Page 1

Service Manual Chassis & Mast FD40N FD45N FD50CN FD50N FD55N

EF12B-00011-up

FG40N FG45N FG50CN FG50N FG55N

EF40-00011-up

MC/FC

EF19D-50001-up EF19D-80001-up EF28C-50001-up EF28C-80001-up

EF29D-50001-up EF29D-80001-up EF33C-50001-up EF33C-80001-up

For use with S6S and TB45 Engine Service Manuals.

99739-57100


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 TB45 gasoline engines or S6S diesel engines. For engine servicing, please refer to the applicable engine service manual. TB45

Gasoline engine

S6S

Diesel engine

<Safety Related Signs> WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or damage to your machine.

NOTE

Indicates a condition that can cause damage to, or shorten service life of, the machine.

1 Pub. No. 99739-57100


SAFETY

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 & MAINTENANCE MANUAL before performing any lubrication or maintenance on these trucks. Improper performance of lubrication or maintenance 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.

Do not operate these trucks unless you have read and understood the instructions in the OPERATION & 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 components 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.

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.

(7) To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments.

Following is a list of basic precautions that should always be observed.

(8) Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite 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 completely.

(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.

2

(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 liquids 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.


(13)Before starting to work on truck, hang "Do not Operate" tag in the Operator's Compartment. (14)Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength 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 corners, or by rubbing against some object or hot surface. Place wiring away from oil pipe.

(20)Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. (21)Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

(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 invisible 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, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly.

3


HOW TO USE THIS MANUAL Lift truck model covered in this manual ŒMC Truck (Mechanical Control System) Mechanically controlled hydraulic system (conventional lever system) ŒFC Truck (Finger-tip Control System) Electronically controlled hydraulic system

MC Truck

Lever

Control valve

FC lever box

Electromagnetic control valve

Flow regulator valve

Electric wiring VCM Controller

FC Truck 216300

ŒGasoline-Engine Trucks (FG)....... Trucks Equipped with TB45 Gasoline Engine ŒDiesel-Engine Trucks (FD) .................... Trucks Equipped with S6S Diesel Engine ŒPowershift Trucks................................... Trucks Equipped with Powershift Transmission

4


HOW TO USE THUS MANUAL(continued) Disassembly diagram(example)

2

1

213445

Sequence 1 Cover, Bolt, Washer (part name) 2 Out put shaft assembly (part name)

Suggestions for Disassembly Output shaft, Removing Remove output shaft using a special tool.

213446

Service Data Unit:mm(in.) A

0.11 to 0.28 (0.004 to 0.011)

B

0.5 (0.012)

Gear Backlash

A: Standard value B: Repair or Service Limit

5


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 Force

SI unit 1N

0.102 kgf

1 lbf

0.4536 kgf

1 kPa

0.0102 kgf/cm2

1 psi

0.0703 kgf/cm2

Pressure

Torque

6

Customary unit

1 N路m

0.102 kgf路m

1 lbf路ft

0.1383 kgf路m


CHAPTER INDEX CHAPTER INDEX

CHAPTER INDEX

Items

GENERAL INFORMATION

Truck Models Covered, Serial Number Locations, Dimensions, Technical Data

1

COOLING SYSTEM

Fan Belt Removal and Installation, Fan Belt Tension

2

ELECTRICAL SYSTEM

Console Box, Chassis Electrical Devices, Battery Maintenance, Electrical Schematic

3

CONTROLLERS

Main Functions of Controller, Input/Output Monitor, Error Codes and Troubleshooting

4

POWER TRAIN

Removal and Installation of Power Line

5

POWERSHIFT TRANSMISSION

Torque Converter, Singe Speed Powershift Transmission Control Valve, Automatic Two-Speed Transmission

6

FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Tire, Front Axle, Reduction, Differential

7

REAR AXLE

Rear Axle, Rear Tire

8

BRAKE SYSTEM

Master Cylinder, Wheel Brake, Brake Booster

9

STEERING SYSTEM

Steering Gear, Power Cylinder, Flow Divider

10

HYDRAULIC SYSTEM

Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve, Down Safety Valve

11

MAST AND FORKS

Simplex and Duplex Masts, Triplex Mast

12

SERVICE DATA

Maintenance Standard, Maintenance Schedule, Periodic Replacement Parts, Lubrication Instruction, Special Tool Needed

13


Chapter 1 GENERAL INFORMATION 1.

Model View............................................................................................... 1-1

2.

Lift Truck Models Covered ..................................................................... 1-2

3.

Serial Number Locations........................................................................ 1-3

4.

Dimensions.............................................................................................. 1-4

5.

Technical Data......................................................................................... 1-5

6.

Performance ............................................................................................ 1-6

1


GENERAL INFORMATION

1. Model View

Chapter 1 GENERAL INFORMATION

MC model

215315

FC model

215316

1-1


GENERAL INFORMATION

2. Lift Truck Models Covered This Service Manual provides service and maintenance information for the following lift trucks: Mounted engine

Gasoline model

Diesel model

Non-electronic control

-

MC / FC

Electronic control

MC / FC

-

Electronic Gasoline engine models

Non-electronic diesel engine models

Truck model

Serial number

Mounted engine

Truck model

Serial number

Mounted engine

FG40N

EF40-00011-up

TB45

FD40N

EF12B-00011-up

S6S

FG45N

EF29D-50001-up

TB45

FD45N

EF19D-50001-up

S6S

FG50CN

EF29D-80001-up

TB45

FD50CN

EF19D-80001-up

S6S

FG50N

EF33C-50001-up

TB45

FD50N

EF28C-50001-up

S6S

FG55N

EF33C-80001-up

TB45

FD55N

EF28C-80001-up

S6S

1-2


GENERAL INFORMATION

3. Serial Number Locations

Name plate

Gasoline engine model serial number

Diesel engine model serial number

Mast serial number

Chassis serial number

Transmission serial number

215340

1-3


GENERAL INFORMATION

4. Dimensions

K

G

L

C

O

E

J

A H

I

B

P

D

N

M F

215339

1-4


GENERAL INFORMATION

5. Technical Data Unit:mm (in.) class Truck model

4 ton class

5 ton class

Gasoline model

FG40N

FG45N

FG50CN

FG50N

FG55N

Diesel model

FD40N

FD45N

FD50CN

FD50N

FD55N

A Maximum lift B Free lift height

3350 (132)

