Mitsubishi fge15zn forklift trucks service repair manual snf34 5800168001 up by 1636645

Service Manual Chassis & Mast

MC/FC

FG10N FG15N FG15ZN FG18N FG18ZN FG20CN FG20N FG20ZN FG25N FG25ZN FG30N FG35AN

F25C-05001-up F25C-55001-up F34-52001-up F25C-75001-up F34-72001-up F34-22001-up F17D-10001-up F35-10001-up F17D-60001-up F35-60001-up F13F-40001-up F13F-60001-up

FGE15N FGE18N FGE20CN FGE20N FGE20ZN FGE25N FGE25ZN FGE30N FGE35AN

FD10N FD15N FD18N FD20CN FD20N FD25N FD30N FD35AN

F16D-04001-up F16D-54001/64001-up F16D-74001/84001-up F16D-24001/28001-up F18C-20001/40001-up F18C-70001/90001-up F14E-10001/20001-up F14E-80001/90001-up

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

F34-00001/19001-up F34-40001/49001-up F34-30001/39001-up F17D-20001/38001-up F35-20001/38001-up F17D-70001/88001-up F35-70001/88001-up F13F-10001/20001-up F13F-80001/90001-up

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> WARNING

Indicates a specific potential hazard resulting in serious bodily injury or death.

CAUTION

Indicates a potentially hazardous situation which, if not 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.

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 & 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. 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 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. (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 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. (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)Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang â&#x20AC;&#x153;Do not Operateâ&#x20AC;? tag in the Operatorâ&#x20AC;&#x2122;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. (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.

(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.

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)

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 Gear Backlash

A: Standard value B: Repair or Service Limit

0.11 to 0.28 mm

0.5 mm

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 Pressure Torque

SI unit

Customary unit

0.102 kgf

1 lbf

0.4536 kgf

1 kPa

0.0102 kgf/cm2

1 psi

0.0703 kgf/cm2

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 INFOMATION

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

COOLING SYSTEM

Fan Belt Removal and Installation, Fan Belt Tension

ELECTRICAL SYSTEM

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

CONTROLLERS

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

POWER TRAIN

Removal and Installation of Power Line

CLUTCHES

Dry-Type Clutch, Wet-Type Clutch

MANUAL TRANSMISSION

Structure, Removal and Installation of Transmission

POWERSHIFT TRANSMISSION

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

FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Tire, Front Axle, Reduction, Differential

REAR AXLE

Rear Axle, Rear Tire

BRAKE SYSTEM

Master Cylinder, Wheel Brake, Brake Booster

STEERING SYSTEM

Steering Gear, Power Cylinder, Flow Divider

HYDRAULIC SYSTEM

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

MAST AND FORKS

Simplex and Duplex Masts, Triplex Mast

SERVICE DATA

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

Chapter 1 GENERAL INFORMATION 1.

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

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

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

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

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

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: Engine mounted

Gasoline-engine truck

Dual fuel gasoline/ LPG-engine truck

Diesel-engine truck

Non-electric controlled

MC / FC

Electric controlled

MC / FC

(FC type is used in torque converter model only.) Electric controlled gasoline engine, Electric controlled dual fuel gasoline/ LPG engine models Truck type

1 ton class

2 ton class

3 ton class

Non-electric controlled gasoline engine, Non-electric controlled dual fuel gasoline/ LPG engine models

Non-electric controlled diesel engine models

Truck model

Serial number

Engine mounted

FG10N

F25C-05001 to

K15

FD10N

F16D-04001 to

S4Q2

FG15N

F25C-55001 to

K15

FD15N

F16D-54001 to

S4Q2

Truck model

FG15ZN

F34-52001 to

K21

FD15N(F)

F16D-64001 to

S4Q2

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

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

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

FG35AN

F13F-60001 to

K25

FD35AN(F)

F14E-90001 to

S4S

FGE35AN

F13F-80001 to

K25E

FGE35AN(F)

F13F-90001 to

K25E

: FC Truck

None : MC Truck

1-2

Engine mounted

FGE15N

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

Serial number

: High-power engine model

: Short wheel base model

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 FD20Nâ&#x20AC;&#x201C;25N)

