Professional Documents
Culture Documents
Ce056 01 0707
Ce056 01 0707
ENGINE
Page Page
ENGINE EXTERIOR VIEW ............. 1-2 D2 PEDAL (OPT) .......................... 1-38 0
ENGINE MAIN PARAMETERS ....... 1-5 COMPONENTS ............................... 1-38
ENGINE PERFORMANCE DISASSEMBLY·INSPECTION· 1
REASSEMBLY ............................. 1-39
CURVES........................................ 1-7 2
ADJUSTMENT ................................ 1-41
ENGINE ASSY .............................. 1-10 TRAVEL AND LOAD HANDLING
REMOVAL·INSTALLATION .............. 1-10 CONTROL DEVICE(OPT)........... 1-43
3
AIR BLEEDING OF THE FUEL
SYSTEM...................................... 1-13
COMPONENTS ............................... 1-43 4
REMOVAL·INSTALLATION............... 1-44
ENGINE THROTTLE OPENING DEGREE 5
INSPECTION·ADJUSTMENT ..... 1-14 ADJUSTMENT.............................. 1-46
4Y ENGINE .................................... 1-14 TROUBLESHOOTING ..................... 1-47 6
1DZ-III·3Z ENGINE .......................... 1-15 DPF-II SYSTEM (OPT) .................. 1-49
AIR CLEANER .............................. 1-17 COMPONENTS ............................... 1-49
7
SPECIFICATIONS ........................... 1-17 CONNECTOR DIAGRAM ................. 1-53 8
COMPONENTS .............................. 1-17 DPF MUFFLER
REMOVAL·INSTALLATION ............ 1-55
AIR CLEANER 9
CLEANING·INSPECTION............... 1-18 DPF MUFFLER DISASSEMBLY·
INSPECTION·REASSEMBLY .......... 1-56
CLOGGING WARNING SYSTEM 10
INSPECTION (OPT) ...................... 1-19 CONTROLLER
REMOVAL·INSTALLATION ............ 1-58
RADIATOR .................................... 1-20
BLOWER
11
COMPONENTS .............................. 1-20 REMOVAL·INSTALLATION ............ 1-59
SPECIFICATIONS ........................... 1-24 DPF VALVE
12
COOLANT CAPACITY AND REMOVAL·INSTALLATION ............ 1-60
ANTIFREEZE TABLE .................... 1-24 DPF VALVE DISASSEMBLY·
13
COOLANT INSPECTION .................. 1-24 INSPECTION·REASSEMBLY .......... 1-61
INDIVIDUAL INSPECTION OF
14
MUFFLER & EXHAUST PIPE....... 1-26
FUNCTIONAL PARTS ................... 1-62
COMPONENTS .............................. 1-26
CONTROLLER ERROR CODE
15
REMOVAL·INSTALLATION .............. 1-29 CLEARING METHOD .................... 1-66
MAINTENANCE OF CATALYTIC DPF FILTER MEMORY
16
MUFFLERS .................................. 1-29 CLEARING METHOD .................... 1-66
BATTERY ...................................... 1-30 REGENERATION METHOD .............. 1-66
17
COMPONENTS .............................. 1-30 DISPLAY OF PAST
ERROR CODES ............................ 1-67
18
SPECIFICATIONS ........................... 1-31
CLEARING OF PAST
INSPECTION .................................. 1-32
ERROR CODES ............................ 1-68 19
FAN BELT TENSION
TROUBLESHOOTING ..................... 1-69
ADJUSTMENT ............................ 1-33 20
ENGINE CONTROLLER ASSY .... 1-94
ACCELERATOR PEDAL .............. 1-35
COMPONENTS .............................. 1-35
ENGINE ECU (4Y) OR ASC 21
CONTROLLOER (1DZ-lll·3Z:OPT)
INSPECTION·ADJUSTMENT ............ 1-36 REMOVAL·INSTALLATION ............ 1-94 E
1-2
1DZ-III Engine
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
1-4
3Z Engine
1-5
Diesel Engine
Vehicle model
1·K2 ton series 2·3 ton series 2·3·J3.5 ton series
Item
Engine model 1DZ-III ← 3Z
Engine type Diesel · 4 cycle ← ←
In-line 4 cylinder,
Number and arrangement of cylinders ← ←
longitudinally mounted
Combustion chamber type Swirl chamber ← ←
Valve mechanism OHV·gear drive ← ←
86.0 × 107.0 98.0 × 115.0
Bore x stroke mm (in) ←
(3.386 × 4.213) (3.858 × 4.528)
Total displacement cm3 (in3) 2486 (151.71) ← 3469 (211.69)
Compression ratio 21.5 ← ←
Maximum power kW (PS)/rpm 38 (52) 2400 41 (55) 2500 42 (57) 2200
Maximum torque N·m (kgf·m)/rpm 157 (16.0) 2300 157 (16.0) 2500 200 (20.4) 1600
BSFC* g/kW·h (g/PS·h)/rpm 250 (184) 1400 ← 245 (180) 1000
Service weight kg (lb) 163 (359) ← 212 (467)
No-load maximum speed rpm 2600 2800 2400
Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)
Torque
Power
BSFC
Torque
Gasoline (Exclusive)
Gasoline (Convertible with LPG)
LPG (Exclusive·Convertible)
Power
Gasoline (Exclusive·Convertible)
LPG (Exclusive·Convertible)
BSFC
1-8
Torque
Power
BSFC
Torque
Power
BSFC
1-9
3Z Engine
Torque
Power
BSFC
1-10
ENGINE ASSY
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
22
27
25
8
28
18 12
26
Removal Procedure
1 Remove the engine hood. (See page 9-10.)
2 Remove the lower panel and toe board.
3 Drain coolant.
4 Remove the battery.
5 Remove the sedimenter bracket set bolt to free the bracket. (1DZ-III·3Z engine vehicle)
6 Disconnect the accelerator wire.
7 Disconnect the fuel hose.
8 Remove the relay block bracket set bolt and free the relay block.
9 Remove the battery set plate.
10 Remove the air cleaner and air inlet.
11 Remove the exhaust cover plate.
12 Disconnect the exhaust pipe.
13 Disconnect the water hose.
14 Disconnect the T/C cooler hose. [Point 1]
15 Remove the radiator and fan shroud.
16 Remove the under cover.
17 Remove the wiring and wire harness clamps around the engine.
18 Remove the oil pump set bolt and free it.
19 Remove the cover plate. [Point 2]
20 Remove the 6 drive plate set bolts. [Point 3]
21 Remove the engine mount nuts.
22 Slightly hoist the engine. [Point 4]
23 Support the torque converter housing with wooden blocks.
24 Separate the torque converter housing and engine. [Point 5]
25 Remove the engine ASSY.
26 Remove the drive plate.
27 Remove the torque converter end plate.
28 Remove the starting motor.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Apply sealant (08833-76002-71 (08833-00080)) before tightening the drive plate set bolt (for connecting
engine and crankshaft).
