Mitsubishi Forklift FB14N2T, FB16(C)N2(T), FB18(C)N2(T), FB20N2(T) service manual

Description Mitsubishi Forklift FB14N2T, FB16(C)N2(T), FB18(C)N2(T), FB20N2(T) service manual

Mitsubishi Forklift truck FB14N2T, FB16(C)N2(T), FB18(C)N2(T), FB20N2(T) pdf service repair manual + operation & maintenance manual

Model, serial numbers covered:
FB14N2T EFB21B 00011 → EFB21B 49999
FB16CN2T EFB22B 00011 → EFB22B 49999
FB18CN2T EFB22B 50011 → EFB22B 99999
FB16N2T EFB23B 00011 → EFB23B 49999
FB18N2T EFB23B 50011 → EFB23B 99999
FB20N2T EFB24B 00011 → EFB24B 49999
FB16CN2 EFB27B 00011 → EFB27B 49999
FB18CN2 EFB27B 50011 → EFB27B 99999
FB16N2 EFB28B 00011 → EFB28B 49999
FB18N2 EFB28B 50011 → EFB28B 99999
FB20N2 EFB29B 00011 → EFB29B 49999

Technical data, specifications, troubleshooting, maintenance, adjusting, assembly, disassembly, removal, installation instructions, electrical diagrams, hydraulic schematics and other information

SERVICE MANUAL CONTENT:
FOREWORD

ABOUT THIS MANUAL
2.1 Safety-related signs
2.2 Safety symbols
2.3 Units
2.4 Interactive links

SAFETY INSTRUCTIONS
3.1 General safety instructions
3.2 Safety instructions for maintenance and repair
3.3 Safety requirements for industrial trucks
3.4 Repairs and structural modifications
3.5 Seat belt
3.6 Wheels
3.7 LOCKOUT and TAGOUT
3.8 Service area safety
3.9 Personal safety
3.10 Work safety
3.11 Operating temperature

GENERAL INFORMATION
4.1 Truck models covered by this manual
4.2 Identification plates and decals
4.3 Special tools
4.4 Operating position
4.5 Operating direction
4.6 Transportation
4.6.1 Lifting the truck
4.6.1.1 Jack points
4.6.1.2 Hoist points
4.6.2 Towing connection
4.6.3 Towing the truck
4.6.4 Brake release
4.7 Assembly and commissioning
4.8 Order spare parts

