Mitsubishi FBC30, FBC35 Forklift Service Manual
Mitsubishi FBC30, FBC35 Forklift Service Manual - Image 2
Mitsubishi FBC30, FBC35 Forklift Service Manual - Image 3
Mitsubishi FBC30, FBC35 Forklift Service Manual - Image 4
Mitsubishi FBC30, FBC35 Forklift Service Manual - Image 5

Mitsubishi FBC30, FBC35 Forklift Service Manual

$50.00

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

Product details

  • Model List:

    • FBC30, FBC35
  • 1. FOREWARD
  • 1.1. How To Read This Manual
  • 2. GENERAL INFORMATION
  • 2.1. MODEL VIEW
  • 2.2. TRUCK MODELS COVERED
  • 2.3. NAME PLATE AND SERIAL NUMBER LOCATIONS
  • 2.4. SPECIFICATIONS
  • 3. BRAKE SYSTEM
  • 3.1. DESCRIPTION
  • 3.1.1. Automatic adjusting device
  • 3.1.2. Brake pedal and associated parts
  • 3.1.3. Parking brake lever mechanism
  • 3.2. DISASSEMBLY AND REASSEMBLY
  • 3.2.1. Master cylinder
  • 3.2.2. Wheel brakes
  • 3.3. INSPECTION AND ADJUSTMENT
  • 3.3.1. Automatic adjusting device
  • 3.3.2. Manual adjustment
  • 3.3.3. Bleeding air out of the brake fluid line
  • 3.3.4. Brake test
  • 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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