PDF Service Manual Mitsubishi FD FG FGE Series Forklift Chassis & Mast - 3 MB
Dive deep into the repair and maintenance of your Mitsubishi forklift with this comprehensive service manual.
It covers the chassis and mast assemblies for the FD, FG, and FGE series trucks.
The manual includes detailed procedures, specifications, and diagrams to guide technicians through complex repairs.
This is the ultimate resource for keeping your Mitsubishi forklift fleet in peak operating condition.
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--- Page 1 ---
Service Manual
Chassis & Mast MC/FC
FG10N F25C-00011-up FGE10N F25C-08011/18001-up
FG15N F25C-50001-up FGE15N F25C-58001/68001-up
FG15ZN F34-50011-up FGE15ZN F34-58011/68001-up
FG18N F25C-70001-up FGE18N F25C-78001/88001-up
FG18ZN F34-70001-up FGE18ZN F34-78001/88001-up
FG20CN F34-20001-up FGE20CN F34-28001/38001-up
FG20N F17D-00011-up FGE20N F17D-08011/18001-up
FG20ZN F35-00011-up FGE20ZN F35-08011/18001-up
FG25N F17D-50001-up FGE25N F17D-58001/68001-up
FG25ZN F35-50001-up FGE25ZN F35-58001/68001-up
FG30N F13F-30011-up FGE30N F13F-38011/48001-up
FG35AN F13F-50001-up FGE35AN F13F-58001/68001-up
FD10N F16D-00011/10001-up
FD15N F16D-50001/60001-up
FD18N F16D-70001/80001-up
FD20CN F16D-85001/87001-up
FD20N F18C-00011/10001-up
FD25N F18C-50001/60001-up
FD30N F14E-30011/40001-up
FD35AN F14E-50001/60001-up
For use with S4Q2, S4S and K15/K21/K25 Engine
Service Manuals. 99719-15120
--- Page 4 ---
COOLING SYSTEM
Specification ............................................................................................ 2 – 1
Structure .................................................................................................... 2 – 2
2
Removal and Installation ...................................................................... 2 – 3
Inspection and Adjustment .................................................................. 2 – 5
Fan Belt Inspection .................................................................................... 2 – 5
Fan Belt Tension ........................................................................................ 2 – 5
Connecting Radiator Hoses ....................................................................... 2 – 5
Unit Layout ................................................................................................ 2 – 5
Coolant ...................................................................................................... 2 – 6
Radiator Cap ............................................................................................. 2 – 6
--- Page 5 ---
ELECTRICAL SYSTEM
Chassis Electrical Devices Wiring Outline (No. 1)
Main harness
Harness, rear
combination
Harness, front
combination
Harness, front
combination
209620
3-1
--- Page 6 ---
ELECTRICAL SYSTEM
Thermoswitch (T/C oil)
Apply an ohmmeter between the terminal and body and
check for continuity (resistance value). Replace the Terminal Body
thermoswitch if the measured insulation resistance value is
not more than the value listed in the table below.
1 M ohm or more
Insulation resistance value (with contact OFF)
(at 500 V megger)
Internal resistance: 0.5 ohm or less (with contact ON)
Allowable load: 0.5 A
NOTE
When installing the thermoswitch, tighten it to the 208547
specified torque.
31.4 to 47.1 N·m
Tightening torque (3.2 to 4.8 kgf·m)
[23.2 to 34.7 lbf·ft]
! CAUTION
Replace the thermoswitch if it was dropped or
abused.
Main specifications
122 ± 3 °C
OFF→ON
(251.6 ± 5.4 °F)
Operating temperature
115 °C (239 °F)
ON→OFF
or higher
Insulation resistance
1 M ohm or more
(with contact OFF)
3-11
--- Page 7 ---
ELECTRICAL SYSTEM
Troubleshooting
Starter System
Weak or dead battery Recharge or replace.
Short or open circuit Repair or replace.
