Mitsubishi Diesel Forklift Truck: FD100NZ, FD120NZ, FD135NZ, FD150ANZ Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Mitsubishi Diesel Forklift Truck.

Original factory manuals for Mitsubishi Lift Trucks contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, without restrictions, contains Searchable Text and bookmarks

Covered models:
    FD100NZ (F15DE-60001-up)
    FD120NZ (F15DE-60001-up)
    FD135NZ (F15DE-60001-up)
    FD150ANZ (F24BE-60001-up)

Format: PDF, 551 Pages
Language: English
Contents:
    Chapter 1 GENERAL INFORMATION
        1. Model View
        2. Applicable Truck Model
        3. Serial Number Locations
        4. Technical Data
        4.1 Dimensions
        4.2 Performance
    Chapter 2 COOLING SYSTEM
        1. Specifications
        2. Structure
        3. Removing Radiator and Intercooler
        3.1 Preparation
        3.2 Removal Sequence
        3.3 Suggestions for Removal
        4. Inspection and Adjustment of Radiator and Intercooler
        4.1 Intercooler
        4.2 Inspecting Fan Belt
        4.3 Radiator
        4.4 Antifreeze and Cooling Water
        5. Installing Radiator and Intercooler
        5.1 Suggestions for Installation
        6. Troubleshooting
        6.1 Service Data
    Chapter 3 ELECTRICAL SYSTEM
        1. Specifications
        2. Chassis Electrical Devices and Wiring Outline.
        2.1 Relay Box
        3. Structure
        3.1 Console Box
        3.2 Function of Meter Panel
        3.3 Side Panel
        3.4 Key Switch (Anti-Restart Switch)
        3.5 Combination Switch
        3.6 Fuse Box Connection Table (Chassis)
        4. Disassembling Console Box
        4.1 Preparation
        4.2 Disassembly Sequence
        5. Reassembling Console Box
        6. Battery and Maintenance
        6.1 Electrolyte Specific Gravity (S.G.) and Charging Adjustment
        6.2 Electrolyte Specific Gravity and State of Charge
        6.3 Precautions for Charging Battery
        6.4 Precautions to Handle Alternator Charging System
        7. Troubleshooting
        7.1 Starter System
        7.2 Gauges
        7.3 Lighting System
        7.4 Alarm Unit
        7.5 Battery
        8. Electrical Schematic
    Chapter 4 CONTROLLERS
        1. Outline
        1.1 System Configuration
        1.2 Color coding
        1.3 Controller External View
        2. Service Tool Functions
        2.1 Menu structure
        2.2 Input Monitor and Output Monitor
        2.3 Fault Status
        2.4 Fault History
        3. Error Code List
        4. Troubleshooting
        4.1 General Precautions
        4.2 VCM-3 Memory Check Error (F01)
        4.3 VCM-3 Battery Voltage Error (F02)
        4.4 VCM-3 Communication Error (F03)
        4.5 MP Communication Error (F07)
        4.6 Lift Lever Neutral Error (F10)
        4.7 Tilt Lever Neutral Error (F11)
        4.8 Attachment 1 Lever Neutral Error (F12)
        4.9 Attachment 2 Lever Neutral Error (F13)
        4.10 Attachment 3 Lever Neutral Error (F14)
        4.11 Shift Lever Error (F16)
        4.12 Vehicle Speed Error (F17)
        4.13 Lift Lever Error (F20)
        4.14 Tilt Lever Error (F22)
        4.15 Attachment 1 Lever Error (F24)
        4.16 Attachment 2 Lever Error (F26)
        4.17 Attachment 3 Lever Error (F28)
        4.18 Joystick Lever Error (F29)
        4.19 VCM-3 Sensor Voltage Error (F31)
        4.20 Vehicle Speed Sensor Error (F34)
        4.21 Output Unit Error (F41)
        4.22 Output Unit Life Control Signal (F42)
        4.23 Output Unit Memory Check Error (F43)
        4.24 Output Unit PWM Voltage Error (F44)
