Mitsubishi Forklift FD100N1 FD120N1 FD135N1 FD150AN1 FD160AN1 Trucks Service Manual – PDF DOWNLOAD
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Mitsubishi Forklift FD100N1 FD120N1 FD135N1 FD150AN1 FD160AN1 Trucks Service Manual – PDF DOWNLOAD
Format: PDF
Language: English
Brand: Mitsubishi
DESCRIPTION:
Mitsubishi Forklift FD100N1 FD120N1 FD135N1 FD150AN1 FD160AN1 Trucks Service Manual – PDF DOWNLOAD
For use with 1204E Diesel Engine Service Manual
Pub No :99799-50100
FD100N1 AF15E-00011-up
FD120N1 AF15E-00011-up
FD135N1 AF15E-00011-up
FD150AN1 AF24C-00011-up
FD160AN1 AF39A-00011-up
FOREWORD:
This service manual is a guide for servicing Mitsubishi forklift trucks. The long productive life of your forklift truck(s) depends on regular and proper 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 the forklift truck. The descriptions, illustrations, and specifications contained in this manual are for forklift 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. For your convenience the instructions are grouped by systems as an easy reference.
SAFETY :
- The proper safe lubrication and maintenance for these lift trucks, recommended by Cat Lift Trucks, are outlined in the SERVICE MANUAL. Read and understand the SERVICE MANUAL before performing any lubrication or maintenance on these lift trucks. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death.
- The serviceman or mechanic may be unfamiliar with many of the systems on this forklift truck. This makes it important to use caution when performing service work. – DO NOT operate these lift trucks unless you have read and understood the instructions in the SERVICE MANUAL. Improper forklift truck operation is dangerous and could result in injury or death.
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 forklift truck components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. The following is a list of basic precautions that should always be observed:
TABLE OF CONTENTS:
Mitsubishi Forklift FD100N1 FD120N1 FD135N1 FD150AN1 FD160AN1 Trucks Service Manual – PDF DOWNLOAD
Chapter 1 GENERAL INFORMATION
1 Model View 1-1
2 Applicable Forklift Truck Models 1-1
3 Serial Number Locations1-2
4 Specifications 1-3
41 Dimensions 1-4
42 Performance1-5
Chapter 2 COOLING SYSTEM
1 Specifications 2-1
2 Structure 2-2
3 Removing Cooling System 2-3
31 Preparation 2-3
32 Removal Sequence of Expansion Tank and Radiator 2-3
33 Removal Sequence of Intercooler and Oil Cooler 2-4
34 Removal Sequence of Cooling Fan2-5
35 Suggestions for Removal2-6
4 Inspecting and Adjusting Radiator and Intercooler 2-7
41 Intercooler 2-7
42 Inspecting Fan Belt2-7
43 Radiator 2-7
44 Antifreeze and Cooling Water 2-8
5 Installing Cooling System2-9
51 Suggestions for Installation 2-9
6 Troubleshooting 2-13
7 Service Data2-14
71 Fan Belt 2-14
72 Radiator 2-14
73 Expansion Tank2-15
74 Intercooler 2-16
75 Oil Cooler2-17
Chapter 3 ELECTRICAL SYSTEM
1 Chassis Electrical Components and Wiring Outline 3-1
11 Electrical Components and Wiring Diagram of Each System 3-2
