Mitsubishi FD20 Forklift Workshop Service Manual

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Basic Information Identification Make: Mitsubishi Forklift Trucks Model: FD20 Product Type: Workshop Service Manual Introduction Market Position Market Position: The Mitsubishi FD20 is a robust and reliable internal combustion (IC)...

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Type: Forklift

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Sku: 83516

Tags: Cars FD20 Forklift Misc Mitsubishi

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Description

Basic Information
Identification
Make:	Mitsubishi Forklift Trucks
Model:	FD20
Product Type:	Workshop Service Manual

Introduction
Market Position
Market Position:	The Mitsubishi FD20 is a robust and reliable internal combustion (IC) engine forklift, designed for demanding warehouse, manufacturing, and logistics operations. It competes in the highly competitive mid-capacity IC forklift segment.
Competitive Analysis
Competitive Analysis:	Key competitors include models from Toyota (e.g., 8-Series FG series), Komatsu (e.g., FG series), Caterpillar (e.g., DP series), and Nissan Forklift. The FD20 typically offers a balance of performance, durability, and cost-effectiveness.
Key Features
Key Features:	Known for its operator comfort, fuel efficiency, strong lifting capacity, and durable construction, making it a popular choice for various industrial applications.

Manual Details
Coverage Areas
Manual Coverage:	Comprehensive repair and service information for Mitsubishi FD20 Forklift Trucks.
Page Count
Page Count:	Estimated 500-1000+ pages (typical for a comprehensive workshop manual of this nature, exact count not provided in product info).
Manual Type
Manual Type:	Workshop Service Manual / Repair Manual
Language
Language:	English (Assumed, as primary language for technical documentation).
Format
Format:	PDF Download (Instant Access)
Applicability
Applicable Model Years:	Specific model years covered would need to be confirmed from the manual's title page or table of contents. Often, workshop manuals cover a range of years for a particular model generation.

Manual Coverage
Systems Covered
Engine:	Detailed diagnostic procedures, component testing, overhaul instructions, specifications for Mitsubishi industrial engines (specific engine model to be confirmed via manual content).
Powertrain:	Transmission (e.g., torque converter, hydrostatic, powershift), drive axle, differential, propeller shaft, brake systems (hydraulic, parking).
Hydraulic System:	Lift and tilt mechanisms, hydraulic pump, control valves, cylinders, hoses, filters, fluid specifications, troubleshooting and repair.
Electrical System:	Wiring diagrams, starter, alternator, battery system, ignition system (if applicable), lighting, sensors, control units, diagnostic trouble codes (DTCs).
Chassis And Steering:	Frame, front axle, rear steering axle, steering column, steering linkage, wheel alignment specifications.
Operator Station And Controls:	Seat, overhead guard, controls (lever, pedal), instrumentation, operator comfort and safety features.
Cooling System:	Radiator, fan, water pump, coolant specifications, thermostat, troubleshooting.
Safety Devices:	Inspection, testing, and maintenance of safety-critical components such as seat belts, brake systems, and hydraulic safety valves.
Mast And Attachments:	Inspection, maintenance, and repair of the forklift mast (lift, tilt, side-shift if equipped) and associated hydraulic cylinders and chains.
Fuel System
Fuel System:	Fuel tank, fuel lines, fuel filter, injection system (if applicable), troubleshooting.
Procedures Included
Maintenance:	Scheduled maintenance intervals, lubrication points, fluid checks and changes, filter replacement, battery maintenance.
Troubleshooting:	Systematic diagnostic flowcharts, common problem identification and solutions, fault code interpretation.
Repair:	Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Overhaul:	Complete engine and transmission overhaul procedures.
Adjustment:	Brake adjustments, clutch adjustments (if applicable), linkage adjustments.
Calibration:	Sensors, control modules (if applicable).
Calibration Procedures:	If applicable, procedures for calibrating sensors or control modules that impact performance or safety.
Special Tools:	Identification and usage of specialized tools required for specific repair or diagnostic procedures.
Technical Depth
Technical Depth:	In-depth technical information suitable for certified technicians and experienced mechanics, covering diagnostics, repairs, and component rebuilds.
Diagnostic Capabilities:	Detailed diagnostic charts, error code interpretation, electrical testing procedures, and troubleshooting guides for identifying and resolving faults.

Manual Specifications
File Format
File Format:	Portable Document Format (PDF)
Print Quality
Print Quality:	High-resolution scans suitable for printing, ensuring clarity of diagrams and text.
Binding Type
Binding Type:	N/A (Digital Format - PDF Download)
Paper Type
Paper Type:	N/A (Digital Format - PDF Download)
Searchability
Searchability:	Likely text-searchable PDF, allowing users to quickly find specific topics.
Completeness
Manual Completeness:	Presumed to be a complete workshop manual, covering all major systems and repair procedures for the specified model.

