This is the Highly Detailed factory service repair manual for theMITSUBISHI FGE15N FORKLIFT TRUCKS, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.MITSUBISHI FGE15N FORKLIFT TRUCKS Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: Chassis and Mast: Foreword Chassis and Mast: General Information Chassis and Mast: Cooling System Chassis and Mast: Electrical System Chassis and Mast: Electrical Schematics Chassis and Mast: Controllers Chassis and Mast: Power Train Chassis and Mast: Clutches Chassis and Mast: Manual Transmission Chassis and Mast: Power shift Transmission Chassis and Mast: Front Axle and Reduction Differential Chassis and Mast: Rear Axle Chassis and Mast: Brake System Chassis and Mast: Steering System Chassis and Mast: Hydraulic System Chassis and Mast: Mast and Forks Chassis and Mast: Service Data Engine: K15, K21, K25 Gasoline: Foreword Engine: K15, K21, K25 Gasoline: General Information Engine: K15, K21, K25 Gasoline: Maintenance Engine: K15, K21, K25 Gasoline: Tune up Engine: K15, K21, K25 Gasoline: Mechanical Engine: K15, K21, K25 Gasoline: Control Engine: K15, K21, K25 Gasoline: Lubrication and Cooling Engine: K15, K21, K25 Gasoline: Fuel Engine: K15, K21, K25 Gasoline: Electrical File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveMITSUBISHI FGE15N FORKLIFT TRUCKS Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!

1. 99719-18100
For use with S4Q2, S4S and K15/K21/K25 Engine
Service Manuals.
FG10N F25C-05001-up
FG15N F25C-55001-up
FG15ZN F34-52001-up
FG18N F25C-75001-up
FG18ZN F34-72001-up
FG20CN F34-22001-up
FG20N F17D-10001-up
FG20ZN F35-10001-up
FG25N F17D-60001-up
FG25ZN F35-60001-up
FG30N F13F-40001-up
FG35AN F13F-60001-up
FD10N F16D-04001-up
FD15N F16D-54001/64001-up
FD18N F16D-74001/84001-up
FD20CN F16D-24001/28001-up
FD20N F18C-20001/40001-up
FD25N F18C-70001/90001-up
FD30N F14E-10001/20001-up
FD35AN F14E-80001/90001-up
FGE15N F34-00001/19001-up
FGE18N F34-40001/49001-up
FGE20CN F34-30001/39001-up
FGE20N F17D-20001/38001-up
FGE20ZN F35-20001/38001-up
FGE25N F17D-70001/88001-up
FGE25ZN F35-70001/88001-up
FGE30N F13F-10001/20001-up
FGE35AN F13F-80001/90001-up
Chassis & Mast MC/FC
Service Manual

2. 1
Pub. No. 99719-18100
FOREWORD
This service manual is a guide for servicing Mitsubishi forklift trucks. For your convenience the instructions are
grouped by systems as a ready reference.
The long productive life of your lift truck(s) depends on regular and proper servicing. Servicing consistent with what
you will learn by reading this service manual.
Read the respective sections of this manual carefully and familiarize yourself with all of the components before
attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks with serial numbers in effect
at the time of printing.
Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring
obligations.
The trucks listed in this manual are powered by K15, K21 or K25 gasoline engines or S4Q2/S4S diesel engines.
For engine servicing, please refer to the applicable engine service manual.
K15, K21 or K25 Gasoline engine
S4Q2, S4S Diesel engine
<Safety Related Signs>
Indicates a specific potential hazard resulting in serious
bodily injury or death.
Indicates a potentially hazardous situation which, if not
avoided, may result in death or serious injury or damage to
the machine.
Indicates a condition that can cause damage to, or shorten
service life of, the machine.
WARNING
CAUTION
NOTE

3. 3
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.
WARNING WARNING

4. 4
(13)Disconnect battery and discharge any capacitors
(electric trucks) before starting to work on truck.
Hang “Do not Operate” tag in the Operator’s Com-
partment.
(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.

