removed bearing in the vise and remove by tapping the yoke portion lightly.

3. Remove the universal joint yoke and remove the remain- ing bearing cup.

4. Remove the spider and bearing cup from the propeller shaft in the same way.

Reassembly: Assemble the universal spider set. 1. Apply MP grease to the needle roller in the bearing cup. 2. Use a brass bar and slightly drive the bearing cup in. 3. Install the spider. 4. Use the brass bar and drive the bearing cup in until the

snap ring groove appears.

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

6. Reassemble the universal joint yoke in the same way.

OIL CONTROL VALVE Page

GENERAL ...................................................................... 14-2

SPECIFICATIONS ....................................................... 14-7

.............................................................. COMPONENTS 14-8

..................................... OIL CONTROL VALVE ASSY 14-10

............................................... REMOVAL-INSTALLATION 14-1 0

............................... CONTROL VALVE LEVER ASSY 14-15

............................................... REMOVALmINSTALLATION 14-1 5

RELIEF PRESSURE ADJUSTMENT (Pn35 - 50. Cu35 - 55 MODEL) ............................ 14-1 6

RELIEF PRESSURE ADJUSTMENT (Pn60 - 80. Cu60.70 MODEL) ................................ 14-1 7

14-2

GENERAL

T1

0

Note: For symbols a @ to @ , respective sectional views are shown on succeeding pages.

@@Solenoid Valve

14-4

@ Filter and Lift Load Check Valve

Filter

@ Flow Divider Valve

@ Relief Valve

<-

@ Needle Valve (Manual Down Valve)

@ Flow Control Valve

#

@ Lift Select Valve

a Tilt Select Valve

14-6

@ Limit Switch @ Lift Lock Check Valve @ ~ i l t Lock Check Valve

ackward switch

Hydraulic Circuit Diagram

,r 1 ! j

Flow control valve

@ Tilt lock check valve

(leak lock valve)

@ Lift lock check valve Pressure (leak lock valve)

detecting port

Relief Valve (For Forward Tilt) (Pn60 - 80, Cu60.70 Model)

B T

A (C2 port)

SPECIFICATIONS

*: The relief set pressure on the forward tilt side is controlled by connecting another relief valve to the CZ port.

Cu35 - 55 Pn35 - 50 Pn60 - 80 Cu60 70

Oil control valve type Add-on type

(1 -, 2-spool monoblock)

Relief set pressure kPa (kgf/cm2) [psi]

L i i

Tilt 181 40 (1 85) 126301

t

181 40 (1 85) [2630]

17.0 (4.49) Flow divider flow rate &min (USgal/min)

Others Built-in flow divider valve

20590 (21 0) [2990] (Forward tilt:

13240 (1 35) [ I 920])*

22.0 (5.81 )

COMPONENTS

OIL CONTROL VALVE ASSY REMOVAL-INSTALLATION

Note: Before disconnecting the lever rod, operate the control levers to bring the mast to the neutral position and fully lower the fork to release the residual pressure in the material handling system piping.

T = N-rn (kgf-cm) [ft-lbf]

Oil control valve ASSY set bolt: T=39.2 (400) [28.9]

Removal Procedure



3 Disconnect the lever rod.

4 Disconnect the wiring.

5 Disconnect the piping.

6 Remove the oil control valve ASSY.



Note: Apply grease (chassis grease) on the oil control valve lever links. Inspect the hydraulic oil level, and add if insufficient.

DISASSEMBLY-INSPECTION-REASSEMBLY

Note: Select a clean location for operation. Since individual parts are finished with high precision, carefully disassemble so as not to damage them.


I I


1 Remove the limit switch and spring cover. [Point 11 2 Remove the tilt spool. 3 Remove the solenoid valve. [Point 21 4 Remove the lift spool. [Point 31 5 Remove relief valve No.1. [Point 41 6 Remove the flow divider valve. [Point 51 7 Remove the filter. [Point 61 8 Remove the lift select valve. [Point 71 9 Remove the tilt select valve. [Point 81 10 Remove the flow control valve. [Point 91 11 Remove the tilt lock check valve. 12 Remove the lift lock check valve. 13 Remove the additional spool. 14 Remove the outlet housing.



Note: Wash each part thoroughly, remove dirt by blowing compressed air and apply hydraulic oil before reassembly.

tilt (-) tilt (+)

Y

Front side (SOL1)

K::; Rear side (SOU)

Point Operations


Check continuity of limit switches.

Forward tilt side: No continuity when the switch is pressed.

Backward tilt side: No continuity when the switch is pressed.

Reassembly : Carefully connect the limit switches on the forward and backward tilt sides in correct positions. Install the one for the forward tilt on the upper side. (It is regular that the both switches must be in pressed state when installed.)


Put a match mark to ensure installation of each solenoid in the correct position.

Inspection: Check continuity of each solenoid.

Inspection: Inspect and wash each orifice to eliminate clogging.

Reassembly: Carefully install SOL1 and SOL2 spools in correct positions.

[Point 31 Disassembly.Reassembly:

Remove the compression spring from the lift spool. SST 0961 0-1 01 60-71 Use the SST with a washer.

Orifice

Service nut

Service bolt


lnspect and wash the orifice to eliminate clogging.

Reassembly: When the relief valve is disassembled, always loosen the adjusting screw fully.


lnspect and wash the orifice to eliminate clogging.


lnspect and wash the filter to eliminate clogging.


Use the service bolt and nut to remove the sleeve. Service bolt size: M I 0 x 1.25

Service nut

Service bolt



Disassembly: Use the service bolt and nut to remove the sleeve. Service bolt size: M I 0 x 1.25

Inspection: lnspect and wash the filter to eliminate clogging.



CONTROL VALVE LEVER ASSY REMOVAL-INSTALLATION I I

I I

Removal Procedure

1 Remove the instrument panel.

2 Disconnect the lever rod.

3 Disconnect the knob switch wiring at the tilt lever.

4 Remove the set bolt.

5 Remove control valve levers. [Point 11



Note: Apply chassis grease on the control valve lever links.

Point Operations


Check the knob switch for continuity.

RELIEF PRESSURE ADJUSTMENT (Pn35 - 50, Cu35 - 55 MODEL) Note:

Always make adjustment according to the procedure described below. Careless adjustment may generate a high pressure to cause damage to the oil pump or other hydraulic devices. Always check that the no-load maximum speed is as specified.

1. Install an oil pressure gauge. (1) Remove the oil pressure detection port plug (illustrated)

installed on the front side of the oil control valve, and install the oil pressure gauge. Plug size: 9/16-18UNF-2B

2. See that the adjusting screw is loosened. (1) Remove the cap nut and packing, loosen the lock nut,

and loosen the adjusting screw until it is about to come off from the body.

3. Start the engine, and check no oil leakage and abnormal noise generation.

4. Adjust the relief pressure. (1) Operate the tilt lever for backward tilting, and gradu-

ally tighten the adjusting screw until the mast starts to be tilted backward. Tilt the mast fully backward.

(2) With the engine running at the maximum speed, operate the tilt lever for backward tilting. Gradually tighten the adjusting screw for adjustment of the pressure upon relief to the standard below, and lock the screw by means of the lock nut.

I For both tilt and lift I 181 40'40~~ (1 85+$ [2630+70O]

\ \uii

5. After the adjustment, place the packing, tighten the cap nut and check the relief pressure again.

6. Remove the oil pressure gauge, and tighten the plug.


RELIEF PRESSURE ADJUSTMENT (Pn60 - 80, Cu60-70 MODEL) Note:

Always make adjustment according to the procedure described below. Careless adjustment may generate a high pressure to cause damage to the oil pump or other hydraulic devices. Always check that the no-load maximum speed is as specified.

1. Install an oil pressure gauge. (1 ) Remove the oil pressure detection port plug (illustrated)

installed on the front side of the oil control valve, and install the oil pressure gauge. Plug size: 911 6-1 8UNF-2B

2. See that the adjusting screw (A) is loosened. (1) Remove the cap nut and packing, loosen the lock nut,

and loosen the adjusting screw (A) until it is about to come off from the body.

3. Start the engine, and check no oil leakage and abnormal noise generation.

4. Adjust the lift and tilt (backward) relief pressure. (1) Operate the tilt lever for backward tilting, and gradu-

ally tighten the adjusting screw (A) until the mast starts to be tilted backward. Tilt the mast fully backward.

(2) With the engine running at the maximum speed, operate the tilt lever for backward tilting. Gradually tighten the adjusting screw (A) for adjustment of the pressure upon relief to the standard below, and lock the screw by means of the lock nut.


I For both tilt (backward) and liff 1 20590?1~~(210+8) P990'FI

5. See that the adjusting screw (B) is loosened. (1) Remove the cap nut and packing, and loosen the ad-

justing screw (B) until it is about to come off from the body.

6. Adjust the tilt (forward) relief pressure. (1) Operate the tilt lever for forward tilting, and gradually

tighten the adjusting screw (B) until the mast starts to be tilted forward. Tilt the mast fully forward.

(2) With the engine running at the maximum speed, operate the tilt lever for forward tilting. Gradually tighten the adjusting screw (B) for adjustment of the pressure upon relief to the standard below.


7. After the adjustment, place the packing, tighten the cap nut and check the relief pressure again.

8. Remove the oil pressure gauge, and tighten the plug.

Tilt (forward) 1 3240';tg0 (1 35';) [ I 92rg0]

SAS Page

........................................................................ GENERAL 15-2

COMPONENTS .............................................................. 15-3

PRECAUTIONS FOR REPAIR ..................................... 15-8

..................... RENEWAL OF SAS CAUTION LABEL 15-11

................................................... FUNCTIONAL PARTS 15-1 2

.............. SAS CONTROLLER REMOVAL-INSTALLATION 15-1 3

............. YAW RATE SENSOR REMOVAL-INSTALLATION 1 5-1 4

..... SWING LOCK CYLINDER REMOVAL-INSTALLATION 15-1 6

.......... TILT ANGLE SENSOR REMOVAL-INSTALLATION 15-1 9

.................... LOAD SENSOR REMOVAL-INSTALLATION 15-20

.................. SPEED SENSOR REMOVAL-INSTALLATION 15-21

....... FORK HEIGHT SWITCH REMOVAL-INSTALLATION 15-22

................................................................... RE-SETTING 15-23

.................................................................... CUSTOMIZE 15-26

..................................................... PLUG-IN ANALYZER 15-27

......................................................... BASIC OPERATION 15-29

....................................................................... ANALYZER 1 5-32

.................................................................... RE-SElTlNG 1 5-42

............................................. OPTION SET (CUSTOMIZE) 15-44

...................................................... TROUBLESHOOTING 1 5-45

...................................................................... DIAGNOSIS 15-47

.................................................. TROUBLESHOOTING 15-50

........................ TROUBLESHOOTING BY ERROR CODE 15-50

TROUBLESHOOTING BY PHENOMENON ...................... 15-94 m CONNECTOR LAYOUT ............................................. 15-136

CONNECTOR DIAGRAMS ....................................... 15-137

GENERAL Composition of SAS (System of Active Stability) This system performs rear wheel swing control (S) and mast tilting control (T) by driving various actuators according to the vehicle movement signals sent to the SAS controller from the sensors and switches installed on necessary portions on the vehicle.

Combination meter SAS warnina lamp

Input +

Functional part

SAS warning lamp & buzzer

Diagnosis (hour meter)

Control S I T

Output +

4 Diagnosis connector 0 1 0 1 1

Plug-in analyzer

, Fork height switch

/

. Swing lock cylinder

Oil control valve SOL1-SOL2

Swing lock lamp Fault diagnosis display (hour meter)

Speed sensor

-

0

Tilt knob switch

Tilt angle sensor

SAS controller Yaw rate sensor

, Oil control valve

0

Forward tilt switch Backward tilt switch

\ Solenoid 1 Solenoid 2

Load sensor

Swing lock cylinder Plug-in analyzer

Diagnosis connector

COMPONENTS

L... ... a 19100148

Controller 1910

Fork height switch (V) 5803

Fork height switch (FV)

10 I r...

: CY 62

5803-0268

5803 10 ..., .

5803-068A

Fork height switch 5803 (FSV: Pn45.50 model) (FSV: Pn60-70, Cu55 - 70 model)

Tilt angle sensor 5803

Load sensor (V-FV) Load sensor (FSV: Pn35 - 50 model)

5803646A

5803

BH

CK

BU

5803-066 5803-065

Load sensor 5803

Speed sensor

(FSV: Pn60-70, Cu35 - 70 model)

Refer to 6801-GJ

5803-070

5803

5803-027

PRECAUTIONS FOR REPAIR Fully understand the functions of SAS (System of Active Stability) before repairing it.

1. Preparation for repair ( I ) When washing the vehicle, care should be taken not

to splash water directly to the electrical components. Don't apply high pressure washing to the controller, tilt angle sensor, lifting height switch, horn button, meters, switches on the instrument panel and electrical components and parts in the engine room.

(2) Remove contamination and/or water from respective sections.

(3) Transport a controller in cushioned packing and open it only before installation. Never transport it unpacked. Care should be taken not to drop the controller or give it impact by allowing contact with other objects.

(4) Part number for a controller varies by the vehicle specifications. Check correct part number in advance.

(5) Should a repair work require matching (re-setting), always park the vehicle on a flat place. (6) Arrange for necessary tools and measuring instrument (such as a plug-in analyzer (SST 09240-

23321 -71) and TOYOTA electrical tester (SST 09082-00050), etc.).

2. During repair (1) Never apply an impact wrench for removing the controller. Lay waste beneath the controller in

precaution for an accidental dropping. (2) Don't turn the key switch ON-OFF for no specific reason when the sensor wiring is disconnected.

Turning the key switch ON in this state causes an error and an error code will be stored in the controller. The error code is not erasable and a maximum of ten errors will be stored. Beyond 10th error code, the older error will be sequentially erased.

(3) When turning the solenoid (for lock cylinder) ON during an "Active Test" of the analyzer, don't keep it ON for more than one (1 ) minute. Since SAS functions are forcibly suspended during an operation check, perform the running test carefully at low speed.

(4) SAS functions are suspended during matching (re-setting). Don't operate the vehicle in this state. (5) Don't turn the key switch ON with one side (RH or LH) of a vehicle jacked up. It is very dangerous to

turn the key switch ON in this state as it releases the swing lock and the vehicle becomes suddenly tilted.

(6) If a vehicle is in tilted condition because of the repair of a flattened tire or otherwise, keep the key switch turned ON throughout from the start of jacking up, tire replacement and lowering to the ground.

(7) When the hydraulic piping is disconnected, apply cover to the fitting and hose to prevent the dirts from entering.

(8) If the oil control valve for manual lowering is loosened, tighten it up to a prescribed torque level. (9) Tighten respective set bolts with prescribed toque. (1 0) Respective sensors require no adjustment during installation. Make initialization during matching

(re-setting). (1 1) To extract a connector, do not pull it by the harness. (1 2) When inspecting the harness, carefully operate so as not to damage connector terminals. (13) The swing lock cylinder must not be disassembled. If disassembled, air enters to make it not re-

usable. (1 4) Do not apply strong impacts to the frame and head guard to prevent the controller from damage. (1 5) The meanings of high and low fork heights in the troubleshooting section are as follows:

Low fork height: From the lowermost position to immediately before actuation of the fork height switch High fork height: Height above the position where the fork height switch is actuated

SAS-ECU

3. Temporary measures (1) If swing lock fails to unlock for some trouble when the

key switch is turned ON, it may be unlocked manually for temporary action. Loosen the illustrated plug of the swing lock cylinder by 1 to 2 turns for unlocking. Care should be taken not to over-loosen it. After the repair, tighten it properly. T = 8 - 10 Nom(80 - 100 kgf-cm)

[5.8 - 7.24 ft-lbf]

(2) If the mast should fail to tilt forward or backward because of the failure of the forward or backward tilt limit switch, tilting operation may be made by extracting SAS-ECU fuse in the relay box for temporary measure. Care should be taken in this case that SAS functions are suspended. The swing control enters the lock state.

(3) If the mast should fail to lower because of some trouble, it can be lowered manually. Loosening the illustrated valve on the top of the oil control valve lowers the mast. Operate the lift lever for lowering with the manual lowering valve loosened. After the repair, tighten it appropriately.

T = 26.5 - 32.4 N-m (270 - 330 kgf-cm) [I 9.5 - 23.9 ft-lbf]

4. Precautions for vehicle modification

H (fork height): mm (in)

Note: Proceed with the alignment (re-setting) procedure after the above-mentioned modif i- cation. (See page 1 5-23.) After modification, replace the caution label affixed on the vehicle with the one matching the new SAS function. When placing a supply order for a mast ASSY, place order for sensors (for lifting height switch, load sensor, mast harness and other SAS related parts) simultaneously if such parts are required.

Content of work

Change controller. (for vehicle without swing control) Remove the lock cylinder.

Change controller. (for vehicle with swing control) Change the rear axle beam. lnstall the lock cylinder.

Change the mast.

Change the mast. Install the lifting height switch. lnstall the mast harness.

Chenge the mast. Remove the lifting height switch. Remove the mast harness.

Install or remove attachment.

Install the mast. Install the lifting height switch. lnstall the mast harness.

Condition

-

Between two H2000 (79) s

H2000 (79) + H2500 (98.5) or above

H2500 (98.5) Or

H2000 (79)

-

-

No.

1

2

3

4

5

Content of modification

Single tire -+ Double tire

Double tire -+ Single tire

Mast replacement

Installation/Removal of attachment

Mast installation (Mast less spec. model)

RENEWAL OF SAS CAUTION LABEL The warning instructions on the SAS caution label affixed to each truck must always agree with the SAS features that particular model owns. You must be strictly careful because the SAS caution label must be changed to the one with different warning in case that the modification on your side may vary the SAS features. Notice that the caution label must be changed in the following cases:

(1) The modification was such as to change the original specification features, tire spec. modification done by the dealar premises for example. Depending on single or double, the SAS caution label must be changed.

(2) The selective function of the mast forward tilt angle control was switched to either of Validation and Invalidation.* (*: See Page 15-26 Customize for the switching method.)

1. Case of Original Specification Feature Change.

Label @I Label 0

Single tire Dual tire

0 0

0 - 0

Single tire Dual tire MAST FUNCTION

2. Case of Switching "Mast forward tilt control Valid/lnvalid."

Label @ Label @

Valid Invalid

0 4 0

0 - 0

REAR STABILIZER Valid Invalid REAR STAEILIZER

Label 0 for use on the SINGLE TIRE models Label 0 for use on the SINGLE TIRE models having the following SAS features: having the following SAS features:

Equipped with swing lock control Equipped with swing lock control Mast forward tilt angle control "VALID". Mast forward tilt angle control "INVALID".

Label 0 Label @

Valid Invalid

0 0 THIS FORKLIFT TRUCK HAS

0 - 0 ACT I VE STAB I L I TY FEATURES.

HAST FUNCTION Valid Invalid

Label @for use on the DUAL TIRE models Label @for use on the DUAL TIRE models having the following SAS feature: having "NO ACTIVE STABILITY FEA- Mast forward tilt angle control "VALID". TURES". (No swing lock control) Mast forward tilt angle control "INVALID".

(No swing lock control)

3. Case of Mast Installation for Mast-Less Spec. models. When you install the mast to the mastless models, make sure the specification features with the mast assembled. Take note that the proper caution label must be chosen to be affixed to the truck. The proper label can be found among four types of the label numbering @ - 0 in the illustration.

FUNCTIONAL PARTS Note:

Read Section 14 for the oil control valve solenoids 1 and 2, forward tilt switch, backward tilt switch and the tilt lever knob switch. Checking of functional parts is described in the troubleshooting.

SAS CONTROLLER REMOVAL-INSTALLATION

Note: SAS controller has a built-in yaw rate sensor. Care should be taken in handling it by preventing the dropping, contact with other objects and so forth. If dropped, replace with a new one. Don't apply the impact wrench in removinglinstalling the set bolts fromlto the oil control valve connector bracket, connector boot bracket, and SAS controller.


Removal Procedure



3 Disconnect the tilt lever rod and the attachment lever rod.

4 Remove the oil control valve connector bracket.

5 Remove the connector boot set plate.

6 Disconnect the connector.

7 Remove the controller.



Note: Apply locking agent (08833-00080) on the threaded portion of the controller set bolts and the boot set plate set bolts before tightening them. Always use genuine controller set bolts. Correct tightening will fail if non-genuine bolts are used. When the SAS controller is replaced, perform the re-setting (read 15-23).

YAW RATE SENSOR REMOVAL-INSTALLATION

Note: Take the utmost care so as not to give a shock or impact on the yaw rate sensor. Don't use an air impact wrench on controller parts wholly.

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

Removal Procedure

1 Remove SAS controller. (See page 5-1 3.)

2 Remove the cover. [Point 11

3 Disconnect the jumper on the base print board connector. [Point 21

4 Loosen the lower set plate mount screw, and remove the yaw rate sensor together with the lower set plate. [Point 31

5 Remove the yaw rate sensor mount screw, and separate the yaw rate sensor from the set plate. [Point 41



Point Operations

[Point I] Removal .Installation:

Use "Torx (size: Torx Tamper Proof T-20)" wrench.


When removing or installing the jumper, take care so as not to harm the base plate connector. Insert firmly when installing. And avoid adverse contact such as to element.

[Point 31 Removal:

Never separate the upper set plate from the lower set plate, in other words, don't loosen three pieces M3 screws. If this screw is loosened, apply thread tightener (08833- 00080) and tighten it to the specified torque. T = 0.49 - 0.88 N.m (5 - 9 kgf-cm)

[0.36 - 0.65 ft-lbf]


Don't change the direction (or orientation) of the yaw rate sensor when re-installing.

SWING LOCK CYLINDER REMOVAL*INSTALLATION


Pn35 - 50 model: T = 10.5 - 24.5 (107 - 250) [7.74-18.11 Cu55 - 70 model: T = 21.6 - 50.4 (220 - 514) [ I 5.9-37.21

Pn35 - 50, Cu35.45 model: T = 16.2 - 37.8 (1 65 - 385) [ I 1.9 - 27.91

Cu55 - 70 model: T = 21.6 - 50.4 (220 - 514) [15.9 - 37.21

Removal Procedure

1 Pn35 - 50, Cu55 - 70 model: Remove the radiator. Cu35-45 model: Remove the counterweight. (See page 9-6.)


3 Remove the swing lock cylinder lower pin.

4 Disconnect the swing lock solenoid connector.

5 Remove the swing lock cylinder upper pin. [Pointl]

6 Remove the swing lock cylinder. [Point 21



Note: Apply chassis grease to the spherical portion of the upper pin and its mounting hole before installation. Apply thread tightener (08833-00070) to the threaded portions of the upper and lower pin set bolts before tightening them. After installation, apply chassis grease from the grease fitting.

Pn35 - 50, Cu55 - 70 model Point Operations

[Point I ] Removal :

SST 0981 0-201 72-71

Cu35.45 model

SST

Pn35 - 50, Cu35.45 model [Point 21 Inspection:

Accumulator inspection 1. Remove the plug from the tip end of the accmulator.

Pn35 - 50, Cu35-45 model: Use a coin or screwdriver. (After the inspection, install the plug by pushing it with a finger.) Cu55 - 70 model: Use a wrench.

2. Measure accumulator depth L. Pn35 - 50, Cu35.45 model: Standard: 45 mm (1.77 in) (40°C (104°F)) Limit : 52 mm (2.05 in) (40°C (104°F)) Cu55 - 70 model: Standard: 61 mm (2.40 in) (40°C (104°F)) Limit : 70 mm (2.76 in) (40°C (1 04°F)) Correct judgment on the standard is difficult at low temperatures because of much variation due to the oil temperature in the lock cylinder. Perform inspection after raising the oil temperature (to approx. 40°C (104°F) or the cylinder body at near your temperature) by traveling back and forth on a rough road (or by heating with an external heater).

If the limit value is exceeded, replace the swing lock cylinder ASSY.

3. Install the plug.

Pn35 - 50, Cu35.45 model

Cu55 - 70 model

Installation: Pn35 - 50, Cu35-45 model: Install with the mark (protruded portion) at the rod end facing outward.

Cu55 - 70 model: Install with the punch mark at the rod end facing outward.

