Mitsubishi Forklift FD60NM FD70NM MC Service Manual – PDF DOWNLOAD
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Mitsubishi Forklift FD60NM FD70NM MC Service Manual – PDF DOWNLOAD
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Language: English
Brand: Mitsubishi
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Mitsubishi Forklift FD60NM FD70NM MC Service Manual – PDF DOWNLOAD
Chassis & Mast MC
FD60NM F20D-20011-up
FD70NM F20D-30011-up, AF20D-40011-up
- 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 related signs Meanings R WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. R CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. NOTE NOTE indicates a condition that can cause damage to or shorten the service life of the machine.
TABLE OF CONTENTS:
Mitsubishi Forklift FD60NM FD70NM MC Service Manual – PDF DOWNLOAD
Chapter 1 GENERAL INFORMATION
1 Model View 1-1
2 Applicable Truck Models1-2
3 Serial Number Locations1-3
4 Dimensions 1-4
5 Specifications 1-5
6 Performance1-6
Chapter 2 COOLING SYSTEM
1 Specifications 2-1
2 Structure 2-2
3 Removing Fan Belt2-3
31 Preparation 2-3
32 Removal Sequence2-4
33 Suggestions for Removal2-4
4 Inspecting and Adjusting Fan Belt2-5
41 Inspecting Fan Belt2-5
42 Adjusting Fan Belt Tension 2-5
5 Installing Fan Belt 2-5
51 Suggestions for Installation 2-5
6 Removing Oil Cooler and Radiator2-6
61 Preparation 2-6
62 Removal Sequence2-6
63 Installation 2-6
7 Inspecting Radiator 2-7
71 Radiator 2-7
72 Radiator Rubber Mount (Rubber Cushion) 2-7
73 Radiator Cap2-7
74 Connecting Hoses 2-7
75 Coolant 2-8
76 Oil Cooler for Transmission 2-9
8 Troubleshooting 2-10
Chapter 3 ELECTRICAL SYSTEM
1 Electrical Components and Wiring Outline 3-1
11 Electrical Components and Wiring Diagram of Each Component3-2
2 Console Box3-6
21 Outline of Console Box 3-6
22 Disassembling Console Box3-7
23 Assembling Console Box3-7
3 Meter Panel 3-8
31 Disassembling Meter Panel 3-8
32 Assembling Meter Panel 3-8
TABLE OF CONTENTS
TOC-2
33 Bulb Replacement 3-8
34 Warning Icons and Indicators 3-9
35 Hour Meter 3-10
36 Fuel Gauge 3-10
37 Connector 3-11
4 Switch Box 3-12
5 Main Electrical Components 3-13
51 Key Switch (Anti-Restart Switch) 3-13
52 Light Switch and Turn Signal Switch 3-14
53 Direction (FNR) Switch3-15
54 Horn 3-16
55 Tank Unit3-16
56 Stop Light Switch 3-17
57 Thermoswitch (T/C Oil) 3-18
58 Fuse Box 3-19
59 Relay Box3-21
510 List of Lights3-26
6 Battery and Maintenance3-28
61 Battery Specific Gravity Condition and Adjustment 3-28
62 Relationship Between Electrolyte Specific Gravity and State of Charge 3-28
63 Precautions for Battery Charging 3-29
7 Wire Color3-30
71 List of Wire Color Codes 3-30
8 Troubleshooting3-31
81 Starter System 3-31
82 Gauges 3-31
83 Light Related Problems 3-32
84 Warning Device Problem3-33
85 Battery-Related Problem 3-34
Chapter 4 POWER TRAIN
1 Removal and Installation 4-1
11 Overhead Guard, Covers, and Air Cleaner Element4-2
12 Removing Harness4-3
13 Removing Driving Control Related Parts4-4
14 Removing Pipes/Hoses, Oil Cooler, and Radiator 4-5
15 Removing Engine and Transmission Unit 4-6
16 Installation 4-7
17 Suggestions for Removing Harnesses and Cables
(Between Transmission and Frame) 4-9
2 Service Data 4-10
Chapter 5 POWERSHIFT TRANSMISSION
1 Specifications5-1
2 Structure 5-2
21 Torque Converter 5-2
22 Transmission5-3
TABLE OF CONTENTS
TOC-3
23 Power Flow 5-4
24 Control Valve 5-5
