Mitsubishi Forklift OPB 20NE 20NEP 10NEF 10NEFP 20NEX 20NEXP TBR30N Trucks Service Manual – PDF DOWNLOAD
DESCRIPTION:
Mitsubishi Forklift OPB 20NE 20NEP 10NEF 10NEFP 20NEX 20NEXP TBR30N Trucks Service Manual – PDF DOWNLOAD
FOREWORD:
This service manual is a guide for servicing lift trucks. The long productive life of your lift truck depends on regular and proper servicing, consistent with the instructions provided in this service manual. Before you start to test, repair or rebuild a lift truck, read the respective sections of this manual carefully and make sure that you know all of the components. The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing. The manufacturer reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience, the instructions are grouped by systems as an easy reference. Unauthorized copying and lending of this material is strictly prohibited.
Work safety:
- Unauthorized truck modification is not permitted. No modifications or alterations to a powered industrial truck, which could affect, for example, capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof.
- This includes changes affecting, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer or his successor approves a modification or alteration, the manufacturer or successor shall also make and approve appropriate changes to the capacity plate, decals, tags and operation and maintenance handbooks.
- Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business, may the user arrange for a modification or alteration to a powered industrial truck, provided, however, that the user:
a. arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety,
b. maintains a permanent record of the design, test(s) and implementation of the modification or alteration,
c. approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook, and © Mitsubishi Forklift Trucks 2013. All rights reserved. Revision: A Document ID: 618022 13 (210) PBP Service Manual
d. affixes a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks.
• Switch off the truck’s power before opening the cover of the motor compartment or the electrical system.
• Relieve all pressure in the air, oil or water systems before disconnecting or removing any lines, fittings or related items. Release the residual pressure when removing a pressurized device.
• With sit-on trucks, dismount the seat for the duration of the service work.
• Before operating, lubricating or repairing the product, read all warning plates and decals on the truck.
• Do not use your hands to check for oil leaks.
• To avoid burns, pay attention to the hot sections and hot fluids in lines, tubes and compartments, even when the truck is idle or off.
• Only use clean oil in the hydraulic system.
• Repairs requiring welding should be performed only with the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal.
• When welding, always disconnect the battery and electronic devices. Remove all paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding.
• Use proper lifting procedures when removing any components.
• Be careful when removing cover plates. Gradually remove the last two bolts or nuts located at opposite ends of the cover or device. Before removing the last two bolts or nuts completely, pry the cover loose to relieve any springs or other pressures.
• Be careful when removing filler caps, breathers and plugs on the truck. Wrap a cloth around the cap or plug to prevent being sprayed or splashed by liquids under pressure. Be aware that the danger of being sprayed or splashed is always greater immediately after stopping the truck, as the fluids are very hot.
• Use only well-maintained tools. Also make sure that you use the tools in a proper way.
• Reinstall all fasteners with the same part number. If a replacement is needed, do not use a fastener of lesser quality.
FILE DETAILS:
Mitsubishi Forklift OPB 20NE 20NEP 10NEF 10NEFP 20NEX 20NEXP TBR30N Trucks Service Manual – PDF DOWNLOAD
Format: PDF
