Toyota 8FGU 15 Repair Manual Supplement

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8FGU 15, 18, 20, 25, 30, 32

8FDU 15, 18, 20, 25, 30, 32

8FGCU 20, 25, 30, 32

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Pub. No. CU066

PRINTED IN USA

Pub. No. CU066

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Page 1 8FGU 15, 18, 20, 25, 30, 32 8FDU 15, 18, 20, 25, 30, 32 8FGCU 20, 25, 30, 32 Supplement Pub. No. CU066 PRINTED IN USA Pub. No. CU066...
Page 2 Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News. (Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL EQUIPMENT 8FGU/8FDU15~32, 8FGCU20~32 REPAIR MANUAL VOL.1/VOL.2 (No.
Page 4 SECTION INDEX NAME SECTION GENERAL ENGINE FRONT AXLE MAST CYLINDER OTHER MODIFICATIONS · SST LIST SERVICE STANDARDS LIST WIRING DIAGRAM...
Page 6 GENERAL Page VEHICLE MODEL...........0-2 FRAME NUMBER...........0-3 COMPONENTS WEIGHT ........0-4 RECOMMENDED LUBRICANT QUANTITY & TYPES ...........0-5...
Page 7 VEHICLE MODEL Pneumatic Tire Models (Pn) (2008.1~) Classification Load Capacity Vehicle Model Transmission Type Engine Series Model 8FGU15 Gasoline Pn15 3000 lbs 8FDU15 1DZ-III Diesel Pn1 ton series 8FGU18 Gasoline Pn18 3500 lbs 8FDU18 1DZ-III Diesel 8FGU20 Gasoline Pn20 4000 lbs 8FDU20 1DZ-III Diesel...
Page 8 FRAME NUMBER Frame No. Punching Position Punching position Series Engine Vehicle model Punching format 8FGU15 8FGU18-30011 8FGU18 1 ton series 8FDU15 1DZ-III 8FDU18-30011 8FDU18 8FGU20 8FGU25-30011 8FGU25 Pneumatic tire 2 ton series 8FDU20 1DZ-III 8FDU25-30011 8FDU25 8FGU30 8FGU32-30011 8FGU32 3 ton series 8FDU30 1DZ-III 8FDU32-30011...
Page 9 COMPONENTS WEIGHT Component Weight kg (lb) 134 (295) Engine 1DZ-III 182 (401) T/C (1 speed) 62 (137) Transmission T/C (2 stator T/C) 130 (287) Pn15 model Approx. 770 (1700) Pn18 model Approx. 905 (1995) Pn20 model Approx. 1170 (2580) Pn25 model Approx.
Page 10 RECOMMENDED LUBRICANT QUANTITY & TYPES Description Application Quantity l (US gal) Classification Type Motor oil Gasoline 4.0 (1.06) SAE30 SH, SJ, SL, SM SAE10W-30 Engine Diesel engine oil Diesel 1DZ-III 7.9 (2.09) SAE30 CE, CF, CF-4 SAE10W-30 T/C (1 speed) 6.0 (1.58) GM Dexron Transmission...
Page 12: Table Of Contents
ENGINE Page ENGINE EXTERIOR VIEW........1-2 ENGINE MAIN PARAMETERS ......1-3 ENGINE PERFORMANCE CURVES .....1-5 ENGINE INSPECTION·ADJUSTMENT....1-7 .........1-7 1DZ-III ENGINE (2008.1~) V-BELT TENSION ADJUSTMENT ......1-9...
Page 13: Engine Exterior View
ENGINE EXTERIOR VIEW 1DZ-III Engine (2008.1~)
Page 14: Engine Main Parameters
ENGINE MAIN PARAMETERS Gasoline Engine (2010.1~) 4Y-HIGH POWER (OPT): Vehicle model All (STD) 8FGU20~32 Item 8FGCU20~32 ← Engine model ← Engine type Gasoline · 4 cycle In-line 4 cylinder, ← Number and arrangement of cylinders longitudinally mounted ← Combustion chamber type Wedge ←...
Page 15 Diesel Engine (2008.1~) Vehicle model · 8FDU15 8FDU20~32 Item ← Engine model 1DZ-III ← Engine type Diesel · 4 cycle In-line 4 cylinder, ← Number and arrangement of cylinders longitudinally mounted ← Combustion chamber type Whirl chamber ← Valve mechanism OHV·gear drive 86.0 ×...
Page 16: Engine Performance Curves
ENGINE PERFORMANCE CURVES 4Y All (STD) (2010.1~) Gasoline (Exclusive·Convertible) Gasoline (Exclusive·Convertible) LPG (Exclusive·Convertible) Torque Power Fuel consumption ratio 4Y-HIGH POWER (OPT): 8FGU/8FGCU 20~32 (2010.1~) Gasoline (Exclusive) Gasoline (Convertible with LPG) LPG (Exclusive·Convertible) Torque Gasoline (Exclusive) Gasoline (Convertible with LPG) LPG (Exclusive·Convertible) Power Gasoline (Exclusive·Convertible) LPG (Exclusive·Convertible)
Page 17 1DZ-III 8FDU15·18 (2008.1~) Torque Power Fuel consumption ratio 1DZ-III 8FDU20~32 (2008.1~) Torque Power Fuel consumption ratio...
Page 18: Engine Inspection·adjustment
ENGINE INSPECTION·ADJUSTMENT Note: • Warm up the engine beforehand, and proceed with inspection and adjustment when the vehicle is in the following state: • Coolant temperature: 75°C (167°F) or above, engine oil temperature: 60°C (140°F) or above, hydraulic oil temperature: 50°C (122°F) or above 1DZ-III ENGINE (2008.1~) Idle Speed Inspection·Adjustment...
Page 19 No-load Maximum Speed Inspection·Adjustment Maximum adjusting screw Install the rev counter. Inspect the no-load maximum speed. (1) While the engine is at standstill, press down the accelerator fully, and check that the adjusting lever is touching the maximum adjusting screw. (2) Start the engine, and measure the engine speed (no-load maximum speed) when the accelerator pedal is fully Accelerator lever...
Page 20: V-Belt Tension Adjustment
V-BELT TENSION ADJUSTMENT Note: • 4Y (2007.1~) • 1DZ-II (2007.1~2007.12) • 1DZ-III (2008.1~) Inspect the V-belt tension. Standard [amount of delfection when pressed with 98 N (10 kgf)] New belts 4Y·1DZ-II·1DZ-III: 7~9 mm (0.28~0.35 in) Belts in use 4Y·1DZ-II·1DZ-III: 8~13 mm (0.31~0.51 in) Standard [When using a tension gauge (SST)] SST 09216-76002-71 (09216-00021)
Page 21 1-10 1-10...
Page 22 FRONT AXLE Page DRY BRAKE MODEL ..........2-2 GENERAL ................ 2-2 COMPONENTS ..............2-4 FRONT AXLE BRACKET·AXLE HOUSING....2-6...
Page 23: Dry Brake Model
DRY BRAKE MODEL GENERAL Pn1 ton series Pn2 ton series...
Page 24 Pn3 ton series...
Page 25: Components
COMPONENTS Pn1 ton series 4201 44[LH] 43[RH] Refer to 4715-01,02 4201-337 Pn2 ton series 4201 44[LH] 43[RH] Refer to 4715-01,02 4201-338...
Page 26 Pn3 ton series 4201 44[LH] 43[RH] Refer to 4715-01,02 4201-339...
Page 27: Front Axle Bracket·axle Housing
FRONT AXLE BRACKET·AXLE HOUSING REMOVAL·INSTALLATION T = N·m (kgf·cm) [ft·lbf] T = 294 ~ 343 (3000 ~ 3500) [217 ~ 253] T = 137 ~ 210 (1400 ~ 2100) [101 ~ 155] Pn1·2 ton series and Cu2·3 ton series T = 108 ~ 159 (1100 ~ 1600) [80 ~ 117] Pn3 ton series T = 127 ~ 190 (1300 ~ 1900) [94 ~ 140] Removal Procedure...