2 Console Box3-15
21 Outline of Console Box 3-15
22 Removing Meter Panel 3-15
23 Installing Meter Panel3-16
3 Main Electrical Components3-17
31 Meter Panel 3-17
32 Select Switch 3-18
33 Brake Warning Icon 3-19
34 Key Switch (Anti-Restart Switch) 3-20
TABLE OF CONTENTS
TOC-2
35 Light Switch and Turn Signal Switch 3-21
36 Direction (FNR) Switch3-23
37 Horn 3-24
38 Fuel Tank Unit 3-25
39 Stop Light Switch 3-25
310 Thermo Switch (T/C Oil) 3-26
311 Speed Sensor 3-27
312 Fuse Box 3-28
313 Relay Box3-29
314 Adjusting Procedure for Accelerator Pedal 3-31
315 Low Air Pressure Switch 3-31
316 List of Lights3-32
4 Battery and Maintenance3-33
41 Battery Specific Gravity Condition and Adjustment 3-33
42 Relationship Between Electrolyte Specific Gravity and State of Charge 3-34
43 Precautions for Battery Charging 3-34
5 Meter panel 3-35
51 Meter Panel Layout3-35
52 Basic Display3-37
53 Basic Operation3-42
54 When a Warning Occurs 3-50
55 When Several Warnings Occur Simultaneously3-52
56 Warning Symbols 3-53
57 Warning Icons 3-54
58 Optional Features 3-55
59 Hour Meter 3-58
510 Troubleshooting 3-59
6 Wire Color3-60
61 List of Wire Color Codes 3-60
7 Troubleshooting3-61
71 Engine Startup Problem 3-61
72 Gauge-Related Problems3-61
73 Light-Related Problems 3-62
74 Warning Device Problems 3-63
75 Battery-Related Problems3-64
Chapter 4 CONTROLLERS
1 Outline4-1
11 System Configuration4-1
12 Color Coding4-3
13 Controller External View 4-4
2 Service Tool Functions4-17
21 Menu Structure4-17
22 Input Monitor and Output Monitor4-18
23 Truck Status 4-23
24 Truck History4-24
3 Diagnostic Code List 4-25
4 Troubleshooting4-27
TABLE OF CONTENTS
TOC-3
41 General Precautions 4-27
42 VCM-7 Memory Check Warning (F01)4-29
43 VCM-7 Battery Voltage Warning (F02)4-30
44 VCM-7 Communication Warning (F03) 4-32
45 Meter Panel Communication Warning (F07)4-34
46 Lift Lever Neutral Warning (F10) 4-35
47 Tilt Lever Neutral Warning (F11) 4-37
48 Attachment 1 Lever Neutral Warning (F12) 4-39
49 Attachment 2 Lever Neutral Warning (F13) 4-41
410 Attachment 3 Lever Neutral Warning (F14) 4-43
411 ECM Communication Warning (F15) 4-45
412 Direction Lever Warning (F16) 4-47
413 Vehicle Speed Warning (F17) 4-48
414 Lift Lever Warning (F20) 4-49
415 Tilt Lever Warning (F22) 4-51
416 Attachment 1 Lever Warning (F24)4-53
417 Attachment 2 Lever Warning (F26)4-55
418 Attachment 3 Lever Warning (F28)4-57
419 Joystick Duplicate Warning (F29) 4-59
420 Vehicle Speed Sensor Warning (F34) 4-61
421 Output Unit Warning (F41) 4-62
422 Output Unit Supply Voltage Warning (F44) 4-63
423 Output Unit Communication Warning (F45)4-65
424 Input Unit Warning (F46)4-67
425 Input Unit Communication Warning (F49) 4-68
426 Lift up Solenoid Warning (F50) 4-70
427 Lift Down Solenoid Warning (F52)4-72
428 Lift Solenoid Leak (F54) 4-74
429 Tilt Forward Solenoid Warning (F55) 4-77
430 Tilt Backward Solenoid Warning (F57)4-79
431 Tilt Solenoid Leak (F59) 4-81
432 Attachment 1A Solenoid Warning (F60) 4-84
433 Attachment 1B Solenoid Warning (F62) 4-86
