Mitsubishi FG10N Manual de usuario
99719-18100
For use with S4Q2, S4S and K15/K21/K25 Engine
Service Manuals.
FG10N F25C-05001-up
FG15N F25C-55001-up
FG15ZN F34-52001-up
FG18N F25C-75001-up
FG18ZN F34-72001-up
FG20CN F34-22001-up
FG20N F17D-10001-up
FG20ZN F35-10001-up
FG25N F17D-60001-up
FG25ZN F35-60001-up
FG30N F13F-40001-up
FG35AN F13F-60001-up
FD10N F16D-04001-up
FD15N F16D-54001/64001-up
FD18N F16D-74001/84001-up
FD20CN F16D-24001/28001-up
FD20N F18C-20001/40001-up
FD25N F18C-70001/90001-up
FD30N F14E-10001/20001-up
FD35AN F14E-80001/90001-up
FGE15N F34-00001/19001-up
FGE18N F34-40001/49001-up
FGE20CN F34-30001/39001-up
FGE20N F17D-20001/38001-up
FGE20ZN F35-20001/38001-up
FGE25N F17D-70001/88001-up
FGE25ZN F35-70001/88001-up
FGE30N F13F-10001/20001-up
FGE35AN F13F-80001/90001-up
Chassis & Mast MC/FC
Service Manual
1
Pub. No. 99719-18100
FOREWORD
This service manual is a guide for servicing Mitsubishi forklift trucks. For your convenience the instructions are
grouped by systems as a ready reference.
The long productive life of your lift 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 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.
The trucks listed in this manual are powered by K15, K21 or K25 gasoline engines or S4Q2/S4S diesel engines.
For engine servicing, please refer to the applicable engine service manual.
K15, K21 or K25 Gasoline engine
S4Q2, S4S Diesel engine
<Safety Related Signs>
Indicates a specific potential hazard resulting in serious
bodily injury or death.
Indicates a potentially hazardous situation which, if not
avoided, may result in death or serious injury or damage to
the machine.
Indicates a condition that can cause damage to, or shorten
service life of, the machine.
WARNING
CAUTION
NOTE
3
SAFETY
The proper and safe lubrication and maintenance
for these lift trucks, recommended by Mitsubishi
Forklift Trucks, are outlined in the OPERATION &
MAINTENANCE MANUAL.
Read and understand the OPERATION & MAINTE-
NANCE MANUAL before performing any lubrica-
tion or maintenance on these trucks.
Improper performance of lubrication or mainte-
nance procedures is dangerous and could result
in injury or death.
The serviceman or mechanic may be unfamiliar with
many of the systems on this truck. This makes it
important to use caution when performing service
work. 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 truck components,
the serviceman or mechanic should check the weights
noted in this Manual. Use proper lifting procedures
when removing any components.
Following is a list of basic precautions that should
always be observed.
(1) Read and understand all warning plates and
decals on the truck before operating, lubricating or
repairing the product.
(2) Always wear protective glasses and protective
shoes when working around trucks. In particular,
wear protective glasses when pounding on any
part of the truck or its attachments with a hammer
or sledge. Use welders gloves, hood/goggles,
apron and other protective clothing appropriate to
the welding job being performed. Do not wear
loose fitting or torn clothing. Remove all rings from
fingers when working on machinery.
(3) Do not work on any truck that is supported only by
lift jacks or a hoist. Always use blocks or jack
stands to support the truck before performing any
disassembly.
(4) Lower the forks or other implements to the ground
before performing any work on the truck. If this
cannot be done, make sure the forks or other
implements are blocked correctly to prevent them
from dropping unexpectedly.
Do not operate these trucks unless you have read
and understood the instructions in the OPERA-
TION & MAINTENANCE MANUAL. Improper truck
operation is dangerous and could result in injury
or death.
(5) Use steps and grab handles (if applicable) when
mounting or dismounting a truck. Clean any mud
or debris from steps, walkways or work platforms
before using. Always face truck when using steps,
ladders and walkways. When it is not possible to
use the designed access system, provide ladders,
scaffolds, or work platforms to perform safe repair
operations.
(6) To avoid back injury, use a hoist when lifting com-
ponents which weigh 23 kg or more. Make sure all
chains, hooks, slings, etc., are in good condition
and are of the correct capacity. Be sure hooks are
positioned correctly. Lifting eyes are not to be side
loaded during a lifting operation.
(7) To avoid burns, be alert for hot parts on trucks
which have just been stopped and hot fluids in
lines, tubes and compartments.
(8) Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located at oppo-
site ends of the cover or device and pry cover
loose to relieve any spring or other pressure,
before removing the last two bolts or nuts com-
pletely.
(9) Be careful when removing filler caps, breathers
and plugs on the truck. Hold a rag over the cap or
plug to prevent being sprayed or splashed by liq-
uids under pressure. The danger is even greater if
the truck has just been stopped because fluids
can be hot.
(10)Always use tools that are in good condition and
be sure you understand how to use them before
performing any service work.
(11)Reinstall all fasteners with same part number. Do
not use a lesser quality fastener if replacements
are necessary.
(12)If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not
roll while working on or under truck.
WARNING
WARNING
4
(13)Disconnect battery and discharge any capacitors
(electric trucks) before starting to work on truck.
