Mitsubishi Forklift FB10 14 15 18(H)CA FB20 25(H)CA,FB28CA FB30CA Trucks Service Manual – PDF DOWNLOAD
FILE DETAILS:
Mitsubishi Forklift FB10 14 15 18(H)CA FB20 25(H)CA,FB28CA FB30CA Trucks Service Manual – PDF DOWNLOAD
Format: PDF
Language: English
Brand: Mitsubishi
DESCRIPTION:
Mitsubishi Forklift FB10 14 15 18(H)CA FB20 25(H)CA,FB28CA FB30CA Trucks Service Manual – PDF DOWNLOAD
FB10/14/15/18(H)CA 221AE0001/E00001-up 256E00001-00791
FB20/25(H)CA,FB28CA 241AC0001/C00001-up 257C00001-01119
FB30CA 251AC0001-up
INTRODUCTION :
- Most accident happens due to the disregard of basic safety rules or precautions. In order to prevent accidents from happening, the factors responsible for accidents must be avoided beforehand. For this reason, please read this manual and fully understand the precautions for safety and the proper procedures and directions for inspection and maintenance before starting operation. Performing maintenance and repair without adequate knowledge may cause inadvertent accidents.
- It is not possible to cover all the possible cases of accidents in this “SERVICE MANUAL-Chassis & Mast”. Therefore, attention should be given to precautions other than the ones mentioned in this “SERVICE MANUAL-Chassis & Mast”. Especially, when repair and maintenance work which are not covered in this “SERVICE MANUAL-Chassis & Mast” are carried out, always work under the direction of an instructor who understands the matter.
Using this “Service Manual-Chassis & Mast”:
This manual has information about the layout and names of main components, explains disassembly, assembly, inspection, adjustment, and maintenance procedures, and contains troubleshooting hints that apply mainly to the model FB-CA1. For FB-CA1J series, refer to FB-CA1 specifications and descriptions if not otherwise specified. It is important to note that in order to improve quality, performance, and safety parts used in this forklift truck are subject to change and that some portions of the contents and illustrations in the Workshop Manual at the time of printing may not be identical due to these changes. Instructions with and marks are very important and must always be followed.
TABLE OF CONTENTS:
Mitsubishi Forklift FB10 14 15 18(H)CA FB20 25(H)CA,FB28CA FB30CA Trucks Service Manual – PDF DOWNLOAD
SAFETY WORK 1
1 Precautions for safe inspection and
maintenance work 1
2 Safety labels 5
3 Model name and serial numbers 9
4 Cautions for maintenance11
5 Tightening torque for bolts 14
6 Data of LOCTITE and THREEBOND products15
1 GENERAL 17
1-1 Appearance 17
1-2 Specifications 18
2 FRONT AXLE (DRIVE) 21
2-1 Location and name 21
2-2 Disassembly and reassembly 22
2-2-1 Front axle – removal and installation 22
2-2-2 Front axle – disassembly and reassembly 28
2-3 Inspection and adjustment 36
2-3-1 Gears – Inspection and replacement 36
2-3-2 Wheel hub and hub bolt – Inspection 36
2-4 Troubleshooting 37
2-4-1 Front axle – troubleshooting 37
3 REAR AXLE (STEERING) 39
3-1 Location and name 39
3-2 Disassembly and reassembly 40
3-2-1 Rear axle – removal and installation 40
3-2-2 Rear axle – disassembly and reassembly 42
3-2-3 Rear axle – Reassembling method and attention 44
3-3 Inspection and adjustment 47
3-3-1 Bushing – inspection 47
3-3-2 Center arm – inspection 47
3-3-3 Tie rod Comp – inspection 47
3-3-4 Knuckle – inspection 47
3-3-5 King pin – inspection 48
3-3-6 Hub and hub bolt – inspection 48
3-3-7 Rear axle Comp – inspection 48
3-4 Troubleshooting 49
3-4-1 Rear axle – troubleshooting 49
4 TYRE 51
4-1 Location, name and tyre size 51
4-1-1 Tyre – location and name 51
4-1-2 Tyre size 52
4-2 Inspection and adjustment 53
4-2-1 Hub nut – inspection 53
4-2-2 Rim and rim bolt – inspection 53
4-2-3 Air pressure – inspection 54
4-2-4 Tyre – visual inspection and replacement 54
4-3 Troubleshooting 55
4-3-1 Tyre – troubleshooting 55
5 STEERING 57
5-1 Location and name 57
