Mitsubishi Forklift FG20S FD20HS FG25S FD25HS FG30S FD30HS Trucks Service Manual – PDF DOWNLOAD
FILE DETAILS:
Mitsubishi Forklift FG20S FD20HS FG25S FD25HS FG30S FD30HS Trucks Service Manual – PDF DOWNLOAD
Format: PDF
Language: English
Brand: Mitsubishi
DESCRIPTION:
Mitsubishi Forklift FG20S FD20HS FG25S FD25HS FG30S FD30HS Trucks Service Manual – PDF DOWNLOAD
For use with K25 and S4S Engine Service Manuals.
Pub.No : 99729-10100
FG20S CF54-10011-up
FG25S CF54-50011-up
FG30S CF55-10011-up
FD20HS CF50-10011-up
FD25HS CF50-50011-up
FD30HS CF51-10011-up
FOREWORD :
This service manual is a guide for servicing Mitsubishi forklift trucks. The long productive life of your 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 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. For engine servicing, please refer to the applicable engine service manual.
SAFETY PRECAUTIONS:
- This service manual contains the proper and safe lubrication and maintenance information recommended by Mitsubishi Forklift Trucks. Please read this service manual carefully and fully understand the procedures before proceeding with any maintenance work. Improper lubrication or maintenance work is dangerous and could result in injury or death.
- Be sure to read this service manual and understand the contents before proceeding with the work. Improper truck operation is dangerous and could result in injury or death. Be sure to familiarize yourself with the systems and components described herein before proceeding with removal or disassembly work. For heavyweight components, BE SURE to check the weight of each component beforehand by referring to this service manual. Also, for safety, use proper lifting equipment for removal/ installation work. Following is a list of basic precautions that should always be observed.
TABLE OF CONTENTS:
Mitsubishi Forklift FG20S FD20HS FG25S FD25HS FG30S FD30HS Trucks Service Manual – PDF DOWNLOAD
Chapter 1 GENERAL INFORMATION
1 Model View 1-1
2 Applicable Truck Model 1-2
3 Serial Number Locations1-3
4 Dimensions 1-4
5 Technical Data 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 Sequence2-3
33 Suggestions for Removal2-3
4 Installing Fan Belt 2-4
41 Suggestions for Installation 2-4
5 Inspecting and Adjusting Cooling System 2-4
51 Fan Belt Inspection2-4
52 Fan Belt Tension Adjustment 2-4
53 Connecting Hoses2-5
54 Cooling Water 2-5
55 Radiator Cap2-5
Chapter 3 ELECTRICAL SYSTEM
1 Electrical Components and Wiring Outline 3-1
11 Locations of Electrical Components 3-1
2 Console Box3-8
21 Console Box Outline 3-8
22 Disassembling Console Box3-9
23 Assembling Console Box3-9
3 Meter Panel 3-10
31 Disassembling Meter Panel 3-10
32 Assembling Meter Panel 3-10
33 Bulb Replacement 3-10
34 Warning Lamps and Indicators3-11
35 Hour Meter 3-12
36 Fuel Gauge 3-12
37 Connector 3-13
4 Main Electrical Components3-15
41 Key Switch 3-15
42 Key Switch (Anti-Restart Switch) 3-15
43 Light Switch and Turn Signal Switch 3-16
44 Direction (FNR) Switch 3-17
TABLE OF CONTENTS
TOC-2
45 GAS/LPG Select Switch 3-18
46 Horn 3-19
47 Tank Unit3-19
48 Brake Oil Level 3-20
49 Stop Light Switch 3-20
410 Thermoswitch (Engine Coolant Temperature) 3-21
411 Relay 3-22
412 Fuse Box 3-25