Mast Serial Number

Transmission Serial Number (Manual Transmission Truck)

Transmission Serial Number (Powershift Transmission Truck)

213449

1-3

GENERAL INFORMATION

4. Dimensions

G C

A I

M F

213450

1-4

GENERAL INFORMATION

5. Technical Data Unit: mm class

1 ton class FG10N

FG15N

FG18N

FG20CN

FGE15N

FGE18N

FGE20CN

FG15ZN

FG18ZN

FD10N

FD15N

FD18N

FD20CN

3000

115

120

C Fork spread

200 to 920

220 to 920

D Fork length

770

920

Gasolineengine truck

Truck model

Diesel-engine truck A Maximum lift B Free lift height

E Tilt angle (forward â&#x20AC;&#x201C; backward)

6-12

F Overall length

2980

3180

3220

3280

Single

1065

Double

1330

H Overall height (with mast lowered)

1990

Overall width G (outside-tooutside of tires) I

Height of the overhead guard

2065

Overall height (with mast extended)

4055

Tread (front wheel)

Tread (rear wheel)

Single

890

Double

1025

M Wheel base

900

1400

N Front overhang

400

415

O Minimum turning radius

1910

1950

1980

2020

Under clearance (at center of frame)

150

1-5

GENERAL INFORMATION

Unit: mm class Gasolineengine truck

Truck model

Diesel-engine truck A Maximum lift B Free lift height C Fork spread

2 ton class

3 ton class

FG20N

FG25N

FG30N

FG35AN

FGE20N

FGE25N

FGE30N

FGE35AN

FG20ZN

FG25ZN

FGE20ZN

FGE25ZN

FD20N

FD25N

FD30N

FD35AN

3000

140

145

220 to 1000

250 to 1000

D Fork length

920

1070

E Tilt angle (forward â&#x20AC;&#x201C; backward)

6-12

F Overall length Overall width G (outside-tooutside of tires)

3410

3625

3795

3860

Single

1150

1275

1290

Double

1480

1490

H Overall height (with mast lowered)

1990

2015

2130

2074

2093

2103

Height of the overhead guard

J Overall height (with mast extended) K

Tread (front wheel)

4055

Single

960

1060

Double

1140

L Tread (rear wheel)

980

M Wheel base

1600

1700

N Front overhang

455

460

495

O Minimum turning radius

2200

2230

2380

2440

Under clearance P (at center of frame)

160

190

200

1-6

GENERAL INFORMATION

6. Performance class

1 ton class FG10N

Truck model

FG15N

FG18N

FG20CN

FGE15N

FGE18N

FGE20CN

FG15ZN

FG18ZN

FD10N

FD15N

FD18N

FD20CN

Gasolineengine truck Diesel-engine truck

Capacity

1000

1500

1750

2000

Load center

500

490 (FG10N)

490 (FG15N) 630 (FGE15N) 570 (FG15ZN)

490 (FG18N) 630 (FGE18N) 570 (FG18ZN)

570 (FG20CN) 630 (FGE20CN)

Loaded

mm/s

Lift speed

Travel speed (Powershift Truck)

630 (FD10N)

630 (FD15N)

630 (FD18N)

630 (FD20CN)

560 (FG10N)

560 (FG15N) 650 (FGE15N) 650 (FG15ZN)

560 (FG18N) 650 (FGE18N) 650 (FG18ZN)

650 (FG20CN) 650 (FGE20CN)

Unloaded

mm/s

690 (FD10N)

690 (FD15N)

690 (FD18N)

690 (FD20CN)

Loaded

km/h

19.0

Unloaded

km/h

19.5

1-7

GENERAL INFORMATION

class

Truck model

2 ton class

Gasolineengine truck Diesel-engine truck

Capacity

Load center

Loaded

mm/s

Lift speed

Travel speed (Powershift Truck)

1-8

3 ton class

FG20N

FG25N

FG30N

FG35AN

FGE20N

FGE25N

FGE30N

FGE35AN

FG20ZN

FG25ZN

FGE20ZN

FGE25ZN

FD20N

FD25N

FD30N

FD35AN

2000

2500

3000

3500

500

520 (FG20N) 580 (FGE20N) 580 (FG20ZN) 640 (FGE20ZN)

