Mitsubishi Forklift RBM20N2 RBM25N2 Trucks Service Manual – PDF DOWNLOAD
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Mitsubishi Forklift RBM20N2 RBM25N2 Trucks Service Manual – PDF DOWNLOAD
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Language: English
Brand: Mitsubishi
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Mitsubishi Forklift RBM20N2 RBM25N2 Trucks Service Manual – PDF DOWNLOAD
Pub.No: 633560-EN A
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 starting to test, repair or rebuild a lift truck, read the respective sections of this manual carefully and familiarize yourself with 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. Trucks are constantly being developed. The graphic illustrations in this manual may differ slightly from the actual design of the truck. The manufacturer reserves the right to modify the design, equipment and technical features without prior notice and without any 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:
• Set the power of the truck to OFF and disconnect the battery connector before you open the cover of the motor compartment or the electrical system.
• Release all pressure in the air, oil or water systems before you disconnect or remove lines, fittings or related items. Release the residual pressure when you remove a pressurized device.
• If it is necessary to work at height during maintenance work, make sure that you use applicable access equipment and follow the safety instructions of the equipment manufacturer.
• With sit-on trucks, remove the seat when you do servicing to the truck.
• Before you operate, lubricate or repair the truck, read all warning plates and stickers on the truck.
• Do not use your hands to find oil leaks.
• To prevent burns, be careful of the hot sections and hot fluids in lines, tubes and compartments, also when the truck is idle or OFF.
• Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.
• Do not mix different lubricants. It is possible that different brands of lubricants are not be compatible with each other. Only use lubricants recommended by the manufacturer.
• Repairs that need welding must be done only with the applicable reference information and by personnel trained 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 you weld, 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 the correct lifting procedures when you remove components.
• Be careful when you remove cover plates. Gradually, remove the last 2 bolts or nuts at the opposite ends of the cover or device. Before you remove the last 2 bolts or nuts, turn the cover loose to release springs or other pressures.
• Be careful when you remove filler caps, breathers and plugs on the truck. Put a cloth around the cap or plug to make sure that you do not become sprayed or splashed by liquids under pressure. Be aware that the liquids spray and splash more easily immediately after you have stopped the truck, because the fluids are very hot.
• Only use well-maintained tools. Also, make sure that you use the tools in a correct way.
• Reinstall all fasteners with the same part number. If a replacement is necessary, do not use a fastener of lesser quality.
• Do not cause damage to the wiring during the removal process. Do not use damaged wiring. When you install the wiring back, make sure the wiring does not touch sharp corners or hot parts. Put all wiring away from the oil pipe.
TABLE OF CONTENTS:
Mitsubishi Forklift RBM20N2 RBM25N2 Trucks Service Manual – PDF DOWNLOAD
Contents 3
1 Foreword 11
2 How to read this manual 12
2 1 Safety-related signs 12
2 2 Symbols and abbreviations 12
2 2 1 Safety symbols 12
2 2 2 Other symbols and abbreviations 14
2 3 Units 14
3 Safety instructions 15
3 1 Safety requirements for industrial trucks 15
3 2 Repairs and structural modifications 16
3 3 Service area safety 16
3 4 Personal safety 17
3 5 Work safety 18
3 6 Operating temperature 19
4 General information 20
4 1 Truck models covered by this manual 20
4 2 Identification plates on the truck 20
4 3 Overview of the truck 22
4 3 1 Overhead guard 22
