ate MITSUBISHI RKL TR FO i-T UCKS Service Manual Chassis & Mast MC/FC FD40N EF12B-00011-up FD45N EF19D-50001-up FD50CN ~ EF19D-80001-up FD50N EF28C-50001-up FD55N EF28C-80001-up FG40N EF40-00011-up FG45N EF29D-50001-up FG50CN _ EF23D-80001-up FG50N EF33C-50001-up FG55N _EF33C-80001-up For use with S6S and TB45 Engine Service Manuals. 99739-57100FOREWORD ‘This service manual is a guide for corvicing Mitsubichi Forklit Trucks. For your canvanience the instructions ara ‘grouped by systems as a ready reference, ‘The long productive life af your if truck{s) dapends on raguiar and proper servicing. Servicing caneistont with what ‘youwill leam by reading this service manual Road tha respective sections of this manual carefully and familiarize yoursell with all of the components batora attampting fo start atest, rapairor rebuild job, ‘The deseriptions, lustrations and spactications contained in this manual are for trucks with serial numbers in effect al the tme ot printing, Mitgubichi Forklift Trucks raterves the right to change specilieations ar designe without notica and without ineurting ‘obligations. ‘The trucks listed in thi manual are powered by TE45 gasoline engines or SES diagal engines, For engine servicing, please refer 1 the applicable engine service manual TB45 Gasoline angine S6S Diesel engine Indicates a potentially hazardous situaton which, if not avoided, could recuft in death or serious injury. Indicates a potentially hazardous situation which, if not ayaided, may recul in minar or maderata injury, or damage {0 your srachine. Indicates a eandition that ean cause damage to, or shorten service lita of, the machine. 1 Pub. No. 99739-57100SAFETY a Warns ‘The proper and safe lubrication and maintenance Yor 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 lubrica- tian or maintenance on these trucks. Improper performance of lubrication or mainte: nance procedures is dangerous and could result in injury or death, ‘The serviceman or mechanie may be unfamiliar with many of the systems an this truck. This makes it important 10 use caution whan performing service ‘work. A knawladge of the system andior componants isimportant bolore the remaval or disassembly of any ‘component Because of the size of come of the truck components, ‘the serviceman ar mechanic should check the weights noted in this Manual. Use proper lilting procedures ‘when removing any components. Follawing is a list of basic precautions that shauld always be observed. (1) Read and understand all warring plales and decals on the truck before operating, lubricating or repairing the product. (2) Aways wear protective glasses and protective ‘shove when working around trucks. Inparticular, ‘wear protective glasses when pounding on ary pat ofthe truek ar Healtachments with a hammer ‘or sledge. Use welders glaves, hood goggles, apron and other pratectve clothing appropiate to ‘the welding job being performed. Do not wear Joase titing ortom clothing, Remove allrings from fingers when working an machinery. (3) Donot work on any truck that is eupported anly by lit jacks or a hoist. Always use blocks or jack stands lo support the truck before performing any disassembly, Lower the lorksor other implements ta the ground belore partorming any work on the tuck. I this ‘eamat be done, make sure tha forks or other implements are blocked correctly ta prevent them from draping unexpectedly a 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, (6) Use steps and grab handles (if applicable} when ‘mounting or diemounting a ruck. Claan any mud ‘or debiis from stops, walkways or work platforms belore using, Always lace truck when using steps, ladders and wakways. When itis not possible to use the dasigned access system, provida ladders, sealtolds, or work platormsto perlorm cate repair operations. (6) Toavoid back injury, use a hoistwhen