16-1

APPENDIX
Page
SST LIST .......................................................................... 16-2
SERVICE STANDARDS LIST ...................................... 16-6
WIRING DIAGRAM ......................................................... 16-19

16
16-2

SST LIST
Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 15

TOYOTA
09082-00030
electrical tester

09216-00021 Belt tension gage

09228-07501 Oil filter wrench

Transmisson &
transfer
09316-60011
bearing
replacer

Output
shaft needle
09319-60020
roller bearing
remover

Rear wheel
09509-55020 bearing nut
wrench

Rear wheel
09509-55030 bearing nut
wrench

Front hub
09608-04031 inner bearing
cone replacer

Brake shoe return

09717-20010
spring remover

Brake shoe return

09718-20010
spring replacer
 16-3

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 15

Snap ring No. 1

09905-00012
expander

09950-40011 Puller B set

09950-50012 Puller C set

09950-60010 Replacer set

Replacer set
09950-60020
No. 2

09950-70010 Handle set

Engine unit
09010-20111-71
hanger

Engine with
09010-23320-71 transmission
hanger

Transmission
09150-10170-71 bearing replacer

Torque converter
clutch drum
09220-22001-71
spring remover & 16
replacer
16-4

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 15

09240-23320-71 Plug-in analyzer

Reamer bolt
09310-23320-71
remover

09320-23000-71 Bearing remover

09350-23320-71 Adapter

Front axle
09370-10410-71
bearing replacer

Drive pinion
09370-20270-71
bearing replacer

Differential carrier
09410-23320-71
stand

09420-23000-71 Bearing remover

09450-23320-71 Adapter

Brake hold down

09510-31960-71 spring remover
and replacer
 16-5

Section
Illustration Part No. Part Name
1 2 4 5 6 7 8 11 12 13 14 15

Oil control valve

09610-10161-71 spring remover
and replacer

Inner mast
09610-22000-71
stopper

Cylinder cap
09620-10100-71 remover and
replacer

Tilt cylinder cap

09630-10110-71 remover and
replacer

09630-23600-71 Deep socket A

09631-22000-71 Wear scale chain

09810-20172-71 Joint pin remover

16
16-6

SERVICE STANDARDS LIST

ENGINE
Engine
4Y Standard See page 1-11.
Idling speed rpm
1DZ-II •2Z Standard 750 ± 25
1• 2 ton series Standard 2600 ± 50
4Y
3 • J3.5 ton series Standard 2800 ± 50

No-load static 1 ton series Standard 2600 ± 50

maximum speed rpm 1DZ-II
2 • 3 ton series Standard 2800 ± 50
2Z Standard 2400 ± 50
Gasoline engine Standard 300 or less
Full relief engine speed down rpm
Diesel engine Standard 200 or less
Air cleaner

Vacuum switch conduction test (con- Gasoline engine Standard 2942 ± 294 (300 ± 30) [22.1 ± 2.2]
duction base) Pa (mm H2O) [mm Hg] Diesel engine Standard 7473 ± 569 (762 ± 58) [56.0 ± 4.3]
Radiator
Radiator cap opening pressure kPa (kgf/cm2) (psi) Standard 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1]
Battery
Electrolyte specific gravity (at 20°C [68°F]) Standard 1.280
Alternator
Fan belt tension (when pushed 4Y Standard 8 ~ 13 (0.31 ~ 0.51)
with 98 N (10 kgf) [22 lbf] mm (in)
1DZ-II •2Z Standard ↑
Fan belt tension 4Y Standard 294 ~ 490 (30 ~ 50) [66 ~ 110]
(when measured with a
tension gage (SST)) N (kgf) [lbf] 1DZ-II •2Z Standard 324 ~ 559 (33 ~ 57) [73 ~ 126]
Accelerator pedal
Pedal roller height (from accelerator Gasoline engine Standard 68 (2.68)
bracket to top of roller) (Reference)
mm (in) Diesel engine Standard 71 (2.80)
 16-7

Tightening torque Unit: N • m (kgf-cm) [ft-lbf]

Engine mounting nut Standard 53.9 ~ 99.0 (550 ~ 1010) [39.8 ~ 73.1]
Torque converter end plate set bolt Standard 49.0 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9]

Drive plate set plate 4Y Standard 56.9 ~ 64.7 (580 ~ 660) [42.0 ~ 47.7]
(for engine crankshaft connection) 1DZ-II •2Z Standard 76.5 ~ 93.2 (780 ~ 950) [56.4 ~ 68.7]
Drive plate set bolt (for torque converter connection) Standard 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
Torque converter housing set bolt Standard 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]

