Toyota 62-8FDU15 Repair Manual Download

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4-23

4 OIL PUMP

4.2 SPECIFICATIONS

Vehicle model

Engine

Specifica-
tion

Maker (Model)

Pump type

Theoretical discharge
cm

(in

)/rev

Pn1 ton series

4YE

STD

KYB (KFS2422)

Gear pump/
single gear

22.0 (1.342)

Steel cabin

KYB (DGP2321)

Gear pump/
double gear

21.5 (1.312)

4YM

KYB (KFS2425)

Gear pump/
single gear

25.7 (1.568)

1ZS

KYB (KFS2422)

Gear pump/
single gear

22.0 (1.342)

1DZ-II

KYB (KFS2425)

Gear pump/
single gear

25.7 (1.568)

Pn2 ton series

4YE

STD

KYB (KFS2422)

Gear pump/
single gear

24.0 (1.464)

Steel cabin

KYB (DGP2323)

Gear pump/
double gear

22.9 (1.397)

4YM

KYB (KFS2427)

Gear pump/
single gear

27.8 (1.696)

1ZS

KYB (KFS2424)

Gear pump/
single gear

24.0 (1.464)

1DZ-II

KYB (KFS2427)

Gear pump/
single gear

27.8 (1.696)

Pn3 ton series

4YE

STD

KYB (KFS2422)

Gear pump/
single gear

24.0 (1.464)

Steel cabin

KYB (DGP2323)

Gear pump/
double gear

22.9 (1.397)

4YM

KYB (KFS2429)

Gear pump/
single gear

29.4 (1.794)

1ZS

KYB (KFS2424)

Gear pump/
single gear

24.0 (1.464)

1DZ-II

KYB (KFS2427)

Gear pump/
single gear

27.8 (1.696)

Cu2/Cu3 ton series

4YE

STD

KYB (KFS2422)

Gear pump/
single gear

24.0 (1.464)

Steel cabin

KYB (DGP2323)

Gear pump/
double gear

22.9 (1.397)

Summary of Contents for 62-8FDU15

Page 1: ...8FGU 15 18 20 25 30 32 8FDU 15 18 20 25 30 32 62 8FDU 15 18 20 25 30 8FGCU 20 25 30 32 Pub No CE118 Supplement...

Page 2: ...ter will be informed by Toyota Industrial Equipment Parts Service News For the service procedures of the mounted engine read the repair manuals listed below as reference together with this manual Ref...

Page 3: ...ontents 1 GENERAL 2 2 STEERING 5 3 MATERIAL HANDLING SYSTEM 17 4 OIL PUMP 22 5 OIL CONTROL VALVE 25 6 SAS OPS 52 7 DISPLAY 55 8 TROUBLESHOOTING 152 9 WIRING DIAGRAM 203 10 SST LIST AND SERVICE STANDAR...

Page 4: ...U25 T C 4YE 4YM Gasoline 8FDU25 T C 1ZS Diesel 62 8FDU25 T C 1DZ II Pn3 ton series Pn30 6000 lbs 8FGU30 T C 4YE 4YM Gasoline 8FDU30 T C 1ZS Diesel 62 8FDU30 T C 1DZ II Pn32 6500 lbs 8FGU32 T C 4YE Gas...

Page 5: ...1 3 1 GENERAL 1 2 FRAME NUMBER Frame No Punching Position Punching position 1...

Page 6: ...5000 8FGU25 4000 1ZS 8FDU20 8FDU25 60011 5000 8FDU25 4000 1DZ II 62 8FDU20 608FDU25 60011 5000 62 8FDU25 Pn3 ton series 6000 4YE 4YM 8FGU30 8FGU32 60011 6500 8FGU32 6000 1ZS 8FDU30 8FDU32 60011 6500 8...

Page 7: ...2 5 2 STEERING 2 STEERING 2 1 GENERAL Hydrostatic Steering Valve 1ZS and 4YE engine A A C C B B D D D A A D B B LS C C 2...

Page 8: ...2 6 2 STEERING 4YM and 1DZ engine W synchronized steering B B A A B B C C C C...

Page 9: ...EERING 4YM engine L synchronized steering 8 3 1 Neutral position spring 2 Housing 3 Check valve 4 Spool 5 Sleeve 6 Cardan shaft 7 Gear rim 8 Gear wheel rotor 9 Relief valve 1 Shock valve No used 9 2 5...

Page 10: ...1001 8 2 to 8 7 83 6 to 88 7 1189 to 1262 6 4 to 6 9 65 3 to 70 4 928 to 1001 8 2 to 8 7 83 6 to 88 7 1189 to 1262 8 2 to 8 7 83 6 to 88 7 1189 to 1262 Hydrostatic steering valve W synchronized steeri...

Page 11: ...2 9 2 STEERING 2 3 COMPONENTS 1ZS and 4YE engine 4507 4YM and 1DZ II engine 4507 2...

Page 12: ...2 10 2 STEERING PS Valve 1ZS and 4YE engine 4503 4YM engine L synchronized steering 4503 4503 036 CM AT AS 32 AP CK AV AC AD CL 30 CJ AA 31 01K INCL 01...

Page 13: ...2 11 2 STEERING 4YM and 1DZ II engine W synchronized steering 4503 2...

Page 14: ...to 80 N m 612 to 816 kgf cm 44 3 to 59 0 ft lbf Disassembly Procedure Step 1 Remove the set bolt and end cover Point 1 Step 2 Remove the gear wheel set drive shaft and distributor plate Point 2 Step...

Page 15: ...isas sembly 2 Two types of set bolts are used Set bolt with 10 mark on the head Set bolt without any mark on the head Use a rod tip bolt with no mark on its head at pos ition A in the illustration at...

Page 16: ...lates in this order from the depth Reassembly When inserting the sleeve W spool into the valve body apply MP grease to the packing ring inner sur face portion in sliding contact with the spool and dus...

Page 17: ...lus trated directions Reassembly Apply MP grease to the ring before assembling with the packing Apply MP grease to the outer periphery of the packing Reassembly Guide the packing W ring to the assembl...

Page 18: ...e and connect the SST adapter SST 09450 23320 71 2 Install the oil pressure gauge Plug size PT1 8 Step 2 Start the engine rotate the steering wheel slowly clockwise and counterclockwise and inspect th...

Page 19: ...IRCUIT DIAGRAM 17 3 2 COMPONENTS 21 3 1 HYDRAULIC CIRCUIT DIAGRAM 4YE and 1ZS engine Without oil cooler 3 7 1 8 2 4 5 6 1 Oil pump 2 Priority valve 3 Oil control valve 4 Steering valve 5 Solenoid valv...

