S1 - YFCE18B - 2 (Chassis Vol 2 Euro 2)

(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧡ಽ
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
Applicable for FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM2P, SG8J series,
equipped with J05E-TI, J08E-TI, P11C-TI engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
This manual is divided into 15 sections with a thumb index for each section at the edge of the pages.
Please note that the publications below have also been prepared as relevant service manuals for the components and sys-
tems in this vehicles.
Manual Name Pub. No.

Chassis Workshop Manual S1-YFCE18B 1/2
J05E-TI Engine Workshop Manual S5-YJ05E12A
J08E-TI Engine Workshop Manual S5-YJ08E29B
P11C-TI Engine Workshop Manual S5-YP11E07B
(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧡ಽ
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S1-YFCE18B 2/2

CHAPTER
MODELS FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM2P, SG8J
EXHAUST BRAKE BR05-001
RETARDER BRAKE BR06-001
BR07-001 BR07-002
PARKING BRAKE
(MODELS: FC, FD, GD) (MODELS: FG, GH, FL, FM, SG)
STEERING EQUIPMENT SR01-001
STEERING UNIT SR02-001
POWER STEERING SR03-001
AX02-001 AX02-002 AX02-003 AX02-004 AX02-005 AX02-006

FRONT AXLE
(LF366) (LF45I) (LF578) (LF571) (MF678) (MF67I)
AX03-001 AX03-002 AX03-003 AX03-004 AX03-005

(DIFFERENTIAL (DIFFERENTIAL (DIFFERENTIAL (DIFFERENTIAL (DIFFERENTIAL
REAR AXLE
GEAR SERIES: GEAR SERIES: GEAR SERIES: GEAR SERIES: GEAR SERIES:
SH13) SH14) SH16) SH17) THD17)
WHEEL AND TIRE AX04-001
SU02-001 SU02-004
SU02-002 SU02-003
SUSPENSION (MODELS: FC, FD, (HENDRICKSON
(MODELS: FL, FM) (MODEL: SG)
GD, FG, GH) HAS 230)
CHASSIS FRAME FC02-001
CAB CA02-001
ELECTRICAL EQUIPMENT EL01-001
DN03-004
DN03-001
DN03-002 DN03-003 (ELECTROMAG-
BRAKE CONTROL (ABS+ES START:
(ABS: WABCO) (ES START) NETIC
DENSO)
RETARDER)
DN06-001 DN06-002
OTHERS
(CAN COMMUNICATION) (HEADLIGHT AUTOLEVELING)
+0&':HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧠㧤ಽ
INDEX: CHASSIS GROUP 1/3
EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
WORKSHOP STEERING EQUIPMENT

MANUAL STEERING UNIT
POWER STEERING
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
WHEEL & TIRE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
COUPLER (5TH WHEEL)
PINTLE HOOK
CAB EQUIPMENT
All rights reserved. This manual may not be

CAB
reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd.
ELECTRICAL EQUIPMENT
ELECTRIC WIRE
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
2A$4AAOQMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧠㧝ಽ
EXHAUST BRAKE BR05–1
EXHAUST BRAKE
BR05
BR05-001
EXHAUST BRAKE SYSTEM ....................BR05-2

SYSTEM DIAGRAM ........................................ BR05-2
TROUBLESHOOTING..................................... BR05-3
ADJUSTMENT................................................. BR05-3
BRAKE CYLINDER
(MODELS: EXCEPT FOR FM2P) .............BR05-4
DATA AND SPECIFICATIONS........................ BR05-4
DESCRIPTION ................................................ BR05-4
COMPONENT LOCATOR ............................... BR05-5
OVERHAUL ..................................................... BR05-6
INSPECTION AND REPAIR ............................ BR05-6
ADJUSTMENT................................................. BR05-7
BRAKE CYLINDER (MODEL: FM2P) ......BR05-9

DESCRIPTION ................................................ BR05-8
OVERHAUL ................................................... BR05-10
INSPECTION AND REPAIR .......................... BR05-11
2A$4AAOQMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧤ᤨ㧞ಽ
BR05–2 EXHAUST BRAKE
EXHAUST BRAKE SYSTEM

SYSTEM DIAGRAM
EN06Z0805J100001
SHTS06Z080500001
1 Clutch switch 5 Magnetic valve

2 Accelerator switch 6 Exhaust brake control cylinder
3 Exhaust brake switch A From power source
4 Indicator light B From air tank
NOTICE
Figure shown above is a typical diagram; refer to Electric Wiring Diagram in the ELECTRIC WIRE chapter and
Brake Piping Diagram in the SERVICE BRAKE chapter for details.
TROUBLESHOOTING
EN06Z0805F300001
Symptom Possible cause Remedy/Prevention

Switch does not work Defective contacts Check and correct.
Open circuit in harness Check and correct.
Valve does not close Valve clogged with carbon Remove carbon.
Burnt shaft Check and correct.
ADJUSTMENT
EN06Z0805H300001
ACCELERATOR SWITCH ADJUSTMENT

(EXAMPLE)
OFF 1. ADJUSTMENT OF THE EXHAUST BRAKE ACCORDING TO
THE ENGINE SPEED
(1) Adjust the engine idling speed by turning the throttle knob.
(2) The accelerator switch should turn on (continuity) when the
engine speed is lower than the following, and off (no continuity)
ON when the engine speed is higher.
NOTICE
Use the accelerator pedal to change engine speeds.
SHTS06Z080500002
(3) Adjust the accelerator switch position if it is out of position.

Assembly standard: 0-0.5 mm {0-0.020 in.}
SHTS06Z080500003
CLUTCH PEDAL SWITCH ADJUSTMENT

The clutch pedal switch should not be knocked against.
When the clutch pedal is depressed, the clearance "A" (between the
buffer and the switch body tip) should have 0.5-1.5 mm {0.020-0.059
in.}.
Assembly standard: 0-0.5 mm {0-0.020 in.}
Assembly standard: 0.5-1.5 mm {0.020-0.059 in.}
SHTS06Z080500004
BRAKE CYLINDER (MODELS: EXCEPT FOR FM2P)

DATA AND SPECIFICATIONS
EN06Z0805I200001
Type Butterfly valve
DESCRIPTION
EN06Z0805C100001
SHTS06Z080500005
1 Blind plate 5 Seal ring

2 Bushing 6 Plate
3 Valve 7 Lever
4 Shaft 8 Cylinder
COMPONENT LOCATOR
EN06Z0805D100001
SHTS06Z080500006
1 Arm 8 Lever
2 Bushing 9 Cover
3 Seal ring 10 Valve
4 Plate 11 Shaft
5 Control cylinder 12 Stud
6 Pin 13 Body
7 Clevis
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 22.6-28.4 {240-280, 18-20} C 19.6-24.5 {200-240, 15-17}
B 10.8-16.7 {120-170, 9-12}
OVERHAUL
EN06Z0805H200001
IMPORTANT POINT - DISMOUNTING

! CAUTION
Do not work on the exhaust brake cylinder while it is still hot. This
can result in personal injury.
IMPORTANT POINTS - ASSEMBLY
1. INSTALLATION OF THE PLATE

(1) Before assembling the brake cylinder, remove the carbon with a
scraper or emery paper (recommended: No.150).
(2) Beveled edge of blind plate is fitted outward as shown in the fig-
ure.
SHTS06Z080500007
2. INSTALLATION OF THE SEAL RINGS

(1) The small and large seal rings must be installed alternately as
shown in the figure.
SHTS06Z080500008
3. INSTALLATION OF THE VALVE

(1) Apply lithium molybdenum grease to the bolt seat surface and bolt
threads.
1 2 (2) Tighten the bolts in order shown in the figure to the specified
60˚ torque below.
Tightening Torque:
9.81 N⋅m {100 kgf⋅cm, 7 lbf⋅ft}
9.81 N·m (3) Mark the bolt heads and shaft in the same direction with paint.
SHAFT
(4) Tighten the bolts 60° (1/6 turn) as in step 2.
(5) Make sure that the paint marks face the same direction.
PAINT MARK
SHTS06Z080500009 NOTICE
When adding torque, never untighten the nuts, even if they have
been overtightened.
INSPECTION AND REPAIR

EN06Z0805H300002
Inspection item Standard Limit Remedy Inspection procedure
Brake cylinder, bush- — — Replace, if necessary. Visual check

ing and seal ring:
Wear, any other dam-
ages
ADJUSTMENT
EN06Z0805H300003
1. CLOSE SIDE ADJUSTMENT

(1) Adjust the clearance between the cylinder and the butterfly valve
with the adjusting screw "A".
SHTS06Z080500011
Limit: B = 0.1 mm {0.0039 in.}

(2) Lock the adjusting screw "A" with a lock nut.
SHTS06Z080500012
2. OPEN SIDE ADJUSTMENT

(1) Set the lever to the open position.
(2) Adjust the butterfly valve may be right angle (90°) to the cylinder
with the adjusting screw "C".
(3) Lock the adjusting screw "C" with a lock nut.
SHTS06Z080500013
SHTS06Z080500014
2A$4AAOQMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧥ᤨ㧡㧢ಽ
BRAKE CYLINDER (MODEL: FM2P)

EN06Z0805I200002
Brake cylinder Slide valve

Type
Control cylinder Spring type with compressed air
DESCRIPTION
EN06Z0805C100002
SHTS06Z080500015
1 Valve 9 Piston rod 17 Poppet valve

2 Liner 10 Collar 18 Connector
3 Liner guide 11 Piston 19 Valve housing
4 Stopper 12 Washer 20 Adapter plate
5 Bushing 13 Taper washer 21 Cylinder
6 Spring seat 14 Gasket 22 Poppet valve cover
7 Piston packing 15 O-ring 23 Wave washer
8 Piston lock nut 16 Spring 24 Retainer
COMPONENT LOCATOR
EN06Z0805D100002
SHTS06Z080500016
1 Bushing 13 O-ring
2 Piston rod 14 Poppet valve
3 Spring seat 15 Poppet valve cover
4 Cylinder 16 Connector
5 Spring 17 Valve housing
6 Collar 18 Valve
7 Piston 19 Liner guide
8 Piston packing 20 Liner
9 Washer 21 Stopper
10 Taper washer 22 Gasket
11 Wave washer 23 Adapter plate
12 Retainer

A 28-31 {280-320, 21-23} D 20-21 {200-220, 14.5-15.9}
B 7.9-8.8 {80-90, 5.8-6.5} E 28-31 {280-320, 21-23}
C 20-21 {200-220, 14.5-15.9} F 50-58 {500-600, 37-43}
OVERHAUL
EN06Z0805H200002
IMPORTANT POINT - DISMOUNTING

! CAUTION
Do not work on the exhaust brake cylinder while it is still hot. This
can result in personal injury.
IMPORTANT POINT - DISASSEMBLY
1. DISASSEMBLE THE BRAKE CYLINDER.

(1) Before disassembling the brake cylinder, put the match marks on
the following the parts.
a. Adapter plate and valve housing
b. Cylinder and adapter plate
c. Poppet valve cover and cylinder
NOTICE
When assembling the brake cylinder, align the match marks on
the each parts.
SHTS06Z080500017
(2) Remove the grease, anti-loose agent, anti-seizing agent and car-
bon completely with a scraper or emery paper.
NOTICE
Do not damage the parts.
IMPORTANT POINT - ASSEMBLY
1. ASSEMBLE THE BRAKE CYLINDER.

NOTICE
Replace the bushing, gasket, poppet valve and O-ring with new
ones.
(1) Apply adequate amount of the silicone grease to the grooves for
O-ring and for sliding surfaces of the component parts.
a. Piston retainer
b. Piston packing and cylinder
c. O-ring
d. Poppet valve
(2) Apply the lock agent for contact surfaces of the component parts.
e. Upper bushing and adapter plate
f. Spring seat and adapter plate
g. Piston and piston rod
h. Piston and piston packing
i. Adapter plate and cylinder
NOTICE
Do not apply the lock agent for the guide bushing hole and
adapter plate hole.
(3) Apply anti-seizing agent to the threads of the bolt, before tighten-
ing the bolts.
SHTS06Z080500018
j. Bolts
(4) After tightening the lock nut, caulk the threads with a punch.
k. Threads

EN06Z0805H300004
Slide valve: — — Clean or replace, Visual check

Wear, any other damage if necessary.
Piston rod: — — Clean or replace, Visual check

Piston: — — Clean or replace, Visual check

Cylinder sliding sur- — — Clean or replace, Visual check

face: if necessary.
Wear, any other damage
2A$4AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧡㧞ಽ
RETARDER BRAKE (ELECTROMAGNETIC RETARDER) BR06–1
RETARDER BRAKE BR06
(ELECTROMAGNETIC RETARDER) BR06-001
RETARDER BRAKE ASSEMBLY ............BR06-2

DIAGRAM ........................................................ BR06-3
DESCRIPTION ................................................ BR06-4
OVERHAUL ..................................................... BR06-7
BR06–2 RETARDER BRAKE (ELECTROMAGNETIC RETARDER)
RETARDER BRAKE ASSEMBLY

EN06Z0806I200001
Retarder type Electromagnetic type

Brake torque 490 N⋅m {5,000 kgf⋅cm, 362 lbf⋅ft}
Cooling system Air cooling type
Control system Electronic control system
Working current Self generating
DIAGRAM
EN06Z0806J100001
SYSTEM DIAGRAM
RETARDER ECU RETARDER MAIN UNIT

CONNECTOR JUMPER CABLE
16P CONTROL UNIT 10P DRIVE UNIT CONNECTOR A 1 LINE
To INTEGRAL UNIT 8P
SCR DRIVE
9 D-1 D-1 4 1
EXCITER 3 2
+24V INDICATOR LIGHT RELAY DRIVE
10 D-10 D-10 A 1 LINE
SPEED
+24V SIGNAL 1 RELAY
11 D-8 D-8 7 6
SPEED 8 5
EXCITER 1
SIGNAL 2
2 D-9 D-9
1 F COIL VOLTAGE
DETECTION 1 2 3
2 6 D-4 D-4 1 4
F COIL VOLTAGE SCR
3 DETECTION 2
15 D-6 D-6
4 F COIL VOLTAGE
DETECTION PWR
16 D-3 D-3 5 8
DIAGNOSIS 6 7
MONITOR FIELD COIL 1
GROUND
3 D-2 D-2
COMBINATION SW GROUND CONNECTOR
13 D-5 D-5 8P B 2 LINE
OFF EXH RET RET
Lo Hi 4 1
GROUND
OFF 14 D-7 D-7 3 2
EXH/B
1 B 2 LINE
2 7
RELAY
3 7 6
1 8 5
EXCITER 2
5
2 3
1 4
8 SCR
To STARTER SW
CIRCUIT
12
5A
5 8
4 6 7
FIELD COIL 2
GND
CONNECTOR
4P
1 TEMP.
SENSOR 1
3 TEMP.
2 SENSOR 2
4 SHILED
CABLE GND
SHTS06Z080600001
DESCRIPTION
EN06Z0806C100001
RETARDER DRUM
POLE
FIELD COIL
EXCITER COIL
EXCITER MAGNET
PROPELLER SHAFT
COIL BRACKET
SHTS06Z080600002
COMPONENT LOCATOR
EN06Z0806D100001
ACCELERATOR SWITCH
CONTROL LEVER
CLUTCH SWITCH
RETARDER MAIN UNIT
CONTROL UNIT
DRIVE UNIT
SHTS06Z080600003
SHTS06Z080600004
1 Retarder drum 2 Retarder coil assembly

A 148-196 {1,500-2,000, 112-148} for FD B 61-91 {620-930, 46-68} for FD
109-147 {1,100-1,500, 82-111} for FG, GH 109-147 {1,100-1,500, 82-111} for FG, GH
OVERHAUL
EN06Z0806H200001
NOTICE
• The main unit is very hot immediately after operating the
retarder. So, cool down enough the unit before starting the
work.
• If the retarder main unit is fouled with mud or sand, cool the
unit down to about ambient temperature. And then wash the
unit by washer with water or hot water.
1. REMOVE THE RETARDER DRUM.

(1) Block the front wheels.
(2) Model for FD
A a. Remove the nut to disconnect the propeller shaft and remove
the retarder drum from the transmission.
NOTICE
• Pay attention not to drop or hit the retarder drum.
• Do not loosen or remove the fixing bolts (A) of the retarder
drum.
• Since the propeller shaft and the retarder drum are fixed
together in case of FD model, prevent the retarder drum from
falling out when dismounting the propeller shaft.
SHTS06Z080600005
(3) Models for FG, GH

A a. Remove the nut and disconnect the propeller shaft from the
transmission.
b. Remove the retarder drum fitting nut and remove the retarder
drum from the transmission.
NOTICE
• Pay attention not to drop or hit the retarder drum.
• Do not loosen or remove the fixing bolts (A) of the retarder
drum.
HINT
Since the propeller shaft and the retarder drum are fixed sepa-
SHTS06Z080600006
rately in case of FG and GH models, the propeller shaft can be dis-
mounted separately.
2. REMOVE THE RETARDER COIL ASSEMBLY.

(1) Disconnect each connector for harness of retarder main unit from
the holder.
SHTS06Z080600007
(2) Remove the universal joint flange fitting nut of transmission and
remove the universal joint flange from the retarder coil assembly.
(3) Remove the retarder coil fitting nut and remove the retarder coil
assembly from the transmission.
SHTS06Z080600008
3. INSTALL THE RETARDER COIL ASSEMBLY.

(1) After tightening the retarder coil assembly temporarily with fitting
nuts (4 pieces), install it to transmission with standard tightening
torque.
(2) Install the universal joint flange to the transmission output shaft
and tighten it with O-ring and nut.
SHTS06Z080600008
4. INSTALL THE RETARDER DRUM.

(1) Model for FD
a. Install the propeller shaft to retarder drum with nuts. (4
pieces).
SHTS06Z080600009
(2) Models for FG, GH

a. After tightening the retarder drum temporarily with fitting nuts
(4 pieces), install it with standard torque.
b. Install the propeller shaft to retarder drum with nuts (4
pieces).
SHTS06Z080600010
2A$4AA(%A(&A)&A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧡㧞ಽ
PARKING BRAKE (MODELS: FC, FD, GD) BR07–1
PARKING BRAKE
BR07
(MODELS: FC, FD, GD) BR07-001
PARKING BRAKE ASSEMBLY ................BR07-2

DESCRIPTION ................................................ BR07-2
SPECIAL TOOL ............................................... BR07-4
OVERHAUL ..................................................... BR07-8
ADJUSTMENT............................................... BR07-11
BR07–2 PARKING BRAKE (MODELS: FC, FD, GD)
PARKING BRAKE ASSEMBLY

EN06Z0807I200001
Parking brake type Internally expanding, duo-servo type
Parking brake control type Lever type control with control cable
Drum inside diameter 203.2 mm {8.0 in.}
Width x length x thickness

Brake lining 45 mm x 195 mm x 5 mm
{1.772 in.} x {7.677 in.} x {0.197 in.}
DESCRIPTION
EN06Z0807C100001
SHTS06Z080700001
1 Grommet 8 Dust cover

2 Brake drum 9 Anchor pin retainer
3 Camshaft 10 Return spring
4 Anchor bracket 11 Shoe adjuster
5 Cam lever 12 Cam lever return spring
6 Bracket 13 Brake shoe assembly
7 Lock pin
PARKING BRAKE LEVER
SHTS06Z080700002
1 Release rod knob 5 Brake lever bracket

2 Compression spring 6 Parking brake switch
3 Parking brake lever 7 Pawl
4 Pawl release rod
TROUBLESHOOTING
EN06Z0807F300001

Too much play noted on parking Excessively large drum-to-lining clear- Readjust the brake properly.
brake lever ance.
Maladjusted control linkage. Readjust.
Not enough braking force Excessively large drum-to-lining clear- Readjust.
ance.
Burnt lining. Repair or replace.
Worn lining. Replace.
Shoes are too dirty with water, dust, Disassemble and clean.
etc.
Linings are soaked with oil. Replace.
Lining get burnt easily Not enough drum-to-lining clearance. Readjust.
Shoe or drum is distorted. Repair or replace.
Springs are broken. Replace.
Can not keep the lever in full stroke Over stroke of lever. Adjust cable length.
position Wear or broken of ratchet. Replace parts.
Not return the lever to running Water inside the cable Replace the cable.
position, when cold weather. (Frozen condition)
(below zero)
SPECIAL TOOL
EN06Z0807K100001
Prior to starting a parking brake adjustment, it is necessary to have the special tool.
Illustration Part number Tool name Remarks
BRAKE SHOE ADJUSTING

S0966-51250
TOOL
COMPONENT LOCATOR
EN06Z0807D100001
PARKING BRAKE
SHTS06Z080700004
1 Grommet 8 Bracket
2 Brake drum 9 Cam lever
3 Return spring 10 Lock pin
4 Camshaft 11 Dust cover
5 Anchor pin retainer 12 Cam lever return spring
6 Anchor bracket 13 Brake shoe assembly
7 Shoe adjuster

A 34.5-51.5 {351-527, 26-38} C 88.5-117.5 {900-1,200, 66-86}
B 12.7-21.6 {130-220, 10-15} D 18-26 {180-260,13-19}
SHTS06Z080700005
1 Parking brake lever assembly 3 Clips

2 Cable 4 To parking brake
SHTS06Z080700006
1 Knob 6 Spacer
2 Compression spring 7 Pawl
3 Lever assembly 8 Pawl release rod
4 Bushing 9 Parking brake sensor assembly (If so equipped)
5 Parking brake switch

A 14.0-32.0 {143-327, 10.34-23.65}
2A$4AA(%A(&A)&A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧤ᤨ㧝㧡ಽ
OVERHAUL
EN06Z0807H200001
IMPORTANT POINTS - DISMOUNTING
1. DISCONNECT THE PROPELLER SHAFT.

(1) Refer to the chapter "PROPELLER SHAFT".
2. REMOVE THE LOCK NUT AND TRANSMISSION OUTPUT

SHAFT FLANGE.
(1) Refer to the chapter "TRANSMISSION MAIN UNIT".
1. REMOVE THE RETURN SPRING.

(1) Use the suitable tool to remove the return spring.
SHTS06Z080700007
1. APPLY HEAT RESISTANCE GREASE ON RUBBING OR

MATCHING FACES OF BRAKE SHOES, CAMSHAFT, SHOE
ADJUSTER AND POSITION THE ADJUSTER IN PLACE.
SHTS06Z080700008
2. INSTALL THE RETURN SPRING.

(1) Use the suitable tool to install the return spring.
SHTS06Z080700009
2A$4AA(%A(&A)&A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧤ᤨ㧝㧢ಽ
3. INSTALL FLANGE YOKE COUPLING.

(1) Install flange onto transmission output shaft and tighten lock nut.
Tightening torque:
587-783 N⋅m {6,000-8,000 kgf⋅cm, 434-578 lbf⋅ft}
(2) Caulk rim part of nut into groove on output shaft.
NOTICE
• Caulked portion should be fitted in the groove thoroughly.
• Caulking should be done without rift.
SHTS06Z080700010
4. APPLY BEARING GREASE ON THE FOLLOWING PARTS.

(1) Pin (Cable)
(2) Both sides of brake lever bracket
(3) Pin (Pawl)
(4) Pawl release rod
SHTS06Z080700011
5. PARKING BRAKE SWITCH.

PARKING BRAKE SWITCH (1) Install the switch to the brake lever bracket.
(2) Adjust the dimension A (Switch button projection) to 2.0 mm
{0.0787 in.} when the parking brake lever is fully released.
(3) Confirm the parking brake indicator light lights, when the lever is
pulled by the notches.
DIMENSION A
SHTS06Z080700012

EN06Z0807H300001
Unit: mm {in.}
Brake lining: 5.0 1.0 Replace. Measure

Lining thickness {0.197} {0.039}
Brake drum: 203.2 204.2 Replace. Measure

Inside diameter {8.0} {8.039}
Brake drum: 0-0.1 0.2 Replace. Measure

Run out {0-0.0039} {0.0078}
ADJUSTMENT
EN06Z0807H300002
1. CHECK THE REMAINING THICKNESS OF THE BRAKE LIN-

ING.
(1) Measure the remaining thickness of lining through the inspection
hole of brake drum. Replace the brake shoe assembly when it is
worn to the service limit.
Assembly standard 5.0 mm {0.1969 in.}

Service limit 1.0 mm {0.0394 in.}
DRUM
INSPECTION HOLE
SHTS06Z080700016
2. ADJUST THE CLEARANCE BETWEEN DRUM AND LINING.

(1) Lift the rear wheel to be adjusted off the ground.
(2) Release the control lever.
(3) Turn the adjuster to reduce the clearance to zero.
SST: Brake shoe adjusting tool (S0966-51250)
SHTS06Z080700017
(4) Turn the adjuster backward by specified notches.

Specified notches: 14 notches
SHTS06Z080700018
(5) Pull the parking brake lever fully to three times and release the
lever. Turn the drum by hand to see that the shoes are not drag-
ging. If there is any dragging, repeat the operation from step 1.
SHTS06Z080700019
3. ADJUST THE CONTROL CABLE.

lever.
SHTS06Z080700019
(2) Adjust the clearance "A" between cable and cam lever on the
parking brake to 1-2 mm {0.040-0.078 in.} by turning the adjusting
CAM LEVER
A
nut.
LOCK NUT
CABLE
ADJUSTING
NUT
SHTS06Z080700020
(3) Pull the parking brake lever with 294 N {30 kgf, 66.14 lbf} force
and make sure that the lever stroke is within assembly standard.
Then lock the adjusting nut with the lock nut.
Assembly standard: 8-11 notches
SHTS06Z080700019
SHTS06Z080700021
2A$4AA()A)*A(.A(/A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧜ಽ
PARKING BRAKE (MODELS: FG, GH, FL, FM, SG) BR07–1
PARKING BRAKE BR07
(MODELS: FG, GH, FL, FM, SG)

BR 07
BR07-002
PARKING BRAKE.....................................BR07-2
DESCRIPTION ................................................ BR07-2
SPECIAL TOOL ............................................... BR07-6
OVERHAUL ................................................... BR07-12
ADJUSTMENT............................................... BR07-15
2A$4AA()A)*A(.A(/A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧤ᤨ㧞㧠ಽ
BR07–2 PARKING BRAKE (MODELS: FG, GH, FL, FM, SG)
PARKING BRAKE
EN06Z0807I200001
Models FG, GH, FL, FM8J, SG FM2P
Parking brake type Internally expanding, duo-servo type
Parking brake control type Lever type control with control cable
Drum inside diameter 254 mm {10.0 in.}
Width x length x thickness Width x length x thickness

Brake lining 75 mm x 300 mm x 7 mm 60 mm x 288 mm x 5.75 mm
{2.952 in.} x {11.811 in.} x {0.275 in.} {2.362 in.} x {11.339 in.} x {0.226 in.}
DESCRIPTION
EN06Z0807C100001
TYPE-A MF06 transmission
SHTS06Z080700001
1 Grommet 7 Lock pin

2 Brake drum 8 Dust cover
TYPE-B EATON FS6109 / FS8209 transmission
SHTS06Z080700002
1 Grommet 7 Lock pin

2 Brake drum 8 Dust cover
TYPE-C ZF9S109 transmission
SHTS06Z080700003
1 Grommet 8 Dust cover

2 Brake drum 9 Anchor pin retainer
7 Lock pin
PARKING BRAKE LEVER
SHTS06Z080700004
1 Release rod knob 5 Brake lever bracket

2 Compression spring 6 Parking brake switch
3 Parking brake lever 7 Pawl
4 Pawl release rod
TROUBLESHOOTING
EN06Z0807F300001

Too much play noted on parking Excessively large drum-to-lining clear- Readjust the brake properly.
brake lever ance.
Not enough braking force Excessively large drum-to-lining clear- Readjust.
ance.
Burnt lining. Repair or replace.
Worn lining. Replace.
Shoes are too dirty with water, dust, Disassemble and clean.
etc.
Linings are soaked with oil. Replace.
Lining get burnt easily Not enough drum-to-lining clearance. Readjust.
Shoe or drum is distorted. Repair or replace.
Springs are broken. Replace.
Can not keep the lever in full stroke Over stroke of lever. Adjust cable length.
position Wear or broken of ratchet. Replace parts.
Not return the lever to running posi- Water inside the cable Replace the cable.
tion, when cold weather. (below (Frozen condition)
zero)
SPECIAL TOOL
EN06Z0807K100001
Prior to starting a parking brake adjustment, it is necessary to have the special tool.
BRAKE SHOE ADJUSTING

S0966-51130
TOOL
COMPONENT LOCATOR
EN06Z0807D100001
PARKING BRAKE (TYPE-A MF06 transmission)
A
10
5
6
3 1
13
4
2
3
9 3
3
11 13
B
7
8
12
SHTS06Z080700006
1 Rubber plug 8 Shoe adjuster

3 Tension spring 10 Bracket
4 Brake lining 11 Lock pin
5 Brake shoe 12 Dust cover
6 Camshaft 13 Spacer
7 Anchor bracket

A 64.5-85.5 {650-870, 48-63} C 17.7-22.6 {180-230, 14-16}
B 147.5-166.5 {1,500-1,700, 109-122} D 34.5-51.5 {351-525, 26-38}
PARKING BRAKE (TYPE-B EATON FS6109 / FS8209 transmission)
D
10
6
3 1
13
4
2
3
9 3
3
11 13
B
7
8
12
SHTS06Z080700007
1 Rubber plug 8 Shoe adjuster

3 Tension spring 10 Bracket
4 Brake lining 11 Lock pin
5 Brake shoe 12 Dust cover
6 Camshaft 13 Spacer
7 Anchor bracket

A 64.5-85.5 {650-870, 48-63} C 17.7-22.6 {180-230, 14-16}
B 147.5-166.5 {1,500-1,700, 109-122} D 147.5-166.5 {1,504-1,698, 108-122}
PARKING BRAKE (TYPE-C ZF9S109 transmission)
SHTS06Z080700008
1 Brake drum 8 Tension spring

2 Grommet 9 Backing plate
3 Brake lining 10 Drum dust cover
4 Brake shoe 11 Spring
5 Shoe adjuster 12 Cam lever
6 Camshaft 13 Bracket
7 Pin 14 Cable

A φ10: 45-55 {460-560, 33-40} C 108.5-147.5 {1,100-1,500, 80-108}
φ12: 71-87 {723-887, 52-64} D 14.7-22.5 {150-230, 11-16}
B 64.5-85.5 {650-870, 48-62}
SHTS06Z080700009
1 Parking brake lever assembly 4 Clips

2 Fixture 5 To parking brake
3 Cable
SHTS06Z080700010
1 Knob 5 Parking brake switch

2 Compression spring 6 Spacer
3 Lever assembly 7 Pawl
4 Bushing 8 Pawl release rod

A 14.0-32.0 {143-327, 10.34-23.65}
OVERHAUL
EN06Z0807H200001
1. DISCONNECT THE PROPELLER SHAFT.

(1) Refer to the chapter "PROPELLER SHAFT".
2. REMOVE THE LOCK NUT AND TRANSMISSION OUTPUT

SHAFT FLANGE.
(1) Refer to the chapter "TRANSMISSION MAIN UNIT".
IMPORTANT POINTS - DISASSEMBLY
1. REMOVE THE RETURN SPRING.

(1) Use the suitable tool to remove the return spring.
SHTS06Z080700011
2. REMOVE THE CAM LEVER.

NOTICE
• Before removing the cam lever, make the aligning marks to
cam lever and camshaft.
SHTS06Z080700012
1. INSTALL THE CAM LEVER.

NOTICE
• When installing the cam lever to camshaft, align the aligning
marks which were applied at disassembly.
SHTS06Z080700012
2. LUBRICATION
(1) Apply heat resistance grease on rubbing or matching faces of
brake shoes, camshaft, shoe adjuster and position the adjuster in
place.
SHTS06Z080700013
3. INSTALL THE RETURN SPRING.

(1) Use the suitable tool to install the return spring.
SHTS06Z080700014
4. INSTALL FLANGE YOKE COUPLING.

(1) Install flange onto transmission output shaft and tighten lock nut.
Tightening torque:
587-783 N⋅m {6,000-8,000 kgf⋅cm, 434-578 lbf⋅ft}
(2) Caulk rim part of nut into groove on output shaft.
NOTICE
• Caulked portion should be fitted in the groove thoroughly.
• Caulking should be done without rift.
SHTS06Z080700015
5. APPLY BEARING GREASE ON THE FOLLOWING PARTS.

(1) Pin (Cable)
(2) Both sides of brake lever bracket
(3) Pin (Pawl)
(4) Pawl release rod
SHTS06Z080700016
6. PARKING BRAKE SWITCH.

PARKING BRAKE SWITCH (1) Install the switch to the brake lever bracket.
(2) Adjust the dimension A (Switch button projection) to 2.0 mm
{0.0787 in.} when the parking brake lever is fully released.
(3) Confirm the parking brake indicator lamp lights, when the lever is
pulled by the notches.
DIMENSION A
SHTS06Z080700017

EN06Z0807H300001
Unit: mm {in.}
Brake lining: 7.0 4.0 Replace.

Lining thickness {0.2756} {0.1575}
Models: FG, GH, FL,
FM8J, SG
5.75 3.1
{0.2264} {0.1220}
Model: FM2P
Brake drum: 254 256 Replace.

Measure
Inside diameter {10.0} {10.079}
Brake drum: 0-0.1 0.2 Replace.

Run out {0-0.0039} {0.0078}
ADJUSTMENT
EN06Z0807H300002
1. CHECK THE REMAINING THICKNESS OF THE BRAKE LIN-

ING.
(1) Measure the remaining thickness of lining through the inspection
hole of brake drum. Replace the brake shoe assembly when it is
worn to the service limit.
DRUM
Models FG, FL, FM8J, SG FM2P
INSPECTION HOLE
Assembly standard 7.0 mm {0.276 in.} 5.75 mm {0.2264 in.}
SHTS06Z080700021
Service limit 4.0 mm {0.157 in.} 3.10 mm {0.1220 in.}
2. ADJUST THE CLEARANCE BETWEEN DRUM AND LINING.

(1) Lift the rear wheel to be adjusted off the ground.
(2) Release the control lever.
(3) Turn the adjuster to reduce the clearance to zero.
SST: Brake shoe adjusting tool (S0966-51130)
SHTS06Z080700022
(4) Turn the adjuster backward by specified notches.

Specified notches:
14 notches (Models: FG, GH, FL, FM8J, SG)
10-12 notches (Model: FM2P)
SHTS06Z080700023
SHTS06Z080700024
3. ADJUST THE CONTROL CABLE.

lever.
SHTS06Z080700024
(2) Adjust the clearance "A" between cable and cam lever on the
parking brake to 1-2 mm {0.040-0.078 in.} by turning the adjusting
CAM LEVER
A
nut.
LOCK NUT
CABLE
ADJUSTING
NUT
SHTS06Z080700025
(3) Pull the parking brake lever with 294 N {30 kgf, 66.14 lbf} force
and make sure that the lever stroke is within assembly standard.
Then lock the adjusting nut with the lock nut.
Assembly standard: 8-11 notches
SHTS06Z080700024
SHTS06Z080700026
2A54AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧡㧢ಽ
STEERING EQUIPMENT SR01–1
STEERING EQUIPMENT
SR01
SR01-001
STEERING SYSTEM................................. SR01-2

TROUBLESHOOTING..................................... SR01-2
SR01–2 STEERING EQUIPMENT
STEERING SYSTEM
TROUBLESHOOTING
EN07Z0701F300001

Hard steering or poor return of Bent steering shaft, sliding shaft or Replace parts.
steering wheel to center column
Universal joint oscillates or catches. Replace universal joint in the assem-
bly.
Column bearing does not revolve or Replace parts.
catch.
Lack of lubrication in steering linkage. Lubricate.
Wheel alignment is incorrect. Refer to the chapter "FRONT AXLE".
Power steering system is faulty. Refer to the chapter "POWER
STEERING".
Tire air pressure is too low. Adjust properly.
Steering wheel shimmy Steering system linkage is loose. Tighten properly.
Too much wear or play in steering link- Replace parts.
age (spline and ball joints).
Other front axle problems. Refer to the chapter "FRONT AXLE".
Power steering gear badly adjusted. Refer to the chapter "POWER
STEERING".
The wheels are out of balance. Balance the wheels.
Wheel wobbles. Replace wheel.
Tire air pressure is not uniform or suffi- Adjust tire pressure.
cient.
Distorted disc wheel. Replace parts.
Abnormal noises Lack of lubrication in steering linkage. Lubricate.
Power steering system is faulty. Refer to the chapter "POWER
STEERING".
STEERING UNIT SR02–1
STEERING UNIT
SR02
SR02-001
STEERING LINKAGE ............................... SR02-2

DESCRIPTION ................................................ SR02-2
SPECIAL TOOL ............................................... SR02-4
COMPONENT LOCATOR ............................... SR02-5
OVERHAUL ..................................................... SR02-8
INSPECTION AND REPAIR .......................... SR02-13
SR02–2 STEERING UNIT
STEERING LINKAGE
DESCRIPTION
EN07Z0702C100001
RIGHT-HAND DRIVE MODEL
SHTS07Z070200001
1 Steering wheel 5 Steering gear unit

2 Horn button 6 Pitman arm
3 Steering column assembly 7 Drag link
4 Dust cover
LEFT-HAND DRIVE MODEL
(REPRESENTATIVE TYPE)
1
3
SHTS07Z070200002
1 Steering wheel 5 Steering gear unit

2 Horn button 6 Pitman arm
4 Dust cover
SPECIAL TOOL
EN07Z0702K100001
Prior to starting a steering linkage overhaul, it is necessary to have these special tools.
S0965-01341 STEERING WHEEL PULLER
S0965-72050 GUIDE Models: FC, FD, GD
2 pieces
S0965-71790 GUIDE Models: except for
FC, FD, GD
Models: except for

S0965-71800 GUIDE
FC, FD, GD
Models: except for

SZ179-20001 NUT
FC, FD, GD
S0965-01260 PITMAN ARM PULLER

COMPONENT LOCATOR
EN07Z0702D100001
SHTS07Z070200009
1 Steering wheel 10 Steering shaft universal joint 19 Steering gear bracket

assembly
2 Horn button 11 Dust cover 20 Flange nut
3 Combination switch 12 Sliding yoke 21 Column upper cover
4 Spiral cable 13 Steering shaft dust cover 22 Column lower cover
5 Windshield wiper switch 14 Steering gear unit 23 Column lower boot
6 Light control switch 15 Steering gear dust seal 24 Column lower tube
7 Steering sensor 16 Pitman arm 25 Pivot bolt
9 Dust seal 18 Lubrication fitting

A 48.5-57.5 {500-600, 37-43} D φ27: 211-289 {2,200-3,000, 156-213}
B φ16: 146-224 {1,500-2,300, 109-167} φ30: 341-439 {3,478-4,476, 252-323}
φ18: 277-423 {2,830-4,310, 206-315} φ36: 391-489 {3,988-4,986, 289-360}
C 146-244 {1,500-2,500, 109-180} E 146-244 {1,500-2,500, 109-180}
F 206-284 {2,100-2,895, 152-209}
G 48.5-77.5 {500-800, 37-57}

(REPRESENTATIVE TYPE) 2
G
16
4
6 5 17
3
18
9 19
7
8 20
10
A
F
15 14
13
D
12
C B
11
SHTS07Z070200010
1 Steering wheel 8 Dust seal 15 Steering gear bracket

2 Horn button 9 Dust cover 16 Flange nut
3 Combination switch 10 Sliding yoke 17 Column upper cover
4 Spiral cable 11 Steering gear unit 18 Column lower cover
5 Light control switch 12 Pitman arm 19 Column lower boot
6 Windshield wiper switch 13 Drag link 20 Column lower tube
7 Steering column assembly 14 Lubrication fitting

A 48.5-57.5 {500-600, 37-43} D φ27: 211-289 {2,200-3,000, 156-213}
B φ16: 146-224 {1,500-2,300, 109-167} φ30: 241-389 {3,000-4,000, 217-286}
φ18: 277-423 {2,830-4,310, 206-315} φ36: 391-489 {4,000-5,000, 289-360}
C 146-244 {1,500-2,500, 109-180} E 146-244 {1,500-2,500, 109-180}
F 206-284 {2,100-2,900, 152-209}
G 48.5-77.5 {500-800, 37-57}
NOTICE
When retightening the nut F, be sure to apply engine oil to the thread and seat surface or be sure to replace the
nut with new one.
OVERHAUL
EN07Z0702H200001
1. REMOVE THE STEERING WHEEL.

(1) Loosen the torx bolt for fixing the horn button using torx wrench.
(2) Remove the horn button from the steering wheel.
SHTS07Z070200011
(3) Remove the connector for the horn.
CONNECTOR FOR HORN
SHTS07Z070200012
(4) Remove the steering wheel lock nut.

(5) Use the special tool or commercial tool to remove the steering
wheel as shown in the figure.
SST: Steering Wheel Puller (S0965-01341)
NOTICE
• Before removing the steering wheel from the steering shaft,
make aligning marks on both so that they can be assembled
in the same position.
• Because the puller hole is made of aluminum and it is easily
damaged, screw the puller bolt deeply.
SHTS07Z070200013 (6) Fix the rotating part of spiral cable with tape etc. to prevent the
spiral cable from rotating.
2. REMOVE THE PITMAN ARM.

(1) Remove the nut, lock washer and plain washer from the sector
shaft.
(2) Using the special tool, remove the pitman arm.
SST: Pitman Arm Puller (S0965-01260)
NOTICE
Do not use wedges or hit with a hammer.
SHTS07Z070200014
2A54AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧤ᤨ㧞㧤ಽ
1. ASSEMBLE THE STEERING SHAFT.
2. INSTALL THE DUST COVER.

(1) The dust cover must be fitted with two bolts facing the relief mark
"REAR" rearward. After tightening, make certain that the white
paint mark will be faced frontward.
3. ASSEMBLE THE STEERING SHAFT.

LUBRICATION FITTING (1) Before assembling, apply chassis grease to the spline of the slid-
SHTS07Z070200015
ing yoke, and after assembling also fill grease through lubrication
fitting.
When replacing parts: 30g (1.1 oz.)
When replenishing parts: 15g (0.5 oz.)
NOTICE
When assembling, take care not to damage the steering shaft
spline.
4. INSTALL THE STEERING WHEEL.

CONNECTOR FOR HORN
(1) Set front axles toward rectilinear direction.
LOCK PIN (NEW)
(2) When spiral cable is new, make sure that the lock pin is seated in
the spiral cable assembly and the seal is not cut. When spiral
HARNESS CLAMP cable is reused, make sure that the neutral position of the spiral
SEAL (NEW) cable does not get out of position.
SPIRAL
CABLE
FRONT
SHTS07Z070200016
NOTICE
When there is no lock pin though the spiral cable is new, or when
the seal is cut though there is a lock pin, or when the neutral posi-
tion of the spiral cable gets out of position in reuse, turn the spiral
cable counterclockwise lightly. And turn it back clockwise by 4
rotations at the point of beginning of the hard steering. Then
match the neutral position marks on the upper side of the spiral
cable assembly.
(3) Pass the spiral cable through the steering wheel opening area
and set the steering wheel straight to install it with nut. When the
NEUTRAL POSITION MARK
spiral cable is new, remove the lock pin. When it is reused,
SHTS07Z070200017 remove the tape etc. for fixing the rotation of the spiral cable.
(4) Tighten the set screw for fixing the horn button after pushing it in
by using a torx wrench.
Tightening Torque:
6.5-13.5 N⋅m {66-138 kgf⋅cm, 4.8-9.9 lbf⋅ft}
SHTS07Z070200011
5. IF NECESSARY, REPLACE THE DRAG LINK DUST SEAL.

(MODELS: FC, FD, GD)
(1) Using a flat blade screwdriver etc., remove the clamp and then
remove the dust seal.
DUST SEAL NOTICE
CLAMP If dust etc. is adhered to the socket groove, remove it.
(2) Set up the ball stud vertically to the end.
(3) Apply grease to the dust seal lip part.
SHTS07Z070200018
(4) Put a dust seal on the end and fit it into the groove. Screw in a
A clamp mounting special tool so that its end plane "A" is located 5
5 mm mm {0.1969 in.} above the upper end of the ball stud screw. At
{0.1969 in.} this moment, make sure that the pointed end of the tool is posi-
tioned to the seal groove as the illustration to the left shows.
B
SPECIAL TOOL SST: Guide (S0965-72050)
(5) Insert a clamp from "A" side of the tool and move it to the direction
of B down to the plane "C". Then drop the clamp slowly into the
C
dust seal groove.
(6) After mounting the clamp, make sure that there is no deformation
SHTS07Z070200019 under torsion or running off the edge of the clamp. If such defor-
mation or running out is found, touch it up by using a flat head
screw driver or its equivalent.
NOTICE
• If the dust seal is damaged or the clamp is deformed, replace
them with new one.
• Do not reuse the clamp once used.
(7) After mounting the clamp, fill the lubrication fitting of the drag link
ball joint with chassis grease.
NOTICE
Fill with grease until it flows out from the hole of dust seal.
6. IF NECESSARY, REPLACE THE DRUG LINK DUST SEAL AND
RELAY ROD. (MODELS: EXCEPT FC, FD, GD)
(1) Observe the following procedure when changing the dust seal.
a. Pry off the dust seal with a screw driver.
b. Put 6.5 g {0.23 oz.} of lithium molybdenum grease in the seal.
c. Use the special tools to install the dust seal onto the socket
without damaging it.
SST:
Dust Cover Guide Inner (S0965-71790)
Dust Cover Guide Outer (S0965-71800)
Dust Cover Guide Nut (SZ179-20001)
SHTS07Z070200020
7. INSTALL THE PITMAN ARM.

(1) Through the pitman arm, install the plain washer and lock washer
to the sector shaft.
(2) Tighten the nut to the specified torque.
NOTICE
Align the aligning marks.
SHTS07Z070200021
8. INSTALL THE DRAG LINK.

(1) Connect the drag link with the pitman arm and with the knuckle
arm.
NOTICE
• At this time, make sure that the arrow "FRONT" or numeral
on the drag link is positioned toward the front of vehicle.
• When handling the drag link, take care not to damage the
dust seal.
(2) Tighten the slotted nuts of the ball studs at both ends of the link to
the specified torque, and then secure the nuts with the cotter pins.
SHTS07Z070200022
9. INSPECT THE STEERING SYSTEM FOR OPERATING ABIL-

ITY.
(1) Place the front wheels on turn tables.
(2) Make sure that the steering wheel turns smoothly without any jolts
or abnormal resistance when the steering wheel is turned full
range.
SHTS07Z070200023
(3) Check the steering wheel free play while engine is idling.
FREE PLAY Wheel Free Play: 15-35 mm {0.591-1.377 in.}
(4) If wheel free play exceeds 15-35 mm {0.591-1.377 in.}, turn the
set screw clockwise to decrease wheel free play and counter-
clockwise to increase it.
! CAUTION
Excessive steering wheel free play may adversely affect vehicle
handling. This can result in personal injury and/or property dam-
age.
SHTS07Z070200024
(5) Measure the steering wheel turning force. Use a spring balancer
to measure the steering wheel turning force.
NOTICE
Measure the steering wheel turning force while the engine is
idling.
Turning force: 20 N {2.0 kgf, 4.4 lbf}
SHTS07Z070200025
(6) The steering wheel must be locked securely in any position up,
down, forward and backward.
! CAUTION
Before moving the vehicle, tighten the lever securely and try to
ADJUSTING
LEVER move the steering wheel up and down, and forward and backward
to make sure that it is locked securely. Never try to adjust the
RELEASE steering wheel position while the vehicle is moving. Any adjust-
ment of the steering wheel while driving can cause the driver to
lose control, and result in personal injury and/or property dam-
LOCK age.
SHTS07Z070200026
(7) Check to see that the combination switch is operating properly.

EN07Z0702H300001
Steering wheel: — — Replace, Visual check

Cracks, distortion and if necessary.
damage
Steering wheel serration: — — Replace, Visual check

Wear and damage if necessary.
Steering column assem- — — Replace, Visual check

bly: Bent, oscillation and if necessary
cracks
Drag link: Cracks and — — Replace the Visual check

damage whole drag link
Ball joint: Play assembly or
Dust seal: Damage replace only
dust cover.
2A54AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧤ᤨ㧡㧢ಽ
POWER STEERING SR03–1
POWER STEERING
SR03
SR03-001
POWER STEERING SYSTEM .................. SR03-2 POWER STEERING PUMP

TROUBLESHOOTING..................................... SR03-2 (MODEL: FM2P)......................................SR03-62
AIR BLEEDING................................................ SR03-3 DATA AND SPECIFICATIONS...................... SR03-62
HYDRAULIC TEST .......................................... SR03-4 DESCRIPTION .............................................. SR03-62
OPERATION.................................................. SR03-63
POWER STEERING GEAR UNIT COMPONENT LOCATOR ............................. SR03-64
(MODELS: FC, FD) ................................... SR03-8 OVERHAUL ................................................... SR03-65
DATA AND SPECIFICATIONS........................ SR03-8
DESCRIPTION ................................................ SR03-8
OPERATION.................................................. SR03-10 OIL RESERVOIR (MODELS: FC, GD) ....SR03-71
SPECIAL TOOL ............................................. SR03-12 DESCRIPTION .............................................. SR03-71
COMPONENT LOCATOR ............................. SR03-12 COMPONENT LOCATOR ............................. SR03-72
OVERHAUL ................................................... SR03-14 OVERHAUL ................................................... SR03-72
INSPECTION AND REPAIR .......................... SR03-17 INSPECTION AND REPAIR .......................... SR03-72
POWER STEERING GEAR UNIT OIL RESERVOIR

(MODELS: GD, FG, GH, FL, FM, SG) .... SR03-18 (MODELS: FD, FG, GH, FL, FM, SG) .....SR03-73
DATA AND SPECIFICATIONS...................... SR03-18 DESCRIPTION .............................................. SR03-73
DESCRIPTION .............................................. SR03-18 COMPONENT LOCATOR ............................. SR03-74
OPERATION.................................................. SR03-20 OVERHAUL ................................................... SR03-75
SPECIAL TOOL ............................................. SR03-22 INSPECTION AND REPAIR .......................... SR03-75
COMPONENT LOCATOR ............................. SR03-24
OVERHAUL ................................................... SR03-27
POWER STEERING PUMP

(MODELS: FC, FD) ................................. SR03-43
DATA AND SPECIFICATIONS...................... SR03-43
DESCRIPTION .............................................. SR03-43
OPERATION.................................................. SR03-44
OVERHAUL ................................................... SR03-47
POWER STEERING PUMP

(MODELS: GD, FG, GH, FL,
FM8J, SG) ............................................... SR03-54
DATA AND SPECIFICATIONS...................... SR03-54
DESCRIPTION .............................................. SR03-54
OPERATION.................................................. SR03-55
OVERHAUL ................................................... SR03-57
2A54AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞ಽ
SR03–2 POWER STEERING
POWER STEERING SYSTEM

TROUBLESHOOTING
EN07Z0703F300001

Fluid leakage Pump Replace pump.
Line joints Replace leaky parts.
Fluid leakage (Gear box) Oil seal, O-rings other than those for Repair oil seal or O-ring.
the seal lock nut and drain plug
Seal lock nut, drain plug Replace lock nut or plug.
Hard steering Steering gear faulty Hydraulic test. Replace piston sub-
(Excessive steering effort) assembly.
(One side is hard)
Hard steering Steering gear pump faulty Hydraulic test.
(Excessive steering effort) Measure pump discharge pressure.
(Both sides are hard) Replace pump.
Incorrect preload of the sector shaft Measure system hydraulic pressure.
bearing Replace piston sub-assembly.
Adjust sector shaft preload.
Hard steering Incorrect preload of the sector shaft Adjust sector shaft preload.
(Excessive steering effort) bearing
(Hard, when starting to steer)
NOTICE
Basic inspection items
• Fluid level, Fluid cleanliness
• Air mixed in fluid
• Tire pressure
• Front alignment
• Steering linkage
• Universal joint
Abnormal noise (Pump) Air sucked in at input pipe Repair and bleed air or replace pump.
NOTICE
Basic inspection items
• Fluid level, fluid cleanliness
• Air mixed in fluid
• Pump piping
• Steering linkage
Abnormal noise Gear box Replace piston sub-assembly.
AIR BLEEDING
EN07Z0703H200001
1. FILL THE OIL RESERVOIR WITH POWER STEERING FLUID.

NOTICE
• Use only specified fluid.
• Do not overfill the oil reservoir.
• Replace old fluid with new fluid after overhauling power
steering gear unit or power steering pump.
• Specified fluid....Refer to recommended lubricant list.
2. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME

WITH STANDS.
NOTICE
Block the rear wheels.
SHTS07Z070300001
3. TURN THE STEERING WHEEL FULLY IN BOTH DIRECTIONS

SEVERAL TIMES.
4. CHECK THE FLUID LEVEL IN THE OIL RESERVOIR.

(1) Add the fluid, if necessary.
SHTS07Z070300002
5. START THE ENGINE AND TURN THE STEERING WHEEL

FULLY IN BOTH DIRECTIONS SEVERAL TIMES WITH
ENGINE IDLING.
NOTICE
The fluid in the oil reservoir should be continuously replenished
while air bleeding so that the oil reservoir never become empty.
6. RETURN THE STEERING WHEEL TO STRAIGHT AHEAD.
SHTS07Z070300003
2A54AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧟ಽ
7. RECHECK THE FLUID LEVEL WHEN THE ENGINE IS

STOPPED.
(1) If necessary, add or decrease the power steering fluid to match
the between "MAX" and "MIN" line.
SHTS07Z070300004
NORMAL
MODELS: EXCEPT FC, GD

SHTS07Z070300005
HYDRAULIC TEST
EN07Z0703H300001
SHTS07Z070300006
HYDRAULIC TEST
1. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME

WITH STANDS.
NOTICE
Block the rear wheels.
SHTS07Z070300001
2. SET THE STOP VALVE AND OIL PRESSURE GAUGE AS

SHOWN IN THE FIGURE.
NOTICE
After setting the stop valve and oil pressure gauge, perform the air
bleeding in the system according to "AIR BLEEDING".
SHTS07Z070300007
3. CHECK THE FLOW CONTROL VALVE OPERATION.

(1) Start the engine and idle then close the stop valve until the fluid
pressure is at 5.0 MPa {51 kgf/cm2,725 Ibf/in.2}.
(2) Run the engine up to 1,500 r/min., then reduce the engine speed
suddenly.
NOTICE
This operation should be repeated more than 5 times.
(3) Good, if the set pressure of 5.0 MPa {51 kgf/cm2, 725 Ibf/in.2} is
recovered immediately.
If the set pressure is not recovered immediately, stop the engine
and replace the flow control valve assembly.
SHTS07Z070300008
(4) Open the stop valve fully.
4. CHECK THE RELIEF VALVE OPERATION.

(1) Run the engine up to 2,000 r/min.
(2) Close the stop valve until the fluid pressure is at "A".
MODEL "A"
FC, FD 13.5 MPa {138 kgf/cm2, 1,963 lbf/in.2}
GD 13.7 MPa {140 kgf/cm2, 1,992 lbf/in.2}
FG, GH, FL, FM, SG 12.8 MPa {131 kgf/cm2, 1,861 lbf/in.2}
NOTICE
Be careful not to exceed "A".
SHTS07Z070300009
(3) Good, if the fluid pressure is maintained at "B".
MODEL "B"
12.7-13.5 MPa
FC, FD
{130-138 kgf/cm2, 1,849-1,963 lbf/in.2}
13.0-13.7 MPa
GD
{133-140 kgf/cm2, 1,890-1,992 lbf/in.2}
12.1-12.8 MPa
FG, GH, FL, FM, SG
{124-131 kgf/cm2, 1,759-1,861 lbf/in.2}
(4) If pressure is higher, stop the engine and replace the flow control
valve assembly.
5. MEASURE THE SYSTEM HYDRAULIC PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Start the engine and idle and then turn the steering wheel to a full
stop.
(3) Apply a force of approx. 147.1 N {15kgf, 33 Ibf} to the steering
wheel and measure the hydraulic pressure.
(4) Repeat the measurement by fully turning the steering wheel in the
opposite direction.
Hydraulic pressure: "B"
(5) If the above pressure is not attained, measure the discharge pres-
sure or stop the engine and repair the power steering gear unit.
SHTS07Z070300010
6. MEASURE THE DISCHARGE PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Start the engine and idle and measure the discharge pressure
with the stop valve fully close.
Discharge Pressure: "B"
NOTICE
Do not allow the stop valve to remain closed for more than 15 sec-
onds.
(3) Open the stop valve fully.
SHTS07Z070300009
7. REMOVE THE STOP VALVE AND OIL PRESSURE GAUGE.

(1) Stop the engine and remove the stop valve and oil pressure
gauge.
NOTICE
After removing stop valve and oil pressure gauge, perform the air
bleeding in according to "AIR BLEEDING".
SHTS07Z070300011
8. INSPECT THE STEERING SYSTEM FOR OPERATION ABIL-

ITY.
(1) Place the front wheels on turn tables then start the engine and
idle.
(2) Check to see that the steering wheel turned smoothly without any
jolts or abnormal resistance, when it is turned fully in both direc-
tions.
(3) Measure the steering wheel turning force.
Turning force: Less than 20 N {2 kgf, 4.41 lbf}
SHTS07Z070300012
POWER STEERING GEAR UNIT (MODELS: FC, FD)

EN07Z0703I200001
Model Integral type power steering
Gear ratio 18.6: 1
Cylinder inside diameter 85 mm {3.346 in.}
DESCRIPTION
EN07Z0703C100001
SHTS07Z070300013
1 Worm ball nut valve assembly 4 Oil seal

2 Sector shaft sub-assembly 5 Adjusting screw
3 Dust cover 6 Adjusting screw lock nut
SHTS07Z070300014
1 Worm ball nut valve assembly 4 Oil seal

2 Sector shaft sub-assembly 5 Adjusting screw
3 Dust cover 6 Adjusting screw lock nut
OPERATION
EN07Z0703C100002
SHTS07Z070300015
SHTS07Z070300016
SPECIAL TOOL
EN07Z0703K100001
Prior to starting a power steering gear unit overhaul, it is necessary to have this special tool.
S0965-01260 PITMAN ARM PULLER
COMPONENT LOCATOR
EN07Z0703D100001
SHTS07Z070300018
1 Worm ball nut valve assembly 6 Pitman arm lock nut

2 Gear housing sub-assembly 7 Adjusting screw lock nut
3 Side cover sub-assembly 8 Dust cover
4 Sector shaft sub-assembly 9 Dust seal
5 Lock washer

A 78.4-117.6 {800-1,200, 58-86} C 73.5-102.9 {750-1,050, 55-75}
B 73.5-102.9 {750-1,050, 55-75}
SHTS07Z070300019
1 Worm ball nut valve assembly 6 Pitman arm lock nut

2 Gear housing sub-assembly 7 Adjusting screw lock nut
3 Side cover sub-assembly 8 Dust cover
4 Sector shaft sub-assembly 9 Dust seal
5 Lock washer

A 78.4-117.6 {800-1,199, 58-86} C 73.5-102.9 {750-1,049, 55-75}
B 73.5-102.9 {750-1,049, 55-75}
OVERHAUL
EN07Z0703H200002
NOTICE
Observe the following instructions before disassembly and
assembly.
1. All functional parts should be clean. Blow dirty parts off with
dry compressed air, then clean them with volatile metal
cleanser. Never use brushes or cloth.
2. Handle rubber parts, seals, etc., in clean condition. Any worn
part should be replaced immediately.
Volatile metal cleanser may attack rubber parts, so they
should never be used. Always use fluid.
3. For disassembling and assembling, only use the specified
fluid.
4. Never use standard tools in place of special tools and when
using the special tools, read the instruction carefully.
1. REMOVE THE PITMAN ARM.

(1) Remove the pitman arm from the sector shaft by using the special
tool, after loosening the lock nut.
SST: Pitman Arm Puller (S0965-01260)
NOTICE
Do not use wedges or hit with a hammer.
SHTS07Z070300020
2. REMOVE THE SIDE COVER ASSEMBLY AND SECTOR SHAFT

SUB-ASSEMBLY.
(1) Loosen the adjusting screw lock nut and then remove the side
cover fitting bolts.
(2) Position the sector shaft so that its gear is in line with the gear
housing opening. Use a plastic hammer to drive out the head of
the sector shaft.
NOTICE
Never use a steel hammer.
(3) Turn the adjusting screw clockwise until it pushes the sector shaft
out of the side cover assembly.
SHTS07Z070300021
3. REMOVE THE WORM BALL NUT VALVE ASSEMBLY.

(1) Remove the valve housing fitting bolts.
SHTS07Z070300197
(2) Turn the worm ball nut valve assembly counterclockwise until it
locks so that valve housing raised from gear housing.
(3) Use a spatula to pry open the valve housing and remove the
worm ball nut valve assembly from gear housing.
SHTS07Z070300023
1. INSTALL THE BALL NUT AND WORM VALVE ASSEMBLY.

(1) Install the O-ring on the ball nut.
NOTICE
Do not allow the ball nut to hit the end of the worm valve assem-
bly.
2. INSTALL THE BALL NUT ASSEMBLY.

(1) Apply the power steering fluid to inside surface of gear housing.
(2) Insert the ball nut assembly into the gear housing.
SHTS07Z070300024
(3) Tighten the valve housing fitting bolts.
SHTS07Z070300025
3. INSTALL THE SECTOR SHAFT ASSEMBLY.

(1) Insert the sector shaft into the side cover assembly then turn the
adjusting screw counterclockwise until the sector shaft contacts
with side cover assembly.
SHTS07Z070300026
(2) Align the center of the ball nut tooth and sector shaft center tooth
then install the sector shaft assembly.
NOTICE
Apply fluid to the serrated part of the sector shaft so that the
housing oil seal will not be damaged.
(3) Tighten the side cover fitting bolt.
(4) Install the adjusting screw lock nut temporary.
(5) Turn the adjusting screw clockwise until the sector shaft tooth
contact with ball nut tooth then hold the adjusting screw lock nut.
SHTS07Z070300027
(6) Turn the adjusting screw counterclockwise fully once then lock
the adjusting screw lock nut.
SHTS07Z070300028
4. MEASURE THE SECTOR SHAFT BACKLASH.