• Bleed air from the fuel system after installation of the engine ASSY. (1DZ-III·3Z engine vehicle)
(See page 1-13.)
1-12
Point Operations
[Point 1]
Removal:
Put match marks on the radiator and torque converter cooler
hose.
[Point 3]
Removal•Installation:
Rotate the drive plate using the crank shaft pulley set bolt, and
remove the drive plate set bolt.
SST(1) [Point 4]
Removal•Installation:
SST(2)
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)
Removal:
Temporarily hoist up until the mount bolt completely comes out
of the hole in the frame.
1-13
[Point 5]
Removal:
Use a flat-head screwdriver for separation.
If the fitting is too tight, change the SST hook position and
adjust the engine angle for easier separation.
ENGINE INSPECTION·ADJUSTMENT
Note:
• Warm up the engine beforehand, and proceed with inspection and adjustment when the vehicle is in the
following state:
• Coolant temperature: 75°C (167°F) or above, engine oil temperature: 60°C (140°F) or above, hydraulic oil
temperature: 50°C (122°F) or above
4Y ENGINE
Note:
• Adjustment is not necessary. The engine speed is
electronically controlled.
• If the engine speed is not within the specified range, there
may be malfunctioning components. In this case,
troubleshoot for the malfunctioning components. (See
section 19.)
Idle Speed Inspection
Rev terminal
1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Inspect the idle speed.
Standard: 750 ± 30 rpm (For both gasoline and LPG)
No-load Maximum Speed Inpsection
1. Attach a rev counter to the terminal for measuring engine
speed (Rev terminal).
2. Start the engine, and measure the engine speed (no-load
maximum speed) when the accelerator is fully pressed down.
Standard: 2570 ± 35 rpm (For both gasoline and LPG)
Rev terminal
1-15
1DZ-III·3Z ENGINE
Idle Speed Inspection·Adjustment
1. Install the rev counter.
Rev counter
Idle adjusting screw 2. Check the return of the accelerator wire, and also check that
the injection pump idle adjusting screw is in contact with the
accelerator lever.
3. Inspect the idle speed.
Standard
1DZ-III: 750 ± 25 rpm
3Z: 775 ± 25 rpm
4. If the standard is not met, loosen the lock nut and adjust with
Accelerator lever the idle adjusting screw.
5. Tighten the lock nut, and inspect the idle speed again.
1-16
AIR CLEANER
SPECIFICATIONS
Single (STD) Double (OPT)
Type Cyclone type ←
Size 7-inch ←
Intake type Fresh air introduction type ←
Outer 18600 (2883)
Filtering area cm2 (in2) 18600 (2883)
Inner 510 (79.1)
Others With evacuator valve ←
COMPONENTS
1703
1-18
25°
2. Individual inspection
(1) Use a mity vac to apply a negative pressure to the
vacuum switch, and inspect for continuity.
Standard
4Y engine vehicle
2630~3218 Pa (270~330 mmAq) (19.9~24.3 mmHg):
continuity exists
1DZ-III·3Z engine vehicles
6904~8042 Pa (704~820 mmAq) (51.7~60.3 mmHg):
continuity exists
1-20
RADIATOR
COMPONENTS
4Y (1·K2 ton series)
1603
4Y (2 ton series)
1603
1-21
1603
1603
1-22
1603
1603
1-23
3Z
1603
1-24
SPECIFICATIONS
Type Crossflow
Fin type Corrugated fin
Coolant capacity (in radiator) See the table below
Cap opening pressure 2) 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1]
kPa (kgf/cm [psi]
Others Built in torque converter cooler
2·3·J3.5 4Y 3.7 (0.98) 9.3 (2.45) 2.8 (0.74) 4.6 (1.21) 0.5 (0.13)
ton 1DZ-III 3.7 (0.98) 7.9 (2.09) 2.4 (0.63) 4.0 (1.06) 0.4 (0.11)
series 3Z 3.7 (0.98) 8.8 (2.33) 2.6 (0.69) 4.4 (1.16) 0.4 (0.11)
Note:
• The total coolant capacity does not include the capacity of the reservoir tank.
• Reservoir tank capacity: 0.47 l (0.124 US gal) (at FULL mark position)
COOLANT INSPECTION
1. Inspect the coolant level.
Check that the coolant level is between FULL and LOW in the
radiator reservoir tank.
(2) Find the concentration of the coolant from the table on the
50% (approximately -38°C) left.
40% (approximately -26°C)
Note:
30% (approximately -16°C)
This graph shows the relationship between coolant
temperature and specific gravity at concentrations of 30, 40
and 50%.
For example when the coolant temperature is 55°C and the
specific gravity is 1.035, the coolant concentration at this time
can be found as follows:
The intersection point of 55°C and 1.035 is between the 30%
line and 40% line, so this point is approximately 35%. In other
Specific gravity
1702
4Y (2 ton series)
1702
1-27
1702
1702
1-28
1702
1702
1-29
REMOVAL·INSTALLATION
Note:
The muffler can be removed by either of the two methods shown below.
(1)Remove the muffler after removing the counterweight.
(2)Remove the muffler after removing the radiator W/ counterweight.
Here, method (1) is explained.
