Service Manual

Service Manual
Internal Combustion Forklift

1D1 / 1D2
INTRODUCTION
This service manual has been prepared to provide necessary information concerning the maintenance and repair
procedures for the 1D1 & 1D2 forklift series (for model codes refer to GI section of this manual).
Any changes effected in the series after publication of this service manual will be announced in a technical bulletin. It is,
therefore, recommended that each relevant technical bulletin be inserted in front of each section and be used together with
the service manual as a reference.
If a new model requires different service method or has undergone a major change, revised sections will be issued to
replace the applicable sections. Each revised section will include the description of how to service the parts for the former
specifications. The publication of a revised section will be announced in the technical bulletin.
This service manual consists of Sixteen sections as shown in the following table, which gives the updated symbols. When
a revised service manual is issued, this ‘‘INTRODUCTION” sheet should be replaced with a revised one.
Section Symbol
GENERAL INFORMATION (GI)
MAINTENANCE (MA)
ENGINE REMOVAL (ER)
AUTOMATIC TRANSMISSION (AT)
DIFFERENTIAL CARRIER (DA)
DRIVE AXLE (DA)
STEERING AXLE (SA)
ROAD WHEEL & TIRE (RT)
BRAKE SYSTEM (BR)
STEERING SYSTEM (ST)
HYDRAULIC SYSTEM (HD)
LOADING MECHANISM (LM)
FUEL & EXHAUST SYSTEMS (FE)
VEHICLE CONTROL SYSTEMS (VC)
BODY & FRAME (BF)
BODY ELECTRICAL SYSTEM (BE)
Edition: August 2019

Publication: SM19GB-01D12Q0
0-0
FOREWORD
This manual contains maintenance and repair procedures.
In order to assure your safety and the efficient functioning of the lift truck, this manual should be
read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely
understood before starting any repair task.
All information in this manual is based on the latest product information at the time of publication.
The right is reserved to make changes in specifications and methods at any time without notice.
IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the technician and the efficient
functioning of the lift truck.
The service methods in this Service Manual are described in such a manner that the service may be
performed safety and accurately.
Service varies with the procedures used, the skills of the technician and the tools and parts available.
Accordingly, anyone using service procedures, tools or parts which are not specifically recommended
by the manufacturer must first completely satisfy himself that neither his safety nor the lift truck’s
safety will be jeopardized by the service method selected.
No modifications or alterations to a powered industrial truck, which may affect, for example,
capacity, stability or safety requirements of the truck shall be made without the prior written
approval of the manufacturer , its authorized representative, or a successor thereof. Contact one of
our authorized dealers before making any modification or alteration to your industrial truck that
may affect, for example braking, steering, visibility and the addition of removable attachments.
After getting approval of the manufacturer , its authorized representative, or a successor thereof,
capacity plate, decals tags and operation and maintenance handbooks shall also be changed to the
appropriate one. Only in the event that the manufacturer is no longer in business and there is no
successor in the interest to the business, the user may arrange for a modification or alteration to a
powered industrial truck, provided, however, that the user shall:
A. Arrange for the modification or alteration to be designed, tested and implemented by an

engineer(s) expert in industrial trucks and their safety;
B. Maintain a permanent record of the design, test(s) and implementation of the modification or
alteration;
C. Approve and make appropriate changes to the capacity plate(s), decals, tags and Instruction
Handbook;
D. Affix a permanent and readily visible label to the truck stating the manner in which the truck
has been modified or altered together with the date of the modification or alteration, and the
name and address of the organization that accomplished the tasks.
© 2018 UniCarriers
GENERAL INFORMATION
SECTION GI
CONTENTS
HOW TO USE THIS MANUAL ............................GI-2 Precaution .................................................... GI-10
Outline Of This Manual ...................................GI-2 Jacking ......................................................... GI-10
Description .....................................................GI-2 Lifting Points ................................................. GI-12
Technical Term Definitions .............................GI-3 Lifting Up Forklift Truck ................................ GI-14
Manual Illustrations ........................................GI-5 TOWING ............................................................ GI-15
IDENTIFICATION INFORMATION .....................GI-6 TIGHTENING TORQUE OF STANDARD
Forklift Model Classification Number ..............GI-6 BOLTS .............................................................. GI-16
IDENTIFICATION ................................................GI-7 Tightening Torque ........................................ GI-16
Identification numbers ....................................GI-7 ABBREVIATION LIST ...................................... GI-17
GENERAL PRECAUTIONS ................................GI-8
General precautions .......................................GI-8
JACKING AND LIFTING ...................................GI-10
HOW TO USE THIS MANUAL
Outline Of This Manual

Symbol Section title Topics
Outline of This Manual, Description, Technical Term Definitions, Manual

GI GENERAL INFORMATION Illustrations, Prefix and Suffix Designations, Identification Numbers, General
Precautions, Basic Operations, Tightening Torque
Lubrication Chart, Maintenance Schedule, Engine Maintenance, Chassis and

MA MAINTENANCE
Body Maintenance
ER ENGINE REMOVAL Removal and Installation
Construction, Removal and Installation, Disassembly and Assembly, Control Valve,

AT AUTOMATIC TRANSMISSION
Input Shaft Assembly, Pump Assembly, Inspection and Adjustment
DF DIFFERENTIAL CARRIER Differential Carrier, Adjustment
DA DRIVE AXLE Construction, Removal and Installation, Disassembly and Assembly
Description, Specification, Trouble Diagnosis and Corrections, Removal and

SA STEERING AXLE Installation, Disassembly and Assembly, Hub, Kingpin, Steering Axle Component
Parts Location, Spindle Details, Service Data and Specifications (SDS)
RT ROAD WHEELS & TIRES Specification, Type of Tire, Application of Hub, Inspection, Installation
Construction, Disassembly and Assembly, Inspection and Adjustment,

BR BRAKE SYSTEM
Troubleshooting, Service Data and Specifications (SDS), Parking Brake
Description, Specification, Trouble Diagnosis and Corrections, Steering Wheel,

ST STEERING SYSTEM
Steering Column, PS Valve, PS Cylinder, Piping
Specification, Service Data and Specifications (SDS), Trouble Diagnosis,

HD HYDRAULIC SYSTEM Precautions, Hydraulic Piping, Oil Pump, Control Valve, Lift (Mast) Cylinder, Tilt
Cylinder, Replacement of Hydraulic Fluid, Hydraulic Piping
Service Data and Specifications (SDS), Trouble Diagnosis, Precautions, Fork, Lift
LM LOADING MECHANISM
Chain, Carriage Assembly, Mast Assembly, 3.5-ton Model Mast
Accelerator Wire, Accelerator Pedal, Fuel System, Exhaust System, LP Tank

FE FUEL & EXHAUST SYSTEMS
Swing Bracket
Vehicle Control System, VCM Setting, Selection of Forklift Specification, Storage

VC VEHICLE CONTROL SYSTEM of Settings, Functional Check, Trouble Diagnosis, VCM-1 Active Test, ECM Active
Test, Diagnosis History, Table of Alarm Code, Inspection
Service Data and Specifications (SDS), Counterweight, Frame, Instrument Frame,

BF BODY & FRAME
Undercover, Overhead Guard, Top Panel, Floor Board, Plastic Cover, Seat
Wire harness, Relay Box, Fuse Box, Combination Meter, Speedometer (Option),
BE BODY ELECTRICAL
Switches, Headlights, Others
Description
This manual contains the information on methods required to
perform appropriate maintenance. This main text describes removal,
disassembly, inspection, assembly, installation, and adjustment
procedures of units. Step-by-step descriptions or service points are
provided for these procedures. Illustrations, values, tightening
torques and SSTs are also provided as required.
GI-2
Technical Term Definitions

SPECIFIC TERMS
WARNING:
Warns you of instructions that must be followed to prevent
severe personal injury and/or fatal accident.
CAUTION:
Warns you of instructions that must be followed to prevent
personal injury and/or damage to some parts of the forklift.
NOTE:
Provides helpful information to perform a smooth and effective
service procedure.
Standard value or specifications:
The allowable range for a given measured value during inspection
and adjustment.
Limit value:
The maximum or minimum acceptable measured value during
inspection and adjustment.
LOCATING DIRECTIONS
The direction (front, rear, left, right, upper, lower) shown in this
manual shows the direction when sitting in the driver seat facing
frontward.
GI-3
Technical Term Definitions (Cont’d)

MEASURING UNITS AND VALUES
Specified torque, pressure, force and other values used in this
Manual are primarily expressed as the SI unit (International System
of Unit). The values following the SI unit and enclosed in
parentheses ( ) are expressed in the metric system and in the
yard/pound system.
Example:
Tightening torque:
9 - 12 N•m (0.9 - 1.2 kg-m, 6.5 - 8.7 ft-lb)
SI unit Metric system Yard/pound system
Main unit conversions:

Conversion
Yard/pound
SI unit Metric system factor to SI
system
unit
Torque and kg-m – 9.807

N•m
moment – ft-lb 1.356
kg – 9.807
Force N
– lb 4.448
kg/cm2 – 98.07
kPa
– psi 6.895
Pressure
2 – 0.0981
kg/cm
MPa
– psi 0.0069
NOTE:
Converting the unit in metric system or yard/pound system to SI unit
is shown below.
Unit in metric system or yard/pound system x conversion factor = SI
unit
GI-4
Manual Illustrations
EXPLODED VIEWS
These contain part names, tightening torques, lubrication points and other information necessary to perform
removal, disassembly, repair, reassembly and installation procedures. (See example below.)
BRT0005
Symbols used in exploded views
Symbol Meaning Symbol Meaning
Specified tightening torque is required for part

installation. When a torque range is given, use the Always replace after every disassembly.
average figure as the standard.
Should be lubricated with specified grease. Select parts of proper thickness.
Should be lubricated with oil. Adjustment is required.
Sealing point
GI-5
IDENTIFICATION INFORMATION
Forklift Model Classification Number

IDENTIFICATION INFORMATION
Explanation Model variation coding
U 1D2 A 25 L Q
DESTINATION
Q: Europe
FUEL TYPE
: Diesel engine
L: LPG
LOAD CAPACITY RATING
15: 1.5 Ton (3,000 lb) model
18: 1.75 Ton (3,500 lb) model
20: 2.0 Ton (4,000 lb) model
25: 2.5 Ton (5,000 lb) model
30: 3.0 Ton (6,000 lb) model
32: 3.2 Ton (6,400 lb) model
TRANSMISSION
A: Automatic transmission
FORKLIFTMODEL
1D1: 1 Ton series
1D2: 2 Ton series
WHEELBASE
: Standard wheelbase
G: Long wheelbase
ENGINE
P: K/GK21 Gasoline engine
U: K/GK25 Gasoline engine
Y: QD32 Diesel engine
TIRE
: Pneumatic tire model
NOTE: Means no indication.
Model Variation
ATLET TCM
Model Serial Number Model Serial Number
GL-15/18 P1D1E7xxxxx  P1D1E7xxxxx FGE15-E1
P1D1E7xxxxx  P1D1E7xxxxx
DL-15/18 Y1D1E7xxxxx  Y1D1E7xxxxx FGE18-E1
GL-20/25 U1D2E7xxxxx  U1D2E7xxxxx FD15-E1

Y1D1E7xxxxx  Y1D1E7xxxxx
FD18-E1
DL-20/25 Y1D2E7xxxxx  Y1D2E7xxxxx
FGE20-E
GL-30/32 UG1D2E7xxxxx  UG1D2E7xxxxx U1D2E7xxxxx  U1D2E7xxxxx
FGE25-E1
DL-30/32 YG1D2E7xxxxx  YG1D2E7xxxxx FD20-E
Y1D2E7xxxxx  Y1D2E7xxxxx
FD25-E1
UniCarriers FGE30-E
UG1D2E7xxxxx  UG1D2E7xxxxx
FGE32-E1
Model Serial Number
P1D1A15L/18L P1D1E7xxxxx  P1D1E7xxxxx FD30-E
YG1D2E7xxxxx  YG1D2E7xxxxx
FD32-E1
Y1D1A15/18 Y1D1E7xxxxx  Y1D1E7xxxxx
U1D2A20L/25L U1D2E7xxxxx  U1D2E7xxxxx
Y1D2A20/25 Y1D2E7xxxxx  Y1D2E7xxxxx
UG1D2A30L/32L UG1D2E7xxxxx  UG1D2E7xxxxx
YG1D2A30/32 YG1D2E7xxxxx  YG1D2E7xxxxx
GI-6
IDENTIFICATION
IDENTIFICATION
Identification numbers
GI-7
GENERAL PRECAUTIONS
GENERAL PRECAUTIONS
General precautions
Please read and thoroughly understand this section as well as the
reference "Precautions".
• Lifting and hoisting work should be performed by persons who
have completed slinging skills training or hoisting skills training.
• Make sure that the work area is well ventilated and free of
flammable materials.
• If work must be performed in an area having poor ventilation,
sufficiently ventilate the area ahead of time.
• When handling flammable or hazardous materials, take sufficient
steps to prevent the occurrence of a fire or disaster.
• Do not smoke when working.
• When working with hot parts, rotating parts, and sliding parts, be
careful not to get burned or injured.
• When working near a running engine, be careful not to touch
rotating or sliding parts.
• Each unit is heavy, so watch your footing when working.
• When performing maintenance, set the parking brake and turn the
ignition switch OFF.
• Electrical circuits can short, therefore, before disassembling and
inspecting, remove rings and other metal items from your body.
• Make an efficient repair by performing the diagnosis after
sufficiently understanding the symptoms of the malfunction. Then
after the work is completed, make sure that everything is working
properly.
• Before performing removal or disassembly work, be thoroughly
familiar with the properly assembled condition.
• When necessary, affix matching marks to parts that will not affect
performance.
• Before removing wiring, memorize the wire colors and wiring
conditions.
• When performing disassembly and inspection work, use the
specified tools or tools that are appropriate for the task.
• When performing disassembly and inspection work, use clean
tools. When a part has been removed, place it in a clean location.
• Organize removed parts in proper order so that they do not get
mixed up.
• Before removing piping and hoses that are under pressure,
release the pressure.
• Before removing the engine and counterweight, block the tires. Do
not jack up the forklift.
• Before inspecting or assembling parts that have been
disassembled, clean and wash them.
• Use the specified nuts and bolts, and tighten them to the specified
torque when assembling.
• After removing oil seals, gaskets, packing, O-rings, lock washers,
cotter pins, and self-locking nuts, replace them with new ones as
indicated in the relevant provisions (non-reusable parts). When
replacing a part, refer to the parts catalog and use the part that
has the same part number (genuine part).
• Replace inner and outer races of tapered or needle roller bearings
as a set.
• Use the specified lubricant and sealing agent.
• Do not allow brake fluid to adhere to the body and other painted
surfaces. If such fluid gets on a painted surface, quickly wipe it off
and wash with water.
• Do not reuse brake fluid that has been removed.
GI-8
GENERAL PRECAUTIONS
• After repairing the hydraulic or brake system, closely inspect for

leakage.
• Do not recklessly release waste oil following an oil change, or
treated oil used for parts. Dispose according to the method
established by law.
• Before performing maintenance, disconnect the battery ground
cable and battery positive (+) cable.
• If, with electronic control specifications, a part is to be welded to a
unit later on, disconnect both of the battery cables (+ and )
before welding. (This action prevents current from circling into the
ECM.)
PRECAUTIONS RELATED TO ELECTRICAL SYSTEM

INSPECTIONS
• Do not pry connectors when inserting or withdrawing them. Such
actions can cause poor contact.
• When withdrawing a connector, do not pull on the wire (cable)
itself.
• When conducting an inspection with a circuit tester, use the
correct range (A, V, ) and polarity (+, ).
• When the task is completed, reconfirm that the wiring is
connected in its original location.
PRECAUTIONS RELATED TO BATTERY HANDLING

WARNING:
• Keep sources of fire away from batteries.
• To keep from getting burned, do not allow battery fluid to get
on your skin or clothing.
• If a large amount of battery fluid spills or leaks out,
immediately neutralize it with a neutralizing agent (such as
baking soda, calcium hydroxide, or sodium carbonate) and
wash it away with a large amount of water.
• Do not leave tools or other metal objects on the battery,
because contact with a terminal can cause a short, burning
anyone nearby, or hydrogen gas emitted from the battery can
ignite and explode.
• If static electricity is produced, a battery can explode.
Therefore, do not wipe or dust off the battery's top surface or
terminal areas with a dry cloth or duster, and do not cover
with a vinyl cover. Use a damp cloth to clean the battery.
CAUTION:
• Leaking battery fluid can cause corrosion, therefore,
securely close the battery fluid cap.
• Do not allow a person to inspect a battery if that person does
not understand how to properly handle batteries.
GI-9
JACKING AND LIFTING
JACKING AND LIFTING
Precaution
CAUTION:
• Do not go under forks or a forklift when cargo handling gear
or travel gear is being operated during maintenance and
inspection work.
• Work on flat, level, hard surfaces.
• Be properly seated in the driver's seat when operating
ignition switches and levers.
• Engage the parking brake when working.
• Do not use square timbers that have been piled on each
other.
• Use square timbers that have sufficient strength to support
the vehicle's weight.
• Do not use square timbers that are cracked or chipped. This
can be dangerous, because the forklift may tip.
• Do not place square timbers of different heights under the
left and right sides of the mast or forklift body. The forklift
will tilt.
Jacking
CAUTION:
• If the front wheels are lifted off the ground with the mast and
left for a long period of time, the mast may gradually tilt back.
Therefore, place a square timber under the front of the frame
on the left and right sides, leaving no gaps.
• Use square timbers having the following dimensions: a
height that barely enables them to be inserted between the
ground and mast when tilted back, longitudinal (front-to-
back) dimension that is 50 to 100 mm (1.97 to 3.94 in) larger
than the longitudinal dimension of the mast rail of the
outside mast, and lateral (left-to-right) dimension that is 20 to
40 mm (0.79 to 1.57 in) larger than the outside dimension of
the outer mast.
• When jacking a forklift, stop when the tire is slightly raised
from the ground.
JACKING FRONT
1. Raise the forks 200 to 300 mm (78.7 to 11.81 in) from the
ground, and tilt the mast completely back.
2. Place a square timber under the mast.
GI-10
JACKING AND LIFTING
3. Tilt the mast forward until the front wheels lift up.
4. Place a square timber under the left and right frame.
5. Block the rear wheels.
JACKING REAR
1. Raise the forks about 100 mm (3.94 in) from the ground, and tilt
them slightly back.
2. Block the front wheels.
3. Place a garage jack under the counterweight center, and then
jack it up.
4. Jack up until the tires are slightly raised from the ground, place
a square timber under the left and right frame, and then slowly
lower the jack.
GI-11
JACKING AND LIFTING
Lifting Points
FRONT SIDE
1. Place chocks behind rear wheels.
GIM0055
GIM0049
GIM0047
2. Lift outer mast with a hoist.
GIM0054
3. Place wooden blocks under both side frames. Gradually lower

front end to ground. Be careful not to dislocate blocks while
lowering.
WARNING:
• Use the same size wooden blocks on both sides of the lift
truck. Wooden blocks should be one-piece and strong
enough to support the weight of the lift truck.
• Do not use a supporting block higher than 300 mm (11.81
in).
• Raise the lift truck just high enough to place the supporting
block under the lift truck.
• Never put your feet or hands under the lift truck while lifting
or lowering it.
• After supporting lift truck with blocks, swing it back and
forth and left and right to see if it is safe.
GIM0052
GI-12
JACKING AND LIFTING
Lifting Points (Cont’d)

REAR SIDE
1. Place chocks in front of front wheels.
GIM0056
2. Lift counterweight with a hoist.
GIM0053
3. Place wooden block under counterweight. Gradually lower rear
end to ground. Be careful not to dislocate blocks while lowering.
WARNING:
• Wooden blocks should be one-piece and strong enough to
support the weight of the lift truck.
• Do not use a supporting block higher than 300 mm (11.81
in).
• Raise the lift truck just high enough to place the supporting
block under the truck.
• Place the same size wooden blocks under the left and right
sides of the frame, as shown in the figure below.
• After supporting lift truck with blocks, swing it back and
forth and from side to side to see if it is safe.
GIM0048
GI-13
JACKING AND LIFTING
Lifting Up Forklift Truck

When lifting the entire forklift truck, secure wire ropes to hook points
(2W MAST) or holes (2F/3F MAST) on both sides of the outer mast
cross beam and to the holes on the counterweight, and then utilize a
lifting device.
WARNING:
• Make sure that the wire ropes do not interfere with the
overhead guard while lifting the truck.
• Ensure that the wire ropes and lifting device are strong
GIM0047
enough to support the lift truck safely, as the lift truck is
extremely heavy.
• Do not use the cab frame (overhead guard) to lift up the
truck.
• Never get under the lift truck while lifting the truck.
GIM0054
GIM0049EU
GI-14
TOWING
Towing
TOWING
Before towing a lift truck, secure a wire rope to traction pin. Make
sure parking brake is released.
WARNING:
• Do not attach towing rope to any points other than those
designated.
• To prevent accidents, do not apply load to wire rope
abruptly.
GIM0050
GI-15
TIGHTENING TORQUE OF STANDARD BOLTS
TIGHTENING TORQUE OF STANDARD BOLTS
Tightening Torque
Specified tightening torque
Nominal diameter Pitch
Grade
(mm) (mm)
(N•m) (kg-m) (ft-lb)
M6 1.00 3-4 0.3 - 0.4 2.2 - 2.9
1.25 8 - 11 0.8 - 1.1 5.8 - 8.0
M8
1.00 8 - 11 0.8 - 1.1 5.8 - 8.0
1.50 16 - 22 1.6 - 2.2 12 - 16
4T M10
1.25 16 - 22 1.6 - 2.2 12 - 16
1.75 26 - 36 2.7 - 3.7 20 - 27
M12
1.25 30 - 40 3.1 - 4.1 22 - 30
M14 1.50 46 - 62 4.7 - 6.3 34 - 46
M6 1.00 6-7 0.6 - 0.7 4.3 - 5.1
1.25 14 - 18 1.4 - 1.8 10 - 13
M8
1.00 14 - 18 1.4 - 1.8 10 - 13
1.50 25 - 35 2.6 - 3.6 19 - 26
M10
1.25 26 - 36 2.7 - 3.7 20 - 27
1.75 45 - 61 4.6 - 6.2 33 - 45
7T M12
1.25 50 - 68 5.1 - 6.9 37 - 50
M14 1.50 76 - 103 7.7 - 10.5 56 - 76
M16 1.50 118 - 157 12.0 - 16.0 87 - 116
M18 1.50 177 - 235 18.0 - 24.0 130 - 174
M20 1.50 245 - 324 25.0 - 33.0 181 - 239
M22 1.50 324 - 441 33.0 - 45.0 239 - 325
M6 1.00 8 - 11 0.8 - 1.1 5.8 - 8.0
1.25 19 - 25 1.9 - 2.5 14 - 18
M8
1.00 20 - 27 2.0 - 2.8 14 - 20
1.50 36 - 50 3.7 - 5.1 27 - 37
M10
1.25 39 - 51 4.0 - 5.2 29 - 38
1.75 65 - 88 6.6 - 9.0 48 - 65
9T M12
1.25 72 - 97 7.3 - 9.9 53 - 72
M14 1.50 108 - 147 11.0 - 15.0 80 - 108
M16 1.50 167 - 226 17.0 - 23.0 123 - 166
M18 1.50 255 - 343 26.0 - 35.0 188 - 253
M20 1.50 343 - 461 35.0 - 47.0 253 - 340
M22 1.50 471 - 632 48.0 - 64.4 347 - 466
CAUTION:
• Special parts are excluded.
• This standard is applicable to bolts having the following marks embossed on the bolt head.
Grade........... Mark
4T ................ 4 or no mark
7T ................ 7
9T ................ 9
GI-16
ABBREVIATION LIST
ABBREVIATION LIST
ABBREVIATION LIST
Abbreviation Description
ABDC After Bottom Dead Center
A/C Air Conditioner
AFM Air Fuel Management
ALT Alternator
APPS Accelerator Pedal Position Sensor
Assy Assembly
ATDC After Top Dead Center
ATM Automatic Transmission
BAT Battery
BBDC Before Bottom Dead Center
BDC Bottom Dead Center
BTDC Before Top Dead Center
C/P Crankshaft Pulley
C/U Control Unit
CAN Can Area Network
Cyl Cylinder
DCM Diesel Control Module
DTC Diagnostic Trouble Code
ECM Engine Control Module
ECO Economy Mode
EGI Electronic General Ignintion (Relay/Fuse)
ELEG Electronically Controlled Gasoline
ELEG.L Electronically Controlled Gasoline/LPG
ELEL Electronically Controlled LPG
ENG Engine
ETC Electronic Throtthle Control
EXH Exhaust
F/L Fusible Link
FC1 Fingertip Controlled ( 1 Auxiliaries)
FC2 Fingertip Controlled ( 2 Auxiliaries)
FET Mosfet
FR Front
GOM General Overseas Market
H02 Heated Oxygen Sensor
I/P Idler Pulley
IAT Intake Air Temperature
IGN Ignition
INT Intake
LCD Liquid Crystal Display
LED Light Emmitting Diode
LH Left Hand
LLC Long Lige Coolant
LPG Liquefied Petroleum Gas
GI-17
ABBREVIATION LIST
MAF Mass Air Flow

MAFS Mass Air Flow Sensor
MC Mechanical Control Valve
MFC Multi Function Control Valve ( Joystick)
MIL Malfunction Indicator Lamp
MTM Mechanical Transmission
MP Meter Panel
MPI Multi Port Injection
NDIS No Distributor Ignistion System
NELEG Non-Electronically Controlled Gasoline
NELEG.L Non-Electronically Controlled Gasoline/LPG
NELEL Non-Electronically Controlled LPG
OBD On Board Diagnostic System
OHV Overhead Valves
OS Oversize
P/S Power Steering
PCV Positive Carter Ventilation
PHASE Camshaft Position Sensor
PNP Park Neutral Position (Manual Transmission)
POS Crankshaft Position Sensor
PTC Positive Temperature Coefficient Heater
PTO Power take Off
QGS Quick Glow System
RH Right Hand
RR Rear
RX Data Link Connector (communication reciever)
SDS Service & Data Specifications
T/M Trans Mission
T/M Tilt Mechanism
TAS Throttle Adjust screw
TDC Top Dead Center
TPS Throttle Position Sensor
TR Transistor
TX Data Link Connector (communication transmitter)
US Undersize
VCM Vehicle Control Module
VSS Vehicle Speed Sensor
WOT Wide Open Throttle
W/P Waterpump Pulley
GI-18
MAINTENANCE
SECTION MA
CONTENTS
LUBRICATION CHART ...............................................MA-2 Inspection of Tire for Wear ....................................MA-23
Lubrication Schedule Chart ..................................... MA-2 Inspection of Wheel Nut ........................................MA-24
Grease and Oil Capacity ......................................... MA-3 BRAKE SYSTEM .......................................................MA-25
MAINTENANCE SCHEDULE ......................................MA-4 Inspection of Brake Fluid Level .............................MA-25
Maintenance Schedule ........................................... MA-4 Inspection/Adjustment of Brake Pedal ..................MA-25
ENGINE MAINTENANCE ............................................MA-6 Adjustment of Inching Pedal ..................................MA-26
Inspection of Cylinder Head Tightening .................. MA-6 Adjustment of Inching Valve ..................................MA-26
Inspection of Manifold Tightening ........................... MA-6 Inspection of Brake Lining for Wear ......................MA-27
Inspection/Adjustment of Valve Clearance ............. MA-7 Adjustment of Shoe Clearance ..............................MA-27
Inspection of Compression Pressure ...................... MA-8 Inspection/Adjustment of Parking Brake
Inspection/Adjustment of Fan Belt ........................ MA-10 Operation Effort .....................................................MA-28
Inspection of Engine Oil Level ............................... MA-10 STEERING ..................................................................MA-29
Replacement of Engine Oil ................................... MA-11 Steering Wheel Free Play .....................................MA-29
Replacement of Engine Oil Filter .......................... MA-11 Steering Wheel Operation Force ...........................MA-29
Inspection of Coolant Level ................................... MA-12 Inspection of Hydraulic Pressure ...........................MA-29
Replacement of Coolant ........................................ MA-13 AUTOMATIC TRANSMISSION ..................................MA-30
Inspection of Radiator ........................................... MA-13 Inspection of Automatic Transmission
Inspection of Radiator Cap .................................... MA-14 Fluid Level .............................................................MA-30
Cleaning / Replacement of LPG filter of Inspection of A/T Line Pressure ............................MA-31
Valve assy solenoid LPG ...................................... MA-14 Inspection of Stall Speed .......................................MA-32
Cleaning LPG filter screen in injector holder ......... MA-15 LOADING MECHANISM ............................................MA-33
Inspection/Replacement of Fuel Filter ................... MA-15 Inspection of Fork ..................................................MA-33
Bleeding Fuel System ........................................... MA-16 Inspection/Adjustment of Carriage Height .............MA-36
Inspection/Adjustment of Injection Pressure Inspection/Adjustment of Lift Chain Tension .........MA-36
for Fuel Injection Nozzle (QD32 Engine) ............... MA-17 Inspection of Carriage Roller .................................MA-37
Inspection/Adjustment of Fuel Injection Inspection of Mast Roller .......................................MA-37
Timing (QD32 Engine) .......................................... MA-18 Adjustment of Mast Roller Clearance ....................MA-38
Tar Extraction from Vaporizer Inspection of Mast Operation ................................MA-40
(Combined Use of Gasoline/LPG) ......................... MA-19 Inspection of Mast Cylinder ...................................MA-40
Inspection/Adjustment of Maximum rpm Inspection of Tilt Cylinder ......................................MA-40
Under Loaded and Unloaded Conditions .............. MA-19 Greasing Point .......................................................MA-40
Inspection of Spark Plug BODY ELECTRICAL ..................................................MA-42
(K/GK21 and K/GK25 Engines) ......................................... MA-20 Inspection/Replacement of Fuses .........................MA-42
Cleaning / Replacement of Air Cleaner ................. MA-20 Replacement of Bulbs ...........................................MA-43
PCV GAS RECIRCULATION DEVICE ......................MA-21 EMERGENCY MAST LOWERING .............................MA-44
System Diagram .................................................... MA-21 Emergency lowering shutt-off valve ......................MA-44
Component Parts Inspection ................................. MA-21
BATTERY ...................................................................MA-22
Inspection of Battery Fluid Level ........................... MA-22
Inspection of Specific Gravity of Battery Fluid ....... MA-22
TIRES AND ROAD WHEELS ....................................MA-23
Tire Air Pressure and Specifications ..................... MA-23
NOTE: This section contains information and specifications for both carbureted general overseas market models, as well as,
electronic control models (manufactured in USA.) Therefore, ensure the specifications or procedures you are looking at
are for the proper fuel delivery system; electronic controlled or carbureted.
LUBRICATION CHART
LUBRICATION CHART Lubrication Schedule Chart
(2000 Hrs.)
(1000 Hrs.)
(500 Hrs.)
(200 Hrs.)
MA-2
LUBRICATION CHART
Grease and Oil Capacity

System/component Applicable model Oil and grease Capacity 2(US gal, Imp gal)
K/GK21 engine 3.8 (1, 7/8)

API SD or SE
K/GK25 engine 3.8 (1, 7/8)
Engine (With oil filter)
QD32 engine (1D1) 7.0 (1-7/8, 1-1/2) without oil filter
API or CD 7.7 (1.1-0.96, 1.1-0.55) with oil filter
QD32 engine (1D2) 6.5 (1-3/4, 1-3/8) without oil filter
7.2 (1.1-0.84, 1.1-0.42) with oil filter
Automatic 1D1 series 8 (2-1/8, 1-3/4)
Type DEXRON or M2C-33E or F
transmission 1D2 series 9 (2-3/8, 2)
1D1 series 3.2 (7/8, 3/4)
Differential 1D2 series (2.0, 2.5 ton ) APIGL-4 or 5 3.5 (7/8, 3/4)
1D2 series (3.0, 3.2 ton ) 5.5 (1-1/2, 1-1/4)
1D1 series 35.9 (9-1/2, 7-7/8)
Hydraulic fluid tank 1D2 series (2.0, 2.5 ton ) Hydraulic oil I.S.O. VG32 46.4 (12-1/4, 10-1/4)
1D2 series (3.0, 3.2 ton ) 51.4 (13-5/8, 11-3/8)
Brake All models DOT3 (F.M.V.S.S. No. 116) -
The greasing points and grease types in use are listed in the above
Greasing point -
lubrication schedule chart.
K/GK21 engine 8.7 (2-1/4, 1-7/8)

Coolant level
(including reservoir K/GK25 engine Long-life Coolant 7.9 (2-1/8, 1-3/4)
tank)
QD32 engine 10.2 (2-3/4, 2-1/4)
MA-3
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE Maintenance Schedule

The first maintenance should be at 1 month or 200 hours (which ever comes first)
after the truck is first put into use. See the (1) marked interval. Periodic mainte-
nance should be performed after specified intervals have elapsed in months or
hours, whichever comes first.
NOTE:
Under dusty, dirty or heavy operations, more frequent maintenance is neces-
sary. All items listed below must be maintained in order to meet and keep emis-
sion control systems operating at design level. Failure to maintain the systems
could compromise the warranty.
I = Inspect. (Correct or replace if necessary.) D = Drain R = Replace A = Adjust
C = Clean T = Retighten L = Lubricate/Grease
Intervals
Inspection point A (months) 1(1) 6 12 18 24 30 … How to check
B (hours) 200(1) 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 …
Oil leakage & Level I I I I I I I I I I I … Visual
Lubrication
Oil R R R R R R R R R R R … Replace
Oil filter R R R R R R R R R R R … Replace
Coolant leakage & Level I I I I I I I I I I I … Visual

Cooling system
Test anti
Coolant I R … freeze /
Replace
Cooling fan I I I I I I I I I I I … Visual
Hoses (Leakage / cracks / damage) I I I I I I I I I I I … Visual
Radiator (damage) I I I I I I I I I I I … Visual
Radiator core (clogged) C C C C C C C C C C C … Clean
Fuel leaks I I I I I I I I I I I … Visual
General
Fuel piping for damage I I I I I I I I I I I … Visual
Water separator D D D D D D D D D D D … Drain

Diesel
Fuel filter R R … Replace

Fuel system
Measure /
Engine Idle A A A A A A … Adjust
LPG cylinder mounting I I I I I I I I I I I … Visual / Feel
Tar in vaporizer D D D D D D D D D D D … Drain
Engine
LPG filter Injector housing C C C C C … Clean

LPG
Filter Element LPG Solenoid valve R R … Replace

Vaporizer Diaphragm R R … Replace
Meassure /
LPG pressure A A A … Adjust
Measure /
Ignition timing A A …
Ignition system
Adjust
LPG
Distributor cap & Rotor I I I I I I I I I I I … Visual

Spark plugs R … Replace
Diesel
Test /
Glow plugs I I I I I I … Meassure
Air cleaner element R R … Replace
PCV valve & Hose I I I I I … Visual
General
Meassure /
Valve clearance Intake & exhaust A A A A A A … Adjust
Visual / Check
Alternator Belt / Fan belt (Tension / cracks) I I I I I I I I I I I … tention
Engine mounting I I I I I I I I I I I … Visual
Starting & Noise I I I I I I I I I I I … Test
Operation
Exhaust smoke I I I I I I I I I I I … Visual
Startermotor I I I I I I I I I I I … Test
Alternator I I I I I I I I I I I … Test
Battery: Mounting, level & Specific gravity I I I I I I I I I I I … Visual / Test
Harness & Connectors I I I I I I I I I I I … Visual
Ground connection I I I I I I I I I I I … Visual / Test
Electric
Fuses I I I I I I I I I I I … Visual
Relays I I I I I I I I I I I … Visual
Switches I I I I I I I I I I I … Test
Lights (all) I I I I I I I I I I I … Test
Horn / buzzer I I I I I I I I I I I … Test
Gauge and Indicators I I I I I I I I I I I … Test
Wipers I I I I I I I I I I I … Visual / Test
MA-4
MAINTENANCE SCHEDULE
Intervals
Inspection point A (months) 1(1) 6 12 18 24 30 … How to check
B (hours) 200(1) 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 …
Transmission Oil level I I I I I I … Visual
Transmission leakage I I I I I I … Visual
Transmission oil & Filter R R R R R … Replace
Stall test and oil pressure I I Test / Measure
Transmission
Oil cooler hoses (Leakage / damage) I I I I I I I I I I I … Visual

Universal joint L L L L L L … Grease
Differential Oil level I I I I I I I I I I I … Visual
Differential leakage I I I I I I I I I I I … Visual
Differential oil R R … Replace
Forward/Reverse function I I I I I I I I I I I … Test
Inching pedal-adjustment I I I I I I … Check
Inching valve adjustment I I I I I I … Check
Cracks, distortion, etc. I I I I I I I I I I I … Visual
Front axle
Mounting bolts I I I I I I I I I I I … Visual

Oil leakage I I I I I I I I I I I … Visual
Wheel play I I I I I I I I I I I … Test
Wheel bearing grease R R … Replace
Fore-aft play I I I I I I I I I I I … Meassure
Chassis & Body maintenance
Silent blocks I I I I I I I I I I I … Visual

Rear axle
Wheel play I I I I I I I I I I I … Test

Tie-rod L L L L L L L L L L L … Grease
Wheel bearing grease R R … Replace
Kingpin L L L L L L L L L L L … Grease
Visual /
Wheel nuts T T T T T T T T T T T … Torque
Wheels
Rim, side rings and wheel disc damage I I I I I I I I I I I … Visual

Tire: pressure, wear, damage and foreign
I I I I I I I I I I I … Visual / Check
materials
Function of steering system I I I I I I I I I I I … Test
Steering system
Mounting of column, orbitrol,

I I I I I I I I I I I … Visual
cylinder & tubes & hoses
Leakage (Valve, Cylinder & Orbitrol) I I I I I I I I I I I … Visual
Tubes and Hoses
I I I I I I I I I I I … Visual
(leakage, mounting, cracks, damaging)
Steering wheel (movement & play) I I I I I I I I I I I … Test
Function of brake system I I I I I I I I I I I … Test
Brake fluid (Level & Condition) I I I I I I I I I I I … Visual
Brake fluid R R … Replace
Brake pedal adjustment I I I I I I … Check
Brake system
Pedal rubbers I I I I I I I I I I I … Visual

Leakage I I I I I I I I I I I … Visual
Brake lining wearing I I … Visual
Brake drum / lining cleaning C C … Clean
Brake tubes & hoses
I I I I I I I I I I … Visual
(mounting, cracks, damaging)
Test /
Hand brake function / effort I I I I I I I I I I … Meassure
Function of hydraulic system I I I I I I I I I I … Test
Hydraulic leakage I I I I I I I I I I … Visual
Hydraulic oil level I I I I I I I I I I … Visual
Hydraulic system
Hydraulic oil replacement R R … Replace

Micron oil filter R R R … Replace
Suction filter C C … Clean
Control valve (Mounting) I I I I I I I I I I … Visual
Movement & Connection of levers I I I I I I I I I I … Test
Hydraulic hoses
(Cracks, damage, Fittings)
Lift & Tilt cylinder mounting I I I I I I I I I I … Visual
Chassis & Body maintenance
Tilt cylinder pin L L L L L L L L L L … Grease

Function of mast I I I I I I I I I I … Test
Mast system (Damage / cracks/ wear) I I I I I I I I I I … Visual
Clearance of each stage I I I I I I I I I I … Meassure
Mast Rail L L L L L L L L L L … Grease
Mast / carraige rollers I I I I I I I I I I … Visual / Test
Back up metals L L L L L L L L L L … Grease
Thrust metals L L L L L L L L L L … Grease
Mast
Lift chains wear / tension I I I I I I I I I I … Meassure

Attachments mounting I I I I I I I I I I … Visual
Attachments L L L L L L L L L L … Grease
Lift chains L L L L L L L L L L … Lubricate
Hose pulley's I I I I I I I I I I … Visual / Test
Mast support L L L L L L L L L L … Grease
Forks (Wearing / Damage / Cracks) I I I I I I I I I I … Visual
Seat belt (function / damage) I I I I I I I I I I … Test / Visual
General
Load capacity plate

( readable / correct)
Warning labels (readable) I I I I I I I I I I … Visual
Overhead guard (damage / cracks) I I I I I I I I I I … Visual
General All bolt and nuts I I I I I I I I I I … Visual
MA-5
ENGINE MAINTENANCE
ENGINE MAINTENANCE Inspection of Cylinder Head Tightening

K/GK21 AND K/GK25 ENGINES
If the cylinder head bolts are loose, retighten them to the following
specified torque in the order shown in the figure.
Unit: N•m (kg-m, ft-lb)
Tightening
Tightening torque
procedure
(1) 19.6 - 23.52 (2.0 - 2.3, 14 - 17)

Tightening for brake-in
(2) 68.6 (7.0, 51)
(3) 0.0 (0.0, 0) Return
(4) 19.6 - 23.52 (2.0 - 2.3, 14 - 17)

Re-tightening
(5) 68.6 (7.0, 51)
QD32 ENGINE
If the cylinder head bolts are loose, retighten them to the following
specified torque in the order shown in the figure.
: 98 - 108 N•m (10 - 11 kg-m, 72 - 80 ft-lb)
Inspection of Manifold Tightening

If the intake/exhaust manifold mounting bolts are loose, retighten
them to the following specified torque.
WARNING:
Do not check the exhaust system until it has cooled off.
Otherwise, you may burn yourself.
: Intake/exhaust manifold
41 - 48 N•m (4.2 - 4.9 kg-m, 30 - 35 ft-lb)
MA-6
ENGINE MAINTENANCE
Inspection of Manifold Tightening (Cont’d)

QD32 ENGINE
If the intake/exhaust manifold mounting nuts and bolts are loose,
retighten them to the following specified torque.
WARNING:
Do not check the exhaust system until it has cooled off.
Otherwise, you may burn yourself.
: Intake manifold
13 - 19 N•m (1.3 - 1.9 kg-m, 9 - 14 ft-lb)
: Exhaust manifold
25 - 29 N•m (2.5 - 3.0 kg-m, 18 - 22 ft-lb)
Inspection/Adjustment of Valve Clearance

CAUTION:
• Always measure the valve clearance while the engine is
warm.
• Just after the engine is stopped, take special care for risk
of burn because the engine is hot.
NOTE:
• The engine warm-up operation should be continued until the
coolant temperature gauge indicates the middle of the scale.

1. Remove rocker cover.
2. Turn the crankshaft so that the No. 1 and No. 4 cylinders come to
their compression TDC. In this state, inspect and adjust the valve
clearance following the figure on the left and the table below.
Item Valve to be inspected/adjusted
Valve type Exhaust Intake Intake Exhaust Exhaust Intake Intake Exhaust
No. 1 cylinder
at TDC of its
(1) (2) (3) (5)
compression
stroke.
No. 4 cylinder
at TDC of its
(4) (6) (7) (8)
compression
stroke.
3. Insert a thickness gauge between the valve stem and the rocker
arm and check that a specified valve clearance is present.
Intake/exhaust valve clearance:
0.38 mm (0.015 in)
4. Inspect all valves. If inappropriate clearance is found in any
valve, adjust the clearance.
5. To adjust the clearance, first loosen the lock nut for the adjusting
screw and turn the adjusting screw.
6. After adjustment, tighten the lock nut while holding the adjusting
screw in place.
: Lock nut
13.7 - 15.7 N•m (1.4 - 1.6 kg-m, 10 - 12 ft-lb)
7. Install the rocker cover.
: Rock cover mounting bolt
14.7 - 16.7 N.m (1.5 -1.7kg-m, 11-13 ft-lb)
MA-7
ENGINE MAINTENANCE
Inspection/Adjustment of Valve Clearance

(Cont’d)
QD32 ENGINE
NOTE:
Adjustment should be made while engine is hot.
To adjust, proceed as follows:
1. Remove valve rocker cover.
2. Turn the crankshaft so that the No. 1 and No. 4 cylinders come
to their compression TDC. In this state, inspect and adjust the
valve clearance following the figure on the left and the table
below.
Item Valve to be inspected/adjusted
Valve type Exhaust Intake Intake Exhaust Exhaust Intake Intake Exhaust
No. 1 cylinder at
TDC of its
compression ① ② ③ ⑤
stroke.
No. 4 cylinder at
TDC of its
④ ⑥ ⑦ ⑧
compression
stroke.
3. Insert a thickness gauge between the valve stem and the rocker
arm and check that a specified valve clearance is present.
Intake/exhaust valve clearance:
0.35mm (0.014 in)
4. Inspect all valves. If inappropriate clearance is found in any
valve, adjust the clearance.
5. To adjust the clearance, first loosen the lock nut for the adjusting
screw and turn the adjusting screw.
6. After adjustment, tighten the lock nut while holding the adjusting
screw in place.
Tightening torque: Lock nut
15 - 19 N•m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
7. Install valve rocker cover.
Inspection of Compression Pressure

1. Warm up the engine sufficiently and then stop it.
Release the fuel pressure. (Electronically controlled
specification)
2. Remove spark plugs.
3. Apply a compression gauge correctly to the cylinder plug hole to
be measured.
4. Set the throttle valve to the fully-open position. Depress the
accelerator pedal to the fully-open position.
5. Crank the engine and read the gauge.
MAT0193L.tif (The same operations can be used for both the non
electronically controlled models and electronically controlled
models)
MA-8
ENGINE MAINTENANCE
Inspection of Compression Pressure

(Cont’d)
NOTE:
• Keep the engine speed at approximately 250 rpm.
• Finish the pressure measurement in as short a time as possible.
Standard compression pressure

Engine
[MPa (bar, kg/cm2, psi)/at 250 rpm]
K/GK21 1.23 (12.26, 12.5, 178)
K/GK25 1.27 (12.7, 13.0, 185)
6. Compression pressure cylinder difference shall be at a

maximum of 0.98 MPa (1.0 bar, 1 kg/cm2, 14 psi) 250 rpm or
less. If any of the cylinders’ pressure is low, remeasure it by
filling small amount of oil into spark plug hole.
NOTE:
• If the pressure rises after filling oil, the piston ring is worn or
damaged.
• If the pressure remains unchanged even after filling oil, the
valve is stuck or inappropriately seated.
• If low compression pressure is observed in two adjacent cylin-
ders and the pressure is not restored even after filling oil, the
head gasket is leaking. In this case, oil and water may enter in
the combustion chamber.
• If the engine speed is not in the specified range: Measure the
battery specific gravity.
QD32 ENGINE
1. Warm up engine.
2. Remove glow plate or injection nozzle.
3. Fit compression gauge adapter to cylinder head. Make sure
bleeder screw of gauge is closed.
: Compression gauge adapter
For glow plug hole
15 - 20 N•m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
4. Disconnect fuel cut solenoid wire and crank engine, then read
gauge indication.
NOTE:
Engine compression measurement should be made as quickly as
possible.
Compression pressure:
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Standard 2,942 (29.4, 30, 427)

Minimum 2,452 (24.5, 25, 356)
Differential limit between cylinders 294 (2.9, 3, 43)
MA-9
ENGINE MAINTENANCE
5. If cylinder compression in one or more cylinders is low, pour a

small quantity of engine oil into cylinders through the nozzle
holes and retest compression.
NOTE:
• If adding oil helps the compression pressure, piston rings may
be worn or damaged.
• If compression pressure stays low, valve may be sticking or
seating improperly.
• If compression pressure in any two adjacent cylinders is low,
and if adding oil does not help the compression, there is
leakage pass on the gasket surface.
Oil and water in combustion chambers can result from this
problem.
Inspection/Adjustment of Fan Belt

Apply a force of approximately 98 N (10 kg, 22 lb) to the middle point
of the fan pulley-to-alternator pulley belt.
Power to push by finger Proper deflection
Engine
[N (kg, lb)] adjustment [mm (in)]
K/GK21
11 - 13 (0.433 - 0.512)
K/GK25 98 (10, 22)
QD32
Inspection of Engine Oil Level

CAUTION:
• Choose a level place for inspection.
• Place the forklift on level ground. Make sure to perform
this inspection before the engine starts. Always wait 10
minutes or more before starting the inspection when
performing this inspection after the engine stops.
1. Open the engine hood.

2. Check the oil level with the engine oil level gauge to see if the oil
level is in the optimum range shown in the figure.
NOTE:
At the same time, check the oil for any contamination. If the oil is
heavily contaminated, replace the engine oil.
MA-10
ENGINE MAINTENANCE
Replacement of Engine Oil

CAUTION:
• Before replacing the engine oil, ensure that the engine oil is
sufficiently cooled down. The engine oil is hot just after the
engine is stopped.
• Wipe away any spilt oil. Spilt oil may cause a fire.
1. Open the engine hood.
2. Remove the oil filler cap.
3. Place an appropriate container under the oil pan. Remove the
drain plug and extract the engine oil.
4. After all engine oil is extracted, install the drain plug and tighten
it to the specified torque.
Engine Tightening torque
K/GK21, K/GK25 29.4 - 39.2 (3.0 - 4.0, 22 - 29)
QD32 54 - 59 (5.5 - 6.0, 40 - 44)
5. If the oil filter requires replacement, replace it referring to the

next procedure.
6. Add the engine oil through the oil filler
7. After filling the engine with engine oil, check the engine oil level
with the engine oil level gauge. Adjust the oil level if necessary.
8. Install the oil filler cap. Start the engine and allow the engine to
idle.
9. Stop the engine and wait for 10 minutes or more until the oil
level stabilizes. Then check the oil level again and adjust the
level if necessary.
Replacement of Engine Oil Filter

CAUTION:
• Before replacing the engine oil filter, ensure that the engine
oil is sufficiently cooled down. The engine oil is hot just
after the engine is stopped.
• Wipe away any spilt oil. Spilt oil may cause a fire.
1. Remove the oil filter with an oil filter wrench.
2. Apply a thin coat of engine oil to the oil seal face of a new oil
filter.
MA-11
ENGINE MAINTENANCE
Replacement of Engine Oil Filter (Cont’d)

3. Insert the oil filter by hand. When the oil seal face contacts the
mounting face, follow the table below to screw in the oil filter
further.
Tightening amount
Engine
after oil seal is contact
K/GK21, K/GK25, QD32 Approx. 2/3 turns
4. Start the engine. Check that no oil leakage is found from the oil
filter mount.
Inspection of Coolant Level

CAUTION:
The coolant is very hot just after the engine is stopped. Do not
attempt to open the radiator cap while the engine is hot. Doing
so may cause hot steam or water to blow out, resulting in
personal injuries. Always ensure that the coolant is cooled
down sufficiently. When opening the radiator cap, wrap the cap
with a shop cloth and turn the cap slowly to release the internal
pressure.
NOTE:
For the coolant, only use the long-life coolant (LLC) with a suitable
density to the vehicle's working environment.
1. Check reservoir tank level.
2. Check if the coolant level is in the optimum range shown in the
figure. Add coolant if necessary.
3. Full coolant to reservoir tank.
CAUTION:
• Do not overfill the coolant system. Excessive coolant may
overflow when the engine is warmed up.
• Do not allow any coolant to spill over. The long-life coolant
(LLC) may damage the paint surfaces. Any coolant on the
paint must be washed off with clean water immediately.
4. After filling up, securely install the reservoir tank or the radiator
cap.
MA-12
ENGINE MAINTENANCE
Replacement of Coolant
CAUTION:
pressure.
NOTE:
For the coolant, only use long-life coolant (LLC) with a suitable
density to the vehicle's working environment.
1. Remove the radiator cover and open the engine hood.
2. Remove the radiator cap.
3. Place an appropriate size of container under the radiator
referring to the table below. Open the drain cock of the radiator
and extract the coolant.
4. After extracting all coolant, securely close the drain cock.
5. Prepare coolant with an optimum density referring to the table
below.
Capacity [ (US
Applicable model LLC density
gal, Imp gal)]
K/GK21 8.7 (2-1/4, 1-7/8) Standard specification:

30% (Approx. -15°C (5°F) of
K/GK25 7.9 (2-1/8, 1-3/4) freeze temperature)
Model for cold areas:
QD32 10.2 (2-3/4, 2-1/4) 50% (Approx. -35°C (-31°F)
of freeze temperature)
6. Add coolant from the radiator filler port. Also add coolant to the
reservoir tank.
7. Referring to the previous procedure, verify that the coolant level
is optimum.
8. Securely attach the radiator cap.
9. Close the engine hood and install the radiator cover.
Inspection of Radiator
Check the radiator core for any coolant leakage and plugged radiator
meshes. If any coolant leakage is observed, replace the radiator
core. For plugging, clean the core by applying compressed air.
Also inspect the radiator hoses for any coolant leakage from the
connections or due to hose deterioration. Retighten any loose
connections and replace any deteriorated parts.
MA-13
ENGINE MAINTENANCE
Inspection of Radiator Cap

CAUTION:
pressure.
1. Remove the radiator cap.
2. Remove any dust and sludge from the sealing face of the cap.
3. Set the radiator cap to a radiator cap tester and apply pressure.
4. Check that the radiator cap can hold the specified pressure.
Standard:
88.3 kPa (0.88 bar, 0.9 kg/cm2, 12.8 psi)
5. If not as specified, replace the radiator cap with a new one.
Cleaning / Replacement of LPG filter of Valve

assy solenoid LPG
1. Disconnect LPG fuel tank.
2. Loosen the filter-cap bolts (item 5).
CAUTION:
LPG fuel may leak out when removing the filter-cap (item 4).
3. Remove LPG filter element (item 1).
4. Visually inspect the element status and clean if necessary.
NOTE:
The manufacturer recommends replacing the LPG filter element.
Cleaning with air pressure can damage the element.
5. If the element is damaged, replace the element.
6. Before installing the filter and filter cap inspect visually the seals
(item 2 and 3) and replace if necessary.
NOTE:
Damaged seals (2-3) can cause LPG fuel leakage to the outside or
reduced filter effect.
7. After assembling inspect connections and piping for LPG fuel
leakages.
MA-14
ENGINE MAINTENANCE
Cleaning LPG filter screen in injector holder

1. Remove LPG fuel hose from vaporizer to injector holder.
CAUTION:
LPG fuel may leak out when removing the fuel hose.
2. Loosen screws (item 6) and remove LPG fuel connector (item 2)
from LPG injector holder (item 7).
3. Remove clip (item 4) with pliers.
4. Remove the filter screen (item 5).
5. Clean the screen filter with brake cleaner.
6. If the filter is damaged or the contamination can not be proper
removed, replace the filter screen.
7. Install filter screen and clip.
8. Before installing the LPG fuel connector (Item 2) visually inspect
the o-seal (item 3) and replace if necessary.
NOTE:
Damaged O-seal (3) can cause LPG fuel leakage to the outside.
9. After assembling inspect connections and piping for LPG fuel
leakages.
Inspection/Replacement of Fuel Filter

CAUTION:
After inspection and replacement, securely install the fuel filter
so as not to allow fuel to leak. Any fuel leakage leads to a fire
accident.
1. Remove the top cover from the fuel pump.
Remove in-tank fuel module for electronically controlled type.
2. Check the internal filter and element for any dirt or moisture.
3. If the filter and element are contaminated, replace them with
new ones. If any water sump is present, clean the filter and
element. For electronically controlled type, clean the filter and
element only.
NOTE:
Fuel filter is not serviceable separately.
QD32 ENGINE
Replacing fuel filter
1. Disconnect fuel filter sensor connector.
2. Loosen drain cock and drain fuel.
3. Remove fuel filter sensor and/or drain cock.
MA-15
ENGINE MAINTENANCE
Inspection/Replacement of Fuel Filter

(Cont’d)
4. Remove fuel filter.
5. Connect fuel filter sensor with drain cock to new fuel filter.
6. Install new fuel filter.
CAUTION:
• Hand-tighten only.
• Do not use wrench to tighten filter.
7. Connect fuel filter sensor connector.
8. Bleed air from fuel system.
Bleeding Fuel System

CAUTION:
Air should be bled out of fuel system when injection pump is
removed or fuel system is repaired.
Protect pump and engine mounts from fuel splash with rags.
If engine will not start after bleeding air, loosen injection tubes
at nozzle side and crank engine until fuel overflows from
injection tube. Tighten injection tube flare nuts.
NOTE:
If the engine does not operate smoothly after it has started, race it
two or three times.
Without air vent screw
Method A
Move the priming pump up and down until there is suddenly more
resistance in the movement.
Method B
1. Loosen injection pump bleeder screw/or disconnect return hose
and priming.
2. Make sure that fuel overflows at bleeder screw/tube end, then
tighten it/connect hose.
MA-16
ENGINE MAINTENANCE
Bleeding Fuel System (Cont’d)

With air vent screw
Method A
1. Loosen the air vent screw (1).
2. Move the priming pump (2) up and down until no further
airbleed comes out of the air vent screw (1).
3. Tighten the air vent screw (1).
4. Move the priming pump (2) up and down until there is suddenly
more resistance in the movement.
Method B
1. Loosen the air vent screw (1).
2. Move the priming pump (2) up and down until no further
airbleed comes out of the air vent screw (1).
3. Tighten the air vent screw (1).
4. Loosen injection pump bleeder screw/or disconnect return hose

and priming.
5. Make sure that fuel overflows at bleeder screw/tube end, then
tighten it/connect hose.
Inspection/Adjustment of Injection Pressure

for Fuel Injection Nozzle (QD32 Engine)
INSPECTION/ADJUSTMENT OF NOZZLE INJECTION OPENING
VALVE PRESSURE
1. Install nozzle to nozzle tester, move up and down manual
handle several times, and bleed air in the pipe and the nozzle.
2. Check indication of pressure gauge injecting the nozzle by
quietly operating handle throughout its stroke range.
3. Tester pressure gauge indicator rises slowly and descends
suddenly when the nozzle tester handle is moved up and down
at the speed of 1 time or more per second. It is usual that the
indicator of the pressure gauge under the jet vibrates in detail,
and reads the injection opening valve pressure by the
instruction pressure of beginning swing the indicator.
QD32 engine
9.087 kPa (98.1 bar, 100 kg/cm2, 1.422 psi)
The standard indicates a new adjustment value.
MA-17
ENGINE MAINTENANCE
Inspection/Adjustment of Injection Pressure

for Fuel Injection Nozzle (QD32 Engine)
(Cont’d)
WARNING:
Do not touch spray during nozzle injection test.
4. To adjust injection pressure, change adjusting shims.
a. Increasing the thickness of adjusting shims increases initial
injection pressure. Decreasing thickness reduces initial pressure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds
approximately to a difference of 471 kPa (4.71 bar, 4.8 kg/cm2,
68 psi) in initial injection pressure
Unit: mm (in)
Thickness
0.1 (0.004)
0.2 (0.008)
0.3 (0.012)
0.4 (0.016)
0.5 (0.020)
0.52 (0.0205)
0.54 (0.0213)
0.56 (0.0220)
0.58 (0.0228)
0.8 (0.031)
NOZZLE SPRAY CONDITION INSPECTION

1. Check for clogging of injection hole, spray condition, and fuel
leakage from injection hole when checking pressure with nozzle
tester.
2. Make sure that straight spray is occurred when operating tester
handle as the speed of approximately 1 time per second.
Inspection/Adjustment of Fuel Injection

Timing (QD32 Engine)
INJECTION TIMING
When the injection timing doesn’t reach in regulated value, adjust it
according to the following procedures.
PLUNGER LIFT ADJUSTMENT

1. Loosen injection pump mounting nuts and mounting bracket
bolt.
2. Remove plug bolt from distributor head and install dial gauge.
3. Plunger lift measurement and adjustment.
(1) Turn crankshaft counterclockwise 20 to 25 degrees from No. 1
piston at T.D.C.
(2) Find dial gauge’s needle rest position at step (1) set position,
then set the gauge to zero.
(3) Turn crankshaft clockwise until No. 1 piston is set at T.D.C.
(4) Read dial gauge indication.
Standard:
0.507 - 0.547 mm (0.0199 - 0.0215 in)
(equivalent to 2° B.T.D.C.)
MA-18
ENGINE MAINTENANCE
Inspection/Adjustment of Fuel Injection

Timing (Cont’d)
(5) If it is not within the above range, turn pump body until it comes
within standard range.
NOTE:
• If indication is smaller than the specified value, turn pump body
counterclockwise.
• If indication is larger than the specified value, turn pump body
clockwise.
Tar Extraction from Vaporizer (Combined

Use of Gasoline/LPG)
CAUTION:
• Do not touch the vaporizer and surrounding components
especially just after the engine is stopped. The heated
surfaces may cause personal injuries such as burns.
• You must depressurize the LPG fuel system before
removing the drain bolt from the vaporizer.
1. Warm up the engine and stop it.
2. Wrap the vaporizer's tar discharge port with a shop cloth and
open the drain cock or loosen the bolt.
3. The exhaust cock is surely closed when the exhaust of the tar
stops or the bolt is surely tightened.
4. Wipe away any tar from the forklift body and surrounding
components.
Inspection/Adjustment of Maximum rpm

Under Loaded and Unloaded Conditions
QD32 ENGINE
1. Warm up the engine.
2. Set the gear in the neutral position to unload the engine.
3. Verify that the maximum speed setscrew on the injection pump
is sealed.
4. Fully depress the accelerator pedal from the idling status and
verify that the accelerator control lever contacts the maximum
speed setscrew. In this state, check the engine speed with no
load.
NOTE:
• If the maximum engine speed with no load is in the specified
range, the maximum engine speed with load does not need to
be checked because it is considered acceptable.
• To check the maximum engine speed with load, follow the same
procedure as that for the gasoline engine. Set the gear in the
neutral position, tilt the mast to its rearmost end, and fully
depress the accelerator pedal.
5. If the maximum engine speed with no load is outside the
specified range, remove the seal from the maximum speed
setscrew on the injection pump and loosen the lock nut. Then
adjust the speed using the maximum speed setscrew.
MA-19
ENGINE MAINTENANCE
Inspection/Adjustment of Maximum rpm

Under Loaded and Unloaded Conditions
(Cont’d)
NOTE:
To adjust the maximum engine speed with load, increase or
decrease the maximum engine speed with no load within the
specified range so that an acceptable maximum engine speed with
load is attained.
6. After adjustment, make sure to tighten the lock nut and seal the
maximum speed setscrew.
7. Depress accelerator pedal fully under no load and, at this point,
read the tachometer indication.
Maximum engine speed (Under no load):
2,400 - 2,500 rpm
8. If indication is lower than specified maximum engine speed, turn
maximum speed adjusting screw counterclockwise 1 or 2
rotations. Then depress accelerator pedal to floor under no load
and, at this point, read indication.
9. If indication is still lower than specified speed, repeat step 8
above until specified engine speed is reached.
10. After adjustment, tighten lock nut securely.
11. Seal with a sealing wire or install a sealing cap.
Inspection of Spark Plug (K/GK21 and

K/GK25 Engines)
1. Remove the spark plug and check for electrode or insulator
burnout. Remove any carbon deposits. If damaged heavily,
replace the plug with a new one.
2. Check the electrode gap
Unit: mm (in)
Engine Plug type Gap
K/GK21 Spark Plug Gap:

(NGK type)
0.8 - 0.9 mm
K/GK25 FR2A-D
(0.031 - 0.035 in)
3. Adjust the gap dimension if necessary.

4. To install the spark plug, tighten it to the specified torque.
: Spark plug
19.6 - 29.4 N•m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)
Cleaning / Replacement of Air Cleaner

1. Release the air cleaner case clamp and open the case.
2. Take out the air cleaner element gently.
3. Visually inspect the element status and clean if necessary.
Note: The manufacturer recommends replacing the air cleaner
element. Cleaning with air pressure can damage the element.
4. To clean the air cleaner element, lightly tap on the element by
hand.
5. If the contamination cannot be eliminated by cleaning or if the
element is damaged, replace the element.
MA-20
PCV GAS RECIRCULATION DEVICE
PCV GAS RECIRCULATION DEVICE System Diagram
Component Parts Inspection

PCV valve
1. At idle, remove PCV valve together with hoses from rocker
cover.
2. Check if hissing sound is heard from the air passage when PCV
valve is operating normally.
ECM0144
3. Check air flow through the PCV valve and sucking air to/from
the INT end.
Blowing air: No air flow
Sucking air: Air flow exists
ECM0145
MA-21
BATTERY
BATTERY Inspection of Battery Fluid Level

1. Verify that the battery fluid level is in the optimum range
indicated on the battery housing.
2. If the fluid level is below the lower limit (LOWER), remove the
cap and add battery fluid to the upper limit (UPPER).
CAUTION:
Do not add battery fluid over the upper limit (UPPER).
3. Close the cap securely. Wash away any spilt battery fluid with
water and wipe to dry.
Inspection of Specific Gravity of Battery

Fluid
1. Using a hydrometer, inspect the specific gravity in each cell of
the battery.
CAUTION:
Ensure that the hydrometer probe is fully inserted in the battery
cell. When taking out the hydrometer from the cell, do not allow
any battery fluid to get outside.
2. To measure the specific gravity, read the upper end of the
hydrometer fluid level that is raised by surface tension.
Fully charged Tolerance
[Fluid temp. 20°C (68°F)] [Fluid temp. 20°C (68F°)]
1.26 1.20 or more
3. If the specific gravity is low, charge the battery. If the battery is

charged appropriately but the specific gravity is below 1.20, the
battery is considered to have reached the end of life.
MA-22
TIRES AND ROAD WHEELS
TIRES AND ROAD WHEELS Tire Air Pressure and Specifications

Measure the tire air pressure to see if the correct tire air pressure is
maintained.
CAUTION:
• Always check the tire air pressure when the tires are
cooled down.
• After measurement, make sure to attach the tire valve caps.
Unit: kPa (bar, kg/cm², psi)
Front tire (drive) Rear tire (steer)

Item
Single Double Wide single Radial J R
Tire size 6.50-10-14PR 6.50-10-14PR - 6.50 R10 5.00-8-8PR 5.00 R8

1.5 ton,
1.75 ton 900 (9.0, 9.18, 900 (9.0, 9.18, 1,000 (10.0, 900 (9.0, 9.18, 1,000 (10.0,
Tire pressure -
130.5) 130.5) 10.20, 145.0) 130.5) 10.20, 145.0)
Tire size 7.00-12-14PR 7.00-12-14PR 27 x 10-12-14PR 7.00 R12 6.00-9-10PR 6.00 R9
2.0 ton,
2.5 ton 900 (9.0, 9.18, 900 (9.0, 9.18, 700 (7.0, 7.14, 1,000 (10.0, 900 (9.0, 9.18, 1,000 (10.0,
Tire pressure
130.5) 130.5) 101.5) 10.20, 145.0) 130.5) 10.20, 145.0)
Tire size 28 x 9-15-14PR 28 x 9-15-14PR - 28 x 9 R15 6.50-10-14PR 6.50 R10
3.0 ton,
3.5 ton 900 (9.0, 9.18, 900 (9.0, 9.18, 1,000 (10.0, 900 (9.0, 9.18, 1,000 (10.0,
Tire pressure -
130.5) 130.5) 10.20, 145.0) 130.5) 10.20, 145.0)
Inspection of Tire for Wear

1. Inspect the remaining depth of the tire grooves. Check the tires
for tread wear, or measure the depth of the tire grooves with a
tire depth gauge.
Repair limit:
5 mm (0.197 in)
2. If any of the tires show a sign of tread wear or the groove depth
is less than the above limit, replace the tire.
3. Inspect the tires for uneven wear referring to the table below. If
uneven wear is found, identify the causal factor and take
appropriate actions. Replace the tire if necessary
MA-23
TIRES AND ROAD WHEELS
Inspection of Wheel Nut

Inspect the wheel nuts for looseness. Tighten them if necessary to
the specified torque, referring to the table below.
CAUTION:
Always tighten the wheel nuts in a diagonal manner.
TIGHTENING TORQUE
Model
Item 1D1 series 1D2 series
1.5 ton, 1.75 ton 2.0 ton, 2.5 ton 3.0 ton, 3.2 ton
167 - 226 246 - 294 441 - 588
Single tire
(17 - 23, 123 - 166) (25 - 29, 182 - 216) (45 - 59, 326 - 433)
167 - 226 246 - 294 540 - 686

(17 - 23, 123 - 166)*1 (25 - 29, 182 - 216)*1 (55 - 69, 399 - 505)*1
Front (drive)
Pneumatictire 167 - 226 246 - 294 589 - 735
Double tire
model (17 - 23, 123 - 166)*2 (25 - 29, 182 - 216)*2 (60 - 74, 435 - 542)*2
79 - 98 246 - 294
—
(8.1 - 9.9, 59 - 72)*2 (25 - 29, 182 - 216)*3
167 - 226 167 - 226
Rear (steer)
(17 - 23, 123 - 166) (17 - 23, 123 - 166)
: Bolt
: Nut
*1: Inner wheel
*2: Outer wheel nut
*3: Hub nut (Outer hub)
NOTE:
For 3.0 ton model, hub bolt fixing nuts are needed to install hub
bolts.
MA-24
BRAKE SYSTEM
BRAKE SYSTEM Inspection of Brake Fluid Level

Open dashboard LH end cover, and then check brake fluid level in
brake reservoir tank. Inspect the brake fluid level in the brake fluid
reservoir tank to see if the level is between the upper limit (MAX) and
lower limit (MIN) shown on the tank. Add fluid if necessary.
CAUTION:
• Only use the authorized genuine brake fluid. Do not mix
different types of brake fluids.
• Do not overfill the reservoir tank to over the upper limit
(MAX).
• Ensure that no foreign materials get into the reservoir tank
when adding brake fluid.
• Do not allow any brake fluid to contact the forklift paint
surfaces.
• If the brake fluid consumption is too large, there is a
possibility of fluid leakage.
Inspection/Adjustment of Brake Pedal

1. Using the stopper bolt, adjust A, the height of the pedal above
the floor (from the floor to the top of the pad). Then lock the
stopper bolt.
2. Adjust the length of the master cylinder push rod.
Adjust the clearance between the push rod and piston by
rotating the push rod. After adjusting, fasten the clevis with the
nut.
3. Check the play (C) of the pedal tread.
CAUTION:
• The clevis pin that joins the brake pedal and push rod must
be securely connected.
• The snap pin must be securely attached.
• When operated, the brake pedal must not catch or
otherwise work improperly.
Unit: mm (in)
Items
Height of pedal A 105 - 115 mm ( 4.13 - 4.53 in)
Clearance between
1 (0.040)
push rod and piston B
Play of pedal thread C 1 - 3 mm ( 0.04 - 0.12 in)
4. Securely tighten the clevis with the nut.
5. If the pedal is properly adjusted, the brake pedal play will meet
the standard: Free play (C).
MA-25
BRAKE SYSTEM
Adjustment of Inching Pedal

1. Adjust and tighten the stopper bolt (inching) so that the height
(A) from the top surface of the floor plate to the center of the
inching pedal meets the standard shown below.
MAT0240L.tif Standard (mm, in): 105-115mm (4.13-4.53 in)
2. Adjust the clearance (c) of the part C bolt and linkage to the
standard indicated below. Then securely tighten with the nut.
Standard (mm, in.): 4.4-5.7mm (0.173-0.224 in)
MAT0228L.tif
Adjustment of Inching Valve

1. Preparation work
• Similar to the aforementioned oil pressure measurement, block
the steering tire and then raise the driving tire off the ground.
• Connect the oil pressure gauge to the clutch oil pressure outlet
port (position D in the figure to the left).
• Adjust the installation length of the inching cable until the
MAT0229L.tif plunger is fully withdrawn.
• Securely tighten the lock nut and tighten the inching cable.
2. Adjustment procedure
• Idle the engine to raise the temperature of the transmission oil.
• Move the forward/reverse shift lever to the forward (F) position.
• Gradually press the inching pedal and force in the plunger.
Record the relationship between the stroke of the plunger and
the clutch oil pressure, Pc.
• Confirm that the aforementioned relationship is the diagram

shown in the figure. At the stroke end of the plunger, however,
the oil pressure must be completely 0 (zero).
MAT0230L.tif
Note: 1 kPa = 0.145 PSI; 1 mm = 0.039 in.
MA-26
BRAKE SYSTEM
Inspection of Brake Lining for Wear

Remove the brake drums and check the thickness of the brake
linings. Replace any brake linings that have been worn out.
Repair limit (mm, in.): 1.0, 0.039
• After replacing the brake linings, check and adjust the
fitting to the brake drums.
Adjustment of Shoe Clearance

CAUTION:
• Before adjusting the shoe clearance, release the parking
brake and loosen the adjusting bolt on the parking brake
lever side to make the shoe contact the anchor pin.
1. Remove the adjusting hole plug on the rear side of the backing
plate and rotate the adjuster until the wheel cannot be rotated.
2. Return the adjuster by 25 to 30 steps to adjust the shoe
BRT0017.tif clearance.
Shoe clearance (mm, in.):

0.25 - 0.5, 0.009 - 0.020 (1D1)
0.1 - 0.35, 0.004 - 0.014(1D2)
3. After adjustment, verify that the wheel rotates smoothly and
there is no brake dragging.
CAUTION:
• After adjustment, mount the adjusting hole plug securely.
4. Verify the automatic adjustment system for proper operation.

• The lever should engage with the next gear tooth when the
adjusting cable is pulled toward the primary shoe. When the
cable is released, the lever should feed forward one tooth and
return to the original position.
• If the lever does not operate normally, check and adjust the
cable guide, return spring mounting position and other
components so that the distance between the lever position on
BRT0106L.tif the ratchet and the adjuster centerline is within the specified
range.
Standard (mm, in.): 7.0 - 9.0, 0.275 - 0.354
NOTE:
• The clearance between the brake drum and the lining is
automatically adjusted according to the level of lining wear
when the foot brake is activated during reverse travel.
• The threated area on the adjuster should be a minimum of 2.6
mm, if there is not enough spring tension, the automatic
adjusting mechanism will not work properly.
MA-27
BRAKE SYSTEM
Inspection/Adjustment of Parking Brake

Operation Effort
CAUTION:
• Preliminarily adjust the brake shoe clearance.
1. Measure the operation force required to move the lever to the
lock position by applying force to point P shown in the figure.
Standard [N (kg) Lbs.]:
MAT0231L.tif 116 - 160 (12 - 16) 26 - 36
2. If the measured operation force is not within the specified range,

perform the following adjustment.
• Unlock lever.
• Adjust adjusting bolt using a screwdriver so that the operation
force required to move the lever to the lock position is within the
standard.
BRT0105L.tif
MA-28
STEERING
STEERING STEERING SYSTEM

Steering Wheel Free Play
While the engine is idling, check the circumferential free play of the
steering wheel.
Standard (mm, in.): 30, 1.18, or less
MAT0232L.tif
Steering Wheel Operation Force

1. Run engine at idling.
2. Attach a spring scale to the steering wheel knob. Pull the spring
scale in the tangential direction of the steering wheel. Read the
scale just when the wheel starts to move and check if the
measurement is within the specified range.
Steering wheel operating force [N (kg) Lbs.]:
7.9 - 11.7 (0.8 - 1.2) 1.76 - 2.65
Inspection of Hydraulic Pressure

1. Verify that the fluid level in the hydraulic fluid tank is appropriate
and remove the plug from the control valve port.
2. Install pressure gauge to port.
3. Start the engine. Turn the steering wheel left and right by two or
three rotations.
HDT0215L.tif 4. Run engine at idling, turn steering wheel fully right or left, and
then apply power in the turning direction.
5. Read the pressure gauge and return the steering wheel to the
straight-ahead position. Check that the measured hydraulic
pressure is within the specified range.
Refer to Page ST-4 or HD-2
CAUTION:
• Finish the measurement within a short time.
NOTE:
• The hydraulic pressure cannot be measured correctly when the
steering wheel is in the straight-ahead position.
6. If the pressure reading is outside the standard range, the oil
pump, flow priority valve or PS relief valve may be
malfunctioning. Identify the causal factor and take appropriate
actions.
MA-29
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION

Inspection of Automatic Transmission Fluid
Level
CAUTION:
• Warm up the engine for approximately 10 minutes before
inspection.
• After idling, stop the engine.
• Wait at least one minute after stopping the engine, and then
check the level.
• Finish the confirmation procedure within 15 minutes after
stopping the engine.
• Only use the authorized genuine hydraulic fluid. Do not mix
different types of fluids.
1. Check the automatic transmission fluid level with the
transmission oil level gauge. The fluid level should be in the
optimum range shown in the figure.
MAT0220L.tif
2. If the fluid level is low, add automatic transmission fluid from the
oil level gauge port.
MAT0221L.tif
MA-30
Inspection of A/T Line Pressure

CAUTION:
• Before inspection, always verify that the automatic
transmission fluid, engine oil and engine coolant are
charged sufficiently. Also warm up the engine for about 10
minutes.
ATT0236L.tif • Jack up the front wheels, block the rear wheels, and
engage the parking brake.
• Set a rev counter when checking so as to check engine
speed.
1. Remove the fluid pressure check plug and install a pressure
gauge as shown in the figure.
a: Main oil pressure
b: Clutch oil pressure
c: T/C inlet oil pressure
CAUTION:
• Do not remove the fluid pressure check plug while the
engine is running or just after the engine is stopped.
2. Start engine, and then make sure that each hydraulic pressure
is within the standard when engine speed is in the following
conditions.
• Start the engine, place the forward/reverse shift lever in neutral,
and then measure the main oil pressure and T/C inlet oil
pressure.
• Move the shift lever to forward and reverse, and measure the
clutch oil pressure.
Engine speed Oil pressure
(rpm) (kPa (bar, kg/cm2, psi)
883 - 1078 (8.8 - 10.8,
Idle speed Standard
Main oil 9 - 11, 128 - 156)
a
pressure 980 - 1274 (9.8 12.7,
1500 - 1700 Standard
10 - 13, 142 - 185)
883 - 1078 (8.8 - 10.8,
Idle speed Standard
Clutch oil 9 - 11, 128 - 156)
b
pressure 980 - 1274 (9.8 12.7,
10 - 13, 142 - 185)
49 - 294 (0.49 - 2.94,
Idle speed Standard
T/C inlet oil 0.5 - 3.0, 7.1 - 42.6)
c
pressure 196 - 539 (1.96 - 5.39,
2.0 - 5.5, 28.4 - 42.6)
• When measuring the forward clutch pressure and reverse clutch

pressure, set the selector lever in the forward position and the
reverse position respectively.
• For the forward clutch pressure and reverse clutch pressure,
also check that the pressure immediately drops to zero when
the selector lever is shifted in the opposite direction of the
measurement position.
MA-31
Inspection of Stall Speed

CAUTION:
• Securely pull the parking brake and install a wheel stopper
to front and rear tires when checking.
• Before inspection, always verify that the automatic
transmission fluid, engine oil and engine coolant are
charged sufficiently. Also warm up the engine for about 10
minutes.
• Set a rev counter when checking so as to check engine
speed.
1. Start the engine, and then turn selector lever to forward
position.
2. Fully slowly depress accelerator pedal with brake pedal fully
depressed.
3. Quickly read the engine speed when it stays at a constant
engine speed, and then release accelerator pedal and return
selector lever to neutral position.
CAUTION:
• Finish inspection within 30 seconds.
• Do not depress inching brake pedal when checking.
• Keep idling for 1 minute or more after checking.
4. Check selector lever reverse position as well as its forward
position.
5. Make sure that engine speed is within the standard.
Engine Stall speed (rpm)
Electronically controlled
K/GK21
specification
1850 - 2150
K/GK25 Electronically controlled
specification
QD32 1850 - 2150
MA-32
LOADING MECHANISM
LOADING MECHANISM
Inspection of Fork
1. Visually inspect the fork and replace it if cracked or damaged.
(To identify minute cracks, use the dye penetrant method.)
2. If the fork is worn by 3 mm (0.12 in) or more compared to a new
one, replace it. (The grounding face at the fork base is prone to
wear.)
MA-33
LOADING MECHANISM
LOADING MECHANISM
Inspection of Fork
• Visually inspect the fork and replace it if cracked or damaged.
(To identify minute cracks, use the dye penetrant method.)
• If the fork is worn by 3 mm, 0.118 in., or more compared to a
new one, replace it. (The grounding face at the fork base is
prone to wear.)
ITA Recommended Practices for the inspection and repair of forks

on fork lift trucks require that a fork be removed from service when
the thickness of the blade has worn by 10% of its original thickness.
FORK WEAR CALIPERS

Forks can be checked for
wear by using a fork wear
caliper which is a "go,no-
go" gauge that will clearly
indicate when the fork
does not comply with the
required standards. The
design of the caliper is
based on the assumption
that on a new fork, the
cross section of the arm
blade between the end of
the taper and the heel, is
the same as the shank.
Because the middle of the
shank is not in contact
with the top or bottom
members of the carriage
and therefore is not
subject to wear, it can be
used as a reference point to initially set the calipers.
Note: Fork wear calipers have two measuring points (see Figure 1):
• The outside, or top jaws, are used to set the calipers.
• The inside, or lower jaws, have been fixed at a point that will
always measure 10% less than the reading recorded by the top
jaws. (See Figure 3 for vendor information).
• Set the top jaws by measuring the thickness of the shank. (See
Figure 2 and vendor information).
The calipers should be squeezed by hand until the top jaws make
contact with both sides of the shank
IMPORTANT
The amount of force used to squeeze the tips of the top jaw against
the fork should be very slight as caliper distortion can occur if
excessive force is used. Care should also be taken when using the
calipers to hold them square across the shank or an incorrect
reading may occur.
Once the top (outside) jaws are set to the thickness of the shank, the
calipers are then ready to check the blade of the fork itself.
Check the fork blade against the shank thickness in the area shown
in Figure 2, and in the vendor information.
MA-34
LOADING MECHANISM
Carefully fit the caliper over the fork blade. If the inside, or lower
jaws, of the calipers pass over the flanks of the fork blade at any
point between the end of the taper and the heel of the fork, the forks
should be replaced.
INCORRECT READINGS
Incorrect readings may be made by accidentally alter the setting of
the calipers when laying them down, or mishandling them when
checking a blade. It is good practice to re-check the calipers setting
on the shank each time before checking the fork blade.
Accuracy in caliper measurement depends on the sense of touch.

