Service Repair Manual for Mitsubishi ESR15N-ESS20N Forklifts PDF

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Mitsubishi Forklift Truck ESR15N-36V ESR18N-36V ESR20N-36V ESR23N-36V EDR13N-36V EDR15N-36V ESS15N-36V ESS20N-36V Service Manual P.NO 99759-7D100 – PDF DOWNLOAD

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Mitsubishi Forklift Truck ESR15N-36V ESR18N-36V ESR20N-36V ESR23N-36V EDR13N-36V EDR15N-36V ESS15N-36V ESS20N-36V Service Manual P.NO 99759-7D100 – PDF DOWNLOAD

Language : English
Pages : 923
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Mitsubishi Forklift Truck ESR15N-36V ESR18N-36V ESR20N-36V ESR23N-36V EDR13N-36V EDR15N-36V ESS15N-36V ESS20N-36V Service Manual P.NO 99759-7D100 – PDF DOWNLOAD

• Chassis, Mast & Options
  ESR15N-36V 2SR3800900-up
  ESR18N-36V 4SR3800900-up
  ESR20N-36V 5SR3800900-up
  ESR23N-36V 7SR3800900-up
  EDR13N-36V 1DR3800900-up
  EDR15N-36V 2DR3800900-up
  ESS15N-36V 2SS3800900-up
  ESS20N-36V 5SS3800900-up

MAST INSTALLATION INSTRUCTIONS
Truck
How the Truck is Shipped 1-1
Uprighting a Cradled Truck 1-1
Option 1: Uprighting with Two Chain Hoist1-2
Option 2: Uprighting with One Chain Hoist and a Forklift Truck1-3
Mast Installation Instructions
Truck System Requirements 1-3
Mast Inspection 1-3
Chain Lubrication1-3
Upright and Carriage Position, Chain Tension1-3
Channel Lubrication1-4
Mast Mounting Bolts and Torque Specifications1-5
Overhead Guard Mounting Bolts and Torque Specifications 1-6
Hydraulic Fluid Level 1-7
Hydraulic Functions1-7
Pump Intake Coupling (Bleed Points) 1-7
GENERAL INFORMATION FEATURES
Glossary2-1
Reach Truck Serial Number Definition2-3
General Overview 2-4
Jacking Truck2-8
Load Wheel Replacement Guide 2-9
Caster Adjustment2-10
Brake Assembly Inspection and Adjustment 2-11
Adjustment of Air Gap with Brake Applied2-11
Friction Disc Replacement2-11
Transmission2-13
THEORY OF OPERATIONS
Solenoid Activation Chart3-1
Main Hydraulic Manifold3-1
Theory of Operation 3-2
Plugging in the Battery 3-2
B+ Feed to3-2
B-Feed to3-2
Additional Safety Circuit (Emergency Power Off)3-2
Turning Key Switch (S2) On3-2
Can Bus Communication3-3
i
TABLE OF CONTENTS
THEORY OF OPERATIONS (continued)
Stepping on the Operator Presence Pedal 3-3
Steer Request 3-3
Electric Steer Controller “APS” 3-4
Travel Request3-4
Plugging Request3-6
Regenerative Braking 3-6
Lift / Lower Request3-6
Lift Activation3-7
Lower Activation3-7
Auxiliary Functions3-7
Tilt Request 3-8
Tilt Activation3-8
Reach / Retract Request3-8
Sideshift Request3-8
Reach / Retract and Sideshift Activation 3-8
Reach / Retract Activation3-8
Sideshift Activation 3-8
Lift Pressure Adjustment 3-9
MaxLowering Speed Adjustment (Mechanical) 3-9
Emergency Lowering3-10
Electrical Lowering Speed Adjustment 3-10
OPERATOR DISPLAY
Operator Display 4-1
General Information 4-2
ESC (Escape) Button4-2
Scroll Left Button 4-2
Scroll Up Button4-2