Language: English
Brand: Mitsubishi
TABLE OF CONTENTS:
Mitsubishi Forklift OPB 20NE 20NEP 10NEF 10NEFP 20NEX 20NEXP TBR30N Trucks Service Manual – PDF DOWNLOAD
Contents 3
1 Foreword 10
2 How to read this manual 11
2 1 Safety-related signs 11
2 2 Symbols and abbreviations 11
2 2 1 Safety symbols 11
2 2 2 Other symbols and abbreviations 13
2 3 Units 13
3 Safety instructions 14
3 1 Service area safety 14
3 2 Personal safety 15
3 3 Work safety 15
4 General information 18
4 1 Truck models covered by this manual 18
4 2 Identification plates on the truck 18
4 3 Overview of the truck 21
4 3 1 Operating position 21
4 3 2 Operating direction 21
4 3 3 Operating devices 22
4 3 4 Control panel 23
4 3 4 1 Control panel controls 23
4 3 5 Control panel for 360° steering 25
4 3 5 1 Control panel controls 25
4 3 6 Side control panel 27
4 3 6 1 Emergency stop button 28
4 3 6 2 Start button 29
4 3 6 3 Key switch 30
4 3 7 Truck display 30
4 3 7 1 Display control buttons 31
4 3 7 2 Main view of the truck display 33
4 3 7 3 Hierarchy of the truck display menus 34
4 3 7 4 Message center 35
4 3 7 5 Main menu 36
4 3 7 6 Performance modes 40
4 3 7 7 Activate the truck with the PIN code 42
4 3 7 8 Program a new PIN code 42
4 3 8 Second level order picking 45
4 3 9 Lifting platform 46
4 3 10 Simplex mast unit 48
4 3 11 Scissor lift 49
© Mitsubishi Forklift Trucks 2015 All rights reserved Revision: A Document ID: 624878 4 (352)
OPB20NE/20NEP/10NEF/10NEFP/20NEX/20NEXP Service Manual
4 3 12 Trailer coupling 50
5 Mechanical maintenance 51
5 1 Lifting points 51
5 1 1 Jack points 51
5 1 2 Hoist points 52
5 2 Transportation 53
5 3 Order spare parts 53
5 4 Truck covers 54
5 4 1 Front mask 55
5 4 2 Front cover 55
5 4 3 Machinery cover 56
5 4 4 Back cover 56
5 4 5 Front bumper 56
5 4 6 Battery cover 57
5 4 6 1 Remove the battery cover lock 58
5 5 Transmission gear 59
5 5 1 Remove the transmission gear 59
5 6 Slewing bearing 61
5 7 Traction wheel 62
5 7 1 Disassemble the traction wheel 63
5 7 1 1 Replace the wheel shaft bolts 63
5 7 2 Assemble the traction wheel 65
5 8 Load wheels 65
5 9 Lifting system and fork carriage 67
5 9 1 Disassemble the linkage mechanism 67
5 10 Castor wheels 70
5 10 1 Remove the castor wheel unit 70
5 10 2 Disassemble the castor wheel 71
5 10 3 Assemble the castor wheel 71
5 11 Drive unit 72
5 11 1 Drive unit suspension 72
5 11 1 1 Replace the springs 73
5 11 2 Replace the shafts of the motor bed 74
5 12 Steering wheel 76
5 12 1 Remove the truck display 76
5 12 2 Adjust the steering wheel 78
5 12 3 Remove the steering wheel 78
5 12 4 Replace the gas spring of the steering wheel 80
5 13 360º steering 84
5 13 1 Remove the 360º steering wheel 84
5 13 2 Remove the truck display 84
5 13 3 Disassemble the 360º steering wheel 85
5 13 4 Replace the sensor of the 360º steering wheel 86
5 13 5 Replace the display control buttons 87
5 13 6 Replace the control switches 88
5 13 7 Replace the parking brake button 89
5 13 8 Replace the emergency stop button 90
5 13 9 Replace the accelerator 91
© Mitsubishi Forklift Trucks 2015 All rights reserved Revision: A Document ID: 624878 5 (352)
OPB20NE/20NEP/10NEF/10NEFP/20NEX/20NEXP Service Manual
5 14 Simplex mast unit 92
5 14 1 Simplex mast unit detailed construction 92
5 14 2 Maintenance of the mast unit 92
5 14 2 1 Daily maintenance 93
5 14 2 2 Monthly maintenance 93
5 14 2 3 Annual maintenance (600 h) 93
5 14 3 Lubricant and fluid recommendations 93
5 14 3 1 Mast chains 93
5 14 3 2 Mast channels 94
5 14 4 Remove the mast unit 94
5 14 5 Disassemble the mast unit 97
5 14 6 Inspect the forks 99
5 14 6 1 Welded forks 99
5 14 7 Mast chains 101
5 14 7 1 Inspect the mast chains 101
5 14 7 2 Inspect the tension of the mast chains 108
5 14 7 3 Adjust the mast chains 109
5 14 7 4 Replace the mast chains 109
5 14 8 Lifting cylinder 111
5 14 8 1 Replace the lifting cylinder 112
5 14 8 2 Sealing housing of the lifting cylinder 114
5 14 8 3 Bleed the lifting cylinder 115
5 15 Operator presence sensing platform 117