3360 (132.5)

150 (5.9)

160 (6.3)

C Fork spread <min - max>

320 - 1184 (12.6 - 46.6)

D Fork length

1220 (48.0)

E Tilt angle <forward - backward>

Deg

F Overall length Overall width G <outside-to-outside of tires>

3000 (118) Single

3130 (123)

1415 (55.5)

Special double

1965 (77.5) 2320 (91.5)

Tread K <front wheel>

2400 (94.5)

4570 (180) 4230 (167)

4590 (181) 4190 (165)

Single

1175 (46.5)

Double

1310 (51.5)

Special double

1445 (57.0)

L Tread <rear wheel> M Wheelbase N Front overhang O Minimum turning radius P Under clearance <at frame>

3360 (132)

2280 (89.5)

With backrest Without backrest

3310 (130)

1460 (57.5) 1780 (70.0)

Height of the overhead guard

Overall height J <with mast extended>

3170 (125)

Double

H Overall height <with mast lowered> I

6 - 10

4330 (170)

1180 (46.5) 1850 (73.0)

2000 (78.5)

577 (22.7) 2580 (101)

2730 (107)

582 (22.9) 2760 (109)

2150 (84.5) 602 (23.7) 2890 (114)

2940 (116)

227 (8.9)

1-5


GENERAL INFORMATION

6. Performance Truck model

Class

Gasoline model

Truck model

4 ton class

kg (lb)

Capacity Load center

FG40N

FG45N

FG50CN

FG50N

FG55N

3500 (8000)

4000 (9000)

4500 (10000)

5000 (11000)

5500 (12000)

mm (in.) Loaded

570 (110)

490 (96)

2FF mast

530 (105)

430 (85)

530 (105)

450 (89)

600 (120)

520 (100)

2FF mast

560 (110)

460 (90)

3FF mast

560 (110)

480 (94)

2SP mast Unloaded

Loaded Forward Travel speed

mm/s (fpm)

1st speed

13.5 (8.5)

2nd speed

22.0 (14.0)

1st speed km/h 2nd speed (mph)

22.5 (14.0)

Loaded

1st speed

18.5 (11.5)

Unloaded

1st speed

Unloaded Reverse

600 (24)

2SP mast 3FF mast

Lift speed

Truck model

Class

Diesel model

Truck model

19.0 (12.0)

kg (lb)

Load center

FD45N

FD50CN

FD50N

FD55N

3500 (8000)

4000 (9000)

4500 (10000)

5000 (11000)

5500 (12000)

Loaded Forward Travel speed

Unloaded Reverse

600 (24) 550 (110)

470 (93)

2FF mast

510 (100)

420 (83)

520 (102)

440 (86)

610 (120)

530 (105)

2FF mast

570 (112)

470 (92)

3FF mast

570 (112)

490 (96)

2SP mast Unloaded

5 ton class

2SP mast 3FF mast

Lift speed

18.5 (11.5)

FD40N

mm (in.) Loaded

21.5 (13.5)

13.5 (8.5)

4 ton class

Capacity

1-6

5 ton class

mm/s (fpm)

13.5 (8.5)

1st speed 2nd speed 1st speed

km/h 2nd speed (mph)

Loaded

1st speed

Unloaded

1st speed

21.5 (13.5)

21.0 (13.0) 13.5 (8.5) 22.0 (13.5) 18.0 (11.0) 18.5 (11.5)

17.5 (11.0)


Chapter 2 COOLING SYSTEM 1.

Specifications.......................................................................................... 2-1

2.

Structure .................................................................................................. 2-2

3.

Removal and Installation........................................................................ 2-3 3.1

4.

Inspection and Adjustment .................................................................... 2-5 4.1 4.2 4.3 4.4

5.

Fan Belt Removal .................................................................................................... 2-3 Fan Belt ................................................................................................................... 2-5 Radiator ................................................................................................................... 2-6 Upper Hose, Lower Hose ........................................................................................ 2-6 Coolant .................................................................................................................... 2-7

Troubleshooting...................................................................................... 2-8

2


COOLING SYSTEM Chapter 2 COOLING SYSTEM

1. Specifications Truck model Item Cooling method Cooling system

Radiator

FG40N

FG45N

FG50CN

FG50N

FG55N

FD40N

FD45N

FD50CN

FD50N

FD55N

Water-cooled, forced circulation Corrugated fin (pressure) type

Water pump

Centrifugal type

Thermostat

Wax pellet type

2-1


COOLING SYSTEM

2. Structure 3

4

3

4

2 2

7

7

1

1

5

5

6 Gasoline model

1 2 3 4

Engine Fan (coupled directly to the engine crankshaft) Shroud Radiator

2-2

6 Diesel model

5 Oil cooler for torque converter 6 Reserve tank 7 Radiator cap

215476


COOLING SYSTEM

3. Removal and Installation 3.1 Fan Belt Removal 1

1

2

3

3

Gasoline model

Diesel model 215477

1 Tension assembly (pulley lock bolt) 2 Alternator lock bolt

3 Fan belt

3.1.1 Start by Remove the radiator cover.

2-3


COOLING SYSTEM

3.1.2 Removal Gasoline model (1) Loosen the pulley lock bolts by rotating 3 to 4 turns. If the pulley lock bolts are not loosened adequately, the fan pulley will not move. Note: Do not remove the pulley lock bolts by loosening them too much.

