Mitsubishi FB161820KT Forklift Service Manual

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Mitsubishi FB161820KT Forklift Service Manual - Image 5

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Mitsubishi FB161820KT Forklift Service Manual

$50.00

Type Of Manual: Service Manual
Number of Pages: 478
Size: 39.4MB
Format: PDF

Category: Mitsubishi Service Manual PDF

Model List:
- FB161820KT Forklift

1. GENERAL INFORMATION
1.1. GENERAL INFORMATION
1.1.1. Vehicle Exterior
1.1.2. Serial Number Locations
1.1.3. Chassis and Mast Model Identification
1.1.4. Dimensions
1.1.5. Technical Data
2. BRAKE SYSTEM
2.1. BRAKE SYSTEM
2.1.1. Specifications
2.1.2. Structure and Functions
2.1.2.1. Caliper Assembly
2.1.2.2. Brake Pedal Assembly
2.1.2.3. Master Cylinder
2.1.2.4. Parking Brake Lever
2.1.3. Procedures and Suggestions for Disassembly and Reassembly
2.1.3.1. Master Cylinder
2.1.4. Inspection and Adjustment
2.1.4.1. Pad Clearance Adjustment
2.1.4.2. Brake Pedal Adjustment
2.1.4.3. Brake Switch Installation
2.1.4.4. Brake Fluid Line Bleeding
2.1.4.5. Parking Brake Adjustment
2.1.5. Troubleshooting
2.1.6. Service Data
3. HYDRAULIC SYSTEM
3.1. HYDRAULIC SYSTEM
3.1.1. Specifications
3.1.2. Structure and Functions
3.1.2.1. Hydraulic Line
3.1.2.2. Control Valve
3.1.2.3. Lift and Tilt Cylinders
3.1.2.4. Flow Regulator Valve
3.1.2.5. Down Safety Valve
3.1.3. Gear Pump
3.1.3.1. Procedures and Suggestions for Removal and Installation
3.1.4. Control Valve
3.1.4.1. Procedures and Suggestions for Removal and Installation
3.1.4.2. Procedures and Suggestions for Disassembly and Reassembly
3.1.5. Lift Cylinders
3.1.5.1. Procedures and Suggestions for Removal and Installation
3.1.5.2. Procedures and Suggestions for Disassembly and Reassembly
3.1.6. Tilt Cylinders
3.1.6.1. Procedures and Suggestions for Removal and Installation
3.1.6.2. Procedures and Suggestions for Disassembly and Reassembly
3.1.7. Flow Regulator Valve
3.1.7.1. Procedures and Suggestions for Disassembly and Reassembly
3.1.8. Suction Strainer and Return Filter
3.1.8.1. Procedures and Suggestions for Removal and Installation
3.1.9. Inspection and Adjustment
3.1.9.1. Hydraulic Tank
3.1.9.2. Control Valve
3.1.9.3. Lift Cylinders and Tilt Cylinders
3.1.9.4. Adjustment Values of Microswitches
3.1.9.5. Procedures for Adjusting Microswitches
3.1.10. Hydraulic Circuit Diagram
3.1.11. Hydraulic Circuits
3.1.12. Troubleshooting
3.1.13. Service Data
4. MAST AND FORKS
4.1. MAST AND FORKS
4.1.1. Mast Systems
4.1.1.1. Mast Type Code Stamping Position
4.1.1.2. Explanation of Mast Type Code
4.1.1.3. Mast Types
4.1.2. Description
4.1.2.1. Dual-stage Panoramic Mast (Simplex Mast)
4.1.2.2. Dual-stage Full Free Panoramic Mast (Duplex Mast)
4.1.2.3. Triple-stage Full Free Panoramic Mast (Triplex Mast)
4.1.2.4. Operation of Dual-stage Full Free Panoramic Mast
4.1.2.5. Operation of Triple-stage Full Free Panoramic Mast
4.1.3. Removal and Installation
4.1.3.1. Mast and Lift Bracket Assembly
4.1.4. Disassembly and Reassembly
4.1.4.1. Dual-stage Panoramic Mast (Simplex Mast)
4.1.4.2. Dual-stage Full Free Panoramic Mast (Duplex Mast)
4.1.4.3. Triple-stage Full Free Panoramic Mast (Triplex Mast)
4.1.5. Inspection and Adjustment
4.1.5.1. Chain Tension Adjustment
4.1.5.2. Clearance Adjustment on Lift Bracket
4.1.5.3. Mast Clearance Adjustment
4.1.5.4. Main Roller Shim Replacement
4.1.5.5. Mast Strip Adjustment
4.1.5.6. Tilt Angle Adjustment
4.1.5.7. Lift Cylinder Stroke Adjustment
4.1.6. Troubleshooting
4.1.7. Service Data
4.1.8. Motor Installation Positions
4.1.9. Specifications
4.1.10. Structures
4.1.11. Tightening of High-power Cable Terminals
4.1.12. Inspection of Brushes for Wear and Brush Replacement
4.1.13. Procedures and Suggestions for Removal and Installation
