Mitsubishi FG50N - User Manual

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Summary

Foreword

Safety Related Signs

Explains the meaning of WARNING, CAUTION, and NOTE symbols used in the manual for safety.

How to Use This Manual

Lift Truck Models Covered

Details the MC Truck and FC Truck models covered in this manual.

Disassembly Diagram Example

Illustrates a typical disassembly sequence for components like the output shaft.

Service Data

Provides technical specifications such as gear backlash for service and repair.

Symbols and Abbreviations

Units

Details the conversion between SI units and customary units used in the manual.

Chapter 1 General Information

Model View

Provides an overview and visual representation of the forklift model.

Lift Truck Models Covered

Lists the specific lift truck models that this manual pertains to.

Serial Number Locations

Indicates the specific locations on the forklift where serial numbers can be found.

Dimensions

Presents the key physical dimensions of the forklift models.

Technical Data

Includes essential technical specifications and data for the forklift.

Performance

Outlines the performance characteristics and capabilities of the forklift.

Summary

Foreword

Safety Related Signs

Explains the meaning of WARNING, CAUTION, and NOTE symbols used in the manual for safety.

How to Use This Manual

Lift Truck Models Covered

Details the MC Truck and FC Truck models covered in this manual.

Disassembly Diagram Example

Illustrates a typical disassembly sequence for components like the output shaft.

Service Data

Provides technical specifications such as gear backlash for service and repair.

Symbols and Abbreviations

Units

Details the conversion between SI units and customary units used in the manual.

Chapter 1 General Information

Model View

Provides an overview and visual representation of the forklift model.

Lift Truck Models Covered

Lists the specific lift truck models that this manual pertains to.

Serial Number Locations

Indicates the specific locations on the forklift where serial numbers can be found.

Dimensions

Presents the key physical dimensions of the forklift models.

Technical Data

Includes essential technical specifications and data for the forklift.

Performance

Outlines the performance characteristics and capabilities of the forklift.

This document is a service manual for Mitsubishi Forklift Trucks, specifically covering models with chassis and mast variations. It is designed to guide technicians through the servicing, repair, and maintenance of these industrial vehicles. The manual is structured to provide comprehensive instructions, organized by various systems of the forklift, making it a ready reference for troubleshooting and repair tasks.

Function Description:

The Mitsubishi Forklift Trucks covered by this manual are industrial vehicles designed for lifting, moving, and stacking materials. They are available in two primary control system configurations:

MC Truck (Mechanical Control System): These models feature a mechanically controlled hydraulic system, utilizing a conventional lever system for operation. This means that the operator directly manipulates levers to control hydraulic functions such as lifting, tilting, and other mast movements. The mechanical linkage provides a tactile and direct connection between the operator's input and the hydraulic system's response.
FC Truck (Finger-tip Control System): These models are equipped with an electronically controlled hydraulic system. Instead of mechanical levers, operators use finger-tip controls, which send electronic signals to a VCM Controller. The VCM Controller then manages electromagnetic control valves and a flow regulator valve to precisely actuate the hydraulic functions. This system offers enhanced ergonomic control and potentially finer adjustments of mast and attachment movements.

The forklifts are powered by either gasoline or diesel engines:

Gasoline-Engine Trucks (FG): These trucks are equipped with TB45 gasoline engines.
Diesel-Engine Trucks (FD): These trucks are equipped with S6S diesel engines.

All models covered are "Powershift Trucks," indicating they feature a powershift transmission, which allows for smooth and efficient gear changes without interrupting power flow from the engine to the drive wheels.

Usage Features:

The manual itself is a critical tool for anyone involved in the maintenance and repair of these specific Mitsubishi forklift models. It provides detailed instructions and diagrams for various procedures, ensuring that servicing is performed correctly and safely. Key sections include:

General Information: This section provides an overview of the truck models, serial number locations, dimensions, and technical data, which are essential for identifying the specific forklift and understanding its basic characteristics.
System-Specific Chapters: The manual is divided into chapters covering major systems such as Cooling System, Electrical System, Controllers, Power Train, Powershift Transmission, Front Axle and Reduction Differential, Rear Axle, Brake System, Steering System, Hydraulic System, and Mast and Forks. Each chapter details the removal, installation, and servicing procedures for components within that system.
Disassembly Diagrams: The manual includes clear disassembly diagrams, illustrating the sequence of removing components. These diagrams are accompanied by part names and suggestions for disassembly, often recommending special tools where necessary.
Service Data: Critical service data, such as gear backlash measurements, are provided with both standard values and repair/service limits, allowing technicians to assess component wear and determine if repair or replacement is needed.
Safety Related Signs: The manual prominently features safety warnings, cautions, and notes to alert users to potential hazards, risks of injury, or conditions that could damage the machine. This emphasizes the importance of safety during all servicing operations.

Maintenance Features:

The manual is designed to facilitate comprehensive and safe maintenance practices:

Regular and Proper Servicing: The foreword stresses that the long productive life of the lift truck depends on regular and proper servicing, consistent with the instructions provided.
Familiarization with Components: Users are advised to read the manual carefully and familiarize themselves with all components before attempting any test, repair, or rebuild job.
Engine Servicing Reference: For engine-specific servicing, the manual directs users to refer to the applicable TB45 gasoline or S6S diesel engine service manuals, indicating a modular approach to documentation.
Safety Protocols: Numerous safety protocols are outlined, including:
- Hanging "Do not Operate" tags before starting work.
- Ensuring welding is performed by trained personnel using correct procedures.
- Preventing damage to wiring during removal and ensuring correct reinstallation.
- Verifying all protective devices (guards, shields) are properly installed and functioning.
- Always supporting the mast and carriage when raised for maintenance.
- Exercising caution with fuel, lubricant, and hydraulic lines to prevent fires and personal injury from high-velocity leaks.
- Tightening connections to the correct torque and ensuring heat shields, clamps, and guards are correctly installed.
- Relieving pressure in air, oil, or water systems before disconnection.
- Checking rotating parts for damage and balance before reuse.
Units and Conversions: The manual uses SI Units and provides a conversion table to customary units (e.g., N to kgf, kPa to kgf/cm², N·m to kgf·m), which is helpful for technicians working with different measurement systems.
Service Data Section: A dedicated "SERVICE DATA" chapter includes maintenance standards, maintenance schedules, periodic replacement parts, lubrication instructions, and a list of special tools needed, providing a complete guide for routine and preventive maintenance.

In summary, this service manual is an indispensable resource for maintaining Mitsubishi Forklift Trucks, offering detailed, system-by-system guidance, safety instructions, and technical data to ensure the reliable and safe operation of these essential industrial machines.