TILT ANGLE SENSOR REMOVAL-INSTALLATION

Removal Procedure



3 Remove the instrument panel (RH).

4 Disconnect the tilt angle sensor link.


6 Remove the tilt angle sensor.



Note: Apply MP grease at the joint of the sensor and link rod end. When the tilt angle sensor is remove/installed or replaced, or when the length of the tilt angle sensor link is adjusted or replaced, proceed with the re-setting procedure. (Read 15-23.)

15-20

LOAD SENSOR REMOVAL-INSTALLATION


FSV: Pn60.70, Cu35 - 70 model - -

5

%,,

To lift cylinder RH Load sensor T = 35.3 - 43.1 (360 - 440) [26.0 - 31.81

Removal Procedure

1 Hoist the inner mast. (V-FV, FSV (Pn35 - 50 model)) [Point 11

2 Remove the front hose cover. (V (Pn60-70, Cu55 - 70 model))

3 Remove the sensor cover.


5 Remove the load sensor.



Note: When the load sensor is replaced, proceed with the re-setting procedure. (Read 15-23.)

Point Operations

[Point 11 Removal.Installation:

Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer mast.

SPEED SENSOR REMOVAL-INSTALLATION


Removal Procedure

1 Remove the speed sensor cover.


3 Remove the speed sensor



FORK HEIGHT SWITCH REMOVAL-INSTALLATION


V mast

FV-FSV mast

T = 14.4 - 33.6 (147 - 343) [I 0.6 - 24.81

Removal Procedure

1 Remove the lower cover.


3 Remove the mast lifting height switch.



RE-SETTING Of the sensors used for SAS, the signal voltage values of the tilt angle sensor and load sensor are stored respectively to the SAS controller for control accordingly when the mast is in vertical state and in no-load state. Therefore, when making service for these sensors or replacing their parts, re-setting (updating of sensor signal voltage values in the standard vehicle condition) is required. Re-setting is also required for the tilt angle sensor when the vehicle attitude is sharply changed and for the load sensor when the weight changes sharply because of the addition/removal of the attachment. Re-setting may be performed by using the hour meter and the tilt knob switch or plug-in analyzer (SST 09240-23321 -71 ) (read 15-42).

'l: Perform re-setting with the mast in the vertical position since the controller calculated the limit position for forward tilting.

Object of re-setting

Re-setting condition

Vehicle indication (hour meter) Analyzer (SST) indication Object sensor

Work example Replacement of SAS controller Removal/lnstallation or replacement of tilt angle sensor Change of the length of tilt angle sensor rod or replacement

Replacement of load sensor Change to other attachment Replacement of mast Replacement of tilt cylinder Adjustment of tilt cylinder uneven tilting

Note: The tilt angle sensor re-setting value of SET1 determines the mast stop position under the automatic fork stop control at horizontal level. Accordingly, if the fork fails to stop at the horizontal level due to the service condition by the user (inclination of the floor, etc.), bring the mast vertical on the site and perform re-setting. (In such a case, the mast stop angle drifts on the level floor.)

Re-setting

Fork stopping position with automatic leveling

Mast in vertical position

SET1

TILT LEVEL

Tilt angle sensor

0 0 0 0 0 0 0 0

required Forward tilting limit

position No-load standard load Mast in vertical

position'l NO load

SET2

CONT-LOAD Tilt angle sensor and load sensor

0 0 0 0 0 0 0 0

STANDARD STATE OF VEHICLE If the surface on which re-setting is to be performed is slanted, error occurs to the standard state. Select a level floor without irregularity for re-setting.

Note: The finishing accuracy of the floors for factories, warehouses and buildings in general calls for the floor inclination to be 0.5" or under. Therefore, re-setting on these floors is not affected. Don't perform re-setting on a floor that is inclined for over 0.5" for draining purpose.

V FV.FSV

- c .- ? m - E E 0 0 7

500 mm (1 9.7 in)

Additional Weight Table

Fork stop position with automatic leveling and forward tilting limit position

Set the vehicle in the following condition so as to have the tilt angle sensor signal voltage value stored with the mast held vertical to the floor surface:Load sensor

No-load standard load Set the vehicle in the following condition so as to have the load sensor signal voltage value stored under no-load condition:

Standard: Raise the fork to a height of 500 mm (19.7 in) for the V mast or raise the rear lift cylinder to a height of 100 mm (3.9 in) for the FV or FSV mast. Place a level (goniometer) at a height of 1200 to 1500 mm (47.2 to 59.1 in) on the front or rear side of the outer mast and set the mast in the vertical position. In the case of a special vehicle with a heavy attachment (exceeding the additional weight shown in the table below), adjust the perpendicularity of the mast with the attachment height at 500 mm (19.7 in), and perform relief at the topmost position.

Note: Keep the fork or attachment installed on the vehicle. Set the mast vertical from a backward tilted position (not from the forward tilted position). In case of a detachable attachment, keep the attachment installed on the vehicle.

kg (1b-S)

Lift height mm (in)

3000 (1 18) or less

3300 (1 30) - 4000 (1 57.5)

4300 (1 69) - 5000 (1 97)

5500 (21 6.5) - 6000 (236)

Pn35 Cu35

1400 (3086)

1400 (3086)

1000 (2205)

1000 (2205)

Pn40

1 500 (3307)

1500 (3307)

1500 (3307)

1200 (2646)

Pn45.50 Cu45

1800 (3968) 1600 (3527)

1500 (3307)

1500 (3307)

Pn60 Cu55.60

2200 (4850)

2000 (4409) 1800 (3968)

1500 (3307)

Pn70 Cu70

2800 (6 1 73)

2500 (551 2)

2000 (4409) 1800 (3968)

Pn80

3200 (7055)

2800 (6 1 73)

2500 (55 1 2)

2000 (4409)

Re-setting connector

Knob switch

& [SET]

0 indication

(-1 H indication

RE-SETTING PROCEDURE

Note: Turning the key switch ON (or starting engine) after disconnecting the re-setting connector causes an error (error code 41) to be displayed and stored to the controller, for which care must be taken.

1. Turn the key switch ON (or start the engine). 2. Disconnect the re-setting connector (orange color).

(1) The hour meter display reads "SET and the SAS lamp turns ON. (The buzzer sounds.)

3. Press the knob switch until the re-setting mode (SET1 is displayed) is displayed (2 seconds or over).

4. Display the set number subject to the re-setting. (1) Set number display changes sequentially each time

the knob switch is pressed for less than 2 seconds.

Note: Pressing the knob switch 2 seconds and over will run the re-setting, for which care should be taken.

'I: indication may be made but actually it is not used.

Set No. SET1

SET2

SET3 "

SET4 'I

5. Set the sensor of the display set number to the standard state (or check if it is in the standard state). Read 15-24 page.

6. Press the knob for 2 seconds or more and execute re- setting.

Object of re-setting Fork stop position with automatic leveling Forward tilting limit position and no-load standard load

- -

0 indication: Re-setting is completed. (SAS lamp starts to blink)

H indication: Check for the sensor abnormality, disconnection of the harness and the short-circuit since the signal voltage value is outside the re-setting rang. (Read the troubleshooting section .)

Note: For re-re-setting, repeat Step 6. To make a separate re-setting, repeat Steps 4 to 6.

7. Connect the re-setting connector and turn the key switch OFF.

CUSTOMIZE The customize function is to invalidate the mast forward tilting angle control. There are two methods to do this; one is to use the hour meter and tilt knob switch and the other method is to use the plug-in analyzer (SST). (See page 1 5-27.)

Caution: When the customize is changed, maintain the caution label of "WARNING." (See page 15-11.)

Re-setting connector CUSTOMIZE PROCEDURE

Note: Turning the key switch ON (or starting engine) after disconnecting the re-setting connector causes an error (error code 41) to be displayed and stored to the controller, for which care must be taken.

1. Turn the key switch ON (or start the engine). 2. Disconnect the re-setting connector.

(1) The hour meter display reads "SET" and the SAS lamp turns ON. (The buzzer sounds.)

3. Set the tilt lever to backward tilt for 5 seconds and over. Then press the knob switch until the option set mode (OPT1 is displayed) is displayed (2 seconds and over), then return the lever.

4. Display the option number to change the option set. (1) Set number display changes sequentially each time

the knob switch is pressed for less than 2 seconds. I 0 ~ t i o n NO. 1 Control name

I OPT1 I Mast forward tilt angle control I I I I

*:Displayed but not in use.

5. Keep the knob switch pressed until the SAS lamp starts blinking (for 2 seconds or over) to change y to n, and n to Y.

y: Control valid n: Control invalid

6. Connect the re-setting connector and turn the key switch OFF.

7. Replace the caution label. (See page 15-1 1 .)

PLUG-IN ANALYZER For the maintenance and service of SAS functions, a separate type plug-in analyzer is introduced as an SST (Special Tool for Service). The plug-in analyzer is designed to read the operating state of sensors and actuators used for the SAS functions and the error information detected by the controller. It serves to check on the operating state of SAS functions and shortens the repair time for a trouble. Moreover, it is installed with save function to file data displayed on the screen in the SST.

SST 09240-23321 -71

Reference Page ,

15-32

15-42

15-44

15-29

m u r D - (I)

S a, .- 3 .o c 2= .O ? 5 m m c g s c ~ 5 0 = & c a = 0 0 .- r Z z E m

Content of function Indication of ten error codes and sub-codes in past. Monitoring input voltage value from the sensors and the output signal, etc. to the solenoid, etc.

8 $

- O , I S "

6

s g LL

save function

0

0

Menu name

Forced operation of solenoids and warning lamps. Display and erasure of save screen

Reading controller part number, ROM part number and controller manufacturing number.

DlAG MEMORY

lNioUT MONITOR

ACT'VE TEST

DATA MANAGE

CONTROLLER NO

RE-SElTlNG

a m a

Implementation of re-setting (updating the sensor signal voltage value in the vehicle standard state).

-- -

ANALYZER

L

3 +

CUSTOMIZE

CONTRAST SET LANGUAGE SET FILE INITIALIZE

Setting validlinvalid of forward tilt restriction control

Adjustment of the screen contrast Change to the display language. Main unit data initialization

Screen Configuration

- SAS MENU 1 ANALYZER -

2 RE-SETTING

3 CUSTOMIZE

1 DlAG MEMORY 2 INIOUT MONITOR

ACTIVE TEST DATA MANAGE

See Page

DlAG MEMORY (1/2) 15-33 --'IN/OUT MENU - SWING DlAG MEMORY DATA (1 (2/2) /2)

1 SWING CONTROL L SWING DATA (2/2) 15-35

2 MAST CONTROL MAST DATA (1/2) MAST DATA (2/2) 15-36

3 ST. KNOB CONTROL ST. KNOB DATA -

- 4 OTHER OTHER DATA d / l ) 15-37

7 END 1

2 INIOUT MONITOR 17END

. .

-4 ACTIVE TEST (1/2) ACTIVE TEST (2/2) 15-38

- DlAG DATA FILE

1 OPEN - FILE 0p-0 FILE NO* (1/2) FlLE NO* (2/2) 15-39

FILE OPEN (2/2) h- FlLE NO* (1/2) FlLE NO* (2/2)

2 DELETE FlLE DELETE d /2 ) FILE DELETE (2/2) 15-40 7 END

H FlLE DELETE (3/4) ~ L E DELETE (4/4) 1 I

5 CONTROLLER NO 1 17END

RE-SETTING MENU 1 TlLT LEVEL

RE-SETTING TlLT LEVEL 1 15-42

2 CONT . LOAD RE-SETTING CONT . ROAD 1 15-43 RE-SETTING TIRE I - RE-SETTING SWING -

17 END

7 END 3-1 CUSTOMIZE d / l ) 1 15-441

TESTER SET MENU 1 CONTRAST SET s CONTRAST SET 1 15-31

2 LANGUAGE SET s LANGUAGE SET 1 15-30

3 FlLE INITIALIZE - FILE INITIALIZE 1 15-31

7 END 1

BASIC OPERATION

Name of Sections and the Switch Functions

Caution on using: Keep the main unit, wire harness, connector, etc. away from the exhaust and other heated sections. Operate the switch with finger tip. Don't give it strong impact from dropping or collision. Don't leave it under the direct rays of the sun for long time.

Name of section

Main unit

A Switch

I Q Q QUENU)

Switch mark indicator

'</ ANALYZER

Connection and Operation of SST 1. Turn the key switch OFF. 2. Open the diagnosis connector cover of the vehicle and

properly connect the connector on the SST side. SST 09240-23321 -71

Note: Since the connector has no locking device, securely connect it to prevent contact defect upon closing the engine hood with the connector in connected state. 3. Turn the key switch ON or start engine.

Position of indication

A

B

C

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 0.

Switch

Selector

switch @

Selector

switch @

Menu

switch @

Mark

t

SAVE

SET

START

<Blank>

4 ~ B l a n l u

4 <Blank>

Function

Move the cursor to the above item.

Move to the preceding page.

Move the cursor to right or left.

Save the screen.

Re-set the display screen.

Initialize the file.

<No function>

Select the item below.

Move to the following page.

<No function>

Determine an item for selection.

Move to MENU screen.

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 @ and 0.

Japanese English

(2) Press MENU switch @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 language, go to Step 8 "TESTER SET."

6. "MAIN MENU" screen (1) Select the menu using selector switch @ and @ and

determine by pressing menu switch @. SAS: Moves to SAS MENU screen. (Step 7) TESTER SET: Moves to TESTER SET screen. (Step 8)

7. "SAS MENU" screen (1) Select the menu using selector switch @) and @ and

determine by pressing menu switch @. ANALYZER: Moves to ANALYZER MENU screen. RE-SETTING: Moves to RE-SETTING screen. CUSTOMIZE: Moves to CUSTOMIZE (111) screen. END: Returns to MAlN MENU screen.

8. "TESTER S E T screen (1) Select the menu using selector switch @ and @ and

press MENU switch @ to determine the setting. CONTRAST SET: Moves to CONTRAST SET screen for contrast adjustment. (Read Step 9.) LANGUAGE SET Moves to LANGUAGE SET screen for changing language. (Read Step 10.) FlLE INITIALIZE: Moves to FlLE INITIALIZE screen for a total erasure of the main unit data. (Read Step 11.) END: Returns to MAlN MENU screen.

CONTRAST SET

CONTRAST LEVEL 4

FlLE INITIALIZE CHECK U Y C)

7

t , 4 4,

FlLE INITIALIZE

00000000 *

< FlLE INITIALIZE

INITIALIZING

L

START

9. "CONTRAST SET" screen (1) Select the level of contrast using selector switch @

and 0. Contrast level: (Light) 1 2 3 4 5 6 7 8 (Dark)

(2) Press the menu switch @ to determine the setting. Then "SAVING-+COMPLETE" appears to the message column and the screen returns to INITIAL SET MENU.

10. "LANGUAGE SET" screen (1) Select other language using selector switch @ and 0-

Japanese English

(2) Press MENU switch @to determine the setting. Then "SAVING+COMPLETE" appears in the message column.

(3) Select END by selector switches @ and @ and press MENU switch @. The INITIAL SET MENU screen re- appears.

11 . "FILE INITIALIZE" screen

Note: Check the databeforehand because the main unit data is initialized.

(1) Have the message displayed on the screen by pressing selector switch @.

(2) Select an item using selector switch @and determine by pressing MENU switch @. N: File initialization can be cancelled.

Y Starts file initialization. Initialization ends when INITIALIZING-+COMPLETE appears to the message column.

(3) Press MENU switch @to return to the TESTER SET MENU screen.

Screen title

c

Removal of SST 1. Check that the screen title is for one of the MENU

screens. 2. Turn the key switch OFF. 3. Disconnect the connector.

Note: To disconnect, hold the body of the connector.

4. Close the diagnosis connector cover

ANALYZER

Message column

1 11 223.3h 42-1 2 1223.3h 41 -1 3 223.3h 42-1 4 23.311 41-1 5 O.Oh

Save function In the screen *1 and *2 in the table, pressing selector switch @saves the content to respective menu of "4 DATA MANGE." Upon running the SAVE function, "SAVING" appears to the message column and "FILE*/COMPLETE FILE*"(* represent- ing the number in the file) appears when the saving normally ends. After checking the file number, press MENU switch @ to return to "ANALYZER MENU" screen.

Page

1 5-33

15-35

15-36

-

15-37

15-38

1 5-39

15-39

15-41

ANALYZER MENU

1 DlAG MEMORY

Content of display and function

lndicates ten error codes and the time of error generation in the past.

lndicates the swing control-related controller data.

lndicates the TILT control-related controller data.

- (Displayed but not in use.)

Indicates other controller data.

2 INIOUT MONITOR

Save function

Yes"

Yes'2

Yes''

Yes''

Forcibly outputs operating signal to a selected item.

Indicates and erases DlAG MEMORY saved data. (Display screen of '1)

lndicates and erases INIOUT MONITOR saved data. (Display screen of '2)

lndicates SAS controller part number, ROM part number and manufacturing number.

3 z W

3

z

DATA

2MASTDATA

3 ST. KNOB DATA

4 OTHER

3 ACTIVE TEST

4 DATA MANAGE

5 CONTROLLER NO

3

5 DlAG

lNloUT

P

DlAG MEMORY (112) SAVE FlLE ERR 1 11 223.3h 42-1 2 1223.3h 41 -1 3 223.3h 42-1 4 23.3h 41-1 5 O.Oh

DlAG MEMORY (112) FlLE FULL 1 11 223.3h 42-1 2 1223.3h 41 -1 3 223.3h 42-1 4 23.3h 41-1 5 O.Oh

Other messages FlLE FULL: Since no free number is available in "FILE MAN-

AGE", press MENU switch @ to return to "ANA- LYZER MENU" screen and erase unnecessary files.

FlLE ERR: Saving disabled for an error.

SAVE

[Action] (1) Press selector switch @ to re-run the saving. (2) If FlLE ERR is displayed again, some abnormality ex-

ists in the file. To recover from the abnormal state, initialize the main unit data on the FlLE INITIALIZE screen. (See the step 11 on page 15-31 .)

4

Note: Since all main unit data is initialized upon FlLE INITIAL- IZE, check the data beforehand.

c

DlAG MEMORY (112)

1 11223.3h 42-1 2 1223.3h 41 -1 3 223.3h 42-1 4 23.3h 41-1 5 O.Oh

OPERATING PROCEDURE 1. Select and enter "1 SAS" in MAIN MENU screen to have

"SAS MENU" displayed on the screen.

DlAG MEMORY (212)

6 O.Oh 7 O.Oh 8 O.Oh 9 O.Oh

10 O.Oh

2. Select and enter "1 ANALYZER" in SAS MENU screen to have "ANALYZER MENU" displayed on the screen.

I I 6 \

(1) (2) (3)

c c

SAVE

SAVE

3. "ANALYZER MENU" screen (1) Using selector switch @ and @ move the cursor to a

desired menu in "ANALYZER MENU" screen and enter by pressing MENU switch @.

(2) Select and enter "END" to return to "SAS MENU" screen.

* "1 DlAG MEMORY This screen displays the hour meter time for generated errors and ten latest error codes and sub-codes sequentially in two separate screens.

c [Descriptions on the contents of display] (1) Sequence of error generation (2) Hour meter time for error generation (3) Error code

[Transfer of page] Selector switch @

[Endl Press MENU switch @ and return to "ANALYZER MENU" screen.

[SAVE] Press selector switch @ from any screen to save the two screens as one file.

"2 INIOUT MONITOR" This menu has the following menus in addition: swing control, TlLT control, ST. KNOB control and other. It can display the following data on the screen:

Menu name

1 SWlNG CONTROL

2 MAST CONTROL

3 ST. KNOB CONTROL

4 OTHER

Content of display

lndicates the swing control-related sensor analog input voltage, switch input state, controller internal calculation value and the signal state to the solenoid.

lndicates the TlLT control-related sensor analog input voltage, switch input state and the signal state to the solenoid.

- (Displayed but not in use.)

lndicates the controller input voltage, hour meter value, RE ADJUST CONNECTOR state and DlAG PIN state.

r SWING DATA (1/2)

YAW SENSOR 2.50V SPEED o.okm'h

SWINGSOL ON

1. Select and enter "2 INIOUT MONITOR" in "ANALYZER MENU" screen to have "INIOUT MENU" displayed on the screen.

2. Move the cursor to the desired menu by using selector switches @ and 0, and determine by pressing MENU

>

SAVE

, & J

SWING DATA (212)

SWlNG - - LOAD 0:90(0.90)~

HEIGHT SW1 ON SW21 OFF SW22 OFF

switch @. END: Return to "ANALYZER MENU."

SAVE

' 4 .

1. SWING DATA

[~escr i~ t ions on the content of display] (1) YAW SENSOR: Yaw rate sensor input voltage (2) SPEED: A speed calculated and recognized by the

controller from the speed sensor signals. (NG is indicated for abnormality.)

(3) SWlNG SOL: Output signal to the swing solenoid. ON for energization: Swing lock resetting OFF for de-energization: Swing lock application

(4) SWING: - (Unused)

(5) LOAD: Load sensor input voltage. (Parentheses) represent the re-setting voltage.

(6) HEIGHT SW 1 : Lifting height switch 1 input signal SW21: Lifting height switch 21 input signal SW22: Not set

See page 15-37 for the relationship between the fork height and the fork height switch (ONIOFF).

2. MAST DATA

(1) 2 ) (3) (4) (5)

,' MAST DATA (112)

TlLT FWD OFF BWD OFF KNOB OFF

HEIGHT SW1 ON SW21 OFF

, SW22 OFF

[Descriptions on the content of display] (1) TILT Tilt angle sensor input voltage. (2) CONT Re-setting voltage (CONT-LOAD) (3) LEVEL: Re-setting voltage (TILT LEVEL) (4) LOAD: Pressure sensor input voltage. (Parenthe-

ses) represent the re-setting voltage. (5) TlLT SOL1 : Output signal to tilt solenoid 1.

SOL2: Output signal to tilt solenoid 2. SOL2 OFF , @

(6)

(7)

MAST DATA (1/2)

TlLT 2.20V O N 2 . 2 0 LEVEL 2.20V

LOAD 0.90(0.90 V TlLT SOL1 ON

SAVE

SAVE '

4 , i

The tilt solenoid output signal ON indicates energization, and OFF de-energization. The combinations are shown in the table below.

4 C

*: Rear tilting operation with the tilt lever knob depressed. Example: If SOL1 is ON and SOL2 is OFF, the tilt hydraulic circuit is considered to be in the state of tilt stop circuit.

(6) TlLT FWD: Tilt forward switch input signal. BWD: Tilt backward switch input signal. KNOB: Tilt knob switch input signal.

(7) HEIGHT SW 1 : Lifting height switch 1 input signal. SW21: Lifting height switch 21 input signal. SW22: Not set.

SOL2


SOL1

OFF

ON

[Endl Press MENU switch @to return to "IN/OUT MENU" screen.

OFF

Semi-open circuit High lift height Rear tilt speed control Low lift height Rear tilt speed control* Front tilt

Full open circuit Low lift height Rear tilt

[SAVE] Pressing selector switch @ from any screen saves the contents of two screens as one file.

ON

Tilt stop circuit Tilt lever neutral Front tilt angle restrain & stop Fork leveling & automatic stop

Not applicable

Low fork height

High fork height

3. ST. KNOB DATA

OTHERDATA (111)

VOLTAGE 12.4V HOURS 11 223.3h RE-SET CN 0 N DlAG PIN 0 N

L

Displayed but not in use.

.

4. OTHER

With lifting height SW provided

SAS controller Lifting height SW1

SW22

[Descriptions of display content] (1) VOLTAGE: Controller supply voltage. (2) HOURS: Hour meter values. (3) RE ADJUST CN: State of re-setting connector. (4) DlAG PIN: State of diagnosis pin.

Without lifting height SW provided

SAS controller

D p l SW22

SW1

SW21

SW22

SWI

SW21

SW22

[Endl Press MENU switch @to return to "INIOUT MENU."

SW1

SW21

SW22

SW1

SW21

SW22

ON

OFF

OFF

OFF

ON

OFF

[SAVE] Press selector switch @ from any screen to save the contents of a screen as one file.

