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

SERVICE MANUAL FB25-35(C)N 624631 English 2015

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 2 (620) FB25-35(C)N Service manual Only adequately trained service persons are allowed to carry out service operations. The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones. It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your truck dealer for qualified, authorized and efficient maintenance service. Copyright © 2015 by Mitsubishi Forklift Trucks, bv. All rights reserved. Mitsubishi Forklift Trucks® is a registered trademark of Mitsubishi Heavy Industries®, Inc. All brand or product names are or may be trademarks of, and are used to identify products and services of, their respective owners. Unauthorized copying and lending are prohibited. Mitsubishi Caterpillar Forklift Asia Pte. Ltd. RCB No.: 199203169H No. 1, Tuas West Street Singapore 637444 MCFA MCFE B.V. 2121 W. Sam Houston Pkwy. N. Hefbrugweg 77 Houston, TX 77043-2305 1332 AM Almere USA The Netherlands Approvals and version history REVISION DATE DESCRIPTION OF CHANGE APPROVED BY A 12.2.2015 First issue R&D Original instructions ___X___ / Translation of the original instructions _______

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 3 (620) FB25-35(C)N Service manual Contents Contents ...................................................................................................................3 1 Foreword ......................................................................................................12 2 How to read this manual .............................................................................13 2.1 Safety-related signs .......................................................................13 2.2 Symbols and abbreviations ............................................................13 2.2.1 Safety symbols....................................................................................13 2.2.2 Other symbols and abbreviations ........................................................15 2.3 Units ...............................................................................................15 3 Safety instructions ......................................................................................16 3.1 Service area safety ........................................................................16 3.2 Personal safety ..............................................................................17 3.3 Work safety ....................................................................................17 4 General information ....................................................................................20 4.1 Truck model covered by this manual .............................................20 4.2 Identification plates on the truck ....................................................20 4.3 Overview of the truck .....................................................................22 4.3.1 Operating devices ...............................................................................22 4.3.2 Control panel.......................................................................................23 4.3.3 Steering wheel ....................................................................................24 4.3.4 Arm rest ..............................................................................................25 4.3.5 Manual levers......................................................................................27 4.3.6 Side control panel ...............................................................................29 4.3.7 Display panel ......................................................................................30 4.3.8 Truck operation modes........................................................................32 4.3.9 Truck display .......................................................................................33 4.3.9.1 Display control buttons ........................................................................34 4.3.9.2 Main view of the truck display..............................................................35 4.3.9.3 Hierarchy of the truck display menus...................................................46 4.3.10 Pedals.................................................................................................50 4.3.10.1 Acceleration pedal and brake pedal ....................................................51 4.3.10.2 Accelerator pedal, operator presence pedal and brake pedal ..............51 4.3.10.3 Dual pedal and brake pedal.................................................................52 4.3.10.4 Pedal functionalities ............................................................................53 4.3.11 Operator’s seat ...................................................................................54 4.3.12 Operating position ...............................................................................54 4.3.13 Driving direction ..................................................................................57 4.3.14 Drawbar pin.........................................................................................58 4.3.15 Motor, hydraulic system and electrical system.....................................59 4.3.16 Electric panel ......................................................................................60 4.3.17 Hydraulic system .................................................................................61 4.3.18 Drive axle ............................................................................................62 4.3.19 Sensors...............................................................................................62