(1) Align the marks on the sector shaft with pitman arm.
(2) Install the pitman arm and tighten the nut finger tight.
(3) Use a dial gauge to check to see that the sector shaft backlash in
neutral position.
L Backlash
RHD model 197 mm {7.76 in.} 0.04-0.20 mm
LHD model 194 mm {7.64 in.} {0.0016-0.0078 in.}
(4) If measurement is not within specification, readjust the backlash

SHTS07Z070300029
with adjusting screw.
5. INSPECT THE WORM VALVE ASSEMBLY ROTATION CONDI-

TION.
(1) Check to see that the worm valve assembly rotates smoothly
without any shocks, abnormal resistance, noise and drag, when
the worm valve assembly rotates full lock in both direction.
6. TIGHTEN THE PITMAN ARM LOCK NUT.
SHTS07Z070300030

EN07Z0703H300002
Unit: mm {in.}
Gear housing — — Replace gear Visual check

sub-assembly: housing sub-
Wear, damage and bearing assembly,
damage if necessary.
Side cover sub-assembly: — — Replace side Visual check

Bearing damage cover sub-
assembly,
if necessary.
O-ring and oil seal: — — Replace, Visual check

Sector shaft — — Replace sector Use the magnetic flow

sub-assembly: shaft sub- detector or color checking
Teeth wear and damage, assembly, instrument
serration damage and if necessary.
adjusting screw thread
damage
Measure the sector shaft — 0.03 Replace sector Measure

adjusting screw end play {0.001} shaft sub-
assembly.
POWER STEERING GEAR UNIT

(MODELS: GD, FG, GH, FL, FM, SG)
EN07Z0703I200002
Type Integral type power steering
GD 19.05: 1
Gear ratio Models:
FG, GH, FL, FM, SG 20.2: 1
GD 90 mm {3.543 in.}
Cylinder inside diameter Models:
FG, GH, FL, FM, SG 100 mm {3.937 in.}
DESCRIPTION
EN07Z0703C100003
4 3 2 1
10 9 8 7 6
SHTS07Z070300035
1 Valve housing assembly 5 Sector shaft 9 Adjusting screw

2 Worm valve assembly 6 Dust cover 10 Adjusting screw lock nut
3 Steel ball 7 Needle roller bearing
4 Ball nut assembly 8 Oil seal
4 3 2 1
6 7 8 9 10
SHTS07Z070300036
1 Valve housing assembly 5 Sector shaft 9 Adjusting screw

2 Worm valve assembly 6 Dust cover 10 Adjusting screw lock nut
3 Steel ball 7 Needle roller bearing
4 Ball nut assembly 8 Oil seal
OPERATION
EN07Z0703C100004
SHTS07Z070300037
SHTS07Z070300038
SPECIAL TOOL
EN07Z0703K100002
Prior to starting a power steering gear unit overhaul, it is necessary to have the following special tools.
Tool and accessory set: S0903-04180
TOOL ASSEMBLY
S0965-71870
• For 85 mm {3.346 in.}
• For 90-110 mm
{3.544-4.330 in.}
(Used together with tool assem-
bly)
S0965-91400 ATTACHMENT ASSEMBLY
S0960-31560 WRENCH ASSEMBLY
INSERTER ASSEMBLY
A:
For 40 mm {1.575 in.}
S0965-71860
For 45 mm {1.772 in.}
For 48 mm {1.890 in.}
For 53 mm {2.087 in.}
For 58 mm {2.283 in.}
(Used together with inserter
assembly)
A
S0965-91410 PRESS FITTER
S0969-91360 NEEDLE
S0965-71840 INSERTER
S0969-41020 CAULKING TOOL
S0965-71850 INSERTER
S0971-21130 BAR
COMPONENT LOCATOR
EN07Z0703D100002

1
A
2
6
B
8
7
7
7
9
10 C
9
11
7
12
3
17
13
14
E 18 15
22 16
19 D
17 13 14 20
7
21
F
SHTS07Z070300049
1 Dust cover 12 Tube clip

2 Plug and seal assembly 13 Back-up ring
3 Oil seal 14 Y-packing
4 Ball bearing 15 Steering body
5 Bearing cage and steel ball 16 Tapered plug
6 Worm shaft assembly 17 Needle roller bearing
7 O-ring 18 Sector shaft
8 Valve housing 19 Adjusting screw
9 Seal ring 20 Retainer
10 Power piston (Ball nut) 21 Side cover
11 Ball tube 22 Lock nut

A 226-245 {2,300-2,500, 167-180} D 8.9-12.7 {90-130, 6.5-9.4}
B 117.7-127.5 {1,200-1,300, 87-94} E 117.7-127.5 {1,200-1,300, 87-94}
C 4.41-5.39 {45-55, 3.2-3.9} F 73.6-83.4 {750-850, 55-61}

1
A
2
7
8
7 7
7
9
C 10
9
11
7
12
3 17
13
14
15 18 E
16 22
19
D
20 14 13 17
7
21
F
SHTS07Z070300050
1 Dust cover 12 Tube clip

2 Plug and seal assembly 13 Back-up ring
3 Oil seal 14 Y-packing
4 Ball bearing 15 Steering body
5 Bearing cage and steel ball 16 Tapered plug
6 Worm shaft assembly 17 Needle roller bearing
7 O-ring 18 Sector shaft
8 Valve housing 19 Adjusting screw
9 Seal ring 20 Retainer
10 Power piston (Ball nut) 21 Side cover
11 Ball tube 22 Lock nut

A 226-245 {2,300-2,500, 167-180} D 8.9-12.7 {90-130, 6.5-9.4}
B 98.1-107.9 {1,000-1,100, 73-79} (GD) E 117.7-127.5 {1,200-1,300, 87-94}
117.7-127.5 {1,200-1,300, 87-94} (FG, GH, FM) F 49.1-53.9 {500-550, 36-40} (GD)
C 4.41-5.39 {45-55, 3.2-3.9} 73.6-83.4 {750-850, 55-61} (FG, GH, FM)
OVERHAUL
EN07Z0703H200003
NOTICE
Observe the following instructions before disassembly and
assembly.
1. All functional parts should be clean. Blow dirty parts off with
dry compressed air, then clean them with volatile metal
cleanser. Never use brushes or cloth.
2. Handle rubber parts, seals, etc., in clean condition. Any worn
part should be replaced immediately.
Volatile metal cleanser may attack rubber parts, so they
should never be used. Always use fluid.
3. For disassembling and assembling, only use the specified
fluid.
4. Never use standard tools in place of special tools and when
using the special tools, read the instruction carefully.
1. BEFORE DISASSEMBLY, SECURE THE POWER STEERING IN

A VISE.
SHTS07Z070300051
2. REMOVE THE SIDE COVER ASSEMBLY AND SECTOR

SHAFT.
(1) Loosen and remove the nut fixing the adjusting screw to the side
cover.
BOLT
(2) Remove the eight bolts and washers fitting the side cover to the
steering body.
NUT
SHTS07Z070300052
(3) Confirm that the power piston is located in the center, and then
gently tap the output end of the sector shaft with a plastic (or
wooden) hammer to remove the sector shaft assembly and the
side cover together from the steering body.
NOTICE
Never use a steel hammer when removing the sector shaft (as the
PLASTIC HAMMER threads will be damaged).
SHTS07Z070300053
(4) Turn the adjusting screw clockwise using a screwdriver to raise

and separate the side cover assembly from the sector shaft
SCREWDRIVER assembly.
ADJUSTING SCREW
SIDE COVER NOTICE
• Do not secure the sector shaft directly in a vise.
• Always use a cloth etc. to protect the sector shaft.
SECTOR SHAFT
SHTS07Z070300054
(5) Remove the O-ring from the groove around the outside of the side
BACK-UP RING cover using the special tool. Then remove the Y-packing from
behind the needle roller bearing and the back-up ring using the
Y-PACKING special tool.
NOTICE
O-RING
It is not necessary to remove the needle bearing unless it is dam-
aged.
SIDE COVER SST: Needle (S0969-91360)
SHTS07Z070300055
3. REMOVE THE VALVE HOUSING AND BALL NUT ASSEMBLY.

(1) Remove the dust cover from the valve housing.
WRENCH ASSEMBLY
(2) Loosen the plug and seal assembly in the valve housing section
using the special tool. At this time, only back off the plug and seal
assembly 180°. Do not remove it.
NOTICE
If the plug and seal assembly is removed, the steel balls (bearing)
in the valve housing may spring out.
SST: Wrench assembly (S0960-31560)
SHTS07Z070300056
(3) Remove the bolts to remove the worm shaft assembly and valve
housing assembly from the steering body.
NOTICE
• Do not damage the internal surface of the steering body
when removing the worm shaft assembly and valve housing
assembly.
• Do not let the steel balls spring out.
• Never damage the power piston.
BOLT
SHTS07Z070300057
4. REMOVE THE ADJUSTING SCREW AND SECTOR SHAFT.

(1) Uncaulk the retainer at two caulked positions.
NOTICE
RETAINER
• Do not disassemble the sector shaft assembly unless it is
damaged.
SECTOR
SHAFT • Do not secure the sector shaft directly in a vise. Always use a
cloth etc. to protect the sector shaft.
SHTS07Z070300058
(2) Remove the retainer using the special tool. Remove the adjusting
RETAINER screw at the same time.
BAR SST: Bar (S0971-21130)
ADJUSTING SCREW
SHTS07Z070300059
5. REMOVE THE WORM SHAFT ASSEMBLY, VALVE HOUSING

STUB SHAFT AND POWER PISTON ASSEMBLY.
(1) Place the assembly on the work bench with the power piston side
VALVE
down. Turn the stub shaft while holding the valve housing, and
HOUSING remove the worm shaft from the power piston.
(2) Let the steel balls assembled in the power piston and ball race of
the worm shaft drop into the power piston.
WORM SHAFT POWER PISTON
NOTICE
Do not tilt the piston as it contains the steel balls. Do not lose the
steel balls.
SHTS07Z070300060
(3) Secure the special tool in a vise.

SST: Attachment assembly (S0965-91400)
WRENCH (4) Remove the O-rings fitted on the contact surfaces of the steering
ASSEMBLY
ATTACHMENT body of the valve housing.
ASSEMBLY (5) Attach the valve housing to the attachment assembly, and
remove the previously loosened plug and seal assembly.
SST: Wrench assembly (S0960-31560)
SHTS07Z070300061
(6) Remove the ball bearing and oil seal from the plug and seal
BEARING assembly.
OIL SEAL
PLUG AND
SEAL ASSEMBLY
SHTS07Z070300062
6. REMOVE THE WORM SHAFT ASSEMBLY AND VALVE HOUS-

VALVE HOUSING ING.
(1) Prepare a plastic box, etc. Hold the valve housing over the box
BEARING CAGE
and remove the worm shaft assembly by pushing it from the
STEEL BALLS power piston side as shown in figure. The side race, steel balls,
SIDE RACE
and bearing cage will come apart and fall into the box.
NOTICE
• Do not lose any steel balls.
• If only one side race and/or steel ball is lost, the worm shaft
and valve housing assembly must be replaced.
Number of the steel balls: 18 pieces.
SHTS07Z070300063
(2) Remove the rotor from the worm shaft assembly, and then
remove the seal ring from the rotor using the special tool.
SEAL RING SST: Needle (S0969-91360)
ROTOR
SHTS07Z070300064
(3) Remove the three seal rings and three O-rings from the valve
SEAL RING (3) housing using the special tool.
SST: Needle (S0969-91360)
O-RING (3)
VALVE HOUSING
SHTS07Z070300065
7. REMOVE THE POWER PISTON.

BALL TUBE SCREW (1) Place the piston's steel balls in a separate container.
WASHER (2) Loosen the screw of the tube clip securing the ball tube using a
PISTON wrench. Remove the ball tube from the power piston by pinching it
CLIP with your fingers and shaking it.
NOTICE
• Never insert a screwdriver etc., between the ball tube and the
piston to pry them apart.
• Check for any steel balls remaining in the ball tube.
Number of the steel balls: 32 pieces.
SHTS07Z070300066
(3) Remove the seal ring and O-ring from the power piston using the
PISTON
special tool.
SEAL RING SST: Needle (S0969-91360)
O-RING
SHTS07Z070300067
8. REMOVE THE STEERING BODY.

OIL SEAL (1) Remove the oil seal, back-up ring, and Y-packing from the section
BACK-UP RING of the steering body contacting the sector shaft.
Y-PACKING
NOTICE
STEERING BODY
Do not remove the needle roller bearing and tapered plug unless
they are damaged.
SHTS07Z070300068

RETAINER 1. INSTALL THE SECTOR SHAFT.
(1) Secure the sector shaft in a vise while protecting the geared base
BAR
of the shaft with a rag.
ADJUSTING
SCREW
(2) Fill the assembly with grease through the adjusting screw hole.
Then, insert the adjusting screw, and fix the retainer using the
special tool.
SST: Bar (S0971-21130)
SHTS07Z070300069
NOTICE
How to tighten the retainer; After fully tightening, back off the
CAULKING TOOL
retainer 180° and then, after retightening it to 4 kgf⋅m, back it off
20°. Ensure the adjusting screw rotates smoothly.
(3) After tightening the retainer, securely caulk it at two positions

using the special tool.
SST: Caulking tool (S0969-41020)
SHTS07Z070300070
2. INSTALL THE SIDE COVER.

O-RING (1) Insert the Y-packing and back-up ring in the bottom of the needle
BACK-UP RING
roller bearing press fitted inside the side cover.
NOTICE
Y-PACKING
• The back-up ring can be assembled easily if inserted by
pinching it with the fingers.
SIDE COVER • After filling the groove with grease, assemble the Y-packing
so that the lip faces to the needle roller bearing side.
SHTS07Z070300071
(2) Form the back-up ring using the special tool.

SST: Inserter assembly (S0965-71860)
NOTICE
INSERTER ASSEMBLY There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 48 mm {1.890 in.}.
INSERTER
SIDE COVER
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SHTS07Z070300072
48 {1.890}
53 {2.087}
58 {2.283}
3. INSTALL THE VALVE HOUSING.

O-RING (1) Insert an O-ring and a seal ring into each of the three narrower
grooves of the five grooves in the valve housing.
(2) Then, form the seal ring using the special tool.
INSERTER
SST: Inserter (S0965-71850)
SEAL RING
SHTS07Z070300073
4. INSTALL THE PLUG AND SEAL ASSEMBLY.

(1) Press fit the oil seal into the inside of the plug and seal assembly
HAND PRESS
using the special tool.
OIL SEAL NOTICE
PRESS FITTER Always use a hand press when press fitting the oil seal.
PLUG SST: Press fitter (S0965-91410)
SHTS07Z070300074
(2) Apply grease to the oil seal and then install the ball bearing.
OIL SEAL
GREASE
SHTS07Z070300075
5. INSTALL THE WORM SHAFT AND THE VALVE HOUSING.

(1) Form the seal ring using the special tool after assembling the seal
INSERTER ring in the outer groove of the rotor.
SEAL RING
ROTOR
SHTS07Z070300076
(2) Insert the rotor between the stub shaft and the worm shaft. At this
ROTOR time, assemble it so that the straight pin in the bottom fits in the
rotor notch.
ROTOR NOTCH
WORM SHAFT STRAIGHT PIN
SHTS07Z070300077
(3) Fit the guide into the special tool and insert the previously assem-
bled worm shaft assembly into the guide with the input side down.
SST: Tool assembly (S0965-71870)
WORM SHAFT
BEARING CAGE NOTICE
GUIDE
There are two kinds of guide as below, and install worm shaft
STEEL BALL
assembly using the guide for power piston diameter 90-110 mm
TOOL {3.544-4.330 in.}.
ASSEMBLY
Unit: mm {in.}
POWER PISTON DIAMETER
SHTS07Z070300078
85 {3.346}
90-110 {3.544-4.330}
(4) Install the race of bearing side (one side), the bearing cage and
the steel balls, and allow the tool assembly to slide down and set
the balls in position.
(5) Remove the guide and fit the other side race.
SIDE RACE
SIDE RACE
BEARING CAGE
STEEL BALL
SHTS07Z070300079
(6) Assemble the valve housing to the worm shaft assembly and pre-
viously assembled bearing sub-assembly by inserting it from the
worm shaft side.
NOTICE
VALVE HOUSING
• When fitting the valve housing, do not damage the seal ring
in the valve housing.
• Inserter (S0965-71850) can be used to form the seal rings of
the valve housing part.
SHTS07Z070300080
(7) Secure the special tool in a vise.

PLUG AND SECTION OF SST: Attachment assembly (S0965-91400)
SEAL ASSEMBLY WITH LIQUID
GASKET IS (8) Fit the previously assembled worm shaft assembly and valve
O-RING APPLIED housing onto the attachment assembly, place the O-ring in the
(SEE NOTE)
inner groove of the valve housing, and screw the plug and seal
assembly into the valve housing.
NOTICE
• Apply liquid gasket (equivalent to ThreeBond 1102) to the
ATTACHMENT
ASSEMBLY screw section of the plug and seal assembly.
• The O-ring must not be fitted in the thread escape groove of
SHTS07Z070300081 the valve housing.
• When assembling the plug and seal assembly, do not let the
stub shaft serration damage the oil seal.
(9) Tighten the plug and seal assembly using the special tool.
LOOSEN THE PLUG SST: Wrench assembly (S0960-31560)
AND SEAL ASSEMBLY
BY 180 FOR STUB SHAFT
SUBSEQUENT WORK NOTICE
Check that the stub shaft rotates smoothly and uniformly while
holding the valve housing.
(10) Loosen the plug and seal assembly by approx 180°.
SHTS07Z070300082
(11) Install O-rings in the groove around the outside of the valve hous-
ing and in the oil port recess.
NOTICE
Do not twist the O-rings.
O-RING
O-RING
SHTS07Z070300083
6. INSTALL THE POWER PISTON.

(1) Fit the O-ring and seal ring in the groove around the outside of the
power piston and form the seal ring using the special tool.
O-RING NOTICE
INSERTER SEAL RING Do not twist the O-ring or stretch the seal ring.
PISTON
SHTS07Z070300084
(2) Place the power piston on the bench.

(3) Fill the ball tube with grease, lay 10-11 steel balls in the tube, and
BALL TUBE place the other side of the ball tube on top.
NOTICE
Never fix the piston in a vise.
STEEL BALL
SHTS07Z070300085
(4) Insert the worm shaft and valve housing assembly in the center
PUNCH STEEL BALL hole of the power piston, align the power piston and worm shaft
STUB SHAFT ball races, and drop the remaining steel balls one by one through
PISTON the piston's ball tube hole.
NOTICE
• Drop the steel balls while turning the stub shaft to facilitate
assembly.
• Steel balls sometimes come out of the hole on the other side
of the ball tube after a certain number are inserted. Plug the
hole with a punch to prevent the steel balls from coming out.
• When installing the steel balls, the worm shaft and valve
SHTS07Z070300086 housing assembly must not be drawn out to its extreme posi-
tion, as the steel balls may drop outside the ball race.
(5) After inserting the steel balls in the power piston, insert the ball
BALL TUBE tube into the power piston and fix it using the clip, washer, and
screw.
NOTICE
Always push in the ball tube by hand. Never force or strike it. If
forced or struck, the ball tube may be deformed, the edge may be
nipped, or otherwise damaged, causing malfunctions.
(6) Tighten the screw to the specified torque.
CLIP
SHTS07Z070300087
(7) Measure the axial play between the power piston and the worm
B (AXIAL PLAY) shaft assembly.
2 mm (0.079 in.) A (point of application) 20 mm {0.787 in.}

F (force) 5 kg
B (axial play) 0.5 mm {0.0197 in.} or less
A
NEUTRAL POSITION F
SHTS07Z070300088
7. INSTALL THE STEERING BODY.

(1) Fit the Y-packing and back-up ring in the groove in front of the
Y-PACKING BACK-UP RING needle roller bearing (in the hole for the steering body output
shaft).
NOTICE
• Back-up ring installation is facilitated by pinching the ring
with the fingers as shown in figure.
• After filling the groove with grease, assemble the Y-packing
so that the lip faces to the needle roller bearing.
STEERING BODY
SHTS07Z070300089
(2) Form the back-up ring using the special tool.

INSERTER ASSEMBLY
NOTICE
INSERTER There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 58 mm {2.283 in.}.
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SHTS07Z070300090
48 {1.890}
53 {2.087}
58 {2.283}
(3) Press fit the oil seal into the steering body using the special tool.
INSERTER ASSEMBLY
(4) Fill the oil seal with grease.

OIL SEAL
SHTS07Z070300091
8. INSTALL THE VALVE HOUSING AND BALL NUT ASSEMBLY.

STEERING BODY
(1) Secure the steering body in the vise.
PISTON (2) Fit the worm shaft and valve housing assembly by inserting it into
the steering body with the power piston gear placed on the side of
the sector shaft. Hold the power piston lightly by hand so that it
does not rotate.
NOTICE
• When inserting the worm shaft and valve housing assembly,
do not damage the piston seal ring.
• Be careful that the O-ring does not fall out.
SHTS07Z070300092
(3) Align the steering body and valve housing oil passage holes and
tighten the bolt to the specified torque.
NOTICE
Insert a bar into the bolt hole to align the body and housing oil
passage holes. Prevent housing rotation to prevent the O-ring
from being cut or dislodged.
SHTS07Z070300200
(4) Tighten the plug and seal assembly (which was previously loos-
ened through 180°) to the specified torque using the wrench
assembly.
WRENCH ASSEMBLY SST: Wrench assembly (S0960-31560)
NOTICE
After applying a thin and uniform coat of liquid gasket to 3-5 whole
threads of the screw part of the plug and seal assembly and tight-
ening it with the indicated torque, apply turning stopper punches
every 180°.
SHTS07Z070300201
Liquid gasket: Equivalent to ThreeBond 1102
(5) Attach the dust cover to the valve housing.
DUST COVER
NUT
SHTS07Z070300202
9. INSTALL THE SIDE COVER ASSEMBLY AND SECTOR

SHAFT.
SCREWDRIVER ADJUSTING SCREW (1) Assemble the side cover assembly to the sector shaft assembly
SIDE COVER by aligning the screw hole in the center of the side cover with the
adjusting screw and turning the adjusting screw.
Install the O-ring around the outside of the side cover.
SECTOR SHAFT
SHTS07Z070300203
(2) Insert the sector shaft into the steering body so that its gear and
the power piston gear engage in the center.
NOTICE
When inserting the sector shaft, do not let the sector shaft serra-
tion damage the lip of the Y-packing. Damage may affect oil tight-
ness.
SHTS07Z070300204
(3) Assemble the side cover to the steering body using the bolts.
STEERING BODY Tighten them to the specified torque.
SIDE COVER
SHTS07Z070300205
10. MEAUSURE THE WORM VALVE ASSEMBLY TURNING

TORQUE. (MODEL: GD)
TURNING TORQUE
Assembly standard: Unit: N⋅m {kgf⋅cm, Ibf⋅ft}
A B
Less than 0.1-0.39
B
0.98 {10, 0.73} {1-4, 0.07-0.29}
A
NEUTRAL
POSITION
SHTS07Z070300206
NOTICE
If measurement is not within specification, readjust the backlash
SHTS07Z070300100
11. MEASURE THE SECTOR SHAFT BACKLASH. (MODELS: GD,

FG, GH, FL, FM, SG)
(1) Align the marks on the sector shaft with pitman arm.
(2) Install the pitman arm and tighten the nut finger-tight.
SHTS07Z070300101
(3) Use a dial gauge to check to see that the sector shaft backlash in
neutral position.
Model L Backlash
GD 226 mm {8.90 in.} 0.05-0.25 mm
FG, GH, FL, FM, SG 270 mm {10.63 in.} {0.002-0.009 in.}
(4) If measurement is not within specification, readjust the backlash

SHTS07Z070300102
12. INSPECT THE WORM VALVE ASSEMBLY ROTATING CONDI-

TION.
(1) Check to see that the worm valve assembly rotate smoothly with-
out any shocks, abnormal resistance, noise and drag, when the
worm valve assembly rotates full lock in both direction.
13. TIGHTEN THE PITMAN ARM LOCK NUT.
SHTS07Z070300103

EN07Z0703H300003
METALLIC PARTS
Inspection item Location Remedy
Steering body • The internal surface of the cyl- Repair or replace the steering body if there is evi-
inder dence of abrasion or stepped wear. Check visu-
ally and by touch for any flaws that may affect
smooth piston stroke.
• Side cover assembly surface Repair or replace the steering body if there is evi-
dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).
• Y-packing groove in the sector Repair or replace the steering body if there is evi-
shaft hole dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).
Sector shaft • Gear Replace the gear if it is severely flawed or worn.

Chipped gears must also be replaced. (Check
visually and by touch)
• Gear shaft and serrations Check for cracks using magnetic-particle test
equipment and a color penetration test. Replace
any cracked parts.
• Needle roller bearing contact Check for wear, flaws or gouging (visually and by
surface touch). Repair or replace if necessary.
• Y-packing contact surface Repair or replace if any flaws, rust or gouging

affecting oil tightness are found (check visually
and by touch).
• Adjusting screw Measure the axial clearance of the adjusting

screw with a dial gauge.
0.01-0.1 mm is acceptable, but if excessive, the
screw must be disassembled for inspection. Also
check whether the adjusting screw rotates
smoothly. If not, the screw must be disassembled
and inspected.
Power piston • Cylinder contact surface Any wear or abrasion that affects smooth piston
stroke must be corrected, or the power piston
must be replaced.
• Rack gear Replace the rack gear if severely flawed, worn or

chipped.
• Steel ball race surface Any wear or flaw that disturbs smooth rotation
and movement of steel balls must be corrected,
or the race must be replaced. (Visual inspection)
• Seal ring and O-ring Replace the seal ring or O-ring if any flaws or
tears affecting oil tightness are found.
Ball tube • Steel ball rotation surface Replace the ball tube if any wear, flaws or goug-
ing that affect smooth ball rotation are found on
the inside at the tube.
• Tang (end) Replace the ball tube if any warping, bending,

flaws or pits that affect smooth ball rotation are
found on the tang.
Inspection item Location Remedy
Worm shaft • Steel ball race surface Repair or replace the race if any wear, flaws or
(stub shaft) pits that affect smooth ball rotation are found.
• Seal ring Any wear, flaw, or gouge affecting oil tightness

must be corrected or the seal ring must be
replaced.
• Y-packing contact surface Any wear, flaw, rust, or gouge which may affect
oil tightness must be corrected or the packing
must be replaced.
• Thrust bearing (steel ball) con- Check the bearing for wear, flaws or pits if shaft
tact surface rotation is stiff or uneven. Repair or replace if
found.
Thrust bearing • Bearing race and steel ball Check the bearing for wear, flaws or pits if shaft
(steel ball) rotation is stiff or uneven. Repair or replace if
and bearing cage found.
• Bearing cage Replace the cage if any flaws or damage affecting

smooth rotation are found.
Rotor • External surface Repair or replace the rotor if any wear, flaws or
gouging affecting smooth rotation are found.
• Chamber Replace the chamber if any flaws, breaks, or

chips affecting steering characteristics are
found.
• Seal ring groove Replace the seal ring if any flaws or tears affect-
ing oil tightness are found.
Side cover • Steering body contact surface Repair or replace the side cover if any flaws,
gouging or rust affecting oil tightness are found.
• Y-packing groove Repair or replace the side cover if any flaws,

• O-ring groove Repair or replace the side cover if any flaws,

Plug and seal • Thrust bearing side race con- Repair or replace the plug and seal assembly if
assembly tact surface any flaws, rust or gouging affecting uniform tight-
ening are found.
• Y-packing press fitted section Replace the plug and seal assembly if any flaws,
rust or gouging affecting oil tightness are found.
• O-ring contact surface Replace the plug and assembly if any flaws, rust
or gouging affecting oil tightness are found.
Bearings Check that the bearing rotates smoothly. Replace

the bearing if rotation is stiff or uneven.
POWER STEERING PUMP (MODELS: FC, FD)

EN07Z0703I200003
Type Vane type
Speed range 500-6,000 r/min.
Relief pressure 12.7-13.5 MPa {130-138 kgf/cm2, 1,849-1,963 lbf/in.2}
Flow rate 11-13 L/min. {2.91-3.42 U.S.gal., 2.42-2.85 lmp.gal.} at 1,000 r/min.
DESCRIPTION
EN07Z0703C100005
SHTS07Z070300104
1 Drive gear 7 Spring seat

2 Retainer ring 8 Side plate
3 Ball bearing 9 Pump shaft
4 Pump body 10 Retainer ring
5 Retainer ring 11 Thrust plate
6 Oil seal
OPERATION
EN07Z0703C100006
SHTS07Z070300105
1 Oil reservoir 5 Flow control valve assembly

2 Vane 6 Relief valve
3 Cam ring A To power steering gear unit
4 Rotor B From power steering gear unit
COMPONENT LOCATOR
EN07Z0703D100003
SHTS07Z070300106
1 Oil hose 4 Power steering pump

2 Power steering pipe 5 Suction hose
3 O-ring

A 56 {575, 47} B 47 {480, 35}
SHTS07Z070300107
1 Retainer ring 12 Oil seal

2 O-ring 13 Pump body
3 Thrust plate 14 Retainer ring
4 Dowel 15 Ball bearing
5 Rotor 16 Retainer ring
6 Vane 17 Pump shaft
7 Cam ring 18 Drive gear
8 Side plate 19 Spring
9 O-ring 20 Flow control valve assembly
10 O-ring 21 O-ring
11 Spring seat 22 Orifice

A 59-78 {602-795, 44-57}
OVERHAUL
EN07Z0703H200004
1. REMOVE THE FLOW CONTROL VALVE ASSEMBLY.

(1) Remove the orifice and flow control valve assembly.
NOTICE
Be careful not to drop, scratch of nick the flow control valve
assembly.
SHTS07Z070300108
2. REMOVE THE THRUST PLATE, ROTOR, VANES, CAM RING

AND SIDE PLATE.
(1) Using a press, lightly push in the thrust plate.
NOTICE
The push-in amount shall be the compression amount of the
spring seat and no more.
(2) Using two pieces of screw drivers, remove the retainer ring.
SHTS07Z070300109
(3) Temporarily install the orifice.

(4) Close the suction port with a finger, using an air gun, apply air
pressure from the pressure feed port and remove the thrust plate.
NOTICE
As oil flow out, cover the power steering pump with rags before-
hand.
(5) Remove the rotor, vane, cam ring and dowel from the pump body.
SHTS07Z070300110
(6) Lightly tap the pump body on the wooden block and remove the
side plate and spring seat.
SHTS07Z070300111
3. REMOVE THE PUMP SHAFT WITH DRIVE GEAR AND BALL

BEARING.
(1) Using a screw driver, remove the retainer ring.
NOTICE
Do not tighten vise too tight when clamping the pump in vise.
SHTS07Z070300208
(2) Using a press, press out the pump shaft with drive gear and ball
bearing.
SHTS07Z070300113
IMPORTANT POINTS - REPLACEMENT
1. REPLACE THE BALL BEARING, DRIVE GEAR AND PUMP

SHAFT.
(1) Using a suitable tool and press, press out the pump shaft from the
drive gear.
SHTS07Z070300114
(2) Using a retainer ring pliers, remove the retainer ring from the
pump shaft.
(3) Using a press, press out the ball bearing.
SHTS07Z070300115
(4) Using a press, press the pump shaft into the ball bearing.
Press fit dimension: 21.4-21.7 mm {0.8426-0.8543 in.}
NOTICE
Install the ball bearing with the blue oil seal facing outside of the
pump.
(5) Install the retainer ring.
NOTICE
Make sure that the retainer ring seats in place.
SHTS07Z070300116
(6) Using a press, press the pump shaft into the drive gear.
NOTICE
• Bring the pump shaft flush with the drive gear.
• Take care to prevent tilt of the pump shaft.
SHTS07Z070300117
2. REPLACE THE OIL SEAL.

(1) Using a suitable tapping rod and a hammer, remove the oil seal
from the pump body.
NOTICE
Do not scrape or damage the inside of pump body.
SHTS07Z070300118
(2) Using a suitable rod and a press, press the oil seal into the pump
body.
Press fit depth: 3.6-3.9 mm {0.1418-0.1535 in.}
NOTICE
• Make sure that oil seal is installed in the correct direction.
• To prevent oil leakage from oil seal due to lip wear, apply lith-
ium base grease to "A" and "B".
SHTS07Z070300119
SHTS07Z070300120
1. INSTALL THE PUMP SHAFT WITH DRIVE GEAR AND BALL

BEARING.
(1) Press the pump shaft with drive gear and ball bearing into the
pump body.
NOTICE
Apply grease to the pump shaft before installing.
SHTS07Z070300121
2. INSTALL THE SPRING SEAT AND SIDE PLATE.

(1) Install the two pieces of spring seats.
(2) Coat the O-ring with power steering fluid and install them to the
side plate.
(3) Align the projection of the side plate with the recess of the pump
body, then install the side plate into the pump body.
SHTS07Z070300122
3. INSTALL THE DOWELS TO THE SIDE PLATE.
4. INSTALL THE CAM RING.

(1) Install the cam ring with the inscribed marks facing downward
(side plate side).
SHTS07Z070300123
5. INSTALL THE ROTOR AND VANE.

(1) Install the rotor into the pump shaft.
(2) Install the vanes with the round end facing outward.
SHTS07Z070300124
6. INSTALL THE THRUST PLATE.

(1) Coat the O-ring with power steering fluid and install it to the thrust
plate.
(2) Install the thrust plate into the pump body.
(3) Using a press, push in the thrust plate, then install the retainer
ring to the pump body.
NOTICE
The push in amount shall be the compression amount of the
spring seat and no more.
SHTS07Z070300125
7. INSTALL THE FLOW CONTROL VALVE ASSEMBLY.

(1) Apply power steering fluid to the flow control valve and check that
it falls smoothly into valve hole by its own weight.
NOTICE
There are four different valves in diameter, therefore be careful
that the mark on both valve and pump body are always matched.
INSCRIBED MARK PART NUMBER

A 44330-2310
B 44330-2320
SHTS07Z070300126 C 44330-2330
D 44330-2340
8. INSPECT THE POWER STEERING PUMP.

(1) Confirm that the shaft rotates smoothly and that there is no abnor-
mal noise.
(2) Using a hexagon socket wrench, check the rotation torque of the
pump shaft.
Standard: 0.27 N⋅m or less {2.8 kgf⋅cm, 0.2 lbf⋅ft} (during rota-
tion)
SHTS07Z070300127

EN07Z0703H300004
Unit: mm {in.}
Oil seal: — — Replace, Visual check

Cam ring inner surface, — — Replace, Visual check

Rotor surface, Vanes: if necessary.
Wear, scratches
and scoring
Side plate: — — Replace, Visual check

Abrasions and flaws if necessary.
Flow control valve assem- — — Replace, Visual check

bly: if necessary.
Wear and damage
Pump shaft bearing: — — Replace, Visual check

Scratched and damage if necessary.
Clearance between pump 0.020-0.087 0.087 Replace pump Measure

shaft and thrust plate {0.0008-0.0034} {0.0034} shaft and thrust
or more plate.
Vane: Wear Height: — Replace rotor Measure

9.2-9.5 and vane with
{0.3623-0.3740} cam ring.
Thickness:
1.965-1.972
{0.0774-0.0776}
Length:
15.953-15.973
{0.6281-0.6288}
2A54AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧡ಽ
Clearance between rotor 0.015-0.030 0.03 Replace rotor Measure

groove and vane {0.0006-0.0011} {0.0012} and vane with
or more cam ring.
Flow control valve: — — Replace flow Measure

leakage control valve
(Apply compressed air: assembly.
392-490 kPa {4-5 kgf/cm2,
57-71 lbf/in.2})
Flow control valve 33.4-38.0 — Replace com- Measure

compression spring: {1.3150-1.4960} pression spring.
Free length
2A54AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧡ಽ
POWER STEERING PUMP

(MODELS: GD, FG, GH, FL, FM8J, SG)
EN07Z0703I200004
Type Vane type
Speed GD 715-4,901 r/min.

Model:
range FG, GH, FL, FM, SG 715-5,239 r/min.
Relief GD 13.0-13.7 MPa {133-139 kgf/cm2, 1,886-1,987 lbf/in.2}

Model:
pressure FG, GH, FL, FM, SG 12.1-12.8 MPa {123-130 kgf/cm2, 1,750-1,849 lbf/in.2}
GD 12.0 L/min. {3.17 U.S.gal., 2.64 lmp.gal.} at 2,000 r/min.

Flow rate Model:
FG, GH, FL, FM, SG 17.0-20.0 L/min. {4.50-5.28 U.S.gal., 3.74-4.39 lmp.gal.} at 2,000 r/min.
DESCRIPTION
EN07Z0703C100007
SHTS07Z070300138
1 Flow control valve assembly 6 Vane 11 Pump body sub-assembly

2 Relief valve 7 Suction connector 12 Spring
3 Flow control spring 8 Oil seal 13 Dowel
4 Rotor 9 Ball bearing 14 Side plate
5 Cam ring 10 Pump shaft 15 Body cover
OPERATION
EN07Z0703C100008
SHTS07Z070300105
1 Oil reservoir 5 Flow control valve assembly

COMPONENT LOCATOR
EN07Z0703D100004
SHTS07Z070300139
1 Lock nut 8 Oil seal 15 Cam ring

2 O-ring 9 Pump body sub-assembly 16 Dowel
3 Drive gear 10 Spring 17 Body cover
4 Snap ring 11 O-ring 18 Flow control valve assembly
5 Woodruff key 12 Side plate 19 Flow control spring
6 Pump shaft 13 Vane 20 Suction connector
7 Ball bearing 14 Rotor 21 Plug

A 99-107 {1,000-1,100 73-79} C 49-69 {500-700, 37-50}
B 22-26 {220-260, 16-18} D 34-44 {350-450, 26-32}
OVERHAUL
EN07Z0703H200005

(1) Remove the plug, flow control valve assembly and spring.
NOTICE
Be careful not to drop, scratch or nick the flow control valve
assembly.
SHTS07Z070300140
2. REMOVE THE BODY COVER.

(1) Loosen the four fixing bolts that secure the body cover, then
remove the cover.
SHTS07Z070300141
3. REMOVE THE VANE PUMP CORE.

(1) As shown in the figure, face the vane pump core side downward
and remove the vane pump core. The vane pump core consists of
the cam ring, rotor and vane. Since dimensional checks of these
parts have been completed, handle the vane pump core carefully.
Remove the side plate and spring.
SHTS07Z070300142
4. DISASSEMBLE THE PUMP SHAFT ASSEMBLY.

(1) Remove the snap ring from the pump body, and push and remove
the spline edge surface of the pump shaft by hand or by using a
plastic hammer. Be careful not to damage the oil seal lip. This
process completes disassembly. Carry out inspection.
SHTS07Z070300143
REPLACEMENT
1. REPLACE THE BALL BEARING, IF NECESSARY.

(1) Use a pair of snap ring pliers to remove the retainer ring.
SHTS07Z070300144
(2) Using a press, press out the ball bearing.
SHTS07Z070300145
(3) Using a press, press in the ball bearing.
SHTS07Z070300146
(4) Using a pair of snap ring pliers, install the retainer ring.
SHTS07Z070300147
2. REPLACE THE OIL SEAL, IF NECESSARY.

(1) Using a screw driver, remove the oil seal.
NOTICE
SHTS07Z070300148
(2) Insert the oil seal as shown in the figure.

NOTICE
To prevent oil leakage from oil seal due to lip wear, apply lithium
base grease to A and B.
(3) Using a press, press in the oil seal into the pump body.
SHTS07Z070300149
1. INSTALL THE PUMP SHAFT.

(1) Apply grease to the oil seal lip.
Recommended: Lithium grease
(2) Use a jig to install the shaft assembly.

(3) Install the snap ring into the groove completely.
SHTS07Z070300150
2. INSTALL THE VANE PUMP CORE.

(1) Press-fit the dowel pin into the pump body, then install in the
order: O-ring, spring, side plate, rotor, cam ring, and vane. Install
the cam ring so that the oval dowel hole is positioned at the valve
side of the body and that the rotation direction is correct. Install
the rotor so that the chamfer side of the spline faces the side
plate. Install the vane so that the radius edge contacts the inner
surface of the cam ring.
SHTS07Z070300151
3. INSTALL THE BODY COVER.

(1) Fit the O-ring and the body cover onto the pump body. Align the
dowel hole in the cover with the dowel pin, press the cover to the
edge surface of the body manually. Temporary tighten the bolts
by hand, then retighten to the specified torque.
SHTS07Z070300152
4. INSTALL THE FLOW CONTROL VALVE.

(1) Insert the flow control spring. Install the flow control valve assem-
bly into the body so that the pin side faces the plug side. Tighten
the plug.
5. INSPECT PUMP SHAFT ROTATING CONDITION.

(1) Check to see that the pump shaft rotates smoothly without abnor-
mal noise.
SHTS07Z070300153

EN07Z0703H300005
Pump shaft: — — Replace, Visual check

Damage if necessary.

Abrasion and flaw if necessary.
Flow control valve assembly: — — Replace, Visual check

Pump shaft bearing: — — Replace, Visual check

Cam ring inner surface: — — Replace the Visual check

Rotor surface: vane pump core,
Vane surface: if necessary.
Wear, scratches and scoring

2A54AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧢ಽ
POWER STEERING PUMP (MODEL: FM2P)

EN07Z0703I200005
Type Vane type
Speed range 625-4,790 r/min.
Relief pressure 12.1-12.8 MPa {123-130 kgf/cm2, 1,750-1,849 lbf/in.2}
Flow rate 15-19 L/min. {3.97-5.01 U.S.gal, 3.30-4.17 lmp.gal} at 2,000 r/min.
DESCRIPTION
EN07Z0703C100009
SHTS07Z070300160
1 Flow control valve assembly 9 Ball bearing

2 Relief valve 10 Woodruff key
3 Spring 11 Pump shaft
4 Pump body 12 Oil seal
5 Rotor 13 Dowel
6 Cam ring 14 Front plate
7 Vane 15 Rear plate
8 Suction connector 16 Pump cover
OPERATION
EN07Z0703C100010
SHTS07Z070300161
1 Reservoir 5 Flow control valve assembly

COMPONENT LOCATOR
EN07Z0703D100005
SHTS07Z070300162
1 Retainer ring 8 O-ring 15 Spring

2 Woodruff key 9 Front plate 16 Pump cover
3 Pump shaft 10 Dowel 17 Pump body sub assembly
4 Bearing 11 Cam ring 18 Flow control valve assembly
5 Oil seal 12 Vane 19 Plug
6 Plain washer 13 Rotor 20 Rear plate
7 Suction connector 14 Cartridge sub assembly

A 29-39 {300-400, 22-28} C 99-107 {1,000-1,100, 73-79}
B 69-96 {700-1,000, 51-72}
2A54AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧣ಽ
OVERHAUL
EN07Z0703H200006
1. REMOVE THE DRIVE GEAR.

(1) Use a commercial puller to remove the drive gear.
NOTICE
Do not tighten vise too tight when clamping the pump in vise.
SHTS07Z070300163
2. REMOVE THE PUMP SHAFT.

! CAUTION
Retainer ring is spring steel and may pop out from the groove
when removing. Wear safety glasses during removal.
(2) Use a sliding hammer and adapter to remove the pump shaft with
bearing.
SHTS07Z070300164
3. REMOVE THE PUMP COVER AND REAR PLATE.

(1) Remove the retainer ring.
(2) Remove the pump cover, spring, and rear plate using a plastic
hammer and rod.
NOTICE
Avoid gripping the rear plate with pliers as this could mar it.
SHTS07Z070300165
4. REMOVE THE ROTOR, VANES, CAM RING, AND FRONT

PLATE.
(1) Using a plastic hammer and rod, tap the rod to remove the front
plate, cam ring, rotor and vanes.
NOTICE
• Be careful to see that the cam ring, rotor, and vanes do not
fall out.
• Avoid gripping the front plate with pliers as this could mar it.
(2) Remove the O-ring from the pump body.
SHTS07Z070300166

(1) Remove the plug, flow control valve assembly and spring.
NOTICE
Be careful not to drop, scratch or nick the flow control valve
assembly.
SHTS07Z070300167
REPLACEMENT
1. REPLACE THE BALL BEARING, IF NECESSARY.

SHTS07Z070300168
(2) Use a press, press out the ball bearing.
SHTS07Z070300169
(3) Use a press to press in the ball bearing.
SHTS07Z070300170
(4) Use a pair of snap ring pliers to install the retainer ring.
SHTS07Z070300171
2. REPLACE THE OIL SEAL, IF NECESSARY.

(1) Use a screw driver to remove the oil seal.
NOTICE
SHTS07Z070300209
(2) Insert the oil seal as shown in the figure.

NOTICE
To prevent oil leakage from oil seal due to lip wear, apply lithium
base grease to A and B.
(3) Using a press, press in the oil seal into the pump body.
SHTS07Z070300173

NOTICE
• Before assembling, clean all the parts and lubricate them
with fluid.
• When assembling the power steering pump, be sure to use
new O-rings.
1. INSTALL THE FLOW CONTROL VALVE ASSEMBLY.

(1) Apply fluid to the valve and check to see that it falls smoothly into
the valve hole by its own weight.
If a problem is detected, replace the flow control valve assembly.
NOTICE
There are three different valve diameters, therefore be careful that
the mark on both valve and the pump body are always matched.
I - Valve: Letter II - Body: Letter
I A B C
Match mark
II A B C
SHTS07Z070300210
(2) Install the spring and the flow control valve assembly, and tighten
the plug.
NOTICE
Apply lithium base grease to an O-ring.
SHTS07Z070300175
2. INSTALL THE PUMP SHAFT.

(1) Using a press, press in the pump shaft with bearing into the pump
body.
NOTICE
When installing the retainer ring, face the chamfer side toward ball
bearing.
SHTS07Z070300176
3. INSTALL THE FRONT PLATE.

(1) Insert the front plate into the pump body as shown in figure.
A: Front plate
B: Pump body
SHTS07Z070300177
4. INSTALL THE CAM RING.

(1) Insert the cam ring with hole "A" aligned with dowel.
NOTICE
At this time, make sure that the hole "A" in the side surface is
positioned toward the ball bearing.
SHTS07Z070300178
5. INSTALL THE ROTOR AND VANE.

(1) Insert the rotor with the cut spline "A" side facing toward the ball
bearing.
(2) Insert the vanes with the rounded part facing outward.
SHTS07Z070300179
6. INSTALL THE REAR PLATE, SPRING, O-RING AND PUMP

COVER.
(1) Insert the rear plate on the cam ring and put the spring on the rear
plate.
(2) Insert the O-ring into the groove of the pump body.
SHTS07Z070300180
(3) Using a press, press in the pump cover and then install the
retainer ring securely.
NOTICE
• Be careful to see that the O-ring is not pinched by the rear
cover.
• With the pump cover pressed in completely fit the retainer
ring to pump body.
SHTS07Z070300181
7. INSPECT PUMP SHAFT ROTATION CONDITION.

(1) Check to see that the pump shaft rotates smoothly without abnor-
mal noise.
SHTS07Z070300182

EN07Z0703H300006
Shaft: — — Replace, Visual check


Abrasion and flaw if necessary.
Flow control valve assembly: — — Replace, Visual check

Ball bearing: — — Replace, Visual check

Cam ring inner surface: — — Replace, Visual check

Rotor surface: if necessary.
Vane surface:
Wear, scratches and scoring

Bushing: — — Replace the Visual check

Scratched and damage pump body,
if necessary.
OIL RESERVOIR (MODELS: FC, GD)

DESCRIPTION
EN07Z0703C100011
SHTS07Z070300190
1 Oil reservoir cap 5 Filter cover seal

2 Oil seal 6 Filter cover
3 Oil strainer 7 Oil filter
4 Spring 8 Filter gasket
COMPONENT LOCATOR
EN07Z0703D100006
SHTS07Z070300191
1 Oil reservoir cap 3 Oil reservoir

2 Oil strainer
OVERHAUL
EN07Z0703H200007

NOTICE
• Use only compressed air to clean the oil filter.
• The oil filter is made of synthetic resin, so never wash it with
hot water, solvent or detergent.
• Before assembling, clean all the parts.

EN07Z0703H300007
Oil strainer: — — Clean or replace, Visual check

Clogged and damage if necessary.
Oil reservoir: — — Replace,

OIL RESERVOIR (MODELS: FD, FG, GH, FL, FM, SG)

DESCRIPTION
EN07Z0703C100012
SHTS07Z070300193
1 Oil reservoir cap 5 Filter cover

2 Oil strainer 6 Filter cover seal
3 Spring 7 Filter seal
4 Oil filter 8 Oil filter gasket
COMPONENT LOCATOR
EN07Z0703D100007
SHTS07Z070300194
1 Oil reservoir cap 6 Filter cover seal

2 Oil strainer 7 Filter seal
3 Spring 8 Oil filter gasket
4 Oil filter 9 Oil reservoir
5 Filter cover
OVERHAUL
EN07Z0703H200008

NOTICE
• Use only compressed air to clean the oil filter.
• The oil filter is made of synthetic resin, so never wash it with
hot water, solvent or detergent.
• Before assembling, clean all the parts.

EN07Z0703H300008
Oil strainer: — — Clean or replace, Visual check

Clogged and damage if necessary.
Oil reservoir: — — Replace,

2A#:AA.(HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧟ಽ
FRONT AXLE (LF366) AX02–1
FRONT AXLE (LF366)

AX02
AX02-001
FRONT AXLE (LF366) .............................. AX02-2

DATA AND SPECIFICATIONS........................ AX02-2
DESCRIPTION ................................................ AX02-3
TROUBLESHOOTING..................................... AX02-4
SPECIAL TOOL ............................................... AX02-5
COMPONENT LOCATOR ............................... AX02-7
OVERHAUL ..................................................... AX02-9
INSPECTION AND ADJUSTMENT ............... AX02-15
INSPECTION AND REPAIR .......................... AX02-16
AX02–2 FRONT AXLE (LF366)
FRONT AXLE (LF366)

EN0860802I200001
Front axle series No. LF366
Axle beam type Reversed Elliot "I" beam
Axle beam material As rolled normalized steels
Brake drum location Inboard mounted
Wheel bearing Two tapered roller bearings
Amount of grease in a hub 430 g {15.1 oz.} at one wheel
King pin thrust bearing Ball bearing
Camber 0°-2°
King pin angle 6°-8°
Wheel alignment Caster 2°
Diagonal tires 1-3 mm {0.0394-0.1181 in.}

Toe-in
Radial tires 0-2 mm {0-0.0787 in.}
Inner turn 50°-53°

Knuckle turning angle
Outer turn 39°
DESCRIPTION
EN0860802C100001
SHTS086080200001
1 Stopper bolt 11 Tie rod

2 Knuckle arm 12 Tie-rod end
3 Axle beam 13 Ball stud
4 Knuckle 14 Oil seal
5 Wheel hub 15 Oil seal guide
6 King pin cover 16 Wheel nut
7 Bushing 17 Hub bolt
8 Thrust washer 18 Hub bolt fitting nut
9 King pin 19 ABS sensor ring (If so equipped)
10 Thrust bearing
TROUBLESHOOTING
EN0860802F300001

Hard steering or poor return of Lack of lubrication in steering linkage Lubricate king pins and ball joints.
steering wheel to center Incorrect front wheel alignment (Toe-in Correct the toe-in.
angle is incorrect.)
Incorrect front wheel alignment (Cam- Inspect king pin bushings for wear or
ber, caster of king pin angles are not deflection of knuckles axle beam and
within specifications.) tie rod, and replace if necessary.
Worn out or damaged thrust bearing Replace thrust bearings.
Tire pressure is too low Inflate to proper pressure.
Vibration or shimmy Incorrect front wheel alignment Adjust or replace parts if necessary.
Worn out king pin bushing Replace king pin bushings.
The preload of the wheel bearing is off Adjust wheel bearing preload.
Badly worn hub bearings Replace hub bearings.
Loose tie-rod ends ball joints Replace all the tie-rod ends.
Loose U-bolt nuts holding the springs Tighten the nuts properly.
to the beams
Loose hub nuts Tighten the hub nuts properly.
Distorted disc wheels Replace the disc wheel.
The tires are out of balance Balance the tires.
Run-out of the tire and wheel rim Correct the run-out of the tire and
wheel rim.
Tire and wheel are out of balance Balance the wheel using a balancing
machine.
Tire pressure is not uniform or suffi- Adjust the pressure of all tires.
cient
Other faults in the steering system Refer to the chapter "STEERING
EQUIPMENT".
Abnormal tire wear Incorrect front wheel alignment Adjust properly or replace parts, if nec-
essary.
Improper tire pressure Adjust to proper pressure.
Grease leakage from wheel hub Worn out oil seal Replace oil seal.
Hub cap is not seated properly Fit the hub cap properly.
Too much grease Apply only the specified amount of
grease.
SPECIAL TOOL
EN0860802K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
S0983-95003 SOCKET WRENCH
S0984-92001 HANDLE
S0965-02051 WHEEL HUB PULLER
S0960-71010 HUB CAP INSTALLER
S0965-71131 KING PIN GUIDE
S0965-41080 PLATE
SL110-01210 NUT
S0965-72050 DUST COVER GUIDE
S0971-21080 BAR
COMPONENT LOCATOR
EN0860802D100001
SHTS086080200011
1 Knuckle arm (Drivers side) 16 Tie-rod arm

2 Axle beam 17 Oil seal guide
3 Thrust washer 18 Oil seal
4 Lock pin 19 Inner wheel hub bearing
5 Thrust bearing 20 Wheel hub
6 Lubrication fitting 21 Outer wheel hub bearing
7 King pin cover 22 Washer
8 King pin 23 Hub bearing lock nut
9 Bushing 24 Cotter pin
10 Oil seal 25 Hub cap
11 Knuckle 26 Wheel nut
12 Stopper bolt lock nut 27 Hub bolt
13 Tie rod 28 Hub bolt fitting nut
14 Dust cover 29 ABS sensor ring (If so equipped)
15 Tie-rod end assembly 30 Caster shim

A 19-25 {194-254, 14-18} E 392-470 {4,000-4,800, 290-347}
B 63.5-84.5 {648-861, 47-62} F 146-244 {1,489-2,488, 108-179}
C 587-783 {5,986-7,984, 433-577} G 150-200 {1,530-2,039, 111-147}
D 37.5-48.5 {383-494, 28-35}
SHTS086080200012
1 Knuckle arm 15 Dust cover

2 Axle beam 16 Tie-rod end assembly
3 Caster shim (If so equipped) 17 Tie-rod arm
4 Thrust washer 18 Oil seal guide
5 Lock pin 19 Oil seal
6 Thrust bearing 20 Inner wheel hub bearing
7 Lubrication fitting 21 Wheel hub
8 King pin cover 22 Outer wheel hub bearing
9 King pin 23 Washer
10 Bushing 24 Hub bearing lock nut
11 Oil seal 25 Cotter pin
12 Knuckle 26 Hub cap
13 Stopper bolt lock nut 27 Wheel nut
14 Tie rod 28 Hub bolt

A 19-25 {194-254, 14-18} E 392-470 {4,000-4,800, 290-347}
B 63.5-84.5 {648-861, 47-62} F 146-244 {1,489-2,488, 108-179}
C 587-783 {5,986-7,984, 433-577} G 150-200 {1,530-2,039, 111-147}
D 37.5-48.5 {383-494, 28-35}
2A#:AA.(HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧝ಽ
OVERHAUL
EN0860802H200001
1. REMOVAL OF THE WHEELS

(1) Refer to the chapter "WHEEL & TIRE".
2. REMOVAL OF THE WHEEL HUB BEARING LOCK NUT

SST:
Socket Wrench (S0983-95003)
Handle (S0984-92001)
SHTS086080200013
3. REMOVAL OF THE WHEEL HUB ASSEMBLY AND THE

OUTER WHEEL HUB BEARING
SST:
Wheel Hub Puller (S0965-02051)
Handle (S0984-92001)
NOTICE
Wheel hub assembly is heavy, therefore be careful when handling
it.
SHTS086080200014
4. REMOVAL OF THE INNER WHEEL HUB BEARING

TOGETHER WITH OIL SEAL GUIDE
(1) Push out the inner wheel hub bearing and oil seal guide with 2
bolts having same size and thread pitches as of stopper bolt.
5. REMOVAL OF THE WHEEL BRAKE

(1) Refer to the chapter "SERVICE BRAKE".
SHTS086080200015
6. DISMOUNTING THE WHEEL BOLT

(1) Remove the nuts.
NOTICE
SOCKET WRENCH Removing the nuts without ABS sensor ring (If so equipped), be
careful not to damage the ring by tool.
(2) Separate the wheel hub and brake drum. (If necessary)
(3) Knock through the wheel bolt using brass bar and hammer.
ABS SENSOR RING NOTICE
Put aligned marks on the wheel hub and brake drum.
SHTS086080200016
7. REMOVAL OF THE LOCK PIN

(1) To prevent damage to the lock pin threading, loosen the lock pin
nut until it is flush with the end of the lock pin, then hammer the
nut to loosen the lock pin.
SHTS086080200017
1. REPLACEMENT OF THE DUST COVER.

NOTICE
Apply lithium molybdenum sulfide grease to the inside and lip
part of the dust cover.
SST: Dust Cover Guide (S0965-72050)
SHTS086080200018
2. REPLACEMENT OF THE WHEEL HUB BEARING RACE

(1) Remove the outer race of bearing by striking the race lightly and
evenly through the 4 access holes in the wheel hub, using a tap-
ping rod.
(2) To install the outer race, use a tapping rod and a hammer, or a
press.
SHTS086080200019
3. REPLACEMENT OF THE HUB BOLTS

(1) Loosen the hub bolt fitting nuts and remove the hub bolts from the
wheel hub.
(2) Install the new hub bolts.
NOTICE
• The right and left hub bolts differ, so install them according
to the chart below.
Marks at "P" Color

RIGHT R Gold
SHTS086080200020
LEFT L Silver
• After tightening the hub bolts and nuts, caulk each at 2

points with a punch.
• If the wheel hub and brake drum are disassembled to replace
the hub bolts, reassemble them so that their aligning marks
are oriented as closely to each other as possible.
SHTS086080200021
4. INSTALLATION OF THE AXLE BEAM

(1) Secure the axle to the leaf springs with U-bolt.
NOTICE
Confirm the direction of caster shim.
SHTS086080200022
5. ADJUSTMENT OF THE CLEARANCE BETWEEN THE

THRUST WASHER AND KNUCKLE
(1) Adjust the clearance with the correct thickness thrust washer.
Clearance: Assembly Standard Less than 0.1 mm {0.0039 in.}
Thickness of Thrust Washer: mm {in.}
1.9 {0.075} 2.0 {0.079} 2.1 {0.083} 2.2 {0.087}
2.3 {0.091} 2.4 {0.094} 2.5 {0.098} 2.6 {0.102}
SST:
King Pin Guide (S0965-71131)
Plate (S0965-41080)
Nut (SL110-01210)
SHTS086080200023 Bar (S0971-21080)
6. ASSEMBLY OF THE WHEEL BRAKE

7. INSTALLATION OF THE OIL SEAL GUIDE

NOTICE
If the oil seal guide is warmed up with hot water, it can easily be
placed.
SHTS086080200024
8. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
1. Inner wheel hub bearing inner race

2. Outer wheel hub bearing inner race
3. Sealing lip of the oil seal
4. Wheel hub
5. Knuckle spindle
(2) Lubricate the king pin with chassis grease, using the lubrication
fittings located on the two king pin covers.
SHTS086080200025
9. INSTALLATION OF THE OIL SEAL, THE WHEEL HUB BEAR-

INGS AND WHEEL HUB ASSEMBLY
(1) Install the inner wheel hub bearing.
NOTICE
• Using a tool as shown simplifies installation.
SHTS086080200026
(2) Install the oil seal in the wheel hub.

(3) Install the wheel hub assembly and the outer wheel hub bearing.
NOTICE
• The wheel hub assembly is heavy, therefore be careful when
handling it.
SHTS086080200027
2A#:AA.(HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧞ಽ
10. ADJUSTMENT OF THE WHEEL HUB BEARING PRELOAD

(1) Tighten the wheel hub bearing lock nut with the specified torque
then loosen the nut by 1/6 - 1/4 turn.
Tightening Torque: 105 N⋅m {1,100 kgf⋅cm, 80 lbf⋅ft}
SHTS086080200028
SHTS086080200029
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
(3) Measure the wheel bearing preload and adjust the preload with
the lock nut, if it exceeds or is less than that specified below.
Assembly standard:
Turning Torque
1.97-4.90 {20-50, 1.5-3.6}
N⋅m {kgf⋅cm, lbf⋅ft}
Spring balancer reading
17.6-43.1 {1.8-4.4, 4.0-9.7}
N {kgf, lbf}
SHTS086080200030
11. INSTALLATION OF THE COTTER PIN

NOTICE
If the holes and the nut groove are not aligned, turn the lock nut
within the limits of the wheel hub bearing preload until the hole
and groove are aligned.
12. INSTALLATION OF THE WHEELS

SHTS086080200031
13. INSTALLATION OF THE HUB CAP

NOTICE
• Before installing the cap, apply wheel hub bearing grease to
the inner surface of the cap.
• Apply silicon based liquid gasket (ThreeBond #1215 or
equivalent) to all around the fitting part of the hub cap with
the hub, then strike it with special tool.
SST: Hub Cap Installer (S0960-71010)
SHTS086080200032
14. TURN THE STEERING WHEEL TO THE FULL RANGE TO THE

RIGHT AND THE LEFT, AND CONFIRM THAT ALL STEERING
LINKAGES MOVE FREELY (ESPECIALLY THE BALL JOINTS).
15. ADJUSTMENT OF BRAKE SYSTEM AIR BLEEDING AND

BRAKE SHOE CLEARANCE
(1) On completion of the front axle overhaul, conduct the followings:
a. Bleed the air from the brake lines according to the section "SER-
VICE BRAKE ASSEMBLY" in the chapter "BRAKE EQUIP-
MENT".
b. Adjust the brake shoe clearance according to the section
SHTS086080200033 "WHEEL BRAKE" in the chapter "SERVICE BRAKE".
INSPECTION AND ADJUSTMENT

EN0860802H300001
1. INSPECTION OF THE WHEEL ALIGNMENT

(1) Park the vehicle on a level surface and check the tire pressure.
SHTS086080200034
(2) Adjust the king pin inclination, caster, and camber.

Refer to the section "DATA AND SPECIFICATIONS".
SHTS086080200035
(3) Check the toe-in.

