<p>Service Manual 99719-59110 For use with S4Q2, S4S and K21/K25 Engine Service Manuals. FG15N EF34L-00011-up FG18N EF34L-40001-up FG20CN EF34L-60001-up FG20N EF17DL-00011-up FG25N EF17DL-50001-up FG30N EF13FL-00011-up FG35N EF13FL-50001-up FD15N EF16D-00011-up FD18N EF16D-40001-up FD20CN EF16D-60001-up FD20N EF18C-00011-up FD25N EF18C-50001-up FD30N EF14E-00011-up FD35N EF14E-50001-up Chassis & Mast MC/FC FOREWORD This service manual is a guide to servicing of Mitsubishi Forklift Trucks. The instructions are grouped by systems to serve the convenience of your ready reference. Long productive life of your forklift trucks depends to a great extent on correct servicing the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing. Mitsubishi forklift truck reserves the right to change specifications or design without notice and without incurring obligation. The trucks are powered by K21/K25 gasoline engines or S4Q2/S4S diesel engines. For the engine servicing, please refer to the applicable engine service manual. Pub. No. 99719-59110 Safety Related Signs The following safety related signs are used in this service manual to emphasize important and critical instructions: Indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicate 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. CAUTION WARNING NOTE 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. 5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. 6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 7. To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments. 8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. 9. Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot. SAFETY The proper and safe lubrication and maintenance for this forklift truck, recommended by Mitsubishi forklift truck, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance. WARNING Do not operate this truck unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death. WARNING WARNING 10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work. 11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. 12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck. 13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang "Do not Operate" tag in the Operator's Compartment. 14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. 15. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Place wiring away form 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 can 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 can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks. 19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly. 20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. 21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. HOW TO USE THIS MANUAL 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 Truck (FG) . . . . . . . . . . . . . . . . . . Equipped with K21 or K25 Gasoline Engine Diesel Engine Tuck (FD) . . . . . . . . . . . . . . . . . . . . Equipped with S4Q2 or S4S Diesel Engine Powershift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipped with Powershift Transmission FC lever box Lever Electromagnetic control valve Hydraulic transducer Same as MC Truck except electronic control system Electric wiring Controller 209602 Lever Control valve Flow regulator valve 209601 MC Truck FC Truck HOW TO USE THIS MANUAL (continued) (Removal, Installation, Assembly and Disassembly) Disassembly diagram (example) Suggestion for disassembling 1. Output shaft, Removing Remove output shaft using a special tool. Service Data A: Standard Value B: Repair or Service Limit 1 2 209603 Sequence 1 Cover , Bolt, Washer (part name) 2 Snap ring ................ (part name) A 0.11 to 0.28 mm Gear Backlash (0.0043 to 0.0110 in.) B 0.5 mm (0.020 in.) 209604 Disassembling sequence Procedures are described in the text. Symbols or abbreviation OP Option R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4) Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8) G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A) Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8) Units 1. SI Units are used in this manual. 