Mitsubishi FG40K FG40KL FG45K FG50K FD40K FD40 FD40KL FD45K FD50K Forklift Trucks Full Service & Repair Manual

Service Manual 99739-16130 For use with S6S and TB45 Engine Service Manual. Chassis, Mast & Options FG40K F29C-00011-up FG40KL F29C-50001-up FG45K F29C-80001-up FG50K F33B-50001-up FD40K F19C-00011-up FD40KL F19C-50001-up FD45K F19C-80001-up FD50K F28B-50001-up

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 forklift 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 design without notice and without incurring obligation. The trucks listed in this manual are powered by TB45 gasoline engines or S6S diesel engines. For engine servicing, please refer to the applicable engine service manual. Pub. No. 99739-16130 Safety Related Signs The following safety related signs are used in this service manual to emphasize important and critical instructions: Indicates a specific potential hazard resulting in serious bodily injury or death. Indicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of, the machine. Indicates a condition that can cause damage to, or shorten service life of, the machine. NOTE WARNING ! CAUTION !

HOW TO READ THIS MANUAL Disassembly diagram (example) Sequence 1. Cover [Bolt, Washer] (part name) 2. Output shaft (part name) Suggestion for disassembly (1) Output shaft removal Symbols or abbreviations 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) Unit: mm (in.) A 0.020 to 0.105 Clearance between (0.00079 to 0.00413) cylinder and piston 0.15 B (0.0059) A: Standard value B: Repair or service limit Disassembly sequence Each disassembly diagram is followed by Disassembly sequence and Suggestions for 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. 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. SAFETY The proper and safe lubrication and maintenance for these forklift trucks, recommended by Mitsubishi, 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 on these trucks. Do not operate these trucks unless you have read and understood the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death. WARNING ! WARNING ! WARNING !

Mitsubishi FG40K FG40KL FG45K FG50K FD40K FD40 FD40KL FD45K FD50K Forklift Trucks Full Service & Repair Manual

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