Mitsubishi FBC25LN Forklift Trucks Service Repair Manual SN A4BC3-30200-UP by 1637912

Service Manual Chassis & Mast FBC15N, FBC18N, FBC18LN A4BC1-10200-up A4BC1-20200-up A4BC1-30200-up

FBC20N, FBC25N A4BC2-10200-up A4BC2-20200-up

FBC25EN, FBC25LN, FBC30N A4BC3-20200-up A4BC3-30200-up A4BC3-40200-up

FBC30LN A4BC4-10200-up

99759-7B110

TABLE OF CONTENTS 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 Front Axle Description ................................................................................................................................... 2.1 General Information ................................................................................................................. 2.1 Removal ....................................................................................................................................... Front Wheels ............................................................................................................................ Method 1.............................................................................................................................. Method 2.............................................................................................................................. Method 3..............................................................................................................................

2.2 2.2 2.3 2.3 2.3

Installation .................................................................................................................................... 2.4 Disassembly ................................................................................................................................. 2.5 Removing Front Wheel Hub ..................................................................................................... 2.6 Inspection after Disassembly ....................................................................................................... 2.7 Reassembly.................................................................................................................................. Axle Housing ............................................................................................................................ Front Wheel Hub ...................................................................................................................... Hub Bearing Preload................................................................................................................ Installation and Setting Preload...........................................................................................

2.8 2.8 2.8 2.10 2.10

Reduction Differential Description ................................................................................................................................... 2.11 Disassembly ................................................................................................................................. 2.12 Inspection after Disassembly ....................................................................................................... 2.13 Reduction Gear ........................................................................................................................ 2.13 Differential ................................................................................................................................ 2.13 Reassembly.................................................................................................................................. 2.14 Inspection and Adjustment........................................................................................................... Side Bearing Preload ............................................................................................................... Reduction Gear Backlash ........................................................................................................ Reduction Gear Face Runout .................................................................................................. Tooth Contact ........................................................................................................................... Tooth Contact Adjustment ........................................................................................................ Transfer Assembly.................................................................................................................... Front Axle ................................................................................................................................. 99759-7B110

2.16 2.16 2.16 2.17 2.17 2.18 2.21 2.23 i

TABLE OF CONTENTS Chapter 3: Transfer Assembly Description ................................................................................................................................... 3.1 Disassembly ................................................................................................................................. 3.2 Disassembly Sequence................................................................................................................ 3.2 Inspection after Disassembly ....................................................................................................... 3.4 Reassembly.................................................................................................................................. 3.5

Chapter 4: Rear Axle Description ................................................................................................................................... 4.1 Rear Wheels................................................................................................................................. 4.2 Removal ................................................................................................................................... 4.2 Steering Cylinder.......................................................................................................................... 4.3 Installation ................................................................................................................................ 4.4 Rear Axle ..................................................................................................................................... Removal ................................................................................................................................... Installation ................................................................................................................................ Disassembly ............................................................................................................................. Inspection after Disassembly ................................................................................................... Reassembly..............................................................................................................................

4.7 4.7 4.8 4.9 4.11 4.12

Inspection and Adjustment........................................................................................................... 4.17 Minimum Turning Radius Adjustment....................................................................................... 4.17

Chapter 5: Brake System Description ................................................................................................................................... 5.1 Automatic Adjusting Device ..................................................................................................... 5.1 General Information ................................................................................................................. 5.1 Master Cylinder Disassembly ............................................................................................................................. 5.2 Inspection after Disassembly ................................................................................................... 5.3 Reassembly.............................................................................................................................. 5.3 Service Brakes Disassembly (FBC15N - FBC18LN) ......................................................................................................... (FBC20N - FBC30LN) ......................................................................................................... Inspection after Disassembly ................................................................................................... Reassembly (FBC15N - FBC18LN) ......................................................................................................... (FBC20N - FBC30LN) ......................................................................................................... Wheel Cylinders Disassembly ............................................................................................................................. Inspection after Disassembly ................................................................................................... Reassembly.............................................................................................................................. Inspection and Adjustment.......................................................................................................