Hang “Do not Operate” tag in the Operator’s Com-
partment.
(14)Repairs, which require welding, should be per-
formed only with the benefit of the appropriate ref-
erence information and by personnel adequately
trained and knowledgeable in welding proce-
dures. Determine type of metal being welded and
select correct welding procedure and electrodes,
rods or wire to provide a weld metal strength
equivalent at least to that of parent metal.
(15)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will it
be damaged in operation by contacting sharp cor-
ners, or by rubbing against some object or hot
surface. Place wiring away from oil pipe.
(16)Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.
(17)Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.
(18)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses could cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Pin hole (very small) leaks could
result in a high velocity oil stream that will be invis-
ible close to the hose. This oil could penetrate the
skin and cause personal injury. Use cardboard or
paper to locate pin hole leaks.
(19)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibra-
tion or rubbing against other parts during opera-
tion. Shields that protect against oil spray onto hot
exhaust components in event of a line, tube or
seal failure, must be installed correctly.
(20)Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are dis-
connected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
(21)Do not operate a truck if any rotating part is dam-
aged or contacts any other part during operation.
Any high speed rotating component that has been
damaged or altered should be checked for bal-
ance before reusing.
5
HOW TO USE THIS MANUAL
Lift truck models covered in this manual
MC Truck (Mechanical Control System)
Mechanically controlled hydraulic system (conventional lever system)
FC Truck (Finger-tip Control System)
Electronically controlled hydraulic system
Gasoline-Engine Trucks (FGE, FG)....... Trucks Equipped with K21 or K25 Gasoline Engine
Diesel-Engine Trucks (FD).................... Trucks Equipped with K21 or K25 Diesel Engine
Powershift Trucks................................... Trucks Equipped with Powershift Transmission
Manual Transmission Trucks................. Trucks Equipped with Manual Transmission
(2 Types of Clutch; Dry and Wet)
213443
MC Truck
FC Truck
Lever
Control valve
FC lever box
VCM Controller
Electric wiring
Electromagnetic control valve
Flow regulator valve
Output unit
Input unit
6
HOW TO USE THIS MANUAL (continued)
(Removal, Installation, Assembly and Disassembly)
Disassembly diagram (example)
Suggestions for Disassembly
Output shaft, Removing
Remove output shaft using a special tool.
A: Standard value
B: Repair or Service Limit
1
2
213445
Sequence
1 Cover, Bolt, Washer (part name)
2 Snap ring (part name)
213446
Service Data
Gear Backlash A 0.11 to 0.28 mm
B 0.5 mm
7
Symbols and abbreviations
Units
(1) SI Units are used in this manual.
(2) The following table shows the conversion of SI
unit and customary unit.
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
RC1/8 Taper pipe thread (external) 1/4 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Item SI unit Customary unit
Force 1 N 0.102 kgf
1 lbf 0.4536 kgf
Pressure
1 kPa 0.0102 kgf/cm2
1 psi 0.0703 kgf/cm2
Torque 1 N·m 0.102 kgf·m
1 lbf·ft 0.1383 kgf·m
CHAPTER INDEX
CHAPTER INDEX
CHAPTER INDEX Items
GENERAL INFOMATION Truck Models Covered, Serial Number Locations,
Dimensions, Technical Data
COOLING SYSTEM Fan Belt Removal and Installation, Fan Belt Tension
ELECTRICAL SYSTEM Console Box, Chassis Electrical Devices,
Battery Maintenance, Electrical Schematic
CONTROLLERS Main Functions of Controller, Input/Output Monitor,
Error Codes and Troubleshooting
POWER TRAIN Removal and Installation of Power Line
CLUTCHES Dry-Type Clutch, Wet-Type Clutch
MANUAL TRANSMISSION Structure, Removal and Installation of Transmission
POWERSHIFT TRANSMISSION
Torque Converter,
Singe Speed Powershift Transmission Control Valve,
Automatic Two-Speed Transmission
FRONT AXLE AND
REDUCTION DIFFERENTIAL Front Tire, Front Axle, Reduction, Differential
REAR AXLE Rear Axle, Rear Tire
BRAKE SYSTEM Master Cylinder, Wheel Brake, Brake Booster
STEERING SYSTEM Steering Gear, Power Cylinder, Flow Divider
HYDRAULIC SYSTEM Tank, Pump, Control Valve, Lift and Tilt Cylinders,
Flow Regulator Valve, Down Safety Valve
MAST AND FORKS Simplex and Duplex Masts, Triplex Mast
SERVICE DATA
Maintenance Standard, Maintenance Schedule,
Periodic Replacement Parts, Lubrication Instruction,
Special Tool Needed
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
Chapter 1 GENERAL INFORMATION
1. Model View............................................................................................... 1-1
2. Truck Models Covered............................................................................ 1-2
3. Serial Number Locations........................................................................ 1-3
4. Dimensions.............................................................................................. 1-4
5. Technical Data......................................................................................... 1-5
6. Performance ............................................................................................ 1-7
1-1
GENERAL INFORMATION
Chapter 1 GENERAL INFORMATION
1. Model View
213447
MC truck
213448
FC truck
Este manual sirve para los siguientes modelos
27
Tabla de contenidos
Otros manuales de Máquina elevadora de Mitsubishi
