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Service Manual: Forklift Truck
Service Manual: Forklift Truck
SEF-0F7BE
SERVICE MANUAL
SERVICE MANUAL
FORKLIFT TRUCK
FHD15T3
FHD18T3
FD20T3
FHD20T3A
FD25T3
FHD25T3A
FD30T3
FHD30T3A
FD35T3S
No. SEF-0F7BE
TCM CORPORATION
FHG15T3
FHG18T3
FG20T3
FHG20T3
FG25T3
FHG25T3
FG30T3
FHG30T3
FG35T3S
No. SEF-0F7BE
FOREWORD
TCMs new forklift trucks with capacities from 1.5 through 3.5 tons feature low operating noise and
reduced vibration as well as improved controllability and higher safety, and come equipped with new
high-performance engines.
The gasoline engines used for this series are equipped with an electronically-controlled fuel supply
unit to reduce emissions from the engine.
The steering system can correct steering wheel knob deviation automatically to provide better driver
control. The instrument panel accommodates optional OK monitors which allow the operator to check
the water level, air cleaner plugging, and battery condition of charge with just a glance. The serviceability
of these trucks has been greatly improved by these changes.
This Service Manual describes all of the major components and their service procedures. We
encourage you to make practical use of it while servicing the trucks.
We also hope you will understand that, due to on-going improvements of the parts and components,
the values and some of the descriptions in this manual are subject to change without notice.
February 2010
The specifications and equipment covered in this manual will vary according to the intended
destination. In our documents and manuals, these differences are coded according to the destination as
follows.
Export specification code
EXA
EXB
EXC
EXE
EXK
EXN
Destination
North America
All regions excluding North America, EU member countries, Oceania and
South Africa
Oceania
EU member countries (excluding Scandinavia)
South Africa
Scandinavia
No. SEF-0F7BE
kN{kgf}[lbf]
km/h[mph]
kg[lbs]
mm[in.]
mm[in.]
mm[in.] A
mm/s[fpm]
Truck model
Gradeability
(unload)
(loaded)
Min. turning radius
mm[in.] B
Min. 90 intersecting aisle
mm[in.] C
Dimensions
mm[in.]
Overall length D
Overall width E
Overall height
(at overhead guard) F
Overall height with
extended mast G
Wheelbase H
Tread
(front) J
(rear) K
Fork overhang L
Rear overhang M
Fork size
(Length (N) x Width (P) x Thickness (Q))
Fork spacing R
(loaded)
Performance
Max. load
Basic load center
Lift height
Tilt angle (fwd-bwd)
Free lift
Lift speed
(unloaded)
(loaded)
Traveling speed
fwd
1st
2nd
rev
1st
2nd
Max. drawbar pull
(unload)
Item
2510 [5530]
890 [35]
920 [36.2]
395 [15.6]
425 [16.7]
920 x 100 x 35
[36.2 x 3.9 x 1.4]
200 - 920
[7.9 - 36.2]
105 [4.1]
4250 [167.3]
1425 [56.1]
2070 [81.5]
2620 [5780]
2670 [5580]
455 [17.9]
920 [36.2]
3195 [125.8]
1100 [43.3]
3165 [124.6]
1070 [42.1]
15.7 {1600}
[3530]
1/5.8
1/3.2
2010 [79.1]
1800 [70.9]
18.6 {1900}
[4190]
1/5.5
1/3.0
1980 [78]
1780 [70.1]
6.9 {700}
[1540]
15.7 {1600}
[3530]
19.5 [12.1]
*
19.5 [12.1]
*
680 [133.9]
650 [127.9]
680 [133.9]
650 [127.9]
FHG18T3
1580 [3500]
660 [129.9]
620 [122.1]
FHD15T3
1360 [3000]
600 [24]
3000 [118.1]
6 - 12
155 [6.1]
FHG15T3
SPECIFICATIONS (1)
2780 [6120]
18.6 {1900}
[4190]
660 [129.9]
620 [122.1]
FHD18T3
No. SEF-0F7BE
kN{kgf}[lbf]
km/h[mph]
kg[lbs]
mm[in.]
mm[in.]
mm[in.] A
mm/s[fpm]
Truck model
Gradeability
(unload)
(loaded)
Min. turning radius
mm[in.] B
Min. 90 intersecting aisle
mm[in.] C
Dimensions
mm[in.]
Overall length D
Overall width E
Overall height
(at overhead guard) F
Overall height with
extended mast G
Wheelbase H
Tread
(front) J
(rear) K
Fork overhang L
Rear overhang M
Fork size
(Length (N) x Width (P) x Thickness (Q))
Fork spacing R
(loaded)
Performance
Max. load
Basic load center
Lift height
Tilt angle (fwd-bwd)
Free lift
Lift speed
(unloaded)
(loaded)
Traveling speed
fwd
1st
2nd
rev
1st
2nd
Max. drawbar pull
(unload)
Item
3580 [7890]
3775 [148.6]
1225 [48.2]
1/5
1/5.6
2400 [94.5]
2110 [83.1]
3210 [7080]
3570 [7870]
4250 [9370]
480 [18.9]
525 [20.7]
1070 x 125 x 45
[42.1 x 4.9 x 1.8]
250 - 1090
[9.8 - 42.9]
140 [5.5]
1000 [39.4]
450 [17.7]
505 [19.9]
1070 x 122 x 40
[42.1 x 4.8 x 1.6]
1/5.6
1/3.0
9.8 {1000}
[2203]
14.2 {1450}
[3192]
970 [38.2]
970 [38.2]
450 [17.7]
435 [17.1]
1070 x 122 x 40
[42.1 x 4.8 x 1.6]
245 - 1020
[9.65 - 40.2]
110 [4.33]
3625 [142.7]
1/5
1/4.2
2240 [88.2]
2010 [79.1]
22.1 {2250}
[5000]
4260 [168]
1700[66.9]
16.7 {1700}
[3754]
4250 [167.3]
1600 [63.0]
3220 [7110]
1/5.6
1/2.8
22.1 {2250}
[5000]
2090 [82.3]
19.5 [12.1]
19.5 [12.1]
2070 [81.5]
3555 [140]
1150 [45.3]
1/5.0
1/3.5
2170 [85.4]
1920 [75.6]
8.3 {850}
[1866]
16.7 {1700}
[3754]
19.0 [11.8]
*
19.0 [11.8]
*
500 [98.4]
490 [96.4]
590 [116.3]
580 [114.2]
2720 [6000]
FG30T3
590 [116.3]
580 [114.2]
640 [125.9]
620 [122.1]
FHG25T3
135 [5.3]
FG25T3
2260 [5000]
640 [125.9]
620 [122.1]
FHG20T3
1810 [4000]
600 [24]
3000 [118.1]
6 - 12
160 [6.3]
FG20T3
SPECIFICATIONS (2)
4260 [9390]
1/5.6
1/4.1
19.6 {2000}
[4400]
540 [106.3]
520 [102.4]
FHG30T3
No. SEF-0F7BE
kN{kgf}[lbf]
km/h[mph]
kg[lbs]
mm[in.]
mm[in.]
mm[in.] A
mm/s[fpm]
Truck model
Gradeability
(unload)
(loaded)
Min. turning radius
mm[in.] B
Min. 90 intersecting aisle
mm[in.] C
Dimensions
mm[in.]
Overall length D
Overall width E
Overall height
(at overhead guard) F
Overall height with
extended mast G
Wheelbase H
Tread
(front) J
(rear) K
Fork overhang L
Rear overhang M
Fork size
(Length (N) x Width (P) x Thickness (Q))
Fork spacing R
(loaded)
Performance
Max. load
Basic load center
Lift height
Tilt angle (fwd-bwd)
Free lift
Lift speed
(unloaded)
(loaded)
Traveling speed
fwd
1st
2nd
rev
1st
2nd
Max. drawbar pull
(unload)
Item
3340 [7360]
3700 [8160]
450 [17.7]
505 [19.9]
1070 x 122 x 40
[42.1 x 4.8 x 1.6]
4390 [9680]
480 [18.9]
525 [20.7]
1070 x 125 x 45
[42.1 x 4.9 x 1.8]
250 - 1090
[9.8 - 42.9]
140 [5.5]
1000 [39.4]
3775 [148.6]
1225 [48.2]
1/4.8
2400 [94.5]
2110 [83.1]
970 [38.2]
970 [38.2]
450 [17.7]
435 [17.1]
1070 x 122 x 40
[42.1 x 4.8 x 1.6]
245 - 1020
[9.65 - 40.2]
110 [4.33]
1/3.5
26.5 {2700}
[6000]
4260 [168]
1700 [66.9]
3625 [142.7]
1/3.5
2240 [88.2]
2010 [99.1]
19.1 {1950}
[4300]
4250 [167.3]
1600 [63.0]
1/2.9
26.5 {2700}
[6000]
9.8 {1000}
[2203]
17.2 {1750}
[3850]
2090 [82.3]
19.5 [12.1]
19.5 [12.1]
2070 [81.5]
3555 [140]
1150 [45.3]
1/5.0
1/2.9
2170 [85.4]
1920 [75.6]
8.3 {850}
[1866]
19.1 {1950}
[4300]
18.5 [11.5]
*
18.5 [11.5]
*
590 [116.1]
520 [102.4]
670 [131.9]
630 [124.0]
2720 [6000]
FD30T3
670 [131.9]
630 [124.0]
640 [126.0]
620 [122.1]
FHD25T3A
135 [5.3]
FD25T3
2260 [5000]
640 [126.0]
620 [122.1]
FHD20T3A
1810 [4000]
600 [24]
3000 [118.1]
6 - 12
160 [6.3]
FD20T3
SPECIFICATIONS (3)
23.5 {2400}
[5300]
540 [106.3]
520 [102.4]
FHD30T3A
No. SEF-0F7BE
kN{kgf}[lbf]
km/h[mph]
kg[lbs]
mm[in.]
mm[in.]
mm[in.] A
mm/s[fpm]
Truck model
Gradeability
(unload)
(loaded)
Min. turning radius
mm[in.] B
Min. 90 intersecting aisle
mm[in.] C
Dimensions
mm[in.]
Overall length D
Overall width E
Overall height
(at overhead guard) F
Overall height with
extended mast G
Wheelbase H
Tread
(front) J
(rear) K
Fork overhang L
Rear overhang M
Fork size
(Length (N) x Width (P) x Thickness (Q))
Fork spacing R
(loaded)
Performance
Max. load
Basic load center
Lift height
Tilt angle (fwd-bwd)
Free lift
Lift speed
(unloaded)
(loaded)
Traveling speed
fwd
1st
2nd
rev
1st
2nd
Max. drawbar pull
(unload)
Item
4940 [10870]
1060 [41.7]
970 [38.2]
495 [19.5]
605 [23.8]
1070 x 150 x 50
[42.1 x 5.9 x 2.0]
300 - 1090
[11.8 - 42.9]
145 [5.7]
4255 [167.5]
1700 [66.9]
2140 [84.3]
3870 [152.4]
1290 [50.8]
1/6.4
1/6
2470 [97.2]
2280 [89.8]
10.8 {1100}
[2420]
18.9 {1930}
[4250]
19.5 [12.1]
*
19.5 [12.1]
*
450 [88.6]
440 [86.6]
3500 [7000]
500 [24]
3000 [118.1]
6 - 12
170 [6.7]
FG35T3S
4820 [10605]
1/6
1/5.5
18.1 {1850}
[4070]
490 [96.5]
460 [90.6]
FD35T3S
SPECIFICATIONS (4)
No. SEF-0F7BE
No. SEF-0F7BE
Free lift
3000 [118.1]
Unit: mm [in.]
