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Mitsubishi Electric Forklift Truck FB25CN, FB25N, FB30CN, FB30N, FB35N Workshop Service Manual
Original factory manuals for Mitsubishi Lift Trucks contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, without restrictions, contains Searchable Text and bookmarks
Covered models:
FB25CN
FB25N
FB30CN
FB30N
FB35N
Format: PDF, 620 Pages
Language: English
Contents:
1 Foreword
2 How to read this manual
2.1 Safety-related signs
2.2 Symbols and abbreviations
2.2.1 Safety symbols
2.2.2 Other symbols and abbreviations
2.3 Units
3 Safety instructions
3.1 Service area safety
3.2 Personal safety
3.3 Work safety
4 General information
4.1 Truck model covered by this manual
4.2 Identification plates on the truck
4.3 Overview of the truck
4.3.1 Operating devices
4.3.2 Control panel
4.3.3 Steering wheel
4.3.4 Arm rest
4.3.5 Manual levers
4.3.6 Side control panel
4.3.7 Display panel
4.3.8 Truck operation modes
4.3.9 Truck display
4.3.9.1 Display control buttons
4.3.9.2 Main view of the truck display
4.3.9.3 Hierarchy of the truck display menus
4.3.10 Pedals
4.3.10.1 Acceleration pedal and brake pedal
4.3.10.2 Accelerator pedal, operator presence pedal and brake pedal
4.3.10.3 Dual pedal and brake pedal
4.3.10.4 Pedal functionalities
4.3.11 Operators seat
4.3.12 Operating position
4.3.13 Driving direction
4.3.14 Drawbar pin
4.3.15 Motor, hydraulic system and electrical system
4.3.16 Electric panel
4.3.17 Hydraulic system
4.3.18 Drive axle
4.3.19 Sensors
4.3.20 Lifting carriage
4.3.21 Integrated sideshift carriage
4.3.22 Hook-on sideshift carriage
4.3.23 Integrated fork positioner with sideshift
4.3.24 Mast
4.3.25 Overhead guard and load support
4.3.26 Nominal capacity height indicator
5 Mechanical maintenance
5.1 Lifting points
5.1.1 Jack points
5.1.2 Hoist points
5.2 Transportation
5.3 Assembly and commissioning
5.4 Order spare parts
5.5 Truck covers
5.5.1 Remove the cover of the hydraulic valve block
5.5.2 Remove the pedal plate
5.5.3 Remove the floor plate
5.5.4 Open the battery door
5.5.5 Open the battery cover
5.5.6 Remove the back cover
5.5.7 Remove the steering wheel cover
5.5.8 Remove the control panel
5.5.9 Remove the step cover
5.5.10 Remove the side plate
5.5.11 Remove the cup holder
5.5.12 Remove the steering wheel front cover
5.6 Steering wheel
5.6.1 Remove the steering wheel unit
5.6.2 Remove the steering wheel gas spring
5.6.3 Remove the lever unit
5.6.4 Remove the levers
5.7 Pedals
5.7.1 Accelerator pedal
5.7.1.1 Remove the accelerator pedal
5.7.2 Brake pedal
5.7.2.1 Adjust the brake pedal
5.7.2.3 Disassemble the brake pedal
5.7.3 Operator presence pedal
5.7.3.1 Remove the operator presence pedal
5.7.4 Dual pedal
5.7.4.1 Remove the dual pedal
5.7.4.2 Adjust the dual pedal
5.7.4.3 Adjust the center position sensor of the dual pedal
5.8 Drive axle
5.8.1 Lifting points of the drive axle
5.8.2 Remove the drive axle
5.8.3 Disassemble the drive axle
5.8.4 Remove the transmission gear
5.8.5 Remove the helical gear stage
5.8.6 Maintain the parking brake actuator
5.8.6.1 Release the parking brake actuator
5.8.6.2 Disassemble the parking brake actuator
5.8.6.3 Replace the O-ring
5.8.6.4 Replace the seal of the piston
5.8.6.5 Install the parking brake actuator
5.8.7 Remove the traction motors
5.8.8 Install the left and right traction motors
5.8.9 Replace the service brake actuator
5.8.9.1 Remove the service brake actuator
5.8.9.2 Replace the spare parts of the service brake actuator
5.8.9.3 Install the service brake actuator
5.8.10 Remove the brake discs and ball ramp actuator
5.8.11 Install the brake discs and the ball ramp actuator
5.8.11.1 Measure the clearance of the air-gap
5.8.12 Disassemble the impulse gear
5.8.13 Remove the breathers
5.8.14 Lubricate the drive axle
5.9 Rear axle
5.9.1 Remove the rear axle
5.9.2 Lubricate the rear axle
5.10 Wheels
5.10.1 Solid rubber wheels
5.10.2 Pneumatic wheels
5.10.2.1 Punctured wheel
5.10.3 Before you replace the wheels
5.11 Front wheels
5.11.1 Remove the front wheel
5.11.2 Install the front wheel
5.11.3 Replace the wheel shaft bolts
5.12 Rear wheels
5.12.1 Remove the rear wheels
5.12.2 Install the rear wheel