ON

OFF

OFF

ON

OFF

OFF

ACTIVE TEST (212) u

J

* The relationships between ON and OFF of SOL1 and SOL2 are as follows:

I I 1

SOL 2

Tilt

circuit half

Tilt

circuit full

Tilt hydraulic circuit closed

"3. ACTIVE TEST" This menu enables to check a selected item through a forcible output of operating signal to it.

Caution: When the swing lock cylinder solenoid is turned ON, drive vehicle at low speed (for test drive, etc.).

Note: "ON" on the screen indicates that the controller is in an output state. Therefore, check operation visually or with the operating sound, etc. Don't allow the solenoid to operate over one minute as it causes a failure.

1. S,elect an item using selector switch @ and set ON-OFF using selector switch a.

[Descriptions of display content] (1) SWING SOL: When set to ON, outputs forcible opera-

tion signal to swing lock cylinder solenoid. (Constantly unlock)

(2) TlLT SOL1 : When set to ON, outputs forcible operation signal to tilt solenoid 1 .*

(3) TlLT SOL2: When set to ON, outputs forcible operation signal to tilt solenoid 2.*

(4) KNOB SOL: - (Unused) (5) WARNING: When set to ON, outputs forcible opera-

tion signal to SAS warning lamp (buzzer , interlocked). (SAS lamp on and continu-

ous buzzer sounding) (6) LOCK LMP: When set to ON, outputs forcible opera-

tion signal to swing lock lamp. (Swing lock lamp on)

(7) SPEED FAIL: Skip this check since this function is not provided:

2. After turning all items OFF or returning to NORMAL setting, press MENU switch @ to return to "ANALYZER MENU" screen.

"4. DATA MANAGE" This menu has DATA MENU for DIAG MEMORY and IN/OUT MONITOR. It can display saved data of DIAG MEMORY and INIOUT MONITOR or erase them. File numbers on "OPEN" and "DELETE" screens indicate the number displayed when the saving ends normally, and the file number is displayed after processing it according to the following rules:

1. Select and enter "4. DATA MANAGE" on "ANALYZER MENU" screen and have "FILE MENUIDATA MENU" displayed on the screen.

2. "DATA MENU" screen Move the cursor to a desired menu on "DATA MENU" using selector switch @) and 0, enter it by pressing MENU switch @ and move to "DIAG DATA FILE" or "IN/ OUT DATA FILE."

3. "DIAG DATA FILE" screen "INIOUT DATA FILE" screen

(1) Select the menu using selector switch @I and @ and press MENU switch @to determine the setting.

OPEN: Moves to "FILE OPEN" screen. (Step 4) DELETE: Moves to "FILE DELETE" screen. (Step 5) END: Returns to "FILE MENU" screen.

Max. number of file

10

Total: 20

Saved to:

1 DIAG MEMORY

File name

2 IN/OUT MONITOR

Manufacturing number of the opposite SAS controller

Add "S" to the end of the manufacturing number of the SAS controller.

Add "T" to the end of the manufacturing number of the SAS controller.

Add "0" to the end of the manufacturing number of the SAS controller.

Example: 800001

Example: 800001 S

Example: 800001 T

-

Example: 800001 0 OTHER

2 + 2 Q

1 SWING CONTROL

2 MAST CONTROL

3 ST. KNOB CONTROL

11 END

1 li 800025T 1 $ 1 8000698 21 END

FlLE DELETE (112)

1 800001 2 800025

t 3 800011 4 800044 5 800003

4 , 6 800107

FlLE NO3 (112) 800011

1 11223.3h 42-1 2 1223.3h 41-1 3 223.3h 42-1 4 23.3h 41-1 5 O.Oh

21 END ALL DELETE

I

4 J

4. "FILE OPEN" screen (1) Select an item using selector switch @I and 0.

END: Returns to "DIAG DATA FILE" or "INIOUT DATA END FILE."

Note: The file name is displayed only when it i s saved. If not saved, only END is displayed.

(2) When entry is made using MENU switch 0, the screen returns to "FILE."

(3) "FILE" screen Saved data is displayed along with the file number and name.


[Endl Press MENU switch @ to return to "FILE OPEN" screen.

5. "FILE DELETE" screen (1) Select an item using selector switch @I and @.

ALL DELETE: Select this for totally erasing files displayed on all the pages of FlLE DE- LETE screen.

END: Returns to "DIAG DATA FILE" or "IN/OUT DATA FILE."

(2) Press MENU switch @to have a message displayed.

CONTROLLER NO (111)

CONTROLLER NO 2421 0-23320-71 -A

ROM NO 24295-23320-71 -A

SERIAL NO 800001 2

(3) Select N or Y using selector switch @ and make entry by pressing MENU switch @. N: File delete can be cancelled.

Y Starts deletion. Operation ends when COMPLETE is displayed in the message column.

(4) Press MENU switch (@to return to the FILE DELETE screen.

"5. DATA" This menu is used to display the part number of the SAS controller, ROM part number and manufacturing number.

[Descriptions of display content] (1) CONTROLLER NO.: Controller part number. (2) ROM NO.: ROM part number. (3) SERIAL NO.: Controller manufacturing number.

[Endl Press MENU switch @to return to "ANALYZER MENU."

RE-SETTING Re-setting can be also performed by using the hour meter and tilt knob switch on the vehicle. Using this menu, re-setting can be made by monitoring the signal voltage of respective sensors on the screen.

"RE-SETTING" screen is also displayed for a specification that requires no re-setting on the part of the vehicle. If re-setting is run on such a vehicle NG will be displayed on the screen.

TlLT LEVEL

2.10v

2.1 OV

Object sensor

Tilt angle sensor

Tilt angle sensor and load sensor

-

-

RE-SETTING MENU

1 TILTLEVEL

2 CONT-LOAD

3 TIRE

4 SWING

Operating Procedure

Re-setting name

RE-SETTING TILT LEVEL

RE-SETTING CONT-LOAD

-

-

1. Select and enter "2. RE-SETTING" on "SAS MENU" screen to have RE-SETTING MENU displayed on the screen.

2. RE-SETTING MENU SCREEN (1) Move the cursor to a desired menu using selector

switch @ and @ and make entry using MENU switch 0.

(2) Selecting and entering "END" returns to "SAS MENU" screen.

3. "RE-SETTING" screen TlLT LEVEL

[Descriptions of display content] (1) TILT: Tilt angle sensor input voltage. (2) MEMORY: Tilt angle sensor re-setting value prior to

the re-setting. (Standard voltage for fork automatic leveling control)

(3) MEMORY: Re-setting value after running re-setting.

-

CONT-LOAD

2.30V

2.30V (5) MEMORY 2.30V OK I D .8ov k! (5) MEMORY 0.80V OK

CONT-LOAD (1) TILT: Tilt angle sensor input voltage. (2) MEMORY: Tilt angle sensor resetting voltage before

resetting (standard voltage for forward tilt restriction control).

(3) LOAD: Load sensor input voltage. (4) MEMORY: Load sensor re-setting value prior to the

re-setting. (5) MEMORY: Re-setting value after running re-setting.

TIRE, SWING Displayed but not in use.

1. Set the sensor to be re-set to the standard state. (Or check that it is in the standard state.) (Read 15-20.)

2. Press SELECTOR switch @ and excute re-setting. OK: Re-setting complete under the indicated voltage. NG: The signal voltage value is outside the re-setting

range. Check for sensor abnormality, harness disconnection and/or short-circuit. (Read Trouble- shooting.)

3. Press MENU switch @ in respective screens to return to "RE-SETTING MENU" screen.

R E I D O P E R A T O R ' S MAHUAL FOR CORRECi O P E R A T I O N . I M 5 P E C T t O l AND

R l L l F T T R Y C I I I I H O U T A C T I V E 4 8 1 1 1 7 7 FELTURES NAY H I I D L E D OPERATE DIFFEREIILY.

2SWlNG W LOCK

OPTION SET (CUSTOMIZE) This menu is used for setting VALIDATION/INVALIDATlON of the mast forward tilt angle control.

Caution: If CUSTOMIZE is changed, perform the maintenance of the label for "WARNING." (See page 15-11.)

Operating Procedure 1. Select and enter "1 SAS" in "MAIN MENU" screen to have

"SAS MENU" displayed on the screen.

2. Select and enter "3 CUSTOMIZE" to have "CUSTOM- IZE" displayed on the screen.

3. "CUSTOMIZE" screen (1 ) Move the cursor to a desired item using selector switch

@ and set W/L using selector switch a. TILT CONT Mast forward tilt angle control. SWING W LOCK: (Display only, not for actual application) W: Valid control L: Invalid control

(2) Press MENU switch @ to return to the SAS MENU screen.

4. Replace the caution label. (See page 15-1 1 .)

15-45

TROUBLESHOOTING

Nothing appears on the screen.

Related Portion

Estimated causes: @) Incomplete contact of connector @ Defective analyzer harness (power supply) @ Defective plug-in analyzer

L

a, N X - m

2

Check 1 : Measure voltage between CN44-12 and CN44. Turn the key switch ON (with engine stopped) Standard: CN44-12 O - CN44-3 0 : 8 - 16 V

1 CN1 ' / I / / CN44 Analyzer CN -

1

Check for disconnection of CN44 and analyzer connectors.

Check 2: Measure voltage between analyzer CN-1 and analyzer CN-13. Turn the key switch ON (with engine stopped) Standard: Analyzer CN-1 O - Analyzer CN-13 0 : 8 - 16 V

6 V m : L

a, - - 2 - f

9

CN44 (REC)

-

2

NG ,

Analyzer CN (REC)

m

Check the screen after making correction.

OK I NG

o a w b-u

--

Defective harness on the vehicle. Check 1 : Measure voltage between CN44-12 and CN44-3.

NG ,

(IG)

CN1-2 CN44-1

CN44-3 (El, GND)

OK v

V &!

Defective analyzer harness. Check 2: Measure voltage between analyzers CN-1 and CN-13.

NG >

m 2

-

OK

13

v

Defective plug-in analyzer.

Screen for data (DIAG MONITOR, voltage values and speed, etc.) does not display data.

Related Portion

Estimated causes @ Incomplete contact of connectors @ Defective analyzer harness (communications) @ Defective SAS controller

&

a, N X - m

2

- $ e - 8 0 0

Check 1 : Check continuity between CN44-1 and CN1-2. Turn the key switch OFF and disconnect CN44 and CN1. Standard: CN44-1 and CB1-2: Continuity shall exist CN1 (REC)

CN44 (REC)

CNI 1 ~ ~ 4 4 Analyzer CN

Check for the disconnection of CN44 and analyzer NG Check the data indication after making connector.

> correction.

NG -

Check continuity between CN44-1 and CN1. NG > Defective harness on the vehicle side.

OK v

Check 2: Check continuity between analyzer CN-6 and CN44-1. 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 1 0 r - l Turn the key switch OFF and disconnect analyzer CN and CN44. Illil21131141l511611711811912d

Standard: Analyzer CN-6 to CN44-1: Continuity shall exist Analyzer CN (REC)

CN44 (TAB)

- -

Check 2: Check continuity between analyzer CN-6 and CN44-1.

--

NG >

~ ~ 4 4 - 1 2 SUS-ECU

Defective analyzer harness.

OK V

-

2:

--

('G)

m o C N 1 - 2 CN44-1

CN44-3

(El , GND)

1

o :

Defective plug-in analyzer. Connect the analyzer to other vehicle and check if the data is displayed.

-

13

m 2

-

OK

Defective SAS controller.

NG >

6 o m : 2.

-

SAS is provided with the following diagnosis function:

DIAGNOSIS When abnormality is detected with SAS sensors and switches, SAS warning lamp starts blinking or is turned ON with the sounding of the buzzer. At the same time, error codes (maximum 5 error codes for multiple errors) are displayed to the hour meter. The SAS controller stores these error codes and their time of generation (in maximum ten memories). Displaying those errors on the hour meter enables to check abnormality that has occurred temporarily. When these error memory contents are displayed on the analyzer (SST), further classified error codes can be checked. (See page 15-50.) Perform repair promptly by referring to a pertinent troubleshooting to the error code concerned.

How to display diagnosis memory

Note: Turning the key switch ON (or starting engine) after removing the DlAG MEMORY short pin causes an error (code 42) displayed and stored to the controller, for which care shpuld be taken.

1. Turn the key switch ON (or start engine). 2. Open the diag connector cover and remove the diag

memory short pin. (1) Ten error codes and the corresponding hour meter

times are displayed sequentially from the latest one. (2) If no error code memory exists, the error number is

followed with a blank space and the hour meter time with a period only.

(3) Upon indicating tenth error code and generation time, the dotted line appears to make separation and the display starts again with the latest error code in memory.

3. Install the diag memory short pin and close the diag connector cover.

Note: lnstall position error may cause a controller failure, for which care should be taken. Don't substitute a short pin with other object.

4. Turn the key switch OFF.

Error code

*I : Stores sub-error codes only to the SAS control without display on the hour meter.

Content

Lifting height switch abnormality

Controller abnormality


Communication abnormality between the controller and the hour

*2: Because of an error code output by the hour meter, no storage is made on the SAS controller.

*3: If an error is detected in the locked state, locking is maintained until the ignition switch is turned OFF.

Rear wheel

Lateral G lock

Controlled as the lower lifting height

Constant locking

Constant locking

Normal control

Phenomenon generated to the machine

swing control

Yaw rate lock

t

+-

t

t

Manual backward

tilting operation

Backward tilting speed is faster for a high lifting height

Slower backward tilting speed for a lower lifting height


t

Manual forward tilting

operation

Normal control

Normal control

Normal control

t

Mast tilt control

Mast backward tilt

speed control

t



t

Mast forward tilt angle control

Operates to a maximum forward tilt position

Operable to a maximum forward tilt position

Operable to a maximum forward tilt position

Normal control

Automatic horizontal

stop control

stops when knob switch is turned ON

stop horizontal

horizontal

t

TROUBLESHOOTING Perform troubleshooting according to the troubleshooting by error code when an error code is displayed, and according to the troubleshooting by phenomenon when no error code is displayed.

TROUBLESHOOTING BY ERROR CODE Troubleshooting by error code is described below in the order of the error code. Perform troubleshooting according to the procedure corresponding to each error code. When the plug in analyzer (SST) is available, use the DlAG MEMORY and check the error code and perform troubleshooting accordingly.

List of Reference Pages for Error Codes and Sub Error Codes

Page '

15-52

15-53

15-54

1 5-56

'

15-57

'

15-61

15-67

15-71

Error code

41

42

51

52

54

61

62

63

Page

15-52

15-53

15-54

15-54

15-56

1 5-56

15-56

1 5-57

1 5-61

1 5-61

1 5-67

15-67

15-71

15-71

15-71

Error code

41 -1

42-1

51 -1

51-2

52-1

52-2

52-3

54- 1

61-1

61 -2

62-1

62-2

63-1

63-2

63-3

Without analyzer (SST)

Error description

Resetting switch abnormality

DlAG switch abnormality

Speed sensor abnormality

Yaw rate sensor abnormality

Swing solenoid abnormality

Load sensor abnormality

Tilt angle sensor abnormality

Tilt lever switch abnormality

With analyzer (SST)

Error description

Resetting switch abnormality

DlAG switch abnormality

Speed sensor open circuit

Speed sensor short circuit

Yaw rate sensor open circuit

Yaw rate sensor short circuit

Yaw rate sensor neutral voltage abnormality

Swing solenoid abnormality

Load sensor open circuit

Load sensor short circuit

Tilt angle sensor open circuit

Tilt angle sensor short circuit

Tilt lever switch simultaneous ON

Forward tilt switch short circuit for 2 minutes

Backward tilt switch short circuit for 2 minutes

* I : The error code is stored in the SAS controller, and display by the hour meter is not made.

'*: Because of the error code output from the hour meter, it is not stored in the SAS controller and checking by the analyzer fails.

Page

15-78

15-80

15-82

15-83

15-87

-

1 5-93

Error code

64

65

66

67

(AF)''

EF

F1"

L

Page

15-78

15-80

1 5-82

1 5-83

-

-

-

-

-

-

-

Error code

64-1

65-1

66-1

67-1

AF-1

AF-2

AF-3

AF-4

EF-1

EF-2

-

Without analyzer (SST)

Error description

Tilt solenoid No.1 abnormality


Tilt angle resetting value abnormality

Fork height switch abnormality (When there is no fork height switch)

Fork height switch abnormality (When fork height switch is used)



Abnormal communication between controller and hour meter

With analyzer (SST)

Error description



Tilt angle resetting value abnormality

Fork height switch abnormality (When there is no fork height switch)

Fork height switch abnormality (When fork height switch is used)

CPU abnormality

ROM abnormality

RAM abnormality

AD conversion abnormality

EEPROM abnormality

EEPROM abnormality

-

Error Code 41 or 41-1 (Re-setting switch abnormality)

Related Portion

P

- - CNI-7 (SWI. Re-setting sw~tch) CN35-1 o

- $ 2 - u m o - - g 2 $ CN35 0 0 CNI-23 (E02, SW - GND) CN35-1

-- CN1

Estimated Causes: @) Connector contact defect @ Resetting connector harness defect @ Controller defect

Inspection 1 : Continuity inspection between CN1 and CN35 Turn the ignition switch OFF, and disconnect CN1 and CN35.

Standard: CN1-7 - CN35-1: Continuity shall exist. CN1-23 - CN35-I: Continuity shall exist.

- Error display check after correction. lnspect connectors CNI and CN35 for disconnection.

CN1 (REC)

NG >

CN35 (REC)

OK I NG

Inspection 1 Inspect continuity between CN1-7 and CN35-1 and between CN1-23 and CN35-1.

Harness defect.

Controller defect.

Error Code 42 or 42-1 (Diag. switch abnormality)

Related Portion

CNl-6 (SW2, DIAGSW)

4 W

CN1-23 (E02, SW - GND)

. Shorting pin

Estimated Causes: @ Disconnected shorting pin @ Connector contact defect @ DlAG connector harness defect @ Controller defect

lnspection 1 : lnspect continuity between CN1 and CN44. Turn the ignition switch OFF and disconnect CN1 and CN44 shorting pin.

Standard: CNI (REC)

CN1-6 - CN44-23: Continuity shall exist. CN1-23 - CN44-22: continu;ty shall exist.

Error display check after correction. lnspect the shorting pin at CN44 for disconnection.

CN44 (REC)

OK , 1 NG

- lnspect the CN1 connector for disconnection.

NG > Error display check after correction.

Inspection 1 NG lnspect continuity between CN1-6 and CN44-23 and

> Harness defect.

between CNI -23 and CN44-22.

OK

Controller defect.

NG >

Error Code 51 (Speed sensor abnormality) Error Code 51-1 (Speed sensor open circuit) Error Code 51-2 (Speed sensor short circuit)

Related Portion

Estimated Causes: @) Connector contact defect @ Speed sensor harness defect @ Speed sensor defect @ Controller defect

a) - - g 8

lnspection 1 : lnspect continuity between harness CN2 and CN22 and between the SPD+/SPD- line and frame.

m

Inspect CN2 and CN22 connectors for disconnection or NG > internal wetting.

Turn the ignition switch OFF and disconnect CN2 and CN22.

Check SAS lamp off after correction.

Standard: CN2-4 - CN22-1: Continuity shall exist. CN2-5 - CN22-2: Continuity shall exist. CN22-1 - CN22-2: No continuity. CN22-1 - Frame: No continuity. CN22-2 - Frame: No continuity.

o 2:

CN2 (REC) CN22 (REC)

OK NG /

lnspection 2: lnspect resistance between sensor CN22-1 and CN22-2 and continuity between CN22-1 or CN22-2 and

c~2-4 (SPD +, speed sensor +) ~~22 .1

CN2.5 (SPD -, speed sensor -) CNZ-2 - CNZ

lnspection 1 Inspect continuity between harness CN2 and CN22 and between the SPD+/SPD- line and frame.

frame.

Harness defect.

Turn the ignition switch OFF and disconnect CN22.

--

8: E l -

---i

Standard: Resistance between CN22-1 and CN22-2: 620 + 60 R (standard) CN22-1 - Frame: No continuity CN22-2 - Frame: No continuity.

E p % (0

lnspection 2 Inspect resistance between sensor CN22-1 and CN22-2 and continuity between CN22-1 or CN22-2 and frame.

CN22 (TAB)

OK

Controller defect.

NG > Speed sensor defect.

lnspection 1 : lnspect continuity between CN2 and CN22.


After correction, make sure the SAS lamp goes out.

Inspect for disconnection and internal wetting of the CN2 and CN22 connectors.

Standard: CN2-4 - CN22-I: Continuity shall exist. CN2-5 - CN22-2: Continuity shall exist. CN22-1 - CN22-2: No continuity.

NG >


OK

lnspection 2: Make sure that speed indication corresponding to the actual speed is made during traveling.

NG

<

V

Connect all connectors, turn the ignoition switch ON (start the engine) and travel.

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU + SWING DATA

Inspection 1 NG > lnspect continuity between harness CN2 and CN22.

Standard: Speed indication shall change depending on the traveling speed.

Harness defect.

YAW SENSOR 2.50V

SWINGSOL ON

OK

lnspection 2 Make sure that speed indication corresponding to the Speed sensor defect. actual speed is made during traveling.

Controller defect.

lnspection 1 : lnspect continuity between the harness SPD+/SPD- line and frame.


After correction, make sure the SAS lamp goes out.

Inspect for disconnection and internal wetting of the CN2 and CN22 connectors.

Standard: CN22-1 - Frame: No continuity. CN22-2 - Frame: No continuity.

NG >

CN22 (REC)

OK

lnspection 2: Make sure that speed indication corresponding to the actual speed is made during traveling.

NG

<

Connect all connectors, turn the ignoition switch ON (start the engine) and travel.


lnspection 1 Inspect continuity between harness SPD+/SPD- line

Standard: Speed indication shall change depending on the traveling speed.

Harness defect.

Error code 52 (Yaw rate sensor abnormality) Error code 52-1 (Yaw rate sensor open circuit) Error code 52-2 (Yaw rate sensor short circuit) Error code 52-3 (Yaw rate sensor neutral voltage abnormality)

SWING DATA (112)

YAW SENSOR 2.50V

SWINGSOL ON

and frame.

Estimated Cause: @ Yaw rate sensor defect

lnspection 2 Make sure that speed indication corresponding to the

Speed sensor defect.

actual speed is made during traveling.

Controller defect.

Error code 54 (Swing solenoid abnormality) Error code 54-1 (Swing solenoid abnormality)

Related Portion

Estimated Causes: @ Connector contact defect @ Swing solenoid harness defect @ Swing solenoid defect @ Diode defect @ Controller defect

B C G) - o m

V)

& - - g 8

(SWN,

- 7 ~ 1

m

Inspection 1 After correction, make sure that the SAS lamp goes out.

Inspect for disconnection and internal wetting of the CN1, CN4, CN7, and CN11 connectors.

U_

NG >

-

--

OK NG

< V

'i3T/ CN7 C N l l l---..A Body ground~ng (El, Body ground~ng)

Swngsolena) CN1-25

li

lnspection 2 lnspect continuity with the diode (between CN1-25 and frame).

0

k!

Diode defect.

-

0

2; -

CN4

- 2

OK NG I

CN4-5

CN~-~( "L -s )

m

CN7-1

lnspection 3 lnspectcontinulty between harness CN1-25 and CN11-1, between the SWN line and frame, and between CN11-2 and frame.

o 2:

CN7-2

Harness defect.

7

0

k

CNl1-1

OK

>>

lnspection 4 Resistance between solenoid CN11-1 and CN11-2, and inspect continuity between CN11-1 and frame.

m 2

Solenoid defect.

CNl l -2

OK

Controller defect.

lnspection 1 : After correction, make sure that the SAS lamp goes out.

Connect all connectors then turn the ignoition switch on (start the engine). Standard: The SAS lamp shall not blink upon swing or slalom traveling (traveling that lights the lock lamp normally). Caution: Perform the traveling test carefully at a low speed.

lnspection 2: lnspect continuity with the diode (between CN1-25 and frame).