Page 28 Point Operations [Point 1] Installation: Apply sealing agent (08826-76002-71 (08826-00090)) to the mating surfaces of the brake backing plate and front axle bracket before installation. Installation: Pn1 ton series: Be careful as the brake backing plate set bolts are different in length.
Page 30 MAST Page V MAST ASSY............3-2 ............3-2 COMPONENTS ......3-3 REMOVAL·INSTALLATION (Pn model) REMOVAL·INSTALLATION ......3-6 (W/LIFT BRACKET) (Pn model) ...3-8 MAST DISASSEMBLY·INSPECTION·REASSEMBLY CHAIN..............3-10 ........3-10 REASSEMBLY (V·FV·FSV) FV·FSV MAST ASSY..........3-11 ............3-11 COMPONENTS QFV MAST ASSY..........3-12 ........3-12 MAST ADJUSTMENT (QFV) STANDARD FOR SELECTING AN OVERSIZE ROLLER ........3-14 LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING) .....3-15...
Page 31: Mast Assy
V MAST ASSY COMPONENTS Pn model 6101 6101-610...
Page 32: Removal·installation (Pn Model)
REMOVAL·INSTALLATION (Pn model) T = N·m (kgf·cm) [ft·lbf] T = 96.0 (979) [70.8] T = 84.0 ~ 156.0 (857 ~ 1591) [62.0 ~ 115.1] Removal Procedure Set the mast vertical and fully lower the fork. Disconnect the chain. [Point 1] Remove the chain wheel.
Page 33 Installation Procedure The installation procedure is the reverse of the removal procedure. Note: • Apply molybdenum disulfide grease to the inner surface of the mast support bushing, the mast support section of the front axle, and the tilt cylinder front pin. •...
Page 34 [Point 4] SST(1) Installation: Use the SST to drive in the tilt bracket bushing from the mast SST(2) outer side. SST 09950-76018-71......... (1) (09950-60010) 09950-76020-71......... (2) (09950-70010) Vehicle outer side Vehicle outer side surface surface Bushing Flush surfaces Bushing Pn1 ton series Other than Pn1 ton series...
Page 35: Removal·installation (W/Lift Bracket) (Pn Model)
REMOVAL·INSTALLATION (W/LIFT BRACKET) (Pn model) T = N·m (kgf·cm) [ft·lbf] T = 96.0 (979) [70.8] T = 84.0 ~ 156.0 (857 ~ 1591) [62.0 ~ 115.1] Removal Procedure Set the mast vertical. Remove the fork. (Refer to page 11-31 of 8FGU/8FDU15~32 repair manual vol.1 (Pub. No. CU052)) Remove the connector bracket, disconnect the connector of the fork height switch.
Page 36 Installation Procedure The installation procedure is the reverse of the removal procedure. Note: • Apply molybdenum disulfide grease to the inner surface of the mast support bushing, the mast support section of the front axle, and the tilt cylinder front pin. •...
Page 37: Mast Disassembly·inspection·reassembly
MAST DISASSEMBLY·INSPECTION·REASSEMBLY Disassembly Procedure Remove the mast fork height switch. Remove the hose cover. Disconnect the high pressure hose. Remove each cylinder rod end set bolt. [Point 1] Remove each cylinder support. [Point 2] Remove each cylinder bottom set bolt. Slide the inner mast upward and remove the lift cylinders.
Page 38 ÇŠÇ‰Ç§ Point Operations Shim [Point 1] Disassembly: Shim adjustment is made at the lift cylinder rod end to prevent uneven lifting by lift cylinders LH and RH. Note the cylinder that was adjusted and the number of shims used. [Point 2] Disassembly: Take a note on the number of cylinder support shims in use.
Page 39: Chain
3-10 3-10 CHAIN REASSEMBLY (V·FV·FSV) Installing direction Applicable mast FV: Lift bracket V: Lift bracket FSV: Inner mast and portion FSV: Lift bracket Center of vehicle Center of Front of vehicle vehicle Rough sketch Cotter pin Cotter pin Cotter pin Install the chain with the cotter pin Install the chain with the cotter pin Install the chain with the cotter pin...
Page 40: Fv·fsv Mast Assy
3-11 FV·FSV MAST ASSY COMPONENTS FV (Pn model) 6101 6101-620 FSV (Pn model) 6101 6101-615...
Page 41: Qfv Mast Assy
3-12 3-12 QFV MAST ASSY MAST ADJUSTMENT (QFV) Lift Roller Adjustment The lift roller adjustments, for most part, are same with FSV mast. Where to be adjusted are as shown: Channel seen from the top Channel seen from the bottom 0 ~ 0.6 mm (0 ~ 0.024 in) 100 mm...
Page 42 3-13 Lift Roller Position on Each Upright: Inner Upper Middle Lower Middle Outer...
Page 43: Standard For Selecting An Oversize Roller
3-14 3-14 STANDARD FOR SELECTING AN OVERSIZE ROLLER Select the mast lower lift rollers and lift bracket upper and The clearance is on The clearance is on lower lift rollers. one side both sides Select the appropriate rollers from the table below so that the minimum clearance between the mast or the lift bracket and the roller is from 0 to 1.0 mm (0 to 0.039 in).
Page 44: Lift Cylinder Rod Shim Adjustment (Prevention Of Uneven Lifting)
3-15 LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING) V·FSV MAST Note: • For left and right lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left and right sides due to tolerances of parts, etc. •...
Page 45: Fv·qfv Mast
3-16 3-16 FV·QFV MAST Note: • For left and right lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left and right sides due to tolerances of parts, etc. • The inspection and adjustment must be made when any of the following parts is replaced: Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner mast SUB-ASSY •...
Page 46 CYLINDER Page LIFT CYLINDER (V)·REAR LIFT CYLINDER (FV·FSV·QFV) ............4-2 ...............4-2 GENERAL ............4-4 SPECIFICATIONS ............4-5 COMPONENTS ........4-10 REMOVAL·INSTALLATION ...4-12 DISASSEMBLY·INSPECTION·REASSEMBLY FRONT LIFT CYLINDER (FV·FSV·QFV) .....4-14 .............4-14 GENERAL ..........4-14 SPECIFICATIONS ............4-15 COMPONENTS ........4-16 REMOVAL·INSTALLATION ...4-17 DISASSEMBLY·INSPECTION·REASSEMBLY TILT CYLINDER ...........4-19 .............4-19 GENERAL ..........4-19 SPECIFICATIONS ............4-20 COMPONENTS...
Page 47: Lift Cylinder (V)·Rear Lift Cylinder (Fv·fsv·qfv)
LIFT CYLINDER (V)·REAR LIFT CYLINDER (FV·FSV·QFV) GENERAL Lift Cylinder (V/Pn1·2·Cu2 ton series)·Rear Lift Cylinder (FSV/Pn1·2·Cu2 ton series) Lift Cylinder (V/Pn3·Cu3 ton series)·Rear Lift Cyllinder (FSV/Pn3·Cu3 ton series)
Page 48 Rear Lift Cylinder (FV/Pn1·2·3·Cu2·3 ton series) Rear Lift Cylinder (QFV)
Page 49: Specifications
SPECIFICATIONS Lift Cylinder (V) Vehicle model Pn1 ton series Pn2·Cu2 ton series Pn3·Cu3 ton series Item Cylinder type Single-acting type Cylinder bore mm (in) 45 (1.77) 50 (1.97) 55 (2.17) Piston rod outside diameter mm (in) 35 (1.38) 40 (1.57) 45 (1.77) Piston seal type U packing...
