Mitsubishi FBC25OBC Forklift Service Manual

Mitsubishi FBC25OBC Forklift Service Manual - Image 2

Mitsubishi FBC25OBC Forklift Service Manual - Image 3

Mitsubishi FBC25OBC Forklift Service Manual - Image 4

mitsubishi fbc25obc forklift service manual 2

Mitsubishi FBC25OBC Forklift Service Manual

$50.00

Type Of Manual: Service Manual
Number of Pages: 343
Size: 7.7MB
Format: PDF

Category: Mitsubishi Service Manual PDF

Model List:
- FBC25OBC Forklift

1. FOREWARD
1.1. How To Read This Manual
2. BRAKE SYSTEM
2.1. DESCRIPTION
2.1.1. Automatic adjusting device
2.1.2. Brake pedal and associated parts
2.1.3. Parking brake lever mechanism
2.2. DISASSEMBLY AND REASSEMBLY
2.2.1. Master cylinder
2.2.2. Wheel brakes
2.3. INSPECTION AND ADJUSTMENT
2.3.1. Automatic adjusting device
2.3.2. Manual adjustment
2.3.3. Bleeding air out of the brake fluid line
2.3.4. Brake test
3. GENERAL INFORMATION
3.1. MODEL VIEW
3.2. TRUCK MODELS COVERED
3.3. NAME PLATE AND SERIAL NUMBER LOCATIONS
3.4. SPECIFICATIONS
4. HYDRAULIC SYSTEM
4.1. DESCRIPTION
4.1.1. Hydraulic Tank
4.1.2. Hydraulic Pump
4.1.3. Control Valve
4.1.4. Tilt Cylinders
4.2. REMOVAL AND INSTALLATION
4.2.1. Hydraulic Pump
4.2.2. Control Valve
4.2.3. Tilt Cylinders
4.3. DISASSEMBLY AND REASSEMBLY
4.3.1. Hydraulic Pump
4.3.2. Control Valve (MC)
4.3.3. Tilt Cylinders
4.4. INSPECTION AND ADJUSTMENT
4.4.1. Hydraulic Tank
4.4.2. Hydraulic Pump
4.4.3. Control Valve
5. INSPECTION GUIDE
5.1. PREFACE TO INSPECTION GUIDE
5.2. INSPECTION GUIDE
6. MAST AND FORKS
6.1. MAST MODEL DESIGNATION
6.1.1. Mast Model Number Location
6.1.2. Mast Model Number Coding
6.1.3. Mast Types
6.2. DESCRIPTION
6.2.1. Dual-stage panoramic mast
6.2.2. Dual-stage full free-lift panoramic mast
6.2.3. Triple-stage full free-lift panoramic mast
6.2.4. Hook device
6.2.5. Lift Cylinders
6.2.6. Flow regulator valve
6.2.7. Down safety valves
6.3. REMOVAL AND INSTALLATION
6.3.1. Mast and lift bracket assembly
6.3.2. Lift cylinders
6.3.3. Element mast piping
6.4. DISASSEMBLY AND REASSEMBLY
6.4.1. Dual-stage panoramic mast
6.4.2. Dual-stage full free-lift panoramic mast
6.4.3. Triple-stage full free-lift panoramic mast
6.4.4. Lift Cylinders
6.4.5. Flow regulator valve
6.4.6. Down safety valves
6.5. INSPECTION AND ADJUSTMENT
6.5.1. Lift chains, chain wheels and chain wheel supports
6.5.2. Lift chain tension
6.5.3. Longitudinal clearance adjustment on mast and lift bracket rollers
6.5.4. Mast strip adjustment
6.5.5. Lateral clearance adjustment on outer mast and inner mast rollers
6.5.6. Lateral clearance adjustment on outer mast and middle mast rollers
6.5.7. Lateral clearance adjustment on middle mast and inner mast rollers
6.5.8. Lateral clearance adjustment on lift bracket rollers
6.5.9. Mast cushion deflection inspection
6.5.10. Lift cylinder stroke adjustment
6.5.11. Hook device inspection
6.5.12. Pulley hose inspection
6.5.13. Flow regulator valve adjustment
6.5.14. Testing
7. REAR AXLE
7.1. DESCRIPTION
7.2. REMOVAL AND INSTALLATION
7.2.1. Rear Tires and Rear Axle
7.3. DISASSEMBLY AND REASSEMBLY
7.3.1. Disassembly
7.3.2. Reassembly
7.4. INSPECTION AND ADJUSTMENT
7.4.1. Toe-in adjustment