• B - A =Toe-in
SHTS086080200036
2. ADJUSTMENT OF THE WHEEL TURNING ANGLE WITH

STOPPER BOLT
(1) Refer to the section "DATA AND SPECIFICATIONS".
SHTS086080200037

EN0860802H300002
Unit: mm {in.}
King pin: — — Replace, Use the magnetic flaw

Wear and damage if necessary. detector or color checking
instrument.
King pin diameter 35 {1.378} 34.85 {1.373} Replace. Measure
Knuckle: — — Replace, Use the magnetic flaw

instrument.
King pin clearance 0.020-0.101 0.35 {0.0138} Replace. Measure

{0.0008-0.0039}
Thrust bearing: — — Replace, Visual check

Burns and pitting if necessary.
Thrust washer wear — 0.5 {0.0197} Replace the thrust Measure

(Clearance between washer.
knuckle and axle beam)
Bearing and race: — — Replace, Visual check

Replace, Visual check

if necessary.
Hub bolts: — — Replace, Visual check

Threads wear and dam- if necessary.
age
Oil seal guide: — — Replace, Visual check

Wear if necessary.
Tie rod: — — Replace, Visual check

Distortion if necessary.
Dust cover: — — Replace. Visual check

Crack
Muddy water in the — — Replace the tie-rod

cover end assembly.
2A#:AA.(KHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧟ಽ
FRONT AXLE (LF45I) AX02–1
FRONT AXLE (LF45I)

AX02
AX02-002
FRONT AXLE (LF45I) ............................... AX02-2

DESCRIPTION ................................................ AX02-3
SPECIAL TOOL ............................................... AX02-5
OVERHAUL ..................................................... AX02-9
AX02–2 FRONT AXLE (LF45I)
FRONT AXLE (LF45I)

EN0861302I200001
Front axle series No. LF45I
Axle beam material Heat-treated carbon steel
Brake drum location Outboard mounted
Camber 0°-2°

Toe-in
Inner turn 42°30'-45°30'

Outer turn 35°

DESCRIPTION
EN0861302C100001
SHTS086130200001
1 Lock pin bolt 11 King pin cover

2 Axle beam 12 Lubrication fitting
3 Stopper bolt 13 Lock pin
4 Tie-rod arm 14 Wheel nut
5 Knuckle arm 15 Lock nut
6 Tie-rod 16 Hub cap
7 Hub bolt 17 Wheel hub bearing
8 Knuckle 18 Wheel hub
9 Thrust washer 19 Ball stud
10 King pin 20 Tie-rod end
TROUBLESHOOTING
EN0861302F300001

to the beams
Distorted disc wheels Replace the disc wheels.
wheel rim.
machine.
cient
EQUIPMENT".
essary.
Hub cap bolts are not tightened prop- Tighten the bolts properly.
erly
grease.
SPECIAL TOOL
EN0861302K100001
S0984-92001 HANDLE
S0965-21210 PULLER SCREW 2 pieces
S0965-72050 DUST COVER GUIDE

S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
COMPONENT LOCATOR
EN0861302D100001
SHTS086130200012
1 Axle beam 17 O-ring

2 Thrust washer 18 Inner wheel hub bearing
3 Lock pin 19 Brake drum
6 King pin 22 Wheel hub bearing lock nut
7 Bushing 23 Lock plate
8 Oil seal 24 Gasket
9 Stopper bolt 25 Wheel hub cap
10 Lock pin bolt 26 Knuckle
11 Knuckle arm 27 Lubrication fitting
12 Tie-rod arm 28 Hub bolt
13 Tie rod 29 Wheel nut
14 Dust cover 30 Outer wheel hub bearing
16 Oil seal guide

A 146-244 {1,500-2,500, 109-326} F 24.5-33.5 {250-341, 19-24}
B 85.5-114.5 {870-1,170, 63-84} G 37.5-48.5 {380-500, 28-36}
C 685-1,175 {7,000-12,000, 507-867} H 37.5-48.5 {380-500, 28-36}
D 8.5-10.5 {85-110, 6.2-7.9} I 20.5-39.5 {210-400, 16-28}
E 96-144 {1,000-1,500, 73-108}
OVERHAUL
EN08613022300001


SST:
Handle (S0984-92001)
SHTS086130200013
3. REMOVAL OF THE WHEEL HUB AND THE OUTER WHEEL

HUB BEARING
SST:
Handle (S0984-92001)
NOTICE
it.
SHTS086130200014

SST: Screw Puller (S0965-21210)

SHTS086130200015

SHTS086130200016
7. SEPARATION OF THE BRAKE DRUM AND WHEEL HUB

(EXAMPLE)
(1) Remove the bolts, and separate the brake drum and wheel hub.
SHTS086130200017
1. REPLACEMENT OF THE DUST COVER

NOTICE
SST: Dust Cover Guide (S0965-72050)
SHTS086130200018

ping rod.
press.
SHTS086130200019

(1) Remove the hub bolts from the wheel hub.
NOTICE
• The left and right hub bolts differ, so install them according
to the chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
SHTS086130200020
4. ASSEMBLY OF THE BRAKE DRUM AND WHEEL HUB

(EXAMPLE)
(1) Assemble the brake drum and wheel hub, and tighten the bolts.
SHTS086130200021
NOTICE
When assembling the brake drum and wheel hub, make sure that
their aligning marks are oriented as closely to each other as pos-
sible.
SHTS086130200022

(1) Secure the axle to the leaf springs with U-bolts.
NOTICE
SHTS086130200023

Assembly Standard: Less than 0.1 mm {0.004 in.}
3.1 {0.122} 3.2 {0.126} 3.3 {0.130} 3.4 {0.134}
3.5 {0.138} 3.6 {0.142} 3.7 {0.146} 3.8 {0.150}
SST:
Plate (S0965-41080)
Nut (SL110-01210)
SHTS086130200024 Bar (S0971-21100)


NOTICE
• Align the stopper bolt hole of the knuckle and oil seal guide
hole.
• If oil seal guide is warmed up with hot water, it can easily be
installed.
• Install the O-ring as shown in the figure.
SHTS086130200025
SHTS086130200026
9. GREASING

4. Wheel hub
5. Knuckle spindle
SHTS086130200027
10. INSTALLATION OF THE WHEEL HUB BEARINGS AND

WHEEL HUB ASSEMBLY
NOTICE
Using a tool as shown, simplifies installation.
SHTS086130200028
2A#:AA.(KHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧣ᤨ㧞㧢ಽ

NOTICE
• Using a tool as shown, simplifies installation.
handling it.
SHTS086130200029

Tightening Torque:
340 N⋅m {3,500 kgf⋅cm, 253 lbf⋅ft}
SHTS086130200030
SHTS086130200031
hands.)
(3) Measure the wheel bearing preload. If it exceeds or it is less than
the standard value shown below, adjust the preload with the lock
nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
23.5-38.0 {2.4-3.9, 5.3-8.6}
N {kgf, lbf}
SHTS086130200032
12. INSTALLATION OF THE LOCK PLATE

NOTICE
• If the holes of the plate are not aligned with the screw holes
of the nut, turn over the plate.
• If alignment is still unattainable, turn the lock nut further
within the limits of wheel hub bearing preload.
SHTS086130200033


NOTICE
Before installing the cap, apply wheel hub bearing grease to the
inner surface of the cap.
SHTS086130200034

16. ADJUSTMENT OF THE BRAKE SYSTEM AIR BLEEDING AND

THE BRAKE SHOE CLEARANCE
(1) On completion of the wheel hub and related parts reassembly,
conduct the followings:
MENT".
SHTS086130200035 b. Adjust the brake shoe clearance according to the section
"WHEEL BRAKE" in the chapter "SERVICE BRAKE".

EN0861302H300001

SHTS086130200036

SHTS086130200037

• B - A =Toe-in
SHTS086130200038

STOPPER BOLT
SHTS086130200039

EN0861302H300002
Unit: mm {in.}
King pin: — — Replace, Use the magnetic flaw detec-

Wear and damage if necessary. tor or color checking instru-
ment.
King pin diameter 40 39.85 Replace. Measure

{1.575} {1.569}
Knuckle: — — Replace, Use the magnetic flaw detec-

ment.
King pin clearance 0.060-0.150 0.35 Replace. Measure

{0.0024-0.0059} {0.0138}

Thrust washer: — 0.5 Replace. Measure

wear (Clearance {0.0197}
between knuckle and
axle beam)


if necessary.

age

Wear if necessary.

Tie-rod end and dust — — Replace, Visual check

cover: if necessary.
Crack

cover (Sealed type ball end assembly.
stud)
2A#:AA.(HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧠ಽ
FRONT AXLE (LF578)

AX02
AX02-003
FRONT AXLE (LF578) .............................. AX02-2

DESCRIPTION ................................................ AX02-3
SPECIAL TOOL ............................................... AX02-5
OVERHAUL ..................................................... AX02-8
FRONT AXLE (LF578)

EN0861102I200001
Front axle series No. LF578
Axle beam material Heat-treated carbon steel
Camber 0°-2°

Toe-in
Inner turn 44°30'-47°30'

Outer turn 36°

DESCRIPTION
EN0861102C100001
SHTS086110200001
1 Axle beam 12 Lock pin

2 Stopper bolt 13 Wheel nut
3 Tie-rod arm 14 Lock nut
4 Knuckle arm 15 Hub cap
5 Tie rod 16 Wheel hub bearing
6 Hub bolt 17 Wheel hub
7 Knuckle 18 Ball stud
8 Thrust washer 19 Tie-rod end
9 King pin 20 Oil seal
10 King pin cover 21 Oil seal guide
11 Lubrication fitting 22 Hub bolt fitting nut
TROUBLESHOOTING
EN0861102F300001

to the beams
wheel rim.
machine.
cient
EQUIPMENT".
essary.
erly
grease.
SPECIAL TOOL
EN0861102K100001
S0984-92001 HANDLE
S0965-21210 SCREW PULLER 2 pieces
SZ179-20001 DUST COVER GUIDE NUT
S0965-71790 DUST COVER GUIDE (INNER) 2 pieces
S0965-71800 DUST COVER GUIDE (OUTER)

S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
COMPONENT LOCATOR
EN0861102D100001
SHTS086110200013

10 Outer wheel hub bearing 26 Knuckle
14 Dust cover 30 Hub bolt fitting nut
16 Oil seal guide

A 147-343 {1,499-3,497, 109-253} E 96-144 {979-1,468, 71-106}
B 85.5-114.5 {872-1,167, 64-84} F 24.5-33.5 {250-341, 19-24}
C 685-1,175 {6,986-11,981, 505-866} G 37.5-48.5 {383-494, 28-35}
D 8.5-10.5 {87-107, 6.3-7.7} H 392-470 {4,000-4,800, 290-347}
OVERHAUL
EN08611022300001


SST:
Handle (S0984-92001)
SHTS086110200014

HUB BEARING
SST:
Handle (S0984-92001)
NOTICE
it.
SHTS086110200015


SHTS086110200016

SHTS086110200017

NOTICE
SST:
SHTS086110200018

ping rod.
press.
SHTS086110200019

wheel hub.
NOTICE
to the chart below.
Marks at "P" Color

RIGHT R Gold
SHTS086110200020
LEFT L Silver
NOTICE
SHTS086110200021

NOTICE
SHTS086110200022

Clearance: Assembly Standard: Less than 0.1 mm {0.004 in.}
3.1 {0.122} 3.2 {0.126} 3.3 {0.130} 3.4 {0.134}
3.5 {0.138} 3.6 {0.142} 3.7 {0.146} 3.8 {0.150}
SST:
Plate (S0965-41080)
Nut (SL110-01210)
SHTS086110200023 Bar (S0971-21100)


NOTICE
hole.
installed.
SHTS086110200024
SHTS086110200025
8. GREASING

4. Wheel hub
5. Knuckle spindle
SHTS086110200026

WHEEL HUB ASSEMBLY
NOTICE
SHTS086110200027

NOTICE
handling it.
SHTS086110200028

Tightening Torque:
343 N⋅m {3,500 kgf⋅cm, 253 lbf⋅ft}
SHTS086110200029
SHTS086110200030
hands.)
nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
27.5-44.1 {2.8-4.5, 6.2-9.9}
N {kgf, lbf}
SHTS086110200031

NOTICE
SHTS086110200032


NOTICE
SHTS086110200033

SHTS086110200034
15. BRAKE SYSTEM AIR BLEEDING AND THE BRAKE SHOE

CLEARANCE ADJUSTMENT
a. Bleed the air from the brake lines chapter according to the section
"SERVICE BRAKE ASSEMBLY" in the chapter "BRAKE EQUIP-
MENT".

EN0861102H300001

SHTS086110200035

Refer to the chapter "DATA AND SPECIFICATIONS".
SHTS086110200036

• B - A =Toe-in
SHTS086110200037

STOPPER BOLT
SHTS086110200038

EN0861102H300002
Unit: mm {in.}

instrument.

{1.575} {1.569}

ment.

{0.0024-0.0059} {0.0138}

Thrust washer: — 0.5 Replace, Measure

Wear (Clearance between {0.0197} if necessary.


if necessary.

Threads wear and if necessary.
damage

Wear if necessary.

Tie-rod end and dust — — Replace. Visual check

cover:
Crack
Muddy water in the cover — — Replace the tie-rod

(Sealed type ball stud) end assembly.
2A#:AA.(A+HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝㧝ಽ
FRONT AXLE (LF57I)

AX02
AX02-004
FRONT AXLE (LF57I) ............................... AX02-2

DESCRIPTION ................................................ AX02-3
SPECIAL TOOL ............................................... AX02-5
OVERHAUL ..................................................... AX02-8
2A#:AA.(A+HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧤ಽ
FRONT AXLE (LF57I)

EN0861202I200001
Front axle series No. LF57I
Axle beam material Chrome molybdenum steel
Camber 0°-2°

Wheel align-
Caster 2°
ment
Toe-in
Inner turn 40°30'-43°30'

Outer turn 34°
Amount of grease in a hub 600 g {21.2 oz} at one wheel

DESCRIPTION
EN0861202C100001
SHTS086120200001
1 Axle beam 12 Lock pin

2 Stopper bolt 13 Wheel nut
3 Tie-rod arm 14 Lock nut
4 Knuckle arm 15 Hub cap
5 Tie rod 16 Wheel hub bearing
6 Hub bolt 17 Wheel hub
7 Knuckle 18 Ball stud
8 Thrust washer 19 Tie-rod end
9 King pin 20 Oil seal
10 King pin cover 21 Oil seal guide
11 Lubrication fitting
TROUBLESHOOTING
EN0861202F300001

to the beams
wheel rim.
machine.
cient
Other faults in the steering system Refer to the chapter, "STEERING
EQUIPMENT".
essary.
erly
grease.
SPECIAL TOOL
EN0861202K100001
S0984-92001 HANDLE
S0965-21210 SCREW PULLER 2 PIECES
S0965-71790 DUST COVER GUIDE (INNER) 2 PIECES

S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
COMPONENT LOCATOR
EN0861202D100001
SHTS086120200013

2 Thrust washer 17 O-ring
4 Thrust bearing 19 Brake drum
5 King pin cover 20 Wheel hub
7 Bushing 22 Wheel hub bearing lock nut
8 Oil seal 23 Lock plate
9 Stopper bolt 24 Gasket
10 Outer wheel hub bearing 25 Wheel hub cap
11 Knuckle arm 26 Knuckle
12 Tie-rod arm 27 Lubrication fitting
14 Dust cover 29 Wheel nut

A 147-343 {1,500-3,500, 109-253} E 96-144 {1,000-1,500, 73-108}
B 85.5-114.5 {900-1,200, 66-86} F 24.5-33.5 {250-341, 19-24}
C 685-1,175 {7,000-12,000, 507-867} G 37.5-48.5 {380-500, 28-36}
D 8.5-10.5 {85-110, 6.2-7.9} H 20.5-39.5 {210-400, 16-28}
OVERHAUL
EN08612022300001

(1) Refer to chapter "WHEEL & TIRE".

SST:
Handle (S0984-92001)
SHTS086120200014

SST:
Handle (S0984-92001)
NOTICE
it.
SHTS086120200015


(1) Refer to chapter "SERVICE BRAKE".
SHTS086120200016

SHTS086120200017

(EXAMPLE)
SHTS086120200018

NOTICE
SST:
SHTS086120200019

ping rod.
press.
SHTS086120200020

NOTICE
The right and left hub bolts differ, so install them according to the
chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
SHTS086120200021

(EXAMPLE)
SHTS086120200018
NOTICE
sible.
SHTS086120200022

NOTICE
SHTS086120200023

3.2 {0.126} 3.3 {0.130} 3.4 {0.134} 3.5 {0.138}
3.6 {0.142} 3.7 {0.146} 3.8 {0.150}
SST:
Plate (S0965-41080)
Nut (SL110-01210)
SHTS086120200024 Bar (S0971-21100)

(1) Refer to chapter "SERVICE BRAKE".

NOTICE
hole.
installed.
SHTS086120200025
SHTS086120200026
9. GREASING

4. Wheel hub
5. Knuckle spindle
SHTS086120200027

WHEEL HUB ASSEMBLY
NOTICE
SHTS086120200028

NOTICE
handling it.
SHTS086120200029

Tightening Torque:
340 N⋅m {3,500 kgf⋅cm, 253 lbf⋅ft}
SHTS086120200031
SHTS086120200030
hands.)
the standard value shown below, and adjust the preload with the
lock nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
23.5-38.0 {2.4-3.9, 5.3-8.6}
N {kgf, lbf}
SHTS086120200032

NOTICE
SHTS086120200033

(1) Refer to chapter "WHEEL & TIRE".

NOTICE
SHTS086120200034

SHTS086120200035
16. BRAKE SYSTEM AIR BLEEDING AND THE BRAKE SHOE

CLEARANCE ADJUSTMENT
MENT".
"WHEEL BRAKE " in the chapter "SERVICE BRAKE".

EN0861202H300001

SHTS086120200036

SHTS086120200037

• B - A =Toe-in
SHTS086120200038

STOPPER BOLT
SHTS086120200039

EN0861202H300002
Unit: mm {in.}

instrument.

{1.772} {1.5689}
Knuckle: — — Replace, Use the magnetic flaw

instrument.

{0.0024-0.0059} {0.0138}

2A#:AA.(A+HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧟㧤ಽ
Thrust washer: — 0.5 Replace the Measure

Wear (Clearance between {0.0197} thrust washer.


if necessary.

Threads wear and if necessary.
damage

Wear if necessary.


Crack
Muddy water in the cover — — Replace the tie-rod

(Sealed type ball stud) end assembly.
2A#:AA/(HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧡ಽ
FRONT AXLE (MF678) AX02–1
FRONT AXLE (MF678)

AX 02
AX02-005
FRONT AXLE (MF678) ............................. AX02-2

DESCRIPTION ................................................ AX02-3
SPECIAL TOOL ............................................... AX02-5
OVERHAUL ................................................... AX02-10
AX02–2 FRONT AXLE (MF678)
FRONT AXLE (MF678)

EN0861402I200001
Front axle series No. MF678
Camber 0°-2°

Wheel align-
Caster 2°
ment
Toe-in
Inner turn Tire size 10.00-20 44°30'-47°30'

Outer turn Tire size 10.00-20 34°

2A#:AA/(HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧟㧜ಽ
DESCRIPTION
EN0861402C100001
SHTS086140200001
1 Axle beam 13 Wheel nut

2 Stopper bolt 14 Lock nut
3 Tie-rod arm 15 Hub cap
4 Knuckle arm 16 Wheel hub bearing
5 Tie-rod 17 Wheel hub
6 Hub bolt 18 Ball stud
7 Knuckle 19 Tie-rod end
8 Thrust washer 20 Oil seal
9 King pin 21 Oil seal guide
10 King pin cover 22 Hub bolt fitting nut
11 Lubrication fitting 23 ABS sensor ring (If so equipped)
12 Lock pin
TROUBLESHOOTING
EN0861402F300001

to the beams
wheel rim.
machine.
cient
EQUIPMENT".
essary.
erly
grease.
SPECIAL TOOL
EN0861402K100001
S0984-92001 HANDLE

S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
COMPONENT LOCATOR
EN0861402D100001
SHTS086140200013

16 Oil seal guide 32 ABS sensor ring (If so equipped)

A 147-343 {1,499-3,497, 109-253} E 96-144 {979-1,468, 71-106}
B 85.5-114.5 {872-1,167, 64-84} F 105.5-144.5 {1,076-1,473, 78-106}
C 685-1,175 {6,986-11,981, 505-866} G 37.5-48.5 {383-494, 28-35}
D 8.5-10.5 {87-107, 6.3-7.7} H 392-470 {4,000-4,800, 290-347}
SHTS086140200014

16 Oil seal guide 32 ABS sensor ring (If so equipped)

A 147-343 {1,499-3,497, 109-253} E 96-144 {979-1,468, 71-106}
B 85.5-114.5 {872-1,167, 64-84} F 105.5-144.5 {1,076-1,473, 78-106}
C 685-1,175 {6,986-11,981, 505-866} G 37.5-48.5 {383-494, 28-35}
D 8.5-10.5 {87-107, 6.3-7.7} H 392-470 {4,000-4,800, 290-347}
OVERHAUL
EN08614022300001


SST:
Handle (S0984-92001)
SHTS086140200015

SST:
Handle (S0984-92001)
NOTICE
it.
SHTS086140200016


SHTS086140200017

SHTS086140200018

NOTICE
SST:
SHTS086140200019

ping rod.
press.
SHTS086140200020

wheel hub.
NOTICE
to the chart below.
Marks at "P" Color

RIGHT R Gold
SHTS086140200021
LEFT L Silver
NOTICE
SHTS086140200022

NOTICE
SHTS086140200023

THRUST WASHER AND KNUCKLE.
Clearance: Assembly Standard: Less than 0.1 mm {0.004 in.}
3.2 {0.126} 3.3 {0.130} 3.4 {0.134} 3.5 {0.138}
3.6 {0.142} 3.7 {0.146} 3.8 {0.150}
SST:
Plate (S0965-41080)
Nut (SL110-01210)
SHTS086140200024 Bar (S0971-21100)


NOTICE
hole.
installed.
SHTS086140200025
SHTS086140200026
8. GREASING

4. Wheel hub
5. Knuckle spindle
SHTS086140200027

WHEEL HUB ASSEMBLY
NOTICE
SHTS086140200028

NOTICE
handling it.
SHTS086140200029

Tightening Torque:
343 N⋅m {3,500 kgf⋅cm, 253 lbf⋅ft}
SHTS086140200031
SHTS086140200030
wheel hub.
lock nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
27.5-44.1 {2.8-4.5, 6.2-9.9}
N {kgf, lbf}
SHTS086140200032

NOTICE
SHTS086140200033


NOTICE
SHTS086140200034


MENT".
"WHEEL BRAKE " in the chapter "SERVICE BRAKE".

EN0861402H300001

SHTS086140200036

SHTS086140200037

• B - A =Toe-in
SHTS086140200038

STOPPER BOLT
SHTS086140200039

EN0861402H300002
Unit: mm {in.}

ment.

{1.969} {1.9626}

ment.

{0.0010-0.0031} {0.0138}

2A#:AA/(HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦᓟ㧝㧞ᤨ㧡㧡ಽ
Thrust washer: — 0.5 Replace the thrust Measure

Wear (Clearance {0.0197} washer.
between knuckle and
axle beam)


if necessary.

age

Wear if necessary.

Tie-rod end and dust — — Replace. Visual check

cover:
Crack

stud)
2A#:AA/(A+HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧢ಽ
FRONT AXLE (MF67I) AX02–1
FRONT AXLE (MF67I)

AX02
AX02-006
FRONT AXLE (MF67I) .............................. AX02-2

DESCRIPTION ................................................ AX02-3
SPECIAL TOOL ............................................... AX02-5
OVERHAUL ................................................... AX02-10
AX02–2 FRONT AXLE (MF67I)
FRONT AXLE (MF67I)

EN0861502I200001
Chassis model FG, GH, SG FL, FM
Front axle series No. MF67I
Camber 0°-2°

Wheel align-
Caster 2°
ment
Toe-in
Tire size 10.00-20 11.00-20 10.00-20
Knuckle turning angle Inner turn 44°30'-47°30' 41°30'-44°30' 39°30'-42°30'
Outer turn 34° 33° 32°

DESCRIPTION
EN0861502C100001
SHTS086150200001
1 Axle beam 11 Lubrication fitting

2 Stopper bolt 12 Lock pin
3 Tie-rod arm 13 Wheel nut
4 Knuckle arm 14 Lock nut
5 Tie-rod 15 Hub cap
6 Hub bolt 16 Wheel hub bearing
7 Knuckle 17 Wheel hub
8 Thrust washer 18 Ball stud
9 King pin 19 Tie-rod end
10 King pin cover 20 ABS sensor ring (If so equipped)
TROUBLESHOOTING
EN0861502F300001

to the beams
wheel rim.
machine.
cient
EQUIPMENT".
essary.
erly
grease.
SPECIAL TOOL
EN0861502K100001
S0984-92001 HANDLE

S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
COMPONENT LOCATOR
EN0861502D100001
SHTS086150200013

14 Dust cover 30 Caster shim
15 Tie-rod end assembly 31 ABS sensor ring (If so equipped)
16 Oil seal guide

A 147-343 {1,499-3,497, 109-253} E 96-144 {979-1,468, 71-106}
B 85.5-114.5 {872-1,167, 64-84} F 105.5-144.5 {1,076-1,473, 78-106}
C 685-1,175 {6,986-11,981, 505-866} G 37.5-48.5 {383-494, 28-35}
D 8.5-10.5 {87-107, 6.3-7.7} H 20.5-39.5 {210-403, 16-29}
SHTS086150200014

2 Thrust washer 17 O-ring
4 Thrust bearing 19 Brake drum
5 Brake chamber bracket 20 Wheel hub
7 Bushing 22 Wheel hub bearing lock nut
9 Stopper bolt 24 Gasket
10 Outer wheel hub bearing 25 Wheel hub cap
11 Knuckle arm 26 Knuckle
12 Tie-rod arm 27 Lubrication fitting
14 Dust cover 29 Wheel nut

A 147-343 {1,499-3,497, 109-253} E 96-144 {979-1,468, 71-106}
B 85.5-114.5 {872-1,167, 64-84} F 105.5-144.5 {1,076-1,473, 78-106}
C 685-1,175 {6,986-11,981, 505-866} G 37.5-48.5 {383-494, 28-35}
D 8.5-10.5 {87-107, 6.3-7.7} H 20.5-39.5 {210-403, 16-29}
OVERHAUL
EN08615022300001


SST:
Handle (S0984-92001)
SHTS086150200015

SST:
Handle (S0984-92001)
NOTICE
it.
SHTS086150200016


SHTS086150200017

SHTS086150200018

(EXAMPLE)
SHTS086150200019

NOTICE
SST:
SHTS086150200020

ping rod.
press.
SHTS086150200021

NOTICE
• The right and left hub bolts differ, so install them according
to the chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
SHTS086150200022

(EXAMPLE)
SHTS086150200019
NOTICE
sible.
SHTS086150200023

NOTICE
SHTS086150200024

3.2 {0.126} 3.3 {0.130} 3.4 {0.134} 3.5 {0.138}
3.6 {0.142} 3.7 {0.146} 3.8 {0.150}
SST:
Plate (S0965-41080)
Nut (SL110-01210)
SHTS086150200025 Bar (S0971-21100)


NOTICE
hole.
installed.
SHTS086150200026
SHTS086150200027
9. GREASING

4. Wheel hub
5. Knuckle spindle
SHTS086150200028

WHEEL HUB ASSEMBLY
NOTICE
SHTS086150200029
2A#:AA/(A+HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧟㧞ಽ

NOTICE
handling it.
SHTS086150200030

Tightening Torque:
343 N⋅m {3,500 kgf⋅cm, 253 lbf⋅ft}
SHTS086150200032
SHTS086150200031
hands.)
lock nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
23.5-38.0 {2.4-3.9, 5.3-8.6}
N {kgf, lbf}
SHTS086150200033
2A#:AA/(A+HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧟㧞ಽ

NOTICE
SHTS086150200034


NOTICE
SHTS086150200035


MENT".

EN0861502H300001

SHTS086150200037

SHTS086150200038

• B - A =Toe-in
SHTS086150200039

STOPPER BOLT
SHTS086150200040

EN0861502H300002
Unit: mm {in.}

ment.

{1.969} {1.9626}

ment.

{0.0010-0.0031} {0.0138}

2A#:AA/(A+HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝㧡ಽ
Thrust washer: — 0.5 Replace the thrust Measure

Wear (Clearance {0.0197} washer.
between knuckle and
axle beam)


if necessary.

age

Wear if necessary.


Crack

stud)
2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧣ಽ
REAR AXLE (DIFFERENTIAL GEAR SERIES: SH13) AX03–1
REAR AXLE AX03
(DIFFERENTIAL GEAR SERIES: SH13) AX03-001
REAR AXLE .............................................. AX03-2

DESCRIPTION ................................................ AX03-2
SPECIAL TOOL ............................................... AX03-4
OVERHAUL ..................................................... AX03-6
AX03–2 REAR AXLE (DIFFERENTIAL GEAR SERIES: SH13)
REAR AXLE
EN0850403I200001
Type Full-floating axle shaft
Housing Banjo type, with extension tubes welded on both ends
Type of drive Hotchkiss drive
DESCRIPTION
EN0850403C100001
SHTS085040300001
1 Differential carrier assembly 8 Outer wheel nut

2 Brake drum 9 Inner wheel nut
3 Oil seal collar 10 Wheel hub
4 Oil seal 11 Axle shaft
5 Wheel hub bearing 12 Lock nut
6 Hub bolt fitting nut 13 ABS sensor ring (If so equipped)
7 Hub bolt 14 Axle housing
TROUBLESHOOTING
EN0850403F300001

Abnormal noise (Bearing system) Worn or damaged pinion bearings Replace bearings.
Worn or damaged differential side Replace bearings.
bearings
Loose pinion bearings Adjust bearings preload.
Loose differential side bearings Adjust bearings preload.
Abnormal noise (Gear system) Inadequate backlash on ring gear and Adjust backlash.
pinion gear
Worn thrust washers Replace.
Worn differential spider Replace.
Worn or damaged ring gear and pinion Replace.
Worn or damaged differential side Replace.
gears and pinions
Loose ring gear tightening bolts Tighten bolts.
Inadequate tooth contact of ring gear Replace or adjust tooth contact.
and pinion gear
Worn pinion spline Replace.
Abnormal noise (Rear axle system) Worn rear axle shaft spline Replace.
Worn hub bearings Replace.
Loose hub bearings Adjust bearing preload.
Loose differential case tightening bolts Tighten bolts.
Abnormal noise (Oil system, etc.) Insufficient oil Add oil; check for leakage.
Poor oil quality Change oil.
Abnormal noise of propeller shaft Refer to the Chapter "PROPELLER
SHAFT".
SPECIAL TOOL
EN0850403K100001
Prior to starting a rear axle overhaul, it is necessary to have these special tools.
S0965-02090 HUB BEARING PULLER
S0984-91601
HANDLE
S0984-92001

COMPONENT LOCATOR
EN0850403D100001
SHTS085040300006
1 Oil seal 11 Hub bolt

2 Oil seal collar 12 Inner wheel nut
3 Inner wheel hub bearing 13 Outer wheel nut
4 Wheel hub 14 Air breather
5 Outer wheel hub bearing 15 Oil filler plug
6 Lock washer 16 Gasket
7 Lock nut 17 Axle housing assembly
8 Lock plate 18 Oil drain plug
9 Axle shaft 19 Differential carrier assembly
10 Hub bolt fitting nut 20 ABS sensor ring (If so equipped)

A 84.5-107.5 {862-1,097, 63-79} E φ12: 84.5-107.5 {862-1,097, 63-79}
B 78.4-117.6 {800-1,200, 58-86} φ14: 113-147 {1,152-1,499, 83-108}
C 78.4-117.6 {800-1,200, 58-86} F 392-470 {4,000-4,800, 290-347}
D 8.33-10.79 {85-110, 6.2-8.0} G 9.8-19.6 {100-200, 7-14}
2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧟㧠ಽ
OVERHAUL
EN0850403H200001


SST: Socket Wrench (S0983-99401)
SHTS085040300007

HUB BEARING
SST:
Handle (S0984-91601)
Handle (S0984-92001)
NOTICE
The wheel hub assembly is heavy, therefore be careful when han-
dling it.
SHTS085040300008

TOGETHER WITH OIL SEAL COLLAR
SST:
Hub Bearing Puller (S0965-02090)
Handle (S0984-91601)
Handle (S0984-92001)
SHTS085040300009


ping rod.
SHTS085040300010
(2) Using a tapping rod and a hammer or a press, install the outer
race.
SHTS085040300011

NOTICE
The left and right hub bolts differ, so install them according to the
chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
NOTICE
Caulk the lock nuts at two points after tightening to the specified
SHTS085040300012
torque.
3. GREASING
(1) Pack sufficient amount of wheel hub bearing grease between the
bearing rollers.
NOTICE
"1": Fill the grease to spaces among the inner race, rollers and
retainer to the extent that there is not any vacancy remained.
SHTS085040300013
(2) Apply wheel hub bearing grease to wheel hub.

NOTICE
• "2": Fill the grease between the oil seal and inner bearing,
and at this time some grease may flow out to the oil seal.
• "3": The grease has to ooze out to the extent that the retainer
is buried.
• "4": After pressing in the inner race of the inner bearing,
apply the grease to the end of race circumferentially with the
width of 15 mm {0.591 in.}.
• "5": When filling the grease to this space, do it up to the line
which connects between the small diameter sides edges of 2
SHTS085040300014
bearings.
• "6": Fill the grease up the half depth of the lock nut.

(1) Install the oil seal and the inner wheel hub bearing.
NOTICE
• If the collar is warmed up with hot water, it can easily be
installed.
SHTS085040300015
NOTICE
handling it.
SHTS085040300016
2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧟㧠ಽ

Tightening Torque:
588-882 N⋅m {6,000-9,000 kgf⋅cm, 433-650 lbf⋅ft}
SHTS085040300007
wheel hub.
SHTS085040300017
Assembly standard:
Turning Torque
4.0-5.4 {39-53, 2.9-4.0}
36.0-48.6 {3.6-4.8, 7.9-10.5}
N {kgf, lbf}
SHTS085040300018

(1) Install the lock plate to the lock nut.
NOTICE
• If the holes of the plate are not aligned with screw holes of
the nut, turn over the plate.
SHTS085040300019
7. BRAKE SYSTEM AIR BLEEDING AND BRAKE SHOE CLEAR-

ANCE ADJUSTMENT
(1) On completion of the front axle overhaul, conduct the followings:
a. Bleed the air from the brake lines according to the section
"SERVICE BRAKE ASSEMBLY" in the chapter "BRAKE
EQUIPMENT".

EN0850403H300001
Wheel hub bearing race: — — Replace, Visual check

Burns, pitting and cracks if necessary.
Wheel hub bearings: — — Replace, Visual check

Hub bolt: — — Replace, Visual check

Oil seal collar: — — Replace, Visual check

Axle shaft spline: — — Replace, Visual check

Axle tube: — — Replace, Visual check

REAR AXLE AX03
(DIFFERENTIAL GEAR SERIES: SH14)

AX03
AX03-002
REAR AXLE .............................................. AX03-2

DESCRIPTION ................................................ AX03-2
SPECIAL TOOL ............................................... AX03-4
OVERHAUL ..................................................... AX03-6
REAR AXLE
EN0851403I200001
DESCRIPTION
EN0851403C100001
SHTS085140300001
1 Differential carrier assembly 7 Wheel nut

2 Brake drum 8 Wheel hub
3 Oil seal collar 9 Axle shaft
4 Oil seal 10 Lock nut
5 Wheel hub bearing 11 Axle housing
6 Hub bolt
TROUBLESHOOTING
EN0851403F300001

bearings
Loose pinion bearings Adjust bearings preload.
Loose differential side bearings Adjust bearings preload.
pinion gear
gears and pinions
and pinion gear
Abnormal noise of propeller shaft Refer to the Chapter "PROPELLER
SHAFT".
2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧟㧣ಽ
SPECIAL TOOL
EN0851403K100001
S0984-91601
HANDLE
S0984-92001

COMPONENT LOCATOR
EN0851403D100001
1
2
3
X
5
12 10 6
7
8
14 1
13 9
B
A
11
E
D
14
15
16
X
18
C G
17
SHTS085140300006
1 Oil seal 10 Hub bolt

2 Oil seal collar 11 Wheel nut
3 Inner wheel hub bearing 12 Air breather
4 Wheel hub 13 Oil filler plug
5 Outer wheel hub bearing 14 Gasket
6 Lock washer 15 Axle housing assembly
7 Lock nut 16 Oil drain plug
8 Lock plate 17 Differential carrier assembly
9 Axle shaft 18 Brake drum

A 84.5-107.5 {862-1,097, 63-79} E 113-147 {1,152-1,499, 83-108}
B 78.4-117.6 {800-1,200, 58-86} F 392-470 {4,000-4,800, 290-347}
C 39.2-68.6 {400-700, 29-50} G 20.5-39.5 {210-402, 16-29}
D 8.33-10.79 {85-110, 6.2-8.0}
OVERHAUL
EN0851403H200001
1. REMOVAL OF THE WHEELS.

2. REMOVAL OF THE BRAKE DRUMS

(1) Loosen the drum set screws and remove the brake drums.
NOTICE
• If the drum does not easily come out, screw the set screws
into the drum removing hole.
• Brake drum is heavy, therefore be careful when handling it.
SHTS085140300007
3. REMOVAL OF THE WHEEL HUB BEARING LOCK NUT.

SHTS085140300008

HUB BEARING.
SST:
Handle (S0984-91601)
Handle (S0984-92001)
NOTICE
dling it.
SHTS085140300009

TOGETHER WITH OIL SEAL COLLAR.
SST:
Handle (S0984-91601)
Handle (S0984-92001)

SHTS085140300010
1. REPLACEMENT OF THE WHEEL HUB BEARING RACE.

ping rod.
SHTS085140300011
race.
SHTS085140300012

(1) Using a brass bar or a hammer, drive out the hub bolts from the
wheel hub.
(2) Using a copper hammer, drive the new hub bolts into the wheel
hub.
P
chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
SHTS085140300013
3. GREASING.
bearing rollers.
NOTICE
SHTS085140300014
2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧟㧣ಽ

NOTICE
is buried.
width of 15 mm {0.591 in.}
SHTS085140300015
bearings.

INGS AND WHEEL HUB ASSEMBLY.
NOTICE
If the collar is warmed up with hot water, it can easily be installed.
SHTS085140300016
NOTICE
handling it.
SHTS085140300017
5. ADJUSTMENT OF THE WHEEL HUB BEARING PRELOAD.

Tightening Torque:
588-882 N⋅m {6,000-9,000 kgf⋅cm, 434-650 lbf⋅ft}
SHTS085140300018
2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧞㧞ಽ
wheel hub.
SHTS085140300019
Assembly standard:
Turning Torque 3.9-5.9
N⋅m {kgf⋅cm, lbf⋅ft} {40-60, 2.9-4.4}
ISO type 23.3-35.2
Spring balancer reading wheel hub {2.4-3.5, 5.2-7.9}
N {kgf, lbf} JIS type 27.4-41.4
wheel hub {2.8-4.2, 6.2-9.3}
SHTS085140300020

NOTICE
SHTS085140300021
7. INSTALLATION OF THE BRAKE DRUM

(1) Install the brake drums and tighten the drum set screws.

SHTS085140300007

ANCE ADJUSTMENT.
conduct the followings.
(2) Bleed the air from the brake lines according to the section "SER-
MENT".
(3) Adjust the brake shoe clearance according to the section

EN0851403H300001






2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧝㧝ಽ
REAR AXLE AX03
REAR AXLE .............................................. AX03-2

DESCRIPTION ................................................ AX03-2
SPECIAL TOOL ............................................... AX03-4
OVERHAUL ..................................................... AX03-6
REAR AXLE
EN0851203I200001
DESCRIPTION
EN0851203C100001
SHTS085120300001

2 Brake drum 9 Inner wheel hub
6 Hub bolt fitting nut 13 Axle housing
7 Hub bolt 14 ABS sensor ring (If so equipped)
TROUBLESHOOTING
EN0851203F300001

bearings
Loose pinion bearings Adjust bearing preload.
Loose differential side bearings Adjust bearing preload.
pinion gear
gears and pinions
and pinion gear
Abnormal noise (Oil system, etc.) Insufficient oil Add oil, check for leakage.
Abnormal noise of propeller shaft Refer to the chapter "PROPELLER
SHAFT".
SPECIAL TOOL
EN0851203K100001
S0960-31360 SOCKET WRENCH For model FG
S0965-01292 WHEEL HUB PULLER For model FG
S0984-91601
HANDLE
S0984-92001
COMPONENT LOCATOR
EN0851203D100001
21
1
2 9 4
3
20 G
4 5
6
11 7 8
H
F
12
14
10 13
16
15
1
9
B
11 5
12 6
13
E 7
8
D A
16 17
18
X
19 C
SHTS085120300006
1 Oil seal 12 Inner wheel nut

2 Oil seal collar 13 Outer wheel nut
9 Axle shaft 20 Sensor ring (if so equipped)
10 Hub bolt fitting nut 21 Brake drum
11 Hub bolt

A 155-199 {1,580-2,030, 114-146} E 113-147 {1,150-1,500, 83-108}
B 78.4-117.6 {800-1,200, 58-86} F 392-470 {4,000-4,800, 290-347}
C 39.2-68.6 {400-700, 29-50} G 20.5-39.5 {210-400, 16-29}
D 8.33-10.79 {85-110, 6.2-8.0} H 9.8-19.6 {100-200, 7.3-14.4}
OVERHAUL
EN0851203H200001


(DRUM LOCATION TYPE: OUTBOARD MOUNTED)
NOTICE
SHTS085120300007

(EXAMPLE) SST:
Handle (S0984-91601)
Handle (S09849-2001)
SHTS085120300008

(EXAMPLE) HUB BEARING
SST:
Handle (S0984-91601)
Handle (S0984-92001)
NOTICE
dling it.
SHTS085120300009

SST:
Handle (S0984-91601)
Handle (S0984-92001)

SHTS085120300010

ping rod.
SHTS085120300011
race.
SHTS085120300012

NOTICE
chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
NOTICE
SHTS085120300013 Caulk the lock nuts at two points after tightening to the specified
torque. (Only models for Hong Kong and Taiwan)
3. GREASING
bearing rollers.
NOTICE
SHTS085120300014

NOTICE
is buried.
width of 15 mm {0.591 in}.
SHTS085120300015
bearings.

NOTICE
SHTS085120300016
NOTICE
handling it.
SHTS085120300017
2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧞㧠ಽ

(EXAMPLE) (1) Tighten the wheel hub bearing lock nut with the specified torque
SST:
Handle (S0984-91601)
Handle (S0984-92001)
Tightening Torque:
588-1,176 N⋅m {6,000-12,000 kgf⋅cm, 434-868 Ibf⋅ft}
SHTS085120300008
wheel hub.
SHTS085120300018

nut.
Assembly standard:
N⋅m {kgf⋅cm, lbf⋅ft} {40-60, 2.9-4.4}
ISO type 23.3-35.2
wheel hub {2.8-4.2, 6.2-9.3}
SHTS085120300019

NOTICE
SHTS085120300020
7. INSTALLATION OF THE BRAKE DRUMS



ANCE ADJUSTMENT
SHTS085120300007
EQUIPMENT".

EN0851203H300001






REAR AXLE AX03
REAR AXLE .............................................. AX03-2

DESCRIPTION ................................................ AX03-2
SPECIAL TOOL ............................................... AX03-5
OVERHAUL ..................................................... AX03-9
REAR AXLE
EN0851503I200001
DESCRIPTION
EN0851503C100001
JIS TYPE WHEEL
SHTS085150300001
1 Differential carrier assembly 9 Inner wheel nut

2 Brake drum 10 Wheel hub
3 Oil seal collar 11 Lock washer
5 Wheel hub bearing 13 Lock plate
6 Hub bolt fitting nut 14 Lock nut
8 Outer wheel nut 16 ABS sensor ring (If so equipped)
ISO TYPE WHEEL
SHTS085150300002
1 Differential carrier assembly 8 Wheel hub

2 Brake drum 9 Lock washer
3 Oil seal collar 10 Axle shaft
7 Wheel nut 14 ABS sensor ring (If so equipped)
TROUBLESHOOTING
EN0851503F300001

bearings
Loose pinion bearings Adjust bearing preload.
Loose differential side bearings Adjust bearing preload.
pinion gear
gears and pinions
and pinion gear
Abnormal noise of propeller shaft Refer to the chapter "PROPELLER
SHAFT".
SPECIAL TOOL
EN0851503K100001
S0984-91601
HANDLE
S0984-92001

COMPONENT LOCATOR
EN0851503D100001
JIS TYPE WHEEL
22
1 4
9
3
21 4 5 G
6
7
11 8
12
F 10 13
8
1 9
H 16
11 5
12 6
7
13
B
D A
15 14
20 15
19
C
18
E
17
SHTS085150300007
1 Oil seal 12 Inner wheel nut

2 Oil seal collar 13 Outer wheel nut
9 Axle shaft 20 O-ring
10 Hub bolt fitting nut 21 Sensor ring (if so equipped)
11 Hub bolt 22 Brake drum

A M12: 83.5-106.5 {850-1,080, 62-78} E 167-213 {1,700-2,200, 123-159}
M14: 148-192 {1,500-2,000, 114-146} F 392-470 {4,000-4,800, 290-347}
B 78.4-117.6 {800-1,200, 58-86} G 20.5-39.5 {210-400, 16-29}
C 39.2-68.6 {400-700, 29-50} H 9.8-19.6 {100-200, 7.3-14.4}
D 8.33-10.79 {85-110, 6.2-8.0}
ISO TYPE WHEEL
SHTS085150300008
1 Oil seal 11 Wheel nut

2 Oil seal collar 12 Air breather
3 Inner wheel hub bearing 13 Oil filler plug
4 Wheel hub 14 Gasket
5 Outer wheel hub bearing 15 Axle housing assembly
6 Lock washer 16 Oil drain plug
7 Lock nut 17 Differential carrier assembly
8 Lock plate 18 O-ring
9 Axle shaft 19 Brake drum
10 Hub bolt 20 ABS sensor ring (If so equipped)

A 148-192 {1,500-2,000, 109-144} E 167-213 {1,700-2,200, 123-159}
B 78.4-117.6 {800-1,200, 58-86} F 9.8-19.6 {100-200, 7.3-14.4}
C 39.2-68.6 {400-700, 29-50} G 20.5-39.5 {210-400, 16-29}
D 8.33-10.79 {85-110, 6.2-8.0}
DEAD AXLE
SHTS085150300009
1 Dead axel tube 9 Lock nut

2 Oil seal guide 10 Lock plate
3 Expansion plug 11 Gasket
4 Oil seal 12 Wheel hub cover
5 Inner wheel hub bearing 13 Hub bolt
6 Wheel hub 14 Inner wheel nut
7 Outer wheel hub bearing 15 Outer wheel nut
8 Lock washer 16 Brake drum

A 8.33-10.79 {85-110, 6.2-8.0} C 20.5-39.5 {210-400, 16-29}
B 10.7-146.6 {1,100-1,500, 81-110}
OVERHAUL
EN0851503H200001


NOTICE
SHTS085150300010

SST:
Handle (S0984-91601)
Handle (S0984-92001)
SHTS085150300011

HUB BEARING
SST:
Handle (S0984-91601)
Handle (S0984-92001)
NOTICE
dling it.
SHTS085150300012

SST:
Handle (S0984-91601)
Handle (S0984-92001)

SHTS085150300013

ping rod.
SHTS085150300014
race.
SHTS085150300015

NOTICE
chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
NOTICE
SHTS085150300016 Caulk the lock nuts at two points after tightening to the specified
torque. (Only models for Taiwan FG, GH and Thailand FG)
3. GREASING
bearing rollers.
NOTICE
SHTS085150300017

NOTICE
is buried.
SHTS085150300018
bearings.

NOTICE
SHTS085150300019
NOTICE
handling it.
SHTS085150300020

SST:
Handle (S0984-91601)
Handle (S0984-92001)
Tightening Torque:
588-1,176 N⋅m {6,000-12,000 kgf⋅cm, 434-868 lbf⋅ft}
SHTS085150300011
2A#:AA5*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝㧣ಽ
wheel hub.
SHTS085150300021

nut.
Assembly standard:
N⋅m {kgf⋅cm, lbf⋅ft} {40-60, 2.9-4.4}
ISO type 23.3-35.2
wheel hub {2.8-4.2, 6.2-9.3}
SHTS085150300022

NOTICE
SHTS085150300023
7. INSTALLATION OF THE BRAKE DRUM


SHTS085150300010

ANCE ADJUSTMENT
EQUIPMENT".

EN0851503H300001






2A#:AA6*&A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧝㧡ಽ
REAR AXLE (DIFFERENTIAL GEAR SERIES: THD17) AX03–1
REAR AXLE AX03
(DIFFERENTIAL GEAR SERIES: THD17)

AX03
AX03-005
REAR AXLE .............................................. AX03-2

DESCRIPTION ................................................ AX03-2
SPECIAL TOOL ............................................... AX03-4
OVERHAUL ..................................................... AX03-6
AX03–2 REAR AXLE (DIFFERENTIAL GEAR SERIES: THD17)
REAR AXLE
EN0851803I200001
Type of drive Torque rod drive
DESCRIPTION
EN0851803C100001
SHTS085180300001

2 Brake drum 8 Inner wheel nut
TROUBLESHOOTING
EN0851803F300001

Abnormal noise (Bearing system) Worn or damaged pinion bearings. Replace bearings.
bearings.
Loose pinion bearings. Adjust bearing preload.
Loose differential side bearings. Adjust bearing preload.
pinion gear.
Worn thrust washers. Replace.
Worn differential spider. Replace.
Worn or damaged ring gear and pin- Replace.
ion.
gears and pinions.
Loose ring gear tightening bolts. Tighten bolts.
and pinion gear.
Worn pinion spline. Replace.
Abnormal noise (Rear axle system) Worn rear axle shaft spline. Replace.
Worn hub bearings. Replace.
Loose hub bearings. Adjust bearing preload.
Loose differential case tightening Tighten bolts.
bolts.
Abnormal noise (Oil system, etc.) Insufficient oil. Add oil, check for leakage.
Poor oil quality. Change oil.
Abnormal noise of propeller shaft. Refer to the chapter "PROPELLER
SHAFT".
SPECIAL TOOL
EN0851803K100001
S0984-91601
HANDLE
S0984-92001

COMPONENT LOCATOR
EN0851803D100001
SHTS085180300006
1 Axle housing assembly 8 Oil seal 15 Hub bolt

2 Air breather 9 Wheel hub bearing 16 Oil seal collar
3 Gasket 10 Wheel hub 17 Inner wheel nut
4 Oil drain plug 11 Lock washer 18 Outer wheel nut
5 Oil filler plug 12 Lock nut 19 O-ring
6 Differential carrier assembly 13 Lock plate 20 Brake drum
7 Through shaft assembly 14 Axle shaft

A 148-192 {1,500-2,000, 109-144} E 167-213 {1,700-2,200, 123-159}
B 78.4-117.6 {800-1,200, 58-86} F 64-84 {650-870, 47-63}
C 39.2-68.6 {400-700, 29-50} G 9.8-19.6 {100-200, 7.3-14.4}
D 8.33-10.79 {85-110, 6.2-8.0} H 20.5-39.5 {210-400, 16-29}
OVERHAUL
EN0851803H200001


NOTICE
SHTS085180300007

SST:
Handle (S0984-91601)
Handle (S0984-92001)
SHTS085180300008

HUB BEARING
SST:
Handle (S0984-91601)
Handle (S0984-92001)
NOTICE
dling it.
SHTS085180300009

SST:
Handle (S0984-91601)
Handle (S0984-92001)

SHTS085180300010

ping rod.
SHTS085180300011
race.
SHTS085180300012

NOTICE
chart below.
Marks at "P" Color

RIGHT R Gold
LEFT L Silver
SHTS085180300013
3. GREASING
bearing rollers.
NOTICE
SHTS085180300014

NOTICE
is buried.
apply the grease to the end of race circumferential with the
SHTS085180300015 which connects between the small diameter sides edges of 2
bearings.

NOTICE
SHTS085180300016
NOTICE
handling it.
SHTS085180300017

SST:
Handle (S0984-91601)
Handle (S0984-92001)
Tightening Torque:
588-1,176 N⋅m {6,000-12,000 kgf⋅cm, 434-868 lbf⋅ft}
SHTS085180300008
2A#:AA6*&A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧞㧡ಽ
hands.)
SHTS085180300018

nut.
Assembly standard:
N⋅m {kgf⋅cm, lbf⋅ft} {40-60, 2.9-4.4}
ISO type 23.3-35.2
wheel hub {2.8-4.2, 6.2-9.3}
SHTS085180300019

NOTICE
SHTS085180300020


ANCE ADJUSTMENT.
EQUIPMENT".
SHTS085180300007 "WHEEL BRAKE" in the chapter "SERVICE BRAKE".

EN0851803H300001






2A#:AA/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧝㧢ಽ
WHEEL & TIRE AX04–1
WHEEL & TIRE

AX04
AX04-001
WHEEL AND TIRE.................................... AX04-2

DESCRIPTION ................................................ AX04-8
TROUBLESHOOTING................................... AX04-13
SPECIAL TOOL ............................................. AX04-15
PRECAUTIONS ............................................. AX04-16
INSPECTION ................................................. AX04-17
SAE, JIS, DIN AND

ISO TYPE WHEEL .................................. AX04-19
OVERHAUL ................................................... AX04-19
SPOKE WHEEL AND

ADAPTER TYPE WHEEL ....................... AX04-25
OVERHAUL ................................................... AX04-25
AX04–2 WHEEL & TIRE
WHEEL AND TIRE

EN08Z0904I200001
The figures given in the table are based on the recommendation by European Tire and Rim Technical Organiza-
tion. (E.T.R.T.O.)
*(1). Tire radius given is dynamic effective radius for dual tires, for single tire, deduct 1.0 mm {0.039 in.} from the
figure given.
*(2). The rims with mark (•) are standard and others may be used.
*(3). The max. air pressure and max. load refer to the recommendation by Japan Automobile Tire Manufacturers'
Association. (J.A.T.M.A.)
*(4). The tire is certified by ECE.
*(5). Some vehicle specifications are not applicable to the following table. Refer to the Owner's Manual for
details.
*(6). The tire is certified by GB.
1. Diagonal tires
Max. air press. Allowable max. load kg {lb.}

*
kPa Tire radius (2)
Tire size
{kgf/cm2, Single Dual mm {in.} Applicable rim size
lbf/in.2}
*
(3) 325 880 840
*
(1) • 16 x 5.50F SDC
7.00-16-6PR {3.25, 47} {1,940} {1,852}
368
*
(3) 500 1,130 1,075 {14.49} • 16 x 5.50F SDC
7.00-16-10PR {5.00, 73} {2,491} {2,370}
600 1,285 1,250 373

7.00-16-12PR • 16 x 5.50F SDC
{6.12, 87} {2,833} {2,756} {14.69}
650 1,450 1,400 389

7.50-16-12PR
{6.63, 94} {3,197} {3,086} {15.31} 16 x 6.00GS
•
*(3) 650 1,510 1,440 383 SDC
7.50-16-14PR {6.50, 94} {3,329} {3,175} {15.08}
550 1,550 1,500

7.50-20-10PR
{5.61, 80} {3,417} {3,307} 451
• 20 x 6.00S
675 1,800 1,750 {17.76}
7.50-20-12PR
{6.88, 98} {3,968} {3,858}
• 16 x 6.40H
650 1,800 1,700 404
8.25-16-14PR 16 x 6.00S SDC
{6.63, 94} {3,968} {3,747} {15.91}
16 X 6.00GS
*(1)
*(3) 575 1,710 1,630
404 • 16 x 6.00GS
8.25-16-14PR {5.75, 83.4} {3,770} {3,593}
{15.91}
600 1,900 1,800

8.25-20-12PR • 20 x 6.50T
{6.12, 87} {4,188} {3,968} 468
675 2,060 1,950 {18.43} • 20 x 6.50T
8.25-20-14PR
{6.88, 98} {4,541} {4,299} 20 x 6.00S
625 2,240 2,060 • 20 x 7.00T

9.00-20-12PR
{6.37, 91} {4,938} {4,541} 20 x 6.50T
488
{19.21} 20 x 6.50T
700 2,500 2,300
9.00-20-14PR 20 x 7.00T
{7.14, 102} {5,511} {5,071}
20 x 7.50V
*
* (1)
(3) 575 2,450 2,210
506 • 20 x 7.50V
10.00-20-12PR {5.75, 83} {5,401} {4,482}
{19.92}

*
kPa Tire radius (2)
Tire size
lbf/in.2}
650 2,650 2,430 20 x 7.00T

10.00-20-14PR
{6.63, 94} {5,842} {5,357} 20 x 7.50T
507
{19.96} 20 x 7.00T
750 3,000 2,725
10.00-20-16PR 20 x 7.50V
{7.65, 109} {6,614} {6,007}
20 x 8.00T
*(1)
*(3) 575 2,585 2,435
520 • 20 x 8.00V
11.00-20-12PR {5.75, 83} {5,699} {5,368}
{20.47}
675 3,000 2,725

11.00-20-14PR 20 x 7.50V
{6.88, 98} {6,614} {6,007} 521
725 3,250 2,900 {20.51} 20 x 7.50V
11.00-20-16PR
{7.39, 105} {7,165} {6,393} 20 x 8.50V
*
* (1)
(3) 575 2,900 2,760
539 • 20 x 8.50V
12.00-20-14PR {5.75, 83} {6,393} {6,085}
{21.22}
675 3,350 3,000

12.00-20-16PR 20 x 8.00V
{6.88, 98} {7,385} {6,613} 540
775 3,750 3,250 {21.26}
12.00-20-18PR 20 x 9.00V
{7.90, 112} {8,267} {7,165}
675 3,650 3,250 • 24 x 8.50V

12.00-24-16PR
{6.88, 98} {8,047} {7,165} 589 24 x 8.00V
775 4,000 3,650 {23.19} 24 x 9.00V
12.00-24-18PR
{7.90, 112} {8,818} {8,047}
*
* (1)
(3) 675 4,990 4,755 • 24 x 10.00WI
642
14.00-24-20PR {6.75, 98} {11,001} {10,483} 24 x 9.00V
{25.28}
2. Radial tires (with tube)

*
kPa Tire radius (2)
Tire size
lbf/in.2}
*(3) 450 1,025 980
• 16 x 5.50F SDC
7.00R-16-8PR {4.5, 65} {2,259} {2,160}
*
* (1)
(3) 525 1,130 1,075
373 • 16 x 5.50F SDC
7.00R-16-10PR {5.25, 76} {2,491} {2,369}
{14.69}
*
(3) 600 1,230 1,170
• 16 x 5.50F SDC
7.00R-16-12PR {6.00, 87} {2,711} {2,579}
625 1,450 1,400 390

7.50R-16-12PR 16 x 6.00GS
{6.37, 91} {3,197} {3,086} {15.35}
*
* (1)
(3) 700 1,510 1,440 • 16 x 6.00GS
387
7.50R-16-14PR {7.00, 102} {3,328} {3,174} SDC
{15.24}
675 1,800 1,750 451 • 20 x 6.00S

7.50R-20-12PR
{6.88, 98} {3,968} {3,858} {17.76} 20 x 6.50T
675 1,800 1,700 418

8.25R-16-14PR • 16 x 6.00GS
{6.88, 98} {3,968} {3,748} {16.46}
*(6) 775 1,950 1,850 409
16 x 6.50H
8.25R-16-18PR {7.90, 112} {4,299} {4,079} {16.10}
675 2,060 1,950 467 • 20 x 6.50T

8.25R-20-14PR
{6.88, 98} {4,541} {4,299} {18.39} 20 x 7.00T
725 2,336 2,050 491

9.00R-20-12PR 20 x 7.00T
{7.39, 105} {5,150} {4,520} {19.29}
• 20 x 7.00T
725 2,500 2,300 494
9.00R-20-14PR 20 x 6.50T
{7.39, 105} {5,511} {5,071} {19.45}
20 x 7.50V
• 20 x 7.50V
725 2,650 2,430 508 20 x 6.50T
10.00R-20-14PR
{7.39, 105} {5,842} {5,357} {20.00} 20 x 7.00T
20 x 8.00V
800 3,000 2,725 511 • 20 x 7.50V

10.00R-20-16PR
{8.16, 116} {6,614} {6,007} {20.12} 20 x 7.00T
• 20 x 8.00V
725 3,000 2,725 523
11.00R-20-14PR 20 x 7.50V
{7.39, 105} {6,614} {6,007} {20.59}
20 x 8.50V
• 20 x 8.00V
800 3,250 2,900 525
11.00R-20-16PR 20 x 7.50V
{8.16, 116} {7,165} {6,393} {20.67}
20 x 8.50V
750 3,350 3,000 542 • 20 x 8.50V

12.00R-20-16PR
{7.65, 109} {7,385} {6,613} {21.34} 20 x 9.00V
850 3,750 3,250 545 • 20 x 8.50V

12.00R-20-18PR
{8.67, 123} {8,267} {7,165} {21.46} 20 x 8.50
700 4,500 4,125 601 20 x 10.00V

14.00R-20-18PR
{7.14, 102} {9,921} {9,094} {23.66} 20 x 10.00W
3. Radial tires (Tubeless)

*
kPa Tire radius (2)
Tire size
lbf/in.2}
• 17.5 x 6.00
205/75R17.5 675 1,500 1,400 366
17.5 x 5.25
122/120 {6.88, 81} {3,307} {3,086} {14.41}
17.5 x 6.75
817.87 2,180 2,060 17.5 x 6.00

215/75R17.5 —
{8.34, 118.6} {4,806} {4,542} 17.5 x 6.75
*
* (1)
(3) 700 1,550 1,500 • 17.5 x 6.75
389
225/80R17.5-14PR {7.00, 102} {3,417} {3,307} 17.5 x 6.00
{15.31}
*
* (1)
(3) 700 1,750 1,650 • 17.5 x 6.75
410
225/90R17.5-14PR {7.00, 102} {3,858} {3,638} 17.5 x 6.00
{16.14}
* *
(4) (1)
720 1,800 1,700
225/90R17.5 410 • 17.5 x 6.00
{7.34, 104} {3,968} {3,748}
-128/126 {16.14}
800 2,500 2,300 452

255/70R22.5 • 22.5 x 7.50
{8.16, 116} {5,511} {5,071} {17.80}
900 2,360 2,180 439

235/70R22.5 • 22.5 x 6.75
{9.18, 131} {5,202} {4,806} {17.28}
* *
(3) (1)
900 2,360 2,180
235/70R22.5 440 22.5 x 6.75
{9.18, 131} {5,202} {4,806}
-138/135 {17.32}
725 1,900 1,800 387

235/70R17.5 17.5 x 6.75
{7.39, 105} {4,189} {3,968} {15.24}
725 1,900 1,800 372

235/75R17.5 17.5 x 6.75
{7.39, 105} {4,189} {3,968} {14.65}
• 22.5 x 7.50
900 2,725 2,500 452
255/70R22.5 22.5 x 6.75
{9.18, 131} {6,007} {5,511} {17.80}
22.5 x 8.25
* *
(3) (1)
900 2,725 2,500
255/70R22.5 453 22.5 x 7.50
{9.18, 131} {6,007} {5,511}
-143/140 {17.83}
255/70R22.5 800 2,500 2,300 452

22.5 x 7.50
-140/137 {8.16, 116} {5,511} {5,071} {17.80}
900 3,150 2,900 465 • 22.5 x 8.25

275/70R22.5
{9.18, 131} {6,944} {6,393} {18.31} 22.5 x 7.50
*
(1)
255/70R22.5 900 3,150 2,900
465 22.5 x 8.25
-148/145 {9.18, 131} {6,944} {6,393}
{18.31}
*
(3)
900 3,150 2,900 465
275/70R22.5 22.5 x 8.25
{9.18, 131} {6,944} {6,393} {18.31}
-148/145
809.05 3,000 2,725 490 • 22.5 x 8.25

275/80R22.5
{8.25, 117.3} {6,613} {6,007} {19.29} 22.5 x 7.50
275/80R22.5 850 3,250 3,000 491

• 22.5 x 7.50
-149/146J {8.67, 123} {7,165} {6,614} {19.33}
882.60 3,450 3,150 467 • 22.5 x 9.00

295/70R22.5
{9.00, 128.0} {7,605} {6,944} {18.39} 22.5 x 8.25

*
kPa Tire radius (2)
Tire size
lbf/in.2}
800 3,350 3,000 507

295/80R22.5 • 22.5 x 8.25
{8.16, 116} {7,385} {6,614} {19.96}
295/80R22.5 850 3,550 3,150 507

22.5 x 9.00
-152/148 {8.67, 123} {7,385} {6,945} {19.96}
825 3,750 3,350 523

315/80R22.5 • 22.5 x 9.00
{8.41, 120} {8,267} {7,385} {20.59}
• 17.5 x 5.25
600 1,285 1,250 381
8R17.5 117/116 • 17.5 x 6.00
{6.12, 87} {2,833} {2,756} {15.00}
17.5 x 6.75
*
* (1) • 17.5 x 6.00
(3) 625 1,450 1,400
389 16 x 6.00GS
8.5R17.5-12PR {6.25, 91} {3,196} {3,086}
{15.31} SDC
*
* (1)
(3) 725 2,030 1,930 • 22.5 x 6.75
470
9R22.5-14PR {7.25, 105} {4,475} {4,255} 22.5 x 6.00
{18.50}
675 2,060 1,950 471

9R22.5-133/131 22.5 x 6.75
{6.88, 98} {4,541} {4,299} {18.54}
671.76 1,700 1,600 408 • 17.5 x 6.00

9.5R-17.5-14PR
{6.85, 97.4} {3,748} {3,527} {16.06} 17.5 x 6.75
671.76 1,700 1,600 408 • 17.5 x 6.00

9.5R-17.5 129/127
{6.85, 97.4} {3,748} {3,527} {16.06} 17.5 x 6.75
*(1)
*(3) 725 2,415 2,300 • 22.5 x 7.50
492
10R22.5-14PR {7.25, 105} {5,324} {5,071} 22.5 x 6.75
{19.37}
850 2,800 2,650 495

10R22.5-144/142 22.5 x 7.50
{8.67, 123} {6,173} {5,842} {19.49}
*
* (1)
(3) 700 2,725 2,500 • 22.5 x 8.25
508
11R22.5-14PR {7.00, 102} {6,007} {5,511} 22.5 x 7.50
{20.0}
*
* (1)
(3) 800 3,000 2,725 • 22.5 x 8.25
508
11R22.5-16PR {8.00, 116} {6,614} {6,007} 22.5 x 7.50
{20.0}
850 3,150 2,900 510

11R22.5-148/145 22.5 x 8.25
{8.67, 123} {6,945} {6,393} {20.08}
*
*(3) (1) • 22.5 x 9.00
725 3,000 2,725
523 22.5 x 7.50
12R22.5-14PR {7.25, 105} {6,614} {6,007}
{20.59} 22.5 x 8.25
*
* (1)
(3) 800 3,250 2,900 • 22.5 x 9.00
523
12R22.5-16PR {8.00, 116} {7,165} {6,393} 22.5 x 8.25
{20.59}
850 3,550 3,150 526

12R22.5-152/148 • 22.5 x 8.25
{8.67, 123} {7,826} {6,944} {20.71}
4. Off the road tires

*
kPa Tire radius (2)
Tire size
{kgf/cm2, Single mm {in.} Applicable rim size
lbf/in.2}
*(1)
*(3) 525 1,600
447 • 6.00S
7.50-20-12PR {5.25, 76} {3,527}
{17.60}
*(3) 525 1,890
*
8.25-20-12PR {5.25, 76} {4,167} (1)
• 6.50T
465
*
(3) 600 2.045 6.00S
{18.31}
8.25-20-14PR {6.00, 87} {4,508}
*
(3) 475 2,120
*(1)
9.00-20-12PR {4.75, 69} {4,674} • 7.00T
485
*(3) 550 2,310 6.50T
{19.09}
9.00-20-14PR {5.50, 80} {5,093}
*
* (1) • 7.50V
(3) 500 2.470
500 7.00T
10.00-20-14PR {5.00, 73} {5,445}
{19.69} 8.00V
*
* (1) • 8.00V
(3) 475 2.605
513 7.50V
11.00-20-14PR {4.75, 69} {5,743}
{20.20} 8.50V
*
(3) 425 2,795
12.00-20-14PR {4.25, 62} {6,162}
*
* (1) • 8.50V
(3) 500 3,075
532 8.00V
12.00-20-16PR {5.00, 73} {6,779}
{20.94} 9.00V
*
(3) 550 3,250
12.00-20-18PR {5.50, 80} {7,165}
*(1) • 8.50V
*
(3) 500 3,460
582 8.00V
12.00-24-16PR {5.00, 73} {7,628}
{22.91} 9.00V
*(1)
*(3) 500 4,000 • 9.00V
606
13.00-24-18PR {5.00, 73} {8,818} 8.50V
{23.86}
*
*(3) (1)
425 3,850 • 10.00WI
584
14.00-20-16PR {4.25, 62} {8,488} 9.00V
{22.99}
*
(3) 425 4,295
14.00-24-16PR {4.25, 62} {9,469}
*
* (1)
(3) 525 4,865 • 10.00WI
635
14.00-24-20PR {5.25, 76} {10,725} 9.00V
{25.00}
*(3) 650 5,510
14.00-24-24PR {6.50, 94} {12,147}
DESCRIPTION
EN08Z0904C100001
SHTS08Z090400001
SAE AND JIS TYPE

1 Tire 5 Inner wheel nut
2 Disc wheel 6 Outer wheel nut
3 Side ring 7 Hub
4 Hub bolt 8 Wheel nut
Hub bolt diameter mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

20 {0.787} 392.27-470.71 {4,000-4,800, 290-347}
A
18 {0.709} 235.36-294.19 {2,400-3,000, 174-216}
20 {0.787} 392.27-470.71 {4,000-4,800, 290-347}
B, C
18 {0.709} 235.36-294.19 {2,400-3,000, 174-216}
SHTS08Z090400002
DIN AND ISO TYPE

1 Tire 4 Hub bolt
2 Disc wheel 5 Wheel nut
3 Side ring 6 Hub
Type Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

DIN 490.34-588.39 {5,000-6,000, 362-433}
A
ISO 490-539 {5,000-5,500, 362-397}
DIN 490.34-588.39 {5,000-6,000, 362-433}
B
ISO 490-539 {5,000-5,500, 362-397}
SHTS08Z090400003
SPOKE WHEEL TYPE

1 Tire 5 Clamp
2 Rim 6 Spoke wheel
3 Clamp bolt 7 Brake drum
4 Clamp nut 8 Band spacer
Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

A 264.78-294.19 {2,700-3,000, 196-216}
B 264.78-294.19 {2,700-3,000, 196-216}
SHTS08Z090400004
ADAPTER TYPE SPOKE WHEEL (Only for rear)

1 Tire 7 Hub bolt
2 Rim 8 Hub nut
3 Clamp bolt 9 Adapter
4 Clamp nut 10 Brake drum
5 Clamp 11 Band spacer
6 Axle shaft 12 Hub
Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

A 294.20-323.61 {3,000-3,300, 217-238}
B 490.34-588.39 {5,000-6,000, 362-433}
SHTS08Z090400005
WHEEL AND TIRE

1 Tire 4 Side ring
2 Tube 5 Disc wheel
3 Flap 6 Valve
TROUBLESHOOTING
EN08Z0904F300001

Excessive wear on edges of tread Under inflated tires Properly inflate with the recommended
pressure.
Vehicle overloading Correct as required by Factory spec.
High speed cornering Correct as required by Factory spec.
Incorrect wheel alignment Set to the correct specifications.
Tires show excessive wear in center Tires overinflated Properly inflate with the recommended
of tread pressure.
Excessive tire wear Improper tire pressure Properly inflate with the recommended
pressure.
Incorrect tire wheel usage Install the correct tire wheel combina-
tion.
Bent wheel Repair or replace.
Front end out of alignment Align front end.
Loose, worn or damaged steering Inspect, repair or replace as required
linkage, joints, suspension compo-
nents, bushing or ball joints
Wheel hopping Rocks or debris wedged between dual Remove the rocks and the debris.
(vehicle vibration and disc wheels
rough steering) Out-of-balance tire and/or hub and Determine the out-of-balance compo-
(Disc wheels) drum nent and balance or replace.
Improper positioning of the side ring Reassemble with ring split, opposite
split (180 degrees) to the valve opening to
improve the balance.
Wheel hopping Loose or worn drive line or suspension Identify the location of vibration care-
(vehicle vibration and fully. Then repair or replace the loos-
rough steering) ened or worn parts. (Refer to
(Vehicle) PROPELLER SHAFT for vehicle vibra-
tion.)
Wobbling Bent or distorted due to the overload- Replace the wheel.
(vehicle vibration and ing or improper handling
rough steering) Loose mountings, damaged studs, Replace worn or damaged parts.
(Disc wheels) wheel nuts, enlarged stud holes, worn Clean mounting surfaces.
or broken hub face, or foreign material
on mounting surfaces
Wobbling Improper alignment Have vehicle aligned.
(vehicle vibration and Loose, worn or broken suspension Repair or replace.
rough steering) parts
(Vehicle)
Cracked or broken wheel discs Metal fatigue resulting from overload- Replace wheel.
(cracks develop in the wheel disc ing
from hand hole to hand hole, from
hand hole to rim, or from hand hole
to stud hole.)

