Mitsubishi Forklift FB14-20A(C)NT FB16-20A(C)N Trucks Service Manual – PDF DOWNLOAD
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Mitsubishi Forklift FB14-20A(C)NT FB16-20A(C)N Trucks Service Manual – PDF DOWNLOAD
Format: PDF
Language: English
Brand: Mitsubishi
DESCRIPTION:
Mitsubishi Forklift FB14-20A(C)NT FB16-20A(C)N Trucks Service Manual – PDF DOWNLOAD
Foreword :
This service manual is a guide for servicing lift trucks. The long productive life of your lift truck depends on regular and proper servicing, consistent with the instructions provided in this service manual. Before you start to test, repair or rebuild a lift truck, read the respective sections of this manual carefully and make sure that you know all of the components. The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing. Trucks are constantly being developed. The graphic illustrations in this manual may differ slightly from the actual design of the truck. The manufacturer reserves the right to modify the design, equipment and technical features without prior notice and without any obligations. For your convenience, the instructions are grouped by systems as an easy reference. Unauthorized copying and lending of this material is strictly prohibited.
Work safety:
TABLE OF CONTENTS:
Mitsubishi Forklift FB14-20A(C)NT FB16-20A(C)N Trucks Service Manual – PDF DOWNLOAD
1 Foreword14
2 How to read this manual15
21 Safety-related signs 15
22 Symbols and abbreviations15
23 Interactive links17
3 Safety instructions 18
31 General safety instructions 18
32 Safety requirements for industrial trucks 18
33 Repairs and structural modifications19
34 Service area safety 19
35 Personal safety20
36 Work safety 20
37 Operating temperature 21
4 General information 23
41 Truck model covered by this manual 23
42 Identification plates of the truck23
43 Overview of the truck 25
431 Overhead guard 25
432 Cabin 26
4321 Cabin 26
4322 Emergency exits 27
433 Operating devices 28
434 Control devices 29
435 Steering wheel 29
436 Arm rest30
437 Manual levers 31
438 Side control panel32
439 Truck display34
4391 Main view of the truck display 34
4392 Hierarchy of the truck display menus35
4310 Pedals 35
43101 Accelerator pedal and brake pedal36
43102 Pedal functionalities 36
4311 Operator’s seat 37
4312 Operating position 37
4313 Operating direction 39
4314 Drawbar pin 40
4315 Motor, hydraulic system and electrical system 41
4316 Electric system41
4317 Hydraulic supply system 43
4318 Drive axle 43
4319 Sensors 44
4320 Lifting carriage 46
4321 Integrated sideshift carriage 47
4322 Hook-on sideshift carriage47
4323 Integrated fork positioner with sideshift48
4324 Mast 49
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Service Manual
4325 Overhead guard and load backrest 49
4326 Nominal capacity height indicator 50
5 Mechanical Maintenance51
51 Lifting points51
511 Jack points51
512 Hoist points51
52 Transportation 51
53 Assembly and commissioning53
54 Order spare parts 54
55 How to clean the truck54
56 Truck covers overview54
561 Remove the cover of the hydraulic valve block55
562 Remove the floor plate56
563 Open the battery door 58
564 Open the battery cover 59
565 Remove the back cover 61
566 Remove the steering wheel cover 61
567 Remove the control panel 62
568 Remove the step cover 63
569 Remove the side plate 64
5610 Remove the right side cover 64
57 Steering wheel 64
571 Remove the steering wheel unit64
572 Remove the steering wheel gas spring65
573 Remove the lever unit 66
5731 Remove the levers 67
58 Pedals 68
581 Accelerator pedal 68
5811 Remove the accelerator pedal69
582 Brake pedal 69
5821 Remove the brake pedal 70
583 Operator presence pedal 71
5831 Remove the operator presence pedal 71
584 Dual pedal 72
5841 Remove the dual pedal plate 73
5842 Remove the dual pedal 74
5843 Adjust the dual pedal 76
5844 Adjust the direction sensor of the dual pedal77
5845 Adjust the dual pedal angle sensor 77
59 Drive axle78
591 Remove the drive axle 79
592 Install the drive axle 81
593 Install the electromechanical parking brake 82
5931 Electromechanical parking brake maintenance 83
510 Rear axle 84
5101 Remove the rear axle (3-wheel models) 84
5102 Remove the rear axle (4-wheel models) 86
5103 Lubricate the rear axle 88
511 Wheels 89
5111 Solid rubber wheels 90
5112 Pneumatic wheels 91
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51121 Punctured wheel 91
5113 Before you replace the wheels92
512 Front wheels 92
5121 Remove the front wheel 92
5122 Install the front wheel 93
5123 Replace the wheel shaft bolts of the front wheel95
513 Rear wheels 95
5131 Remove the rear wheels (3–wheel models) 95
