PDF Service Manual Mitsubishi FB20K FB25K FB30K FB35K PAC Forklift - 1 MB
This is the complete service manual for the Mitsubishi FB20K PAC through FB35K PAC series electric forklifts.
It is a vital resource for service technicians, containing detailed procedures for diagnostics, repairs, and maintenance.
The manual covers all systems, including electrical, hydraulic, and mechanical components.
Ensure your Mitsubishi forklifts are serviced to factory standards for maximum reliability and safety.
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--- Page 1 ---
Service Manual
Chassis, Mast & Options
FB20K PAC EFB8C-00011-up
FB25K PAC EFB8C-50001-up
FB30K PAC EFB9C-00011-up
FB35K PAC EFB9C-50001-up
For use with FB20K PAC - FB35K PAC
Controller Service Manual. 99759-5A110
--- Page 4 ---
VEHICLE ELECTRICAL COMPONENTS
14
15
211649
14 Parking brake switch 15 Brake fluid level sensor
2-2
--- Page 5 ---
VEHICLE ELECTRICAL COMPONENTS
Key Switch
Terminal B M1, M2
Connection Main fuse
Logic card
destination Battery
(OFF)
I (ON)
206806A
Lighting Switch
Terminal 2 5 3 6
Connection Head Working
Battery Battery
destination lamps lamp
OFF 2
6 3 5 2 3
ON (1)
ON (2) 5
21 6
Head
Lamp Fuse
Working
Lamp
211137
2-12
--- Page 6 ---
VEHICLE ELECTRICAL COMPONENTS
Inspection of machine side components
Shown in the following table are the machine side basic
components that must be inspected first when a problem
occurs in the FC system and the conditions and points for
performing their checking.
Conditions in the
Check item What to check Remedy
machine
Hydraulic line Hoses, pipes and connectors for damage Repair leaking or
and sign of leak. damaged parts.
Key switch OFF Hydraulic devices Check control valve and hydraulic Repair damaged or
Emergency switch cylinders for damage and oil leaks. leaking parts, if any.
ON
Electrical connectors Check connectors for tightness, burns and
and wires breakage; check wires for insulator Repair.
stripping and signs of rubbing.
System check lamp Check to be sure the lamp goes ON and Replace lamp bulb if
OFF properly; if not, check the bulb. blown.
Hydraulic devices Refer to the sections
With your hands off control levers, see if
dealing with control
the solenoid valves and hydraulic pump are
valve and hydraulic
making any abnormal sounds.
pump, respectively.
Key switch ON
Operate the control levers to see if any (Proper function of
Emergency switch
abnormal sound, indicative of flow solenoid valves is
OFF
throttling, comes from control solenoid essential to
valve or from any other solenoid valve. troubleshooting.)
Work attachments Check each work attachment for the
See “4. Troubleshooting
following:
guide for solenoid
(a) Does it work properly?
control valves” on page
(b) Does it “inch” properly?
2-26.
(c) Does mast go down with proper speed?
2-22
--- Page 7 ---
POWER TRAIN
Battery Removal and Installation
Removal
1. Disconnect the battery plug.
2. Release the fastener and fully open the battery cover.
Hook the cover to hold it up.
3. Remove both side covers.
103064
4. Remove the battery restraint.
208365
5. Using a hoist, lift the battery case out of the vehicle.
Truck Models 2 ton class and 3 ton class and
Item 2.5 ton class 3.5 ton class
Battery weight 1385 kg (3053 lb) 1872 kg (4127 lb)
Installation
Follow the removal sequence in reverse. 208075
3-4
--- Page 8 ---
TRANSFER AND DIFFERENTIAL
Procedures and Suggestions for Disassembly and Reassembly
Transfer and Differential Gear Disassembly
32 33
34
31
28
27
29
26
25
22
24
23
9
17 19 18 30
8 12
14
10
13
11
16
15
7
21 20
3 1 2
6 4 5 1 2 3 211756
Sequence
1 Bolt 13 Cover 25 O-ring
2 Bearing cap 14 O-ring 26 O-ring
3 Retainer 15 Bearing outer race Remove parts 27 and 28 as a unit.
16 Bearing inner race
Remove parts 4 to 7 as an assembly. 27 Second gear
17 Bearing outer race
4 Differential gear assembly 28 Bearing outer race
5 Bolt Remove parts 18 and 19 as a unit. 29 Bearing inner race
6 Output gear 18 Third shaft 30 Spacer
7 Ball bearing 19 Bearing inner race 31 Snap ring
8 Bolt 20 Spacer Remove parts 32 and 33 as a unit.
9 Motor bracket 21 Third gear
10 Nut 22 Bolt 32 Input gear
11 O-ring 23 Lock plate 33 Ball bearing
12 Bolt 24 Second shaft 34 Transfer gear case
4-4
--- Page 9 ---
TRANSFER AND DIFFERENTIAL
Service Data
A : Standard value
Unit : mm (in.)
