4-107

H9-1, 2, 3 Unload valve solenoid abnormality

Related portion

CN89
CN104-26 (12, SOLP+)
1
CPU Unload valve
board solenoid
CN104-27 (13, SOLP–)
2

Conditions for error detection

Output if the unload valve solenoid line from the CPU board to the unload valve solenoid
is open or shorted.
H9-1 Unload valve solenoid open-circuit defect
H9-2 Unload valve solenoid load short-circuit defect
H9-3 Unload valve solenoid drive circuit MOS short-circuit defect

• H9-1

ACTIVE TEST: ACT-5 PSOL H9-1 error is not indicated.

The unload valve solenoid is set to ON by the • Connector connection check
active test.
H9-1 error is indicated.

Disconnect battery plug.

Disconnect CN104. 9.9 ± 1 Ω (at 25 °C)
CN104-26 (12) • CPU board defect
↔

Resistance measurement
CN104-27 (13)
Other than 9.9 ± 1 Ω
(at 25 °C)

Disconnect CN89.
9.9 ± 1 Ω (at 25 °C)
CN89-1 (12) • Harness defect
↔

Resistance measurement
CN89-2 (13)
Other than 9.9 ± 1 Ω
(at 25 °C)

• Unload valve solenoid defect

4-108

• H9-2

ACTIVE TEST: ACT-5 PSOL H9-2 error is not indicated.

The unload valve solenoid is set to ON by the • Connector connection check
active test.
H9-2 error is indicated.

Disconnect battery plug.

Disconnect CN89.

ACTIVE TEST: ACT-5 PSOL H9-1 error is indicated.

The unload valve solenoid is set to ON by the • Unload valve solenoid defect
active test.
H9-2 error is

Disconnect battery plug.

Disconnect CN104. Continuity
CN104-26 (12) • Harness defect
↔

Continuity check
CN104-27 (13)
No continuity

• CPU board defect

• H9-3
H9-3 error is not
ACTIVE TEST: ACT-5 PSOL indicated.
The unload valve solenoid is set to ON by the • Connector connection check
active test.
H9-3 error is indicated.

Disconnect battery plug, disconnect CN104.

10 V or more
Connect battery plug and turn the key switch to
• Harness defect
ON.
CN104-26 (12) ~ CN104-23 (N2)
CN104-27 (13) ~ CN104-23 (N2)
Less than 10 V

• CPU board defect

 4-109

TRAVELING CONTROLLER SYSTEM

WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
30-1 Traveling controller low voltage

Related portion

F1
P1 P2 P3

Traveling
controller

Condition for error detection

Output when the battery voltage (P3) line of traveling controller detects low voltage.

If 31-1, CB-1 occur at the same time, perform troubleshooting for 31-1, CB-1 first.
Yes
Turn the key switch to OFF and then ON again. • Troubleshooting of 31-1 error is
Is 31-1 error displayed? performed.
No
CB-1 error is indicated.
If it runs, does an error come out? • Troubleshooting of CB-1 error is
30-1 error is performed.
No error
indicated. • P3 cable and terminal check
• F1 fuse check
ANL : I/O MONITOR 1 I/O1-13
Again, key switch is set to OFF and ON. Run and 32 V or more
• Traveling controller defect
check the VBBD voltage when an error occurs.
Less than 32 V

ANL : I/O MONITOR 1 I/O1-8

Again, key switch is set to OFF and ON. Run and Less than 32 V
• Battery plug check
check the VB80 voltage when an error occurs.
• Battery charge
32 V or more

Again, key switch is set to OFF and ON. Run and 32 V or more
check the traveling controller input voltage P3-N1 • Traveling controller defect
when on error occurs.
Less than 32 V

Again, key switch is set to OFF and ON. Run and 32 V or more
check the battery voltage P2-N1 when an error • P3 cable and terminal check
occurs. • F1 fuse check
Less than 32 V
• MB contactor defect
4-110

31-1 Traveling controller starting voltage drops

Related portion

F1
P1 P2 P3 Traveling
controller

CPR
CN104-9 (55, CPR)

F7 CN136 CPU
CN104-1 (18, B80V) board
4
CN104-2
(18, B80V)

Condition for error detection

Output when it is detected that P3 voltage of traveling controller does not exceed the
setting value with the key switch ON.

No
Turn the key switch to OFF and then ON again. • Battery plug check
Is 31-1 error displayed? • Traveling controller cable and terminal
Yes check
• CPR check
ANL. : I/O MONITOR 1 I/O1-13 48 V or more • Harness check
VBBD : Traveling controller DC_BUS voltage • Traveling controller defect
check
Less than 48 V

P3 48 V or more
• Traveling controller defect
↔

Voltage measurement
N1
Less than 48

ANL. : I/O MONITOR 1 I/O1-9 48 V or more

VBKS : Key start voltage check CPR resistance value check
Less than 48 Approx. 20 Ω Other than
approx. 20 Ω
• F1 fuse check • CPR defect

ANL. : I/O MONITOR 1 I/O1-8 48 V or more

B80V : Battery voltage check • CPU board defect

Less than 48

P1 48 V or more
• F7 fuse check
↔

Voltage measurement
N1
Less than 48 V

• Battery charge
 4-111

32-1 Traveling controller EEP-ROM abnormality

Related portion

Traveling
controller

Condition for error detection

Internal data is abnormal at the time of traveling controller starting.
The EEP-ROM element on the CPU board in traveling controller is damaged.

Even if it repeats the key switch with OFF and No Was traveling controller exchanged
ON, does 32-1 error occur? immediately before?
Yes No Yes

• Traveling • Normal
controller
• Traveling controller defect connector check
(ID signal)
4-112

33-1 CPU → Traveling controller communication abnormality

Related portion

CN103-1 (145, CANH) CN110-3 (145, CANH)

CN103-2 (146, CANL) CN110-4 (146, CANL)
CN103-3 (147, CANGND) CN110-6 (147, CANGND)
CPU board Traveling
CN104-25 (42, KEYSTART) CN110-7 (42, KEYSTART) controller
CN112
1
R
2
3

Condition for error detection

Output when traveling controller cannot receive the communication data from the CPU board
within fixed time.

Does AD-1 error display or diagnosis memory Yes

• Troubleshooting of AD-1 error is performed.
memorize?
No

Was traveling controller exchanged immediately Yes

• The plug check of CN103, CN104, CN110
before?
and CN112 connectors is performed, the
No key switch is set to OFF and ON, and it
checks that an error is not displayed.

Do you switch OFF and turn ON the key switch No error

• CN103, CN104, CN110, CN112 connector
and generate an error?
check
33-1 error is indicated. AD-1 or AD-2 is indicated. • Harness check
(AD-1 and AD-2 are not • Troubleshooting of AD-1 or AD-2 error is
indicated.) performed.
• Harness check
• Traveling controller defect
(There is the possibility that CPU is defect.)
 4-113

A0-1, 2 Main drive circuit overheat•main pump circuit overheat

Related portion

CN113
CN104-14, 15 (44, VBMB) 1
CN104-24 (39, FAN–) 2 FAN

CN114
CPU Traveling 1
board controller 2 FAN

Material handling CN115

controller 1
2 FAN

Condition for error detection

Output when the temperature detected by the traveling/material handling main circuit thermo-
sensor exceeds the specified level.

If A0-4 occurs at the same time, perform troubleshooting for A0-4 first.
(Fan arrangement)
No abnormality The controller cover was opened and it saw from
Allow the vehicle to stand for a while (about 15 • Normal the front of vehicle
min.) and operate. Material
Upper Traveling
Immediate indication of overheat symbol handling
controller
controller

ANL : ACTIVE TEST ACT-1

Turn all cooling fans ON and check that it is Fan
Not running
running. ANL : ACTIVE TEST ACT-1
Running FAN : ON/OFF (Fan voltage)
A0-2
The voltage check when the Fan is ON.
A0-1
20 V or more Less than 20 V
ANL. : I/O MONITOR 1 I/O1-1
THCD : Traveling controller thermo-sensor CN113 (4) (5)-1
reading while traveling.
↔

Voltage measurement
The temperature The temperature CN113 (4) (5)-2
does not change. changes. 20 V or more Less than 20 V

• Traveling con- • Is the exhaust port cov-

troller defect ered with paper? • Fan check • Harness defect between
• Is it overloaded? • Connector CN104 and CN113 (4) (5)
disconnection

ANL. : I/O MONITOR 1 I/O1-2 CN105-4 (5)

THCP : Material handling controller thermo-
↔

Voltage measurement
sensor reading while material handling N1
The temperature The temperature Either is more All are less than
does not change. changes. than 5 V. 5 V.

• Material han- • Is the exhaust port cov- • CPU board defect • Resistance check in the
dling controller ered with paper? main controller
defect • Is it overloaded?
4-114

A1-2 Traveling controller

Related portion

F1
P3

Traveling
controller

Condition for error detection

Output when the battery voltage line of the traveling controller overvoltage is detected.

If A1-1 occurs at the same time, perform troubleshooting for A1-1 first.

Turn the key switch to OFF and then ON again.

Less than
Yes ANL: I/O MONITOR 1 I/O1-13 110 V
Is A1-2 error displayed? • Traveling
VBBD: Traveling controller
No controller defect.
DC_BUS voltage value
110 V or more
110 V or
more
Battery voltage check. • Replace battery.
80 V spec. : approx. 80 V
72 V spec. : approx. 72 V
• Traveling controller defect

NG (∞ Ω)
F1 fuse inspection • Replace F1 fuse.
OK (0 Ω)
Yes
Was the battery plug disconnected during • Do not disconnect battery plug during
traveling? traveling except in an emergency.
No

• Check battery plug.

 4-115

A2-2 Traveling controller board overheat

Related portion

Traveling controller

PCB Thermo-sensor

Condition for error detection

Output when the voltage detected by the thermo-sensor in the controller exceeds the
specified level.

If A0-4, 5 occur at the same time, perform troubleshooting for A0-4, 5 first.

ANL : I/O MONITOR 1 I/O1-5 100 °C or more

TBD: Traveling controller board temperature • Allow vehicle to stand for a while.
check. (approx. 30 min.)
Less than 100 °C

Has the vehicle been subjected to continuous Yes

• Stop vehicle and perform check test with
overloaded operation?
standard load after 30 minutes.
No

• Traveling controller
4-116

AA-2 Traveling controller thermo-sensor abnormality

Related portion

Traveling controller

PCB Thermo-sensor

Condition for error detection

Output when the thermo-sensor in the controller abnormality is detected.

If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.
• To correct, replace the traveling controller.
 4-117

C1-1 Traveling controller current sensor offset abnormality

Related portion

Traveling controller

Current sensor

Condition for error detection

Output when the current sensor offset compensation is detected at the time of the
traveling controller starting.

• To correct, replace the traveling controller.

4-118

C1-2 Traveling controller over current abnormality

Related portion

P7

Traveling P8
Drive motor
controller
P9

Condition for error detection

Output when the traveling controller over current is detected.

Even if it repeats the key switch with ON-OFF, No

does C1-2 error occur? • Drive motor cable check
• Drive motor continuity check
Yes

• Traveling controller defect

 4-119

C2-1 Drive motor overheat

Related portion

Drive motor
Traveling
controller

Temperature sensor

Condition for error detection

Output when the temperature sensor value of drive motor exceeds the setting value.

If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.
• To correct, allow the vehicle to stand for a while (about 30 minutes).
4-120

C2-2 Drive motor thermo-sensor abnormality

Related portion

CN52
CN110-13 (88, TD+) 1
Traveling Drive motor
controller CN1110-10 (83, TD-) thermo-sensor
2
J53

Condition for error detection

Output when motor thermo-sensor output value outside the specified range (open or
short circuit) is detected.

If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.

ANL : I/O MONITOR 1 I/O1-3 –50 °C or less

TD: Temperature check
195°C or more
Disconnect battery plug and disconnect CN52.

Disconnect battery plug, disconnect CN52, and connect

SST2 to the harness.
ANL : I/O MONITOR 1 I/O1-3
TD: Temperature check
195 °C or more –50 °C or less
ANL : I/O MONITOR 1 I/O1-3
TD: Temperature check
195 °C or more –50 °C or less
CN110-13 (88)
↔

Voltage measurement
•Thermo-sensor N1
defect Less than 1 V 1 V or more

• Harness defect • Traveling controller

defect
 4-121

C3-1 Traveling controller main circuit thermo-sensor abnormality

Related portion

Traveling controller

Thermo-sensor

Condition for error detection

Output when the heat sink thermo-sensor in the driver is abnormal.

If AD-1 occurs at the same time, perform troubleshooting for AD-1 first.
• To correct, replace the traveling controller.
4-122

C8-1 Drive motor speed sensor abnormality

Related portion

CN110-9 (80, SSD+) CN53-1 (80, SSD+)

CN110-11 (81, SSD1) CN53-2 (81, SSD1)

Traveling
controller CN110-12 (82, SSD2) CN53-3 (82, SSD2)

CN110-10 (83, SSD–) CN53-4 (83, SSD–)

Drive motor
CN53
speed sensor

Condition for error detection

Output when the traveling controller detects abnormality of drive motor speed sensor.
C8-1 Drive motor speed sensor defect

Disconnect battery plug, connect SST19 to

CN110, and connect CN1 and CN3 of SST19.

Connect battery plug, turn the key switch to ON,

and check the state of LED of SST at the time of One of LEDs turns OFF.
• Check the CN1 and CN3 connection of SST.
running.
2 LEDs ON 2 LEDs OFF

• Traveling controller defect

Disconnect battery plug, connect SST19 to
CN110, and connect CN2 and CN3 of SST19.

Connect battery plug, turn the key switch to ON, NG (Both 2 LEDs blink).
and check the state of LED of SST at the time of • Traveling controller defect
running.
Other than NG

Disconnect CN53, and check the voltage of

CN53 of harness side. NG (all 8 V ~ 13 V)
1 pin (+) ~ 4 pin (-) • Drive motor speed sensor defect
2 pin (+) ~ 4 pin (-)
3 pin (+) ~ 4 pin (-)
Other than NG

• Harness defect
 4-123

MATERIAL HANDLING CONTROLLER SYSTEM

WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
30-3 Material handling controller low voltage

Related portion

F1
P1 P2 P3

Material
handling
controller

Condition for error detection

Output when the battery voltage (P3) line of material handling controller detects low voltage.

If 31-3, CB-1 occur at the same time, perform troubleshooting for 31-3, CB-1 first.
Yes
Turn the key switch to OFF and then ON again. Troubleshooting of 31-3 error is
Is 31-3 error displayed? performed.
No
CB-1 error is indicated.
If lift operation is carried out, does an error come Troubleshooting of CB-1 error is performed.
out?
30-3 error is No error
indicated. • P3 cable and terminal check
• F1 fuse check
ANL : I/O MONITOR 1 I/O1-14 32 V or more
• Material handling controller defect
Again, key switch is set to OFF and ON. Carry out
lift operation and check the VBBP voltage when
an error occurs.
Less than 32 V

ANL : I/O MONITOR 1 I/O1-8

Again, key switch is set to OFF and ON. Carry out Less than 32 V
• Battery plug check
lift operation and check the VB80 voltage at the
• Battery charge
time of an error.
32 V or more

Again, key switch is set to OFF and ON. Carry out 32 V or more
lift operation and check the material handling • Material handling controller defect
controller input voltage P3-N1 when an error
occurs.
Less than 32 V

Again, key switch is set to OFF and ON. Carry out 32 V or more
lift operation and check the battery voltage P2-N1 • P3 cable and terminal check
when an error occurs. • F1 fuse check
Less than 32 V
• MB contactor defect
4-124

31-3 Material handling controller starting voltage drops

Related portion

F1
P1 P2 P3 Material
handling
controller

CPR
CN104-9 (55, CPR)

F7 CN136 CPU
CN104-1 (18, B80V)
4 board
CN104-2 (18, B80V)

Condition for error detection

Output when it is detected that P3 voltage of material handling controller does not
exceed the setting value with the key switch ON.

No
Turn the key switch to OFF and then ON again. • Battery plug check
Is 31-3 error displayed? • Material handling controller cable and
Yes terminal check
• CPR check
ANL. : I/O MONITOR 1 I/O1-14 48 V or more • Harness check
VBBP : Material handling controller DC_BUS • Material handling controller defect
voltage check
Less than 48 V

P3 48 V or more
↔

Voltage measurement • Material handling controller defect

N1
Less than 48 V

ANL. : I/O MONITOR 1 I/O1-9 48 V or more

CPR resistance value check
VBKS : Key start voltage check
Approx. 20 Ω Other than
Less than 48 V approx. 20 Ω
• F1 fuse check • CPR defect

ANL. : I/O MONITOR 1 I/O1-8 48 V or more

• CPU board defect
B80V : Battery voltage check
Less than 48 V

P1 48 V or more
• F7 fuse check
↔

Voltage measurement
N1
Less than 48 V

• Battery charge
 4-125

32-3 Material handling controller EEP-ROM abnormality

Related portion

Material
handling
controller

Condition for error detection

Internal data is abnormal at the time of material handling controller starting.
The EEP-ROM element on the CPU board in material handling controller is damaged.

Even if it repeats the key switch with OFF and No Was material handling controller
ON, does 32-3 error occur? exchanged immediately before?
Yes No Yes

• Material handling • Normal

controller
• Material handling controller defect connector check
(ID signal)
4-126

33-3 CPU → Material handling controller communication abnormality

Related portion

CN103-1 (145, CANH) CN111-3 (145, CANH)

CN103-2 (146, CANL) CN111-4 (146, CANL)
CN103-3 (147, CANGND) CN111-6 (147, CANGND)
Material
CPU board handling
CN104-25 (42, KEYSTART) CN111-7 (42, KEYSTART) controller

CN112
1
R
2
3

Condition for error detection

Output when material handling controller cannot receive the communication data from the CPU
board within fixed time.

Does AD-5 error display or diagnosis memory Yes

• Troubleshooting of AD-5 error is performed.
memorize?
No

Is material handling controller exchanged Yes

• The plug check of CN103, CN104, CN111
immediately before?
and CN112 connectors is performed, the
No key switch is set to OFF and ON, and it
checks that an error is not displayed.

Did an error occur when the key switch was No error

• CN103, CN104, CN111, CN112
turned to ON from OFF?
connector check
33-3 error is indicated. AD-5 or AD-6 is indicated. • Harness check
(AD-5 and AD-6 are not • Troubleshooting of AD-5 or AD-6 error is
indicated.) performed.
• Harness check
• Material handling controller defect
(There is the possibility that CPU is
defect.)
 4-127

A1-4 Material handling controller high voltage

Related portion

F1
P3

Material
handling
controller

Condition for error detection

Output when the battery voltage line of the material handling controller overvoltage is detected.

If A1-1 occurs at the same time, perform troubleshooting for A1-1 first.

Turn the key switch to OFF and then ON again.

Less than
Yes ANL: I/O MONITOR 1 I/O1-14
110 V
Is A1-4 error displayed? VBBP: Material handling controller • Material
No DC_BUS voltage value handling
controller defect
110 V or more
110 V or
more
Battery voltage check • Replace battery.
80 V spec. : approx. 80 V
72 V spec. : approx. 72 V
• Material handling controller defect
NG (∞ Ω)
F1 fuse inspection • Replace F1 fuse.
OK (0 Ω)
Yes
Was the battery plug disconnected during • Do not disconnect battery plug during
traveling? traveling except in an emergency.
No

• Check battery plug.

4-128

A2-3 Material handling controller board overheat

Related portion

Material handling
controller
PCB Thermo-sensor

Condition for error detection

Output when the voltage detected by the thermo-sensor in the controller exceeds the
specified level.

If A0-4, 5 occur at the same time, perform troubleshooting for A0-4, 5 first.

ANL : I/O MONITOR 1 I/O1-6 100 °C or more

TBP: Material handling controller board • Allow vehicle to stand for a
temperature check. while. (approx. 30 min.)
Less than 100 °C

Has the vehicle been subjected to continuous Yes

• Stop vehicle and perform check test with
overloaded operation?
standard load after 30 minutes.
No

• Material handling controller defect

 4-129

AA-4 Material handling controller thermo-sensor abnormality

Related portion

Material handling
controller
PCB Thermo-sensor

Condition for error detection

Output when the thermo-sensor in the controller abnormality is detected.

If AD-5 occurs at the same time, perform troubleshooting for AD-5 first.
• To correct, replace the material handling controller.
4-130

E1-1 Material handling controller current sensor offset abnormality

Related portion

Material handling
controller

Current sensor

Condition for error detection

Output when the current sensor offset compensation is detected at the time of the
material handling controller starting.

• To correct, replace the material handling controller.

 4-131

E1-2 Material handling controller over current abnormality

Related portion

P14

Material P15
handling Pump motor
controller P16

Condition for error detection

Output when the material handling controller over current is detected.

Even if it repeats the key switch with ON-OFF, No

• Pump motor cable check
does E1-2 error occur?
• Pump motor continuity check
Yes

• Material handling controller defect

4-132

E2-1 Pump motor overheat

Related portion

Pump motor
Material
handling
controller

Temperature sensor

Condition for error detection

Output when the temperature sensor value of pump motor exceeds the setting value.

If AD-5 occurs at the same time, perform troubleshooting for AD-5 first.
• To correct, allow the vehicle to stand for a while (about 30 minutes).
 4-133

E2-2 Pump motor thermo-sensor abnormality

Related portion

CN57 CN55
CN111-13 (89, TP+) 6 2
Material Pump motor
handling CN111-10 (87, TP-) 5 1 thermo-sensor
controller J19

Condition for error detection

Output when motor thermo-sensor output is outside the standard range (open or short
circuit) is detected.

If AD-5 occurs at the same time, perform troubleshooting for AD-5 first.