434 Attachment 1 Solenoid Leak (F64)4-88
435 Attachment 2A Solenoid Warning (F65) 4-91
436 Attachment 2B Solenoid Warning (F67) 4-93
437 Attachment 2 Solenoid Leak (F69)4-95
438 Attachment 3A Solenoid Warning (F70) 4-98
439 Attachment 3B Solenoid Warning (F72) 4-100
440 Attachment 3 Solenoid Leak (F74)4-102
441 Unload Solenoid Warning (F75)4-105
442 Unload Solenoid Leak (F79) 4-107
443 Transmission Forward Solenoid Warning (F85)4-109
444 Transmission Reverse Solenoid Warning (F87) 4-111
445 Transmission Solenoid Leak (F89) 4-113
446 VCM-7 Speed Change Solenoid 1 Warning (F93) 4-115
447 VCM-7 Speed Change Solenoid 2 Warning (F94) 4-117
448 VCM-7 Speed Change Solenoid Leak (F95) 4-119
449 VCM-7 Setting Warning (F96) 4-121
TABLE OF CONTENTS
TOC-4
Chapter 5 POWER TRAIN
1 Specifications5-1
2 Structure 5-2
3 Reduction Ratio 5-3
4 Removing and Installing Engine and Transmission Unit 5-4
41 Preparation 5-4
42 Removing Overhead Guard, Covers, and Air Cleaner Element 5-5
43 Removing Harnesses 5-6
44 Disconnecting Pipes and Hoses5-7
45 Preparation for Removing Engine and Transmission Unit 5-9
46 Removing Engine and Transmission Unit5-10
5 Installing Engine and Transmission Unit 5-11
51 Suggestions for Installation 5-11
52 Capacity and Brand of Oils and Cooling Water 5-13
Chapter 6 3-SPEED POWERSHIFT TRANSMISSION
1 Specifications6-1
2 Structure 6-2
21 Torque Converter 6-2
22 Transmission6-3
23 Power Flow – Forward6-4
24 Power Flow – Reverse 6-5
25 Control Valve6-6
26 Main Regulator Valve 6-6
27 3 Speed Transmission Hydraulic Lines6-7
28 Automatic 3 Speed Shift Mechanism 6-9
29 Torque Converter Drive Control6-10
3 Removing Transmission 6-11
31 Removing Torque Converter6-11
4 Installing Transmission6-12
5 Disassembling Torque Converter 6-13
51 Disassembly Sequence 6-13
52 Suggestions for Disassembly6-13
6 Inspecting and Repairing Torque Converter6-14
7 Assembling Torque Converter 6-17
71 Assembly Sequence 6-17
72 Suggestions for Assembling Torque Converter6-18
8 Disassembling Transmission6-19
81 Disassembly Sequence of Control Valve and External Parts 6-19
82 Disassembling Transmission Cover and Output, 1st/3rd Clutch, Forward Clutch,
Reverse Clutch, and Input Shafts 6-20
83 Suggestions for Disassembling Transmission 6-21
84 Disassembly Sequence of Stator Shaft and Oil Pump 6-23
85 Suggestions for Disassembling Oil Pump6-24
86 Disassembly Sequence of Forward Clutch Shaft Assembly 6-26
TABLE OF CONTENTS
TOC-5
87 Suggestions for Disassembling Forward Clutch Shaft Assembly 6-27
88 Disassembly Sequence of 1st/3rd Speed Clutch Shaft Assembly 6-28
89 Suggestions for Disassembling 1st/3rd Clutch Shaft Assembly6-28
810 Disassembly Sequence of Reverse Clutch Shaft Assembly 6-29
811 Suggestions for Disassembling Reverse Clutch Shaft Assembly 6-29
9 Inspecting and Repairing Transmission 6-30
10 Assembling Transmission6-33
101 Assembly Sequence of Forward Clutch Assembly
(1st/3rd Clutch Shaft Assembly) (Reverse Clutch Shaft Assembly) 6-33