413 Glow Timer and Glow Relay (Diesel Model) 3-26
414 Front Combination Light3-28
415 Front Combination Harness 3-29
416 Rear Combination Light (Option) 3-30
417 Rear Combination Harness (Option) 3-31
418 List of Lights3-32
5 Battery and Maintenance3-33
51 State of Charge and Electrolyte Specific Gravity (SG) Adjustment3-33
52 Specific Gravity Reading and State of Charge 3-33
53 Precautions for Battery Charging 3-33
6 Wire Color3-34
61 List of Wire Color Codes 3-34
7 Troubleshooting3-35
71 Starter System 3-35
72 Gauges 3-35
73 Lighting System3-36
74 Alarm Unit 3-37
75 Battery3-37
Chapter 4 POWER TRAIN
1 Installation of Engine and Transmission Assembly
(for Dual Gas/LPG Models) 4-1
11 Removal Sequence of Overhead Guard Cover, Air Cleaner, and Others 4-1
12 Suggestions for Removing Overhead Guard Cover, Air Cleaner,
and Others 4-2
13 Removal Sequence of Controls4-3
14 Suggestions for Removing Controls 4-3
15 Suggestions for Installing Controls 4-3
16 Preparation for Removing Pipes and Radiator 4-4
17 Removal Sequence of Pipes and Radiator 4-4
18 Suggestions for Installing Pipes and Radiator 4-4
19 Preparation for Removing Engine and Transmission Assembly 4-5
110 Removal Sequence of Engine and Transmission Assembly 4-5
111 Suggestions for Removing Engine and Transmission Assembly 4-5
112 Suggestions for Installing Engine and Transmission Assembly4-6
2 Installation of Engine and Transmission Assembly
(for Diesel Model) 4-7
21 Removal Sequence of Overhead Guard Cover, Air Cleaner, and Others 4-7
22 Suggestions for Removing Overhead Guard Cover, Air Cleaner,
and Others 4-8
TABLE OF CONTENTS
TOC-3
23 Preparation for Removing Pipes and Radiator 4-9
24 Removal Sequence of Pipes and Radiator 4-9
25 Suggestions for Removing Pipes and Radiator4-9
26 Suggestions for Installing Pipes and Radiator 4-9
27 Preparation for Removing Engine and Transmission Assembly 4-10
28 Removal Sequence of Engine and Transmission Assembly4-10
29 Suggestions for Removing Engine and Transmission Assembly 4-10
210 Suggestions for Installing Engine and Transmission Assembly4-10
Chapter 5 POWERSHIFT TRANSMISSION
1 Structure 5-1
11 External View of Torque Converter Transmission 5-1
12 External View of Control Valve 5-2
13 Transmission Components 5-3
14 Torque Converter Components 5-5
15 Torque Converter Drive Control Components5-6
16 Schematic Diagram of Powershift Transmission Hydraulic System 5-7
2 Removing Transmission 5-8
21 Suggestions for Removal5-8
3 Installing Transmission 5-8
31 Suggestions for Installation 5-8
4 Disassembling Torque Converter Transmission 5-9
41 Preparation 5-9
42 Removing Transmission Accessories 5-10
43 Removing Oil Pump 5-14
44 Removing Transmission Housing 5-15
45 Removing Input Shaft, Idler Shaft, and Output Gear 5-17
46 Disassembling Transmission Housing 5-19
47 Disassembling Torque Converter Housing 5-19
48 Disassembling Idler Shaft 5-20
49 Disassembling Output Gear5-21
410 Disassembling Forward Side Input Shaft Gear Assembly 5-22
411 Disassembling Reverse Side Input Shaft Gear 5-26
412 Disassembling Oil Pump5-27
5 Assembling Torque Converter Transmission 5-29
51 Assembling Transmission Housing 5-29
52 Assembling Idler Shaft Assembly 5-29
53 Assembling Output Gear Assembly 5-30