Truck Models
2 ton class, 2.5 ton class 3 ton class, 3.5 ton class
Item
Third gear shaft taper roller bearing preload
(Tangential force required at output gear mounting A 42 to 84 (4.3 to 8.6) [9.5 to 19]
bolt to rotate output gear) N (kgf) [lbf]
Bolt 1 A 33 ± 3 (3.4 ± 0.3) [24.6 ± 2.2]
Bolt 2 A 59 ± 6 (6.0 ± 0.6) [43.4 ± 4.3]
Bolt tightening torque Bolt 3 A 118 ± 10 (12.0 ± 1.0) [86.8 ± 7.2]
N·m (kgf·m) [lbf·ft] Bolt 4 A 123 ± 10 (12.5 ± 1.0) [90.4 ± 7.2]
Bolt 5 A 108 ± 10 (11.0 ± 1.0) [79.6 ± 7.2]
Bolt 6 A 108 ± 10 (11.0 ± 1.0) [79.6 ± 7.2]
End play of side gear (S) A 0.19 (0.007)
Differential gear backlash A 0.9 to 1.3°
Transfer and Differential
1
6 2
5
End play (S)
Backlash
4 3
211762
4-14
--- Page 10 ---
FRONT AXLE
Inspection and Repair
1. Axle shaft 2
(1) Insert the differential side gear to the axle shaft, and
measure looseness in the rotating direction with a dial
gauge.
A: Standard value B: Repair or service limit
Unit: mm (in.)
0.07 to 0.17
Looseness of axle A
(0.0028 to 0.0067)
shaft spline
B 0.5 (0.020)
200235
(2) Measuring axle shaft bend
(a) Attach a dial gauge to the center of the axle shaft,
and rotate the axle shaft. Measure bend of the axle
shaft.
A: Standard value B: Repair or service limit
Unit: mm (in.)
Axle shaft bend A 0.5 (0.020) or less
(1/2 of gauge reading) B 1.0 (0.039)
(b) Attach a dial gauge to the edge of the flange, and
rotate the axle shaft. Measure deflection of the
flange.
A: Standard value B: Repair or service limit
Unit: mm (in.)
A 0.08 (0.0031) 200276
Flange deflection
B 0.5 (0.020)
2. Seal retainer 18
Check for wear or damage on the retainer circumference.
3. Brake drum 8
If uneven wear or damage is found on the inner surface of
the brake drum, grind and repair.
A: Standard value B: Repair or service limit
Unit: mm (in.)
Inner diameter of A 310 + 00.15 (12.2 + 00.0059 )
brake drum B 312.0 (12.283)
4. Hub bearings
Examine the rollers and bearing races for grooving,
abrasive wear, pitting, bruising, or corrosion. Replace both
the outer race and inner race of damaged bearings.
5-8
--- Page 12 ---
REAR AXLE
Suggestions for Reassembly
1. Use the special tool to insert and press-fit the needle
bearing 1 into the kingpin bore in the rear axle upper 2
boss from outside. Upper boss
2. Use the special tool to insert and press-fit the oil seal 2
into the kingpin bore with the lip positioned as shown
in the illustration.
1
211068
Upper boss
3. Use the special tool to insert and press-fit the needle
bearing 3 into the kingpin bore in the rear axle lower
Lower boss 4
boss from outside.
4. Use the special tool to insert and press-fit the oil seal 4
into the kingpin bore with the lip positioned as shown
in the illustration.
5. Temporarily install the bearing 6 and knuckle 5 in the
rear axle body and measure the clearance “A”. The 3
clearance must be 0.3 mm (0.01 in.) or less for both the
right and left sides of the axle. If the clearance exceeds
the specification, adjust it with the shim 7. The shim is
available in two thicknesses: 0.6 mm (0.02 in.) and 0.2 211069
mm (0.008 in.).
Lower boss
6. Grease the roller surfaces of each needle bearing, oil
seal lip surface, and periphery of both kingpin ends,
and then insert the kingpin 8 from under the rear axle.
7. Visually check the alignment of the stopper bolt hole in
the knuckle 5 and the locking hole in the kingpin 8,
then lock the kingpin in the knuckle holding the
stopper bolt and nut 9.
8. Install the grease nipples. Fully grease the kingpin and
bearings through the grease nipples.