5 15 1 Maintenance of the operator presence sensing platform 118
5 15 1 1 Replace the spring 118
5 15 1 2 Replace the operator platform sensor 119
5 15 1 3 Replace the rubber stoppers 121
5 16 Lifting platform 123
5 16 1 Remove the lifting platform 123
5 16 2 Replace the spring 126
5 16 3 Replace the lifting platform sensor 128
5 16 4 Replace the rubber stoppers 130
5 16 5 Replace the wiring harness 132
5 16 6 Remove the lifting platform cylinder 133
5 16 7 Remove the lifting platform pedal 134
5 16 8 Bleed the side cylinder 135
5 16 9 Guidance rollers 136
5 16 9 1 Adjust the guidance rollers 136
5 17 Scissor lift 137
5 17 1 Remove the scissor lift carriage 137
5 17 2 Disassemble the scissor lift fork 140
5 17 3 Disassemble the scissors 141
5 17 4 Remove the scissor lift hydraulic cylinder 142
5 18 Trailer towing unit 143
5 18 1 Trailer coupling 143
5 18 1 1 Adjust the height of the trailer coupling 143
5 18 1 2 Remove the trailer coupling 144
© Mitsubishi Forklift Trucks 2015 All rights reserved Revision: A Document ID: 624878 6 (352)
OPB20NE/20NEP/10NEF/10NEFP/20NEX/20NEXP Service Manual
5 18 2 Load wheels 144
5 18 2 1 Remove the load wheels 144
5 18 2 2 Adjust the brake disc of the load wheel 145
5 18 2 3 Adjust the coil of the electrical brake 147
5 18 2 4 Remove the coil of the electrical brake 148
6 Electrical operation 149
6 1 Schematic diagram 149
6 2 Power source 152
6 3 Safety circuit (emergency stop button) 152
6 4 Key switch 152
6 5 Traction 153
6 6 AC motor operation 153
7 Battery maintenance 154
7 1 Safety precautions concerning the handling of lead-acid batteries 155
7 2 Battery maintenance 156
7 2 1 Daily maintenance 156
7 2 2 Weekly maintenance 156
7 2 3 Monthly maintenance 156
7 2 4 Annual maintenance 156
7 2 5 General maintenance 157
7 2 6 Storage 157
7 2 7 Malfunctions 157
7 2 8 How to clean batteries 157
7 3 Charge the battery 159
7 4 Measure the specific gravity of the battery 162
7 5 Replace the battery 163
8 Electric system maintenance 164
8 1 Control panel 164
8 1 1 Emergency stop button for models without the lifting platform 164
8 1 2 Emergency stop button for models with the lifting platform 165
8 1 3 Start button 166
8 1 4 Key switch 167
8 1 5 Pedestrian control buttons (optional) 168
8 2 Electric panel 169
8 2 1 Discharge the controllers 170
8 2 2 Traction controller 171
8 2 3 Traction controller connector 171
8 2 3 1 CNA external connector 172
8 2 3 2 Description of the power connections 175
8 2 4 Steering controller 175
8 2 4 1 CNA external connector 176
8 2 4 2 CNB external connector 177
8 2 4 1 Description of the power connections 177
8 2 5 Contactors and relays 178
8 2 6 Fuses 179
© Mitsubishi Forklift Trucks 2015 All rights reserved Revision: A Document ID: 624878 7 (352)
OPB20NE/20NEP/10NEF/10NEFP/20NEX/20NEXP Service Manual
8 2 7 Remove the controller fan 180
8 3 Truck connector 181
8 3 1 Replace the truck connector 182
8 4 Motor compartment 183
8 4 1 Remove the drive unit 184
8 4 2 Disassemble the drive unit 185
8 4 3 Traction motor 187
8 4 3 1 Install the traction motor 187
8 4 3 2 Assemble the splined shaft-hub connection 188
8 4 3 3 Temperature sensor check 189
8 4 3 4 Steering motor 191
8 4 4 Pump motor 192
8 4 4 1 Solenoid valve 193
8 4 5 Magnetic brake 194
8 4 5 1 Adjust the air gap of the magnetic brake 194
8 4 5 2 Coil resistance measurement 194
8 5 Sensors 195
8 5 1 Battery cover lock sensor 197
8 5 1 1 Remove the battery cover lock sensor 198
8 5 2 Pressure sensor 199
8 5 3 Steering reference sensor 200
8 5 4 Steering wheel sensor 201
8 5 5 Forks lift upper limit sensor 202
8 5 5 1 Adjust the forks lift upper limit sensor 203
8 5 6 HALL sensor 204
8 5 6 1 Replace the HALL sensor 205
8 5 7 Operator platform sensor 206
8 5 8 Mast operating speed reduction sensor 207
8 5 9 Scissor lift sensors 208
8 5 9 1 Scissor lift upper limit sensor and slow driving speed sensor 208
8 5 10 Lifting platform sensors 209
