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Mitsubishi FG40N1-55N1, FG40NM1-55NM1 Chassis and Mast Service Manual 99739-7B120
Mitsubishi FG40N1-55N1, FG40NM1-55NM1 Chassis and Mast Service Manual 99739-7B120 - Image 2
Mitsubishi FG40N1-55N1, FG40NM1-55NM1 Chassis and Mast Service Manual 99739-7B120 - Image 3
Mitsubishi FG40N1-55N1, FG40NM1-55NM1 Chassis and Mast Service Manual 99739-7B120 - Image 4
Mitsubishi FG40N1-55N1, FG40NM1-55NM1 Chassis and Mast Service Manual 99739-7B120 - Image 5
mitsubishi fg40n1 55n1 fg40nm1 55nm1 chassis and mast service manual 99739 7b120 2
mitsubishi fg40n1 55n1 fg40nm1 55nm1 chassis and mast service manual 99739 7b120 3
mitsubishi fg40n1 55n1 fg40nm1 55nm1 chassis and mast service manual 99739 7b120 4
mitsubishi fg40n1 55n1 fg40nm1 55nm1 chassis and mast service manual 99739 7b120 5

Mitsubishi FG40N1-55N1, FG40NM1-55NM1 Chassis and Mast Service Manual 99739-7B120

$50.00

  • Type Of Manual: Service Manual
  • Manual ID: 99739-7B120
  • Number of Pages: 644
  • Size: 34.3MB
  • Format: PDF
Category:
  • Model List:

    • FG40N1, FG45N1, FG50CN1, FG50N1, FG55N1, FD40NM1, FD45NM1, FD50CNM1, FD50NM1, FD55NM1
  • 1. Vol 1
  • 1.1. FOREWORD
  • 1.2. HOW TO USE THIS MANUAL
  • 1.3. CHANGE LOG
  • 1.4. CHAPTER 1 GENERAL INFORMATION
  • 1.4.1. Model View
  • 1.4.1.1. Model View
  • 1.4.2. Forklift Truck Models Covered
  • 1.4.2.1. ForkliftTruck Models Covered
  • 1.4.3. Serial Number Locations
  • 1.4.3.1. Serial Number Locations
  • 1.4.4. Dimensions
  • 1.4.4.1. Dimensions
  • 1.4.5. Technical Data
  • 1.4.5.1. Technical Data
  • 1.4.5.2. Performance
  • 1.4.6. Performance
  • 1.4.6.1. Performance
  • 1.5. CHAPTER 2 COOLING SYSTEM
  • 1.5.1. Specifications
  • 1.5.1.1. Specifications
  • 1.5.2. Structure
  • 1.5.2.1. Structure
  • 1.5.3. Removal and Installation
  • 1.5.3.1. Fan Belt Removal
  • 1.5.4. Inspection and Adjustment
  • 1.5.4.1. Fan Belt
  • 1.5.4.2. Radiator
  • 1.5.4.3. Upper Hose, Lower Hose
  • 1.5.4.4. Coolant
  • 1.5.5. Troubleshooting
  • 1.5.5.1. Troubleshooting
  • 1.6. CHAPTER 3 ELECTRIC SYSTEM
  • 1.6.1. Chassis Electrical Devices Wiring Outline
  • 1.6.1.1. Gasoline Model
  • 1.6.1.2. Diesel Model
  • 1.6.1.3. Gasoline and Diesel Models
  • 1.6.1.4. Power Relay Supersession
  • 1.6.2. Structure
  • 1.6.2.1. Console Box
  • 1.6.2.2. Main Electrical Components
  • 1.6.2.3. Table of Lamps
  • 1.6.3. Console Box
  • 1.6.3.1. Disassembly
  • 1.6.4. Battery Maintenance
  • 1.6.4.1. State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
  • 1.6.4.2. Specific Gravity Reading and State of Charge
  • 1.6.4.3. Charging Precautions
  • 1.6.5. Instrument Panel
  • 1.6.5.1. Instrument Panel Screen Components
  • 1.6.5.2. Basic Screen Display
  • 1.6.5.3. Basic Operation
  • 1.6.5.4. When an Error Occurs
  • 1.6.5.5. Warning Lamps
  • 1.6.5.6. Optional Functions
  • 1.6.5.7. Hour Meters
