Mitsubishi Electric Forklift Truck FB40, FB45, FB50 Workshop Service Manual

Service Manual Chassis & Mast FB40 FB45 99759-56120 FB50

Table of contents Drive compartment .................................................................................... 1 General Truck Data ................................................................................... 2 Test and Setting Values ............................................................................. 5 Torques ...................................................................................................... 8 Parameter and options setting................................................................. 10 Pedal mode ............................................................................................. 13 Lift parameter setting ............................................................................... 14 Force to zero ........................................................................................... 16 Hydraulic functions locked for Multi Pilot trucks ...................................... 17 Steering parameter settings .................................................................... 18 Operating Program Setting ...................................................................... 19 Truck Standard Parameter Setting .......................................................... 20 Battery Parameter Setting ....................................................................... 21 Disk brake................................................................................................ 23 Brake system ........................................................................................... 24 Spring-loaded parking brake ................................................................... 25 Block diagram .......................................................................................... 26 Electrical System ..................................................................................... 27 Service note:............................................................................................ 27 Display in Error Logbook ......................................................................... 28 Diagnostic Mode ...................................................................................... 29 Service LISA ............................................................................................ 35 Commissioning with the Service LISA ..................................................... 36 Parameter Overview ................................................................................ 37 Contactors ............................................................................................... 40 Exposing the traction and lift controllers .................................................. 41 Exposing the CANION interface .............................................................. 41 Fan .......................................................................................................... 42 Electrical fuses ........................................................................................ 43 Solo pilot connector layout ...................................................................... 44 Multi pilot connector layout ...................................................................... 55 Drive ........................................................................................................ 65 Travel switch/Accelerator pedal ............................................................... 66 Controller Functional Description ............................................................ 67 Exposing the traction and lift controllers .................................................. 68 Traction current controller ........................................................................ 69 Drive ........................................................................................................ 70 Wheels/Axles ........................................................................................... 70 Operating Instructions ............................................................................. 71 Wiring Diagrams ...................................................................................... 72 Hydraulic system ..................................................................................... 74 Multi-Pilot ................................................................................................. 76 Solo Pilot Block Diagram ......................................................................... 78 Multi-Pilot Block Diagram ........................................................................ 79 Hydraulic System..................................................................................... 80 Control valve............................................................................................ 82 Chassis / load section connection .......................................................... 86 Maintenance of Mitsubishi Products ........................................................ 86 Maintenance checklist ............................................................................. 89 Additional test items for UVV inspection.................................................. 92 Steering system block diagram ............................................................... 93 Steering axle Design ............................................................................... 94 Power steering pump............................................................................... 95 Steering system ....................................................................................... 96 SLC 018 305 Steering Controller............................................................. 97 Checking the Electrical Installation .......................................................... 98 Operating the Steering Computer............................................................ 99 Special Function Menu .......................................................................... 100 Operating Data Display ......................................................................... 102 I/O Data Display (Diagnostics) .............................................................. 107 Error Log................................................................................................ 108 Axle Adjustment ......................................................................................112 Starting an Adjustment ...........................................................................113 Preparing Steering Mode........................................................................118 Version Display .......................................................................................118 Error List (not password protected) ........................................................119