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 4 (620) FB25-35(C)N Service manual 4.3.20 Lifting carriage ....................................................................................66 4.3.21 Integrated sideshift carriage ................................................................66 4.3.22 Hook-on sideshift carriage...................................................................67 4.3.23 Integrated fork positioner with sideshift................................................67 4.3.24 Mast ....................................................................................................68 4.3.25 Overhead guard and load support .......................................................68 4.3.26 Nominal capacity height indicator ........................................................69 5 Mechanical maintenance ............................................................................70 5.1 Lifting points ...................................................................................70 5.1.1 Jack points ..........................................................................................70 5.1.2 Hoist points .........................................................................................70 5.2 Transportation ................................................................................71 5.3 Assembly and commissioning........................................................72 5.4 Order spare parts ...........................................................................73 5.5 Truck covers...................................................................................73 5.5.1 Remove the cover of the hydraulic valve block ....................................75 5.5.2 Remove the pedal plate ......................................................................75 5.5.3 Remove the floor plate ........................................................................76 5.5.4 Open the battery door .........................................................................77 5.5.5 Open the battery cover........................................................................77 5.5.6 Remove the back cover.......................................................................78 5.5.7 Remove the steering wheel cover .......................................................79 5.5.8 Remove the control panel ...................................................................79 5.5.9 Remove the step cover .......................................................................80 5.5.10 Remove the side plate.........................................................................81 5.5.11 Remove the cup holder .......................................................................81 5.5.12 Remove the steering wheel front cover ...............................................82 5.6 Steering wheel ...............................................................................82 5.6.1 Remove the steering wheel unit ..........................................................83 5.6.2 Remove the steering wheel gas spring ................................................84 5.6.3 Remove the lever unit .........................................................................84 5.6.4 Remove the levers ..............................................................................86 5.7 Pedals ............................................................................................87 5.7.1 Accelerator pedal ................................................................................87 5.7.1.1 Remove the accelerator pedal.............................................................87 5.7.2 Brake pedal .........................................................................................88 5.7.2.1 Adjust the brake pedal.........................................................................89 5.7.2.3 Disassemble the brake pedal ..............................................................90 5.7.3 Operator presence pedal.....................................................................92 5.7.3.1 Remove the operator presence pedal .................................................92 5.7.4 Dual pedal ...........................................................................................93 5.7.4.1 Remove the dual pedal .......................................................................94 5.7.4.2 Adjust the dual pedal...........................................................................96 5.7.4.3 Adjust the center position sensor of the dual pedal..............................96 5.8 Drive axle .......................................................................................97 5.8.1 Lifting points of the drive axle ..............................................................99 5.8.2 Remove the drive axle.........................................................................99 5.8.3 Disassemble the drive axle ...............................................................101

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 5 (620) FB25-35(C)N Service manual 5.8.4 Remove the transmission gear ..........................................................102 5.8.5 Remove the helical gear stage ..........................................................105 5.8.6 Maintain the parking brake actuator ..................................................113 5.8.6.1 Release the parking brake actuator ................................................... 113 5.8.6.2 Disassemble the parking brake actuator............................................ 115 5.8.6.3 Replace the O-ring ............................................................................ 116 5.8.6.4 Replace the seal of the piston ...........................................................116 5.8.6.5 Install the parking brake actuator....................................................... 117 5.8.7 Remove the traction motors ..............................................................119 5.8.8 Install the left and right traction motors .............................................. 121 5.8.9 Replace the service brake actuator ................................................... 123 5.8.9.1 Remove the service brake actuator ................................................... 123 5.8.9.2 Replace the spare parts of the service brake actuator ....................... 123 5.8.9.3 Install the service brake actuator ....................................................... 125 5.8.10 Remove the brake discs and ball ramp actuator ................................ 127 5.8.11 Install the brake discs and the ball ramp actuator .............................. 128 5.8.11.1 Measure the clearance of the air-gap ................................................130 5.8.12 Disassemble the impulse gear ..........................................................132 5.8.13 Remove the breathers....................................................................... 134 5.8.14 Lubricate the drive axle .....................................................................137 5.9 Rear axle ......................................................................................138 5.9.1 Remove the rear axle ........................................................................138 5.9.2 Lubricate the rear axle....................................................................... 140 5.10 Wheels .........................................................................................141 5.10.1 Solid rubber wheels........................................................................... 141 5.10.2 Pneumatic wheels .............................................................................141 5.10.2.1 Punctured wheel ...............................................................................142 5.10.3 Before you replace the wheels ..........................................................142 5.11 Front wheels .................................................................................143 5.11.1 Remove the front wheel ....................................................................143 5.11.2 Install the front wheel ........................................................................144 5.11.3 Replace the wheel shaft bolts............................................................ 146 5.12 Rear wheels .................................................................................151 5.12.1 Remove the rear wheels ...................................................................151 5.12.2 Install the rear wheel .........................................................................152 5.12.3 Replace the wheel shaft bolts of the rear wheel ................................ 154 5.13 Brakes ..........................................................................................156 5.13.1 Bleed the service brake .....................................................................156 5.14 Mast .............................................................................................157 5.14.1 Detailed construction.........................................................................158 5.14.1.1 Simplex mast .................................................................................... 158 5.14.1.2 Duplex mast with initial lift ................................................................. 159 5.14.1.3 Triplex mast ......................................................................................160 5.14.2 Maintenance of the mast ...................................................................161 5.14.2.1 Daily maintenance.............................................................................161 5.14.2.2 Monthly maintenance ........................................................................161 5.14.2.3 Annual maintenance (600 h) ............................................................. 161 5.14.3 Lubricant recommendations ..............................................................162

