Mitsubishi Diesel Forklift Truck FD100NM1(S), FD120NM1(S), FD135NM1(S), FD150ANM1(S) Operating and Maintenance Instructions

FC/LC Original Instructions 99790-27110 Operation & Maintenance Manual Keep this manual in your forklift truck as a ready reference FD100NM1 F15E-90011-99999 FD100NM1S F15E-90011-99999 FD120NM1 F15E-90011-99999 FD120NM1S F15E-90011-99999 FD135NM1 F15E-90011-99999 FD135NM1S F15E-90011-99999 FD150ANM1 F24C-20011-39999 FD150ANM1S F24C-20011-39999

FOREWORD i FOREWORD How to Use This Manual This four-wheel sit-down counterbalanced forklift trucks made for material lifting and transport ion (hereinafter referred to as forklift truck) are designed for the personal aged 18 years old or above. SAFE and EFFICIENT OPERATION of a forklift truck depends to a great extent on the skill and alertness of the operator. To develop the skill, the operator should read this manual to understand the following points: (1) Working capabilities and limitations of the forklift truck (2) Make-up of the forklift truck (3) Safe driving and load handling procedures It is the employer's responsibility to make sure the operator can see, hear, and has the physical and mental ability to operate the forklift truck safely. It is also important that a qualified person experienced in forklift truck operation should guide new operators through several driving and load handling operations before they attempt to operate the forklift truck on their own. Note: - This manual contains information necessary for the operation and "Do-it-yourself" maintenance of standard forklift trucks. - Optional equipment is sometimes installed; it can change some operating characteristics described in this manual. Before operating such a forklift truck, make sure the necessary instructions are available and understood. - Forklift truck operator training is provided through your authorized Mitsubishi forklift truck dear. They will be glad to help you and answer any questions you may have about operating your new truck. Forklift trucks are NOT intended for use on public roads. - If you resell a forklift truck, be sure to attach the original Operation & Maintenance Manual to the forklift truck. In some countries, strict regulations do not allow imported forklift trucks for resale. For resale information, contact your authorized Mitsubishi forklift truck dealer. - If a forklift truck is resold from another country, an Operation & Maintenance Manual attached to the forklift truck may not meet your country's rules and regulations. For manual information, contact your authorized Mitsubishi forklift truck dealer. The following safety signs and NOTE are used in this manual to emphasize important and critical instructions: R This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Be sure to read these precautionary instructions and all safety related decals installed on your forklift truck before you operate it. R DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. R WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. R CAUTION CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Note: Note indicates important matters and useful information on operation and maintenance.

FOREWORD ii Mitsubishi Nichiyu Forklift Asia Pacific Pte. Ltd. (MNA)/ Mitsubishi Caterpillar Forklift Europe B.V. (MCFE) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method, or operating technique not specifically recommended by MNA/MCFE is used, you must satisfy yourself that it does not pose a safety hazard to yourself and others. You should also ensure the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures you choose. All information, specifications, and illustrations in this manual are based on the latest data available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the most complete and current information from your authorized Mitsubishi forklift truck dealer before starting any job. Additional manuals are available from your authorized Mitsubishi forklift truck dealer. DIRECTIONAL TERMS: The directions "Left", "Right", "Front", and "Rear" are given from the viewpoint of the operator facing forward. Truck model Engine model Serial number Control lever FD100NM1 FD100NM1S 6D16-TL Diesel Engine F15E-90011-99999 FC/LC FD120NM1 FD120NM1S F15E-90011-99999 FD135NM1 FD135NM1S F15E-90011-99999 FD150ANM1 FD150ANM1S F24C-20011-39999 Abbreviation - FC is short for fingertip control. - LC is short for lever control.