3
4
2
Removal Procedure
1 Remove the counterweight. (See page 9-11.)
2 Separate the union between the exhaust pipe and muffler.
3 Remove the exhaust pipe fixation bolts.
4 Remove the muffler.
5 Disconnect the tail pipe from the muffler.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Use a new gasket.
BATTERY
COMPONENTS
4Y
1901
1DZ-III
1901
1-31
3Z
1901
SPECIFICATIONS
Battery type list (The battery is selected according to the equipped engine).
4Y 1DZ-III 3Z
Engine
Speciffication High capacity
STD STD STD Cold weather
battery
VARTA VARTA VARTA VARTA VARTA
Battery Type
540 200 036 562 019 048 574 012 068 600 131 080 610 200 085
JIS 34B19L(S) 55D23L 95D31L 115D31L 130E41L
Voltage V 12 ← ← ← ←
20-hour rated capaxity Ah 36 60 75 100 110
Specific gravity of battery fluid in use
1.280 ← ← ← ←
(at 20°C (68°F))
Battery weight kg (lb) 10.6 (23.4) 15.3 (33.7) 19.3 (42.6) 23.2 (51.2) 25.8 (56.9)
1-32
INSPECTION
1. Inspect the battery fluid level.
Inspect that the battery fluid level is between the UPPER and
LOWER lines. Add distilled water if insufficient. Do not overfill
UPPER
above the upper fluid limit.
LOWER
Battery Removal
1. Disconnect battery terminals.
Note:
Disconnect the negative terminal first.
2. Remove the battery stopper.
3. Remove the battery.
Battery Installation
The installation procedure is the reverse of the removal procedure.
1-33
1DZ-III
A: 8~13 mm (0.31~0.51 in)
B: 11~18 mm (0.43~0.71 in)
3Z
A: 8~13 mm (0.31~0.51 in)
B: 17~26 mm (0.67~1.02 in)
Fixing bolt
ACCELERATOR PEDAL
COMPONENTS
4Y
2601
1DZ-III·3Z
2601
1-36
INSPECTION·ADJUSTMENT
B 1. Inspect the angle of the accelerator pedal.
1DZ-III
A Vehicle Type 3Z
1·K2 ton 2·3 ton
Rod series series
A: When the accelerator is OFF 45° 45° 45°
B: At full throttle (reference) 19° 17° 14°
Stopper bolt Adjust by adjusting the length of the rod or stopper bolt.
(3) Adjust the height of the stopper bolt so that the difference
between the VPA1 output (V) in the full throttle position
and the initial VPA1 output (V) is 2.4 V or greater, and the
VPA2 output (V) in the full throttle position is less than 4.6
V.
(Note: the change in output per single turn of the stopper
bolt is 0.06 V)
(4) After adjustment, apply thread tightener (08833-76002-71
(08833-00080)) to the threaded section of the stopper bolt
lock nut and reassemble it.
(5) Clear the learned values.
For the 4Y:
Remove the battery plug for more than 10 seconds, then
reconnect it.
For diesel vehicles with travel and load handling control:
Turn the key ON with the accelerator sensor connector
disconnected. (An accelerator sensor error will be
detected.)
Then, turn the key OFF and reconnect the accelerator
sensor connector.
(6) Check that the VPA1 and VPA2 values displayed with the
accelerator OFF are within a range specified below of the
values displayed inside the brackets.
Standard: Within ± 0.1 V
1-38
D2 PEDAL (OPT)
COMPONENTS
4Y 2601
1DZ-III·3Z
1-39
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
1
3
29 (296) [21.4]
Disassembly Procedure
1 Remove the pin and separate the pad W/switch from the pedal. [Point 1]
2 Remove the switch ASSY. [Point 2]
3 Remove the holder W/magnet. [Point 3]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Apply grease on the inner surface of each bushing.
• After reassembly, adjust the direction switch. (See page 1-41)
[Point 2]
Inspection:
Check continuity of direction switches.
Forward side:
c Continuity between c and d when the forward switch is
Forward
d pressed.
Reverse side:
e
Continuity between c and e when the reverse switch is
pressed.
Reverse
Reassembly:
Reassemble in the following order:
1. Install the switch on the pedal.
Set the switch while fully pressing it onto the pad.
Apply locking agent (08833-76002-71 (08833-00080)) at the
tip end of the screw before tightening the nut.
[Point 3]
Reassembly:
Since the holder W/magnet needs height adjustment, set it
temporarily in a low position. See page 1-41 for adjustment.
1-41
ADJUSTMENT
Note:
• Refer to page 1-36 for accelerator sensor adjustment.
• Direction switch adjustment is explained here.
3. 3. Where the pad starts moving slightly is the position that the
magnet come to contact with the accelerator pedal pad plate.
Then thread in by a half (1/2) turn from that point.
8 ~ 11 mm
(0.31 ~ 0.43 in)
Link
Lock nut
Stopper bolt
Stopper bolt
Adjusting Pedal Height (for Diesel Vehicles Except
Travel and Load Handling Control Model)
Link 1. Adjust the stopper bolt height so that the link contacts the
stopper bolt on the engine side when the pedal is depressed.
At this time, the pedal play should be adjusted to within 0.4 to
1.7°.
Reference:
B 1DZ-III
Vehicle Type 3Z
1·K2 ton series 2·3 ton series
A mm (in) 22 (0.87) 27 (1.06) 34 (1.34)
A
B 14° 13° 11°
C 32°
C
1-43
2607
3Z
2607
1-44
REMOVAL·INSTALLATION
LBA26-006
Removal Procedure
1 Open the engine hood and disconnect the negative terminal of the battery.
2 Remove the battery.
3 Remove the relay block bracket set bolt and free the relay block.
4 Remove the sedimenter.
5 Remove the battery set plate.
6 Disconnect the injection pump side link.
7 Remove the actuator. [Point 1]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• After installation, adjust the throttle opening degree. (Refer to 1-46)
• After installation, operate the accelerator pedal and check that the links are working normally.
1-45
[Point 1]
Inspection:
Inspect the actuator.
1. Check that the actuator shaft can be manually turned smoothly
without sticking.