TORQUE CONVERTER
Transmission cover & control valve ASSY
Standard 88.8 (3.496)
Regulator valve spring free length mm (in)
Limit 84.4 (3.323)
Standard 70.3 (2.768)
Inching valve spring free length (plug side) mm (in)
Limit 66.8 (2.630)
Standard 49.9 (1.965)
Inching valve spring free length (valve side) mm (in)
Limit 47.4 (1.866)
Standard 86.0 (3.386)
Accumulator valve spring free length (inner side)
mm (in) Limit 81.7 (3.217)
Standard 117.0 (4.606)
Accumulator valve spring free length (outer side)
mm (in) Limit 111.2 (4.378)
Standard 53.5 (2.106)
F/R shift valve spring free length
Limit 50.8 (2.000)
Standard 59.8 (2.354)
Safety valve spring free length
Limit 56.8 (2.236)
Torque converter and oil pump
Oil pump driven gear to pump body clearance mm (in) Limit 0.3 (0.012)
Oil pump driven gear to crescent clearance mm (in) Limit 0.4 (0.016)
Oil pump drive gear to crescent clearance mm (in) Limit ↑
Pump body to each gear clearance mm (in) Limit 0.1 (0.004)
Oil pump drive gear bushing to stator shaft
Limit 0.15 (0.0059)
clearance mm (in)
16-8

Transmission
Main shaft thrust clearance mm (in) Standard 0.20 ~ 0.62 (0.0079 ~ 0.0244)
Output shaft thrust clearance mm (in) Standard 0.03 ~ 0.51 (0.0012 ~ 0.0201)
Each clutch shaft to seal ring clearance mm (in) Limit 0.2 (0.008)
Standard 2.6 (0.102)
Clutch disc thickness mm (in)
Limit 2.3 (0.091)
Standard 2.0 (0.079)
Clutch plate thickness mm (in)
Limit 1.8 (0.071)
Standard 3.4 (0.134)
Camber plate warpage height mm (in)
Limit 3.1 (0.122)
4-disc type 0.8 ~ 1.3 (0.031 ~ 0.051)
Clutch disc to backing plate clearance mm (in) Standard
5-disc type 1.0 ~ 1.6 (0.039 ~ 0.063)
Standard 63.4 (2.496)
Clutch piston return spring free length mm (in)
Limit 58.5 (2.303)
Measurement and tests
4Y Standard 2100
Stall speed rpm 1DZ-II Standard 2100
2Z Standard 2050
At idling Standard 735 ~ 1324 (7.5 ~ 13.5) [107 ~ 192]
Main pressure kPa (kgf/cm2) [psi]
At 2000 rpm Standard 834 ~ 1373 (8.5 ~ 14.0) [121 ~ 199]
At idling Standard 735 ~ 1324 (7.5 ~ 13.5) [107 ~ 192]
Clutch pressure kPa (kgf/cm2) [psi]
At 2000 rpm Standard 834 ~ 1324 (8.5 ~ 13.5) [121 ~ 192]
Torque converter pressure
At 2000 rpm Standard 49 ~ 441 (0.5 ~ 4.5) [7.1 ~ 64]
(outlet pressure) kPa (kgf/cm2) [psi]
Tightening torque Unit: N • m (kgf-cm) [ft-lbf]
Oil pump set bolt Standard 9.81 ~ 18.6 (100 ~ 190) [7.24 ~ 13.8]
Stator shaft set bolt Standard 9.81 ~ 15.7 (100 ~ 160) [7.24 ~ 11.6]
Oil strainer set bolt Standard 9.81 ~ 15.7 (100 ~ 160) [7.24 ~ 11.6]
Oil pan set bolt Standard 5.9 ~ 7.8 (60 ~ 80) [4.34 ~ 5.79]
Side cover set bolt Standard 3.92 ~ 6.86 (40 ~ 70) [2.89 ~ 5.06]
M6: 9.6 ~ 14.4 (98 ~ 145) [7.09 ~ 10.5]
Transmission cover (upper cover) set bolt Standard M8: 9.81 ~ 15.7 (100 ~ 160) [7.24 ~ 11.6]
 16-9