ANL : I/O MONITOR 1 I/O1-4 –50 °C or less

TP: Temperature check
195°C or more
Disconnect battery plug and disconnect CN55.

Disconnect battery plug, disconnect CN55, and

connect SST2 to the harness.
ANL : I/O MONITOR 1 I/O1-4
TP: Temperature check
195 °C or more –50 °C or less
ANL : I/O MONITOR 1 I/O1-4
TP: Temperature check
195 °C or more –50 °C or less
CN111-13 (89)
↔

Voltage measurement
•Thermo-sensor defect N1
Less than 1 V 1 V or more

•Harness defect • Material handling

controller defect
4-134

E3 Material handling controller main circuit thermo-sensor abnormality

Related portion

Material handling controller

Thermo-sensor

Condition for error detection

Output when the heat sink thermo-sensor in the driver is abnormal.

If AD-5 occurs at the same time, perform troubleshooting for AD-5 first.
• To correct, replace the material handling controller.
 4-135

E8 Pump motor speed sensor abnormality

Related portion

CN111-9 (84, SSP+) CN57-1 (84, SSP+)

CN111-11 (85, SSP1) CN57-2 (85, SSP1)

Material
handling CN111-12 (86, SSP2) CN57-3 (86, SSP2)
controller
CN111-10 (87, SSP–) CN57-4 (87, SSP–)

Pump motor
CN57
speed sensor

Condition for error detection

Output when the material handling controller detects abnormality of pump motor speed
sensor.
E8 Pump motor speed sensor defect

Disconnect battery plug, connect SST19 to

CN111, and connect CN1 and CN3 of SST19.

Connect battery plug, turn the key switch to ON, One of LEDs turns OFF.
and check the state of LED of SST at the time of • Check the CN1 and CN3 connection of SST.
lift operation.
2 LEDs ON 2 LEDs OFF

• Material handling controller defect

Disconnect battery plug, connect SST19 to
CN111, and connect CN2 and CN3 of SST19.

Connect battery plug, turn the key switch to ON, NG (Both 2 LEDs blink.)
and check the state of LED of SST at the time of • Material handling controller defect
lift operation.
Other than NG

Disconnect CN57, and check the voltage of

CN57 of harness side. NG (all 8 V ~ 13 V)
1 pin (+) ~ 4 pin (-) • Pump motor speed sensor defect
2 pin (+) ~ 4 pin (-)
3 pin (+) ~ 4 pin (-)
Other than NG

• Harness defect
4-136

SAS SYSTEM
WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
51-1 Drive motor speed sensor abnormality

Related portion

Main harness Sub-harness

CN151
CN103-5 (324, SSO+) CN142-4 (324, SSN+)
4
SCPU
CPU CN103-6 (325, SSO–) CN142-5 (325, SSN–) board
5
board

CN103-3 (147, CANGND)

Condition for error detection

Output if the speed detection line from the CPU board to the SCPU board is disconnected.
51-1 Speed sensor open-circuit defect

Disconnect battery plug, disconnect CN103 and No continuity (∞ Ω)

• Main harness defect
CN151.
CN103-5 (324) ~ CN151-4 (324)
CN103-6 (325) ~ CN151-5 (325)
Continuity (0 Ω)
Other than (1) 5 V
Connect CN103, connect battery plug, and check and (2) 0 V
• CPU board defect
the continuity.
(1) CN151-4 (324) ~ CN103-3 (147)
(2) CN151-5 (325) ~ CN103-3 (147)
(1) 5 V
(2) 0 V
Disconnect battery plug, disconnect CN142. No continuity (∞ Ω)
• Sub-harness defect
CN151-4 (324) ~ CN142-4 (324)
CN151-5 (325) ~ CN142-5 (325)
Continuity (0 Ω)
Other than (1) approx. 1
Connect CN142 and CN151, connect battery V and (2) 0 V
• CPU board defect
plug and turn the key switch to ON, and check the
or
voltage.
• SCPU board defect
(1) CN142-4 (324) ~ CN103-3 (147)
(2) CN142-5 (325) ~ CN103-3 (147)
(1) Approx. 1 V
(2) 0 V
• SCPU board defect
 4-137

52-1, 2, 3 Yaw rate sensor abnormality

Related portion

CN144-1 (321, SYR+)

SCPU CN144-3 (322, SYR) Yaw rate

board sensor
CN144-2 (323, SYR–)

Condition for error detection

Output if the yaw rate sensor output voltage is outside the standard range (open or short
circuit), or if the yaw rate sensor output voltage while the vehicle is stationary is outside
the standard range (neutral voltage).
52-1 Yaw rate sensor open-circuit defect
52-2 Yaw rate sensor short-circuit defect
52-3 Yaw rate sensor neutral voltage defect

• 52-1, 2
ANL. : I/O MONITOR 2
Measure the yaw rate sensor voltage. Less than 0.1 V
0.1 V or more
Check the CN144 connector
(visually). Abnormal
Normal
Does 52-1 remain? Yes • Repair or replace.
No (No indication) (Indicated)
• SCPU board defect
• Yaw rate sensor defect
• Disconnect and reconnect CN144 to make sure
that 52-1 is not indicated.

• 52-3
ANL. : I/O MONITOR 2
Measure the yaw rate sensor voltage while the Outside the standard range 2.2 V
vehicle is stationary. or less, or 2.8 V or more
Within the standard
Check the CN144 connector
range (2.2 ~ 2.8 V) Abnormal
(visually).
Normal
Does 52-3 remain? • Repair or replace.
Yes
No (No indication) (Indicated)
• SCPU board defect
• Yaw rate sensor defect
• Disconnect and reconnect CN144 to make sure
that 52-3 is not indicated.
4-138

54-1, 2 Swing lock solenoid abnormality

Related portion
Sub-harness Main harness
CN152 CN94
CN148-1
SCPU
DC/SD (327, SOLS+)
board 1 4
board
CN148-6 Swing lock
(328, SOLS–) solenoid
6 5
CN146 CN147

Condition for error detection

Output if the swing lock solenoid line from the DC/SD board to the swing lock solenoid is
open or shorted.
54-1 Swing lock solenoid open-circuit defect
54-2 Swing lock solenoid OCL defect

• 54-1
54-1 error is not
ACTIVE TEST: ACT-3 SSOL indicated.
The swing lock solenoid is set to ON by the active • Connector connection check
test.
54-1 error is indicated.

Disconnect battery plug.

Disconnect CN152. (main harness side)
CN152-1 (327) 5.5 ± 1 Ω
(at 25 °C)
↔

Resistance measurement
CN152-6 (328)
Other than 5.5 ± 1 Ω
(at 25 °C) ACTIVE TEST: ACT-3 SSOL
The SST5 and the CN146 ~ CN147 harness are
replaced , and the swing lock solenoid is set to ON by the
active test.
Check signal “1”. Check signal “0”.
(Normality) (Abnormality)
• Sub-harness defect
• DC/SD board defect
• SCPU board defect
• CN146 ~ CN147 harness
Disconnect battery plug.
Disconnect CN94. 5.5 ± 1 Ω (at 25 °C)
• Main harness defect
(Swing lock solenoid harness side)
CN94-4 (327)
Resistance measurement
↔

CN94-5 (328)
Other than 5.5 ± 1 Ω
(at 25 °C)
• Sub-harness defect
• Swing lock solenoid defect
 4-139

• 54-2

ACTIVE TEST: ACT-3 SSOL 54-2 error is not indicated.

The swing lock solenoid is set to ON by the active • Connector connection check
test.
54-2 error is indicated.

Disconnect battery plug.

Disconnect CN94.

ACTIVE TEST: ACT-3 SSOL

54-1 error is indicated.
The swing lock solenoid is set to ON by the active • Sub-harness defect
test. • Swing lock solenoid defect
54-2 error is indicated.

Disconnect battery plug.

Disconnect CN152. Continuity
CN152-1 (327) • Main Harness defect
↔

Continuity check
CN152-6 (328)
No continuity

ACTIVE TEST: ACT-3 SSOL

The SST-5 and the CN146 ~ CN147 harness are Check signal "0”. (Abnormality)
replaced, and the swing lock solenoid is set to
ON by the active test.

Check signal • SCPU board defect

“1”. (Normality)

• Sub-harness defect
• DC/SD board defect
• CN146 ~ CN147 harness defect
4-140

71-1,2 Tire angle sensor abnormality

Related portion

Sub-harness CN151 Main harness CN94

CN142-11 (316, POTH+)
11 1

SCPU CN142-3 (317, POTH) Tire angle

board 3 2
sensor

CN142-8 (320, SPOT–)

8 3

Condition for error detection

Output if the tire angle sensor output voltage is outside the standard range.
71-1 Tire angle sensor open-circuit defect
71-2 Tire angle sensor short-circuit defect

• 71-1
71-2 error is
Disconnect battery plug, disconnect CN94. indicated.
• Tire angle sensor defect
Connect SST2 between CN94-1 and
CN94-2(Main harness side).
Connect battery plug and turn the key switch to ON.
71-2 error is not indicated.

Disconnect battery plug.

Disconnect CN151. No continuity
• Main harness defect
(SST2 is the connection state.)
CN151-11(316)
Continuity check
↔

CN151-3(317)
Continuity

CN151-3(317)
Continuity check No continuity
• SCPU board defect
↔

CN151-8(320) • Sub-harness defect

Continuity

• Main harness defect

 4-141

• 71-2

Disconnect battery plug, disconnect CN94,

Change to 71-1 error.
connect battery plug, and turn the key switch to
ON.
71-2 error is indicated.
Disconnect battery plug.
Disconnect CN142.
Connect SST2 between CN94-2 and
Disconnect battery plug. CN94-3.
Disconnect CN151. (Main harness side)
CN151-11 (316) CN142-3 (317)
Continuity check
↔

Continuity check

↔
CN151-3 (317) CN142-8 (320)
Continuity No continuity Continuity No
continuity

• Main harness defect • SCPU board defect • Tire angle sensor defect • Harness defect
• Sub-harness defect
4-142

72-1, 2, 3, 4 Steering angle sensor abnormality

Related portion
Sub-harness CN150 Main harness CN19
CN141-17 (311, STS+)
17 1

Cn141-6 (312, STS1) 6 4

SCPU Steering an-
CN141-7 (313, STS2)
board 7 5 gle sensor
CN141-8 (314, STSC)
8 6

CN141-16 (315, STS–)

16 3

Condition for error detection

Output if the sensor line from the SCPU board to the steering angle sensor is open or
shorted.
72-1 Steering angle sensor STS1 defect
72-2 Steering angle sensor STS2 defect
72-3 Steering angle sensor STSC defect
72-4 Steering angle sensor open-circuit defect

• 72-1
Connect battery plug and turn the key switch to ON. 72-1 error is not indicated.
Turn the steering wheel.
72-1 error is indicated.
• Connector connection check

72-1 error disappears and

Disconnect battery plug, and connect SST7 to CN19. Connect 72-2 error is indicated.
battery plug and turn the key switch to ON.
Turn the steering wheel.
72-1 error is indicated. • Steering angle sensor defect

Check voltage value change upon turning the steering wheel.

CN141-6 (312) Not change
↔

Voltage measurement
CN141-16 (315)
• Main harness defect
Change
• Sub-harness defect

• SCPU board defect

 4-143

• 72-2
Connect battery plug and turn the key switch to ON. 72-2 error is not indicated.
Turn the steering wheel.
72-2 error is indicated.
• Connector connection check

72-2 error disappears and

Disconnect battery plug, and connect SST7 to CN19. Connect 72-1 error is indicated.
battery plug and turn the key switch to ON. Turn the steering
wheel.
• Steering angle sensor defect
72-2 error is indicated.

Check voltage value change upon turning the steering wheel.

CN141-7 (313) Not change
↔

Voltage measurement
CN141-16 (315)
• Main harness defect
Change • Sub-harness defect

• SCPU board defect

• 72-3
Connect battery plug and turn the key switch to ON. 72-3 error is not indicated.
Turn the steering wheel.
72-3 error is indicated.
• Connector connection check

Disconnect battery plug, and connect SST7 to CN19. Connect

battery plug and turn the key switch to ON.

ANL. : I/O MONITOR 4-1 STS : (STS1) (STS2) (STSC) ON (“1” indication)
Check the steering angle indication (STSC).
OFF (“0” indication)
• Steering angle sensor defect

Disconnect battery plug and disconnect CN150.

CN150-8 (314) Approx. 5 V
↔

Voltage measurement
CN150-16 (315)
• Main harness defect
Approx. 0 V

• SCPU board defect

• Sub-harness defect
4-144

• 72-4
Connect battery plug and turn the key switch to ON. 72-4 error is not indicated.
Turn the steering wheel.
72-4 error is indicated.
• Connector connection check

Disconnect battery plug , and connect SST7 to CN19. Connect

battery plug and turn the key switch to ON.

CN19-1 (311) [SST7 : CN A-3]

↔

Voltage measurement Approx. 0 V

CN19-3 (315) [SST7 : CN A-1]
Approx. 15 V
Disconnect battery plug and disconnect CN150.
(Controlle side connector)
Approx. 15 V CN150-17 (311)

↔
Voltage measurement
CN150-16 (315)
• Main harness defect Approx. 0 V

• SCPU board defect

• Sub-harness defect
Check voltage value change upon turning the steering wheel.
Not change
STS1 : CN B-8 (312) ~ CN A-1(315)
STS2 : CN B-7 (313) ~ CN A-1(315)
STSC : CN B-4 (314) ~ CN A-1(315) • Steering angle sensor defect
Change

Check voltage value change upon turning the steering wheel.

Not change
(SCPU board side)
CN141-6 (312) ~ CN141-16 (315)
CN141-7 (313) ~ CN141-16 (315) • Main harness defect
Change • Sub-harness defect

• SCPU board defect

 4-145

73-1, 2 Steering knob position correcting solenoid abnormality

Related portion

Sub-harness Main harness

CN152 CN98
SCPU DC/SD CN148-2 Steering
board board 2 1 knob
(329, SOLST+)
position
CN148-5 correcting
5 2
(330, SOLST-) solenoid
CN146 CN147

Condition for error detection

Output if the steering knob position correcting solenoid line from the SCPU board to the steering
knob position correcting solenoid is open or shorted.
73-1 Steering knob position correcting solenoid open-circuit defect
73-2 Steering knob position correcting solenoid OCL defect

• 73-1

ACTIVE TEST : ACT-4 KSOL 73-1 error is not indicated.

The steering knob position correcting solenoid is set to ON by • Connector connection check
the active test .
73-1 error is indicated.

Disconnect battery plug.

Disconnect CN152.
10 ± 1 Ω
CN152-2 (329) (at 25°C)
↔

Resistance measurement
CN152-5 (330)
Other than 10 ± 1 Ω ACTIVE TEST : ACT-4 KSOL
(at 25°C) The SST5 and the CN146 ~ CN147 harness are
Check signal “1”. replaced, and the steering knob position correcting
(Normality) solenoid is set to ON by the active test.
Check signal “0”.
• Sub-harness defect (Abnormality)
• DC/SD board defect
• CN146 ~ CN147 harness defect • SCPU board defect

Disconnect battery plug.

Disconnect CN98. 10 ± 1 Ω (at 25°C)
CN98-1 (329) • Main harness defect
↔

Resistance measurement
CN98-2 (330)
Other than 10 ± 1 Ω
(at 25°C)

• Sub-harness defect
• Steering knob position correcting solenoid defect
4-146

• 73-2
73-2 error is
ACTIVE TEST : ACT-4 KSOL not indicated.
The steering knob position correcting solenoid is set to ON by • Connector connection check
the active test.
73-2 error is indicated.

Disconnect battery plug.

Disconnect CN98.

73-1 error is
ACTIVE TEST : ACT-4 KSOL not indicated.
The steering knob position correcting solenoid is set to ON by • Sub-harness defect
the active test. • Steering knob position correcting solenoid
73-2 error is indicated. defect

Disconnect battery plug.

Disconnect CN152. Continuity
CN152-2 (329) • Main harness defect
↔

Continuity check
CN152-5 (330)
No continuity

ACTIVE TEST : ACT-4 KSOL

The SST5 and the CN146 ~ CN147 harness are replaced, and
the steering knob position correcting solenoid is set to ON by Check signal “0”.
the active test. (Abnormality)

Check signal “1”.

(Normality) • SCPU board defect

• Sub-harness defect
• DC/SD board defect
• CN146 ~ CN147 harness defect
 4-147

74-1 Tire angle matching value abnormality

Related portion

• SCPU board

Condition for error detection

Output if the tire angle matching value is outside the standard range.
74-1 Tire angle matching value abnormality

• 74-1
• SCPU board defect
4-148

AF-5, 6, 7, 8 SCPU board abnormality

Related portion

SCPU board

CPU

Condition for error detection

Output when the abnormality of CPU operation is detected.
AF-5, 6, 7, 8 SCPU board abnormality

• AF-5, 6, 7, 8
• SCPU board defect
 4-149

EF-5, 6 EEP-ROM abnormality

Related portion

SCPU board

EEP-ROM

Condition for error detection

Output when abnormality of the EEP-ROM is detected.
EF-5, 6 SCPU board abnormality

• EF-5, 6
• SCPU board defect
4-150

FE-4, 5 Main controller → SAS controller communication abnormality

Related portion

Main harness Sub-harness

CN150
CN101-14 (307, SMTSA) CN141-4 (307, SMTSA)
4
CPU SCPU
board board
CN101-15 (308, SMTSK) CN141-12 (308, SMTSK)
12

Condition for error detection

Output upon no communication within the specified time period or frequent error
detection in the received data.
FE-4 Communication defect
FE-5 Communication data defect

• FE-4, 5

Disconnect battery plug, disconnect CN101 and

CN141. No continuity
• Main harness defect
CN101-14 (307) ~ CN141-4 (307)
CN101-15 (308) ~ CN141-12 (308)
Continuity

• CPU board defect

or
• SCPU board defect
 4-151

F0 PS main circuit abnormality

Related portion

CN145-1 CN51 CN49

(340, TMPSG)
CN149 2 2
CN145-2 Main
(P24, SH+) controller
4 4
SCPU CN50
board
CN145-3 (N1, SH–)
1 1 1
PS
PS main motor
circuit 3 3 2

Condition for error detection

Output when short-circuit of PS main circuit transistor is detected.
F0 PS main circuit defect.

Disconnect battery plug, disconnect CN49 and turn the key F0 error is not indicated.
switch to ON.
F0 error is indicated.

NG Check the connection of CN149.

OK

• Reconnects
TMPS defect

Disconnect battery plug, connect CN149 and turn the

key switch to ON.
OK (0.5 ~ 4 V) CN149-1 (340)
Voltage measurement
↔

SH (shunt) - Level side

• SCPU board is normal. NG (Other than 0.5 ~ 4 V)

• SCPU board defect

Turn the key switch to OFF, and disconnect
battery plug. No continuity (∞ Ω)
CN145-2 (P24)
↔

Continuity check
CN145-3 (N1)
Continuity (0 Ω) • Harness defect
or
• Shunt resistance defect
• SCPU board defect
4-152

MULTI-DISPLAY COMMUNICATION SYSTEM

WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
F1-1, 2 Main controller → Multi display communication abnormality

Related portion

CN103-16 (141, SMTDA) 3 CN70-22 (141, SMTDA)

CPU Multi
board display
CN103-13 (144, SMTDK) 7 CN70-23 (144, SMTDK)

Condition for error detection

Output when abnormality of communication data from the CPU board is detected.
F1-1,2 : Main controller → Multi display communication abnormality

Other error codes, if any, cannot be displayed because communication from the CPU board is disabled
when F1-1 occurs. F1-1 remains on the multi-display screen regardless of key switch ON or OFF.

CN103, CN70 and CN1 connection condition NG

• Correct the defect.
check
OK

Disconnect battery plug, disconnect CN103 and

CN70. No continuity
• Harness defect
CN103-16 (141) ~ CN70-22 (141) (Between CN103 and CN70)
CN103-13 (144) ~ CN70-23 (144)
Continuity

• CPU board defect

• Multi-display defect
 4-153

WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED

Multi-display is not displayed.

Related portion

CPU CN1
Multi-
board
CN103-10 (16, D15V) 2 display
CN70-14 (16, D15V)

CN103-12 (14, GNDD) 1 CN70-30 (14, GNDD)

Condition for error detection

The power supply is not supplied to the multi-display.
Multi-display defect

NO
Run and cargo work operation can be performed. See page 4-151. (Vehicle does not move.)
YES

Disconnect battery plug, disconnect CN1, and Disconnect battery plug, disconnect CN1
connect battery plug. and CN103.
NG (0 V)
CN1-2 (16) 1. Continuity check
↔

Voltage measurement CN1-2 (16) ~ CN103-10

CN1-1 (14) CN1-1 (14) ~ CN103-12
OK (Approx. 15 V) 2. Short-circuit check
CN1-2 (16) ~ CN1-1 (14)
OK 1. Approx. 0 Ω OK 1. ∞ Ω
Disconnect battery plug, connect CN1, 2. ∞ Ω 2. Approx.
disconnect CN70, and connect battery plug. 0Ω
CN70-14 (16)
• CPU board defect • Harness defect
↔

Voltage measurement
CN70-30 (14) (Between CN1 and
CN103)
OK (Approx. 15 V) NG (0 V)

• Multi-display defect • Harness defect

(Between CN1 and CN70)
4-154

Vehicle does not move.