Damaged hub bolt holes (hub bolt Loose wheel mounting • Replace wheel and check the
holes become worn, elongated or installation of correct hub bolts
deformed, metal builds up around and nuts.
hub bolt hole edges, cracks develop • Check the cracked or broken hub
from hub bolt hole to hub bolt hole.) bolt-replace.
• Check the worn hub face-
replace.
• Check the broken or cracked
hub-replace.
• Clean mounting surfaces
(Retighten the wheel nuts period-
ically.)
• Rust streaks fanning out from
hub bolt holes: indicates that the
wheel nuts are or have been
loosen.
Tire slippage on rim (Disc wheels) Improper storage or operating condi- Correct as required.
tions
Poor maintenance Follow the proper maintenance proce-
dures.
Rust, corrosion or bead seating Correct as required.
Loss of pressure Follow the proper maintenance proce-
dures.
Tire mounting difficulties Mismatched tire and rim sizes Correct as required.
(Wheel rims) Defective or mismatched rings for the Correct as required.
rim
Tires overinflated Properly inflate with the recommended
pressure.
Corrosion and dirt Correct as required.
Loose inner wheel Excessive hub bolt stand out from the Replace with the proper length hub
mounting face of hub allowing the bolt.
wheel nut to bottom out
Improper torque Follow the recommended torque pro-
cedure.
Wrong inner nut Use correct inner nuts.
Broken hub bolts Loose wheel nuts Replace the hub bolt and follow the
proper torque procedures.
Overloading Replace the hub bolt.
Stripped threads Excessive clamp load Replace hub bolt and follow the proper
torque procedures.
Rust streaks from hub bolt holes Loose wheel nuts Check complete assembly, replace
damaged parts and follow the proper
torque procedures.
Damaged inner or outer wheel nuts Loose wheel assembly Replace wheel nuts. Check the proper
torque procedures.
Frozen inner or outer wheel nuts Corrosion or damage Replace wheel nuts and hub bolts.
SPECIAL TOOL
EN08Z0904K100001
Prior to starting a wheel and tire overhaul, it is necessary to have these special tools.
S0967-21010 LEVER
S0967-21020 LEVER
S0967-21040 LEVER
S0960-91210 LEVER
S0960-91220 RUBBER HUMMER

PRECAUTIONS
EN08Z0904C100002
! CAUTION
Failure to comply with the following procedures may result in faulty positioning of the tire and/or rim parts, and
can cause the assembly to burst with a explosive force sufficient to cause serious physical injury or death.
1. DEFLATION AND DISASSEMBLY

(1) Always check the tire/rim assembly for the proper components seating prior to the removal from the vehicle.
(2) Always deflate the tire by removing the valve core prior to removing the wheel from vehicle or disassembling of the
components.
(3) Never position your body in front of the rim during deflation.
(4) Always follow the assembly and disassembly procedures outlined in this instruction manual and obtain safety litera-
ture from the Authorities.
(5) Never use a steel hammer to assemble or disassemble the rim components. Use a lead, brass, or plastic type mallet.
2. RIM INSPECTION
(1) Always select the proper tire size and construction to match the rim or wheel rating and size.
(2) Never use damaged, worn, or corroded rims, wheels, or mounting hardware.
(3) Always clean and repaint lightly rusted rims.
(4) Never use a rim or wheel component you cannot identify.
3. ASSEMBLY AND INFLATION

(1) Always perform the double check to see that the removable rings are properly seated before inflating.
(2) Always inflate the tire in a safety cage or use a portable lock ring guard. Use a clip-on type air chuck with a remote
valve so that you can stand clear during the tire inflation.
(3) Never attempt to seat the rings while the tire is totally or partially inflated.
(4) Never re-inflate or add inflation pressure to a tire that has been run flat or seriously under inflated without removing
and checking for ring seating and rim damage.
(5) Tire pressure should be checked while cold. Do not bleed air from tires while hot. This will result in an under inflated
condition. Under inflated tires build up excessive heat due to overdeflection that may result in sudden tire deteriora-
tion, causing severe handling problems.
(6) Never use an assembly with excessive side ring play, wide gaps between ring ends, or butting ring ends.
(7) Never hammer on the components of an inflated or partially inflated assembly.
INSPECTION
EN08Z0904H300001
1. GENERAL INSPECTION
(1) Check the tire tread wear (groove depth) and tire damage. If the
slip sign on the tire tread comes out, replace the tire.
Groove depth (Remaining groove)
General running: 1.6 mm {0.063 in.}
High-speed running: 3.2 mm {0.126 in.}
SHTS08Z090400011
(2) Check the air pressure.

If improper, inflate the tire to the proper pressure as previously
described in this chapter.
SHTS08Z090400012
2. CHECK RUNOUT IN THE TIRE AND WHEEL RIM.

NOTICE
Eliminate any flat spots in the tire by driving the vehicle a little.
(1) Jack up the vehicle and the check the runout in the tire and wheel
rim.
Unit: mm {in.}
Tire Wheel rim
Lateral runout Less than 2.5 {0.098} Less than 1.8 {0.071}
Radial runout Less than 2.5 {0.098} Less than 1.8 {0.071}
SHTS08Z090400013
(2) If the wheel rim does not conform to the runout limits, try re-
mounting the wheel in a different position.
(3) If the wheel rim is still not within 1.8 mm {0.072 in.} of runout, then
replace it with a new rim.
(4) If the tire does not conform to runout standards, reinstall it in dif-
ferent position on the rim.
3. WHEEL AND TIRE BALANCING.

(1) Driving with a rim or tire that is unbalanced may cause the vehicle
and steering wheel to shimmy, and will produce an abnormal tire
wear.
SHTS08Z090400014
In this situation, we recommend that you should balance the
wheels.
• Static balancing
This is relatively effective when operating at low speeds; however,
if operating at high speeds, dynamic balancing is recommended.
• Dynamic balancing
Please balance the wheels, using a balancing machine.

EN08Z0904H300002
Tire: — — Replace, Visual check

Damage, foreign matter, if necessary.
etc.
Tubeless tire: — — Replace, Visual check

Tube: — — Replace, Visual check

Air leakage if necessary.
Wheel (With tube): — — Replace, Visual check

Cracks and deformation if necessary.
Wheel (Tubeless tire): — — Replace, Visual check

Cracks and deformation if necessary.
Rim (Tubeless tire): — — Replace, Visual check

Pipe, nut and O-ring of — — Replace, Visual check

the valve (tubeless tire): if necessary.
Damage
SAE, JIS, DIN AND ISO TYPE WHEEL

OVERHAUL
EN08Z0904H200001
IMPORTANT POINT - REMOVAL
1. REMOVE THE WHEEL AND TIRE.

(1) Loosen the wheel nuts, but do not remove them.
(2) Raise the vehicle until the tire clear the floor.
(3) Remove the wheel nuts and tire from the hub and drum.
On dual tires, the inner wheel nuts will also have to be removed
for the inner tire to be removed.
NOTICE
• Be sure to apply the wheel stoppers in the front or rear tires.
• The wheel nuts on the right side of the vehicle have right
SHTS08Z090400022
hand threads, and those on the left side have left hand
threads.
1. DISASSEMBLE THE WHEEL AND TIRE (WITH TUBE).

(1) Place the wheel and tire on the floor with side ring up.
(2) Make certain that the tire is completely deflated with the valve
core removed.
(3) With a suitable tools, insert the hook end between the side ring
and side wall of the tire and pry the bead loose from the side ring
with a downward pressure on the tools.
(4) Continue prying progressively around the tire until the bead is
completely freed from side ring.
SHTS08Z090400023
(5) With the special tool, pry the side ring from its groove in the rim by
prying progressively around the tire until the ring is freed.
SST: Lever (S0967-21040)
SHTS08Z090400024
(6) Turn the assembly over and unseat the second tire bead from the
rim. Lift the rim from the tire.
Remove the tube and flap, if any, from the tire.
SHTS08Z090400025
2. DISASSEMBLE THE WHEEL AND TIRE (TUBELESS).

(1) Make certain the tire completely deflated with the valve core
removed.
(2) With the tire lying flat, loosen both beads with the special tool or
by standing on the tire with your heels close to the rim.
SST: Rubber hammer (S0960-91220)
SHTS08Z090400026
(3) With the wide side of the rim down, lubricate the top bead.
(4) With the stops toward the rim, insert the spoon ends of the special
tools about 250 mm {10 in.} apart. Holding the bead in the well
with one foot, pull one tool towards the center of the rim.
SST: Lever (S0960-91210)
SHTS08Z090400027
(5) Hold the tool in position with one foot and pull the second tool
toward the center of the rim. Progressively work the bead off the
rim, taking additional bites with the tools as necessary.
SHTS08Z090400028
(6) Stand the assembly in a vertical position.

Lubricate the second bead.
(7) At the top of the assembly, insert the straight end of the tool
between the bead and back the flange of the rim at about 45
degrees angle.
Turn the tool so that it is perpendicular to the rim. Pry the second
bead off.
SHTS08Z090400029
1. ASSEMBLY THE WHEEL AND TIRE (WITH TUBE).

(1) Insert the tube and the flap into the tire and partially inflate to
round out the tube. Apply the rubber lubricant to the inside and
outside surfaces of both beads and to that portion of the tube and
flap that appears between the beads. Lay the rim flat on the floor
with the valve slot up. Align the valve with the rim valve slot, and
place the tire onto the rim, and insert the valve through the valve
slot.
SHTS08Z090400030
(2) Place the side-ring on the rim base so that the ring split is oppo-
site to the valve stem. Place the leading end of the ring into the
groove in the rim as shown.
SHTS08Z090400031
(3) Starting at the valve side progressively walk the side-ring into
place. Check to ensure that the ring is fully seated in the groove.
SHTS08Z090400032
(4) Place the tire assembly in a safety cage and inflate the tire as pre-
viously described in this chapter. Again check the side-ring, tap-
ping lightly with a mallet to ensure the proper engagement. Check
to see that the beads are properly seated. Completely deflate the
tire to prevent the tube from the buckling. Reinflate according to
the recommended pressure, and check the tire assembly.
SHTS08Z090400033
2. ASSEMBLY THE WHEEL AND TIRE (TUBELESS).

(1) Be sure that the proper valve is used and is properly installed in
the rim.
Valve nut tightening torque: 12.7 N⋅m {130 kgf⋅cm, 9.4 lbf⋅ft}
(2) Inspect the rim to ensure that the bead seats are clean and
smooth.
(3) Place the rim on the floor with the wide side down and lubricate
the first bead of the tire and upper bead seat of the rim.
SHTS08Z090400034
(4) Push the first bead into the well of the rim and onto the rim as far
as possible.
With the special tool, hammer the first bead so that the bead gets
over the rim flange.
SHTS08Z090400035
(5) Insert the lever between the rim flange and the tire bead and then
raise the lever so that the bead gets over the rim flange.
SST: Lever (S0960-91210)
SHTS08Z090400036
(6) With the special tool, hammer the tire tread so that the bead and
the rim will be seated.
(7) Inflate the tire as described in this chapter, making certain that all
the safety precautions are followed. Check for the leakage.
SHTS08Z090400037
IMPORTANT POINTS - INSTALLATION
1. INSTALL THE WHEEL AND TIRE.

(1) Be sure to check all parts and replace any parts that are overly
worn or damaged. Clean and remove any foreign matter from hub
bolts, wheel nuts and wheel side is contacting with the brake
drum.
SHTS08Z090400038
(2) Apply lubricant (engine oil or grease) to the thread part of the hub
bolts and wheel nuts.
SHTS08Z090400039
(3) Rotate the wheel if necessary and check to see that the hub bolts
are in the center of the wheel's hub bolt holes, then tighten the
wheel nuts lightly.
NOTICE
The wheel nuts on the right side of the vehicle have right hand
threads, and those on the left side have left hand threads.
SHTS08Z090400040
(4) Using a wheel nut wrench, tighten the wheel nuts in accordance
with specified torque using diagonal method.
Tightening torque
490.34-588.39
DIN type
{5,000-6,000, 362-434}
10 stud
392.27-470.71
8 stud
SAE and {4,000-4,800, 290-347}
JIS type 6 stud
235.36-294.19
5 stud
{2,400-3,000, 174-217}
490-539
ISO type
{5,000-5,500, 362-497}
NOTICE
Tighten the wheel nuts with several repetitions in the tightening
order so as to reach the proper torque evenly and gradually.
! CAUTION
SHTS08Z090400041 The specified torque should be referred to the torque tightening
wheel nuts. Tightening it with incorrect can cause the wheel to
come off while driving. This can result in physical injury and/or
property damage due to the loss of vehicle control.
When the vehicle, wheels, or wheel nuts are new, the wheel nuts
should be checked and tightened with specified torque at 50-100
km {30-60 miles} since they may not be well tightened. The tight-
ening torque should be checked with the proper torque wrench.
2. THE FOLLOWING ORDER AND INSTRUCTIONS ARE NECES-

SARY FOR INSTALLING THE DUAL TIRES.
(1) Installation procedures for the inner wheel nuts are the same as in
1. through 4. above.
(2) Installation procedures for the outer wheel nuts are the same as
above.
(3) When only the outer wheel is replaced, first tighten all the inner
wheel nuts to the specified torque. Then mount the outer wheel
and tighten all the outer wheel nuts to the specified torque.
NOTICE
• Install the dual rear wheels with their valve stems positioned
at 180 degrees apart to facilitate inflation.
• Tighten all the inner nuts and outer nuts according to the
above-mentioned procedures.
3. WHEEL AND TIRE BALANCING

wear.
wheels.
SPOKE WHEEL AND ADAPTER TYPE WHEEL

OVERHAUL
EN08Z0904H200002
IMPORTANT POINT - REMOVAL
1. REMOVAL OF THE RIM AND TIRE.

(1) Loosen the clamp nuts, but do not remove them completely.
(2) Raise the vehicle until the tire clear from floor.
(3) Remove the clamp nuts and then use the special tool to pry off the
clamps.
SST: Lever (S0967-21010)
NOTICE
Block the wheels.
SHTS08Z090400042
(4) On the dual tires, the band spacer will also have to be removed
and then remove the inner wheel.
SHTS08Z090400043
1. DISASSEMBLE THE RIM AND TIRE.

(1) Place the wheel on the floor with valve side up.
(2) Make sure the tire is completely deflated with the valve core
removed.
(3) With the special tools, insert the hook end between the rim and
side wall of tire and pry the bead loose from the rim with a down-
ward pressure on the tools.
SST: Lever (S0967-21010, S0967-21020)
SHTS08Z090400044
(4) Continue prying progressively around the tire until the bead is
completely freed from the rim.
(5) Make a matching marks on the segments.
(6) Place the special tool in the rim joint groove and pry the rim seg-
ments apart.
SST: Lever (S0967-21010)
(7) Remove the rim segments.
SHTS08Z090400045
1. ASSEMBLE THE RIM AND TIRE.

(1) Clean the rim segments and check for damages, if there is any
damage, repair or replace.
(2) Fit the tube and flap in the tire.
(3) Place the segment with valve hole in the tire.
The valve must point upwards.
SHTS08Z090400046
(4) Place the other segment on the first one as shown in the figure.
NOTICE
Align the matching marks on the segments.
SHTS08Z090400047
(5) Place the other segment together with the first one.
Fit the segment so that the valve lies against the side of the hole
marked with an arrow.
SHTS08Z090400048
(6) With the special tool, pry the segments to fit the last segment in
position.
SST: Lever (S0967-21020)
NOTICE
Do not pull upwards.
(7) Install the valve core and then inflate the tire as previously
described in this chapter, making sure that all the safety precau-
tions are followed. Check for the leakage.
SHTS08Z090400049
IMPORTANT POINTS - INSTALLATION
1. INSTALL THE SINGLE WHEEL.

(1) Clean the spoke ends, rim edges, clamps and nuts.
(2) Lubricate the clamp bolts.
(3) Install the wheel over the spoke ends so that the valve and rim
stopper are between two spokes.
(4) Install two clamps and nuts on opposite sides of the rim as indi-
cated by arrows on the drawing.
Tighten the nuts lightly.
SHTS08Z090400050
(5) Install the remaining clamps and nuts.

Tighten the nuts in sequence round the rim edge to sufficient
torque as described in this chapter.
(6) Check and retighten the nuts after driving the vehicle in a dis-
tance.
SHTS08Z090400051
2. INSTALL THE DUAL WHEEL.

(1) Clean the spoke ends, rim edge, band spacer, clamps and nuts.
(2) Lubricate the clamp bolts.
(3) Install the inner wheel so that the valve and rim stopper are
between two spokes.
SHTS08Z090400052
(4) Install the band spacer over the spokes so that it may tightened
up against the inner wheel rim.
The band spacer stopper must be between two spokes. Make
sure that the band spacer stopper does not cover the inner wheel
valve.
SHTS08Z090400053
(5) Install the outer wheel and press it, and then tighten up against
the band spacer. Make sure that the rim stopper and valve are
between two spokes and diagonally to the inner wheel valve.
Install two top clamps and nuts as indicated by the arrows on the
drawing and tighten the nuts lightly.
SHTS08Z090400054
(6) Install the remaining clamps and nuts.

(7) Tighten the nuts in sequence round the rim edge to sufficient
torque as previously described in this chapter.
(8) Check and retighten the nuts after driving the vehicle in a dis-
tance.
SHTS08Z090400055
3. WHEEL AND TIRE BALANCING

wear.
wheels.
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧝㧤ಽ
SUSPENSION (MODELS: FC, FD, GD, FG, GH) SU02–1
SUSPENSION SU02
(MODELS: FC, FD, GD, FG, GH) SU02-001
LEAF SUSPENSION ASSEMBLY ............ SU02-2

DATA AND SPECIFICATIONS........................ SU02-2
DESCRIPTION ................................................ SU02-5
TROUBLESHOOTING..................................... SU02-7
SPECIAL TOOL ............................................... SU02-7
COMPONENT LOCATOR ............................... SU02-8
OVERHAUL ................................................... SU02-14
INSPECTION AND REPAIR .......................... SU02-19
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧝㧢ಽ
SU02–2 SUSPENSION (MODELS: FC, FD, GD, FG, GH)
LEAF SUSPENSION ASSEMBLY

EN09A0102I200001
MODELS: FC, FD
FRONT SUSPENSION
Type Semi-elliptic leaf springs with shock absorber
Span 1,300 mm {51.181 in.}
Width 70 mm {2.760 in.}
Dimensions of leaf Multi leaf spring Taper leaf spring

springs: 10 mm {0.394 in.} 18.5 mm {0.728 in.} 18.5 mm {0.728 in.}
Thickness of leaves
19.8 mm {0.780 in.} 19.8 mm {0.780 in.}
11 mm {0.433 in.}
14.0 mm {0.551 in.} 16.2 mm {0.638 in.}
Type Single acting Double acting
Stroke 255 mm {10.039 in.} 255 mm {10.039 in.}

Shock absorbers:
Min. length 359 mm {14.134 in.} 359 mm {14.134 in.}
Max. length 614 mm {24.173 in.} 614 mm {24.173 in.}
REAR SUSPENSION
Type Semi-elliptic main and auxiliary leaf springs
Span 1,300 mm {51.181 in.}
Dimensions of main leaf springs: Width 70 mm {2.760 in.}
Thickness of leaves 11 mm {0.433 in.}
Span 900 mm {35.433 in.}
Dimensions of auxiliary leaf Width 70 mm {2.760 in.}

springs: 9 mm {0.354 in.}
Thickness of leaves
10 mm {0.394 in.}
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧝㧣ಽ
MODEL: GD
FRONT SUSPENSION
Span 1,300 mm {51.181 in.}
Width 70 mm {2.760 in.}
Multi leaf spring Taper leaf spring
10 mm 18.5 mm 18.5 mm 18.5 mm 18.5 mm

10 mm {0.394 in.} {0.728 in.} {0.728 in.} {0.728 in.} {0.728 in.}
Dimensions of
leaf springs: {0.394 in.} 11 mm 19.8 mm 19.8 mm 19.8 mm 19.8 mm
Thickness of
{0.433 in.} {0.780 in.} {0.780 in.} {0.780 in.} {0.780 in.}
leaves
14.0 mm 16.2 mm
11 mm 12 mm 14.0 mm 16.2 mm {0.551 in.} {0.638 in.}
{0.433 in.} {0.472 in.} {0.551 in.} {0.638 in.} 12 mm 12 mm
{0.472 in.} {0.472 in.}
Shock Stroke 270 mm {10.630 in.} 261 mm {10.276 in.}

absorbers: Min. length 365 mm {14.370 in.} 360 mm {14.173 in.}
Stabilizer (If so equipped) Torsion bar Torsion bar
REAR SUSPENSION
Span 1,300 mm {51.181 in.}
Width 70 mm {2.760 in.}

Dimensions of main leaf springs:
11 mm {0.433 in.}
Thickness of leaves
10 mm {0.394 in.}
Span 900 mm {35.433 in.}

Dimensions of auxiliary leaf
Width 70 mm {2.760 in.}
springs:
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧝㧤ಽ
MODELS: FG, GH
FRONT SUSPENSION (MULTI LEAF SPRING)
Span 1,470 mm {57.87 in.}
Width 80 mm {3.15 in.}
13 mm 13 mm 13 mm 13 mm
{0.512 in.} {0.512 in.} {0.512 in.} {0.512 in.}
Dimensions of leaf springs:
10 mm 12 mm 10 mm 16 mm
Thickness of leaves
{0.394 in.} {0.472 in.} {0.394 in.} {0.629 in.}
10 mm 10 mm
— —
{0.394 in.} {0.394 in.}
Type Single acting
Stroke 252 mm {9.921 in.} 260 mm {10.236 in.}

Shock absorbers:
Min. length 382 mm {15.039 in.} 390 mm {15.354 in.}
Stabilizer (If so equipped) Torsion bar
FRONT SUSPENSION (TAPER LEAF SPRING)
Span 1,470 mm {57.87 in.}
19.5 mm 19.5 mm 21 mm 21 mm
{0.768 in.} {0.768 in.} {0.827 in.} {0.827 in.}
10 mm 16 mm 10 mm 16 mm
Thickness of leaves
{0.394 in.} {0.629 in.} {0.394 in.} {0.629 in.}
10 mm 10 mm
— —
{0.394 in.} {0.394 in.}
Type Double acting
Stroke 249 mm {9.803 in.}

Shock absorbers:
Min. length 381 mm {15.000 in.}
Max. length 630 mm {24.803 in.}
REAR SUSPENSION
Span 1,400 mm {55.12 in.}
Dimensions of main leaf springs: Width 90 mm {3.54 in.}
Span 980 mm {39.37 in.}

Dimensions of auxiliary leaf springs:
11 mm {0.43 in.}
Thickness of leaves
12 mm {0.47 in.}
REAR SUSPENSION (DUMP MODEL)
Span 1,400 mm {55.12 in.}
Dimensions of main leaf springs Width 80 mm {3.15 in.}
Span 1,000 mm {39.37 in.}

Dimensions of auxiliary leaf springs
11 mm {0.43 in.}
Thickness of leaves
12 mm {0.47 in.}
DESCRIPTION
EN09A0102C100001
FRONT SUSPENSION
SHTS09A010200001
1 Shock absorber 5 Leaf spring assembly

2 Spring bumper 6 Spring pin
3 Shackle 7 Stabilizer (If so equipped)
4 U-bolt
REAR SUSPENSION (MODELS: FC, FD, GD)
SHTS09A010200002
1 Spring pin 4 Main leaf spring assembly

2 Auxiliary leaf spring assembly 5 Shackle
3 U-bolt 6 Spring bumper
REAR SUSPENSION (MODELS: FG, GH)
SHTS09A010200003
1 Spring pin 5 Spring pad

2 Auxiliary leaf spring assembly 6 Spring bumper
3 Main leaf spring assembly 7 Shackle
4 U-bolt
TROUBLESHOOTING
EN09A0102F300001

Rough ride Broken leaves Replace the leaves. Check the load
capacity rating.
Cracked or damaged Replace the leaves. Check the load
capacity rating.
Overloading Decrease the load.
Heavy sway Inoperative shock absorber Replace the shock absorber.
Leaves broken at the center bolt Loosen U-bolts Replace the leaves and tighten the U-
hole bolts to specified torque.
Squeaking of the leaves Friction between the leaves Replace the silencers and/or apply
chassis grease between leaves.
SPECIAL TOOL
EN09A0102K100001
Prior to starting a suspension overhaul, it is necessary to have these special tools.
MODELS: FC, FD, GD
S0983-92204 SOCKET WRENCH For front U-bolt
S0960-31160 SOCKET WRENCH For rear U-bolt
MODELS: FG, GH
S0983-93202
SOCKET WRENCH For rear U-bolt
S0983-93203
S0984-12560 BAR For rear U-bolt

COMPONENT LOCATOR
EN09A0102D100001
FRONT SUSPENSION (MODELS: FC, FD, GD)
SHTS09A010200009
1 U-bolt 16 Center bolt

2 Spring bumper 17 Clip
3 Lubrication fitting 18 Inter leaf
4 Lock nut 19 Lock plate
5 Lock washer 20 Spacer
6 Spring pin 21 Plain washer
7 U-bolt nut 22 Bracket
8 Spacer (Driver's seat side only) 23 Cushion
9 Leaf spring assembly 24 Caster shim
10 Thrust washer 25 Stabilizer
11 Shackle 26 Holder
12 Shock absorber 27 Stabilizer
13 Cushion washer 28 Rubber bushing
14 Bushing 29 Stabilizer lever
15 Rivet 30 Stabilizer link pin

A (Models: FC, FD) 76-114 {775-1,162, 57-84} D (Models: FC, FD) 200-280 {2,040-2,855, 148-206}
(Model: GD) 73-109 {745-1,110, 55-81} (Model: GD) 290-410 {2,960-4,180, 218-307}
B 64-93 {653-948, 48-68} E 105-145 {1,071-1,478, 78-106}
C 85-108 {870-1,100, 63-79} F 73-109 {745-1,111, 54-80}
FRONT SUSPENSION (MODELS: FG, GH)
SHTS09A010200010
1 U-bolt 15 Clip
2 Spring pad 16 Rivet
3 Spring bumper 17 Stabilizer link rod
4 Thrust washer 18 Holder
5 Spring pin 19 Stabilizer
6 Shackle 20 Rubber bushing
7 Lubrication fitting 21 Stabilizer lever
8 Leaf spring assembly 22 Stabilizer link pin
9 Shock absorber 23 Caster shim
10 Cushion washer 24 Spacer
11 Shock absorber pin 25 Center bolt
12 Lock washer 26 Cushion
13 Nut 27 Spacer (Driver's seat side only)
14 Bushing

A 236-324 {2,406-3,303, 174-238} G 167-225 {1,700-2,300, 123-165}
B 64-93 {653-948, 48-68} (Taper leaf spring)
C 85-108 {870-1,100, 63-79} 236-324 {2,406-3,303, 174-238}
D 390-440 {3,977-4,486, 288-324} (Multi leaf spring)
E 73-109 {745-1,111, 54-80} H 105-145 {745-1,111, 54-80}
F 96-144 {979-1,468, 71-106}
REAR SUSPENSION (MODELS: FC, FD, GD)
SHTS09A010200011
1 U-bolt 8 Main leaf spring assembly

2 Spring pad 9 Shackle
3 Slide seat 10 Clip
4 Auxiliary leaf spring assembly 11 Rivet
5 Spring pin 12 Bushing
6 Lubrication fitting 13 Center bolt
7 Thrust washer

A 73-109 {745-1,111, 54-80} C 265-315 {2,703-3,212, 196-232}
B 85-108 {870-1,100, 63-79} D 73-109 {745-1,111, 54-80}
REAR SUSPENSION (MODELS: FG, GH)

1
D
B
9
7
4 12 8
3
5 11 7
8
6
9
F
5
A 7
8 10
9 13
10
C
14
13
SHTS09A010200012
1 U-bolt 8 Lubrication fitting

2 Spring pad 9 Thrust washer
3 Slide seat 10 Main leaf spring assembly
4 Spacer 11 Spacer
6 Spring bumper 13 Rivet
7 Spring pin 14 Bushing

A 73-109 {745-1,110, 54-80} D 73-109 {745-1,110, 54-80}
B 226-284 {2,300-2,900, 167-209} E 64-86 {650-870, 47-63}
C 640-740 {6,530-7,540, 472-545} F 61-91 {620-920, 45-67}
OVERHAUL
EN09A0102H200001
1. SUPPORT OF THE FRAME WITH STANDS

(1) Park the vehicle on level ground.
(2) Be sure to block the wheels before dismounting.
SHTS09A010200013
(3) Jack up the axle, and support the frame with stands.
(4) Remove the tires.
SHTS09A010200014
2. REMOVAL OF THE U-BOLT

(1) Remove the shock absorber. (Front suspension only)
(2) Support the axle with a floor jack.
(3) Remove the U-bolt mounting nuts.
NOTICE
When cutting off the U-bolts (Due to rusted threads) with a torch,
never direct the flame toward the leaves or allow sparks to come
in contact with the leaves.
SST:
Name Part No. Model
SHTS09A010200015 S0983-92204 FC, FD, GD
Socket Wrench for Front U-bolt
S0960-31160 FG, GH
S0960-31160 FC, FD, GD
Socket Wrench for Rear U-bolt S0983-93202
FG, GH
S0984-12560
3. REMOVAL OF THE SPRING PIN (FRONT SUSPENSION)

(1) Remove the lubrication fitting.
(2) Uncaulk the nut with a chisel, then loosen the nut.
SHTS09A010200016
(3) Use a brass rod to remove the spring pins from the shackle and
spring bracket.
SHTS09A010200017
4. REMOVAL OF THE SPRING PIN (REAR SUSPENSION)

(1) Remove the lubrication fitting and spring pin lock bolt.
SHTS09A010200018
spring bracket.
SHTS09A010200019
1. REPLACEMENT OF THE EYE BUSHING

(1) Use a suitable tool to press out the old eye bushing.
(2) Use a suitable tool to press in the new eye bushing.
SHTS09A010200020
2. DISASSEMBLY OF THE LEAF SPRING

! CAUTION
When removing the center bolt lock nut, the spring leaves may
jump. Care should be taken to avoid possible personal injury.
(1) Remove the clip bolts.
(2) Use a vise or an arbor press to hold the leaf spring near the cen-
ter bolt.
(3) Remove the center bolt.
(4) Loosen a vise or an arbor press slowly, and separate the leaves.
SHTS09A010200021
1. ASSEMBLY OF THE LEAF SPRING

! CAUTION
When clamping the spring leaves, they may jump. Care should be
taken to avoid possible personal injury.
(1) Apply coating on the leaf after removing rust, and apply chassis
grease on both surfaces at leaves.
SHTS09A010200022
(2) Align the leaf holes and silencers (Front suspension only), then
secure the leaves with a vise or an arbor press.
(3) Insert the center bolt and tighten the lock nut.
NOTICE
When reassembling the leaf spring, replace the center bolt with a
new one.
SHTS09A010200023
(4) Tighten the clip bolts.

NOTICE
When tightening the clip bolts, use a new clip bolts.
(5) Use a punch to peen the thread of the clip bolts.
SHTS09A010200024
IMPORTANT POINTS - MOUNTING
1. INSTALLATION OF THE SPRING PIN

(1) Use a copper hammer to install the spring pin with thrust washers.
NOTICE
Apply chassis grease on the surface of the eye bushing and
spring pin before installing.
(2) Install the spring pin lock bolt and nut.
(3) Install and secure the lock nut.
SHTS09A010200025
2. INSTALLATION OF THE U-BOLT

(1) Place the caster shim between the spring seat and leaf spring. (If
so equipped)
NOTICE
When installing the caster shim, the thick end should face;
front of the vehicle. (Models: FC, FD, GD)
rear of the vehicle. (Models: FG, GH)
Models: FC, FD, GD Models: FG, GH
SHTS09A010200029 To Front
(2) Put the spacer between the caster shim and leaf spring of the
driver's seat side. (For front suspension)
(3) Lift the axle using a jack and align the hole of the leaf spring cen-
ter bolt and the hole of the axle I-beam.
NOTICE
Axle and suspension assembly are heavy, therefore be careful
when handling them.
(4) Put the spring bumper or the spring pad on the leaf spring.
(5) Set the U-bolts so that they catch the spring bumper or the spring
pad and tighten the U-bolt nuts temporarily.
SHTS09A010200030
(6) Using the special tool, tighten the U-bolt nuts (4 pieces) alter-
nately right and left and equally.
After repeating this operation 3 to 5 times, tighten the nuts to the
1 3 specified torque.
FRONT
SST:
Name Part No. Model
S0983-92204 FC, FD, GD
Socket Wrench for Front U-bolt
2 4 S0960-31160 FG, GH
S0960-31160 FC, FD, GD
SHTS09A010200031
Socket Wrench for Rear U-bolt S0983-93202
FG, GH
S0984-12560
3. ADJUSTMENT OF THE SUSPENSION AFTER ASSEMBLING

(1) If the vehicle inclination is observed after assembling suspension,
correct it by inserting the following spacer between the spring and
the axle.
Spacer:
Model Part No. Thickness
FC, FD, GD SZ940-82568
Front suspension FG, GH (Except Hong Kong) SZ940-85155 4.5 mm {0.177 in.}
FG, GH (Hong Kong) SZ940-85169
FC, FD, GD SZ940-85053
6.0 mm {0.236 in.}
Rear suspension FG (Thailand Cargo, Taiwan) SZ940-85018
FG (Thailand Dump, Chile, Hong Kong), GH SZ940-85086 4.5 mm {0.177 in.}
4. LUBRICATION
(1) Lubricate the following parts with chassis grease.
1. Spring pins
SHTS09A010200032
2. Auxiliary spring slide seats
SHTS09A010200033

EN09A0102H300001
MODELS: FC, FD, GD

Unit: mm {in.}
Spring pin: Outside Front 25 {0.984} 24.7 Replace. Measure

diameter {0.9724}
Rear 30 {1.181} 29.7

{1.1693}
Clearance between spring pin 0.125 0.5 Replace the pin Measure
and eye bushing {0.0049} {0.0197} and/or bushing.
Thrust washer: Front 2.0 {0.079} 1.5 {0.059} Replace. Measure

Wear
Rear 3.0 {0.118} 2.5
{0.0984}
Leaf: — More than Replace. Measure

Damage and wear 15%
Silencer: 3.0 1.0 Replace, Measure

Wear {0.118} {0.0394} if necessary.
Spring bumper: — — Replace, Visual check

Damage and wear if necessary.
U-Bolt: — — Replace, Visual check

Shock absorber: — — Replace, Visual check

Operation, oil leak and dam- if necessary.
age
Cushion: — —
Damage and wear
Shock absorber pin and — —

bracket:
Damage and wear
Shackle: — — Replace, Visual check

Stabilizer Bar: Replace, Visual check

(If so equipped)
Stabilizer Sleeve:
Wear
(If so equipped)
Stabilizer Bushing:
Wear
(If so equipped)
MODELS: FG, GH
Unit: mm {in.}

diameter {1.170}
Rear 30 {1.181} 29.7

{1.170}
38 {1.496} 3.5
{0.138}
Clearance between spring pin 0.020-0.125 0.5 Replace the pin Measure
and eye bushing {0.0008-0.0049} {0.0196} and/or bushing.
Thrust washer: Front Pivot side 1.8 Replace. Measure

Wear 2.3 {0.091} {0.0709}
Shackle side 3.5

4.0 {0.157} {0.138}
Rear Pivot side 1.5

2.0 {0.079} {0.059}
Pivot side 2.5

3.0 {0.118} {0.0984}
Shackle side 3.5

4.0 {0.157} {0.138}
Shackle side 2.5

3.0 {0.118} {0.0984}

Damage and wear 15%




age
Cushion: — —
Damage and wear

bracket:
Damage and wear


(If so equipped)
Stabilizer Sleeve:
Wear
(If so equipped)
Stabilizer Bushing:
Wear
(If so equipped)
2A57AA(.A(/HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧝㧥ಽ
SUSPENSION (MODELS: FL, FM) SU02–1
SUSPENSION (MODELS: FL, FM)

SU02
SU02-002
LEAF SUSPENSION ASSEMBLY ............ SU02-2

DESCRIPTION ................................................ SU02-3
SPECIAL TOOL ............................................... SU02-4
OVERHAUL ..................................................... SU02-7
SU02–2 SUSPENSION (MODELS: FL, FM)

EN09A0102I200001
FRONT SUSPENSION
Span 1,470 mm {57.874 in.}
Multi leaf spring Taper leaf spring
Dimensions of leaf 10 mm 10 mm 19.5 mm

springs: {0.394 in.} {0.394 in.} {0.768 in.}
Thickness of
leaves 12 mm 11 mm 19.5 mm
{0.472 in.} {0.433 in.} {0.768 in.} 10 mm
13 mm 12 mm {0.394 in.}
{0.512 in.} {0.472 in.}
252 mm 260 mm
Stroke 249 mm {9.803 in.}
{9.921 in.} {10.236 in.}
Shock absorbers: 382 mm 390 mm
Min. length 381 mm {15.000 in.}
{15.039 in.} {15.354 in.}
634 mm 650 mm
Max. length 630 mm {24.803 in.}
{24.961 in.} {25.590 in.}
REAR SUSPENSION
Type Semi-elliptic leaf springs with torque rods
Span 1,300 mm {51.181 in.}
Width 90 mm {3.543 in.}

16 mm {0.63 in.}
Thickness of leaves
18 mm {0.71 in.}
DESCRIPTION
EN09A0102C100001
FRONT SUSPENSION
SHTS09A010200001
1 Shock absorber 4 U-bolt

2 Spring bumper 5 Leaf spring assembly
3 Shackle 6 Spring pin
REAR SUSPENSION
SHTS09A010200002
1 Torque rod bracket 4 Torque rod

2 U-bolt 5 Leaf spring assembly
3 Trunnion assembly
TROUBLESHOOTING
EN09A0102F300001

capacity rating.
capacity rating.
Leaves broken at the center bolt Loosen U-bolts Tighten to specified torque.
hole
SPECIAL TOOL
EN09A0102K100001
S0960-31010 SOCKET WRENCH For rear U-bolt
S0940-41060 HANDLE
COMPONENT LOCATOR
EN09A0102D100001
FRONT SUSPENSION
SHTS09A010200006
1 U-bolt 11 Leaf spring assembly

2 Spring pad 12 Caster shim
3 Spring bumper 13 Spacer (Driver's seat side only)
4 Thrust washer 14 Shock absorber pin
5 Spring pin 15 Center bolt
6 Shackle 16 Bushing
7 Lock plate 17 Clip
8 Lubrication fitting 18 Rivet
9 Cushion washer 19 Cushion
10 Shock absorber 20 Collar

A (Taper leaf spring) C 85-108 {870-1,100, 63-79}
167-225 {1,700-2,300, 125-168} D 390-440 {3,977-4,486, 288-324}
(Multi leaf spring) E 73-109 {745-1,111, 54-80}
236-324 {2,406-3,303, 174-238} F 236-324 {2,406-3,303, 174-238}
B 64-93 {653-948, 48-68}
REAR SUSPENSION
SHTS09A010200007
1 Leaf spring assembly 9 Dust shield 17 Trunnion bracket

2 Spring pad 10 Shim 18 Torque rod
3 U-bolt 11 Clamp plate 19 Rubber bushing
4 Nut 12 Lock plate 20 Torque rod bracket
5 Bushing 13 Trunnion gasket 21 Center bolt
6 Trunnion seat 14 Trunnion cover 22 Clip
7 Oil-seal 15 Breather valve 23 Rivet
8 Trunnion collar 16 Lubrication fitting

A 782-978 {7,975-9,972, 577-721} D 341-459 {3,478-4,680, 254-339}
B 236-324 {2,407-3,303, 174-238} E 37-49 {378-499, 28-36}
C 170-230 {1,734-2,345, 126-169} F 226-284 {2,300-2,900, 167-209}
OVERHAUL
EN09A0102H200001

SHTS09A010200008
SHTS09A010200009

NOTICE
SST:
Socket Wrench for Front U-bolt (S0960-31160)
Socket Wrench for Rear U-bolt (S0960-31010)
SHTS09A010200010 Handle (S0940-41060)
SHTS09A010200011
3. REMOVAL OF THE SPRING PIN (FRONT SUSPENSION)

(2) Uncaulk the nut with a chisel, then loosen the nut. (Front side of
spring)
SHTS09A010200012
(3) Remove the spring pin lock bolt. (Rear side of spring)
spring bracket.
SHTS09A010200013
4. REMOVAL OF THE LEAF SPRING FROM THE TRUNNION

SEAT.
(1) Remove the leaf spring from the trunnion seat.
SHTS09A010200014
5. REMOVE OF THE TRUNNION SEAT

(1) Remove the trunnion shaft cover.
(2) Uncaulk the lock plate of the clamp plate bolts with a chisel, then
remove the bolts, lock plate, clamp plate and shims.
(3) Remove the trunnion seat from trunnion shaft.
! CAUTION
Since the trunnion seat is too heavy, be careful not to drop it on
your feet.
SHTS09A010200015

SHTS09A010200016
2. REPLACEMENT OF THE RUBBER BUSHING

(1) Use a commercial tool to press out the old tubber bushing.
(2) Use a commercial tool to press in the new rubber bushing.
SHTS09A010200017

! CAUTION
ter bolt.
SHTS09A010200018

! CAUTION
grease on both surfaces at leaves.
SHTS09A010200019
(2) Align the leaf holes and silencers (Front suspension only), then
secure the leaves with a vise or an arbor press.
NOTICE
new one.
SHTS09A010200020

NOTICE
SHTS09A010200021

NOTICE
(3) Install secure the lock nut.
SHTS09A010200022
2. INSPECT THE CLEARANCE BETWEEN THE CLAMP PLATE

AND THE TRUNNION SEAT.
NOTICE
• Replace the oil seal and trunnion gasket with new ones.
• Apply chassis grease to lip of the oil seal and the inside of
the bushing.
• Insert two trunnion seat bolts before installing the trunnion
seat on the trunnion shaft.
(1) Install the trunnion seat to the trunnion shaft.
(2) Set the shim and clamp plate and tighten the bolts with the lock
SHTS09A010200023
plate.
(3) Inspect the clearance between the clamp plate and trunnion seat.
Standard clearance: 0.05-0.1 mm {0.0020-0.0039 in.}
Service limit: 0.4 mm {0.0157 in.}
NOTICE
If the standard clearance is not correct, adjust the clearance by
decreasing or increasing the shim.
The following shims are available.
0.30 mm {0.0118 in.}, 0.40 mm {0.0157 in.},
0.45 mm {0.0177 in.}, 0.50 mm {0.0197 in.}.
(4) Lock the clamp plate bolts with the lock plate.
SHTS09A010200024

(1) Put the spacer on the front axle I-beam part of the driver's seat
side. (For front suspension)
SHTS09A010200028
(2) Place the caster shim between the spring seat and leaf spring.
NOTICE
When installing the caster shim, the thick end should face the rear
of the vehicle.
To Front
SHTS09A010200027
NOTICE
when handing them.
(4) Put the spring pads on the leaf springs.

(5) Set the U-bolt so that they catch the spring pads and tighten the
U-bolt nuts temporarily.
SHTS09A010200010
2A57AA(.A(/HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝㧤ಽ
FRONT SST:
Handle (S0940-41060)
2 4 4. ADJUSTMENT OF THE SUSPENSION AFTER ASSEMBLING

SHTS09A010200029
the axle.
Spacer:
Part No. Thickness
Front suspension SZ940-85155 4.5 mm {0.177 in.}
5. LUBRICATION
a. Spring pins
b. Spring surface of the spring and axle housing
c. Trunnion shaft
SHTS09A010200030
SHTS09A010200031
NOTICE
Use the lubrication fitting to chassis grease the trunnion shaft,
until the grease flows out from the breather valve of trunnion seat
and trunnion cover.
SHTS09A010200032
2A57AA(.A(/HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧡㧤ಽ

EN09A0102H300001
Unit: mm {in.}
Spring pin: 30 29.7 Replace. Measure

Outside diameter. {1.181} {1.170}
Thrust washer: Pivot side 2.5 Replace. Measure

Wear 3.0 {0.0984}
{0.118}
Shackle side 3.5

4.0 {0.138}
{0.157}

Damage and wear 15%


2A57AA(.A(/HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧜ಽ

age
Cushion: — —
Damage and wear

bracket:
Damage and wear


Trunnion shaft outside 100 — Replace, Measure

diameter. {3.937} if necessary.
Clearance between trunnion 0.26-0.43 0.7 Replace,

shaft and bushing. {0.0103-0.0169} {0.0275} if necessary.
Dust shield: — — Replace,

Trunnion oil seal: — — Replace, Visual check

2A57AA(.A(/HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧜ಽ
Rubber bushing: — 15 In case cracks Measure and Visual check

Damage and crack {0.59} have developed
on the rubber
circumference in
the range (A or
B) shown in fig-
ure, replace the
torque rod bush-
ing.
2A57AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧞㧝ಽ
SUSPENSION (MODEL: SG) SU02–1
SUSPENSION (MODEL: SG)

SU02
SU02-003
LEAF SUSPENSION ASSEMBLY............ SU02-2

DESCRIPTION ................................................ SU02-3
SPECIAL TOOL ............................................... SU02-5
OVERHAUL ..................................................... SU02-9
2A57AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧞ಽ
SU02–2 SUSPENSION (MODEL: SG)

EN09A0102I200001
FRONT SUSPENSION Unit: mm {in.}
Span 1,470 {57.874}
Width 80 {3.149}
11 {0.433}
Thickness of leaves
12 {0.472}
Type Single acting
Stroke 260 {10.236}

Shock absorbers:
Min. length 390 {15.354}
Max. length 650 {25.591}
REAR SUSPENSION Unit: mm {in.}
Span 1,400 {55.118}
Width 90 {3.543}
10 {0.394}
Thickness of leaves
12 {0.472}
Span 980 {38.583}
Dimensions of auxiliary leaf springs: Width 90 {3.543}
Thickness of leaves 10 {0.433}
Type Double acting
Stroke 285 {11.220}

Shock absorbers:
Min. length 475 {18.700}
Max. length 760 {29.921}
Stabilizer Torsion bar

2A57AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧞ಽ
DESCRIPTION
EN09A0102C100001
FRONT SUSPENSION
SHTS09A010200001
1 Shock absorber 5 Leaf spring assembly

2 Spring bumper 6 Spring pin
4 U-bolt
2A57AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧞㧡ಽ
REAR SUSPENSION
SHTS09A010200002
1 Spring pin 6 Spring bumper

3 Main leaf spring assembly 8 Stabilizer
4 U-bolt 9 Shock absorber
5 Spring pad
2A57AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧟ಽ
TROUBLESHOOTING
EN09A0102F300001

capacity rating.
capacity rating.
Leaves broken at the center bolt Loosen U-bolts Tighten to specified torque.
hole
SPECIAL TOOL
EN09A0102K100001
S0983-93202
SOCKET WRENCH For rear U-bolt
S0983-93203
S0984-12560 BAR For rear U-bolt

COMPONENT LOCATOR
EN09A0102D100001
FRONT SUSPENSION
SHTS09A010200006
1 U-bolt 15 Clip
2 Spring pad 16 Rivet
3 Spring bumper 17 Cushion washer (If so equipped)
4 Thrust washer 18 Stabilizer link rod (If so equipped)
5 Spring pin 19 Holder (If so equipped)
7 Lubrication fitting 21 Rubber bushing (If so equipped)
8 Leaf spring assembly 22 Stabilizer lever (If so equipped)
9 Shock absorber 23 Stabilizer link pin (If so equipped)
10 Cushion washer 24 Caster shim
11 Shock absorber pin 25 Spacer (Driver's seat side only)
12 Lock washer 26 Center bolt
13 Nut 27 Cushion (If so equipped)
14 Bushing

A 236-324 {2,406-3,303, 174-238} E 73-109 {745-1,111, 54-80}
B 64-93 {653-948, 48-68} F 96-144 {979-1,468, 71-106}
C 85-108 {870-1,100, 63-79} G 236-324 {2,406-3,303, 174-238}
D 390-440 {3,977-4,486, 288-324} H 105-145 {745-1,111, 54-80}
REAR SUSPENSION
SHTS09A010200007
1 Spring pin 11 Shock absorber 21 Stabilizer bar sleeve

2 Shackle 12 Inter leaf 22 Stabilizer bar
3 Lubrication fitting 13 Bushing 23 Link pin
4 U-bolt 14 Clip 24 Stabilizer bar lever
5 Spring pad 15 Rivet 25 Silencer
6 Spring bumper 16 Center bolt 26 Auxiliary leaf spring assembly
7 Thrust washer 17 Stabilizer holder bracket 27 Main leaf spring assembly
8 Cushion 18 Slotted nut 28 Slide seat
9 Shock absorber upper bracket 19 Pin
10 Cotter pin 20 Stabilizer holder

A 73-109 {745-1,111, 54-80} F 167-225 {1,700-2,290, 123-166}
B 640-740 {6,530-7,540, 472-545} G 108-225 {1,100-2,290, 80-166}
C 86-107 {870-1,100, 63-79} H 110-130 {1,122-1,325, 82-95}
D 64-85 {650-870, 47-62} I 171-229 {1,744-2,335, 127-168}
E 340-460 {3,670-4,690, 265-339}
OVERHAUL
EN09A0102H200001

SHTS09A010200008
SHTS09A010200009

(1) Remove the stabilizer. (Rear suspension only)
NOTICE
SST:
SHTS09A010200010 Socket Wrench for Rear U-bolt (S0983-93202)
Bar (S0984-12560)
3. REMOVAL OF THE SPRING PIN (FRONT SIDE SPRING)

(2) Uncaulk the nut with a chisel, then loosen the nut. (Front side of
spring)
SHTS09A010200011
(3) Remove the spring pin lock bolt. (Rear side of spring)
spring bracket.
SHTS09A010200012
4. REMOVAL OF THE SPRING PIN (REAR SUSPENSION)

(1) Remove the lubrication fitting and spring pin lock bolt.
SHTS09A010200013
spring bracket.
SHTS09A010200014

SHTS09A010200015

! CAUTION
ter bolt.
SHTS09A010200016

! CAUTION
grease on both surface at leaves.
SHTS09A010200017
(2) Align the leaf holes and secure the leaves with a vise or an arbor
press.
NOTICE
new one.
SHTS09A010200018

NOTICE
SHTS09A010200019

NOTICE
(3) Install and secure the lock nut.
SHTS09A010200020

(1) Place the caster shim between the spring seat and leaf spring.
NOTICE
When installing the caster shim, the thick end should face the rear
of the vehicle.
To Front
SHTS09A010200023
(2) Put the spacer between the caster shim and leaf spring of the
driver's seat side. (For front suspension)
NOTICE
when handling them.
(4) Put the spring bumper and the spring pad on the leaf spring.
(5) Set the U-bolts so that they catch the spring bumper and the
spring pad and tighten the U-bolt nuts temporarily.
SHTS09A010200010
FRONT SST:
Bar (S0984-12560)
2 4
SHTS09A010200024
3. ADJUSTMENT OF THE SUSPENSION AFTER ASSEMBLING

the axle.
Spacer:
Part No. Thickness
Front suspension SZ940-85155 4.5 mm {0.177 in.}
Rear suspension SZ940-85018 6.0 mm {0.236 in.}
4. LUBRICATION
a. Spring pins
SHTS09A010200025
b. Auxiliary spring slide seats
SHTS09A010200026

EN09A0102H300001
Unit: mm {in.}

diameter {1.170}
Rear 38 {1.496} 37.7

{1.484}
Thrust washer: Front Pivot side 2.5 Replace. Measure

Wear 3.0 {0.118} {0.0984}
Shackle side 3.5

4.0 {0.157} {0.138}
Rear Pivot side 1.5

2.0 {0.079} {0.059}
Shackle side 3.5

4.0 {0.157} {0.138}

Damage and wear 15%




age
Cushion: — —
Damage and wear

bracket:
Damage and wear


Stabilizer Sleeve:
Wear
Stabilizer Bushing:
Wear
Inter leaf: 1.6 0.8 Replace, Visual check

2A57AA*#5A0QAVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧞㧞ಽ
SUSPENSION (HENDRICKSON HAS 230) SU02–1
SUSPENSION SU02
(HENDRICKSON HAS 230) SU02-004
SUSPENSION ASSEMBLY....................... SU02-2

DESCRIPTION ................................................ SU02-2
SPECIAL TOOL ............................................... SU02-3
OVERHAUL ..................................................... SU02-5
SU02–2 SUSPENSION (HENDRICKSON HAS 230)
SUSPENSION ASSEMBLY
EN09A0202I200001
MODEL FG, GH
TYPE HENDRICKSON HAS 230
DESCRIPTION
EN09A0202C100001
6 4 5
7
3
1
2
SHTS09A020200001
1 Air spring 5 Height control valve

2 Main support member 6 Frame hanger
3 Torque rod 7 Shock absorber
4 Transverse rod
TROUBLESHOOTING
EN09A0202F300001

Abnormal sound occurs from the Eccentric wear of the shock absorber Replace the pin and/or rubber bush-
spring while driving. fitting pin ing.
Wear and deflection of the rebound Remove the rebound roller and/or
roller rebound bolt spacer.
Uncomfortably (Rolling and pitch- Deflection and damage of the bush- Replace the bushings.
ing) ings of the torque rod and the trans-
verse rod
Faulty of the shock absorber Replace the shock absorber.
Faulty of the leveling valve Repair the leveling valve.
Vibration of the steering wheel, and Deflection of the bushing in the torque Replace the bushings.
the car shake rod and the transverse rod
Looseness of the torque rod and the Replace the lock nut and tighten with
transverse rod bracket bolt the specified torque.
Vehicle height is not adjusted cor- Faulty of the leveling valve Repair the parts.
rectly.
SPECIAL TOOL
EN09A0202K100001
Prior to starting a suspension overhaul, it is necessary to have this special tool.