        4.25 Output Unit Communication Error (F45)
        4.26 Input Unit Error (F46)
        4.27 Input Unit Life Control Signal (F47)
        4.28 Input Unit Memory Check Error (F48)
        4.29 Input Unit Communication Error (F49)
        4.30 Lift Up Solenoid Error (F50)
        4.31 Lift Down Solenoid Error (F52)
        4.32 Lift Solenoid Leak (F54)
        4.33 Tilt Forward Solenoid Error (F55)
        4.34 Tilt Backward Solenoid Error (F57)
        4.35 Tilt Solenoid Leak (F59)
        4.36 Attachment 1A Solenoid Error (F60)
        4.37 Attachment 1B Solenoid Error (F62)
        4.38 Attachment 1 Solenoid Leak (F64)
        4.39 Attachment 2A Solenoid Error (F65)
        4.40 Attachment 2B Solenoid Error (F67)
        4.41 Attachment 2 Solenoid Leak (F69)
        4.42 Attachment 3A Solenoid Error (F70)
        4.43 Attachment 3B Solenoid Error (F72)
        4.44 Attachment 3 Solenoid Leak (F74)
        4.45 Unload Solenoid Error (F75)
        4.46 Unload Solenoid Leak (F79)
        4.47 Transmission Forward Solenoid Error (F85)
        4.48 Transmission Backward Solenoid Error (F87)
        4.49 Transmission Solenoid Leak (F89)
        4.50 VCM3-OP Memory Check Error (F91)
        4.51 VCM3-OP Battery Voltage Error (F92)
        4.52 VCM3-OP Speed Change Solenoid 1 Error (F93)
        4.53 VCM3-OP Speed Change Solenoid 2 Error (F94)
        4.54 VCM3-OP Speed ChangeSolenoid Leak (F95)
        4.55 VCM3-OP Setting Error (F96)
        4.56 VCM3-OP Communication Error (F97)
    Chapter 5 TILTABLE SYSTEM
        1. Specifications
        2. Structure
        2.1 Outline
        2.2 Hand Pump
        2.3 Tiltable Cylinder
        2.4 Hydraulic Latch A and B
        3. Filling Fluid
        4. Bleeding Tiltable Cylinder
        5. Hydraulic Circuit Schematic
        6. Service Data
        6.1 Tiltable Cylinder
        6.2 Cylinder bracket
        6.3 Pin A and B
        TOC-4
    Chapter 6 POWER TRAIN
        1. Specifications
        2. Structure
        3. Reduction Ratio
        4. Removal and Installation of Engine and Transmission Unit
        4.1 Preparation
        4.2 Removing Covers and Engine Control Cables
        4.3 Removing Harnesses
        4.4 Disconnecting Pipes and Hoses
        4.5 Preparation for Removal of Engine and Transmission Unit
        4.6 Removing Engine and Transmission
        5. Installing Engine and Transmission
        5.1 Suggestions for Installation
        5.2 Capacity and Brand of Oils and Cooling Water
    Chapter 7 3-SPEED POWERSHIFT TRANSMISSION
        1. Specifications
        2. Structure
        2.1 Torque converter
        2.2 Transmission
        2.3 Power Flow - Forward
        2.4 Power Flow - Reverse
        2.5 Control Valve
        2.6 Main Regulator Valve
        2.7 3-Speed Transmission Hydraulic Circuit
        2.8 Automatic 3-Speed Shift Mechanism
        2.9 Torque Converter Drive Control
        3. Removing Transmission
        3.1 Removing Torque Converter
        4. Installing Transmission
        5. Disassembling Torque Converter
        5.1 Disassembly Sequence
        5.2 Suggestions for Disassembly
        6. Inspecting and Correcting Torque Converter
        7. Reassembling Torque Converter
        7.1 Reassembly Sequence
        7.2 Suggestions for Torque Converter Reassembly
        8. Disassembling Transmission
        8.1 Disassembly Sequence of Control Valve and External Parts
        8.2 Disassembling Transmission Cover and Output, 1st/3rd Clutch,
        Forward Clutch, Reverse Clutch, and Input Shafts.