Adjusting screw

Lock nut

Fan pulley Pulley lock bolts

(2) Loosen the lock nut. (3) Loosen the adjusting screw and push the fan pulley against the crankshaft pulley side to remove the belt. Diesel model (1) Loosen the pulley lock bolts and the alternator lock bolts by rotating 3 to 4 turns. If the lock bolts are not loosened adequately, the alternator will not move. Note: Do not remove the lock bolts by loosening them too much. (2) Push the alternator pulley against the fan side to remove the belt. 3.1.3 Installation For installation, follow the removal sequence in reverse. Also follow the instructions below. (1) Before installing the belt, turn the fan to check for smooth rotation. Replace the bearing if it generates unusual noises. (2) After installing the belt, check that the pulley moves when pushing the tension belt. (3) Tighten the lock bolts and lock nut firmly.

2-4

Fan belt 216926


COOLING SYSTEM

4. Inspection and Adjustment 4.1 Fan Belt 4.1.1 Fan Belt Inspection (1) Check the belt for contamination from oil, grease or dust. Replace the belt if needed when the contamination is found. When the belt is slightly contaminated, clean it with a rag or paper towel. Do not use gasoline, oil or any other solvent for cleaning. (2) During the engine overhaul or belt tension adjustment, check the condition of the belt. Replace the belt if it has any damage. 4.1.2 Fan Belt Tension Apply force, as specified below, perpendicularly to the belt midway between the fan pulley and tension pulley (or crank shaft pulley), and make sure the belt tension is within the specified range.

Force

98 N (9.99 kgf) [22.03 lbf]

Belt tension

11 to 13 mm (0.43 to 0.51 in.)

Gasoline model

Diesel model 215478

2-5


COOLING SYSTEM

4.2 Radiator 4.2.1 Radiator unit Check the core for foreign substances such as dust. If foreign substances are adhered to the core surface, remove them by blowing compressed water from the opposite direction.

Be careful not to damage the water pipe while cleaning.

4.2.2 Radiator rubber mount Replace radiator rubber mount if it is hardened and has no elasticity.

4.2.3 Radiator cap Unit: Kpa (kgf/cm2) [psi] Opening pressure

88 Âą 14.7 (0.9 Âą 0.15) [12.77 Âą 2.13]

Vacuum valve

0 to 4.9 (0 to 0.05) [0 to 0.71]

4.3 Upper Hose, Lower Hose 4.3.1 Connecting Hoses (1) Check the hoses and replace them if they are swollen or damaged.

Diesel model

(2) When connecting the hoses to the radiator, make sure that their ends are fully inserted into the fittings and secure them with clamps.

215479

2-6


COOLING SYSTEM

4.4 Coolant 4.4.1 Draining coolant (1) Drain the coolant from the radiator by loosening the drain cock.

Diesel model

(2) Drain the coolant from the reservoir tank. Coolant quantity

Unit: liter (cu.in.)

Item

Gasoline

Diesel

Total quantity of coolant (including coolant in hoses)

15.95 (973.3)

12.94 (789.6)

Reservoir tank (FULL level)

0.65 (39.7)

0.65 (39.7) 215480

Be sure to store antifreeze/coolant mixture carefully because it is hazardous waste. Ask your local dealer for information pertaining to the proper disposal of the coolant.

4.4.2 Refilling coolant Mix antifreeze with soft water (tap water) at the proper concentration as shown below and fill the radiator and reserve tank up to the specified level.

Diesel model

Example: MHI Long Life Coolant Temperature °C (°F) Concentration (%)

-39 -30 -25 (-38) (-22) (-13) 55

50

45

-20 (-4)

-15 (5)

-10 (14)

40

35

30

215481

Antifreeze concentration ratio varies depending on brands. Be sure to mix the coolant according to a manufacture's recommended mix ratio.

4.4.3 Coolant level check (1) Warm up the engine while paying attention to any unusual noises. (2) Stop the engine and check the reserve tank for coolant level, then refill if needed.

2-7


COOLING SYSTEM

5. Troubleshooting Condition

Leaking coolant from radiator

Engine overheated

Leaking oil from oil cooler hose

2-8

Possible cause

Action

Damaged radiator core or tank

Replace

Damaged radiator hoses

Replace

Hose clamp is defective.

Replace

Drain cock is defective.

Replace

Radiator fins are clogged.

Clean

Fins are excessively distorted.

Replace

Loose belt

Check the belt for tension, elongation, and cracks. Replace the belt if such defect is found.

Not enough coolant

Refill

Insufficient tightening torque of hose clamp

Retighten or replace


Chapter 3 ELECTRIC SYSTEM 1.

Chassis Electrical Devices Wiring Outline ........................................... 3-1 1.1 1.2 1.3

2.

Structure .................................................................................................. 3-4 2.1 2.2 2.3

3.

List of Wire Colors ................................................................................................. 3-42

Troubleshooting.................................................................................... 3-43 7.1 7.2 7.3

8.

Instrument Panel Screen Components.................................................................. 3-20 Basic Screen Display............................................................................................. 3-21 Basic Operation ..................................................................................................... 3-24 When an Error Occurs........................................................................................... 3-29 Warning Lamps ..................................................................................................... 3-31 Optional Functions................................................................................................. 3-32 Hour Meters........................................................................................................... 3-39 Troubleshooting..................................................................................................... 3-41

Wire Color .............................................................................................. 3-42 6.1

7.

State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment ..................... 3-19 Specific Gravity Reading and State of Charge ...................................................... 3-19 Charging Precautions ............................................................................................ 3-19

Instrument Panel ................................................................................... 3-20 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

6.

Disassembly .......................................................................................................... 3-18

Battery Maintenance ............................................................................. 3-19 4.1 4.2 4.3

5.

Console Box ............................................................................................................ 3-4 Main Electrical Components.................................................................................... 3-6 Table of Lamps...................................................................................................... 3-17

Console Box .......................................................................................... 3-18 3.1

4.

