Mitsubishi Forklift EV 100ZX Controller & Optional TR3000 Controller Service Manual PDF

Description

Mitsubishi Forklift Trucks EV 100ZX Controller & Optional TR3000 Controller Service Manual

FILE DETAILS:

Mitsubishi Forklift Trucks Chassis Mast Service Manual 99759-70100 – PDF DOWNLOAD

Language : English
Pages : 646
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Mitsubishi Forklift Trucks Chassis Mast Service Manual 99759-70100 – PDF DOWNLOAD

• EV100ZX Controller
  2FBC15 & 2FBC18 A2BC1-20001-up
  2FBC20 & 2FBC25 A2BC2-20001-up
  2FBC25E & 2FBC30 A2BC3-20001-up
• Optional TR3000 Controller
  2FBC15 & 2FBC18 A2BC1-60001-up
  2FBC20 & 2FBC25 A2BC2-60001-up
  2FBC25E & 2FBC30 A2BC3-60001-up
• 99759-70100

Chapter 1: General Information
Scope 1.1
Truck Models Covered 1.1
Nameplate and Serial Number Locations . 1.2
Dimensions 1.3
Dimensions Chart 1.4
General Information (Standard Models) 1.5
Chapter 2: Front Axle & Reduction Differential
Description. 2.1
Front Axle 2.1
General Information 2.1
Front Wheels . 2.2
Removal . 2.2
Method 1 . 2.3
Method 2 . 2.3
Method 3 . 2.3
Installation . 2.4
Axle Disassembly 2.5
Removing Front Wheel Hub . 2.6
Inspection after Disassembly 2.7
Axle Shafts 2.7
Reassembly. 2.8
Axle Housing. 2.8
Front Wheel Hub. 2.8
Hub Bearing Preload 2.9
Reduction Differential . 2.1 O
Description. 2.1 O
Disassembly . 2.11
Removing Bearing Inner Races 2.11
Inspection after Disassembly 2.12
Reduction Gear. 2.12
Differential. 2.12
Reassembly. 2.13
Inspection and Adjustment 2.15
Side Bearing Preload 2.15
Reduction Gear Backlash 2.15
Reduction Gear Face Run out. 2.16
Tooth Contact 2.16
Tooth Contact Adjustment. 2.17
TABLE OF CONTENTS
ii
Chapter 3: Transfer Case
Description. 3.1
Earlier Version 3.1
Later Version 3.2
Disassembly . 3.3
Removal 3.3
Reassembly. 3.4
Chapter 4: Rear Axle
Description. 4.1
Rear Axle . 4.1
Rear Wheels 4.2
Removal 4.2
Installation . 4.3
Rear Axle . 4.5
Removal 4.5
Installation 4.6
Disassembly 4.7
Inspection after Disassembly 4.9
Reassembly. 4.1 O
Inspection and Adjustment 4.15
Minimum Turning Radius Adjustment 4.15
Chapter 5: Brake System
Description. 5.1
Automatic Adjusting Device. 5.1
Master Cylinder. 5.2
Disassembly/Earlier Version 5.2
Disassembly/Later Version 5.3
Inspection after Disassembly 5.5
Reassembly. 5.5
Service Brakes 5.6
Disassembly (2FBC15/18) . 5.6
Disassembly (2FBC20/25/25E/30) 5.7
Inspection after Disassembly 5.9
Reassembly (2FBC15/18) . 5.1 O
Reassembly (2FBC20/25/25E/30). . 5.11
Wheel Cylinders . 5.14
Disassembly/Earlier Version 5.14
Disassembly/Later Version 5.15
Inspection after Disassembly 5.16
Reassembly. 5.16
Inspection and Adjustment 5.17
TABLE OF CONTENTS
Chapter 6: Steering System
Description . 6.1
Steering System with EV1 00ZX Controller 6.1
Oil Flow Sequence 6.1
General Information . 6.1
Steering System with Optional TR3000 Controller 6.2
Oil Flow Sequence 6.2
General Information . 6.2
Steering Gear. 6.3
Removal. 6.3
Steering Gear with EV1 00ZX Controller 6.4
Steering Gear with Optional TR3000 Controller . 6.5
Inspection after Removal 6.6
Installation 6.6
Disassembly . 6.7
Steering Gear with EV1 00ZX Controller . 6.7
Steering Gear with Optional TR3000 Controller . 6.8
Inspection after Disassembly 6.12
Reassembly . 6.13
Truck with EV1 00ZX Controller. 6.13
Truck with Optional TR3000 Controller 6.14
Inspection after Reassembly. 6.19
Steer Pump – Trucks with EV1 00ZX Controller Only 6.20
Removal. 6.20
Installation 6.21
Disassembly. 6.22
Inspection after Disassembly 6.25
Reassembly . 6.26
Inspection after Reassembly. 6.29
Chapter 7: Hydraulic System
Description . 7.1
Schematic for Trucks with EV1 00ZX Controller . 7.1
Schematic for Trucks with Optional TR3000 Controller . 7.2
Hydraulic Tank . 7.3
Hydraulic Pump for Trucks with EV100ZX Controller 7.4
Hydraulic Pump for Trucks with Optional TR3000 Controller 7.5
Control Valve 7. 7