Page 20: ...SYSTEM With oil cooler 3 7 1 8 2 4 5 6 10 9 1 Oil pump 2 Priority valve 3 Oil control valve 4 Steering valve 5 Solenoid valve OPT 6 Power steering cylinder 7 Lift tilt and ATT cylinder 8 Oil tank 9 Oi...

Page 21: ...LING SYSTEM 4YM and 1DZ II engine Without oil cooler 3 7 1 8 2 4 5 6 1 Oil pump 2 Flow divider 3 Oil control valve 4 Steering valve 5 Solenoid valve OPT 6 Power steering cylinder 7 Lift tilt and ATT c...

Page 22: ...SYSTEM With oil cooler 3 7 1 8 2 4 5 6 10 9 1 Oil pump 2 Flow divider 3 Oil control valve 4 Steering valve 5 Solenoid valve OPT 6 Power steering cylinder 7 Lift tilt and ATT cylinder 8 Oil tank 9 Oil...

Page 23: ...3 21 3 MATERIAL HANDLING SYSTEM 3 2 COMPONENTS 6801 3...

Page 24: ...4 22 4 OIL PUMP 4 OIL PUMP 4 1 GENERAL 22 4 2 SPECIFICATIONS 23 4 3 PERFORMANCE TEST 24 4 1 GENERAL 4Y STD 1ZS 1DZ II...

Page 25: ...pump single gear 24 0 1 464 Steel cabin KYB DGP2323 Gear pump double gear 22 9 1 397 4YM KYB KFS2427 Gear pump single gear 27 8 1 696 1ZS KYB KFS2424 Gear pump single gear 24 0 1 464 1DZ II KYB KFS24...

Page 26: ...600 118 640 126 565 111 600 118 575 113 600 118 4YM 600 118 640 126 565 111 600 118 575 113 600 118 1ZS 615 121 655 129 590 116 630 124 600 118 640 126 1DZ II 615 121 655 129 590 116 630 124 600 118...

Page 27: ...5 25 5 OIL CONTROL VALVE 5 OIL CONTROL VALVE 5 1 OIL CONTROL VALVE ASSY 26 5 2 OIL CONTROL VALVE ASSY MINI LEVER AND JOYSTICK LEVER 39 5 3 RELIEF PRESSURE ADJUSTMENT 50 5...

Page 28: ...5 26 5 OIL CONTROL VALVE 5 1 OIL CONTROL VALVE ASSY 5 1 1 GENERAL 1ZS and 4YE engine T2 CF S2 P R C1 LS S1 C3 C5 T1 C2 C4 X1 X2 X3 X4 X1 X2 X3 X4...

Page 29: ...5 27 5 OIL CONTROL VALVE X1 X1 INLET Priority valve Relief valve Electromagnetic proportional reducing valve 5...

Page 30: ...T1 Electromagnetic proportional reducing valve Load check valve Priority valve Gauge port Flow regulator valve Load check valve Tilt backward lock valve Tilt backward lock SOL Load check valve Tilt co...

Page 31: ...ic proportional reducing valve Load check valve Priority valve Gauge port Flow regulator valve Load check valve Tilt backward lock valve Tilt backward lock SOL Load check valve Tilt control valve Tilt...

Page 32: ...59 Flow regulator flow volume L min US gal min 50 13 2 60 15 8 75 19 8 Lowering speed specification mm sec fpm V Pn No load 550 108 500 98 500 98 Loaded 500 98 500 98 500 98 V Cu No load 500 98 500 98...

Page 33: ...5 31 5 OIL CONTROL VALVE 5 1 3 COMPONENTS 1ZS and 4YE engine ASSY FITTING 6705 1DZ II and 4YM engine ASSY FITTING 6705 5...

Page 34: ...5 32 5 OIL CONTROL VALVE 1DZ II and 4YM engine INLET OUTLET LIFT TILT 6705 1DZ II and 4YM engine ATT 6705...

Page 35: ...p 2 Remove the lift limit switch and spring cover Point 3 Step 3 Remove the lift spool Point 4 Step 4 Remove the tilt control SOL Point 5 Step 5 Remove the backward tilt lock SOL Point 6 Step 6 Remove...

Page 36: ...Disassembly Put match marks to prevent solenoid installation in an incorrect position Reassembly Align match marks for reassembly Inspection Check the lift lock solenoid for continuity Reference Resi...

Page 37: ...No continuity when the switch is pressed Reassembly Be careful not to mistake the lowering side and lifting side SST Washer Point 4 Disassembly and Reassembly Remove the compression spring from the l...

Page 38: ...at 20 C Inspection Check and clean any clogged filter Reassembly Carefully reassemble to prevent incorrect installation of each solenoid spool 1 2 3 4 Point 7 Inspection Check the tilt limit switch fo...

Page 39: ...Point 10 Inspection Check and clean any clogged filter a Adjusting screw A Lock nut 1 Adjusting sleeve B Lock nut 2 Reassembly When the relief valve is disassembled temporarily in stall it after fitt...

Page 40: ...of current to plate 4 unit of short No 5 unit serial No and whose 5 unit start from 00001 Stamp 3 unit aim pressure Mention I P current rank H L each 1unit Stamp the current value that calculated tha...

Page 41: ...5 39 5 OIL CONTROL VALVE 5 2 OIL CONTROL VALVE ASSY MINI LEVER AND JOYSTICK LEVER 5 2 1 GENERAL 1ZS and 4YE engine T2 CF S2 P R C1 LS S1 C3 C5 T1 C2 C4 X1 X2 X3 X4 X1 X2 X3 X4 5...

Page 42: ...5 40 5 OIL CONTROL VALVE X1 X1 INLET Priority valve Relief valve Electromagnetic proportional reducing valve...

Page 43: ...T1 Electromagnetic proportional reducing valve Load check valve Priority valve Gauge port Flow regulator valve Load check valve a2 a1 b1 b2 b3 a3 Load check valve Decompression valve Tilt control valv...

Page 44: ...Electromagnetic proportional reducing valve Load check valve Priority valve Gauge port Flow regulator valve Load check valve a2 a1 b1 b2 b3 a3 Load check valve Tilt control valve Tilt control SOL ATT...

Page 45: ...9 Flow regulator flow volume L min US gal min 50 13 2 60 15 8 75 19 8 Lowering speed specification mm sec fpm V Pn No load 550 108 500 98 500 98 Loaded 500 98 500 98 500 98 V Cu No load 500 98 500 98...

Page 46: ...5 44 5 OIL CONTROL VALVE 5 2 3 COMPONENTS 1ZS and 4YE engine ASSY FITTING 6705...