4 3 2 Operating devices 24
4 3 3 Control panel 25
4 3 4 Steering wheel 26
4 3 5 Arm rest 27
4 3 6 Display panel 28
4 3 7 Truck operation modes 29
4 3 8 Truck display 31
4 3 8 1 Display control buttons 32
4 3 8 2 Main view of the truck display 33
4 3 8 3 Hierarchy of the truck display menus 45
4 3 9 Driving mode selector 49
4 3 10 Pedals 52
4 3 11 Operator’s seat 53
4 3 12 Drive unit, hydraulic system and instrument panel 54
4 3 12 1 Instrument panel 55
4 3 12 2 Hydraulic system 56
4 3 12 3 Motor compartment 57
4 3 12 4 Load wheel steering motors and controllers 57
4 3 13 Sensors 58
4 3 14 Reach carriage 60
4 3 15 Mast unit 60
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5 Mechanical maintenance 61
5 1 Lifting points 61
5 1 1 Jack points 61
5 1 2 Hoist points 62
5 2 How to tow the truck 62
5 2 1 Release the magnetic brake manually 63
5 3 Transportation 65
5 4 Assembly and commissioning 66
5 4 1 Install the mast 66
5 5 Order spare parts 70
5 6 How to clean the truck 70
5 7 Truck covers 71
5 7 1 Remove the machinery cover 72
5 7 2 Remove the front bumper 72
5 7 3 Remove the floor plate 72
5 7 4 Open the machinery top cover 73
5 7 5 Open the instrument panel 74
5 7 6 Remove the instrument panel cover 75
5 7 7 Remove the control panel 76
5 7 8 Remove the cup holder 76
5 7 9 Remove the reach carriage cover 77
5 7 10 Remove the load wheel cover 77
5 8 Steering wheel 78
5 8 1 Remove the steering wheel 78
5 9 Transmission gear 79
5 9 1 Remove the transmission gear 79
5 10 Slewing bearing 80
5 10 1 Lubricate the slewing bearing 81
5 11 Traction wheel 82
5 11 1 Disassemble the traction wheel 83
5 11 1 1 Replace the wheel shaft bolts 83
5 11 2 Assemble the traction wheel 85
5 12 Corner supports 85
5 12 1 Replace the corner supports 86
5 13 Load wheels 87
5 13 1 Remove the load wheel motor 88
5 13 2 Change the pivot bearing of load wheel 88
5 13 3 Change the load wheel brake 89
5 13 4 Load wheel brake maintenance 90
5 13 5 Change the steering angle sensor 91
5 14 Battery roller frame 92
5 14 1 Remove the battery roller frame 92
5 15 Reach carriage 93
5 15 1 Lubricate the rollers of the reach carriage 94
5 15 2 Adjust the guidance rollers of the reach carriage 95
5 15 3 Remove the reach carriage 97
5 15 4 Remove the reach cylinder 99
5 15 5 Replace the reach carriage hoses 100
5 16 Mast 105
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5 16 1 Detailed construction 106
5 16 2 Maintenance of the mast 107
5 16 2 1 Daily maintenance 107
5 16 2 2 Monthly maintenance 107
5 16 2 3 Annual maintenance (1 000 h) 107
5 16 3 Lubricant recommendations 108
5 16 3 1 Mast chains 108
5 16 3 2 Mast channels 108
5 16 4 Remove the lifting carriage 109
5 16 5 Remove the forks 111
5 16 6 Remove the fork frame 112
5 16 7 Replace the fork frame bearings 113
5 16 8 Replace the slide bearings of the forks 114
5 16 9 Remove the mast 115
5 16 10 Disassemble the mast 118
5 16 11 Mast chains 127
5 16 11 1 Inspect the mast chains 128
5 16 11 2 Examine the tension of the mast chains 135
5 16 11 3 Adjust the mast chains 136
5 16 11 4 Replace the mast chains 136
5 16 12 Guidance rollers 141
5 16 12 1 Adjust the guidance rollers 142
5 16 12 2 Replace the guidance rollers 142
5 16 13 Main rollers 144
5 16 14 Free lift cylinder 145
5 16 14 1 Replace the free lift cylinder 145
5 16 14 2 Sealing housing of the free lift cylinder 150
5 16 14 3 Bleed out the air from the free lift cylinder 151
5 16 15 Side cylinders 153
5 16 15 1 Replace the side cylinders 154
5 16 15 2 Sealing housing of the side cylinder 156
5 16 15 3 Bleed out the air from the side cylinders 159
5 16 16 Tilt cylinder 160
5 16 16 1 Remove the tilt cylinder 161
5 16 16 2 Sealing housing of the tilt cylinder 162
5 16 17 Fork positioner cylinders 163
5 16 17 1 Remove the fork positioner cylinders 164
5 16 17 2 Sealing housing of the fork positioner cylinder 166
5 16 18 Fork inspection 167
5 17 Operator’s seat 171
5 17 1 Replace the seat switch 171
5 18 Arm rest 174
5 18 1 Remove the arm rest 174
5 18 2 Open the arm rest 175
5 18 3 Remove the arm rest levers 175