To get a delicate touch of the caliper against the fork, the caliper
should be held "lightly" with a "firm" grip.
FORK WEAR
The most common cause of fork wear is when the fork is allowed to
drag on the floor due to lift chain stretch, tire wear (especially
cushion tires), etc. The area that fork wear usually appears is
illustrated in Figure 4.
Note: Fork calipers are available under Part Number FORKO-

GAUGE.
FORK WEAR VERSUS CAPACITY
FORK CAPACITIES PER PAIR
MA-35
LOADING MECHANISM
Inspection/Adjustment of Carriage Height

1. Set the mast upright and fully lower the carriage.
CAUTION:
Before inspecting and adjusting the carriage height, remove the
fork or park the forklift in a place where the fork will not be
grounded.
2. Measure the distance from the ground level to the carriage

bottom end to see if it fulfills the following criterion.
Standard:
76 mm -0/+6 mm (2.99 in -0/+0.24)
3. If not as specified, loosen the lock nut and adjust with the lift
chain adjusting nut.
MAM0224
Inspection/Adjustment of Lift Chain Tension

CAUTION:
Before this maintenance work, always ensure that the carriage
height is appropriate.
1. Set the mast upright and raise the fork by 20 to 30 mm (0.787 to
1.181 in) from the ground level.
2. For the 2W mast, pull the lift chain at the middle point and check
the deflection. For the 2F and 3F masts, press the lift chain at
the middle point and check the deflection.
Standard:
25 - 30 mm (0.984 - 1.181 in)
3. If the deflection is outside the specified range, loosen the lock
nut and adjust the chain tension with the lift chain adjusting nut.
CAUTION:
• Ensure that equivalent tension is applied to the left side
and right side of the lift chain.
• After adjustment, always check the carriage operation for
smoothness.
MA-36
LOADING MECHANISM
Inspection of Carriage Roller

1. If the carriage roller does not operate smoothly or has
undergone deformation, stepped wear or damage, replace it.
2. Check the clearance between the carriage roller rolling face and
the inner mast. If the clearance is outside the specified range,
replace the carriage roller with a new one with an appropriate
size.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Inspection of Mast Roller

1. If the mast roller does not operate smoothly or has undergone
deformation, stepped wear or damage, replace it.
2. Check the clearance between the mast roller rolling face and
the mast rail. If the clearance is outside the specified range,
replace the mast roller with a new one with an appropriate size.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
MA-37
LOADING MECHANISM
Adjustment of Mast Roller Clearance

1. Preliminarily set the roller pitches (dimension L) of the inner and
outer masts referring to the table below.
CAUTION:
For the 3F and 3V mast, set the roller pitches in two steps: first
for the inner and middle masts, then for the middle and outer
masts. Setting the roller pitches of the three masts at once will
deteriorate the stability.
2W MAST
Unit: mm (in)
Dimension L
Lifting height
1D1, 1D2
3,000 (118.1)
311 (12.2)
3,300 (129.9)
3,500 (137.8) 346 (13.6)
3,700 (145.7) 371 (14.6)
4,000 (157.5)
4,500 (177.2) 411 (16.2)
5,000 (196.9)
2F MAST
Unit: mm (in)
Dimension L
Lifting height
1D1 1D2
3,000 (118.1)
282 (11.10) 284 (11.2)
3,300 (129.9)
3,500 (137.8) 350(13.78) 354 (13.9)
3,700 (145.7) 402(15.83) 404 (15.9)
4,000 (157.5) 482(18.98) 484 (19.1)
3F AND 3V MAST
MA-38
LOADING MECHANISM

(Cont’d)
Unit: mm (in)
Mast lifting up 1D1 G1D2 1D2
3F 3850, 4300
519 (20.43)
(151.57, 169.29)
367(14.45) 369 (14.53)
4750 (187.01) 504 (19.84)
5154 (202.91) 494 (19.45)
5500 (218.50) 382(15.04) 574 (22.60) 384 (15.12)
6000 (236.22) 417(16.42) 669 (26.34) 419 (16.50)
6500 (255.91) 502(19.76) 754 (29.68) 504 (19.84)
7000 (275.59) 602(23.70) 854 (33.62) 604 (23.78)
3V 3850, 4300, 4700
469 (18.46)
(151.57, 169.29, 185.04)
5050 (198.82) 484 (19.06)
5500 (218.50) — — 519 (20.43) — —
6000 (236.22) 669 (26.34)
6500 (255.91) 794 (31.26)
7000 (275.59) 854 (33.26)
3600, 4050, 4500, 4900
369 (14.53) 369 (14.53)
(141.73, 159.45, 177.17, 192.91)
5250 (206.69) 384 (15.12) 384 (15.12)
—
5750 (226.38) 419 (16.50) 419 (16.50)
6330 (249.21) 504 (19.84) 504 (19.84)
6880 (270.87) 604 (23.78) 604 (23.78)
2. Slide the mast to the leftmost or rightmost end. Check the

clearance between the mast and the opposite mast roller. If the
clearance is outside the specified range, adjust it with the
clearance adjusting shims for the roller.
Standard:
0.1 - 0.6 mm (0.004 - 0.24 in)
Shim type:
0.5, 1.0, 2.0 mm (0.02, 0.04, 0.08 in)
CAUTION:
Create an equivalent clearance at both the right and left sides
wherever possible.
MA-39
LOADING MECHANISM

(Cont’d)
3. Visually inspect the mast liner. Replace it if worn excessively or
damaged.
4. Check the clearance between the mast liner and the inner mast.
If not as specified, adjust the clearance using the shims.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim type:
0.5, 1.0 mm (0.02, 0.04 in)
Inspection of Mast Operation

1. Raise, lower, and tilt forward/backward the mast. The mast
should generate no drag feel or unusual noises.
2. Check that the mast support maintains an appropriate free play
and the mast support cap bolt has no looseness.
Inspection of Mast Cylinder

1. Operate the cylinder and check that no dragging and unusual
noises are present.
2. Check that no oil leaks are present.
3. The piston rod should be free from scratches.
4. The cylinder tube should be free from dents and damages.
Inspection of Tilt Cylinder

Check the following points:
a. No dragging or unusual noises are present during operation.
b. No oil leaks are present.
c. The piston rod should be free from scratches.
d. The tilt cylinder rod and lock nut are not loose.
Greasing Point
TILT CYLINDER PIVOT PIN
Supply grease from the grease nipple.
MA-40
LOADING MECHANISM
Greasing Point (Cont’d)

LIFT CHAIN
Apply gasoline engine oil to the entire surface of the chain.
MAST SUPPORT
Supply grease from the grease nipple.
MAST ROLLER AND MAST LINER

1. Apply grease to the roller sliding faces and mast liner.
2. Apply grease to the rolling face of the roller and the rail of the
thrust metal contact face.
MA-41
BODY ELECTRICAL
BODY ELECTRICAL Inspection/Replacement of Fuses

Check and replace the fuses as necessary by referring to the figure
on the left.
CAUTION:
• When installing a new fuse, always use the one with the
specified capacity referring to the fuse box label.
• If the replaced fuse is burnt again, the electrical system
is considered to have malfunctions. Immediately
identify and remove any causal factors.
BCM0252
MA-42
BODY ELECTRICAL
Replacement of Bulbs
When replacing any burnt bulb, refer to the table below.
CAUTION:
When installing a new bulb, always use the one with the
specified capacity.
Rated voltage 12V
Wattage
Description Quantity Color
(W)
Headlight (halogen) 55 2 White
Front turn signal light 21 2 Orange
Stop/tail light 21/5 Red

Rear
combination Turn signal 21 2 Orange
light
Reverse 21 White
Operation lamp (OPT) 55 1 White
Yellow/
Pato lamp (OPT) 2.2 1
Red
MA-43
EMERGENCY MAST LOWERING
EMERGENCY MAST LOWERING Emergency lowering shutt-off valve

NOTE:
• When the forks and masts cannot be lowered with/without load.
• First of all, check the following:
For joystick valve

NOTE:
• Check that C1 solenoid and solenoid for lift operate normally.
Refer to the VC section.
• Operate the control valve lever toward the mast lowered side,
and then make sure that the pump operates (turns). If not,
repair the forklift by referring to the VC section.
If the above steps are OK, the forks and masts can be lowered with
the following procedure.
1. Turn key switch to OFF, disconnect the battery connection.
2. Remove the floor mat and floor board.
3. Loosen lock nut of shut-off valve on the lower side of control
valve.
4. Loosen the screw counterclockwise until it stops.
CAUTION:
Mast will begin to lower when screw is first turned.
Return
1. Screw in the screw until it stops.
2. Loosen lock nut.
3. Install the floor board and floor mat, and then install the battery.
CAUTION:
Always return to the lift lock function after repair.
MA-44
ENGINE REMOVAL
SECTION ER
CONTENTS
SERVICE DATA AND SPECIFICATIONS .......... ER-2 ENGINE REMOVAL AND INSTALLATION ....... ER-4
Tightening Torque .......................................... ER-2 Precaution ...................................................... ER-4
REMOVAL AND INSTALLATION ...................... ER-3 Construction ................................................... ER-5
Description ..................................................... ER-5
Removal ......................................................... ER-6
Installation ...................................................... ER-8
Adjustment ..................................................... ER-8
SERVICE DATA AND SPECIFICATIONS
ENGINE WEIGHT
Unit: N (kg, lb)
K/GK21 3531 (794)
K/GK25 3835 (862)
QD-32 --
ENGINE MOUNTING SHIM (THREE TYPES)

Unit: mm (in)
0.6(0.024)
Thickness mm (in) 1.2 (0.047)
2.3 (0.091)
Tightening Torque
Unit N-m kg-m ft-lb in-lb
Transmission housing securing bolt
Part C (Gasoline engine) 44- 54 4.4 - 5.6 32 - 40 --
Part C (Diesel engine) 42 -51 4.2 - 5.3 31 - 38 --
Part D (Gasoline engine) 42 -51 4.2 - 5.3 31 - 38 --
Part E 30 - 37 3.0 -3.8 22 - 27 --
Part F 42 - 51 4.2 - 5.3 31 -38 --
Drive plate securing bolt 49 - 54 5.0 - 5.6 37- 40 --
Drive axle housing securing nut
1D1 19 - 24 1.9 - 2.5 14 -18 --
1D2 39 - 51 3.9 - 5.3 29 - 38 --
Drive shaft fixing bolt
1D1 40 - 53 4.0 - 5.5 29- 39 --
1D2 74 - 88 7.5 - 9.0 55 -65 --
Steering wheel nut 17 - 21 1.7 - 2.2 13 -15 --
Engine mounting securing bolt (to frame) 74 -93 7.5 - 9.5 55 - 68 --
Engine mounting centerbolt 49 - 68 5.0 - 7.0 37 - 50 --
Hydraulic oil pump securing bolt 25 - 31 2.5 - 3.2 18 - 23 --
Upper overhead guard fixing bolt 78 - 98 7.9 - 10.0 58 -72 --
Rain guard fixing bolt 13 - 15 1.3 - 1.6 10 -11 --
Brake pedal assembly fixing bolt 37 - 50 3.7 -5.1 27 - 36 --
Brake tube bracket fixing bolt 6.0 -7.6 0.61 - 0.78 -- 53 - 67
Brake master cylinder fixing bolt 9.2 - 11.7 0.93 - 1.2 -- 81 - 104
Radiator fixing bolt 3.9 - 4.5 0.39 - 0.46 -- 34 - 39
Muffler front tube securing nut (to exhaust) 20 - 24 2.0 - 2.5 15 -18 --
Main muffler fixing bolt 9.2 - 11.7 0.93 -1.2 -- 81 - 104
Radiator shroud fixing bolt 6.4 -7.4 0.65 - 0.76 -- 57 - 65
Radiator reservoir tank fixing bolt 3.9 - 4.5 0.39 - 0.46 -- 34 - 39
Air cleaner fixing bolt 13 - 15 1.3 - 1.6 10 - 11 --
Air horn fixing nut 8.5 - 10.7 0.86 - 1.1 -- 75 -95
Console box fixing bolt 26 - 33 2.6 - 3.4 19 -24 --
Counterweight fixing bolt
1D1 295- 441 30 - 45 217 - 325 --
1D2 491 - 617 50 -63 362 - 455 --
LPG cylinder bracket fixing bolt 98 -127 10 - 13 73 - 94 --
Under cover fixing bolt 13 -15 1.3 - 1.6 10 - 11 --
Floor board fixing bolt 13 -15 1.3 - 1.6 10 - 11 --
Rear cross member fixing bolt 78 - 98 7.9 - 10.0 58 - 72 --
Top panel stayfixing bolt 5.1 - 6.4 0.52 - 0.66 -- 46 - 57
Top panel fixing bolt 13 - 15 1.3 - 1.6 10 - 11 --
ER-2
REMOVAL AND INSTALLATION
Piping and Radiator (Models with Torque Converter)
Order of removal
1. Reservoir tank 7. Oil cooler hose (radiator - torque-converter
2. Hose (upper) transmission)
3. Hose (lower) 8. Cooling fan
4. Hose (hydraulic tank - control valve) 9. Fan belt
5. Hose (hydraulic tank - oil pump) 10.Shroud
6. Hose (oil pump - control valve)
Preparation work
1. Remove cylinder block drain plug, and drain the coolant.
2. Loosen the petcock at the bottom of the radiator, and drain the
coolant.
Removal
Disconnect the cooler hose from the torque-converter transmission
side, and then attach it to the right side of the frame.
Installation
Install in the reverse order of removal.
ER-3
ENGINE REMOVAL AND INSTALLATION
Precaution
In case of LPG models, release pressure from the fuel line under the
following procedures.
1) Turn the discharge valve at the side of the cylinder slowly in a

clockwise direction until it is fully closed.
2) Allow the engine to run until it stops naturally (fuel exhausted).
3) Turn the ignition switch to the OFF position.
CAUTION:
Disconnect the battery ground cable from the battery before
removal.
Place chocks on the front and rear wheels to prevent the lift
truck from moving.
ERM0023 Do not remove the engine until the exhaust and cooling
systems have completely cooled off.
Adjust the length of the lifting device as required in order to
suspend the engine safely.
Be sure to use an engine lifting device with locking hooks.
When removing the engine from the forklift, be especially
careful not to hit it any of the adjacent parts.
Never get under a lifted engine.
ER-4
Construction
K/GK21 AND K/GK25
ERM0021
QD32
ERM0022
Description
The removal and installation of engines should be done with the
engine unit alone or with the transmission and difference carrier
attached, according to the situation.
ER-5
Removal
METHOD 1 (WHEN REMOVING THE ENGINE

ASSEMBLY)
1. Remove the butterfly nut and disconnect the minus battery
terminal from battery.
2. Disconnect the plus battery terminal from battery, and remove
battery.
3. Remove instrument cover and floor mat. (Refer to BF section.)
ERM0024
4. Remove top panel, top panel stay, rear cover, rear cross
members, radiator cover, floor board, under cover, rear under
cover and center under cover. (Refer to BF section.)
5. Remove LPG cylinder bracket (LPG models) and
counterweight.
6. Open the radiator drain cock to drain coolant. If necessary,

remove console box (on models with a joystick lever).
7. Remove air cleaner and radiator reservoir tank.
8. Disconnect radiator hoses (upper and lower) from radiator.
9. Remove radiator shroud.
10. Disconnect oil cooler hoses from radiator and plug the hose
openings to prevent oil from leaking.
11. Remove muffler assembly and radiator.
12. Disconnect fuel hoses, vacuum hoses and hot water hoses
(LPG) from engine.
ERM0025 13. Disconnect harness connectors from engine. (Starter,
alternator, carburetor, water thermo sensor, oil pressure switch,
etc.) (Refer to BE section.)
14. Remove the brake pedal assembly from the master cylinder,
with the master cylinder remaining attached to the forklift.
(Refer to BR section.)
15. Disconnect the accelerator wire and idle control wire (Diesel
engine) from engine.
16. Remove rain guard and upper overhead guard.
ERM0026
ER-6
Removal (Cont’d)
17. Attach wire ropes to the engine slingers and slightly lift engine.
18. Remove hydraulic oil pump from engine.
19. Loosen the engine mounting center bolts and remove engine
mounting bolts from frame.
20. Support the transmission with wooden blocks.
ERM0027
21. Remove the drive plate securing bolts and the bolts securing
the engine to the transmission housing, and separate engine
and transmission.
22. Gradually lift engine assembly and move it away from the lift
truck.
ERM0028
METHOD 2 (WHEN REMOVING ENGINE WITH THE

TRANSMISSION AND DIFFERENTIAL CARRIER)
1) Use the same procedures (steps 1 through 17) as in Method 1.
2) Disconnect harness connectors from transmission (F-R
solenoid valve, speed sensor, oil temperature sensor, etc.)
3) Remove steering wheel.
4) Remove drain plug from differential case and drain A/T fluid and
differential oil.
5) Remove drive shafts on both sides.
6) Attach wire ropes to engine slingers and gear carrier housing,
and slightly lift engine.
7) Remove hydraulic oil pump from engine.
8) Loosen engine mounting center bolts and remove engine
mounting bolts from the frame.
ERM0029
9) Remove nuts securing differential carrier housing to drive axle

housing.
10) Gradually lift engine with the transmission and differential
carrier attached, and move it away from lift truck.
ERM0030
ER-7
Installation
Installation is conducted in reverse order of the removal.
Adjustment
1) Lower the forklift to the appropriate position, and slide the
center bracket from the engine side to the forklift side.
2) Completely secure the left and right drive axle mounting
brackets to the body.
3) Lower the engine, and temporarily attach the right side center
bracket to the body side bracket.
4) Tighten the center bracket and the body side bracket, after
tightening the mounting bolt of the rubber section to the
appropriate torque.
CAUTION:
If the clearance on the left side is 0 mm (0 in) in this condition,
conduct the following procedures to the right side.
5) Temporarily attach the left side center bracket to the bodyside

bracket, and tighten the mounting bolt of the rubber section to
the appropriate torque.
6) Under this condition, select a shim and insert it between the left
side center bracket and the body side bracket.
7) After inserting the shim, attach the left side center bracket to the
body side bracket completely.
CAUTION:
Tighten transmission housing securing bolts as follows:
Part C (Gasoline engine)
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
Part C(Diesel engine)
: 42 - 51 N•m (4.2 - 5.3 kg-m, 31 - 38ft-lb)
Part D (Gasoline engine)
: 42 - 51 N•m (4.2 - 5.3 kg-m, 31 - 38ft-lb)
Part E
: 30 - 37 N•m (3.0 - 3.8 kg-m, 22 - 27ft-lb)
ERM0034
Part F
: 42 - 51 N•m (4.2 - 5.3 kg-m, 31 - 38 ft-lb)
When installing, make sure the harness connectors are
connected correctly.
After installation, adjust the accelerator control system. (Refer
to FE section.)
Do not forget to add engine coolant, A/T fluid and differential
oil.
Adjust the engine as necessary.
ER-8
SECTION AT
CONTENTS
SERVICE DATA AND SPECIFICATIONS Adjustment of Inching Valve ......................... MA-23
(SDS) ................................................................... MA-2 Removal and Installation .............................. MA-24
General Specification...................................... MA-2 Disassembly ................................................. MA-24
Adjustment Value............................................ MA-3 Torque Converter Housing ........................... MA-25
Tightening Torque........................................... MA-4 Torque Converter ......................................... MA-25
TROUBLE DIAGNOSES AND Oil Pump ....................................................... MA-26
CORRECTIONS .................................................. MA-5 Main transmission Case ............................... MA-26
OIL CIRCUITOIL CIRCUIT.................................. MA-8 Disassembly of Clutch Drum Assembly........ MA-28
Oil Passages from Oil Strainer to Control Control Valve ................................................ MA-32
Valve Body...................................................... MA-8 Oil Pump ....................................................... MA-33
Oil Passages from Control Valve Body to Reduction Gear ............................................ MA-33
Main Shaft..................................................... MA-10 Torque Converter ......................................... MA-35
OIL PRESSURE CIRCUIT DIAGRAM .............. MA-11 Oil Pump ....................................................... MA-36
AUTOMATIC TRANSMISSION......................... MA-15 Clutch Drum.................................................. MA-37
Construction.................................................. MA-15 Tightening Torque ........................................ MA-38
Test............................................................... MA-20 SPECIAL SERVICE TOOLS ............................. MA-39
Adjustment of Brake Pedal ........................... MA-22
Adjustment of Inching Pedal ......................... MA-22
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification
Torque converter
1-speed A/T
Type Symmetrica, 3-element, 1-stage, 2-phase torque converter
Transmission
Type 1-speed forward and 1-speed reverse, constant-mesh
Clutch Multi-disc clutch
Number of drive plate

Forward 6
Reverse 6
Number of drive plate
Forward 6
Reverse 6
Oil pump
Internally intermeshing involute gear pump
Type
Automatic transmission fluid DEXRONTM or M2C-33E or F
Lubrication system Forced lubrication by oil pump
Cooling system Water-cooled by oil cooler
1D1/1D2 SERIES: ATM AND FINAL DRIVE (F/D)

Out Line
1. Basically ATM and Final Drive (F/D) follow current model.
2. New ATM established for K/GK21 engine in P1 series: New combination of gear ratio: ATM and Final Drive
(F/D).
(New type)
Vehicle P1 P2 P3
Engine QD32 K/GK21 QD32 K/GK25 QD32 K/GK25
T/C stall torq ratio 2.8 2.8 2.8 2.8 2.8 2.8
Gear ratio 3.105 2.762 2.762 3.105 2.762 3.105
ATM
STD Shift change
Electric Electric Electric Electric Electric Electric
control
Model H263 (2P) H263 (2P) H296 (4P) H296 (4P) H310 (4P) H310 (4P)
F/D
Gear ratio 5.286 5.857 5.857 5.857 6.166 6.166
T/C stall torq ratio 2.8 2.8 2.8 2.8 2.8 2.8
Gear ratio 2.762 2.762 2.762 3.105 2.762 3.105
ATM
Low
Shift change
noise Electric Electric Electric Electric Electric Electric
control
(OPT)
Model H263 (2P) H263 (2P) H296 (4P) H296 (4P) H310 (4P) H310 (4P)
F/D
Gear ratio 5.286 5.857 5.857 5.857 6.166 6.166
AT-2
Adjustment Value
Unit: mm (in)
Item Service standard Repair limit
Torque converter External diameter of the oil slide of the oil pump 41.915 - 41.965 —
sleeve (1.6502 - 1.6522)
Lateral runout of driven plate 0.2 (0.008) 0.5 (0.020)
Oil pump Gap between inner gear and oil pump cover 0.02 - 0.04 0.08 (0.0031)
(0.0008 - 0.0016)
Gap between outer gear and oil pump cover 0.02 - 0.04 0.08 (0.0031)
(0.0008 - 0.0016)
Gap between the outer gear tooth tips and the 0.20 - 0.34 0.38 (0.0150)
crescent (0.0079 - 0.0134)
Gap between the external circumference of the 0.09 - 0.18 0.25 (0.0098)
outer gear and the oil pump housing (0.0035 - 0.0071)
Internal diameter of the oil pump sleeve bushing 42.00 - 42.039 42.139 (1.6590)
(1.6535 - 1.6551)
Clutch drum Wear of drive plate 2.5 - 2.65 2.2 (0.087)
(0.0984 - 0.1043)
Wear of driven plate 1.53 - 1.67 1.4 (0.055)
(0.0602 - 0.0657)
Seal ring groove width 2.26 - 2.29 2.4 (0.094)
(0.0890 - 0.0902)
Seal ring width 2.05 - 2.15 2.01 (0.0791)
(0.0807 - 0.0846)
Clearance between retaining plate and snap ring 1.8-2.4(0.071-0.094) 6.5 (0.256)
HYDRAULIC PRESSURE VALUE

Unit: kPa (bar, kg/cm2, psi)
Engine speed
700 rpm 2,000 rpm
Hydraulic pressure
883 - 1,078 980 - 1,274
Main pressure
(8.8 - 10.8, 9 - 11, 128 - 156) (9.8 - 12.7, 10 - 13, 142 - 185)
883 - 1,078 980 - 1,274
Clutch pressure
(8.8 - 10.8, 9 - 11, 128 - 156) (9.8 - 12.7, 10 - 13, 142 - 185)
49 - 294 196 - 539
T/C inlet pressure
(0.49 - 2.94, 0.5 - 3.0, 7.1 - 42.6) (1.96 - 5.39, 2.0 - 5.5, 28.4 - 42.6)
ENGINE STALL REVOLUTION

Unit: rpm
K/GK21 + K/GK25 QD32
1850 - 2150 rpm 1850 - 2150 rpm
OIL CAPACITY
Unit : l (lmp qt)
Oil capacity in transmission case 5.5 (4 7/8).
Oil capacity in torque converter 2.5 (2-1/4)
AT-3
Tightening Torque
ATM0101
: N•m (kg-m, in-lb) : N•m (kg-m, ft-lb)

: 9.2 - 11.7 (0.93 - 1.2, 81 - 104) : 16 - 20 (1.6 - 2.1, 12 - 15)
: 3.8 - 5.0 (0.38 - 0.51, 33 - 44) : 30 - 40 (3.1 - 4.1, 22 - 30)
: 275 - 343 (28 - 35, 203 - 253)
: 76 - 98 (7.8 - 10.0, 56 - 72)
: 246 - 294 (25 - 30, 181 - 216)
: 89 - 118 (9.1 - 12.0, 66 - 87)
AT-4
TROUBLE DIAGNOSES AND CORRECTIONS
Condition Probable cause Corrective action
Low output Torque converter
Low oil pressure
(1) Insufficient oil quantity Add oil.
(2) Air sucked from suction side Retighten or change packing.
(3) Clogged oilfilter Clean or replace.
(4) Worn oil pump (low discharge) Replace.
(5) Fatigue of regulator valvecoil spring Replace.
(6) Malfunction of regulator valve spool Repair or replace.
(7) Worn piston ringor O-ring Replace.
Brake in stator freewheel cam Replace torque converter assembly.
Seize stator freewheel Replace torque converter assembly.
Broken blades or interference of blade Replace torque converter assembly.
Transmission
Use of improper oil or air bubbles
(1) Air sucked from suction side Replace.
Retighten or change packing.
(2) Air bubbles due to too low torque Adjust.
converter pressure
(3) Water in oil Change oil.
Improper position of brake shift spool and Adjust.
link lever
Slippery clutch
(1) Low main pressure Replace oil pump, control valve.
(2) Wear on piston ring or O-ring Replace.
(3) Break in clutch piston Replace.
(4) Seizure or drag of clutch plate Replace.
Solenoid valve
Broken solenoid valve, foreign objects ordirt, Replace solenoid valve assembly.
or poor electrical power
Unusual rise of oil temperature Torque converter
Improper oil quantity Add or reduce oil.
Clogged oil filter (insufficient circulating Clean or replace.
quantity)
Interference of wheel vane Replace torque converter assembly.
Faulty stat or freewheel Replace torque converter assembly.
Air sucked into system. Retighten or change gasket.
Wateroil tank or transmission case Change oil.
To large resistance in piping (insufficient Repair or replace.
circulating quantity)
Worn or seize bearing Repair or replace.
Faulty instrument Replace.
Transmission
Dragging of clutch Replace clutch plate or solenoid valve
assembly.
Worn or seized bearing Replace.
AT-5
Noisy operation Torque converter

Break in drive plate Replace drive plate.
Worn or faulty bearing Replace torque converter assembly.
Interference of vane wheel. Replace torque converter assembly.
Loose bolt Retighten or replace.
Worn spline Replace torque converter assembly.
Noise in gear pump Repair or replace.
Transmission
Dragging of clutch due to seizure Replace clutch plate.
Worn or seized bearing Replace.
Break in gear Replace.
Loose bolt Retighten or replace.
Worn spline Replace.
Cavitation caused by clogged strainer Clean or replace.
Unusual main pressure/torque Too high pressure
converter oil pressure Clogged oil filter (outlet side) Clean.
Malfunction of regulator valve Repair or replace valve.
Clean or repair.
Too large resistance in piping Repair.
Cold weather (when high viscosity oil is Repair.
used)
Use of improper oil Change oil.
Too low pressure
Faulty gear pump(wear) Replace.
Excessive oil leak
(1) Faulty regulator valve coil spring Replace.
(2) Faulty regulator valve spool Repair or replace valve.
(3) Faulty modulator valve coil spring Replace.
Air is sucked into system. Retighten or change packing.
Insufficient oil Add.
Clogged oil filter Clean or replace.
Transmission
Excessive oil leak Replace.
Solenoid valve
Broken solenoid valve, foreign objects or Replace solenoid valveassembly.
dirt, or poor electrical power
Oil leak from torque converter/ Oil leak from oil seal Replace oil seal. Replace pump boss,
transmission/Solenoid valve coupling, etc.
Oil leak from jointing surfaces of case Retighten bolts or change packing.
Oil leak from joint or pipe Repair or replace pipe gasket.
Oil leak from drain plug Retighten or replace gasket.
Cracks or blow holes Repair or replace.
Flowing out of oil from transmission case Change oil.
and tank Retighten or replace packing.
Leakage from the solenoid valve seal Replace O-ring and gasket.
Leakage from the solenoid valve Replace solenoid valve assembly if
necessary.
Excessive oil Reduce oil.
AT-6
No transmission of power Torque converter

Break in drive plate Replace.
Insufficient oil Add oil.
Faulty oil pump driving system Replace.
Broken shaft Replace.
No oilpressure Replace.
Transmission
Insufficient oil Add oil.
Improper location of inching spool and link Adjust.
lever
Improper location of forward/reverse spool Adjust.
and link lever
Clutch acting in both directions
(1) Faulty piston ring of servo case Replace.
(2) Clutch seizure/deformation Replace.
(3) Broken conical plate Replace.
Seized clutch Replace.
Broken shaft Replace.
Break in clutch drum (snap ring groove) Replace.
Broken snap ring for clutch drum Replace.
Foreign matter caught in oil passage to Clean or replace.
clutch
Worn shaft spline Replace.
Solenoid valve
Broken solenoid valve, foreign objectsor Replace solenoid valve assembly.
dirt, or poor electrical power
AT-7
OIL CIRCUITOIL CIRCUIT
Oil Passages from Oil Strainer to Control Valve Body
ATM0102
AT-8
ATM0103
AT-9
Oil Passages from Oil Strainer to Control Valve Body (Cont’d)
ATM0104
ATM0105
AT-10
Oil Passages from Control Valve Body to Main Shaft
ATM0106
ATM0107
AT-11
OIL PRESSURE CIRCUIT DIAGRAM
NEUTRAL RANGE
ATM0108
AT-12
FORWARD RANGE
ATM0109
AT-13
REVERSE RANGE
ATM0110
AT-14
INCHING
ATM0111
AT-15
Construction
ATM0112
1 Drive cover 10 Reverse gear 19 Orifice

2 Turbine runner 11 Control valve 20 Drive pinion shaft
3 Stator 12 Clutch piston 21 Pinion shaft spacer
4 One-way clutch 13 Return spring 22 Reduction gear
5 Pump impeller 14 Clutch drum 23 Bearing cover
6 Oil pump sleeve 15 Forward gear 24 Idler gear
7 Oil pump housing 16 Servo case 25 Idler shaft
8 Oil pump cover 17 Needle bearing 26 Solenoid valve
9 Main shaft 18 Oil pump
AT-16
Construction (Cont’d)
TRANSMISSION
ATM0113
AT-17
OIL PUMP AND TORQUE CONVERTER
ATM0114
CONTROL VALVE
ATM0115
1 Inching valve 5 Relief valve 8 Check valve

2 Regulator valve 6 Modulator spring 9 Check spring
3 Regulator spring 7 Modulator piston 10 Modulator plug
4 Side plate
AT-18
SOLENOID VALVE
ATM0116
1 Body 8 Pin 14 Stopper

2 Spool 9 Solenoid coil 15 Plug
3 Plug 10 Bolt 16 Tube
4 Pin 11 O-ring 17 Plunger
5 Spring 12 O-ring 18 O-ring
6 Retainer A 13 O-ring 19 Snap ring
7 Retainer B
Specifications
Applied voltage V 10 - 15
Oil temperature °C (°F) -30 to 130 (-22 to 266)
Coil resistance /°C (°F) 5.4/20 (68)
ATT0132
AT-19
Forward solenoid (SOL.a) and reverse solenoid (SOL.b) are as
figure.
The SOL.a lead-wire is white and the SOL.b lead-wire is black.
ATM0123
Inspection
Inspection item Factory-set value Service limits Out-of-limits countermeasure
Coil wire is cut or shorted.
5.4±5% 5.4±10% [20°C
Coil resistance Replace the solenoid valve
[20°C(68°F)] (68°F)]
assembly.
Coil insulation is bad. Replace
Coil insulation resistance More than 100 M 10 M
the solenoid valve assembly.
Replace the O-ring on the
Oil leaking from Solenoid valve -- Oozing out
Solenoid valve.
Troubleshooting
Trouble symtoms Possible cause Corrective action
Solenoid valve dose not Foreig object is caught in 1. Checkcontinuity.
operate properly. the spool. The solenoid valve should be installed to the
a. When the solenoid valve is transmission assembly.
energized, the spool is not 2. When it does not operate properly, push the pin 5
changed over and so the several times with your fingers, then check the
power is not transmitted to continuity again.
the forklift. When it operates properly, go to step 8.
b. When the current to the 3. When it does not operate properly, remove
solenoid valve is cut off, thesolenoid valve body from the transmission
the spool is not changed assembly; then perform steps 4 to 8 below.
over and so the power to 4. Blow air from the port hole to the spool 4.
the forklift is not turned off. 5. Push the pin 5 several times, then check the
continuity.
At this time, visually check the spool 4 can move
from the port hole.
6. When it operates properly, install it to the
transmission assembly, then check the continuity.
7. When it does not operate properly, replace the
solenoid valve as an assembly.
8. By changing over the solenoid valve sevaral times,
check that the Solenoid valve operates properly.
Pushing pressure of pin 5 = approx. 10 - 29 N
(1 - 3 kg, 2 - 7lb)
Before performing the steps shown above, be sure
to take safety measures such as jacking up the front
wheels, etc.
AT-20
Test
LINE PRESSURE TEST
Tools and equipment
Oil pressure gauge assembly
(with adapters)
ST0221S000
Engine tachometer
Wrench
Sealing tape
Chock
Test procedures
1. Before testing, check coolant, engine oil and torque converteroil;
warm up torque converter oil to operating temperature.
2. Secure front and rear wheels with chocks and apply hand brake.
3. Remove blind plug and connect oil pressure gauge to its opening.
4. Mount engine tachometer.
5. Measure clutch oil pressure while engine is running more than
1,000 rpm with gears shifted into Forward or Reverse position.
6. Measure torque converter oil pressure while engine is
runningmore than 1,000 rpm.
If oil pressure builds up in the FORWARD (or the REVERSE)
position, shift gears to the REVERSE (or the FORWARD)
position.
Oil pressure should drop to zero upon gearshifting.
Hydraulic Pressure Value

Unit: kPa (bar, kg/cm2, psi)
Engine speed
700 rpm 2,000 rpm
Hydraulic pressure
883 - 1,078 980 - 1,274

Main pressure
(8.8 - 10.8, 9 - 11, 128 - 156) (9.8 - 12.7, 10 - 13, 142 - 185)
883 - 1,078 980 - 1,274
Clutch pressure
(8.8 - 10.8, 9 - 11, 128 - 156) (9.8 - 12.7, 10 - 13, 142 - 185)
49 - 294 196 - 539
T/C inlet pressure
(0.49 - 2.94, 0.5 - 3.0, 7.1 - 42.6) (1.96 - 5.39, 2.0 - 5.5, 28.4 - 42.6)
ATM0117
AT-21
Test (Cont’d)
STALL TEST
The purpose of this test is to check for transmission and engine
malfunction by measuring the maximum engine rpm while truck is in
a stalled condition. Compere measured values with standard values.
Tools and equipment

Engine tachometer
Chock
Test procedures
1. Before testing, check coolant, engine oil and torque converteroil;
warm up torque converter oil to operating temperature.
2. Mount engine tachometer in a location visible from operator's
seat.
3. Secure front and rear wheels with chocks and apply hand brake.
Besure to depress brake pedal firmly with the left foot before
depressing accelerator pedal.
Do not depress inching brake pedal.
4. Turn selector lever into position "F"
5. Slowly depress accelerator pedal fully.
Quickly read and record engine rpm when engine begins to rotate
steadily and then release accelerat or pedal.
Engine stall speed:
K/GK21 1850 - 2150
K/GK25 1850 - 2150
QD32 1850 - 2150
6. Shift selector lever to neutral and run engine at approximately
1,500 rpm for more than one minute to cool down torque
converter oil and coolant.
7. Make similar stall test in position "R".
8. After the stall test "F" and "R" cool down the motor and
transmission, keeping the motor running at idle for at least 1
minute.
CAUTION:
The stall test operation specified in item (5) should be made
within 30 seconds.
If it takes too long, oil deteriorates and clutches are adversely
affected.
Sufficient cooling time should be given between tests.
AT-22
Adjustment of Brake Pedal

1. Using the stopper bolt, adjust A, the height of the pedal above the
floor (from the floor to the top of the pad). Then lock the stopper
bolt.
2. Adjust the length of the master cylinder push rod.
Adjust the clearance between the push rod and piston by rotating
the push rod. After adjusting, fasten the clevis with the nut.
3.Check the play (C) of the pedal tread.

CAUTION
• The clevis pin that joins the brake pedal and push rod must be
securely connected.
• The snap pin must be securely attached.
• When operated, the brake pedal must not catch or otherwise
work improperly.
•Unit: mm (in)
Items
Height of pedal A 140 (5.51)
Clearance between
1 (0.040)
push rod and piston B
Play of pedal thread C 1-3 mm (0.04 - 0.12 in)
4. Securely tighten the clevis with the nut.
5. If the pedal is properly adjusted, the brake pedal play will meet the
standard: Free play (C)
Adjustment of Inching Pedal

1. Adjust and tighten the stopper bolt (inching) so that the height (A)
from the top surface of the floor plate to the center of the inching
pedal meets the standard shown below.
Standard (mm, in): 105 - 115 mm (4.13 - 4.53 in)
2. Adjust the clearance (c) of the part C bolt and linkage to the
standard indicated below. Then securely tighten with the nut.
Standard (mm, in.):
4.4 - 5.7 mm (0.173 - 0.224 in)
MAT0228
AT-23
Adjustment of Inching Valve

1. Preparation work
• Similar to the aforementioned oil pressure measurement, block
the steering tire and then raise the driving tire off the ground.
• Connect the oil pressure gauge to the clutch oil pressure outlet
port (position D in the figure to the left).
• Adjust the installation length of the inching cable until the
MAT0229L.tif plunger is fully withdrawn.
• Securely tighten the lock nut and tighten the inching cable.
1. Adjustment procedure
• Idle the engine to raise the temperature of the transmission oil.
• Move the forward/reverse shift lever to the forward (F) position.
• Gradually press the inching pedal and force in the plunger.
Record the relationship between the stroke of the plunger and
the clutch oil pressure, Pc.
• Confirm that the aforementioned relationship is the diagram

shown in the figure. At the stroke end of the plunger, however,
the oil pressure must be completely 0 (zero).
MAT0230L.tif
Note: 1 kPa = 0.145 PSI; 1 mm = 0.039 in.
AT-24
REMOVAL AND DISASSEMBL Y

INSTALLATION
CONTROL VALVE
1. Remove differential carrier with
engine and transmission.
Refer to ER section for removal.
2. Separate engine from transmission
case.
3. Remove torque converter.
4. Remove differential carrier
Inching spool
mounting bolts, and remove dif-
ferential carrier from transmission
case.
2-speed A/T
Control valve body assembly

FAT266
FPD137
5. To install, reverse order of re-

moval.
FAT267
Removal and Installation

Disassembly
AT-25
1. Remove transmission control TORQUE CONVERTER HOUSING

valve assembly.
1. Remove two attaching bolts from
regulator valve cover.
FAT253
FAT250 5. Inspect all parts for damage.