2. The following table shows the conversion of SI unit and customary unit. Item SI unit Customary unit Force 1 N 0.1012 kgf 1 lbf 0.4536 kgf Pressure 1 kPa 0.0102 kgf/cm2 1 psi 0.0703 kgf/cm2 Torque 1 Nm 0.1012 kgfm 1 lbfft 0.1383 kgfm GROUP INDEX Items 1 2 3 4 5 6 7 8 9 10 11 12 13 GROUP INDEX GENERAL INFORMATION COOLING SYSTEM ELECTRICAL SYSTEM CONTROLLERS POWER TRAIN POWERSHIFT TRANSMISSION FRONT AXLE AND REDUCTION DIFFERENTIAL REAR AXLE BRAKE SYSTEM STEERING SYSTEM HYDRAULIC SYSTEM MAST AND FORKS SERVICE DATA Fan removal and installation, Fan belt inspection and adjustment Console box, Chassis electrical devices, Battery maintenance, Electrical system schematic Main functions, Service tool functions, Input/output monitor, Error codes and troubleshooting Removal and installation Torque converter, 1-speed transmission, Control valve, Automatic 2-speed transmission Front tires, Front axle, Reduction and differential Rear tires, Rear axle, Toe-in, Minimum turning radius Master cylinder, Wheel cylinders, Wheel brakes, Brake booster Model view, Truck models covered, Serial number locations, Dimensions, Technical data Steering gear, Power cylinder, Flow divider Hydraulic tank, Gear pump, Control valve, Lift and tilt cylinders, Flow regulator valve, Down safety valve Simplex mast, Duplex mast, Triplex mast Maintenance standards, Periodic service chart, Periodic replacement parts, Lubrication instructions, Special tools Model View ............................................................................................... 1 1 Truck Models Covered ........................................................................... 1 2 Serial Number Locations ...................................................................... 1 3 Dimensions ............................................................................................... 1 4 Technical Data ......................................................................................... 1 5 1 GENERAL INFORMATION 1-1 GENERAL INFORMATION Model View MC Truck 210991 FC Truck 210992 1-2 Truck Models Covered This Service Manual furnishes servicing and maintenance information for the following trucks: (FC type is used in torque converter model only.) GENERAL INFORMATION Engine control LPG engine Diesel engine Standard MC/FC (Non-electronic control) Electronic control MC/FC Truck class Truck model Model code - serial number Engine mounted Truck model Model code - serial number Engine mounted LPG engine models Diesel engine models 1 ton class FG15N FG18N FG20CN FG20N FG25N FG30N FG35N EF34L-00011-up EF34L-40001-up EF34L-60001-up EF17DL-00011-up EF17DL-50001-up EF13FL-00011-up EF13FL-50001-up K21 K21 K21 K21 K21 K25 K25 FD15N FD18N FD20CN FD20N FD25N FD30N FD35N EF16D-00011-up EF16D-40001-up EF16D-60001-up EF18C-00011-up EF18C-50001-up EF14E-00011-up EF14E-50001-up S4Q2 S4Q2 S4Q2 S4S S4S S4S S4S 2 ton class 3 ton class 1-3 GENERAL INFORMATION Serial Number Locations 210993 1-4 GENERAL INFORMATION Dimensions L I O K C G B H A J P M N D F E 210994 1-5 Ref. Model Gasoline-engine FG15N FG18N No. Truck Diesel-engine (FD15N) (FD18N) Item Truck A Maximum lift 3000 (118) B Free lift 115 (4.5) C Fork spread (outside) 200 to 920 (7.9 to 36.2) D Fork length 920 (36.2) E Tilt angle (forward backward) 6 12 F Overall length 3180 (125.2) 3221 (126.8) G Overall width (outside of tires) Single tire 1065 (41.9) Dual tire 1330 (52.4) H Overall height (to top of mast lowered) 1995 (78.5) I Overall height (to top of overhead guard) 2065 (81.3) J Overall height (mast extended) 4055 (159.6) K Tread (front) Single tire 890 (35) Dual tire 1025 (40.4) L Tread (rear) 900 (35.4) M Wheelbase 1400 (55.1) N Front overhang 400 (15.7) O Minimum turning radius 1950 (76.8) 1980 (78) P Underclearance (at frame) 150 (5.9) GENERAL INFORMATION Technical Data Unit: mm (in.) 1-6 GENERAL INFORMATION FG20CN FG20N FG25N FG30N FG35N (FD20CN) (FD20N) (FD25N) (FD30N) (FD35AN) 3000 (118.1) 115 (4.5) 140 (5.5) 150 (5.9) 220 to 1000 (8.7 to 39.4) 250 to 1000 (9.8 to 39.4) 920 (36.2) 1070 (42.1) 6 12 3279 (129.1) 3408 (134.2) 3625 (142.7) 3795 (149.4) 3860 (152) 1065 (41.9) 1150 (45.3) 1275 (50.2) 1290 (50.8) 1480 (58.3) 1490 (58.7) 1995 (78.5) 2045 (80.5) 2180 (85.8) 2065 (81.3) 2070 (81.5) 2095 (82.5) 2105 (82.9) 4055 (159.6) 4085 (160.8) 4055 (159.6) 890 (35) 960 (37.8) 1060 (41.7) 1140 (44.9) 900 (35.4) 980 (38.6) 1400 (55.1) 1600 (63) 1700 (66.9) 415 (16.3) 455 (17.9) 490 (19.3) 2020 (79.5) 2200 (86.6) 2230 (87.8) 2380 (93.7) 2440 (96.1) 150 (5.9) 160 (6.3) 190 (7.5) 200 (7.9) Unit: mm (in.) Specification ............................................................................................ 