4.1.14. Procedures and Suggestions for Disassembly and Reassembly
4.1.15. Troubleshooting
4.1.16. Service Data
4.1.17. Checks and Repairs
5. Options Supplement
5.1. FORWORD
5.2. AMBER STROBE KIT
5.3. BACK BUZZER KIT
5.4. HEAD LAMP KIT (48 V AND 36 V) (Not applicable to EU models)
5.5. REARVIEW MIRROR KIT (Not applicable to EU models)
5.6. ADDITIONAL-ON CONTROL VALVE KIT (For MC model)
5.7. FOOT-OPERATED DIRECTION CONTROL KIT (Not applicable to US EE model)
5.8. EE MODEL AND EE UNCOVERED BATTERY MODEL (US EE model)
6. OPTIONS
6.1. OPTIONS
6.1.1. Rearview Mirror Kit
6.1.2. Backup Buzzer Kit
6.1.3. Working Lamp Kit
6.1.4. Tire Kit (Solid)
6.1.5. Tire Kit (Nonmarking Cushion)
6.1.6. Foot Direction Control Kit
7. POWER TRAIN
7.1. POWER TRAIN
7.1.1. Procedures and Suggestions for Removal and Installation
7.1.1.1. Removal
7.1.1.2. Installation
7.1.2. Service Data
8. REAR AXLE
8.1. REAR AXLE
8.1.1. Structure and Functions
8.1.1.1. Rear Wheels
8.1.2. Procedures and Suggestions for Removal and Installation
8.1.2.1. Rear Wheels
8.1.2.2. Rear Axle
8.1.3. Procedures and Suggestions for Disassembly and Reassembly
8.1.3.1. Steering Axle
8.1.3.2. Rear Axle Assembly
8.1.4. Inspection and Adjustment
8.1.4.1. Making sure of Minimum Turning Radius
8.1.5. Service Data
9. SERVICE DATA
9.1. SERVICE DATA
9.1.1. Inspection Standards
9.1.2. Periodic Replacement of Parts
9.1.2.1. Critical Safety Parts
9.1.3. Lubricating Standards
9.1.3.1. Lubrication Chart
9.1.3.2. Lubricant Quantities
9.1.3.3. Recommended Lubricant
9.1.4. Main Component Weights
9.1.5. Tightening Torques for Standard Bolts and Nuts
9.1.6. Special Tool Table
10. STEERING SYSTEM
10.1. STEERING SYSTEM
10.1.1. Specifications
10.1.2. Structure and Functions
10.1.2.1. General
10.1.2.2. Steering Control Valve
10.1.3. Procedures and Suggestions for Removal and Installation
10.1.3.1. Steering Column Assembly
10.1.4. Steering Control Valve
10.1.4.1. Disassembly
10.1.4.2. Inspection
10.1.4.3. Reassembly
10.1.5. Hydraulic Circuit Diagram
10.1.6. Troubleshooting
10.1.7. Service Data
11. TRANSFER UNITS
11.1. TRANSFER UNITS
11.1.1. Specifications
11.1.2. Structure and Functions
11.1.3. Procedures and Suggestions for Disassembly and Reassembly
11.1.3.1. Disassembly
11.1.3.2. Inspection after Disassembly
11.1.3.3. Reassembly
11.1.4. Service Data
12. VEHICLE ELECTRICAL COMPONENTS
12.1. VEHICLE ELECTRICAL COMPONENTS
12.1.1. Console Box
12.1.1.1. Functions of Central Vehicle Monitor System
12.1.1.2. Electrical Components in Console Box
12.1.1.3. Disassembly and Reassembly
12.1.2. Direction Lever
12.1.3. Accelerator Control
12.1.4. Key Switch
12.1.5. Lighting Switch
12.1.6. Lamp Specification Chart
12.1.7. Troubleshooting of Lighting and Horn Systems
13. Chassis, Mast, Options
13.1. SERVICE MANUAL CHASSIS, MAST, AND OPTIONS
13.1.1. FOREWORD
13.1.2. HOW TO USE THIS MANUAL
13.1.3. GROUP INDEX
14. MAIN CONTROLLER
14.1. MAIN CONTROLLER
14.1.1. Outline
14.1.2. Controller Components (Part 1)
14.1.3. Controller Components (Part 2)
14.1.4. Logic Card Components
14.1.5. Controller Models
14.1.6. Operation Outline
14.1.7. Drive System
14.1.7.1. Neutral Position
14.1.7.2. Powering
14.1.7.3. Drive Motors Current Table (48 V type)
14.1.7.4. Drive Motors Current Table (36 V type)
14.1.7.5. Regeneration
14.1.7.6. Steering and Turns
14.1.7.7. Lever Regeneration Characteristic (48 V type)
14.1.7.8. Lever Regeneration Characteristic (36 V type and EE option type)
14.1.7.9. Auto Regeneration Characteristic (48 V type)
14.1.7.10. Auto Regeneration Characteristic (36 V type and EE option type)
14.1.7.11. Steering Characteristic (1.6 ton type)
14.1.7.12. Steering Characteristic (1.8 ton type)
14.1.7.13. Steering Characteristic (2.0 ton type)
14.1.8. Hydraulic System
