Market Segment:
Industrial Material Handling Equipment (Counterbalance Forklift Trucks)
Key Competitors:
Toyota, Hyster, Yale, Komatsu, Nissan Forklift, Caterpillar (during the period these models were produced).
Product Type Focus:
Diesel-powered counterbalance forklifts, designed for robust material handling in various industrial settings.
Manual Purpose:
To provide comprehensive diagnostic, repair, maintenance, and overhaul information for authorized service technicians and experienced owners.
Covered Models:
Mitsubishi FD35, FD40, FD45, FD50, FD50C Forklift Trucks
Estimated Page Count:
Varies by specific model variant, typically 800-1200 pages for comprehensive coverage.
Manual Type:
Complete Workshop Service and Repair Manual
Language:
English (Assumed, standard for these manuals)
Format:
Downloadable Digital Format (e.g., PDF)
Engine:
Detailed diagnostics, overhaul, fuel system, cooling system, lubrication, ignition/starting systems (for gasoline variants), exhaust system.
Transmission:
Service, repair, and overhaul of powershift and hydrostatic transmissions (if applicable), clutch, torque converter, drive shafts, differentials.
Hydraulics:
Hydraulic system operation, pump servicing, cylinder repair, valve body diagnosis and repair, hose and fitting specifications, troubleshooting.
Brakes:
Brake system diagnostics, hydraulic brake operation, drum/disc brake servicing, parking brake, hydraulic fluid specifications.
Electrical:
Wiring diagrams, component testing, starter motor, alternator/generator, battery system, lighting system, fuse and relay identification, troubleshooting.
Chassis And Body:
Frame, steering system, front axle, rear axle, mast assembly, carriage, forks, counterweight, operator compartment, controls, seat, safety guards.
Safety Systems:
Operator presence system, overhead guard, load backrest, mast tilt safety, emergency stop procedures.
Maintenance:
Scheduled maintenance checks, lubrication points, fluid changes, filter replacement intervals, tire pressure checks.
Troubleshooting:
Diagnostic flowcharts, common fault identification, symptom-based problem solving for all major systems.
Repair:
Step-by-step repair instructions for all components and systems, including disassembly, inspection, repair, and reassembly.
Overhaul:
Complete engine, transmission, and hydraulic system overhaul procedures with detailed specifications.
Disassembly And Assembly:
Detailed procedures for removing and reinstalling major components and sub-assemblies.
Depth Of Information:
Comprehensive, covering basic maintenance to complete engine/transmission rebuilds and advanced diagnostics.
Diagnostic Tools:
Likely includes information on using specialized diagnostic tools or equipment if applicable to the era.
Specifications:
Torque specifications, clearance measurements, timing settings, fluid capacities, pressure readings, electrical resistance values.
File Format Details:
PDF format, typically with searchable text for efficient navigation. High resolution for clear diagrams and images.
Print Quality Considerations:
Digital format allows for high-quality printing of individual pages or sections. Diagrams and illustrations are crucial for accuracy.
Binding Type For Printed:
N/A (Digital Download), but original manuals were typically perfect bound or spiral bound.
Paper Type For Printed:
N/A (Digital Download), but original manuals often used durable, coated paper for workshop environments.
Engine Options:
Likely equipped with reliable Mitsubishi diesel engines. Specific models may vary by region and year. Common options might include models from the S4S, S4Q, S6S series, or similar industrial diesel engines from reputable manufacturers if re-powered.
Typical Power Output:
Varies by engine and load capacity, but generally in the range of 40-80 HP for these capacities. Torque figures are critical for lifting performance.
Injection System:
Direct injection (typical for modern diesel engines of the era), potentially with indirect injection on older models.
Cooling Type:
Liquid-cooled, pressurized system with radiator, fan, and coolant.
Transmission Type:
Powershift transmission is common for this class of forklift, offering smooth gear changes under load.
Optional Transmission:
Hydrostatic transmission may be an option on some models for enhanced maneuverability and precise control, especially in tighter spaces.
Powershift Features:
Torque converter, multi-stage clutch packs, hydraulic control for gear engagement.
Transmission Fluid Type:
Specific Automatic Transmission Fluid (ATF) or equivalent, such as DEXRON® III/MERCON® or equivalent, as per Mitsubishi's recommendation. Capacity varies by model.
Lift Capacity:
FD35: 3500 kg (7700 lbs); FD40: 4000 kg (8800 lbs); FD45: 4500 kg (9900 lbs); FD50: 5000 kg (11000 lbs); FD50C: 5000 kg (11000 lbs) with specific center of load considerations.
Mast Height:
Highly variable depending on mast type (e.g., 2-stage, 3-stage) and extended height. Manual will cover standard, full-free lift, and high-lift masts.
Operating Weight:
Approximate operating weights range from 4500 kg to 6000 kg, depending on configuration and attachments.
Design Standards:
Designed to meet relevant industry safety standards for forklift trucks (e.g., ANSI B56.1, ISO 3691). Manual will reference these.
Operator Presence System:
Standard feature to prevent forklift movement or hydraulic functions when the operator is not seated.
Overhead Guard:
Provides protection for the operator from falling objects.
Load Backrest:
Prevents the load from shifting towards the operator during carriage movement.
Mast Safety:
Features like load-holding valves to prevent unintended mast lowering.
Daily Checks:
Engine oil level, coolant level, hydraulic oil level, tire condition and pressure, brake operation, horn, lights, fork inspection, mast operation.
Weekly Checks:
Battery water level (if applicable), check for leaks, visual inspection of hydraulic hoses and fittings.
Monthly Checks:
Air cleaner service, fuel filter check/drain, inspect drive belts, lubrication of mast channels and pivot points.
Periodic Service:
Engine oil and filter change (e.g., every 250-500 operating hours), transmission fluid and filter change (e.g., every 1000-2000 operating hours), hydraulic filter change (e.g., every 500-1000 operating hours), coolant flush and replacement.
Engine Oil Type:
API CG-4 or higher grade diesel engine oil, viscosity typically 15W-40 or 10W-30 depending on ambient temperature. Capacity varies by engine model.
Hydraulic Fluid Type:
ISO VG 46 or VG 32 hydraulic oil (depending on operating temperature and manufacturer spec), or universal tractor transmission fluid (UTTF) if specified. Capacity varies.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid for hydraulic brake systems. Never mix with other types.
Common Wear Items:
Fork wear, mast roller wear, hydraulic cylinder seals, transmission clutch packs, brake linings/pads, engine glow plugs (diesel), fuel injectors.
Trouble Areas:
Hydraulic system leaks, transmission shifting problems, engine starting issues in cold weather, electrical connector corrosion.
