Mitsubishi Chasis Manual Service
Mitsubishi Chasis Manual Service
Mitsubishi Chasis Manual Service
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
1
Pub. No. 99719-18100
SAFETY
WARNING WARNING
The proper and safe lubrication and maintenance Do not operate these trucks unless you have read
for these lift trucks, recommended by Mitsubishi and understood the instructions in the OPERA-
Forklift Trucks, are outlined in the OPERATION & TION & MAINTENANCE MANUAL. Improper truck
MAINTENANCE MANUAL. operation is dangerous and could result in injury
or death.
Read and understand the OPERATION & MAINTE-
NANCE MANUAL before performing any lubrica- (5) Use steps and grab handles (if applicable) when
tion or maintenance on these trucks. mounting or dismounting a truck. Clean any mud
Improper performance of lubrication or mainte- or debris from steps, walkways or work platforms
nance procedures is dangerous and could result before using. Always face truck when using steps,
in injury or death. ladders and walkways. When it is not possible to
use the designed access system, provide ladders,
The serviceman or mechanic may be unfamiliar with scaffolds, or work platforms to perform safe repair
many of the systems on this truck. This makes it operations.
important to use caution when performing service (6) To avoid back injury, use a hoist when lifting com-
work. A knowledge of the system and/or components ponents which weigh 23 kg or more. Make sure all
is important before the removal or disassembly of any chains, hooks, slings, etc., are in good condition
component. and are of the correct capacity. Be sure hooks are
positioned correctly. Lifting eyes are not to be side
Because of the size of some of the truck components, loaded during a lifting operation.
the serviceman or mechanic should check the weights (7) To avoid burns, be alert for hot parts on trucks
noted in this Manual. Use proper lifting procedures which have just been stopped and hot fluids in
when removing any components. lines, tubes and compartments.
(8) Be careful when removing cover plates. Gradually
Following is a list of basic precautions that should back off the last two bolts or nuts located at oppo-
always be observed. site ends of the cover or device and pry cover
loose to relieve any spring or other pressure,
(1) Read and understand all warning plates and before removing the last two bolts or nuts com-
decals on the truck before operating, lubricating or pletely.
repairing the product. (9) Be careful when removing filler caps, breathers
(2) Always wear protective glasses and protective and plugs on the truck. Hold a rag over the cap or
shoes when working around trucks. In particular, plug to prevent being sprayed or splashed by liq-
wear protective glasses when pounding on any uids under pressure. The danger is even greater if
part of the truck or its attachments with a hammer the truck has just been stopped because fluids
or sledge. Use welders gloves, hood/goggles, can be hot.
apron and other protective clothing appropriate to (10)Always use tools that are in good condition and
the welding job being performed. Do not wear be sure you understand how to use them before
loose fitting or torn clothing. Remove all rings from performing any service work.
fingers when working on machinery. (11)Reinstall all fasteners with same part number. Do
(3) Do not work on any truck that is supported only by not use a lesser quality fastener if replacements
lift jacks or a hoist. Always use blocks or jack are necessary.
stands to support the truck before performing any (12)If possible, make all repairs with the truck parked
disassembly. on a level, hard surface. Block truck so it does not
(4) Lower the forks or other implements to the ground roll while working on or under truck.
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.
3
(13)Disconnect battery and discharge any capacitors (20)Relieve all pressure in air, oil or water systems
(electric trucks) before starting to work on truck. before any lines, fittings or related items are dis-
Hang “Do not Operate” tag in the Operator’s Com- connected or removed. Always make sure all
partment. raised components are blocked correctly and be
(14)Repairs, which require welding, should be per- alert for possible pressure when disconnecting
formed only with the benefit of the appropriate ref- any device from a system that utilizes pressure.
erence information and by personnel adequately (21)Do not operate a truck if any rotating part is dam-
trained and knowledgeable in welding proce- aged or contacts any other part during operation.
dures. Determine type of metal being welded and Any high speed rotating component that has been
select correct welding procedure and electrodes, damaged or altered should be checked for bal-
rods or wire to provide a weld metal strength ance before reusing.
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.