FAT252
2. Remove inching spool by re-

moving four bolts at control valve 2. Screw bolt into thread hole
assembly. (M6 x 1.0) on head of pressure re-
3. Remove select spool, accumulator gulator valve and force regulator TORQUE CONVERTER
piston and springs by removing four valve out.
bolts at select spool housing. 3. Remove pressure regulator valve & I. Remove six attaching bolts (M 10)
spring. from drive plate assembly.
4. Remove inlet relief valve. check 2. Remove drive plate assembly and
Inching SPOOI~~ pilot converter boss.
ball and spring.
(ontrol valve ~bOdY J
:lfl
assembly
~elect spool . Drive plate assembly
" • II 'LV .t!'
~ /1 ''''',u<,~'CJ, [7/
~~ ~V;r ,I
~~~'
~~""---- Accumulator piston
FAT251
4. Thoroughly clean all parts and

check for scores, wear or damage. If
necessary, replace faulty parts.
Final drive assembly
FAT268
3. Inspect all parts for damage.
Torque Converter Housing

Torque Converter
AT-26
OIL PUMP 2. Remove attaching bolts from Measure clearance between inner gear
pump cover and remove cover. and pump cover and clearance be-
I . Remove five attaching bolts from
tween outer gear and pump cover.
oil pump assembly and remove oil
pump from transmission case. 2-speed AIT
Standard:
0.03 - 0.065 mm
(0.0012 - 0.0026 in)
Service limit:
0.1 mm (0.004 in)
=----~
--- -:-=:::=-:----
= =
FAT046
1 Oil pump housing

2 Outer gear
3 Inner gear
FAT254
MAIN TRANSMISSION CASE
3. Thoroughly clean pump inner and Measure clearance between outer gear I. Remove differential carrier
outer parts and check inner and outer and oil pump housing. mounting bolts. and remove differ-
gears in pump for wear. ential carrier from transmission case.
2-speed AfT
4. Check the oil pump housing seal Standard:
and oil seal for wear. 2-speed AfT
0.17-0.23mm
5. Assembly is in the reverse order
(0.0067 - 0.0091 in)
of disassembly. Observe the follow-
Service limit:
ing:
0.25 mm (0.0098 in)
Measure clearance between tooth top
of outer gear and crescent.
2-speed AfT
Standard:
0.15 - 0.21 mm
(0.0059 - 0.0083 in) FPD137
Service limit:
0.25 mm (0.0098 in)
2. Remove 1st and 2nd clutch druw
assembly from transmission case.
Oil Pump
Main transmission Case
AT-27
3. Remove oil strainer assembly, 5. Remove retaining bolt from oil

four retaining bolts and strainer pipe assembly and remove oil pipe
assembly. assembly.
4. Using plastic hammer remove 6, Remove reverse clutch drum as-
strainer case. sembly from transmission case.
Oil pipe assembly

Oi'I stratner
' assembly,,- ic>
StuJ~are~r
Oil strainer packing ~~
LI/
~ ~y'
li~
I
1°: 0
FAT269
7. Remove cooler relief valve fitting, 8. Remove all core plugs from trans-
cooler relief valve spring and check mission case and final drive assembly
ball assembly, for proper cleaning of oil passages,
Pressurel
regulator \
~@, valve \
Valve cover~ >('1" \

Valve packing /
'I
'1> ~
Pressure regulator valve spring
~@
> '-PlUg
"\.-Drain plug
FAT270
AT-28
Disassembly of Clutch Drum Assembly

Disassemble forward side and reverse side with the same
procedure.
1. Pull out the gear spacer.
2. Remove snap ring from the groove.

CAUTION:
Never reuse the snap ring.
3. Remove the thrust washer.
4. Remove the forward gear.
5. Remove the needle bearing.
AT-29

(Cont’d)
6. Remove the thrust washer.
7. Remove snap ring.

CAUTION:
Hold the snap ring with one hand, so that the ring does not
come out.
8. Turn over the clutch drum to remove the clutch disc.
AT-30

(Cont’d)
9. Push down the retainer plate using a press, and remove the
snap ring holding the clutch piston return spring from the groove.
CAUTION:
Never reuse the snap ring.
AT-31

(Cont’d)
10. Remove the spring.
11. Remove the piston from the clutch drum. When it is stuck too
tight and cannot be removed, introduce air into the shaft hole to
pull it out.
(1) is for forward
(2) is for reverse
12. Remove the D-ring.

CAUTION:
Never reuse the D-ring.
AT-32

(Cont’d)
13. Remove the O-ring.
CAUTION:
Never reuse the O-ring.
14. Remove the seal ring.

CAUTION:
• Never reuse the seal ring.
• When assembling the seal ring, never open it any more than
necessary. Because it is made of resin, it can break easily.
Control Valve
15. Loosen control valve bolts.
Tightening torque:
16 - 20 N•m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
AT-33
Oil Pump
1. Remove the mounting bolts of the oil pump assembly.
Tightening torque:
16 - 20 N•m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
CAUTION:
Never reuse steel washers and O-rings.
2. Remove the oil pump cover fixing bolts.

Tightening torque:
3.7 - 5.0 N•m (0.38 - 0.51 kg-m, 33 - 44 in-lb)
3. Remove the inner and outer gears.
Reduction Gear
1. Flatten the lock washer that has been caulked.
AT-34
Reduction Gear (Cont’d)

2. Remove the lock nut.
Tightening torque:
245 - 294 N•m (25 - 30 kg-m, 181 - 217 ft-lb)
3. Remove the lock washer.
4. Lift the reduction gear by using tire levers.
5. Remove the bearing.
AT-35
Reduction Gear (Cont’d)

6. Remove the spacer.
7. Remove the reduction gears.
Torque Converter
• Inspect the damage and oil leakage of the torque converter. If
any malfunction is found, replace the entire assembly.
• Measure the external diameter of the oil slide of the oil pump
sleeve.
Standard: 41.915 - 41.965 mm (1.6502 - 1.6522 in)
• Clean the inside of the torque converter with the following

procedure.
1. Remove the old oil.

CAUTION:
Tilt the torque converter right and left several times until no oil
comes out from the inside.
2. Pour in 1.5  (2-5/8 Imp qt) of kerosene, and tilt the converter
right and left several times to clean the inside until no foreign
material comes out.
CAUTION:
Remove the kerosene completely.
3. Pour in about 1  (1-3/4 Imp qt) of the Automatic transmission

fluid to clean the inside in the same manner as the step 2. (2-3
times)
CAUTION:
Tilt the converter right and left to remove the oil completely.
AT-36
Oil Pump
• Inner and outer gears that have worn down or been damaged on
the tooth surfaces shall be replaced.
• Measure the clearances between the inner gear (1), outer gear
(2) and the oil pump cover. Replace the parts that have values
over the limits.
Standard: 0.02 - 0.04 mm (0.0008 - 0.0016 in)
Repair limit: 0.08 mm (0.0031 in)
• Measure the gap between the outer gear tooth tips and the
crescent. Replace the parts that have values over the limits.
Standard: 0.20 - 0.34 mm (0.0079 - 0.0134 in)
• Measure the gap between the external circumference of the

outer gear and the oil pump housing.
Standard: 0.09 - 0.18 mm (0.0035 - 0.0071 in)
• Measure the oil pump sleeve bushing internal diameter of the oil
pump housing
Standard: 42.00 - 42.039 mm (1.6535 - 1.6551 in)
AT-37
Clutch Drum
• If the drive (1) or driven plate (2) is worn out or damaged,
replace it.
Drive plate Standard: 2.5 - 2.65 mm (0.0984 - 0.1043 in)
Repair limit:2.2 mm (0.087 in)
Driven plate Standard: 1.53 - 1.67 mm (0.0602 - 0.0657 in)
• When the spring is worn out or damaged, or the spring retainer
is deformed, replace them.
• When the piston slide surface is damaged, replace the piston.
• Measure the width of the mainshaft seal ring groove.

Seal ring groove
Standard:2.26 - 2.29 mm (0.0890 - 0.0902 in)
• Measure the seal ring width
Seal ring width
Standard: 2.05 - 2.15 mm (0.0807 - 0.0846 in)
AT-38
Tightening Torque
N•m (kg-m, in-lb)*
Item Tightening torque
Clutch housing cover fixing bolt 16 - 20 (1.6 - 2.1, 12 - 15)

Torque converter housing Torque converter housing, transmission case
30 - 40 (3.1 - 4.1, 22 - 29)
joining bolt
Oil pump cover, oil pump housing jonining

3.7 - 5.0 (0.38 - 0.51, 33 - 44)*
Oil pump bolt
Oil pump assembly bolt 16 - 20 (1.6 - 2.1, 12 - 15)
Suction filter spacer fixing bolt 16 - 20 (1.6 - 2.1, 12 - 15)
Air breather 4.4 - 5.8 (0.45 - 0.60, 39 - 52)*
Draining plug 25 - 34 (2.5 - 3.5, 18 - 25)

Transmission
Oil temperature sensor 31 - 47 (3.2 - 4.8, 23 - 34)
Orifice plug 4.4 - 5.8 (0.45 - 0.60, 39 - 52)*
Oil pipe fixing bolt 16 - 20 (1.6 - 2.1, 12 - 15)
Control valve mounting bolt 16 - 20 (1.6 - 2.1, 12 - 15)
Solenoid valve fixing bolt 2.9 - 3.8 (0.30 - 0.39, 26 - 34)
Side plate fixing bolt 16 - 20 (1.6 - 2.1, 12 - 15)

Control valve
Inching valve stopper bolt 16 - 20 (1.6 - 2.1, 12 - 15)
Regulator, torque converter relief valve plug 20 - 29 (2.1 - 3.0, 14 - 21)

Hydraulic pressure inspecting port plug 4.4 - 5.8 (0.45 - 0.60, 39 - 52)*
AT-39
SPECIAL SERVICE TOOLS
SPECIAL SERVICE TOOLS
Tool number Description

Tool name
KV31101400
Clutch spring compressor
NT793
ST0221S000 Oil pressure

gauge
NT794
AT-40
DIFFERENTIAL CARRIER
SECTION DF
SERVICE DATA AND SPECIFICATIONS ................ 2
General Specifications ......................................... 2
Inspection and Adjustment ................................... 3
Tightening Torque ................................................ 3
TROUBLE DIAGNOSIS AND CORRECTIONS ........ 5
DIFFERENTIAL CARRIER ....................................... 6
Construction ......................................................... 6
Removal and Installation ...................................... 8
Disassembly ......................................................... 8
Inspection ........................................................... 11
Adjustment ......................................................... 15
General Specifications
1D1 SERIES
Applied model Y1D1A15 - 18 P1D1A15 - 18
Model H263
Gear ratio 5.286 5.857
Number of teeth (Ring gear/Drive pinion) 37/7 41/7
Differential gear 2-pinion
Number of teeth (Side gear/Pinion mate gear) 16/10
Oil capacity  (US qt, Imp qt) 2.7 (2-7/8, 2-3/8)
1D2 SERIES
Applied model U1D2A20 - 25 UG1D2A30 - 32
1D2A20 - 25 YG1D2A30 - 32
Model H296 H310
Gear ratio 5.857 6.166
Number of teeth (Ring gear/Drive pinion) 41/7 37/6
Differential gear 4-pinion
Number of teeth 18/10 16/10

(Side gear/Pinion mate gear)
Oil capacity  (US qt, Imp qt) 3.0 (3-1/8, 2-5/8) 5.5 (5-7/8, 4-7/8)
DF-2
Inspection and Adjustment

Drive pinion starting torque
Nm (kg-cm, in-lb)
A/T models 1.8 - 2.3 (18 - 23, 16 - 20)
Backlash mm (in)
Side gear to pinion mate 0.15 - 0.20 (0.0059 - 0.0079)
gear
Drive pinion to ring gear
H263 0.18 - 0.23 (0.0071 - 0.0091)

H296 & H310 0.20 - 0.28 (0.0079 - 0.0110)
Distance between left and right
bearing caps
(Side bearing preload)
mm (in)
H263 262.88 - 262.93
(10.3496 - 10.3516)
H296 282.86 - 282.93
(11.1358 - 11.1390)
H310 302.85 - 302.93
(11.9232 - 11.9264)
SIDE GEAR THRUST WASHER

Unit: mm (in)
H263 H296 H310
1.55 (0.0610) 1.54 (0.0606)
1.60 (0.0630) 1.57 (0.0618)
1.65 (0.0650) 1.60 (0.0630)
— 1.63 (0.0642)
— 1.66 (0.0654)
— 1.69 (0.0665)
Tightening Torque
Unit Nm kg-m ft-lb
Differential case to ring gear
H263 197 - 225 20 - 23 145 - 166
H296 198 - 224 20.2 - 22.8 145 - 166
H310 255 - 294 26 - 30 188 - 216
Differential case
H263 — — —
H296 74 - 81 7.5 - 8.3 55 - 60
H310 98 - 137 10 - 14 73 - 101
Drive pinion lock nut
275 - 343 28 - 35 203 - 253
Drive pinion sleeve to gear carrier
77 - 98 7.8 - 10.0 57 - 72
Side bearing cap bolt
H263 79 - 98 8 - 10 58 - 72
H296 90 - 117 9.1 - 12.0 66 - 86
H310 128 - 147 13 - 15 94 - 108
Differential carrier to transmission
31 - 40 3.1 - 4.1 23 - 29
Differential carrier to axle housing
H263 19 - 24 1.9 - 2.5 14 - 18
H296 & 39 - 51 3.9 - 5.3 29 - 38
H310
DF-3
DRIVE PINION BEARING ADJUST SHIM

Unit: mm (in)
0.15 (0.0059)
0.18 (0.0071)
0.20 (0.0079)
0.25 (0.0098)
0.30 (0.0118)
0.50 (0.0197)
PINION HEIGHT ADJUST SHIM

Unit: mm (in)
0.05 (0.0020)
0.07 (0.0028)
0.10 (0.0039)
0.30 (0.0118)
0.50 (0.0197)
1.00 (0.0394)
DF-4
TROUBLE DIAGNOSIS AND CORRECTIONS
Gear carrier failures can be classified as oil leakage, seizure, unusual

noise, noisy operation, and damage, according to the phenomena.
Shown below are the trouble phenomena, their possible causes, and
remedies to be taken.
Condition Possible cause Corrective action
Oil leakage Distinguish between oil staining and oil leakage, and locate the point of leak, then take proper corrective
action.
Worn, faulty, or improperly installed oil seal Replace oil seal.
Loose gear carrier mounting bolts Retighten, or replace gasket.
Faulty gasket Replace gasket.
Loose filler plug or drain plug Retighten.
Clogged or faulty air breather Repair or replace.
Faulty axle housing O-ring Replace.
Worn, faulty, or improperly installed axle shaft oil seal Replace oil seal.
Seizure Replace any seized or damaged parts. Check related parts for condition. Repair or replace them if
necessary.
Bearing seizure Replace.
Too large preload Disassemble and readjust.
Too small backlash Disassemble and readjust.
Insufficient oil, or use of improper oil Add or replace oil as specified.
Unusual noise Before disassembling the gear carrier, make sure that the noise is not being produced in clutch,
transmission or wheel bearing.
1. When starting off or Improper hypoid gear backlash Readjust.
shifting gears Improper differential gear backlash Readjust.
Too small drive pinion bearing preload Readjust.
Pitted or worn gear tooth surface, or broken tooth Replace.
Loose pinion nut, or any other bolts and nuts Retighten.
Insufficient oil, or use of improper oil Add or change oil as specified.
2.When making a turn Abnormally worn or broken differential gear Replace.

Abnormally worn or broken thrust washer Replace.
Broken pinion mate shaft Replace.
Seized or broken side bearing Replace.
Insufficient oil, or use of improper oil Add or change oil as specified.
Gear noise Perform test carefully as gear noise is often mistaken for engine noise, transmission noise, or wheel bearing
noise.
Test method:
Check for gear noise in coasting, accelerating, or in constant-speed driving, or by jacking up the front
wheels.
Improper contact of hypoid gear teeth Adjust, or replace as a gear set.
Improper hypoid gear backlash Readjust.
Worn, or broken hypoid gear tooth surface Replace as a gear set.
Seized hypoid gear Replace as a gear set.
Improper pinion bearing Readjust.
Seized, or broken pinion bearing Replace.
Seized or broken side bearing Replace.
Differential case runout Replace.
Loose bolts and nuts Retighten.
DF-5
Construction
H263 (2-pinion)
DFM0051
1. Drive pinion 14. Nut 27. Pinion mate shaft

2. Drive pinion front bearing 15. Gear carrier 28. Mate gear thrust washer
3. O-ring 16. Knock pin 29. Mate gear
4. Oil seal 17. Side bearing cap Tightening torque
5. Distance piece 18. Side bearing adjust nut : 246 - 294 (25 - 30, 181 -216)
6. Pinion height adjust shim 19. Side bearing : 9 - 11 (0.9 - 1.2, 79 -104)
7. Drive pinion bearing sleeve 20. Lock plate : 197 - 225 (20 - 23, 145 -166)
8. Drive pinion bearing adjust shim 21. Side bearing cap bolt : 79 - 98 (8 - 10, 58 -72)
9. Drive pinion rear bearing 22. Gasket : 76 - 98 (7.8 - 10.0, 57 -72)
10. O-ring (large) 23. Differential case : 275 - 343 (28 - 35, 203 - 253)
11. Drive pinion bearing lock nut 24. Ring gear
12. Bearing (rear end) 25. Side gear thrust washer
13. Washer 26. Side gear
DF-6
H296 and H310 (4-pinion)
DFM0052
1 Drive pinion 17 Side bearing cap Tightening torue

2 Drive pinion front bearing 18 Side bearing adjust nut : 246 - 294 (25 - 30, 181 -216)
3 O-ring 19 Side bearing : 9 - 11 (0.9 - 1.2, 79 -104)
4 Oil seal 20 Lock plate : 197 - 225 (20 - 23, 145 -166)
5 Distance piece 21 Side bearing cap bolt : 79 - 98 (8 - 10, 58 -72)
6 Pinion height adjust shim 22 Gasket : 76 - 98 (7.8 - 10.0, 57 -72)
7 Drive pinion bearing sleeve 23 Differential case : 275 - 343 (28 - 35, 203 - 253)
8 Drive pinion bearing adjust shim 24 Ring gear : N•m (kg-m, ft-lb)
9 Drive pinion rear bearing 25 Side gear thrust washer : N•m (kg-m, in-lb)
10 O-ring (large) 26 Side gear
11 Drive pinion bearing lock nut 27 Pinion mate shaft
12 Bearing (rear end) 28 Mate gear thrust washer
13 Washer 29 Mate gear
14 Nut
15 Gear carrier
16 Knock pin
DF-7
CAUTION:
• Be careful when removing and installing differential carrier with
engine and transmission as they are heavy.
1. Remove differential carrier with engine and transmission.
NOTE:
Refer to ER section for removal.
2. Separate engine from transmission case.

3. Remove torque converter.
4. Remove oil pump.
5. Pull out drive pinion rear end cover.

6. Remove drive pinion fixing nut at drive pinion rear end.
7. Remove differential carrier mounting bolts, and remove differential

carrier from transmission case.
8. To install, reverse order of removal.
Disassembly
PRE-DISASSEMBLY INSPECTION
Before disassembly, thoroughly inspect the following items.
• Backlash between ring gear and drive pinion
• Tooth contact
• Ring gear and differential gear for smooth rotation
And correctly diagnose the cause of malfunction.
Disassembly
CAUTION:
• Except when replacing the ring gear set, measure the drive gear
DFT0053L
backlash before disassembling and use it for reference during
assembly.
Measure the backlash of ring gear and drive pinion.

Backlash:
0.18 - 0.23mm, ( 0.0071 - 0.0091in.) ( H263)
0.20 - 0.28mm, ( 0.008 - 0.011in.) (H296 + H310)
DF-8
Disassembly (Cont'd)
DIFFERENTIAL CASE
1.Remove side bearing adjusting nut lock plate.
2. Loosen side bearing cap bolts and remove adjusting nut using Tool.
3. Remove side bearing caps.
NOTE: Mark cap on one side so that it can be easily replaced in the
correct position.
4. Remove differential case assembly with side bearing outer races.
NOTE: Do not confuse R.H. side and L.H. side bearing outer races.
Removal of tapered roller bearing

Check the tapered roller bearing (inner) that was pressed into the drive
pinion. If it is normal, it does not have to be removed.
DFT0055L
5. Remove side bearing inner races with Tool.

• Do not remove side bearing unless absolutely necessary.
• To prevent damage to bearing, engage puller paws with groove.
• Be careful not to confuse left and right hand parts.
6. Remove ring gear by loosening ring gear bolts.

Tap ring gear off from differential case using soft hammer.
7. Remove differential case mounting bolts and separate differential
case at center portion (4-pinion model only).
DF-9
8. Drive out pinion mate shaft lock pin with Tool from ring gear side
(2-pinion model only).
9. Draw out pinion mate shaft and remove pinion mate gears, side gears
and thrust washers (2-pinion model only).
NOTE:
Put marks on gear and thrust washer so that they can be reinstalled in
their original positions from which they were removed.
DRIVE PINION
1. Remove lock nut from drive pinion, remove rear end cover.
2. Remove snap ring on drive pinion front end and remove bearing
support plate and lock plate (3 ton models only) of drive pinion roller
bearing (4-pinion models only).
3. Remove lock bolt and lock plate from input frange.

4. Drive out input frange with from differential carrier side.
DF-10
Check oil seal

Check the oil seal that was tapped into the carrier cover. If it is normal,
it does not have to be removed.
5. Remove oil seals from carrier cover (A/T models only).
6.Using press, remove bearing inner race from drive pinion.
Inspection
Thoroughly clean and check each disassembled part. Repair or
replace any damaged or unserviceable part.
Part name Condition and corrective action
Ring gear and drive pinion • If tooth contact is incorrect, check the cause, and adjust to contact properly when
reassembling.
• If damage to teeth is very slight, repair by using oil stone.
• If worn excessively, or if readjustment is impossible, replace the gears as a set.
• If cracks, damage, or seizure is found on tooth face, replace the gears as a set.
Side gears and pinion mate gears • If damage to tooth surface is very slight, repair by using oil stone.
• If cracks or damage is found on tooth face, replace with new one.
• If wear or seizure is found on thrust washer contacting surface, replace with new one.
Bearings • Replace if seizure, flaking, wear, rust, or binding or noise in rotation is found.
Thrust washers • Replace if seizure, damage, or uneven wear is noted.
Oil seals • Replace if fatigue, damage, or uneven wear is found.
• Do not reuse any oil seal that has been removed once.
Gear carrier • If wear or damage is noted on the bearing fitting surface, replace with new one.
Differential case • Replace the case if wear or crack is found on sliding portion.
DF-11
Inspection and Correction
Ring gear, drive pinion

• Check the tooth contact of the ring gear and drive pinion, and check
for wear, pitching, galling, and tooth loss.
• If the damage is slight and the part can be reused, correct it with an
oilstone or hand grinder.
• If replacement is necessary, replace the ring gear and drive pinion
as a set.
Differential
• Check for galling in the area in which the differential case and side
bearing inner race are joined.
• Check for cracks in the differential case, and wear and damage to
DFT0057L the sliding parts of the side gear and spacer.
• Check the side gear and pinion mating gear teeth for wear, damage,
and galling. Check the spacer holder for wear and damage.
Assembly
1. Place the ring gear on the differential case.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head with a
hammer.
Installation of drive gear

DFT0057L
When installing the ring gear to the differential case, apply Loctite No.
271 to the bolt and tighten to the specified torque.
Tightening torque [N•m (kg-m) Ft./Lbs.]
H263 197 - 225 20 - 23 145 - 166
H296 198 - 224 20.2 - 22.8 145 - 166
H310 255 - 294 26 - 30 188 - 216
Assembly of pinion mating gear

• Adjust the backlash of the side gear and pinion mating gear by using
the side gear spacer.
• Measure the backlash. If it exceeds the usage limit, replace the
spacer with a new one.
Standard (mm, in.):
DFT0059L 2S 0.15 - 0.20mm, (0.059 - 0.0079in.)
DF-12
Assembly (Cont'd)
Assembly of differential case assembly
• Install the differential case assembly to the differential carrier, and
temporarily tighten the bearing cap.
Installation of bearing cap

• The bearing cap is integrally constructed with the differential carrier,
so carefully note the alignment marks to ensure that the left and right
sides are assembled correctly.
Preload adjustment
9. While turning the ring gear by hand, lightly tap the back face of the
gear with a copper hammer to make it fit.
10. Install the spring balance to the bolt, and read the force that is
DFT0060L S applied when the gear starts to turn.
11. Adjust by turning the left and right adjustment screws.
Preload [N•m (kg-m) Ft./Lbs] :
14.7 - 29.4 (1.49 - 2.9) 131 - 262 (1F1, 1F2 series)
12.8 - 24.5 (1.3 - 2.4) 114 - 218 (J1F2, G1F2 series)
Assembly Differential carrier
Insertion of oil seal

• Tap and insert the oil seal into the carrier cover using a installer
(SST: NF91263-05400).
DFT0062L S CAUTION:
• When installing the oil seal, note the direction of the lip.
Applying grease to oil seal

• Apply grease to the oil seal that was tapped into the carrier cover.
Specified grease: NBW-2
Adjustment of drive pinion preload

1. After tapping in the tapered roller bearing, measure the difference
between the drive pinion and tapered roller bearing. Although the
measured dimension will serve as a target value for the shim
thickness.
2. Insert a shim having the measured dimension, and then tighten the
plate.
There are 6 shim thicknesses: 0.15, 0.18, 0.20, 0.25, 0.30,
0.50 mm, ( 0.0059, 0.0071, 0.0079, 0.0098, 0.0118, 0.0197 in.)
3. Install the spring balance to the screw hole of the input flange, and
pull in the tangential direction. Check the preload of the tapered
roller bearing, using the weight that was applied when movement
started. Adjust the size of the shim until the specified tensile force is
obtained.
Drive pinion preload:
1.8 - 2.3 N•m(18 - 23 kg-cm, 16 - 20 in-lb)
DF-13
Assembly (Cont'd)
Tooth contact adjustment of ring gear and drive pinion

1. After checking the drive pinion preload, reverse the differential carrier.
2. Assemble the differential case into the differential carrier. When
doing so, carefully check the alignment marks affixed on the bearing
cap and adjusting nut.
3. Turning the adjusting nut, make sure that the backlash is proper.
Place the dial indicator needle so that it is perpendicular to the
surfaces of the ring gear teeth. Then moving the ring gear forward/
backward (direction of rotation), check the deflection of the dial
indicator needle.
DFT0066L S
Backlash (mm, in.):
0.18 - 0.23 mm, (0.0071 - 0.0091 in) ( H263)
0.20 - 0.28 mm, (0.0079 - 0.0110 in.) (H296+H310)
(Between ring gear and pinion)
4. When turning the adjusting nut, turn the same amount in the same
direction.
DFT0067L S
5. Apply a thin film of minimum (red lead) uniformly over both surfaces
of 3 to 4 ring gear teeth. Turn the ring gear by hand several times
forward and backward, and determine acceptability based on the
shape of the area in which the teeth make contact. (Refer to
"ADJUSTMENT".)
DFT0068L S
Tightening bearing cap

After checking the contact of the ring gear teeth, tighten the bearing
cap to the specified torque.
Tightening torque [N•m (kg-m) Ft./Lbs.]:
79 - 98 (8 - 10) 58 - 72 (H263)
90 - 117 (9.1 - 12.0) 66 - 86 (H296)
128 - 147 (13 - 15) 94 - 108 (H310)
DF-14
Adjustment
Ring gear tooth contact
After replacing the ring gear and drive pinion, check and adjust the
gear tooth contact as described below.
DFT0061L S 1. Calculate the machining tolerance written on the surface of the drive
pinion teeth. Then insert a shim and assemble.
Shim size = Standard - (Machining tolerance)
Example: Machining tolerance - 0.10 mm, 0.004 in.
0.8 mm, 0.031 in. - (-0.10 mm, -0.004 in.) =
0.8 mm, 0.031 in. + 0.10 mm, 0.004 in. = 0.9 mm, 0.035 in.
2. If satisfactory tooth contact cannot be obtained for a gear assembled
as described by the differential carrier’s order of assembly, adjust as
shown below.
Ring gear tooth contact
Tooth contact Adjustment procedure
DFT0069L At least half

1 Satisfactory
makes contact.
1. Move ring gear away from center.

Small end (only) 2. Insert drive pinion shim to deepen engagement
DFT0070L DFT0074L
2 makes strong
contact. (Toe) and correct backlash.
1. Move ring gear toward center.

DFT0071L Large end (only) DFT0075L
2. Remove drive pinion shim to reduce
3 makes strong
contact. (Heel) engagement depth and correct backlash.
1. Insert drive pinion shim to slightly deepen

DFT0072L Tooth top (only) DFT0076L engagement.
4 makes strong
contact. (Face) 2. Move ring gear away from center to correct
backlash.
1. Remove drive pinion shim to slightly reduce

Tooth bottom
DFT0073L (only) makes DFT0077L engagement depth.
5
strong contact. 2. Move ring gear slightly toward center to correct
(Flank)
backlash.
CAUTION:
• For toe and heel contact, determine acceptability by looking at the contact on the ring gear outside part
(convex side). Moreover, for face and flank contact, repeat the aforementioned adjustment procedure until
satisfactory contact is obtained.
DF-15
DRIVE AXLE
SECTION DA
CONTENTS
SERVICE DATA AND SPECIFICATIONS ..........LM-2
TROUBLE DIAGNOSES AND CORRECTIONS LM-3
DRIVE AXLE .......................................................LM-4
GENERAL SPECIFICATIONS
Full floating, direct frame mount
Axle
type 1D2 1D2
1D1
(2.0t - 2.5t) (3.0t - 3.2t)
Tread
890 (35.04) 965 (37.99) 1,005 (39.57)
mm (in)
INSPECTION AND ADJUSTMENT

Wheel hub rotation starting 10 - 29 (1 - 3, 2 - 7)
torque at hub bolt N (kg, lb)
Axial play of wheel Less than 0.08 (0.0031)

bearingmm (in)
TIGHTENING TORQUE
1D1 series 1D2 series
2.0 - 2.5 ton 3.0 & 3.2 ton
N|b1m kg-m ft-lb N|b1m kg-m ft-lb N|b1m kg-m ft-lb
Axle case to axle tube -- -- -- 118 - 147 12 - 15 87 - 108 118 - 147 12 - 15 87 - 108
Axle mounting bracket to backing 79 - 105 8.0 - 10.8 58 - 78 128 - 166 13.0 - 94 - 122 128 - 166 13.0 - 94 - 122
plate 17.0 17.0
Axle mounting bracket to frame 187 - 235 19 - 24 138 - 173 324 - 372 33 - 38 239 - 274 324 - 372 33 - 38 239 - 274
Axle case to differential carrier 19 - 24 1.9 - 2.5 14 - 18 39 - 51 3.9 - 5.3 29 - 38 39 - 51 3.9 -5.3 29 - 38
Drive wheel hub to axle shaft 40 - 53 4.0 -5.5 29 - 39 74 - 88 7.5 - 9.0 55 - 65 74 - 88 7.5 -9.0 55 - 65
Brake tube flare nut 15 - 17 1.5 -1.8 11 - 13 15 - 17 1.5 - 1.8 11 - 13 15 - 17 1.5 -1.8 11 - 13
Road wheel nut
Single tire 167 - 225 17 - 23 123 - 166 246 - 294 25 -30 181 - 216 442 - 588 45 - 60 326 _433
Double tire
Direct connecting type
Hub bolt installing nut -- -- -- -- -- 344 - 441 35 - 45 254 - 325
Inner nut -- -- -- -- -- -- 540 - 686 55 - 70 398 - 506
Outer nut -- -- -- -- -- -- 589 - 735 60 - 75 434- 542
Outer hub type
Inner wheel attaching 167 - 225 17 - 23 123 - 166 246 - 294 25 - 30 181 - 216 -- -- --
nut
Outer wheel attaching 167 - 225 17 - 23 123 - 166 246 - 294 25 - 30 181 - 216 -- -- --
nut
Outer hub connecting 79 - 98 8 - 10 58 - 72 246 - 294 25 - 30 181 -216 -- -- --
nut
Rim set bolt 69 - 98 7 - 10 51 - 72 157 - 196 16 - 20 116 - 114 -- -- --
DA-2
Condition Corrective action Probable cause
Abnormal noise Loose axle mounting bracketbolts Tighten.

Loose axle tube mounting bolts Tighten.
Before attempting a correction, make sure Loose wheel nuts Tighten.
the noise is coming from the drive shaft-- Other retaining parts loose Tighten.
not from the final drive gear. Worn or damaged wheel bearing Replace.
Wheel bearing not properly adjusted Adjust.
Worn axle shaft splines Replace.
Insufficientlubrication Lubricate.
Unstable driving Loose wheel nut Tighten.

Deformed road wheel Replace.
Also refer to the Trouble Diagnoses and Worn ordamaged wheel bearing Replace.
Corrections in the RA section. Loose axle mounting bracket bolts Tighten.
Wheelbearing not properly adjusted Adjust.
Improper tirepressure Adjust.
Oil leakage Worn or damaged axle shaft oil seal Replace.

Final drive improperly installed Replace gasket.
Loose filler or drain plug Tighten.
Damaged axle tube O-ring Replace.
DA-3
DRIVE AXLE
DRIVE AXLE
DA-4
DRIVE AXLE
PNEUMATIC TIRE MODEL

1D1 single-tire
FAM0052
Outer hub type double-tire for 1D2 2.0-ton & 2.5-ton models
DA-5
DRIVE AXLE
1D2 single-tire for 2.0-ton & 2.5-ton models
FAM0054
1D2 direct connecting type double tire for 3.0&3.2-ton models and single-tire for 3.0&3.2-ton models
FAM0055
DA-6
STEERING AXLE
SECTION SA
CONTENTS
DESCRIPTION .................................................... SA-2 KINGPIN ........................................................... SA-11
SPECIFICATION ................................................. SA-2 Removal ....................................................... SA-11
TROUBLE DIAGNOSES AND Inspection ..................................................... SA-11
CORRECTIONS .................................................. SA-2 Installation .................................................... SA-12
CONSTRUCTION ................................................ SA-3 STEERING AXLE COMPONENT PARTS
REMOVAL AND INSTALLATION ...................... SA-4 LOCATION ........................................................ SA-13
Steering Tire ................................................... SA-4 SERVICE DATA AND
Steering Axle .................................................. SA-5 SPECIFICATIONS (SDS) ................................. SA-14
DISASSEMBLY AND ASSEMBLY ..................... SA-8 Steering Axle Upper Surface ........................ SA-14
STEERING AXLE HUB ....................................... SA-9 Steering Axle Front Surface ......................... SA-15
Removal ......................................................... SA-9
Inspection ....................................................... SA-9
Installation ...................................................... SA-9
Wheel Bearing Adjustment ........................... SA-10
NOTE: This section contains information and specifications for both carbureted overseas market models, as well as,
electronic control models. Therefore, ensure the specifications or procedures you are looking at are for the proper
fuel delivery system; electronic controlled or carbureted.
DESCRIPTION
DESCRIPTION
The spindle has been installed to the axle center with the Elliot
system. The mount to a frame is attached through the mounting
bushing made from rubber into front and rear of the center of axle
center, and front and rear plays are adjusted by shims. For this
reason, axle center is swung in the vertical direction focusing on
mounting part.
SPECIFICATION
Model
1D1 1D2
Item
Steering axle type Elliot
Suspension type Center support, swing type
Camber () 0 0
Caster () 0 0
Wheel alignment
Toe-in (mm) 0 0
Kingpin inclination () 0 0
Maximum Inner wheel () 82.5 80.6

steering angle Outer wheel () 57.3 55.0

Possible cause Corrective action
Loose wheel nut Tightening
Improperly adjusted wheel bearing Adjustment
Improperly adjusted mounting shims Adjustment
Insufficient lubrication Applying grease
Insufficient tightening Tightening
SA-2
CONSTRUCTION
CONSTRUCTION
RAT0027L V
Casting axle center has been adopted instead of conventional metal

plate type.
And, the following parts have been adopted:
• Pre-compression rubber type roll control mechanism
• All oil pressure type PS system
• Knob position control system
Roll control mechanism

• Rubber has been adopted so as to improve rotation ability and
stability. Required roll power was secured from roll angle zero
point, and driving stability at turning has been improved.
Axle center
• Casting axle center has been adopted instead of conventional
metal plate type.
• Axle mounting bushing was made from rubber so as to optimize
strength and to improve both durability and driving ability together
with rubber for roll control.
• Grease nipple under the steering axle was uncovered. The
protrusion is provided into axle center lower so as to protect the
grease nipple from damage when the stones get kicked up.
SA-3
Kingpin
• Tire slice angle sensor was installed in right kingpin upper for tire
slice angle detection of knob position control system.
Spherical bushing
• Independent external seal is set as a dust reliability improvement
of spherical bushing.

Steering Tire
Removal
1. Wheel nut
2. Steering tire
RAT0028L
Preparation work
1. Pull handbrake lever, and then set chocks to front tires.
2. Loosen wheel nut by about 2 rotations, and then lift the forklift
with the jack or the crane.
• Use of jack
Apply the jack to the jacking point under the counterweight and lift.
RAT0029L
• Use of crane
Use the weight lifting up hole of and lift up.
CAUTION:
RAT0030L
• Place wood under the frame to prevent the forklift from
dropping when using either lifting method.
SA-4
INSTALLATION
Install in the reverse order of removal.
CAUTION:
• Tighten wheel nuts to the specified torque evenly.
• Wheel nut
Tightening torque [N•m (kg-m) Ft./Lbs]:
1D1 & 1D2: 167 - 226 (17 - 23) 123 - 167
RAT0031Çk
Steering Axle
Removal
RAT0032L V
Order of removal
1. Steering tire, wheel nut 4. Axle mounting bushing
2. PS piping 5. Steering axle assembly
3. Axle mounting cap, bolt
SA-5
Preparation work
1. Pull parking brake lever, and then set chocks to drive tires.
2. Jack up the forklift and support the lower side of the frame on
both sides with wood.
RAT0029L
Removal
• Support steering axle center with the garage jack.
RAT0033L
• Remove PS piping (2).

• Remove axle mounting cap bolts (4).
• Lower the garage jack, and pull out steering axle center.
RAT0034L
SA-6
INSTALLATION
Note the following, and install in the reverse order of removal.
1. Axle center pin top and bottom clearance adjustment
• Put shim downward to adjust when there is top and bottom
clearance between axle center pin and bushing.
Shim thickness (mm, in.):
RAT0035L
1.2, 0.047 (40006-47600)
1.6, 0.063 (40008-47600)
2. Axle center pin front and rear clearance adjustment

• Adjust shim so that front and rear clearance between axle center
pin and rear frame becomes less than 0.6 mm, 0.024 in.
Shim thickness (mm, in.):
RAT0036L 1.0, 0.039 (40571-FJ100)
2.3, 0.091 (40572-FJ100)
0.6, 0.024 (40573-FJ100)
3. Axle mounting cap installation

• Axle mounting cap bolt
1D1: 50 - 70 ( 5.2 - 7.2 ) 37 - 52
1D2: 68 - 92 ( 6.9 - 9.4) 50 - 68
SA-7
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY

Disassembly
RAT0037L W
Order of disassembly
1. Hub cap, lock screw, lock washer, wheel bearing 7. Knuckle spindle, needle bearing, thrust bearing,
nut, bearing spindle shim, grease seal, wheel angle sensor (RH),
2. Steering axle hub, inner bearing, grease seal sensor cover (RH)
3. Tie-rod bar, tie-rod clevis pin *Wheel angle sensor [sensor cover (metal plate), sensor
4. PS power cylinder cover upper (rubber), sensor, sensor cover lower
5. Lock screw, lock nut (rubber)]
6. Knuckle spindle, needle bearing, thrust bearing, 8. Kingpin
spindle shim, grease seal, kingpin cap (LH) 9. Kingpin dust cover (LH)
10.Grease nipple
11.Axle mounting cap, bolt
12.Axle mounting bushing, shim (upper/lower), shim
(front/rear)
SA-8
STEERING AXLE HUB
STEERING AXLE HUB

Removal
• Jack up and securely support body with safety stands.
• Remove tires, and then remove hub caps.
RAT0038L
• Loosen lock screw, and then remove lock washer, wheel bearing
nut, and outer bearing.
• Pull out steering axle hub.
CAUTION:
• Do not drop outer bearing.

• Pull out inner bearing.
• Do not damage grease seal.
• Drive out inner race remaining hub by using hub groove.
Inspection
Clean each disassembled part and check.
Wheel bearing
• Check for damage, seizure, peeling, improper rotation, and noise.
Replace if necessary.
Hub, spindle
• Check for cracks (by dye test). Replace if necessary.
Grease seal
• Check for damage and wear. Make sure that oil seal is removed
from spindle. Replace if necessary.
Installation
• Apply wheel bearing grease (NWB-2) to each roller, race surface,
and grease seal lip of wheel bearing.
• Adjust wheel bearing. (Refer to "(4) Wheel Bearing Adjustment".)
• Do not apply grease to inside inner race (where it is engaged to
spindle).
SA-9
STEERING AXLE HUB
Wheel Bearing Adjustment

1. Rotate steering axle hub with one hand, and then tighten wheel
bearing nut until it is hard to rotate.
2. Return wheel bearing nut approximately 60.
3. Rotate steering axle hub several turns under this condition to fit
RAT0039L bearing.
4. Rotate steering axle hub with one hand again, tighten wheel
bearing nut until it is hard to rotate, and then return it
approximately 60.
5. Align lock washer protrusion with spindle groove and lock washer
hole with thread hole of wheel bearing nut, and then tighten lock
screws (2).
CAUTION:
• Position lock washer so that both holes are close if the holes
are not aligned. And then, rotate wheel bearing nut so as to
align with the nearest hole.
6. Turn and return steering axle hub several times, and then make
sure that rotation starting force is within the standard.
Rotation starting force
(Reading of hub bolt spring balance) [N•m (kg-m) Lbs]:
0.1 - 2.9 (0.01-0.29) 0.07-2.14
CAUTION:
• Readjust if it is outside the standard.
7. Check steering axle hub axial direction for looseness.

Axial direction gap: 0.08 mm, 0.003 in., or less
CAUTION:
• Readjust if looseness is still detected.
SA-10
KINGPIN
KINGPIN
Removal
1. Disassemble spindle and tie-rod bar.
2. Loosen lock nut, and then remove lock screw.
3. Remove grease nipple, dust cover, and wheel angle sensor from
kingpin upper, and then drive out kingpin downward while
positioning a piece of metal on the kingpin.
RAT0040Çk CAUTION:
• Hold kingpin so as not to drop.

• Install the plate for wheel angle sensor positioning to kingpin
RH. Do not deform the plate when installing.
RAT0041Çk
4. Remove spindle together with thrust bearing and shim.

5. Pull out grease seal and needle bearing if necessary.
Inspection
Clean each disassembled part and check.
Needle bearing, thrust bearing

• Check for damage, seizure, peeling, improper rotation, noise,
corrosion, and deformation. Replace if necessary.
• Check seal and O-ring of needle bearing and thrust bearing for
damage and excessive wear. Replace if necessary.
Spindle
• Check for cracks (by dye test). Replace if necessary.
Grease seal
• Check for cracks (by dye test). Replace if necessary. Also replace
if grease seal is removed from steering axle.
SA-11
KINGPIN
Installation
CAUTION:
• Assemble wheel angle sensor correctly so as to correctly

operate knob position correction system function.
• See the following procedure for assembly.
• Assemble kingpin from lower side facing up. (Shim may be

damaged if assembling in incorrect direction.)
• Assemble bearing to spindle upper and shim to spindle lower.
• Install thrust bearing with cover side facing up, and then adjust
axial direction looseness with shim so that it is within the standard.
Standard (mm, in.): 0.2, 0.008 or less
• Adjusting shim
RAT0042Çk
Applied model Thickness (mm, in.)
0.20, 0.008
1D1 series
0.60, 0.024
0.20, 0.008
1D2 series
0.60, 0.024
• Assemble upper needle bearing with seal side facing up and lower
needle bearing with seal side facing down.
• Assemble kingpin grease seal with the dent facing outward.
RAT0043Çk
• Apply wheel bearing grease (NWB-2) to lower part of thrust

bearing (A) and gap between boss and spindle (B) until the grease
begins to ooze.
RAT0042Çk
SA-12
STEERING AXLE COMPONENT PARTS LOCATION
STEERING AXLE COMPONENT PARTS

LOCATION
RAT0045L W
1D2 Roll Control structure from 01-2012
Plate for Frame Rubber

putting Rubber
rubber on Plate for
Bolts
putting Bolts
rubber on
RAT0101EU RAT0100EU
SA-13

Steering Axle Upper Surface
RAT0047L V
Model
1D1 1D2
Item
Toe-in (mm, in.) Standard 0
Caster () Standard 0
Camber () Standard 0
(1) Tie-rod bar connecting pin mounting bolt tightening torque[N•m (kg-m) In./Lbs.] Standard 7.2 - 10.8 (0.7 - 1.1) 64 - 96
(2) Kingpin lock nut tightening torque [N•m (kg-m) Ft./Lbs.] Standard 31 - 42 (3.2 - 4.3) 23 - 31
137 - 186 225 - 255

(3) PS cylinder mounting bolt tightening torque [N•m (kg-m) Ft./Lbs.] Standard (14.0 - 19.0) (23 - 26)
101 - 137 166 - 188
(4) PS piping flare nut tightening torque [N•m (kg-m) Ft./Lbs.] Standard 39 - 43 (4.0 - 4.4) 29 - 32
(5) Top and bottom clearance of axle center pin (mm, in.) Standard There is no clearance.
Front: Less than 0.6, 0.023

(6) Front and rear clearance of axle center pin (mm, in.) Standard
Rear: Less than 0.6, 0.023
(7) Axle mounting cap mounting bolt tightening torque

Standard 50 - 70 (5.2 - 7.2) 37 - 52
[N•m (kg-m) Ft./Lbs.]
Maximum steering angle (°) (8) Inner wheel Standard 82.5 80.6
(For cushion tires, see page SA2)
(9) Outer wheel Standard 57.3 55.0
SA-14
Steering Axle Front Surface
RAT0048L U
Model
1D1 1D2
Item
(1) Kingpin axial direction clearance (mm, in.) Standard 0.2, 0.008 or less
(2) Rotation starting force of wheel bearing

(Reading of hub bolt spring balance) Standard 0.5 - 4.9 (0.05 - 0.50) 0.11 - 1.10
(For compact pneumatic models, see SA-10) N (kg) Lbs.
4.4 - 6.6
(3) Lock screw tightening torque [N•m (kg-m) In./Lbs.] Standard (0.4 - 0.7)
36 - 59
(4) Wheel nut tightening torque 167 - 226

(For cushion tires, see page RT-5) [N•m (kg-m) Ft./Lbs] Standard (17 - 23)
123 - 167
44.1 - 63.7 68.6 - 98

(5) Rim aligning bolt tightening torque [N•m (kg-m) Ft./Lbs] Standard {4.5 - 6.5) (7.0 - 10.0}
33 - 47 51 - 72
(6) Roll control plate mounting bolt tightening torque

Standard 110 - 150 (11.3 - 15.4) 81 - 111
[N•m (kg-m) Ft./Lbs]
(7) Wheel angle sensor harness clip mounting bolt tightening torque
Standard
[N•m (kg-m) In./Lbs] 7.2 - 10.8
(0.7 - 1.1}
(8) Wheel angle sensor cover mounting bolt tightening torque 64 - 96
Standard
[N•m (kg-m) In./Lbs.]
SA-15
ROAD WHEEL & TIRE
SECTION RT
CONTENTS
SPECIFICATION................................................. MA-2
Tire Air Pressure and Specifications ...............MA-2
Inspection of Tire for Wear ..............................MA-2
Inspection of Wheel Nut ..................................MA-3
SPECIFICATION
SPECIFICATION
Tire Air Pressure and Specifications

Measure the tire air pressure to see if the correct tire air pressure is
maintained.
• Always check the tire air pressure when the tires are cooled
down.
• After measurement, make sure to attach the tire valve caps.
Unit: kPa (bar, kg/cm², psi)
Front tire (drive) Rear tire (steer)

Item
Single Double Wide single Radial J R
Tire size 6.50-10-14PR 6.50-10-14PR - 6.50 R10 5.00-8-8PR 5.00 R8

1.5 ton,
1.75 ton 900 (9.0, 9.18, 900 (9.0, 9.18, 1,000 (10.0, 900 (9.0, 9.18, 1,000 (10.0,
Tire pressure -
130.5) 130.5) 10.20, 145.0) 130.5) 10.20, 145.0)
Tire size 7.00-12-14PR 7.00-12-14PR 27 x 10-12-14PR 7.00 R12 6.00-9-10PR 6.00 R9
2.0 ton,
2.5 ton 900 (9.0, 9.18, 900 (9.0, 9.18, 700 (7.0, 7.14, 1,000 (10.0, 900 (9.0, 9.18, 1,000 (10.0,
Tire pressure
130.5) 130.5) 101.5) 10.20, 145.0) 130.5) 10.20, 145.0)
Tire size 28 x 9-15-14PR 28 x 9-15-14PR - 28 x 9 R15 6.50-10-14PR 6.50 R10
3.0 ton,
3.5 ton 900 (9.0, 9.18, 900 (9.0, 9.18, 1,000 (10.0, 900 (9.0, 9.18, 1,000 (10.0,
Tire pressure -
130.5) 130.5) 10.20, 145.0) 130.5) 10.20, 145.0)
Inspection of Tire for Wear
1. Inspect the remaining depth of the tire grooves. Check the tires for
tread wear, or measure the depth of the tire grooves with a tire
depth gauge.
Repair limit:
5 mm (0.197 in)
2. If any of the tires show a sign of tread wear or the groove depth is
less than the above limit, replace the tire.
3. Inspect the tires for uneven wear referring to the table below. If
uneven wear is found, identify the causal factor and take
appropriate actions. Replace the tire if necessary
NOTE: The color tires may wear sooner compared with black tires.
RT-2
SPECIFICATION
Inspection of Wheel Nut

Inspect the wheel nuts for looseness. Tighten them if necessary to the
specified torque, referring to the table below.
CAUTION:
Always tighten the wheel nuts in a diagonal manner.
TIGHTENING TORQUE
Model
Item 1D1 series 1D2 series
1.5 ton, 1.75 ton 2.0 ton, 2.5 ton 3.0 ton, 3.2 ton
167 - 226 246 - 294 441 - 588

Single tire
(17 - 23, 123 - 166) (25 - 29, 182 - 216) (45 - 59, 326 - 433)
167 - 226 246 - 294 540 - 686

(17 - 23, 123 - 166)*1 (25 - 29, 182 - 216)*1 (55 - 69, 399 - 505)*1
Front (drive)
Pneumatictire 167 - 226 246 - 294 589 - 735
Double tire
model (17 - 23, 123 - 166)*2 (25 - 29, 182 - 216)*2 (60 - 74, 435 - 542)*2
79 - 98 246 - 294
—
(8.1 - 9.9, 59 - 72)*2 (25 - 29, 182 - 216)*3
167 - 226 167 - 226
Rear (steer)
(17 - 23, 123 - 166) (17 - 23, 123 - 166)
: Bolt
: Nut
*1: Inner wheel
*2: Outer wheel nut
*3: Hub nut (Outer hub)
NOTE:
For 3.0 ton model, hub bolt fixing nuts are needed to install hub bolts.
RT-3
BRAKE SYSTEM
SECTION BR
SERVICE DATA AND SPECIFICATIONS SERVICE BRAKE ............................................. BR-11
(SDS) ...................................................................BR-2 Brake Pedal and Inching Brake Pedal ......... BR-11
TROUBLE DIAGNOSIS AND CORRECTIONS ..BR-3 Master Cylinder ............................................ BR-12
Service Brake ................................................ BR-3 Brake Piping ................................................. BR-13
Hand Brake ................................................... BR-4 Drive Axle Brake ........................................... BR-14
Brake Rooster ............................................... BR-4 HAND BRAKE .................................................. BR-15
ADJUSTMENT ....................................................BR-5 SPECIAL SERVICE TOOL ............................... BR-16
Service Brake ................................................ BR-5
Hand Brake .................................................... BR-9
TIGHTNING TORQUE
GENERAL SPECIFICATIONS
N•m kg-m ft-lb in-lb
1D1 1D2
Pedal stopper lock nut Push 12 - 14 1.2 - 1.5 9 - 10 --
Drive axle brake
rod lock nut 16 - 21 1.6 - 2.2 12 - 15 --
Hydraulic, duo-servo drum with Contact bolt lock nut 19 - 25 1.9 - 2.6 14 - 18
Type auto-adjuster
Pedal bracket attaching bolt 37 - 50 3.7 - 5.1 27 - 36 --
Drum inner diameter Master cylinder attaching
254 (10) 310 (12-1/5) 9 - 11 0.9 - 1.2 -- 79 - 104
mm (in)
bolt/nut
Lining mm (in) 48.5 x 4.87 x 60.0 x 5.67 x 343.6
(Width x thickness x 279.3 (1.909 x (2.362 x 0.2232 x Wheel cylinder attaching bolt
length) 0.1917 x 11.0) 13.53) D01 8 - 11 0.8 - 1.2 -- 70 - 104
Wheel cylinder inner D02 18 - 26 1.8 - 2.7 13 - 19 --
diameter 22.22 (7/8) 28.57 (1-1/8) Back plate attaching nut
mm (in) D01 59 - 78 6.0 - 8.0 44 - 57 --
Master cylinder D02 98 - 117 10 - 12 73 - 86 --
Type Single conventional Brake tube flare nut 15 - 17 1.5 - 1.8 11 - 13 --
Inner diameter Brake house flare nut 17 - 19 1.7 - 2.0 13 - 14
17.46 (11/16) 23.81(15/16)
mm (in) Hand brake fixing bolt 9 - 11 0.9 - 1.2 79 - 104
Stroke mm (in) 33 (1.30) Hand brake cable adjusting 19 - 25 1.9 - 2.6 14 - 18 --
lock nut
INSPECTION AND ADJUSTMENT

1D1 1D2
Brake pedal mm (in)
Pedal free play 1 - 3 (0.04 - 0.12)
Pedal height 105 - 115 (4.13 - 4.53)
Depressed height 85.3 - 95.4 79.4 - 97.3
Inching brake pedal
Pedal height mm (in) 105 - 115 (4.13 - 4.53)
Clearance between con-
4.4 - 5.7 (0.173 - 0.224)
tact bolt and brake pedal
Master cylinder
Allowable clearance
between cylinder and Less than 0.15 (0.0059)
piston mm (in)
Drive axle brake
Wear limit of brake lining
1.0 (0.039)
mm (in)
Brake drum mm (in)
Out of roundness Less than 0.03 (0.0012)
Radial runout Less than 0.05 (0.0020)
Repair limit 254.3 (10.01) 310.8 (12.24)
Hand brake
Pulling force
N (kg,lb) 167 - 225 (17 - 23, 37 - 51)
BR-2
SERVICE BRAKE
Insufficient braking force Oil leakage in brake lines Correct and replenish.
Air in brake lines Bleed air.

Water or oil on linings Clean or replace.
Uneven wear or contact of brake linings Grind or replace.
Worn linings Replace.

Improper functioning of master cylinder or wheel Correct or replace.Clean.
cylinder
Clogged oil lines
Clean.
Improper functioning of brake booster Correct or replace.
Unequal braking (lift truck Uneven tire pressure Adjust.
veers to one side) Brakes out of adjustment Adjust.
Water or oil on brake linings Clean or replace.
Foreign particles in brake drum Clean.

Deteriorated lining surfaces Grind or replace.
Improper contact of linings Grind or correct.
Worn lining Replace.

Worn, warped, rusted or damaged brake drums Correct or replace.
Improper operation of wheel cylinder Correct or replace.
Improper sliding of shoes Adjust.
Loose back plat ebolts Tightening or replace.

Warped back plates Replace.
Improperly adjusted wheel bearings Adjust or replace.
Clogged oil lines Clean.

Brake dragging No free play of brake pedal Adjust.
Improper shoe sliding Adjust.

Improper operation of wheel cylinder Adjust or replace.
Faulty piston cup Replace.
Weak or broken return springs Replace.

Clogged master cylinder return port Clean.
Clogged oil lines Clean.
Wheel bearing out of adjustment Adjust or replace.

Improper functioning of brake booster Correct or replace.
BR-3

Brake squeaking Brake drag Refer to above.
Improper returning of piston Replace.
Deteriorated lining surfaces Grind or replace.

Improper contact of shoes with linings Replace.
Excessively worn shoes or back plates Clean and apply brake grease.
Foreign particles on frictional surfaces of drums Clean.

Frictional surfaces of drum worn runout Replace.
Deformed or improperly installed shoes Replace or correct.
Loose back plate bolts Tighten.

Worn anchors Replace.
Improper contact of linings Correct or replace.
Improperly installed anti-rattle springs Correct.

Brake noise Rough frictional surfaces of drums Grind or replace.
Drum out of center or excessively warped drum Replace.
Rough lining surfaces Grind or replace.

Excessive pedal stroke Brake out of adjustment Adjust.
Air in oil lines Bleed air.
Oil leakageor insufficient oil Check and correct.
Dislocation or improper returning of shoes Correct.

Improper contact of linings Correct.
HAND BRAKE
Insufficient braking force Open or elongated wire Replace.
Water or oil on linings Clean or replace.

Uneven wear or contact of brake linings Grind or replace.
BR-4
ADJUSTMENT
ADJUSTMENT
Service Brake
BRAKE PEDAL
1. Adjust brake pedal height "H" to the specified value with lock nut
of pedal stopper.
Brake pedal height "H":
105 - 115 mm (4.13 - 4.53 in)
Pedal stopper lock nut:
: 12 - 14
(1.2 - 1.5 kg-m, 9 -10 ft-lb)
BRM0042
2. Adjust push rod length of master cylinder or brake booster until

pedal free play is within specified value, then tighten lock nut
securely.
Pedal free play:
1 - 3 mm (0.04 - 0.12 in)
Push rod lock nut:
: 16 - 21
(1.6 - 2.2 kg-m, 12 - 15ft-lb)
BRM0043
3. Check depressed height.If it is not as specified, check brake

system.
Depressed height:
1D1: 85.3-96.4
1D2: 79.4-97.3
BRM0044
4. Depress and release pedal several times to see if it travels

smoothly over its entire stroke without binding, twisting or
interfering with adjacent parts.
BR-5
ADJUSTMENT
5. Depress and release pedal several times. make sure stop lamp
switch comes on when pedal is depressed 10 to 20 mm (0.39 to
0.79 in) and goes off when it is released.
BR-6
ADJUSTMENT
Service Brake (Cont’d)

BRAKE SHOE
The shoe-to-drum clearance automatically adjusts for lining wear
when the foot brake is operated while moving forward.
INCHING BRAKE PEDAL

1. Adjust inching pedal height "H" to the specified value with inch-
ing pedal stopper.
Inching pedal height "H":
105 - 115 mm (4.13 - 4.53 in)
Pedal stopper lock nut:
: 12 - 14 N•m (1.2 - 1.5 kg-m, 9 -10 ft-lb)
BRM0045
2. Adjust clearance between contact bolt and brake pedal.

Clearance:
4.4 - 5.7 mm (0.173 - 0.224 in)
Contact bolt lock nut:
: 19 - 25 N•m (1.9 - 2.6 kg-m, 14 -18 ft-lb)
BRM0046
BR-7
ADJUSTMENT
Service Brake (Cont’d)
BRM0065
3. Adjusting the inching cable length using the adjusting nut so that
the inching lever turns to the lock position when the inching pedal is
depressed.
BR-8
ADJUSTMENT
Hand Brake
BRM0047
Before adjusting hand brake, make sure that drive axle brake is
functioning properly.
1. Park the forklift.
2. Put blocks at the tires (wheels) on the drive side.
3. Adjust nut B until thread length "L" is 15.5 mm (0.610 in) and
then tighten lock nut A.
4. To lock the lever, push the adjusting bolt in direction "Q" to point
"P" where the grip load becomes 167 to 225 N (17 to 23 kg, 37
to 50 lb).
5. Turn the adjusting bolt with a screwdriver. Adjust the opera-
tional force to lock the hand brake lever to the standard value.
Standard value at the tip of the hand brake lever
(point P):
167 - 225 N (17 - 23 kg, 37 - 50 lb)
BRM0063
BR-9
ADJUSTMENT
Hand Brake (Cont’d)

NOTICE:
• The operational force to lock the hand brake lever increases by
turning the adjusting bolt clockwise.
• The operational force to lock the hand brake lever decreases by
turning the adjusting bolt counterclockwise.
BR-10
SERVICE BRAKE
SERVICE BRAKE
Brake Pedal and Inching Brake Pedal
BRM0048
CAUTION:
CAUTION:
• To avoid splashing brake fluid on painted surfaces and
other parts, always place a container or rag under brake
tubes.
• When removing flare nut, use Tool GG94310000.
• Never use open end or adjustable wrench.
• Discard cotter pin after removal; install new one.
• Make sure pedal travels smoothly over its entire stroke
without binding, twisting, etc. and makes no contacting
noise.
• Use DOT 3 (F.M.V.S.S. No. 116) brake fluid only.
INSPECTION
• Check the following parts, replace or repair if necessary.
• Pedal bushing for wear, deformation or other damage
• Pedal shaft for bending or other damage
• Pedal arm for bending or other damage
• Return spring for weakness
• Pedal pad for damage
BR-11
SERVICE BRAKE
Master Cylinder
BRM0049
BR-12
SERVICE BRAKE
Brake Piping
BRM0060
BR-13
SERVICE BRAKE
Drive Axle Brake
BRM0064
BR-14
HAND BRAKE
HAND BRAKE
BRM0062
BR-15
SPECIAL SERVICE TOOL
SPECIAL SERVICE TOOL
Toolnumber
Description
Tool name
GG94310000
Flare nut torque wrench
NT792
BR-16
STEERING SYSTEM
SECTION ST
CONTENTS
SPECIFICATION ................................................. ST-2 PS VALVE ..........................................................ST-10
TROUBLE DIAGNOSIS AND Parts Construction .........................................ST-10
CORRECTIONS .................................................. ST-3 Disassembly ..................................................ST-12
STEERING WHEEL ............................................ ST-4 Inspection ......................................................ST-13
Removal ......................................................... ST-4 Assembly .......................................................ST-14
Inspection ....................................................... ST-4 Trouble Diagnosis and Corrections ...............ST-17
Installation ...................................................... ST-4 PS CYLINDER ...................................................ST-19
Inspection After Installation ............................ ST-5 Specification ..................................................ST-19
STEERING COLUMN ......................................... ST-6 Installation .....................................................ST-20
Tilt Lock Lever ................................................ ST-6 Troubleshooting ............................................ST-21
Grease Application to Shaft Assembly Disassembly ..................................................ST-23
and Spline ...................................................... ST-7 Inspection After Assembly .............................ST-28
Steering Height Adjustment ............................ ST-8 Periodical Inspection and Maintenance .........ST-29
OIL PRESSURE TEST ........................................ ST-9
Oil Pressure Test and Adjustment .................. ST-9
NOTE: This section contains information and specifications for both carbureted overseas market models, as well as,
electronic control models (manufactured in USA.) Therefore, ensure the specifications or procedures you are looking
at are for the proper fuel delivery system; electronic controlled or carbureted.
SPECIFICATION
SPECIFICATION
1D2
Item 1D1
2.0 - 2.5 ton 3.0 - 3.2 ton
Power steering system Full hydraulic system
Inner wheel () 82.5 80.6

Maximum steering angle
Outer wheel () 57.3 54.0
System Full hydraulic PS valve
PS valve Type PS valve with ultra-low input level (Plugged star type)
Valve discharge (cm3/rev), in.3 69, 4.2 96, 4.2 120, 7.3
Rod diameter (mm, in.) 45, 1.77 50, 1.97
PS power cylinder Inner diameter (mm, in.) 65, 2.56 70, 2.76
Stroke (mm, in.) 167, 6.57 197, 12.7
PS flow rate (L/min, Qt/min.) 11.5 (2-1/2)
[MPa
Relief pressure (kg/cm2) See chart below
PSI]
Specified oil Hydraulic oil I.S.O. VG32
Relief Pressures
Relief
Models Mpa (bar, kgf/cm2, psi)
Steering Main
1D1 7.8 (78.5; 80; 1,138)

18.1 (181, 184.6, 2625)
1D2 8.8 (88.3; 90; 1,280))
ST-2

Symptom Possible causes Corrective action
Vibration, impact, instability of • Insufficient tire air pressure Adjust.

steering wheel • Worn kingpin and needle bearing Replace.
• Excessive free play of drag rod and tie rod ball joints Replace.
• Worn and loose spherical bushing Replace.
• Insufficiently adjusted or worn wheel bearing Adjust or replace.
• Worn kingpin thrust bearing Replace.
• Deformed or unevenly worn tires and road wheels Repair or replace.
• Loose joint Tighten.
• Loose spool of PS valve Tighten and replace.
• Damaged control valve, broken or deteriorated coil spring Replace.
Excessive steering wheel effort Adjustment

• Insufficient tire air pressure Grease and replace
• Insufficient lubrication of kingpin malfunctioning parts.
• Foreign objects, insufficient oil Replace and fill oil.
• Deformed or interfered tie-rod bar Repair or replace.
• Insufficiently adjusted or worn wheel bearing Adjust or replace.
• Insufficient oil in oil tank Fill.
• Insufficient air bleeding Bleeding.
• Oil leakage from hoses and tubes, or clogging of oil passage Replace or clean.
• Insufficient hydraulic pressure Refer to the following.
• Damaged control valve Replace.
• Damaged piston seal of PS cylinder Replace.
Insufficient hydraulic pressure • Oil leakage from hoses, tubes and joints, or clogging of oil passage Replace or clean.
• Malfunctioning hydraulic pump Refer to "TROUBLE
DIAGNOSIS AND
CORRECTIONS" in
HD section.
Forklift rolling away in a certain • Insufficient matching of left and right tires Adjust or replace.
direction • Insufficiently adjusted brake Adjust.
Forklift wobbling (straight-line • Malfunctioning PS valve Replace.

instability) • Worn or inappropriately adjusted wheel bearing Adjust or replace.
• Loose road wheel Tighten.
• Excessive free play of tie-rod clevis pin Replace.
• Deformed road wheel Replace.
Excessive free play of steering • Worn steering shaft and PS valve-connecting spline Replace.
wheel • Loose PS valve mounting bolt Tighten.
• Inappropriately adjusted wheel bearing Adjust.
Inappropriate steering wheel • Malfunctioning spool Disassemble, clean,

return travel and replace.
• Inappropriate centering spring of PS valve Replace.
• Inappropriate wheel alignment Adjust.
• Insufficient tire air pressure Adjust.
ST-3
STEERING WHEEL
STEERING WHEEL
Removal
• Remove the horn button.
• Remove the steering wheel retaining nut and remove the steering
wheel using the steering wheel puller.
STT0089L
CAUTION:
• Do not tap steering wheel mounting nut with a hammer. It

causes the malfunction of PS valve meter controller.
Inspection
• Check the steering wheel for any damages, cracks or deformation
and replace it as necessary.
• If the serration section is deformed, replace it. (Check steering
shaft serration also.)
Installation
In 1D1/1D2, combination switch auto return function is operated by
steering wheel operation.
In addition, a full hydraulic steering system is adopted, which
features a function that corrects the knob position by detecting the
steering wheel rotation and road wheel steering angle (knob position
control system). It is necessary to retain steering wheel and steering
wheel angle sensor. The following paragraphs explain that
procedure.
1. Position the P section of the combination switch as shown and
apply grease (NAV-1) to the Q section (bottom of steering wheel
boss).
2. With the Forklift front wheels set in the straight-ahead position (the
wheels should be directly straightforward), locate the steering
wheel in the position as shown and align its projections to the
switch holes by turning left and right several times.
To check if the projections are correctly aligned to the switch
holes, verify that the combination switch's auto return function
operates normally.
3. If the auto return does not function normally, repeat steps.
STT0090L S
4. After ensuring that the projections and holes are aligned correctly,
tighten the steering wheel nut.
18 - 22 (1.8 - 3.3) 13 - 16
5. Install the horn pad.
ST-4
STEERING WHEEL
CAUTION:
• Neutral knob position must be redetected after removing and

installing or replacing steering wheel angle sensor of steering
axle.
• Refer to "3. SELECTION OF FORKLIFT SPECIFICATION (3)"
in VC section.
Inspection After Installation
Inspection of steering wheel for play

• Make sure that steering wheel play is within the standard on the
circumference with engine stopped.
Play: 30 mm, 1.18 in., or less
ST-5
STEERING COLUMN
STEERING COLUMN
STM0063
Tilt Lock Lever
STM0052
CAUTION:
When installing the tilt lock lever, pay attention to the items
below:
Loosen the tilt lock lever, and check that the steering wheel
moves smoothly at all tilt angles.
When the steering wheel is positioned where the forklift moves
straight ahead, check that the tilt lock lever faces the direction
as shown in the figure.
STM0053
STEERING COLUMN LOCK LEVER

NOTE:
When installing the steering column lock lever, be sure to fol-
lowthe steps below:
1. Assemble the steering column lock lever and the bracket
tempo-rarily.
2. Press the temporarily assembled tilt lock lever assembly against
the front-side of the forklift, and secure with bolts.
3. Check P for looseness.
STM0054
ST-6
STEERING COLUMN
Grease Application to Shaft Assembly and Spline

1. Remove connecting bolts (✩ as shown in the figure) between the
universal joint and the lower column at the lower-side of the shaft
assembly.
2. Remove the universal joint and the shaft at the lower-side.
3. Apply the proper amount of heavy duty grease or equivalent to
the spline.
4. Assemble the universal joint and the shaft (in the reverse order of
removal).
STM0055
ST-7
STEERING COLUMN
Steering Height Adjustment
STM0056
As the steering column mounting bolt holes have been made lon-
ger, the steering wheel height can be variably adjusted by a maxi-
mum of 50 mm (1.97 in), by loosening the column mounting bolts
and sliding the column.
ST-8
OIL PRESSURE TEST
OIL PRESSURE TEST

Oil Pressure Test and Adjustment
WARNING:
Wear protective eyewear. High pressure fluid leaks can cause
loss of vision or eye damage.
OIL PRESSURE TEST
1. Stop engine.
2. Remove plug from control valve high pressure pipe port, and
STM0065
install pressure gauge.
3. Start engine and warm hydraulic oil to about 50°C (122°F).
4. Rotate steering wheel to left and right two or three times.
5. With engine running at approx. 1,000 rpm, fully turn steering
wheel in either direction and keep as it is.
6. Read pressure on gauge indicator.
STM0057
OIL PRESSURE ADJUSTMENT

1. Proceed with oil pressure test, and keep pressure gauge
attached to inspection port.
2. Loosen lock nut on control valve and adjust adjusting screw.
Test engine speed:
1,500 - 2,000 rpm
Specified pressure:
1D1
STM0066
7.8 ( 78.5; 80; 1,138) {Mpa (bar; kg/cm2; psi)}
1D2
8.8 ( 88.3; 90; 1,280)
Set screw clockwise turn:
Pressure up
Counterclockwise turn:
Pressure down
Never remove pressure gauge and always check it when
adjusting pressure.
ST-9
PS VALVE
PS VALVE
Parts Construction
Component parts location
STT0099L X
ST-10
PS VALVE
Parts list
No. Description Quantity Remarks
1 Screw 6
2 Retainer screw assembly 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
6 - - Missing number
7 Spacer plate 1
8 Drive 1
9 Control parts assembly 1 Including items Nos. 10 to 12
10 Housing (1)
11 Sleeve (1)
12 Spool (1)
13 Pin 1
14 Centering spring 4 Ultra-low input version
15 - - Missing number
16 Race bearing 2
17 Thrust needle bearing 1
18 O-ring 1
19 Oil seal 1
20 Dust seal 1
21 Retaining ring 1
22 Seal gland bushing 1
23 O-ring 2
24 O-ring 1
25 Adapter screw 1
26 Ball 1
27 Plug 1
28 O-ring 1
29 Nameplate 1
30 Rivet 2
ST-11
PS VALVE
Disassembly
Be careful the following when repairing PS valve.
• Work in a clean place.
• Clean unit around the port before disconnecting piping.
• Remove dust or dirt on the joint of circumference of unit using wire
brush.
• Be careful so as not to dent and damage because parts drop and
contact.
CAUTION:
• Take care not to be injured by any sharp, machined edges in

the sleeve, spool and housing.
Necessary tool
• Torque wrench (Torque: 50 N•m (5.1 kg-m)), 37 Ft./Lbs.
• Socket for 5/12"-12 points
• Flat-bladed screwdriver (Large)
• Flat-bladed screwdriver (Small)
• Tool for inserting spring (Part No.: 600057)
• Plastic hammer
• A small amount of grease
• Vise
• Oil-based maker
Disassembly of gerotor side
1. Hold the main body with a vise with end cap side facing up. Make
sure to hold it at the mounting flange of the housing by applying
moderate pressure. Do not apply excessive pressure. Use copper
plates between the component and the vise as necessary.
STT0100L S
2. Remove the six screws and one retainer screw assembly.

3. Remove the end cap.
4. Remove the O-ring from the end cap.
5. Remove the following parts from the gerotor star.
Plug and O-ring
6. Take out the spacer from the inner spline of the gerotor star.
NOTE:
• Depending on the gerotor's displacement, some units have no spacers and
others have two spacers, etc.
7. Remove the gerotor. Do not allow the star to drop from the gerotor
outer ring.
8. Remove the O-ring from the gerotor ring.
9. Remove the O-ring from the gerotor.
10. Remove the drive.
11. Remove the spacer plate.
12. Remove the O-ring from the housing.
13. Using a flat-bladed screwdriver, remove the adapter screw from
the housing.
14. Remove the housing from the vise and remove the ball by turning
the housing upside down.
CAUTION:
• Do not drop or lose the ball.
ST-12
PS VALVE
Disassembly of control side

1. Place the housing on a clean fabric with the flange side facing up so
that the finished faces are not damaged. Lift the end of the retaining
ring with a flat-bladed screwdriver and remove it from the housing.
STT0101L S CAUTION:
• Always wear safety goggles. The retaining ring may pop out of the
housing.
2. Place the housing on a clean fabric so that the axial direction of the
main body is held in a horizontal direction. After setting the pin to a
level position by turning the spool and sleeve assembly, slightly push
out the spool and sleeve assembly to remove the seal gland bushing
from the housing.
NOTE:
• The spool and sleeve assembly mentioned above includes the sleeve,
spool, pin, centering spring and flat spring.
3. Remove the oil seal from the seal gland bushing.

4. Remove the dust seal from the seal gland bushing using a flat-bladed
screwdriver.
5. Remove the two race bearings, thrust needle and O-ring.
6. Press the inner spline of the spool with thumb and pull off the spool
and sleeve assembly from the opposite side to the housing flange. At
that time, ensure that the sleeve outer wall is not caught in the
housing inner wall.
STT0102L S
CAUTION:
• Depending on the spool/sleeve combinations, even a 180 shift in

position may render the unit inoperative. To prevent such a symptom,
put alignment marks at the positions shown in figure on the spool and
sleeve assembly during this step.
7. Pull out the pin from the spool and sleeve assembly.
CAUTION:
• Always wear safety goggles. The centering spring may pop out of the
spool.
8. Slightly push forward the spool in the sleeve and carefully remove the
centering spring from the spool with fingers.
9. Pull out the sleeve from the spool. To do so, gently turn the sleeve while
pulling it.
Inspection
Inspect the fitting faces of all parts. Any parts with scratches or burrs must
be replaced. These may cause oil leakage.
Clean all metal parts with clean solvent and dry them by blowing air. Do not
use cloth or paper. Lint or particles from these materials may enter the main
body, resulting in contamination of the hydraulic system and subsequent
symptoms.
Do not use files or sandpaper on the parts.
CAUTION:
• Take care not to be injured by any sharp, machined edges in the sleeve,
spool and housing.
ST-13
PS VALVE
Assembly
CAUTION:
• Assemble a new O-ring and seal when assembling.

• Apply a small amount of clean grease to O-rings before assembly.
• Do not confuse O-rings (23) and (24) because they are sizes very
near.
Reassembly on control side
1. Slowly insert the spool in the sleeve while turning the spool. After that,
hold the spool spline and try to turn it. The spool should turn smoothly in
the sleeve.
WARNING:
• Make sure to align the two parts correctly by referring to the
alignment marks that have been placed during disassembly.
Misalignment may cause malfunctions, resulting in serious accidents.
2. Position the spool and sleeve correctly by aligning the two opposite spring
grooves. Insert the spring inserting tool in the spring grooves. Arrange the
centering springs as shown in the figure and fit them to the inserting tool
so that the end cutouts face downward.
STT0103L S
CAUTION:
• Ensure that the centering springs are arranged and positioned

correctly. Incorrect positions or arrangement may lead to
malfunctions.
Ultra-low input version:
Centering spring 4
3. Slightly lift the spool from the sleeve. While pressing and holding the
opposite end of the centering spring, push them into the grooves of the
spool and sleeve. At that time, make sure to slide the inserting tool at the
same speed as pushing the springs. After inserting the springs, align the
STT0104L S spring ends to the sleeve periphery.
CAUTION:
• Always wear safety goggles. The centering spring may pop up from
the spool.
4. Insert the pin in the sleeve hole and align both ends of the pin with the
sleeve periphery.
5. Place the housing on a clean fabric so that the axial direction of the main
body is held in a horizontal direction. Insert the spool and sleeve
assembly from the opposite end to the housing flange.
Verify that the spool and sleeve assembly can turn smoothly in the
housing in this status.
CAUTION:
• When inserting the spool and sleeve assembly, ensure that they are not
slanted and caught by the housing inner wall. During the insertion
process, turn the assembly left and right to a small stroke while
keeping the pin in a horizontal position.
• After insertion, the spool and sleeve assembly must be flush with the
housing end face. Do not insert the assembly further. Any excessive
insertion may cause the pin to drop in the inner portion of the housing.
ST-14
PS VALVE
6. Place the housing on a clean flat surface and install the O-ring.
7. Install the two race bearings and thrust needle bearing. Make sure
to insert the thrust needle bearing between the race bearings.
(In the order of race bearing, thrust needle bearing, and then race
bearing)
8. Install the dust seal into the seal gland bushing. Ensure that the
flat face of the dust seal comes to the seal gland bushing side.
9. Attach the oil seal to the seal gland bushing.
CAUTION:
• Ensure that the oil seal is not twisted and deformed.
10.Insert the seal gland bushing in the spool while turning the
bushing. Lightly tap on the bushing with a plastic hammer to
insert it to the specified position.
11.Install the retaining ring into the housing.
CAUTION:
• Expand the retaining ring with a flat-bladed screwdriver so

that the entire periphery of the ring fits into the housing
groove.
• Always wear safety goggles. The retaining ring may pop out
of the housing.
Assembly of gerotor side

1. Hold the main body with a vise with end cap side facing up. Make
sure to hold it at the mounting flange of the housing by applying
moderate pressure. Do not apply excessive pressure. Use copper
plates between the component and the vise as necessary.
2. Put the ball into the bolt hole shown in the figure.
NOTE:
• This bolt hole is for attaching the retainer screw assembly.
STT0105L S
3. Install the adapter screw into the hole in which the ball has been
put.
4. Attach the O-ring onto the housing.

5. Place the spacer plate and align the bolt holes.
NOTE:
• The bolt hole differs from the oil hole in pitch and diameter.
ST-15
PS VALVE
6. Turn the spool and sleeve assembly so that the pin and the
housing port are parallel. Insert the drive and engage the drive
yoke and the pin.
For accurate positioning, draw a line on the drive end face parallel
to the pin using a marker pen.
7. Attach the O-ring to the gerotor.
CAUTION:
• There are two gerotors (23) (24). Ensure that the correct one is
selected.
STT0106L 2S
8. Position the O-ring side of the gerotor toward the spacer plate and
assemble it while aligning the concaves of the gerotor star gear to
the line marked. At that time, ensure that the pin, drive and star
concaves are all aligned parallel as shown in the figure.
Turn the gerotor ring to align the bolt holes while keeping the drive
and the gerotor star engaged with each other.
WARNING:
• Make sure to restore the correct positional relation. Incorrect
combinations will cause a malfunction, which may lead to
serious accidents.
CAUTION:
• Be sure to perform above steps 6 to 8 because they are

important procedure for mating valve timing.
• The bolt hole differs from the oil hole in pitch and diameter.
9. Install the spacer into the spline of the gerotor star.

10. Fit the plug to the gerotor star.
Attach the O-ring to the plug and fit the plug into the star groove
of the gerotor.
11. Attach the O-ring to the end cap. Place the end cap on the
gerotor and align the bolt holes.
12.Apply oil to the threads of the six screws and a retainer screw,
and install them into the end cap. Ensure that the retainer screw
fits in to the correct positions instructed in the sectional structure
view. Tighten the seven screws to approximately 14.7 N•m
(1.5 kg-m), 11 Ft./Lbs., as the initial tightening. Then tighten them
STT0108L S to the specified torque in the order shown in the figure.
Tightening torque [N•m (kg-m)]: 20.6 (2.1); 15 Ft./Lbs.
13. Install the handle to the spool and verify that the spool can rotate.
ST-16
PS VALVE
Trouble Diagnosis and Corrections

High-effort steering 1. Hydraulic system

• High backpressure • Lower backpressure to under allowable level.
• Set steering relief valve pressure too low • Reset pressure.
2. PS valve
• No centering to column • Repair. (If the steering effort is reduced when
the PS valve retaining bolts are loosened, the
cause is incorrect centering.)
• Seizure due to foreign objects between spool • Replace.
and sleeve or sleeve and housing
• Excessive tightening torque of end cap screw • Evenly tighten to correct torque.
• Missing ball in emergency steering check • Install ball.
valve
3. Direct valve or other attached control valves

• Excessive tightening torque of port connector • Tighten to the specified torque.
• Excessive tightening torque of retaining bolts • Tighten to the specified torque.
• Foreign object in relief valve • Disassemble, clean, reassemble, adjust set
pressure or replace valve assembly.
• Foreign object between housing and spool • Replace valve assembly.
• Malfunction (inappropriate operation) • Replace valve assembly.
• Clogged orifice • Disassemble, clean, reassemble.
• Incorrect assembly of control spring • Replace with optimum spring.
4. Pump
• Not operating • Activate.
• Worn, malfunctioning • Replace.
• Reverse rotation • Repair.
5. Forklift
• Excessive wear of mechanical parts • Lubricate or replace bearing joint.
Steering wheel will not return to 1. Hydraulic system

neutral position after it is released, • High backpressure • Lower pressure to under allowable level.
or steering wheel turns
spontaneously (except load 2. PS valve
reaction type). • Seizure due to foreign objects between spool • Replace.
and sleeve
• No centering to column • Repair.
• Damaged centering spring • Replace spring.
Cylinder does not follow steering 1. Hydraulic system

wheel at all or only unsatisfactorily, • Air inclusion • Bleed the air.
wheel slip is too large.
2. PS valve
• Worn internal parts • Replace, clean, reassemble, and adjust set
pressure.
• Insufficient tightening torque of end cap screw • Evenly tighten to correct torque.
• Missing drive or spacer • Assemble correctly.
Cylinder does not follow steering 3. Direct valve or other attached control valves
wheel at all or only unsatisfactorily, • Foreign objects in overload relief valve and • Disassemble, clean, reassemble, and adjust
wheel slip is too large. anti-cavitation check valve set pressure or replace valve assembly.
• Damaged O-ring • Replace.
4. Pump
• Insufficient volume efficiency • Replace.
5. Cylinder
• Damaged piston seal • Replace.
Steering wheel is pulled back or 1. Hydraulic system

wheel kick symptom occurs. • Incorrect piping to 4 ports • Repair.
2. PS valve
• Incorrect valve timing assembly • Assemble correctly.
ST-17
PS VALVE
Vibration 1. Hydraulic system

• Air inclusion • Bleed the air.
2. Forklift
• Worn mechanical joints • Replace worn parts.
Unusual noise (including unusual 1. Hydraulic system

release noise) • Noise by interference of hydraulic piping • Eliminate interference.

• Foreign objects in steering relief valve or • Disassemble, clean, reassemble, and adjust
overload relief valve or excessive wear set pressure or replace valve assembly.
Oil leakage 1. PS valve [Worn or damaged axle (spool) oil

seal]
• Contaminated fluid • Replace fluid and filter element.
• High backpressure • Lower pressure to under allowable level.
• Rust on spool sealing face • Replace assembly.
• Damage in disassembly/assembly [Damaged • Replace.
O-ring for fitting face (gerotor)]
• Bite during disassembly/assembly • Replace.
• Damaged O-ring groove • Replace relevant parts.
• Insufficient tightening torque of end cap screw • Tighten to correct torque.

• Loose direct retaining bolts to PS valve • Tighten to correct torque.
• Damaged O-ring • Replace.
• Damaged sealing face and groove • Replace relevant parts or assembly.
ST-18
PS CYLINDER
PS CYLINDER
Construction
STT0110L U
1. Cylinder tube 7. Backup ring 13. Spherical bushing

2. Piston rod 8. Wiper ring 14. Snap ring
3. Cylinder head 9. O-ring 15. Tie rod
4. Bushing 10. O-ring 16. Nut
5. Snap ring 11. Slip seal 17. Washer
6. U-ring 12. O-ring
Specification
Standard specification
Forklift model
1D1 1D2
Items
Cylinder outer diameter (mm, in.) 75, 2.95 80, 3.15
Cylinder inner diameter (mm, in.) 65, 2.56 70, 2.76
Piston rod diameter (mm, in.) 45, 1.77 50, 1.97
Stroke (mm, in.) 167, 6.57 197, 7.76
In relation to the above standard specifications, the antirust version

has modified the rod surface treatment (hard chrome plating to
nickel chrome plating) and the outside paint (antirust paint).
ST-19
PS CYLINDER
Removal
1. Jack up the forklift and support it securely with a rigid rack.
2. Disconnect the hydraulic tube from the PS cylinder.
3. Remove the tie-rod clevis pin connecting the piston rod and tie rod
bar.
4. Remove the bolt from the steer axle joint.

5. Turn the kingpin and pull it aside from the steer axle.
Installation
• Clean the inner wall of the spherical bushing mounting hole to
prevent risk of seizure due to foreign objects.
• Apply grease to the sliding faces and dust cover lips.
• PS cylinder mounting bolt
137 - 186 (14 - 18) 101 - 137 (L01)
225 - 255 (23 - 26) 166 - 188 (L02)
• Tie-rod clevis pin mounting bolt

Tightening torque [N•m (kg-m) In./Lbs.]:
7.2 - 10.8 (0.74 - 1.10) 64 - 96
• Flare nut
Tightening torque [N-m (kg-m) Ft./Lbs]:
39 - 43 (4.0 - 4.4) 29 - 32
ST-20
PS CYLINDER
Troubleshooting
Condition Possible causes Corrective action
Oil leakage from piston rod Piston 14. Eliminate the scratches and smoothen the sliding face (1.5
sliding face rod s or less) using oilstone. If the oil still leaks, the sealing
*: Refer to "(8) Inspection • Rust or scratches on sliding parts such as U-ring may be damaged by the scratches.
After Assembly" for face, which can be felt by Overhaul the piston.
judgement. fingernails. 15. If the scratches and rust zone is too wide to repair with
oilstone, replace the piston rod, U-ring, seals such as the
wiper ring, and piston rod bearings.
1. Re-plate or replace the piston rod.

• Detached plating 2. At the same time, inspect the seals and piston rod
bearings, and replace them if necessary.
Rod • Foreign object in inner/outer 1. Remove the foreign objects.

packing faces 2. Replace any damaged packing.
(U-ring)
• Scratches on inner/outer 1. Replace.
faces
1. The symptom may be caused by adiabatic compression of

residual air in the cylinder.
• Lip and groove partially
2. After replacing the packing, always perform initial
carbonized (burnt)
operations at low pressure and low speed to bleed the air
from the cylinder sufficiently.
1. Replace.
2. The packing may have reached its end of life or the fluid
• Packing deteriorated in
may have been deteriorated or overheated.
elasticity and shredded in
• Replace the fluid.
pieces
• Check the fluid temperature. (The desirable temperature is
• Lip faces widely lost
80C or less.)
• Check for any partially heated portion.
1. Replace.
2. The packing may be subject to excessive high pressure.
• Excessive projection of
• Check the operation pressure.
packing heel
• If equipped with a buffer ring, the buffer ring may be the cause.
Check the buffer ring.
Backup ring 1. As a rule, also replace the rod packing.

(If equipped with a buffer ring, the buffer ring should be
replaced at the same time.)
• Largely deformed
2. The cause may be excessive high pressure. In this case,
follow the above instructions for the excessive projection of
packing heel.
Wiper ring • Foreign objects in lip 1. Remove the foreign objects.
• Damaged lip Other damages 1. Replace.
Bearing • Too much wear resulting in 1. Replace.

materials excessive gap with piston rod
(Refer to "(6) Disassembly",
"Maintenance criteria".)
• Large scratches on sliding 1. Replace.

face 2. At the same time, inspect the piston rod.
Oil leakage from piston rod Cylinder 1. Remove the scratches and rust with oilstone.
• Cylinder head used in piston
sliding face head 2. If not repairable, replace the cylinder head.
rod contains rust or scratches
*: Refer to "(8) Inspection
on seal fitting face. Refer to
After Assembly" for
"Bearing materials" above.
judgement.
ST-21
PS CYLINDER
Condition Possible causes Corrective action
Oil leakage from cylinder O-ring 1. Remove the foreign objects.

head fitting face 2. Replace the damaged O-ring.
• Foreign objects in inner/outer
3. Inspect the tube inner face: If any scratches or rust are
faces
present, smoothen the surface with oilstone.
• Damaged O-ring
4. Inspect the O-ring groove of the cylinder head: Same as
above. After checking the above points, replace the O-ring.
Cylinder 1. Disassemble the cylinder head and inspect the O-ring. If

head damaged, replace it.
2. After inspection, tighten to the specified torque.
• Looseness
Refer to "Assembly".
3. When tightening, securely hold the component so that it
does not rotate.
Tie rod and 1. Replace all tie rods and nuts. Tighten them to the specified
• Looseness, stretch, damage
nut torque.
Cylinder tube 1. Replace with a new one.

2. Oil leakage from fitting faces may be caused by excessive
• Excessive swelling
high pressure (including cushion pressure). Check tube for
swelling and deformation and inspect the circuit pressure.
Inappropriate functioning Piston rod or • Excessive bending 1. Replace with a new one.
No smooth operation cylinder tube deformation over specified Also inspect the seals and sliding parts, which may be
limit damaged. Replace them if necessary.
(Bending deformation: Refer
to "(6) Disassembly",
"Maintenance criteria".)
Cylinder tube 1. Replace with a new one. As in the above, also inspect the