Page 47: ...he lift lock SOL and flow regulator valve Point 2 Step 2 Remove the tilt control SOL Point 3 Step 3 Remove the proportional solenoid a Point 4 Step 4 Remove the proportional solenoid b Point 5 Step 5...

Page 48: ...Disassembly Put match marks to prevent solenoid installation in an incorrect position Reassembly Align match marks for reassembly Inspection Check the lift lock solenoid for continuity Reference Resi...

Page 49: ...gged filter Inspection Check and clean any clogged orifice Reassembly Carefully reassemble to prevent incorrect installation of each solenoid spool 1 2 5 6 3 7 Point 4 Inspection Check the proportiona...

Page 50: ...continuity Measurement terminal 1 5 Continuity exists Measurement terminal 2 6 Continuity exists Measurement terminal 3 7 Continuity exists A Adjusting screw A Disassembly Before disassembly measure...

Page 51: ...1 for tilt relief pressure adjustment because the adjustment is not necessary When replacing the relief valve change the setting value H and L rank it is necessary Refer to chapter of the display for...

Page 52: ...ressure gauge Remove the oil pressure detecting plug installed on the left side of the oil control valve and install the oil pressure gauge there Plug size 9 16 18UNF Fitting size 9 16 18UNF PF1 4 Fit...

Page 53: ...ft lever to lift the fork fully 3 While running the engine at the maximum speed op erate the lift lever to the lifting side Gradually tighten adjusting sleeve B to make the oil pressure in the re lief...

Page 54: ...6 52 6 SAS OPS 6 SAS OPS 6 1 SAS FUNCTION 6 1 1 COMPONENTS Load Sensor 4Y engine 5803 Load Sensor 1ZS engine 5803...

Page 55: ...6 53 6 SAS OPS 6...

Page 56: ...6 54 6 SAS OPS Load Sensor 1DZ II engine 5803...

Page 57: ...eeling adjustments and specification setting as a service function On this model a graphic LCD Liquid Crystal Display has been adopted and this provides various informa tion to be easy to understand w...

Page 58: ...indicator Auto speed control indicator Eco mode indicator NEW Planned maintenance hour warning indicator Menu lock indicator NEW Meter Odometer Trip meter Planned maintenance hour meter Warning funct...

Page 59: ...1 second after the key switch is turned ON 7 1 3 2 Status screen The status screen is displayed after the initial screen Function activation indicator Speedometer Function activation indicator Low sp...

Page 60: ...hen the oper ator presses the low speed setting switch This indicator lights when the low speed setting is effective and the vehicle speed is limited at a preset level In case this setting is level 8...

Page 61: ...switch is turned on under the above condition However the buzzer doesn t sound at that time when the elapsed time has just exceeded the preset hour while the vehicle is in operation The indicator is d...

Page 62: ...ing default models are preset in mile And export SPEC OPT E E C SPEC OPT mm kg indicator SPEC OPT are preset in km h 3 Planned maintenance hour meter The planned maintenance hour meter displays preset...

Page 63: ...que Converter oil temperature overheat warning The indicator blinks when the oil temperature level be comes more than or equal to level 9 approx 120 degrees C The entire gauge blinks at level 10 appro...

Page 64: ...eturns 1 Low speed level setting screen switch 2 switch 3 switch 4 The low speed level setting function is set up on this screen Switch 2 Select the lower level Switch 3 Select the higher level Switch...

Page 65: ...trator s Second Password Switching of Menu Lock When menu lock setting is released the operator can set it 7 1 6 2 Administrator password Password Entry Procedure NOTICE If an operation error occurs d...

Page 66: ...PLAY Step Display Operation Vehicle response 5 When the second password has been set password screen is displayed Enter the password Other Skip this screen 6 Administrator menu screen is displayed aut...

Page 67: ...DISPLAY 7 1 6 3 Setting menu for administrator Use switch 1 to select the desired item and press switch 4 each setting screen will appear Select END on the menu and press switch 4 the status screen re...

Page 68: ...peed limiter setting screen switch 2 switch 3 switch 4 The travel speed limiter level is set on this screen Switch 2 Select the lower level Switch 3 Select the higher level Switch 4 Display the menu s...

Page 69: ...lue same The function is turned off when 10h is set for maintenance hour meter and the switch 2 is pressed to decrease the setting time The current value is kept but the maintenance indicator and the...

Page 70: ...econd password can be registered by continuing to press switch 1 for 2 seconds after entering the password by using switch 1 to 4 If the switch 4 is pressed for 2 seconds or more before re gistration...

Page 71: ...T displayed Eco mode is NOT changed Menu lock indicator is displayed on the status screen when menu lock setting is YES Switch 2 Selecting Yes Switch 3 Selecting No Switch 4 Returning to menu screen C...

Page 72: ...ng Yes Switch 3 Selecting No Switch 4 Returning to menu screen Conditions to release Menu lock vary by optionset items MENULOCK SPEC In factory setting MENU LOCK SPEC is preset in A on US domestic mod...

Page 73: ...ning TUNING Makes fine adjustment of trav eling and material handling functions 2 As reques ted by cus tomer Option Setting OPTIONSET Specification set ting Sets each vehicle option and other specific...

Page 74: ...or the multi function display 4 During the condition that is listed in matching 5 When tire size is changed or tire is replaced 6 When removing installing or replacing oil control valve 7 2 2 PASSWORD...

Page 75: ...When pressing the switches a short beep sounds and after 2 seconds repeated short beeps sound 5 When the service second password MASK PASS WORD has been set Password screen is displayed Enter the pas...

Page 76: ...er the password on the general screen to display the service function MASK MENU screen Switch 1 Switch 4 Step 2 Select a desired function using switch 1 Then press switch 4 set to display the function...

Page 77: ...DISPLAY 1 ANALYZER This function indicates the electrical system status and reads the error information detected by the controller Switch 1 Switching selection to next item Switch 4 To ANALYZER MENU s...

Page 78: ...and material handling Switch 1 Switching selection to next item Switch 4 To TUNING MENU screen 3 OPTIONSET Use this function to match control of the controller or dis play according to the set options...

Page 79: ...xt item Switch 4 To MATCHING MENU screen 5 WHEEL RADIUS This function rewrites the tire information in the controller for correcting the speed indication odometer and trip meter Switch 1 Switching sel...

Page 80: ...e mask second password Switch 1 Switching selection to next item Switch 4 To MASK PASSWORD screen 9 MANAGER PASS CLR Deletes the manager second password Switch 1 Switching selection to next item Switc...

Page 81: ...ance hour meter Switch 1 Switching selection to next item Switch 4 To METER START screen NOTICE After start counting the meters METER START will not be displayed on the service function MASK MENU scre...