  • 1.6.5.8. Troubleshooting
  • 1.6.6. Wire Color
  • 1.6.6.1. Wire Color
  • 1.6.6.2. List of Wire Colors
  • 1.6.7. Troubleshooting
  • 1.6.7.1. Starter System
  • 1.6.7.2. Gauges
  • 1.6.7.3. Lighting System
  • 1.6.7.4. Short Horn Service Life
  • 1.6.7.5. Horn Contact Ring Failures
  • 1.7. CHAPTER 4 CONTROLLERS
  • 1.7.1. Outline
  • 1.7.1.1. Outline
  • 1.7.2. Main Functions of Controllers
  • 1.7.2.1. Main Functions of Controllers
  • 1.7.2.2. Instrument Panel
  • 1.7.2.3. VCM (Vehicle Control Module) 4
  • 1.7.2.4. ECM (Gasoline Engine Control Module)
  • 1.7.2.5. DCM (Diesel Engine Control Module)
  • 1.7.2.6. Remote Input/Output Units
  • 1.7.2.7. OCM (Optional Control Module)
  • 1.7.2.8. GSE Connector
  • 1.7.3. Service Tool Functions
  • 1.7.3.1. Service Tool Menus
  • 1.7.3.2. Service Tool Box
  • 1.7.4. Mast Interlock System
  • 1.7.4.1. Function
  • 1.7.4.2. Mast Interlock System of VCM-4 Controller, Checking Procedure
  • 1.7.4.3. Active Test Inspection Procedure
  • 1.7.5. Driving Interlock System
  • 1.7.5.1. Function
  • 1.7.5.2. Driving Interlock System, Checking Procedure
  • 1.7.5.3. Active Test Inspection Procedure
  • 1.7.6. Seat Belt Warning Lamp
  • 1.7.6.1. Function
  • 1.7.6.2. Seat Belt Warning Lamp Checking Procedure
  • 1.7.7. Parking Brake Warning Buzzer and Lamp
  • 1.7.7.1. Function
  • 1.7.7.2. Parking Brake Warning Buzzer/Lamp Checking Procedure
  • 1.7.7.3. Parking Brake Warning Buzzer/Lamp Checking Procedure with Key in OFF Position
  • 1.7.8. Harness Code List
  • 1.7.8.1. Harness Code List
  • 1.7.9. Controller Output Details
  • 1.7.9.1. VCM-4 Controller
  • 1.7.9.2. Seat Switch/Seat Belt Switch
  • 1.7.9.3. Parking Brake Switch
  • 1.7.9.4. Direction Lever
  • 1.7.9.5. Speed Sensor
  • 1.7.9.6. T/M Solenoid
  • 1.7.9.7. Unload Solenoid
  • 1.7.9.8. Lift Lock Solenoid
  • 1.7.9.9. Warning Buzzer
  • 1.7.9.10. Warning Buzzer Relay
  • 1.7.9.11. Warning Buzzer Circuit
  • 1.7.9.12. Instrument Panel
  • 1.7.9.13. OCM
  • 1.7.9.14. Service Brake Solenoid
  • 1.7.9.15. Parking Brake Solenoid
  • 1.7.10. Error Codes and Troubleshooting
  • 1.7.10.1. Error Code Display
  • 1.7.10.2. Diagnosis Table (F Code)
  • 1.7.10.3. Error Codes and Troubleshooting
  • 1.7.11. Locations of Sensors and Switches
  • 1.7.11.1. Locations of Sensors and Switches
  • 1.8. CHAPTER 5 POWER TRAIN
  • 1.8.1. Removal and Installation (MC Models)
  • 1.8.1.1. Removal and Installation of Engine and Transmission Assembly (LPG Models)
  • 1.8.1.2. Removal and Installation of Engine and Transmission Assembly (Diesel Models)
  • 1.8.2. Removal and Installation (FC Models)
  • 1.8.2.1. Removal of Engine and Transmission Assembly
  • 1.8.2.2. Suggestions for Replacing Wet Disc Brake Oil and Filter
  • 1.8.3. Removal and Installation (Wet disc brake)
  • 1.8.3.1. Removal of Engine and Transmission Assembly
  • 1.8.4. Service Data
  • 1.8.4.1. Service Data