54 Inspecting Input Shaft Gear Assembly 5-31
55 Assembling Forward Side Input Shaft Gear Assembly 5-33
56 Assembling Reverse Side Input Shaft Gear Assembly5-38
57 Assembling and Installing Oil Pump Assembly5-39
58 Assembling Torque Converter Housing 5-44
59 Installing Transmission Housing 5-47
510 Installing Transmission Accessories 5-49
511 Installing Servo Case Assembly5-51
6 Disassembling Control Valve 5-56
61 Removing Control Valve Accessories 5-56
TABLE OF CONTENTS
TOC-4
62 Removing Valve Body Plate 5-56
63 Removing Plugs 5-57
64 Removing Strainer5-58
65 Disassembling Regulator Valve Section 5-58
66 Disassembling Accumulator Valve Section 5-59
67 Disassembling Inching Valve Section5-60
68 Removing Oil Seal and Plug5-62
7 Assembling Control Valve 5-63
71 Assembly Sequence of Control Valve5-63
72 Suggestions for Assembly 5-64
73 Washing and Inspecting 5-64
74 Installing Valve Plug and Oil Seal 5-65
75 Assembling Inching Valve Section5-66
76 Assembling Accumulator Valve Section 5-68
77 Assembling Regulator Valve Section 5-69
78 Installing Strainer 5-71
79 Installing Plug 5-71
710 Installing Valve Body Plate and Breather Cover5-73
711 Assembling Control Valve Accessories 5-73
8 Inspection and Adjustment 5-75
81 Oil Pressure Measurement 5-75
82 Adjusting Brake (Inching) Pedal 5-77
83 Adjusting Inching Cable 5-79
9 Troubleshooting5-80
10 Service Data 5-85
101 Pump Boss 5-85
102 Pilot Boss5-86
103 Oil Pump 5-86
104 Flexible Plate5-87
105 Clutches 5-87
106 Input Shaft 5-88
Chapter 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
1 Structure 6-1
11 2 Ton Class 6-1
12 3 Ton Class 6-2
2 Removing Front Wheels 6-3
21 Preparation 6-3
22 Removal 6-4
3 Installing Front Wheels6-4
4 Removing Front Axle and Reduction Differential 6-5
41 Preparation 6-5
42 Removal Sequence6-5
43 Suggestions for Removal6-6
5 Installing Front Axle6-6
6 Disassembling Front Axle6-7
61 Disassembly Sequence 6-7
TABLE OF CONTENTS
TOC-5
62 Suggestions for Disassembly 6-8
7 Inspection and Repair After Disassembling Front Axle 6-9
8 Assembling Front Axle 6-10
9 Disassembling Reduction Differential6-12
91 Disassembly Sequence 6-12
92 Suggestions for Disassembly 6-13
10 Inspection and Repair
After Disassembling Reduction Differential 6-15
11 Assembling Reduction Differential6-16
111 Assembly Sequence 6-16
112 Suggestions for Assembly 6-17
113 Adjustment 6-21
12 Troubleshooting 6-23
13 Service Data6-24
131 Hub and Wheels 6-24
132 Reduction Differential6-25
Chapter 7 REAR AXLE
1 Rear Axle Structure 7-1
11 Main Components7-1
12 Specifications for Wheel Alignment and Steering Angle7-2
13 Main Components of Wheel Hub Section 7-2
14 Main Components of Kingpin Section 7-3
15 Main components of Tie Rod Section7-3
16 Main Components of Rear Axle Center Section 7-4
17 Main Components of Steering Cylinder 7-5
2 Removing Rear Wheels 7-6
21 Suggestions for Removal7-6
3 Installing Rear Wheels 7-6
4 Removing Rear Axle Assembly7-7
41 Removal Sequence7-7
42 Suggestions for Removal7-7
5 Inspection and Repair After Disassembling Rear Axle Assembly 7-7
6 Installing Axle Assembly7-8
7 Disassembling Wheel Hub 7-8
71 Disassembly Sequence 7-8
72 Suggestions for Disassembly 7-9
8 Inspection and Repair After Disassembling Wheel Hub Section 7-9
