Mitsubishi Forklift Truck EOP15 EOP24 EOP15P EOP24P Service Manual – PDF

Description

Mitsubishi Forklift Truck EOP15 EOP24 EOP15P EOP24P Service Manual P.NO WENB8560-01 – PDF DOWNLOAD

FILE DETAILS:

Mitsubishi Forklift Truck EOP15 EOP24 EOP15P EOP24P Service Manual P.NO WENB8560-01 – PDF DOWNLOAD

Language : English
Pages : 428
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Mitsubishi Forklift Truck EOP15 EOP24 EOP15P EOP24P Service Manual P.NO WENB8560-01 – PDF DOWNLOAD

• EOP15 1EOP240500-up
  EOP24 1 EOP240500-up
  EOP1 SP 1 EOP240500-up
  EOP24P 1 EOP240500-up

Warning Pages
Manual Overview
MITSUBISHI Orderpicker Service Manual
Table of Contents
Table of Contents
a
i
Using the Manuali
Table of Contents
Description
iii
1-1
Truck Overview 1-2
Use1-2
‘fype1-2
Power1-3
Capacity1-3
Mast1-3
Controls 1-3
Indicators 1-3
Vehicle Specification1-4
Specification Plate1-5
Mechanical1-7
Chassis 1-8
Power Section Frame1-8
Battery Compartment1-8
Battery Connector1-8
Outriggers1-8
Covers1-8
Mast Assembly 1-9
Mast Main Frame 1-9
Telescopic Frame(s) 1-9
Mast Bearings 1-9
Forks1-9
Operator’s Compartment1-9
Compartment Dimensions1-9
Compartment Floor 1-9
Side Gates1-9
Overhead guard 1-10
Tether1-10
Operator’s Controls1-10
Operator Compartment Options 1-10
Steering1-12
iii PDMM-0067
Table of Contents MITSUBISHI Orderpicker Service Manual
Drive Unit1-12
Pivot Bearing 1-12
Gear Housing1-12
Gear Reduction Assembly1-12
Drive Motor1-12
Drive Wheel1-12
Hydraulic1-13
Lift/Lower System1-13
Lift Pump1-13
Lift Motor1-13
Lift Cylinder Assembly1-13
Flow Controls 1-13
Reservoir1-13
Return Line Filter1-13
Lift Chain1-13
Lift/Lower Hydraulic Manifold Assembly1-14
Solenoid 1 (SOLl)1-15
Solenoids 2 and 3 (SOL2) and (SOL3)1-15
Solenoid 3 (SOL3)1-15
Electrical 1-19
General1-19
System Displays 1-19
Operator System Display1-19
Steering Indicator or Keypad (Optional)1-19
Maintenance Displays 1-20
Electronic Control System1-20
Interface Card Assembly 1-20
Carriage Wiring Board1-20
Travel System 1-21
EVl00LX System1-21
Drive Motor1-21
Travel Contactors1-21
Coil Drivers1-21
Directional/Speed Control Assembly1-22
24″ Mast Switch (Sll)1-22
150″ Mast Switch (S26)1-22
Solenoid 12 (SOL12) (Vehicles equipped with electronic power steering) 1-22
Electric Steering 1-23
Kill (Deadman) Switch (S2)1-23
Emergency off Switch (S21)1-23
Over-the-Mast Cables1-23
Miscellaneous Circuits1-29
Options1-30
Wire Guidance1-30
PDMM-0067 iv
MITSUBISHI Orderpicker Service Manual Table of Contents
Unpacking and Inspection 2-1
Receiving Truck2-2
Reasons For Visual Inspections2-2
What to Look For2-2
Visual Inspection/Conditions2-2
Installation Procedure2-4
Cradled Trucks 2-5
Visual Inspection 2-5
Uncradling2-6
Uprighting a Cradled Vehicle2-6
Procedure 12-6
Procedure 22-7
Gasket Removal 2-8
Greasing Mast Uprights2-8
Battery 2-8
Battery Charger2-8
Battery Installation2-9
Functional Inspection 2-10
Vehicle Operation2-10
Warranty 2-10
What To Look For2-10
Functional Installation Checklist 2-11
