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Mitsubishi FG15N-35NM, FD20N-35NM Chassis and Mast Service Manual 99729-70100
Mitsubishi FG15N-35NM, FD20N-35NM Chassis and Mast Service Manual 99729-70100 - Image 2
Mitsubishi FG15N-35NM, FD20N-35NM Chassis and Mast Service Manual 99729-70100 - Image 3
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Mitsubishi FG15N-35NM, FD20N-35NM Chassis and Mast Service Manual 99729-70100

$50.00

  • Type Of Manual: Service Manual
  • Manual ID: 99729-70100
  • Number of Pages: 717
  • Size: 49.2MB
  • Format: PDF
Category:
  • Model List:

    • FG15N, FG15NM, FG18N, FG18NM, FG20CN, FG20CNM, FG20N, FG20NM, FG25N, FG25NM, FG28N, FG28NM, FG30N, FG30NM, FG33N, FG33NM, FG35N, FG35NM, FD20N, FD20NM, FD25N, FD25NM, FD28N, FD28NM, FD30N, FD30NM, FD33N, FD33NM, FD35N, FD35NM
  • 1.
  • 1.1. CHAPTER 1 GENERAL INFORMATION
  • 1.1.1. Model View
  • 1.1.1.1. MC Model
  • 1.1.1.2. FC Model
  • 1.1.2. Truck Models Covered
  • 1.1.3. Serial Number Locations
  • 1.1.4. Dimensions
  • 1.1.5. Technical Data
  • 1.1.6. Performance
  • 1.2. CHAPTER 2 COOLING SYSTEM
  • 1.2.1. Specifications
  • 1.2.1.1. Structure
  • 1.2.2. Removal and Installation
  • 1.2.2.1. Fan Belt Removal
  • 1.2.2.2. Suggestions for Removal
  • 1.2.2.3. Installation
  • 1.2.3. Inspection and Adjustment
  • 1.2.3.1. Fan Belt Inspection
  • 1.2.3.2. Fan Belt Tension
  • 1.2.3.3. Connecting Hoses
  • 1.2.3.4. Unit Layout
  • 1.2.3.5. Coolant
  • 1.2.3.6. Radiator Cap
  • 1.3. CHAPTER 3 ELECTRICAL SYSTEM
  • 1.3.1. Chassis Electrical Components and Wiring Outline
  • 1.3.1.1. D04EG Engine Model
  • 1.3.1.2. K21/25, K21/25E, and S4S Engine Models
  • 1.3.1.3. Electrical Components and Wiring Diagram of Each System
  • 1.3.2. Console Box
  • 1.3.2.1. Outline of Console Box
  • 1.3.2.2. Removing Meter Panel
  • 1.3.3. Main Electrical Components
  • 1.3.3.1. Meter Panel
  • 1.3.3.2. Key Switch (Anti-Restart Switch)
  • 1.3.3.3. Light Switch and Turn Signal Switch
  • 1.3.3.4. Direction (FNR) Switch
  • 1.3.3.5. Horn
  • 1.3.3.6. Tank Unit
  • 1.3.3.7. Brake Fluid Sensor
  • 1.3.3.8. Stop Light Switch
  • 1.3.3.9. Thermoswitch for Engine Coolant Temperature (K21/25 Engine Model and S4S Engine Model)
  • 1.3.3.10. Thermoswitch (T/C Oil)
  • 1.3.3.11. QGS Controller
  • 1.3.3.12. Fuse Box
  • 1.3.3.13. Relay Box
  • 1.3.3.14. List of Lights
  • 1.3.4. Battery Maintenance
  • 1.3.4.1. Battery Specific Gravity Condition and Adjustment
  • 1.3.4.2. Relationship Between Electrolyte Specific Gravity and State of Charge
  • 1.3.4.3. Precautions for Battery Charging
  • 1.3.5. Meter Panel
  • 1.3.5.1. Meter Panel Layout
  • 1.3.5.2. Basic Display
  • 1.3.5.3. Basic Operation
  • 1.3.5.4. When Diagnostic Code Is Shown on Display
  • 1.3.5.5. When Several Warnings Occur Simultaneously
  • 1.3.5.6. Warning Symbol
