Mitsubishi Forklift FD70N1 Chassis & Mast Service Manual – PDF DOWNLOAD
DESCRIPTION:
Mitsubishi Forklift FD70N1 Chassis & Mast Chassis & Mast Service Manual – PDF DOWNLOAD
- 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 forklift trucks, recommended by Mitsubishi Forklift Trucks, are outlined in the SERVICE MANUAL. Read and understand the SERVICE MANUAL before performing any lubrication or maintenance on these forklift 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 forklift 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:
FILE DETAILS:
Mitsubishi Forklift FD70N1 Chassis & Mast Service Manual – PDF DOWNLOAD
Format: PDF
Language: English
Brand: Mitsubishi
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mitsubishi Forklift FD70N1 Chassis & Mast Service Manual – PDF DOWNLOAD
Chapter 1 GENERAL INFORMATION
1 Model View 1-1
2 Applicable Truck Models 1-2
3 Serial Number Locations 1-3
4 Dimensions 1-4
5 Specifications 1-5
6 Performance 1-6
Chapter 2 COOLING SYSTEM
1 Specifications 2-1
2 Structure 2-2
3 Removing Fan Belt 2-3
3 1 Preparation 2-3
3 2 Removal Sequence 2-4
3 3 Suggestions for Removal 2-4
4 Inspecting Fan Belt 2-5
5 Removing Intercooler, Oil Cooler, and Radiator 2-5
5 1 Preparation 2-5
5 2 Removal Sequence 2-5
5 3 Installation 2-5
6 Installing Fan Belt 2-6
6 1 Suggestions for Installation 2-6
7 Inspecting Radiator 2-7
7 1 Radiator 2-7
7 2 Expansion Tank 2-7
7 3 Radiator Rubber Mount (Rubber Cushion) 2-7
7 4 Pressure Cap 2-7
8 Connecting Hoses 2-7
9 Coolant 2-8
9 1 Intercooler 2-8
9 2 Oil Cooler for Transmission 2-9
10 Troubleshooting 2-9
Chapter 3 ELECTRICAL SYSTEM
1 Electrical Components and Wiring Outline 3-1
1 1 Electrical Components of Each System 3-2
2 Console Box 3-15
2 1 Outline of Console Box 3-15
2 2 Removing Meter Panel 3-16
2 3 Installing Meter Panel 3-17
3 Main Electrical Components 3-18
3 1 Meter Panel 3-18
3 2 SCR Warning Icon 3-19
TABLE OF CONTENTS
TOC-2
3 3 DEF (Diesel Exhaust Fluid) 3-20
3 4 Key Switch (Anti-Restart Switch) 3-22
3 5 Light Switch and Turn Signal Switch 3-23
3 6 Direction (FNR) Switch 3-24
3 7 Horn 3-25
3 8 Stop Light Switch 3-25
3 9 Thermoswitch (T/C Oil) 3-26
3 10 Fuse Box 3-27
3 11 Relay Box 3-28
3 12 List of Lights 3-34
4 Battery and Maintenance 3-35
4 1 Battery Specific Gravity Condition and Adjustment 3-35
4 2 Relationship Between Electrolyte Specific Gravity and State of Charge 3-35
4 3 Precautions for Battery Charging 3-36
5 Meter Panel 3-37
5 1 Meter Panel Layout 3-37
5 2 Basic Display 3-39
5 3 Basic Operation 3-43
5 4 When a Warning Occurs 3-51
5 5 When Several Warnings Occur Simultaneously 3-53
5 6 Warning Symbols 3-56
5 7 Warning Icons 3-57
5 8 Optional Features 3-58
5 9 Hour Meter 3-65
5 10 Troubleshooting 3-67
6 Wire Color 3-68
6 1 List of Wire Color Codes 3-68
7 Troubleshooting 3-69
7 1 Engine Startup Problem 3-69
7 2 Gauge-Related Problem 3-69
7 3 Light Related Problems 3-70
7 4 Warning Device Problem 3-71
7 5 Battery-Related Problem 3-72
Chapter 4 CONTROLLER
1 Outline 4-1
2 Main Functions of Controllers 4-2
