Mitsubishi Forklift FD10N, FD15N, FD18N, FD20N(CN), FG25N, FD30N, FD35AN, FG15N, FG18N, FG20N(CN), FG25N, FG30N, FG35N Operating Manual

Operation & Maintenance Manual 99710-5W110 Keep this manual in your forklift truck as a ready reference FC/MC 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 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 Original Instructions

i i FOREWORD The Occupational Safety and Health Administration (OSHA) prohibits employees under the age of 18 years old from operating forklift trucks, and is now mandating operator training 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: 1. Read and understand the working capabilities and limitations of the forklift truck. 2. Read and understand the make-up of the forklift truck. 3. Read and understand the safe driving and load handling procedures contained in this manual. And, most important, 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. It is the responsibility of the employer to make sure the operator can see, hear and has the physical and mental ability to operate the forklift truck safely. 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 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. NOTICE: – If you resell a forklift truck, be sure to attach its Operation & Maintenance Manual to the forklift truck. In some country, its strict regulation does not allow imported forklift trucks for resale. For resale information, contact your authorised Mitsubishi forklift truck dealer. – If a forklift truck is resold from another country, an Operation & Maintenance attached to the forklift truck may not meet your country’s rules and regulations. For manual information, contact your authorized Mitsubishi forklift truck dealer. A00001

ii ii HOW TO USE THIS MANUAL The following safety signs and NOTICE are used in this manual to emphasize important and critical instructions. 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. This is the safety alert symbol. It is used to alert you of potential personal injury hazards or damage that could occur to property or the environment. Obey all safety messages that follow this symbol to reduce the risk of serious injury, death, or damage. This indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. This indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or damage to your forklift truck. CAUTION Be sure to read these precautionary instructions and all safety related decals installed on your lift truck before you operate it. B00001

iii iii iii TABLE OF CONTENTS SAFETY RULES FOR FORKLIFT TRUCK OPERATORS General ..................................................................................................... 1 Warning Decals, Location ........................................................................ 2 Warning Decals, Description .................................................................... 4 Lubrication and Maintenance Chart ....................................................... 10 Safety Rules ........................................................................................... 12 Operating Precautions ............................................................................ 19 Working Precautions .............................................................................. 22 LP-Gas ................................................................................................... 26 KNOW YOUR FORKLIFT TRUCK Serial Number and Capacity Plate ......................................................... 27 Electrical Components ........................................................................... 28 Model View ............................................................................................. 29 Driving Switches and Controls................................................................ 32 Instrument Panel .................................................................................... 35 Operating Switches and Controls ........................................................... 53 Operator's Seat ...................................................................................... 60 Seat Belt ................................................................................................. 62 Integrated Presence System .................................................................. 64 Parking Brake Safety Warning ............................................................... 68 Fuses and Lamps ................................................................................... 69 Fork Locking Pins ................................................................................... 70 Changing Forks ...................................................................................... 70 Drawbar Pin ............................................................................................ 71 Assist Grip .............................................................................................. 71 Engine Hood........................................................................................... 72 Hydraulic Tank Oil Level / Filler Hole ..................................................... 73 Fuel Filler ................................................................................................ 73 Brake Tank Oil Level / Air Breather ........................................................ 73 HOW TO AVOID A TIPOVER; HOW TO SURVIVE ONE Know What Forklift Truck Stability Is ...................................................... 74 Center of Gravity (CG)............................................................................ 74 Stability and Center of Gravity (Top View) ............................................. 74 Stability and Center of Gravity (Side View) ............................................ 75 Forklift Truck Stability Base .................................................................... 75 Capacity (Weight and Load Center) ....................................................... 75 Capacity Plate ........................................................................................ 76 Do’s and Don’ts to Avoid Tipover ........................................................... 77 How to Survive in a Tipover ....................................................................80 REFUELING Gasoline and Diesel Engine Equipped ...................................................81 LP-Gas Engine Equipped .......................................................................82 OPERATION New Forklift Truck Break-in ....................................................................84 Before Starting Engine............................................................................84 Starting Diesel Engine ............................................................................86 Starting LP-Gas Engine ..........................................................................87 Engine Won't Start ..................................................................................88 Starting with Jumper Cables ...................................................................89 After Starting Engine...............................................................................90 Before Moving Forklift Truck ...................................................................91 Forklift Truck Operation ..........................................................................92 Stopping Forklift Truck ............................................................................97 Parking Forklift Truck (After Stopping)....................................................98 Leaving Forklift Truck (FC Model) ..........................................................99 OPERATING TECHNIQUES Stacking Methods .................................................................................101 Handling Loads Safely ..........................................................................102 Correct Operating Steps and Blinking of the Mast Interlock Indicator Lamp.........................................................103 Incorrect Operating Steps and Blinking of the Mast Interlock Indicator Lamp.........................................................104 Inching Into and Lifting the Load...........................................................106 Traveling with the Load.........................................................................107 Unloading..............................................................................................108 Working on Grades ...............................................................................110 STORING THE FORKLIFT TRUCK End of Each Shift Storage ....................................................................112 Long Term Storage ...............................................................................113 TRANSPORTATION HINTS Forklift Truck Shipping ..........................................................................114 Forklift Truck Lifting and Tiedown Information ......................................114