14.1.8.1. Chopper Model
14.1.8.2. Contactor Model
14.1.9. Fail-safe System
14.1.9.1. Output Power Control at Low Battery Voltage
14.1.9.2. Overheat
14.1.9.3. Brush Wear
14.1.9.4. Maximum Vehicle Speed Control (SUO 7)
14.1.9.5. Output Power Control During Braking
14.1.9.6. Chat Timer (SUO 24)
14.1.9.7. Seat Switch Timer (SUO 25)
14.1.10. Malfunction Detection (Run Time Diagnosis)
14.1.11. Malfunction Data Record (History Folder)
14.1.11.1. Data Storage
14.1.11.2. Review of Stored Data
14.1.12. Setting
14.1.12.1. Printed Circuit Board Settings
14.1.12.2. Adjustment of Remaining Battery Level
14.1.12.3. Setup Options
14.1.13. Self-diagnosis
14.1.14. Other Functions
14.1.15. Display Unit
14.1.15.1. BDI (Battery Discharge Indicator)
14.1.15.2. Hourmeters and Time Display
14.1.15.3. Vehicle Speed and Error Code Display
14.1.15.4. Action Lights (LEDs)
14.1.16. Inspection and Adjustment
14.1.16.1. Inspection and Adjustment Tools
14.1.16.2. Removal and Installation of Logic Card
14.1.16.3. Tightening of High-tension Cable Terminals
14.1.16.4. Component Testing
14.1.17. Service Data
14.1.18. Tightening Torque
15. TROUBLESHOOTING FOR CONTROL CIRCUITS
15.1. TROUBLESHOOTING FOR CONTROL CIRCUITS
15.1.1. General Information
15.1.2. Alarm List
15.1.3. E0 Right Motor,Overheating
15.1.4. E1 Left Motor,Overheating
15.1.5. E2 Pump Motor,Overheating
15.1.6. E3 Controller,Overheating
15.1.7. E4 Right Motor,Worn Brushes
15.1.8. E5 Left Motor,Worn Brushes
15.1.9. E6 Pump Motor,Worn Brushes
15.1.10. Brake Oil,Low Level
15.1.11. Right Motor,Faulty Armature Circuit
15.1.12. Right Motor,Transistor Wire Breakage
15.1.13. Right Motor,Shorted Transistor
15.1.14. Right Motor,Faulty Transistor Drive
15.1.15. Right Motor,Faulty Current Sensor
15.1.16. Right Motor,Armature Over-current
15.1.17. Right Motor,Stall Timer
15.1.18. Right Motor,Faulty Field Circuit
15.1.19. Right Motor,Faulty Field Drive
15.1.20. Right Motor,Field Over-current
15.1.21. Left Motor,Faulty Armature Circuit
15.1.22. Left Motor,Transistor Wire Breakage
15.1.23. Left Motor,Shorted Transistor
15.1.24. Left Motor,Faulty Transistor Drive
15.1.25. Left Motor,Faulty Current Sensor
15.1.26. Left Motor,Armature Over-current
15.1.27. Left Motor,Stall Timer
15.1.28. Left Motor,Faulty Field Circuit
15.1.29. Left Motor,Faulty Field Drive
15.1.30. Left Motor,Field Over-current
15.1.31. Pump Motor,Faulty Circuit
15.1.32. Pump Motor,Transistor Wire Breakage
15.1.33. Pump Motor,Shorted Transistor
15.1.34. Pump Motor,Faulty Transistor Drive
15.1.35. Pump Motor,Faulty Current Sensor
15.1.36. Pump Motor,Armature Over-current
15.1.37. Line Contactor,Abnormality
15.1.38. Regeneration Contactor,Abnormality
15.1.39. Pump Contactor,Abnormality
15.1.40. Regeneration Diode,Abnormality
15.1.41. Right Armature Diode,Abnormality
15.1.42. Left Armature Diode,Abnormality
15.1.43. Pump Armature Diode,Abnormality
15.1.44. Right Motor,Wire Breakage
15.1.45. Left Motor,Wire Breakage
15.1.46. Pump Motor,Wire Breakage
15.1.47. Steering Sensor,Abnormality
15.1.48. Accelerator,Abnormality
15.1.49. Right Vehicle Speed Sensor,Abnormality
15.1.50. Left Vehicle Speed Sensor,Abnormality
15.1.51. E Direction Lever and Accelerator,Faulty Setting
15.1.52. (E)Seat Switch,Faulty Setting
15.1.53. H1 Lift Lever,Faulty Setting
15.1.54. H2 Tilt Lever,Faulty Setting
15.1.55. H3 Attachment 1 Lever,Faulty Setting
15.1.56. H4 Attachment 2 Lever,Faulty Setting
15.1.57. Data Communication,Abnormality
15.1.58. EEPROM,Abnormality
15.1.59. Logic Card,Faulty Initial Setting
15.1.60. Controller,Abnormality
15.1.61. Battery Voltage,Excessively Low (For 48-V Vehicles Only)
15.1.62. Battery Voltage,Excessively High (For 36-V Vehicles Only)

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