2 1 Structure .................................................................................................... 2 2 Removal and Installation ...................................................................... 2 3 Inspection and Adjustment .................................................................. 2 5 Fan Belt Inspection .................................................................................... 2 5 Fan Belt Tension ........................................................................................ 2 5 Connecting Radiator Hoses ....................................................................... 2 5 Unit Layout ................................................................................................ 2 5 Coolant ...................................................................................................... 2 6 Radiator Cap ............................................................................................. 2 6 2 COOLING SYSTEM 2-1 COOLING SYSTEM Specification Truck Models 1 ton class 2 ton class 3 ton class Items Type Water-cooled, forced circulation Radiator Corrugated fin (pressure) type Water pump Centrifugal type Thermostat Wax Pellet Type Cooling System 2-2 COOLING SYSTEM Structure Hose layout S4Q2 engine K21, K25 engines S4S engine Lower hose Shroud Radiator Upper hose S4Q2, S4S Reservoir tank K21, K25 209611 Fan (directly coupled to engine) 209610 2-3 COOLING SYSTEM Removal and Installation Fan Belt Removal Start by: Remove the radiator cover. Suggestion 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 be moved. 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. Engine Fan 2 1 209612 Sequence 1 Tension pulley assembly, Bolt 2 Fan belt Fan Tension pulley 209613 2-4 COOLING SYSTEM Installation To install, follow the removal sequence in reverse. Also follow the instructions given below. (1) Before installing the belt, turn the fan to check for smooth rotation. Replace the bearing if it generates abnormal sound. (2) After installing the belt, push it to make sure that the tension pulley moves, then tighten the pulley lock bolt firmly. 2-5 COOLING SYSTEM Inspection and Adjustment Fan Belt Inspection (1) Check the belt for contamination with oil, grease and dust. Replace the belt if required. When the contamination is slight, remove it clean with rag or wiping paper. Do not use gasoline, oil or any other solvent to clean the belt. (2) During engine overhaul or belt tension adjustment, closely check the belt for condition. Replace the belt with a new one if it has any sort of damage. Fan Belt Tension Apply a force of 98 N (10 kgf) [22 lbf] perpendicularly to the belt at a point midway between the fan pulley and tension pulley. Adjust the tension so that belt deflection becomes between 11 to 13 mm (0.43 to 0.51 in.). Connecting Radiator Hoses When connecting the hoses to the radiator, fit their ends fully on the fittings and secure them with clamps. Tighten the clamp bolts to the torques indicated below. Make sure that each hose is correctly connected and prevented from disconnection by the flare of the fitting. Clamp bolt tightening torques Unit Layout 3.92 to 5.88 Nm Upper and lower hoses (0.4 to 0.59 kgfm) [2.9 to 4.3 lbfft] 2.94 to 4.9 Nm Cooler hose (0.3 to 0.5 kgfm) [2.2 to 3.6 lbfft] Fan pulley Tension pulley 209614 Hose 209615 Standard type Electronic control type 209616 2-6 COOLING SYSTEM Coolant Fill the radiator with coolant containing antifreeze. Start and operate the engine to let it warm up while checking for abnormal noise. Make sure that the quantity of coolant is as specified by checking the level in the reserve tank. Quantity of coolant Radiator Cap Truck Models 1 ton class 2 ton class 3 ton class Items Engine 3.95 (1.04) Radiator 2.2 (0.58) Reserve tank (FULL level) 0.65 (0.17) 0.65 (0.17) 0.65 (0.17) Total quantity of coolant 6.8 (1.80) 7.4 (1.96) 8.7 (2.30) (including coolant in hoses) Oil cooler 0.094 (0.02) Unit: liter (U.S. gal.) 90 15 kPa Opening pressure (0.92 0.15 kgf/cm2) [13.1 2.2 psi] 0 to 5 kPa Vacuum valve (0 to 0.05 kgf/cm2) [0 to 0.73 psi] Chassis Electrical Devices Wiring Outline ....................................... 