MAIN COMPONENTS
5.1 Truck covers
5.2 Overhead guard
5.3 Cabin
5.3.1 Manual holder
5.3.2 Emergency exits (cabin truck)
5.3.2.1 Open the operator door
5.3.2.2 Open the rear window
5.4 Operator's seat
5.5 Operating devices
5.5.1 Steering wheel
5.5.2 Mini steering wheel
5.5.3 Armrest
5.5.3.1 Armrest with fingertip controls
5.5.3.2 Ergologic armrest
5.5.3.3 Dual joystick armrest
5.5.3.4 Control functions
5.5.4 Manual levers
5.5.5 Side control panel
5.6 Display panel
5.6.1 Emergency stop button
5.6.2 Key switch
5.6.3 Display control buttons
5.6.4 Truck display
5.6.4.1 Main view of the truck display
5.6.4.2 Menu hierarchy
5.7 Pedals
5.7.1 Accelerator pedal
5.7.2 Brake pedal
5.7.3 Electronic friction lock pedal (option)
5.7.4 Dual pedal
5.7.5 Pedal functionalities
5.8 Electric system
5.8.1 Electrical operation
5.8.1.1 Overview
5.8.1.2 How to use the schematic diagram
5.8.1.3 Power source
5.8.1.4 Safety circuit (emergency stop button)
5.8.1.5 Key switch
5.8.1.6 Traction
5.8.2 Controllers
5.8.3 Vehicle master controller
5.8.3.1 Vehicle master controller connectors
5.8.3.1.1 Vehicle Master Controller, Connector A
5.8.3.1.2 Vehicle Master Controller, Connector B
5.8.4 Traction controller
5.8.4.1 Traction controller connectors
5.8.4.1.1 CNA external connector
5.8.4.1.2 Description of the power connections
5.8.5 Pump controller
5.8.5.1 Pump controller connectors
5.8.5.1.1 CNA external connector
5.8.5.1.2 Description of the power connections
5.8.6 Sensors and switches
5.8.6.1 Horn switch
5.8.7 Option panel
5.8.8 Fuses
5.8.8.1 Location of the fuses in the electric panel
5.8.8.2 Location of the fuses for optional equipment
5.8.9 Relays and contactors
5.8.9.1 Main relays and contactors
5.8.9.2 Option panel relays
5.8.10 DC/DC converter
5.8.11 Armrest connector
5.8.12 Display connector
5.9 Hydraulic operation
5.9.1 Hydraulic operation overview
5.9.2 Hydraulic operation lifting/lowering
5.9.3 Hydraulic symbols
5.9.4 Hydraulic valve unit with fingertip controls
5.9.4.1 Manual lowering valve
5.9.5 Hydraulic valve unit with manual levers
5.9.5.1 Clamp release valve
5.9.6 Hydraulic supply system
5.9.7 Hydraulic flow distribution with additional hydraulic functions
5.9.7.1 Additional hydraulic functions in a truck with the armrest
5.9.7.2 Additional hydraulic functions in a truck with the manual levers
5.10 Drive axle
5.11 Brakes
5.11.1 Service brake
5.11.2 Parking brake
5.12 Rear axle
5.13 Steering unit
5.14 Load handling
5.14.1 Lifting carriage
5.14.2 Integrated sideshift carriage
5.14.3 Integrated fork positioner with sideshift
5.14.4 Load backrest
5.15 Mast
5.15.1 Simplex mast
5.15.2 Duplex mast
5.15.3 Triplex mast
5.15.4 Mast chains
5.15.5 Main rollers
5.15.6 Mast cylinders
5.15.6.1 Free lift cylinder
5.15.6.2 Side cylinders
5.15.6.3 Tilt cylinders
5.15.7 Automated performance reduction based on lift height
5.16 Wheels
5.16.1 Solid rubber wheels
5.16.2 Pneumatic wheels