        8.3 Suggestions for Transmission Disassembly
        8.4 Disassembly Sequence of Stator Shaft and Oil Pump
        8.5 Suggestions for Oil Pump Disassembly
        8.6 Disassembly Sequence of Forward Clutch Shaft Assembly
        8.7 Suggestions for Disassembly of Forward Clutch Shaft Assembly
        8.8 Disassembly Sequence of 1st/3rd Speed Clutch Shaft Assembly
        8.9 Suggestions for Disassembly of 1st/3rd Clutch Shaft Assembly
        8.10 Disassembly Sequence of Reverser Clutch Shaft Assembly
        8.11 Suggestions for Disassembly of Reverse Clutch Shaft Assembly
        9. Inspecting and Correcting Transmission
        10. Reassembling Transmission
        10.1 Reassembly Sequence of Forward Clutch Assembly (1st/3rd Clutch Shaft Assembly)
                (Reverse Clutch Shaft Assembly)
        10.2 Suggestions for Reassembly of Forward Clutch Assembly (1st/3rd Clutch Shaft Assembly)
                (Reverse Clutch Shaft Assembly)
        10.3 Reassembly Sequence of StatorShaft and Oil Pump
        10.4 Suggestions for Stator Shaft and Oil Pump Reassembly
        10.5 Reassembly Sequence of Input Shaft,Forward Clutch, 1st/3rd Speed Clutch, Reverse Clutch,
                Output Shafts and Transmission Cover
        10.6 Suggestions for Reassembly of Input Shaft, Forward Clutch, 1st/3rd Spe Clutch, Reverse Clutch,
                OutputShafts and Transmission Cover
        10.7 Reassembly Sequence of Control Valve and External Parts
        11. Disassembling Control Valve
        11.1 Disassembly Sequence
        12. Inspecting and Correcting Control Valve
        13. Reassembling Control Valve
        13.1 Preparation
        13.2 Reassembly Sequence
        13.3 Suggestions for Control Valve Reassembly
        14. Disassembling Main Regulator Valve
        14.1 Disassembly Sequence
        15. Inspecting and Correcting of Main Regulator Valve
        16. Reassembling Main Regulator Valve
        16.1 Suggestions for Reassembly
        17. Adjustment
        17.1 Adjusting Brake Pedal and Inching Pedal
        17.2 Measuring Oil Pressure
        17.3 Measuring Stall Speed
        17.4 10 m (33 ft) Acceleration Test
        17.5 Testing Automatic 3-Speed Transmission Functions
        18. Troubleshooting
        19. Service Data
        19.1 Stall Speed and Oil Pressure
        19.2 Pump Boss
        19.3 Pilot Boss
        19.4 Oil Pump
        19.5 Stator
        19.6 Flexible Plate
        19.7 Clutch
        19.8 Input Shaft, Forward, Reverse, and 1st/ 3rd Speed Clutch Shafts, and Servo Case
        19.9 Backlash of Gears
        19.10 Control Valve
        19.11 Main Regulator Valve
        19.12 Inching Pedal Control
    Chapter 8 FRONT AXLE AND REDUCTION DIFFERENTIAL
        1. Specifications
        2. Structure
        2.1 Outline
        2.2 Reduction Differential
        3. Removing Front Wheels
        3.1 Preparation
        3.2 Removal Sequence
        3.3 Suggestions for Removal
        4. Installing Front Wheels
        4.1 Suggestions for Installation
        5. Removing Front Axle and Reduction Differential
        5.1 Preparation
        5.2 Removal Sequence
        5.3 Suggestions for Removal
        6. Installing Front Axle and Reduction Differential
        6.1 Suggestions for Installation
        7. Removing Reduction Differential
        7.1 Preparation
        7.2 Removal Sequence
        7.3 Suggestions for Removal
        8. Installing Reduction Differential
        8.1 Suggestions for Installation
        9. Disassembling Hub Reduction
        9.1 Preparation (On-truck Condition)
        9.2 Disassembly Sequence of Hub Reduction