5. 5
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
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)
213443
MC Truck
FC Truck
Lever
Control valve
FC lever box
VCM Controller
Electric wiring
Electromagnetic control valve
Flow regulator valve
Output unit
Input unit

6. 6
HOW TO USE THIS MANUAL (continued)
(Removal, Installation, Assembly and Disassembly)
Disassembly diagram (example)
Suggestions for Disassembly
Output shaft, Removing
Remove output shaft using a special tool.
A: Standard value
B: Repair or Service Limit
1
2
213445
Sequence
1 Cover, Bolt, Washer (part name)
2 Snap ring (part name)
213446
Service Data
Gear Backlash
A 0.11 to 0.28 mm
B 0.5 mm

7. 7
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

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

9. 1
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

10. 1-1
GENERAL INFORMATION
Chapter 1 GENERAL INFORMATION
1. Model View
213447
MC truck
213448
FC truck

11. 1-2
GENERAL INFORMATION
2. Truck Models Covered
This Service Manual provides servicing and maintenance information for the following trucks:
(FC type is used in torque converter model only.)
Note: Characters at the end of truck model should be read as follows:
(F) : FC Truck
None : MC Truck
Z : High-power engine model
C : Short wheel base model
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 -
Truck type
Electric controlled gasoline engine,
Electric controlled dual fuel gasoline/
LPG engine models
Non-electric controlled diesel engine models
Non-electric controlled gasoline engine,
Non-electric controlled dual fuel gasoline/
LPG engine models
Truck model Serial number
Engine
mounted
Truck model Serial number
Engine
mounted
1 ton class
FG10N F25C-05001 to K15 FD10N F16D-04001 to S4Q2
FG15N F25C-55001 to K15 FD15N F16D-54001 to S4Q2
FG15ZN F34-52001 to K21 FD15N(F) F16D-64001 to S4Q2
FGE15N F34-00001 to K21E FD18N F16D-74001 to S4Q2
FGE15N(F) F34-19001 to K21E FD18N(F) F16D-84001 to S4Q2
FG18N F25C-75001 to K15 FD20CN F16D-24001 to S4Q2
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 - - -
2 ton class
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 - - -
3 ton class
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 - - -

12. 1-3
GENERAL INFORMATION
3. Serial Number Locations
213449
Chassis Serial NumberName Plate Gasoline Engine Serial Number
Diesel Engine Serial Number
(2, 3 ton classes)
Diesel Engine Serial Number
(1 ton class and FD20N–25N)
Transmission Serial Number
(Powershift Transmission Truck)
Transmission Serial Number
(Manual Transmission Truck)
Mast Serial Number

13. 1-4
GENERAL INFORMATION
4. Dimensions
213450
A
B
H
J
E
D N
P
M
F
I
L
O
KCG

14. 1-5
GENERAL INFORMATION
5. Technical Data
Unit: mm
Truck model
class 1 ton class
Gasoline-
engine truck
FG10N FG15N FG18N FG20CN
FGE15N FGE18N FGE20CN
FG15ZN FG18ZN
Diesel-engine
truck
FD10N FD15N FD18N FD20CN
A Maximum lift 3000 3000 3000 3000
B Free lift height 115 115 115 120
C Fork spread 200 to 920 200 to 920 200 to 920 220 to 920
D Fork length 770 920 920 920
E Tilt angle (forward – backward) 6-12 6-12 6-12 6-12
F Overall length 2980 3180 3220 3280
G
Overall width
(outside-to-
outside of tires)
Single 1065 1065 1065 1065
Double 1330 1330 1330 -
H Overall height (with mast lowered) 1990 1990 1990 1990
I Height of the overhead guard 2065 2065 2065 2065
J Overall height (with mast extended) 4055 4055 4055 4055
K
Tread
(front wheel)
Single 890 890 890 890
Double 1025 1025 1025 -
L Tread (rear wheel) 900 900 900 900
M Wheel base 1400 1400 1400 1400
N Front overhang 400 400 400 415
O Minimum turning radius 1910 1950 1980 2020
P
Under clearance
(at center of frame)
150 150 150 150