DIFFERENTIAL
Differential
1·2 ton series Standard 0.2 ~ 0.3 (0.008 ~ 0.012)
Ring gear backlash mm (in)
3• J3.5 ton series Standard 0.3 ~ 0.4 (0.012 ~ 0.016)
Standard 22.12 (0.8709)
Differential pinion bore 1·2 ton series
Limit 22.22 (0.8748)
mm (in)
Standard 24.67 (0.9713)
3·J3.5 ton series
Limit 24.77 (0.9752)
Standard 22.00 (0.8661)
Spider outside diameter 1·2 ton series
mm (in) Limit 21.75 (0.8563)
Standard 24.50 (0.9646)
3·J3.5 ton series
Limit 24.25 (0.9547)
Standard 1.6 (0.063)
Side gear thrust washer thickness mm (in)
Limit 1.3 (0.051)
Standard 1.6 (0.063)
Pinion gear thrust washer thickness mm (in)
Limit 1.0 (0.039)
Drive pinion bearing starting torque
Standard 8.82 ~ 13.23 (90 ~ 135) [6.51 ~ 9.77]
N·m (kgf-cm) [ft-lbf]
Tightening torque Unit: N • m (kgf-cm) [ft-lbf]
Drive pinion lock nut Standard 343.2 ~ 392.3 (3500 ~ 4000) [253.23 ~ 289.40]
Drive pinion rear cover set bolt Standard 15.7 ~ 19.6 (160 ~ 200) [11.6 ~ 14.5]
Differential carrier cover set bolt Standard 29.4 ~ 44.1 (300 ~ 450) [21.71 ~ 32.56]
Ring gear set bolt Standard 127.4 ~ 176.5 (1300 ~ 1800) [94.06 ~ 130.23]
1• 2 ton series Standard 43.2 ~ 53.9 (440 ~ 550) [31.83 ~ 39.79]
Differential upper case set bolt
3• J3.5 ton series Standard 86.3 ~ 103.0 (880 ~ 1050) [63.67 ~ 75.97]
Differential case bearing cap set bolt Standard 117.7 ~ 137.3 (1200 ~ 1400) [86.82 ~ 101.29]
Differential front cover set bolt Standard 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
Differential carrier set bolt Standard 88.3 ~ 117.7 (900 ~ 1200) [65.1 ~ 86.82]
16-10

FRONT AXLE
Front axle shaft hub

Front axle bearing starting 1 ton series Standard 24.5 ~ 99.0 (2.5 ~ 10.1) [5.5 ~ 22.3]
force N (kgf) [lbf] Others Standard 19.6 ~ 78.4 (2.0 ~ 8.0) [4.40 ~ 17.6]
Tightening torque Unit: N·m (kgf-cm) [ft-lbf]
1 ton series Standard 78.0 ~ 108 (800 ~ 1100) [57.9 ~ 79.59]
Brake drum set nut
2 ton series Standard 147.1 ~ 186.3 (1500 ~ 1900) [108.5 ~ 137.47]
(hub bolt set nut)
3• J3.5 ton series Standard 166.7 ~ 205.9 (1700 ~ 2100) [123.0 ~ 151.9]
Bearing lock nut stopper bolt Standard 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
1• 2 ton series Standard 69.0 ~ 88.0 (700 ~ 900) [50.7 ~ 65.1]
Axle shaft set bolt
3• J3.5 ton series Standard 98.0 ~ 127 (1000 ~ 1300) [72.35 ~ 94.06]
1 ton series Standard 108.5 ~ 196.1 (1100 ~ 2000) [79.59 ~ 144.7]
Front wheel hub nut
2 ton series Standard 176.5 ~ 392.3 (1800 ~ 4000) [130.2 ~ 289.4]
(single tire)
3• J3.5 ton series Standard 294.2 ~ 588.4 (3000 ~ 6000) [217.1 ~ 434.1]

Front wheel hub nut 1• 2 ton series Standard 176.5 ~ 392.3 (1800 ~ 4000) [130.2 ~ 289.4]
(double tire) 3• J3.5 ton series Standard 294.2 ~ 588.4 (3000 ~ 6000) [217.1 ~ 434.1]
 16-11

REAR AXLE
Rear axle ASSY
Rear axle ASSY front to rear clearance mm (in) Standard 0.7 (0.028) or less
Rear axle center pin bushing
Limit 52.0 (2.047)
inside diameter mm (in)
Rear axle hub and steering knuckle
1 ton series Standard 15 ~ 39 (1.5 ~ 4.0) [3.3 ~ 8.8]
Rear axle hub starting force
(at hub bolt) N (kgf) [lbf] 2·3·J3.5 ton
Standard 15 ~ 44 (1.5 ~ 4.5) [3.3 ~ 9.9]
series
King pin outside diameter mm (in) Limit 27.8 (1.094)
Steering knuckle starting force
Standard 19.3 (2.0) [4.4] or less
(at front end of knuckle) N (kgf) [lbf]
Rear axle cylinder
Rear axle cylinder piston rod outside diameter
Limit 49.92 (1.9654)
mm (in)
Rear axle cylinder piston rod bend mm (in) Limit 0.5 (0.017)
1 ton series Limit 76.35 (3.0059)

