MITSUBISHI FG55N FORKLIFT TRUCKS Service Repair Manual SN: EF33C-80001-UP

CF/CMtsaM&sissahC
Service Manual
FD40N EF12B-00011-up
FD45N EF19D-50001-up
FD50CN EF19D-80001-up
FD50N EF28C-50001-up
FD55N EF28C-80001-up
FG40N EF40-00011-up
FG45N EF29D-50001-up
FG50CN EF29D-80001-up
FG50N EF33C-50001-up
FG55N EF33C-80001-up
99739-57100
For use with S6S and TB45 Engine
Service Manuals.

1
Pub. No. 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>
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury, or damage
to your machine.
Indicates a condition that can cause damage to, or shorten
service life of, the machine.
WARNING
CAUTION
NOTE

2
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 & MAINTE-
NANCE MANUAL before performing any lubrica-
tion or maintenance on these trucks.
Improper performance of lubrication or mainte-
nance procedures is dangerous and could result
in injury or death.
The serviceman or mechanic may be unfamiliar with
many of the systems on this truck. This makes it
important to use caution when performing service
work. A knowledge of the system and/or components
is important before the removal or disassembly of any
component.
Because of the size of some of the truck components,
the serviceman or mechanic should check the weights
noted in this Manual. Use proper lifting procedures
when removing any components.
Following is a list of basic precautions that should
always be observed.
(1) Read and understand all warning plates and
decals on the truck before operating, lubricating or
repairing the product.
(2) Always wear protective glasses and protective
shoes when working around trucks. In particular,
wear protective glasses when pounding on any
part of the truck or its attachments with a hammer
or sledge. Use welders gloves, hood/goggles,
apron and other protective clothing appropriate to
the welding job being performed. Do not wear
loose fitting or torn clothing. Remove all rings from
fingers when working on machinery.
(3) Do not work on any truck that is supported only by
lift jacks or a hoist. Always use blocks or jack
stands to support the truck before performing any
disassembly.
(4) Lower the forks or other implements to the ground
before performing any work on the truck. If this
cannot be done, make sure the forks or other
implements are blocked correctly to prevent them
from dropping unexpectedly.
Do not operate these trucks unless you have read
and understood the instructions in the OPERA-
TION & MAINTENANCE MANUAL. Improper truck
operation is dangerous and could result in injury
or death.
(5) Use steps and grab handles (if applicable) when
mounting or dismounting a truck. Clean any mud
or debris from steps, walkways or work platforms
before using. Always face truck when using steps,
ladders and walkways. When it is not possible to
use the designed access system, provide ladders,
scaffolds, or work platforms to perform safe repair
operations.
(6) To avoid back injury, use a hoist when lifting com-
ponents which weigh 23 kg or more. Make sure all
chains, hooks, slings, etc., are in good condition
and are of the correct capacity. Be sure hooks are
positioned correctly. Lifting eyes are not to be side
loaded during a lifting operation.
(7) To avoid burns, be alert for hot parts on trucks
which have just been stopped and hot fluids in
lines, tubes and compartments.
(8) Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located at oppo-
site ends of the cover or device and pry cover
loose to relieve any spring or other pressure,
before removing the last two bolts or nuts com-
pletely.
(9) Be careful when removing filler caps, breathers
and plugs on the truck. Hold a rag over the cap or
plug to prevent being sprayed or splashed by liq-
uids under pressure. The danger is even greater if
the truck has just been stopped because fluids
can be hot.
(10)Always use tools that are in good condition and
be sure you understand how to use them before
performing any service work.
(11)Reinstall all fasteners with same part number. Do
not use a lesser quality fastener if replacements
are necessary.
(12)If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not
roll while working on or under truck.

3
(13)Before starting to work on truck, hang "Do not
Operate" tag in the Operator's Compartment.
(14)Repairs, which require welding, should be per-
formed only with the benefit of the appropriate ref-
erence information and by personnel adequately
trained and knowledgeable in welding proce-
dures. 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 cor-
ners, or by rubbing against some object or hot
surface. Place wiring away from oil pipe.
(16)Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
(17)Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.
(18)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses could cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Pin hole (very small) leaks could
result in a high velocity oil stream that will be invis-
ible close to the hose. This oil could penetrate the
skin and cause personal injury. Use cardboard or
paper to locate pin hole leaks.
(19)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibra-
tion or rubbing against other parts during opera-
tion. Shields that protect against oil spray onto hot
exhaust components in event of a line, tube or
seal failure, must be installed correctly.
(20)Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are dis-
connected 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 dam-
aged or contacts any other part during operation.
Any high speed rotating component that has been
damaged or altered should be checked for bal-
ance before reusing.