Page 82: ...ng 2 In Out monitor function I O MONITOR This function displays the analog input values from individual sensors in the traveling material handling FHPS SAS and OPS systems Monitoring the displayed val...

Page 83: ...take air temperature THW Coolant temperature sensor voltage THW Coolant temperature PIM Intake pipe negative pressure sensor voltage PIM Intake manifold pressure 4 10 VPA1 Accelerator pedal position s...

Page 84: ...ing speed BATT Battery voltage PA Accelerator pedal position THW Coolant temperature 2 5 ATM Atmospheric pressure PIM Intake manifold pressure past turbocharger MAF Intake air mass THA Intake air temp...

Page 85: ...g speed ACCSW Accelerator switch BRKSW Brake switch PKBSW Parking brake switch SPARE Spare 2 3 SEAT Seat switch DRF Forward traveling switch DRR Reverse traveling switch RYF Forward reverse traveling...

Page 86: ...er angle sensor 2 voltage TPSOL Tilt proportional valve solenoid current TSOL Tilt solenoid 5 7 POTA1 Attachment 1 lever angle sensor 1 voltage At tachment 1 lever angle sensor 2 voltage A1SOL Attachm...

Page 87: ...y forced operation BUZZER Warning buzzer forced operation SWG TEST LMP Swing lock operation check RELIEF SOL Electromagnetic relief valve forced operation 8 VERSION Program version 1 1 DISPLAY Display...

Page 88: ...ext item Switch 4 To I O TRAVELING screen 4 I O M HANDLING Switch 1 Switching selection to next item switch 4 To I O M HANDLING screen 5 I O STEERING Switch 1 Switching selection to next item Switch 4...

Page 89: ...ted on the screen and press enter switch 4 to display DIAG MEMORY 1 2 screen Step 3 Press switch 4 on DIAG MEMORY 2 2 screen to return to the ANALYZER MENU screen NOTICE When no error codes are displa...

Page 90: ...7 88 7 DISPLAY DIAG MEMORY 2 2 Displays diagnosis 6 to 10 Switch 4 Returning to the ANALYZER MENU screen...

Page 91: ...of the 4Y engine controller switch various input values including input voltage from the sensor correction value of the control and output condition to the relay Operating Procedure Step 1 Display the...

Page 92: ...type ADJ Engine specification discrimination signal Displays states of engine specification discrimination sig nal Switch 4 To I O ENGINE CTRL 2 10 screen I O ENGINE CTRL 2 10 MREL EFI main relay dri...

Page 93: ...rd Display Accelerator pedal position sensor 1 voltage standard Accelerator sensor 1 voltage standard 0 2 to1 3 V when accelerator is not operated 1 4 to 4 1 V during maximum pressing of accelerator A...

Page 94: ...e idle after warm up IM Electronic throttle motor current Displays current flowing to the electronic throttle motor Standard 0 2 to 10 0 A Switch 4 To I O ENGINE CTRL 6 10 screen I O ENGINE CTRL 6 10...

Page 95: ...CTRL 6 10 PIM Intake pipe negative pressure sensor voltage Intake manifold pressure refer to I O ENGINE CTRL 3 10 VF VF voltage LPG CNG Displays the voltage V output from VF terminal Standard 2 0 to 3...

Page 96: ...screen NOTICE You cannot move directly from I O ENGINE CTRL screen to the screen of the other items Return to ANALYZER MENU screen once then move to screen of each item I O ENGINE CTRL 1 5 NE Engine s...

Page 97: ...level THF Fuel Temperature C Display fuel Temperature QF Fuel injection quantity Display fuel injection quantity Switch 4 To I O ENGINE CTRL 4 5 screen I O ENGINE CTRL 4 5 NE Engine speed rpm Traveli...

Page 98: ...perating Procedure Step 1 Display the ANALYZER MENU screen Switch 1 Switch 4 Step 2 Press switch 1 twice to check that 3 I O TRAVEL ING is selected and press enter switch 4 to dis play I O TRAVELING 1...

Page 99: ...pedal type BRKSW Brake switch Display states of brake switch Vehicle without brake switch BRKSW 0 Always Vehicle with brake switch BRKSW 1 ON when brake pedal is depressed BRKSW 0 OFF when brake peda...

Page 100: ...eling position Displayed code DRF 1 ON DRR 0 OFF Direction lever Neutral position Displayed code DRF 0 OFF DRR 0 OFF Direction lever Reverse travel position Displayed code DRF 0 OFF DRR 1 ON RYF Forwa...

Page 101: ...ate SWN 0 OFF Non energized swing lock state PRES Load sensor voltage and MPa display Displays input voltage from the load sensor to the control ler and detected pressure Standard at no load 0 5 to 4...

Page 102: ...nsors Operating Procedure Step 1 Display the ANALYZER MENU screen Switch 1 Switch 4 Step 2 Press switch 1 3 times to check that 4 I O M HANDLING is selected and press enter switch 4 to display I O M H...

Page 103: ...lt switch STD lever vehicle Tilt lever Forward tilt position Displayed code MF 1 ON MR 0 OFF Tilt lever Neutral position Displayed code MF 0 OFF MR 0 OFF Tilt lever Backward tilt position Displayed co...

Page 104: ...FF 0 OFF TSOL 0 OFF 0 OFF 0 OFF 1 ON 0 OFF 1 ON 0 OFF BTSL SEAT 1 ON 1 ON 1 ON 1 ON 1 ON 1 ON 0 OFF I O M HANDLING 2 7 MA Tilt angle sensor voltage V Displays the input voltage from the tilt angle sen...

Page 105: ...to 0 85 A LSOL Lift lowering lock solenoid Refer to I O M HANDLING 1 7 Switch 4 To I O M HANDLING 4 7 screen I O M HANDLING 4 7 POTT Tilt lever angle sensor 1 voltage V tilt lever angle sensor 2 volta...

Page 106: ...side Attachment 1 lever angle sensor 1 voltage 1 8 to 4 1 V Attachment 1 lever angle sensor 2 voltage 0 3 to 2 9 V Attachment 1 lever Forward tilt side Attachment 1 lever angle sensor 1 voltage 0 4 to...

Page 107: ...ide Attachment 2 lever angle sensor 1 voltage 1 8 to 4 1 V Attachment 2 lever angle sensor 2 voltage 0 3 to 2 9 V Attachment 2 lever Forward tilt side Attachment 2 lever angle sensor 1 voltage 0 4 to...

Page 108: ...l hand ling 0 3A to 0 75A MU Lift raising switch Displays status of lift raising switch Refer to I O M HANDLING 1 7 Mini lever Joystick vehicle MALL Material handling operations switch Displays status...