2 1 Meter Panel 4-3
2 2 VCM-6 (Vehicle Control Module) 4-3
2 3 ECM (Engine Control Module) 4-3
2 4 Input and Output Units (FC model) 4-3
2 5 Gateway Controller 4-3
2 6 HCU (Heater Control Unit) 4-3
2 7 GSE Connector 4-4
3 Service Tool 4-5
3 1 Service Tool Menus 4-5
3 2 Outline of Toolbox 4-7
4 Mast Interlock System 4-22
TABLE OF CONTENTS
TOC-3
4 1 Function 4-22
4 2 Checking the Operation of Mast Interlock System of VCM-6 Controller 4-23
4 3 Active Test Inspection Procedure 4-26
5 Driving Interlock System 4-29
5 1 Controller Function 4-29
5 2 Checking the Operation of Driving Interlock Function 4-30
5 3 Active Test Inspection Procedure 4-34
6 Seat Belt Warning Icon 4-36
6 1 Function of Seat Belt Warning Icon 4-36
6 2 Checking the Operation of Seat Belt Warning Icon 4-37
7 Parking Brake Warning Alarm and Warning Icon 4-38
7 1 Checking the Operation of Parking Brake Warning Alarm/Warning Icon 4-38
7 2 Parking Brake Warning Alarm 4-39
7 3 Checking the Operation of Parking Brake Warning Alarm/Warning Icon With Key
in OFF Position 4-41
8 Harness Codes 4-42
8 1 VCM-6 Controller 4-42
8 2 Input Unit and Output Unit 4-45
8 3 ECM 4-49
8 4 Meter Panel 4-53
8 5 Seat Switch 4-55
8 6 Parking Brake Switch 4-55
8 7 Direction Lever Switch 4-55
8 8 Travel Speed Sensor 4-56
8 9 T/M Solenoid 4-56
8 10 Unload Solenoid 4-56
8 11 Warning Alarm 4-57
8 12 Warning Alarm Relay 4-57
8 13 Warning Alarm Circuit 4-58
9 Truck Status Display and Troubleshooting 4-59
9 1 Truck Status Display 4-59
9 2 Diagnosis Table (F Code) 4-60
9 3 LED Blink Pattern 4-73
9 4 Diagnostic Codes and Troubleshooting 4-74
Chapter 5 POWER TRAIN
1 Removal and Installation 5-1
1 1 Overhead Guard, Covers, Fuel System, Intake System, and Exhaust System
5-2
1 2 Removing Harness 5-3
1 3 Removing Driving Control Related Parts 5-4
1 4 Removing Pipes, Hoses, and Radiator 5-5
1 5 Removing Engine and Transmission Unit 5-6
1 6 Installation 5-7
2 Removal and Installation 5-9
2 1 Suggestions for Removing Engine Cover and Seat 5-9
2 2 Suggestions for Removing Harnesses and Cables (Between Transmission and
Frame) 5-10
TABLE OF CONTENTS
TOC-4
2 3 Suggestions for Installing Exhaust pipe and Heat Insulator 5-10
2 4 Piping Diagram for DEF and Coolant 5-12
2 5 Suggestions for Installing DEF System 5-13
3 Service Data 5-15
Chapter 6 POWERSHIFT TRANSMISSION
1 Specifications 6-1
2 Structure 6-2
2 1 Torque Converter 6-2
2 2 Transmission 6-3
2 3 Power Flow 6-4
2 4 Control Valve 6-5
2 5 Main Regulator Valve 6-6
2 6 Hydraulic Lines Diagram of Powershift Transmission 6-7
2 7 Automatic Gear Shifting Mechanism 6-9
2 8 Torque Converter Drive Control 6-10
3 Removal and Installation 6-11
3 1 Removal 6-11
3 2 Installation 6-11
4 Disassembling Torque Converter 6-12
4 1 Disassembly Sequence 6-12
4 2 Suggestions for Disassembly 6-12
5 Inspection and Repair of Torque Converter 6-13
6 Assembling Torque Converter 6-15
6 1 Assembly Sequence 6-15
6 2 Suggestions for Assembly 6-16
7 Transmission (2nd Gear) 6-18
7 1 Disassembling Control Valve and External Parts 6-18