Related portion

F6
P1 P2 CN104-14, 15 (44, VBMB)

F7 CN104-1, 2 (18, B80V)

CPU
board
P0 F5 CN103-4 (43, VBKY)

CN103-7 (41, VBBT)

N2 CN104-22 (N2, N2)

P1 (+)
Less than 25 V
• Battery charge
↔

Voltage measurement
N1 (-)
25 V or more

NG (∞ Ω)
Check the F7 fuse • F7 fuse exchange
OK (0 Ω)

Check the voltage between 1pin and 22pin of

CN104. Less than 25 V
1pin (+) • Harness check
↔

Voltage measurement
22pin (-)
25 V or more OK
(Voltage of (2) is 15 V or
more, and voltage
difference of (1) and (2) is
Check the voltage with the key switch ON. less than 13 V.)
(1) CN103-4 pin (+) ~ CN104-22 pin (-) • CPU board defect
(2) CN103-7 pin (+) ~ CN104-23 pin (-)
Other than OK
NG
Check the F5 fuse. • F5 fuse exchange
OK
NG
Check the key switch. • Key switch exchange
OK

P0 (+) Other than approx. 48 V

• Battery plug or battery check
↔

Voltage measurement
N1 (-)
Approx. 48 V

• Harness check
 4-155

Only a run is impossible.

Related portion
CN9
CN101-1 (45, DSF) 5
CN101-2 (46, DSR) 4 Direction
switch
CN101-16 (51, LS–) 1
J1

CN26
CN102-1 (64, SWAC)
CPU
board CN102-2 (52, POTA)
Accelerator
CN102-14 (53, POTA+) potentiometer
CN102-22 (51, POT–)
J2
CN142
CN101-5 (67, LSD) 7
8 Seat switch
J1

Yes
Has beep sound come out? • Accelerator OFF, direction OFF, and
No parking OFF (It returns.)

ANL. : I/O MONITOR 2 I/O2-1 Both have no change.

Check the accelerator switch SWAC and POTA • Accelerator check
value when an accelerator is stepped on.
Both are changeful.

ANL. ; I/O MONITOR 2 I/O2-2 No change

DSF and DSR value check when direction • Direction check
operation of is done.
Changes.

ANL. ; I/O MONITOR 2 I/O2-3 Display “0”

• Seat switch check
LSD value check when sitting on a seat.
Display “1”

Voltage measures with direction ON and

accelerator ON.*1 Other than OK
P7 (+) ~ N1 (-) • Traveling controller defect
P8 (+) ~ N1 (-) *1: When it cannot measure, even if it does
P9 (+) ~ N1 (-) not sit on the seat, it can measure by
OK disconnecting CN43 and connecting
All approx. 40 V (approx. 36 V) The SST8.
inside of ( ) is 72 V battery.
Yes
Does it run slowly? Motor cable check
No OK NG
• C8-1 troubleshooting • Cable repair
No implementation
Is there sound from the motor? • Motor cable and motor check
Yes 40 ~ 50 model
16 ~ 35 model
Rotates.
Does a turn of the handle rotate PS motor? • Machine part check of brake, piping, gear,
Does not rotate. etc.

• Troubleshooting implementation in case

PS motor does not rotate.
4-156

Only material handling operation cannot be performed.

Lift operation cannot be carried out only when a Yes ANL. I/O MONITOR 3
certain specific lever is operated. The value check when operating the lever
No which cannot carry out material handling
operation.
Value change With no value
Display “1” change
Voltage measures by Lift ON. • Lever potentiometer check
P14 (+) ~ N1 (-)
P15 (+) ~ N1 (-) ANL. I/O MONITOR 3
P16 (+) ~ N1 (-) The current value of the proportionality
Other than OK OK valve which cannot carry out material
All approx. 40 V (approx. 36 V) handling operation is checked.
• Material handling controller The inside of ( ) is 72 V battery. Less than Approx. 0.5 A
defect approx. 0.5 A or more
Motor cable check
• Control valve check
NG OK
The solenoid resistance of the
• Cable repair proportionality valve which cannot carry
out material handling operation is
checked.
Other than Approx. 7 Ω
approx. 7 Ω
• Solenoid check • Harness check

40 ~ 50 model Check the solenoid resistance of unload

valve.
Approx. 10 Ω Other than
approx. 10 Ω
• Solenoid check
16 ~ 35 model
The harness connected to CN89 is
checked.
OK NG

• Harness defect
• E8 troubleshooting implementation
 4-157

PS motor does not rotate (16 ~ 35 model).

Related portion
CN51 CN49

CN145-1 2 2
(340, TMPSG) Contactor
CN149 panel
SCPU 4 4
CN145-2 (P24, SH+) CN50
board
1 1 1
CN145-3 (N1, SH–) PS
motor
PS main
3 3 2
circuit

F3 fuse check NG • F3 fuse exchange

OK

Voltage measurement when turning the handle

Other than 0 V
CN50-1 pin • PS motor check
↔

Voltage measurement
CN50-2 pin
0V

Open-circuit
Shunt resistance value check • Shunt resistance defect
Short-circuit

NG • TMPS defect
TMPS check
OK

• SCPU board defect

 5-1

MOTOR
Page
DRIVE MOTOR .................................................................5-2
0
GENERAL..........................................................................5-2
1
SPECIFICATIONS .............................................................5-2
COMPONENTS..................................................................5-3 2
REMOVAL • INSTALLATION..............................................5-4 3
DISASSEMBLY • INSPECTION • REASSEMBLY................5-6 4
PUMP MOTOR ..................................................................5-9
5
GENERAL..........................................................................5-9
6
SPECIFICATIONS ...........................................................5-10
COMPONENTS................................................................5-10 7
REMOVAL • INSTALLATION............................................5-12 8
DISASSEMBLY • INSPECTION • REASSEMBLY..............5-14 9
POWER STEERING MOTOR (16 ~ 35 MODEL) ....5-17
10
GENERAL........................................................................5-17
SPECIFICATIONS ...........................................................5-17
11
COMPONENTS................................................................5-18 12
REMOVAL • INSTALLATION............................................5-19 13
DISASSEMBLY • INSPECTION • REASSEMBLY..............5-21
14
Motorlager, lista över P/N.....................................5-25 15
16
17
18
19
20
21
22
5-2

DRIVE MOTOR
GENERAL

SPECIFICATIONS
Model
16⋅18 20 ~ 35 40 ~ 50
Item
Type 3-phase AC ← ←
Nominal voltage V 72/80 ← ←
Rated output kW 12.0/13.3 15.4/17.1 14.9/16.6
Dimensions mm(in) φ270 × 260 φ270 × 285 φ270 × 340
(outside diameter × length) (10.63 × 10.24) (10.63 × 11.22) (10.63 × 13.39)
Weight kg (lb) 62 (137) 73 (161) 96 (212)
Insulation class Class F ← ←
 5-3

COMPONENTS
1401

0
1
2
3
4
5
6
7
8
FJ [NO.1]
9
10
11
12
13
FJ [NO.2]
14
15
16
17
18
19
20
21
22
5-4

REMOVAL • INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

2 6

T = 45.0 ~ 55.0 (460 ~ 560)

[33.3 ~ 40.5]

Removal Procedure
1 Remove the drive unit & drive motor W/front axle ASSY. (See page 6-6.)
2 Remove the drive motor sensor bracket, terminal bracket, and sensor cover.
3 Place match marks between the end bracket, stator ASSY, and gear case.
4 Remove the nuts and through bolts. [Point 1]
5 Remove the end bracket. [Point 2]
6 Remove the stator ASSY W/rotor ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply MP grease to the rotor ASSY spline.
 5-5

Point Operations
[Point 1]

Removal:
After removing the through bolts, use a hoist to lift the yoke
ASSY.

0
1
Installation:
2
4
2
After tightening the through bolts until they touch bottom,
tighten the nuts in the order shown in the figure.
3

1
4
5
3

6
7
Installation:
When replacing the motor with a new one, be sure to re-
move the stopper bolt and spacer installed in the center of
Spacer
the end bracket. (They are not installed hereafter.) 8
Stopper bolt
9
10
11
[Point 2]
12
Removal:
Use a plastic hammer to tap lightly on the end bracket to 13
remove it.
14
Installation:
Use a plastic hammer to tap lightly on the end bracket to 15
install it.
16
Installation: 17
Wave Align the speed sensor harness with the notch in the end
washer bracket and install the end bracket.
When doing this, do not forget to install the wave washer.
18
19
20
21
22
5-6

DISASSEMBLY • INSPECTION • REASSEMBLY

Note:
• Do not apply a shock to the bearing W/speed sensor.

OBS! Lager finns som separat reservdel. P/N på sensorlagret:

7FBMF 16-35 = 14160-F9802-71

7FBMF 40-50 = 14160-F9801-71

1
2

Disassembly Procedure
1 Remove the rotor ASSY W/bearing. [Point 1]
2 Remove the bearing. [Point 2]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 5-7

Point Operations
[Point 1]

Inspection:
Measure the stator ASSY insulation resistance.
Measurement locations: Between the stator and each ter-
minal (U, V, W)

Standard: 1 MΩ or more

Inspection:
Measure the speed sensor insulation resistance.
Measurement locations: Between the stator and the speed
sensor connector terminals (4 locations)

Standard: ∞ Ω

Inspection:
Measure the temperature sensor insulation resistance.
Measurement locations: Between the stator and the tem-
perature sensor connector terminals (2 locations).

Standard: ∞ Ω

Measurement locations: Between the temperature sensor

connector terminals

Standard: 0.5 ~ 1.0 kΩ

[Point 2]

Disassembly:
SST SST 09950-76014-71
(SST 09950-40011)
5-8

L/speed sensor Reassembly:

Use the following procedure to install the bearing.

1. Install the bearing (L/speed sensor).

SST 09370-20270-71
SST

W/speed sensor 2. Install the bearing (W/speed sensor).

Tapping on the bearing could damage the sensor. Use
a press to install the bearing.
SST SST 09411-41800-71
 5-9

PUMP MOTOR
GENERAL
16 ~ 35 model

40 ~ 50 model
5-10

SPECIFICATIONS
Model
16⋅18 20 ~ 35 40 ~ 50
Item
Type 3-phase ← ←
Nominal voltage V 72/80 ← ←
Rated output kW 12.0/13.5 16.9/18.6 22.8/25.4
Dimensions mm (in) φ240 × 324 φ240 × 339 φ260 × 427
(outside diameter × length) (9.45 × 12.76) (9.45 × 13.35) (10.24 × 16.81)
Weight kg (lb) 57 (126) 60 (132) 97 (214)
Insulation class Class F ← ←

COMPONENTS
16 ~ 35 model 1402
 5-11

40 ~ 50 model 1402
5-12

REMOVAL • INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
16 ~ 35 model

T = 16.2 ~ 37.8
8 T = 39.0 ~ 91.0 (165 ~ 385)
8
(398 ~ 928) [11.9 ~ 27.9]
[28.8 ~ 67.1]

40 ~ 50 model

T = 16.2 ~ 37.8
8 T = 39.0 ~ 91.0 8 (165 ~ 385)
(398 ~ 928) [11.9 ~ 27.9]
[28.8 ~ 67.1]
 5-13

Removal Procedure
1 Remove the battery. (See page 13-10.)
2 Remove the counterweight. (See page 11-10.)
3 Remove the motor cable.
4 Disconnect the speed sensor and temperature sensor connectors.
5 Remove the oil pump set bolts and separate the oil pump from the pump motor.
6 Disconnect the swing lock solenoid connector.
7 Remove the lock cylinder cover.
8 Remove the lock cylinder lower pin and slide the swing lock cylinder to the left. [Point 1]
9 Remove the pump motor. [Point 2]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply lock agent (08833-76001-71 (08833-00070)) to the threads of the lock cylinder lower pin set
bolt and tighten the bolt.

Point Operations
[Point 1]

Removal Installation:
•

Jack up the rear axle and support the frame on wooden

blocks.

[Point 2] (40 ~ 50 model)

Removal Installation:
•

To prevent the right rear insulator bolt from being dam-

aged, connect shackles to the two left side wire ropes, and
then tilt and raise up the pump motor.

Installation:
Apply lock agent (08833-76002-71 (08833-00080)) to the
threads of the right rear insulator bolts and tighten the
Apply lock bolts.
agent here
5-14

DISASSEMBLY • INSPECTION • REASSEMBLY

Note:
• Do not apply a shock to the bearing W/speed sensor.
• The minimum unit of the parts supply for the bearing consists of “Rotor ASSY W/bearing” even
though the bearing is seperable on actual service.
T = N·m (kgf·cm) [ft·lbf]

16 ~ 35 model: 40 ~ 50 model:
T = 22.5 ~ 27.5 (229 ~ 280) T = 45 ~ 55 (459 ~ 561)
[16.6 ~ 20.3] [33.2 ~ 40.6]

Disassembly Procedure
1 Remove the end bracket (terminal side). [Point 1]
2 Remove the rotor ASSY W/bearing. [Point 2]
3 Remove the bearing. [Point 3]
4 Remove the stator ASSY. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 5-15

Match marks Point Operations

[Point 1]

Disassembly:
Put match marks between the end bracket, stator ASSY,
and end bracket (terminal side).

Reassembly:
Align the match marks when installing.

Reassembly:
Align the speed sensor harness with the slot in the end
bracket (terminal side) and install the end bracket.

[Point 2]

Inspection:
Measure the speed sensor insulation resistance.
Measurement locations: Between the stator and the speed
sensor connector terminals (4 locations).

Standard: ∞ Ω

[Point 3]
SST (1)
Disassembly:
SST 09950-76014-71 ............(1)
(SST 09950-40011)
SST 09950-76018-71 ............(2)
(SST 09950-60010)
SST (2)

L/speed sensor Reassembly:

SST Use the following procedure to install the bearing.

1. Install the bearing (L/speed sensor).

SST 09370-20270-71
5-16

W/speed sensor 2. Install the bearing (W/speed sensor).

Tapping on the bearing could damage the sensor. Use
a press to install the bearing.
SST SST 09411-41800-71

[Point 4]

Inspection:
Measure the stator ASSY insulation resistance.
Measurement locations: Between the stator and each ter-
minal (U, V, W)

Standard: 1 MΩ or more

Inspection:
Measure the temperature sensor insulation resistance.
Measurement locations: Between the stator and the tem-
perature sensor connector terminals (2 locations)

Standard: ∞ Ω

Measurement locations: Between the temperature sensor

connector terminals

Standard: 0.5 ~ 1.0 kΩ

Installation:
Do not forget to install the wave washer in the end bracket.

Wave washer
 5-17

POWER STEERING MOTOR (16 ~ 35 MODEL)

GENERAL

SPECIFICATIONS
Model
16 ~ 35
Item
Type DC permanent magnet type enclosed motor
Nominal voltage V 70
Rated output kW 1.0
Dimensions (outside diameter × length) mm φ114 × 268
(in) (4.49 × 10.55)
Insulation class F
Brush size (thickness × width × length) mm 8 × 20 × 25
(in) (0.31 × 0.79 × 0.98)
Number of brushes 4
Weight kg (lb) 10.6 (23.4)
5-18

COMPONENTS
1403
 5-19

REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

7 5

T = 20 ~ 30 (200 ~ 300)
[14.7 ~ 21.7]

Removal Procedure
1 Open the seat stand and disconnect the battery plug.
2 Remove the front toe board.
3 Disconnect the PS motor connector.
4 Disconnect the piping.
5 Remove the fitting. (outlet)
6 Remove the PS motor ASSY W/PS pump ASSY.
7 Remove the PS pump ASSY from the PS motor ASSY. [Point1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 5-20

Pump set bolt Point Operations

[Point 1]
Removal:
PS pump set bolts are located as shown in the figure.

Pump set bolt

Oldham’s joint
Installation:
When assembling the PS motor and pump, fill molybde-
num disulfide grease in the groove on the oldham’s joint.
PS motor

Apply Molybdenum disulfide

grease to fill the groove.
 5-21

DISASSEMBLY • INSPECTION • REASSEMBLY

3 5

1
5
3

5
5

Disassembly Procedure
1 Remove the cover connector ASSY. [Point1]
2 Remove the brushes.
3 Remove the commutator frame ASSY W/brush holder ASSY. [Point2]
4 Remove the brush holder ASSY from the commutator frame ASSY.
5 Remove the harness, brush spring and brushes from the brush holder. [Point3]
6 Remove the No.2 bracket.
7 Remove the armature ASSY from the yoke ASSY. [Point4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Check the insulation between the motor connector terminal and the motor body after reassembly.
Standard: 1MΩ or more (with a DC 500 V megohmmeter)
5-22

Match marks Point Operations

[Point 1]

Disassembly:
Apply match marks between the commutator frame ASSY,
yoke ASSY, and No.2 bracket.

Reassembly:
Align the match marks and assemble.

Inspection:
Measure the insulation resistance between the connector
terminal and the motor body.

Standard: 1 MΩ or more

[Point 2]

SST
Disassembly:
SST 09950-76014-71
(SST 09950-40011)

Inspection:
Reassemble the armature coil and commutator frame
ASSY W/brush holder ASSY. Hook a spring balance to the
brush spring. Measure the reading on the instant when the
spring comes off from the brush.

Spring force
Standard: 4.7 N (0.48 kgf) [1.26 lbf]
Limit: 4.3 N (0.43 kgf) [0.95 lbf]

Inspection:
Measure the insulation resistance between the brush hold-
er ASSY and commutator frame ASSY.

Standard: 1 MΩ or more
 5-23

[Point 3]
Inspection:
Inspect the brush for wear and contact state.

Brush length
Standard : 25 mm (0.98 in)
Limit : 15 mm (0.59 in)

[Point 4]
Disassembly:
1. Remove the bearings.
SST
SST 09950-76014-71
(SST 09950-40011)

Commutator frame ASSY side 2. Install the bearings.

SST 09950-76018-71......(1)
SST (2) (SST 09950-60010)
SST 09950-76020-71......(2)
(SST 09950-70010)
SST (1)

No.2 bracket side SST 09700-30200-71

Inspection:
If the commutator surface is roughened, correct it with
sandpaper (#600 or similar) and clean it well.
If the surface is excessively rough, repair with a lathe.

Commutator outside diameter

Standard: 50 mm (1.97 in)
Limit: 45 mm (1.77 in)
5-24

Inspection:
When the commutator is repaired, undercut the mica.

Undercut
Undercut depth
Standard: 0.8 mm (0.031 in)
Limit: 0.3 mm (0.012 in)

Mica

Inspection:
Measure the commutator runout.

Standard: 0.03 mm (0.0012 in) or less

Inspection:
Measure the insulation resistance of the armature coil.

Standard: 1 MΩ or more
 TOYOTA INDUSTRIAL EQUIPMENT 5-25

SERVICE Internal Use Only

INFORMATION
REF . NO. TIEE –SI0401 DATE : 19/01/04

TITLE: 7FBMF motor bearings part number list

1°) Applicable models:

7FBMF Range

2 °) Content:

Find the availability of the 7FBMF bearings as spare parts

Motor PN Motor Range Std bearings Bearing Rpm sensor

14110-F1132-71 Drive 1t 14160-F9803-71 14160-F9801-71

14120-F1131-71 Drive 1t 14160-F9803-71 14160-F9801-71
14110-F2132-71 Drive 2-3t 14160-F9803-71 14160-F9801-71
14120-F2131-71 Drive 2-3t 14160-F9803-71 14160-F9801-71
14110-F3072-71 Drive 4-5t 14160-F9803-71 14160-F9801-71
14310-F1130-71 Pump 1t 14160-F9804-71 14160-F9802-71
14310-F2130-71 Pump 2-3t 14160-F9804-71 14160-F9802-71
14310-F3070-71 Pump 4-5t 14160-F9805-71 14160-F9801-71
04145-F1010-71 (kit
14150-F1090-71 Steering pump 1-3,5
2 x bearings)

A] DRIVE MOTOR

Bearing Rpm sensor

16-50: 14160-F9801-71

Bearing
16-50: 14160-F9803-71

TOYOTA INDUSTRIAL EQUIPMENT EUROPE

If you have any questions about this issue, Technical Department
please contact the tehnical department.
 TOYOTA INDUSTRIAL EQUIPMENT
5-26
SERVICE
INFORMATION
B] PUMP MOTOR

Bearing Rpm sensor

16-35: 14160-F9802-71
40-50: 14160-F9801-71

Bearing
16-35: 14160-F9804-71
40-50 : 14160-F9805-71

C] STEERING MOTOR

Bearing kit (2 bearings+washer)

16-35 : 04145-F1010-71

TOYOTA INDUSTRIAL EQUIPMENT EUROPE

If you have any questions about this issue, Technical Department
please contact the tehnical department.
 6-1

DRIVE UNIT
Page
GENERAL ..........................................................................6-2
0
SPECIFICATIONS ............................................................6-3
1
COMPONENTS .................................................................6-4
2
DRIVE UNIT ASSEMBLY ...............................................6-6
REMOVAL • INSTALLATION..............................................6-6 3
DISASSEMBLY • INSPECTION • REASSEMBLY..............6-12 4
DIFFERENTIAL CASE ASSEMBLY ..........................6-15 5
DISASSEMBLY • INSPECTION • REASSEMBLY..............6-15
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
6-2

GENERAL
16·18 model

20 ~ 35 model
 6-3

40 ~ 50 model

0
1
2
3
4
5
6
7
8
9
SPECIFICATIONS
Model 10
16 18
•
20 25
•
30 35
•
40 ~ 50
Item
Drive unit gear No.1 number of teeth 11
16 15 ← 15
(Motor shaft gear)
Drive unit gear No.2 number of teeth Large: 89 Large: 96 Large: 88 12
←
(Idle gear) Small: 11 Small: 11 Small: 19
Drive unit gear No.3 number of teeth 13
54 60 ← 51
(Differential gear)
Total reduction ratio 27.307 34.909 ← 15.747*
14
Drive unit oil level (US gal) 5.9 (1.56) ← 6.5 (1.72) 11 (2.90) 15
*: Excluding wheel reduction
16
17
18
19
20
21
22
6-4

COMPONENTS
16 ~ 35 model 3305

40 ~ 50 model
 6-5

16·18 model, 40 ~ 50 model 4101

0
1
2
3
4
5
6
7
8
20 ~ 35 model 9
10
11
12
13
14
15
16
17
18
19
20
21
22
6-6

DRIVE UNIT ASSEMBLY

REMOVAL • INSTALLATION
T = N·m (kgf·cm) [ft·lbf]
16 ~ 35 model

11

T = 185 ~ 344
(1900 ~ 3500)
[137.5 ~ 253.2]

16 15

18 17
19
21

T = 51.0 ~ 64.7
(520 ~ 660)
19 [37.6 ~ 47.8]

T = 45.0 ~ 55.0 (460 ~ 560)

[33.3 ~ 40.5]

13
20
14

13
T = 108 ~ 137
(1100 ~ 1400)
[79.5 ~ 101.3]
14

T = 108 ~ 137
(1100 ~ 1400)
[79.5 ~ 101.3]
 6-7

T = N·m (kgf·cm) [ft·lbf]

40 ~ 50 model

11

T = 235 ~ 294 (2400 ~ 3000)

[173.6~217.1]

16 15

21 18 17
19

19 T = 51.0 ~ 64.7 (520 ~ 660)

[37.6 ~ 47.8]

T = 45.0~55.0 (460~560)
[33.3~40.5]

20

14

13 13

14 13

T = 221 ~ 323 (2250 ~ 3300)

13 [162.8~238.8]
6-8

Removal Procedure
1 Remove the mast ASSY. (See page 13-10.)
2 Open the seat stand and disconnect the battery plug.
3 Drain the drive unit oil. [Point 1]
4 Jack up the vehicle and remove the front wheels. [Point 2]
5 Remove the front toe board.
6 Remove the lower panel. (40 ~ 50 model)
7 Disconnect the drive motor wiring.
8 Disconnect the speed sensor connector and temperature sensor connector.
9 Disconnect the front brake piping.
10 Disconnect the parking brake piping.
11 Remove the drive unit & front axle ASSY. [Point 3]
12 Support the drive unit & front axle ASSY with wooden blocks or other suitable objects.
13 Remove the front axle ASSY with front axle bracket and the O-ring. [Point 4]
14 Remove the front axle shaft (inner).
15 Remove the parking brake cover. [Point 5]
16 Remove the gasket, cone spring washer, and washer. [Point 6]
17 Remove the parking brake piston with parking brake housing.
18 Remove the brake disc, plate, and gasket.
19 Remove the drive motor sensor bracket and terminal bracket.
20 Remove the drive motor set nut and through bolt. [Point 7]
21 Remove the drive motor ASSY. [Point 8]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Apply MP grease to the drive motor ASSY splines.
• After installation, bleed air from the brake. (See page 10-25.)

