Mitsubishi FB40N, FB45N, FB50CN, FB50N, FB50NH, FB55NH Service Manual 658099 EN B

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Mitsubishi FB40N, FB45N, FB50CN, FB50N, FB50NH, FB55NH Service Manual 658099 EN B

$50.00

Type Of Manual: Service Manual
Manual ID: 658099
Language: EN B
Number of Pages: 576
Size: 16.1MB
Format: PDF

Category: Mitsubishi Service Manual PDF

Model List:
- FB40N, FB45N, FB50CN, FB50N, FB50NH, FB55NH

1. Table of contents
2. Foreword
3. How to read this manual
3.1. Safety-related signs
3.2. Safety symbols
3.3. Units
3.4. Interactive links
4. Safety instructions
4.1. General safety instructions
4.2. Safety requirements for industrial trucks
4.3. Repairs and structural modifications
4.4. Seat belt
4.5. Wheels
4.6. LOCKOUT and TAGOUT
4.7. Service area safety
4.8. Personal safety
4.9. Work safety
4.10. Operating temperature
5. General information
5.1. Truck models covered by this manual
5.2. Identification plates and decals
5.3. Special tools
5.4. Operating position
5.5. Operating direction
5.6. Transportation
5.6.1. Lifting the truck
5.6.2. Towing connection
5.6.3. Towing the truck
5.6.4. Brake release
5.7. Assembly and commissioning
5.8. Order spare parts
6. Main components
6.1. Truck covers
6.2. Overhead guard
6.3. Cabin
6.3.1. Manual holder
6.3.2. Emergency exits
6.4. Operators seat
6.5. Operating devices
6.5.1. Steering wheel
6.5.2. Mini steering wheel
6.5.3. Armrest
6.5.4. Manual levers
6.5.5. Side control panel
6.6. Display panel
6.6.1. Emergency stop button
6.6.2. Key switch
6.6.3. Display control buttons
6.6.4. Truck display
6.7. Pedals
6.7.1. Accelerator pedal
6.7.2. Brake pedal
6.7.3. Electronic friction lock pedal (option)
6.7.4. Dual pedal
6.7.5. Pedal functionalities
6.8. Battery inspection hatch
6.9. Electric system
6.9.1. Electrical operation
6.9.2. Controllers
6.9.3. Vehicle master controller
6.9.4. Traction controller
6.9.5. Pump controller
6.9.6. Steering controller
6.9.7. Sensors and switches
6.9.8. Option panel
6.9.9. Fuses
6.9.10. Relays and contactors
6.9.11. DC/DC converter
6.9.12. Armrest connector
6.9.13. Display connector
6.9.14. Steering feedback device
6.10. Hydraulic operation
6.10.1. Hydraulic operation overview
6.10.2. Hydraulic operation lifting/lowering
6.10.3. Hydraulic symbols
6.10.4. Hydraulic valve unit with fingertip controls
6.10.5. Hydraulic valve unit with manual levers
6.10.6. Hydraulic supply system
6.10.7. Hydraulic flow distribution with additional hydraulic functions
6.11. Drive axle
6.12. Brakes
6.12.1. Service brake
6.12.2. Parking brake
6.13. Rear axle
6.14. Load handling
6.14.1. Lifting carriage
6.14.2. Integrated sideshift carriage
6.14.3. Hook-on sideshift
6.14.4. Integrated fork positioner with sideshift
6.14.5. Load backrest
6.15. Mast
6.15.1. Simplex mast
6.15.2. Triplex mast
6.15.3. Mast chains
6.15.4. Main rollers
6.15.5. Mast cylinders
6.15.6. Automated performance reduction based on lift height
6.16. Wheels
6.16.1. Solid rubber wheels
6.16.2. Pneumatic wheels
6.16.3. Cushion wheels
7. Maintenance
7.1. Maintenance intervals
7.2. Truck covers
7.2.1. Remove the pedal plate
7.2.2. Open the battery door
7.2.3. Remove the back cover
7.2.4. Remove the steering wheel cover
7.2.5. Remove the control panel
7.2.6. Remove the side control panel
7.2.7. Remove the front top side cover
7.2.8. Remove the air intake cover
7.2.9. Remove the interior panel
7.2.10. Remove the electric panel cover
7.2.11. Remove the step cover
7.2.12. Open the side door
7.2.13. Remove the right side cover
7.3. Cabin
7.3.1. Windshield washer tank
7.3.2. Examine the air filters of the heater
7.3.3. Replace the air filters of the air conditioner
7.3.4. Cabin seals
7.3.5. Air conditioner unit
7.4. Drive unit
7.4.1. Leakage check of the drive axle
7.4.2. Fastening of the drive axle
7.4.3. Lubricate the drive axle
7.4.4. Test the parking brake
7.4.5. Maintenance of the parking brake and the service brake
7.4.6. Test the regenerative brake
7.5. Hydraulics
7.5.1. Hydraulic system maintenance
7.5.2. Leakage check of the hydraulic system