        9.3 Suggestions for Hub Reduction Disassembly
        9.4 Disassembly Sequence of Wheel Brake
        9.5 Suggestions for Wheel Brake Disassembly
        10. Inspecting and Correcting Hub Reduction
        10.1 Reassembly Sequence of Wheel Brake
        10.2 Suggestions for Wheel Brake Reassembly
        10.3 Reassembly Sequence of Hub Reduction
        10.4 Suggestions for Reassembling of Hub Reduction
        11. Disassembling Reduction Differential
        11.1 Preparation
        11.2 Disassembly Sequence of Differential Gear Assembly
        11.3 Suggestions for Disassembling of Differential Gear Assembly
        11.4 Disassembly Sequence of Reduction and Parking Brake Assembly
        11.5 Suggestions for Disassembling of Reduction and Parking Brake Assembly
        11.6 Inspecting and Correcting Reduction and Parking Brake Assembly
        12. Reassembling Reduction Differential
        12.1 Reassembly Sequence of Differential Gear Assembly
        12.2 Suggestions for Reassembling Differential Gear Assembly
        12.3 Adjusting Preload of Reduction Pinion
        12.4 Adjusting the Contact Between Gear and PinionTeeth
        12.5 Reassembly Sequence of Reduction and Parking Brake Assembly
        12.6 Reassembling Reduction and Parking Brake Assembly
        12.7 Assembly Sequence of Reduction Differential
        12.8 Suggestions for Reassembling of Reduction Differential
        13. Troubleshooting
        14. Service Data
        14.1 Front Axle
        14.2 Reduction Differential
    Chapter 9 REAR AXLE
        1. Specifications
        2. Structure
        2.1 Rear Axle
        2.2 Power Steering Cylinder
        3. Removing Rear Wheel
        3.1 Preparation
        3.2 Removal Sequence
        3.3 Suggestions for Removal
        4. Installing Rear Wheel
        4.1 Suggestions for Installation
        5. Removing Rear Axle
        5.1 Preparation
        5.2 Removal Sequence
        6. Installing Rear Axle
        6.1 Suggestions for Installation
        7. Disassembling Rear Axle Assembly
        7.1 Disassembly Sequence
        7.2 Suggestions for Removal
        8. Reassembling Rear Axle
        8.1 Reassembly Sequence
        9. Disassembling Power Steering Cylinder
        9.1 Disassembly Sequence
        9.2 Suggestions for Disassembly
        10. Inspecting and Adjusting Power Steering Cylinder
        11. Reassembling Power Steering Cylinder
        11.1 Reassembly Sequence
        11.2 Suggestions for Reassembly
        12. Adjustment
        12.1 Measuring Minimum Turning Radius
        13. Troubleshooting
        14. Service Data
        14.1 Rear Axle
        14.2 Power Steering Cylinder
    Chapter 10 BRAKE SYSTEM
        1. Specifications
        2. Structure
        2.1 Outline of Wheel Brake System
        2.2 Air Governor
        2.3 Relay Valve
        2.4 Brake Control Valve
        2.5 Air Master
        2.6 Wheel Brake
        2.7 Parking Brake System
        2.8 Parking Brake Lever
        2.9 Parking Brake
        3. Removing Wheel Brake
        3.1 Preparation
        3.2 Removal Sequence
        3.3 Suggestions for Removal
        4. Installing Wheel Brake
        4.1 Suggestions for Installation
        5. Disassembling Wheel Brake
        5.1 Disassembly Sequence
        5.2 Suggestions for Disassembly
        6. Inspecting and Correcting Wheel Brake
        7. Reassembling Wheel Brake
        7.1 Reassembly Sequence of Wheel Brake
        7.2 Suggestions for Reassembly
        8. Disassembling Wheel Cylinder
        8.1 Disassembly Sequence of Wheel Cylinder
        9. Inspecting and Correcting Wheel Cylinder
        10. Reassembling Wheel Cylinder