Starter will not crank
Poor continuity in starter switch Replace.
engine
Starter or starter relay defective Replace.
Forward-reverse lever not in neutral Move lever to neutral
Starter switch position (ATM truck) position.
Turning off starter Open or short circuit Repair or replace.
switch will not stop Engine stop solenoid defective Replace or readjust.
engine
Control timer defective Replace.
Gauges
Rigid board defective Replace.
Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Water Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
temperature
accurately
gauge Loose terminal connection Repair.
Will indicate higher Circuit between gauge and gauge unit Repair.
than actual grounded
temperature Gauge internally defective Replace.
Rigid board defective Replace.
Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
accurately
Loose terminal connection Repair.
Fuel gauge Circuit between gauge and gauge unit Repair.
Will indicate “full” open or short
regardless of amount
of fuel left in tank Gauge internally defective Replace.
Gauge unit defective Replace.
Will indicate Circuit between gauge and gauge unit Repair.
“empty” regardless grounded
of amount of fuel Gauge unit defective Replace.
left in tank Gauge internally defective Replace.
3-21
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Pub No. 99719-15120
3-35
--- Page 9 ---
Pub No. 99719-15120
3-55
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Pub No. 99719-15120
3-75
--- Page 11 ---
Pub No. 99719-15120
3-95
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Pub No. 99719-15120
3-115
--- Page 13 ---
CONTROLLERS
5. VCM-2 I/O Monitor: Other control 1
GSE VCM–2 –> VCM–2
Oil press MAIN [Hex, MPa]
Oil press LIFT [Hex, MPa] Input/Output monitor
Oil press MAIN 18.5[MPa]
Oil press LIFT 14.8[MPa]
Weight 0 set SW ON/OFF
Enter SW ON/OFF Weight 0 set SW OFF
Enter SW OFF
Next SW ON/OFF Next SW OFF
Auto light sig ON
Auto light sig ON/OFF Auto light OUT ON
Auto light OUT ON/OFF
Seat SW ON
Seat SW timer ON
Seatbelt SW ON
Seat SW ON/OFF
Seat SW timer ON/OFF << [1][2][3][4][5][6] >>
Seatbelt SW ON/OFF View Tool
6. VCM-2 I/O Monitor: Other control 2
Park brake alarm ON/OFF GSE VCM–2 –> VCM–2
Over load alarm ON/OFF Input/Output monitor
Over speed alarm ON/OFF Park brake alarm OFF
Over load alarm OFF
Over speed alarm OFF
Coolant low SW ON/OFF
Coolant low SW OFF
Air cleaner SW ON/OFF Air cleaner SW OFF
T/M warning SW ON/OFF T/M warning SW OFF
Fuel warning SW OFF
Fuel warning SW ON/OFF Park brake SW OFF
Park brake SW ON/OFF
AUX in1 OFF AUX out1 ON
AUX in2 ON AUX out2 OFF
AUX in1 ON/OFF AUX out3 OFF
AUX in2 ON/OFF << [1][2][3][4][5][6] >>
AUX out1 ON/OFF View Tool
AUX out2 ON/OFF
AUX out3 ON/OFF
4-8
--- Page 14 ---
CONTROLLERS
(8) Verify the current values of unload solenoid and lift
lock valve solenoid outputs on the screen.
If the values are not 2500 mA or around, there is a Input/Output monitor
possibility of error. Unload output ON 2486[mA]
Lift lock output ON 2486[mA]
Tilt lock valve output OFF 10[mA]
Lift lowering speed changing switch OFF
Lift lowering operation limit switch OFF
Tilt operation limit switch OFF
Mast lift-up height [lower]switch OFF
Snow mode switch OFF
Vertical tilt switch ON
Tilt angle sensor signal +2.5 [V]
<< [1][2][3][4][5] >>
Fig. 1-22 Solenoid current value
confirmation screen
(9) After the confirmation, return the key to OFF position
to release the active test.
