Mitsubishi FD20A, F18B Forklift Service Manual
Mitsubishi FD20A, F18B Forklift Service Manual - Image 2
Mitsubishi FD20A, F18B Forklift Service Manual - Image 3
Mitsubishi FD20A, F18B Forklift Service Manual - Image 4
Mitsubishi FD20A, F18B Forklift Service Manual - Image 5

Mitsubishi FD20A, F18B Forklift Service Manual

$50.00

  • Type Of Manual: Service Manual
  • Number of Pages: 538
  • Size: 27.5MB
  • Format: PDF
Category:

Product details

  • Model List:

    • FD20A, F18B
  • 1. FOREWORD
  • 1.1. FOREWARD
  • 2. GENERAL INFORMATION
  • 2.1. TRUCK MODELS COVERED
  • 2.2. SERIAL NUMBER LOCATIONS
  • 2.3. DIMENSIONS
  • 2.4. TECHNICAL DATA
  • 3. BRAKE SYSTEM
  • 3.1. DESCRIPTION
  • 3.1.1. AUTOMATIC ADJUSTING DEVICE
  • 3.1.2. BRAKE PEDAL AND ASSOCIATED PARTS
  • 3.2. DISASSEMBLY AND REASSEMBLY
  • 3.2.1. MASTER CYLINDER
  • 3.2.2. SERVICE BRAKES
  • 3.2.3. WHEEL CYLINDERS
  • 3.3. INSPECTION AND ADJUSTMENT
  • 3.3.1. AUTOMATIC ADJUSTING DEVICE
  • 3.3.2. MANUAL ADJUSTMENT
  • 3.3.3. BRAKE PEDAL ADJUSTMENT
  • 3.3.4. BLEEDING AIR OUT OF THE BRAKE FLUID LINE
  • 3.3.5. BRAKE TEST
  • 4. COOLING SYSTEM
  • 4.1. DESCRIPTION
  • 4.2. REMOVAL AND INSTALLATION
  • 4.3. INSPECTION AND ADJUSTMENT
  • 4.3.1. FAN BELT INSPECTION
  • 4.3.2. FAN BELT ADJUSTMENT
  • 5. ELECTRICAL SYSTEM
  • 5.1. DESCRIPTION
  • 5.1.1. CONSOLE BOX
  • 5.2. DISASSEMBLY AND REASSEMBLY
  • 5.2.1. CONSOLE BOX
  • 5.2.2. COMPONENTS INSIDE THE CONSOLE BOX
  • 5.2.3. COMBINATION METER
  • 5.2.4. WARNING LAMP AND INDICATOR BULB REPLACEMENT
  • 5.3. MAJOR ELECTRICAL COMPONENTS
  • 5.3.1. STARTER SWITCH (ANTI-RESTART TYPE)
  • 5.3.2. LIGHTING SWITCH
  • 5.3.3. FUSE BOX
  • 5.4. CARE OF THE BATTERY
  • 5.5. LAMP BULB SPECIFICATIONS
  • 5.6. ELECTRICAL SYSTEM SCHEMATIC
  • 6. FRONT AXLE AND REDUCTION DIFFERENTIAL
  • 6.1. DESCRIPTION
  • 6.2. REMOVAL AND INSTALLATION
  • 6.2.1. FRONT WHEELS
  • 6.2.2. FRONT AXLE AND REDUCTION DIFFERENTIAL
  • 6.3. DISASSMEBLY AND REASSEMBLY
  • 6.3.1. FRONT AXLE
  • 6.3.2. REDUCTION DIFFERENTIAL
  • 6.4. ADJUSTMENT
  • 6.4.1. TOOTH CONTACT ADJUSTMENT
  • 7. HYDRAULIC SYSTEM
  • 7.1. DESCRIPTION
  • 7.1.1. HYDRAULIC SYSTEM
  • 7.1.2. HYDRAULIC TANK
  • 7.1.3. HYDRAULIC PUMP
  • 7.1.4. CONTROL VALVE
  • 7.1.5. LIFT AND TILT CYLINDERS
  • 7.1.6. FLOW REGULATOR VALVE
  • 7.1.7. DOWN SAFETY VALVE
  • 7.2. REMOVAL AND INSTALLATION
  • 7.2.1. HYDRAULIC PUMP
  • 7.2.2. CONTROL VALVE
  • 7.2.3. LIFT CYLINDERS
  • 7.2.4. TILT CYLINDERS
  • 7.3. DISASSEMBLY AND REASSEMBLY
  • 7.3.1. HYDRAULIC PUMP
  • 7.3.2. CONTROL VALVE
  • 7.3.3. LIFT CYLINDERS
  • 7.3.4. TILT CYLINDERS
  • 7.3.5. FLOW REGULATOR VALVE
  • 7.4. INSPECTION AND ADJUSTMENT
  • 7.4.1. HYDRAULIC TANK
  • 7.4.2. CONTROL VALVE
  • 7.4.3. LIFT AND TILT CYLINDERS