Rear axle cylinder inside 2 ton series Limit 80.35 (3.1634)

diameter mm (in) 3 ton series Limit 84.40 (3.3228)
J3.5 ton series Limit 87.40 (3.4409)
16-12

Rear wheel alignment

Toe-in mm (in) Standard 0 ± 4 (0 ± 0.16)
1.5 ton model Standard 1960 (77.2)
1.75 ton model Standard 1980 (78.0)

Minimum turning 2.0 ton model Standard 2170 (85.4)

radius mm (in) 2.5 ton model Standard 2240 (88.2)
3.0 ton model Standard 2400 (94.5)
J3.5 ton model Standard 2500 (98.4)
Tightening torque Unit: N • m (kgf-cm) [ft-lbf]
Axle bracket cap set bolt Standard 117.7 ~ 166.7 (1200 ~ 1700) [86.82 ~ 123.0]
King pin lock bolt and lock nut Standard 44.1 ~ 53.9 (450 ~ 550) [32.6 ~ 39.8]
Divided rim bolt set nut 1 ton series Standard 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
2 ton series Standard 49.0 ~ 68.4 (500 ~ 700) [36.2 ~ 50.7]
Rear axle cylinder rod guide set nut Standard 88 ~ 118 (900 ~ 1200) [65.1 ~ 86.8]
Rear axle cylinder set bolt Standard 116.7 ~ 215.8 (1700 ~ 2200) [123.00 ~ 159.17]
Divided rim Standard 88.3 ~ 157.0 (900 ~ 1600) [65.1 ~ 115.8]
1 ton series
Side ring rim Standard 88.3 ~ 157.0 (900 ~ 1600) [65.1 ~ 115.8]
Hub nut
Divided rim Standard 117.6 ~ 196 (1200 ~ 2000) [86.82 ~ 144.7]
2 ton series
Side ring rim Standard 176.4 ~ 392 (1800 ~ 4000) [130.2 ~ 289.4]
3·J3.5 ton series Side ring rim Standard 117.6 ~ 196 (1200 ~ 2000) [86.82 ~ 144.7]

STEERING
Hydrostatic steering valve ASSY

Relief pressure 1• 2 • 3 ton series Standard 8040+-4090 (82+-50) [1170+- 700]

kPa (kgf/cm2) [psi] J3.5 ton series Standard 8340+-4090 (85+-50) [1210+- 700]
Tightening torque Unit: N • m (kgf-cm) [ft-lbf]
Mast jacket set nut Standard 34.3 ~ 53.9 (350 ~ 550) [25.3 ~ 39.8]
Steering wheel set nut Standard 24.5 ~ 58.8 (250 ~ 600) [18.1 ~ 43.4]
Steering valve ASSY set bolt Standard 29.4 ~ 39.2 (300 ~ 400) [21.7 ~ 28.9]
Steering valve end cap set screw Standard 24 ~ 36 (245 ~ 367) [17.7 ~ 26.6]
 16-13

BRAKE
Front brake (1 ton series)
Hold down spring free length mm (in) Standard 25.5 (1.004)
Standard 102.2 (4.024)
Anchor to shoe spring free length mm (in)
Limit Replace if any clearance in coil exists.
Strut to shoe spring free length mm (in) Standard 19.7 (0.776)
Standard 99.4 (3.913)
Adjuster spring free length mm (in)
Limit Replace if any clearance in coil exists.
Standard 4.9 (0.193)
Brake lining length mm (in)
Limit 1.0 (0.039)
Wheel cylinder to piston clearance mm (in) Limit 0.125 (0.00492)
Standard 254 (10.00)
Brake drum inside diameter mm (in)
Limit 256 (10.08)
Front brake (2 • 3 ton series)
Standard 32.3 (1.272)
Hold down spring free length mm (in)
Limit 29.1 (1.146)
Standard 124.5 (4.902)
Actuator spring free length mm (in)
Limit No clearance between coil turns
Standard 106 (4.17)
Anchor to shoe spring free length mm (in)
Limit No clearance between coil turns
Standard 23 (0.91)
Strut to shoe spring free length mm (in)
Limit 20 (0.79)
Standard 86 (3.39)
Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 7.0 (0.276)
Brake lining thickness mm (in)
Limit 2.0 (0.079)
Wheel cylinder to piston clearance mm (in) Limit 0.145 (0.00571)
Standard 310 (12.20)
Brake drum inside diameter mm (in)
Limit 312 (12.28)
Front brake (J3.5 ton series)
Hold down spring free length mm (in) Standard 44.0 (1.732)