9 Assembling Wheel Hub Section 7-10
91 Suggestions for Assembly 7-10
92 Assembling and Adjusting Wheel Bearing 7-10
10 Disassembling Knuckle Section (Kingpin) 7-12
101 Preparation 7-12
102 Suggestions for Disassembly 7-12
11 Inspection After Disassembly Knuckle Section (Kingpin)7-13
TABLE OF CONTENTS
TOC-6
12 Assembling Knuckle Section (Kingpin) 7-14
121 Suggestions for Assembly 7-14
13 Removing Steering Cylinder 7-15
131 Preparation 7-15
132 Suggestions for Removal7-15
14 Disassembling Steering Cylinder 7-16
141 Disassembly Sequence 7-16
142 Suggestions for Disassembly7-17
15 Inspection and Repair After Disassembling Steering Cylinder 7-17
16 Assembling Steering Cylinder 7-18
161 Suggestions for Assembly 7-18
17 Disassembling Tie Rod7-18
171 Disassembly Sequence 7-18
172 Suggestions for Disassembly7-18
18 Assembling Tie Rod 7-18
181 Suggestions for Assembly 7-18
Chapter 8 BRAKE SYSTEM
1 Structure of Brake System8-1
2 Disassembling Master Cylinder8-2
21 Disassembly Sequence 8-2
3 Inspection and Repair After Disassembling Master Cylinder8-3
4 Assembling Master Cylinder8-3
41 Suggestions for Assembly 8-3
5 Structure of Wheel Brakes 8-4
6 Disassembling Wheel Brakes8-5
61 Preparation 8-5
62 Disassembly Sequence 8-5
63 Suggestions for Disassembly8-6
7 Inspection and Repair After Disassembling Wheel Brakes 8-7
8 Assembling Wheel Brakes8-8
81 Assembly Sequence 8-8
82 Suggestions for Assembly 8-9
9 Disassembling Wheel Cylinder 8-10
91 Disassembly Sequence 8-10
10 Inspection and Repair After Disassembling Wheel Cylinder8-11
11 Assembling Wheel Cylinder 8-11
12 Inspecting and Adjusting Brake System 8-12
121 Operation Test of Automatic Adjuster8-12
122 Manual Adjustment Procedure8-13
123 Adjusting Parking Brake Cable 8-14
124 Adjusting Brake Pedal8-15
125 Bleeding Brake Oil Line 8-16
126 Braking Performance Test8-16
127 Adjusting Parking Brake Lever 8-17
TABLE OF CONTENTS
TOC-7
13 Troubleshooting 8-18
14 Service Data8-20
Chapter 9 STEERING SYSTEM
1 Structure and Functions 9-1
11 General 9-1
12 Steering Valve 9-2
13 Steering Column 9-3
2 Disassembling and Assembling Pipes and Hoses 9-4
21 Suggestions for Disassembly and Assembly9-4
3 Disassembling Steering Wheel and Steering Valve 9-5
31 Disassembly Sequence 9-5
32 Suggestions for Disassembly 9-5
4 Installing Steering Wheel and Steering Valve 9-6
5 Installation 9-7
51 Inspection After Installation9-7
6 Removing Steering Valve 9-8
7 Installing Steering Valve 9-8
8 Disassembling Tilt Lock Lever 9-8
9 Assembling Tilt Lock Lever 9-9
10 Disassembling Steering Valve 9-10
101 Disassembly Sequence 9-10
102 Suggestions for Disassembly 9-11
11 Inspection After Disassembly 9-12
12 Assembling Steering Valve 9-13
121 Assembly Sequence 9-13
13 Troubleshooting 9-18
14 Service Data9-19
Chapter 10 HYDRAULIC SYSTEM
1 Structure and Functions 10-1
11 Outline 10-1
12 Hydraulic Lines Diagram10-2
13 Hydraulic Tank 10-3
14 Gear Pump 10-4
15 Control Valve 10-5
16 Down Safety Valve10-6
17 Lift Cylinder (First Cylinder for Duplex and Triplex Mast)10-7
18 Lift Cylinder (Second Lift Cylinder for Simplex Mast and Triplex Mast) 10-8
19 Lift Cylinder (Second Lift Cylinder for Duplex Mast) 10-11
110 Tilt Cylinder 10-14
2 Removing Hydraulic Pump 10-16