Brake Design ......................................................................................... 137 Brake Disassembly ................................................................................ 138 Brake and Gearbox Housing Assembly ................................................. 141 Spring-Loaded Brake Assembly / Cylinder Length Adjustment ............. 145 Bleeding the Brake System ................................................................... 146 Speed sensor ........................................................................................ 148 Steering angle sensor replacement / adjustment .................................. 149 Spring Loaded Brake Test and Removal ............................................... 151 Main brake cylinder (single stage) ......................................................... 155 Maintenance and Repairs...................................................................... 155 Measuring the minimum braking ratio and braking distance ................. 156 FB series ............................................................................................... 158 Guidelines for Installing Brake Lines ..................................................... 159 Parking Brakes ...................................................................................... 160 Requirements ........................................................................................ 160 Tests ...................................................................................................... 161 Steering Aux. Motor Connection Layout ................................................ 162 Fork Arms .............................................................................................. 163 Length check of load chains .................................................................. 165 Control valve standard setting ............................................................... 166 Optional version for large auxiliary consumers ..................................... 168 Pressure relief valve setting (DBV)........................................................ 170 Checking the line break safety device ................................................... 170 Lowering speed setting.......................................................................... 170 Information and Service Display ............................................................ 170 Instrument panel and LCD display ....................................................... 171 Functional description and display functions ......................................... 172 Switch functions..................................................................................... 173 Settings.................................................................................................. 174 Instructions for the prevention of accidents and damage to equipment when performing servicing, checking and repair operations on fork lift trucks equipped with electronic assemblies ........ 177 Instructions for the prevention of functional failures and damage to equipment when performing cleaning operations on fork lift truck .... 179

1 Drive compartment Item Description 1 Mast 2 Overhead guard 3 Driver’s seat 4 Steering column 5 Steering axle 6 Counterweight 7 Drive unit 8 Hydraulic reservoir 9 Hydraulic unit 10 Fork carriage 11 Spring-loaded cylinder 12 Electrical system 13 Steering unit ﬁg. 1

2 FB 40 FB 45 FB 50 A Chassis/Superstructure: Capacity t See operating instructions and data plate Load centre of gravity mm Load distance (DZ mast +32 mm) mm Wheelbase mm Turning radius mm Net weight (including battery) Kg Axle load with load front/rear Kg Axle load w.o. load front/rear Kg B Drive Type of controller Type See operating instructions Rated tow force w / w.o. load S2/60 min. N Max. tow force w / w.o. load S2/5 min. N Gradeability w/w.o. load S2/30min. % General Truck Data

3 FB 40 FB 45 FB 50 Max. gradeability w/w.o. load S2/5min. % See operating instructions Acceleration time w. /w.o. load to 10 m sec Noise level, driver’s ear db(A) Travel speed w/w.o. load km/h G Mast / Load Section Mast height (retracted) mm See operating instructions Mast height (extended) mm Overhead Guard Height (cabin + 15mm) mm Free lift mm Lift mm Fork dimensions s/e/l mm 50 x 125 x 1150 50 x 150 x 1150  Fork carriage DIN 15173, class / type A, B    Fork carriage width mm

4 FB 40 FB 45 FB 50 G1 Attachments Attachment coupling type / DIN    I Hydraulic system Pump motor Capacity at S3 15% kW    K Battery Battery in accordance with DIN   

5 Test and Setting Values FB 40 FB 45 FB 50 B Drive Traction motor output (S2 = 60 min) kW    Current consumption D Brake Service brake    Service brake pressure bar    Spring-loaded accumulator cylinder spring pre-tension (lift) mm    E Wheels/Axles Full rubber tyres See operating instructions Front tyre size Rear tyre size Track width, front mm Track width, rear mm

6 FB 40 FB 45 FB 50 F Steering system Steer motor kW    Pressure relief valve (not adjustable) bar    Impact valve (not adjustable) bar    G Mast / Load Section Mast lift cylinder line break safety device LB3C 0,8-70 (s=) mm Line break safety device / Lowering brake valve LB4C 0,8-110 Free lift cylinder (s=) mm G1 Attachments Max. operating pressure bar    Oil ﬂow for attachments I / min    H Chassis / load section connection Mast / fork carriage fwd./rev. tilt α°/β°   

7 FB 40 FB 45 FB 50 I Hydraulic system Lift speed w/w.o. load m/s See operating instructions Lowering speed w/w.o. load m/s K Battery Battery V/Ah See operating instructions and data plate Battery weight Kg

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Mitsubishi Electric Forklift Truck FB40, FB45, FB50 Workshop Service Manual

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