  • 1.3.5.7. Warning and Indicator Icons
  • 1.3.5.8. Optional Functions
  • 1.3.5.9. Hour Meter
  • 1.3.5.10. Troubleshooting
  • 1.3.6. Wire Color
  • 1.3.6.1. List of Wire Color Codes
  • 1.3.7. Troubleshooting
  • 1.3.7.1. Engine Startup Problem
  • 1.3.7.2. Gauge Related Problem
  • 1.3.7.3. Light Related Problems
  • 1.3.7.4. Warning Device Problem
  • 1.3.7.5. Battery Related Problem
  • 1.4. CHAPTER 4 CONTROLLERS
  • 1.4.1. Outline
  • 1.4.2. Main Functions
  • 1.4.2.1. Main Functions of Controllers
  • 1.4.2.2. Meter Panel
  • 1.4.2.3. VCM (Vehicle Control Module)
  • 1.4.2.4. ECU (Engine Control Unit)
  • 1.4.2.5. ECM (Gasoline Engine Control Module)
  • 1.4.2.6. DCM (Diesel Engine Control Module)
  • 1.4.2.7. Remote Input/Output Units
  • 1.4.2.8. GSE Connector
  • 1.4.3. Service Tool Functions
  • 1.4.3.1. Service Tool Menus
  • 1.4.3.2. Toolbox
  • 1.4.4. Mast Interlock System
  • 1.4.4.1. Function
  • 1.4.4.2. Checking Mast Interlock System of VCM Controller
  • 1.4.4.3. Active Test Inspection Procedure
  • 1.4.5. Driving Interlock System
  • 1.4.5.1. Controller Function
  • 1.4.5.2. Checking Driving Interlock Function
  • 1.4.5.3. Active Test Inspection Procedure
  • 1.4.6. Seat Belt Warning Icon
  • 1.4.6.1. Functions of Seat Belt Warning Icon
  • 1.4.6.2. Checking Seat Belt Warning Icon
  • 1.4.7. Parking Brake Warning Alarm and Icon
  • 1.4.7.1. Checking the Operation of Parking Brake Warning Alarm/Icon
  • 1.4.7.2. Parking Brake Warning Alarm
  • 1.4.7.3. Checking the Operation of Parking Brake Warning Alarm/Icon With Key in OFF Position
  • 1.4.8. Harness Codes
  • 1.4.8.1. VCM (K21/25, K21/25E, and S4S engine models)
  • 1.4.8.2. VCM (D04EG engine model)
  • 1.4.8.3. Input Unit and Output Unit (FC Models)
  • 1.4.8.4. ECU (D04EG engine model)
  • 1.4.8.5. OCM
  • 1.4.8.6. Meter Panel
  • 1.4.8.7. Seat Switch
  • 1.4.8.8. Parking Brake Switch
  • 1.4.8.9. Direction Lever Switch
  • 1.4.8.10. Speed Sensor
  • 1.4.8.11. T/M Solenoid
  • 1.4.8.12. Unload Solenoid
  • 1.4.8.13. Lift Lock Solenoid
  • 1.4.8.14. Tilt Lock Solenoid
  • 1.4.8.15. Warning Alarm
  • 1.4.8.16. Warning Alarm Relay
  • 1.4.8.17. Warning Buzzer Circuit
  • 1.4.8.18. Meter Panel
  • 1.4.9. Truck Status Display and Troubleshooting
  • 1.4.9.1. Truck Status Display
  • 1.4.9.2. Diagnosis Table (F Code)
  • 1.4.9.3. LED Blink Pattern
  • 1.4.9.4. Diagnostic Codes and Troubleshooting
  • 1.5. CHAPTER 5 POWER TRAIN
  • 1.5.1. Removal and Installation (MC Models)
  • 1.5.1.1. Removal of Engine and Transmission Assembly (for Gasoline Engine Model)
  • 1.5.1.2. Removal of Engine and Transmission Assembly (for Diesel Engine Model)
  • 1.5.2. Removal and Installation (FC Models)
  • 1.5.2.1. Removal of Engine and Transmission Assembly
  • 1.6. CHAPTER 6 POWERSHIFT TRANSMISSION
  • 1.6.1. Structure and Functions