• Dent
seals and sliding parts.
Piston rod • Excessive wear and 1. Replace with a new one. As in the above, also inspect the
Cylinder tube damage of sliding faces, seals and sliding parts.
Sliding part foreign objects in piston and 2. Remove the foreign objects. As in the above, also inspect
materials cylinder head sliding faces the seals and sliding parts.
Internal oil leakage Piston seal 1. Replace with a new one. Also inspect the inside of the
• Scratches or wear
Piston rod moves cylinder tube.
spontaneously during
operation or specified Cylinder tube 1. Remove scratches and rust by honing or with oilstone to
speed output is not smoothen the surfaces. If the damaged area is too large to
• Scratches or rust inside
available. repair, replace the cylinder tube.
2. Replace the piston seal.
Valves • Leakage from valves 1. Check the valve leakage amount and service as necessary.
Spongy operation feel Air 1. Bleed the air.

• Cylinder without air bleeder
Make several strokes at low pressure and low speed to bleed
air.
• Cylinder with air bleeder
• Residual air in cylinder Unload the cylinder so that the internal temperature builds up
excessively. Loosen the air bleeder and extract air.
(Reference)
The cylinder may stroke slightly when it is stopped abruptly.
This is caused by the compressibility of the fluid. In particular,
the phenomenon is likely to occur with long cylinders.
Too much impact at a Pin bushing 1. Measure the dimensions of the pin and pin bushing.
• Too large gap between
changeover point between Pin Replace the parts if the dimensions exceed the allowable
mounting and pin bushing
expansion and retraction. limits.
Noise during cylinder Lubrication • Insufficient lubrication 1. Lubricate.

operation
Pin bushing 2. Replace with a new one and lubricate.
• Bite in fitting face
Pin
ST-22
PS CYLINDER
CAUTION:
• The hydraulic fluid expands or shrinks due to changes in the

ambient temperature and pressure. The resultant cylinder
stroke may be recognized incorrectly as internal oil leakage.
• When checking for any internal oil leakage, ensure that the
temperature and pressure do not change during the check.
Disassembly
Preparation
Before starting disassembly work, make the following preparations.
• Work bench
Prepare a wide and robust workbench so that the components on
the bench are supported stably and securely.
General precautions
• Before disassembling the cylinder, remove soil and dust from the
cylinder outside wall.
• All components are precision-made. Always handle the
components with great care. Do not allow the components to hit
other parts or drop on the floor.
• When working, do not use excessive force. Tapping strongly or
prying forcibly may create burrs or damage the components,
rendering the component unusable and causing oil leakage and
performance deterioration. Always work with patience.
• Do not interrupt disassembly or assembly work in the interim
wherever possible. Moisture and dust may enter the exposed
components and rust may develop later. If it is inevitable to
interrupt the work, take appropriate measures for rustproofing and
dustproofing.
Maintenance criteria
The sliding parts and sealing parts must be replaced according to
the following criteria.
• Bushing
When one-fourth of the periphery is worn out and turned copper
brown
• Seals
Whenever the cylinder is disassembled
• Spherical bearing
If a significant bite is observed
• Piston rod
If a bend of 0.5 mm, 0.020 in. / 1.0 mm, 0.039 in. or more is
observed
ST-23
PS CYLINDER
Disassembly
1. Extract fluid.
2. Place the cylinder on a horizontal surface.
3. Set the piston rod in the neutral position.
4. Loosen the nut and remove the tie rod.
5. Remove the cylinder heads.
CAUTION:
• There are two cylinder heads. Before removing each cylinder

head, prepare an appropriate container to collect oil drained
from the joint between cylinder head and cylinder tube.
6. Pull out the piston rod.
CAUTION:
• When removing the piston rod, make sure to hold the rod in a
horizontal position and pull it with great care. The piston rod
may drop abruptly as soon as it comes off from the cylinder,
resulting in component damage.
7. Remove the piston seal.

• To remove the slip seal, place a flat-bladed screwdriver as shown
in the figure, and then hit the end of the screwdriver with a hammer
to cut the seal.
STT0113L S • To remove the O-ring, use a spatula.
CAUTION:
• Do not reuse sealing parts.
8. Disassemble the U-ring and wiper ring.

• To remove the U-ring and backup ring, use a screwdriver or an
equivalent tool.
• The wiper ring is press-fit. To remove it, apply the tip of a
STT0114L S screwdriver to the rubber portion and tap on the screwdriver to
take out the ring.
CAUTION:
• Do not reuse sealing parts.
9. Disassemble the bushing.

• Insert a screwdriver in the open end of the snap ring, and pry out
STT0115L S the ring.
• To remove the bushing, use the jig and a press to push it out.
ST-24
PS CYLINDER
10.Remove the pin bushing.

• Remove the snap ring.
Insert the tip of a screwdriver in the open end of the snap ring, and
pry out the ring from the groove.
STT0116L S If the ring is the C-snap type, use pliers to remove it.
• To remove the pin bushing, push it out by using a press as shown
in the figure.
11.Cleaning and storage

• Clean the removed parts with kerosene and apply a thin coat of
fluid. When storing the parts, cover them with sheets of
appropriate materials.
• Do not leave the parts exposed to the ambient air. Otherwise the
parts may exhibit only deteriorated performance when
reassembled due to rust and dust adhesion.
Assembly
CAUTION:
• The paint of the components may flake off and enter inside
the cylinder, resulting in oil leakage. When assembling,
exercise extreme caution not to allow any paint to come off.
Install the pin bushing (spherical bearing).

1. Press-fit the bushing into the piston rod and tube using the
installation jig. (Apply a thin coat of fluid beforehand.)
2. Attach the snap ring (or C-snap) to hold the pin bushing in place.
STT0117L S
Assembly of cylinder head

1. Press-fit the bushing using the press-fit jig.
(Before assembling, apply a thin coat of fluid to the inner face of
the cylinder head. After press-fitting, ensure that no height
difference is present.)
ST-25
PS CYLINDER
2. Install the wiper ring using an impact block.
STT0118L S
STT0119L S
3. Assembly of U-ring
• Attach the backup ring and U-ring in order into the U-ring groove.
• Ensure that the U-ring is correctly positioned and free from
damage.
STT0120L S • Reverse installation will lead to oil leakage.
• After attaching the rings, verify that no permanent deformation,
such as wrinkles, is created.
4. Install the snap ring to retain the bushing.
5. Install the O-ring.
CAUTION:
STT0121L S • Ensure that the size of the O-ring and the installation position
are correct.
ST-26
PS CYLINDER
Assembly of piston seals

1. Attach the O-ring into the groove.
• Ensure that the O-ring is not twisted.
2. Push the slip seal onto the piston while stretching the seal. The
slip seal insertion jig will help to attach it safely. Heating the slip
seal to approximately 80C (176F) also facilitates the assembly
work.
STT0122L S
3. If the slip seal is still stretched when fitted onto the piston,
straighten it with the straightening jig.
• The stretched slip seal will prevent subsequent assembly work.
STT0123L S
Assembly of piston rod, cylinder head and cylinder tube

1. Hold the tube in a horizontal position.
2. Insert the piston rod into the tube.
CAUTION:
• Ensure that the slip seal is not damaged.
3. Insert the piston rod into the cylinder head. When inserting the
rod, ensure that the lips of the wiper ring and U-ring are not
damaged by the height gap of the piston rod. The insertion jig will
help to assemble safely.
STT0124L S 4. Insert the cylinder head into the cylinder tube.
CAUTION:
• Ensure that the antirust O-ring is not caught and damaged by

the tube end face.
ST-27
PS CYLINDER
Installation and tightening of tie rod

1. Install the tie rod and nut and hold the two cylinder heads in place.
CAUTION:
• Ensure that the cylinder heads are positioned correctly.
2. Tighten the nut to the specified torque using a torque wrench.

Tightening torque [N•m (kg-m) In./Lbs]:
9.3 (0.95) 82.7
Test operation
1. Run the engine at idle while lifting up rear wheels.
2. Turn the handle left/right rapidly or slowly, and then repeat several
times. However, do not turn the handle to full stroke at first,
increase the stroke gradually.
Do not move the cylinder rapidly from the beginning.
Doing so will cause aeration.
3. Raise engine speed gradually and repeat above operations to fill
the cylinder with oil.
4. Lubricate both end bushings.
Inspection After Assembly

The cylinder should operate smoothly and exhibit no irregular status when fully stroked
No-load operation test
5 times or more with no load.
Dimensional inspection Check the most retracted length and stroke specified in the drawings.
The cylinder should exhibit no looseness, permanent deformation and external leakage
when the test pressure specified in the drawings is applied to the stroke end for three
minutes or more.
Withstanding pressure test
CAUTION:
・Before starting the test, retain the cylinder securely using the M14 threaded
holes at the cylinder head mount.
Check the rod for any oil leakage. (Refer to the quantitative judgement for oil leakage
External leakage check
from rod.)
Internal leakage check The oil leakage amount must be 3 ml, 0.10 Fl. oz. /10 min. or less.
ST-28
PS CYLINDER
Periodical Inspection and Maintenance

To ensure a longer life and satisfactory performance of the PS cylinder, regularly perform inspections and
maintenance based on the "Self-inspection list". If any symptom is found, diagnose and repair it without delay
based on "(5) Troubleshooting".
CAUTION:
• When performing periodical inspections/maintenance, avoid any potential risk by adopting appropriate
protective measures to the workplace and controlling one’s behavior in a reasonable manner.
Self-inspection list
Inspection/
maintenance Inspection and maintenance contents Daily Monthly Annual Remarks
point
Cleanness of cylinder (particularly rod sliding face) ❍
Oil leakage from piping connections and mounting
Appearance ❍
parts
Paint detachment, exfoliation, rust ❍
Smooth motion, unusual noises or conditions ❍
Response ❍
Oil leakage from sliding face ❍
Operation
Internal leakage ❍
Correct operation pressure ❍
Correct set pressure of overload relief valve ❍
Contamination or deterioration of fluid ❍
Hydraulic fluid Periodical replacement of fluid ❍
Periodical inspection of filter ❍
Greasing to bushing ❍
Unusual noise or seizing of bushing ❍
Mount to main Loose or worn bushing ❍

body Bushing seal functionality ❍
Loose or missing screws ❍✟
Additional tightening to mounting bolts ❍
Worn sliding face ❍
If the piston rod
Scratches or dent on sliding face ❍ sliding face is to be
exposed for a long
Piston rod Plating detachment from sliding face ❍
period of time, apply
Bend of sliding face ❍ antirust oil to the
piston rod.
Cracks or damages of welds ❍
Loose nuts and bolts ❍
Cylinder tube Additional tightening of nuts and bolts ❍
(including
piping) Cracks or damages of welds ❍
Large depression or dent on tube ✟❍
ST-29
PS CYLINDER
Quantitative judgement for oil leakage from rod

• Judge from the oil rings that are created after 20 strokes at a fluid
temperature of 20°C to 40°C (68 to104°F).
• The deformed oil ring A below suggests possible oil leakage. Take
appropriate measures referring to "(5) Troubleshooting".
ST-30
HYDRAULIC SYSTEM
SECTION HD
CONTENTS
SPECIFICATIONS .............................................. HD-2 Inspection .....................................................HD-33
Hydraulic Pump (Gear Pump) ........................HD-2 Assembly ......................................................HD-33
Control Valve ..................................................HD-2 Installation ....................................................HD-33
Tilt Cylinder ....................................................HD-2 Hydraulic Pressure Test and Adjustment .....HD-34
SERVICE DATA.................................................. HD-6 LIFT (MAST) CYLINDER...................................HD-36
Hydraulic Oil for Use and Oil Level ................HD-6 Component Parts Location ...........................HD-36
Adjustment Value ...........................................HD-6 Trouble Diagnosis and Corrections ..............HD-37
Parts for Adjustment .......................................HD-6 Description ...................................................HD-37
Tightening Torque ..........................................HD-7 Mast Cylinder (3F Mast) Inner Part Drain
TROUBLE DIAGNOSIS ...................................... HD-8 Method .........................................................HD-41
Hydraulic Pump (Gear Pump) ........................HD-8 Full Free Cylinder (2F, 3F Mast) ..................HD-41
Control Valve ..................................................HD-8 Removal .......................................................HD-42
Tilt Cylinder ....................................................HD-9 Installation ....................................................HD-45
Lift (Mast) Cylinder .......................................HD-10 Adjustment ...................................................HD-46
SERVICE INFORMATION ................................ HD-10 TILT CYLINDER ................................................HD-47
HYDRAULIC PIPING ........................................ HD-11 Component Parts Location ...........................HD-47
Hydraulic Circuit Diagram (MC models) .......HD-12 Removal .......................................................HD-48
Hydraulic Piping ...........................................HD-14 Disassembly .................................................HD-48
HYDRAULIC PUMP .......................................... HD-22 Assembly ......................................................HD-49
Component Parts Location ...........................HD-22 TROUBLE DIAGNOSIS AND
Component Parts Location ...........................HD-23 CORRECTIONS.................................................HD-50
Removal (e.g. Vehicles with Gasoline REPLACEMENT OF HYDRAULIC FLUID ........HD-51
Engines) .......................................................HD-23 Inspection .....................................................HD-51
Disassembly .................................................HD-24 HYDRAULIC FINGERTIP CONTROL ...............HD-51
Inspection .....................................................HD-24 Hydraulic piping ............................................HD-51
Assembly ......................................................HD-25 Joystick System Option ................................HD-52
Test Operation ..............................................HD-26 Hydraulic Circuit Diagram (FC models) ........HD-53
CONTROL VALVE............................................ HD-28 Installation ....................................................HD-54
Component Parts Location ...........................HD-28 Disassembly .................................................HD-54
Specifications ...............................................HD-29 EMERGENCY LOWERING OF MAST ..............HD-55
Lift lock .........................................................HD-30 ATTACHMENTS (option)..................................HD-56
Unload Valve ................................................HD-31 Hook On Side Shift........................................HD-56
Removal .......................................................HD-32 Integrated Side Shift......................................HD-57
Disassembly .................................................HD-32 Integrated Fork Positioner.............................HD-58
SPECIFICATIONS
SPECIFICATIONS
Hydraulic Pump (Gear Pump)

Forklift type 1D2 Series
1D1 Series
Engine type K/GK21+QD32 K/GK25 QD32
Theoretical discharge volume cc (lmp fl oz) 24.0 (0.84) 32.8 (1.15) 29.4 (1.03)
Discharge pressure [MPa (bar, kg/cm2, psi)] 18.1 (181.4, 185, 2,631)
Control Valve
Forklift type 1D1 Series 1D2 Series
Main relief pressure [MPa (bar, kg/cm2, psi)] 18.1 (181.4, 185, 2,631)
Normal flow rate [ (US gal, Imp gal)/min] 85 (22-1/2, 18-3/4)
Power steering relief pressure

7.8 (78.5; 80; 1,138) 8.8 (88.3; 90; 1,280)
[MPa (bar, kg/cm2, psi)]
Tilt Cylinder
Forklift type 1D1 Series 1D2 Series
Cylinder type Double acting, piston
- 3700 169 (6.65) 161 (6.34)

2F
4000 - 4200 114.5 (4.51) 110 (4.33)
Stroke [mm
- 3700 169 (6.65) 161 (6.34)
(in)] 2W
4000 - 5000 114.5 (4.51) 110 (4.33)
3F, 3V All height 114.5 (4.51) 110 (4.33)
Cylinder bore inner diameter [mm (in)] 65 (2.56) 70 (2.76)
Cylinder bore outer diameter [mm (in)] 77 (3.03) 84 (3.31)
Piston rod diameter [mm (in)] 25 (0.98) 30 (1.18)
- 3700 6° - 12°
2F
4000 - 4200 6° - 6°
Tilt angle
- 3700 6° - 12°
(Forward tilt - backward tilt) 2W
4000 - 5000 6° - 6°
3F, 3V All height 6° - 6°
HD-3
SPECIFICATIONS
General Specifications (Cont’d)

General Specifications
LIFT CYLINDER (Except 3V mast)
Mast name 2W 3000 2F 3000 3F 5500
Model & lifting 1D1 1D2 G1D2 1D1 1D2 G1D2 1D1 1D2 G1D2
capacity 15, 18 20, 25 30 15, 18 20, 25 30 15, 18 20, 25 30
Lift cyl. Lift cyl. Lift cyl. Lift cyl. Lift cyl. Lift cyl.
1,500 1,500 1,500 1,470 (57.87) 1,470 (57.87) 1,470 (57.87) 1,780 (70.08) 1,780 (70.08) 1,780 (70.08)
Stroke mm (in)
(59.06) (59.06) (59.06) Full-free cyl. Full-free cyl. Full-free cyl. Full-free cyl. Full-free cyl. Full-free cyl.
765 (30.12) 765 (30.12) 765 (30.12) 970 (38.19) 970 (38.19) 970 (38.19)
Cylinder ID
45 (1.77) 50 (1.97) 55 (2.17) 45 (1.77) 45 (1.77) 50 (1.97) 45 (1.77) 45 (1.77) 50 (1.97)
mm (in)
Cylinder OD
Lift 55 (2.17) 60 (2.36) 65 (2.56) 55 (2.17) 55 (2.17) 60 (2.36) 55 (2.17) 55 (2.17) 60 (2.36)
mm (in)
cyl.
Piston rod
diameter 35 (1.38) 40 (1.57) 45 (1.77) 32 (1.26) 35 (1.38) 38 (1.50) 32 (1.26) 35 (1.38) 38 (1.50)
mm (in)
Mast name 2W 3000 2F 3000 3F 5500

Model & lifting 1D1 1D2 G1D2 1D1 1D2 G1D2 1D1 1D2 G1D2
capacity 15, 18 20, 25 30 15, 18 20, 25 30 15, 18 20, 25 30
Cylinder ID
70 (2.76) 75 (2.95) 80 (3.15) 70 (2.76) 75 (2.95) 80 (3.15)
mm (in)
Full
Cylinder OD
free 83 (3.27) 87 (3.43) 92 (3.62) 83 (3.27) 87 (3.43) 92 (3.62)
mm (in) —
lift
cyl. Piston rod
diameter 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00)
mm (in)
LIFT CYLINDER (3V mast)

LIFT CYLINDER FULL-FREE CYLINDER
Cylinder Piston rod Cylinder Piston rod

Stroke ±3.5 (Tube) inner outer Stroke ±3.5 (Tube) inner outer
Series Ton Mast name diameter diameter diameter diameter
mm mm mm mm mm mm
3V360 1,235 565
3V405 1,385 640
3V450 1,535 715
3V490 1,670 780

1D1
45 36 50 40
15/18
3V525 1,780 845
3V575 1,935 940
3V633 2,100 1,065
3V688 2,250 1,190
HD-4
SPECIFICATIONS
LIFT CYLINDER FULL-FREE CYLINDER
Cylinder Piston rod Cylinder Piston rod

Stroke ±3.5 (Tube) inner outer Stroke ±3.5 (Tube) inner outer
Series Ton Mast name diameter diameter diameter diameter
mm mm mm mm mm mm
3V360 1,235 565
3V405 1,385 640
3V450 1,535 715
1D2 3V490 1,670 780

20/25 50 40 55 45
3V525 1,780 845
3V575 1,935 940
3V633 2,100 1,065
3V688 2,250 1,190
3V385 1,285 640
3V430 1,435 715
3V470 1,570 780
G1D2 3V505 1,680 845

55 45 60 50.8
30
3V555 1,835 940
3V600 1,935 1,065
3V650 2,060 1,190
3V700 2,250 1,250
Suction filter
Applied model 1D1/1D2
Filter type Wire gauze
Diameter mm (in) 100 (3.94)
Filtration accuracy (mesh) 125
Filter area cm2 (sq in) 620 (96.1)
Micron filter
Applied model 1D1/1D2
Filter type Filter paper (cartridge) type
Filtration sizeμm 20
HD-5
SERVICE DATA
SERVICE DATA
Hydraulic Oil for Use and Oil Level

1D2 Series
Forklift type
1D1 Series
2.0, 2.5 ton 3.0 - 3.2 ton
Item
Hydraulic fluid type hydraulic oil I.S.O. VG32
Oil level Oil level

35.9 (9-1/2; 7-7/8) 46.4 (12-1/4; 10-1/2) 51.4 (13-5/8; 11-3/8)
[ (US gal, Imp gal)] in tank
Adjustment Value
Control valve
Unit: mm (in)
Item Repair limit Remarks
Clearance between plunger and valve 0.02 (0.0008) All models
Tilt cylinder
Unit: mm (in)
Clearance between cylinder head bushing and piston rod 0.2 (0.008)
Clearance between cylinder tube and piston 0.2 (0.008)
Lift (mast) cylinder

Unit: mm (in)
Clearance between cylinder head bushing and piston rod 0.2 (0.008)
Clearance between cylinder tube and piston 0.7 (0.028)
Parts for Adjustment

Unit: mm (in)
Part name Thickness type Remarks
Use by selecting a number

Parallel adjustment shim for mounting to the full free cylinder’s inner mast 1.0 (0.039)
of sheets.
Use by selecting a number

Lift cylinder top edge height adjusting shim 1.0 (0.039)
of sheets.
HD-6
SERVICE DATA
Tightening Torque
Location Tightening torque

Pump assembly bolt 46 - 48 (4.7 - 5.0, 34 - 35)
Pumpmounting bolt 25 - 31 (2.5 - 3.2, 18 - 22)
Hydraulic pump Pipe connector at intake side G1 91.4 - 108.9 (9.3 - 11, 68 - 80)
Pipe connector at suction side G1/2 79 - 88 ( 8 - 9; 58 -65)
Nut at hose side G1/2 39 - 44 (4 - 4.5; 29 - 32)
Control valve assembly
M10 25 (2.6, 18)
Tie rod nut
3/4 79 - 88 (8.0 - 9.0, 59 - 64)
Control valve
Connector 1/2 39 - 44 (4.0 - 4.5, 29 - 32)
3/8 34 - 39 (3.5 - 4.0, 25 - 28)
Control valve assembly nuts 20 - 29 (2.0 - 3.0, 15 - 21)
Rod head lock bolt 108 - 147 (11 - 15, 80 - 108)
1D1 Series 206 (21.0, 152)
Piston tightening nut
1D2 Series 343 (35 ; 253)
Tilt cylinder
1D1 Series 265 - 421 (27 -43; 195 - 310)
Cylinder head
1D2 Series 295 - 469 (30-48; 218 - 346)
Connector 1/4 20 - 39 (2.0 - 4.0, 15 - 28)
Lift cylinder 2W, 1D1 170 - 240 (17.3 - 24.5; 125 - 175)
Cylinder head
(Apply Three Bond #1901 at 1D2 240 - 305 (24.5 - 31.1; 175 - 225)
thread portion.)
3F/3V 1D1/1D2 170 - 240 ( 17.3 -24.5; 125 -175)
2W, 3F, 3V 44 - 54 (4.4 - 5.6, 33 - 39)
Cylinder-retaining bolt
Top edge 78 - 98 (8.0 - 9.9, 58 - 72)
Bolt 2F
Bottom edge 44 - 54 (4.4 - 5.6, 33 - 39)
U-bolt lock nut 26 - 32 (2.6 - 3.3, 20 - 23)
Adjust bolt lock nut 74 - 94 (7.5 - 9.6, 55 - 69)
2F,3F 1D1 353 - 380 (36 - 38.7; 260 - 280)
2F,3F 1D2 380 - 407 (38.7 - 41.5 ; 280 - 300)
Cylinder head
3V 1D1 240 - 305 (24.5 - 31.1 ; 175 - 225)
3V 1D2 270 - 340 (27.5 - 34.7; 200 - 250)
Full free cylinder
Air plug 2.94 - 4.90 (0.30 - 0.49, 2.2 - 3.6)
Cylinder-retaining bolt 128 - 156 (13 - 16, 95 - 115)
2.75 ton or less 93 - 127 (9.4 - 13.0, 69 - 93)
Lift chain mounting nut
3.0 ton 142 - 192 (14 - 20, 105 - 141)
HD-7
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
If the hydraulic system functions incorrectly, identify the possible causes by referring to the table below and take
appropriate actions.
Hydraulic Pump (Gear Pump)

No oil from hydraulic pump • Low oil level in tank • Add oil to specified level.
• Clogged suction pipe or filter • Clean oil line and tank. If oil is dirty,
change.
Low discharge pressure on oil pump • Gear shaft bushing wear or faulty backing • Replace it with a new one.
ring
• Poor adjustment of relief valve • By using oil pressure gauge, raise
pressure at the specified level.
• While air is taken in • Check for looseness of pipe at suction
side.
• When oil level in tank is low, fill the oil at
the specified level on the specified
conditions.
• When air bubbles are observed in the
tank, leave it until they disappear.
Noise is emitted from hydraulic pump. • Cavitations are caused by hose • Correct hose deformation by removing
deformation at suction side or filter foreign objects.
clogging.
• Air intake from suction joint part • Tighten connecting rod nut.
• Operating fluid viscosity is too high. • Replace it with operating fluids of
appropriate viscosity.
• Air bubbles are mixed in operating fluid. • Bleed air, remove foreign objects and
replace operating fluids.
Operating fluid leaks from hydraulic pump. • Pump oil seal or poor body seal. • Replace it with a new one.
• Wear of gear sliding surface (increase of • Replace it with a new one.
internal leak)
Control Valve
Stick symptom of plunger • Dust adhered in the valve housing and • Clean valve housing and plunger.
plunger sliding part
• Contamination of operating fluid • Replace operating fluid.
• Damage of return spring • Replace it with a new one.
• Valve housing is mounted in strain. • Loosen mounting bolts and check.
• Bending of plunger • Replace valve housing and plunger as an
assembly.
Oil leak from oil seal • Entry of foreign material, painting powder • Clean by removing seal.
and dust
• Distortion of seal plate • Clean seal plate and tighten the bolt.
• Wear or damage of seal • Replace it with a new one.
• Damage of plunger • Replace it with a new one.
Cylinder’s natural downing or natural • Valve housing and plunger wear • Replace valve housing and plunger as an
forward tilt assembly.
• Oil leak from cylinder • Check cylinder and replace any
inoperative parts.
When control lever is shifted up from neutral • Foreign objects are caught in the load • Disassemble check valve and clean.
position to the upper position, it does not check valve.
operate smoothly. (It temporarily drops at • Poppet of load check valve or seat part • Replace or perform lapping correction.
the initial operation.) damage
HD-8
TROUBLE DIAGNOSIS
At engine stop, if control lever is operated in • Wear or damage of tilt lock plunger • Replace plunger and tilt housing valve as
tilt forward, mast is tilted forward. an assembly.
• Spring breakage of tilt lock plunger • Replace it with a new one.
• Oil leakage from tilt cylinder piston O-ring • Replace it with a new one.
Cylinder insufficient speed or poor operation • Relief valve wear or seat surface damage • Replace relief valve assembly.
• Poor operation by entry of foreign material
in relief valve • Clean or replace relief valve.
• Hydraulic pump malfunction
• Refer to "(1) Hydraulic pump (gear pump)"
for details.
Mast is unstable or does not move when • Stuck and damage of tilt lock plunger • Replace plunger and tilt housing valve as
control lever is moved to "forward tilt" while an assembly.
engine is running. • Because foreign material is entered into • Disassemble and clean.
the space between valve and tilt lock
plunger, valve does not move.
Tilt Cylinder
Oil leakage (Sliding surface between cylinder head and

piston rod)
• U-ring is damaged, or foreign matter is • Replace it with a new one.
entered.
• Foreign material in wiper ring lips portion • Remove and clean. Or replace it with a
• Wiper ring lips damage new one.
• Piston rod sliding surface damage • Replace wiper ring.
• Damage that can be modified shall be
smoothed by oilstone. When the
modification is not possible, replace it with
• Peeling of piston rod hard chromium as assembly.
plating • Replace it with a new one.
(Connecting part between cylinder head
and cylinder tube)
• O-ring damage
(Cylinder tube welding part) • Replace it with a new one.
• Damage and crack
(Others) • Replace it with a new one.
• Looseness of hose connector
• Deterioration and damage of hose and • Tighten to the specified torque.
tube • Replace it with a new one.
Cylinder tilts forward without control lever • Cylinder tube sliding surface damage • Damage that can be modified shall be
operation smoothed by oilstone. When the
modification is not possible, replace it with
a new one.
• Piston sliding surface damage • Replace piston rod as an assembly.
• Piston O-ring damage • Replace it with a new one.
• Backup ring damage • Replace it with a new one.
• Control valve malfunction • Refer to "(2) Control valve" for details.
Mast swings back and forth when brake is • Mix of air • Operate cylinder for about five minutes (10
applied at proceeding backward. to 20 strokes) and bleed air.
• Replace O-ring and cylinder with new
• Leakage from piston O-ring ones.
HD-9
SERVICE INFORMATION
Lift (Mast) Cylinder

Oil leakage • U-ring damage on cylinder head side, • Replace it with a new one.
(Sliding surface between cylinder head or mixed entry of foreign matter
and piston rod) • Foreign material in wiper ring lips • Remove and clean. Or replace it with
portion a new one.
• Wiper ring lips damage • Replace wiper ring.
• Piston rod sliding surface damage • Damage that can be modified shall be
smoothed by oilstone. When the
modification is not possible, replace it
with as assembly.
• Peeling of piston rod hard chromium • Replace it with a new one.
plating
Cylinder lowering without control lever • Lips damage on piston U-ring, or • Replace it with a new one.
operation, poor power output mixed entry of foreign matter
• Cylinder tube sliding surface damage • Replace it with a new one.
• Piston ring sliding surface damage • Replace it with a new one.
• Down safety valve malfunction • Replace down safety valve.
Lowering of cylinder at an unusual • Flow regulator valve plunger return • Replace flow regulator valve as an
speed spring worn out and breakage assembly.
(Extremely slow) • Fixing of foreign material at flow • Replace flow regulator valve as an
regulator valve sliding part assembly.
• Down safety valve malfunction • Replace down safety valve.
CAUTION:
• The possible causes and corrective actions shown in the table should be deemed as the referential
information. Customer's complaints must be listened to carefully. Check the actual forklift status when
diagnosing.
SERVICE INFORMATION
CAUTION:
• When removal and installation, turn ignition switch OFF to stop

engine and then turn ignition switch ON to release any residual
pressure from the piping. (due to the lift and tilt lock function)
• To prevent foreign objects from entering, be careful to keep
clean at workshop.
• When cutting off pipes, be careful to avoid splashing hydraulic
fluid to other parts by covering waste cloth around the cutting
areas.
• When connecting pipes, be careful not to enter foreign objects
from entering into pipes.
• Place disassembled parts on clean cloth or clean sheet of paper.
Be careful not to stain, scratch or damage parts.
• Lifting should be performed only by a technician who has
received training for slinging or hoisting.
• Operation involving heavy load should be performed by two
persons.
NOTE:
• For installation and removal of mast, refer to "LM" section.
HD-10
HYDRAULIC PIPING
HYDRAULIC PIPING
Screw tightening torque [N•m (kg-m) Ft./Lbs]:

G1/4 19.7 - 39.2 (2 - 4) 15 - 29
G3/8 29.5 - 58.8 (3 - 6) 22 - 43
G1/2 58.9 - 98.0 (6 - 10) 44 - 72
PS flow dividing valve built in the control valve. For this reason, oil
pressure is supplied to a control valve for piping of one from a pump.
In addition, steering box is supplied via control valve.
HD-11
HYDRAULIC PIPING
Hydraulic Circuit Diagram (MC models)
HD-12
HYDRAULIC PIPING
Hydraulic Piping (Flow regulator valve)
CAUTION:
Make sure the Flow Regulator Valve (FRV) is located at the correct
position when changing masts between MC & FTC models.
Refer to above figure.
HD-13
HYDRAULIC PIPING
Hydraulic Piping
2W mast piping
HDT0233L.tif V
2F mast piping
3F mast piping
HD-14
HYDRAULIC PIPING
HDT0205L.tif V
HD-15
HYDRAULIC PIPING
3V mast piping
HDM0105
HD-16
HYDRAULIC PIPING
2W Attachment piping
HDT0206L.tif Y
HD-17
HYDRAULIC PIPING
2F attachment piping
HD-18
HYDRAULIC PIPING
3F attachment piping
HD-19
HYDRAULIC PIPING
2F/3F attachment piping High visibility mast (option)
8-11 (0.8-1.1) 2.8-8.0
3-4 (0.3-0.4) 2.2-2.9
36-51 (3.7-5.2) 27-38
HD-19A
HYDRAULIC PIPING
3V attachment piping
HDM0106
HD-20
HYDRAULIC PIPING
Carriage piping
HDT0168J.tif V
HDT0137P.tif V
HD-21
HYDRAULIC PUMP
HYDRAULIC PUMP
Component Parts Location
SGP1 type
HDT0207L.tif X
HD-22
HYDRAULIC PUMP
HDT0208L.tif X
Removal (e.g. Vehicles with Gasoline Engines)

• Remove the air cleaner.
Disconnect the intake hose and suction tube and the hydraulic pump
connection.
CAUTION:
• Extracting a small amount of oil from the tank in advance by using an

oil pan is recommended. Otherwise, some oil will inevitably overflow
from the tank when the suction hose is disconnected.
• Loosen the two mounting bolts and remove the hydraulic pump.
HD-23
HYDRAULIC PUMP
CAUTION:
• Cover the surrounding area with a shop cloth in order to prevent

contamination due to any oil overflow.
• Ensure that no foreign materials get into the hydraulic pump and
piping through the openings.
Disassembly
CAUTION:
• Before disassembly, always remove any contamination from the

pump surfaces.
• Before disassembly, prepare new parts for all necessary
consumables such as gasket and oil seal.
• Before disassembly, put a pair of alignment marks on the body
and rear cover as well as the body and front cover.
• Do not remove the oil seal unless it is necessary (e.g. oil
leakage).
• Before removing the bearing boxes, always put an identification
HDT0011.tif mark on each bushing so that their original mounting positions
are easily identified.
Inspection
Clean disassembled parts with solvents, and check any crack or
damage.
Gasket, 3-shape gasket

• When pump disassembly, always replace with a new one.
Drive gear, driven gear

• If any cracks or damage in axle and gear, replace with pump
assembly.
• If any damage or wear in gear teeth and tooth top, replace with pump
assembly.
• Spline of drive gear is badly deformed, replace with pump assembly.
• When outer diameter part of shaft is worn, replace with pump
assembly.
HD-24
HYDRAULIC PUMP
Bushing
• If seizure, unusual wear (deep striation, step wear etc.), replace with
pump assembly.
• Also, be careful of press-in direction of oil seal. (Face dust lip to
outside.).
CAUTION:
• Malfunction in seized, unusual wear, persistent high pressure

for which no specified cause can be found, oil viscosity is too
low or high, contamination may be the cause. Check relief
pressure of relief valve and oil.
Body
• Remains of contact of the gear tooth point are replacing with pump
assembly, when it becomes beyond a semicircle circumference.
• Replace pump assembly, if there are creep phenomenon (face is
ruined and rasp) in contact surface with bushing.
HDT0013.tif
Assembly
Install in the reverse order of removal, follow the instructions below.
• Clean each part with treated oil before assembly. Blow air to prevent
the entry of foreign objects.
• Gasket and 3-shape gasket apply operating fluid and then install.
• Do not confuse the order of attachment and the directions of each
part article (distinction by the side of drive driven, distinction of front
rear side, etc.).
• When insert shaft of drive gear into oil seal of front cover, wrap vinyl
tape around the spline at shaft edge to avoid damage. When resin
layer of inner surface of bushing is worn, replace with pump
assembly.
• Tighten pump assembly bolt crisscross pattern. Divide into 3 - 4 times
HDT0014.tif without fastening with regulation torque at once, when binding tight,
and increase and fasten torque one by one.
88.2 - 93.1(9 - 9.5) 65 - 69
• Check putting in little oil from exhaust duct and an intake duct after
an assembly, turning a drive gear shaft by hand, and turning
smoothly.
HD-25
HYDRAULIC PUMP
Test Operation
After installing the pump, perform a test operation by following the
steps below.
1. Remove rocker cover.
1. Verify that the oil level in the tank is correct. Attach an oil pressure
gauge to the control valve.
HDT0015.tif
CAUTION:
• For the details on how to attach an oil pressure gauge and

adjust the oil pressure, refer to "7. Control Valve".
2.Actuate the pump. While raising the hydraulic pressure from 0 to 18.1
MPa (0 to 185 kg/cm2) step by step using the adjusting screw on the
relief valve, check the resultant temperature rise by touching the pump
body.
If the pump body is too hot in comparison with the hydraulic fluid
temperature, the pump may be assembled incorrectly. Disassemble,
inspect and reassemble the pump.
3.Set the relief valve set pressure.
Relief valve set pressure

[MPa (kg/cm2)PSI]
Forklift type
1D1 Series 1D2 Series
Item
Main relief valve set pressure 18.1 (185) 2624
HD-26
HYDRAULIC PUMP
4. Checking of the pump displacement

Measure the fork rising speed with no load. If the speed is in the
specified range, the pump displacement is normal.
Rising speed with no load
Forklift (mm/sec, in./sec.)
Ton Engine Option
model
2W mast 2F mast 3F mast 3V mast
K/GK21 630 590 590 550
1D1 K/GK21 Low noise 460 450 450 410

1.5 & 1.8
type QD32 690 640 640 630
QD32 Low noise 540 530 530 480
K/GK25 700 670 660 650
K/GK25 Low noise 590 610 610 550
2.0 & 2.5
QD32 660 660 650 610
QD32 Low noise 580 560 550 530
K/GK25 580 520 560 560
1D2 K/GK25 Low noise 500 500 480 470

3.0
type QD32 550 510 530 520
QD32 Low noise 470 430 460 440
K/GK25 580 520 560 560
K/GK25 Low noise 500 500 480 470
3.2
QD32 550 510 530 520
QD32 Low noise 470 430 460 440
5. Lower and raise the fork with no load and check for any incorrect
operations.
HD-27
CONTROL VALVE
CONTROL VALVE
Cargo control valve

• Feature:
To address human mistakes in the cargo handling lever operation,
the control valve now incorporates a lift lock valve and unload valve.
HDT0211L.tif X
HD-28
CONTROL VALVE
Flow dividing valve
HDT0212L.tif X
Specifications
Forklift type
1D1 type 1D2 type
Item
Type MSV04
Main relief valve set pressure [MPa (kg/m2) PSI] 18.1 (185) 2624
Relief valve type Cartridge type
Cylindrical spring
Plunger type
return type
Normal flow rate (/min, Qts/min) 85, 89.8
HD-29
CONTROL VALVE
Lift lock
HDT0213L.tif W
6. Function
While the operator is not seated in the seat, the lift will not lower
even if the cargo handling lever is moved to the downward direction.
7. System
The lift lock valve inside the cargo control valve enables the lift
lowering operation only when the seat switch is ON (operator is
seated).
NOTE:
This function may be effective against the following risks
• When the operator gets on or off the Forklift, a part of the operator's body
inadvertently pushes the lift lever with, almost causing personal injuries.
• The operator leans toward the mast for some reason and inadvertently
pushes the lift lever. The resultant fork operation almost catches the
operator's body and could cause personal injury.
HD-30
CONTROL VALVE
8. Release
When it becomes impossible to cancel the lock function of a lift lock,
it cancels with a lift lock release screw.
Method
• Loosen screw lock nut of lift lock release and tighten screw for lift lock
release screw. Then move the lift lever down, the fork will be lowered.
• After repairing lift lock malfunction, loosen lift lock release screw to the
original location (where operation force is light). Then be sure to securely
lock by lock nut.
CAUTION:
• During loading works, the seat switch turns OFF only 3 seconds
after the operator is unseated. This is to prevent any abrupt
stop of cargo handling operations due to the above protective
function. Keep in mind that the above protection will not work
for 3 seconds after standing up from the seat.
Unload Valve
HDT0214L.tif W
HD-31
CONTROL VALVE
9. Function
While the operator is not seated on the seat, the fork will not tilt
forward even if the cargo lever is moved to the forward tilt position.
(The engine is idling.)
10.System
• The unload valve inside the cargo control valve routes the hydraulic
pressure to the bypass circuit while the operator is not seated. In an
idling state, this prevents the cargo control valve pressure from
building up and thus locks the tilt lock valve.
• When the seat switch turns ON (operator is seated), the unload valve
closes the bypass circuit and allows the tilt lock valve to be released.
CAUTION:
• In a fast idle state, the increased internal pressure of the cargo

control valve releases the tilt lock valve, canceling the tilt lock
function.
NOTE:
This function may be effective against the following risks
• When the operator gets on or off the forklift, a part of the operator's body
inadvertently pushes the tilt lever, almost dropping the cargo from the fork.
CAUTION:
• The seat switch turns OFF only 3 seconds after the operator is
unseated. This is to prevent any abrupt stop of cargo handling
operations due to the above protective function. Keep in mind
that the tilt lock function will not work for 3 seconds after
standing up from the seat.
Removal
2. Tilt the mast fully backward and lower the mast to the lowest stop.
3. Return the mast to the neutral position.
4. Turn the key switch to ON (do not start the engine) and release the
residual pressure from the piping.
CAUTION:
• Ensure that no foreign materials get into the piping and control
valve.
• The control valve is heavy. When removing it, hold it carefully
and securely so that it will not slip from hands.
Disassembly
CAUTION:
• Do not disassemble the main relief valve assembly. It must

be replaced as an assembly.
• Do not loosen the lock nut. If it is loosened, the set pressure
must always be adjusted after assembly and installation.
• Do not loosen the poppet (load check) and poppet spring
HDT0018.tif located on the inlet housing-to-outlet housing interface.
HD-32
CONTROL VALVE
Inspection
Clean disassembled parts with solvents, blows with air and a foreign
materials etc. is removed completely.
If deformation, cracks, damage and unusual wear are found, replace it.
O-ring, wiper ring

• When disassembly, always replace with a new one.
Valve housing and plunger

• Measure the inner and outer diameters of the plunger. If the gap
between the plunger and the housing exceeds the specified limit,
replace the housing and plunger as an assembly.
Tolerance limit of gap between plunger and
housing (mm, in.): 0.02, 0.0008
Assembly
• The housing pieces must be assembled in the correct order.
• Ensure that no foreign materials get into the control valve.
• Apply hydraulic oil or grease to the O-rings, O-ring attaching faces,
wiper rings and plunger.
• Tie rod nut
Tightening torque [N•m (kg-m) Ft./Lbs.] :
24.5 - 29.4 (2.5 - 2.9) 23.7 - 28.4 (M10 size  3)
24.5 - 29.4 (2.5 - 2.9) 23.7 - 28.4 (M8 size  2)
• Main relief valve assembly
Tightening torque [N•m (kg-m) Ft./Lbs]: 49 (5.0) 47.3
Installation
• Ensure that no foreign materials get into the piping and control valve.
• Control valve assembly nuts
Tightening torque [N•m(kg-m) Ft./Lbs.]:
20 - 29 (2.0 - 3.0) 19.3 - 28.0
• After connecting the piping, apply relief pressure and make sure that
no fluid leakage is present.
CAUTION:
• After installation, operate lift and tilt, perform tilt relief for 3
seconds at high idle and bleed the valve.
HD-33
CONTROL VALVE
Hydraulic Pressure Test and Adjustment
CAUTION:
• When checking the hydraulic pressure, always wear protective

goggles. High-pressure hydraulic fluid may blow out and hit
eyes. There is a possibility of high-pressure operation oil
leaking and becoming blind in an eye.
• This inspection includes mast-raising operations. Ensure that
sufficient clearance is secured around the forklift.
Hydraulic pressure test

1. Turn the key switch to OFF. (Verify that the engine is stopped.)
2. Remove the floor mat and floorboard.
3. Remove the high-pressure pipe connector plug from the pump port
of the control valve.
HDT0215L.tif 4. Install the adapter to the plug hole and connect an oil pressure
gauge.
Adapter connector tightening torque
[N•m (kg-m) Ft./Lbs.]: 39.2 - 44.1 (4 - 4.5) 37.9 - 45.6
5. Start the engine. Referring to the table below, operate the control
lever and check the pressure reading.
MPa (kg/cm2 ) PSI
Forklift type
1D1 1D2
Lever operation
Raising, forward tilting, backward

18.1 (185) 2624
tilting positions
6. If the measured pressure is outside the specified range, adjust the

hydraulic pressure.
Hydraulic pressure adjustment

1. Remove the cap nut from the main relief valve assembly and loosen
the lock nut.
2. Start the engine and fully open the throttle. While operating the
lever, adjust the hydraulic pressure by turning the adjust screw of
the main relief valve.
HDT0216L.tif To raise the pressure : Turn clockwise
To lower the pressure : Turn counterclockwise
CAUTION:
• Remember that one turn of the adjust screw causes a pressure

change of 6.9 to 7.8 MPa (70 to 80 kg/cm2) (1000 to 1131 PSI). Do
not attempt to turn the adjust screw to a large angle in one step.
• Make sure to turn the adjust screw little by little while
observing the pressure gauge reading.
3. After adjustment, hold the adjust screw securely and tighten the lock
nut. Then attach the cap nut.
4. Check the pressure again.
HD-34
CONTROL VALVE
Mounting adjustment of limit switch bracket
HDT0234L.tif U
HD-35
LIFT (MAST) CYLINDER
HDT0242L.tif X
CAUTION:
• During disassembly, in the case of withdrawal of piston rod

ASSY from cylinder tube, be sure to unplug first.
HD-36
Trouble Diagnosis and Corrections

Conditions Possible causes Action
Oil leakage from packing on U-ring (cylinder head)
cylinder head side • Mixed entry of foreign matter Remove foreign matter.
• Lip part damage of U-ring is inner and outer Replace U-ring with a new one.
surfaces
Wiper ring
• Mixed entry of foreign matter in wiper ring lip Remove foreign matter.
portion.
• Wiper ring lips damage Replace wiper ring with a new one.
Piston rod
• Piston rod sliding surface damage For small damage, make the sliding surface
smooth by using an oilstone. For large damage,
replace piston rod assembly with a new one.
• Peeling of hard chromium plating Replacement of piston rod assembly
Cylinder lowering without U-ring (piston)
control lever operation and poor • Mixed entry of foreign matter Remove foreign matter.
power output with piston side • Lip portion damage of U-ring inner/outer diameter Replacement of U-ring assembly
on damage of packing
• Cylinder tube sliding surface damage Replacement of cylinder tube assembly
• Piston ring sliding surface damage Replacement of piston ring
Description
The 2W mast incorporates the soft landing function. The soft landing
function automatically decelerates the fork lowering speed just before
the fork contacts with the ground. It is activated 23 mm, 0.91 in., (or 46
mm, 1.81 in., if measured from the fork position) before the piston
bottom stroke end.
HDT0235L.tif
System operation
1. When the piston position is higher than the point 23mm, 0.91 in.,
upward from the bottom stroke end, the hydraulic fluid below the
piston flows out freely.
HDT0140P.tif
HD-37
2. When the piston lowers further, the bottom projection gets into the
cushion bearing, creating a new hydraulic fluid chamber. In this
state, the hydraulic fluid in the cushion chamber must pass through
the narrow ring-like gap between the cushion bearing and the
bottom projection, resulting in slowdown of the piston movement.
HDT0232L.tif
3. The piston makes the last 23 mm, 0.91 in., stroke at a decreased
speed. This is the mechanism of the soft landing.
HDT0235L.tif
Lift cylinder (2w mast)

Inside part drain method
HDT0236L.tif V
CAUTION:
• When pulling out a piston rod, be sure to unplug first. (To

prevent piston from being damaged)
HD-38

Inside drain method
HDT0218L.tif X
CAUTION:
• Unplug when perform disassembly.
HD-39
Description
NOTE:
• Usually, when it descends from cylinder maximum height by empty load, the
air by the side of a rod passes along the check valve of a piston with
operation oil, and enters a cushion room. When it is repeated, rod side will
become a vacuum.
• When operation oil infiltrates into a rod side, it is returned to a cushion room
through a check valve, and maintaining a normal state is continued.
HDT0219L.tif
Mast cylinder (2f mast)

HDT0240L.tif V
HD-40
Mast Cylinder (3F Mast) Inner Part Drain Method

HDT0238L.tif V
Full Free Cylinder (2F, 3F Mast)

HDT0239L.tif V
HD-41
Removal
CAUTION:
• Be careful not to get caught of hands and legs, when perform the
procedure.
Preparation for lift (mast) cylinder removal

1. Remove the carriage assembly together with the fork.
(Refer to the LM section.)
HDT0220L.tif 2. Jack up the forklift front so that about 120 mm ground clearance is
created under the outer mast bottom end. (Refer to the GI section.)
3. Operate a control lever, a mast fully backward and descend to the
bottom dead end. Then, a mast neutrality, a key switch is turned
OFF, and engine is suspended.
CAUTION:
• Always lower the lift (mast) cylinder to the bottom stroke end to
release any residual pressure from the piping.
2W lift cylinder, 2F mast cylinder

1. Remove the upper retaining nut (2W mast) of the lift (mast) cylinder
or bolt (2F mast).
2. Suspend the inner mast with a nylon sling or wire.
3. Remove the lift (mast) hose, return hose (2W mast) and lift pipe (2F
HDT0221L.tif mast) from the lift (mast) cylinder.
CAUTION:
• Plug the hose openings to prevent hydraulic fluid leakage.
HDT0222L.tif
4. Remove the lower retaining bolt from the lift (mast) cylinder.
HDT0223L.tif
HD-42
5. Remove the U-bolt and remove the lift (mast) cylinder from the front.
CAUTION:
• When removing the lift (mast) cylinder, always work with an

assistant. The cylinder is very heavy.
• When removing the U-bolt, always support the lift (mast)
cylinder so that it will not fall down.
HDT0220L.tif
3F mast cylinder
1. Suspend and lift the inner mast so that the inner mast lower beam is
located above the outer mast tilt beam.
CAUTION:
• While lifting the inner mast, ensure that the slackened chain and
hoses are not pinched.
2. Remove the chain anchor at the inner mast side and separate the
mast chain from the inner mast.
3. Remove the hydraulic piping from the bottom of the full free cylinder.
4. Remove the hose pulley support from the top of the middle mast
and remove the chain wheel.
HDT0035P.tif 5. Place a square wood block of 100 mm, 39.4 in.,G in height under
the inner mast and lower the inner mast.
CAUTION:
• When lowering the inner mast, ensure that the chain and hoses
are not pinched.
6. Attach the suspender hook to the upper beams of the inner mast
and middle mast.
HD-43
7. Remove the upper retaining bolt from the mast cylinder.

8. Suspend and lift the inner mast and middle mast together and
remove the mast cylinder top.
9. Separate the mast cylinder hose from the mast cylinder. Separate
the mast hose from the mast by removing the mast hose clamp-
HDT0179P.tif retaining bolt.
CAUTION:
• Plug the hose openings to prevent hydraulic fluid leakage.
HDT0224L.tif
10.Remove the lower retaining bolt (below surface of outer mast

support) from the mast cylinder.
HDT0034.tif
11.Remove U-bolt and remove the mast cylinder from the front.
CAUTION:
HDT0225L.tif • When removing the U-bolt, always support the mast cylinder
so that it will not fall down.
• When removing the mast cylinder, always work with an
assistant. The cylinder is very heavy.
HD-44
Full free cylinder

1. Remove the carriage assembly together with the fork.
(Refer to the LM section.)
2. Operate a control lever, a mast fully backward and descend to the
bottom dead end. Then, a mast vertically, a key switch is turned
OFF, and engine is suspended.
CAUTION:
• Always lower the full free cylinder to the bottom stroke end to
release any residual pressure from the piping.
3. Remove hydraulic pipe from the full free cylinder.
CAUTION:
• Plug the pipe openings to prevent hydraulic fluid leakage.
4. Suspend the full free cylinder with a nylon sling or wire.

5. Remove full free cylinder-retaining bolt, and remove full free
cylinder by pulling up.
LMT0215L.tif
Installation
Full free cylinder (2F, 3F mast)

• Add an appropriate number of shims to make the inner mast cylinder
and full free cylinder parallel to each other.
Shim thickness (mm, in.) : 1.0, 0.039
LMT0036.tif • Cylinder-retaining bolt
Tightening torque [N•m (kg-m) Ft./Lbs] :
128 - 157 (13 - 16) 94.5 - 116
Lift cylinder, mast cylinder

• Position the cylinder to the lower beam hole of the outer mast and set
the piston rod to the cylinder-retaining bracket of the inner mast.
• Tighten the lower retaining bolt of the cylinder.
44 - 54 (4.4 - 5.6) 32 - 40
• Tighten the upper retaining nut or bolt of the cylinder.
Tightening torque [N•m (kg-m) Ft./Lbs.] :
44 - 54 (4.4 - 5.6) 32 - 40 (2W, 3F mast)
78 - 98 (8.0 - 9.9) 58 - 72 (2F mast)
• Tentatively attach the clamp to the cylinder with the clamp bolt.
HD-45
• Align the U-bolt to the mast-side bracket and attach the nut to the
outer mast, hand tighten only.
• Next, tighten the double nut to the specified torque.
26 - 32 (2.6 - 3.3) 19 - 24
HDT0225L.tif • Hand tighten adjust bolt, and make sure that stopper contacted
the cylinder. Hold the adjust bolt in place with a proper fitting
flathead screwdriver and tighten the lock nut.
26 - 32 (2.6 - 3.3) 19 - 24
• Make sure to seal the taper threads of the piping using a seal tape.
Do not allow seal tape fragments etc. to enter hydraulic pipes.
• The hydraulic units use an O-ring seal at the couplings. When
attaching an O-ring, always use an O-ring guide over the coupling
thread so that the O-ring is not damaged.
• When connecting a coupling, first tighten the lock nut by hand so that
the coupling and the pipe are aligned correctly. Then tighten the lock
nut to the specified torque.
CAUTION:
NOTE:
• After installing the cylinders, adjust the cylinder height referring to the LM
section.
Adjustment
Bleeding
1. Add hydraulic fluid to the upper limit of the level gauge.
2. Raise the mast slowly. Then lower it slowly.
3. After lowering the mast to the bottom stroke end, check the hydraulic
fluid level in the tank. If hydraulic fluid is reduced, add it to the upper
limit of the level gauge.
4. Repeat steps 2 and 3 until the hydraulic fluid level in the tank is kept
unchanged.
5. Raise and lower the cylinder to check for smooth operation.
HDT0039.tif
2F, 3F mast
NOTE:
• In addition, no need to bleed the full free cylinder (2F, 3F mast). Full stroke
is repeated 7 to 8 times.
HD-46
TILT CYLINDER
TILT CYLINDER
HDT0226L.tif V
HD-47
TILT CYLINDER
Removal
• Lower fork to the bottom dead end.
• In connection with an outer mast, remove bolt and the pivot pin of a
tilt cylinder.
HDT0227L.tif
• Remove 2 hydraulic pipes to tilt cylinder in connector.

• In connection with a body frame, remove bolt, pivot pin and tilt
cylinder.
HDT0228L.tif
Disassembly
• Cylinder is pinched with a vise, from two ports, compressed air is sent
by turns, a piston rod is operated, and oil is extracted from a cylinder.
• Loosen the thread of cylinder head, remove cylinder head from
cylinder tube.
CAUTION:
• Be careful not to damage O-ring.
• Remove piston rod assembly from cylinder tube assembly.
CAUTION:
• Be careful not to damage O-ring.
• Remove pin bushing from rod head. (Rotate bushing and pull out
from long hole.)
HDT0229L.tif
HD-48
TILT CYLINDER
• Loosen the bolt of rod head, remove rod head from piston rod ASSY.
• Remove cylinder head.
• Remove piston O-ring and backup ring of piston.
HDT0230L.tif
Cylinder head
• Remove O-ring by pulling it by holding two fingers.
• Remove U-ring and wiper ring by using a screwdriver.
CAUTION:
HDT0231L.tif
• When the U-ring and wiper ring are removed once, always
replace them with new ones.
Assembly
• Assemble in the reverse order of disassembly.
CAUTION:
• After assembly and installation, make sure the tilt cylinders are
adjusted correctly, to avoid the mast from flexing in most forward or
backward position (refer to LM section).
CAUTION:
• For each part, lubricate with an operating fluid.

• When assembly, be sure to avoid foreign matter such dust from
entering.
• O-ring prevention from torsion.
• When insert the cylinder head to piston rod, avoid damaging O-
ring, wiper ring, etc. with screw thread.
• When install pin bushing to rod head, assemble the grease slot
of a rod head and the slot of the pin bushing perimeter are in
agreement.
[N•m (kg-m) Ft./Lbs.]

Forklift
1D1 type 1D2 type
Item
Rod head tightening nut 108 - 147 (11 - 15) 80 - 109
Piston tightening nut 206 (21 ; 152) 343 (35; 253)
265 - 421 295 - 469

Cylinder head tightening torque
(27 -43; 195 -310) (30 - 48; 218 - 346)
HD-49

Conditions Possible causes Action
U-ring (cylinder head)

• Mixed entry of foreign material in packing Remove foreign material.
portion
• Damage in U-ring Replace U-ring with a new one.
Wiper ring
• Mixed entry of foreign material in wiper Remove foreign material.
Oil leakage from sliding surface
ring lip portion
between cylinder head and
• Wiper ring lips damage Replace wiper ring with a new one.
piston rod assembly
Piston rod
• Piston rod sliding surface damage Make the small sliding surface smooth by
using an oilstone.
For large damage, replace piston rod
assembly with a new one.
• Peeling of hard chromium plating Replacement of piston rod assembly
Oil leakage from cylinder head O-ring

and cylinder tube • O-ring damage Replacement of O-ring
Oil leakage from cylinder tube Cylinder tube

welding part • Damage of cylinder tube welding part Replacement of cylinder tube assembly
Cylinder tube
• Cylinder tube sliding surface damage Replacement of cylinder tube
(For small damage, make it smooth by
using an oilstone.)
Cylinder tilts forward without Piston

control lever operation • Piston sliding surface damage Replacement of piston rod assembly
O-ring
• O-ring damage Replacement of O-ring
Backup ring
• Backup ring damage Replacement of backup ring
Looseness of connector
• Deterioration of tube and hose Hydraulic pressure is slowly operated in a
cylinder, some cylinder tube ports by the
side of high pressure and connectors of a
Mixed entry of air into cylinder hose are loosened, and air is extracted.
If oil begins to appear from a connector
part, a connector will operate a grade
cylinder for 5 minutes (10 - 20 times) in
total.
HD-50
REPLACEMENT OF HYDRAULIC FLUID
REPLACEMENT OF HYDRAULIC FLUID

Inspection
Dirt or deterioration of hydraulic fluid causes malfunction of control valve. Hydraulic oil must be replaced per
maintenance schedule.
Replacement procedures
1. Start engine, raise lift cylinder full stroke.
2. Control lever is returned neutrally, engine is stopped and the lift
cylinder upper side hose is removed.
3. Control lever is operated to lift cylinder descent, a lift cylinder is
dropped gradually, and the oil in a lift cylinder is returned to a tank.
4. Remove tank drain plug and drain the oil.
5. Install drain plug of each hose and tank, fill in new hydraulic fluid.
6. When hydraulic fluid is replaced, following the instructions below.
CAUTION:
• Deposition dust in tank must be completely cleaning. (Remove

drain plug under side.)
• Clean suction filter and hydraulic fluid cap.
• Oil level should supply with oil to come in the middle of the
maximum line of a level gauge, and a minimum line, when oil has
entered in piping, hydraulic power unit.
HYDRAULIC FINGERTIP CONTROL
HYDRAULIC PIPING FINGERTIP CONTROL

Hydraulic piping
Installing after removal hydraulic pipe, follow the instruction below.
CAUTION:
• Make sure to seal the taper threads using a seal tape. Do not
allow seal tape fragments etc. to enter hydraulic pipes.
• The hydraulic units use an O-ring seal at the couplings. When
attaching an O-ring, always use an O-ring guide over the
coupling thread so that the O-ring is not damaged. When
connecting a coupling, first tighten the lock nut by hand so that
the coupling and the pipe are aligned correctly. Then tighten the
lock nut to the specified torque.
• Tightening torque is as the torque shown in "HYDRAULIC PIPING".
HD-51
Joystick System Option

• For tilt piping, first place the fork horizontal (tipped slightly forward)
and turn the key switch off. Next, loosen the piping and let set while
the remaining pressure escapes.
• For lift piping, place the fork at the lowest position, turn the key switch
off, loosen the shut-off valve and let the remaining pressure escape.
• For attachment piping (3rd and 4th)
• Union connector
Place the attachment in neutral, turn the key switch off, loosen the
piping, and let set while the remaining pressure escapes.
• Coupling
Installing and removing the cup may be difficult if the remaining
pressure inside the piping is high. If this is the case, turn the key
switch ON and while idling tip the lever (3rd and 4th) backwards or
forwards, and one of the cups will come off. Then tip the lever in the
other direction and remove the other cup.
In 1D1/1D2, combination switch auto return function is operated by
steering wheel operation.
CAUTION:
• Before removing hydraulic lines or piping, the oil pressure

remaining in hydraulic lines is completely bled off.
• To prevent foreign matter from entering, always maintain a clean
workplace.
• When disconnecting pipes, cover the surrounding area with rag
and ensure oil does not contaminate other parts.
• Never allow foreign matter to enter pipes when connecting.
• Put disassembled parts on clean paper or rag and use care not
to contaminate, scratch or dent them.
• Always assign lifting operations to qualified operators trained in
slinging or hoisting procedures.
• When handling heavy parts, two people should perform the
work.
• For the removal of instrument inner cover, floor mat and floor panel,
refer to BF section.
• For removal and installation of mast, refer to LM section.
HD-52
Hydraulic Circuit Diagram (FC models)
1. Hydraulic pump 6. Tilt valve 11. Down safety valve

2. Suction filter 7. Attachment valve (Opt) 12. Micron filter
3. Power steering cylinder 8. Lift cylinder 13. Hydraulic fluid tank
4. Control valve 9. Tilt cylinder 14. Power steering valve
5. Lift valve 10. Flow regulator valve 15. Tilt leveling solenoid valve (Opt)
16. C1 / Unload solenoid valve
HD-53
Installation
To install, reverse the order of removal. Pay attention to the following points.
• Never allow foreign matter to enter pipes or control valve.
• After connecting pipes, apply relief pressure to check for any oil leaks.
• After connecting lever and control valve, adjust the clearance between control valve switch and dog and
implement centering by referring to VC section.
Disassembly
JOYSTICK CONTROL VALVE
HD-54
EMERGENCY LOWERING OF MAST
EMERGENCY LOWERING OF MAST
Hydraulic Test
Emergency lowering shutt-off valve
• When the forks and masts cannot be lowered with/without load.
• First of all, check the following:
For joystick valve

• Check that C1 solenoid and solenoid for lift operate normally. Refer to
the VC section.
• Operate the control valve lever toward the mast lowered side, and then
make sure that the pump operates (turns). If not, repair the forklift by
referring to the VC section.
If the above steps are OK, the forks and masts can be lowered with the
following procedure.
1. Turn key switch to OFF, disconnect the battery connection.
2. Remove the floor mat and floor board.
3. Loosen lock nut of shut-off valve on the lower side of control valve.
4. Loosen the screw counterclockwise until it stops.
CAUTION:
Mast will begin to lower when screw is first turned.
Return
1. Screw in the screw until it stops.
2. Tighten lock nut.
3. Install the floor board and floor mat, and then install the battery.
CAUTION:
Always return to the lift lock function after repair.
HD-55
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HD-58
LOADING MECHANISM
SECTION LM
CONTENTS
SERVICE DATA AND SPECIFICATIONS ................ 2 Removal ............................................................... 9
Adjustment Value ................................................. 2 Inspection ........................................................... 10
Adjusting Parts ..................................................... 3 Adjustment ......................................................... 10
Tightening Torque ................................................ 3 Installation .......................................................... 12
TROUBLE DIAGNOSIS ............................................ 4 MAST ASSEMBLY ................................................. 13
SERVICE INFORMATION ........................................ 5 Component Parts Location ................................. 13
FORK ........................................................................ 6 Removal ............................................................. 17
Removal ............................................................... 6 Disassembly ....................................................... 18
Inspection ............................................................. 6 2W mast ........................................................... 18
Installation ............................................................ 6 2F/3F/3V mast .................................................. 20
LIFT CHAIN ............................................................... 7 Inspection ........................................................... 21
Removal ............................................................... 7 Assembly ............................................................ 21
Inspection ............................................................. 7 2W mast ........................................................... 21
Installation ............................................................ 7 2F/3F/3V mast .................................................. 25
Adjustment ........................................................... 7 Installation .......................................................... 30
CARRIAGE ASSEMBLY .......................................... 9 Adjustment ......................................................... 31
Component Parts Location ................................... 9
NOTE: This section contains information and

specifications for both carbureted general
overseas market models, as well as,
electronic control models (manufactured
in USA.) Therefore, ensure the
specifications or procedures you are
looking at are for the proper fuel delivery
system; electronic controlled or
carbureted.
Adjustment Value
Unit: mm (in)
1D2
Item 1D1
2.0, 2.5 ton 3.0, 3.2 ton
Clearance between outer mast and inner mast side roller side surface 0.1 - 0.6 (0.004 - 0.024)
Clearance between mast and mast liner 0.1 - 0.6 (0.004 - 0.024)
Clearance between mast and lower mast roller rolling surface 0.1 - 0.6 (0.004 - 0.024)
Inner mast and outer mast 2W 2700, 3000, 3300
311 (12.24)
roller pitch (106.30, 118.11, 129.92)
3500 (137.80) 346 (13.62)
3700 (145.67) 371 (14.61)
4000, 4500, 5000
411 (16.18)
(157.46, 177.17, 196.85)
2F 3000, 3300 (118.11, 129.92) 282 (11.10) 284 (11.84)
3500 (137.80) 352 (13.85) 354 (13.94)
3700 (145.67) 402 (15.83) 404 (15.91)
4000 (157.46) 482 (11.10) 484 (19.06)
4200 (165.35) — 484 (19.06)
3F 3850, 4300 (151.57, 169.29) 369 (14.53) 519 (20.43)
4750 (187.01) 369 (14.53) 504 (19.84)
5150 (202.76) 369 (14.53) 494 (19.45)
5500 (218.50) 384 (15.12) 574 (22.60)
6000 (236.22) 419 (16.50) 669 (26.34)
6500 (255.91) 504 (19.84) 754 (29.68)
7000 (275.59) 604 (23.78) 854 (33.62)
3V 3600, 4050, 4500, 4900
369 (14.53)
(141.73, 159.45, 177.17, 192.91)
5250 (264.69) 384 (15.12)
—
5750 (226.38) 419 (16.50)
6330 (249.21) 504 (19.84)
6880 (270.87) 604 (23.78)
3850, 4300, 4700
469 (18.46)
(151.57, 169.29, 185.04)
5050 (198.82) 484 (19.06)
5550 (218.50) — — 519 (20.43)
6000 (236.22) 669 (26.34)
6500 (255.91) 794 (31.26)
7000 (275.59) 854 (33.26)
Clearance between inner mast and carriage roller side surface 0.1 - 0.6 (0.004 - 0.024)
Clearance between inner mast and carriage roller rolling surface 0.1 - 0.6 (0.004 - 0.024)
Mast tilting angle Forward 6°
Back- 2W, 2F - 3700 12°
ward 4000 - 6°
3F, 3V 6°
Distance from carriage lower end to ground 76 (2.99)
Difference between inner mast lower end and outer mast lower end (3F,
0
3V mast)
Lift chain tension 25 - 30 (0.98 - 1.18)
LM-2
Adjusting Parts
Unit: mm (in)
Unit 1D1 1D2; G1D2
Carriage roller 97.0, 97.5, 98.0 115.0, 115.5, 116.0
(3.82, 3.84, 3.86) (4.53, 4.55, 4.57)
Carriage roller adjusting shim 0.50, 1.00, 2.00 (0.020, 0.040, 0.079)
Carriage side roller and thrust metal adjusting shim 0.50, 1.00, 2.00 (0.020, 0.040, 0.079)
Mast liner adjusting shim 0.5, 1.0 (0.020, 0.040)
Mast roller diameter 2W, 2F Outer mast side 97.0 (3.82) 115.0 (4.53)
Inner mast side 105.0, 105.5, 106.0 123.0, 123.5, 124.0
(4.13, 4.15, 4.17) (4.84, 4.86, 4.88)
3F, 3V Outer mast side 105.0 (4.13),
97.0 (3.82) 115.0 (4.53)(CG1D2,
G1D2)
Middle mast upper 105.0 (4.13),
97.0 (3.82) 115.0 (4.53)(CG1D2,
G1D2)
Middle mast lower 105.0, 105.5, 106.0 123.0, 123.5, 124.0
(4.13, 4.15, 4.17) (4.84, 4.86, 4.88)
Inner mast side 97.0, 97.5, 98.0 115.0, 115.5, 116.0
(3.82, 3.84, 3.86) (4.53, 4.55, 4.57)
Mast roller adjusting shim 0.50, 1.00, 2.00 (0.020, 0.040, 0.079)
Mast cylinder adjusting shim 1.0 (0.040)
Full free cylinder adjusting shim (2F, 3F) 1.0 (0.040)
Tightening Torque
Item Location Tightening torque [N•m (kg-m, ft-lb)]
Backrest installation Backrest securing bolt 177 - 225 (18 - 23, 131 - 165)
Lift chain installation Anchor bolt lock nut 1D1 92 - 124 (9.4 - 13; 68 - 91)
1D2 142 - 192 (15 - 19, 105 - 141)
Adjusting bolt lock nut 1D1 92 - 124 (9.4 - 13; 68 - 91)
1D2 142 - 192 (15 - 19, 105 - 141)
Carriage assembly Side roller securing bolt 1D1 14 - 18 (1.4 - 1.8 ; 10 - 13)
1D2; G1D2 25 - 35 (2.6 - 3.6; 19 - 26)
Mast assembly Lift cylinder securing bolt (2W) (upper/lower) 44 - 54 (4.4 - 5.6, 32 - 40)
Mast cylinder securing bolt (2F, 3F, 3V) Upper 78 - 98 (8.0 - 10.0, 58 - 72)
Lower 44 - 54 (4.4 - 5.4, 32 - 40)
U-bolt lock nut 26 - 32 (2.6 - 3.3, 19 - 24)
U-bolt adjusting bolt lock nut 74 - 94 (7.5 - 9.6, 54 - 69)
Full free cylinder securing bolt (2F, 3F) 128 - 156 (13 - 16, 94 - 115)
Full free cylinder securing bolt (3V) 44 - 54 (4.4 - 5.6, 32 - 40)
Mast assembly　 Mast support cap securing bolt 1D1 89 - 118 (9.1 - 12.0, 66 - 87)
installation 1D2; G1D2 206 - 265 (21 - 27, 152 - 195)
Pivot pin lock bolt 26 - 32 (2.6 - 3.3, 19 - 24)
Tilt cylinder rod lock nut 108 - 147 (11 - 15, 80 - 108)
Chain guide securing bolt (2W) 14 - 18 (1.4 - 1.8 ; 10 - 13)
LM-3
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS

Forks do not raise or lower • Improperly adjusted carriage bracket assembly • Adjust clearance between parts (such as
smoothly. inner surface of inner mast, and side roller,
thrust liner, and carriage roller). Replace
malfunctioning parts with new ones.
• Adjust using shim(s) or mast liner.
• Improperly adjusted inner mast-to-outer mast
clearance or roller-to-mast clearance • Apply grease to contacting/sliding surface of
• Insufficient lubrication parts.
• Remove foreign materials.
• Caught foreign materials in functional parts • Adjust.
• Deformed inner mast • Adjust or replace.
• Bent carriage bracket assembly
Fork rising unstable. • Improperly adjusted lift chain(s) • Adjust lift chain.
Mast rollers do not rotate. • Solidified grease on rollers or sliding surfaces or • Clean mast rollers and grease.
accumulated dirt/dust
• Mast roller(s) are improperly installed. • Check and adjust mast rollers.
• Roller(s) are broken or damaged. • Replace mast rollers.
Mast emits noise. • Insufficient lubrication • Apply grease
• Improperly adjusted mast rollers, side rollers and/or • Adjust.
mast lingers
• Worn chain wheels, mast rollers and/or mast liner • Replace.
• Damaged mast rollers • Replace mast rollers.
CAUTION:
• The possible causes and corrective actions shown in the
table should be deemed as the referential information.
Customer's complaints must be listened to carefully. Check
the actual forklift status when diagnosing.
LM-4
SERVICE INFORMATION
SERVICE INFORMATION
CAUTION:
• Mast of the loading mechanism parts such as forks, mast,
carriages, etc. are heavy. The hoisting and movement of
those objects are inherently dangerous. Therefore, be
extremely careful and always employ an assistant when
you remove them.
• When removing/installing cylinder, always perform the
procedure with two persons because of heavy weight,
paying attention not to catch hands by components.
• Be extremely careful to protect your hands, feet, etc., when
performing maintenance work on or moving heavy objects.
• Lifting and hoisting work should be performed by persons
who have completed slinging skills training or hoisting
skills training.
• Before removing hydraulic piping, stop the engine and
ensure the ignition switch is turned to the ON position
again, and that oil pressure remaining in hydraulic lines is
completely bled off using the control lever.
NOTE:
• The fork must be remove as required to make maintenance
work easier to perform.
• Disassembly of the carriage bracket assembly requires the
removal of the forks. Following the removal of forks, remove
the carriage bracket from the mast.
• If the carriage bracket assembly need not be disassembled
upon removal, remove it with the forks installed to it. This
will prevent the carriage bracket assembly from toppling
over.
• When the mast assembly is removed together with carriage
bracket, remove the fork beforehand.
• The abbreviation is used about the specification of mast in the
text as follows.
• 2W mast: 1 series 2 step wide view mast
• 2F mast: 1 series 2 step full free lift mast
• 3F mast: 1 series 3 step full free lift mast
LM-5
FORK
Removal
FORK
CAUTION:
For removal of the fork and carriage assembly as a unit, refer to
"CARRIAGE ASSEMBLY".
1. Fully tilt the masts forward. (The fork tips must not contact the
ground.)
2. Pull up the lock pin at the top of one of the forks, and move the
fork to the notch at the center of the carriage.
3. Lift the fork tip, disengage the jaw of the fork from the carriage,
and shift the fork to the side.
4. Pull up the lock pin at the top of another fork, and move the fork
to the notch at the center of the carriage.
5. Lower the fork.
6. When the carriage is separated from the forks, back up the
forklift.
Inspection
• Check the forks for wear. If wear exceeds 3 mm (0.1 in), replace
the forks with new ones.
• Visually check the forks for cracks, deformation or separation of
welds. Replace if necessary.
• Check the fork using a dye penetration method. If they are
cracked, replace with new ones.
Installation
Install in the reverse order of removal, following the instructions
below.
CAUTION:
After installing both forks, check to ensure that the lock pins
are properly locked.
LM-6
LIFT CHAIN
LIFT CHAIN
Removal
1. Support the carriage by placing a wooden block under it or
using a crane.
2. Lower the mast cylinder to loosen the lift chains, and then
remove the chain anchor bolts from the carriage.
3. Disengage the lift chains at the lift chain joint links and adjusting
bolts on the mast side. (Refer to "Component Parts Location" in
"MAST ASSEMBLY".)
4. Remove the lift chains from the chain wheel.
Inspection
• Visually check the lift chains for cracks, breaks or damage.
Replace the left and right lift chains as a unit if necessary.
• Raise the forks approximately 20 mm (0.8 in) to 30 mm (1.2 in)
above the ground to check the lift chain for elongation. Replace
the left and light lift chains as a unit if necessary.
NOTE:
• Cracks or breakages often occur at the ends of the lift chains.
• Elongation often occurs in portions of the lift chain which experi-
ences contact with the chain wheel.
Installation
below.
CAUTION:
• Before installing the chain anchor bolts, ensure that the lift
chain is not twisted.
• Replace discard old cotter pins with new ones.
Adjustment
CAUTION:
• Before adjusting chain tension, park the forklift on flat and
solid ground.
• On pneumatic tire models, inflate the tires to the specified
pressure.
• As for the 3F mast, adjust the mast chain and lift chain.
1. Set the mast upright and fully lower the carriage.
2. Turning the adjusting nut in or out, adjust the carriage until its
lower end above the ground is within the standard.
Standard: 76 mm (2.99 in)
LM-7
LIFT CHAIN
3. For the 3F mast, before the adjustment of the lift chain

mentioned above, raise the carriage gradually to adjust the
adjusting nut of the mast chain so that the difference between
the inner mast lower end and the outer mast lower end
conforms to the standard.
Standard: 0 mm (0 in)
For models with fork (Reference)

1. Lower the forks on the floor, and adjust the lift chain with the
adjusting nut until there is no looseness of the lift chain. And
then lock the lock nut.
2. Make sure that the chain is not twisted.
3. Check for properly lifting up.
4. Make sure that inner mast upper beam carriage stopper and
carriage do not contact when the forks are fully raised up.
LM-8
CARRIAGE ASSEMBLY

CARRIAGE ASSEMBLY
Removal
NOTE:
Removal of the carriage and fork as a unit prevents the carriage from
toppling to the ground.
1. Set the mast in the vertical position, and then lower the forks to
the ground.
NOTE:
When removing the carriage without forks, attach a wire/nylon sling,
and then support the carriage using a hoist or crane.
2. Disengage the lift chains at the adjusting bolt and lift chain joint
links on the mast side, and then drape the lift chains over the
backrest.
3. Raise the inner mast, and then remove the carriage from the
mast.
CAUTION:
Be careful to prevent the mast from catching the removed
lifting chain.
LM-9
CARRIAGE ASSEMBLY
Removal (Cont’d)
4. Back up the forklift, and then remove the carriage from the
mast.
CAUTION:
Be sure to lower the inner mast to the ground after backing the
forklift up.
Inspection
Carriage roller, side roller, and shim
• If the carriage roller does not operate smoothly or has
undergone deformation, stepped wear or damage, replace it.
Carriage
• Visually check the forks for cracks, deformation or separation of
welds. Replace if necessary.
• Check the fork using a dye penetration method. If they are
cracked, replace with new ones.
Adjustment
1. Select suitable carriage rollers so that the clearance between
the inner mast rail and the carriage roller rolling surface are
within the standard.
Standard : 0.1 - 0.6 mm (0.004 - 0.024 in)
Roller type: 1D1 97.0, 97.5 mm (3.82, 3.84 in)
1D2, G1D2 115.0, 115.5 mm (4.53, 4.55 in)
NOTE:
On the 6-roller type, select upper/lower carriage roller only. Center
roller is not necessary to be selected. Use the smallest one of the
available rollers as a center roller.
2. Measure the inner wall width (A) of the inner mast. Measuring
points are upper/lower ends of the inner mast and center of the
crossbeam.
LM-10
CARRIAGE ASSEMBLY
Adjustment (Cont’d)
3. Measure the pitch of the left and right carriage side rollers,
carriage rollers and thrust liner (at point B B, and B")
NOTE:
• The upper and middle carriage rollers for 6-roller models are
used only for mast rollers. The lower carriage roller is guided
and rolls to the right and left within the rail corner.
• Independent side rollers are located on the upper portion of the
carriage assembly.
4. Calculate carriage clearances by subtracting the maximum

pitch values of the carriage side rollers, carriage rollers and
thrust liner from the measured minimum inner wall width of the
inner mast.
5. Whenever possible, adjust left and right shims evenly to
equalize left and light clearance.
Standard: 0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
For use with carriage side rollers and thrust liner
0.5, 1.0, 2.0 mm (0.020, 0.040, 0.079 in)
For use with carriage rollers 0.5, 1.0, 2.0 mm
(0.020, 0.040, 0.079 in)
CAUTION:
Be extremely careful when adjusting carriage clearances.
Improper adjustment may cause the carriage bracket to deviate
either to the left or right, or tilting of the finger. These
conditions may result in unequal heights for the left and right
forks.
LM-11
CARRIAGE ASSEMBLY
6. After adjustment, always check the carriage assembly operation
for smoothness.
CAUTION:
Apply grease to the rolling face of the roller and the thrust liner
contact face.
Installation
below.
CAUTION:
Replace cotter pins with new ones.
LM-12
MAST ASSEMBLY
MAST ASSEMBLY

2W mast
LM-13
MAST ASSEMBLY
2F mast
LM-14
MAST ASSEMBLY
3F mast
LM-15
MAST ASSEMBLY
Mast Assembly (Cont’d)

3V MAST
LM-16
MAST ASSEMBLY
Removal
CAUTION:
When removing the mast assembly, ensure the forks are
removed beforehand. This is a precaution to ensure the safest
possible maintenance procedure.
NOTE:
• If the carriage assembly need not be disassembled, remove the
carriage assembly together with the forks prior to removing the
mast assembly. (Refer to "CARRIAGE ASSEMBLY".)
• If a pit or lift is not available, raise the front end of the forklift,
and then, remove the front tires before working on the mast
assembly. (Refer to GI section for lifting information.)
1. Remove the hydraulic hoses (lift hose, return hose, etc.) then
plug their openings.
CAUTION:
Turn the ignition switch to the OFF position, and then move the
control lever. This will relieve remaining oil pressure in the
hydraulic lines. (Refer to HD section.)
NOTE:
When removing the lift hose together with the carriage assembly,
relieve oil pressure in the hydraulic lines beforehand. Attach a lifting
wire or nylon sling to the carriage, then suspend it in the air with a
hoist to facilitate access to the mast assembly.
2. Attach a lifting wire or nylon sling to the upper beam of the mast,
and then support the mast assembly using a hoist.
CAUTION:
Be sure to support mast assembly to prevent mast assembly
from falling down.
3. Remove the mast support cap bolts, and then remove the mast
support cap from the front axle located behind the inner sides of
the front tires.
CAUTION:
To prevent later confusion, temporarily reinstall the mast
support caps (upper, lower, left and right) to their
corresponding locations on the mast assembly.
LM-17
MAST ASSEMBLY
Removal (Cont’d)
4. Remove the pivot pin lock bolts, and then remove the pivot pins
securing the tilt cylinder to the mast assembly.
5. Start engine, and then fully tilt the tilt cylinder backward
(cylinder compressed condition).
CAUTION:
Be sure to retract the tilt cylinder all the way, so as not to
interfere with the tilt bracket that may be caused to damage tilt
cylinder when installing the mast assembly.
6. Using a hoist, lift the mast assembly up and away from the
forklift, and then lower it horizontally onto blocks.
CAUTION:
• Be careful not to damage to brake pipes, etc. while lifting or
moving the mast assembly away from the forklift.
• When removing the mast assembly and carriage as a unit,
securely fasten the tilt beam and carriage (finger bar) with a
rope or wire. This prevents carriage movement when mast
assembly is transferred to the ground.
• Always ensure the mast assembly rests on a flat and solid
surface after it has been removed.
7. When the mast and carriage assembly are removed as a unit,
remove the carriage assembly from the mast as fellows:
• Attach a lifting wire or nylon sling to the carriage and lift using a
hoist.
• Disengage the lift chains at the lift joint link and adjusting bolt on
the mast side, and then place the disengaged lift chains on the
carriage.
• Slide the carriage down and extract it from the lower side of the
inner mast.
CAUTION:
Do not allow the mast assembly to snag or catch the lift chain
when removing the carriage from the inner mast.
Disassembly
2W MAST
1. Remove the hydraulic lines from the mast cylinders.
2. Remove the mounting bolts from the upper ends of the mast
cylinders.
LM-18
MAST ASSEMBLY
Disassembly (Cont’d)
3. Draw out the inner masts upward, and then remove the bolts
and the U-bolts from the lower ends of the lift cylinders. Remove
the mast cylinders.
4. Remove the chain wheels if necessary.
5. Slide the inner mast down. Remove the four mast rollers from
the lower end of the inner mast and upper end of the outer
mast.
CAUTION:
• Be careful not to catch your hands by sliding mast.
• Be careful not to catch your hands when roller is being
removed from mast.
6. Remove the mast liner from the outer mast.
7. Attach a lifting wire or nylon sling. Using a hoist, lift the lifting
wire or nylon sling until the inner mast is lifted free of the outer
mast.
CAUTION:
Be sure to remove the mast rollers in advance, otherwise, inner
mast cannot be removed from the outer mast with the mast
rollers installed in position.
LM-19
MAST ASSEMBLY
2F/3F/3V MAST
1. Remove the piping connected to the head block (with the chain
wheel) and full-free cylinder.
NOTE:
Remove the chain wheels from the head block if necessary.
2. Remove full-free cylinder.

3. Remove the mast chain and chain wheel. (3F/3V mast)
4. Remove the piping connected to the mast cylinder.
LMM0252
5. Remove the mast cylinder mounting bolts (upper and lower) or

nuts, and U-bolts, and then remove mast cylinder.
LM-20
MAST ASSEMBLY
6. Slide the inner mast and middle mast (3F/3V mast) downward,
and then remove the mast roller.
CAUTION:
• Do not remove the rollers of the 3F/3V mast at one time.
Remove the rollers of the inner mast first, then those of the
middle mast in this order.
• Be careful not to pinch your hand when the mast slides.
• Be careful not to pinch your hand when the roller is being
LMT0100J
removed from the mast.
7. Remove the liner from the outer mast and middle mast (3F/3V
mast).
8. Pass nylon slings or wires in the mast of inner mast first, then
the middle mast (3F/3V mast) in this order. While lifting them by
a hoist, etc., pull them upward over the outer mast.
CAUTION:
Because the inner mast and the middle mast (3F/3V mast)
cannot be pulled out if the mast roller has not been removed,
special care should be taken.
LMM0254
Inspection
Mast roller
Check for unsmooth rotation, deformation, stepped wear or damage.
Replace if necessary.
Mast liner
Check for wear or damage. Replace if necessary.
Chain wheel
Check for unsmooth rotation, cracks or damage. Replace if
necessary.
Piping
Check for cracks, breakage or damage. Replace if necessary.
Mast
Check for cracks, damage or breakage at welds. Replace if
necessary.
Assembly
CAUTION:
Assemble the mast assembly while adjusting various parts.
2W MAST
1. Attach a lifting wire or nylon sling to the inner mast. Using a
hoist, lift the inner mast and guide it into position for
reinstallation to the outer mast.
2. Slide the inner mast down, and then install the mast liner and
outer mast rollers.
LM-21
MAST ASSEMBLY