Page 109: ...to check that 5 I O STEER ING is selected and press enter switch 4 to dis play I O STEERING 1 1 screen NOTICE You cannot move directly from I O STEER ING screen to the screen of the other items Return...

Page 110: ...on 360 of the steering wheel is divided by 160 and the value is set to 80 when the knob is in the position as indicated in the illustration Vehicle without synchronized steering K POS Always Vehicle w...

Page 111: ...hour meter value BATT Battery voltage V Displays battery voltage Standard 8 0 to 16 0V THO Torque converter oil temperature sensor voltage V and oil temperature C Displays input voltage from the torq...

Page 112: ...OAD SOL Unused OPTION RLY T C interlock relay forced operation 4 ON Traveling is possible OFF Traveling is not pos sible BUZZER 3 Warning buzzer forced operation ON Buzzer ON OFF Buzzer OFF SWG TEST L...

Page 113: ...he ANALYZER MENU screen Switch 1 Switch 2 Switch 4 Switch 3 Step 2 Press switch 1 6 times to check that 7 ACTIVE TEST is selected and press enter switch 4 to dis play ACTIVE TEST 1 3 screen Switch 1 M...

Page 114: ...tch 4 Returning to ANALYZER MENU screen ACTIVE TEST 2 3 NOTICE When performing ACTIVE TEST 2 3 item make sure to sit on the seat correctly If not OPS is activated and material handling operation may b...

Page 115: ...olenoid operation display Check the swing lock operation states according to travel ing and material handling states by OPS light Vehicle without swing lock Unused Vehicle with swing lock ON Indicated...

Page 116: ...itch 4 Returning to ANALYZER MENU screen NOTICE You cannot move directly from VERSION screen to the screen of the other items Re turn to ANALYZER MENU screen once then move to screen of each item VERS...

Page 117: ...tem Level initial setting value 1 2 3 4 5 6 7 8 LIFT DOWN START Lift lowering adjustment 1 Play at the beginning of lift down operation Wide Small INCH Lift lowering adjustment 2 Inching speed during...

Page 118: ...Backward tilt adjustment 3 Maximum speed during tilt backward oper ation Slow Fast ACC Backward tilt adjustment 4 Acceleration speed during tilt backward operation Weak Strong DEC Backward tilt adjus...

Page 119: ...trong DEC Attachment 1 lever backward tilt side ad justment 5 Deceleration speed during the attachment 1 lever pull operation Weak Strong ATT2 PUSH START Attachment 2 lever forward tilt side ad justme...

Page 120: ...Strong DEC Attachment 2 lever backward tilt side ad justment 5 Deceleration speed during the attachment 2 lever pull operation Weak Strong ATT3 PUSH START Attachment 3 lever forward tilt side ad justm...

Page 121: ...justment 4 Acceleration speed during the attachment 3 lever pull operation Weak Strong DEC Attachment 3 lever backward tilt side ad justment 5 Deceleration speed during the attachment 3 lever pull ope...

Page 122: ...tch 4 To tuning level setting screen 4 ATT1 LEVER Mini lever Joy stick vehicles only Switch 1 Switching selection to next item Switch 4 To tuning level setting screen 5 ATT2 LEVER Mini lever Joy stick...

Page 123: ...hat 1 GENERAL is selected and press enter switch 4 to display TUNE GEN screen NOTICE You cannot move directly from level setting screen of GENERAL to the screen of the other items Return to TUNING MEN...

Page 124: ...CE You cannot move directly from level setting screen of LIFT LEVER to the screen of the other items Return to TUNING MENU screen once then move to level setting screen of each item LIFT DOWN Lift dow...

Page 125: ...NOTICE You cannot move directly from level setting screen of TILT LEVER to the screen of the other items Return to TUNING MENU screen once then move to level setting screen of each item TILT FWD Tilt...

Page 126: ...ICE You cannot move directly from level setting screen of ATT1 LEVER to the screen of the other items Return to TUNING MENU screen once then move to level setting screen of each item ATT1 PUSH Attachm...

Page 127: ...CE You cannot move directly from level setting screen of ATT2 LEVER to the screen of the other items Return to TUNING MENU screen once then move to level setting screen of each item ATT2 PUSH Attachme...

Page 128: ...E You cannot move directly from level setting screen of ATT3 LEVER to the screen of the other items Return to TUNING MENU screen once then move to level setting screen of each item ATT3 PUSH Attachmen...

Page 129: ...to enable disable buzzer sound when seat switch is off YES Enabled Default NO Disabled PKB BUZZER 1 Setting to enable disable park ing brake off warning YES Enabled NO Disabled CONV BUZZER Unused TEMP...

Page 130: ...1 These are set according to the vehicle specification at the time of shipment 2 4Y engine equipped model only 3 Mini lever Joystick specification vehicle only 4 Please set this setting to the number...

Page 131: ...to next item Switch 2 Setting from NO to YES Switch 3 Setting from YES to NO Switch 4 Returning to service function MASK MENU screen Option set screen 3 Switch 1 Switching selection to next item Swit...

Page 132: ...SPLAY Option set screen 5 Switch 1 Switching selection to next item Switch 2 Setting 5 4 3 2 3 4 2 3 NO to YES Switch 3 Setting 2 3 4 5 2 3 3 4 YES to NO Switch 4 Returning to service function MASK ME...

Page 133: ...etic relief valve EMRV is set for each electromagnetic relief valve before shipping and it is registered to SAS OPS controller So MATCHING is necessary when maintaining or replacing parts for electrom...

Page 134: ...sensor 11 When replacing attachment 1 lever angle sensor 12 When replacing attachment 2 lever angle sensor 13 When removing installing or replacing oil control valve 7 2 6 3 BEFORE STARTING MATCHING...

Page 135: ...hment at a height of 500 mm 19 7 in and perform relief at the topmost posi tion Set the mast in the vertical position from the backward tilted position by operating the tilt lever in the forward tilti...

Page 136: ...witch 1 and press enter switch 4 to move to the service function MASK MENU setting screen of the selected item Step 4 Press enter switch 4 while selecting 4 END menu to return to service function MASK...

Page 137: ...7 135 7 DISPLAY NOTICE 2 MINI LEVER will not be displayed other than on mini lever and joystick specification vehicle 7...

Page 138: ...You cannot move directly from each matching set screen of SAS to the matching set screen of the other items Return to MATCH ING MENU screen once then move to match ing set screen of each item TILTL LE...

Page 139: ...matching is performed press switch 1 OK is indic ated on the display Switch 1 Pressing this for more than 2 seconds will per form matching Switch 4 To SWING LEVEL screen SWING LEVEL Screen Unused Swit...

Page 140: ...urrent vehicle condi tion value NOTICE You cannot move directly from each matching set screen of MINI LEVER to the matching set screen of the other items Return to MATCHING MENU screen once then move...