Gasoline Model........................................................................................................ 3-1 Diesel Model............................................................................................................ 3-2 Gasoline and Diesel Models.................................................................................... 3-3

Starter System....................................................................................................... 3-43 Gauges .................................................................................................................. 3-43 Lighting System ..................................................................................................... 3-44

Electrical Schematic ............................................................................. 3-46

3


ELECTRIC SYSTEM Chapter 3 ELECTRIC SYSTEM

1. Chassis Electrical Devices Wiring Outline 1.1 Gasoline Model

Instrument panel

Transmission control solenoid

Head lamp

Front combination lamp Rear combination lamp Front combination harness Rear combination harness Seat

Seat switch To armrest (FC model only) Thermoswitch

Harness B

Back-up buzzer Stop lamp switch

Relay box Fuse box

Battery Battery cable (+)

VCM (Vehicle control module)

OCM (Option control module) (Wet disc brake only) Battery cable (-) To engine harness To starter Earth

To engine harness

ECM (Engine control module)

215355

3-1


ELECTRIC SYSTEM

1.2 Diesel Model Transmission control solenoid Instrument panel Head lamp Front combination lamp Rear combination lamp Front combination harness

Rear combination harness

Seat

Seat switch To armrest (FC model only)

Back-up buzzer

Harness B Stop lamp switch

Fuse box Thermoswitch (Sending unit)

OCM (Option control module) (Wet disc brake only)

Relay box

DCM (Diesel control module) (Wet disc brake only) Glow timer Glow relay Battery Battery cable (+) Earth

Battery cable (-)

To starter

3-2

215356


ELECTRIC SYSTEM

1.3 Gasoline and Diesel Models

Console Box Instrument panel Combination switch

Parking brake switch Warning buzzer

Key switch

Horn Select switch

Horn harness

Control valve FC

MC

Output unit

Output harness

Control valve

Control valve

Transmission Parking brake valve FC control lever

FC Armrest Input unit

Harness

Parking brake pressure switch

Speed sensor

Thermoswitch (T/C oil) 215357

3-3


ELECTRIC SYSTEM

2. Structure 2.1 Console Box 4

1 2 3 4 5 6 7 8

Water temperature gauge Fuel gauge Hour meter, warning lamps Instrument panel Key switch Light switch, turn signal switch Direction Lever Speedometer

8

3

2

1

N

ᵦᶐ

ᵣᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾ

6

7 5

214140

3-4


ELECTRIC SYSTEM

2.1.1 Function of Instrument Panel

A

B

C

L

D

E

F

G

H

M

I

J

K

N

O 214141

Ref. Name of indicators and warning lamps A

Parking brake warning lamp

B

Seat belt warning lamp

C

Charge warning lamp

D

Multi-purpose warning lamp

E

Torque converter oil temperature warning lamp

When turned off

When glows or blinks

Remark

Normal

This lamp glows when the parking brake is applied.

-

Fastened

This lamp glows when the seat belt is not fastened.

-

Normal charging

This lamp glows when charging is not normal. (This lamp glows all the time while the engine is stopped.)

-

Normal

This lamp glows when a minor failure occurs or operating cautions are issued.

-

Normal temperature

This lamp glows when the torque converter oil temperature is not normal.

-

-

F

Engine oil pressure warning lamp

Normal

This lamp glows when the engine oil pressure is low. (This lamp glows all the time while the engine is stopped.)

G

Engine warning lamp

Normal

This lamp glows when the engine is failed.

-

H

Glow pilot indicator lamp

Preheating completed

This lamp glows when the glow plug heating is ON.

-

I

Flex control indicator lamp

-

This lamp glows when sudden acceleration or full reverse (shifting of travel to the opposite direction) activates protective function.

Option

J

Mast interlock indicator lamp

-

When mast interlock is activated (glows)

-

K

Cursor buttons

-

-

-

L

Fuel gauge

M

LCD screen

N

Water temperature gauge

O

Enter/display switch button

Indicates remaining fuel amount with key in "ON" position -

-

Indicates water temperature with key in "ON" position -

-

-

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

3-5


ELECTRIC SYSTEM

2.2 Main Electrical Components 2.2.1 Key switch The diesel model uses a distributor type injection pump. Its starter switch is equipped with an automatic fuel cut engine stop mechanism. The gasoline model is also equipped with an automatic fuel cut engine stop mechanism. (Key switch with anti-restart lock) This key switch has an anti-restarting function. This switch has a built-in anti-restart lock, so the key switch cannot be turned from the | (ON) to the (START) position while the engine is running. This prevents engine trouble or starter breakage caused by an operator's improper operation when starting the engine. The gasoline and diesel models use the same key switch. On the diesel model, the key switch is electrically connected to the engine so that the | (ON) key switch position turns on the glow plugs. (OFF) (ON) M

ST (START)

G

B 215358

Connection Table Terminal

G

B

M

ST

OFF

Key in and out Yes

ON (when operating)

○---------

-----------○

No

START (when starting engine)

○---------

-----------○----------- -----------○

No

3-6


ELECTRIC SYSTEM

2.2.2 Combination switch (1) Light switch, turn signal switch Forward of truck

Light switch turn signal lever L

10° N

OFF

10° R

1

OFF

25° 25

2 °2 5

°

3

Light switch turn signal switch connector T-1 L-3 L-1

T-3

T-2

L-2 L-4

Horn contact Light switch connector Terminal Target Knob position

L-1

L-2

L-3

L-4

Power

Tail, clearance lamp

Head lamp

Power

T-1

T-2

T-3

Flash unit

Turn signal lamp (Right)

Turn signal lamp (Left)

OFF 1 2 3 Turn signal switch connector Terminal Target Lever position R (Right) N (Neutral) L (Left) 215359

3-7


ELECTRIC SYSTEM (2) Direction switch

Forward of truck Forward-reverse selector lever (FNR)

10°

F N

10°

OFF

R

Forward-reverse shift change switch (FNR)

5

4 2

1 3

Connection table Terminal Wire color

Lever position

1

2

3

4

5

L/B

B

L/R

B

L/W

F (Forward) N (Neutral) R (Reverse) 215360

3-8


ELECTRIC SYSTEM

2.2.3 Horn Check that the horn activates when applying the specified voltage to both terminals of the horn, T1 and T2. Replace the horn if it does not activate or its sound is unusual.

