Sef 2a0de
Sef 2a0de
Sef 2a0de
SEF-2A0DE
R
SERVICE MANUAL
SERVICE MANUAL
FORKLIFT TRUCK
No. SEF-2A0DE
TCM CORPORATION
No. SEF-2A0DE
FOREWORD
TCM’s new forklift trucks with capacities from 2.0 through 3.5 tons feature low operating noise and
reduced vibration as well as improved controllability and higher safety, and come equipped with new
high-performance engines.
The gasoline engines are equipped with an FTI system, auto-choke, and idle-up device, while the
diesel engines come with an auto grow system to improve startability.
The steering system can correct steering wheel knob deviation automatically to provide better driver
control. The instrument panel accommodates optional OK monitors which allow the operator to check
the water level, air cleaner plugging, and battery condition of charge with just a glance. The service-
ability of these trucks has been greatly improved by these changes.
The trucks are equipped with traveling and load handling interlock systems (the traveling interlock
system is only available on automatic transmission trucks) which turn on switches that prevent the
truck from moving and disable the load handling system if the operator is not in the operator’s seat.
This Service Manual describes all of the major components and their service procedures. We en-
courage you to make practical use of it while servicing the trucks.
We also hope you will understand that, due to on-going improvements of the parts and components,
the values and some of the descriptions in this manual are subject to change without notice.
September, 2012
No. SEF-2A0DE
(Empty page)
SPECIFICATIONS (1)
Truck model FG20C3 FHG20C3 FG25C3 FHG25C3 FG30C3 FHG30C3
Item FG20T3 FHG20T3 FG25T3 FHG25T3 FG30T3 FHG30T3
Performance
Max. load kg[lbs] 2000 [4000] ← 2500 [5000] ← 3000 [6000] ←
Basic load center mm[in.] 500 [24] ← ← ← ← ←
Lift height mm[in.] 3000 [118.1] ← ← ← ← ←
Tilt angle (fwd-bwd) ° 6 - 12 ← ← ← ← ←
Free lift mm[in.] A 110 [4.3] ← ← ← 165 [6.5] ←
Lift speed mm/s[fpm]
(unloaded) 580 [114.2] 620 [122.1] ← ← 490 [96.5] 520 [102.4]
(loaded) 540 [106.3] 600 [118.1] ← ← 440 [86.6] 500 [98.4]
Traveling speed km/h[mph] C3 T3 C3 T3 C3 T3 C3 T3 C3 T3 C3 T3
fwd 1st 8.5 [5.3] 19.0 [11.8] 9.0 [5.4] 19.0 [11.8] 8.5 [5.3] 19.0 [11.8] 9.0 [5.4] 19.0 [11.8] 9.0 [5.4] 19.5 [12.1] 9.5 [5.9] 19.5 [12.1]
2nd 19.0 [11.8] * 19.0 [11.8] * 19.0 [11.8] * 19.0 [11.8] * 19.5 [12.1] * 19.5 [12.1] *
rev 1st 8.5 [5.3] 19.0 [11.8] 9.0 [5.4] 19.0 [11.8] 8.5 [5.3] 19.0 [11.8] 9.0 [5.4] 19.0 [11.8] 9.0 [5.4] 19.5 [12.1] 9.5 [5.9] 19.5 [12.1]
2nd 19.0 [11.8] * 19.0 [11.8] * 19.0 [11.8] * 19.0 [11.8] * 19.5 [12.1] * 19.5 [12.1] *
Max. drawbar pull kN{kgf}[lbf] C3 T3 C3 T3 C3 T3 C3 T3 C3 T3 C3 T3
(unload) 8.3{850} ← ← ← ← 9.8 {1000} ← ←
[1866] [2203]
(loaded) 12.3{1250} 16.7{1700} 14.2{1450} 22.1{2250} 12.3{1250} 16.7{1700} 14.2 {1450} 22.1{2250} 10.8{1100} 14.2{1450} 12.7{1300} 19.6{2000}
[2765] [3754] [3192] [4968] [2765] [3754] [3192] [4968] [2428] [3192] [2855] [4406]
Gradeability C3 T3 C3 T3 C3 T3 C3 T3 C3 T3 C3 T3
(unload) 1/5.0 ← ← ← ← 1/5.0 ← ←
(loaded) 1/5.0 1/3.5 1/4.2 1/2.8 1/5.2 1/4.2 1/4.8 1/3.0 1/7.2 1/5.6 1/5.6 1/4.1
Min. turning radius mm[in.] B 2170 [85.4] ← 2240 [88.2] ← 2400 [94.5] ←
Min. 90° intersecting aisle mm[in.] C 1920 [75.6] ← 2010 [79.1] ← 2110 [83.1] ←
Dimensions
Overall length mm[in.] D 3550 [139.8] ← 3625 [142.7] ← 3775 [148.6] ←
Overall width mm[in.] E 1150 [45.3] ← ← ← 1225 [48.2] ←
Overall height
(at overhead guard) mm[in.] F 2070 [81.5] ← ← ← 2090 [82.3] ←
Overall height with
extended mast mm[in.] G 4030 [158.7] ← ← ← 4250 [167.3] ←
Wheelbase mm[in.] H 1600 [63.0] ← ← ← 1700[66.9] ←
Tread mm[in.]
(front) J 970 [38.2] ← ← ← 1000 [39.4] ←
(rear) K 970 [38.2] ← ← ← ← ←
Fork overhang L 445 [17.5] ← 450 [17.7] ← 480 [18.9] ←
Rear overhang mm[in.] M 435 [17.1] ← 505 [19.9] ← 525 [20.7] ←
Fork size mm[in.] 1070 x 122 x 40 ← ← ← 1070 x 125 x 45 ←
(Length (N) x Width (P) x Thick (Q) [42.1 x 4.8 x 1.6] [42.1 x 4.9 x 1.8]
Fork spacing mm[in.] R 245 - 1020 ← ← ← 250 - 1090 ←
[9.65 - 40.2] [9.8 - 42.9]
Under clearance (at mast) mm[in.] 110 [4.3] ← ← ← 140 [5.5] ←
Weight
Operating weight kg[lbs] 3210 [7077] 3220 [7099] 3570 [7871] 3580 [7893] 4250 [9370] 4260 [9392]
No. SEF-2A0DE
SPECIFICATIONS (2)
Truck model FD20C3Z FHD20C3A FD25C3Z FHD25C3A FD30C3Z FHD30C3A
Item FD20T4 FHD20T3A FD25T4 FHD25T3A FD30T4 FHD30T3A
Performance
No. SEF-2A0DE
Unit: mm [in.]
3000 [118.1]
Free lift
[4786.2 - 5511.4]/290
Ignition timing (before TDC) °/rpm 2 ± 1/700 * *
Injection timing (before TDC) °/rpm * 15.7 - 17.0 9 ± 0.5
Injection start pressure MPa{kgf/cm2}[psi] * 13.7 {140} [1987] 11.8 {120} [1711.4]
10 ± 2 [0.39 ± 0.079]/ 8 ± 1 [0.315 ± 0.039]/ 10 ± 2 [0.39 ± 0.079]/
Fan belt deflection mm[in.]/N{kgf}[lbf] 98 {10} [22.03] 58.8 - 68.6 {6 - 7} [13.2 - 15.4] 98 {10} [22.03]
20.6 ± 3.9 {2.1 ± 0.4}
Gas cylinder mounting bolt torque N-m{kgf-m}[lbf-ft] [15.19 ± 2.88] * *
Standard truck mm [in.] 117 ± 5 [4.6 ± 0.197] * 117 ± 5 [4.6 ± 0.197]
Clutch pedal height
Clutch pedal play mm [in.] 0 - 5 [0 - 0.197] * 0 - 5 [0 - 0.197]
Clutch pedal travel mm [in.] 65 ± 10 [2.56 ± 0.39] * 65 ± 10 [2.56 ± 0.39]
Power train
Clutch disc thickness mm [in.] 9.1 ± 0.3 [0.36 ± 0.012] * 9.1 ± 0.3 [0.36 ± 0.012]
1.08 - 1.47 {10.9 - 15}
Transmission clutch oil pressure MPa{kgf/cm2}[psi] ← *
[156.6 - 213.2]
Inching pedal height mm [in.] 117 ± 5 [4.6 ± 0.197] ← *
Inching pedal play mm [in.] 0 [0] 40 [1.57] *
Clearance between inching pedal and floor mm [in.] 90 ± 5 [3.54 ± 0.197] ← ←
plate (with clutch disengaged)
0.69 ± 0.03 {7.0 ± 0.3} [100.1 ± 4.35]
Tire Front (single, double) MPa{kgf/cm }[psi]
2
0.69 ± 0.03 {7.0 ± 0.3} [100.1 ± 4.35] ← ←
inflation
pressure 0.69 ± 0.03 {7.0 ± 0.3}
Rear MPa{kgf/cm }[psi]
2
[100.1 ± 4.35] ← ←
470.7 - 549.2 {48 - 56}
Front N-m{kgf-m}[lbf-ft] [347.2 - 405.1] ← ←
Hub nut torque
Wheels and axles
Tilt cylinder piston rod lock bot and nut N-m{kgf-m}[lbf-ft] 107.9 ± 20.6 {11.0 ± 2.1}
torque [79.58 ± 15.19] ← ←
Lift cylinder natural drop mm [in.]/min less than 60 [2.36]/10 ← ←
Tilt cylinder natural inclination (extension of piston rod) mm [in.]/min less than 20 [0.79]/10 ← ←
Fork lifting speed mm [in.]/sec 580+0 -50 [22.8 ] 670-0 [26.4+0
+50
-1.97 ] 670-0 [26.4+0
+50
-1.97 ]
Truck model FHG20C3 FHG20T3 FHD20C3A FHD20T3A FHG30C3 FHG30T3 FHD30C3A FHD30T3A
Item FHG25C3 FHG25T3 FHD25C3A FHD25T3A
Unloaded maximum rpm 2800 ± 100 2600 ± 100 2800 ± 100 2600 ± 100
Idling rpm 800 ± 50 800 ± 25 800 ± 50 800 ± 25
Valve C: Cold Intake valve mm [in.] H: 0.38 ± 0.02 [0.015 ± 0.0008] C: 0.25 - 0.02 [0.0098 ± 0.0008] H: 0.38 ± 0.02 [0.015 ± 0.0008] C: 0.25 ± 0.02 [0.0098 ± 0.0008]
clearance H: Hot Exhaust valve mm [in.] H: 0.38 ± 0.02 [0.015 ± 0.0008] C: 0.25 - 0.02 [0.0098 ± 0.0008] H: 0.38 ± 0.02 [0.015 ± 0.0008] C: 0.25 ± 0.02 [0.0098 ± 0.0008]
1.5/1.28 {15.3} 2.84 - 3.23 {29 - 33} 1.5/1.28 {15.3} 2.84 - 3.23 {29 - 33}
Compression MPa{kgf/cm2}[psi]/rpm [210.3]/250 [412.8 - 469]/290 [210.3]/2500 [412.8 - 469]/290
Engine
Gas cylinder mounting bolt torque 20.6 ± 3.9 {2.1 ± 0.4} 20.6 ± 3.9 {2.1 ± 0.4}
N-m{kgf-m}[lbf-ft] * *
[15.19 ± 2.88] [15.19 ± 2.88]
Standard truck mm [in.] 117 ± 5 [4.6 ± 0.197] ← ← ←
Clutch pedal height
117 ± 5 [4.6 ± 0.197] ← ← ←
Clutch pedal play mm [in.] 0 - 5 [0 - 0.197] ← ← ←
Clutch pedal travel mm [in.] 65 ± 10 [2.56 ± 0.39] ← ← ←
Power train
Held in position
Unloaded ← ← ←
on 20% slope
Parking brake braking force
Held in position
Loaded ← ← ←
on 15% slope
0.25 - 0.45 [0.0098 -
Clearance between brake drum and lining mm [in.] 0.4 - 0.45 [0.016 - 0.018] ← ←
0.018]
Lining thickness mm [in.] -5 [0.276-0.197 ]
7+0 +0
← 8+0
-5 [0.315-0.197 ]
+0
←
Brake drum inner diameter mm [in.] 310+2-0 [12.205-0
+0.079
] ← 314-0 [12.362+0.079
+2
-0 ] ←
470.7 - 549.2 {48 - 56}
Brake drum mounting bolt torque N-m{kgf-m}[lbf-ft] [347.2 ± 405.1] ← ← ←
205.9 - 225.6 {21 - 23}
Back-up plate mounting bolt torque N-m{kgf-m}[lbf-ft] [151.86 ± 166.39] ← ← ←
Fork thickness mm [in.] 40+0-4 [1.575-0.157 ]
+0
← 45+0
-4 [1.772-0.157 ]
+0
←
dling system
Load han-
Tilt cylinder piston rod lock bot and nut N-m{kgf-m}[lbf-ft] 107.9 ± 20.6 {11.0 ± 2.1}
torque [79.58 ± 15.19] ← ← ←
Lift cylinder natural drop mm [in.]/min less than 60 [2.36]/10 ← less than 50 [1.97]/10 ←
Tilt cylinder natural inclination (extension of piston rod) mm [in.]/min less than 20 [0.79]/10 ← ← ←
Fork lifting speed mm [in.]/sec 620+0 -50 [22.8-1.97 ]
+0
640 +0
-50 [25.2+0
-1.97 ] 520+0-50 [20.58-1.97 ]
+0
540 +0
-50 [21.3+0
-1.97 ]
N-m{kgf-m}[lbf-ft] 197.1[145.37
- 295.2 {20.1 - 30.1}
Front ← ← ←
- 217.73]
Rim assembling bolt torque
N-m{kgf-m}[lbf-ft] 60.8[44.84
Rear - 90.2 {6.2 - 9.2}
- 66.53] ← ← ←
Fore-and-aft clearance of steering axle mm [in.] 1+1-0 [0.039-0
+0.039
] ← ← ←
