This service manual provides comprehensive information for the maintenance and repair of Mitsubishi forklift trucks, specifically focusing on models equipped with the "Controller" system. The manual covers various models including FBC15N, FBC18N, FBC18LN, FBC20N, FBC25EN, FBC25N, FBC25LN, FBC30N, and FBC30LN, with specific serial number ranges for each. The document is structured to guide technicians through servicing procedures, emphasizing safety and proper operational practices.
Function Description:
The core of the Mitsubishi forklift truck's operation, as detailed in this manual, revolves around the "Controller" system. This system is responsible for managing the truck's traveling, lifting, and safety functions. It comprises a "Logic Unit" and an "Inverter," which work in conjunction to control the various motors and actuators.
The "Logic Unit" acts as the central brain, containing a "Logic Card" that processes input signals from various switches (Key switch, Direction lever, Accelerator, Service brake, Parking brake, Seat switch, Seat belt switch, DRS switch, Horn switch, etc.). Based on these inputs, the Logic Unit executes control over traveling, lifting, and safety functions. It communicates with the "Inverter" via the Controller Area Network (CAN) to send motor control commands and receive sensing data. Additionally, the Logic Unit communicates with a "Display" unit through a serial communication protocol (RS232C) to show truck conditions and setting data.
The "Inverter" is responsible for controlling the AC induction traction (drive) motor and, in "Transistor Control Type" systems, the AC induction pump motor. It receives commands from the Logic Unit and translates them into appropriate motor control signals.
The manual describes two main system configurations for lifting control:
- Contactor Control Type: In this configuration, the DC pump motor is controlled by a contactor. The Logic Unit sends a "Contactor control signal" to manage the pump motor, which drives the hydraulic pump for the lift and tilt cylinders. A "Lift lock solenoid valve" is also controlled by the Logic Unit to manage hydraulic functions.
- Transistor Control Type: This more advanced configuration utilizes an additional "Pump Inverter" with its own "DSP card" to control an AC induction pump motor. This allows for more precise and efficient control of the hydraulic pump, which in turn operates the lift and tilt cylinders. Similar to the Contactor Control Type, a "Lift lock solenoid valve" is present.
Both configurations include a "Steering motor" (M) and a "Traction motor" (IM) controlled by the "Traction Inverter" (which includes a "DSP card" and "Sensors"). The hydraulic system, whether DC or AC pump motor driven, involves a "Hydraulic control valve assembly" with "Micro switches" and "Sensors" to manage the lift and tilt cylinders.
Important Technical Specifications:
While specific numerical specifications for components like motor power or battery voltage are not explicitly listed on the provided pages, the manual outlines the fundamental architecture and communication protocols:
- Communication:
- Logic Unit and Inverter: Controller Area Network (CAN)
- Logic Unit and Display: RS232C serial communication protocol
- Units: The manual uses SI Units, with conversion tables provided for customary units (e.g., Force: 1 N = 0.1020 kgf; Pressure: 1 kPa = 0.0102 kgf/cm²; Torque: 1 N·m = 0.1020 kgf·m).
- Thread Types: Specifications for various pipe threads are mentioned, including Taper pipe thread (external) 1/4 inch (R1/4), Taper pipe thread (internal) 1/8 inch (Rc1/8), Straight pipe thread (external) 1/4 inch (G1/4A), and Straight pipe thread (internal) 1/8 inch (Rp1/8).
- Gear Backlash (Example): A service data example shows a standard gear backlash of 0.11 to 0.28 mm (0.0043 to 0.0110 in.) and a repair/service limit of 0.5 mm (0.020 in.). This indicates the level of precision expected in mechanical components.
Usage Features:
The manual implicitly describes features related to the truck's operation and control:
- Comprehensive Control: The Logic Unit integrates control for traveling, lifting, and safety, ensuring coordinated operation.
- Display Unit Feedback: The display unit provides operators with real-time information on truck conditions and settings, enhancing operational awareness.
- Safety Functions: The Logic Unit incorporates various safety functions, processing inputs from switches like the seat switch and seat belt switch to ensure safe operation.
- DRS Modes: The mention of "Diagnosis/Run/Setup (DRS) Modes" indicates that the controller supports different operational modes for diagnostics, normal running, and configuration.
- Setup Options: The "Setup Option" section suggests that various parameters of the truck's operation can be configured, allowing for customization to specific operational needs or operator preferences. This includes details on "Operation Procedure" and "Details of Setup Options."
Maintenance Features:
The service manual is primarily a maintenance and repair guide, offering extensive features for technicians:
- Structured Information: Instructions are grouped by systems for easy reference.
- Safety Emphasis: The manual prominently features "WARNING," "CAUTION," and "NOTE" signs to highlight potential hazards, risks of damage, and important conditions. A detailed "SAFETY" section outlines numerous precautions, including wearing protective gear, proper lifting techniques, handling hot parts, and safe removal of components.
- Disassembly Diagrams and Sequences: The "HOW TO USE THIS MANUAL" section illustrates how to interpret disassembly diagrams, which show components in an exploded view, and provides a sequence of steps for removal and reassembly.
- Service Data: Critical measurements and limits (e.g., gear backlash) are provided to guide technicians in determining when a component needs repair or replacement.
- Troubleshooting: A dedicated "TROUBLESHOOTING FOR CONTROL CIRCUITS" section addresses issues like faulty central vehicle monitor systems, diagnosis indications, and other abnormalities, aiding in efficient problem identification.
- Component-Specific Procedures: The manual details procedures for various components:
- Controller: Covers system configuration, features, setup options, diagnosis, removal and installation, and basic checks. This includes specific procedures for inverter discharging, replacing the inverter, ensuring proper thermal transfer, and replacing DSP cards, logic units, logic cards, and power supply cards.
- Motors: Provides information on motor installation positions, specifications, structures, tightening of high-power cable terminals, and procedures for removal, installation, disassembly, and reassembly.
- Basic Checks: Includes instructions for testing tools, measuring card voltage, checking contactor coils and tips, checking the inverter, and performing regeneration checks.
- AC Motor System Basics and Troubleshooting: Offers foundational knowledge and troubleshooting steps for AC motor systems.
- Asbestos Handling: Specific precautions are outlined for handling parts containing asbestos, including avoiding compressed air, brushing, or grinding, and recommending moist cloth cleaning, vacuum cleaners with particle filters, well-ventilated areas, masks, and adherence to environmental regulations.
- General Repair Practices: Emphasizes using tools in good condition, reinstalling fasteners with the correct part numbers, working on level surfaces, disconnecting batteries and discharging capacitors (for electric trucks), proper welding procedures, protecting wiring, and supporting masts and carriages during maintenance.
- Fluid System Safety: Warnings are given regarding loose or damaged fuel, lubricant, and hydraulic lines, and the danger of high-velocity oil streams from pinhole leaks.
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