Mitsubishi Forklift Truck EDR13N-24V ESR15N-24V ESR18N-24V ESR20N-24V ESS15N-24V ESS20N-24V Service Manual PDF

Description

Mitsubishi Forklift Truck EDR13N-24V ESR15N-24V ESR18N-24V ESR20N-24V ESS15N-24V ESS20N-24V Service Manual P.NO WENB2902-01 – PDF DOWNLOAD

FILE DETAILS:

Mitsubishi Forklift Truck EDR13N-24V ESR15N-24V ESR18N-24V ESR20N-24V ESS15N-24V ESS20N-24V Service Manual P.NO WENB2902-01 – PDF DOWNLOAD

Language : English
Pages : 495
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Mitsubishi Forklift Truck EDR13N-24V ESR15N-24V ESR18N-24V ESR20N-24V ESS15N-24V ESS20N-24V Service Manual P.NO WENB2902-01 – PDF DOWNLOAD

• Chassis, Mast & Options
  EDR13N-24V 1DR2300700-up
  ESR15N-24V 2SR2300700-up
  ESR18N-24V 4SR2300700-up
  ESR20N-24V 5SR2300700-up
  ESS15N-24V 2SS2300700-up
  ESS20N-24V 5SS2300700-up

INSTALLATION INSTRUCTIONS
Truck
How the Truck is Shipped 1-1
Uprighting a Cradled Truck 1-1
Option 1: Uprighting with Two Chain Hoist 1-1
Option 2: Uprighting with One Chain Hoist and a Forklift Truck1-2
Mast Installation Instructions
Truck System Requirements 1-3
Mast Inspection1-3
Chain Lubrication 1-3
Upright and Carriage Position, Chain Tension 1-3
Channel Lubrication 1-3
Mast Mounting Bolts and Torque Specifications1-4
Overhead Guard Mounting Bolts and Torque Specifications1-5
Hydraulic Fluid Level 1-6
Hydraulic Functions 1-6
Pump Intake Coupling (Bleed Points) 1-6
2 GENERAL INFORMATION & FEATURES
Glossary2-1
Reach Truck Serial Number Definition 2-3
General Overview 2-4
Jacking Truck 2-7
Load Wheel Replacement Guide 2-8
Caster Adjustment2-9
Brake Assembly Inspection and Adjustment 2-10
Adjustment of Air Gap with Brake Applied 2-10
Friction Disc Replacement 2-10
Drive Assembly 2-12
3 THEORY OF OPERATIONS
Plugging in the Battery 3-1
B+ Feed to 3-1
B- Feed to 3-1
Additional Safety Circuit (Emergency Power Off) 3-1
Turning Key Switch (S2) ON 3-1
RS485 Bus Communications 3-2
Stepping on the Operator Presence Pedal 3-2
Steer Request3-3
Steer Motor Controller 3-4
Travel Request 3-5
Plugging Request3-6
Regenerative Braking 3-7
Lift/Lower Request 3-8
Lift Activation 3-8
Lower Activation 3-8
Auxiliary Functions 3-9
Tilt Request3-9
Tilt Activation 3-9
Reach/Retract Request 3-9
Side Shift Request 3-9
Reach/Retract and Side Shift Activation 3-10
Reach/Retract Activation 3-10
Side Shift Activation 3-10
iii
TABLE OF CONTENTS
3 THEORY OF OPERATIONS (continued)
Solenoid/Valve Activation Chart 3-11
Lift Pressure Adjustment3-12
Maximum Lowering Speed Adjustment (Mechanical)3-12
Emergency Lowering 3-12
Electrical Lowering Speed Adjustment 3-13
4 OPERATOR DISPLAY
Operator Display 4-1
Self Test 4-2
Operating Hours 4-2
Battery State-of-Charge 4-2
Normal Conditions 4-2
Fault Conditions 4-3
Travel Speed Indicator 4-3
Access to Parameter Values 4-3
5 BPK PROGRAMMING AND SETTINGS
Section Overview 5-1
General Information 5-1
Up & Down Buttons 5-1
Left & Right Buttons 5-2
Teach-In Procedure for Hall Effect Sensors 5-2
Extended Menus 5-3
Default Settings for Pump Controller 5-4
Pump Controller Parameters 5-5
Pump Controller Fault Codes 5-10
Default Settings for Traction Controller 5-12
Traction Controller Parameters 5-13
Traction Controller Fault Codes 5-17
Default Settings for Steering Controller 5-20
Steering Controller Parameters 5-21
Steering Controller Fault Codes 5-23
6 SETUP USING THE BPS SOFTWARE
Section Overview 6-1
General Information 6-1
Parameter Changes 6-2
Fault Conditions 6-4
7 SETUP AND OPTION INSTALLATION