Assembly (Cont’d)
CAUTION:
Be sure to install mast rollers in the correct places, since the
inner and outer mast rollers are different in diameter.
Outer mast roller diameter: 1D1 97.0 mm (3.82 in)
1D2, G1D2 115.0 mm (4.52 in)
3. Select suitable mast rollers so the clearance between the rolling
contact surfaces on the inner mast roller and outer mast rail are
Standard: 0.1 - 0.6 mm (0.004 - 0.024 in)
Available roller sizes: 1D1 105.0, 105.5 mm
(4.13, 4.15 in)
1D2, G1D2 123.0, 123.5 mm
(4.84, 4.86 in)
Apply a coat of grease to the rolling contact surface of the mast.
CAUTION:
After adjustment, ensure that the mast assembly moves smooth.
4. Adjust the mast liner with the following procedure.
• Measure the clearance between inner mast and mast liner
using a feeler gauge.
• If the clearance is outside the standard, use the same number
and thickness of shims on each side to adjust the clearance.
Standard : 0.1 - 0.6 mm (0.004 - 0.024 in)
Shim : 0.5, 1.0 mm (0.02, 0.04 in)
CAUTION:
When installing the mast liner after making shim adjustments,
apply a coat of bearing grease to the sliding surface of the mast
liners and mast.
NOTE:
The mast liners are push-in type for easy positioning in the mast.
ADJUSTMENTS WITH MAST INSTALLED TO FORKLIFT.

• Remove carriage assembly and mast cylinder. (Refer to
"CARRIAGE ASSEMBLY" for removal of carriage assembly, HD
section for removal of mast cylinder.)
• Lower the inner masts approximately 120 mm (4.72 in), and
then adjust the mast liner.
LM-22
MAST ASSEMBLY
Assembly (Cont’d)
5. Adjust the mast rollers using adjusting shims with the following
procedure.
• Adjust the roller pitch (Dimension L) for the inner mast and outer
mast rollers according to the forklift model series, as shown in
the table below.
(2W mast)
Unit: mm (in)
Dimension L
Lifting height
1D1 1D2
2,700 (106.3)
3,000 (118.1) 311 (12.2) 311 (12.2)
3,300 (129.9)
3,500 (137.8) 346 (13.6) 346 (13.6)
3,700 (145.7) 371 (14.6) 371 (14.6)
4,000 (157.5)
4,500 (177.2) 411 (16.2) 411 (16.2)
5,000 (196.9)
• Move the inner mast all the way to either side of the inner wall of
the outer mast.
• Measure the clearance between the mast and mast roller on the
opposite side using a feeler gauge.
CAUTION:
• The clearance between the mast and mast roller must be
measured at four points (upper, lower, left and right).
• Lower the inner mast, and then measure the clearance between
mast and mast roller at or near the tilt beam of the outer mast.
• Equally adjust the clearance between the outer mast roller and
inner mast on the left and right sides of the mast assembly
using the mast roller adjusting shim on each side until the
clearance is within the standard.
• The left and right inner mast roller shim must be adjusted
equally as much as possible using the minimum valve of the
measurements obtained from the upper and tilt beam points of
outer mast.
Standard : 0.1 - 0.6 mm (0.004 - 0.024 in)
Shim : 0.5, 1.0, 2.0 mm (0.020, 0.040, 0.079 in)
6. Install the chain wheels on the inner masts if previously

removed.
LM-23
MAST ASSEMBLY
Assembly (Cont’d)
7. Position the mast cylinder to the lower beam hole of the outer
mast and set the piston rod to the mast cylinder-retaining
bracket of the inner mast, and tighten mounting bolts and nuts
of mast cylinder upper and lower ends.
Tightening torque:
Upper ends: 78 - 98 N•m (7.9 - 10.0 kg-m, 57 - 72 ft-lb)
Lower ends: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
8. Install the U-bolt into the mast cylinder, and then secure it with
U-bolt lock nuts by tightening by hand.
Tightening torque: 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 24 ft-lb)
9. Tighten the adjusting bolts using a screwdriver, and then tighten
more 1/2 to 1 turn after contacting the stopper on the tip with
mast cylinder.
10. Tighten adjusting bolt lock nut to the specified torque.

11. Install pipes.

12. For the mast assembly and carriage which were removed as a
unit, adjust the carriage mast rollers. After adjusting carriage lift
rollers, attach a lifting wire or nylon sling to the carriage, and
then install it to the inner mast using a hoist. (Refer to
"CARRIAGE ASSEMBLY" for adjustment of mast roller.)
13. Place the lift chains on the chain wheels, engage the lift chains
at the chain joint links and adjusting bolts, and then install to the
outer mast.
CAUTION:
CAUTION:
Assemble the mast assembly while adjusting various parts.
LM-24
MAST ASSEMBLY
2F/3F/3V MAST
CAUTION:
When adjusting the 2F/3F/3V masts, do not adjust them at one
time. Adjust the middle mast first, and then the inner mast in
this order.
1. Pass nylon slings or wires in the mast of the middle mast (3F/3V
mast) first, and then the inner mast in this order. While lifting
them by a hoist, insert them from over the outer mast.
2. Slide the inner mast and the middle mast (3F/3V mast) toward
the bottom of the outer mast, and install the liner, outer mast
roller, and middle mast upper roller.
CAUTION:
To roller diameters of the mast rollers differ on the inner mast
side, middle mast upper and lower sides (3F mast), and outer
mast side. When installing the mast rollers, be sure to install
them in the proper positions.
Middle mast upper side roller diameter:
1D1, C1D1: 97.0 mm (3.819 in)
1D2, C1D2: 102.0 mm (4.016 in)
G1D2: 115.0 mm (4.528 in)
Outer mast roller diameter:
1D1, C1D1: 97.0 mm (3.819 in)
LMT0214 1D2, C1D2: 105.0 mm (4.134 in)
G1D2: 115.0 mm (4.528 in)
• As for the adjustment of other mast rollers, refer to step 4. on the
next page.
3. Adjust the liner with the following procedure.
• Measure the clearance between the mast roller and the inner
mast on the inside of the inner mast and middle mast (3F mast)
using a feeler gauge.
• When the measured value is out of the standard, perform the
shim adjustment to the right and left evenly.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
Shim:
0.5, 1.0 mm (0.020, 0.039 in)
LMM0255
CAUTION:
When installing the liner after making shim adjustments, apply
a coat of bearing grease to the sliding surface of the liners and
mast.
NOTE:
The liners are push-in type for easy positioning in the mast.
ADJUSTMENT OF MAST INSTALLED TO FORKLIDT

(2F MAST).
• Hang the mast using wire, etc., and remove the carriage
assembly and mast cylinder. (Refer to "CARRIAGE
ASSEMBLY" for removal of carriage assembly, HD section for
removal of mast cylinder.)
• Lower the inner mast by approximately 120 mm (4.72 in), and
then perform the shim adjustment mentioned above, and then
replace the mast liner.
LM-25
MAST ASSEMBLY
Assembly (Cont’d)
ADJUSTMENT OF MAST INSTALLED TO

FORKLIFT (3F/3V MAST).
• Hang the mast using a wire, etc., and remove the carriage
assembly. Refer to “CARRIAGE ASSEMBLY”.
• Remove mast chain.
• Remove master cylinder. Refer to HD section.
• Lower the inner mast by approximately 120 mm (4.72 in), replace
the liner of the middle mast side, and then perform the shim
adjustment.
• Lower the inner mast and middle mast simultaneously for
approximately 120 mm (4.72 in), replace the liner of the outer
mast side, and then perform the shim adjustment.
4. Install the inner mast roller, mast roller of the middle mast lower
side, and perform the shim adjustment with the following
procedure.
• Set the roller pitches (Dimension “L”) of the inner mast, middle
mast (3F/3V mast), and outer mast to the dimensions indicated in
the table according to the mast lifting height.
Unit: mm (in)
Dimension L
Lifting height
1D1 1D2
3,000 (118.1)
282 (11.1) 284 (11.2)
3,300 (129.9)
3,500 (137.8) 352 (13.8) 354 (13.9)
2F
3,700 (145.7) 402 (15.8) 404 (15.9)
4,000 (157.5) 484 (19.1)
484 (19.1)
4,200 (165.4) —
Unit: mm (in)
Dimension “L”
Lifting height 1D1 ; 1D2;
1D2 2.0-2.5 ton 3.0 - 3.2 ton
3850, 4300 (151.57, 169.29) 519 (20.43)
4750 (187.01) 369 (14.53) 504 (19.84)
5154 (202.91) 494 (19.45)
3F 5500 (216.54) 384 (15.12) 574 (22.60)
6000 (236.22) 419 (16.50) 669 (26.34)
6500 (255.91) 504 (19.84) 754 (29.68)
7000 (275.59) 604 (23.78) 854 (33.62)
3600, 4050, 4500, 4800
369 (14.53) —
(141.73, 159.45, 177.17, 192.91)
5250 (206.69 384 (16.50) —
5750 (226.38) 419 (16.50) —
6330 ( 249.21) 504 (19.84) —
6880 ( 270.87) 604 (23.78) —
3V 3850, 4300, 4700
— 469 (18.46)
(151.57, 169.29, 185.04)
5050 (198.82) — 484 (19.06)
5550 (218.50) — 519 (20.43)
6000 (236.22) — 609 (23.98)
6500 (255.91) — 794 (31.26)
7000 (275.59) — 854 (33.26)
LM-26
MAST ASSEMBLY
LMT0035
CAUTION:
• For the 3F/3V mast, set the roller pitches in two steps: first
for the inner and middle masts, then for the middle and outer
masts. Setting the roller pitches of the three masts at once
will deteriorate the stability.
• Fix the mast with a rope or a wire to prevent it from sliding.
• Select the mast roller so that the clearance between the mast
roller of the inner mast side and the outer mast (middle mast for
3F/3V mast), and between the mast roller of the middle mast
lower side and the rail and roller sliding surface of the outer mast
(for 3F/3V mast) conform the standard value.
Standard:
0.1 - 0.6 mm (0.004 - 0.024 in)
2F mast roller types:
Inner mast side
1D1 : 105.0, 105.5 mm (4.13, 4.15 in)
LMT0027
1D2 : 123.0, 123.5 mm (4.84, 4.86 in)
3F/3V mast roller types:

Middle mast lower side
1D1: 105.0, 105.5, 106.0 mm
(4.134, 4.154, 4.173 in)
1D2: 123.0, 123.5, 124.0 mm
(4.843, 4.862, 4.882 in)
Inner mast side/middle mast upper side/outer mast side
1D1: 97.0, 97.5, 98.0 mm
(3.819, 3.839, 3.858 in)
1D2: 115.0, 115.5, 116.0 mm
(4.528, 4.547, 4.567 in)
• Place the inner mast or the middle mast (for 3F/3V mast) to the
end of the side, and measure the clearance between the mast
and the mast roller of the opposite side using a feeler gauge.
CAUTION:
Perform measurement for the mast rollers at four points: upper,
lower, right, and left sides (eight points for 3F/3V mast).
• Adjust the shim of the mast roller to the right and left as equally as
possible, so that the closest clearance between the mast roller of
the outer mast side and inner mast (middle mast for 3F/3V mast),
LMT0030 and that between the mast roller of the middle mast upper side and
the inner mast (for 3F/3V mast) conform to the standard values.
Standard: 0.1 - 0.6 mm (0.004 - 0.024 in)
Shim: 0.50, 1.00, 2.00 mm (0.020, 0.039, 0.079 in)
LM-27
MAST ASSEMBLY
Assembly (Cont’d)
• Adjust the shim of the mast roller to the right and left as equally as
possible, so that the closest clearance between the mast roller of
the inner mast side and outer mast (middle mast for 3F/3V mast),
and that between the mast roller of the middle mast lower side
and the inner mast (for 3F/3V mast) conform to the standard
values.
Standard: 0.1 - 0.6 mm (0.004 - 0.024 in)
Shim: 0.50, 1.00, 2.00 mm (0.020, 0.039, 0.079 in)
LMT0031
• Apply a coat of grease to the rolling contact surface of the mast.
CAUTION:
After adjustment, ensure that the mast assembly moves
smooth.
LMM0247
5. Set the mast cylinder to the hole of the lower beam on the outer
mast, and set the piston rod to the cylinder set hole on inner
mast (middle mast for 3F/3V mast). Tighten the mounting bolts
and nuts at the upper and lower ends of the cylinder.
Upper end:
: 78 - 98 N•m (7.9 - 10.0 kg-m, 58 - 72 ft-lb)
Lower end:
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
6. Install the U-bolt into the lift cylinder, and then secure it with U-
bolt adjusting nuts by tightening by hand. Then tighten the lock
nut.
: 26 - 32 N•m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
LMT0158L
LM-28
MAST ASSEMBLY
Assembly (Cont’d)
7. Tighten the adjusting bolts by hand, and then tighten more 1/2
to 1 turn after contacting the stopper on the tip with lift cylinder.
8. Tighten adjusting bolt lock nut to the specified torque.
: 74 - 94 N•m (7.5 - 9.6 kg-m, 55 - 69 ft-lb)
9. Install the piping to the mast cylinder.
10. Install the chain wheel and mast chain (3F/3V mast).
LMT0213L
11. Install the full-free cylinder. At this time, perform the shim
adjustment so that the inner mast and full-free cylinder become
parallel (3F mast).
Shim: 1.0 mm (0.039 in)
: 128 - 156 N•m (13 - 16 kg-m, 94 - 115 ft-lb)
LMT0036
Mounting bracket of full free cylinder to be inserted into the

notch of inner mast 2nd-beam. After surface A of 2nd-beam
touches surface B of mounting bracket, bolt is to be tightened.
(3V mast)
: 44 - 54 N•m (4.4 - 5.6 kg-m, 32 - 40 ft-lb)
HDM0163
12. Install the piping of the head lock (with the chain wheel) and full-
free cylinder.
13. For the mast assembly and carriage which were removed as a
unit, adjust the carriage lift rollers. After adjusting carriage lift
rollers, attach a lifting wire or nylon sling to the carriage, and
then install it to the inner mast using a hoist. Refer to
“CARRIAGE ASSEMBLY” for adjustment of lift roller.
14. Place the lift chains on the chain wheels, engage the lift
chains at the chain joint links and adjusting bolts, and then
install to the full-free cylinder.
CAUTION:
LM-29
MAST ASSEMBLY
Installation
1. Attach a lifting wire or nylon sling to the mast assembly, and
then lift the mast assembly using a hoist.
CAUTION:
• Before lifting the mast assembly (if equipped with the
carriage assembly), lower the carriage assembly ass the
way down. Securely fasten the carriage finger bar to the tilt
beam.
• Make sure that the lift chains are placed on the chain
wheels.
• Make sure that the lift chains are not twisted.
2. Apply a coat of grease to the mast supports. Temporarily install
the bushings.
3. Apply a coat of grease to the inner walls of the bushings. Place
the mast support onto the drive axle mount, and then install the
mast support caps.
Tightening torque:
1D1: 89 - 118 N•m (9.1 - 12.0 kg-m, 66 - 87 ft-lb)
1D2: 206 - 265 N•m (21 - 27 kg-m; 152 - 195 ft-lb)
CAUTION:
Do not confuse the direction (left, right, upper or lower) of the
mast support caps during installation.
4. Turn the ignition switch to the ON position. Extend the tilt
cylinder using the tilt lever until the pivot pin holes in the tilt
cylinders and mast are aligned. Insert the pivot pins into the
holes, and then secure with the bolts.
CAUTION:
Be careful not to catch your hands by the tilt cylinder and mast
when the tilt lever is operated.
5. Install the lift hoses to their connections such as return hoses.
CAUTION:
Ensure that the lift hoses shall not be twisted during
installation.
6. Apply a coat of grease to the mast supports and tilt cylinder
pivot.
7. Lift and tilt the mast several times. Make sure that no oil leakage
occur at or around the hydraulic lines, and that the mast
operates smoothly without binding.
8. Check the lift chains for proper tension. Replace if necessary.
(Refer to "LIFT CHAIN".)
LM-30
MAST ASSEMBLY
Adjustment
Adjustment of cylinder height
NOTE:
To prevent mast from being twisted and deformed, adjust the
cylinder height. Be sure to adjust when reassembling the mast,
especially when replacing only one cylinder.
1. Check that forklift is placed horizontally and that tire air pressure
is correct.
2. Slowly raise mast without load, and then check that right and
left mast cylinders reach to its stroke end simultaneously.
3. If one cylinder is delayed, adjust delayed cylinder by inserting
shims.
Thickness of shims: 1.0 mm (0.040 in)
4. Repeat the adjustment above until there is no difference
between the right and left cylinders.
(Adjusting procedure)
1. The rectangular lumber [250 mm (9.84 in) or more] is put on the
bottom of the inner mast.
2. Lower mast until it touches the rectangular lumber.
3. Remove cylinder fixing nut.
4. Remove emergency valve nut, and then tighten the screw until
the screw feels heavy (release of emergency valve).
5. Lower the cylinder using the mast lever.
CAUTION:
After finishing shim adjustment, be sure to return emergency
valve screw and nut to their origninal condition.
LM-31
MAST ASSEMBLY
Adjustment of mast tilting angle
1. Inflate the tires to the standard (pneumatic-tire models).
(Refer to MA section.)
2. Park the forklift on flat and solenoid ground.
3. Tilt the mast assembly all the way forward, then check the left
and right sides of the mast to ensure that the forward tilt angle is
Standard:
1D1 + 1D2: 6°
NOTE:
Mast backward tilting angle (1D1 + 1D2)
Unit: mm (in)
Lifting height Standard

- 3700 12°
2W/2F
4000 - 6°
3F/3V All 6°
4. Loosen the lock nuts and turn the tilt cylinder rods using a
wrench until their strike lengths are within the standard.
CAUTION:
• Adjust the piston rod stroke lengths to the lengths of the
piston rod thread portions do not exceed the repair limit.
Repair limit: 1D1 10 mm (0.39 in)
1D2 15 mm (0.59 in)
• Adjust the piston stroke lengths so that the tilt angle of the
left and right masts are identical.
• Tilt the mast forward and backward. If the left and right
masts are improperly adjusted, make fine adjustments of
the tilt cylinder stroke lengths as required.
NOTE:
The backward tilt angle of the mast is automatically set by adjusting
the forward tilt angle.
5. Tighten lock nut after adjustment.
Tightening torque: 108 - 147 N•m
(11 - 15 kg-m, 80 - 108 ft-lb)
LM-32
MAST ASSEMBLY
6. Paint alignment marks on matching areas between the tilt
cylinder rod and rod head, and the rod head and lock nut.
7. Operate the mast several times to ensure that it moves

smoothly without binding.
LM-33
ENGINE CONTROL, FUEL & EXHAUST SYSTEMS
SECTION FE
CONTENTS
ENGINE CONTROL SYSTEM ............................ FE-2 FUEL SYSTEM LPG ............................................FE-6
Component Parts Location ............................. FE-2 Hose Connection Layout .................................FE-6
ACCELERATOR WIRE FUEL SYSTEM QD32 ENGINE ...........................FE-7
(DIESEL ENGINE MODEL) ................................ FE-3 Fuel Tank and Piping Layout ...........................FE-7
Adjustment ..................................................... FE-3 INTAKE SYSTEM ................................................FE-8
Installation ...................................................... FE-3 EXHAUST SYSTEM ..........................................FE-10
ACCELERATOR PEDAL .................................... FE-4 Installation .....................................................FE-10
Inspection and adjustment ............................. FE-4 Standard ........................................................FE-11
Assembly ........................................................ FE-4 Overhead Muffler ...........................................FE-12
FUEL SYSTEM ................................................... FE-5 Overhead Muffler low noise ...........................FE-13
Precaution ...................................................... FE-5
Fuel Tank Gauge Unit .................................... FE-5 NOTE: This section contains information and
Fuel Piping ..................................................... FE-5 specifications for both carbureted general
Fuel Valve and Elbow Connector ................... FE-5 overseas market models, as well as,
in USA.) Therefore, ensure the specifications
or procedures you are looking at are for the
proper fuel delivery system; electronic
controlled or carbureted.
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
FE-2
ACCELERATOR WIRE (DIESEL ENGINE MODEL)
ACCELERATOR WIRE (DIESEL ENGINE MODEL)
Adjustment
Pull the outer casing in the direction shown by the arrow in the figure
and fix with the lock nut at the point where the outer casing is
returned 0.5 - 1.0 mm (0.020 - 0.039 in) from where the throttle lever
began to move.
Installation
Observe the following notes during installation:
• Accelerator wire bending radius must be as large as possible.
• Be careful not to bend inner wire and outer casing sharply since
they may become deformed or damaged.
FE-3
ACCELERATOR PEDAL
ACCELERATOR PEDAL
Inspection and adjustment

1) Depress accelerator pedal until accelerator control lever is in
contact with maximum speed setting screw.
2) At this point, stopper bolt must be in contact with accelerator
pedal. If necessary, adjust stopper bolt. After adjusting stopper
bolt, tighten lock nut.
3) After properly adjusting both accelerator wire and accelerator
pedal (as described above), check ensure throttle lever is in
contact with idle adjustment screw.
• Fix with the lock nut at the point where the stopper bolt is returned
1 rotation from where the stopper bolt contacts the accelerator
pedal when the throttle lever is fully depressed.
: 10.8 - 14.6 N•m (1.1 - 1.5 kg-m, 8 - 10 ft-lb)
• Ensure that the throttle lever is full open when the accelerator
pedal is in the fully depressed position, and full closed when the
accelerator pedal is back in the home position.
Assembly
Observe the following notes during assembly:
• Ensure accelerator shaft return spring is properly installed on the
bracket.
• Apply chassis grease to sliding parts.
FE-4
FUEL SYSTEM
FUEL SYSTEM
Precaution
CAUTION:
Before working on the fuel system take the following
precautions.
• Be sure to turn ignition switch "OFF" and then disconnect
battery ground cable.
• Have a well-ventilated working area.
• Keep away from arcs, sparks, flames or lit cigarettes.
Fuel Tank Gauge Unit
Fuel Piping
• Insert fuel tube more than 25 mm (0.98 in) when connecting fuel
hose with fuel tube.
• Securely clamp pipe and hose clips at designated points and in
correct direction.
• Make sure pipes and hoses are not deformed or damaged.
• Keep fuel lines at least 51 mm (2.00 in) away from electrical
parts.
Fuel Valve and Elbow Connector

• Do not disconnect elbow connector and fuel valve unless
absolutely necessary.
• When installing elbow connector or fuel valve, be sure to
apply a coat of locking sealant to screw threads.
FE-5
FUEL SYSTEM LPG
FUEL SYSTEM LPG
Hose Connection Layout
FE-6
FUEL SYSTEM QD32 ENGINE
FUEL SYSTEM QD32 ENGINE
Fuel Tank and Piping Layout
FE-7
INTAKE SYSTEM
INTAKE SYSTEM
K / GK - engine
1. Air hose 4. Heat insulator

2. Air duct assembly 5. Air cleaner assembly
3. Air horn
FE-8
INTAKE SYSTEM
GD32- engine
1. Resonator assy 4. Air horn

2. Air hose resonator assy 5. Heat insulator
3. Air duct assembly 6. Air cleaner assembly
FE-9
EXHAUST SYSTEM
EXHAUST SYSTEM
CAUTION:
Start work on the exhaust system after making sure that the
engine has sufficiently cooled down.
Installation
When connecting exhaust (muffler inlet parts) use the "Exhaust
Sealant Kit, 20720-N2225" to eliminate gas leakage at joint.
• The sealant should be used within guaranty term indicated on the
case.
• Exposure of sealant to the skin may cause a rash. Wash sealant
off the skin with water.
• Do not keep the sealant tube in a place where the ambient
temperature is 40°C (104°F) or above. A sealant hardened at
40°C (104°F) or above cannot be used. The most suitable storage
temperature is from 15 to 35°C (59 to 95°F). If sealant becomes
hardened because of low temperature, warm the sealant tube
with lukewarm water until the sealant is softened. Do not warm
the tube at a temperature of over 40°C (104°F).
• Thoroughly read the instruction sheet before using the sealant.
NOTE:
The sealant is used for the joint of an overhead muffler (on the
counterweight). Other parts need not be used.
FE-10
EXHAUST SYSTEM
Standard
FE-11
EXHAUST SYSTEM
Overhead Muffler
CAUTION:
After installation, check for gas leaks from the tube
connection part. When removing each part, make sure the
exhaust system has cooled down to normal temperature.
FE-12
EXHAUST SYSTEM
Overhead Muffler low noise
CAUTION:
After installation, check for gas leaks from the tube
connection part. When removing each part, make sure the
exhaust system has cooled down to normal temperature.
FE-13
VEHICLE CONTROL SYSTEMS
SECTION VC
CONTENTS
VEHICLE CONTROL SYSTEM ................................ 2 TABLE OF DIAGNOSIS TROUBLE CODE (DTC).. 42
Vehicle Control System ........................................ 2 COMBINATION METER ......................................... 48
VCM SETTING ........................................................ 11 ECM Active Test ................................................. 54
VCM Setting ....................................................... 11 Neutral Level Adjustment of Tilt Angle Sensor... 61
COMBINATION METER ......................................... 12 Diagram of Combination Meter .......................... 63
Combination Meter Arrangement ....................... 12 VEHICLE CONTROL MODULE ............................. 64
Changing Meter Display (Normal mode) ............ 13 Diagram.............................................................. 64
Combination Meter Explanation Description ...... 13 Terminal Layout.................................................. 65
Clock .................................................................. 14 UNIT INSPECTION AND ADJUSTMENT............... 67
Water Temp. Gauge ........................................... 16 Inspection ........................................................... 67
Fuel Gauge ......................................................... 17 Joystick Control System (Option) ....................... 75
Forward-reverse (F/R) Lever Position ................ 18 REFERENCE DATA ............................................... 81
Warning Lights ................................................... 18 VCM input/output monitor................................... 81
LCD Warning Symbols ....................................... 19 ECM input/output monitor................................... 85
Malfunction Code ............................................... 21 MP input/output monitor ..................................... 88
Inspection Timing ............................................... 21
Driver Recognition Mode .................................... 21
Manager Mode ................................................... 22
LPG Remaining Time Management ................... 26 NOTE: This section contains information and
Fault Adjustment Diagnostic Mode ..................... 29 specifications for both carbureted general
Set Mode ............................................................ 36 overseas market models, as well as,
in USA.) Therefore, ensure the
specifications or procedures you are
looking at are for the proper fuel delivery
system; electronic controlled or
carbureted.
VEHICLE CONTROL SYSTEM
Vehicle Control System

SYSTEM CONFIGURATION
1D1 and 1D2 models are equipped with an engine control module (ECM)* for controlling the engine, meter panel for
controlling the warning lights and diagnosis, and vehicle control module (VCM) for controlling the forklift entirely.
These control modules contribute to the enhancement of forklift functionalities. Refer to “VEHICLE CONTROL
SYSTEM COMPONENTS”.
NOTE:
*ECM: Installed in gasoline models and dual-fuel models
COMMUNICATION SYSTEM
The CAN system adopted for the data communication among the VCM, meter panel and ECM allows each control
module to retrieve only necessary data from the two-wire communication line and thus perform reliable control
operations. The adoption of CAN also contributes to reduction of communication wires needed for transmitting a lot
of information, simplifying the wire harness system and reducing the amount of wires needed.
VEHICLE CONTROL MODULE (VCM)

VCM, located bellow the battery mounting plate, controls multiple functions of the forklift. As the VCM hardware, two
variants are available. One is for those with the mechanical cargo control valve (MC). The other is for those with the
electrical cargo control valve (FC). Any forklift-to-forklift differences such as engine type, transmission gear ratio
and optional controls are reflected in the firmware, to which an optimum data set is written according to each forklift
variant.
VCM control functions are shown in “VCM CONTROL LIST”. As in the battery drive models, the VCM adopts a fully
centralized control scheme including cargo handling, traveling and other functions, contributing to improved
serviceability as well as more efficient forklift layout and advanced functionality.
VC-2
Vehicle Control System (Cont’d)

VEHICLE CONTROL SYSTEM COMPONENTS
VC-3

VCM CONTROL LIST
Applicable
Control Item Function Description Remarks Input Output
model
Cargo control Mast interlock Locks cargo system while operator is Mast interlock All Seat switch • C/V unload solenoid
control not seated on driver seat. indicator light standard (MC)
lighting. models • C/V lift lock solenoid
(MC)
• Each C/V proportional
solenoid valve (FC)
• Mast interlock indicator
signal
Tilt neutral stop Tilting forward while pressing this Option for • Tilt leveling switch C/V tilt lock solenoid
control button automatically stops tilt all models • Tilt operation
operation when fork is held at a level detection switch
position. However, this system does • Cargo detection
not operate when a load is on it. hydraulic pressure
sensor
• Tilt angle detection
sensor
Joystick control Controls cargo handling according to Standard Each joystick signal Each C/V proportional
joystick operations. for models solenoid valve
with
joystick
controls
Transmission Transmission Activates or deactivates forward or Standard Forward/backward shift • T/M forward solenoid
control solenoid control backward transmission solenoid for ATM, lever signal • T/M backward solenoid
according to forward/backward shift 2ATM • T/M forward 2 solenoid
lever. models • Neutral indicator signal
Forward/backward Deactivates forward/backward Forward/ Standard • Seat switch • T/M forward solenoid
interlock control transmission solenoids to stop forklift backward travel for ATM, • Forward/backward • T/M backward solenoid
while operator is not seated in driver interlock indicator 2ATM shift lever signal • T/M forward 2 solenoid
seat. in meter blinks. models • Forklift speed sensor • Forward/backward travel
interlock indicator signal
Transmission Reduce engine revolution when the ECM reduce rpm Standard / Transmission overheat ECM reduce engine rpm to
overheat control transmission overheat switch (122°C) Only for switch via VCM 1600
is detected. ECM
models
Engine control Maximum speed Sends max. forklift speed limit signal ECM restricts Option for Max. speed changeover Forklift speed limit
changeover to engine control module according max. forklift ECM switch
control to max. speed changeover switch speed. models
position (HIGH or LOW) in instrument
panel.
Throttle sensitivity Sends status of throttle sensitivity ECM adjusts Option for Power/eco changeover Switch status signal
(power/eco) changeover switch in instrument throttle ECM switch
changeover panel to ECM. sensitivity. models
control
Oil pressure Reduce engine revolution when the oil ECM reduce rpm Standard / Oil pressure switch via ECM reduce engine rpm to
control pressure low (approx. 0.2 bar) is Only for Meter panel 1600
detected for more then 5 seconds. ECM
models
Overheat • Reduces engine heat generation by reducing maximum engine speed and regulating maximum throttle opening when
prevention engine coolant temperature reaches approximately 110°C (230°F).
control • Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or more when engine coolant
temperature reaches approximately 135°C (275°F).
• Transmission overheat control; Reduce engine revolution when the transmission overheat switch (122 °C is detected.
Transmission overheat switch via VCM. ECM reduce engine rpm to 1600.
Warning control Warning light Activates or deactivates the following Each warning Partial • Seat belt switch Warning light signal to
control warning lights in meter according to light to meter option for • Radiator coolant level meter
status of corresponding switches and turns ON all models detection switch
sensors: All models • Air cleaner clogging
Seat belt warning (Option for detection switch
Radiator fluid level warning some • Torque converter fluid
Air cleaner clogging warning models) temperature switch
Torque converter fluid temp warning
etc.
Parking brake Operates audible alarm when All • Seat switch Warning buzzer
warning control operator stands up from seat without standard • Parking brake signal
applying parking brake. While key is models
OFF, operates audible alarm
whenever parking brake is not applied
irrelevant of driver presence on seat.
Over speed Operates audible alarm when forklift Special Forklift speed sensor Warning buzzer
warning speed exceeds specified limit. equipment
Glow control Glow control Heats glow plug when KEY ON. Glow light Standard • Water temp signal Glow plug drive relay
lighting. for models • Battery voltage
with
DIESEL
VC-4

QUICK GLOW SYSTEM
NOTE:
Glow timer unit is deleted.
Glow timer’s function is taken in VCM.
Glow System for QD32 engine is controlled by only the coolant temp.
But this Quick Glow System is controlled by coolant temp. Battery
voltage and terminal voltage of glow plug. And this system is added
the chopping control.
Operation
a. When coolant temperature below 50C (122F) (temperature
detected by water temperature sensor)
1. Operational sequence
2. Ignition switch “ON”

When the ignition switch is turned to “ON”, the glow pilot light comes
on and, at the same time, the glow relay activates. Current then
flows through the glow plug in each pre-combustion chamber to
provide a quick preheat function.
The duration of time the glow pilot light is on (light “ON” time
duration) is shown in the graph at left. The light “ON” time duration
differs according to the coolant temperature. For example, when the
coolant temperature is 0C (32F), the light “ON” time duration is
approximately 3.5 seconds.
VC-5

The glow plug quick preheat time duration is shown in the graph at
left. The preheat time duration differs according to the voltage
applied across the glow plug terminals.
For example, when the glow plug terminal voltage is 11 volts, the
quick preheat time duration is approximately 10 seconds.
If the ignition switch is “ON” even after the quick preheat time has
elapsed, the glow relay repeatedly turns on and off for an additional
period of 20 seconds, intermittently providing a quick preheat
function. This intermittent quick preheat operation is called
“chopping”. The duration of time the glow relay is ON is called
“chopping-ON time” and the duration of time the glow relay is OFF,
“chopping-OFF time”.
The figure at left shows an operational sequence of “chopping-ON

time”. The lower the glow plug terminal voltage, the longer the
“chopping-ON time” (quick preheat time).
The table at right shows an operational sequence of “chopping-OFF

time”. The “chopping-OFF time” differs according to whether the
ignition switch is in the “ON” or “START” position.
When the ignition switch is in the “START” position, the “chopping-
OFF time” is shorter than when it is in the “ON” position.
Ignition switch position Chopping-OFF time

“ON” 3.00.6 sec.
“START” 1.20.3 sec.
3. Ignition switch “START”

When the ignition switch is turned from the “ON” to the “START”
position, the glow relay turns on and off, providing a quick preheat
function intermittently.
During the quick preheat operation, the “chopping-ON time” and the
“chopping-OFF time” are the same as those previously outlined.
4. After starting the engine
After the ignition switch returns from the “START” to the “ON”
position, the quick preheat function continues intermittently for 20
seconds.
b. When coolant temperature greater than 50C (122F)
(temperature detected by the water temperature sensor)
1. Operational sequence
2. Ignition switch “ON”
When the ignition switch is turned “ON”, the glow pilot light comes on
for 1 to 2 seconds but the quick preheating system does not activate.
VC-6

3. Ignition switch “START”.
The “chopping-ON time” and “chopping-OFF time” durations are the
same as those previously outlined under the topic “Coolant
temperature below 50C (122F)”.
PARKING BRAKE WARNING BUZZER

A warning buzzer sounds when the driver stands up from the seat
without applying the parking brake.
Ignition Seat Parking brake Warning

switch Seated Unseated Applied Released buzzer
○ － ○ － ×
○ －－ ○ ×
ON
－ ○ ○ － ×
－ ○ － ○ ○
○ － ○ ×
○ －－ ○ ○
OFF
－ ○ ○ － ×
－ ○ － ○ ○
NOTE:
3-second delay is implemented for detection of unseated status.
Input Output
Parking brake switch (CAN data)
Warning buzzer
Seat switch
MAST LOCK
This locks the cargo handling equipment while the operator is not
seated in the driver seat.
Operator Mast lock Mast interlock indicator light
Seated × ×
Unseated ○ lighting
NOTE:
3-second delay is implemented for detection of unseated status.
(When the operator unseats himself from the driver seat, the current
cargo operation will be stopped after 3 seconds.)
Input Output
Mast interlock indicator light (CAN data)
C/V unload solenoid (MC)
Seat switch
C/V lift lock solenoid (MC)
C/V proportional solenoid (FC)
VC-7

T/M NEUTRAL LOCK
This prevents the forklift from running while the operator is not in
the driver seat.
Forklift speed
T/M T/M interlock
Operator 4 km/h (2 MPH) 4 km/h (2 MPH) lock indicator light
or less or more
Seated －－ × ×
Unseated ○ ○ ○ Blinking
NOTE:
• Once the T/M interlock is activated, the driver must first set the
shift lever to the neutral position to release the interlock.
• 3-second delay is implemented for detection of unseated status.
Input Output
Seat switch T/M interlock indicator light (CAN data)
T/M forward solenoid
Speed sensor
T/M backward solenoid
WARNING LIGHT CONTROL

This lights up the following warning lights in the meter according to
the signals from the respective sensors.
• System warning
• Seat belt warning
• Radiator coolant level warning
• Air cleaner clogging warning
• Torque converter fluid temp.
Input Output
Seat belt switch
Radiator coolant level detection switch
Warning light signals (CAN data)
Air cleaner clogging detection switch
Torque converter fluid temp. switch
VC-8

TILT LEVELING
When forward tilt is commanded while the tilt leveling switch is ON, the tilt operation automatically stops as soon as
the fork is held at a level position.
Tilt leveling switch Fork level
Forklfit
Mast angle Set level or Tilt operation
condition ON OFF Set level or less
more
○ － ○ － Stops at a level position
○ － Automatically stops in the － ○ Stops when switch is pressed.
Unladen ○ － horizontal fork position. ○ －
Normal operation
○ －－ ○
－ ○ No tilt leveling
○ － • No automatic forward stop to ○ －
○ － horizontal － ○
Loaded • No movement when turning Normal operation
○ － ○ －
on the tilt-horizontal switch
○ －－ ○
• No tilt leveling is performed in backward tilting.
• When the fork is loaded, the tilt operation is stopped as soon as the tilt leveling switch is pressed.
• Once the tilt leveling is activated, the operator cannot perform further tilt operations unless the tilt leveling switch
and tilt operation lever are restored.
NOTE:
• The neutral level for the tilt angle sensor must be adjusted individually for each forklift. (To absorb any variants in
sensor mounting and mast differences.) With a completed forklift, hold the mast upright (with the fork held at a
level position) and register the tilt angle sensor value at that time in VCM.
• The weight pressure for the Hydraulic pressure sensor must be adjusted individually for each forklift. (To absorb
mast differences.)
With a completed forklift, hold the mast upright and raising to the top and register the hydraulic pressure sensor
valve at that time in VCM.
MC model
Input Output
Tilt leveling switch
Tilt angle sensor
C/V tilt lock solenoid
Hydraulic pressure sensor
Tilt operation detection switch
FC model
Input Output
Tilt leveling switch
Tilt angle sensor C/V proportional solenoid valve, tilt
Hydraulic pressure sensor
VC-9
THROTTLE POSITION CHANGEOVER CONTROL

The changeover switch in the instrument panel allows changeover of
the throttle sensitivity.
Changeover conditions
Changeover
Driving Stopping Remarks
operation
Power to eco × ○
Switchable only when acceleration
Eco to power × ○ pedal is released.
NOTE:
The WOT position is the same in both the power mode and eco
mode. Therefore, this control is only effective for smaller throttle
openings.
MAXIMUM SPEED CHANGEOVER CONTROL

The changeover switch in the instrument panel allows selection of
two forklift speed limits.
The two speed limits available now are 20 km/h (12 MPH) and 10
km/h (6 MPH).
CAUTION:
Do not change the maximum speed when the forklift is running.
Doing so could cause the load to shift.
VC-10
VCM SETTING
VCM Setting
VCM SETTING
NECESSARY RE-SETTING ITEMS

When the VCM, wheel angle sensor, or tilt angle sensor is replaced,
the following set items must be reset by using a meter panel.
Neutral Hydraulic
Neutral
level of pressure
level of tilt
Replaced part Specification wheel sensor
angle
angle level when
sensor
sensor unloaded
VCM ○ ○ △ △
Wheel angle sensor － ○ －－
Fork, mast －－ △ △
NOTE:
○ : Setting required
△ : Setting required for vehicles with Tilt leveling switch (option)
- : No need for setting
VC-11
COMBINATION METER
Combination Meter Arrangement

COMBINATION METER
① Multipurpose warning light ⑤ Charge warning light ⑩ Water temp. gauge (top center of LCD)
② Engine check light (gasoline engine forklifts ⑥ Parking brake warning light ⑪ Fuel gauge (bottom center of LCD)
only)
⑦ Seat belt warning light ⑫ Operation buttons
③ Glow pilot light (diesel engine forklifts only) ⑧ Liquid Crystal Display (LCD) ⑬ Time (right side of LCD)
④ Oil pressure warning light ⑨ Selector lever position (left side of LCD)
NOTE:
• In place of the time, the date or hour meter may be displayed.
• While driving, this display changes to the speedometer when the
forklift speed is 4 km/h (2 MPH) or higher.
• This display also indicates the inspection timing, malfunctions and
warnings.
CAUTION:
The display time and date will be reset if the battery cable is
disconnected or the battery is replaced. If the display has been
reset, set the time and date again.
VC-12
COMBINATION METER
Changing Meter Display (Normal mode)
CAUTION:
• The display time and date will be reset if the battery cable is
disconnected or the battery is replaced. If the display has
been reset, set the time and date again.
• The display screen cannot switch when the trouble display
screen or some display screens of the mast interlock
warning, the remaining LPG warning or the torque converter
fluid temperature warning is displayed.
NOTE:
For the changes market with an (*), refer to page VC-38.
Combination Meter Explanation Description
METER ILLUMINATION
An illumination light is provided for meters to ensure visibility at
night.
OPERATION BUTTONS
Use these buttons to change the display, make settings (time and
date) and enter the password.
VC-13
COMBINATION METER
Clock
CAUTION:
The time and date will be reset if the battery cable is
disconnected (for example, when the battery is replaced). Set
the time and date again.
When the ignition switch is turned on, the start display appears,
followed by the normal display (clock display).
NOTE:
Press the buttons to change the display to the date or hour meter.
SETTING TIME
NOTE:
• Press the button to change from hours  minutes 
confirmed.
• Press both the and buttons at the same time to return to
the previous display.
• Press the button to change the number up.
• Press the button to change the number down.
VC-14
COMBINATION METER
Clock (Cont’d)
DATE
CAUTION:
The time and date will be reset if the battery cable is
disconnected (for example, when the battery is replaced). Set
the time and date again.
Press the button on the normal display (clock display) to change
from the time display to the date display. Press again to return to
the normal display.
SETTING DATE
NOTE:
• Press the button to change the setting item from year 
month  day  hour  minute  confirmed.
• Press both the and buttons at the same time to return to
the previous setting item.
• Press the button to change the number up.
• Press the button to change the number down.
VC-15
COMBINATION METER
Clock (Cont’d)
HOUR METER
The buttons can be used to change from the normal display (clock
display) to the hour meter display.
The hour meter ordinarily displays the total ignition time that the
ignition is on, however it is possible to change the display to the total
engine operating time.
To change the hour meter totaling pattern, refer to page VC-39 Item:
B2-04 (upper).
Water Temp. Gauge

Indicates the current water temperature in levels 0 - 4. When level 2
is indicated, the coolant temperature is correct. When the indication
reaches level 4, the display begins to blink, and the multipurpose
warning light illuminates to inform the operator of the high water
temperature.
CAUTION:
• If level 4 is indicated, stop the forklift and allow the engine to
cool while idling. After the engine has sufficiently cooled
down, turn the engine off, and check the coolant level and
fan belt deflection.
Note to the operator:
• All ECCS forklifts in North America have a creep home
feature that will reduce engine RPMs if the coolant
temperature remains near the “H” position.
VC-16
COMBINATION METER
Fuel Gauge
Indicates the current fuel level in levels 0 - 5.
When level 5 is indicated, the fuel tank is full.
When the indication reaches level 0, the display begins to blink, and
the multipurpose warning light illuminates to inform the operator of
the nearly empty fuel tank. The fuel tank is nearly empty. Add fuel
immediately.
NOTE:
• If the forklift is an LPG - gasoline dual fuel forklift, the fuel gauge
will not work when the forklift is operated with LPG.
• When operating the forklift with LPG, check from time to time to
be sure that the LPG level warning light is not lit and that the LPG
level alarm is not on.
• To check the remaining amount of LPG, use the fuel gauge on the
LPG cylinder.
VC-17
COMBINATION METER
Forward-reverse (F/R) Lever Position
When the selector lever is in the “F” position, the display appears as
shown here.
When the selector lever is in the “N” position, the display appears as
shown here.
When the selector lever is in the “R” position, the display appears
as shown here.
• When the selector lever is in the “F” or “R” position and the
operator is not seated on the operator’s seat, the display blinks.
Sit on the operator’s seat and shift the selector lever to Neutral
(N), then shift it again to Forward (F) or Reverse (R) in order to
drive.
• When there is an error in the selector lever signal, the display
blinks.
Warning Lights
Following is an explanation of the meaning and method of correction
when a warning light illuminates.
MULTIPURPOSE WARNING LIGHT

This warning illuminates when one of the LCD warning symbols
illuminates. It also illuminates when the water temperature is high or
the fuel level is low. If this light illuminates during operation, stop
operation immediately, report to the person having management
duties and take necessary measures.
MALFUNCTION INDICATOR LIGHT

(GASOLINE/LPG ENGINE FORKLIFTS ONLY)
This warning illuminates when there is malfunction with an engine
sensor or air-fuel ratio control.
VC-18
COMBINATION METER
Warning Lights (Cont’d)

GLOW PILOT LIGHT
(DIESEL ENGINE FORKLIFTS ONLY)
This warning light illuminates when the ignition switch is turned on,
and it turns off when glow plug preheating is completed.
CAUTION:
If the light remains illuminated after the glow plugs are
preheated, this indicates a malfunction in the glow system.
OIL PRESSURE WARNING LIGHT

This warning illuminates when the oil pressure is low (approx. 0.2
bar for more than 5 seconds). For ECM models the engine rpm is
reduced to 1600 rpm.
CAUTION:
If the light illuminates under ordinary operating conditions,
stop the engine immediately and check the engine lubrication
system.
CHARGE WARNING LIGHT

This warning illuminates when there is a malfunction with the charge
system.
CAUTION:
If the light illuminates or flickers occasionally during normal
operating conditions, the alternator and electrical system
should be checked.
PARKING BRAKE WARNING LIGHT

This warning illuminates when the parking brake lever has been
pulled.
SEAT BELT WARNING LIGHT

This warning illuminates when the seat belt is not fastened.
LCD Warning Symbols

When a forklift warning occurs, a warning symbol and the
multipurpose warning light illuminate. Following is an explanation of
the meaning and method of correction when a warning symbol
illuminates.
MAST INTERLOCK WARNING

This warning illuminates when the ignition switch is turned on and
the operator is not seated on the seat. Loading operation is
prohibited at this time. Loading becomes possible when the operator
is seated on the seat.
VC-19
COMBINATION METER
Warning Lights (Cont’d)

LPG LEVEL WARNING/LPG RACK LOCK
WARNING (LPG AND DUAL FORKLIFTS ONLY)
This warning illuminates when the LPG level is low or when the LPG
remainig time has passed (in case this function is activated. See
function: LPG remaining time management). Replace the LPG fuel
cylinder before the fuel (LPG) runs out. This warning also illuminates
when the LPG rack lock is not securely set. (In this case, the warning
buzzer also sounds.)
CAUTION:
• For LPG tank mount bracket & low LPG fuel: the light is
illuminated when the key is turned on. If the light remains on
and the warning buzzer sounds with the key on or after the
engine is started, the LPG tank mounting bracket (either
swing out or swing down type) is not secure (latched). Turn
off the engine, set the parking brake and then check the tank
mounting bracket and latch correctly fixed.
• The LPG tank is out of or nearly out of fuel. Have LPG
cylinder tank replaced immediately.
TORQUE CONVERTER FLUID TEMP. WARNING

This warning illuminates when the transmission temperature switch
is activated, detecting transmission fluid temperature over 122°C.
For ECM models, the engine rpm is reduced to 1600 rpm. If this
warning symbol illuminates, move the forklift to a safe location and
allow it to idle in order to lower the fluid temperature. When
the fluid temperature has returned to normal, the warning turns
off.
NOTE:
Check the level of automatic transmission fluid.
RADIATOR LEVEL WARNING
This warning illuminates when the engine coolant level is low. Add
coolant.
CAUTION:
Continuing to drive while the light is illuminated may lead to
overheating of the engine.
AIR CLEANER WARNING

This warning illuminates when the air cleaner has become clogged. If
this warning symbol illuminates, promptly clean or replace the air
cleaner.
FUEL FILTER WARNING (FOR DIESEL ENGINE

FORKLIFTS)
This warning illuminates when the fuel filter has become full with water.
If this warning symbol illuminates, promptly drain the water from the fuel
filter.
CAUTION:
Continuing to drive while the light is illuminated may lead to a
reduction in the engine output or engine damage.
VC-20
COMBINATION METER
Malfunction Code
When controller malfunction occurs, an error code is displayed.
Press a button while the error code is displayed in order to display
the cause of the malfunction.
Refer to page VC-42 for the list of error code.
Inspection Timing
When the time for regular inspection approaches, this warning
illuminates for 15 seconds after the ignition switch is turned on. This
does not affect driving.
Refer to page VC-40 for the setting method.
Driver Recognition Mode

Registering a password can restrict the drivers of the forklift.
You can register a password for up to 5 persons (A to E).
Refer to page VC-22 for the setting method.
VC-21
COMBINATION METER
Manager Mode
Manager mode can be used by the manager to check and reset the
operating time for each operator, and to change passwords.
NOTE:
The manager must not disclose to the operators the password
required to enter manager mode.
VC-22
COMBINATION METER
Manager Mode (Cont’d)

SETTING ITEM (MANAGER MODE)
This section explains what setting can be changed or browsed by operating the button in each display screen of the
manager mode. For each operation procedure, refer to “METHOD OF CHANGE SETTING VALUE” on the next
page.
Item Indication Setting value Explanation
PASS ENTRY ON/OFF Enable/disable the operator password entry function.
A0-01 After an operator has entered the password, then it will not be necessary for the same
ENTRY TIME 00h~24h
operator to enter the password again for the amount of time set here.
PASS A **** (0~9) Change password “A” for the operator password entry function.
A0-02
PASS B **** (0~9) Change password “B” for the operator password entry function.
PASS C **** (0~9) Change password “C” for the operator password entry function.
A0-03
PASS D **** (0~9) Change password “D” for the operator password entry function.
PASS E **** (0~9) Change password “E” for the operator password entry function.
A0-04
PASS MANAGER **** (0~9) Change the manager mode password.
A*****.* C*****.* – Display each key hours when passwords “A” - “D” are used.
B1-01
B*****.* D*****.* –
Display each key hours when passwords “E” are used.
B1-02 E*****.* –
B2 MANAGE RESET NO/YES Reset ALL hours of passwords “A” - “E”.
CAUTION:
Each password before shipment is shown as follows. Please
change all set values of passwords after using to prevent
leaking of the passwords.
Indication Password
PASS A 1234 (& 8653)
PASS B 2345 (& 8653)
PASS C 3456 (& 8653)
PASS D 4567 (& 8653)
PASS E 5678 (& 8653)
PASS MANAGER 8653 (& 8653)
VC-23
COMBINATION METER

METHOD OF CHANGE SETTING VALUE
(*1):Change the operator password input (*4):Change the password for operator “B” (*7):Change the password for operator “E”
function OFF  ON. 2222  3344. 5555  6677.
(*2):Change the password entry OFF time (*5):Change the password for operator “C” (*8):Change the password for manager 6666
12h  24h. 3333  4455.  7788.
(*3):Change the password for operator “A” (*6):Change the password for operator “D”
1111  2233. 4444  5566.
NOTE:
To change the value, refer to “Input procedure of number”.
VC-24
COMBINATION METER
(*1): The operating time of each operator can be seen.

(Example)
Operating time of “A”: 10000.0 hours
Operating time of “B”: 20000.0 hours
Operating time of “C”: 30000.0 hours
Operating time of “D”: 40000.0 hours
Operating time of “E”: 50000.0 hours
CAUTION:
The operating time of each operator cannot be changed.
Only reset is possible.
(*2): The operating time of each operator can be reset.

Select “NO” on the display screen: Reset is not performed
Select “YES” on the display screen: Reset is performed
CAUTION:
When performing the reset, the operating times of all operators
“A” to “E” are reset to 00000.0 hour. It is not possible to reset
only the operating time of a selected operator.
VC-25
COMBINATION METER

METHOD OF NUMERIC INPUT
Example) Change the number to “245” after changing “555” to “285”,
and then set it.
(a) The number (hundreds digit) when flashing can be changed.
(b) The number changes to “2”.
(c) The flashing moves to the tens digit. The hundreds digit is set to
“2”.
(d) The number changes to “8”.
(e) The flashing moves to the ones digit. The tens digit is set to “8”.
(f) The flashing returns to the tens digit. The changing of the tens
digit becomes possible again.
(g) The number changes to “4”.
(h) The flashing moves to the ones digit. The tens digit is set to “4”.
(i) All numbers are changed, and then set to “245”.
LPG Remaining Time Management

With this function, the operator sets the time interval between LPG fuel
cylinder replacements. Then, when this time reaches zero, this function
illuminates the LPG level warning symbol and multipurpose warning
light to warn the operator of the need to replace the LPG fuel cylinder.
LPG remaining time management is recommended for the following
types of situations.
• The timing for replacement of the LPG fuel cylinder is
predetermined.
• The LPG level warning appears too early (or too late) on the
forklift that is currently being used.
CAUTION:
• When LPG remaining time management function is activated,
the LPG level warning system is disabled.
• Set a time with a sufficient amount of leeway.
• After replacing the LPG fuel cylinder, be sure to set the time
setting again. Otherwise, the time setting continues after
LPG fuel cylinder replacement, and this may result in the
LPG level warning symbol turning on at an unintended time.
• Please note that the count continues even if this system is
used with gasoline at DUAL fuel forklift.
VC-26
COMBINATION METER
LPG Remaining Time Management (Cont’d)
NOTE:
Following is an explanation of how to set the time setting for the first
time.
Example: Setting the time to 12.3 hours
NOTE:
LPG Remaining time management warning can only be switched
OFF via Fault Adjustment Diagnostic Mode,
=>Set => VCM=> B1-18 lower, LPG hour control On/Off
VC-27
COMBINATION METER
LPG Remaining Time Management (Cont’d)
NOTE:
Following is an explanation of how to set the time setting for the
second and later times.
Example 1: Changing the time from 12.3 hours (previous setting) to
6.5 hours.
Example 2: Using the same 12.3 hours setting (previous setting)
again
VC-28
COMBINATION METER
Fault Adjustment Diagnostic Mode
CAUTION:
• Do not inform others about this password because it may be
abused by being marketed. If an incorrect password is input
3 times, “PASS ERR” is displayed and the system cannot be
operated. Turn the key OFF, and then input the password
again.
• Perform Input/Output monitor and ACTIVE TEST under the
forklift operation status.
• <Precautions for Service/Inspection>
When removing the battery terminal, the clock display and
calendar display of the meter are reset. Always set the
clock and calendar again if the battery terminal is removed
for service/inspection, etc.
VC-29
COMBINATION METER
Monitor Mode
INPUT/OUTPUT MONITOR FUNCTION
CAUTION:
Check each item of input/output monitor under the engine start
(operation) status.
NOTE:
When checking each component, operate each component if
necessary.
VC-30
COMBINATION METER
Monitor Mode (Cont’d)

Item Display Item Remarks
A1-01 (Upper) **.* km/h Forklift speed sensor output
A1-01 (Lower) **.*** MPa Oil pressure sensor output OPT: tilt leveling system
A1-02 (Upper) **.* V Tilt angle sensor output OPT: tilt leveling system
A1-02 (Lower) **.* V Wheel angle sensor output OPT: Steering synchronizer
A1-03 (Upper) **.* % Acceleration sensor opening angle
A1-03 (Lower) ON/OFF Ignition start switch
A1-04 (Upper) ON/OFF Mast height switch OPT
A1-04 (Lower) ON/OFF Lift down switch
A1-05 (Upper) ON/OFF Tilt forward operation limit switch OPT: tilt leveling system
A1-05 (Lower) ON/OFF Speed limit switch OPT: Speed selector H/L
Power/eco switch Power: OFF/Eco: ON for
A1-06 (Upper) ON/OFF
ECM models only
A1-06 (Lower) ON/OFF Seat switch
A1-07 (Upper) ON/OFF Seat belt switch
A1-07 (Lower) ON/OFF Accelerator pedal switch
A1-08 (Upper) ON/OFF Tilt leveling switch OPT: tilt leveling system
A1-08 (Lower) ON/OFF Coolant low level switch
A1-09 (Upper) ON/OFF Air cleaner clogging switch
A1-09 (Lower) ON/OFF T/M warning switch
A1-10 (Upper) ON/OFF Inching switch
A1-10 (Lower) ON/OFF MFC1-4 change switch Finger tip control only
A1-11 (Upper) ON/OFF Engine auto start switch not equipped
A1-11 (Lower) ON/OFF FC emergency interception relay output Finger tip control only
A1-12 (Upper) ON/OFF Auto light relay output not equipped
A1-12 (Lower) ON/OFF Warning 1 buzzer output
A1-13 (Upper) ON/OFF Warning 2 buzzer output not equipped
A1-13 (Lower) ON/OFF Neutral signal output
A1-14 (Upper) ON/OFF Reserve output 1 Reserve
A1-14 (Lower) ON/OFF Starter drive relay output not equipped
A1-15 (Upper) ON/OFF Engine stop relay output not equipped
A1-15 (Lower) ON/OFF Glow plug drive relay
A1-16 (Upper) ON/OFF T/M forward solenoid operation
A1-16 (Lower) ON/OFF T/M forward 2nd solenoid operation 2nd speed ATM
A1-17 (Upper) ON/OFF T/M backward solenoid operation
A1-17 (Lower) **** mA T/M solenoid current
A1-18 (Upper) ON/OFF Power steering correction solenoid operation OPT: Steering synchronizer
A1-18 (Lower) **** mA Power steering correction solenoid current OPT: Steering synchronizer
A1-19 (Upper) ON/OFF Tilt lock solenoid operation OPT: tilt leveling system
A1-19 (Lower) **** mA Tilt lock solenoid current OPT: tilt leveling system
A1-20 (Upper) ON/OFF Lift lock solenoid operation
A1-20 (Lower) **** mA Lift lock solenoid current
VC-31
COMBINATION METER
CAUTION:
(operation) status.
NOTE:
necessary.
VC-32
COMBINATION METER

A1-21 (Upper) ON/OFF Unload/C1 solenoid operation C1 OPT: FC
A1-21 (Lower) **** mA Unload/C1 solenoid current C1 OPT: FC
A1-22 (Upper) ** % FC lift sensor opening angle OPT: FC
A1-22 (Lower) ON/OFF FC lift up switch operation OPT: FC
A1-23 (Upper) ON/OFF FC lift down switch operation OPT: FC
A1-23 (Lower) **** mA FC lift sensor current OPT: FC
A1-24 (Upper) ** % FC tilt sensor opening angle OPT: FC
A1-24 (Lower) ON/OFF FC tilt forward switch operation OPT: FC
A1-25 (Upper) ON/OFF FC tilt backward switch operation OPT: FC
A1-25 (Lower) **** mA FC tilt sensor current OPT: FC
A1-26 (Upper) ** % FC 3-spool sensor opening angle OPT: FC
A1-26 (Lower) ON/OFF FC 3-spool A side switch operation OPT: FC
A1-27 (Upper) ON/OFF FC 3-spool B side switch operation OPT: FC
A1-27 (Lower) **** mA FC 3-sensor current OPT: FC
A1-32 (Upper) ON/OFF Selector lever (F) FR lever “F” side: ON
A1-32 (Lower) ON/OFF Selector lever (N) FR lever “N” side: ON
A1-33 (Upper) ON/OFF Selector lever (R) FR lever “R” side: ON
A1-33 (Lower) ON/OFF Selector lever (2F) FR lever “2F” side: ON
A1-34 (Upper) **.* V DC battery voltage Battery voltage display
A1-34 (Lower) —
A2-01 (Upper) **** rpm Engine speed
A2-01 (Lower) ON/OFF Idle switch
A2-02 (Upper) ** % Throttle opening angle
A2-02 (Lower) ***** mV Battery voltage
A2-03 (Upper) ** % Accelerator pedal opening position
A2-03 (Lower) *** C Engine coolant temperature
A2-04 (Upper) *** s Injection pulse GAS
A2-04 (Lower) *** s Injection pulse LPG
A2-05 (Upper) ON/OFF Starter switch
A2-05 (Lower) ON/OFF Neutral switch
A2-06 (Upper) ON/OFF Electricity load switch
A2-06 (Lower) ON/OFF Brake switch
VC-33
COMBINATION METER
CAUTION:
(operation) status.
NOTE:
necessary.
VC-34
COMBINATION METER

A2-07 (Upper) ON/OFF Air conditioner switch
A2-07 (Lower) DONE/NOT Learned air-fuel ratio value clear
A2-08 (Upper) EXE/NOT Idle Air Volume Learning (Factory) Do not use
A2-08 (Lower) EXE/NOT Idle Air Volume Learning (Normal)
A2-09 (Upper) EXE/NOT Ignition timing adjustment
A2-09 (Lower) EXE/NOT Air-fuel ratio adjustment
A2-10 (Upper) EXE/NOT Power balance adjustment
A2-10 (Lower) EXE/NOT Fuel pressure clear
A2-11 (Upper) DONE/NOT Self-diagnosis result clear
A2-11 (Lower) *** mV Mass air flow sensor signal
A2-12 (Upper) *** % Charging efficiency GAS
A2-12 (Lower) *** % Charging efficiency LPG
A2-13 (Upper) 100% Air-fuel ratio (Gasoline) Limit: 75 to 125
A2-13 (Lower) 100% Air-fuel ratio (LPG) Limit: 75 to 125
A2-14 (Upper) ON/OFF Change fuel switch 1 signal
A2-14 (Lower) ON/OFF Change fuel switch 2 signal
A2-15 (Upper) GAS/LPG/NEU Fuel control
A2-15 (Lower) ON/OFF Mast high switch 1 signal OPT
A2-16 (Upper) ON/OFF Mast high switch 2 signal OPT
A2-16 (Lower) LEAN/RICH O2 sensor RICH/LEAN judgement signal
A2-17 (Upper) ON/OFF Fuel pump relay signal
A2-17 (Lower) ON/OFF LPG interception valve relay signal
A2-18 (Upper) ON/OFF Throttle relay signal
A2-18 (Lower) ON/OFF Heated oxygen sensor heater signal
A2-19 (Upper) DONE/NOT Fully-closed learning update empirical flag
A2-19 (Lower) DONE/NOT Idle Air Volume Learning (Factory/Normal) completion flag
A2-20 (Upper) ON/OFF CONSULT-II connecting flag
A2-20 (Lower) ** deg Ignition timing signal Limit: 0 to 10
A2-21 (Upper) **** mV Heated oxygen sensor output voltage signal
A2-21 (Lower) **C Intake air temperature sensor signal
A2-22 (Upper) *.** kPa LPG fuel pressure sensor signal
A2-22 (Lower) —
A3-01 (Upper) ON/OFF Parking brake switch
A3-01 (Lower) ON/OFF Brake oil low level
A3-02 (Upper) ON/OFF Engine oil pressure low level
A3-02 (Lower) ***C Engine coolant temperature
A3-03 (Upper) ***  Fuel level
A3-03 (Lower) ON/OFF Turn signal (right)
A3-04 (Upper) ON/OFF Turn signal (left)
A3-04 (Lower) ON/OFF Fuel warning switch
NOTE:
Ignition timing of input/output monitor can display negative value. It cannot be performed only for Active test.
VC-35
COMBINATION METER
Set Mode
CONTROLLER SETTING FUNCTION
CAUTION:
Perform the controller setting under key ON status. (Engine
stop status)
VC-36
COMBINATION METER
Set Mode (Cont’d)

Item Name of item Setting value Content
(Controller type)
MC: Mechanical valve
Controller type for MC/FC1/FC2/ FC1: Proportional solenoid valve (TWIN lever) / (Single function / 1-axis joystick)
B1-01 (Upper)
cargo control valve MFC FC2: Proportional solenoid valve (SINGLE lever) / (Double function / 2-axis joystick)
MFC: Proportional solenoid valve (Multifunction lever) / (both lift/tilt + 3rd/4th att. are
controller with double function joystick)
MTM/ATM/ (Transmission type)
B1-01 (Lower) Transmission type
2ATM MTM: Clutch ATM: 1st speed torque-converter 2ATM: 2nd speed torque converter
(Engine type)
ELEG.L: Electronically controlled gasoline/LPG
ELEG.L/
NELEG.L: Non-electronically controlled gasoline/LPG (Not specified)
NELEG.L/
ELEG: Electronically controlled gasoline (Not specified)
ELEG/NELEG/
NELEG: Non-electronically controlled gasoline (Not specified)
B1-02 (Upper) Engine type ELEL/NELEL/
ELEL: Electronically controlled LPG
D(QD32)/
NELEL: Non-electronically controlled LPG
D(S4Q2)/
D (QD32): Diesel (QD32)
D(TD42)
D (S4Q2): Diesel (S4Q2) (Not specified)
D (TD42): Diesel (TD42) (Not specified)
Cargo lever limit (Cargo lever limit switch setting for MC models)
B1-02 (Lower) OFF/ON
switch For 4/5 spool MC-models set on
Cargo control valve (Series number of control valve)
B1-03 (Upper) 2V/3V/4V/5V
series number 2V: 2 spools 3V: 3 spools 4V: 4 spools 5V: 5 spools *Used for FC control
(Load capacity [ton])
1t: Pneumatic 1t 2t: Pneumatic 2t 3-5t: Pneumatic
1t/2~3t/3~5t/
B1-03 (Lower) Load capacity (ton) 3-5t C1t: Cushion 1t (Not specified) C2-3t: Cushion 2-3t (Not
C1t/C2~3t
specified) 3t: Pneumatic 3t P1-2t: Pneumatic 2.0t at 1t SERIES
(Not specified) AUX: 1Dx ALL TRUCKS
ECM controller with/
B1-04 (Upper) ON/OFF with/without of ECM
without
DCM controller with/
B1-04 (Lower) ON/OFF with/without of DCM (Not specified)
without
B1-05 (Upper) Speed limiter ON/OFF Setting of maximum forklift speed control
B1-05 (Lower) Tilt leveling control ON/OFF Setting of tilt leveling control
B1-06 (Upper) Power eco control ON/OFF Setting of power/eco control
B1-06 (Lower) Auto stop/Auto start ON/OFF Setting of auto stop/start (option) (if set ON B1-20 will appear)
B1-07 (Upper) Loading capacity ON/OFF Setting of weight meter (not equipped)
B1-07 (Lower) Speed alarm ON/OFF Setting of speed alarm
B1-08 (Upper) Weight alarm ON/OFF Setting of weight alarm (not equipped)
B1-08 (Lower) Auto light control ON/OFF Setting of auto light control (not equipped)
(Setting of cylinder diameter) *Used for calculation of weight.
1t system: 45 mm (mast 2W), 65 mm (mast 2F, 3F), 50 mm (mast 3V)
B1-09 (Upper) Cylinder diameter ****mm 2-2.5t of 2t system: 50 mm (mast 2W), 70 mm (mast 2F, 3F), 54 mm (mast 3V)
3t of 2t system: 55 mm (mast 2W), 80 mm (mast 2F, 3F), 57 mm (mast 3V)
3.2t of 2t system: 60 mm (mast 2W), 90 mm (mast 2F, 3F), 65 mm (mast 3V)
B1-09 (Lower) Gear ratio ***.**dec (Setting of gear ratio) For the gear ratio list, refer to page VC-40.
Speed alarm setting
B1-10 (Upper) **.*km/h Setting of warning forklift speed for speed alarm (low speed)
value 1
Speed alarm setting
B1-10 (Lower) **.*km/h Setting of warning forklift speed for speed alarm (high speed)
value 2
Weight alarm setting
B1-11 (Upper) **.*t Warning weight of weight alarm
value
LO-Speed [out]
B1-11 (Lower) **.*km/h Forklift speed limit of maximum forklift speed control (high speed)
B1-12 (Upper) LI-Speed [in] **.*km/h Forklift speed limit of maximum forklift speed control (low speed)
Wheel angle center Voltage of wheel angle sensor in the straight-ahead position at knob position
B1-12 (Lower) **.*V
neutral correction control
NOTE:
Change the setting value: Press or .
Set the setting value: Press to decide the setting range.
VC-37
COMBINATION METER
Set Mode (Cont’d)
CAUTION:
Perform the controller setting under key ON status. (Engine
stop status)
VC-38
COMBINATION METER
Set Mode (Cont’d)

Item Name of item Setting value Content
Tilt angle sensor
B1-13 (Upper) **.*V Voltage of tilt angle sensor when setting the mast to vertical at tilt leveling control
neutral
Oil pressure value when setting the mast to vertical and when lifting it up again, used
B1-13 (Lower) Tare weight pressure **.***MPa
to calculate the weight
Auto light volume
B1-14 (Upper) ***Lx Setting of auto light control OFF level (Not specified)
setting value
Auto light hysteresis
B1-14 (Lower) ***Lx Setting of auto light control ON level (Not specified)
setting value
Speedometer display
B1-15 (Upper) km/h /MPH Setting of speedometer unit
switching
Weight display
B1-15 (Lower) kg/lb Setting of weight meter unit
switching
******(Maximum
Display of forklift chassis number
B1-16 (Upper) Chassis number 26-digit display)
(* The set value is only displayed. It cannot be changed.)
(Display only)
B1-16 (Lower) — —
B1-17 (Upper) Seat SW N.O/N.C Setting of seat switch N.O./N.C.
B1-17 (Lower) Seat belt SW N.O/N.C Setting of seat belt switch N.O./N.C.
**.** (Display
B1-18 (Upper) Software version Software version of VCM (Only displayed)
only)
B1-18 (Lower) LPG hour control ON/OFF Switch On/Off LPG remaining time management control
B1-19 (Upper) Battery voltage 12V/24V Setting of forklift battery voltage specification
JPN/ENG/GER/ (Setting of meter display language)
B1-19 (Lower) Display language FRE/ESP JPN: Japanese ENG: English GER: German FRE: French
B1-20 (Upper) Seat leaving time OFF-999sec Setting of drive of seat time, recommended not to set under 30 sec.
Setting of forklift not used time while idling, recommended not to set under 30
B1-20 (Lower) Non activity time OFF-999sec secs, and only for LPG truck with FTC.
(Setting of inspection period)

Service reminder OFF/1M/3M/ OFF: Reminder function OFF 1M: 1 month 2M: 2 months 3M: 3 months
B2-01 (Upper)
setting 6M/12M/MANU 6M: 6 months 12M: 12 months MANU: reminder function at manual for settings see
B2-01 and B2-02
HOUR/DATE/ HOUR: Hour meter DATE: Date FIRST: First-come
B2-01 (Lower) Reminder manual
FIRST (Used when the set value is MANU on the service reminder setting.)
B2-02 (Upper) Set time of hour meter *****.*h Set key hours when the next service is (when MANU service is selected).
B2-02 (Lower) Date (YY/MM/DD) **/**/** Used when the set value is MANU on the service reminder setting.
**.** (Display The IGN ON cumulative time of hour meter is displayed
B2-03 (Upper) Hour meter (IGN ON)
only) (It is only displayed and the setting cannot be changed.)
Hour meter (Engine **.** (Display The engine operation time of hour meter is displayed
B2-03 (Lower)
operation) only) (It is only displayed and the setting cannot be changed.)
(The customer set the hour meter that is displayed at normal use)
B2-04 (Upper) Hour meter display IGN/ENG
IGN: IGN ON cumulative time ENG: Engine operation time
Check and set the password for manager mode
B2-04 (Lower) Password (Manager) ****
(Check it when the user forgot the setting, etc.)
**.** (Display
B2-05 (Upper) MP software version Software version of MP (Only displayed)
only)
B2-05 (Lower) — —
NOTE:
Change the setting value: Press or .
Set the setting value: Press to decide the setting range.
VC-39
COMBINATION METER
Set Mode (Cont’d)

List of Gear Ratio
NOTE:
For the setting of B1-09 (Lower) “Gear ratio” in VCM setting, please
set the setting value according to the forklift condition by referring to
the following table.
Reduction Number of Gear ratio
Tire T/M Engine Remarks Tire
gear ratio cog pulse Hz 1 km/h
K/GK21 0.294 5.857 58 51.08
QD32 0.294 5.286 59 46.90
P1
K/GK21 Low noise 0.294 5.857 58 51.08
QD32 Low noise 0.294 5.286 58 46.10
ATM
K/GK25 0.335 5.857 59 45.61
P2
QD32 0.335 5.857 58 44.83
K/GK25 0.335 6.167 59 45.31
P3
QD32 0.335 6.167 58 44.55
Description service reminder function

When setting the service reminder function on the controller setting
(MP setting), “MAINTE PERIOD” is displayed as shown in the figure
so as to indicate to the user that the inspection period is near. (It
displays for 15 seconds at the time of each KEY ON.)
CAUTION:
• After the inspection, reset the service reminder function
(clear the display of “MAINTE PERIOD”) and return it to the
customer.
• The display time and date will be reset if the battery cable is
disconnected or the battery is replaced. If the display has
been reset, set the time and date again.
B2-01 (Upper) B2-01 (Lower)

“MAINTE PERIOD” display time
Service reminder function Reminder manual
OFF — Not displayed.
1M — It is displayed from 25 days after the set day.
3M — It is displayed from 2 months and 20 days after the set day.
6M — It is displayed from 5 months after the set day.
12M — It is displayed from 11 months after the set day.
It is displayed when the hour meter reaches B2-02 (Upper) “Set time of hour
HOUR
meter”. The key hours are used for calculation.
It is displayed when the calendar reaches B2-02 (Lower) “Date (YY/MM/
DATE
MANU DD)”.
It is displayed when the hour meter reaches B2-02 (Upper) “Set time of hour
FIRST meter” or when the calendar reaches B2-02 (Lower) “Date (YY/MM/DD)”.
(*Please set both.)
VC-40
COMBINATION METER
Set Mode (Cont’d)

DIAGNOSIS HISTORY
CAUTION:
Confirm the diagnosis history in the state of ignition switch
turn ON.
VC-41
TABLE OF DIAGNOSIS TROUBLE CODE (DTC)
Fault Adjustment Diagnostic Mode (Cont’d)

Error
Item Detection condition Action
code
- - Normal Normal
E-** ECM error codes See EC-section of K/GK-engine service manual See EC-section of K/GK-engine service manual
EEPROM check sum, Control module stops operation (only
F-01 VCM memory check
Controller type not matched executes CAN communications)
F-02 Battery voltage incorrect Has been 8V or less or 17V or more for 1,000 ms Turns OFF all solenoid outputs (Restorable)
VCM communication
F-03 No CAN communication available for 2 seconds from VCM Only issues diagnosis message (Restorable)
malfunction
ECM communication Operates with ECM data set to default
F-04 No CAN communication available for 2 seconds from ECM
malfunction (Restorable)
DCM communication Operates with DCM data set to default
F-05 No CAN communication available for 2 seconds from DCM
malfunction (Restorable)
Meter panel
No CAN communication available for 2 seconds from meter Operates with meter panel data set to default
F-07 communication
panel (Restorable)
malfunction
Lift lever neutral incorrect Turns OFF Lift solenoid (FC) output
F-10 Has been outside (2.3V to 2.7V) at Key on.
(FC) (Restorable)
Tilt lever neutral incorrect Turns OFF Tilt solenoid (FC) output
(FC) (Restorable)
Attach 1 lever neutral Turns OFF Attach 1 solenoid (FC) output
incorrect (FC) (Restorable)
• Duplicated shift lever inputs continued for 2 sec Turns OFF T/M forward/backward solenoid
F-16 Shift lever malfunction
• ALL off shift lever inputs continued for 2 sec outputs (Restorable)
Only issues diagnosis message. Sends 0
Forklift speed outside range (0 to 30 km/h) continued for 400
F-17 Forklift speed km/h forklift speed signal to other control
ms
modules (Restartable)
• Has been outside (0.2V to 4.8V) for 400 ms. • Turns OFF Lift solenoid (FC) output
F-20 Lift lever incorrect (FC)
• Sig1+Sig2 has been outside (5V8%) for 400 ms. • Before 400 ms, control neutral.
• Has been outside (0.2V to 4.8V) for 400 ms. • Turns OFF Tilt solenoid (FC) output
F-22 Tilt lever incorrect (FC)
• Sig1+Sig2 has been outside (5V8%) for 400 ms. • Before 400 ms, control neutral.
Attach1 lever incorrect • Has been outside (0.2V to 4.8V) for 400 ms. • Turns OFF Attach1 solenoid (FC) output
F-24
(FC) • Sig1+Sig2 has been outside (5V8%) for 400 ms • Before 400 ms, control neutral.
F-26
F-28
• Has been outside (0.2V to 4.8V) for 400 ms •not change T/M solenoid at Auto-2ATM
F-30 Accel sensor incorrect
• “Sig1” - “Sig2 x 2” has been outside (0V0.3V) for 400 ms. •Before 400 ms, control as not stepping on.
Input signal of 0.1V or less continued for 400 ms Stops displaying cargo weight, avoids tilting
F-32 Hydraulic pressure sensor
Input signal of 4.9V or more continued for 400 ms when tilt leveling is ON
Input signal of 4.9V or more continued for 400 ms Stops displaying speedometer, interlocks
F-34 Forklift speed sensor
Input signal of 1.3V or less continued for 400 ms T/M, ignores forklift speed in creep control
Input signal of 0.27V (10-deg.) or less continued for 400 ms
F-36 Tire angle sensor Avoids knob position correction
Input signal of 4.72V (170-deg.) or less continued for 400 ms
Input signal of 0.1V or less continued for 400 ms
F-38 Tilt angle sensor Avoids tilting when tilt leveling is ON
Input signal of 4.9V or more continued for 400 ms
Only wheel steering angle sensor signal has been changing
F-40 Steering Avoids knob position correction
for 2 seconds, or steering angle sensor input is unusual
• Current value of 50 mA or less continued for 1,000 ms
F-50 Lift up solenoid (FC) Turns OFF Lift up solenoid (FC) output
• Current value of 1.5A or more continued for 1,000 ms
F-52 Lift down solenoid (FC) Turns OFF Lift down solenoid (FC) output
Leakage from Lift solenoid Current value of 180 mA or more continued for 1,000 ms at
F-54 Turns OFF all solenoid (FC) output
(FC) controlling OFF solenoid.
VC-42
FAULT ADJUSTMENT DIAGNOSTIC MODE (CONT’D)

TABLE OF DTC (CONT'D)
Error
Item Detection condition Action
code
F-55 Tilt fwd solenoid (FC) Turns OFF Tilt fwd solenoid (FC) output
F-57 Tilt bwd solenoid (FC) Turns OFF Tilt bwd solenoid (FC)
Leakage from Tilt solenoid Current value of 180 mA or more continued for 1,000 ms at
(FC) controlling OFF solenoid.
F-60 Attach 1 A solenoid (FC) Turns OFF Attach 1 A solenoid (FC) output
F-62 Attach 1 B solenoid (FC) Turns OFF Attach 1 B solenoid (FC) output
Leakage from Attach 1 Current value of 180 mA or more continued for 1,000 ms at
solenoid (FC) controlling OFF solenoid.
Unload (MC)/C1 (FC) • Current value of 160 mA or less continued for 180 ms Turns OFF Unload (MC)/C1 (FC) solenoid
F-75
solenoid • Current value of 2.4A or more continued for 200 ms (FC) output
Leakage from Unload Current value of 180 mA or more continued for 600 ms at
(MC)/C1 (FC) solenoid controlling OFF solenoid.
• Current value of 160 mA or less continued for 180 ms
F-77 Lift lock valve Turns OFF lift lock valve output
• Current value of 3.4A or more continued for 200 ms
Leakage from Lift lock Current value of 180 mA or more continued for 600 ms while
F-79 Turns OFF Lift lock solenoid output
solenoid output signal is off
Power steering correction • Current value of 160 mA or less continued for 400 ms Turns OFF power steering correction
F-80
solenoid • Current value of 3.54A or more continued for 200 ms solenoid output
Current value of 160 mA or less continued for 1,800 ms
F-82 Tilt lock valve Current value of 2.88A or more (w/o knob position correction) Turns OFF tilt lock valve output
continued for 200 ms
Leakage from Tilt lock Current value of 180 mA or more continued for 600 ms at
F-83 Turns OFF Tilt lock solenoid output
solenoid controlling OFF solenoid.
Leakage from Power
Current value of 180 mA or more continued for 600 ms while
F-84 steering correction Turns OFF Tilt lock solenoid output
output signal is off
solenoid
F-85 T/M forward solenoid Turns OFF T/M forward solenoid output
Current value of 3.8A or more continued for 200 ms
F-86 T/M backward solenoid Turns OFF T/M backward solenoid output
F-87 T/M forward 2 solenoid Turns OFF T/M forward 2 solenoid output
Leakage from T/M Current value of 280 mA or more continued for 600 ms while Turns OFF T/M forward/backward solenoid
F-89
solenoid output signal is off outputs
P-03 VCM Communication error No CAN communication available for 2 seconds from VCM Error code displayed
P-04 ECM communication error No CAN communication available for 2 seconds from ECM ECM is set in fail safe function
P-05 DCM Communication error No CAN communication available for 2 seconds from DCM DCM is set in fail safe function
P-07 MP communication error No CAN communication available for 2 seconds from MP Error code is displayed
VC-43

DISPLAY OF DTC FOR VCM
VC-44

DISPLAY OF DTC FOR VCM (CONT’D)
VC-45

DISPLAY OF DTC FOR ECM
VC-46

DISPLAY OF DTC FOR METER PANEL
DESCRIPTION OF DISPLAY FOR DIAGNOSIS

HISTORY
VC-47
COMBINATION METER
ACTIVE TEST MODE

COMBINATION METER
NOTE:
*1: The display screen switches to “CAUTION TO MOVE” that warns
that the forklift may move suddenly. Select YES. ACTIVE TEST can
be performed by pressing .
VC-48
COMBINATION METER
Active Test Mode (Cont’d)

Item Setting value Name of item Remarks
D1-01 (Upper) ON/OFF Auto light relay output

D1-01 (Lower) ON/OFF Warning buzzer output 1
D1-02 (Upper) ON/OFF Warning buzzer output 2
D1-02 (Lower) ON/OFF Neutral signal output
D1-03 (Upper) ON/OFF Engine stop relay output
D1-03 (Lower) ON/OFF FC emergency interception relay output OPT: FC
D1-04 (Upper) ON/OFF Reserve (Output 1)
D1-04 (Lower) ON/OFF Starter drive relay output
NOTE:
• For ACTIVE TEST of VCM and MP, Change the display OFF 
ON by pressing or , and then perform ACTIVE TEST by
pressing . When completing ACTIVE TEST, the system is
changed to the next item.
• For ACTIVE TEST of ECM, refer to page VC-54.
• Always perform ACTIVE TEST under the engine start (operating)
status.
VC-49
COMBINATION METER
VC-50
COMBINATION METER

D1-05 (Upper) ON/OFF Glow plug drive relay output

D1-05 (Lower) ON/OFF Unload/C1 solenoid MC & FC
D1-06 (Upper) ON/OFF Lift lock valve solenoid
D1-06 (Lower) ON/OFF Tilt lock valve solenoid OPT: tilt leveling system
D1-07 (Upper) ON/OFF Power steering correction solenoid OPT: steering synchronizer
D1-07 (Lower) ON/OFF T/M forward solenoid
D1-08 (Upper) ON/OFF T/M backward solenoid
D1-08 (Lower) ON/OFF T/M forward (2nd) solenoid
D1-09 (Upper) ON/OFF FC Lift (up) solenoid OPT: FC
D1-09 (Lower) ON/OFF FC Lift (down) solenoid OPT: FC
D1-10 (Upper) ON/OFF FC Tilt (forward) solenoid OPT: FC
D1-10 (Lower) ON/OFF FC Tilt (backward) solenoid OPT: FC
D1-11 (Upper) ON/OFF FC Attach 1 (A) solenoid OPT: FC
D1-11 (Lower) ON/OFF FC Attach 1 (B) solenoid OPT: FC
NOTE:
status.
VC-51
COMBINATION METER
NOTE:
*2: For ECM ACTIVE TEST, refer to “ECM Active Test”.
VC-52
COMBINATION METER

D1-14 (Upper) ON/OFF Reserve (D/A1)

D1-14 (Lower) ON/OFF Reserve (D/A2)
D2-01 (Upper) ON/OFF Idle Air Volume (Normal) (1)
D2-01 (Lower) ON/OFF Air-fuel ratio adjustment (2) Proper value: 100
D2-02 (Upper) ON/OFF Air-fuel ratio clear (3)
D2-02 (Lower) ON/OFF Ignition timing adjustment (4) Proper value: 0
D2-03 (Upper) ON/OFF Fuel pressure clear (5)
D2-03 (Lower) ON/OFF Power balance (6) Not for LPG trucks
D2-04 (Upper) ON/OFF Self-diagnosis clear

D2-04 (Lower) — —
D3-01 (Upper) ON/OFF Turn signal relay
D3-01 (Lower) — —
NOTE:
status.
(1) Idle Air Volume Learning (4) Ignition timing adjustment

To learn ECM the required air flow for idle rpm → Perform Function of ignition timing adjust → To manually adjust
this test when ECM / Throttle positioner is replaced or when ignition timing temporary, overriding Oxygen sensor info →
the engine runs improperly. ECM return to normal function using oxygen sensor when
Standard Idle speed: 700±50 rpm engine is restarted.
Ignition timing: 0±2/700°( BTDC/rpm) Proper value: 0°
Adjustment range: 0 - 10°
(2) Air-fuel ratio adjustment (5) Fuel pressure clear

To manually adjust Fuel/Air ratio temporary, overriding Function of Fuel pressure release → To manually close/
Oxygen sensor Info. → ECM return to normal function using deactivate Fuel pump relay / LPG interception valve so
oxygen sensor when engine is restarted. eventually engine will stall.
Proper value: 100%
Adjustment range: 75 - 125% (6) Power balance
When the engine does not run smoothly or the misfires
occur in some cylinders, forcibly stop each cylinder in
(3) Air-fuel ratio clear “Power balance”, and then check which cylinder has the
To reset Air/Fuel ratio to default value → ECM will start to
malfunction (Not for LPG trucks).
readjust the Air/Fuel ratio value using the oxygen sensor and
learn this value to its memory → Perform this function when
the engine runs bad or new major components are installed. (7) Self-diagnosis cl
Function of Self-diagnostic results clear → To reset Error
log of ECM
VC-53
COMBINATION METER
ECM Active Test

IDLE AIR VOLUME LEARNING:
PERFORM (CANCEL) IDLE AIR VOLUME LEARNING
(NORMAL).
VC-54
COMBINATION METER
ECM Active Test (Cont’d)

AIR-FUEL RATIO ADJUSTMENT:
CHANGE THE ADJUSTMENT VALUE FROM 85 DEC
TO 100 DEC, AND THEN ADJUST AIR-FUEL RATIO.
PRECAUTIONS FOR ECM ACTIVE TEST

Air-fuel ratio adjustment
For performing the test of air-fuel ratio adjustment, please refer to
Test item Proper value Adjustment range
Air-fuel ratio adjustment 100 75-125
Air-fuel ratio adjustment

First, the current adjustment value is displayed. Set the adjustment
value to “100” (Proper value), and then perform the adjustment once.
Check the adjustment value again. Confirm that the adjustment
value is changed to “100”. If the adjustment value does not change,
set the adjustment value to “100” and perform the adjustment.
Reference: Whether the air-fuel ratio is adjusted or not can be
checked by performing the adjustment with the adjustment value
between 75 and 125 since second times. (Please note that the
proper test may not be performed when performing the adjustment
without the adjustment range “75 - 125”.)
VC-55
COMBINATION METER

LEARNED AIR-FUEL RATIO VALUE:
CLEAR (CANCEL) LEARNED AIR-FUEL RATIO
VALUE.
VC-56
COMBINATION METER

IGNITION TIMING ADJUSTMENT:
CHANGE THE ADJUSTMENT VALUE FROM 5 DEC
TO 0 DEC, AND THEN ADJUST IGNITION TIMING.

Ignition timing adjustment
For performing the test of ignition timing adjustment, please refer to
Test item Proper value Adjustment range