5.4 5.5 5.7 5.8 5.9 5.12 5.13 5.13 5.14

99759-7B110

TABLE OF CONTENTS Chapter 6: Steering System Steering System Description ................................................................................................................................... Steering System ...................................................................................................................... Oil Flow Sequence .............................................................................................................. General Information.............................................................................................................

6.1 6.1 6.1 6.1

Steering Gear Steering Wheel Removal ................................................................................................................................... 6.2 Installation ................................................................................................................................ 6.2 Steering Gear............................................................................................................................... 6.3 Inspection after Removal ............................................................................................................. 6.4 Disassembly ................................................................................................................................. Working Rules and Tips ........................................................................................................... Suggestions ............................................................................................................................. Inspection after Disassembly ...................................................................................................

6.5 6.6 6.6 6.6

Reassembly.................................................................................................................................. 6.7 Steer Pump Removal ....................................................................................................................................... 6.8 Installation .................................................................................................................................... 6.9 Disassembly ................................................................................................................................. Sequence ................................................................................................................................. Working Rules and Tips ........................................................................................................... Suggestions ............................................................................................................................. Inspection after Disassembly ...................................................................................................

6.10 6.10 6.11 6.11 6.13

Reassembly.................................................................................................................................. Sequence ................................................................................................................................. Suggestions ............................................................................................................................. Inspection after Reassembly....................................................................................................

6.14 6.14 6.15 6.17

Chapter 7: Hydraulic System Hydraulic System Description ................................................................................................................................... Schematics .............................................................................................................................. Hydraulic Tank.......................................................................................................................... Hydraulic Pump ....................................................................................................................... Control Valve ............................................................................................................................ Lift and Tilt Cylinders................................................................................................................ Down Safety Valve ...................................................................................................................

7.1 7.1 7.5 7.6 7.8 7.9 7.10

Removal and Installation Warning................................................................................................ 7.11

99759-7B110

iii

TABLE OF CONTENTS Hydraulic Pump Removal ....................................................................................................................................... 7.12 Installation .................................................................................................................................... 7.13 Disassembly ................................................................................................................................. 7.14 Working Rules and Tips ........................................................................................................... 7.14 Suggestions ............................................................................................................................. 7.16 Inspection after Disassembly ....................................................................................................... Body ......................................................................................................................................... Mounting Flange Face ............................................................................................................. Bushes and Balance Plate....................................................................................................... Gears .......................................................................................................................................

7.18 7.18 7.18 7.18 7.18

Reassembly.................................................................................................................................. 7.19 Inspection after Reassembly........................................................................................................ 7.23 Control Valve Removal ....................................................................................................................................... 7.24 Installation .................................................................................................................................... 7.25 Disassembly ................................................................................................................................. 7.26 Suggestions ................................................................................................................................. 7.27 Reassembly.................................................................................................................................. 7.27 Lift and Tilt Cylinders Removal Lift Cylinders ............................................................................................................................ 7.28 Tilt Cylinders ............................................................................................................................ 7.31 Disassembly Lift Cylinders ............................................................................................................................ 7.33 Tilt Cylinders ............................................................................................................................ 7.34 Inspection after Disassembly ................................................................................................... 7.35 Precautions for Reassembly ........................................................................................................ 7.35 Inspection and Adjustment Hydraulic Tank.............................................................................................................................. 7.36 Control Valve ................................................................................................................................ 7.37 Lift and Tilt Cylinders.................................................................................................................... 7.40 Adjusting Method ..................................................................................................................... 7.41 Testing ...................................................................................................................................... 7.42

Chapter 8: Mast and Forks Description ................................................................................................................................... 8.1 Removal and Installation.............................................................................................................. 8.2

99759-7B110

TABLE OF CONTENTS Disassembly ................................................................................................................................ 8.4 Inspection after Disassembly ....................................................................................................... 8.6 Reassembly.................................................................................................................................. 8.7 Inspection and Adjustment........................................................................................................... Forks ........................................................................................................................................ Chain Tension Adjustment ....................................................................................................... Clearance Adjustment on Lift Bracket...................................................................................... Mast Clearance Adjustment ..................................................................................................... Main Roller Shim Replacement ............................................................................................... Mast Strip Adjustment.............................................................................................................. Tilt Angle Adjustment ............................................................................................................... Lift Cylinder Stroke Adjustment................................................................................................ Bleeding Lift Cylinders .............................................................................................................