15. 1-6
GENERAL INFORMATION
Unit: mm
Truck model
class 2 ton class 3 ton class
Gasoline-
engine truck
FG20N FG25N FG30N FG35AN
FGE20N FGE25N FGE30N FGE35AN
FG20ZN FG25ZN
FGE20ZN FGE25ZN
Diesel-engine
truck
FD20N FD25N FD30N FD35AN
A Maximum lift 3000 3000 3000 3000
B Free lift height 140 145 145 145
C Fork spread 220 to 1000 220 to 1000 250 to 1000 250 to 1000
D Fork length 920 920 1070 1070
E Tilt angle (forward – backward) 6-12 6-12 6-12 6-12
F Overall length 3410 3625 3795 3860
G
Overall width
(outside-to-
outside of tires)
Single 1150 1150 1275 1290
Double 1480 1480 1490 1490
H Overall height (with mast lowered) 1990 1990 2015 2130
I Height of the overhead guard 2074 2074 2093 2103
J Overall height (with mast extended) 4055 4055 4055 4055
K
Tread
(front wheel)
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
P
Under clearance
(at center of frame)
160 160 190 200

16. 1-7
GENERAL INFORMATION
6. Performance
Truck
model
class 1 ton class
Gasoline-
engine truck
FG10N FG15N FG18N FG20CN
FGE15N FGE18N FGE20CN
FG15ZN FG18ZN
Diesel-engine
truck
FD10N FD15N FD18N FD20CN
Capacity kg 1000 1500 1750 2000
Load center mm 500 500 500 500
Lift speed
Loaded mm/s
490 (FG10N)
490 (FG15N)
630 (FGE15N)
570 (FG15ZN)
490 (FG18N)
630 (FGE18N)
570 (FG18ZN)
570 (FG20CN)
630 (FGE20CN)
630 (FD10N) 630 (FD15N) 630 (FD18N) 630 (FD20CN)
Unloaded mm/s
560 (FG10N)
560 (FG15N)
650 (FGE15N)
650 (FG15ZN)
560 (FG18N)
650 (FGE18N)
650 (FG18ZN)
650 (FG20CN)
650 (FGE20CN)
690 (FD10N) 690 (FD15N) 690 (FD18N) 690 (FD20CN)
Travel speed
(Powershift
Truck)
Loaded km/h 19.0 19.0 19.0 19.0
Unloaded km/h 19.5 19.5 19.5 19.5

17. 1-8
GENERAL INFORMATION
Truck
model
class 2 ton class 3 ton class
Gasoline-
engine truck
FG20N FG25N FG30N FG35AN
FGE20N FGE25N FGE30N FGE35AN
FG20ZN FG25ZN
FGE20ZN FGE25ZN
Diesel-engine
truck
FD20N FD25N FD30N FD35AN
Capacity kg 2000 2500 3000 3500
Load center mm 500 500 500 500
Lift speed
Loaded mm/s
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)
Unloaded mm/s
600 (FG20N)
590 (FGE20N)
660 (FG20ZN)
660 (FGE20ZN)
600 (FG25N)
590 (FGE25N)
660 (FG25ZN)
660 (FGE25ZN)
530 (FG30N)
530 (FGE30N)
450 (FG35AN)
440 (FGE35AN)
660 (FD20N) 660 (FD25N) 530 (FD30N) 450 (FD35AN)
Travel speed
(Powershift
Truck)
Loaded km/h 19.0 19.0 19.0 19.0
Unloaded km/h 19.5 19.5 19.5 19.5

18. 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
3.2 Suggestions for Removal ........................................................................................2-3
3.3 Installation ...............................................................................................................2-4
4. Inspection and Adjustment.................................................................... 2-5
4.1 Fan Belt Inspection..................................................................................................2-5
4.2 Fan Belt Tension .....................................................................................................2-5
4.3 Connecting Hoses ...................................................................................................2-5
4.4 Unit Layout ..............................................................................................................2-6
4.5 Coolant ....................................................................................................................2-6
4.6 Radiator Cap ...........................................................................................................2-6