TABLE OF CONTENTS TOC-1 1. SAFETY RULES FOR FORKLIFT TRUCK OPERATORS ................ 1-1 General ............................................................................... 1-1 Warning Decals, Location...................................................... 1-2 Description of Danger, Warning, and Caution Decals .............. 1-4  Fasten Seat Belt Decal ...................................................................... 1-4  Survive in a Tipover Decal ................................................................. 1-4  Operation Warning Decal ................................................................. 1-5  Overhead Guard Decal ..................................................................... 1-5  Radiator Cap Warning Decal ............................................................. 1-6  No Access With Engine Running Decal .............................................. 1-6  Parking Brake Decal .......................................................................... 1-6  No Riders Warning Decal .................................................................. 1-6  Pinch Points Decal ............................................................................ 1-7  No One on the Fender ....................................................................... 1-7  No One Under / On Forks and No One Between  Mast and Chassis Decal ..................................................................... 1-7  Brake Warning Buzzer Decal ............................................................. 1-8  Capacity Plate ................................................................................... 1-8  Backup Alarm Decal .......................................................................... 1-8  Operator Restraint System Decal ...................................................... 1-9  No Contamination Permissible Decal ................................................ 1-9 Safety Rules....................................................................... 1-10 Operating Precautions........................................................ 1-20 Working Precautions .......................................................... 1-24 2. KNOW YOUR FORKLIFT TRUCK .......................................... 2-1 Serial Number and Capacity Plate ......................................... 2-1 Electrical Components .......................................................... 2-2 Model View.......................................................................... 2-3  FC Model (Type A) ............................................................................. 2-4  FC Model (Type B) ............................................................................. 2-4  LC Model ........................................................................................... 2-5 Driving Switches and Controls ............................................... 2-6  Key Switch ........................................................................................ 2-7  Direction Lever (Powershift) ............................................................. 2-7  Inching Pedal .................................................................................... 2-7  Turn Signal / Light Switch ................................................................ 2-8  Steering Column Tilt Lever ............................................................... 2-8 Meter Panel ......................................................................... 2-9  Warning Icons Glow Check ............................................................. 2-10  LCD Screen ...................................................................................... 2-10  Warning Icons and Indicators ......................................................... 2-11  Basic Screen Display ....................................................................... 2-13  Basic Operation .............................................................................. 2-16  When Diagnostic Code Is Shown on Display ................................... 2-23  When Several Warnings Occur Simultaneously .............................. 2-25  Warning Symbols ........................................................................... 2-26  Warning Icons ................................................................................ 2-27  Optional Features ........................................................................... 2-28 Side Panel .......................................................................... 2-32  Speed Mode Selector Switch .......................................................... 2-32  Brake Warning Icon ........................................................................ 2-32 Integrated Presence System ............................................... 2-33  Mast Interlock System .................................................................... 2-33  Mast Interlock System Functions .................................................... 2-34  Driving Interlock System ................................................................ 2-35  Driving Interlock System Functions ................................................ 2-36  Neutral System ............................................................................... 2-36  Neutral System Functions ............................................................... 2-36  Seat Belt Warning Icon ................................................................... 2-37  Seat Belt Warning Functions ........................................................... 2-37  Parking Brake Warning Alarm and Warning Icon ............................ 2-38  Parking Brake Warning Functions ................................................... 2-38 Operating Switches and Controls......................................... 2-39  FC Control Box (Type-A) .................................................................. 2-39  FC Control Box (Type-B) .................................................................. 2-39  Lift Switch ....................................................................................... 2-39  Tilt Switch ....................................................................................... 2-39  Lowering Speed Selector Switch (Optional) .................................... 2-40  Direction Switch (Optional) ............................................................. 2-40  Attachment Switch A/B (Optional) ................................................. 2-40  Selector Switch Between Fourth and Fifth Attachment (Optional) . 2-40  Other Controls (Standard) ............................................................... 2-41  Emergency Mast Stop Button .......................................................... 2-41  Forward and Backward Adjustment Stopper Knob  (FC Control Box Type-A) .................................................................. 2-42  Up and Down Adjustment Stopper Knob (FC Control Box Type-A) .. 2-42  Forward and Backward Adjustment (FC Control Box Type-B) .......... 2-43  Up and Down Adjustment (FC Control Box Type-B) ......................... 2-43  LC Control Box ................................................................................. 2-43  Lift Lever ......................................................................................... 2-44  Tilt Lever ......................................................................................... 2-44  Attachment Lever A/B (Option) ...................................................... 2-44 Operator Seat .................................................................... 2-45  Seat Adjustment ............................................................................. 2-45  Forward and Back Adjustment ........................................................ 2-45  Reclining Angle Adjustment ........................................................... 2-46  Adjustment of Suspension .............................................................. 2-46  Pocket for the Operation & Maintenance Manual ........................... 2-46  Operator Presence Switch and Buzzer ............................................. 2-46 Seat Belt ........................................................................... 2-47 Fork Locking Pins ............................................................... 2-49 Drawbar Pin ...................................................................... 2-50 Assist Grips and Foot Step ................................................... 2-50 Engine Hood ...................................................................... 2-51  Hood Latch ...................................................................................... 2-51 Hydraulic Tank Oil Filler Hole .............................................. 2-51 Fuel Filler .......................................................................... 2-52 Air Tank ............................................................................. 2-52 3. HOW TO AVOID A TIPOVER / HOW TO SURVIVE ONE .............. 3-1 Know What Forklift Truck Stability Is ..................................... 3-1 Center of Gravity (CG) ............................................................ 3-1 Stability and Center of Gravity (Top View) .............................. 3-1 Forklift Truck Stability Base................................................... 3-2 Capacity (Weight and Load Center) ........................................ 3-2 Capacity Plate ...................................................................... 3-3  Sample .............................................................................................. 3-3 Do’s and Dont’s to Avoid Tipover ............................................ 3-4 How to Survive in a Tipover................................................... 3-9 4. REFUELING ..................................................................... 4-1 Diesel Engine Equipped ......................................................... 4-1 5. OPERATION .................................................................... 5-1 New Forklift Truck Break-in ................................................... 5-1 Before Starting Engine ......................................................... 5-1