7.5.3. Replace the hydraulic oil return filter
7.5.4. Replace the air breather filter
7.5.5. Cleaning of the hydraulic oil suction filter
7.5.6. Oil level
7.5.7. Operation of the hydraulics
7.5.8. Relief valves
7.5.9. Hydraulic oil change
7.5.10. Hoses and cylinders
7.5.11. Lubricate the pump axle splines
7.5.12. Lubricate the steering unit pump axle splines
7.5.13. Clean the oil tank
7.6. Mast
7.6.1. Mounting of the mast
7.6.2. Wear level of the mast rollers and contact surfaces
7.6.3. Chain tension
7.6.4. Chain lubrication
7.6.5. Chain wear measurement
7.6.6. Check the chain anchors and locking pins
7.6.7. Check the cylinders and piston rods
7.6.8. Lifting and lowering speed
7.6.9. Lubrication of the mast channel surfaces
7.6.10. Lifting test
7.6.11. Examine the welding in the mast for cracks
7.6.12. Mounting of any attachments and load-carrying components
7.6.13. Examine the welding of the cylinders and masts for cracking
7.6.14. Examine the rollers, pins and welds for cracking and damage
7.6.15. Apply grease to the lubrication points of the tilt cylinder
7.6.16. Additional mast attachments
7.7. Lifting carriage
7.7.1. Examine the welding in lifting carriage for cracks
7.7.2. Examine the load backrest for cracks
7.7.3. Fork inspection
7.7.4. Maintenance of the integrated sideshift carriage
7.7.5. Maintenance of the integrated fork positioner with sideshift
7.8. Rear axle
7.8.1. Lubricate the rear axle
7.8.2. Examine the operating condition of the bearings, check for looseness of the bearings
7.8.3. Examine the welds for cracks
7.8.4. Examine the mounting of the rear axle
7.8.5. Examine the condition of the rubber spring
7.9. Wheels
7.9.1. Damage and wear in the wheels
7.9.2. Before you replace the wheels
7.9.3. Front wheels
7.9.4. Rear wheels
7.10. Electrics
7.10.1. Test the functionality of sensors
7.10.2. Steering wheel functions
7.10.3. Horn
7.10.4. Electrical connections tightening torques
7.10.5. Cables and wiring
7.10.6. Examine and clear the alarm history
7.10.7. Insulation resistance test
7.10.8. Discharge the controllers
7.10.9. Emergency stop button functionality check
7.10.10. Key switch functionality check
7.10.11. Replace the filter of the air intake
7.11. Safety
7.11.1. Inspect the seat belt
7.12. General
7.12.1. How to clean the truck
7.12.2. Lubrication
7.12.3. Examine the welding in the truck frame for cracking
7.12.4. Examine the truck frame and the lifting carriage
7.12.5. Examine the overhead guard for deformation, cracking and damage
7.12.6. Examine the gas springs
7.12.7. Examine the condition and position of the identification plates
7.12.8. Examine the covers
7.12.9. Safety functions
7.12.10. Examine the fastening of the steering wheel
8. Battery maintenance
8.1. Lead-acid batteries
8.1.1. Safety with lead-acid batteries
8.1.2. General information
8.1.3. Requirements for battery charging areas
8.1.4. Charge the battery
8.1.5. Charge the battery with easy charging
8.1.6. Battery maintenance
8.1.7. Malfunctions
8.1.8. Acquire a new battery
8.1.9. Storage
8.2. Lithium-ion batteries
8.2.1. General information
8.2.2. Safety signs
8.2.3. Requirements for battery charging areas
8.2.4. Charge the battery
8.2.5. Battery maintenance
8.2.6. Acquire a new battery
8.2.7. Storage
8.3. Replace the battery
8.3.1. General safety instructions
8.3.2. Replace the battery with a lifting device
8.3.3. Remove the battery with the battery sideway exchange tools
8.3.4. Install a battery with the battery sideway exchange tools
9. Repair
9.1. Repair drive unit
9.1.1. Drive axle lifting and handling
9.1.2. Remove the drive axle
9.1.3. Remove the motor and cover of the drive axle
9.1.4. Replace the brake discs
9.1.5. Replace the hub and main seal
9.1.6. Install the motor and cover of the drive axle
9.1.7. Install the drive axle
9.1.8. Bleed the service brake
9.2. Repair rear axle
9.2.1. Remove the rear axle
9.3. Repair hydraulic system
9.3.1. Remove the pump motor
9.3.2. Disassemble the steering unit
9.3.3. Set the lifting pressure
9.3.4. Disassemble the coils
9.3.5. Disassemble the M1, M2 and M9 valves
