This workshop service repair manual covers Mitsubishi Diesel Forklift Trucks, specifically models FD100, FD115, FD135, and FD150A, equipped with the 6D16 Diesel engine. These robust machines are designed for heavy-duty...
This workshop service repair manual covers Mitsubishi Diesel Forklift Trucks, specifically models FD100, FD115, FD135, and FD150A, equipped with the 6D16 Diesel engine. These robust machines are designed for heavy-duty industrial material handling, built upon Mitsubishi's long heritage of producing reliable and durable equipment. The FD series forklifts represent a significant advancement in material handling technology, offering powerful performance and operational efficiency essential for demanding work environments. Their engineering prioritizes uptime and safety, making them a trusted choice in competitive industrial sectors.
This comprehensive factory workshop service manual provides detailed information for the operation, maintenance, and repair of your Mitsubishi forklift. It covers all major systems, including the engine, powertrain, chassis, mast, and hydraulic systems, with specific procedures for disassembly, assembly, adjustment, and troubleshooting. The manual is intended for forklift mechanics, maintenance technicians, and service departments, offering factory-level detail to ensure accurate service and maximize the longevity and performance of your equipment. With 782 pages of content, it serves as an indispensable resource for maintaining these industrial workhorses.
Provides authorized factory repair and maintenance procedures, essential for maximizing uptime and ensuring safety in demanding operational environments.
Target Audience
User Base:
Forklift mechanics, maintenance technicians, fleet managers, and service departments.
Manual Content Focus
Emphasis:
Detailed technical instructions, diagrams, and specifications for accurate service and repair.
📋 Manual Details
Coverage Areas
Primary Focus:
Operation, Maintenance, and Repair
Page Count
Total Pages:
782
Manual Type
Type:
Factory Workshop Service Manual
Language
Language:
English
Format
File Format:
ZIP (Contained Set of PDF Manuals)
📖 Manual Coverage
Systems Covered
Chassis Mast:
General Information, Cooling System, Electrical System, Power Train, 2-Speed Powershift Transmission, 3-Speed Powershift Transmission, Front Axle and Reduction Differential, Rear Axle, Brake System, Steering System, Hydraulic System, Masts and Forks, Hydraulic Fork Positioner, Hydraulic Side Shifters
Engine:
6D16 Diesel Engine (General, Lubrication, Fuel and Engine Control, Cooling, Intake and Exhaust, Electrical System, Special Equipment)
Procedures Included
Maintenance:
Periodic maintenance, lubrication instructions, maintenance chart, fan belt adjustment, component inspection and adjustment
Repair Rebuild:
Removal and installation of major components (engine, transmission, axles, steering, brakes, hydraulic components, masts, forks), detailed disassembly and assembly procedures
Diagnostics Troubleshooting:
Troubleshooting for various systems including hydraulic fork positioner, electrical system schematics provided
Technical Depth
Depth:
Comprehensive factory-level detail for mechanics and experienced technicians, covering routine maintenance to major component overhaul.
📊 Manual Specifications
File Format
PDF Quality:
High quality, original factory scans
Searchability:
Searchable Text
Print Quality
Printability:
Printable without restrictions
Binding Type
Type:
Digital (PDF within ZIP archive)
Paper Type
Simulated Type:
N/A (Digital format)
Navigation
Bookmarks:
Included
⚙️ Engine Specifications
Primary Engine
Model:
6D16 Diesel
Performance
Displacement:
Details available in the 6D16 Diesel Engine Service Manual, expected to be around 7.5L based on typical Mitsubishi diesel applications of this era.
Horsepower Torque:
Specific figures for each forklift model (FD100, FD115, FD135, FD150A) are detailed within the manual, dependent on tuning and application.
Fuel System
Type:
Diesel Injection System (details on fuel pumps, injectors, and control systems covered)
Cooling
System Type:
Water-cooled (details on radiator, fan, water pump, thermostat removal, installation, and adjustment are provided).
Lubrication
System Type:
Forced lubrication (oil pump, filter, oil cooler details and procedures are covered).