COMPONENT LOCATOR
EN09A0202D100001
J
F
B D A
B A
10 9 2 18
1 C
17 15
16
8
5 D G
B
D
14 A C
7
H
6
13
A
E
11 12
4
B
SHTS09A020200003
1 Air spring 11 Frame hanger

2 Cross channel 12 Torque rod
3 Main support member 13 Rebound roller
4 Spring seat 14 Back plate
5 U-bolt 15 Transverse rod
6 Top pad 16 Channel reinforcement
7 Lower shock absorber bracket 17 Back up plate
8 Shock absorber 18 Upper shock absorber bracket
9 Height control valve X From air tank
10 Threaded extension rod Y From height control valve

A 352-434 {3,590-4,425, 260-320} F 41-61 {418-622, 30-45}
B 203-277 {2,070-2,825, 150-204} G 27-40 {275-408, 20-30}
C 70-98 {714-1,000, 52-72} H 541-609 {5,517-6,210, 400-450}
D 11-17 {112-173, 8-12} J 6-7 {61-71, 4.4-5.1}
E 67-95 {683-968, 50-70}
OVERHAUL
EN09A0202H200001
1. SUPPORT THE FRAME WITH THE STAND.

(1) Park the vehicle on the level ground.
SHTS09A020200004
(3) Jack up the axle, and support the frame with the stand.
SHTS09A020200005
2. REMOVAL OF MAIN SUPPORT MEMBERS

FRAME HANGER (1) Release air pressure from the air springs.
(2) Remove the height control valve link from the valve by removing
the nut and the lock washer.
AIR SPRING
SHTS09A020200006
(3) Remove the rebound bolts, lock nuts, washers, spacer tube, and
REBOUND BOLT rebound roller from the frame hanger.
ROLLER
SPACER TUBE
SHTS09A020200007
(4) Raise the rear of frame, high enough to remove the load from
main support member.
SHTS09A020200008
(5) Remove the U-bolt lock nuts and washers.

(6) Remove the U-bolts, bottom cap, and top pad.
(7) Remove both the lock nuts and washers which connect the cross
channel to both the main support members.
(8) Lift cross channel off the main support member with jacks.
(9) Remove the main support member assembly.
SHTS09A020200009
3. REPLACEMENT OF THE SPRING SEAT

(1) Remove the spring seat.
SHTS09A020200010
4. REPLACEMENT OF THE TORQUE ROD BUSHINGS

(1) Remove the straddle mount bar pin lock nuts and washers at the
axle end of the torque rod.
(2) Loosen the rebound bolt lock nut in the frame hanger.
(3) Remove the straddle mount bar pin lock nuts, bolts, and washers
at the frame hanger ends of the torque rod.
LOCK NUTS
SHTS09A020200011
(4) Push out oil bushings. Use a vertical shop press with a capacity of
at least 10 tons. Steel tube receiving tool is required. These bush-
ings are not cartridge type bushings. They do not have outer met-
als. Support the torque rod end on receiving tool with the end tube
of torque rod centered on tool. Push directly on the bushing strad-
dle mount bar pin until the bushing clears the torque rod end tube.
! CAUTION
Be sure the torque rod is securely supported on the press bed for
RECEIVING TOOL safety.
Do not use heat or cutting torch to remove the bushings from the
torque rod. The use of heat will adversely affect a strength of the
SHTS09A020200012
torque rod.
(5) Clean and inspect the torque rod ends, removing any nick with
emery cloth.
(6) Lubricate the torque rod ends and the new rubber bushings with a
vegetable base oil (cooking oil or lard). Do not use a petroleum or
soap base lubricant.
(7) Press in new bushings. Support the torque rod end on receiving
tool with end tube of torque rod centered on receiving tool. Strad-
dle mount bar pin bushing must have mounting flats positioned
zero degrees to shank of torque rod as shown in the figure. Press
RECEIVING TOOL directly straddle mount bar pin of bushing. Bushing must be cen-
tered within torque rod end tubes. When pressing in new bush-
SHTS09A020200013
ings, overshoot desired final position by approximately 3/16 and
press bushing again from opposite side to center bushing within
torque rod end.
5. REPLACEMENT OF THE FRAME HANGER SLIPPER PADS

(1) In most cases removal of the rebound roller and spacer may be
required to disassemble the slipper pad. Remove the rebound
bolt lock nut, washer bolt rebound roller and spacer.
(2) Procure the slipper pad locally from Hendrickson's Agent.
PIN
SLIPPER PAD
SHTS09A020200014
6. REMOVAL OF CROSS CHANNEL

(1) Remove the lock nuts and washers which connect the air spring
to cross channel.
CROSS CHANNEL (2) Raise the cross channel by using jack if required.
LOCK NUT
SHTS09A020200015
7. REMOVAL OF AIR SPRING

FRAME HANGER (1) Remove the air line to the air spring seat.
(2) Remove the brass air fittings from the air spring.
(3) Remove the lock nuts and washers which connect the air spring
to the upper air spring frame hanger.
(4) Remove the air spring.
(5) Remove the air spring frame hanger.
AIR SPRING
SHTS09A020200016
8. REMOVAL OF SHOCK ABSORBER FRAME HANGER

BRACKET BRACKET
(1) Remove the lock nuts and washers at both ends of the shock
absorber.
(2) Remove the shock absorber completely from the chassis.
(3) Remove the lock nuts and washers which connect the shock
absorber bracket to the frame.
(4) Remove the shock absorber bracket.
SHOCK ABSORBER
SHTS09A020200017
9. REMOVAL OF SHOCK ABSORBER LOWER BRACKET

(1) Remove the shock absorber completely from the chassis.
(2) Remove the lock nuts and washers which connect the cross
channel to the main support member.
(3) Remove the shock absorber lower bracket by sliding the bracket
to rear.
LOWER BRACKET
SHTS09A020200018
10. REMOVAL OF TRANSVERSE ROD

CHANNEL REINFORCEMENT (1) Remove the lock nuts and washers which connect the transverse
rod to the frame.
(2) Remove the lock nuts and washers which connect to the axle
bracket.
(3) Use Owatonna Tool Company's tool set to remove and install the
torque rod bushings. Follow their instructions.
BACK UP PLATE
SHTS09A020200019

BACK UP PLATE
1. INSTALLATION OF TRANSVERSE ROD

(1) Assemble the washer and lock nut to the bolt. Tighten the lock nut
to specified torque.
(2) Install the back up plate.
Thickness: 10 mm {0.394 in.}
(3) Position the straddle mount end of torque rod at the transverse
rod to the frame, tighten the lock nuts to specified torque.
SHTS09A020200020
2. INSTALLATION OF FRAME HANGER

A
(1) Install new slipper pad.
ROLL PIN (2) Raise the main support member to secure slipper pad in place.
(3) Drive new roll pin in place with punch until flush with the front of
frame hanger.
(4) Tighten fasteners to specified torque.
B 3. CHECK THE AIR LEAKAGE.

(1) Apply soapy water for each joint of air line and charge the com-
SLIPPER PAD pressed air of 780 kPa {8.0 kgf/cm2, 110 lbf/in.2} then check the
leakage.
SHTS09A020200021
4. ADJUSTMENT OF THE VEHICLE HEIGHT
NOTICE
• Adjustment should be done only after assembling.
• Adjustment should be done with the air pressure of 71-86
kPa {7.0-8.5 kgf/cm2, 99-120 lbf/in.2}, keeping on supplying
the air while rotating the engine at the idle speed.
(1) Measure the shock absorber length between upper and lower
pins.
Assembly standard: Unit: mm {in.}
Model Dimension "A"
FG, GH 583.6 {22.98}
(2) If the shock absorber length is not the assembly standard, adjust
the extension rod length, so that the shock absorber length is the
assembly standard.
THREADED EXTENSION ROD
DIMENSION "A"
SHTS09A020200022
2A57AA*#5A0QAVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧞㧣ಽ

EN09A0202H300001
Air spring: — — Replace, Visual check

Wear, damage and crack if necessary.
Main support member: — — Replace, Visual check

Crack and damage if necessary.
Cross channel: — — Replace, Visual check

Spring seat: — — Replace, Visual check


Pad: — —
Wear, damage and crack

age
Upper and lower brackets: — —

Crack and damage
Rebound roller: — — Replace, Visual check

Slipper pad: — —
Torque rod: — — Replace, Visual check

Torque rod bushings: — —

Transverse rod: — — Replace, Visual check

Transverse rod bushings: — —

Channel reinforcement: — —
Crack and damage
Back up plate: — —
Crack and damage
2A(%AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧞㧟ಽ
CHASSIS FRAME FC02–1
CHASSIS FRAME
FC02
FC02-001
CHASSIS FRAME ..................................... FC02-2

TROUBLESHOOTING..................................... FC02-2
REPAIR ........................................................... FC02-2
INSPECTION AND REPAIR ............................ FC02-8
FC02–2 CHASSIS FRAME
CHASSIS FRAME
TROUBLESHOOTING
EN10Z1102F300001

Frame distortion Flattening or breakage of springs on Replace spring
(Vehicle inclination) one side
Incorrect mounting (Attachment of Correct mounting
heavy weight on one side of the vehi-
cle)
Bent frame Overloading or concentrated weight on • Correct load
rear end of frame • Correct with frame correction
device
Frame cracking or rivets breaking Wrong body mounting Correct mounting
Overloading • Improvement of the usage
• Reinforce with stiffener
REPAIR
EN10Z1102H200001
1. REPLACEMENT OF LOOSENED RIVETS

(1) Clean the frame.
NOTICE
While inspecting or repairing, stop the vehicle engine and block
the wheels. When cleaning with a steam cleaner, use safety gog-
gles.
SHTS10Z110200001
(2) Drill out the head of the loosened rivets with a drill or grind.
NOTICE
When drilling, do not use the gloves. They can get caught up in
the drill.
SHTS10Z110200002
(3) Ream out the hole with a reamer.
SHTS10Z110200003
(4) Rivet with proper force, using a pneumatic riveter.
Rivet Rivet hole

φ10 mm Standard: φ11 mm {φ0.43 in.}
{φ0.39 in.} Repair limit: φ11.5 mm {φ0.45 in.}
SHTS10Z110200004 φ16 mm Standard: φ17 mm {φ0.67 in.}
(5) If it is impossible to tighten with rivets, finish the rivet hole with a
reamer and tighten with reamer bolts.
NOTICE
The tensile strength of the bolts must be above 686 MPa {70 kgf/
mm2, 99,562 lbf/in.2}
Tightening Torque:
10 mm {0.39 in.} Bolt: 37.27-49.03 N⋅m {380-500 kgf⋅cm, 28-36
lbf⋅ft}
12 mm {0.47 in.} Bolt: 63.74-85.32 N⋅m {650-870 kgf⋅cm, 47-62
lbf⋅ft}
14 mm {0.55 in.} Bolt: 107.88-147.09 N⋅m {1,100-1,500 kgf⋅cm,
SHTS10Z110200005
80-108 lbf⋅ft}
123-166 lbf⋅ft}
181-238 lbf⋅ft}
254-339 lbf⋅ft}
348-462 lbf⋅ft}
2. REPAIRING OF FRAME CRACKS

(1) Perform the procedure for preventing the enlargement of cracks.
NOTICE
Do not make drill holes on the frame flanges except when repair-
ing the cracks.
SHTS10Z110200006
(2) Make the V-shape groove with a grinder along the frame crack
according the following table.
Unit: mm {in.}
t x° s a
4.5 {0.18} 90 1.0 {0.039} 0
6 {0.24} 70 1.0 {0.039} 0
7 {0.28} 70 1.5 {0.059} 1 {0.039}
8 {0.31} 70 1.5 {0.059} 1 {0.039}
9 {0.35} 70 1.5 {0.059} 1 {0.039}
SHTS10Z110200007 10 {0.39} 60 1.5 {0.059} 1 {0.039}
12 {0.47} 60 1.5 {0.059} 1 {0.039}
16 {0.63} 60 2.0 {0.079} 1 {0.039}
(3) Use an electric welder.

Refer to page FC02-8 for WELDING CONDITION (WHEN
WELDING ROD IS USED).
! CAUTION
• Disconnect the negative battery ground cable before using
arc welding equipment.
• While welding, make sure that there are no flammable materi-
als such as oil, rags, etc. around. As welded parts becomes
extremely hot and sparks are present, make sure that there
are no items such as harnesses, tubes, pipes, suspension
component, etc. which may be damaged.
SHTS10Z110200008
• If material is allowed to sputter onto the spring leaf during
welding its strength will be significantly diminished. It should
therefore be covered with a protective sheet. Also, for the
same reason, the spring leaf should never be used as a
ground for arc welding.
• When arc welding, ventilate or wear antitoxic mask for nox-
ious gas.
• To prevent burns, electric shock and gas poisoning during
arc welding, wear a helmet, apron, antitoxin mask, safety
goggles, arm coverings, leg covering, safety boots and
gloves.
(4) After welding, shake the grinder crosswise the bead line "A",
CORRECT WRONG
along direction "B", to polish the welded area as illustrated in "C".
Grind and polish the bead line "A" so that the frame surface
becomes even.
C B
SHTS10Z110200009
(5) Reinforcement patching method.

Patch-plate with ends squared off rather than tapered can cause
CORRECT WRONG
damage.
The patching plate thickness should be the same as the frame.
LESS
THAN 30º
SHTS10Z110200010
CORRECT WRONG
SHTS10Z110200011
CORRECT WRONG
SHTS10Z110200012
2A(%AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧞㧥ಽ
(6) Be sure to fasten the bolts at the hole locations of ups and downs
(use rivets or perform the plug welding).
CORRECT WRONG
SHTS10Z110200013
(7) Diameter of plug welding hole

.} NOTICE
in
4 Prohibit plug welding on the flange.
.98
{0
m
m
25 PLUG WELDING
t (unit: mm {in.}) dφ
d
t 3.2 {0.126} 15
4.5 {0.177} 15
6 (0.236} 18
SHTS10Z110200014
(8) Interval of the holes
a ≥ 50 mm {1.969 in.}+d/2
e1 e1 b ≥ 3d
e1e2 ≥ 701 mm {27.598 in.}+a
a d
dφ: 20 or less
b b d
e2
SHTS10Z110200015
(9) Method of fixing on the flange

CORRECT WRONG
RIVETS OR REAMER BOLT

PLUG WELDING
SHTS10Z110200016
(10) Method of welding on the flange

CORRECT WRONG
DO NOT WELD HERE

40 20
30
25
30
SHTS10Z110200017
CORRECT WRONG
PROHIBIT WELDING
THE BRACKET
AROUND THE HOLE
OVER 30 mm {1.2 in.}
SHTS10Z110200018
(11) In welding, be sure that there is no undercut "A" or the overlap "B"
CORRECT WRONG of the bead and a pin hole.
NOTICE
An experienced professional welder should always perform the
A
welding since a poor welding job on the frame can cause damage.
SHTS10Z110200019
WELDING CONDITION
(WHEN WELDING ROD IS USED)
Electric current (Unit: A)
Rod dia φ 3.2 mm {0.126 in.} 4 mm {0.157 in.} 5 mm {0.197 in.}
Vertical Vertical Vertical

Welding position Flat Flat Flat
overhead overhead overhead
Weld Metal (Hot roll

plate)
Tensile strength; 441
MPa {45 kgf/mm2, 64.004
lbf/in.2}
Welding Rod
80-130 60-110 120-180 100-150 170-250 130-200
MPa {43 kgf/mm2, 61.160
lbf/in.2}
Illuminate type (JIS
Mechanical D4301 AWS E6019)
property of Coated electrode
weld metal Weld Metal (Hot roll
& rod plate)
MPa {55 kgf/mm2, 78.228
lbf/in.2}
Welding Rod
90-140 80-130 141-190 110-160 180-250 —
MPa {50 kgf/mm2, 71.116
lbf/in.2}
Illuminate type (JIS
D4301 AWS E6019)
Coated electrode
NOTICE
• Diameter of welding rod φ3.2 mm {0.126 in.} or φ4 mm {0.157
in.} - plate thinner than 5 mm {0.197 in.}
• Diameter of welding rod φ4 mm {0.157 in.} or φ5 mm {0.197
in.} - plate thicker than 6 mm {0.236 in.}

EN10Z1102H300001
Looseness of the rivets — — Replace the

rivet,
if necessary.
Frame cracking — — Repair the

frame.
2A%#AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧞㧠ಽ
CAB CA02–1
CAB
CA02
CA02-001
CAB ASSEMBLY ......................................CA02-2

DATA AND SPECIFICATIONS........................ CA02-2
TROUBLESHOOTING..................................... CA02-3
DISMOUNTING AND MOUNTING .................. CA02-4
CAB MOUNTING PARTS..........................CA02-7

COMPONENT LOCATOR ............................... CA02-7
OVERHAUL ................................................... CA02-10
DOOR ......................................................CA02-14
COMPONENT LOCATOR ............................. CA02-14
OVERHAUL ................................................... CA02-15
SEAT .......................................................CA02-18
INSTRUMENT PANEL ............................CA02-25

DISMOUNTING AND MOUNTING ................ CA02-26
HEATER AND AIR CONDITIONER ........CA02-27

DISMOUNTING AND MOUNTING ................ CA02-28
WINDSHIELD ..........................................CA02-30
REPLACEMENT ............................................ CA02-31
CA02–2 CAB
CAB ASSEMBLY
EN11Z1202I200001
Type All steel welded construction, safety glass fitted to all windows
Tilt system Torsion bar
Tilt angle 44° ("Over-tilt" position: 50°)

CAB CA02–3
TROUBLESHOOTING
EN11Z1202F300001
CAB TILT
Cab does not tilt up. Cab mounting hook does not release. Inspection of cab mounting hook
mechanism.
Safety rod does not release. Inspection of safety rod mechanism.
Damaged torsion bar Replace torsion bar.
Cab tilting is difficult. Heavy items in or attached to cab Adjustment of shim for anchor lever or
removal of the heavy items.
Tilt up force is weak. Adjustment of shim for anchor lever.
Replace torsion bar.
Cab does not lock to cab mounting Mounting hook does not operate. Adjustment of mounting hook mecha-
member. nism.
Cab mounting cushion is not correctly Correct installation of cab mounting.
installed.
DOOR
Door does not close properly. Door is not adjusted Adjust door installing.
Striker is not adjusted Adjustment of shim for door lock striker
Damaged door lock Replace door lock.
Door does not lock by inside lock Deformation of rod Replace rod.
knob. Rod is disconnected Connect rod.
Door does not lock by key. Rod is disconnected Connect rod.
Damaged lock cylinder Replace lock cylinder.
Door does not open by outside han- Outside handle push rod is not Adjust push rod.
dle. adjusted.
Door does not open by inside han- Inside handle is not installed properly. Install inside handle properly.
dle. Deformation of rod Replace rod.
Rod is disconnected. Connect rod.
Inside handle does not return to its Interference between rods. Replace rod.
normal position. Inside handle is not installed properly. Adjust inside handle.
Return spring is damaged. Replace inside handle.
Door window goes down while driv- Window is not in the glass holder. Repair.
ing. Regulator is damaged. Replace regulator.
Regulator makes abnormal noise Window sill weather strip is installed Install properly or replace clips.
while driving. improperly.
CA02–4 CAB
BLOWER
Malfunction of blower when power Blown fuse Change fuse or check for short circuit.
is ON. Malfunction in heater relay Inspect relay.
Malfunction of heater blower switch Inspect power switch.
Malfunction of register Check register.
Blower motor malfunction Replace motor.
Damaged electrical wiring or poor Repair as necessary.
grounding
DISMOUNTING AND MOUNTING

EN11Z1202H100001
1. BEFORE DISMOUNT THE CAB

• Be sure to block the front wheels.
• Disconnect the battery cable from the battery ground terminal.
• Drain engine coolant, clutch fluid and refrigerant of the air condi-
tioner.
2. CAB INSIDE
(1) Remove the parking brake cable retainer spring and pin. (Models
with center parking brake)
SHTS11Z120200001
3. CAB FRONT SIDE

(EXAMPLE: RHD MODEL)
CAB-CHASSIS HARNESS BOX (1) Remove the front bumper and open the front panel.
(2) Remove the cab-chassis harness box lid and disconnect all the
connectors of the harness connected to the cab and chassis.
SHTS11Z120200002
(3) Disconnect the inlet hose from washer tank.

CHASSIS HARNESS INLET

FIXING BRACKET
CONNECTOR
SHTS11Z120200003
CAB CA02–5
4. AFTER TILTING THE CAB

(1) Disconnect the parking brake cable (only models with center park-
ing brake) and transmission control cables.
SHTS11Z120200004
(2) Remove the harness clips located under the floor of the cab. Dis-
GROMMET connect the air brake hoses and clutch hose.
(3) Remove the cab stopper release cable (If so equipped).
CONTROL
CABLE
SHTS11Z120200005
5. REMOVE ANCHOR LEVER

(1) Raise the cab to OVER-TILT position.
Refer to "CAB TILT OPERATING TENSION ADJUSTMENT (1)
OVER-TILT".
Suspend the cab with crane or hoist as shown in figure.
! CAUTION
Do not raise cab excessively, because the cab will fall forward.
SHTS11Z120200006
(2) Remove the set screws of the anchor lever, and pull out the
anchor levers.
Remove the cab stopper stay.
Slowly lower the cab with crane or hoist.
! DANGER
Never go under the cab when lowering the cab. It is very danger-
ous.
SHTS11Z120200007
CA02–6 CAB
6. DISMOUNTING CAB ASSEMBLY

(1) Open the doors and hook the hooks of the cab lifting device.
SHTS11Z120200008
(2) Initially raise the cab so that most of its weight is borne by the lift-
ing device, then remove the bolts of the tilt hinge brackets.
SHTS11Z120200009
(3) Pull the cab tilt latch rod and lift the cab slowly.
NOTICE
Make sure that all of connecting parts are disconnected.
(4) Set the cab on a cab stand.
TILT LATCH ROD
SHTS11Z120200010
7. CAB MOUNTING
(1) Pay attention to the points below, and mount in the reverse order
of dismounting.
1. Steering sliding shaft inserting
2. Anchor lever fitting position
3. Damage or interference of harness wire, cable and hose
CAB CA02–7
CAB MOUNTING PARTS

COMPONENT LOCATOR
EN11Z1202D100001
FRONT SIDE
SHTS11Z120200011
1 Torsion bar 4 Collar

2 Cab stopper stay 5 Tilt hinge bracket
3 Fitting collar 6 Cab stopper release cable (If so equipped)

A 156-244 {1,591-2,488, 116-179} B 34.5-51.5 {352-525, 26-37}
NOTICE
• Apply chassis grease between moving parts.
• Tighten the bolts to the following torque unless otherwise specified.
Tightening torques:
Bolt diameter (mm) 8 10 12 14 16
N⋅m 18-26 34.5-51.5 61.0-91.0 96.0-144.0 152.0-228.0

HEXAGON
SPOTTED kgf⋅cm 184-265 352-525 622-927 979-1,468 1,550-2,325
PORTION
lbf⋅ft 13-19 26-37 45-67 71-106 112-168
N⋅m 21.5-31.5 41.5-61.5 73.0-108.0 144.0-216.0 228.0-342.0

FLANGED
SPOTTED kgf⋅cm 220-321 423-627 745-1,100 1,468-2,202 2,325-3,487
PORTION
lbf⋅ft 16-23 31-45 54-80 106-159 168-252
CA02–8 CAB
REAR SIDE
SHTS11Z120200012
1 Adjusting shim 5 Rebound rubber

2 Cab mounting cushion 6 Anchor lever
3 Eye bolt 7 Bracket
4 Stopper 8 Seat

A 34.5-51.5 {352-525, 26-37} D 110-150 {1,122-1,529, 82-110}
B Standard cab: 55.0-82.0 {561-836, 41-60} E 34.5-51.5 {352-525, 26-37}
Wide cab: 96-144 {979-1,468, 71-106} F Standard cab: 150-180 {1,530-1,835, 111-132}
C 55.0-82.0 {561-836, 41-60} Wide cab: 200-300 {2,040-3,059, 148-221}
NOTICE
Tightening torques:
N⋅m 18-26 34.5-51.5 61.0-91.0 96.0-144.0 152.0-228.0

HEXAGON
SPOTTED kgf⋅cm 184-265 352-525 622-927 979-1,468 1,550-2,325
PORTION
lbf⋅ft 13-19 26-37 45-67 71-106 112-168
N⋅m 21.5-31.5 41.5-61.5 73.0-108.0 144.0-216.0 228.0-342.0

FLANGED
SPOTTED kgf⋅cm 220-321 423-627 745-1,100 1,468-2,202 2,325-3,487
PORTION
lbf⋅ft 16-23 31-45 54-80 106-159 168-252
CAB CA02–9
SHTS11Z120200013
1 Dust cover 4 Tilt latch rod

2 Cab lock 5 Tilt latch
3 Release latch 6 Cab lock lever

A 34.5-51.5 {352-525, 26-37}
NOTICE
N⋅m 18-26 34.5-51.5 61.0-91.0 96.0-144.0 152.0-228.0

HEXAGON
SPOTTED kgf⋅cm 184-265 352-525 622-927 979-1,468 1,550-2,325
PORTION
lbf⋅ft 13-19 26-37 45-67 71-106 112-168
N⋅m 21.5-31.5 41.5-61.5 73.0-108.0 144.0-216.0 228.0-342.0

FLANGED
SPOTTED kgf⋅cm 220-321 423-627 745-1,100 1,468-2,202 2,325-3,487
PORTION
lbf⋅ft 16-23 31-45 54-80 106-159 168-252
CA02–10 CAB
OVERHAUL
EN11Z1202H200001
FRONT CAB MOUNTING PARTS
1. TORSION BAR INSPECTION

(1) Visually inspect the torsion bars for rust.
If it is severely rusted, replace torsion bars.
NOTICE
• A rusted torsion bar may be broken while tilting, and it will be
very dangerous.
• Visually inspect the fitting collars for wear or fatigue.
• If it is slight wear or fatigue, replace the collars.
SHTS11Z120200014
SHTS11Z120200015
2. TORSION BAR INSTALLING

(1) Check the marks on the torsion bars, then install them as shown
in figure.
FRONT
NOTICE
• Be sure to install the levers in their correct positions.
• If the cab is raised with the torsion bars improperly installed,
the torsion bars will drastically lose strength, and then it
must be replaced with new ones.
SHTS11Z120200016
3. STANDARD CAB TILT OPERATING TENSION

(1) Tilt the cab several times, without lifting by hand, to determine the
average rise of the cab.
UP DOWN
255 N 510 N
{26 kgf, 57 lbf} {52 kgf, 114.6 lbf}
or less or less
SHTS11Z120200017
CAB CA02–11
4. CAB TILT OPERATING TENSION ADJUSTMENT

(1) OVER-TILT
a. Remove the radiator grille.
b. Tilt up the cab and remove the cab stopper release cable (If
so equipped) from the brackets.
SHTS11Z120200018
c. Pull out the pin at the lower part of cab stopper stay bracket.
SHTS11Z120200019
d. Align the hole on the cab stopper stay with the hole for OVER-
TILT at the upper part of the cab stopper stay bracket and
insert 12 mm {0.472 in.} pin.
Use a cotter pin so that the pin does not come out.
! CAUTION
Make sure that the cab stopper pin is locked. If it is not properly
locked, the cab may fall.
SHTS11Z120200020
(2) ADJUSTING SHIM INSTALLING

a. Adjust the cab tilt operating tension by increasing or decreas-
ing the number of shims when cab tilt up to OVER-TILT posi-
tion.
For each 6 mm {0.24 in.} thick shim added, the cab tilt up
effort by hand will be reduced about 49N {5 kgf, 11Ibf}.
However, do not add more than 4 shims (Maximum 4 shims).
When more than 5 shims are needed, or the torsion bar sage,
replace the torsion bar.
If the clearance between the stopper rubber and the anchor
lever is too narrow to insert the spacers, tilt the cab for 3-5
times to obtain the clearance.
SHTS11Z120200021
CA02–12 CAB
REAR CAB MOUNTING PARTS
1. CAB LOCK MECHANISM ADJUSTMENT

Adjust dimension A, B, C, D, E and F as follows:
SHTS11Z120200022
Unit: mm {in.}
Position Related parts Dimensions
A: Eye bolt, crank pin off set * Mark bolts 9-13 {0.36-0.51}
B: Tilt latch, pin clearance Tilt latch adjusting bolt 3-6 {0.12-0.23}
C: Hook, eye bolt clearance Mounting member attaching bolt 12-22 {0.48-0.86}
D: Hook, eye bolt clearance Mounting member attaching bolt 20-30 {0.79-1.18}
E: Mounting member, tilt latch clearance Mounting member attaching bolt 20-22 {0.79-0.86}
F: Mounting member, tilt latch clearance Mounting member attaching bolt 9-11 {0.36-0.43}
CAB CA02–13
2. CAB LOCK LEVER OPERATING RESISTANCE ADJUSTMENT

(1) Adjust the mounting cushion shims to bring the operating tension
of the lock lever to "A". If the cab is not directly aligned, the oper-
ating resistance of the lock lever increases. In this case, correct
the cab mounting cushions.
Assembly standard:
Operating tension "A"
Standard cab 166-266 N {17-27 kgf, 38-59 lbf.}
Wide cab 127-207 N {13-21 kgf, 29-46 lbf.}
SHTS11Z120200023
3. CAB MOUNTING CUSHION ADJUSTMENT

(1) If the cab shifts sideways, loosen the mounting rubber attaching
bolts and adjust the mounting rubbers so that there is no clear-
ance there.
NOTICE
Replace cab mounting rubbers which are hardened or deformed.
SHTS11Z120200024
4. INSPECTION
(1) Operate the cab lock lever, and confirm that each part operates
smoothly, that the hook and eye bolt fit in the lock position, and
that the stopper pin is securely inserted.
! CAUTION
If the stopper pin is not inserted securely in place while driving,
external shock such as road bumps or collision may cause a tilt-
STOPPER PIN ing of the cab. This can result in personal injury and/or property
damage. If the stopper pin is lost, immediately install a new stop-
per pin. Make sure that the hook engages with the eye bolt
securely.
SHTS11Z120200025
CA02–14 CAB
DOOR
COMPONENT LOCATOR
EN11Z1202D100002
SHTS11Z120200026
1 Lock cylinder 9 Inside upper trim

2 Weather strip 10 Door frame
3 Outside handle 11 Armrest
4 Striker 12 Door assist grip
5 Door lock 13 Outer oscillate-proof
6 Regulator 14 Glass run weather strip
7 Inside hole cover 15 Ashtray
8 Inside trim 16 Inside handle case

A 4.4-6.6 {45-67, 3.3-4.8} D 2.0-3.0 {20-30, 1.5-2.1}
B 7.2-10.8 {74-110, 5.4-7.9} E 7.2-10.8 {74-110, 5.4-7.9}
C 10.8-20.2 {110-206, 8.0-14.8} F 18-26 {184-264, 13.3-19.0}
CAB CA02–15
OVERHAUL
EN11Z1202H200002
1. REMOVE REGULATOR HANDLE.

(1) Use a piece of cloth to catch the two ends of the retainer ring and
pull the cloth back and forth as shown, to remove the ring.
SHTS11Z120200027
2. REMOVE INSIDE TRIM.

(1) Remove the parts below in the listed.
CLIP POSITION (Refer to the section "COMPONENT LOCATOR" in the compo-
nent "DOOR".)
a. Ashtray
b. Armrest
c. Inside upper trim
REMOVE TRIM d. Inside handle case
RAISING UP.
(2) Pull off the inside trim.
SHTS11Z120200028
3. REMOVE WINDOW.
(1) Disconnect regulator from window channel.
SHTS11Z120200029
4. REMOVE DOOR LOCK.

(1) Disconnect the lock cylinder from the door lock.
CLAMP (2) Remove the lock cylinder.
(3) Remove the door lock with rods.
SHTS11Z120200030
CA02–16 CAB
5. SERVICE HOLE COVER AND REGULATOR INSTALLING

(1) Stick butyl rubber tape along lower tangent line of the drain hole of
the door.
(2) Insert the regulator handle with retainer ring into the regulator.
SHTS11Z120200031
6. DOOR HINGE ADJUSTMENT

(1) Remove the corner panel.
SHTS11Z120200032
(2) Make vertical and horizontal adjustments by loosening the hinge

bolts on the door.
SHTS11Z120200033
(3) Make depth adjustments by loosening the hinge bolts on the body.
SHTS11Z120200034
CAB CA02–17
7. STRIKER ADJUSTMENT
(1) Check the engagement between the door lock and the striker.
Make the top and bottom contact even.
(2) Perform adjustment so that the outside of the door and the out-
side of the rear quarter panel are flush with each other. After
adjustment, properly tighten the bolts.
NOTICE
When adjusting the door in the vertical direction, do not force in
into alignment by using the door lock striker.
SHTS11Z120200035
G
E
SECTION OF B-B SECTION OF A-A

A
A B B
D D
C C
I I
SECTION OF D-D SECTION OF C-C
SHTS11Z120200036
CLEARANCES BETWEEN BODY AND DOOR Unit: mm {in.}

E 6.0-9.0 {0.24-0.35} I 14.4-18.4 {0.57-0.72}
F 12.5-16.5 {0.50-0.64} J 6.0-9.0 {0.24-0.35}
G 6.0-9.0 {0.24-0.35} K 11.3-15.3 {0.45-0.60}
H 12.5-16.5 {0.50-0.64}
CA02–18 CAB
SEAT
COMPONENT LOCATOR
EN11Z1202D100003
DRIVER'S SEAT (RIGHT-HAND DRIVE MODEL)
SHTS11Z120200037
1 Seat back 5 Seat tilt adjuster handle

2 Seat back cover 6 Seat adjuster (If so equipped)
3 Seat cushion 7 Seat suspension (If so equipped)
4 Seat reclining lever 8 Wire (If so equipped)

A 17.5-32.5 {179-331, 13-23} D 11.8-14.7 {120-150, 9-11}
B 27.1-41.0 {280-420, 20-30} E 40.1-53.9 {410-550, 30-40}
C 20.5-34.3 {210-350, 15-25}
CAB CA02–19
DRIVER'S SEAT (LEFT-HAND DRIVE MODEL)
SHTS11Z120200038
1 Seat back 5 Seat tilt adjuster handle

2 Cover 6 Seat adjuster
3 Seat cushion 7 Seat leg
4 Seat reclining knob 8 Seat suspension

A 17.5-32.5 {179-331, 13-23} D 11.8-14.7 {120-150, 9-11}
B 27.1-41.0 {280-420, 20-30} E 40.1-53.9 {410-550, 30-40}
C 20.5-34.3 {210-350, 15-25}
CA02–20 CAB
ASSISTANT'S SEAT
SHTS11Z120200039
1 Seat back 3 Seat cushion

2 Seat reclining cover

A 17.5-32.5 {179-331, 13-23} C 11.8-14.7 {120-150, 9-11}
B 20.5-34.3 {210-350, 15-25}
CAB CA02–21
CENTER SEAT (IF SO EQUIPPED)
SHTS11Z120200040
1 Seat back 3 Center grip

2 Cushion

A 17.5-32.5 {179-331, 13-23} B 14.5-32.5 {148-331, 11-23}
CA02–22 CAB
AIR SUSPENSION SEAT
SHTS11Z120200041
1 Seat suspension 3 Clip

2 Air hose
CAB CA02–23
SEAT BELT (RIGHT-HAND DRIVE MODEL)
SHTS11Z120200042
1 Outer seat belt (Driver's seat) 5 Center seat belt

2 Seat belt guide 6 Inner seat belt (Assistant's seat)
3 Seat belt cover 7 Outer seat belt (Assistant's seat)
4 Inner seat belt (Driver's seat)

A 29-55 {296-560, 22-40}
CA02–24 CAB
SEAT BELT (LEFT-HAND DRIVE MODEL)
SHTS11Z120200043
1 Outer seat belt (Driver's seat) 5 Center seat belt

2 Seat belt guide 6 Inner seat belt (Assistant's seat)
3 Seat belt cover 7 Outer seat belt (Assistant's seat)
4 Inner seat belt (Driver's seat)

A 29-55 {296-560, 22-40}
CAB CA02–25
INSTRUMENT PANEL
COMPONENT LOCATOR
EN11Z1202D100004
SHTS11Z120200044
1 Steering column upper cover 10 Lower right cover

2 Steering column lower cover 11 Panel upper cover
3 Steering column lower tube 12 Switch board panel
4 Steering column lower boots 13 Cluster finish panel
5 Pedal bracket support 14 Cluster housing
6 Upper panel 15 Cluster bezel
7 Instrument panel cross member 16 Upper right cover
8 Gusset 17 Side cover
9 Lower center cover

A 2.8-3.2 {29-32, 2.1-2.3} C 7.5-16.5 {77-168, 5.6-12.1}
B 1.5-2.5 {16-25, 1.2-1.8} D 9.5-16.5 {96-168, 7.0-12.1}
CA02–26 CAB

EN11Z1202H100002
1. BEFORE REMOVE THE INSTRUMENT PANEL.

(1) Disconnect the battery cable from the battery ground terminal.
2. REMOVE THE UPPER RIGHT COVER.

(1) Remove the lower bolt on the upper right cover.
(2) Pull the upper right cover toward you, remove the 4 clips of this
side.
! CAUTION
• When pulling the upper right cover, be careful not to damage
the clips.
• Be sure to remove the 4 clips of this side previously because
pulling out the upper right cover at one time may damage it.
SHTS11Z120200045
(3) Pull the upper right cover straight with both hands to remove the
inner clip and remove the upper right cover.
SHTS11Z120200046
3. REMOVE THE SWITCH BOARD PANEL.

(1) Remove the throttle control knob.
(2) Remove the wire of the front lid opener.
(3) Remove the bolt and pull out the switch board panel.
PIN
REMOVE THE THROTTLE CONTROL KNOB.
SHTS11Z120200047
4. REMOVE THE INSTRUMENT PANEL CLUSTER.

(1) Remove the cable of the blower part.
(2) Loosen the bolt to remove the instrument panel cluster.
SHTS11Z120200048
CAB CA02–27
HEATER AND AIR CONDITIONER

COMPONENT LOCATOR
EN11Z1202D100005
SHTS11Z120200049
1 Blower assembly 3 Control panel assembly

2 Air conditioner assembly (If so equipped)

A 3.9-4.9 {40-50, 2.9-3.6} C 1.4-2.4 {14-24, 1.0-1.7}
B 3.9-4.9 {40-50, 2.9-3.6}
CA02–28 CAB

EN11Z1202H100003
1. CONNECTING HEATER CONTROL CABLES (RHD MODEL)

NOTICE
• Do not bend the inner cable when installing the cable
• Set the cable at pulled state and make sure the link pressed
against the boss. Set position is as follows.
Cable Cab width Color Position
A: Mode switch Standard GRAY

FACE
(If so equipped) Wide NATURAL
B: Temperature control Standard BLACK

MAX COOL
(If so equipped) Wide BLUE
C: Inside and outside Standard GRAY

OUTSIDE
air switch Wide NATURAL
SHTS11Z120200050
2. CONNECTING HEATER CONTROL CABLES (LHD MODEL)

NOTICE
• Do not bend the inner cable when installing the cable.
• Set the cable at pulled state and make sure the link is
pressed against the boss. Set position is as follows.
Cable Cab width Color Position
A: Mode switch Standard GLAY

FACE
(If so equipped) Wide NATURAL
B: Temperature control Standard BLACK

MAX COOL
(If so equipped) Wide BLUE
C: Inside and outside Standard BLACK

OUTSIDE
air switch Wide BLUE
SHTS11Z120200051
CAB CA02–29
3. MOUNTING BLOWER ASSEMBLY.

(1) Press the blower assembly against the dash panel at 15 mm
{0.59 in.} below the installation hole.
SHTS11Z120200052
(2) Hold the blower assembly up 15 mm {0.59 in.} to align it with the
installation hole.
SHTS11Z120200053
(3) Slide the blower assembly to the vehicle front until it is inserted
into the installation hole.
SHTS11Z120200054
CA02–30 CAB
WINDSHIELD
COMPONENT LOCATOR
EN11Z1202D100006
SHTS11Z120200055
1 Weatherstrip 3 Back window

2 Windshield glass
CAB CA02–31
REPLACEMENT
EN11Z1202H100004
1. BEFORE REPLACE THE WINDSHIELD.

(1) Remove the windshield wiper.
2. REMOVE THE WINDSHIELD.

LIP (1) Cut the lip of the weatherstrip with a knife.
(2) The windshield is heavy so remove it using at least two persons.
SHTS11Z120200056
3. MOUNTING THE WINDSHIELD.

(1) Clean the weatherstrip, mounting flange of cab and contact sur-
face of the window.
(2) Repair any wavy area at the mounting flange as necessary.
(3) Insert the working string as shown in the figure.
STRING
WEATHERSTRIP
SHTS11Z120200057
(4) Pull the working string from the interior of the cab, and gradually
install the lip of the weatherstrip on the mounting flange.
(5) During this operation, knock the glass from outside. Use soapy
water as necessary.
(6) After install the glass properly, knock the glass from inside and
outside.
SHTS11Z120200058
4. INSTALL THE WINDSHIELD WIPER.

(1) Install the wiper arm.
Assembly standard: Unit: mm {in.}
Clearance (A) Clearance (B)
30-50 {1.2-1.9} 70-90 {2.8-3.5}
A
ASSISTANT'S SIDE DRIVER'S SIDE
SHTS11Z120200059
ELECTRICAL EQUIPMENT EL01–1
ELECTRICAL EQUIPMENT
EL01
EL01-001
ELECTRICAL PARTS ............................... EL01-2

DATA AND SPECIFICATIONS.........................EL01-2
TROUBLESHOOTING......................................EL01-3
GENERAL INSTRUCTION ...............................EL01-4
HANDLING PRECAUTION.............................EL01-10
INSPECTION ..................................................EL01-11
(EXCEPT INDONESIA) ..................................EL01-29
(FOR INDONESIA) .........................................EL01-30
SPEEDOMETER
CONVERSION RATE LIST ............................EL01-32
2A'.AA/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧞㧡ಽ
EL01–2 ELECTRICAL EQUIPMENT
ELECTRICAL PARTS
EN12Z1601I200001
ELECTRICAL SYSTEM
Voltage Direct current 24 volts
Ground Negative (-) ground
BULB WATTAGE RATING
Headlight 75/70W
Fog light (If so equipped) 70W
Clearance light 5W
Front turn signal light 21W
12W Models for Taiwan, Thailand and Indonesia

Front side turn signal light
21W Models for Chile, Hong Kong and Singapore
Side turn signal light

10W
(Only model for Hong Kong)
Dome light 10W
Fluorescent light (If so equipped) 100V-18W

Rear turn signal light
21/5W Models for Chile, Hong Kong and Singapore

Stop/Tail light
25/10W Models for Taiwan, Thailand and Indonesia

Back up light

License plate light
Roof marker light

5W
(Only model for Chile)
Spot light (Tractor only) 35W
GAUGE TYPE
Fuel Coil type
Coolant temperature Coil type
Tachometer Coil type
Speedometer Coil type
Air pressure Coil type

TROUBLESHOOTING
EN12Z1601F300001
STARTING SYSTEM
Engine does not operate Poor contact condition Clean or replace contacts.
(Starter switch)
Engine does not operate (Battery) Open circuit in harness Check and correct.
Short circuit between electrodes Replace battery.
Poor contact condition of battery termi- Clean or retighten.
nal
Engine does not operate Improper viscosity oil Change oil.
(Engine oil)
Engine does not operate Defective or poor contact of starter Repair or replace.
(Starter relay) relay
Engine does not operate (Starter) Starter does not operate Repair or replace. Refer to the chapter
"STARTER".
HEADLIGHT CIRCUIT
Headlight does not turn on Bulb burned out Replace bulb.
(Headlight) Not grounded Check the grounding.
Headlight does not turn on (Fuse) Fuse burned out Replace fuse.
Headlight does not turn on Defective relay Replace relay.
(Headlight relay)
Headlight does not turn on Broken wire between relay and switch Repair wire.
(Lighting switch) Defective switch Replace switch.
TURN SIGNAL CIRCUIT

Turn signal does not work Bulb burned out Replace bulb.
(Turn signal light) Broken wire Repair wire.
Turn signal does not work (Fuse) Fuse burned out Replace fuse.
Turn signal does not work Not grounded Check the grounding.
(Turn signal flasher) Defective flasher Replace flasher.
Turn signal does not work Broken wire between fuse and switch Repair wire.
(Turn signal switch) Defective switch Replace switch.
TAIL AND LICENSE PLATE LIGHT CIRCUIT

Tail and license plate light does not Bulb burned out Replace bulb.
turn on (Light) Not grounded Check the grounding.
Tail and license plate light does not Fuse burned out Replace fuse.
turn on (Fuse)
Tail and license plate light does not Defective relay Replace relay
turn on (Tail light relay)
Tail and license plate light does not Broken wire between fuse and switch Replace wire.
turn on (Lighting switch) Defective switch Replace switch.
GENERAL INSTRUCTION
EN12Z1601C100001
! CAUTION
Be sure to disconnect the ground cable before servicing the elec-
trical circuits except for testing on-vehicle.
1. WIRING CODE
(1) Wiring colors are indicated by a code.
B : Black Lg : Light green P : Pink

Br : Brown R : Red
G : Green W : White
L : Blue Y : Yellow
(2) The first letter indicates the ground wire color and second letter
indicated the strip color.
(3) Arabic numerals indicates the cross sectional area of wire.
Example: 3 indicates 3 mm2 {0.0047 in.2}
SHTS12Z160100001
2. CONNECTOR
(1) The connector consists of the male and female connectors.
Male and female connectors are classified according to the shape
of the terminals in the connector.
Male and female connectors are provided with a lock, so that they
can not be separated easily.
To separate the connectors, unlock the lock, then hold one con-
nector with one hand and the other one with the other hand, and
pull each other.
NOTICE
When the connector is disconnected by pulling the wires, the con-
nection between the terminals and the wires will be damaged.
SHTS12Z160100002
(2) Removing the terminal from the connector.

a. Insert a miniature screwdriver or a terminal puller between
terminal and connector, and unlock the lock between terminal
and connector.
b. When the lock has been released, pull the wire to remove the
terminal.
(3) Installing the terminal in the connector.
a. Insert the terminal into the connector until it clicks.
b. Pull the wire to confirm correct lock engagement.
SHTS12Z160100003
3. FUSE
(EXAMPLE: RIGHT-HAND DRIVE) (1) The power supply must be switched off for fuse replacement.
Use a proper amperage fuse.
NOTICE
Wire burning may be caused when a fuse with an excessively
large current capacity is used.
If the fuse should blow frequently, investigate the cause and cor-
rect it.
SHTS12Z160100004
4. FUSIBLE LINK
(1) The cause of an overload current should be determined and cor-
rected before a melted fusible link is replaced.
A melted fusible link can be determined swollen or melted insula-
tion of the link.
SHTS12Z160100005
5. DIODE
(1) Diode allows the flow of electric current in only one direction.
SHTS12Z160100006
6. SOLENOID VALVE
(1) Solenoid valve controls the current of compressed air by electric.
Check the continuity between terminals. If there is no continuity,
replace the solenoid valve.
SHTS12Z160100007
RELAY (TYPE, COLOR, PART No., NAME AND INSPECTION)

NOTICE
Refer to the section "FUSE AND RELAY BLOCK" in the chapter "ELECTRIC WIRE" for the alignments of relays.
SHTS12Z160100008
Color Part No. Name
TYPE-1 Dark gray S8592-02660 Headlight relay (Main, dimmer)
Tail light relay (No.1, 2)
Horn relay
Backup light relay (If so equipped)
Rear fog light relay (If so equipped)
Automatic transmission back-up light relay (If so equipped)
Automatic transmission neutral relay (If so equipped)
EATON P.T.O. relay (If so equipped)
ECU main relay
Cab tilt up relay (If so equipped)
Cab tilt down relay (If so equipped)
Rear power window relay (If so equipped)
Actuator power relay
Fog light relay (If so equipped)
TYPE-2 Green S8592-02650 Power relay (No.1, 2, 3, 4)
Power accessory relay
Light check relay (If so equipped)
Heater relay (If so equipped)
Air conditioner relay (If so equipped)
Air conditioner condenser relay (If so equipped)
TYPE-3 Light gray S8292-02570 Stop light relay
TYPE-4 Orange S8592-02680 Lo-Hi indicator light relay (If so equipped)
ABS exhaust brake cut relay (If so equipped)
ABS warning light relay (If so equipped)
Hour meter relay (If so equipped)
TYPE-5 Yellow S8592-02700 ABS solenoid relay (If so equipped)
TYPE-6 Purple S8592-02710 ABS motor relay (If so equipped)
TYPE-7 Light brown S8592-02510 Engine stop motor relay (If so equipped)
TYPE-8 Blue S8592-02670 Actuator power relay (If so equipped)

1. TYPE-1 INSPECTION
(1) Apply voltage to terminals;
24V to terminal 1,
S8592-02660 Ground to terminal 2.
5 3 (2) Under normal condition, terminals 3 and 5 switch on.
2 5 3
1 2
SHTS12Z160100009
24V to terminal 1,
2 5 3
1 2
SHTS12Z160100010
24V to terminal 1,
5
1 2 1 2
SHTS12Z160100011
24V to terminal 1,
S8592-02680 4 Ground to terminal 2.
2 5 3 3 (2) Under normal condition, relay switches the continuity from termi-
4 5 nals 3 and 4 to 3 and 5.
1 2
1
SHTS12Z160100012
24V to terminal 2,
5 3 (2) Under normal condition, terminal 3 and 5 switch on.
1
3 5 1 2
SHTS12Z160100013
24V to terminal 2,
5 3 (2) Under normal condition, terminal 3 and 5 switch on.
1
3 5 1 2
SHTS12Z160100014
S8592-02510 24V to terminal 1,
4 Ground to terminal 2.
5 4
3 (2) Under normal condition, relay switches the continuity from termi-
2
1 2
3
SHTS12Z160100015
24V to terminal 1,
S8592-02670 4 Ground to terminal 2.
2 5 3 3 (2) Under normal condition, relay switches the continuity from termi-
1 2
1
SHTS12Z160100016
HANDLING PRECAUTION
EN12Z1601C100002
BATTERY
1. CONVERSION FORMULA FOR SPECIFIC GRAVITY

(1) The specific gravity of the electrolyte changes according to the
temperature of the electrolyte itself, therefore a temperature of
20°C {68°C} is used as reference temperature.
Consequently, if the temperature is not 20°C when the specific
gravity is measured, it is necessary to convent the measured
value to value calculated under the following conversion formula
at 20°C.
Temperature conversion formula: S20=St+0.0007(t-20)
(2) Where,
SHTS12Z160100017
• "S20" is the specific gravity at 20°C (Reference temperature)
• "St" is the specific gravity at the measuring temperature
• "t" is the temperature during measurement
• "0.0007" is the temperature coefficient of the electrolyte
NOTICE
As a rough guide, if the temperature of the electrolyte rises or falls
by 15°C (59°F), the specific gravity of the electrolyte will vary by
about 0.01.
2. BATTERY CHARGING
• Be careful of the following points.
(1) While the battery is being charged, ensure that the temperature of
the electrolyte does not rise above 45°C {113°F}.
(2) While the battery is being charged, be particularly careful to keep
it away from sources of fire.
(3) The amount of electrolyte must be within the specified level.
Specific gravity when battery is fully charged:
1.270-1.290 at 20°C {68°F}
3. CLEANING THE BATTERY

SHTS12Z160100018 • If the terminals at the top of the battery are dirty, clean them with
cold water or lukewarm water.
• Apply a light coating of grease to the terminals to prevent them
from rusting so as to prevent faulty contact.
4. CONNECTING THE BATTERY CABLES

• Clamp the cables securely to prevent improper contact between
the cables and the battery terminals.
• Be very careful not to connect the (+) and (-) leads in reverse.
(Because this may cause damage to the equipment and batteries)
INSPECTION
EN12Z1601H300001
POWER SUPPLY CIRCUIT
1. FUSIBLE LINK BLOCK INSPECTION

(1) Check the voltage between fusible link block terminal A and chas-
sis body ground.
(2) Under normal condition, the voltage is about 24V.
B B B
(3) If it is not correct, check the battery cable, wiring harness, etc.
B
• Battery cable (Open circuit, loosen connection, etc.)
A
B • Wiring harness (Open circuit, etc.)
• Battery (Discharged)
B
NOTICE
B
B Group "A" terminals: From battery
B
Group "B" terminals: To each electrical parts
B
SHTS12Z160100019
2. FUSE BLOCK INSPECTION

(1) Check the voltage between group A terminals of fuse block and
cab body ground.
(2) Under normal condition, the voltage is about 24V.
(3) If it is not correct, check the circuit from battery to fuse.
• Coupler connection between cab harness and chassis harness
• Coupler connection of each electrical parts
• Cab harness and chassis harness
(Open circuit, against short, etc.)
• Fusible link burn out
NOTICE
SHTS12Z160100020
Group A terminals: From battery
Group B terminals: To each electrical parts
ENGINE STARTING CIRCUIT
1. STARTER SWITCH INSPECTION

(1) Check the continuity between terminals.
M2 ACC
ST B M1
Terminals
B ACC M2 M1 ST
Switch position
LOCK
ACC
SHTS12Z160100021 ON
ST
2. STARTER RELAY INSPECTION

24V to terminal S,
Ground to terminal E.
(2) Under normal condition, terminals C and B switch on.
SHTS12Z160100023
GAUGE, METER AND WARNING CIRCUIT
1. FUEL GAUGE SENDER UNIT INSPECTION

(1) Measure resistance between terminals.
Float position F 1/2 E

Resistance: Ω 0-1.2 29.5-32.5 146.5-153.5
SHTS12Z160100024
2. COOLANT TEMPERATURE GAUGE SENDER UNIT INSPEC-

TION
(1) Warm up the sender gauge and measure the resistance between
the terminal and the body ground.
Temperature 75°C {167°F} 100°C {212°F}

Resistance:Ω 79-92 35.5-42.5
SHTS12Z160100025
3. BRAKE FLUID LEVEL SWITCH INSPECTION

Between terminals
Float position UP No continuity
Float position DOWN Continuity
SHTS12Z160100026
4. BRAKE STROKE WARNING SWITCH (Installed at the service

brake air booster) INSPECTION
Between terminals
PUSH Continuity
FREE No continuity
STROKE WARNING NOTICE

SWITCH When the head of the detector is depressed, the warning light
goes on to indicate brake shoe needs adjustment or lining
SHTS12Z160100027
replacement.
5. AIR PRESSURE SWITCH INSPECTION

(1) Apply air pressure.
(2) Check the continuity between terminal and body ground.
Low pressure switch Unit: kPa {kgf/cm2, lbf/in.2}
Seal color Operating pressure circuit
Yellow 490 {5.0, 71.1}
Blue 274.6 {2.8, 39.8}
NC
Pink 588.4 {6.0, 85.3}
None 539.4 {5.5, 78.2}
SHTS12Z160100028
Spring brake switch, Buzzer cancel switch and Trailer hand brake
switch Unit: kPa {kgf/cm2, lbf/in.2}
Connector
Operating pressure circuit
color
Black 539.4 {5.5, 78.2} NC
Light gray 49 {0.5, 7.1} NO
NC (Normal close): Continuity at less than operation pressure.

NO (Normal open): Continuity at more than operation pressure.
6. OIL PRESSURE SWITCH INSPECTION

(1) Start engine and disconnect the coupler.
(2) Check the continuity between terminal and engine ground.
Terminal Engine ground
Engine stop
Engine running
SHTS12Z160100029
7. REVOLUTION SENSOR INSPECTION

If the revolution sensor is normal, there will be continuity between
the terminals.
SHTS12Z160100031
8. PARKING BRAKE SWITCH INSPECTION

Terminals
A B C D
Switch position
PUSH
FREE
SHTS12Z160100032
HEADLIGHT CIRCUIT
1. COMBINATION SWITCH INSPECTION

Lighting (ON, OFF):
Terminals
EL LT LH
Switch position
OFF
TAIL
TAIL AND HEAD
Lighting (HIGH, LOW):
Terminals
ED DL DU EP
Switch position
PASSING
LOW BEAM
HIGH BEAM
SHTS12Z160100036
Turn signal:
Terminals
BT TL TR
Switch position
LEFT
OFF
RIGHT
Hazard warning:
Terminals
HF HL HR HT
Switch position
OFF
ON
Exhaust brake and electromagnetic retarder:
Terminals
EB E1 E3 BE E2
SHTS12Z160100037 Switch position
OFF
Windshield wiper and washer:
Terminals
WW EW WI WL WH
Switch position
OFF
WIPER: INT
MEDIUM
HIGH
WASHER: ON
2. HEADLIGHT RELAY INSPECTION

(1) Refer to "RELAY (TYPE, COLOR, PART No., NAME AND
INSPECTION)" in the section "GENERAL INSTRUCTION".
HEADLIGHT BEAM CONTROL CIRCUIT

(IF SO EQUIPPED)
1 1. HEADLIGHT BEAM LEVELING CONTROL SWITCH INSPEC-
2 TION
3 (1) Measure resistance between terminals.
Between No.1 and No.3 terminals
Switch position Resistance
0 1.60 kΩ
12V 1 2.07 kΩ
2 2.54 kΩ
1.6 k
3 3.01 kΩ
5 470
330
4 4 3.48 kΩ
470
3 330
S
ACT 2 470 5 3.95 kΩ
1 470 ILL
0
470 Between No.1 and No.2 terminals
430 Resistance
4.38 kΩ
SHTS12Z160100042
TURN SIGNAL, HAZARD, CLEARANCE,

TAIL AND LICENSE PLATE LIGHT CIRCUIT
1. TURN SIGNAL FLASHER INSPECTION

(1) Wire the turn signal flasher, bulbs, battery and fuse as shown in
figure.
(2) Under normal condition, bulbs turn on and off.
NOTICE
Take care quantity of installing bulbs.
Models for Taiwan and Thailand
SHTS12Z160100043 21W x 1 pcs, 12W x 1 pcs, 25W x 1 pcs,
TURN SIGNAL:
LED x 1 pcs
21W x 2 pcs, 12W x 2pcs, 25W x 2 pcs,
HAZARD WARNING:
LED x 1 pcs
Models for Chile and Singapore

TURN SIGNAL: 21W x 3 pcs, LED x 1 pcs
HAZARD WARNING: 21W x 6 pcs, LED x 2 pcs
Models for Hong Kong

TURN SIGNAL: 21W x 2 pcs, 10W x 1 pcs, LED x 1 pcs
HAZARD WARNING: 21W x 4 pcs, 10W x 2 pcs, LED x 2 pcs
Models for Indonesia

TURN SIGNAL: 21W x 2 pcs, 12W x 1 pcs, LED x 1 pcs
HAZARD WARNING: 21W x 4 pcs, 12W x 2 pcs, LED x 2 pcs
2. PARKING LIGHT SWITCH INSPECTION (IF SO EQUIPPED)

T
P1 Terminals
B2 T P B2 TB P1
Switch position
P
OFF
TB
ON
SHTS12Z160100044
STOP LIGHT CIRCUIT
1. STOP LIGHT SWITCH INSPECTION

Terminals
1 2
Switch position
PUSH
FREE
SHTS12Z160100046
FOG LIGHT CIRCUIT (IF SO EQUIPPED)
1. FOG LIGHT SWITCH INSPECTION

2
Terminals
1 1 2
Switch position
OFF
ON
SHTS12Z160100048
2. FOG LIGHT RELAY INSPECTION

BACKUP LIGHT CIRCUIT
1. BACKUP LIGHT SWITCH INSPECTION

Between terminals
PUSH Continuity
FREE No continuity
SHTS12Z160100050
DOME LIGHT CIRCUIT
1. DOME LIGHT INSPECTION

(1) Apply voltage to terminals and check the bulbs lighting.
SHTS12Z160100051
2. COURTESY SWITCH INSPECTION

(1) Check the continuity between terminal and body ground.
Between terminals
PUSH No continuity
FREE Continuity
SHTS12Z160100052
FLUORESCENT LIGHT CIRCUIT (IF SO EQUIPPED)
1. FLUORESCENT LIGHT SWITCH INSPECTION

1
Terminals
1 2
Switch position
OFF
2 ON
SHTS12Z160100053
POWER WINDOW CIRCUIT (IF SO EQUIPPED)
1. DRIVER'S SIDE SWITCH INSPECTION

DRIVER'S SIDE:
Terminals
+B DU DD E
Switch position
AUTO CLOSE
CLOSE
OFF
IG PU PD
OPEN
+B DD DU B2 E WL
AUTO OPEN
SHTS12Z160100054
ASSISTANT'S SIDE: LOCK SWITCH OFF POSITION

Terminals
+B PU PD E WL
Switch position
CLOSE
OFF
OPEN
ASSISTANT'S SIDE: LOCK SWITCH ON POSITION

Terminals
+B PU PD E WL
Switch position
CLOSE
OFF
OPEN
2. ASSISTANT'S SIDE SWITCH INSPECTION

Terminals
SU U IG D SD
Switch position
CLOSE
OFF
OPEN
D SD U SU IG
SHTS12Z160100058
3. POWER WINDOW MOTOR INSPECTION

(RIGHT-HAND DRIVE) (1) Check the continuity between terminals. If there is no continuity,
replace the motor.
(2) Apply 24V to terminals, inspect the motor operation as below.
Terminals
Direction of rotation 1 2
(View from out put shaft)
CLOCKWISE + -
COUNTERCLOCKWISE - +
1 2
SHTS12Z160100060
(LEFT-HAND DRIVE)
2 1
SHTS12Z160100061
2A'.AAPQAVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧡㧞ಽ
WINDSHIELD WIPER CIRCUIT
1. WIPER MOTOR INSPECTION

(1) Apply 24V to terminals, the motor operates as below.
NOTICE
Connect a 10A fuse between the terminal and the 24V power
source. If the fuse is burned out or the motor does not operate,
replace the motor.
SHTS12Z160100063 Terminals
LW LB L LR
Switch position
OFF
LOW
HIGH
2. WASHER PUMP INSPECTION

(1) Check the continuity between terminals of the motor.
If no continuity, replace jar and pump assembly.
NOTICE
Do not apply voltage to the pump motor for operational with an
empty jar, or the motor will be damaged.
SHTS12Z160100065
ENGINE STOP CIRCUIT (IF SO EQUIPPED)
1. ENGINE STOP ELECTRIC MOTOR INSPECTION

(1) Wire the engine stop electric motor as shown in the figure.
(2) Under normal condition, it should be operated as below.
Electric current
+ -
Lever position
PULL G W
RETURN G B
NOTICE
Connect a 10A fuse between the terminal and the 24V power
source. If the fuse is burned out or the motor does not operate,
replace the motor.
SHTS12Z160100066
2. ENGINE STOP RELAY

POWER DOOR LOCK CIRCUIT (IF SO EQUIPPED)
1. DRIVER'S SIDE DOOR LOCK SWITCH INSPECTION

(1) Check the continuity between terminals. If there is no continuity,
replace the switch.
Terminals
1 2 3
Lever position
LOCK
SHTS12Z160100068 UNLOCK
SHTS12Z160100069
2. ASSISTANT'S SIDE AND REAR LEFT SIDE DOOR LOCK

ACTUATOR INSPECTION
(1) Check the continuity between terminals. If there is no continuity,
replace the actuator.
SHTS12Z160100071
Terminals
1 2
Lever position
LOCK + -
UNLOCK - +
SHTS12Z160100072
3. DOOR LOCK CONTROLLER INSPECTION

(1) Wire the door lock controller as shown in the figure.
(2) Check the function.
Less than T
DOOR KNOB SWITCH
LOCK
UNLOCK
LOCK OUTPUT ON
"8"
OFF
T
UNLOCK OUTPUT ON
"7"
OFF
T T
SHTS12Z160100074
POWER MIRROR CIRCUIT (IF SO EQUIPPED)
1. POWER MIRROR SWITCH INSPECTION

1 2 3 4
Terminals
1 2 3 4
Lever position
CLOSE
SHTS12Z160100076
OFF
SET
2. POWER MIRROR RELAY INSPECTION

(1) Check the function as shown below the wiring diagram.
3 2 1
8 7 6 5 4
SHTS12Z160100076
POWER MIRROR RELAY
SET
4
1
SET
M STARTER
CLOSE SWITCH
3 POWER MIRROR
SWITCH
POWER MIRROR
MOTOR
8
CLOSE
BATTERY
(24V)
2 6
SHTS12Z160100077
3. POWER MIRROR MOTOR INSPECTION

Terminals
Direction of rotation 1 2
(View from out put shaft)
COUNTERCLOCKWISE + -
CLOCKWISE - +
SHTS12Z160100080
HEATER AND COOLER CIRCUIT (IF SO EQUIPPED)
1. BLOWER SWITCH INSPECTION

Terminals
E C M1 M2 H P P
Switch position
OFF
1
2 LIGHT
3
4
SHTS12Z160100082
2. COOLER CONTROL SWITCH

Terminals
A/C 5 6
Switch position
OFF
6 5 ON
SHTS12Z160100084
3. CONDENSER ASSEMBLY INSPECTION

(1) Check continuity between terminals.
Terminal
LB WB LY
Switch position
OFF
LO
HIGH
SHTS12Z160100084
4. POWER RELAY No.2 INSPECTION
EXHAUST BRAKE CIRCUIT
1. CLUTCH PEDAL SWITCH INSPECTION

Terminals
1 2
Switch position
PUSH
FREE
SHTS12Z160100046
2. ACCELERATOR PEDAL SWITCH INSPECTION

Between terminals
PUSH Continuity
FREE No continuity
SHTS12Z160100086
ES START CIRCUIT (IF SO EQUIPPED)
1. ES MAIN SWITCH INSPECTION

7 2
6
5 Terminals
5 6 7
1 Switch position
OFF
ON
SHTS12Z160100087
2. RELEASE TIMING SWITCH INSPECTION

Terminals
5 1 2
Switch position
FAST
SLOW
POWER TAKE-OFF CIRCUIT (IF SO EQUIPPED)
1. CLUTCH PEDAL SWITCH INSPECTION

Terminals
1 2
Switch position
PUSH
FREE
SHTS12Z160100090
2. TRANSMISSION P.T.O. SWITCH INSPECTION

3
2 Terminal
1 2 3 4
Switch position
1
4 OFF
ON
SHTS12Z160100091
3. P.T.O. POSITION SWITCH INSPECTION

Between terminals
PUSH Continuity
FREE No continuity
SHTS12Z160100093
INTER-AXLE DIFFERENTIAL LOCK CIRCUIT

(IF SO EQUIPPED)
3
1. INTER-AXLE DIFFERENTIAL LOCK
2
1
Terminal
1 2 3
Switch position
OFF
SHTS12Z160100094
ON
2A'.AAPQAVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧡㧠ಽ

(EXCEPT INDONESIA)
EN12Z1601H300002
ADJUSTMENT OF PULSE CONVERSION RATE

NOTICE
Be sure to carry out the adjustment of pulse conversion rate when
you replace the combination meter.
HINT
This is a device that enables a fine-tuning of compensating ratio
of speedometer without modifying the speedometer driven gear of
the transmission.
1. CONNECTING INPUT TOOL

(1) Remove the combination meter.
(2) Disconnect the wire harness connector (White, 18 pin) and con-
CABLE BETWEEN METER
AND HINO-BOWIE
nect the interface box (Hino-Bowie) with the PC unit, which is
PC
Hino-DX is installed.
INTERFACE BOX
(HINO-BOWIE) NOTICE
Do not disconnect other connectors.
SST: Interface Box (Hino-Bowie) (S0912-11040)
Cable between meter & Hino-Bowie (S0904-21180)
Hino Diagnostic eXplorer (Hino-DX)
WIRE HARNESS CONNECTOR

(WHITE, 18 PIN)
SHTS12Z160100098
2. THE METHOD OF WRITING IN OR READING OUT THE CON-

VERSION RATE
(1) Set the starter switch to "ON", and then turn on the power of PC to
start up the Hino-DX.
(2) Select "File", "Operation by system", then "Meter correction (M)".
(3) Carry out writing in or reading out the conversion rate in accor-
dance with the instructions.
SHTS12Z160100099
3. DISCONNECTING INPUT TOOL

CONVERSION RATE RECORD SEAL (1) Turn off the power of PC unit, and then turn the starter switch to
"LOCK" position.
(2) Disconnect the interface box (Hino-Bowie) from the combination
meter, and connect the wire harness connector (White, 18 pin).
(3) Write conversion rate on a new caution plate (conversion rate
record seal and stick it on the back side cover of the combination
meter.
New caution plate No.
Thailand S7658-84080
SHTS12Z160100100
Except Thailand S7658-83800
(4) Install the combination meter.