Page 141: ...seconds will per form matching Switch 4 Returning to MATCHING MENU screen NOTICE LEVER4 screen will be displayed according to the number of ways being set 7 2 6 7 MATCHING EMRV EMRV Perform the settin...

Page 142: ...f short No 5 unit serial No and whose 5 unit start from 00001 Stamp 3 unit aim pressure Mention I P current rank H L each 1unit Stamp the current value that calculated than an approximate expression e...

Page 143: ...1 Enter the password on the general screen to display the service function MASK MENU screen Switch 1 Switch 2 Switch 4 Switch 3 Step 2 Press switch 1 4 times to check that 5 WHEEL RADIUS is selected...

Page 144: ...LID 348 3 0 ton model 28X9 15 12PR STD 361 WIDE TREAD 361 28X9 15 7 00 SOLID 365 WIDE TREAD SOLID 365 29X8 15 12PR DUAL 390 DUAL SOLID 387 Cushion 1 0 ton model 18X6X12 1 8 STD 240 NON MARKING 240 SMO...

Page 145: ...ted and press enter switch 4 to display the SPEED LIMIT SET screen Step 3 Change the speed limit to desired value with switch 2 and switch 3 and press enter switch 4 to set the value and return to ser...

Page 146: ...MENU screen Switch 1 Switch 2 Switch 4 Switch 3 Step 2 Press switch 1 6 times to check that 6 IDLE AD JUSTMENT is selected and press enter switch 4 to display the IDLE ADJUSTMENT screen IDLE ADJUSTMEN...

Page 147: ...f shipment Operating Procedure Step 1 Enter the password on the general screen to display the service function MASK MENU screen Switch 1 Switch 4 Step 2 Press switch 1 7 times to check that 8 MASK PAS...

Page 148: ...d password setting screen press switch 1 for two seconds or more without any digits entered The password is deleted and OK is displayed after the opera tion NOTICE The delete mask second password oper...

Page 149: ...hat you are ready for the set password operation Press switch 1 for two seconds or more to perform Pass word Set When the setting is completed OK is dis played NOTICE Password Set is not possible unti...

Page 150: ...general screen to display the service function MASK MENU screen Switch 1 Switch 4 Step 2 Press switch 1 8 times to check that 9 MANAGER PASS CLR is selected and press enter switch 4 to display the MAN...

Page 151: ...o display the CONTRAST screen NOTICE After completing the meter start setting 11 METER START will not be displayed on the service function MASK MENU screen Switch 1 Switch 2 Switch 4 Switch 3 Step 3 C...

Page 152: ...2 Press switch 1 10 times to check that 11 METER START is selected and press enter switch 4 to display the METER START screen NOTICE The speed limit of the Low speed level setting function is 8OFF whe...

Page 153: ...mpleted Step 5 Press switch 4 to return to service function MASK MENU screen NOTICE After completing the meter start setting METER START will not be displayed on the service function MASK MENU screen...

Page 154: ...8 152 8 TROUBLESHOOTING 8 TROUBLESHOOTING 8 1 DIAGNOSIS CODE LIST 153 8 2 WARNING LIST 154 8 3 WHEN NO ERROR CODE IS DISPLAYED 155 8 4 WHEN ERROR CODE IS DISPLAYED 189...

Page 155: ...rmality P port 61 4 61 4 Blinking SAS OPS Pressure sensor VCC short abnormality P port EC 1 EC 1 Blinking SAS OPS Unload solenoid open circuit or load short abnormality EC 2 EC 2 Blinking SAS OPS Elec...

Page 156: ...except lifting disabled High battery voltage Use a bat tery of the specified voltage On SAS OPS Swing lock control is always locked Low battery voltage Charge or replace the battery On SAS OPS Tilt op...

Page 157: ...8 155 8 TROUBLESHOOTING 8 3 WHEN NO ERROR CODE IS DISPLAYED Defect causes related to SAS OPS 8...

Page 158: ...nsor installa tion Link installation part destroyed damaged Accelerator pedal position check Check the opening degree of the accel erator pedal when not operated If not close to 0 installation check o...

Page 159: ...limit setting Change SAS OPS con troller Controller defect Replace Travel and load handling control For vehicles with travel and load handling control Despite being loaded at high lifting height the...

Page 160: ...check or re place switch Display setting Maximum speed limiter speed limiter setting enabled Check the setting content of the max imum speed limiter check the setting content of the speed limit settin...

Page 161: ...Disconnection fault Harness connector ON OFF check with analyzer Harness check or re place switch 4YE 1ZS engine model Mini lever or Joy stick When lifting a heavy load it is unable to lift upward or...

Page 162: ...leak fault Harness connector Load sensor voltage check Mount a load ground the forks and check the change in voltage If there is no change perform a harness check or re place the sensor 4YE engine mod...

Page 163: ...s connector Harness check or re place buzzer Display setting OPS leaving seat notification buzzer setting disabled Check setting values with option set Change SAS OPS con troller Controller defect Rep...

Page 164: ...wer sup ply side lead in side Disconnection fault Harness connector Harness check or re place buzzer Lowering lever switch Lever defect Lowering lever signal line Disconnection fault Harness connector...

Page 165: ...ing lever poten tiometer unit Lever defect Material hand ling lever line Power supply signal ground Disconnection fault Harness connector Short or link fault Harness con nector Material handling lever...

Page 166: ...t Harness connector Harness check or re place buzzer Parking brake switch unit Open fault stuck in released state internal damage Parking brake detection mech anism Always released Parking brake line...

Page 167: ...ess check or replace the switch SAS OPS con troller Controller defect Replace Buzzer related Only models with MULTI FUNCTION DIS PLAY DX or E E C SPEC option Vehicles with MULTI FUNCTION DISPLAY DX or...

Page 168: ...fect Replace Vehicles with MULTI FUNCTION DISPLAY DX Torque converter oil temperature indic ator continually dis plays overheat warn ing indication Torque con verter oil temper ature sensor unit Short...

Page 169: ...ad sensor voltage check Peform lift relief and check the change in voltage If there is no change perform an installation check or replace the sensor Lifting height switch unit Disconnection fault Inte...

Page 170: ...ive test Harness check or re place solenoid Load sensor unit Sensor defect Load sensor line Power supply signal ground Disconnection fault Harness connector Short or leak fault Harness connector Load...

Page 171: ...installation check or replace the sensor Horizontal matching value for tilt angle sensor Does not match actual status re match Follow matching pro cedure to rematch Automatic fork leveling switch unit...

Page 172: ...the voltage rises If there is no change perform an installation check or replace the sensor Load sensor no load matching value Does not match actual status re match Follow matching pro cedure to rema...