Page 50: Components
COMPONENTS Lift Cylinder (V/Pn1·2·Cu2 ton series) 6503 02[LH] 01[RH] 02K=(INCL. ) 01K=(INCL. ) 6503-284 Lift Cylinder (V/Pn3·Cu3 ton series) 6503 02[LH] 01[RH] 02K=(INCL. ) 01K=(INCL. ) 6503-285...
Page 51 Rear Lift Cylinder (FV) 6503 02[LH] 01[RH] 6503-287 Rear Lift Cylinder (FSV/Pn1·2·Cu2 ton series) (2009.7~) 6503 02[LH] 01[RH] 02K=(INCL. 01K=(INCL. 6503-255...
Page 52 Rear Lift Cylinder (FSV/Pn3·Cu3 ton series) (2009.7~) 6503 02[LH] 01[RH] 02K=(INCL. 01K=(INCL. 6503-256 Rear Lift Cylinder (QFV) 6503 02[LH] 01[RH] 6503-309...
Page 53 Lift Cylinder (V) 6503 6503-283 Rear Lift Cylinder (FV) 6503 6503-286...
Page 54 Rear Lift Cylinder (FSV) 6503 6503-254A Rear Lift Cylinder (QFV) 6503 6503-308...
Page 55: Removal·installation
4-10 4-10 REMOVAL·INSTALLATION Removal Procedure Set the mast vertical and lower the fork fully. Remove the lift cylinder rod end set bolt. Hoist the inner mast by slinging with a wire and disconnect the end of each lift cylinder rod. [Point 1] Hoist the inner mast further so that the lift cylinder ASSY can be removed toward the front of the vehicle.
Page 56 4-11 Installation Procedure The installation procedure is the reverse of the removal procedure. Note: After installing the lift cylinder, follow the steps below. 1. Repeat full-stroke raising and lowering without load to bleed air and check normal functioning. 2. Check the hydraulic oil level and add if insufficient. 3.
Page 57: Disassembly·inspection·reassembly
4-12 4-12 DISASSEMBLY·INSPECTION·REASSEMBLY T = N·m (kgf·cm) [ft·lbf] *: Tightening torque Pn2·Cu2 ton Pn3·Cu3 ton Pn1 ton series series series (2290) (2550) (3600) [166.0] [184.4] [260.4] 244 ~ 271 271 ~ 298 298 ~ 325 (2488 ~ 2764) (2764 ~ 3041) (3041 ~ 3317) [180 ~ 200] [200 ~ 220]...
Page 58 4-13 Point Operations [Point 1] Disassembly•Reassembly: If the cylinder cover is a U-groove type, use the SST. SST 09620-10100-71 [Point 2] Inspection: Measure the piston rod outside diameter. Unit: mm (in) Vehicle model Standard Limit Pn1 ton series 35 (1.38) 34.92 (1.3748) Pn2·Cu2 ton series 40 (1.575)
Page 59: Front Lift Cylinder (Fv·fsv·qfv)
4-14 4-14 FRONT LIFT CYLINDER (FV·FSV·QFV) GENERAL SPECIFICATIONS FV·FSV Vehicle model Item Pn1 ton series Pn2·Cu2 ton series Pn3·Cu3 ton series Cu2·Cu3 ton series Cylinder type Single acting type Cylinder bore mm (in) 70 (2.76) 75 (2.95) 85 (3.25) 75 (2.95) Piston rod outside diameter mm (in) 50.8 (2.00)
Page 60: Components
4-15 COMPONENTS FV, FSV, QFV 6502...
Page 61: Removal·installation
4-16 4-16 REMOVAL·INSTALLATION Removal Procedure Remove the lift bracket W/ fork. Disconnect the piping. Remove the front lift cylinder. Installation Procedure The installation procedure is the reverse of the removal procedure. Note: After installing the lift cylinder, follow the steps below. (1) Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
Page 62: Disassembly·inspection·reassembly
4-17 DISASSEMBLY·INSPECTION·REASSEMBLY T = N·m (kgf·cm) [ft·lbf] 3·4 Disassembly Procedure Remove the chain wheel support. Remove the cylinder cover. [Point 1] Remove the piston rod. [Point 2] Remove the wear ring and U packing. Remove the check valve. Remove the safety down valve from the cylinder. [Point 3]...
Page 63 4-18 4-18 Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure. Note: • Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion. • Apply sealant (08833-76002-71 (08833-00080)) to the 1/3 to 1/2 of circumference cylinder cover on the part shown in the illustration to reassemble it.
Page 64: Tilt Cylinder
4-19 TILT CYLINDER GENERAL Pn model Cu model SPECIFICATIONS Cylinder type Double acting type Pn1·2 ton series 70 (2.76) Cylinder bore mm (in) Pn3 ton series 80 (3.15) Cu2·3 ton series 75 (2.96) Pn1·2 ton series 30 (1.18) Piston rod outside diameter mm (in) Pn3 ton series 35 (1.38)
Page 65: Components
4-20 4-20 COMPONENTS 6511 Pn model 01K=(INCL. ) 6511-301 Cu model 01K=(INCL. ) 6511-303...
Page 66: Removal·installation
4-21 REMOVAL·INSTALLATION T = N·m (kgf·cm) [ft·lbf] T = 96.0 (979) [70.8] T = 61.2 (624) [45.2] Removal Procedure Open the engine hood. Remove the toe board and lower panel. Remove the side cover W/ step. Hoist the mast temporarily. Disconnect the hoses.
Page 67 4-22 4-22 Installation Procedure The installation procedure is the reverse of the removal procedure. Note: • Apply molybdenum disulfide grease on the portions for inserting tilt cylinder front and rear pins before installation. • Pre-coated bolts are used for the tilt cylinder rear pin set bolt. When installing, either replace the set bolt with a new part or apply locking agent (08833-76001-71 (08833-00070)) to the threaded portion before tightening.
Page 68: Disassembly·inspection·reassembly
4-23 DISASSEMBLY·INSPECTION·REASSEMBLY T = N·m (kgf·cm) [ft·lbf] Pn1·2, Cu2·3 ton series: T = 436 (4450) [322.0] Pn3 ton series: T = 725 (7390) [534.7] 2•7 T = 110 (1122) [81.2] Pn1·2, Cu2·3 ton series: T = 353 (3600) [260.5] Pn3 ton series: T = 392 (4000) [289.2] Disassembly Procedure Before disassembling, measure the total length of the tilt cylinder when fully contracted, and make a note.
Page 69 4-24 4-24 Point Operations [Point 1] Disassembly•Reassembly: Check the total length L of the tilt cylinder when fully contracted. [Point 2] Reassembly: Assemble the boot to the vehicle with its air bleeding holes vertical. Air bleeding hole [Point 3] Disassembly•Reassembly: SST 09620-10100-71 [Point 4] Inspection:...
Page 70 4-25 Reassembly: Use a cylinder rod insertion guide (SST) to reassemble. Pn1·2 ton series: SST 09659-26600-71 Pn3 ton series: SST 09660-26600-71 Cu2·3 ton series: Cylinder SST 09661-26600-71 Cylinder rod [Point 5] Inspection: Measure the piston rod outside diameter. Standard: Pn1·2, Cu2·3 ton series: 30.0 mm (1.181 in) Pn3 ton series: 35.0 mm (1.378 in) Limit:...
Page 71: Mast Forward Backward Tilt Angle Adjustment (Adjustment Of Uneven Tilting)
4-26 4-26 MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (ADJUSTMENT OF UNEVEN TILTING) Note: Adjust the mast forward and backward tilt angles (uneven tilting) when the tilt cylinder and mast ASSY are replaced or overhauled. After adjustment, perform SAS matching. (Refer to section 16 of 8FGU/8FDU15-32 repair manual vol.1 (Pub. No.