4
HOW TO USE THIS MANUAL
Lift truck model 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
Gasoline-Engine Trucks (FG)....... Trucks Equipped with TB45 Gasoline Engine
Diesel-Engine Trucks (FD) .................... Trucks Equipped with S6S Diesel Engine
Powershift Trucks................................... Trucks Equipped with Powershift Transmission
FC lever box
Lever
VCM Controller
Electric wiring
Flow regulator valve
Electromagnetic control valve
Control valve
MC Truck
FC Truck
216300

5
HOW TO USE THUS MANUAL(continued)
Disassembly diagram(example)
Suggestions for Disassembly
Output shaft, Removing
Remove output shaft using a special tool.
Service Data
1
2
213445
Sequence
1 Cover, Bolt, Washer (part name)
2 Out put shaft assembly (part name)
213446
Unit:mm(in.)
Gear Backlash
A
0.11 to 0.28
(0.004 to 0.011)
B
0.5
(0.012)
A: Standard value B: Repair or Service Limit

6
Symbols and abbreviations
Units
(1) SI Units are used in this manual.
(2) The following table shows the conversion of SI
unit and customary unit.
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)
Item SI unit Customary unit
Force
1 N 0.102 kgf
1 lbf 0.4536 kgf
Pressure
1 kPa 0.0102 kgf/cm2
1 psi 0.0703 kgf/cm2
Torque
1 N·m 0.102 kgf·m
1 lbf·ft 0.1383 kgf·m

CHAPTER INDEX
CHAPTER INDEX
CHAPTER INDEX Items
GENERAL INFORMATION
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
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
1
2
3
4
5
6
7
8
9
10
11
12
13

1
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

1-1
GENERAL INFORMATION
Chapter 1 GENERAL INFORMATION
1. Model View
MC model
215315
215316
FC model

1-2
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

1-3
GENERAL INFORMATION
3. Serial Number Locations
215340
Diesel engine model serial number
Name plate
Chassis serial number
Gasoline engine model serial number
Transmission serial numberMast serial number

1-4
GENERAL INFORMATION
4. Dimensions
A
B
H
J
E
D N
P
M
F
I
L
O
K
CG
215339

1-5
GENERAL INFORMATION
5. Technical Data
Unit:mm (in.)
Truck model
class 4 ton class 5 ton class
Gasoline model FG40N FG45N FG50CN FG50N FG55N
Diesel model FD40N FD45N FD50CN FD50N FD55N
A Maximum lift 3350 (132) 3360 (132.5)
B Free lift height 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 6 - 10
F Overall length 3000 (118) 3130 (123) 3170 (125) 3310 (130) 3360 (132)
G
Overall width
<outside-to-outside
of tires>
Single 1415 (55.5) 1460 (57.5)
Double 1780 (70.0)
Special double 1965 (77.5)
H Overall height <with mast lowered> 2320 (91.5) 2400 (94.5)
I Height of the overhead guard 2280 (89.5)
J
Overall height
<with mast
extended>
With backrest 4570 (180) 4590 (181)
Without backrest 4230 (167) 4190 (165) 4330 (170)
K
Tread
<front wheel>
Single 1175 (46.5)
Double 1310 (51.5)
Special double 1445 (57.0)
L Tread <rear wheel> 1180 (46.5)
M Wheelbase 1850 (73.0) 2000 (78.5) 2150 (84.5)
N Front overhang 577 (22.7) 582 (22.9) 602 (23.7)
O Minimum turning radius 2580 (101) 2730 (107) 2760 (109) 2890 (114) 2940 (116)
P Under clearance <at frame> 227 (8.9)