19. 2-1
COOLING SYSTEM
Chapter 2 COOLING SYSTEM
1. Specifications
Items
Truck type
1 ton class 2 ton class 3 ton class
Cooling system
Cooling method Water-cooled, forced circulation
Radiator Corrugated fin (pressure) type
Water pump Centrifugal type
Thermostat Wax pellet type

20. 2-2
COOLING SYSTEM
2. Structure
213451
S4Q2
S4S
Hose layout
S4Q2 engine
K15, K21,
K25 engines
S4S engine
Lower hose
Shroud
Upper hose
Radiator
Reservoir tank
K15, K21, K25
Fan (directly coupled to engine)

21. 2-3
COOLING SYSTEM
3. Removal and Installation
3.1 Fan Belt Removal
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.
1 Tension pulley assembly, bolt
2 Belt
213452
Engine
Fan
21
213453
Tension
pulley
Fan

22. 2-4
COOLING SYSTEM
3.3 Installation
To install, follow the removal sequence in reverse.
Also follow the instructions given below.
(1) Before installing the belt, turn the fan to check for
smooth rotation. Replace the bearing if it gener-
ates abnormal sound.
(2) After installing the belt, push it to make sure that
the tension pulley moves, then tighten the pulley
lock bolt firmly.

23. 2-5
COOLING SYSTEM
4. Inspection and Adjustment
4.1 Fan Belt Inspection
(1) Check the belt for contamination from oil, grease
or dust. Replace the belt if required. When the
contamination is slight, clean the belt with a rag or
paper towel. Do not use gasoline, oil or any other
solvent to clean the belt.
(2) During the engine overhaul or belt tension adjust-
ment, check the condition of the belt. Replace the
belt if it has any damage.
4.2 Fan Belt Tension
Apply a force of 98 N (10 kgf) perpendicularly to the
belt at a point midway between the fan pulley and ten-
sion pulley. Adjust the belt tension between 11 to 13
mm.
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.
213454
Tension
pulley
Fan pulley
213455
Hose

24. 2-6
COOLING SYSTEM
4.4 Unit Layout
4.5 Coolant
Fill the radiator with coolant containing antifreeze.
After starting the engine and letting it warm up during
operation, check for abnormal noises. Check the cool-
ant level in the reserve tank to ensure it meets the
specification.
4.6 Radiator Cap
213456
Coolant quantity
Item
Truck type
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
Opening pressure 88±14.7 kPa
Vacuum valve 0 to 4.9 kPa

25. 3
Chapter 3 ELECTRIC SYSTEM
1. Chassis Electrical Devices Wiring Outline ........................................... 3-1
1.1 (One) .......................................................................................................................3-1
1.2 (Two) .......................................................................................................................3-2
2. Structure .................................................................................................. 3-3
2.1 Console Box ............................................................................................................3-3
2.2 Major Electrical Components...................................................................................3-5
2.3 Table of Lamps......................................................................................................3-15
3. Console Box .......................................................................................... 3-16
3.1 Disassembly ..........................................................................................................3-16
4. Battery Maintenance............................................................................. 3-17
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment.....................3-17
4.2 Specific Gravity Reading and State of Charge......................................................3-17
4.3 Charging Precautions............................................................................................3-17
5. Instrument Panel................................................................................... 3-18
5.1 Instrument Panel Screen Element.........................................................................3-18
5.2 Basic Screen Display.............................................................................................3-19
5.3 Basic Operation.....................................................................................................3-22
5.4 When an Error Occurs...........................................................................................3-28
5.5 Warning Lamps .....................................................................................................3-30
5.6 Optional Functions.................................................................................................3-31
5.7 Hour Meters...........................................................................................................3-38
5.8 Troubleshooting.....................................................................................................3-40
6. Wire Color.............................................................................................. 3-41
6.1 List of Wire Colors .................................................................................................3-41
7. Troubleshooting.................................................................................... 3-42
7.1 Starter System.......................................................................................................3-42
7.2 Gauges..................................................................................................................3-42
7.3 Lighting System.....................................................................................................3-43
8. Electrical Schematic ............................................................................. 3-45