8 5 10 1 Lifting platform upper limit sensor 210
8 5 10 2 Lifting platform slow operating speed sensor 211
8 5 11 Operator presence sensor of the lifting platform 212
8 6 Lifting platform pedal 213
8 7 Horn 214
8 7 1 Diode test with a multimeter 214
9 Electric system adjustments and measurements 216
9 1 Adjusting the electrical steering 216
9 1 1 Assembly of the reference sensors 216
9 1 2 Steering teaching 217
9 2 Insulation resistance test 217
9 2 1 Test voltage 217
9 2 2 Insulation tester check 218
9 2 3 Measure the insulation resistance 218
9 2 3 1 Insulation resistance of the truck 219
9 2 3 2 Insulation resistance of the battery 220
© Mitsubishi Forklift Trucks 2015 All rights reserved Revision: A Document ID: 624878 8 (352)
OPB20NE/20NEP/10NEF/10NEFP/20NEX/20NEXP Service Manual
10 Hydraulic operation 221
10 1 Hydraulic symbols 224
10 2 Hydraulic oil recommendations 226
10 3 Maintenance points of the hydraulic system 227
10 4 Hydraulic aggregate 227
10 4 1 Disassemble the hydraulic aggregate 227
10 4 2 Disassemble the hydraulic oil tank 228
10 5 Replace the hydraulic cylinder 229
10 6 Hydraulic system with the lifting platform 231
10 7 Hydraulic system with the simplex mast 232
11 Digital console 233
11 1 Connect the digital console to the truck 233
11 2 Select the controller 234
11 3 Adjust the parameters with the digital console 235
12 Parameter descriptions 236
12 1 Traction controller 236
12 2 Pump controller 246
12 3 Steering controller 251
13 Alarm codes 255
13 1 Traction controller 255
13 2 Pump controller 267
13 3 Steering controller 273
14 Service data 281
14 1 Special tightening torques 281
14 2 Tightening torques for standard bolts and nuts 281
14 3 Maintenance check list 283
14 4 Lubrication 286
14 4 1 Hydraulic oil 286
14 4 2 Transmission oil 286
14 5 Special tools 287
15 Options 289
15 1 Accessory rack 291
15 1 1 Install the accessory rack 292
15 1 1 1 Install the list bracket 293
15 1 1 2 Install the computer rack 294
15 1 1 3 Install the bottle rack 295
15 1 1 4 Install the pen rack 296
15 1 2 Install the garbage bin 296
15 2 Visual Assistant 297
15 2 1 Install Visual Assistant 298
15 3 Equipment pocket 300
15 3 1 Install the equipment pocket 300
© Mitsubishi Forklift Trucks 2015 All rights reserved Revision: A Document ID: 624878 9 (352)
OPB20NE/20NEP/10NEF/10NEFP/20NEX/20NEXP Service Manual
15 4 Picking plane 301
15 4 1 Install the picking plane 301
15 5 DC-DC converter 302
15 5 1 Install the DC-DC converter 303
15 6 Folding seat 304
15 6 1 Install the folding seat 304
15 7 Padded backrest 306
15 7 1 Install the padded backrest 306
15 8 Battery connector + cables 307
15 8 1 Replace the battery connector 307
15 9 Charger connector 308
15 9 1 Replace the charger connector 308
15 10 Quick battery replacement 309
15 10 1 Remove an empty battery with the battery replacement device 309
15 10 2 Install a full battery with the battery replacement device 310
15 11 Hot storage modification 311
15 12 Cold storage modification 312
15 13 Warning light 313
15 13 1 Install the warning light to the accessory rack 313
15 13 2 Install the warning light to the safety bar 315
15 14 Drive alarm 317
15 14 1 Install the drive alarm 317
15 15 Abbot2 318
15 15 1 Install the Abbot2 319
15 15 2 Install the iButton 320
15 15 3 Install the SIM card 321
15 16 Load support 322
15 16 1 Install the load support 322
15 16 2 Install the load support to a truck with the scissor lift 323
15 17 Rubber bumper 324
15 17 1 Install the rubber bumper 324
15 18 Battery cover plate 325
15 18 1 Install the battery cover plate 325
15 19 Pallet entry / exit rollers 326
15 19 1 Disassemble the pallet entry / exit rollers 326
15 20 High performance pack 327
15 20 1 Load sensing cylinder 328
15 20 1 1 Remove the load sensing cylinder 328
15 20 2 Intelligent Drive Assistant (IDA) 331
15 21 Pedestrian control buttons 332
16 Technical specification 333
17 Index 340
APPENDIX A: Stickers 345
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