5 18 4 Remove the arm rest buttons 177
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6 Electrical operation 178
6 1 How to use the schematic diagram 178
6 2 Power supply 180
6 3 Safety circuit (emergency stop button) 180
6 4 Key switch 180
6 5 Traction 181
7 Battery maintenance 182
7 1 Safety regulations concerning the handling of lead-acid batteries 183
7 2 Battery maintenance 184
7 2 1 Daily maintenance 184
7 2 2 Weekly maintenance 184
7 2 3 Monthly maintenance 184
7 2 4 Annual maintenance 185
7 2 5 General maintenance 185
7 2 6 Storage 185
7 2 7 Malfunctions 185
7 2 8 How to clean batteries 185
7 3 Requirements for battery charging areas 187
7 4 Charge the battery 189
7 5 Measure the specific gravity of the battery 192
7 6 Acquire a new battery 192
7 7 Replace the battery 192
7 7 1 Guide the battery connector cables 197
7 7 2 Quick battery replacement 197
8 Electric system maintenance 198
8 1 Display panel 198
8 1 1 Emergency stop button 198
8 1 1 1 Emergency stop button functionality check 199
8 1 2 Key switch 199
8 1 2 1 Key switch functionality check 200
8 2 Pedals 201
8 2 1 Operator presence pedal 201
8 2 1 1 Operator presence pedal functionality check 202
8 2 1 2 Remove the operator presence pedal 202
8 2 2 Accelerator pedal 203
8 2 2 1 Accelerator pedal functionality check 205
8 2 2 2 Remove the accelerator pedal 205
8 2 3 Brake pedal 205
8 2 3 1 Brake pedal functionality check 207
8 2 3 2 Remove the brake pedal 207
8 2 3 3 Bleed the load wheel brakes 209
8 3 Instrument panel 214
8 3 1 Discharge the controllers 215
8 3 2 Vehicle controller 216
8 3 3 Vehicle controller connectors 216
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8 3 3 1 CNA external connector 217
8 3 3 2 CNB external connector 219
8 3 4 Traction controller 220
8 3 5 Traction controller connectors 220
8 3 5 1 CNA external connector 221
8 3 5 2 Description of the power connections 222
8 3 6 Pump controller 223
8 3 7 Pump controller connectors 223
8 3 7 1 CNA external connector 224
8 3 7 2 Description of the power connections 225
8 3 8 Steering controller 226
8 3 9 Steering controller connectors 226
8 3 9 1 CNA external connector 227
8 3 9 2 Description of the power connections 228
8 3 10 Fuses 229
8 4 Motor compartment 231
8 4 1 Traction motor 231
8 4 1 1 Remove the traction motor 232
8 4 1 2 Lubricate the traction motor axle splines 233
8 4 1 3 Temperature sensor check 234
8 4 1 4 HALL sensor 235
8 4 2 Steering motor 236
8 4 2 1 Remove the steering motor 237
8 4 2 2 Temperature sensor check 237
8 4 2 3 HALL sensor 238
8 4 3 Magnetic brake 240
8 4 3 1 Coil resistance measurement 240
8 4 3 2 Install the magnetic brake 240
8 4 3 3 Adjust the air gap of the magnetic brake 242
8 4 3 4 Release the magnetic brake manually 242
8 4 4 Pump motor 244
8 4 4 1 Remove the pump motor 244
8 4 4 2 Lubricate the pump axle splines 245
8 4 4 3 Replace the HALL sensor 246
8 5 Sensors 247
8 5 1 Steering wheel sensor 247
8 5 1 1 Steering wheel sensor functionality check 247
8 5 1 2 Steering control safety circuit check 248
8 5 2 Steering reference sensor 249
8 5 2 1 Steering reference sensor functionality check 249
8 5 3 Reach limit and end stop laser sensor 250
8 5 3 1 Reach limit and end stop laser sensor functionality check 251
8 5 3 2 Laser sensor maintenance 252
8 5 4 Battery lock sensor 252
8 5 4 1 Battery lock sensor functionality check 253
8 5 5 Pressure sensor 253
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8 5 5 1 Pressure sensor functionality check 253
8 5 6 Height reference sensor 254
8 5 6 1 Height reference sensor functionality check 254
8 6 Lowering cut-off sensor 255
8 6 1 1 Lowering cut-off sensor functionality check 255
8 6 1 2 Replace the lowering cut-off sensor 256
9 Electric system adjustments and measurements 257
9 1 Calibrate the arm rest levers 257
9 2 Insulation resistance test 257
9 2 1 Test voltage 257
9 2 2 Insulation tester check 257
9 2 3 Measure the insulation resistance 258
9 2 3 1 Insulation resistance of the truck 258
9 2 3 2 Insulation resistance of the battery 259
10 Hydraulic operation 260