Anchor to shoe spring free length Standard 138.2 (5.441)

(On the side of lining W/pin) mm(in) Limit No clearance between coil turns

Anchor to shoe spring free length Standard 121.2 (4.772)

(On the side of lining L/ pin) mm(in) Limit No clearance between coil turns
Strut to shoe spring free length mm (in) Standard 31.4 (1.236)
16-14

Standard 125.4 (4.937)

Adjuster spring free length mm (in)
Limit No clearance between coil turns
Standard 5.6 (0.220)
Brake lining thickness mm (in)
Limit 1.0 (0.039)
Wheel cylinder to piston clearance mm (in) Limit 0.15 (0.0059)
Standard 317.5 (12.500)
Brake drum inside diameter mm (in)
Limit 319.5 (12.579)
Parking brake

Parking brake operating force 1~3 ton series Standard 147 ~ 196 (15 ~ 20) [33 ~ 44]
(measured at center
of lever knob) N (kgf) [lbf] J3.5 ton series Standard 196 ~ 245 (20 ~ 25) [44 ~ 55]

Brake pedal
Brake pedal height
Standard 150 ~ 155 (5.91 ~ 6.10)
(from toe board: with pad) mm (in)
Brake pedal play mm (in) Standard 3 ~ 7 (0.12 ~ 0.28)
Brake pedal depressed height (with pad) mm (in) Standard 90 (3.54) or more
Brake master cylinder push rod play mm (in) Standard 1 (0.04)
Inching pedal stroke until 1 ton series: 30 ~ 35 (1.18 ~ 1.38)
Standard
interlocking with brake mm (in) Others: 20 ~ 30 (0.79 ~ 1.18)
Inching cable set dimension mm (in) Standard 17.5 (0.689)
Inching pedal play (until start
Standard 3 ~ 5 (0.12 ~ 0.20)
of inching lever movement) mm (in)
Tightening torque Unit: N • m (kgf-cm) [ft-lbf]
1 ton series Standard 78.5 ~ 107.9 (800 ~ 1100) [57.9 ~ 79.57]
Brake drum set nut
2 ton series Standard 147.1 ~ 186.3 (1500 ~ 1900) [108.5 ~ 137.5]
(hub bolt set nut)
3 • J3.5 ton series Standard 166.7 ~ 205.9 (1700 ~ 2100) [123.00 ~ 151.9]
Backing plate set bolt Standard 117.7 ~ 137.3 (1200 ~ 1400) [86.80 ~ 101.3]
1 ton series Standard 7.85 ~ 11.77 (80 ~ 120) [5.79 ~ 8.68]
Wheel cylinder set bolt 2 • 3 ton series Standard 14.7 ~ 19.6 (150 ~ 200) [10.85 ~ 14.47]
J3.5 ton series Standard 17.7 ~ 26.5 (180 ~ 270) [13.0 ~ 19.5]
 16-15

MATERIAL HANDLING SYSTEM

Natural drop test
Natural drop mm (in) Limit 45 (1.77)
Natural forward tilt test
1 ton series Standard 15 (0.59) or less
Natural forward tilt mm (in) 2 ton series Standard 20 (0.79) or less
3 • J3.5 ton series Standard 25 (0.98) or less
Oil leak test
Lift cylinder oil leak amount cm3 (in3) Standard 8 (0.49) or less
Tilt cylinder oil leak amount (total for lift and tilt) cm3 (in3) Standard 16 (0.98) or less

MAST
Mast adjustment (V mast)

Mast Inner mast roller clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)

rollers Outer mast roller clearance mm (in) Standard 0 ~ 0.5 (0 ~ 0.017)
Lift Middle and lower lift roller clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
bracket
rollers Side roller clearance mm (in) Standard 0 ~ 0.6 (0 ~ 0.024)
Mast strip to inner mast clearance mm (in) Standard 0 ~ 0.8 (0 ~ 0.031)
Mast strip thickness mm (in) Limit 1.5 (0.059)
Fork
Fork front end misalignment mm (in) Limit 10 (0.39)

Tightening torque Unit: N • m (kgf-cm) [ft-lb]

Mast support cap set bolt Standard 68.6 ~ 107.9 (700 ~ 1100) [50.7 ~ 79.57]
Back rest set bolt Standard 99.54 ~ 184.9 (1015 ~ 1885) [73.42 ~ 136.4]
Chain adjusting nut Standard 49.0 ~ 78.0 (500 ~ 800) [36.2 ~ 57.9]
16-16

