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Mitsubishi FB25CN, FB25N, FB30CN, FB30N, FB35N Electric Forklift Truck Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Mitsubishi Electric Forklift Truck, models FB25CN, FB25N, FB30CN, FB30N, FB35N.

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 Operator°s 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 Operator°s 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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