10 1 Hydraulic symbols 264
10 2 Hydraulic oil recommendations 265
10 3 Maintenance points of the hydraulic system 266
10 3 1 Replace the hydraulic oil return filter (sieve) 267
10 3 2 Clean the hydraulic oil suction filter 268
10 4 Hydraulic system 269
10 4 1 Disassemble the hydraulic system 270
10 5 Hydraulic valve unit 272
10 5 1 Valve M1 275
10 5 2 Valves M3, M4, M7 and M8 275
10 5 3 Valves M2, M5, M6, M9 and M10 276
10 5 4 Emergency lowering valve 276
10 5 5 Set the lifting pressure 276
10 5 6 Disassemble the valves 278
11 TruckTool Diagnostics 279
11 1 Location of the service socket 280
11 1 1 Connect TruckTool to the service socket 280
12 Parameter descriptions 282
12 1 VCM master 282
12 2 Traction controller 296
12 3 Pump controller 297
12 4 EPS controller 299
13 Alarm codes 301
13 1 VCM 302
13 1 1 VCM master alarms 302
13 1 2 VCM slave alarms 379
13 2 Traction controller 431
13 3 Display 475
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13 4 Pump controller 485
13 5 EPS 529
13 5 1 EPS master 529
13 5 2 EPS slave 583
13 6 Arm rest controller 631
14 Service data 686
14 1 Special tightening torques 686
14 2 Tightening torque for standard bolts and nuts 686
14 3 Maintenance check list 688
14 4 Lubrication 692
14 4 1 Hydraulic oil 692
14 4 2 Transmission oil 692
14 4 3 Heavy duty grease for slewing bearing 693
14 4 4 Brake fluid 693
14 4 5 Pump axle splines 693
14 4 6 Traction motor axle splines 693
14 4 7 Lubrication points 693
14 4 8 Mast chains 693
14 4 9 Mast channels 693
14 4 10 Fork positioner 693
14 5 Hazardous waste and disposal 694
14 6 Special tools 694
14 7 Storage 697
14 7 1 Return the truck to operation 697
14 8 Decommissioning 697
15 Options 698
15 1 Special color labels 700
15 2 Customer design labels 700
15 3 Truck display languages 701
15 4 Accessory rack 702
15 4 1 Install the accessory rack 703
15 4 2 Install the list bracket 703
15 4 3 Install the computer rack 704
15 4 4 Install the rear view mirror 704
15 5 Accessory rack under the truck floor 705
15 5 1 Install the accessory rack under the floor 705
15 6 Reading lamp 705
15 6 1 Install the reading lamp 706
15 7 Audio system 707
15 7 1 Install the audio system 707
15 8 Warning light 709
15 8 1 Install the warning light 709
15 9 Warning light with an extension arm 711
15 9 1 Install the warning light with an extension arm 711
15 10 Working lights 713
15 10 1 Install the working lights 713
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15 11 Blue spot rear light 715
15 11 1 Install the blue spot rear light 715
15 12 Operator compartment fan 718
15 12 1 Install the operator compartment fan 718
15 13 Drive alarm (programmable) 720
15 13 1 Install the drive alarm 720
15 14 Steel safety net for overhead guard 721
15 14 1 Install the steel safety net to the overhead guard 721
15 15 Plexiglass safety cover for the overhead guard 722
15 15 1 Install the plexiglass safety cover to the overhead guard 723
15 16 Left shoulder protection plate 724
15 16 1 Install the left shoulder protection plate 724
15 17 Fire extinguisher 725
15 17 1 Install the fire extinguisher 725
15 18 DC-DC converter 727
15 18 1 Install the DC-DC converter 728
15 19 Battery changing device for 2 batteries 729
15 19 1 Remove an empty battery with the battery changing device for 2
batteries 730
15 19 2 Install a charged battery with the battery changing device for 2 batteries 732
15 20 Battery connector + cables 735
15 20 1 Replace the battery connector 735
15 21 Charger connector 737
15 21 1 Replace the charger connector 737
15 22 Load weight indicator 738
15 23 Operator’s seat options and accessories 739
15 23 1 Arm rest 739
15 23 2 Backrest extension for MSG65/MSG75 741
15 23 2 1 Backrest extension adjustment 741
15 23 3 Seat belt for MSG20 seat 741
15 23 3 1 Install the seat belt 742
15 24 PIN code access to the Start switch 742
15 25 Abbot 2 743
15 25 1 Install the Abbot 2 744
16 Technical specification 745
16 1 RBM20N2, RBM25N2 746
16 2 Mast heights 749
17 Index 750
APPENDIX A: Stickers 753
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.