Speed Hall Effect Sensors Adjustment Overview 7-1
Speed Hall Effect Sensors Calibration Procedure—Teach-In Method 7-1
Travel Alarm Option 7-2
Cold Storage Option 7-3
Reverse Light Option 7-5
Height Display Option 7-5
Lift Limit Cutout with Bypass Option 7-6
Perform Height Calibration 7-6
Program the Lift Limit Height 7-7
Program the Half Speed Height 7-7
Program the Deceleration Ramp for Half Speed Lift 7-7
Weight Function Option 7-8
Calibrate Weight Display 7-8
TABLE OF CONTENTS
7 SETUP AND OPTION INSTALLATION (continued)
Minimum Load Adjustment 7-8
Maximum Load Adjustment 7-9
Reverse Steering Option 7-9
8 MAST
Contents8-1
Periodic Inspection 8-1
Inspection8-1
500 Hour Inspection 8-1
Troubleshooting8-3
Mast Removal 8-5
Cylinders
Main Lift Cylinder 8-4
Free Lift Cylinder 8-6
Cylinder Operation 8-9
Main Lift Cylinder Service 8-11
Free Lift Cylinder Service 8-15
Mast Uprights
Upright Description 8-17
Upright Chain Inspection 8-18
Cracked Plates 8-19
Ultimate Strength Failure 8-19
Tight Joints8-19
Chain Length Adjustments
Periodic Inspection—Triple-Stage Upright (TSU) Chain Length Adjustments8-20
Periodic Inspection—Chain Lubrication 8-22
General Guidelines 8-22
Chain Removal and Replacement 8-23
Lift Chains (Standard & TSU) 8-23
Primary Cylinder/Carriage Chains (TSUs) 8-23
Other Chain Service Notes 8-23
Periodic inspection—Upright & Lift Bracket Removal & Replace Roller Shim Adjustments
Lift Bracket Removal Preparation 8-24
Removal & Replace Roller Shim 8-25
Upright & Lift Bracket Removal 8-26
Upright Removal 8-31
Upright Disassembly
Rail Cylinders—Rollers and Shims8-31
Cable, Hose and Chain Sheaves 8-33
Free Lift Cylinder 8-33
Cable and Chain Sheaves 8-34
Shimming8-35
Lift Bracket Assembly
Checks and Adjustments 8-36
Shimming
Roller Clearance Inspection—Service 8-41
Checking Lower Roller Clearance with upright 6″ from fully retracted position8-41
When using a Pry Bar 8-41
“C” Clamp Method 8-42
Determining the Number of Shims needed to make roller adjustment8-47
Shim Adjustment8-48
Lift Bracket & Fork Carriage Assembly 8-48
iv
TABLE OF CONTENTS
MAST (continued)
Fork Removal 8-49
Lift Bracket Service—Fork Carriage Removal
Models Equipped with Side Shift Only8-49
Model Equipped with Tilt Only 8-50
Servicing Lift Bracket Arm Rollers 8-51
Tilt Cylinder Overhaul—Cylinder Removal 8-53
ITA Lift Bracket with Side Shifter 8-53
ITA Lift Bracket without Side Shifter 8-54
Cylinder Removal 8-54
Disassembly8-55
Retainer Assembly 8-55
Piston Rod and Piston 8-55
Cleaning and Inspection8-56
Reassembly8-56
Retainer Assembly 8-56
Reach Cylinder Overhaul—Cylinder Removal
Remove the Fork Carriage 8-57
Preparation, Cleaning And Inspection 8-57
Disassembly8-59
Retainer Assembly 8-59
Piston Rod and Piston 8-59
Cleaning and Inspection8-59
Reassembly8-60
Retainer Assembly 8-60
Sideshift Cylinder Overhaul—Cylinder Removal
Remove Forks 8-61
Preparation, Cleaning And Inspection 8-61
Disassembly8-61
Retainer Assembly 8-61
Cleaning and Inspection8-63
Reassembly8-63
Reach and Side Shift Selector Valve
Preparation8-63
Hydraulic Schematic
For Mast model S/N 40HR-MT-001 through 40HR-MT-111 and
For Mast model S/N 45HR-MT-001 through 45HR-MT-1028-65
For Mast model S/N 40HR-MT-112 through Present and
For Mast model S/N 45HR-MT-103 through Present8-66
Reach and Tilt Selector Valve
Disassembly8-67
Mounting Selector Valve 8-67
Connecting Hydraulic Plumbing 8-68
Lift Bracket Service
Side Shifter Solenoid Control Valve 8-68
Installation—Mount Selector Valve 8-69
Install Hoses8-69
Connect Coils8-69