No. SEF-0F7BE
No. SEF-0F7BE
TABLE OF CONTENTS
1. ENGINE ............................................................................................................................................ 1
No. SEF-0F7BE
1. ENGINE
1. ENGINE
Gasoline and LPG engine
Item
Truck Model
Name
Type
No. of cylinders Bore x stroke
mm [in.]
Total displacement
cc [in.3]
Compression ratio
GAS:
LPG (Exclusive):
Dual fuel:
Performance
Rated speed
rpm
Rated output
kW {PS} [HP]
GAS (Exclusive and Dual):
LPG (Exclusive):
LPG (Dual):
Max. torque
N-m {kgf-m} [lbs-ft]/rpm
GAS (Exclusive and Dual):
LPG (Exclusive):
LPG (Dual):
Full-load rated fuel consumption
g/kW-h {g/PS-h}/rpm
GAS (Exclusive and Dual):
LPG (Exclusive):
LPG (Dual):
No-load minimum speed
rpm
Weight
kg [lbs]
GAS:
LPG (Exclusive):
Dual fuel:
Dimensions
mm [in.]
Ignition order
Rotational direction
FG20T3
FG25T3
FG30T3
FHG15T3
FHG18T3
FHG20T3
FHG25T3
FHG30T3
FG35T3S
K21
K25
4-cycle, water-cooled, in-line, overhead valve type gasoline engine
4 89 x 83.0
4 89 x 100
4 [3.50 x 3.27]
4 [3.50 x 3.94]
2065 [126]
2488 [151.8]
8.7
9.3
8.7
9.2
2700
38.7 {52.6} [51.9]
40.0 {54.3} [53.7]
39.8 {54.1} [53.4]
303 {223}/1600
230 {169}/2000
235 {173}/2000
700 rpm (off the truck)
302 {222}/1600
215 {158}/1600
223 {164}/1600
151 [333]
152 [335]
151 [333]
152 [335]
152 [335]
153 [337]
719.4 x 568 x 726 [28.3 x 22.4 x 28.6]
1-3-4-2
Clockwise when viewed from the fan
-1-
1. ENGINE
Diesel engine
Truck Model
FHD15T3
FHD18T3
Item
Name
Type
No. of cylinders- Bore x stroke mm [in.]
Total displacement
cc
Compression ratio
Performance
Rated speed
rpm
Rated output
kW [HP]
N-m{kgf-m}[lbf-ft]
Maximum torque
Full-load rated fuel consumption g/kwh{g/psh}
No-load minimum speed
rpm
Weight
kg [lbs]
Dimensions (L x W x H)
mm [in.]
Ignition order
Rotational direction
FD20T3
FD25T3
FD30T3
FHD20T3A
FHD25T3A
FHD30T3A
FD35T3S
TD27
QD32
4-cycle, water-cooled, in-line,
overhead valve type diesel engine with swirl chamber
4-96 x 92 [4-3.78 x 3.62]
4-99.2 x 102 [4-3.91 x 4.02]
2663
3153
24.6
22
2300
41 [55]
170 {17.3} [125]/ 2300
253 {186}
750
259 [571]
2300
44 [60]
189 {19.3} [139.4]/ 1800
255 {187}
750
262 [578]
1 3 4 2
Clockwise when viewed from fan.
-2-
1. ENGINE
This series comes equipped with either a gasoline or diesel engine. The engine is installed inside the
truck frame along with the drive unit to deliver power to both the drive and hydraulic systems.
The engine is rubber mounted at four points in the frame.
ENGINE-SIDE BRACKET
Apply LOCTITE#262
BRACKET
Apply LOCTITE#262
FRAME-SIDE
BRACKET
Apply LOCTITE#262
RUBBER MOUNT
Apply LOCTITE#262
View
View
1. ENGINE
ALTERNATOR
INJECTOR
(GAS)
AIR FLOW METER
INJECTOR
(LPG)
THROTTLE
CHAMBER
IGNITION COIL
DRAIN PLUG
(WATER)
PRESSURE SWITCH
STARTER
DRAIN PLUG
OIL FILTER
1. ENGINE
Model
Item
K21
Main Construction
Type of cylinder liner
Valve operation
Suction valve
opens at BTDC:
-4
closes at ABDC:
40
Exhaust valve
opens at BBDC:
36
closes at ATDC:
Valve clearance,
suction valve
exhaust valve
Ignition system
Ignition type
Ignition timing
Ignition order
1 - 3 - 4 - 2
Ignition coil
Incorporated in igniter
Ignition plug
FR2A-D (NGK)
Spark gap
Governor
Air cleaner
Lubrication system
Forced lubrication
Lubrication pump
Gear type
Filter paper
Full-flow filtration
Water-cooling, forced circulation
Pusher type, 10-blade,
O.D. of 400 mm [15.8 in.]
Drive
Water pump
Drive
Water temperature regulator
Starting motor
Voltage
12 V
Output
1.2 kW
-5-
K25
1. ENGINE
Model
Item
K21
Charging generator
Voltage
12 V
Output
50 A
Generation
Drive
3-phase a.c.
V-belt drive, pulley ratio 1:2.15
Voltage/current regulator
Type
Transistor type
(built in charging generator)
-6-
K25
1. ENGINE
ALTERNATOR
FUEL FILTER
DRAIN PLUG
(WATER)
STARTER
DRAIN PLUG
(OIL)
INJECTION
PUMP
OIL FILTER
1. ENGINE
Model
TD27
QD32
Bosch distributor type
10 mm x 2.2 mm [0.394 in. x 0.087 in.]
Throttle type
Vane type
Filter paper type with sedimenter
Item
Main Construction
Valve system
Fuel system
Injection pump
Plunger (diameter x stroke)
Injection nozzle
Fuel feed pump
Fuel filter
Governor
Governing
Lubrication
Lubrication system
Pump
Drive
Oil pressure regulator
Oil pressure indicator
Filtration
Oil cooler
Cooling system
Cooling method
Cooling fan
Drive
Pump
Drive
Water temperature regulator
Type
Temperature at which valve
begins to open
Temperature at which valve
opens fully
Starting motor
Type
Voltage
Output
Stopping device
Engine preheater
Gear type
Gear-driven
Regulator valve
Switch type
Full-flow, filter paper type
Incorporated, water cooling
Water cooling
Pusher type with 6 blades
O.D.: 380 mm [14.96 in.]
Belt drive
Centrifugal type
Belt drive
Wax type
82C [179.6F]
95C [203F]
2.8 kW
Provided
-8-
1. ENGINE
Model
Item
Charging generator
Type
Voltage
Output
Drive
Automatic charging regulator
Reference data
Oil sump capacity
Cooling water volume
Valve clearance
Suction valve
Exhaust valve
Valve operation
Suction valve opens at BTDC
closes at ABDC
Exhaust valve opens at BBDC
closes at ATDC
Injection timing (BTDC)
Injection start pressure
Compression pressure
TD27
QD32
A.C. generation,
diode rectification
12 V
60 A
Belt drive
IC type
(built in generator)
16
52
66
12
5
9.8 MPa
{100 kgf/cm2}
[1421 psi]
2.94 MPa
{30 kgf/cm2}
[426 psi]
(200 rpm)
-9-
1. ENGINE
to ENGINE
STOP VALVE
CAP
LEVEL SENDER
FULL
3/4
1/2
1/4
EMPTY
FUEL PUMP
DRAIN PLUG
1. ENGINE
to ENGINE
from
PUMP
QUICK CONNECTOR
REGULATOR
to CHAMBER
CHAMBER
JET
FILTER
PUMP
FILTER
1. ENGINE
from ENGINE
to FUEL
FILTER
CAP
STOP VALVE
FULL
1/2
EMPTY 17L
DRAIN PLUG
1. ENGINE
The fuel level sender converts the fuel level in the fuel tank into an electric current signal. Its
construction is shown in Figure 1.7. The resistance element is a variable resistor made of nichrome wire.
The slider that changes the resistance is connected to the float.
When the float is at the top level, the resistance value between the grounding and the G terminal is
in the range of about 9.5 to 10.5 . As the float lowers, the resistance value becomes greater. Changes in
the resistance are transmitted to the CPU in the combination meter. The fuel meter indicator moves in the
F direction when the resistance is small and moves in the E direction when the resistance value is
large.
In addition, if the float lowers near to the bottom, the CPU sends the signal to light the fuel lamp to
inform the operator that fuel should be added.
FUEL
METER
FUEL LEVEL
SENDER
BATTERY
FULL
FUEL LAMP
3/4
Float
Resistance value ()
FULL
10 0.5
3/4
19
1/2
32 1.0
1/4
49.5
EMPTY
87 1.5
1/2
1/4
EMPTY
FLOAT
View A
1. ENGINE
ENGINE COOLING
WATER TEMP. GAUGE
FUEL METER
HOUR METER
1.
2.
3.
4.
5.
6.
- 14 -
1. ENGINE
PUMP
CARTRIDGE
LEVEL SWITCH
DRAIN COCK
for diesel engine model
CARTRIDGE
(FILTER)
O-RING
SENSOR
DRAIN COCK
(for water removal)
Fig. 1.10
- 15 -
1. ENGINE
PUMP
- 16 -
1. ENGINE
CYLINDER
SOLENOID VALVE
(w/ FILTER)
AIR HORN
RELIEF VALVE
VAPORIZER
1. ENGINE
Vaporizer
The vaporizer has a construction shown in Fig. 1.13. It converts high-pressure gas supplied from the
LPG cylinder into low-pressure gas.
High-pressure gas from the LPG cylinder flows between the valve seat and valve and enters the
pressure-reducing chamber so that the pressure inside the pressure-reducing chamber rises. Therefore,
the diaphragm pushes up the diaphragm spring and the hook pulls up the valve lever so that the valve is
pressed against the valve seat. The higher the pressure inside the pressure-reducing chamber, the stronger
the valve is pressed against the valve seat. When the pressure inside the pressure-reducing valve is high
enough to reach the set value, the gas flow is cut off by the valve.
When the pressure inside the pressure-reducing valve drops below the set value, the diaphragm spring
is decompressed to reduce the lever pulling-up force. This opens the valve to allow high-pressure LPG to
enter the pressure-reducing chamber.
This process is repeated to maintain the pressure inside the pressure-reducing chamber at a constant
value.
14 15 mm
[0.55 0.59 in.]
to INJECTOR HOLDER
1. VALVE
2. VALVE SEAT
3. PRESSURE-REDUCING
CHAMBER
4. DIAPHRAGM
5.
6.
7.
8.