26. 3-1
ELECTRIC SYSTEM
Chapter 3 ELECTRIC SYSTEM
1. Chassis Electrical Devices Wiring Outline
1.1 (One)
213457
Harness, front
combination
Harness, front
combination
Main harness
Harness, rear
combination

27. 3-2
ELECTRIC SYSTEM
1.2 (Two)
213458
Clip
VCM(Vehicle control module)
ECM
(Gasoline
engine control
module)
DCM
(Diesel engine
control module)
Key
Starter switch
Transmission
Back buzzer
Harness,
rear combination
Battery seat
Fuse box, Fuse
Harness, front
combination
Relay box, RelayVehicle speed sensor
(Pulse generator)
Horn
GLE Connector
Connector
bracket
GSE Connector
Harness, front
combination
Main harness
Warning buzzer
Select switch
Output unit
Input unit
QGS Controller

28. 3-3
ELECTRIC SYSTEM
2. Structure
2.1 Console Box
1 Water temperature gauge
2 Fuel gauge
3 Hour meter, various warning lights
4 Instrument panel
5 Starter switch
6 Lighting switch, turn signal switch
7 Forward-reverse lever
214140
N
2
4 3 1
6
7
5

29. 3-4
ELECTRIC SYSTEM
2.1.1 Function of Instrument Panel
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.
Ref. No.
Name of indicators and warning
lamps
When turned off When glows or blinks Remark
A Parking brake warning lamp Normal
When parking brake is applied
(glows)
-
B Seat belt warning lamp Fastened
When seat belt is not fastened
(glows)
-
C Charge warning lamp Normal charging
When charging is not normal
(glows / When engine is not run-
ning always glows)
-
D Multi-purpose warning lamp Normal
When a minor failure occurs or
operating caution is being issued
(glows)
-
E
Torque converter fluid temperature
warning lamp
Normal temperature
When torque converter fluid tem-
perature is not normal (glows)
-
F Engine oil pressure warning lamp Normal
When engine oil pressure is low
(glows / When engine is not run-
ning always glows)
-
G Engine warning lamp Normal When the engine is failed (glows) -
H Glow pilot lamp Preheating completed When the grow plug is ON (glows) -
I Smart shift indicator lamp -
When protective function of sud-
den acceleration/full reverse
(shifting in the opposite direction of
traveling) is activated (glows)
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

30. 3-5
ELECTRIC SYSTEM
2.2 Major Electrical Components
2.2.1 Starter switch
The diesel-engine truck, which uses a distributor type
injection pump, is provided with an engine automatic
stop mechanism of the starter switch fuel cut system.
The gasoline-engine truck is also provided with an
engine automatic stop mechanism of the fuel cut sys-
tem.
(Starter switch with Anti-Restart Lock)
This starter switch has an anti-restarting function.
This switch has a built-in anti-restart lock, so the key
cannot be turned from (ON) to (START) position
while the engine is running. This prevents starter
breakage or flywheel damage caused by an operator
restarting the truck when the engine is running.
The gasoline- and diesel-engine models use the same
starter switch. In the diesel -engine models, the l (ON)
position of the switch is for energizing the glow plugs.
Connection Table
B
MST
G
213459
(OFF)
(ON)
(START)
For gasoline truck (12V)
Terminal G B M ST Key in and out
OFF Yes
ON (when operating) ○--------- -----------○ No
START
(when starting engine)
○--------- -----------○----------- -----------○ No

31. 3-6
ELECTRIC SYSTEM
2.2.2 Lighting switch, turn signal switch
213460
T-3 L-2
L-4
L-5
L-3L-1
T-2
T-1
421
3 5
4
2
31
5
Light switch/
turn signal lever
Front
Direction lever
Wheel angle sensor
Light switch/
turn signal switch
Horn contact
Horn
Wheel angle sensor connector
Shift change switch
(F, N, R)
Forward of truck
Boot
Horn contact
Boot
Lighting switch,
turn signal switch
Lighting switch,
turn signal switch
Forward-reverse
selector switch