Be sure to place the key in OFF position whenever
proceeding with next procedure.
• If there is a error, see “Error Codes” of Section 5.2
and check each item listed in the error codes F-75,
F-77, and F-79.
4-18
--- Page 15 ---
CONTROLLERS
4. Parking Brake Warning Buzzer and Lamp
4.1 Function
The parking brake is a double action type designed to be Manual Parking brake warning light
released while pushing the lever top knob. Irrespective of the
engine being stopped or running, leaving the operator’s seat
with the parking brake released activates the operator present
switch to sound the warning buzzer and flicker the warning.
! CAUTION
1. Prior to operating the forklift truck, be sure to 103884
check the parking brake warning buzzer and
light for function.
Powershift Parking brake warning light
2. The buzzer and warning light are for reminding
the operator to apply the parking brake when
leaving the forklift truck. Be sure to maintain
them so that they are always in order.
3. When and after parking the forklift truck:
• Select a place with level and hard surface.
• Place the direction lever to the neutral
position. 103885
• Lower the forks until the fork tips touch the
floor.
• Apply the parking brake.
• Stop the engine and remove the key.
4. When replacing the operator’s seat, be sure to
use Mitsubishi genuine seat with operator
present switch.
Controller Function
Sends the warning signal to sound the buzzer when the
operator is not seated in the seat with the parking brake
released when the key is in ON position.
When the key is in OFF position, the controller does not
activate since the power is not supplied to the controller. In
such a case, the buzzer will sound by releasing the parking
brake through the relay circuit.
4-28
--- Page 16 ---
CONTROLLERS
Err
Description Probable cause Check point
code
F54 Lift sol leak 1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
4. Lift sol bad 4. Lift sol connection check
5. Controller bad
F55 Tilt FW sol err 1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
4. Tilt FW sol bad 4. Tilt FW sol connection check
5. Controller bad
F57 Tilt BW sol err 1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
4. Tilt BW sol bad 4. Tilt BW sol connection check
5. Controller bad
F59 Tilt sol leak 1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
4. Tilt sol bad 4. Tilt sol connection check
5. Controller bad
4-38
--- Page 17 ---
CONTROLLERS
er
ch/
al switch
S
(
Fig. 7-7 Direction Lever
7.5 Speed Sensor
Transmission (Right side)
0.5G/B
0.5G
703
702
702 703
(Black)
Speed sensor
212815
Speed sensor
Fig. 7-8 Speed Sensor
4-48
--- Page 19 ---
POWER TRAIN
(4) Connect the accelerator pedal link on the floor plate to
the throttle cable. Check that the throttle lever is at the
full-open position when the accelerator pedal is fully
depressed.
(5) Bleed the air out of the brake fluid circuit after
connecting the brake pipe.
(6) When installing the exhaust pipe, use a new gasket.
(7) Connect the ground (negative) cable to the battery only
after making sure that all wiring is connected properly.
(8) Refill the engine, radiator, and transmission with
oils/coolant, and check for leakage. Unless otherwise
specified, use soft water (tap water) mixed with
antifreeze at a concentration of 35%.
(9) Bleed the air out of the fuel circuit of the engine.
(10) After checking the parts, start the engine and check
that the clutch booster functions properly (wet-type
clutch transmission trucks only). Operate the mast
lifting/tilting and steering, and check the hydraulic oil
level. Also recheck the engine oil, coolant and
transmission oil levels.
5-10
--- Page 20 ---
CLUTCHES
Principal Differences between Dry-type and Wet-type Clutches
Clutch cover assembly Clutch disc Input shaft Clutch housing
Engine
mounted S4Q2 S4S
K21 K25 K15
Items
Dry-type
Identification
mark Yellow Blue Black
Spring 12 pieces 12 pieces 8 pieces
Identification 209815 209818
mark
209814
209617
Wet-type
Engine
mounted S4S S4Q2
K25 K21, K15
Items
Identification
mark Brown Pink
Spring 12 pieces 10 pieces
209816 209819
Clutch pedal Clutch shifter shaft Release bearing E/G packing
Grease lubricated type Not provided
Dry-type:
L = 40.6 mm (1.60 in.)