21 Removal Sequence10-16
22 Suggestions for Removal10-16
TABLE OF CONTENTS
TOC-8
3 Installing Hydraulic Pump10-16
31 Suggestions for Installation 10-16
4 Disassembling Hydraulic Pump10-17
41 Disassembly Sequence 10-17
42 Suggestions for Disassembly10-17
5 Inspecting and Repairing Hydraulic Pump 10-18
6 Assembling Hydraulic Pump10-18
61 Suggestions for Assembly 10-18
62 Operation Test 10-18
7 Removing Lift Cylinders 10-19
8 Disassembling Lift Cylinder
(First Cylinder for Duplex and Triplex Masts)10-19
81 Disassembly Sequence 10-19
82 Suggestions for Disassembly10-20
9 Inspecting Lift Cylinder
(First Cylinder for Duplex and Triplex Masts)10-20
10 Assembling Lift Cylinders
(First Cylinder for Duplex and Triplex Masts)10-21
101 Assembly Sequence 10-21
102 Suggestions for Assembly 10-21
11 Disassembling Lift Cylinder
(Second Cylinder for Simplex Mast and Triplex Mast)10-22
111 Disassembly Sequence 10-22
112 Suggestions for Disassembly10-23
12 Inspecting Lift Cylinder
(Second Cylinder for Simplex Mast and Triplex Mast)10-24
13 Assembling Lift Cylinders
(Second Cylinder for Simplex Mast and Triplex Mast)10-25
131 Assembly Sequence 10-25
132 Suggestions for Assembly 10-25
14 Removing Tilt Cylinders 10-26
141 Preparation 10-26
142 Removal Sequence10-26
143 Suggestions for Removal10-26
15 Installing Tilt Cylinders10-26
151 Suggestions for Installation 10-26
16 Disassembling Tilt Cylinder 10-27
161 Disassembly Sequence 10-27
162 Suggestions for Disassembly10-27
17 Inspection After Disassembling Tilt Cylinder10-28
18 Assembling Tilt Cylinder 10-28
181 Assembly Sequence 10-28
182 Suggestions for Assembly 10-29
19 Piping 10-30
191 Piping for Diesel Engine Models 10-30
TABLE OF CONTENTS
TOC-9
192 Piping for Dual Gas/LPG Engine Models 10-31
20 Removing Suction Strainer and Return Filter 10-32
201 Removal Sequence10-32
202 Suggestions for Removal10-32
21 Inspecting Suction Strainer and Return Filter 10-32
22 Installing Suction Strainer and Return Filter10-32
221 Suggestions for Installation 10-32
23 Inspection and Adjustment 10-33
231 Inspecting and Adjusting Hydraulic Tank 10-33
232 Inspecting Control Valve10-33
233 Vertical Drift Test 10-35
234 Tilt Drift Test10-36
24 Troubleshooting 10-36
241 Hydraulic Tank 10-36
242 Gear Pump 10-37
243 Control Valve 10-37
244 Lift and Tilt Cylinders 10-38
25 Service Data10-39
251 First Cylinder for Duplex and Triplex Masts10-40
252 Second Cylinder for Simplex and Triplex Masts 10-41
253 Second Cylinder for Duplex Mast 10-42
254 Tilt Cylinder 10-43
26 Outline of Control Valve 10-44
261 Hydraulic Lines Diagram of Hydraulic Control Valve 10-45
262 Inlet Section10-46
263 Lift and Tilt Section (Lift Function)10-48
264 Lift and Tilt Section (Tilt Function)10-51
265 Unload Valve10-53
27 Removing Control Valve 10-54
271 Removal Sequence10-54
28 Installing Control Valve 10-54
281 Suggestions for Installation 10-54
29 Disassembling Control Valve – Inlet Section10-55
291 Disassembly Sequence 10-55
292 Suggestions for Disassembly 10-55
30 Disassembling Control Valve – Lift Valve 10-56
301 Disassembly Sequence 10-56
302 Suggestions for Disassembly 10-56
31 Disassembling Control Valve – Tilt Valve 10-57
311 Disassembly Sequence 10-57