Scroll Down Button 4-2
Scroll Right Button 4-2
Enter Key4-2
Battery State of Charge4-2
Parking Brake 4-2
Clock 4-2
Mode of Operation (Optional) 4-2
Travel Direction 4-2
Travel Speed Indicator4-2
Text Messaging 4-3
Shelf Selector (Option)4-3
Load Weight Display 4-3
Turn KEY On 4-4
Under General Settings4-4
History Folder 4-5
ii
TABLE OF CONTENTS
OPERATOR DISPLAY (continued)
Shelf Height (Option) 4-5
To Change Self Height Option 4-6
Mode of Operation (Performance Modes I,II,III and IV)4-6
Thermal Monitoring4-7
SelfTest4-7
Operation Hours 4-7
Battery State of Charge 4-7
OPERATOR DISPLAY INFORMATION & PROGRAMMING
Password Protected Mode
Management Mode 5-1
How to Enter “Management”Mode5-1
Service Mode5-1
How to Enter “Service Mode” 5-1
Display Enabled Functions
General Settings 5-2
History Folder 5-2
Password Manage5-2
Parameters 5-2
Display Parameters5-2
Configuration Settings5-2
Display Parameters
Pre-Height Selection 5-3
How to Activate the “Pre-select Shelf Height Setting”Function 5-3
Mode Change5-4
How to Change the “Mode Change”Function5-4
Height Display *Service Mode Only* 5-5
How to Activate the “Height Display”Function 5-5
Weight Display *Service Mode Only*5-6
How to Activate the “Weight Display”Function5-6
LCD Contrast5-7
How to Change “LCD Contrast” 5-7
LCD Heater 5-8
How to Activate the “LCD Heater Control”Function 5-8
Keyless Entry “Pin Code”*Service Mode Only*5-9
How to Activate the “Keyless Entry”Function5-9
Truck Parameters *Service Mode Only*5-10
How to Access “Truck Parameters 5-10
BDI Curve 5-11
BDI Timer5-11
BDI Reset 5-11
iii
TABLE OF CONTENTS
OPERATOR DISPLAY INFORMATION & PROGRAMMING (continued)
Low Batt 5-11
Maintenance Warning 5-11
Stand-by-Timer 5-11
Travel Alarm 5-11
Max Speed Fwd5-11
Max Speed Bwd5-12
Release Braking 5-12
Inverse Braking 5-12
Steer Sensitivity5-12
Forward Steering5-12
Lower Stop / Batt Lock 5-12
Cutback Linear 5-12
Cutback 1 Speed5-12
Cutback 2 Height / Cutback 2 Speed 5-12
Cutback 3 Height / Cutback 3 Speed 5-12
PreSensor Low 5-13
PreSensor Low 5-13
Real Load Weight 5-13
Max Lift 5-13
FreeLift 5-13
LiftLimit5-13
Reach 25-14
Retract 2 5-14
Reach2 / Retr25-14
2nd Pump 5-14
E Cushion 5-14
Wheel Centering 5-14
Diagnostics
Diagnostics *Service Mode Only* 5-15
How to Access “Onboard Diagnostics” 5-15
Digital Inputs 5-15
Analog Inputs5-16
Outputs 5-16
Temperatures5-17
Motor Controls5-17
Service
Service *Service Mode Only* 5-18
How to Access “Service”5-18
Set Maintenace Intervals5-18
Clear History Folder 5-18
Reset Pre-Height Select5-19
Restore Truck Param5-19
Restore Perf Mode 5-19
Restore Passwords 5-19
iv
TABLE OF CONTENTS
OPERATOR DISPLAY INFORMATION & PROGRAMMING (continued)
Height Detection (Option)
Height Detection Overview 5-20
Height Detection Installation5-21
Pre_Selected Shelf Height Option 5-22
To Change the Shelf Height 5-22
Cold Storage Option5-24
Operator Mode Entering Chart5-25
Management Mode Entering Chart5-27