6-10
--- Page 13 ---
REAR AXLE
Service Data
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Models
2.0 ton class, 3.0 ton class,
2.5 ton class 3.5 ton class
Item
Toe-in (deg) A 1° 29´
Caster (deg) A 0°
Camber (deg) A 0°
Inward (deg) A 83° 6´
Steering angle
Outward (deg) A 56° 33´
Tangential force at hub bolt 1 N (kgf) [lbf] A 6.7 to 67 (0.7 to 7) [1.54 to 15.4]
A 0.8 (0.03) or less
Front and back clearance for center pin 2 (total)
B 1.2 (0.047)
Tightening torque of steering cylinder bolt 3
A 262 ± 10 (26.7 ± 1) [193.2 ± 7.4]
N·m (kgf·m) [lbf·ft]
Outer nut tightening torque 4 N·m (kgf·m) [lbf·ft] A 156.9 ± 15.7 (16.0 ± 1.6) [115.7 ± 11.6]
Rear axle
Tightening torque of stopper bolt nut 5 N·m (kgf·m) [lbf·ft] A 66.7 ± 6.67 (6.8 ± 0.68) [49.2 ± 4.9]
Allowable tread groove depth 6 (wear limit) 5 (0.2)
Tightening torque of elbow nut 7 N·m (kgf·m) [lbf·ft] A 39.2 (4.0) [28.9]
Tightening torque of wheel nut 8 N·m (kgf·m) [lbf·ft] A 156.9 ± 15.7 (16.0 ± 1.6) [115.7 ± 11.6]
6
5 7
4
1
8
3
2
211662
6-20
--- Page 14 ---
BRAKE SYSTEM
Reservoir Tank
The brake fluid reservoir tank is located under the
dashboard on the left-hand side. It incorporates a brake Connector
fluid level sensor, which consists of a reed switch (this is
built into the bottom of the reservoir tank) and a float (this
follows changes in fluid level). The float contains a
permanent magnet.
When the fluid level drops below the minimum level Cap Reservoir
marked on the tank, the switch closes, causing the brake
Float
fluid level indicator to illuminate. While the fluid level is
sufficiently high, the switch remains open and the indicator Fluid level
Max
remains off.
Min
Switch Permanent
magnet
To master cylinder
208379
Wheel Cylinder
A wheel cylinder is located in each wheel brake assembly.
When the brake pedal is depressed, pressurized brake fluid
Body
from the master cylinder enters the wheel cylinder body
through the inlet port. The fluid acts on the left and right- Piston Connecting link
hand pistons, causing them to expand the primary and
secondary shoes via the corresponding connecting links.
When the brake pedal is released, the pistons are moved
back to their original positions by the brake shoe return
spring in the wheel brake assembly.
Spring
Each wheel cylinder has a bleeder screw, which is used to Bleeder screw
remove any air that enters the brake system when the
system is serviced. The bleeder screw is loosened to
remove the air.
Inlet port
208385
7-7
--- Page 15 ---
BRAKE SYSTEM
Master Cylinder and Fluid Reservoir
Disassembly
208390
Sequence
1 Clevis, Lock nut, Push rod 6 Return spring
2 Boot 7 Cylinder body
3 Stopper ring 8 Filler, Clamp
4 Secondary cup, Piston 9 Fluid reservoir
5 Spring seat, Primary cup, Cup spacer
NOTE
Parts marked with () are included in the repair kit.
7-17
--- Page 16 ---
BRAKE SYSTEM
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Models
3 ton class 3.5 ton class
Item
Inside diameter of cylinder body 1 A 28.58 + 0.052
0 (1.1252 + 0.00205
0 )
Diameter of piston 2 A 28.58 –– 0.020 – 0.00079
0.053 (1.1252 – 0.00209 )
Clearance between cylinder and piston A 0.020 to 0.105 (0.00079 to 0.00413)
B 0.15 (0.0059)
Diameter of piston cup (lip side) 3 A 30.5 ± 0.125 (1.201 ± 0.0049)
Wheel cylinder
B (Replace every year)
Return spring 4 Free length A 58 (2.28)
Length under test force A 22 (0.87)
Test force A 13 ± 1 (1.3 ± 0.1) [2.9 ± 0.2]
N (kgf) [lbf] B (Replace every year)
Tightening torque Wheel cylinder bolts 5 A 17.65 to 26.48 (1.8 to 2.7) [13.0 to 19.5]
N·m (kgf·m) [lbf·ft] Bleeder screw 6 A 5.88 to 8.83 (0.6 to 0.9) [4.3 to 6.5]
200426
7-27
--- Page 17 ---
STEERING SYSTEM
Tilt Steering Assembly
2
1
4
5
A
4
C
B
A
C
8
B
3
7
9 6
209575
1 Steering wheel 6 Drive shaft
2 Column bushing 7 Universal joint
3 Steering shaft 8 Tilt lock knob
4 Column housing 9 Steering valve
5 Horn cord
The tilt steering assembly is installed to the bracket The tilt steering assembly can tilt ± 6° around the
under the dashboard. universal joint.