102 Suggestions for Assembling Forward Clutch Assembly
(1st/3rd Clutch Shaft Assembly) (Reverse Clutch Shaft Assembly) 6-34
103 Assembly Sequence of Stator Shaft and Oil Pump6-35
104 Suggestions for Assembling Stator Shaft and Oil Pump 6-36
105 Assembly Sequence of Input Shaft, Forward Clutch, 1st/3rd Speed Clutch,
Reverse Clutch, Output Shafts, and Transmission Cover 6-37
106 Suggestions for Assembling Input Shaft, Forward Clutch, 1st/3rd Speed Clutch,
Reverse Clutch, Output Shafts, and Transmission Cover 6-38
107 Assembly Sequence of Control Valve and External Parts6-40
11 Disassembling Control Valve 6-41
111 Disassembly Sequence 6-41
12 Inspecting and Repairing Control Valve 6-42
13 Assembling Control Valve 6-43
131 Preparation 6-43
132 Assembly Sequence 6-43
133 Suggestions for Assembling Control Valve 6-43
14 Disassembling Main Regulator Valve 6-44
141 Disassembly Sequence 6-44
15 Inspecting and Repairing Main Regulator Valve 6-44
16 Assembling Main Regulator Valve6-44
161 Suggestions for Assembly 6-44
17 Adjustment 6-45
171 Adjusting Brake Pedal and Inching Pedal6-45
172 Checking Oil Pressure6-47
173 Stall Speed Measurement 6-50
174 10 m Start Acceleration Test6-50
175 Testing Automatic 3 Speed Transmission Functions 6-51
18 Troubleshooting 6-52
19 Service Data6-57
191 Stall Speed and Oil Pressure6-57
192 Pump Boss 6-57
193 Pilot Boss6-58
194 Oil Pump6-58
195 Stator 6-59
196 Flexible Plate 6-60
197 Clutches 6-61
198 Input Shaft, Forward, Reverse, and 1st/ 3rd Speed Clutch Shafts, and Servo Case
6-62
199 Backlash of Gears 6-63
TABLE OF CONTENTS
TOC-6
1910 Control Valve6-64
1911 Main Regulator Valve 6-65
1912 Inching Pedal Control6-65
Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
1 Specifications7-1
2 Structure 7-2
21 General Description (FD100N1 to FD150AN1) 7-2
22 General Description (FD160AN1) 7-4
23 Reduction Differential7-8
3 Removing Front Wheels 7-9
31 Preparation 7-9
32 Removal Sequence7-9
33 Suggestions for Removal7-10
4 Installing Front Wheels7-11
41 Suggestions for Installation 7-11
5 Removing Front Axle and Reduction Differential 7-12
51 Preparation 7-12
52 Removal Sequence7-13
53 Suggestions for Removal7-14
6 Installing Front Axle and Reduction Differential7-15
61 Suggestions for Installation 7-15
7 Removing Reduction Differential 7-16
71 Preparation 7-16
72 Removal Sequence7-16
73 Suggestions for Removal7-16
8 Installing Reduction Differential7-17
81 Suggestions for Installation 7-17
9 Disassembling Hub Reduction (FD100N1 to FD150AN1)7-17
91 Preparation (On-Truck Condition) 7-17
92 Disassembly Sequence of Hub Reduction 7-17
93 Suggestions for Disassembling Hub Reduction7-19
94 Disassembly Sequence of Wheel Brake 7-20
95 Suggestions for Disassembling Wheel Brake 7-20
10 Inspecting and Repairing Hub Reduction (FD100N1 to FD150AN1) 7-21
101 Assembly Sequence of Wheel Brake 7-23
102 Suggestions for Assembling Wheel Brake 7-23
103 Assembly Sequence of Hub Reduction 7-24
104 Suggestions for Assembling Hub Reduction7-25
11 Disassembling Hub Reduction (FD160AN1)7-27