Up

Operating voltage: DC12V (Gasoline and diesel models)

T1

Note: The proper installation of the horn to the lift truck is shown in the illustration. T2 Down Vent hole T1

Contact Coil

T2

215361

2.2.4 Tank unit

3/4

424.2 mm (16.7 in.)

F 242.7 mm (9.56 in.)

61.2 mm (2.41 in.)

Illustration shows gasoline model.

1/2

Pressure relief valve 1/4

Fuel pump Fuel filter

E

Fuel suction strainer

Referential Standards Float position

E

1/4

1/2

3/4

F

Standard resistance value (Ω)

80

(49.5)

32

(19)

10

Tolerance (Ω)

+12 +2

±3

+1.0 - 0.5

The number in parenthesis is a reference value.

215362

3-9


ELECTRIC SYSTEM

2.2.5 Stop lamp switch Apply an ohmmeter across the terminals and check that the stop lamp switch is turned ON and OFF when the push rod protrusion is at the specified value.

Push rod

Measure the insulation resistance value across the terminals when the push rod is pushed in. Replace the stop lamp switch if its measured insulation resistance value is less than the value below. Insulation resistance value

2 mm (0.08 in.)

4 mm (0.16 in.)

1 M Ω or more (at 500 V megger)

M10×1.25

OFF

ON 215363

Rated voltage: DC12V 2.2.6 Thermoswitch (Engine cooling water temperature) (1) Apply an ohmmeter between the terminal and body of the sending unit and check for continuity (resistance value).

Body

Terminal

(2) Replace the sending unit if there is no continuity or the resistance value measured is outside the standard resistance value. Note: The illustration is for gasoline models.

215364

Gasoline model Temperature [°C (°F)]

60 ± 0.2 (140 ± 32.36)

65 ± 0.2 (149 ± 32.36)

80 ± 0.2 (176 ± 32.36)

100 ± 0.3 (210 ± 32.54)

125 ± 0.3 (257 ± 32.54)

130 ± 0.3 (266 ± 32.54)

80 ± 10

67 ± 7.8

40.6 ± 3.7

22.2 ± 1.4

11.3 ± 0.4

10 ± 0.3

Temperature [°C (°F)]

50 (122)

60 ± 0.2 (140 ± 32.36)

80 (176)

100 (212)

106 ± 0.3 (222.8 ± 32.54)

120 (248)

Standard resistance value (Ω)

(80)

56.3 ± 5

(29.5)

(16.5)

14.3 ± 0.5

(10)

Standard resistance value (Ω)

Diesel model

3-10


ELECTRIC SYSTEM

2.2.7 Thermoswitch (T/C oil) Apply an ohmmeter between the terminal and body and check for continuity (resistance value). Replace the thermoswitch if its measured insulation resistance value is less than the value below.

Terminal

Body

1 M Ω or more (with contact point OFF) (with 500 V megger)

Insulation resistance value

Internal resistance: 0.5 Ω or less (with contact point ON) Allowable load: 0.5 A Note: When installing the thermoswitch, tighten it to the specified torque. 31.4 to 47.1 N·m (3.2 to 4.8 kgf·m) [23.2 to 34.8 lbf·ft]

Tightening torque

215365

Replace the thermoswitch if it is dropped or abused. Technical data Operating temperature

OFF to ON

122 ± 3°C (251.6 ± 37.4°F)

ON to OFF

115 °C (239 °F) or higher

Insulation resistance (with contact point OFF)

1 M Ω or more

2.2.8 Parking brake switch Measure the insulation resistance between each terminal. (1) Parking switch at pulled position Between terminals B and W Insulation resistance

P

100 M Ω or more (at 500 V megger) Push

Pull

(2) Parking switch at pushed position

6 mm (0.24 in.) (Stroke)

Between terminals B and R Insulation resistance

100 M Ω or more (at 500 V megger)

Operation method: Push-pull operation Contact resistance: 1a-ab

W

B

R

215366

3-11


ELECTRIC SYSTEM

2.2.9 Relay box

Relay box 2 (Gasoline model only)

Relay box 1

Illustration shows gasoline model

Starter relay Flasher relay

EGI relay

Ignition relay

Back-up lamp relay

ETC motor relay

MAIN/C relay

Fuel pump relay

Warning buzzer relay

Relay box 1

EGI relay

Relay box 2 (Gasoline model only)

215367

3-12


ELECTRIC SYSTEM (1) Relay box 1

Item

Truck model Gasoline and diesel models

Rated operating voltage

‫‣‫‬″•‧‟•‣
••

Coil rating [at 20°C (68°F)]

‼″⁂″⁀

‵‴‣⁓›‟⁄‟‣․⁈ ″‵‪‪‥․․‣‒‿•․ ․‧․‥• ‸‽‣‣•

CB relay (Ignition relay, back-up lamp relay, and starter relay)

DC12 V

Working voltage

DC3.0 to 7.0 V

Open-circuit voltage

DC1.2 to 3.9 V

Coil resistance

80 Ω ± 10%

Rated exciting current

z

168 mA ± 10%

‪


‪


‥•

X ‥•

‪


‪‧

‪


‪‧

Connection diagram (Bottom view)

Y

215368

CM relay (Warning buzzer relay) Coil rating [at 20°C (68°F)] Item Rated operating voltage Working voltage Open-circuit voltage Coil resistance Rated exciting current

Truck model Gasoline and diesel models

․‧․‥• ‸‽‣․″ ‫‣‫‬″•…‟•‣
•• ″‵‿‥․․․‣‒‿‣․

DC12 V DC 30 to 7 V DC 0.5 to 3.1 V 120 Ω ± 10% 117.6 mA ± 10%

z

‪‧

‪‧

‪


‥•

‥•

X ‪
⁓

‪
 ‪


Y

‪


Connection diagram (Bottom view)

215370

3-13


ELECTRIC SYSTEM (2) Relay box 2 (gasoline models only) CM relay (EGI relay, MAIN/C relay, ETC motor relay, and fuel pump relay) ․‧․‥• ‸‽‣․″ ‫‣‫‬″•…‟•‣
•• ″‵‿‥․․․‣‒‿‣․

Coil rating [at 20°C (68°F)] Item Rated operating voltage Working voltage Open-circuit voltage Coil resistance Rated exciting current

Truck model Gasoline model DC12 V DC 30 to 7 V DC 0.5 to 3.1 V 120 Ω ± 10%

z

117.6 mA ± 10%

‪‧

‪‧

‪


‥•

‥•

X ‪
⁓

‪
 ‪


Y

‪


Connection diagram (Bottom view)

215370

3-14


ELECTRIC SYSTEM

2.2.10 Glow timer (diesel model) Inspecting the output time when key switch is turned to ON When a tester is applied to terminal 6 and terminal 3 and a voltage of 24 V is applied between terminals 4 and 3, there should be continuity between 6 and terminal 3 for 6 seconds. Replace the glow timer with a new one if it does not function properly.