2. Check the resistance of the actuator.
Tester range: Ω × 1 range
Standard
Between (1) and (3): Approx. 2.5~3.7 Ω
Between (2) and (3): Approx. 2.5~3.7 Ω
Between (1) and (4): Approx. 5.0~7.4 Ω
Between (2) and (5): Approx. 5.0~7.4 Ω
Inspection:
Measure the insulation resistance between each actuator
terminal and body.
Tester range: Ω × 1 M range
Standard: 100 MΩ or more
[Point 2]
Inspection:
Inspect the continuity of the limit switch.
Standard
Free position: ∞ Ω
When pushed 2.3 mm (0.091 in) or more: 0 Ω
1-46
2. Tighten the adjustment bolt on the idle switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
(OFF→ON). (It is possible to tighten up to 1/4 turn from the
Idle switch switching point)
3. Fix the adjustment bolt with the lock nut.
Lock nut
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.
Adjustment bolt
2. Tighten the adjustment bolt on the NMR switch side from the
state where the switch and bolt are not in contact (switch OFF)
and adjust the bolt to the point where the switch switches
Adjustment (OFF→ON). (It is possible to tighten up to 1/4 turn from the
NMR switch bolt switching point)
3. Fix the adjustment bolt with the lock nut.
Lock nut 4. Unlock the injection pump lever from fully open state.
Note:
When fixing with the lock nut, take care that the adjustment
bolt does not turn together.
1-47
TROUBLESHOOTING
This page contains troubleshooting advice for the mechanical system of the travel and load handling control device.
In the case of an error code being recieved, or trouble with the electrical system, refer to the troubleshooting section.
● Idle switch open error
Check the injection pump
Check that the injection pump return spring is Not broken A defect in the mechanical system of the travel and
not broken. load handling control device.
Check the components of the travel and load
Broken
handling control device.
There is
Move the link by hand, and check that there is interference
no interference with surrounding parts. Remove the interference.
There is no interference
There is
looseness or
Check that there is no looseness or rattling in the rattling
motor bracket. Retighten the installation bolts.
There is no looseness
or rattling
There is
Check that there is no bending in the connecting bending
rod or bracket. Replace defective components.
There is no bending
There is
Check that there is no catching on the sliding catching
portion of the ball joint. Clean and grease the joint section.
There is no catching
90°C (194°F )
Check that the temperature around the motor in or more
use is 90°C (194°F) or less. Outside the range of the motor operation warranty.
● No NMR
Check the injection pump
Check that there is NMR when starting the A defect in the mechanical system of the travel and load
There is NMR handling control device.
engine and turning the pump lever to the fully-
open position with your hand. Check the components of the travel and load handling
control device (refer to 1-47).
There is no NMR
5701
1-50
1702
1702
1-51
1702
3Z (2 ton series)
1702
1-52
1702
1-53
CONNECTOR DIAGRAM
1-54
1-55
3
1
Removal Procedure
1 Remove the radiator cover.
2 Remove the weight.
3 Open the engine hood, and disconnect the heater and temperature sensor connector.
4 Cut the tie-wrap and pull the heater and temperature sensor harness out toward the rear of the vehicle.
5 Disconnect the back pressure sensor connecting hose.
6 Disconnect the exhaust pipe from the muffler.
7 Remove the DPF muffler ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Replace the gasket between the muffler and exhaust pipe with a new one.
• When the muffler ASSY is replaced, clear the memory. (See page 1-66.)
1-56
T = 12.0~15.0 3
(122~153)
[8.85~11.07] 2
Disassembly Procedure
1 Remove the outlet pipe.
2 Remove the 16 bolts. [Point 1]
3 Remove the DPF heater ASSY.
4 Remove the DPF jacket ASSY. [Point 2]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Replace the DPF jacket ASSY gasket with a new one.
• When the DPF jacket ASSY is replaced, clear the memory. (See page 1-66.)
1 Point Operations
[Point 1]
4 7 Reassembly:
5 Install the bolts, nuts and washers in the illustrated order.
Note:
3 Use the specified bolts, nuts and washers. Use of general
8
items may cause malfunctions.
6
2
1-57
[Point 2]
Inspection:
Replace the DPF jacket ASSY if its center or inside wall is
blackened with soot when seen from the outlet side.
1-58
CONTROLLER REMOVAL·INSTALLATION
Note:
Since the two wires from the controller to the outlet are both black, put tags showing the connecting
positions.
T = N·m (kgf·cm) [ft·lbf]
6 3
T = 1.2~1.8
(12~18)
[0.89~1.33]
Removal Procedure
1 Open the engine hood, and disconnect the battery negative terminal.
2 Remove the step.
3 Remove the bracket set bolts.
4 Disconnect the wiring from the controller to the outlet.
5 Disconnect the controller connector.
6 Remove the controller ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the controller is replaced, turn the ignition key switch ON and check no error is present.
1-59
BLOWER REMOVAL·INSTALLATION
Note:
Since the blower is to be removed from under the frame, operate in a pit.
View A
5
3 7
Removal Procedure
1 Open the engine hood, and disconnect the battery negative terminal.
2 Remove the toe board.
3 Remove under cover from the vehicle.
4 Disconnect the connector.
5 Disconnect the blower hose from the blower.
6 Remove the blower set bolts, and remove the blower W/ bracket from under the vehicle.
7 Remove the blower ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the blower wiring clamp is removed, replace it with a new one.
1-60
6
2
2 5
3 5
4
7
Removal Procedure
1 Disconnect the battery negative terminal.
2 Disconnect the DPF air cleaner hose (air cleaner side) and blower hose (flow rate sensor side).
3 Disconnect the back pressure sensor connector and back pressure sensor hose, and remove the back pressure
sensor.
4 Disconnect the DPF valve hose.
5 Disconnect the DPF valve connector and blower sensor connector.
6 Remove the base & bracket W/ DPF parts ASSY from the vehicle. Disconnect the wire harness clamps from the
base & bracket.
7 Remove the DPF valve W/ fitting. [Point 1]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1]
Installation:
Install the DPF valve in the correct direction.
The arrow marked on the valve body must be pointing the front
of the vehicle.