111 Disassembly Sequence of Hub Reduction 7-27
112 Suggestions for Disassembling Hub Reduction7-28
113 Disassembly Sequence of Wheel Brake 7-30
12 Inspecting and Repairing Hub Reduction (FD160AN1) 7-31
121 Assembly Sequence of Wheel Brake 7-33
122 Suggestions for Assembling Wheel Brake 7-33
TABLE OF CONTENTS
TOC-7
123 Assembly Sequence of Plates in Wheel Brake and Brake Cover7-34
124 Suggestions for Assembling Plates in Wheel Brake and Brake Cover7-35
125 Assembly Sequence of Hub Reduction 7-36
126 Suggestions for Assembling Hub Reduction Assembly 7-37
13 Disassembling Reduction Differential 7-42
131 Preparation 7-42
132 Disassembly Sequence of Differential Gear Assembly7-43
133 Suggestions for Disassembling Differential Gear Assembly7-43
134 Disassembly Sequence of Reduction and Parking Brake Assembly 7-44
135 Suggestions for Disassembling Reduction and Parking Brake Assembly 7-44
136 Inspecting and Repairing Reduction and Parking Brake Assembly7-45
14 Assembling Reduction Differential 7-47
141 Assembly Sequence of Differential Gear Assembly 7-47
142 Suggestions for Assembling Differential Gear Assembly7-48
143 Adjusting Preload of Reduction Pinion 7-50
144 Adjusting the Contact Between Gear and Pinion Teeth 7-52
145 Assembly Sequence of Reduction and Parking Brake Assembly 7-56
146 Assembling Reduction and Parking Brake Assembly 7-57
147 Assembly Sequence of Reduction Differential 7-58
148 Suggestions for Assembling Reduction Differential 7-58
15 Troubleshooting 7-59
16 Service Data7-60
161 Front Axle (FD100N1 to FD150AN1) 7-60
162 Front Axle (FD160AN1) 7-61
163 Reduction Differential7-64
Chapter 8 REAR AXLE
1 Specifications 8-1
2 Structure 8-2
21 Rear Axle8-2
22 Power Steering Cylinder 8-3
3 Removing Rear Wheel8-4
31 Preparation 8-4
32 Removal Sequence8-5
33 Suggestions for Removal8-6
4 Installing Rear Wheel 8-6
41 Suggestions for Installation 8-6
5 Removing Rear Axle 8-7
51 Preparation 8-7
52 Removal Sequence8-7
6 Installing Rear Axle8-9
61 Suggestions for Installation 8-9
7 Disassembling Rear Axle Assembly 8-10
71 Disassembly Sequence 8-10
72 Suggestions for Removal8-11
8 Assembling Rear Axle8-13
TABLE OF CONTENTS
TOC-8
81 Assembly Sequence 8-13
9 Disassembling Power Steering Cylinder 8-18
91 Disassembly Sequence 8-18
92 Suggestions for Disassembly8-19
10 Inspecting and Adjusting Power Steering Cylinder 8-20
11 Assembling Power Steering Cylinder 8-21
111 Assembly Sequence 8-21
112 Suggestions for Assembly 8-21
12 Adjustment 8-23
121 Measuring Minimum Turning Radius 8-23
13 Troubleshooting8-25
14 Service Data 8-26
141 Rear Axle8-26
142 Power Steering Cylinder 8-27
Chapter 9 BRAKE SYSTEM
1 Specifications9-1
11 Dry Brake System 9-1
12 Wet Brake System 9-1
2 Structure 9-2
21 Outline of Wheel Brake System (Dry Brake System) 9-2
22 Outline of Wheel Brake System (Wet Brake System) 9-3
23 Structure of Oil Cooled Braking System 9-4
24 Air Dryer 9-5
25 Relay Valve 9-8
26 Brake Control Valve9-10
27 Air Master (Dry Brake System) 9-11
28 Booster (Wet Brake System)9-14