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 6 (620) FB25-35(C)N Service manual 5.14.3.1 Mast chains.......................................................................................162 5.14.3.2 Mast channels ...................................................................................162 5.14.4 Lifting carriage ..................................................................................162 5.14.4.1 Remove the lifting carriage ................................................................163 5.14.4.2 Adjust the rollers of the lifting carriage ............................................... 166 5.14.4.3 Replace the guidance rollers of the lifting carriage ............................ 166 5.14.4.4 Replace the main rollers of the lifting carriage ................................... 167 5.14.5 Remove the mast ..............................................................................167 5.14.6 Disassemble the simplex mast ..........................................................170 5.14.7 Disassemble the duplex mast............................................................ 174 5.14.8 Disassemble the triplex mast............................................................. 179 5.14.9 Fork inspection..................................................................................186 5.14.10 Mast chains.......................................................................................190 5.14.10.1 Inspect the mast chains.....................................................................191 5.14.10.2 Inspect the tension of the mast chains............................................... 199 5.14.10.3 Adjust the mast chains ...................................................................... 199 5.14.10.4 Replace the mast chains ...................................................................202 5.14.11 Main rollers of the mast .....................................................................205 5.14.11.1 Replace the main rollers of the mast .................................................205 5.14.12 Free lift cylinder.................................................................................207 5.14.12.1 Replace the free lift cylinder ..............................................................207 5.14.12.2 Sealing housing of the free lift cylinder .............................................. 210 5.14.13 Side cylinders.................................................................................... 212 5.14.13.1 Replace the side cylinders ................................................................212 5.14.13.2 Sealing housing of the side cylinder ..................................................215 5.14.14 Tilt cylinders ......................................................................................216 5.14.14.1 Remove the tilt cylinders ...................................................................217 5.14.14.2 Sealing housing of the tilt cylinder ..................................................... 218 5.14.14.3 Lubrication points of the tilt cylinder................................................... 220 5.14.15 Sideshift cylinder ...............................................................................220 5.14.15.1 Remove the piston of the sideshift cylinder ....................................... 221 5.14.15.2 Sealing housing of the sideshift cylinder ............................................ 222 5.15 Hook-on sideshift .........................................................................223 5.15.1 Remove the hook-on sideshift frame .................................................223 5.15.2 Remove the hook-on sideshift cylinder piston.................................... 225 5.16 Arm rest........................................................................................226 5.16.1 Remove the arm rest .........................................................................226 5.16.2 Open the arm rest .............................................................................227 5.16.3 Remove the arm rest levers ..............................................................228 5.16.4 Remove the thumb plate ...................................................................229 5.16.5 Replace the arm rest padding ...........................................................230 6 Electrical operation ...................................................................................231 6.1 How to use the schematic diagram ..............................................231 6.2 Power source ...............................................................................234 6.3 Safety circuit (emergency stop button) ........................................234 6.4 Key switch ....................................................................................234

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 7 (620) FB25-35(C)N Service manual 6.5 Traction ........................................................................................235 7 Battery maintenance .................................................................................236 7.1 Safety regulations concerning the handling of lead-acid batteries .......................................................................................237 7.2 Battery maintenance ....................................................................238 7.2.1 Daily maintenance.............................................................................238 7.2.2 Weekly maintenance .........................................................................238 7.2.3 Monthly maintenance ........................................................................238 7.2.4 Annual maintenance .........................................................................239 7.2.5 General maintenance ........................................................................239 7.2.6 Storage .............................................................................................239 7.2.7 Malfunctions ......................................................................................239 7.2.8 How to clean batteries....................................................................... 240 7.3 Recharge the battery....................................................................242 7.4 Measure the specific gravity of the battery ..................................245 7.5 Replace the battery ......................................................................245 7.5.1 Replace the battery with the standard equipment .............................. 246 7.5.2 Guide the battery cable .....................................................................248 7.5.3 Battery sideway exchange ................................................................249 8 Electric system maintenance ...................................................................250 8.1 Display panel ................................................................................250 8.1.1 Emergency stop button .....................................................................250 8.1.1.1 Emergency stop button functionality check........................................ 251 8.1.2 Key switch.........................................................................................251 8.1.2.1 Key switch functionality check ...........................................................252 8.2 Electric panel ................................................................................253 8.2.1 Discharge the controllers...................................................................254 8.2.2 Remove the electric panel ................................................................. 255 8.2.3 Vehicle controller...............................................................................256 8.2.4 Vehicle controller connectors ............................................................ 256 8.2.4.1 CNA external connector ....................................................................257 8.2.4.2 CNB external connector ....................................................................259 8.2.5 Traction controller .............................................................................261 8.2.6 Traction controller connectors ...........................................................261 8.2.6.1 CNA external connector ....................................................................262 8.2.6.2 Description of the power connections ................................................265 8.2.7 Pump controller .................................................................................265 8.2.8 Pump controller connectors...............................................................266 8.2.8.1 CNA external connector ....................................................................267 8.2.8.2 Description of the power connections ................................................268 8.2.9 Fuses ................................................................................................269 8.3 Motor compartment ......................................................................271 8.3.1 Traction motor ...................................................................................272 8.4 Pump motor..................................................................................272 8.4.1 Pump motor (2.5 ton models) ............................................................ 272 8.4.2 Pump motor (3.0 and 3.5 ton models) ............................................... 273 8.4.3 Remove the pump motor ...................................................................273