Engine Specifications
Primary Engine
Engine Type:	Internal Combustion (IC) Engine. Specific engine model (e.g., Mitsubishi S4S, S6S or similar industrial diesel/LPG variants) would be detailed in the manual.
Performance
Lift Capacity:	Typically around 2000 kg (4500 lbs) for the FD20 model designation, though variations may exist based on specific configurations.
Engine Displacement:	Likely in the 2.5L to 4.0L range, depending on the specific Mitsubishi industrial engine fitted. (e.g., S4S: ~2.5L, S6S: ~3.3L).
Horsepower Range:	Typically 40-60 HP, depending on engine variant.
Fuel System
Fuel Type:	Diesel or LPG (Liquefied Petroleum Gas), depending on the specific configuration of the FD20.
Injection System:	Indirect or Direct Injection (Diesel) / Vaporizer and Mixer System (LPG).
Torque Specifications
Torque Values:	Critical torque values for cylinder head bolts, main bearings, connecting rod bolts, and other critical engine components will be provided.
Engine Codes
Engine Codes:	Specific engine model codes (e.g., S4S-DT, S6S-DTI) and their associated specifications will be listed.

Transmission
Standard
Transmission Type:	Automatic Transmission (e.g., Torque Converter with Electronic Control or Powershift).
Optional
Optional Transmission:	N/A (typically one primary automatic transmission option for this class).
Features
Transmission Features:	Smooth shifting, optimized power delivery, and durability for industrial applications.
Transmission Coolant Capacity:	Specific capacity for transmission fluid will be listed, crucial for proper fluid changes.

Dimensions
Exterior
Overall Length:	Varies based on mast and attachment, but typically around 2500-3000 mm (excluding forks).
Overall Width:	Typically around 1100-1300 mm.
Weights
Operating Weight:	Generally in the range of 3500-4500 kg, depending on configuration and optional equipment.
Fork Length:	Standard 1070 mm (42 inches), with optional lengths available.
Axle Load Ratings:	Front and rear axle load capacities, important for safe operation and load balancing.

Safety Features
Ratings
Safety Standards:	Designed to meet relevant OSHA (Occupational Safety and Health Administration) and industry safety standards for forklift operation.
Active Features
Active Safety Features:	Operator presence sensing system, brake interlock, audible alarms (backup alarm), safety lighting (headlights, taillights, strobes).
Passive Features
Passive Safety Features:	Operator compartment protection (OHG - Overhead Guard), seat belts, robust chassis design.

Technology Features
Infotainment
Infotainment Features:	Basic operator display with indicators for engine temperature, oil pressure, battery charge, hour meter, and warning lights. Advanced infotainment systems are generally not present in industrial forklifts of this class.
Driver Assistance
Driver Assistance Features:	Operator presence system, power steering, safety interlocks. Advanced driver-assistance systems (ADAS) are typically not featured.
Connectivity
Connectivity Features:	None (This is an industrial forklift, not a passenger vehicle).

Maintenance
Service Intervals
Daily Checks:	Fluid levels (engine oil, hydraulic oil, coolant, brake fluid), tire pressure, brakes, lights, horn, visual inspection for leaks or damage.
Hourly Maintenance:	Lubrication of mast channels, lift chains, steering components, operator checks. Specific intervals (e.g., every 50, 100, 250, 500, 1000 hours) will be detailed in the manual.
Fluid Specifications
Engine Oil Type:	API CD/CF/CF-4 or higher, SAE 10W-30 or 15W-40 (specific recommendation depends on engine and operating temperature).
Hydraulic Fluid Type:	ISO VG 32 or 46 hydraulic oil (e.g., Texaco Rando HD, Mobil DTE 10 Excel series, or equivalent).
Transmission Fluid Type:	Dexron III/Mercon or equivalent ATF (Automatic Transmission Fluid) - specific type highly dependent on the transmission model.
Coolant Type:	Ethylene glycol based antifreeze/coolant, typically a 50/50 mix with distilled water. (e.g., Shellzone, Prestone).
Known Issues
Common Issues:	Potential wear on lift chains, mast rollers, hydraulic cylinder seals, common engine maintenance items (e.g., glow plugs on diesel, carburetor adjustments on LPG), brake system wear, and drive axle maintenance.
Fluid Capacities
Engine Oil Capacity:	Specific oil capacity for the engine will be provided, typically in liters or quarts.
Hydraulic Oil Capacity:	Specific hydraulic oil capacity for the forklift's systems will be detailed.
Filter Part Numbers
Engine Oil Filter P N:	Example: 123900-35100 (Illustrative; actual part number to be verified in manual).
Hydraulic Filter P N:	Example: 91451-00100 (Illustrative; actual part number to be verified in manual).
Fuel Filter P N:	Example: 31A60-00010 (Illustrative; actual part number to be verified in manual).

Vehicle History
Brand Heritage
Brand Heritage:	Mitsubishi Forklift Trucks has a long-standing reputation for producing reliable and durable material handling equipment, part of the broader Mitsubishi Heavy Industries group.
Model Evolution
Model Evolution:	The FD series represents Mitsubishi's evolution of IC forklifts, with continuous improvements in engine technology, operator ergonomics, and hydraulic systems over various generations. Specific production years covered by the manual are crucial for accurate service.
Technology Integration:	Details on the integration of electronic controls for powertrain management, hydraulics, and operator interfaces across different production runs.
Production
Production Locations:	Mitsubishi forklifts are manufactured globally, with significant production facilities in Japan and other international locations.