  • 1.9. CHAPTER 6 POWERSHIFT TRANSMISSION
  • 1.9.1. Structure
  • 1.9.1.1. Transmission
  • 1.9.1.2. Power Transmission Path
  • 1.9.1.3. Torque Converter
  • 1.9.1.4. Powershift Transmission Control
  • 1.9.1.5. Control Valve
  • 1.9.1.6. Main Regulator Valve
  • 1.9.1.7. Parking Brake Activation
  • 1.9.1.8. Releasing parking brake with the release bolt
  • 1.9.1.9. Schematic Diagram of Powershift Transmission Hydraulic System
  • 1.9.1.10. Powershift Transmission External View
  • 1.9.2. Removal and Installation
  • 1.9.2.1. Removal
  • 1.9.2.2. Installation
  • 1.9.3. Transmission Exterior Parts
  • 1.9.3.1. Disassembly
  • 1.9.3.2. Reassembly
  • 1.9.4. Torque Converter
  • 1.9.4.1. Disassembly
  • 1.9.4.2. Inspection and Repair
  • 1.9.4.3. Reassembly
  • 1.9.5. Transmission
  • 1.9.5.1. Disassembly
  • 1.9.5.2. Inspection and Repair
  • 1.9.5.3. Reassembly
  • 1.9.6. F2 Clutch Pack Assembly
  • 1.9.6.1. Disassembly
  • 1.9.6.2. Inspection and Repair
  • 1.9.6.3. Reassembly
  • 1.9.7. F1 Clutch Pack Assembly
  • 1.9.7.1. Disassembly
  • 1.9.7.2. Inspection and Repair
  • 1.9.7.3. Reassembly
  • 1.9.8. R1 Clutch Pack Assembly
  • 1.9.8.1. Disassembly
  • 1.9.8.2. Inspection and Repair
  • 1.9.8.3. Reassembly
  • 1.9.9. Parking Brake Assembly
  • 1.9.9.1. Disassembly
  • 1.9.9.2. Inspection and Repair
  • 1.9.9.3. Reassembly
  • 1.9.10. Gear Pump Assembly
  • 1.9.10.1. Disassembly
  • 1.9.10.2. Inspection and Repair
  • 1.9.10.3. Reassembly
  • 1.9.11. Control Valve
  • 1.9.11.1. Disassembly
  • 1.9.11.2. Inspection and Repair
  • 1.9.11.3. Reassembly
  • 1.9.12. Main Regulator Valve
  • 1.9.12.1. Disassembly
  • 1.9.12.2. Inspection and Repair
  • 1.9.12.3. Reassembly
  • 1.9.13. Inspection and Adjustment
  • 1.9.13.1. Oil Pressure Measurement
  • 1.9.13.2. Brake Inching Pedal Adjustment
  • 1.9.13.3. Inching Cable, Adjustment
  • 1.9.14. Troubleshooting
  • 1.9.14.1. Troubleshooting
  • 1.9.14.2. DTC F-85, F-87, F-93
  • 1.9.14.3. Diagnostic Trouble Code DTC-F88
  • 1.9.15. Service Data
  • 1.9.15.1. Service Data
  • 2. Vol 2
  • 2.1. CHAPTER 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
  • 2.1.1. Specifications
  • 2.1.1.1. Specifications
  • 2.1.2. Structure
  • 2.1.2.1. Standard Model (with Drum Brake)
  • 2.1.2.2. Option Model (with Wet Disc Brake)
  • 2.1.3. Removal and Installation
  • 2.1.3.1. Front Wheels (Common to Standard and Option Truck)
  • 2.1.3.2. Shoe and Lining (Standard Truck)
  • 2.1.3.3. Wet Disc Brake Assembly (Option Truck)
  • 2.1.3.4. Front Axle Assembly (Standard Truck)
  • 2.1.3.5. Front Axle Assembly (Option Truck)
  • 2.1.3.6. Removal and Installation of Each Assembly (Standard Truck)
  • 2.1.3.7. Removal and Installation of Each Assembly (Option Truck)
  • 2.1.4. Disassembly and Reassembly
  • 2.1.4.1. Tube Assembly and Final Reduction (Standard Truck)
  • 2.1.4.2. Tube Assembly and Final Reduction (Option Truck)