The connector of the core must be facing the front of the
vehicle as well. (The core can be turned by hand.)
Front
(Blower side)
1-61
1
T = 20.6~30.4 (210~310) [15.2~22.4]
Disassembly Procedure
1 Fix the valve body in a vise, and loosen the lock nut.
2 Separate the valve body and core, and remove the plunger and spring. [Point 1]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1]
Inspection:
Clean off soot accumulated in the valve body, plunger, and
core with compressed air.
Replace the valve ASSY if any damage or wear is seen on the
plunger seat.
Plunger seat
Reassembly:
Core Install the spring in the correct direction.
Face the minor diameter side of the spring to the valve body
side.
Spring
Body
1-62
Starter relay
Display
Main relay
Blower
Controller Buzzer
For the temperature sensor
Heater
Connector for heater
Inspect the heater coil resistance.
Inspection method: Measure the resistance between both
terminals of wiring from the heater
Tester range: Ω × 1 range
Standard: Approx. 17 Ω
1-63
Temperature Sensor
Connector for temperature sensor Inspect the temperature sensor continuity.
Inspection method: Measure the resistance between both
terminals of the temperature sensor
connector.
Tester range: Ω × 1 range
Standard: Approx. 1 Ω
Note:
Do not scratch gold plating on the connector pins at the time
of inspection.
DPF Blower
Inspect the DPF blower for continuity.
Inspection method: Measure the resistance between both
terminals of the DPF blower.
Tester range: Ω × 1 range
Standard: Approx. 2.2 Ω
Note:
Do not scratch gold plating on the connector pins at the time
of inspection.
Inline Filter
Muffler side
Inspect the outlet on the back pressure sensor side for soot
accumulation. If soot is seen, replace the sensor.
Note:
Back pressure Muffler Regarding the direction of the inline filter. Do not install in the
sensor side side reverse direction after inspection. Check the direction by the
Soot "DENSO" mark direction. Although no direction is specified
for installation of a new filter, it is recommended to install with
the "DENSO" mark facing the back pressure sensor side.
A
View A Mark
DPF Valve
Measure the resistance between both terminals of the DPF valve
wiring.
Inspection method: Between both terminals of the valve
connector
Tester range: Ω × 1 range
Standard: Approx. 18 Ω
Note:
The part has a direction, so take care not to reassemble it in
the opposite direction.
1-64
Main Relay
Remove the main relay and inspect the function.
Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Tester range: Ω × 1 range
Standard: 0Ω
Main relay
Heater Relay
C A Inspect the function.
Inspection method: Inspect continuity between terminals C
and D, with the battery voltage applied to
terminals A and B.
Tester range: Ω × 1 range
Standard: 0Ω
D B
Buzzer
Inspect the buzzer for continuity.
Display
1. Disconnect the controller connector, and measure the applied
battery voltage on the wiring side.
BATT Inspection method: Between BATT terminal ⊕ of the
controller connector (wiring side)
and body ground
Tester range: DC 50 V range
Standard: 10~14 V
1-65
Note:
Regarding cleaning of the DPF filter
When the amount of soot reaches the limit, a buzzer sounds and 6 LEDs on the display flash. In this state, it
is necessary to perform regeneration process immediately. If the machine continues to be used in this
condition, a warning LED will light up and an error code "5-1" is generated. When the vehicle has reached
this condition, it is necessary to replace or to clean the filter.
If you feel that "We are carrying out regeneration process periodically, but the movement time is getting
shorter", it is recommended that you clean the filter.
Cleaning the filter
• Clean the filter when it is cold (when you feel no heat on touching it with your hand).
• Face the IN side of the filter downwards and apply high pressure water from above the OUT side. (The
filter is designed to withstand high pressure water to 5 MPa.)
• When no more white residual ash comes out under high pressure water, cleaning is finished.
After cleaning, always perform a "DPF filter memory clear".
1-66
REGENERATION METHOD
1. Connect the external power cord (AC 200 V).
2. Press the regeneration switch until the buzzer sounds.
Note:
• The regeneration process ends in about 50 minutes
(about 70 minutes in case of high collection). One soot
soot amount indicating LED goes out every ten minutes,
and the process ends when all LEDs go out.
Press • If the buzzer does not sound when the regeneration
switch is pressed, an internal switch defect may be the
cause.
3. Disconnect the external power cord (AC 200 V).
Note:
• During the regeneration process, the engine does not start even though the ignition key switch is turned
to the START position. In this case the buzzer sounds to warn the operator.
• If the external power supply (AC 200 V power) is cut off for more than one minute during the
regeneration process, the buzzer will sound and the regenerating LED will blinks to warn the operator.
• While the power cord is kept connected after the end of regeneration, the engine does not start even
though the ignition key switch is turned to the START position. In this case, the buzzer sounds and the
warning LED blinks to warn the operator.
1-67
Operation Procedure
1. Turn the ignition key switch ON (engine in stopped state).
2. Press the FILTER, MODE and RESET switches at a time until
the buzzer sounds.
Press
Soot amount indicationg LED 4. Press the FILTER and MODE switches at a time until the
buzzer sounds.
5. The display becomes as follows:
When there is no past error code:
All LEDs are kept off for 5 seconds.
When there are any past error codes:
After the soot quantity display LEDs are kept off for one
second, the error codes are displayed one by one for five
seconds each from the oldest one. The buzzer sounds each
time the error code is switched over. The display is repeated
Press within 10 âüDz
10ïbà»ì‡Ç seconds after all codes are displayed.
6. After checking the display, turn the ignition key switch OFF.
1-68
Operation Procedure
1. Turn the ignition key switch ON (engine in stopped state).
2. Press the FILTER, MODE, and RESET switches at a time until
the buzzer sounds.
Press
TROUBLESHOOTING
How to Approach Diagnosis
On detecting an abnormal area the controller lights a warning LED on the display and sounds a buzzer. The detected
abnormal area is then displayed as an error code using the soot amount indicating LEDs. When the warning LED
lights, pressing and holding the MODE switch for about one second will display the error code using the soot amount
indicating LEDs.
