Mitsubishi FD20A, F18A Forklift Service Manual

Mitsubishi FD20A, F18A Forklift Service Manual - Image 2

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mitsubishi fd20a f18a forklift service manual 2

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Mitsubishi FD20A, F18A Forklift Service Manual

$50.00

Type Of Manual: Service Manual
Number of Pages: 603
Size: 13.7MB
Format: PDF

Category: Mitsubishi Service Manual PDF

Model List:
- FD20A, F18A

1. HOW TO READ THIS MANUAL
1.1. Introduction
2. GENERAL INFORMATION
2.1. External view
2.2. Truck models covered
2.3. Nameplate and serial number locations
2.4. Dimensions
2.5. Technical data
3. BRAKE SYSTEM
3.1. Description
3.1.1. Automatic adjusting device
3.1.2. Brake pedal and associated parts
3.1.3. Parking brake lever mechanism
3.2. Disassembly and Reassembly
3.2.1. Master cylinder
3.2.2. Wheel brakes
3.2.3. Wheel cylinders
3.2.4. Inspection and adjustment
4. CLUTCHES
4.1. Description
4.1.1. Types of drive
4.1.2. Dry-type clutch
4.1.3. Wet-type clutch
4.1.4. Clutch assister (for wet-type clutch pedal)
4.2. Disassembly and reassembly
4.2.1. Dry-type clutch
4.2.2. Wet-type clutch
4.2.3. Pressure plate assembly disassembly and reassembly
4.2.4. Clutch assister disassembly and reassembly
4.3. Inspection and adjustment
4.3.1. Clutch assister adjustment
4.3.2. Relationship between wet-type clutch pedal play and operating force
4.3.3. Clutch pedal adjustment
5. COOLING SYSTEM
5.1. Description
5.2. Removal and installation
5.3. Inspection and adjustment
6. ELECTRICAL EQUIPMENT
6.1. Description
6.1.1. Console box
6.1.2. Printed circuit
6.2. Disassembly and reassembly
6.3. Care of the battery
6.4. Major electrical components
6.5. Lamp bulb specifications
7. HYDRAULC
7.1. Description
7.1.1. Hydraulic tank
7.1.2. Hydraulic pump
7.1.3. Control valve
7.1.4. Lift and tilt cylinders
7.1.5. Flow regulator valve
7.1.6. 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
7.3.6. Down safety valve
7.4. Inspection and adjustment
7.4.1. Hydraulic tank
7.4.2. Hydraulic pump
7.4.3. Control valve
7.4.4. Lift and tilt cylinders
7.4.5. Testing
8. INSPECTION GUIDE
8.1. Inspection guide
9. MANUAL TRANSMISSION
9.1. Description
9.1.1. Synchronizer construction and operation
9.2. Removal and installation
9.3. Disassembly and reassembly
9.3.1. Disassembly
9.3.2. Reassembly
10. MAST AND FORKS
10.1. Description
10.2. Removal and installation
10.3. Disassembly and reassembly
10.4. Inspection and adjustment
10.4.1. Chain tension adjustment
10.4.2. Lateral clearance between outer and inner masts
10.4.3. Mast strip adjustment
10.4.4. Lateral clearance on lift bracket
10.4.5. Mast adjustment chart
11. POWER TRAIN
11.1. Removal and installation
11.1.1. Removal and engine, transmission (or torque converter), reduction gear and differential as an assembly
11.2. Removal of engine proper
12. POWERSHIFT TRANSMISSION
12.1. Description
12.1.1. Hydraulic circuit diagram
12.1.2. Control
12.2. Removal and installation
12.3. Disassembly and reassembly
12.3.1. Torque converter
12.3.2. Transmission
12.3.3. Control valve
12.4. Inspection and adjustment
12.4.1. Oil pressure measurement
12.4.2. Clutch valve testing
12.4.3. Stall speed measurement
12.4.4. m (33-ft) starting acceleration test
12.4.5. Inching pedal adjustment
13. REAR AXLE
13.1. Description
13.2. Removal and installation
13.2.1. Rear tires
13.2.2. Rear axle
13.3. Disassembly and reassembly
13.3.1. Disassembly
13.3.2. Reassembly
13.4. Inspection and adjustment
13.4.1. Toe-in adjustment
13.4.2. Minimum turning radius adjustment
14. REDUCTION DIFFERENTIAL AND FRONT AXLE
14.1. Description
14.2. Removal and installation
14.2.1. Front tires
14.3. Disassembly and reassembly
14.3.1. Front axle
14.3.2. Reduction gear and differential
14.4. Inspection and adjustment
14.4.1. Side bearing preload adjustment
14.4.2. Reduction gear backlash adjustment
14.4.3. Face runout measurement
14.4.4. Tooth contact adjustment
15. STEERING SYSTEM