🔧 Transmission
Standard
Type:
Powershift Transmission (available in 2-speed and 3-speed configurations)
Optional
Configuration:
2-Speed Powershift and 3-Speed Powershift
Features
Components:
Torque Converter, Transmission, Power Flow, Control Valve, Main Regulator Valve, Hydraulic Controls, Speed Selector System, Control System
Gear Ratios:
Specific gear ratios for both 2-speed and 3-speed transmissions are detailed.
📐 Dimensions
Exterior
Model Variations:
Dimensions (length, width, height, mast height, fork length) vary by specific model (FD100, FD115, FD135, FD150A) and mast type. Refer to the 'General Information' section for exact specifications.
Weights
Operating Weight:
Operating weight specifications are provided for each model variant within the manual.
Load Capacity:
The model designations (e.g., FD100, FD135) indicate nominal load capacities in hundreds of kilograms or pounds, with precise figures detailed in the manual.
🛡️ Safety Features
Ratings
Industrial Standards:
Adherence to relevant industrial safety standards for forklift operation (e.g., ANSI/ITSDF, ISO) is implied by factory manual content.
Active Features
Braking System:
Hydraulic drum or wet disc brakes (depending on model specifics), parking brake. Detailed testing and adjustment procedures are included.
Passive Features
Operator Protection:
Operator compartment design, mast and fork safety features (e.g., down safety valve). Specific details on mast types (Simplex) are present.
💡 Technology Features
Infotainment
System:
N/A (Industrial equipment focused on functionality, not infotainment)
Driver Assistance
Features:
Basic operational controls. Advanced driver-assistance systems are not typical for this class of forklift.
Connectivity
Features:
N/A
Electrical System
Components:
Console Box, Major Components, Lamp Bulb Specifications, Batteries, Electrical System Schematic.
Schematics:
Detailed electrical system schematics are provided, crucial for diagnosing electrical faults.
🔧 Maintenance
Service Intervals
Routine Checks:
Daily checks, weekly checks, monthly checks are typically outlined in the 'Maintenance Chart'.
Major Servicing:
Scheduled servicing for engine (oil/filter changes), transmission, hydraulics, and other wear components at specified operating hours (e.g., 250, 500, 1000 hours).
Fluid Specifications
Engine Oil:
Specific SAE viscosity grade and API service classification for the 6D16 engine are detailed in the engine manual.
Transmission Fluid:
Type and capacity for the Powershift transmission (likely Dexron-III or equivalent) are specified.
Hydraulic Fluid:
Type and capacity for the hydraulic system are detailed in the Chassis and Mast manual.
Coolant:
Antifreeze/coolant type and mixture ratio are specified for the cooling system.
Known Issues
Common Failures:
Typical wear items in forklifts of this age and type can include hydraulic cylinder seals, lift chain wear, transmission solenoids, engine injector seals, and exhaust system components. The manual will aid in diagnosing and repairing these.
Preventative Maintenance
Key Checks:
Regular inspection of mast rollers, tilt lock, tire condition, brake performance, and hydraulic system leaks are critical for safe operation and longevity.
Technical Data
Tightening Torques:
Comprehensive list of tightening torques for standard bolts and nuts is provided in the 'Service Data' section.
Lubrication Points:
Detailed lubrication instructions for all critical moving parts are included.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Heavy Industries, Ltd. (and its forklift division)
Model Evolution
Forklift Development:
Mitsubishi has a long history of producing reliable industrial equipment. These FD series models represent robust diesel-powered forklifts designed for demanding industrial applications.
Production
Era Estimation:
Based on the serial number prefixes (F15C, F24A), these models likely represent production from the 1990s through the early 2000s, a period of significant development in forklift technology.
🏆 Awards & Recognition
Recognitions
Quality:
Mitsubishi products are generally recognized for their robustness and reliability in industrial applications.
Certifications
Industrial Standards:
Factory manuals ensure adherence to manufacturer's specifications and intended operational parameters.
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