Page 173: ...ion check or replace the sensor Load sensor no load matching value Does not match actual status re match Follow matching pro cedure to rematch Tilt angle sensor unit Sensor defect Tilt angle sensor in...

Page 174: ...djustment defect Automatic fork leveling switch line Power sup ply signal ground Disconnection fault Harness connector ON OFF check with analyzer Harness check or re place switch C V tilt control valv...

Page 175: ...sensor Does not match actual status re match Follow matching pro cedure to rematch Automatic fork leveling switch unit Open fault in ternal damage Automatic fork leveling switch detection mech anism m...

Page 176: ...ing switch is pressed Tilt angle sensor unit Sensor defect Tilt angle sensor installation Link installation part destroyed damaged Tilt angle sensor voltage check Tilt to forward and backward tilt pos...

Page 177: ...rform an installation check or replace the sensor Tire angle sensor matching value Does not match actual status re match Follow matching pro cedure to rematch Steering angle sensor unit Sensor defect...

Page 178: ...r matching value Does not match actual status re match Follow matching pro cedure to rematch Steering angle sensor unit Sensor defect Steering angle sensor installa tion Cam or steering wheel defect C...

Page 179: ...speed not detected cor rectly sensor tip has metallic particle adhered Vehicle speed sensor line SPD side SPD side Leak fault Har ness connector Check sensor voltage and vehicle speed with the ana lyz...

Page 180: ...liary equip ment operation Check battery voltage with the ana lyzer Keep the engine at high speed for a while SAS OPS con troller setting Not matched Follow matching pro cedure to rematch Meter unit M...

Page 181: ...ss connector Switch ground line Disconnection fault Harness connector ON OFF check with analyzer Harness check or re place switch C V lift lower lock valve Stuck internal damage Using an active test t...

Page 182: ...lt Harness connector Switch ground line Disconnection fault Harness connector ON OFF check with analyzer Harness check or re place switch C V tilt control valve Stuck internal damage Turn the tilt sol...

Page 183: ...t lock solenoid ON and operate to back ward tilt using an active test If backward tilt can not be performed replace the C V backward tilt lock valve Seat switch unit Open fault in ternal damage Seat s...

Page 184: ...lower lock valve Stuck internal damage Using an active test turn the lift lower lock solenoid OFF and perform lower operation If lowering can be performed replace the C V lift lower lock valve C V unl...

Page 185: ...n fault Harness connector ON OFF check with analyzer Harness check or re place switch C V unload valve Stuck internal damage For cowl lever vehicles Turn the unload valve solenoid OFF and perform lift...

Page 186: ...r Turn the forward and reverse travel inter rupt relays ON and operate forward and reverse travel using an active test If forward travel can be performed re place the forward travel interrupt relay If...

Page 187: ...ness check Seat switch unit Open fault in ternal damage Seat switch line Signal ground Disconnection fault Harness connector ON OFF check with analyzer Harness check or re place switch Direction leve...

Page 188: ...converter interlock relay for backward movement SAS OPS con troller Internal damage Replace the control ler The torque converter interlock does not operate SAS OPS con troller is set Option set is not...

Page 189: ...s diagram Check the har nesses and repaire or replace them Replace the fuses Ignition switch main body Open failure Ignition switch harness Wire breakage short circuit or leakage Harness con nector fu...

Page 190: ...auto engine stop function The meter or dis play does not turn off even when the engine stops Power shut off relay main body only for models with MULTI FUNCTION DIS PLAY DX Short circuit Power shut of...

Page 191: ...8 189 8 TROUBLESHOOTING 8 4 WHEN ERROR CODE IS DISPLAYED 8...

Page 192: ...essure sensor A21 20 5PBR 31 PBRK 1 B A103 2 P 3 E P port STEP1 1 Disconnect the battery negative terminal after inspecting and correcting disconnection and water entry of A103 and A21 2 Reconnect all...

Page 193: ...lt Procedure 61 3 is displayed Go to STEP3 page 191 61 4 is displayed Pressure sensor defect STEP3 Inspection for harness continuity and short circuit A21 4 3 2 1 23 24 35 29 27 34 31 28 22 30 32 33 2...

Page 194: ...6 25 21 5 6 20 8 18 17 19 7 9 10 11 12 13 14 15 16 1 Inspect for continuity and short circuiting of the harness in the same state as for step 3 Portion to be checked Standard A21 31 to A21 5 No contin...

Page 195: ...ter inspecting and correcting disconnection and water entry of A103 and A21 2 Reconnect all connectors and the battery negative terminal 3 Turn the ignition key switch ON engine stopped and check whet...

Page 196: ...e No continuity Judgment Result Procedure NG Harness defect OK SAS OPS ECU defect STEP4 Individual inspection for pressure sensor A21 4 3 2 1 23 24 35 29 27 34 31 28 22 30 32 33 26 25 21 5 6 20 8 18 1...

Page 197: ...nload solenoid A20 5 USOL 9 E02 A12 1 2 SAS OPS ECU STEP1 1 Disconnect the battery negative terminal 2 After inspecting and correcting disconnection and water entry of A12 and A20 reconnect all connec...

Page 198: ...P3 Inspection for harness continuity and short circuit 1 Turn the ignition key switch OFF and disconnect A20 w SAS A109 wo SAS and A12 Portion to be checked Standard A20 5 to A12 1 Continuity A109 14...

Page 199: ...E STEP1 1 Disconnect the battery negative terminal 2 After inspecting and correcting disconnection and water entry of A21 and A102 reconnect all connectors and the battery negative terminal 3 Turn th...

Page 200: ...dure OK Go to STEP3 page 196 NG Electromagnetic relief solenoid defect STEP3 Inspection for harness continuity and short circuit A21 4 3 2 1 23 24 35 29 27 34 31 28 22 30 32 33 26 25 21 5 6 20 8 18 17...

Page 201: ...2 E STEP1 1 Disconnect the battery negative terminal 2 After inspecting and correcting disconnection and water entry of A21 and A102 reconnect all connectors and the battery negative terminal 3 Turn t...

Page 202: ...o STEP3 page 196 NG Electromagnetic relief solenoid defect STEP3 Inspection for harness continuity and short circuit A21 4 3 2 1 23 24 35 29 27 34 31 28 22 30 32 33 26 25 21 5 6 20 8 18 17 19 7 9 10 1...

Page 203: ...RSO SAS OPS ECU Electromagnetic relief solenoid A21 6 RSO 1 B A102 2 E STEP1 1 Disconnect the battery negative terminal 2 After inspecting and correcting disconnection and water entry of A21 and A102...

