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Summary of Contents for FB16KT

Page 1: ...Service Manual 99719 5A100 For use with FB16KT FB20KT Chassis Service Manual Controller FB16KT EFB4A 00011 up FB18KT EFB5A 00011 up FB20KT EFB5A 50001 up ...

Page 2: ...iptions illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing Mitsubishi reserves the right to change specifications or design without notice and without incurring obligation Pub No 99719 5A100 Safety Related Signs The following safety related signs are used in this service manual to emphasize important and...

Page 3: ...ays 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...

Page 4: ...ses 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 exces...

Page 5: ... Output shaft Removing Remove output shaft using a special tool Service Data A Standard Value B Repair or Service Limit 1 2 209603 Sequence 1 Cover Bolt Washer part name 2 Snap ring part name A 0 11 to 0 28 mm Gear Backlash 0 0043 to 0 0110 in B 0 5 mm 0 020 in 209604 Disassembling sequence Procedures are described in the text ...

Page 6: ... external 1 4 inch formerly PF1 4 A Rp1 8 Straight pipe thread internal 1 8 inch formerly PS1 8 Units 1 SI Units are used in this manual 2 The following table shows the conversion of SI unit and customary unit Item SI unit Customary unit Force 1 N 0 1020 kgf 1 lbf 0 4536 kgf Pressure 1 kPa 0 0102 kgf cm2 1 psi 0 0703 kgf cm2 Torque 1 N m 0 1020 kgf m 1 lbf ft 0 1383 kgf m ...

Page 7: ...roller components Inspection and adjustment Service data TROUBLESHOOTING Faulty central vehicle monitor system Faulty diagnosis indication FOR CONTROL or Other abnormalities CIRCUITS MOTORS Drive motor Pump motor EPS motor GROUP INDEX 1 2 3 ...

Page 8: ...eration Characteristic 48 V type 1 11 Steering Characteristic 1 6 ton type 1 12 Steering Characteristic 1 8 ton type 1 13 Steering Characteristic 2 0 ton type 1 14 Hydraulic System 1 15 Manual Control Model 1 15 Finger tip Control Model 1 15 Fail safe System 1 16 Output Power Control at Low Battery Voltage 1 16 Overheat 1 17 Brush Wear 1 17 Maximum Vehicle Speed Control SUO 7 1 17 Output Power Con...

Page 9: ...gnosis 1 19 Other Functions 1 20 Display Unit 1 20 BDI Battery Discharge Indicator 1 20 Hourmeters and Time Display 1 20 Vehicle Speed and Error Code Display 1 21 Action Lights LEDs 1 21 Inspection and Adjustment 1 30 Inspection and Adjustment Tools 1 30 Removal and Installation of Logic Card 1 30 Tightening of High tension Cable Terminals 1 31 Component Testing 1 32 Service Data 1 73 Tightening T...

Page 10: ...perate the drive motors pump motor and power steering system Logic card The logic card is a printed circuit board located on the main controller panel Most of the circuits on the board are used to control input and output voltages to and from the microprocessor Microprocessor MPU The software in the microprocessor controls the drive system pump motor and central vehicle monitor system CVMS Selecto...

Page 11: ... 1 206795A 1 Logic card 2 Head capacitors 3 Current sensor 4 Regeneration contactor 5 Lift fuse 325 A 6 Line contactor 7 Line fuse 500 A 8 DRS switch for malfunction diagnosis and program option setting 9 Power steering fuse 50 A 1 2 9 6 7 4 5 3 8 ...

Page 12: ...Hydraulic system diode D1P 2 Drive system diode D1L 3 Drive system diode D1R 4 Drive system IGBT T1L 5 Drive system IGBT T1R 6 Hydraulic system IGBT T1P 7 Regeneration system diode D2 8 Temperature sensor NOTE IGBT stands for Insulated Gate Bipolar Transistor ...

Page 13: ...c Card Components 206797 1 Selector switches SW1 to SW8 2 Microprocessor MPU 3 CN1 connector Pin Nos 1 to 22 4 CN2 connector Pin Nos 23 to 38 5 CN3 connector Pin Nos 39 to 64 Odd number pins on tops Even number pins on bottom ...

Page 14: ...2 0 tons The maximum vehicle speed varies depending on load weight as shown in the table below Voltage Hydraulic control Remarks 48 V Chopper Maximum field current of drive motor 40 A Maximum armature current of drive motor 250 A Truck Models FB16KT FB18KT FB20KT Travel Speeds 48 V km h mph 16 14 10 8 7 16 14 10 8 7 16 14 10 8 7 Unloaded Loaded Gradeability Loaded 48 V 19 17 15 ...

Page 15: ...When the direction lever is in the neutral position the controller turns the regeneration contactor OFF and cuts off the current to the armature When the lever is moved to the neutral position while the vehicle is moving the vehicle continues traveling due to inertia When the lever is shifted to neutral from forward or reverse position the controller maintains the neutral mode for five seconds and...

Page 16: ...Current Table 48 V type 207520 Armature Current Table 207521 Shunt Current Table High power mode Standard mode Economy mode Thermal Battery 0 mode Brake Limit mode High power Standard Economy mode Thermal Battery 0 mode Brake Limit mode ...

Page 17: ...t Regen Speed Power Tilt eration eration lift lift regen A Normal M M Std M M M 14 2 2 7 9 6 3 b High F F Power F M M 16 3 3 7 10 6 3 performance C Economy S S Eco S M M 12 1 1 6 8 6 3 d Long travel F M Power M M M 16 2 3 7 9 6 3 E Short shuttle S F Eco F M M 12 3 2 7 10 6 3 SUO 7 8 9 2 3 4 23 M Medium SUO Setup options F Fast S Slow ...