(FOR INDONESIA)
EN12Z1601H300005
ADJUSTMENT OF PULSE ADJUST COMPUTER

HINT
This is a device that enables a fine-tuning of compensating ratio
of speedometer without modifying the speedometer driven gear of
the transmission.
1. CONNECTING INPUT TOOL

(1) Remove the instrument panel cover of assistant seat side in the
cabin.
(2) Remove the seal around the screws by using a tool with a sharp
point end.
SHTS12Z160100101
(3) Remove the screws and then the cover of pulse adjust computer.
(4) If you disconnected the wire harness connector of the vehicle
when removing the cover of pulse adjust computer, connect again
the wire harness connector.
(5) Connect the input tool connector.
SST: Input tool (S0963-02400)
SHTS12Z160100102
2. THE METHOD OF WRITING IN OR READING OUT THE CON-

VERSION RATE
NOTICE
The vehicle condition at writing in or reading out: Starter switch is
turned on.
(1) Reading out the conversion rate.
a. The "RD/STP" key is pushed.
b. Reading out the conversion rate correctly, "GOOD" is indi-
cated and buzzer is rung for three seconds, then the conver-
sion rate which is written in the pulse adjust computer is
indicated.
(Reading out it incorrectly, "bad 0" is indicated and buzzer is
rung. In this case, put the connector again.)
c. It becomes a condition of writing the conversion rate when the
set key is pushed after reading out the conversion rate.
HINT
Refer to operation manual which belongs to input tool for details.
(2) Writing in the conversion rate.
a. While the condition of inputting the conversion rate (" *.****"
indication), the conversion rate is inputted to push the ten key
or [UP] [DOWN] key.
If the conversion rate is inputted, omit a decimal point.
EX.) When you want to input the conversion rate "1.8210",
push the ten key as "18210" and the set key.
SHTS12Z160100103
NOTICE
Refer to the following "Pulse conversion rate table".
b. If the set key is pushed, the input value is decided.
When it is inputted correctly, the buzzer is rung and the dis-
play becomes the same condition before inputting with ten
key.
c. The "WR/STR" key is pushed.

Writing in the conversion rate correctly, "GOOD" is indicated
and buzzer is rung for three seconds, then the conversion rate
which is contained an error and which was actually written in
the pulse converter is indicated.
Writing in it incorrectly, "bad 0" is indicated and buzzer is
rung.
In this case, write in it correctly again.
3. DISCONNECTING INPUT TOOL

(1) Turn the starter switch to "LOCK" position.
(2) Disconnect the input tool connector and mount the cover of pulse
adjust computer.
(3) Apply new seal (S8317-91140) on the screws to seal them.
(4) Write conversion rate on a new caution plate (conversion rate
record seal (S7658-83800) and stick it on the place.
(5) Mount the instrument panel cover of assistant seat side.
SHTS12Z160100104
SPEEDOMETER CONVERSION RATE LIST

EN12Z1601H300004
LX06 TRANSMISSION SERIES
SHTS12Z160100105
SHTS12Z160100106
SHTS12Z160100107
LJ06, MF06 TRANSMISSION SERIES
SHTS12Z160100108
SHTS12Z160100109
SHTS12Z160100110
EATON TRANSMISSION (SPEEDOMETER CORRECTION RATE 0.96)
SHTS12Z160100111
SHTS12Z160100112
EATON TRANSMISSION (SPEEDOMETER CORRECTION RATE 0.98)
SHTS12Z160100113
SHTS12Z160100114
ZF TRANSMISSION
SHTS12Z160100115
SHTS12Z160100116
SHTS12Z160100117
SHTS12Z160100118
2A&0AA&'051A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧡㧢ಽ
BRAKE CONTROL (ABS+ES START: DENSO) DN03–1
BRAKE CONTROL
DN03
(ABS+ES START: DENSO) DN03-001
ANTI-LOCK BRAKE .................................DN03-2 ABNORMALITY OF REAR RIGHT WHEEL SENSOR:

HANDLING PRECAUTIONS ........................... DN03-2 EXCESSIVE AIR GAP, OR ADHESION OF IRON
SYSTEM DIAGRAM ........................................ DN03-3 PIECE (DIAGNOSIS CODE 38) .................... DN03-61
CHASSIS SIDE ABNORMALITY OF REAR LEFT WHEEL SENSOR:
CONNECTOR PIN ASSIGNMENT .................. DN03-4 EXCESSIVE AIR GAP, OR ADHESION OF IRON
INSPECTION PIECE (DIAGNOSIS CODE 39) .................... DN03-61
(ABS SYSTEM OPERATION AND LOW VOLTAGE OR OVERVOLTAGE OF
FAILURE DIAGNOSTICS)............................... DN03-8 POWER SUPPLY
TROUBLESHOOTING BY (DIAGNOSIS CODE 41) ................................ DN03-62
USING DIAGNOSIS MONITOR..................... DN03-22 ABNORMALITY OF POWER SUPPLY VOLTAGE
TABLE OF TROUBLE CODE ........................ DN03-24 (DIAGNOSIS CODE 42) ................................ DN03-62
DISCONNECTION OF SOLENOID RELAY ABNORMALITY OF ABS ACTUATOR:
(DIAGNOSIS CODE 11) ................................ DN03-25 BRAKE FLUID PRESSURE SENSOR
SHORT CIRCUIT OF SOLENOID RELAY (DIAGNOSIS CODE 46) ................................ DN03-63
(DIAGNOSIS CODE 12) ................................ DN03-29 ABNORMALITY OF STOP LIGHT SWITCH
DISCONNECTION OF MOTOR RELAY (DIAGNOSIS CODE 49) ................................ DN03-67
(DIAGNOSIS CODE 13) ................................ DN03-31 ABNORMALITY OF MOTOR: NO ROTATION
SHORT CIRCUIT OF MOTOR RELAY (DIAGNOSIS CODE 51) ................................ DN03-68
(DIAGNOSIS CODE 14) ................................ DN03-35 ABNORMALITY OF EXHAUST BRAKE CUT RELAY
ABNORMALITY OF SOLENOID (DIAGNOSIS CODE 66) ................................ DN03-69
FOR FRONT RIGHT WHEEL ABNORMALITY OF AIR PRESSURE SIGNAL
(DIAGNOSIS CODE 21) ................................ DN03-37 (DIAGNOSIS CODE A1)................................ DN03-70
ABNORMALITY OF SOLENOID DISCONNECTION / SHORT CIRCUIT OF
FOR FRONT LEFT WHEEL VEHICLE SPEED SENSOR
(DIAGNOSIS CODE 22) ................................ DN03-39 (DIAGNOSIS CODE B1)................................ DN03-70
ABNORMALITY OF SOLENOID ABNORMALITY OF CLUTCH STROKE SENSOR
FOR REAR RIGHT WHEEL (DIAGNOSIS CODE B2)
(DIAGNOSIS CODE 23) ................................ DN03-42 (ONLY VEHICLE WITH ES START).............. DN03-71
ABNORMALITY OF SOLENOID ABNORMALITY OF NEUTRAL SWITCH
FOR REAR LEFT WHEEL (DIAGNOSIS CODE B3)
ABNORMALITY OF ES SOLENOID STICKING AT "ON" POSITION OF
(DIAGNOSIS CODE 25) ................................ DN03-46 RELEASE TIMING SWITCH (DIAGNOSIS CODE B5)
ABNORMALITY OF FRONT RIGHT WHEEL SENSOR (ONLY VEHICLE WITH ES START).............. DN03-74
(DIAGNOSIS CODE 31) ................................ DN03-49 ABNORMALITY OF ES START MAIN SWITCH
ABNORMALITY OF FRONT LEFT WHEEL SENSOR (DIAGNOSIS CODE B6)
ABNORMALITY OF REAR RIGHT WHEEL SENSOR IMPERFECT INITIAL SETTING
(DIAGNOSIS CODE 33) ................................ DN03-55 (DIAGNOSIS CODE B7)
ABNORMALITY OF REAR LEFT WHEEL SENSOR (ONLY VEHICLE WITH ES START).............. DN03-76
(DIAGNOSIS CODE 34) ................................ DN03-58 ABNORMALITY OF TACHOMETER SIGNAL
ABNORMALITY OF FRONT RIGHT WHEEL SENSOR: (DIAGNOSIS CODE B8)
EXCESSIVE AIR GAP, OR ADHESION OF IRON (ONLY VEHICLE WITH ES START).............. DN03-76
PIECE (DIAGNOSIS CODE 35) .................... DN03-61
ABNORMALITY OF FRONT LEFT WHEEL SENSOR:
EXCESSIVE AIR GAP, OR ADHESION OF IRON
PIECE (DIAGNOSIS CODE 36) .................... DN03-61
2A&0AA&'051A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧞㧤ಽ
DN03–2 BRAKE CONTROL (ABS+ES START: DENSO)
ANTI-LOCK BRAKE
HANDLING PRECAUTIONS
EN16Z0803F200001
1. ABOUT CONNECTORS
(1) When vehicle placed on speed meter tester, or jacked up to rotate
the tires, there is a case that ECU memorize failure code. But, this
is not abnormal. Clear the failure code on ECU in any case of hav-
ing done that type of maintenance service.
(2) Before performing an inspection work, check that each connector
is surely connected.
(3) When taking off connector, do it without fail at the "LOCK" position
of starter key.
(4) Any parts presumed to be abnormal should not be repaired, but
change it.
(5) After clearing the failure memories recorded in the past, perform
SHTS16Z080300001
failure diagnosis again and check the current failure.
(6) After completing the diagnosis analysis, clear the diagnosis mem-
ories in the past.
(7) Unless otherwise specified, the drawing of connector is one
viewed from connected surface. But, test bar should be inserted
from back side for measuring.
However, check the terminals at the connected part of such water
proof connectors as ABS actuator, etc. In this case, be careful not
to short the terminals.
(8) The connector is displayed from the view of the mating surface
when the connector lock is positioned above.
Reference
• Female connector: The terminal is female.
• Male connector: The terminal is male.
SHTS16Z080300002
(9) As for the terminal numbers of the connector, the first terminal is
located on the top right terminal of the male connector and the top
left terminal of the female connector.
Reference:
When viewed from the mating surface, the terminal numbers
of both connectors are located symmetrically (reversed hori-
zontally).
(10) When disconnecting the connectors, be sure to position the
starter switch "LOCK".
2. ABOUT DIAGNOSIS MONITOR

SHTS16Z080300003 (1) Erase the previous damage data after they have been recorded,
then perform the damage diagnosis again and confirm the current
damage.
(2) After the damage analysis is completed, delete the previous dam-
age data.
.
SYSTEM DIAGRAM
EN16Z0803J100001
INPUT SIGNAL OUTPUT SIGNAL

ABS+ES start ECU
ABS actuator
Front left wheel sensor

ABS solenoid valve
for front left wheel
Front right wheel sensor ABS control function ABS solenoid valve
for front right wheel
Rear left wheel sensor ABS solenoid valve ABS solenoid valve
control function for rear left wheel
ABS solenoid valve

Rear right wheel sensor
for rear right wheel
ES start main switch

Exhaust brake
Exhaust brake relay
Release timing switch control function
Stop light switch

(For operation check)
Neutral switch ABS actuator

(For checking
operation release) ES solenoid valve SM1
Courtesy switch
(For alarming while ES solenoid valve SM1
driver not seated)
Parking brake switch 1

(For checking
ES start ES start indicator
operation release)
control function (In combination meter)
Parking brake switch 2
(For checking ES start buzzer
alarm suspension) (In combination meter)
Clutch stroke sensor

(For controlling
operation release)
Malfunction code
Brake fluid pressure sensor (Diagnosis code)
Vehicle speed sensor

Switch off ABS to allow
normal brake operation
Malfunction
Diagnosis monitor
diagnostic function
ABS warning light
Engine ECU Fail-safe function

(Engine revolutions) (Safety function)
SHTS16Z080300004
CHASSIS SIDE CONNECTOR PIN ASSIGNMENT

EN16Z0803F200002
22 PIN CONNECTOR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
VIEW CHASSIS HARNESS
16 17 18 19 20 21 22
SHTS16Z080300005
No. Signal No. Signal
1 Rear reducing solenoid valve 12 Neutral switch
2 ES solenoid valve SM1 (Front) - 13 —
3 ES solenoid valve SM1 (Front) + 14 Ground 4
4 ES solenoid valve SM2 (Rear) - 15 Ground 3
5 ES solenoid valve SM2 (Front) + 16 Front retaining solenoid valve
6 Solenoid relay test 17 —
7 Rear retaining solenoid valve 18 —
8 Front reducing solenoid valve 19 —
9 — 20 —
10 — 21 —
11 — 22 —
31 PIN CONNECTOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
SHTS16Z080300006
1 Relay power supply 17 —
2 Ground 1 18 Motor relay test
3 Ground 2 19 —
4 Clutch pedal stroke sensor power supply 20 Rear retaining solenoid valve
5 — 21 —
6 — 22 —
7 — 23 —
8 Front retaining solenoid valve 24 Solenoid relay
9 Front reducing solenoid valve 25 Front right wheel sensor -
10 — 26 Front right wheel sensor +
11 — 27 Front left wheel sensor +
12 Motor relay 28 Front left wheel sensor -
13 — 29 —
14 — 30 Rear reducing solenoid valve
15 Clutch pedal stroke sensor signal 31 —
16 Clutch pedal stroke sensor ground

24 PIN CONNECTOR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
SHTS16Z080300007
1 Stop light switch 13 —
2 ES start indicator light 14 —
3 ECU power supply (Battery) 15 Rear right wheel sensor -
4 — 16 Rear right wheel sensor +
5 Buzzer output 17 —
6 ABS warning light 18 Test mode startup
7 ECU power supply (Ignition) 19 Diagnosis startup
8 — 20 —
9 — 21 Parking brake switch
10 Exhaust brake relay 22 Rear left wheel sensor +
11 Parking brake switch 2 23 Rear left wheel sensor -
12 — 24 —
28 PIN CONNECTOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
SHTS16Z080300008
1 — 15 Brake fluid pressure sensor shield ground
2 Courtesy switch 16 —
3 Main switch (OFF) 17 —
4 Main switch (ON) 18 Exhaust brake relay monitor
5 Release timing switch (FAST) 19 —
6 Release timing switch (SLOW) 20 —
7 Engine revolution signal input 21 —
8 Vehicle speed sensor 22 —
9 — 23 —
10 — 24 Brake fluid pressure sensor power supply
11 — 25 Brake fluid pressure sensor signal
12 — 26 —
13 — 27 —
14 Brake fluid pressure sensor shield ground 28 —

INSPECTION (ABS SYSTEM OPERATION AND FAILURE

DIAGNOSTICS)
EN16Z0803F200003
OPERATION CHECK OF ABS FUNCTION

Perform an operation check every year for ABS function in the following manner:
1. CHECK OF OPERATING CONDITION

(1) Check operating condition of the system, according to the following "CHECK OF ABS OPERATING CONDITION".
2. PREPARATION BEFORE CHECKING OPERATING CONDITION.

(1) Under the vehicle stopping condition, check any fluid leak from ABS actuator by depressing the brake pedal.
When any fluid leak is found at the connection part of pipe connectors, retighten the connectors.
At the same time, when leaking from ABS actuator, replace ABS actuator with the new one.
(2) By releasing the brake pedal, check any leakage from ABS actuator.
3. CHECK OF ABS OPERATING CONDITION UNDER THE VEHICLE RUNNING.

NOTICE
Perform ABS operating condition check under the vehicle running with much attention on the following points.
• Do it at a spacious and safe place.
• Do it with no payload on the vehicle.
• Put white tape or the like along the tire side face so that tire rotating condition may be also checked.
(1) Switch starter key "ON" and check that ABS warning light will go on and go off thereafter.
(2) By driving the vehicle at the speed of 20-30 km/h {12-19 mile/h}, put a sudden brake and check that all wheels with
ABS system will not be locked.
MALFUNCTION DIAGNOSIS BY WARNING LIGHT
ILLUMINATING LIGHT CAUSE OF MALFUNCTION FAIL-SAFE FUNCTION
POWER SUPPLY RELATED

• Fuse burned out.
• Wire harness connector disconnected. ABS all system not operating.
• Bad contact with wire harness. (As normal braking operation)
• Wire broken in wire harness.
• Low battery voltage.
WHEEL SENSOR RELATED

• Sensor clearance too wide.
ABS warning light is lit • Bad sensor unit. ABS all system not operating.
under the vehicle running • Broken wire in wire harness. (As normal braking operation)
condition. • Wire harness connector disconnected or bad
contact.
ABS ACTUATOR RELATED

• Wire broken or short circuit in solenoid coil.
ABS all system not operating.
• Broken wire in wire harness of ABS actuator, (As normal braking operation)
wire harness connector disconnected, bad
contact.
ECU ABS all system not operating.

• Internal malfunction in ECU. (As normal braking operation)
NOTICE
ABS warning light will continue to be lit even when any abnormal condition is seen in ABS mechanism for a while
and come back to the normal condition.
In this case, it can be reset by stopping the vehicle and turning the starter key on "LOCK".
1. LIGHTING AND FLASHING ON/OFF OF WARNING LIGHT IN CONNECTION WITH DIAGNOSIS MONITOR.
• Lighting and flashing on/off of warning light in connection with diagnosis monitor.
Connectors to ABS warning light condition

connect with
Mode
diagnosis Vehicle stopping Vehicle running
monitor.
Abnormal Lights up Lights up
Flashing (Test mode dis-

OPT: ATM Sensor check mode Flashing (Test mode display)
play)
ABS mode Flashing (Test mode display) Not light up
Abnormal Flashing (Indicates diagnosis code) Lights up

STD: ABS/ASR
Not abnormal Diagnosis code flashes (Correct code) Not light up
Diagnosis code flashes (Sensor check code also

Abnormal Lights up
flashes before completing sensor check)
OPT: ATM
Sensor check code flashes (Diagnosis code also
AND Sensor check mode Diagnosis code flashes
flashes when it is available)
STD: ABS/ASR
Diagnosis code flashes (Correct code flashes when
ABS mode Not light up
system is normal)
ABS TEST MODE
1. START-UP OF TEST MODE

(1) Switching starter key to "LOCK" position, connect a dedicated harness wire with diagnosis connector (white color)
and diagnosis monitor with "OPT: ATM" connector.
HINT
Refer to "TROUBLE SHOOTING BY USING DIAGNOSIS MONITOR", concerning the connection of diagnosis moni-
tor.
(2) Switch starter key "ON" position.
2. CHECK OF TEST MODE DISPLAY

(1) Check that after turning the starter key "ON", ABS warning light will be lit for 3 seconds, "initial valve check" to "ECU
output" will be shown in the order, and then "test mode" will be displayed. Do not step on the brake pedal until "test
mode" will be displayed.
(2) Start engine when ABS warning light does not go off after "ECU output", check that "test mode" will be displayed in a
few seconds.
In this case, do not depress the brake pedal before checking "test mode display".
NOTICE
• ABS warning light will not go off if the relating parts or the wiring are not good and "test mode" will not be
displayed. This is a moment when ECU memorizes "malfunction spot" in diagnosis monitor code.
At the same time, ABS warning light will not also go off when any abnormality is seen on the fluid pressure
sensor. In this case, there is a case that diagnosis monitor code may not be memorized.
• When ABS warning light remains not lit, there are cases that its bulb or wiring of lighting system are not
good.
HINT
In order to avoid a wrong installation of ABS ECU, output "ECU code" when starting up "test mode".
Since the codes to be installed are different from model to model, check well the proper codes to meet with the
model when starting up "Test mode".
Lighting and flashing on/off of warning light in connection with diagnosis monitor.
Specification ECU code
ABS 1
ABS+ES start 2
ON
ABS
warning light
OFF
3.0 second 0.13 second 0.13 second
(Initial check) 0.5 0.5
second second
Identification by frequency of flashing on/off (Example) Code 2 Test mode display.
SHTS16Z080300009
3. STARTING THE CHECK

• Confirming that "test mode" will be displayed after "ECU code" displaying in ABS warning light, perform fluid sensor
check and speed sensor check.
(1) Fluid sensor check
a. After releasing the brake pedal for more than 1 sec., check ABS warning light going on by depressing the pedal
with pedal effort of more than 147 N {15 kgf, 33 lbf}.
b. With ABS warning light lit, keep depressing the pedal for 1 second.
Removing your foot from the brake pedal, check that ABS warning light will be returned to "test mode display".
Pedal effort of brake pedal

More than 1 second
(Fluid pressure)
"ON"
ABS warning light
"OFF"
SHTS16Z080300010
NOTICE
When ABS warning light does not go on even with enough pedal effort, malfunction of fluid sensor may be its
cause.
(2) Speed sensor check
a. Starting engine, check that ABS warning light be put into "test mode" flashing on/off.
b. By taking off the vehicle in straight direction without making wheel-spin and speeding up to more than 45 km/h,
keeping it at a given speed for 1 second, check that ABS warning light went off.
NOTICE
• When making wheel-spin, there is a case that speed sensor check will not be completed.
• There is a case that by starting sensor check in steered condition, ABS warning light does not go off after
the check.
Do not make wheel-spin

in this area
km/h
45
Vehicle speed
"ON"
ABS warning light
"OFF"
Light goes on when Light goes on and off Light goes off
the check is completed, when the vehicle is while the vehicle
running at a given speed stopping. running.
of more than 45km/h {28 mile/h}.
SHTS16Z080300011
NOTICE
When the sensor is abnormal and the check is not completed, different from the above mentioned condition, light
flashes on and off even under the vehicle running condition.
4. CHECKING COMPLETION
(1) When speed sensor check is correctly completed, ABS warning light goes to the following lighting condition:
• While the vehicle stopping: ABS warning light goes on and off. "Test mode display"
(It flashes on and off even when it is not correctly completed)
• While the vehicle is running: ABS warning light goes off.
NOTICE
• When the sensor check is not completed or the sensor is abnormal, it goes on.
even under the vehicle running condition.
• When the sensor check is correctly completed (light goes off while the vehicle running), ABS will become
possible to operate. When it is not completed or it is abnormal, ABS will not operate.
5. CHECK FOR SENSOR CHECK CODE AND DIAGNOSIS MONITOR CODE.

(1) After the sensor check is completed, check the system condition by "flashing on/off status" of ABS warning light.
a. Connect dedicated harness wire with diagnosis connector (white color) and diagnosis monitor with "STD: ABS/
ASR" connector.
HINT
Refer to "Malfunction Diagnosis", concerning the connection of diagnosis monitor.
b. Check flashing on/off condition of ABS warning light.
• Correct code display: System is correct.
• Abnormal code display: System is abnormal.
ABS warning light flashing on/off condition.
Correct code : Sensor check completed , Correct system
"ON"
ABS warning light
"OFF"
0.25 sec. 0.25 sec.
Abnormal code: Example "73"
"ON"
ABS warning light
"OFF"
0.5 sec. 0.5 sec. 1.5 sec. 2.5 sec.
* Abnormal code is found in Diagnosis monitor code and Sensor check code.
When there exist more than 2 abnormal codes, the display will be repeated in the order from smaller number of the codes.
SHTS16Z080300012
c. When abnormal code is displayed, repair the defective part.

NOTICE
When only diagnosis monitor code is displayed, repair its defective part and clear off diagnosis monitor code.
After clearing off it, check that ABS warning light is correctly operating.
(2) How to clear off diagnosis monitor code and sensor check code.
• Under the vehicle stopping condition, connecting "STD: ABS/ASR" connectors and turning starter key "ON", depress
the brake pedal by more than 8 times for 5 sec.
NOTICE
Depress the pedal deeply so that "ON" and "OFF" of stop light switch may be surely recognized.
• Or, under the vehicle stopping condition, connecting "STD: ABS/ASR" connectors and turning starter key on, connect
and disconnect the connector for "OPT: ATM" by more than 4 times for 8 sec. (Use 2 diagnosis monitors)
• When correct code is displayed, perform completing operation for test mode.
NOTICE
• When sensor check code is displayed, repairing the defective part, clear off diagnosis monitor code. After
clearing off, start an operation to "1. START-UP OF TEST MODE".
• When diagnosis monitor code and sensor check code are displayed, clear off diagnosis monitor code,
repairing its defective part. After clearing off, start an operation to start up "1. START-UP OF TEST MODE".
• When sensor check code completes "test mode", it will be automatically cleared off.
6. COMPLETION OF TEST MODE.

(1) Turn starter key to "LOCK" position.
(2) Remove diagnosis monitor. (Connector for "STD: ABS/ASR", connector for "OPT: ATM")
(3) Turn starter key "ON" position.
NOTICE
Unless an operation for (1) - (3) is performed, previous test mode will be displayed.
HOW TO TAKE A COUNTER-MEASURE WHEN OUTPUTTING SENSOR CHECK CODE
Sensor
check Description Contents Counter-measure
code
Abnormal voltage output on front The check for voltage output at vehi- Check diagnosis monitor code 31.
71
RH wheel sensor cle speed of less than 5 km/h is not
completed.
Abnormal voltage output on front Check diagnosis monitor code 32.
72
LH wheel sensor
Abnormal voltage output on rear Check diagnosis monitor code 33.

73
RH wheel sensor
Abnormal voltage output on rear Check diagnosis monitor code 34.

74
LH wheel sensor
Abnormal frequency output on The check for "noise" or "frequency Check diagnosis monitor code 31.
75
front RH wheel sensor change" at vehicle speed of more
than 45 km/h {28 mile/h} is not com-
Abnormal frequency output on pleted. Check diagnosis monitor code 32.
76
front LH wheel sensor
Abnormal frequency output on rear Check diagnosis monitor code 33.

77
RH wheel sensor
Abnormal frequency output on rear Check diagnosis monitor code 34.

78
LH wheel sensor
Abnormal voltage output on G sen- The check for sensor output is not Check diagnosis monitor code 43.
79
sor. completed.
Abnormal output on fluid sensor The check for sensor output is not Check diagnosis monitor code 46.
81
(ABS actuator) completed.
OPERATION CHECK FOR ES START FUNCTION

1. CHECK FOR DISPLAY CODE ON ES START INDICATOR.
(1) When a wrong operation or any malfunction on ABS+ES start
ECU is produced, its malfunction will be notified by such warning
means as warning buzzer, lighting or flashing on/off of an indica-
tor light as it follows:
NOTICE
When any malfunction is displayed, diagnose it through diagnosis
function.
SHTS16Z080300013
Display and warning item Indicator

Warning buzzer Warning content Treatment
light
Under "ON" condition of starter Lighting for

switch, check if the light light up or not 3 second
ES start is operating
Lighting 1 short beeping
(After engine starting)
Operation
ES start is released Lighting off No beeping
Perform failure
Defects of signal
Failure alarm Blinking Beeping continuously diagnosis by diagnosis
switches or sensors
Warning function.
Initialization is
Non-adjustment alarm Blinking No beeping Initialize.
not completed.
Door (either driver's

side or assistant's side) Pull parking brake
Driver not seated Lighting Beeping continuously
opens when ES start lever.
alarm
is operating
Starter switch is set to

"LOCK" when ES start Pull parking brake
Starter switch OFF Beeping continuously
Lighting off lever or set main
alarm is operating during
neutral position. switch to "OFF".
Vehicle moves when Pull parking brake

Vehicle moving alarm Lighting Beeping continuously lever or step brake
ES start is operating.
Caution to pedal
mis-operation
Operation time from
1 to 9 minutes
1 minute has passed:
1 short beeping
2 minutes have
passed: Displaying every
Operation time Lighting 2 short beeping minute ES start Release ES start.
information 9 minutes have operation time
passed:
9 short beeping
Operation time
10 minutes or more:
5 short beeping
continuously
SHTS16Z080300014
• Check the battery voltage.

Standard: 0V or more
• Check that the ES start controller connectors are connected correctly.
• Check the fuse.
• Check that the speed sensor connector is connected correctly.
• Check that the ES start valve connector is connected correctly.
• Check that the clutch hydraulic switch connector is connected correctly.
• Check that the clutch stroke sensor connector is connected correctly.
• Check that the back-up light switch connector is connected correctly.
• Check that the neutral switch connector is connected correctly.
2. OPERATION CHECK
(1) Normal operation check
a. Turn starter key "ON" position.
b. ES start indicator light in the meter goes on for 3 second.
c. Then, when only ES start light flashes on and off, it means that 0-point adjustment of clutch and initial setting of
release position are not made. Accordingly, make them. At the same time, when ES start indicator light flashes
on and off and the buzzer beeps continuously, it means that the switch or the sensor is not good. Checking those
defective parts through diagnosis function, repair them.
(2) 0-point adjustment of clutch and initial setting of release position.
a. Make 0-point adjustment of clutch and initial setting of release position.
(3) Operation check
NOTICE
This check should be performed on "brake tester" or at place where protective device against the vehicle taking
off since vehicle taking off operation is needed.
a. The followings should be fulfilled.
• Starter key: "ON".
• ES start main switch: "ON".
• Parking switch: "RELEASE".
• Vehicle speed: 0 km/h {0 mile/h}
b. After depressing the brake pedal for approx. 1 second, check that the buzzer beeps once, ES start indicator light
flashes on and off, and ES start will operate.
c. Check that braking force is retained.
d. By normal operation for taking off (by shifting gear for clutch connection), check that ES start will be released.
.
3. WARNING FUNCTION
(1) ES start system alerts by beeping the warning buzzer and lighting or blinking the indicator light to classify the alarms
when dangerous operations or failures occur.
NOTICE
When a failure alarm is displayed, perform the failure diagnosis by using diagnosis function.
Indicator
Warning buzzer Item Warning content Treatment
light
Non-adjustment
Blinking No beeping Initialization is not completed. Initialize.
alarm
Perform failure diagnosis

Blinking Failure alarm Defects of signal switches or sensors.
by diagnosis function.
When starter key was cut off during

ES start operation under the condition
Driver not
Lighting Beeping that the door was opened while ES Pull parking brake lever.
seated alarm
continuously start is operating or parking lever is
not pulled at "Neutral" position of shift.
When the vehicle moves while ES

Vehicle moving Pull parking brake lever
Lighting start is operating. (Shift: "Neutral"
alarm or step brake pedal.
position)
Operating time of ES start is notified

to the driver every 1 min.
• During 1 to 9 min. after operat-
ing: To beep intermittently every
Refer to such minutes as time is lapsing. Stepping deeply on the
Operation time
Lighting "Warning con- brake pedal, pull the
information • More than 10 min. after operat-
tent" parking brake lever.
ing: To beep 5 times continu-
ously.
• Example: 3 min. after operating.
"Beep", "Beep", "Beep".
ES START: MALFUNCTION DIAGNOSIS FROM VARIOUS CONDITION
ES start does not work.
Check if a wrong operation was made or not ?

Engine does not operate.
ES start main switch is positioned at "OFF".
Brake pedal is not depressed.
Parking brake lever is pulled back.
Wrong operation was made.

Restart the operation.
Wrong operation was not made.
Check M power source under "ON" position of starter key.
Warning was made ?
It was made.
Table of warning kinds.
It was not made.
Check stop light switch.
Check parking brake switch.
Check vehicle speed sensor.
Check clutch stroke sensor.
Check the piping for brake fluid.
Check ABS actuator.
Malfunction of ABS+ES start ECU.
SHTS16Z080300015
ES start is not released. (Release by taking off operation.)
Check if a wrong operation was made or not.

The gear remaining shifted to "neural position"
Taking off operation is not correctly made.

Warning was made ?
It was made.
It was not made.
Check neutral switch.
Check ABS actuator.

SHTS16Z080300016
ES start is not released. (Release by parking brake.)
Check if a wrong operation was made or not.

Parking brake lever is not pulled.

Warning was made ?
Warning was made.

Warning was not made.
Check ABS actuator.
SHTS16Z080300017
ES start is not released. (Release by ES start main switch.)
Check if wrong operation was made or not.

Main switch is not positioned at "RELEASE".

Warning was made ?
It was made.
It was not made.
SHTS16Z080300018
Initial setting for releasing position can not be made.
Check if wrong operation was made or not ?

Check if is out of the following condition or not ?

Release position is being adjusted.
Warning was made ?
It was made.
It was not made.
Check neutral switch.
SHTS16Z080300019
Dragging the brake (Vehicle moving back)
Adjustment of releasing position
SHTS16Z080300020
TROUBLESHOOTING BY USING DIAGNOSIS MONITOR

EN16Z0803F200004
1. DIAGNOSIS MONITOR
(1) Diagnosis monitor alerts the failure location with sound and light
by being connected to the special diagnosis connector of the
ABS+ES start system.
SHTS16Z080300021
2. CONNECT THE DIAGNOSIS MONITOR

(RIGHT-HAND DRIVE)
(1) Disconnect the centralized diagnosis connector (upside the accel-
FIXING DUMMY erator pedal) from the dummy connector.
CONNECTOR
NOTICE
The centralized diagnosis connector is usually connected to the
fixing dummy connector. So, disconnect the connector from the
dummy connector and pull it to use. When the connector is not in
use, connect it firmly to the fixing dummy connector.
BLACK CONNECTOR
WHITE CONNECTOR
SHTS16Z080300022
SHTS16Z080300023
(2) Connect the dedicated harness to the centralized diagnosis con-

nector and diagnosis monitor to the connector tagged by "STD:
ABS/ASR".
SST:
STD:ABS/ASR
OPT:AIRSUS
Dedicated Harness (S0963-02300)

Diagnosis monitor (S0963-01370)
(3) Turn the starter switch to "ON" position.
OPT:ATM
SHTS16Z080300024
3. MALFUNCTION CODE DISPLAY

(1) Malfunction codes, regardless of the current or the past ones, will be repeatedly displayed in the order from smaller
number of malfunction codes.
Correct code : Finishing sensor check, the system is correct.
"ON"
ABS warning light
"OFF"
0.25 sec. 0.25 sec.
Incorrect code: Example "73 "
"ON"
ABS warning light
"OFF"
0.5 sec. 0.5 sec. 1.5 sec. 2.5 sec.
* Abnormal code is formed by diagnosis monitor code and sensor check one.
When more than 2 abnormal codes are found, they will be displayed in the order from smaller number of the codes.
SHTS16Z080300025
4. CLEARING OFF OF MALFUNCTIONS IN THE PAST.

(1) How to clear off diagnosis monitor code and sensor check code.
• Stop the vehicle and connect "STD: ABS/ASR" connector and step on the brake pedal by more than 8 times for 5
second by turning starter key "ON".
NOTICE
Depress the brake pedal deeply so that "ON" or "OFF" of stop light switch can be clearly recognized.
• Or, stop the vehicle and connect "STD: ABS" connector, connect and disconnect "OPT: ATM" connector by more than
4 times during 8 second under "ON" position of starter key.
NOTICE
Use 2 diagnosis monitors.
• When correct code is displayed, perform finishing operation of test mode.
HINT
Sensor check code will be automatically deleted when finishing test mode.
.
TABLE OF TROUBLE CODE

EN16Z0803F200005
DIAGNOSIS
TROUBLE CONTENTS REFER PAGE
CODE
11 Disconnection of solenoid relay DN03-25
12 Short circuit of solenoid relay DN03-29
13 Disconnection of motor relay DN03-31
14 Short circuit of motor relay DN03-35
21 Abnormality of solenoid for front right wheel DN03-37
22 Abnormality of solenoid for front left wheel DN03-39
23 Abnormality of solenoid for rear right wheel DN03-42
24 Abnormality of solenoid for rear left wheel DN03-44
25 Abnormality of ES solenoid DN03-46
31 Abnormality of front right wheel sensor DN03-49
32 Abnormality of front left wheel sensor DN03-52
33 Abnormality of rear right wheel sensor DN03-55
34 Abnormality of rear left wheel sensor DN03-58
35 Abnormality of front right wheel sensor: Excessive air gap, or adhesion of iron piece. DN03-61
36 Abnormality of front left wheel sensor: Excessive air gap, or adhesion of iron piece. DN03-61
38 Abnormality of rear right wheel sensor: Excessive air gap, or adhesion of iron piece. DN03-61
39 Abnormality of rear left wheel sensor: Excessive air gap, or adhesion of iron piece. DN03-61
41 Low voltage or overvoltage of power supply DN03-62
42 Abnormality of power supply voltage DN03-62
46 Abnormality of ABS actuator: Brake fluid pressure sensor DN03-63
49 Abnormality of stop light switch DN03-67
51 Abnormality of motor: No rotation DN03-68
66 Abnormality of exhaust brake cut relay DN03-69
A1 Abnormality of air pressure signal DN03-70
B1 Disconnection/short circuit of vehicle speed sensor DN03-70
B2 Abnormality of clutch stroke sensor (only vehicle with ES start) DN03-71
B3 Abnormality of neutral switch (only vehicle with ES start) DN03-73
B5 Sticking at "ON" position of release timing switch (only vehicle with ES start) DN03-74
B6 Abnormality of ES start main switch (only vehicle with ES start) DN03-75
B7 Imperfect initial setting (only vehicle with ES start) DN03-76
B8 Abnormality of tachometer signal (only vehicle with ES start) DN03-76
NOTICE
Diagnosis code "A" means "10", "B" means "11".
DISCONNECTION OF SOLENOID RELAY (DIAGNOSIS CODE 11)

EN16Z0803F200006
1. FUSE CHECK
(1) Set the starter switch to "LOCK", check the ABS solenoid 30A
RIGHT-HAND DRIVE fuse.
Standard: No abnormality
LEFT-HAND DRIVE
SHTS16Z080300026
.
NO
Replace the ABS solenoid fuse.
YES
2. RELAY CHECK
(1) Disconnect the 31 pin connector of the ECU.
(2) Measure the resistance between 1st and 24th terminals of the 31
pin connector (chassis harness side).
Standard: 160-340 Ω
SHTS16Z080300027
.
NO
Go to the item "6".
YES
(3) Remove the ABS solenoid relay, measure the resistance between
3rd and 5th terminals of the relay.
1
Standard: More than 500 Ω
3 5
SHTS16Z080300028
.
NO
Abnormality of the ABS solenoid relay.
YES
3. WIRE HARNESS CHECK

(1) Disconnect the 24 pin connector of ABS actuator.
1
(2) Measure the resistance between 16th terminal of the 24 pin con-
2 3 nector of ABS actuator (chassis harness side) and 2nd terminals
of the ABS solenoid relay (socket side).
Standard: Less than 5 Ω
4
SHTS16Z080300029
.
NO
Abnormality of the wire harness.
YES
4. RELAY CHECK
(1) Remove the ABS solenoid relay, check the continuity between 3rd
1 and 5th terminals of relay when a battery voltage was applied
between 1st and 2nd terminals of relay.
Standard:
3 5 Turning on electricity between 1st and 2nd terminals:
It is conducted between 3rd and 5th terminals.
Not turning on electricity:
2 It is not conducted between 3rd and 5th terminals.
SHTS16Z080300030
.
NO
YES
5. ECU CHECK
ECU VIEW (1) Connect all the connector and relay, turn the starter switch to
"ON".
(2) Measure the voltage between 1st and 2nd terminals of the 31 pin
connector of ECU. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300031
.
NO
Abnormality of the ECU power supply circuit.
YES
(3) Measure the voltage between 24th and 2nd terminals of the 31
ECU VIEW pin connector. (Leaving the connector connected with ECU.)
Standard: Less than 2V
SHTS16Z080300032
.
NO
YES
(4) Measure the voltage between 6th terminal of the 22 pin connector
ECU VIEW and 2nd terminal of the 31 pin connector. (Leaving the connector
connected with ECU.)
Standard: 20-28V
SHTS16Z080300033
.
NO
YES
Normal.

(1) Turn the starter switch to "LOCK", disconnect the 31 pin connec-
1
tor of ECU.
2 3
(2) Measure the resistance between 1st terminal of the 31 pin con-
nector of ECU (chassis harness side) and 4th terminal of the ABS
solenoid relay (socket side).
4 Standard: Less than 5 Ω
SHTS16Z080300034
.
NO
YES
(3) Measure the voltage between 24th terminal of the 31 pin connec-
tor of ECU (chassis harness side) and 1st terminal of the ABS
1 solenoid relay (socket side).
3
2
SHTS16Z080300035
.
NO
YES
7. RELAY CHECK
1 1st and 2nd terminals.
3 5
SHTS16Z080300036
.
NO
YES
Normal.
.
SHORT CIRCUIT OF SOLENOID RELAY (DIAGNOSIS CODE 12)

EN16Z0803F200007
1. RELAY CHECK
(1) Set the starter switch to "LOCK", remove the ABS solenoid relay
1
from the relay block.
(2) Measure the resistance between 3rd and 5th terminals.
3 5
SHTS16Z080300037
.
NO
YES
(3) Measure the resistance between 1st and 2nd terminals of the
ABS solenoid relay.
1
3 5
SHTS16Z080300038
.
NO
YES
(4) Check the continuity between 3rd and 5th terminals ABS solenoid
relay when a battery voltage was applied between 1st and 2nd
1 terminals.
Standard:
Turning on electricity between 1st and 2nd terminals:
3 5 It is conducted between 3rd and 5th terminals.
It is not conducted between 3rd and 5th terminals.
2
SHTS16Z080300039
.
NO
YES
2. ECU CHECK
ECU VIEW (1) Install the ABS solenoid relay, turn the starter switch to "ON".
Standard: 20-28V
SHTS16Z080300040
.
NO
YES
SHTS16Z080300041
.
NO
YES
Normal.
.
DISCONNECTION OF MOTOR RELAY (DIAGNOSIS CODE 13)

EN16Z0803F200008
1. FUSE CHECK
(1) Set the starter switch to "LOCK", check the ABS 50A fusible link.
.
NO
Replace the fusible link.
YES
2. RELAY CHECK
(1) Disconnect the 31 pin connector of ECU.
(2) Measure the resistance between 1st and 12th terminals of the 31
pin connector.
SHTS16Z080300042
.
NO
Go to the item "6".
YES
(3) Remove the ABS motor relay, measure the resistance between
3rd and 5th terminals.
1
Standard: more than 500 Ω
3 5
SHTS16Z080300043
.
NO
Abnormality of the ABS motor relay.
YES

(1) Disconnect the 24 pin connector of ABS actuator.
3
(2) Measure the resistance between 2nd terminal of the 24 pin con-
1 4 nector of ABS actuator (chassis harness side) and 1st terminal of
the ABS motor relay (socket side).
2
SHTS16Z080300044
NO
YES
4. RELAY CHECK
(1) Check the continuity between 3rd and 5th terminals of ABS motor
1 relay when a battery voltage was applied between 1st and 2nd
terminals.
Standard:
3 5 Turning on electricity between 1st and 2nd terminals:
It is conducted between 3rd and 5th terminals.
2 It is not conducted between 3rd and 5th terminals.
SHTS16Z080300045
.
NO
YES
5. ECU CHECK
ECU VIEW (1) Connect the connector and relay, turn the starter switch to "ON".
Standard: 20-28V
SHTS16Z080300046
.
NO
YES
SHTS16Z080300047
.
NO
YES
Standard: 20-28V
SHTS16Z080300048
.
NO
YES
Normal.

3 nector of ECU (chassis harness side) and 2nd terminal of the
1 4
ABS motor relay (socket side).
SHTS16Z080300049
.
NO
YES
nector of ECU (chassis harness side) and 3rd terminal of the ABS
3
motor relay (socket side).
1 4 Standard: Less than 5 Ω
SHTS16Z080300050
.
NO
YES
7. RELAY CHECK
1
1st and 2nd terminals.
3 5
SHTS16Z080300051
.
NO
YES
Normal.
.
SHORT CIRCUIT OF MOTOR RELAY (DIAGNOSIS CODE 14)

EN16Z0803F200009
1. RELAY CHECK
(1) Set the starter switch to "LOCK", remove the ABS motor relay
1
from the relay block.
(2) Measure the resistance between 3rd and 5th terminals.
3 5
SHTS16Z080300052
.
NO
YES
ABS motor relay.
1
3 5
SHTS16Z080300053
.
NO
YES
(4) Check the continuity between 3rd and 5th terminals of the ABS
motor relay when a battery voltage was applied between 1st and
1 2nd terminals.
Standard:
Turning on electricity between 1st and 2nd terminals:
3 5 It is conducted between 3rd and 5th terminals.
It is not conducted between 3rd and 5th terminals.
2
SHTS16Z080300054
.
NO
YES
2. ECU CHECK
ECU VIEW (1) Install the ABS motor relay, turn the starter switch to "ON".
Standard: 20-28V
SHTS16Z080300055
.
NO
Abnormality of ECU power supply circuit.
YES
SHTS16Z080300056
.
NO
YES
Normal.
.
ABNORMALITY OF SOLENOID FOR FRONT RIGHT WHEEL

(DIAGNOSIS CODE 21)
EN16Z0803F200010
1. CHECK ITEM
(1) Firstly, perform the check of "DISCONNECTION OF SOLENOID
RELAY (DIAGNOSIS CODE 11)".
2. ACTUATOR CHECK
(1) Set the starter switch to "LOCK", disconnect the 24 pin connector
of ABS actuator.
(2) Measure the resistance between 16th and 19th terminals of the
24 pin connector (actuator side).
Standard: 26-40 Ω
SHTS16Z080300057
.
NO
Abnormality of the ABS actuator.
YES
Standard: 13-20 Ω
SHTS16Z080300058
.
NO
YES

nector of ECU (chassis harness side) and 19th terminal of the 24
pin connector of ABS actuator (chassis harness side).
SHTS16Z080300059
.
NO
YES
SHTS16Z080300060
.
NO
YES
4. ECU CHECK
ECU VIEW (1) Connect all the connector, turn the starter switch to "ON".
tor and 2nd terminal of the 31 pin connector of ECU. (Leaving the
connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300061
.
NO
Abnormality of the ECU power supply voltage.
YES
Standard: 20-28V
SHTS16Z080300062
.
NO
YES
Normal.
.
ABNORMALITY OF SOLENOID FOR FRONT LEFT WHEEL

(DIAGNOSIS CODE 22)
EN16Z0803F200011
1. CHECK ITEM
2. ACTUATOR CHECK
of ABS actuator.
Standard: 26-40 Ω
SHTS16Z080300063
.
NO
YES
Standard: 13-20 Ω
SHTS16Z080300064
.
NO
YES

SHTS16Z080300065
.
NO
YES
SHTS16Z080300066
.
NO
YES
4. ECU CHECK
(2) Measure the voltage between 8th and 2nd terminals of the 31 pin
Standard: 20-28V
SHTS16Z080300067
.
NO
YES
(3) Measure the voltage between 9th and 2nd terminals of the 31 pin
ECU VIEW connector. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300068
.
NO
YES
Normal.
.
ABNORMALITY OF SOLENOID FOR REAR RIGHT WHEEL

(DIAGNOSIS CODE 23)
EN16Z0803F200012
1. CHECK ITEM
2. ACTUATOR CHECK
of ABS actuator.
(2) Measure the resistance between 6th and 16th terminals of the 24
pin connector (actuator side).
Standard: 26-40 Ω
SHTS16Z080300069
.
NO
YES
Standard: 13-20 Ω
SHTS16Z080300070
.
NO
YES

SHTS16Z080300071
.
NO
YES
SHTS16Z080300072
.
NO
YES
4. ECU CHECK
pin connector of ECU. (Leaving the connector connected with
ECU.)
Standard: 20-28V
SHTS16Z080300073
.
NO
YES
Standard: 20-28V
SHTS16Z080300074
.
NO
YES
Normal.
.
ABNORMALITY OF SOLENOID FOR REAR LEFT WHEEL

(DIAGNOSIS CODE 24)
EN16Z0803F200013
1. CHECK ITEM
2. ACTUATOR CHECK
of ABS actuator.
Standard: 26-40 Ω
SHTS16Z080300075
.
NO
YES
Standard: 13-20 Ω
SHTS16Z080300076
.
NO
YES

SHTS16Z080300077
.
NO
YES
SHTS16Z080300078
.
NO
YES
4. ECU CHECK
of ECU and 2nd terminal of the 31 pin connector of ECU. (Leaving
the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300079
.
NO
YES
(3) Measure the voltage between 1st terminal of the 22 pin connector
Standard: 20-28V
SHTS16Z080300080
.
NO
YES
Normal.
.
ABNORMALITY OF ES SOLENOID (DIAGNOSIS CODE 25)

EN16Z0803F200014
1. CHECK ITEM
2. ACTUATOR CHECK
of ABS actuator.
Standard: 26-40 Ω
SHTS16Z080300081
.
NO
YES
(3) Measure the resistance between13th and 20th terminals of the 24

Standard: 26-40 Ω
SHTS16Z080300082
.
NO
YES

(2) Measure the resistance between 3rd terminal of the 22 pin con-
SHTS16Z080300083
.
NO
YES
(3) Measure the resistance between 2nd terminal of the 22 pin con-
SHTS16Z080300084
.
NO
YES
SHTS16Z080300085
.
NO
YES
SHTS16Z080300086
.
NO
YES
4. ECU CHECK
(2) Measure the voltage between 3rd terminal of the 31 pin connector
Standard: 20-28V
SHTS16Z080300087
.
NO
YES
Standard: 20-28V
SHTS16Z080300088
.
NO
YES
Normal.
.
ABNORMALITY OF FRONT RIGHT WHEEL SENSOR

(DIAGNOSIS CODE 31)
EN16Z0803F200015
1. SENSOR CHECK
(1) Perform the following checks:
• No damage at the sensor tip.
• No adhesion of foreign material of more than 1 mm3.
• No clearance between sensor and the face to be installed.
• No air gap expansion between sensor and sensor rotor.
.
NO
Repair or replace the sensor installing part.
YES
of ECU.
31 pin connector (chassis harness side).
Standard: 0.8-2.0 kΩ
SHTS16Z080300089
.
NO
Go to the item "3".
YES
2. ECU CHECK
(1) Connect the connector, check the continuity between 2nd and
ECU VIEW 25th terminals of the 31 pin connector of ECU. (Leaving the con-
nector connected with ECU.)
Standard: Continuity
SHTS16Z080300090
.
NO
Abnormality of the ECU.
YES
(2) Connect oscilloscope between 2nd and 26th terminals of the 31

ECU VIEW pin connector, measure any waveform to be output when running
at speed of 30 km/h {19 mile/h}. (Leaving the connector con-
nected with ECU.)
OSCILLOSCOPE Standard: Waveform output
SHTS16Z080300091
.
NO
YES
Normal.

(1) Disconnect the connector of front right wheel sensor.
nector of ECU (chassis harness side) and 1st terminal of the sen-
sor connector (chassis harness side).
SHTS16Z080300092
.
NO
YES
nector of ECU (chassis harness side) and 2nd terminal of the
sensor connector (chassis harness side).
SHTS16Z080300093
.
NO
YES
4. SENSOR CHECK
connector of front right wheel sensor (sensor side).
SHTS16Z080300094
.
NO
Abnormality of the sensor.
YES
Normal.
.
ABNORMALITY OF FRONT LEFT WHEEL SENSOR

(DIAGNOSIS CODE 32)
EN16Z0803F200016
1. SENSOR CHECK
• No adhesion of foreign material of more than 1 m m3.
.
NO
YES
of ECU.
SHTS16Z080300095
.
NO
Go to the item "3".
YES
2. ECU CHECK
(1) Connect the connector, check the continuity between 2nd and
ECU VIEW 28th terminals of the 31 pin connector of ECU. (Leaving the con-
nector connected with ECU.)
SHTS16Z080300096
.
NO
YES
(2) Connect oscilloscope between 2nd and 27th terminals of the 31

ECU VIEW pin connector, measure any waveform to be output when running
at speed of 30 km/h {19 mile/h}. (Leaving the connector con-
nected with ECU.)
OSCILLOSCOPE Standard: Waveform output
SHTS16Z080300097
.
NO
YES
Normal.

(1) Disconnect the connector of front left wheel sensor.
SHTS16Z080300098
.
NO
YES
SHTS16Z080300099
.
NO
YES
4. SENSOR CHECK
connector of front left wheel sensor (sensor side).
SHTS16Z080300100
.
NO
YES
Normal.
.
ABNORMALITY OF REAR RIGHT WHEEL SENSOR

(DIAGNOSIS CODE 33)
EN16Z0803F200017
1. SENSOR CHECK
.
NO
YES
of ECU.
SHTS16Z080300101
.
NO
Go to the item "3".
YES
2. ECU CHECK
ECU VIEW (1) Connect the connector, check the continuity between 15th termi-
nal of the 24 pin connector of ECU and 2nd terminal of the 31 pin
SHTS16Z080300102
.
NO
YES
(2) Connect oscilloscope between 16th terminal of the 24 pin connec-

ECU VIEW tor and 2nd terminal of the 31 pin connector, measure any wave-
form to be output when running at speed of 30 km/h {19 mile/h}.
(Leaving the connector connected with ECU.)
Standard: Waveform output
OSCILLOSCOPE
SHTS16Z080300103
NO
YES
Normal.

(1) Disconnect the connector of rear right wheel sensor.
SHTS16Z080300104
.
NO
YES
SHTS16Z080300105
.
NO
YES
4. SENSOR CHECK
connector of rear right wheel sensor.
SHTS16Z080300106
.
NO
YES
Normal.
.
ABNORMALITY OF REAR LEFT WHEEL SENSOR

(DIAGNOSIS CODE 34)
EN16Z0803F200018
1. SENSOR CHECK
.
NO
YES
of ECU.
SHTS16Z080300107
.
NO
Go to the item "3".
YES
2. ECU CHECK
ECU VIEW (1) Connect the connector, check the continuity between 23th termi-
nal of the 24 pin connector of ECU and 2nd terminal of the 31 pin
SHTS16Z080300108
.
NO
YES
(2) Connect oscilloscope between 22th terminal of the 24 pin connec-

ECU VIEW tor and 2nd terminal of the 31 pin connector, measure any wave-
form to be output when running at speed of 30 km/h {19 mile/h}.
Standard: Waveform output
OSCILLOSCOPE
SHTS16Z080300109
.
NO
YES
Normal.

