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    FD40-FD50 SALES MANUAL

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    432 views70 pages

    FD40-FD50 Sales Manual

    Uploaded by

    Lui David

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 70
    Sales Manual FD/FG40N-55N MITSUBISHI FORKLIFT TRUCKS ¢ we MITSUBISHI Contents Introduction Range overview Exgoromic operator postion Productive and versatile Satety Easy maintorance ‘Applications and industries Product presentation Operator Position Ful suspension soat Entry and ext Layoutof controls ‘Steering whee! and steering column Hydrate controls Pedal system Patking brake Overhaad guard Backup hanélowth hom bulton Instrument panel ED his Engine cover Mast Product Details Engines -Diesol Log Exhaust system Airintake {Cootng system Transmission Fron axle and final reduction Tyros Braking system ‘Services Mast Hydraulics and vale Book Special Options rgonomie FC Hydraulic corrls Backup handle wih hom button ‘Appendix -2 ‘Specticalons, Nose, vibration and emiasons us consumption Dimensions, weight able, yes ‘Appendix: Residual capacty charts Lee LL Introduction FDIFG4ON-55N New N-Range counter balanced IC truck range (Our completely new 4.0 -5.5 ton truck further extends our N— Range FDIFG4ON - 55N product ine. This modal range is sold worldwide (with regional variations) and build in three production facilities: Almere - The Netherlands; Houston - United States and Sagamihara - Japan. Trucks produced in Sagamihara- Japan are sold in Asia, Oceania and South Africa, ‘SMM 013 11-2010 Bee LL Introduction N-Range overview for capacity 4.0 through 5.5 ton Range overview with Mods | Fue! | Rated Atfoad | Wheelbase capacity and load center capacity contre. | (mm) oo) (eum) FoION | Bissat_| «000 500 1850 Foan | arpa | «000 500 1850 [roisw [ieset [4500 500 2000) [Foasw Torte [soo 500 2000 Fos0cN | Diese! _| s000 500 2000 Fesocn | erure | so00 500 2000 oso | Dieset_| 5000 500 2180 Fos5N | Dieser_| 5500 00 2160 rassn[arupe | ss00 500 2180 Performance Performance: industrial The truck is designed for lowest TCO (total cost of ownership). The drive engines, built to last train has a new designed transmission, part of the gear reduction has moved to the front axle. The new truck is powered by an industrial strength diesel engine, or a high performance high torque Gasoline/LPG engine, Engine power and torque are an optimum combination with low RPM and low fuel ‘consumption. A specially positioned air-intake behind the operator position, land a cyclone air cleaner protect the fuel system and engine against dust and dirt Ergonomic operator position ‘The operator compartment layout is designed to facilitate easy access, both getting on the truck as well as leaving the truck. A full hydrostatic steering system allows precise steering with low effort. The seat is a full suspension seat with weight and position adjustment controls, The overhead guard has increased torso clearance. All features and functionalities contribute to reduce strain on the operator. Low noise, vibrations, a clear LCD display and ‘additional operator support features reduce the effort to drive and operate the truck, Ergonomic operator ‘SMM 013 12010 Poteet Ey De et IPS2 system Introduction Productive and versatile ‘Smart design has resulted in a much shorter truck. Especially for the ‘smallest truck FO/FGA0N, the reduction make it very compact. The ‘additional 5.5 tonnes truck completes the range and fits neatly between the five and six tonnes capacities Safety ‘Standard on the truck are: a seat with operator restraints and seat belt, and backup alarm. An electronic parking brake is easy to operate and has a audible reminder. The IPS2 system uses a seat switch to prevent hydraulic actions. The parking brake is automatically activated 3 seconds after the operator leaves the seat, provided the truck speed is below 0.4 kmh Easy maintenance ‘Standard service intervals are set at 500 hours. A special counter in the VOM keeps track of the hours the engine has been running. Daily checks of the truck and engine are made almost effortless and easy to do. The floor plate can be removed without tools in a matter of seconds, The engine cover ‘opens wide for excellent access to engine and transmission components. The new LCD meter display in the instrument panel informs the operator of ‘maintenance and service requirements. For instance when something is wrong with truck or engine fault codes andior error codes are displayed. With these error codes trouble shooting is made easier and raises availabilty and productivity of the truck ‘SMM 013 