5-2 Disassembly and reassembly 58
5-2-1 Steering linkage – removal and installation 58
5-2-2 Steering linkage – disassembly and reassembly 60
5-3 Inspection and adjustment 62
5-3-1 Joint – inspection and replacement 62
5-3-2 Knob – inspection and replacement 62
5-3-3 Steering wheel – inspection and replacement 62
5-3-4 Torque sensor neutral – check and adjustment 63
5-3-5 Checking by voltage 65
5-3-6 Actuator ass’y – inspection and adjustment 66
5-4 Troubleshooting 67
5-4-1 Steering linkage – troubleshooting 67
6 BRAKE 69
6-1 Location and name 69
6-1-1 Foot brake linkage – main part names 69
6-1-2 Parking brake linkage – main part names 70
6-2 Disassembly and reassembly 71
6-2-1 Wheel brake – removal and installation 71
6-2-2 Wheel brake – disassembly and reassembly 74
6-3 Inspection and adjustment 75
6-3-1 Brake drum – inspection, repair and replacement 75
6-3-2 Shoe & lining – inspection and replacement 75
6-3-3 Adjustor ass’y – inspection and replacement 76
6-3-4 Wheel cylinder ass’y
– inspection and replacement 76
6-3-5 Master cylinder ass’y
– inspection and replacement 77
6-3-6 Brake pedal – inspection 77
6-3-7 Parking lever – inspection and adjustment 78
6-3-8 Brake linkage – adjustment 78
6-3-9 Brake air bleeding 80
6-4 Troubleshooting 82
6-4-1 Brake – troubleshooting 82
7 HYDRAULIC SYSTEM 83
7-1 Oil pipimng circuit 83
7a HYDRAULIC PUMP 85
7a-1Location and name 85
7a-2Disassembly and reassembly 86
7a-2-1 Hydraulic pump – removal and installation 86
7a-3Inspection and adjustment 87
7a-3-1 Hydraulic pump – inspection 87
7a-4Troubleshooting 88
7a-4-1 Hydraulic pump – troubleshooting 88
7b OIL TANK AND OIL PIPING 89
7b-1Location and name 89
7b-1-1 Plastic oil tank – main part names 89
7b-1-2 Iron oil tank – main part names 89
7b-2Disassembly and reasembly 90
7b-2-1 Oil tank – precautions 90
7b-2-2 Oil piping replacement – precautions 90
7b-3Inspection and adjustment 91
7b-3-1 Oil – inspection 91
7b-3-2 Recommended oil and quantity 91
7b-3-3 Oil tank and filters – cleaning and check 92
7b-4Troubleshooting 92
7b-4-1 Oil tank – troubleshooting 92
7c CONTROL VALVE 93
7c-1Location and name 93
7c-2Disassembly and reassembly 95
7c-2-1 Control valve – removal and installation 95
7c-2-2 Inner kit of control valve – replacement 98
7c-3Inspection and adjustment 99
7c-3-1 Relief pressure – measurement 99
7c-3-2 Microswitch – adjustment 100
7c-4Troubleshooting 101
7c-4-1 Control valve – troubleshooting 101
7d CYLINDER 103
7d-1Location and name 103
7d-1-1 Lift cylinder – main part names 103
7d-1-2 Tilt cylinder – main part names 105
7d-2Disassembly and reassembly 106
7d-2-1 Lift cylinder – removal :
2SP – mast (2 – stage simplex) 106
7d-2-2 Lift cylinder – removal :
2FP-mast (2-stage duplex), 3FP-mast (3-stage triplex) 108
7d-2-3 Tilt cylinder – removal 111
7d-2-4 Lift cylinder – installation and adjustment 112
7d-2-5 Tilt cylinder – installation 113
7d-2-6 Lift cylinder – disassembly and reassembly 114
7d-2-7 Tilt cylinder – disassembly and reassembly 124
7d-3Inspection and adjustment 125
7d-3-1 Cylinder comp – inspection 125
7d-3-2 Piston rod – inspection 125
7d-3-3 Drift for lift and tilt – inspection 126
7d-4Variation of the tilt cylinder 127
7d-4-1 Tilt angle by masts 127
7d-5Troubleshooting 128
7d-5-1 Cylinder – troubleshooting 128
8 MAST 129
8-1 Location and name 129
8-2 Disassembly and reassembly 131
8-2-1 Lift bracket – removal 131
8-2-2 Mast ass’y – removal 131
8-2-3 Mast – disassembly and reassembly 133
8-3 Inspection and adjustment 136
8-3-1 Mast, lift bracket and roller shaft – inspection 136
8-3-2 Back shoe – inspection 137
8-3-3 Lift chain – inspection and replacement 137
8-3-4 Chain bolt – inspection 138
8-3-5 Chain wheel – inspection 138
8-3-6 Hose pulley – inspection 139
8-3-7 Roller – inspection and replacement 139
8-3-8 Fork – inspection and replacement 140
8-3-9 Lift chain – inspection and adjustment 141
