Description

Mitsubishi FD80N, FD90N, FD100N, FD120N, FD135N 2008 Training Manual

You’ve got a Mitsubishi FD80N, FD90N, FD100N, FD120N, FD135N 2008 Training Manual in front of you – and that’s the difference between a comeback job and a done-right repair. I’ve seen techs chase electrical gremlins on these 8–16 ton forklifts for half a day because they trusted a scanned copy from some forum. This is the actual Mitsubishi Heavy Industries dealer training book. Not a reprint. Not a third-party summary. 168 pages of what the factory expected their own technicians to know.

Electronic Control System – What the Factory Says

The Electronic Control System chapter covers the ECU logic for the FD80N through FD135N. You’ll find the pinout for the main controller, the sensor resistance checks, and the override procedures. Need to clear a fault code without a dealer scan tool? The manual spells out the manual reset sequence. Page 5 shows the chassis serial number locations and capacity plate – that matters because Mitsubishi changed the control harness between FD80N and FD135N at serial number break points. Ignore that and you’ll order the wrong sensor.

Transmission System: Factory Shift Points and Pressure Checks

Transmission work on the FD100N and FD120N is where most shops lose money. The wrong clutch pack clearance turns a smooth-shifting truck into a bucking one. This manual gives the OEM line pressures, the shift timing specs, and the valve body torque sequence. No aftermarket chart – the figures come straight from Mitsubishi’s Manual Transmission engineering group. Page 3 lists the model lineup with rated capacities so you know exactly which transmission variant you’re dealing with.

Brake System – Not the Place for Aftermarket Torque Tables

The Brake System section covers the wet disc brakes used on all these models. I’ve watched a junior tech snap a caliper bolt because he used a generic torque spec from a parts store lookup. That bolt is M10 x 1.25, and the manual calls for a specific angle after the initial torque. That’s in the Brake System chapter. This isn’t the place to guess. The FD135N with its higher GVW uses a different master cylinder – the manual explains the difference using the chassis serial number prefixes listed on page 3.

6M60-TL Diesel Engine and Controls – Real Diagnostics

You get a full breakdown of the 6M60-TL diesel engine: the common-rail injection timing, the EGR valve position sensor calibration, and the turbocharger wastegate adjustment. The OCR excerpt in the manual shows the fuel system schematic with pressure test points. If you’ve got a FD90N or FD100N that won’t start when hot, the Electronic Control System chapter walks you through the fuel pressure sensor output test. Automotive Industry Overview standards for diesel emissions diagnostics – this manual matches them.

Electro-Hydraulic Valve Control – Why OEM Documentation Wins

The Electro-Hydraulic Valve Control system on these forklifts is touchy. The solenoid resistance specs and the hydraulic spool clearances are not published anywhere else. Mitsubishi’s training manual gives the disassembly sequence and the O-ring part numbers. The Cab Lift System and Steering chapters also tie in – the steering control valve uses the same solenoids. Without the factory wiring diagram, you’re guessing which wire goes to which pin on the controller. This book has it.

1. Does this manual cover the FD150AN or FD160AN?

It covers FD80N, FD90N, FD100N, FD120N, and FD135N. The FD150AN and FD160AN have separate service manuals listed in the introduction (page 4).

2. Are torque values given in foot-pounds?

Values stated in Newton-meters. Use a conversion chart – the manual does not provide imperial equivalents.

3. What about the cab lift system – is it complete?

The Cab Lift System chapter in this 2008 training manual covers the hydraulic circuit flow diagram, relief valve setting, and cylinder rebuild specs. It does not include mast repair – that’s in the chassis service manual (part number 99709-52100). This is the training manual for dealer techs, so it focuses on diagnostics and system operation, not every single nut and bolt.

4. Can I use this manual for a FD100N with a different engine?

Only if the engine is the 6M60-TL. The manual’s engine section is specific to that diesel. No other engine data.

You don’t have to take my word for it. I’ve been in the shop since before these trucks were built. This is the same binder Mitsubishi handed to dealer techs in 2008 – no blurry photos, no missing pages, no generic rewrite. If you’re working on an 8–16 ton Mitsubishi forklift and you want the job done once, this is what you need. Access the Factory Manual and put the guesswork away.