1-6
GENERAL INFORMATION
6. Performance
Truck
model
Class 4 ton class 5 ton class
Gasoline
model
Truck model FG40N FG45N FG50CN FG50N FG55N
Capacity
kg
(lb)
3500
(8000)
4000
(9000)
4500
(10000)
5000
(11000)
5500
(12000)
Load center mm (in.) 600 (24)
Lift speed
Loaded
2SP mast
mm/s
(fpm)
570 (110) 490 (96)
2FF mast 530 (105) 430 (85)
3FF mast 530 (105) 450 (89)
Unloaded
2SP mast 600 (120) 520 (100)
2FF mast 560 (110) 460 (90)
3FF mast 560 (110) 480 (94)
Travel
speed
Forward
Loaded
1st speed
km/h
(mph)
13.5 (8.5)
2nd speed 22.0 (14.0) 21.5 (13.5)
Unloaded
1st speed 13.5 (8.5)
2nd speed 22.5 (14.0)
Reverse
Loaded 1st speed 18.5 (11.5)
Unloaded 1st speed 19.0 (12.0) 18.5 (11.5)
Truck
model
Class 4 ton class 5 ton class
Diesel
model
Truck model FD40N FD45N FD50CN FD50N FD55N
Capacity
kg
(lb)
3500
(8000)
4000
(9000)
4500
(10000)
5000
(11000)
5500
(12000)
Load center mm (in.) 600 (24)
Lift speed
Loaded
2SP mast
mm/s
(fpm)
550 (110) 470 (93)
2FF mast 510 (100) 420 (83)
3FF mast 520 (102) 440 (86)
Unloaded
2SP mast 610 (120) 530 (105)
2FF mast 570 (112) 470 (92)
3FF mast 570 (112) 490 (96)
Travel
speed
Forward
Loaded
1st speed
km/h
(mph)
13.5 (8.5)
2nd speed 21.5 (13.5) 21.0 (13.0)
Unloaded
1st speed 13.5 (8.5)
2nd speed 22.0 (13.5)
Reverse
Loaded 1st speed 18.0 (11.0) 17.5 (11.0)
Unloaded 1st speed 18.5 (11.5)

2
Chapter 2 COOLING SYSTEM
1. Specifications.......................................................................................... 2-1
2. Structure .................................................................................................. 2-2
3. Removal and Installation........................................................................ 2-3
3.1 Fan Belt Removal....................................................................................................2-3
4. Inspection and Adjustment.................................................................... 2-5
4.1 Fan Belt ...................................................................................................................2-5
4.2 Radiator...................................................................................................................2-6
4.3 Upper Hose, Lower Hose ........................................................................................2-6
4.4 Coolant ....................................................................................................................2-7
5. Troubleshooting...................................................................................... 2-8

2-1
COOLING SYSTEM
Chapter 2 COOLING SYSTEM
1. Specifications
Item
Truck model
FG40N FG45N FG50CN FG50N FG55N
FD40N FD45N FD50CN FD50N FD55N
Cooling
system
Cooling method Water-cooled, forced circulation
Radiator Corrugated fin (pressure) type
Water pump Centrifugal type
Thermostat Wax pellet type

2-2
COOLING SYSTEM
2. Structure
6
5
3 4
1
2
7
6
5
3 4
1
2 7
Gasoline model Diesel model 215476
1 Engine
2 Fan (coupled directly to the engine crankshaft)
3 Shroud
4 Radiator
5 Oil cooler for torque converter
6 Reserve tank
7 Radiator cap

2-3
COOLING SYSTEM
3. Removal and Installation
3.1 Fan Belt Removal
3.1.1 Start by
Remove the radiator cover.
1
2
215477
1
Gasoline model Diesel model
3 3
1 Tension assembly (pulley lock bolt)
2 Alternator lock bolt
3 Fan belt

2-4
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 ade-
quately, the fan pulley will not move.
Note: Do not remove the pulley lock bolts by loosen-
ing them too much.
(2) Loosen the lock nut.
(3) Loosen the adjusting screw and push the fan pul-
ley 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 gener-
ates 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.
216926
Adjusting screw
Fan belt
Fan pulley
Pulley
lock bolts
Lock nut

2-5
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 con-
tamination is found. When the belt is slightly con-
taminated, 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 adjust-
ment, 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

2-6
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.
4.2.2 Radiator rubber mount
Replace radiator rubber mount if it is hardened and
has no elasticity.
4.2.3 Radiator cap
4.3 Upper Hose, Lower Hose
4.3.1 Connecting Hoses
(1) Check the hoses and replace them if they are
swollen or damaged.
(2) When connecting the hoses to the radiator, make
sure that their ends are fully inserted into the fit-
tings and secure them with clamps.
Be careful not to damage the water pipe while clean-
ing.
Unit: Kpa (kgf/cm2) [psi]
Opening
pressure
88 ± 14.7 (0.9 ± 0.15) [12.77 ± 2.13]
Vacuum valve 0 to 4.9 (0 to 0.05) [0 to 0.71]
Diesel model
215479