Page 72 OTHER MODIFICATIONS Page BODY..............5-2 ....5-2 TOE BOARD REMOVAL·INSTALLATION SAS/OPS ..............5-3 ............5-3 SAS FUNCTION...
Page 73: Body
BODY TOE BOARD REMOVAL·INSTALLATION Removal Procedure Remove the mat. Remove the lower panel. Remove the rear toe board. Disconnect the accelerator connector and harness clamp. (Vehicles with accelerator sensor) [Point 1] Alternatively, disconnect the accelerator cable. Remove the front toe board. Installation Procedure The installation procedure is the reverse of the removal procedure.
Page 74: Sas/Ops
SAS/OPS SAS FUNCTION COMPONENTS Tilt Angle Sensor 5803 5803-533A...
Page 75 TILT ANGLE SENSOR REMOVAL·INSTALLATION T = N·m (kgf·cm) [ft·lbf] T = 12.0 (122) [8.8] T = 17.0 (173) [12.5] T = 17.0 (173) [12.5] Removal Procedure Remove the lower panel. Remove the toe board. Disconnect the tilt angle sensor link rod. Disconnect the connector.
Page 76 · SST LIST SERVICE STANDARDS LIST Page SST LIST ..............6-2 SERVICE STANDARDS LIST ........6-4...
Page 77 SST LIST : Newly adopted SST Section Illustration Part No. Part Name 09216-76002-71 Belt tension gage (09216-00021) 09610-22000-71 Inner mast stopper Cylinder cap remover and 09620-10100-71 replacer 09630-23600-71 Deep socket A 09651-26600-71 Piston rod insert guide 09652-26600-71 Piston rod insert guide 09653-26600-71 Piston rod insert guide 09659-26600-71...
Page 78 Section Illustration Part No. Part Name 09661-26600-71 Piston rod guide 09810-20172-71 Joint pin remover 09950-76014-71 Puller B set (09950-40011) 09950-76018-71 Replacer set (09950-60010) 09950-76020-71 Handle set (09950-70010)
Page 79 SERVICE STANDARDS LIST ENGINE Engine Idle speed 1DZ-III Standard 750 ± 30 8FDU15·18 Standard 2600 ± 50* No-load static maximum speed * : In the case of vehicles equipped 1DZ-III 8FDU20~32 Standard 2800 ± 50* with travel and load handling control, the rpm tolerance is .
Page 80 CYLINDER Lift cylinder (V) Standard 35 (1.38) Pn1 ton series Limit 34.92 (1.3748) Standard 40 (1.57) Pn2·Cu2 ton Piston rod outside diameter mm (in) series Limit 39.92 (1.5717) Standard 45 (1.77) Pn3·Cu3 ton series Limit 44.92 (1.7685) Standard 45 (1.77) Pn1 ton series Limit 45.20 (1.7795)
Page 81 Front lift cylinder (FV·FSV·QFV) Standard 50.8 (2.0) Piston rod outside diameter mm (in) Limit 50.72 (1.9969) Standard 70 (2.76) Pn1 ton series Limit 70.35 (2.7697) Standard 75 (2.95) Pn2·Cu2·Cu3 Cylinder bore mm (in) (QFV) ton series Limit 75.35 (2.9665) Pn3·Cu3 Standard 85 (3.35) (FV·FSV) ton...
Page 82 Pn1·2, Cu2·3 ton series Standard 353 (3600) [260.5] Tilt cylinder cover Pn3 ton series Standard 392 (4000) [289.2] Pn1·2, Cu2·3 ton series Standard 436 (4450) [322.0] Tilt cylinder piston lock nut Pn3 ton series Standard 725 (7390) [534.7] Tilt cylinder front pin set bolt Standard 96.0 (979) [70.8] Tilt cylinder rear pin set bolt...
Page 84 WIRING DIAGRAM CHAPTER 1 INTRODUCTION CHAPTER 2 ELECTRICAL WIRING ROUTINGS AND RELAY LOCATIONS CHAPTER 3 SYSTEM CIRCUITS CHAPTER 4 GROUND POINTS CHAPTER 5 FUSES FOR POWER SUPPLY CHAPTER 6 CONNECTOR LIST...
Page 86 E1-1 INTRODUCTION CHAPTER 1 INTRODUCTION CHAPTERS OF THIS SECTION ................E1-2 HOW TO READ CHAPTERS Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS ELECTRICAL WIRING ROUTINGS ............E1-3 RELAY LOCATIONS JUNCTION BLOCK (J/B) / RELAY BLOCK (R/B) ........E1-4 Chapter 3 SYSTEM CIRCUITS POWER SUPPLY CIRCUIT ..............
Page 87: Chapters Of This Section
E1-2 INTRODUCTION CHAPTERS OF THIS SECTION This section consists of the following 6 chapters: Chapter 1 INTRODUCTION Gives brief explanation of each chapter, provides instructions on how to use this manual, and defines the abbreviations used in the electrical circuit diagrams. Chapter 2 ELECTRICAL WIRING Electrical wiring routings show installation positions, ground points, ROUTINGS and...
Page 88: How To Read Chapters
E1-3 INTRODUCTION HOW TO READ CHAPTERS Chapter 2 ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS ELECTRICAL WIRING ROUTINGS Electrical wiring routings show installation positions, ground points, connector numbers, and part names related to wire harnesses, connectors, relay blocks and junction blocks used in the forklift. (Connector codes are the same as those used in the electrical wiring diagrams.) E2-10 E2-11...
Page 89: Relay Locations
E1-4 INTRODUCTION RELAY LOCATIONS Relay locations show connectors connected to junction blocks, relays, fuses and internal circuit diagrams. E2-21 E2-20 RELAY LOCATIONS ENGINE ROOM R/B:ENGINE ROOM LEFT JUNCTION BLOCK:LEFT STEP(INNER CIRCUIT SEE PAGE E2-24) BLACK 1B 90980-12506 * 1:15A E-THRO (4Y-E) 90980-12383 7.5A ECU-B2 (1DZ, 2Z) * 2:7.5A (1DZ, 2Z)
Page 90 E1-5 INTRODUCTION [A] Junction block /relay block Indicates a junction block or relay block name, its location and a reference page for an internal circuit diagram. [B] Connector code and color Indicates the code and color of a connector connected to a junction block. [C] Connector part number Indicates the part number of a connector.
Page 91: Chapter 3 System Circuits
E1-6 INTRODUCTION Chapter 3 SYSTEM CIRCUITS (1) SYSTEM CIRCUITS A system circuit consists of a power source circuit diagram and respective system circuit diagrams. A power source circuit diagram shows the connections from the power source to fuses. A system diagram shows the connections from fuses to ground points of each system.
Page 92 E1-7 INTRODUCTION [A] Section page [G] Page-to-page connection code Indicates the page number for the section. Indicates a wire harness continues onto the [B] System title following page from the matching code. Indicates a system name. [H] Harness to harness connector [C] Part name and connector code Indicates a connector code that connects two wire Indicates a part name and connector code to be...
Page 93 E1-8 INTRODUCTION Chapter 3 SYSTEM CIRCUITS (2) E3-12 ENGINE CONTROL (4Y-E)
Page 94 E1-9 INTRODUCTION [I] Terminal number [L] Wire color Indicates a terminal number of a connector to be Indicates a wire harness color. connected. When two alphabetical codes are indicated, for [J] Junction block connector example "W-B", the first letter indicates the basic Indicates a connector code connected to a wire color and the second letter indicates the color junction block.
Page 95: Reference Page
E1-10 INTRODUCTION REFERENCE PAGE PARTS Code See Page Code See Page Code See Page Code See Page A 20 E2-8 E2-2 G 21 E2-2 E2-2 A 25 E2-10 E2-2 G 25 E2-2 E2-14 A 27 E2-10 E2-2 G 26 E2-2 E2-8 A 35 E2-10...