Point Operations
[Point 1]
Removal:
Remove the drain plugs on the bottom of the drive unit gear
case and the bottom of the front axle ASSY, then drain the
oil.
Installation:
A A
Install the drain plug “A” with sealing compound (08826-
76002-71 (08826-00090)) or the seal tape for the reinstal-
lation. (The renewal of the plug needs no sealing agent.)
 6-9

Installation:
After installation, fill with the specified oil to the prescribed
level.

B = Within 15 mm (0.59 in)

[Point 2]
Removal:
Jack up the vehicle and then support the frame on both
sides with wooden blocks.

[Point 3]
Removal:
Perform the following procedure.
1. Use a hoist and garage jack to support the drive unit &
front axle ASSY.

2. Remove the front axel bracket set bolts (for joining the
RH LH
frame). Use an SST to remove the reamer bolt shown
in the figure.
16⋅18 model

20⋅25 model

30⋅35 model

40 ~ 50
model
6-10

SST 09310-23320-71

3. Operate the hoist and garage jack to remove the drive

SST unit and drive motor with front axle bracket with front
axle ASSY.

40 ~ 50 model Reamer bolts [Point 4]

Installation:
40 ~ 50 model
Install the reamer bolts in the positions shown in the figure.
Installation:
40 ~ 50 model
Apply lock agent (08833-76001-71 (08833-00070)) to the
set nut threads and tighten the nut.
Installation:
LH RH
Reamer bolts Apply MP grease to the O-ring and then install the O-ring.

[Point 5]
Removal Installation:
•

Uniformly loosen (tighten) the parking break cover set bolts

in order in opposing pairs. Otherwise the bolt deformation
by the inclined cover should occur.

[Point 6]
Installation:
Make sure the cone spring washer is oriented correctly and
then install it.

4 [Point 7]
2 Installation:
After tightening the through bolts until they contact the bot-
tom, tighten the nuts in the order shown in the figure.

1
3
 6-11

[Point 8]
Removal:
Use a hoist and fiber rope to lift the drive motor ASSY and
then install it while keeping it level.
6-12

DISASSEMBLY • INSPECTION • REASSEMBLY

T = N·m (kgf·cm) [ft·lbf]

16 ~ 35 model:
2 T = 49.0 ~ 78.5 (500 ~ 800)
[36.2 ~ 57.9]
40 ~ 50 model:
T = 94.5 ~ 175.5 (960 ~ 1800)
[69.5 ~ 130.2]

Disassembly Procedure
1 Remove the oil seal. [Point 1]
2 Turn the gear case LH upward, stand it up, and remove it. [Point 2]
3 Remove drive unit gear No.1. [Point 3]
4 Remove drive unit gear No.2 and the differential ASSY with drive unit gear No.3. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
After reassembly, apply MP grease to the oil seal lip and drive unit gear No.1 inner spline.
 6-13

SST (1) Point Operations

[Point 1]
SST (2)
Reassembly:
SST 09950-76018-71 ............(1)
(SST 09950-60010)
SST 09950-76020-71 ............(2)
(SST 09950-70010)

[Point 2]
Disassembly:
Insert a flathead screwdriver into the gear case notch, and
then tap the opposite side with a plastic hammer.

Reassembly:
Apply liquid gasket (08826-76002-71 (08826-00090)) to
the gear case LH and the mating surface.

[Point 3]
Disassembly:
SST 09950-76014-71 ............(1)
(SST 09950-40011)
SST 09950-76018-71 ............(2)
(SST 09950-60010)

SST (1)
SST (2)
6-14

Drive motor side Reassembly:

SST 09950-76018-71 ............(1)
(SST 09950-60010)
SST (2)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
Seal surface
SST (1) Orient the bearing seal surface upward (motor side) and
reassemble.

Parking brake side SST 09700-30200-71

SST

[Point 4]
Disassembly:
SST 09950-76014-71
(SST 09950-40011)

SST

Reassembly:
SST 09950-76018-71 ............(1)
(SST 09950-60010)
SST 09950-76020-71 ............(2)
SST (2)
(SST 09950-70010)
SST (1)

No.2 Reassembly:
Engage drive unit gears No.2 and No.3 and reinstall them
No.3
in the gear case.
 6-15

DIFFERENTIAL CASE ASSEMBLY

DISASSEMBLY • INSPECTION • REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]
16 18 model, 40 ~ 50 model
•

T = 127.5 ~ 176.5 (1300 ~ 1800)

[94.1 ~ 130.2]

4
1

T = 43.1 ~ 53.9 (440 ~ 550)

20 ~ 35 model [31.8 ~ 39.8]
T = 127.5 ~ 176.5 (1300 ~ 1800)
[94.1 ~ 130.2]

T = 43.1 ~ 53.9
(440 ~ 550)
[31.8 ~ 39.8]
6-16

Disassembly Procedure
1 Remove the differential case bearing. [Point 1]
2 Remove the differential upper case. [Point 2]
3 Remove the side gear, pinion gear, and spider. [Point 3]
4 Remove drive unit gear No.3. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
SST(2) [Point 1]
Disassembly:
SST 09950-76014-71 ............(1)
SST(2)
(SST 09950-40011)
SST 09950-76018-71 ............(2)
(SST 09950-60010)

Reassembly:
SST SST 09421-33020-71

[Point 2]

Match mark Disassembly:

Put match marks on the case.
Reassembly:
Reassemble the case making sure the alignment marks
are aligned.
Reassembly:
Apply lock agent (08833-76001-71 (08833-00070)) to the
set bolt threads and install the case.

[Point 3]
Inspection:
Measure the differential pinion inside diameter.

Standard: 22.12 mm (0.8709 in)

Limit: 22.22 mm (0.8748 in)
 6-17

16⋅18 model, 40 ~ 50 model Inspection:

Measure the spider outside diameter.
Standard: 22.00 mm (0.8661 in)
Limit: 21.75 mm (0.8563 in)

20 ~ 35 model

Inspection:
Measure the side gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.3 mm (0.051 in)

Inspection:
Measure the pinion gear thrust washer thickness.
Standard: 1.6 mm (0.063 in)
Limit: 1.0 mm (0.039 in)

Reassembly:
Position the side gear thrust washer with the oil groove fac-
ing the tooth surface side and install the washer.

Oil groove

Apply grease in Reassembly:

these locations. Evenly apply washer grease (molybdenum disulfide
grease) to both sides of the pinion gear thrust washer and
install the washer.
6-18

[Point 4]
Reassembly:
Apply lock agent (08833-76001-71 (08833-00070)) to the
set bolt threads and install the washer. Incrementally tight-
en the bolts in order in opposing pairs, and then make the
final tightening in circular order to the specified torque.
 7-1

FRONT AXLE
Page
GENERAL ..........................................................................7-2
0
SPECIFICATIONS ............................................................7-6
1
COMPONENTS .................................................................7-6
2
TIRES • WHEELS .............................................................7-10
FRONT AXLE ASSY (16 ~ 35 MODEL) ....................7-11 3
REMOVAL • INSTALLATION............................................7-11 4
DISASSEMBLY • INSPECTION • REASSEMBLY..............7-13 5
FRONT AXLE ASSY (40 ~ 50 MODEL) ....................7-16 6
REMOVAL • INSTALLATION............................................7-16
7
DISASSEMBLY • INSPECTION • REASSEMBLY..............7-19
FRONT AXLE BRACKET .............................................7-23
8
REMOVAL • INSTALLATION (16 ~ 35 MODEL) ..............7-23 9
REMOVAL • INSTALLATION (40 ~ 50 MODEL) ..............7-26 10
11
12
13
14
15
16
17
18
19
20
21
22
 7-2
GENERAL
7
16 • 18 model
2
 7-3
20 • 25 model
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
7-4
30 • 35 model
 7-5
40 ~ 50 model
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
7-6

SPECIFICATIONS
Model
16 ~ 35 40 ~ 50
Item
Front axle type Half-floating
Suspension type Fixed frame
Reduction unit type  Planetary gear reduction
Reduction ratio  3.0

COMPONENTS
16 ~ 35 model 4201
 7-7

16 ~ 35 model 4201
7-8

40 ~ 50 model 4201
 7-9

40 ~ 50 model 4201

'28%/(
7-10

TIRES • WHEELS
1. Adjusting the Inflating Pressure

Caution:
• Do not inflate tires beyond the specified pressure
because it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it
in a safety fence.

Specified Inflating Pressure

Classification Specification Tire size Rim type Inflating pressure kPa (kgf/cm2) [psi]
STD 21×8-9-14PR Side ring 900 (9.0) [128]
16 18 model
•
Wide 21×8-9-14PR Side ring 900 (9.0) [128]
Oversize 6.50-10-14PR Side ring 1000 (10.0) [142]
STD 21×8-9-14PR Side ring 900 (9.0) [128]
Wide 21×8-9-14PR Side ring 900 (9.0) [128]
20 model
Oversize 23×9-10-18PR Side ring 900 (9.0) [128]
Oversize wide 23×9-10-18PR Side ring 900 (9.0) [128]
STD 23×9-10-18PR Side ring 900 (9.0) [128]
25 model
Wide 23×9-10-18PR Side ring 900 (9.0) [128]
STD 250-15-18PR Side ring 950 (9.5) [135]
40 model
Double tire 7.00-15-12PR Side ring 825 (8.25) [117]
45 model STD 250-15-18PR Side ring 950 (9.5) [135]
V FV mast Double tire 7.00-15-12PR Side ring 825 (8.25) [117]
45 model
Double tire 7.00-15-12PR Side ring 825 (8.25) [117]
FSV mast
50 model Double tire 7.00-15-12PR Side ring 825 (8.25) [117]

2. Wheel Disassembly Reassembly

•

Caution:
Always discharge air fully before disassembling the
wheel. Otherwise, it is very dangerous since the rim may
come off suddenly due to the internal pressure.
 7-11

FRONT AXLE ASSY (16 ~ 35 MODEL)

REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 80 ~ 120 (820 ~ 1220)

[59.3 ~ 88.3]

Removal Procedure
1 Drain the oil from the drive unit. [Point 1]
2 Jack up the vehicle and remove the front wheel. [Point 2]
3 Remove the front axle assembly and O-ring.
4 Remove the front axle shaft (inner).

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply MP grease to the O-ring.
7-12

Point Operation
[Point 1]
Removal:
Remove the drain plugs on the bottom of the drive unit
gear case and the bottom of the front axle assembly, and
drain the oil.
Installation:
A A Install the drain plug “A” with sealing compound (08826-
76002-71 (08826-00090)) or the seal tape for the
reinstallation. (The renewal of the plug needs no sealing
agent.)

Installation:
After installation, fill with the specified oil to the prescribed
level.

B B = Within 15 mm (0.59 in)

[Point 2]
Removal:
Jack up the vehicle and then support the frame on both
sides with wooden blocks.
 7-13

DISASSEMBLY • INSPECTION • REASSEMBLY

T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 2.0 ~ 3.9 (20 ~ 40)

[1.5 ~ 2.9]
T = 196.0 ~ 343.0 (2000 ~ 3500)
[144 ~ 253]

1
2

3 6

5
4

Disassembly Procedure
1 Remove the lock nuts. [Point 1]
2 Remove the inner bearing.
3 Remove the front axle hub assembly.
4 Remove the oil seal. [Point 2]
5 Remove the outer bearing.
6 Remove the bearing outer race. [Point 3]
7 Remove the front axle shaft (outer). [Point 4]
8 Remove the hub bolts.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
7-14

Point Operation
SST [Point 1]
Reassembly:
Adjust the front axle shaft starting force.
1. Tighten the lock nuts to the specified torque.
SST 09509-76002-71 (SST 09509-55020)
2. Rotate the hub 4 to 5 times to break in the bearing.
3. Back off the lock nut 30º to 60º, and align the lock nut
plate hole and the screw hole of the lock nut. Turn the
hub 4 to 5 times again at this position.
4. Install a knock pin in the front axle hub and use a
spring scale to measure the starting force.
Standard:
16 ~ 25 model:
15.0 ~ 42.4 N (1.5 ~ 4.3 kgf) [3.3 ~ 9.5 lbf]
30 • 35 model:
19.9 ~ 63.7 N (2.0 ~ 6.5 kgf) [4.4 ~ 14.3 lbf]
When not within the standard, adjust by increasing or
decreasing the lock nut tightness.

5. Apply lock agent (08833-76002-71 (08833-00080)) to

the lock nut screw threads and tighten the nut to the
specified torque.

[Point 2]
Reassembly:
SST Tap in the oil seal to the front axle hub end surface.
SST 09700-30200-71
Reassembly:
Apply MP grease to the lip of the oil seal.

[Point 3]
Disassembly:
Use a brass bar to remove the bearing outer race.
 7-15

[Point 4]
Disassembly:
When the outer bearing still remains on the front axle
(2)
(1)
shaft (outer), use an SST to remove it.
SST 09420-23001-71 ............(1)
SST 09950-76019-71 ............(2)
(SST 09950-60020)
7-16

FRONT AXLE ASSY (40 ~ 50 MODEL)

REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

4 3
3

T = 221 ~ 323 (2250 ~ 3300)

[162.8 ~ 238.8]

Removal Procedure
1 Drain the oil from the drive unit. [Point 1]
2 Jack up the vehicle and remove the front wheel. [Point 2]
3 Remove the front axle assembly, plate, and O-ring. [Point 3]
4 Remove the front axle shaft (inner).

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply MP grease to the O-ring.
 7-17

Point Operation
[Point 1]
Removal:
Remove the drain plugs on the bottom of the drive unit
gear case and the bottom of the front axle assembly, and
drain the oil.
Installation:
A A Install the drain plug “A” with sealing compound (08826-
76002-71 (08826-00090)) or the seal tape for the
reinstallation. (The renewal of the plug needs no sealing
agent.)

Installation:
After installation, fill with the specified oil to the prescribed
level.

B B = Within 15 mm (0.59 in)

[Point 2]
Removal:
Jack up the vehicle and then support the frame on both
sides with wooden blocks.

[Point 3]
Match mark
Removal:
Place match marks on the front axle assembly and front
axle bracket.
Installation:
Install making sure the match marks are aligned properly.

Removal installation:
•

SST 09421-30840-71 ............(1)

SST 09010-20111-71.............(2)
SST (2)
There is a danger the plate will fall down, so lay out waste
cloths under the front axle assembly to soften the fall of
SST (1)
the plate in case it falls.
7-18

Installation:
Apply MP grease to the O-ring and then insert it to the
position shown in the figure.
Installation:
Always be sure to tighten the set nuts after the bolts have
been secured to prevent the O-ring from being damaged.
(Bolts do not rotate.)
Installation:
Apply lock agent (08833-76001-71 (08833-00070)) to the
O-ring set nut threads and screw on the nuts.
 7-19

DISASSEMBLY • INSPECTION • REASSEMBLY

T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 294.0 ~ 343.0
T = 176.4 ~ 235.2 (3000 ~ 3500)
(1800 ~ 2400) [217.1 ~ 253.2]
[130.2 ~ 173.6]
2
1

T = 264.8 ~ 294.2 4
(2700 ~ 3000)
7
[195.3 ~ 217.1]

12
9

5 8

11

10

Disassembly Procedure
1 Remove the lock nuts. [Point 1]
2 Remove the planet gear carrier assembly W/inner bearing.
3 Remove the inner bearing. [Point 2]
4 Remove the planetary gear. [Point 3]
5 Remove the front axle hub assembly.
6 Remove the internal gear.
7 Remove the inner bearing outer race. [Point 4]
8 Remove the oil seal. [Point 5]
9 Remove the outer bearing outer race. [Point 6]
10 Remove the front axle shaft (outer) W/outer bearing.
11 Remove the outer bearing. [Point 7]
12 Remove the hub bolts.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Apply lock agent (08833-76001-71 (08833-00070)) to the internal gear set bolt threads and screw
in the bolts.
• Apply lock agent (08833-76001-71 (08833-00070)) to the hub bolt set nut threads and screw on
the nuts.
7-20

Point Operations
[Point 1]
Reassembly:
Adjust the front axle shaft startup force.
1. Tighten a new lock nut to the specified torque.
T = 294.0 ~ 343.0 N⋅m (3000 ~ 3500 kgf⋅cm)
[217.1 ~ 253.2 ft⋅lbf]
2. Rotate the front axle hub 4 to 5 times to break in the
bearing.

3. Install a knock pin in the front axle hub and use a

spring scale to measure the starting force.

Standard:
56 ~ 100 N (5.7 ~ 10.2 kgf) [13 ~ 22 lbf]

When not within the standard, increase or decrease

the shim thickness to adjust the starting force.
Increase the shim thickness to increase the startup
Lock nut plate
force, and decrease the shim thickness to decrease
Shim the startup force.
Shim thickness:
0.1 • 0.4 • 1.0 mm (0.004 • 0.016 • 0.039 in)
Orient the lock nut plate with the oil groove facing up
and then install the plate.

4. Tighten down the lock nut.

Do not tighten down so much that the lock nut is
cracked.

A = 1 mm (0.039 in) or less.

[Point 2]
Disassembly:
SST 09420-23001-71 ............(1)
SST (2) SST 09950-76019-71 ............(2)
(SST 09950-60020)

SST (1)
 7-21

[Point 3]
Inspection:
Measure the planetary gear shaft outside diameter.

Standard: 22.0 mm (0.866 in)

Limit: 21.85 mm (0.8602 in)

Reassembly:
Tap in the needle bearing up to the end of the planetary gear.
SST 09950-76018-71 ............(1)
Make flush Make flush (SST 09950-60010)
SST 09950-76020-71 ............(2)
(SST 09950-70010)
Tap the needle bearings up to both ends of the planetary
gear. When doing this, make sure the marked surface of
the needle bearing is facing outward.
SST (2) Make flush Make flush Do not apply grease to the needle bearing and the plane-
tary gear shaft.
SST (1)

[Point 4]
Disassembly:
Use a brass bar to remove the bearing outer race.

[Point 5]
Reassembly:
SST Tap in the oil seal up to the end of the front axle hub.
SST 09700-30200-71
Reassembly:
Apply MP grease to the lip of the oil seal.

[Point 6]
Disassembly:
Use a brass bar to remove the bearing outer race.
7-22

[Point 7]
Disassembly:
SST 09420-23001-71
SST
 7-23

FRONT AXLE BRACKET

REMOVAL • INSTALLATION (16 ~ 35 MODEL)
Note:
The following work is for removing and installing only one side of the front axle bracket. When
installing/removing both sides at the same time, remove the drive unit & front axle assembly from
the vehicle before removing front axle brackets. (See page 6-6.)
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 185 ~ 344
(1900 ~ 3500)
[137.5 ~ 253.2]
7

T = 108 ~ 137 (1100 ~ 1400)

[79.5 ~ 101.3]

T = 46 ~ 66 (470 ~ 670)
[34 ~ 48]

11
10 T = 80 ~ 120
(820 ~ 1220)
[59 ~ 88]
7-24

Removal Procedure
1 Move the mast assembly. (See page 13-10.)
2 Drain the oil from the drive unit. [Point 1]
3 Jack up the vehicle and remove the front wheel. [Point 2]
4 Disconnect the front brake piping.
5 Support the gear case on wooden block.
6 Remove the front axle assembly W/front axle bracket and the O-ring. [Point 3]
7 Remove the front axle shaft (inner).
8 Remove the front axle assembly and O-ring.
9 Remove the disc and pressure plate.
10 Remove the 1 brake piston guide W/piston. [Point 4]
11 Remove the O-ring and D-ring from the front axle bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Apply MP grease to the O-ring and D-ring.
• After installation, bleed air from the brake. (See page 10-25.)