29 Wheel Brake (Dry Brake System) 9-16
210 Parking Brake System 9-17
211 Parking Brake Lever 9-18
212 Parking Brake 9-19
3 Removing Wheel Brake 9-20
31 Preparation 9-20
32 Removal Sequence (Dry Brake System) 9-20
33 Suggestions for Removal (Dry Brake System) 9-21
4 Installing Wheel Brake9-23
41 Suggestions for Installation (Dry Brake System) 9-23
5 Disassembling Wheel Brake (Dry Brake System) 9-24
51 Disassembly Sequence 9-24
52 Suggestions for Disassembly9-25
6 Inspecting and Repairing Wheel Brake (Dry Brake System) 9-26
7 Assembling Wheel Brake (Dry Brake System) 9-27
71 Assembly Sequence 9-27
72 Suggestions for Assembly 9-28
8 Disassembling Wheel Cylinder (Dry Brake System)9-30
TABLE OF CONTENTS
TOC-9
81 Disassembly Sequence 9-30
9 Inspecting and Repairing Wheel Cylinder (Dry Brake System) 9-31
10 Assembling Wheel Cylinder9-31
101 Suggestions for Assembly 9-31
11 Disassembling Air Master (Dry Brake System) 9-32
111 Disassembly Sequence 9-32
112 Suggestions for Disassembly 9-32
12 Assembling Air Master (Dry Brake System) 9-33
121 Suggestions for Assembly 9-33
13 Disassembling Booster (Wet Brake System)9-34
131 Disassembly Sequence 9-34
132 Suggestions for Disassembly 9-35
14 Assembling Booster (Dry Brake System)9-36
141 Suggestions for Assembly 9-36
15 Disassembling Parking Brake 9-37
151 Disassembly Sequence 9-37
16 Inspecting and Repairing Parking Brake 9-38
17 Assembling Parking Brake 9-38
171 Suggestions for Assembly 9-38
18 Disassembling Brake Control Valve 9-39
181 Disassembly Sequence 9-39
19 Assembling Brake Control Valve 9-40
191 Suggestions for Assembly 9-40
20 Disassembling Air Dryer 9-41
201 Disassembly Sequence 9-41
21 Inspecting and Repairing Air Dryer9-42
211 Scheduled Inspection of Air Dryer9-42
212 Inspecting and Adjusting Air Dryer After Assembly 9-43
22 Assembling Air Dryer 9-45
221 Suggestions for Assembly 9-45
23 Adjusting and Testing Actuation 9-48
231 Inspecting Wheel Brake 9-48
232 Inspecting Booster (Wet Brake System) 9-49
233 Bleeding Brake System 9-49
234 Bleeding Brake Pedal 9-50
235 Inspecting Brake Control Valve9-50
236 Adjusting Parking Brake 9-51
237 Replacing Brake Cooling Oil9-52
238 Flushing Brake Cooling Oil System 9-55
24 Troubleshooting 9-56
241 Wheel Brake9-56
242 Parking Brake 9-57
243 Air Dryer 9-57
25 Service Data9-58
251 Brake Pedal 9-58
252 Brake Control Valve 9-58
TABLE OF CONTENTS
TOC-10
253 Air Master (Dry Brake System) 9-59
254 Booster (Wet Brake System)9-61
255 Wheel Brake (Dry Brake System) 9-62
256 Wheel Cylinder (Dry Brake System)9-63
257 Parking Brake Lever 9-63
258 Parking Brake Drum 9-64
259 Air Dryer 9-65
Chapter 10 STEERING SYSTEM
1 Specifications10-1
2 Structure 10-1
21 Steering System10-1
22 Steering Valve 10-4
23 Steering Column 10-6
3 Removing and Installing Steering Valve Piping 10-8
31 Main Components 10-8
32 Suggestions for Disassembly and Assembly10-9
4 Removing and Installing Steering Wheel, Steering Valve, and Tilt Lock
Lever 10-10
41 Removing Steering Wheel 10-12
42 Installing Steering Wheel10-12