4 5 3 6

Initial characteristic (Normal temperature and humidity, Vcc=12 V) Preglow timer 6.0 ±

1.4 0

sec

Environmental characteristic (-30°C to 70°C, Vcc=7 V to 15 V) Preglow timer 6.0 ±

2.0 0.6

sec OFF

ON

Key switch

ST

5

Glow relay Battery DC12V

6

4

Controller 3

Glow plug

Lamp

Connection diagram 215371

2.2.11 Glow relay (diesel model) (1) Apply an ohmmeter across terminal 3 and terminal 4 and measure the resistance value of the relay coil. Replace the coil if there is no continuity or the resistance value measured is out of standard resistance value. Coil resistance

13 Ω

(2) Measure the insulation resistance value between terminal 1 and terminal 2. Replace the coil if its measured insulation resistance value is less than the value below. Insulation resistance value

Rated voltage: DC12V

1 3

1 M Ω or more (at 500 V megger)

2

4 Connection diagram 1

3

2

4

215372

3-15


ELECTRIC SYSTEM

2.2.12 Fuse box

Fuse box Illustration shows diesel model

Working lamp 15A

Back-up lamp

A/C 20A

15A Instrument panel 10A

Spare

Glow timer 10A VCM 20A

*1 20A 30A

ETC 15A

Wiper 15A

Head lamp 15A Stop lamp 10A Horn *1 *1 EGI EGI 10A 30A 30A Fuse puller

10A

15A Spare

SBF 100A Battery

SBF 100A Alternator

*2 SBF 50A Glow *1: Gasoline model only *2: Diesel model only

215373

3-16


ELECTRIC SYSTEM

2.3 Table of Lamps Item

Head lamp

Turn signal lamp

Quantity

Lens color

2

Colorless

2

Amber

Valve Illustration

Remark

Standard

Standard (Installed to head guard)

Combination lamp (front) Clearance lamp

2

Amber

Turn signal lamp

2

Amber

Standard

Tail and stop lamp

2

Red

Standard

Back-up lamp

2

Colorless

Standard

Type of lamps

Combination lamp (rear)

3-17


ELECTRIC SYSTEM

3. Console Box 3.1 Disassembly 5

2

4

3

1

216938

3.1.1 Preparation Place the key 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 the bolt, then remove console box assembly 5.

3.1.3 Installation For installation, follow the removal sequence in reverse.

3-18


ELECTRIC SYSTEM

4. Battery Maintenance 4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment Specific gravity reading at 20째C (68째F)

Condition

Adjustment

1.280 to 1.265

Good

If the difference in S.G. between any two cells is 0.020 or less, continue to use as is. If the difference is more than 0.020, discharge the battery in an efficient manner. If the battery recovers, charge the battery to adjust the electrolyte S.G.

1.260 to 1.225

Half charged

1.220 (0.2) or less

Recharge battery to adjust electrolyte S.G. Check for any short-circuited cables or corroded cable connections in the electrical system.

Recharge battery. Battery low (caution required) If the difference in S.G. is too much, charge the battery to adjust the electrolyte S.G.

Recharge the battery until its voltage and S.G. stabilize and remain constant for more than 2 hours. A cell with a low S.G. may Charge the battery to adjust the electrolyte S.G. It should read cause a short circuit. between 1.280 and 1.265. If the difference in S.G. is It is caused when electrolyte If the difference in S.G. is more than 0.040 and a low S.G. is more than 0.040. leaks or electrolyte rate is too found in any of the cells, replace the battery with a new one. high or too low. Conduct a high current discharge test after leaving the battery for 12 to 96 hours.

4.2 Specific Gravity Reading and State of Charge To tell whether a battery is fully charged, check the electrolyte S.G. of each cell with hydrometer or the electrolyte reduction speed. If the electrolyte in battery cell decreases to the level where the pole plates are exposed within one month, it may be overcharged. If the electrolyte amount remains sufficient for more than three months, the battery may be charged less.

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 (A) should not be exceeded. (3) During charging, adjust the charging current so that the electrolyte temperature does not exceed 45째C (113째F). (4) When connecting cables to battery terminals, always connect the (+) terminal first, and when disconnecting, remove the (-) terminal first. (5) Ventilate well during the battery charge because hydrogen gas is generated.

+

Identification 55D23L (Gasoline) 130E41L (Diesel)

Be sure to turn OFF the key switch and light switch before disconnecting or connecting the battery cables. (This prevents damage to the IC regulator.)

215375

3-19


ELECTRIC SYSTEM

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

Warning lamps

ٖ button

ٌ button

Enter/display switch button (Ο button)

LCD screen

215114

The LCD screen consists of six areas: main area, fuel gauge area, travel direction area, symbol mark area, hour meter area, and water temperature gauge area. The main area is divided into two parts: right and left.

Travel direction

Symbol mark (Optional feature)

Time/hour meter display

Note: The instrument panel has functions below to protect circuits in the panel. Instrument panel internal (ambient) temperature

-

85°C (185°F) or higher

LCD screen is not displayed.

105°C (221°F) or higher

Backlight goes off.

Note: a) Back-up light illuminates both the fuel mark and water temperature mark on the LCD from inside. b) Warnings are not automatically turned off for safety reasons. c) When the temperature is extremely low [0°C (32°F) or below], the response of the LCD display is slower.