Cold Storage Conditioning2-12
‘fypes of Oils2-12
Classes of Cold Storage2-12
Hydraulic System Oil Change Procedure2-13
Storage2-14
Storage Warranty 2-14
Motors2-14
Hydraulic System2-14
Hydraulic Cylinders2-14
Lift/Steering Chains2-14
Electronics2-14
Battery2-15
Greasing Mast Uprights2-15
Vehicle – General 2-15
V PDMM-0067
Table of Contents MITSUBISHI Orderpicker Service Manual
Operating Instructions3-1
EVl00LX Operator System Display3-2
Display Test 3-2
Hour Meter3-2
Battery Discharge Indicator3-2
Status Codes3-2
Informational Messages 3-3
Performance Limiting Codes 3-3
Fault Codes (For trucks with electronic power steering and wire guidance)3-4
Audible Alarm (For trucks with electronic power steering) 3-4
Operator’s Daily Checklist3-5
Visual Checks3-5
Operational Checks3-5
Start Up Procedure3-6
Forward/Reverse Travel3-6
Braking 3-7
Plugging3-7
Parking 3-7
Electronic Power Steering Modes of Operation3-8
Run Mode 3-8
Configure Mode 3-8
Maintenance Mode3-8
Learn Mode3-8
Piezo Sounder3-9
Piezo Sounder Tone Patterns3-9
Passwords3-10
To Enter Or Change A Password 3-10
Entering CONFIG or MAINT Mode3-13
Configure Mode3-14
Configure Mode Standard Features 3-15
Configure Mode Program Tree 3-16
Maintenance Mode Program Tree3-1 7
Maintenance Mode 3-18
Static Maintenance Mode3-18
Active Maintenance Mode3-19
Learn3-20
When to Run Learn3-20
Details Pertaining to Learn3-21
Learning Wire Frequency3-21
Learning Guide Wire Offsets3-22
Learning Steer3-23
PDMM-0067 vi
MITSUBISHI Orderpicker Service Manual Table of Contents
Theory of Operation4-1
EVl00LX Control Panel4-2
System Components4-2
Silicon Controlled Rectifiers4-2
Diode Rectifiers4-3
Thermal Protector (TP) 4-3
Sensor (Sensor 1)4-3
Control Features4-5
Creep Speed 4-5
Controlled Acceleration 4-5
Current Limit4-5
Plugging4-5
IA Current Dropout 4-6
Speed Limit 1 /Speed Limit 34-6
Static Return to Off 4-6
Accelerator Volts Hold-Off4-6
Coil Driver Modules4-6
Thermal Cutback4-7
Pulse Monitor Trip (PMT) 4-7
Internal Resistance Compensation4-7
Stored Fault Code 4-7
Battery Discharge Indication4-8
Hour Meter4-8
On Board Diagnostics4-8
Basic SCR Controller Circuit Operation 4-9
Wiring Conventions 4-12
Operation of The Travel System4-13
Introduction4-13
Sequence 1 – Truck at Rest4-13
Sequence 2 – Connect the Battery4-13
Sequence 2A – Keyswitch is Closed (S-1)4-14
Sequence 3 -Closing the Deadman Switch 4-14
Sequence 4 – PMT Test4-14
Sequence 5 – Directional Contactor Closure4-15
Sequence 6 – REC 1 Turn On 4-15
Sequence 7 – REC 5 Turn On 4-16
Sequence 8 – Reverse Charging the 1 C Capacitor4-16
Sequence 9 – REC 2 Turn On and REC 1 Turn Off 4-1 7
Sequence 10 – Flyback Current 4-1 7
Sequence 11 – IA or Bypass Contactor Operation4-18
Sequence 12 – Controlled Plugging4-19
Lift/Lower System4-20
System Overview 4-20
Unique System Features4-20
Single-Speed Lift/Lower4-21
Two-Speed Lift/Lower4-24
vii PDMM-0067
Table of Contents MITSUBISHI Orderpicker Service Manual
Two-Speed Lift/Lower Functions4-25