2-7
COOLING SYSTEM
4.4 Coolant
4.4.1 Draining coolant
(1) Drain the coolant from the radiator by loosening
the drain cock.
(2) Drain the coolant from the reservoir tank.
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.
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.
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)
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.
Diesel model
215480
Example: MHI Long Life Coolant
Temperature
°C (°F)
-39
(-38)
-30
(-22)
-25
(-13)
-20
(-4)
-15
(5)
-10
(14)
Concentra-
tion (%)
55 50 45 40 35 30
Antifreeze concentration ratio varies depending on
brands. Be sure to mix the coolant according to a
manufacture's recommended mix ratio.
215481
Diesel model

2-8
COOLING SYSTEM
5. Troubleshooting
Condition Possible cause Action
Leaking coolant from radiator
Damaged radiator core or tank Replace
Damaged radiator hoses Replace
Hose clamp is defective. Replace
Drain cock is defective. Replace
Engine overheated
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
Leaking oil from oil cooler hose Insufficient tightening torque of hose
clamp
Retighten or replace

3
Chapter 3 ELECTRIC SYSTEM
1. Chassis Electrical Devices Wiring Outline ........................................... 3-1
1.1 Gasoline Model........................................................................................................3-1
1.2 Diesel Model............................................................................................................3-2
1.3 Gasoline and Diesel Models....................................................................................3-3
2. Structure .................................................................................................. 3-4
2.1 Console Box ............................................................................................................3-4
2.2 Main Electrical Components....................................................................................3-6
2.3 Table of Lamps......................................................................................................3-17
3. Console Box .......................................................................................... 3-18
3.1 Disassembly ..........................................................................................................3-18
4. Battery Maintenance............................................................................. 3-19
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment.....................3-19
4.2 Specific Gravity Reading and State of Charge......................................................3-19
4.3 Charging Precautions............................................................................................3-19
5. Instrument Panel................................................................................... 3-20
5.1 Instrument Panel Screen Components..................................................................3-20
5.2 Basic Screen Display.............................................................................................3-21
5.3 Basic Operation.....................................................................................................3-24
5.4 When an Error Occurs...........................................................................................3-29
5.5 Warning Lamps .....................................................................................................3-31
5.6 Optional Functions.................................................................................................3-32
5.7 Hour Meters...........................................................................................................3-39
5.8 Troubleshooting.....................................................................................................3-41
6. Wire Color.............................................................................................. 3-42
6.1 List of Wire Colors .................................................................................................3-42
7. Troubleshooting.................................................................................... 3-43
7.1 Starter System.......................................................................................................3-43
7.2 Gauges..................................................................................................................3-43
7.3 Lighting System.....................................................................................................3-44
8. Electrical Schematic ............................................................................. 3-46

3-1
ELECTRIC SYSTEM
Chapter 3 ELECTRIC SYSTEM
1. Chassis Electrical Devices Wiring Outline
1.1 Gasoline Model
215355
Rear combination lamp
Rear combination harness
Seat switchSeat
To armrest
(FC model only)
Back-up buzzer
Thermoswitch
Battery
To starter
To engine harness
ECM (Engine control module)
To engine harness
Earth
Relay box
Fuse box
Battery cable (+)
Battery cable (-)
Transmission
control solenoid
Stop lamp switch
Head lamp
Instrument panel
Harness B
Front
combination lamp
Front
combination harness
VCM
(Vehicle control module)
OCM
(Option control module)
(Wet disc brake only)

3-2
ELECTRIC SYSTEM
1.2 Diesel Model
215356
OCM
(Option control module)
Instrument panel
Head lamp
Front
combination lamp
Front
combination harness
Harness B
Stop lamp switch
Transmission
control solenoid
Relay box
DCM
(Diesel control module)
Fuse box
Battery cable (-)
Earth
Battery
Battery cable (+)
To starter
Thermoswitch
(Sending unit)
Back-up buzzer
To armrest
(FC model only)
Seat switch
Seat
Rear combination harness
Rear combination lamp
Glow relay
Glow timer

3-3
ELECTRIC SYSTEM
1.3 Gasoline and Diesel Models
215357
Instrument panel
Combination switch
Select switch
Parking brake switch
Horn harness
Horn
Warning buzzer Key switch
Control valve
Output unit
Output harness
Control valve
Parking brake valve
Parking brake
pressure switch
Harness
FC control lever
Input unit
Thermoswitch (T/C oil)Speed sensor
MC FC
Console Box
Control valve
Transmission
FC Armrest