Dry-type
With grease nipple
209821 209824
Provided
L
Wet-type
209823
Without grease nipple
209820
Wet-type:
L = 40.6 mm (1.60 in.)
209822 209825
6-2
--- Page 21 ---
CLUTCHES
Inspection and Repair
(1) Clutch disc assembly
(a) Clutch disc thickness
209839
A: Standard value B: Repair or service limit
Item Dry-type Wet-type
A Both sides: 9.2 ± 0.3 (0.362 ± 0.0118) Both sides: 6.0 ± 0.3 (0.236 ± 0.0118)
Clutch disc thickness
mm (in.) B Each side: 1.5 (0.059) Each side: 0.4 (0.016)
Both sides: 2.1 (0.08) Both sides: 0.8 (0.031)
Replace the clutch disc if wear exceeds the service
limit.
NOTE
If the facings are badly worn beyond the service limit,
the release cylinder is no longer effective in
compensating for facing wear, causing the clutch to slip.
In such a case, replace the clutch disc immediately.
(b) Tightness of facing rivets
Check the clutch disc for broken or fatigued torsion
springs and loose rivets. Also check for hardened
friction surfaces and oil or grease on the surfaces.
Replace the clutch disc if defective.
209840
(c) Disc face runout
Measure the clutch disc for face runout. Replace the
clutch disc if defective.
A: Standard value
1.0 mm (0.039 in.)
Face runout (at rim) A
max.
(d) Others
Check for hub spline wear, worn damper and scratches 209841
on the friction surfaces.
6-12
--- Page 22 ---
CLUTCHES
Inspection and Repair (3) Return spring
(1) Cylinder body (a) Check the return spring for scars, wear and
perpendicularity. Replace if defective.
(a) Check the inside surfaces for scratches, uneven
wear and corrosion. (b) Measure the free length of the return spring.
Replace if the measurement exceeds the service
(b) Check the inlet and relief ports for condition.
limit.
Also check the joint for damaged threads.
(2) Piston assembly A: Standard value B: Repair or service limit
Free length of return A 81 mm (3.19 in.)
! CAUTION spring B 74.2 mm (2.92 in.)
The piston assembly is a periodic replacement
part. For safety, however, its replacement at (4) Push rod
each time of disassembly is recommended.
(a) Check the push rod for bending and
deformation. Replace if defective.
(a) Check the piston assembly for scratches,
(5) Boot
uneven wear and damage on the sliding contact
surface. Repair it if defect is minor or replace (a) Check the boot for cracks, damage and tear.
if damaged. Replace if defective.
(b) Check the piston cups for damaged lip, chafed (b) Check the boot for interference with the
base, wear and swelling. Replace if defective cylinder and push rod. Replace the boot if it
using the repair kit. has no or little interference.
(c) Measure the clearance between the piston (6) Filler union
assembly and cylinder body. Replace the (a) Check the filler union for cracks and scars.
piston assembly together with the cylinder Replace if any size of crack or scar is found.
body if the measurement exceeds the service
(b) Check the filler union for deformation.
limit.
Replace if excessively deformed.
A: Standard value B: Repair or service limit
Clearance between piston A 0.016 to 0.086 Reassembly
and cylinder (0.0006 to 0.0034)
To reassemble, follow the reverse of disassembly
mm (in.) B 0.15 (0.0059) sequence performing the following with particular care.
(1) Wash all metal parts with volatile cleaning solvent.
(d) Check the piston cups for interference. After washing, blow off the solvent completely
Replace them using the repair kit if the with compressed air.
interference is less than the service limit. (2) Apply a thin coat of rubber grease (METAL
A: Standard value B: Repair or service limit RUBBER #20) or brake fluid to the inside surface
Unit: mm (in.) of cylinder body and the peripheral surface of
piston cups.