MAINTENANCE
6.1 Maintenance intervals
6.2 Truck covers
6.2.1 Remove the cover of the hydraulic valve block
6.2.2 Remove the pedal plate
6.2.3 Open the battery door
6.2.4 Open the battery cover
6.2.5 Remove the back cover
6.2.6 Remove the steering wheel cover
6.2.7 Remove the control panel
6.2.8 Remove the side control panel
6.2.9 Remove the step cover
6.2.10 Remove the side plate
6.2.11 Remove the right side cover
6.2.12 Open the roof cover (cabin trucks)
6.2.13 Remove the rear spoiler cover
6.3 Cabin
6.3.1 Windshield washer tank
6.3.2 Cabin seals
6.4 Drive unit
6.4.1 Fastening of the drive axle
6.4.2 Leakage check of the drive axle
6.4.3 Lubricate the drive axle
6.4.3.1 Oil volume measurement
6.4.4 Test the parking brake
6.4.5 Test the regenerative brake
6.4.6 Electromechanical parking brake maintenance
6.5 Hydraulics
6.5.1 Hydraulic system maintenance
6.5.2 Leakage check of the hydraulic system
6.5.3 Replace the hydraulic oil return filter
6.5.4 Replace the air breather filter
6.5.5 Cleaning of the hydraulic oil suction filter
6.5.5.1 Remove the hydraulic oil suction filter
6.5.6 Oil level
6.5.7 Operation of the hydraulics
6.5.8 Relief valves
6.5.9 Hydraulic oil change
6.5.10 Hoses and cylinders
6.5.11 Lubricate the pump axle splines
6.5.12 Clean the oil tank
6.6 Mast
6.6.1 Mounting of the mast
6.6.2 Wear level of the mast rollers and contact surfaces
6.6.3 Chain tension
6.6.4 Chain lubrication
6.6.5 Chain wear measurement
6.6.6 Check the chain anchors and locking pins
6.6.7 Check the cylinders and piston rods
6.6.8 Lifting and lowering speed
6.6.9 Lubrication of the mast channel surfaces
6.6.10 Lifting test
6.6.11 Examine the welding in the mast for cracks
6.6.12 Mounting of any attachments and load-carrying components
6.6.13 Examine the welding of the cylinders and masts for cracking
6.6.14 Examine the rollers, pins and welds for cracking and damage
6.6.15 Apply grease to the lubrication points of the tilt cylinder
6.6.16 Additional mast attachments
6.7 Lifting carriage
6.7.1 Examine the welding in lifting carriage for cracks
6.7.2 Examine the load backrest for cracks
6.7.3 Fork inspection
6.7.4 Maintenance of the integrated sideshift carriage
6.7.4.1 Check the sliding blocks
6.7.4.2 Adjust the lower hooks
6.7.5 Maintenance of the integrated fork positioner with sideshift
6.7.5.1 Check the sliding blocks
6.7.5.2 Adjust the lower hooks
6.8 Rear axle
6.8.1 Lubricate the rear axle (3-wheel models)
6.8.1.1 Oil volume measurement and oil change
6.8.2 Lubricate the rear axle (4-wheel models)
6.8.3 Examine the operating condition of the bearings, check for looseness of the bearings
6.8.4 Examine the welds for cracks
6.8.5 Examine the mounting of the rear axle
6.8.6 Examine the condition of the rubber spring
6.9 Wheels
6.9.1 Damage and wear in the wheels
6.9.2 Before you replace the wheels
6.9.3 Front wheels
6.9.3.1 Remove the front wheel
6.9.3.2 Install the front wheel
6.9.3.3 Replace the wheel shaft bolts of the front wheel
6.9.4 Rear wheels
6.9.4.1 Remove the rear wheels (3-wheel models)
6.9.4.2 Install the rear wheel (3-wheel models)
6.9.4.3 Replace the wheel shaft bolts of the rear wheel (3-wheel)
6.9.4.4 Remove the rear wheels (4-wheel models)
6.9.4.5 Install the rear wheel (4-wheel models)
6.9.4.6 Replace the wheel shaft bolts of the rear wheel (4-wheel)
6.10 Electrics
6.10.1 Test the functionality of sensors
6.10.1.1 Traction motor sensors
6.10.1.2 Steering motor sensors
6.10.1.3 Pump motor sensors
6.10.1.4 Battery door sensor
6.10.1.5 Pressure sensor
6.10.1.6 Rear axle sensor
6.10.1.6.1 Rear axle sensor (3-wheel models)
6.10.1.6.2 Rear axle sensor (4-wheel models)
6.10.1.7 Tilt angle sensor
6.10.1.8 Mast height sensor
6.10.1.9 Steering wheel sensor
6.10.1.10 Mini steering wheel sensors
6.10.1.10.1 Mini steering wheel sensor
6.10.1.10.2 Mini steering wheel armrest sensor
6.10.1.11 Accelerator pedal sensor
6.10.1.12 Brake pedal sensor
6.10.1.13 Electronic friction lock pedal sensor
6.10.1.14 Dual pedal sensors
6.10.1.14.1 Dual pedal direction sensors
6.10.1.14.2 Dual pedal angle sensor
6.10.1.15 Manual lever sensors
6.10.1.16 Seat belt switch
6.10.1.17 Seat switch
6.10.1.18 Side control panel switches
6.10.1.19 Steering column driving direction selection switch
6.10.1.20 Clamp release switch
6.10.1.21 Autolight sensor
6.10.2 Steering wheel functions
6.10.3 Horn
6.10.4 Electrical connections tightening torques
6.10.5 Cables and wiring
6.10.6 Examine and clear the alarm history
6.10.7 Insulation resistance test
6.10.7.1 Test voltage
6.10.7.2 Check the insulation tester
6.10.7.3 Measure the insulation resistance
6.10.7.3.1 Truck insulation resistance
6.10.7.3.2 Battery insulation resistance
6.10.8 Discharge the controllers
6.10.9 Emergency stop button functionality check
6.10.10 Key switch functionality check
6.11 Safety
6.11.1 Inspect the seat belt
6.12 General
6.12.1 How to clean the truck
6.12.2 Lubrication
6.12.3 Examine the welding in the truck frame for cracking
6.12.4 Examine the truck frame and the lifting carriage
6.12.5 Examine the overhead guard for deformation, cracking and damage
6.12.6 Examine the gas springs
6.12.7 Examine the condition and position of the identification plates
6.12.8 Examine the covers
6.12.9 Safety functions
6.12.10 Examine the fastening of the steering wheel