8.8 8.8 8.9 8.10 8.13 8.15 8.15 8.16 8.17 8.17

Service Data ................................................................................................................................ 8.18 Troubleshooting ............................................................................................................................ 8.20

Chapter 9: Troubleshooting Front Axle and Reduction Differential .......................................................................................... 9.1 Brake System ............................................................................................................................... 9.2 Steering System........................................................................................................................... 9.4 Hydraulic System ......................................................................................................................... 9.6 Rear Axle ..................................................................................................................................... 9.8 Mast and Forks ............................................................................................................................ 9.9

Chapter 10: Maintenance Service Data Maintenance Service Data........................................................................................................... Front Axle and Reduction Differential ...................................................................................... Transfer Case ........................................................................................................................... Rear Axle ................................................................................................................................. Brake System ........................................................................................................................... Steering System,...................................................................................................................... Hydraulic System ..................................................................................................................... Mast and Forks (Simplex Mast) ............................................................................................... Mast and Forks ........................................................................................................................

10.1 10.1 10.3 10.4 10.6 10.11 10.13 10.16 10.17

Tightening Torques for Standard Bolts and Nuts ......................................................................... Fine Thread—With Spring Washer .......................................................................................... Fine Thread—Without Spring Washer ..................................................................................... Coarse Thread—With Spring Washer...................................................................................... Coarse Thread—With Spring Washer......................................................................................

10.18 10.18 10.18 10.18 10.18

Tightening Torques for Standard Bolts and Nuts with Standard Threads .................................... 10.19 Coarse Thread—Inches ........................................................................................................... 10.19 99759-7B110

TABLE OF CONTENTS Tightening Torques for Taperlock Studs ....................................................................................... 10.19 Coarse Threadâ&#x20AC;&#x201D;Inches ........................................................................................................... 10.19 Maintenance Chart....................................................................................................................... 10.20 Planned Replacement Parts ........................................................................................................ 10.26 Lubrication Information................................................................................................................. Chart ........................................................................................................................................ Fuel and Lubricant Specifications ............................................................................................ Recommended Brands of Lubricants.......................................................................................

10.27 10.27 10.28 10.28

Weight of Major Components (Approximate) ............................................................................... 10.29 Special Service Tools ................................................................................................................... 10.30 Special Tool Illustrations........................................................................................................... 10.31 Inspection Guide .......................................................................................................................... 10.34

99759-7B110

NOTES

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GENERAL INFORMATION

Scope This service manual deals with all components or systems of the Mitsubishi forklift trucks, except for the electrical system, which is covered in a separate manual.

8609141A

Truck Models Covered This service manual furnishes service and maintenance information for the following trucks.

Truck Model

Serial Number

FBC15N, FBC18N, FBC18LN

A4BC1-10200-up A4BC1-20200-up A4BC1-30200-up A4BC2-10200-up A4BC2-20200-up A4BC3-20200-up A4BC3-30200-up A4BC3-40200-up A4BC4-10200-up

FBC20N, FBC25N FBC25EN, FBC25LN, FBC30N

FBC30LN

99759-7B110

1.1

GENERAL INFORMATION

Nameplate and Serial Number Locations

Mast serial number

Chassis serial number Power steering motor serial number

Traction motor serial number Hydraulic motor serial number

Nameplate 8609141

1.2

99759-7B110

GENERAL INFORMATION

Dimensions

8609142

8609143

99759-7B110

1.3

GENERAL INFORMATION

Dimensions Chart Ref#

Truck Model

FBC15N, FBC18N

FBC18LN

FBC20N, FBC25N

FBC25EN

FBC25LN

FBC30N

FBC30LN

3320 (130)

3340 (131)