43 Inspecting Steering Wheel After Installation10-16
44 Removing Steering Valve10-16
45 Installing Steering Wheel10-17
46 Disassembling Tilt Lock Lever 10-17
47 Assembling Tilt Lock Lever 10-18
5 Disassembling Steering Valve 10-19
51 Disassembly Sequence 10-19
52 Suggestions for Disassembling Steering Valve10-20
53 Inspecting Steering Valve after Disassembly10-23
6 Assembling Steering Valve 10-24
61 Preparation 10-24
62 Assembly Sequence 10-24
63 Suggestions for Assembly 10-25
7 Troubleshooting10-30
8 Service Data 10-31
Chapter 11 HYDRAULIC SYSTEM
1 Specifications11-1
2 Structure 11-2
21 Hydraulic Line 11-2
22 Hydraulic Tank 11-4
23 Gear Pump 11-5
24 Priority Valve11-6
25 Control Valve11-7
26 Lift and Tilt Cylinders 11-9
TABLE OF CONTENTS
TOC-11
27 Flow Regulator Valve 11-10
3 Removing Control Valve 11-11
31 Preparation 11-11
32 Removal Sequence11-12
33 Suggestions for Removal11-12
4 Removing Lift Cylinders 11-13
41 Suggestions for Removal11-14
5 Installing Lift Cylinders 11-14
51 Suggestions for Installation 11-14
6 Removing Tilt Cylinders 11-15
61 Preparation 11-15
62 Removal Sequence11-15
63 Suggestions for Removal11-16
7 Removing Gear Pump11-17
8 Disassembling Gear Pump 11-18
81 Preparation 11-18
82 Disassembly Sequence 11-18
83 Suggestions for Disassembly 11-19
9 Inspecting and Repairing Gear Pump11-19
10 Assembling Gear Pump 11-20
101 Preparation11-20
102 Assembly Sequence 11-20
103 Suggestions for Assembly 11-21
11 Installing Gear Pump 11-21
12 Disassembling Priority Valve11-22
121 Disassembly Sequence 11-22
122 Suggestions for Disassembly 11-22
13 Assembling Priority Valve 11-22
131 Suggestions for Assembly 11-22
14 Disassembling and Assembling Control Valve 11-23
141 Disassembly Sequence 11-23
142 Assembly Sequence 11-23
143 Suggestions for Assembly 11-23
144 Disassembling Inlet Valve Assembly 11-24
145 Cleaning and Inspecting Inlet Valve Assembly 11-29
146 Assembling Inlet Valve Assembly 11-29
147 Disassembling and Assembling Tilt Valve Assembly 11-33
148 Cleaning and Inspecting Tilt Valve Assembly 11-35
149 Assembling Tilt Valve Assembly 11-35
1410 Disassembling and Assembling Attachment Valve Assembly 11-37
1411 Cleaning and Inspecting Attachment Valve Assembly 11-39
1412 Assembling Attachment Valve Assembly11-39
15 Disassembling Flow Regulator Valve 11-41
151 Disassembly Sequence 11-41
16 Inspecting and Repairing Flow Regulator Valve 11-41
17 Assembling Flow Regulator Valve 11-41
TABLE OF CONTENTS
TOC-12
18 Disassembling Lift Cylinder 11-42
181 Disassembly Sequence 11-42
182 Suggestions for Disassembly11-43
19 Inspecting Lift Cylinder 11-45
20 Assembling Lift Cylinders11-47
201 Assembly Sequence 11-47
202 Suggestions for Assembly 11-47
21 Disassembling Tilt Cylinder 11-49
211 Disassembly Sequence 11-49
212 Suggestions for Disassembly11-50
22 Inspecting and Repairing Tilt Cylinder11-51
23 Assembling Tilt Cylinder 11-53
231 Assembly Sequence 11-53
232 Suggestions for Assembly 11-53
24 Inspecting and Adjusting Hydraulic System 11-54
241 Hydraulic Oil11-54