7.4.2. Minimum Turning Radius Adjustment
8. REDUCTION DIFFERENTIAL AND FRONT AXLE
8.1. DESCRIPTION
8.2. REMOVAL AND INSTALLATION
8.2.1. Front tires
8.3. DISASSEMBLY AND REASSEMBLY
8.3.1. Front axle
8.3.2. Reduction gear and differential
8.4. INSPECTION AND ADJUSTMENT
8.4.1. Side bearing preload and adjustment
8.4.2. Reduction gear backlash adjustment
8.4.3. Face runout measurement
8.4.4. Tooth contact adjustment
8.5. TRANSFER CASE
8.5.1. Disassembly
8.5.2. Reassembly
9. SERVICE DATA
9.1. MAINTENANCE STANDARDS
9.1.1. Reduction differential and front axle
9.1.2. Rear axle
9.1.3. Brake system
9.1.4. Steering system
9.1.5. Hydraulic system
9.1.6. Masts and forks
9.2. TIGHTENING TORQUE CHART
9.3. MAINTENANCE SCHEDULE
9.4. PERIODICAL REPLACEMENT PARTS
9.5. LUBRICATION CHART
9.6. FUEL AND LUBRICANT SPECIFICATIONS
9.7. RECOMMENDED BRANDS OF LUBRICANTS
9.8. WEIGHT OF MAJOR COMPONENTS
9.9. SPECIAL SERVICE TOOLS
10. STEERING SYSTEM
10.1. DESCRIPTION
10.1.1. Removal of steering pump/motor removal assembly
10.1.2. Steer pump disassembly
10.1.3. Steer pump reassembly
10.2. REMOVAL AND INSTALLATION
10.2.1. Steering gear and power cylinder
10.3. DISASSEMBLY AND REASSEMBLY
10.3.1. Steering gear
10.3.2. Power cylinder
10.4. INSPECTION AND ADJUSTMENT
10.4.1. Steering wheel free play
10.4.2. Steering effort
10.5. HYDRAULIC PRESSURE MEASUREMENT AND ADJUSTMENT
11. TROUBLESHOOTING
11.1. TRANSFER GEAR, REDUCTION DIFFERENTIAL AND FRONT AXLE
11.2. REAR AXLE
11.3. BRAKE SYSTEM
11.4. STEERING SYSTEM
11.5. HYDRAULIC SYSTEM
11.6. MASTS AND FORKS
12. COMPONENT ASSEMBLY AND ADJUSTMENT
12.1. Component Location
12.2. Dashboard and Seat
12.3. Console Box Assembly
12.4. Combination Meter Assembly
12.5. Controller Compartment
12.5.1. Contractors-RB (Regenerative Braking), 1A, FW (Field Weakening), PS (Power Steering) and Pump (Hydraulic)
12.5.2. Contractor – FR (Forward/Reverse)
12.5.3. EV100 LX Traction Logic Card and Hydraulic Logic Card Checks and Adjustments
12.5.4. EV100 LX Handset
12.5.5. Brake Bracket
12.5.6. Pump Contactor Hydraulic Control Adjustment-Lift Switch
12.5.7. SCR Hydraulic Control Adjustment
13. DESCRIPTION OF LIFT TRUCK CIRCUIT
13.1. EV100 LX Control Panel
13.1.1. Control Panel Layout
13.1.2. Component Identification
13.1.3. Test Points
13.1.4. Logic Switch Sequence
13.1.5. Power Circuit Sequence
13.1.6. Traction Control Logic Flow Chart
13.1.7. Control Features
13.2. Console
13.2.1. Hour Meter
13.2.2. Fault Indicator
13.2.3. Battery Discharge Indicator (BDI)
13.2.4. Brake Fluid Level Warning Circuit
13.2.5. Motor Protection Circuits
13.3. Horn Circuit
13.4. Options
13.4.1. Optional Backup Alarm
13.4.2. Optional Warning Light or Strobe
13.4.3. Optional Head Lamps, Working Lamps Tail Lamps-36/48V
13.4.4. Optional Head Lamps, Working Lamps Tail Lamps-12V
13.4.5. Optional Stop Light-36/48V
13.4.6. Optional Stop Light-12V
14. FOREWARD
15. GENERAL INFORMATION
15.1. Truck Models
15.2. External View
15.3. Name Plate and Serial Number Locations
15.4. Technical Data
15.4.1. General
15.4.2. Basic Dimensions
15.4.3. Performance
15.4.4. Control
15.4.5. Power Line
15.4.6. Axles Wheels
15.4.7. Brake System