3-4
ELECTRIC SYSTEM
2. Structure
2.1 Console Box
1 Water temperature gauge
2 Fuel gauge
3 Hour meter, warning lamps
4 Instrument panel
5 Key switch
6 Light switch, turn signal switch
7 Direction Lever
8 Speedometer
214140
N
2
4 38 1
6
7
5

3-5
ELECTRIC SYSTEM
2.1.1 Function of Instrument Panel
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.
Ref. Name of indicators and warning lamps When turned off When glows or blinks Remark
A Parking brake warning lamp Normal
This lamp glows when the parking
brake is applied.
-
B Seat belt warning lamp Fastened
This lamp glows when the seat belt is
not fastened.
-
C Charge warning lamp Normal charging
This lamp glows when charging is not
normal.
(This lamp glows all the time while
the engine is stopped.)
-
D Multi-purpose warning lamp Normal
This lamp glows when a minor failure
occurs or operating cautions are
issued.
-
E
Torque converter oil temperature warn-
ing lamp
Normal temperature
This lamp glows when the torque con-
verter 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 accel-
eration or full reverse (shifting of
travel to the opposite direction) acti-
vates protective function.
Option
J Mast interlock indicator lamp -
When mast interlock is activated
(glows)
-
K Cursor buttons - - -
L Fuel gauge Indicates remaining fuel amount with key in "ON" position -
M LCD screen - - -
N Water temperature gauge Indicates water temperature with key in "ON" position -
O Enter/display switch button - - -
214141
A B C D E F G H I J K
L M N O

3-6
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 auto-
matic 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 pre-
vents 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 electri-
cally connected to the engine so that the | (ON) key
switch position turns on the glow plugs.
Connection Table
215358
ST M
G B
(OFF)
(ON)
(START)
Terminal G B M ST Key in and out
OFF Yes
ON (when operating) ○--------- -----------○ No
START
(when starting engine)
○--------- -----------○----------- -----------○ No

3-7
ELECTRIC SYSTEM
2.2.2 Combination switch
(1) Light switch, turn signal switch
215359
Power Power
Tail,
clearance lamp
Head lamp
L - 1 L - 2 L - 3 L - 4
T - 1
Turn signal switch connector
Terminal
Target
Knob position
Terminal
Target
Lever position
Flash unit
Turn signal
lamp (Right)
Turn signal
lamp (Left)
R (Right)
N (Neutral)
L (Left)
OFF
1
2
3
T - 2 T - 3
Horn contact
T-1
T-3
L-2
L-4
T-2
L-1
L-3
Light switch
turn signal switch connector
Light switch connector
Forward of truck
Light switch
turn signal lever
L
N
R
OFF 1
2
3
10°10°
25° 25° 25°
OFF

3-8
ELECTRIC SYSTEM
(2) Direction switch
215360
10°10°
F
N
R
Forward-reverse selector lever (FNR)
Forward of truck
Forward-reverse
shift change switch (FNR)
4
2
3
1
5
Connection table
F (Forward)
N (Neutral)
R (Reverse)
L/B
1 2 3 4 5Terminal
Lever position
Wire color
B BL/R L/W
OFF

3-9
ELECTRIC SYSTEM
2.2.3 Horn
Check that the horn activates when applying the spec-
ified voltage to both terminals of the horn, T1 and T2.
Replace the horn if it does not activate or its sound is
unusual.
Operating voltage: DC12V (Gasoline and diesel mod-
els)
Note: The proper installation of the horn to the lift
truck is shown in the illustration.
2.2.4 Tank unit
215361
Vent hole
Up
Down
Contact
Coil
T1
T2
T1
T2
215362
F
3/4
242.7mm
(9.56in.)
61.2mm
(2.41in.)
424.2mm
(16.7in.)
1/2
Illustration shows gasoline model.
Pressure relief valve
Fuel pump
Fuel filter
Fuel suction strainer
The number in parenthesis is a reference value.
E
1/4
E 1/4 1/2 3/4 F
Referential Standards
Float position
Standard resistance value (Ω)
Tolerance (Ω)
80 (49.5) 32 (19) 10
– –
+12
+2
±3
+1.0
- 0.5

