Mitsubishi Forklift Trucks FD15N, FD18N, FD20CN Service Repair Manual

99719-5M110 For use with S4Q2, S4S and K21/K25 Engine Service Manuals. FG15N EF34L-02001-up FG18N EF34L-41001-up FG20CN EF34L-61001-up FG20N EF17DL-01001-up FG25N EF17DL-53001-up FG30N EF13FL-02001-up FG35N EF13FL-51001-up FD15N EF16D-01001-up FD18N EF16D-41001-up FD20CN EF16D-61001-up FD20N EF18C-01001-up FD25N EF18C-55001-up FD30N EF14E-03001-up FD35N EF14E-52001-up Chassis & Mast MC/FC Service Manual

1 Pub. No. 99719-5M110 FOREWORD This service manual is a guide for servicing Mitsubishi Forklift Trucks. For your convenience the instructions are grouped by systems as a ready reference. The long productive life of your lift truck(s) depends on regular and proper servicing. Servicing consistent with what you will learn by reading this service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual are for trucks with serial numbers in effect at the time of printing. Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring obligations. The trucks listed in this manual are powered by K21 or K25 gasoline engines or S4Q2 or S4S diesel engines. For engine servicing, please refer to the applicable engine service manual. K21 or K25 Gasoline engine S4Q2 or S4S Diesel engine <Safety Related Signs> Indicates a specific potential hazard resulting in serious bodily injury or death. Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury or damage to the machine. Indicates a condition that can cause damage to, or shorten service life of, the machine. WARNING CAUTION NOTE

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

3 (13)Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang "Do not Operate" tag in the Operator's Com- partment. (14)Repairs, which require welding, should be 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 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 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 dis- connected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. (21)Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for bal- ance before reusing.

4 HOW TO USE THIS MANUAL Lift truck models covered in this manual MC Truck (Mechanical Control System) Mechanically controlled hydraulic system (conventional lever system) FC Truck (Finger-tip Control System) Electronically controlled hydraulic system Gasoline-Engine Trucks (FG)....... Trucks Equipped with K21 or K25 Gasoline Engine Diesel-Engine Trucks (FD) .................... Trucks Equipped with S4Q2 or S4S Diesel Engine Powershift Trucks................................... Trucks Equipped with Powershift Transmission 213443 MC Truck FC Truck Lever Control valve FC lever box VCM Controller Electric wiring Electromagnetic control valve Flow regulator valve Output unit Input unit

5 HOW TO USE THIS MANUAL (continued) (Removal, Installation, Assembly and Disassembly) Disassembly diagram (example) Suggestions for Disassembly Output shaft, Removing Remove output shaft using a special tool. Service Data 1 2 213445 Sequence 1 Cover, Bolt, Washer (part name) 2 Snap ring (part name) 213446 Unit: mm (in.) Gear Backlash A 0.11 to 0.28 (0.004 to 0.01) B 0.5 (0.02) A: Standard value B: Repair or Service Limit

6 Symbols and abbreviations Units (1) SI Units are used in this manual. (2) The following table shows the conversion of SI unit and customary unit. OP Option R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4) RC1/8 Taper pipe thread (external) 1/4 inch (formerly PT1/8) G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A) Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8) Item SI unit Customary unit Force 1 N 0.102 kgf 1 lbf 0.4536 kgf Pressure 1 kPa 0.0102 kgf/cm 2 1 psi 0.0703 kgf/cm 2 Torque 1 N·m 0.102 kgf·m 1 lbf·ft 0.1383 kgf·m

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

Mitsubishi Forklift Trucks FD15N, FD18N, FD20CN Service Repair Manual

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