Page 96: Chapter 4 Ground Points Ground Points
E1-11 INTRODUCTION Chapter 4 GROUND POINTS GROUND POINTS These tables describe related systems for each ground point. E4-2 GROUND POINTS CODE GROUND POINT LOCATION SYSTEM NAME PAGE SAS/OPS SYSTEM E3-36 CLEARANCE LAMP E3-72 STOP LAMP E3-76 STROBE LIGHT E3-52 FRONT PLATE LEFT OUTSIDE TURN SIGNAL LAMP E3-70 BACK UP LAMP BUZZER...
Page 97: Chapter 6 Connector List Connector List
E1-12 INTRODUCTION Chapter 6 CONNECTOR LIST CONNECTOR LIST E6-3 CONNECTOR LIST A 43 A 44 A 45 A 46 A 47 DARK GRAY DARK GRAY DARK GRAY 9 10 11 12 13 90980-11162 90980-11168 90980-10807 90980-10942 90980-11594 A 48 A 49 A 50 A 51 A 52...
Page 98: Wire To Wire
E1-13 INTRODUCTION HARNESS TO HARNESS CONNECTOR E6-13 WIRE to WIRE BLACK GRAY 90980-10797 90980-109 80 90980-10795 90980-11036 90980-10796 90980-10979 90980-11035 90980-10794 GRAY 99144 -12239 90980 -10906 90980-107 99 90980-10798 DARK GRAY 10 11 12 13 14 15 90980-10871 9098 0-10870 90980-11089 90980-1119 4 90980-11088...
Page 99: Abbreviations
E1-14 INTRODUCTION ABBREVIATIONS The following abbreviations are used in this section. Abbreviations Explanation Auto Speed Control ASSY Assembly Compressed Nutural Gas Diesel Particulate Filter Electronic Control Unit Front Junction Block Left-Hand Liquefied Petroleum Gas Manual Transmission Operator Presence Sensing Power Steering Relay Block Right-Hand Rear...
Page 100: Glossary Of Terms And Symbols
E1-15 INTRODUCTION GLOSSARY OF TERMS AND SYMBOLS BATTERY GROUND RELAY SWITCH, MANUAL 1. NORMALLY 1. NORMALLY CLOSED OPEN HEADLIGHTS CAPACITOR (Condenser) 2. NORMALLY 2. NORMALLY 1. SINGLE OPEN CLOSED FILAMENT CIGARETTE LIGHTER RELAY, DOUBLE THROW SWITCH, DOUBLE THROW 2. DOUBLE FILAMENT DIODE HORN...
Page 101 MEMO...
Page 102 E2-1 CHAPTER 2 ELECTRICAL WIRING ROUTINGS AND RELAY LOCATIONS ELECTRICAL WIRING ROUTINGS ENGINE ROOM (4Y-E) ..............E2-2 ENGINE ROOM (1DZ) ............... E2-4 INSTRUMENT PANEL ..............E2-6 FRONT BODY ................... E2-8 MAST AREA ..................E2-10 REAR BODY (NO.1) ................ E2-12 REAR BODY (NO.2) ................ E2-14 RELAY LOCATIONS JUNCTION BLOCK (J/B) / RELAY BLOCK (R/B) ......
Page 103 E2-2 ELECTRICAL WIRING ROUTINGS ENGINE ROOM(4Y-E) ENGINE WIRE BATTERY STARTER WIRE to E2-8 ENGINE EARTH WIRE BATTERY EARTH WIRE ENGINE SUB WIRE...
Page 104 E2-3 ELECTRICAL WIRING ROUTINGS ALTERNATOR ENGINE WIRE to ENGINE SUB WIRE ALTERNATOR ALTERNATOR THROTTLE POSITION SENSOR(WITH MOTOR) INJECTOR NO.1 ENGINE UPPER EARTH INJECTOR NO.2 INJECTOR NO.3 ENGINE UPPER EARTH INJECTOR NO.4 VACUUM SENSOR REAR PILLAR LEFT UNDER EARTH FCM STEP MOTOR WATER TEMPERATURE SENDER WATER TEMPERATURE SENSOR G2 SENSOR...
Page 105 E2-4 ELECTRICAL WIRING ROUTINGS ENGINE ROOM(1DZ) ENGINE EARTH WIRE to E2-8 BATTERY STARTER WIRE BATTERY EARTH WIRE ENGINE WIRE...
Page 106 E2-5 ELECTRICAL WIRING ROUTINGS ALTERNATOR ALTERNATOR WATER TEMPERATURE SENDER WATER TEMPERATURE SENSOR OIL PRESSURE SWITCH FUSIBLE LINK BLOCK ASSY GLOW PLUG INJECTOR PUMP STARTER GLOW PLUG RELAY FUEL CUT SOLENOID OPEN CLOSE SWITCH STEP MOTOR ALTERNATOR FUSIBLE LINK BLOCK-1 DISCONNECT SWITCH(BATT) DISCONNECT SWITCH(ALT) DISCONNECT SWITCH(ALT) DISCONNECT SWITCH(BATT)
Page 107 E2-6 ELECTRICAL WIRING ROUTINGS INSTRUMENT PANEL BODY MAIN WIRE FR STAY WIRE RH b MAST SENSOR WIRE BODY SUB NO.1 WIRE HEAD GUARD SW WIRE FR STAY WIRE LH INSTRUMENT PANEL WIRE ACCEL SUB WIRE WIPER SUB WIRE j INSTRUMENT PANEL SW WIRE m 12V PWR SUPPLY WIRE to E2-10 to E2-10...
Page 108 E2-7 ELECTRICAL WIRING ROUTINGS HORN SWITCH BODY MAIN WIRE to INSTRUMENT PANEL WIRE IGNITION SWITCH BODY MAIN WIRE to ACCEL SUB WIRE STEERING SENSOR BODY MAIN WIRE to WIPER SUB WIRE LIGHT CONTROL SWITCH BODY MAIN WIRE to WIPER SUB WIRE STOP LAMP SWITCH INSTRUMENT PANEL WIRE to BODY MAIN WIRE BRAKE WARNING SWITCH...
Page 109 E2-8 ELECTRICAL WIRING ROUTINGS FRONT BODY ENGINE WIRE SIDE RH WIRE to E2-2 to E2-4 to E2-14 ENGINE ROOM R/B to E2-12 2-STATOR SUB WIRE SIDE LH WIRE to E2-6 T/C HEAT GAUGE WIRE BODY MAIN WIRE [1DZ W/O ASC] [1DZ W/ ASC] [4Y-E]...
Page 110 E2-9 ELECTRICAL WIRING ROUTINGS FUSIBLE LINK BLOCK ASSY BODY MAIN WIRE to J/B DIAGNOSIS DIODE ENGINE WIRE to J/B JUNCTION CONNECTOR SIDE LH WIRE to J/B CAN JOINT CONNECTOR CAN JOINT CONNECTOR CAN JOINT CONNECTOR CAN JOINT CONNECTOR BODY MAIN WIRE to SIDE RH WIRE CAN JOINT CONNECTOR ENGINE ECU BODY MAIN WIRE to ENGINE WIRE...
Page 111 E2-10 ELECTRICAL WIRING ROUTINGS MAST AREA *1:V MAST *2:EXCEPT V MAST HEAD GUARD SW WIRE BODY MAIN WIRE BODY SUB NO.1 WIRE to E2-14 FR STAY WIRE LH MAST SENSOR WIRE...