lifting com: ponents which weigh 23 kg or mare. Make sure all chains, hooks, slings, etc., are in good condition and are of the corree! eapacily. Be gure hoaks are positioned corractly. Liting eyas ara not to be side loaded during a iting operation (7) Toavoid bums, be alert for hotparis on trucks which have just been stopped and hot fluids in lings, tubes and compartments, (@) Be caretul when remaving cover plates. Gradually bback off the last two bolts or nuts located at oppa- sile endé of the cover or deviee and pry cover loose ta relieve any spring oF other pressure, belore removing the last twa bolts or nuts cam pletely. (8) Be careful when removing filer caps, breathers and plugs on the truck. Hold a rag over the cap ar plug ta prevent baing sprayed or spiastad by liq- uids underpressure, The danger is even greater it the truck has just been stopped because fluids canbahot (10}Aways use tools thatare in good candition and be sure you understand how to use them betore performing any service work. (11)Reinstall ail fasteners with same part number. Do ‘not use a Jacser quality {aetener if replacements are necessary, (12}H possible, make all repairs with the truck parked ‘na level, hard eurlaee. Block ruck 0 it dass not roll while working on or under truck.(13)Belore starting ta work on truck, hang "Da not “Operate” tag in the Cperator's Compartment (14)Repairs, which require welding, should be per- ‘formed only with the bane of the appropriate ref ‘erence informatan and by personnel adequately rained and knowledgeable in welding prace- ‘dures. Determine type of metal being weldad and ‘select correct welding procedure and electrodes, rode of wire to provide a weld matal strength ‘equivalent at least to that of parent metal (15)Do nat damage wiring during remaval operations, Rainetail the wiring soit i nat damaged nor wil be damaged in operation by contacting sharp car ‘ners, 0” by eubbing against some dbject or hot sunlace, Place wiring away tram oil pipe. (16)Be sure all protective davices including guards ‘and shisids are propery installed and functioning ‘corractly before staring a repair. I a guard or shield must be removed to perlorm the repair ‘work, use extra caution, (17)Ahways suppor the mast and carriage to keep ‘eamage or attachments raisadwhen mainten anes ‘or repair work is porformed, which raquires the mast in the raised positon. (18)Lonse or damaged fuel, lubrieart and hydraulic lines, tubes and hases coud cause fires. Do not bend or strike high pressure lines or install ones ‘which have been bent ar damaged. Inspect lines, ‘tubes and hoses caretully. Do not check for leaks. ‘with your hands. Pin hole (very small) leaks could result in alhigh velocity oll steam that will be invis- lle clase fo the hase. This oll could penetaie the ‘skin and cause pereonal injury, Use cardboard ar paper to lacate pin hole leaks. (19)Tigiten connections to the correct torque, Make ‘sure thal all heat chields, clamps and guards are installed comactly to avoid excessive heat, vibra- ton ormubbing agains! other paris during opera- ‘ton. Shields that protect agains! oilspray onta hot exhaust components in event of a ling, tube or ‘seal failure, must be installed eorreetly (20}Retiove all pressure in ar, oll or water systems belove any lines, fitings or related items are dis- connected or removed. Ahvays make sure all raised componants are blocked corectly and be alert far possible pressure when disconnecting any device (rom a system that ublizes pressure. (21)Do not operate a tuckit any rotating partis dam- aged ar contacts any ather part during operation. Any high speed rotating eamponent that has been damaged or altered shauld be checked for bal- ance before rousing.HOW TO USE THIS MANUAL Lift truck model covered in this manual «MIC Truck (Mechanical Comtral Systam) Mechanically contralled