3310 (130)

3045 (119)

Maximum Lift

Free Lift

115 (4.5)

130 (5.1)

135 (5.3)

Maximum Fork Spacing (outside to outside)

818 (32.0)

Fork Length

1070 (42)

Tilt Angle (forward/backward)

5°/6°

Overall Length

3050 (120)

3125 (123)

3155 (124)

3255 (128)

3325 (131)

Overall Width (outside of tires)

945 (37)

970 (38)

1055 (41.5)

1103 (43.5)

Overall Height (to top of mast, lowered)

2105 (83)

2110 (83.5)

Overall Height (to top of overhead guard)

2180 (86)

2210 (87)

Overall Height (to top of mast, extended)

4570 (180)

4550 (179)

Tread (front)

793 (31)

818 (32)

875 (34.5)

900 (35.5)

Tread (rear)

826 (32.5)

900 (35.5)

Wheelbase

1170 (46)

1280 (50.5)

1380 (54.5)

Front Overhang

376 (14.8)

394 (15.5)

406 (16)

Rear Overhang

434 (17.2)

509 (20.2)

411 (16)

469 (18.5)

Underclearance (at center of wheelbase)

118 (4.6)

124 (4.9)

Unit: mm (in.)

1.4

99759-7B110

GENERAL INFORMATION

General Information (Standard Models) Truck Model Units

FBC15N

FBC18N

FBC18LN

meters

3.3

2095

2335

2595

2685

2870

2695

2865

3335

3530

(4620)

(5140)

(5720)

(5920)

(6330)

(5940)

(6320)

(7353)

(7770)

3295

3535

3795

4285

4420

4495

4665

5135

5330

(7270)

(7790)

(8370)

(9470)

(9880)

(9940)

(10320)

(11353)

(11770)

Standard Controller Standard Simplex Mast Size Battery

(standard axle)

With Max.

kg (lb)

Work Performance

Battery

Traveling Performance

FBC30N

FBC30LN

kg/mm

1350/600 1600/600

Load Center

(lb/in.)

(3000/24) (3500/24) (4000/24) (4000/24) (5000/24) (5500/24) (5000/24) (6000/24) (6500/24)

Maximum Fork Height Lift Speed (Rated Load)

mm (in.)

1800/600 1800/600

33235 (131)

2275/600 2275/600 2500/600

3340 (131)

2725/600 2950/600

3315 (131) 3345 (131)

36V

m/sec.

.38 (75)

.36 (71)

.34 (67)

.32 (63)

.28 (55)

.25 (49)

.23 (45)

48V

(fph)

.53 (104)

.49 (96)

.47 (93)

.45 (89)

.38 (75)

.36 (71)

.31 (61)

Lowering Speed (rated load)

Free Lift

.50 (98) degrees

5° / 6°

mm (in.)

Travel Speed

36V

km/h

(Without Load)

48V

(mph)

115 (4.5) 18 (11.2)

130 (5.1)

17.3 (10.8)

17.4 (10.8)

135 (5.3) 17.0 (10.6)

17.1 (10.6)

18.2 (11.3)

Minimum Turning

1790

1840

1990

2045

Radius

(in.)

(70.5)

(72.5)

(78.5)

(80.5)

36V

60min.

Output

48V

HP(kW)

Transfer

Type

Gear

Ratio

Reduction

Type

Gear

Ratio

Traction Motor

Power Train

FBC25EN FBC25LN

Rated Capacity/

Tilt Angle (forward/backward)

Differential

8.3 (6.2) 9.2 (6.8)

12.1 (9.0)

13.7 (10.2)

14.2 (10.6)

17.2 (12.8)

Spur 3.538

3.067 Bevel

4.571

Axle Housing

99759-7B110

FBC25N

MHI SX Controller

Without Service Weight

FBC20N

5.0 Banjo

Gear Type/

Gears

Straight Bevel/2

Number

Pinions

Straight Bevel/2

1.5

GENERAL INFORMATION Truck Model

Power Steering System

Units

FBC15N

FBC18N FBC18LN FBC20N

Type

FBC25N FBC25EN FBC25LN FBC30N FBC30LN

Dynamic Load Sense Inside

83°

54°

56°

Degrees

Turning Angle Outside Steering Wheel Diameter

mm (in.) kgf/cm2 (psi) [kPa]

Cylinder Minimum Test Pressure

328 (13) 107 (1522) [10,500]

Type

163 (2320) [16,000]

Self-Adjusting Duo-Servo

Inside Drum mm (in.) Diameter

254

+0 0.13(10.00 +0 0.0051)

Service Brake Brake System

Lining Thickness

mm (in.)