  • 1.6.1.1. Transmission
  • 1.6.1.2. Torque Converter
  • 1.6.1.3. Control System for Powershift Transmission
  • 1.6.1.4. Hydraulic System Schematic of Powershift Transmission
  • 1.6.2. Removal and Installation
  • 1.6.2.1. Removal
  • 1.6.2.2. Installation
  • 1.6.3. Outline
  • 1.6.3.1. Overall View of Powershift Transmission
  • 1.6.3.2. Overall View of Control Valve
  • 1.6.4. Powershift Transmission, Disassembly
  • 1.6.4.1. Preparation
  • 1.6.4.2. Transmission External Parts, Removal
  • 1.6.4.3. Oil Pump Assembly, Removal
  • 1.6.4.4. Transmission Housing, Removal
  • 1.6.4.5. Input Shaft, Idler Shaft, and Output Gear, Removal
  • 1.6.4.6. Transmission Housing, Disassembly
  • 1.6.4.7. Torque Converter Housing, Disassembly
  • 1.6.4.8. Idler Shaft, Disassembly
  • 1.6.4.9. Output Gear, Disassembly
  • 1.6.4.10. Forward Input Shaft Gear Assembly, Disassembly
  • 1.6.4.11. Reverse Input Shaft Gear Assembly, Disassembly
  • 1.6.4.12. Oil Pump Body, Disassembly
  • 1.6.5. Powershift Transmission, Assembly
  • 1.6.5.1. Transmission Housing, Assembly
  • 1.6.5.2. Torque Converter Housing, Assembly
  • 1.6.5.3. Idler Shaft Assembly, Assembly
  • 1.6.5.4. Output Gear Assembly, Assembly
  • 1.6.5.5. Input Shaft Gear Assembly, Inspection
  • 1.6.5.6. Forward Input Shaft Gear Assembly, Assembly
  • 1.6.5.7. Reverse Input Shaft Gear Assembly, Assembly
  • 1.6.5.8. Oil Pump Assembly, Assembly and Installation
  • 1.6.5.9. Torque Converter Housing, Assembly
  • 1.6.5.10. Transmission Housing, Installation
  • 1.6.5.11. Servo Case Assembly, Installation
  • 1.6.5.12. Transmission External Parts, Installation
  • 1.6.6. Control Valve, Disassembly
  • 1.6.6.1. Control Valve External Parts, Removal
  • 1.6.6.2. Valve Body Plate, Removal
  • 1.6.6.3. Plugs, Removal
  • 1.6.6.4. Strainer, Removal
  • 1.6.6.5. Regulator Valve Section, Removal
  • 1.6.6.6. Accumulator Valve Section, Removal
  • 1.6.6.7. Inching Valve Section, Removal
  • 1.6.6.8. Oil Seal and Plug, Removal
  • 1.6.7. Control Valve, Assembly
  • 1.6.7.1. Control Valve
  • 1.6.7.2. Washing and Inspection
  • 1.6.7.3. Valve Plug and Oil Seal, Installation
  • 1.6.7.4. Inching Valve Section, Assembly
  • 1.6.7.5. Accumulator Valve Section, Assembly
  • 1.6.7.6. Regulator Valve Section, Assembly
  • 1.6.7.7. Strainer, Installation
  • 1.6.7.8. Plugs, Installation
  • 1.6.7.9. Valve Body Plate, Breather Cover, Installation
  • 1.6.7.10. Control Valve External Parts, Removal
  • 1.6.8. Inspection and Adjustment
  • 1.6.8.1. Oil Pressure Measurement
  • 1.6.8.2. Brake (Inching) Pedal, Adjustment
  • 1.6.8.3. Inching Cable, AdjustmentStart by
  • 1.6.9. Troubleshooting
  • 1.6.9.1. Powershift Transmission
  • 1.6.10. Service Data
  • 1.7. CHAPTER 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
  • 1.7.1. Structure
  • 1.7.1.1. ton class
  • 1.7.1.2. ton class