(1) Disconnect the 31 pin connector of ECU and the connector of rear
left wheel sensor.
SHTS16Z080300110
.
NO
YES
SHTS16Z080300111
.
NO
YES
4. SENSOR CHECK
connector of rear left wheel sensor (sensor side).
SHTS16Z080300112
.
NO
YES
Normal.
.
ABNORMALITY OF FRONT RIGHT WHEEL SENSOR:

EXCESSIVE AIR GAP, OR ADHESION OF IRON PIECE
(DIAGNOSIS CODE 35)
EN16Z0803F200019
1. CHECK ITEM
(1) Perform the check of "ABNORMALITY OF FRONT RIGHT
WHEEL SENSOR (DIAGNOSIS CODE 31)".
.
ABNORMALITY OF FRONT LEFT WHEEL SENSOR:

(DIAGNOSIS CODE 36)
EN16Z0803F200020
1. CHECK ITEM
(1) Perform the check of "ABNORMALITY OF FRONT LEFT WHEEL
SENSOR (DIAGNOSIS CODE 32)".
.
ABNORMALITY OF REAR RIGHT WHEEL SENSOR:

(DIAGNOSIS CODE 38)
EN16Z0803F200021
1. CHECK ITEM
(1) Perform the check of "ABNORMALITY OF REAR RIGHT WHEEL
.
ABNORMALITY OF REAR LEFT WHEEL SENSOR:

(DIAGNOSIS CODE 39)
EN16Z0803F200022
1. CHECK ITEM
(1) Perform the check of "ABNORMALITY OF REAR LEFT WHEEL
.
LOW VOLTAGE OR OVERVOLTAGE OF POWER SUPPLY

(DIAGNOSIS CODE 41)
EN16Z0803F200023
1. POWER SUPPLY VOLTAGE CHECK

ECU VIEW (1) Set the starter switch to "ON", measure the voltage between 7th
terminal of the 24 pin connector of ECU and 2nd terminal of the
31 pin connector of ECU. (Leaving the connector connected with
ECU.)
Standard: 20-32V
SHTS16Z080300113
.
NO
Abnormality of the power supply circuit.
YES
ABNORMALITY OF POWER SUPPLY VOLTAGE (DIAGNOSIS CODE 42)

EN16Z0803F200024
1. POWER SUPPLY VOLTAGE CHECK

terminal of the 24 pin connector of ECU and 2nd terminal of the
31 pin connector of ECU. (Leaving the connector connected with
ECU.)
Standard: 20-32V
SHTS16Z080300114
.
NO
Abnormality of the power supply circuit.
YES
.
ABNORMALITY OF ABS ACTUATOR:

BRAKE FLUID PRESSURE SENSOR (DIAGNOSIS CODE 46)
EN16Z0803F200025
1. SENSOR CHECK
and 15th terminal of the 28 pin connector of ECU. (Leaving the
connector connected with ECU.)
Standard: 4.5-5.5V
SHTS16Z080300115
.
NO
Go to the item "5".
YES
(2) Measure the voltage between 24th and 14th terminal of the 28 pin
ECU VIEW connector. (Leaving the connector connected with ECU.)
Standard: 4.5-5.5V
SHTS16Z080300116
.
NO
Go to the item "5".
YES

tor of ECU and the 3 pin connector of ABS actuator.
nector of ECU (chassis harness side) and 2nd terminal of the 3
SHTS16Z080300117
.
NO
YES
3. ABS ACTUATOR CHECK

(2) Measure the voltage between 25th and 15th terminals of the 28
pin connector of ECU when depressing the brake pedal. (Leaving
Standard:
0 MPa {0 kgf/cm2, 0 lbf/in.2}: Approx. 0.5V
9.8 MPa {100 kgf/cm2, 1,442 lbf/in.2}: Approx. 2.5V
19.6 MPa {200 kgf/cm2, 2,845 lbf/in.2}: Approx. 4.5V
SHTS16Z080300118
.
NO
YES
4. ECU CHECK
ECU VIEW (1) Measure the voltage between 24th terminal of the 28 pin connec-
tor of ECU and 2nd terminal of the 31 pin connector of ECU.
Standard: 4.85-5.15V
SHTS16Z080300119
.
NO
YES
ECU VIEW tor and 2nd terminal of the 31 pin connector. (Leaving the connec-
tor connected with ECU.)
Standard: 0.3-0.7V
SHTS16Z080300120
.
NO
YES
(3) Turn the starter switch to "LOCK", check the continuity between
ECU VIEW 15th terminal of the 28 pin connector and 2nd terminal of the 31
pin connector. (Leaving the connector connected with ECU.)
SHTS16Z080300121
.
NO
YES
(4) Check the continuity between 14th terminal of the 28 pin connec-
ECU VIEW tor and 2nd terminal of the 31 pin connector. (Leaving the connec-
tor connected with ECU.)
SHTS16Z080300122
.
NO
YES
Normal.

tor of ECU and the 3 pin connector of ABS actuator.
nector of ECU (chassis harness side) and 1st terminal of the 3 pin
connector of ABS actuator (chassis harness side).
SHTS16Z080300123
.
NO
YES
nector of ECU (chassis harness side) and 3rd terminal of the 3 pin
connector of ABS actuator (chassis harness side).
SHTS16Z080300124
.
NO
YES
Normal.
.
ABNORMALITY OF STOP LIGHT SWITCH (DIAGNOSIS CODE 49)

EN16Z0803F200026

of ECU and the connector of stop light switch.
(2) Check the continuity between 1st terminal of the 24 pin connector
of ECU (chassis harness side) and 1st terminal of the switch con-
nector (chassis harness side).
SHTS16Z080300125
.
NO
Disconnection of the wire harness.
YES
(3) Connect all the connector, turn the starter switch to "ON".
ECU VIEW (4) Measure the voltage between 1st terminal of the 24 pin connector
Standard: 20-28V
SHTS16Z080300126
.
NO
Ground short of the wire harness.
YES
2. STOP LIGHT SWITCH CHECK

(1) Turn the starter switch to "LOCK", disconnect the connector of
CONNECTOR stop light switch.
(SWITCH SIDE) (2) Measure the resistance between 1st and 3rd terminal of the stop
light switch.
Standard:
Pushing in the shaft: Continuity
Not pushing in the shaft: No continuity
SHTS16Z080300127
.
NO
Abnormality of the stop light switch.
YES
Perform the engine ECU check because it is conceivable that

abnormality of the signal transmitted from the stop light to
engine ECU.
ABNORMALITY OF MOTOR: NO ROTATION (DIAGNOSIS CODE 51)

EN16Z0803F200027

of ABS actuator.
(2) Connecting (+) terminal of battery with 2nd terminal of the 24 pin
connector (actuator side), (-) terminal of battery with 1st terminal,
and check if motor operates or not.
NOTICE
• Be careful not to short.
• Be careful not to make a mistake to (+) against (-).
Standard: Motor operates
SHTS16Z080300128
.
NO
Abnormality of the motor.
YES
(3) Connecting ammeter, measure the current while motor operating

under no load.
Standard: Less than 4A
SHTS16Z080300129
.
NO
Abnormality of the motor.
YES
.
ABNORMALITY OF EXHAUST BRAKE CUT RELAY

(DIAGNOSIS CODE 66)
EN16Z0803F200028

of ECU and exhaust brake cut relay of the relay block.
1
3 2
4
5
tor of ECU (chassis harness side) and 5th terminal of the relay
connector (chassis harness side).
SHTS16Z080300130
.
NO
YES

3 tor of ECU (chassis harness side) and 3rd terminal of the relay
1
2 4
connector (socket side).
5 Standard: Continuity
SHTS16Z080300131
.
NO
Ground short of the wire harness.
YES
2. EXHAUST BRAKE CUT RELAY CHECK

(1) When 24V is applied and is not applied between 2nd and 1st ter-
2
minals of exhaust brake cut relay, check the continuity between its
3 4th and 3rd terminals.
4
NOTICE
Connect (+) side with 1st terminal of relay.
2nd and 1st terminals 4th and 3rd terminals

24V is conducted No continuity
1 Not conducted Continuity
SHTS16Z080300132
.
NO
Abnormality of the exhaust brake cut relay.
YES
Normal.
ABNORMALITY OF AIR PRESSURE SIGNAL (DIAGNOSIS CODE A1)

EN16Z0803F200029
1. CHECK ITEM
(1) Check if any abnormality on meter display (Indicator of air pres-
sure) is seen or not. When any abnormality found, check low
pressure warning switch and air gauge sensor.
.
DISCONNECTION / SHORT CIRCUIT OF VEHICLE SPEED SENSOR

(DIAGNOSIS CODE B1)
EN16Z0803F200030

of ECU and the 18 pin connector (white) of combination meter.
(2) Check the continuity between 8th terminal of the 28 pin connector
of ECU (chassis harness side) and 17th terminal of the 18 pin
connector of combination meter (chassis harness side).
SHTS16Z080300133
.
NO
YES
Abnormality of the combination meter or vehicle speed sensor.
.
ABNORMALITY OF CLUTCH STROKE SENSOR

(DIAGNOSIS CODE B2) (ONLY VEHICLE WITH ES START)
EN16Z0803F200031

of ECU and the connector of clutch stroke sensor.
of ECU (chassis harness side) and 1st terminal of the sensor con-
SHTS16Z080300134
.
NO
YES
tor of ECU (chassis harness side) and 2nd terminal of the sensor
SHTS16Z080300135
.
NO
YES
tor of ECU (chassis harness side) and 3rd terminal of the sensor
SHTS16Z080300136
.
NO
YES
2. CLUTCH STROKE SENSOR CHECK

(2) Measure the voltage between 1st and 3rd terminals of the clutch
stroke sensor.
Standard: 4-6V
SHTS16Z080300137
.
NO
Abnormality of the clutch stroke sensor.
YES
Perform the initial setting of released position for ES start.

NOTICE
When this code is output in spite of performing the initial
setting, abnormality of clutch stroke sensor is considered
as its cause.
.
ABNORMALITY OF NEUTRAL SWITCH (DIAGNOSIS CODE B3)

(ONLY VEHICLE WITH ES START)
EN16Z0803F200032

of ECU and the connector of neutral switch.
tor of ECU (chassis harness side) and 2nd terminal of the switch
SHTS16Z080300138
.
NO
YES
(3) Connect the 22 pin connector of ECU, leaving the connector of

neutral switch disconnected, turn the starter switch to "ON".
(4) Measure the voltage between 2nd terminal of the switch connec-
tor (chassis harness side) and chassis ground.
Standard: More than 20V
SHTS16Z080300139
.
NO
Replace the wire harness, or abnormality of
the power supply "M".
YES
2. NEUTRAL SWITCH CHECK

(1) Check the continuity between 1st and 2nd terminals of the con-
nector of neutral switch (switch side).
Standard:
Putting in gear: No continuity
Putting in neutral: continuity
NOTICE
Within allowable range for excessive play of shifting lever, check
that it can not be shifted.
SHTS16Z080300140
.
NO
Abnormality of the neutral switch.
YES

STICKING AT "ON" POSITION OF RELEASE TIMING SWITCH

(DIAGNOSIS CODE B5) (ONLY VEHICLE WITH ES START)
EN16Z0803F200033

of ECU.
(2) Check the continuity between 5th and 6th terminals of the 28 pin
Standard: No continuity
SHTS16Z080300141
.
NO
Short circuit of the wire harness.
YES
2. RELEASE TIMING SWITCH CHECK

(1) Remove the release timing switch, check the continuity between
each terminal of switch when putting the switch on "SLOW" or
2 1 "FAST" sides.
5 Standard:
Between 5th and 2nd terminals: Continuity

"SLOW" side
Between 5th and 1st terminals: No continuity
Between 5th and 2nd terminals: No continuity
"FAST" side
Between 5th and 1st terminals: Continuity
SHTS16Z080300142
.
NO
Abnormality of the release timing switch.
YES
.
ABNORMALITY OF ES START MAIN SWITCH (DIAGNOSIS CODE B6)

EN16Z0803F200034

of ECU and the connector of ES start main switch.
of ECU (chassis harness side) and 7th terminal of the switch con-
SHTS16Z080300143
.
NO
Disconnection the wire harness.
YES
(3) Check the continuity between 3rd terminal of the 28 pin connector
of ECU (chassis harness side) and 6th terminal of the switch con-
SHTS16Z080300144
.
NO
YES
2. ES START MAIN SWITCH CHECK

(1) Check the continuity between each terminal of ES start main
switch when putting the main switch "ON" or "OFF".
7 6 5 Standard:
Main switch Between 5th and 7th terminals: Continuity

"ON" Between 5th and 6th terminals: No continuity
Main switch Between 5th and 7th terminals: No continuity
"OFF" Between 5th and 6th terminals: Continuity
SHTS16Z080300145
.
NO
Abnormality of the ES start main switch.
YES

IMPERFECT INITIAL SETTING (DIAGNOSIS CODE B7)

EN16Z0803F200035
1. CHECK ITEM
(1) Perform the initial setting of ES start.
Refer to "INITIAL SETTING OF ES START" in the section
"ADJUSTMENT" in the chapter "ES START (EASY & SMOOTH
START SYSTEM) (DENSO)".
.
ABNORMALITY OF TACHOMETER SIGNAL (DIAGNOSIS CODE B8)

EN16Z0803F200036

of ABS+ES start ECU and the 12 pin connector of engine ECU.
of ABS+ES start ECU (chassis harness side) and 5th terminal of
the connector of engine ECU (chassis harness side).
SHTS16Z080300146
.
NO
YES
2. ENGINE ECU CHECK

ECU VIEW (2) By using a oscilloscope, measure the voltage between 7th termi-
nal of the 28 pin connector of ABS+ES start ECU and chassis
ground.
NOTICE
Check the waveform by stepping on the accelerator at "neutral
position" of gear while engine is running.
Standard: Under the pulse waveform of less than 25V to more
than 6V, pulse interval will be shortened in proportion to
engine revolution.
SHTS16Z080300147
.
NO
Abnormality of the engine ECU.
YES
Abnormality of the ABS+ES start ECU.
.
2A&0AA9#$%1A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧟㧝ಽ
BRAKE CONTROL (ABS: WABCO) DN03–1
BRAKE CONTROL (ABS: WABCO)

DN03
DN03-002
ANTI-LOCK BRAKE .................................DN03-2 SHORT-CIRCUIT AND

SYSTEM DIAGRAM ........................................ DN03-2 WIRING DISCONNECTION OF
HANDLING PRECAUTIONS ........................... DN03-3 WHEEL SENSOR, RH ON REAR AXLE
INSPECTION (ABS SYSTEM OPERATION (DIAGNOSIS CODE 4-3) ............................... DN03-37
AND FAILURE DIAGNOSTICS) ...................... DN03-4 SHORT-CIRCUIT AND
TABLE OF TROUBLE CODE .......................... DN03-9 WIRING DISCONNECTION OF
ARRANGEMENT OF WHEEL SENSOR, LH ON REAR AXLE
CONNECTOR PIN......................................... DN03-10 (DIAGNOSIS CODE 4-4) ............................... DN03-40
ABNORMALITY OF ABNORMAL SIGNAL OF
ABS CONTROL VALVE AND HARNESS WIRE, THE WHEEL SENSOR, RH ON FRONT AXLE
RH ON FRONT AXLE (DIAGNOSIS CODE 5-1) ............................... DN03-42
(DIAGNOSIS CODE 2-1) ............................... DN03-11 ABNORMAL SIGNAL OF
ABNORMALITY OF THE WHEEL SENSOR, LH ON FRONT AXLE
ABS CONTROL VALVE AND HARNESS WIRE, (DIAGNOSIS CODE 5-2) ............................... DN03-43
LH ON FRONT AXLE ABNORMAL SIGNAL OF
(DIAGNOSIS CODE 2-2) ............................... DN03-14 THE WHEEL SENSOR, RH ON REAR AXLE
ABNORMALITY OF (DIAGNOSIS CODE 5-3) ............................... DN03-43
ABS CONTROL VALVE AND HARNESS WIRE, ABNORMAL SIGNAL OF
RH ON REAR AXLE THE WHEEL SENSOR, LH ON REAR AXLE
(DIAGNOSIS CODE 2-3) ............................... DN03-17 (DIAGNOSIS CODE 5-4) ............................... DN03-44
ABNORMALITY OF ABNORMALITY IN SENSOR RING,
ABS CONTROL VALVE AND HARNESS WIRE, RH ON FRONT AXLE
LH ON REAR AXLE (DIAGNOSIS CODE 6-1) ............................... DN03-44
(DIAGNOSIS CODE 2-4) ............................... DN03-20 ABNORMALITY IN SENSOR RING,
EXCESSIVE AIR GAP AND SIGNAL LH ON FRONT AXLE
DISCONTINUATION OF WHEEL SENSOR, (DIAGNOSIS CODE 6-2) ............................... DN03-44
RH ON FRONT AXLE ABNORMALITY IN SENSOR RING,
(DIAGNOSIS CODE 3-1) ............................... DN03-23 RH ON REAR AXLE
EXCESSIVE AIR GAP AND (DIAGNOSIS CODE 6-3) ............................... DN03-44
SIGNAL DISCONTINUATION OF ABNORMALITY IN SENSOR RING,
WHEEL SENSOR, LH ON FRONT AXLE LH ON REAR AXLE
EXCESSIVE AIR GAP AND SIGNAL ABNORMALITY ON THE SUB BRAKE CUT RELAY
DISCONTINUATION OF (DIAGNOSIS CODE 7-3) ............................... DN03-45
WHEEL SENSOR, RH ON REAR AXLE ABNORMALITY ON ABS WARNING LIGHT
(DIGNOSIS CODE 3-3) ................................. DN03-27 (DIAGNOSIS CODE 7-4) ............................... DN03-46
EXCESSIVE AIR GAP AND ABNORMALITY OF POWER SUPPLY
SIGNAL CONTINUATION OF (LOW VOLTAGE)
WHEEL SENSOR, LH ON REAR AXLE (DIAGNOSIS CODE 8-1) ............................... DN03-46
(DIAGNOSIS CODE 3-4) ............................... DN03-29 ABNORMALITY OF POWER SUPPLY
SHORT-CIRCUIT AND (OVER VOLTAGE)
WIRING DISCONNECTION OF (DIAGNOSIS CODE 8-2) ............................... DN03-46
WHEEL SENSOR, RH ON FRONT AXLE ABNORMALITY OF ABS ECU
SHORT-CIRCUIT AND ABNORMALITY OF GROUND HARNESS
WIRING DISCONNECTION OF (DIAGNOSIS CODE 8-5) ............................... DN03-47
WHEEL SENSOR, LH ON FRONT AXLE
(DIAGNOSIS CODE 4-2) ............................... DN03-34
DN03–2 BRAKE CONTROL (ABS: WABCO)
ANTI-LOCK BRAKE
SYSTEM DIAGRAM
EN16Z0803J100001
INPUT SIGNAL ABS ECU OUTPUT SIGNAL
Front left wheel sensor
Front right wheel sensor ABS control valve for

front left wheel
Rear left wheel sensor

ABS control function ABS control valve for
front right wheel
(ABS control valve control

Rear right wheel sensor function)
ABS control valve for
rear left wheel
ABS control valve for

rear right wheel
Sub brake cut relay
Sub brake control

function
Malfunction code
(diagnostic code)
Malfunction diagnostic
function
Switches off ABS to allow

normal brake operation
Fail-safe function
(safety function)
ABS warning light
SHTS16Z080300001
EN16Z0803F200001
1. ABOUT CONNECTORS
(1) Before performing the inspection operation, make sure that all
connectors are connected securely.
(2) Do not contact the tester bar to the connection surface of the con-
nector. This may cause terminal damage or a short-circuit.
(3) All connectors in the connector diagram are observed from the
contact surfaces. However, the tester bar is put from the rear side.
SHTS16Z080300002
Reference
SHTS16Z080300003
Reference:
zontally).

damage.
age data.
.
INSPECTION
(ABS SYSTEM OPERATION AND FAILURE DIAGNOSTICS)
EN16Z0803F200002
ABS SYSTEM REGULAR INSPECTION

Inspect the operation of the ABS system once per year in accordance with the procedure below.
OPERATION STATUS INSPECTION
1. PREPARATION BEFORE INSPECTION

(1) With the vehicle stopped, step on the brake pedal and check for air leakage from the ABS control valves. If air leaking
from the pipe connectors is found by applying soapy water, or the like, correct the problem by tightening the connec-
tors or take a similar corrective action. Also, if air is leaking from the ABS control valve body, replace the ABS control
valve.
(2) Release the brake pedal and inspect the exhaust status of the ABS control valves.
The above inspection should be carried out on all ABS control valves.
2. ABS OPERATION STATUS INSPECTION IN TEST DRIVE

NOTICE
When inspecting the ABS operation status in a test drive, exercise caution with regard to the following points.
• Use a large, safe area for the test.
• Conduct the test with nothing loaded on the vehicle.
• Apply white tape, or the like, to the sides of the front and rear wheels to enable you to determine the wheel's
rotational status.
• Even in case of tractor model, perform a test drive without hauling trailer
(1) Turn the starter switch "ON". Confirm that the ABS warning light lights and then goes off.
(2) Start driving the vehicle and, accelerate to a speed of vehicle to 20-30 km/h {12.4-18.6 mile/h}, then apply the brakes
hard. Confirm that none of the wheels are locked.
FAILURE DIAGNOSTICS BASED ILLUMINATION OF WARNING LIGHT
ABS WARNING LIGHT CAUSE OF MALFUNCTION FAIL-SAFE FUNCTION
Lighting POWER SUPPLY RELATED Entire ABS system becomes non-

(While running) • Fuse burned out functional. (Brakes of wheels return
to normal breaking operation.)
• Wire harness connector disconnected
• Bad contact with wire harness
• Wire broken in wire harness
• Low battery voltage
• Short circuit of ABS valve harness with +24V
power supply harness
WHEEL SENSOR RELATED ABS becomes non-functional on

• Sensor clearance too wide wheels in the system where sensor
malfunctioned, and those wheels
• Bad sensor unit
return to normal braking operation.
• Broken wire in wire harness
• Wire harness connector disconnected or bad
contact
ABS CONTROL VALVE RELATED ABS becomes non-functional on

• Wire broken or short circuit in solenoid coil wheel in the system where ABS con-
trol valve malfunctioned, and those
• Broken wire in wire harness of ABS control
wheel return to normal braking opera-
valve, wire harness connector disconnected,
tion.
bad contact
ECU Entire ABS system becomes non-

• Internal malfunction in ECU functional. (Brakes of wheels return
to normal breaking operation.)
NOTICE
The ABS warning light may remain lit if the ABS system experiences a temporary malfunction and then recovers.
Should this occur, reset it by turn "LOCK" the starter switch temporarily while the vehicle is stopped. Then start
driving the vehicle. If the light goes off when a speed of vehicle exceeds 7 km/h {4.3 mile/h}, ABS is working nor-
mally.
ABS SYSTEM FAILURE DIAGNOSTICS FLOWCHART

WHEN THE ENGINE IS STARTED UP
INSPECTION DETERMINATION REMEDIAL ACTION
Turn the starter switch "ON"
No
Does the ABS warning light go on and Yes

Normal
then go off?
No (Does not go off) No (Does not go on)

Check the wiring between
Is an electricity turned on to the bulb Yes
ABS warning light and
of ABS warning light?
ABS ECU.
No
Yes
Is the fuse burned out? Replace the fuse.
No Broken wire or short in wire Check the wiring of power

harness of power supply system supply system.
WHEN STARTING TO DRIVE
Start driving
(driving speed more than 7 km/h {4.3 mile/h}
Yes
Does the ABS warning light go off? Normal
No
Yes Check the power supply

Is the power supply voltage abnormal?
voltage.
No
Are the ABS ECU harness connectors Yes Check the harness
loose or disconnected? connectors.
No
Is there anything wrong with the solenoid Yes Replace ABS control
coil of the ABS control valve? valve.
No Incorrect clearance between the Inspect and adjust the

wheel sensors and the sensor clearance.
rings (abnormal sensor output)
SHTS16Z080300005
WHILE DRIVING AND BRAKING
Yes
Does the ABS warning light keeping go off. Normal
Inspect the power supply

Yes Temporary drop in power supply
Is lit the light from time to time? system and the CAN
voltage (function will recover)
communication system.
No
Does the light lit when the brakes Yes Broken wire or short in the ABS Inspect the ABS control
are applied? control valve system valve system.
No
Is there a broken wire or short in the wheel Yes Inspect the wheel sensor
sensor system? system.
No
Is there a broken wire or short in the power Yes Inspect power supply
supply system? system.
No
ABS ECU malfunction Replace the ABS ECU.
SHTS16Z080300006
TROUBLE DIAGNOSIS BY MALFUNCTION DIAGNOSING FUNCTION OF ABS ECU

ABS system memorizes all malfunction contents occurred so far in the ECU. Push the ABS diagnosis switch, by which is
changed to diagnosis mode, ABS warning light flashes on and off to advise the trouble contents.
DIAGNOSIS SWITCH OF ABS SYSTEM

Locate diagnosis switch of ABS system on lower left of driver's side console panel.
Set the starter switch to "ON" and push the ABS diagnosis switch for 0.5-3.0 seconds, which is led to the diagnosis mode,
the ABS warning light flashes on and off to inform the trouble codes.
(LEFT-HAND DRIVE) (RIGHT-HAND DRIVE)
P P
ABS DIAGNOSIS SWITCH ABS DIAGNOSIS SWITCH

SHTS16Z080300007
NOTICE
ABS diagnosis switch reverts automatically to "OFF" position.
MALFUNCTION DIAGNOSIS WHEN PRESENTLY HAVING TROUBLES

It indicates repeatedly "an current occurring trouble". When having more than two troubles, the latest trouble is displayed.
Confirm the trouble contents together with a "TABLE OF TROUBLE CODE", in the page DN03-9.
When set the starter switch to "OFF", or detecting the driving speed with the wheel sensor, trouble indication will be fin-
ished.
ON
CONNECTING FOR 0.5-3.0 SECONDS
ABS DIAGNOSIS SWITCH
ON 0.5 SECONDS
ABS WARNING LIGHT
1.5 SECONDS 1.5 SECONDS 4.0 SECONDS 1.5 SECONDS 4.0 SECONDS 1.5 SECONDS
1a 1b 1a 1b 1a 1b
ERROR CODE 1a-1b = 3-4 : Left wheel sensor of rear axle: air gap large.
SHTS16Z080300008
WHEN PRESENTLY NOT HAVING TROUBLE

The last eight troubles occurred will be indicated in the order from the last one.
Even when more than eight troubles are occurred, only latest eight troubles will be indicated without showing other prior
one before the latest four ones.
Once the trouble contents are finished to be indicated, it will finish automatically.
ON
ON 0.5 SECONDS
ABS WARNING LAMP

1.5 SECONDS 4.0 SECONDS 1.5 SECONDS
1a 1b 2a 2b
ERROR CODE
Lastly occurred error 1a-1b = 2-2 : Abnormality in modulator valve of left wheel on front axle.
Second error from the last 2a-2b = 7-3 : Abnormality in the cut relay of sub brake.
SHTS16Z080300009
ELIMINATION OF PAST TROUBLE HISTORY

Once push the ABS diagnosis switch, by which trouble memories will be eliminated.
And just after ABS warning light flashes on/off by 8 times, the ABS system cord will be displayed repeatedly at interval of 4
seconds and will light on/off consecutively.
When set the starter switch to "OFF" once and pushed the ABS warning light will go on and off when the driving speed
reaches to 7-10 km/h {4.3-6.2 mile/h}.
NOTICE
Past trouble history can not be eliminated when having trouble.
ON
ON 0.5 SECONDS 0.5 SECONDS
ABS WARNING LIGHT

1.5 SECONDS 4.0 SECONDS 4.0 SECONDS
It flashes on/off System cord
quickly by 8 times (flashing on/off by 2 times)
After ABS warning light flashes on/off quickly by 8 times, the system cord will be displayed repeatedly.
SHTS16Z080300010
TABLE OF TROUBLE CODE

EN16Z0803F200003
OUTPUT CORRESPONDING TERMINAL

CODE TROUBLE
TROUBLE CONTENTS NUMBER OF ABS ECU
PORTION
a b (CONNECTOR PIN No.)
1 1 Normal — —
1 Front axle right wheel abnormal 18 pin connector-5th, 6th
2 Front axle left wheel abnormal 18 pin connector-17th, 18th

2 ABS control valve
3 Rear axle right wheel abnormal 18 pin connector-10th, 16th
4 Rear axle left wheel abnormal 18 pin connector-11th, 12th
1 Front axle right wheel abnormal 18 pin connector-2nd, 3rd
2 ABS wheel sensor Front axle left wheel abnormal 18 pin connector-14th, 15th
3
3 air gap Rear axle right wheel abnormal 18 pin connector-7th, 13th
2 ABS wheel sensor Front axle left wheel abnormal 18 pin connector-14th, 15th
4 disconnection and
3 short-circuit Rear axle right wheel abnormal 18 pin connector-7th, 13th
2 Front axle left wheel abnormal 18 pin connector-14th, 15th

5 ABS wheel sensor
3 Rear axle right wheel abnormal 18 pin connector-7th, 13th
1 Front axle right wheel abnormal —
2 Front axle left wheel abnormal —

6 ABS sensor ring
3 Rear axle right wheel abnormal —
4 Rear axle left wheel abnormal —
1 CAN communication abnormal 15 pin connector-5th, 15th
7 3 System Sub brake cut relay abnormal 15 pin connector-6th
4 Warning light abnormal 15 pin connector-11th
1 Power supply abnormal (Low voltage) 15 pin connector-8th
2 Power supply abnormal (Over voltage) 15 pin connector-8th
8 3 ECU Internal abnormality —
4 Internal abnormality —
5 Earth abnormal 15 pin connector-4th, 13th

ARRANGEMENT OF CONNECTOR PIN

EN16Z0803F200004
NOTICE
Different terminal numbers from below listed figure are stamped on the connector unit. However, verify it in refer-
ence to this figure.
ABS ECU
18-PIN CONNECTORS
1 2 3 4 5 6
7 8 9 10 11 12
A
13 14 15 16 17 18 CAB SIDE HARNESS
VIEW A
15-PIN CONNECTORS
1 2 3 4 5
6 7 8 9 10 B
11 12 13 14 15 CAB SIDE HARNESS
VIEW B
ABS CONTROL VALVE
1 2
C
3 4 CAB SIDE HARNESS
VIEW C
ABS WHEEL SENSOR
2 1 D
CAB SIDE HARNESS
VIEW D
SHTS16Z080300011
ABNORMALITY OF ABS CONTROL VALVE AND HARNESS WIRE,

RH ON FRONT AXLE (DIAGNOSIS CODE 2-1)
EN16Z0803F200005
1. CHECK THE VOLTAGE BETWEEN TERMINALS.

ECU VIEW (1) Set the starter switch to "ON".
18 PIN CONNECTORS 15 PIN CONNECTORS (2) Measure the voltage 6th terminal of 18 pin connectors and 13th
one of 15 ones.
Standard: 1V or less
SHTS16Z080300012
.
NO
Abnormality of harness
YES
(3) Measure the voltage 5th terminal of 18 pin connectors and 13th
ECU VIEW one of 15 pin ones.
18 PIN CONNECTORS 15 PIN CONNECTORS Standard: 1V or less
SHTS16Z080300013
.
NO
YES
Temporary malfunction because of abnormality of harness

2. CHECK THE RESISTANCE BETWEEN TERMINALS.

18 PIN CONNECTORS 15 PIN CONNECTORS (1) Set the starter switch to "LOCK", disconnect the 15 and 18 pin
connectors of ABS ECU.
(2) Measure the resistance between 6th terminal of 18 pin connec-
tors and 13th terminal of 15 pin connectors.
Standard: 10-20 Ω
SHTS16Z080300014
.
NO
Go to the item 3.
YES

18 PIN CONNECTORS 15 PIN CONNECTORS tors and 13 one of 15 ones.
Standard: 10-20 Ω
SHTS16Z080300015
.
NO
Go to the item 3.
YES
Temporary malfunction because of abnormality of the harness
3. CHECK THE RESISTANCE OF THE ABS CONTROL VALVE.

(1) Disconnect the connector of ABS control valve.
1 (2) Measure the resistance between 1st-4th terminals and 3rd-4th
terminals (Control valve side).
4 3 Standard: 11.1-19.2 Ω
SHTS16Z080300016
.
NO
Abnormality of control valve
YES
4. CHECK THE CONTINUITY BETWEEN TERMINALS.

(2) Check the continuity between 6th terminal of 18 pin connectors
and 13th one of 15 ones.
SHTS16Z080300017
.
NO
YES

18 PIN CONNECTORS 15 PIN CONNECTORS and 13th one of 15 ones.
SHTS16Z080300018
.
NO
YES
.

LH ON FRONT AXLE (DIAGNOSIS CODE 2-2)
EN16Z0803F200006

one of 15 ones.
SHTS16Z080300019
.
NO
YES
SHTS16Z080300020
.
NO
YES


Standard: 10-20 Ω
SHTS16Z080300021
.
NO
Go to the item 3.
YES

Standard: 10-20 Ω
SHTS16Z080300022
.
NO
Go to the item 3.
YES


terminals (control valve side).
4 3 Standard: 11.1-19.2 Ω
SHTS16Z080300016
.
NO
YES

SHTS16Z080300023
.
NO
YES

SHTS16Z080300024
.
NO
YES


RH ON REAR AXLE (DIAGNOSIS CODE 2-3)
EN16Z0803F200007

one of 15 ones.
SHTS16Z080300025
.
NO
YES
SHTS16Z080300026
.
NO
YES


Standard: 10-20 Ω
SHTS16Z080300027
.
NO
Go to the item 3.
YES

Standard: 10-20 Ω
SHTS16Z080300028
.
NO
Go to the item 3.
YES


terminals (Control valve side).
4 3 Standard: 11.1-19.2 Ω
SHTS16Z080300016
.
NO
YES

SHTS16Z080300029
.
NO
YES

SHTS16Z080300030
.
NO
YES


LH ON REAR AXLE (DIAGNOSIS CODE 2-4)
EN16Z0803F200008

one of 15 ones.
SHTS16Z080300031
.
NO
YES
SHTS16Z080300032
.
NO
YES


Standard: 10-20 Ω
SHTS16Z080300033
.
NO
Go to the item 3.
YES

Standard: 10-20 Ω
SHTS16Z080300034
.
NO
Go to the item 3.
YES


terminals (control valve side).
4 3 Standard: 11.1-19.2 Ω
SHTS16Z080300016
.
NO
YES

SHTS16Z080300035
.
NO
YES

SHTS16Z080300036
.
NO
YES

EXCESSIVE AIR GAP AND SIGNAL DISCONTINUATION OF WHEEL

SENSOR, RH ON FRONT AXLE (DIAGNOSIS CODE 3-1)
EN16Z0803F200009
1. CHECK THE AIR GAP OF WHEEL SENSOR.

(1) Insert a wheel sensor till it touches to the sensor ring.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer
or attempt to pry it into place with a screwdriver, or the like. Doing
so could damage the wheel sensor.
SHTS16Z080300037
2. CHECK THE CLAMPING BUSHING.

SHOULD MAKE CONTACT (1) Make sure that wheel sensor is securely fixed.
NOTICE
SENSOR RING Change the clamping bushing when it can pulled off or pushed in
HUB with a weak force.
3. CHECK THE SENSOR RING.

(1) Refer to the chapter "ABS & ASR (WABCO, FOR AIR OVER
HYDRAURIC BRAKE)" or "ABS & ASR (WABCO, FOR FULL
AIR BRAKE)".
CLAMPING BUSHING
WHEEL SENSOR
SHTS16Z080300038

(1) Set the starter switch to "LOCK", disconnect the 18 pin connec-
tors of ABS ECU.
(2) Connecting the tester between 2nd and 3rd terminals of 18 pin
connectors, measure its voltage by rotating the tire by one time for
5 seconds.
Standard: 150-1,999 mV
SHTS16Z080300039
.
NO
Go to the item 5.
YES


(1) Measure the resistance between 2nd and 3rd terminals of 18 pin
connectors.
SHTS16Z080300040
.
NO
Go to the item 6.
YES

(1) Disconnect the connector of wheel sensor.
(2) Measure the resistance between terminals of wheel sensor.
SHTS16Z080300041
.
NO
Abnormality wheel sensor
YES
.

SENSOR, LH ON FRONT AXLE (DIAGNOSIS CODE 3-2)
EN16Z0803F200010

(1) Insert a wheel sensor till it touches to the sensor ring.
NOTICE
SHTS16Z080300037

SHOULD MAKE CONTACT (1) Make sure that wheel sensor is securely fixed.
NOTICE
HUB with a weak force.

AIR BRAKE)".
CLAMPING BUSHING
WHEEL SENSOR
SHTS16Z080300038

tors of ABS ECU.
(2) Connecting the tester between 15th and 14th terminals of 18 pin
5 seconds.
SHTS16Z080300042
.
NO
Go to the item 5.
YES


(1) Measure the resistance between 14th and 15th terminals of 18
pin connectors.
SHTS16Z080300043
.
NO
Go to the item 6.
YES

SHTS16Z080300041
.
NO
YES
.

SENSOR, RH ON REAR AXLE (DIGNOSIS CODE 3-3)
EN16Z0803F200011

CLAMPING BUSHING (1) Insert a wheel sensor till it touches to the sensor ring.
PUSH NOTICE

WHEEL SENSOR (1) Make sure that wheel sensor is securely fixed.
NOTICE
SHTS16Z080300044
with a weak force.

AIR BRAKE)".

tors of ABS ECU.
5 seconds.
SHTS16Z080300045
.
NO
Go to the item 5.
YES


(1) Measure the resistance between 7th and 13th terminals of 18 pin
connectors.
SHTS16Z080300046
.
NO
Go to the item 6.
YES

SHTS16Z080300041
.
NO
YES
.
EXCESSIVE AIR GAP AND SIGNAL CONTINUATION OF WHEEL

SENSOR, LH ON REAR AXLE (DIAGNOSIS CODE 3-4)
EN16Z0803F200012

CLAMPING BUSHING (1) Insert a wheel sensor till it touches to the sensor ring.
PUSH NOTICE

WHEEL SENSOR (1) Make sure that wheel sensor is securely fixed.
NOTICE
SHTS16Z080300044
with a weak force.

AIR BRAKE)".

tors of ABS ECU.
5 seconds.
SHTS16Z080300047
.
NO
Go to the item 5.
YES


connectors.
SHTS16Z080300048
.
NO
Go to the item 6.
YES

SHTS16Z080300041
.
NO
Abnormality of wheel sensor
YES
.
SHORT-CIRCUIT AND WIRING DISCONNECTION OF WHEEL

SENSOR, RH ON FRONT AXLE (DIAGNOSIS CODE 4-1)
EN16Z0803F200013

18 PIN CONNECTORS 15 PIN CONNECTORS (2) Measure the voltage 2nd terminal of 18 pin connectors and 13th
one of 15 ones.
SHTS16Z080300049
.
NO
YES

(2) Check the continuity between 2nd terminal of 18 pin connectors
SHTS16Z080300050
.
NO
YES


tors of ABS ECU.
(2) Connecting the tester between 2nd and 3rd terminals of 18 pin
5 seconds.
SHTS16Z080300051
.
NO
Go to the item 4.
YES

(1) Measure the resistance between 2nd and 3rd terminals of 18 pin
connectors.
SHTS16Z080300052
.
NO
Go to the item 5.
YES


SHTS16Z080300053
.
NO
YES
.

SENSOR, LH ON FRONT AXLE (DIAGNOSIS CODE 4-2)
EN16Z0803F200014

one of 15 ones.
SHTS16Z080300054
.
NO
YES

SHTS16Z080300055
.
NO
YES


tors of ABS ECU.
5 seconds.
SHTS16Z080300042
.
NO
Go to the item 4.
YES

(1) Measure the resistance between 14th and 15th terminals of 18
pin connectors.
SHTS16Z080300043
.
NO
Go to the item 5.
YES


SHTS16Z080300053
.
NO
YES
.

SENSOR, RH ON REAR AXLE (DIAGNOSIS CODE 4-3)
EN16Z0803F200015

one of 15 ones.
SHTS16Z080300056
.
NO
YES

connectors of ABS ECU
SHTS16Z080300057
.
NO
YES


tors of ABS ECU.
5 seconds.
SHTS16Z080300045
.
NO
Go to the item 4.
YES

connectors.
SHTS16Z080300046
.
NO
Go to the item 5.
YES


SHTS16Z080300053
.
NO
YES
.

SENSOR, LH ON REAR AXLE (DIAGNOSIS CODE 4-4)
EN16Z0803F200016

one of 15 ones.
SHTS16Z080300058
.
NO
YES

SHTS16Z080300059
.
NO
YES


tors of ABS ECU.
5 seconds.
SHTS16Z080300047
.
NO
Go to the item 4.
YES

connectors.
SHTS16Z080300048
.
NO
Go to the item 5.
YES


SHTS16Z080300053
.
NO
YES
ABNORMAL SIGNAL OF THE WHEEL SENSOR, RH ON FRONT AXLE

(DIAGNOSIS CODE 5-1)
EN16Z0803F200017
1. CHECK THE WHEEL SENSOR.

(1) Inspect the harness and the connectors of wheel sensor.
(2) Inspect the installed status and also damage, breakage of wheel
sensor.

AIR BRAKE)".

(1) Make sure that wheel sensor is securely fixed.
4. CHECK THE WHEEL HUB BEARING.

(1) Check the play of wheel hub bearing.
5. CHECK THE TIRE.

(1) Make sure that the tire size is correct.
.
ABNORMAL SIGNAL OF THE WHEEL SENSOR, LH ON FRONT AXLE

EN16Z0803F200018

sensor.

AIR BRAKE)".


5. CHECK THE TIRE.

.
ABNORMAL SIGNAL OF THE WHEEL SENSOR, RH ON REAR AXLE

EN16Z0803F200019

sensor.

AIR BRAKE)".


5. CHECK THE TIRE.

.
ABNORMAL SIGNAL OF THE WHEEL SENSOR, LH ON REAR AXLE

EN16Z0803F200020

sensor.

AIR BRAKE)".


5. CHECK THE TIRE.

.
ABNORMALITY IN SENSOR RING, RH ON FRONT AXLE

EN16Z0803F200021

(1) Inspect on damage of the sensor ring, installing status of the sen-
sor holder and the play of wheel hub bearing.
.
ABNORMALITY IN SENSOR RING, LH ON FRONT AXLE

EN16Z0803F200022

.
ABNORMALITY IN SENSOR RING, RH ON REAR AXLE

EN16Z0803F200023

.
ABNORMALITY IN SENSOR RING, LH ON REAR AXLE

EN16Z0803F200024

.
ABNORMALITY ON THE SUB BRAKE CUT RELAY

EN16Z0803F200025

EXHAUST BRAKE CUT RELAY (1) Set the starter switch to "LOCK", remove the sub brake cut relay.
(RIGHT-HAND DRIVE)
(2) Set the starter switch to "ON".
EXHAUST BRAKE CUT RELAY

(LEFT-HAND DRIVE)
SHTS16Z080300060
(3) Measure the voltage terminal of sub brake cut relay and ground
bolt.
Standard: 20V or more
GROUND BOLT
SHTS16Z080300061
.
NO
YES

tors of ABS ECU.
and terminal of sub brake cut relay.
SHTS16Z080300062
NO
YES

(1) Measure the resistance between terminals of the sub brake cut
relay.
SHTS16Z080300063
.
NO
Abnormality of sub brake cut relay
YES
ABNORMALITY ON ABS WARNING LIGHT (DIAGNOSIS CODE 7-4)

EN16Z0803F200026
1. CHECK THE ABS WARNING LIGHT.

(1) Make sure that it lights when the starter key is turned "ON" and
goes off after some moments.
(2) Check the harness when it does not light.
.
SHTS16Z080300064
ABNORMALITY OF POWER SUPPLY (LOW VOLTAGE)

EN16Z0803F200027
1. CHECK THE BATTERY.
2. CHECK THE CONTACT OF CONNECTOR AND THE BURNED

OUT OF FUSE.
.
ABNORMALITY OF POWER SUPPLY (OVER VOLTAGE)

EN16Z0803F200028
1. CHECK THE BATTERY AND THE ALTERNATOR.

.
ABNORMALITY OF ABS ECU (DIAGNOSIS CODE 8-3)

EN16Z0803F200029
1. ERASE THE DIAGNOSIS CODE, AND OUTPUT THE DIAGNO-

SIS CODE AGAIN.
Standard: Diagnosis code 1-1
.
NO
Abnormality of ABS ECU
YES
Normality
ABNORMALITY OF GROUND HARNESS (DIAGNOSIS CODE 8-5)

EN16Z0803F200030
1. CHECK THE CONTINUITY BETWEEN TERMINALS AND THE

BOLT IN THE CAB.
BOLT IN CAB tors of ABS ECU.
(2) Make sure that the continuity exists between 4th, 9th terminals of
15 pin connectors and the bolt in the cab.
SHTS16Z080300065
.
NO
YES
• Abnormality of ABS ECU

• Temporary malfunction because of abnormality of harness
.
2A&0AA'55A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧟㧠ಽ
BRAKE CONTROL (ES START) DN03–1
BRAKE CONTROL (ES START)

DN03
DN03-003
ES START
(EASY & SMOOTH START) SYSTEM ......DN03-2
HANDLING PRECAUTIONS ........................... DN03-2
SYSTEM DIAGRAM ........................................ DN03-3
ARRANGEMENT OF CONNECTOR PIN........ DN03-4
PRE-INSPECTION .......................................... DN03-5
TROUBLESHOOTING..................................... DN03-6
FAILURE DIAGNOSIS BY
USING DIAGNOSIS MONITOR..................... DN03-10
HOW TO DELETE
THE DIAGNOSIS CODE 8 ............................ DN03-12
HOW TO DELETE
THE DIAGNOSIS CODE 12 .......................... DN03-13
HOW TO DELETE
THE DIAGNOSIS CODE 13 .......................... DN03-14
DAMAGE ANALYSIS BY
DIAGNOSIS CODE ....................................... DN03-16
POWER MALFUNCTION
(NO DIAGNOSIS CODE)............................... DN03-16
POWER SUPPLY VOLTAGE MALFUNCTION
(DIAGNOSIS CODE 2) .................................. DN03-19
CLUTCH STROKE SENSOR SYSTEM DAMAGE
SPEED SENSOR SYSTEM DAMAGE
ES START CONTROL VALVE DAMAGE
CLUTCH FLUID PRESSURE SWITCH DAMAGE
CLUTCH STROKE SENSOR POWER SYSTEM
MALFUNCTION (DIAGNOSIS CODE 9) ....... DN03-26
NEUTRAL SWITCH AND
BACK-UP LIGHT SWITCH MALFUNCTION
(DIAGNOSIS CODE 11) ................................ DN03-27
NEUTRAL SWITCH SYSTEM OR
SPEED SENSOR SYSTEM MALFUNCTION
STOP LIGHT SWITCH DAMAGE
ES START CONTROLLER MALFUNCTION
ES MAIN SWITCH DAMAGE
ES START RELEASE TIMING SWITCH
DN03–2 BRAKE CONTROL (ES START)
ES START (EASY & SMOOTH START) SYSTEM

EN16Z0803F200001
1. ABOUT CONNECTORS
SHTS16Z080300001
Reference
SHTS16Z080300002
Reference:
zontally).

damage.
age data.
.
SYSTEM DIAGRAM
EN16Z0803F200002
ES MAIN SWITCH
RELEASE TIMING
SWITCH
ES START CONTROL
STOP LIGHT SWITCH VALVE
ES START
CONTROLLER
NEUTRAL SWITCH
COURTESY SWITCH
PARKING BRAKE ES START

SWITCH 1 SLOPE INDICATOR LIGHT
SENSOR
PARKING BRAKE
SWITCH 2
BUZZER
BACK UP LIGHT
SWTCH
CLUTCH FLUID
PRESSURE SWITCH
CLUTCH STROKE
SENSOR
SPEED SENSOR
DIAGNOSIS MONITOR
SHTS16Z080300004

EN16Z0803F200003
ES START CONTROLLER
26-PIN CONNECTOR
1 2 3 4 5 6 7 8 9 10 11
A
15 16 18 19 20 2122 24
CAB SIDE HARNESS
VIEW A
No. CODE SIGNAL No. CODE SIGNAL

1 +B Power 14
2 KYSW Starter switch 15 KY2 Starter switch
3 GND System ground 16 GND2 System ground 2
4 M/V+ ES start control valve output 17
5 PR ES start warning light 18 PKB1 Parking brake switch No.2
6 NTL Neutral switch 19 PKB Parking brake switch No.1
7 RVS Back-up light switch 20 DR Courtesy switch
8 STP Stop light switch 21 DIC Diagnosis monitor input
9 ON ES main switch "ON" 22 OFF ES main switch "OFF"
10 SSIG Speed sensor signal 23
11 FTSW Release timing switch "FAST" 24 SLSW Release timing switch "SLOW"
12 25
13 26
12-PIN CONNECTOR
1 2 3
B
7
CAB SIDE HARNESS
VIEW B
No. CODE SIGNAL No. CODE SIGNAL

1 C+B Clutch stroke sensor power 7 S-S Clutch stroke sensor ground
2 CSS Clutch stroke sensor signal 8
3 CLT Clutch fluid pressure switch 9
4 10
5 11
6 12
SHTS16Z080300005
PRE-INSPECTION
EN16Z0803F200004
1. CHECKING DISPLAY CODES OF ES INDICATOR LIGHT

(1) ES start controller alerts by beeping the warning buzzer and light-
ing or blinking the indicator light to classify the alarms when mal-
functions or failures occur.
NOTICE
When a failure alarm is displayed, perform the failure diagnosis by
using diagnosis function.
SHTS16Z080300006
Display and warning item Indicator

Warning buzzer Warning content Treatment
light
Under "ON" condition of starter Lighting for

Beeping once
switch, check if the lamp lights or not one second
ES start is operating Lighting Beeping once

Operation
ES start is released Lighting off No beeping
Perform failure
Defects of signal
Failure alarm Blinking Beeping continuously diagnosis by diagnosis
switches or sensors
Warning function.
Initialization is
Non-adjustment alarm Blinking No beeping Initialize.
not completed.
Door (either driver's

side or assistant's side) Pull parking brake
Quitting seat alarm Lighting Beeping continuously
opens when ES start lever.
is operating
Starter switch is set to

"LOCK" when ES start Pull parking brake
Starter switch OFF Beeping continuously
Lighting off lever or set main
alarm is operating during
neutral position. switch to "OFF".
Vehicle moves when Pull parking brake

Vehicle moving alarm Lighting Beeping continuously lever or step brake
Caution to pedal
mis-operation
Operation time from
1 to 9 minutes
1 minute has passed:
beeping once
2 minutes have
passed: Displaying every
Operation time Lighting beeping two times minute ES start Release ES start.
information 9 minutes have operation time
passed:
beeping nine times
Operation time
10 minutes or more:
Beeping continuously
SHTS16Z080300007
• Check the battery voltage.

Reference value: More than 20V
• Check that the ES start controller connectors are connected correctly.
• Check the fuse.
• Check that the speed sensor connector is connected correctly.
• Check that the ES start valve connector is connected correctly.
• Check that the clutch hydraulic switch connector is connected correctly.
• Check that the clutch stroke sensor connector is connected correctly.
• Check that the back-up light switch connector is connected correctly.
• Check that the neutral switch connector is connected correctly.
TROUBLESHOOTING
EN16Z0803F300001
THE ES START OPERATION FAILS.
1 Is there an operation malfunction?

The starter switch is in either the [LOCK] or [ACC] position.
The ON/OFF switch is in the [OFF] position.
The brake pedal is released.
The parking brake lever is pulled back.
Going forward downhill.
Going in reverse uphill.
An operation malfunction occurred.
Correct the operation.

An operation malfunction did not occur.
2 Set the starter key to [ON] and check the main power.
3 Check if a warning is occurred.

A warning occurred.
Refer to table of warning
A warning did not occur.
4 Check the stop light switch.
5 Check the parking brake switch.
6 Check the speed sensor.
7 Check the clutch stroke sensor.
8 Check the air piping.
9 Check the ES start control valve.
10 The ES start controller is damaged.

SHTS16Z080300008
THE ES START IS NOT CANCELED.

(THE CANCEL OPERATION IS PERFORMED BY THE STARTING OPERATION.)
1 Check if there was an operation malfunction.
The gear shift lever is in neutral.
The start operation is not performed correctly.

A warning occurred.
3 Check the neutral switch and the back-up lamp switch.
SHTS16Z080300009

(THE CANCEL OPERATION IS PERFORMED BY THE PARKING BRAKE.)
The parking brake must not be pulled back.

A warning occurred.

SHTS16Z080300010

(THE CANCEL OPERATION IS PERFORMED BY THE ES MAIN SWITCH.)
The main switch is not set to [OFF] .

A warning occurred.

SHTS16Z080300011
THE INITIAL SETTING OF THE CANCEL POSITION CANNOT BE PERFORMED.
1 Check if an operation malfunction occurred.


2 Check if the following conditions are not satisfied.

The ES start operation is currently being performed.
The 0-point adjustment is being performed.
The cancel position is being adjusted.

A warning occurred.
5 Check the neutral switch and the back-up light switch.
SHTS16Z080300012
THE 0-POINT ADJUSTMENT OF THE SLOPE SENSOR CANNOT BE PERFORMED.
1 Check if an operation malfunction occurred.


2 Check if the following conditions are not satisfied.

The ES start operation is currently being performed.
The initial setting of the cancel position is being performed.
The cancel position is being adjusted.

A warning occurred.

SHTS16Z080300013
THE BRAKE IS NOT RELEASED WHEN THE CANCELLATION IS PERFORMED.

(OR VEHICLE SLIDES DOWN.)
Adjust the release timing.
SHTS16Z080300014
FAILURE DIAGNOSIS BY USING DIAGNOSIS MONITOR

EN16Z0803F200005
1. FAILURE DIAGNOSIS BY USING DIAGNOSIS MONITOR

by being connected to the special diagnosis connector of ES start
system.
SHTS16Z080300015
2. CONNECTION OF THE DIAGNOSIS MONITOR

(1) Set the ES main switch to [ON].
(2) Set the starter switch to [ON].
ON
SHTS16Z080300025
(3) Disconnect the centralized diagnosis connector (upside the accel-

(RIGHT-HAND DRIVE) erator pedal) from the dummy connector.
FIXING DUMMY NOTICE
CONNECTOR Centralized diagnosis connector is normally coupled with fixed
type dummy connector. So, use it by disconnecting from the
dummy one and pulling it to this side. When not using it, make
sure to leave it connected with fixed type dummy one.
BLACK CONNECTOR
WHITE CONNECTOR
SHTS16Z080300017
SHTS16Z080300018
(4) Connect the dedicated harness to the centralized diagnosis con-

nector and diagnosis monitor to the connector tagged by "ES
start".
SST:
Dedicated harness (S0963-02300)
Diagnosis monitor (S0963-01370)
SHTS16Z080300019
3. DISPLAYING THE FAILURE CODE

(1) Because the failure codes are output repeatedly in ascending
order of failure codes without distinguishing present and past fail-
ures, delete the past failure by referring "4. Deleting the past fail-
ures".
HINT
If there are no failure codes, the system outputs "Diagnosis code
1".
4. DELETING THE PAST FAILURES

NOTICE
SHTS16Z080300026
Regarding the diagnosis codes 8, 12 and 13, the way of deleting
the past codes is different. Refer to the individual way of deleting.
(1) Record the first diagnosis code output.
(2) Disconnect the diagnosis monitor while keeping the starter key at
"ON" position.
NOTICE
If the starter key is set to "LOCK" position, the past failures can-
not be deleted. Make sure to keep the key at "ON" position.
(3) Wait for several seconds. Then connect the diagnosis monitor to
output the present failure.
.
HOW TO DELETE THE DIAGNOSIS CODE 8

EN16Z0803F200006
1. DELETING PROCEDURE
(1) Turn the starter switch to "ON" position and ES main switch
"OFF".
OFF (2) After having repaired the failure, step and release the clutch pedal
for more than three times to make the controller recognize the
ON/OFF of hydraulic switch.
HINT
Until the controller recognizes the ON/OFF of hydraulic switch, the
diagnosis code cannot be deleted.
SHTS16Z080300021
(3) Turn ES main switch "ON".

(4) Connect the diagnosis monitor and check that the diagnosis code
8 is output.
ON
SHTS16Z080300022
(5) Disconnect the diagnosis monitor while keeping the starter switch
at "ON" position.
check that the diagnosis code 8 has been deleted.
.
SHTS16Z080300023

EN16Z0803F200007
(1) Turn the starter switch to "ON" position and ES main switch
"OFF".
OFF (2) After having repaired the failure, engage and disengage the trans-
mission for more than three times to make the controller recog-
nize the ON/OFF of neutral switch.
HINT
Until the controller recognizes the ON/OFF of neutral switch, the
SHTS16Z080300024

12 is output.
ON
SHTS16Z080300025
"ON" position.
.
SHTS16Z080300026

EN16Z0803F200008
(1) Turn the stater switch to "ON" position and ES main switch "OFF".
(2) After having repaired the failure, step and release the brake pedal
OFF for more than three times to make the controller recognize the
ON/OFF of stop light switch.
HINT
Until the controller recognizes the ON/OFF of stop light switch, the
SHTS16Z080300021

13 is output.
ON
SHTS16Z080300027
"ON" position.
.
SHTS16Z080300028
DIAGNOSIS CODE TABLE
Diagnosis
Inspection item Diagnosis monitor and indicator light output
code No.
1 Normal
2 Power harness voltage malfunction
Clutch stroke sensor system damage

3
(disconnection, short-circuit)
4 Speed sensor system damage
7 ES start control valve damage
Clutch fluid pressure switch system

8
damage
Clutch stroke sensor power system

9
malfunction
Neutral switch and back up light switch

11
malfunction
Neutral switch system or speed sensor

12
system malfunction
13 Stop light switch damage
16 ES start controller malfunction
18 ES main switch damage
21 Release timing position switch damage

DAMAGE ANALYSIS BY DIAGNOSIS CODE

EN16Z0803F200009
NOTICE
1. When replacing the clutch hydraulic switch, always initialize the brake releasing position.
2. When replacing the clutch stroke sensor, always initialize the brake releasing position.
3. When replacing ES start controller, always initialize the brake releasing position and perform 0 point adjust-
ment of slope sensor.
POWER MALFUNCTION (NO DIAGNOSIS CODE)

EN16Z0803F200010
1. MEASURE THE VOLTAGE BETWEEN TERMINALS.

(1) Set the starter switch to [LOCK] and remove the 26-pin connector
of the ES start controller.
(2) Set the starter switch [ON] and measure the voltage between the
terminal 2 and 3 and the terminal 15 and 16 of the 26-pin connec-
tor (harness side).
Standard value: More than 20V
SHTS16Z080300042
.
NO
• Less than 20 V: Go to the item 3.
• 0 V: Go to the item 4.
YES
2. CHECK THE OPERATION OF THE ES START SYSTEM.

Standard: Normal operation
.
NO
ES start controller malfunction
YES
ES start controller connector contact failure, faulty harness con-

tact failure
3. MEASURE THE VOLTAGE OF BATTERY.

(1) Measure the voltage between the (+) terminal and the (-) terminal
of the battery.
SHTS16Z080300043
.
NO
Battery malfunction
YES
Power supply harness contact failure or disconnection

4. CHECK THE ES START FUSE.

(1) Check the ES start fuse in the fuse block.
Standard: Not melting
.
NO
Go to the item 6.
YES

(1) Measure the voltage between the (+) terminal and the (-) terminal
of the battery.
SHTS16Z080300043
.
NO
Battery malfunction
YES
6. RECHECK THE ES START FUSE.

(1) Set the starter switch to [LOCK], replace the fuse and set the
starter switch [ON].
Standard: Not melting
.
NO
Go to the item 7.
YES
Normal
7. CHECK THE CONDUCTIVITY BETWEEN TERMINALS.

(1) Set the starter switch to [LOCK], remove the 26-pin connector of
the ES start controller and check the conductivity between the ter-
minal 2 and 3 and the terminal 15 and 16 of the 26-pin connector
(harness side).
Standard: No conductivity
SHTS16Z080300044
.
NO
Short-circuit in the harness
YES
8. RECHECK THE OPERATION OF THE ES START SYSTEM.

.
NO
YES
ES start controller connector contact failure, faulty harness con-

tact failure
.
POWER SUPPLY VOLTAGE MALFUNCTION (DIAGNOSIS CODE 2)

EN16Z0803F200011

(1) Set the starter switch to [LOCK] and remove the 26-pin connector
of the ES start controller.
(2) Measure the voltage between the terminal 2 and 3 and the termi-
nal 15 and 16 of the 26-pin connector (harness side.)
SHTS16Z080300045
.
NO
Go to the item 3.
YES

(1) Measure the voltage between the (+) terminal and (-) terminal of
the battery.
SHTS16Z080300043
.
NO
Battery malfunction
YES
3. CHECK THE DIAGNOSIS CODE.

(1) Erase the diagnosis monitor memory and confirm the diagnosis
code by diagnosis functions again.
Standard: Diagnosis code: 1
SHTS16Z080300046
.
NO
YES
• Harness contact failure

• Charging system malfunction
CLUTCH STROKE SENSOR SYSTEM DAMAGE (DIAGNOSIS CODE 3)

EN16Z0803F200012
1. CHECK THE CLUTCH STROKE SENSOR.

(1) Check the installation location of the clutch stroke sensor.
Standard: Correct installation
SHTS16Z080300047
.
NO
Install the sensor correctly.
YES
(2) Measure the voltage of the set position.

Standard voltage: 0.28-0.77V
2. CHECK THE CONDUCTIVITY BETWEEN THE TERMINALS.

(1) Remove the 12-pin connector of the ES start controller and clutch
stroke sensor connector and check the conductivity between the
terminal 1 and 1, the terminal 2 and 2 and the terminal 7 and 3 of
both connectors (harness side).
Standard: Conductivity
SHTS16Z080300048
.
NO
Harness disconnection
YES
3. MEASURE THE RESISTANCE BETWEEN TERMINALS.

(1) Measure the resistance between the terminal 2 and 3 of the con-
nector (sensor side).
Standard value:
When pressing the clutch pedal: Approx. 2 kΩ
When releasing the clutch pedal: Approx. 700 Ω
SHTS16Z080300049
.
NO
Clutch stroke sensor damage
YES
Go to diagnosis code 9.
SPEED SENSOR SYSTEM DAMAGE (DIAGNOSIS CODE 4)

EN16Z0803F200013
1. CHECK THE SPEEDOMETER OPERATION.

(1) Check if the speedometer operates correctly when driving.
SHTS16Z080300050
.
NO
Speed sensor or pulse adjust computer mal-
function
YES

(1) Remove the 26-pin connector of the ES start controller and pulse
adjust computer connector and check the conductivity between
the terminal 10 and 2 of both connectors (harness side).
SHTS16Z080300051
.
NO
YES
Go to the item 3 after checking the pulse adjust computer.

3. CHECKING THE DIAGNOSIS CODE

(1) After having restored the connector and deleted the past failures,
drive the vehicle at 30 km/h or above for more than two minutes.
Then output again the diagnosis code. (This is because vibrations
are necessary for slope sensor output. Inspection by circuit tester
has no meaning.)
SHTS16Z080300052
.
NO
Connector or harness contact failure
YES
ES START CONTROL VALVE DAMAGE (DIAGNOSIS CODE 7)

EN16Z0803F200014

(1) Remove the 26-pin connector of the ES start controller and the
ES start control valve connector. Check the conductivity between
CHASSIS terminal 4 and terminal 1 and the chassis ground and terminal 2
BOLT (harness side).
SHTS16Z080300053
.
NO
YES

(1) Check the conductivity between terminal 1 and terminal 2 of the
ES start valve connector (harness side).
SHTS16Z080300054
.
NO
YES
3. MEASURE THE RESISTANCE BETWEEN TERMINALS.

(1) Measure the resistance between terminal 1 and terminal 2 of the
connector (part side).
Standard value: 30-45 Ω
SHTS16Z080300055
.
NO
ES start control valve malfunction
YES
4. CHECK THE ES START VALVE OPERATION.

(1) Apply the power voltage and check the ES start control valve
operation.
SHTS16Z080300056
.
NO
ES start control valve malfunction
YES
5. RECHECK THE DIAGNOSIS CODE.

(1) Erase the diagnosis code and output the diagnosis code again.
SHTS16Z080300057
.
NO
Faulty contact in harness or connector
YES
.
CLUTCH FLUID PRESSURE SWITCH DAMAGE (DIAGNOSIS CODE 8)

EN16Z0803F200015

(1) Remove the 12-pin connector of the ES start controller and clutch
fluid pressure switch connector and check the conductivity
CHASSIS between the terminal 3 and the terminal 1 and the chassis ground
BOLT and the terminal 2 (harness side).
SHTS16Z080300058
.
NO
YES
2. CHECK THE CLUTCH FLUID.

(1) Check if the clutch fluid level is between L and H of the reservoir
tank.
Standard: Between L and H
SHTS16Z080300059
.
NO
Supply the clutch fluid.
YES

(1) Check the conductivity between the terminal 1 and 2 of the clutch
fluid pressure switch (switch side).
Standard: When pressing the clutch pedal: Conductivity
When releasing the clutch pedal: No conductivity
SHTS16Z080300060
.
NO
Clutch fluid pressure switch malfunction
YES
4. CHECK THE CLUTCH STROKE SENSOR.

(1) Check the installation location of the clutch stroke sensor.
Standard: Correct installation
SHTS16Z080300061
.
NO
Install the sensor correctly.
YES
(2) Measure the voltage of the set position.

Standard voltage: 0.28-0.77V

(1) Erase the diagnosis code. Press the clutch pedal a few times and
output the diagnosis code again.
NOTICE
The way of deleting the past failure is different to others.
Refer to the section of the "How to delete the diagnosis code
8".
SHTS16Z080300062
.
NO
Faulty contact in connector or harness
YES
Clutch fluid pressure switch malfunction
.
CLUTCH STROKE SENSOR POWER SYSTEM MALFUNCTION

(DIAGNOSIS CODE 9)
EN16Z0803F200016

(1) Remove the 12-pin connector of the ES start controller. Check the
conductivity between terminals 1 and 7 and terminals 2 and 7 of
the ES start controller connector (harness side).
SHTS16Z080300063
.
NO
YES

(1) After having restored the ES start controller connector, remove
the clutch stroke sensor connector and set the starter switch [ON].
Measure the voltage between the terminals 1 and 3 of the clutch
stroke sensor connector (harness side).
NOTICE
Be careful not to make a short-circuit.
Standard value: 4-6V
SHTS16Z080300064
.
NO
Go to the item 3.
YES
Clutch stroke sensor malfunction


(1) Erase the diagnosis code. Output the diagnosis code again.
SHTS16Z080300065
.
NO
Connector or harness contact failure.
YES
NEUTRAL SWITCH AND BACK-UP LIGHT SWITCH MALFUNCTION

(DIAGNOSIS CODE 11)
EN16Z0803F200017

(1) Remove the 26-pin connector of ES start controller and set the
CHASSIS BOLT starter switch to [ON]. Measure the voltage between the harness
connector terminal 6 and the chassis ground.
Standard value:
When the transmission is in gear: Less than 1V
When the transmission is in neutral: More than 20V
SHTS16Z080300066
.
NO
Neutral switch malfunction, disconnection or
installation error
YES

(1) Measure the voltage between the harness connector terminal 7
CHASSIS BOLT and the chassis ground.
Standard value:
When the transmission is in reverse: More than 20V
When the transmission is in other position: Less than 1V
SHTS16Z080300067
.
NO
Back-up light switch malfunction, disconnec-
tion or installation error
YES

(1) Erase the diagnosis code. Shift into reverse and output the diag-
nosis code again.
SHTS16Z080300068
.
NO
Connector or harness contact failure.
YES
.
NEUTRAL SWITCH SYSTEM OR SPEED SENSOR SYSTEM

MALFUNCTION (DIAGNOSIS CODE 12)
EN16Z0803F200018

(1) Remove the 26-pin connector of the ES start controller and the
neutral switch connector. Check the conductivity between terminal
6 and terminal 1 of both connectors (harness side).
SHTS16Z080300069
.
NO
YES

(1) Restore the ES start controller connector and set the starter
CHASSIS BOLT switch to [ON]. Measure the voltage between the neutral switch
connector terminal 1 and the chassis ground.
SHTS16Z080300070
.
NO
Harness or power supply malfunction
YES

(1) Check the conductivity between connector terminal 1 and 2 of the
part side.
NOTICE
Check that the switch does not change within the motion range of
the shift lever.
Standard:
When the transmission is in gear: No conductivity
When the transmission is in neutral: Conductivity
SHTS16Z080300071
.
NO
Neutral switch malfunction
YES
4. CHECK THE SPEEDOMETER OPERATION.