15.1. Description
15.1.1. Flow divider operation
15.2. Removal and installation
15.2.1. Steering gear and power cylinder
15.3. Disassembly and reassembly
15.3.1. Steering gear
15.3.2. Power cylinder
15.3.3. Flow divider
15.4. Inspection and adjustment
15.4.1. Steering wheel free play
15.4.2. Steering effort
15.4.3. Hydraulic pressure measurement and adjustment
16. TROUBLESHOOTING
16.1. Electrical equipment
16.2. Clutches
16.3. Manual transmission
16.4. Powershift transmission
16.5. Reduction differential and front axle
16.6. Rear axle
16.7. Brake system
16.8. Steering system
16.9. Hydraulic system
16.10. Mast and forks
17. SERVICE MANUAL
17.1. GENERAL
17.1.1. Distinctive features of DPK injection pump
17.1.2. Features representing departures from the DPA injection pump
17.2. SPECIFICATIONS (for 4DQ5, S4E and S4E2 engines)
17.3. DESCRIPTION
17.3.1. Component parts of the DPK pump
17.3.2. Fule flow in the DPK pump
17.3.3. Transfer pump
17.3.4. Regulator valve
17.3.5. Metering valve
17.3.6. Fuel pressurization and distribution
17.3.7. Governor mechanism
17.3.8. Adjustment of maximum injection quantity
17.3.9. Increase of injection quantity for engine starting
17.3.10. Torque control
17.3.11. Automatic timing advancer
17.3.12. Shutoff solenoid valve
17.3.13. Cold advance mechanism
17.3.14. Fuel filter
17.4. INSPECTION AND ADJUSTMENT
17.4.1. Dismounting the DPK pump for inspection
17.4.2. Remounting the DPK pump
17.4.3. Matching the DPK pump to the engine for injection timing
17.4.4. Priming the fuel circuit
17.4.5. Adjusting the DPK pump for idling and maximum speeds
17.4.6. Torque Control adjustment
17.5. TROUBLESHOOTING GUIDE
17.5.1. SYMPTON Engine is hard to start or will not start.
17.5.2. SYMPTON Loss of power/poor fuel economy.
17.5.3. SYMPTON Excessive exhaust smoke.
17.5.4. SYMPTON The engine will not settle at the set speed limits (on idling speed and max. speed).
17.5.5. SYMPTON The engine runs erratically or misfires.
17.5.6. SYMPTON The engine knocks.
17.5.7. SYMPTON The engine lacks power gradually and stalls, all by itself.
17.5.8. SYMPTON The engine stalls easily.
17.5.9. SYMPTON The engine gives white exhaust smoke at the time of cold starting.
17.5.10. SYMPTON The engine gives white exhaust smoke even after it has been warmed up.
17.5.11. SYMPTON The engine knocks after it has been warmed up and, when loaded, runs noisy.
17.5.12. SYMPTON The engine will not stop running promptly.
17.6. DISASSEMBLY AND REASSEMBLY (For reference only)
17.6.1. Disassembly
17.6.2. Reassembly
17.7. COMPONENT PARTS
17.8. LUCAS SERVICE NETWORK
18. FOREWARD
19. FOREWORD
19.1. Foreward
19.2. List of Abbreviations
20. GENERAL INFORMATION
20.1. Exterior Views
20.2. Nomenclature and Sectional Views
20.3. Major Data and Specifications
20.4. Performance Curves
20.5. Engine Serial Number Location
20.6. Tips on Disassembly and Reassembly
21. COOLING SYSTEM
21.1. Description
21.2. Removal
21.3. Water Pump Disassembly
21.4. Inspection and Repair
21.5. Water Pump Reassembly
21.6. Installation
22. CRANKCASE AND MAJOR RUNNING PARTS
22.1. Description
22.2. Disassembly
22.3. Inspection and Repair
22.4. Reassembly
23. CYLINDER HEAD AND VALVE MECHANISM
23.1. Description
23.2. Removal
23.3. Disassembly
23.4. Inspection and Repair
23.5. Reassembly
23.6. Installation
24. CYLINDER SLEEVES, PISTONS AND CONNECTING RODS
24.1. Description
24.2. Removal
24.3. Disassembly
24.4. Inspection and Repair
24.5. Reassembly
24.6. Installation
25. ELECTRICAL SYSTEM
25.1. Description
25.2. Starter
25.3. Alternator
25.4. Glow Plugs
26. FLYWHEEL AND TIMING GEARS
26.1. Description
26.2. Removal
26.3. Inspection and Repair
26.4. Installation
27. FUEL SYSTEM
27.1. Description
27.2. Fuel Filter
27.2.1. Description
27.2.2. Removal and Installation
27.2.3. Disassembly and Reassembly
27.2.4. Inspection
27.3. Fuel Injection Pump (DPA)
27.3.1. Description
27.3.2. Removal and Installation
27.3.3. Idiling and Maximum speed Adjustments
27.4. Fuel Injection Nozzels