When the regenerating LED flashes with the ignition key switch ON, this indicates that the previous regeneration was
aborted partway due to a drop in voltage of the external power supply (AC 200 V), and the error code is 7-2. In this
case performing regeneration again will reset the error code without clearing the error code.
The connector numbers (A to M) specified in troubleshooting are the same as those shown on the connector diagram
on page 1-49.
*: For error code 7-2, the regenerating LED flashes instead of the warning LED.
1-70
Before Troubleshooting
1. Check that there was no interruption during regeneration such as the plug being accidentally pulled from the
power socket or some other circumstance.
If there has been an interruption during regeneration, the regenerating LED will flash when the ignition key
switch is turned ON. Carry out regeneration again. In this case it is not necessary to perform an error code clear
operation. If a regeneration interruption reoccurs, carry out the troubleshooting for error code 7-2.
2. Check that the battery voltage is the specified voltage (10~14 V).
If it deviates from the specified voltage, charge or replace the battery.
3. Check that the bulbs for the display are not blown. (Refer to 1-65)
If the LEDs on the display do not light when the ignition key switch is turned ON, replace the display.
4. Check that the display does not always light.
Repair or replace the display wiring.
1-71
Troubleshooting
Error Code 1-1 or 1-2
Inspection 1: NG
Inspect the heater resistance. Defective heater ASSY.
OK
NG
Inspection 2:
Defective temperature sensor.
Inspect the temperature sensor for continuity.
OK
Inspection 3: NG
Inspect continuity between the temperature sensor and Repair or replace the wiring.
controller.
OK
Inspection 4: NG
Inspect continuity between the heater relay and controller. Repair or replace the wiring.
OK
Inspection 1:
Heater resistance inspection
Disconnect the heater connector.
Tester range: Ω × 1
Measurement terminals Both terminals of heater connector: E-1 - E-2
Standard Approx. 17 Ω
Heater connector
(E) Heater connector
ÉCÉâÉXÉgë“Çø 2 1
OK → To inspection 2
NG → Defective heater ASSY
1-72
Inspection 2:
Temperature sensor continuity inspection
Disconnect the temperature sensor connector.
Tester range: Ω × 1
Measurement terminals Both terminals of temperature sensor connector: I-1 - I-2
Standard Approx. 1 Ω
2 1
OK → To inspection 3
NG → Defective temperature sensor
Inspection 3:
Temperature sensor wiring continuity inspection
Disconnect the temperature sensor and controller connector.
Tester range: Ω × 1
Controller connector B-8 - Temperature sensor connector I-1
Measurement terminals
Controller connector B-21 - Temperature sensor connector I-2
Standard 0Ω
2 1
1 2
Temperature sensor
Controller connector connector
OK → To inspection 4
NG → Repair or replace the wiring
1-73
Inspection 4:
Heater relay wiring continuity check
Disconnect the heater relay and controller connectors.
Tester range: Ω × 1
Measurement terminals Controller connector B-10 ~ Heater relay 3
Standard 0Ω
Heater relay 3
(B) Controller connector
Heater relay 3
Controller connector
NG
Inspection 1:
Temperature sensor defect.
Inspect the temperature sensor for continuity.
OK
Inspection 2: NG
Inspect continuity of the wiring between the temperature Repair or replace the wiring.
sensor and controller.
OK
Controller defect.
Inspection 1:
Temperature sensor continuity inspection
See inspection 2 of error code 1-1.
OK → To inspection 2
NG → Temperature sensor defect
Inspection 2:
Temperature sensor wiring continuity inspection
See inspection 3 of error code 1-1.
OK → Controller defect
NG → Repair or replace the wiring
1-75
NG
Inspection 1:
Temperature sensor defect.
Inspect the temperature sensor for continuity.
OK
Inspection 2: NG
Inspect continuity of the wiring between the temperature Repair or replace the wiring.
sensor and controller.
OK
NG
Inspection 3:
Repair or replace the power cord.
Measure the power supply voltage (AC 190~220 V).
OK
Inspection 4: NG
Inspect continuity of the wiring between the heater relay Repair or replace the wiring.
and controller.
OK
NG
Inspection 5:
Heater ASSY defect.
Inspect the heater resistance.
OK
Controller defect.
Inspection 1:
Temperature sensor continuity inspection
See inspection 2 of error code 1-1.
OK → To inspection 2
NG → Temperature sensor defect
Inspection 2:
Temperature sensor wiring continuity inspection
See inspection 3 of error code 1-1.
OK → To inspection 3
NG → Repair or replace the wiring
1-76
Inspection 3:
Power supply voltage inspection
Connect the power cord to the power outlet.
Tester range: AC 500 V
Measurement terminals Power cord terminals
Standard AC 190~220 V
OK → To inspection 4
NG → Repair or replace the power cord
Inspection 4:
Heater relay wiring continuity inspection
See inspection 4 of error code 1-1.
OK → To inspection 5
NG → Repair or replace the wiring
Inspection 5:
Heater resistance inspection
See inspection 1 of error code 1-1.
OK → Controller defect
NG → Heater ASSY defect
1-77
OK
Inspection 1:
Controller defect
Inspect the back pressure sensor input.
NG
Inspection 2: OK
Inspect continuity of the wiring between the back pressure Back pressure sensor defect
sensor and the controller.
NG
Inspection 1:
Back pressure sensor input check
Voltage measurement between terminals
Controller connector: Back pressure sensor connector in connected state
Stop the engine and turn the ignition key switch ON.
B3 ~ B16
Measurement terminals Controller connector Controller connector
B4 ~ B16
Standard B3 ~ B16 : 5 ± 0.25 V, B4 ~ B16 : 1.5 ± 0.5 V
OK → Controller defect
NG → To inspection 2
Inspection 2:
Back pressure sensor wiring continuity inspection
Disconnect the back pressure sensor and controller connector.
Tester range: Ω × 1
B4 ~ J1
Measurement terminals Controller connector B16 ~ Back pressure sensor connector J2
B3 ~ J3
Standard 0Ω
1 2 3
Controller connector
Inspection 1: NG
Check the pipes and hoses connecting functional parts of Repair or replacement
the DPF-II system for leakage or clogging.