8-3-10 Mast lean- adjustment 142
8-4 Troubleshooting 143
8-4-1 Mast · Lift bracket · Fork – troubleshooting 143
9 MOTOR 145
9-1 Location and name 145
9-1-1 Traction motor – main part names 145
9-1-2 Hydraulic motor – main part names 146
9-1-3 EPS motor – main part names 146
9-1-4 Motors – specifications 147
9-2 Disassembly and reassembly 148
9-2-1 Traction motor – removal and installation 148
9-2-2 Hydraulic motor – removal and installation 149
9-2-3 EPS motor – removal and installation 151
9-2-4 Traction motor – disassembly and reassembly 152
9-2-5 Hydraulic motor – disassembly and reassembly 153
9-2-6 EPS motor – disassembly and reassembly 153
9-3 Inspection and adjustment 154
9-3-1 Rotor comp – inspection and replacement
(Traction and Hydraulic motor) 154
9-3-2 Armature comp – inspection and replacement 155
9-3-3 Brush, Brush holder and Spring (EPS motor)
– inspection and replacement 155
9-3-4 Motor ASS’Y (Traction/Hydraulic motor) – inspection 157
9-3-5 Motor ASS’Y (EPS motor) – inspection 158
9-3-6 Oil seal and permanent magnet(EPS motor)
– inspection and replacement 159
9-4 Troubleshooting 159
9-4-1 Motor – troubleshooting 159
10 ELECTRIC PARTS 161
10-1Location and name 161
10a CONTROL UNIT 163
10a-1Location and name 163
10a-2Disassembly and reassembly 164
10a-2-1 Control unit – removal and installation 164
10a-2-2 Control unit – disassembly and reassembly 166
10a-3Check and replacement 168
10a-3-1 FET module comp – inspection and replacement 169
10a-3-2 Capacitor – inspection and replacement 170
10a-3-3 EPS controller – specifications 171
10b DISPLAY PANEL AND DIRECTIONAL SWITCH 173
10b-1Display panel
– Disassembly and reassembly 173
10b-1-1 Display panel – disassembly and reassembly 173
10b-2Directional switch
– Disassembly and reassembly 174
10b-2-1 Display panel – disassembly and name 174
10b-2-2 Wiring of directional switch 175
10c ACCELERATOR 177
10c-1Disassembly and reassembly 177
10c-1-1 Accelerator linkage – removal and installation 177
10c-2Inspection and adjustment 178
10c-2-1 Potentiometer – adjustment 178
10c-2-2 Accelerator linkage – adjustment 179
10d MAIN CONTACTOR AND FUSE 181
10d-1Disassembly and reassembly 181
10d-1-1 Control unit – removal and installation 181
10d-2Inspection and replacement 183
10d-2-1 Main contactor – inspection and replacement 183
10d-2-2 Fuse – replacement 183
10e BUILT-IN CHARGER (OPTION) 185
10e-1Disassembly and reassembly 185
10e-1-1 Charger ass’y – disassembly and reassembly 185
10e-1-2 Transformer – disassembly and reassembly 186
10e-1-3 Built-in charger – specification 187
10e-2Inspection and replacement 189
10e-2-1 Magnetic contactor – inspection 189
10e-2-2 Plug comp and receptacle – inspection and replacement 189
10e-2-3 Fuse and fuse base – inspection 189
10e-2-4 Transformer – inspection 190
10e-2-5 Diode – inspection 190
10e-3Inspection After Assembly 191
10e-3-1 Timer – inspection 191
10e-3-2 Earth – inspection 192
10e-3-3 Reserve function – inspection 192
10e-4Charging procedure 193
10e-4-1 Automatic charge (Daily charge) 193
10e-4-2 Reserve charge 197
10e-4-3 Balancing charge 206
10e-5Voltage tap 208
10e-5-1 Power supply voltage – check 208
10e-5-2 Voltage tap – selection 208
10e-5-3 Voltage tap – changing 209
10e-5-4 Fuse (three-phase voltage) – replacement 209
10f BATTERY 211
10f-1Disassembly and reassembly211
10f-1-1 Battery – removal and installation 211
10f-2Inspection and adjustment 212
10f-2-1 Battery – inspection 212
10f-2-2 Battery – Cleaning 213
10g MPU BOARD 215
10g-1Location and name 215
10g-1-1 MPU board 215
10g-1-2 EPS controller board (EPS / DSP board) 216
11 LASER POINTER (OPTION) 217
11-1Adjustment 217
11-1-1 Fork level – adjustment 217
11-1-2 Laser optical axis – adjustment 217
12 SERVICE DATA 219
12-1Annual Inspection Service Data 219
12-2Standard work hours 220
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