3 1 Structure .................................................................................................... 3 3 Console box .............................................................................................. 3 3 Major Electrical Components ..................................................................... 3 5 Lamp Bulb Specifications .......................................................................... 3 17 Console Box ............................................................................................. 3 18 Disassembly .............................................................................................. 3 18 Instrument Panel ....................................................................................... 3 19 Battery Maintenance .............................................................................. 3 20 Wire Color .................................................................................................. 3 21 Troubleshooting........................................................................................ 3 22 Electrical Schematic ............................................................................. 3 27 3 ELECTRICAL SYSTEM 3-1 ELECTRICAL SYSTEM Chassis Electrical Devices Wiring Outline (No. 1) Main harness Harness, front combination Harness, front combination Harness, rear combination 209620 3-2 ELECTRICAL SYSTEM Chassis Electrical Devices Wiring Outline (No. 2) Starter switch Key Select switch Warning buzzer Harness, Front combination Controller Horn Connector bracket Vehicle speed sensor (Pulse generator) Transmission Relay box, Relay Harness, Front combination Fuse box, Fuse Battery seat Clip Back buzzer Harness, Rear combination Main harness 209621 3-3 ELECTRICAL SYSTEM Structure Console box 1 Water temperature gauge 2 Fuel gauge 3 Various warning lights 4 Instrument panel 5 Starter switch 6 Lighting switch, turn signal switch 7 Forward-reverse lever 1 6 5 3 4 2 7 209622 3-4 ELECTRICAL SYSTEM Function of Instrument Panel Description of function Inspection method of blown bulbs for Instrument panel Each warning lamp and indicator lamp are normal if they illuminate with the starter switch turned ON, and no bulbs are blown. A B C D E F G K L3 L2 L1 L J I H 209623 Code Name of monitor When not illuminated When illuminated Remarks or flashing A Brake fluid level warning lamp Normal level Low level B ATM: Torque converter fluid temperature warning lamp Normal temperature Overheat ATM truck MTM: Clutch wear lamp Normal Clutch worn MTM truck C Engine oil pressure warning lamp Normal oil pressure Low oil pressure D Seat belt reminder warning lamp Fastened Not fastened Multi-purpose warning lamp (illuminates when E warnings indicated by printed symbols occur or minor Normal Malfunction Printed symbol failures occur) F Charge warning lamp Normal charging Abnormal charging system G Glow pilot lamp Preheating completed Engine being Diesel-engine truck preheated H Load/unload interlock lamp Free Locked I Fr, Re interlock lamp Free Locked (flashing) Neutral lamp F or R Neutral J Fuel gauge Indicate remaining fuel amount with key in "ON." K Water temperature gauge Overheat if pointer enters the red zone. L Liquid crystal (normally acting as hour meter) Indicate operating hours with key in "ON." L1 Fuel filter warning lamp Normal Water drain required Diesel-engine truck L2 Coolant level warning lamp Normal level Low level Option L3 Clogged air cleaner element warning lamp Normal element Clogged Option When major failures occur, bulbs A, C, D, E, and H simultaneously flash. Position and contentof printed symbols 3-5 ELECTRICAL SYSTEM Major Electrical Components Starter switch The diesel-engine turck, which uses a disributor type injection pump, is provided with an engine automatic sop mechanism of the fuel cut system by the starter switch. The gasoline-engine truck is also provided with an engine automatic stop mechanism of the fuel cut system. Starter switch (with Anti-Restart Lock) This 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 the engine from troubles on starting or starter breakage caused by casual re- starting while the engine is running. The gasoline- and diesel-engine models use the same starter switch. In the diesel-engine models, (ON) position of the switch is for energizing the glow plugs. Connection Table