Master mm (in.) Cylinder ID Wheel Cylinder ID

Traveling System

Park Brake

Lever Operating Effort

6 (0.24) 22.22 (0.8748)

22.22 (0.8748)

Type

1.6

4.87 (0.19)

28.58 (1.1252)

Mechanical, Mounted on Front Wheels kgf (lbf) [N]

25 to 30 (55 to 66) [245 to 295]

Front Wheels

Fixed Type

Rear Wheels

Center Pivot Type

Mounting

Wheel Alignment

Oscillation Angle Camber

3° Degrees 1°

99759-7B110

GENERAL INFORMATION Truck Model Units

FBC15N

FBC18N FBC18LN FBC20N

Type Hydraulic Pump

Gear

Make Model

Casappa KP20â&#x20AC;&#x201C;24.5

Parker Hydraulics, Inc. 25R029

25 (1.526)

29 (1.77)

Displacement cc (cu in.)

Hydraulic System

Make Control Valve

Interval Valve

Husco International

Model

9510 Sectional Valve

Relief

kgf /cm2

Pressure

(psi) [kPa]

Flow Regulator

AUX

158 (2250) [15513]

Lift Tilt

185 (2630) [18133}

Type

Variable

Regulated liter Flow Rate (cu.in.) / min

Lift Cylinders

FBC25N FBC25EN FBC25LN FBC30N FBC30LN

45 (2746)

60 (3661)

68 (4150)

45 (1.77)

50 (1.97)

55 (2.17)

63 (2.48)

70 (2.75)

80 (3.15)

8 (4.8)

24 (6.3)

30 (7.9)

mm (in.) Tilt Cylinders

Hydraulic Tank Capacity liter (Approx)

1 (US gal.)

Mast and Forks

Mast Mast Dimensions (Flange Inside Width x THK x WEB THK) Main Rollers

Roller type CL 100 x 42 x 11 (3.94 x 0.59 x 0.47)

Outer mm (in.)

100 x 60 x 10 (3.94 x 0.67 x 0.47)

Inner Type

Side Rollers

mm (in.)

115 x 30 (3.94 x 1.18)

42 x 36 (1.65 x 1.42)

1070x100x35 (36x4x1.3) 240 / 818 (9.4/32)

BL634

BL834

1070 x100 x40 (42 x 3.9 x 1.6)

1070 x 125 x 45 (42 x 5 x 1.8)

240 / 920

285 / 960

min/max

Voltage

36/48

Amp Hours (6 hr. rate)

Battery

115 x 30 (4.53 x 1.58)

BL534

Forks (Lgth x Wdth x Thk)

Compartment

Height-Center

Dimensions

Height-Edges

99759-7B110

#6309 Ball Bearing

Lubricating type needle roller bearing

Lift Chains

Weight (Min/Max)

100 x 27 (3.94 x 1.18)

Type Diameter x Width

115 x 45 x 11 (4.53 x 0.83 x 0.51)

#6308 Ball Bearing

Diameter x Width

Fork Spacing (out to out)

115 x 46 x 12 4.53 x 0.79 x 0.51)

36/48

36V

900

1400

48V

700

1100

36/48

598 (23.6) 589 (23.2)

mm (in.)

Length

705 (27.8)

Width

903 (35.5) kg (lb)

750/1200 (1650/2650)

772 (30.4)

872 (34.3) 1000 (39.4)

1000/1600 1315/1600 (2200/3550) (2900/3550)

1400/1800 (3100/4000)

1.7

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