OK
Inspection 2: NG
After leaving in idle state for about 30
Check the pipes connecting functional parts of the DPF-II
minutes, conduct inspection 3.
system for freezing.
OK
Inspection 3: NG
Check the in-line filter for clogging. Replace the in-line filter.
OK
OK
Inspection 5:
Controller defect
Check the back pressure sensor input.
NG
Inspection 6: OK
Inspect continuity of the wiring between the back pressure Back pressure sensor defect
sensor and the controller.
NG
Inspection 1:
DPF-II system gas leakage inspection
Check the pipes and hoses that connect parts for leakage or clogging.
OK → To inspection 2
NG → Repair or replacement
Inspection 2:
Pipe freezing check
Check the pipes and hoses that connect parts for freezing.
OK → To inspection 3
NG → To inspection 3 after defrosting.
Inspection 3:
In-line filter clogging check
OK → To inspection 4
NG → Replacement
1-79
Inspection 4:
Valve outlet soot leakage check
Valve
Valve outlet Blower
Flow rate sensor
To exhaust manifold
OK → To inspection 5
NG → Replace the valve, flow rate sensor, blower and DPF air cleaner, and clean or replace the piping.
Inspection 5:
Back pressure sensor input check
Voltage measurement between terminals
Controller connector: Back pressure sensor connector in connected state
(1) Stop the engine and turn the ignition key switch ON.
B3 ~ B16
Measurement terminals Controller connector Controller connector
B4 ~ B16
Standard B3 ~ B16 : 5 ± 0.25 V, B4 ~ B16 : 1.5 ± 0.5 V
(2) Start the engine and keep the NMR running. (*)
Measurement terminals Controller connector B4 ~ Controller connector B16
Standard B4 ~ B16 : Value measured between B4 and B16 in (1) above + 0.2 V or more
(*) Perform this inspection only when three or more soot amount indicating LEDs are lit.
OK → Controller defect
NG → To inspection 6
Inspection 6:
Back pressure sensor wiring continuity check
See inspection 2 of error code 2-1.
OK → Back pressure sensor defect
NG → Repair or replace the wiring.
1-80
Inspection 1:
Check that the charge lamp on the combination meter NG Inspect the alternator by referring to the
comes on upon turning the ignition key switch ON and alternator section in the engine repair
goes out upon turning it to the START position. manual.
OK
Inspection 2: NG
Inspect continuity of the L signal wiring between the Repair or replace the wiring.
alternator and controller.
OK
Controller defect.
Inspection 1:
Charge lamp lighting inspection
Charge lamp
OK → To inspection 2
NG → To alternator inspection in the engine repair manual
Inspection 2:
Alternator L signal wiring continuity inspection
Disconnect the alternator and controller connectors.
Tester range: Ω × 1
Measurement terminals Controller connector B19 ~ Alternator terminal 1
Standard 0Ω
Alternator connector
(B) Controller connector Alternator
1 2 3
Controller connector
OK → Controller defect
NG → Repair or replace the wiring
1-81
Error Code 3-2 (For Vehicles without Travel and Load Handling Control)
Inspection 1:
Inspect the engine rpm sensor installed on the injection NG
pump. Replace the injection pump ASSY.
OK
Inspection 2: NG
Inspect continuity of the wiring between the engine rpm Repair or replace the wiring.
sensor and controller.
OK
Controller defect.
Inspection 1:
Engine rpm sensor individual inspection
Disconnect the engine rpm sensor connector.
Tester range: Ω × 1 k
Measurement terminals Between both terminals M-1 and M-2 of rpm sensor
Standard Approx. 1 kΩ
2 1
3
OK → To inspection 2
NG → Replace the injection pump ASSY.
1-82
Inspection 2:
Engine rpm sensor wiring continuity inspection
Disconnect the engine rpm sensor and controller connectors.
Tester range: Ω × 1
B7 ~ M2
Measurement terminals Controller connector Engine rpm sensor connector
B20 ~ M1
Standard 0Ω
1 2
3
Controller connector
OK → Controller defect
NG → Repair or replace the wiring
1-83
Error Code3-2 (For Vehicles with Travel and Load Handling Control)
Inspection 1: NG
Carry out the relevant troubleshooting.
Check the error display of the meter.
OK
Inspection 2: NG
Inspect for continuity between the ASC controller and the Wiring repair or replacement.
DPF controller.
OK
Inspection 3:
NG
Remove the ASC controller, directly connect the engine
rpm sensor and the DPF controller and check for any DPF controller defective.
errors.
OK
Inspection 1:
Check for errors in the vehicle
OK → To inspection 2
NG → To relevant troubleshooting
1-84
Inspection 2:
Continuity check of harness between ASC controller and DPF controller
Disconnect the ASC controller connector and DPF controller connector.
Tester range: Ω × 1
25 ~ B7
Measurement terminals ASC controller connector DPF controller connector
38 ~ B20
Standard 0Ω
17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42
OK → To inspection 3
NG → Repair or replace the wiring
Inspection 3:
Engine rpm sensor operation check when directly connected to the DPF controller
After clearing the error code disconnect the ASC controller connector, short circuit 25 to 36, and 24 to 38 of the
connector and start the engine. Check that an error reoccurs by the lighting of the warning LED (this time the
meter displays error 18-2).
17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42
Inspection 1:
Inspect the blower air cleaner for gas leakage during NG Replace the valve, flow rate sensor,
engine running. blower and/or DPF air cleaner, and
clean or replace the piping.
OK
Inspection 2: OK
Controller defect
Inspect the flow rate sensor input.
NG
Inspection 3: OK
Inspect continuity of the wiring between the flow rate Flow rate sensor defect
sensor and controller.
NG
Controller defect
Inspection 1:
Air cleaner gas leakage inspection
Check that there is no exhaust gas leakage from the blower air cleaner outlet.
Air cleaner
OK → To inspection 2
NG → Replace the valve, flow rate sensor, blower and/or DPF air cleaner, and clean or replace the piping.