312 Suggestions for Disassembly 10-57
32 Disassembling Control Valve – End Cover Section 10-58
321 Disassembly Sequence 10-58
33 Disassembling Control Valve – End Cover Section 10-58
34 Assembling Control Valve – End Cover Section10-59
341 Suggestions for Assembly 10-59
TABLE OF CONTENTS
TOC-10
35 Assembling Attachment Section (Option) 10-60
351 Assembly Sequence 10-60
352 Suggestions for Assembly 10-61
Chapter 11 MAST AND FORKS
1 Simplex Mast11-1
11 Mast System11-1
12 Structure and Functions (5V25D to 5V30D) 11-2
13 Removal Sequence of Mast and Lift Bracket Assembly 11-4
14 Suggestions for Removing Mast and Lift Bracket Assembly11-4
15 Suggestions for Installing Mast and Lift Bracket Assembly 11-6
16 Removal Sequence of Mast and Lift Bracket11-7
17 Suggestions for Disassembling Mast and Lift Bracket11-7
18 Inspection of Mast and Lift Bracket (All Mast Models)11-8
19 Assembly Sequence of Lift Bracket Roller (All Mast Models)11-9
110 Lift Bracket Clearance Adjustment (All Mast Models)11-10
111 Installing Mast Rollers (All Mast Models)11-12
112 Installing Mast Strips (All Mast Models) 11-13
113 Installing Lift Cylinders 11-14
114 Connecting Chains11-15
115 Installing Hydraulic Lines11-16
116 Removing and Installing Mast Rollers and Strips
Without Removing Mast from Truck 11-18
117 Inspection and Adjustment 11-19
118 Inspecting Forks (All Mast Models)11-19
119 Inspecting and Adjusting Chain Tension (All Mast Models)11-20
120 Measuring Chain Elongation (All Mast Models)11-21
121 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(All Mast Models) 11-22
122 Adjusting Mast Roller Clearance (All Mast Models) 11-24
123 Inspecting and Adjusting Mast Strip Clearance (All Mast Models)11-25
124 Adjusting Mast Tilt Angle (All Mast Models)11-26
125 Inspecting and Adjusting Right and Left Lift Cylinder Stroke
(All Mast Models) 11-26
126 Troubleshooting 11-27
127 Service Data 11-28
2 Duplex Mast11-30
21 Mast System11-30
22 Structure and Functions (5F25C to 5F30C) 11-31
23 Removal Sequence of Mast and Lift Bracket Assembly 11-33
24 Suggestions for Removing Mast and Lift Bracket Assembly11-33
25 Suggestions for Installing Mast and Lift Bracket Assembly 11-35
26 Disassembly Sequence of Mast and Lift Bracket11-36
27 Preparation for Disassembling Mast and Lift Bracket11-36
28 Suggestions for Disassembling Mast and Lift Bracket11-37
29 Inspection of Mast and Lift Bracket (All Mast Models)11-38
210 Assembly Sequence of Lift Bracket Roller (All Mast Models)11-39
211 Lift Bracket Clearance Adjustment (All Mast Models)11-40
212 Installing Mast Rollers (All Mast Models)11-42
TABLE OF CONTENTS
TOC-11
213 Installing Mast Strips (All Mast Models) 11-43
214 Installing Second Lift Cylinder 11-44
215 Installing First Lift Cylinder 11-45
216 Connecting Chains11-45
217 Installing Hydraulic Lines 11-46
218 Removing and Installing Mast Rollers and Strips
Without Removing Mast from Truck 11-48
219 Inspection and Adjustment 11-49
220 Inspecting Forks (All Mast Models) 11-49
221 Inspecting and Adjusting Chain Tension (All Mast Models)11-51
222 Measuring Chain Elongation (All Mast Models)11-52
223 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(All Mast Models) 11-53