520 (FG25N) 580 (FGE25N) 580 (FG25ZN) 640 (FGE25ZN)

460 (FG30N) 510 (FGE30N)

390 (FG35AN) 430 (FGE35AN)

630 (FD20N)

630 (FD25N)

500 (FD30N)

420 (FD35AN)

600 (FG20N) 590 (FGE20N) 660 (FG20ZN) 660 (FGE20ZN)

600 (FG25N) 590 (FGE25N) 660 (FG25ZN) 660 (FGE25ZN)

530 (FG30N) 530 (FGE30N)

450 (FG35AN) 440 (FGE35AN)

Unloaded

mm/s

660 (FD20N)

660 (FD25N)

530 (FD30N)

450 (FD35AN)

Loaded

km/h

19.0

Unloaded

km/h

19.5

Chapter 2 COOLING SYSTEM 1.

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

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

Removal and Installation........................................................................ 2-3 3.1 3.2 3.3

Fan Belt Removal .................................................................................................... 2-3 Suggestions for Removal ........................................................................................ 2-3 Installation ............................................................................................................... 2-4

Inspection and Adjustment .................................................................... 2-5 4.1 4.2 4.3 4.4 4.5 4.6

Fan Belt Inspection.................................................................................................. 2-5 Fan Belt Tension ..................................................................................................... 2-5 Connecting Hoses ................................................................................................... 2-5 Unit Layout .............................................................................................................. 2-6 Coolant .................................................................................................................... 2-6 Radiator Cap ........................................................................................................... 2-6

COOLING SYSTEM

1. Specifications Items Cooling method Cooling system

Radiator

Chapter 2 COOLING SYSTEM

Truck type 1 ton class

2 ton class

3 ton class

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

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

Upper hose

S4Q2 S4S

Reservoir tank K15, K21, K25

S4S engine

213451

2-2

COOLING SYSTEM

3. Removal and Installation 3.1 Fan Belt Removal Engine

Fan

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 pulley will not move. Note: Do not loosen the lock bolt to such an extent that the bolt would be removed. (2) Move the tension pulley fully toward the fan, then remove the belt.

Fan

Tension pulley

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 generates 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 adjustment, 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 tension pulley. Adjust the belt tension between 11 to 13 mm.

Fan pulley

Tension pulley

213454

4.3 Connecting Hoses When connecting the hoses to the radiator, fit their 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.

Hose

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 coolant 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)

0.65

Total quantity of coolant (including coolant in hoses)

6.8

7.4

8.7

4.6 Radiator Cap Opening pressure

88Âą14.7 kPa

Vacuum valve

0 to 4.9 kPa

2-6

Chapter 3 ELECTRIC SYSTEM 1.

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

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

List of Wire Colors ................................................................................................. 3-41

Troubleshooting.................................................................................... 3-42 7.1 7.2 7.3

Instrument Panel Screen Element......................................................................... 3-18 Basic Screen Display............................................................................................. 3-19 Basic Operation ..................................................................................................... 3-22 When an Error Occurs........................................................................................... 3-28 Warning Lamps ..................................................................................................... 3-30 Optional Functions................................................................................................. 3-31 Hour Meters........................................................................................................... 3-38 Troubleshooting..................................................................................................... 3-40

Wire Color .............................................................................................. 3-41 6.1

State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment ..................... 3-17 Specific Gravity Reading and State of Charge ...................................................... 3-17 Charging Precautions ............................................................................................ 3-17

Instrument Panel ................................................................................... 3-18 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

Disassembly .......................................................................................................... 3-16

Battery Maintenance ............................................................................. 3-17 4.1 4.2 4.3

Console Box ............................................................................................................ 3-3 Major Electrical Components................................................................................... 3-5 Table of Lamps...................................................................................................... 3-15

Console Box .......................................................................................... 3-16 3.1

(One) ....................................................................................................................... 3-1 (Two) .......................................................................................................................3-2