5132 Install the rear wheel (3-wheel models) 97
5133 Replace the wheel shaft bolts of the rear wheel (3-wheel)99
5134 Remove the rear wheels (4-wheel models) 100
5135 Install the rear wheel (4-wheel models) 101
5136 Replace the wheel shaft bolts of the rear wheel (4-wheel) 103
514 Mast 105
5141 Detailed construction 105
51411 Simplex mast 106
51412 Duplex mast 107
51413 Triplex mast 108
51414 Maintenance of the mast 108
514141 Daily maintenance 108
514142 Monthly maintenance 109
514143 Annual maintenance (1000 h) 109
51415 Lubricant recommendations 109
514151 Mast chains 109
514152 Mast channels 110
51416 Lifting carriage 110
514161 Remove the lifting carriage 110
514162 Adjust the rollers of the lifting carriage 114
514163 Replace the guidance rollers of the lifting
carriage 114
514164 Replace the main rollers of the lifting carriage 115
514165 Replace the load backrest 116
51417 Remove the mast 116
51418 Disassemble the simplex mast 119
51419 Disassemble the duplex mast 123
514110 Disassemble the triplex mast 128
514111 Fork inspection 134
514112 Mast chains 138
5141121 Inspect the mast chains 138
5141122 Inspect the tension of the mast chains 145
5141123 Adjust the mast chains 146
5141124 Replace the mast chains 149
514113 Main rollers of the mast 152
5141131 Replace the main rollers of the mast 152
514114 Free lift cylinder 154
5141141 Replace the free lift cylinder 154
5141142 Sealing housing of the free lift cylinder 157
514115 Side cylinders 158
5141151 Replace the side cylinders 159
5141152 Sealing housing of the side cylinder 162
514116 Tilt cylinders 163
5141161 Remove the tilt cylinders 163
5141162 Disassemble the tilt cylinder 165
5141163 Lubrication points of the tilt cylinder 167
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Service Manual
515 Hook-on sideshift 167
5151 Remove the hook-on sideshift frame 168
5152 Remove the hook-on sideshift cylinder piston 169
516 Integrated sideshift carriage 171
5161 Disassemble the protection grid 171
5162 Maintenance of the integrated sideshift carriage 172
5163 Disassemble the mobile frame 173
5164 Replace the sliding blocks 175
5165 Adjust the lower hooks 175
5166 Replace the cylinder gaskets 175
5167 Bleed the hydraulic circuit of the integrated sideshift carriage 176
5168 Troubleshooting integrated sideshift carriage 177
517 Integrated fork positioner with sideshift 178
5171 Assemble the integrated fork positioner 178
5172 Assemble the hydraulic system 179
5173 Assemble the forks 179
5174 Maintenance of the integrated fork positioner with sideshift 181
5175 Special maintenance of the integrated fork positioner with
sideshift 183
5176 Disassemble the right fork shifting cylinder 184
5177 Disassemble the left fork shifting cylinder 185
5178 Disassemble the mobile frame of the positioner 186
5179 Replace the gaskets on the side shifting cylinders 188
51710 Disassemble the upper sliding blocks and lower rollers 188
51711 Disassemble the fork supports 189
51712 Replace the gaskets of the fork-moving cylinder 191
51713 Reset the equipment and bleed the hydraulic circuit 192
51714 Hydraulic system (Fork positioner) 193
51715 Troubleshooting the integrated fork positioner with sideshift 194
518 Operator’s seat 196
5181 MSG20 196
51811 Remove the operator’s seat from the truck 196
51812 Replace the seat paddings 197
51813 Replace the seat base 198
51814 Replace the weight adjustment handle 201
51815 Replace the seat rails 202
51816 Install the seat arm rest 204
51817 Ground the operator’s seat 205
5182 MSG65 207
51821 Remove the operator’s seat from the truck 207
51822 Replace the seat padding 207
51823 Replace the seat base 209
51824 Remove the seat base 209
51825 Install the seat base 210
51826 Replace the seat belt 212
51827 Replace the seat switch 213
51828 Replace the weight adjustment handle 214
51829 Replace the seat rails 215
518210 Replace the gas spring 216
518211 Install the hip guard 217
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Service Manual
518212 Ground the operator’s seat 218
5183 MSG75 219
51831 Remove the operator’s seat from the truck 220
51832 Replace the seat paddings 220
51833 Replace the seat base 220
51834 Replace the seat belt 221
51835 Replace the seat switch 221
51836 Replace the weight adjustment handle 221
51837 Replace the gas spring 221
51838 Replace the compressor 222
51839 Replace the compressor tank 222
518310 Ground the operator’s seat 223
519 Manual holder 223
5191 Open the manual holder 223
5192 Replace the manual holder 224
520 Arm rest 225
5201 Remove the arm rest 225
5202 Open the arm rest 226