27.4.1. Description
27.4.2. Removal and Installation
27.4.3. Disassembly and Reassembly
27.4.4. Inspection
27.4.5. Testing and Adjustment
28. LUBRICATION SYSTEM
28.1. Description
28.2. Removal
28.3. Disassembly
28.4. Inspection and Repair
28.5. Reassembly
28.6. Installation
29. OVERHAUL INSTRUCTIONS
29.1. When to Overhaul the Engine
29.2. Testing the Compression Pressure
29.3. Bench Test
29.4. Performance Tests
30. SPECIAL SERVICE TOOLS
30.1. Special Service Tools
31. BALE CLAMPS
31.1. ATTACHMENTS, TRUCKS AND MASTS COVERED
31.2. SPECIFICATIONS (1)-DIMENSIONS AND PERFORMANCE
31.3. SPECIFICATIONS (2)- RATED CAPACITIES
31.4. DESCRIPTION
31.5. REMOVAL AND INSTALLATION
31.6. DISASSEMBLY AND REASSEMBLY
31.7. INSPECTION AND ADJUSTMENT
31.8. TROUBLESHOOTING
31.9. SERVICE DATA
32. LOAD STABILIZERS
32.1. SPECIFICATIONS
32.2. DESCRIPTION
32.3. REMOVAL AND INSTALLATION
32.4. DISASSEMBLY AND REASSEMBLY
32.5. INSPECTION AND ADJUSTMENT
32.6. TROUBLESHOOTING
32.7. SERVICE DATA
33. MAST PIPINGS
33.1. Description
33.1.1. Type and features
33.1.2. Mast-and-piping combinations
33.2. Construction
33.2.1. Inner pulley type
33.2.2. Side pulley type
33.2.3. Center pulley type
33.2.4. Hose reel type
33.2.5. Hose reel
33.2.6. Junction block
33.3. Removal and installation
33.3.1. Inner pulley type (dual-stage panoramic mast with 3-element piping for pneumatic-tire models)
33.3.2. Side pulley type (dual-stage panoramic mast with 5-element piping for pneumatic-tire models)
33.3.3. Center pulley type (dual-stage, full free panoramic mast with 3-element piping for pneumatic-tire models)
33.3.4. Center pulley type (triple-stage, full free panoramic mast with 3-element piping for pneumatic-tire models
33.3.5. Hose reel type (dual-stage/triple-stage, full free panoramic mast with 4-element piping (right side) or 5-element piping (both s
33.3.6. General precautions for removal and installation
33.4. Disassembly and reassembly
33.4.1. Hose reel
33.4.2. Juntion block
33.5. Troubleshooting
33.6. Service data
34. ROLL CLAMPS
34.1. ATTACHMENTS, TRUCKS AND MASTS COVERED
34.2. SPECIFICATIONS (1)-DIMENSIONS AND PERFORMANCE
34.3. SPECIFICATIONS (2) – RATED CAPACITIES
34.4. DESCRIPTION
34.5. REMOVAL AND INSTALLATION
34.6. DISASSEMBLY AND REASSEMBLY
34.7. INSPECTION AND ADJUSTMENT
34.8. TROUBLESHOOTING
34.9. SERVICE DATA
35. ROTATING FORKS
35.1. Attachments, trucks and masts covered
35.2. Specifications (1) – Dimensions and performance
35.3. Specifications (2) – Rated capacities
35.4. Description
35.5. Removal and installation
35.6. Disassembly and reassembly
35.7. Inspection and adjustment
35.8. Troubleshooting
35.9. Service data
36. SIDE-SHIFTERS
36.1. PNEUMATIC-TIRE MODELS
36.2. Attachments, trucks and mast covered
36.3. Applicable masts
36.4. Specifications (1) – Dimensions and performance
36.5. Specifications (2) – Rated capacities
36.6. Description
36.7. Removal and installation
36.8. Disassembly and reassembly
36.9. Inpection and adjustment
36.10. Troubleshooting
36.11. Service data
36.12. CUSHION-TIRE MODELS
36.13. Attachments, trucks and masts covered
36.14. Applicable masts
36.15. Specifications – Dimensions and performance
36.16. Description
36.17. Service data
37. SPECIAL MASTS
37.1. Trucks and masts covered
37.2. Description
37.2.1. Dual-stage full free panoramic mast
37.2.2. Triple-stage full free panoramic mast
37.2.3. Hook device
37.2.4. Lift cylinders
37.2.5. Flow reulator valve
37.2.6. Down safety valves
37.3. Removal and installation
37.3.1. Mast assembly
37.3.2. Lift cylinders
37.4. Disassembly and reassembly
37.4.1. Dual-stage full free panoramic mast
37.4.2. Triple-stage full free panoramic mast
37.4.3. Lift cylinders
37.4.4. Flow regulator valve
37.4.5. Down safety valves
37.5. Inspection and adjustment
37.5.1. Lift chains, chain wheels and chain wheel supports
37.5.2. Lift chain tension adjustment
37.5.3. Lift bracket stopper position inspection

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