Mitsubishi FB161820KT Forklift Service Manual
Mitsubishi FB161820KT Forklift Service Manual - Image 2
Mitsubishi FB161820KT Forklift Service Manual - Image 3
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Mitsubishi FB161820KT Forklift Service Manual - Image 5

Mitsubishi FB161820KT Forklift Service Manual

$50.00

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

Product details

  • 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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