4
HOW TO USE THIS MANUAL
Lift truck models covered in this manual
MC Truck (Mechanical Control System)
Mechanically controlled hydraulic system (conventional lever system)
FC Truck (Finger-tip Control System)
Electronically controlled hydraulic system
MC Truck
Lever
Control valve
FC lever box
Output unit
Input unit
VCM Controller
Electric wiring
FC Truck
Gasoline-Engine Trucks (FGE, FG)....... Trucks Equipped with K21 or K25 Gasoline Engine
Diesel-Engine Trucks (FD).................... Trucks Equipped with K21 or K25 Diesel Engine
Powershift Trucks................................... Trucks Equipped with Powershift Transmission
Manual Transmission Trucks................. Trucks Equipped with Manual Transmission
(2 Types of Clutch; Dry and Wet)
5
HOW TO USE THIS MANUAL (continued)
(Removal, Installation, Assembly and Disassembly)
Disassembly diagram (example)
213445
Sequence
1 Cover, Bolt, Washer (part name)
2 Snap ring (part name)
213446
Service Data
A 0.11 to 0.28 mm
Gear Backlash
B 0.5 mm
A: Standard value
B: Repair or Service Limit
6
Symbols and abbreviations
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
RC1/8 Taper pipe thread (external) 1/4 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Units
(1) SI Units are used in this manual.
(2) The following table shows the conversion of SI
unit and customary unit.
7
CHAPTER INDEX
CHAPTER INDEX
1. Model View
Chapter 1 GENERAL INFORMATION
MC truck
213447
FC truck
213448
1-1
GENERAL INFORMATION
213449
1-3
GENERAL INFORMATION
4. Dimensions
G C K L
A
I
H
B P
D N M
F
213450
1-4
GENERAL INFORMATION
5. Technical Data
Unit: mm
class 1 ton class
FG10N FG15N FG18N FG20CN
Gasoline- FGE15N FGE18N FGE20CN
Truck model engine truck FG15ZN FG18ZN
Diesel-engine
FD10N FD15N FD18N FD20CN
truck
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
Overall width Single 1065 1065 1065 1065
G (outside-to-
outside of tires) Double 1330 1330 1330 -
1-5
GENERAL INFORMATION
Unit: mm
class 2 ton class 3 ton class
FG20N FG25N FG30N FG35AN
Gasoline- FGE20N FGE25N FGE30N FGE35AN
Truck model engine truck FG20ZN FG25ZN
FGE20ZN FGE25ZN
Diesel-engine
FD20N FD25N FD30N FD35AN
truck
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
Overall width Single 1150 1150 1275 1290
G (outside-to-
outside of tires) Double 1480 1480 1490 1490
1-6
GENERAL INFORMATION
6. Performance
class 1 ton class
FG10N FG15N FG18N FG20CN
Gasoline- FGE15N FGE18N FGE20CN
Truck
engine truck FG15ZN FG18ZN
model
Diesel-engine
FD10N FD15N FD18N FD20CN
truck
Capacity kg 1000 1500 1750 2000
Load center mm 500 500 500 500
490 (FG15N) 490 (FG18N)
570 (FG20CN)
490 (FG10N) 630 (FGE15N) 630 (FGE18N)
Loaded mm/s 630 (FGE20CN)
570 (FG15ZN) 570 (FG18ZN)
630 (FD10N) 630 (FD15N) 630 (FD18N) 630 (FD20CN)
Lift speed
560 (FG15N) 560 (FG18N)
650 (FG20CN)
560 (FG10N) 650 (FGE15N) 650 (FGE18N)
Unloaded mm/s 650 (FGE20CN)
650 (FG15ZN) 650 (FG18ZN)
690 (FD10N) 690 (FD15N) 690 (FD18N) 690 (FD20CN)
Travel speed Loaded km/h 19.0 19.0 19.0 19.0
(Powershift
Truck) Unloaded km/h 19.5 19.5 19.5 19.5
1-7
GENERAL INFORMATION
1-8
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 2
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
COOLING SYSTEM
1. Specifications
Chapter 2 COOLING SYSTEM
Truck type
Items
1 ton class 2 ton class 3 ton class
Cooling method Water-cooled, forced circulation
Radiator Corrugated fin (pressure) type
Cooling system
Water pump Centrifugal type
Thermostat Wax pellet type
2-1
COOLING SYSTEM
2. Structure
Radiator
Shroud
Hose layout
S4Q2 engine
Lower hose
K15, K21,
K25 engines
Reservoir tank
S4Q2 K15, K21, K25
Upper hose S4S
S4S engine
213451
2-2
COOLING SYSTEM
Engine
Fan
1 2
213452
213453
2-3
COOLING SYSTEM
3.3 Installation
To install, follow the removal sequence in reverse.