BATTERY MAINTENANCE
7.1 Lead-acid batteries
7.1.1 Safety with lead-acid batteries
7.1.2 General information
7.1.3 Requirements for battery charging areas
7.1.4 Charge the battery
7.1.4.1 After the battery is charged
7.1.5 Battery maintenance
7.1.5.1 General maintenance
7.1.5.2 How to clean the battery
7.1.5.3 Daily maintenance
7.1.5.4 Weekly maintenance
7.1.5.5 Monthly maintenance
7.1.5.5.1 Measure the specific gravity of the battery
7.1.5.6 Annual maintenance
7.1.6 Malfunctions
7.1.7 Acquire a new battery
7.1.8 Storage
7.2 Lithium-ion batteries
7.2.1 General information
7.2.2 Safety signs
7.2.3 Requirements for battery charging areas
7.2.4 Charge the battery
7.2.4.1 Recharging a lithium-ion battery
7.2.4.2 Before charging
7.2.4.3 After charging
7.2.4.4 Opportunity charging
7.2.4.5 Battery balancing
7.2.5 Battery maintenance
7.2.5.1 Examine the battery
7.2.5.2 How to clean the battery
7.2.5.3 Malfunctions
7.2.5.4 Service and repair
7.2.6 Acquire a new battery
7.2.7 Storage
7.3 Replace the battery
7.3.1 General safety instructions
7.3.2 Replace the battery with a lifting device
7.3.3 Remove the battery with the battery sideway exchange tools
7.3.4 Install a battery with the battery sideway exchange tools