Lift/Lower Functional Block Diagram4-26
Fork Hang-Up Protection4-27
Braking4-28
Process4-28
Steering4-29
Manual Cable Steering4-29
Manual Cable Steering Theory of Operation4-30
Electronic Power Steering4-30
Electronic Power Steer System (Optional)4-31
Signal Paths4-31
Signal Interface 4-31
Theory of Operation4-34
Steer Controller Card4-37
Display Card 4-39
Filter Card 4-40
Steer Encoder Card4-41
Steer Position Encoder (SPE)4-41
Home Proximity Sensor (HP)4-41
Speed Prox 1 and Speed Prox 2 Sensors 4-41
1 0o Position Sensor (Manual Steer Only) 4-41
Carriage Wiring Board4-42
BUS + /BUS-4-42
Wire Guidance4-43
Systems Concept 4-43
Warehouse Installed Equipment (WIE) 4-43
Truck Installed Equipment (TIE) 4-43
Antennas4-43
Filter Card 4-46
Wire Guidance Auto /Manual Switch (S45) 4-46
Wire Guidance LED’s4-46
Wire Guidance Sequence of Operation4-4 7
Theory of Operation4-48
Learn Mode4-49
Rail Guidance4-53
Auto Steer Centering Description4-53
Sequence of Operation 4-53
PDMM-0067 viii
MITSUBISHI Orderpicker Service Manual Table of Contents
Maintenance 5-1
General Maintenance Instructions5-2
Maintenance Practices5-2
Jacking Truck5-3
Welding Procedures5-4
Electrostatic Discharge Damage 5-5
Proper Handling of Static Sensitive Devices 5-6
Special Tools Required 5-7
Shunt Locations5-10
Planned Maintenance 5-11
Introduction5-11
Maintenance Manual5-11
Planned Maintenance Schedule5-11
Time Requirements 5-11
General Truck Operation5-11
Gearbox Oil Level5-12
Reservoir Oil Level5-12
Truck Lubrication Points5-12
Electrical Connections5-12
Electrical Grounds5-12
Wiring Harness Check5-13
Switches and Contactors5-13
Motor Brush Wear5-13
Hydraulic Cylinder5-13
Hydraulic Lines5-13
Brake & Linkage5-13
Wheels5-13
Accessories5-13
Battery5-14
Chain Condition 5-14
Steering Assembly 5-14
Lift Pump Spline5-14
Inspection Schedule5-15
Batteries 5-19
Battery Cleaning 5-19
Battery Cleaning Procedure5-19
Battery Electrical Leakage To Frame Test5-20
Battery Discharge Indicator (BDI)5-21
Internal Resistance Compensation5-21
Battery Charging5-24
Charging Process5-24
Hydrometer Use5-25
Voltage Check5-26
Adding Water To Battery5-26
Battery History Record5-26
ix PDMM-0067
Table of Contents MITSUBISHI Orderpicker Service Manual
Motors5-28
Motor Cleaning5-28
Brush Care5-29
Brush Replacement5-30
Motor Overheating5-31
Motor Stud Terminals 5-32
Motor Test for Open Circuits5-33
Motor Open Circuit Test Procedure 5-33
Motor Short-Circuit Test 5-33
Armature Shorts 5-34
Motor Grounds Test5-34
Vehicle Grounds General5-35
Ground Test Procedure5-35
Hydraulic5-36
Oil Selection5-36
Changing Reservoir Fluid5-36
Reservoir Fluid Level 5-36
Changing Reservoir Filter5-36
Bleeding Hydraulic System 5-37
Adjustment and Repair5-38
Power Section 5-38
Drive Transmission Service 5-38
Drive Tire Replacement 5-45
Drive Motor Removal5-45
Skid Pad Replacement5-4 7
Brake5-48
Brake Adjustment 5-48
Brake Inspection5-48
Brake Master Cylinder Replacement5-49
Deadman Switch Adjustment 5-52
Lift/Lower System5-53
PDMM-0067