TABLE OF CONTENTS TOC-2 Starting Engine ................................................................... 5-3 Engine Won't Start ............................................................... 5-4 After Starting Engine ........................................................... 5-5 Before Moving Forklift Truck ................................................. 5-6 Forklift Truck Operation ........................................................ 5-7  Changing Speed ................................................................................ 5-8  Changing Direction ........................................................................... 5-8  Operating Techniques ....................................................................... 5-9  Steering (Turning) ............................................................................ 5-9  Inching ........................................................................................... 5-10 Stopping Forklift Truck ....................................................... 5-11 Parking Forklift Truck (After Stopping) ................................ 5-12 6. OPERATING TECHNIQUES ................................................. 6-1 Stacking Methods ................................................................ 6-1  Stacking Different Size Loads ............................................................ 6-1  Stacking Small Identical Loads ......................................................... 6-1  Stacking Large Identical Loads .......................................................... 6-1 Handling Loads Safely .......................................................... 6-2  Adjusting Fork Spread ...................................................................... 6-3 Before Operating the Forklift Truck ....................................... 6-4 Blinking of the Mast Interlock Indicator Icon ......................... 6-5 Lifting the Load.................................................................... 6-7 Traveling With the Load ........................................................ 6-9 Unloading .......................................................................... 6-10 Working on Grades............................................................. 6-13  Normal Travel Position ................................................................... 6-13  Traveling on a Grade ....................................................................... 6-13  Stopping on a Grade ....................................................................... 6-13 Starting on a Grade (Engine Stalls on a Grade) ..................... 6-14 7. STORING THE FORKLIFT TRUCK ......................................... 7-1 End of Each Shift Storage...................................................... 7-1 Long Term Storage............................................................... 7-1  Storage Within Three Months ........................................................... 7-1  Storage Exceeding Three Months ...................................................... 7-2 8. TRANSPORTATION HINTS ................................................. 8-1 Forklift Truck Loading and Shipping ...................................... 8-1 Forklift Truck Lifting and Tie Down Information ..................... 8-1 9. SPECIAL SITUATIONS ...................................................... 9-1 Care in Cold Weather ............................................................ 9-1  Fuel Oils and Lubrication Oils ............................................................ 9-1  Battery .............................................................................................. 9-1  Engine Coolant ................................................................................. 9-2 Care in Hot Weather ............................................................. 9-2  Fuel Oils and Lubrication Oils ............................................................ 9-2  Battery .............................................................................................. 9-2  Engine Coolant ................................................................................. 9-2 Severe Dust or Lint Conditions .............................................. 9-3  Air Cleaner Element .......................................................................... 9-3  Engine Oil and Engine Oil Filter ........................................................ 9-3  Hydraulic Oil ..................................................................................... 9-3  Hydraulic Tank Return Filter ............................................................. 9-3 10. TROUBLESHOOTING ...................................................... 10-1 Stalled Engine ................................................................... 10-1 If a Tire Blows Out .............................................................. 10-1  If a Tire Blows out During Travel or Operation ................................. 10-1 Replacing Tires .................................................................. 10-1 Before Replacing Tires ........................................................ 10-3  To raise front wheel ........................................................................ 10-3  To Remove Front Wheel .................................................................. 10-4  To Install Front Wheel ..................................................................... 10-6  To Remove Rear Wheel ................................................................... 10-7  To Install Rear Wheel ...................................................................... 10-8  To Add Air to Tires ........................................................................... 10-8 Starting With Jumper Cables .............................................. 10-9 If Lights Won't Glow.......................................................... 10-11  How to Check Fuses and Lights ..................................................... 10-11 If the Engine Coolant Temperature Gauge Shows RED Zone ..10-12 If Torque Converter Oil Temperature Warning Icon Glows (Powershift) ...................................................................... 10-13 If the Forklift Truck Won’t Change Direction ........................ 10-14 If the Mast Stops Moving.................................................... 10-14 If the Mast and Attachments Malfunction .......................... 10-15 Diagnostic Codes and Explanations .................................... 10-16 11. MAINTENANCE ............................................................. 11-1 General ............................................................................. 11-1 Inspection Precautions....................................................... 11-2 Maintenance Schedule ....................................................... 11-3  Every 10 Service Hours or Daily (Prestart), Whichever Comes First ..11-3  Every 50 Service Hours or Weekly, Whichever Comes First .............. 11-4  One Month (30 days) or 200 Service Hours After Delivery of  a New Forklift Truck, Whichever Comes First ................................... 11-5  Every 500 Service Hours or 3 Months, Whichever Comes First ......... 11-5  Every 1000 Service Hours or 6 Months, Whichever Comes First ....... 11-6  Every 2000 Service Hours or 12 Months, Whichever Comes First ..... 11-6  Every 1 to 2 years ............................................................................ 11-7  Every 2 years ................................................................................... 11-7  2 to 4 years ...................................................................................... 11-7 Every 10 Service Hours or Daily (Prestart), Whichever Comes First ........................................................ 11-8  Faulty Operation Found the Day Before ........................................... 11-8  Oil, Fuel, or Coolant Leaks ............................................................... 11-8  Brake Pedal ..................................................................................... 11-8  Parking Brake Lever ........................................................................ 11-9  Service Brake ................................................................................... 11-9  Air Tank ......................................................................................... 11-10  Engine Coolant .............................................................................. 11-10  Lights ........................................................................................... 11-11  Horn .............................................................................................. 11-12  Icons of Meter Panel ...................................................................... 11-12  Backup Alarm ................................................................................ 11-12  Backup Light ................................................................................. 11-12  Stop Light ..................................................................................... 11-13  Battery .......................................................................................... 11-13  Mast Interlock System ................................................................... 11-14  Driving Interlock System ............................................................... 11-15  Parking Brake Warning Alarm and Warning Icon .......................... 11-16  Seat Belt Warning Icon and Alarm ................................................ 11-16  Engine (Exhaust, Noise, and Vibration) ......................................... 11-17  Engine Oil ...................................................................................... 11-18  Fuel ............................................................................................... 11-19  Overhead Guard ............................................................................ 11-19