Point Operations
[Point 1]
Removal:
Remove the drain plugs on the bottom of the drive unit gear
case and the bottom of the front axle assembly, and drain
the oil.
Installation:
A A Install the drain plug “A” with sealing compound (08826-
76002-71 (08826-00090)) or the seal tape for the
reinstallation. (The renewal of the plug needs no sealing
agent.)

Installation:
After installation, fill with the specified oil to the prescribed
level.

B B = Within 15 mm (0.59 in)

[Point 2]
Removal:
Jack up the vehicle and then support the frame on both
sides with wooden blocks.
 7-25

[Point 3]
Removal:
Perform the following procedure.
1. Remove the front axle bracket set bolts (that connect
with the gear case).
2. Use a hoist and garage jack to support the front axle
assembly with front axle bracket.

RH LH 3. Remove the front axle bracket set bolts (that connect

with the frame). Use an SST to remove the reamer
16 • 18 model bolts shown in the figure.

20 • 25 model

30 • 35 model

SST 09310-23320-71
SST

4. Operate the hoist and garage jack to remove the front

axle assembly W/front axle bracket.

[Point 4]
Service bolts
Removal:
After removing the set bolts, use service bolts to remove
the brake piston guide W/piston.

Service bolt size: M10 × 1.25

Installation:
Apply lock agent (08833-76001-71 (08822-00070)) to the
piston guide set bolt screw threads and then uniformly
tighten the bolts.
7-26

REMOVAL • INSTALLATION (40 ~ 50 MODEL)

Note:
The following work is for removing and installing only one side of the front axle bracket. When
installing/removing both sides at the same time, remove the drive unit & front axle assembly from
the vehicle before removing front axle brackets. (See page 6-6.)
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 235 ~ 294
(2400 ~ 3000)
7 [173.6 ~ 217.1]

T = 221 ~ 323
(2250 ~ 3300)
6
[162.8 ~ 238.8]

11 T = 45 ~ 60 (460 ~ 610)
[33.3 ~ 44.1]
10

9
8
T = 221 ~ 323
(2250 ~ 3300)
12
[162.8 ~ 238.8]

8
 7-27

Removal Procedure
1 Move the mast assembly. (See page 13-10.)
2 Drain the oil from the drive unit. [Point 1]
3 Jack up the vehicle and remove the front wheel. [Point 2]
4 Disconnect the front brake piping.
5 Support the gear case on wooden block.
6 Remove the front axle assembly W/front axle bracket and the O-ring. [Point 3]
7 Remove the front axle shaft (inner).
8 Remove the front axle assembly and O-ring.
9 Remove the plate.
10 Remove the disc and pressure plate.
11 Remove the brake piston guide W/piston. [Point 5]
12 Remove the O-ring, D-ring, and backup ring from the front axle bracket. [Point 6]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Apply MP grease to the O-ring and D-ring.
• After installation, bleed air from the brake. (See page 10-25.)

Point Operations
[Point 1]
Removal:
Remove the drain plugs on the bottom of the drive unit gear
case and the bottom of the front axle assembly, and drain
the oil.
Installation:
A A Install the drain plug “A” with sealing compound (08826-
76002-71 (08826-00090)) or the seal tape for the
reinstallation. (The renewal of the plug needs no sealing
agent.)

Installation:
After installation, fill with the specified oil to the prescribed
level.

B B = Within 15 mm (0.59 in)

7-28

[Point 2]
Removal:
Jack up the vehicle and support both sides of the frame on
wooden blocks.

[Point 3]
Removal:
Perform using the following procedure.
1. Remove the front axle bracket set nuts (that connect
with the gear case).
2. Use a hoist to suspend the front axle assembly with
front axle bracket.

3. Remove the front axle bracket set bolts (that connect

RH LH with the frame). Use an SST to remove the reamer
bolts shown in the figure.

SST 09310-23320-71

4. Operate the hoist to remove the front axle assembly

W/front axle bracket.

SST

Reamer bolts Installation:

Install the reamer bolts in the position shown in the figure.
Installation:
Apply lock agent (08833-76001-71 (08833-00070)) to the
front axle bracket set nut screw threads and then tighten
the nuts.

LH Reamer bolts RH
 7-29

[Point 4]
Removal:
Place match marks on the front axle assembly and front
axle bracket.
Installation:
Install making sure the match marks are aligned properly.

Match mark

Installation:
Apply MP grease to the O-ring and then insert it to the
position shown in the figure.
Installation:
Always be sure to tighten the set nuts after the bolts have
been secured to prevent the O-ring from being damaged.
(Bolts do not rotate.)
Installation:
O-ring
Apply lock agent (08833-76001-71 (08833-00070)) to the
set nut threads and screw on the nuts.

[Point 5]
Removal:
SST After removing the set bolts, use an SST to remove the
brake piston guide W/piston.
SST 09810-20172-71
Removal:
Apply lock agent (08833-76001-71 (08833-00070)) to the
set bolt screw threads and then uniformly tighten the bolts.

[Point 6]
Piston
Installation:
Make sure to install the backup ring in the correct position.

Backup ring
 8-1

REAR AXLE
Page
GENERAL ..........................................................................8-2
0
SPECIFICATIONS ............................................................8-6
1
COMPONENTS .................................................................8-7
2
TIRES • WHEELS .............................................................8-10
REAR AXLE ASSY (16 ~ 35 MODEL) ......................8-11 3
REMOVAL • INSTALLATION............................................8-11 4
REAR AXLE ASSY (40 ~ 50 MODEL) ......................8-13 5
REMOVAL • INSTALLATION............................................8-13 6
REAR AXLE HUB • STEERING KNUCKLE
(16 ~ 35 MODEL) .........................................................8-15
7
REMOVAL • INSTALLATION............................................8-15 8
REAR AXLE HUB • STEERING KNUCKLE 9
(40 ~ 50 MODEL) .........................................................8-20
10
REMOVAL INSTALLATION............................................8-20
•
11
REAR AXLE CYLINDER ..............................................8-24
REMOVAL • INSTALLATION (16 ~ 35 MODEL) ..............8-24 12
REMOVAL • INSTALLATION (40 ~ 50 MODEL) ..............8-26 13
DISASSEMBLY • INSPECTION • REASSEMBLY..............8-28 14
REAR WHEEL ALIGNMENT (16 ~ 35 MODEL) .....8-30
15
REAR WHEEL ALIGNMENT (40 ~ 50 MODEL) .....8-32
16
17
18
19
20
21
22
 8-2

GENERAL
8

16 ~ 25 model
 8-3

30⋅35 model

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
8-4

40 ~ 50 model
 8-5

Rear Axle Cylinder

16 ~ 35 model

0
1
2
3
4
5
6
7
8
40 ~ 50 model
9
10
11
12
13
14
15
16
17
18
19
20
21
22
8-6

SPECIFICATIONS
Rear axle type Elliot type
Rear axle suspension type Center-supported right-left rocking type
Toe-in mm (in) 0 (0)
Camber degree 16 ~ 35 model: 1.5°, 40 ~ 50 model: 0°
Wheel alignment
Caster degree 0°
King pin angle 0°
16 model: 1870 (73.6)
18 model: 1870 (73.6)
20 model: 2020 (79.5)
25 model: 2030 (79.9)
Minimum turning radius (outermost) mm (in) 30 model: 2160 (85.0)
35 model: 2215 (87.2)
40 model: 2680 (105.5)
45 model: 2680 (105.5)
50 model: 2740 (107.9)
Cylinder type Double acting
Piston rod outside 16 ~ 35 model: 50.0 (1.969)
Rear axle cylinder diameter mm (in) 40 ~ 50 model: 55.0 (2.165)
16 ~ 35 model: 76.0 (2.992)
Cylinder bore mm (in)
40 ~ 50 model: 90.0 (3.543)
 8-7

COMPONENTS
16 ~ 25 model 4301

30 35 model
•
8-8

40 ~ 50 model 4301

16 ~ 35 model 4302
 8-9

40 ~ 50 model 4302
8-10

TIRES • WHEELS
1. Adjusting the Inflating Pressure

Caution:
• Do not inflate tires beyond the specified pressure
because it may cause dangerous tire bursting.
• When inflating a tire removed from the vehicle, place it
in a safety fence.

Specified Inflating Pressure

Inflating pressure
Model Tire size Rim type
kPa (kgf/cm2) [psi]
16 18 model
•
5.00-8-8PR Divided 800 (8.0) [114]
5.00-8-8PR Side ring 800 (8.0) [114]
20 model 5.00-8-10PR Side ring 1000 (10.0) [142]
25 model 18 × 7-8-16PR Divided 750 (7.5) [107]
18 × 7-8-16PR Side ring 750 (7.5) [107]
30 35 model
•
– – –
– – –
40 45 model
•
7.00-12-12PR Divided 850 (8.5) [121]
7.00-12-12PR Side ring 850 (8.5) [121]
50 model 7.00-12-14PR Side ring 900 (9.0) [128]

Chamfering
2. Wheel Disassemly⋅Reassembly

Caution:
Always discharge air fully before disassembling the
wheel. Otherwise, it is very dangerous since the rim may
come off suddenly due to the internal pressure.

Note:
Install each divided rim set bolt with its head on the
Outer rim
outer rim side and the chamfered portion facing the
center of the wheel.

T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 29.4 ~ 44.1 (300 ~ 450)
16 ~ 20 model
[21.7 ~ 32.6]
T = 78.5 ~ 117.7 (800 ~ 1200)
25 model
[57.9 ~ 86.8]
T = 117.7 ~ 176.5 (1200 ~ 1800)
40 ~ 50 model
[86.8 ~ 130.2]
 8-11

REAR AXLE ASSY (16 ~ 35 MODEL)

REMOVAL • INSTALLATION
T = N m (kgf cm) [ft lbf]
• • •

8
3 9

2*

T = 128 ~ 175 (1310 ~ 1780)

2* Hub nut [94.78 ~ 128.8]
16 ~ 20 model T = 88.3 ~ 157.0 (900 ~ 1600) [65.12 ~ 115.8]
25 ~ 35 model T = 117.6 ~ 196 (1200 ~ 2000) [86.82 ~ 144.7]

Removal Procedure
1 Chock the front wheels.
2 Jack up the vehicle and remove rear wheels.
3 Remove the swing lock cylinder lower pin.
4 Disconnect the rear axle cylinder hose.
5 Disconnect the tire angle sensor connector.
6 Support the rear axle ASSY with a garage jack.
7 Remove the rear axle ASSY. [Point 1]
8 Remove the center pin bushing. [Point 2]
9 Remove the rear axle damper.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, add grease through each grease fitting. Add molybdenum disulfide grease at the
rear axle beam center pins (two places) and swing lock cylinder lower pin. Use MP grease to other
grease fittings.
8-12

Point Operations
[Point 1]
Inspection:
Measure the rear axle front to rear clearance.
1. Before removing the rear axle ASSY, measure the
front to rear clearance on the rear side.

Standard clearance: 0.7 mm (0.028 in) or less

2. If the measured value does not satisfy the standard,

remove the rear axle ASSY and make adjustment by
selecting the spacer.

Spacer thickness:
0.5⋅1.2⋅2.3⋅3.0⋅3.5⋅4.0⋅4.5 and 5.0 mm
(0.020⋅0.047⋅0.091⋅0.118⋅0.138⋅0.157⋅0.177 and
0.197 in)

Removal:
Draw different match marks on the rear axle bracket caps
front and rear to prevent confusion.

Installation:
Install after aligning the match mark.

Match mark

[Point 2]
Inspection:
Inspect the inside diameter of the rear axle center pin
bushing.

Limit: 52.0 mm (2.047 in)

Installation:
Apply molybdenum disulfide grease to the bushing before
installation.
16 ~ 30 model Installation:
Install the bushing by aligning the grease groove in the
bushing with the grease fitting position. (16 ~ 30 model)

Grease
groove
 8-13

REAR AXLE ASSY (40 ~ 50 MODEL)

REMOVAL • INSTALLATION
T = N m (kgf cm) [ft lbf]
• • •

8
7
3

T = 176.4 ~ 392 (1800 ~ 4000)

[130.2 ~ 289.4]

T = 128 ~ 175 (1310 ~ 1780)

[94.78 ~ 128.8]

Removal Procedure
1 Chock the front wheels.
2 Jack up the vehicle and remove rear wheels.
3 Remove the swing lock cylinder lower pin.
4 Disconnect the rear axle cylinder hose.
5 Disconnect the tire angle sensor connector.
6 Support the rear axle ASSY with a garage jack.
7 Remove the rear axle ASSY. [Point 1]
8 Remove the center pin bushing. [Point 2]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, add grease through each grease fitting. Add molybdenum disulfide grease at the
rear axle beam center pins (two places) and swing lock cylinder lower pin. Use MP grease to other
grease fittings.
8-14

Point Operations
[Point 1]
Inspection:
Measure the rear axle front to rear clearance.
1. Before removing the rear axle ASSY, measure the
front to rear clearance on the rear side.

Standard clearance: 1.0 mm (0.039 in) or less

2. If the measured value does not satisfy the standard,

remove the rear axle ASSY and make adjustment by
selecting the spacer.

Spacer thickness:
0.6⋅1.2⋅2.3⋅3.2 and 4.5 mm
(0.024⋅0.047⋅0.091⋅0.125 and 0.177 in)

3. Install the spacer at the rear side center pin.

Removal:
Draw different match marks on the rear axle bracket caps
front and rear to prevent confusion.

Installation:
Install after aligning the match mark.

Match mark

[Point 2]
Inspection:
Inspect the inside diameter of the rear axle center pin
bushing.

Limit: 67.0 mm (2.638 in)

Installation:
Apply molybdenum disulfide grease to the bushing before
installation.
 8-15

REAR AXLE HUB • STEERING KNUCKLE (16 ~ 35 MODEL)

REMOVAL • INSTALLATION
T = N m (kgf cm) [ft lbf]
• • •

9 7

11
12
10

T = 49.0 ~ 78.5 (500 ~ 800)

[36.2 ~ 57.9]

11
9
3
5
2
11 6
5
T = 44.1 ~ 53.9 (450 ~ 550)
[32.6 ~ 39.8]
4

Removal Procedure
1. Jack up the vehicle and remove rear wheels.
2. Remove the hub caps. [Point 1]
3. Remove the castle nut and claw washer. [Point 2]
4. Remove the outer bearing and axle hub. [Point 3]
5. Remove the bearing outer race from the axle hub. [Point 4]
6. Remove the inner bearing and oil seal. [Point 5]
7. Disconnect the tie rod (on the knuckle side). [Point 6]
8. Remove the king pin cover (on the LH side) or the tire angle sensor (on the RH side).
9. Remove the king pin lock bolt and king pin. [Point 7]
10. Remove the thrust bearing, spacer and steering knuckle.
11. Remove the king pin oil seal and needle bearing. [Point 8]
12. Remove the bushing from the steering knuckle. [Point 9]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, add MP grease through grease fittings.
8-16

Point Operations
[Point 1]
Installation:
Fill MP grease in the hub cap, and install by tapping the
flange portion.
(Instead of MP grease filling, spraying grease over the
castle nut is also usable.)

[Point 2]
Installation:
Adjust the rear axle hub starting force.
1. Install the claw washer in the correct direction.
2. Install the castle nut and temporarily tighten it to a
torque of 15 to 32 N⋅m (150 to 330 kgf⋅cm) [10.9 to
23.9 ft⋅lbf].
3. Rotate the hub by 3 to 5 turns to run in the bearing.
Claw washer 4. Set a spring scale on a hub bolt, and measure the
starting force.

Standards:
16 ~ 20 model 15 ~ 39 N (1.5 ~ 4.0 kgf) [3.3 ~ 8.5 lbf]
25 ~ 35 model 15 ~ 44 N (1.5 ~ 4.5 kgf) [3.3 ~ 9.9 lbf]
5. If the measured value does not satisfy the standard,
adjust the degree of castle nut tightening for
adjustment.
6. Install a new cotter pin.

[Point 3]
SST Removal:
SST 09950-76014-71
(SST 09950-40011)

Installation:
Install the axle hub and outer bearing.
1. Fill MP grease in the axle hub and knuckle spindle.
2. Install the axle hub.
3. Use the SST and install the outer bearing roller.
SST 09370-20270-71

SST
 8-17

[Point 4]
Removal:
SST(2)
Use a brass bar and remove the bearing outer race.

SST(1) Installation:
SST 09950-76019-71 ............(1)
(SST 09950-60020)
SST 09950-76020-71 ............(2)
(SST 09950-70010)

[Point 5]
SST Removal:
SST 09950-76014-71
(SST 09950-40011)

Installation:
Install the oil seal and inner bearing.
1. Use the SST and install the oil seal.
SST 09370-10410-71

SST

2. Use the SST and install the inner bearing.

SST 09370-20270-71

SST

[Point 6]
Match mark
Removal:
Mark the end pin punch mark position to the plate side.

Installation:
Install by matching the end pin punch mark position to the
marking on the plate side.
8-18

Installation:
To install the end pin lock nut, install the cone washer in
the direction shown in the figure and tighten to a specified
torque.

T = 49.0 ~ 78.5 N⋅m (500 ~ 800 kgf⋅cm)

[36.2 ~ 57.9 ft⋅lbf]

Cone washer

[Point 7]
Inspection:
Measure the king pin outside diameter.

Limit: 27.8 mm (1.094 in)

Installation:
Measure the steering knuckle starting force.
1. Temporarily install the king pin and king pin lock bolt.
Select the spacer so as to minimize vertical looseness
of the knuckle, and install it on top of the thrust bearing.
Spacer thickness:
16 ~ 20 model : 0.5 and 1.0 mm
(0.020 and 0.039 in)
25 ~ 35 model : 3.0, 3.5, 4.0 and 4.5 mm
(0.118, 0.138, 0.157 and 0.177 in)
2. Set a spring scale at the tip end of the knuckle
spindle, and measure the starting force.

Spacer Standard: 19.3 N (2.0 kgf) [4.4 lbf] or less

installing
position
3. If the measured value exceeds the standard, check
the king pin for bend, the needle bearing for damage
and axle beam for deformation.

4. Tighten the lock nut for the king pin lock bolt.
 8-19

[Point 8]
SST(2) Removal:
Remove the king pin oil seal and needle bearing.
1. Use a straight-edge screwdriver to remove the dust
seal and oil seal.
2. Use the SST and remove the needle bearing.
SST 09950-76018-71 .....(1)
SST(1) (SST 09950-60010)
SST 09950-76020-71 .....(2)
(SST 09950-70010)

Installation:
Install the needle bearing and king pin oil seal.
1. Use the SST and install the needle bearing.
Check the needle bearing press-fitting surface,
0 mm pressing direction and installation depth.
(0 in)
SST 09950-76018-71 .....(1)
(SST 09950-60010)
SST 09950-76020-71 .....(2)
(SST 09950-70010)
2. Install the dust seal.
4 mm 3. Use the SST and install the oil seal.
(0.16 in) SST 09950-76018-71 .....(1)
(SST 09950-60010)
SST 09950-76020-71 .....(2)
Punched
surface
(SST 09950-70010)

Needle bearing
Press-fitting direction

[Point 9]
Bushing
Installation:
Press-in the bushing flush to the lower surface of the
knuckle. (Clearance on the upper side will be used for the
grease well.)

Flush
8-20

REAR AXLE HUB • STEERING KNUCKLE (40 ~ 50 MODEL)

REMOVAL • INSTALLATION
T = N m (kgf cm) [ft lbf]
• • •

11
10

11 10
11

9 3

6 2
T = 44.1 ~ 53.9
(450 ~ 550) 5
T = [32.6 ~ 39.8]
4

Removal Procedure
1 Jack up the vehicle and remove rear wheels.
2 Remove the hub caps. [Point 1]
3 Remove the castle nut and claw washer. [Point 2]
4 Remove the outer bearing and axle hub. [Point 3]
5 Remove the bearing outer race from the axle hub. [Point 4]
6 Remove the inner bearing and oil seal. [Point 5]
7 Disconnect the tie rod (on the knuckle side).
8 Remove the king pin cover (on the LH side) or the tire angle sensor (on the RH side).
9 Remove the king pin lock bolt and king pin. [Point 6]
10 Remove the thrust bearing, spacer and steering knuckle.
11 Remove the king pin oil seal and needle bearing. [Point 7]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, add MP grease through grease fittings.
 8-21

Point Operations
[Point 1]
Installation:
Fill MP grease in the hub cap, and install by tapping the
flange portion.
(Instead of MP grease filling, spraying grease over the
castle nut is also usable.)

[Point 2]
Installation:
Adjust the rear axle hub starting force.
1. Install the claw washer in the correct direction.
2. Install the castle nut and temporarily tighten it to a
torque of 15 to 32 N·m (150 to 330 kgf·cm) [10.9 to
23.9 ft·lbf].
3. Rotate the hub by 3 to 5 turns to run in the bearing.
Claw washer

4. Set a spring scale on a hub bolt, and measure the

starting force.

Standard: 43 ~ 72 N (4.4 ~ 7.3 kgf) [9.7 ~ 16.1 lbf]

5. If the measured value does not satisfy the standard,

adjust the degree of castle nut tightening for
adjustment.
6. Install a new cotter pin.