Steering axle center pin diameter mm [in.] 50+0-0.1 [1.97-0.004 ]
+0
← ← ←
Steering axle bushing inner diameter mm [in.] 50+0-0.1 [1.97-0.004 ]
+0
← ← ←
Steering wheel play in rotational direction mm [in.] 15 - 30 [0.59 - 1.18] ← ← ←
Steering system
Held in position
Unloaded ← ← ←
on 20% slope
Parking brake braking force
Held in position
Loaded ← ← ←
on 15% slope
Clearance between brake drum and lining mm [in.] 0.4 - 0.45 [0.016 - 0.018] ← ← ←
Lining thickness mm [in.] -5 [0.276-0.197 ]
7+0 +0
← ← ←
Brake drum inner diameter mm [in.] 310+2-0 [12.205-0
+0.079
] ← ← ←
470.7 - 549.2 {48 - 56}
Brake drum mounting bolt torque N-m{kgf-m}[lbf-ft] [347.2 ± 405.1] ← ← ←
205.9 - 225.6 {21 - 23}
Back-up plate mounting bolt torque N-m{kgf-m}[lbf-ft] [151.86 ± 166.39] ← ← ←
Fork thickness mm [in.] 45+0-4 [1.772-0.157 ]
+0
← ← 50+0
-4 [1.772-0.157 ]
+0
dling system
Load han-
Tilt cylinder piston rod lock bot and nut N-m{kgf-m}[lbf-ft] 107.9 ± 20.6 {11.0 ± 2.1}
torque [79.58 ± 15.19] ← ← ←
Lift cylinder natural drop mm [in.]/min less than 60 [2.36]/10 ← ← ←
Tilt cylinder natural inclination (extension of piston rod) mm [in.]/min less than 20 [0.79]/10 ← ← ←
Fork lifting speed mm [in.]/sec 580+0 -50 [22.8-1.97 ]
+0
460+0
-50 [18.1+0
-1.97 ] 490+0
-50 [19.3+0
-1.97 ] 490+0
-50 [19.3+0
-1.97 ]
(Empty page)
No. SEF-2A0DE
1. ENGINE .........................................................................................................................................1
1.1 GENERAL DESCRIPTION..........................................................................................................2
1.1.1 FUEL SYSTEM.................................................................................................................. 11
1.1.2 COOLING SYSTEM..........................................................................................................18
1.1.3 ACCELERATOR PEDAL..................................................................................................23
1.1.4 AIR CLEANER..................................................................................................................24
1.1.5 MUFFLER..........................................................................................................................30
1. ENGINE
■ Gasoline engine
Truck Model FHG20T3
FG20C3 FG20T3 FHG20C3
FHG25T3
FG25C3 FG25T3 FHG25C3
FHG30T3
FG30C3 FG30T3 FHG30C3
Item FG35T3S
Name K21 K25
Type 4-cycle, water-cooled, in-line, overhead valve type gasoline engine
No. of cylinders- Bore x stroke mm [in.] 4-89 x 83 [4-3.50 x 3.27] 4-89 x 100 [4-3.50 x 3.94]
Total displacement cm3 2065 2488
Compression ratio 8.7 ←
Performance
Rated speed rpm 2250 2100
Rated output kW{PS} 34.6 {48.6} 39.5 {54.3}
Maximum torque N-m{kgf-m}[lbf-ft] 153.5 {15.7} [113.1] / 1600 188.1 {19.2} [138.7] / 1600
Full-load rated fuel consumption g/kw·h{g/ps·h} 288 {212} 285 {210}
No-load minimum speed rpm 800 ←
Weight kg [lbs] 138 [304] ←
Dimensions (L x W x H) mm [in.] 723.9 x 590.3 x 726 [28.5 x 23.24 x 28.58]
Ignition order 1–3– 4– 2
Rotational direction Clockwise when viewed from fan.
■ Diesel engine
Truck Model FD20T4
FD20C3Z FHD20C3A FHD20T3A
FD25T4
FD25C3Z FHD25C3A FHD25T3A
FD30T4
FD30C3Z FHD30C3A FHD30T3A
Item FD35T4SE
Name C240 V2403 QD32
4-cycle, water-cooled in-line,
Type
overhead valve, swirl-chamber type diesel engine
4-86 x 102 4-87 x 102.4 4-99.2 x 102
No. of cylinders- Bore x stroke mm [in.]
[4-3.39 x 4.02] [4-3.43 x 4.03] [4-3.91 x 4.02]
Total displacement cm3 2369 2434 3153
Compression ratio 21.3 23.2 22
Performance
Rated speed rpm 2500 2600 2300
Rated output kW{PS} 35.4 {48.1} 35.5 {48.3} 44 {59.8}
Maximum torque N-m{kgf-m}[lbf-ft] 140 {14.3} [103.3]/1800153 {15.6} [112.9]/1600 189 {19.3} [139.4]/1800
Full-load rated fuel consumption g/kw·h{g/ps·h} 292.3 {215} 260 {191} 255 {187}
No-load minimum speed rpm 700 825 750
Weight kg [lbs] 252 [556] 214 [472] 262 [578]
693 x 550.5 x 689 787 x 506 x 734 794 x 616 x 747
Dimensions (L x W x H) mm [in.]
[27.28 x 21.67 x 27.13] [30.98 x 19.92 x 28.9] [31.26 x 24.25 x 29.41]
Ignition order 1– 3– 4– 2
Rotational direction Clockwise when viewed from fan.
-1-
1. ENGINE
Note: The engine configuration of the sketch should be used for reference.
Apply LOCTITE#262
RUBBER MOUNT
Apply LOCTITE#262
View A View B
-2-
1. ENGINE
DISTRIBUTOR
CARBURETOR
THERMO-SENSOR GOVERNOR
GENERATOR
FUEL PUMP
STARTER MOTOR
PRESSURE SWITCH
DRAIN PLUG (OIL) OIL FILTER DRAIN PLUG (WATER)
-3-
1. ENGINE
Model
K21 K25
Item
Main Construction
Type of cylinder liner Cylinder and cylinder block ←
case into one piece
Valve operation
Suction valve opens at BTDC: 14° ←
closes at ABDC: 30° ←
Exhaust valve opens at BBDC: 32° ←
closes at ATDC: 12° ←
Valve clearance, Suction valve 0.38 mm [0.01496 in.] ←
Exhaust valve 0.38 mm [0.01496 in.] ←
Ignition system Full-transistor type ←
Ignition timing BTDC 2° at 700 rpm 0° / 700
Ignition order 1–3–4–2 ←
Ignition coil Incorporated in distributor ←
Distributor T6T877 (Mitsubishi Electric) ←
Ignition plug FR2A-D (Nihon Tokushu Yogyo) ←
Spark gap 0.8 mm – 0.9 mm ←
[0.0315 in. – 0.0354 in.]
Governor Pneumatic type ←
Carburetor Nikki ←
Gas valve diameter 30 mm [1.18 in.] ←
Venturi diameter 24 mm [0.95 in.] 26 mm [1.02 in.]
Fuel pump Diaphragm type ←
Air cleaner Filter paper type ←
Lubrication system Force circulation ←
Lubrication pump Gear type ←
Lubrication oil filter Filter paper type ←
Filtration Full-flow filtration ←
Cooling system Water-cooled, forced circulation ←
Cooling fan Pusher type, 10 blades ←
O.D.: 400 mm [15.75 in.]
Drive V-belt drive ←
with pulley ratio of 1:1.10
Water pump Centrifugal type ←
Drive V-belt drive ←
with pulley ratio of 1:1.10
Water temperature regulator Wax type (valve-opening ←
temperature: 82 °C [179.6°F])
Starting motor Magnet shift type ←
Voltage 12 V ←
Output 1.2 kW ←
-4-
1. ENGINE
Model
K21 K25
Item
Charging generator
Voltage 12 V ←
Output 50 A ←
Generation 3-phase AC ←
Drive V-belt drive ←
with pulley ratio of 1:2.15
Voltage/current regulator
Type Transistor type ←
(built in charging generator)
Water and oil capacities
Lubrication oil 3.8 liters [1.004 U.S. gal] ←
(oil pan 3.5 liters [0.925 U.S. gal,
oil filter 0.3 liters [0.079 U.S. gal)
Cooling water 3.5 liters [0.925 U.S. gal] ←
for engine only
-5-
1. ENGINE
INJECTION PUMP
DRAIN PLUG
-6-
1. ENGINE
THERMO-
SENSOR
ALTERNATOR
OIL FILTER
INJECTION PUMP
OIL PRESSURE SWITCH
STARTER
DRAIN PLUG MOTOR
Max torque
More than 138.5 Nm/approx. 1800 min-1
Shaft torque
(N-m)
Max output
34.7 +220 /kW/2500 min-1
Shaft output
(kW)
-7-
1. ENGINE
ALTERNATOR
FUEL FILTER
DRAIN PLUG
(WATER)
STARTER
INJECTION
PUMP
OIL FILTER
DRAIN PLUG
(OIL)
-8-
1. ENGINE
Engine model
V2403 240 QD32
Item
Main Construction
Valve system Overhead type ← ←
Fuel system
Injection pump Bosch type Bosch distributor
type
Plunger (diameter x stroke) 5.75 mm x 7 mm 9 mm x 2.2 mm 11 mm x 2.88 mm
[0.226 in. x 0.276 in.] [0.354 in. x 0.087 in.] [0.433 in. x 0.113 in.]
Injection nozzle Throttle type ← ←
Fuel feed pump Plunger type Diaphragm type Vane type
Fuel filter Filter paper type, ← ←
with sedimenter
Governor
Governing Centrifugal, ← ←
all-speed control
Lubrication Forced lubrication ← Fuel oil lubrication
Lubrication system
Pump Trochoid type ← Gear type
Drive Gear Cam shaft Gear
Oil pressure regulator Ball, spring type Piston, spring type Regulator vale type
Oil pressure indicator Switch type ← ←
Filtration Full-flow, ← ←
filter paper type
Oil cooler Incorporated, ← ←
water-cooling type
Cooling system
Cooling method Water cooling ← ←
Cooling fan Pusher type ← ←
with 6 blades
O.D.: 380 mm ← O.D.:430 mm
[14.96 in.] [16.93 in.]
Drive Belt drive ← ←
Pump Centrifugal type ← ←
Drive Belt drive ← ←
Water temperature regulator
Type Wax type ← ←
emperature at which valve
T 71°C [159.8°F] 82°C [176.9°F] ←
begins to open
emperature at which valve
T 85°C [185°F] 95°C [203°F] ←
opens fully
Starting motor
Type Magnet shift type ← ←
Voltage 12 V ← ←
Output 2.0 kW 2.2 kW 2.8 kW
Stopping device Fuel cut-off type ← ←
Engine preheater Provided ← ←
-9-
1. ENGINE
Engine model
V2403 240 QD32
Item
Charging generator
Type A.C. generation, ← ←
diode rectification
Voltage 12 V ← ←
Output 60 A 45 A 60 A
Drive Belt drive ← ←
Automatic charging regulator IC type
(built in generator)
Reference data
Oil sump capacity 7.6 liters 5.2 liters 6.5 liters
[2.01 U.S. gal] max. [1.37 U.S. gal] max. [1.72 U.S. gal] max.
5.8 liters 4.0 liters 5.0 liters
[1.53 U.S. gal] min. [1.06 U.S. gal] min. [1.32 U.S. gal] min.
Cooling water volume 3.7 liters 5.2 liters 6.2 liters
[0.98 U.S. gal] [1.37 U.S. gal] [1.64 U.S. gal]
Valve clearance
Suction valve 0.18 - 0.22 mm 0.45 mm [0.018 in.] 0.35 mm [0.014 in.]
[0.007 - 0.009 in.] (at warm) (at warm)
(at cold)
Exhaust valve 0.18 - 0.22 mm 0.45 mm [0.018 in.] 0.35 mm [0.014 in.]
[0.007 - 0.009 in.] (at warm) (at warm)
(at cold)
Valve operation
Suction valve opens at BTDC 12° 11° 16°
closes at ABDC 36° 49° 52°
Exhaust valve opens at BBDC 57° 51° 66°
closes at ATDC 12° 9° 12°
Injection timing (BTDC) 15.5 - 17.0° 9° 2°
Injection start pressure 13.7 MPa 11.8 MPa 9.8 MPa
{140 kgf/cm2} {120 kgf/cm2} {100 kgf/cm2}
[1987 psi] [1711 psi] [1421 psi]
Compression pressure 3.24 - 3.72 MPa 3.0 MPa 2.94 MPa
{33 - 38 kgf/cm2} {31 kgf/cm2} {30 kgf/cm2}
[470 - 540 psi] [435 psi] [426 psi]
(290 rpm) (200 rpm) (200 rpm)
- 10 -
1. ENGINE
DRAIN PLUG
Fig. 1.6 Fuel Tank (Trucks with a K21 or K25 Gasoline Engine)
- 11 -
1. ENGINE
View A
FUEL FILTER
CAP
FUEL LEVEL
SIGNAL SENDER
DRAIN PLUG
- 12 -
1. ENGINE
FUEL LEVEL
SIGNAL SENDER
FUEL FILTER
CAP
DRAIN PLUG
- 13 -
1. ENGINE
FUEL FILTER
FUEL LEVEL
SIGNAL SENDER CAP
DRAIN PLUG
- 14 -
1. ENGINE
The fuel level signal sender converts the fuel level in the fuel tank into an electric current signal.
Its construction is shown in Figure 1.10. The resistance element is a variable resistor made of
nichrome wire. The slider that changes the resistance is connected to the float.
When the float is at the top level, the resistance value between the grounding and the “G” terminal
is in the range of about 9.5 to 10.5 Ω. As the float lowers, the resistance value becomes greater.
Changes in the resistance are transmitted to the CPU in the combination meter. The fuel meter
indicator moves in the “F” direction when the resistance is small and moves in the “E” direction
when the resistance value is large.
In addition, if the float lowers near to the bottom, the CPU sends the signal to light the fuel lamp
to inform the operator that fuel should be added.
FUEL
METER
A
FUEL LEVEL
SIGNAL SENDER
FUEL LAMP
BATTERY
FULL
3/4
1/4
EMPTY
FLOAT
View A
- 15 -
1. ENGINE
ENGINE COOLING
FUEL METER WATER TEMP. GAUGE
HOUR METER
1. SEAT BELT WARNING LIGHT (OPTION) 7. AIR CLEANER WARNING LIGHT (OPTION)
2. LOAD HANDLING AND TRAVELING 8. RADIATOR WATER LEVEL WARNING
INTERLOCK WARNING LIGHT LIGHT (OPTION)
3. PREHEATER INDICATOR 9. BATTERY ELECTROLYTE WARNING LIGHT
(FOR DIESEL TRUCKS) (OPTION)
4. NEUTRAL WARNING LIGHT 10. BATTERY CHARGE WARNING LIGHT
5. ENGINE OIL PRESSURE WARNING LIGHT 11. PARKING BRAKE WARNING LIGHT
6. SEDIMENTOR WARNING LIGHT (OPTION)
(FOR DIESEL TRUCKS) 12. FUEL LEVEL WARNING LIGHT
- 16 -
1. ENGINE
SPRING
PUMP
FILTER
CARTRIDGE
FUEL LEVEL
SWITCH
DRAIN COCK
- 17 -
1. ENGINE
CAP
OIL COOLER
RADIATOR
RESERVE TANK
DRAIN VALVE
Note: The oil cooler is installed only on the automatic transmission trucks.
- 18 -
RADIATOR-SIDE
BRACKET
RUBBER
FRAME-SIDE
BRACKET
RESERVE TANK
Detail of A
RADIATOR
CAP (Valve opening pressure:
49 kPa {0.5 kgf/cm2} [7.11psi])
- 19 -
Fig. 1.14 Cooling System (Trucks with a K21 or K25 Gasoline Engine)
1. ENGINE
1. ENGINE
RADIATOR-SIDE
BRACKET
RUBBER RUBBER
FRAME-SIDE BRACKET
- 20 -
Fig. 1.15 Radiator (Trucks with a V2403 Diesel Engine)
RADIATOR-SIDE
BRACKET
RUBBER RUBBER
FRAME-SIDE BRACKET
RESERVE TANK
Detail of A
RADIATOR
CAP (valve opening pressure:
49 kPa [0. 5 kgf/cm2} [7.11psi]]
- 21 -
Fig. 1.16 Radiator (Trucks with a C240 Diesel Engine)
1. ENGINE
RADIATOR-SIDE
1. ENGINE
BRACKET
RUBBER
FRAME-SIDE
BRACKET
- 22 -
Fig. 1.17 Cooling System (Trucks with a QD32 Diesel Engine)
1. ENGINE
92mm
64mm
18mm
QD32
83.5mm
53.5mm
LINK A
PEDAL
STOPPER
19mm
H C240
125mm
QD32
C240
LINK A
15mm
STOPPER
PEDAL
77mm
123mm
V2403
H
18mm
V2403,K21,K25
1. Adjust the wire length with the nut B so that the looseness of the link A is 0.5 to 1.0 mm
[0.0197 to 0.0394 in.] when the engine is running at idle rpm.
2. Adjust the pedal height (H) so that the pedal comes in contact with the stopper when the
engine is running at high idle rpm.
- 23 -
1. ENGINE
AIR CLEANER
OUTSIDE AIR
to ENGINE
Fig. 1.19 Air Cleaner Location (Trucks with a K21 or K25 Gasoline Engine)
- 24 -
1. ENGINE
LATCH
ELEMENT
COVER to ENGINE
EVACUATION VALVE
View A
Fig. 1.20 Air Cleaner (Trucks with a K21 or K25 Gasoline Engine)
- 25 -
1. ENGINE
AIR CLEANER
OUTSIDE AIR
- 26 -
1. ENGINE
AIR CLEANER
OUTSIDE AIR
- 27 -
1. ENGINE
AIR CLEANER
OUTSIDE AIR
Fig. 1.23 Air Cleaner Location (Trucks with a QD32 Diesel Engine)
- 28 -
1. ENGINE
to ENGINE
FILTER BODY
EVACUATION VALVE
View A
- 29 -
1. ENGINE
1.1.5 MUFFLER
The muffler is installed between the radiator and the counterweight at the rear of the truck to
reduce exhaust noise from the engine.
MUFFLER
EXHAUST
QD32
MUFFLER
EXHAUST
Fig. 1.25 Exhaust System (Trucks with a K21 or K25 Gasoline Engine, or a C240 or QD32 Diesel Engine)
- 30 -
1. ENGINE
V2403
MUFFLER
EXHAUST
- 31 -
NOTE
2. MANUAL TRANSMISSION SYSTEM
- 33 -
2. MANUAL TRANSMISSION SYSTEM
- 34 -
2. MANUAL TRANSMISSION SYSTEM
MATCH MARK
33. SET BOLT 39. BACK-UP LAMP SWITCH 45. “O”-RING 51. SNAP RING
34. SUPPORT 40. SHIFT FORK 46. SHAFT 52. YOKE
35. SPACER 41. OIL DIPSTICK 47. SNAP RING 53. BUSHING
36. NEUTRAL SWITCH 42. BREATHER 48. WASHER 54. SHAFT
37. SHIFT FORK 43. PIN 49. BALL 55. BUSHING
38. FORK SHAFT 44. LEVER 50. SPRING 56. SNAP RING
- 35 -
2. MANUAL TRANSMISSION SYSTEM
Gearshifting
When the speed range and direction shift levers are operated, the sleeves move to connect the
gears to the clutch hub and main shaft. The power is thus transmitted in the following order: main
drive shaft, input gear, Hi gear or Lo gear, synchromesh mechanism, main shaft, synchromesh
mechanism, reverse or forward gear, output gear, and output shaft.
Power flow:
Fwd 1st: ①→②b→④→⑫→⑩→⑬→⑮→⑥→⑦
Fwd 2nd: ①→②a→③→⑪→⑩→⑬→⑮→⑥→⑦
Rev 1st: ①→②b→④→⑫→⑩→⑬→⑭→⑤→⑨→⑧→⑦
Rev 2nd: ①→②a→③→⑪→⑩→⑬→⑭→⑤→⑨→⑧→⑦
- 36 -
2. MANUAL TRANSMISSION SYSTEM
(2) Synchronizer
Figure 2.4 shows a sectional view of the synchronizer that synchronizes gears which are about to
mesh by letting the block ring come in contact with the tapered flanks of the gears.
Outer ring
(block ring): The block ring has a female cone friction surface which is the mating
surface of the male friction surface of the middle ring (synchronizing
cone) ④ . The outer ring also has three equally spaced notches on its
circumference, with which it is guided to the index position along with the
sleeve splines ⑧ through the insert ⑨ in the process of synchronization.
Middle ring
(synchronizing cone): The middle ring meshes with the hole in the gear ⑤ via a latch. It has
female and male (inner and outer diameters) cone friction surfaces which
mate with the outer ring and inner ring.
Inner ring
(block ring): It has a male cone friction surface which mates with the female friction
surface of the middle ring (synchronizing cone) ④ .
Insert: The center projection of the insert is fitted in the inner annular groove
provided in the splines ⑧ of the sleeve ⑦ . It is forced against the inner
side of the sleeve splines ⑧ by the annular spring ⑩ so that initial load is
created to guide the outer ring ② to the index position.
- 37 -
2. MANUAL TRANSMISSION SYSTEM
The synchronizer operates in the following six steps from neutral to the completion of
synchronization. In the explanation given below, the gear ⑬ in Figure 2.4 is regarded as a gear to be
synchronized.
① First step
When the shift arm ⑫ is moved to the left by
operating the shift levers, the sleeve ⑦ and insert ⑨
also move to the left.
When the insert ⑨ moves a distance of X1, it
displaces the outer ring (block ring) ② a distance of
X 2.
Fig. 2.5
② Second step
If the sleeve ⑦ further moves, the raised section
of the insert ⑨ rides on the annular groove in the
sleeve splines ⑧ to force the outer ring (block ring)
② farther toward the gear side.
When the raised section of the insert ⑨ has
ridden completely on the annular groove, it means
that the sleeve ⑦ has shifted a distance of Z.
Fig. 2.6
③ Third step
The force applied through the insert ⑨ on the
outer ring (block ring) ② creates friction force on
the cone friction surface to make the block ring’s
notches to come in contact with the side face of the
insert as shown in Figure 2.7. At this time, the inner
ring (block ring) also has friction force on its cone
friction surface. (The position occupied by the block
ring teeth ① and the sleeve splines ⑧ is called an
index position.)
Fig. 2.7
- 38 -
2. MANUAL TRANSMISSION SYSTEM
④ Fourth step
When the outer ring (block ring) ② takes the
position shown in the step 3, the sleeve ⑦ moves a
clearance of Z so that chamfer of the teeth ① of the
outer ring (block ring) ② comes in contact with the
chamfer of the sleeve splines ⑧ .
This produces a cone torque Tc necessary for
synchronization on the cone friction surface, thus
causing synchronization.
Fig. 2.8
⑤ Fifth step
When the relative speed of the synchronized
constant-mesh gear ⑬ against the sleeve ⑦ becomes
zero (or when synchronization is completed), the
cone torque Tc also becomes zero.
At this time, Ti becomes smaller than Tc so
that the outer ring (block ring) ② moves in the
circumferential direction, passing the sleeve splines
⑧ through the teeth ① and the synchronization
action stops completely.
Fig. 2.9
Both the outer ring (block ring) ② and the inner
ring ③ are in idle state because they have no longer any external force. This allows the sleeve splines
⑧ to easily pass through the teeth ① of the outer ring (block ring) ② .
⑥ Sixth step
When the synchronization has been completed, the sleeve splines ⑧ pass the outer ring (block ring)
② , moving a clearance of Y1 as shown in Figure 2.6. This lets the chamber of the sleeve splines ⑧ come
in contact with the chamfer of the dog teeth ⑥ of the gear ⑤ . The contact of the two chamfers produces
a torque TG which acts on the dog teeth ⑥ to pass the sleeve splines ⑧ , causing the gear ⑤ and constant-
mesh gear ⑬ to move in the circumferential direction. The sleeve splines ⑧ pass the dog teeth ⑥ of the
gear ⑤ to complete the engagement.
Fig. 2.10
- 39 -
2. MANUAL TRANSMISSION SYSTEM
RELEASE LEVER
55 ± 0.7 mm
[2.17 ± 0.028 in.]
PRESSURE SPRING
PRESSURE PLATE
CLUTCH COVER
- 40 -
2. MANUAL TRANSMISSION SYSTEM
- 41 -
2. MANUAL TRANSMISSION SYSTEM
10 mm
[0.394 in.] 12 mm [0.472 in.]
(limit) (Max. allowance)
55 ± 0.7 mm
[2.17 ± 0.028 in.]
Apply molybdenum
disulfide-based grease.
CLUTCH DISC
CLUTCH COVER
- 42 -
2. MANUAL TRANSMISSION SYSTEM
1. BLEEDER 6. PUSHROD
2. CYLINDER 7. BOOT
3. SPRING 8. LOCK NUT
4. CUP 9. YOKE
5. PISTON
1. YOKE
from RESERVE TANK 2. PUSHROD
3. BOOT
to RELEASE CYLINDER 4. SNAP RING
5. STOP PLATE
Section A A 6. PISTON
7. CUP
8. SPRING
9. VALVE ROD
10. CYLINDER
- 43 -
2. MANUAL TRANSMISSION SYSTEM
RESERVE
TANK Brake pedal play: 10 mm [0.394 in.]
Clutch pedal play: 0 - 5 mm [0 - 0.197 in.]
CLUTCH RELEASE
CYLINDER
- 44 -
2. MANUAL TRANSMISSION SYSTEM
View A
85 mm 105 mm 3 mm
[3.35 in.] [4.13 in.] [0.118 in.]
Detail of brake master cylinder Detail of clutch master cylinder Detail of brake lamp switch
- 45 -
NEUTRAL
SWITCH
Detail of A
2. MANUAL TRANSMISSION SYSTEM
BACK-
UP LAMP
OIL FILL CAP SWITCH
Detail of B (W/ DIPSTICK)
- 46 -
Fig. 2.18
BREATHER
DRAIN PLUG
2. MANUAL TRANSMISSION SYSTEM
- 47 -
2. MANUAL TRANSMISSION SYSTEM
1. CLUTCH CASE
2. CLUTCH COVER
3. CLUTCH DISC
4. THRUST BEARING
5. MAIN DRIVE SHAFT
6. RETAINER
7. SPRAY NOZZLE
8. ARM
9. OIL SEAL
10. YOKE
11. LOCK PIN
12. SHAFT
13. SNAP RING
- 48 -
2. MANUAL TRANSMISSION SYSTEM
RELEASE
LEVER
PRESSURE PLATE
Section A-A
Section B-B
- 49 -
2. MANUAL TRANSMISSION SYSTEM
BRAKE PEDAL
CLUTCH PEDAL
CLUTCH RELEASE
CYLINDER
CLUTCH BOOSTER
- 50 -
2. MANUAL TRANSMISSION SYSTEM
- 51 -
2. MANUAL TRANSMISSION SYSTEM
1. BLEEDER 6. CYLINDER
2. SPRING 7. PUSHROD
3. CUP 8. BOOT
4. PACKING 9. LOCK NUT
5. PISTON 10. CLEVIS
- 52 -
2. MANUAL TRANSMISSION SYSTEM
FILTER
NOZZLE
MAIN PUMP
OIL COOLER
- 53 -
NOTE
3. AUTOMATIC TRANSMISSION SYSTEM
- 55 -
3. AUTOMATIC TRANSMISSION SYSTEM
TRANSMISSION CHARGING
CLUTCH PACK CONTROL VALVE PUMP
TORQUE
CONVERTER
COUNTER GEAR
OUTPUT FLANGE
OIL SEAL
STRAINER
OUTPUT GEAR
- 56 -
3. AUTOMATIC TRANSMISSION SYSTEM
BREATHER CONVERTER
RELIEF VALVE
INLINE FILTER
View A
- 57 -
3. AUTOMATIC TRANSMISSION SYSTEM
STATOR WHEEL
Detail of A
ONE-WAY CLUTCH
- 58 -
3. AUTOMATIC TRANSMISSION SYSTEM
CASE
“O”-RING
Tightening torque:
0.98 – 2.94 N-m {0.1 – 0.3 kgf-m}
[0.723 – 2.17 lbf-ft]
DRIVE GEAR
OIL SEAL
Section A - A
SUCTION
PORT
DISCHARGE
PORT
View C
View B
- 59 -
3. AUTOMATIC TRANSMISSION SYSTEM
3.1.3 TRANSMISSION
The transmission is a power-shift type consisting of a clutch pack assembly, an output shaft, a
reverse gear, and transmission control valve. (See Figures 3.1 and 3.2.)
BALL BEARING
BALL BEARING
LUBRICATION OIL
SEAL RING
SEAL RING
- 60 -
3. AUTOMATIC TRANSMISSION SYSTEM
① In neutral
With the solenoid vale in neutral, the oil is blocked by the solenoid valve and therefore all the oil
supplied from the charging pump flows to the torque converter.
TORQUE
CONVERTER
OIL COOLER
INLINE FILTER
TORQUE
CONVERTER
RELIEF VALVE
0.39 – 0.69 MPa
{3.98 – 7.04 kgf/cm2}
[56.6 – 100.1 psi]
CHOKE
ø1.4
MAIN RELIEF VALVE INCHING VALVE
CHARGING
PUMP SOLENOID VALVE
SHUTTLE VALVE
ACCUMULATOR
CLUTCH PACK
ASSEMBLY
- 61 -
3. AUTOMATIC TRANSMISSION SYSTEM
② In forward gear
As the solenoid valve is switch to the forward position, the oil flows to the forward clutch pack
while the shuttle valve moves to the right to allow the oil to flow also to the accumulator. Until
the accumulator is filled with oil, the clutch oil pressure increases gradually and the clutch lock-up
pressure is weak. Once the accumulator is filled with oil, however, the clutch lock-up oil pressure
rises rapidly to the specified value to lock up the forward clutch pack completely.
TORQUE
CONVERTER
OIL COOLER
INLINE FILTER
TORQUE
CONVERTER
RELIEF VALVE
0.39 – 0.69 MPa
{3.98 – 7.04 kgf/cm2}
[56.6 – 100.1 psi]
CHOKE
ø1.4
MAIN RELIEF VALVE INCHING VALVE
COIN FILTER
CHARGING
PUMP SOLENOID VALVE
SHUTTLE VALVE
ACCUMULATOR
CLUTCH PACK
ASSEMBLY
Fig. 3.7 Transmission Oil Pressure Circuit Diagram (in forward gear)
- 62 -
3. AUTOMATIC TRANSMISSION SYSTEM
③ In reverse gear
When the solenoid valve is switch to the reverse position, the oil flows to the reverse clutch pack
while the shuttle valve moves to the left to allow the oil to flow also to the accumulator. Until the
accumulator is filled with oil, the clutch oil pressure increases gradually and the clutch lock-up
pressure is weak. Once the accumulator is filled with oil, however, the clutch lock-up oil pressure
rises rapidly to the specified value to lock up the reverse clutch pack completely.
TORQUE
CONVERTER
OIL COOLER
INLINE FILTER
TORQUE
CONVERTER
RELIEF VALVE
0.39 – 0.69 MPa
{3.98 – 7.04 kgf/cm2}
[56.6 – 100.1 psi] CHOKE
ø1.4
MAIN RELIEF VALVE INCHING VALVE
COIN FILTER
CHARGING
PUMP SOLENOID VALVE
SHUTTLE VALVE
ACCUMULATOR
CLUTCH PACK
ASSEMBLY
Fig. 3.8 Transmission Oil Pressure Circuit Diagram (in reverse gear)
- 63 -
3. AUTOMATIC TRANSMISSION SYSTEM
④ Inching
When the inching spool is pushed in, the oil flowing to the clutch pack assembly is drained
through the inching spool piston. In addition, the oil returning from the clutch pack assembly is also
drained.
CHOKE
ø1.4
INCHING VALVE
- 64 -
3. AUTOMATIC TRANSMISSION SYSTEM
SOL B
(REV)
SOL A
(FWD)
Detail of connector
CABLE
to INCHING
PEDAL
MANUAL BUTTON
(the forward position is SOLENOID VALVE
selected by pushing)
SHUTTLE VALVE
INCHING VALVE
CHOKE
ø1.4
- 65 -
3. AUTOMATIC TRANSMISSION SYSTEM
SNAP RING
PLUG
“O”-RING
SNAP RING SPOOL
SNAP RING
PLUG
“O”-RING
SHUTTLE
VALVE PISTON
SPRING
PLUG
SPRING
SPRING
SPRING
VALVE
“O”-RING
SNAP RING
PISTON
OIL SEAL
“O”-RING
COIN FILTER
Detail of lever
- 66 -
TORQUE
CONVERTER
CHARGING OIL
PRESSURE
SOL B SOL A
(REV) (FWD)
CHARGING PUMP
OIL PRESSURE
FWD CLUTCH
OIL PRESSURE
REV CLUTCH
OIL PRESSURE
to OIL COOLER
- 67 -
Fig. 3.12 Oil Pressure Check Ports
DRAIN PLUG
OIL TEMP. SENSOR
MOUNTING AREA SUCTION STRAINER
3. AUTOMATIC TRANSMISSION SYSTEM
3. AUTOMATIC TRANSMISSION SYSTEM
NOTE
- 68 -
4. DRIVE AXLE
4. DRIVE AXLE
Truck Model FG20C3 FG20T3 FD20C3Z FD20T4 FG30C3 FG30T3
FHG20C3 FHG20T3 FHD20C3A FHD20T3A FHG30C3 FHG30T3 FG35T3S
FG25C3 FG25T3 FD25C3Z FD25T4 FD30C3Z FD30T4 FD35T4SE
Item FHG25C3 FHG25T3 FHD25C3A FHD25T3A FHD30C3A FHD30T3A
Type Full-floating type ← ←
Wheel
Size 2-7.00-12-12PR(I) 2-28-9-15-12PR(I) 2-250-15-16PR(I)
Tread pattern J-LUG ← ←
Rim
Type Split type Disc type ←
Size 5.00S-12DT 7.00T-15 ←
Tire inflation pressure 690 kPa {7.0 kgf/cm } [100 psi]
2
← 850 kPa {8.7 kgf/cm2}
[123 psi]
- 69 -
4. DRIVE AXLE
Tightening torque:
96 – 111 N-m
{9.8 – 11.3 kgf-m}
[70.8 – 81.9 lbf-ft]
- 70 -
Fill this space with
100 cm3 of grease.
Tightening torque:
471 – 549 N-m
Tightening torque: {48.0 – 56.0 kgf-m}
206 – 226 N-m [347.4 – 404.9 lbf-ft]
{21.0 – 23.0 kgf-m}
[151.9 – 166.7 lbf-ft]
Tightening torque:
392 – 559 N-m
{40.0 – 57.0 kgf-m}
[289.1 – 412.3 lbf-ft]
Fig. 4.1 Drive Axle (Trucks with capacities from 2.0 to 2.5 tons)
1. HOUSING 6. TAPERED ROLLER BEARING
2. AXLE SHAFT 7. TAPERED ROLLER BEARING
3. WHEEL BRAKE 8. OIL SEAL
4. BRAKE DRAM & HUB 9. ADJUSTMENT NUT
View A 5. OIL SEAL 10. LOCK NUT
Tightening torque:
96 – 111 N-m
{9.8 – 11.3 kgf-m}
[70.8 – 81.9 lbf-ft]
- 71 -
Fill this space with
100 cm3 of grease.
Tightening torque:
471 – 549 N-m
Tightening torque: {48.0 – 56.0 kgf-m}
206 – 226 N-m [347.4 – 404.9 lbf-ft]
{21.0 – 23.0 kgf-m}
[151.9 – 166.7 lbf-ft] Tightening torque:
392 – 559 N-m
{40.0 – 57.0 kgf-m}
[289.1 – 412.3 lbf-ft]
Tightening torque:
471 – 549 N-m
{48.0 – 56.0 kgf-m}
[347.4 – 404.9 lbf-ft]
Tightening torque:
96 – 111 N-m
{9.8 – 11.3 kgf-m}
[70.8 – 81.9 lbf-ft]
- 72 -
Tightening torque:
206 – 226 N-m
{21.0 – 23.0 kgf-m}
[151.9 – 166.7 lbf-ft]
Tightening torque:
392 – 559 N-m
the hub starting torque for the specified value, LOCK WASHER
LOCK NUT
gradually tightening the adjustment nut.
Starting force: 49 – 147.1 N {5 – 15kgf} Fig. 4.4 Filling Grease
[11 – 33.1 lbf]
(4) Install the lock washer and lock nut and secure
the lock nut by bending the tang on the lock
washer.
Fig. 4.6 Wheel Assembly (Trucks with capacities from 2.0 to 2.5 tons)
- 73 -
4. DRIVE AXLE
- 74 -
4. DRIVE AXLE
0.4 - 0.5 mm
[0.016 - 0.020]
- 75 -
4. DRIVE AXLE
NOTE
- 76 -
5. BRAKE SYSTEM
5. BRAKE SYSTEM
Truck Model FG20C3 FG20T3 FD20C3Z FD20T4 FG30C3 FG30T3
FHG20C3 FHG20T3 FHD20C3A FHD20T3A FHG30C3 FHG30T3 FG35T3S
FG25C3 FG25T3 FD25C3Z FD25T4 FD30C3Z FD30T4 FD35T4SE
Item FHG25C3 FHG25T3 FHD25C3A FHD25T3A FHD30C3A FHD30T3A
Type Front two-wheel braking internal expansion, hydraulic type
Pedal ratio 5.3 ← ←
Master cylinder bore 19.05 mm [0.75 in.] [3/4] ← ←
Wheel brake
Type Duo-servo type ← ←
Wheel cylinder bore 28.58 mm [1.13 in.] [9/8] ← ←
Brake drum inner dia. 310 mm [12.21 in.] ← 314 mm [12.36 in.]
Lining size 324 x 60 x 7 mm 344 x 60 x 5.7 mm 348 x 76 x 7.7 mm
[12.76 x 2.36 x 0.28 in.] [13.5 x 2.36 x 0.22 in.] [13.7 x 2.99 x 0.30 in.]
Surface brake 4 x 19440 mm2 4 x 20640 mm2 4 x 26450 mm2
[4 x 38.37 in.2] [4 x 31.99 in.2] [4 x 41.00 in.2]
Parking brake
Type Front two-wheel braking internal expansion, mechanical type
- 77 -
5. BRAKE SYSTEM
CABLE
RESERVE TANK
- 78 -
5. BRAKE SYSTEM
View A
85 mm 3 mm
[3.35 in.] [0.02 in.]
- 79 -
5. BRAKE SYSTEM
to WHEEL
YOKE BRAKE
NUT
PUSH ROD
SPRING
BOOT
PRIMARY CUP
SECONDARY CUP CHECK VALVE
PISTON
The check valve works to leave some pressure inside the wheel cylinder and brake pipe in order
to lock up the piston cup of the wheel cylinder. This prevents oil leakage and the occurrence of vapor
lock.
- 80 -
5. BRAKE SYSTEM
m tion
ANCHOR PIN
The wheel brake consists of two pairs of brake
dru ec
of n dir
shoes, a wheel cylinder and an adjuster. The brake
io
tat
Working force
shoe, one end of it being connected to the anchor pin
Ro
SECONDARY
PRIMARY
and the other end to the adjuster, is forced against
the backing plate with a hold spring and pin.
In addition, the wheel brake is provided with
a parking brake mechanism and an automatic
ADJUSTER
clearance adjuster.
(1) Wheel brake operation Fig. 5.4 Braking Operation in Forward Travel
As the wheel cylinder presses the primary and
secondary shoes with an equal force to the brake
drum, they turn together with the brake drum until
the secondary shoe top comes in contact with the
Working force
anchor pin. When the secondary shoe top comes
SECONDARY
PRIMARY
in contact with the anchor pin, the brake lining-
to-brake drum friction force is produced and the
primary shoe presses against the secondary shoe
with force greater than offered by operation of the
wheel cylinder, thus providing large braking force.
(See Figure 5.4)
In reverse travel, the braking force works in the Fig. 5.5 Braking Operation in Reverse Travel
reverse direction. (See Figure 5.5)
SECONDARY SHOE
PIN
(2) Parking brake
The parking brake unit is built in the wheel brake
LEVER STRUT
unit and consists of a lever and a strut. The lever is
pinned to the primary shoe and movement of the
lever is transmitted to the secondary shoe through
the strut.
PRIMARY SHOE
- 81 -
5. BRAKE SYSTEM
CABLE
SPRING
GUIDE
SPRING LEVER
ADJUSTER
ADJUSTER
LEVER
Fig. 5.7 Trucks with Capacities from 2.0 Fig. 5.8 Trucks with Capacities from 3.0 to
to 2.5 tons 3.5 tons
- 82 -
5. BRAKE SYSTEM
RELEASE
BUTTON RELEASE
BUTTON
LEFT-SIDE CABLE
- 83 -
5. BRAKE SYSTEM
Section C - C
Shoe expands in
this direction.
Section A - A
Section B - B
Fig. 5.12 Wheel Brake (Trucks with capacities from 2.0 to 2.5 tons)
- 84 -
5. BRAKE SYSTEM
Section C - C Section E - E
Section D - D
Shoe expands in
this direction.
Section A - A
Section B - B
- 85 -
5. BRAKE SYSTEM
Section C - C
Section E - E
Section D - D
Section K - K
Section A - A
Section B - B
- 86 -
5. BRAKE SYSTEM
- 87 -
5. BRAKE SYSTEM
NOTE
- 88 -
6. STEERING SYSTEM
6. STEERING SYSTEM
Truck Model FG20C3 FG20T3 FD20C3Z FD20T4 FG30C3 FG30T3
FHG20C3 FHG20T3 FHD20C3A FHD20T3A FHG30C3 FHG30T3 FG35T3S
FG25C3 FG25T3 FD25C3Z FD25T4 FD30C3Z FD30T4 FD35T4SE
Item FHG25C3 FHG25T3 FHD25C3A FHD25T3A FHD30C3A FHD30T3A
Steering axle
Type Center-pin supported, Elliot type with box-shaped
cross section of weld construction
King pin spacing 810 mm [31.89 in.]
King pin angle 0°
Toe-in 0 mm
Camber 1°
Caster 0°
Steering angle
Inner wheel 79°
Outer wheel 54° 57°
Orbitrol
Type Open-centered, non-load reaction type
with steering wheel knob deviation control
Discharge 96 cm3 [5.86 in.3]/rev
Power cylinder
Type Double-acting piston type
Cylinder bore 71 mm [2.80 in.] 80 mm [3.15 in.]
Piston rod diameter 40 mm [1.57 in.] 50 mm [1.97 in.]
Stroke 143 mm [5.63 in.] 177 mm [6.97 in.]
Flow divider valve
Pressure setting 8.8 MPa {90 kgf/cm2} [1276 psi]
- 89 -
6. STEERING SYSTEM
STEERING SUPPORT
SENSOR (REAR)
POWER CYLINDER
Note: The illustrations show the steering axle of the 2- to 2.5-ton trucks.
- 90 -
6. STEERING SYSTEM
NEEDLE BEARING
HUB
CAP
LOCK NUT
Note: The illustrations show the steering axle of the 2- to 2.5-ton trucks.
- 91 -
6. STEERING SYSTEM
STEERING WHEEL
ORBITROL
- 92 -
6. STEERING SYSTEM
6.1.3 ORBITROL
The orbitrol sends pressure oil from the pump selectively to the steering cylinder. It consists
primarily of a control valve and a metering device.
The control valve used in this orbitrol is not an ordinary spool type whose spool moves in the
axial direction, but a rotary type consisting of a sleeve and a spool, which rotates to switch over the
oil passages. The housing has four ports which lead to the pump, tank, right and left chambers of the
steering cylinder, respectively. Between the P port and T port is a check valve provided.
The metering device consists of an internally-toothed stator and an externally-toothed rotor. It
works as an oil motor under normal operating conditions and can be used as a hand pump if the truck
becomes disable for any reason. The rotor is mechanically linked to the sleeve with the drive shaft so
that feedback operation is possible.
The sleeve is interlocked with the motor’s rotor through the cross pin and drive shaft while the
spool is splined to the steering shaft.
EPACS CONTROLLER
CONTROLLER STATUS
DISPLAY (LED)
DEVIATION
CONTROL VALVE
T PORT L PORT
P PORT R PORT
SOLENOID
- 93 -
6. STEERING SYSTEM
Fig. 6.6
- 94 -
6. STEERING SYSTEM
The returning oil from the power cylinder flows, passing through the cylinder port R, groove ⑪
in the valve housing, oil hole ⑰ in the sleeve, groove ⑲ in the spool, oil hole in the sleeve, and
groove ⑧ in the valve housing, back to the oil tank.
Fig. 6.7
(2) Relationship between the rotating speed and operating force of the steering wheel
The force required to operate the orbitrol is basically a valve operating force (the force required
to compress the centering spring: 2.9 N-m {0.3 kgf-m} [2.14 lbf-ft]). That is, there is no mechanical
linkage between the steering wheel and the tires, and thus the operating force of the steering wheel
remains constant regardless of the rotating speed of the steering wheel. The discharge of oil from the
orbitrol rotor to the steering cylinder is 96 cc/revolution.
- 95 -
6. STEERING SYSTEM
BUSHING BUSHING
6.5 mm
[0.256 in.]
BOLT Tightening torque:
27.7 – 41.5 N-m {282.5 – 423.2 kgf-cm}
[20.43 – 30.6 lbf-ft]
Apply ThreeBond #1324N.
BUSHING
PISTON ROD CAP PACKING “O”-RING ROD PACKING
DUST SEAL
View A
- 96 -
6. STEERING SYSTEM
CONTROLLER
STEERING WHEEL
ANGLE SENSOR
- 97 -
6. STEERING SYSTEM
STATUS
OUTPUT OF
P/D ANALOG POWER COMPENSATION VALVE
CIRCUIT TRANSISTOR DRIVING SIGNAL
INPUT OF
TIRE ANGLE BUFFER
DETECTION
POTENTIOMETER
STATUS
INDICATING CENTER POSITION
LED
SETTING
W TERMINAL
Blu
CONTROL UNIT
L/G
Br NORMALLY CLOSED VALVE
SOL
VALVE
(Sumitomo Denso)
(Sumitomo Denso)
R
POWER
NOISE FILTER Bl SUPPLY
INPUT
(about 50 mA, with solenoid valve off)
Pi
CONTROLLER
OPERATING STATUS LED Y
Pu
STEERING WHEEL
ROTATIONAL POSITION
LEAD-OUT WIRE FROM CONTROLLER: AUTOMOTIVE HEAT-RESISTANT, LOW-VOLTAGE WIRE AEX 0.5 f (Sumitomo Denso)
- 98 -
6. STEERING SYSTEM
- 99 -
6. STEERING SYSTEM
NOTE
- 100 -
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
Truck Model FHD20T3A
FHD20C3A
FHD2553A
FHD25C3A
FD20C3Z FD20T4 FHG20C3 FHG20T3 FHD3053A
FHD30C3A
FD25C3Z FD25T4 FHG25C3 FHG25T3 FD35T4SE
FG20C3
FD30C3Z FD30T4 FHG30C3 FHG30T3 FG20T3
FG25C3
FG25T3
FG30C3
Item FG30T3
Main pump
Type Gear type
Model name SGP1A31.9 SGP1A27 SGP1A33.2 SGP1A30.8
Discharge 31.9 cm3 [2.0 in.3]/rev 27.8 cm3 [1.7 in.3]/rev 33.2 cm3 [2.0 in.3]/rev 30.8 cm3 [1.9 in.3]/rev
Control valve
Type 2-spool sliding type, with relief valve,
flow divider and tilt-lock valve
Model name MSV04A
Pressure setting
Main 17.7 MPa {180 kgf/cm2} [2567 psi]
Steering 8.8 MPa {90 kgf/cm2} [1276 psi]
Lift cylinder
Type Single-acting piston
Cylinder bore 2 - 2.5 t: 50 mm [1.97 in.], 3 t: 55 mm [2.17 in.], 3.5 t: 60 mm [2.36 in.]
Stroke 1495 mm [58.9 in.]
Tilt cylinder
Type Double-acting piston
Cylinder bore 80 mm [3.15 in.] (FHD20 - 25: 70 mm [2.76 in.])
Rod diameter 35 mm [1.38 in.] (FHD20 - 25: 30 mm [1.18 in.])
Stroke 128 mm [5.04 in.] (FD35: 135 mm [5.32 in.])
Oil tank
Capacity 32 liters [8.45 U.S. gal] (FD35: 37 liters [9.77 U.S. gal])
- 101 -
7. HYDRAULIC SYSTEM
- 102 -
7. HYDRAULIC SYSTEM
TOOTH SPACE
SUCTION PORT
DISCHARGE PORT
: Oil flow
Fig. 7.3 Pressure Distribution on Side-Plate Side Fig. 7.4 Pressure Distribution on Gear Side
- 103 -
7. HYDRAULIC SYSTEM
Wipe depth
0.01 – 0.06 mm
Eccentricity [0.00039 – 0.0024 in.]
Center of
pump body
Discharge
port Suction port
Trace of wipe
CROSS SECTION A - A
- 104 -
7. HYDRAULIC SYSTEM
PF PORT
B2 PORT
A2 PORT
T1 PORT
P PORT
A1 PORT
MAIN RELIEF
VALVE SOLENOID VALVE
(LIFT LOCK)
- 105 -
7. HYDRAULIC SYSTEM
(b) MF flow pressure is higher than PF flow pressure (during load handling)
When the load handling means is operated, the MF
flow pressure increases and thus the entire oil pressure
of the hydraulic system also increases. Since the PF
flow pressure is lower than the MF flow pressure, the
priority flow begins to increase. Therefore, the pressure
differential across the control orifice increases so that
the FD spool moves in the direction that closes the PF
throttle hole, to keep the control flow constant. (See
Figure 7.8.)
- 106 -
7. HYDRAULIC SYSTEM
SPOOL
TANK OIL UNLOADING
SPRING OIL PASSAGE
PASSAGE
Fig. 7.9
Fig. 7.10
(c) Spool pushed (lowering the forks) Hydraulic pressure acts
on the back of the lock
When the spool is pushed down, the unloading poppet to prevent the
poppet from opening.
oil passage remained still open to allow the oil
discharged from the pump to return to the tank oil
passage.
② Solenoid energized
The oil returning from the A port flows through
the control orifice of the lock poppet to the
solenoid valve before flowing to the return oil
passage, thus producing a pressure difference
that causes the lock poppet to open. The oil
flowing through the lock poppet returns,
Fig. 7.12
passing through the spool land that opens in the
tank oil passage direction, back to the tank. The spool is returned to neutral by the return spring.