Two-Stage Lift Cylinder Removal 5-53
2-Stage Lift Cylinder Service5-54
2-Stage Lift Cylinder Reassembly5-55
Center Lift Cylinder Removal
(3-Stage)5-55
Center Lift Cylinder Service (3-Stage) 5-56
Center Lift Cylinder (3-Stage) Reassembly 5-58
High Pressure Relief Valve Adjustment5-58
Lift/Lower Manifold Service5-59
Bleeding Side Lift Cylinders5-60
Procedure5-60
Bleeding Center Cylinder5-61
Directional/Speed Controller Removal From Vehicle5-61
Potentiometer Removal (VRl) 5-61
Directional/Speed Controller Assembly 5-63
X
MITSUBISHI Orderpicker Service Manual Table of Contents
Lift/Lower Return Spring Replacement5-66
VR2 Replacement5-67
2-Stage Elevating System Service Notes5-68
3-Stage Elevating System Service Notes5-72
End Cap Pulley Assembly5-73
Mast Shimming 5-7 4
Steering5-77
Manual Steering Wire Rope Adjustment 5-77
Manual Steering Wire Rope Replacement5-78
Service Notes5-82
xi PDMM-0067
Table of Contents MITSUBISHI Orderpicker Service Manual
Troubleshooting 6-1
Introduction6-2
Codes and Tests6-2
Troubleshooting Procedure6-2
Electrical6-4
Wiring-General 6-4
Board and Component Swapping Precautions6-7
Likelihood of Component Failure6-7
Handling Printed Circuit Cards 6-7
Contactors-General 6-8
Contactors-Specific6-9
Testing Other Electrical Components 6-10
EVl00LX Component Tests6-12
Hydraulics6-13
Hydraulic Leakage6-13
Maintenance Tips6-16
Lift/Lower Hydraulic Troubleshooting6-1 7
Hydraulic Problems6-18
Troubleshooting EVl OOLX Control System6-20
Handset6-22
Operation6-22
Function Set-Up Procedures6-24
GE Status Codes 6-30
PDMM-0067
Status Code – Blank Display6-30
Status Code – 01 6-32
Status Code – 02 6-34
Status Code – 03 6-36
Status Code – 046-38
Status Code – 05 6-40
Status Code – 066-42
Status Code – 07 6-44
Status Code – 08 6-46
Status Code – 09 6-48
Status Code – 156-50
Status Code – 166-51
Status Code – 1 7 6-52
Status Code – 23 6-53
Status Code – 246-54
Status Code – 25 6-55
Status Code -41 6-56
Status Code – 426-57
Status Code – 43 6-58
Status Code – 446-59
Status Code – 45 6-60
Status Code – 466-61
xii
MITSUBISHI Orderpicker Service Manual Table of Contents
Status Code – 4 7 6-62
Status Code – 48 6-63
Status Code – 49 6-64
Status Code – 50 6-65
Status Code – 51 6-66
Status Code – 52 6-67
Status Code – 53 6-68
Status Code – 546-69
Status Code – 576-70
Troubleshooting The Interface Card System 6-71
LEARN (Interface Card Setup) Procedure and Troubleshooting6-71
Initial Precautions6-71
Setup Procedure6-72
Sl Dip Switch Setting/Configuration6-74
S2 Dip Switch Setting/Configuration6-74
Interface Card Codes6-75
Codes6-76
Code 06-76
Code 1
Code 2
Code 3
Code4
Code 5
Code 6
Code 7
Code 8
Code 9
Code A
Code C
Coded
Code E
Code F
Code H
CodeJ
Code L
Code U
Code Y6-87
Troubleshooting The Electronic Power Steering System6-89
Maintenance Mode – Static 6-89
Maintenance Mode – Active6-89
Electronic Power Steering Systems6-91
No Fault Code Displayed6-92
Guidance Not Learned6-93
Code 52 6-94
Code 53 6-95
xiii PDMM-0067