Poteet Ey De et Typical applications Applications ‘Our FD/FG40-55N models are designed to function flawlessly in all sorts of applications and environments. The standard truck has a well balanced design for every day work. Adding options will make this productive truck ‘even better suited for special applications in difficult environments. Dust Prevention and Clogging Prevention packages offer further protection against harsh working conditions. Stevedoring ‘Stevedoring applications are often multiple-shift (24/7), outside and sometimes in coastal areas or sea ports. IC trucks are the preferred product to support this application Timber Forkforkit trucks on timber yards nearly always operate outside on uneven roads with very wide loads. Productivity (stability and residual capacity) is significantly improved when the truck is equipped with dual drive wheels {factory option). Brick and Block ‘These applications are often dusty and require trucks equipped with ‘additional fiters to avoid dust reaching delicate fuel, transmission or hydraulic parts (special air fiter, hydraulic fiter, brake booster filters, etc.) Dedicated option packages are available. Dual drive wheels are recommended in situations with uneven floors and high stacking is required. A side-shifter can provide precise stacking. Some brick and block applications involve dual pallets and require four forks or special clamps. ‘SMM 013 Poteet Ey sob LL Applications Concrete & Clay Pipe ‘This type of application is often dusty and requires additional filters. A Dust Prevention option package will help to shield the engine against the damaging effects of dust. Also special attachments (poles) are used in this, industry Recycling & Metal Industry In the recycling industry trucks should be protected with a Clogging Prevention package (option). This package will prevent clogging of the radiator with lint and small parts of paper. It prevents the engine from overheating. Solid pneumatic tyres are recommended to shield against punctured tyres. ‘A double air fiter is already standard on the truck, a Dust Protection package is recommended and combines existing options at a reduced price. ‘SMM 013 pee ad Applications Bottling Industry Health and safety regulations in the bottling industry require IC trucks to have low exhaust emissions. The FG40-55N models are equipped with the efficient and high performance TB45 LPG engine with standard a 3-way catalytic converter. On the FD40-50N models with the S6S diesel engines, a catalytic converter is available as a factory option, a particle / soot fer as a CSM option. ‘Some bottling applications require a double pallet handler, others are pallet- less and require a slip-sheet pushipull attachment. Pape Most paper applications require paper roll clamps. In particle-rich ‘environments, large core radiators (less clogging) and extra fers can help reduce downtime. The low overhead guard height of 250mm allows this, truck to enter most industrial standard containers. A special Clogging Protection package is available as an option to prevent fibres and paper particles entering the truck and engine. Itis a dedicated ‘combination of existing options offered at a reduced price to provide an adequate protection for the application. ‘SMM 013 11-2010 Poteet Ey De et Product Presentation Standard configuration Engines Diesel engine © Mitsubishi S6S Standard i Displacement: 4996 co High torque 6-cylinder © Rated output: 57.5 KW @ 2300 rpm engines © Maxtorque: 260'Nm @ 1700 cpm © Electic system: 12V + LPG engine: Nissan TB45 © Displacement: 4500 cc © Rated output 72 kW @ 2300 rpm © Max torque 280 Nm @ 1200 rpm © Electre system: 12V Standard: 3 Elecvonié engine management with ECM-module 3-Way catalytic converter ‘© Regulated 3-way catalytic converter (closed-loop fuel (on LPG) Configuration system) ‘$8S Diesel or TB45 LPG engine Power-shift automatic transmission; dashboard switch to set transmission into first gear or automatic Drum brake system Cyclone air cleaner Ar intake positioned on counter weight Low exhaust Low noise package Large capacity radiator and high speed fan Ful hydrostatic steering 2.Way hydraulic control valve Mechanical hydraulic lever controls + IPS2 presence detection system plus safety system Instrument panel including an LCD meter display + Operator access PIN code standard + Tiltoylinders + Overhead guard (250mm high) + Tillable steering column + Audible back-up alarm Electronic parking brake + Rubber floor mat ‘SMM 013 Bee LL Product Presentation Two front work lights, two front combination lights and two rear combination lights Vinyl covered full suspension