32. 3-7
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
abnormal.
Operating voltage: DC12V
(Gasoline and diesel trucks)
Note:The installed position is that of an actual truck as
shown in the illustration.
2.2.4 Tank Unit
213463
T1
T2
Up
Down
Contact
Coil
Vent hole
213464
3/4
1/4
Referential Standards
Tolerance (ohm)
E 1/4 1/2
+12
+2
3/4 F
80 49.5 32 19 10
±3
+1.0
-0.5
E
F
1/2
Fuel pump Pressure relief
valve
Fuel filter
Float position
Standard resistance
value (ohm)

33. 3-8
ELECTRIC SYSTEM
2.2.5 Brake fluid sensor
Refer to the brake system.
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 ter-
minals when the push rod is pushed in.
Replace the switch if the measured insulation resis-
tance value is less than the value listed below.
Rated voltage DC12V
213465
IndicatororON
activatingposition
(emergency
energization)
3±2mm
Insulation
resistance value
1 M ohm or more
(with megger tester at 500V)
213466
Push
rod
OFF ON
M10×1.25
4 2mmmm

34. 3-9
ELECTRIC SYSTEM
2.2.7 Direction lever assembly (Powershift truck)
2.2.8 Backup lamp switch (Manual T/M truck)
213467
(10)(10)
Connection table
G/W B B/R B L/W
1 2 3 4 5
Forward of vehicle
F Forward
N Neutral
R Reverse
F Forward
N Neutral
R Reverse
Lever position
Terminal
Wire color
Connector of FNR switch
Connector of
FNR switch
213468
(0.5 RL)
ON OFF
19.5 mm
2 mm 2 mm
M12×1.75
Shift rail
(for forward-reverse)
Backup lamp switch
Transmission case

35. 3-10
ELECTRIC SYSTEM
2.2.9 Neutral switch
2.2.10 Thermoswitch
(Engine cooling water temperature)
(1) Apply an ohmmeter between the terminal and
body of the sender unit and check for continuity
(resistance value).
(2) Replace the sender unit if there is no continuity or
the measured resistance value is outside the stan-
dard resistance value.
Note:The illustration is for a gasoline-engine truck.
214882
(0.5 RL)
ONOFF
19.5mm
2mm2mm
M12×1.75
Neutral switch
Transmission
case
Shift rail
213470
TerminalBody
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 resis-
tance value (ohm)
80±10 67±7.8 40.6±2.7 22.2±1.4 11.3±0.4 10±0.3
Diesel-engine truck
Temperature
[°C (°F)]
50±0.2 60±0.2 80±0.2 100±0.3 105±0.3 120±0.3
Standardresistance
value (ohm)
80±10 56.3±5 29.5±2.5 16.5±0.8 14.3±0.5 10±0.3

36. 3-11
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.
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.
Insulation resistance
value
1 M ohm or more
(with contact point OFF)
(with megger tester at 500V)
Tightening torque 31.4 to 47.1 N·m
CAUTION
Replace the thermoswitch if it is dropped or abused.
Technical data
Operating temperature
OFF to ON 122±3°C
ON to OFF 115 °C or higher
Insulation resistance
(with contact point OFF)
1 M ohm or more
213471
Terminal Body

37. 3-12
ELECTRIC SYSTEM
2.2.12 Power relay
(Powershift T/M truck, for backup lamps)
(1) CB relay
(2) CM relay
Coil rating [at 20 °C (68°F)]
Items
Truck type
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%
215202
(Bottom view)
Connection diagram
Coil rating [at 20 °C (68°F)]
Items
Truck type
Gasoline and diesel engine lift
trucks
Rated operating voltage DC12V
Working voltage DC 3.0 to 7 V
Open-circuit voltage DC 0.5 to 3.1 V
Coil resistance 120 ohm ±10%
Rated exciting current 117.6 mA±10%
215203
(Bottom view)
Connection diagram