Service Mode Entering Chart5-29
MAST
Where to Find Serial Number on Mast6-1
Hydraulic Manifold with Cover6-1
Hydraulic Manifold with Cover Removed 6-1
Contents6-2
Periodic Maintenance 6-2
Inspection 6-2
500 Hour Inspection 6-2
Troubleshooting6-3
Mast Removal 6-4
Cylinders
Main Lift Cylinder6-4
Description 6-4
Free Lift Cylinder6-5
Description 6-5
Cylinder Operation6-6
Cylinder Raising 6-6
Cylinder Lowering 6-6
Main Lift Cylinder Service
Main Lift Cylinder Disassembly 6-7
Cleaning and Inspection6-7
Main Lift Cylinder Reassembly 6-8
Piston Rod and Piston6-8
Retainer / Retainer Assembly6-8
Free Lift Cylinder Service
Free Lift Cylinder Disassembly 6-9
Cleaning and Inspection6-9
Free Lift Cylinder Reassembly6-10
v
TABLE OF CONTENTS
MAST (continued)
Piston Rod and Piston6-10
Retainer / Retainer Assembly6-10
Mast Uprights
Upright Desciption6-11
Outer Upright Assembly 6-11
Intermediate Upright Assembly6-11
Inner Upright Assembly6-11
Upright Chain Inspection
Elongation 6-12
Edge Wear6-12
Turning or Protruding Pins6-12
Cracked Plates6-13
Fatigue Cracking6-13
Stress-Corrosion Cracking 6-13
Corrosion Fatigue6-13
Ultimate Strength Failure6-13
Tight Joints6-13
Chain Length Adjustment 6-14
Periodic Inspection
Triple-Stage Upright (TSU) Chain Length Adjustment6-14
Chain Lubrication6-16
General Guidelines 6-16
Chain Removal and Replacement
Lift Chains (Standard & TSU) 6-17
Primary Cylinder / Carriage (TSU’s) 6-17
Other Chain Service Notes 6-17
Periodic Inspection—Upright & Lift Bracket Removal &
Replace Roller Shim Adjustments
Lift Bracket Removal Preperation 6-18
Removal & Replace Roller Shim 6-19
Upright & Lift Bracket Removal 6-23
Upright Removal6-23
Preparation6-23
Disconnect Battery6-23
Upright Disassembly
Rail Cylinders6-25
Rollers and Shims6-25
Cable, Hose and Chain Sheaves6-27
Free Lift Cylinder6-27
Cable and Chain Sheaves6-28
Lift Bracket Assembly
Shimming6-30
Pantograph Carriage Roller6-30
vi
TABLE OF CONTENTS
MAST (continued)
Checks and Adjustments6-30
Roller Clearance Inspection6-35
Service 6-35
Checking Lower Roller Clearance with
Upright 6″ from Fully Retracted Position 6-35
When Using a Pry Bar6-35
“C” Clamp Method 6-36
Checking Upper Roller Clearance with
Upright Extended Approx 1/2 Full Extension 6-37
Checking Upper Roller Clearance with
Upright Extended Approx to Full Extension 6-39
Checking Lower Roller clearance with
Upright Extended Approx Within 6”of Full Extension 6-40
Fork Removal
Lift Bracket Service 6-43
Fork Carriage Removal6-43
Models Equipped with Sideshift Only6-43
Models Equipped with Tilt Only6-44
Servicing Lift Bracket Arm Rollers 6-45
Tilt Cylinder Overhaul6-47
Cylinder Removal 6-47
ITA Lift Brackets
ITA Lift Bracket with Sidesifter6-47
ITA Lift Bracket without Sideshifter 6-48
Cylinder Removal 6-48
Preparation and Cleaning6-48
Disassembly 6-49
Retainer Assembly 6-49
Piston Rod and Assembly6-49
Cleaning and Inspection6-50