Table of Contents MITSUBISHI Orderpicker Service Manual
Code 59 6-96
Code 91 6-97
Code 92 6-98
Code 936-100
Code 946-101
Code 966-101
Code 9C6-102
Code 9E6-102
Code 9F
Code 9H
Code 9J
Code 9K
Code 9L
Code CO
Code Cl
Code C2
Code C3
Code CS
Code C6
Code CS
Code C9
Code CA
Code CC
Code CE
Code CF
Code CJ
Code CL
Code CP
Code CU
Code CY
Code EC
Code Fl
Code F2
Code F3
Code F7
Code F9
Code FA
Code FB
Code FC
Analog Input Tests6-129
Test A50 – Steer Controller Power Supply Voltage6-129
Test A51 – Steer Controller Battery Sense Voltage6-130
Test A52 – Maximum Drive Unit Rotation 6-131
Test A53 – Display Left Tractor Guidance Coil Voltage6-132
Test A54 – Display Right Tractor Guidance Coil Voltage6-134
Test A55 – Display Load Left Guidance Coil Voltage6-135
Test A56 – Display Right Guidance Coil Voltage6-136
PDMM-0067 xiv
MITSUBISHI Orderpicker Service Manual Table of Contents
Test A57 – Display Tractor Near Wire Coil Voltage6-137
Test A58 – Display Load Near Wire Coil Voltage6-138
Test A59 – Display Average Distance from Guide Wire6-139
Test A60 – Display Peak Distance from Guide Wire6-140
Test A61 – Display Average Heading Angle Magnitude6-141
Test A62 – Display Peak Heading Angle 6-142
Test A63 – Display Average Guide Wire Signal Strength6-143
Test A64 – Steer Input Encoder6-144
Digital Input Tests 6-145
Test 150 – Display Auto/Manual Switch Position6-146
Test 151 – Drive Unit Position Encoder Count6-147
Test 152 – Steer Feedback Connector6-148
Test 153 – Wire Guidance Board Status 6-149
Test 154 – Home Position Switch6-150
Test 155 – Display Channel A of Steer Encoder 6-151
Test 156 – Display Channel B of Steer Encoder 6-152
Test 157 – Home Proximity Switch Connection 6-153
Test 158 – Brake Deadman Switch (S2) 6-154
Test 159 – Steer Input Encoder Connection6-155
Test 162 – Speed Proximity Connection 6-156
Test 163 – Speed Proximity Connection6-157
Test 166 – Rail Switch Input6-158
Test 168 – Rail Switch Connection 6-159
Digital Output Tests6-160
Test 050 – Display LEDs6-160
Test 051 – Audible Alarm 6-161
Test 052 – Toggle ESTOP Output6-162
Test 053 – Toggle Wire Guidance Speed Limit Output6-163
Test 054 – Toggle Speed Limit Output6-164
Appendix7 -1
Lubrication Equivalency Chart 7 -2
Standard Torque Data For Bolts7 -4
Conversion Table 7 -7
Decimal Equivalent Chart 7 -8
Schematic – Electrical 7 -11
Schematic – Hydraulic7-19
Decal Replacement7-21
Pin-By-Pin Description/Function7-24
Pin-By-Pin Voltages – EVl00LX Truck Control System7-27
Fault Codes/Component Association7-31
Brush Replacement7 -35
Index8-1

DESCRIPTION:

Mitsubishi Forklift Truck EOP15 EOP24 EOP15P EOP24P Service Manual P.NO WENB8560-01 – PDF DOWNLOAD

Manual Overview:

This manual contains operating and maintenance instructions for the specific equipment listed on the cover. It is organized by major topics covering all areas of the truck, as follows:

The following symbols are used throughout this manual to represent a condition or hazard of which the operator should be aware.

G.B 27/01/25