  • 1.7.1.3. ton class
  • 1.7.2. Removal and Installation
  • 1.7.2.1. Front Wheels
  • 1.7.2.2. Front Axle and Reduction Differential
  • 1.7.3. Disassembly and Assembly
  • 1.7.3.1. Front Axle
  • 1.7.3.2. Reduction Differential
  • 1.7.4. Troubleshooting
  • 1.7.5. Service Data
  • 1.8. CHAPTER 8 REAR AXLE
  • 1.8.1. Structure and Functions
  • 1.8.1.1. Rear Axle in General
  • 1.8.1.2. Structure of Each Component
  • 1.8.1.3. Steering Cylinder
  • 1.8.2. Removal and Installation
  • 1.8.2.1. Rear Wheel and Rear Axle Assembly
  • 1.8.3. Disassembly and Assembly
  • 1.8.3.1. Wheel Hub, Disassembly, and Assembly
  • 1.8.3.2. Knuckle (King Pin), Disassembly and Assembly
  • 1.8.3.3. Steering Cylinder, Disassembly and Assembly
  • 1.8.3.4. Tie Rod, Disassembly and Assembly
  • 1.9. CHAPTER 9 BRAKE SYSTEM
  • 1.9.1. Structure
  • 1.9.1.1. Brake System
  • 1.9.2. Disassembly and Assembly
  • 1.9.2.1. Master Cylinder
  • 1.9.2.2. Wheel Brakes
  • 1.9.2.3. Wheel Cylinder
  • 1.9.3. Inspection and Adjustment
  • 1.9.3.1. Automatic Adjuster Test
  • 1.9.3.2. Manual Adjustment
  • 1.9.3.3. Parking Brake Cable Adjustment
  • 1.9.3.4. Brake Pedal Adjustment
  • 1.9.3.5. Brake Lines Bleeding
  • 1.9.3.6. Braking Performance Test
  • 1.9.3.7. Parking Brake Lever
  • 1.9.4. Troubleshooting
  • 1.9.5. Service Data
  • 1.10. CHAPTER 10 STEERING SYSTEM
  • 1.10.1. Structure and Functions
  • 1.10.1.1. Steering Valve
  • 1.10.1.2. Steering Column
  • 1.10.2. Disassembly and Assembly
  • 1.10.2.1. Steering Wheel and Steering Valve, Removal and Installation
  • 1.10.2.2. Steering Wheel
  • 1.10.2.3. Steering Valve
  • 1.10.2.4. Tilt Lock Lever
  • 1.10.3. Steering Valve
  • 1.10.3.1. Disassembly
  • 1.10.3.2. Assembly
  • 1.10.4. Troubleshooting
  • 1.10.5. Service Data
  • 1.11. CHAPTER 11 HYDRAULIC SYSTEM
  • 1.11.1. Structure and Functions
  • 1.11.1.1. Outline
  • 1.11.1.2. Hydraulic Circuit Diagram (for Models with MC Control Valve)
  • 1.11.1.3. Hydraulic Circuit Diagram (for Models with FC Control Valve)
  • 1.11.1.4. Hydraulic Tank
  • 1.11.1.5. Hydraulic Pump (Gear Pump)
  • 1.11.1.6. Control Valve
  • 1.11.1.7. Flow Regulator Valve (for Models with FC Control Valve Only)
  • 1.11.1.8. Down Safety Valve
  • 1.11.1.9. Lift Cylinder
  • 1.11.1.10. Tilt Cylinder
  • 1.11.2. Disassembly and Reassembly
  • 1.11.2.1. Hydraulic Pump
  • 1.11.2.2. Lift Cylinder
  • 1.11.2.3. Tilt Cylinder
  • 1.11.2.4. Flow Regulator Valve
  • 1.11.2.5. Piping
  • 1.11.2.6. Suction Strainer and Return Filter
  • 1.11.3. Inspection and Adjustment
  • 1.11.3.1. Hydraulic Tank
  • 1.11.3.2. Control Valve
  • 1.11.3.3. Descent Test
  • 1.11.3.4. Forward Tilt Test
  • 1.11.4. Troubleshooting
  • 1.11.5. Service Data
  • 1.11.6. MC Control Valve
  • 1.11.6.1. Control Valve, Removal and Installation
  • 1.11.6.2. Disassembly and Assembly