3-20

Fuel gauge

Main display

Water temperature gauge 215115


ELECTRIC SYSTEM

5.2 Basic Screen Display 5.2.1 LCD screen display with the key switch in the ON position With the key switch turned to the ON position, LCD screen displays the brand logo screen, the password authentication screen, and the normal display screen in sequence. Also, error history is displayed by pressing a button. (1) Brand logo screen When the engine key is turned to the ON position, the brand logo screen is displayed for 2 seconds while lamp check is being executed.

215116

(2) Password authentication screen (Optional function) Inputting the registered password in advance enables an operator to operate the lift truck.

215117

(3) Standard display screen The screen shows the conditions of the lift truck.

215118

3-21


ELECTRIC SYSTEM

5.2.2 Speed meter display This display shows current lift truck speed. Speed meter display

Note: Actual speed

Display

0.1 to 1.0 km/h (0.06 to 0.62 Mph)

1 km/h (0.62 Mph)

1.1 to 2.0 km/h (0.68 to 1.24 Mph)

2 km/h (1.24 Mph)

• • • • 24.1 to 25.0 km/h (14.97 to 15.53 Mph)

• • • • 25 km/h (15.53 Mph)

215119

Speed display value is rounded to a higher number. 5.2.3 Fuel gauge This gauge shows the remaining amount of fuel (gasoline or diesel fuel). It shows the remaining amount of fuel just after the key switch is turned to the ON position. After that, the remaining amount is displayed for 2 minutes on average.

Fuel gauge

Note: E (Empty) remaining amount Truck model

Remaining amount

4.0 to 5.5 ton

14.3 liter (872.6 cu.in.) or less

With fuel gauge image

Note: LPG dual fuel truck shows gasoline remaining amount only.

Without fuel gauge image (LE models)

3-22

215120


ELECTRIC SYSTEM

5.2.4 Water temperature display This display shows engine coolant temperature. Water temperature gauge

Note: The graph below shows the relation between engine coolant temperature and water temperature gauge shown on the LCD.

215121

Engine coolant temperature - the number of dots in the gauge Range displayed on LCD screen (50 to 120°C) [122 to 248°F]

Diesel model Gasoline model

50

Number of dots in the gauge (Dots)

44 dots

40 Range of overheating (red zone)

30

29 dots

Pertinent range of temperature (rough standard for diesel/gasoline model)

20

10 Overheat (red zone) temperature • Diesel model: Approx. 109 °C (228.2 °F) or higher • Gasoline model: Approx. 107 °C (224.6 °F) or higher

0

0

10

20

30

40

50

60

70

80

90

100

110

120

130 (°C)

0

50

68

86

104

122

140

158

176

194

212

230

248

266 (°F)

Engine coolant temperature (°C) [°F]

215122

3-23


ELECTRIC SYSTEM

5.2.5 Direction display This display shows truck traveling direction. If the direction lever is positioned to a place other than N (neutral) position when starting the engine, symbol N blinks and the engine can not be started. If an operator leaves the seat while the engine is running and the direction lever is placed to other than the N (neutral) position, the symbol N blinks and the transmission is electrically shifted to the N (neutral) position.

Travel direction

Note: Travel direction display changes to the signals from the direction lever.

215123

Forward

0.5sec

Reverse

Neutral

0.5sec

Travel interlock indication (powershift truck) 215377

5.3 Basic Operation 5.3.1 How to use operation buttons There are three types of manual operation buttons: Ů&#x152; button, Ů&#x2013; button, and ٤ button, which are located on the right side of the instrument panel. The operation of each button varies with the item being displayed on the screen. Button operation is available only when the key switch is in the ON position and not available when the engine is running. Note that adjustment of screen contrast and selection between the hour meter display and the time display are available even when the engine is running.

Short press of button It is effective when the button is pressed for less than two seconds.

Long press of button It is effective when the button is pressed for more than two seconds.

Multiple button presses It is effective when more than two buttons are long pressed at the same time.

3-24

button button

button

215125


ELECTRIC SYSTEM

5.3.2 How to adjust the screen contrast Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running. Button

Press

Display Light → Dark

ٌ

Short Dark → Light

ٖ

Note: The screen becomes dark when the temperature inside the instrument panel (ambient temperature) is high, and the screen becomes light when the temperature is low.

5.3.3 How to display the clock time Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running. With a short press of the ٤ button, the display alternately changes between the hour meter and the clock time.

Time/hour meter

With a long press of the ٌ button while the clock is displayed, the clock display alternately changes between 12-hour and 24-hour mode. Button

Press

Display

٤

Short

Hour meter ←→ clock

Long

12-hour mode display ←→24-hour mode display

(with clock time display) ٌ

215126

3-25


ELECTRIC SYSTEM

5.3.4 How to set up the clock time (1) Turn the key switch to the ON position. (2) Select clock time display (when the hour meter is being displayed). Button

Press

Display

٤

Short

Clock time blink

Blinking

(3) Select time adjust mode and unit adjust mode. Button

Press

Display

٤

Long

Time unit adjust mode

215127

(4) Time unit adjustment Button

ٌ

ٖ ٤

Press

Display

Short

01→12 or 24 (one hour at each press)

Long

01→12 or 24 (continuous)

Short

12 or 24→01 (one hour at each press)

Long

12 or 24→01 (continuous)

Short

After adjusting, change to the minute adjust mode.

Digits to be adjusted is blinking

215128

Note: When the time display is set to the 12-hour mode display, 11:00 AM changes to 00:00 PM at noon. (5) Minute adjustment Button

ٌ ٖ ٤

Press

Display

Short

01→59 (one minute at each press)

Long

00→59 (continuous)

Short

59→00 (one minute at each press)

Long

59→00 (continuous)

Short

After adjusting, change to the standard screen.