5203 Remove the arm rest levers 227
5204 Remove the thumb plate 227
5205 Replace the arm rest padding 228
521 Cabin 229
5211 Operator door 229
52111 Open the operator door 229
52112 Remove the opening handle of the operator door 230
52113 Remove the cover plate of the operator door 231
52114 Replace the lock of the operator door 232
52115 Replace the gas spring of the operator door 233
52116 Adjust the operator door 234
5212 Side door 235
52121 Replace the opening lever of the side door 235
52122 Replace the gas spring of the side door 237
5213 Open the roof cover (cabin trucks) 237
5214 Rear window 239
52141 Open the rear window (cabin truck) 239
52142 Replace the gas spring of the rear window 240
52143 Remove the rear window 241
5215 Windshield washer (cabin truck) 242
52151 Replace the windshield wiper 242
52152 Remove the motor of the windshield wipers 243
52153 Windshield washer tank 244
5216 Cabin seals 245
5217 Sun guard 248
52171 Remove the sun guard 248
5218 Radio 249
52181 Remove the radio 249
5219 Reading light 251
52191 Remove the reading light 251
52110 Heater 251
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Service Manual
521101 Remove the heater 252
521102 Replace the air filter of the heater 253
6 Electrical operation 255
61 Overview 255
62 How to use the schematic diagram 255
63 Power source 257
64 Safety circuit (emergency stop button) 257
65 Key switch 258
66 Traction 258
7 Battery maintenance 260
71 General information 260
72 Safety with lead-acid batteries 261
73 Battery maintenance 261
731 Daily maintenance 262
732 Weekly maintenance 262
733 Monthly maintenance 262
734 Annual maintenance 262
735 General maintenance 263
736 Storage 263
737 Malfunctions 263
738 How to clean batteries 263
739 How to clean vehicle traction batteries 263
7310 How to avoid damage to the plastic parts of batteries 264
74 Requirements for battery charging areas 264
75 Charge the battery 266
76 Measure the specific gravity of the battery 267
77 Replace the battery 268
771 Replace the battery with the standard equipment 269
772 Battery sideway exchange 271
8 Electric system maintenance 273
81 Display panel 273
811 Emergency stop button 273
8111 Emergency stop button functionality check 274
812 Key switch 274
8121 Key switch functionality check 274
82 Electric system 275
821 Discharge the controllers 276
822 Remove the electric panel 276
823 Vehicle master controller 278
8231 Vehicle master controller connectors 278
82311 Vehicle Master Controller, Connector A 279
82312 Vehicle Master Controller, Connector B 280
824 Traction controller 281
825 Traction controller connectors 282
8251 CNA external connector 282
8252 Description of the power connections 285
826 Pump controller 285
827 Pump controller connectors 286
8271 CNA external connector 286
8272 Description of the power connections 287
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828 Location of the fuses in the electric panel 288
83 Motor compartment 289
831 Traction motor 289
84 Pump motor 289
841 Pump motor (14 and 16 ton models) 290
842 Pump motor (18 and 20 ton models) 290
843 Remove the pump motor 290
844 Lubricate the pump axle splines 292
85 Rear compartment 293
851 4-wheel steering unit 293
852 Disassemble the 4–wheel steering unit 294
853 Steering controller 295
8531 Steering controller connectors 296
8532 CNA external connector 296
854 Option panel 298
86 Sensors 298
861 Traction motor sensors 298
8611 Temperature sensor 298
8612 Rotation sensor 299
8613 Replace the rotation sensor 300
862 Steering motor sensors 301
8621 Temperature sensor 301
8622 Rotation sensor 301
863 Pump motor sensors 302
8631 Temperature sensor 302
8632 Rotation sensor 303
864 Battery door sensor 303
8641 Functionality check of the battery door sensor 304
8642 Replace the battery door sensor 304
865 Pressure sensor (optional) 306
8651 Functionality check of the pressure sensor 306
866 Rear axle sensor 306
8661 Functionality check of the rear axle sensor (4 wheel
models) 308
8662 Replace the rear axle sensor (4 wheel models) 308
867 Steering wheel sensor 310
8671 Functionality check of the steering wheel sensor 310
868 Accelerator pedal sensor 311
8681 Functionality check of the accelerator pedal 312
869 Brake pedal sensor 313
8691 Functionality check of the brake pedal sensor 313
8610 Operator presence pedal sensor 314
86101 Functionality check of the operator presence pedal
sensor 314
8611 Dual pedal sensors 315
86111 Angle sensor 315
86112 Functionality check of the angle sensor 316
86113 Direction switches 316
86114 Functionality check of the direction switch 317
