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.
1
Pub. No. 99719-18100
SAFETY WARNING The proper and safe lubrication and maintenance for these lift trucks, recommended by Mitsubishi Forklift Trucks, are outlined in the OPERATION & MAINTENANCE MANUAL.
Read and understand the OPERATION & 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.
3
(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.
4
(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)
5
HOW TO USE THIS MANUAL (continued) (Removal, Installation, Assembly and Disassembly)
Disassembly diagram (example)
2
1
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
6
A
0.11 to 0.28 mm
B
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
1N
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
7
CHAPTER INDEX CHAPTER INDEX
CHAPTER INDEX
Items
GENERAL INFOMATION
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
CLUTCHES
Dry-Type Clutch, Wet-Type Clutch
6
MANUAL TRANSMISSION
Structure, Removal and Installation of Transmission
7
POWERSHIFT TRANSMISSION
Torque Converter, Singe Speed Powershift Transmission Control Valve, Automatic Two-Speed Transmission
8
FRONT AXLE AND REDUCTION DIFFERENTIAL
Front Tire, Front Axle, Reduction, Differential
9
REAR AXLE
Rear Axle, Rear Tire
10
BRAKE SYSTEM
Master Cylinder, Wheel Brake, Brake Booster
11
STEERING SYSTEM
Steering Gear, Power Cylinder, Flow Divider
12
HYDRAULIC SYSTEM
Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve, Down Safety Valve
13
MAST AND FORKS
Simplex and Duplex Masts, Triplex Mast
14
SERVICE DATA
Maintenance Standard, Maintenance Schedule, Periodic Replacement Parts, Lubrication Instruction, Special Tool Needed
15
Chapter 1 GENERAL INFORMATION 1.
Model View............................................................................................... 1-1
2.
Truck Models Covered............................................................................ 1-2
3.
Serial Number Locations........................................................................ 1-3
4.
Dimensions.............................................................................................. 1-4
5.
Technical Data......................................................................................... 1-5
6.
Performance ............................................................................................ 1-7
1
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
MC / FC
MC / FC
Electric controlled
MC / FC
MC / FC
-
(FC type is used in torque converter model only.) Electric controlled gasoline engine, Electric controlled dual fuel gasoline/ LPG engine models 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
Z
: High-power engine model
C
: 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
L
K
O
E
J
A I
H
B
P
D
N
M F
213450
1-4
GENERAL INFORMATION
5. Technical Data Unit: mm class
1 ton class FG10N
FG15N
FG18N
FG20CN
FGE15N
FGE18N
FGE20CN
FG15ZN
FG18ZN
FD10N
FD15N
FD18N
FD20CN
3000
3000
3000
3000
115
115
115
120
C Fork spread
200 to 920
200 to 920
200 to 920
220 to 920
D Fork length
770
920
920
920
Gasolineengine truck
Truck model
Diesel-engine truck A Maximum lift B Free lift height
E Tilt angle (forward â&#x20AC;&#x201C; backward)
6-12
6-12
6-12
6-12
F Overall length
2980
3180
3220
3280
Single
1065
1065
1065
1065
Double
1330
1330
1330
-
H Overall height (with mast lowered)
1990
1990
1990
1990
Overall width G (outside-tooutside of tires) I
Height of the overhead guard
2065
2065
2065
2065
J
Overall height (with mast extended)
4055
4055
4055
4055
K
Tread (front wheel)
L
Tread (rear wheel)
Single
890
890
890
890
Double
1025
1025
1025
-
M Wheel base
900
900
900
900
1400
1400
1400
1400
N Front overhang
400
400
400
415
O Minimum turning radius
1910
1950
1980
2020
Under clearance (at center of frame)
150
150
150
150
P
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
3000
3000
3000
140
145
145
145
220 to 1000
220 to 1000
250 to 1000
250 to 1000
D Fork length
920
920
1070
1070
E Tilt angle (forward â&#x20AC;&#x201C; backward)
6-12
6-12
6-12
6-12
F Overall length Overall width G (outside-tooutside of tires)
3410
3625
3795
3860
Single
1150
1150
1275
1290
Double
1480
1480
1490
1490
H Overall height (with mast lowered)
1990
1990
2015
2130
I
2074
2074
2093
2103
Height of the overhead guard
J Overall height (with mast extended) K
Tread (front wheel)
4055
4055
4055
4055
Single
960
960
1060
1060
Double
1140
1140
1140
1140
L Tread (rear wheel)
980
980
980
980
M Wheel base
1600
1600
1700
1700
N Front overhang
455
460
495
495
O Minimum turning radius
2200
2230
2380
2440
Under clearance P (at center of frame)
160
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
kg
1000
1500
1750
2000
Load center
mm
500
500
500
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
19.0
19.0
19.0
Unloaded
km/h
19.5
19.5
19.5
19.5
1-7
GENERAL INFORMATION
class
Truck model
2 ton class
Gasolineengine truck Diesel-engine truck
Capacity
kg
Load center
mm
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
500
500
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
19.0
19.0
19.0
Unloaded
km/h
19.5
19.5
19.5
19.5
Chapter 2 COOLING SYSTEM 1.