[Point 3]
SST Removal:
SST 09120-23600-71

Installation:
Install the axle hub and outer bearing.
1. Fill MP grease in the axle hub and knuckle spindle.
2. Install the axle hub.
3. Use the SST and install the outer bearing roller.
SST 09370-20270-71

SST
Fill grease
8-22

[Point 4]
Removal:
SST (2) Use a brass bar and remove the bearing outer race.

SST (1) Installation:

SST 09950-76019-71 ............(1)
(SST 09950-60020)
SST 09950-76020-71 ............(2)
(SST 09950-70010)

SST
[Point 5]
Removal:
SST 09950-76014-71
(SST 09950-40011)

Installation:
Install the oil seal and inner bearing.
1. Install the oil seal.
2. Use the SST and install the inner bearing.
SST 09316-76008-71
(SST 09316-60011)

SST

[Point 6]
Installation:
Measure the king pin outside diameter.

Limit: 34.8 mm (1.370 in)

 8-23

Installation:
Measure the steering knuckle starting force.
1. Temporarily install the king pin and king pin lock bolt.
Select the spacer so as to minimize vertical looseness
of the knuckle, and install it to lower side of the
steering knuckle.
Spacer thickness: 0.15, 0.25, and 0.35 mm
(0.006, 0.010, and 0.014 in)
2. Set a spring scale at the tip end of the knuckle
spindle, and measure the starting force.

Standard: 19.3 N (2.0 kgf) [4.4 lbf] or less

3. If the measured value exceeds the standard, check

the king pin for bend, the needle bearing for damage
and axle beam for deformation.

4. Tighten the lock nut for the king pin lock bolt.

[Point 7]
SST(2) Removal:
Remove the king pin oil seal and needle bearing.
1. Use a straight-edge screwdriver to remove the dust
seal and oil seal.
2. Use the SST and remove the needle bearing.
SST 09950-76018-71 .....(1)
SST(1)
(SST 09950-60010)
SST 09950-76020-71 .....(2)
(SST 09950-70010)
Installation:
Install the needle bearing and king pin oil seal.
1. Use the SST and install the needle bearing.
0 mm
(0 in)
Check the needle bearing press-fitting surface,
pressing direction and installation depth.
SST 09950-76018-71 .....(1)
(SST 09950-60010)
SST 09950-76020-71 .....(2)
(SST 09950-70010)
4 mm 2. Install the dust seal.
(0.16 in)
3. Use the SST and install the oil seal.
SST 09950-76018-71 .....(1)
Punched
(SST 09950-60010)
surface
SST 09950-76020-71 .....(2)
(SST 09950-70010)

Needle bearing
Press-fitting direction
8-24

REAR AXLE CYLINDER

REMOVAL • INSTALLATION (16 ~ 35 MODEL)
T = N m (kgf cm) [ft lbf]
• • •

T = 166.7 ~ 215.8
(1700 ~ 2200)
[123.0 ~ 159.1]

3
3

2
5

Removal Procedure
1 Jack up the vehicle.
2 Disconnect the tie rod (on the piston rod side). [Point 1]
3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 2]
4 Remove the rear axle cylinder.
5 Remove the bushing from the piston rod. [Point 3]

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 8-25

Point Operations
Match mark
[Point 1]
Removal:
Mark the end pin punch mark position to the plate side.

Installation:
Install by matching the end pin punch mark position to the
marking on the plate side.

Installation:
To install the end pin lock nut, install the cone washer in
the direction shown in the figure and tighten to a specified
torque.

T = 49.0 ~ 78.5 N⋅m (500 ~ 800 kgf⋅cm)

[36.2 ~ 57.9 ft⋅lbf]

Cone washer

[Point 2]
Installation:
Install the fitting in the direction shown in the figure.

A = 60°

A A

Bushing [Point 3]
Installation:
Press-in the bushing flush to the lower surface of the rod
on both ends. (Clearance on the upper side will be used
for the grease well.)

Flush
8-26

REMOVAL • INSTALLATION (40 ~ 50 MODEL)

T = N m (kgf cm) [ft lbf]
• • •

T = 421.7 ~ 470.7
(4300 ~ 4800)
[311.1 ~ 347.3]

3
3

2
4

Removal Procedure
1 Jack up the vehicle.
2 Disconnect the tie rod (on the piston rod side). [Point 1]
3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 2]
4 Remove the rear axle cylinder.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 8-27

Point Operations
Match mark
[Point 1]
Removal:
Mark the punch mark position on each of cylinder end pins
LH and RH.

Installation:
Install each cylinder end pin by aligning the punch mark
with the mark.

[Point 2]
Installation:
Install the fitting in the direction shown in the figure.

A = 20°

A
A A
A
8-28

DISASSEMBLY • INSPECTION • REASSEMBLY

T = N m (kgf cm) [ft lbf]
• • •

16 ~ 35 model

T = 88 ~ 118 1 4
T = (900 ~ 1200)
T = [65.1 ~ 86.8]

T = 88 ~ 118
T = (900 ~ 1200)
T = [65.1 ~ 86.8]

40 ~ 50 model

1
T = 117.7 ~ 137.3 4
T = (1220 ~ 1400)
T = [86.82 ~ 101.3]
2

3
1

T = 117.7 ~ 137.3
T = (1220 ~ 1400)
T = [86.82 ~ 101.3]
 8-29

Disassembly Procedure
1 Remove the through bolt.
2 Remove the piston rod guide.
3 Remove the piston rod. [Point 1]
4 Inspect the cylinder. [Point 2]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Coat hydraulic oil before reassembly.

Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.

Limit:
16 ~ 35 model: 49.92 (1.9654 in)
40 ~ 50 model: 54.91 (2.1618 in)

Inspection:
Measure the bend of the piston rod.
Limit: 0.5 mm (0.020 in)
Reassembly:
Warm the seal ring to a little below 80°C (176°F) in hot oil
or water before installation.
Do not stretch it excessively.
Caution:
Operate carefully to avoid scalding.

[Point 2]
Inspection:
Measure the rear axle cylinder bore.

Limit:
16 ~ 35 model: 76.35 mm (3.0059 in)
40 ~ 50 model: 90.40 mm (3.5591 in)
8-30

REAR WHEEL ALIGNMENT (16 ~ 35 MODEL)

Toe-in Inspection
1. Check to see that dimensions Ar and Al of the rear axle cylinder are equal.
2. Measure the toe-in (Bf-Br).
Standard: 0 ± 4 mm (0 ± 0.16 in)

Bf

OUT IN IN OUT

Al Ar

Rl Rr

Br

Toe-in Adjustment
Plate
Front side
1. Check to see that Ar and Al of the rear axle cylinder are
equal.
2. Match the punch marks on the end pin (eccentric pin)
RH
and the plate to the front side for all four points as shown
LH
in the figure.
Punch mark
 8-31

3. Measure and adjust the toe-in (Bf-Br).

OUT
OUT Standard: 0 ± 4 mm (0 ± 0.16 in)

IN IN
IN IN If the measured value exceeds the standard, remove the
lock plate and make adjustment using end pins (1) and (2)
in the range where the difference between Rl and Rr is
within 0 ± 3 mm (0 ± 0.12 in).
(1) (1)
(2) (2) (1) When measured value > 4 mm (0.16 in)
Measure Rl and Rr. Adjust the end pins (1) and (2) of
the smaller value to the IN side.
(2) When measured value < 4 mm (0.16 in)
Measure Rl and Rr. Adjust the end pins (1) and (2) of
the greater value to the OUT side.

Note:
• If Rl equals to Rr, adjust the same amount of the LH
and RH sides.
• If the standard is not attained by adjustment on one
side, make adjustment also on other side.

4. After adjustment, fully steer the tires and check to see

that they do not come into contact with the vehicle body.
8-32

REAR WHEEL ALIGNMENT (40 ~ 50 MODEL)

Toe-in Inspection
1. Check to see that dimensions Ar and Al of the rear axle cylinder are equal.
2. Measure the toe-in (Bf-Br).
Standard: 0 ± 4 mm (0 ± 0.16 in)

Bf

OUT IN IN OUT

Al Ar

Rl Rr

Br

Toe-in Adjustment
Punch mark on plate side 1. Check to see that Ar and Al of the rear axle cylinder are
equal.
2. Align the punch mark on the cylinder end pin (eccentric
pin) with the punch mark on the plate on the front side
for both the LH and RH sides.
3. Measure and adjust the toe-in (Bf-Br).
Standard: 0 ± 4 mm (0 ± 0.16 in)
If the measured value does not satisfy the standard,
Punch mark on cylinder end pin side make adjustment by the cylinder end pin in the range
where the difference between Rl and Rr is within 0 ± 3
mm (0.12 in).
(1) When measured value > 4 mm (0.16 in):
Measure Rl and Rr, and adjust the cylinder end pin on
OUT OUT
the smaller side toward IN.
IN
IN (2) When measured value < 4 mm (0.16 in):
Measure Rl and Rr, and adjust the cylinder end pin on
the greater side toward OUT.
Note:
• If Rl equals to Rr, adjust the same amount on the LH
and RH sides.
• If the standard is not attained by adjustment on one
side, make adjustment also on the other side.
4. Install the plate. The plate can be installed with either face up.
5. After adjustment, fully steer the tires and check to see
that they do not come into contact with the vehicle body.
 9-1

STEERING
Page
GENERAL ..........................................................................9-2
0
SPECIFICATIONS ............................................................9-4
1
COMPONENTS .................................................................9-4
2
STEERING WHEEL • MAST JACKET ..........................9-7
REMOVAL • INSTALLATION..............................................9-7 3
DISASSEMBLY • INSPECTION • REASSEMBLY..............9-11 4
HYDROSTATIC STEERING VALVE ASSY .............9-12 5
TROUBLESHOOTING .....................................................9-12
6
REMOVAL • INSTALLATION............................................9-13
7
DISASSEMBLY • INSPECTION • REASSEMBLY..............9-14
RELIEF PRESSURE 8
INSPECTION • ADJUSTMENT ...................................9-18 9
POWER STEERING PUMP ASSY 10
(16 ~ 35 MODEL) .........................................................9-19
GENERAL........................................................................9-19
11
SPECIFICATIONS ...........................................................9-19 12
COMPONENTS................................................................9-19 13
REMOVAL • INSTALLATION............................................9-20
14
15
16
17
18
19
20
21
22
 9-2

GENERAL
9
 9-3

Hydrostatic Steering Valve

1 9 2 5 4 6 7

0
1. Neutral position spring
2. Housing
3. Check valve
1
2
4. Spool
5. Sleeve
6. Cardan shaft
7. Gear rim
8. Gear wheel (rotor) 3
9. Relief valve

4
5
6
3
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
9-4

SPECIFICATIONS
Model
16 ~ 35 40 ~ 50
Item
Steering wheel diameter mm (in) 360 (14.2)
Steering wheel play (at idling) mm (in) 20 ~ 50 (0.79 ~ 1.97)
Power steering type Hydrostatic steering
Type (manufacturer) OSPC (Danfoss)
Delivery cm (in)/rev 80 (4.88) 125 (7.63)
Hydrostatic steering
valve Rated flow rate (US gal)/min 18 (4.8) 15 (4.0)
Relief set pressure kPa
8040 (82)[1170] 11770 (120) [1710]
(kgf/cm2) [psi]

COMPONENTS
4501
48

01

10

49
BF

AE

30

94120-40800

46

AC

AK

AC
4501-050A
 9-5

4502

0
1
2
3
4
5
6
7
8
9
16 ~ 35 model 4507
10
11
12
13
14
15
16
17
18
19
20
21
22
9-6

40 ~ 50 model 4507

4503
 9-7

STEERING WHEEL • MAST JACKET

REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 25 ~ 26
5
(255 ~ 612)
[18.4 ~ 44.3]

2
16 ~ 35 model
11
10

12
3

T = 10 ~ 14
(102 ~ 143)
[7.4 ~ 10.3]
9 13

14 T = 8.4 ~ 14
(86 ~ 143)
17 [6.2 ~ 10.3]
14

16

T = 29.4 ~ 39.2
T = 34.3 ~ 53.9 (300 ~ 400)
(350 ~ 550) [21.7 ~ 28.9]
[25.3 ~ 39.8]

15
9

9
9-8

Removal Procedure
1 Open the seat stand and disconnect the battery plug.
2 Remove the steering wheel. [Point 1]
3 Remove the steering column cover.
4 Disconnect the connectors of the display, key switch and lamp switch.
5 Remove the steering column cover W/display. [Point 2]
6 Remove the front toe board.
7 Remove the lower panel. (40 ~ 50 model)
8 Disconnect the parking brake switch ASSY connector.
9 Remove the instrument panel.
10 Disconnect the direction switch connector and remove the direction switch.
11 Disconnect the turn signal switch connector and remove the turn signal switch ASSY. [Point 3]
12 Disconnect the steering sensor connector and remove the steering sensor. [Point 4]
13 Remove the spring pin and collar. [Point 5]
14 Remove the tilt lock mechanism. [Point 6]
15 Remove the steering valve set bolts and keep the valve free.
16 Remove the tension spring.
17 Remove the mast jacket ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Apply MP grease to the sliding surface of the tilt lock device and the collar of the mast jacket set
bolt.
• Fill MP grease at the coupling between the tilt steering shaft and steering valve.
 9-9

SST Point Operations

[Point 1]
Removal:
SST 09950-76003-71
(SST 09950-50012)

Installation:
Steering wheel installation procedure.
Shaft
1. Apply rubber grease on sliding face A of the turn
mark signal switch.
2. Make a hole at the surface of the cancelcam become
driver’s seat side.
3. Install the steering wheel while aligning the steering
knob end shaft mark and steering knob at the angle
shown in the figure.
A Hele
Standard: B = 14° ± 6°
4. After installation, rotate the steering wheel. As the
steering wheel is rotated, the 3 pins on the turn signal
B
switch ASSY are automatically set in the holes on the
steering wheel side.
Shaft
mark
Steering
knob

[Point 2]
Collar Sensor
Installation:
Thin Install the collar and rubber in the illustrated direction.

Thick Rubber

[Point 3]
Installation:
Install the screw as shown in the figure.
9-10

[Point 4]
Installation:
Fix the installed sensor by tightening the tapping screw
after inserting the positioning pin on the sensor side into
the hole on the bracket side.
Fixing without pin insertion may damage the sensor due to
concentricity error. Tighten the tapping screw carefully so
as not to damage the plastic portion by overtightening.
Pin Drilled hole for pin

Positioning [Point 5]
Large notch
Small notch

mark
Steering shaft Installation:
Install the collar with the larger notch aligned with the
steering shaft positioning mark.

Collar

Removal Installation:
Pay sufficient attention so as not to damage the collar
Dia.
when the spring pin is removed and installed.
Drive in the spring pin so as not to allow it to come out of
collar diameter.
Driving in
Spring pin

Steering shaft

Column cover [Point 6]

line
Tilt lever Installation:
Install so that the tilt lever line and column-cover line are
in parallel as shown in the figure, and check to see if tilt
lock operation is normal.

Tilt lever line

 9-11

DISASSEMBLY • INSPECTION • REASSEMBLY

Disassembly Procedure
1 Remove the snap ring.
2 Remove the tilt steering shaft.
3 Remove the bearing.
4 Remove the turn signal switch bracket.

Reassembly Procedure
The reassembly procedure is the reverse of the removal procedure.
9-12

HYDROSTATIC STEERING VALVE ASSY

TROUBLESHOOTING
Fault Possible cause Remedy
1. Steering wheel is 1.1 No or insufficient oil pressure • Repair or replace oil pump.
heavy to turn • Repair or replace flow divider valve.
1.2 Pressure relief valve is stuck in • Repair or clean pressure relief
open position or setting pres- valve.
sure is too low. • Adjust the valve to the correct pres-
sure.
1.3 Too much friction at mechani- • Lubricate joints of steering link or
cal parts of the vehicle repair if necessary.
• Check steering column installation.
2. Regular adjustments of 2.1 Leaf spring without sufficient • Replace leaf springs.
the steering wheel are spring force or broken
necessary. (“Meander- 2.2 Worn gear wheel set • Replace gear wheel set.
ing”)
2.3 Seized cylinder or worn piston • Replace defects parts.
seal.
3. The steering wheel 3.1 Leaf springs are stuck or bro- • Replace leaf springs.
turns on its own. ken and have therefore
reduced spring force.
3.2 Inner and outer spools are • Clean steering unit.
stuck, possibly due to dirt.
4. Backlash 4.1 Cardan shaft worn or broken • Replace Cardan shaft.
4.2 Leaf springs without spring • Replace leaf springs.
force or broken
4.3 Worn splines on the steering • Replace steering column.
column
5. Steering wheel turns 5.1 Gear wheel set worn • Replace gear wheel set.
completely without
moving the wheels.
6. Steering is too slow 6.1 Insufficient oil supply to steer- • Repair or replace oil pump.
and heavy when oper- ing unit
ated quickly. 6.2 Relief valve setting too low • Adjust valve to correct setting.
6.3 Relief valve stuck due to dirt • Clean the valve.
7. Heavy kick-back in 7.1 Wrong setting of Cardan shaft • Correct setting as shown in Repair
steering wheel in both and gear-wheel set Manual.
directions
8. Turning the steering 8.1 Hydraulic hoses for the steer- • Reverse the hoses.
wheel moves the ing cylinders have been con-
steered wheels in nected reversely.
opposite direction.
9. Leakage at either input 9.1 Shaft seal defective • Replace shaft seal.
shaft, end cover, gear- 9.2 Screws loose • Tighten screws.
wheel set, housing or
9.3 O-rings defective • Replace O-ring.
top part.
 9-13

REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

5
T = 29.4 ~ 39.2
(300 ~ 400)
[21.7 ~ 28.9]

Removal Procedure
1 Open the seat stand and disconnect the battery plug.
2 Remove the front toe board.
3 Remove the lower panel. (40 ~ 50 model)
4 Remove the steering column cover.
5 Remove the instrument panel (LH).
6 Disconnect the piping.
7 Remove the steering valve ASSY.
8 Remove the fitting.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Fill MP grease at the coupling between the tilt steering shaft and steering valve.
9-14

DISASSEMBLY • INSPECTION • REASSEMBLY

T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 40 ~ 60 (408 ~ 612) [29.5 ~ 44.3]

5
6

3
5

4 4

T = 24 ~ 36 (245 ~ 367) [17.7 ~ 26.6]

Disassembly Procedure
1 Remove the end cover. [Point 1]
2 Remove the gear wheel set, cardan shaft and distributor plate. [Point 2]
3 Remove the check valve.
4 Remove the sleeve W/spool and bearing. [Point 3]
5 Remove the O-ring, kin-ring and dust seal ring. [Point 4]
6 Remove the relief valve. [Point 5]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Wash each part with clean hydraulic oil before assembly.
 9-15

Point Operations
[Point 1]
Disassembly:
Put a match mark.
Reassembly:
Align the match marks.

Disassembly:
When removing each set bolt, carefully operate so as not
to lose the steel ball.
Reassembly:
Put the steel ball in the position shown in the figure before
installing each set bolts.
Reassembly:
As one out of seven set bolt is a bolt with pin, install it in
Steel ball the correct position.

[Point 2]
Reassembly:
Pay attention to the following points at the time of
Parallel reassembly.
1. Fit the gearwheel (rotor) and cardan shaft so that the
tooth base in the rotor is positioned in relation to the
shaft slot as shown. Turn the gear rim so that the
seven through holes match the holes in the housing.

2. Guide the carden shaft down into the bore so that the
Parallel
slot is parallel with the connection flange.

Flange

3. Align the match marks on the distributor plate and gear

wheel made at the time of disassembly.
When these parts are replaced, match the holes in the
housing and plate at the time of reassembly.
9-16

[Point 3]
Disassembly:
Extract the spool W/sleeve upward. Otherwise, the spool
cross pin may move during extraction and cause sticking.

Reassembly:
Set and install the neutral position spring correctly.

Reassembly:
Pay attention to the bearing direction for installation. (See
the figure.)

Chamfering

Sleeve

Reassembly:
Place the housing with its flanged side facing down, and
insert the spool W/sleeve into the housing. Set the cross
pin of the spool in horizontal state during insertion.

O-ring [Point 4]
Reassembly:
Install the kin-ring and O-ring correctly.

Note:
For SST No. SJ150-9000-11, please inquire at the nearest
Danfoss service shop.
Kin-ring
(Refer to Parts & Service News Ref. No. GE-7022 of July
1, 1997 for detail.)
 9-17

1. Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool into the bore
for the spool W/sleeve.
2. Apply O-ring and kin-ring with hydraulic oil and place
them on the tool.

3. Hold the outer part of the assembly tool in the bottom

of the steering unit housing and guide the inner part of
the tool right to the bottom.

4. Press and turn the O-ring W/kin-ring into position in

the housing.
5. Draw the inner and outer parts of the assembly tool
out of the steering unit bore, leaving the guide from
the inner part in the bore.

[Point 5]
Disassembly:
Do not remove the relief valve unless it is judged
defective.
The valve seat cannot be removed.
Disassembly:
Measure the screwed-in depth of the relief valve adjusting
screw before starting disassembly.

Reassembly:
Reassemble by adjusting to the screwed-in depth of the
valve spring retainer measured before disassembly. After
installing the steering valve ASSY on the vehicle,
measure the relief pressure. If it is not within the standard
range, adjust it by changing the screwed-in depth of the
retainer.
9-18

RELIEF PRESSURE
INSPECTION • ADJUSTMENT
1. Install a pressure gauge on the P port of the brake
change valve.

P 2. Set the knob position control solenoid to off in the

ANALYZER MENU screen. (See page 3-19.)

3. When the steering wheel is rotated beyond the end,

relief state is obtained. Read the pressure on the
pressure gauge at this time.