Turn the ignition switch OFF and disconnect CN1 and CN4. CNl (REC)

Standard: CN1-25 (Digital circuit tester 0 ) - Frame (Digital circuit tester 0 ) : No continuity. CNI -25 (Digital circuit tester 0 ) - Frame (Digital circuit tester 0 ) : Continuity shall exist. CNI -25 (Analog circuit tester 0 ) - Frame (Analog circuit tester 0 ) : No continuity. CN1-25 (Analog circuit tester 0 ) - Frame (Analog circuit tester 0 ) : Continuity shall exist.

lnspection 3: lnspect continuity between harness CNI -25 and CNI 1-1, between the SWN line and frame, and between CN11-2 and frame.

Turn the ignition switch OFF and disconnect CNI and CN11.

Standard: CN1-25 - CNI 1-1 : Continuity shall exist. CNI 1-1 (Digital circuit tester O) - Frame (Digital circuit tester 0 ) : No continuity.

CNl (REC) CNI 1-1 (Analog circuit tester O) - Frame (Analog circuit tester 0 ) : No continuity. CN11-2 - Frame: Continuity shall exist. CN11-1 (Digital circuit tester O) - CN11-2 (Digital circuit tester 0 ) : No continuity. CN11-1 (Analog circuit tester 0 ) - CN11-2 (Analog circuit tester O): No continuity.

& CN11 (REC)

lnspection 4: Resistance between solenoid CN11-1 and CN11-2 and inspect continuity between CN11-1 and frame.

Turn the ignition switch OFF and disconnect C N l l

Standard: CNI 1-1 - Frame: No continuity. Resistance between CN11-1 and CN11-2: Approx. 6 i2 (20°C).

C N l l (TAB)

lnspection 1 : After correction, make sure that the SAS larnp goes out.

Connect all connectors then turn the ignition switch ON (stop the engine).

Inspection 1 After correction, make sure that the SAS lamp goes out.

Inspect for disconnection and internal wetting of the CNl , CN4, CN7, and CNI 1 connectors.

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + ACTIVE TEST

NG >

Standard: The SAS larnp shall not blinkupon returning to the ANALYZER MENU by setting the SWING SOL to ONH (for 1 second or more) and OFF (for 1 second or more).

OK NG

< V

ACTIVE TEST (112)

TILT SOL2 KNOB SOL

lnspection 2 lnspect continuity with the diode (between CN1-25 and frame).

.L

Return to the ANALYZER MENU.

' Diode defect.

OK

lnspection 3 lnspect continuity between harness CN1-25 and CNI 1-1, between the SWN line and frame, and between CN11-2 and frame.

OK

lnspection 4 Resistance between solenoid CN11-1 and CN11-2 and inspect continuity between CN11-1 and frame.

Solenoid defect.

OK

Controller defect.

lnspection 2: Inspect continuity with the diode (between CNl-25 and frame).

Turn the ignition switch OFF and disconnect CN1 and CN4. CN1 (REC)

Standard: CN1-25 (Digital circuit tester 0 ) - Frame (Digital circuit tester O): No continuity. CN1-25 (Digital circuit tester O) - Frame (Digital circuit tester 0 ) : Continuity shall exist. CN1-25 (Analog circuit tester O) - Frame (Analog circuit tester 0 ) : No continuity. CNI -25 (Analog circuit tester O) - Frame (Analog circuit tester 0 ) : Continuity shall exist.

lnspection 3: Inspect continuity between harness CN1-25 and CN11-1, between the SWN line and frame, and between CN11-2 and frame.

Turn the ignition switch OFF and disconnect CN1 and CNI I .

Standard: CN1-25 - CN11-1: Continuity shall exist. CNI 1-1 (Digital circuit tester 0 ) - Frame (Digital circuit tester 0 ) : No continuity. CN11-1 (Analog circuit tester O) - Frame (Analog circuit tester 0 ) : No continuity. CN11-2 - Frame: Continuity shall exist. CN1 (REC)

CNI 1-1 (Digital circuit tester O) - CN11-2 (Digital circuit tester 0 ) : No continuity. CN11-1 (Analog circuit tester O) - CN11-2 (Analog circuit tester 8 ) : No continuity.

C N l l (REC)

lnspection 4: Resistance between solenoid CN11-1 and CN11-2 and inspect continuity between CNI 1-1 and frame.

Turn the ignition switch OFF and disconnect CNI I

Standard: CNI 1-1 - Frame: No continuity. Resistance between CN11-1 and CN11-2: Approx. 6 C2 (20°C).

C N l l (TAB)

Error code 61 (Load sensor abnormality) Error code 61-1 (Load sensor open circuit) Error code 61-2 (Load sensor short circuit)

Related Portion

Estimated Causes: @ Connector contact defect @ Load sensor harness defect @ Load sensor defect @ Controller defect

P

- 9 - 8

m

--

o a w k c

--

After correction, check SAS lamp indication.

Inspect for disconnection of the CNI , CN3, and CN26 connectors.

--

:e LA

NG >

CN1 CN3 CN26

CN1-l(5PRS. Loadsensorpower)

CN1-18 (PRES, Loadsensor)

CN1-22 (€01. Sensor GND)

, A 2

OK NG <

V

i5

-

-

o :

CN3-1 CN26-3

CN~-2 CN26-2

CN3-5 CN26-1 -


lnspect for internal wetting of the CN1 , CN3, and CN26 connectors.

0

NG , OK NG

< v

Inspection 1 Inspect continuity between CN1 and CN26.

NG >

OK OK

NG +I Inspection 2 Inspect continuity between CN1 and CN3.

Replace the load sensor then check SAS lamp indication.

Harness defect.

Inspection 3 lnspect continuity between CN3 and CN26.

NG OK

NG >

Controller defect.

Harness defect.

CN3 connector defect.

lnspection 1 : lnspect continuity between CNI and CN26.


Standard: CNI -1 - CN26-3: Continuity shall exist. CN1-18 - CN26-2: Continuity shall exist. CN1-22 - CN26-1: Continuity shall exist. CN1-1 - CN1-18: No continuity. CN1-1 - CN1-22: No continuity. CN1-18 - CN1-22: No continuity.

lnspection 2: lnspect continuity between CNI and CN3.


Standard: CN1-1 - CN3-1: Continuity shall exist. CN1-18 - CN3-2: Continuity shall exist. CNI-22 - CN3-5: Continuity shall exist. CN1-1 - CN1-18: No continuity. CNI -1 - CNI -22: No continuity. CNI-18 - CN1-22: No continuity.

lnspection 3: lnspect continuity between CN3 and CN26.


Standard: CN3-1 - CN26-3: Continuity shall exist. CN3-2 - CN26-2: Continuity shall exist. CN3-5 - CN26-1: Continuity shall exist. CN3-1 - CN3-2: No continuity. CN3-1 - CN3-5: No continuity. CN3-2 - CN3-5: No continuity.



Inspect for disconnection of the CNI, CN3, and CN26 connectors.

NG )


OK NG <

V

Inspect for water entry into the CN1, CN3, and CN26 connectors.

NG )


OK NG <

W

OK lnspection 1 lnspect continuity between CN1 and CN26.

NG

lnspection 2 lnspect continuity between CNI and CN3.

NG ) Harness defect.

OK 1 lnspection 3 Inspect continuity between CN3 and CN26.


OK

) CN3 connector defect.

lnspection 4 Inspect the voltage of the load sensor when the mast is in each status.

OK

Controller defect.

NG )

1

Load sensor defect.



Standard: CN1-1 - CN26-3: Continuity shall exist. CN1-18 - CN26-2: Continuity shall exist. CNI -22 - CN26-1: Continuity shall exist. CN1-1 - CN1-22: No continuity. CN1-18 - CN1-22: No continuity. CN1 (REC) CN26 (REC)



Standard: CNI -1 - CN3-1: Continuity shall exist. CN1-18 - CN3-2: Continuity shall exist. CNI -22 - CN3-5: Continuity shall exist. CN1-1 - CNI -22: No continuity. CN1-18 - CN1-22: No continuity.


CN3 (TAB)


Standard: CN3-1 - CN26-3: Continuity shall exist. CN3-2 - CN26-2: Continuity shall exist. CN3-5 - CN26-1: Continuity shall exist. CN3-1 - CN3-5: No continuity. CN3-2 - CN3-5: No continuity. CN3 (REC) CN26 (REC)

lnspection 4: lnspect the voltage of the load sensor when the mast is in each status.

Turn the ignition switch ON (start the engine).

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU + MAST DATA

Standard: Load value Fully lowered state (with the lift cylinder pressure released):

0.10 to 1.00 v Relief state at the uppermost end:

3.5 to 4.8 V

TlLT 2.20V CONT 2.20V LEVEL 2.20V

SOL2 OFF

lnspect for water entry to the inside of the CN1, CN3, and CN26 connectors.

NG )


OK NG

< V

OK lnspection 1 lnspect continuity between CNI and CN26.

NG

lnspection 2 Inspect continuity between CNI and CN3.


OK

lnspection 3 Inspect continuity between CN3 and CN26.


OK

> CN3 connector defect.

I

lnspection 4 lnspect the voltage of the load sensor when the mast is in each status.

OK

Controller defect.

NG ) Load sensor defect.



Standard: CN1-1 - CNI-18: No continuity.

CNl (REC)



Standard: CNI -1 - CNI-18: No continuity.

CN1 (REC)



Standard: CN3-1 - CN3-2: No continuity.

CN3 (REC)

lnspection 4: lnspect the voltage of the load sensor when the mast is in each status.



Standard: Load value Fully lowered state (with the lift cylinder pressure released):

0.1 0 to 1 .OO V Relief state at the uppermost end:

3.5 to 4.8 V

a Error code 62 (Tilt angle sensor abnormality) a Error code 62-1 (Tilt angle sensor open circuit) a Error code 62-2 (Tilt angle sensor short circuit)

Related Portion

Estimated Causes: @) Connector contact defect @ Tilt angle sensor harness defect @ Tilt angle sensor defect @ Controller defect

L

w - - 0 L - s 0 0

CN27

m a I-

0 W - c

Inspect the tilt angle sensor for disconnection NG After correction, check SAS lamp indication. from the link and damages.

OK NG Y 7

Inspect for connector disconnection between NG After correction, check SAS lamp indication. CN1 and CN27.

OK / NG - v

CN1-14 (5MA, Tilt angle sensor power) CN27-1

CN1-17 (MA, Tilt angle sensor)

CN1-22 (E01, Sensor GND)

P

Inspect for water entry into the connector between CN1 and CN27.

NG 7-


OK / NG v


NG )

-~

Harnessdefect.

OK

Tilt angle sensor defect. lnspection 2 lnspect the tilt angle sensor.

OK

Controller defect.

NG )



Standard: CN1-14 - CN27-1: Continuity shall exist. CN1-17 - CN27-2: Continuity shall exist. CN1-22 - CN27-3: Continuity shall exist. CN1-14 - CN1-17: No continuity. CN1-14 - CN1-22: No continuity. CN1-17 - CN1-22: No continuity. CN1 (REC) CN27 (REC)

lnspection 2: lnspect the potential change upon tilt operation.

Remove the tilt angle sensor and perform re-setting after installing the tilt angle sensor

Standard: Measure resistance between tilt angle sensor terminals. CN27-1 - CN27-3: 1.5 kR + 0.3 kR CN27-2 - CN27-3: 0 kR when the sensor lever is free:

1.5 kR + 0.3kR when the sensor lever is in full stroke:

(ij) CN27 (TAB)

Inspect the tilt angle sensor for disconnection After correction, check SAS lamp from the link and damages. indication.

Inspect for connector disconnection between After correction, check SAS lamp CNI and CN27. indication.

Inspect for water entry into the CN1 and CN27 After correction, check SAS lamp connectors. indication.

lnspection 2 lnspect the potential change upon tilt operation. Tilt angle sensor defect.


I Controller defect. I

NG > Harness defect.



Standard: CN1-14 - CN27-1: Continuity shall exist. CN1-17 - CN27-2: Continuity shall exist. CN1-14 - CN1-22: No continuity. CNI -1 7 - CN1-22: No continuity.




Analyzer: MAIN MENU i SAS MENU +ANALYZER MENU -+ IN OUT MENU i MAST DATA

Standard: The tilt value shall be 0.1 - 4.8 V when the mast is tilted fully backward from the full forward position. The value shall rise as the mast is tilted backward.

lnspection 1 : lnspect continuity between CN1 and CN27



Inspect the tilt angle sensor for disconnection from the link and damages.

Standard: CN1-22 - CN27-3: Continuity shall exist. CN1-14 - CN1-17: No continuity.

NG )


OK


I NG V



Inspect for connector disconnection between CNI and CN27.

Standard: The tilt value shall be 0.1 - 4.8 V when the mast is tilted fully backward from the full forward tilt position. The value shall rise as the mast is tilted backward.

NG )


SOL2 OFF


OK I NG

v

Inspect for water entry into the CNI and CN27 NG After correction, check SAS lamp connectors.

> indication.

lnspection 1 lnspect continuity between CN1 and CN27.

NG Harnessdefect.

OK

Tilt angle sensor defect. Inspection 2 Inspect the potential change upon tilt operation.

OK

Controller defect.

NG >

Error code 63 (Tilt lever switch abnormality) Error code 63-1 (Both tilt lever switches ON at the same time) Error code 63-2 (Forward tilt switch 2-minute short circuit) Error code 63-3 (Backward tilt switch 2-minute short circuit)

Related Portion

Estimated Causes: @ Connector contact defect @ Tilt switch harness defect @ Forward tilt switch defect

Forward CN34-2 tilt switch

& -

@) Backward tilt switch defect @ Tilt switch mounting defect @ Controller defect

- - e - s o 0

* After the ignition switch is turned ON, make sure that the SAS lamp is lit upon tilting forward and backward. Make sure that the 2-minute waiting SAS lamp blinks when the tilt lever is on the neutral position.

- -

CN1 CN34

m < I-

Inspect for water entry into the CN1 and CN34 NG After correction, check SAS lamp connectors. ) indication.*

OK

v

lnspection 1 lnspect continuity through the tilt lever switch wiring.

NG ) Controller defect.

OK

o Ot

Inspection 3 Inspect continuity between CN1 and CN34.

Inspection 2 Inspect continuity through the tilt lever switch only

OK )

P

CN1-9 (MR,'T~I~ lever SW2 (backward))

CN1-23 (E02, SW - GND)

(mounted on the vehicle).

/

OK NG

NG

0 l L l

V

In a I-

Inspection 4 lnspect continuity through the tilt lever switch only (removed from the vehicle).

CN34-3

Tilt lever switch mounting defect.

Tilt lever switch abnormality.

NG Harness defect.

~ ~ 3 4 - 4

OK +

Backward tilt switch


lnspection 1 : lnspect continuity through the tilt lever switch wiring.

Turn the ignition switch OFF and disconnect CNI. CN1 (REC)

Standard:

lnspection 2: lnspect continuity through the tilt lever switch only (mounted on the vehicle).

CN1-10 - CN1-23

CN1-9 - CN1-23


Standard: CN34 (TAB)

Lever at backward tilt position

No continuity.

Continuity shall exist.

Lever at neutral position

No continuity.

No continuity.

Lever at forward tilt position


No continuity.




No continuity.


CN34-1 - CN34-2

CN34-3 - CN34-4

Standard: CN1 - I 0 - CNI-9: No continuity. CNI-10 - CN1-23: No continuity. CNI-9 - CNI -23: No continuity.

lnspection 4: lnspect continuity through the tilt lever switch only (removed from the vehicle).


No continuity.

No continuity.




No continuity.

CN1 (REC)

CN34 (TAB)

Standard: Upper side switch (switch on the top when mounted on the vehicle)

Lower side switch (switch on the bottom when mounted on the vehicle)

CN34-1 - CN34-2

Switch free


CN34-3 - CN34-4

Switch depressed

No continuity.

Switch free


Switch depressed

No continuity.

* After the ignition switch is turned ON, make sure that the SAS lamp is lit upon tilting forward and backward.

Inspect for water entry into the CN1 and CN34 connectors. -

lnspection 1 : lnspect continuity through the tilt lever switch wiring.


Standard: CNl (REC)

NG > After correction, check SAS lamp

indication.*

OK

lnspection 2: lnspect continuity through the tilt lever switch only (mounted on the vehicle).


Standard:

NG V

CNI -1 0 - CN1-23

CNI -9 - CN1-23

@ CN34 (TAB)

Inspection 1 Inspect continuity through the tilt lever switch wiring.


No continuity.

No continuity.

OK . Controller defect.

lever operation.

CN34-1 - CN34-2

CN34-3 - CN34-4



No continuity.

NG


No continuity.



No continuity.

No continuity.

V



No continuity.

Inspection 2 Inspect continuity through the tilt lever switch only (mounted on the vehicle).


No continuity.


OK Inspection 3 > Inspect continuity between CNI Harness defect.

and CN34.

NG CN34 connector defect.

lnspection 4 lnspect continuity through the tilt lever switch only (removed from the vehicle).

OK

Tilt lever switch mounting defect.

NG , Tilt lever switch abnormality.



Standard: CNI-10 - CNI -9: No continuity. CN1-10 - CN1-23: No continuity. CN1-9 - CN1-23: No continuity.



CNl (REC)

CN34 (TAB)

Standard: Upper side switch (switch on the top when mounted on the vehicle)

Lower side switch (switch on the bottom when mounted on the vehicle)

CN34-1 - CN34-2

lnspection 5: lnspect the switch output upon tilt lever operation.

Turn the ignition switch ON (stop the engine).

Analyzer: MAIN MENU -+ SAS MENU + ANALYZER MENU + IN OUT MENU -+ MAST DATA

Standard:

Switch free


CN34-3 - CN34-4

Switch depressed

No continuity.

KNOB OFF HEIGHT SW1 ON

S W 2 1 OFF S W 2 2 OFF

Switch free


Forward tilt

Backward tilt

Switch depressed

No continuity.


OFF

OFF

Lever tilted forward

ON

OFF

Lever tilted backward

OFF

ON

* I : Make sure that the 2-minute waiting SAS lamp blinks when the tilt lever is at the neutral position. *': This tilt lever switch is the upper switch among two switches mounted on the second spool of the

control valve.

Inspect for water entry into the NG After correction, check SAS lamp CN1 and CN34 connectors.

> indication.*' -~

NG

lnspection 1 Inspect continuity between CNI -1 0 Controller defect. and CN1-23. tilt lever is at the neutral position.

NG > CNI connector defect.

V

lnspection 2 lnspect continuity between CN34-1

1 and CN34-2. and CN1-23 (harness only).

NG

Inspection 1 : lnspect continuity between CNI -I 0 and CN 1 -23.

lnspection 4 lnspect continuity through the tilt lever switch only (removed from the vehicle).*2

Turn the ignition switch OFF and disconnect CN1 .

Standard: CN1 - I 0 - CN1-23: No continuity.

OK

Tilt lever switch mounting defect.*2

NG ,

CN1 (REC)

Tilt lever switch abnormality.

lnspection 2: lnspect continuity between CN34-1 and CN34-2. (Inspect on the connector at the tilt switch side.)



lnspection 3: lnspect continuity between CNI-10 and CNI -23 (harness only).


Standard: CNI -1 0 - CNI -23: No continuity. -



Standard: Upper side switch (switch on the top when mounted on the vehicle) CN34 (TAB)

Switch free

lnspection 5: lnspect the switch output when the tilt lever is at the neutral position.

Switch depressed

CN34-1 - CN34-2


I

Continuity shall exist. I No continuity.



SW21 SW22 OFF OFF

Standard: FORWARD OFF when the tilt lever is at the neutral position c

-1 c 6

SAS lamp indication check after correction.*'

Inspect for water entry into the CN1 and CN34 connectors.

NG >

OK I NG V

Inspection 5 lnspect the switch output with the tilt lever in the neutral position.

Inspection 1 Inspect continuity between CN1-9 and CN1-23.

OK > OK > Controller defect.

CN1 connector defect. NG NG

> V

Inspection 2 Inspect continuity between CN34-3 and CN34-4.

OK >

NG inspection).

Inspection 3 Inspect continuity between CNI-9 and CN 1-23. (Individual harness

Harness defect.

OK

NG >I CN34 connector

Inspection 4 lnspect continuity of the tilt lever switch alone (after removal from the vehicle).**

>I OK

Tilt lever switch installation defect.*2

* I : Wait for 2 minutes with the tilt lever in the neutral position, and check if the SAS lamp blinks. *2: This tilt lever switch is the lower one out of two switches in stalled on the second spool of the control

valve.

abnormality.

NG > Tilt lever switch abnormality.

lnspection 1 : lnspect continuity between CN1-9 and CNI-23.

Turn the ignition switch OFF and disconnect CN1. CN1 (REC)

Standard: CNI-9 - CN1-23: No continuity.

lnspection 2: lnspect continuity between CN34-3 and CN34-4. (Inspect on the connector at the tilt switch side.)



lnspection 3: lnspect continuity between CNI-9 and CN1-23 (harness only).


Standard: CNI-9 - CN1-23: No continuity.

lnspection 4: lnspect continuity of the tilt lever switch alone (after removal from the vehicle).

Turn the ignition switch OFF and disconnect CN34,

Standard: Lower switch (switch on the lower side when installed on the vehicle)

@ CN34 (TAB)

CN1 (REC)

CN34 (TAB)

lnspection 5: lnspect the switch output when the tilt lever is at the neutral position.

Turn the ignition switch ON (engine in stopped state)

Switch in pressed state

No continuity. CN34-3 - CN34-4


Switch in free state


Standard: BACKWARD OFF state when the tilt lever is in the neutral position.


SW21 OFF SW22 OFF

Error code 64 (Tilt solenoid No.1 abnormality) Error code 64-1

Related Portion

r Tilt Solenoid

CN1-13 (TLTI , Tilt solenoid1 ) CN12-1 No.1 - L

al - -- - rn 0 0 m 2 4 w A L - c

I- CT E 2 0 o CN~-24 (El, Main GND) CN 12-2 L

i! l-ll CN12

Estimated Causes: @ Connector contact defect @ Tilt solenoid No.1 harness defect

@ Tilt solenoid No.1 defect @ Controller defect

Make sure that the SAS lamp blinks NG Make sure that the SAS lamp blinks when the tilt immediately after the key is turned on.

> lever is operated after the key is turned on. -

OK

- Inspect for disconnection of the CNl and NG > After correction, check SAS lamp indication. CN12 connectors.

NG

- Inspect for water entry into the CN1 and CN12 NG , After correction, check SAS lamp indication. connectors. -

NG

Inspection 1 lnspect resistance through the tilt solenoid No.1 wiring.

NG OK Inspection 3 NG , Harnessdefect.

inspect continuity between OK V CNI and CN12.

lnspection 2 Inspect resistance through the tilt CN12 connector defect. solenoid No.1 only. NG , Solenoid defect.

lnspection 4 Harness defect.

solenoid No.1 + line and power lnspect continuity between the tilt OK > Controller defect. (12 V) line.

OK > Controller defect.

lnspection 1 : lnspect resistance through the tilt solenoid No.1 wiring.

Turn the ignition switch OFF and disconnect CNI. CNl (REC)

Standard: CN1-13 (Digital circuit tester O) - CNI-24 (Digital circuit tester O): Resistance Approx. 10 LR CNI-13 (Analog circuit tester O) - CN1-24 (Analog circuit tester 0): Resistance Approx. 10 LR

lnspection 2: lnspect resistance through the tilt solenoid No.1 only.

Turn the ignition switch OFF and disconnect CN12. ~ ~ 1 2 (TAB)

Standard: CN12-1 (Digital circuit tester O) - CN12-2 (Digital circuit tester 0): Resistance Approx. 10 R CN12-1 (Analog circuit tester O) - CN12-2 (Analog circuit tester 0): Resistance Approx. 10 52



Standard: CNI-13 - CN12-I: Continuity shall exist. CN1-24 - CN12-2: Continuity shall exist. CNI -1 3 - CNI-24: No continuity. CNl (REC) CN12 (REC)

lnspection 4: lnspect continuity between the tilt solenoid No.1 + line and power (1 2 V) line.


Standard: CNI -11 - CNI-13: No continuity.