8612 Lever sensors, manual levers 317
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86121 Functionality check of the lever sensors 317
8613 Seat belt switch 318
86131 Functionality check of the seat belt switch 318
8614 Seat switch 318
86141 Functionality check of the seat switch 319
8615 Switches of the side control panel 319
8616 Manual control switches 320
8617 Driving direction selection switch 320
86171 Functionality check of the driving direction selection
switch 321
8618 Horn switch 322
87 Actuators 322
871 Traction parking brake 322
872 Steering feedback device 323
9 Electric system adjustments and measurements 324
91 Calibrate the arm rest levers 324
92 Insulation resistance test 324
921 Test voltage 324
922 Check the insulation tester 324
923 Measure the insulation resistance 324
9231 Insulation resistance of the truck 325
9232 Insulation resistance of the battery 326
10 Hydraulic operation 327
101 Hydraulic operation overview 327
102 Hydraulic operation lifting/lowering 329
103 Hydraulic symbols 330
104 Hydraulic oil recommendations 332
105 Hydraulic valve unit with fingertip controls 333
1051 Emergency lowering valve 334
106 Hydraulic valve unit with manual levers 334
1061 Clamp release valve 335
107 Hydraulic supply system 336
108 Hydraulic flow distribution with additional hydraulic functions 336
1081 Additional hydraulic functions in a truck with the arm rest 337
1082 Additional hydraulic functions in a truck with the manual levers 338
109 Hydraulic system maintenance 338
1091 Remove the hydraulic oil suction filter 338
1092 Clean the oil tank 340
1093 Replace the hydraulic oil return filter 342
1094 Replace the air breather filter 344
1095 Set the lifting pressure 344
1096 Disassemble the coils 346
1097 Disassemble the M1, M2 and M9 valves 347
1098 Remove the clamp release valve 347
11 TruckTool Diagnostics 349
111 Overview 349
112 Location of the service socket 349
12 Parameter descriptions 350
13 Service data 351
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Service Manual
131 Special tightening torques 351
132 Tightening torques for standard bolts and nuts 351
133 Maintenance check list 352
134 Oils and lubricants 357
1341 Lubrication points 358
1342 Rear axle 358
1343 Mast chains 358
1344 Mast channels 358
1345 Pump axle splines 358
135 Special tools 359
136 Troubleshooting 361
1361 Troubleshooting case examples 362
1362 Traction 362
1363 Brakes 362
1364 Hydraulics 363
1365 Steering 363
1366 Charging 364
14 Options 365
141 Options 365
142 Accessory rack 368
143 A4 paper holder 369
144 Smart backup alarm 371
145 Road light kit 373
1451 Turn signals 374
1452 Brake lights 374
1453 Front lights 375
146 Amber strobe 377
1461 Install the amber strobe on top of the overhead guard 377
1462 Install the amber strobe under the overhead guard 379
1463 Amber strobe wiring 379
147 Blue point front light 379
1471 Install the blue point front light 380
148 Blue point rear light 381
1481 Install the blue point rear light under the overhead guard 381
1482 Remove the blue point lights 383
149 DC-DC converter 383
1491 Install the DC-DC converter 383
1410 USB connector 384
1411 Automated performance reduction based on lift height 385
14111 Install the mast height sensor 386
1412 Tilt angle sensor / display status indication with FC 388
14121 Install the tilt angle sensor 389
1413 Load weight indicator 391
1414 Operator’s seat options and accessories 391
14141 Arm rest 392
14142 Install the arm rest in the MSG65 seat 392
14143 Adjust the height of the arm rest 394
14144 Backrest extension for MSG65 396
141441 Install the mounting bracket of the backrest
extension 396
141442 Backrest extension adjustment 396
1415 Fire extinguisher 397
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1416 Battery sideway exchange tools 398
14161 Requirements for power pallet trucks used to move batteries of
counterbalance trucks 398
14162 Installation of the battery sideway exchange tool 399
14163 Install a battery with the battery sideway exchange tools 399
14164 Disassemble the battery locking mechanism 402
1417 Wide view mirror 404
14171 Install the wide view mirror 404
1418 Rear view mirror 405
14181 Install the rear view mirror 406
1419 External rear view mirrors 407
14191 Install the external rear view mirror 407
1420 Hydraulic accumulator 408
14201 Install the hydraulic accumulator 408
15 Technical specifications 411
151 Dimensions 411
152 Technical data 413
APPENDIX A: Stickers 420
APPENDIX B: Truck display languages 425
APPENDIX C: Maintenance check list 426
Index 432
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