Page 18: ...ic selected by SUO 22 see pages 1 10 and 1 23 b Mode 2 Accelerator regeneration The regeneration function is activated when the accelerator pedal is released The amount of regeneration is determined by the automatic regeneration characteristic selected by SUO 23 see pages 1 11 and 1 23 When the vehicle speed is 1 km h 0 62 mph or slower the regeneration function is inactive 3 Regeneration mode pri...

Page 19: ...1 10 MAIN CONTROLLER Lever Regeneration Characteristic 48 V Type 207524 207525 Armature Current Table Range 5 Range 1 Shunt Current Table Range 3 4 5 Range 1 2 ...

Page 20: ...1 11 MAIN CONTROLLER Auto Regeneration Characteristic 48 V Type 207528 207529 Armature Current Table Shunt Current Table Range 5 Range 1 Range 5 Range 1 2 3 ...

Page 21: ...ure Current Table 90 60 30 0 30 60 90 100 80 60 40 20 0 I Left Motor Right Motor Steering Angle degrees Left Right 207532 Shunt Current Table 90 60 30 0 30 60 90 100 80 60 40 20 0 20 40 60 80 100 120 Steering Angle degrees I Left Right Left Motor Right Motor 207533 ...

Page 22: ...ure Current Table Shunt Current Table 90 60 30 0 30 60 90 100 80 60 40 20 0 20 40 60 80 100 120 Steering Angle degrees I Left Right Left Motor Right Motor 90 60 30 0 30 60 90 100 80 60 40 20 0 I Left Motor Right Motor Steering Angle degrees Left Right 207534 207535 ...

Page 23: ...ure Current Table Shunt Current Table 90 60 30 0 30 60 90 100 80 60 40 20 0 20 40 60 80 100 120 Steering Angle degrees I Left Right Left Motor Right Motor 90 60 30 0 30 60 90 100 80 60 40 20 0 I Left Motor Right Motor Steering Angle degrees Left Right 207536 207537 ...

Page 24: ...aulic levers are used to operate the pump motor The fixed duties selected by the setup options below provide chopper control for the IGBTs 1 Start lift speed SUO 2 and top lift speed SUO 3 The two stage lift lever is used to set the speed The first stage is for the start lift speed and the second stage is for the top lift speed Do not set the start lift speed faster than the top lift speed 2 Tilt ...

Page 25: ...e battery voltage momentary becomes higher than 22 V and less than 25 V the following limit control is activated When this happens the Battery LED on the display flashes Drive motors The output power is controlled according to the powering characteristic In the 48 V vehicle the brake limit mode is activated Brake limit mode Drive motor power is controlled while the brake pedal is depressed See pag...

Page 26: ... is controlled when the service brake or parking brake is applied 1 Service brake Maximum shunt current 15 A maximum armature current 125 A 2 Parking brake Maximum shunt current 15 A maximum armature current 125 A 3 Normal Maximum shunt current 40 A maximum armature current 250 A Chat Timer SUO 24 When the following conditions remain for the time duration set by SUO 24 the line contactor turns OFF...

Page 27: ... switch to R then to D When there is no data to display a done indication appears The display does not repeat showing data from the beginning 2 To delete data Operate the DRS switch until the display shows done With done on the display keep the DRS switch at S for more than one second then return the DRS switch to R This deletes all data in the memory then the done indication on the display flashe...

Page 28: ...ard is replaced be sure to perform this setting first Set the DRS switch to S Set the seat switch to OFF Shift the direction lever to R hold the accelerator pedal pressed then turn the key switch on The display indicates done Set the DRS switch to R Self diagnosis Check the input and output status For details refer to the self diagnosis table Set the DRS switch to D and turn on the key switch to e...

Page 29: ...eaches the set speed an alarm signal logic card hardware output signal is generated 4 Tire size adjustment SUO 27 This function provides a correction value to compensate for a diameter change resulting from tire wear It is used to adjust the vehicle speed data Display Unit BDI Battery Discharge Indicator The battery discharge level is indicated by the 10 segment LCD This indication is based on the...

Page 30: ...r or the controller overheats 4 Battery The indicator flashes when the BDI has one indicator segment and stays lit when the BDI has no segment The indicator flashes when the battery voltage momentarily becomes higher than 22 V and lower than 25 V The indicator turns off when the voltage exceeds 25 V The indicator lights when the battery voltage momentarily becomes lower than 22 V Once all the indi...

Page 31: ... STANDARD 1 2 3 2 2 3 POWERFUL This option sets the time which indicates the maintenance time for the operator The amount of time set by this operation is added to the truck s hourmeter at that time 100 to 500 hours in and the total value is stored in memory as 50 hr increments the maintenance time When the truck s Attached to the 10 Service Indicator hourmeter reaches maintenance time value the p...

Page 32: ...to 99 0 Reduction 2 Auxiliary Input for 17 Lift and Drive Same as 11 Same as 11 0 Speed 3 18 Auxiliary Travel Travel speed limit for 17 48 V type 5 to 16 km h 10 Speed Limit 3 19 Auxiliary Power Power reduction ratio for 17 0 to 99 0 Reduction 3 If a drive motor stalls for the amount 20 Stall Timer time set by this option the motor 2 to 10 sec 5 current gets to 0 1 Brake regen accelerator must be ...

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