CN1 (REC)

Error code 65 (Tilt solenoid No.2 abnormality) Error code 65-1

Related Portion

Estimated Causes: @ Connector contact defect @ Tilt solenoid No.2 defect @ Tilt solenoid No.2 harness defect @ Controller defect

-- CN1-12 (TLT2, Tilt solenoid 2)

L

al - - m U 2 a w - I- tx C 0 o CN1-24 (El, Main GND)

P I I I I YES

L U CN13 l-l

r

Tilt solenoid No.2

lnspect for disconnection of the CN1 and After correction, check SAS lamp indication.* CN13 connectors.

o w iI

-

Make sure that the SAS lamp blinks when the tilt lever backward operation is performed with the mast at a low lifting height after the ignition switch is turned ON.

YES

- AL

m a I-

Make sure that the SAS lamp blinks immediately after the key is turned on.

lnspect for water entry into the CNI and CN13 connectors.

*: Make sure that the SAS lamp blinks when the tilt lever backward operation is performed with the mast at a low lifting height after the ignition switch is turned on.

CN13-1

CN13-2

NO >

Inspection 1 lnspect resistance through the tilt solenoid No.2 wiring.

NG , Atter correction, check SAS lamp indication.*

NG OK Inspection 3 NG 3 Harness defect.

lnspect continuity between OK Y CNI and CN13.

lnspection 2 Inspect resistance through the tilt CN13 connector defect. solenoid No.2 only.

Inspection 4 NG > Harness defect. lnspect continuity between the tilt > solenoid No.2 + line and power OK (1 2 V) line. > Controller defect.


lnspection 1 : lnspect resistance through the tilt solenoid No.2 wiring.

Turn the ignition switch OFF and disconnect CNI. CNl (REC)

Standard: CN1-12 (Digital circuit tester O) - CN1-24 (Digital circuit tester O): Resistance Approx. 10 R CNI -1 2 (Analog circuit tester O) - CN1-24 (Analog circuit tester O): Resistance Approx. 10 Q

lnspection 2: lnspect resistance.through the tilt solenoid No.2 only.

Turn the ignition switch OFF and disconnect CN13. C N I ~ (TAB)

Standard: CN13-1 (Digital circuit tester O) - CN13-2 (Digital circuit tester 0 ) : Resistance Approx. 10 R CN13-1 (Analog circuit tester O) - CN13-2 (Analog circuit tester O): Resistance Approx. 10 i2



Standard: CNI -1 2 - CN13-1: Continuity shall exist. CN1-24 - CN13-2: Continuity shall exist. CN1-12 - CNI -24: No continuity. CNI (REC) CN13 (REC)

lnspection 4: lnspect continuity between the tilt solenoid No.2 + line and power (1 2 V) line.


Standard: CN1-11 - CN1-12: No continuity. CN1 (REC)

Error code 66 66-1 (Tilt angle/NL load re-setting value abnormality)

Estimated Cause: @ Controller defect

Controller abnormality. Turn onloff the ignition switch to check error indication.

NG >

OK W

Reset the controller to the normal status.

-

Error code 67 67-1 (Lifting height switch abnormality)

<When there is no fork height switch:>

Related Portion

Mast harness

Short circuit

-. - .

Estimated Causes: @ Connector contact defect @ (Lifting height switch) Harness defect @ Controller defect

L a, - - 2 - c

5

-

m 6

7

o W

Inspect for disconnection of the CN1 and CN3 NG After correction, check SAS lamp indication. connectors.

Inspect for water entry into the CN1 and CN3 NG After correction, check SAS lamp indication. connectors.

NG

Inspection 1 OK lnspect continuity through the mast harness wiring.

) Controller defect.

NG

chl I CN3

CN1-23 (E02, SW - GND)

CN1-3 (MH1, Lifting height sensor 1 )

CN1-4 (MH21, Lifting height sensor 21)

CN3-3

CN3-7

CN3-4 $

Mast harness defect. lnspection 2 lnspect continuity through the mast harness only.

$ a:

NG )

OK

Harness defect. lnspection 3 lnspect continuity between CN1 and CN3.

NG >

OK

> CN3 connector defect.

lnspection 1 : lnspect continuity through the mast harness wiring.


Standard: CNI-23 - CNI-3: Continuity shall exist. CN1-23 - CNI -4: No continuity.

CNl (REC)

lnspection 2: lnspect continuity through the mast harness only.


Standard: CN3-3 - CN3-7: Continuity shall exist. CN3-3 - CN3-4: No continuity. CN3-3 - CN3-8: No continuity. CN3-4 - CN3-8: No continuity.



Standard: CNI-23 - CN3-3: Continuity shall exist. CN1-3 - CN3-7: Continuity shall exist. CNI -23 - CNI-3: No continuity. CNI -23 - CN1-4: No continuity. CN1-3 - CN1-4: No continuity. CNI-3 - CN1-5: No continuity. CN1-4 - CN1-5: No continuity.

CN3 (REC)

CN1 (REC) CN3 (TAB)

lnspection 1 : lnspect continuity through the mast harness wiring.

-

Inspect for disconnection of the NG After correction, check SAS lamp CN1 and CN3 connectors.

> indication.


OK

Standard: CN1-23 - CNI-3: Continuity shall exist. CNI-23 - CN1-4: No continuity. CNI -4 - CN1-5: No continuity.

&

NG

V

lnspection 2: lnspect continuity through the mast harness only.

Inspect for water entry into the NG After correction, check SAS lamp CNI and CN3 connectors.

> indication.

lnspection 1 lnspect continuity through the mast harness wiring.

NG > CN1 connector defect.

lnspection 2 Inspect continuity through the Mast harness defect. mast harness only.

lnspection 3 Inspect continuity between CN1 Harness defect. and CN3.



CN1 (REC)

Standard: CN3-3 - CN3-7: Continuity shall exist. CN3-3 - CN3-4: No continuity. CN3-3 - CN3-8: No continuity. CN3-4 - CN3-8: No continuity.

CN3 (REC)

Inspection 3: lnspect continuity between CNI and CN3.


Standard: CN1-23 - CN3-3: Continuity shall exist. CNI -3 - CN3-7: Continuity shall exist. CNI -23 - CNI -3: No continuity. CNI -23 - CNI -4: No continuity. CNI -3 - CN1-4: No continuity.

CN1 (REC) CN3 (TAB)

Inspection 4: lnspect the output of the lifting height switch.



Standard: SWI : ON SW21: OFF SW22: OFF KNOB OFF

HEIGHT SW1 SW21 OFF ON

SW22 OFF

Error code 67 67-1 (Lifting height switch abnormality)

<When fork height switch is used:>

Related Portion

Estimated Causes: @ Connector contact defect @ (Lifting height switch) Harness defect

@ Lifting height switch defect @ Controller defect

P

Inspect for disconnection of the CNI , CN3, and CN31 After correction, check SAS lamp connectors. ~ndication.*

L

a, - - f

S

--

m 2

-

%

lnspection 1 lnspect continuity through the lifting height switch wiring. Controller defect.

CN 1 CN3

CN1-23 (E02, SW - GND)

(MH1, Lifting CN1-3 height sensor 1)


L

lnspection 2 lnspect continuity through the lifting switch only.

m

P I Lifting height switch defect.

-

0

2:

-

After correction, check SAS lamp indication.*

Inspect for water entry into the CN1, CN3, and CN31 connectors.

- c 0 .-

2 E D .- a, r

- D c .- = 1

CN3-3 CN31-I

CN3-7 CN31-2

CN3-4 CN31-3

NG )

I lnspection 4 lnspect continuity between CN1 and CN3.


t"l Harness defect.

CN31

-7

2 I-

I lnspection 5 lnspect continuity between CN3 and CN31

OK >

t"--l Harness defect.

3 CC

-


-

-

-

OK

> --


*: If the SAS lamp blinks at a particular lifting height, check SAS lamp indication at the height.

lnspection 1 : lnspect continuity through the lifting height switch wiring.

Turn the ignition switch OFF and disconnect CNI.

Standard:

CN1 (REC)

Large lifting height

No continuity.


CN1-23 - CN1-3

CNI-23-CN1-4 >

CN1-3-CNI-4

lnspection 2: lnspect continuity through the lifting switch only.

Small lifting height


No continuity.

No continuity.


Standard:

CN31-1 - CN31-2

CN31-1 -CN31-3


CN31-2 - CN31-3




No continuity.

No continuity.

Standard: CN1-23 - CN31-1: Continuity shall exist. CNI -3 - CN31-2: Continuity shall exist. CN1-4 - CN31-3: Continuity shall exist. CN1-23 - CN1-3: No continuity. CN1-23 - CNI-4: No continuity. CN1-3 - CN1-4: No continuity.


No continuity.


CN31 (REC)

CNl (REC) CN31 (TAB)



(1) If continuity does not exist between connector terminals in which continuity should exist in inspection 3:

Standard: CN1-23 - CN3-3: Continuity shall exist. CN1-3 - CN3-7: Continuity shall exist. CN1-4 - CN3-4: Continuity shall exist.

(2) If continuity exist between connector terminals in which continuity should not exist in inspection 3:

Standard: CN1-23 - CN1-3: No continuity. CNI-23 - CN1-4: No continuity. CN1-3 - CN1-4: No continuity. CN1 (REC)





(2) If continuity exists between connector terminals in which continuity should not exist in inspection 3:

Standard: CN3-3 - CN3-7: No continuity. CN3-3 - CN3-4: No continuity. CN3-7 - CN3-4: No continuity.

CN3 (REC)

Inspect for disconnection of the NG After correction, check SAS lamp CNI, CN3, and CN31 connectors.

> indication.*

Inspect for water entry into the NG After correction, check SAS lamp CNI , CN3, and CN31 connectors.

> indication.* -

NG

lnspection 1 Inspect continuity through the > Inspect the output of the lifting Controller defect. lifting height switch wiring. height switch in each mast status.

NG

lnspection 2 Inspect continuity through the Lifting height switch defect. lifting switch only.

lnspection 3 Inspect continuity between CNI CN31 connector defect. and CN31.

lnspection 4 lnspect continuity between CN1 and CN3.

Inspect continuity between CN3 Harness defect.


*: If the SAS lamp blinks at a particular lifting height, check SAS lamp indication at the height.

lnspection 1 : lnspect continuity through the lifting height switch wiring.


Standard:

CN1 (REC)


No continuity.


CNI-23 - CN1-3

CN1-23 - CN1-4

CN1-3 - CN1-4

Inspection 2: lnspect continuity through the lifting switch only.


Standard:



No continuity.

No continuity.

inspection 3: lnspect continuity between CNI and CN31.


No continuity.


CN31-1 - CN31-2

CN31-1 - CN31-3

CN31-2 -CN31-3




No continuity.

No continuity.

Standard: CNI -23 - CN31-1: Continuity shall exist. CN1-3 - CN31-2: Continuity shall exist. CN1-4 - CN31-3: Continuity shall exist. CNI -23 - CN1-3: No continuity. CNI -23 - CN1-4: No continuity. CN1-3 - CN1-4: No continuity.

CN31 (REC)

CN1 (REC) CN31 (TAB)




Standard: CN1-23 - CN3-3: Continuity shall exist. CNI -3 - CN3-7: Continuity shall exist. CN1-4 - CN3-4: Continuity shall exist.

CN1 (REC) CN3 (TAB)

(2) If continuity does not exist between connector terminals in which continuity should not exist in inspection 3:

Standard: CN1-23 - CNI-3: No continuity. CN1-23 - CNI -4: No continuity. CN1-3 - CNI -4: No continuity. CN1 (REC)


Turn the ignition switch OFF and disconnect CN3 and CN31



(2) If continuity exists between connector terminals in which continuity should not exist in inspection 3:

Standard: CN3-3 - CN3-7: No continuity. CN3-3 - CN3-4: No continuity. CN3-7 - CN3-4: No continuity. CN3 (REC)

lnspection 6: lnspect the output of the lifting height switch in each mast status.


Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Standard:

MAST DATA (212)

KNOB OFF HEIGHT SW1

SW21 SW22 OFF OFF


OFF

ON

OFF

SW1

SW21

SW22


ON

OFF

OFF

Error code F1 (Controller - hourmeter communication abnormality)

Related Portion

Estimated Causes: @ Connector contact defect @ Hourmeter harness defect @ Hourmeter defect @ Controller defect

t - - g F 0 0

lnspection 1 : lnspect continuity between CN2 and CN41 and between CN2 and CN42. Turn the ignition switch OFF and disconnect CN2, CN41, and CN42.

Standard:

$ El-

--

I-

CN2-3 - CN41-4: Continuity shall exist. CN~ I (REG) CN2-12 - CN41-3: Continuity shall exist. CN2-11 - CN42-12: Continuity shall exist.

C N ~ (REC)

- t C .- - o m C .-

6 0

After correction, check indication. Inspect for slip off of the CN2, CN41, and CN42 connectors.

Inspection 2: ~ ~ 4 2 (REC) lnspect continuity between CN2 and CN41 and between CN2 and CN42. Turn the ignition switch ON (stop the engine).

2 a

m o ,5E

NG )

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU +OTHER DATA OTHER DATA (111)

Standard: VOLTAGE HOURS 11223.3h 12.4V

The correct time is indicated by the hourmeter (0.1 hour shortage permissible).

CN2-3 (HRM1, Clock) CN41-4

(342-1 2 (HRM2,Transm1ssion) CN41-3

CN41

CN2-11 (HRM3, Recept~on) CN42-12

CN2 CN42

OK

lnspection 1 Inspect continuity between CN2 and CN41 and between CN2 and CN42.

NG Harness defect.

OK

Hourmeter defect. Inspection 2 lnspect the communication line.

OK

Controller defect.

NG )

TROUBLESHOOTING BY PHENOMENON For SAS control related troubleshooting on failures with no error code indicated, procedures are described for without analyzer (SST) and with analyzer (SST). For combination meter (SAS) related troubles, a procedure contains the case without analyzer (SST) and the case with analyzer (SST). Perform troubleshooting according to each procedure.

List of pages to be referenced by symptom

a a, . .- + o = .

0 La a o

c 0 .- + o TS 3 i5 - - + - v, 2 2 g 0 0 > .- C

2

2 2 C

c .- C

'3 .r a

S

Description

Stability not provided during traveling. (Locking hardly or not provided during traveling.)

Swing lock always occurs during traveling or loading work. Or, swing lock frequently occurs

Active fork leveling is not provided. (Does not stop at a horizontal position but tilts at the forward-most position.)

Active fork leveling is not provided. (Stops at a non-horizontal position.)

Active fork leveling is not provided. (Stops at a position when the knob switch is pressed.)

The active mast rear tilt speed control is not regulatated, or the backward tilting speed is always slow.

The mast does not perform frontlrear tilt.

No error code is indicated although SAS warning lamp blinks.

" - " (underscore) is displayed on the hourmeter.

The SAS warning lamp is always lit.

When the ignition switch is turned on, the SAS warning lamp is not lit.

No hourmeter indication

The buzzer is not interlocked with the SAS warning lamp.

When the ignition switch is turned on, the swing lock lamp is not lit.

Page to be

Without analyzer

1 5-95

15-1 00

15-1 02

15-1 08

15-110

15-114

15-119

15-1 28

15-1 28

15-1 29

15-131

1 5-1 33

15-1 34

15-1 35

referenced

With analyzer

1 5-97

15-1 01

15-1 05

15-1 09

15-112

15-1 17

15-1 24

t

t

t

t

t

t

t

Stability not provided during traveling. (Locking hardly or not provided during traveling.)

Visually inspect for damages on the lock cylinder and pin.

I L I Lock cylinder component failure.

Hasn't any tire burst or isn't tire air pressure low? NG )

lnspection 1 Is the error code recorded?

YES 4 Is there any current error in the record?

Tire burstlair pressure abnormality.

I @ Make sure that the lock lamp is not lit when the (

NO , I NO ,YES

Go to that error code.

1 s im~ lv (Fork heiahtt 500 m h (19.7 ih) or lower). I

-

parking lever is operated slightly strongly.

@ Make sure that the lock lamp is not lit when the fork is lowered and the speed is araduallv increased

All OK

Does this trouble occurs during traveling with a large lifting height only?

NG )

I Can the mast be tilted to the forward-most I

Yaw rate sensor internal abnormality (Replace the yaw rate sensor). -

I" I position with a large lifting height and without I

Inspection 2 - NG )

lnspect operation of the lifting height switch.

load (excluding relief)? Doesthe mast stop at an a~~roximatelv 1 dearee front tilted Dosition I ' 1 5 4 Load sensor abnormality.

Lifting height switch abnormality.

I whei'the fork is i t theGpper-most poiition with I

I OK

Does this trouble occur only when a load is provided?

I no-load relief? I 1 OK

lnspect to see if the speed sensor body and sensor mounted state are normal. NG 4 Speed sensor defect.

lnspection 3 Make sure that the rear axle does not switch when the connector of the lock cylinder solenoid is removed and a front wheel goes over a step.

OK I Yaw rate sensor defect or controller defect (Replace the yaw rate sensor or controller).

OK 1

NG Failure such as lock cylinder internal leak, leak of operation oil to the outside, or solenoid sticking.

lnspection 1 : Is the error code recorded?

Turn ignition switch ON then remove the diagnosis shorting pin and check error code indication on the hourmeter display.

Standard: Errors near the current time shall not exist.

lnspection 2: Inspect operation of each lifting height switch.

Standard: Tilt backward at heights of small lifting height (fast) and large lifting height (slow), respectively, without load. The speeds shall be different.

Inspection 3: Make sure that the rear axle does not switch when the connector of the lock cylinder solenoid is removed and a front wheel goes over a step. (Alternatively, lift the rear of the vehicle with a jack and make sure that the rear axle does not swing.)

Standard: Remove the lock cylinder solenoid connector on a flat road. A front wheel or rear wheel shall be lifted when swing lock is performed and a front wheel goes over a step.

Caution: Front tire Perform this operation without load and at a small lifting height. Check for rocking for a large lifting height mast. After check, return to a flat road then connect the connector.

Slope

Note: Since this inspection requires connector removal and ignition switch ON, an error occurs, the SAS lamp blinks, and the error code is indicated and stored.

-

Hasn't any tire burst or isn't tire air pressure low? lLj Tire burstiair pressure abnormality. I J.

Visually inspect for damages on the lock cylinder and NG > Lock cylinder component failure. pin.

Inspection 2 - YES Is the error code recorded?

) Is there any current error in the record?

Inspection 1 Make sure that the rear axle does not swing when a front wheel goes over a step after swing SOL OFF.

NO ),I No 1 YES

Go to that error code.

OK I

NG )

Failure such as lock cylinder internal leak, leak of operation oil to the outside, or solenoid sticking.

OK

lnspection 4 @ Is the yaw rate sensor voltage change normal upon accelerated swing

along a circle with an approximately 2-meter (6.6 ft) radius? (Inspect the

lnspection 3 Does the speed value change according to the traveling seed?

1 right and left, respectively.) @ Make sure that the lock lamp is not lit when the parking lever is operated

slightly strongly. @ Make sure that the lock lamp is not lit when the fork is lowered and the

speed is gradually increased simply. (Fork height: 500 mm (1 9.7 in) or

NG )

lower)

All OK I

Speed sensor defect.

Yaw rate sensor internal

(Replace the yaw rate

Does this trouble occur during traveling with a large lifting height only?

NO YES I . , i

I I lnspection 5 Inspect operation of each lifting height switch (LIFTING

W :";.height switch

HEIGHT SW1, SW21 ONIOFF).

I Does this trouble occur only when a load is provided? I


YES Can the mast be tilted to the forward-most position with a large lifting height and without load (excluding relief)? Does the mast stop at an approximately 1 degree front tilted position when the fork is at the upper-most position with no-load relief?

& Load sensor defect.

lnspection 1 : See that the rear axle does not swing when one front wheel rides on a high place after swing solenoid OFF.

Analyzer: MAlN MENU + SAS MENU -+ ANALYZER MENU + ACTIVE TEST

Standard: When one front wheel rides on a high place after the swing solenoid is set to ON and OFF on a flat road, one front or rear wheel shall float above the ground. Caution: Perform this inspection with no load at a low fork height.

ACTIVE TEST (112)

TILT SOL2 KNOB SOL

lnspection 2: Is any error code recorded?

Analyzer: MAlN MENU -+ SAS MENU +ANALYZER MENU + DlAG MEMORY

Standard: NO error shall be displayed near the current time on the hour meter. c

c DlAG MEMORY (112)

FILE ERR 1 11223.3h42-1 2 1223.311 41-1 3 223.3h 42-1

lnspection 3: Does the speed value change according to the traveling speed?

Analyzer: MAlN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU -+ SWING DATA

Standard: During traveling the speed value shall change according to the varying vehicle speed.

Note: The speed value is in a range of 95 to 130% of the actual vehicle speed.

YAW SENSOR 2.50V

SWING SOL ON

lnspection 4: @ Let the vehicle travel with acceleration on a circle whose radius is approx. 2 m (79 in), and check if the

yaw sensor voltage variation is appropriate (check for each of right and left turns).

Analyzer: MAlN MENU -+ SAS MENU -+ANALYZER MENU -+ IN OUT MENU -+ SWING DATA

Standard: At a low fork height with no load, travel with gradual acceleration (a t a speed of 5 to 6 kmlh (3.1 - 3.7 milelh)) on a circle whose radius is approx. 2 m (6.6 ft) (with respect to the center of the vehicle). The yaw sensor voltage shall vary smoothly.

YAW SENSOR 2.50V

SWINGSOL ON

In right turn

In left turn

Inspection 5: Check functioning of each fork height switch (ONJOFF of fork height SW1 and SW21).

2.5 V (stationary state) + approx. 3.0 V

2.5 V (stationary state) + approx. 2.0 V

Analyzer: MAlN MENU -+ SAS MENU -+ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Standard: @ Lift and lower the fork at around 2,200 mm (86.6 in) to actuate the fork height switch. Only fork height SW1 is ON at a low fork height (below the fork height switch). Only SW21 is ON at a high fork height (above the fork height switch).

MAST DATA (212)


SW21 OFF SW22 OFF

-

Swing lock always occurs during traveling or loading work. Or, swing lock frequently occurs.

lnspection 1 : Inspect operation of lifting height switch.

Lock is always maintained (bracing kept) and the rear axle does not swing when the vehicle goes over a step although the lock lamp is not lit (upon engine start).

Standard: Tilt backward at heights of small lifting height (fast) and large lifting height (slow), respectively, without load. The speeds shall be different.

YES > Lock cylinder solenoid valve sticking.

NO -

@ Make sure that the lock lamp is not lit when the parking lever is operated slightly strongly.

@ Make sure that the lock lamp is not lit when the fork is lowered and the speed is gradually increased simply. (Fork height: 500 mm (1 9.7 in) or lower)

NG > Yaw rate sensor internal defect. (Replace the yaw rate sensor).

All OK

Inspection 1 Inspect the operation of the lifting height switch.

- NG > Lifting height switch defect. -

OK

Can the mast be tilted to the forward-most position with a large lifting height and without load (excluding relief)? Does the mast stop at an approximately 1 degree front tilted position when the fork is at the upper-most position with no-load relief?

OK

Yaw rate sensor defect or controller defect. (Replace the yaw rate sensor or controller.)

NG ) Load sensor defect.

Lock is always maintained (bracing kept) and the rear axle does not swing when the vehicle goes over a step although the lock lamp is not lit (upon engine start).

Inspection 1 a Is the yaw rate sensor voltage change normal upon accelerated swing along a circle with an approximately 2-meter (6.6 ft) radius? (Inspect the right and left, respectively.)

@ Make sure that the lock lamp is not lit when the parking lever is operated slightly strongly.

@ Make sure that the lock lamp is not lit when the fork is lowered and the speed is gradually increased simply. (Fork height: 500 mm (19.7 in) or lower).

I All OK

Yaw rate sensor internal abnormality (Replace the yaw rate sensor).


lnspection 2 Inspect the operation of each the lifting height switch. (LIFTING Lifting height switch. HElGHTSW1, SW21 ONfOFF)

OK

Inspection 1 : @ Is the yaw rate sensor voltage change normal upon accelerated swing along a circle with an approxi-

mately 2-meter (6.6 ft) radius? (Inspect the right and left, respectively.)

Can the mast be tilted to the forward-most position with a large lifting height and without load (excluding relief)? Does the mast stop at an approximately 1 degree front tilted position when the fork is at the upper-most position with no-load relief?