REPAIR
8.1 Repair drive unit
8.1.1 Drive axle lifting and handling
8.1.2 Remove the drive axle
8.1.3 Disassemble the drive axle
8.1.4 Assemble the drive axle
8.1.5 Install the electromechanical parking brake
8.1.6 Install the drive axle
8.1.7 Test the drive axle
8.2 Repair rear axle
8.2.1 Rear axle lifting and handling
8.2.2 Rear axle (3-wheel models)
8.2.2.1 Remove the rear axle (3-wheel models)
8.2.2.2 Disassemble the rear axle (3-wheel models)
8.2.2.3 Assemble the rear axle (3-wheel models)
8.2.2.4 Install the rear axle (3-wheel models)
8.2.2.5 Test the rear axle (3-wheel models)
8.2.3 Remove and install the rear axle (4-wheel models)
8.3 Repair hydraulic system
8.3.1 Remove the pump motor
8.3.2 Disassemble the steering unit
8.3.3 Set the lifting pressure
8.3.4 Disassemble the coils
8.3.5 Disassemble the M1, M2 and M9 valves
8.3.6 Remove the clamp release valve
8.4 Repair mast
8.4.1 Remove the mast
8.4.2 Disassemble the mast
8.4.2.1 Disassemble the simplex mast
8.4.2.2 Disassemble the duplex mast
8.4.2.3 Disassemble the triplex mast
8.4.3 Repair mast chains
8.4.3.1 Adjust the mast chains
8.4.3.2 Replace the mast chains
8.4.4 Repair free lift cylinder
8.4.4.1 Replace the free lift cylinder
8.4.4.2 Sealing housing of the free lift cylinder
8.4.5 Repair side cylinders
8.4.5.1 Replace the side cylinders
8.4.5.2 Sealing housing of the side cylinder
8.4.5.3 Bleed out air from the side cylinders
8.4.6 Repair tilt cylinders
8.4.6.1 Remove the tilt cylinders
8.4.6.2 Disassemble the tilt cylinder
8.4.7 Replace the main rollers of the mast
8.5 Repair lifting carriage
8.5.1 Remove the lifting carriage
8.5.2 Adjust the rollers of the lifting carriage
8.5.3 Replace the sliding pads of the lifting carriage
8.5.4 Replace the main rollers of the lifting carriage
8.5.5 Replace the load backrest
8.5.6 Repair integrated sideshift carriage
8.5.6.1 Troubleshooting integrated sideshift carriage
8.5.6.2 Disassemble the mobile frame
8.5.6.3 Replace the sliding blocks
8.5.6.4 Remove the piston of the integrated sideshift cylinder
8.5.6.5 Sealing housing of the integrated sideshift cylinder
8.5.6.6 Disassemble the upper sliding blocks and lower rollers
8.5.7 Repair integrated fork positioner with sideshift
8.5.7.1 Troubleshooting the fork positioner with sideshift
8.5.7.2 Hydraulic system (Fork positioner)
8.5.7.3 Disassemble the fork shifting cylinders
8.5.7.4 Disassemble the mobile frame of the positioner
8.5.7.5 Disassemble the fork supports
8.5.7.6 Replace the seals of the fork shifting cylinder
8.5.7.7 Install the forks
8.5.7.8 Connect the hydraulic hoses
8.5.7.9 Assemble the integrated fork positioner
8.5.7.10 Reset the equipment and bleed the hydraulic circuit
8.5.8 Repair hook-on sideshift carriage
8.5.8.1 Remove the hook-on sideshift frame
8.5.8.2 Remove the hook-on sideshift cylinder piston
8.6 Repair pedals
8.6.1 Remove the accelerator pedal
8.6.2 Remove the brake pedal
8.6.3 Remove the electronic friction lock pedal
8.6.4 Remove the dual pedal plate
8.6.5 Remove the dual pedal
8.6.6 Adjust the dual pedal
8.6.7 Adjust the direction sensor of the dual pedal
8.6.8 Adjust the dual pedal angle sensor
8.7 Repair steering wheel
8.7.1 Remove the steering wheel unit
8.7.2 Remove the steering wheel gas spring
8.7.3 Remove the lever unit
8.7.4 Remove the levers
8.8 Repair mini steering wheel
8.8.1 Disassemble the mini steering wheel
8.8.2 Disassemble the mini steering wheel holder
8.9 Repair armrest
8.9.1 Remove the armrest
8.9.2 Remove the armrest base plate
8.9.3 Replace the armrest padding
8.9.4 Fingertip control armrest
8.9.4.1 Remove the armrest levers
8.9.4.2 Remove the thumb plate
8.9.5 Ergologic armrest
8.9.5.1 Remove the joystick
8.9.5.2 Replace the switches and horn button
8.9.6 Dual joystick armrest
8.9.6.1 Remove the dual joystick
8.9.6.2 Remove the operating direction selection switch
8.9.7 Calibrate the armrest
8.10 Repair operator's seat
8.10.1 Remove the operator's seat from the truck
8.10.2 Replace the seat switch
8.10.3 MSG65
8.10.3.1 Replace the seat padding
8.10.3.2 Replace the seat base
8.10.3.2.1 Remove the seat base
8.10.3.2.2 Install the seat base
8.10.3.3 Replace the seat belt
8.10.3.4 Replace the weight adjustment handle
8.10.3.5 Replace the seat rails
8.10.3.6 Replace the gas spring
8.10.3.7 Ground the operator's seat
8.11 Repair electric system
8.11.1 Remove the electric panel
8.11.2 Replace the horn
8.12 Repair sensors and switches
8.12.1 Replace the rotation sensor
8.12.2 Replace the battery door sensor
8.12.3 Replace the rear axle sensor
8.12.4 Replace the tilt angle sensor
8.12.5 Replace the mast height sensor
8.12.5.1 Simplex mast
8.12.5.2 Duplex and triplex mast
8.12.5.3 Adjust the mast height sensor
8.12.6 Replace the sensors of the hydraulic valve unit with manual levers
8.12.7 Replace the manual lever switches
8.12.8 Replace the steering wheel sensor
8.12.9 Replace the mini steering wheel sensors
8.12.9.1 Replace the mini steering wheel sensor
8.12.9.2 Replace the mini steering wheel armrest sensor
8.12.10 Replace the pressure sensor
8.12.11 Replace the horn switch
8.12.12 Replace the side control panel switches
8.12.13 Replace the autolight sensor
8.13 Repair cabin
8.13.1 Operator door
8.13.1.1 Remove the opening handle of the operator door
8.13.1.2 Remove the cover plate of the operator door
8.13.1.3 Replace the lock of the operator door
8.13.1.4 Replace the gas spring of the operator door
8.13.1.5 Adjust the operator door
8.13.1.6 Adjust the operator door lock
8.13.2 Side door
8.13.2.1 Replace the opening lever of the side door
8.13.2.2 Replace the gas spring of the side door
8.13.3 Rear window
8.13.3.1 Replace the gas spring of the rear window
8.13.3.2 Remove the rear window
8.13.4 Manual holder
8.13.4.1 Replace the manual holder
8.13.5 Windshield washer (cabin truck)
8.13.5.1 Replace the windshield wiper
8.13.5.2 Remove the motor of the windshield wipers
8.13.6 Sun guard
8.13.6.1 Remove the sun guard