7 2 Disassembling Transmission Cover and Input/Counter/Output Shafts
6-19
7 3 Suggestions for Disassembly 6-20
7 4 Disassembling Stator Shaft and Oil Pump 6-21
7 5 Suggestions for Disassembly 6-22
7 6 Disassembling Input Shaft Subassembly 6-23
7 7 Suggestions for Disassembly 6-24
7 8 Disassembling Countershaft Subassembly 6-26
7 9 Suggestions for Disassembly 6-26
8 Inspection and Repair 6-27
8 1 Oil Pump 6-27
8 2 Stator Shaft 6-27
8 3 Friction Plate and Mating Plate 6-27
8 4 Input Shaft and Countershaft Clutch Drum 6-28
8 5 Input Shaft and Countershaft 6-29
8 6 Gears 6-29
8 7 Magnetic Strainer Assembly 6-29
8 8 Oil Seals of Transmission Cover and Torque Converter Case 6-29
9 Assembly 6-30
TABLE OF CONTENTS
TOC-5
9 1 Input Shaft Subassembly (Countershaft Subassembly) 6-30
9 2 Suggestions for Assembly 6-31
9 3 Stator Shaft and Oil Pump 6-32
9 4 Suggestions for Assembly 6-33
9 5 Input Shaft, Countershaft, Output Shaft, and Transmission Cover 6-34
9 6 Suggestions for Assembly 6-35
9 7 Control Valve and External Parts 6-36
9 8 Disassembling Control Valve 6-37
9 9 Suggestions for Disassembly 6-38
9 10 Inspection and Repair 6-38
9 11 Assembly 6-39
9 12 Disassembling Main Regulator Valve 6-40
9 13 Inspecting and Correcting of Main Regulator Valve 6-40
9 14 Assembling Main Regulator Valve 6-40
10 Adjustment 6-41
10 1 Measuring Oil Pressure 6-41
10 2 Testing Clutch Valve 6-42
10 3 Measuring Stall Speed 6-42
10 4 10 Meter Start Acceleration Test 6-43
10 5 Testing Automatic 2-Gear Transmission Functions 6-43
10 6 Adjusting Inching Pedal 6-44
11 Troubleshooting 6-46
12 Service Data 6-51
12 1 Stall Speed 6-51
12 2 Pump Boss 6-51
12 3 Pilot Boss 6-52
12 4 Oil Pump 6-52
12 5 Stator 6-53
12 6 Flexible Plate 6-54
12 7 Clutches 6-55
12 8 Input Shaft, Countershaft, and Transmission Cover 6-56
12 9 Backlash of Gears 6-57
12 10 Control Valve 6-58
12 11 Main Regulator Valve 6-59
12 12 Inching Pedal Control 6-60
Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
1 Specifications 7-1
2 Structure 7-2
3 Removing Front Wheels 7-3
3 1 Preparation 7-3
3 2 Removal Sequence 7-3
3 3 Suggestions for Removal 7-3
4 Installing Front Wheels 7-4
4 1 Suggestions for Installation 7-4
5 Removing Front Axle and Reduction Differential Assembly 7-5
5 1 Preparation 7-5
5 2 Removal Sequence 7-5
TABLE OF CONTENTS
TOC-6
5 3 Suggestions for Removal 7-6
6 Installing Front Axle and Reduction Differential Assembly 7-6
6 1 Suggestions for Installation 7-6
7 Disassembling and Assembling Front Axle 7-7
7 1 Preparation 7-7
7 2 Disassembly Sequence 7-7
7 3 Suggestions for Disassembly 7-8
8 Inspecting and Repairing Front Axle 7-9
9 Assembling Front Axle 7-11
9 1 Preparation 7-11
9 2 Assembly Sequence 7-11
9 3 Suggestions for Assembly 7-12
10 Disassembling Reduction Differential 7-14
10 1 Preparation 7-14
10 2 Disassembly Sequence 7-15
10 3 Suggestions for Disassembly 7-16
11 Inspecting and Repairing Reduction Differential 7-17
12 Assembling Reduction Differential 7-18
12 1 Assembly Sequence 7-18
12 2 Suggestions for Assembly 7-19
13 Troubleshooting 7-25
14 Service Data 7-26