Reassembly 6-50
Retainer Assembly 6-50
Reach Cylinder Overhaul
Cylinder Removal6-50
Remove Forks6-50
Remove the Fork Carriage 6-51
Preparation, Cleaning and Inspection 6-51
Disassembly 6-53
Retainer Assembly 6-53
Piston Rod and Piston6-53
Cleaning and Inspection 6-53
Reassembly6-54
Retainer Assembly6-54
vii
TABLE OF CONTENTS
MAST (continued)
Sideshift Cylinder Overhaul
Cylinder Removal—Lift Bracket6-55
Remove Forks6-55
Preparation Cleaning and Inspection6-55
Disassembly 6-55
Retainer Assembly 6-55
Lift Bracket Service
Cleaning and Inspection6-57
Reassembly6-57
Reach and Sideshift Selector Valve
Preparation 6-57
Mast Hydraulic Schematic 6-59
Reach and Tilt Selector Valve
Removal6-60
Disassembly 6-60
Mounting Selector Valve 6-60
Connecting Hydraulic Plumbing6-61
Sideshifter Solenoid Control Valve
Removal6-62
Installation 6-63
Mount Selector Valve 6-63
Install Hoses 6-63
Connect Coils 6-63
Servicing a Double Reach Lift Bracket 6-64
Installing Reach Cylinders 6-66
Reach and Tilt Selector Valve Service
Disassembly 6-67
Cleaning6-68
Reassembly—Solenoid Valves6-69
Reassembly—Counterbalance Valves6-71
Installation 6-71
Sideshifter Selector Valve
Disassembly 6-72
Cleaning6-72
Reassembly6-73
Mast Triline Hose / Cable Routing 6-74
Field Replacement of Mast Triline Harness6-75
Mast “Auxiliary”Hydraulic Flushing Procedure 6-77
viii
TABLE OF CONTENTS
HYDRAULIC SCHEMATICS
Legend7-1
Standard Performance with Tilt 7-2
Standard Performance with Tilt and Sideshift7-3
High Performance with Tilt 7-4
High Performance with Tilt and Sideshift 7-5
CONTROLLER
System Configuration and Outline8-1
System Configuration8-1
Outline 8-2
Logic Unit 8-2
Inverter 8-2
Output Unit (RIO) 8-3
Display Unit8-3
APS (Advanced Power Steering) Unit8-3
External Logic 8-4
Logic Unit 8-4
Inverter 8-5
Output Unit 8-6
Display Unit8-7
Controller Area Network (CAN) 8-8
AC Motor System Basics8-9
Feature of AC Motor8-9
Speed Control of Induction Motor 8-9
Inverter 8-10
Function8-11
Traction Control Function8-11
Powering8-11
Limitation of Maximum Travel Speed8-12
Regeneration 8-13
Controlled Roll Back8-13
Steering 8-14
Stall Timer8-14
Free Lift8-14
Hydraulic Control Function8-16
Hydraulic Controller 8-16
Priority 8-17
Inhibition of Simultaneous Operation 8-17
Attachments 2 and 38-17
Steering Control Function 8-18
OPP (Operator Presence Pedal) Function8-19
Preventing Operator’s Absence8-19
Other Functions 8-20
ix
TABLE OF CONTENTS
CONTROLLER (continued)
BDI (Battery Discharge Indicator)8-20
Service Indicator8-20
Hour Meter Function 8-20
Chime Control Function8-21
Battery Voltage Monitor8-21
Display Function (See Display Section)8-22
Normal Operation Display8-22
Error Display8-23
Password Display 8-23
Removal and Installation 8-24
Inspecting Before Replacing Controllers 8-24
Checking Inverter and DSP Card 8-24
Checking Logic Card8-25
Checking Power Supply Card8-26
Checking Output Unit 8-27
Checking Display Unit8-28