  • 7.4.4. FLOW REGULATOR VALVE
  • 7.4.5. TESTING
  • 8. MASTS AND FORKS
  • 8.1. DESCRIPTION
  • 8.2. REMOVAL AND INSTALLATION
  • 8.3. DISASSEMBLY AND REASSEMBLY
  • 8.4. INSPECTION AND ADJUSTMENT
  • 8.4.1. CHAIN TENSION ADJUSTMENT
  • 8.4.2. CLEARANCE ADJUSTMENT LIFT BRACKET
  • 8.4.3. MAST CLEARANCE ADJUSTMENT
  • 8.4.4. MAIN ROLLER SHIM REPLACEMENT
  • 8.4.5. MAST STRIP ADJUSTMENT
  • 8.4.6. TILT ANGLE ADJUSTMENT
  • 8.4.7. LIFT CYLINDER STROKE ADJUSTMENT
  • 8.4.8. MAST ADJUSTMENT CHART
  • 9. POWER TRAIN
  • 9.1. REMOVAL AND INSTALLATION
  • 9.1.1. ENGINE TRANSMISSION
  • 10. POWERSHIFT TRANSMISSION
  • 10.1. DESCRIPTION
  • 10.1.1. HYDRAULIC CIRCUIT
  • 10.1.2. CONTROL
  • 10.2. REMOVAL AND INSTALLATION
  • 10.3. DISASSEMBLY AND REASSEMBLY
  • 10.3.1. TRANSMISSION ASSEMBLY
  • 10.4. INSPECTION AND ADJUSTMENT
  • 10.4.1. TESTING HYDRAULIC PRESSURE
  • 10.4.2. ADJUSTING INCHING PEDAL
  • 10.4.3. TESTING CLUTCH VALVE
  • 10.4.4. TESTING STALL SPEED
  • 10.4.5. M (33-FT) START ACCELERATION TEST
  • 11. REAR AXLE
  • 11.1. DESCRIPTION
  • 11.2. REMOVAL AND INSTALLATION
  • 11.2.1. REAR WHEELS
  • 11.2.2. REAR AXLE
  • 11.3. DISASSEMBLY AND REASSEMBLY
  • 11.3.1. DISASSEMBLY
  • 11.3.2. REASSEMBLY
  • 11.4. INSPECTION AND ADJUSTMENT
  • 11.4.1. TOE-IN ADJUSTMENT
  • 11.4.2. MINIMUM TURNING RADIUS ADJUSTMENT
  • 12. SERVICE DATA
  • 12.1. MAINTENANCE STANDARDS
  • 12.1.1. POWERSHIFT TRANSMISSION
  • 12.1.2. FRONT AXLE AND REDUCTION DIFFERENTIAL
  • 12.1.3. REAR AXLE
  • 12.1.4. BRAKE SYSTEM
  • 12.1.5. STEERING SYSTEM
  • 12.1.6. HYDRAULIC SYSTEM
  • 12.1.7. MAST AND FORKS
  • 12.2. TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
  • 12.3. MAINTENANCE CHART
  • 12.4. PERIODIC REPLACEMENTS PARTS
  • 12.5. LUBRICATION CHART
  • 12.5.1. FUEL AND LUBRICANT SPECIFICATIONS
  • 12.5.2. RECOMMENDED BRANDS OF LUBRICANTS
  • 12.5.3. REFILL CAPACITIES (APPROXIMATE)
  • 12.6. WEIGHT OF MAJOR COMPONENTS (APPROXIMATE)
  • 12.7. SPECIAL SERVICE TOOLS
  • 12.8. INSPECTION GUIDE
  • 13. STEERING SYSTEM
  • 13.1. DESCRIPTION
  • 13.2. REMOVAL AND INSTALLATION
  • 13.2.1. STEERING GEAR AND POWER CYLINDER REMOVAL
  • 13.3. DISASSEMBLY AND REASSEMBLY
  • 13.3.1. STEERING GEAR
  • 13.3.2. POWER CYLINDER
  • 13.4. INSPECTION AND ADJUSTMENT
  • 13.4.1. STEERING WHEEL FREE PLAY
  • 13.4.2. SHEERING EFFORT
  • 13.4.3. RELIEF VALVE SETTING ADJUSTMENT
  • 14. TROUBLESHOOTING
  • 14.1. ELECTRICAL SYSTEM
  • 14.2. POWERSHIFT TRANSMISSION
  • 14.3. FRONT AXLE AND REDUCTION DIFFERENTIAL
  • 14.4. REAR AXLE
  • 14.5. BRAKE SYSTEM
  • 14.6. STEERING SYSTEM
  • 14.7. HYDRAULIC SYSTEM
  • 14.8. MASTS AND FORKS
  • 15. FOREWORD
  • 15.1. Foreward
  • 16. GENERAL
  • 16.1. SPECIFICATIONS
  • 16.2. SECTIONAL VIEWS
  • 16.2.1. Q7 Longitudinal Sectional View