Primary A Approx. 1.0 (0.039)
(3) Be careful not to damage the lip of piston cups.
cup B 0.4 (0.016)
Piston cup
interference
Secondary A Approx. 1.1 (0.043)
cup B 0.4 (0.016)
6-22
--- Page 23 ---
CLUTCHES
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model
1 ton class 2 ton class 3 ton class
Item
Inside diameter 1 A 15.875 (0.625)
A 0.016 to 0.086 (0.0006 to 0.0034)
Clearance between piston and cylinder 2
B 0.15 (0.0059)
Diameter of piston cup 3 A 17.0 ± 0.2 (0.669 ± 0.008)
Clutch
Free length of return spring 4 A 81 (3.19)
master
cylinder
(common 1 2
to dry- and
wet-types)
4 3
204807
Inside diameter 1 A 22.22 (0.875)
A 0.020 to 0.105 (0.00079 to 0.00414)
Clearance between piston and body 2
B 0.15 (0.0059)
Diameter of piston cup 3 A 24 ± 0.2 (0.94 ± 0.008)
Clutch
release Free length of return spring 4 A 43 (1.69)
cylinder
(common
to dry- and 3
4 1 2
wet-types)
206436
6-32
--- Page 24 ---
MANUAL TRANSMISSION
Control Covers, Shift Rails and Forks
7
4
12
1
14
3
5 8
6
10
2
10
11
9
13
9
209875
Sequence
1 Control cover 8 Shift lever
2 Control plate cover, Bolts, Washers 9 Plug, Gasket
3 Lock pin, Nut 10 Spring and steel ball
4 Shift lever, Needle bearing, Oil Seal 11 Shift rail (F – R)
5 Shift lever 12 Shift fork (F – R)
6 Lock pin, Nut 13 Shift rail (H – L)
7 Shift lever, Needle bearing, Oil Seal 14 Shift fork (H – L)
7-5
--- Page 25 ---
MANUAL TRANSMISSION
Suggestions for Reassembly
(1) Needle bearing
(a) Apply gear oil to the needle bearings before they
are installed.
(2) Synchromesh assembly
(a) Align three grooves on the outer circumference of
the synchronizer hub with the synchronizer sleeve
before the sleeve and hub are assembled together.
(b) Apply molybdenum disulfide grease to the contact
faces of the cone on the gear and the cones of the
synchronizer rings.
Aligning
position
209891
(3) Thrust washer
(a) One side of the thrust washer faces the bearing and Bearing
side
the other side faces the gear. Make sure that the Gear side
thrust washers are installed correctly.
209892
(4) Nut
(a) Tighten the nuts to the specified torque. Never use
an impact wrench.
A: Standard value
245 ± 24.5 N·m
Tightening torque A (25.0 ± 2.5 kgf·m)
[180 ± 18 lbf·ft]
7-15
--- Page 27 ---
POWERSHIFT TRANSMISSION
Output Gear Assembly and Idler Shaft
Disassembly
1
2
209914
Sequence
1 Input gear assembly 2 Idler shaft
Inspections after Disassembly
(1) Torque converter housing and transmission housing
(a) Check for crack or wear.
(2) Magnet strainer
(a) Check for clogging and damage.
(3) Gear and shaft
(a) Check for wear and other damage.
(4) Output flange
(a) Check the splines for wear and other damage.
(b) Check the sliding surface to the oil seal for
damage.
8-10
--- Page 28 ---
POWERSHIFT TRANSMISSION
MEMO
8-20
--- Page 29 ---
POWERSHIFT TRANSMISSION
(2) Lubricating internal parts
(a) Apply ATF to the internal gear, drive gear and the
Internal gear Oil pump body
inside surfaces of the oil pump body before
reassembling them.
Drive gear 209927
(3) Operation check