14 1 Front Axle 7-26
14 2 Reduction Differential 7-27
Chapter 8 REAR AXLE
1 Specifications 8-1
2 Structure 8-2
2 1 Rear Axle 8-2
2 2 Power Steering Cylinder 8-3
3 Removing Rear Wheels 8-4
3 1 Preparation 8-4
3 2 Removal Sequence 8-4
3 3 Suggestions for Removal 8-5
4 Installing Rear Wheels 8-5
4 1 Suggestions for Installation 8-5
5 Removing Rear Axle 8-6
5 1 Preparation 8-6
5 2 Removal Sequence 8-6
6 Installing Rear Axle 8-8
6 1 Suggestions for Installation 8-8
7 Disassembling Rear Axle Assembly 8-9
7 1 Disassembly Sequence 8-9
7 2 Suggestions for Removal 8-10
8 Assembling Rear Axle 8-12
TABLE OF CONTENTS
TOC-7
8 1 Assembly Sequence 8-12
9 Disassembling Power Steering Cylinder 8-17
9 1 Disassembly Sequence 8-17
9 2 Suggestions for Disassembly 8-18
10 Inspecting and Adjusting Power Steering Cylinder 8-19
11 Assembling Power Steering Cylinder 8-20
11 1 Assembly Sequence 8-20
11 2 Suggestions for Assembly 8-20
12 Adjustment 8-22
12 1 Measuring Minimum Turning Radius 8-22
13 Troubleshooting 8-23
14 Service Data 8-24
14 1 Rear Axle 8-24
14 2 Power Steering Cylinder 8-25
Chapter 9 BRAKE SYSTEM
1 Specifications 9-1
2 Structure 9-2
2 1 Brake System 9-2
2 2 Wheel Brake 9-3
2 3 Brake Booster 9-4
2 4 Master Cylinder 9-5
2 5 Parking Brake 9-6
3 Disassembly and Assembly 9-7
3 1 Disassembling Wheel Brake 9-7
3 2 Inspecting and Repairing Wheel Brake 9-9
3 3 Assembling Wheel Brake 9-11
3 4 Disassembling Wheel Cylinder 9-14
3 5 Inspecting and Repairing Wheel Cylinder 9-15
3 6 Assembling Wheel Cylinder 9-15
3 7 Disassembling Master Cylinder 9-16
3 8 Inspecting and Repairing Master Cylinder 9-17
3 9 Assembling Master Cylinder 9-18
3 10 Inspecting and Repairing Master Cylinder 9-18
3 11 Disassembling Parking Brake 9-19
3 12 Inspecting and Repairing Parking Brake 9-19
3 13 Assembling Parking Brake 9-20
3 14 Adjusting Parking Brake Lever 9-20
3 15 Inspecting and Repairing Parking Brake Lever 9-20
3 16 Checking Parking Brake Lever Operating force 9-20
4 Adjustment and Actuation Test 9-21
4 1 Wheel Brake 9-21
4 2 Testing Brake Booster Actuation 9-24
4 3 Vacuum Pump and Vacuum Pump Controller Actuation Test 9-25
4 4 Parking Brake 9-25
5 Troubleshooting 9-26
TABLE OF CONTENTS
TOC-8
6 Service Data 9-28
6 1 Brake System 9-28
6 2 Master Cylinder 9-29
6 3 Wheel Cylinder 9-30
6 4 Wheel Brake 9-31
6 5 Parking Brake Lever 9-32
6 6 Parking Brake 9-32
Chapter 10 STEERING SYSTEM
1 Structure and Functions 10-1
1 1 General 10-1
1 2 Steering Valve 10-2
1 3 Steering Column 10-4
2 Disassembling and Assembling Pipes and Hoses 10-5
2 1 Suggestions for Disassembly and Assembly 10-5
3 Disassembling Steering Wheel and Steering Valve 10-6
3 1 Disassembly Sequence 10-6
3 2 Suggestions for Disassembly 10-6
4 Installing Steering Wheel and Steering Valve 10-7
4 1 Suggestions for Installation 10-8
4 2 Inspection After Installation 10-8
5 Removing Steering Valve 10-9
6 Installing Steering Valve 10-9
7 Disassembling Tilt Lock Lever 10-12
8 Assembling Tilt Lock Lever 10-13
9 Disassembling Steering Valve 10-14
9 1 Disassembly Sequence 10-14