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 8 (620) FB25-35(C)N Service manual 8.5 Sensors ........................................................................................275 8.5.1 Traction motor sensors...................................................................... 275 8.5.1.1 Temperature sensor ..........................................................................275 8.5.1.2 Rotation sensor .................................................................................278 8.5.2 Pump motor sensors .........................................................................280 8.5.2.1 Temperature sensor ..........................................................................280 8.5.2.2 Rotation sensor .................................................................................281 8.5.3 Battery door sensor ........................................................................... 282 8.5.3.2 Functionality check of the battery door sensor................................... 283 8.5.3.3 Replace the battery door sensor ....................................................... 283 8.5.4 Pressure sensor ................................................................................284 8.5.4.1 Functionality check of the pressure sensor ........................................ 285 8.5.5 Rear axle sensor ...............................................................................286 8.5.5.1 Functionality check of the rear axle sensor ........................................ 286 8.5.5.2 Replace the rear axle sensor............................................................. 287 8.5.6 Parking brake sensor ........................................................................288 8.5.6.1 Functionality check of the parking brake sensor ................................ 289 8.5.7 Steering wheel sensor ....................................................................... 289 8.5.7.1 Functionality check of the steering wheel sensor ............................... 290 8.5.8 Accelerator pedal sensor...................................................................290 8.5.8.1 Functionality check of the accelerator pedal ...................................... 291 8.5.9 Brake pedal sensor ........................................................................... 292 8.5.9.1 Functionality check of the brake pedal sensor ................................... 292 8.5.10 Operator presence pedal sensor ....................................................... 293 8.5.10.1 Functionality check of the operator presence pedal ........................... 293 8.5.11 Dual pedal sensors ........................................................................... 294 8.5.11.1 Angle sensor ..................................................................................... 294 8.5.11.2 Functionality check of the angle sensor ............................................. 295 8.5.11.3 Center position sensor ...................................................................... 296 8.5.12 Lift/lower lever sensor, manual levers ............................................... 297 8.5.12.1 Functionality check of the lift/lower lever sensor ................................ 297 8.5.13 Seat belt switch .................................................................................298 8.5.13.1 Functionality check of the seat belt switch ......................................... 298 8.5.14 Seat switch .......................................................................................299 8.5.14.1 Functionality check of the seat switch ............................................... 299 8.5.14.2 Replace the seat switch ....................................................................300 8.5.15 Switches of the side control panel ..................................................... 302 8.5.16 Manual control switches ....................................................................304 8.5.17 Stop light switch ................................................................................305 8.5.18 Driving direction selection switch ....................................................... 306 8.5.18.1 Functionality check of the driving direction selection switch ............... 307 8.5.19 Horn switch .......................................................................................308 9 Electric system adjustments and measurements ..................................310 9.1 Calibrate the arm rest levers ........................................................310 10 Hydraulic operation ...................................................................................311