5.12.3 Replace the wheel shaft bolts of the rear wheel
5.13 Brakes
5.13.1 Bleed the service brake
5.14 Mast
5.14.1 Detailed construction
5.14.1.1 Simplex mast
5.14.1.2 Duplex mast with initial lift
5.14.1.3 Triplex mast
5.14.2 Maintenance of the mast
5.14.2.1 Daily maintenance
5.14.2.2 Monthly maintenance
5.14.2.3 Annual maintenance (600 h)
5.14.3 Lubricant recommendations
5.14.3.1 Mast chains
5.14.3.2 Mast channels
5.14.4 Lifting carriage
5.14.4.1 Remove the lifting carriage
5.14.4.2 Adjust the rollers of the lifting carriage
5.14.4.3 Replace the guidance rollers of the lifting carriage
5.14.4.4 Replace the main rollers of the lifting carriage
5.14.5 Remove the mast
5.14.6 Disassemble the simplex mast
5.14.7 Disassemble the duplex mast
5.14.8 Disassemble the triplex mast
5.14.9 Fork inspection
5.14.10 Mast chains
5.14.10.1 Inspect the mast chains
5.14.10.2 Inspect the tension of the mast chains
5.14.10.3 Adjust the mast chains
5.14.10.4 Replace the mast chains
5.14.11 Main rollers of the mast
5.14.11.1 Replace the main rollers of the mast
5.14.12 Free lift cylinder
5.14.12.1 Replace the free lift cylinder
5.14.12.2 Sealing housing of the free lift cylinder
5.14.13 Side cylinders
5.14.13.1 Replace the side cylinders
5.14.13.2 Sealing housing of the side cylinder
5.14.14 Tilt cylinders
5.14.14.1 Remove the tilt cylinders
5.14.14.2 Sealing housing of the tilt cylinder
5.14.14.3 Lubrication points of the tilt cylinder
5.14.15 Sideshift cylinder
5.14.15.1 Remove the piston of the sideshift cylinder
5.14.15.2 Sealing housing of the sideshift cylinder
5.15 Hook-on sideshift
5.15.1 Remove the hook-on sideshift frame
5.15.2 Remove the hook-on sideshift cylinder piston
5.16 Arm rest
5.16.1 Remove the arm rest
5.16.2 Open the arm rest
5.16.3 Remove the arm rest levers
5.16.4 Remove the thumb plate
5.16.5 Replace the arm rest padding .
6 Electrical operation
6.1 How to use the schematic diagram
6.2 Power source
6.3 Safety circuit (emergency stop button)
6.4 Key switch
6.5 Traction
7 Battery maintenance
7.1 Safety regulations concerning the handling of lead-acid batteries
7.2 Battery maintenance
7.2.1 Daily maintenance
7.2.2 Weekly maintenance
7.2.3 Monthly maintenance
7.2.4 Annual maintenance
7.2.5 General maintenance
7.2.6 Storage
7.2.7 Malfunctions
7.2.8 How to clean batteries
7.3 Recharge the battery
7.4 Measure the specific gravity of the battery
7.5 Replace the battery
7.5.1 Replace the battery with the standard equipment
7.5.2 Guide the battery cable
7.5.3 Battery sideway exchange
8 Electric system maintenance
8.1 Display panel
8.1.1 Emergency stop button
8.1.1.1 Emergency stop button functionality check
8.1.2 Key switch
8.1.2.1 Key switch functionality check
8.2 Electric panel
8.2.1 Discharge the controllers
8.2.2 Remove the electric panel
8.2.3 Vehicle controller
8.2.4 Vehicle controller connectors
8.2.4.1 CNA external connector
8.2.4.2 CNB external connector
8.2.5 Traction controller
8.2.6 Traction controller connectors
8.2.6.1 CNA external connector
8.2.6.2 Description of the power connections
8.2.7 Pump controller
8.2.8 Pump controller connectors
8.2.8.1 CNA external connector
8.2.8.2 Description of the power connections
8.2.9 Fuses
8.3 Motor compartment
8.3.1 Traction motor
8.4 Pump motor
8.4.1 Pump motor (2.5 ton models)
8.4.2 Pump motor (3.0 and 3.5 ton models)
8.4.3 Remove the pump motor
8.5 Sensors
8.5.1 Traction motor sensors
8.5.1.1 Temperature sensor
8.5.1.2 Rotation sensor
8.5.2 Pump motor sensors
8.5.2.1 Temperature sensor
8.5.2.2 Rotation sensor
8.5.3 Battery door sensor
8.5.3.2 Functionality check of the battery door sensor
8.5.3.3 Replace the battery door sensor
8.5.4 Pressure sensor
8.5.4.1 Functionality check of the pressure sensor
8.5.5 Rear axle sensor
8.5.5.1 Functionality check of the rear axle sensor
8.5.5.2 Replace the rear axle sensor
8.5.6 Parking brake sensor
8.5.6.1 Functionality check of the parking brake sensor
8.5.7 Steering wheel sensor
8.5.7.1 Functionality check of the steering wheel sensor
8.5.8 Accelerator pedal sensor
8.5.8.1 Functionality check of the accelerator pedal
8.5.9 Brake pedal sensor
8.5.9.1 Functionality check of the brake pedal sensor
8.5.10 Operator presence pedal sensor