  • 16.2.2. Q7 Transverse Sectional View
  • 16.2.3. S4S Longitudinal Sectional View
  • 16.2.4. S4S Transverse Sectional View
  • 16.3. PERFORMANCE CURVES
  • 16.3.1. Q7
  • 16.3.2. S4S
  • 17. COOLING SYSTEM
  • 17.1. DECRIPTION
  • 17.2. WATER PUMP
  • 17.2.1. Disassembly and Inspection
  • 17.3. THERMOSTAT
  • 17.3.1. Inspection
  • 18. ELECTRICAL SYSTEM
  • 18.1. STARTER
  • 18.1.1. Disassembly
  • 18.1.2. Inspection and Repair
  • 18.1.3. Reassembly
  • 18.2. ALTERNATOR
  • 18.2.1. Disassembly
  • 18.2.2. Inspection
  • 18.2.3. Reassembly
  • 18.3. HEATER PLUGS
  • 18.3.1. Inspection
  • 19. ENGINE PROPER
  • 19.1. CYLINDER HEAD AND VALVE MECHANISM
  • 19.1.1. Disassembly
  • 19.1.2. Inspection and Repair
  • 19.1.3. Reassembly
  • 19.1.4. Valve Clearance Inspection and Adjustment
  • 19.2. TIMING GEARS, CAMSHAFT AND OIL PAN
  • 19.2.1. Disassembly
  • 19.2.2. Inspection and Repair
  • 19.2.3. Reassembly
  • 19.3. FLYWHEEL
  • 19.3.1. Disassembly
  • 19.3.2. Inspection and Repair
  • 19.3.3. Reassembly
  • 19.4. PISTON, CONNECTING RODS, CRANKSHAFT AND CRANKCASE
  • 19.4.1. Disassembly
  • 19.4.2. Inspection and Repair
  • 19.4.3. Reassembly
  • 20. FUEL SYSTEM
  • 20.1. DESCRIPTION
  • 20.1.1. Draining (distributor type injection pump)
  • 20.1.2. Priming
  • 20.2. FUEL FILTER
  • 20.2.1. Disassembly and Inspection
  • 20.3. INJECTION NOZZLES
  • 20.3.1. Disassembly
  • 20.3.2. Inspection and Adjustment
  • 20.3.3. Reassembly
  • 20.4. INJECTION PUMP
  • 20.4.1. Removal
  • 20.4.2. Installation
  • 20.4.3. Adjusting Injection Timing
  • 20.4.4. Adjusting the Idling and Maximum Speeds
  • 21. INLET AND EXHAUST SYSTEMS
  • 21.1. DESCRIPTION
  • 21.2. EXHAUST MANIFOLD
  • 21.2.1. Inspection and Repair
  • 22. LUBRICATION SYSTEM
  • 22.1. DESCRIPTION
  • 22.2. OIL PUMP
  • 22.2.1. Disassembly
  • 22.2.2. Inspection and Repair
  • 22.2.3. Reassembly
  • 22.3. OIL FILTER
  • 22.3.1. Disassembly and Inspection
  • 22.4. RELIEF VALVE
  • 22.4.1. Inspection
  • 23. MAINTENANCE STANDARDS
  • 23.1. MAINTENANCE STANDARDS
  • 23.2. TIGHTENING TORQUE
  • 23.2.1. Important Bolts and Nuts
  • 23.2.2. Standard Bolts
  • 23.2.3. Standard Studs
  • 23.2.4. Standard Plugs
  • 23.2.5. Tightening Torques For Major Components
  • 23.3. SEALANT APPLICATION DATA
  • 24. SPECIAL TOOLS
  • 24.1. SPECIAL TOOLS
  • 25. TROUBLESHOOTING
  • 25.1. TROUBLESHOOTING (CHART 1)
  • 25.2. TROUBLESHOOTING (CHART 2)
  • 26. WORKSHOP THEORY
  • 26.1. SUGGESTIONS ON DISASSEMBLY AND REASSEMBLY
  • 26.1.1. Oil Seals
  • 26.1.2. O-rings
  • 26.1.3. Bearings
  • 26.1.4. Lock Plates
  • 26.1.5. Split Pins and Spring Pins
  • 26.2. TESTING THE COMPRESSION PRESSURE
  • 27. GENERAL
  • 27.1. GENERAL
  • 27.1.1. Foreword
  • 27.1.2. How To Use This Manual
  • 27.1.3. Outline