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 9 (620) FB25-35(C)N Service manual 10.1 Hydraulic symbols ........................................................................315 10.2 Hydraulic oil recommendations ....................................................318 10.3 Hydraulics with fingertip controls .................................................319 10.4 Hydraulics with manual levers .....................................................320 10.5 Hydraulic valve unit with fingertip controls ...................................320 10.5.1 Valve M1, M2, M3, M4, M5, M6, M7 and M8 ..................................... 323 10.5.2 Valve M9 and M10 ............................................................................ 324 10.5.3 Emergency lowering valve ................................................................324 10.5.4 PDS valve .........................................................................................324 10.5.5 Clamp release valve..........................................................................325 10.6 Hydraulic valve unit with manual levers .......................................326 10.6.1 Emergency lowering valve ................................................................328 10.7 Hydraulic system maintenance ....................................................328 10.7.1 Remove the hydraulic oil suction filter ............................................... 329 10.7.2 Replace the hydraulic oil return filter .................................................330 10.7.3 Replace the air breather filter ............................................................ 330 10.7.4 Set the lifting pressure....................................................................... 331 10.7.5 Disassemble the valves.....................................................................333 10.7.6 Remove the 4/5 auxiliary function selection valve block .................... 333 10.7.7 Remove the clamp release valve....................................................... 334 10.7.8 Remove the PDS valve .....................................................................335 10.7.9 Remove the auxiliary function pressure limit valve ............................ 336 10.7.9.1 Adjust the auxiliary pressure limit valve ............................................. 336 10.8 Hydraulic system ..........................................................................337 10.9 Hydraulics with additional hydraulic functions .............................338 10.9.1 Additional hydraulic functions in a truck with the arm rest .................. 338 10.9.1.1 Hydraulics with 4 section control valve .............................................. 338 10.9.1.2 Hydraulics with 4 section control valve .............................................. 338 10.9.2 Additional hydraulic functions in a truck with the manual levers ......... 339 10.9.2.1 Hydraulics with the 3 section control valve and the reel clamp .......... 339 10.9.2.2 Hydraulics with the 4 section control valve ........................................ 339 11 TruckTool Diagnostics ..............................................................................341 11.1 Location of the service socket......................................................342 11.1.1 Remove the service socket cover ......................................................342 12 Parameter descriptions ............................................................................343 12.1 VCM master .................................................................................343 12.2 Traction controller ........................................................................354 12.3 Pump controller ............................................................................354 13 Alarm codes ...............................................................................................355 13.1 VCM .............................................................................................356 13.1.1 VCM master alarms ..........................................................................356 13.1.2 VCM slave alarms .............................................................................383 13.2 Traction controller ........................................................................401 13.2.1 Traction controller right master alarms .............................................. 401 13.2.2 Traction controller right slave alarms .................................................428 13.2.3 Traction controller left master alarms ................................................441

© Mitsubishi Forklift Trucks 2015. All rights reserved. Revision: A Document ID: 624631 10 (620) FB25-35(C)N Service manual 13.2.4 Traction controller left slave alarms ................................................... 474 13.3 Pump controller ............................................................................487 13.3.1 Pump controller master alarms..........................................................487 13.3.2 Pump controller slave alarms ............................................................ 516 13.4 Arm rest alarms ............................................................................526 13.5 Truck display alarms ....................................................................536 14 Service data ...............................................................................................539 14.1 Special tightening torques ............................................................539 14.2 Tightening torque for standard bolts and nuts .............................539 14.3 Maintenance check list .................................................................541 14.4 Lubrication....................................................................................546 14.4.1 Hydraulic oil ......................................................................................546 14.4.2 Transmission oil ................................................................................546 14.4.3 Brake oil ............................................................................................546 14.4.4 Lubrication points ..............................................................................546 14.4.5 Rear axle ..........................................................................................546 14.4.6 Mast chains.......................................................................................547 14.4.7 Mast channels ...................................................................................547 14.5 Special tools .................................................................................547 15 Options .......................................................................................................551 15.1 Accessory clamp ..........................................................................552 15.2 A4 paper holder............................................................................553 15.3 Smart backup alarm .....................................................................555 15.4 Road light kit ................................................................................558 15.4.1 Turn signals ......................................................................................559 15.4.2 Brake lights .......................................................................................560 15.4.3 Front lights ........................................................................................562 15.5 Amber strobe................................................................................563 15.6 Automatic working lights ..............................................................566 15.7 Blue spot rear light .......................................................................568 15.8 DC-DC converter..........................................................................571 15.8.1 Install the DC-DC converter...............................................................571 15.9 12 V connector .............................................................................572 15.10 Automated performance reduction based on lift height ...............573 15.11 Tilt angle sensor / display status indication with FC ....................577 15.12 Load weight indicator and overload warning system ...................580 15.13 Operator’s seat options and accessories .....................................582 15.13.1 Arm rest ............................................................................................582 15.13.2 Backrest extension for MSG65 ..........................................................586 15.13.2.1 Backrest extension adjustment..........................................................586 15.14 Fire extinguisher...........................................................................586 15.15 Battery sideway exchange tools ..................................................587 15.15.1 Installation of the battery sideway exchange tool ............................... 588 15.15.2 Replace the battery with the battery sideway exchange tools ............ 589 15.15.3 Guide the battery cable .....................................................................593

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

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