8.5.10.1 Functionality check of the operator presence pedal
8.5.11 Dual pedal sensors
8.5.11.1 Angle sensor
8.5.11.2 Functionality check of the angle sensor
8.5.11.3 Center position sensor
8.5.12 Lift/lower lever sensor, manual levers
8.5.12.1 Functionality check of the lift/lower lever sensor
8.5.13 Seat belt switch
8.5.13.1 Functionality check of the seat belt switch
8.5.14 Seat switch
8.5.14.1 Functionality check of the seat switch
8.5.14.2 Replace the seat switch
8.5.15 Switches of the side control panel
8.5.16 Manual control switches
8.5.17 Stop light switch
8.5.18 Driving direction selection switch
8.5.18.1 Functionality check of the driving direction selection switch
8.5.19 Horn switch
9 Electric system adjustments and measurements
9.1 Calibrate the arm rest levers
10 Hydraulic operation
10.1 Hydraulic symbols
10.2 Hydraulic oil recommendations
10.3 Hydraulics with fingertip controls
10.4 Hydraulics with manual levers
10.5 Hydraulic valve unit with fingertip controls
10.5.1 Valve M1, M2, M3, M4, M5, M6, M7 and M8
10.5.2 Valve M9 and M10
10.5.3 Emergency lowering valve
10.5.4 PDS valve
10.5.5 Clamp release valve
10.6 Hydraulic valve unit with manual levers
10.6.1 Emergency lowering valve
10.7 Hydraulic system maintenance
10.7.1 Remove the hydraulic oil suction filter
10.7.2 Replace the hydraulic oil return filter
10.7.3 Replace the air breather filter
10.7.4 Set the lifting pressure
10.7.5 Disassemble the valves
10.7.6 Remove the 4/5 auxiliary function selection valve block
10.7.7 Remove the clamp release valve
10.7.8 Remove the PDS valve
10.7.9 Remove the auxiliary function pressure limit valve
10.7.9.1 Adjust the auxiliary pressure limit valve
10.8 Hydraulic system
10.9 Hydraulics with additional hydraulic functions
10.9.1 Additional hydraulic functions in a truck with the arm rest
10.9.1.1 Hydraulics with 4 section control valve
10.9.1.2 Hydraulics with 4 section control valve
10.9.2 Additional hydraulic functions in a truck with the manual levers
10.9.2.1 Hydraulics with the 3 section control valve and the reel clamp
10.9.2.2 Hydraulics with the 4 section control valve
11 TruckTool Diagnostics
11.1 Location of the service socket
11.1.1 Remove the service socket cover
12 Parameter descriptions
12.1 VCM master
12.2 Traction controller
12.3 Pump controller
13 Alarm codes
13.1 VCM
13.1.1 VCM master alarms
13.1.2 VCM slave alarms
13.2 Traction controller
13.2.1 Traction controller right master alarms
13.2.2 Traction controller right slave alarms
13.2.3 Traction controller left master alarms
13.2.4 Traction controller left slave alarms
13.3 Pump controller
13.3.1 Pump controller master alarms
13.3.2 Pump controller slave alarms
13.4 Arm rest alarms
13.5 Truck display alarms
14 Service data
14.1 Special tightening torques
14.2 Tightening torque for standard bolts and nuts
14.3 Maintenance check list
14.4 Lubrication
14.4.1 Hydraulic oil
14.4.2 Transmission oil
14.4.3 Brake oil
14.4.4 Lubrication points
14.4.5 Rear axle
14.4.6 Mast chains
14.4.7 Mast channels
14.5 Special tools
15 Options
15.1 Accessory clamp
15.2 A4 paper holder
15.3 Smart backup alarm
15.4 Road light kit
15.4.1 Turn signals
15.4.2 Brake lights
15.4.3 Front lights
15.5 Amber strobe
15.6 Automatic working lights
15.7 Blue spot rear light
15.8 DC-DC converter
15.8.1 Install the DC-DC converter
15.9 12 V connector
15.10 Automated performance reduction based on lift height
15.11 Tilt angle sensor / display status indication with FC
15.12 Load weight indicator and overload warning system
15.13 Operators seat options and accessories
15.13.1 Arm rest
15.13.2 Backrest extension for MSG65
15.13.2.1 Backrest extension adjustment
15.14 Fire extinguisher
15.15 Battery sideway exchange tools
15.15.1 Installation of the battery sideway exchange tool
15.15.2 Replace the battery with the battery sideway exchange tools
15.15.3 Guide the battery cable
15.16 Rear view mirror
15.17 External rear view mirrors
15.18 Wide view mirror
15.19 Dead angle mirror overview
15.20 Hydraulic accumulator
15.21 Wide thread fenders
15.22 Abbot 2
16 Technical specification
16.1 FB25N, FB25CN, FB30N, FB30CN and FB35N
17 Index
APPENDIX A: Stickers .
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