Load sensor abnormality. NG 1

Standard: With a small lifting height and without load, perform accelerated swing along an approximately 2-meter radius circle (based on the vehicle center) gradually (up to 5 to 6 kmlh (3.1 - 3.7 milelh)). The yaw rate sensor voltage shall change.

SWING DATA (112) SAVE 1c

Swing to the right

Swing to the left

YAW SENSOR 2.50V 1 SPEED o . o k m / h F ]

SWINGSOL ON

2.5 V (stop) to Approx.3.0 V

2.5 V (stop) to Approx. 2.0 V

Inspection 2: Inspect the operation of each the lifting height switch. (LIFTING HEIGHT SWI , SW21 ONJOFF)

Analyzer: MAIN MENU -+ SAS MENU +ANALYZER MENU + IN OUT MENU -+ MAST DATA

Standard: @) Lift and lower the fork at a height of approximately 2200 mm (87 in) to activate the lifting height switch.

Note: LIFTING HEIGHT SWI only is turned ON for a small lifting height (below the switch). LIFTING HEIGHT SW21 only is turned ON for a large lifting height (above the switch).

MAST DATA (212)

KNOB OFF HEIGHT SW1 SW21 OFF ON

SW22 OFF

Stopping with automatic leveling fails. (Does not stop at a horizontal position but tilts at the forward-most position.)

Related Portion

Tilt angle sensor

Active fork leveling switch

-

z =

- : 0 0

--

; +,I

--

r 0 - .- 5 I3) c .- - 0, > w - s . - o 0, > .- - 8

$

- CN1-14 (5MA, Tilt angle sensor power) CN27-1


CNI-22 (E01, Sensor GND)

I~N 1 CN33 w

--

CN1 CN27

z - - 2 - s

S

CN33-1

CN33-2

--

m

-

o a, E

,I

CN1-8 (MN Tilt knob SW)

CN~-23 (E02 SW-GND)

-

%! I-

-

*: Tilt the mast forward especially slowly on a vehicle with an attachment.

OK Check if automatic stop occurs upon forward tilting by approx. 1 degree in tilting operation immediately after relief in the uppermost position in no-load lifting.*

NG

lnspect for link bending and damages of the tilt angle sensor.

NG , After repair, check active fork leveling.

OK NG -

Inspection 1 NG > Tilt angle sensor defect. lnspect the tilt angle sensor.

OK

Make sure that natural forward tilt is obviously large. (Can the motion be checked visually?)

NG , Control valve solenoid No.1 sticking or tilt lock check valve sticking defect.

OK

After re-setting again, check active fork leveling. NG , Controller defect.

I After correction, check active fork leveling.

lnspect for slip off of the CNI and CN33 connecto'rs. NG

>

OK ] NG

- Inspection 2 Inspect continuity of the active fork leveling switch wiring.


NG

lnspection 3 Inspect continuity of the active fork leveling switch only.

NG > Active fork leveling switch defect.

OK


OK



lnspection 1 : lnspect the tilt angle sensor.

Turn the ignition switch OFF and remove the tilt angle sensor.

Standard:

lnspection 2: lnspect continuity of the active fork leveling switch wiring.


Standard:

Sensor lever with full stroke

1.5kR + 0.3kR CN27-2 - CN27-3

lnspection 3: lnspect continuity of the active fork leveling switch only.


Standard:

Sensor lever free

OkQ

CNI-8-CNI-23


Active fork leveling switch free

No continuity


Active fork leveling switch with full stroke


Active fork leveling switch with full stroke

Continuity shall exist. - CN33-1 - CN33-2

Standard: CNI-8 - CN33-1: Continuity shall exist. CNI-23 - CN33-2: Continuity shall exist.


No continuity

CN27 (TAB)

CN1 (REC)

CN33 (TAB)

CNl (REC)

CN33 (REC)

lnspect the output of the active fork leveling switch.

lnspect the output of the tilt angle sensor.

.L

lnspection 3 lnspect the tilt angle sensor.

I I

NG

Make sure that natural forward tilting is obviously large. (Can the motion be checked visually?) sticking defect.

OK I

After repair, check active fork leveling.

Inspect for link bending and damages of the tilt angle sensor.

3

&

Controller defect.

OK I NG

NG >

Inspection 4 Inspect the leveling stored value of the tilt angle sensor.

NG ,

L

After re-setting again, check active fork leveling.

OK

Inspection 5 lnspect continuity of the active fork leveling switch wiring.

I CN33 connector defect. I

NG I

After correction, check active fork leveling.

- lnspect for slip off of the CNI and CN33 connectors.

Inspection 7 lnspect continuity between CNI and CN33.

OK I NG

NG '


NG

OK I


Active fork leveling switch defect. lnspection 6 lnspect continuity of the active fork leveling switch only.

OK i I I

NG

lnspection 1 : lnspect the output of the active fork leveling switch.


Analyzer: MAlN MENU + SAS MENU +ANALYZER MENU -+ IN OUT MENU + MAST DATA

Standard:


SW21 OFF SW22 OFF

KNOB

lnspection 2: lnspect the output of the tilt angle sensor.



OFF


Active fork leveling switch depressed

ON

Standard: When the tilt operation is performed and the mast is moved from the forward-most tilt position to the backward-most tilt position, the potential shall rise between 0.1 V and 4.9 V along with backward tilting.


SOL2 OFF

lnspection 3: lnspect the tilt angle sensor


Standard:

I I Sensor lever free I Sensor lever with full stroke 1

CN27 (TAB)

lnspection 4: lnspect the leveling stored value of the tilt angle sensor.


Analyzer: MAIN MENU 4 SAS MENU +ANALYZER MENU + IN OUT MENU -+ MAST DATA

Standard: The TlLT value shall be smaller than the LEVEL value when the tilt is at the forward-most position.

TlLT 2.20V



Standard:



Standard:


Continuity shall exist. CN1-8-CN1-23



No continuity



Continuity shall exist. CN33-1 - CN33-2

Standard: CN1-8 - CN33-1: Continuity shall exist. CNI -23 - CN33-2: Continuity shall exist.


No continuity

CN1 (REC)

CN33 (TAB)

CN33 (REC)

1 5-1 08

Active fork leveling is not provided. (Stops at a non-horizontal position.)

Related Portion:

Tilt angle sensor

L

a,

=. C 0 0

Inspection 1 : lnspect the tilt angle sensor.

m a

7-

o w

I-[r



-- CN1-14 (5MA, Tilt angle sensor power) CN27-1


CNI-22 (E01, Sensor GND)

--

Standard:

CNI CN27.

NG ) After repair, check active fork leveling.

OK NG

CN27 (TAB)

Inspection 1 lnspect the tilt angle sensor.

-

NG > Tilt angle sensor defect.

CN27-2 - CN27-3

OK

Sensor lever free

OkQ

Is there possibility of deviation of the stored leveling position due to worn-out tires or vehicle deterioration?

Sensor lever with full stroke

1.5kQ f 0.3kQ

NG ) After re-setting again, check active fork leveling.

OK t - - -

Controller defect.



Standard:


NG > After repair, check active fork leveling.

NG

lnspection 1 lnspect the tilt angle sensor.

CN27 (TAB)

lnspection 2: lnspect the stored leveling value of the tilt angle sensor.

NG >

Sensor lever with full-stroke

1.5kQ + 0.3kR CN27-2 - CN27-3


Tilt angle sensor defect.

OK

Sensor lever free

OkQ

Analyzer: MAIN MENU -+ SAS MENU +ANALYZER MENU -, IN OUT MENU -+ MAST DATA

Standard: The TlLT value shall be the LEVEL value + 0.05 V when the mast is upright.


Inspection 2 Inspect the stored leveling value of the tilt angle sensor.

Note: Set the mast slowly forward from the backward-tilted position.

NG

Controller defect.

NG '

MAST DATA (112) SAVE 1C

Active fork leveling is not provided. (Stops at a position when the knob switch is pressed.)

Related Portion

Tilt angle sensor

Load sensor

- -

-- -- CN1-14 (5MA, Tilt angle sensor power) CN27-1

2 CN1-17 (MA, Tilt angle sensor) u.

CN1-22 (E01, Sensor GND)

-- CN1 CN27

L

a, =

- : 0 0

$ I-

--

Lifting height switch

1 N l u

CN3

--

m E 2

CN1-1 (5V power, 5PRS)

L

0 V)

s 2 g 3 V) (0

E

- g s 0 0

L a, - - 2 - K

6

CN3-1 CN26-3

CN3-2 CN26-2

CN3-5 CN26-1

m 2

--

m Q I-

-

0

k! $

LU

0 UJ cC

CN31

I - =

-

m a I-

o w II

-I

c 0 - .- 2 E 0) .- a, s 0) s .- - - .-

CN3-3 CN31-1 -

CN1-18 (Signal,PRES)

CN1-22 (GND, EO1)

CN1-23 (E02, SW-GND)


(MH21, Lift~ng CN1-4 height s e n s o r 21)

CN3

CN3-7 ~ ~ 3 1 - 2

CN3-4 CN31-3

m 2 0

-

E-

-

Without analyzer m Make sure that active fork leveling is possible with a fork lifting heioht of a~~roximatelv 500 mm (1 9.6 in) and approximately 500 . . I mG(19.6 h) without load. I

NG I L

4-

Controller defect. Make sure that active fork leveling is possible with a fork lifting height of approximately 500 mm (19.6 in) and approximately 500 mm (19.6 in) with a load on the fork.

.L

NG I OK

>

Controller defect. Check if automatic leveling is possible at a high position without any load.

J.

Check if automatic leveling occurs after resetting again.

NG 1

OK >

After repair, check active fork leveling. Inspect for link bending and damages of the tilt angle sensor.

Inspection 1 Inspect the tilt angle sensor.

L

OK I NG

NG ,

OK I

NG >

Controller defect. After re-setting again, check active fork leveling.

J.

lnspection 1 : lnspect the tilt angle sensor. Turn the ignition switch OFF and remove the tilt angle sensor.

Tilt angle sensor detect.

NG >

.L

Standard:

Controller defect. lnspection 2 lnspect continuity of the lifting height switch only.

Controller defect.

OK 1

- NG

Lifting switch defect.

lnspection 2: lnspect continuity of the lifting height switch only. Turn the ignition switch OFF and disconnect CN31.

Standard:


1.5kR + 0.3kQ CN27-2 - CN27-3

Sensor lever free

OkR

CN27 (TAB)

CN31-1 - CN31-2

CN31-1 - CN31-3 CN31 (REC)

Fork height: Approximately 500 mm (1 9.6 in)

Continuity shall~exist.

No continuity

With analyzer D Make sure that active fork leveling is possible with a fork lifting heiaht of a~~roxirnatelv 500 rnrn (1 9.6 in) and approximately 500 I . . I rnm(19.6 h) without load. I

NG I J.

Make sure that active fork leveling is possible with a fork lifting height of approximately 500 mm (19.6 in) and approxlrnately 500 rnrn (1 9.6 in) with a load on the fork.

NG

&-

I Controller defect.

OK >

Controller defect. -

Check if automatic leveling is possible at a high position without any load.

&

Controller defect.

OK >

Tilt angle sensor detect. Inspection 1 lnspect the tilt angle sensor.

NG

OK I

NG >


Inspection 2 Inspect the stored leveling value of the tilt angle sensor.

J

+ Controller defect.

OK I NG

NG ,

NG

After repair, check active fork leveling. Inspect for link bending and damages of the tilt angle sensor.

Make sure that active fork leveling is possible with a fork lifting height of approxlmately 500 rnrn (19.6 in) and approxlmately 500 mrn (19.6 in) with a load on the fork.

Replace the load sensor, and check if automatic leveling occurs at a high fork

+-

OK I NG

NG ,

OK I I i

OK 1 position without a load. I NG

Inspection 3 Inspect the road sensor output signal.

+-

J Controller defect.

NG >

+-

Controller defect. Inspection 4 lnspect the output of the lifting height switch.

lnspection 5 lnspect continuity of the lifting height switch only.

NG I

OK >

Lifting height switch defect.

OK I



Standard:

CN27 (TAB)

lnspection 2: lnspect the stored leveling value of the tilt angle sensor.


1.5kR + 0.3kR CN27-2 - CN27-3


Sensor lever free

OkQ

Analyzer: MAlN MENU + SAS MENU + ANALYZER MENU --+ IN OUT MENU + MAST DATA

Standard: The TlLT value with the mast tilted fully backward is greater than the LEVEL value.

lnspection 3: lnspect the load sensor output signal.

TlLT 2.20V

LEVEL 2.20V

Turn the ignition switch ON (Start the engine).

Analyzer: MAlN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU + MAST DATA

Standard: The LOAD value is the value in ( ) + 0.2 V or lower. (Fork lifting height of approximately 500 mm (1 9.6 in) without load.)

lnspection 4: lnspect the lifting height switch output signal.


SOL2 OFF

Turn the ignition switch ON (Start the engine).

Analyzer: MAlN MENU -+ SAS MENU +ANALYZER MENU --+ IN OUT MENU + MAST DATA

Standard: When the fork height is 500 mm (19.6 in). the LIFTING HEIGHT output shall be as follows: SW1: ON MAST DATA (212)

SW21: OFF sw22: OFF KNOB OFF

HEIGHT SW1 ON SW21 OFF

lnspection 5: SW22 OFF

lnspect continuity of the lifting height switch only.

Turn the ignition switch OFF and disconnect CN31

Standard:

CN31 (REC)

CN31-1 - CN31-2 CN31-1 - CN31-3

Fork height: Approximately 500 mm (19.6 in)

Continuity shall exist. - No continuity

The active mast rear tilt speed is not regulated, or the backward tilting speed is always slow. Related Portion

Tilt solenoid No. 2

Lifting height switch

& =

g o 0

z - - g - g 0

CNl CN3

--

m

CN1 CN13 u

o 2;

I

m o a w I-II

m 2

CN1-23 (E02, SW-GND)


(MH21, Lifting CN~-4 he~ght sensor 21)

c U - .- 3 (O

E .- 0, w r 0 c .- - - .- -J

Tilt solenoid No.2

U

E

-

-

-

CN3-3 CN31-1 -

CN1-12 (TLT2, Tilt solenoid 2)

CN1-24 (El, Main GND)

-

CN31

CN3-7 ~ ~ 3 1 - 2

CN3-4 CN31-3 -

- AL

m

CN13-1

CN13-2

o w II

0

2:-

-

m 4 I-

-

Without analyzer

( Stopping with automatic leveling 1 I occurs when tilted forward I

(without pressing the automtic leveling switch) when the fork is raised to approx. 500 mm (1 9.6 in) without a load.

Stopping with automatic leveling occurs upon automatic leveling switch operation when the fork is raised to approx. 500 mm (1 9.6 in) without a load.

lnspection 1 Check the automatic leveling Controller defect.

switch wiring for continuity.

lnspection 2 Check continuity of the Automatic leveling switch defect.

automatic leveling switch alone.

1 OK

I

CN33 coneector defect.

Inspection 3 Check continuity between CN1 and CN33.

lnspection 4 Check continuity of the fork heigh switch alone.

J.

Fork height switch abnormality.

NG >

Touch tilt solenoid No.2 (the front one on the control valve) and check the solenoid operating sound when the fork is raised to approx. 500 mm (1 9.6 in) without a load. (Check with the engine in stopped state.)*

Harness defect.

4

Controller defect. sticking defect.

*: Since the solenoid may be hot after lifting operation, carefully prevent the hand from getting scalded.

lnspection 1 : lnspect continuity of the active fork leveling switch wiring.


Standard:



Standard:


Continuity shall exist. CN1-8- CN1-23



No continuity.



Continuity shall exist. - CN33-1 - CN33-2

Standard: CNI-8 - CN33-1: Continuity shall exist. CNI -23 - CN33-2: Continuity shall exist.


No continuity.

CN1 (REC)

CN33 (TAB)

CN1 (REC)

CN33 (REC)

lnspection 4: lnspect continuity of the lifting height switch only.


Standard:

CN31 (REC)


No continuity.


CN31-1 - CN31-2

CN31-1 - CN31-3



No continuity.

After correction, check the backward tilting speed.

I NG

1 With analyzer I OK -

lnspection 1 lnspect the output signal of the active fork leveling switch.

lnspection 2 lnspect continuity of the active fork leveling switch wiring.

I fork leveling switch only. I I 1

OK I

NG 1

J. NG I

OK >

lnspection 3 Inspect continuity of the active

I and CN33. I I I

CN1 connector or controller defect.

NG 4 Active fork leveling switch defect. I &


lnspection 4 Inspect continuity between CN1

lnspect the output signal of the solenoid operating sound when the fork is raised to approx. 500 mm (1 9.6 in) Controller defect. without a load. (Check with the engine

NG 4 Harness defect.

lnspection 6 Inspect continuity of the lifting NG > Lifting height switch defect. height switch only.

OK I

valve No.2 sticking defect.

lnspection 1 : lnspect the output signal of the active fork leveling switch.

L


Controller defect.

Analyzer: MAIN MENU -+ SAS MENU -+ ANALYZER MENU + IN OUT MENU -+ MAST DATA


Standard:


SW21 SW22 OFF OFF


ON KNOB


OFF



Standard:



Standard:

-


Continuity shall exist. CN1-8-CN1-23



No continuity




Standard: t

CNI -8 - CN33-1: Continuity shall exist. CN1-23 - CN33-2: Continuity shall exist.


No continuity

lnspection 5: lnspect the output signal of the lifting height switch.

CN1 (REC)

CN33 (TAB)

CN1 (REC)

CN33 (REC)


Analyzer: MAIN MENU 4 SAS MENU +ANALYZER MENU 4 IN OUT MENU -+ MAST DATA

Standard: When the fork height is 500 mm (19.6 in). the LIFTING HEIGHT output shall be as follows: SW1: ON SW21: OFF SW22: OFF c

7

lnspection 6: lnspect continuity of the lifting height switch only.


Standard:

KNOB OFF HEIGHT SW1

SW21 OFF SW22 OFF

~- -

CN31-1 - CN31-2

CN31-1 - CN31-3



No continuity.


No continuity.

Continuity shall exist. CN31 (REC)

15-119

The mast does not perform forwardlbackward tilt.

Related Portion

Neither forward nor backward tilting fails.

Tilt lever switch

lnspection 1 Check the tilt lever switch wiring for continuity.

L

w - - o Z c

8

" 1

Touch tilt solenoid No.1 (solenoid valve on the upper rear side (truck FWD) of the control valve) and check the solenoid operating sound when the tilt lever is operated.(Check with the engine in stopped state.)*

I-

-

, CNI-10 (MF, Tilt lever SWl (forward))

controlvalve for solenoid No.1.

rno < W a

Check tilting operation after correction.

Check CN34 connector for disconnection.

F' Controller defect.

NG

NG

lnspection 2 Check continuity of the tilt Check continuity between Harness defect. lever switch alone (without CNI and CN34.


CN1 CN34

lnspection 4 Check continuity of the tilt Tilt lever switch defect. lever switch alone (after

CNI-9 (MU; Tilt lever SW2 (backward))

-

removal from the vehicle). b

CN34-1

Tilt lever switch installation defect.

z

* Since the solenoid may be hot after lifting operation, carefully prevent the hand from getting scalded.

CN1-23 (E02, SW-GN -

C Go to the next page.

(3434-2 - Forward tilt switch

-.

2 I-

CN34-4 -

CN34-3

Backward tilt switch

Continued

Inspect for slip off of the CN1 and NG CN34 connectors.

After correction, check the tilt operation.

lnspection 5

< I NG

Inspect continuity of the forward

NG

lnspection 6 Inspect continuity of the forward > f l l Inspect continuity between CN1 NG: tilt lever switch only (mounted on Harness defect.

the vehicle). and CN34.

Forward tilt lever switch mounting I defect.

Controller defect.

NG

lnspection 8 L

After repair, check backward tilting.

I NG

tilt lever switch wiring.


lnspect continuity of the forward tilt lever switch only (removed

lnspection 9 Inspect continuity of the Controller defect. backward tilt lever switch wiring.

Forward tilt lever switch defect.

l o K > f l i N G > lnspect continuity of the backward tilt lever switch only

Inspect continuity between CN1 Harness defect.

(mounted on the vehicle). - .A I I

from the vehicle).

Nti J,

I -1 CN34 connector defect. I

1 lnspection 12 inspect continuity of the backward tilt lever switch onlv

151 Backward tilt lever switch defect. I I (removed from the vehicle). I I I

Backward tilt lever switch mounting defect.

lnspection I : Check the tilt lever switch wiring for continuity. Turn the ignition switch OFF and disconnect CN1.

Standard:

lnspection 2: Check continuity of the tilt lever switch alone (without removal from the vehicle). Turn the ignition switch OFF and disconnect CN34.

Standard:

CLI. t n r r r t

Tilt lever in backward

No continuity


lnspection 3: Check continuity between CN1 and CN34. Turn the ignition switch OFF and disconnect CNI and CN34.

Tilt lever in forward


No continuity

CN1-10-CNI-23

CN1-9-CN1-23

Standard:

Tilt lever in neutral

No continuity

No continuity

Tilt lever in backward

No continuity


Tilt lever in forward


No continuity

CN34-1 - CN34-2

CN34-3 - CN34-4 CN34 (TAB)


No continuity

No continuity

CN1-10 - CN34-1

CNI -9 - CN34-3

CN1-23 - CN34-2

CN1-23 - CN34-4

CNl (REC) Continuity shall exist.



Continuity shall exist. CN34 (REC)

lnspection 4: Check continuity of the tilt lever switch alone (after removal from the vehicle). Turn the ignition switch OFF and disconnect CN34.

Standard:

lnspection 5: Inspect continuity of the forward tilt lever switch wiring. Turn the ignition switch OFF and disconnect CN1.

Standard:

CN34-1 - CN34-2

CN34-3 - CN34-4 CN34 (TAB)

When the forward tilt switch is pressed

No continuity


Switch in free



When the backward tilt switch is pressed


No continuity

CNl (REC)

Tilt lever at forward

Continuity shall exist. CNI -1 0 - CNI -23


No continuity

lnspection 6: lnspect continuity of the forward tilt lever switch only (mounted on the vehicle).


Standard:

CN34 (TAB)





Standard: CN1-10 - CN34-I: Continuity shall exist. CN1-23 - CN34-2: Continuity shall exist.

Tilt lever neutral

No continuity

Inspection 8: ~ ~ 3 4 (REG)

lnspect continuity of the forward tilt lever switch only (removed from the vehicle).

Turn the ignition switch OFF and disconnect CN34. Remove the forward tilt lever switch (upper-side switch on the control valve).

Standard:

CN34 (TAB)

lnspection 9: lnspect continuity of the backward tilt lever switch wiring.

Switch depressed

No continuity CN34-1 - CN34-2


Switch free


Standard:

CN1 (REC)



Tilt lever neutral

No continuity

lnspection 10: lnspect continuity of the backward tilt lever switch only (mounted on the vehicle).


Standard:





Standard: CN1-9 - CN34-3: Continuity shall exist. CNI -23 - CN34-4: Continuity shall exist.

Tilt lever neutral

No continuity

CN34 (TAB)

- CN1 (REC)

@ CN34 (REC)

lnspection 12: lnspect continuity of the backward tilt lever switch only (removed from the vehicle).

Turn the ignition switch OFF and disconnect CN34. Remove the backward tilt lever switch (lower-side switch on the control valve).

Standard:

CN34 (TAB)

i

Switch depressed


Switch free


lnspection 1 lnspect the switch output signal when the tilt lever is olserated.

NG

I I operating so;nd when the tilt lever is operated. (Che5k with the engine in stopped state.) Controller defect.

Inspect slip off of the CN34 connector.

&


possible.

Touch tilt solenoid No.1 (solenoid valve NG , on the upper rear side (truck FWD) of

NG

Solenoid No.1 ~0fltr0l valve sticking defect.

After correction, check the tilt operation.

control valve) and check the solenoid

lnspection 2 lnspect the switch output signal when the tilt lever is operated for forward tilting.

I lever switch wiri;lg. I I NG I

I

J

lnspection 4 Inspect continuity of the forward tilt 1 OK ,)I Inspect continuity between CN1 NG , T I Harness defect. lever switch only (mounted on the vehicle).

OK ,

lnspection 3 lnslsect continuity of the forward tilt

Controller defect,

NG

.L Forward tilt lever switch mounting defect.