9 2 Suggestions for Steering Valve Disassembly 10-15
9 3 Inspection After Disassembly 10-17
10 Assembling Steering Valve 10-18
10 1 Preparation 10-18
10 2 Assembly Sequence of Steering Valve 10-18
10 3 Suggestions for Assembly 10-19
11 Troubleshooting 10-23
12 Service Data 10-24
Chapter 11 HYDRAULIC SYSTEM
1 Specifications 11-1
2 Structure 11-2
2 1 Hydraulic Line 11-2
2 2 Hydraulic Tank 11-3
2 3 Gear Pump 11-4
2 4 MC Control Valve 11-5
2 5 FC Control Valve 11-12
2 6 Lift Cylinder 11-19
TABLE OF CONTENTS
TOC-9
2 7 Tilt Cylinder 11-22
2 8 Flow Regulator Valve 11-23
2 9 Down Safety Valve 11-24
2 10 Hydraulic System Diagram 11-25
3 Removing Gear Pump 11-26
3 1 Preparation (#1) 11-26
3 2 Removal Sequence 11-26
3 3 Suggestions for Removal 11-26
4 Removing Control Valve 11-27
4 1 Removal Sequence 11-27
5 Removing Lift Cylinders 11-29
5 1 Preparation (#2) 11-29
5 2 Removal Sequence 11-29
6 Removing Tilt Cylinders 11-31
6 1 Preparation (#3) 11-31
6 2 Removal Sequence 11-31
7 Disassembling Gear Pump 11-32
7 1 Disassembly Sequence 11-32
7 2 Suggestions for Disassembly 11-33
8 Inspecting and Repairing Gear Pump 11-33
9 Assembling Gear Pump 11-34
9 1 Assembly Sequence 11-34
9 2 Suggestions for Assembly 11-35
10 Disassembling Lift Cylinder 11-36
10 1 Disassembly Sequence 11-36
10 2 Suggestions for Disassembly 11-37
11 Inspecting and Repairing Lift Cylinder 11-38
12 Assembling Lift Cylinders 11-39
12 1 Assembly Sequence 11-39
12 2 Suggestions for Assembly 11-40
13 Disassembling Tilt Cylinder 11-41
13 1 Disassembly Sequence 11-41
13 2 Suggestions for Disassembly 11-41
14 Inspecting and Repairing Tilt Cylinder 11-42
15 Assembling Tilt Cylinder 11-44
15 1 Assembly Sequence 11-44
15 2 Suggestions for Assembly 11-44
16 Disassembling Flow Regulator Valve 11-45
16 1 Disassembly Sequence 11-45
17 Inspecting and Repairing Flow Regulator Valve 11-46
18 Assembling Flow Regulator Valve 11-46
19 Disassembling Down Safety Valve 11-46
19 1 Disassembly Sequence 11-46
20 Inspecting Down Safety Valve 11-46
21 Assembling Down Safety Valve 11-46
TABLE OF CONTENTS
TOC-10
22 Inspecting and Adjusting Hydraulic System 11-47
22 1 Hydraulic Oil 11-47
22 2 Suction Strainer and Return Filter 11-47
22 3 Test Operation of Gear Pump 11-47
22 4 Control Valve 11-48
22 5 Adjusting Priority Relief Valve 11-50
22 6 Adjusting Overload Relief Valve (Option) 11-51
22 7 Adjusting Flow Regulator Valve 11-51
23 Tests 11-52
23 1 Vertical Drift Test 11-52
23 2 Tilt Drift Test 11-52
24 Troubleshooting 11-53
25 Service Data 11-56
25 1 Gear Pump 11-56
25 2 MC Control Valve 11-57
25 3 FC Control Valve 11-58
25 4 Hydraulic Tank 11-59
25 5 Flow Regulator Valve 11-59
25 6 Lift Cylinder 11-60
25 7 Tilt Cylinder 11-62
Chapter 12 MAST AND FORKS
1 Simplex Mast 12-1
1 1 Mast System 12-1
1 2 Structure and Functions 12-2
1 3 Removal Sequence of Mast and Lift Bracket Assembly 12-4
1 4 Suggestions for Removing Mast and Lift Bracket Assembly 12-4
1 5 Suggestions for Installing Mast and Lift Bracket Assembly 12-7
1 6 Disassembly Sequence of Mast and Lift Bracket 12-8