        10.1 Suggestions for Reassembly
        11. Disassembling Air Governor
        11.1 Disassembly Sequence
        12. Reassembling Air Governor
        13. Disassembling Air Master
        13.1 Disassembly Sequence
        13.2 Suggestions for Disassembly
        14. Reassembling Air Master
        14.1 Suggestions for Reassembly
        15. Disassembling Parking Brake
        15.1 Disassembly Sequence
        16. Inspecting and Correcting Parking Brake
        17. Reassembling Parking Brake
        17.1 Suggestions for Reassembly
        18. Disassembling Brake Control Valve
        18.1 Disassembly Sequence
        19. Reassembling Brake Control Valve
        19.1 Suggestions for Reassembly
        20. Disassembling Air Dryer
        20.1 Disassembly Sequence
        21. Inspecting and Correcting Air Dryer
        21.1 Scheduled Inspection of Air Dryer
        22. Reassembling Air Dryer.
        22.1 Suggestions for Reassembly
        23. Adjustment and Operational Test
        23.1 Inspecting Wheel Brake
        23.2 Bleeding Brake System
        23.3 Bleeding Brake Pedal
        23.4 Inspecting Brake Control Valve
        23.5 Adjusting Parking Brake
        24. Troubleshooting
        24.1 Wheel Brake
        24.2 Parking Brake
        24.3 Air Dryer
        25. Service Data
        25.1 Brake Pedal
        25.2 Brake Control Valve
        25.3 Air Master
        25.4 Wheel Brake
        25.5 Wheel Cylinder
        25.6 Parking Brake Lever
        25.7 Parking Brake Drum
        25.8 Air Dryer
    Chapter 11 STEERING SYSTEM
        1. Specifications
        2.1 Steering System
        3.1 Main Components
        3.2 Suggestions for Disassembly and Reassembly
        4.2 Installing Steering Wheel
        4.4 Removing Steering Valve
        4.5 Installing Steering Wheel
        4.7 Reassembling Tilt Lock Lever
        5.1 Disassembly Sequence of Steering Valve
        5.3 Inspection after Disassembly
        6.1 Preparation
        6.2 Reassembly Sequence of Steering Valve
    Chapter 12 HYDRAULIC SYSTEM
        1. Specifications
        2. Structure
        2.1 Hydraulic Line
        2.2 Hydraulic Tank
        2.3 Priority Valve
        2.4 Control Valve
        2.5 Lift and Tilt Cylinders
        2.6 Flow Regulator Valve
        3. Removing Control Valve
        3.1 Preparation
        3.2 Removal Sequence
        3.3 Suggestions for Removal
        4. Removing Lift Cylinders
        4.1 Suggestions for Removal
        5. Installing Lift Cylinders
        5.1 Suggestions for Installation
        6. Removing Tilt Cylinders
        6.1 Preparation
        6.2 Removal Sequence
        6.3 Suggestions for Removal
        7. Removing Gear Pump
        8. Disassembling Gear Pump
        8.1 Preparation
        8.2 Disassembly Sequence
        8.3 Suggestions for Disassembly
        9. Inspecting and Correcting Gear Pump
        10. Reassembling Gear Pump
        10.1 Preparation
        10.2 Suggestions for Reassembly
        11. Installing Gear Pump
        12. Disassembling Priority Valve
        12.1 Disassembly Sequence
        12.2 Suggestions for Disassembly
        13. Reassembling Priority Valve
        13.1 Suggestions for Reassembly
        14. Disassembly and Reassembly of Control Valve
        14.1 Disassembly Sequence
        14.2 Reassembly Sequence
        14.3 Suggestions for Reassembly
        14.4 Disassembling Inlet Valve Assembly
        14.5 Cleaning and Inspecting Inlet Valve Assembly
        14.6 Reassembling Inlet Valve Assembly
        14.7 Disassembly and Reassembly of Tilt Valve Assembly
        14.8 Cleaning and Inspection of Tilt Valve Assembly