Specifications.......................................................................................... 2-1
2.
Structure .................................................................................................. 2-2
3.
Removal and Installation........................................................................ 2-3 3.1 3.2 3.3
4.
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
2
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
1
2 213452
1 Tension pulley assembly, bolt 2 Belt
3.2 Suggestions for Removal (1) Loosen the tension pulley lock bolt by three or four turns. If the bolt is loosened insufficiently, the tension 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)
L
0.65
0.65
0.65
Total quantity of coolant (including coolant in hoses)
L
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
2.
Structure .................................................................................................. 3-3 2.1 2.2 2.3
3.
List of Wire Colors ................................................................................................. 3-41
Troubleshooting.................................................................................... 3-42 7.1 7.2 7.3
8.
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
7.
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
6.
Disassembly .......................................................................................................... 3-16
Battery Maintenance ............................................................................. 3-17 4.1 4.2 4.3
5.
Console Box ............................................................................................................ 3-3 Major Electrical Components................................................................................... 3-5 Table of Lamps...................................................................................................... 3-15
Console Box .......................................................................................... 3-16 3.1
4.
(One) ....................................................................................................................... 3-1 (Two) .......................................................................................................................3-2
Starter System....................................................................................................... 3-42 Gauges .................................................................................................................. 3-42 Lighting System ..................................................................................................... 3-43
Electrical Schematic ............................................................................. 3-45
3
ELECTRIC SYSTEM
1. Chassis Electrical Devices Wiring Outline
Chapter 3 ELECTRIC SYSTEM
1.1 (One)
Main harness
Harness, rear combination
Harness, front combination
Harness, front combination
213457
3-1
ELECTRIC SYSTEM
1.2 (Two)
Starter switch QGS Controller Key
Main harness
Harness, rear combination
Select switch
Back buzzer
Warning buzzer Harness, front combination Input unit VCM(Vehicle control module)
GSE Connector
Clip
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
4
3
2
1
ᵮ
N
ᵦᶐ
ᵤ
ᵦ
ᵣᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾ
ᵡ
6
7 5
214140
3-3
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. 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)
-
F
Engine oil pressure warning lamp
Normal
When engine oil pressure is low (glows / When engine is not running always glows)
-
G
Engine warning lamp
Normal
When the engine is failed (glows)
-
H
Glow pilot lamp
Preheating completed
When the grow plug is ON (glows)
Option
A
Parking brake warning lamp
B
Seat belt warning lamp
C
Charge warning lamp
D
Multi-purpose warning lamp
E
I
Smart shift indicator lamp
-
When protective function of sudden acceleration/full reverse (shifting in the opposite direction of traveling) is activated (glows)
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 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
M
G
B
(START)
213459
Connection Table For gasoline truck (12V) Terminal
G
B
M
ST
OFF
Key in and out Yes
ON (when operating)
○--------- -----------○
START (when starting engine)
○--------- -----------○-----------
No -----------○
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
4
3
5
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)
Up
T1
Note:The installed position is that of an actual truck as shown in the illustration. T2 Down Vent hole Contact Coil 213463
2.2.4 Tank Unit
F
3/4
1/2 Fuel pump
Pressure relief valve
1/4 Fuel filter E
Referential Standards Float position
E
1/4
1/2
3/4
F
Standard resistance value (ohm)
80
49.5
32
19
10
+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
2
3
4
5
B
B/R
B
L/W
Lever position F Forward N Neutral R Reverse
213467
2.2.8 Backup lamp switch (Manual T/M truck)
ONޓOFF 19.5 mm 2 mm
2 mm Shift rail (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
2
Colorless
2
Amber
Type of lamp
Illustration
Remark
Standard:
Standard: Head guard Installed
Combination Lamp (front)
Combination Lamp (rear)
Valve
Clearance lamp
2
Colorless
Turn signal lamp
2
Amber
Standard:
Tail and Stop lamps
2
Red
Standard:
Backup lamps
2
Colorless
3-15
ELECTRIC SYSTEM
3. Console Box 3.1 Disassembly
6
5
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
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
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