Page 112 E2-11 ELECTRICAL WIRING ROUTINGS FRONT COMBINATION LAMP RIGHT HEAD LAMP RIGHT HEATER SWITCH FRONT WIPER SWITCH REAR WIPER SWITCH LPG WARNING SWITCH FAN SWITCH FAN MOTOR(B) FAN MOTOR(E) MAST SWITCH FRONT COMBINATION LAMP LEFT HEAD LAMP LEFT BODY MAIN WIRE to MAST SENSOR WIRE BODY SUB NO.1 WIRE to BODY MAIN WIRE FR STAY WIRE RH to BODY MAIN WIRE HEAD GUARD SW WIRE to BODY MAIN WIRE...
Page 113 E2-12 ELECTRICAL WIRING ROUTINGS REAR BODY(NO.1) *1:CABIN *2:EXCEPT CABIN *3:W/ SYNCHRONIZED STEERING *4:SPEED CONTROL PACKAGE *5:MINI LEVER W/ ARMREST & JOYSTICK LEVER *6:W/ CABIN, MINI LEVER, LPG YELLOW FREIGHT SPEC. *7:EX YELLOW FREIGHT SPEC. *8:EX SPECIAL DUAL TIRE to E2-14 HOOD SUB NO.1 WIRE RR UPR MAIN WIRE to E2-8...
Page 114 E2-13 ELECTRICAL WIRING ROUTINGS YAW RATE SENSOR FUEL SENDER GAUGE & FUEL PUMP SEDIMENTARY SWITCH SEAT SWITCH REAR WIPER MOTOR REAR COMBINATION LAMP LEFT REAR COMBINATION LAMP RIGHT REAR WIPER RELAY REAR HORN SWITCH LED REAR COMBINATION LAMP LEFT LED REAR COMBINATION LAMP RIGHT SMART ALARM(+) SMART ALARM(-) BEACON LAMP LEFT(B)
Page 115 E2-14 ELECTRICAL WIRING ROUTINGS REAR BODY(NO.2) *1:DX CABIN *2:W/ HEATER W/O DX CABIN RR UPR SUB RH WIRE to E2-12 RR UPR MAIN WIRE to E2-6 BODY SUB NO.1 WIRE BLOWER UL-S WIRE to E2-8 BACK BUZZER WIRE SIDE RH WIRE...
Page 116 E2-15 ELECTRICAL WIRING ROUTINGS FRONT WASHER MOTOR HEATER RELAY REAR WASHER MOTOR O2 SENSOR IN AIR SENSOR AIR CLEANER WARNING SWITCH AIR CLEANER WARNING SWITCH RADIATOR WARNING SWITCH COMPARTMENT LAMP COMPARTMENT LAMP SWITCH(+) COMPARTMENT LAMP SWITCH(-) WORK LAMP WORK LAMP SWITCH(+) WORK LAMP SWITCH(-) HEATER RESISTOR HEATER BLOWER MOTOR...
Page 117 E2-16 RELAY LOCATONS FUSIBLE LINK BLOCK ASSY (INNER CIRCUIT : SEE PAGE E2-22) (EXCEPT UL-GS, UL-LPS AND UL-DS TYPE) [FRONT] MAIN GLOW 100A 120A [REAR] BLACK BLACK 90980-11881 90980-11996...
Page 118 E2-17 RELAY LOCATONS FUSIBLE LINK BLOCK-1 : ENGINE ROOM LEFT (UL-GS TYPE, UL-LPS TYPE, UL-DS TYPE) FUSIBLE LINK BLOCK -2 : ENGINE ROOM LEFT (UL-DS TYPE)
Page 119 E2-18 RELAY LOCATONS ENGINE ROOM R/B : ENGINE ROOM LEFT * 1:15A E-THRO (4Y-E) 7.5A ECU-B2 (1DZ) * 2:LPG MAIN RELAY (4Y-E) ASC RELAY (1DZ) * 3:15A (4Y-E) SPARE 7.5A (1DZ) * 4:HEAD LAMP RELAY(W/ KEY OFF) SPARE 7.5A SHORT PIN (FULL HARNESS W/O KEY OFF) 7.5A RR WIP...
Page 120 E2-19 RELAY LOCATONS J/B : LEFT STEP (INNER CIRCUIT : SEE PAGE E2-24) 90980-12506 90980-12383 *1:BACK UP LAMP RELAY (EZ PEDAL) T/C FR RELAY 90980-12320 T/C RR RELAY 90980-12308 HORN RELAY 90980-12311 FLASHER RELAY...
Page 121 E2-20 RELAY LOCATONS CAN JOINT CONNECTOR : INSIDE OF THE ECU BOX (INNER CIRCUIT : SEE PAGE E2-27) BLUE BLACK BROWN 90980-12355 90980-12355 90980-12355 90980-10871 JUNCTION TERMINAL 90980-12355...
Page 122 E2-21 RELAY LOCATONS JUNCTION CONNECTOR BLACK A65 JUNCTION CONNECTOR (A) BLACK G73 JUNCTION CONNECTOR (B) BLUE A66 BLUE G29 GRAY JUNCTION CONNECTOR GRAY JUNCTION CONNECTOR (E) 7 8 9 11 12 13 JUNCTION CONNECTOR (J)
Page 123 E2-22 RELAY LOCATONS [FUSIBLE LINK BLOCK ASSY INNER CIRCUIT] 100A ALT 60A GLOW 120A MAIN...
Page 124 E2-23 MEMO...
Page 125 E2-24 RELAY LOCATONS [J/B INNER CIRCUIT (1/3)] *1:EZ PEDAL 13 1C 1 1D 31 1A 14 1D 33 1B 15 1D 15 1E 32 1A 16 1E 15 1B 16 1B BACK UP LAMP RELAY (*1) 23 1E 28 1B 25 1E 24 1E 13 1A...
Page 126 E2-25 RELAY LOCATONS [J/B INNER CIRCUIT (2/3)] 34 1A HORN RELAY 16 1C 17 1A 4 1E 8 1E 33 1A 6 1C 32 1C 14 1C 16 1A 14 1A 10 1C 25 1A 27 1C 7 1B 24 1D 6 1B 6 1E 15 1A...
Page 127 E2-26 RELAY LOCATONS [J/B INNER CIRCUIT (3/3)] 18 1B 7 1C 9 1C 6 1A 27 1B 21 1D 30 1B 11 1D 7 1E 23 1D 22 1C 14 1B 20 1B 8 1C 16 1D 2 1B 14 1E 25 1C 20 1A 28 1E...
Page 128 E2-27 RELAY LOCATONS [CAN JOINT CONNECTOR INNER CIRCUIT] JUNCTION TERMINAL...
Page 129 MEMO...
Page 130 E3-1 CHAPTER 3 SYSTEM CIRCUITS POWER SOURCE POWER SOURCE ...................... E3-2 CHARGING ......................... E3-4 STARTING ........................E3-6 ENGINE FUEL ........................... E3-8 ENGINE CONTROL (4Y-E) ..................E3-10 GLOW ........................E3-16 ASC ........................... E3-20 LPG WARNING SYSTEM (4Y-E) ................E3-24 CHASSIS POWER SHIFT TRANSMISSION ................E3-26 EZ PEDAL .........................
Page 131: Power Source
E3-2 POWER SOURCE...
Page 132 E3-3 POWER SOURCE PARTS Code See Page Code See Page Code See Page Code See Page E2-6 G 77 E2-2,4 G 87 E2-4 E2-6 A 24 E2-8,16 G 80 E2-2,4 E2-2 G 76 E2-2,4 G 86 E2-2 E2-4 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B...
Page 133: Charging
E3-4 CHARGING...
Page 134 E3-5 CHARGING PARTS Code See Page Code See Page Code See Page Code See Page E2-2,4 G 24 E2-2,4,16 G 78 E2-2,4 E2-2 G 75 E2-2,4 G 79 E2-2,4 E2-2,4 G 76 E2-2,4 E2-6 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17...