Ignition timing adjustment 0 0-10
Ignition timing adjustment

First, the current ignition timing is displayed. Set the adjustment
value to “0” (Proper value), and then perform the adjustment once.
Whether the ignition timing is adjusted or not can be checked by
performing the adjustment with the adjustment value between 0 and
10 since second times. (Please note that the proper test may not be
performed when performing the adjustment without the adjustment
range “0 - 10”.)
When the ignition timing is a minus, “99” is displayed.
VC-57
COMBINATION METER

FUEL PRESSURE CLEAR:
PERFORM (CANCEL) FUEL PRESSURE CLEAR.
WARNING:
When the engine is stopped, the residual fuel pressure remains
in the fuel piping. Always perform this procedure to release any
residual fuel pressure when disconnecting the fuel piping.
VC-58
COMBINATION METER

POWER BALANCE:
STOP NO. 3 CYLINDER IN POWER BALANCE.
CAUTION:
LPG model does not have the power balance function. Do not
perform this adjustment.
If it is performed, the screen will stop. Please cancel the
function by turning the ignition key OFF.
The engine cylinder status is shown by O or X as in the above figure.
These symbols mean No. 1 cylinder, No. 2 cylinder, No. 3 cylinder,
No. 4 cylinder, No. 5 cylinder and No. 6 cylinder from the left. (*
Since this forklift has only 4 cylinders, No. 5 cylinder and No. 6
cylinder are not used for ACTIVE TEST even though these are
displayed.)
The cylinder stops by changing the set values of each cylinder from
O to X and performing the adjustment.
VC-59
COMBINATION METER

SELF-DIAGNOSIS CLEAR: PERFORM (CANCEL)
SELF-DIAGNOSIS.
VC-60
COMBINATION METER
Neutral Level Adjustment of Tilt Angle

Sensor
When replace the tilt angle sensor, perform the neutral level
adjustment for the new sensor.
To modify the current setting, the following procedure will be
executed.
SETTING NEUTRAL LEVEL OF TILT ANGLE

SENSOR (NOT SPECIFIED)
1. Sit on the seat (the seat switch turns on) and operate the tilt so
that the fork is held at a level position.
2. Check the value of “TILT ANG” (A1-02).
3. “TILT ANG” is set to the value of “TILT ANG. N” (B1-13).

Setting procedure, refer to page VC-38.
SETTING HYDRAULIC SENSOR LEVEL (IF THERE IS

TILT LEVELING STOP FUNCTION, IT IS
NECESSARY.)
1. Sit in the seat (the seat switch turns on) and raise the fork fully
with no load.
Lower the forks till approximate 10 cm above the ground. Make
sure that the mast is in vertical position.
VC-61
COMBINATION METER
2. Check the value of “OIL PRES” (A1-01).
3. Change “W-pres (B1-13)” value to the value measured at point

2 (Oil pres A1-01)
VC-62
COMBINATION METER
Diagram of Combination Meter
VC-63
VEHICLE CONTROL MODULE
Diagram
VC-64
Terminal Layout
MECHANICAL CONTROL VALVE
VC-65
Terminal Layout (Cont’d)

FINGER CONTROL VALVE (OPTION)
VC-66
UNIT INSPECTION AND ADJUSTMENT
Inspection
NOTE:
The following paragraphs describe the inspection procedures for the
switches, sensors and solenoid valves related to the VCM control
functions.
SWITCHES
Seat switch
Check continuity when the switch lever is depressed (seating of
seat).
Lift down detection switch

Check continuity when the switch lever is depressed.
Tilt leveling switch (option)

Check continuity.
When press button: Continuity should not exist.
When do not press button: Continuity should exist.
Tilt operation detection switch (option)

Check continuity when the switch lever is depressed.
VC-67
Inspection (Cont’d)
Seat belt switch
Check continuity.
When insert buckle: Continuity should not exist.
When disconnect buckle: Continuity should exist.
Radiator coolant level detection switch (option)

Check continuity when it detects that radiator coolant is under the
LOW position in reservoir tank.
Air cleaner clogging detection switch (option)

Check continuity when applying air pressure.
Additional air pressure:
5.7 - 6.7 kPa (0.057 - 0.067 bar, 0.058 - 0.068 kg/cm2,
0.83 - 0.97 psi)
CAUTION:
Replace if continuity is exist with the air pressure not applied.
VC-68
Torque converter fluid temperature switch (option)
Check continuity when oil temperature is 122°C (252°F) or more.
CAUTION:
Replace if continuity is exist with the temperature not added.
Remaining LPG detection switch (option)

Check continuity when applying air pressure.
Additional air pressure:
7.8 - 11.7 kPa (0.078 - 0.117 bar, 0.080 - 0.119 kg/cm2,
1.13 - 1.70 psi) or less
CAUTION:
Replace if continuity is exist with the air pressure not applied.
Parking brake switch

Check continuity when the switch lever was depressed and not
depressed.
Forward/backward shift lever (For except 2 speed ATM)

Check continuity at each lever position between the following
terminals.
Lever position Terminal with continuity
Forward 2-3
Neutral 1-4
Reverse 2-5
VC-69
Oil pressure switch
Check continuity when oil pressure is bellow 14.7-29.4 kPa (0.14-
0.29 bar).
Forward/backward shift lever (for 2 speed ATM)

Check continuity at each lever position between the following
terminals.
Lever position Terminal with continuity
Forward-1 2-6
Forward-2 2-3
Neutral 1-4
Reverse 2-5
VC-70
Throttle sensitivity adjusting switch and maximum speed
changeover switch
Check continuity by operating the switch.
SENSORS
Cargo detection hydraulic pressure sensor (option)
Turn ignition switch ON and check output voltage while connecting
harness.
Output voltage (V): 0.005 - 4.9 (Power supply - output)
Battery voltage (V): 5 ± 0.5 (Power supply - GND)
VC-71
Tilt angle sensor (option)
Turn ignition switch ON and check output voltage while connecting
harness.
Output voltage (V): 0.5 - 4.5 (Terminal No. 2 - 3)
Battery voltage (V): 5 ± 0.5 (Terminal No. 1 - 3)
Forklift speed sensor

Check resistance.
Item Resistance
Normal 2 - 3
Malfunction 0 or 
VC-72
SOLENOID VALVES
C/V unload solenoid
Check resistance.
Item Resistance
Normal 7 - 9
C/V lift lock solenoid

Check resistance.
Item Resistance
Normal 7 - 9
VC-73
C/V tilt lock solenoid (option)
Check resistance.
Item Resistance
Normal 11 - 3
T/M forward/backward solenoid (pneumatic model)

Check resistance.
Item Resistance
Normal 4 - 7
VC-74
T/M forward/backward solenoid (cushion model)
Check specifications.
Applied voltage 10 - 15V

Oil temperature 30 - 130°C (22 - 266°F)
Coil resistance 5.4/20°C (68°F)
Joystick Control System (Option)

JOYSTICK CONTROL VALVE
INSPECTION
Check resistance between terminals using circuit tester ( range).
Normal condition
Terminals Remarks
(for reference)
A (+) - A () 7.5±25%

B (+) - B () 7.5±25% 20°C (68°F)
C1 (+) - C1 () 8.0±25%
VC-75

FORWARD-REVERSE SWITCH (till 03-10-2017)
Inspection
Check continuity between terminals using circuit tester (Ω range).
Normal condition ( range)

Terminals
Neutral F position R position
No continuity No continuity
1-2 Continuity
() ()
No continuity No continuity
2-3 Continuity
() ()
CSM0146
CONTROL VALVE LEVER

1-lever type (Till week 26-2013)
CSM0147
VC-76
Joystick Control System (Option) (Cont'd)

Specification
Lever operation angle ±22.5°

Electrical angle (potention) ±18°
Rated voltage (V) DC 5±0.5
Output voltage (V) 0.5 - 4.5 (±0.05)
2-lever type and 3rd, 4th type (Till week 26-2013)
CSM0148
Specification
Lever operation angle ±20° - 22°

Output voltage (V) 0.5 - 4.5 (±0.05)
Inspection
Check the output voltage using circuit tester (DC-V range) (Refer to
above).
VC-77
Joystick Control System (Option) FORWARD-REVERSE SWITCH (from 03-10-2017)

Inspection: Check continuity between terminals using circuit tester (Ω range).
F position 1-2 continuity.

R position 2-3 continuity.
N position 1-2-3 no-continuity.
SUB-HARN rocker type FNR SW
CONTROL VALVE LEVER

1-lever type (From week 27-2013)
CSM0147
VC-78

Specification
Lever operation angle ±22.5°

Output voltage (V) 0.5 - 4.5 (±0.05)
2-lever type and 3rd, 4th type (From week 27-2013)
CSM0148
Specification
Lever operation angle ±30°

Output voltage (V) 0.5 - 4.5 (±0.05)
Inspection
Check the output voltage using circuit tester (DC-V range) (Refer to
above).
VC-79

EMERGENCY STOP BUTTON
CSM0149
Inspection
Check continuity between terminals using circuit tester ( range).
Terminals Normal condition Pushing the button
1-3 Continuity No continuity

2-4 Continuity No continuity
VC-80
REFERENCE DATA
Reference data input output monitor

REFERENCE DATA
VCM input/output monitor

Displayed
Displayed value value
Item Name Display screen (Key ON, neutral (Equipment Remarks
condition) operating
condition)
A1-01 Forklift speed 20.0 km/h 20.0 km/h Forklift speed sensor
(upper) sensor signal output
*.** MPa (Fluctuate) Value changes at lift
A 1 S P E E D 16 . 5 k m / h
A1-01 Oil pressure height and load/
0 1 O I L P RE S 1 8 . 5 42 M P a
(Lower) sensor signal unload (Tilt leveling
system: OPT)
0.0 V (Standard) OPT( tilt leveling
A1-02 Tilt angle function) Value
(Upper) sensor signal changed depend the
mast angle.
A 1 T I L T ANG 12 . 5 V When operate the
Wheel turning 0 2 WHE E L A NG 12 . 5 V steering angle sensor,
A1-02 0.70 (Left)/
angle sensor 2.26 V change the value
(Lower) 4.37(Right)
signal (Steering
synchronizer: OPT)
A1-03 Accelerator 0.00% (Fixed) Not equipped
(Upper) sensor signal
A 1 A CC E L S E N 45 . 5 %
A1-03 0 3 I GN ST SW O FF OFF (Key OFF) ON (Starting Ignition start switch for
IGN ST SW
(Lower) engine) Diesel engine
OFF ON When operate the
A1-04 Mast height Mast height switch,
(Upper) SW change to ON (Tilt
leveling system: OPT)
A 1 M AS T H I GH SW OF F
0 4 L I F T O P E S W O FF OFF ON (Lift lever When operate the lift
Lift lowering
A1-04 operated) lever to down side,
operation limit
(Lower) change to ON. (4
SW
spool valve: OPT)
OFF ON (Tilt lever When operate the tilt
Forward tilt
A1-05 operated) lever to forward,
operation limit
(Upper) change to ON (Tilt
SW
A 1 T I LT O P E S W OF F leveling system: OPT)
Forklift speed 0 5 S PE E D L I M I T S W O FF OFF(Low ON (High OPT: Speed selector
A1-05
limit [outside] position) position) (H/L) for ECM models
(Lower)
SW
OFF (Power ON (ECO Power/Eco selector
A1-06 Power Eco
mode) mode) for ECM models
(Upper) SW
A 1 P O W E R E CO SW OF F (Standard)
A1-06 0 6 S EA T S W O FF ON (sitting ) OFF (Not Seat switch operation
Seat SW
(Lower) sitting)
A1-07 OFF (Not ON (Fastened) Seat belt switch
Seat belt SW
(Upper) fastened) operation
OFF (Not ON When depress the
A 1 S EA T B E L T SW OF F
A1-07 Accelerator 0 7 A CC E L S W O FF depressed) (Depressed) accelerator pedal,
(Lower) pedal SW change to ON. (QD32
with ATM)
ON (Not pushed) OFF (Pushed) Tilt leveling switch
A1-08 Tilt horizontal (N.C type) for Tilt
(Upper) support SW leveling system
A 1 T I L T S T OP SW OF F (Option)
0 8 C OO L AN T L O W S W O FF
A1-08 Coolant low OFF ON (Low level) Coolant level switch
(Lower) level SW (Option)
VC-81
REFERENCE DATA
VCM input/output monitor (cont'd)

Displayed
condition)
A1-09 Air cleaner OFF ON (Clogged) Air cleaner clogging
(Upper) clogging SW switch (Option)
A 1 A I R C L E AN E R S W O F F OFF ON (Warning) This warning comes
A1-09 T/M warning 0 9 T /M WA R N I N G S W O FF when Temperature of
(Lower) SW ATM oil over 122
degree C
A1-10 OFF (Fixed) Not equipped
Inching SW
(Upper)
A 1 I NC H I N G S W OF F OFF(single function) Off single function
MFC 4 step
A1-10 1 0 M FC CH A NG E S W O FF joystick, ON when
changeover
(Lower) dual function joystick
SW
is allowed
A1-11 Engine auto OFF (Fixed) Not equipped
(Upper) start SW
FC A 1 A U T O S T AR T S W OF F ON (Fixed) Not equipped
A1-11 emergency 1 1 F C R EL A Y O FF
(Lower) cutout relay
output
A1-12 Auto light OFF (Fixed) Not equipped
(Upper) relay output
A 1 A UT O L I GH T R L Y OF F OFF ON (Buzzer When operate the
A1-12 Warning 1 1 2 W AR N 1 BU Z ZE R O FF operated) warning buzzer,
(Lower) buzzer output
change to ON.
A1-13 Warning 2 OFF (Fixed) Not equipped
(Upper) buzzer output
A 1 W AR N 2 BU Z Z E R OF F
A1-13 Neutral signal 1 3 N -S I GN A L O FF OFF (Neutral) ON (Forward & Neutral signal (FR-
(Lower) output Reverse) SW position)
A1-14 Auxiliary OFF (Fixed) Not equipped
(Upper) output 1
A 1 R ES E RV E (O U T ) OF F
A1-14 Starter driving 1 4 S TA R TO R R E LA Y O FF OFF (Fixed) Not equipped
(Lower) relay output
A1-15 Engine stop ON (Fixed) Not equipped
(Upper) relay output
A 1 E NG . ST O P R E L A Y OF F OFF (Key OFF) ON (Glow) When the glow lamp
A1-15 Glow plug 1 5 G LO W R E LA Y O FF is lighting, change to
(Lower) driving relay
ON (Diesel engine)
T/M control OFF (Neutral & ON (Forward) ATM forward solenoid
A1-16
valve [forward] reverse) operation
(Upper)
output
T/M control A 1 T /M SO L ( F W ) OF F 9 mA (SOL OFF) 1653 mA(SOL ATM solenoid current
A1-16 valve 2 1 6 T /M SO L 2 ( F W) O FF ON) output for Forward &
(Lower) [forward] reverse
output
T/M control OFF (Neutral & ON (Reverse) ATM reverse solenoid
A1-17 valve forward) operation
(Upper) [backward]
output A 1 T /M SO L ( B W ) OFF
1 7 T /M SO L 2 23 4 m A 9 mA (SOL OFF) 1653 mA(SOL ATM solenoid current
A1-17 T/M control
ON) output for Forward 2-
(Lower) valve current
speed
VC-82
REFERENCE DATA
Displayed
condition)
Power OFF ON (PS When operate the PS
steering Correcting) correction solenoid,
A1-18
correction change to ON
(Upper)
solenoid (Steering
output A 1 P S SO L OFF synchronizer: OPT)
Power 1 8 1 9 mA (SOL OFF) 2240 mA (SOL When operate the PS
P S S OL 12 4 m A
steering ON) correction solenoid,
A1-18
correction change the value
(Lower)
solenoid (Steering
current synchronizer :OPT)
OFF (Tilt ON (at tilt When operate the tilt
Tilt lock operating) leveling) lock solenoid, change
A1-19
solenoid to ON
(Upper)
output (Tilt leveling system:
A 1 T - L OCK SO L OFF OPT)
9 mA (SOL OFF) 1600 mA (SOL When operate the tilt
1 9 T - L OCK SO L 1 23 4m A
Tilt lock ON) lock solenoid, change
A1-19
solenoid the value
(Lower)
current (Tilt leveling system:
OPT)
ON (Key ON & sit) OFF (Key ON & Lift lock solenoid
Lift lock
A1-20 not sit) operation for MC
solenoid
(Upper) (Mechanical HYD-
output
A 1 L - L OCK SO L OFF valve)
Lift lock 2 0 L - L O CK SO L 1 23 4 m A 1046 mA (SOL 9 mA (SOL Lift lock solenoid
A1-20
solenoid ON) OFF) current output for MC
(Lower)
current
ON (Key ON & sit) OFF (Key ON & Unload solenoid valve
Unload/C1
A1-21 ON (Operating) not sit) operation for MC
solenoid
(Upper) OFF (Not C1 solenoid valve
output A 1 U LO A D C 1 S O L OFF operating) operation for FC
Unload/C1 2 1 U LO A D C 1 S O L 1 23 4m A 1046 mA (SOL 9 mA (SOL Unload (for MC) / C1
A1-21
solenoid ON) OFF) (for FC) solenoid
(Lower)
current valve current output
0 % (Neutral '-99 (Up)/99 FC lift sensor
A1-22 position) (Down) operating angle (Up
FC sensor [lift]
(Upper) and down side)
A 1 F C S EN ( L I F T ) 6 4 %
(Option)
2 2 F C L I F T (U P ) O FF
A1-22 FC lift [up] OFF (Neutral & ON (Up) FC lilt up switch
(Lower) output Down) operation (Option)
A1-23 FC lift [down] OFF (Neutral & ON (Down) FC lilt down switch
(Upper) output Up) operation (Option)
A 1 FC L I F T (D N ) OFF
A1-23 2 3 F C L IF T 1 23 4 m A 4 mA (Neutral 1034 mA (UP/ FC lilt sensor current
FC lift current
(Lower) position) down) output (Option)
0 % (Neutral '99(Forward)/- FC tilt sensor
A1-24 position) 99(Backward) operating angle
FC sensor [tilt]
(Upper) (Forward and
A 1 F C S EN ( T I L T ) 6 4 % backward) (Option)
FC tilt 2 4 F C T I L T (F W ) O FF OFF(Neutral & ON (Forward) FC tilt forward switch
A1-24
[forward] Backward) operation (Option)
(Lower)
output
FC tilt OFF (Neutral & ON (Backward) FC tilt backward
A1-25
[backward] forward) switch operation
(Upper) A 1 F C T I LT (B W ) OFF
output (Option)
A1-25 2 5 F C T ＩL T 1 23 4ｍA 4 mA (Neutral 1024mA(Forwa FC tilt sensor current
FC tilt current
(Lower) position) rd/Backward) output (Option)
VC-83
REFERENCE DATA
Displayed
condition)
0 % (Neutral '99(Forward)/- FC 3 spool sensor
A1-26 FC sensor position) 99(Backward) operating angle
(Upper) [attachment 1] (Forward and
A 1 F C S EN ( AT T 1 ) 6 4% backward) (OPT)
FC 2 6 F C AT T 1 (A) OF F OFF(Neutral & ON (Forward) FC tilt sensor current
A1-26
attachment 1 Backward) output (Option)
(Lower)
[A] output
FC OFF (Neutral & ON (Backward) FC 3 spool backward
A1-27
attachment 1 forward) switch operation
(Upper)
[B] output (Option)
A 1 FC A TT 1 ( B ) OFF
FC 2 7 F C A TT 1 1 23 4 ｍ A 4 mA (Neutral 1017mA(Forwa FC 3 spool sensor
A1-27
attachment 1 position) rd/Backward) current output
(Lower)
current (Option)
0 % (Neutral '99(Forward)/- FC 4 spool sensor
A1-28 FC sensor position) 99(Backward) operating angle
(Upper) [attachment 2] (Forward and
A 1 F C S EN ( A T T 2 ) 6 4 % backward) (OPT)
FC 2 8 F C A TT 2 (A ) O FF OFF(Neutral & ON (Forward) FC 4 spool forward
A1-28
attachment 2 Backward) switch operation
(Lower)
[A] output (Option)
FC OFF (Neutral & ON (Backward) FC 4 spool backward
A1-29
attachment 2 forward) switch operation
(Upper)
[B] output (Option)
A 1 FC A T T 2 ( B) O FF
FC 2 9 FC AT T 2 1 2 3 4 ｍA 4 mA (Neutral 1017mA(Forwa FC 4 spool sensor
A1-29
attachment 2 position) rd/Backward) current output
(Lower)
current (Option)
A1-30 FC sensor 0% (MC) '-99% (FC) Not equipped
(Upper) [attachment 3]
FC A 1 F C S EN ( A T T 3 ) 6 4 % OFF (MC) OFF (FC) Not equipped
A1-30 3 0 F C A TT 3 (A ) O FF
attachment 3
(Lower)
[A] output
FC OFF (MC) OFF (FC) Not equipped
A1-31
attachment 3
(Upper)
[B] output
A 1 FC A TT 3 ( B ) OFF
FC 3 1 F C A TT 3 1 23 4 m A 0 mA (MC) 0 mA (MC) Not equipped
A1-31
attachment 3
(Lower)
current
A1-32 OFF (Neutral & ON (Forward) ATM selector lever
Shift lever (F)
(Upper) reverse)
A 1 S HI F T L EV E R( F ) OF F
A1-32 3 2 S HI F T L EV E R ( N ) O FF ON (Neutral OFF (Forward ATM selector lever
Shift lever (N)
(Lower) position) & reverse)
A1-33 OFF (Neutral & ON (Reverse) ATM selector lever
Shift lever (R)
(Upper) forward)
A 1 S H I F T L EV E R( R ) OF F OFF (Neutral & ON (2-speed ATM selector lever 2-
A1-33 Shift lever 3 3 S HI F T L E V E R ( 2 F ) O FF forward&revwerse forward) speed
(Lower) (2F)
)
A1-34 DC power 12.5 V 14.0 V
(Upper) voltage
A 1 B AT VO L . 11 . 5 V
A1-34 3 4
(Lower)
VC-84
REFERENCE DATA
ECM input/output monitor

Displayed
condition)
Engine 731 rpm 2725 rpm Engine speed monitor
A2-01
revolution
(Upper)
speed
A 2 E NG . RE V 1 2 3 8 rpm
0 1 I DL E S W O FF OFF (Not ON When depress the
A2-01 Idle SW
depressed) (Depressed) accelerator pedal,
(Lower) signal
change OFF to ON.
0% 99% When depress the
A2-02 Throttle accelerator pedal fully,
(Upper) opening up to 99 %.(Power
A 2 T H R O TT L E A NG L E 4 0 % side)
Battery 0 2 B AT VO L . 1 0 0 0 0 mV Battery voltage
A2-02
voltage 13.10 V 14.24 V
(Lower)
signal
Accelerator 0% 99% When depress the
A2-03
opening accelerator pedal fully,
(Upper)
angle up to 99 %.
A 2 A C C E L A NG L E 7 4%
Engine 0 3 C OO L AN T T E MP 1 0 0°C changing value Engine coolant
A2-03
coolant temperature
(Lower)
temperature
Fuel 4.6 ms Waving value When depress the
A2-04 injection (GAS) accelerator pedal, the
(Upper) pulse width value is waving.
GAS
A 2 I N J P UL S E G AS 1 0 0μ s
Fuel 0 4 I N J P UL S E L PG 1 0 0 μs 4.6 ms Waving value When depress the
A2-04 injection (LPG/GAS) accelerator pedal, the
(Lower) pulse width value is waving.
LPG
A2-05 OFF (Key OFF) ON (Clanking Starter switch
Starter SW
(Upper) engine) operation
A 2 S TA R T S W O F F OFF (Neutral) ON (Forward & When operate ATM
A2-05 0 5 N EU T RA L S W O FF Reverse) FR-SW to Forward/
Neutral SW
(Lower) reverse, change OFF
to ON.
OFF (SW OFF) ON (SW ON) When operate the
A2-06 Electric load
lighting switch,
(Upper) SW
change OFF to ON.
A 2 E LE C L O AD SW O FF
0 6 B RA K E S W O FF OFF (Not ON When depress the
A2-06
Brake SW depressed) (Depressed) brake pedal, change
(Lower)
OFF to ON.
A2-07 OFF (Fixed) Not equipped.
A/C SW
(Upper)
A/F ratio A 2 A I R C ON SW O F F NOT While executing
A2-07 0 7 A / F A L P HA CL R D O NE
learned Active test, Change
(Lower)
value clear NOT to DONE
Rapid TAS NOT While executing
A2-08
learning Active test, Change
(Upper)
(factory) NOT to EXE
A 2 I DL E A I R V OL F E X E
Rapid TAS 0 8 I DL E A I R V OL N E XE NOT While executing
A2-08
(Lower)
(normal) NOT to EXE
Ignition NOT While executing
A2-09
timing Active test, Change
(Upper)
adjustment NOT to EXE
A 2 I GN YI M IN G AD F E X E
0 9 A / F A L P HA AD J E XE NOT While executing
A2-09 A/F ratio
Active test, Change
(Lower) adjustment
NOT to EXE
VC-85
REFERENCE DATA
ECM input/output monitor (cont'd)
Power NOT While executing
A2-10
balance Active test, Change
(Upper)
correction NOT to EXE
A 2 P OW E R B AL A NC E E X E
1 0 F UE L P R ES CL R E XE NOT While executing
A2-10 Air flow
Active test, Change
(Lower) meter signal
NOT to EXE
Self NOT While executing
diagnosis Active test, Change
A2-11
result NOT to EXE
(Upper)
deletion
A 2 S E L F - D I AG CL R D O NE
completed
1 1 A I R FLO W 15 0 m V
1.70 V 1.70 V When increase the
A2-11 Air flow
engine speed, change
(Lower) meter signal
the value.
Cylinder 26% Waving value When depress the
A2-12 intake fill-up accelerator pedal, the
(Upper) efficiency value is waving.
GAS
A 2 C HA R G EFF GA S 1 0 0%
Cylinder 1 2 C HA R G E FF LP G 1 0 0% 26% Waving value When depress the
A2-12 intake fill-up accelerator pedal, the
(Lower) efficiency value is waving.
LPG
A/F ratio 101% Waving value When depress the
A2-13 correction (75-125%) accelerator pedal, the
(Upper) amount value is waving.
(gasoline) A 2 A /F A L P HA GA S 1 0 0%
A/F ratio 1 3 A / F A L P HA LP G 1 0 0% 101% Waving value When depress the
A2-13
correction (75-125%) accelerator pedal, the
(Lower)
amount LPG value is waving.
Fuel OFF (GAS) ON (LPG) When change the fuel
A2-14
changeover selector to LPG,
(Upper)
SW1 signal change OFF to ON.
A 2 C HG FU E L S W1 O F F
Fuel 1 4 C HG FU E L S W2 O FF ON (GAS) OFF (LPG) When change the fuel
A2-14
changeover selector to GAS,
(Lower)
SW2 signal change ON to OFF.
GAS (GAS) LPG (LPG) When set the fuel
A2-15 Fuel control selector to Neutral,
(Upper) signal change GAS/LPG to
A 2 F UE L C O NT R OL G AS
1 5 M AS T H I GH SW 1 OFF NEU.
A2-15 Mast high OFF (Fixed) Not equipped.
(Lower) SW1 signal
A2-16 Mast high OFF (Fixed) Not equipped.
(Upper) SW2 signal
O2 sensor A 2 M AS T H I GH SW 2 O FF LEAN / RICH LEAN / RICH When depress
A2-16 rich/lean 1 6 O 2 S EN S OR L E AN accelerator pedal,
(Lower) judgement change LEAN / RICH.
signal
OFF (Key OFF: ON (Starting When start the engine
A2-17 Fuel pump
GAS) engine: GAS) as GAS, change OFF
(Upper) relay signal
to ON.
A 2 F U E L PU M P R E L A Y O F F
LPG cutoff 1 7 L PG RE L AY O FF OFF (Key OFF: ON (Starting When start the engine
A2-17
valve relay LPG) engine: LPG) as LPG, change OFF
(Lower)
signal to ON.
OFF (Key OFF) ON (Key ON) When turn the key
A2-18 Throttle
SW to ON, change
(Upper) relay signal
OFF to ON.
A 2 T H R O TT L E R EL A Y O F F
1 8 O 2 S EN HE A TE R O FF OFF (Key OFF) ON (Key ON) When turn the key
A2-18 O2 sensor
SW to ON, change
(Lower) heater signal
OFF to ON.
VC-86
REFERENCE DATA
ECM input/output monitor (cont'd)
Full closure DONE While executing
A2-19
(Upper)
update flag NOT to DONE
Rapid TAS DONE While executing
learning A 2 O FF AC C E L PO . D O NE Active test, Change
A2-19 (factory/ 1 9 I D L E A I R C OM P D O NE NOT to DONE
(Lower) normal)
completion
flag
CONSULT II OFF ON If connect the
A2-20
connection CONSULT 2 to the
(Upper)
flag truck, change to ON
A 2 C ON CO N SU L T II O F F
2 0 I GN TI M IN G - 30 d e g '-1 deg Changing value When increase the
A2-20 Ignition
engine speed, change
(Lower) timing signal
the value.
O2 sensor 60 - 800 mV 150 - 800 mV When increase the
A2-21 output engine speed, change
(Upper) voltage the value.
signal
A 2 O 2 S EN VO L . 1 0 0 0 mV
Intake air 2 1 A I R TE M P S EN - 2 0°C Changing value Intake air temperature
A2-21 temperature sensor monitor
(Lower) sensor
signal
LPG fuel 30.00 kPa (LPG LPG fuel pressure
A2-22 pressure sensor monitor on
(Upper) sensor injector holder
A 2 L PG P R E SS 30. 0 0K P a
signal 2 2
A2-22
(Lower)
VC-87
REFERENCE DATA
MP input/output monitor
Displayed
condition)
A3-01 Parking OFF OFF When apply PKB,
(Upper) brake SW change OFF to ON
A3-01 Low brake A 3 P KB SW O FF OFF OFF Option
0 1 B RA K E O I L L OW O FF
(Lower) fluid level
A3-02 Low engine OFF OFF Engine oil pressure
(Upper) oil pressure switch monitor
Engine coolant
Engine A 3 E NN . PR E S L OW O F F
A3-02 temperature
coolant 0 2 E NN . TE M P 1 0 5°C 83 °C
(Lower) monitor(separate 1
temperature
therminal sensor)
A3-03 15  (FULL) 80  (EMPTY) Fuel level monitor
Fuel level
(Upper)
OFF (Neutral & ON (Right When operate the
A 3 F UE L L E VE L 1 0 0Ω
A3-03 Turn signal 0 3 T UR N S I G ( R H) O FF Left) hand) turn signal switch to
(Lower) (right) right hand, change to
ON
OFF (Neutral & ON (Left hand) When operate the
A3-04 Turn signal Right) turn signal switch to
(Upper) (left) left hand, change to
ON
OFF ON (Warning) For LPG,
-With pressure
sensor(1F): when
down the fuel
pressure to 1.0 kgf/
A 3 T UR N SI G ( L H) OF F cm2, change to ON.
0 4 F UE L WA R N SW O FF -With temp
A3-04 Fuel warning
sensor(1D); When the
(Lower) SW
sensor has detected
an phase change the
signal is ON.
For Diesel, when the
sedimenter water
level warning comes,
change to ON.
VC-88
BODY AND FRAME
SECTION BF
CONTENTS
BODY AND FRAME .................................................. 2
Precaution ............................................................ 2
Service Data and Specifications (SDS) ................ 2
Tightening Torque ................................................ 3
Cab Frame (Overhead Guard) ............................. 4
Top Panel ............................................................. 6
Counterweight ...................................................... 8
Floor Board ........................................................... 9
Under Cover ....................................................... 10
Instrument Cover ................................................ 11
Seat .................................................................... 12
Joystick Control System (Option) ....................... 15
BODY AND FRAME
BODY AND FRAME Precaution

• Ensure crane and lifting wire are strong enough to support
weight of overhead guard assembly and counterweight.
• Be extremely careful when lifting overhead guard assembly and
counterweight because they are heavy.
• Never get under the lifting overhead guard assembly and
counterweight.
• Remove and install top panel without seat because seat is
heavy.
Service Data and Specifications (SDS)

COUNTERWEIGHT
1D1 1D2
Model ton (lb)
1.5 (3,308) 1.75 (3,859) 2.0 (4,410) 2.5 (5,513) 3.0 (6,615) 3.2 (7,055)
Weight N (kg, lb) 6,828 (696, 1,534) 8,780 (895, 1,973) 10,003 (1,020, 2,249) 13,534 (1,380, 3,043) 16,966 (1,730, 3,815) 18,639 (1,900, 4,189)
BF-2
BODY AND FRAME
Tightening Torque
N•m kg-m ft-lb in-lb
Instrument frame (to front pillar) 78 - 98 7.9 - 10.0 58 - 72 –

Rear crossmember (to rear pillar) 78 - 98 7.9 - 10.0 58 - 72 –
Upper overhead guard (to side overhead guard) 78 - 98 7.9 - 10.0 58 - 72 –
Rain guard (to overhead guard) 13 - 15 1.3 - 1.6 10 - 11 –
Cab frame assembly
Air inlet finisher (to overhead guard) 3.0 - 3.8 0.30 - 0. 39 – 26 - 33
(Overhead guard)
Mirror (to front pillar) 13 - 15 1.3 - 1.6 10 - 11 –
Instrument frame (to frame assembly) 78 - 98 7.9 - 10.0 58 - 72 –
Cab mounting rubber (to frame) 59 - 83 6.0 - 8.5 44 - 61 –
Cab frame assembly (to frame) 137 - 196 14 - 20 101 - 145 –
Top panel hinge guide (to overhead guard) 13 - 15 1.3 - 1.6 10 - 11 –
Top panel hinge (to top panel) 13 - 15 1.3 - 1.6 10 - 11 –
Top panel hinge (to overhead guard) 13 - 15 1.3 - 1.6 10 - 11 –
Top stay (to top panel and top panel hinge guide) 13 - 15 1.3 - 1.6 10 - 11 –
Top panel
Rear panel (to top panel hinge) 13 - 15 1.3 - 1.6 10 - 11 –
Top panel lock assembly (to top panel) 5.1 - 6.4 0.52 - 0.66 – 46 - 57
Top panel lock lever (to top panel lock assembly) 2.9 - 3.8 0.30 - 0.39 – 26 - 34
Top panel striker (to cabin lower frame) 13 - 15 1.3 - 1.6 10 - 11 –
1D1 392 - 441 40 - 45 290 - 325 –
Counterweight
1D2 490 - 618 50 - 63 362 - 455 –
Over fender (to frame) 26 - 32 2.6 - 3.3 19 - 23 –
Floor board Floor board (to pedal bracket assembly) 13 - 15 1.3 - 1.6 10 - 11 –
Under cover (to frame) 13 - 15 1.3 - 1.6 10 - 11 –
Center cover (to frame) 13 - 15 1.3 - 1.6 10 - 11 –
Under cover Rear cover (to frame) 13 - 15 1.3 - 1.6 10 - 11 –
Front cover (to frame) 13 - 15 1.3 - 1.6 10 - 11 –
Step plate (to frame) 13 - 15 1.3 - 1.6 10 - 11 –
Seat Seat (to frame) 13 - 15 1.3 - 1.6 10 - 11 –
Instrument inner cover LH (to instrument frame) 5.0 - 6.4 0.51 - 0.66 – 45 - 57
Instrument inner cover RH (to instrument frame) 5.0 - 6.4 0.51 - 0.66 – 45 - 57
Instrument cover
Steering column cover (to instrument frame) 5.0 - 6.4 0.51 - 0.66 – 45 - 57
Tilt cylinder cover RH (to instrument cover) 5.0 - 6.4 0.51 - 0.66 – 45 - 57
BF-3
BODY AND FRAME
Cab Frame (Overhead Guard)
BF-4
BODY AND FRAME
Cab Frame (Overhead Guard) (Cont’d)

REMOVAL
2. Disconnect the plus battery terminal from battery, and remove
battery and bracket.
3. Remove instrument covers, tilt covers, floor mat and floor board.
4. Disconnect harness connectors from cab frame assembly.
5. Disconnect hydraulic connectors from tilt cylinder, and remove
tilt cylinder.
6. Remove parking brake bracket, accelerator pedal and idle
control cable (Diesel engine model).
7. Remove grommet of filler neck.
8. Remove air cleaner and reservoir tank.
9. Attach wire or rope to cab frame assembly and slightly lift it with
a hoist or crane.
10. Remove cab mounting insulator fixing nuts, and remove cab
frame assembly.
INSPECTION
Cab mounting insulator
Check cab mounting insulator for deformation, crack and leakage.
INSTALLATION
BF-5
BODY AND FRAME
Top Panel
BF-6
BODY AND FRAME
Top Panel (Cont’d)

REMOVAL
2. Disconnect the minus battery terminal from battery, and remove
battery.
3. Disconnect harness connector from seat, and remove seat.
4. Disconnect seat harness connector from body harness.
5. Open top panel and remove top stays.
6. Close top panel and remove hinges from it.
7. Open hinge and rear cover, and remove top panel.
INSTALLATION
INSPECTION
When rollers cannot move smoothly or emit an abnormal sound,
apply grease around the rollers.
BF-7
BODY AND FRAME
Counterweight
BF-8
BODY AND FRAME
Floor Board
BF-9
BODY AND FRAME
Under Cover
BF-10
BODY AND FRAME
Instrument Cover
BF-11
BODY AND FRAME
Seat
BF-12
BODY AND FRAME
Grammer Seat Exploded view (option)
BF-13
BODY AND FRAME
Grammer Seat Front & Side view (option)
Harness layout Heated Seat (option)
BF-14
BODY AND FRAME

NOTE:
Joysticks and top cover till week 26 2013.
FNR switch till 03-10-2017.
BF-15
BODY AND FRAME
Joystick Control System (Option)(Cont’d)

NOTE: Joysticks and top cover till week 26 2013. FNR switch till 03-10-2017.
CSM0151
BF-16
BODY AND FRAME

NOTE:
Joysticks and top cover from week 27 2013.
FNR switch from 03-10-2017.
BF-17
BODY AND FRAME
Joystick Control System (Option)(Cont’d)

NOTE: Joysticks and top cover from week 27 2013. FNR switch from 03-10-2017.
CSM0151
BF-18
BODY ELECTRICAL SYSTEM
SECTION BE
CONTENTS
HOW TO USE THIS MANUAL ............................BE-I Inspection ......................................................BE-20
WIRE HARNESS .................................................BE-2 HEADLAMPS ....................................................BE-21
Body harness front panel side ........................BE-2 Lamp Specification ........................................BE-21
HARNESS LAYOUT ............................................BE-3 Headlights ......................................................BE-21
Body harness QD32 Engine ...........................BE-3 Front Turn Signal Light ...................................BE-22
Body harness K/GK-engine ............................BE-4 Rear Combination Light .................................BE-23
Seat harness ...................................................BE-5 Back Operation Light / Pato Lamp .................BE-24
Fingertip control harness ................................BE-6 OTHERS .............................................................BE-25
Tilt leveling control sub harness ......................BE-7 Backup Buzzer ...............................................BE-25
WIRING INSPECTION .........................................BE-8 Horn ...............................................................BE-25
Description .......................................................BE-8 Speed Sensor ................................................BE-25
Inspection ........................................................BE-8 OPTIONAL LIGHTS............................................BE-26
FUSE BOX .......................................................BE-9 Blue / Red light.............................................BE-26
Fuse .................................................................BE-9 Specifications and precautions......................BE-27
Removal ...........................................................BE-9 LED lights........................................................BE-28
Installation ........................................................BE-9 Wiring diagram K/GK-engine electronic,
Inspection ........................................................BE-9
mechanical controlled ............................. BCM0252
Fuse identification ..........................................BE-10
Wiring diagram K/GK-engine electronic
Optional Fuses ...............................................BE-11
controlled, finger tip model ...................... BCM0253
Inspection ......................................................BE-11
Wiring diagram QD-32 engine,
Fusible Link ....................................................BE-11
mechanical controlled ............................. BCM0254
COMBINATION METER .....................................BE-12
Wiring diagram QD-32 engine,
Description .....................................................BE-12
finger tip model........................................ BCM0255
Combination Meter Arrangement ...................BE-12
Warning Light .................................................BE-13
List of Warning Light Operation .....................BE-14
Light Specification ..........................................BE-15
Trouble Code Displays ...................................BE-15
Fuel Gauge and Engine Coolant Temperature Gauge.....BE-15
Hour Meter ......................................................BE-15
Speed Display Control ....................................BE-15
Speed Display System ................................... BE-16
SWITCHES .........................................................BE-17
Combination Switch .......................................BE-17
Tilt Leveling Switch (Option) ..........................BE-18
Maximum Speed Switch (Option) ..................BE-19
Throttle Sensitivity Adjustment Switch (Option)......BE-19
Engine Stop Switch ........................................BE-20
Trouble Diagnosis (Cont'd)

SYMBOLS
(*) INDICATES INCHES-POUNDS
BE-I
Trouble Diagnosis (Cont'd)

SYMBOLS FOR HARNESS CONNECTOR
FEMALE CONNECTOR
• When a harness connector is viewed from A (terminal side), the
outer frame of the connector symbol is indicated with a single
line. In addition, the direction indicator shows "TS" (Terminal
Side) in description type font.
EGM0050
• When a harness connector is viewed from B (harness side), the

outer frame of the connector symbol is indicated with double
lines. In addition, the direction indicator shows "HS" (Harness
Side) in description type font.
• Terminal assignments of a connector viewed from A and B are
mirror images, indicating just as they are seen.
EGM0051
MALE CONNECTOR
The illustration method is the same as that for a female connector,
the black guide box, however, indicates a male connector (the white
guide box a female connector).
EGM0052
SINGLE UNIT (CONTROL UNIT)

A single control unit is viewed only from A, and the illustration is as
shown in the figure.
EGM0053
(*) INDICATES INCHES-POUNDS
BE-II
Connector Terminal Inspection
CONNECTOR INSPECTION PROCEDURE
In circuit inspection, inappropriate connector probing will cause
connector damages and/or poor connection. The probes provided
with the circuit tester may be too large to probe connector terminals
without damaging them. Always use alligator clips and "T" pins
according to following the procedure.
INSPECTION FROM HARNESS SIDE

For a standard connector without any waterproofing, use "T" pins
from the harness side.
• For a connector with a rear cover, such as ECM
connectors, remove the rear cover before the inspection.
• For a waterproof connector, do not probe the terminals
from the harness side. Doing so may damage the seal.
EGM0054 INSPECTION FROM TERMINAL SIDE

1. Female terminal
• Female connector terminals have a small notch difference
inside. Insert a "T" pin along the step to inspect.
• Do not insert any objects to a female connector terminal
other than the corresponding male connector terminal.
EGM0055
• In case of a female connector terminal without any notches,

remove the retainer before probing.
Connector Terminal Inspection
EGM0056
2. Male terminal
For a male connector terminal, apply a "T" pin to the surface of the
terminal.
• Do not bend terminals.
EGM0057
BE-III
Inspection for Electrical System

DESCRIPTION
• If the malfunction can be traced directly to the electrical system,
first check for items such as burned-out fuses and fusible links,
broken wires or loose connectors, pulled-out terminals, and
improper connections.
• If a fuse or a fusible link is blown out, determine the possible
cause and restore it. Always replace it with a new fuse or fusible
link of the specified capacity.
• When removing a connector, do not apply excessive force to the
main body by grasping and twisting.
• Do not pull a connector off by tugging on the harness.
• For a lock-type connector, disengage its lock first, then
disconnect the connector by holding the main body of the
connector.
EGM0058
• Before connecting a connector, check terminals for bends or

breakage. Connect it securely.
• For a lock-type connector, press it until its lock is securely
engaged.
• When installing parts, prevent harnesses from being snagged
or overextended.
EGM0059
BE-IV
Control Unit and Electronic Component

PRECAUTIONS
• Never reverse polarity of battery terminals.
• Install only parts specified for each model.
• Before replacing a control unit, check input and output signals
to/from the control unit, and component functions.
• When disconnecting a connector, do not twist or apply
excessive force.
• For a bolt-type connector, loosen the bolt first, then hold the
main body of the connector to disconnect.
• Before connecting a connector, check terminals for bends or
breakage. Connect it securely. For a bolt-type connector, screw
in the bolt until the colored lug is flush with the surface to be
sure it is securely connected.
• Do not drop, hit, or subject control units to impact.
• Be sure to protect control units from condensation caused by a
sudden shift in temperature, or from raindrops or splashes. If
any water drops adhere to the unit, dry it well prior to
installation.
• Be sure to protect control unit connectors from oil.
• Avoid cleaning control units with benzine.
• Do not open a top or bottom cover on a control unit.
EGM0062
• When using a circuit tester, ensure the appropriate distance

between test probes. A longer distance is recommended,
because if the distance is too short, it may cause contact of the
test probes, resulting in a short circuit. A short circuit allows
battery voltage to be applied directly to the control unit, resulting
in damage to its internal power transistors.
• Use the specified check adapter to check input and output
signals to/from control units.
EGM0063
BE-V
WIRE HARNESS
WIRE HARNESS
For maintainability, harnesses were divided into four categories: body
harnesses, seat harness, guard harnesses and option harnesses.
Body harness front panel side
BEM0801EU
1. Pass_W / engine stop relay 9. Fuse box

2. Parking brake buzzer relay 10. wiper switch
3. Ignition relay 11. power/ eco switch
4. Combination switch 12. speed select switch
5. Ignition switch 13. back operation lamp switch
6. Horn relay 14. handbrake buzzer
7. Turn signal relay
8. Combination meter
BE-2
HARNESS LAYOUT
HARNESS LAYOUT
Body harness QD32 Engine
BEM0802EU
1. Ground connection engine 13. VCM controller

2. To Fuel Cut Solenoid 14. Mounting Plate Battery
3. To Fuel level sensor 15. Battery
4. Combination switch 16. Glow relay
5. To Glow Plugs 17. Back buzzer/ reverese relay
6. To Rear Combination lamp/ Pato lamp 18. Starter relay
7. To rear combination lamp 19. Coolant Level sensor
8. Coolant Temperature sensor 20. Speed sensor
9. Transmission Forward/ Reverse Solenoid 21. Transmission Oil temparature sensor
10. Stop Lamp Switch 22. Air cleaner clogged sensor
11. Ground connection Chassis 23. Bypass connector engine stop switch
12. Engine Oil pressure Switch
BE-3
HARNESS LAYOUT
Body harness K/GK-engine
BEM0803EU
1. Ground connection engine 22. Air cleaner clogged sensor

2. Coolant temperature sensor ECM 23. Ignition coil
3. Thermo sensor MP 24. LPG main injector
4. To seat harness 25. LPG pressure sensor
5. ECM controller 26. LPG assistant injector
6. To Rear Combination lamp/ Pato lamp 27. ETC (electric throttle position controller)
7. To rear combination lamp 28. To O2 sensor
8. To POS/PHASE sensors 29. Air flow sensor
9. Transmission Forward/ Reverse Solenoid 30. PTC heater relay
10. Stop Lamp Switch 31. LPG M/C relay
11. Ground connection Chassis 32. ETC relay
12. Engine Oil pressure Switch 33. Starter relay
13. VCM controller 34. Back buzzer/ reverse relay
14. Mounting Plate Battery 35. EGI relay
15. Battery 36. LPG low level warning controller
16. Fusible links 37. Radiator
17. Battery cable 38. Valve assy solenoid LPG
18. Body harness 39. LPG low level warning switch
19. Coolant level sensor 40. Vaporizer assy (incl PTC heater)
20. Speed sensor 41. Bypass connector engine stop switch
21. Transmission Oil temperature sensor
BE-4
HARNESS LAYOUT
Seat harness
BEM0805EU
1. To Body harness 3.To seat / seat belt switch

2. Seat harness 4. Engine stop switch
BE-5
HARNESS LAYOUT
Fingertip control harness
BEM0804EU
1. Body harness 3. FC_N / FC power relay

2. Fingertip control (FC) harness 4. Relay function differs per model, see body harness k / QD engine
of previous pages
BE-6
HARNESS LAYOUT
Tilt leveling control sub harness
BEM0806EU
1. Body harness 3. Tilt Angle sensor

2. Sub harness Tilt Leveling control 4. Hydraulic pressure sensor
BE-7
WIRING INSPECTION
WIRING INSPECTION
WARNING:
Before starting to work on any part of electrical system, remove rings
and jewelry to prevent an accidental short circuit, and turn off ignition
switch and then disconnect battery ground cable.
Description
Cables are covered with color-coded vinyl for easy identification.
In the wiring diagram, colors are indicated by one or two alphabetical
letters.
It is recommended that the battery be disconnected before performing
any electrical service.
Color code Color of the wire
B Black
BR Brown
CH Dark brown
DG Dark green
G Green
GY Gray
L Blue
LG Light green
OR Orange
P Pink
PU Purple
R Red
SB Skye blue
W White
Y Yellow
When the wire color is striped, the base color is given first, followed by the stripe color as
shown below:
Example: L/W = Blue with White Stripe
Inspection
Inspect all electrical circuits, referring to wiring diagrams. Circuits
should be tested for continuity or short circuit with a circuit tester.
Before inspecting circuit, ensure that:
1. Each electrical component part or cable is securely fastened to its
connector or terminal.
2. Each connection is firmly in place and free from rust and dirt.
3. No cable covering shows any evidence of cracks, deterioration or
other damage.
4. Each terminal is a safe distance away from any adjacent metal parts.
5. Each cable is fastened to its proper connector or terminal.
6. Wiring is kept away fromany adjacent parts with sharp edges.
7. Wiring is kept away from any rotating or moving parts.
8. Cables between fixed portions and moving parts are long enough to
withstand
BE-8
WIRING INSPECTION
FUSE BOX
Fuse
Removal
1. Remove fuse box cover by pushing and turning the hook on cover.
CAUTION:
Be careful not to damage cover.
2. Take out use extractor equipped with inside of cover and remove
fuse with fuse extractor.
CAUTION:
Draw out fuse toward you.
Installation
1. Always use a fuse of specified capacity.
2. Return fuse extractor to original position and install fuse in reverse
order of removal.
BEM0101
NOTE:
• When removing fuse box, disconnect harness connector and remove
fuse box cover.
• Insert a small screw driver into hook to unlock, then remove fuse box
from bracket.
• When installing fuse box, insert part to be fitted into bracket and
securely lock with hook.
BEM0102
Inspection
Check for blown fuse by referring to the right side of the figure. Replace
blown fuse with a new one.
CAUTION:
• When replacing fuse, always use one of specified capacity,
indicated on the fuse capacity label.
• If fuse blows again after replacing, electrical trouble is
considered.
• Immediately inspect and eliminate cause of the trouble.
BEM0199
BE-9
WIRING INSPECTION
Fuse identification
LPG
Power supply No FUSE Applicable parts

capacity
(A)
Ignition key 1 15 Engine electrical

switch parts
BEM0807EU
2 15 VCM, Meter panel
supply, Speed slect
switch, PS select
switch
3 10 Turn signal power,

patrol light back-up
buzzer
4 20 Option (Key on)
Battery 5 20 EGI relay, ECM
6 20 stop lamp, meter

pannel
7 20 PTC relay, ETC

relay
8 20 Lights
DIESEL
Power supply No FUSE Applicable parts

capacity
(A)
Ignition key 1 10 Engine electrical

switch parts
2 15 VCM, Meter panel

supply,
3 10 Turn signal power,

patrol light
4 20 Option (Key on)
Battery 5 Option (Battery)
6 10 stop lamp, meter

pannel
7 10 PBK/BZR relay
8 20 Lights
BE-10
WIRING INSPECTION
Optional Fuses
Inspection
Refer to the above "Inspection".
BEM0104EU
Fusible Link
Inspection
Check for blown fusible link using circuit tester.
CAUTION:
If fusible link is blown, replace with a new one of specified
capacity.Also, check related electrical parts to determine the
cause of problem,and repair if necessary.
BEM0105
BEM0200
BE-11
COMBINATION METER
COMBINATION METER
Description
• Adoption of compact-size meter panel
• Standardization of meters and warning lights
Hour meter, engine coolant temperature gauge, fuel gauge, brake
warning light, seat belt warning light, oil pressure warning light,
charge warning light, mast interlock warning light, and multipurpose
warning light were made standard features for all vehicles.
• Trouble code displays
Forklift malfunction information is displayed as a trouble code on the
hour meter LCD. When a major trouble code is displayed, the
following warning lights simultaneously flash on and off: Brake
warning light, mast interlock warning light, multipurpose warning
light, oil pressure warning light.
Combination Meter Arrangement
1. Multipurpose warning light 5. Charge warning light 10. Water temp. gauge (top center of LCD)
2. Engine check light (gasoline engine forklifts 6. Parking brake warning light 11. Fuel gauge (bottom center of LCD)
only) 7. Seat belt warning light 12. Operation buttons
3. Glow pilot light (diesel engine forklifts only) 8. Liquid Crystal Display (LCD) 13. Time (right side of LCD)
4. Oil pressure warning light 9. Selector lever position (left side of LCD)
BE-12
COMBINATION METER
Warning Light
A black-face lens (making warning marks invisible after the light
turns off) was adopted. When the key is turned ON, all light up,
enabling bulb checks.
Neutral indicator light (Standard feature in ATM models)

• Lights up when the selector lever is in the neutral position.
Neutral indicator light (Standard feature in ATM models)

• Uses the same meter panel light as the neutral indicator light.
• When the driver is not seated, flashes on and off when the selector
lever is in the F or R position.
Brake warning light

• Lights up when the parking brake is engaged. (Standard feature in
all models)
• Lights up when the brake fluid is low. (Option setting)
Seat belt warning light (Standard feature in all models)

• Lights up when the seat belt is not fastened.
Oil pressure warning light (Standard feature in all models)

• As is currently the case, lights up when the lubrication system is
malfunctioning.
Charge warning light (Standard feature in all models)

• As is currently the case, lights up when the charging system is
malfunctioning.
Glow pilot (Standard feature in diesel-powered models)

• As is currently the case, lights up when the key switch is in the ON
position, and turns off when warm-up is completed.
LPG warning light (Standard feature in gasoline/LPG dual-

fuel models)
• Lights up when the remaining amount of LPG is low.
Multipurpose warning light (Standard feature in all models)

• Lights up when the following LCD warning is displayed:
Clutch wear warning (Optional for clutch-operated models)

Torque converter fluid temperature warning light (Optional for
torque-converter models)
Radiator level warning
Air cleaner clog warning (Optional feature in all models)
Fuel filter warning (Standard feature in diesel-powered models)
• When an LCD warning is displayed, "○" flashes on and off in the

warning mark's digit LCD.
Mast interlock warning light (Standard feature in all models)

• Flashes on and off when mast interlock is activated.
BE-13
COMBINATION METER
List of Warning Light Operation

Normal Status after Key- Status after Engine
Item Mark
Switch is Turned OFF, then ON Start-up
BET0119L.tif
Charge warning light ON Light off
BET0120L.tif
Engine oil pressure warning light ON Light off
Glow pilot light BET0121L.tif Light on → Light off after

Light off
(diesel-powered models only) glow is completed
BET0122L.tif Light off after seat

Seat belt Warning light ON
belt is fastened
Brake warning light Light off after

BET0123L.tif
ON parking brake is
Brake fluid level warning light (G.O.M.Only) released
BET0124L.tif
Loading interlock indicator light ON Light off
LPG level warning light (gasoline/LPG dual-fuel BET0125L.tif

ON Light off
models only)
Neutral position light (torque-converter models only) Light off after

BET0126L.tif selector bar is
F/R interlock indicator light (torque-converter models ON
moved to forward or
only) reverse position
BET0127L.tif
Multipurpose warning light ON Light off
BET0128L.tif
Air cleaner clogging warning
BET0129L.tif
Radiator coolant level warning
Normally, the hour meter is displayed.

Clutch wear warning (clutch-operated vehicles BET0130L.tif During a malfunction, the multipurpose warning
only- G.O.M. only) light lights up and a "O" is displayed for the
warning mark on the LCD panel.
Torque converter fluid temperature warning
BET0131L.tif
light (automatic transmission oil temperature
warning) (torque-converter models only)
Sediment water level warning (fuel filter drain BET0132L.tif

warning light) (diesel engine models only)
BE-14
COMBINATION METER
Light Specification
Parts name Wattage (W)/12V Qty Remarks
Fuel gauge, engine coolant temperature

Light 1.4 1
gauge and hour meter
Charge warning light 1.4 1
Engine oil pressure warning light

1.4 1
(Oil pressure warning light)
(Diesel-powered vehicles
Glow pilot light 1.4 1
only)
Seat belt warning light 1.4 1
Brake warning light 1.4 1
Warning Brake fluid level warning light 1.4 1 Optional vehicles

light
Mast interlock indicator light 1.4 1
Gasoline/LPG dual-fuel
LPG level warning 1.4 1
vehicles only
Torque-converter vehicles
Neutral position light 1.4 1
only
Torque-converter vehicles
F/R interlock indicator light 1.4 1
only
Multipurpose warning light 1.4 1
Trouble Code Displays

• Forklift malfunction information is displayed as a trouble code on the
hour meter LCD.
• There are two types of trouble codes: major trouble codes and minor
trouble codes. Driving system malfunctions and engine control
system malfunctions were set as major troubles.
• When a major trouble code is displayed, the following warning lights
simultaneously flash on and off, prompting the operator to
immediately shut down the forklift:
Brake warning light, mast interlock warning light, multipurpose
warning light, oil pressure warning light.
• When a minor trouble code is displayed, the multipurpose warning
light lights up.
Fuel Gauge and Engine Coolant Temperature Gauge

• Reset-to-zero types are used.
• The intermediate range of the engine coolant temperature gauge
was set to 90 to 105C.
Hour Meter
• The hour meter is displayed when engine is running.
Speed Display Control

• Pulse signals are output to the combination meter and speedometer,
based on speed information from the VCM.
BE-15
COMBINATION METER
1. Multipurpose warning light 5. Charge warning light 10. Water temp. gauge (top center of LCD)
2. Engine check light (gasoline engine forklifts 6. Parking brake warning light 11. Fuel gauge (bottom center of LCD)
only)
7. Seat belt warning light 12. Operation buttons
3. Glow pilot light (diesel engine forklifts only) 8. Liquid Crystal Display (LCD) 13. Time (right side of LCD)
4. Oil pressure warning light 9. Selector lever position (left side of LCD)
Speed Display System

• The VCM receives output from the speed sensor and sends speed
data to the combination meter via CAN transmission.
• The speedometer displays the speed by receiving prescribed pulse
signals from the combination meter.
• The number of pulse signals is computed by the combination
meter at a ratio of 360 Hz to 30 km/h, 18.6 MPH.
Speed sensor
Sine wave
VCM
CAN transmission
Combination meter
Pulse signal
Speedometer
BE-16
SWITCHES
SWITCHES
Combination Switch
DESCRIPTION
• The turn signals and F/R switches were integrated into a single unit. Also, a light switch structure was adopted.
• An auto return function was adopted for the turn signal lever.
• Three-stage light switches were adopted, with the third stage being auto light mode (optional).
• A single-stage forward/single-stage reverse system was adopted for the selector lever.
Light switch
Switch position Lights
•Meter illumination light

•Tail light
1st step
•Clearance lights (forklift inspection
specifications)
•Meter illumination light

•Tail light
2nd step •Clearance light (forklift inspection
specifications)
•Headlight
Turn signal switch

• This switch is used to indicate the forklift's direction of travel. If the
light switch is moved forward or toward the driver, the direction
indicator will flash on and off.
To turn left: Press the switch away from the driver.
To turn right: Pull the switch toward the driver.
NOTE:
• Selector lever (torque-converter models) is installed on left side
when the other switches are on the right side (option). The operation
is the same.
Selector lever (torque-converter models)

• Switch for changing moving direction (forwards or backwards) Lever
position is forward/backward when moving forward/backward
direction. The middle position is neutral.
NOTE:
• On the right side (option), the operation is the same too.
BE-17
SWITCHES
Tilt Leveling Switch (Option)

• When the mast is in a backward tilted position, the subsequent
forward tilt operation can stop automatically when the forks reach the
horizontal position.
• If the operator executes a forward tilt operation while pressing the tilt
horizontal switch, the mast will move according to the loading
conditions and height as shown in the table below.
Loading
Lifting height Forward tilt operation of mast
condition
Low lifting height Automatically stops in the horizontal fork

Without load
position.
High lifting height
Low lifting height

With load No automatic forward stop to horizontal
High lifting height
With load: Turning on the tilt-horizontal switch during operation will not automatically stop tilt in
horizontal direction but will continue in manual operation mode.
CAUTION:
• It is assumed that the horizontal position at which the forks

automatically stop is a position where the ground surface is flat.
If the ground is not flat, do not use this function.
NOTE:
• If there are two levers, the tilt horizontal switch is attached to the tilt
lever.
• The tilt horizontal switch will be ON while pressed, and OFF when
released.
• If the tilt horizontal switch is not pressed, normal forward and
backward tilting will occur.
• Moreover, if a forward tilt operation automatically stops via the tilt
horizontal switch, forward and backward tilt operations cannot be
executed until the tilt horizontal switch is released and the control
lever is returned to the neutral position.
BE-18
SWITCHES
Maximum Speed Switch (Option)

This switch is used to switch the maximum speed to High (H) or Low
(L). If it is not necessary to restrict the maximum speed, press the H
side. If restricting the maximum speed is desired, press the L side.
The side of the switch that was pressed will light up, highlighting the
selection.
Throttle Sensitivity Adjustment Switch (Option)

• This switch is used to switch the acceleration to Power (power mode)
or ECO (Economy mode).
• When normal acceleration is required, press the Power side. When
gentle acceleration is desired, press the Eco side.
• The side of the switch that was pressed will light up, highlighting the
selection. Settings can be changed in the conditions shown below.
○ : OK X: NG
Switching Operation Driving Stopping
From power mode to Economy mode X ○

From Economy mode to power mode X ○
NOTE:
Switching from the ECO mode to the POWER mode can be made
Inspection
• Using circuit tester (set to ohm range), check for continuity in turn
signal switch circuit with switch set to the following positions: L, N, R.
Switch position Terminals
OFF No (2-3)
ON 1-2 (-3)
START 1-2-3-4
Switch
position
OFF ON START
Terminal
1(B) ○ ○
2(IG) ○ ○
4(ST) ○
BE-19
SWITCHES
Engine Stop Switch
BEM0123
Inspection
Check continuity between terminals using circuit tester ( range).
Terminals Neutral Pushing the Remarks

condition switch
2-3 No continuity Continuity Using the

circuit
1-2 Continuity No continuity Reference
BEM0121
BEM0122
BE-20
HEADLAMPS
HEADLAMPS
Lamp Specification
Description Wattage Quantity Color Remarks
(W)
Headlamp 55 2 White
Front turn signal lamp 23 2 Orange
Rear combination lamp Stop/tail lamp 21/5 2 Red
Turn signal 21 Orange
Reverse 21 White
Back operation lamp (Opt) 35 1 White
Pato lamp (Opt) 33 1 Yellow/Red
CAUTION:
• When installing a new bulb, always use the one with the specified capacity.
• Do not touch halogen bulb surface by hand. When adherence of oil by hand, it cause the light bulb burn
out.
Headlights
BEM0130
1.Guard cover 4.Reflector 6.Spring

2.Lens 5.Housing 7.Protector
3.Bulb
BE-21
HEADLAMPS
1. Remove headlight securing nut.

2. Disconnect harness connector.
3. Remove lens securing screw when replacing bulb.
4. Install in the reverse order of removal.
Aiming adjustment
• Adjust the angle 10 degree to downward from horizontal surface.
Front Turn Signal Light
BEM0131
1. Lens 2.Housing 3.Bulb

1. Remove bracket securing screws.
BE-22
HEADLAMPS
Rear Combination Light
BET0147L.tifÅ@V
1. Lens 4. Back operation light 7. Lens securing screw

2. Stop and tail light bulb 5. Housing
3. Turn signal bulb 6. Protector

1. Remove lens securing screws from rear pillar.
3. Remove screw when replacing bulb.
BE-23
HEADLAMPS
Back Operation Light / Pato Lamp
BEM0133
1. Rim 5. Bulb 8. Washer

2. Lens securing screw 6. Reflector 9. Nut
3. Lens 7. Housing 10. Bracket
4. Packing

1. Remove nut.
BE-24
OTHERS
OTHERS
Backup Buzzer

11.Disconnect harness connector and remove bolts.
12.Install in the reverse order of removal.
NOTE:
• For prevent buzzer sound during nighttime or urban area, activation switch
BET0151L.tif ON/OFF is available on instrument panel. (G.O.M. Only)
Horn

13.Disconnect horn harness connector.
14.Remove bolt and horn.
15.Install in the reverse order of removal.
NOTE:
BET0152L.tif • Earthing type changed from body type to wire type.
• Improving the reliability and eliminate horn relay.
Speed Sensor

16.Unfasten sensor, remove from transmission case.
17.Install in the reverse order of removal. Replace when O-ring get
scratched.
BET0153L.tif CAUTION:
• Prevent oil leak when installing.
Gap between sensor and gear (mm, in.): 1.0, 0.039

Lock nut tightening torque: [N-m (kg-m) Ft./Lbs.]:
35.3 - 43.1 (3.6 - 4.4) 26 - 32
CAUTION:
• Prevent interference between sensor and gear.
BE-25
OPTIONAL LIGHTS
Blue / Red light

BET0154L
• After connecting the connectors, place them

inside the RR RH OHG pillar
BET0155L
• Wiring diagram Blue/

Red lamp activated by
reverse
<Blue / Red Lamp>
<Blue / Red Lamp>
BET0156L
BE-26
OPTIONAL LIGHTS
Blue / Red light

Specifications and precautions
• Blue/Red light are rated from 12V to 110V.

At 12V, they use 0.50A.
The IP rating is IP69K.
BET0157L
• After installation and or replacement of the Blue/Red

lamp assembly, always make sure the lamp is
correctly adjusted, refer to figures on the left.
• NOTE (for Blue light only) on photobiological

safety (according to IEC 62471). The warning light
Model 770 (only variant BLU) is assigned to risk
group 2 with regard to its photobiological safety. Due
to the wavelength of blue light used, an eye injury
may result. The risk varies with the distance. The
aversion response of a person exposed to the light
source is usually sufficient to prevent eye injuries.
BET0158L CAUTION:
Please note the inadvertent activation of the

BET0159L warning light must be prevented during
maintenance work on the forklift.
Please attach a warning sign (Blue lights installed

from factory are equipped with this sign) for
photobiological safety when installing the warning
light. This sign must be visible and legible. It should
be installed in such a way that an observer is not
unnecessarily exposed to the light source.
RISK GROUP 2 CAUTION

Possibly hazardous optical
radiation emitted
BET0160L
BE-27
OPTIONAL LIGHTS
LED lights
Rear Combination lights
BET0161L
Front & Rear working lights and Beacon Light
BET0162L
BE-28
OPTIONAL LIGHTS
LED lights
• Wiring diagram LED indicators
BET0163L
Specifications
• Front operation lights are rated

from 12V to 48V.
At 12V they use 12A.
IP rating IP67.
400 Lumen
BET0164L
• Rear Combination lights are rated

from 12V to 48V.
At 12V they use 1.6A
IP rating IP67.
BET0165L
BE-29
OPTIONAL LIGHTS
LED lights
Specifications
BET0166L • The Beacon light is rated from

10V to 100V.
At 12V it uses 220 mA.
IP rating is IP55.
At 12V it flashes at 1.4 Hz (84 flashes/min).
• The rear operation light is rated from

9V to 60V.
At 12V it uses 1.25A.
1400 Lumen.
BET0167L
BE-30
MANN + HUMMEL SMF®-AR
Diesel Particle Filter with
Active Regeneration
Installation Manual
Index No.: 1059009S01_D Version 0908

Contact information
Contents
This installation manual is a component part of the
scope of delivery. It must be kept in a safe place 1 General information............................................3
2 Safety ...................................................................3
and must be transferred as part of the device in
2.1 Warning labels and symbols ........................3
the event of resale. 2.2 General information......................................3
We reserve the right to make technical 2.3 Intended use.................................................3
modifications to the filter and/or the content of this 3 Function Description SMF®-AR System ..........4
installation manual without notification. 4 System Overview, SMF®-AR .............................5
5 Installation Criteria .............................................6
Reprinting, translation and copying this document 5.1 General information......................................6
by any means, requires the written approval of the 5.2 Installation position, additive dosing system 6
publisher. 5.3 Installation position, filter system with
Copyright is with the publisher. differential pressure sensor .........................7
5.4 Installation position, electronic system.........8
This installation manual is not subject to any
5.5 Installing the additive dosing system............8
updating service. 5.6 Installing the SMF®-AR filter system .........11
All rights reserved. 6 Example Configurations...................................12
You can find out the updated version by contacting 7 Installation, Electronic Control Unit................20
7.1 Installation, ECU.........................................20
7.2 Installation, indicator module and alarm
MANN+HUMMEL GMBH buzzer ........................................................20
Geschäftsbereich Industriefilter 7.3 Installation, differential pressure/temperature
sensor ........................................................21
Brunckstr. 15 7.4 Installation, air flow sensor (AFS) ..............22
D - 67346 Speyer 8 Cable Harness ...................................................23
Internet: http://www.mann-hummel.com/ 8.1 Installation and connection, cable harness 24
9 Programming the ECU from a CD ...................26
E-mail: si.retrofit@mann-hummel.com 9.1 Starting up the software .............................26
9.2 Key entry ....................................................27
9.3 Connection, diagnosis interface to the
system........................................................27
9.4 Diagnosis software for the system .............28
9.5 Creating the system configuration..............28
9.6 Setting the speed factor .............................29
9.7 Setting the tank curve.................................30
9.8 Defining the configuration and engine
characteristics............................................32
9.9 Configuration of the ECU ...........................35
9.10 Checking the configuration.........................35
10 Function Description, Indicator Module .........36
10.1 General information....................................36
10.2 System start ...............................................36
10.3 Key description overview............................37
10.4 SMF®-AR System error list........................43
11 Checklist ............................................................45
MANN + HUMMEL Industrial Filters 2

1 General information 2.2 General information

Read this installation manual thoroughly before The filter housing of the SMF®-AR
beginning to install and start the SMF®-AR system heats up during operation and
systems. can cause burns if touched with bare
It serves to provide instructions on installing skin. When the filter housing has
SMF®-AR systems and is suited for mechanics heated up, it is a potential source of a
trained by Mann + Hummel. fire or ignition hazard.
It is essential to observe the instructions stipulated The device must be positioned so that
by the manufacturer and documented in this the diesel particle filter cannot come
installation manual. When installing the SMF®-AR into contact with easily flammable
system, ensure the components are handled with materials (e.g. including dry grass).
the necessary care and attention because
handling the SMF®-AR system improperly could
lead to permanent damage. Failure to observe the The additive used is hazardous to
information voids any rights to claims against health and is subject to special hazard
MANN+HUMMEL according to the warranty terms. warnings.
Applicable accident prevention regulations and all
other generally accepted industrial safety and
health laws must also be observed.
Equipment and fittings installed in the device by
the manufacturer can vary. As a result, there may 2.3 Intended use
be deviations between the information in this
manual and your device. The SMF®-AR system has been exclusively
We cannot exclude the possibility of errors. designed for filtering the exhaust of diesel engines.
Observation of the operating and maintenance
Illustrations may not be representative in all cases. manual and maintaining the inspection and
Connect MANN+HUMMEL if there is any maintenance conditions are considered part of the
confusion. intended use.
We reserve the right to make modifications and The manufacturer is not liable for damages in the
amendments. case of unintended use. Applicable accident
©2008 MANN+HUMMEL GmbH. prevention regulations and all other generally
All rights reserved. accepted industrial safety and health laws must
Status 10/2008 also be observed.
The operator is obliged to inspect the SMF®-AR
2 Safety system once a week for visible signs of damage
2.1 Warning labels and symbols and defectives and to report any changes
(including in the operational behavior) which could
This label (or descriptive pictogram) impair its functional safety.
indicates sections which concern your The filter may only be installed and maintained by
safety. Failure to observe the trained, authorized personnel.
information leads to the potential risk of
personal injury. The applicable legal and safety regulations must
be observed when using and operating the filter
This label indicates sections which system. This also applies when implementing
must be strictly observed to prevent the accessories.
risk of damage or destruction of the The SMF®-AR system has been constructed
SMF®-AR system and device. according to state-of-the-art technology and
This label indicates that special accepted safety-related regulations. However, the
attention must be paid to the functional safety of aftermarket and second hand
information in order to ensure trouble- units can be at risk when:
free, economic operation. • the SMF®-AR system is used improperly,
• the operating conditions have changed,
• reconstructions have been made without
consultation with the manufacturer,

• essential maintenance and repair work has The control unit monitors the electrical function of
been neglected. all the components in the dosing system. If errors
Only use the SMF®-AR system for its intended occur during driving operation, they are displayed
use when in a safe working condition, taking the on the indicator module. The error code can be
relevant safety and risk aspects into account and downloaded and the fault localized using a
observing the operating and maintenance manual. diagnosis unit or PC / laptop with corresponding
software.
Faults, particularly those which affect safety,
should be investigated immediately! Please pay attention to the system overview on
Page 5 of this installation manual.
3 Function Description
SMF®-AR System
The SMF®-AR system is comprised of a sintered
metal particle filter (SMF®) with a fully automatic
regeneration unit (AR). This is capable of oxidizing
the soot accumulated in the filter, in any engine
operating states, without any support from the
engine management and without upstream
catalyst.
The system is suitable for retrofitting on existing
machines already in use. The sintered metal filter
retains particles produced while the engine is
running with an efficiency factor of almost 100%.
The sensors mounted on the filter constantly
monitor the exhaust temperature and exhaust
back pressure in the filter. This determines the
increasing quantity of soot in the filter as the
engine running time lengthens. When sufficient
soot has accumulated in the filter, the electronic
control unit automatically triggers a regeneration.
In order for the soot oxidation to be possible in a
short time and with a low external power supply,
an additive is mixed with the diesel fuel by the
automatic dosing system.
The regeneration procedure of the filter is initiated
according to the filter load.
In this case, the electrical heater elements are
switched on for approximately two minutes.
If the device is started after being filled with fuel,
the system independently detects the fuel quantity
filled and doses the additive in the fuel return line
accordingly.
A piston pump is used as the dosing pump. While
the engine is running, it doses the additive in the
return flow of the device fuel line (leading from the
engine to the tank). The return flow feeds the
additive, which has already been mixed, in the fuel
tank.

Differential pressure
Speed signal Indicator module and Sintered metal diesel particle filter (SMF®)
sensor
generator diagnosis connection
MANN + HUMMEL Industrial Filters

4 System Overview, SMF®-AR
Alarm buzzer
Diesel engine
Ground
Air flow sensor
Pressure measuring point upstream

from filter
Fuel gauge Temperature sensor
Fuse Sintered metal filter
Heating element
Pressure measuring point downstream from
filter
Measuring and control line
Additive filter Differential pressure measurement
Fuel tank Dosing pump
Additive line
Additive tank Electronic control
unit Power supply
5
5 Installation Criteria • The installation position of the additive

tank must be chosen so that it is possible
5.1 General information to fill it by inserting a funnel in the filling
neck.
Before beginning any work, it is
essential to ensure all the component • The additive system must be fitted in the
locations are defined in accordance engine compartment.
with the installation criteria! • The dosing pump must be positioned and
Disconnect the appliance battery mounted horizontally (± 5°) under the
before starting any work. additive tank.
The dosing pump can be installed as
5.2 Installation position, additive required in axial direction (± 180°).
dosing system
• The length of cable between the ECU and Pay attention to the direction of flow
dosing pump may be a maximum of 4 (marked on the dosing pump)!
meters.
• The additive system must be positioned • The hoses from the additive tank to the
near the fuel return line. dosing pump, including additive filter, may
be maximally 0.6 meters long.
• The dosing pump must be installed a
maximum of 5 cm hose length from the
return flow line.
Fuel gauge
sensor Tank ventilation
Additive
5 cm
filter
Dosing pump
Additive Electronic control unit
tank

5.3 Installation position, filter system with differential pressure sensor

• The filter system can replace the OE • The lengths of cable from the ECU to the
silencer. Alternatively, the particle filter filter housing to connect the heater may be
system can be installed in other locations a maximum of 4 meters.
in the exhaust system. Pay attention here The lengths of the cables supplied are 1
to sufficient space from other meter. Alternatively, only one of the
components. optionally available extension cables (up
The filter system can be installed to max. 3 meters) may be assembled.
horizontally or vertically (standing or • The ground cable must be connected to
hanging). the filter system. Pay attention to good
• The hose lengths to the differential ground contact at the ground points or
pressure sensor may be a maximum of battery.
1.5 meters. (Max. 100A).
• The installation position of the differential • To assemble the filter system, the
pressure sensor must be selected so that optionally available holders can be used
it is positioned sufficiently high above the and must be taken into account when
pressure measuring point and the defining the installation position.
pressure lines can be installed with a
constant incline down to the measuring
points. The filter system must be assembled
To rule out the accumulation of mechanically disconnected from the
condensation in the pressure sensor, the engine!
pressure connections must point vertically Assembly is only permitted on the
downwards. device chassis and not on the engine!
Pay attention to the thermal insulation
of the filter system (optionally
available)!
Differential pressure Sintered metal filter (SMF)

gauge
Temperature sensor
Ground
Electronic control unit (ECU)

5.4 Installation position, electronic • The length of cable from the fuse holder
system (3) to the battery must not be altered.
• The air flow sensor (4) must be installed in
• The indicator module (1) must be the engine air intake between the air filter
positioned within the visual range of the and engine (5). In the case of devices with
driver/operator. The length of cable to the an exhaust turbocharger, the air flow
ECU (control unit) may be shortened but sensor must be installed between the air
not extended (an extension of 10 m with filter and turbocharger.
signal amplifier is available on option).
• The length of cable from the ECU (2) to Observe the direction of flow of the air
the battery must not be altered but can be flow sensor.
freely selected between 600 mm and
3000 mm. Only one extension may be
used.
4
5
Ground and control line

Differential pressure measurement
Additive line
Power supply
2
5.5 Installing the additive dosing system

The additive used is hazardous to R65 - hazardous to health
health. Damage to the lungs is possible if swallowed.
R48/22 - hazardous to health: R66 - hazardous to health:
Risk of damage to health following Repeated contact can lead to chapped or cracked
longer exposure through swallowing. skin.
Contains: Ferrocene derivate

4 2
1
• Select a suitable location for the additive

tank (1).
1 9
Comment: It is preferable to position
the additive tank near the fuel return
. line.
• Fix the additive tank to the device.

• Connect the additive filter (2) to the
additive tank with the rubber hose (3).
Observe the direction of flow!
• The hose from the additive tank to the 3
additive filter should be as short as
possible. 2
• Select a suitable location for the dosing
pump (4). 4 8
The dosing pump (4) must be positioned
and mounted horizontally (± 5°) under the
additive tank.
The dosing pump can be installed as
required in axial direction (± 180°).
• Fix the dosing pump to the device using 4
the clip supplied (max. hose length 0.6 m).
Pay attention to the direction of flow

(marked on the dosing pump)!

• Insert the T-piece connector (5) in the fuel

return line (6) to the device fuel tank.
• Connect the hose from the dosing pump to
the return flow line using the hose 7
supplied (7) (50 mm).
• After having laid the hose from the
additive tank to the return flow line, check
the hose connection for leaks and ensure
it does not rub against other components.
• Attach the tank label (8) supplied in a
visible position on the additive tank.
Additive tank, filling

5
• Fill the optionally available additive (9) in
the additive tank.
The additive dosing system may only

be operated with the additive DT 7
approved by MANN + HUMMEL.
10
Additive tank, venting
• Mount the tank ventilation (10).
• Screw the tank ventilation in the additive
tank and fix the hose.
• After installing the tank ventilation, check
the venting hose is protected against
chaffing on other components.

5.6 Installing the SMF®-AR filter

system
Differential pressure gauge
Sintered metal filter (SMF)
Temperature sensor
Ground
Electronic control unit
(ECU)
Installing the SMF®-AR filter system

• Disconnect the appliance battery. In the case of horizontal installation,
• Determine the installation location for the the heater connection must always be
filter system. at the top.
The filter system can replace the OE • Disassemble the OE silencer, if necessary.
silencer. Alternatively, the particle Install and connect the filter system.
filter system can be installed in other • Install the temperature sensor.
locations in the exhaust fume
system. Pay attention here to
sufficient space from other Ensure the temperature sensor is not
components. bent during installation.
The sound-absorbing effect of the
SMF-AR silencer cannot be Mounting the SMF®-AR filter system
guaranteed to be comparable to
The filter system must be installed
OEM silencers.
decoupled from the engine by means
It is recommended to complete a of a flex pipe.
noise level measurement in order to
fulfill and any applicable noise level The filter system must be insulated if If
regulations. risk of combustibles or human skin
contact could exist!
• The installation position must be selected
so that the filter system can be
disassembled for maintenance and all the • The filter is fixed by means of the optionally
lines can be postioned without touching available system holder.
each other.
Piping of the SMF®-AR filter system
• The filter system can be installed
horizontally, vertically or hanging. • Connect the pressure measuring points
upstream and downstream from the filter.

6 Example Configurations
SMF®-AR filter system 1.8m²
axial-axial
19
18
17
16
15
1 14
2 13
3 12
11
4 10
9
8
7
6
5
Key
1 Gasket 11 Bearing / System holder (option)
2 Flange 12 Heater module
3 Temperature sensor connection 13 Heater connection
4 Measuring tube 14 SMF filter
5 Pressure sensor before filter connection 15 Gasket
6 Inlet cone, axial 16 Clip connection, tightening torque 15 Nm
7 Clip connection, tightening torque 15 Nm 17 Gasket
8 Gasket 18 Outlet cone, axial
9 Distance ring 19 Pressure sensor after filter connection
10 Wire mesh

SMF®-AR filter system 1.8m²

radial-radial
1 19
3 2 18
17
16
4 15
14
5 13
12
11
10
9
8
7
6
Key
1 Measuring tube 11 Bearing / System holder (option)
2 Temperature sensor connection 12 Heater module
3 Pressure sensor before filter connection 13 Heater connection
4 Flange 14 SMF® filter
5 Gasket 15 Gasket
6 Inlet cone, radial 16 Clip connection, tightening torque 15 Nm
8 Gasket 18 Outlet cone, radial
9 Distance ring 19 Pressure sensor after filter connection
10 Wire mesh

SMF®-AR filter system 2.7+3.8m²

axial-axial
When assembling the SMF® filter, filter

system and heater, the installation
markings must be in line!
23
22
21
20
19
18
16
15 17
1 14
2
3 13
12
11
4 10
9
8
7
6
5
Key
1 Gasket 13 Gasket
2 Flange 14 Bearing / System holder (option)
3 Temperature sensor connection 15 Heater module
4 Measuring tube 16 Heater connection
5 Pressure sensor before filter connection 17 Installation marking, filter system
6 Inlet cone, axial 18 SMF® filter
7 Clip connection, tightening torque 15 Nm 19 Installation marking, SMF® filter
8 Gasket 20 Gasket
9 Bearing / System holder (option) 21 Clip connection, tightening torque 15 Nm
10 Filter housing extension 22 Outlet cone, axial
11 Clip connection, tightening torque 15 Nm 23 Pressure sensor after filter connection
12 Wire mesh

SMF®-AR filter system 2.7-3.8m²

radial-radial
23
1
3 2 22
21
20
19
18
4 17
15
5 14 16
13
12
11
10
9
8
7
6
Key
1 Measuring tube 12 Wire mesh
2 Temperature sensor connection 13 Gasket
3 Pressure sensor before filter connection 14 Bearing / System holder (option)
4 Flange 15 Filter system
5 Gasket 16 Installation marking, filter system
6 Inlet cone, radial 17 Heater connection
7 Clip connection, tightening torque 15 Nm 18 SMF® filter
8 Bearing / System holder (option) 19 Installation marking, SMF® filter
9 Gasket 20 Gasket
10 Filter housing extension 21 Clip connection, tightening torque 15 Nm
11 Clip connection, tightening torque 15 Nm 22 Outlet cone, axial
23 Pressure sensor after filter connection

SMF®-AR filter system 5.4 m²

axial-axial
28
27
26
25
23 24
22
21
20
19
18
17
16
15
14
13
12
11
8 10
7 9
6
5
4
3
1 2
Key
1 Transition piece 15 Clip connection, tightening torque 15 Nm
2 Pressure sensor connection, after filter 16 Gasket
3 Gasket 17 Filter housing extension
4 Outlet cone, axial 18 Gasket
5 System holder, tightening torque 25 Nm (option) 19 Clip connection, tightening torque 15 Nm
6 Clip connection, tightening torque 15 Nm 20 System holder, tightening torque 25 Nm (option)
7 Gasket 21 Inlet cone, axial
8 SMF® filter 22 Gasket
9 Gasket 23 Transition piece
11 Heater housing 25 Flange
12 Installation marking, SMF® filter 26 Measuring tube
13 Inner wire mesh 27 Pressure sensor before filter connection
14 Outer wire mesh 28 Temperature sensor connection


radial-radial
28
26 25
27 24
23
22
21
20
19
1
18
2 17
3 16
15
14
13
12
11
8 10
7 9
6
5
4
Key
1 Pressure sensor after filter connection 15 Clip connection, tightening torque 15 Nm
2 Transition piece 16 Gasket
4 Outlet cone, radial 18 Gasket
7 Gasket 21 Inlet cone, radial
13 Outer wire mesh 27 Pressure sensor before filter connection
14 Inner wire mesh 28 Temperature sensor connection


axial-axial
28
27
26
25
24
23
22
21
20
19
18
10
16
15
14
13
12
9 11
8 10
7
6
5
4
2 3
1
Key
1 Transition piece 15 Clip connection, tightening torque 15 Nm
2 Pressure sensor after filter connection 16 Gasket
4 Outlet cone, axial 18 Gasket
7 Gasket 21 Inlet cone, axial


radial-radial
28
26 25
27 24
23
22
21
20
19
1
18
2 17
16
3 15
14
13
11
12
8 10
9
7
6
5
4
Key
1 Pressure sensor after filter connection 15 Clip connection, tightening torque 15 Nm
2 Transition piece 16 Gasket
4 Outlet cone, radial 18 Gasket
7 Gasket 21 Inlet cone, radial

7 Installation, Electronic Control Unit

7.1 Installation, ECU
Do not install the ECU with the

connector strip at the top. Risk
through penetration of moisture! 1
• Find a suitable installation location for the

ECU (1) in the device.
Comment:
It is preferable to assemble the ECU
where it is protected from spray. The
fixation tabs can be adapted to the
installation position.
The ambient temperature may not
exceed max. 80°C!
• Fix the ECU in place. If necessary, use
the additional holding bracket supplied.
7.2 Installation, indicator module and alarm buzzer

Comment:
The installation location should be
within the visible range of the
driver/operator. 2
• Find a suitable location for the indicator
module (2) and alarm buzzer in the
device interior.
• Assemble the indicator module using the
holding bracket supplied.
• The alarm buzzer must be installed in the
driver's/operator's working area (refer to
Ch. 8, Cable harness).

7.3 Installation, differential pressure/temperature sensor

• Install the differential pressure sensor (3)
The hoses to the differential pressure

sensor may be maximally 1.5 meters
long.
The installation position of the differential

pressure sensor must be selected so that
it is positioned sufficiently high above the
pressure measuring point and the
pressure lines can be laid with a constant
incline down to the measuring points.