1 7 Suggestions for Disassembling Mast and Lift Bracket 12-9
1 8 Inspecting Mast and Lift Bracket 12-10
1 9 Assembly Sequence of Lift Bracket Roller 12-11
1 10 Adjusting Lift Bracket Clearance 12-12
1 11 Installing Outer/Inner Mast Rollers 12-14
1 12 Installing Mast Strips 12-15
1 13 Installing Lift Cylinders 12-16
1 14 Connecting Chains 12-17
1 15 Installing Hydraulic Lines 12-18
1 16 Removing and Installing Mast Rollers and Strips Without Removing Mast From
Forklift Truck 12-20
1 17 Inspection and Adjustment 12-20
1 18 Inspecting Forks 12-21
1 19 Inspecting and Adjusting Chain Tension 12-22
1 20 Measuring Chain Elongation 12-23
1 21 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 12-24
1 22 Adjusting Mast Roller Clearance 12-25
1 23 Mast Strip Clearance Inspection and Adjustment 12-27
1 24 Adjusting Mast Tilt Angle 12-27
1 25 Inspecting and Adjusting Right and Left Lift Cylinder Stroke 12-28
TABLE OF CONTENTS
TOC-11
1 26 Troubleshooting 12-29
1 27 Service Data 12-30
2 Triplex Mast 12-32
2 1 Mast System 12-32
2 2 Structure and Functions 12-33
2 3 Removal Sequence of Mast and Lift Bracket Assembly 12-35
2 4 Suggestions for Removing Mast and Lift Bracket Assembly 12-35
2 5 Suggestions for Installing Mast and Lift Bracket Assembly 12-38
2 6 Disassembly Sequence of Mast and Lift Bracket 12-39
2 7 Preparation for Disassembling Mast and Lift Bracket 12-39
2 8 Suggestions for Disassembling Mast and Lift Bracket 12-40
2 9 Inspecting Mast and Lift Bracket 12-41
2 10 Assembly Sequence of Lift Bracket Roller 12-42
2 11 Adjusting Lift Bracket Clearance 12-43
2 12 Installing Outer/Middle/Inner Mast Rollers 12-45
2 13 Installing Mast Strips 12-46
2 14 Installing Second Lift Cylinder 12-47
2 15 Installing First Lift Cylinder 12-48
2 16 Connecting Chains 12-49
2 17 Installing Hydraulic Lines 12-50
2 18 Removing and Installing Mast Rollers and Strips Without Removing Mast From
Forklift Truck 12-52
2 19 Inspection and Adjustment 12-54
2 20 Inspecting Forks 12-54
2 21 Inspecting and Adjusting Chain Tension 12-55
2 22 Measuring Chain Elongation 12-56
2 23 Adjusting Clearance Between Lift Bracket Roller and Inner Mast 12-57
2 24 Adjusting Mast Roller Clearance 12-58
2 25 Inspecting and Adjusting Mast Strip Clearance 12-62
2 26 Adjusting Mast Tilt Angle 12-62
2 27 Inspecting and Adjusting Right and Left Second Lift Cylinder Stroke 12-63
2 28 Troubleshooting 12-64
2 29 Service Data 12-65
Chapter 13 SIDE SHIFTER
1 Applicable Attachment Type 13-1
2 Specifications 13-1
3 Structure 13-2
4 Removing Side Shifter 13-4
4 1 Preparation 13-4
4 2 Removing Side Shifter Assembly 13-5
4 3 Suggestions for Removal 13-5
5 Installing Side Shifter 13-6
5 1 Suggestions for Installation 13-6
6 Disassembling Side Shifter Assembly 13-7
6 1 Preparation 13-7
6 2 Disassembly Sequence 13-7
6 3 Suggestions for Disassembly 13-9
TABLE OF CONTENTS
TOC-12
7 Inspecting and Repairing Side Shifter Assembly 13-9
8 Assembling Side Shifter Assembly 13-9
8 1 Suggestions for Assembly 13-9
9 Disassembling Side Shifter Cylinder 13-10