Page 135: Starting
E3-6 STARTING...
Page 136 E3-7 STARTING PARTS Code See Page Code See Page Code See Page Code See Page E2-6 G 32 E2-4 E2-2,4 E2-2 A 41 E2-6 G 35 E2-8 E2-2 E2-12 A 85 E2-8 G 39 E2-8 E2-4 E2-6 G 23 E2-2 E2-2 E2-2 E2-6...
Page 137: Fuel
E3-8 FUEL...
Page 138 E3-9 FUEL PARTS Code See Page Code See Page Code See Page Code See Page G 31 E2-4 G 34 E2-4 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18 BODY MAIN WIRE to J/B E2-8,18...
Page 139: Engine Control (4Y-E)
E3-10 ENGINE CONTROL (4Y-E)
Page 140 E3-11 ENGINE CONTROL (4Y-E)
Page 141 E3-12 ENGINE CONTROL (4Y-E)
Page 142 E3-13 ENGINE CONTROL (4Y-E)
Page 143 E3-14 ENGINE CONTROL (4Y-E) PARTS Code See Page Code See Page Code See Page Code See Page A 20 E2-6 E2-2 G 21 E2-2 E2-2 A 25 E2-8 E2-2 G 25 E2-2 E2-2 A 27 E2-8 E2-2 G 26 E2-2 E2-2 A 35 E2-8...
Page 144 E3-15 MEMO...
Page 145: Glow
E3-16 GLOW...
Page 146 E3-17 GLOW...
Page 147 E3-18 GLOW PARTS Code See Page Code See Page Code See Page Code See Page E2-6 G 24 E2-2,4,16 G 75 E2-2,4 G 87 E2-4 A 41 E2-6 G 30 E2-4 G 82 E2-4 E2-6 A 85 E2-8 G 33 E2-4 G 83 E2-4...
Page 148 E3-19 MEMO...
Page 149: Asc
E3-20...
Page 150 E3-21...
Page 151 E3-22 PARTS Code See Page Code See Page Code See Page Code See Page A 34 E2-8,19 G 36 E2-4 G 38 E2-8 G 43 E2-8 G 31 E2-4 G 37 E2-4 G 39 E2-8 E2-6 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B...
Page 152 E3-23 MEMO...
Page 153: Lpg Warning System (4Y-E)
E3-24 LPG WARNING SYSTEM (4Y-E)
Page 154 E3-25 LPG WARNING SYSTEM (4Y-E) PARTS Code See Page Code See Page Code See Page Code See Page A 36 E2-8 A 65 E2-8 G 29 E2-8 E2-2 A 37 E2-8 A 66 E2-8 G 73 E2-8 E2-2 A 38 E2-8 A 88 E2-6...
Page 155: Power Shift Transmission
E3-26 POWER SHIFT TRANSMISSION...
Page 156 E3-27 POWER SHIFT TRANSMISSION...
Page 157 E3-28 POWER SHIFT TRANSMISSION PARTS Code See Page Code See Page Code See Page Code See Page A 20 E2-6 A 41 E2-6 A 73 E2-8 A 76 E2-8 A 21 E2-6 A 55 E2-8 A 74 E2-8 E2-8 A 26 E2-8 A 64 E2-8...
Page 158 E3-29 MEMO...
Page 159: Ez Pedal
E3-30 EZ PEDAL...
Page 160 E3-31 EZ PEDAL...
Page 161 E3-32 EZ PEDAL PARTS Code See Page Code See Page Code See Page Code See Page E2-6 A 21 E2-6 A 82 E2-8 A 84 E2-8 A 20 E2-6 A 78 E2-6 A 83 E2-8 A 85 E2-8 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B...
Page 162 E3-33 MEMO...
Page 163: Sas/Ops System
E3-34 SAS/OPS SYSTEM...
Page 164 E3-35 SAS/OPS SYSTEM...
Page 165 E3-36 SAS/OPS SYSTEM...
Page 166 E3-37 SAS/OPS SYSTEM PARTS Code See Page Code See Page Code See Page Code See Page E2-6 A 14 E2-6 A 29 E2-8,19 E2-12 E2-6 A 15 E2-6 A 42 E2-6 E2-12 E2-6 A 18 E2-6 A 45 E2-8 E2-6 E2-6 A 19 E2-6...
Page 167: Mini Lever
E3-38 MINI LEVER...
Page 168 E3-39 MINI LEVER PARTS Code See Page Code See Page Code See Page Code See Page A 21 E2-6 A 52 E2-6 E2-12 A 23 E2-6 A 64 E2-8 E2-12 A 51 E2-6 E2-12 E2-12 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B...
Page 169: Diag
E3-40 DIAG...
Page 170 E3-41 DIAG PARTS Code See Page Code See Page Code See Page Code See Page A 25 E2-8 A 31 E2-8,19 A 66 E2-8 A 27 E2-8 A 36 E2-8 G 29 E2-8 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B...
Page 171: Rear Working Lamp
E3-42 REAR WORKING LAMP...
Page 172 E3-43 REAR WORKING LAMP PARTS Code See Page Code See Page Code See Page Code See Page T 11 E2-14 T 12 E2-14 T 13 E2-14 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18...
Page 173: Compartment Lamp
E3-44 COMPARTMENT LAMP...
Page 174 E3-45 COMPARTMENT LAMP PARTS Code See Page Code See Page Code See Page Code See Page E2-14 E2-14 T 10 E2-14 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18 BODY MAIN WIRE to J/B E2-8,18...
Page 175: Strobe Light
E3-46 STROBE LIGHT...
Page 176 E3-47 STROBE LIGHT PARTS Code See Page Code See Page Code See Page Code See Page S 17 E2-12 S 18 E2-12 S 19 E2-12 S 20 E2-12 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18...
Page 177: Combination Meter
E3-48 COMBINATION METER...
Page 178 E3-49 COMBINATION METER...
Page 179 E3-50 COMBINATION METER PARTS Code See Page Code See Page Code See Page Code See Page E2-6 A 81 E2-8 E2-2,4 G 75 E2-2,4 E2-6 E2-14 G 14 E2-2 E2-12 A 20 E2-6 E2-14 G 22 E2-2,4 E2-12 A 36 E2-8 E2-14 G 35...
Page 180 E3-51 MEMO...
Page 181: Multi Display
E3-52 MULTI DISPLAY...
Page 182 E3-53 MULTI DISPLAY PARTS Code See Page Code See Page Code See Page Code See Page A 27 E2-8 A 33 E2-8,19 E2-6 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18...
Page 183: Front Wiper & Washer
E3-54 FRONT WIPER & WASHER...
Page 184 E3-55 FRONT WIPER & WASHER PARTS Code See Page Code See Page Code See Page Code See Page E2-14 E2-10 E2-6 E2-6 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18 BODY MAIN WIRE to J/B...
Page 185: Rear Wiper & Washer
E3-56 REAR WIPER & WASHER...
Page 186 E3-57 REAR WIPER & WASHER PARTS Code See Page Code See Page Code See Page Code See Page E2-14 E2-12 E2-12 E2-10 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18 BODY MAIN WIRE to J/B...
Page 187: Horn & W/ Rear Horn Switch
E3-58 HORN & W/ REAR HORN SWITCH...
Page 188 E3-59 HORN & W/ REAR HORN SWITCH PARTS Code See Page Code See Page Code See Page Code See Page E2-6 S 11 E2-12 E2-6 A 49 E2-8 E2-6 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18...
Page 189: Head Lamp
E3-60 HEAD LAMP...
Page 190 E3-61 HEAD LAMP PARTS Code See Page Code See Page Code See Page Code See Page E2-6 E2-10 E2-10 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18 BODY MAIN WIRE to J/B E2-8,18...
Page 191: Turn Signal Lamp
E3-62 TURN SIGNAL LAMP...