(1) Check if the speedometer operates correctly when driving.
SHTS16Z080300050
.
NO
Go to the item 5 after checking the speed sen-
sor and pulse adjust computer.
YES
Go to the item 5 after checking the pulse adjust computer.

(1) Erase the diagnosis code. Accelerate and decelerate from 0 to 50
km/h more than 10 times. Output the diagnosis code again.
NOTICE
Refer to the section of the "How to delete the diagnosis code 12".
SHTS16Z080300072
.
NO
YES
.
STOP LIGHT SWITCH DAMAGE (DIAGNOSIS CODE 13)

EN16Z0803F200019

(1) Set the starter switch to [LOCK], remove the 26-pin connector of
the ES start controller and the connector of the stop light switch.
(2) Check the conductivity between the terminal 8 and 1 of both con-
nectors (harness side).
SHTS16Z080300073
.
NO
Harness contact failure or disconnection
YES
2. CHECK A SHORT-CIRCUIT BETWEEN TERMINALS.

(1) Check if the harness connectors between terminal 8 and terminal
CHASSIS BOLT 1 of 26-pin connector (harness side) and between terminal 8 and
chassis ground cause a short-circuit.
SHTS16Z080300074
.
NO
YES
3. CHECK THE VOLTAGE OF TERMINALS.

(1) Restore the connector and set the starter switch to "ON" and
CHASSIS BOLT measure the voltage between No.8 terminal of 26-pin connector
of ES start controller and chassis ground.
Standard value:
When stepping brake pedal: Less than 1V
When releasing brake pedal: More than 18V
SHTS16Z080300075
.
NO
Go to the item 4.
YES
Go to the item 5.
4. CHECK THE STOP LIGHT SWITCH.

(1) Check the stop light switch.
.
NO
Stop light switch malfunction
YES

(1) Erase the diagnosis code. Repeat for more than five times in suc-
cession the acceleration from 0 km/h to 50 km/h or above and the
deceleration from 50 km/h to 0 km/h. Output the diagnosis code
again.
NOTICE
Refer to the section of the "How to delete the diagnosis code 13".
SHTS16Z080300076
.
NO
YES
ES START CONTROLLER MALFUNCTION (DIAGNOSIS CODE 16)

EN16Z0803F200020
1. CHECK THE DIAGNOSIS CODE.

(1) Erase the diagnosis code and output the diagnosis code again.
SHTS16Z080300077
.
NO
YES
Normal
.
ES MAIN SWITCH DAMAGE (DIAGNOSIS CODE 18)

EN16Z0803F200021

(1) Set the starter switch to [LOCK], and remove the 26-pin connector
of ES start controller and the connector of ES main switch.
(2) Check the conductivity between terminal 9 and terminal 7 and
between terminal 22 and terminal 6 of both connectors (harness
side).
SHTS16Z080300078
.
NO
YES

(1) Check a short-circuit of harness connector between terminal 9
and terminal 1 of 26-pin connector, between terminal 9 and chas-
sis ground, between terminal 22 and terminal 1 and between ter-
minal 22 and chassis ground.
CHASSIS
BOLT
SHTS16Z080300079
.
NO
YES

(1) Set the starter switch to [ON] and measure the voltage between
the terminal 9 of the 26-pin connector and chassis ground and
between the terminal 22 and chassis ground.
Standard value:
When main switch is [ON]:
CHASSIS
BOLT Between terminal 9 and chassis ground: More than 20V
Between terminal 22 and chassis ground: Less than 1V
When main switch is [OFF]:
Between terminal 22 and chassis ground: More than 20V
SHTS16Z080300080
.
NO
Go to the item 4.
YES
Go to the item 5.
4. CHECK THE ES MAIN SWITCH.

(1) Check the ES main switch.
Standard: Normal
.
NO
ES main switch malfunction
YES

(1) Erase the diagnosis code and set the ES main switch to [ON].
ON
SHTS16Z080300025
(2) More than 10 seconds later, output the diagnosis code again.
SHTS16Z080300081
.
NO
YES
.
ES START RELEASE TIMING SWITCH (DIAGNOSIS CODE 21)

EN16Z0803F200022

(1) Set the starter switch to [LOCK] and disconnect the connector of
26-pin connector of ES start controller and the connector of
release timing switch.
(2) Check the conductivity between the terminal 11 and terminal 1
and between terminal 24 and terminal 2 of both connectors (har-
ness side).
SHTS16Z080300082
.
NO
YES

(1) Check a short-circuit of harness connector between terminal 11
and terminal 1 of 26-pin connector, between terminal 11 and
chassis ground, between terminal 24 and terminal 1 and between
terminal 24 and chassis ground.
CHASSIS
BOLT
SHTS16Z080300083
.
NO
YES

(1) Set the starter switch to [ON] and measure the voltage between
the terminal 11 of the 26-pin connector and chassis ground and
between the terminal 24 and chassis ground.
Standard value:
When release timing switch is [FAST]:
CHASSIS
BOLT Between terminal 11 and chassis ground: More than 20V
When release timing switch is [SLOW]:
Between terminal 24 and chassis ground: More than 20V
SHTS16Z080300084
.
NO
Go to the item 4.
YES
Go to the item 5.
4. CHECK THE RELEASE TIMING SWITCH.

(1) Check the release timing switch.
Standard: Normal
.
NO
Release timing switch malfunction
YES
5. RECHECKING THE DIAGNOSIS CODE

(1) Delete the past failures. Press for more than three seconds
"FAST" and "SLOW" side each of the release timing switch. Then
output again the diagnosis code.
SHTS16Z080300085
.
NO
YES
.
2A&0AA46&A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧟㧢ಽ
BRAKE CONTROL (ELECTROMAGNETIC RETARDER) DN03–1
BRAKE CONTROL DN03
(ELECTROMAGNETIC RETARDER) DN03-004
ELECTROMAGNETIC RETARDER .........DN03-2

SYSTEM DIAGRAM ........................................ DN03-3
ARRANGEMENT OF CONNECTOR PIN IN
RETARDER ECU ............................................ DN03-4
PRE-INSPECTION .......................................... DN03-6
FAILURE DIAGNOSIS BY
USING DIAGNOSIS MONITOR....................... DN03-9
DIAGNOSIS CODE TABLE ........................... DN03-10
MALFUNCTION OF THE EXCITER UNIT IN THE
MAIN UNIT (DIAGNOSIS CODE 2)............... DN03-11
MALFUNCTION OF THE FIELD COIL (F COIL) UNIT
IN THE MAIN UNIT (DIAGNOSIS CODE 3) .. DN03-12
MALFUNCTION OF
THE TEMPERATURE SENSOR UNIT IN THE MAIN
UNIT (DIAGNOSIS CODE 4)......................... DN03-13
FAILURE OF THE DRIVE UNIT
FAILURE OF THE CONTROL UNIT
DN03–2 BRAKE CONTROL (ELECTROMAGNETIC RETARDER)
ELECTROMAGNETIC RETARDER
EN16Z0803F200001
1. ABOUT CONNECTORS
SHTS16Z080300001
Reference
SHTS16Z080300002
Reference:
zontally).
(6) When disconnecting the connector, be sure to set the starter
switch to "LOCK".

damage.
age data.
(3) If a failure that makes the indicator light blink occurs, make sure to
delete the past failure after repair has been completed. Otherwise
the indicator light does not stop blinking even if the failure does
not exist.
.
SYSTEM DIAGRAM
EN16Z0803F200002
RETARDER ECU RETARDER MAIN UNIT

CONNECTOR JUMPER CABLE
16P CONTROL UNIT 10P DRIVE UNIT CONNECTOR A 1 LINE
To INTEGRAL UNIT 8P
SCR DRIVE
9 D-1 D-1 4 1
EXCITER 3 2
+24V INDICATOR LIGHT RELAY DRIVE
10 D-10 D-10 A 1 LINE
SPEED
+24V SIGNAL 1 RELAY
11 D-8 D-8 7 6
SPEED 8 5
EXCITER 1
SIGNAL 2
2 D-9 D-9
1 F COIL VOLTAGE
DETECTION 1 2 3
2 6 D-4 D-4 1 4
F COIL VOLTAGE SCR
3 DETECTION 2
15 D-6 D-6
4 F COIL VOLTAGE
DETECTION PWR
16 D-3 D-3 5 8
DIAGNOSIS 6 7
MONITOR FIELD COIL 1
GROUND
3 D-2 D-2
COMBINATION SW GROUND CONNECTOR
13 D-5 D-5 8P B 2 LINE
OFF EXH RET RET
Lo Hi 4 1
GROUND
OFF 14 D-7 D-7 3 2
EXH/B
1 B 2 LINE
2 7
RELAY
3 7 6
1 8 5
EXCITER 2
5
2 3
1 4
8 SCR
To STARTER SW
CIRCUIT
12
5A
5 8
4 6 7
FIELD COIL 2
GND
CONNECTOR
4P
1 TEMP.
SENSOR 1
3 TEMP.
2 SENSOR 2
4 SHILED
CABLE GND
SHTS16Z080300004
ARRANGEMENT OF CONNECTOR PIN IN RETARDER ECU

EN16Z0803F200003
CONTROL UNIT (16 PIN CONNECTOR)
1 2 3 4
5 6 7 8
A
9 10 11 12
13 14 15 16 CAB SIDE HARNESS
VIEW A
SHTS16Z080300005
1 Ignition power 9 Stop light relay output
2 Lever switch Lo 10 Indicator light and Diagnosis output
3 — 11 Diagnosis switch
4 Temperature sensor 1 12 Analogue ground
5 Ground 13 —
6 Lever switch Hi 14 —
7 — 15 —
8 Temperature sensor 2 16 —
DRIVE UNIT (8 PIN CONNECTOR)
1 2 3 4
A
5 6 7 8
CAB SIDE HARNESS
VIEW A
SHTS16Z080300006
CIRCUIT A
1 Field coil 2 5 Field coil 6
3 Exciter 2 7 Exciter 6
CIRCUIT B
PRE-INSPECTION
EN16Z0803F200004
CHECKING SYSTEM STATUS

1. Check the indicator light on the instrument panel (When
operating the retarder).
INDICATOR
LIGHT CONDI- SYSTEM STATUS
TION
Normal (But the indicator light does not turn

LIGHTING on at the vehicle speed 10 km/h or below
because the retarder does not operate then.)
Failure (Check the operation because faulty

SHTS16Z080300007
operation may turn the indicator light off. The
LIGHTING OFF indicator light does not turn on at the vehicle
speed 10 km/h or below because the retarder
does not operate then.)
Failure (The operation is not cancelled by

BLINKING
turning "OFF" the retarder control lever.)
2. Check the battery voltage.

3. Check the fuse.
4. Check that the connector of retarder ECU is connected cor-

rectly.
5. Check that the connector of drive unit is connected correctly.
6. Check that the connector of retarder main unit is connected

correctly.
7. Check that the connector of clutch switch is connected cor-

rectly.
8. Check that the connector of accelerator switch is connected

correctly.
.
INSPECTION OF THE INPUT AND OUTPUT OF THE CONTROL UNIT

1. CHECK THE CONDUCTIVITY OF HARNESS.
(1) Set the starter switch to "LOCK" position. Disconnect 16-pin con-
nector of the retarder ECU and check the conductivity between
No.5 terminal of the connector (harness side) and chassis
GROUND
ground.
SHTS16Z080300008
.
NO
Replace the harness.
YES
2. INSPECT THE VOLTAGE OF CONTROL UNIT.

(1) Set the starter switch to "ON" position.
(2) Measure the voltage between No.1 and No.5 terminals of 16-pin
connector (harness side).
Standard value: Approx. 24V
SHTS16Z080300009
NO
Check the fuse.
YES
3. INSPECT THE INDICATOR LIGHT CIRCUIT.

(1) Set the starter switch to "LOCK" position, connect No.5 and No.10
terminals of 16-pin connector with a harness.
(2) Turn the starter switch to "ON" position, check that the indicator
light turns on.
Standard: Lighting
SHTS16Z080300010
NO
Check the fuse.
YES
4. INSPECT THE STOP LIGHT CIRCUIT.

(1) Set the starter switch to "LOCK" position, connect No.5 and No.9
terminals of 16-pin connector with a harness.
(2) Turn the starter switch to "ON" position, check that the stop light
turns on.
Standard: Lighting
SHTS16Z080300011
NO
Check the fuse.
YES
5. INSPECT THE RETARDER CONTROL LEVER CIRCUIT

(1) Set the starter switch to "ON" position, set the retarder control
lever at the second (LOW) without stepping the clutch pedal. At
this moment, measure the voltage between No.2 and No.5 termi-
nals of the 16-pin connector (harness side).
SHTS16Z080300012
NO
Check the clutch switch, accelerator switch
and retarder control lever.
YES
6. INSPECT THE RETARDER CONTROL LEVER CIRCUIT.

(1) Set the starter switch to "ON" position, set the retarder control
lever at the third (Hi) without stepping the clutch pedal. At this
moment, measure the voltage between No.6 and No.5 terminals
of the 16-pin connector (harness side).
SHTS16Z080300013
NO
Check the clutch switch, accelerator switch
and retarder control lever.
YES
Test OK.
.
INSPECTION OF FUSE
1. Remove the lower cover of the assistant seat side. check the
fuse for electromagnetic retarder. if it is blown out, replace it
with new one.
2. Remove the lower cover of the assistant seat side. check the
fuse for power supply. if it is blown out, replace it with new
one.
.
FAILURE DIAGNOSIS BY USING DIAGNOSIS MONITOR

EN16Z0803F200005
The electromagnetic retarder stores the history of failures and its contents up to the present in its computer. Connecting
the diagnosis monitor to the special connector can monitor the failure contents.
1. DIAGNOSIS MONITOR
by being connected to the special diagnosis connector of electro-
magnetic retarder.
SST: Diagnosis monitor (S0963-01370)
SHTS16Z080300014
2. CONNECT THE DIAGNOSIS MONITOR.

(RIGHT-HAND DRIVE) (1) Locate two intensive diagnosis connectors on lower right of the
FIXING DUMMY instrument panel. Connect the special wiring harness to the black
CONNECTOR connector and diagnosis monitor to the connector tagged by
"electromagnetic retarder".
SST: Special wiring harness for intensive diagnosis connec-
tor (S0963-02300)
BLACK CONNECTOR
WHITE CONNECTOR
SHTS16Z080300015
SHTS16Z080300016
NOTICE
The intensive diagnosis connector is usually connected to the fix-
ing dummy connector. So, disconnect the connector from the
dummy connector and pull it to use. When the connector is not in
use, connect it firmly to the fixing dummy connector.
(2) Set the starter switch to "ON".
3. DISPLAYING THE FAILURE CODE

(1) The failure codes are output repeatedly in ascending order of fail-
ure codes without distinguishing present and past failures.
SHTS16Z080300017
4. DELETE THE PAST FAILURES

(1) Record the first diagnosis code output.
(2) Disconnect the diagnosis monitor while keeping the starter switch
at "ON" position.
NOTICE
If the starter switch is set to "LOCK" position, the past failures
cannot be deleted. Make sure to keep the switch at "ON" position.
output the present failure.
.
SHTS16Z080300018
DIAGNOSIS CODE TABLE

EN16Z0803F200006
Diagnosis
Inspection item Diagnosis monitor and indicator light output
code No.
1 Normalcy of the system
Malfunction of the exciter unit in the

2
main unit
Malfunction of the field coil (F coil) unit

3
in the main unit
Malfunction of the temperature sensor

4
unit in the main unit
6 Failure of the drive unit
7 Failure of the control unit

MALFUNCTION OF THE EXCITER UNIT IN THE MAIN UNIT

(DIAGNOSIS CODE 2)
EN16Z0803F200007
1. MEASURE THE RESISTANCE BETWEEN THE TERMINALS

OF THE RETARDER MAIN UNIT.
(1) Set the starter switch to "LOCK" position. Disconnect 8-pin con-
nectors of both A line and B line of the retarder main unit.
(2) Measure the resistance between terminals No.1 and No.5, termi-
nals No.2 and No.6 of each connector A and B (main unit side).
Standard value: 1.11Ω (At 20°C {68°F})
SHTS16Z080300025
.
NO
Replace the retarder main unit (Except for
retarder drum).
YES

(1) Disconnect 8-pin connectors (black) of A line and B line of the
retarder main unit and drive unit and measure the conductivity
between each terminal for the exciter of the connector (harness
side).
RETARDER MAIN UNIT RETARDER ECU
Terminal No.5 Terminal No.8

MAIN UNIT RETARDER
SIDE ECU SIDE
SHTS16Z080300026
.
NO
YES
3. CHECK THE CONNECTORS.

.
NO
Couple the connector properly.
YES
Replace the retarder ECU.

MALFUNCTION OF THE FIELD COIL (F COIL) UNIT IN THE MAIN UNIT

(DIAGNOSIS CODE 3)
EN16Z0803F200008

OF THE RETARDER MAIN UNIT.
(1) Set the starter switch to "LOCK" position, disconnect 8-pin con-
nectors of both A line and B line of the retarder main unit.
(2) Measure the resistance between terminals No.3 and No.7, termi-
nals No.4 and No.8 of each connector A and B (main unit side).
Standard value: 2.8 Ω (At 20°C {68°F})
SHTS16Z080300027
NO
retarder drum).
YES

(1) Disconnect 8-pin connectors (black) of A line and B line of the
retarder main unit and retarder ECU, measure the conductivity
between each terminal for the field coil of the connectors (harness
side).
RETARDER MAIN UNIT RETARDER ECU
MAIN UNIT RETARDER Terminal No.4 Terminal No.1

SIDE ECU SIDE
SHTS16Z080300028
NO
YES
Replace the retarder ECU.
.
MALFUNCTION OF THE TEMPERATURE SENSOR UNIT

IN THE MAIN UNIT (DIAGNOSIS CODE 4)
EN16Z0803F200009

OF RETARDER MAIN UNIT.
(1) Set the starter switch to "LOCK" position, disconnect each con-
nector of the temperature sensor of the retarder main unit side.
(2) Measure the resistance between terminals of each connector
(main unit side).
A LINE Terminal No.1 Terminal No.3
B LINE Terminal No.2 Terminal No.3

B LINE A LINE
Standard value: 50-300 kΩ (At 20°C {68°F})
SHTS16Z080300029
.
NO
retarder drum).
YES
2. CHECK THE CONDUCTIVITY OF THE HARNESS.

(1) Disconnect the connectors of temperature sensor of retarder main
unit and 16-pin connector of retarder ECU, measure the conduc-
tivity between the terminals of connector (harness side).
TEMPERATURE SENSOR RETARDER ECU

SHTS16Z080300030
Reference: Conductivity
.
NO
YES
Perform the damage analysis of "MALFUNCTION OF THE

EXCITER UNIT IN THE MAIN UNIT (DIAGNOSIS CODE 2)"
and "MALFUNCTION OF THE FIELD COIL (F COIL) UNIT IN
THE MAIN UNIT (DIAGNOSIS CODE 3)".
FAILURE OF THE DRIVE UNIT (DIAGNOSIS CODE 6)

EN16Z0803F200010
1. Because internal failure has occurred in the drive unit sec-

tion of the retarder ECU, replace the retarder ECU.
.
FAILURE OF THE CONTROL UNIT (DIAGNOSIS CODE 7)

EN16Z0803F200011
1. Because internal failure has occurred in the control unit sec-

tion of the retarder ECU, replace the control unit.
.
2A&0AAOQMWLKAMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧟㧣ಽ
OTHERS (CAN COMMUNICATION) DN06–1
DN06 OTHERS (CAN COMMUNICATION) DN06-001
CAN COMMUNICATION ...........................DN06-2

CAN COMMUNICATION LINE ........................ DN06-2
INSPECTION WHEN CAN COMMUNICATION
LINE IS ABNORMAL ....................................... DN06-3
DN06–2 OTHERS (CAN COMMUNICATION)
CAN COMMUNICATION
CAN COMMUNICATION LINE
EN16Z1606F200001
1. CAN COMMUNICATION LINE

(1) CAN communication line is composed of 2 harnesses namely the CAN communication H line and L line and a twist
pair line is used for the harness.
ENGINE ECU JOINT CONNECTOR METER ECU

CAN COMMUNICATION H LINE CAN COMMUNICATION H LINE
CAN COMMUNICATION L LINE CAN COMMUNICATION L LINE
DRIVE MASTER ECU

CAN COMMUNICATION H LINE
CAN COMMUNICATION L LINE
SHTS16Z160600001
EN16Z1606F200002
1. ABOUT CONNECTORS
SHTS16Z160600002
Reference
SHTS16Z160600003
Reference:
zontally).
(6) When disconnecting the connector, be sure to set the starter
switch to "LOCK".
SHTS16Z160600004

(1) Erase the previous damage data after they have been recorded,
damage.
(2) After the damage analysis is completed, erase the previous dam-
age data.
(3) If a failure that makes the indicator lamp blink occurs, make sure
to erase the past failure after repair has been completed. Other-
wise the indicator lamp does not stop blinking even if the failure
does not exist.
.
INSPECTION WHEN CAN COMMUNICATION LINE IS ABNORMAL

EN16Z1606F200003
1. CHECK THE CONTINUITY BETWEEN TERMINALS OF CAN

CA2H COMMUNICATION H LINE.
(1) Check the continuity between "CA2H" terminal of engine ECU
connector (32 pin) and 4th (KRG) terminal of joint connector CAN
(12 pin).
KRG
SHTS16Z160600005
NO
YES

CA2L COMMUNICATION L LINE.
(1) Check the continuity between "CA2L" terminal of engine ECU
connector (32 pin) and 1st (KRH) terminal of joint connector CAN
(12 pin).
KRH
SHTS16Z160600006
NO
YES
Proceed to 3.

COMMUNICATION H LINE.
(1) Check the continuity between "MMT+" terminal of meter connec-
tor (22 pin) and 12th (E4L) terminal of joint connector CAN (12
pin).
E4L
MMT+
SHTS16Z160600007
NO
YES

E4M COMMUNICATION L LINE.
(1) Check the continuity between "MMT-" terminal of meter connector
(22 pin) and 8th (E4M) terminal of joint connector CAN (12 pin).
MMT-
SHTS16Z160600008
NO
YES
Proceed to 7.

COMMUNICATION H LINE.
(1) Check the continuity between "CANH" terminal of drive master
ECU connector (10 pin) and 12th (E4L) terminal of joint connector
CAN (12 pin).
E4L
CANH
SHTS16Z160600009
NO
YES

E4M COMMUNICATION L LINE.
(1) Check the continuity between "CANL" terminal of drive master
ECU connector (10 pin) and 8th (E4M) terminal of joint connector
CAN (12 pin).
CANL
SHTS16Z160600010
NO
YES
Proceed to 7.

CONNECTOR.
(1) Confirm that the joint connector CAN is plugged completely.
SHTS16Z160600011
(2) With the connector plugged, check the continuity between termi-
nals of joint connector.
L LINE H LINE
• Between terminals of CAN communication L line.
• Between terminals of CAN communication H line.
SHTS16Z160600012
NO
Replace or repair the connector.
YES
Proceed to 8.
8. CHECK THE CONTINUITY BETWEEN CAN COMMUNICATION

CA2H +24V GND H LINE AND POWER LINE.
(1) Disconnect the connectors of all the ECU.
(2) Check the continuity between "CA2H" terminal of engine ECU
connector (32 pin) and "+24V", "GND" terminals of diagnosis con-
nector (16 pin).
SHTS16Z160600013
NO
Proceed to 9.
YES
Replace all the CAN harness in case that either or both continu-
ities between terminals "CA2H" and "+24V", "GND".
9. CHECK THE CONTINUITY BETWEEN CAN COMMUNICATION

CA2L +24V GND L LINE AND POWER LINE.
(1) Check the continuity between "CA2L" terminal of engine ECU
connector (32 pin) and "+24V", "GND" terminals of diagnosis con-
nector (16 pin).
SHTS16Z160600014
NO
Proceed to 10.
YES
Replace all the CAN harness in case that either or both continu-
ities between terminals "CA2L" and "+24V", "GND".
10. CONFIRM THE FAILURE ECU.

(1) Unplug the connectors of each ECU in turn, when the DTC code about CAN communication goes out, replace the
corresponding ECU.
.
11. INSPECTION AFTER CORRECTION OF CAN COMMUNICATION LINE

(1) After completing repair of CAN communication line, run a test and verify that any failure does not occur.
(2) When any abnormal condition occurs again in the CAN communication line, inspect CAN communication line again.
2A&0AA*#.8A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧤ᤨ㧟㧤ಽ
OTHERS (HEADLIGHT AUTOLEVELING) DN06–1
OTHERS DN 06
(HEADLIGHT AUTOLEVELING)
DN06
DN06-002
HEADLIGHT AUTOLEVELING .................DN06-2

OVERVIEW ..................................................... DN06-2
COMPONENT LOCATOR ............................... DN06-4
WRITING-IN OF CONTROLLED CONSTANT FOR
AUTOLEVELING ECU..................................... DN06-7
FRONT VEHICLE HEIGHT SENSOR .......DN06-9

COMPONENT LOCATOR ............................... DN06-9
OVERHAUL ................................................... DN06-11
ADJUSTMENT OF LINK ROD....................... DN06-12
REAR VEHICLE HEIGHT SENSOR .......DN06-13

COMPONENT LOCATOR ............................. DN06-13
REPLACEMENT ............................................ DN06-15
ADJUSTMENT OF LINK ROD....................... DN06-16
FAILURE DIAGNOSIS ............................DN06-17

HANDLING PRECAUTIONS ......................... DN06-17
ARRANGEMENT OF CONNECTOR PIN...... DN06-18
NON-OPERATION
(WARNING LIGHT DISPLAY) ....................... DN06-19
NON-OPERATION
(WARNING LIGHT NOT LIT)......................... DN06-25
OPERATING (OCASIONALLY
WARNING LIGHT LIGHTING)....................... DN06-29
FREQUENTLY OPERATING WHILE DRIVING
(WARNING LIGHT GOES OFF) .................... DN06-31
INITIAL SETTING NOT PISSIBLE
(NO INITIAL SETTING YET: WARNING LIGHT
FLASHING 2 TIMES. INITIAL SETTING DONE ONLY
ONE TIME: WARNING LIGHT "OFF".).......... DN06-32
"CONSTANT" CAN NOT BE WRITTEN IN
(WARNING LIGHT TURN OFF) .................... DN06-34
DN06–2 OTHERS (HEADLIGHT AUTOLEVELING)
HEADLIGHT AUTOLEVELING
OVERVIEW
EN16Z1606C100001
FUNCTION
• Headlight autoleveling is a system which will be installed on models with discharge headlights, with which the upper
or lower direction of the light axis will be ensured at a given level, regardless of vehicle posture change to be influ-
enced by the loading condition on the rear body.
• The system will not only assure excellent visibility at night time, but will also prevent dazzling ray being shone against
vehicle running ahead or oncoming vehicle.
SYSTEM
• Vehicle speed signal to be output by the speed sensor as well as vehicle height signal to be output by the vehicle
height sensors installed on the LH front and LH rear wheels of the vehicle are inputted into the autoleveling ECU.
• The ECU will control the light axis of the headlight by computing a change of pitch angle of the vehicle posture with
these signals and also wheelbase information memorized in the ECU, and by activating headlight actuator to respond
against changing amount of the vehicle posture.
Autoleveling ECU
1. Vehicle stopping=Judgement for stop or run.

Vehicle speed sensor
2. Vehicle running=Judement for acceleration
or deceleration.
Input vehicle speed pulse
signal into ECU.
Headlight
Headlight relay Judgement for Judgement for actuator
ON/OFF operation (IG-ON on operation
Input of headlight on/off while Vehicle stopping or
signal. driving at a constant speed.)
Fr. Vehicle height sensor
Computation
Input of Fr.vehicle height Actuator LH
for vehicle
signal.
posture.
Rr.vehicle height sensor Voltage output indicated
by actuator operation.
Input of Rr.vehicle height
signal.
Actuator RH
Initial setting tool Memory of vehicle
height sensor value Voltage output indicated
Input of initial setting by actuator operation.
(0 point adjustment) signal
DC/DC converter Indicator for adjusting

Failed judgement
High intensity discharge
Convertion of power light axis
voltage to 15 V.
Warning light indicated to
go on when judging failed
IG Power supply (24V)
one.
Interface ECU Constant for wheelbase
Hino-DX
SHTS16Z160600001
COMPUTATION FOR CHANGE AMOUNT OF VEHICLE POSTURE
Basic formula (Vacant vehicle = Vehicle posture 0 )
*CA of Fr. Vehicle height (mm) CA of Rr. Vehicle height (mm)

Vehicle posture (deg.) = tan 1
Wheelbase (mm)
*CA : Change amount
SHTS16Z160600002
PARAMETER FOR LIGHT AXIS ADJUSTMENT

• Light axis control will be done by always reading the vehicle posture change while the vehicle is stopping.
• The light axis control will not be done while the vehicle accelerated or decelerates on road and running on severe
roads. But, it will be done only once when the vehicle run at a constant speed between stop-run-stop to correct a
wrong recognition of the vehicle posture to be memorized, for example when the vehicle is running over the road
curb.
Vehicle status Starter key Headlight Remarks

Stopping ON Lighting Light axis always controlled.
Controlled only once when running at a
Running at constant
ON Lighting given speed after starting out from stop-
speed
ping.
Vehicle speed (km/h) Controlled only once while

running at constant speed.
Running at
constant speed 60km/h
Always controlled : vehicle stopping
Accelerated/
Decelerated
Not controlled : while accelerating/decelerating
Vehicle stopping 0km/h
SHTS16Z160600003
COMPONENT LOCATOR
EN16Z1606D100001
LOCATION OF COMPONENTS
AUTOLEVELING ECU VEHICLE SPEED SENSOR

INTERFACE ECU
DC/DC CONVERTER
REAR VEHICLE HEIGHT SENSOR
FRONT VEHICLE HEIGHT SENSOR
HEADLIGHT ACTUATOR
SHTS16Z160600004
AUTOLEVELING ECU
• Controls the autoleveling function.
• Controls the headlight actuator, by judging from the vehicle posture and running status with signals from the vehicle
height sensor and the speed sensor.
• Once the system failure is detected, the autoleveling warning light will turn on at the meter-panel.
SHTS16Z160600005
INTERFACE ECU
• For the autoleveling ECU, writing-in of the constant per vehicle model will be needed.
• The interface ECU will function between the autoleveling ECU and the writing-in tool (Hino-DX) as an interface when
writing the constant.
SHTS16Z160600006
HEADLIGHT ACTUATOR
• By activating the low-beam headlights the toward upper/lower directions with control signals from the autoleveling
ECU, light axis direction will be controlled.
HEADLIGHT ACTUATOR
SHTS16Z160600007
VEHICLE HEIGHT SENSOR (FRONT, REAR)

• By detecting the high/low height of the vehicle through the vehicle height sensor, installed at the front/rear part of the
vehicle, it will output the vehicle height change signal in the autoleveling ECU.
VEHICLE HEIGHT SENSOR VEHICLE HEIGHT

SENSOR
FRONT REAR
SHTS16Z160600008
VEHICLE SPEED SENSOR

• It is composed of a hole IC and permanent magnet, which is installed at the take-out mouth for speed meter cable of
transmission unit.
• It will detect the speed by signaling 8 pulses per one rotation of the drive axle.
• Vehicle speed sensor will be used commonly with the speed meter.
PULSE GENERATING PART
SHTS16Z160600009
DC/DC CONVERTER (24V→15V)

• It will supply the system with conversion of battery voltage of the vehicle.
SHTS16Z160600010
AUTOLEVELING WARNING LIGHT

• By a signal from the autoleveling ECU, the autoleveling warning light will turn on.
P
P
AUTOLEVELING WARNING LIGHT

SHTS16Z160600011
WRITING-IN OF CONTROLLED
CONSTANT FOR AUTOLEVELING ECU
EN16Z1606H200001
INTRODUCTION
1. INITIAL SETTING OF ECU (WRITING-IN OF CONROLLED

CONSTANT)
(1) Due to the fact that the vehicle posture may change by model, a
difference of installing rear body, etc., (Due to occurring of vehicu-
lar deviation during initial period), autoleveling ECU should be
corrected on the basis of the vehicle posture without any load on
the rear body, for which initial treatment (Writing-in of Controlled
constant) will be needed to be performed.
NOTICE
When changing the ECU, writing-in of controlled constant will be
needed
2. Hino-DX
(1) Writing-in of the controlled constant of autoleveling ECU should
be performed by Hino-DX.
To connect with the vehicle, an interface box (Hino Bowie) will be
needed.
SST: Interface Box (Hino-Bowie) (S0912-11040)
Cable between vehicle & Hino-Bowie (S0904-21220)
Diagnosis software:
Hino Diagnostic eXplorer (Hino-DX)
HINT
• Cable between Hino-Bowie & PC is packed in a set with the
SHTS16Z160600012 Hino Bowie. Use either for RS-232 or for USB.
• Read the manual, attached to the Hino-Bowie.
• Install the software of Hino Diagnostic eXplorer (Hino-DX) on
the PC unit. Refer to the manual attached to CD for installing
procedures.
CONNECTION OF HINO-DX AND WRITING-IN OF

CONTROLLED CONSTANT
1. CONNECTION OF HINO-DX.
(1) Connect the Hino Bowie with the trouble diagnosis connector,
located at the lower part of LH under the instrument panel of the
driver's seat.
(2) Connect Hino Bowie with the PC unit, on which the Hino DX is
installed.
(3) Turn the starter switch to "ON" position.
(4) Turn on the power of the PC to start up the Hino-DX.
TROUBLE DIAGNOSIS CONNECTOR
HINT
When using the Hino-Bowie, the power will come "ON" the
moment it is connected with the vehicle and the power light (Red)
SHTS16Z160600013 on Hino-Bowie unit will turn on.
2. PROCEDURE ON HOW TO WRITE-IN THE CONTROLLED

CONSTANT
(1) Select "File", "Operation by system", then "Headlight
autoleveling".
SHTS16Z160600014
(2) Select vehicle specifications with the appropriate vehicle type and
wheel-base code from the pull down menu. Refer to the vehicle
specification code chart that corresponds to the wheel-base
length (The wheel-base code corresponds to the wheel-base on
the production code), then click on "Over write" to set the variable
headlight projection angle.
NOTICE
• The correct vehicle specifications must be entered for the
system to function properly.
• Please note that the variable headlight projection angle also
SHTS16Z160600015
differs by the vehicle grade (with high intensity discharge
headlights).
(3) Click on "Read-out" to confirm the setting.
SHTS16Z160600016
FRONT VEHICLE HEIGHT SENSOR

COMPONENT LOCATOR
EN16Z1606D100002
MODEL: FD
SHTS16Z160600017
1 Link rod bracket 3 Vehicle height sensor bracket

2 Link rod 4 Vehicle height sensor

A 8-11 {82-112, 5.9-8.1} B 18-26 {184-244, 14-17}
MODELS: FG, GH
SHTS16Z160600018
1 Vehicle height sensor bracket 3 Link rod

2 Link rod bracket 4 Vehicle height sensor

A 8-11 {82-112, 5.9-8.1} B 18-26 {184-244, 14-17}
OVERHAUL
EN16Z1606H200002
NOTICE
When changing and adjusting a front vehicle height sensor (Sen-
sor itself, Dimension relating to Link Rod), make sure to write in
"Controlled constant".
Refer to "WRITING-IN OF CONTROLLED CONSTANT FOR
AUTOLEVELING ECU".
REMOVAL OF FRONT VEHICLE HEIGHT SENSOR

1. REMOVAL OF FRONT VEHICLE HEIGHT SENSOR.
LEVER
(1) Remove off the link rod from link rod bracket by unscrewing the
nut.
(2) Separate the connector out of the vehicle height sensor.
(3) Remove the harness clamp from the vehicle height sensor.
(4) With unscrewing the bolt, remove the vehicle height sensor
assembly out of the vehicle height sensor bracket.
VEHICLE HEIGHT NOTICE
SENSOR LINK ROD Do not separate the vehicle height sensor from the lever.
SHTS16Z160600019 HINT
Replace the vehicle height sensor in every 4 years with a new one.
HOW TO INSTALL FRONT VEHICLE HEIGHT SEN-

(REPRESENTATIVE TYPE) SOR
LEVER
1. HOW TO INSTALL THE FRONT VEHICLE HEIGHT SENSOR
(1) Tighten the bolt after installing the vehicle height sensor on the
vehicle height sensor bracket.
Tightening Torque:
8-11 N⋅m {82-112 kgf⋅cm, 5.9-8.1 lbf⋅ft}
VEHICLE HEIGHT (2) Connect the connector with the vehicle height sensor.
SENSOR LINK ROD (3) Install the harness clamp on the vehicle height sensor bracket.
SHTS16Z160600020 (4) Perform "LENGTH ADJUSTMENT OF THE LINK ROD"
described in next page.
(5) Installing the link rod on the link rod bracket, tighten the nut.
Tightening Torque:
18-26 N⋅m {184-244 kgf⋅cm, 14-17 lbf⋅ft}
ADJUSTMENT OF LINK ROD

EN16Z1606H200003
1. LENGTH ADJUSTMENT OF LINK ROD.

(1) Adjust Length "L" of link rod to the standard value.
Model Length "L" of link rod (mm {in.})
FD 140 {5.5}
FG, GH 170 {6.7}
MODEL: FD
VEHICLE HEIGHT
SENSOR
LINK ROD
SHTS16Z160600021
MODELS: FG, GH
LINK ROD
VEHICLE HEIGHT
SENSOR
SHTS16Z160600022
REAR VEHICLE HEIGHT SENSOR

COMPONENT LOCATOR
EN16Z1606D100003
MODEL: FD
SHTS16Z160600023
1 Vehicle height sensor bracket 4 Vehicle height sensor harness

3 Link rod

A 8-11 {82-112, 5.9-8.1} B 18-26 {184-244, 14-17}
MODELS: FG, GH
SHTS16Z160600024
1 Vehicle height sensor bracket 3 Link rod


A 8-11 {82-112, 5.9-8.1} B 18-26 {184-244, 14-17}
REPLACEMENT
EN16Z1606H200004
REMOVAL OF REAR VHEHICLE HEIGHT SENSOR

1. REMOVAL OF REAR VHEHICLE HEIGHT SENSOR
LINK ROD (1) By unscrewing the nut, remove the link rod out of the link rod
bracket.
(2) Disconnect the connector from the vehicle sensor
(3) Remove the harness clamp out of the vehicle height sensor.
LEVER (4) Unscrewing the bolt, remove off the vehicle height sensor assem-
bly from the vehicle height sensor bracket.
NOTICE
VEHICLE HEIGHT SENSOR Do not separate the vehicle height sensor from the lever.
SHTS16Z160600025 HINT
Replace the vehicle sensor in every 4 years with a new one.
INSTALLATION OF REAR VEHICLE HEIGHT SEN-

SOR
LINK ROD 1. INSTALLATION OF REAR VEHICLE HEIGHT SENSOR
(1) Tighten the bolt after installing the vehicle height sensor assembly
on the vehicle height sensor bracket.
Tightening Torque:
LEVER 8-11 N⋅m {82-112 kgf⋅cm, 5.9-8.1 lbf⋅ft}
(2) Connect the connector with the vehicle height sensor.

VEHICLE HEIGHT SENSOR (3) Install the harness clamp on the vehicle height sensor bracket.
SHTS16Z160600026 (4) Perform "LENGTH ADJUSTMENT OF THE LINK ROD"
described in the next page.
(5) Tighten the nut after installing the link rod on the link rod bracket.
Tightening Torque:
18-26 N⋅m {84-244 kgf⋅cm, 14-17 lbf⋅ft}
ADJUSTMENT OF LINK ROD

EN16Z1606H200005
1. LENGTH ADJUSTMENT OF LINK ROD.

(1) Length adjustment of link rod to standard value.
Model Length "L" of Link Rod (mm {in.})
FD 160 {6.3}
FG, GH 150 {5.9}
MODEL: FD
LINK ROD
VEHICLE HEIGHT SENSOR

SHTS16Z160600027
MODELS: FG, GH
LINK ROD
VEHICLE HEIGHT SENSOR
SHTS16Z160600028
FAILURE DIAGNOSIS
EN16Z1606F200001
1. ABOUT CONNECTORS
(1) When vehicle placed on speed meter tester, or jacked up to rotate
the tires, there is a case that ECU memorize failure code. But, this
is not abnormal. Clear the failure code on ECU in any case of hav-
ing done that type of maintenance service.
(2) Before performing an inspection work, check that each connector
is surely connected.
(3) When taking off connector, do it without fail at the "LOCK" position
of starter key.
(4) Any parts presumed to be abnormal should not be repaired, but
change it.
(5) After clearing the failure memories recorded in the past, perform
SHTS16Z160600029
failure diagnosis again and check the current failure.
(6) After completing the diagnosis analysis, clear the diagnosis mem-
ories in the past.
(7) Unless otherwise specified, the drawing of connector is one
viewed from connected surface. But, test bar should be inserted
from back side for measuring.
However, check the terminals at the connected part of such water
proof connectors as ABS actuator, etc. In this case, be careful not
to short the terminals.
Reference
SHTS16Z160600030
Reference:
zontally).

damage.
age data.
.

EN16Z1606F200002
AUTOLEVELING ECU
22 pin connector
VIEW
CHASSIS HARNESS
SHTS16Z160600032
No. Code Signal No. Code Signal
1 IG Power 12 E1 Ground
2 LH1 Left/Right actuator power 13 LH3 Left/Right actuator ground
3 — — 14 — —
4 LH2 Left actuator signal 15 RH2 Right actuator signal
5 WNG Warning light 16 INIT Diagnostic connector
6 — — 17 — —
7 SPDR Vehicle speed sensor signal 18 HDLP Headlight signal
8 TX Serial communication TX 19 RX Serial communication RX
9 SGR Rear vehicle height sensor ground 20 SGF Front vehicle height sensor ground
10 SHR Rear vehicle height sensor signal 21 SHF Front vehicle height sensor signal
11 SBR Rear vehicle height sensor power 22 SBF Front vehicle height sensor power
INTERFACE ECU
22 pin connector
VIEW
CHASSIS HARNESS
SHTS16Z160600033
No. Code Signal No. Code Signal
1 — — 12 — —
2 — — 13 — —
3 — — 14 — —
4 — — 15 — —
5 — — 16 — —
6 — — 17 — —
7 PCGD PC-ground 18 — —
8 RX-2 Diagnostic connector RX 19 TX-S Serial communication TX
9 TX-2 Diagnostic connector TX 20 RX-2 Serial communication RX
10 — — 21 — —
11 +12V Power 22 GND Ground

NON-OPERATION (WARNING LIGHT DISPLAY)

EN16Z1606F200003
1. ELECTRICAL CONTINUITY CHECK BETWEEN THE TERMI-

NALS.
BODY GROUND
(1) Set the starter switch to "LOCK" position, remove 22 pin connec-
tor of autolevelling ECU and front/rear vehicle height sensors.
(2) Check electrical continuity between 20th, 21st, 22nd terminals of
22 pin connector (Vehicle harness side) and body ground.
Standard: No electrical continuity.
SHTS16Z160600034
(3) Check electrical continuity between 9th, 10th, 11th terminals of 22

pin connector (Vehicle harness side) and body ground.
BODY GROUND
SHTS16Z160600035
NO
Short in the wire.
YES

NALS.
(1) Check electrical continuity between 20th, 21st, 22nd and 1st ter-
minals of 22 pin connector (Vehicle harness side).
SHTS16Z160600036
(2) Check electrical continuity between 9th, 10th, 11th and 1st termi-
nals of 22 pin connector (Vehicle harness side).
Standard: No electrical continuity
SHTS16Z160600037
NO
Short in the wire.
YES

NALS.
(1) Check electrical continuity between 22 pin connector (Vehicle har-
ness side) and each terminal of front/rear vehicle height sensor
connectors (Vehicle harness side).
NOTICE
There are cases that connector shapes are different from model.
ECU Front vehicle height sensor

20th terminal 2nd terminal
21st terminal 3rd terminal
SHTS16Z160600038
22nd terminal 1st terminal
ECU Rear vehicle height sensor

10th terminal 3rd terminal
11th terminal 1st terminal
Standard: Electrical continuity
SHTS16Z160600039
.
NO
Short in the wire.
YES

(1) Connecting 22 pin connectors with front/rear vehicle height sen-
BODY GROUND sor connectors, Set the starter switch to "ON" position.
(2) Check voltage between 22nd terminal of 22 pin connector (Vehi-
cle harness side) and body ground.
Standard value: 4.5-5.5V
NOTICE
Connector in the drawing is a view from mating face.
SHTS16Z160600040
(3) Check voltage between 22nd terminal of 11 pin connector (Vehi-

BODY GROUND cle harness side) and body ground.
Standard value: 4.5-5.5V
NOTICE
SHTS16Z160600041
(4) Remove link rod out of the lever of front/rear vehicle height sen-
(REPRESENTATIVE TYPE) sors.
LEVER
LINK ROD
SHTS16Z160600042
(5) Checking voltage between 21st and 20th terminals of 22 pin con-
nector (Vehicle harness side), check voltage change when operat-
ing the lever at low/high position.
Standard: As shown in the figure, voltage should change.
NOTICE
SHTS16Z160600043
Vehicle height
goes down.
Vehicle height
goes up.
4.5
Output voltage
2.5
0.5
(V) 50 Std. vehicle 50
height position
Vehicle height Vehicle height
going down Shaft rotation angle ( ) going up
direction direction
Electrical operation range
SHTS16Z160600044
(6) Checking voltage between 10th and 9th terminals of 22 pin con-
nector (Vehicle harness side), Check voltage change when oper-
ating the lever at low/high position.
Standard: As shown in the Figure, voltage should change.
NOTICE
SHTS16Z160600045
Vehicle height
goes down.
Vehicle height
goes up.
4.5
Output voltage
2.5
0.5
50 Std. vehicle 50
(V) height position
direction Electrical operation range direction
SHTS16Z160600046
.
NO
Abnormality of vehicle height sensor.
YES

NALS.
BODY GROUND
(1) Set the starter switch to "LOCK" position, remove 22 pin connec-
tor of autolevelling ECU and right/left Headlight leveling actuator.
(2) Check electrical continuity between 2nd, 13th terminals of 22 pin
connector (Vehicle harness side) and body ground.
SHTS16Z160600047
(3) Check electrical continuity between 4th, 15th terminals of 22 pin

connector (Vehicle harness side) and body ground.
BODY GROUND
SHTS16Z160600048
NO
Short in the wire.
YES

NALS.
(1) Check electrical continuity between 2nd, 13th and 1st terminals of
22 pin connector (Vehicle harness side).
SHTS16Z160600049
(2) Check electrical continuity between 4th, 15th and 1st terminals of
22 pin connector (Vehicle harness side).
SHTS16Z160600050
NO
Short in the wire.
YES

NALS.
ness side) and each terminal of right/left Headlight leveling actua-
tor connectors (Vehicle harness side).
ECU Right actuator

2nd terminal 3rd terminal
AUTOLEVELING 15th terminal 2nd terminal
ECU
SHTS16Z160600051
ECU Left actuator

Standard: Electrical continuity

AUTOLEVELING
ECU
SHTS16Z160600052
.
NO
Short in the wire.
YES
8. CHECK FOR ONLY LEVELLING ACTUATOR.

(1) Connecting 3rd terminal of levelling actuator connector (Part side)
with (+) terminal of 12V power supply, connect 1st terminal with (-)
2.4 - 9.6V
one.
(2) Check the actuator operation when the voltage changing within a
range where voltage by 20-80% (2.4-9.6V) of electrical power
2 supply is connected with 2nd terminal.
Standard: Operating correctly
12V 3 1
SHTS16Z160600053
NO
Failure in Headlight levelling actuator.
YES
Abnormality of Autolevelling ECU.
.
NON-OPERATION (WARNING LIGHT NOT LIT)

EN16Z1606F200004

AOTOLEVELING ECU NALS.
BODY GROUND (1) Set the starter switch to "LOCK" position, remove 22 pin connec-
tor of autolevelling ECU and DC/DC converter connector (for
Headlight leveling).
(2) Check electrical continuity between 1st, 12th terminals of 22 pin
connector (Vehicle harness side) of autoleveling ECU and body
ground.
SHTS16Z160600054
NO
Short in the wire.
YES

AUTOLEVELING ECU NALS.
(1) Check electrical continuity between 1st and 12th terminals of 22
pin connector (Vehicle harness side) of autoleveling ECU.
SHTS16Z160600055
NO
Short in the wire.
YES

NALS.
AUTOLEVELING ECU ness side) of autoleveling ECU and each terminal of DC/DC con-
verter connector (Vehicle harness side).
ECU DC/DC converter

1st terminal 2nd terminal
12th terminal 3rd terminal
Standard: Electrical continuity.

SHTS16Z160600056
.
NO
Short in the wire.
YES
4. VOLTAGE CHECK BETWEEN THE TERMINALS.

AUTOLEVELING ECU (1) Set the starter switch to "ON" position, check electrical continuity
BODY GROUND between 1st terminal of 22 pin connector (Vehicle harness side)
of autoleveling ECU and body ground.
Standard: 14-16V
SHTS16Z160600057
NO
Abnormality of DC/DC convertor or short in the
wire.
YES

AUTOLEVELING ECU (1) Turning Headlight switch "ON", check input voltage between 18th
BODY GROUND terminal of 22 pin connector (Vehicle harness side) of autoleveling
ECU and body ground.
Standard value: 24V
SHTS16Z160600058
NO
Failure in signal system of Headlight.
(Such as Harness disconnected)
YES

BODY GROUND (1) Set the starter switch to "LOCK" position, remove right/left head-
light leveling actuator connectors.
(2) Check electrical continuity between 2nd, 13th terminals of 22 pin
connector (Vehicle harness side) of autoleveling ECU and body
ground.
SHTS16Z160600059
(3) Check electrical continuity between 4th, 15th terminals of 22 pin

AUTOLEVELING ECU connector (Vehicle harness side) of autoleveling ECU and body
BODY GROUND ground.
SHTS16Z160600060
NO
Short in the wire.
YES

(1) Check electrical continuity between 2nd, 13th and 1st terminals of
22 pin connector (Vehicle harness side) of autoleveling ECU.
SHTS16Z160600061
(2) Check electrical continuity between 4th, 15th and 1st terminals of
AUTOLEVELING ECU 22 pin connector (Vehicle harness side) of autoleveling ECU.
SHTS16Z160600062
NO
Short in the wire.
YES

NALS.
ness side) of autoleveling ECU and each terminal of right/left
headlight leveling actuator connectors (Vehicle harness side).
ECU Right actuator

AUTOLEVELING 15th terminal 2nd terminal
ECU
SHTS16Z160600063
ECU Left actuator

AUTOLEVELING
ECU
SHTS16Z160600064
.
NO
Short in the wire.
YES
9. CHECK FOR ONLY LEVELLING ACTUATOR.

(1) Connecting 3rd terminal of levelling actuator connector (Part side)
with (+) terminal of 12V power supply, connect 1st terminal with (-)
2.4 - 9.6V
one.
(2) Check the actuator operation when the voltage changing within a
range where voltage by 20-80% (2.4-9.6V) of electrical power
2 supply is connected with 2nd terminal.
Standard: Operating correctly
12V 3 1
SHTS16Z160600065
NO
Failure in Headlight levelling actuator.
YES
Abnormality of Autolevelling ECU.
.
OPERATING (OCASIONALLY WARNING LIGHT LIGHTING)

EN16Z1606F200005
1. VOLTAGE CHECK OF VEHICLE HEIGHT SENSOR

AUTOLEVELING ECU (1) Check any looseness in link rod of vehicle height sensor.
BODY GROUND (2) Set the starter switch to "ON" position, measure the voltage
between 22th terminal of 22 pin connector (Vehicle harness side)
of autoleveling ECU and body ground.
Standard: 4.5-5.5V
NOTICE
SHTS16Z160600066
(3) Measure the voltage between 11th terminal of 22 pin connector

AUTOLEVELING ECU (Vehicle harness side) of autoleveling ECU and body ground.
BODY GROUND
Standard: 4.5-5.5V
NOTICE
(4) Remove link rod out of the lever of front/rear vehicle height sen-
sors.
SHTS16Z160600067
(5) Checking voltage between 21st and 20th terminals of 22 pin con-
AUTOLEVELING ECU nector (Vehicle harness side) of autoleveling ECU, check voltage
change when operating the lever at low/high position.
Standard: As shown in the Figure, voltage should change.
NOTICE
SHTS16Z160600068
Vehicle height
goes down.
Vehicle height
goes up.
4.5
Output voltage
2.5
0.5
(V) 50 0 (Std. vehicle 50
height position)
direction direction
Electrical operation range
SHTS16Z160600069
(6) Checking voltage between 10th and 9th terminals of 22 pin con-
nector (Vehicle harness side) of autoleveling ECU, check voltage
AUTOLEVELING ECU
change when operating the lever at low/high position.
Standard: As shown in the figure, voltage should change.
NOTICE
SHTS16Z160600070
Vehicle height
goes down.
Vehicle height
goes up.
4.5
Output voltage
2.5
0.5
50 0 (Std. vehicle 50
(V) height position)
direction Electrical operation range direction
SHTS16Z160600071
.
NO
YES
Abnormality of autoleveling ECU.
.
FREQUENTLY OPERATING WHILE DRIVING

(WARNING LIGHT GOES OFF)
EN16Z1606F200006

tor of autolevelling ECU and vehicle speed sensor connector.
(2) Check electrical continuity between 7th terminal of 22 pin connec-
tor (Vehicle harness side) of autoleveling ECU and body ground.
SHTS16Z160600072
NO
Short in the wire.
YES

(1) Check electrical continuity between 1st and 7th terminals of 22
pin connector (Vehicle harness side) of autoleveling ECU.
SHTS16Z160600073
NO
Short in the wire.
YES
3. WAVE FORM CHECK OF VEHICLE SPEED SENSOR IN

AUTOLEVELING AUTOLEVELLING ECU.
ECU (1) Connect 22 pin connector of autolevelling ECU and the vehicle
speed sensor connector.
(2) Connect 7th and 12th terminals of 22 pin connector with oscillo-
OSCILLOSCOPE
scope (Voltage axis: 5V-DIV, Time axis: 20msec/DIV).
(3) Starting Engine, you drive out the vehicle slowly with a careful
attention to around the vehicle and check an output of signal wave
form.
Standard: Wave form is output.
NOTICE
SHTS16Z160600074 Connector in the drawing is a view from mating face.
.
NO
Failure in vehicle speed sensor system.
YES
Abnormality of autoleveling ECU.

INITIAL SETTING NOT PISSIBLE (NO INITIAL SETTING YET:

WARNING LIGHT FLASHING 2 TIMES. INITIAL SETTING DONE ONLY
ONE TIME: WARNING LIGHT "OFF".)
EN16Z1606F200007
1. INITITIAL SETTING CONDUCT AGAIN.

(1) Starting Engine, with a much careful attention to around the vehi-
cle, you can slowly move ahead or back the vehicle.
(2) Initial setting operation should be performed again after stopping
the vehicle.
Standard: Correct finish of initial setting operation.
.
NO
Go to the item 2.
YES
Normal.
2. OPERATION CHECK
(1) Check all items (Warning light to be on/off) that are not operating.
Standard: No abnormality.
SHTS16Z160600075
NO
Correction of all abnormal items.
YES
3. OUTPUT VOLTAGE CHECK OF VEHICLE HEIGHT SENSOR.

(1) Set the starter switch to "ON" position.
AUTOLEVELING ECU (2) Check the voltage between 21st and 20th terminals of 22 pin con-
nector (Vehicle harness side) of autolevelling ECU. (Do it under
no load on the body)
NOTICE
Connector in the Figure is a view from mating face.
SHTS16Z160600076
(3) Check voltage between 10th and 9th terminals of 22 pin connec-
tor (Vehicle harness side) of autoleveling ECU. (Do it under no
load on the body)
AUTOLEVELING ECU
HINT
When initial setting performed while not within the range of volt-
age, it will flash 2 times even when initial setting performed and
warning light turn off.
NOTICE
SHTS16Z160600077
NO
YES
4. WAVE FORM CHECK OF VEHICLE SPEED SENSOR OF

AUTOLEVELING AUTOLEVELLING ECU.
ECU (1) Set the starter switch to "LOCK" position, connect 7th and 12th
terminals of 22 pin connector of autolevelling ECU with Oscillo-
scope (Voltage axis: 5V-DIV, Time axis: 20msec/DIV).
OSCILLOSCOPE
(2) Check output of signal wave form under the vehicle stopping con-
dition.
Standard: No wave form.
SHTS16Z160600078
NO
Failure in vehicle speed sensor system.
YES
Failure in autolevelling ECU or in any initial setting tool.
.
"CONSTANT" CAN NOT BE WRITTEN IN

(WARNING LIGHT TURN OFF)
EN16Z1606F200008
1. LIGHTING CHECK OF WARNING LIGHT.

(1) Check whether warning light turn off or flashes (when initial set-
ting not yet done) just after warning light lighting for 3 sec.
.
NO
No power is supplied to autolevelling ECU
(Connector is not connected. Harness is dis-
connected due to broken DC/DC converter or
YES
no electrical power) or failure in autolevelling
ECU.

INTERFACE ECU (1) Set the starter switch to "LOCK" position, remove 22 pin connec-
BODY GROUND tor of interface ECU.
(2) Turn the starter switch to "ON" position, measure the voltage
between 11th terminal of 22 pin connector (Vehicle harness side)
of interface ECU and body ground.
Standard: 14-16V
NOTICE
SHTS16Z160600079
NO
Failure in DC/DC converter for autoleveling or
malfunction of harness.
YES

tor of autoleveling ECU.
(2) Check electrical continuity between 8th, 19th of 22 pin connector
(Vehicle harness side) of autoleveling ECU and body ground.
SHTS16Z160600080
NO
Short in the wire.
YES

(1) Check electrical continuity between 8th, 19th and 1st of 22 pin
connector (Vehicle harness side) of autoleveling ECU.
SHTS16Z160600081
NO
Short in the wire.
YES

INTERFACE ECU NALS.
BODY GROUND (1) Check electrical continuity between 8th, 9th of 22 pin connector
(Vehicle harness side) of interface ECU and body ground.
SHTS16Z160600082
NO
Short in the wire.
YES

INTERFACE ECU NALS.
(1) Check electrical continuity between 8th, 9th and 11th of 22 pin
connector (Vehicle harness side) of interface ECU.
SHTS16Z160600083
NO
Short in the wire.
YES
Failure in interface ECU. When not improved regardless of

changing Interface ECU, replace autolevelling ECU with a new
one.
.
%1.12*10HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧠㧥ಽ
Pub. No. S1-YFCE18A 2/2 ’06-9

S1-YFCE18B 2/2 ’06-11
%1.12*10HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧠㧥ಽ

S1 - YFCE18B - 2 (Chassis Vol 2 Euro 2)

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

S1 - YFCE18B - 2 (Chassis Vol 2 Euro 2)

Uploaded by

Copyright:

Available Formats

(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧡ಽ

Manual Name Pub. No.

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

MANUAL NO. S1-YFCE18B 2/2

EXHAUST BRAKE BR05-001

RETARDER BRAKE BR06-001

STEERING EQUIPMENT SR01-001

STEERING UNIT SR02-001

POWER STEERING SR03-001

AX02-001 AX02-002 AX02-003 AX02-004 AX02-005 AX02-006

AX03-001 AX03-002 AX03-003 AX03-004 AX03-005

WHEEL AND TIRE AX04-001

CHASSIS FRAME FC02-001

ELECTRICAL EQUIPMENT EL01-001

INDEX: CHASSIS GROUP 1/3

WORKSHOP STEERING EQUIPMENT

WHEEL & TIRE

COUPLER (5TH WHEEL)

All rights reserved. This manual may not be

INDEX: CHASSIS GROUP 2/3

INDEX: CHASSIS GROUP 3/3

CAB EQUIPMENT CONTROL

EXHAUST BRAKE BR05–1

EXHAUST BRAKE SYSTEM ....................BR05-2

BRAKE CYLINDER (MODEL: FM2P) ......BR05-9

BR05–2 EXHAUST BRAKE

EXHAUST BRAKE SYSTEM

1 Clutch switch 5 Magnetic valve

EXHAUST BRAKE BR05–3

Symptom Possible cause Remedy/Prevention

ACCELERATOR SWITCH ADJUSTMENT

(3) Adjust the accelerator switch position if it is out of position.

CLUTCH PEDAL SWITCH ADJUSTMENT

BR05–4 EXHAUST BRAKE

BRAKE CYLINDER (MODELS: EXCEPT FOR FM2P)

Type Butterfly valve

1 Blind plate 5 Seal ring

EXHAUST BRAKE BR05–5

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

BR05–6 EXHAUST BRAKE

IMPORTANT POINT - DISMOUNTING

IMPORTANT POINTS - ASSEMBLY

1. INSTALLATION OF THE PLATE

2. INSTALLATION OF THE SEAL RINGS

3. INSTALLATION OF THE VALVE

INSPECTION AND REPAIR

Inspection item Standard Limit Remedy Inspection procedure

Brake cylinder, bush- — — Replace, if necessary. Visual check

EXHAUST BRAKE BR05–7

1. CLOSE SIDE ADJUSTMENT

Limit: B = 0.1 mm {0.0039 in.}

2. OPEN SIDE ADJUSTMENT

BR05–8 EXHAUST BRAKE

BRAKE CYLINDER (MODEL: FM2P)

Brake cylinder Slide valve

1 Valve 9 Piston rod 17 Poppet valve

EXHAUST BRAKE BR05–9

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

BR05–10 EXHAUST BRAKE

IMPORTANT POINT - DISMOUNTING

IMPORTANT POINT - DISASSEMBLY

1. DISASSEMBLE THE BRAKE CYLINDER.

(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧡ಽ