Service Manual

Chassis & Mast MC/FC

FG10N F25C-05001-up FGE15N F34-00001/19001-up
FG15N F25C-55001-up FGE18N F34-40001/49001-up
FG15ZN F34-52001-up FGE20CN F34-30001/39001-up
FG18N F25C-75001-up FGE20N F17D-20001/38001-up
FG18ZN F34-72001-up FGE20ZN F35-20001/38001-up
FG20CN F34-22001-up FGE25N F17D-70001/88001-up
FG20N F17D-10001-up FGE25ZN F35-70001/88001-up
FG20ZN F35-10001-up FGE30N F13F-10001/20001-up
FG25N F17D-60001-up FGE35AN F13F-80001/90001-up
FG25ZN F35-60001-up
FG30N F13F-40001-up
FG35AN F13F-60001-up

FD10N F16D-04001-up
FD15N F16D-54001/64001-up
FD18N F16D-74001/84001-up
FD20CN F16D-24001/28001-up
FD20N F18C-20001/40001-up
FD25N F18C-70001/90001-up
FD30N F14E-10001/20001-up
FD35AN F14E-80001/90001-up

For use with S4Q2, S4S and K15/K21/K25 Engine

Service Manuals. 99719-18100
 FOREWORD
This service manual is a guide for servicing Mitsubishi forklift trucks. For your convenience the instructions are
grouped by systems as a ready reference.
The long productive life of your lift truck(s) depends on regular and proper servicing. Servicing consistent with what
you will learn by reading this service manual.
Read the respective sections of this manual carefully and familiarize yourself with all of the components before
attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks with serial numbers in effect
at the time of printing.
Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring
obligations.
The trucks listed in this manual are powered by K15, K21 or K25 gasoline engines or S4Q2/S4S diesel engines.
For engine servicing, please refer to the applicable engine service manual.

K15, K21 or K25 Gasoline engine

S4Q2, S4S Diesel engine

<Safety Related Signs>

Indicates a specific potential hazard resulting in serious
WARNING bodily injury or death.
Indicates a potentially hazardous situation which, if not
CAUTION avoided, may result in death or serious injury or damage to
the machine.

NOTE Indicates a condition that can cause damage to, or shorten

service life of, the machine.

1
Pub. No. 99719-18100
 SAFETY
WARNING
The proper and safe lubrication and maintenance
for these lift trucks, recommended by Mitsubishi
Forklift Trucks, are outlined in the OPERATION &
MAINTENANCE MANUAL.
Read and understand the OPERATION & MAINTE-
NANCE MANUAL before performing any lubrica-
tion or maintenance on these trucks.
Improper performance of lubrication or mainte-
nance procedures is dangerous and could result
in injury or death.
The serviceman or mechanic may be unfamiliar with
many of the systems on this truck. This makes it
important to use caution when performing service
work. A knowledge of the system and/or components
is important before the removal or disassembly of any
component.
Because of the size of some of the truck components,
the serviceman or mechanic should check the weights
noted in this Manual. Use proper lifting procedures
when removing any components.
Following is a list of basic precautions that should
always be observed.
(1) Read and understand all warning plates and
decals on the truck before operating, lubricating or
repairing the product.
(2) Always wear protective glasses and protective
shoes when working around trucks. In particular,
wear protective glasses when pounding on any
part of the truck or its attachments with a hammer
or sledge. Use welders gloves, hood/goggles,
apron and other protective clothing appropriate to
the welding job being performed. Do not wear
loose fitting or torn clothing. Remove all rings from
fingers when working on machinery.
(3) Do not work on any truck that is supported only by
lift jacks or a hoist. Always use blocks or jack
stands to support the truck before performing any
disassembly.
(4) Lower the forks or other implements to the ground
before performing any work on the truck. If this
cannot be done, make sure the forks or other
implements are blocked correctly to prevent them
from dropping unexpectedly.
WARNING
Do not operate these trucks unless you have read
and understood the instructions in the OPERA-
TION & MAINTENANCE MANUAL. Improper truck
operation is dangerous and could result in injury
or death.
(5) Use steps and grab handles (if applicable) when
mounting or dismounting a truck. Clean any mud
or debris from steps, walkways or work platforms
before using. Always face truck when using steps,
ladders and walkways. When it is not possible to
use the designed access system, provide ladders,
scaffolds, or work platforms to perform safe repair
operations.
(6) To avoid back injury, use a hoist when lifting com-
ponents which weigh 23 kg or more. Make sure all
chains, hooks, slings, etc., are in good condition
and are of the correct capacity. Be sure hooks are
positioned correctly. Lifting eyes are not to be side
loaded during a lifting operation.
(7) To avoid burns, be alert for hot parts on trucks
which have just been stopped and hot fluids in
lines, tubes and compartments.
(8) Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located at oppo-
site ends of the cover or device and pry cover
loose to relieve any spring or other pressure,
before removing the last two bolts or nuts com-
pletely.
(9) Be careful when removing filler caps, breathers
and plugs on the truck. Hold a rag over the cap or
plug to prevent being sprayed or splashed by liq-
uids under pressure. The danger is even greater if
the truck has just been stopped because fluids
can be hot.
(10)Always use tools that are in good condition and
be sure you understand how to use them before
performing any service work.
(11)Reinstall all fasteners with same part number. Do
not use a lesser quality fastener if replacements
are necessary.
(12)If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not
roll while working on or under truck.
3
(13)Disconnect battery and discharge any capacitors (20)Relieve all pressure in air, oil or water systems
(electric trucks) before starting to work on truck. before any lines, fittings or related items are dis-
Hang “Do not Operate” tag in the Operator’s Com- connected or removed. Always make sure all
partment. raised components are blocked correctly and be
(14)Repairs, which require welding, should be per- alert for possible pressure when disconnecting
formed only with the benefit of the appropriate ref- any device from a system that utilizes pressure.
erence information and by personnel adequately (21)Do not operate a truck if any rotating part is dam-
trained and knowledgeable in welding proce- aged or contacts any other part during operation.
dures. Determine type of metal being welded and Any high speed rotating component that has been
select correct welding procedure and electrodes, damaged or altered should be checked for bal-
rods or wire to provide a weld metal strength ance before reusing.
equivalent at least to that of parent metal.
(15)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will it
be damaged in operation by contacting sharp cor-
ners, or by rubbing against some object or hot
surface. Place wiring away from oil pipe.
(16)Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
(17)Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.
(18)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses could cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Pin hole (very small) leaks could
result in a high velocity oil stream that will be invis-
ible close to the hose. This oil could penetrate the
skin and cause personal injury. Use cardboard or
paper to locate pin hole leaks.
(19)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibra-
tion or rubbing against other parts during opera-
tion. Shields that protect against oil spray onto hot
exhaust components in event of a line, tube or
seal failure, must be installed correctly.

4
 HOW TO USE THIS MANUAL
Lift truck models covered in this manual
MC Truck (Mechanical Control System)
Mechanically controlled hydraulic system (conventional lever system)
FC Truck (Finger-tip Control System)
Electronically controlled hydraulic system

MC Truck
Lever

Control valve

FC lever box

Output unit

Input unit

VCM Controller

Electric wiring

FC Truck

Electromagnetic control valve

Flow regulator valve
213443

Gasoline-Engine Trucks (FGE, FG)....... Trucks Equipped with K21 or K25 Gasoline Engine
Diesel-Engine Trucks (FD).................... Trucks Equipped with K21 or K25 Diesel Engine
Powershift Trucks................................... Trucks Equipped with Powershift Transmission
Manual Transmission Trucks................. Trucks Equipped with Manual Transmission
(2 Types of Clutch; Dry and Wet)

5
 HOW TO USE THIS MANUAL (continued)
(Removal, Installation, Assembly and Disassembly)
Disassembly diagram (example)

213445
Sequence
1 Cover, Bolt, Washer (part name)
2 Snap ring (part name)

Suggestions for Disassembly

Output shaft, Removing
Remove output shaft using a special tool.

213446

Service Data
A 0.11 to 0.28 mm
Gear Backlash
B 0.5 mm

A: Standard value
B: Repair or Service Limit

6
 Symbols and abbreviations
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
RC1/8 Taper pipe thread (external) 1/4 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

Units
(1) SI Units are used in this manual.
(2) The following table shows the conversion of SI
unit and customary unit.

Item SI unit Customary unit

1N 0.102 kgf
Force
1 lbf 0.4536 kgf
1 kPa 0.0102 kgf/cm2
Pressure
1 psi 0.0703 kgf/cm2
1 N·m 0.102 kgf·m
Torque
1 lbf·ft 0.1383 kgf·m

7
 CHAPTER INDEX
CHAPTER INDEX

CHAPTER INDEX Items

Truck Models Covered, Serial Number Locations,

GENERAL INFOMATION
Dimensions, Technical Data 1
COOLING SYSTEM Fan Belt Removal and Installation, Fan Belt Tension
2
Console Box, Chassis Electrical Devices,
ELECTRICAL SYSTEM
Battery Maintenance, Electrical Schematic 3
Main Functions of Controller, Input/Output Monitor,
CONTROLLERS
Error Codes and Troubleshooting 4
POWER TRAIN Removal and Installation of Power Line
5
CLUTCHES Dry-Type Clutch, Wet-Type Clutch
6
MANUAL TRANSMISSION Structure, Removal and Installation of Transmission
7
Torque Converter,
POWERSHIFT TRANSMISSION Singe Speed Powershift Transmission Control Valve,
Automatic Two-Speed Transmission
8
FRONT AXLE AND
REDUCTION DIFFERENTIAL
Front Tire, Front Axle, Reduction, Differential 9
REAR AXLE Rear Axle, Rear Tire 10
BRAKE SYSTEM Master Cylinder, Wheel Brake, Brake Booster 11
STEERING SYSTEM Steering Gear, Power Cylinder, Flow Divider 12
Tank, Pump, Control Valve, Lift and Tilt Cylinders,
HYDRAULIC SYSTEM
Flow Regulator Valve, Down Safety Valve 13
MAST AND FORKS Simplex and Duplex Masts, Triplex Mast
14
Maintenance Standard, Maintenance Schedule,
SERVICE DATA Periodic Replacement Parts, Lubrication Instruction,
Special Tool Needed
15
 Chapter 1 GENERAL INFORMATION
1. Model View............................................................................................... 1-1
2. Truck Models Covered............................................................................ 1-2
3. Serial Number Locations........................................................................ 1-3 1
4. Dimensions.............................................................................................. 1-4
5. Technical Data......................................................................................... 1-5
6. Performance ............................................................................................ 1-7
 GENERAL INFORMATION

1. Model View
Chapter 1 GENERAL INFORMATION

MC truck

213447

FC truck

213448

1-1
GENERAL INFORMATION

2. Truck Models Covered

This Service Manual provides servicing and maintenance information for the following trucks:

Dual fuel gasoline/

Engine mounted Gasoline-engine truck LPG-engine truck
Diesel-engine truck
Non-electric controlled MC / FC MC / FC MC / FC
Electric controlled MC / FC MC / FC -

(FC type is used in torque converter model only.)

Electric controlled gasoline engine,

Electric controlled dual fuel gasoline/
LPG engine models
Non-electric controlled diesel engine models
Non-electric controlled gasoline engine,
Truck type
Non-electric controlled dual fuel gasoline/
LPG engine models
Engine Engine
Truck model Serial number Truck model Serial number
mounted mounted
FG10N F25C-05001 to K15 FD10N F16D-04001 to S4Q2
FG15N F25C-55001 to K15 FD15N F16D-54001 to S4Q2
FG15ZN F34-52001 to K21 FD15N(F) F16D-64001 to S4Q2
FGE15N F34-00001 to K21E FD18N F16D-74001 to S4Q2
FGE15N(F) F34-19001 to K21E FD18N(F) F16D-84001 to S4Q2
FG18N F25C-75001 to K15 FD20CN F16D-24001 to S4Q2
1 ton class
FG18ZN F34-72001 to K21 FD20CN(F) F16D-28001 to S4Q2
FGE18N F34-40001 to K21E - - -
FGE18N(F) F34-49001 to K21E - - -
FG20CN F34-22001 to K25 - - -
FGE20CN F34-30001 to K25E - - -
FGE20CN(F) F34-39001 to K25E - - -
FG20N F17D-10001 to K21 FD20N F18C-20001 to S4S
FG20ZN F35-10001 to K25 FD20N(F) F18C-40001 to S4S
FGE20N F17D-20001 to K21E FD25N F18C-70001 to S4S
FGE20N(F) F17D-38001 to K21E FD25N(F) F18C-90001 to S4S
FGE20ZN F35-20001 to K25E - - -
FGE20ZN(F) F35-38001 to K25E - - -
2 ton class
FG25N F17D-60001 to K21 - - -
FG25ZN F35-60001 to K25 - - -
FGE25N F17D-70001 to K21E - - -
FGE25N(F) F17D-88001 to K21E - - -
FGE25ZN F35-70001 to K25E - - -
FGE25ZN(F) F35-88001 to K25E - - -
FG30N F13F-40001 to K25 FD30N F14E-10001 to S4S
FGE30N F13F-10001 to K25E FD30N(F) F14E-20001 to S4S
FGE30N(F) F13F-20001 to K25E FD35AN F14E-80001 to S4S
3 ton class
FG35AN F13F-60001 to K25 FD35AN(F) F14E-90001 to S4S
FGE35AN F13F-80001 to K25E - - -
FGE35AN(F) F13F-90001 to K25E - - -

Note: Characters at the end of truck model should be read as follows:

(F) : FC Truck
None : MC Truck
Z : High-power engine model
C : Short wheel base model
1-2
 GENERAL INFORMATION

3. Serial Number Locations

Name Plate Chassis Serial Number Gasoline Engine Serial Number

Diesel Engine Serial Number

(2, 3 ton classes)

Diesel Engine Serial Number

(1 ton class and FD20N–25N)

Mast Serial Number Transmission Serial Number Transmission Serial Number

(Manual Transmission Truck) (Powershift Transmission Truck)

213449

1-3
GENERAL INFORMATION

4. Dimensions

G C K L

A
I
H

B P

D N M
F

213450

1-4
 GENERAL INFORMATION

5. Technical Data
Unit: mm
class 1 ton class
FG10N FG15N FG18N FG20CN
Gasoline- FGE15N FGE18N FGE20CN
Truck model engine truck FG15ZN FG18ZN

Diesel-engine
FD10N FD15N FD18N FD20CN
truck
A Maximum lift 3000 3000 3000 3000
B Free lift height 115 115 115 120
C Fork spread 200 to 920 200 to 920 200 to 920 220 to 920
D Fork length 770 920 920 920
E Tilt angle (forward – backward) 6-12 6-12 6-12 6-12
F Overall length 2980 3180 3220 3280
Overall width Single 1065 1065 1065 1065
G (outside-to-
outside of tires) Double 1330 1330 1330 -

H Overall height (with mast lowered) 1990 1990 1990 1990

I Height of the overhead guard 2065 2065 2065 2065
J Overall height (with mast extended) 4055 4055 4055 4055

Tread Single 890 890 890 890

K
(front wheel) Double 1025 1025 1025 -
L Tread (rear wheel) 900 900 900 900
M Wheel base 1400 1400 1400 1400
N Front overhang 400 400 400 415
O Minimum turning radius 1910 1950 1980 2020
Under clearance
P 150 150 150 150
(at center of frame)

1-5
GENERAL INFORMATION

Unit: mm
class 2 ton class 3 ton class
FG20N FG25N FG30N FG35AN
Gasoline- FGE20N FGE25N FGE30N FGE35AN
Truck model engine truck FG20ZN FG25ZN
FGE20ZN FGE25ZN
Diesel-engine
FD20N FD25N FD30N FD35AN
truck
A Maximum lift 3000 3000 3000 3000
B Free lift height 140 145 145 145
C Fork spread 220 to 1000 220 to 1000 250 to 1000 250 to 1000
D Fork length 920 920 1070 1070
E Tilt angle (forward – backward) 6-12 6-12 6-12 6-12
F Overall length 3410 3625 3795 3860
Overall width Single 1150 1150 1275 1290
G (outside-to-
outside of tires) Double 1480 1480 1490 1490

H Overall height (with mast lowered) 1990 1990 2015 2130

I Height of the overhead guard 2074 2074 2093 2103
J Overall height (with mast extended) 4055 4055 4055 4055

Tread Single 960 960 1060 1060

K
(front wheel) Double 1140 1140 1140 1140
L Tread (rear wheel) 980 980 980 980
M Wheel base 1600 1600 1700 1700
N Front overhang 455 460 495 495
O Minimum turning radius 2200 2230 2380 2440
Under clearance
P 160 160 190 200
(at center of frame)

1-6
 GENERAL INFORMATION

6. Performance
class 1 ton class
FG10N FG15N FG18N FG20CN
Gasoline- FGE15N FGE18N FGE20CN
Truck
engine truck FG15ZN FG18ZN
model

Diesel-engine
FD10N FD15N FD18N FD20CN
truck
Capacity kg 1000 1500 1750 2000
Load center mm 500 500 500 500
490 (FG15N) 490 (FG18N)
570 (FG20CN)
490 (FG10N) 630 (FGE15N) 630 (FGE18N)
Loaded mm/s 630 (FGE20CN)
570 (FG15ZN) 570 (FG18ZN)
630 (FD10N) 630 (FD15N) 630 (FD18N) 630 (FD20CN)
Lift speed
560 (FG15N) 560 (FG18N)
650 (FG20CN)
560 (FG10N) 650 (FGE15N) 650 (FGE18N)
Unloaded mm/s 650 (FGE20CN)
650 (FG15ZN) 650 (FG18ZN)
690 (FD10N) 690 (FD15N) 690 (FD18N) 690 (FD20CN)
Travel speed Loaded km/h 19.0 19.0 19.0 19.0
(Powershift
Truck) Unloaded km/h 19.5 19.5 19.5 19.5

1-7
GENERAL INFORMATION

class 2 ton class 3 ton class

FG20N FG25N FG30N FG35AN
Gasoline- FGE20N FGE25N FGE30N FGE35AN
Truck
engine truck FG20ZN FG25ZN
model
FGE20ZN FGE25ZN
Diesel-engine
FD20N FD25N FD30N FD35AN
truck
Capacity kg 2000 2500 3000 3500
Load center mm 500 500 500 500
520 (FG20N) 520 (FG25N)
580 (FGE20N) 580 (FGE25N) 460 (FG30N) 390 (FG35AN)
Loaded mm/s 580 (FG20ZN) 580 (FG25ZN) 510 (FGE30N) 430 (FGE35AN)
640 (FGE20ZN) 640 (FGE25ZN)
630 (FD20N) 630 (FD25N) 500 (FD30N) 420 (FD35AN)
Lift speed
600 (FG20N) 600 (FG25N)
590 (FGE20N) 590 (FGE25N) 530 (FG30N) 450 (FG35AN)
Unloaded mm/s 660 (FG20ZN) 660 (FG25ZN) 530 (FGE30N) 440 (FGE35AN)
660 (FGE20ZN) 660 (FGE25ZN)
660 (FD20N) 660 (FD25N) 530 (FD30N) 450 (FD35AN)
Travel speed Loaded km/h 19.0 19.0 19.0 19.0
(Powershift
Truck) Unloaded km/h 19.5 19.5 19.5 19.5

1-8
 Chapter 2 COOLING SYSTEM
1. Specifications.......................................................................................... 2-1
2. Structure .................................................................................................. 2-2
3. Removal and Installation........................................................................ 2-3
3.1 Fan Belt Removal .................................................................................................... 2-3
3.2 Suggestions for Removal ........................................................................................ 2-3
3.3 Installation ............................................................................................................... 2-4 2
4. Inspection and Adjustment .................................................................... 2-5
4.1 Fan Belt Inspection.................................................................................................. 2-5
4.2 Fan Belt Tension ..................................................................................................... 2-5
4.3 Connecting Hoses ................................................................................................... 2-5
4.4 Unit Layout .............................................................................................................. 2-6
4.5 Coolant .................................................................................................................... 2-6
4.6 Radiator Cap ........................................................................................................... 2-6
 COOLING SYSTEM

1. Specifications
Chapter 2 COOLING SYSTEM

Truck type
Items
1 ton class 2 ton class 3 ton class
Cooling method Water-cooled, forced circulation
Radiator Corrugated fin (pressure) type
Cooling system
Water pump Centrifugal type
Thermostat Wax pellet type

2-1
COOLING SYSTEM

2. Structure

Fan (directly coupled to engine)

Radiator
Shroud
Hose layout

S4Q2 engine

Lower hose

K15, K21,
K25 engines

Reservoir tank
S4Q2 K15, K21, K25
Upper hose S4S
S4S engine

213451

2-2
 COOLING SYSTEM

3. Removal and Installation

3.1 Fan Belt Removal

Engine

Fan

1 2
213452

1 Tension pulley assembly, bolt

2 Belt

3.2 Suggestions for Removal

(1) Loosen the tension pulley lock bolt by three or
four turns.
If the bolt is loosened insufficiently, the tension Fan
pulley will not move.
Note: Do not loosen the lock bolt to such an extent that
the bolt would be removed. Tension
pulley
(2) Move the tension pulley fully toward the fan, then
remove the belt.

213453

2-3
COOLING SYSTEM

3.3 Installation
To install, follow the removal sequence in reverse.
Also follow the instructions given below.
(1) Before installing the belt, turn the fan to check for
smooth rotation. Replace the bearing if it gener-
ates abnormal sound.
(2) After installing the belt, push it to make sure that
the tension pulley moves, then tighten the pulley
lock bolt firmly.

2-4
 COOLING SYSTEM

4. Inspection and Adjustment

4.1 Fan Belt Inspection
(1) Check the belt for contamination from oil, grease
or dust. Replace the belt if required. When the
contamination is slight, clean the belt with a rag or
paper towel. Do not use gasoline, oil or any other
solvent to clean the belt.
(2) During the engine overhaul or belt tension adjust-
ment, check the condition of the belt. Replace the
belt if it has any damage.

4.2 Fan Belt Tension

Apply a force of 98 N (10 kgf) perpendicularly to the
belt at a point midway between the fan pulley and ten- Fan pulley
sion pulley. Adjust the belt tension between 11 to 13
mm.
Tension
pulley

213454

4.3 Connecting Hoses

When connecting the hoses to the radiator, fit their
Hose
ends fully on the fittings and secure them with clamps.
Make sure that each hose is correctly connected and
over the flare of the fitting.

213455

2-5
COOLING SYSTEM

4.4 Unit Layout

213456

4.5 Coolant
Fill the radiator with coolant containing antifreeze.
After starting the engine and letting it warm up during
operation, check for abnormal noises. Check the cool-
ant level in the reserve tank to ensure it meets the
specification.

Coolant quantity
Truck type
Item
1 ton class 2 ton class 3 ton class
Reservoir tank (FULL level) L 0.65 0.65 0.65
Total quantity of coolant
L 6.8 7.4 8.7
(including coolant in hoses)

4.6 Radiator Cap

Opening pressure 88±14.7 kPa
Vacuum valve 0 to 4.9 kPa

2-6
 Chapter 3 ELECTRIC SYSTEM
1. Chassis Electrical Devices Wiring Outline ........................................... 3-1
1.1 (One) ....................................................................................................................... 3-1
1.2 (Two) .......................................................................................................................3-2
2. Structure .................................................................................................. 3-3
2.1 Console Box ............................................................................................................ 3-3
2.2 Major Electrical Components................................................................................... 3-5
2.3 Table of Lamps...................................................................................................... 3-15
3. Console Box .......................................................................................... 3-16
3.1 Disassembly .......................................................................................................... 3-16 3
4. Battery Maintenance ............................................................................. 3-17
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment ..................... 3-17
4.2 Specific Gravity Reading and State of Charge ...................................................... 3-17
4.3 Charging Precautions ............................................................................................ 3-17
5. Instrument Panel ................................................................................... 3-18
5.1 Instrument Panel Screen Element......................................................................... 3-18
5.2 Basic Screen Display............................................................................................. 3-19
5.3 Basic Operation ..................................................................................................... 3-22
5.4 When an Error Occurs........................................................................................... 3-28
5.5 Warning Lamps ..................................................................................................... 3-30
5.6 Optional Functions................................................................................................. 3-31
5.7 Hour Meters........................................................................................................... 3-38
5.8 Troubleshooting..................................................................................................... 3-40
6. Wire Color .............................................................................................. 3-41
6.1 List of Wire Colors ................................................................................................. 3-41
7. Troubleshooting.................................................................................... 3-42
7.1 Starter System....................................................................................................... 3-42
7.2 Gauges .................................................................................................................. 3-42
7.3 Lighting System ..................................................................................................... 3-43
8. Electrical Schematic ............................................................................. 3-45
 ELECTRIC SYSTEM

1. Chassis Electrical Devices Wiring Outline

Chapter 3 ELECTRIC SYSTEM

1.1 (One)

Main harness

Harness, rear
combination

Harness, front
combination

Harness, front
combination

213457

3-1
ELECTRIC SYSTEM

1.2 (Two)

Starter switch
QGS Controller
Key
Main harness

Harness,
rear combination
Select switch

Back buzzer
Warning buzzer

Harness, front
combination

Input unit
VCM(Vehicle control module)

GSE Connector

Clip Battery seat

GLE Connector ECM DCM

(Gasoline (Diesel engine
Connector Harness, front engine control control module)
bracket combination module)

Horn

Output unit
Fuse box, Fuse

Vehicle speed sensor Relay box, Relay

(Pulse generator)

Transmission

213458

3-2
 ELECTRIC SYSTEM

2. Structure
2.1 Console Box

4 3
1 Water temperature gauge 1
2
2 Fuel gauge
3 Hour meter, various warning lights ᵮ

ᵦᶐ

4 Instrument panel
N
ᵤ ᵦ
6
5 Starter switch ᵣᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾ ᵡ

6 Lighting switch, turn signal switch

7 Forward-reverse lever

7
5

214140

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ELECTRIC SYSTEM

2.1.1 Function of Instrument Panel

A B C D E F G H I J K

L M N O
214141

Name of indicators and warning

Ref. No. When turned off When glows or blinks Remark
lamps
When parking brake is applied
A Parking brake warning lamp Normal -
(glows)
When seat belt is not fastened
B Seat belt warning lamp Fastened -
(glows)
When charging is not normal
C Charge warning lamp Normal charging (glows / When engine is not run- -
ning always glows)
When a minor failure occurs or
D Multi-purpose warning lamp Normal operating caution is being issued -
(glows)
Torque converter fluid temperature When torque converter fluid tem-
E Normal temperature -
warning lamp perature is not normal (glows)
When engine oil pressure is low
F Engine oil pressure warning lamp Normal (glows / When engine is not run- -
ning always glows)
G Engine warning lamp Normal When the engine is failed (glows) -
H Glow pilot lamp Preheating completed When the grow plug is ON (glows) -
When protective function of sud-
den acceleration/full reverse
I Smart shift indicator lamp - Option
(shifting in the opposite direction of
traveling) is activated (glows)
When mast interlock is activated
J Mast interlock indicator lamp - -
(glows)
K Cursor buttons - - -
L Fuel gauge Indicates remaining fuel amount with key in “ON” position. -
M LCD screen - - -
N Water temperature gauge Indicates water temperature with key in “ON” position. -
O Enter/display switch button - - -

Description of function
Inspection method of blown bulbs for instrument panel
All warning and indicator lamps are normal, if they glow, when the starter switch is turned to the I (ON) position.

3-4
 ELECTRIC SYSTEM

2.2 Major Electrical Components

2.2.1 Starter switch
The diesel-engine truck, which uses a distributor type
injection pump, is provided with an engine automatic
stop mechanism of the starter switch fuel cut system.
The gasoline-engine truck is also provided with an
engine automatic stop mechanism of the fuel cut sys-
tem.
(Starter switch with Anti-Restart Lock)
This starter switch has an anti-restarting function.
This switch has a built-in anti-restart lock, so the key
cannot be turned from (ON) to (START) position
while the engine is running. This prevents starter
breakage or flywheel damage caused by an operator
restarting the truck when the engine is running.
The gasoline- and diesel-engine models use the same
starter switch. In the diesel -engine models, the l (ON)
position of the switch is for energizing the glow plugs.

(OFF)

(ON)
ST M

(START)

G B
213459

Connection Table
For gasoline truck (12V)
Terminal G B M ST Key in and out
OFF Yes
ON (when operating) ○--------- -----------○ No
START
○--------- -----------○----------- -----------○ No
(when starting engine)

3-5
ELECTRIC SYSTEM

2.2.2 Lighting switch, turn signal switch

Light switch/
turn signal lever

Boot

Horn contact

Wheel angle sensor

Boot

Direction lever

Front
Lighting switch,
turn signal switch

Forward of truck
Lighting switch,
turn signal switch

Forward-reverse
selector switch

Light switch/
turn signal switch
Shift change switch
(F, N, R)
4 T-3 L-2
T-1 L-4
2

T-2 L-5
L-1 L-3
5 Wheel angle sensor connector
1 3
Horn contact
1 2 4
Horn

3 5

213460

3-6
 ELECTRIC SYSTEM

2.2.3 Horn
Check that the horn activates when applying the spec-
ified voltage to both terminals of the horn T1 and T2. Up
Replace the horn if it does not activate or its sound is
abnormal.
Operating voltage: DC12V
(Gasoline and diesel trucks)
T1

Note:The installed position is that of an actual truck as

shown in the illustration.
T2
Down
Vent hole

Contact

Coil

213463

2.2.4 Tank Unit

3/4

1/2

Fuel pump Pressure relief

valve
1/4
Fuel filter

Referential Standards
Float position E 1/4 1/2 3/4 F
Standard resistance
80 49.5 32 19 10
value (ohm)
+12 +1.0
Tolerance (ohm) 㧙 ±3 㧙
+2 -0.5

213464

3-7
ELECTRIC SYSTEM

2.2.5 Brake fluid sensor

Refer to the brake system.

energization)
activating position
(emergency
Indicator or ON
3 ± 2 mm
213465

2.2.6 Stop lamp switch

Connect a tester across the terminals and check that
the lamps turn ON and OFF when the push rod
extended projection is to the specified value. Push
Measure the insulation resistance value across the ter- rod
minals when the push rod is pushed in.
Replace the switch if the measured insulation resis-
4 2mm
tance value is less than the value listed below. mm
OFF ON
M10×1.25
Insulation 1 M ohm or more
resistance value (with megger tester at 500V)
213466
Rated voltage DC12V

3-8
 ELECTRIC SYSTEM

2.2.7 Direction lever assembly (Powershift truck)

Forward of vehicle

F Forward
(10㩩) (10㩩)
N Neutral

R Reverse

Connector of
  FNR switch

  
Connector of FNR switch

Connection table
Terminal 1 2 3 4 5

Wire color G/W B B/R B L/W

Lever position
F Forward
N Neutral
R Reverse

213467

2.2.8 Backup lamp switch (Manual T/M truck)

ON‫ޓ‬OFF
19.5 mm
2 mm 2 mm

Shift rail Backup lamp switch

(for forward-reverse)
Transmission case
M12×1.75

(0.5 RL)

213468

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ELECTRIC SYSTEM

2.2.9 Neutral switch

Neutral switch

(0.5 RL)
Transmission
case

19.5 mm
2 mm
M12×1.75

ON‫ޓ‬OFF
2 mm

Shift rail
214882

2.2.10 Thermoswitch
(Engine cooling water temperature)
Body Terminal
(1) Apply an ohmmeter between the terminal and
body of the sender unit and check for continuity
(resistance value).
(2) Replace the sender unit if there is no continuity or
the measured resistance value is outside the stan-
dard resistance value.
Note:The illustration is for a gasoline-engine truck.

213470
Gasoline-engine truck
Temperature
60±0.2 65±0.2 80±0.2 100±0.3 125±0.3 130±0.3
[°C (°F)]
Standard resis-
80±10 67±7.8 40.6±2.7 22.2±1.4 11.3±0.4 10±0.3
tance value (ohm)

Diesel-engine truck
Temperature
50±0.2 60±0.2 80±0.2 100±0.3 105±0.3 120±0.3
[°C (°F)]
Standard resistance
80±10 56.3±5 29.5±2.5 16.5±0.8 14.3±0.5 10±0.3
value (ohm)

3-10
 ELECTRIC SYSTEM

2.2.11 Thermoswitch (T/C oil)

Apply an ohmmeter between the terminal and body
and check for continuity (resistance value). Replace Terminal Body
the switch if the measured insulation resistance value
is not more than the value listed below.

1 M ohm or more
Insulation resistance
(with contact point OFF)
value
(with megger tester at 500V)

Internal resistance: 0.5 ohm or less

(with contact point ON)
Allowable load: 0.5 A
Note:When installing the thermoswitch, tighten it to the
specified torque.

Tightening torque 31.4 to 47.1 N·m

213471
CAUTION
Replace the thermoswitch if it is dropped or abused.

Technical data
OFF to ON 122±3°C
Operating temperature
ON to OFF 115 °C or higher
Insulation resistance
1 M ohm or more
(with contact point OFF)

3-11
ELECTRIC SYSTEM

2.2.12 Power relay

(Powershift T/M truck, for backup lamps)

(1) CB relay

Coil rating [at 20 °C (68°F)]

Truck type
Items Gasoline and diesel engine lift
trucks
Rated operating voltage DC12V
Working voltage DC3.0 to 7.0 V
Open-circuit voltage DC1.2 to 3.9 V
Coil resistance 80 ohm ±10%
Rated exciting current 168mA±10%

Connection diagram
(Bottom view)

215202

(2) CM relay

Coil rating [at 20 °C (68°F)]

Truck type
Items Gasoline and diesel engine lift
trucks
Rated operating voltage DC12V
Working voltage DC 3.0 to 7 V
Open-circuit voltage DC 0.5 to 3.1 V
Coil resistance 120 ohm ±10%
Rated exciting current 117.6 mA±10%

Connection diagram
(Bottom view)

215203

3-12
 ELECTRIC SYSTEM

2.2.13 QGS controller (Diesel truck)

When the starter key switch turns from OFF to ON, the
QGS controller turns the glow lamp and glow plugs to
ON during the time period shown below.
When the key switch is turned to the START position,
glow lamp and glow plugs are also turned ON.

Water temperature
Items (Water temperature ON time Connector A Connector B
resistance value)
1 2 3
-15°C (12.1 K ohm) 10.0 ± 2.0 sec. 㧭
Glow lamp
0°C (5.9 K ohm) 6.4 ± 1.3 sec.
Glow plug
+10°C (3.8 K ohm) 3.0 ± 0.6 sec. 㧮
4 5 6
Rated voltage: DC12V Connector A Connector B

Connection diagram 213472

3-13
ELECTRIC SYSTEM

2.2.14 Fuse box

Fuse box, Fuse

Working lamp
15A
A/C
Back up/Others 20A
Head lamp
15A
15A Stop lamp
Instrument panel
10A 10A
QGS ETC Wiper Horn
Spare EGI
10A 15A 15A 10A
VCM 30A 30A EGI
20A
20A 30A
Fuse puller

10A 15A
SBF 100A SBF 100A SBF 50A
Spare Battery Alternator Glow

213480

3-14
 ELECTRIC SYSTEM

2.3 Table of Lamps

Valve
Items Qty Lens color Remark
Illustration

Head lamps 2 Colorless Standard:

Turn signal
2 Amber
lamp

Standard:
Combination
Head guard
Lamp (front)
Installed

Clearance
2 Colorless
lamp
Type of lamp

Turn signal
2 Amber Standard:
lamp

Combination Tail and

2 Red Standard:
Lamp (rear) Stop lamps

Backup lamps 2 Colorless

3-15
ELECTRIC SYSTEM

3. Console Box
3.1 Disassembly

2
5

213483

3.1.1 Start by
Place the starter switch to the OFF position, and
remove the cable from the ground side of the battery.

3.1.2 Removal sequence

(1) Disconnect the electrical wiring from connector 1.

(2) Remove the screw using a Phillips screwdriver
and remove cover 2.
(3) Remove the screw and then, remove cover
(U-Re) 3.
(4) Remove the screw and then, remove cover
(U-Fr) 4.
(5) Remove direction lever (FNR lever), turn signal
lever 5.
(6) Remove the bolt and then, remove console box
assembly 6.
3.1.3 Installation
To install, follow the removal sequence in reverse.

3-16
 ELECTRIC SYSTEM

4. Battery Maintenance
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment

Specific gravity reading

Condition Adjustment
at 20°C (68°F)
If difference in S.G. between any two cells is 0.020 or less, continue to
use as is.
1.280 to 1.265 Good
if the difference is greater than 0.020, apply the high rated discharge
to correct, then charge the battery referring to the S.G.
Recharge battery and adjust electrolyte S.G. Make sure there is nei-
1.260 to 1.225 Half charged ther faulty components, loosely connected cables nor corroded con-
nections.
Recharge battery.
1.220 or less Low battery, requiring cares
If difference in S.G. is large, adjust it during recharging.
Recharge until voltage and S.G. stabilize and have remained constant
A cell with a low S.G. is in shorted for more than 2 hours.
If difference in S.G. is condition. During recharging, adjust S.G.1.280 to 1.265
more than 0.040 Electrolyte leakage or excessive/ If difference in S.G. is more than 0.040 and a low S.G. is found in cer-
diluted electrolyte tain cells only, replace battery. After leaving battery for 12 to 96 hours,
conduct a high current discharge test.

4.2 Specific Gravity Reading and State of Charge

Fully charged condition can be verified by the electro-
lyte S.G. (1.280 to 1.265), and also the reduction
speed of electrolyte implies the battery condition. If the
electrolyte is rapidly reduced (pole plates exposed),
over-charging is suspected, or no reduction of electro-
lyte in three months or more, insufficient charging is
suspected.
4.3 Charging Precautions
(1) In slow charging, the charging current should be
about 1/10 the capacity of the battery being
charged.
(2) In quick charging, the battery capacity in ampere
should not be exceeded.
(3) During charging, adjust the charging current so
that the electrolyte temperature does not exceed
45°C (113°F).
(4) When connecting cables to battery terminals,
always connect the (+) terminal first, and when
disconnecting, remove the (-) terminal first.
Identification
(5) During charging, hydrogen gas is generated, 213484
which requires attention to ventilation. Identification
34B19L
(Gasoline-engine truck)
CAUTION 55D23L
Be sure to turn OFF the starter switch and lighting 75D26L
(Diesel-engine truck)
switch before disconnecting or connecting the battery 95D31L
cables.
(to prevent IC regulator from damage.)

3-17
ELECTRIC SYSTEM

5. Instrument Panel
5.1 Instrument Panel Screen Element
Instrument panel screen consists of warning lamps,
LCD (Liquid Crystal Display) screen, and ٌ and
ٖ buttons, and enter/display switch button).

Warning lamps button

button

LCD screen

215114
The LCD screen consists of main area, fuel gauge
area, travel direction area, symbol mark area, hour Travel Symbol mark Time/hour meter
meter area and water temperature gauge area. The direction (Optional feature) display
main area is divided into two parts; right and left.
Note:The instrument panel has functions below to pro-
tect circuits in the panel.

Instrument panel internal

–
(ambient) temperature
Display on the LCD is
85 °C or higher
automatically not displayed.
Back light is automatically
105 °C or higher
turned to off.

Note:(a)Back light illuminates left fuel mark and right

water temperature mark on LCD from inside.
Fuel gauge Main display Water temperature
(b) Warnings will not automatically be turned off gauge
for safety reasons. 215115
(c) When the temperature is extremely low (0°C
or below), the response of the LCD display be-
comes slow.

3-18
 ELECTRIC SYSTEM

5.2 Basic Screen Display

5.2.1 LCD screen display with the key switch in the
ON position
When the key switch is turned to the ON position, the
LCD screen displays the brand logo screen, the pass-
word authentication screen, and the standard display
screen in this order. Pressing a button can also show
the error history display on the screen.
(1) Brand logo screen
When the key switch is turned to the ON position,
the brand logo screen will be displayed for 2 sec-
onds while the lamps are being checked.

215116

(2) Password authentication screen

(Display by optional function)
Inputting the registered password in advance
makes it possible to operate the lift truck.

215117

(3) Standard display screen

The screen changes to the standard display
screen that shows the conditions of the lift truck.

215118

3-19
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