Starter System....................................................................................................... 3-42 Gauges .................................................................................................................. 3-42 Lighting System ..................................................................................................... 3-43

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

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

GLE Connector Connector bracket

Harness, front combination

Battery seat

ECM (Gasoline engine control module)

DCM (Diesel engine control module)

Horn Output unit Fuse box, Fuse Vehicle speed sensor (Pulse generator)

Relay box, Relay

Transmission

213458

3-2

ELECTRIC SYSTEM

2. Structure 2.1 Console Box 1 2 3 4 5 6 7

Water temperature gauge Fuel gauge Hour meter, various warning lights Instrument panel Starter switch Lighting switch, turn signal switch Forward-reverse lever

ᵮ

ᵦᶐ

ᵤ

ᵦ

ᵣᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾ

ᵡ

7 5

214140

3-3

ELECTRIC SYSTEM 2.1.1 Function of Instrument Panel

O 214141

Ref. No.

Name of indicators and warning lamps

When turned off

When glows or blinks

Remark

Normal

When parking brake is applied (glows)

Fastened

When seat belt is not fastened (glows)

Normal charging

When charging is not normal (glows / When engine is not running always glows)

Normal

When a minor failure occurs or operating caution is being issued (glows)

Torque converter fluid temperature warning lamp

Normal temperature

When torque converter fluid temperature is not normal (glows)

Engine oil pressure warning lamp

Normal

When engine oil pressure is low (glows / When engine is not running always glows)

Engine warning lamp

Normal

When the engine is failed (glows)

Glow pilot lamp

Preheating completed

When the grow plug is ON (glows)

Option

Parking brake warning lamp

Seat belt warning lamp

Charge warning lamp

Multi-purpose warning lamp

Smart shift indicator lamp

When protective function of sudden acceleration/full reverse (shifting in the opposite direction of traveling) is activated (glows)

Mast interlock indicator lamp

When mast interlock is activated (glows)

Cursor buttons

Fuel gauge

LCD screen

Water temperature gauge

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 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 system. (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

(START)

213459

Connection Table For gasoline truck (12V) Terminal

OFF

Key in and out Yes

ON (when operating)

○--------- -----------○

START (when starting engine)

○--------- -----------○-----------

No -----------○

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 2

T-1

T-2 5

1 3

T-3

L-2

L-1

L-3

Wheel angle sensor connector 1 2

L-4

L-5

Horn contact Horn

213460

3-6

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 abnormal. Operating voltage: DC12V (Gasoline and diesel trucks)

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 E

Referential Standards Float position

1/4

1/2

3/4

Standard resistance value (ohm)

49.5

+12 +2

㧙

±3

㧙

+1.0 -0.5

Tolerance (ohm)

213464

3-7

ELECTRIC SYSTEM

(emergency energization)

3 Âą 2 mm

Refer to the brake system.

Indicator or ON activating position

2.2.5 Brake fluid sensor

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

1 M ohm or more (with megger tester at 500V)

Push rod

4 mm

M10Ă&#x2014;1.25

2mm

OFF ON

213466

Rated voltage DC12V

3-8

ELECTRIC SYSTEM 2.2.7 Direction lever assembly (Powershift truck) Forward of vehicle

N Neutral

(10㩩) (10㩩)

F Forward

R Reverse

Connector of FNR switch

Connector of FNR switch Connection table 1

Terminal

Wire color G/W

B/R

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 (for forward-reverse)

Backup lamp switch Transmission case

M12×1.75

(0.5 RL) 213468

3-9

ELECTRIC SYSTEM 2.2.9 Neutral switch

Neutral switch

(0.5 RL) Transmission case

ON‫ޓ‬OFF 19.5 mm 2 mm 2 mm

M12×1.75

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 standard resistance value. Note:The illustration is for a gasoline-engine truck. 213470

Gasoline-engine truck Temperature [°C (°F)]

60±0.2

65±0.2

80±0.2

100±0.3

125±0.3

130±0.3

Standard resistance value (ohm)

80±10

67±7.8

40.6±2.7

22.2±1.4

11.3±0.4

10±0.3

Temperature [°C (°F)]

50±0.2

60±0.2

80±0.2

100±0.3

105±0.3

120±0.3

Standard resistance value (ohm)

80±10

56.3±5

29.5±2.5

16.5±0.8

14.3±0.5

10±0.3

Diesel-engine truck

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 the switch if the measured insulation resistance value is not more than the value listed below.