Gasoline-engine truck (12 V) Diesel-engine truck (24 V) M G1 G2 S B1 B2 (OFF) (ON) (START) 208540 Terminal B1, B2 G1 G2 M S Connected to Battery, alternator, Fuse box FNR lever Key position fuse box OFF ON (when driving) START (when starting engine) Terminal B1, B2 G1 G2 M S Connected to Battery, Fuse box, Neutral switch alternator, engine stop, (starter), fuse box control timer glow timer Key position relay (glow plug) OFF ON (when preheating) (when driving) START (when starting engine) 3-6 ELECTRICAL SYSTEM Lighting switch and turn signal switch Lighting switch and turn signal switch Horn contact Horn Steering angle sensor Forward-reverse selector switch T-3 L-2 L-4 L-5 L-3 L-1 T-2 T-1 4 2 1 4 2 3 1 5 209627 Lighting and turn signal lever Boot Horn contact Steering angle sensor Boot Forward-reverse lever Lighting switch, turn signal switch Forward of truck 209625 Lighting switch, turn signal switch Forward of truck Forward-reverse selector switch 209626 3-7 ELECTRICAL SYSTEM Horn Check that the horn sounds when applying the specified voltage to both terminals of the horn, T1 and T2. Replace the horn with a new one if it does not sound or its sound is abnormal. Operating voltage: DC 12 V (gasoline-engine truck) : DC 24 V (diesel-engine truck) Note: The installed position in an actual truck is as per the illustration. Tank Unit Up Down Coil T1 T2 Vent hole Contact 209628 1/2 3/4 F 1/4 E Fuel pump Pressure relief valve Fuel filter 210782 Float position E 1/4 1/2 3/4 F Standard resistance value (ohm) 80 49.5 32 19 10 Tolerance (ohm) +12 3 +1.0 +12 -0.5 Referential Standards 3-8 ELECTRICAL SYSTEM Brake fluid sensor Refer to the brake system. Stop lamp switch Connect a tester across the terminals and check that the lamps turn ON and OFF when the push rod extended projection is to the specified value. Measure the insulation resistance value across the terminals when the push rod is pushed in. Replace the switch with a new one if the measured insulation resistance value is not more than the value listed below. Rated voltage: DC 12 V Indicator ON activating position(emergency energization)3 2 mm(0.12 0.08 in.)206672 OFF ON (illuminates) 4 (0.16) 2 (0.08) Push rod M10x1.25 Unit : mm (in.) 208543 Insulation resistance value 1 M ohm or more (at 500 V megger) 3-9 ELECTRICAL SYSTEM Forward-reverse lever assembly (ATM truck) (10)(10)(10)F1 Forward 1 F2 Forward 2 N Neutral R Reverse Forward of vehicle 209632 Wire color GR/L B G/R B L/W Lever position F (Forward) N (Neutral) R (Reverse) Connection table 3-10 ELECTRICAL SYSTEM Sender unit (engine coolant temperature) (1) Apply a tester to the sender unit between the terminal and body and check for continuity (resistance value). (2) Replace the sender unit with a new one if there is no continuity or the measured resistance value is outside the standard resistance value. Note: The illustration is for a gasoline-engine truck. Gasoline-engine truck Diesel-engine truck (3) When installing the sender unit, tighten it to the specified torque. Terminal Body 208546 Temperature 50 60 80 100 106 120 [C (F)] (122) (140) (176) (212) (222.8) (248) Standard resistance 80 56.3 29.5 16.5 14.3 10 value (ohm) Temperature 50 70 100 110 120 [C (F)] (122) (158) (212) (230) (248) Standard resistance 136 66 27.2 20.5 17.2 value (ohm) Sender unit tightening 19.6 to 27.4 Nm torque (2.0 to 2.8 kgfm) [14.5 to 20.2 lbfft] 3-11 ELECTRICAL SYSTEM Thermoswitch (T/C oil) Apply a tester to the terminal and body and measure the insulation resistance value. Replace the thermoswitch with a new one if the measured insulation resistance value is not more than the value listed in the table below. Internal resistance: 0.5 ohm or less (with contact ON) Allowable load: 0.5 A Note: When installing the thermoswitch, tighten it to the specified torque. Body Terminal 208547 1 M ohm or more Insulation resistance value (with contact OFF) (at 500 V megger) CAUTION Replace the thermoswitch with a new one if an impact is given to it or if it is dropped. Main specifications OFFON 122 3 C Operating temperature (251.6 37.4 F) ONOFF 115 C (239 F) or higher Insulation resistance 1 M ohm or more (with contact OFF) 31.4 to 47.1 Nm Tightening torque (3.2 to 4.8 kgfm) [23.2 to 34.7 lbfft] 3-12 ELECTRICAL SYSTEM Power relay (ATM truck, for backup lamps) Inspection of coil Apply a tester to