1-86
Inspection 2:
Flow rate sensor input check
Voltage measurement between terminals
Controller connector: Flow rate sensor connector in connected state
Stop the engine and turn the ignition key switch ON.
B1 ~ B15
Measurement terminals Controller connector Controller connector
B5 ~ B15
Standard B1 ~ B15 : Battery voltage, B5 ~ B15 : 2.0 V or less
OK → Controller defect
NG → To inspection 3
Inspection 3:
Flow rate sensor wiring cointinuity inspection
Disconnect the flow rate sensor and controller connector.
Tester range: Ω×1
B1 ~ K3
Measurement terminals Controller connector B15 ~ Forw rate sensor connector K2
B5 ~ K1
Standard 0Ω
1 2 3
Controller connector
Inspection 1: NG
Inspect the air cleaner for clogging. Clean or replace the air cleaner.
OK
Inspection 2: NG
Inspect the piping between the air cleaner and blower Clean or replace the piping.
sensor for clogging or leakage.
OK
Inspection 3: NG
Inspect continuity of the wiring between the blower and Repair or replace the piping.
controller.
OK
Inspection 4: NG
Inspect the blower. Blower defect.
OK
NG
Inspection 5:
DPF valve defect.
Inspect the DPF valve.
OK
NG
Inspection 6:
Inspect the wiring between the DPF valve and controller. Repair or replace the wiring.
OK
OK
Inspection 7: OK
Inspect the flow rate sensor input. Controller defect
NG
Inspection 8: NG
Inspect continuity between the flow rate sensor and Reapair or replace the wiring.
controller.
OK
Inspection 9: OK
Inspect the piping between the blower sensor and muffler Flow rate sensor defect
for clogging.
NG
Inspection 1:
Air cleaner clogging inspection
Check that the blower air cleaner is not clogged.
Air cleaner
OK → To inspaection 2
NG → Clean or replace the air cleaner
1-89
Inspection 2:
Gas leakage inspection
Check that no exhaust gas is leaking from the piping that connects the blower air cleaner and flow rate sensor.
Air cleaner
OK → To inspection 3
NG → Clean or replace the piping
Inspection 3:
Blower wiring continuity inspection
Disconnect the blower and controller connectors.
Tester range: Ω × 1
B1 ~ F2
Measurement terminals Controller connector Blower connector
B12 ~ F1
Standard 0Ω
(F) Blower
(B) Controller connector connector
Blower
connector
1 2
Controller connector
OK → To inspection 4
NG → Repair or replace the wiring
Inspection 4:
Blower individual inspection
See page 1-62.
OK → To inspection 5
NG → Blower defect
1-90
Inspection 5:
DPF valve individual inspection
See page 1-62.
OK → To inspection 6
NG → DPF valve defect
Inspection 6:
DPF valve wiring continuity inspection
Disconnect the DPF valve and controller connectors.
Tester range: Ω × 1
B1 ~ D2
Measurement terminals Controller connector DPF valve connector
B11 ~ D1
Standard 0Ω
DPF valve
connector
(D) DPF valve
(B) Controller connector connector
Controller connector
OK → To inspection 7
NG → Repair or replace the wiring
Inspection 7:
Flow rate sensor input check
See inspection 2 of error code 4-1.
OK → Controller defect
NG → To inspection 8
Inspection 8:
Flow rate sensor wiring continuity inspection
See inspection 3 of error code 4-1.
OK → To inspection 9 after DPF muffler individual inspection
NG → Repair or replace the wiring
Inspection 9:
Clogged piping inspection
Check that the piping between the blower sensor and muffler is not clogged.
Valve
Flow rate sensor
To muffler
OK
Inspection 1:
Controller defect
Inspect the flow rate sensor input.
NG
Inspection 2: OK
Inspect continuity of the wiring between the flow rate Flow rate sensor defect
sensor and controller.
NG
Inspection 1:
Flow rate sensor input check
See inspection 2 of error code 4-1.
OK → Controller defect
NG → To inspectinon 2
Inspection 2:
Flow rate sensor wiring continuity check
See inspection 3 of error code 4-1.
OK → Flow rate sensor defect
NG → Repair or replace the wiring
Error Code 5-1
Replace the DPF filter.
Error Code 6-1
Replace the controller.
1-92
Inspection 1: NG
Charge or replace the battery.
Inspect the battery voltage (10~14 V).
OK
Inspection 2: NG
Inspect the wiring defect between the battery and controller. Repair or replace the wiring.
OK
Controller defect.
Inspection 1:
Battery voltage inspection
Check that the battery voltage is between 10 and 14 V.
OK → Controller defect
NG → Charge or replace the battery
Inspection 2:
Wiring inspection
Inspect the wiring between the battery and controller for continuity.
OK → Controller defect
NG → Repair or replace the wiring
NG
Inspection 2:
Power code defect.
Inspect continuity of the power cord.
OK
Inspection 3: NG
Check that the AC wiring for the controller is correctly Correct wiring connection.
connected to the external power receptacle.
OK
Inspection 4:
Connect the power cord and check that the voltage at NG
cord terminals is AC 200 V. Connect the cord to the Controller defect.
vehicle and check for correct functioning when the
regeneration switch on the display is pressed.
OK
Inspection 1:
Power supply inspection
Check that the power breaker is not opened and the power cord is securely connected.
OK → To inspection 2
NG → Check for correct functioning of LEDs after the correction
Inspection 2:
Power cord continuity inspection
Inspect continuity between the terminals at both ends of the power cord.
OK → To inspection 3
NG → Power cord defect
Inspection 3: ]
Controller AC wiring inspection
Check that the wiring between the controller and outlet is securely connected.
OK → To inspection 4
NG → Correct wiring connection
Inspection 4:
Power supply voltage inspection
Connect the power cord.
Tester range: AC 500 V
Measurement terminals Power cord terminals
Standard AC 190~220 V
Before Troubleshooting
1 Open the engine hood.
2 Remove the toe board and lower panel.
3 Remove the side cover W/stop.
4 Remove the side cover bracket.
5 Remove the ECU box cover.
6 Disconnect the controller connector.
7 Remove the controller.
Installation Procedure
The installation procedure is the reverse of the removal procedure