9.3.6. Remove the clamp release valve
9.4. Repair mast
9.4.1. Using the mast bearing tool
9.4.2. Remove the mast
9.4.3. Disassemble the mast
9.4.4. Repair mast chains
9.4.5. Repair free lift cylinder
9.4.6. Repair side cylinders
9.4.7. Repair tilt cylinders
9.4.8. Replace the main rollers of the mast
9.5. Repair lifting carriage
9.5.1. Remove the lifting carriage
9.5.2. Adjust the rollers of the lifting carriage
9.5.3. Replace the guidance rollers of the lifting carriage
9.5.4. Replace the main rollers of the lifting carriage
9.5.5. Replace the load backrest
9.5.6. Repair integrated sideshift carriage
9.5.7. Repair hook-on sideshift carriage
9.5.8. Troubleshooting the fork positioner with sideshift
9.5.9. Repair integrated fork positioner with sideshift
9.5.10. Repair hook-on fork positioner with sideshift
9.6. Repair pedals
9.6.1. Remove the accelerator pedal
9.6.2. Remove the brake pedal
9.6.3. Disassemble the brake pedal
9.6.4. Remove the electronic friction lock pedal
9.6.5. Remove the dual pedal plate
9.6.6. Remove the dual pedal
9.6.7. Adjust the dual pedal
9.6.8. Adjust the direction sensor of the dual pedal
9.6.9. Adjust the dual pedal angle sensor
9.7. Repair steering wheel
9.7.1. Remove the steering wheel unit
9.7.2. Remove the steering wheel gas spring
9.7.3. Remove the lever unit
9.7.4. Remove the levers
9.8. Repair mini steering wheel
9.8.1. Disassemble the mini steering wheel
9.8.2. Disassemble the mini steering wheel holder
9.9. Repair armrest
9.9.1. Remove the armrest
9.9.2. Remove the armrest base plate
9.9.3. Replace the armrest padding
9.9.4. Fingertip control armrest
9.9.5. Dual joystick armrest
9.9.6. Calibrate the armrest
9.10. Repair operators seat
9.10.1. Remove the operators seat from the truck
9.10.2. Replace the seat padding
9.10.3. Replace the seat belt
9.10.4. Replace the seat switch
9.10.5. Replace the gas spring
9.10.6. Replace the seat armrest
9.10.7. Adjust the height of the seat armrest
9.10.8. Ground the operators seat
9.10.9. MSG65
9.10.10. MSG75
9.11. Repair electric system
9.11.1. Remove the electric panel
9.11.2. Remove the contactor panel
9.11.3. Replace the horn
9.12. Repair sensors and switches
9.12.1. Replace the rotation sensor
9.12.2. Replace the battery door sensor
9.12.3. Replace the side door sensor
9.12.4. Replace the rear axle sensor
9.12.5. Replace the tilt angle sensor
9.12.6. Replace the mast height sensor
9.12.7. Replace the sensors of the hydraulic valve unit with manual levers
9.12.8. Replace the manual lever switches
9.12.9. Replace the steering wheel sensor
9.12.10. Replace the mini steering wheel sensors
9.12.11. Replace the pressure sensor
9.12.12. Replace the parking brake sensor
9.12.13. Replace the horn switch
9.12.14. Replace the side control panel switches
9.12.15. Replace the autolight sensor
9.13. Repair cabin
9.13.1. Remove the cabin or the overhead guard
9.13.2. Operator door
9.13.3. Rear window
9.13.4. Manual holder
9.13.5. Windshield washer (cabin truck)
9.13.6. Sun guard
9.13.7. Reading light
9.13.8. Cabin fan
9.13.9. Heater
9.13.10. HVAC
9.14. Replace the gas spring of the battery door
10. TruckTool Diagnostics
10.1. Overview
10.2. Location of the service socket
11. Parameter descriptions
12. Service data
12.1. Special tightening torques
12.2. Tightening torques for standard bolts and nuts
12.3. Oils and lubricants
12.3.1. Lubrication points
12.3.2. Rear axle
12.3.3. Mast chains
12.3.4. Mast channels
12.3.5. Pump axle splines
12.4. Air conditioner
12.5. Troubleshooting
12.5.1. Troubleshooting case examples
12.5.2. Traction
12.5.3. Brakes
12.5.4. Hydraulics
12.5.5. Steering
12.5.6. Charging
13. Options
13.1. Options overview
13.2. Accessory rack
13.3. A4 paper holder
13.4. Computer holder
13.5. Scanner holder
13.6. Holder arm
13.7. Reverse drive handle with horn button
13.8. Loose mast components
13.9. Smart backup alarm
13.10. Rear combination and tail lights kit
13.10.1. Turn signals
13.10.2. Brake lights
13.10.3. Front lights
13.11. Amber strobe

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