Discharging Electric Charges from Inverters and APS Unit8-29
Replacing Inverter 8-30
Replacing DSP (Digital Signal Processor) Card8-32
Replacing Logic Unit 8-34
Replacing Logic Card8-35
Replacing Power Supply Card8-36
Replacing Output Unit 8-37
Replacing APS (Advanced Power Steering) Unit8-38
Basic8-38
Basic Items8-38
Testing Tools 8-38
Pin by Pin Voltage Measurement8-39
Pin by Pin Measurement Chart 8-40
Coil Resistances8-50
Checking Contactor 8-51
Checking Contactor Coil 8-51
Checking Contactor Tip8-51
Checking Inverter 8-52
Regeneration Check 8-52
TROUBLESHOOTING FOR CONTROL CIRCUITS
General Information 9-1
Before Replacing Devices 9-1
Connection of the Service Tool 9-1
How to Clean Harness Connectors and System Components 9-2
CAN-BUS Reach Truck AC 9-3
x
TABLE OF CONTENTS
TROUBLESHOOTING FOR CONTROL CIRCUITS (continued)
Troubleshooting9-4
E0 Traction Motor, Overheating9-4
E2 Pump Motor 1, Overheating 9-8
E3 Pump Motor 2, Overheating 9-11
E4 Steer Motor, Overheating 9-14
E5 Traction Inverter, Overheating 9-17
E7 Pump Inverter 1, Overheating9-20
E8 Pump Inverter 2, Overheating9-23
E9 Steer Inverter, Overheating9-26
A5 Traction Motor, Over-Current9-29
14 Traction Motor Current Sensor Fault 9-32
15 Traction Motor, Over-Current 9-34
16 Traction Motor, Stall Timer Speed Fault9-37
34 Pump Motor 1, Current Sensor Fault9-39
35 Pump Motor 1, Over-Current9-41
40 Line Contactor Fault 9-44
45 Traction Motor Open 9-46
47 Pump Motor 1, Open 9-49
48 Pump Motor 2, Open 9-52
49 Steer Motor, Open9-55
51 Traction Lever Sensor Fault9-58
52 Traction Motor Pulse Input Fault 9-61
55 FC Solenoid Fault 9-64
56 FC Solenoid Current Leak 9-67
57 Pump Motor 1 Pulse Input Fault 9-69
58 Pump Motor 2 Pulse Input Fault 9-72
59 Steer Motor Pulse Input Fault 9-75
60 Display Communication Fault 9-78
61 Parameter Write Fault 9-81
62 Logics Fault9-82
63 Traction Inverter Fault 9-83
65 Pump Inverter 1 Fault 9-86
66 Pump Inverter 2 Fault 9-89
68 Output Unit Fault9-92
71 APS Controller Fault 9-94
78 Battery Voltage Too Low 9-96
79 Battery Voltage Too High9-98
81 Pressure Sensor Fault9-100
82 Steer Stepper Motor Fault9-103
85 Brake Switch Fault9-105
86 Height Sensor Fault9-107
88 Logic Fault Multipurpose Output #1, Travel Alarm9-110
88 Logic Fault Multipurpose Output #2, Horn9-112
94 Pump Motor 2, Current Sensor Fault9-114
95 Pump Motor 2, Over-Current9-116
xi
TABLE OF CONTENTS
TROUBLESHOOTING FOR CONTROL CIRCUITS (continued)
(E) Incorrect Start9-119
(H1) Lift Lever, Faulty Setting9-121
(H2) Tilt Switch, Faulty Setting 9-123
(H3) Reach Switch, Faulty Setting 9-125
(H4) Sideshift Switch, Faulty Setting9-127
(Lo) Battery Low9-129
Component Identification9-131
Electrical Diagrams9-135
Wiring Schematic
Wiring Diagram
PLANNED MAINTENANCE
Maintenance Locations10-1
Maintenance Intervals10-2
Service Data
Recommended Lubricants10-3
Fluid Capacities 10-3
xii
TABLE OF CONTENTS

G.B 27/01/25