  • 2.1.4.3. Wear Gauge for Wet Disc Brakes
  • 2.1.4.4. Reduction Differential (Common to Standard and Option Truck)
  • 2.1.4.5. Troubleshooting (Common to Standard and Option Truck)
  • 2.1.4.6. Service Data
  • 2.2. CHAPTER 8 REAR AXLE
  • 2.2.1. Structure and Functions
  • 2.2.1.1. Rear Axle in General
  • 2.2.1.2. Structure of Each Component
  • 2.2.1.3. Steering Cylinder
  • 2.2.2. Removal and Installation
  • 2.2.2.1. Rear Wheel and Rear Axle Assembly
  • 2.2.3. Disassembly and Reassembly
  • 2.2.3.1. Disassembly and Reassembly of Wheel Hub
  • 2.2.3.2. Disassembly and Reassembly of Knuckle (King Pin)
  • 2.2.3.3. Disassembly and Reassembly of Steering Cylinder
  • 2.2.3.4. Disassembly and Reassembly of Tie Rod
  • 2.2.4. Troubleshooting
  • 2.2.4.1. Troubleshooting
  • 2.2.5. Service Data
  • 2.2.5.1. Service Data
  • 2.3. CHAPTER 9 BRAKE SYSTEM
  • 2.3.1. Structure
  • 2.3.1.1. Brake System (Dry type brake)
  • 2.3.1.2. Wheel Brakes (Dry type brake)
  • 2.3.1.3. Parking Brake Valve (Dry type brake)
  • 2.3.1.4. Brake System (Wet type brake)
  • 2.3.1.5. Wet Disc Brake Assembly
  • 2.3.1.6. Parking Brake Valve (Wet type brake)
  • 2.3.1.7. Auto Deceleration Valve (Wet type brake)
  • 2.3.2. Disassembly and Reassembly
  • 2.3.2.1. Wheel Brakes (Dry type brake)
  • 2.3.2.2. Wheel Cylinder (Dry type brake)
  • 2.3.2.3. Parking Brake Valve (Dry type brake)
  • 2.3.2.4. Wet Disc Brake Assembly
  • 2.3.2.5. Parking Brake Valve (Wet type brake)
  • 2.3.3. Inspection and Adjustment
  • 2.3.3.1. Automatic Adjuster Test (Dry type brake)
  • 2.3.3.2. Manual Adjustment (Dry type brake)
  • 2.3.3.3. Brake Pedal Adjustment (Common to dry and wet type)
  • 2.3.3.4. Brake Lines Bleeding (Dry type brake)
  • 2.3.3.5. Braking Performance Test (Dry type brake)
  • 2.3.3.6. Procedure for Flushing and Air Bleeding after Assembly (Wet type brake)
  • 2.3.3.7. Braking performance test (Wet type brake)
  • 2.3.3.8. Oil Pressure Measurement (Dry type brake)
  • 2.3.3.9. Oil Pressure Measurement (Wet type brake)
  • 2.3.3.10. Parking Brake Emergency Release (Common to dry and wet type)
  • 2.3.4. Troubleshooting
  • 2.3.4.1. Troubleshooting
  • 2.3.4.2. Brake Light Staying On
  • 2.3.5. Service Data
  • 2.3.5.1. Service Data
  • 2.4. CHAPTER 10 STEERING SYSTEM
  • 2.4.1. Structure and Functions
  • 2.4.1.1. Steering System
  • 2.4.1.2. Steering Valve
  • 2.4.1.3. Steering Column
  • 2.4.2. Disassembly and Reassembly
  • 2.4.2.1. Valves, Hoses and Pipes, Disassembly and Reassembly
  • 2.4.2.2. Removal and Installation of Steering Wheel and Steering Valve
  • 2.4.2.3. Steering Wheel
  • 2.4.2.4. Steering Valve
  • 2.4.2.5. Tilt Lock Lever
  • 2.4.3. Steering Valve
  • 2.4.3.1. Disassembly Procedure
  • 2.4.3.2. Reassembly Sequence
  • 2.4.4. Troubleshooting
  • 2.4.4.1. Troubleshooting
  • 2.4.5. Service Data
  • 2.4.5.1. Service Data