TABLE OF CONTENTS TOC-3  Assist Grips ................................................................................... 11-20  Seat Belt ....................................................................................... 11-20  Seat Adjustment ........................................................................... 11-20  Hydraulic Oil ................................................................................. 11-21  Tilt Cylinder Locknuts ................................................................... 11-22  Lift Chains ..................................................................................... 11-22  Mast and Forks ............................................................................. 11-24  Wheel Nuts ................................................................................... 11-26  Tires and Rims .............................................................................. 11-26  Steering Wheel ............................................................................. 11-27  Accelerator Pedal ......................................................................... 11-27  Inching Pedal ................................................................................ 11-27  Transmission Oil ........................................................................... 11-28 Every 50 Service Hours or Weekly, Whichever Comes First .... 11-29  Fan and Alternator Drive Belt ....................................................... 11-29  Air Cleaner .................................................................................... 11-30 One Month (30 Days) or 200 Service Hours After Delivery of a New Forklift Truck, Whichever Comes First ....................... 11-32  Cooling Fan ................................................................................... 11-32  Battery - Electrolyte Specific Gravity ............................................. 11-32  Engine Oil and Oil Filter ................................................................ 11-32  Bolts and Nuts .............................................................................. 11-32 Every 500 Service Hours or 3 Months, Whichever Comes First 11-33  Engine Oil and Oil Filter ................................................................ 11-33  Fuel Filter ..................................................................................... 11-34 Lubrication Chart .............................................................. 11-36  Fan Belt Pulleys ............................................................................ 11-37  Mast Support ............................................................................... 11-37  Fork Guide Bar .............................................................................. 11-37  Mast Strips Surfaces ...................................................................... 11-37  Mast and Lift Bracket Side Rollers ................................................. 11-38  Lift Chains ..................................................................................... 11-38  Tilt Socket Pins ............................................................................. 11-38  Tilt Cylinder Pins ........................................................................... 11-38  Tie Rod Pins .................................................................................. 11-39  Rear Axle Supports ....................................................................... 11-39 Every 1000 Service Hours or 6 Months, Whichever Comes First ...................................................... 11-40  Air Dryer Desiccant ....................................................................... 11-40  Air Cleaner .................................................................................... 11-40  Universal Joints ............................................................................ 11-40  Powershift Transmission .............................................................. 11-41  Hydraulic System .......................................................................... 11-43  Front Axle ..................................................................................... 11-44 Every 2000 Service Hours or 12 Months, Whichever Comes First ...................................................... 11-45  Brake Fluid ................................................................................... 11-45  Air Dryer Desiccant ....................................................................... 11-45  Engine Coolant ............................................................................. 11-46  Hydraulic Oil ................................................................................. 11-49 Parts to be Replaced Periodically ....................................... 11-50 12. SERVICE DATA ............................................................... 12-1 Fuel Information................................................................ 12-1  Fuel Specifications .......................................................................... 12-1 Coolant Information........................................................... 12-1  Coolant Water ................................................................................ 12-2  Antifreeze Solution ......................................................................... 12-2 Recommended Fuels and Oils .............................................. 12-3 Specifications (Standard Models) ........................................ 12-4 Refill Capacities ................................................................. 12-5 Capacities and Forklift Truck Weight (Standard Models) ....... 12-5 13. TO THE MITSUBISHI FORKLIFT TRUCK OWNER .................. 13-1 The Importance of Genuine Parts ........................................ 13-1 Proper Disposal of Your Forklift Truck .................................. 13-1 Instructions for Ordering Parts ............................................ 13-2 Service Registration ........................................................... 13-3