Also follow the instructions given below.
(1) Before installing the belt, turn the fan to check for
smooth rotation. Replace the bearing if it 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.
2-4
COOLING SYSTEM
213454
213455
2-5
COOLING SYSTEM
213456
4.5 Coolant
Fill the radiator with coolant containing antifreeze.
After starting the engine and letting it warm up during
operation, check for abnormal noises. Check the cool-
ant level in the reserve tank to ensure it meets the
specification.
Coolant quantity
Truck type
Item
1 ton class 2 ton class 3 ton class
Reservoir tank (FULL level) L 0.65 0.65 0.65
Total quantity of coolant
L 6.8 7.4 8.7
(including coolant in hoses)
2-6
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 3
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
ELECTRIC SYSTEM
1.1 (One)
Main harness
Harness, rear
combination
Harness, front
combination
Harness, front
combination
213457
3-1
ELECTRIC SYSTEM
1.2 (Two)
Starter switch
QGS Controller
Key
Main harness
Harness,
rear combination
Select switch
Back buzzer
Warning buzzer
Harness, front
combination
Input unit
VCM(Vehicle control module)
GSE Connector
Horn
Output unit
Fuse box, Fuse
Transmission
213458
3-2
ELECTRIC SYSTEM
2. Structure
2.1 Console Box
4 3
1 Water temperature gauge 1
2
2 Fuel gauge
3 Hour meter, various warning lights ᵮ
ᵦᶐ
4 Instrument panel
N
ᵤ ᵦ
6
5 Starter switch ᵣᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾ ᵡ
7
5
214140
3-3
ELECTRIC SYSTEM
A B C D E F G H I J K
L M N O
214141
Description of function
Inspection method of blown bulbs for instrument panel
All warning and indicator lamps are normal, if they glow, when the starter switch is turned to the I (ON) position.
3-4
ELECTRIC SYSTEM
(OFF)
(ON)
ST M
(START)
G B
213459
Connection Table
For gasoline truck (12V)
Terminal G B M ST Key in and out
OFF Yes
ON (when operating) ○--------- -----------○ No
START
○--------- -----------○----------- -----------○ No
(when starting engine)
3-5
ELECTRIC SYSTEM
Light switch/
turn signal lever
Boot
Horn contact
Boot
Direction lever
Front
Lighting switch,
turn signal switch
Forward of truck
Lighting switch,
turn signal switch
Forward-reverse
selector switch
Light switch/
turn signal switch
Shift change switch
(F, N, R)
4 T-3 L-2
T-1 L-4
2
T-2 L-5
L-1 L-3
5 Wheel angle sensor connector
1 3
Horn contact
1 2 4
Horn
3 5
213460
3-6
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. Up
Replace the horn if it does not activate or its sound is
abnormal.
Operating voltage: DC12V
(Gasoline and diesel trucks)
T1
Contact
Coil
213463
3/4
1/2
Referential Standards
Float position E 1/4 1/2 3/4 F
Standard resistance
80 49.5 32 19 10
value (ohm)
+12 +1.0
Tolerance (ohm) 㧙 ±3 㧙
+2 -0.5
213464
3-7
ELECTRIC SYSTEM
energization)
activating position
(emergency
Indicator or ON
3 ± 2 mm
213465
3-8
ELECTRIC SYSTEM
Forward of vehicle
F Forward
(10㩩) (10㩩)
N Neutral
R Reverse
Connector of
FNR switch
Connector of FNR switch
Connection table
Terminal 1 2 3 4 5
213467
ONޓOFF
19.5 mm
2 mm 2 mm
(0.5 RL)
213468
3-9
ELECTRIC SYSTEM
Neutral switch
(0.5 RL)
Transmission
case
19.5 mm
2 mm
M12×1.75
ONޓOFF
2 mm
Shift rail
214882
2.2.10 Thermoswitch
(Engine cooling water temperature)
Body Terminal
(1) Apply an ohmmeter between the terminal and
body of the sender unit and check for continuity
(resistance value).
