Mitsubishi Truck FD40NB, FD45NB, FG50NB, FD55NB, FG40N, FG45N, FG50N, FG55N Operating and Maintenance Instructions

Original Instructions MC/FC FG40N CF40A-00011-up FG45N CF29E-50001-up FG50CN CF29E-80001-up FG50N CF33D-50001-up FG55N CF33D-80001-up FD40NB CF12D-00011-up FD45NB CF19F-50001-up FD50CNB CF19F-80001-up FD50NB CF28E-50001-up FD55NB CF28E-80001-up 99730-5B100 Operation & Maintenance Manual Keep this manual in your forklift truck as a ready reference

i FOREWORD This four-wheel sit-down counterbalanced forklift trucks made for material lifting and transportation (hereinafter referred to as forklift truck) are designed for the personnel aged 18 years old or above, and operator training is required for all forklift truck operators. 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 may be offered through your authorized Mitsubishi forklift truck dealer. They will be glad to help you and answer any questions you may have about operating your new forklift 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. - If your forklift truck has an attachment, refer to the attachment supplier for the proper attachment operating instructions.

FOREWORD ii How to Use This Manual 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. This sign indicates prohibited matters. 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 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.

FOREWORD iii  Truck Models Covered in This Manual Truck type Truck model Engine model Transmission Control lever Wet Disc Brake 4 ton model FG40N TB45 Powershift MC / FC optional FG45N TB45 Powershift MC / FC optional FD40NB 854F Powershift MC / FC optional FD45NB 854F Powershift MC / FC optional 5 ton model FG50CN TB45 Powershift MC / FC optional FG50N TB45 Powershift MC / FC optional FG55N TB45 Powershift MC / FC optional FD50CNB 854F Powershift MC / FC optional FD50NB 854F Powershift MC / FC optional FD55NB 854F Powershift MC / FC optional Abbreviation - TB45 engine symbolizes electronic controlled LPG model. - 854F engine symbolizes electronic controlled diesel model. - MC is short for mechanical control levers. - FC is short for fingertip electronic control levers.