(See Figure 7.12.)
- 107 -
7. HYDRAULIC SYSTEM
- 108 -
7. HYDRAULIC SYSTEM
SPOOL
TANK UNLOAD
PASSAGE PASSAGE
Fig. 7.17
- 109 -
7. HYDRAULIC SYSTEM
- 110 -
7. HYDRAULIC SYSTEM
- 111 -
7. HYDRAULIC SYSTEM
- 112 -
7. HYDRAULIC SYSTEM
the main poppet and thus the passage to the tank port
is also opened to allow the pressure oil to flow into the
Fig. 7.27 Port Relief Valve (open)
tank. (See Figure 7.27.)
(c) Anticavitation
If the oil pressure at the port A or B is lower than the oil pressure in the tank passage, a force
occurs in the direction that opens the main poppet because of the difference in area across the main
poppet. This force opens the main poppet to direct the oil from the tank passage into the port A or B,
thus preventing the actuator pressure from going negative. (See Figure 7.27.)
- 113 -
7. HYDRAULIC SYSTEM
TILT LEVER
ATTACHMENT LEVER
LIFT LEVER (OPTION)
CONTROL VALVE
SPACER
Detail of A
- 114 -
7. HYDRAULIC SYSTEM
CASE
- 115 -
7. HYDRAULIC SYSTEM
1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. “U”-RING
5. HOLDER
6. “O”-RING
7. BUSHING
8. CYLINDER
9. ROD
10. LOCK RING
11. PISTON
12. WEAR RING
13. PACKING
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN
- 116 -
7. HYDRAULIC SYSTEM
1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. “U”-RING
5. HOLDER
6. “O”-RING
7. BUSHING
8. CYLINDER
9. ROD
10. LOCK RING
11. PISTON
12. WEAR RING
13. PACKING
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN
- 117 -
7. HYDRAULIC SYSTEM
FREE FLOW
CONTROLLED FLOW
1. CASE 5. SLEEVE
2. SPRING 6. ORIFICE
7. SPRING
3. BALL
8. “O”-RING
4. PISTON
9. NIPPLE
- 118 -
7. HYDRAULIC SYSTEM
- 119 -
7. HYDRAULIC SYSTEM
CAP
SUCTION FILTER
BREATHER
to LIFT
CYLINDER
STEERING
to PUMP RETURN
RETURN FILTER
DRAIN PLUG
- 120 -
CONTROL VALVE
to LIFT CYLINDER
ORBITROL
TILT CYLINDER
(RIGHT)
OIL TANK
- 121 -
The pipe should be
pointed inwards.
STEERING CYLINDER
7. HYDRAULIC SYSTEM
7. HYDRAULIC SYSTEM
NOTE
- 122 -
8. LOAD HANDLING SYSTEM
Inner channel
- 123 -
8. LOAD HANDLING SYSTEM
1. INNER CHANNEL
2. OUTER CHANNEL
3. END ROLLER
4. SHIM
5. END ROLLER
6. SHIM
7. SLIPPER
8. SHIM
9. PIN
10. CAP
11. BUSHING
- 124 -
8. LOAD HANDLING SYSTEM
8.1.2 CARRIAGE
The carriage has end rollers installed with bearings on its end roller shafts welded to the carriage.
The end rollers are shim adjusted and roll along inside the inner channel assembly.
The fore-and-aft load is sustained by the end rollers and the lateral load by the side rollers
provided at the lower part of the carriage. When the forks are raised to the top position, the top end
rollers come out beyond the top of the upright.
1. FORKS
2. STOPPER
3. SPRING
4. HANDLE
5. CARRIAGE
6. END ROLLER
7. LOCK BOLT
8. SIDE ROLLER
9. SHIM
10. SHIM
11. SPACER
12. LOAD BACKREST
- 125 -
8. LOAD HANDLING SYSTEM
channels.
CARRIAGE
Lower side
SIDE ROLLER
(shim adjusted)
END ROLLER
END ROLLER
Upper side
INNER CHANNEL
CHANNEL
adjusted)
ROLLER
SLIPPER
adjusted)
OUTER
(shim
END
(shim
- 126 -
Upper side Lower side
OUTER CHANNEL
END ROLLER
END ROLLER (shim adjusted)
(shim adjusted)
END ROLLER
- 127 -
(shim adjusted)
END ROLLER
(shim adjusted)
SLIPPER
(shim adjusted)
NOTE
- 128 -
9. ELECTRIC WIRING
9. ELECTRIC WIRING
The electric components of the truck are wired through several types of wire harnesses and color
coded by circuit.
The wire harnesses are connected with connectors (2 types) or screw.
B Black R Red
G Green W White
L Blue Y Yellow
Example: Yellow coating with a blue marking P Pink Sb Light blue Example: White coating without marking
Housing
Plug-in type
Screw type
The dotted lines in the circuit diagrams are given for optional equipment.
- 129 -
9. ELECTRIC WIRING
Battery
Capacity 36 Ah
Voltage 12 V
Electrolyte specific gravity 1.280 (20°C)
Headlights
Capacity 12 V - 55 W
Front combination lights
Capacity
Parking brake light 12 V - 10 W
Turn signal light 12 V - 27 W
Rear combination lights
Capacity
Tail/brake light 12 V - 8 W / 23 W
Turn signal light 12 V - 27 W
Back-up light 12 V - 10 W
Work light (option)
Capacity 12 V - 55 W
License number plate light (option)
Capacity 12 V - 10 W
- 130 -
9. ELECTRIC WIRING
9.1.1 BATTERY
The battery case has a shape as shown in Figure
9.1 and is located on the left-side frame of the truck.
The negative (-) terminal of the battery is
connected to the truck frame and the positive (+)
terminal is connected to the B terminal of the starter
motor and to the fuse box (through a fusible link
wire) and the B terminal of the starter switch.
BATTERY
- 131 -
9. ELECTRIC WIRING
■ OFF position
The position in which the starter key is inserted
or drawn out. The battery power supply is turned
OFF.
The engine comes to a stop when the starter BR
OFF B R1
switch is turned to this position. B
ON
BR
CAUTION START
The battery is always connected to the terminal
B even when the starter switch is in the OFF
position. Use caution to prevent short-circuiting R1
■ Start position
When the starter switch is turned to the START position, the terminal B is also connected to the
terminal R1 .
This action activates the starter relay to run the starter motor.
<Reference>
If the operator’s hand is removed from the starter key at the START position, the key will return
to the ON position.
- 132 -
9. ELECTRIC WIRING
N IG1IG2VF VF2 ST VR Ra B Ig S
FUEL
12V
HOUR METER GND
5V
DC/DC
DC/DC
OIL PRESSURE
3BG
3BY
WATER TEMP.
2LR
WL
YR
AIR CLEANER
SEDIMENTER
INTER LOCK
FUEL LEVEL
E/G CHECK
SEAT BELT
RADIATOR
BrB NEUTRAL
LY KEY ON +
BATTERY
PARKING
BR CHARGE
BATT. +
LEVEL
LB GLOW
GND
B
L
Alternator
5BY
3B
B
Glow plug
E Diesel truck relay
3BY
3BL
BrB
2LR
2YL
2YL
WL
WL
B
3BY
B
R (LEVEL)
BR L (RELAY) TIMER QOS
1 2 3 4 5 6 7
5BW
WL
BW
5BY
OG
2YL
WL
LB
LY
B
B
To A 40B
Starter
B B
F.L.W. 3BL
S
0.85R
5BY 5BY
3BG
3BG
3BY
3BY
3A T/M YG YR Distributor
(Ignition coil) spark plug
3A METER LY LY
3BG 7.5A BACK RY
3A E/G WG WG WG
7.5A INTERLOCK
- & OPTION 2L
㧖
LW Gasoline truck
40B
3B
5BW
Grounding
E/G (frame) Glow
EARTH
plug
Diesel truck
- 133 -
9. ELECTRIC WIRING
(3) Fuses
Each of the electric circuits is provided with
Fuse box
a fuse to protect the electric devices and wiring
against overcurrent.
As shown in Figure 9.7, fuses are contained in the
fuse box which is installed in the position indicated
in Figure 9.5.
CAUTION
••If a fuse is blown out, locate the cause and
troubleshoot properly before replacing the fuse
with a new one of the same capacity. Fig. 9.5
Fig. 9.6
- 134 -
9. ELECTRIC WIRING
SPARE FUSE, 3A
ԩԨ FUSE PULLER
SPARE FUSE, 15A
1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
10
- 135 -
9. ELECTRIC WIRING
LIGHTING SWITCH
*1㧗
*1㧙
VR ST VF N
Ra VF2 IG1 IG2
LT TL
LH EL TR TB
- 136 -
9. ELECTRIC WIRING
FRONT FRONT
COMBINATION LIGHTING COMBINATION
HEADLIGHT LIGHT (LEFT) LIGHT (RIGHT) HEADLIGHT
(LEFT) SWITCH (RIGHT)
OFF
T
H
EL LT LH
RW
RW
WB
WB
Y
Y
to (+) TERMINAL
Lg
Br
R
GW
GW
RY
RY
OF BATTERY
G
G
B
B B B B
B B B B
G RW RW G
GW GR GL GW
RY RY RY RY
RW
RY
2R
Lg
Br
R
B
RB
GL
RL
2B
G GR GL G
RW RW RW RW
RB RB RB RB
TAIL LIGHT (8W) B B B B TAIL LIGHT (8W)
RL RL RL RL
- 137 -
9. ELECTRIC WIRING
FRONT FRONT
COMBINATION TURN SIGNAL COMBINATION
R
LIGHT (LEFT) SWITCH
N LIGHT (RIGHT)
L
TB TL TR
RW
RW
WB
WB
Y
Y
GR
GB
GL
GW
GW
RY
RY
G
G
B
B
B B B B
B B B B
G RW RW G
GW GR GL GW
RY RY RY RY
FLASHER UNIT
E B L
WY
GB
B
to STARTER
SWITCH (BR)
RW
GR
RB
GL
RL
2B
G GR GL G
RW RW RW RW
RB RB RB RB
TURN SIGNAL (23W) B B B B
RL RL RL RL
TURN SIGNAL (23W)
- 138 -
9. ELECTRIC WIRING
(3) Headlight
The headlight has a structure as shown in Figure 9.11 and consists primarily of a housing, a rim, a
lens and a light bulb.
HOUSING
LENS
㧗 GROUND
- 139 -
9. ELECTRIC WIRING
TURN SIGNAL
GROUND
SIDE MARKER
View A
TURN SIGNAL
BACK-UP LIGHT GROUND
BRAKE LIGHT TAIL LIGHT
View A
- 140 -
9. ELECTRIC WIRING
FRONT
COMBINATION
LIGHT
- 141 -
9. ELECTRIC WIRING
1. Use caution not to get burnt because the surface of a bulb is hot soon after it is turned
off.