seat with seat-belt and operator restraints + Single drive pneumatic tyres + English Language markings + Paris Book Tool Box + Operations and maintenance manual Options + Information about options is in this document and also to be found in the Price list. ‘SMM 013 12010 pee ad Operator Position Easy on and off access Entry and exit ‘The grab bar, wide step with industrial anti-slip plate, thick rubber floor mat, and hip restraints (extra grip) allow easy entry and exit. The step height from the floor is 483 mm, Full suspension seat ‘Standard on this model is a full suspension vinyl seat for maximum operator comfort. Forward-reverse adjustability, horizontal travel is 150mm. For ‘optimum suspension the seat can be adjusted to the operator's weight (50- 120kg) by turning a knob at the front of the seat. A rotary dial indicates the selected weight range.All seats are equipped with ORS operator restraint system and a seat belt Full suspension seat with armrest and FC control Steering wheel ‘The three spoke steering whee! has a diameter of 320 mm and comes standard with a steering knob, Travel direction ‘The directional handle (forward- ineutral- Ireverse-) is located on the left hand side of the steering column. Starting can be one in neutral only (standard safety feature). Restarting an already running engine is automatically blocked. 10 ‘SMM 013 A Poth te A et Operator Position Light switch handle ‘The light switch handle is located on the right hand side of the steering column, There are four positions possible by turning the knod on the handle. The handle also functions 4s a direction light indicator switch. Dashboard switches ‘The dashboard has five positions for switches to control options. There is, ‘one switch standard on the truck, which can set the transmission in first gear or turtle mode. When switched in the upper position the transmission is in automatic mode and therefore switches gears automatically. Two forward speeds are available, in turtle mode the forward transmission is fixed in first gear. Steering column adjustment ‘The steering column is infinitely adjustable over 12 degrees of tit to allow adjustment for the ‘operator. This titing is spring assisted for easy and fine control ofthe tt angle, ‘SMM 013 peed Operator Position Hydraulic controls Ergonomic positioned MC hydraulic controts Manual Control hydraulic functions are offered 28 standard, The factory-set hydraulic system relief pressure is 191 Bar, similar forthe relief pressure for attachments, Pedal system ‘The automotive pedal layout enables easy operation for all operators. The pedal size, height and angle have been designed for optimum operator comfort. The pedals are of the ‘through the floor design’, reducing operator fatigue, The floor area is amongst the largest in the industry for this size of truck. Key and Operator Access Code (PIN) A startor key is provided to start the engine, the key lock is on the right hand Operator Acces Code side of the steering column. (PIN) standard ‘An Operator Access Code (PIN-code) is standard supported on the truck. This PIN-code is switched off when delivered from the factory to allow easy transport. Once at the dealers or end customer this feature can be switched ‘on and operator codes assigned using 'Up-Time’ software. R ‘SMM 013 11-2010 MITSUBISHI De Be Electronic parking brake IPS2 system Operator Position Parking brake ‘The parking brake mechanism is of the ‘negative brake activation’ type and built into the transmission unit. The park brake is released by applying hydraulic pressure, without pressure the park brake is activated. Without hydraulic pressure available, a special bolt is needed to mechanically release the park brake, 1Ps2 Innormal operation your forklift truck will drive in a creep mode when the direction lever is placed in the forward or reverse position at engine idling (not pressing the accelerator pedal). The driving interlock system will not allow the forklft truck's transmission to stay in the forward or reverse position when you are out of the operator's seat. If the operator leaves the operator's seat for 3 seconds, a switch in the operator's seat activates the driving interlock system. This action causes the system to cut power and to electrically shift the transmission to neutral. The transmission will disengage but the direction lever will not physically move to the neutral position. To reactivate the transmission, sit in the operator's seat and place the direction lever to the neutral position and back to the direction of travel The parking brake will work when the forklift truck is on level ground, synchronizing