Page 192 E3-63 TURN SIGNAL LAMP PARTS Code See Page Code See Page Code See Page Code See Page E2-6 E2-12 S 22 E2-12 E2-10 S 13 E2-12 S 23 E2-12 E2-12 S 14 E2-12 E2-10 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17...
Page 193: Clearance Lamp
E3-64 CLEARANCE LAMP...
Page 194 E3-65 CLEARANCE LAMP PARTS Code See Page Code See Page Code See Page Code See Page E2-6 E2-10 S 13 E2-12 A 89 E2-6 E2-12 S 14 E2-12 A 94 E2-6 E2-12 E2-10 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B...
Page 195: Back Up Lamp Buzzer & Smart Alarm
E3-66 BACK UP LAMP BUZZER & SMART ALARM...
Page 196 E3-67 BACK UP LAMP BUZZER & SMART ALARM...
Page 197 E3-68 BACK UP LAMP BUZZER & SMART ALARM PARTS Code See Page Code See Page Code See Page Code See Page E2-6 A 80 E2-6 S 13 E2-12 E2-12 A 41 E2-6 A 81 E2-8 S 14 E2-12 E2-14 A 78 E2-6 A 84 E2-8...
Page 198 E3-69 MEMO...
Page 199: Stop Lamp
E3-70 STOP LAMP...
Page 200 E3-71 STOP LAMP PARTS Code See Page Code See Page Code See Page Code See Page E2-6 E2-12 S 14 E2-12 E2-12 S 13 E2-12 S 21 E2-12 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18...
Page 201: Heater
E3-72 HEATER...
Page 202 E3-73 HEATER PARTS Code See Page Code See Page Code See Page Code See Page E2-14 E2-10 E2-14 E2-14 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B E2-8,18 BODY MAIN WIRE to J/B E2-8,18...
Page 203: Fan
E3-74...
Page 204 E3-75 PARTS Code See Page Code See Page Code See Page Code See Page E2-10 E2-10 E2-10 RELAY BLOCK , JUNCTION BLOCK Code See Page Relay Block Name or Joining Wire Harness to J/B E2-8,17 ENGINE ROOM R/B WIRE TO WIRE Code See Page Joining Wire Harness and Wire Harness...
Page 205: Can
E3-76...
Page 206 E3-77 PARTS Code See Page Code See Page Code See Page Code See Page A 20 E2-6 A 29 E2-8,19 A 33 E2-8,19 G 39 E2-8 A 25 E2-8 A 31 E2-8,19 A 34 E2-8,19 E2-6 A 27 E2-8 A 32 E2-8,19 A 36 E2-8...
Page 207: Earth To Earth
E3-78 EARTH TO EARTH...
Page 208 E3-79 EARTH TO EARTH WIRE TO WIRE Code See Page Joining Wire Harness and Wire Harness E2-8 BODY MAIN WIRE to SIDE LH WIRE EARTH Code See Page Name E2-8 FRONT PLATE LEFT OUTSIDE EARTH E2-8 FRONT PLATE LEFT OUTSIDE EARTH E2-8 FRONT PLATE LEFT OUTSIDE EARTH E2-8...
Page 209 MEMO...
Page 210 E4-1 CHAPTER 4 GROUND POINTS...
Page 211 E4-2 GROUND POINTS CODE LOCATION SYSTEM NAME PAGE BACK UP LAMP BUZZER & SMART ALARM E3-66 CLEARANCE LAMP E3-64 COMPARTMENT LAMP E3-44 EZ PEDAL E3-30 E3-74 FRONT PLATE LEFT OUTSIDE EARTH HEAD LAMP E3-60 POWER SHIFT TRANSMISSION E3-26 SAS/OPS SYSTEM E3-34 STOP LAMP E3-70...
Page 212 E5-1 CHAPTER 5 FUSES FOR POWER SUPPLY...
Page 213 E5-2 FUSES FOR POWER SUPPLY FUSIBLE LINK BLOCK ASSY FUSE SYSTEM NAME PAGE GLOW GLOW E3-16 100A CHARGING E3-4 FUSIBLE LINK BLOCK-1 FUSE SYSTEM NAME PAGE 100A CHARGING E3-4 FUSIBLE LINK BLOCK-2 FUSE SYSTEM NAME PAGE GLOW GLOW E3-16 ENGINE ROOM R/B FUSE SYSTEM NAME PAGE...
Page 214 E5-3 FUSES FOR POWER SUPPLY FUSE SYSTEM NAME PAGE CHARGING E3-4 CLEARANCE LAMP E3-64 COMBINATION METER E3-48 ENGINE CONTROL (4Y-E) E3-10 FRONT WIPER & WASHER E3-54 GAUGE GLOW E3-16 HEAD LAMP E3-60 HEATER E3-72 REAR WIPER & WASHER E3-56 SAS/OPS SYSTEM E3-34 ENGINE CONTROL (4Y-E) E3-10...
Page 215 MEMO...
Page 216 E6-1 CHAPTER 6 CONNECTOR LIST CONNECTOR LIST PARTS CONNECTOR ............... E6-2 WIRE TO WIRE WIRE TO WIRE ................. E6-8...
Page 217 E6-2 CONNECTOR LIST 90980- 10171 90980- 11155 90980- 10214 90980- 10807 90980- 10935 90980- 10996 A 1 0 A 1 1 A 1 2 A 1 3 A 1 4 D A R K G R A Y G R A Y G R A Y B L A C K B L A C K...
Page 218 E6-3 CONNECTOR LIST A 4 9 A 5 1 A 5 2 A 5 5 A 5 6 B L A C K G R A Y G R A Y 90980- 11235 90980- 10899 90980- 11168 90980- 10896 90980- 10890 A 6 4 A 6 5 A 6 6...
Page 219 E6-4 CONNECTOR LIST G 1 7 G 1 8 G 1 9 G 2 1 G 2 2 G 2 3 G 2 4 G R E E N B L A C K G R A Y D A R K G R A Y B L A C K B L A C K B L A C K...
Page 220 E6-5 CONNECTOR LIST D A R K G R A Y 90980- 11162 7003- 1191- 02 90980- 09222 99142- 15080 99142- 16080 7003- 1172- 02 7003- 1182- 02 90980- 09481 D A R K G R A Y B L A C K G R A Y G R A Y 90980- 11248...
Page 221 E6-6 CONNECTOR LIST B L A C K B L A C K B L A C K B L A C K 90980- 11885 90980- 11885 90980- 11885 90980- 11885 90980- 11594 B L A C K B L A C K B L A C K B L A C K B L A C K...
Page 222 E6-7 CONNECTOR LIST 90980- 12506 20 21 23 24 90980- 12383 16 17 19 20 21 22 90980- 12320 90980- 12308 90980- 12311 X X X X X X X X X X X X X X X...
Page 223 E6-8 WIRE TO WIRE A C 2 A C 4 A G 1 D A R K G R A Y G R A Y B L A C K 90980- 10942 90980- 10941 12 11 90980- 11240 90980- 11239 90980- 10815 90980- 10814 A G 2...
Page 224 E6-9 WIRE TO WIRE A Q 2 A a 1 A b 2 B L A C K B L A C K 90980- 11349 90980- 10891 90980- 11348 90980- 10890 90980- 12382 90980- 12381 A h 1 A h 2 B A 1 B n 1 G R A Y...
Page 225 E6-10 WIRE TO WIRE S T 1 U A 1 U A 3 B L U E B L A C K G R A Y 90980- 10795 90980- 11036 90980- 11035 90980- 10794 90980- 10895 90980- 10894 U B 1 Y O 1 G R A Y 16 15 14 13 12 11 10...
Page 226 Published by 1st Printing: Apr. 2010 Pub. No. CU066 Printed in USA...

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