15.4.8. Steering System
15.4.9. Steering Motor
15.4.10. Steering Pump
15.4.11. Power Steering
15.4.12. Hydraulic System
15.4.13. Hydraulic Pressure for Attachment
15.4.14. Battery
15.5. Description
15.6. Storage
15.7. Maintenance
15.7.1. Motor Maintenance Schedule
15.7.2. Bearings
15.7.3. Insulation
15.7.4. Brushes
15.7.5. Commutator
15.7.6. Mechanical
15.7.7. Cleaning
15.8. Traction, Pump and Steering Disassembly
15.8.1. Failure
15.8.2. Renewal Parts
15.9. Unsatisfactory Brush Performance
15.9.1. Table 1 Primary Sources of Unsatisfactory Brush Performance
15.9.2. Table 2 Indications Appearing at Brushes
15.9.3. Table 3 Indications Appearing as Heat
15.9.4. Table 4 Indications Appearing at Commutator Surface
15.10. Commutator Check Chart
15.10.1. Satisfactory Commutator Surfaces
15.10.2. Poor Commutator Surfaces
15.10.3. Causes of Poor Commutator Conditions
16. RECOMMENDED REASSEMBLY PRACTICE
17. TESTING EQUIPMENT RECOMMENDATIONS
18. TROUBLESHOOTING
18.1. Introduction
18.2. Tools and Required Equipment
18.3. Frame Resistance Check
18.4. SCR Gerneral Maintenance
18.5. Status Code Descriptions
18.6. Status Code Instructions
18.7. Component Check
18.7.1. Control Card
18.7.2. Capacitor 1C
18.7.3. Contractors F/R (Forward/Reverse), 1A, PS (Power Steering), FW (Field Weakening), RB (Regenerative Braking) and Pump (Hydraulic
18.7.4. Potentiometer in Accelerator
18.7.5. SCRs (1 REC, REC and REC)
18.7.6. Rectifiers (3 REC, 4 REC, and Diode Blocks)
18.7.7. Thermal Protector (TP)
18.7.8. Filter Block (23 FIL, etc.)
18.7.9. Choke and Reactor T3-T4
18.8. Replacement of EV100 LX Components
18.8.1. Stud Semiconductors
18.8.2. Module Semiconductors
18.8.3. Capacitor
18.8.4. REC, 23 REC, and 25 REC
18.8.5. Filter Mounting Block
18.9. Secondary Troubleshooting
18.9.1. Table 1 Failures that Cause Reduced or No Motor Torque with SCR Control
18.9.2. Table 2 Failures that Cause Full or No Motor Torque with SCR Control
18.9.3. Table 3 Misoperation of Other Features
18.10. EV100 LX Hygraulic Pump Control Troubleshooting
18.10.1. Table 4 Failures that Cause Reduced or No Motor Torque with SCR Control
18.10.2. Table 5 Failures that Cause No Motor Torque with SCR Control
18.11. Power Cable Connections
18.12. Traction Control Card Wire Harness Connections
18.12.1. Panel Connector
18.12.2. TB Connections
18.12.3. A B Plugs
18.13. Hydraulic Pump SCR Control Card Wire Harness Connections
18.13.1. Panel Connector
18.13.2. TB Connections
18.13.3. A B Plugs
18.14. Traction Control Components
18.14.1. Potentiometer (for Accelerator)
18.14.2. Acclerator Switch
18.14.3. Brake Switch
18.15. Pump Driver
18.16. Hydraulic Control Components
18.16.1. Hydraulic Control Switch (Standard)
18.16.2. Hydraulic Control Switch (Tilt/Auxiliary)
18.16.3. Hydraulic Control Switch (Lift)
18.16.4. Potentiometer (for SCR Hydraulic Control)
18.17. Options
18.17.1. Relay for 12-Volt Stop Lamp
18.17.2. Volt DC/Dc Convertor
18.18. Console
18.19. EV100LX Electrical Schematic – Trucks Equipped with Contactor Hydraulics
18.20. EV100LX Electrical Schematic – Trucks Equipped with Optional SCR Hyrdaulics

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