  • 1.11.7. FC Control Valve
  • 1.11.7.1. Disassembly and Assembly
  • 1.12. CHAPTER 12 MAST AND FORKS
  • 1.12.1. Simplex Mast
  • 1.12.1.1. Mast System
  • 1.12.2. Structure and Functions
  • 1.12.2.1. Simplex (Dual Panoramic) Mast (5V15C to 5V35C)
  • 1.12.2.2. Mast Operation
  • 1.12.3. Removal and Installation
  • 1.12.3.1. Mast and Lift Bracket Assembly
  • 1.12.4. Disassembly and Assembly
  • 1.12.4.1. Simplex Mast Disassembly
  • 1.12.4.2. Simplex Mast Assembly
  • 1.12.5. Removal and Installation of Mast Rollers and Strips without Removing Mast from Truck
  • 1.12.5.1. Simplex Mast
  • 1.12.6. Inspection and Adjustment
  • 1.12.6.1. Simplex Mast
  • 1.12.6.2. Forks
  • 1.12.6.3. Chain Tension Inspection and Adjustment
  • 1.12.6.4. Checking Chain Elongation
  • 1.12.6.5. Adjusting Clearance Between Lift Bracket Roller and Inner Mast
  • 1.12.6.6. Mast Roller Clearance Adjustment
  • 1.12.6.7. Mast Strip Clearance Inspection and Adjustment
  • 1.12.6.8. Tilt Angle Adjustment
  • 1.12.6.9. Right and Left Lift Cylinder Stroke Inspection and Adjustment
  • 1.12.7. Troubleshooting
  • 1.12.7.1. Simplex Mast
  • 1.12.8. Service Data
  • 1.12.8.1. Simplex Mast
  • 1.12.9. Duplex Mast
  • 1.12.9.1. Mast System
  • 1.12.10. Structure and Functions
  • 1.12.10.1. Duplex (Dual Stage Full Free Panoramic) Mast (5F15C to 5F35C)
  • 1.12.10.2. Mast Operation
  • 1.12.11. Removal and Installation
  • 1.12.11.1. Mast and Lift Bracket Assembly
  • 1.12.12. Disassembly and Assembly
  • 1.12.12.1. Duplex Mast Disassembly
  • 1.12.12.2. Duplex Mast Assembly
  • 1.12.13. Removal and Installation of Mast Rollers and Strips without Removing Mast from Truck
  • 1.12.13.1. Duplex Mast
  • 1.12.14. Inspection and Adjustment
  • 1.12.14.1. Duplex Mast
  • 1.12.14.2. Forks
  • 1.12.14.3. Chain Tension Inspection and Adjustment
  • 1.12.14.4. Checking Chain Elongation
  • 1.12.14.5. Adjusting Clearance Between Lift Bracket Roller and Inner Mast
  • 1.12.14.6. Mast Roller Clearance Adjustment
  • 1.12.14.7. Mast Strip Clearance Inspection and Adjustment
  • 1.12.14.8. Tilt Angle Adjustment
  • 1.12.14.9. Right and Left Lift Cylinder Stroke Inspection and Adjustment
  • 1.12.15. Troubleshooting
  • 1.12.15.1. Duplex Mast
  • 1.12.16. Service Data
  • 1.12.16.1. Duplex Mast
  • 1.12.17. Triplex Mast
  • 1.12.17.1. Mast System
  • 1.12.18. Structure and Functions
  • 1.12.18.1. Triplex (Triple-Stage Full Free Panoramic) Mast (5M15C to 5M35C)
  • 1.12.18.2. Mast Operation
  • 1.12.19. Removal and Installation
  • 1.12.19.1. Mast and Lift Bracket Assembly
  • 1.12.20. Disassembly and Assembly
  • 1.12.20.1. Triplex Mast Disassembly
  • 1.12.20.2. Triplex Mast Assembly
  • 1.12.21. Removal and Installation of Mast Rollers and Strips without Removing Mast from Truck
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