with the driving interlock. However, when the forklift truck is on an incline, the forklift truck will start to move in the direction of the downgrade, Even ifthe driving interlock system is activated, the forklft truck ‘may move in the direction of the downgrade when the forkift truck Js on a grade. In this case, apply the brakes and sit securely in the operator's seat, Overhead guard ‘The overhead guard is designed to protect the operator while allowing maximum forward and upward Visibilly. The standard overhead guard height is 2250 mm. This allows the truck to drive into a standard container, ‘SMM 013 11-2010 feed Operator Position Backup handle with horn button (Option) Backup handle with horn button (Optional) ‘backup handle with integrated hom button isan option, This handle offers the driver a solid grip for his right hand whilst driving the truck in reverse. It can help prevent strain in the back and improves safety. The hom button can be used to activate the horn without taking the hands of the steering wheel. Engine cover The engine cover is well insulated on the inside to reduce noise from the engine compartment and also to soften vibrations, Mast ‘All masts have been designed for ‘optimum visibility. Features include small flanges, deep webs and pulley and chains fitted at 45°. ‘A wide range of masts is available with simplex, duplex and triplex mast types. Various mast heights can serve ‘customers requirements, For more details you should check the specification sheet and the mast charts in the Appendix ofthis manual “ ‘SMM 013 peed Operator Position Instrument Panel Display shows vital truck The instrument panel with LCD display provides essential information on the information. truck, the engine and the operational status of the truck. Information on the driving direction, tuck speed, maintenance and fuels displayed. Besides Error and Fault codes are visual information also audible signals can be provided, such as backup a convenient indication of alarm, seat belt warning and parking brake status. problems. The indicator lights on the instrument panel are (left to right): 41. Parking brake indication 2. Seat belt warning 3. Battery charging 4. General warning indicator 5. Powershift torque converter oll temperature indicator 6. Engine oll temperature warning indicator 7. Check light LPG engine trucks 8 Glow indicator (diesel engines only) 9% Optional 10. Mast interlock indicator ‘The LCD meter panel has: © Speedometer Fuel gauge (diesel only) Engine coolant gauge Digital clock Timers: key-on, engine-on, seat-switch on ‘Transmission oil temperature indicator Forward, neutral reverse direction indicator Engine oll pressure indicator Alternator charging indicator Glow indicator (diesel only) General waming light Maintenance indicator Parking brake indicator ‘SMM 013 MITSUBISHI De et Frame and body Three frame types Low profile counterweight Product Details Frame and body ‘An important first step in designing a strong and durable forklift truck is designing a robust frame. The Finite Element Modelling (FEM) design process used by our designers does just that. FEM utilises computer programs to model the truck frame. Loads are applied to the computer frame and the computer mathematically calculates the stresses incurred by the frame. Once the stresses are identified, engineers can make changes to the frame “model” to eliminate or reduce the stresses, This process is repeated nti a desired frame model is achieved. Then the actual frame is built and further stress testing is done to confirm the computer results. ‘The complete frame assembly consists of two side frames, tanks, a rear ccross-member, a front crass member, front and rear towers to mount the head guard on. The front dashboard is bolted to the frame. A’unitized” frame construction simply means all of these sub-weldments are welded together to produce a one piece frame weldment. “Unitize” construction provides ‘exceptional frame rigidity and maintenance free durabilly.The hydraulic tank is located on the right side while the fuel tank is located on the left side of the frame. Both tanks are completely integrated and are a structural part of the chassis Three different frames are used for the truck depending on the capacity of the truck. Moder Wheelbase | Wa Wa improvement compared to K-nodel FDIFGAON | 1850 mm | 2580 mm | 185 mm (5.7%) FDIFGAN | 2000mm _| 2730mm_| 45 mm (1.0%) FDIFGSOON | 2000mm | 2760 mm | 6O mm (2.1%) FDIFGON [2160 mm | 2800 mmm | TS mm (2.5%) FDIFGSEN | 2160mm | 2040 mm | No Kmodel mn range ‘The FO/FGA0N has the smallest frame size, the FD/FG45N and FD/FGSOCN compact truck share the same frame, The FDIFGSON and FD/FGSN have the largest frame, Compared to the previous K-model an Improvement has been accomplished, most significantly for the smallest model Counter weight ‘The counterweight is the weight to keep the forklift truck in balance with ang without load. The counter weight is shaped and sized to provide sufficient residual capacity for the truck with an optimum turning radius. Airflow through the counterweight is guaranteed for the cooling system. The ‘counterweight does not obstruct the rearward visibility of the operator. 