Mitsubishi FB20NT, FB16NT, FB18NT Service Manual

Service Manual

99759-5B110

Chassis, Mast & Options

FB16NT

EFB11-20011-up

FB18NT EFB13-20011-up
FB20NT EFB13-70001-up

MC/FC

For use with FB16NT-FB20NT
Controller Service Manual.

FOREWORD

This service manual is a guide for servicing Mitsubishi forklift trucks. For your convenience
the instructions are grouped by systems as a ready reference.

The long productive life of your forklift trucks depend on regular and proper servicing.
Servicing consistent with what you will learn by reading this service manual. Read the
respective sections of this manual carefully and familiarize yourself with all of the components
before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual are for trucks with
serial numbers in effect at the time of printing. Mitsubishi forklift trucks reserves the right to
change specifications or design without notice and without incurring obligation.

Safety Related Signs

The following safety related signs are used in this service
manual to emphasize important and critical instructions:

Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided, may
result in death or serious injury or
damage to the machine.

Indicates a condition that can cause
damage to, or shorten service life of,
the machine.

NOTE

WARNING

!

CAUTION

!

Pub. No. 99759-5B110

HOW TO READ THIS MANUAL

Disassembly diagram (example)

Sequence

1. Cover, Bolt, Washer (part name)

2. Output shaft (part name)

Suggestion for disassembly

(1) Output shaft removal

Unit: mm (in.)

A

0.020 to 0.105

Clearance between

(0.00079 to 0.00413)

cylinder and piston

0.15

B

(0.0059)

A: Standard value B: Repair or service limit

Disassembly sequence

Each disassembly diagram is followed
by Disassembly sequence and
Suggestions for disassembly.

4. Lower the forks or other implements to the ground
before performing any work on the truck. If this
cannot be done, make sure the forks or other
implements are blocked correctly to prevent them
from dropping unexpectedly.

5. Use steps and grab handles (if applicable) when
mounting or dismounting a truck. Clean any mud
or debris from steps, walkways or work platforms
before using. Always face truck when using
steps, ladders and walkways. When it is not
possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
perform safe repair operations.

6. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lb.) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are of the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting
operation.

7. To avoid burns, be alert for hot parts on trucks
which have just been stopped and hot fluids in
lines, tubes and compartments.

8. Be careful when removing cover plates.
Gradually back off the last two bolts or nuts
located at opposite ends of the cover or device and
pry cover loose to relieve any spring or other
pressure, before removing the last two bolts or
nuts completely.

9. Be careful when removing filler caps, breathers
and plugs on the truck. Hold a rag over the cap or
plug to prevent being sprayed or splashed by
liquids under pressure. The danger is even greater
if the truck has just been stopped because fluids
can be hot.

The serviceman or mechanic may be unfamiliar with
many of the systems on this truck. This makes it
important to use caution when performing service
work. A knowledge of the system and/or components
is important before the removal or disassembly of any
component.

Because of the size of some of the truck components,
the serviceman or mechanic should check the weights
noted in this Manual. Use proper lifting procedures
when removing any components.

Following is a list of basic precautions that should
always be observed.

1. Read and understand all warning plates and decals
on the truck before operating, lubricating or
repairing the product.

2. Always wear protective glasses and protective
shoes when working around trucks. In particular,
wear protective glasses when pounding on any
part of the truck or its attachments with a hammer
or sledge. Use welders gloves, hood/goggles,
apron and other protective clothing appropriate to
the welding job being performed. Do not wear
loose-fitting or torn clothing. Remove all rings
from fingers when working on machinery.

3. Do not work on any truck that is supported only
by lift jacks or a hoist. Always use blocks or jack
stands to support the truck before performing any
disassembly.

SAFETY

The proper and safe lubrication and
maintenance for these forklift trucks,
recommended by Mitsubishi forklift truck, are
outlined in the OPERATION & MAINTENANCE
MANUAL.

Improper performance of lubrication or
maintenance procedures is dangerous and
could result in injury or death. Read and
understand the OPERATION & MAINTENANCE
MANUAL before performing any lubrication or
maintenance on these trucks.

Do not operate these trucks unless you have
read and understand the instructions in the
OPERATION & MAINTENANCE MANUAL.
Improper truck operation is dangerous and
could result in injury or death.

WARNING

!

WARNING

!

WARNING

!

10. Always use tools that are in good condition and
be sure you understand how to use them before
performing any service work.

11. Reinstall all fasteners with same part number.
Do not use a lesser quality fastener if
replacements are necessary. Do not mix metric
fasteners with standard nuts and bolts.

12. If possible, make all repairs with the truck
parked on a level, hard surface. Block truck so it
does not roll while working on or under truck.

13. Disconnect battery and discharge any capacitors
(electric trucks) before starting to work on truck.
Hang “Do not Operate” tag in the Operator’s
Compartment.

14. Repairs, which require welding, should be
performed only with the benefit of the
appropriate reference information and by
personnel adequately trained and knowledgeable
in welding procedures. Determine type of metal
being welded and select correct welding
procedure and electrodes, rods or wire to provide
a weld metal strength equivalent at least to that
of parent metal.

15. Do not damage wiring during removal
operations. Reinstall the wiring so it is not
damaged nor will it be damaged in operation by
contacting sharp corners, or by rubbing against
some object or hot surface. Do not connect
wiring to a line containing fluid.

16. Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution.

17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.

18. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for
leaks with your hands. Pin hole (very small)
leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can
penetrate the skin and cause personal injury. Use
cardboard or paper to locate pin hole leaks.

19. Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat,
vibration or rubbing against other parts during
operation. Shields that protect against oil spray
onto hot exhaust components in event of a line,
tube or seal failure, must be installed correctly.

20. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.

21. Do not operate a truck if any rotating part is
damaged or contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.

GROUP INDEX

GROUP INDEX

Items

1

2

3

4

5

6

7

8

9

10

11

GENERAL INFORMATION

VEHICLE ELECTRICAL
COMPONENTS

Serial number locations, Dimensions, Technical data

Console box, Key switch, Lamp specification chart

POWER TRAIN

TRANSFER UNITS

REAR AXLE

Procedure and suggestions for removal and installation

Procedures and suggestions for disassembly and reassembly

BRAKE SYSTEM

STEERING SYSTEM

Rear axle, Rear wheels

Caliper, Brake pedal, Master cylinder

Steering control valve

HYDRAULIC SYSTEM

MASTS AND FORKS

Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve,
Down safety valve

Simplex mast, Duplex mast, Triplex mast

SERVICE DATA

Inspection standards, Periodic replacement of parts, Lubrication
standards, Main component weight, Tightening torque for standard bolts
and nuts, Special tools

OPTIONS

Rearview mirror kit, Backup buzzer kit, Working lamp kit, Tire kit

Vehicle Exterior ....................................................................................... 1 – 1

Models ....................................................................................................... 1 – 1

Serial Number Locations ...................................................................... 1 – 2

Chassis and Mast Model Identification ............................................ 1 – 3

Dimensions .............................................................................................. 1 – 4

Technical Data ......................................................................................... 1 – 5

1

GENERAL INFORMATION