3-10
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.
Measure the insulation resistance value across the ter-
minals when the push rod is pushed in.
Replace the stop lamp switch if its measured insula-
tion resistance value is less than the value below.
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).
(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.
Insulation resistance value
1 M Ω or more
(at 500 V megger)
215363
M10×1.25
OFF ON
2 mm
(0.08 in.)
4 mm
(0.16 in.)
Push rod
215364
Terminal
Body
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)
Standard resis-
tance value (Ω)
80 ± 10 67 ± 7.8 40.6 ± 3.7 22.2 ± 1.4 11.3 ± 0.4 10 ± 0.3
Diesel model
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 resis-
tance value (Ω)
(80) 56.3 ± 5 (29.5) (16.5) 14.3 ± 0.5 (10)

3-11
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.
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.
2.2.8 Parking brake switch
Measure the insulation resistance between each ter-
minal.
(1) Parking switch at pulled position
(2) Parking switch at pushed position
Operation method: Push-pull operation
Contact resistance: 1a-ab
Insulation resis-
tance value
1 M Ω or more
(with contact point OFF)
(with 500 V megger)
Tightening torque
31.4 to 47.1 N·m
(3.2 to 4.8 kgf·m)
[23.2 to 34.8 lbf·ft]
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
215365
Terminal Body
Between terminals B and W
Insulation
resistance
100 M Ω or more (at 500 V megger)
Between terminals B and R
Insulation
resistance
100 M Ω or more (at 500 V megger)
215366
P
W B R
6 mm (0.24 in.) (Stroke)
PushPull

3-12
ELECTRIC SYSTEM
2.2.9 Relay box
215367
Relay box 2
(Gasoline model only)
Relay box 1
Illustration shows gasoline model
Relay box 1 Relay box 2
(Gasoline model only)
Warning buzzer relay
Flasher relay
Starter relay
Back-up lamp relay
Ignition relay
Fuel pump relay
ETC motor relay
EGI relay
MAIN/C relay
EGI relay

3-13
ELECTRIC SYSTEM
(1) Relay box 1
CB relay (Ignition relay, back-up lamp relay, and
starter relay)
CM relay (Warning buzzer relay)
Coil rating [at 20°C (68°F)]
Item
Truck model
Gasoline and diesel models
Rated operating voltage 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 168 mA ± 10%
215368
Connection diagram
(Bottom view)
z
X
Y
Item
Truck model
Gasoline and diesel models
Working voltage DC 30 to 7 V
Open-circuit voltage DC 0.5 to 3.1 V
Rated exciting current 117.6 mA ± 10%
215370
Connection diagram
(Bottom view)
z
X
Y

3-14
ELECTRIC SYSTEM
(2) Relay box 2 (gasoline models only)
CM relay (EGI relay, MAIN/C relay, ETC motor relay,
and fuel pump relay)
Item
Truck model
Gasoline model
Working voltage DC 30 to 7 V
Open-circuit voltage DC 0.5 to 3.1 V
Rated exciting current 117.6 mA ± 10%
215370
Connection diagram
(Bottom view)
z
X
Y

3-15
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 termi-
nal 3 for 6 seconds. Replace the glow timer with a new
one if it does not function properly.
Initial characteristic (Normal temperature and humidity,
Vcc=12 V)
Preglow timer 6.0 ± 0
1.4
sec
Environmental characteristic (-30°C to 70°C, Vcc=7 V
to 15 V)
Preglow timer 6.0 ± 0.6
2.0
sec
2.2.11 Glow relay (diesel model)
(1) Apply an ohmmeter across terminal 3 and termi-
nal 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 stan-
dard resistance value.
(2) Measure the insulation resistance value between
terminal 1 and terminal 2.
Replace the coil if its measured insulation resis-
tance value is less than the value below.
Rated voltage: DC12V
215371
Controller
Key switch
ON
ST
OFF
Glow
relay
LampGlow
plug
5 4
6
3Battery
DC12V
Connection diagram
5
3
6
4
Coil resistance 13 Ω
Insulation resistance value
1 M Ω or more
(at 500 V megger)
215372
3
4
1
2
1
2
3
4
Connection diagram