SAFETY RULES FOR FORKLIFT TRUCK OPERATORS 1-1  SAFETY RULES FOR FORKLIFT TRUCK OPERATORS  General The safety rules and regulations in this section are representative of some, but not all rules and regulations that apply to forklift trucks. Rules are paraphrased without representation that they have been reproduced verbatim. All forklift truck users should be familiar with their Local, Regional, and National regulations. Operate this forklift truck in accordance with local regulations. The most effective way of reducing the risk of serious injuries, or even death, to you and others, is for you to know how to operate the forklift truck properly. Drive alertly and avoid maneuvers or conditions that could cause accidents. Be professional. Do not operate your forklift truck if it is in need of maintenance, repair or appears to be unsafe in any way. Report all unsafe conditions immediately to your supervisor, then contact your authorized Mitsubishi forklift truck dealer. Do not attempt any adjustments or repairs unless you are trained and authorized to do so. Continuing improvement and advancement of product design may have caused changes to your forklift truck, which are not included in this publication. Whenever a question arises regarding your forklift truck, or this publication, please contact your authorized Mitsubishi forklift truck dealer for the latest available information.

SAFETY RULES FOR FORKLIFT TRUCK OPERATORS 1-2  Warning Decals, Location - There are several specific decals on your forklift truck. Their exact location and description of the potential hazard are reviewed in this manual. See attachment manufactures documentation for attachment decals. Please take the time to familiarize yourself with these decals. - Make sure you can read all decals. If you cannot, clean, or replace them. Use a cloth and soap and water to clean them. - You must replace a decal if it is damaged, missing, or cannot be read. If a decal is on a part that is changed, make sure a new decal is placed on the new part. Contact your authorized Mitsubishi forklift truck dealer for new decals. D00974 1 3 2 9 12 13 11 4 7 10 8 6 5 14 DANGER (1) Fasten Seat Belt Decal (2) Survive in a Tipover Decal WARNING (3) Operation Warning Decal (4) Overhead Guard Decal (5) Brake Warning Buzzer Decal (6) Radiator Cap Warning Decal (7) No Access With Engine Running Decal (8) No Riders Warning Decal (9) Parking Brake Decal (10) Pinch Point Decal (11) No One on the Fender Warning Decal (12) No One Under/On Forks and No One Between Mast and Chassis Decal (13) Capacity Plate (14) Backup Alarm Decal

Mitsubishi Diesel Forklift Truck FD100NM1(S), FD120NM1(S), FD135NM1(S), FD150ANM1(S) Operating and Maintenance Instructions

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