9 1 Disassembly Sequence 13-10
9 2 Suggestions for Disassembly 13-12
10 Inspecting and Repairing Side Shifter Cylinder 13-13
11 Assembling Side Shifter Cylinder 13-14
11 1 Assembly Sequence 13-14
11 2 Suggestions for Assembly 13-16
12 Inspecting and Adjusting Side Shifter Cylinder 13-16
13 Troubleshooting 13-17
14 Service Data 13-19
14 1 Cylinders for Side Shifter and Side Shifter With Fork Positioner 13-19
Chapter 14 FORK POSITIONER
1 Applicable Attachment Type 14-1
2 Specifications 14-1
3 Structure 14-2
4 Suggestions for Removal and Installation 14-4
4 1 Removal 14-4
4 2 Suggestions for Removal 14-6
4 3 Inspection and Repair 14-7
5 Installation 14-8
5 1 Suggestions for Installation 14-8
6 Disassembly and Assembly 14-9
6 1 Disassembly Sequence 14-9
6 2 Suggestion for Disassembly 14-10
7 Inspection and Repair 14-11
8 Assembly 14-12
8 1 Assembly Sequence 14-12
8 2 Suggestion for Assembly 14-12
9 Inspection and Adjustment 14-13
9 1 Inspecting right and left shift amounts 14-13
10 Troubleshooting 14-14
11 Service Data 14-15
11 1 Side Shifter Cylinder 14-15
Chapter 15 SERVICE DATA
1 Maintenance Schedule 15-1
2 Tightening Torques for Standard Bolts and Nuts 15-6
2 1 Metric Fine Thread 15-6
2 2 Metric Coarse Thread 15-8
TABLE OF CONTENTS
TOC-13
3 Periodic Replacement Parts 15-10
3 1 Safety Critical Parts 15-11
4 Lubrication Schedule 15-13
4 1 Lubrication Chart 15-13
4 2 Recommended Fuels and Oils 15-14
4 3 Adjustment Value and Oil Capacity 15-15
4 4 Fuel Information 15-16
4 5 Coolant Information 15-17
4 6 DEF Information 15-19
5 Weight of Major Devices 15-21
6 Special Tools 15-22
6 1 Special Service Tools 15-22
Chapter 16 OPTIONS
1 CSQ Radiator Kit 16-1
2 Radiator Indicator Kit 16-2
3 Armrest FNR Control Kit 16-3
4 Backup Handle Kit 16-4
5 Extinguisher kit 16-5
6 Load Meter 2SP Kit 16-6
7 Rear View Mirror (Fender) Kit 16-7
8 Rear View Mirror (HG) Kit 16-8
9 Strobe Light (Above) Kit 16-9
10 Turn Signal Kit 16-10
11 Tire House Cover Kit 16-11
12 Under Cover Kit 16-12
13 Utility Tray Kit 16-13
14 Drawbar Pin Kit 16-14
15 Weight Hook Kit 16-15
16 Clear Roof Kit 16-16
17 Large Capacity Alternator Kit 16-17
18 Power Select Switch Kit 16-18
19 Speed Limiter Switch Kit 16-19
20 Dust Proof Breather Kit 16-20
21 Steering Wheel With Knob Kit 16-21
22 Dust Indicator Kit 16-22
23 Elevated Air Intake Kit 16-23
24 Pre-Cleaner Kit 16-24
25 Dual Element Air Cleaner Kit 16-25
26 CV Plug Kit (3v) 16-26
27 Floor Mat Kit 16-27
TABLE OF CONTENTS
TOC-14
Chapter 17 HOW TO READ CIRCUIT DIAGRAMS
1 Description of Circuit Diagrams 17-1
1 1 Circuit Diagrams 17-1
1 2 Connector Diagrams 17-1
2 How to Read Circuit Diagrams 17-2
2 1 Symbols 17-3
2 2 Sheet Symbol 17-6
2 3 Connecting Lines 17-7
2 4 Equipment 17-8
2 5 Relay Contactor and Coil 17-9
2 6 Connectors 17-9
2 7 Indication of Connecting Line 17-10
2 8 Indication of GND (Earth) 17-10
2 9 Indication of Another Specification 17-11
3 How to Read Connector Diagrams 17-12
4 Abbreviation 17-14
Chapter 18 CIRCUIT DIAGRAM
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