terminal 1 and terminal 2 and measure the resistance value of the relay coil. Replace the coil with a new one if there is no continuity or the resistance value measured is outside the standard resistance value. Inspection of contact (1) Measure the insulation resistance value between terminal 3 and terminal 4. Replace the contact with a new one if the measured insulation resistance value is not more than the value listed in the table below. (2) Apply the tester to terminal 3 and terminal 4. (3) When applying a voltage of 12 V ON and OFF across terminal 1 and terminal 2 under the above condition, check to see if the relay activates to cause continuity or not between terminal 3 and terminal 4. Replace the relay with a new one if it does not activate properly. Coil rating [at 20C (68F)] 2 4 3 1 1 2 3 4 Diode Connection diagram 208548 Insulation resistance value 10 M ohm or more (at 500 V megger) Resistance value of coil Gasoline-engine truck 80 ohm 10 % Diesel-engine truck 320 ohm 10 % CAUTION This part operates on DC 12 V (gasoline-engine truck) or DC 24 V (diesel-engine truck) power supply. Be careful not to make a mistake when inspecting. CAUTION As the relay has an integrated diode between terminals, be careful about the polarity when inspecting, Replace the relay with a new one if an impact is given to it or if it is dropped. Truck type Gasolin/Diesel-engine truck Item Rated operating voltage DC 12 V Working voltage DC 8 V or less Open-circuit voltage DC 0.6 to 6 V or more Coil resistance 80 ohm 10 % Rated exciting current 150 mA 10 % 3-13 ELECTRICAL SYSTEM Glow timer (diesel-engine truck) Inspection of output time when starter switch is turned to ON When a tester is applied to terminal 2 and terminal 1 and a voltage of 24 V is applied between terminal 3 and terminal 1, there is continuity between terminal 2 and terminal 1 for 15 3 seconds. Replace the glow timer with a new one if it does not operate properly. Inspection of output time when starter switch is turned to START When a tester is applied to terminal 2 and terminal 1 and a voltage of 24 V is applied between terminal 4 and terminal 1, there is continuity between terminal 2 and terminal 1 for 5 seconds. Replace the glow timer with a new one if it does not operate properly. Rated voltage: DC 12 V 3 (1.25 BY: ATM truck) 4 (1.25 WL) 1 (0.85 B) 2 (1.25 BR) Starter switch Glow relay Glow timer Battery Glow plug Glow indicator lamp 3 4 2 1 OFF (ON) (START) 208549 3-14 ELECTRICAL SYSTEM Glow relay (diesel-engine truck) Inspection of coil Apply a tester to terminal 3 and terminal 4 and measure the resistance value of the relay coil. Replace the coil with a new one if there is no continuity or the measured resistance value is outside the standard resistance value. Inspection of contact (1) Measure the insulation resistance value between terminal 1 and terminal 2. Replace the contact with a new one if the measured insulation resistance value is not more than the value listed in the table below. (2) Apply a tester to terminal 1 and terminal 2. (3) When applying a voltage of 12 V ON and OFF across terminal 3 and terminal 4 under the above condition, check to see if the relay activates to cause continuity or not between terminal 1 and terminal 2. Replace the relay with a new one if it does not activate properly. Coil rating [in case of 20C (68F)] Rated operating voltage: DC 12 V Coil resistance: 52 ohm Rated exciting current: 80 mA Fuel pump (gasoline-engine truck) 1 1 2 3 4 2 3 4 Connection diagram 208550 Fuel pump 209640 Resistance value of coil 52 ohm [at 20 C (68 F)] Insulation resistance valve 1 M ohm or more (at 500 V megger) 3-15 ELECTRICAL SYSTEM Solenoid valve (for speed selector valve) This is an ON/OFF valve (normal open type). The valve opens the IN/OUT circuit in a non-energized condition. Rated operating voltage: DC 12 V Solenoid valve (for SR-SF selector valve) This is an ON/OFF valve (normal open type). The valve opens the IN/OUT circuit in a non-energized condition. Rated operating voltage: DC 12 V Wiring to the solenoid valve terminal on SR side Wire gauge and color 1.25 Br / tag is attached. Wiring to the solenoid valve terminal on SF side Wire gauge and color 1.25 LgR / tag is attached. F R CAUTION The valve for DC 12 V has an identification mark "12 V NO" on the body side. Terminal OUT IN Mark