OK >

I ' I

NG OK /

I Go to the next page.

After correction, check the forward tilting operation.

lnspect for slip off of the CN1 and CN34 connectors.

Controller defect.

lnspect continuity of the forward tilt lever switch only (removed from the

NG ,

Forward tilt lever switch defect.

OK

vehicle).

, I NG

-

Continued

lnspection 1 : lnspect the switch output signal when the tilt lever is operated for backward tilting. Turn the ignition switch ON (stop the engine). Analyzer: MAlN MENU + SAS MENU -+ ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

lnspection 7 lnspect the switch output signal when the tilt lever is operated for backward tilting.

Standard:

OK ,

lnspection 2: lnspect the switch output signal when the tilt lever is operated for forward tilting. Turn the ignition switch ON (stop the engine). Analyzer: MAlN MENU -+ SAS MENU -+ ANALYZER MENU + IN OUT MENU + MAST DATA

NG

TILT FWD

TILT BWD

Standard:

lnspect for slip off of the CN1 and CN34 connectors.

Tilt lever neutral

OFF

OFF

MAST DATA (212) 1 SAVE

NG > After correction, check the backward tilting operation.

OK < I NG

Inspect continuity of the Controller defect. backward tilt lever switch wiring. 0


ON

OFF


ON

OFF

TILT FWD

TILT BWD

lnspection 9 lnspect continuity of the backward tilt lever switch only (mounted on the vehicle).

Tilt lever at backward

OFF

ON

Tilt lever neutral

OFF

OFF

OK >

lnspection 10 Inspect continuity between CNI Harness defect. and CN34.

NG OK

V

lnspection 11 lnspect continuity of the backward tilt lever switch only (removed from the vehicle).

OK

lnspection 3: lnspect continuity of the forward tilt lever switch wiring.


Standard:

CNl (REC)

lnspection 4: lnspect continuity of the forward tilt lever switch only (mounted on the machine).


Continuity shall exist. CNI -1 0 - CNI -23


Tilt lever neutral

No continuity

Standard:

CN34 (TAB)





Tilt lever neutral

No continuity

Standard: CN1-10 - CN34-I: Continuity shall exist. CN1-23 - CN34-2: Continuity shall exist.

CN1 (REC)

CN34 (REC)

lnspection 6: lnspect continuity of the forward tilt lever switch only (removed from the machine).

Turn the ignition switch OFF and disconnect CN34. Remove the forward tilt lever switch (upper-side switch on the control valve).

Standard:

CN34 (TAB)

lnspection 7: lnspect the switch output signal when the tilt lever is operated for backward tilting.

Turn the ignition switch ON (stop the engine). Analyzer: MAIN MENU -+ SAS MENU +ANALYZER MENU -+ IN OUT MENU -+ MAST DATA

Switch depressed


Standard:

Switch free


KNOB OFF HEIGHT SW1 SW21 OFF ON

SW22 OFF


OFF

ON

TILT FWD

TILT BWD -

Tilt lever neutral

OFF

OFF

lnspection 8: lnspect continuity of the backward tilt lever switch wiring.


Standard:

inspection 10: lnspect continuity between CN1 and CN34.


Continuity shall exist. CNI-9 - CN1-23


Tilt lever neutral

No continuity



Standard: CN1-9 - CN34-3: Continuity shall exist. CN1-23 - CN34-4: Continuity shall exist.

Tilt lever neutral

No continuity

CN1 (REC)

lnspection 9: lnspect continuity of the backward tilt lever switch only (mounted on the vehicle).


Standard:

CN34 (TAB)

CN34-3 - CN34-4

@ CN34 (REC)

lnspection 11 : lnspect continuity of the backward tilt lever switch only (removed from the vehicle).

Switch free


Turn the ignition switch OFF and disconnect CN34. Remove the backward tilt lever switch (lower-side switch on the control valve).

Switch depressed

No continuity

Standard:

CN34 (TAB)

No error code is indicated although SAS warning lamp blinks. " - " (underscore) is displayed on the hourmeter.

Related Portion

CN2-3 (HRMI ,Clock) CN41-4

CN2-12 (HRM2,Transmission) CN41-3 g 2 - & " I - E

t - - CN41

C 9 m O .- o - -E i5: m s S .-

CN2-11 (HRM3,Reception) CN42-12 2 E " I - 0

CN2 CN42

Estimated Causes: Connector contact defect @ Hourmeter defect

@ Hourmeter harness defect @ Controller defect

lnspection 1 : lnspect continuity between CN2 and CN41 and between CN2 and CN42. Turn the ignition switch OFF and disconnect CN2, CN41, and CN42.

CN2 (REC)

Standard: CN2-3 - CN41-1: Continuity shall exist. CN2-12 - CN41-3: Continuitv shall exist.

After correction, check indication. Inspect for slip off of the CN2, CN41, and CN42 connectors.

\ ,

CN2-11 - CN42-12: continuity shall exist.

Inspection 2: ~ ~ 4 2 (REC) lnspect continuity between CN2 and CN41 and between CN2 and CN42. Turn the ignition switch ON (stop the engine).

NG )

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + IN OUT MENU +OTHER DATA Display the hourmeter time on the analyzer.

OK NG

OTHER DATA (111)

VOLTAGE 12.4V HOURS 11223.3h RE-SET CN DlAG PIN

lnspection 1 lnspect continuity between CN2 and CN41 and between CN2 and CN42.

Standard: Same time as the time displayed on the hourmeter (0.1 hour shortage permissible).


OK

Hourmeter defect. lnspection 2 lnspect the communication line.

OK

Controller defect.

NG )

-- --

The SAS warning lamp is always lit.

Related Portion

---CN1-11 (IG, Power) CN6-3 - 2 m 0 - m o X m 2 CN1-24 (El, Main GND) -

- 2 & E e C -- a c CN1 Frame h/ CN~-11 CN6 o m O CN2-1 - 0 Q : W

1 5 I- a (RLY, SAS lamp relay) ~ ~ 5 . 1 0 $ 2 (r)

I- cc 3 3

CN2 CN5

c a- .-

CN41-1 2 2 5 .- K - O ' 5 2

CN>- O E

Estimated Causes: @ Re-setting not complete @ SAS lamp relay defect @ SAS-ECU fuse defect @ Low battery voltage @ Connector contact defect @ Controller defect @ Power system harness defect

Re-setting complete (when the controller is replaced).

NG ) After re-setting, SAS lamp indication.

Inspect the SAS-ECU fuse. NG > After correction, SAS lamp indication.

OK 1 NG V

lnspect for slip off of the CN1, CN2, CN5, CN6, and CN41 connectors.

NG > After correction, SAS lamp indication.

- lnspection 1 lnspect continuity between CNI and CN6, between CN2 and CN5, between CN1 and the frame, between CN6 and the relay block, between CN5 and the relay block, and between CN5 and CN41.


OK

Defect of the power supply harness before the relay block. SAS-ECU fuse defect. Battery voltage defect.

SAS lamp relay defect.

Inspection 2 Inspect the supply voltage of the controller.

OK

Controller defect.

NG )

OK

Inspection 3 lnspect the SAS lamp relay.

NG >

lnspection 1 : lns~ect continuity between CNI and CN6, between CN2 and CN5, between CN6 and the relay block, between CN5 a d the relay block, and between CN5 and CN41.

Turn the ignition switch OFF and disconnect CN1, CN5, CN6, CN41, and the SAS lamp relay.

Standard: CNI -11 - CN6-3: Continuity shall exist. CNI -24 - Frame: Continuity shall exist. CN2-1 - CN5-11: Continuity shall exist. CN6-3 - SAS lamp relay terminal 2: Continuity shall exist. CN5-10 - SAS lamp relay terminal 3: Continuity shall exist. CN5-11 - SAS lamp relay terminal 1 : Continuity shall exist. CN5-10 - CN41-1: Continuity shall exist.

lnspection 2: lnspect the supply voltage of the controller. Turn the ignition switch ON (stop the engine).

Standard: CN1-11 - CN1-24: 11 - 16V

lnspection 3: lnspect the SAS lamp relay.

With analyzer: Turn the ignition switch ON (stop the engine).

CN1 (REC)

CN2 (REC)

CN5 (TAB)

CN6 (TAB)

SAS lamp relay

CN1 (REC)

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU + ACTIVE TEST Operate the SAS lamp forcibly.

Standard: C OFF - Turned off ON - Lit

C @

Without analyzer: The controller is defective if the lamp is kept lit even after replacing the SAS lamp relay.

ACTIVE TEST (212)

LOCKLMP El:!

SPEED FAIL OFFI ION

15-1 31

When the ignition switch is turned on, the SAS warning lamp is not lit.

Related Portion

CN5-10 lamp relay)

CN2

Estimated Causes: @ SAS lamp bulb blown @ Power system harness defect @ GAUGE fuse defect @ SAS lamp relay defect @ Connector contact defect @ Controller defect

After the bulb is replaced, SAS lamp indication. Check to see if the SAS lamp bulb is blown.

NG )

OK +-I NG -- Check to see if the combination meter fuse is NG After the fuse is replaced, SAS lamp blown. > indication.

OK NG

V - lnspect for slip off of the CN5 and CN41 connectors.

NG ) After correction, SAS lamp indication.

NG

lnspection 1 lnspect continuity between CN2 and CN5, between CN5 and the relay block, and between CN5 and CN41.


OK

lnspection 2 lnspect the SAS lamp relay.

OK

Controller defect.

NG ) SAS lamp relay defect.

Inspection 1 : Inspect continuity between CN2 and CN5, between CN5 and the relay block, and between CN5 and CN41.

Turn the ignition switch OFF and disconnect CN2, CN5, CN41, and the SAS lamp relay.

Standard: CN2-1 - CN5-11: Continuity shall exist. CN5-10 - SAS lamp relay terminal 3: Continuity shall exist. CN5-11 - SAS lamp relay terminal 1 : Continuity shall exist. CN5-10 - CN41-1: Continuity shall exist.

CN2 (REC)

CN5 (TAB)

Inspection 2: Inspect the SAS lamp relay.

With analyzer Turn the ignition switch ON (stop the engine).

Analyzer: MAIN MENU + SAS MENU +ANALYZER MENU +ACTIVE TEST

Operate the SAS lamp forcibly.

Standard: QI OFF - Turned off ON - Lit

C @

Without analyzer: The controller is defective if the lamp is kept lit even after replacing the SAS lamp relay.

ACTIVE TEST (212)

SPEED FAIL OFFI ION

No hourmeter indication

Related Portion

Frame

Estimated Causes: @) Hourmeter not started @ Connector contact defect @ Hourmeter harness defect

lnspection 1 : lnspect continuity between CN37 and CN41, between CN37 and the frame, and between CN42 and the relay block.

NG Connect CN37 and check hourrneter Hourmeter started? ) indication. -~

NG

Turn the ignition switch OFF and disconnect CN37, CN41, and GAGE fuse.

lnspection 1 lnspect continuity between CN37 and CN41, between CN37 and the frame, and between CN42 and the relay block.

Standard: CN37 - CN41: Continuity shall exist. CN37 - Frame: Continuity shall exist. ~ ~ 3 7 (REC) CN~ I (REC)

CN42 - Controller-side terminal of the GAUGE fuse in the relay block: Continuity shall exist.

OK

Hourrneter defect.

NG >

a 1 1 1 2 i 3 E 6 1 ~ 7 ~ 8 ~ 9 ~ 1 0 ~ 1 1 ~ 1 ~ Y Y

CN37 (TAB) CN42 (REC)

Harnessdefect.

The buzzer is not interlocked with the SAS warning lamp.

Related Portion

Estimated Causes: @ Hourmeter not started @ Connector contact defect @ Hourmeter harness defect @ Buzzer defect

NG Connect CN37 then check hourmeter Hourmeter started? > indication.

OK NG

Inspect for slip off of the CN2, CN5, CN37, and NG CN43 connectors.

> After correction, check error indication.

OK (< I NG

(RLY, SAS lamp relay)

lnspection 1 Inspect continuity between CN2 and CN5, between CN5 and the relay block, between Harness defect. CN43 and the relay block, between CN5 and CN37, and between CN37 and CN43.

I Buzzer defect. I

L a, - - g - 'z

S

lnspection 1 : lnspect continuity between CN2 and CN5, between CN5 and the relay block, between CN43 and the relay block, between CN5 and CN37, and between CN37 and CN43. Turn the ignition switch OFF and disconnect CN2, CN5, CN37, CN43, and the GAUGE fuse in the relay block.

-

+

Standard:

Y 0 o 5 X a - a, [r

CN2-1 CN5-11 - 1

-

CN2-1 - CN5-11: Continuity shall exist. C N ~ (REC)

CN5-10 - SAS lamp relay terminal 3: Continuity shall exist. CN5-11 - SAS lamp relay terminal 1 : Continuity shall exist.

& CN43 (REC)

CN43-2 - Controller-side terminal of the GAUGE fuse in the relay block: Continuity shall exist. CN5-11 - CN37-1: Continuity shall exist. -

a CN37 (TAB)

CN37-1 - CN43-1: Continuity shall exist.

CN5 (TAB)

3

L-

m u a w

CN43-2 - -

L

CN2

a CN5-10 P

a, N N 2 m

CN5

CN37 CN43 -

m a +

CN43-1 - CN37-1 -

o w cc

P

2 rr

z I-

m 2

o

-

When the ignition switch is turned on, the swing lock lamp is not lit.

Related Portion

- -- - - z m 0 CN2-9 (OUT1, Swing lock lamp output) CN42-9 -

Controller 2 E O m 5

CN2 g 2 5 CN42-6 .- a 6 - - 0

CN42

-- Relay block

P

Estimated Causes: @ Swing lock lamp bulb blown @ GAUGE fuse defect @ Connector contact defect @ Swing lock lamp harness defect @ Controller defect

lnspection 1 : lnspect continuity between CN2 and CN42 and between CN42 and the relay block. Turn the ignition switch OFF and disconnect CN2, CN42, and the GAGE fuse in the relay block.

Check to see if the swing lock lamp bulb is blown.

Standard: CN2-9 - CN42-9: Continuity shall exist. C N ~ (REC)

CN42-6 - Controller-side terminal of the GAUGE fuse in the relay 1- i 112131415161 [71819110)11[12113

block: Continuity shall exist. - ~ ~ 4 2 (REC)

NG Replace the bulb then check swing lock )

lamp indication. ,

OK +--I NG - Replace the fuse then check swing lock lamp indication.

C

Check to see if the combination meter fuse is blown.

NG >

OK NG

V

After correction, check swing lock lamp indication. -~

Inspect for slip off of the CN2 and CN42 connectors.

NG )

OK t - NG

lnspection 1 Inspect continuity between CN2 and CN42 and between CN42 and the relay block.

OK

Controller defect.

NG >

- Harness defect.

15-1 36

CONNECTOR LAYOUT

Note: WIH: Wire harness The SAS controller sequence is explained in section 16 (Page 16-24). *: Except UL-S

CONNECTOR DIAGRAMS

TAB

TAB

SPD+ SPD-

C

HRM3 HRM2 SPD 1-1 TRG

CN3 One fork height switch CN4 (UL-S)

TAB

CN3 No fork height switch

- TAB

7 BR-W CN3-3 Shortin -1'

TAB REC

Note: *:Terminal not related to SAS

TAB

CN7-1 3 Y-G

TAB

No. 1 2 3

. 4 5

- 6 7

.9 10 11

REC

S LAMP RLY-4 (UL-S)

C R-L R-B R-W G-Y R-G W

LG-B

12 ( (UL-S) I I

J I I * * * I *

G-W P-G L-W

* CN41-1, CN37-1

CN2-1

BIW-B (UL-S)

* WISPLICE-B (UL-S)

CN6 CN9 (Except UL-S)

TAB

TAB

J * * CNl-11 * * * * * * * *

No. 1 2 3 4 5 6 7 8 9 10 11

p+zGq 2 W-B BODYEARTH03

J * * F=ECU-IG (L)

SAS-LAMP RLY (-S) I * I

* * * I

No. 1 2

4 5 6 7 8 9

10 11

C BIB-W B-W B-R B-W

R B-Y LG-R

L- Y

W-L R-Y

TAB

C B-

B-W

B-R

B-W v

B-Y LG-R L-W

Y W-L R-Y

CN8 (Except UL-S) CN1-13

TAB

TAB

CN3-5 5V or GND P-G CN1-8

CN3-2 BR WISPLICE-A CN3-1

TAR PtEC

GND

CNl -1 4 CN1-17

WISPLICE-A

CN1-10

3 Y-B CN1-9 WISPLICE-A

In case of one Fork height fork height sw~tch switch TAB

TAB NO.\ C I J 1 I BR I WISPLICE-A

NO

TAB FEC

L-W CN43-1 GND CN41-6

REC

CN37-1 FUSE GAUGE

SAS Lamp relay (Base side)

CN5-11 2 B-R F=ECU-IG CN6-3

CN5-10 4 W-B CN9-5lCN512 UL-S

APPENDIX Page

SST LIST ........................................................................ 16-2

SERVICE STANDARDS LIST ...................................... 16-6

WIRING DIAGRAM ......................................................... 16-19

SST LIST jl : Newlv ado~ted SST

16-6

SERVICE STANDARDS LIST ENGINE

Engine (G4 (GM6-262)) Engine speeds rpm I Standard / See page 1-9

Engine (132)

750 k 25

2400 k 50

2600 k 50

250 or less

350 or less

Standard

Standard

Standard

Standard

Standard

Idling speed rpm

No-load static maximum speed

rpm Full relief engine speed down

rpm Air cleaner

Pn35 - 50 model

Pn60 - 80 model

Pn35 - 50 model

Pn60 - 80 model

Vacuum switch continuity test

(Continuity shall exist.) Pa (rnmHzO, rnrnHg) [inH?O, inHg]

7473 f 569 (762 + 58,56.0 k 4.3)

[30.00 k 2.28,2.25 k 0.1 691

~4 (GM~-262)

132

Fan drive

Standard

Fan belt flexure (when pushed with

29 N (3 kgf) [6.6 Ibfj) mm (in) Standard 6 - 8 (0.24 - 0.31)

Battery-Spark Plug 1.280

1.4 (0.055)lin initial state

1.6 (0.063)

Specific gravity of electrolyte (at 20°C [68"F])

Spark plug gap

mm (in)

Standard

Standard

Limit

Alternator 8 - 16 (0.31 - 0.63)

8 - 13 (0.31 - 0.51)

294 - 392 (30 - 40) [66 - 881

196 - 392 (20 - 40) [44 - 881

Alternator drive V-belt tension (when pushed with 98 N (10 kgf) [22 Ibf])

rnm (in) Alternator drive V-belt tension (when measured with a tension gauge (SST))

N (kgf) [Ibfl

~4 (GM~-262)

132

~4 (GM~-262)

132

Accelerator pedal

Standard

Standard

Standard

Standard

99 k 1 (3.90 k 0.04)

80'; (3.15 +:.")

80 +: (3.15+io8)

Pedal roller height (from accelerator bracket to top of roller) mm (in)

G4 (GM6-262)

Accelerator pedal (EEC spec.)

Pedal roller height (from accelerator bracket to top of roller) mm (in)

Electronic governor

Air governor

Standard

Standard

1 32

G4 (GM6-262)

Standard

Tightening torque Unit: N-m (kgf-cm) [ft-lbfl

Electronic governor

Air governor

1 32

Engine mounting nut

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Flywheel set bolt

108 k 1 (4.25 + 0.04)

80 +2,(3.15+:.08)

Standard

53.9 - 99.0 (550 - 1010) C39.8 - 73.11

98.07 - 156.9 (1 000 - 1600) r2.35 - 11 5.81

1' 49.0 - 78.0 (500 - 800) L36.2 - 57.91

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

G4 (GM6-262)

132

80 +2,(3.15+:-08)

Torque converter end plate set bolt

Flexible plate set bolt (for flyweel connection)

TORQUE CONVERTER & TRANSMISSION ASSY

Transmission cover & control valve

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Regulator valve spring free length

mm (in)

Accumulator spring free length

mm (in)

153.5 (6.043)

135.5 (5.31 5)

148.0 (5.827)

131 .O (5.1 57)

150.0 (5.906)

135.0 (5.31 5)

153.5 (6.043)

138.5 (5.453)

27 (1.06)

24 (0.94)

63.3 (2.49)

58 (2.28)

70.00 (2.7559)

69.85 (2.7450)

8.30 (0.3268)

8.1 7 (0.321 7)

0.03 - 0.07 (0.0012 - 0.0028)

0.1 5 (0.0059)

lnner

Outer

lnner

Outer

Stator shaft outside diameter (at portion in sliding

contact with oil pump gear) mm (in)

Driven gear to pump body clearance

mm (in)

Pump drive gear bush to stator shaft clearance

mm (in)

Pump body surface to driveldriven gear clearance

mm (in)

Inching regulator spring free length

mm (in)

Inching return spring free length

mm (in)

Torque converter

Pump boss outside diameter

mm (in)

Stator (No.2) roller outside diameter

mm (in)

Stator (No.2) hub to cam clearance

mm (in)

Stator shaft No.2 & oil pump

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

55.0 (2.1 65)

54.9 (2.1 61)

0.1 2 - 0.20 (0.0047 - 0.0078)

0.3 (0.01 2)

0.03 - 0.079 (0.001 2 - 0.0031 1)

0.15 (0.0059)

0.05 - 0.1 0 (0.0020 - 0.0039)

0.1 3 (0.0051)

Transmission Main shaft piston seal ring side clearance mm (in)

Main shaft servo seal ring side clearance mm (in)

Clutch disc plate thickness

mm (in)

Clutch plate thickness

mm (in)

Clutch camber plate warp

mm (in)

Clutch return spring free length

mm (in)

Clutch piston ring side clearance mm (in)

Limit

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Limit

0.30 (0.012)

0.29 (0.01 1 )

2.6 (0.1 02)

2.3 (0.091)

2.3 (0.091)

2.1 (0.083)

3.4 (0.1 34)

3.1 (0.122)

56 (2.20)

50 (1.97)

0.15 (0.0059)

Measurement-Test

Stall speed rPm

Main pressure kPa (kgf/cm2) [psi]

Clutch operating pressure

kPa (kgf/cm2) [psi]

Torque converter outlet pressure

kPa (kgf/cm2) [psi]

G4 (GM6-262)

132

At idling

At 1500 rpm

At idling

At 1500 rpm

At 1500 rpm


Standard

Standard

Standard

Standard

Standard

Standard

Standard

Solenoid valve set bolt

Pump boss set bolt

Drive cover set bolt

Pilot boss set bolt


Stator shaft No.2 & oil pump set bolt

Oil filter

Torque converter & transmission case set bolt

Inching valve ASSY set bolt

Suction filter set bolt

Output coupling set bolt

1 950

1 950

588 (6) [85] or more

981 - 1373 (10 - 14) 1142 - 1991

588 (6) [85] or more

981 - 1373 (10 - 14) [I42 - 1991

167 - 441 (1.7 - 4.5) [24 - 641

4.9 - 7.8 (50 - 80) [3.6 - 5.81

18.6 - 24.5 (1 90 - 250) [I 3.7 - 18.11

18.6 - 24.5 (1 90 - 250) [I 3.7 - 18.11

18.6 - 24.5 (1 90 - 250) [I 3.7 - 18.11

18.6 - 24.5 (190 - 250) [13.7 - 18.11

18.6 - 24.5 (1 90 - 250) [I 3.7 - 18.11

14.7 - 19.6 (150 - 200) [10.9 - 14.51

35.2 - 44.1 (360 - 450) [26.0 - 32.61

18.6 - 24.5 (1 90 - 250) [I 3.7 - 18.11

18.6 - 24.5 (1 90 - 250) [I 3.7 - 18.11

107.9 - 127.5 (1 100 - 1300) [79.59 - 94.061

DIFFERENTIAL

Differential

Ring gear backlash mm (in)

Differential pinion bore mm (in)

Spider outside diameter

mm (in)

Side gear thrust washer thickness

mm (in)

Pinion gear thrust washer thickness

mm (in)

Drive pinion bearing starting torque

N-m (kgf-cm) [ft-lbf]

Standard

Standard

Limit

Standard

Limit

Standard

Limit

Standard

Limit

Standard

0.2 - 0.3 (0.008 - 0.012)