Standard:

kPa (kg/cm2) [psi]

+490 +5 +70
16 ~ 35 model 8040 0 (85 0 ) [1170 0 ]
+490 +5 +70
40 ~ 50 model 11770 0 (120 0 ) [1710 0 ]

3. If the standard is not satisfied, remove the steering valve

and make adjustment by turning the steering valve
adjusting screw.
 9-19

POWER STEERING PUMP ASSY (16 ~ 35 MODEL)

GENERAL

SPECIFICATIONS
Pump model 16 ~ 35 model TCP-031-A
Theoretical delivery cm3(in3)/rev. 3.15 (0.1922)

COMPONENTS
4510
9-20

REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

4
7
5

T = 20 ~ 30
4 (200 ~ 300)
[14.7 ~ 21.7]

Removal Procedure
1 Open the seat stand and disconnect the battery plug.
2 Remove the front toe board.
3 Disconnect the PS motor connector.
4 Disconnect the piping.
5 Remove the fitting (outlet).
6 Remove the PS motor W/PS pump ASSY.
7 Remove the PS pump ASSY from PS motor. [Point 1]
8 Remove the fitting (inlet).

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 9-21

PS pump
PS motor Point Operations
[Point 1]
Oil tank
side fitting Removal⋅Installation:
PS pump set bolts are located as shown in the figure.

High pressure
side fitting
PS pump set bolts

Oldham’s joint
Installation:
When assembling the PS motor and pump, fill molybde-
num disulfide grease in the groove on the oldham’s joint.
PS motor

Apply Molybdenum disulfide

grease to fill the groove.
 10-1

BRAKE
Page
GENERAL ........................................................................10-2
0
SPECIFICATIONS ..........................................................10-6
1
COMPONENTS ...............................................................10-7
2
FRONT BRAKE.............................................................10-10
DISASSEMBLY • INSPECTION • REASSEMBLY 3
(16 ~ 35 MODEL).........................................................10-10
4
DISASSEMBLY • INSPECTION • REASSEMBLY
(40 ~ 50 MODEL).........................................................10-12 5
PARKING BRAKE ........................................................10-15 6
DISASSEMBLY • INSPECTION • REASSEMBLY............10-15 7
BRAKE VALVE .............................................................10-18
8
TROUBLESHOOTING ...................................................10-18
9
REMOVAL • INSTALLATION..........................................10-18
DISASSEMBLY • INSPECTION • REASSEMBLY............10-20 10
BRAKE CHANGE VALVE ..........................................10-22 11
REMOVAL • INSTALLATION (16 ~ 35 MODEL) ............10-22 12
REMOVAL • INSTALLATION (40 ~ 50 MODEL) ............10-23
13
DISASSEMBLY • INSPECTION • REASSEMBLY............10-24
14
BRAKE AIR BLEEDING .............................................10-25
BRAKING FORCE INSPECTION .............................10-25
15
BRAKE HYDRAULIC PRESSURE INSPECTION 16
(16 ~ 35 MODEL) .......................................................10-26 17
BRAKE HYDRAULIC PRESSURE INSPECTION
18
(40 ~ 50 MODEL) .......................................................10-27
PARKING BRAKE SWITCH INSPECTION............10-28 19
BRAKE PEDAL INSPECTION • ADJUSTMENT ....10-29 20
21
22
 10-2

GENERAL
Front Brake
10

16 ~ 25 model

30 ~ 35 model
 10-3

40 ~ 50 model

0
1
2
3
4
5
6
7
8
9
Parking Brake
10
11
12
13
14
15
16
17
18
19
20
21
22
10-4

Brake Valve
16 ~ 35 model

From
oil pump To oil tank

To PS

To front brake

40 ~ 50 model

From
To front brake oil pump To oil tank

To PS
 10-5

Brake Change Valve

X X

0
1
Y A 2
T
3
4
P
5
6
PS 7
8
Y
9
X - X sectional view Y - Y sectional view
10
11
12
13
14
15
16
17
18
19
20
21
22
10-6

Hydraulic circuit diagram

T (till tank) A (till p-broms)

P (från pump) PS (till bromsventil)

SPECIFICATIONS
Model
16 ~ 25 30⋅35 40 ~ 50
Item
Type Wet disc brake
Brake lining dimensions
0.5 × 221 × 150 0.8 × 276 × 200
(Thickness × Outside diameter ×
Foot brake (0.02 × 8.70 × 5.91) (0.03 × 10.9 × 7.87)
Inside diameter) mm (in)
Number of discs 2 discs × 2 3 discs × 2 1 disc × 2
Lubricating oil SHELL DONAX TD
Type Full power CHPS
Input piston outside diameter
25.4 (1.00)
mm (in)
Brake valve Input piston stroke mm (in) 11.5 (0.45) 12.2 (0.48)
Maximum hydraulic pressure
7.85 (80.0) [1138] 12.7 (130) [1849]
MPa (kgf/cm2) [psi]
Oil used Hydraulic oil ISO VG32
Type Wet disc brake
Parking brake Number of discs 2
Lubricating oil SHELL DONAX TD
 10-7

COMPONENTS
16 ~ 35 model 4201

40 ~ 50 model

(DOUBLE)
10-8

4601

16 ~ 35 model 4704
 10-9

40 ~ 50 model 4704
10-10

FRONT BRAKE
DISASSEMBLY • INSPECTION • REASSEMBLY (16 ~ 35 MODEL)
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 31 ~ 45 (320 ~ 460)
5 [23.2 ~ 33.3]

T = 46 ~ 66 (470 ~ 670)
[34.0 ~ 48.5]

Disassembly Procedure
1 Remove the front axle ASSY and front axle shaft (inner). (See page 7-11.)
2 Remove the disc and pressure plate. [Point 1]
3 Remove the brake piston guide W/piston. [Point 2]
4 Remove the O-ring and D-ring from the front axle bracket.
5 Remove the spring. [Point 3]
6 Remove the piston guide and D-ring. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Apply MP grease to the O-ring and D-ring.
• After reassembly, bleed the air from the brakes. (See page 10-25.)
 10-11

Point Operations
[Point 1]

Inspection:
Measure the disc thickness.

Standard: 6.0 mm (0.236 in)

Limit: 5.6 mm (0.220 in)

Inspection:
Measure the pressure plate thickness.

Standard: 3.2 mm (0.126 in)

Limit: 2.6 mm (0.102 in)

[Point 2]

Disassembly:
After removing the set bolts, use service bolts to remove
the brake piston guide W/piston.

Service bolt size M10 × 1.25

Reassembly:
Service bolts Apply lock agent (08833-76001-71 (08833-00070) to the
set bolt threads and then uniformly tighten the set bolts in
order in opposing pairs.

A [Point 3]
Inspection:
Measure the spring warp.

Limit: A = 1.2 mm (0.047 in)

Reassembly:
Apply lock agent (08833-76001-71 (08833-00070) to the
set bolt threads, and tighten the set bolt.

[Point 4]

SST
SST Disassembly Reassembly:
•

Use a press and SST.

SST: 09950-76019-71
(SST: 09950-60020)
Disassembly Reassembly:
•

Be sure the press is oriented correctly.

10-12

DISASSEMBLY • INSPECTION • REASSEMBLY (40 ~ 50 MODEL)

T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 10.5 ~ 24.5
(110 ~ 250)
[7.8 ~ 18.1]

T = 45 ~ 60 3
(460 ~ 610)
[33.2 ~ 44.1]

Disassembly Procedure
1 Remove the front axle ASSY and front axle shaft (inner). (See page 7-16.)
2 Remove the disc and pressure plate. [Point 1]
3 Remove the brake piston guide W/piston. [Point 2]
4 Remove the O-ring, D-ring, and backup ring from the front axle bracket. [Point 3]
5 Remove the spring. [Point 4]
6 Remove the piston guide, D-ring, and backup ring. [Point 5]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Apply MP grease to the O-ring and D-ring.
• After reassembly, bleed the air from the brakes. (See page 10-25.)
 10-13

Point Operations
[Point 1]

Inspection:
Measure the disc thickness.

Standard: 5.6 mm (0.220 in)

Limit: 5.2 mm (0.205 in)

Inspection:
Measure the pressure plate thickness.

Standard: 3.2 mm (0.126 in)

Limit: 2.6 mm (0.102 in)

[Point 2]

SST Disassembly:
After removing the set bolts, use an SST to remove the
brake piston guide W/piston.
SST 09810-20172-71
Reassembly:
Apply lock agent (08833-76001-71 (08833-00070) to the
set bolt threads and then uniformly tighten the set bolts in
order in opposing pairs.

Front axle [Point 3]

bracket Backup ring
Reassembly:
Make sure the backup ring reassembly position is correct.

[Point 4]
Disassembly:
Use the press to push down the spring and then remove
the set bolts.
Reassembly:
Apply lock agent (08833-76002-71 (08833-00080) to the
set bolt threads.
Reassembly:
Use the press to push down the spring and then screw in
the set bolts.
10-14

Inspection:
Measure the free length of the spring.

Standard: 38 mm (1.50 in)

Limit: 34 mm (1.34 in)

Service bolts [Point 5]

Disassembly:
Use service bolts to remove the piston guide.

Service bolt size: M10 × 1.25

Reassembly:
Piston
Use the press to reassemble the components.
Make sure the backup ring reassembly position is correct.

Backup ring
 10-15

PARKING BRAKE
DISASSEMBLY • INSPECTION • REASSEMBLY
T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 26 ~ 48
(265 ~ 490) 3
[19.2 ~ 35.5]

6
4

T = 51.0 ~ 64.7 (520 ~ 660)

[37.6 ~ 47.8]

Disassembly Procedure
1 Remove the drive unit & front axle ASSY. (See page 6-6.)
2 Remove the parking brake cover. [Point 1]
3 Remove the gasket, cone spring washer, and washer. [Point 2]
4 Remove the parking brake piston W/parking brake housing.
5 Remove the parking brake piston and ring seal (D-ring). [Point 3]
6 Remove the brake disc, plate, and gasket. [Point 4]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Apply MP grease to the ring seal (D-ring).
10-16

Point Operations
[Point 1]
Disassembly Reassembly:
•

Uniformly loosen (tighten) the set bolts in order in opposing

pairs. Otherwise the bolt deformation by the inclined cover
should occur.

[Point 2]
Inspection:
A Measure the cone height of the cone spring washer.

Standard: 7.0 mm (0.276 in)

Limit: 6.35 mm (0.250 in)

Reassembly:
Make sure the cone spring washer reassembly position is
correct.

[Point 3]
Disassembly Reassembly:
•

Use a press.

[Point 4]
Inspection:
Measure the brake disc thickness.

Standard: 3.4 mm (0.134 in)

Limit: 3.06 mm (0.1205 in)
 10-17

Inspection:
Measure the plate thickness.

Standard: 2.5 mm (0.098 in)

Limit: 2.26 mm (0.0890 in)
10-18

BRAKE VALVE
TROUBLESHOOTING
Phenomenon Probable Cause Corrective Action
• Fluid leak from the hydraulic piping • Repair, add hydraulic fluid
causing the fluid level in the tank to drop
• Insufficient stroke due to a loose input • Adjust
piston double nut
Braking is poor, delayed • Fatigue breakage of input spring • Replace
• Damaged reaction piston O-ring • Replace
• Debris in spool • Clean, repair
• Excessive play due to loose clevis lock nut • Adjust the clevis
• Air has gotten in • Bleed out the air
• Spool remains depressed due to a loose • Adjust
Brakes drag clevis lock nut
• Debris in spool • Clean, repair

REMOVAL • INSTALLATION
16 ~ 35 model

5
 10-19

40 ~ 50 model

4
4

5
3

Disassembly Procedure
1 Remove the front toe board.
2 16 ~ 35 model: Remove the instrument panel LH.
40 ~ 50 model: Remove the lower panel.
3 Disconnect the piping.
4 Remove the push rod clevis pin.
5 Remove the brake valve.
6 Remove the fitting.

Installation Procedure
The installation rocedure is the reverse of the removal procedure.

Note:
• After installation, bleed the air from the brakes. (See page 10-25.)
• After installation, perform brake pedal adjustment. (See page 10-29.)
10-20

DISASSEMBLY • INSPECTION • REASSEMBLY

Note:
• All components are machined to a high-precision finish. Be careful not to damage them while
working.
• Conduct the work in a clean location.
T = N⋅m (kgf⋅cm) [ft⋅lbf]

1
3

4
T = 49.0 ~ 78.4 (500 ~ 800)
[36.2 ~ 57.9]

T = 67.7 ~ 107.9
(690 ~ 1100)
[49.9 ~ 79.6] 9
10
8

7
6

Disassembly Procedure
1 Remove the push rod.
2 Remove the boots.
3 Remove the lock nut, snap ring, and plate washer. [Point 1]
4 Remove the input piston and compression spring. [Point 2]
5 Remove the cylinder cap from the input piston. [Point 3]
6 Remove the hole plug.
7 Remove the closed valve, valve return spring, and spring retainer. [Point 4]
8 Remove the reaction piston guide W/reaction piston and the brake valve spool.
9 Remove the reaction piston guide.
10 Remove the reaction piston.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
• Carefully clean all components, blow them off with compressed air to remove dirt, coat them
with hydraulic oil, and then reassembly them.
• Apply silicon grease to the cylinder cap and then reinstall the cap.
• Apply MP grease to the end of the push rod.
 10-21

Point Operations
[Point 1]
Reassembly:
Adjust the input piston stroke.
1. Install the plate washer.
2. Place the snap ring onto the input piston.
3. Screw on the lock nut and adjust the input piston stroke.

Standard:16 ~ 35 model: A = 11.5 ± 1.0 mm

(0.453 ± 0.039 in)
A
40 ~ 50 model: A = 12.2 ± 1.0 mm
(0.480 ± 0.039 in)
4. Tighten the lock nuts.
5. Reinstall the snap ring.
Adjust:
After reassembly, check the brake hydraulic pressure.
(16 ~ 35 model: See page 10-26, 40 ~ 50 model: See page
10-27)
When lower than the standard value: Enlarge dimension A.
When higher than the standard value: Decrease dimension A.

[Point 2]
Inspection:
Measure the free length of the compression spring.

Standard: 16 ~ 35 model: 20 mm (0.79 in)

40 ~ 50 model: 21 mm (0.83 in)
Limit: 16 ~ 35 model: 18.0 mm (0.709 in)
40 ~ 50 model: 18.9 mm (0.744 in)

[Point 3]
Reassembly:
Make sure the cylinder cap is reinstalled in the correct ori-
entation.
SST 09471-22000-71

SST

[Point 4]
Inspection:
Measure the free length of the valve return spring.

Standard: 16 ~ 35 model: 20 mm (0.79 in)

40 ~ 50 model: 21.9 mm (0.862 in)
Limit: 16 ~ 35 model: 18.0 mm (0.709 in)
40 ~ 50 model: 19.7 mm (0.776 in)
10-22

BRAKE CHANGE VALVE

REMOVAL • INSTALLATION (16 ~ 35 MODEL)

4
3

Removal Procedure
1 Remove the front toe board.
2 Disconnect the change valve solenoid connector.
3 Disconnect the piping.
4 Remove the change valve.
5 Remove the fitting.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, bleed the air from the brakes. (See page 10-25.)
 10-23

REMOVAL • INSTALLATION (40 ~ 50 MODEL)

5
4

4 3

Removal Procedure
1 Remove the front toe board.
2 Disconnect the change valve solenoid connector.
3 Disconnect the parking brake pipe from the parking brake side.
4 Disconnect the piping.
5 Remove the change valve W/bracket.
6 Remove the bracket and parking brake pipe.
7 Remove the fitting.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, bleed the air from the brakes. (See page 10-25.)
10-24

DISASSEMBLY • INSPECTION • REASSEMBLY

Note:
• All components are machined to a high-precision finish. Be careful not to damage them while
working.
• Conduct the work in a clean location.
T = N⋅m (kgf⋅cm) [ft⋅lbf]

2
T = 49 (500)
[36.2]
1
4

T = 19.6 (200)
[14.5]

Disassembly Procedure
1 Remove the compression spring and steel ball.
2 Remove the filter.
3 Remove the spring.
4 Remove the solenoid. [Point 1]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point 1]
Inspection
Check the solenoid continuity.

Measurement locations: Between both solenoid con-

nector terminals.
Standard: Continuity exists.
 10-25

BRAKE AIR BLEEDING

Note:
Use two people to bleed the air.
1. Remove the bleeder plug cap and connect an air bleed
hose.
2. Turn the key switch to ON.
3. Step on the brake pedal.
4. Loosen the bleeder plug, and when the air stops
escaping from the air bleed hose, tighten the bleeder
plug and return the brake pedal.
5. Move the air bleed hose and replace the cap.

BRAKING FORCE INSPECTION

1. Inspect the braking force by means of a brake tester or traveling test.
Braking distance (without load)

Initial speed of braking km/h (mph) Max. speed

Braking distance m (ft) 5.0 (16.4) or less

PARKING BRAKE RELEASE PRESSURE

1. Install a pressure gauge in the P port of the brake

change valve.
2. Turn the key switch and seat switch to ON.
3. Select forward or reverse travel direction switch.
4. Read the pressure gauge while releasing, and applying
the parking brake.

5. The pressure should be between 25-30 bar.

P
10-26

BRAKE HYDRAULIC PRESSURE

INSPECTION (16 ~ 35 MODEL)
1. Install a pressure gauge in the P port of the brake
change valve.

2. Turn the key switch to ON and then measure the

P hydraulic pressure when the brake pedal is completely
depressed.
Standard: 7850 ± 500 kPa (80 ± 5 kgf/cm2)
[1138 ± 71 psi]

The following are probable causes when the measured

value does not satisfy the standard.
• Brake valve abnormality (incorrect input piston stroke
adjustment, defective seal, clogged pipe, wearing, etc.)
• Abnormality between the oil tank and the brake valve.
3. Turn the key switch to OFF.
4. Remove the SST and connect the brake pipe.
5. Disconnect the pipe on one of the sides of the three-way
valve and connect the oil pressure gauge via the SST.
SST
SST 09472-22000-71
6. Turn the key switch to ON and measure the hydraulic
pressure when the brake pedal is completely depressed
for 15 sec.
Standard: 7850 ± 500 kPa (80 ± 5 kgf/cm2)
[1138 ± 71 psi]

7. Disconnect the pipe from the opposite side of the three-

way from the one that was disconnected in Step 7 and
repeat Steps 7 and 8.

When the measured value in Step 4 is normal and the

measured values in Steps 8 to 9 do not satisfy the
standard, the following are probable causes.
• Front brake abnormality (Defective disc brake piston
seal, debris, wearing, etc.)
• When the measurement is taken at the three-way RH,
the LH front brake is abnormal.
• When the measurement is taken at the three-way LH,
the RH front brake is abnormal.

Note:
If the disc brake piston seal is defective, the hydraulic oil
could get into the drive unit oil and excessively raise the
level of the drive unit oil.
8. Remove the oil pressure gauge, reconnect the pipe, and
bleed the air from the brakes. (See page 10-25.)
 10-27

BRAKE HYDRAULIC PRESSURE

INSPECTION (40 ~ 50 MODEL)
1. Install a pressure gauge in the P port of the brake
change valve.

2. Turn the key switch to ON and then measure the

P hydraulic pressure when the brake pedal is completely
depressed.
Standard: 12700 ± 500 kPa (130 ± 5 kgf/cm2)
[1849 ± 71 psi]
The following are probable causes when the measured
value does not satisfy the standard.
• Brake valve abnormality (incorrect input piston stroke
adjustment, defective seal, clogged pipe, wearing, etc.)
• Abnormality between the oil tank and the brake valve.

3. Turn the key switch to OFF.

4. Remove the SST and Union and connect the brake pipe.
5. Disconnect one of the pipes from the three-way valve,
connect the union, and connect the oil pressure gauge
SST via the SST.
Union: 47711-21320-71
SST 09472-22000-71
6. Turn the key switch to ON and measure the hydraulic
pressure when the brake pedal is completely depressed
Union for 15 sec.
Standard: 12700 ± 500 kpa (130 ± 5 kgf/cm2)
[1849 ± 71 psi]
7. Disconnect the pipe from the opposite side of the three-
way from the one that was disconnected in Step 7 and
repeat Steps 7 and 8.
When the measured value in Step 4 is normal and the
measured values in Steps 8 to 9 do not satisfy the
standard, the following are probable causes.
• Front brake abnormality (Defective disc brake piston
seal, debris, wearing, etc.)
• When the measurement is taken at the three-way RH,
the LH front brake is abnormal.
• When the measurement is taken at the three-way LH,
the RH front brake is abnormal.
Note:
If the disc brake piston seal is defective, the hydraulic oil
could get into the drive unit oil and excessively raise the
level of the drive unit oil.
8. Remove the oil pressure gauge, reconnect the pipe, and
bleed the air from the brakes. (See page 10-25.)
10-28

Unlock PARKING BRAKE SWITCH INSPECTION

Lock

1. Remove the instrument panel LH and disconnect the

parking brake switch connector.

2. Release the lock and remove the parking brake switch.

3. Check the continuity when the parking brake switch is

OFF turned to ON/OFF.
ON Measurement locations: Between both terminals of the
parking brake key switch connector.

Standard: ON 0 Ω
OFF ∞ Ω
 10-29

BRAKE PEDAL INSPECTION • ADJUSTMENT

Stopper bolt

Brake valve Stopper bolt protrusion

B
C

A
D
1. Inspect brake pedal height A. (From toe board to top of pedal)

16 ~ 35 model: Standard: A = 143 ~ 148 mm (5.63 ~ 5.87 in) (with pedal pad)
40 ~ 50 model: Standard: A = 135.5 ~ 140.5 mm (5.33 ~ 5.53 in) (with pedal pad)

If the measured value does not satisfy the standard, make adjustment by changing the stopper bolt
protrusion.