25 Main Regulator Valve 5-6
26 Hydraulic Lines Diagram of Powershift Transmission5-7
27 Automatic Gear Shifting Mechanism5-8
28 Torque Converter Drive Control 5-9
3 Removal and Installation5-10
31 Removal 5-10
32 Installation 5-10
4 Disassembling Torque Converter 5-11
41 Disassembly Sequence 5-11
42 Suggestions for Disassembly 5-11
5 Inspecting and Repairing Torque Converter5-12
6 Assembling Torque Converter 5-14
61 Assembly Sequence 5-14
62 Suggestions for Assembly 5-15
7 Transmission (2nd Gear) 5-17
71 Disassembling Control Valve and External Parts 5-17
72 Disassembling Transmission Cover and Input/Counter/Output Shafts 5-18
73 Suggestions for Disassembly 5-19
74 Disassembling Stator Shaft and Oil Pump 5-20
75 Suggestions for Disassembly 5-21
76 Disassembling Input Shaft Subassembly5-22
77 Suggestions for Disassembly 5-23
78 Disassembling Countershaft Subassembly 5-25
79 Suggestions for Disassembly 5-25
8 Inspection and Repair5-26
81 Oil Pump5-26
82 Stator Shaft 5-26
83 Friction Plate and Mating Plate5-26
84 Input Shaft and Countershaft Clutch Drum 5-27
85 Input Shaft and Countershaft 5-28
86 Gears 5-28
87 Magnetic Strainer Assembly5-28
88 Oil Seals of Transmission Cover and Torque Converter Case 5-28
9 Assembly5-29
91 Input Shaft Subassembly (Countershaft Subassembly) 5-29
92 Suggestions for Assembly 5-30
93 Stator Shaft and Oil Pump 5-31
94 Suggestions for Assembly 5-32
95 Input Shaft, Countershaft, Output Shaft, and Transmission Cover5-33
96 Suggestions for Assembly 5-34
97 Control Valve and External Parts 5-35
98 Disassembling Control Valve 5-36
99 Suggestions for Disassembly 5-37
910 Inspection and Repair5-37
911 Assembly5-38
912 Disassembling Main Regulator Valve 5-39
913 Inspecting and Correcting Main Regulator Valve 5-39
TABLE OF CONTENTS
TOC-4
914 Assembling Main Regulator Valve 5-39
10 Adjustment 5-40
101 Measuring Oil Pressure 5-40
102 Testing Clutch Valve 5-41
103 Measuring Stall Speed5-41
104 10 Meter Start Acceleration Test 5-42
105 Testing Automatic 2-Gear Transmission Functions5-42
106 Adjusting Inching Pedal 5-43
11 Troubleshooting5-45
12 Service Data 5-50
121 Stall Speed 5-50
122 Pump Boss 5-50
123 Pilot Boss5-51
124 Oil Pump 5-51
125 Stator 5-52
126 Flexible Plate5-53
127 Clutches 5-54
128 Input Shaft, Countershaft, and Transmission Cover 5-55
129 Backlash of Gears 5-56
1210 Control Valve 5-57
1211 Main Regulator Valve 5-58
1212 Inching Pedal Control5-58
Chapter 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
1 Specifications6-1
2 Structure 6-2
3 Removing Front Wheels 6-3
31 Preparation 6-3
32 Removal Sequence6-3
33 Suggestions for Removal6-3
4 Installing Front Wheels6-4
41 Suggestions for Installation 6-4
5 Removing Front Axle and Reduction Differential Assembly 6-5
51 Preparation 6-5
52 Removal Sequence6-5
53 Suggestions for Removal6-6
6 Installing Front Axle and Reduction Differential Assembly 6-6
61 Suggestions for Installation 6-6
7 Disassembling and Assembling Front Axle 6-7
71 Preparation 6-7
72 Disassembly Sequence 6-7
73 Suggestions for Disassembly6-8
8 Inspecting and Repairing Front Axle 6-9
9 Assembling Front Axle 6-11
91 Preparation 6-11
92 Assembly Sequence 6-11
TABLE OF CONTENTS
TOC-5
93 Suggestions for Assembly 6-12
10 Disassembling Reduction Differential 6-14
101 Preparation 6-14
102 Disassembly Sequence 6-15
103 Suggestions for Disassembly 6-16
11 Inspecting and Repairing Reduction Differential 6-17