Page 204: ...o STEP3 page 196 NG Electromagnetic relief solenoid defect STEP3 Inspection for harness continuity and short circuit A21 4 3 2 1 23 24 35 29 27 34 31 28 22 30 32 33 26 25 21 5 6 20 8 18 17 19 7 9 10 1...

Page 205: ...9 203 9 WIRING DIAGRAM 9 WIRING DIAGRAM 9 1 ELECTRICAL WIRING ROUTINGS 204 9 2 RELAY LOCATIONS 207 9 3 SYSTEM CIRCUITS 208 9 4 CONNECTOR LIST 216 9...

Page 206: ...49 A11 A12 m1 A10 A14 A13 m1 A10 A12 A56 A49 Q1 A15 Ah2 Ah1 jA1 mA1 QA2 Aa1 mA1 QA2 AQ2 AQ2 rA1 AA1 Ab2 mM mM A102 A103 A102 MINI LEVER 1 4Y M 1DZ 2 4Y E 1ZS h A r a B b R U Q m j d WIPER SUB WIRE h F...

Page 207: ...S ECU A21 SAS OPS ECU A23 MINI LEVER ECU A41 LEFT T C SHIFT SWITCH A42 TILT ANGLE SENSOR A49 HORN A51 CONTROL VALVE PUSH SOLENOID A52 CONTROL VALVE PULL SOLENOID A56 BACK TILT SOLENOID A78 EZ PEDAL DI...

Page 208: ...UB WIRE Ab2 BODY MAIN WIRE to MAST SENSOR WIRE Ah1 BODY MAIN WIRE to WIPER SUB WIRE Ah2 BODY MAIN WIRE to WIPER SUB WIRE QA2 INSTRUMENT PANEL WIRE to BODY MAIN WIRE jA1 INSTRUMENT PANEL SW WIRE to BOD...

Page 209: ...S IG 1ZS 4YE 9 ST RELAY 4Y E 4Y M 1DZ EFI MAIN RELAY 1ZS GLOW PLUG RELAY SEE PAGE E2 6 SPARE SPARE SPARE EFI 1 BLR 5 RR WIP FR WIP HORN ALT S STOP ACC B TAIL ECU B HTR WORK LP HEAD ST GAUGE BACK LP SF...

Page 210: ...1A 15 1B 7 1B 1 1A 19 1B 3 1B 19 1B 8 T C FR RELAY 2 1 3 4 T C RR RELAY 2 1 3 4 A20 A A21 B SAS OPS ECU 1 B IG 3 B E11 4 B E12 22 B SP1 23 B SP1 10 B E42 9 B E41 8 B BATT 11 B BUZZ 17 A BSW 9 A E02 8...

Page 211: ...T ANGLE SENSOR 3 1 2 1 OX1 5 OX1 1 YO3 2 YO3 SEAT SWITCH EEC X10 2 1 SEAT SWITCH EEC Y10 1 2 1 AA2 1 AD1 2 AA2 2 AD1 A14 LIFT UP SWITCH LIFT DOWN SWITCH LIFT SWITCH 1 D 3 U 4 E 2 E A13 TILT FR SWITCH...

Page 212: ...B 16 R W 20 R W 20 21 R 20 21 R W 9 R W 9 R W 9 1E 31 1A 23 1C 8 1E 28 1C 32 1C 27 1C 17 1C 1 1B 4 1C 18 1C 24 B SYSTEM POWER SUPPLY CONTROL AREA LCD OPS BRAKE OPS Q1 COMBINATION METER 1 IG 11 PKBI 3...

Page 213: ...E ROOM R B 1A E2 12 E3 5 BODY MAIN WIRE to J B 1B E2 12 E3 5 BODY MAIN WIRE to J B 1C E2 12 E3 5 BODY MAIN WIRE to J B 1E E2 12 E3 5 SIDE LH WIRE to J B WIRE TO WIRE Code See Page Name AA2 E2 12 BODY...

Page 214: ...1 6 rA1 3 AA1 3 rA1 d11 LED HEAD LAMP LEFT 2 1 R11 LED HEAD LAMP RIGHT 2 1 HEAD LAMP RIGHT R6 1 2 r1 KEY OFF HEAD RELAY 3 5 2 1 HEAD LAMP LEFT d6 1 2 1 RA4 1 dA4 RA4 3 dA4 3 15A HEAD BAT 2 1 TAIL OFF...

Page 215: ...me 1 E3 4 ENGINE ROOM R B 1A E2 12 E3 5 BODY MAIN WIRE to J B 1C E2 12 E3 5 BODY MAIN WIRE to J B WIRE TO WIRE Code See Page Name AA1 page 204 BODY MAIN WIRE to BODY MAIN WIRE RA4 E2 14 FR STAY WIRE R...

Page 216: ...TAIL RELAY 3 5 2 1 r1 KEY OFF HEAD RELAY 2 1 3 5 TAIL S14 LED REAR COMBINATION LAMP RIGHT 3 4 TAIL S13 LED REAR COMBINATION LAMP LEFT 3 4 CLEARANCE FRONT COMBINATION LAMP LEFT d1 2 3 CLEARANCE FRONT...

Page 217: ...ODY MAIN WIRE to J B 1B E2 12 E3 5 BODY MAIN WIRE to J B 1C E2 12 E3 5 BODY MAIN WIRE to J B 1E E2 12 E3 5 SIDE LH WIRE to J B WIRE TO WIRE Code See Page Name AA1 page 204 BODY MAIN WIRE to BODY MAIN...

Page 218: ...6 REAR SOLENOID RELAY A84 NATURAL S 6020 6161 1 2 3 4 5 6 EZ PEDAL MAIN RE LAY A85 NATURAL S 6020 6161 1 2 3 4 5 6 NEUTRAL START RELAY A102 BROWN 90980 11155 2 1 ELECTROMAGNETIC RELIEF SOLENOID A103 G...

Page 219: ...STANDARDS LIST 10 SST LIST AND SERVICE STANDARDS LIST 10 1 SST LIST 217 10 2 SERVICE STANDARDS LIST 218 10 1 SST LIST Illustration Part No Part Name Section 1 2 3 4 09610 10161 71 Oil control valve s...

Page 220: ...o 1117 Relief set pressure W synchronized steering MPa kgf cm2 psi Pn1 ton series 4YM Standard 7 5 to 8 0 76 5 to 81 6 1088 to 1160 1DZ II Standard Pn2 ton series 4YM Standard 8 1 to 8 6 82 6 to 87 7...

Page 221: ...Published by 1st Printing Mar 2016 Pub No CE118 Printed in USA...

Page 222: ...PRINTED IN USA Pub No CE118...

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Toyota 62-8FDU15, Repair Manual

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