2. Use caution not to contaminate the bulb surface or reflector surface with lubricant.
STOP/TAIL
LIGHT
LENS 23W/8W-12V
SCREW
SCREW
BODY
SIDE MARKER
LIGHT
10W-12V
LENS
SOLENOID VALVE
(AUTOMATIC
TRANSMISSION
TRUCKS ONLY)
STARTER RELAY
FUSIBLE LINK
BACK-UP BUZZER
FLASHER UNIT
View A
AUTO-CHOKE RELAY
View B
Fig. 9.17 Location of Electrical Components (Trucks with a K21/K25 Gasoline Engine)
- 143 -
9. ELECTRIC WIRING
DIODE
SOLENOID VALVE
(AUTOMATIC
TRANSMISSION
TRUCKS ONLY)
BATTERY
FUSE BOX
10P
BACK-UP BUZZER
NEUTRAL
SAFETY RELAY
NEUTRAL RELAY View A
TAIL LIGHT RELAY
HORN
View B
HEADLIGHT RELAY
Fig. 9.18 Location of Electrical Components (Trucks with a V2403 Diesel Engine)
- 144 -
9. ELECTRIC WIRING
DIODE
SOLENOID VALVE
(AUTOMATIC
TRANSMISSION
TRUCKS ONLY)
FLASHER UNIT
FUSE BOX
BATTERY
STARTER RELAY
TIMER
BACK-UP BUZZER
NEUTRAL
SAFETY RELAY
NEUTRAL RELAY
Fig. 9.19 Location of Electrical Parts (Trucks with a C240 Diesel Engine)
- 145 -
9. ELECTRIC WIRING
TIMER
DIODE
SOLENOID VALVE
(AUTOMATIC
TRANSMISSION
TRUCKS ONLY)
STARTER RELAY
FUSIBLE LINK
BACK-UP BUZZER
NEUTRAL
SAFETY RELAY
NEUTRAL RELAY View A
TAIL LIGHT RELAY HORN
HEADLIGHT RELAY
View B
Fig. 9.20 Location of Electrical Parts (Trucks with a QD32 Diesel Engine)
- 146 -
9. ELECTRIC WIRING
COMBINATION
METER
ALARM
SEAT
SWITCH
PARKING BRAKE
SWITCH
TIMER
View B
- 147 -
to LIGHTING SWITCH
3BG
2LR 3BY to STARTER SWITCH
9. ELECTRIC WIRING
G
to HORN SWITCH
for OPTIONAL B
ELECTRICAL PARTS
to COMBINATION METER
O WR
to HORN
LW
BR YG L LY RW YW WG RB
2B G
WB YB WR B BrR BrB LB
W GY
to ORBITROL
2L to PARKING
B LY BRAKE SWITCH
BW GO WBr RB B
to WIRE HARNESS, P
OVERHEAD GUARD
Sb
(LEFT)
B RY B to WIRE HARNESS,
LW
GR RW OVERHEAD GUARD
B
(RIGHT)
- 148 -
B RY B
GL RW
to REAR WORK
LIGHT SWITCH
WR WL 2LR
B B 2YL
to NEUTRAL RB
to HEADLIGHT RELAY
WL BrB GW BrW GW BrW
2L 3BY3BG B B
2YL BrW 2B to CONTROL VALVE to CONTROL VALVE
YR 2R LW
to NEUTRAL RELAY LIFT LOCK INTERLOCK
YB GO BW WBr GW GB W RW GR GL
YW YG WB LY GY Y BrR BrB RY BR
WL WG LG LB
V OL Sb WR
for ELECTRONICALLY
CONTROLLED
ENGINES ONLY to WIRE HARNESS, COWL
to WIRE HARNESS,
ECM
to BRAKE LIGHT
to LEAD WIRE, SIL SWITCH
for AUTOMATIC
to OK TRANSMISSION
MONITORS TRUCKS ONLY
(OPTION)
to FR VALVE
to FUSE BOX
to DIODE
for NON-
ELECTRONICALLY for MANUAL
CONTROLLED TRANSMISSION
to AUTO- to GROUND TRUCKS ONLY
CHOKE ENGINES ONLY
RELAY to FUEL LEVEL to FUEL CUT-OFF to BACK-
SIGNAL SENDER VALVE UP LIGHT
SWITCH
to METER
to DIODE to WATER TEMP. to NEUTRAL
SWITCH
SENSOR for NON-
to BATTERY ELECTRONICALLY
to STARTER CONTROLLED
ENGINES ONLY
to DISTRIBUTOR
to FLASHER
UNIT to POTENTIOMETER to OIL PRESSURE
to STARTER SWITCH
RELAY
to ALTERNATOR
to BACK-UP BUZZER
to REAR
COMBINATION
LIGHT
to SEAT SWITCH
to REAR WORK
LIGHT (OPTION)
FUSE BOX
Fig. 9.23 Wire Harness, Engine (Trucks with a K21 or K25 Gasoline Engine)
- 149 -
9. ELECTRIC WIRING
3BG3BY 2L
GL GR RW W
2B BrW 2YL
BR BrR GB GW WBr BW GO YB
LW 2R YR
LB Lg Y GY LY WB YG YW
WR RL OL V
to PARKING BRAKE
LIGHT SWITCH
BrY RB
Br
to
SOLENOID
V OL
G G
VALVE
to FLASHER
to QOS3 UNIT G G
to DIODE
to STARTER to GLOW PLUG OL V
TIMER
3B
WY B RELAY
WG LB 2YL
GB
2YL B to GROUND 5BW
B LG OG
3BL 3BY
YB
to FUEL LEVEL
to GLOW SIGNAL SENDER 3BL to STARTER to OIL PRESSURE
PLUG SWTICH
RELAY YW
B
WR to METER to WATER
B
SEDIMENTER
5BW
WB B
5BY
to FUEL
WG PUMP
LG
5BY
B WG
LW Lg BrR
GW B L
OL
Br
G
V
LW to BATTERY to WATER TEMP.
2L
WY GY BrY 2R to FUEL CUT-OFF SENSOR
to INTERLOCK
WG Y LY YR
WG 2BL VALVE
B
TIMER 3BY 3BG
3BY 3BG OG
to WATER TEMP. WG
FUSE BOX SIGNAL SENDER
5BY
BR
15A HEAD AND B
RW Y GR
3BY 2R POSITION RL B
7.5A RB RL GL
STOP
7.5A
BrY
HORN
to BACK-UP to ALTERNATOR
3BY
15A
GY
RWL OPTION
BUZZER
2L W
3BG
7.5A
WY
TURN SIGNAL
B
to REAR
3A TIMER to SEAT SWITCH Br B COMBINATION
3A
YR
METER to REAR
2B
LIGHT
LY
3BG
7.5A
Y
BACK-UP BUZZER WORK LIGHT
3A ENGINE
WG
7.5A OPTION
LW
Fig. 9.24 Wire Harness, Engine (Trucks with a V2403 Diesel Engine)
- 150 -
9. ELECTRIC WIRING
3BG3BY 2L
GL GR RW W
2B BrW 2YL
BR BrR GB GW WBr BW GO YB
LW 2R YR
LB Lg WL Y GY LY WB YG YW
WR RL OL V
5BW
to NEUTRAL SWITCH
5BY
to GLOW 3BL YB
WG 5BY
to OIL PLUG B
LG to STARTER E
to QOS WY B SWITCH 3B
TIMER
GB
2YL B
WG LB 2YL
B LG OG to FLASHER 3BL 3BY WG
UNIT
to STARTER to POTENTIOMETER LR
RELAY LG BR to ALTERNATOR
BW GO WBr YG
LR B
7.5A OPTION
to SEAT WORK LIGHT
LW
SWITCH
Fig. 9.25 Wire Harness, Engine (Trucks with a C240 Diesel Engine)
- 151 -
9. ELECTRIC WIRING
to BRAKE
to LEAD WIRE, SIL LIGHT SWITCH
for AUTOMATIC
to OK TRANSMISSION
MONITORS TRUCKS ONLY
(OPTION)
to FR VALVE
to FUSE BOX
to DIODE
to GROUND
for MANUAL TRANSMIS-
to RESISTOR SION TRUCKS ONLY
to FUEL
to DETECTOR LEVEL to OIL PRESSURE to BACK-
SIGNAL
to METER SWITCH UP LIGHT
SENDER SWITCH
to
to STARTER NEUTRAL
to DIODE SWITCH
to GLOW PLUG
to BATTERY to WATER
TEMP.
SIGNAL
to GLOW SENDER
PLUG to FUEL CUT-OFF
VALVE
to
FLASHER
to QOS3 UNIT to POTENTIOMETER
TIMER to STARTER to ALTERNATOR
RELAY
to WATER TEMP.
FUSE BOX to WATER SENSOR
SEDIMENTER
to BACK-UP to REAR
BUZZER COMBINATION LIGHT
to SEAT SWITCH
to REAR
WORK LIGHT
(OPTION)
Fig. 9.26 Wire Harness, Engine (Trucks with a QD32 Diesel Engine)
- 152 -
9. ELECTRIC WIRING
COMBINATION METER
HOUR FUEL WATER
for AUTOMATIC CPU METER METER TEMP. ILLUMINATION
TRANSMISSION RW
EMPTY
FUEL
SW
N OFF OFF R
12V
(LEFT)
5V
1 T N HEADLIGHT
DC/DC
DC/DC
R χ
COM
2 H L
(RIGHT)
AIR CLEANER
ON
SEDIMENTER
OIL PRESS.
WB
RW
GLOW PLUG
RW
WB
SEAT BELT
Y
Y
RADIATOR
INTERLOCK
PTG PTS PT+ OV PV N IG1IG2 VF VF2 ST VR Ra B Ig S HO- HO+ EL LT LH TB TL TR
NEUTRAL
PARKING
CHARGE
BATTERY
+
LY KEY ON +
ENGINE
HORN
NO
GND
3BY
3BG
2LR
WBr
Lg
Br
GB
GR
GL
RY
RY
GW
YR
YR
OL
WL
Sb
Sb
BW
GO
LY
GW
B
G
G
B
B
B
B
G
V
W
B
(FOR OPTION)
RB
BrR
BrB
BrW
(FOR OPTION)
B
YG
BR
YB
LB
WB
WG
YL
RG
RB
WR
YW
Y
L
B
Sb
P
GY
LW
2B
LW
2L
B
W
O
B B B B
B B B B
G RW RW G
GW GR GL GW
RY RY RY RY
RB
㔚Ḯ 5V LG ALARM BUZZER
࿁〝
Ry3
2YL
2LR
BrB
BrW
BrW
WL
Br
RY
2R
Lg
RW
WL
GW
GW
B
B
TRANSMISSION TRUCKS
12F675
BrW
3BY
3BG
WBr
2YL
BrR
BrB
BrW
LY
YL
RG
Sb
RW
RY
2B
YR
OL
WL
Sb
2R
BW
GO
LY
2L
LW
GB
GR
GL
BR
YB
LB
WB
WG
WR
YW
YG
GY
LG
GW
Y
P
V
FR
Ry2 Ry3
BrW
3BY
3BG
WBr
2YL
BrR
BrW
LY
YL
RG
RW
2B
YR
OL
WL
RL
2R
BW
GO
LY
2L
LW
GB
GR
GL
BR
YB
WR
YW
YG
GY
Lg
GW
F R
Y
W
V
1 4 7 8 9 10 6 3 5 2
B SAFETY LIGHT LIGHT RELAY CONTROL VALVE
BrR
RELAY RELAY
LW
WR
WL
LB
RW
RELAY
L
B
W
W
B
B
BrR BrR BrR BrR
RW RW RW Lg
BRAKE
BrY
WR WR WR GW
RB
LW LW LW LW
L L L L LIGHT SW
OL
G
G
V
W W W OL
G G G G
WL WL WL V
LB LB LB Br for MANUAL TRANSMIS-
OL
SION TRUCKS
G
G
V
B B B B
BACK-UP LIGHT SW
AUTO-CHOKE B WR
RELAY
Y
RL
LG
BR
2YL
3BY
3BL
B
WY
GB
B
RG
FUSIBLE LINK B
5BY
0.85R
5BY
SPARK PLUG To A STARTER
20B
B B
WG 3BL C
FUSE BOX
3BG
3BG
3BY
3BY
DISTRIBUTOR YB
3BY 15A HEAD & POSITION 2R 2R
7.5A STOP BrY BrY
5BY
OIL PRESS. SW
3BY 7.5A HORN GY GY B
5BY
20B To B 15A
3B E
RWL OPTION
+ A 7.5A
3BY R(LEVEL)
3BG TURN SIGNAL WY WY
BR L(RELAY)
BATTERY 12V
Y 3A TIMER YG YR
3A
7.5A
METER LY LY
REGULATOR SEAT BELT RELAY
3BG BACK-UP BUZZER RY Y
3A ENGINE WG WG YL RADIATOR
-
BATTERY
7.5A INTERLOCK
2L 2L
B LEVEL
SENSOR
& OPTION
BrW
CAP SEAT BELT SW
LY
B
W
LW LW
20B
3B
SENSOR W
B
W W W Br
REAR WORK LIGHT B B B
RW
GR
GL
RL
RB
Y
BACK-UP BUZZER
POTENTIOMETER
RL
Sb
LICENSE NUMBER
Y
B
RW
PLATE LIGHT
RW
GR
GL
RL
RB
G GR GL G
TAIL LIGHT (8W) RW
RB
RW
RB
RW
RB TAIL LIGHT
RW
RB (8W)
STOP LIGHT (23W) B
RL
B
RL
B
RL STOP LIGHT
B
RL (23W)
BACK-UP LIGHT (STD: 10W) BACK-UP LIGHT (STD: 10W)
(RRE: 20W) (RRE: 20W)
REAR COMBI. LIGHT REAR COMBI. LIGHT
(LEFT) (RIGHT)
- 153 -
9. ELECTRIC WIRING
COMBINATION METER
for AUTOMATIC CPU HOUR METER FUEL METER WATER TEMP. ILLUMINATION
TRANSMISSION RW
12V
HEADLIGHT SW
5V
R 1 T N
DC/DC
DC/DC
(LEFT)
χ
NO COM
2 ON H L
RW
RW
WB
WB
RG AIR CLEANER
PTS OV IG1 VF ST Ra
WB SEDIMENTER
WGENGINE CHECK
Y
Y
GLOW PLUG
BrR INTERLOCK
PTG PT+ PV N IG2 VF2 VR B Ig S HO- HO+ EL LT LH TB TL TR
BrWSEAT BELT
RADIATOR
BrB NEUTRAL
BATTERY
RB PARKING
BR CHARGE
HORN
B GND
3BG
3BY
WBr
GW
GW
2LR
GO
BW
GR
GB
WL
RY
YR
YR
RY
OL
GL
OIL
Sb
LY
Sb
Lg
W
Br
G
G
R
B
B
V
WR
YW
YG
YB
RB
LY
LB
YL
(FOR OPTION) (FOR OPTION)
B
L
Sb
P
GY
LW
LW
2B
2L
W
O
B
B B B B
B B B B
G RW RW G
GW GR GL GW
RY RY RY RY
RB
㔚Ḯ 5V LG ALARM BUZZER
࿁〝
Ry3
BrW
BrW
GW
GW
2LR
RW
Ry1
2YL
BrB
WL
WL
RY
2R
Lg
Br
R
B
B
12F675
TRANSMISSION TRUCKS
3BG
3BY
WBr
BrW
BrW
WG
GW
RW
WR
2YL
GO
BW
WB
YW
BrR
GR
RG
BrB
GB
YG
GY
WL
LW
RY
YR
BR
OL
GL
YB
LG
2R
Sb
2B
Sb
LY
LB
LY
YL
2L
W
P
Y
V
Ry2 Ry3 BRAKE SOL.
