Mitsubishi FD40N User manual

CF/CMtsaM&sissahC
Service Manual
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 EF29D-80001-up
FG50N EF33C-50001-up
FG55N EF33C-80001-up
99739-57100
Foruse with S6S and TB45 Engine
Service Manuals.

1
Pub. No. 99739-57100
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 TB45 gasoline engines or S6S diesel engines.
For engine servicing, please refer to the applicable engine service manual.
TB45 Gasoline engine
S6S Diesel engine
<Safety Related Signs>
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury, or damage
to your machine.
Indicates a condition that can cause damage to, or shorten
service life of, the machine.
WARNING
CAUTION
NOTE

3
(13)Before starting to work on truck, hang "Do not
Operate" tag in the Operator's Compartment.
(14)Repairs, which require welding, should be per-
formed only with the benefit of the appropriate ref-
erence information and by personnel adequately
trained and knowledgeable in welding proce-
dures. 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 opera-
tion. 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 dam-
aged 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 model 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 TB45 Gasoline Engine
Diesel-Engine Trucks (FD) .................... Trucks Equipped with S6S Diesel Engine
Powershift Trucks................................... Trucks Equipped with Powershift Transmission
FC lever box
Lever
VCM Controller
Electric wiring
Flow regulator valve
Electromagnetic control valve
Control valve
MC Truck
FC Truck
216300

5
HOW TO USE THUS MANUAL(continued)
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 Out put shaft assembly (part name)
213446
Unit:mm(in.)
Gear Backlash A0.11 to 0.28
(0.004 to 0.011)
B0.5
(0.012)
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/cm2
1 psi 0.0703 kgf/cm2
Torque 1 N·m 0.102 kgf·m
1 lbf·ft 0.1383 kgf·m

CHAPTER INDEX
CHAPTER INDEX
CHAPTER INDEX Items
GENERAL INFORMATION 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

1
Chapter 1 GENERAL INFORMATION
1. Model View............................................................................................... 1-1
2. Lift Truck Models Covered..................................................................... 1-2
3. Serial Number Locations........................................................................ 1-3
4. Dimensions.............................................................................................. 1-4
5. Technical Data......................................................................................... 1-5
6. Performance............................................................................................ 1-6


BUYNOW
ThenInstantDownload
theCompleteManual
Thankyouverymuch!