Servicing a Double Reach Lift Bracket 8-70
Double Reach Without Sideshifter 8-70
Installing Reach Cylinders 8-72
Reach and Tilt Selector Valve Service
Disassembly8-73
Cleaning8-74
Reassembly—Solenoid Valves 8-75
v
TABLE OF CONTENTS
MAST (continued)
Reassembly Counterbalance Valves 8-77
Installation877
Side Shift Selector Valve Service
Disassembly8-78
Cleaning8-78
Reassembly8-79
Mast Triline Hose / Cable Routing 8-80
Mast to Pantograph Cable Assembly 8-80
Field Replacement of Mast Triline Hoses 8-81
Mast “Auxiliary”Hydraulic Flushing Procedure8-83
9 ELECTRICAL
General Overview 9-1
Diagram of Controllers 9-2
Connector Numbering 9-3
Pump Controller Wiring Diagram 9-4
Pump Controller—Key Switch and Analog and Digital Outputs9-5
Pump Controller—Valve 46—Tilt and Sideshift Selection9-5
Pump Controller—Valves Y41, Y43, Y44 and Y459-5
Pump Controller—Connection for Thermistor, Encoder and Fans9-5
Pump Controller—Height Measurement, Pressure Sensor, and Top Limit Override9-6
Pump Controller—Set Value for Speed Pump and Digital Inputs9-6
Pump Controller—RS485 Interface 9-7
Traction Controller Wiring Diagram 9-8
Traction Controller—Key Switch, Analog Output and Digital Output for K129-9
Traction Controller—Main Contactor and Additional Inputs9-9
Traction Controller—Connections for the Motor (Brake, Thermistor & Encoder)9-9
Traction Controller—Buzzer and Additional Inputs X5 9-10
Traction Controller—Set Value for Traction Speed and Digital Inputs9-10
Traction Controller—RS485 Interface 9-11
Steering Controller Wiring Diagram 9-12
Steering Controller—Key Switch and Position Sensors9-13
Steering Controller—Safety Circuit 9-13
Steering Controller—Digital Inputs, Digital Outputs 9-13
Steering Controller—Connections for the Motor (Thermistor and Encoder)9-13
Steering Controller—Input for the Stepper Motor at the Steering Wheel9-14
Steering Controller—RS485 Interface 9-14
10 ELECTRICAL SCHEMATICS
How to Use the Schematic 10-1
Schematic (1/12)—Power Supply—24 Volt 10-2
Schematic (2/12)—Main Power Circuits 10-3
Schematic (3/12)—Drive Circuit 10-4
Schematic (4/12)—Steering Circuits 10-5
Schematic (5/12)—Hydraulic Schematic Circuits 10-6
Schematic (6/12)—Hydraulic Control Output Circuits 10-7
Schematic (7/12)—Hydraulic Sensing Circuits 10-8
Schematic (8/12)—Pump and Traction Encoders/Temp Sensing Circuit10-9
Schematic (9/12)—Horns, Light, and Travel Alarms10-10
Schematic (10/12)—Fans10-11
Schematic (11/12)—Communication Connections10-12
Schematic (12/12)—Cold Storage Use—Option10-13
Location of Components on Schematic10-14
vi
vii
TABLE OF CONTENTS
11 HYDRAULIC SCHEMATICS
Hydraulic Schematic / Diagram 11-1
12 TROUBLESHOOTING & PIN BY PIN VOLTAGES
Fault Condition or Status Report Display Information Example12-1
Traction Controller Fault Codes 12-2
Steering Controller Fault Codes 12-5
Pump Controller Fault Codes 12-9
Pin-by-Pin Voltages Worksheet12-11
13 PLANNED MAINTENANCE
Maintenance Locations13-1
Maintenance Intervals 13-2
Recommended Oils13-3
Fluid Capacities13-3

DESCRIPTION:

Mitsubishi Forklift Truck EDR13N-24V ESR15N-24V ESR18N-24V ESR20N-24V ESS15N-24V ESS20N-24V Service Manual P.NO WENB2902-01 – PDF DOWNLOAD

Mitsubishi Forklift Trucks Important Safety Information:

•  Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules and precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
• Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.
• Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.
• Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

G.B 27/01/25