iv iv iv SPECIAL SITUATIONS Care in Cold Weather ........................................................................... 115 Care in Hot Weather ............................................................................. 116 Severe Dust or Lint Conditions ............................................................. 116 TROUBLESHOOTING Changing a Tire .................................................................................... 117 Stalled Engine ...................................................................................... 122 When the Temperature Gauge Shows Red Zone ................................ 122 Torque Converter Oil Temperature Warning Lamp Glows (Powershift)123 Trouble with the LP-Gas Equipment..................................................... 123 Driving Interlock Indicator Lamp Blinks or Glows, and the Forklift Truck Stops Moving ..................................................... 124 Mast Interlock Indicator Lamp Blinks or Glows, and the Mast and Attachments Stop Moving (FC Model) / the Mast Stops Moving (MC Model) ..................................................... 126 The Mast and Attachments Malfunctions (FC Model) .......................... 127 Error Codes and Explanations ............................................................. 128 MAINTENANCE General ................................................................................................. 130 Inspection Precautions ......................................................................... 131 Maintenance Schedule ......................................................................... 132 Every 10 Service Hours or Daily (Pre-Start), Whichever Comes First .137 Every 50 Service Hours or Weekly, Whichever Comes First ............... 155 One Month (30 days) or 200 Service Hours After Delivery of a New Truck, Whichever Comes First .................................................. 159 Parts to Be Changed Periodically ......................................................... 166 SERVICE DATA Fuel Information ................................................................................... 167 Coolant Information .............................................................................. 168 Recommended Fuels and Oils ............................................................. 170 Specifications (Standard Models) ......................................................... 171 Specifications (only for the forklift truck with wet disc brake) ............... 172 Refill Capacities .................................................................................... 173 Capacities and Forklift Truck Weight (Standard Models) ..................... 174 TO THE MITSUBISHI FORKLIFT TRUCK OWNER The Importance of Genuine Parts.........................................................175 Dispose of your forklift truck properly ...................................................175 Instructions for Ordering Parts ..............................................................176 Service Registration..............................................................................177 APPENDIX General .................................................................................................178 Specifications........................................................................................179 INDEX INDEX ...................................................................................................190

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 apply to forklift trucks. Rules are paraphrased without representation and have been reproduced verbatim. Your forklift truck was manufactured in accordance with EN1726-1(CEN), the National Fire Protection Association (NFPA) No. 505 and the American National Standards Institute, Inc. / Industrial Truck Standards Development Foun- dation (ANSI/ITSDF) B56.1, Safety Standard for Low and High Forklift Trucks. 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 acci- dents. Be professional. DO NOT operate a forklift truck if it is in need of maintenance, repair or appears to be unsafe in any way. Report all unsafe conditions immedi- ately to your supervisor, then contact your authorized 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 regard- ing your forklift truck, or this publication, please consult your authorized Mitsubishi forklift truck dealer for the latest available information. All forklift truck users should be familiar with their Local, Regional, and National regulations. United States users should be familiar with the Occupational Safety and Health Administration (OSHA), and ANSI/ITSDF B56.1, Safety Stan- dard for Low and High Forklift Trucks. You should also be familiar with areas of use of different types of forklift trucks as specified in the National Fire Protection Association (NFPA) 505.

SAFETY RULES FOR FORKLIFT TRUCK OPERATORS 2 2 2 ◆ Warning Decals, Location – There are several specific warning decals on your forklift truck. Their exact location and description of the potential hazard are reviewed in this section. Please take the time to familiarize yourself with these decals. – Make sure you can read all warning and instruction decals. If you cannot, clean or change them. Use a cloth and soap and water to clean them. – You must change 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. D00501 Fuel decal How to Open Engine Hood Only for WDB Fasten Seat Belt decal Hoist Point decal No One Under Forks decal No One Between Mast and Truck decal Integrated Presence System decal No One On Forks decal Parking Brake decal Radiator Cap Warning decal No Access With Engine Running decal 91A82-06200 97M81-04600 DIESEL 91A81-07100 ENG 91282-14100

SAFETY RULES FOR FORKLIFT TRUCK OPERATORS 3 3 3 D00002 With Load Backrest extension decal Precautions for Handling E.C.U. decal (Inside of Right Step) Requirement Tires Authorized With Overhead Guard decal No Riders decal Operation Warning decal Crush Point decal Capacity plate OPERATION WITHOUT THIS DEVICE IN PLACE MAY BE HAZARDOUS ENG 90A82-05700 ALLOWABLE WORKING CAPACITY OPERATION WITHOUT THIS DEVICE IN PLACE MAY BE HAZARDOUS ENG 90A82-05700 91382-09300 91A81-07700

SAFETY RULES FOR FORKLIFT TRUCK OPERATORS 4 4 4 ◆ Warning Decals, Description • Parking Brake When leaving machine, apply parking brake! Parking brake is not automatically applied. ALARM will activate if parking brake is not applied when get off truck or turn off key switch. Adjust parking brake lever properly. See Operation & maintenance manual for more information. Located to the left front of the operator's seat. Proper operating force: Only for wet disc brake When parking brake is applied while vehicle is moving, check and service parking brake. • No Rider To avoid serious injury, DO NOT carry pas- sengers. This forklift truck is designed for only one operator and no riders. Located to the right front of the operator's seat. Unit: N (kgf) [lbf] 1 ton model 150 to 200 (15 to 20) [34 to 45] 2 ton model 200 to 250 (20 to 25) [45 to 56] 3 ton model 230 to 250 (23 to 25) [52 to 56] D00004 D00231 91A82-06200 D00503 D00005 91382-09300 D00234

Mitsubishi Forklift FD10N, FD15N, FD18N, FD20N(CN), FG25N, FD30N, FD35AN, FG15N, FG18N, FG20N(CN), FG25N, FG30N, FG35N Operating Manual

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