TABLE OF CONTENTS TOC-1 1. SAFETY RULES FOR FORKLIFT TRUCK OPERATORS ................ 1-1 General ................................................................................ 1-1 Location of Decals and Plates ............................................... 1-2 Decals for LPG Model ............................................................ 1-4 Description of Danger, Warning, and Caution Decals .............. 1-5  Survive in a Tipover Decal ................................................................. 1-5  No Riders Warning Decal .................................................................. 1-6  Operation Warning Decal ................................................................. 1-6  Overhead Guard Decal ..................................................................... 1-7  Pinch Points Decal ............................................................................ 1-7  No Access With Engine Running Decal .............................................. 1-7  Radiator Cap Warning Decal ............................................................. 1-8  Parking Brake Adjustment Decal ...................................................... 1-8  No One Under / On Forks and  No One Between Mast and Chassis Decal .......................................... 1-8  Load Backrest Extension Decal .......................................................... 1-9  Capacity Plate ................................................................................... 1-9  Precautions for Handling ECU Decal .................................................. 1-9 Safety Rules ....................................................................... 1-10 Operating Precautions ........................................................ 1-19 Working Precautions........................................................... 1-24 LPG .................................................................................... 1-31 2. KNOW YOUR FORKLIFT TRUCK .......................................... 2-1 Serial Number and Capacity Plate ......................................... 2-1 Electrical Components .......................................................... 2-2 Model View.......................................................................... 2-3  MC Model ......................................................................................... 2-4  FC Model ........................................................................................... 2-4 Driving Switches and Controls ............................................... 2-5  Key Switch ........................................................................................ 2-6  Direction Lever ................................................................................. 2-6  Turn Signal / Light Switch ................................................................ 2-7  Steering Column Tilt Lever ............................................................... 2-8  Inching Pedal ................................................................................... 2-8  Side Panel ......................................................................................... 2-9 Engine Oil Warning Icon ...................................................... 2-10 Meter Panel ....................................................................... 2-11  Warning Icons Glow Check ............................................................. 2-12  LCD Screen ...................................................................................... 2-12  Warning Icons and Indicators ......................................................... 2-13  Basic Screen Display ....................................................................... 2-15  Basic Operation .............................................................................. 2-18  When Diagnostic Code Is Shown on Display ................................... 2-25  When Several Warnings Occur Simultaneously .............................. 2-27  Warning Symbols ........................................................................... 2-30  Optional Functions ......................................................................... 2-31  Optional Functions to Use With Wet Disc Brakes (WDB) ................. 2-36 Integrated Presence System ................................................ 2-37  Mast Interlock System .................................................................... 2-37  Driving Interlock System ................................................................. 2-38  Driving Interlock System Functions ................................................ 2-39  Neutral System ............................................................................... 2-39  Neutral System Functions ............................................................... 2-39  Seat Belt Warning Icon ................................................................... 2-40  Seat Belt Warning Functions .......................................................... 2-40  Parking Brake Warning Icon and Warning Alarm ........................... 2-41  Parking Brake Warning Functions .................................................. 2-42  Parking Brake Dragging Warning ................................................... 2-42 Operating Control Levers and Switches ................................ 2-43  Lift Lever ......................................................................................... 2-43  Tilt Lever ......................................................................................... 2-44  Attachment Lever ........................................................................... 2-44 FC Control Box .................................................................... 2-45  Lift Switch ....................................................................................... 2-45  Tilt Switch ....................................................................................... 2-46  Other Controls ................................................................................. 2-46  Emergency Mast Stop Button .......................................................... 2-47  Forward and Back Adjustment Stopper Knob .................................. 2-47  Up and Down Adjustment Stopper Knob ........................................ 2-48  Attachment Lever A/B (Option) ...................................................... 2-48  Selector Switch Between Fourth and Fifth Attachment (Option) .... 2-48  Lowering Speed Selector Switch (Option) ....................................... 2-48  Mast Interlock System Functions .................................................... 2-49 Operator Seat ..................................................................... 2-50  Seat Adjustment ............................................................................. 2-50  Forward and Back Adjustment ........................................................ 2-50  Reclining Angle Adjustment ........................................................... 2-50  Adjustment of Suspension .............................................................. 2-51  Pocket for the Operation & Maintenance Manual ........................... 2-51  Operator Presence Switch and Alarm .............................................. 2-51 Seat Belt ............................................................................ 2-52 Engine Hood....................................................................... 2-54  Hood Latch ...................................................................................... 2-54 Fork Locking Pins ................................................................ 2-55 Replacing Forks .................................................................. 2-55 Assist Grips and Foot Step.................................................... 2-56 Drawbar Pin ....................................................................... 2-56 Hydraulic Tank Oil Level / Filler Hole .................................... 2-57 Fuel Filler ........................................................................... 2-57  Brake Tank Oil Level / Air Breather (If Equipped) ............................ 2-57 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 ............................................ 3-3 How to Survive in a Tipover................................................... 3-8 4. REFUELING ..................................................................... 4-1 Diesel Engine Model.............................................................. 4-1 LPG Engine Model ................................................................. 4-2  For Standard LPG Tank ...................................................................... 4-3 5. OPERATION .................................................................... 5-1 New Forklift Truck Break-in .................................................. 5-1 Before Starting Engine ......................................................... 5-1 Starting Engine ................................................................... 5-3  LPG Engine Model ............................................................................. 5-3  Diesel Engine Model ......................................................................... 5-3 Engine Won't Start................................................................ 5-4  When Engine Is "Flooded" ................................................................ 5-5  When Engine Is Started After Long Recess ........................................ 5-5