242 Test Operation of Gear Pump 11-54
243 Control Valve11-55
244 Adjusting Main Relief Valve 11-55
245 Checking Priority Valve Function 11-57
25 Drift Test 11-58
251 Loaded Drift Test 11-58
252 Tilt Drift Test11-58
26 Troubleshooting11-59
27 Service Data 11-62
271 Gear Pump 11-62
272 Control Valve11-63
273 Priority Valve11-64
274 Hydraulic Tank 11-65
275 Flow Regulator Valve 11-66
276 Lift Cylinder 11-67
277 Tilt Cylinder 11-68
Chapter 12 MAST AND FORKS
1 Specifications12-1
11 Mast 12-1
12 Forks 12-2
2 Structure 12-3
3 Removing Mast and Lift Bracket 12-4
31 Removal Sequence12-4
32 Suggestions for Removal12-5
4 Disassembling Mast Assembly 12-7
41 Disassembly Sequence 12-7
42 Suggestions for Disassembly12-8
5 Inspecting and Repairing Mast Assembly12-9
TABLE OF CONTENTS
TOC-13
6 Assembling Mast Assembly 12-11
61 Suggestions for Assembly 12-11
7 Adjusting Mast Assembly 12-16
8 Troubleshooting 12-20
9 Service Data12-21
Chapter 13 SIDE SHIFTER
1 Applicable Attachment Models13-1
2 Specifications 13-2
21 Applicable Forks 13-3
3 Structure 13-4
31 Side Shifter 13-4
32 Side Shifter With Fork Positioner 13-5
4 Removing Main Roller and Side Roller From Lift Bracket13-6
41 Removal Sequence13-6
5 Adjusting Lift Bracket Clearance 13-7
6 Installing Main Roller and Side Roller 13-7
61 Suggestions for Installation 13-7
7 Disassembling Side Shifter Cylinder 13-8
71 Disassembly Sequence 13-8
72 Suggestions for Disassembly 13-8
8 Assembling Side Shifter Cylinder 13-9
81 Assembly Sequence 13-9
82 Suggestions for Assembly 13-9
9 Inspecting and Adjusting Side Shifter Cylinder13-9
10 Troubleshooting 13-10
Chapter 14 FORK POSITIONER
1 Applicable Attachment Models14-1
2 Specifications 14-2
21 Fork Positioner 14-2
22 Applicable Forks 14-3
3 Structure 14-4
4 Removing Main Roller and Side Roller From Lift Bracket14-5
41 Removal Sequence14-5
5 Adjusting Lift Bracket Clearance 14-6
6 Installing Main Roller and Side Roller 14-6
61 Suggestions for Installation 14-6
7 Troubleshooting 14-7
Chapter 15 SERVICE DATA
1 Maintenance Schedule15-1
TABLE OF CONTENTS
TOC-14
2 Tightening Torques for Standard Bolts and Nuts 15-8
21 Metric Fine Thread15-8
22 Metric Coarse Thread 15-10
3 Periodic Replacement Parts 15-12
31 Location of Periodic Replacement Parts 15-13
4 Lubrication Schedule 15-14
41 Lubrication Chart 15-14
42 Fuel and Lubricant Specifications 15-15
43 Adjustment Value and Oil Capacity 15-16
5 Weight of Major Devices 15-17
6 Special Tools15-18
Chapter 16 HOW TO READ CIRCUIT DIAGRAMS
1 Description of Circuit Diagrams16-1
11 Circuit Diagrams16-1
12 Connector Diagrams 16-1
2 How to Read Circuit Diagrams 16-2
21 Symbols 16-3
22 Sheet Symbol 16-6
23 Connecting Lines 16-7
24 Equipment 16-8
25 Relay Contactor and Coil 16-9
26 Connectors 16-9
27 Indication of Connecting Line 16-10
28 Indication of GND (Earth)16-10
29 Indication of Another Specification 16-11
3 How to Read Connector Diagrams 16-12
4 Abbreviation16-14
Chapter 17 CIRCUIT DIAGRAM
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