LIGHT
Ry1 SW (LIFT (INTER- VALVE
Ry2
TIMER UNIT
3BG
3BY
WBr
BrW
BrW
GW
RW
WR
2YL
GO
BW
WB
YW
BrR
GR
RG
GB
YG
GY
LW
YR
BR
OL
GL
YB
RL
2R
NEUTRAL HEADLIGHT TAIL
2B
LY
LB
LY
YL
LOCK) LOCK)
2L
Lg
W
Y
NEUTRAL
V
1 4 7 8 9 10 6 3 5 2 F R
SAFETY RELAY LIGHT RELAY
WR
RW
B
BrR
LW
WL
CONTROL VALVE
LB
W
W
W
G
B
B
B
L
BrR
RW
BrR
Lg RELAY RELAY
BrY
RB
WR GW
LW LW
OL
L L
G
G
V
W OL
G G
WL V
LB Br
OL
G
G
V
B B
1 2 3 4 5 6 FUEL LEVEL YW
3BL C STARTER OIL PRESS. SW DIODE
SIGNAL B
E B L SENDER WG
FUEL CUT-OFF
WG
AIR CLEANER
2YL
OG
WG
LG
5BW
LB
LG
5BY
B
BL
VALVE
3BY
2YL
3BL
B
WY
GB
B
RG
FUSIBLE LINK B
0.85R
5BY 5BY 5BY B
WG R (LEVEL) ALTERNATOR
3BG
3BG
3BY
3BY
3BY GY GY YG
40B
To B
15A RWL SEDIMENTER
+ A
3BG 7.5A TURN SIGNAL WY WY WB
RELAY SIGNAL SENDER
Y 3A TIMER YG YR B
3A METER LY LY
3BG 7.5A BACK-UP BUZZER RY Y
OG
WATER TEMP.
3A ENGINE WG WG YL RADIATOR B
SENSOR
- BATTERY
7.5A INTERLOCK
2L 2L
B LEVEL
SENSOR
BrW
LY
CAP
W
B
LW LW
40B
RB
GL
RL
2B
POTENTIOMETER
RB
GL
RL
2B
G GR GL G
TAIL LIGHT (8W) RW
RB
RW
RB
RW
RB
RW
RB
TAIL LIGHT (8W)
STOP LIGHT (23W) B
RL
B
RL
B
RL
B
RL
STOP LIGHT (23W)
BACK-UP LIGHT (10W) BACK-UP LIGHT (10W)
REAR COMBI. LIGHT REAR COMBI. LIGHT
(LEFT) (RIGHT)
- 154 -
9. ELECTRIC WIRING
COMBINATION METER
for AUTOMATIC CPU HOUR METER FUEL METER WATER TEMP. ILLUMINATION
TRANSMISSION RW
ࡈࡘࠛ࡞
C A J G H E N D M B L K F
PARKING
FUEL
ORBITROL F SW HORN SW SW
HEADLIGHT N
OFF OFF R
BRAKE SW HEADLIGHT
SW
12V
(LEFT)
5V
R 1 T N
(RIGHT)
DC/DC
DC/DC
χ
NO COM
2 ON H L
RW
RW
WB
WB
AIR CLEANER
SEDIMENTER
ENGINE CHECK
PTS OV IG1 VF ST Ra
GLOW PLUG
Y
Y
INTERLOCK
PTG PT+ PV N IG2 VF2 VR B Ig S HO- HO+ EL LT LH TB TL TR
SEAT BELT
RADIATOR
NEUTRAL
BATTERY
PARKING
CHARGE
BATT. +
HORN
GND
3BG
3BY
GW
WBr
GW
2LR
GO
BW
GR
GB
WL
RY
YR
YR
RY
OIL
OL
GL
Sb
LY
Sb
Lg
W
G
Br
G
R
B
B
V
WG
BrW
WR
RB
YW
WB
BrR
RG
YG
BrB
BR
RB
YB
LY
LB
YL
(FOR OPTION)
B
(FOR OPTION)
Y
L
Sb
P
GY
LW
LW
2B
2L
W
O
B
B B B B
B B B B
G RW RW G
GW GR GL GW
RY RY RY RY
RB
5V LG ALARM BUZZER
Ry3
BrW
GW
BrW
GW
2LR
Ry1
RW
2YL
BrB
WL
WL
RY
2R
Lg
Br
R
B
B
12F675
TRANSMISSION TRUCKS
3BG
3BY
WBr
BrW
BrW
WG
GW
RW
WR
2YL
GO
BW
WB
YW
GR
BrR
RG
BrB
GB
YG
GY
WL
LW
RY
YR
BR
OL
GL
YB
LG
2R
Sb
2B
Sb
LY
LB
LY
YL
2L
W
P
Y
V
Ry2 Ry3
BRAKE SOL.
LIGHT
Ry1
SW (LIFT
VALVE
(INTER-
Ry2
TIMER UNIT
3BG
3BY
WBr
GW
BrW
BrW
RW
WR
2YL
GO
BW
WB
YW
GR
BrR
RG
GB
YG
GY
WL
LW
YR
BR
OL
GL
YB
RL
2R
2B
LY
LB
LY
YL
2L
Lg
W
NEUTRAL HEADLIGHT TAIL LOCK) LOCK)
Y
V
1 4 7 8 9 10 6 3 5 2
NEUTRAL F R
RW
B
BrR
LW
WL
LB
W
W
W
CONTROL VALVE
G
B
B
B
L
BrY
RB
WR WR WR GW
LW LW LW LW
L L L L
OL
G
G
V
W W W OL
G G G G
WL WL WL V
LB LB LB Br
OL
for MANUAL TRANSMISSION TRUCKS
G
G
V
B B B B
WL
BR
LG
LG
LG
LR
LR
B
E B L WB
AIR CLEANER
WG
WG
2YL
OG
5BW
LG
LG
5BY
LB
FUEL CUT-
B
B
NEUTRAL SW
3BY
2YL
3BL
OFF VALVE
B
WY
GB
B
RG
FUSIBLE LINK B
0.85R
5BY 5BY 5BY To A
B 20B
3B B B
WG
E
R (LEVEL) 3BL C
STARTER
3BG
3BG
3BY
3BY
3BY GY GY YG
To B
20B RWL
RELAY
15A
+ A
3BG 7.5A TURN SIGNAL WY WY SIGNAL SENDER
BATTERY 12V
Y 3A TIMER YG YR
3A METER LY LY
7.5A BACK-UP BUZZER OG
WATER TEMP.
RADIATOR
3BG RY Y
B
3A ENGINE WG WG YL
SENSOR
7.5A INTERLOCK B LEVEL
BATTERY 2L 2L
SENSOR
-
BrW
LY
W
B
CAP LW LW
SEAT BELT SW
20B
SENSOR
3B W
B
ENGINE (OPTION)
SEAT SW
GROUNDING RL
B
WBr WBr WBr
GO GO GO
BW BW BW
RW
GR
RB
GL
RL
2B
POTENTIOMETER
RB
GL
RL
2B
G GR GL G
- 155 -
9. ELECTRIC WIRING
COMBINATION METER
for AUTOMATIC CPU HOUR METER FUEL METER WATER TEMP. ILLUMINATION
TRANSMISSION RW
EMPTY
FUEL
SW
N OFF OFF R
12V
5V
(LEFT) 1 T N
(RIGHT)
DC/DC
DC/DC
R χ
COM
H L
AIR CLEANER
2 ON
SEDIMENTER
ENGINE CHECK
GLOW PLUG
WR HOUR METER
YG WATER TEMP.
WB
RW
RW
WB
INTERLOCK
Y
Y
PTG PTS PT+ OV PV N IG1IG2 VF VF2 ST VR Ra B Ig S HO- HO+ EL LT LH TB TL TR
SEAT BELT
RADIATOR
NEUTRAL
BATTERY
BATTERY
PARKING
LY KEY ON +
HORN
CHARGE
+
NO
YW FUEL
GND
OIL
3BY
3BG
2LR
WBr
Lg
Br
GB
GR
GL
RY
GW
YR
YR
OL
WL
Sb
GW
RY
Sb
BW
GO
LY
B
G
R
B
B
G
G
B
B
W
RB
(FOR OPTION)
BrR
BrB
BrW
B
BR
YB
WB
LB
WG
YL
RG
RB
(FOR OPTION)
Y
L
B
Sb
P
GY
LW
2B
LW
2L
B
W
O
B B B B
B B B B
G RW RW G
GW GR GL GW
RY RY RY RY
RB
㔚Ḯ 5V LG ALARM BUZZER
࿁〝
Ry3
2YL
2LR
BrB
BrW
BrW
WL
Br
RY
2R
Lg
RW
WL
GW
GW
B
B
12F675
TRANSMISSION TRUCKS
BrW
3BY
3BG
WBr
2YL
BrR
BrB
BrW
Sb
LY
YL
RG
RW
RY
2B
YR
OL
WL
Sb
2R
BW
GO
LY
2L
LW
GB
GR
GL
BR
YB
WB
LB
WG
WR
YW
YG
GY
LG
GW
BRAKE
Y
W
V
Ry2 Ry3
LIGHT FR
Ry1 SW (LIFT (INTER- VALVE
TIMER UNIT
Ry2
BrW
3BY
3BG
WBr
2YL
BrR
BrW
LY
YL
RG
RW
2B
YR
OL
WL
RL
2R
BW
GO
LY
2L
LW
GB
GR
GL
BR
YB
WB
LB
WR
YW
YG
GY
Lg
GW
NEUTRAL
Y
W
V
1 4 7 8 9 10 6 3 5 2 F R
B SAFETY RELAY LIGHT RELAY CONTROL VALVE
BrR
LW
WR
WL
LB
RW
L
B
B
B
W
W
BrR
RW
BrR
RW
BrR
RW
BrR
Lg RELAY RELAY
BrY
WR WR WR GW
RB
LW LW LW LW
L L L L
OL
G
G
V
W W W OL
G G G G
WL WL WL V
LB LB LB Br
for MANUAL TRANSMISSION TRUCKS
OL
G
G
V
B B B B
BACK-UP LIGHT SW
STARTER FLASHER GLOW PLUG DETECTOR
B WR
RELAY UNIT
RELAY DIODE RESISTOR To A 40B
STARTER Y
1 2 3 4 5 6 7
SIGNAL SENDER
YW
3BL
S
DIODE
(600V 3A×2)
B YR
LG
FUEL CUT-OFF
LG
BR
WG
WG WL
E B L
AIR CLEANER
WB
LY
RY
2YL
WL
5BY
5BW
VALVE
B
B
OG
LB
WL
BW
LY
B
NEUTRAL SW
2YL
3BY
3BL
B
WY
GB
B
RG
FUSIBLE LINK B
0.85R
5BY 5BY 5BY B
3B E
3BY S (LEVEL) REGULATOR
FUSE BOX
3BG
3BG
3BY
3BY
BR L (RELAY)
5BW
3BY 15A HEAD & POSITION 2R 2R GLOW PLUG
7.5A STOP BrY BrY
SEDIMENTER SEAT BELT
3BY 7.5A HORN GY GY YG
WATER TEMP.
5BY
40B To B
RELAY SIGNAL SENDER
15A RWL OPTION RY
+ A 7.5A
3BG TURN SIGNAL WY WY
BATTERY 12V
Y 3A TIMER YG YR
3A METER LY LY
3BG 7.5A BACK-UP BUZZER RY Y
RADIATOR
OG
B
WATER TEMP.
3A ENGINE WG WG YL
LEVEL SENSOR
BATTERY
7.5A INTERLOCK B
2L 2L
SENSOR
- & OPTION
BrW
CAP
LY
B
W
LW LW
SEAT BELT SW
40B
3B
SENSOR W
B
W W W Br
REAR WORK LIGHT B B B
ENGINE SEAT SW
GROUNDING RL
B
WBr WBr WBr
GO GO GO
BW BW BW
2B
RW
GR
GL
RL
RB
Y
POTENTIOMETER
RW
GR
GL
RL
RB
G GR GL G
TAIL LIGHT (8W) RW
RB
RW
RB
RW
RB TAIL LIGHT
RW
RB (8W)
STOP LIGHT (23W) B
RL
B
RL
B
RL STOP LIGHT
B
RL (23W)
BACK-UP LIGHT (STD: 10W) BACK-UP LIGHT (STD: 10W)
(RRE: 20W) (RRE: 20W)
REAR COMBI. LIGHT REAR COMBI. LIGHT
(LEFT) (RIGHT)
- 156 -
No. SEF-2A0DE
Issued: February, 2006
Revised: May, 2008
Revised: March, 2009
Revised: September, 2012
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