12 Assembling Reduction Differential 6-18
121 Assembly Sequence 6-18
122 Suggestions for Assembly 6-19
13 Troubleshooting 6-24
14 Service Data6-25
141 Front Axle 6-25
142 Reduction Differential6-26
Chapter 7 REAR AXLE
1 Specifications 7-1
2 Structure 7-2
21 Rear Axle7-2
22 Power Steering Cylinder 7-3
3 Removing Rear Wheels 7-4
31 Preparation 7-4
32 Removal Sequence7-4
33 Suggestions for Removal7-5
4 Installing Rear Wheels 7-5
41 Suggestions for Installation 7-5
5 Removing Rear Axle 7-6
51 Preparation 7-6
52 Removal Sequence7-6
6 Installing Rear Axle7-8
61 Suggestions for Installation 7-8
7 Disassembling Rear Axle Assembly 7-9
71 Disassembly Sequence 7-9
72 Suggestions for Removal7-10
8 Assembling Rear Axle7-12
81 Assembly Sequence 7-12
9 Disassembling Power Steering Cylinder7-17
91 Disassembly Sequence 7-17
92 Suggestions for Disassembly 7-18
10 Inspecting and Adjusting Power Steering Cylinder 7-19
11 Assembling Power Steering Cylinder7-20
111 Assembly Sequence 7-20
112 Suggestions for Assembly 7-20
12 Adjustment 7-22
121 Measuring Minimum Turning Radius 7-22
13 Troubleshooting 7-23
TABLE OF CONTENTS
TOC-6
14 Service Data 7-24
141 Rear Axle7-24
142 Power Steering Cylinder 7-25
Chapter 8 BRAKE SYSTEM
1 Specifications8-1
2 Structure 8-2
21 Brake System8-2
22 Wheel Brake 8-3
23 Brake Booster 8-4
24 Master Cylinder8-5
25 Parking Brake 8-6
3 Disassembly and Assembly 8-7
31 Disassembling Wheel Brake 8-7
32 Inspecting and Repairing Wheel Brake 8-9
33 Assembling Wheel Brake8-11
34 Disassembling Wheel Cylinder 8-14
35 Inspecting and Repairing Wheel Cylinder 8-15
36 Assembling Wheel Cylinder8-15
37 Disassembling Master Cylinder8-16
38 Inspecting and Repairing Master Cylinder 8-17
39 Assembling Master Cylinder8-18
310 Inspecting and Repairing Master Cylinder 8-18
311 Disassembling Parking Brake 8-19
312 Inspecting and Repairing Parking Brake 8-19
313 Assembling Parking Brake 8-20
314 Adjusting Parking Brake Lever 8-20
315 Inspecting and Repairing Parking Brake Lever 8-20
316 Checking Parking Brake Lever Operating force8-20
4 Adjustment and Actuation Test8-21
41 Wheel Brake 8-21
42 Testing Brake Booster Actuation 8-24
43 Vacuum Pump and Vacuum Pump Controller Actuation Test 8-25
44 Parking Brake 8-26
5 Troubleshooting8-27
6 Service Data 8-29
61 Brake System8-29
62 Master Cylinder8-30
63 Wheel Cylinder 8-31
64 Wheel Brake 8-32
65 Parking Brake Lever 8-33
66 Parking Brake 8-33
Chapter 9 STEERING SYSTEM
1 Structure and Functions 9-1
11 General 9-1
12 Steering Valve 9-2
TABLE OF CONTENTS
TOC-7
13 Steering Column 9-4
2 Disassembling and Assembling Pipes and Hoses 9-6
21 Suggestions for Disassembly and Assembly9-6
3 Disassembling Steering Wheel and Steering Valve 9-7
31 Disassembly Sequence 9-7
32 Suggestions for Disassembly 9-8
4 Installing Steering Wheel and Steering Valve 9-9
41 Suggestions for Installation 9-11
42 Inspection After Installation9-12
5 Removing Steering Valve9-13
6 Installing Steering Valve9-13
7 Disassembling Tilt Lock Lever 9-16
8 Assembling Tilt Lock Lever 9-17
9 Disassembling Steering Valve 9-18
91 Disassembly Sequence 9-18
92 Suggestions for Steering Valve Disassembly9-19
93 Inspection After Disassembly 9-21
10 Assembling Steering Valve 9-22
101 Preparation 9-22
102 Assembly Sequence of Steering Valve 9-22
103 Suggestions for Assembly 9-23
11 Troubleshooting 9-27
12 Service Data9-28
Chapter 10 HYDRAULIC SYSTEM
1 Specifications 10-1
2 Structure 10-2