3-16
ELECTRIC SYSTEM
2.2.12 Fuse box
215373
Fuse box
*1: Gasoline model only
*2: Diesel model only
Instrument panel
10A
Glow timer
10A
VCM
20A
10A
15A
EGI
30A
EGI
30A
Working lamp
15A
ETC
15A
20A 30A
15A
Spare
Spare
20A
Wiper
15A
Head lamp
15A
Horn
10A
Stop lamp
10A
Fuse puller
SBF 50A
Glow
SBF 100A
Alternator
SBF 100A
*1
A/C
*1 *1
*2
Illustration shows diesel model
Back-up lamp
Battery

3-17
ELECTRIC SYSTEM
2.3 Table of Lamps
Item Quantity Lens color
Valve
Remark
Illustration
Type of
lamps
Head lamp 2 Colorless Standard
Combination
lamp (front)
Turn signal
lamp
2 Amber
Standard
(Installed to
head guard)
Clearance
lamp
2 Amber
Combination
lamp (rear)
Turn signal
lamp
2 Amber Standard
Tail and
stop lamp
2 Red Standard
Back-up
lamp
2 Colorless Standard

3-18
ELECTRIC SYSTEM
3. Console Box
3.1 Disassembly
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.
216938
5
2
4
3
1

3-19
ELECTRIC SYSTEM
4. Battery Maintenance
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
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
45°C (113°F).
(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.
Specific gravity reading
at 20°C (68°F)
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
Recharge battery to adjust electrolyte S.G. Check for any
short-circuited cables or corroded cable connections in the
electrical system.
1.220 (0.2) or less Battery low (caution required)
Recharge battery.
If the difference in S.G. is too much, charge the battery to
adjust the electrolyte S.G.
If the difference in S.G. is
more than 0.040.
A cell with a low S.G. may
cause a short circuit.
It is caused when electrolyte
leaks or electrolyte rate is too
high or too low.
Recharge the battery until its voltage and S.G. stabilize and
remain constant for more than 2 hours.
Charge the battery to adjust the electrolyte S.G. It should read
between 1.280 and 1.265.
If the difference in S.G. is more than 0.040 and a low S.G. is
found in any of the cells, replace the battery with a new one.
Conduct a high current discharge test after leaving the battery
for 12 to 96 hours.
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
+
55D23L (Gasoline)
130E41L (Diesel)
Identification

3-20
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.
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.
Note: The instrument panel has functions below to
protect circuits in the panel.
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 dis-
play is slower.
Warning lamps button
button
LCD screen Enter/display switch button
(Ο button)
215114
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.
Fuel gauge Main display Water temperature
gauge
Travel
direction
Symbol mark
(Optional feature)
Time/hour meter
display
215115

3-21
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 press-
ing 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.
(2) Password authentication screen
(Optional function)
Inputting the registered password in advance
enables an operator to operate the lift truck.
(3) Standard display screen
The screen shows the conditions of the lift truck.
215116
215117
215118

3-22
ELECTRIC SYSTEM
5.2.2 Speed meter display
This display shows current lift truck speed.
Note:
Speed display value is rounded to a higher number.
5.2.3 Fuel gauge
This gauge shows the remaining amount of fuel (gaso-
line or diesel fuel). It shows the remaining amount of
fuel just after the key switch is turned to the ON posi-
tion. After that, the remaining amount is displayed for 2
minutes on average.
Note:
Note: LPG dual fuel truck shows gasoline remaining
amount only.
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)
Speed meter display
215119
E (Empty) remaining amount
Truck model Remaining amount
4.0 to 5.5 ton
14.3 liter
(872.6 cu.in.)
or less
Fuel gauge
With fuel gauge image
Without fuel gauge image (LE models) 215120

3-23
ELECTRIC SYSTEM
5.2.4 Water temperature display
This display shows engine coolant temperature.
Note: The graph below shows the relation between
engine coolant temperature and water tempera-
ture gauge shown on the LCD.
Water temperature gauge
215121
50
40
30
20
10
0
100 20 30 40 50 60 70 80 90 100 110 120 130
44 dots
29 dots
Engine coolant temperature - the number of dots in the gauge
Diesel model
Gasoline model
Range of overheating (red zone)
Pertinent range of temperature (rough standard for diesel/gasoline model)
Overheat (red zone) temperature
215122
Numberofdotsinthegauge(Dots)
Engine coolant temperature (°C) [°F]
(°C)
0 50 68 86 104 122 140 158 176 194 212 230 248 266 (°F)
Range displayed on
LCD screen (50 to 120°C)
[122 to 248°F]
• Diesel model: Approx. 109 °C (228.2 °F) or higher
• Gasoline model: Approx. 107 °C (224.6 °F) or higher