To rule out the accumulation of

condensation in the pressure sensor, the
pressure connections must point
vertically downwards. 3
• Establish the connection between the

differential pressure sensor and
measuring points using the hoses and
clips supplied. Comment:
The 8 mm "HI" connection on the
differential pressure sensor must be
connected to the measuring point
upstream from the filter.
• The 6 mm "REF" connection on the
differential pressure sensor must be
connected to the measuring point
downstream from the filter.
• Screw the exhaust temperature sensor
(4) in the measuring tube of the SMF®-
AR system.
4
Pay attention that it is not bent.

7.4 Installation, air flow sensor (AFS)

• The AFS must be installed in the engine
air intake between the air filter and
engine. In the case of devices with an
exhaust turbocharger, the AFS must be
installed between the air filter and
turbocharger.
• Observe the direction of flow of the AFS
(5). (Refer to the arrow on the housing
(6)).
• The AFS must not be removed from the
AFS SMF-AR 1.2 - 3.8
plastic housing and must be installed in
the engine unaltered. Changes to the
stabilizing section (length and diameter of AFS SMF-AR 5.4 - 8.1
5
the plastic tube) lead to malfunctions.
• It is essential to check for leaks in the
intake air flow after installing the AFS.
Leaks can lead to engine damage.
Installation, AFS in the SMF®-AR 1.2 – 3.8
• The AFS must be installed horizontally
(±85°) and may be turned a maximum of
±85° from the 12 o'clock position in axial
direction. 6
• Complete the electrical connection to the
cable harness supplied in accordance
with the circuit diagram (refer to
Appendix).
Installation, AFS in the SMF®-AR 5.4 – 8.1
• There are four different diameters of AFS
available for selection for installation in
the SMF®-AR 5.4 – 8.1 in accordance
with the engine. Please take into account
prior to assembly.
• The gasketed screws in the air flow
sensor must not be opened.
• Horizontally, the AFS can be installed
tipped +135° or -45° (see figure.)
• Axially, the AFS can be installed rotated
360° (see figure)
• Only the hose clips supplied may be used
for installation purposes.
• The AFS requires a power supply of 12V.
The 24/12 V voltage converter supplied
must be used for connection of the power
supply in order to convert the 24 V on-
board supply to 12 V. Refer to the circuit
diagram for the connections (refer to
Appendix).

8 Cable Harness
Indicator module
Indicator module Indicator module

2-pin plug 4-pin plug Fill level 2 Speed Fill level 1
red
black
Alarm buzzer
black
yellow / blue
blue / pink
blue / lilac
red / white
black / red
green Device
yellow /
brown /
fuse
black
Power supply Power supply

Terminal 15 (after Terminal 15
fuse) (before fuse)
Adapter cable blue / gray ECU

red / white
brown
black
Air flow sensor
Cable harness
white
black / white
Dosing pump
Temperature sensor
Diagnosis cable connection
Assignment, see
brown / blue
4-pin plug
blue / brown
Indicator module
red / white
brown / white
blue / white
Pressure
sensor
brown
red
red
blue
black
Fuse
Fuse
red
red
Heater
Terminal 31 Terminal 30
Battery

8.1 Installation and connection, cable harness
Connection, air flow sensor signal cable

Before starting any work, disconnect • The appropriate adapter cable must be
the negative pole of the battery! used to connect the air flow sensor.
In the case of 24 V on-board power
• The cable harness must be connected supply, the voltage converter supplied
according to the cable harness diagram. must be used with the SMF-AR 5.4 and
8.1!
Connection, electric heater • Cable length: 4 m
• Lay the power cable to the filter heater • The signal cable can be shortened, if
and connect it via the connection plug. necessary, and connected to the crimp-
• Cable length: 1.5m shrink connectors supplied.
Extensions in lengths of 1, 2 or 3 m
(option) Connection, engine speed signal cable
• Lay the signal cable from the ECU to the
The power cable to the electric heater appliance generator and connect the plug
may only be lengthened by one connectors to Terminal W or signal out put
extension! from Alternator.
• Cable length: 4 m
Connection, ground strap • The signal cable can be shortened, if
necessary, and connected to the crimp-
• Establish an electrical connection between
shrink connectors supplied.
the filter housing and appliance chassis or
ground point using the ground strap
supplied. Pay attention to good ground Connection, fill level sensor 1 signal cable
contact at the ground points or battery. This is only used when the fuel gauge sensor is
Grind the contact bare. existing on equipment.
• Position the signal cable to the fuel gauge
Connection, temperature sensor sensor and connect it to the tank signal
• Position the signal cable to the line with the plug.
temperature sensor at the filter inlet and • Cable length: 4 m
connect it. • The signal cable can be shortened, if
• Cable length: 4 m necessary, and connected to the crimp-
• The signal cable can be shortened, if shrink connectors supplied.
Connection, differential pressure sensor

signal line
• Position the connecting line to the
differential pressure sensor and connect it.
• Cable length: 4 m
• The signal cable can be shortened, if

Fill level sensor 2 Connection, power supply

This is only used if a resistance fuel level sensor battery positive pole / 100A
has been retrofitted. • Lay the cable harness from the ECU to the
• The line is the sorter of the two fuel level appliance battery and connect it to the
sensors wires and can be extended by positive pole.
max. 4 m. Comment: The fuses must be removed
• Connect to the positive pole of the fuel from the fuse holders before making
gauge sensor. connections to the battery and only
• The negative pole of the fuel gauge replaced when all the work has been
sensor is connected to ground. completed.·
• Other fuel gauge sensor systems may • Optional cable lengths: 0.6 / 1.0 / 2.0 /
only be used following consultation with 3.0m
your service partner. Connection, power supply
Connection, dosing pump ground battery negative pole
• Lay the connecting cable to the additive • Connect the electrical connection to the
dosing pump and connect it.· negative pole.·
• Cable length 4 m· • Selectable cable lengths: 0.6 / 1.0 / 2.0 /
• The control line can be shortened, if 3.0 m
necessary, and connected to the crimp- Connection, voltage ignition positive pole
shrink connectors supplied. • Connect the electrical connection to the
Connection, indicator module signal cable positive pole of the ignition via the fuse.
• Lay the cable from the ECU to the Connection, alarm buzzer
indicator module. • Connect according to the cable connection
Comment: Connect plugs A and B diagram.
jointly to the indicator module.
Plug B serves as the diagnosis
interface. If necessary, disconnect the
plug and establish a connection to the
PC using the diagnosis cable.·
• Cable length: 5 m .
The signal cable can be shortened, if
The signal cable must not be extended!

9 Programming the ECU from a CD

Important information:
The following description of the
diagnosis software relates to
Version 1.2.2.45. When using a
control unit from software Version
0.10.155, this diagnosis software
(V.1.2.2.45) must be used. The
diagnosis software is compatible
with older control unit software
versions.
CD content Installation and starting up

• Diagnosis software: Diagnose.exe • First of all, copy all the files supplied on the
• Configuration files: *.cf_/ *.da_ CD into a separate folder on the PC. The
software is immediately ready to use and
• This manual as a .pdf document need not be installed separately.
• Diagnosis software manual as a .pdf • The diagnosis cable required can be
document obtained from MANN+HUMMEL.
9.1 Starting up the software

• After starting the diagnosis software for
the first time, select "Options / Serial
Port" to define the serial port
(COM1,COM2,..) which connects the PC
to the control unit.
• The baud rate of the serial port must be
set to 38400 Baud.
• If the PC is not equipped with a serial
port, use an appropriate USB serial
adapter. Trouble-free operation of the Software Version
diagnosis software is not guaranteed with Diagnosis Software
all USB serial adapters currently on the
market. Further information is available
from your service partner.
Software Version
Diagnosis Software

9.2 Enter key

• A key must be defined in order to use the
diagnosis software. It can be entered
using the "Options / Enter key" menu 1
option (1).
• Customers can obtain their personal key
from MANN+HUMMEL.
9.3 Connection, diagnosis interface to the system

• In order to connect the diagnosis
software with the system, connect the
four-pin plug on the download cable with
the diagnosis interface on the cable
harness (refer to cable harness diagram
“Connection, Diagnosis cable”).
Alternatively, you can also use the
indicator module plug.

9.4 Diagnosis software for the

system
• Communication is activated by selecting
the "Connect/Start connection" menu
option (2). When a connection has been 2
established successfully, "Connection
established" appears at the bottom left
of the diagnosis software.
9.5 Creating the system configuration

• In order for the SMF®-AR system to
function properly, two device-specific
parameters must be set (speed
conversion factor and tank curve).
• The speed conversion factor and
recording of the tank curve are entered in
the "Tank" register in the diagnosis
software. Input of this data is saved in an
individual file. The diagnosis software
combines this data with the configuration
files provided from the CD.

9.6 Setting the speed factor

• In order to define the correct speed factor
(3), the crankshaft pulley must be defined
in relation to the alternator pulley. E.g. a 3
crankshaft diameter (driving wheel) of 12
cm and alternator pulley of 3 cm result in
a transmission ratio (speed factor) of
0.25.
4
• The alternator pulley must be connected
directly on the crankshaft pulley. If this is
not the case, the transmission ratios must
be calculated individually.
The speed factor determined is entered
in the software.
• The speed factor determined can be
checked while the engine is running and
corrected, if necessary. To do this, enter
the speed factor in the corresponding
field and test it by pressing the "Speed
check" button. The current speed,
established by the ECU, can be read in
the field (4) above the "Speed check"
button.
• When starting up the device, the speed
signal must be checked with the actual
engine speed via the diagnosis software.

9.7 Setting the tank curve

8
• The tank curve (5) is recorded with the
aid of the diagnosis software. A condition
for recording is that the device tank is
completely empty. In order to record the
tank characteristic, the ignition must be
switched on.
7
• First of all, enter the maximum tank
volume in the corresponding field (6) in
the diagnosis software. Then enter the 6 5
supporting points (7) required for the
measurement. 11
• The sampling points define the individual
measuring points when filling the tank.
The number of sampling points must be 10
adapted individually to the max. tank
volume. The increment should be
between 3% and 10% of the maximum 9
tank volume.
12
Fuel sensor settings (8): ,
Selection Description
Fuel sensor is available Activate when a fill level sensor already exists in the device.
Reinstall the fuel sensor Activate when a fill level sensor has been retrofitted in the device.

• During the next step, the tank curve is • If all the sampling points have been
recorded after pressing the "restart processed but the tank is not fully filled,
calibration" button (9). Then follow the press the "Additional sampling point"
instructions which appear. During the button to set another sampling point (a
course of compiling the tank curve, the maximum of 15 sampling points are
tank must be filled with a specific fuel permitted) or fill the tank fully on reaching
quantity in increments. The fuel quantity the last sampling point.
is oriented on the number of sampling • After the tank curve has been created, the
points and maximum tank volume. tank characteristic curve is displayed as a
• Use the "Fuel level" input field (10) to graph in the diagnosis software label in
correct the quantity of fuel filled. comment and save the tank curve by hitting
• You start with an empty tank and the Save button.
software defines individual numbers of • The X-axis indicates the tank content as a
liters which should then be filled. percentage and the Y-axis indicates the
• The “current tank level” (11) actually value for the respective tank content.
filled must now be entered respectively • The appearance of the characteristic curve
and the software thus compiles the tank shows whether its creation was successful. It
curve point-by-point. must show a continuous upward or
• If the tank filling is completed before downward trend (in the case of an inverted
reaching the sampling points, press the fuel gauge sensor). In addition, the
"Tank full" button to end recording of the difference between the minimum and
tank curve. maximum digital measured values (which
can be read on the diagram's Y-axis) must
be at least 400 AD (Analog/Digital – refer to
tank curve units).

9.8 Defining the configuration and engine characteristics

Filter size On-board Inlet cone Outlet cone Air flow M+H part number Designatio Config. file Engine
power sensor n characteristics
(AFS) file
Axial/ Axial/
1.2 m² 12 V Hitachi 1051540S01 EP50 243*.cf_ 243*.da_
Radial Radial
Axial/ Axial/
1.2 m² 12 V Hitachi 1051541S01 EP100 244*.cf 244*.da_
Radial Radial
Axial/ Axial/
1.2 m² 12 V Bosch 1032436S01 Bosch 245*.cf_ 245*.da_
Radial Radial
1.8 m² 12 V Axial Axial Hitachi 1051546S01 DO 63,5 191*.cf_ 191*.da_

1.8 m² 12 V Axial Radial Hitachi 1051546S01 DO 63,5 192*.cf_ 192*.da_
1.8 m² 12 V Radial Axial Hitachi 1051546S01 DO 63,5 193*.cf_ 193*.da_
1.8 m² 12 V Radial Radial Hitachi 1051546S01 DO 63,5 194*.cf_ 194*.da_
1.8 m² 12 V Axial Axial Bosch 1032436S01 Bosch 51*.cf_ 51*.da_
1.8 m² 12 V Axial Radial Bosch 1032436S01 Bosch 52*.cf_ 52*.da_
1.8 m² 12 V Radial Axial Bosch 1032436S01 Bosch 53*.cf_ 53*.da_
1.8 m² 12 V Radial Radial Bosch 1032436S01 Bosch 54*.cf_ 54*.da_
1.8 m² 12 V Axial Axial Hitachi 1051540S01 EP 50 122*.cf_ 122*.da_
1.8 m² 12 V Axial Radial Hitachi 1051540S01 EP 50 123*.cf_ 123*.da_
1.8 m² 12 V Radial Axial Hitachi 1051540S01 EP 50 124*.cf_ 124*.da_
1.8 m² 12 V Radial Radial Hitachi 1051540S01 EP 50 125*.cf_ 125*.da_
1.8 m² 12 V Axial Axial Hitachi 1051547S01 DO 76 195*.cf_ 195*.da_
1.8 m² 12 V Axial Radial Hitachi 1051547S01 DO 76 196*.cf_ 196*.da_
1.8 m² 12 V Radial Axial Hitachi 1051547S01 DO 76 197*.cf_ 197*.da_
1.8 m² 12 V Radial Radial Hitachi 1051547S01 DO 76 198*.cf_ 198*.da_

Filter size On-board Inlet cone Outlet Air flow M+H part Designation Config. file Engine
power cone sensor number characteristics
(AFS) file



Filter size On-board Inlet cone Outlet cone Air flow M+H part Designation Config. file Engine
power sensor number characteristics
(AFS) file
5.4 m² 24 V Axial/Radial Axial/Radial Bosch 1032436S01 Bosch 77*.cf_ 77*.da_

5.4 m² 24 V Axial/Radial Axial/Radial Hitachi 1051543S01 EP 300 146*.cf_ 146*.da_
5.4 m² 24 V Axial/Radial Axial/Radial Hitachi 1051548S01 DO 89 223*.cf_ 223*.da_
5.4 m² 24 V Axial/Radial Axial/Radial Hitachi 1051549S01 DO 101,5 224*.cf_ 224*.da_
8.1 m² 24 V Axial/Radial Axial/Radial Hitachi 1051548S01 DO 89 225*.cf_ 225*.da_

8.1 m² 24 V Axial/Radial Axial/Radial Hitachi 1051549S01 DO 101,5 226*.cf_ 226*.da_
(*)Version number of the files

• After setting the speed factor and recording the tank curve, press the "Create engine characteristics
file" button (12, Page 23) to create the individual configuration. To do this, select the respective
configuration file (depending on the filter size, inlet and outlet cone, inner pipe diameter, air flow
sensor; refer to table).
• The diagnosis software generates a configuration file (file extension: *.cfg) and an engine
characteristics file (file extension: *.dat).

9.9 Configuration of the ECU

The configuration file and engine characteristics
file are loaded individually with the aid of the
diagnosis software. Open the "File" menu and
execute "Load configuration" and "Load
engine characteristics". Pay attention that the
files produced (correct filter size, inlet and outlet
cone, inner pipe diameter, air flow sensor) are
selected. This can be seen by the first two digits
of the configuration and engine characteristics
file.
9.10 Checking the configuration
• A check must then be made to ensure

the individual files have been loaded
correctly.
• The configuration and engine
characteristics version appear in the
"Event/ Errorstack" tab controls. The
first two digits of the configuration and Engine
engine characteristics version must Software
match the number in the table. Serial number
• If the numbers do not match, the previous
step must be repeated. Configuration

10 Function Description, Indicator Module

indicator module relates to software
versions from 1.10. The software
version is displayed during the
power up phase of the indicator
module.
10.1 General information

• The indicator module provides the user
with all the necessary information on
measured values, error messages and 1
settings via LCD (1).
• An event is indicated by means of the 2
yellow control lamp (2).
3
• An alarm is indicated when the red
control lamp (3) flashes. 4
• The "Menu" sensor button (5) is used to
activate the menu; the individual menu
options are selected and confirmed by 5
pressing the "OK" sensor button (4).
• The contact-sensitive sensor buttons also
enable the user to navigate through the
menus and to acknowledge alarm 1 Display
signals.
2 "Event" control lamp
• Pressing the sensor buttons is confirmed
when the buttons light up briefly. 3 "Alarm" control lamp
4 "OK" sensor button
5 "Menu" sensor button
10.2 System start

• After switching on the ignition, the
"Event" button (yellow control lamp)
lights up briefly. The red "Alarm" control
lamp on the indicator module lights up for
approx. 10 seconds.
• In addition, the two contact-sensitive
sensor buttons ("Menu" and "OK")
approx. 10 sec. to complete a self-
calibration. Do not touch the sensor
buttons during the calibration phase.
• The indicator module is then ready to
operate. The "Measured values"
submenu appears in the display with the
values last activated.

10.3 Key description overview "Selection" menu overview
• "Menu" sensor button > Navigation • Measured values: Displays the current
through the menu structure > Exit from operating parameters
the current submenu • Fault: Displays the current fault
• "OK" sensor button > Select the menu • Contrast: Set the display contrast
option currently displayed
• Language: Select the language
• The sensor buttons light up briefly to
acknowledge being pressed. • Back-lighting: Activate/Deactivate the back-
lighting
• Pressing the "Menu" and "OK" buttons
simultaneously alters the contrast.
Yellow "Event" control lamp

"Lamp flashes": Request for emergency
regeneration
• Run engine at nominal speed for approx.
10 min. Regeneration starts within this
period (indicated by the yellow lamp
lighting up continuously).
"Lamp on continuously“: Automatic
regeneration in operation.
• When automatic regeneration is in
operation, the device must not be
switched off. Normal drive operation must
be maintained until the yellow control
lamp goes out.
Red "Alarm" control lamp

"Lamp flashes": Severe error.
The device must be shutdown immediately.
Contact your service partner!
• A severe error has occurred or the
system has been damaged. Contact your
service partner immediately.
"Lamp on continuously“: Error; inform your
service partner!
• An error has occurred or the system has
failed. Contact your service partner.

Navigating using the "Menu" sensor

button“
• The two sensor buttons, "Menu" and
"OK" are used to navigate through the
menus which appear in the display.
Actuation of the contact-sensitive
"Menu" sensor button is acknowledged
by the sensor buttons flashing briefly.
Press the "Menu" sensor button to open
the main menu. The main menu contains
several submenus which can be scrolled
through by pressing the "Menu" sensor
button again.
The second line of the display indicates
the menu option which is currently
selected.
Navigating using the "OK" sensor button

The "OK" sensor button is used to set the
current submenu. Actuation of the contact-
sensitive "OK" sensor button is acknowledged by
the sensor buttons flashing briefly. The "OK"
sensor button is used to scroll through the
submenus (e.g. in "Measured values" submenu:
Change various operating parameters; in Error
menu: Switch between errors which are currently
pending).
"Contrast" menu
• Press the "Menu" sensor button to select
the "Contrast" submenu in order to
adjust the contrast setting of the display.
Actuation of the contact-sensitive
"Menu" sensor button is acknowledged
• Press the "OK" sensor button to display
the "Contrast" submenu.

Adjusting the "Contrast" menu setting
• The value last set appears in the display.

Change the contrast value by pressing
the "OK" sensor button. The contrast is
increased or decreased according to the
value. If you press the sensor button
continuously, the contrast changes
quickly.
• Press the "Menu" sensor button to return
to the main menu.
Note: The contrast can be adjusted at any time
by pressing the two sensor buttons
simultaneously, e.g. following a system start in
the "Measured values" submenu.
"Back-lighting" menu
• The "Back-lighting“ menu is used to

switch the display's back-lighting on or
off. Press the "Menu" sensor button to
select the "Back-lighting" submenu.
the "Back-lighting" submenu.
Adjusting the "Back-lighting" menu

setting
• The back-lighting can be switched on or

off by accessing the "Back-lighting"
submenu and pressing the "OK" sensor
button.
• When the required setting is set, return to
the main menu by pressing the "Menu"
sensor button, "Menu Back-lighting"
appears in the display.

"Language" menu
• Press the "Menu" sensor button to select

the "Language“ submenu in order to
adjust the language setting of the display.
Actuation of the contact sensitive "Menu"
sensor button is acknowledged by the
sensor buttons flashing briefly.
the "Language" submenu.
Adjusting the "Language" setting
The language setting appears in the display.

Press the "OK" sensor button to set the
language required. (Sprache = language in
German)
•
• When the required language setting is
set, return to the main menu by pressing
the "Menu" sensor button, "Menu
Language" appears in the display.
• If a different language has been set, this
is subsequently used in the display.
"Measured values" menu
• This menu option can be used to call in

various measured values, depending on
the configuration. To access this menu
option, press the contact-sensitive
"Menu" sensor button as often as
necessary until "Menu Measured
values" appears in the display.
• Each time the "Menu" sensor button is
pressed, the sensor buttons light up
briefly as an acknowledgement.

Displaying the measured data in the "Measured values" menu

In this case, the temperature upstream
from the filter is displayed. Other
measured data can be called in by
pressing the "OK" sensor button. Entries
are acknowledged by the "Menu" sensor
button flashing and the next measured
value then appears in the display.
• Press the "Menu" sensor button in order
to return to the main menu, which is
acknowledged by the sensor buttons
flashing.
General error memory
• The error memory can be displayed from

the "Error" menu. To access this menu
option, press the contact-sensitive
"Menu" sensor button as often as
necessary until "Menu Error" appears in
the display.
pressed, the sensor buttons light up
briefly as an acknowledgement.
When"Menu Error" appears in the
display, press "OK" to display the
content.
"Error" submenu
• If there is no error message pending, the

value for the number of errors is "0". "1"
is a default value and indicates that there
are no faults present. If an error message
has already been issued and cleared, the
value displayed is that of the last error
message.
• The message "Not active" stipulates
that the last error indicated no longer
exists. Pressing the "OK" sensor button
has no effect on the display. Press the
"Menu" sensor button in order to return
to the main menu, which is
acknowledged by the "OK" sensor button
flashing.

"Error" submenu -
with 1 error message
• If there is one error message pending,

the value for the number of errors is "1".
"1" is a default value and indicates that
previous errors have been deactivated.
• To access the new error message, press
the "OK" sensor button.
• In the example illustrated, error no. 30 is

displayed and the 2nd line contains a
brief description. This error is stored in
the alarm memory and can be called in
again later.
flashing.
"Error" submenu -
with 2 error messages
• If there are two error messages pending,

the value for the number of errors is "2".
"1" is a default value and indicates that
previous errors have been deactivated.
To access the new error messages,
press the "OK" sensor button.
• Press the sensor button again to switch
between the individual error messages.
acknowledged by the sensor buttons
flashing.

10.4 SMF®-AR System error list
No. Display message Error/Event Description

1 Error Cabling to the fill level sensor is defective
3 Error Cabling to the fill level sensor is defective in

the case of a pulsed fill level sensor
4 Error Dosing pump feeds air
(no additive in tank or feed line is clogged)
5 Error Dosing pump is defective
8 Event Fill additive
9 Error Dosing control is defective
10 Error Defective in the dosing pump cabling
11 Error In the case of fill level sensors:

poor signal quality
13 Event Regeneration must be executed
14 Event Loading strategy has detected the filter load
15 Event Too high a load in the DPF

18 Error Error in the DPF heater
30 Error Short circuit/Cable break in the

pressure/temperature sensors
31 Error Pressure sensor is defective
32 Error Short circuit/Cable break in air flow sensor

electrics
33 Error Temperature sensor is defective
36 Error DPF is defective
37 Error DPF is overloaded
39 Error 5 V short circuit
44 Event Clean the filter
48 Error Regeneration is not possible
53 Error Red lamp is defective
54 Error Yellow lamp is defective

11 Checklist
SMF®-AR filter system Electronic control unit (ECU)
• Check the heater cable is connected • Check the ECU is fixed firmly and correctly
correctly to the cable harness. installed in the device.
• Check the temperature sensor is • Check the connection plugs are connected
connected correctly to the filter and cable properly to the ECU.
harness.
• Check the differential pressure sensor is
• Check the pressure measuring points are
connected correctly on the filter system.
• Check the correct system holder is
installed.
• Check the pipes are connected correctly
• Check the exhaust system does not leak.
Differential pressure and exhaust fume General information

temperature sensor
• Check that the pressure hoses are • Check correct installation:
positioned without kinks to the differential > Check all cables for any signs of chaffing
pressure sensor. against the device body and heat / short
• Correct connection to the differential circuit protection.
pressure sensor: > Check all pressure/fuel and additive lines
> Pressure measuring point upstream are laid without kinks.
from filter must be connected to "HI" on > Check all installed parts and device parts
the differential pressure sensor (8 mm). involved in the assembly are firmly fixed.
> Pressure measuring point downstream • Reconnect the battery and check the fuses.
from filter must be connected to "REF" on • Complete a trial run.
the differential pressure sensor (6 mm).
• Complete a leak test and check the layout is
correct.
Additive dosing system • Read out the ECU; in the case of errors,
refer to the Diagnostics Manual (software).
• Check the tank is fixed firmly and
correctly installed in the device. • Complete the installation certificate /
maintenance manual.
• Check all the additive hoses are laid
without kinks, firmly fixed and there are • Complete the customer instruction.
no signs of abrasion or leaks. • Enclose the operating and maintenance
• The additive dosing system may only be manual with the device documents.
operated with the additive DT 7 approved • Attach the label in the working area.
by MANN+HUMMEL.
Cable harness
• Check all the cables for signs of abrasion
from device or engine parts.
• Check the insulation on the cable
harness (short-circuit proof).

MANN+HUMMEL, locations
Joint enterprises

The MANN+HUMMEL Group is an internationally Filters for the international spare parts market are
active business with its company headquarters in sold under the names of internationally renowned
Ludwigsburg (Germany) and employs over 9,500 customer brand names as well as our own MANN-
staff worldwide in more than 40 locations. FILTER brand.
The company develops, produces and sells The industrial filter business division, with its head
innovative technical components and systems office in Speyer (Germany), has specialized in the
for the automobile industry and many other particular demands of customers from the off-
market sectors. highway forklift and engine technology,
High quality filtration products for devices, compressed air and vacuum technology and
engines and industrial applications play a key mechanical engineering and construction
role in our business activities. The initial business sectors.
equipment business with the world's leading MANN+HUMMEL Industrie filter provides a wide
forklift, machine and system manufacturers range of high-performance products concerned
defines the basis for quality and performance with the filtration and separation of air, gases and
capabilities of the products. liquids for these and other industrial sectors.
MANN+HUMMEL GMBH, Geschäftsbereich Industriefilter

67346 Speyer, Germany, Telephone +49 (62 32) 53-80, Fax +49 (62 32) 53-88 99
E-mail: if.info@mann-hummel.com, Internet: www.mann-hummel.com

Diesel Particle Filter with
Active Regeneration
Operating and Maintenance Manual
Index No.: 1059007S01_D Version 0908

Contact information 1 Foreword

This operating and maintenance manual should be
This operating and maintenance manual is aimed
retained and must be transferred as a part of the
to help you become familiar with the SMF®-AR
device in the event of resale.
system and its intended use.
We reserve the right to make technical
The operating and maintenance manual contains
modifications to the filter and/or the content of this
important information on operating the system
operating and maintenance manual without
safely, properly, and economically. Observation of
notification.
the information will help prevent potential risks and
Reprinting, translation, and copying of this reduce repair costs and downtimes as well as
document, by any means, requires the written increase reliability and the service life of the
approval of the publisher. machine.
Copyright is with the publisher. The manual must be available to every person
All rights reserved. charged with working on the filter system.
Find out the currently valid version by contacting: Scope of delivery
The SMF®-AR system is delivered partly
MANN+HUMMEL GMBH preassembled. This operating and maintenance
Geschäftsbereich Industriefilter manual is a component part of the scope of
delivery.
Brunckstr. 15
Warranty
D - 67346 Speyer
It is essential to observe the instructions stipulated
Internet: http://www.mann-hummel.com/
by the manufacturer and documented in this
E-mail: si.retrofit@mann-hummel.com operating and maintenance manual.
Failure to observe the information voids any rights
Contents to claims against MANN+HUMMEL according to
the terms of the warranty and liability in respect of
1 Foreword ..............................................................2 all personal injury and property damage.
2 Safety....................................................................3
2.1 Warning labels and symbols ........................3 The high standards of safety and quality set by
2.2 General information ......................................3 MANN+HUMMEL GmbH are guaranteed by
2.3 Intended use.................................................3 continous development. Equipment and fittings
3 System Overview, SMF®-AR..............................4 installed in the device by the manufacturer can
4 Function Description ..........................................5 vary. As a result, there may be deviations between
4.4 Function description, indicator module.........5 the information in this manual and your device.
5 Operation .............................................................5
6 Maintenance ........................................................6 Hence, this manual may be subject to errors.
6.1 General information ......................................6 Consecuently, please undestand that any rights to
6.2 Maintenance indicator ..................................6 claims resulting from the information and
6.3 Conditions for completing various illustrations in this manual are excluded.
maintenance ................................................7
6.4 Maintenance interval ....................................7 Notes for the operator:
6.5 Filter module maintenance ...........................8 The operator is responsible for the provision of
6.6 Filling the additive tank...............................16 working equipment complying with basic health
7 Indicator Module Function Description ..........20 and safety requirements in accordance with the
7.1 SMF®-AR System error list ........................27 Ordinance on Industrial Safety and Health. This
8 Checklist ............................................................29 includes ensuring that working equipment is only
9 Related Documents...........................................30
used within the scope of its intended purpose. The
operator can define individual inspection plans and
intervals in addition to those stipulated in the
operating and maintenance manual.

2 Safety 2.3 Intended use

The SMF®-AR system has been exclusively
2.1 Warning labels and symbols designed for filtering the exhaust of diesel engines.
Reading and understanding of the operating and
This label (or descriptive pictogram)
maintenance manual along with keeping records
indicates sections which concern your
of the inspection and maintenance conditions are
safety. Failure to observe the
considered part of the intended use.
information leads to the potential risk of
personal injury. The manufacturer is not liable for damage due to
negligent use. Applicable accident prevention
This label indicates sections which regulations and all other generally accepted
must be strictly observed to prevent the industrial safety and health laws must also be
risk of damage or destruction of system observed.
parts.
The operator is obliged to inspect the SMF®-AR
This label indicates that special system once a week for visible signs of damage
attention must be paid to the and defects and to report any changes (including
information in order to ensure trouble- in the operating behavior) which could impair its
free, economic operation. functional safety.
The filter may only be installed and maintained by
trained, authorized personnel. Qualified personnel
The filter housing of the SMF®-AR are considered those persons who are trained with
system heats up during operation and assembly, starting up, operation and maintenance.
can cause burns if touched. When the
filter housing has heated up, it is a The applicable legal and safety regulations must
potential source of a fire or ignition be observed when using and operating the filter
hazard. system. This also applies when implementing
accessories.
The device must be positioned so that
the diesel particle filter cannot come The SMF®-AR system has been constructed
into contact with easily flammable according to state-of-the-art technology and
materials (e.g. including dry grass). accepted safety-related regulations. However, the
functional safety of after market or second hand
units can be at risk when:
The additive used is hazardous to • the SMF®-AR system is used improperly,
health and is subject to special hazard
warnings. • the operating conditions have changed,
• reconstructions have been made without
consultation with the manufacturer,
• essential maintenance and repair work has
Wear a dust mask during cleaning been neglected.
work to prevent inhaling soot and ash! Only use the SMF®-AR system for its intended
use when in a technically sound condition, taking
the relevant safety and risk aspects into account
and observing the operating and maintenance
manual.
Faults, particularly those which affect safety,
When cleaning the SMF® filter, a should be confronted immediately!
water solution containing soot and ash
is produced. The water mixture must
be disposed of via the oil separator or
in compliance with local law!

Differential pressure
Speed signal Indicator module and sensor
Sintered metal diesel particle filter (SMF®)
generator diagnosis connection

Alarm buzzer
3 System Overview, SMF®-AR
Diesel
engine Ground
Air flow sensor
Pressure measuring point upstream from

filter
Temperature sensor
Fuel gauge
Fuse Sintered metal filter
Heating element
Pressure measuring point downstream
from filter
Measuring and control line
Additive filter Differential pressure measurement
Fuel tank
Dosing pump Additive line
Additive tank Electronic control Power supply
unit
4
4 Function Description
The SMF®-AR system is comprised of a diesel
particle filter, produced using sintered metal
technology, and a fully automatic, regeneration
unit. This is capable of regenerating the soot
accumulated in the filter, in any engine operating
states, without any support from the engine
management and without intervention by the
driver. When sufficient soot has accumulated in
the filter, the control unit automatically triggers a
regeneration.
In order for all the soot to burn-off in a short time
leaving practically no residue, an additive is added
automatically to the diesel fuel by the dosing
system which lowers the ignition temperature of
the soot and increases the burn-off speed.
4.4 Function description, indicator

module
After switching on the ignition, the indicator module
(see Fig.) completes a self-test (approx. 10 sec). 1
During the self-test, the Event and Alarm lamps
light up briefly. The indicator module is then ready 2
to operate
Do not touch the buttons on the
3
indicator module during the self-test.
The device can be operated during the
test phase.
4
The two sensor buttons can be used to navigate

through the menu which appears in the display.
5
If one or both of the control lamps do
light up during the test phase, a fault
has occurred. Bild 1 Indicator module
Contact your service partner in this
case.
5 Operation
1 Display
Button description 2 Event control lamp
"Menu" sensor button:
3 Alarm control lamp
• Navigate through the menu structure
4 “OK” sensor button
• Exit from the current menu
5 “Menu” sensor button
"OK" sensor button:
• Select the current menu option
The sensor buttons 4 and 5 light up briefly to
acknowledge being pressed.
Pressing the "Menu" and "OK" buttons

Menu selection
Measured values:
• Displays the current operating parameters
Fault:
• Displays the current fault
Contrast:
• Set the display contrast
Language:
• Select the language
Back-lighting:
• Activate/Deactivate the back-lighting
(Refer to Ch. 7 for more information on the indicator

module.)
6 Maintenance
Read this operating and maintenance
manual thoroughly before starting
maintenance work on an SMF®-AR
system. It is specifically for the Waste disposal code for Germany, Austria and
maintenance of SMF®-AR systems. Switzerland:
• 13 05 02 Sludge from oil/water separators
The instructions describe the individual working
• 13 05 06 Oils from oil/water separators
steps and guides you through the maintenance
and diagnosis software. • California maintenance instruction for waste
When completing the work, pay attention to disposal
observe the individual working steps, otherwise
there is a risk of damaging the entire SMF®-AR
filter system. 6.2 Maintenance indicator
It is essential to observe the instructions The fully automatic, independent regeneration
stipulated by the manufacturer and documented unit in the SMF®-AR system is monitored by the
in this operating and maintenance manual. electronic control unit. The red control lamp lights
During maintenance of the SMF®-AR system, up in the case of damage or pending
ensure the components are handled with the maintenance work. In such a case, the operator
necessary care and attention because handling must immediately contact the service partner.
the SMF®-AR system improperly could lead to The following maintenance is necessary
permanent damage to it. according to the messages:
Generally applicable accident prevention If the "clean filter" message appears, complete
regulations and all other generally accepted the filter module maintenance on pages 8-15.
industrial safety and health laws must also be If the "fill additive tank" message appears, fill the
observed. additive tank as described on pages 15 -19.
Failure to observe the maintenance instructions
voids any rights to claims against
MANN+HUMMEL GmbH according to the terms
of warranty and liability.

6.3 Conditions for completing Filling the additive tank

various maintenance • Prescribed additive
Cleaning the filter (MANN+HUMMEL no.:
10 367 32 S01 / 1VE = 1 l.)
• Cleaning equipment (washing area) with oil
separator • Filling funnel
• Industrial high-pressure cleaner (commercially • Copper gasket

available model), refer to "Requirements of the
high pressure cleaner", Page 11 Changing the additive filter
• Cleaning support (option) • Additive filter
• Dust mask (MANN+HUMMEL no.: 10 326 15 S01) and
hose clamps
• New seals for filter case and wire mesh:
- 1048830S01 Wire mesh for 1.8 - 2.7 • Disconnecting pliers for hoses
- 1047348S01 Wire mesh for 3.8 • Collecting vessel
- 1047045S01 Wire mesh for 5.4 - 8.1
- 1037247S01 Seal for filter 1.2 - 2.7 Resetting the maintenance software
- 1047351S01 Seal for filter 3.8
- 1032405S01 Seal for filter 5.4 - 8.1; • PC with diagnosis software installed
319 mm
• Diagnosis cable
• Torque wrench (MANN+HUMMEL no.: 10 326 11 S01)
• Clamp for differential pressure sensor • Request key from MANN+HUMMEL.
6.4 Maintenance interval

The device operator is provided with the
necessary information regarding the
maintenance by means of the indicator
module.

6.5 Filter module maintenance

Prior to system disassembly
• To ensure correct reassembly later, a
permanent marking (4) must be applied to the
filter housing (1), filter flange (2) and outlet
cone (3).
Make the markings with a scriber or waterproof
marker pen (only applies to the SMF-AR1.2 -
3.8).
The marking must be applied clearly
enough for the filter to be
reassembled in exactly the same
position!
In the case of the SMF-AR 5,4 and 8,1, a
marking is applied at the factory.
Disassembling the system

5
• Before disassembling the system, loosen the 7
8
ground strap (1) on the filter housing.
• Disconnect the electric plugs for the
temperature sensor (4) and heater (3).
6
• Disassemble the connections for the
differential pressure sensor upstream from the
filter (2) and downstream from the filter (5). 4 1 3
• Disassemble the filter by releasing the
connections (6) and (7) from the exhaust gas
system.
• Unlock the clamps (8). 2
Assembling the cleaning support

(option)
• Slide the two support arms (1) on the filter
holder (2) up to the stops (3) (only applies to
the SMF-AR 1.2 and 3.8).
• To clean the SMF-AR 5,4 and 8,1, they must
be inserted vertically with the clean side at the
bottom.

Disassembling the SMF® filter - Part 1

Wear a dust mask to prevent
inhaling soot and ash!
• Remove the outlet cone (1) with seal.
Direction of flow
Disassembling the SMF® filter - Part 2

• Release the filter housing (1) together with the
2nd seal (2) carefully from the SMF® filter (3),
pull them out and set them down on the filter
flange, protecting them from external damage.
The SMF® filter may only be carried
on its flange ring!
The filter pockets must not be Direction of flow
damaged!
• Remove the wire mesh (if present).
Assembling the cleaning support

(option)
Outlet side
The SMF® filter should only be
Direction of flow
cleaned with the cleaning support
(1) mounted!
Pay attention that the sintered metal filter is

handled carefully and cleaned thoroughly. Inlet side
If handled and cleaned improperly, the filter
pockets on the SMF® filter could be damaged
permanently. For this reason, the filter should be
mounted on the cleaning support (only applies to
SMF-AR 1.2 – 3.8).
• The cleaning support (1) must stand firmly.
• Slide the SMF® filter carefully in the cleaning
support (2), pushing from the outlet side.

Requirements of the high pressure Disposing of soot and ashes

cleaner When cleaning the SMF® filter, a water
• Maximum 2200 PSI pressure solution containing soot and ash is
produced. The water mixture must be
• Operation with warm or cold water without disposed of via the oil separator or
any chemical cleaning agents added. disposed of according to local law!
Basic requirements Waste disposal code for Germany, Austria

• The jets must be set to a wide water jet.
and Switzerland:
• The minimum distance between the jet and

13 05 02 Sludge from oil/water separators
filter must not be less than 15 cm during
cleaning. 13 05 06 Oils from oil/water separators
Observe the following sequence of

cleaning steps!
Cleaning step 1
Outlet side
• Clean the SMF® filter opposite to the direction
of flow. Cleaning direction
Also clean in the spaces.
To clean the SMF-AR 5,4 and 8,1,
insert them vertically with the outlet
side at the bottom.
• Turn the SMF® filter carefully and clean

around the circumference.
Direction of flow
Inlet side
Cleaning step 2
Outlet side
• Clean the filter towards the outlet side in order
to clean the soot and ash from under the
flange.
• Turn the SMF® filter carefully and clean
around the circumference.
Direction of flow
Inlet side

Cleaning step 3
Outlet side
• Clean the inlet side of the filter.
• Turn the SMF® filter carefully and clean the
inlet flange of the front end.
• Disassemble the cleaning support. Observe
the information on Page 9 "Assembling the
cleaning support".
• After completing the cleaning work, leave the
filter to dry in the ambient air for approx. 2
hours or blow it dry with compressed air.
Direction of flow
It is essential to avoid temperatures
below freezing point! Inlet side
Installing SMF® filter 1.2 + 2.7 + 3.8 m²

Clean the sealing surfaces prior to
assembly!
• Slide the SMF® filter (1) with new seal

(MANN+HUMMEL no.: 1037247S01 (1.2 +
2.7) or 1047351S01 (3.8)) (2) carefully in the
filter housing.
The installation marking (1) on the
SMF® filter must be in line with the
marking (3) on the filter system.
• Insert the new wire mesh (MANN+HUMMEL

no.: 1048830S01 or 1047348S01) (4) for
centering between the SMF® filter and filter
system.
Filter housing final assembly

The markings must be in line again
for reassembly!
• Tighten the clamp connections with a

tightening torque of 18 ft-lbs.

Installing the SMF® filter 1.8 m²

assembly!

(MANN+HUMMEL no.: 1037247S01) (2)
loosely and carefully in the filter housing (3).
• Lay the new wire mesh (MANN+HUMMEL
no.: 1048830S01) (4) evenly on the SMF®
filter in the filter system for centering.
• Press the wire mesh carefully in the filter
pockets. When the wire mesh is flush under
the filter pockets, the spacer (5) must be
installed and the wire mesh pushed
downwards.
• Now turn the complete, loosely preassembled
filter system upside down and set the spacer
on a level surface. Pressing the filter system
carefully to push the SMF® filter in fully.
Filter housing final assembly, see above!
Installing the SMF® filter 5.4 + 8.1 m²

assembly!

(MANN+HUMMEL no.: 1032405S01) carefully
in the filter housing.
The installation marking on the
SMF® filter must be in line with the
marking on the filter system.
• Insert the new wire mesh (MANN+HUMMEL

no.: 1047045S01) between the SMF® filter
and filter system for centering purposes.
Filter housing final assembly
The markings must be in line again
for reassembly!
• Tighten the clamp connections with a

tightening torque of 18 ft-lbs.

Cleaning the differential pressure lines

Since the differential pressure lines could clog
with soot and condensation over a period of
time, they must also be serviced within the scope
of cleaning the filter.
Do not mix up the lines connected
to the pressure sensor!
Mark them prior to disassembly.
If the lines have become porous or
are otherwise damaged, replace
them with hose material (complying
with EN/ISO 73379) approved by
MANN+HUMMEL!
Pay attention the lines are not
kinked or droop when laid!
Disconnect the pressure lines from the pressure
sensor and blow through.
After cleaning the hoses, install them again
ensuring there are no kinks and connect to the
pressure sensor.
Installing the system

4
• The SMF® filter must be installed in the
exhaust gas system using the connections (1) 2
and (2).
Ensure all the connection lines are
installed without any kinks and do
not make contact! 1
The differential pressure lines (3)
and (4) must not be mixed up! 5 8
• Reconnect the 3 electric plugs for the 6

temperature sensor (5) and heater (6). 7
• Reassemble the connections for the
differential pressure sensor upstream from the 8
filter (6) and downstream from the filter (7). 3
• The grounding strap (7) is connected to the
heater output on the filter housing in the case
of the SMF-AR 1.2 – 3.8.
• For the SMF-AR 5.4 – 8.1, the grounding
strap is connected to any of the V-clamps (8)
on the filter.

Other necessary work

After completing the cleaning work,
other measures must be taken! 1
Reset the maintenance software after completing

cleaning of the filter.
In this case, it is essential to observe the
following chapters of this operating and
maintenance manual.
• Connect the diagnosis cable to the diagnosis
connector of the cable harness and a PC.
• Install the diagnosis software on the PC and
start it. The appliance ignition must be
switched on.
• The start screen appears after starting the
diagnosis software.
To establish a connection to the appliance,
open the "Connect" menu and select the
"Start connection" command (1).
Entering the key

1
• Open the "Options" menu (1) and click on
2
the "Enter key" command (2).
• Enter the key, which must be obtained from
MANN+HUMMEL (si.retrofit@mann-
hummel.com), and confirm it by clicking "OK"
(3).

Acknowledging filter maintenance 1

• Open the "Connect" menu (1) and click on
the "Start timer" command (2). 2
• Then open the

"Order" menu (1), select the "new filter" 1
command (2) and confirm it by clicking "OK"
(3).
2
3
Checking the settings following filter

maintenance
• In order to display the values, click on the 1
"++" button (red circle) in the "Select" field.
• To control the setting, view the "Actual
values" option and check the "Additiv in
filter" value (2). If the value has been reset to
zero, the command has been executed and
the device is ready for use again.
• Close the diagnosis software.
• Disconnect the diagnosis cable.
• Enter the data for the "Filter module 2
maintenance" in the maintenance report (see
Appendix).

6.6 Filling the additive tank

The additive used is hazardous to R65 - hazardous to health
health. Damage to the lungs is possible if swallowed.
R48/22 - hazardous to health: R66 - hazardous to health:
Risk of damage to health following Repeated contact can lead to chapped or cracked
longer exposure through skin.
swallowing. Contains: Ferrocene derivate
General information
Replace the additive filter (2) with a new one
each time before filling the additive tank (1).
• When changing the additive filter, pay
attention to the direction of flow. This is
indicated on the additive filter by means of an
arrow.
If the additive is spilled in the engine
1
compartment, carry out an engine
wash observing the applicable
hazard warnings and safety
information!
Direction of flow
Changing the additive filter

• The hose between the additive tank to the
additive filter must be crimped, using an
appropriate pair of pliers, so that no additive 2
can escape.
Pay attention not to damage the

hose!
• Clear up any escaped additive after

completing the work by cleaning.
Change the clamps on the hose.
• When installing the filter, pay attention that
the direction of flow arrow points towards the
additive pump.
• Check the hoses for signs of chafe marks and
seal quality.
• If there are leaks and chafe marks on the
system hoses, replace the hoses with new
ones made of an appropriate hose material
(complying with EN/ISO 73379).

Tank ventilation, fill level measuring

• A fill level meter (1) is mounted on the tank
ventilation.
2
• The additive tank must be filled to the top
marking on the fill level meter (1).
1
• The hose (2) may be shorter or longer than
that depicted, depending on the installation
conditions.
Filling the additive tank

• Insert a clean funnel (1) in the filler neck so
that the additive can be filled without spilling.
Contamination in the additive can

lead to failure or damage to the
system!
Only use the additive prescribed
(MANN+HUMMEL DT7).
• After filling, fit a new copper gasket 18 x 22 in

the tank ventilation.
• Fix the venting valve above the additive tank
again.

Resetting the maintenance software for

filling the additive
• Connect the diagnosis cable to the diagnosis 1
connector of the cable harness and a PC.
• Install the diagnosis software on the PC and
start it.
After starting the PC, the start screen appears.
To establish a connection to the device, open the
"Connect" menu and select the "Start
connection" command (1).
Entering the key 1
• Open the "Options" menu (1) and click on 2

the "Enter key" command (2).
• Enter the key, which must be obtained from
MANN+HUMMEL, and confirm it by clicking
"OK" (3).
Acknowledging filling the additive 1

• Open the "Connect" menu (1) and click on
the "Start timer" command (2).
2

• Then open the

"Order" menu (1), select the "Additive 1
refilled" command (2) and confirm it by
clicking "OK" (3).
2
3
Checking the settings after filling the tank

• In order to display the values, click on the 1
"++" button (1) in the "Select" field.
• To control the setting, view the "Actual
values" option and check the "Additiv
spent" value (2).
If the value has been reset to 20 (self-
venting), the command has been executed
and the device is again ready for use.
• Close the diagnosis software.
• Disconnect the diagnosis cable. 2
Enter the data for the "Fill additive tank" in the
maintenance report (refer to Appendix).

7 Indicator Module Function Description
indicator module relates to software
versions from 1.10. The software
version is displayed during the
power up phase of the indicator
module.
General information
The indicator module provides the user with all
the necessary information on measured values,
error messages and settings via the (1). 1
• An event is indicated by means of the yellow
control lamp (2).
2
• An alarm is indicated when the red control 3

lamp (3) flashes. 4
• The "Menu" sensor button (5) is used to
activate the menu; the individual menu
options are selected and confirmed by 5
pressing the "OK" sensor button (4).
• The contact-sensitive sensor buttons also
enable the user to navigate through the
menus and to acknowledge alarm signals. 1 Display
• Pressing the sensor buttons is confirmed 2 "Event" control lamp
when the buttons light up briefly.
3 "Alarm" control lamp
4 "OK" sensor button
5 "Menu" sensor button
System start
• After switching on the ignition, the "Event"

button (yellow control lamp) lights up briefly.
The red "Alarm" control lamp on the indicator
module lights up for approx. 10 seconds.
• In addition, the two contact-sensitive sensor
buttons ("Menu" and "OK") approx. one
minute to complete a self-calibration. Do not
touch the sensor buttons during the
calibration phase.
• The indicator module is then ready to operate.
The "Measured values" submenu appear in
the display with the values last activated.

Key description overview "Selection" menu overview
• "Menu" sensor button > Navigation through • Measured values: Displays the current operating
the menu structure > Exit from the current parameter
submenu.
• Fault: Displays the current fault
• "OK" sensor button > Select the menu option
• Contrast: To set the display contrast
currently displayed.
• Language: Select the language
• The sensor buttons light up briefly to
acknowledge being pressed. • Back-lighting: Activate/Deactivate the back-
lighting
• Pressing the "Menu" and "OK" buttons
Yellow "Event" control lamp

"Lamp flashes": Request for emergency
regeneration
• Run engine at nominal speed for approx. 10
min. Regeneration starts within this period
(indicated by the yellow lamp lighting up
continuously during regeneration).
"Lamp on continuously": Automatic
regeneration in operation.
• When automatic regeneration is in operation,
the device must not be switched off. Normal
drive operation must be maintained until the
yellow control lamp goes out.
Red "Alarm" control lamp

"Lamp flashes": Severe error; inform service
partner!
• A severe error has occurred or the system
has been damaged. The device must be
shutdown immediately.
"Lamp on continuously": Error; inform service
partner!
• An error or system failure has occurred or
maintenance must be completed.

Navigating using the "Menu" sensor

button“
• The two sensor buttons, "Menu" and "OK"
are used to navigate through the menus
which appear in the display.
Actuation of the contact-sensitive "Menu"
sensor button is acknowledged by the sensor
buttons flashing briefly.
Press the "Menu" sensor button to open the
main menu. The main menu contains several
submenus which can be scrolled through by
pressing the "Menu" sensor button again.
The second line of the display indicates the
menu option which is currently selected.
Navigating using the "OK" sensor button
• The "OK" sensor button is used to set the

current submenu. Actuation of the contact-
sensitive "OK" sensor button is acknowledged
The "OK" sensor button is used to scroll
through the submenus (e.g. in "Measured
values" submenu: Change various operating
parameters; in Error menu: Switch between
errors which are currently pending).
"Contrast" menu
• Press the "Menu" sensor button to select the

"Contrast“ submenu in order to adjust the
contrast setting of the display. Actuation of
the contact sensitive "Menu" sensor button is
acknowledged by the sensor buttons flashing
briefly.
• Press the "OK" sensor button to display the
"Contrast" submenu.

Adjusting the "Contrast" menu setting

Change the contrast value by pressing the
"OK" sensor button. The contrast is
increased or decreased according to the
value. If you press the sensor button
continuously, the contrast changes quickly.
• Press the "Menu" sensor button to return to
the main menu.
Note: The contrast can be adjusted at any time
by pressing the two sensor buttons
simultaneously, e.g. following a system start in
"Back-lighting" menu
• The "Back-lighting“ menu is used to switch

the display's back-lighting on or off. Press the
"Menu" sensor button to select the "Back-
lighting" submenu.
"Back-lighting" submenu.
Adjusting the "Back-lighting" menu

setting
• The back-lighting can be switched on or off by

accessing the "Back-lighting" submenu and
pressing the "OK" sensor button.
• When the required setting is set, return to the
main menu by pressing the "Menu" sensor
button, "Menu Back-lighting" appears in the
display.

"Language" menu
• Press the "Menu" sensor button to select the

"Language" submenu in order to adjust the
language setting of the display. Actuation of
the contact-sensitive "Menu" sensor button is
acknowledged by the sensor buttons flashing
briefly.
"Language" submenu.
Adjusting the "Language" setting
• The language last set appears in the display.

Press the "OK" sensor button to set the
language required.
• When the required language setting is set,
return to the main menu by pressing the
"Menu" sensor button, "Menu Language"
appears in the display.
• If a different language has been set, this is
subsequently used in the display .
"Measured values" menu
• This menu option can be used to call in

various measured values, depending on the
configuration. To access this menu option,
press the contact-sensitive "Menu" sensor
button as often as necessary until "Menu
Measured values" appears in the display.
pressed, the sensor buttons light up briefly as
an acknowledgement.
"Measured values" submenu.

Displaying the measured data in the "Measured values" menu
• The value last set appears in the display. In

this case, the temperature upstream from the
filter is displayed. Other measured data can
be called in by pressing the "OK" sensor
button. Entries are acknowledged by the
"Menu" sensor button flashing and the next
measured value then appears in the display.
• Press the "Menu" sensor button in order to
return to the main menu, which is
acknowledged by the sensor buttons flashing.
General error memory
• The error memory can be displayed from the

"Error" menu. To access this menu option,
press the contact-sensitive "Menu" sensor
button as often as necessary until "Menu
Error" appears in the display.
pressed, the sensor buttons light up briefly as
an acknowledgement. When"Menu Error"
appears in the display, press "OK" to display
the content.
"Error" submenu
• If there is no error message pending, the

value for the number of errors is "0". "1" is a
default value and indicates that there are no
faults present. If an error message has
already been issued and cleared, this value
displayed is that of the last error message.
• The message "Not active" stipulates that the
last error indicated no longer exists. Pressing
the "OK" sensor button has no effect on the
display. Press the "Menu" sensor button in
order to return to the main menu, which is
flashing.

"Error" submenu -
with 1 error message
• If there is one error message pending, the

default value and indicates that previous
errors have been deactivated.
• To access the new error message, press the
"OK" sensor button.
• In the example illustrated, error no.30 is

displayed and the 2nd line contains a brief
description. This error is stored in the alarm
memory and can be called in again later.
flashing.
"Error" submenu -
with 2 error messages
• If there are two error messages pending, the

default value and indicates that previous
errors have been deactivated. To access the
new error messages, press the "OK" sensor
button.
• Press the sensor button again to switch
between the individual error messages.
acknowledged by the sensor buttons flashing.

7.1 SMF®-AR System error list
No. Display message Error/Event Description

3 Error Cabling to the fill level sensor is defective in

the case of a pulsed fill level sensor
4 Error Dosing pump feeds air
(no additive in tank or feed line is clogged)
8 Event Fill additive
9 Error Dosing control is defective
10 Error Defective in the dosing pump cabling
11 Error In the case of fill level sensors:

poor signal quality
13 Event Regeneration must be executed
14 Event Loading strategy detects filter load
15 Event Too high a load of the diesel particle filter

(DPF)

20 Event Loading strategy detects filter load
30 Error Short circuit/Cable break in the

pressure/temperature sensors
31 Error Pressure sensor is defective
32 Error Short circuit/Cable break in air flow sensor

electrics
33 Error Temperature sensor is defective
37 Error DPF is defective
39 Error 5 V short circuit
44 Event Clean the filter
48 Error Regeneration is not possible
53 Error Red lamp is defective
54 Error Yellow lamp is defective

8 Checklist
SMF®-AR filter system Electronic control unit (ECU)
• Check the heater cable is connected correctly • Check the ECU is fixed firmly and correctly
to the cable harness. installed in the device.
• Check the temperature sensor is connected • Check the connection plugs are connected
correctly to the filter and cable harness. properly to the ECU.
• Check the differential pressure sensor is
• Check the pressure measuring points are
connected correctly on the filter system.
• Check the correct system holder is installed.
• Check the pipes are connected correctly
• Check the exhaust system does not leak.
Differential pressure and exhaust fume General information

temperature sensor
• Check that the pressure hoses are laid • Check correct installation:
without kinks to the differential pressure > Check all cables for any signs of chaffing
sensor. against the device body and heat / short circuit
protection.
• Correct connection to the differential pressure
> Check all pressure/fuel and additive lines are
sensor:
laid without kinks.
> Pressure measuring point upstream from
> Check all installed parts and device parts
filter must be connected to "HI" on the
involved in the assembly are firmly fixed.
differential pressure sensor (8 mm).
> Pressure measuring point downstream from • Reconnect the battery and check the fuses.
filter must be connected to "REF" on the
• Complete a trial run.
differential pressure sensor (6 mm).
• Complete a leak test and check the layout is
correct.
Additive dosing system
• Read out the ECU; in the case of errors, refer to
• Check the tank is fixed firmly and correctly the Diagnostics Manual (software).
installed in the device.
• Complete the installation certificate /
• Check all the additive hoses are laid without maintenance manual.
kinks, firmly fixed and there are no signs of
abrasion or leaks. • Complete the customer instruction.
• The additive dosing system may only be • Enclose the operating and maintenance manual
operated with the additive DT 7 approved by with the device documents.
MANN+HUMMEL. • Attach the label in the working area.
Cable harness
• Check all the cables for signs of abrasion

from device or engine parts.
• Check the insulation on the cable harness
(short-circuit proof).

9 Related Documents
In addition to this operating and maintenance manual, the following documents must also be observed and
applied:
The following were applied for the product: European norms, harmonization documents, national standards
as well as manufacturer and customer-specific specifications.

Maintenance Report
Device Data
Device manufacturer:
Device type:
Device no.:
Registration date:
Serial no. ECU:
Installation date of the SMF-AR® system:
Maintenance Mileage/Operating hours: Date:
Type of maintenance: ⃞ Filter module maintenance ⃞ Additive tank filling
Comments
Name / Address of service partner:
Name of mechanic:
Date: Stamp:
Signature:

MANN+HUMMEL, locations
Joint enterprises

The MANN+HUMMEL Group is an internationally Filters for the international spare parts market are
active business with its company headquarters in sold under the names of internationally renowned
Ludwigsburg (Germany) and employs over 9,500 customer brand names as well as our own MANN-
staff worldwide in more than 40 locations. FILTER brand.
The company develops, produces and sells The industrial filter business division, with its head
innovative technical components and systems office in Speyer (Germany), has specialized in the
for the automobile industry and many other particular demands of customers from the off-
market sectors. highway vehicle and engine technology,
High quality filtration products for devices, compressed air and vacuum technology and
engines and industrial applications play a key mechanical engineering and construction business
role in our business activities. The initial sectors.
equipment business with the world's leading MANN+HUMMEL Industriefilter provides a wide
equipment, machine and system manufacturers range of high-performance products concerned
defines the basis for quality and performance with the filtration and separation of air, gases and
capabilities of the products. liquids for these and other industrial sectors.
MANN+HUMMEL GMBH, Geschäftsbereich Industriefilter

67346 Speyer, Germany, Telephone +49 (62 32) 53-80, Fax +49 (62 32) 53-88 99
E-mail: if.info@mann-hummel.com, Internet: www.mann-hummel.com

MANUAL DE TALLER
WORKSHOP MANUAL
airconditioner
1D2 DIESEL
1D2 LPG
1D1 DIESEL
Refrigerant Quantity 1DX Climatizers:

Climasur --> 0.65Kg R134a
Rosti --> 1.00Kg R134a
Always check what kind of Climatizer is installed.
Climasur information see page 27
MANUAL DE TALLER WORKSHOP MANUAL
Antes de efectuar el diagnostico es Before diagnosis the following is necessary:

necesario:
1. Conectar los tubos de servicio a las 1. Connect the service tubes to the
correspondientes válvulas del corresponding compressor's valves.
compresor. 2. Stabilize the A/C installation functioning
2. Estabilizar el funcionamiento de la 3. Make the feature test.
instalación A/C. 4. Note the pressure values indicated by the
3. Hacer la prueba de prestación. service gauges fittings
4. Tomar buena nota de los valores de
presión indicados por los manómetros
de servicio.
Diagnostico del funcionamiento de la Diagnosis of “Rosti” Air Conditioning

instalación de Aire Acondicionado “Rosti”. installation working order.
1) La instalación A/C no enfría. 1) The A/C installation does not cool.

2) La instalación A/C no enfría lo 2) The A/C installation does not cool
bastante. enough
3) La instalación A/C enfría de manera no 3) The A/C installation does not cool
continuada. constantly.
4) La instalación A/C hace ruido. 4) The installation is noisy
1) La instalación A/C no enfría: 1) The A/C installation does not cool.
Cuando la instalación de Aire Acondicionado When the Air Conditioning installation does
no enfría hay que seguir una serie de pautas not cool, a series of guidelines must be
para llegar a la solución del problema. Dichas followed in order to solve the problem. The
pautas son: guidelines are:
1. Revisar el fusible de la instalación. Si 1. Check the installation's fuse. If it is worn

se ha fundido, cambiarlo. out, change it.
2. Revisar la parte eléctrica de la 2. Check the electric part of the

instalación. Puede haber cortes o installation. There might be short
averiada, si es el caso corregir esos circuits or it may be broken down. This
cortes o los daños que existan. should be the case, correct the short
También revisar los puntos de masa de circuits or the existing damage. Also
la instalación y vigilar que no estén check the mass points of the installation
interrumpidos o sean ineficaces. and see they are not cut off or
inefficient.
3. Controlar que a la bobina del embrague
del compresor llegue corriente y no 3. Check that current/electricity reaches the
esté rota. compressor clutch's coil and it is not
broken.
1
4. Los enlaces eléctricos del termostato se 4. The electric links of the thermostat have
han fundido o el sensor del termostato worn out or the thermostat sensor is not
es ineficiente. efficient.
5. El monosoplador del evaporador no 5. The evaporator's centrifugal blower

esta conectado o los contactos del single is not connected or the engine's
motor se han fundido. contacts have worn out.
6. El interruptor de arranque o algún relé 6. The starting switch or some relay has
esta fundido worn out.
7. Controlar la tensión de la correa. 7. Check the belt's tension. Apply the

Aplicar la tensión correcta o bien correct tension or change the belt.
cambiar la correa.
8. The compressor is broken down or
8. El compresor esta averiado o gripado. galling.
9. Las válvulas del compresor no 9. The compressor's valves do not work

funcionan bien, esto se evidencia a well: this is shown in all rotation
todos los regímenes de rotación, por systems, by light variations of both
ligeras variaciones de las indicaciones gauges fittings indications.
de ambos manómetros.
10. La válvula de expansión se ha 10. The expansion valve is blocked in

bloqueado en posición abierta. Esto se ''open'' position. This is shown by a
evidencia por un valor normal de la normal value of the discharge pressure
presión de descarga y un alto valor de and a high value of the suction pressure.
la presión de aspiración.
11. La válvula del agua de la instalación de 11. The water valve of the heating
calefacción no funciona. Esto se installation does not work. This is shown
evidencia a través de aire demasiado as hot air coming from the heater or the
caliente que sale del calefactor o del evaporator.
evaporador.
12. Alguna tubería de la instalación esta 12. Some installation hose is broken.
rota.
13. La instalación tiene algunas perdidas. 13. The installation has some leaks.
14. Se presenta alguna obstrucción del 14. Should a blocking appear on the drying
filtro secador o en la válvula de filter or on the expansion valve, a
expansión. Puede detectarse alguna blocking can be detected in the hoses or
obstrucción en los tubos o en el the interchanger.
intercambiador.
15. The sealing joint in the compressor's
15. La junta de estanqueidad en el árbol shaft has flaws.
del compresor tiene defectos.
2
2) La instalación A/C no enfría lo bastante: 2) The A/C installation does not cool enough.
1. El motor del electroventilador gira 1. The axial motor fan engine turns slowly.
despacio.
2. The electromagnetic compressor's clutch
2. El embrague electromagnético patina. slips.
3. El paso de aire en los canales de los 3. The air flow in the diffuser's tubes is
difusores esta obstruido. blocked.
4. El paso de aire de aspiración del 4. The suction air flow from the interior is
habitáculo esta obstruido. blocked.
5. Es insuficiente la cantidad de aire a 5. The air quantity through the condenser is

través del condensador (las aletas están not sufficient (the blades are blocked by
obstruidas por polvo, barro o insectos). dust, mud or insects).
6. El evaporador esta obstruido. 6. The evaporator is blocked.
7. La cantidad de fluido refrigerador no es 7. The cooling fluid quantity is not

suficiente. sufficient.
8. El elemento filtrante en la conexión de 8. The filtering element is blocked on the

entrada de la válvula de expansión esta expansion valve entry connection: this is
obstruida: esto es detectado por los detected by the pressure values indicated
valores indicados por los manómetros by the service gauges fittings; if they are
de servicio; si son normales o indican normal or indicating a slow discharge
un ligero aumento de la presión de pressure increase and a small suction
descarga y una pequeña disminución pressure decrease at the same time to the
de la presión de aspiración al mismo evaporator's hot air exit.
tiempo de la salida de aire caliente del
evaporador.
9. El sensor termostático de la válvula de 9. The expansion valve thermostat sensor

expansión ya no contiene la carga de no longer contains the gas load; this is
gas; esto es evidenciado por una shown by a very low suction pressure
presión de aspiración demasiado baja y and excessive water formation in the
por una excesiva formación de agua en evaporator and the suction piping.
el evaporador y en la tubería de
aspiración.
10. El filtro secador esta obstruido; esto es 10. The dryer filter is blocked: this is shown
evidenciado por un valor de la presión by a superior discharge pressure value to
de descarga superior a la normal y por the normal one, and an inferior suction
un valor de presión de aspiración pressure value to the normal one and the
inferior a la normal, y la tubería de la piping from the filter installation to the
instalación del filtro a la válvula de expansion valve is cold with possible ice
expansión esta fría con posible formation.
formación de hielo.
3
11. Excesiva humedad en la instalación: 11. Excessive humidity in the installation:

esto es evidenciado por los grandes this is shown by the high pressure values
valores de las presiones con respecto a considering the normal ones.
los valores normales.
12. Presencia de aire en la instalación: esto 12. Air presence in the installation: this is
es evidenciado por los grandes valores shown by the high pressure values
de las presiones con respecto a los considering the normal ones and at the
valores normales y al mismo tiempo same time possible bubble formations on
posibles formaciones de burbujas en el the pilot glass.
cristal piloto.
13. Defective thermostat: this is shown by a
13. Termostato defectuoso: esto es very intermittent functioning of the
evidenciado por el funcionamiento electromagnetic clutch.
demasiado intermitente del embrague
electromagnético.
3) La instalación A/C enfría de manera no 3) The A/C installation does not cool
continuada: constantly.
1. El interruptor de puesta de 1. The starting switch, the evaporator

funcionamiento, el conmutador del centrifugal blower single switchboard or
monosoplador del evaporador o el the axial motor fan engine can be
motor del electroventilador pueden ser defective.
defectuosos.
2. El punto de masa de la bobina del 2. The mass point of the electromagnetic

embrague electromagnético no esta clutches coil is not well connected.
bien conectado.
3. El embrague electromagnético del 3. The compressor's electromagnetic clutch

compresor patina. slips.
4. Entre las aletas del evaporador se esta 4. Between the evaporator's blades, ice is
formando hielo: esto puede ser dado forming: the reason might be excessive
por una excesiva humedad del humidity of the environment, lack of
ambiente, falta de regulación en el regulation in the heating control of the
control del calentamiento en la válvula expansion valve or too low regulation of
de expansión o por la regulación the thermostat.
demasiado baja del termostato.
5. Válvula de expansión defectuosa: esto 5. Expansion valve defective: this is shown

es evidenciado por un valor demasiado by a lower or higher suction pressure
bajo o demasiado alto de la presión de value.
aspiración
6. Evaporador obstruido. 6. Blocked evaporator.
4
4) La instalación A/C hace ruido: 4) The A/C installation is noisy
1. La bobina del embrague 1. The electromagnetic clutches coil has

electromagnético tiene su bobinado defective winding or the electric
defectuoso o bien la conexión eléctrica connection is not very efficient.
no es muy eficaz.
2. la correa de transmisión esta 2. The transmission belt is loose or worn

destensada o desgastada. out.
3. El embrague electromagnético hace 3. The electromagnetic clutch is noisy.

ruido.
4. The compressor is noisy: this depends
4. El compresor hace ruido: esto depende on the lack of tightening of the
de la falta de apriete de los ajustes o de adjustments or the worn out parts form
las piezas interiores desgastadas. the interior.
5. Algunas piezas de la carrocería pueden 5. Some parts of the bodywork might have
estar montadas de manera no correcta. been wrong assembled.
6. El nivel de aceite del compresor es 6. The compressor's oil level is not

insuficiente. sufficient.
7. El monosoplador del evaporador hace 7. The evaporator's centrifugal blower

ruido: el motor eléctrico esta muy single is noisy: the electric engine is
desgastado. very worn out.
8. La instalación ha sido llenada con una 8. The installation was filled with an
cantidad excesiva de fluido excessive quantity of cooling fluid,
refrigerador, ruidos o vibraciones en la noises or vibrations in the discharge
tubería de descarga, vibraciones en el piping, vibrations in the compressor,
compresor, excesivos valores de las excessive values of the discharging and
presiones de descarga y aspiración, suction pressures, bubbles or
burbujas o condensaciones en el cristal condensation on the pilot glass.
piloto.
9. La instalación ha sido cargada con una 9. The installation was filled with
cantidad insuficiente de fluido insufficient quantity of cooling fluid:
refrigerador: silbido en el alojamiento whistling in the evaporator's interior
del evaporador cerca de la válvula de close to the expansion valve, bubbles
expansión, burbujas o condensaciones or condensation on the pilot glass, low
en el cristal piloto, bajos valores de las values of the suction and discharge
presiones de aspiración y descarga. pressures.
10. Demasiada humedad en la instalación: 10. Too much humidity in the installation:
la válvula de expansión hace ruido, el the expansion valve makes noise, the
valor de la presión de aspiración es suction pressure value is low.
bajo.
5
MANUAL DE INTERVENCION INTERVENTION MANUAL

COMPRESOR COMPRESSOR
Desmontaje del compresor. Disassembling of the compressor.
• Colocar la carretilla sobre un foso. • Put the wheelbarrow on top of an

• Cortar el contacto, desconectar el inspection pit.
terminal negativo de la batería y vaciar • Cut the power, disconnect the battery's
el circuito del Aire Acondicionado. negative terminal and drain the Air
• Desmontar la tapa inferior de Conditioning circuit.
protección del motor. • Dismantle the inferior head of the
• Desenchufar el conector eléctrico del engine's protection.
compresor. • Unplug the compressor's electric
• Destensar el compresor. connector.
• Retirar la correa del compresor. • Loosen the compressor.
• Desmontar los racores del compresor y • Remove the compressor's belt.
taparlos junto a las salidas del • Dismantle the compressor's fittings and
compresor con tapones estancos. cover them next to the compressor's exit
• Soltar el taco tensor del compresor with blocking stoppers.
(1D2 Diesel) o el soporte de la • Release the compressor's tensor plug
excéntrica (1D2 LPG y 1D1 Diesel). 1D2 Diesel) or the Eccentric support
(ver imágenes) (1D2 LPG and 1D1 Diesel).
• Desmontar los tornillos de fijación del (look at the pictures)
compresor. • Dismantle the compressor's binding
screws.
1D2 DIESEL 1D2 DIESEL
6
1D2 LPG 1D2 LPG
1D1 DIESEL 1D1 DIESEL
Montaje del compresor. Compressor's assembling.
Montar los elementos en orden inverso del Assemble the elements in reverse order of
desmontaje respetando los puntos siguientes: dismantling, respecting the following points:
• Sustituir y lubricar con el lubricante • Replace and lubricate with the specific
especifico las juntas tóricas de los lubricant the ring joints of the
racores del compresor. compressor's fittings.
• Apretar los tornillos de fijación según • Tighten the binding screws according to
el siguiente par de apriete: the following torque setting.
7
Par de apriete (N/m) (coeficiente de Torque setting (N/m) (friction rate μ = 0.14)
fricción μ=0.14) Metrics (thread ) Quality 8.8
Métrica (paso) Calidad 8.8 M10 (150) 52
M10 (150) 52 M12 (175) 88
M12 (175) 88
• Apretar las mangueras según el • Tighten the hoses according to the

siguiente par de apriete: following torque setting:
Par de apriete Torques
Manguera 5/8” (compresor/evaporador): Hose 5/8'' (compressor/evaporator): 32,4Nm

32,4 Nm
Hose 1/ 2 ''(compressor/condenser): 23,5Nm
Manguera 1/2” (compresor/condensador):
23,5 Nm
• Llenar el circuito con la cantidad de • Fill the circuit with the prescribed
fluido refrigerante prescrita. coolant fluid quantity.
• Conectar la batería. • Connect the battery.
CONDENSADOR CONDENSER
Desmontaje del condensador. Disassembling of the condenser.
• Cortar el contacto y desconectar la • Cut the contact and disconnect the

batería. battery.
• Vaciar el circuito del Aire • Empty the Air Conditioning circuit.
Acondicionado.
• Desconectar el conector del • Disconnect the axial motor fan
electroventilador. connector.
• Desmontar el plafón superior del cajón • Dismantle the upper cover of the
condensador. condenser drawer.
• Soltar la manguera de 1/2” del • Release the condenser 1 / 2'' hose ( the
condensador (la que sube del one that goes up the compressor) and
compresor) y tapar con tapones cover with blocking stoppers the hose
estancos tanto el racor de la manguera fitting and also the condenser's exit.
como la salida del condensador.
• Soltar la manguera de 3/8” del filtro (la • Release the filter's 3/8'' hose (the one
que sube del evaporador) y tapar con that goes up the evaporator) and cover
tapones estancos tanto el racor de la with blocking stoppers the hose fitting
manguera como la salida del filtro. and also the filter's exit.
• Retirar el cajón condensador de la • Remove the machine's condenser
maquina, desmontando los tornillos drawer, dismantling the screws that hold
que lo sujetan a la carretilla. it to the wheelbarrow.
• Desconectar la manguera de 3/8” del • Disconnect the condenser's 3/8'' hose
condensador tapando el racor de la covering the loose hose fitting with a
8
manguera suelta con un tapón estanco. blocking stopper.

• Soltar el filtro deshidratador del • Release the condenser's dryer filter.
condensador.
• Sacar el condensador defectuoso del • Take out the defective condenser from
cajón. the drawer.
Montaje del condensador. Assembling of the condenser.
Montar los elementos en sentido inverso del Assemble the elements in reverse order of
desmontaje, usando el condensador nuevo, dismantling, using the new condenser,
respetando los puntos siguientes. respecting the following points.
especifico las juntas tóricas de los lubricant the condenser's fittings ring
racores del condensador. joints.
el siguiente par de apriete: the following torque setting.
fricción μ=0.14) Metrics (thread) Quality 8.8