TABLE OF CONTENTS TOC-2 After Starting Engine ........................................................... 5-6 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  Leaving Forklift Truck (FC Model) ................................................... 5-13  For Use With Wet Disc Brake (If Equipped) ...................................... 5-14 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 ...................................................................... 6-2 Correct Operating Steps ........................................................ 6-4 Incorrect Operating Steps ..................................................... 6-6 Lifting the Load.................................................................... 6-8 Traveling With the Load ...................................................... 6-10 Unloading .......................................................................... 6-11 Working on Grades............................................................. 6-13  Normal Travel position ................................................................... 6-13  Traveling on a Grade ....................................................................... 6-13  Stopping on a Grade ....................................................................... 6-14  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  Fuel system ....................................................................................... 7-1  Engine cooling system ...................................................................... 7-2  Other ................................................................................................ 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 (Diesel Model) .......................................................... 9-2  Engine Coolant (LPG Model) ............................................................. 9-2 Care in Hot Weather ............................................................. 9-3  Fuel Oils and Lubrication Oils ............................................................ 9-3  Battery .............................................................................................. 9-3  Engine Coolant ................................................................................. 9-3 Severe Dust or Lint Conditions .............................................. 9-4  Air Cleaner Element .......................................................................... 9-4  Engine Oil and Engine Oil Filter ........................................................ 9-4  Hydraulic Oil ..................................................................................... 9-4  Hydraulic Tank Return Filter ............................................................. 9-4 10. TROUBLESHOOTING ....................................................... 10-1 If a Tire Blew Out ................................................................ 10-1  If a Tire Blows out During Travel or Operation ................................. 10-1 Stalled Engine ..................................................................... 10-1  Before Starting the Engine Again .................................................... 10-1 If the Engine Coolant Temperature Gauge Shows RED Zone .... 10-2 If Torque Converter Oil Temperature Warning Icon Glows (Powershift)........................................................................ 10-3 Trouble With the LPG Equipment .......................................... 10-3 Starting With Jumper Cables ................................................ 10-3 If Lights Won't Glow ............................................................ 10-5  How to Check Fuses and Lights ....................................................... 10-6 If the Forklift Truck Won’t Change Direction .......................... 10-8 If the Forklift Truck Won’t Move ........................................... 10-9 If the Mast Stops Moving ................................................... 10-10 If the Mast and Attachments Malfunction (FC Model) ........... 10-11 If a Tire Blew Out ............................................................... 10-12  If a Tire Blew Out During Travel or Operation ................................ 10-12 Replacing Tires .................................................................. 10-12  Before Replacing a Tire ................................................................. 10-13  To Remove Wheel ......................................................................... 10-14  To Raise Front Wheel .................................................................... 10-15  To Raise Rear Wheel ...................................................................... 10-16  To Install Wheel ............................................................................ 10-16  To Add Air to Tires ......................................................................... 10-17 Replacing Dual Tires (Optional) .......................................... 10-18  To Remove Outer Tire .................................................................... 10-18  Dual Tire (Optional) ....................................................................... 10-18  To Remove Inner Tire .................................................................... 10-18  To Install Inner Tire ....................................................................... 10-19  To Install Outer Tire ....................................................................... 10-19 Rear Tire ........................................................................... 10-20  To Remove Tire ............................................................................. 10-20  To Install Tire ................................................................................ 10-21 Diagnostic Codes and Explanations ..................................... 10-22 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 200 Service Hours or Weekly, Whichever Comes First ............ 11-5  Every 500 Service Hours or 3 Months, Whichever Comes First ......... 11-6  Every 1000 Service Hours or 6 Months, Whichever Comes First ....... 11-7  Every 2000 Service Hours or 12 Months, Whichever Comes First ..... 11-7  Others ............................................................................................. 11-9 Every 10 Service Hours or Daily (Prestart), Whichever Comes First ....................................................... 11-10  Faulty Operation Found the Day Before ......................................... 11-10  Brake Hoses, Pipes, and Joints ...................................................... 11-10  Brake Pedal ................................................................................... 11-10  Parking Brake Switch .................................................................... 11-11  Brake Pump .................................................................................. 11-11  Brake Oil (For Use With Wet Disc Brake Option) ............................ 11-12  Cooling Fan ................................................................................... 11-12