TRUCKTOOL DIAGNOSTICS
9.1 Overview
9.2 Location of the service socket
9.3 Parameter descriptions

SERVICE DATA
10.1 Special tightening torques
10.2 Tightening torques for standard bolts and nuts
10.3 Oils and lubricants
10.3.1 Lubrication points
10.3.2 Rear axle
10.3.3 Mast chains
10.3.4 Mast channels
10.3.5 Pump axle splines
10.4 Troubleshooting
10.4.1 Troubleshooting case examples
10.4.2 Traction
10.4.3 Brakes
10.4.4 Hydraulics
10.4.5 Steering
10.4.6 Charging

OPTIONS
11.1 Options overview
11.2 Accessory rack
11.3 A4 paper holder
11.4 Computer holder
11.5 Scanner holder
11.6 Holder arm
11.7 Reverse drive handle with horn button
11.8 Smart backup alarm
11.9 Rear combination and tail lights kit
11.9.1 Turn signals
11.9.2 Brake lights
11.9.3 Front lights
11.10 Amber strobe
11.10.1 Install the amber strobe under the overhead guard
11.11 Autolight sensor
11.11.1 Install the autolight sensor
11.12 Blue point light
11.12.1 Blue point front light
11.12.1.1 Install the blue point front light
11.12.2 Blue point rear light
11.12.2.1 Install the blue point rear light under the overhead guard
11.12.3 Remove the blue point lights
11.13 Working lights
11.13.1 Install the working lights
11.14 Red stripe
11.14.1 Install the red stripe safety lights
11.15 USB connector
11.16 Plastic storage locker
11.16.1 Install the plastic storage locker
11.17 Load weight indicator and overload notification
11.18 Operator's seat options and accessories
11.18.1 Seat armrest
11.18.1.1 Install the seat armrest
11.18.1.2 Adjust the height of the seat armrest
11.18.2 Backrest extension (MSG65)
11.18.2.1 Install the mounting bracket of the backrest extension
11.18.2.2 Adjust the backrest extension
11.18.3 Swivel seat
11.19 Battery sideway exchange system
11.19.1 Requirements for power pallet trucks used to move batteries of counterbalance trucks
11.19.2 Battery sideway exchange tools
11.19.2.1 Install the battery sideway exchange tool
11.19.2.2 Disassemble the battery locking mechanism
11.20 Wide view mirror
11.20.1 Install the wide view mirror
11.21 Rear view mirror
11.21.1 Install the rear view mirror
11.22 Side-view mirrors
11.22.1 Install the side-view mirrors
11.23 Hydraulic accumulator
11.23.1 Install the hydraulic accumulator
11.23.2 Remove the hydraulic accumulator
11.23.3 Adjust the hydraulic stabilization circuit
11.24 Front cover
11.24.1 Install the rubber front cover
11.25 Sun guard
11.26 Reading light
11.26.1 Install the reading light
11.27 Cabin fan
11.27.1 Install the cabin fan
11.28 Fender extensions
11.29 Tilt angle sensor / display status indication
11.29.1 Install the tilt angle sensor
11.30 Hook-on sideshift

TECHNICAL SPECIFICATIONS

LABELS

TRUCK DISPLAY LANGUAGES