Lift and Tilt Cylinders . 7.8
Flow Regulator Valve . 7.9
Down Safety Valve. 7 .1 0
Removal and Installation General Warning . 7.11
iii
TABLE OF CONTENTS
iv
Chapter 7: Hydraulic System, continued
Hydraulic Pump. 7.12
Removal 7.12
Trucks with EV1 00ZX Controller. 7.12
Trucks with Optional TR3000 Controller. 7.13
Installation . 7.14
Trucks with EV100ZX Controller . 7.14
Trucks with Optional TR3000 Controller. 7.14
Disassembly 7.15
Trucks with EV1 00ZX Controller. 7.15
Trucks with Optional TR3000 Controller. 7.16
Inspection after Disassembly 7.20
Body 7.20
Bushes and Balance Plate 7.20
Gears 7.20
Priority Valve (Trucks with Optional TR3000 Controller Only) 7.29
Disassembly 7.29
Reassembly. 7.32
Control Valve . 7.35
Removal 7.35
Trucks with EV1 00ZX Controller. 7.35
Trucks with Optional TR3000 Controller. 7.36
Installation . 7.37
Disassembly 7.38
Inspection after Reassembly 7.40
Reassembly. 7.40
Lift and Tilt Cylinders. 7.41
Removal 7.41
Lift Cylinders/Earlier Version. 7.41
Lift Cylinders/Later Version. 7.43
Installation . 7.45
Tilt Cylinders/Earlier Version. 7.46
Tilt Cylinders/Later Version. 7.47
Disassembly 7.49
Lift Cylinders. 7.49
Tilt Cylinders/Earlier Version. 7.50
Tilt Cylinders/Later Version. 7.51
Inspection after Disassembly 7.52
Precautions for Reassembly 7.52
TABLE OF CONTENTS
Chapter 7: Hydraulic System, continued
Flow Regulator Valve 7.53
Disassembly . 7.53
Inspection and Adjustment . 7.54
Hydraulic Tank 7.54
Control Valve 7.55
Lift and Tilt Cylinders 7.57
Adjusting Method 7.58
Testing 7.59
Chapter 8: Mast and Forks/Earlier Version
Description 8.1
Components . 8.1
Removal and Installation 8.3
Mast and Lift Bracket Assembly . 8.3
Disassembly 8.6
Inspection after Disassembly 8.8
Reassembly 8.9
Inspection and Adjustment . 8.1 O
Forks . 8.10
Chain Tension Adjustment 8.11
Clearance Adjustment on Lift Bracket 8.12
Mast Clearance Adjustment 8.14
Main Roller Shim Replacement 8.17
Mast Adjustment Chart . 8.20
Chapter 9: Mast and Forks/Later Version
Description 9.1
Components . 9.1
Removal and Installation 9.2
Mast and Lift Bracket Assembly . 9.2
Disassembly 9.4
Inspection after Disassembly 9.6
Reassembly 9. 7
Inspection and Adjustment. 9.8
Forks . 9.8
Chain Tension Adjustment 9.9
Clearance Adjustment on Lift Bracket 9.1 O
Mast Clearance Adjustment 9.13
Main Roller Shim Replacement 9.15
Mast Strip Adjustment. 9.15
Tilt Angle Adjustment 9.16
Lift Cylinder Stroke Adjustment 9.17
Bleeding Lift Cylinders 9.17
Service Data. 9.18
Troubleshooting . 9.20
V
TABLE OF CONTENTS
vi
Chapter 10: Troubleshooting Section
Front Axle and Reduction Differential 10.1
Brake System 10.2
Steering System . 10.4
Hydraulic System . 10.6
Rear Axle. 10.8
Mast and Forks 10.9
Chapter 11: Maintenance Service Data Section
Maintenance Service Data . 11.1
Front Axle and Reduction Differential 11.1
Transfer Case 11.3
Rear Axle . 11 .4
Brake System . 11.6
Steering System 11.11
Hydraulic System . 11.13
Mast and Forks (Simplex Mast) 11.18
Tightening Torques for Standard Bolts and Nuts 11.23
Fine Thread – With Spring Washer. 11.23
Fine Thread – Without Spring Washer 11.24
Coarse Thread – With Spring Washer . 11.25
Coarse Thread – Without Spring Washer . 11.26
Maintenance Chart 11.27
Periodic Replacement Parts 11.33
Lubrication 11.34
Lubrication Chart. 11.34
Fuel and Lubricant Specifications 11.35
Recommended Brands of Lubricants 11.36
Weight of Major Components (Approximate) 11.37
Special Service Tools . 11.38
Special Tool Illustrations 11.39
Inspection Guide 11.42

DESCRIPTION:

Mitsubishi Forklift Trucks Chassis Mast Service Manual 99759-70100 – PDF DOWNLOAD

General Information :

• The frame supports hold the front axle housing in such a manner as to allow a limited amount of rotary motion of the housing, the rotary sliding surfaces being lubricated with grease.
• The cushion tire is press-fitted to the outer ring of the wheel hub

G.B 27/01/25