21 Hydraulic Line 10-2
22 Hydraulic Tank 10-3
23 Gear Pump 10-4
24 Control Valve 10-5
25 Lift Cylinder 10-12
26 Tilt Cylinder 10-13
27 Flow Regulator Valve 10-14
28 Down Safety Valve10-15
29 Hydraulic System Diagram 10-16
3 Removing Gear Pump10-17
31 Preparation 10-17
32 Removal Sequence10-17
33 Suggestions for Removal10-17
4 Removing Control Valve 10-18
41 Removal Sequence10-18
5 Removing Lift Cylinders 10-19
51 Removal Sequence10-19
6 Removing Tilt Cylinders 10-21
TABLE OF CONTENTS
TOC-8
61 Preparation (#3)10-21
62 Removal Sequence10-21
7 Disassembling Gear Pump 10-22
71 Disassembly Sequence 10-22
72 Suggestions for Disassembly10-23
8 Inspecting and Repairing Gear Pump 10-24
9 Assembling Gear Pump 10-25
91 Assembly Sequence 10-25
92 Suggestions for Assembly 10-26
10 Disassembling Lift Cylinder 10-27
101 Disassembly Sequence 10-27
102 Suggestions for Disassembly10-28
11 Inspecting and Repairing Lift Cylinder10-29
12 Assembling Lift Cylinders10-31
121 Assembly Sequence 10-31
122 Suggestions for Assembly 10-31
13 Disassembling Tilt Cylinder 10-32
131 Disassembly Sequence 10-32
132 Suggestions for Disassembly10-32
14 Inspecting and Repairing Tilt Cylinder10-33
15 Assembling Tilt Cylinder 10-35
151 Assembly Sequence 10-35
152 Suggestions for Assembly 10-35
16 Disassembling Flow Regulator Valve 10-36
161 Disassembly Sequence 10-36
17 Inspecting and Repairing Flow Regulator Valve10-37
18 Assembling Flow Regulator Valve 10-37
19 Disassembling Down Safety Valve 10-37
191 Disassembly Sequence 10-37
20 Inspecting Down Safety Valve 10-37
21 Assembling Down Safety Valve 10-37
22 Inspecting and Adjusting Hydraulic System 10-38
221 Hydraulic Oil10-38
222 Suction Strainer and Return Filter 10-38
223 Test Operation of Gear Pump 10-38
224 Control Valve10-39
225 Adjusting Priority Relief Valve 10-41
226 Adjusting Overload Relief Valve (Option)10-42
227 Adjusting Flow Regulator Valve10-42
23 Tests 10-43
231 Vertical Drift Test 10-43
232 Tilt Drift Test10-43
24 Troubleshooting10-44
25 Service Data 10-48
251 Gear Pump 10-48
TABLE OF CONTENTS
TOC-9
252 Control Valve 10-49
253 Hydraulic Tank 10-50
254 Flow Regulator Valve 10-50
255 Lift Cylinder 10-51
256 Tilt Cylinder 10-52
Chapter 11 MAST AND FORKS
1 Simplex Mast 11-1
11 Mast System11-1
12 Structure and Functions 11-2
13 Removal Sequence of Mast and Lift Bracket Assembly 11-5
14 Suggestions for Removing Mast and Lift Bracket Assembly11-6
15 Suggestions for Installing Mast and Lift Bracket Assembly 11-9
16 Disassembly Sequence of Mast and Lift Bracket 11-10
17 Suggestions for Disassembling Mast and Lift Bracket 11-11
18 Inspecting Mast and Lift Bracket 11-12
19 Assembly Sequence of Lift Bracket Roller 11-14
110 Adjusting Lift Bracket Clearance 11-16
111 Installing Outer/Inner Mast Rollers11-18
112 Installing Mast Strips 11-19
113 Installing Lift Cylinders 11-20
114 Connecting Chains11-21
115 Installing Hydraulic Lines11-22
116 Removing and Installing Mast Rollers and Strips Without
Removing Mast From Forklift Truck 11-24
117 Inspection and Adjustment 11-25
118 Inspecting Forks 11-25
119 Inspecting and Adjusting Chain Tension11-27
120 Measuring Chain Elongation11-28
121 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 11-29
122 Adjusting Mast Roller Clearance 11-30
123 Inspecting and Adjusting Mast Strip Clearance11-32
124 Adjusting Mast Tilt Angle11-32
125 Inspecting and Adjusting Right and Left Lift Cylinder Stroke 11-33
