Product Type:
Workshop Service Repair Manual
Product Name:
Mitsubishi Diesel Forklift Truck FD100 FD115 FD135 FD150A Workshop Service Repair Manual
Vehicle Type:
Diesel Forklift Truck
Covered Models:
FD100 (F15C-60001-up), FD115 (F15C-60001-up), FD135 (F15C-60001-up), FD150A (F24A-60011-up)
Engine Code Primary:
6D16 Diesel
Segment:
Heavy-duty industrial material handling equipment
Competitors:
Komatsu, Toyota, Hyster, Yale, Caterpillar forklifts
Value Proposition:
Provides authorized factory repair and maintenance procedures, essential for maximizing uptime and ensuring safety in demanding operational environments.
User Base:
Forklift mechanics, maintenance technicians, fleet managers, and service departments.
Emphasis:
Detailed technical instructions, diagrams, and specifications for accurate service and repair.
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)
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
Depth:
Comprehensive factory-level detail for mechanics and experienced technicians, covering routine maintenance to major component overhaul.
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.
Type:
Diesel Injection System (details on fuel pumps, injectors, and control systems covered)
System Type:
Water-cooled (details on radiator, fan, water pump, thermostat removal, installation, and adjustment are provided).
System Type:
Forced lubrication (oil pump, filter, oil cooler details and procedures are covered).
Type:
Powershift Transmission (available in 2-speed and 3-speed configurations)
Configuration:
2-Speed Powershift and 3-Speed Powershift
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.
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.
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.
Industrial Standards:
Adherence to relevant industrial safety standards for forklift operation (e.g., ANSI/ITSDF, ISO) is implied by factory manual content.
Braking System:
Hydraulic drum or wet disc brakes (depending on model specifics), parking brake. Detailed testing and adjustment procedures are included.
Operator Protection:
Operator compartment design, mast and fork safety features (e.g., down safety valve). Specific details on mast types (Simplex) are present.
System:
N/A (Industrial equipment focused on functionality, not infotainment)
Features:
Basic operational controls. Advanced driver-assistance systems are not typical for this class of forklift.
Components:
Console Box, Major Components, Lamp Bulb Specifications, Batteries, Electrical System Schematic.
Schematics:
Detailed electrical system schematics are provided, crucial for diagnosing electrical faults.
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).
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.
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.
Key Checks:
Regular inspection of mast rollers, tilt lock, tire condition, brake performance, and hydraulic system leaks are critical for safe operation and longevity.
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.
Manufacturer:
Mitsubishi Heavy Industries, Ltd. (and its forklift division)
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.
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.