CYLINDER
Lift cylinder (V • SV)
1 ton series Limit 34.92 (1.3748)

Piston rod outside 2 ton series Limit 39.92 (1.5433)

diameter mm (in) 3 ton series Limit 44.92 (1.7685)
J3.5 ton series Limit ↑
1 ton series Limit 45.20 (1.7795)
2 ton series Limit 50.20 (1.9764)
Cylinder bore mm (in)
3 ton series Limit 55.35 (2.1791)
J3.5 ton series Limit 60.35 (2.3760)
Piston rod bend mm (in) Limit 2.0 (0.079)
Rear lift cylinder (FV • FSV)
FV Limit 31.92 (1.2567)
1 ton series
FSV Limit 34.92 (1.3748)
FV Limit ↑
2 ton series
Piston rod outside FSV Limit 39.92 (1.5717)
diameter mm (in)
FV Limit ↑
3 ton series
FSV Limit 44.92 (1.7685)
FV Limit 39.92 (1.5717)
J3.5 ton series
FSV Limit 44.92 (1.7685)
1 ton series Limit 45.20 (1.7795)
2 ton series Limit 50.20 (1.9764)
Cylinder bore mm (in)
3 ton series Limit 55.35 (2.1791)
J3.5 ton series Limit 60.35 (2.3760)
Piston rod bend mm (in) Limit 2.0 (0.08)
Front lift cylinder (FV • FSV)
1 ton series Limit 69.91 (2.7524)

Piston rod outside 2 ton series Limit 74.91 (2.9429)

diameter mm (in) 3 ton series Limit 84.90 (3.3425)
J3.5 ton series Limit 59.91 (2.3587)
1 ton series Limit 85.40 (3.3622)
2 ton series Limit 90.40 (3.5591)
Cylinder bore mm (in)
3 ton series Limit 105.40 (4.1496)
J3.5 ton series Limit 90.40 (3.5590)
Piston rod bend mm (in) Limit 2.0 (0.079)
 16-17

Tilt cylinder
Cylinder bore mm (in) Limit 70.35 (2.7697)
Piston rod outside diameter mm (in) Limit 29.92 (1.1780)
Piston rod bend mm (in) Limit 1.0 (0.039)
Tightening torque Unit: N • m (kgf-cm) [ft-lbf]
Lift cylinder cover Standard 343.2 ~ 441.3 (3500 ~ 4500) [253.2 ~ 325.6]
Flow regulator valve Standard 58.8 ~ 68.7 (600 ~ 700) [43.4 ~ 50.7]
Safety down valve Standard 29.4 ~ 39.2 (300 ~ 400) [21.7 ~ 28.9]
Front lift cylinder rod guide Standard 343.2 ~ 441.3 (3500 ~ 4500) [253.2 ~ 325.6]
Tilt cylinder piston castle nut Standard 260.0 ~ 350.0 (2650 ~ 3570) [191.7 ~ 258.3]
Tilt cylinder cover Standard 260.0 ~ 350.0 (2650 ~ 3570) [191.7 ~ 258.3]

OIL PUMP
Oil pump ASSY (4Y)
Bushing inside diameter mm (in) Limit 20.095 (0.7894)
Bushing axial length mm (in) Limit 21.957 (0.8644)
Gear shaft outside diameter mm (in) Limit 19.964 (0.7860)
Body inside surface flaw depth mm (in) Limit 0.14 (0.0055)
Oil pump ASSY (1DZ-II)
Bushing inside diameter mm (in) Limit 14.77 (0.5555)
Side plate tickness mm (in) Limit 1.9 (0.075)
Gear shaft outside diameter mm (in) Limit 18.935 (0.74547)
Body inside surface flaw depth mm (in) Limit 0.1 (0.004)
Oil pump ASSY (2Z)
Bushing inside diameter mm (in) Limit 22.23 (0.8752)
Side plate tickness mm (in) Limit 4.83 (0.1902)
Gear shaft outside diameter mm (in) Limit 21.95 (0.8642)
Body inside surface flaw depth mm (in) Limit 0.15 (0.0059)
16-18

OIL CONTROL VALVE

Oil control valve
1 ton series Standard 17162+- 4900 (175+-50) [2489+-710]
Lift 2 • 3 ton series Standard 18142+- 4900 (185+-50) [2631+-710]
Relief set pressure J3.5 ton series Standard ↑
kPa (kgf/cm2) [psi]
1 ton series Standard 11770+- 4900 (120+-50) [1707+-710]
Tilt 2 • 3 ton series Standard 14710+- 4900 (150+-50) [2133+-710]
J3.5 ton series Standard 15690+- 4900 (160+-50) [2276+-710]