        14.9 Reassembling Tilt Valve Assembly
        14.10 Disassembly and Reassembly of AttachmentValve Assembly
        14.11 Cleaning and Inspecting Attachment Valve Assembly
        14.12 Reassembling Attachment Valve Assembly
        15. Disassembling Flow Regulator Valve
        15.1 Disassembly Sequence
        16. Inspecting and Correcting Flow Regulator Valve
        17. Reassembling Flow Regulator Valve
        18. Disassembling Lift Cylinder
        18.1 Disassembly Sequence
        18.2 Suggestions for Disassembly
        19. Inspecting Cylinder
        20. Reassembling Lift Cylinder
        20.1 Reassembly Sequence
        20.2 Suggestions for Reassembly
        21. Disassembling Tilt Cylinder
        21.1 Disassembly Sequence
        21.2 Suggestions for Disassembly
        22. Inspecting and Correcting Tilt Cylinder
        23. Reassembling Tilt Cylinder
        23.1 Reassembly Sequence
        23.2 Suggestions for Reassembly
        24. Inspecting and Adjusting Hydraulic System
        24.1 Hydraulic Oil
        24.2 Test Operation of Gear Pump
        24.3 Control Valve
        24.4 Adjusting Main Relief Valve
        24.5 Checking Priority Valve Function
        25. Tests
        25.1 Vertical Drift Test
        25.2 Tilt Drift Test
        26. Troubleshooting
        27. Service Data
        27.1 Gear Pump
        27.2 Control Valve
        27.3 Priority Valve
        27.4 Hydraulic Tank
        27.5 Flow Regulator Valve
        27.6 Lift Cylinder
        27.7 Tilt Cylinder
    Chapter 13 MASTS AND FORKS
        1. Specifications
        2. Structure
        3. Removing Mast and Lift Bracket
        3.1 Removal Sequence
        3.2 Suggestions for Removal
        4. Disassembling Mast Assembly
        4.1 Disassembly Sequence
        4.2 Suggestions for Disassembly
        5. Inspecting and Correcting Mast Assembly
        6. Reassembling Mast Assembly
        6.1 Suggestions for Reassembly
        7. Adjusting Mast Assembly
        8. Troubleshooting
        9. Service Data
    Chapter 14 FORK POSITIONER
        1. Applicable Attachment Model
        1.1 Simultaneous Move Fork Positioner
        1.2 Independent Move Fork Positioner
        2. Specifications
        2.1 Fork Positioner
        2.2 Applicable Fork Blade
        3. Structure
        4. Removing Fork Positioner
        4.1 Preparation
        4.2 Removal Sequence of Fork Positioner (Simultaneous Move Type)
        4.3 Removal Sequence of Fork Positioner (Independent Move Type)
        4.4 Suggestions for Removal of Fork Positioner
        5. Inspecting and Correcting ForkPositioner
        6. Installing Fork Positioner
        6.1 Suggestions for Installation
        7. Disassembling Fork Positioner Cylinder
        7.1 Disassembly Sequence
        7.2 Suggestions for Disassembly
        8. Inspecting and Correcting Fork Positioner Cylinder
        9. Reassembling Fork PositionerCylinder
        9.1 Reassembly Sequence
        9.2 Suggestions for Reassembly
        10. Inspection and Adjustment after Reassembly of Fork Positioner
        11. Troubleshooting
        12. Service Data
    Chapter 15 Service Data
        1. Maintenance Schedule
        2. Tightening Torques for Standard Bolts and Nuts
        2.1 Metric fine thread
        2.2 Metric coarse thread
        3. Periodic Replacement Parts
        3.1 Location of Periodic Replacement Parts
        4. Lubrication Instructions
        4.1 Lubrication Chart
        4.2 Recommended Fuels and Oils
        4.3 Adjustment Value and Oil Quantities
        5. Weight of Major Devices
        6. Special tools
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