hycraulicsystem (carventional lever system) sFC Truck (Fingar-tip Control System) Electronically cantrolled hydraulic system 216300 “Gasoline Engine Trucks (FG)...... Trucks Equioped with TE45 Gasoline Engine *Digsol-Engina Trucks (FD) Trucks Equipped with $88 Diesal Engine sPowershift Trucks. Trucks Equipped with Powershift TransmissionHOW TO USE THUS MANUAL(continued) Disassembly diag ram(example) 24s Sequence 1 Cover, Bolt, Washer (part name) 2 Out put shaft assembly (part name) ‘Suggestions for Disassembly ‘Output shatt, Removing Remave output shalt using a special tool. misuse Service Data Unit:mm(in.) aiiwoze Gear Bacsasn 2 05 | tig ‘i Blandan valve &! Ropairor Serva Lint‘Symbols and abbreviations oP Opkan Taper pipe avead (acternal) 1M iach leemary P18) ‘Taper pipe Bead (actena 1 eh (oemery PTB) ‘Seaigh pipe Pvead (extemal) 114 (tarmenty PIAA) ‘Seaight pipe nread (mera) 1/8 inch torment P'S.1/8) Units: (1) S1Units are used in this manual, (2) The following table chawe the conversion of SI unit and customary unit Tam ‘Stunt Cusiemary unt a jee tet tia 0.0102 Kater? Pras pt ‘car0a quent iNew Ogle eave Teta CEI kginCHAPTER INDEX CHAPTER INDEX ‘GENERAL INFORMATION Items Truck Models Covered, Serial Number Locations, Dimensions, Technical Data COOLING SYSTEM Fan Belt Removal and Installation, Fan Belt Tension Console Box, Chassis Electrical Devices, ELS TECAL SYSTEM Battery Maintenance, Electrical Schematic Main Functions of Controller, Input/Output Monitor, Sopmetiere Etror Codes and Troubleshooting POWER TRAIN Removal and Installation of Power Line POWERSHIFT TRANSMISSION | Torque Converier, Singe Speed Powershift Transmission Control Valve, Automatic Two-Speed Transmission FEOUCHONDIFRERENTIAL 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 wrommicsveran [ane cuss angie MAST AND FORKS Simplex and Duplex Masts, Triplex Mast SERVICE DATA | Maintenance Standard, Maintenance Schedule, Periodic Replacement Parts, Lubrication Instruction, Special Tool Needed io) ES fe) i i fe (=)Chapter 1 GENERAL INFORMATION Pape py > Model View. Lift Truck Models Covered .. Serial Number Locations. Dimensions. Technical Data. Performance ..1. Model ViewGENERAL INFORMATION 2. Lift Truck Models Covered ‘This Serviee Manual provides cervioe and maintenanee information for tha fellowing lilt trucks: Mounted engine Gasoline modal Diesel modal Non dlecroris conivol z MO IFG Blectorie control MG TFG = Bectranié Gasaline engine models Renesas deolangine Woe I Tuck model | Seralnumber | Mounted engine | Trukmedel | Seal aumber | Mourledengne FG4ON EFAO0001 up Tes | ~FOWN | EFIZ5-0001Iw SS FGASN | EFZO0-S000iup | ‘THIS | —-FOGN | EFISDS000iup SES Fas0on | EFZSD-s000p | ‘Teas | _—-FDSOGN | EFI9D-8000Tup Ses FGSON | EFSC-5000Tup | —<‘TE4S | _——~FOSON | ERZ6C-SO00Tup Ses FGSSN | EFSaC-gm00Tap | Teas | __FOSEN | EReC-B000Tup “S65GENERAL INFORMATION 3. Serial Number Locations Name plate Gasaline engine model serial numberGENERAL INFORMATION 4. Dimensions aisa39GENERAL INFORMATION 5. Technical Data tritmm tin) ois ancl Son cass Tauck modal | Gasaine medal | FSaon | — FOTN] rN Diesel model FDAON FD45N FDSON FDSSN A | Maximum iif 3350 (132) 3360 (132.5) B | Free it height 150 (5.9) 160 (6.3) |For spread «min mas 30 iet (126-88) 8 [Fak ingih 7229 (8.0) = [tang comand backward Deg 570 [Gren engin Ha Ta | TIO UH | SY | STOUT | SHH | Gverall width ‘Single 1415 (55.5) ‘1460 (57.5) G | 2220 15) 2400 (815) 1 [agit afite ow mead guard BOS Sreral haght [Wah Bacio STOTT, BO TT * See ‘Without backrest 14230 (167) “4190 (165) 4380 (170) ‘Single 1175 (46.5) *[Beatwnea, [Dubie 31051) Special double 1445 (57.0), 1 [ead cea whoo 1180 (6.5) 7 | Wreebase OTE) TS) Fie BIH W Front overmarg STFA 3 (SG B37 0 | Minimum toring radius 2ee0 (101) | Brea Twn | 2760 (109) | ZapatT4) | 20 Te P | Under clearance 227 (8.3)GENERAL INFORMATION 6. Performance Lc Class 4 ton class Son class ‘nome ‘Truck model Fawn | FG4sw | FGSOCN | FGSON | FGSSN wg] a0 | aan | —a00 | so | 5800 exe te)| @o00) | e000) | (ro) | «rt000) | 12000) ‘Load cenier ‘mm fin) 600 (24) 25P mast | 570 (110) 480 (98) Loaded | 2FFimasi 530 (105) 430 (85) 3FEmast | mmis) 580 (105) 250 (88) Lc epeee DSP mast | (om) a0 (#20) 520 (100) Unioaded | 2FF mast 560 (110) 40 00) ‘SFF mast ‘560 (110) 480 (84) tea ‘istspeed 13.5(8.5) | ca Brel speed Fn (a0 Asa bai Tatapee | kmh 13.5165) speed Unloaded | a speed | (meh | 225 (14.0) Toaded_| Tatepeed TSS) fevene | saded | lstapeed THO TTZOF TET nea Class 4 ton class Sion class Diesel pero ‘Truck model FDAON FDASN FDSOCN FDSON: FDSSN ig] a0] aan | — aso] —m00 | sav Capacity (}} B000) | 2000) | (000) | (14000) | 112000) Toad con Ry 00 BH ‘2SP mast ‘550 (110) 470 (93) Loaded [2FFmast 510 100) 8) OFF mast | mms B20 (102) a0 (85) Hepes SP mast | (tm) G10 (120) "550 (705) 370 (112) “470 (@2) aa el ieee 21.5 (13.5) 21.0 (13.0) risa 13565) speed 22.0 (13.5) Loaded | 1stspeed 18.0,(11.0) 17-5 (11.0) Revere | ioaded | lstapeed es)Chapter 2 COOLING SYSTEM Specifications. Structure Removal and Installation 1 Fan Balt Removal... Inspection and Adjustment... 41 Fan Balt 42° Radator. 43° Upper Hose, Lawer Hose 44 Codant Troubleshooting,GGOLING SYSTEM 1. Specifications “Trak mde item FGaON FGHEN ] FG50GN | — FGEON FEN FOMON roasn | FDsocN | FOSON FDSEN Coating method ‘Water cooled, forced czculation Cooling | Racator Comagated fn (pressure) ypo syaem [Water pump | “Can gal ype ] Thermostat 1 Wax peietiype‘COOLING SYSTEM 2. Structure 1 Engine 5 Gilepoler for torques converter 2 Fan (coupled directly to the engine crankshat 6 Racerva tark, 3 Shroud 7 Radiator cap 4 Radiator 22COOLING SYSTEM 3. Removal and Installation 3.1_Fan Belt Removal Gasoline model Diesel model 1 Tension assembly (pulley lock bott) 3 Fan belt 2 Atlemator lock batt 41.4 Startby Ramave the radatar cover. 23‘COOLING SYSTEM 3.1.2 Removal Gasoline model (1) Loosen the pullay lock bolts by rolating 3 0 4 ture, IV the pulley lock bots are not laasened ade- ‘quately, the fan pulay well not move, Note: Do nat remove the pulley lock bolts by loosen ing them too much. (2) Loosen the nek nut (2) Loasan the adjusting screw and push the fan pub ley against the crankshaft pulley side to remove ‘he batt Diesel model (1) Loasen the pulley jock baits and the alternator lock bolts by rotating 3 fo 4 turns. IW the lock bolts ara nal loosened adequately, the alternator will nat mave, Nota: Donat remove the lock bolls by loosening them ‘00 much. (2) Pusi the altematar pulley against the lan side to remove the belt 3.4.3 Installation For installation, follow the removal sequence in reverse. Algo follow the inelnictions below. (1) Blelore installing the belt, turn the fan to check for ‘smooth rotation. Replace the bearing if il gener: alos unusual noices. (2) Alter installing the bell, check that the pulley moves when pushing the tension bel (3) Tigttan the lock bolts and tock nut firmiy.GGOLING SYSTEM 4. Inspection and Adjustment 4.1 Fan Belt 4.1.1 Fan Belt Inspection (1) Check the belt for contamination tom oil, grease ‘or dust. Replace the belt if neaded when the con: ‘amination is Jaund. When the belt is slightly con: ‘aminated, clean it with a rag or paper towel. Do ‘not use gasoline, oll or any other solvent for eaning. (2) During the engine overhaul or belt tension adjust ment, check the condition af tha belt. Replace the bell if it has ary damage, 44.2 Fan Belt Tension Apply foree, as specified below, pemendiculary to the bbell midway between the fan pulley and tension pulley (orcrank shat pulley), and make sure the belt tension is within the specified range. Fore 96 N (9.99 kg (22.09 Bi] [Batterson Tito 13mm (043 10 O5Tin) Gasoine model Diesel madot 21648‘COOLING SYSTEM 4.2 Radiator 42.4 Radiator unit ‘Check the core for foreign substances such as dust. It foreign substances are adhered to the core surface, remove them by blwing compressed water from the ‘opposite diractian, Be caraful nat to damage the waar pipe while clean ing 42.2 Radiator rubber mount Replace radiator rubber mount if it is hardaned and has no elastiety, 42.3 Radiatorcap Unit: Koa (kgliem?} ips] pening [an 27 (094 018)(1277 42:3) [Vauun wave | OAS ROOHDBOT] 43. UpperHose, Lower Hose 43.1 Connecting Hoses (1) Check tha hoses and replace them if they are ‘swollan or damaged (2) When connecting the hoses to the radiatar, make ‘sure that their ends are Lully ingertad into the fit ‘tings and soeure them with clamps.GGOLING SYSTEM 4.4 Coolant 4.4.1 Draining coolant (1) Drain the coolant from the radiator by loos ening the drain cack, (2) Drain the coolant! from the reservoir tank. ‘Coolant quantity Unit: tar (6uin.) Toial quantity af coolant 1585 12.54 (including coolant in hoses) | (9733) | (789.6) 706s | 06s Resanoirtark (FULLIeval)) G67) 7) Be sure to store antilreezalcoolart mixture carefully because i is hazardous waste. Ack your local dealer {or information pertaining to the proper disposal of the coolant, 4.4.2 Ralilling coolant Mix antifreeze with soft water (Lap water) al the proper ‘concenivation as shown below ard fil the radiator and reserve tank up 1 the specified lavel. Example: MHI Lang Life Coolant Terpeture | 29] 30] 25] 20] 18] 0 cn a8) | -22)| 1 | 4) | | 14 ear as | [as | wo | as | a tion (26) Antiteeze concentation rato varies depending on brands. Be sure to mix the coolant according ta a manufacture’s recommended mix ratio 216481 4.4.3 Coolant level check (1) Warm up the engine while paying attention to any ‘unusual noieas. (2) Stop the engina and check the rasene tank for ‘codiant level, then refill needed,‘COOLING SYSTEM 5. Troubleshooting fetes Candifon I Fossbie cause ‘ation | Damaged radiator core or tank Replace ‘Damaged radiator noses Replace ‘Leaking coolant from radiator pee e va [Hose clamps detective Roplace [Drain cookie dofeciva Roplaco “Radiator ns are dogged ‘Ciaan PC Taplace Engine ovomeated i [Gheck he bat fr tension, elongation, Loose bet land oracks. Replace the bel such | ‘defects found [Natenough coon Rafi [leaking of Fom ollcooiarhoss Insuficiont ightaning toque afFoso | Ratighian or opiacaChapter 3 ELECTRIC SYSTEM Chassis Electrical Devices Wiring Outline 11 Gasoline Model 12 Diesel Model 13 Gasoline and Diesel Models...... Structure 21 Console Box 22 Main Electrical Components, 23° Table of Lamps. HT Console Box 3-18 31 Disassembly 318 Battery Maintenance... 3-19 41 State cf Charge and Electrolyte Specific Gravity (S.G.) Adjustment. 319 4.2 Specific Gravity Reading and State of Charge 349 43° Charging Precautions 319 Instrument Panel ... 51 Instrument Panel Screen Components. 3:20 52 Basic Screen Display. 321 5S BAC OpSralion ce innnannnennesinmintiineicanuseteteneceteninins eee 54 When an Error Occurs. 3:29 55 Waming Lamps 331 56 Optional Functions. 332 57 Hour Meters. 3:30 58 Troubleshooting 341 Troubleshooting 7.1 Starter System. 43 FQ CII is esisss cerns cevtcaennianacersbse scvisacaneinnasa ened oacnerinias natin snenttaasersbas iatiiaiee SAD 7.3 Lighting Systom. 344ELECTRIC SYSTEM 1. Chassis Electrical Devices Wiring Outline 1.1_ Gasoline Model vom’ (Vehicle contral module) (Option control module) (Wet disc brake oniy) Battery cable) ‘Toengine hamess OM (Engine contra module) aysass 31ELECTRIC SYSTEM 1.2 Diesel Model a Transmission i canital solenoid From ‘Seat switch To armrest (FC model onty) - “Thermswtch (Option cortrot module) (Sending unt) 1 (Wet dise brake only) om \(Diesel contro! module) |(Wetdlise brake arly) Battary cable (-) Tostarer 28386 32ELECTRIC SYSTEM 1.3 Gasoline and Diesel Models Console Box Parking brake valve FC Armrest fed eesti - 21887 33