2. Inspect brake pedal play B.

Standard: B = 5 ~ 9 mm (0.20 ~ 0.35 in)

If the measured value does not satisfy the standard, make adjustment by changing the brake valve
push rod length.

3. Check brake valve push rod play C with the brake pedal in the above state.

Standard: C = 1 mm (0.04 in)

4. After the adjustment, fully depress the brake pedal and inspect the pedal height D in that state.

16 ~ 35 model: Standard: D = 100 mm (3.94 in) or more

40 ~ 50 model: Standard: D = 100 mm (3.94 in) or more
 11-1

BODY
Page
COMPONENTS ...............................................................11-2
0
OPEN THE SEAT STAND METHOD.........................11-7
1
SEAT STAND ASSY ......................................................11-8
REMOVAL • INSTALLATION............................................11-8
2
SEAT STAND ADJUSTMENT .........................................11-9 3
COUNTERWEIGHT......................................................11-10 4
REMOVAL • INSTALLATION..........................................11-10 5
DRIVER’S SEAT ...........................................................11-11
6
REMOVAL • INSTALLATION..........................................11-11
7
FUSE ................................................................................11-12
FUSE INSTALLATION POSITION.................................11-12
8
NAMES (APPLICABLE PORTIONS) AND 9
CAPACITIES ...............................................................11-12
10
11
12
13
14
15
16
17
18
19
20
21
22
11-2

COMPONENTS
16 ~ 35 model 5101
(20, 25, 30, 35 WIDE TREAD)

(BATT.ROLL OUT,HI-HEIGHT BATT)

16 ~ 35 model
 11-3

40 ~ 50 model 5101
(DOUBLE) (BATT.ROLL OUT) (HI-HEIGHT BATT)

0
83[RH, REAR]

83[RH, FRONT]
1
2
3
4
(BATT.ROLL OUT,HI-HEIGHT BATT)
5
6
7
8
40 ~ 50 model 9
10
11
12
13
14
15
16
17
18
19
20
21
22
11-4

16 ~ 35 model 5201

40 ~ 50 model
 11-5

16 ~ 35 model 40 ~ 50 model 5301

0
1
2
3
4
5
6
7
8
40 ~ 50 model 9
10
11
12
13
14
15
16
17
18
19
20
21
22
11-6

16 ~ 35 model 5702

[L/RR COMBI]

[BUZZER]

40 ~ 50 model

DK[L/RR COMBI]

[L/RR COMBI]
 11-7

OPEN THE SEAT STAND METHOD

1. Pull the lock release lever and incline the steering post forward.
2. Move the mini lever box to the most backward position. (16 ~ 35 model)
Tilt up the mini lever box to the most backward position. (40 ~ 50 model)
3. Move the seat to the most forward position. (16 ~ 35 model)
Move the seat to the most backward position. (40 ~ 50 model)
4. Open the seat stand.
16 ~ 35 model

1 2 3 4

40 ~ 50 model

1 2 3 4
11-8

SEAT STAND ASSY

REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

2 4

16·18 model

T = 10.5 ~ 24.5
(107 ~ 250)
[7.7 ~ 18.1]

Removal Procedure
1 Open the seat stand ASSY and disconnect the battery plug.
2 Remove the mini lever. (See page 16-27)
3 Remove the mini lever stand.
4 Remove the driver’s seat. (See page 11-11)
5 16 18 model: Disconnect the damper stay from the seat stand ASSY.
•

20 25 model: Disconnect the two damper stays from the seat stand ASSY.
•

30 ~ 50 model: Disconnect the three damper stays from the seat stand ASSY.
6 Disconnect the wiring.
7 Close the seat stand ASSY and remove the seat stand ASSY set bolts.
8 Remove the seat stand ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, perform seat stand adjustment. (See page 11-9)
 11-9

16 ~ 35 model Striker SEAT STAND ADJUSTMENT

Ellipse
A
1. Striker adjustment
(1) Install the bolts in the middle of the striker ellipse.
Forward
(2) 16 ~ 35 model:
Backward
Adjust by moving the striker backward when the lock
is too tight, or forward when the lock is too loose.
40 ~ 50 model:
Adjust by adding a shim when the lock is too tight, or
removing the shim when the lock is too loose.

40 ~ 50 model (3) Apply MP grease to area A shown in the figure.

Note:
When adjustment cannot be sufficiently made using the
striker alone, adjust the lock bracket.

Shim

2. Seat stand release wire and lock bracket adjustment

(1) Install the seat stand release wire in the position
shown in the figure.
(2) Loosen the lock bracket set bolt and adjust the
bracket ellipse.

Ellipes
11-10

COUNTERWEIGHT
REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

2
16 ~ 35 model:
T = 300 ~ or more
(3060 ~ or more)
[221.4 ~ or more]
40 ~ 50 model:
T = 420 ~ or more
(4280 ~ or more)
[309.7 ~ or more]

Removal Procedure
1 Remove the weight cap and temporarily hoist the counterweight slinging with a wire rope.
2 Remove the drawbar, and remove the counterweight set bolt.
3 Remove the counterweight.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
See page 0-17 for the mass of the counterweight.
 11-11

DRIVER’S SEAT
REMOVAL • INSTALLATION

4
3

Removal Procedure
1 Open the seat stand and disconnect the battery plug.
2 Disconnect the seat switch connector.
3 Hang the driver’s seat Temporarily.
4 Remove the driver’s seat set nuts.
5 Remove the driver’s seat. [Point 1]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Point Operation
[Point 1]
Inspection:
Push on the seat cushion and check continuity of the seat
switch.
Free : OFF (∞ Ω)
Push : ON (0 Ω)
11-12

FUSE
FUSE INSTALLATION POSITION
All other fuses are installed on the contactor panel.

F5 F4

F6 F3

F7

F1

NAMES (APPLICABLE PORTIONS) AND CAPACITIES

16 ~ 18 model 20 ~ 35 model 40 ~ 50 modle
F1 For drive 500A 600A 700A
F3 For PS 40A ← ←
F4 For lamps 10A ← ←
F5 For control circuit 10A ← ←
F6 For SAS & solenoid 10A ← ←
F7 For DC-DC converter 10A ← ←

Caution for fuse replacement

Always disconnect the battery plug and discharge CO (overall capacitor) by connection between P3 and
N1 with a resistance of about 100 Ω before replacing any fuse.
Instrumentpanel 11-13

Modellkod 7FBMF16-50
Serienummer
5702145 METER & SWITCH
(0208- )[2/2]
 12-1

MATERIAL HANDLING SYSTEM

Page
HYDRAULIC SYSTEM DIAGRAM .............................12-2
0
COMPONENTS ...............................................................12-3
1
RETURN FILTER ............................................................12-6
REMOVAL • INSTALLATION (16 ~ 35 MODEL) ..............12-6
2
REMOVAL • INSTALLATION (40 ~ 50 MODEL) ..............12-7 3
SUCTION FILTER ..........................................................12-8 4
REMOVAL • INSTALLATION (16 ~ 35 MODEL) ..............12-8 5
REMOVAL • INSTALLATION (40 ~ 50 MODEL) ..............12-9
6
NATURAL DROP TEST ..............................................12-10
7
NATURAL FORWARD TILT TEST ..........................12-10
OIL LEAK TEST............................................................12-11
8
LIFT CYLINDER ............................................................12-11 9
TILT CYLINDER ............................................................12-12 10
11
12
13
14
15
16
17
18
19
20
21
22
 12-2

HYDRAULIC SYSTEM DIAGRAM

12

16 ~ 35 model

Lift cylinder
Oil control valve

Return filter

Oil tank

Tilt cylinder
Steering valve
Brake valve

Brake
change Suction filter Oil pump
valve

Solenoid
valve
PS pump
Pump
Parking motor
brake
PS motor
Power steering cylinder Front brake

40 ~ 50 model

Lift cylinder
Oil control valve

Tilt cylinder
Return
filter
Steering
valve Brake valve

Oil pump
Suction filter

Solenoid Brake Pump

valve change motor
valve
Parking
brake
Power steering cylinder Front brake
 12-3

COMPONENTS
16 18 model
•
6801

45 [REAR] [BATT.ROLL OUT,HI-HEIGHT BATT]

45 [FRONT]
45 [FRONT]
45 [REAR]

0
[OIL FULL]
1
2
[MAST LESS]

3
4
5
6
7
8
9
20 ~ 35 model
[OIL FULL]
10
59 [FRONT]
11
45 [REAR]

45 [FRONT] 59 [REAR]
45 [FRONT]
45 [REAR]
12
[BATT.ROLL OUT,HI-HEIGHT BATT]
[OIL FULL] 13
[MAST LESS] 14
15
16
17
18
19
20
21
22
12-4

40 ~ 50 model 6801

40 ~ 50 model

(MAST LESS)
 12-5

16 ~ 50 model (V) 6801

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
12-6

RETURN FILTER
REMOVAL • INSTALLATION (16 ~ 35 MODEL)
T = N⋅m (kgf⋅cm) [ft⋅lbf]

Removal Procedure
1 Drain hydraulic oil.
2 Remove the front toe board.
3 Disconnect the piping.
4 Remove the return filter.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 12-7

REMOVAL • INSTALLATION (40 ~ 50 MODEL)

T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 11.5 (117)
[8.46]
5
4

Removal Procedure
1 Remove the hood (LH).
2 Remove the guard.
3 Remove the oil tank cover.
4 Disconnect the piping.
5 Remove the return filter.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
12-8

SUCTION FILTER
REMOVAL • INSTALLATION (16 ~ 35 MODEL)
T = N⋅m (kgf⋅cm) [ft⋅lbf]

20 ~ 35 model
3

6
7

5
T = 11.5 (117)
[8.46]

T=9.8 ~ 14.7 (100 ~ 150)

[7.24 ~ 10.9]

Removal Procedure
1 Open the seat stand and disconnect the battery plug.
2 Drain hydraulic oil.
3 Remove the battery plug set bolts.
4 Disconnect the motor fan connector.
5 Remove the motor fan W/bracket.
6 Remove the motor fan (lower). (20 ~ 35 model)
7 Remove the oil tank cover W/oil level gage.
8 Remove the suction filter.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 12-9

REMOVAL • INSTALLATION (40 ~ 50 MODEL)

Note:
Do not subject the SAS controller to shocks as it cannot withstand them.
T = N⋅m (kgf⋅cm) [ft⋅lbf]
6

T = 11.5 (117) [8.46]

4
3

8
9

Removal Procedure
1 Open the seat stand and disconnect the battery plug.
2 Drain hydraulic oil.
3 Remove the hood ASSY (LH).
4 Remove the SAS controller cover.
5 Disconnect the SAS connector.
6 Remove the SAS controller W/bracket.
7 Disconnect the piping.
8 Remove the oil tank cover W/suction filter.
9 Remove the suction filter.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
12-10

NATURAL DROP TEST

1. Set the mast in the vertical position with the standard
load on the fork. Lift the fork by 1 to 1.5 m (40 to 59 in),
and turn the key switch to OFF.

2. Draw datum lines on the inner and outer masts, and

measure the drop in 15 minutes.

Limit: 45 mm (1.77 in)

NATURAL FORWARD TILT TEST

1. Set the mast in the vertical position with standard load
on the fork. Lift the fork by about 50 cm (19.7 in) and
turn the key switch to OFF.

2. Measure the tilt cylinder rod extension in 15 minutes.

Limit: 15 mm (0.59 in)

 12-11

OIL LEAK TEST

LIFT CYLINDER

1. Set the mast in the vertical position with the standard

load on the fork. Lift the fork by 1 to 1.5 m (40 to 59 in).
2. 16 ~ 35 model:
(1) Slowly tilt the mast fully forward, and turn the key switch
to OFF.
(2) Drain hydraulic oil.
(3) After waiting for 5 minutes, disconnect the oil control
16 ~ 35 model
valve to oil tank hose. Place a measuring cylinder
under the fitting and measure the amount of oil
leaking in one minute.
(4) After measurement, replenish hydraulic oil to tank.
3. 40 ~ 50 model:
(1) Slowly tilt the mast fully foward, and turn the key switch
to OFF.
(2) After waiting for 5 minutes, disconnect the oil control
valve to oil tank hose. Place a measuring cylinder
under the fitting and measure the amount of oil
leaking in one minute.
40 ~ 50 model
Standard (at lift port):
16 ~ 35 model: 8 cm3 (0.49 in3) or less
40 ~ 50 model: 10 cm3 (0.61 in3) or less

Note:
If the natural drop is great even though the oil leak
amount is within the standard, the lift lock valve or lift
cylinder packing is defective.
12-12

TILT CYLINDER

1. Set the mast in the vertical position with standard load

on the fork. Lift the fork by about 50 cm (19.7 in) and
turn the key switch to OFF.
2. 16 ~ 35 model:
(1) Drain hydraulic oil.
(2) After waiting for 5 minutes, disconnect the oil control
valve to oil tank hose. Place a measuring cylinder
under the fitting and measure the amount of oil
leaking in one minute.
16 ~ 35 model
(3) After measurement, replenish hydraulic oil to tank.
3. 40 ~ 50 model:
(1) After waiting for 5 minutes, disconnect the oil control
valve to oil tank hose. Place a measuring cylinder
under the fitting and measure the amount of oil
leaking in one minute.

Standard (total for lift and tilt):

16 ~ 35 model: 16 cm3 (0.98 in3) or less
40 ~ 50 model: 20 cm3 (1.22 in3) or less

40 ~ 50 model 4. The leak amount at the tilt port is the total leak amount
less the leak amount from the lift port.

Note:
If the natural forward tilt is great even though the oil leak
amount is within the standard, either the tilt lock valve or
the tilt cylinder packing is defective.
 13-1

MAST
Page Page
V MAST ASSY................................. 13-2 COMPONENTS.............................. 13-36 0
COMPONENTS................................ 13-2 MAST ADJUSTMENT 1
(FV • FSV MAST, 16 ~ 35 MODEL) 13-41
REMOVAL • INSTALLATION............ 13-7 2
MAST ADJUSTMENT
REMOVAL • INSTALLATION
(W/LIFT BRACKET) .................... 13-10
(FV • FSV MAST, 3
40 ~ 50 MODEL).......................... 13-45
MAST DISASSEMBLY • INSPECTION 4
LIFT CYLINDER ROD SHIM
REASSEMBLY ............................ 13-12
ADJUSTMENT (PREVENTION 5
LIFT BRACKET DISASSEMBLY • OF UNEVEN LIFTING) ............. 13-56
INSPECTION • REASSEMBLY..... 13-15 6
MAST ADJUSTMENT 7
(V MAST, 16 ~ 35 MODEL) ......... 13-17
MAST ADJUSTMENT
8
(V MAST, 40 ~ 50 MODEL) ......... 13-22 9
MAST ROLLER REMOVAL •
INSTALLATION........................... 13-29 10
CHAIN (16 ~ 35 MODEL)............ 13-30 11
INSPECTION ................................. 13-30 12
REASSEMBLY (V • FV • FSV) .......... 13-30
13
ADJUSTMENT ............................... 13-31
14
CHAIN (40 ~ 50 MODEL)............ 13-32
INSPECTION ................................. 13-32
15
REASSEMBLY (V • FV • FSV) .......... 13-32 16
ADJUSTMENT ............................... 13-35 17
FORK ............................................... 13-35 18
REMOVAL ..................................... 13-35
19
INSTALLATION ............................. 13-35
INSPECTION ................................. 13-35
20
FV • FSV MAST ASSY .................. 13-36 21
22
 13-2

V MAST ASSY
6

COMPONENTS
16 ~ 30 model 35 model 6101

40 ~ 50 model
 13-3

16 18 model
•
6301

0
1
2
3
4
5
6
7
8
20 25 model
•

9
10
11
12
13
14
15
16
17
18
19
20
21
22
13-4

30 model 6301

35 model
 13-5

40 45 model
•
50 model 6301

0
(BACKREST LESS) (BACKREST LESS) 1
2
3
4
5
6
7
8
9
16 ~ 25 model 30 model 6302
10
11
12
13
14
15
16
17
18
19
20
21
22
13-6

35 model 6302

40 45 model
•
50 model
 13-7

REMOVAL • INSTALLATION
T = N⋅m (kgf⋅cm) [ft⋅lbf]

10

11

2 T = 86.3 ~ 129.4
(880 ~ 1320)
[63.7 ~ 95.48]
4

T = 147.1 ~ 343.2
(1500 ~ 3500)
[108.5 ~ 253.2]

Removal Procedure
1 Set the mast vertically and fully lower the fork.
2 Disconnect the chain. [Point 1]
3 Remove the chain wheel. [Point 2]
4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift
bracket, and slowly run the vehicle backward to depart from the lift bracket.)
5 Remove the front toe board.
6 Disconnect the fork height switch and load sensor wiring.
7 Disconnect the overflow hose and high pressure hose.
8 Slightly hoist the mast.
9 Remove the mast support cap. [Point 3]
10 Remove the tilt cylinder front pin. [Point 4]
11 Remove the mast ASSY.
13-8

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
• Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease on the tilt cylinder front pin.
• Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast, or either lift
cylinder is replaced. (See page 13-56.)
• Adjust the chain tension after installation. (See page 13-31 and 13-35.)
• When the mast is replaced, perform SAS matching after installation. (See page 3-51.)
Point Operations
SST [Point 1]
Removal Installation:
•

16 ~ 35 model
SST 09630-23600-71
40⋅55 model
SST 09630-31720-71
50 model
SST 09630-33900-71

[Point 2]
SST
Removal:
If the fitting is hard, use the SST for removal.
SST 09950-76014-71
(SST 09950-40011)

[Point 3]
Removal:
40 ~ 50 model
Put match marks.

Installation:
40 ~ 50 model
Align the match marks.

Match mark

[Point 4]
Removal:
Put match marks to clarify relative positions of the front
pin, stopper plate, and lock bolt. Match marks, however,
are unnecessary when the mast or mast ASSY is replaced
since mast tilt angle adjustment is to be done after the
replacement.
 13-9

Removal:
SST 09810-20172-71

SST
13-10

REMOVAL • INSTALLATION (W/LIFT BRACKET)

T = N⋅m (kgf⋅cm) [ft⋅lbf]

T = 86.3 ~ 129.4
(880 ~ 1320)
[63.7 ~ 95.48]

T = 147.1 ~ 343.2
(1500 ~ 3500) 7
[108.5 ~ 253.2]

Removal Procedure
1 Set the mast vertically.
2 Remove the fork. (See page 13-35.)
3 Remove the front toe board.
4 Disconnect the wiring of the fork height switch and load sensor.
5 Disconnect the overflow hose and high pressure hose.
6 Slightly hoist the mast.
7 Remove the mast support cap. [Point 1]
8 Remove the tilt cylinder front pin. [Point 2]
9 Remove the mast ASSY W/lift bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 13-11

Note:
• Apply MP grease on the mast support bushing and mast support cap interior surfaces and on
the tilt cylinder front pin.
• Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast, or either
lift cylinder is replaced. (See page 13-56.)
• When the mast is replaced, perform SAS matching after installation. (See page 3-51.)

Point Operations
[Point 1]
Removal:
40 ~ 50 model
Put match marks.

Installation:
40 ~ 50 model
Match mark Align the match marks.

[Point 2]
Removal:
Put match marks to clarify relative positions of the front
pin, stopper plate, and lock bolt. Match marks, however,
are unnecessary when the mast or mast ASSY is replaced
since mast tilt angle adjustment is to be done after the
replacement.

Removal:
SST 09810-20172-71

SST
13-12

MAST DISASSEMBLY • INSPECTION REASSEMBLY

40⋅45 model 16 ~ 35 model 50 model

3 3
3

4
2

7
8 7

Disassembly Procedure
1 Remove the fork height switch.
2 Disconnect the overflow hose and high pressure hose.
3 Remove each cylinder rod end set bolt, and take each rod end off. [Point 1]
4 Remove each cylinder support. [Point 2]
5 Remove each cylinder bottom set bolt. (16 ~ 35 model)
6 Remove each lift cylinder.
7 Slide the inner mast in the lowering direction, and remove the lift rollers.
8 Remove the mast strip. [Point 3]
9 Remove the outer mast.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
 13-13

Point Operations
Shim
[Point 1]
Disassembly:
Shim adjustment has been made at the lift cylinder rod
end for prevention of cylinder uneven motion between the
left and right sides. Take a note on which side the shim
adjustment is made and the number of shims in use.

16 ~ 35 model [Point 2]
16 ~ 35 model
Disassembly:
Take a note of the number of cylinder support shims in
Shim use.

Reassembly:
Adjust the cylinder support shim if the mast or either
cylinder is replaced.
With the cylinder rod end inserted in the inner mast, insert
shim(s) between the cylinder support and outer mast to
40⋅45 model
eliminate the clearance. The shim thickness should be
slightly greater than the clearance.
Shim 40⋅45 model
Disassembly:
Take a note of the number of cylinder support shims used.

Reassembly:
When the mast or cylinder is replaced, adjust the shim at
40⋅45 model Support the cylinder support. With the cylinder rod end inserted in
(0.20 in)
5 mm

the inner mast, eliminate the clearance between the cylin-

Clearance

der support and outer mast by inserting shims. The shim

thickness should be slightly thicker than the clearance.
Reassembly:
Clearance

The supports can be used in either the upper or lower di-

rection. Since a level difference of 5 mm (0.20 in) will arise
depending on the direction, install in the direction with the
Cylinder least clearance with the cylinder.

50 model 50 model
Disassembly:
Take a note of the number of cylinder support shims in
use.

Reassembly:
Shim
Adjust the cylinder support shim if the mast or either
cylinder is replaced.
With the cylinder rod end inserted to the inner mast, insert
shim(s) between the cylinder support and outer mast to
eliminate the clearance. The shim thickness should be
slightly greater than the clearance.