224 Adjusting Mast Roller Clearance (All Mast Models) 11-54
225 Inspecting and Adjusting Mast Strip Clearance (All Mast Models)11-56
226 Adjusting Mast Tilt Angle (All Mast Models)11-57
227 Inspecting and Adjusting Right and Left Lift Cylinder Stroke
(All Mast Models) 11-57
228 Troubleshooting 11-58
229 Service Data11-59
3 Triplex Mast11-61
31 Mast System11-61
32 Structure and Functions (5M25D to 5M30D) 11-62
33 Removal Sequence of Mast and Lift Bracket Assembly 11-64
34 Suggestions for Removing Mast and Lift Bracket Assembly11-64
35 Suggestions for Installing Mast and Lift Bracket Assembly 11-66
36 Disassembly Sequence of Mast and Lift Bracket (All Mast Models) 11-67
37 Preparation for Disassembling Mast and Lift Bracket11-67
38 Suggestions for Disassembling Mast and Lift Bracket 11-68
39 Inspecting Mast and Lift Bracket (All Mast Models) 11-69
310 Assembly Sequence of Lift Bracket Roller (All Mast Models) 11-70
311 Lift Bracket Clearance Adjustment (All Mast Models)11-71
312 Installing Mast Rollers (All Mast Models)11-73
313 Installing Mast Strips (All Mast Models) 11-74
314 Installing Second Lift Cylinder 11-75
315 Installing First Lift Cylinder 11-76
316 Connecting Chains11-77
317 Installing Hydraulic Lines 11-78
318 Removing and Installing Mast Rollers and Strips
Without Removing Mast from Truck 11-80
319 Inspection and Adjustment 11-81
320 Inspecting Forks (All Mast Models) 11-81
321 Inspecting and Adjusting Chain Tension (All Mast Models)11-82
322 Measuring Chain Elongation (All Mast Models)11-83
323 Adjusting Clearance Between Lift Bracket Roller and Inner Mast
(All Mast Models) 11-84
324 Adjusting Mast Roller Clearance (All Mast Models) 11-85
325 Inspecting and Adjusting Mast Strip Clearance (All Mast Models)11-87
326 Adjusting Mast Tilt Angle (All Mast Models)11-88
327 Inspecting and Adjusting Right and Left Lift Cylinder Stroke
(All Mast Models) 11-88
TABLE OF CONTENTS
TOC-12
328 Troubleshooting 11-89
329 Service Data 11-90
Chapter 12 SERVICE DATA
1 Maintenance Schedule12-1
2 Tightening Torques for Standard Bolts and Nuts 12-6
21 Metric Fine Thread12-6
22 Metric Coarse Thread 12-8
3 Periodic Replacement Parts 12-9
31 Safety Critical Parts12-10
4 Lubrication Schedule 12-11
41 Lubrication Chart 12-11
42 Fuel and Lubricant Specifications 12-13
43 Adjustment Value and Oil Capacity 12-14
5 Special tools 12-15
51 Special Service Tools (Powershift Transmission) 12-15
52 Special Service Tools (Front Axle and Reduction Differential) 12-17
53 Special Service Tools (Brake System) 12-19
54 Special Service Tools (Steering System) 12-19
55 Special Service Tools (Hydraulic System)12-20
Chapter 13 HOW TO READ CIRCUIT DIAGRAMS
1 Description of Circuit Diagrams13-1
11 Circuit Diagrams13-1
12 Connector Diagrams 13-1
2 How to Read Circuit Diagrams 13-2
21 Symbols 13-3
22 Sheet Symbol 13-6
23 Connecting Lines 13-7
24 Equipment 13-8
25 Relay Contactor and Coil 13-9
26 Connectors 13-9
27 Indication of Connecting Line 13-10
28 Indication of GND (Earth)13-10
29 Indication of Another Specification 13-11
3 How to Read Connector Diagrams 13-12
Chapter 14 CIRCUIT DIAGRAM FOR DUAL GAS/LPG ENGINE MODELS
Chapter 15 CIRCUIT DIAGRAM FOR DIESEL ENGINE MODELS
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