Terminal

Body

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

Insulation resistance value

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 Operating temperature Insulation resistance (with contact point OFF)

OFF to ON

122±3°C

ON to OFF

115 °C or higher 1 M ohm or more

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 Open-circuit voltage

DC 3.0 to 7 V 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.

Items

Glow lamp Glow plug

Water temperature (Water temperature resistance value)

ON time

-15°C (12.1 K ohm)

10.0 ± 2.0 sec.

0°C (5.9 K ohm)

6.4 ± 1.3 sec.

+10°C (3.8 K ohm)

3.0 ± 0.6 sec.

Rated voltage: DC12V

Connector A

Connector B 1 2 3 㧭㧮 4 5 6 Connector A Connector B

Connection diagram

213472

3-13

ELECTRIC SYSTEM 2.2.14 Fuse box

Fuse box, Fuse

Working lamp 15A Back up/Others 15A

Spare

Head lamp 15A

Instrument panel 10A QGS 10A VCM 20A

10A

A/C 20A

ETC 15A

Spare 20A

30A

Wiper 15A

Horn 10A

Stop lamp 10A EGI 30A

EGI 30A Fuse puller

15A SBF 100A Battery

SBF 100A Alternator

SBF 50A Glow

213480

3-14

ELECTRIC SYSTEM

2.3 Table of Lamps

Items

Head lamps

Turn signal lamp

Qty

Lens color

Colorless

Amber

Type of lamp

Illustration

Remark

Standard:

Standard: Head guard Installed

Combination Lamp (front)

Combination Lamp (rear)

Valve

Clearance lamp

Colorless

Turn signal lamp

Amber

Standard:

Tail and Stop lamps

Red

Standard:

Backup lamps

Colorless

3-15

ELECTRIC SYSTEM

3. Console Box 3.1 Disassembly

2 5 4

3 1

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 at 20째C (68째F)

Condition

Adjustment

1.280 to 1.265

Good

If difference in S.G. between any two cells is 0.020 or less, continue to use as is. if the difference is greater than 0.020, apply the high rated discharge to correct, then charge the battery referring to the S.G.

1.260 to 1.225

Half charged

Recharge battery and adjust electrolyte S.G. Make sure there is neither faulty components, loosely connected cables nor corroded connections.

1.220 or less

Low battery, requiring cares

If difference in S.G. is more than 0.040

A cell with a low S.G. is in shorted condition. Electrolyte leakage or excessive/ diluted electrolyte

Recharge battery. If difference in S.G. is large, adjust it during recharging. Recharge until voltage and S.G. stabilize and have remained constant for more than 2 hours. During recharging, adjust S.G.1.280 to 1.265 If difference in S.G. is more than 0.040 and a low S.G. is found in certain 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 electrolyte 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 electrolyte 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 45째C (113째F). (4) When connecting cables to battery terminals, always connect the (+) terminal first, and when disconnecting, remove the (-) terminal first. (5) During charging, hydrogen gas is generated, which requires attention to ventilation.

Identification

Identification 34B19L

CAUTION Be sure to turn OFF the starter switch and lighting switch before disconnecting or connecting the battery cables. (to prevent IC regulator from damage.)

213484

55D23L 75D26L 95D31L

(Gasoline-engine truck) (Diesel-engine truck)

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

LCD screen

215114

The LCD screen consists of 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 or higher

Display on the LCD is automatically not displayed.

105 °C or higher

Back light is automatically turned to off.

Note:(a)Back light illuminates left fuel mark and right water temperature mark on LCD from inside. (b) Warnings will not automatically be turned off for safety reasons. (c) When the temperature is extremely low (0°C or below), the response of the LCD display becomes slow.

3-18

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 When the key switch is turned to the ON position, the LCD screen displays the brand logo screen, the password 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 seconds 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

Thank you very much for your reading. Please Click Here Then Get More Information.