  • 27.1.4. Specifications
  • 28. ADJUSTMENT, BENCH TEST, PERFORMANCE TEST
  • 28.1. ADJUSTMENTS, BENCH TEST, PERFORMANCE TESTS
  • 28.1.1. Adjustments
  • 28.1.2. Bench Test
  • 28.1.3. Performance Tests
  • 29. COOLING SYSTEM
  • 29.1. COOLING SYSTEM
  • 29.1.1. Cooling System
  • 29.1.2. Water Pump
  • 29.1.3. Thermostat
  • 30. DISASSEMBLY, ENGINE MAIN PARTS
  • 30.1. DISASSEMBLY, ENGINE MAIN PARTS
  • 30.1.1. Preparation before Disassembly
  • 30.1.2. Electrical System
  • 30.1.3. Fuel System (Distributor type Pump)
  • 30.1.4. Fuel System (In-line type pump)
  • 30.1.5. Oil System
  • 30.1.6. Cooling System
  • 30.1.7. Inlet and Exhaust System
  • 30.1.8. Cylinder Heads and Valve Mechanism, Disassembly
  • 30.1.9. Flywheel, Disassembly
  • 30.1.10. Timing Gears, Disassembly
  • 30.1.11. Pistons, Connecting Rods, Crankshaft, Crankcase and Tapet, Disassembly
  • 31. ELECTRICAL SYSTEM
  • 31.1. ELECTRICAL SYSTEM –
  • 31.1.1. Starter
  • 31.1.2. Alternator
  • 31.1.3. Glow Plugs
  • 31.1.4. Stop Solenoid (In-line type injection pump)
  • 32. FUEL SYSTEM
  • 32.1. FUEL SYSTEM
  • 32.1.1. Fuel System
  • 32.1.2. Fuel Filter
  • 32.1.3. Injection Nozzle
  • 32.1.4. Fuel System Bleeding
  • 33. GENERAL INSTRUCTIONS
  • 33.1. GENERAL INSTRUCTIONS
  • 33.1.1. Determination of Overhaul Timing
  • 33.1.2. Testing Compression Pressure
  • 33.1.3. Tips on Disassembly and Reassembly
  • 33.1.4. Precautions for Disassembly and Reassembly
  • 34. INLET AND EXHAUST SYSTEM
  • 34.1. INLET AND EXHAUST SYSTEM
  • 34.1.1. Description
  • 34.1.2. Exhaust Manifold
  • 35. INSPECTION AND REPAIR, ENGINE MAIN PARTS
  • 35.1. INSPECTION AND REPAIR, ENGINE MAIN PARTS
  • 35.1.1. Inspection and Repair of Cylinder Head and Valve Mechanism
  • 35.1.2. Inspection and Repair, Flywheel and Timing Gear
  • 35.1.3. Inspection and Repair Piston, Connecting Rod, Crankshaft, Crankcase and Tappet
  • 36. LUBRICATION SYSTEM
  • 36.1. LUBRICATION SYSTEM
  • 36.1.1. Lubrication System
  • 36.1.2. Oil Pump
  • 36.1.3. Oil Filter
  • 36.1.4. Oil Pressure Relief
  • 37. MAINTENANCE STANDARD
  • 37.1. MAINTENANCE STANDARDS
  • 37.1.1. Maintenance Standards Table
  • 37.1.2. Tightening Torques
  • 37.1.3. Sealants and Lubricants Table
  • 37.1.4. Maintenance Schedule
  • 38. REASSEMBLY, ENGINE MAIN PARTS
  • 38.1. REASSEMBLY, ENGINE MAIN PARTS
  • 38.1.1. Reassembly Piston, Connecting Rod, Crankshaft, Crankcase and Tappets
  • 38.1.2. Reassembly, Timing Gear
  • 38.1.3. Reassembly, Flywheel
  • 38.1.4. Reassembly, Cylinder Head and Valve Mechanism
  • 39. SPECIAL TOOL
  • 39.1. SPECIAL TOOLS
  • 39.1.1. Special Tool List
  • 40. TROUBLESHOOTING
  • 40.1. TROUBLESHOOTING
  • 40.1.1. Causes of Engine Problems and Remedies
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