16 ‘SMM 013 eee La Product Details Truck label ‘On the dashboard of the truck a label provides mandatory information about the truck model, manufacturer, nominal capacity, nominal engine power, tyres and serial number. Industrial strength 6- Diesel engine cylinder diese! engine ‘The industrial-strength 6-cylinder in-line Mitsubishi Heavy Industries S6S engine was specifically designed for use in industrial fork trucks. it offers excellent power and reliability, The Mitsubishi S6S diesel has eamed the reputation of an ‘environmentally friendly’ engine because ofits low emissions, low noise, and good fuel economy. The SBS is a smooth running diesel engine which generates very litle vibration, Two important design features contribute to this feature: the crankshattis precision balanced both statically and dynamically, and specially tuned rubber engine mounts are used at the fan end of the engine to reduce vibration. Inherently a six cylinder engine produces fewer vibrations than a four cylinder (most competitors offer 4-cyinder engines on this class of trucks). To further increase strength and durabilty, the crankshaft is botted to the engine block with seven main bearings. This means that itis supported at each journal of the crankshaft and also at both ends. Collectively, these design features result in a strong, durable and very smooth running diese! engine, ‘The $6S is an indirect diesel with swirltype pre combustion chamber. Fuel is injected first into the pre combustion chamber for initial combustion of the atomized fuel, followed by complete burning in the cylinder. 0 ‘SMM 013 Peete Product Details This design reduces combustion noise, increases torque output at lower ‘engine speeds, guarantees perfect combustion, very low emissions and reduces diesel smell Most diesel engines require a water separator to prevent engine fouling due to condensation (water particles) in the fuel. The S6S features an in-line plunger type fuel injection pump; a water separator is not required. In this ‘case, condensation is forced into the pre-combustion chamber and is. ‘evaporated during the comaustion process. Technical figures: * Displacement 4996 co Compression Ratio 22:1 Bore x Stroke 94 x 120 mm, ‘Output 57.4 KW / 2450 rpm Torque 260 Nm / 1700 rpm + Sump 12 litre (good cooling and lubrication) + MHI Altemator 12V/35A, Battery 12V/ 60 An, + Starter motor: diesel 12V/3.0 kW ; LPG 12VI1.4 kW Diesel fuel tank capacity is 115 lite Is ‘SMM 013 11-2010 eee La Product Details LPG engine ‘The powerful cylinder inline TB45 engine (4.5 liter, 72 at 2800pm, 280 Nm at 1200 rpm) is designed for high performance industrial applications. The modem mult+por fuel injection system and drive-by-wire Low emissions and very tote contol provide engine power while reducing noise and uel fuel efficient with high consumption. The Engine Control Module (ECM) controls ignition, ‘on-the-fly’ output power timing adjustment and reduces performance in case of overheating to prevent expensive engine damage. Adjustments (for example adjusting air- {uel ratio due to dirty air cleaners) are done automatically In combination withthe standard 3-way catalytic converter this engine's ‘exhaust emission values are extremely low (EPA* compliant) B45 Nissan LPG engine electronically controlled ‘The engine block and cylinder head are made of cast iton for strength and durability. Because both are of the same material, thermo-elastic characteristics are equal, reducing the possibilty of cracking ‘The TB45 engine features overhead valve design. The intake and exhaust valves are located in the cylinder head as opposed to the engine block and are opened by hydraulic liters driven by the camshaft within the block assembly. The overhead valve design provides top performance, longer engine life, better fuel economy and generally less repairs compared with the block design. The crankshaft in the TB45 engine is supported by seven ‘main bearings. This type of construction provides excellent strength and

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