126 Troubleshooting 11-34
127 Service Data11-35
2 Triplex Mast11-37
21 Mast System11-37
22 Structure and Functions 11-38
23 Removal Sequence of Mast and Lift Bracket Assembly 11-41
24 Suggestions for Removing Mast and Lift Bracket Assembly11-42
25 Suggestions for Installing Mast and Lift Bracket Assembly 11-45
26 Disassembly Sequence of Mast and Lift Bracket 11-46
27 Preparation for Disassembling Mast and Lift Bracket11-46
28 Suggestions for Disassembling Mast and Lift Bracket 11-47
29 Inspecting Mast and Lift Bracket 11-48
210 Assembly Sequence of Lift Bracket Roller 11-50
211 Adjusting Lift Bracket Clearance 11-52
212 Installing Outer/Middle/Inner Mast Rollers 11-54
213 Installing Mast Strips 11-55
TABLE OF CONTENTS
TOC-10
214 Installing Second Lift Cylinder 11-56
215 Installing First Lift Cylinder 11-57
216 Connecting Chains11-58
217 Installing Hydraulic Lines11-59
218 Removing and Installing Mast Rollers and Strips Without
Removing Mast From Forklift Truck 11-61
219 Inspection and Adjustment 11-63
220 Inspecting Forks 11-63
221 Inspecting and Adjusting Chain Tension11-65
222 Measuring Chain Elongation11-66
223 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 11-67
224 Adjusting Mast Roller Clearance 11-68
225 Inspecting and Adjusting Mast Strip Clearance11-72
226 Adjusting Mast Tilt Angle11-72
227 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke11-73
228 Troubleshooting 11-74
229 Service Data11-75
Chapter 12 SIDE SHIFTER
1 Applicable Attachment Type 12-1
2 Specifications12-1
3 Structure 12-2
4 Removing Side Shifter12-3
41 Preparation 12-3
42 Removing Side Shifter Assembly 12-3
43 Suggestions for Removal12-4
5 Installing Side Shifter 12-5
51 Suggestions for Installation 12-5
6 Disassembling Side Shifter Assembly12-6
61 Preparation 12-6
62 Disassembly Sequence 12-6
63 Suggestions for Disassembly12-7
7 Inspecting and Repairing Side Shifter Assembly 12-7
8 Assembling Side Shifter Assembly12-7
81 Suggestions for Assembly 12-7
9 Disassembling Side Shifter Cylinder 12-8
91 Disassembly Sequence 12-8
92 Suggestions for Disassembly12-8
10 Inspecting and Repairing Side Shifter Cylinder12-9
11 Assembling Side Shifter Cylinder 12-10
111 Assembly Sequence 12-10
112 Suggestions for Assembly 12-10
12 Inspecting and Adjusting Side Shifter Cylinder12-10
13 Troubleshooting12-11
14 Service Data 12-12
141 Side Shifter Cylinder 12-12
TABLE OF CONTENTS
TOC-11
Chapter 13 SERVICE DATA
1 Maintenance Schedule13-1
2 Tightening Torques for Standard Bolts and Nuts 13-6
21 Metric Fine Thread13-6
22 Metric Coarse Thread 13-8
3 Periodic Replacement Parts 13-10
31 Safety Critical Parts13-11
4 Lubrication Schedule 13-13
41 Lubrication Chart 13-13
42 Fuel and Lubricant Specifications 13-14
43 Adjustment Value and Oil Capacity 13-15
5 Weight of Major Devices 13-17
6 Special Tools13-18
61 Special Service Tools 13-18
Chapter 14 HOW TO READ CIRCUIT DIAGRAMS
1 Description of Circuit Diagrams14-1
11 Circuit Diagrams 14-1
12 Connector Diagrams 14-1
2 How to Read Circuit Diagrams 14-2
21 Symbols 14-3
22 Sheet Symbol 14-6
23 Connecting Lines 14-7
24 Equipment 14-8
25 Relay Contactor and Coil14-9
26 Connectors 14-9
27 Indication of Connecting Line 14-10
28 Indication of GND (Earth)14-10
29 Indication of Another Specification 14-11
3 How to Read Connector Diagrams14-12
4 Abbreviation14-14
Chapter 15 CIRCUIT DIAGRAM
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.