Push down the knob, and move the steering wheel
forward and backward.
8-4
--- Page 18 ---
STEERING SYSTEM
(10) Reassembling the end cap
• Install the drive spacer in the Gerotor set. Install the
O-ring in the end cap. Install the end cap in the
Gerotor set and align the holes.
208244
• Apply oil to bolt threads and tighten bolts evenly in
the sequence as shown in the illustration on the right.
The tightening torque is shown in the table below.
14.7 N·m
Initial torque for screws (1.5 kgf·m)
[10.8 lbf·ft]
23.5 N·m
Finishing torque for screws (2.4 kgf·m)
[17.3 lbf·ft] 200677
After installing the end cap, install the steering shaft to the
spool and make sure the spool rotates smoothly.
8-14
--- Page 19 ---
HYDRAULIC SYSTEM
Solenoid Control Valve
This drawing shows the three-valve type. 208125A
1 Proportioning solenoids 7 End cover P: From hydraulic pump
2 Main relief valve 8 Emergency shut-off valve T1: To hydraulic tank
3 Inlet section (with built-in (for releasing lift lock) T2: From steering gear
flow divider valve) 9 Shut-off valve assembly A1: To lift cylinders
4 Lift section (No. 1 valve) (for attachment section) A2: To tilt cylinder (rod end)
5 Tilt section (No. 2 valve) B2: To tilt cylinder (head end)
6 Attachment section A3: To attachment cylinder
(No. 3 and No. 4 valves) B3: To attachment cylinder
The control valve consists of the inlet section 3, lift The lift section 4 contains a directional control valve
section 4, tilt section 5, attachment section 6, end that supplies oil to the lift cylinder. Oil used to raise
section 7, and main relief valve 2. and lower the lift cylinder flows in and out through the
The inlet section has two ports. The P port is the inlet A1 port. The control spool is moved by pilot pressure,
for oil supplied by the hydraulic pump; it is a high- which is controlled by a proportioning solenoid. A lift
pressure port. The T2 port is the inlet for oil returning lock valve and an emergency shutoff valve are fitted for
from the steering gear; it is a low-pressure port. This use in the event of an emergency.
section incorporates a flow divider valve, which The tilt section 5 contains a directional control valve
controls the rate at which oil flows to the lift and tilt that controls the supply of oil to the tilt cylinder. The
sections and the rate at which oil flows to the A2 port is connected to the rod end, and the B2 port is
attachment section. Attached to the outside of the inlet connected to the head end. In terms of construction, the
section is the main relief valve 2, which limits the tilt section is almost the same as the lift section.
maximum pressure in the high-pressure circuit. Also The attachment section 6 has the A3 port and the B3
attached to the outside of the inlet section is the shut-off port. In terms of construction, it is almost the same as
valve 9, which serves to forcibly relieve the oil pressure the tilt section.
in the attachment section. Also attached is a pilot relief
The end section 7 has the T1 port, which forms part of
valve, which limits the maximum level of the pilot
the line through which oil returns to the hydraulic tank.
pressure that moves the No. 1, No. 2, No. 3, and No. 4
valves’ control spools.
9-5
--- Page 20 ---
HYDRAULIC SYSTEM
Lift section
A1
“b1”SOL
Low-pressure oil
207442
Manual Lift Lowering Operation
In case the proportional electromagnetic pressure
control valve on the “b1” SOL side malfunctions and
disallows lift lowering operation, opening the shut-off
valve creates a pilot oil passage to allow the operation
of the load check valve.
9-15
--- Page 21 ---
HYDRAULIC SYSTEM
Lift and Tilt Cylinders
Lift cylinder (Simplex mast)
(Triplex mast second cylinder)
1 2 3 Inlet
Top end Bottom end
213459
(Duplex and triplex mast first cylinder)
Top end Bottom end
1 2 3 Inlet 213460
(Duplex mast second cylinder)
Top end Bottom end
To first cylinder Inlet
000825C
Tilt cylinder
213461
The left and right lift cylinders are a single-acting type. The left and right tilt cylinders are a double-acting type.
Air and oil remaining inside air chamber 1 of the rod The piston rod carries a screw-on socket. This socket is