TABLE OF CONTENTS TOC-3  Engine Coolant (Diesel Model) ...................................................... 11-13  Engine Coolant (LPG Model) ......................................................... 11-14  Fan and Alternator Belt (Diesel Model) ......................................... 11-16  Battery ......................................................................................... 11-17  Battery Terminal ........................................................................... 11-17  Electric Wires ................................................................................ 11-17  Horn ............................................................................................. 11-18  Icons of Meter Panel ..................................................................... 11-18  Backup Lights ............................................................................... 11-18  Stop Lights ................................................................................... 11-18  Turn Signal Lights ........................................................................ 11-19  Head Lights and Working Lights (If Equipped) ............................. 11-19  Mast Interlock System .................................................................. 11-19  Driving Interlock System ............................................................... 11-20  Parking Brake Warning Icon and Warning Alarm ......................... 11-21  Engine (Exhaust, Noise, and Vibration) ......................................... 11-21  Engine Oil (Diesel Model) ............................................................. 11-22  Engine Oil (LPG Model) ................................................................. 11-23  Assist Grips ................................................................................... 11-25  Overhead Guard ............................................................................ 11-25  Operator Seat ............................................................................... 11-25  Seat Belt ....................................................................................... 11-26  Rear View Mirror (If Equipped) ..................................................... 11-26  Fuel .............................................................................................. 11-26  Fuel System (Diesel Model) .......................................................... 11-27  Hydraulic Oil ................................................................................. 11-27  Lift Chains ..................................................................................... 11-29  Lift and Tilt Cylinder ..................................................................... 11-30  Mast and Forks ............................................................................. 11-30  Lift Cylinder Mounting Bolts ......................................................... 11-32  Mast Strips and Roller Surfaces ..................................................... 11-32  Tilt Cylinder Socket Bolts .............................................................. 11-32  Load Backrest Extension and Lift Bracket ..................................... 11-33  Steering Wheel and Column ......................................................... 11-33  Accelerator Pedal .......................................................................... 11-33  Inching Pedal ............................................................................... 11-34  Powershift Transmission .............................................................. 11-34  Tires and Rims .............................................................................. 11-35  Wheel Nuts ................................................................................... 11-36  Oil Leaks and Damage of Piping ................................................... 11-36  Oil, Fuel, or Coolant Leaks ............................................................. 11-37 Every 50 Service Hours or Weekly, Whichever Comes First .... 11-37  Hydraulic Hoses, Pipes, and Joints ................................................ 11-37  Lift Chains ..................................................................................... 11-37  Air Cleaner Element ...................................................................... 11-38 One Month (30 days) or 200 Service Hours After Delivery of a New Forklift Truck, Whichever Comes First ....................... 11-40  Primary Fuel Filter (Diesel Model) ................................................ 11-40  Secondary Fuel Filter (Diesel Model) ............................................. 11-40  Return Oil Filter and Wash Strainer in Hydraulic System ............... 11-40 Every 500 Service Hours or 3 Months, Whichever Comes First 11-42  Engine Oil Warning Icon ............................................................... 11-42  Engine Oil (Diesel Model) ............................................................. 11-43  Primary Fuel Filter (Diesel Model) ................................................ 11-45  Secondary Fuel Filter (Diesel Model) ............................................. 11-46  Mast Supports .............................................................................. 11-48  Tilt Sockets ................................................................................... 11-48  Tilt Cylinders ................................................................................. 11-48  Lift Bracket Side Rollers ................................................................ 11-48  Mast Strips and Roller Surfaces ..................................................... 11-49  King Pins ....................................................................................... 11-49  Tie Rod Pins .................................................................................. 11-49  Rear Axle Center Pins .................................................................... 11-49  Universal Joint .............................................................................. 11-50  Grease Nipples .............................................................................. 11-50 Every 1000 Service Hours or 6 Months, Whichever Comes First ...................................................... 11-50  Brake/Inching Pedal Rod .............................................................. 11-50  Water Pump (Diesel Model) .......................................................... 11-50  Breather Element (Diesel Model) .................................................. 11-51  Differential Oil .............................................................................. 11-52 Every 2000 Service Hours or 12 Months, Whichever Comes First ...................................................... 11-53  Engine Coolant (Diesel Model) ...................................................... 11-53 Parts to Be Changed Periodically ....................................... 11-55  Safety Critical Parts ...................................................................... 11-55 12. SERVICE DATA ............................................................... 12-1 Fuel Information ................................................................ 12-1  Diesel Fuel Specifications ................................................................ 12-1  Liquefied Petroleum (LPG) .............................................................. 12-2 Coolant Information ........................................................... 12-2  Coolant Water ................................................................................. 12-3  Antifreeze Solution ......................................................................... 12-3 Recommended Fuels and Oils .............................................. 12-4 Specifications ..................................................................... 12-5 Capacities and Forklift Truck Weights................................... 12-7 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 14. APPENDIX .................................................................... 14-1 Fuel Specifications .............................................................. 14-1 Noise Level ......................................................................... 14-1 Vibration Level ................................................................... 14-1 Forklift Trucks Operating on LP-Gas: .................................... 14-1 Climate Conditions ............................................................. 14-1 Specifications ..................................................................... 14-2  Dimensions & Performance (4t to 5.5t Model) ................................ 14-3  Mast Performance and Capacity (4t to 5.5t Model) ......................... 14-5  Capacities at Various Load Centers .................................................. 14-8

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Mitsubishi Truck FD40NB, FD45NB, FG50NB, FD55NB, FG40N, FG45N, FG50N, FG55N Operating and Maintenance Instructions

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