SAS
Tightening torque Unit: N·m (kgf-cm) [ft-lbf]
SAS controller set bolt Standard 7.0 ~ 16.0 (71 ~ 163) [5.1 ~ 11.8]
Tire angle sensor set bolt Standard 1.0 ~ 2.0 (10 ~ 20) [0.72 ~ 1.4]
Tire angle sensor cover set bolt Standard 7.0 ~ 16.0 (71 ~ 163) [5.1 ~ 11.8]
Upper side: 10.5 ~ 24.5 (107 ~ 250) [7.74 ~ 18.1]
Swing lock cylinder pin set bolt Standard
Lower side : 16.2 ~ 37.8 (162 ~ 378) [11.7 ~ 27.3]
Tilt angle sensor set bolt Standard 7.0 ~ 16.0 (71 ~ 163) [5.1 ~ 11.8]
Load sensor Standard 35.3 ~ 43.1 (360 ~ 440) [26.0 ~ 31.8]
Speed sensor set bolt Standard 3.0 ~ 7.0 (31 ~ 71) [2.2 ~ 5.1]
Fork height switch ASSY set bolt Standard 14.4 ~ 33.6 (147 ~ 343) [10.6 ~ 24.8]
 16-19

WIRING DIAGRAM
Page

WIRING DIAGRAM EXPLANATION .................................. 16-20

WIRE TO WIRE LIST (ROUTE) ........................................ 16-22
WIRE TO WIRE LIST (CONNECTOR) .............................. 16-23
POWER FUSES (R/B) ...................................................... 16-25
ELECTRICAL SHIFT TORQUE CONVERTER .................. 16-26
CHARGING ....................................................................... 16-27
FUEL (1DZ-II • 2Z) .............................................................. 16-28
FUEL & IGNITION (4Y) ..................................................... 16-29
FUEL & IGNITION (LPG & GASOLINE • LPG ONLY) ......... 16-30
INTAKE HEATER (2Z) ....................................................... 16-31
GLOW (1DZ-II) ................................................................. 16-32
EMISSION CONTROL (GASOLINE) ................................. 16-33
EMISSION CONTROL (LPG) ............................................ 16-34
REAR WORK LAMP ......................................................... 16-35
HEAD LAMP ..................................................................... 16-36
CLEARANCE LAMP (ILLUMINATION LAMP) .................... 16-37
STOP LAMP ..................................................................... 16-38
TURN SIGNAL LAMP ....................................................... 16-39
ROTARY LIGHT (BEACON) .............................................. 16-40
HORN ............................................................................... 16-41
T/C HEAT GAUGE ............................................................ 16-42
LOW LPG LEVEL ALARM ................................................ 16-43
COMBINATION METER .................................................... 16-44
16-20

WIRING DIAGRAM EXPLANATION

Wire to Wire List (Route)

Wire to wire connector No.

Indicates the No. of the connector which connect wire harnesses.
EF 1 .
Indicates the wire harnesses to be connected. EF, for example, indicates connection of E wire female
connector (terminal = female) and F wire male connector (terminal = male).
(See the wire to wire list (connector) for symbols such as E and F for each portion.)
Wire to Wire List (Connector)

Wire to wire connector No.

Portion Symbol
E/G E
Connector color
FR F Indicates the color of
the connector.
T/M T
Side S
RR LWR L
SAS connector No.
RR VPR U (CN6)
A number with CN is common
Instrument panel I with the SAS connector.

FR STAY A
Wire to wire No.
Mast M No. of the connector
that connects wire
harnesses.
Wire harness symbol
Symbol of each wire harness
which is used as the leading
character of a part connctor No.
or wire to wire connector No.
Connector shape and terminal Nos.
Shape of the connector that connects wire
harnesses. Each number indicates the terminal no.
position.
 16-21

Wiring Diagram of Each System

Wire color
Wire harness color.

Terminal No.
Terminal No. of the
mating connector.