(2) Replace the sender unit if there is no continuity or
the measured resistance value is outside the stan-
dard resistance value.
Note:The illustration is for a gasoline-engine truck.
213470
Gasoline-engine truck
Temperature
60±0.2 65±0.2 80±0.2 100±0.3 125±0.3 130±0.3
[°C (°F)]
Standard resis-
80±10 67±7.8 40.6±2.7 22.2±1.4 11.3±0.4 10±0.3
tance value (ohm)
Diesel-engine truck
Temperature
50±0.2 60±0.2 80±0.2 100±0.3 105±0.3 120±0.3
[°C (°F)]
Standard resistance
80±10 56.3±5 29.5±2.5 16.5±0.8 14.3±0.5 10±0.3
value (ohm)
3-10
ELECTRIC SYSTEM
1 M ohm or more
Insulation resistance
(with contact point OFF)
value
(with megger tester at 500V)
213471
CAUTION
Replace the thermoswitch if it is dropped or abused.
Technical data
OFF to ON 122±3°C
Operating temperature
ON to OFF 115 °C or higher
Insulation resistance
1 M ohm or more
(with contact point OFF)
3-11
ELECTRIC SYSTEM
(1) CB relay
Connection diagram
(Bottom view)
215202
(2) CM relay
Connection diagram
(Bottom view)
215203
3-12
ELECTRIC SYSTEM
Water temperature
Items (Water temperature ON time Connector A Connector B
resistance value)
1 2 3
-15°C (12.1 K ohm) 10.0 ± 2.0 sec. 㧭
Glow lamp
0°C (5.9 K ohm) 6.4 ± 1.3 sec.
Glow plug
+10°C (3.8 K ohm) 3.0 ± 0.6 sec. 㧮
4 5 6
Rated voltage: DC12V Connector A Connector B
3-13
ELECTRIC SYSTEM
Working lamp
15A
A/C
Back up/Others 20A
Head lamp
15A
15A Stop lamp
Instrument panel
10A 10A
QGS ETC Wiper Horn
Spare EGI
10A 15A 15A 10A
VCM 30A 30A EGI
20A
20A 30A
Fuse puller
10A 15A
SBF 100A SBF 100A SBF 50A
Spare Battery Alternator Glow
213480
3-14
ELECTRIC SYSTEM
Valve
Items Qty Lens color Remark
Illustration
Turn signal
2 Amber
lamp
Standard:
Combination
Head guard
Lamp (front)
Installed
Clearance
2 Colorless
lamp
Type of lamp
Turn signal
2 Amber Standard:
lamp
3-15
ELECTRIC SYSTEM
3. Console Box
3.1 Disassembly
2
5
213483
3.1.1 Start by
Place the starter switch to the OFF position, and
remove the cable from the ground side of the battery.
3-16
ELECTRIC SYSTEM
4. Battery Maintenance
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
3-17
ELECTRIC SYSTEM
5. Instrument Panel
5.1 Instrument Panel Screen Element
Instrument panel screen consists of warning lamps,
LCD (Liquid Crystal Display) screen, and ٌ and
ٖ buttons, and enter/display switch button).
LCD screen
215114
The LCD screen consists of main area, fuel gauge
area, travel direction area, symbol mark area, hour Travel Symbol mark Time/hour meter
meter area and water temperature gauge area. The direction (Optional feature) display
main area is divided into two parts; right and left.
Note:The instrument panel has functions below to pro-
tect circuits in the panel.
3-18
ELECTRIC SYSTEM
215116
215117
215118
3-19
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