of 12 V NO 208536 3-16 ELECTRICAL SYSTEM Fuse Box QGS/OTHERS 10A VCM 20A 10A 15A EGI 30A EGI 30A ETC 15A A/C 20A 20A 30A METER PANEL 10A BACK UP/OTHERS 15A SPARE WORKING LAMP 15A HEAD LAMP 15A WIPER 15A HORN 10A STOP LANP 10A FUSE PULLER SBF 50A GLOW SBF 100A ALTNR SBF 100A BATTERY SPARE 209646 209645 Fuse box, Fuse 3-17 ELECTRICAL SYSTEM Lamp Bulb Specifications Item No. of Watts Color of lens Shape Remarks Type of lamp bulbs 12 volt 24 volt Head lamps 2 Colorless 45 60 Turn 2 Amber 27 25 Combination signals Standard: Installed on lamps (front) Clearance overhead guard 2 Amber 10 12 lamps Turn 2 Amber 27 25 signals Combination Tail/stop 2 Red 8/23 10/25 lamps (rear) lamps Backup 2 Colorless 10 12 lamps Working lamps 4 Colorless 45 60 Optional (front and rear) License plate lamp 1 Colorless 10 12 Optional Socket color: Instrument panel lamps 7 Colorless 3 3 12 V (Blue) 24 V (Dark Gray) 200016 3-18 ELECTRICAL SYSTEM Console Box Disassembly (1) Disconnect the electrical wiring from connector 1. (2) Remove the screw using a flatblade 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 forward-reverse lever (FNR lever) and turn signal lever 5. (6) Remove the bolt and then, remove console box assembly 6. Reassembly Follow the disassembly sequence in reverse. 6 4 2 5 1 5 3 209648 3-19 ELECTRICAL SYSTEM Instrument Panel Disassembly Sequence 1 Meter cover 2 Dial 3 Water temperature gauge 4 Liquid crystal 5 Fuel gauge 6 Meter case 7 Rigid board 8 Bulb 9 Socket 206480 CAUTION Be careful not to damage the rigid board when disassembling the instrument panel. Reassembly To reassemble the instrument panel, follow the reverse of disassembly procedure. Bulb replacement For bulb replacement, remove the socket from the rigid board by turning it counterclockwise. For configuration of the indicator lights, refer to page 3-4. 3-20 ELECTRICAL SYSTEM Battery Maintenance 1. State of charge and electrolyte specific gravity (S.G.) adjustment 2. Specific gravity reading and state of charge To check the battery for state of charge, take hydrometer readings on its electrolyte. The battery may be fully charged if the S.G. reading is 1.280 to 1.265 at 20C (68F). The state of charge can be told from the way the electrolyte level goes down to expose the cell plates. If addition of distilled water is necessary every month or so, the battery is overcharged. If addition is not required for more than 3 months, it is likely that the battery is inadequately charged. 3. Charging precautions (1) In slow charging, the charging current should be about 1/10 the capacity of the battery to be charged. (2) In quick charging, the battery capacity in ampere should not be exceeded. (3) During charging, adjust the charging current to prevent the electrolyte temperature from rising beyond 45C (113F). (4) When connecting the cables to the battery, begin with the cable for the positive (+) terminal. When disconnecting them from the battery, begin with the cable for the negative () terminal. CAUTION Be sure to turn OFF the starter switch and lighting switch before disconnecting or connecting the battery cables to prevent the IC regulator from suffering damage. Specific gravity reading State of charge Adjustment at 20C (68F) 1.280 to 1.265 Fully charged If difference in S.G. between any two cells is 0.020 or more, discharge the battery to minimize the difference and then recharge battery. Adjust S.G. during recharging. 1.260 to 1.225 One-half charged Recharge battery and adjust electrolyte S.G. Make sure there is neither faulty components, loosely connected cord nor corroded connection. 1.220 or below Discharged Recharge battery. If difference in S.G. is large, adjust it during recharging. If difference in S.G. is A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remained more than 0.040 is in shorted condition. constant for more than 2 hours. Electrolyte leakage, During recharging, adjust S.G. to 1.280 to 1.265. or excessive/diluted If difference in S.G. is more than 0.040 and a low S.G. is electrolyte. found in certain cells only, replace battery. After leaving battery for 12 to 96 hours, conduct a high current discharge test. IDENTIFICATION 34B19L 55D23L (Gasoline-engine truck) 75D26L 95D31L (Diesel-engine truck) 209650 Thank you very much for your reading. Please Click Here Then Get More Information. </p>