Vehicle W/neutral SW

Part connector symbol

Wire to wire connector No. Symbol of the connector to be connected
No. of the connector that connects with a part. It is related to the symbol in
wire harnesses. the circuit diagram above.
16-22

WIRE TO WIRE LIST (ROUTE)

W/H: Wire harness

 MAST
Portion Symbol
E/G E
FR F
T/M T
Side S
RR LWR L (CN6)

RR UPR U
Instrument panel I
FR STAY A INSTRUMENT
T/C HEAT PANEL
GAUGE SUB
Mast M
WIRE TO WIRE LIST (CONNECTOR)

ACCEL SW O
(CN5)
OPT
SIDE
Portion Symbol
DPF display J
T/C heat gauge N
DPF FL P SIDE SIDE SIDE
LPG PRESS SW
(France spec.) X

(CN4)
16-23
16-24
 HEAD LAMP

TAIL LAMP, CLEARANCE LAMP, METER ILLUMINATION

BUS BAR
STOP LAMP

BUS BAR
POWER FUSES (R/B)

REAR WORKING LAMP

W (4Y, 1DZ-II)
B-R (2Z)
(1DZ-II)
(1DZ-II)

ALTERNATOR SENSING

TWO-
TWO-

SPOOL
SPOOL
DPF SYSTEM
DPF ECU
HORN
HOUR METER, WATER TEMPERATURE GAUGE, FUEL METER, WARNING LAMP, BACKUP
BUZZER, T/C OIL TEMPERATURE GAUGE, STROBE, SAS BUZZER

TURN SIGNAL LAMP, FLASHER RELAY

TWO-
SPOOL
ALTERNATOR, GLOW PLUG TIMER, IGNITION COIL, EMISSION
CONTROL ECU
EMISSION CONTROL ABCV, INJECTION, LPG MAIN SOLENOID, LPG SLOW SOLENOID
FUEL CUT SOLENOID, FUEL PUMP, VEHICLE SPEED CONTROL ECU
SAS ECU, STEERING ANGLE SENSOR

TWO-
SPOOL
SAS ECU

ELECTRONICALLY SHIFTING T/C

STARTING MOTOR RELAY (COIL SIDE), GLOW PLUG TIMER
16-25
16-26

ELECTRICAL SHIFT TORQUE CONVERTER

 CHARGING

(2Z, 1DZ-II, 4Y)

16-27
16-28

FUEL (1DZ-II • 2Z)

BODY GROUND
 FUEL & IGNITION (4Y)

X7V
FUEL CUT
SOLENOID

BODY
GROUND
16-29
 16-30

(LPG ONLY VEHICLE)

(LPG/GASOLENE VEHICLE)

LPG SELECTOR
SWITCH

ENG REV
SWITCH

LPG RELAY
FUEL & IGNITION (LPG & GASOLINE• LPG ONLY)

LPG LPG
GASOLINE FUEL CUT SOLENOID SOLENOID
SOLENOID SOLENOID (MAIN) (SLOW)

BODY
GROUND
 (CN42)
INTAKE HEATER (2Z)

STARTING
MOTOR RELAY

STARTING
GLOW LAMP SYSTEM
(COMBINATION
METER)

ALTERNATOR

BODY
GROUND
16-31
 16-32

GLOW (1DZ-II)

STARTING
MOTOR RELAY

STARTING
SYSTEM

(COMBINATION
METER)

GLOW RELAY
(IN R/B)

ALTERNATOR

BODY
GROUND
 CARBURETOR

IDLE SW

EMISSION CONTROL
EMISSION CONTROL (GASOLINE) (3-Way Catalytic Converter System)

CHECK WATER
CONNECTOR TEMPERATURE
O2
SENSOR

SWITCH

ENGINE
BLOCK
BODY GROUND BODY
GROUND
16-33
 16-34

LPG
SYSTEM

LPG LPG
SOLENOID SOLENOID
(SLOW) (MAIN)

EMISSION CONTROL
EMISSION CONTROL (LPG) (3-Way Catalytic Converter System)

CHECK
CONNECTOR

O2
SENSOR

INTAKE MANIFOLD
 REAR WORK LAMP

REAR
WORKING
LAMP SW

REAR WORKING
LAMP PILOT LP
16-35
16-36

HEAD LAMP
 (IN R/B)

RR COMBINATION
CLEARANCE LP
FR COMBINATION
CLEARANCE LP
ILLUMINATION LAMP
(COMBINATION METER)
(CN42)
CLEARANCE LAMP (ILLUMINATION LAMP)
16-37
 16-38

STOP LAMP

PLUG RECEPTACLE

4 6
 16-39

TURN SIGNAL LAMP

FLASHER

BODY GROUND
16-40

ROTARY LIGHT (BEACON)

ROTARY
LIGHT
 HORN

HORN

HORN
SW
16-41
16-42

T/C HEAT GAUGE

BODY GROUND
 16-43

LOW LPG LEVEL ALARM

16-44

COMBINATION METER
(4Y, 2Z,
1DZ-II)

(1DZ-II)
16-45