38. 3-13
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.
Rated voltage: DC12V
Items
Water temperature
(Water temperature
resistance value)
ON time
Glow lamp
Glow plug
-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.
213472
1 32
4 65
Connection diagram
Connector A Connector B
Connector BConnector A

39. 3-14
ELECTRIC SYSTEM
2.2.14 Fuse box
213480
Instrument panel
10A
QGS
10A
VCM
20A
10A 15A
EGI
30A
EGI
30A
15A
ETC
15A
20A 30A
15A
Spare
15A
15A
10A
10A
SBF 50ASBF 100ASBF 100A
Fuse box, Fuse
Back up/Others
Working lamp
Wiper
Head lamp
Horn
Stop lamp
Fuse puller
GlowAlternatorBatterySpare
A/C
20A

40. 3-15
ELECTRIC SYSTEM
2.3 Table of Lamps
Items Qty Lens color
Valve
Remark
Illustration
Typeoflamp
Head lamps 2 Colorless Standard:
Combination
Lamp (front)
Turn signal
lamp
2 Amber
Standard:
Head guard
Installed
Clearance
lamp
2 Colorless
Combination
Lamp (rear)
Turn signal
lamp
2 Amber Standard:
Tail and
Stop lamps
2 Red Standard:
Backup lamps 2 Colorless

41. 3-16
ELECTRIC SYSTEM
3. Console Box
3.1 Disassembly
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.
213483
6
4
2
5
1
5
3

42. 3-17
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
Fully charged condition can be verified by the electro-
lyte S.G. (1.280 to 1.265), and also the reduction
speed of electrolyte implies the battery condition. If the
electrolyte is rapidly reduced (pole plates exposed),
over-charging is suspected, or no reduction of electro-
lyte in three months or more, insufficient charging is
suspected.
4.3 Charging Precautions
(1) In slow charging, the charging current should be
about 1/10 the capacity of the battery being
charged.
(2) In quick charging, the battery capacity in ampere
should not be exceeded.
(3) During charging, adjust the charging current so
that the electrolyte temperature does not exceed
45°C (113°F).
(4) When connecting cables to battery terminals,
always connect the (+) terminal first, and when
disconnecting, remove the (-) terminal first.
(5) During charging, hydrogen gas is generated,
which requires attention to ventilation.
Specific gravity reading
at 20°C (68°F)
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 nei-
ther faulty components, loosely connected cables nor corroded con-
nections.
1.220 or less Low battery, requiring cares
Recharge battery.
If difference in S.G. is large, adjust it during recharging.
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 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 cer-
tain cells only, replace battery. After leaving battery for 12 to 96 hours,
conduct a high current discharge test.
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.)
Identification
34B19L
(Gasoline-engine truck)
55D23L
75D26L
(Diesel-engine truck)
95D31L
213484Identification

43. 3-18
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).
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.
Note:The instrument panel has functions below to pro-
tect circuits in the panel.
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 be-
comes slow.
Warning lamps button
button
LCD screen
215114
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.
Fuel gauge Main display Water temperature
gauge
Travel
direction
Symbol mark
(Optional feature)
Time/hour meter
display
215115

44. 3-19
ELECTRIC SYSTEM
5.2 Basic Screen Display
5.2.1 LCD screen display with the key switch in the
ON position
When the key switch is turned to the ON position, the
LCD screen displays the brand logo screen, the pass-
word authentication screen, and the standard display
screen in this order. Pressing a button can also show
the error history display on the screen.
(1) Brand logo screen
When the key switch is turned to the ON position,
the brand logo screen will be displayed for 2 sec-
onds while the lamps are being checked.
(2) Password authentication screen
(Display by optional function)
Inputting the registered password in advance
makes it possible to operate the lift truck.
(3) Standard display screen
The screen changes to the standard display
screen that shows the conditions of the lift truck.
215116
215117
215118

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