Métrica (paso) Calidad 8.8 M8 (125) 25.5
M8 (125) 25.5
• Apretar las mangueras según el • Tighten the hose according to the

Manguera 1/2” (compresor/condensador): Hose 1 / 2'' (compressor/condenser) : 23,5

23,5 Nm Nm
Manguera 3/8” (condensador/filtro): 13,7 Hose 3/8'' (condenser/filter): 13,7 Nm

Nm Hose 3/8'' (filter/evaporator): 13,7 Nm
Manguera 3/8” (filtro/evaporador): 13,7 Nm
9
o
fluido refrigerante prescrita. coolant fluid quantity.
• Conectar la batería • Connect the battery.
ELECTROVENTILADOR AXIAL MOTOR FAN
Desmontaje del electroventilador. Disassembling of the axial motor fan.

batería. battery.
• Desconectar el conector del • Disconnect the axial motor fan

electroventilador. connector.
• Desmontar el plafón superior del cajón • Dismantle the upper cover of the
condensador. condenser drawer.
• Soltar el electroventilador del plafón • Release the axial motor fan from the
desmontando los tornillos de fijación. upper cover dismantling the binding
screws.
Montaje del electroventilador. Assembling of the axial motor fan.
Montar los elementos en sentido inverso del Assemble the elements in reverse order of the
desmontaje, usando el nuevo electroventilador. dismantling, using the new axial motor fan.
FILTRO DESHIDRATADOR DRYER FILTER
Desmontaje del filtro deshidratador Disassembling of the dryer filter
• Realizar el mismo desmontaje del • Carry out the same dismantling of the
condensador hasta retirar el cajón condenser until removing the condenser
condensador de la carretilla. drawer from the wheelbarrow.
• Desconectar la manguera de 3/8” del • Disconnect the filter's 3/8'' hose covering
filtro tapando el racor de la manguera the loose hose fitting with a blocking
suelta con un tapón estanco. stopper.
• Soltar el filtro deshidratador del • Release the condenser's dryer filter.
condensador.
Montaje del filtro deshidratador. Assembling of the dryer filter.
desmontaje, usando el filtro deshidratador dismantling, using the new dehydrating filter
nuevo respetando los puntos siguientes. according to the following points.
especifico las juntas tóricas de los lubricant the condenser's ring joints and
10
racores del condensador y del filtro the dehydrating filter.

deshidratador. • Tighten the binding screws according to
• Apretar los tornillos de fijación según the following torque setting:
el siguiente par de apriete:
Métrica (paso) Calidad 8.8 M8 (125) 25.5
M8 (125) 25.5
• Apretar las mangueras según el • Tighten the hose according to the

Manguera 1/2” (compresor/condensador): Hose 1 /2'' (compressor/condenser): 23,5Nm

23,5 Nm
Hose 3/8'' (condenser/filter): 13,7 Nm
Manguera 3/8” (condensador/filtro): 13,7
Nm Hose 3/8'' (filter/evaporator): 13,7 Nm
fluido refrigerante prescrita. cooling fluid quantity.
EVAPORADOR, CALEFACCION Y EVAPORATOR, HEATING AND

VALVULA DE EXPANSION EXPANSION VALVE
Desmontaje del evaporador, calefacción y válvula de Disassembling of the evaporator, heating and
expansión. expansion valve.
Nota: obstruir los conductos o elementos de Note: block the pipes or air conditioning
climatización inmediatamente después de elements immediately after dismantling
desarmarlos.
• Cortar el contacto y desconectar la • Cut the contact and disconnect the battery.
batería.
• Vaciar el circuito del Aire • Empty the Air Conditioning circuit.
Acondicionado.
• Levantar el Top Panel de la carretilla y • Lift the wheelbarrow Top Panel and
desconectar el conector de entrada de disconnect the electricity entry connection
corriente al cajón evaporador que esta to the evaporator drawer, next to the air
al lado del filtro de aire. filter.
• Abrir el cierre “cangrejo” del cajón • Open the evaporator's drawer ''crab'' lock.
evaporador.
11
• Soltar las mangueras del Aire • Release the Air Conditioning hoses, in
Acondicionado, para ello desmontamos order to do that we dismantle the
la válvula de expansión sacando los expansion valve pulling out the screws that
tornillos que la fijan al evaporador. bind it to the evaporator.
• Soltar las mangueras de calefacción • Release the heating hoses from the tap and
tanto del grifo como del radiador. also from the radiator. Remember the
Recordar que la manguera de presión pressure hose is connected to the heating
va conectada al grifo de calefacción. tap.
• Retirar el tubo de desagüe del cajón • Remove the drain tube from the evaporator
evaporador. drawer.
• Desmontar el cajón evaporador del • Dismantle the evaporator drawer from the
soporte superior, soltando los dos upper support, releasing the two screws
tornillos que lo sujetan. that hold it.
• Abrir la tapa cierre lateral del cajón • Open the evaporator drawer side closed to
evaporador para tener acceso tanto al have access to the evaporator and also to
evaporador como a la calefacción. the heating.
Montaje del evaporador, calefacción y válvula de Assembling of the evaporator, heating and
expansión. expansion valve.
Nota: Sustituir y lubricar con el lubricante Note: replace and lubricate with the specific
especifico las juntas tóricas de los racores. lubricant the fittings ring joints.
desmontaje. dismantling.
Apretar los tornillos de fijación según el Tighten the binding screws according to the
12
M6 (100) 10 M8 (125) 25.5
M8 (125) 25.5 M10 (125) 50
M10 (125) 50 M10 (150) 52
M10 (150) 52

Manguera 5/8” (compresor/evaporador) : Hose 5/8'' (compressor/evaporator): 32,4

32,4 Nm Nm
Manguera 3/8” (filtro/evaporador): 13,7 Nm Hose 3/8'' (filter/evaporator): 13,7 Nm
MONOSOPLADOR CENTRIFUGAL BLOWER SINGLE
Desmontaje del monosoplador. Disassembling of the centrifugal blower single.
Nota: obstruir los conductos o elementos de Note: Block the tubes or air conditioning
climatización inmediatamente después de elements immediately after dismantling.
desarmarlos.
evaporador, calefacción y válvula de evaporator, heating and expansion valve
expansión hasta retirar el cajón until removing the evaporator drawer
evaporador del soporte de sujeción. from the fixing support.
• Abrir la tapa cierre lateral del cajón • Open the evaporator drawer's side
evaporador para tener acceso. closing lock in order to have access.
• Desmontar la chapa mandos del plafón • Dismantle the control sheet from the
salida aire. upper cover air exit.
• Soltar el plafón salida aire del cajón • Release the upper cover air exit from the
evaporador. evaporator drawer.
• Desmontar la chapa que sujeta el • Dismantle the sheet that holds the
monosoplador. centrifugal blower single.
13
Montaje del monosoplador. Assembling of the centrifugal blower single.
Nota: Sustituir y lubricar con el lubricante Note: Replace and lubricate with the specific
desmontaje. dismantling.
el siguiente par de apriete: the following torque setting:
M6 (100) 10 M8 (125) 25.5
M8 (125) 25.5 M10 (125) 50
M10 (125) 50 M10 (150) 52
M10 (150) 52

Manguera 5/8” (compresor/evaporador) : Hose 5/8'' ( compressor/evaporator): 32,4

32,4 Nm Nm
Manguera 3/8” (filtro/evaporador): 13,7 Nm Hose 3/8'' ( filter/evaporator): 13,7 Nm
TERMOSTATO THERMOSTAT
Desmontaje del termostato. Disassembling of the thermostat.
Nota: obstruir los conductos o elementos de Note: Block the tubes or air conditioning
climatización inmediatamente después de elements immediately after dismantling.
desarmarlos.
monosoplador hasta soltar el plafón centrifugal blower single until releasing
salida aire del cajón evaporador. the upper cover air exit of the evaporator
• Desmontar el termostato de la chapa de drawer.
mandos soltando el botón de mando y • Dismantle the control sheet thermostat,
fijarse en el recorrido que hace el bulbo releasing the control button and pay
del termostato. attention to the trajectory the
thermostat's bulb makes.
14
• Desconectar los cables del termostato y • Disconnect the thermostat's cables and
recordar la posición original. remember the original position.
Montaje del termostato. Assembling of the thermostat.
Nota: Sustituir y lubricar con el lubricante Note: Replace and lubricate with the specific
• Montar los elementos en sentido • Assemble the elements in reverse order of

inverso del desmontaje, colocando el the dismantling, placing the new
termostato nuevo en la chapa mandos thermostat in the control sheet in the same
en la misma posición que el defectuoso position as the defective one and doing the
y haciendo el mismo recorrido con el same trajectory with the bulb until
bulbo hasta pincharlo en el evaporador. puncturing it into the evaporator.
• Colocar el botón de mando en el • Place the control button in the thermostat.
termostato.
• Conectar los cables del termostato en la • Connect the thermostat's cables in the
misma posición que la original. same position as original.
• Montar la chapa mandos. • Assemble the control sheet.
Apretar los tornillos de fijación según el Tighten the binding screws according to the
M6 (100) 10 M8 (125) 25.5
M8 (125) 25.5 M10 (125) 50
M10 (125) 50 M10 (150) 52
M10 (150) 52
• Tighten the hoses according to the
• Apretar las mangueras según el following torque setting:
siguiente par de apriete:
Torques
Par de apriete
Hose/ 5/8'' (compressor/evaporator): 32,4
Manguera 5/8” (compresor/evaporador) : Nm
32,4 Nm Hose/ 3/8'' (filter/evaporator): 13,7 Nm
• Fill the circuit with the prescribed

• Llenar el circuito con la cantidad de cooling fluid quantity.
fluido refrigerante prescrita. • Connect the battery.
• Conectar la batería.
15
CONMUTADOR SWITCH
Desmontaje del conmutador. Disassembling of the switch.

batería. battery.
• Desmontar la chapa de mandos del • Dismantle the control sheet of the
plafón salida aire del cajón evaporador. evaporator drawer's upper cover air exit.
• Separar el botón de mando para poder • Separate the control button in order to
sacar el conmutador. pull out the switch.
• Desconectar los cables del conmutador • Disconnect the switch cables
recordando su colocación original. remembering the original placing.
Montaje del conmutador. Assembling of the switch.
• Colocar el nuevo conmutador en la • Place the new switchboard in the control

chapa mandos en la misma posición sheet in the same position as the
que el defectuoso. defective one.
• Conectar los cables en la misma • Connect the cables in the same position
posición que el sustituido. as the replaced ones.
• Sujetar de nuevo el botón de mando al • Hold again the switch control button.
conmutador. • Assemble the control sheet to the
• Montar la chapa mandos al plafón evaporator drawer's upper cover air exit.
salida aire del cajón evaporador. • Connect the battery.
• Conectar la batería.
16
RELE, FUSIBLE RELAY, FUSE
La caja de los reles y del fusible esta situada al The relay's and fuse box is located on the
lado de la batería. battery side.
OPERACIONES DE MANTENIMIENTO MAINTENANCE OPERATION
Angulo de montaje del compresor Compressor’s assembly angle
Manutención y sustitución del compresor . Compressor’s maintenance and substitution.
Al principio, toda la carga de aceite se At the initially, all the oil load is found in the
encuentra en el compresor, o, respectivamente, compressor, or, respectively, in the
en la tubería del agente frigorífico. refrigerating agent's pipe.
Tras haber puesto en funcionamiento el After starting the air conditioner, the oil flows
acondicionador de aire, el aceite circula jointly with the refrigerating agent through the
conjuntamente con el agente frigorífico por la whole system.
totalidad del sistema.
If, for example, the compressor shall be
Si, por ejemplo, se desmonta el compresor, dismantled, it will never contain the entire
nunca se encuentra en éste la totalidad del amount of oil, but only the partial amount
contenido de aceite, sino únicamente la corresponding to the compressor.
cantidad parcial correspondiente al compresor.
If a large amount of oil was lost, the
corresponding amount of new oil shall be
Si se ha perdido una gran cantidad de aceite,
replaced in the system.
ha de reponerse en el sistema la
correspondiente cantidad de aceite nuevo.
Carga y control del nivel de aceite lubricante.

Load and control of the lubricating oil level
Los compresores, al momento de su
At the time of manufacture, the compressors
fabricación, son cargados con aceite lubricante
are loaded with the following lubricating oil
en las siguientes cantidades:
amounts:
17
- Modelo RT5H09 = (100 ± 15) cc - Model RT5H09 = (100 ± 15) cc

- Modelo RT7H13 = (135 ± 15) cc - Model RT7H13 = (135 ± 15) cc
Normalmente no se requiere el control de Usually the oil control is not required, only in
aceite, sólo en caso de que existan pérdidas o case of waste or breakage of equipment's
roturas en las tuberías del equipo o la pipes or the substitution of some component.
sustitución de algún componente.
Para controlar el nivel del aceite es necesario In order to control the oil's level it requires to
cumplir con los procedimientos descritos a carry out the following procedures:
continuación:
1) Determine the compressor’s
1) Determinar el ángulo de assembly angle (it shall be
montaje del compresor (tendrá important for step 5).
importancia en el paso 5). 2) Slowly dismantle the oil's load
2) Desmontar despacio el tapón de plug, look into the hole and turn
carga del aceite, mirar dentro the clutch's plate until the
del agujero y girar el plato del internal parts are placed as
embrague hasta que las piezas shown in the following figure
interiores estén colocadas como
en la figura siguiente.
1- Compresor visto desde arriba. 1- Compressor seen from above

2- Orificio de llenado. 2- Filling orifice
3- Vista de la biela ( con compresor inclinado 3- Connecting rod’s view (with compressor
en el sentido contrario de las agujas del reloj). leaned counter-clockwise).
4- Vista de la biela ( con compresor inclinado 4- Connecting rod's view (with compressor
en sentido del reloj). leaned clockwise)
- Cuando el compresor está inclinado hacia - When the compressor leans to the left
la izquierda (en el sentido contrario del reloj) (counter-clockwise) turn the clutch until the
girar el embrague hasta que las partes internas internal parts are situated as shown in position
se presentan como en la posición 3. 3.
- Cuando el compresor está inclinado hacia - When the compressor leans to the right
la derecha (sentido del reloj) girar el embrague (clockwise) turn the clutch until the internal
hasta que las partes internas se presentan como parts are situated as shown in position 4.
en la posición 4.
3) Poner la varita del nivel hasta la 3) Put level wand to the stop
posición de parada. La posición position. The stop position is
18
de parada viene determinada por determined by the curve

la curva que se encuentra en la situated on the wand.
varita.
La posición de parada debe tener la curva The stop position must have the curve to the
hacia la izquierda, si el compresor está left if the compressor is leaned to the right.
inclinado hacia la derecha.
La posición de parada debe tener la curva The stop position must have the curve to the
hacia la derecha, si el compresor está inclinado right if the compressor is leaned to the left.
hacia la izquierda.
4) Una vez puesta la varita sacarla y 4) After placing the wand, take it
determinar el nivel de aceite out and determine the oil level
contando el numero de las counting the number of marks
marcas (incrementos) bañadas en (increases) dipped in oil.
el aceite).
5) Usar el cuadro a continuación 5) Use the following chart to
para determinar el correcto nivel determine the correct oil level
de aceite en función del ángulo depending on the compressor's
de inclinación del compresor. leaning angle.
Angulo de Nivel de aceite aceptable Leaning angle Accepted oil level increase
inclinación – en incrementos -degree-
grados- Accepted oil level
RT5H09 increase
RT7H13 RT5H09 RT7H13
0 4-6 3-5
0 4-6 3-5 10 6-8 5-7
10 6-8 5-7 20 8-10 6-8
20 8-10 6-8 30 10-11 7-9
30 10-11 7-9 40 11-12 8-10
40 11-12 8-10 50 12-13 8-10
50 12-13 8-10 60 12-13 9-11
60 12-13 9-11 90 15-16 9-11
90 15-16 9-11
6) If the number of marks

6) Si el numero de marcas (o (increases) read on the level
incrementos) leídas en la varita wand do not match the above
de nivel no están de acuerdo con chart, increase or remove oil
el cuadro de arriba, aumentar o until obtaining a number of
quitar aceite hasta obtener un marks equal to the medium
número de marcas iguales al value of the values indicated in
valor medio de los valores the chart.
19
indicados en el cuadro. 7) Assemble the oil plug, making

7) Montar el tapón de aceite, sure the retaining ring should
observando que el anillo tórico not be bent and the contact
de retén no este doblado y que surfaces are clean. If the
las superficies de contacto estén retaining ring should present
limpias. Si el anillo de retén abrasion, replace it. Screw on
presenta abrasiones, sustituirlo. the plug with a torque of 7.8-
Atornillas la tapa con un par de 11.7N tightened.
apriete de 7.8-11.7 N.
Recordamos que no es necesario controlar el Note that the oil control is not required in a
aceite en un mantenimiento rutinario, no routine maintenance, nevertheless if there are
obstante si existen razones para efectuar dicho grounds to make such control it is required to
control hay que proceder como se indica a proceed as indicated below:
continuación:
Paso 1º - Poner el compresor en marcha lenta Step1 º - Put compressor in slow motion for 10
10 minutos. minutes.
Paso 2º - Recuperar del equipo de aire Step 2 – Retrieve all coolant from air
acondicionado todo el refrigerante, poniendo conditioner, making sure the lubricating oil will
atención para que no salga también el aceite not come out at the same time.
lubricante.
Paso 3º - Cumplir con las instrucciones Step 3 – Carry out the instructions indicated
indicadas arriba en los puntos 1-7. above, points 1-7.
Por si se presenta la necesidad de sustituir el In case the compressor should have to be

compresor, añadir las siguientes cantidades de replaced, add the following amounts of oil,
aceite, siempre teniendo en cuenta que los always taking into account that manufactured
compresores de fábrica vienen ya con un nivel compressors already come with an oil level.
de aceite (punto 9.2.1). (point 9.2.1)
1D2 Diesel / LPG : + 100 cc 1D2 Diesel / LPG : + 100 cc

1D1 Diesel : + 100 cc 1D1 Diesel : + 100 cc
Aceite recomendable : SUNISO SL100 Recommended oil : SUNISO SL100
Carga de gas refrigerante (equipo nuevo). Refrigerant gas load (new equipment).
1- Conectar la máquina de carga al equipo 1- Connect the machine load to the air
de aire acondicionado, para ello conditioning equipment, so place the
taps, valves HP (red) and LP (blue) in
colocamos los grifos de las válvulas HP
takes load of air conditioning equipment.
(rojo) y LP (azul) en las tomas de carga
del equipo de aire acondicionado. 2- We perform vacuum by no less than 20
2- Efectuamos el vacío por un tiempo no minutes, opening HP (red) and LP
inferior a 20 minutos, abriendo HP (rojo) (blue).
y LP (azul).
20
3- Pasado ese tiempo iniciamos la carga de 3- Past that time began the charge of
gas refrigerante. Abrimos HP (rojo) para refrigerant gas. To open HP (red) so that
que entre gas refrigerante. refrigerant gas.
4- Cuando no entre más gas refrigerante en
4- When no more refrigerant gas in the
el circuito, cerramos el grifo de la
circuit, we closed the taps, valves and
válvula HP (rojo) y ponemos la maquina
put the machine in operation. Connect
en funcionamiento. Conectamos el aire the air conditioning and open the tap of
acondicionado y abrimos el grifo de la the LP (blue) valve, this way ended up
válvula LP (azul), de esta manera with the total filled circuit.
acabamos con el total llenado del
circuito. 5- We turn off the loading machine and
5- Apagamos la máquina de carga y disconnect the hoses of takes charge of
desconectamos las mangueras de las the air conditioning equipment.
tomas de carga del equipo de aire
acondicionado.
Carga de gas recomendada para las carretillas Burden of gas recommended for Forklift
1D2 Diesel, 1D2 LPG y 1D1 Diesel : 1D2 Diesel, 1D2 LPG and 1D1 Diesel:
1000 gr de gas refrigerante 1000 gr of refrigerant gas
Carga de gas refrigerante (equipo usado). Refrigerant gas load (used equipment).
1- Recuperamos el gas refrigerante del 1- To recover the refrigerant gas of the

circuit.
circuito.
2- It detects and corrects the problem
2- Se detecta y corrige el problema que which could be: leak of refrigerant,
pudo ser: fuga de refrigerante, humedad moisture in the system or change of
en el sistema o cambio de unidad. unit.
3- Conectar la máquina de carga al equipo 3- Connect the machine load to the air
de aire acondicionado, para ello conditioning equipment, so place the
colocamos los grifos de las válvulas HP taps, valves HP (red) and LP (blue) in
(rojo) y LP (azul) en las tomas de carga takes load of air conditioning
del equipo de aire acondicionado. equipment.
4- Efectuamos el vacío por un tiempo no 4- We perform vacuum by no less than 20

inferior a 20 minutos, abriendo HP (rojo) minutes, opening HP (red) and LP
(blue), put in the necessary amount of
y LP (azul), echándole la cantidad
oil
necesaria de aceite.
5- Pasado ese tiempo iniciamos la carga de 5- After that time began the charge of
gas refrigerante. Abrimos HP (rojo) para refrigerant gas. To open HP (red) so
que entre gas refrigerante. that refrigerant gas.
6- Cuando no entre más gas refrigerante en
el circuito, cerramos el grifo de la 6- When no more refrigerant gas in the
válvula HP (rojo) y ponemos la maquina circuit, we closed the taps, valves and
en funcionamiento. Conectamos el aire put the machine in operation. Connect
21
acondicionado y abrimos el grifo de la the air conditioning and open the tap of
válvula LP (azul), de esta manera the LP (blue) valve, this way ended up
acabamos con el total llenado del with the total filled circuit.
circuito.
7- We turn off the loading machine and
7- Apagamos la máquina de carga y
disconnect the hoses of takes charge of
desconectamos las mangueras de las
the air conditioning equipment.
tomas de carga del equipo de aire
acondicionado.
Burden of gas recommended for Forklift

Carga de gas recomendada para las carretillas 1D2 Diesel, 1D2 LPG and 1D1 Diesel:
1D2 Diesel, 1D2 LPG y 1D1 Diesel :
1000 gr of refrigerant gas

1000 gr de gas refrigerante
22
WIRING DIAGRAM, Airconditioning (Rosti) 1D1/1D2
23
CLIMASUR
CLIMATIZER OPERATOR’S AND SERVICE MANUAL
This Climatizer system has 3 controls (see picture):
Control 1: Ventilation control
A fan is drawn on this control. It has 4 positions:
0- Off.
1- Minimum speed (airflow minimum)
2- Middle speed
3- Maximum speed
Control 2: Air Temperature control
This control consists in a manual tap with 2 positions:
- 0: Air temperature is minimum.

- Max: Air temperature is maximum.
Air temperature can be regulated placing the control in zones between 0 and max.
Control 3: Air conditioner control.
Button with 2 positions:
- On: Air conditioner works.

- Off: Air conditioner does not work. System can operate as ventilation and heater.
24
OPERATIBILITY OPTIONS:
Note: At least one of the diffuser should be open when this system runs.
 Ventilation:
- Control 1: Positions 1,2 or 3.

- Control 2: Position 0.
- Control 3: Off.
 Heater:

- Control 2: Open total or partially.
- Control 3: Off.
System works as a normal heater. Airflow is controlled with control 1, and the direction of airflow
can be changed turning the air diffusers.
 Air conditioner:

- Control 2: Position 0.
- Control 3: On.
Note: To wait some minutes if control 2 has been opened previously.
 Demisting glasses
 Control 1: Positions 1,2 or 3.

 Control 2: Open total or partially.
 Control 3: On.
The manufacturer recommends turning off the control 3
after this operation. OTHER INDICATIONS:
 Don’t place drink cans or similar near air diffusors.
SERVICE INDICATIONS:
 To check cooling fluid quantity at least once per year: This one must be 0,65 Kg. of 134 a.
 It’s not permitted running this system during maintenance / service operations. To use plugs or
similar to avoid air, water or strange objects entrance.
 Compressor of this system is SANDEN (used by Renault, Peugeot, VW, AUDI, SEAT,
MERCEDES, etc.) and oil type is PAG 20. After reparation or maintenance, new quantity of this oil
must be introduced.
25
 Quantities:
- Evaporator detaching:……….. To add 15cc.

- Condenser detaching………… To add 10cc.
- Hoses detaching………………To add 10cc (with each hose)
- Compressor detaching…………. To add 25 cc.
- With new compressor: To check that the minimum quantity of oil is 120 cc.
NOTES ABOUT EUROPEAN REGULATIONS:
 THIS CLIMATIZER SYSTEM HAS BEEN DESIGNED WITH THE EMISSION

SPECIFICATIONS OF 2006/ 40/ CE.
 THE GASS EMISSION WITH GLASSHOUSE EFFECT OF THIS SYSTEM IS LESS THAN 70%
THAN THE LIMITS FIXED BY EUROPEAN DIRECTIVES ABOUT AIR CONDITION SYSTEMS
IN MOTOR VEHICLES.
26
WIRING DIAGRAM
Climatizer (Climasur)
27
INSTALLATION INSTRUCTIONS
OPTIONAL
LPG LOW LEVEL WARNING SYSTEM
1D1 (page 2-8) / 1D2 (page 8-13)
1
1D1 STEP 1
A
Add the Bracket Bulk Head (A) to the Solenoid Assembly Valve (B).
1D1 STEP 2
Add the SW-LPG (A) together with the Tube Assembly (B).
2
1D1 STEP 3
A
A
B
B
S/D S/B
Mount the Valve Assy. Outlet (A) according to the LPG bottle mounting variant and the
Valve Assy. Safety (B).
Variant S/D: Swing Down

Variant S/B: Swing Back
Mounting angle:
NOTE: On any of this variants or retrofit a plug must be used on the opposite outlet.
3
1D1 STEP 4
A
B
Connect the two wires from the temperature sensor from the SW-LPG (A) and connect
them to the body harness wiring, located under the Valve Assy. Solenoid and identified
with a white label marking (SW) (B).
(B)
4
1D1 STEP 5
A B
Mount the Bracket Assy. Relay (A) next to the battery and mount the Controller Assy.
(B) to it.
5
1D1 STEP 6
Install a 1M Relay (A) to the relay bracket situated above the ECM (Pic1). Connect the
Controller Assy. connector (B) to the body harness located under the battery (Pic.2) and
the relay as well to the connector located at the same level of the relay.
Pic 1 Pic 2
1D1 STEP 7
-With temp
sensor(1D);
A3-04 Fuel OFF ON When the
(Lower) warning (Warning) sensor has
detected
SW an phase
change the
signal is ON.
6
On the Meter Panel turn ON the FUEL WARN SW see (VC-89).
Useful information on Service Manual:
VC-21
VC-27-29
VC-40
VC-89
FE-6
Variant S/B
Parts Description Parts Number Quantity

Bracket Bulk Head 17924GJ01A 1
Bolt-Hex 81108121G 1
Bolt-Hex 81108201B 2
*SW-LPG (S/B) 17908GJ10A 1
Valve Assy. Outlet 17907GJ01C 1
Valve Assy. Outlet 17907GJ01B 1
Valve Assy. Safety 1790890H70 1
Clamp 2421089944 1
1M Relay 252306K201 1
Variant S/D
Parts Description Parts Number Quantity

*SW-LPG (S/D) 17908GJ30A 1
Valve Assy. Outlet 17907GJ01A 1
Clamp 2421089944 1
1M Relay 252306K201 1
7
1D2 STEP 1
A
A1
Attach the Bracket Bulk Head (A) and the Solenoid Assembly Valve (B) to the
original bracket (A1).
1D2 STEP 2
C
D B
Attach the SW-LPG (C) together with the Tube Assembly (D) to the Bracket Bulk
Head (A) and to the Solenoid Assembly Valve (B).
Note: Use Gas tape to isolate the joins between (B) and (D).
8
1D2 STEP 3
E
E
E1 F
E1
W/O CABIN CABIN
Mount the Valve Assy. Outlet (E) and (E1) according to the LPG bottle mounting
variant and mounting angle. (see below) to the Valve Assy. Safety (F).
Variant S/D: Swing Down

Variant S/B: Swing Back
Note: E1 is the outlet valve to the LPG bottle.
Mounting angle of E and E1:
E1 E
NOTE: On any of this variants or retrofit a plug must be used on the opposite outlet.
9
1D2 STEP 4
G
H
Connect the two wires from the temperature sensor from the SW-LPG (G) and connect
them to the body harness wiring, located under the Valve Assy. Solenoid and identified
with a white label marking (SW) (H).
(H)
10
1D2 STEP 5
I J
Mount the Bracket Assy. Relay (I) next to the battery and mount the Controller Assy.
(J) to it.
11
1D2 STEP 6
Install a 1M Relay (K) to the relay bracket situated above the ECM (Pic1). Connect the
Controller Assy. connector (L) to the body harness located under the battery (Pic.2) and
the relay as well to the connector located at the same level of the relay.
Pic 1 Pic 2
12
1D2 STEP 7
-With temp
sensor(1D);
A3-04 Fuel OFF ON When the
(Lower) warning (Warning) sensor has
detected
SW an phase
change the
signal is ON.
On the Meter Panel turn ON the FUEL WARN SW see (VC-89).
Useful information on Service Manual DX:
VC-21
VC-27-29
VC-40
VC-89
FE-6
Variant W/O CABIN
Parts Description Parts Number Item ID Quantity

Bracket Bulk Head 17924GJ31A A 1
Bolt-Hex 81108161B X 4
Bolt-Hex 81108121G X 1
SW-LPG (S/B) 17908GJ30A C 1
1M Relay 252306K201 1
Variant CABIN
Parts Description Parts Number Item ID Quantity

SW-LPG (S/D) 17908GJ30A 1
Connection 17907GJ30D 1
1M Relay 252306K201 1
13
OPTION
ASSEMBLY
INSTRUCTIONS
Product in question
Crystal Cabin Kit
Designed for
1D1/1D2
KIT#: 99410 GJ30F (N)

1ST Edition
December 2007
ASSEMBLY INSTRUCTIONS
ASSEMBLY ORDER: PAGE
1.- ASSEMBLY OF FRONT SIDE 3
2.- ASSEMBLY OF REAR FRAME 8
3.- ASSEMBLY OF DOORS 17
4.- ASSEMBLY OF HEATER 22
5.- ASSEMBLY OF STEEL ROOF 29
6.- ASSEMBLY OF NOISE 32

REDUCTION KIT
2
1.- ASSEMBLY OF FRONT SIDE.
KTNI 0084 60550 GJ30A FRONT SIDE KIT

1D1/1D2
ITEM Nº PART NAME
QTY
1 GLASS-WS 1
3 BRKT-FRAME UPR A 1
4 BRKT-FRAME LWR 1
8 BOLT-SPL 3
9 MIRROR ASSY-INSIDE 1
10 BRKT 1
11 BOLT-SPL 2
12 NUT HEX-SPL 2
13 HEX-BOLT 2
14 BUSH 2
15 INTERNAL LIGHT 1
16 NUT-HEX 2
17 BRKT-INTERNAL LIGHT 1
18 HARN-INTERNAL LIGHT 1
19 BOLT-SPL 2
1.1 Assemble BRKT FRAME LWR (4), using the holes for fixing plastic parts,
with bolt (13). It's necessary to INSTAL the BUSH 73747 FA300 (14).
3
1.2 Dismantle plastic parts 50550 FA300, 50580 FA300, 50590 FA300 and
assemble relay as it's shown in PICTURE 1.
4
PICTURE 1
1.3 Assemble the FRONT GLASS (1).
1.4 Install BRACKET FRAME UPR (3) and fix it with 3 self-drilling screws (8).
5
1.5 Install panoramic mirror (9) together with the BRKT-INTERNAL LIGHT (17)
in overhead guard. Install the INTERNAL LIGHT (15) after connecting the
HARN-INTERNAL LIGHT (18). The Mirror must be installed in the most
possible advanced position in the overhead guard.
1.6 Connect the HARN WIPER (8) and assemble plastic parts, (shown in item
1.2), again.
6
7
2.- ASSEMBLY OF REAR FRAME.
(1D2 MODEL)
KTNI 0104 90100 GJ30A REAR SIDE KIT -1D2-

1D2
ITEM Nº PART NAME
QTY
1 DOOR ASSY-BACK, OTR 1
4 BOLT-SPL M8x20 4
9 BOSS 4
10 INSUL-UPR, RH 1
11 BRKT-INSUL, LH 1
11 BRKT-INSUL, RH 1
12 FLAT WASH Ø6x18x1,5 4
13 NUT-BLIND M6 4
25 HARN-BACK WDW WIPER 1
28 COVER-BACK DOOR EXH 1
46 BOLT-SPL M8x16 2
56 EXH COVER 1
57 INSUL-UPR, LH 1
61 INSUL-RR UPR, RH 1
62 INSUL-RR UPR, LH 1
8
2.1- WITH LOW MUFFLER
2.1.1 Dismantle rear combination lamp protector if applicable.
2.1.2 Put REAR GLASS FRAME (1) and fix it with four bolts (4).
2.1.3 Install the BOSS (9), BRKT-INSUL, LH & RH (11) and INSUL-UPR, LH &
RH (57 &10) fixing with (12 & 13) and assemble rear combination lamp
9
protector again if applicable. After, install INSUL-RR UPR, LH & RH (61 &
62) inside side of cabin.
2.1.4 Connect the HARN WIPER (25) as shown.
10
2.2- WITH OVERHEAD MUFFLER
The process for assembly the rear frame is the same as in the case of low
muffler except the following items.
2.2.1 Take off the EXH COVER (56, 46), which is in the rear frame. Assemble
the COVER-BACK DOOR EXH (28) inside cabin, fixing it with the same
KNOB of RAD COVER which cams with the truck.
2.2.2 Install new OVERHEAD MUFFLER BRACKET instead the standard

bracket of the truck, in the case of the truck doesn’t have this new bracket
as standard.
11
NOTE: If the truck is with LPG system, it's necessary in both cases (low and
overhead muffler) to make a hole in the PLUG in order to pass through
the LPG hose.
12
2.- ASSEMBLY OF REAR FRAME.
(1D1 MODEL )
KTNI 0103 90100 GJ00A REAR SIDE KIT -1D1-

1D1
ITEM Nº PART NAME
QTY
1 DOOR ASSY-BACK, OTR 1
4 BOLT-SPL M8x20 4
9 BOSS 4
10 INSUL-UPR, RH 1
11 BRKT-INSUL, RH 1
11 BRKT-INSUL, LH 1
12 FLAT WASH Ø6x18x1,5 4
13 NUT-BLIND M6 4
25 HARN-BACK WDW WIPER 1
46 KNOB 2
56 DOOR ASSY-BACK, LWR 1
57 INSUL-UPR, LH 1
61 INSUL-UPR, RH 1
62 INSUL-UPR, LH 1
63 BOSS 2
2.1- WITH LOW MUFFLER
13
2.1.1 Put REAR GLASS FRAME (1) and fix it with four bolts (4).
2.1.2 Install the DOOR ASSY-BACK,LWR (56) and fix it with two KNOBS (46)
and the knob Radiator Cover which comes with the truck.
14
2.1.3 Install the BOSS (9), BRKT-INSUL, LH & RH (11) and INSUL-UPR, LH &
RH (57 &10) fixing with (12 & 13) and assemble the rear combination lamp
protector again if applicable. After, install INSUL-RR UPR, LH & RH (62 &
61) inside side of cabin.
2.1.4 Connect the HARN WIPER as it's indicated in the item 2.1.4 in the case of
1D2 models
15
2.2- WITH OVERHEAD MUFFLER
The process for assembly rear frame is the same as in the case of low muffler
except the following item.
2.2.1 Install new OVERHEAD MUFFLER BRACKET instead the standard

bracket of the truck, in the case of the truck doesn’t have this new bracket
as standard.
16
3.- ASSEMBLY OF DOORS.
KTNI 0085/0102 80100/80101 GJ00A

KTNI 0088/0101 80100/80101 GJ30A DOORS KIT
1D1 1D2
ITEM Nº PART NAME
QTY QTY
1 DOOR ASSY-FRAMED, RH/LH 1 1
12 WASH 1 1
18 WASH-SPL 6 6
19 BOLT-SPL 6 6
23 BRKT-STAY, RH/LH 1 1
29 STAY ASSY-BACK DOOR 1 1
30 LOCK NUT 1 1
31 BOLT-SPL 2 2
42 WASH 2 2
45 SEAL-BODY SIDE FR, RH/LH 1 1
48 SHIM-DOOR LOCK 1 1
50 HDL-ROD 1 1
51 PROTR-ROD 1 1
52 STRIKER-DOOR, RH/LH 1 1
54 FLAT WASH 1 1
58/59 REAR SIDE GLASS, RH/LH 1 1
60 ADHESIVE 1 1
3.1 Install STRIKER DOOR RH and LH (45 or 52 depending of versions) in front
off the plugs of the pillar with BOLTS (29 OR 31).
17
3.2 Put the DOOR RH and LH (1) and fix them to the rear pillars with BOLTS
(9 or 19) and WASH (8 or 18) and adjust it.
3.3 Put the auto-adhesive SEAL BODY (37 in CRISTAL model; 45 in FRAMED
model), which covers open step, over the BRKT DOOR and adjust it to
the step.
18
3.4 Assemble gas stay BRKT (53 or 23) and fix the GAS STAY (52 or 29).
3.5 Adhesive LABELS in doors and front side as show.
19
3.6 In the 1D2 models, install REAR SIDE GLASSES (58, 59) with ADHESIVE
SIKAFLEX 255-FC (60) or similar.
Instructions for fixing REAR SIDE GLASS:
20
1.- Clean the metal surface of the cabin frame in place where you
will put the adhesive on.
2.- Apply the adhesive on the metal cabin frame.
3.- Put the REAR SIDE GLASS on the adhesive, and press it by
hand.
4.- Wait approx. 2 hours.
21
4.- ASSEMBLY OF HEATER.
KTNI0105 27100 GJ30A HEATER KIT

1D1/1D2
ITEM Nº PART NAME
QTY
10 BRKT-FR HEATER 1
11 SEAL RUB 1
12 PLATE DOOR 2
13 COVER 2
20 WASH PLAIN 14
21 WASHER WAVE 1
22 WASH SPL 1
23 BOLT 2/1
24 NUT SPRING 1
25 NUT SPRING 2
22
4.1 ASSEMBLY OF HEATER UNIT.
4.1.1 Assembly of heater unit in truck with electrical &
mechanical levers.
4.1.1.1 Install BRKT HEATER (10) and assemble the joystick unit again over
this bracket using 3 bolts (23). These 3 bolts are the references shown in
next picture:
4.1.1.2 Assemble the HEATER UNIT (8), and fix it with a WASH (22) and two
NUTS (24,25)
4.1.1.3 Cut a portion of frame seal (30 mm) and pass through this hole the
heater hoses as shown.
23
4.1.1.4 Change the standard BRKT DOOR for the new one ((12) special for
heating version) and assemble the BODY SEAL ((11) special for heating
version too), which covers open step, and the rubber COVER (13). This
change only in the right side.
24
4.1.2 Assembly of heater unit in truck with mechanical levers
for hydraulic functions.
The assembly process of the heater in trucks with mechanical levers is
the same that in the case of electrical levers models, except an difference,
which is to cut a portion of the floor as shown in PICTURE 2 .
PICTURE 2
4.2 CONNECTION OF HEATER HOSE
25
4.2.1 DIESEL ENGINE.
4.2.1.1 Install the CONNECTORS (30) in the engine, and assemble the hoses
A, B as shown in the PICTURE.
4.2.1.2 Connect the HARN HEATER.
26
4.2.2 LPG ENGINE.
4.2.2.1 Cut the engine hoses as it's indicated in the PICTURE and assemble
the CONNECTORS (29).
Assemble the hoses A, B in the connectors.
27
4.2.2.2 Connect the HARN HEATER as it's indicated in the item 4.2.2.1 (Diesel
engine)
In all the cases when the assembly is finished, to check the following items is
necessary:
1.- The level of coolant.

2.- If there is any leakage in the circuit system.
3.- The system works correctly
5.- ASSEMBLY OF STEEL ROOF.
28
KTNI 0024 73791 FA310 NOISE REDUCTION KIT
1D1/1D2
ITEM Nº PART NAME
QTY
1 ROOF ASSY 1
3 HEN-BOLT M8x40 4
4 FLAT WASH 4
5 RUB WASH 4
6 INSUL 1
7 INSUL- LH 1
8 INSUL-RH 1
9 INSUL 1
5.1. Locate the auto-adhesive INSUL (7, 7, 8 and 9) as shown.
29
5.2. Fix the STEEL ROOF (1) over the INSUL with the BOLTS (3, 4 and 5).
30
6.- ASSEMBLY OF
NOISE REDUCTION KIT.
COTA 73161 NOISE REDUCTION KIT

3300/3400 GJ00A/GJ30A
1D1/1D2
ITEM Nº PART NAME
QTY
1 INSUL-SET FLOOR 1
2 INSUL-DASH LWR, LH 1
3 INSUL-DASH UPR 1
4 INSUL-DASH LWR, RH 1
5 INSUL-FR FLOOR, RR 1
6 INSUL-ENG COVER 1
7 INSUL-ROOF B 1
8 INSUL-RAIN, LH 1
9 INSUL-RAIN, RH 1
10 INSUL-ROOF, C 3
11 INSUL-ROOF, D 1
12 INSUL-ROOF, A 1
6.1. Install over the cab frame the SEALS (8 and 9)
31
6.2. Disassemble the front covers (50550 FA300, 50580 FA300 and 50590
FA300) from the truck and install the INSULATORS (2,3,4).
6.3 Remove the floor and install the INSULATORS (1,5).
32
6.4 Assemble floor and front covers again.
6.5 Dismantle the seat and the top panel knob and put on the ENGINE COVER
INSUL (6).
33
NOTE: For fixing this ENGINE COVER INSUL, use magic tape.
6.6 Assemble the seat again over THE TOP PANEL.

6.7. Assemble the auto-adhesive OVER HEAD GUARD INSULATORS (7, 10
and 11)
34
6.8 Assemble the overhead guard insulators cover (12), with magic tape.
6.9. Apply sealant SIKAFLEX 221 in marked places. This sealant can be
applied in other zones, in which the customer considers it's necessary.
35
APPLY
SEALANT
APPLY
SEALANT
36
Technical Information
Speed Limiter for 1D1/1D2 Model QD32 Diesel Engine (Optional)
1. Introduction
This optional specification limit the maximum speed (forklift speed) to the set speed in 1D1/1D2 QD32
diesel engine model with automatic transmission (model type: Y1DXA).
2. Specifications
1) System limits two maximum speed of the track.
- Default speed limit: 10 km/h
- Recommended speed limit: 8 km/h or more
CAUTION: If the set speed is lower than 8 km/h, forklift speed may become instable.
2) Controlling forklift speed

Forklift speed limited by operating the forklift speed switch (High/Low SW).
H (High) side: No speed limitation (regular driving)

L (Low) side: Speed limiter works (maximum speed limited)
Vehicle Vehicle performance

Speed Select SW Speed
Condition
Driving Loading
When stopped - - Normal
L (Low) side (Speed control Lower than

(Full: normal) (Full: normal) *
system is ON) limit speed
When driving
Faster than
Forklift speed control Controlled *
limit speed
H (High) side (Forklift speed control is OFF) Full (normal) Full (normal) *
*: While driving the loading operation is prohibited.

3) Parts for changing set forklift speed
To change the settings, the following components are necessary.
- Diagnosis Kit-Speed (settings/diagnosis kit)
Component parts: (1) Interface

(2) Serial cable (for connection between interface and PC)
(3) Interface cable (for connection between interface and forklfit)
(4) Software (for settings/diagnosis)
- Computer (PC)
Computer specifications OS: Windows 98SE/Me/2000/XP
Free HDD space necessary: 650 kB or more
Required memory: 128 MB or more (256 MB recommended)
3. Units Layout
4. Explanation Regarding Operation of Forklift Speed Control
CAUTION: Depending on the road surface conditions or the conditions of loading operations,
there may be cases where the set (restricted) forklift speed and sense of acceleration change
temporarily. When driving downhill, keep taking your foot off the accelerator.
Note: When the track has no load, the set (restricted) forklift speed may not be achieved when
driving uphill. In addition, there may also be cases where the forklift speed exceeds the set
(restricted) forklift speed when driving downhill.
5. System Diagram
6. How to Set the Limitation Speed
1) Connect the cables between the interface unit and the PC and between the interface unit and the
forklift.
- Connect the serial cable to the PC and interface.

- Connect the interface cable (yellow) to No. 17 terminal
(MAINTE CONN) of the forklift.
- Connect the interface cable (red/green) to the (+) terminal

of the battery.
- Connect the interface cable (black/blue) to the (-) terminal

of the battery.
2) Turn the ignition switch to ON position.

3) Double-click the “AGBDiag3.exe” icon on the PC, and start the “AGBDiag3" settings software.
4) The start title and main screen are displayed.

5) Check the communication setting between PC and controller (DCU). (Only as for the initial setting)
- From the main screen, select “Options” “Programs” or click the “Program Settings” icon.
When selecting from main menu
When selecting from

“Program Settings” icon
- The “Settings” dialog box is displayed. Select the communication port from “Inter face for the
Communication with the ECU” drop-down menu. Click “OK” and confirm the settings.
Selecting example
6) Set the control speed.

- From the main screen, select “Parameter” “AGB-Parameters”.
- The current settings are displayed.
- Select the line for "Maximum Speed Limit”, and double-click.
- The “Change Parameter” dialog box is displayed. Enter a value for “Maximum Speed Limit” from an
allowable range and change the setting. Click “OK” and confirm the settings.
CAUTION: Do not change the values for other parameters.

- When the “Transmit” button is clicked, a dialog box for confirming transmission is displayed. Click
“Yes” to start transmission.
- The data is transmitted, and transmission is complete when a confirmation dialog box indicating
“Transmitting of parameters successfully finished.” is displayed. Click the “OK” button.
- Turn the ignition switch to OFF position. The changed setting value is reflected the next time the
ignition switch is turned ON.
7) Disconnect the cables between the interface unit and the PC and between the interface unit and
the forklift.
7. Measures during Abnormalities
It is possible to confirm the condition of errors by using the Diagnosis Kit-Speed (settings/diagnosis kit).
1) Connect the cables between the interface unit and the PC and between the interface unit and the
forklift in the same manner as for changing the settings.
2) Turn the ignition switch to ON position.

3) Double-click the “AGBDiag3.exe” icon on the PC, and start the “AGBDiag3" settings software.
4) From the main screen, select “Extras” “Failure Memory”.
5) The “Failure Memory" screen is displayed, and the error codes that have been recorded in the
DCU are displayed.
- Active: A “✓” mark is displayed next to errors that are currently occurring.
- Count: The number of times the error occurred is displayed.
- Label: Error code and explanation of error contents.
- To erase an error code, select the line of the code and click the “Delete” button.
6) Table of error codes
Error Code Error Probable Cause Solution
The speed signal line is

22 Speed signal abnormality short-circuited with the Inspect the harness
grounding wire
The speed signal line is

short-circuited with the
24 Speed signal abnormality
positive-side, or is
disconnected
The potentiometer line of
Abnormality with the
the actuator is
31 potentiometer of the
short-circuited or
actuator
disconnected
There is a memory
33 DCU abnormality reading or writing error in Replace the DCU
the actuator
Occurs when the rotation
Inspect the rotation
Rotation pulse pulse number is a value
34 pulse number and
abnormality other than a permissible
confirm the set value
value
The DCU was initialized
35 DCU initialization error Reset the DCU
with wrong data
The actuator line is

Inspect the harness
41 Actuator abnormality short-circuited with the
and actuator
positive-side
42 Actuator abnormality short-circuited with the
grounding wire
short-circuited with the
43 Actuator abnormality
positive-side and the
grounding wire
44 Actuator abnormality
disconnected
The gear of the actuator is

45 Actuator abnormality Replace the actuator
damaged
8. Wiring Diagrams
LICENSE PLATE OPTION
Diesel Version
Assembly Instruction
LPG Version
Assembly Instrution
Circuit Diagram
GPS TRACKER OPTION
Assembly Instruction
GPS Control Unit

GPS TRACKER OPTION
Sub Harness
LED Status description

ENGINE AUTO STOP QD32
Component Location
ENGINE AUTO STOP QD32
Circuit Diagram
USB-connector OPTION
Component Location
NOTE: In wet or moist conditions don't use the USB connector and keep the lit closed in case truck is not equipped
with a cabin.
1. USB connector.
2. Dashboard cover for PKB- & Hydraulic levers.
3. USB connector 2 x USB output (front).
4. USB connecotr + & 1 connections (rear).
5. USB connector side.
6. USB connector mounting nut. (Hand tighten till securely fixed in position).
Diagram & Harness Layout
Wiring Diagram
Harness Layout
LPG Reserve tank
Components
Filter Reserve Tank
A. Filter element with magnet & spring.

• Micron rating 7 micron.
• Filtering surface 14800 mmq.
LPG Reserve tank
Component Location
1 Reserve fuel tank
2 Filter
3 Seal (flat side facing downwards)
4 Coupler for hose from LPG cylinder
5 Coupler to LPG safety valve on truck
6 Mounting bracket
Bracket Assy.
1 Spacer 10 Plate Bracket

2 Bolt-Hex 19.6 - 22.6 Nm 11 Protective hose
3 Bolt 12 Rubber Damper
4 Catch Assy. 13 Collar Spacer
5 Bolt 14 Bolt Hex
6 Bolt 15 Washer
7 Spacer 16 Nut Hex with conical washer
8 Washer 17 Nut
9 Nut-Hex 18 Washer
19 Support plate bracket
NOTE : For bolts without tightening torque specification, refer to maintenance section to
tightening torque specification list.
LPG Reserve tank
Component Location
Hose routing
Counterweight mounting hole locations
M12 x 1.75, 22 mm deep effective.
M10 x 1.25, 20 mm deep effective.
1 Clamp 7 Spiral protector

2 LPG interception valve 8 Hose from LPG cylinder to reserve tank
3 LPG safety valve 9 LPG cylinder valve
4 Hose from reseve tank to LPG safety valve
5 LPG cylinder
6 LPG reserve tank
LPG Reserve tank
Wiring diagram
INTEGRAL FORKS POSITIONER
1 DESCRIPTION AND OPERATION

1.1 Positioner
2 ASSEMBLY INSTRUCTIONS
2.1 Integral Positioner
2.2 Hydraulic system
2.3 Forks assembly
2.4 Testing
3 USER INSTRUCTIONS
3.1 Controls and recommendations
3.2 Manoeuvres to avoid
3.3 Prohibited manoeuvres
4 MAINTENANCE
4.1 Introduction
4.2 Scheduled maintenance
4.3 Extraordinary maintenance
4.4 Hydraulic system layout
5 TROUBLESHOOTING
1 DESCRIPTION AND OPERATION
1.1 Positioner (FIG.001)
Device for positioning the loading forks using, as a base,

the mobile frame of the integral side-shifter (the load is
supported by the chrome-plated bars (material 42CrMo4
quenched and tempered) with supports moved by
differential diameter cylinders (Ø36-42) in series.
The loading forks are attached to the FEM profile of the
supports and fixed using the side screws.
The supports are operated by cylinders and slide on a
chrome bar with self-lubricating INA bushings. The
supports are equipped with scrapers and grease nipples
to lubricate the chamber of the bushings and shoes if
necessary.
The screws and fittings are surface treated to prevent
any attack by rust.
The hydraulic system is connected via inlets positioned
based on the type of mast. The connection
fittings are threaded metric cone 24° DIN 3861 (for the
2W mast) and with 3/8" gas thread (for 2F-3F-3V masts).
The hydraulic system for positioning the forks is
equipped with a valve made by Bolzoni assembled with
Oil-Control cartridges to ensure a perfect synchronism of the forks.
2 ASSEMBLY INSTRUCTIONS
2.1 Integral Positioner

Install the integral positioner in the mask of the forklift according to the instructions of the mast itself.
Connect the equipment by means of the lifting chains according to the instructions of the mast/forklift.
Adjust it again in accordance with the instructions of the mast/forklift.
Connect the system on the mast of the forklift to the connections of the equipment's side-shift cylinder
(fixed frame upper bar), tightening in accordance with the regulations of the fittings used.
2.2 Hydraulic system
2.2.1 Connect, with flexible hoses complete with terminal fittings, the
system on the mast of the forklift to fittings "q1 (forks closure)" and "q2
(forks opening) (Fig.003-A-B-C) of the equipment, tightening according
to the regulations of the fittings used.
2.2.2 Perform some test movements to check the perfect hydraulic

seal of the fittings, the speed and the synchronism of the forks
movement. In the event of an oil leak, remove the affected fittings and
clean them thoroughly. The synchronism of the forks is guaranteed by
the valve and the cylinders in series with different diameters (Ø36-42).
See the table at the end of section 4.4 for the flow rates of the oil and
recommended pressures.
2.2.3 At this point perform some unloaded side-shift manoeuvres, as

far as the end of stroke in both directions and hold under pressure for
a few seconds.
Then carry out a leak-proof control of the hydraulic connections. Any small oil leaks require the disassembly and cleaning of the
fittings. Tighten them to the correct torque in accordance with the regulations.
Note: The
tightening
torque of the
cartridges
"Ca" (in
case of
disassembly
and
reassembly)
is equal to
50-59 Nm
max. (24mm
hex key).
2.3 Forks assembly (Fig.002)
2.3.1 Raise the fork retaining pin in pos. “e”.

2.3.2 Remove the 2 screws "h" and washers "i", verify that the self-locking screws "f" are positioned at the inner edge of the support.
2.3.3 Insert the fork into the support with the FEM profile.
2.3.4 Tighten the 2 screws "h" and related "SCHNORR" type knurled safety washers "i" at a torque of 235 Nm (164 Ft/Lbs) for FEM2
positioner and 360Nm (252 Ft / Lbs) for FEM3 positioner.
2.3.5 Tighten the self-locking screws "f" against the fork.
2.3.6 Perform the same procedure for the other fork.
IMPORTANT: The maximum permitted length of the forks is 2400 mm.
Fork positioning diagram on the support (valid specularly for both supports of the positioner).
Note: The positioner has been designed to mount the fork sections with the hook dimensions below, according to forklift
specifications
3. 3
3.USER INSTRUCTIONS
3.1 Controls and recommendations
- Introduce the loaded fork as centrally as possible

- Keep the load close to the ground for greater stability of the forklift when manoeuvring
- Keep the load tilted (tips of the fork raised) during the movement of the forklift
- Act gently on the command levers to avoid a sudden burst of pressure in the hydraulic circuit compromising the stability of the load
- Adapt the speed of the forklift to the stability and nature of the load and the difficulties caused by spaces and dimensions
- Pay attention to inclined surfaces and the unevenness of the ground since these limit the stability of the load
- Before introducing the forks, adjust their position so that no force is exerted against the foot of the pallet
3.2 Manoeuvres to avoid
- Moving loads in excess of the nominal load

- Moving an unstable load
- Picking up a load with a single fork even if of a low weight
- Moving a flanked load using the load already on the forks
- Performing movements or manoeuvres fast with the load lifted high.
- Performing side-shift or positioning travel of the forks with the load on the forks and forklift moving
- Follow al other instructions indicated in the forklift's user manual
3.3 Prohibited manoeuvres
- It is not a clamp (do not to use the forks to secure the load in opening or closing)
- Use the equipment for purposes other than those for which it was designed
- Operate the movements control lever when the equipment is under maintenance
- Use the lift truck if visibility is poor due to the oversize of the load
- Tamper with the equipment
- Linger in the working area of the equipment or the lift truck;
- Use the equipment if the structure is deformed, however slight, or there is a malfunction
- Follow al other instructions indicated in the forklift's user manual
4 MAINTENANCE
4.1 Introduction
The equipment is delivered with guides and shoes lubricated with high quality grease, so as to ensure the normal adjustment and
polish of the sliding surfaces in the initial usage period. The user must lubricate the sliding tracks of the lower supports "G4" before
the forks have been fitted in order to ensure good sliding without friction during opening and closing (forks positioning). The user
should also grease the bushings sliding zone "G3" on the chromed bar.
The recommended lubricant is ISO X M2 grease (SHELL ALVANIA GREASE R2 or equivalent).
For the use of the equipment in excessively dusty environments ISO CB 32 oil is recommended (ESSO NUTO 32 or equivalent).
The maintenance indicated on following pages relates to the correct use of equipment in a slightly dusty environment.
4.2 Scheduled maintenance (Fig.006, 006-1)
4.2.1 Every 1000 hours.
- Control the bolts tightness torque at points “C1” 106 Nm (74

Ft/Lbs) wrench (ch1 = 19 mm).
- Control the bolts tightness torque at points “C2”. (see point
2.3.4 for the tightening torque and the size of the wrench).
- Control the tightness of pins “C4” Allen key 6 mm; if loose,
clean with solvent along with the holes, leave to dry and
tightened again with “Loctite 270” threadlocker.
- Check the hydraulic seal of the fittings.
- Clean the sliding guides of the shoes, greasing in points
“G1”, ”G2”, ”G3”, ”G4”.
- Check the general condition of the equipment.
- Specific control of the condition of the hoses.
- Check the integrity of the lower and upper shoes of both the
side-shifter as well as the fork supports.
- Check tightness of the bolts on the lower hooks "C3", with a
torque of 145 Nm for positioner FEM2 or torque of 235 Nm for
positioner FEM3;
- Control the hydraulic connections (if necessary, tighten the
fittings to the cylinders according to the regulations of the
fittings used).
- Check for tightness of the cylinder seals (if necessary or if
due to a leak dismantle the cylinders according to the
instructions in sections 4.3.1, 4.3.6, 4.3.9).
Warning: There are special washers under the bolts "C1", which in the event of removal or replacement must be refitted as shown
below, then tighten the bolts at the torque indicated above.
4.2.2 Every 2000 hours
- In addition to that indicated in the previous point, carry out:

- The disassembly of the mobile frame according to instructions in section 4.3.5 for general cleaning of the parts and to control the
wear of the upper shoes (the limit thickness of which is 2 mm or 0.08 inches, below which the replacement of the parts is necessary)
and the lower shoes of the side-shifter (the limit thickness of which is 3 mm or 0.12 inches, below which the replacement of the parts
is necessary).
- The disassembly of the frame supports according to instructions in section 4.3.8 for general cleaning of the parts and to control the
wear of the lower shoes. When the metal profile began to slip on the lower bar, the shoes need to be replaced with new ones.
- The control of the cylinder stems and the guide bushings; the scratched or dented stem and scratched or worn bushings, as well as
the excessive play of the stem (> 0.25 mm. or 0.001 inches) requires the replacement of parts.
4.3 EXTRAORDINARY MAINTENANCE
4.3.1 Preliminary operations
- Before performing any extraordinary

maintenance, turn off the forklift and
remove the pressure in the supply
circuit (refer to the forklift's manual).
- Make sure that the pump is not

engaged and the lever of the distributor
is not operated during the entire
maintenance operation.
4.3.2 Disassembly of the fork shift right

cylinder (Driver's view) (Fig.007-D)
- Remove the hydraulic connection pipes

from the right cylinder (Driver's view)
observing the precautions mentioned in
section 4.3.1
- Remove the circlip pos. “cs01” using a
screwdriver “u01”.
- Extract the pin pos. “cs02” with a diam. 8
mm punch “u02”.
- Remove the spring pin pos. “cs03” with a
diam. 4 mm punch “u03”.
- Remove the pin pos. “cs05” using a T.E.
M6 screw and extractor.
To reassemble the cylinder perform the operations in reverse order.
4.3.3 Disassembly of the fork shift left cylinder (Driver's view) (Fig.007-S)
- Remove the hydraulic connection pipes from the

left cylinder (Driver's view) observing the precautions
mentioned in section 4.3.1
- Unscrew bolts “C1” with a wrench (ch1=19 mm),
remove them along with the special washers (see
diagram below).
- Release the right support from the bracket by
sliding it on the chrome bar.
- Remove the circlip pos. “cs01” using a screwdriver
“u01”.
- Extract the pin pos. “cs02” with a diam. 8 mm
punch “u02”.
- Remove the cylinder from the seat.
To reassemble the cylinder perform the operations in
reverse order. At the time of reassembly, the bolts
"C1" with the special washers must be tightened with
a tightening torque as per section 4.2.1.
4.3.4 Disassembly of the flanged valve on the right

cylinder (driver's view) (only in case of O-ring
replacement) (Fig.007)
- The valve can be removed without having to

dismantle the cylinder
- Step1: Unscrew the self-locking nut C6 with a Hex
wrench (ch4= 10 mm).
- Remove the bracket “St1”.
- Step2: Remove the hydraulic connection pipes from
the flanged valve on the right cylinder (driver's view)
observing the precautions mentioned in section 4.3.1
- Step3: Unscrew the screws “C5” with an Allen key
(ch3 = 5 mm), remove them together with the knurled
washers.
- Step4: Lift the valve slightly and remove it sideways
as in the figure.
- Step5: There is an O-ring “OR” between the valve and
the cylinder that must be replaced.
- The reassembly of the valve must be carried out in
reverse order. Make sure the O-ring "OR" has been
correctly positioned in its seat before securing the valve
to prevent damage to the seal.
Important:
- The screws "C5" and relative knurled washers are
tightened with tightening torque of 17.5 Nm (12.2
Ft/Lbs).
- The reassembly of the pipes on the valve must be
performed by connecting “q1-P1” and “q2-P2” as in the
figures at point 4.4 (Fig.010-A, Fig.010-B, Fig.010-C).
- When reassembling the bracket "St1", if the Nylon
washer of the self-locking nut "C6" is worn replace it
with a new one.
- Tighten the nut “C6” on the bracket “St1”, until the
pipe is secured. Make sure the pipes are well secured.
4.3.5 Disassembly of the positioner mobile frame

(Fig.007-1A, 007-1)
- Inlets “q1” and “q2” can be in the positions as shown in

Fig.007-1A depending on the forklift model.
- Remove the hydraulic circuit connecting pipes of the

forklift mast from the fittings "q1" and "q2" in the case of
fixing (A) referred to the precautions in point 4.3.1.
- Remove the hydraulic circuit connecting pipes of the

positioner from fittings "q1" and "q2" in the case of fixing (B)
referred to the precautions in point 4.3.1. (in this case the
bulkhead fittings remain fixed to the fixed frame).
- Remove the flange bolts "Vs" with a hex wrench 13 mm.

Keep the bolts that will be re-used to secure the pipe
supporting bracket when resetting the mobile frame with a
torque of 58 Nm (40 Ft/Lbs).
- Dismantle the forks by extracting them from the supports

performing the procedure referred to in point 2.3 in reverse.
- Dismantle the lower hooks "G" by loosening the screws that

block them using a 10mm socket wrench for the fem2 positioners
and a 12mm socket wrench for the fem3 positioners.
- Slide the straps, attached to a suitable lifting means

of sufficient lifting capacity, under the upper
crosspiece of the mobile frame, then slightly rotate
the frame forward and then lift it to free it from the
fixed frame together with the hoses (still attached)
and the hose supporting bracket.
NB: WITH THE FRAME DISMANTLED (Fig.007-2) DO NOT

PRESSURISE THE HYDRAULIC CIRCUIT.
4.3.6 Replacement of the side-shift cylinders seals (Fig.007-3, 007-4)
- Dismantle the mobile frame as per point 4.3.5 having previously observed the precautions mentioned in section 4.3.1
- Dismantle the supply hoses from the cylinder
- Extract the stem “Ct05”
- Remove the scraper ring “Ct04”
using a screwdriver
- Remove the snap ring “Ct03”
with a DIN 5256 clamp
- Extract the stem guide “Ct02”
- Remove and replace the seal
“Ct01” in the correct direction (Fig.007-4)
- Replace, with particular attention to the
cleanliness of the parts (grease the seat of the
bushing): the stem guide “Ct02”, the snap ring
“Ct03”
(check it is correctly inserted in its seat)
the scraper ring “Ct04” in the correct direction
(Fig.007-4) and the stem “Ct05”, reassemble the
supply hoses making sure there are no leaks
- Reassemble the mobile frame as per point 4.3.5 in
reverse order. See point 4.2.1 for the tightening
torque of the screws “C3” that secure the hooks “G”
4.3.7 Dismantling the upper and/or lower shoes

- Dismantle the mobile frame as per point 4.3.5
- Dismantling of the upper shoes interlocked on
the upper and/or lower bar using a pointed tool
(screwdriver).
- Assemble the interlocking shoes in their seats.
- Reassemble the mobile frame as per point 4.3.5 in reverse order. See point 4.2.1 for the tightening torque of the screws “C3” that
secure the hooks “G”.
4.3.8 Dismantling the fork supports

- Open the forks to their maximum.
- Observe the precautions mentioned in section 4.3.1.
- Remove the forks from the supports following the procedure in point
2.3 in reverse order.
- Remove the bolts “C1” (wrench ch1 = 19 mm) with related special
washers.
- Unscrew the screws “C4” with a 6 mm Allen key.
- Supporting the support, start to slide one of the two chrome bars and
leave it half inserted.
- With the utmost care, remove the support from the chrome bar.
- Clean the shoe area and the chamber of the bushings.
- This is the moment to replace the shoes if they are worn to such an
extent as to be flush with the shoe retaining lip "Sp".
- Smear grease on the bushings chamber and the shoe and
reassemble everything following the procedure in reverse. Ensure the
correct installation of the supports (left and right).
- Tighten the bolts “C4” with “Loctite 270” threadlocker following the
precautions in point 4.2.1 making sure to have centred the hole in the
chrome bar.
- Tighten the above mentioned bolts “C1” with the related special
washers with a tightening torque as in point 4.2.1
- Assemble the forks as per point 2.3.
4.3.9 Replacement of the fork shift cylinder

seal (Fig.008)
- After having performed one or more operations
as per point 4.3.2 and/or 4.3.3.
- Unscrew the cap "cs05", with a pin wrench, and
remove it along with the stem "cs02" and parts
"cs08", "cs09" and "cs10" of the cylinder casing
- Unscrew (Allen key 3 mm) the dowel "cs10" from
the stem extension "cs09", then (17 13 mm hex
wrench) while keeping the stem immobile unscrew
the extension "cs09"
- Seal replacement procedures “cs01”, “cs03”,
“cs04”, “cs06”, “cs07” and “cs08”
- The reassembly of the cylinder must be
performed in reverse order to that indicated
above, with particular attention to cleaning and
checking the exact orientation of the seals “cs06”,
Pin wrench
“cs07”, “cs03” and “cs04” (Det.004)
- Warning: Tighten the dowel “cs10” with “Loctite
Screwdriver
243”.
- The same disassembly and replacement method Det. 004
of seals is valid for the right cylinder (driver's view) 17 mm Hex wrench
of the supply system.
Allen key 3 mm
4.3.10 Hydraulic system bleeding cap (Fig.009)
- A bleeder cap "Sf" is present on the valve of the right cylinder (driver's view) to remove the air accumulated inside the hydraulic
circuit.
4.3.11 Equipment restoration
After each maintenance operation, restore the equipment to the initial condition and perform the tests referred to in point 2.5.
4.4 HYDRAULIC
SYSTEM LAYOUT
(forks positioning)
(Fig.010-A, Fig.010-B)
- To spread/open the
forks, introduce
pressure in q2
- To approach/close the
forks, introduce
pressure in q1
Cyl1=Ø42mm
Cyl2=Ø36mm
(Fig.012) Valve system
layout with OIL-
Control cartridge. The
calibration of the
cartridges "Ca"
(standard 100 bar) is
based on the
operating pressure of
the Forklift.
Warning (Fig.010-C):
During the reassembly of

the hydraulic pipes on the
valve, the rigid pipe "T"
must be kept turned
downward.
There must be at least 5 mm
of the play between the
protective plate and the rigid
pipe, so that when the
positioner is working at full
load the plate (bending)
cannot come into contact
with the pipe.
Fig.012
Table of the recommended oil flow rates and operating pressures.
Fork positioner oil flow rate
Minimum 7 l/min. Recommended 9 l/min. Maximum 15 l/min.
Side-shifter oil flow rate
Minimum 4 l/min. Recommended 10 l/min. Maximum 15 l/min.
Hydraulic functions and recommended pressures

2 hydraulic functions
Fork positioner pressure Min. 14 MPa (maximum pressure at the distributor 25 MPa)
Side-shifter pressure Min. 12 MPa Max. 22 MPa (maximum pressure at the distributor 25 MPa)
4.4.1 Side-shifter hydraulic system
With regard to the side-shifting, introducing oil in the chamber of the right cylinder (driver's view) the positioner shifts to the right,
while introducing oil in the chamber of the left cylinder (driver's view) it shifts to the left.
5 TROUBLESHOOTING
FAULTS CAUSES SOLUTION

5.1 The forks do not shift Obstructions or accumulation of dirt on sliding Remove the obstructions, clean and grease the sliding
tracks tracks
Insufficient hydraulic pressure Control and/or regulation of the pressure delivered by
the forklift's pump
Hydraulic circuit blocked or broken Eliminate the obstruction or replace the damaged pipe
Leak inside the cylinder (worn seals) Control and possible replacement of the seals, see
point “4.3.2” and/or “4.3.3” and “4.3.9”
5.2 The shifting of the forks is too slow Insufficient oil flow. Control and regulation of the flow delivered by the
hydraulic circuit. Adjust the forklift's oil flow.
Obstructions in the hydraulic circuit Eliminate the obstruction or replace the damaged pipe
Leak inside the cylinder (worn seals) Control and possible replacement of the seals, see
point “4.3.2” and/or “4.3.3” and “4.3.9”
Leak between the flanged valve and the Try tightening the screws “C5” on the valve more, see
cylinder point “4.3.4”, if the problem persists, remove the valve
and replace the O-ring as in point “4.3.4”
5.3 The shifting of the forks is too fast High oil flow Control and regulation of the flow delivered by the
hydraulic circuit. Adjust the forklift's oil flow.
5.4 The forks do not shift in a Obstructions or accumulation of dirt on sliding Remove the obstructions, clean and grease the sliding
synchronized manner tracks tracks
Incorrect regulation of the cartridge “Ca” on Verify the correct operation of the cartridges "Ca", the
the valve. standard calibration is 150 bar
5.5 The side-shift does not occur at all Frame deformed Replace the frame removing it as in point 4.3.5
Mud or other obstruction on the track of the Clean the track and lubricate shoes as in point 4.2.1
lower rollers
FAULTS CAUSES SOLUTION

Deteriorated hoses Replace the pipes
Obstruction in the hydraulic circuit Eliminate the obstruction
Insufficient pressure Increase the pressure
Deteriorated pump Repair or replace the pump of the forklift
Defective cylinder Replace the seals and/or the related guides and if
necessary the stem as in point 4.3.6
5.6 The side-shift is too slow Worn cylinder seal Replace the seals and if necessary the stem guide
as in point 4.3.6
Worn sliding shoes Replace the shoes after cleaning and lubrication
as in point “4.3.7”, “4.2.1” and “4.2.2”
Emulsified oil, the pump draws in air Check the oil level in the tank of the forklift
Deteriorated pump Repair or replace the pump of the forklift
Insufficient pressure Increase the pressure
5.7 The side-shift occurs with jolts or Air in the hydraulic system Bleed the forklift's system and check the oil level
irregularly Debris or other materials on the track of the Clean the track and lubricate shoes as in point 4.2.1
lower shoes
Worn sliding shoes Replace the shoes after cleaning and lubrication as in
point “4.3.7”, “4.2.1” and “4.2.2”
5.8 The side-shift occurs on one side only Air in the system Bleed the system
Defective cylinder Replace the seals and/or the caps with related guides
plus the stems, if damaged as in point "4.3.6"
NOTE: If there are difficulties or in the case of defects other than those listed, please contact BOLZONI Technical Support Service.
WIRING DIAGRAM, Airconditioning (Rosti) 1D1/1D2
23
WIRING DIAGRAM
Climatizer (Climasur)
27
SERVICE
Trouble Diagnosis Error Definition BULLETIN
Model : K/GK21, K/GK25,1D1/1D2, LPG/Gasoline
Issue : SB-K2-EC-1101
Date : April 2011
Description:
In order to improve time on diagnostic operations, we find crucial to understand the service
manual information related to displayed error codes.
1D1 and 1D2 models are equipped with 3 communicating systems, an engine control
module (ECM), controlling the engine, meter panel controlling the warning lights and
diagnosis, and vehicle control module (VCM) controlling the forklift entirely.
These control modules contribute to the enhancement of forklift functionality. These 3
systems communicate via CAN Bus. An Error code (E/F/P-error) will be displayed when
the meter panel or one of the two control modules (ECM/VCM) are reporting a malfunction.
Some of the E-error codes are triggered by different symptoms. Therefore it is necessary to
run a self diagnosis using the procedure described in this bulletin. On the ECM self-
diagnosis you will be able to read stored ECM errors delivered as Pxxxx error codes and
Uxxxx error codes.
Description of the forklift communication system:
Meter panel shows there is an error code

in one of the two control modules.
It shows an E/F/P-error code.
1-VCM sends own VCM diagnostic error codes

E/F-error codes to meter panel.
ECM sends E-error codes to
meter panel.
2- VCM sends the diagnostic error codes from the
VCM +ECM.
ECM sends the diagnostic E-error codes.
VCM
ECM stores 4 digit error codes
VCM stores E/F/P error in history file

The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts book for the correct part number, not to this Bulletin
SB-1D-EC-1101Trouble Diagnosis Error Definition.doc Page 1 of 6 12/07/2011

SERVICE
Model : K/GK21, KGK25,1D1/1D2, LPG/Gasoline
Date : April 2011
After knowing how the communication system works, we will give you an example of a
situation:
1) You found an error code on meter panel.
In this picture,
ure, you find the error code E-23 and in
the picture below you find the cause of malfunction
and you know that it’s the VCM that is reporting
E-23 that error, what you don’t know is, why the VCM is
reporting an error and what is being reported as
malfunction.
2) You saw the error code and which control module is reporting a malfunction, now you
look in the Service Manual and you search for this error code.
Service Manual, Section EC (Engine Control), Page 35.

SERVICE
Date : April 2011
3) Now you proceed to find exactly what triggers the error code, which means, to know what
is creating the E-error code. At this moment you go to the next page of your SM where you
find all the 4 digit error codes related to E-23 error code in this case, page 36.
4) Now you know exactly what is creating the error code E-03.
The cause is error code U1001
5) as you see the error code E-23 can be produced by several Pxxxx error code as
mentioned above. In this case you will need to perform the self diagnostic procedure in
order to read out the 4 digit ECM error code.

SERVICE
Date : April 2011
Make a self-diagnosis function (see SM-EC-43)
Steps for self-diagnosis:
To start this operation the truck is turned off for at least more than 10 seconds.
1) Turn ignition switch ON with accelerator pedal released.
After approximately 3 seconds counting the throttle positioner motor

stopped his self check. The safety belt warning light will turn off.

SERVICE
Date : April 2011
2) When the safety belt warning light is turned off, fully depress the accelerator pedal and
then release it. Quickly repeat this cycle 5 times within 5 seconds (end in release position).
3) After finishing the above step and you fished in the release position, you wait 7 seconds.
At this moment (after 7 seconds) you fully depress the accelerator pedal for 10 seconds.
4) At this moment the diagnostic mode II self-diagnostic result starts, and will give the code
by blinking the (Engine check light). Make sure to release the accelerator pedal once the
engine light starts to blink other wise, you will only read one error code.

SERVICE
Model : K/GK21, KGK25,1D1/1D2, LPG/Gasoline
Date : April 2011
5) To interpret the code:
For example error code P1124
1 blink
…pause…
1 blink
…pause…
2 blinks
…pause…
4 blinks
4) If more codes are stored, the blinking code will flash it one after the other until it comes
back to the first error code.
In order to link the E-error code to the 4 digit P/U error codes in the SM, you had to adjust
the 2 pages from the SM in order to identify them as you can see on fig.1.
Fig.1 (example of page SM-EC-35 and SM-EC-36)

13-8-2008
Pagina 1
Service Bulletin
Issue : SB-1D-HD-0801
Date : July 2008
Model(s) : 1D1/1D2
Subject : Mast interchangeability D01/D02-1D1/1D2
Outline:
Interchanging masts between D01/D02 and 1D1/1D2 will, in some cases, make changes on the
hydraulic circuit necessary.
Because hydraulic system configuration is different on D01/D02 and 1D1/1D2, a Flow Regulator
Valve (FRV) has to be installed regarding the truck control type. This bulletin is issued to explain
which parts have to be replaced to have a proper mast configuration for each truck.
Modification:
The modification is applicable for the following mast types:
• 2W
• 2F
• 3F
• 3V
Mast from 1D1/1D2 to D01/D02
1D1/1D2 configuration D01/D02 configuration Modification

Fingertip control Fingertip control No modification
Fingertip control Mechanical Install FRV
Mechanical Fingertip control Install FRV
Mechanical Mechanical Install FRV
Whenever you order parts, refer to the parts book for correct part number, not to this Service Bulletin
SB-1D-HD-0801 Mast interchangeability.doc Page 1 of 3 13/08/2008

13-8-2008
Pagina 2
Service Bulletin
Date : July 2008
Mast from D01/D02 to 1D1/1D2
D01/D02 configuration 1D1/1D2 configuration Modification

Mechanical Fingertip control No modification
Fingertip control Mechanical Remove FRV
Mechanical Mechanical Remove FRV
Location of the flow regulator valve (FRV)
The FRV is located on the cross bar of the mast, see illustration bellow
FRV
Connection tube

13-8-2008
Pagina 3
Service Bulletin
Date : July 2008
Installation of Flow Regulator Valve (FRV):
To install the FRV on the mast, the connection tube and its band have to be replace by the FRV and
its band.
Removing the Flow Regulator Valve (FRV):
When removing the FRV from the mast, a connection tube and its band have to be installed in place
of the FRV and its band.
Flow regulator valve (FRV)
Band FRV
Band connection tube
Connection tube
Affected parts:
FRV Connection tube

1.5-1.75 ton 58080-2G010 1.5-2.5 ton 69350-FJ111
2.0-2.5 ton 58080-3G000 3.0-3.2 ton 69350-FK311
3.0-3.2 ton 58080-3G100
Band tube 59675-FJ601
Band FRV 59675-L7400

13-8-2008
Pagina 1
Service Bulletin
Issue : SB-1D-LM-0801
Date : July 2008
Model(s) : 1D1/1D2
Subject : Mast interchangeability D01/D02-1D1/1D2
Outline:
Interchanging masts between D01/D02 and 1D1/1D2 will, in some cases, make changes on the
hydraulic circuit necessary.
Because hydraulic system configuration is different on D01/D02 and 1D1/1D2, a Flow Regulator
Valve (FRV) has to be installed regarding the truck control type. This bulletin is issued to explain
which parts have to be replaced to have a proper mast configuration for each truck.
Modification:
The modification is applicable for the following mast types:
• 2W
• 2F
• 3F
• 3V
Mast from 1D1/1D2 to D01/D02
1D1/1D2 configuration D01/D02 configuration Modification

Fingertip control Mechanical Install FRV
Mechanical Fingertip control Install FRV
Mechanical Mechanical Install FRV
SB-1D-LM-0801 Mast interchangeability.doc Page 1 of 3 13/08/2008

13-8-2008
Pagina 2
Service Bulletin
Date : July 2008
Mast from D01/D02 to 1D1/1D2
D01/D02 configuration 1D1/1D2 configuration Modification

Mechanical Fingertip control No modification
Fingertip control Mechanical Remove FRV
Mechanical Mechanical Remove FRV
Location of the flow regulator valve (FRV)
The FRV is located on the cross bar of the mast, see illustration bellow
FRV
Connection tube

13-8-2008
Pagina 3
Service Bulletin
Date : July 2008
Installation of Flow Regulator Valve (FRV):
To install the FRV on the mast, the connection tube and its band have to be replace by the FRV and
its band.
Removing the Flow Regulator Valve (FRV):
When removing the FRV from the mast, a connection tube and its band have to be installed in place
of the FRV and its band.
Flow regulator valve (FRV)
Band FRV
Band connection tube
Connection tube
Affected parts:
FRV Connection tube

1.5-1.75 ton 58080-2G010 1.5-2.5 ton 69350-FJ111
2.0-2.5 ton 58080-3G000 3.0-3.2 ton 69350-FK311
3.0-3.2 ton 58080-3G100
Band tube 59675-FJ601
Band FRV 59675-L7400

1-9-2008
Service Bulletin
Issue : SB-1D-VC-0801
Date : August 2008
Model(s) : 1D1/1D2
Subject : Error code clearing from ECM
Outline:
Since trucks equipped with a K21/K25 engine are in the field for some months, we see an
increasing number of inquiries regarding clearing the ECM errors.
Failing to clear the ECM errors from the ECM will result in a poor engine performance, even if
the error has been corrected.
The VCM memory has to be cleared as well, since the error codes of the ECM are stored in
this memory as well. It is not possible to remove the E-errors from the VCM without clearing
them from the ECM memory first.
The procedure to clear ECM errors can be found on the Service Manual DVD, Internal
Combustion-1F1/1F2, Engine Gas/LPG K15/K21/K25, Engine control System, EC-52.
The procedure to clear the VCM memory is described in the Service Manual DVD, Internal
Combustion,1F1/1F2 or 1D1/1D2 forklift, Vehicle Control System, VC-41
Procedure:
When on the truck, go to the Diagnostic Mode using the correct password.
To clear the ECM memory, follow this procedure:

1. In Diagnostic Mode select ‘TEST’ (D. TEST).
2. Confirm the caution text.
3. Select ‘ECM’ (2. ECM).
4. Go to D2,04.
5. Press
6. Press
7. Press
8. After a short period this message is displayed:
You have successfully cleared the ECM memory.
Whenever you order parts, refer to the parts book, not to this Service Bulletin
SB-1D-VC-0801 Error code clearing from ECM.doc Page 1 of 2 01/09/2008

1-9-2008
Service Bulletin
Date : August 2008
To clear the VCM memory, follow this procedure:
1 In Diagnostic Mode select ‘Alarm’ (C. ALARM).with Then press
2 Select ‘Clear All’ with Then press
3 Select ‘Yes’ with Then press
You have successfully cleared the VCM memory.
Whenever you order parts, refer to the parts book, not to this Service Bulletin
SB-1D-VC-0801 Error code clearing from ECM.doc Page 2 of 2 01/09/2008

SERVICE
BULLETIN
Error code F16, Shift lever malfunction
Model : 1D1; 1D2
Date : December 2008
Description:
Error code F16, shift lever malfunction can occur due to short circuit caused by water entry.
An error F16 occurs when water enters the diode causing a short circuit in the diode of the
shift lever circuit.
This water entry can happen for example when cleaning the truck with water.
This diode is located in the main chassis harness; below the battery towards the radiator
The diode can be identified as a yellow color plastic device, see picture bellow.
Advise:
In case of an error code F16, make sure that the diode and connector of diode is dry.
To prevent future problems the diode should be completely taped together with the main
chassis harness.
A new harness design will be implemented in 2009.
Battery location
Diode is yellow collored
The diode can

also be located a
little bit up
towards the
radiator
SB-1D-VC-0803 F16 error code.doc Page 1 of 1 19/12/2008

SERVICE
FTC Mode change procedure BULLETIN
Model :1D1/1D2 finger tip controlled (VCM Version 6.64.)
Issue : SB-1D-VC 0901

Date : July 2009
Description:
A new version of the VCM software has been introduced.

The 6.64 version of the VCM software gives a better control of the hydraulic mast
movements.
With this upgrade there have been also introduced a feature to choose different mode
setting: SOFT, STANDARD and FAST.
The recommended mode is STANDARD.
Follow the instructions how to change the mode setting:
1. IMPORTANT: Make sure the following conditions are met:
a. The forward/reverse (F/R) lever is in reverse (R) position.

b. The seat switch is off (no driver on the seat)
c. The parking brake is applied.
SB-VC-1D-0901 FTC Mode change procedure.doc Page 1 of 3 24/07/2009

SERVICE
FTC Mode change procedure BULLETIN

Date : July 2009
2. Enter the dealer mode as usual:
Press upper arrow while turning the key ON
Enter the Dealer password and

press:
3. Proceed to B1- 03 (upper) : valve unit.

SERVICE
BULLETIN
FTC Mode change procedure

Date : July 2009
This setting can have four different values; 2V, 3V, 4V or 5V.
a. 2V is the standard setting.

B 1 VA L VE UN I T 2 V
0 3 LOAD CAPA 1 ｔ
b. 3V is the soft setting.
0 3 LOAD CAPA 1 ｔ
c. 4V or 5V for the fast setting.

0 3 LOAD CAPA 1 ｔ
} are the same
0 3 LOAD CAPA 1 ｔ
NOTE: This FTC mode change is only possible on truck equipped with the VCM software
version 6.64: 29310GG15G and 29310GG15F with yellow dot.
Applied chassis models:
Y1D1E700385
P1D1E700896
Y1D2-701308
U1D2E700853
YG1D2E701037
UG1D2E700477

SERVICE
F34 Error Code BULLETIN
Model : 1D1/1D2
Date : April 2010
IMPORTANT INFORMATION
Outline:
The error code F34 is triggered with a malfunction of the speed sensor.
As described in the VC section of the service manual.
This error code can as well be triggered by misconnecting the VCM.
When connecting the VCM the other way around (CN1 in place of CN2 and the other way
around) the ignition supply is applied to the speed sensor signal input of the VCM.
This damage caused to the VCM is irreversible, and the VCM has to be replaced.

SERVICE
F34 Error Code BULLETIN
Model : 1D1/1D2
Date : April 2010
Installation:
When installing a new VCM, this has to be installed with the P/N & S/N indication label
to the outside of the truck, as shown i the picture below
CN1
CN2
P/N & S/N

indication
label

Double Element Air Cleaner 1D Model
Model :1DX
Issue : SB-1D-EF-1101
Date : July 2011
Description:
For 1D diesel models a double air filter can be ordered.
INNER ELEMENT
16546-GJ30A OUTER ELEMENT:
16546-FA00A
AIR CLEANER
Although this filter element is theoretical possible to fit on LPG trucks, it is strongly advised not
to do as this double air filter will cause less airflow and make the engine control more difficult,
which can lead to difficult start , not good engine running or less performance.
SB-1D-EF-1101 Double Element Air Cleaner Model (bl).doc Page 1 of 1 15/12/2015

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Internal Combustion Forklift

Edition: August 2019

IMPORTANT SAFETY NOTICE

A. Arrange for the modification or alteration to be designed, tested and implemented by an

Outline Of This Manual

Outline of This Manual, Description, Technical Term Definitions, Manual

Lubrication Chart, Maintenance Schedule, Engine Maintenance, Chassis and

ER ENGINE REMOVAL Removal and Installation

Construction, Removal and Installation, Disassembly and Assembly, Control Valve,

DF DIFFERENTIAL CARRIER Differential Carrier, Adjustment

DA DRIVE AXLE Construction, Removal and Installation, Disassembly and Assembly

Description, Specification, Trouble Diagnosis and Corrections, Removal and

Construction, Disassembly and Assembly, Inspection and Adjustment,

Description, Specification, Trouble Diagnosis and Corrections, Steering Wheel,

Specification, Service Data and Specifications (SDS), Trouble Diagnosis,

Accelerator Wire, Accelerator Pedal, Fuel System, Exhaust System, LP Tank

Vehicle Control System, VCM Setting, Selection of Forklift Specification, Storage

Service Data and Specifications (SDS), Counterweight, Frame, Instrument Frame,

Technical Term Definitions

Technical Term Definitions (Cont’d)

SI unit Metric system Yard/pound system

Main unit conversions:

Torque and kg-m – 9.807

Symbols used in exploded views

Symbol Meaning Symbol Meaning

Specified tightening torque is required for part

Forklift Model Classification Number

Explanation Model variation coding

NOTE: Means no indication.

GL-20/25 U1D2E7xxxxx  U1D2E7xxxxx FD15-E1

• After repairing the hydraulic or brake system, closely inspect for

PRECAUTIONS RELATED TO ELECTRICAL SYSTEM

PRECAUTIONS RELATED TO BATTERY HANDLING

3. Place wooden blocks under both side frames. Gradually lower

Lifting Points (Cont’d)

2. Lift counterweight with a hoist.

Lifting Up Forklift Truck

MAF Mass Air Flow

LUBRICATION CHART Lubrication Schedule Chart

Grease and Oil Capacity

K/GK21 engine 3.8 (1, 7/8)

1D1 series 3.2 (7/8, 3/4)

1D2 series (3.0, 3.2 ton ) 5.5 (1-1/2, 1-1/4)

1D1 series 35.9 (9-1/2, 7-7/8)

1D2 series (3.0, 3.2 ton ) 51.4 (13-5/8, 11-3/8)

Brake All models DOT3 (F.M.V.S.S. No. 116) -

K/GK21 engine 8.7 (2-1/4, 1-7/8)

MAINTENANCE SCHEDULE Maintenance Schedule

Oil filter R R R R R R R R R R R … Replace

Coolant leakage & Level I I I I I I I I I I I … Visual

Fuel piping for damage I I I I I I I I I I I … Visual

Water separator D D D D D D D D D D D … Drain

Fuel filter R R … Replace

LPG filter Injector housing C C C C C … Clean

Filter Element LPG Solenoid valve R R … Replace

Distributor cap & Rotor I I I I I I I I I I I … Visual

Exhaust smoke I I I I I I I I I I I … Visual

Oil cooler hoses (Leakage / damage) I I I I I I I I I I I … Visual