DIAPHRAGM SPRING
HOOK
LEVER
PRESSURE CHECK
PORT PLUG
1. ENGINE
CRANKSHAFT
POSITION (POS)
SENSOR
O-RING
FRONT COVER
CHAIN HOUSING
O-RING
CAMSHAFT POSITION
(PHASE) SENSOR
- 19 -
1. ENGINE
MAIN
INJECTOR
HARNESS
CONNECTOR
(for main injector)
HARNESS
CONNECTOR
(for assist
injector)
HOLDER
ASSIST
INJECTOR
FUEL
PRESSURE
SENSOR
ELECTRONIC
CONTROL
THROTTLE
INTAKE MANIFOLD
- 21 -
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ltank(
G
a
s
o
l
i
n
e
)
Map
sensor
1. ENGINE
mOo
o
h
F
M
1. ENGINE
CAP
OIL COOLER
RADIATOR
RESERVE TANK
DRAIN VALVE
- 22 -
RESERVE TANK
RADIATOR
FRAME-SIDE
BRACKET
RUBBER
Detail of
RADIATOR-SIDE
BRACKET
1. ENGINE
- 23 -
RESERVE TANK
RADIATOR
FRAME-SIDE
BRACKET
RUBBER
Detail of
RADIATOR-SIDE
BRACKET
1. ENGINE
- 24 -
1. ENGINE
is pressed with
ADJUSTMENT
BOLT
PULLEY NUT
K21, K25
TD27, QD32
- 25 -
1. ENGINE
CAP
K21
K25
8.0 [2.11]
9.0 [2.38]
Unit: liter
TD27, QD32
*
9.9 [2.62]
DRAIN COCK
- 26 -
1. ENGINE
Description
Make sure the accelerator fully-open stroke is within the specified range.
Step
can be controlled according to AWU ouptut, but not the stroke.
With the accelerator fully opened, make sure APS1 output is within the
range of 4.4 to 4.6 V.
With the accelerator fully closed, make sure APS1 output is 0.67 to 0.87V.
29 mm
PEDAL
CABLE
SENSOR
ASP1
AVCC1
AVCC2
ASP2
14 mm
Detail of area
Detail of sensor
1. ENGINE
LINK
PEDAL
Pedal height
Unit: mm [in.]
TD27, QD32
H
19 [0.75]
is 0.5 to 1.0 mm
1. ENGINE
AIR CLEANER
OUTSIDE AIR
to ENGINE
Fig. 1.28 Air Cleaner (Gas-powered, 1.5- to 1.8-ton trucks with K21 or K25)
- 29 -
1. ENGINE
AIR CLEANER
OUTSIDE AIR
to ENGINE
Fig. 1.29 Air Cleaner (Gas-powered, 2.0- to 3.5-ton trucks with K21 or K25)
- 30 -
1. ENGINE
LATCH
COVER
ELEMENT
FILTER BODY
to ENGINE
OUTSIDE AIR
EVACUATION VALVE
View
1. ENGINE
AIR CLEANER
OUTSIDE AIR
to ENGINE
1. ENGINE
OUTSIDE AIR
ELEMENT
LATCH
COVER
to ENGINE
FILTER BODY
EVACUATION VALVE
View
1. ENGINE
to ENGINE
ELEMENT
CLAMP
EVACUATION
VALVE
Free air
- 34 -
1. ENGINE
1.1.7 MUFFLER
The muffler helps reduce the sound of escaping gases of the engine, and it is provided between the
radiator and the counterweight at the rear of the truck.
from ENGINE
Detail of area
EXHAUST EMISSION
CONTROL SYSTEM
(THREE-WAY CATALYST)
MUFFLER
EXHAUST
1.5 to 1.8 t
Detail of area
from ENGINE
MUFFLER
EXHAUST
EXHAUST EMISSION CONTROL SYSTEM
(THREE-WAY CATALYST)
2 to 3.5 t
1. ENGINE
TD27
QD32
MUFFLER
EXHAUST
- 36 -
The automatic transmission system consists of a torque converter and a power-shift transmission as
shown in Figures 2.1 and 2.2.
- 37 -
TRANSMISSION
CONTROL VALVE
CLUTCH PACK
CHARGING
PUMP
TORQUE
CONVERTER
COUNTER GEAR
OUTPUT FLANGE
OIL SEAL
STRAINER
OUTPUT GEAR
BREATHER
CONVERTER
RELIEF VALVE
INLINE FILTER
View
TURBINE WHEEL
PUMP WHEEL
STATOR WHEEL
Detail of
ONE-WAY CLUTCH
CASE
O-RING
Tightening torque:
0.98 2.94 N-m {0.1 0.3 kgf-m}
[0.723 2.17 lbf-ft]
DRIVE GEAR
OIL SEAL
Tightening torque:
20 26 N-m
{2.04 2.65 kgf-m}
[14.75 19.18 lbf-ft]
DRIVEN GEAR
STATOR SUPPORT
Section
SUCTION
PORT
DISCHARGE
PORT
View
View
2.1.3 TRANSMISSION
The transmission is a power-shift type consisting of a clutch pack assembly, an output shaft, a reverse
gear, and transmission control valve. (See Figures 2.1 and 2.2.)
(1) Clutch pack assembly
The clutch pack assembly consists of forward and reverse clutch packs, each of which consists
primarily of a piston, a spring, clutch discs and a steel plate.
The piston is always forced against the far end of the drum by the spring. When the oil pressure is
applied, the piston locks up the inner and outer discs.
The clutch lock-up oil is supplied through the groove in the clutch shaft and the lubrication oil is fed
through the oil hole in one end of the shaft.
OUTER DISC
INNER DISC
CHECK BALL
SEAL RING
PISTON
O-RING
SNAP RING
END PLATE
SPRING
SNAP RING
BALL BEARING
BALL BEARING
BALL BEARING
BALL BEARING
LUBRICATION OIL
FWD CLUTCH
OIL PRESSURE
SEAL RING
SEAL RING
SNAP RING
SNAP RING
FORWARD GEAR
REVERSE GEAR
TORQUE
CONVERTER
TORQUE
CONVERTER
RELIEF VALVE
OIL COOLER
INLINE
FILTER
INCHING VALVE
CHOKE
1.4
COIN FILTER
TRANSMISSION CONTROL VALVE
CHARGING
PUMP
SOLENOID VALVE
SHUTTLE VALVE
ACCUMULATOR
CLUTCH PACK
ASSEMBLY
In forward gear
As the solenoid valve is switch to the forward position, the oil flows to the forward clutch pack while
the shuttle valve moves to the right to allow the oil to flow also to the accumulator. Until the accumulator
is filled with oil, the clutch oil pressure increases gradually and the clutch lock-up pressure is weak. Once
the accumulator is filled with oil, however, the clutch lock-up oil pressure rises rapidly to the specified
value to lock up the forward clutch pack completely.
TORQUE
CONVERTER
OIL COOLER
INLINE
FILTER
TORQUE
CONVERTER
RELIEF VALVE
0.39 0.69 MPa
{3.98 7.04 kgf/cm2}
[56.6 100.1 psi]
INCHING VALVE
CHOKE
1.4
COIN FILTER
TRANSMISSION CONTROL VALVE
CHARGING
PUMP
SOLENOID VALVE
SHUTTLE VALVE
ACCUMULATOR
CLUTCH PACK
ASSEMBLY
Fig. 2.7 Transmission Oil Pressure Circuit Diagram (in forward gear)
- 44 -
In reverse gear
When the solenoid valve is switch to the reverse position, the oil flows to the reverse clutch pack
while the shuttle valve moves to the left to allow the oil to flow also to the accumulator. Until the
accumulator is filled with oil, the clutch oil pressure increases gradually and the clutch lock-up pressure
is weak. Once the accumulator is filled with oil, however, the clutch lock-up oil pressure rises rapidly to
the specified value to lock up the reverse clutch pack completely.
TORQUE
CONVERTER
OIL COOLER
INLINE
FILTER
TORQUE
CONVERTER
RELIEF VALVE
0.39 0.69 MPa
{3.98 7.04 kgf/cm2}
[56.6 100.1 psi]
CHOKE
1.4
INCHING VALVE
COIN FILTER
TRANSMISSION CONTROL VALVE
CHARGING
PUMP
SOLENOID VALVE
SHUTTLE VALVE
ACCUMULATOR
CLUTCH PACK
ASSEMBLY
Fig. 2.8 Transmission Oil Pressure Circuit Diagram (in reverse gear)
- 45 -
Inching
When the inching spool is pushed in, the oil flowing to the clutch pack assembly is drained through
the inching spool piston. In addition, the oil returning from the clutch pack assembly is also drained.
CHOKE
1.4
INCHING VALVE
- 46 -
SOL B
(REV)
SOL A
(FWD)
Detail of connector
ACCUMULATOR
to BRAKE
PEDAL
MANUAL BUTTON
(the forward position is
selected by pushing)
SHUTTLE VALVE
SOLENOID VALVE
INCHING VALVE
CHOKE
1.4
SNAP RING
PLUG
O-RING
SNAP RING
SPOOL
SNAP RING
PLUG
SHUTTLE VALVE
O-RING
PLUG
PISTON
SPRING
SPRING
SPRING
SPRING
VALVE
Detail of Inching valve
O-RING
SNAP RING
PISTON
O-RING
OIL SEAL
COIN FILTER
Detail of lever
SOL B
(REV)
DRAIN PLUG
to OIL COOLER
REV CLUTCH
OIL PRESSURE
SOL A
(FWD)
CHARGING PUMP
OIL PRESSURE
TORQUE
CONVERTER
CHARGING OIL
PRESSURE
SUCTION STRAINER
- 49 -
NOTE
- 50 -
3. DRIVE AXLE
3. DRIVE AXLE
Truck Model
FHG15T3 FHG18T3
FHD15T3 FHD18T3
Item
Type
Wheel
Size
Tread pattern
Rim
Type
FG20T3
FHG20T3
FG25T3
FHG25T3
FD20T3
FHD20T3A
FD25T3
FHD25T3A
Full-floating type
FG30T3
FHG30T3
FD30T3
FHD30T3A
2-6.50-10-10PR(I)
J-LUG
2-7.00-12-12PR(I)
2-28x9-15-12PR(I)
Split type
Disc type
5.00S x 12DT
7.00T x 15
FG35T3S
FD35T3S
2-250-15-16PR(2)
The drive axle has a construction as shown in Figures 3.1 and 3.2 and is mounted on the front area of
the frame.
It has a wheel hub and a wheel brake at its each spindle end and an axle shaft running through its
center. The wheel hub is provided with a brake drum, which is installed on the spindle through two
tapered roller bearings. The two tapered roller bearings have oil seals to prevent grease inside from
oozing out and water from entering the brake unit.
At the center of the housing is a differential which transmits the power from the transmission to the
right and left wheels.
- 51 -
- 52
1. HOUSING
2. AXLE SHAFT
3. WHEEL BRAKE
4. BRAKE DRAM & HUB
5. OIL SEAL
Tightening torque:
150 175 N-m
{1500 1750 kgf-cm}
[110.6 129.1 lbf-ft]
Tightening torque:
98 113 N-m
{980 1130 kgf-cm}
[72.3 83.3 lbf-ft]
Apply LOCTITE #262.
3. DRIVE AXLE
Fig. 3.1 Drive Axle (Trucks with capacities from 1.5 to 1.8 tons)
- 53 -
View
1. HOUSING
2. AXLE SHAFT
3. WHEEL BRAKE
4. BRAKE DRAM & HUB
5. OIL SEAL
Tightening torque:
206 226 N-m
{2100 2300 kgf-cm}
[151.9 166.7 lbf-ft]
Tightening torque:
392 559 N-m
{4000 5700 kgf-cm}
[289.1 412.3 lbf-ft]
Tightening torque:
471 549 N-m
{4800 5600 kgf-cm}
[347.4 404.9 lbf-ft]
Tightening torque:
96 111 N-m
{980 1130 kgf-cm}
[70.8 81.9 lbf-ft]
3. DRIVE AXLE
Fig. 3.2 Drive Axle (Trucks with capacities from 2.0 to 2.5 tons)
- 54 -
View
1. HOUSING
2. AXLE SHAFT
3. WHEEL BRAKE
4. BRAKE DRUM & HUB
5. OIL SEAL
Tightening torque:
206 226 N-m
{2100 2300 kgf-cm}
[151.9 166.7 lbf-ft]
Tightening torque:
392 559 N-m
{4000 5700 kgf-cm}
[289.1 412.3 lbf-ft]
Tightening torque:
471 549 N-m
{4800 5600 kgf-cm}
[347.4 404.9 lbf-ft]
Tightening torque:
96 111 N-m
{980 1130 kgf-cm}
[70.8 81.9 lbf-ft]
3. DRIVE AXLE
- 55 -
1.
2.
3.
4.
HOUSING
AXLE SHAFT
WHEEL BRAKE
BRAKE DRUM
View A
5.
6.
7.
8.
Tightening torque:
206 226 N-m
{21.0 23.0 kgf-m}
[151.9 166.7 lbf-ft]
9.
10.
11.
12.
OIL SEAL
HUB
AXLE SUPPORT
OIL SEAL
Tightening torque:
392 559 N-m
{40.0 57.0 kgf-m}
[289.1 412.3 lbf-ft]
Tightening torque:
96 111 N-m
{9.8 11.3 kgf-m}
[70.8 81.9 lbf-ft]
Tightening torque:
471 549 N-m
{48.0 56.0 kgf-m}
[347.4 404.9 lbf-ft]
3. DRIVE AXLE
3. DRIVE AXLE
ADJUSTMENT NUT
LOCK WASHER
LOCK NUT
4. RIM (INSIDE)
5. RIM (OUTSIDE)
6. ASSEMBLING BOLT
Fig. 3.7 Wheel Assembly (Trucks with capacities from 1.5, 2.0 to 2.5 tons)
- 56 -
3. DRIVE AXLE
- 57 -
3. DRIVE AXLE
0.4 0.5 mm
[0.016 0.02 in.]
Tightening torque:
45 5 N-m
{458.9 51.0 kgf-cm}
[33.2 3.69 lbf-ft]
Tightening torque:
157 20 N-m
{1601 203.9 kgf-cm}
[115.8 14.8 lbf-ft]
(Apply ThreeBond #1324N.)
Tightening torque:
45 5 N-m {458.9 51.0 kgf-cm}
[33.2 3.69 lbf-ft]
(Apply ThreeBond #1324N.)
Tightening torque:
78 10 N-m {795 102.0 kgf-cm}
[57.5 7.38 lbf-ft]
(Apply ThreeBond #1324N.)
1. LOCK NUT
2. TAPERED ROLLER
BEARING
3. DRIVEN GEAR
4. TAPERED ROLLER
BEARING
5. DRIVE PINION GEAR
6. WASHER
7. CROSS CASE
(PLANE HALF)
8. ADJUSTMENT NUT
9. TAPERED ROLLER
BEARING
10. SIDE GEAR
11. PINION GEAR
12. RING GEAR
13. THRUST WASHER
14. CROSS CASE
(FLANGE HALF)
15. SPIDER
16. BALL BEARING
17. DRIVE GEAR
18. ROLLER BEARING
19. OIL SEAL
20. INPUT FLANGE
Fig. 3.8 Reduction Gear and Differential (Trucks with capacities from 1.5 to 1.75 tons)
- 58 -
3. DRIVE AXLE
0.4 to 0.5 mm
[0.016 to 0.02 in.]
Let the front end of the speed sensor
come in slight contact with the tip of
a gear tooth and then back it off 1/4 1/3 of a turn.
SPEED SENSOR
(OPTION)
Tightening torque:
23 3 N-m
{234.5 30.6 kgf-cm}
[17.0 2.21 lbf-ft]
Tightening torque:
45 5 N-m
{458.9 51.0 kgf-cm}
[33.2 3.69 lbf-ft]
Tightening torque:
23 3 N-m
{234.5 30.6 kgf-cm}
[17.0 2.21 lbf-ft]
Tightening torque:
216 20 N-m
{2203 203.9 kgf-cm}
[159.3 14.8 lbf-ft]
Tightening torque:
157 20 N-m
{1601 203.9 kgf-cm}
[115.8 14.8 lbf-ft]
1. LOCK NUT
2. TAPERED ROLLER
BEARING
3. DRIVEN GEAR
4. TAPERED ROLLER
BEARING
5. DRIVE PINION GEAR
6. WASHER
7. CROSS CASE
(PLANE HALF)
8. ADJUSTMENT NUT
9. TAPERED ROLLER
BEARING
10. SIDE GEAR
11. PINION GEAR
12. RING GEAR
13. THRUST WASHER
14. CROSS CASE
(FLANGE HALF)
15. SPIDER
16. BEARING
17. BALL BEARING
18. DRIVE GEAR
19. ROLLER BEARING
20. OIL SEAL
21. INPUT FLANGE
Tightening torque:
78 10 N-m
{795 102.0 kgf-cm}
[57.5 7.38 lbf-ft]
Fig. 3.9 Reduction Gear and Differential (Trucks with capacities from 2.0 to 3.5 tons)
- 59 -
3. DRIVE AXLE
NOTE
- 60 -
4. BRAKE SYSTEM
4. BRAKE SYSTEM
Truck Model
FHG15T3
FHG18T3
FHD15T3
FHD18T3
FG20T3
FHG20T3
FG25T3
FHG25T3
FG30T3
FHG30T3
FD30T3
FHD30T3A
FG35T3S
FD35T3S
FD20T3
FHD20T3A
FD25T3
FHD25T3A
Item
Type
Pedal ratio
Master cylinder bore
Wheel brake
Type
Wheel cylinder bore
Brake drum inner dia.
Lining size
Surface brake
Parking brake
Type
The brake system is a front two-wheel braking internal expansion, hydraulic type consisting of a brake
pedal, master cylinder and wheel brakes.
4.1.1 BRAKE PEDAL
The brake pedal unit has a structure as shown in Figure 4.1 and is installed through a bracket on the
left side of the frame.
Pedal movement pushes the master cylinder piston through the push rod, converting brake pedal effort
to oil pressure.
- 61 -
4. BRAKE SYSTEM
RESERVE TANK
115 mm
[4.53 in.]
Fig. 4.1 Brake Pedal (Trucks with capacities from 1.5 to 1.75 tons) 1/2
- 62 -
4. BRAKE SYSTEM
View
85 mm
[3.35 in.]
3 mm
[0.02 in.]
Fig. 4.2 Brake Pedal (Trucks with capacities from 1.5 to 1.75 tons) 2/2
- 63 -
4. BRAKE SYSTEM
CABLE
BRAKE PEDAL (RIGHT)
RESERVE TANK
Brake pedal play: 10 mm [0.394 in.]
Inching pedal play: 50 mm [1.969 in.]
Fig. 4.3 Brake Pedal (Trucks with capacities from 2.0 to 3.5 tons) 1/2
- 64 -
4. BRAKE SYSTEM
View
3 mm
[0.02 in.]
85 mm
[3.35 in.]
Fig. 4.4 Brake Pedal (Trucks with capacities from 2.0 to 3.5 tons) 2/2
- 65 -
4. BRAKE SYSTEM
from RESERVE
TANK
SNAP RING
to WHEEL
BRAKE
YOKE
NUT
PUSH ROD
BOOT
SECONDARY CUP
SPRING
PRIMARY CUP
CHECK VALVE
PISTON
- 66 -
PRIMARY
SECONDARY
Working force
ADJUSTER
SECONDARY
Working force
PRIMARY
ANCHOR PIN
Ro
tat
io
of n dir
dru ec
m tion
4. BRAKE SYSTEM
PIN
SECONDARY SHOE
STRUT
LEVER
PRIMARY SHOE
- 67 -
4. BRAKE SYSTEM
CABLE
SPRING
GUIDE
SPRING
ADJUSTER
LEVER
ADJUSTER
LEVER
Fig. 4.11
- 68 -
4. BRAKE SYSTEM
RELEASE
BUTTON
View
RIGHT-SIDE CABLE
LEFT-SIDE CABLE
4. BRAKE SYSTEM
Section
Shoe expands in
this direction.
Section
Section
1. PUSHROD
2. PISTON
3. CUP
4. SPRING
5. CYLINDER
6. SPRING
7. SPRING
8. ROD
9. LEVER
10. SECONDARY SHOE
11. BACKING PLATE
12. ADJUSTER
13. SPRING
14. CABLE
Fig. 4.14 Wheel Brake (Trucks with capacities from 2.0 to 2.5 tons)
- 70 -
4. BRAKE SYSTEM
Section
Section
Section
Shoe expands in
this direction.
Section
Section
1. PUSHROD
2. PISTON
3. CUP
4. SPRING
5. SPRING
6. STRUT
7. SPRING
8. SECONDARY SHOE
9. BACKING PLATE
10. PIN
11. SPRING
12. LEVER
13. ADJUSTER
14. SPRING
15. PRIMARY SHOE
16. BRAKE LEVER
Fig. 4.15 Wheel Brake (Trucks with capacities from 1.5 to 1.75 tons and 3.0 to 3.5 tons)
- 71 -
4. BRAKE SYSTEM
Poor braking
Noisy brake
Uneven braking
Soft or spongy
brake
Probable cause
Remedy
Repair.
3. Overheated brake
Adjust contact.
Replace.
Adjust.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
1. Contaminated lining
Replace.
Repair or replace.
Replace.
Repair or replace.
Adjust.
Repair.
Adjust.
- 72 -
5. STEERING SYSTEM
5. STEERING SYSTEM
Truck Model
FHG15T3
FHD15T3
FHG18T3
FHD18T3
Item
FG20T3
FHG20T3
FG25T3
FHG25T3
FD20T3
FHD20T3A
FD25T3
FHD25T3A
FG30T3
FHG30T3
FD30T3
FHD30T3A
FG35T3S
FD35T3S
Steering axle
Type
King pin spacing
Toe-in
0 mm
Camber
Caster
Steering angle
Inner wheel
78
Outer wheel
54
78.9
54.1
57
Orbitrol
Type
Discharge
Power cylinder
Type
Cylinder bore
71 mm [2.8 in.]
80 mm [3.15 in.]
40 mm [1.57 in.]
50 mm [1.97 in.]
Stroke
177 mm
[6.97 in.]
- 73 -
5. STEERING SYSTEM
KNUCKLE
(RIGHT)
KNUCKLE
(LEFT)
SUPPORT
(FRONT)
YOKE
(LEFT)
STEERING
SENSOR
SUPPORT
(REAR)
YOKE
(RIGHT)
See Fig. 5.3.
POWER CYLINDER
AXLE
Detail of
Fig. 5.1 Steering Axle (Trucks with capacities from 1.5 to 1.75 tons)
- 74 -
5. STEERING SYSTEM
KNUCKLE
(LEFT)
SUPPORT
(FRONT)
YOKE
(LEFT)
KNUCKLE
(RIGHT)
YOKE
(RIGHT)
STEERING
SENSOR
SUPPORT
POWER CYLINDER
Detail of
Fig. 5.2 Steering Axle (Trucks with capacities from 2.0 to 3.5 tons)
- 75 -
5. STEERING SYSTEM
NEEDLE BEARING
OIL SEAL
THRUST BEARING
HUB
CAP
LOCK NUT
TAPERED ROLLER BEARING
OIL SEAL
OIL SEAL
NEEDLE BEARING
OIL SEAL
LOCK PIN
KING PIN
- 76 -
5. STEERING SYSTEM
STEERING WHEEL
ORBITROL
- 77 -
5. STEERING SYSTEM
5.1.3 ORBITROL
The orbitrol sends pressure oil from the pump selectively to the steering cylinder. It consists primarily
of a control valve and a metering device.
The control valve used in this orbitrol is not an ordinary spool type whose spool moves in the axial
direction, but a rotary type consisting of a sleeve and a spool, which rotates to switch over the oil
passages. The housing has four ports which lead to the pump, tank, right and left chambers of the steering
cylinder, respectively. Between the P port and T port is a check valve provided.
The metering device consists of an internally-toothed stator and an externally-toothed rotor. It works
as an oil motor under normal operating conditions and can be used as a hand pump if the truck becomes
disable for any reason. The rotor is mechanically linked to the sleeve with the drive shaft so that feedback
operation is possible.
The sleeve is interlocked with the motors rotor through the cross pin and drive shaft while the spool
is splined to the steering shaft.
EPACS CONTROLLER
CONTROLLER STATUS
DISPLAY (LED)
DEVIATION
CONTROL VALVE
T PORT
L PORT
P PORT
R PORT
SOLENOID
5. STEERING SYSTEM
Fig. 5.7
- 79 -
5. STEERING SYSTEM
The returning oil from the power cylinder flows, passing through the cylinder port R, groove in the
valve housing, oil hole in the sleeve, groove in the spool, oil hole in the sleeve, and groove in
the valve housing, back to the oil tank.
(c) When steering wheel is turned clockwise
As the steering wheel is turned clockwise, the
grooves in the spool shift to the right in relation to the
oil holes and grooves in the sleeve so that oil holes
in the spool get out of line with holes
in the sleeve.
The oil that has flowed into groove
thus far begins
to flow into oil hole
in the sleeve and then flows
through grooves
and
in the spool, oil hole
in
the sleeve, and oil passage
in the valve housing to
the hydraulic motor. The hydraulic motor thus rotates in
the clockwise direction and the oil discharged from the
in the sleeve,
hydraulic motor flows through oil hole
groove
in the spool, and oil hole
in the sleeve to
the cylinder port R in the housing and thus actuates the
power cylinder.
The returning oil from the power cylinder flows,
passing through the cylinder port L, groove
in the
housing, oil hole in the sleeve, groove in the spool,
oil hole
in the sleeve and groove
in the housing
back to the oil tank.
Fig. 5.8
(2) Relationship between the rotating speed and operating force of the steering wheel
The force required to operate the orbitrol is basically a valve operating force (the force required to
compress the centering spring: 2.9 N-m {0.3 kgf-m} [2.14 lbf-ft]). That is, there is no mechanical linkage
between the steering wheel and the tires, and thus the operating force of the steering wheel remains
constant regardless of the rotating speed of the steering wheel. The discharge of oil from the orbitrol
rotor to the steering cylinder is 96 cc/revolution.
(3) Neutral feedback of orbitrol
The neutral feedback function of the orbitrol is performed by the valve switching over the oil passages
according to the reaction force of the centering spring. (If the steering wheel is turned and then released
with the engine turned off, it will automatically return to the straight-ahead position.) Should the neutral
feedback not function properly, the steering wheel might turn by itself when the operator does not turn it.
- 80 -
5. STEERING SYSTEM
BUSHING
BUSHING
6.5 mm
[0.256 in.]
BOLT
Tightening torque:
27.7 41.5 N-m {282.5 423.2 kgf-cm}
[20.43 30.6 lbf-ft]
BUSHING
PISTON ROD
CAP
PACKING
O-RING
ROD PACKING
DUST SEAL
View
5. STEERING SYSTEM
CONTROLLER
STEERING WHEEL
ANGLE SENSOR
Wire color
Function
Input of power supply
Red
(rated voltage: 12 V or +24V)
Black
Pin No.
1
Pink
Yellow
Purple
Output for solenoid valve driving
Brown signal (-)
2
Plug
White Input of initial setting (+)
receptacle
(F)
Plug
Blue
Input of initial setting (GND)
receptacle
(M)
5. STEERING SYSTEM
STATUS
INDICATING LED
INPUT OF TIRE
ANGLE DETECTION
POTENTIOMETER
OUTPUT OF
COMPENSATION VALVE
DRIVING SIGNAL
POWER
TRANSISTOR
P/D ANALOG
CIRCUIT
BUFFER
STATUS
INDICATING
LED
INPUT OF POWER
SUPPLY (DC10VDC26.4 V)
NOISE
FILTER
CENTER POSITION
SETTING
DC/DC
CONVERTER
INITIAL SETTING
W TERMINAL
Blu
L/G
Br
SOL
VALVE
(Sumitomo Denso)
R
Bl
NOISE FILTER
(Sumitomo Denso)
POWER
SUPPLY
INPUT
(about 50 mA, with solenoid valve off)
Pi
Y
Pu
CONTROLLER
OPERATING STATUS LED
OUTPUT VOLTAGE OF
TIRE ANGLE DETECTION
POTENTIOMETER
STEERING WHEEL
ROTATIONAL POSITION
LEAD-OUT WIRE FROM CONTROLLER: AUTOMOTIVE HEAT-RESISTANT, LOW-VOLTAGE WIRE AEX 0.5 f (Sumitomo Denso)
5. STEERING SYSTEM
LED
1 blink
2 blinks
3 blinks
4 blinks
Off
6. HYDRAULIC SYSTEM
6. HYDRAULIC SYSTEM
FG20T3
FHG20T3
FG25T3
FHG25T3
FG30T3
FHG30T3
FD30T3
FD35T3S
Truck Model
FHG15T3
FHG18T3
FHD15T3
FHD18T3
Item
FD20T3
FD25T3
FHD20T3A
FHD25T3A
FHD30T3A
FG35T3S
Main pump
Type
Model name
Discharge
Gear type
KFP2328
KFP2325
SGP1A30.8
SGP1A27
SGP1A36
SGP1A32
28.2 cm /rev
24.5 cm /rev
30.8 cm /rev
27.8 cm /rev
36.6 cm /rev
33.2 cm3/rev
Control valve
Type
Model name
2-spool sliding type, with relief valve, flow divider and tilt-lock valve
KVMF-70VPF
MSV04A
Pressure setting
Main
Steering
Lift cylinder
Type
Cylinder bore
Single-acting piston
45 mm [1.77 in.]
Stroke
Tilt cylinder
Type
Double-acting piston
Cylinder bore
65 mm [2.56 in.]
80 mm [3.15 in.]
Rod diameter
30 mm [1.18 in.]
35 mm [1.38 in.]
Stroke
Oil tank
Capacity
- 85 -
6. HYDRAULIC SYSTEM
The hydraulic system consists of a main pump, a control valve, lift cylinders and tilt cylinders. The oil
is supplied from the tank at the right side of the frame.
6.1.1 MAIN PUMP
The main pump is a gear type directly driven by the engine PTO device and picks up oil from the oil
tank and sends to the control valve.
The main pump consists of a pump body, a pair of gears, bushings and packings. This pump uses
pressure-balanced bearings and a special lubrication method to minimize the clearance of the gear flank.
The pressure-balanced method is to press the pressure plate toward the gear side by introducing part
of the discharge oil between the pressure plate and the pump body.
COVER
MOUNTING
FLANGE
GEAR PLATE
DRIVEN GEAR
DRIVE GEAR
SNAP RING
SIDE PLATE
(PLATE SEAL)
OIL SEAL
(BACK UP)
(PLATE SEAL)
SIDE PLATE
Section
Section
Fig. 6.1 Main Pump (Trucks with capacities from 1.5 to 1.75 tons)
- 86 -
6. HYDRAULIC SYSTEM
1. DRIVE GEAR
2. SNAP RING
3. OIL SEAL
4. BUSHING
5. FRONT COVER
6. BODY
7. GASKET
8. BUSHING
9. REAR COVER
10. DRIVEN GEAR
11. SIDE PLATE
12. GASKET
Fig. 6.2 Main Pump (Trucks with capacities from 2.0 to 3.5 tons)
- 87 -
6. HYDRAULIC SYSTEM
TOOTH SPACE
SUCTION PORT
DISCHARGE PORT
: Oil flow
6. HYDRAULIC SYSTEM
Eccentricity
Wipe depth
0.01 0.06 mm
[0.00039 0.0024 in.]
Center of
pump body
Discharge
port
Suction port
Trace of wipe
CROSS SECTION A - A
- 89 -
6. HYDRAULIC SYSTEM
LIFT PLUNGER
TILT PLUNGER
PORT T
PORT B2
PORT P
PORT A2
PORT PF
PS RELIEF VALVE
PORT A1
6. HYDRAULIC SYSTEM
PORT P
SPOOL
PF RELIEF VALVE
LOW PRESSURE
PASSAGE
Section
PLUNGER
Section
PORT T
Section
6. HYDRAULIC SYSTEM
Fig. 6.9
(b) When the oil pressure in the high-pressure oil
passage HP reaches to the preset pilot spring
force, the pilot poppet E opens to allow the oil
to flow around the poppet, passing through the
drilled hole, to the low-pressure side LP.
Fig. 6.10
(c) When the pilot poppet E opens, the pressure at
the back of the poppet D drops to cause pressure
differential between the high-pressure side HP
and the low-pressure side, so that the poppet D
is opened to allow the oil to flow directly to the
low-pressure oil passage LP.
Fig. 6.11
(d) If the pressure in the high-pressure oil passage
HP is lower than the pressure in the low-pressure
oil passage LP, the poppet D opens due to the
difference in area between
and
to allow
enough oil to flow from the low-pressure oil
passage LP into the high-pressure oil passage HP
to fill the space.
Fig. 6.12
- 92 -
6. HYDRAULIC SYSTEM
PORT A
RETURN SPRING
PLUNGER
LOW PRESSURE
PASSAGE
PORT B
PORT A
6. HYDRAULIC SYSTEM
PORT B
PORT A
TILT CYLINDER
PORT B
PORT A
SPRING
POPPET PLUNGER
PORT A
PLUNGER
POPPET
Fig. 6.17
PORT A
PLUNGER
POPPET
Fig. 6.18
- 94 -
PORT B
PORT B
6. HYDRAULIC SYSTEM
COMBINATION VALVE
Fig. 6.19 Control Valve (Trucks with capacities from 2.0 to 3.5 tons)
- 95 -
6. HYDRAULIC SYSTEM
P PORT
PF
THROTTLE
MF FLOW
MF THROTTLE
PF FLOW
CONTROL
ORIFICE
MAIN
RELIEF
FD SPOOL
LOAD CHECK
to LOAD HANDLING
TANK PASSAGE
CONTROL VALVE
PF
PORT
PR
RELIEF
- 96 -
6. HYDRAULIC SYSTEM
to PORT A1
LOAD CHECK
PARALLEL
PASSAGE
SPRING
SPOOL
TANK PASSAGE
Fig. 6.22
(b) Spool pulled out (when forks are lifted)
The unload passage is closed so that the oil from
the pump flows through the parallel passage to push
open the load check and lock poppet and enters the lift
cylinders through the port A1. The spool is returned to
neutral by the return spring. (See Figure 6.23.)
Fig. 6.23
(c) Spool pushed in (when forks are lowered)
When the spool is pushed in, the unload passage is
not closed and thus the oil from the pump returns to the
tank passage. The oil that has the lift cylinders through
the port A1 flows to the return passage, returning into
the oil tank. The spool is returned to neutral by the
return spring. (See Figure 6.24.)
Fig. 6.24
- 97 -
UNLOAD
PASSAGE
6. HYDRAULIC SYSTEM
LOAD CHECK
PORT A1
PORT A2
PORT B2
PARALLEL
PASSAGE
SPRING
SPOOL
PILOT
SPOOL
TANK
PASSAGE
Fig. 6.25
Fig. 6.26
Fig. 6.27
Fig. 6.28
UNLOAD
PASSAGE
6. HYDRAULIC SYSTEM
SPRING
LOAD CHECK
PORT B
PORT A
PARALLEL
PASSAGE
SPOOL
TANK
PASSAGE
Fig. 6.29
(b) Spool pulled out
The unload passage is closed and the oil from the
pump flows through the parallel passage to push open
the load check and enters the cylinder through the port
A. The oil returning from the cylinder flows through the
port B, past the tank passage, back into the oil tank.
If the load inside the cylinder is higher than the relief
valve pressure setting, the relief valve opens to allow
oil to return into the oil tank. The spool is returned to
neutral by the return spring. (See Figure 6.30.)
(c) Spool pushed in
The unload passage is closed and the oil from the
pump flows through the parallel passage to push open
the load check and enters the cylinder through the port
B. The oil returning from the cylinder flows through the
port A, past the tank passage, back into the oil tank.
If the load inside the cylinder is higher than the relief
valve pressure setting, the relief valve opens to allow
oil to return to the tank passage. The spool is returned to
neutral by the return spring. (See Figure 6.31.)
- 99 -
Fig. 6.30
Fig. 6.31
UNLOAD
PASSAGE
6. HYDRAULIC SYSTEM
PILOT POPPET
MAIN
POPPET
SEAT
SLEEVE
ORIFICE
SPRING
CHAMBER
- 100 -
6. HYDRAULIC SYSTEM
PF FLOW
MAIN POPPET
VALVE BODY
SPRING
TANK PASSAGE
- 101 -
6. HYDRAULIC SYSTEM
PORT A OR B
TANK PASSAGE
(c) Anticavitation
If the oil pressure at the port A or B is lower than the oil pressure in the tank passage, a force occurs
in the direction that opens the main poppet because of the difference in area across the main poppet. This
force opens the main poppet to direct the oil from the tank passage into the port A or B, thus preventing
the actuator pressure from going negative. (See Figure 6.37.)
- 102 -
6. HYDRAULIC SYSTEM
TILT LEVER
LIFT LEVER
ATTACHMENT LEVER
(OPTION)
CONTROL VALVE
SPACER
Detail of
6. HYDRAULIC SYSTEM
PISTON
SPRING
CASE
6. HYDRAULIC SYSTEM
1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. U-RING
5. HOLDER
6. O-RING
7. BUSHING
8. CYLINDER
9. ROD
10. LOCK RING
11. PISTON
12. WEAR RING
13. PACKING
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN
6. HYDRAULIC SYSTEM
1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. U-RING
5. HOLDER
6. O-RING
7. BUSHING
8. CYLINDER
9. ROD
10. LOCK RING
11. PISTON
12. WEAR RING
13. PACKING
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN
6. HYDRAULIC SYSTEM
1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. U-RING
5. HOLDER
6. O-RING
7. BUSHING
8. CYLINDER
9. ROD
10. LOCK RING
11. PISTON
12. WEAR RING
13. PACKING
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN
6. HYDRAULIC SYSTEM
Mast side
1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. U-RING
5. HOLDER
6. O-RING
7. BUSHING
8. CYLINDER
9. ROD
10. LOCK RING
11. PISTON
12. WEAR RING
13. PACKING
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
6. HYDRAULIC SYSTEM
LIFT CYLINDER
(RIGHT)
LIFT CYLINDER
(LEFT)
from
CONTROL
VALVE
to OIL
TANK
FLOW
REGULATOR
VALVE
Fig. 6.44
FREE FLOW
CONTROLLED FLOW
LIFT CYLINDER SIDE
1. CASE
2. SPRING
3. BALL
4. PISTON
5. SLEEVE
6. ORIFICE
7. SPRING
8. O-RING
9. NIPPLE
6. HYDRAULIC SYSTEM
1. JOINT
2. DUST SEAL
3. BUSHING
4. O-RING
5. PACKING
6. CYLINDER CAP
7. LOCK RING
8. O-RING
9. ROD
10. CYLINDER
- 110 -
11. PISTON
12. PACKING
13. LOCK NUT
6. HYDRAULIC SYSTEM
CAP
SUCTION FILTER
BREATHER
to PUMP
to LIFT
CYLINDER
STEERING
RETURN
RETURN FILTER
DRAIN PLUG
- 111 -
TILT CYLINDER
(LEFT)
ORBITROL
CONTROL VALVE
to LOWER
PART OF LIFT
CYLINDER
to UPPER
PART OF LIFT
CYLINDER
Fig. 6.48 Hydraulic Oil Piping (Trucks with capacities from 1.5 to 1.75 tons)
- 112 -
POWER CYLINDER
PUMP
TILT CYLINDER
(RIGHT)
OIL TANK
6. HYDRAULIC SYSTEM
TILT CYLINDER
(LEFT)
ORBITROL
CONTROL VALVE
to LIFT CYLINDER
PUMP
POWER CYLINDER
TILT CYLINDER
(RIGHT)
OIL TANK
6. HYDRAULIC SYSTEM
- 113 -
6. HYDRAULIC SYSTEM
NOTE
- 114 -
Item
FHG15T3
FHG18T3
FHD15T3
FHD18T3
Name
VM-0A7
Type
FG20T3
FHG20T3
FG25T3
FHG25T3
FD20T3
FHD20T3A FG30T3
FD30T3
FD25T3
FHG30T3 FHD30T3A
FHD25T3A
VM-2N5
VM-2N9
VM-2Y5
Hydraulic
Hydraulic
Lift chain
FG35T3S
FD35T3S
Channel shape
Outer channel
A :
44 mm [1.73 in.]
A :
48 mm [1.89 in.]
A :
60 mm [2.36 in.]
B :
A :
43 mm [1.69 in.]
A :
48 mm [1.89 in.]
A :
B :
D :
D :
D :
Inner channel
72 mm [2.83 in.]
- 115 -
76 mm [2.99 in.]
45 mm [1.77 in.]
76 mm [2.99 in.]
The roller-type two-stage telescopic upright consists of an outer channel, an inner channel and a
carriage.
7.1.1 OUTER AND INNER CHANNELS
The outer and inner channels are of welded construction. The outer channel has a support at its lower
part, with which the upright assembly is mounted on the drive axle.
The outer channel is supported to the frame through the tilt cylinders, which extend and retract to tilt
the upright forward and backward, respectively.
The end rollers are installed on the lower outside of the inner channel and upper inside of the outer
channel with shims.
1. INNER CHANNEL
2. OUTER CHANNEL
3. END ROLLER
4. SHIM
5. END ROLLER
6. SHIM
7. SLIPPER
8. SHIM
9. PIN
10. CAP
11. BUSHING
1. INNER CHANNEL
2. OUTER CHANNEL
3. END ROLLER
4. SHIM
5. END ROLLER
6. SHIM
7. SLIPPER
8. SHIM
9. PIN
10. CAP
11. BUSHING
7.1.2 CARRIAGE
The carriage has end rollers installed with bearings on its end roller shafts welded to the carriage. The
end rollers are shim adjusted and roll along inside the inner channel assembly.
The fore-and-aft load is sustained by the end rollers and the lateral load by the side rollers provided at
the lower part of the carriage. When the forks are raised to the top position, the top end rollers come out
beyond the top of the upright.
1. FORKS
2. STOPPER
3. SPRING
4. HANDLE
5. CARRIAGE
6. END ROLLER
7. LOCK BOLT
8. SIDE ROLLER
9. SHIM
10. SHIM
11. SPACER
12. LOAD BACKREST
1. FORKS
2. STOPPER
3. SPRING
4. HANDLE
5. CARRIAGE
6. END ROLLER
7. LOCK BOLT
8. SIDE ROLLER
9. SHIM
10. SHIM
11. SPACER
12. LOAD BACKREST
END ROLLER
(shim adjusted)
END
ROLLER
(shim
adjusted)
SLIPPER
(shim
adjusted)
END
ROLLER
(shim
adjusted)
OUTER CHANNEL
INNER CHANNEL
SIDE ROLLER
(shim adjusted)
CARRIAGE
END ROLLER
(shim adjusted)
- 121 -
SLIPPER
(shim
adjusted)
END
ROLLER
(shim
adjusted)
OUTER
CHANNEL
INNER CHANNEL
Upper side
END ROLLER
END ROLLER
(shim adjusted)
SIDE ROLLER
Lower side
CARRIAGE
END ROLLER
(shim adjusted)
- 122 -
SLIPPER
(shim adjusted)
END ROLLER
(shim adjusted)
OUTER
CHANNEL
INNER CHANNEL
Upper side
END ROLLER
(shim adjusted)
END
ROLLER
(shim
adjusted)
SIDE ROLLER
(shim adjusted)
Lower side
END ROLLER
(shim adjusted)
SIDE ROLLER
(shim adjusted)
8. ELECTRIC WIRING
8. ELECTRIC WIRING
The electric components of the truck are wired through several types of wire harnesses and color
coded by circuit.
The wire harnesses are connected with connectors (2 types) or screw.
Table 8.1 Color symbols and examples
Black
Red
Green
White
Blue
Yellow
Orange
Lg Light green
Pink
Lb Light blue
Plug-in type
Connection type
Plug-in side
Receptacle side
Remarks
The alphabetic letters means colors.
(Table 8.1)
Housing
Plug
Screw type
The dotted lines in the circuit diagrams are given for optional equipment.
- 123 -
LW
- 124 -
Sb
71
B
19
RY
21
GR
18
B
20
RW
14
3BY
66
BrW
15
2R
17
3BG
13
2B
108
LW
5
YB
8
YW
126
GO
6
YG
127
BW
63
WB
125
WBr
4
LY
155
GW
48
GY
109
2L
86
2YL
82
YR
WIRE HARNESS,
OVERHEAD GUARD
(LEFT)
2L
2B
for OPTIONAL
ELECTRICAL PARTS
91
V
12
GB
83
Y
92
Sb
93
WL
95
OL
96
YR
1
RW
149
BrB
157
WG
85
OL
RED TAPE
2
W
143
BrR
170
WL
87
V
98
Y
52
B
51
G
163
BrB
164
B
121
B
73
2R
74
RY
120
LY
122
WBr
Sb
11
GR
150
RY
147
LG
84
Sb
10
GL
9
BR
64
LB
37
WR
113
2LR
107
2YL
27
BR
47
GR
77
R
78
RW
42
3BG
43
3BY
to KEY SWITCH
44
2LR
28
YB
35
YG
100
L
49
WR
145
RB
160
B
34
LY
30
RW
141
BrR
to LIFT LOCK
VALVE
152
GW
158
BrW
142
B
36
YW
102
BrB
156
WG
159
BrW
103
RB
62
LB
LW
B
GY
LG
RB
70
B
57
RY
59
GL
56
B
58
RW
to WIRE HARNESS,
OVERHEAD GUARD
(RIGHT)
to HORN
to ALARM BUZZER
to INTERLOCK
VALVE
151
GW
to COMBINATION METER
46
GB
to PARKING SWITCH
61
WB
45
GL
to SAFETY RELAY
111
WL
112
B
39
R
76
Lg
79
B
41
Lg
72
Br
75
B
123
GO
40
Br
to NEUTRAL RELAY
161
WL
162
B
124
BW
to ORBITROL
to HORN SWITCH
97
YR
WHITE TAPE
94
O
to F/R SWITCH
to LIGHTING SWITCH
8. ELECTRIC WIRING
BR
- 125 GB
WY
YR
BrR
Lg
3BY
3BY
YW
to STARTER RELAY
3BY
3BL
LY
WG
2R
OL
BrY
LW
2YL
GY
WY
to FLASHER UNIT
LG
WG
DIODE
LG
to AUTO
CHOKE RELAY
2L
LW
to FUSE BOX
RL
3BG
3BG
SI
WL
BrR
GY
to BACK-UP
BUZZER
YG
GO
Br
3B
LW
2R
5BY
WG
BR 3BY
5BY
3B
Not used
RB
3BL
Y
RL
RW
RB
2B
GL
GR
WG
7.5A
3A
7.5A
3A
3A
7.5A
15A
7.5A
7.5A
Y
RL
YR
WL
LW OPTION
WG E/G
Y BACK
LY METER
YR T/M
WY TURN
2L RWL OPTION
GY HORN
AND
2R HEAD
POSITION
BrY STOP
YB
to OIL PRESSURE
SWITCH
FUSE BOX
3BG
3BG
3BY
3BY
15A
Not used
DIODE
Not used
G
V
OL
OL
to F/R VALVE
to ALTERNATOR
to STARTER
WBr
to REAR WORK
LIGHT
GO
to STEERING
POTENTIOMETER
BW
YG
BrY
to BRAKE LAMP
SWITCH
to WATER
TEMPERATURE
SENDER
to FUSIBLE LINK
WIRE
WR
YR
2B BrW 2YL
3BG 3BY 2L
GROUND
YW
YB
Normally connected
BW
to SEAT
SWITCH
Br
LY
GW WBr
GB
3BY
3BY
3BG
3BG
GW Br
OL
Lg
WR
LB
RY
BR
RW
BrB
GR
GL
BrB RB
2B RY LB
to WIRE
HARNESS, ECM
8. ELECTRIC WIRING
8. ELECTRIC WIRING
DIODE
to BRAKE
LAMP
SWITCH
to FUSE BOX
to BACK-UP
LAMP RELAY
GROUND
to FUEL
LEVEL
SENDER
to RELAY
to METER to OIL
FUSE BOX
PRESSURE
SWITCH
to GLOW PLUG
to ALTERNATOR
to WATER
TEMP.
SENDER
to BATTERY
to FLASHER
UNIT
DIODE
to STARTER
RELAY
QOS3
to TIMER
to DETECTOR
to SEDIMENTER
to WATER TEMP.
SENSOR
to STEERING
POTENTIOMETER
to GLOW PLUG
RELAY
to BACK-UP BUZZER
to REAR WORK
LIGHT (OPTION)
VIEW Z
CONNECTION
RIGHT
SIDE
STEP
RIGHT
STEP
SEAT SWITCH
LPG SWITCH
F/R SOLENOID
4P
4P
GAS
DIODE
GAS
LPG
FLASHER UNIT
ECM
6P
10P 2P 8P 4P 4P
6P
6P
6P
6P
BATTERY -
10P
10P
to SEAT SWITCH
TIMER
W/H ECM
FUSIBLE
LINK WIRE
YB
BY
YG
ALTERNATOR
AUTO CHOKE
RELAY
FUSE BOX
LPG
- 127 -
Fig. 8.4 Location of Electrical Parts (Engine powered trucks with K21 or K25)
RELAY
POT
6P
STARTER RELAY
6P
9P 12P 16P
LPG SOL
ACCELERATOR
POTENTIOMETER
2P
2P
DIODE (BLUE)
PARKING
SWITCH
BACK-UP BUZZER
SPEED UNIT
2P
2P
HORN
SAFETY RELAY
NEUTRAL RELAY
NO
COM
NC
2P
2-3t
1t
ALARM
8. ELECTRIC WIRING
SEAT SWITCH
4P 2P 2P
DIODE
4P
F/R SOLENOID
FUEL SENSOR
BACK-UP RELAY
FLASHER UNIT
DETECTOR
GLOW RELAY
TIMER (QOS)
DIODE (BLUE)
9P 12P 16P
8. ELECTRIC WIRING
FUSE BOX
2P 8P 4P
6P
WIRE HARNESS,
ENGINE
STARTER RELAY
RESISTOR
WIRE HARNESS,
FRONT GUARD
DIODE
DIODE (BLUE)
HEAD
LAMP RELAY
TAIL LAMP
RELAY
to WIRE HARNESS,
ENGINE
to WIRE HARNESS,
OVERHEAD GUARD
(LEFT)
- 128 -
Fig. 8.5 Locations of Electrical Parts (Engine-powered trucks with T27, QD32)
6P
6P
6P
to WIRE HARNESS,
REAR COMBINATION LAMP
to SEAT SWITCH
WIRE HARNESS,
ENGINE
2P
2P
4P
to STEERING
WHEEL
Detail of area B
RELAY (SIL)
RELAY
RELAY (IC)
TIMER
BACK-UP BUZZER
(2 - 3.5 t)
BACK-UP BUZZER
(1.5 - 1.8 t)
2P
HORN
SAFETY RELAY
NEUTRAL RELAY
WIRE HARNESS,
OVERHEAD GUARD
(RIGHT)
ALARM
H
EA
TE
BATTERY -
to LPG
SOLENOID
(LPO TRUCKS,
LPG TRUCKS)
LPG SOL
to WIRE
HARNESS,
ENGINE
RBBrB
LB RY 2B
CO
Lg
SW
RB
10
to ECO SWITCH
(OPTION)
to SPEED
SENSOR
GAS
GW
GW WB
RL
BW G
RG
- 129 -
4
RG B
2B
Br
Br
BW Y
RG B
3
LR
RG B
YW BrY
to WATER
TEMPERATURE
SENSOR
to CRANK ANGLE
SENSOR
to MAP SENSOR
Lg
RG
to WIRE HARNESS,
CONTROLLER
WB GW
LPG
to LPG SELECTOR
SWITCH
TAS
to PTC
HEATER
(OPTION)
2W
PT
C
WL
ETC
to BATTERY (-)
for CONSULT
BrB
Lg WG
YR BrY
YB BrY
LW
LOOP
RG B
LB
to IGNITION COIL
RG
to INJECTOR
B B
BrY
63
Sb
OPTION
LW
BrB BrY
RB
BrR 2BrG
A-1
WG
W B
BrW Sb
WG
BL
43
to O2 SENSOR
YR YB WL
2L
WL WR
A-2
to FUSE
BW YB YW BW
BL
Lg
Br
LR LB
YL
to LPG INJECTOR
WB WL
YW
GW
Br
WY
to FAST TAS
LEARNING SWITCH
2W
2L
A-3
Br
BL
WB
Br
WL
BL
BrW BrW
Br
Br
BY
LB YR GW G YW WR
BrB
BG RB
BrB
LB
RG
BrR
BR
W Y
BrR
W Lg RL R YB YL
2Br
25
BR
PTC HEATER
FUEL PUMP
MAIN CRANK
W
B BW
RB P
BrR 2BrG
ETC MOTOR
W R
Lg RY BW BR
EGI
EGI
YW YR
Lg YR BW
BL
BW
89
to THROTTLE
CHAMBER
LB
to VARI VSP
B-1
6
B
ER
LT
FI
to OIL FILTER
97
GR
POT
B
GW
to RELAY
GR
YW
GW BW
YR
2Br
BrB RB
BR
to ACCELERATOR POTENTIOMETER
BG
OP
B-2
BL BY BR BrG WG
230C2-42161
VARI VSP
B-3
2Br WB WL
8. ELECTRIC WIRING
3BG
20B
LG
BR
E 3B
ALTERNATOR
WG
BATTERY
55B24R
BR
AUTO CHOKE
LG
WL
RELAY 5
FUEL PUMP
BL
WL
GASOLINE
FUEL PUMP
BrW
BrY
WG
Sb
2BrR
BrB
2BrG
2L
GY
BrY
2R
WG
YR
LY
LW
WG
1 2 3 4 5 6 7 8
BrB
9 10111213141516
CONSULT
()
FUEL INJ.
ECM
EGI
ETC
EGI
OPTIONS
HORN
STOP
ENGINE
F/R VALVE
BACK
BR R1
STARTER MOTOR
KEY SWITCH
3BG
OFF
7.5A
7.5A
7.5A
7.5A
15A
7.5A
15A
15A
7.5A
7.5A
15A
3A
3BG
3BY
3A
2LR
3BY
METER
OPTIONS
Lg
ENGINE
20B
BrR
2BrR
2BrG
BrR
2Br
BR
BR
2RG
LOOP
B
3BY
B
2LR
RG
STARTER
WL
1
WB
2
BrY
2LR
3BL
W
B
B
R
W
W
3
2 O2 SNS FR 1
SW GOVERNOR(ECO)
B
WY
WG
1
2
THROT
3
CHAMBER
5
(ETC)
4
6
RELAY 3
ETC MOTOR
RB
BG
LPG INJ
**
#1
WL
2LR
BrB
BrB
N SAFETY
ELECTROLYTIC
CAPACITOR
RELAY 2
EGI
RELAY 1
EGI
*
*
*
*
LB
BrB
RY
WY
RB
WL
WR
BL
YB
YW
YR
Y
WG
LW
LR
LB
Lg
BL
W
B
B
R
W
W
RB
BG
WL
WB
Br
Br
BR
BrG
INJ#1
INJ#2
INJ#3
INJ#4
VARI VSP 54
PRES 71
LPGPRES 31
TW 73
TA 34
QA+ 51
AVCC 48
GND-A 67
SNOWSW 12
SLOW INJ 11
APS1 106
AVCC 90
GND-A 82
APS2 98
AVCC2 91
GND-A2 83
VSP8 33
AVCC 49
FUELSW#2 32
FUELSW#1 70
POS 13
PHASE 14
METER
PANEL
HOUR METER
FUEL LEVEL
METER
WATER TEMP.
METER
WATER TEMP.
FUEL LEVEL
HOUR METER
GND
YL
LB
YR
YW
YB
Lg
BW
RB
BY
GR
YR
BR
GW
YW
BW
RL
GW
Br
CPU
2
1
2
1
FUEL
EMPTY
3
2
12V
5V
1 W/TEMP SEN
AIR FLOW
METER
2 AIR/TEMP SEN
3
ACCEL
WORK
UNIT
(APS)
BW
G
BY
BW
2
Lg
1
RELAY 4
MAIN/C **
Br
Br
WG
YB
E/G CHECK
OIL PRESSURE
CHARGE
PARKING
SEAT BELT
BATTERY
LEVEL
RADIATOR
AIR CLEANER
- 130 -
BR
BrB
NEUTRAL
SEDIMENTER
LY
BrR
DC/DC
KEY ON +
RW
INTER LOCK
DC/DC
BATT. +
ILLUMINATION
BW
3
MAP
Lg
1
SEN
(OPTION SCS1015)
R1(SEE TABLE 1,USUALLY OPEN)
FUEL/PRES
**
SEN
BW
4
Br
5
BW
1
** 1 Br
SPEED SENSOR
Br
GR
YR
BR
GW
YW
BW
SW SNOW(ECO)
Lg
GW
6 SPEED SEN 4
WB
5 UNIT
1
B
2
3
5
6
3
2
4
1
5 CRANK/ANGLE
4
6 SEN(POS)
3 CRANK/ANGLE
1
2 SEN(PHASE)
Br
WATER TEMP.
SENSOR
YG
YG
YW
WR
S TAS SW 52
GND 1
GND 2
GND 115
Module) GND 116
FUEL SENSOR
B
YW
ECM(Engine Control
30 LED
102 NEUT
84 H/LMP
56 GOVERNORSW
101 BRAKE
24 O2HFR
35 O2SFR
78 GND-A
23
42
22
41
109 IGNSW
80 IGN#4
81 IGN#2
61 IGN#3
62 IGN#1
85 KLINE
113 FPR
5 MOTOR1
4 MOTOR2
66 GND-A2
50 TPS1
69 TPS2
47 AVCC2
3 VMOT
104 MOTRLY
118 VB
121 VB
111 SSOFF
110 BATT
GW
WB
7.5A
2B
3B
SW-OIL PRESS
OPTIONS
NEUTRAL LAMP
BrB
B
B
WL
FLASHER
GB
WY
L-L'
R-R'
TB TR TL
EL LT
SW LTG
DIRECTION SWITCH
LH
Lg
R
Ry1
LB
B
GW LIFT LOCK
Ry3
WR GW
5V
10
CONTROL VALVE
GW
INTERLOCK
B
SW SEAT
SEAT
B
RW
BACK BUZZER
SW BRAKE
RB
BrY
POSITION
HEAD LAMP
RY
B
Sb RL
OPTIONS
2R
Br
RWL
SW HORN
B
OFF
HORN
SW TURN SIGNAL
GB
3A
B
B
5BY
2RG
2B
GL
YR
7.5A
B
WR
B
GND
VARI
VSP
TAS
WY
WG LB
GR
G
YR
WR
LW
GY
OL
LW
2B
Br
V
TURN
7.5A
LW
FUSE BOX
2L
R
O
WL
PARKING SW
PIC
12F675
TIMER UNIT
Sb
2B
LB
B
RL
RB
8. ELECTRIC WIRING
CLEARANCE
TURN SIGNAL
CLEARANCE
B
BACK-UP
Ry2
OL
Ry3
G
V
RW
Ry1
F/R VALVE
OL
F
G
LG Lg
ALARM
LICENSE LAMP
RW
B
TAIL
STOP
BACK-UP
RW
RB
RL
B
TURN SIGNAL
GR
TAIL
STOP
RL
B
TURN SIGNAL
RW
RB
GL
TURN SIGNAL
RY
GR GW
RW G
GL GW
RW G
RY
HEAD LAMP(L.H.)
HEAD LAMP(R.H.)
BrR
Lg
WL
W
3BY
FUSIBLE LINK
5BY
5BY
RB
LG
L
3BY
3BL
A
D
N
G
H
J
K
L
M
B
F
C
G
Ry2
RW
WL V
W OL
B
B
B
B
5BY
BATTERY 12V
3B
40B
To B
BATT. CAP
SENSOR
F.L.W.
0.85R
5BY
10
LW
Ry3
WR
Ry2
3BG
3BG
3BY
3BY
STARTER RELAY
Ry2
7.5A
3A
7.5A
3A
3A
7.5A
15A
7.5A
7.5A
15A
FUSE BOX
Ry1
Ry3
E B
LW
LW
R.W.L
2L
2L
WG
WG
E/G
LY
YR
INTERLOCK
& OPTUON
LY
METER
RY
YG
T/M
WY
GY
BrY
2R
BACK
WY
TURN
RWL OPTION
GY
BrY
STOP
HORN
2R
TIMER QOS
BrR
RW
WR
LW
L
W
G
WL
LB
B
1 2 3 4 5 6 7
FLASHER UNIT
B
B
RW
GR
RY
OPTION
TERMINALS
Sb
Sb
GLOW RELAY
BrR
RW
WR
LW
L
W
G
WL
LB
B
DETECTOR
BrR
RW
WR
LW
L
W
G
WL
LB
B
for RRE
YR
Y
G
RW
RB
B
RL
BACK
BUZZER
Sb
P
GR
RW
RB
B
RL
B Ig
ON
HO-HO+
HORN SWITCH
H
OFF
EL LT LH
TB TL TR
B
RW
GL
RW
RB
B
RL
BACK(STD : 10W)
(RRE : 20W)
TAIL (8W)
STOP (23W)
TURN (23W)
REAR CONBINATION
LAMP (R.H.)
G
RW
RB
B
RL
LICENCE
LAMP
WBr
GO
BW
WBr
GO
BW
- 131 -
RL
YW
WR
FUEL LEVEL
SENDING UNIT
REAR CONBINATION
LAMP (L.H.)
BACK(STD : 10W)
(RRE : 20W)
TAIL (8W)
STOP (23W)
TURN (23W)
OL
RESISTOR
DIODE
V
B
BrR
Lg
GW
LW
L
OL
G
V
Br
B
Sb
3BG
3BY
2LR
GB
OFF
GR
PTGPTSPT+OV PV
GL
LITING SWITCH
Lg
KEY SWITCH
WR HOUR METER GND
YW FUEL LEVEL
YG WATER TEMP.
W
3BY
3BG
RW
RY
2B
YR
Y
OL
WL
V
Sb
2R
BW
GO
WBr
LY
2L
LW
2YL
GB
DIRECTION SWITCH
GND
B
Br
5V
DC/DC
BATT. +
12V
LY
YL
RY
RADIATOR
LEVEL
SENSOR
GLOW
PLUG
5BW
ILLUMINATION
3BL
40B
RW
BW
GO
WBr
POTENTIOMETER
YB
STARTER
To A
NEUTRAL SAFTY
RELAY
SEDIMENTER
WG
BRAKE LAMP
SWITCH
WATER TEMP.
METER
FUEL LEVEL
METER
RW
METER PANEL
PARKING BRAKE SW
for STD & EXE,N,A
& SIL &OKM
BrB
WL
B
Br
OG
YG
BR
REGULATOR
WATER TEMP.
SENDING UNIT
L (RELAY)
S (LEVEL)
SEAT BELT SW
SEAT SW
LG
RB
OPTION
TERMINALS
WL
YR
RL
B
B
RW
GL
RY
B
B
G
GW
RY
NEUTRAL SW.
CLUTCH ONLY
ALARM BUZZER
INTERLOCK
SOLENOID
BrW
CONTROL VALVE
LIFT LOCK
SOLENOID
3BY
3B
5BY
OIL PRESS. SW
NEUTRAL RELAY
HORN
RG
VALVE
F/R
TOR-CON ONLY
AIR CLEANER
DIODE UNIT
(600V 3A2)
HOUR METER
CPU
FUEL
EMPTY
GR
BR
OIL PRESSURE
YB
GLOW
LB
RY
WL
WL
WG E/G CHECK
B
COM
NO
RB
Y
WB
RW
TIMER UNIT
2YL
PIC
12F675
Ry1
3BY
5V
3BL
RW
2B
LW
2L
W
O
BrR
B
B
G
GW
RY
BW
B
LB
5BY
E/G
EARTH
40B
WY
GO
5BY
GW
B
G
3BG
3BG
3BY
3BY
GB
WBr
5BW
WL
B
RL
ORBIT ROL
YR
WG
BrW
8. ELECTRIC WIRING
RY
HEAD
FRONT COMBINATION
LAMP (L.H)
LAMP (L.H)
2YL
OG
B
LB
WL
BW
LY
LY
B
WB
LY
RY
Sb
WL
LG
LG
GY
DC/DC
2B
YR
Y
OL
WL
V
RL
2R
BW
GO
WBr
LY
2L
LW
2YL
GB
W
3BY
3BG
RW
BrB NEUTRAL
2YL
KEY ON +
GR
2B
Br
BATTERY
LEVEL
Y
2LR
RADIATOR
YL
B
AIR CLEANER
RG
RY
CHARGE
GL
BrR
BR
YB
WB
LB
WG
BrB
WR
YW
YG
GY
LG
GW
BrW
2B
BR
WR
YW
YG
GY
Lg
GW
BrW
Y
RW
GR
GL
RL
RB
2R
BrW
G
GW
PARKING
RB
B
B
LY
Y
BrW
YL
RG
GL
BrR
BR
YB
WB
LB
Lg
LY
WB SEDIMENTER
BrY
RB
LW
B
GW
RW
WB
Y
G
B
GW
W
OL
OL
W
G
G
B
G
G
B
V
V
B
LY
Y
BrW
YL
RG
RW
GR
GL
RL
RB
(Empty page)
No. SEF-0F7BE
MARKETING GROUP:
105-0003, Japan