Note: • Second time display is not available. • If more than 3 minutes have passed since the last button operation, the display automatically returns to the standard screen. • Precision errors are one minute or less per month. • When a battery is changed, the time resets. Be sure to set the time after changing a battery. • If the engine is started during the setup procedure, the setup being made is cancelled and the display returns to the standard screen.

3-26

Digits to be adjusted is blinking

215129


ELECTRIC SYSTEM

5.3.5 How to display the hour meter Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running. With a short press of the ٤ button, the display alternately changes between the clock time and the hour meter. Button

Press

Display

٤

Short

Clock ←→ hour meter

Hour meter

215130

5.3.6 How to change types of hour meters Turn the key switch to the ON position. There are three counters: key-on time, engine-on time, and seat switch-on time. The counter display changes with a long press of the ٌ button. Button

ٌ

Press

Display

Long

Key-on time ↓ Engine-on time ↓ Seat switch-on time

Key-on time display

Engine-on time display

Key-on time: Accumulated key switch ON time. Engine-on time: Accumulated engine operation time. This is helpful in comparing the wear of engine related parts to the actual engine operation hours. Seat switch-on time: Accumulated time the operator has seated. This is helpful in comparing the actual working hours to the actual hours of operation.

Seat switch-on time display

215131

Note: • When six minutes have passed, 0.1 hour is added. • Warranty is terminated based on the key-on time.

3-27


ELECTRIC SYSTEM

5.3.7 How to display the error history Turn the key switch to the ON position. A long press on the three buttons at the same time brings up the error history display. Button

Press

Display

ٌٖ٤

Multiple

Error history

button button

button

Error message displays only the F error codes. Error codes are displayed from the latest error ( -1) up to the past 32 errors ( -32). Oldest data (error) exceeding the limit (32 errors) is automatically erased.

215125

Note: Use the service tool to erase the error message being displayed. To change the error code display, operate the ٖ or the ٌ button. Button

ٌ

Press

Error history

Hour meter

Error code

Display Old → New

Short New → Old

ٖ

A long press on the three buttons at the same time returns to the standard display screen. Button

Press

Display

ٌٖ٤

Multiple

Standard display screen

Error history display With , buttons, error record on the display changes.

215133

The illustration shows the error history screen when there is no error record.

When there is no error record

Note: • If more than 3 minutes have passed since the last button operation, the display automatically returns to the standard screen. • If the engine is started during the setup procedure, the setup being made is cancelled and the display returns to the standard screen.

215134

3-28


ELECTRIC SYSTEM

5.4 When an Error Occurs When an error occurs, the corresponding error code is displayed on the screen. The error code will be erased by placing the key switch to the ON position after solving the cause of the trouble and then by turning the key switch to the OFF position. (The error code remains displayed until the cause of the trouble is solved.) Refer to the engine service manual for the error codes related to engine troubles (error codes from ECM). The priority order of the error display is: engine failures, serious failures, and minor failures.

Engine warning lamp glows

When an engine failure occurs, the error code alternately changes between black characters on a white background and white characters on a black background. 215135

5.4.1 When an engine failure occurs The corresponding error code is displayed in the main area, and the black and white in the error code display is reversed. Also the engine warning lamp glows.

5.4.2 When a serious failure occurs The corresponding error code is displayed in the main area, and the black and white in the error code display is reversed. Also all warning lamps shown in the figure (right) will blink.

Warning lamps within the dotted line boxes blink

When a serious failure occurs, the error code alternately changes between black characters on a white background to white characters on a black background.

215136

3-29


ELECTRIC SYSTEM

5.4.3 When a minor failure occurs The corresponding error code is displayed in the main area, and the black and white in the error code display is reversed. Also the multi-purpose warning lamp glows.

Multi-purpose warning lamp glows

Note: The minor failure display is also shown when the fuel gauge reaches the empty level (E).

The error code and symbol alternately change between black characters/lines on a white background to white characters/lines on a black background. 215137

5.4.4 Error symbols Error symbols displayed in the main area are as follows: Symbol

3-30

Name

Indicated condition

Fuel filter warning lamp

This lamp glows when the water in the fuel filter needs to be drained. (diesel model)

Low coolant level warning lamp

This lamp glows when the coolant level is low. (option)

Clogged air cleaner element warning lamp

This lamp glows when the air cleaner element is clogged. (option)

Low fuel level warning lamp

When fuel level is low (on E level) (On the LPG/gasoline dual fuel model, this lamp glows when the gasoline level becomes low.)

LPG level warning lamp

On the LPG model, this lamp glows when the LPG level becomes low. (option)


ELECTRIC SYSTEM

5.5 Warning Lamps The function of each warning lamp is shown in the table below. Lamp

Name

Color

Glow (blink) condition

Model applicable

Parking brake warning lamp

Red

This lamp glows when the parking brake is applied.

All models (Standard)

Seat belt warning lamp

Red

This lamp glows when the seat belt is not fastened.

All models (Standard)

Charge warning lamp

Red

This lamp glows when charging is not normal. (Glows/the lamp glows all the time while the engine is stopped)

All models (Standard)

Multi-purpose warning lamp

Red

This lamp glows when a minor failure occurs All models (Standard) or operating cautions are issued.

Torque converter oil temperature warning lamp

Red

This lamp glows when the torque converter oil temperature is not normal.

Powershift transmission models (Standard)

Engine oil pressure warning lamp

Red

This lamp glows when the engine oil pressure is low. (Glows/the lamp glows all the time while the engine is stopped)

All models (Standard)

Engine warning lamp

Amber

This lamp glows when the engine is failed.

Electronic control gasoline engine models (Standard)

Glow pilot indicator lamp

Amber

This lamp glows when the glow plug heating Diesel engine models is ON. (Standard)

Flex control indicator lamp

Amber

This lamp glows when sudden acceleration or full reverse (shifting of travel to the opposite direction) activates protective function.

Option

Mast interlock indicator lamp

Amber

When mast interlock is activated (glows)

All models (Standard)

3-31


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Mitsubishi fg45n forklift trucks service repair manual sn ef29d 50001 up  
Mitsubishi fg45n forklift trucks service repair manual sn ef29d 50001 up  
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