3-24
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.
Note: Travel direction display changes to the signals
from the direction lever.
5.3 Basic Operation
5.3.1 How to use operation buttons
There are three types of manual operation buttons:
button, button, and button, which are
located on the right side of the instrument panel. The
operation of each button varies with the item being dis-
played 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.
Travel direction
215123
0.5sec 0.5sec
215377
Forward Reverse Neutral
Travel interlock indication (powershift truck)
215125
button
button
button

3-25
ELECTRIC SYSTEM
5.3.2 How to adjust the screen contrast
Turn the key switch to the ON position. Screen con-
trast can be adjusted while the engine is running.
Note: The screen becomes dark when the tempera-
ture inside the instrument panel (ambient tem-
perature) is high, and the screen becomes light
when the temperature is low.
5.3.3 How to display the clock time
trast can be adjusted while the engine is running. With
a short press of the button, the display alternately
changes between the hour meter and the clock time.
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
Short
Light → Dark
Dark → Light
Short Hour meter ←→ clock
(with clock time
display)
Long
12-hour mode display
←→24-hour mode display
Time/hour meter
215126

3-26
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).
(3) Select time adjust mode and unit adjust mode.
(4) Time unit adjustment
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
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.
Short Clock time blink
Long Time unit adjust mode
Blinking
215127
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 min-
ute adjust mode.
Digits to be adjusted is blinking
215128
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.
Digits to be adjusted is blinking
215129

3-27
ELECTRIC SYSTEM
5.3.5 How to display the hour meter
trast can be adjusted while the engine is running. With
a short press of the button, the display alternately
changes between the clock time and the hour meter.
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.
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.
Note: • When six minutes have passed, 0.1 hour is
added.
• Warranty is terminated based on the key-on
time.
Short Clock ←→ hour meter
Hour meter
215130
Long
Key-on time
↓
Engine-on time
↓
Seat switch-on time
Key-on time display
Engine-on time display
Seat switch-on time display
215131

3-28
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.
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.
Note: Use the service tool to erase the error message
being displayed.
To change the error code display, operate the
or the button.
A long press on the three buttons at the same time
returns to the standard display screen.
The illustration shows the error history screen 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.
Multiple Error history
215125
button
button
button
Short
Old → New
New → Old
Multiple Standard display screen
Error history display
With , buttons,
error record on the
display changes.
Error history Hour meter Error code
215133
When there is no error record
215134

3-29
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 solv-
ing 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 fail-
ures, serious failures, and minor failures.
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
is reversed. Also all warning lamps shown in the figure
(right) will blink.
When an engine failure occurs, the error code alternately
changes between black characters on a white background
and white characters on a black background.
Engine warning lamp glows
215135
Warning lamps within the dotted line boxes blink
215136
When a serious failure occurs, the error code alternately
changes between black characters on a white background
to white characters on a black background.

3-30
ELECTRIC SYSTEM
5.4.3 When a minor failure occurs
is reversed. Also the multi-purpose warning lamp
glows.
Note: The minor failure display is also shown when
the fuel gauge reaches the empty level (E).
5.4.4 Error symbols
Error symbols displayed in the main area are as follows:
Multi-purpose warning lamp glows
The error code and
symbol alternately
change between black
characters/lines on a
white background to
white characters/lines
on a black background.
215137
Symbol 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)

3-31
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 warn-
ing 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.
Charge warning
lamp
Red
This lamp glows when charging is not nor-
mal.
(Glows/the lamp glows all the time while the
engine is stopped)
Multi-purpose warn-
ing lamp
Red
This lamp glows when a minor failure occurs
or operating cautions are issued.
Torque converter oil
temperature warn-
ing 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 pres-
sure is low.
(Glows/the lamp glows all the time while the
engine is stopped)
Engine warning
lamp
Amber This lamp glows when the engine is failed.
Electronic control gaso-
line engine models
(Standard)
Glow pilot indicator
lamp
Amber
This lamp glows when the glow plug heating
is ON.
Diesel engine models
(Standard)
Flex control indicator
lamp
Amber
This lamp glows when sudden acceleration
or full reverse (shifting of travel to the oppo-
site direction) activates protective function.
Option
Mast interlock indi-
cator lamp
Amber When mast interlock is activated (glows) All models (Standard)

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MITSUBISHI FG55N FORKLIFT TRUCKS Service Repair Manual SN: EF33C-80001-UP

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