  • 2.4.6. STC (Snap-to-Connect)
  • 2.4.6.1. Installing and Removing STC Connector
  • 2.4.6.2. Connection and Latching Check
  • 2.4.6.3. STC Components
  • 2.5. CHAPTER 11 HYDRAULIC SYSTEM
  • 2.5.1. Structure and Functions
  • 2.5.1.1. Outline
  • 2.5.1.2. Hydraulic Circuit Diagram (for models with MC control valve)
  • 2.5.1.3. Hydraulic Circuit Diagram (for models with FC control valve)
  • 2.5.1.4. Hydraulic Tank
  • 2.5.1.5. Hydraulic Pump (Gear Pump)
  • 2.5.1.6. Control Valve
  • 2.5.1.7. Flow Regulator Valve (models with FC control valve only)
  • 2.5.1.8. Down Safety Valve
  • 2.5.1.9. Lift Cylinder
  • 2.5.1.10. Tilt Cylinder
  • 2.5.2. Disassembly and Reassembly
  • 2.5.2.1. Hydraulic Pump
  • 2.5.2.2. Lift Cylinder
  • 2.5.2.3. Tilt Cylinder
  • 2.5.2.4. Flow Regulator Valve
  • 2.5.2.5. Piping
  • 2.5.2.6. Suction Strainer and Return Filter
  • 2.5.3. Inspection and Adjustment
  • 2.5.3.1. Hydraulic Tank
  • 2.5.3.2. Control Valve
  • 2.5.3.3. Natural Descent Test
  • 2.5.3.4. Natural Forward Tilt Test
  • 2.5.4. Troubleshooting
  • 2.5.4.1. Troubleshooting
  • 2.5.5. Service Data
  • 2.5.5.1. Service Data
  • 2.5.6. MC Control Valve
  • 2.5.6.1. Outline
  • 2.5.6.2. Names of Parts
  • 2.5.6.3. Control Valve Operation
  • 2.5.6.4. Pressure Control (Relief) Valve Operation
  • 2.5.6.5. Flow Regulating Valve (FRV)
  • 2.5.6.6. Cautions for use
  • 2.5.7. FC Control Valve
  • 2.5.7.1. Structure and Functions
  • 2.5.7.2. Procedures and Suggestions for Removal and Installation
  • 2.5.7.3. Disassembly and Reassembly
  • 2.5.8. Hydraulic Oil Tank Breather
  • 2.5.8.1. Hydraulic Oil Tank Breather
  • 2.6. CHAPTER 12 MAST AND FORKS
  • 2.6.1. Simplex Mast
  • 2.6.1.1. Mast System
  • 2.6.2. Structure and Functions
  • 2.6.2.1. Simplex Mast (Dual Panoramic 5V40C to 5V50C)
  • 2.6.2.2. Mast Operation
  • 2.6.3. Removal and Installation
  • 2.6.3.1. Mast and Lift Bracket Assembly
  • 2.6.4. Disassembly and Reassembly
  • 2.6.4.1. Simplex Mast Disassembly
  • 2.6.4.2. Simplex Mast Reassembly
  • 2.6.5. Removal and Installation of Mast Rollers and Strips without Removing
  • 2.6.5.1. Simplex Mast
  • 2.6.6. Inspection and Adjustment (Simplex Mast)
  • 2.6.6.1. Inspection and Adjustment (Simplex Mast)
  • 2.6.6.2. Forks
  • 2.6.6.3. Chain Tension Inspection and Adjustment
  • 2.6.6.4. Chain Elongation Measurement
  • 2.6.6.5. Clearance Adjustment between Lift Bracket Roller and Inner Mast
  • 2.6.6.6. Mast Roller Clearance Adjustment
  • 2.6.6.7. Mast Strip Clearance Inspection and Adjustment
  • 2.6.6.8. Mast Tilt Angle Adjustment
  • 2.6.6.9. Right and Left Lift Cylinder Stroke Inspection and Adjustment
  • 2.6.7. Troubleshooting (Simplex Mast)
  • 2.6.7.1. Troubleshooting (Simplex Mast)
  • 2.6.8. Service Data (Simplex Mast)
  • 2.6.8.1. Service Data (Simplex Mast)
  • 2.6.9. Duplex Mast
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