22.1 2 (0.8709)

22.22 (0.8748)

22.00 (0.8661 )

21.75 (0.8563)

1.6 (0.063)

1.3 (0.051 )

1.6 (0.063)

1 .O (0.039)

8.82 - 13.23 (90 - 135) [6.51 - 9.771


Drive pinion lock nut

Drive pinion rear cover set bolt

Differential carrier cover set bolt

Ring gear set bolt

Differential upper case set bolt

Differential case bearing cap set bolt

Differential carrier set bolt

Standard

Standard

Standard

Standard

Standard

Standard

Standard

343.2 - 392.3 (3500 - 4000) [253.2 - 289.41

15.7 - 19.6 (1 60 - 200) [I 1.6 - 14.51

39.2 - 53.9 (400 - 550) [28.9 - 39.81

127.4 - 176.5 (1 300 - 1800) [94.06 - 130.21

43.1 - 53.9 (440 - 550) [31.8 - 39.81

11 7.7 - 137.3 (1 200 - 1400) [86.82 - 1 01.31

49.1 - 78.5 (500 - 800) [36.2 - 57.91

FRONT AXLE Pn35 - 50 Model

Pn60 - 80 Model

Front axle ASSY

22.0 (0.866)

22.18 (0.860)

22.0 (0.866)

21.85 (0.873)

68.6 - 127.5 (7 - 13) [ I 5 - 291

Planet gear bush inside diameter mm (in)

Planet gear shaft outside diameter mm (in)

Front axle shaft starting force (Measured at axle

housing set bolt) N (kgf) [Ibfl

Front axle ASSY

Standard

Limit

Standard

Limit

Standard

Tightening torque Unit: N-m (kgf-cm) [ft-lbf]

26.0 (1.024)

25.85 (1.01 8)

26.0 (1.024)

26.18 (1.031)

88.2 - 156 (9 - 16) [20 - 351



Front axle hub starting force (Measured at hub bolt)

N (kgf) [Ibfl

Brake ASSY set nut

Hub bolt lock nut

Axle shaft lock nut

Front axle housing set bolt

Front axle bracket set bolt (for fixing on frame)

Front axle bracket set bolt

Front wheel hub nut

(Single tire, double tire (inside), double tire (outside))

Standard

Limit

Standard

Limit

Standard


Standard

Standard

Standard

Standard

Standard

Standard

Standard

Brake ASSY set bolt

Hub bolt lock nut

Front axle housing set bolt


Front wheel hub nut (inside, outside)

Brake drum set bolt

Planet gear carrier cover set bolt

Planet gear carrier set bolt

M12: 88.3 - 11 7.7 (900 - 1200) [65.1 - 86.81

MI 4: 11 7.7 - 137.3 (1 200 - 1400) [86.82 - 101.31

264.8 - 294.2 (2700 - 3000) [195.3 - 217.11

294.2 - 343.2 (3000 - 3500) 1217.1 - 253.21

180.4 - 323.6 (1 840 - 3300) [ I 33.1 - 238.81

235.4 - 294.2 (2400 - 3000) [173.6 - 217.11

294.2 - 392.3 (3000 - 4000) [217.1 - 289.41

294.2 - 588.4

(3000 - 6000) 121 7.1 - 434.11

300.0 - 400.0 (3060 - 4080) [221.4 - 295.21

294.2 - 588.4 (3000 - 6000) [217.1 - 434.11

180 - 323 (1 840 - 3290) [ I 33.1 - 238.01

343 - 441 (3500 - 4500) 1253.2 - 325.61

294.2 - 588.4 (3000 - 6000) [217.1 - 434.11

137.3 - 205.9 (1 400 - 21 00) [ I 01.3 - 151.91

20.4 - 30.6 (208 - 31 2) [ I 5.0 - 22.61

98.1 - 127.5 (1 000 - 1300) [72.4 - 94.11

- - - --

Cu35-45 Model

Cu55 - 70 Model

Front axle ASSY




N (kgf) [Ibfl

Front axle ASSY

Standard

Limit

Standard

Limit

Standard




N (kgf) [Ibfl

26.0 (1.024)

25.85 (1 .018)

26.0 (1.024)

26.18 (1.031)

49 - 118 (5 - 12) [I1 - 261


Brake ASSY set bolt

Hub bolt lock nut


Front wheel hub nut

Brake drum set bolt


Standard

Limit

Standard

Limit

Standard

88.3 - 11 7.7 (900 - 1200) [65.1 - 86.81

264.8 - 294.2 (2700 - 3000) [ I 95.3 - 217.11

245 - 324 (2500 - 3300) [ I 80.9 - 238.81

294.2 - 323.6 (3000 - 3300) [217.1 - 238.81

88.3 - 137.3 (900 - 1400) [65.1 - 101.3]

20.4 - 30.6 (208 - 31 2) [ I 5.0 - 22.61

26.0 (1.024)

25.85 (1 .018)

26.0 (1.024)

26.1 8 (1.031 )

88.2 - 156 (9 - 16) [20 - 351


Planet gear carrier set bolt 98.1 - 127.5 (1 000 - 1300) [72.4 - 94.11

Brake ASSY set bolt

Hub bolt lock nut


Front wheel hub nut


Planet gear carrier set bolt

300.0 - 400.0 (3060 - 4080) 1221.4 - 295.21

264.8 - 294.2 (2700 - 3000) [ I 95.3 - 217.11

343 - 441 (3500 - 4500) [253.2 - 325.61

294.2 - 323.6 (3000 - 3300) [217.1 - 238.81

20.4 - 30.6 (208 - 31 2) [ I 5.0 - 22.61

98.1 - 127.5 (1 000 - 1300) [72.4 - 94.11

REAR AXLE Pn35 - 80 Model

Rear axle ASSY

Rear axle ASSY front to rear clearance mm (in) Standard

Limit

Limit

Rear axle center pin bushing

inside diameter mm (in)

1.0 (0.039) or less

67.0 (2.638)

Front: 82.0 (3.228) Rear: 67.0 (2.638)

Pn35 - 50 model

Pn60 - 80 model

Rear axle hub and steering knuckle

Rear axle hub starting force

(at hub bolt) N (kgf) [Ibfl

King pin outside diameter

mm (in)

43 - 72 (4.4 - 7.3) [9.7 - 16.11

78 - 157 (8.0 - 16.0) [ I 7.6 - 35.31

34.8 (1.370)

39.8 (1.567)

Pn35 - 50 model

Pn60 - 80 model

Pn35 - 50 model

Pn60 - 80 model

19.3 (2.0) [4.4] or less

Standard

Standard

Limit

Limit

Steering knuckle starting force (at front end of knuckle) N (kgf) [Ibfl

Standard

Rear axle cylinder

Rear axle cylinder piston rod

outside diameter mm (in)

54.91 (2.1 61 8)

69.91 (2.7524)

Pn35 - 50 model

Pn60 - 80 model

0.5 (0.01 7)

95.40 (3.7559)

105.40 (4.1496)

Limit

Limit

Limit

Limit

Limit

Rear axle cylinder piston rod bend mm (in)

Rear axle cylinder inside

diameter mm (in)


Pn35 - 50 model

Pn60 - 80 model

128 - 175 (1 31 0 - 1780) [94.78 - 128.81

44.1 - 53.9 (450 - 550) [32.6 - 39.81

63.7 - 73.5 (650 - 750) [47.0 - 54.31

11 7.6 - 176.4 (1 200 - 1800) [86.82 - 130.21

11 7.7 - 137.3 (1 200 - 1400) [86.82 - 101.31

421.7 - 470.7 (4300 - 4800) [311.1 - 347.31

176.5 - 196.1 (1 800 - 2000) [ I 30.2 - 144.71

294.1 - 588.4 (3000 - 6000) 1217.1 - 434.11

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Axle bracket cap set bolt

King pin lock bolt and lock

nut

Pn35 - 50 model

Pn60 - 80 model

Divided rim bolt set nut (Pn35 - 45 model only)

Rear axle cylinder rod guide set nut

Rear axle cylinder set bolt

Hub nut Pn35 - 50 model

Pn60 - 80 model

Cu35 - 70 Model

Rear axle ASSY

Rear axle ASSY front to rear clearance mm (in)

Rear axle center pin bushing inside diameter mm (in)

Standard

Limit

1.0 (0.039) or less

Front: 82.0 (3.228) Rear: 67.0 (2.638)

Rear axle hub and steering knuckle

Rear axle hub starting force

(at tire periphery) N (kgf) [lbf]

Cu35.45 model

Cu55 - 70 model

King pin outside diameter mm (in)

Steering knuckle starting force (at front end of knuckle) N (kgf) [Ibfl

Standard

Standard

29 - 44 (3.0 - 4.5) [6.6 - 9.91

78 - 157 (8.0 - 16.0) [ I 7.6 - 35.31

Limit

Standard

39.8 (1 567)

19.3 (2.0) [4.4] or less

Rear axle cylinder

Rear axle cylinder piston rod outside diameter mm (in)

Rear axle cylinder piston rod bend mm (in)

Limit

Limit

Limit

Limit

Rear axle cylinder inside

diameter mm (in)

54.91 (2.1 61 8)

0.5 (0.01 7)

87.40 (3.4409)

90.40 (3.5591)

Cu35.45 model

Cu55 - 70 model


Axle bracket cap set bolt

King pin lock bolt and lock nut

Rear axle cylinder rod guide set nut

Rear axle cylinder set bolt

Standard

Standard

Standard

Standard

128 - 175 (1 31 0 - 1780) 194.78 - 128.81

63.7 - 73.5 (650 - 750) 147.0 - 54.31

11 7.7 - 137.3 (1 200 - 1400) [86.82 - 1 01.31

421.7 - 470.7 (4300 - 4800) [311.1 - 347.31

STEERING

BRAKE

Hydrostatic steering valve ASSY

Relief pressure

kPa (kgf/cm2) [psi]

Front brake

Standard

Standard

Standard

Pn35 - 45 model

Pn50 - 80, Cu70 model

Cu35 - 60 model

961 O%gO (98';) [ I 390+i0]

11 1 OO",O (1 1 (113';) [ I 61 O+iO]

91 20%'~ (93';) [ I 320'07OI

Tightening torque Unit: N-m (kgf-cm) [ft-lbf]

31 7.5 (1 2.50)

319.5 (1 2.58)

9.3 (0.36)

4.3 (0.1 7)

10.0 (0.39)

1 .O (0.039)

Standard

Limit

Standard

Limit

Standard

Limit

Brake drum bore mm (in)

34.3 - 53.9 (350 - 550) [25.3 - 39.81

24.5 - 58.8 (250 - 600) [ I 8.1 - 43.41

29.4 - 39.2 (300 - 400) [21.7 - 28.91

24 - 36 (245 - 367) [19.7 - 26.61

Mast jacket set nut

Steering wheel set nut

Steering valve ASSY set bolt

Steering valve end cap set screw

Brake lining thickness

mm (in)

Brake lining livet sinking mm (in)

Brake booster

Standard

Standard

Standard

Standard

Pn35 - 50,

Cu35-45 model

Pn60 - 80, Cu55 - 70 model

Pn60 - 80, Cu55 - 70 model

0.032 (0.0013)

0.032 (0.001 3)

Master cylinder piston side clearance mm (in)

Power piston side clearance mm (in)

Limit

Limit

Parking brake

Lever operating force

(kgf) [IbfJ

Standard

Standard

Pn35 -45, Pn60-70, Cu35 - 70 model

Pn50, Pn80 model

196 - 245 (20 - 25) [44 - 551

245 - 294 (25 - 30) [55 - 661

Brake pedal

150 - 155 (5.91 - 6.10)

3 - 7 (0.12 - 0.28)

1 (0.04)

90 (3.54 ) or more

26 - 32 (1.02 - 1.26)

1 - 3 (0.04- 0.12)

Pedal height (from toe board to

top center of pedal) mm (in) With pad Standard

Pedal play mm (in)

Push rod play mm (in)

Pedal height in fully depressed state mm (in)

Inching pedal stroke until interlocking with brake

mm (in)

lnching pedal play (until start of inching valve spool

movement) mm (in)

Standard

Standard

Standard

Standard

Standard

MATERIAL HANDLING SYSTEM


Parking brake actuator lever set bolt

Wheel cylinder

set bolt

Natural drop test

Natural drop mm (in)

Fork

13.7 - 22.6 (140 - 230) [ I 0.1 - 16.61

69.6 - 94.1 (710 - 960) 151.4 - 69.51

125.5 - 170.6 (1 280 - 1740) [92.6 - 125.91

186.3 - 255.0 (1 900 - 2600) [ I 37.5 - 188.11

122.6 - 166.7 (1 250 - 1700) 190.4 - 123.01

186.3 - 255.0 (1 900 - 2600) [ I 37.5 - 188.11

17.7 - 26.5 (1 80 - 270) [ I 3.0 - 19.51

Pn35 - 50, Cu35.45 model

Pn35-40 model

Pn45 model

Limit

10 (0.39) Front end misalignment mm (in)

45 (1.77)

Natural forward tilt test

Limit

Upper

Lower

Upper

Lower

Natural forward tilt mm (in)

Mast adjustment (V mast)

Standard

Standard

Standard

Standard

Pn50 model

Pn60 - 80, Cu55 - 70 model

Standard

Standard

Limit

Mast lift roller mm (in)

25 (0.98)

Oil leak test

Inner mast roller clearance

Outer mast roller clearance

Lower lift roller clearance

Upper side roller clearance

Lower side roller clearance

Side roller clearance

Lift bracket roller

mm (in)

Lift cylinder oil leak amount (at lift port) cm3 (in3)

Tilt cylinder oil leak amount (total for lift and tilt) cm3 (in3)

Mast strip to inner mast clearance mm (in)

Pn35-40,

Cu35-45 model

Pn45 - 80, Cu55 - 70 model

Standard

Standard

Standard

Standard

Standard

Standard

Limit

Limit

0 - 0.8 (0 - 0.031)

0 - 0.8 (0 - 0.031)

0 - 0.5 (0 - 0.020)

0 - 0.5 (0 - 0.020)

0.5 - 1 .O (0.020 - 0.039)

0 - 0.8 (0 - 0.031)

Standard

8 (0.49)

16 (0.98)

0 - 0.8 (0 - 0.031)

Lift cylinder (V)

Piston rod outside

diameter mm (in)


Limit

Limit

Limit

Limit

Limit

Limit

Limit

Pn35 - 50, Cu35.45

Pn6O - 80, Cu55

Pn35.40, Cu35

Pn45-50, Cu45

Cu55

Pn60 - 80

49.92 (1.9654)

54.91 (2.1 61 8)

65.35 (2.5728)

70.35 (2.7697)

75.35 (2.9665)

80.35 (3.1594)

2.0 (0.079) Piston rod bend mm (in)

Rear lift cylinder (FV.FSV)

44.92 (1.7685)

49.92 (1.9654)

54.91 (2.1618)

65.35 (2.5728)

70.35 (2.7697)

75.35 (2.9665)

80.35 (3.1 594)



FV

FSV

FSV

FV

FSV

FSV

FSV

Pn35 - 45, Cu35.45

Pn35 - 50, Cu35.45

Pn60, Cu55 - 70

Pn35 - 50, Cu35.45

Pn35 - 50, Cu35 - 55

Cu55

Pn60 - 70, Cu60

Front lift cylinder (FV.FSV)

Limit

Limit

Limit

Limit

Limit

Limit

Limit

69.91 (2.7524)

95.40 (3.5779)

1 05.40 (4.1 496)

11 0.40 (4.3465)

120.40 (4.7402)

2.0 (0.079)

Piston rod outside diameter mm (in) FV-FSV

FVoFSV

FV-FSV

FSV

FSV


Tilt cylinder

Limit

Limit

Limit

Limit

Limit

Piston rod bend mm (in)

Pn35-40, Cu35

Pn45-50, Cu45

Cu55

Limit

Cylinder bore

mm (in)

Piston rod outside

diameter mm (in)

Limit

Limit

Limit

Limit

Limit

Pn35 - 50, Cu35.45

Cu55 - 70, Pn60 - 80

Pn35 - 50, Cu35-45

Cu55 - 70, Pn60 - 80

90.40 (3.5591)

100.40 (3.937)

39.92 (1.571 7)

44.92 (1.7685)

1 .O (0.039) Piston rod bend mm (in)

343.2 - 441.3 (3500 - 4500) [253.2 - 325.61

343.2 - 441.3 (3500 - 4500) [253.2 - 325.61

284 - 421 (2900 - 4300) [209.8 - 31 1 . l ]

284 - 421 (2900 - 4300) [209.8 - 311 . l ]

343 - 441 (3500 - 4500) [253.2 - 325.61

88.3 - 98.1 (900 - 1000) [65.12 - 72.351

58.8 - 68.6 (600 - 700) [43.4 - 50.61

343.2 - 441.3 (3500 - 4500) [253.2 - 325.61

392.3 - 490.3 (4000 - 5000) [289.4 - 361.81

245.2 - 343.2 (2500 - 3500) [ I 80.9 - 253.21

343.2 - 441.3 (3500 - 4500) [253.2 - 325.61

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard


Lift cylinder cover FV rear cylinder cover

FSV rear cylinder

V: Pn35 - 80, Cu35 - 70

Pn35 - 45

Cu35.45

Lift cylinder cover

Lift rod guide

I I RH, LH


Safety down valve

RH cyl.

LH cyl.

Pn35 - 50 Cu35-45 RH, LH

Pn60-70 Cu55 - 70

Pn35.40' Cu35

Pn45, Cu45

Pn50 - 70 Cu55 - 70

Front lift

cylinder cover

Tilt cylinder piston castle nut

Tilt cylinder cover

FV

FSV

FSV

OIL PUMP

OIL CONTROL VALVE

Oil pump

Body inner face flaw depth mm (in)

Bushing inside diameter mm (in)

Plate thickness mm (in)

Gear shaft outside diameter mm (in)

SAS

Oil control valve

Relief set pressure (common to lift and tilt) kPa (kgf/cm2) [psi]

Relief set pressure (common to lift and tilt (backward)) kPa (kgf/cm2) [psi]

Relief set pressure (tilt (forward)) kPa (kgf/cm2) [psi]

0.05 (0.002)

0.1 (0.004)

24.1 (0.949)

17.1 (0.673)

2.65 (0.1 043)

4.85 (0.1909)

46.27 (1.821 7)

33.05 (1.301 2)

Front or middle side

Rear side


Rear side


Rear side


Rear side



Limit

Limit

Limit

Limit

Limit

Limit

Limit

Limit

Oil pump body set bolt

Pn35 - 50, Cu35 - 55 model

Pn60 - 80, Cu60.70 model

Pn60 - 80, Cu60.70 model

98.1 (1 000) [72.4]


SAS controller set bolt

Standard

Standard

Standard

Outlet housing set bolt

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Swing lock cylinder

upper pin set bolt

Swing lock cylinder

lower pin set bolt

18140 +FO(l 85';) [2630'i0]

20590 +rO (21 0';) [2990'i0]

13240 + r O ( l 35';) [I 920'g0]

34.3 - 44.1 (350 - 450)

125.3 - 32.61

10 - 15 (102 - 153) [7.3 - 11.11

10.5 - 24.5 (107 - 250) [7.74 - 18.11

21.6 - 50.4 (220 - 51 4) [15.9 - 37.21

16.2 - 37.8 (1 65 - 385) [ I 1.9 - 27.91

21 -6 - 50.4 (220 - 51 4) [ I 5.9 - 37.21

6.9 - 15.8 (69 - 161) [5.0 - 11.61

35.3 - 43.1 (360 - 440) [26.0 - 31.81

3.0 - 7.0 (31 - 71) [2.2 - 5.11

14.4 - 33.6 (1 47 - 343) [ I 0.6 - 24.81

Pn35 - 50, Cu35-45 model

Cu55 - 70 model

Pn35 - 50, Cu35-45 model

Cu55 - 70 model

Tilt angle sensor set bolt

Load sensor

Speed sensor set bolt

Fork height switch ASSY set bolt

WIRING DIAGRAM

LP 0 0 0 0 0

0 0 0 0 0

0 0 0 0 -

0 0 0 0 0 0 0 0 0 0

o - - - -

0'2

-

-

O O O O O

O O O O O

0 0 0 0 0 O O O O - 0 0 0 0 0

O O O O O

0 0 0 0 0

0 0 0 0 -

03

D

-

-

- - - -

-

- -

-

NAME BATTERY, RELAY BOX ELECTRIC SHIFT TIC STARTING BACK UP LAMP BACK BUZZER SMART ALARM ELECTRIC SHIFT TIC (EZ PEDAL) STARTING BACK UP LAMP BACK BUZZER SMART ALARM CHARGING SAS ECU FUEL SYSTEM (GASOLINE) IGNITION SYSTEM FUEL SYSTEM (LPG EXCLUSIVE) IGNITION SYSTEM 3 WAY CATALYTIC SYSTEM FUEL SYSTEM (LPG EXCLUSIVE) ELECTRONIC GOVERNOR CONTROL SYSTEM IGNITION SYSTEM 3 WAY CATALYTIC SYSTEM FUEL SYSTEM (LPG EXCLUSIVE) IGNITION SYSTEM FUEL SYSTEM (LPG EXCLUSIVE) ELECTRONIC GOVERNOR CONTROL SYSTEM IGNITION SYSTEM FUEL SYSTEM (LPG CONVERTIBLE) IGNITION SYSTEM FUEL SYSTEM (DIESEL) IGNITION SYSTEM HEAD LAMP TIC OIL TEMPERATURE INDICATOR INDICATOR STROBE LIGHT COMBINATION METER COMBINATION METER (EZ PEDAL) STOP LAMP TAIL LAMP CLEARANCE LAMP TURN SIGNAL LAMP COMPARTMENT LIGHT REAR WORKING LAMP ENGINE SHUT DOWN DEVICE LPG WARNING INDICATOR INTAKE HEATER PARKING BRAKE LAMP SAFETY START SW MOTION ALARM

G

-

-

-

-

0 - -

OJ

GILP

-

-

-

0

0 - - -

0 0 - 0 0 -

0 - - -

0'3

LPS

-

-

d'

o'!

-

-

Page 16-20

16-21

16-22

16-23 16-24

16-25

16-26

16-27

16-28

16-29

16-30

1 6-31

16-32

16-33

16-34 16-35 16-36

16-37

16-38

16-39

16-40 16-41 16-42

16-43

ELECTRIC SHIFT TIC, STARTING, BACK UP LAMP, BACK BUZZER, SMART ALARM

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B A T T E R Y

D l SCONNECT S V

UL-LPS

16-24

SAS ECU

FUEL SYSTEM (GASOLINE), IGNITION SYSTEM

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, 3 WAY CATALYTIC SYSTEM

FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM

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FUEL SYSTEM (LPG EXCLUSIVE), ELECTRONIC GOVERNOR CONTROL SYSTEM, IGNITION SYSTEM

C O M B l N A T i O N METER (CHECK E C U & CHARGE LAMP)

W~ISAS NOIIIN~I ' ( 3 i a 1 ~ t 1 3 ~ ~ 0 3 gd i ) W~LSAS land

OE-9 1

FUEL SYSTEM (DIESEL), IGNITION SYSTEM

16-32

HEAD LAMP

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x n 1-8 T, G ~ 1 8 ~ 3 ~ a o a {I

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DISCXMECT SV QD I--

- - I I

- . -G. L P. G A p WATER TEW SV (OPT)

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W (UL-G. LP. G/LP) B-R (UL-D)

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I

DISCONNECT SV w QD

I (UL-G.LP.G/LP) FFgFI

B A T T E R Y

U)

RR cu"8INATION L M RH (STOP LAW

TAIL LAMP, CLEARANCE LAMP

- -I

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0 0 ~ 0

- - A t l 3 1 1 V 8

1 1 1 1 A d a d (a- in) tl-e

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16-38

TURN SIGNAL LAMP

(dr(H1 NMU

COMPARTMENT LIGHT, REAR WORKING LAMP

16-40

ENGINE SHUT DOWN DEVICE

LPG VARNl NG SV I

w LPG WARNlNG

BUZZER

16-42

INTAKE HEATER

toyota forklift 7fgu35 service

Documents

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